Installation Guidelines 8 - 22 kW Air-Cooled Generators * * NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS. * DEADLY EXHAUST FUMES! OUTDOOR INSTALLATION ONLY! ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! This manual should remain with the unit. This manual must be used in conjunction with the appropriate owner’s manual. To locate in Spanish, go to http://www.generac.com/service‐support/product‐support‐lookup To locate in French, go to http://www.generac.
FREQUENTLY ASKED QUESTIONS This list of Frequently Asked Questions (FAQs) are the frequently asked installation questions that pertain to ALL Home Standby models. Some questions may not be applicable to the model(s) covered in this publication. Please review the Safety Section of your product’s Owners or Installation Manual before operating your Home Standby Generator.
Table of Contents Frequently Asked Questions...................................................................................ii Section 1 Safety and General Information 1.1 Introduction ............................................................................................................................. 1 1.1.1 Read This Manual Thoroughly ..................................................................................................................... 1 1.1.2 How to Obtain Service ..............
Table of Contents Section 6 Electrical Connections 6.1 Generator Connections ........................................................................................................27 6.2 Control Wiring .......................................................................................................................27 6.3 Main AC Wiring .....................................................................................................................28 6.4 Battery Requirements ......................
Section 1 Safety and General Information 1.1 — Introduction Thank you for purchasing this compact, high performance, air-cooled, engine-driven generator. It is designed to automatically supply electrical power to operate critical loads during a utility power failure. This unit is factory installed in an all-weather, metal enclosure that is intended exclusively for outdoor installation. This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).
Safety and General Information 1.1.2— How to Obtain Service When the generator requires servicing or repairs, contact a Dealer for assistance. Service technicians are factorytrained and are capable of handling all service needs. For assistance locating a dealer, call our dealer locater at 800333-1322 or visit us at www.generac.com/dealer-locator.
Safety and General Information • 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.
Safety and General Information 1.2.4— 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.
Safety and General Information 1.3.3— Standards Index Applicable national, state or local laws, codes and regulations pertaining to the installation of engine-generator power systems must be strictly complied with. Always use the current acceptable version or edition of the applicable code or standard which applies to your jurisdiction. In the absence of pertinent local laws and standards, the following published booklets may be used as a guide (these apply to localities which recognize NFPA and IBC): 1.
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Section 2 Unpacking and Inspection 2.1 — General NOTE: After unpacking, carefully inspect the contents for damage. It is advised to unpack and inspect the unit immediately upon delivery to detect any damage that may have occurred in transit. Any claims for shipping damage need to be filed as soon as possible with the freight carrier. This is especially important if the generator will not be installed for a period of time.
Unpacking and Inspection Figure 2-1. Crated Generator 3. Remove bolts and clamps. Exercise caution when removing the generator. Dragging it off the pallet WILL damage the base. The generator must be lifted from the wooden pallet to remove. Lid Front Access Panel Remove Crating Clamps (4) Figure 2-2. Generator on Pallet 4. 8 The lid will be locked. A set of keys is located behind the breaker door. Open the breaker door and cut the zip tie to remove the keys.
Unpacking and Inspection Figure 2-3. Circuit Breaker Box and Keys (As Shipped) 5. There are two locks securing the lid, one on each side. To properly open the lid, press down, on the lid, above the side lock and unlock the latch. 6. Repeat for the other side. If pressure is not applied from the top, the lid may appear stuck. NOTE: Always verify that the side locks are unlocked before attempting to lift the lid. 7. Once the lid is open, remove the front access panel by lifting it up and out.
Unpacking and Inspection Connection Area (Under Control Panel) Fuel Regulator Battery Compartment Loose Parts Figure 2-5. Customer Connection Area/Loose Parts Location 9.
Unpacking and Inspection 2.
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Section 3 Site Selection and Preparation 3.1 — Site Selection No operable windows or openings in the wall permitted within 5 ft (1.52 m) from any point of the generator. Existing Wall 60 in (1524 mm) Clearance from operable windows, doors or any openings in the wall. 36 in (914 mm) 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.
Site Selection and Preparation Install the generator set, in its protective enclosure, outdoors, where adequate cooling and ventilating air is always available (Figure 1.9). Consider these factors: • The installation of the generator must comply strictly with NFPA 37, NFPA 54, NFPA 58 and NFPA 70 standards. • Install the unit where air inlet and outlet openings will not become obstructed by leaves, grass, snow, etc.
