Generac Power Systems EcoGen Series, 005818-0, EcoGen 6kW Owner's Manual
Owner's Manual
EcoGen 6kW Generator
C
LISTE
D
U
S
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 .............................................. 1
Read This Manual Thoroughly ................................................1
Safety Rules ............................................. 1
Contents ...............................................................................1
Operation and Maintenance....................................................1
How to Obtain Service ...........................................................1
Standards Index .....................................................................3
General Information ................................. 4
1.1 Unpacking/Inspection .....................................................4
1.2 Protection Systems ........................................................4
1.3 Emission Information......................................................4
1.4 The Generator ................................................................5
1.5 Specifications ................................................................5
1.6 Ready to Run .................................................................5
1.7 Fuel Requirements and Recommendations ......................6
1.8 Fuel Consumption ..........................................................6
1.9 Location .........................................................................6
1.10 Battery Requirements .....................................................9
1.11 Battery Installation ..........................................................9
1.12 The Battery ....................................................................9
1.13 Battery Charger ............................................................10
Operation ................................................ 12
3.1 Control Panel Interface .................................................12
3.2 Automatic Operation .....................................................13
3.3 Sequence of Automatic Operation .................................13
3.4 Side Compartment .......................................................14
3.5 Protection Systems ......................................................14
Maintenance ........................................... 16
4.1 Fuse .............................................................................16
4.2 Checking the Engine Oil Level .......................................16
4.3 Changing the Engine Oil ................................................16
4.4 Changing the Engine Air Cleaner ...................................17
4.5 Spark Plugs ..................................................................17
4.6 Battery Maintenance .....................................................18
4.7 Adjusting GT-530 Valve Clearance .................................18
4.8 Cooling System ............................................................19
4.9 Attention After Submersion ...........................................19
4.10 Corrosion Protection.....................................................19
4.11 Out of Service Procedure ..............................................19
4.12 Service Schedule .........................................................21
Troubleshooting ..................................... 22
5.1 Troubleshooting Guide ..................................................22
Post Installation Start-up and
Adjustments ........................................... 10
2.1 Activate the Generator ..................................................10
2.2 Before Initial Startup .....................................................10
2.3 Electrical Checks ..........................................................10
2.4 Generator Tests Under Load ..........................................12
2.5 Checking Automatic Operation ......................................12
Appendix................................................. 23
6.1 Menu System Navigation ..............................................23
Installation Diagrams ............................ 25
Oil Make-up System ............................... 29
Notes ....................................................... 30
Warranty ................................................. 32
Safety Rules
INTRODUCTION
Thank you for purchasing this compact, high performance, air-cooled,
engine-driven generator. It is designed to supply electrical power to
operate an inverter/battery charger as a component in an off-grid power
solution.
This unit is factory installed in an all-weather, metal enclosure and is
intended exclusively for outdoor installation. This generator will operate
using vapor withdrawn liquid propane (LP).
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.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Dealer
for starting, operating and servicing procedures.
SAFETY RULES
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.
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.
CONTENTS
This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries for the 6kW
LP, V-twin GT-530 Engine.
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 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.
HOW TO OBTAIN SERVICE
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.
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. ______________
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
n
property of others.
This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
Data Label Sample
1
Safety Rules
IMPORTANT SAFETY INSTRUCTIONS! SAVE THESE INSTRUCTIONS – The manufacturer suggests that these 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
n
equipment.
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, 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, neglect-
n
ing 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 run-
n
ning generators.
Installation must always comply with applicable codes, standards, laws and regula-
n
tions.
A running generator gives off carbon monoxide, and odorless, colorless poison gas.
n
Breathing in carbon monoxide can cause
headaches, fatigue, diziness, nausea, vomitting, confusion, fainting, siezures or death.
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, discon-•
nect 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.
EXHAUST HAZARDS
Generator engine exhaust contains DEADLY carbon monox-•
ide, an odorless, colorless poisonous gas. Breathing carbon
monoxide can cause: dizziness, throbbing temples, nausea,
muscular twitching, headache, vomiting, weakness and sleepiness, inability to think clearly, fainting, unconsciousness or
even death. If you experience any carbon monoxide poisoning
symptoms, move into fresh air and immediately seek medical
attention.
Never operate the generator set with the vehicle inside any •
garage or other enclosed area.
