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Installation Guidelines
PWRgenerator™ Air-Cooled Generators
9 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)
Register your Generac product at:
WWW.GENERAC.COM
1-888-GENERAC
(888-436-3722)
SAVE THIS MANUAL FOR FUTURE REFERENCE
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Table of Contents
Related Manuals for Generac Power Systems PWRgenerator 9 kW
Summary of Contents for Generac Power Systems PWRgenerator 9 kW
- Page 1 ® Installation Guidelines PWRgenerator™ Air-Cooled Generators 9 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) Register your Generac product at: WWW.GENERAC.COM 1-888-GENERAC...
- Page 2 Use this page to record important information about this generator. Record the information found on the unit data label on this page. For the location of the unit data label, see the owner’s Model: manual. The unit has a label plate affixed to the inside parti- tion, to the left of the control panel console.
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Page 3: Table Of Contents
Table of Contents Section 1: Safety Rules & General Proximity to Utilities ..........14 Information Transportation Recommendations ......15 Introduction ..............1 Suitable Mounting Surface ........15 Read This Manual Thoroughly ........1 Placement on Roofs, Platforms, and Other Safety Rules ..............1 Supporting Structures ..........15 How to Obtain Service ..........2 General Hazards ............2 Section 4: Generator Placement... - Page 4 Table of Contents Section 7: Control Panel Startup / Testing Control Panel Interface ..........31 Using the AUTO/MANUAL/OFF Buttons ....31 Generator Setup ............31 Activation ..............31 Setting The Exercise Timer ........33 Before Initial Startup ..........33 Install Wizard ............33 Commissioning with PWRcell ........
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Page 5: Section 1: Safety Rules & General Information
Safety Rules & General Information Section 1: Safety Rules & General Information Introduction Safety Rules Thank you for purchasing this PWRgenerator, a compact, The manufacturer cannot anticipate every possible high performance, air-cooled, engine-driven generator. It circumstance that might involve a hazard. The alerts in is designed to automatically supply direct current (DC) this manual, and on tags and decals affixed to the unit, electrical power to the Generac PWRcell Clean Energy... -
Page 6: How To Obtain Service
Safety Rules & General Information How to Obtain Service WARNING When the unit requires servicing or repairs, contact Gen- erac Customer Service at 1-888-GENERAC (1-888-436- Electric shock. Only a trained and licensed electrician should perform wiring and connections to unit. Failure to 3722) or visit www.generac.com for assistance. -
Page 7: Exhaust Hazards
Safety Rules & General Information • Inspect generator regularly, and contact the near- est IASD for parts needing repair or replacement. DANGER Electrocution. Do not wear jewelry while Exhaust Hazards working on this equipment. Doing so will result in death or serious injury. DANGER (000188) Asphyxiation. -
Page 8: Explosion Hazards
Safety Rules & General Information WARNING WARNING Risk of Fire. Unit must be positioned in a Explosion. Do not dispose of batteries in a fire. Batteries are explosive. Electrolyte solution can cause manner that prevents combustible material burns and blindness. If electrolyte contacts skin or eyes, accumulation underneath. -
Page 9: General Rules
Safety Rules & General Information General Rules • Verify capacity of NG meter or LP tank in regards to providing sufficient fuel for both the unit and other household and operating appliances. DANGER Standards Index Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. - Page 10 Safety Rules & General Information This list is not all-inclusive. Check with the Authority Hav- ing Local Jurisdiction (AHJ) for any local codes or stan- dards which may be applicable to your jurisdiction. The above listed standards are available from the following internet sources: www.nfpa.org www.iccsafe.org...
