® Installation Guidelines 3 Phase 60 Hz Air-Cooled Generators 20 kW WARNING This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury. (000209a) Register your Generac product at: WWW.GENERAC.COM 1-888-GENERAC (888-436-3722) Para español, visita: http://www.generac.com/service-support/product-support-lookup Pour le français, visiter : http://www.generac.
Use this page to record important information about your generator set. Model: Serial: Prod Date Week: Volts: LPV Amps: NG Amps: Hz: Phase: Controller P/N: Record the information found on your unit data label on this page. For the location of the unit data label, see your owner’s manual. The unit has a label plate affixed to the inside partition, to the left of the control panel console.
Table of Contents Section 1: Safety Rules & General Information Section 5: Fuel Conversion / Gas Connections Introduction ..........................................................1 Fuel Requirements and Recommendations ... 17 Read This Manual Thoroughly ....................................1 Fuel Conversion ................................................ 17 How to Obtain Service .................................................1 Safety Rules .........................................................
Table of Contents Electrical Checks ...............................................34 Generator Tests Under Load ............................34 Checking Automatic Operation ........................35 Installation Summary ........................................35 Shutting Generator Down While Under Load or During An Extended Outage .............................35 To turn the generator OFF: ....................................... 35 To turn the generator back ON: ................................
Safety Rules & General Information Section 1: Safety Rules & General Information 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.
Safety Rules & General Information Safety Rules Study these SAFETY RULES carefully before installing, operating, or servicing this equipment. Become familiar with this installation manual, the 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.
Safety Rules & General Information Electrical Hazards WARNING Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death or serious injury. (000228) WARNING Injury and equipment damage. Do not use generator as a step. Doing so could result in falling, damaged parts, unsafe equipment operation, and could result in death or serious injury. (000216) DANGER Electrocution.
Safety Rules & General Information Fire Hazards Explosion Hazards DANGER WARNING Fire hazard. Do not obstruct cooling and ventilating airflow around the generator. Inadequate ventilation could result in fire hazard, possible equipment damage, death or serious injury. (000217) Explosion and fire.Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury.
Safety Rules & General Information General Rules • Fully comply with all relevant NEC, NFPA, and DANGER Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. Failure to do so will result in death or serious injury. (000190) DANGER Electrical backfeed. Use only approved switchgear to isolate generator from the normal power source. Failure to do so will result in death, serious injury, and equipment damage.
Safety Rules & General Information Standards Index WARNING This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury. (000209a) • Strictly comply with all applicable national, state, and local laws, as well as codes or regulations pertaining to the installation of this enginegenerator power system.
Unpacking and Inspection Section 2: Unpacking and Inspection General NOTE: Carefully inspect the contents for damage after unpacking. 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 1. Remove the tape to remove the keys. 2. Use the keys to open the lid of the generator. NOTE: The enclosed keys provided with this unit are intended for service personnel use only. 3. Two locks secure the lid; one on each side (A in Figure 2-4). Press down on the lid above the side lock, and unlock the latch to properly open the lid. 4. Repeat for the other side. The lid may appear stuck if pressure is not applied from the top.
Unpacking and Inspection Intake Side Panel Removal 3. Lift the intake panel up and away from the generator. See Figure 2-5. The intake side panel (A) must be removed to access the battery compartment, fuel regulator, and sediment trap. NOTE: Always lift the intake side panel straight up before pulling away from enclosure. Do not pull the panel away from the enclosure before lifting up (D). 1. Raise the lid and remove the front panel. 2.
Unpacking and Inspection Generator Main Line Circuit Breaker Parts Shipped Loose This is a 3-pole circuit breaker (generator disconnect) rated according to relevant specifications. See “A” in Figure 2-8. C A B 003586 A B 003740 Figure 2-8. Generator Main Line Circuit Breaker The breaker can be locked in the OFF (OPEN) position for security during maintenance or transfer switch service. Use an appropriately-sized padlock (not included) with a shackle long enough to pass through both lock tabs (B).
