Installation Guidelines 60 Hz Air-Cooled Generators 9 kW to 22 kW WARNING Loss of life. 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. (000209b) Activate your Honeywell product at: WWW.ACTIVATEGEN.COM 888-922-8482 (888-9-ACTIVATE) Para español, visita: http://www.honeywellgenerators.com/service-support/owner-support Pour le français, visiter : http://www.honeywellgenerators.
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 4: Generator Placement Introduction ..........................................................1 Fascia Installation (If Applicable) .................... 18 Read This Manual Thoroughly ....................................1 Safety Messages .........................................................1 How to Obtain Service .................................................1 Safety Rules ....................................................
Table of Contents Section 7: Control Panel Start-Up/Testing Control Panel Interface .....................................31 Using the AUTO/MANUAL/OFF Buttons ................. 31 Generator Setup .................................................31 Activation .................................................................. 31 Cold Smart Start ....................................................... 33 Setting The Exercise Timer ....................................... 34 Before Initial Start-up ...........
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 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 Battery Hazards DANGER DANGER Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury. (000188) WARNING 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 Explosion. Do not dispose of batteries in a fire. Batteries are explosive.
Safety Rules & General Information Before You Begin • Contact the local inspector or city hall to be aware 1. National Fire Protection Association (NFPA) 70: The NATIONAL ELECTRIC CODE (NEC) * of all federal, state, and local codes which could impact installation. Secure all required permits before installing. 2. NFPA 10: Standard for Portable Fire Extinguishers * • Carefully read and follow all procedures and safety 4.
Unpacking and Inspection Section 2: Unpacking and Inspection General NOTE: Carefully inspect the contents for damage after unpacking. Unpack and inspect the unit immediately upon delivery to identify any damage which 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 1. Remove outer shipping carton. 2. See Figure 2-1.
Unpacking and Inspection 6. See Figure 2-3. Remove bolts and pallet brackets (A). Exercise caution when removing the generator. Do not drag unit off pallet. Doing so will damage the base. The generator must be lifted from the wooden pallet to remove. 7. See Figure 2-4. Two locks (A) secure the lid; one on each side. Press down on the lid above the side lock, and unlock the latch to properly open the lid.
Unpacking and Inspection Intake Side Panel Removal 3. Lift intake panel up and away from the generator. 4. Perform a visual inspection for any hidden freight damage. Contact the freight carrier if damage is present. 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 intake side panel straight up before pulling away from enclosure. Do not pull panel away from enclosure before lifting up (D). 1.
Unpacking and Inspection Generator Main Line Circuit Breaker Parts Shipped Loose See Figure 2-8. The 2-pole circuit breaker (generator disconnect) (A) is rated according to relevant specifications. A E B C D 001803 B A 001810 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).
Unpacking and Inspection Auxiliary Shutdown Switch CAUTION Equipment Damage. The auxiliary shutdown switch is not to be used to power down the unit under normal operating circumstances. Doing so will result in equipment damage. (000399) All generators are equipped with an external means of shutting down the generator which complies with the latest NEC code requirement. The primary generator shutdown sequence is described in Control Panel StartUp/Testing. See Figure 2-10.
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Site Selection and Preparation Section 3: Site Selection and Preparation Site Selection C D B 3 ft* (0.91 m) E 5 ft (1.52 m) 5 ft (1.52 m) 3 ft* (0.91 m) A B 3 ft (0.91 m) B F 001751 G D 001789 Figure 3-1. Installation Clearances ID Description A Top of generator — B Front and end clearance Minimum clear distances cannot include shrubs, bushes, or trees. * See IMPORTANT NOTE on next page.
Site Selection and Preparation See Figure 3-1. Install the generator set, in its protective enclosure, outdoors where adequate cooling and ventilating air is always available. Consider these factors: • The installation of the generator must comply strictly with ICC IFGC, 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 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 frequently available for installation, it has become apparent that exception (2) would be beneficial for many residential and commercial installations.