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Page 11: Section 2: Unpacking And Inspection
Unpacking and Inspection Section 2: Unpacking and Inspection General Unpacking Proceed as follows to unpack unit: NOTE: Carefully inspect contents for damage after unpacking. Unpack and inspect unit immediately upon 1. Remove outer shipping carton. delivery to identify any damage which may have occurred 2. -
Page 12: Opening The Lid
Unpacking and Inspection Front Access Panel Removal IMPORTANT NOTE: DO NOT perform next step until generator has been transported to installation site. Figure 2-5. Remove front access panel (A) by lifting it straight up and out once lid is open. 4. -
Page 13: Intake Side Panel Removal
Unpacking and Inspection Customer Connections and Loose Intake Side Panel Removal Parts Figure 2-6. Intake side panel (C) must be removed to access battery compartment, solenoid valve assembly, Figure 2-7 Figure 2-8 for customer connections and sediment trap. and loose parts location. Figure 2-10 illustrates parts shipped loose. -
Page 14: Generator Main Line Circuit Breaker (Generator Disconnect)
Unpacking and Inspection Generator Main Line Circuit Breaker Auxiliary Shutdown Switch (Generator Disconnect) CAUTION Figure 2-9. The 2-pole main line circuit breaker (MLCB) (generator disconnect) (A) is rated according to Equipment Damage. The auxiliary shutdown switch relevant specifications. is not to be used to power down the unit under normal operating circumstances. -
Page 15: Section 3: Site Selection And Preparation
Site Selection and Preparation Section 3: Site Selection and Preparation Site Selection Carbon Monoxide Site selection is critical for safe generator operation. It is DANGER important to discuss these factors with the installer when selecting a site for generator installation: Asphyxiation. -
Page 16: Potential Co Entry Points
Site Selection and Preparation Potential CO Entry Points Protect the Structure Verify structure itself is correctly caulked and sealed to Figure 3-1. Generator exhaust can enter a structure prevent air from leaking in or out. Voids, cracks, or open- through large openings, such as windows and doors. ings around windows, doors, soffits, pipes, and vents can However, exhaust and CO can also seep into the struc- allow exhaust gas to be drawn into the structure. -
Page 17: Fire Prevention
Site Selection and Preparation Fire Prevention The generator must be installed at a safe distance away Distance Requirements from combustible materials. Engine, alternator, and Figure 3-2. Minimum clearances must be main- exhaust system components become very hot during tained around the generator enclosure. These clear- operation. -
Page 18: Fire Codes, Standards, And Guidelines
Site Selection and Preparation Fire Codes, Standards, and Guidelines Generator Maintenance Generator installation must comply strictly with ICC Regular maintenance is crucial for minimizing exhaust IFGC, NFPA 37, NFPA 54, NFPA 58, and NFPA 70 stan- emissions and reducing the risk of fire or equipment fail- dards. -
Page 19: Transportation Recommendations
Site Selection and Preparation Transportation Recommendations Placement on Roofs, Platforms, and Other Supporting Structures Use a suitable cart or equipment to carry generator, including wooden pallet, to installation site. Place card- Where required to place generator on a roof, platform, board between cart and generator to prevent any dam- deck, or other supporting structure, generator must be age or scratches to generator. - Page 20 Site Selection and Preparation This page intentionally left blank. Installation Guidelines for PWRgenerator Air-Cooled Generators...
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Page 21: Section 4: Generator Placement
Generator Placement Section 4: Generator Placement Generator Placement Three mounting holes are available if codes require securing generator to concrete. Mounting holes are Figure 4-1. All air-cooled generators come with a located inside the generator compartment—two in front composite pad. This composite pad elevates the genera- and one in back. - Page 22 Generator Placement This page intentionally left blank. Installation Guidelines for PWRgenerator Air-Cooled Generators...