Site Selection and Preparation Section 3: Site Selection and Preparation Site Selection D 5 ft (1.52 m) B 3 ft (0.91 m) C E 5 ft (1.52 m) A 3 ft (0.91 m) B 3 ft (0.91 m) B F 001751 G D 001789 Figure 3-1. Installation Clearances ID Description Comments A Top of generator — B Front and end clearance Minimum clear distances cannot include shrubs, bushes, or trees. C Rear clearance 18 in (45.
Site Selection and Preparation Install the generator set, in its protective enclosure, outdoors where adequate cooling and ventilating air is always available (Figure 3-1). Consider these factors: – The generator must be installed on a level surface. The generator must be level within 0.5 in (13 mm) all around. • The installation of the generator must comply – The generator is typically placed on pea gravel, compacted soil, crushed stone, or a concrete pad. Check local codes to see what type is required.
Site Selection and Preparation generator enclosure would not pose any ignition risk to nearby combustibles or structures, with or without fire service personnel response. Site Preparation • Locate the mounting area as close as possible to the transfer switch and fuel supply. • Leave adequate room around the area for service access (check local code), and place high enough to keep rising water from reaching the generator. • Choose an open space that will provide adequate and unobstructed airflow.
Site Selection and Preparation Transportation Recommendations Use a suitable cart or equipment 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. IMPORTANT NOTE: Do not lift, carry, or move the generator by grasping the louvers. Doing so may bend or damage the sheet metal.
Generator Placement Section 4: Generator Placement Generator Placement All air-cooled generators come with a non-sinking direct to dirt (DTD) composite base pad. The DTD pad elevates the generator and helps prevent water from pooling around the base. (Figure 4-1). The DTD pad allows the generator to be placed on three types of surfaces: • directly on level, solid ground • on 4 in (102 mm) of compacted pea gravel • on a concrete pad 003748 Check local codes to see what type of site base is required.
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Fuel Conversion / Gas Connections Section 5: Fuel Conversion / Gas Connections Fuel Requirements and Recommendations Always 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. DANGER Explosion and fire.Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away.
Fuel Conversion / Gas Connections Fuel Consumption Generator 20 kW Natural Gas Propane 1/2 Load Full Load 1/2 Load Full Load 6.20 / 219 8.69 / 307 2.39 / 9.03 / 87 3.56 / 13.48 / 130 * Natural gas is in m3/h / ft3/h ** Propane is in gal/h / l/h (LP) / ft3/h (LPV) *** Values given are approximate These are approximate values. Use the appropriate spec sheet or owner’s manual for specific values.
Fuel Conversion / Gas Connections Natural Gas Pipe Sizing To determine correct gas pipe size, 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 meters / feet) allowed for the pipe sizes on top. Pipe sizes are measured by inside diameter (ID) to include any fittings, valves (must be full flow), elbows, tees, or angles. NOTE: Add 2.5 ft (0.76 m) per any bend, tee, or angle in the pipe to the overall distance.
Fuel Conversion / Gas Connections Installing and Connecting Gas Lines Flexible Fuel Line DANGER Explosion and fire.Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury. (000192) IMPORTANT NOTE: Natural gas and LP vapor are highly volatile substances. Strictly adhere to all safety procedures, codes, standards, and regulations.
Fuel Conversion / Gas Connections Checking Gas Line Connections 1. Check for leaks by spraying all connection points with a non-corrosive gas leak detection fluid. The solution should not be blown away or form bubbles. 2. Check gas pressure at the regulator in the generator by following these steps. • Close gas supply valve. • Remove the top gas pressure test port from the regulator (see Figure 5-4) and install the gas pressure tester (manometer).
Fuel Conversion / Gas Connections Natural Gas Vapor Installation (typical) F B A C J G D E H L K 001808 NG BTU = ft3/h X 1000 Megajoules = m3/h X 37.26 A BTU and pressure decal B Minimum distance from rear obstruction C Manual shutoff valve (pressure port optional) D Pipe nipple (field supplied) E Flexible fuel line F Check distance with gas provider. See Site Selection .