GENERAL HAZARDS
For safety reasons, the manufacturer recommends that this equip-•
ment be installed, serviced and repaired by a Service Dealer or
other competent, qualified electrician or installation technician who
is familiar with applicable codes, standards and regulations. The
operator also must comply with all such codes, standards and
regulations.
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.
2
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 stand-•
ing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
Safety Rules
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 genera-•
tor 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 star t 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 department with any questions pertaining to fire extinguishers.
STANDARDS INDEX
In the absence of pertinent standards, codes, regulations and
laws, the published information listed below may be used for
installation guidance 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.
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.
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.
3
General Information
Only qualified electricians or contractors
should attempt such installations, which must
n
comply strictly with applicable codes, standards and regulations.
1.1 UNPACKING/INSPECTION
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.
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
turn the locks on both ends. If pressure is not applied from the top,
the roof may appear stuck. Always verify that the side locks are
unlocked before attempting to lift the roof.
1.2 PROTECTION SYSTEMS
Unlike an automobile engine, the generator may have to run for
long periods of time with no operator present to monitor engine
conditions. For that reason, the engine is equipped with the following systems that protect it against potentially damaging conditions:
1. Low Oil Pressure Sensor 6. Low Battery
2. High Temperature Sensor 7. Under-frequency
3. Overcrank 8. Undervoltage
4. Overspeed 9. Overvoltage
5. RPM Sensor 10. Internal Failure
There are readouts on the control panel to notify personnel that
one of these failures has occurred. There is a Status message on
the display that displays when all of the conditions described in the
"Ready to Run" section are true.
1.3 EMISSION INFORMATION
The Environmental Protection Agency requires that this generator
comply with exhaust emission standards. This generator is certified to meet the applicable EPA emission levels. Additional information regarding the requirements set by the EPA is as follows:
The generator 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. It is important to follow the maintenance specifications in the "Maintenance" section to ensure that the engine complies with the applicable emission standards for the duration of the
engine’s life. This engine is certified to operate on Liquid Propane
fuel. The emission control system on the generator consists of the
following:
Fuel Metering System•
Carburetor/mixer assembly•
Fuel regulator•
Air Induction System•
Intake pipe/manifold•
Air cleaner•
Ignition System•
Spark plug•
Ignition module•
The Emissions Compliance Period referred to on the Emissions
Compliance Label indicates the number of operating hours for
which the engine has been shown to meet Federal emission
requirements. See the table below to determine the compliance
period for the generator. The displacement of the generator is listed
on the Emissions Compliance Label.
Displacement Category Compliance Period
A 300 Hours
< 66 cc
66 cc -
< 225 cc
225 cc
B 125 Hours
C 50 Hours
A 500 Hours
B 250 Hours
C 125 Hours
A 1000 Hours
B 500 Hours
C 250 Hours
4
General Information
1.4 THE GENERATOR
Figure 1.1 – 6kW, V-twin, GT-530 Engine
(door removed)
Air Filter External Oil Fill/Dipstick
Engine
Oil Fill
Engine Oil
Dipstick
Enclosure
Oil FilterExhaust
Figure 1.2 – Data Label Sample
Battery
Compartment
Composite
Base
Control
Panel
Data
Label
Circuit
Breaker
Fuel Inlet
(back)
Fuel
Regulator
1.5 SPECIFICATIONS
1.5.1 GENERATOR
Fuel Type ....................................................................................... LP vapor only
Rated Voltage ......................................................................................... 120 VAC
Rated Maximum Load Current (Amps) at 120 Volts (LP)* .............................50.0
Main Circuit Breaker ................................................................................ 50 Amp
Phase ................................................................................................................1
Number of Rotor Poles .......................................................................................2
Rated AC Frequency ....................................................................................60 Hz
Battery Requirement ........................ Group 26R, 12 Volts and 525 CCA Minimum
Weight (unit only in lbs.) ................................................................................387
Enclosure ..................................................................................................... Steel
Normal Operating Range: This unit is tested in accordance to UL 2200 standards
with an operating temperature of 20 °F (-29 °C) to 122 °F. (50 °C). For areas
where temperatures fall below 32 °F (0 °C), a cold weather kit is highly recommended. When operated above 104º F (40º C) there may be a decrease in engine
power. (Please reference the engine specifications section).
These generators are rated in accordance with UL2200, Safety Standard for
Stationary Engine Generator Assemblies; and CSA-C22.2 No. 100-04 Standard
for Motors and Generators.