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Page 23: Section 5: Fuel Conversion / Gas Connections
Fuel Conversion / Gas Connections Section 5: Fuel Conversion / Gas Connections Fuel Requirements and Piping strength and connections should be given special consideration for installations in areas at risk for flooding, Recommendations tornadoes, hurricanes, earthquakes, unstable ground. DANGER IMPORTANT NOTE: Use an approved pipe sealant Explosion and fire. -
Page 24: Fuel Consumption
Fuel Conversion / Gas Connections Fuel Consumption Natural Gas* Propane** Generator 1/2 Load Full Load 1/2 Load Full Load 9 kW 1.5 / 51.6 2.5 / 88.9 0.5 / 2.0 / 20.0 0.9 / 3.4 / 33 * Natural gas is in m /h / ft ** Propane is in gal/h / L/h (LP) / ft /h (LPV) -
Page 25: Natural Gas Pipe Sizing
Fuel Conversion / Gas Connections Natural Gas Pipe Sizing To determine correct NG pipe size, find the kW rating of NOTE: See Table B.3.2 in NFPA 54 or Table A.2.2 in the generator in the left column, and trace to the right. The ICC IFGC, Equivalent Lengths of Pipe Fittings and number to the right is maximum length (measured in ft / Valves for the correct values to be added to overall fuel... -
Page 26: Installing And Connecting Fuel Lines
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: NG and LP gas are highly vola- tile substances. -
Page 27: Checking Fuel Line Connections
Fuel Conversion / Gas Connections Checking Fuel Line Connections Checking Fuel Pressure Proceed as follows to check fuel pressure at fuel solenoid valve in the generator. 1. Close fuel supply valve. 2. See Figure 5-3. Remove inlet side fuel pressure test port from fuel solenoid valve and install fuel pressure tester (manometer). -
Page 28: Natural Gas Installation (Typical)
Fuel Conversion / Gas Connections Natural Gas Installation (Typical) 013472 NG BTU/h = ft /h X 1000 Megajoules/h = m /h X 37.26 Fuel data decal Minimum distance from rear obstruction—see Distance Requirements Manual fuel shutoff valve (pressure port optional) Must be located no more than 6 ft (1.83 m) away from fuel inlet Pipe fittings (field supplied) Flexible fuel line... -
Page 29: Lp Gas (Vapor) Installation (Typical)
Fuel Conversion / Gas Connections LP Gas (Vapor) Installation (Typical) 013473 LPG BTU/h = ft /h X 2500 Megajoules/h = m /h X 93.15 Fuel data decal Minimum distance from rear obstruction—see Distance Requirements Manual fuel shutoff valve (pressure port optional) Must be located no more than 6 ft (1.83 m) away from fuel inlet. - Page 30 Fuel Conversion / Gas Connections This page intentionally left blank. Installation Guidelines for PWRgenerator Air-Cooled Generators...
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Page 31: Section 6: Electrical Connections
Electrical Connections Section 6: Electrical Connections Generator Connections Figure 6-1. The electrical wiring enclosure is located behind an access panel on intake end of unit. Remove intake side panel as directed in Intake Side Panel Removal, and then remove access panel. Connect wires according to diagram and tables. -
Page 32: Control Wiring
Electrical Connections Control Wiring 013305 Figure 6-1. Electrical Wiring Connections Table 6-3. REbus and Ground Connections Table 6-1. Electrical Wiring Connection Points (Copper Conductors) Description See national and/or local codes to verify correct wire sizes. Power lug RE+ Conductor Description Torque Spec Range Power lug RE-... -
Page 33: Main Dc Wiring
Electrical Connections Main DC Wiring Battery Installation NOTE: Main DC wiring must be in accordance with local jurisdiction and codes. See Article 215.12(C)(2) in the WARNING NEC for correct identification for DC Feeder conductors. Explosion. Batteries emit explosive gases while NOTE: Raceway connections to the generator must be charging. -
Page 34: Connecting The Battery
Electrical Connections Battery Disposal Connecting the Battery WARNING WARNING Explosion. Batteries emit explosive gases. Environmental Hazard. Always recycle batteries at an Always connect positive battery cable first to official recycling center in accordance with all local avoid spark. Failure to do so could result in laws and regulations. -
Page 35: Section 7: Control Panel Startup / Testing
Control Panel Startup / Testing Section 7: Control Panel Startup / Testing Control Panel Interface 1. The display interface will launch Install Wizard upon first power-up of the generator. The control panel interface is located under the enclo- 2. Follow on-screen instructions on generator along sure lid. - Page 36 Control Panel Startup / Testing Display Reads Troubleshooting Language English Use arrow keys to scroll to desired Language can be changed later using language. the EDIT menu. Press ENTER to select. 002227 Activate me (ENT) or ESC to run in manual If ESCAPE is pressed instead of ENTER, generator will only run in Press ENTER to begin...
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Page 37: Setting The Exercise Timer
Control Panel Startup / Testing Setting The Exercise Timer This generator is equipped with a configurable exercise timer. There are two settings for the exercise timer: • Day/Time: Generator will start and exercise for period defined, on day of week and at time of day specified. - Page 38 Control Panel Startup / Testing Note: If language was Power Up Unit previously programmed this goes directly to “Select Hour” FIRMWARE V X.XX UP ARROW = HARDWARE V X.XX Language DOWN ARROW = + English - Install Wizard + Espanol - + Francais - + Portuguese - Defaults to English.