Fuel Conversion / Gas Connections LP Vapor Installation (typical) F G B C A D J K M E H L 001809 LP BTU = ft3/h X 2500 Megajoules = m3/h X 93.15 A BTU and pressure decal B Minimum distance from rear obstruction C Manual shutoff valve (pressure port optional) D Pipe nipple (field supplied) E Flexible fuel line F Check distance with gas provider. See Site Selection .
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Electrical Connections Section 6: Electrical Connections Generator Connections See Figure 6-1. The electrical wiring enclosure is located behind an access panel on the intake end of the unit. Remove the intake side panel as directed in Intake Side Panel Removal, and then remove the access panel. Connect wires according to the diagram and tables. 1. Remove the main AC / control wiring knock-out plugs from the back of the generator. 2.
Electrical Connections Control Wiring A C2 B C1 E1 E2 E3 G F H J 003750 D Figure 6-1. Electrical Wiring Connections Table 6-1.
Electrical Connections . Table 6-4. Ground and Neutral Connections (Copper or Aluminum Conductors) Refer to national and/or local codes to verify correct wire sizes. No. Description Recommended Wire Size Torque Spec 1 Power wire terminals 2/0 to 8 AWG 120 in-lb (13.56 Nm) 2 Large neutral lug 2/0 to 14 AWG 120 in-lb (13.56 Nm) 3 Large ground lug 2/0 to 14 AWG 120 in-lb (13.56 Nm) 4 Neutral bus bar 4-6 AWG 8 AWG 10-14 AWG 35 in-lb (3.95 Nm) 25 in-lb (2.82 Nm) 20 in-lb (2.
Electrical Connections Battery Requirements 12 volts, Group 26R-540CCA minimum, or Group 35AGM-650CCA minimum. Battery Installation B A + – WARNING Explosion. Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury. (000137a) WARNING (000138a) • (Group 26R batteries only): Fill the battery with the proper electrolyte fluid if necessary.
Control Panel Start-Up/Testing Section 7: Control Panel Start-Up/Testing Control Panel Interface Activation DANGER Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury. (000191) • Press the OFF button on the control panel, remove fuses, and disconnect battery cables to prevent accidental startup before performing any maintenance on the generator.
Control Panel Start-Up/Testing Table 7-1. Activation Chart Display Reads Language English Troubleshooting + Use arrow keys to scroll to desired language. Press ENTER to select. Language can be changed later using the EDIT menu. Press ENTER to begin the activation process. If ESCAPE is pressed instead of ENTER, the generator will only run in manual mode (for test purposes) and NOT ACTIVATED will be displayed. You will need to remove the 7.
Control Panel Start-Up/Testing Table 7-1. Activation Chart Display Reads Troubleshooting Select Hour (0-23) - 6 + 002231 Activation is complete when all digits are entered above and your screen shows this display. Follow the controller prompts to continue setting the time function. Refer to your Owner’s Manual with questions. What happens if “Wrong Passcode Try Again” appears? Re-enter the activation code. If a second attempt is unsuccessful, check the number against the code given on activategen.com.
Control Panel Start-Up/Testing Before Initial Start-up NOTE: The unit has been run and tested at the factory prior to being shipped and does not require any type of break-in. CAUTION Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage. (000135) NOTE: The unit comes filled with 5W-30 weight organic oil from the factory. Check the oil level and add the appropriate viscosity and amount if necessary.
Control Panel Start-Up/Testing Power Up Unit Note: If language was previously programmed this goes directly to “Select Hour” FIRMWARE V 1.01 HARDWARE V 1.05 Language UP ARROW = Install Wizard + English + Espanol + Francais + Portuguese - + Defaults to English if not selected.
Control Panel Start-Up/Testing Electrical Checks DANGER Electrocution. High voltage is present at transfer switch and terminals. Contact with live terminals will result in death or serious injury. (000129) WARNING Phase rotation must be compatible. Incompatible phase rotation could result in equipment damage, death or serious injury. (000226a) IMPORTANT NOTE: DO NOT test automatic operation or apply any loads before verifying phase rotation! NOTE: Maximum unbalanced loading is 25%.