Site Selection and Preparation Figure 3-2. Southwest Research Institute Decal Southwest Research Institute Decal (located inside the generator, next to the generator’s data decal) http://www.swri.org/4org/d01/fire/listlab/listprod/director.htm 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 in (457 mm) from any point of the generator enclosure to a stationary wall, building or structure.
Site Selection and Preparation 3.2.1— Material sufficient for level installation • Dig a rectangular area approximately 5 in (127 mm) deep and about 6 in (152 mm) longer and wider than the footprint of the generator. Fill with pea gravel, crushed stone or any other non-combustible material sufficient for level installation. Compact and level the material. A concrete pad can be poured if desired or required.
Section 4 Generator Placement 4.1 — Generator With the Site Selection and Preparation performed, proceed with placement and installation of the generator itself. All of the air-cooled generators come with a composite pad. The composite pad elevates the generator and helps prevent water from pooling around the bottom of the generator (Figure 3.1). You can place the generator with a composite pad on 4 in (102 mm) of pea gravel that is compacted or on a concrete pad.
Generator Placement 4.2 — Fascia Installation (If Applicable) • Locate the four (4) threaded black rubber bumpers located in the Owner’s manual bag. • Remove the four (4) bumpers from the bag and screw them into threaded holes located inside the end pieces of the fascia (two each) opposite one another (A). • Once the bumpers are installed, snap one of the end pieces into one of the front / rear pieces of fascia. Repeat this action with the other two remaining pieces of fascia.
Section 5 Fuel Conversion/Gas Connections 5.1 — Fuel Conversion The generator was configured for natural gas operation at the factory. Switching over to LP Vapor is a simple procedure. NOTE: The fuel selection (LP/NG) must be updated, on the controller, during initial power up using the Installation Wizard. NOTE: The orange fuel conversion knob is located on the top of the fuel mixer on the V-twin engine and under the fuel mixer on the single cylinder engine.
Fuel Conversion/Gas Connections NOTE: All pipe sizing, construction and layout must comply with NFPA 54 for natural gas applications and NFPA 58 for liquid propane applications. Once the generator is installed, verify that the fuel pressure NEVER drops below it’s required fuel pressure rating. For further information regarding NFPA requirements refer to their website at www.nfpa.org.
Fuel Conversion/Gas Connections 5.4 — Fuel Line Sizing • First, determine what size pipe is required. Refer to NFPA 54 for NG or NFPA 58 for LP for further information. • Always refer to the owner’s manual for the proper BTU / megajoule and required gas pressures. To calculate BTU or Megajoules: – Natural Gas: BTU = Cubic feet / hour x 1000 Megajoules = Cubic meters / hour x 37.26 – Liquid Propane Vapor: BTU = Cubic feet / hour x 2500 Megajoules = Cubic meters / hour x 93.
Fuel Conversion/Gas Connections 5.4.2— LP Vapor Pipe Sizing To properly use this chart, find the kW rating of the generator in the left column, and trace to the right. The number to the right is the maximum length (measured in feet / meters) allowed for the pipe sizes on top. The pipe sizes are measured by inside diameter (ID) to include any fittings, valves (must be full flow), elbows, tees or angles. Add 2.5 ft (.76 m) per any bend, tee or angle in the pipe to the overall distance.
Fuel Conversion/Gas Connections Figure 5-2. Full Flow Shutoff Valve / Accessory Valve with Manometer Port NOTE: Figure 5-2 illustrates a full flow shutoff valve and a Generac accessory valve with a manometer port for making fuel pressure checks. This accessory valve permits making pressure checks without going into the generator enclosure. Sediment Trap Figure 5-3.
Fuel Conversion/Gas Connections Figure 5-4. Incorrect Routing of Flexible Hose 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.
Fuel Conversion/Gas Connections BTU and Pressure Decal BEST PRACTICE SPECIFIED BY THE REGULATOR MANUFACTURER GAS METER CAPABLE OF PROVIDING NATURAL GAS AT THE REQUIRED VOLUME MANUAL SHUT OFF VALVE TRAP 11 kW and Below = 5"-7" WC REGULATOR 16 kW and Above = 3.5"-7" WC REGULATOR 0000001 GAS MAIN 2-5 PSI NG BTU = CUBIC FEET/HOUR X 1000 Figure 5-6.
Fuel Conversion/Gas Connections NOTE: When sizing a secondary regulator for LP or high pressure natural gas applications be sure to note the maximum individual load capabilities which will be lower than total capacity. This could impact generator starting performance if sized too small. NOTE: It is not recommended to reduce the fuel pipe size exiting the secondary regulator unless necessary to accommodate the ½” or ¾” flexible fuel line that is shipped with the generator.