1.5.2 ENGINE
Type of Engine .........................................................................................GT-530
Number of Cylinders ..........................................................................................2
Rated Horsepower @ 3,600 rpm* ...................................................................18
Displacement ............................................................................................. 530cc
Cylinder Block .........................................................Aluminum w/Cast Iron Sleeve
Valve Arrangement ..................................................................... Overhead Valves
Ignition System ................................................................. Solid-state w/Magneto
Recommended Spark Plug ..................................................................... BPR6HS
Spark Plug Gap ................................................................. 0.76 mm (0.030 inch)
Compression Ratio.......................................................................................9.5:1
Starter ..................................................................................................... 12 VDC
Oil Capacity Including Filter ..........................................................Approx. 1.7 Qts
Recommended Oil Filter ............................................................. Part # 070185F
Recommended Air Filter ...............................................................Part # 0E9371
Operating RPM............................................................................................2,600
* Engine power is subject to and limited by such factors as fuel Btu content, ambi-
ent temperature and altitude. Engine power decreases about 3.5 percent for each
1,000 feet above sea level; and also will decrease about 1 percent for each 6 C
(10 F) above 16 C (60 F) ambient temperature.
1.6 READY TO RUN
The "Ready to Run" on the display is ready when all of the following
conditions are true:
1. The AUTO/OFF/MANUAL switch is set to the AUTO position.
2. The utility voltage being supplied to the unit is being sensed
by the PCB. If the utility sense voltage is not connected to the
unit or if it is below approximately 150-160 volts AC, then
the system will display the message "No Utility Present". This
indicates that if the AUTO/OFF/MANUAL switch is placed in
the Auto position, the generator will start.
3. No alarms are present, for example, low oil pressure, high
temperature, etc.
5
General Information
1.7 FUEL REQUIREMENTS AND RECOMMENDATIONS
This unit uses a LP vapor withdrawal system only. This type of
system uses the vapors formed above the liquid fuel in the storage
tank.
Recommended fuels should have a Btu content of at least 2,520
Btus per cubic foot for LP gas. Ask the fuel supplier for the Btu
content of the fuel.
Required fuel pressure for liquid propane, 10 inches to 12 inches
of water column (0.36 to 0.43 psi). The primary regulator for the
propane supply is NOT INCLUDED with the generator.
NOTE:
All pipe sizing, construction and layout must comply NFPA 58
for liquid propane applications. Once the generator is installed,
verify that the fuel pressure NEVER drops below 10 inches
water column.
Prior to installation of the generator, the installer should consult
local fuel suppliers or the fire marshal to check codes and regulations for proper installation. Local codes will mandate correct routing of gaseous fuel line piping around gardens, shrubs and other
landscaping to prevent any damage.
Special considerations should be given when installing the unit
where local conditions include flooding, tornados, hurricanes,
earthquakes and unstable ground for the flexibility and strength of
piping and their connections.
Use an approved pipe sealant or joint compound on all threaded
fitting.
All installed gaseous fuel piping must be purged and leak tested
prior to initial start-up in accordance with local codes, standards
and regulations.
1.8 FUEL CONSUMPTION
Unit
6 kW 0.82/30 1.47/54
** LP is in gallons per hour/cubic feet per hour.
*** Values given are approximate.
Verify that gas pipe and regulator is capable of providing enough
fuel flow to include household appliances.
Gaseous fuels such as liquid propane (LP)
gas are highly explosive. Even the slightest
spark can ignite fuel and cause an explo-
sion. No leakage of fuel is permitted. LP gas
is heavier than air and tends to settle in low
areas.
1/2 Load Full Load
LP Vapor
NOTE:
A minimum of one approved manual shut-off valve must be
installed in the gaseous fuel supply line. The valve must be easily accessible. Local codes determine the proper location.
1.9 LOCATION
The engine exhaust fumes contain carbon
monoxide, which can be DEADLY. This dan-
n
gerous gas, if breathed in sufficient concentrations, can cause unconsciousness or
even death. This generator 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.
Operate the generator outdoors ONLY.
• Keep exhaust gases from entering a confined
area through windows, doors, ventilation, crawl
spaces or other openings (Figure 1.3).
• It is highly recommended that carbon monoxide detector(s) be installed indoors according
to the manufacturer's instructions/recommendations.