Control Panel Start-Up/Testing 8. Set the generator MLCB (generator disconnect) to ON (CLOSED). Loads are now powered by the standby generator. 9. Turn on the circuit breakers/electrical loads that are powered by the generator one by one. 10. Connect a calibrated AC voltmeter and a frequency meter across terminal lugs E1 and E2; E2 and E3; E1 and E3. Voltage should be approximately 208 volts and frequency should be approximately 60 Hz.
Control Panel Start-Up/Testing 002389 Figure 7-3. Disconnect Battery Charger Cable 8. Perform required maintenance procedure(s). To turn the generator back ON: 1. See Figure 7-3. Connect white battery charger cable. 2. Install the intake side panel and front panel. (See Intake Side Panel Removal.) 3. Install the 7.5 amp fuse in the control panel. 4. Follow the steps described in the Installation Wizard (Figure 7-2). Place controller in AUTO. Allow the unit to run for one minute with no load. 5.
Troubleshooting Section 8: Troubleshooting System Diagnosis Problem Engine will not crank. Cause 1. Blown fuse. 2. Loose, corroded, or defective battery cables. 3. Defective starter contact. 4. Defective starter motor. 5. Discharged battery. Correction 1. Correct short circuit condition by replacing 7.5 amp fuse in generator control panel. If fuse continues to blow, contact an IASD for assistance. 2. Tighten, clean, or replace as necessary.* 3. *See #2. 4. *See #2. 5. Charge or replace battery.
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Quick Reference Guide Section 9: Quick Reference Guide System Diagnosis To clear an active alarm, press the OFF button, ENTER button, then press AUTO. Contact an Independent Authorized Service Dealer (IASD) if the alarm reoccurs. Table 9-1. System Diagnosis Active Alarm NONE LED Problem Things to Check Check MLCB FLASHING Unit running in AUTO but (generator GREEN no power in house. disconnect). Solution Check MLCB (generator disconnect). If it is ON, contact an IASD.
Quick Reference Guide Table 9-1. System Diagnosis (Continued) Active Alarm LED Problem Things to Check Solution UNDERSPEED RED Unit will not start in AUTO with utility loss. Check the LED’s / screen for alarms. Contact an IASD. STEPPER OVERCURRENT RED Unit will not start in AUTO with utility loss. Check the LED’s / screen for alarms. Contact an IASD. MISWIRE RED Unit will not start in AUTO with utility loss. Check the LED’s / screen for alarms. Contact an IASD.
Accessories Section 10: Accessories Performance enhancing accessories are available for air-cooled generators. Accessory Cold Weather Accessories*— • Battery Pad Warmer Description • Recommended in areas where temperatures fall below 0 °F (-18 °C). (Not necessary for use with AGM-style batteries) • Oil Warmer • Breather Warmer • Recommended in areas where temperatures fall below 0 °F (-18 °C). • Recommended in areas where heavy icing occurs.
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Diagrams Section 11: Diagrams Installation Drawing (10000007616—1 of 2) MOUNTING TO CONCRETE PAD HOLE LOCATIONS FOR OPTIONAL MOUNTING TO A CONCRETE PAD 521 [20.5] 16.0 [5/8] DIA.CLEARANCE HOLE (3) PLACES, 3/8 DIA. MASONRY ANCHOR BOLTS RECOMMENDED 68.0 [2.7] 196.6 [7.74] 456.6 [18.0] 392.7 [15.5] FRONT OF UNIT MAIN AC/CONTROL WIRING HOLE FOR 1 1/4" CONDUIT MAIN AC/CONTROL WIRING HOLE FOR 3/4" CONDUIT FUEL INLET : 3/4" NPT REQUIRED FUEL PRESSURE : NATURAL GAS : 3.
Diagrams Installation Drawing (10000007616—2 of 2) AIR INTAKE 457.2 [18.0] 914 [36.0] MINIMUM OPEN AREA ON SIDES AND FRONT AIR INTAKE AIR OUTLET TOP VIEW "DO NOT LIFT BY ROOF" RIGHT VIEW INTAKE PANEL REMOVED 30.2 [ 12] LIFTING HOLES 4 CORNERS 1218 [47.9] 1232 [48.5] 127 [5.
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Part No. 10000003886 Rev. B 02/14/17 ©2017 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) www.generac.