Section 6 Electrical Connections 6.1 — Generator Connections NOTE: Control wiring may be already wired on pre-wired generators. If so, tighten the 5’ whip conduit inside of the enclosure. If not, wiring must be in accordance with local jurisdiction and codes. 1. Remove the appropriate Main AC/Control Wiring Knock-out Plug from the back of the generator. 2. Install the conduit and Main AC and Control Wires between the generator and the transfer switch. See Figure 2.
Electrical Connections Figure 6-1. Control Wiring (Behind Control Board) NOTE: Wires 23, 194 and 0 must be run through the provided wire shielding provided in the manual bag to separate the low voltage from the high voltage wires unless the requirement of 300.3(c)(1) of the NEC are met (see the Parts Shipped Loose section). NOTE: Must be connected to keep battery charged whether unit is running or not. 6.3 — Main AC Wiring Figure 6-2.
Electrical Connections 2. Remove the two cap plugs located behind the breaker door and to the right of the Main Breaker. 3. Loosen the lugs of the Main Breaker through the access holes. 4. Insert a power wire (E1 or E2) through the opening in the back cover and into the bottom lug. Torque to the proper specification. NOTE: There are three (3) screws inside the top of the breaker panel (behind the breaker door). Removing these screws will allow the entire breaker box to be carefully pulled out.
Electrical Connections Red Lead From Starter Contactor Black Lead To Frame Red (+) Black (-) 12VDC System 12VDC Figure 6-3. Battery Cable Connections NOTE: In areas where temperatures regularly fall below 32 °F (0 °C), a pad type battery heater and engine oil warmer are required to be installed to aid in cold climate starting. This is available as a cold weather kit through an independent authorized service dealer and is also available on Generac.com.
Section 7 Control Panel 7.1 — Control Panel Interface 7.1.1— Using Auto/Manual/Off Buttons With AUTO mode active, the engine may crank and start at any time without warning. Such automatic starting occurs when utility power source voltage droops below a preset level or during the normal exercise cycle.
Control Panel 7.2 — Generator Activation 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 to activate again, even if you disconnect the generator battery.
Control Panel Low Speed Exercise ProĮůe - 22 kW Generators 3800 3600 Exerrcise Speed (RPM) 3400 3200 3000 2800 2600 2400 2200 2000 1800 0 sec 5s 10 s 15 s 20 s 25 s 30 s 35 s 40 s 45 s 1 min 5 min Exercise Time Figure 7-2. Engine speed during exercise - 22 kW Units 3200 Low Speed Exercise PrŽĮůĞ - 16 to 20 kW Generators Exerccise Speed (RPM) 3000 2800 2600 2400 2200 2000 0 sec 5s 10 s 1 min 5 min Exercise Time Figure 7-3.
Control Panel ACTIVATION CHART Display Reads: Up Arrow = (+) Language - English + Generator Active is displayed on the LCD screen when the unit is first powered up. After displaying firmware and hardware version codes, as well as other system information, the Installation Wizard is launched, and the Language screen is displayed. If the wrong language is selected, it may be changed later using the Edit menu. Use the ARROW keys to scroll to desired language. Press ENTER.
Control Panel 7.3 — Before Initial Start-Up NOTE: These units have been run and tested at the factory prior to being shipped and do not require any type of break-in. Never operate the engine with the oil level below the “Add” mark on the dipstick. Doing this could damage the engine. NOTE: This unit comes filled with 30 weight organic oil from the factory. Check the oil level and add the appropriate viscosity and amount if necessary. 7.3.
Control Panel "Generator" "AcƟve" This will only come up the Įrst Ɵme the generator is powered. If ESC is pressed to skip the acƟvaƟon process, the baƩĞry must be disconnected to allow acƟvaƟon again and this process will reiniƟĂůŝze. If power is removed aŌĞr a successful acƟvaƟon, the data is remembered and the acƟvaƟon steps are skipped. ENTER "Install Wizard" ".......
Control Panel 7.3.2— Interconnect System Self Test Feature Upon power up, the controller will go through a system self test which will check for the presence of utility voltage on the DC circuits. This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the DC terminal block. If utility voltage is detected, the controller will display a warning message, indicating a mis-wire, and lock out the generator, preventing damage to the controller.