• The generator must me mounted safely per
applicable codes and the manufacturer's specifications. Do NOT alter or add to the exhaust
system, or do anything that might render the
exhaust system unsafe or in noncompliance
with applicable codes and standards.
1.9.1 GENERATOR
Install the generator set, in its protective enclosure, outdoors,
where adequate cooling and ventilating air is always available
(Figure 1.3). Consider these factors:
The installation of the generator • must comply strictly with
NFPA 37, NFPA 58, and NFPA 70 standards.
Install the unit where air inlet and outlet openings will not •
become obstructed by leaves, grass, snow, etc.. If prevailing
winds will cause blowing or drifting, consider using a windbreak to protect the unit.
Install the generator on high ground where water levels will not •
rise and endanger it.
Allow sufficient room on all sides of the generator for mainte-•
nance and servicing. This unit must be installed in accordance
with current applicable NFPA 37 and NFPA 70 standards; as
well as any other federal, state and local codes for minimum
distances from other structures. DO NOT install under wooden
decks or structures unless there is at least four (4) feet of clearance above the generator, three (3) feet of clearance on sides
and front, and 18 inches of clearance at back of unit.
Install the unit where rain gutter down spouts, roof run-off, •
landscape irrigation, water sprinklers or sump pump discharge
does not flood the unit or spray the enclosure, including any air
inlet or outlet openings.
6
General Information
Install the unit where services will not be affected or obstructed, •
including concealed, underground or covered services such as
electrical, fuel, phone, air conditioning or irrigation.
Where strong prevailing winds blow from one direction, face the •
generator air inlet openings to the prevailing winds.
Install the generator as close as possible to the fuel supply, to •
reduce the length of piping.
Install the generator as close as possible to the transfer switch. •
REMEMBER THAT LAWS OR CODES MAY REGULATE THE
DISTANCE AND LOCATION.
The genset must be installed on a level surface. The base frame •
must be level within two (2) inches all around.
The generator is typically placed on pea gravel or crushed •
stone. Check local codes if a concrete slab is required. If a
concrete base slab is required, all federal, state and local codes
should be followed. Special attention should be given to the
concrete base slab which should exceed the length and width
of the generator by a minimum of six (6) inches (0.152 meters)
on all sides.
Figure 1.3 – Generator Clearances
Annex A — Explanatory Material
A4.1.4 (2) Means of demonstrating compliance are by means
of full scale fire test or by calculation procedures.
Because of the limited spaces that are frequently available for
installation, it has become apparent that exception (2) would be
beneficial for many residential and commercial installations. With
that in mind, the manufacturer contracted with an independent
testing laboratory to run full scale fire tests to assure that the
enclosure would not ignite combustible materials outside the
enclosure.
The criteria was to determine the worst case fire scenario within
the generator and to determine the ignitability of items outside the
engine enclosure at various distances. The enclosure is constructed of non-combustible materials and the results and conclusions
from the independent testing lab indicated that any fire within the
generator enclosure would not pose any ignition risk to nearby
combustibles or structures, with or without fire service personnel
response.
Based on this testing and the requirements of NFPA 37, Sec 4.1.4,
the guidelines for installation of the generators listed above are
changed to 18 inches (457mm) from the back side of the generator to a stationary wall or building. For adequate maintenance and
airflow clearance, the area above the generator should be at least
4 feet with a minimum of 3 feet at the front and ends of the enclosure. This would include trees, shrubs and vegetation that could
obstruct airflow. See the diagram on the reverse of this page and
the installation drawing within the owner’s manual for details.
Generator exhaust contains DEADLY carbon monoxide gas. This
dangerous gas can cause unconsciousness or death. Do not place
the unit near windows, doors, fresh air intakes (furnaces, etc.) or
any openings in the building or structure, including windows and
doors of an attached garage.
1.9.2 NEW INSTALLATION GUIDELINES FOR
STATIONARY AIR-COOLED GENERATORS
The National Fire Protection Association has a standard for the
installation and use of stationary combustion engines. That
standard is NFPA 37 and its requirements limit the spacing of an
enclosed generator set from a structure or wall (Figure 1.4).
NFPA 37, Section 4.1.4, Engines Located Outdoors. Engines, and
their weatherproof housings if provided, that are installed outdoors
shall be located at least 5 ft. from openings in walls and at least 5
ft. from structures having combustible walls. A minimum separation shall not be required where the following conditions exist:
1. The adjacent wall of the structure has a fire resistance rating
of at least 1 hour.