Site Selection and Preparation Material Sufficient for Level Installation See Figure 3-3. Prepare a rectangular area approximately 5 in (127 mm) deep (A) and approximately 6 in (152 mm) longer and wider (B) than the footprint of the generator. Verify the surface where the generator will be mounted is compacted, leveled, and will not erode over time. A concrete pad can be poured if desired or required. B A 000856 Figure 3-3.
Generator Placement Section 4: Generator Placement Generator Placement See Figure 4-1. 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. See Figure 4-2. Three mounting holes are available if codes require securing the generator to the concrete. The mounting holes are located inside the generator compartment—two at the front and one in back.
Generator Placement Fascia Installation (If Applicable) • Locate the four threaded black rubber bumpers supplied with the loose parts. (See Parts Shipped Loose.) • See Figure 4-3. Remove the bumpers from the bag and screw them into threaded holes located inside the end pieces of the fascia (two each) opposite one another (A). B A C 000614 Figure 4-3. Fascia Installation • Snap one of the end pieces into one of the front/ rear pieces of fascia.
Fuel Conversion / Gas Connections Section 5: Fuel Conversion / Gas Connections Fuel Requirements and Recommendations 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) NOTE: Natural gas is lighter than air and will collect in high areas. LP gas is heavier than air and will settle in low areas. LP gas should only use a vapor withdrawal system.
Fuel Conversion / Gas Connections Fuel Consumption Table 5-1. Fuel Consumption Chart Generator Natural Gas Propane 1/2 Load Full Load 1/2 Load Full Load 9 kW 2.55 / 90 3.40 / 120 0.87 / 3.29 / 32 1.37 / 5.20 / 50 11 kW 3.03 / 107 4.50 / 159 1.22 / 4.62 / 44 1.97 / 7.45 / 72 16 kW 6.17 / 218 8.75 / 309 2.03 / 7.70 / 74 2.94 / 11.11 / 107 20 kW 5.78 / 204 8.52 / 301 2.37 / 8.99 / 87 3.56 / 13.48 / 130 22 kW 6.46 / 228 9.26 / 327 2.53 / 9.57 / 92 3.90 / 14.
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 feet / meters) 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 Fuel Lines . 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 Fuel Line Connections Perform Leak Test Check Fuel Pressure 1. Check fuel pressure at the regulator in the generator by following these steps. • Close fuel supply valve. • Remove the top fuel pressure test port from the regulator (see Figure 5-4) and install the fuel pressure tester (manometer). • Open the fuel supply valve and verify the pressure is within the specified values. • Record static fuel pressure: DANGER Explosion and fire.
Fuel Conversion / Gas Connections Natural Gas Vapor Installation (Typical) F B A C J G E D H L K 001808 NG BTU/h = ft3/h X 1000 Megajoules/h = m3/h X 37.
Fuel Conversion / Gas Connections LP Vapor Installation (Typical) F G B A C J K M E D H L 001809 LP BTU/h = ft3/h X 2500 Megajoules/h = m3/h X 93.
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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 B A C1 1 1 1 0 1 DC GROUND 2 194 2 2 0 1 1 DC GROUND 2 194 1 1 2 N1 UTILITY SENSE N2 3 T1 VAC LOAD 3 SUPPLY 2 + 12 VDC 3 23 3TRANSFER E1 C2 N1 UTILITY SENSE N2 E2 2 + 12 VDC 2 3 23 3TRANSFER 3 T1 VAC LOAD 3 SUPPLY 005810 J H D F G Figure 6-1. Electrical Wiring Connections Table 6-1.
Electrical Connections . Table 6-4. Ground and Neutral Connections or Aluminum Conductors) (Copper Refer to national and/or local codes to verify correct wire sizes. Conductors of AC and DC circuits, rated 1000 volts nominal or less, shall be permitted to occupy the same equipment, cable, or conduit. All conductors shall have an insulation rating equal to at least the maximum circuit voltage applied to any conductor within the equipment, cable, or conduit. See NEC 300.3(C)(1). No.