Control Panel 7. When certain that utility supply voltage is compatible with transfer switch and load circuit ratings, turn OFF the utility power supply to the transfer switch to simulate a power outage. NOTE: Do not remove the N1 and N2 fuses in order to simulate an outage. 8. On the generator panel, push the MANUAL button. The engine should crank and start. 9. Let the engine warm up for about five minutes to allow internal temperatures to stabilize.
Control Panel 13. Set the generator’s main circuit breaker to the OFF (or open) position. 14. Let the engine run at no-load for 2-5 minutes. 15. Push the generator’s OFF button. The engine should shut down. 7.7 — Checking Automatic Operation To check the system for proper automatic operation, proceed as follows: 1. Ensure that the generator is OFF. 2. Install front cover of the transfer switch. 3.
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Section 8 Troubleshooting 8.1 — System Diagnosis Problem Engine will not crank. Cause 1. Fuse blown. 2. Loose, corroded or defective battery cables. 3. Defective starter contact. 4. Defective starter motor. 5. Dead Battery. Correction 1. Correct short circuit condition by replacing 7.5 Amp fuse in generator control panel. 2. Tighten, clean or replace as necessary.* 3. *See #2. 4. *See #2. 5. Charge or replace battery. Engine cranks but will not start. 1. Out of fuel. 2. Defective fuel solenoid (FS).
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Section 9 Quick Reference Guide 9.1 — System Diagnosis Table 9-1. System Diagnosis Problem LED Unit running in AUTO but no power in house. GREEN Things to Check Check MLCB. Active Alarm NONE Solution Check MLCB if the MLCB is in the ON position. If it is in the ON position contact the servicing dealer. Unit shuts down during operation. RED Check the LED’s / Screen for alarms. HIGH TEMPERATURE Check ventilation around the generator, intake, exhaust and rear of generator.
Quick Reference Guide Table 9-1. System Diagnosis (Continued) Problem LED Things to Check Active Alarm Solution Unit will not start in AUTO with utility loss. RED Check the LED’s / Screen for alarms. UNDERSPEED Contact servicing dealer. Unit will not start in AUTO with utility loss. RED Check the LED’s / Screen for alarms. STEPPER OVERCURRENT Contact servicing dealer. Unit will not start in AUTO with utility loss. RED Check the LED’s / Screen for alarms. MISWIRE Contact servicing dealer.
Section 10 Accessories 10.1 — Descriptions Accessory Description Cold Weather Kit Required in areas where temperatures regularly fall below 32 ºF (0 ºC). Scheduled Maintenance Kit Includes all pieces necessary to perform maintenance on the generator along with oil recommendations. Auxiliary Transfer Switch Lockout Enables any of the transfer switches to completely lock out one large electrical load by tying into its control system. Fascia Skirt Wrap Standard on 22 kW units.
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Installation Guidelines for Air-Cooled Generators T1 EVOLUTION PANEL GROUNDING ELECTRODE CONNECTION (LOCATED ON THE REAR OF UNIT) N1 N2 0 194 23 WHITE T1 TOP VIEW N1 N2 0 194 23 GREEN E1 E2 NOTE: INSTALLATION MUST MEET ALL NATIONAL, STATE AND LOCAL ELECTRICAL CODES.
48 0 EVOLUTION PANEL GROUNDING ELECTRODE CONNECTION (LOCATED ON THE REAR OF UNIT) T1 194 23 WHITE T1 TOP VIEW N1 N2 0 194 23 GREEN E1 E2 SIDE VIEW GFCI BREAKER E1 E2 GENERATOR OUTPUT CIRCUIT BREAKER 2 POLE NEUTRAL BAR GROUND BAR PANELBOARD UTILITY METER SOCKET DISCONNECT BONDING CONNECTION IN PANELBOARD LOAD SHED DEVICE TO GROUNDING ELECTRODE N1 N2 T1 C 0D9618-TO STANDBY (C2 & VR2) UTILITY (C1 & VR1) E1 T1 N1 RTSY TRANSFER SWTICH - 2013 MODEL A BONDING JUMPER IS PROVIDED BET
Diagrams 11.2 — Installation Diagram 11.
Diagrams 50 Installation Guidelines for Air-Cooled Generators
Part No. 0K5804 Rev. A 04/15/2014 Printed in USA © Generac Power Systems, Inc. All rights reserved Specifications are subject to change without notice. No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc. Generac Power Systems, Inc. S45 W29290 Hwy. 59 Waukesha, WI 53189 1-888-GENERAC (1-888-436-3722) generac.
