Installation Guidelines 7 kW PowerPact ™ Generator * * 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.
WARNING! California Proposition 65 Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. WARNING! California Proposition 65 This product contains or emits chemicals known to the state of California to cause cancer, birth defects, and other reproductive harm.
Table of Contents 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 Control Wiring .....................................................................................................................27 6.2 Main AC Wiring ...................................................................................................................28 6.3 Battery Requirements ........................................................................................................29 6.4 Battery Installation ...........................
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 This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).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 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.
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 NOTE: DO NOT use this generator in critical life support applications. Strictly comply with all applicable national, state and local laws, as well as codes or regulations pertaining to the installation of this engine-generator power system. Use the most current version of applicable codes or standards relevant to the local jurisdiction, generator used, and installation site. NOTE: Not all codes apply to all products and this list is not all-inclusive.
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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 Circuit Breaker (MLCB) Control Panel Figure 2-2. Circuit Breaker / Control Panel 8 3. There are four fasteners securing the top lid. Remove the 4 Allen fasteners and lift the top lid from the generator enclosure. 4. Once the lid is open, remove the front panel by lifting it up and out. Also open the door covering the customer connection area. 5. Perform a visual inspection for any hidden freight damage.
Unpacking and Inspection Valve Cover Spark Plug Airbox Customer Connection Area Exhaust Vents External Breaker and Control Panel Muffler (not visible) Alternator (not visible) Control Panel Battery (not included) Starter Motor Figure 2-3. Inspect for Damage 2.4 — Parts Shipped Loose “Loose Shipped Parts” are located inside the unit, in front of the engine or under the alternator.
Unpacking and Inspection FLEX FUEL LINE (cable strapped to battery cable or alternator bolt) FASTENERS FOR BATTERY TERMINALS BATTERY BRACKET AND SCREW BATTERY TERMINAL CAP O-RING FUEL JET MLCB TERMINAL CAPS Figure 2-4.
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 the back side of the generator to a stationary wall or building.
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 4 in (102 mm) of pea gravel, crushed stone or any other non-combustible material sufficient for level installation, or on a concrete pad. Compact and level the material. A concrete pad can be poured if desired or required.
Site Selection and Preparation 3.2.2— Transportation Recommendations • Use a two wheeled hand cart or metal rails to carry the generator (including the wooden pallet) to the installation site. Place cardboard between the hand cart and the generator to prevent any damage or scratches to the generator. • Remove bolts and pallet brackets. 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 the clamps.
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Section 4 Generator Placement 4.1 — Generator Lift the generator from the wooden pallet and place it on 4 in (102 mm) of pea gravel, crushed stone or any other noncombustible material sufficient for level installation, or on a concrete pad. Check local codes to see what type of site base is required. If a concrete pad is required, all federal, state and local codes should be followed. Place the generator on its mounting pads and position correctly as per the dimensional information given in Section 2.
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Section 5 Fuel Conversion/Gas Connections 5.1 — Fuel Conversion The generator was configured for natural gas (NG) operation at the factory. The following procedure will enable the generator to operate on LP vapor fuel. 1. Remove the four 6mm Allen head fasteners and lift the top lid from the generator enclosure. 2. Remove the two 4mm Allen head fasteners. Lift and remove the rear panel. 3. Use a pliers to squeeze the hose clamp and slide from the fuel inlet fitting. 4.
Fuel Conversion/Gas Connections 5.2 — Fuel Requirements and Recommendations With LP gas, use only the vapor withdrawal system. This type of system uses the vapors formed above the liquid fuel in the storage tank. The engine has been fitted with a fuel system that meets the specifications of the 1997 California Air Resources Board for tamper-proof dual fuel systems. The unit will run on natural gas or LP gas, but it has been factory set to run on natural gas.
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 5.5 — Installing and Connecting Gas Lines 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.
Fuel Conversion/Gas Connections 3. When connecting the gas line to the generator, use the provided section of UL Listed or AGA-approved flexible fuel line installed horizontally 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 Top Lid Field Connection Box Control Panel Cover Rear Panel Fuel Line Entrance Electrical Access Panel Electrical Connections Entrance Figure 5-5. Fuel Line and Electrical Locations 5. Remove the top lid and rear panel. 6. Check for leaks by spraying all connection points with a soap solution made of dish washing soap and water. You should not see the solution be “blown away” or form “bubbles”.
Fuel Conversion/Gas Connections Gas Pressure Port Manometer Figure 5-6. Checking Pressure with Manometer Check Distance with Gas Provider BTU and Pr essure Decal Manual Shut Off Valve With Pressure Port Size Gas M eter fo r Generator Load Plus All Appliance Loads Fuel Pressure 5-7” Water Column 0000001 Flexible Fuel Line Sediment Trap NG BTU = CUBIC FEET/HOUR X 1000 Megajoules = Cubic Meters/Hour X 37.