Electrical Connections Battery Requirements Connect cables to battery posts as follows: 12 volts, Group 26R-540CCA minimum, or Group 35AGM-650CCA minimum. WARNING Explosion. Batteries emit explosive gases. Always connect positive battery cable first to avoid spark. Failure to do so could result in death or serious injury. (000133) NOTE: Do not use external battery chargers. Battery Installation WARNING Explosion. Batteries emit explosive gases while charging. Keep fire and spark away.
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 mode 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. 002227 - Enable Wi-Fi? Yes + Use arrow keys to either enable or disable Wi-Fi (if equipped). If YES, refer to the Wi-Fi manual. If NO, continue. 004498 Activate me (ENT) or ESC to run in manual Press ENTER to begin the activation process.
Control Panel Start-Up/Testing Table 7-1. Activation Chart Display Reads Troubleshooting Use arrow keys to scroll and find the first number of your activation code. Press ENTER to select. Repeat this step until all digits have been entered. Use ESCAPE to correct previous digits. Serial 123456789 Passcode XXXXX +/- 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 Setting The Exercise Timer This generator is equipped with a configurable exercise timer. There are two settings for the exercise timer: • Day/Time: The generator will start and exercise for the period defined, on the day of the week and at the time of day specified. During this exercise period the unit runs for five minutes on all models, and then shuts down. • Exercise frequency (how often the exercise will take place): Can be set to Weekly, Biweekly, or Monthly.
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.
36 YES or NO Æ ENTER - 14 + * Select Hour (0-23) Å Cold Smart Start? Fuel Selection + NG or LP - No + Yes or No - Setup Wi-Fi? ENTER + English + Espanol + Francais + Portuguese + ...... - Language Note: If language was previously programmed this goes directly to “Select Hour” Use UP and DOWN arrows. to select YES or NO. Press ENTER.
Installation Guidelines for 60 Hz Air-Cooled Generators ENTER SUB MENUS DATE/TIME * * Re-try using a higher quality USB drive. File names on the USB cannot have more than 8 characters. Possible Message(s): Corrupted File Invalid File File Not Found Unsupported Device* Switched to OFF Hours of Protection 0 (H) ENTER SETUP WIFI SYSTEM - 0 + Select Minute (0-59) ENTER ESC * ENTER ENTER * USB: X.XX Current: V X.XX * Install Wizard Set Exercise...
Control Panel Start-Up/Testing Check Manual Transfer Switch Operation DANGER Electrocution. High voltage is present at transfer switch and terminals. Contact with live terminals will result in death or serious injury. (000129) Refer to the Manual Transfer Operation section of the owner’s manual for procedures. Electrical Checks DANGER Electrocution. High voltage is present at transfer switch and terminals. Contact with live terminals will result in death or serious injury.
Control Panel Start-Up/Testing 8. Verify gas pressure while running. Record running gas pressure:________ 9. Set the generator main line circuit breaker (generator disconnect) to ON (CLOSED). Loads are now powered by the standby generator. 10. Turn on the circuit breakers/electrical loads to be powered by the generator one by one. 11. Connect a calibrated AC voltmeter and a frequency meter across terminal lugs E1 and E2. Voltage should be approximately 240 volts and frequency should be approximately 60 Hz.
Control Panel Start-Up/Testing Shutting Generator Down While Under Load Or During A Utility Outage 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) IMPORTANT NOTE: To avoid equipment damage, follow these steps, in order, during utility outages. Shutdowns may be required during utility outages to perform routine maintenance or to conserve fuel. To turn the generator OFF: 1.
Troubleshooting Section 8: Troubleshooting Generator Troubleshooting Problem Engine will not crank. Engine cranks but will not start. Engine starts hard and runs rough. Generator is set to OFF, but the engine continues to run. No AC output from generator. Cause Correction Blown fuse. Correct short circuit condition by replacing 7.5 A fuse in generator control panel. Contact an Independent Authorized Service Dealer (IASD) if fuse continues to blow. Loose, corroded, or faulty battery cables.