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Page 39: Commissioning With Pwrcell
Control Panel Startup / Testing Commissioning with PWRcell 3. See Figure 7-6. Use up and down arrow buttons to configure PWRgenerator settings. Press center See documents included with PWRcell Inverter and button to select desired setpoint. See Table 2 PWRgenerator for complete system commissioning. PWRgenerator setting descriptions. -
Page 40: Enabling Pwrgenerator
Control Panel Startup / Testing Enabling PWRgenerator 2. Select “Enable” and press center button. Use right arrow key and press center button to confirm. Proceed as follows to enable PWRgenerator: 3. Verify on PWRgenerator device page PWRgenera- 1. Set generator MLCB (generator disconnect) to ON tor status reads “Standby.”... -
Page 41: Electrical Checks
Control Panel Startup / Testing Generator Tests Under Load 15. Turn off electrical loads when testing under load is complete. 16. Press generator OFF mode button. The engine will DANGER shut down. Electrocution. Do not manually transfer under load. 17. Set generator MLCB (generator disconnect) to Disconnect transfer switch from all power sources OFF (OPEN). -
Page 42: Checking Automatic Operation
Control Panel Startup / Testing The generator is ready for automatic operation. The 4. Verify generator MLCB (generator disconnect) and engine will crank and start when PWRcell Inverter calls PWRcell Inverter DC disconnect circuit breaker are for power generation. Choose PWRgenerator from PWR- OFF (OPEN). -
Page 43: Section 8: Troubleshooting
Troubleshooting Section 8: Troubleshooting Generator Troubleshooting Problem Cause Correction Correct short circuit condition by replacing 7.5 Blown fuse. A fuse in generator control panel. Contact an IASD if fuse continues to blow. Loose, corroded, or faulty battery cables. Engine will not crank Faulty starter contact. - Page 44 Troubleshooting Problem Cause Correction Excessive engine oil. Adjust oil to correct level. Faulty engine breather. Contact an IASD for assistance. Unit consumes See Engine Oil Requirements in owner’s large amounts of Incorrect type or viscosity of oil. manual. Damaged gasket, seal, or hose. Inspect for oil leaks.
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Page 45: Section 9: Quick Reference Guide
Quick Reference Guide Section 9: Quick Reference Guide System Diagnosis To clear an active alarm, press ENTER button twice and then press AUTO. If alarm reoccurs, contact an IASD. Active Alarm Problem Actions Solution FLASHING Unit running in AUTO but Check generator MLCB Check generator MLCB (generator NONE... - Page 46 Quick Reference Guide Active Alarm Problem Actions Solution Unit will not start in AUTO Check LED’s / Screen OVERVOLTAGE Contact an IASD. with utility loss. for alarms. AUXILIARY Check auxiliary Set auxiliary shutdown switch(es) to Unit will not start. SHUTDOWN shutdown switch(es).
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Page 47: Section 10: Accessories
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). • Recommended in areas where temperatures fall below 0 °F (-18 °C). •... - Page 48 Accessories This page intentionally left blank. Installation Guidelines for PWRcell Air-Cooled Generators...
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Page 49: Section 11: Diagrams
Diagrams Section 11: Diagrams Installation Drawing (A0001919138 rev A—1 of 2) MOUNTING TO CONCRETE PAD HOLE LOCATIONS FOR OPTIONAL MOUNTING TO A CONCRETE PAD [20.5] 16 [5/8] DIA. CLEARANCE HOLE (3) PLACES, 10 [3/8] DIA. MASONRY ANCHOR BOLTS RECOMMENDED [7.7] [15.5] [2.7] FRONT OF UNIT... -
Page 50: Installation Drawing (A0001919138 Rev A-2 Of 2)
Diagrams Installation Drawing (A0001919138 rev A—2 of 2) AIR INTAKE 457 [18.0] MINIMUM OPEN AREA 914 [36.0] MINIMUM OPEN AREA AIR OUTLET AIR INTAKE 914 [36.0] MINIMUM OPEN AREA TOP VIEW 914 [36.0] MINIMUM OPEN AREA "DO NOT LIFT BY ROOF" RIGHT VIEW INTAKE PANEL REMOVED LIFTING HOLES 4 CORNERS:... - Page 52 ©2022 Generac Power Systems, Inc. S45 W29290 Hwy. 59 All rights reserved. Waukesha, WI 53189 Specifications are subject to change without notice. 1-888-GENERAC (1-888-436-3722) No reproduction allowed in any form without prior written www.generac.com consent from Generac Power Systems, Inc.