Fuel Conversion/Gas Connections Check Distance with Gas Provider BTU and Pressure Decal Check Distance with Regulator Manufacuter Primary Fuel Pressure Regulator Per LP Provider Manual Shut Off Valve Secondary Fuel Pressure Regulator Flexible Fuel Line Sediment Trap NG BTU = CUBIC FEET/HOUR X 2500 Megajoules = Cubic Meters/Hour X 93.15 Manual Shut Off Valve With Pressure Port Size fuel tank large enough to provide required BTUs for generator and ALL connected appliance loads.
Section 6 Electrical Connections 6.1 — Control Wiring Control Wire Recommended Length and Size Maximum Wire Length Recommended Wire Size 1-115 ft (1-35 m) No. 18 AWG 116-185 ft (36-56 m) No. 16 AWG 186-295 ft (57-89 m) No. 14 AWG 296-460 ft (90-140 m) No.
Electrical Connections NOTE: Control wiring must be in accordance with local jurisdiction and codes. 1. Remove the plug from the field connection box. 2. Remove the two Allen screws to remove the electrical access panel. The access panel will hang off of the grounding wire. * Do not pull the panel causing the ground wire to detach from the grounding bus bar. 3. Install the conduit and Main AC and Control Wires between the generator and the transfer switch (Figure 6-2).
Electrical Connections NOTE: Main AC wiring must be in accordance with local jurisdiction and codes. 1. Strip the insulation off the wire ends. Do not remove excessive insulation. 2. Open the controller access panel and latch it. Loosen the lugs of the Main Breaker through the access holes. 3. Insert a power wire (E1 or E2) into the bottom lug of the Main Breaker. Torque to the proper specification. 4. Connect the Neutral wire to the Neutral Lug and torque to the required specification. See Figure 6.
Electrical Connections + Shorting battery terminal can cause equipment damage. Use caution to avoid shorting terminal during connection. Black Lead to Engine Block (-) Red Lead from Starter Contactor (+) BATTERY 12 VDC Figure 6-3. Battery Cable Connections Battery Bracket Installed Screw Battery Bracket Figure 6-4. Battery Installation 15. Install the 7.5 Amp ATO® fuse in the generator control panel. 16. Assemble the battery access panel with the 2 hex head screws and tighten securely. 17.
Section 7 Installation Checks and Tests 7.1 — Control Panel Interface 7.1.1— Using Auto/Manual/Off/Set Exercise Buttons * before performing work on or around the generator or transfer switch. Failure to do so can Engine may start without notice. Press the OFF button, remove fuses and disconnect battery cause death or serious injury.
Installation Checks and Tests 7.2 — Before Initial Start-Up * 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. NOTE: Do not use or add synthetic oil until the generator has operated for a minimum of 50 hours. 7.
Installation Checks and Tests 7.3.3— Setting Exercise Timer This generator is equipped with an exercise timer. Once it is set, the generator will start and exercise every seven days, on the day of the week and at the time of day specified. During this exercise period, the unit runs for approximately 12 minutes and then shuts down. Transfer of loads to the generator output does not occur during the exercise cycle unless utility power is lost.
Installation Checks and Tests + Contact with "hot" electrically charged components can cause electrical shock or electrocution. Failure to correctly follow this procedure can result in death or serious injury. 10.Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1 and E2. Voltage should be 236-240 at a frequency of 62-63 Hertz at no load. If it’s not, verify that the MLCB is closed and verify AC output and frequency (Hertz or Hz) at the MLCB.
Installation Checks and Tests 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. Turn ON the utility power supply to the transfer switch, using the means provided (such as a utility main line circuit breaker). NOTE: Transfer Switch will transfer back to utility position. 4. Set the generator’s main circuit breaker to its ON (or CLOSED) position. 5.
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Section 8 Troubleshooting 8.1 — Troubleshooting Guide 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.
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Section 9 Quick Reference Guide 9.1 — System Diagnosis Problem Unit running in AUTO but no power in house. Unit shuts down during operation. Unit was running and shut down. Attempts to restart. Things to Check Active Alarm Solution Check MLCB NONE Check MLCB. Contact servicing dealer if MLCB is in the ON position. Check for alarms HIGH TEMPERATURE Check ventilation around the generator, intake, exhaust and rear of generator. If no obstruction contact servicing dealer.
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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.
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Section 11 Diagrams 11.1 — Installation Diagram Drawing 0K8350 Rev.
Diagrams Drawing 0K8350 Rev.
Diagrams 11.
Diagrams Drawing 0K7328 Rev.
Diagrams Drawing 0K7328 Rev.
Diagrams Drawing 0K7328 Rev.
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Part No. 0K6022 Rev. B 09/24/2014 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.