Troubleshooting Problem No transfer to standby after utility source failure. Unit consumes large amounts of oil. Wi-Fi network connection broken or intermittent Cause Correction MLCB (generator disconnect) is OFF (OPEN). Reset generator disconnect to ON (CLOSED). Faulty transfer switch coil Contact an IASD for assistance Faulty transfer relay. Contact an IASD for assistance Transfer relay circuit open. Contact an IASD for assistance Faulty control logic board.
Quick Reference Guide Section 9: Quick Reference Guide System Diagnosis To clear an active alarm, press the ENTER button twice and then press AUTO. If the alarm reoccurs, contact an Independent Authorized Service Dealer (IASD). Table 9-1. System Diagnosis Active Alarm NONE LED Problem FLASHING Unit running in AUTO but GREEN no power in house. Things to Check Solution Check MLCB (generator disconnect). Check MLCB. If it is ON, contact an IASD.
Quick Reference Guide Table 9-1. System Diagnosis (Continued) Active Alarm LED Problem Things to Check Solution MISWIRE RED Unit will not start in AUTO with utility loss. Check the LED’s / Screen for alarms. Contact an IASD. OVERVOLTAGE RED Unit will not start in AUTO with utility loss. Check the LED’s / Screen for alarms. Contact an IASD. AUXILIARY SHUTDOWN RED Unit will not start. Check the auxiliary Set auxiliary shutdown switch(es) to shutdown switch(es). CLOSED (I).
Accessories Section 10: Accessories Performance enhancing accessories are available for air-cooled generators. Accessory Description Cold Weather Accessories*— • Battery Pad Warmer • 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 (10000010258 rev B—1 of 2) MOUNTING TO CONCRETE PAD HOLE LOCATIONS FOR OPTIONAL MOUNTING TO A CONCRETE PAD 521 [20.5] 16 [5/8] DIA. CLEARANCE HOLE (3) PLACES, 10 [3/8] DIA. MASONRY ANCHOR BOLTS RECOMMENDED 768 [30.2] 679 [26.8] 197 [7.7] 393 [15.5] 68 [2.7] 849 [33.4] FRONT OF UNIT 267 [10.5] 356 [14.
Diagrams Installation Drawing (10000010258 rev B—2 of 2) AIR INTAKE 457 [18.0] MINIMUM OPEN AREA 914 [36.0] MINIMUM OPEN AREA AIR INTAKE AIR OUTLET 914 [36.0] MINIMUM OPEN AREA TOP VIEW 914 [36.0] MINIMUM OPEN AREA "DO NOT LIFT BY ROOF" LIFTING HOLES 4 CORNERS: 30 [ 1.2] - MUST BE LIFTED WITH STEEL RODS - RECOMMENDED LIFTING ROD SIZE: 25 [ RIGHT VIEW INTAKE PANEL REMOVED 1.0] 1218 [48.0] 127 [5.0] GRAVEL PAD/ COMPACTED SOIL 48 1232 [48.
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Generac Power Systems, Inc. S45 W29290 Hwy 59 Waukesha, WI 53187 ©Generac Power Systems, Inc. All rights reserved. Specifications subject to change without notice. honeywellgenerators.com The Honeywell trademark is used under license from Honeywell International Inc. Honeywell International Inc. makes no representation or warranties with respect to this product. This product is manufactured by Generac Power Systems, Inc., Waukesha, WI 53189, USA.
8 7 6 5 4 3 SH 1/1 REV B WINDCHILL VERSION 1 B.15 AIR INTAKE 457 [18.0] MINIMUM OPEN AREA MOUNTING TO CONCRETE PAD 914 [36.0] MINIMUM OPEN AREA D D HOLE LOCATIONS FOR OPTIONAL MOUNTING TO A CONCRETE PAD 16 [5/8] DIA. CLEARANCE HOLE (3) PLACES, 10 [3/8] DIA. MASONRY ANCHOR BOLTS RECOMMENDED 768 [30.2] AIR INTAKE AIR OUTLET 521 [20.5] 679 [26.8] 914 [36.0] MINIMUM OPEN AREA 197 [7.7] 393 [15.5] 68 [2.7] TOP VIEW 914 [36.0] MINIMUM OPEN AREA 849 [33.