2. The weatherproof enclosure is constructed of noncombus-
tible materials and it has been demonstrated that a fire within
the enclosure will not ignite combustible materials outside the
enclosure.
If the AUTO/OFF/MANUAL switch is not set to
its OFF position, the generator can crank and
start as soon as the battery cables are con-
nected. If the battery charger power supply
is not turned off, sparking can occur at the
battery posts and cause an explosion.
7
General Information
Figure 1.4 – Installation Guidelines
No windows or openings in the wall permitted
within 5 feet from any point of the generator.
60 inches 60 inches
36 inches
These guidelines are based upon fire
testing of the generator enclosure and
the manufacturer’s requirement for air
flow for proper operation. Local codes
may be different and more restrictive
than what is described here.
Existing Wall
18 inches
Minimum Distance
Top of Generator
36 inches
Clearance from windows,
36 inches
Clearance from the ends and front of the
generator should be 36 inches. This
would include shrubs, trees and any
kind of vegetation. Clearance at the top
should be a minimum of 48 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.
doors, any openings in the
wall, shrubs or vegetation
over 12” in height
60” Minimum
60” Recommended
Minimum From Ends
Generator
18 inches
Minimum
This drawing supersedes installation instructions in all Carrier air-cooled installation and owner’s manuals dated
This drawing supersedes installation instructions in all air-cooled installation and owner's manuals dated previous to May 26, 2007.
previous to May 26, 2007.
8
General Information
1.10 BATTERY REQUIREMENTS
See the Specifications section for correct battery size and rating.
1.11 BATTERY INSTALLATION
Fill the battery with the proper electrolyte fluid if necessary and
have the battery fully charged before installing it.
Before installing and connecting the battery, complete the following steps:
1. Set the generator's AUTO/OFF/MANUAL switch to OFF.
2. Turn off utility power supply to the transfer switch.
3. Remove the 7.5A fuse from the generator control panel.
Battery cables were factory connected at the generator (Figure
1.5). Connect cables to battery posts as follows:
4. Connect the red battery cable (from starter contactor) to the
battery post indicated by a positive, POS or (+).
5. Connect the black battery cable (from frame ground) to the
battery post indicated by a negative, NEG or (—).
6. Install battery post covers supplied with the generator.
Figure 1.5 – Battery Cable Connections
NOTE:
Dielectric grease should be used on battery posts to aid in the
prevention of corrosion.
NOTE:
Damage will result if battery connections are made in reverse.
NOTE:
In areas where temperatures regularly fall below 32° F (0° C) it
is recommended that a pad type battery heater be installed to
aid in cold climate starting.
1.12 THE BATTERY
Do not dispose of the battery in a fire. The
battery is capable of exploding.
A battery presents a risk of electrical shock
and high short circuit current. The following
precautions are to be observed when working on batteries:
• Remove the 7.5A fuse from the generator control panel.
• Remove watches, rings or other metal objects.
• Use tools with insulated handles.
• Wear rubber gloves and boots.
• Do not lay tools or metal parts on top of the
battery.
• Disconnect charging source prior to connecting
or disconnecting battery terminals.
Do not open or mutilate the battery.
Released electrolyte has been known to
n
be harmful to the skin and eyes, and to be
toxic.
The electrolyte is a dilute sulfuric acid that
is harmful to the skin and eyes. It is electri-
n
cally conductive and corrosive.
The following procedures are to be observed:
• Wear full eye protection and protective clothing.
• Where electrolyte contacts the skin, wash it off
immediately with water.
• Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek
medical attention.
• Spilled electrolyte is to be washed down with
an acid neutralizing agent. A common practice
is to use a solution of 1 pound (500 grams)
bicarbonate of soda to 1 gallon (4 liters) of
water. The bicarbonate of soda solution is to
be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be
flushed with water and the area dried.
Lead-acid batteries present a risk of fire
because they generate hydrogen gas. The following procedures are to be followed:
• DO NOT SMOKE when near the battery.
• DO NOT cause flame or spark in battery area.
• Discharge static electricity from body before
touching the battery by first touching a grounded metal surface.
Be sure the AUTO/OFF/MANUAL switch is
set to the OFF position before connecting
n
the battery cables. If the switch is set to
AUTO or MANUAL, the generator can crank
and start as soon as the battery cables are
connected.
9
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