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DR Power DR PRO-11KW Installation Manuallines

60hz air-cooled home standby generator
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Installation Guidelines

60 Hz Air-Cooled Generators
11 kW and 20 kW
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.
Register your DR Power Equipment
product at
www.drpower.com
1-855-447-3734
www.drpower.com/pages/content/customer-support/product-support
WARNING
(000209b)

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Summary of Contents for DR Power DR PRO-11KW

  • Page 1: Installation Guidelines

    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 DR Power Equipment product at www.drpower.com 1-855-447-3734 Para español , visita: www.drpower.com/pages/content/customer-support/product-support...
  • Page 2 Use this page to record important information about your generator set. Record the information found on your unit data label on this page. For the location of the unit data label, see your owner’s Model: manual. The unit has a label plate affixed to the inside partition, to the left of the control panel console.

  • Page 3: Table Of Contents

    Table of Contents Section 1: Safety Rules & General Section 4: Generator Placement Information Generator Placement ........17 Introduction ............1 Fascia Installation (If Applicable) ....18 Read This Manual Thoroughly ........1 Safety Messages ............1 Section 5: Fuel Conversion / Gas How to Obtain Service ..........1 Connections Safety Rules ............2...
  • Page 4 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 ........35 Installation Wizard ............. 35 Interconnect System Self Test Feature .....

  • Page 5: Introduction

    Safety Rules & General Information Section 1: Safety Rules & General Information Introduction DANGER Thank purchasing this compact, high Indicates a hazardous situation which, if not avoided, performance, air-cooled, engine-driven generator. It is will result in death or serious injury. designed to automatically supply electrical power to operate critical loads during a utility power failure.

  • Page 6: Safety Rules

    Safety Rules & General Information Safety Rules WARNING Study these SAFETY RULES carefully before installing, Equipment damage. Only qualified service personnel may operating, or servicing this equipment. Become familiar install, operate, and maintain this equipment. Failure to follow with this installation manual, the owner’s manual, and proper installation requirements could result in death, serious with the unit.

  • Page 7: Exhaust Hazards

    Safety Rules & General Information Electrical Hazards WARNING DANGER Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local Electrocution. Contact with bare wires, laws and regulations. Failure to do so could result in terminals, and connections while generator environmental damage, death or serious injury.

  • Page 8: Fire Hazards

    Safety Rules & General Information Fire Hazards Explosion Hazards DANGER WARNING Explosion and fire. Fuel and vapors are extremely Fire hazard. Do not obstruct cooling and flammable and explosive. No leakage of fuel is ventilating airflow around the generator. Inadequate permitted.

  • Page 9: Battery Hazards

    Safety Rules & General Information General Rules Battery Hazards DANGER DANGER Electrocution. Do not wear jewelry while Loss of life. Property damage. Installation must always working on this equipment. Doing so will comply with applicable codes, standards, laws and result in death or serious injury. regulations.

  • Page 10: Before You Begin

    Safety Rules & General Information Before You Begin 1. National Fire Protection Association (NFPA) 70: The NATIONAL ELECTRIC CODE (NEC) * • Contact the local inspector or city hall to be aware 2. NFPA 10: Standard for Portable Fire Extinguishers * of all federal, state, and local codes which could impact installation.

  • Page 11: Section 2: Unpacking And Inspection

    Unpacking and Inspection Section 2: Unpacking and Inspection General Unpacking 1. Remove outer shipping carton. NOTE: Carefully inspect the contents for damage after unpacking. Unpack and inspect the unit immediately 2. See Figure 2-1. Remove the wood frame. upon delivery to identify any damage which may have occurred in transit.
  • Page 12 Unpacking and Inspection 6. See Figure 2-3. Remove bolts and pallet brackets 7. See Figure 2-4. Two locks (A) secure the lid; one (A). Exercise caution when removing on each side. Press down on the lid above the side generator. Do not drag unit off pallet. Doing so will lock, and unlock the latch to properly open the lid.

  • Page 13: Intake Side Panel Removal

    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 Figure 2-5. The intake side panel (A) must be damage. Contact the freight carrier if damage is removed to access the battery compartment, fuel present.

  • Page 14: Generator Main Line Circuit Breaker

    Unpacking and Inspection Generator Main Line Circuit Breaker Parts Shipped Loose Figure 2-8. The 2-pole circuit breaker (generator disconnect) rated according relevant specifications. 001803 Keys 001810 Flexible fuel line Figure 2-8. Generator Main Line Circuit Breaker Battery terminal cap Rubber mounts (only for units including fascia) The breaker can be locked in the OFF (OPEN) position Fascia (if applicable) for security during maintenance or transfer switch...

  • Page 15: Auxiliary Shutdown Switch

    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.
  • Page 16 Unpacking and Inspection This page intentionally left blank. Installation Guidelines for 60 Hz Air-Cooled Generators...

  • Page 17: Section 3: Site Selection And Preparation

    Site Selection and Preparation Section 3: Site Selection and Preparation Site Selection 5 ft (1.52 m) 5 ft (1.52 m) 3 ft* 3 ft* (0.91 m) (0.91 m) 3 ft (0.91 m) 001751 001789 Figure 3-1. Installation Clearances Description Comments Top of generator —...

  • Page 18: Verify Wi-Fi Range

    Site Selection and Preparation • Figure 3-1. Install the generator set, in its protective Install the generator as close as possible to the fuel enclosure, outdoors where adequate cooling and supply to reduce the length of piping. REMEMBER ventilating air is always available. Consider these factors: THAT LAWS OR CODES MAY REGULATE THE DISTANCE AND LOCATION.

  • Page 19: Annex A - Explanatory Material

    Site Selection and Preparation Annex A — Explanatory Material DANGER A4.1.4 (2) Means of demonstrating compliance are by means of full scale fire test or by calculation procedures. Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Because of the limited spaces frequently available for Failure to do so will result in death or serious injury.

  • Page 20: Material Sufficient For Level Installation

    Site Selection and Preparation Material Sufficient for Level Installation Figure 3-3. Prepare 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.

  • Page 21: Section 4: Generator Placement

    Generator Placement Section 4: Generator Placement Generator Placement Figure 4-2. Three mounting holes are available if codes require securing the generator to the concrete. Figure 4-1. All air-cooled generators come with a The mounting holes are located inside the generator non-sinking direct to dirt (DTD) composite base pad.

  • Page 22: Fascia Installation (If Applicable)

    Generator Placement Fascia Installation (If Applicable) • Locate the four threaded black rubber bumpers supplied with the loose parts. (See Parts Shipped Loose.) • 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).

  • Page 23: Section 5: Fuel Conversion / Gas Connections

    Fuel Conversion / Gas Connections Section 5: Fuel Conversion / Gas Connections Fuel Requirements and IMPORTANT NOTE: Use an approved pipe sealant or joint compound on all threaded NPT fittings. Recommendations NOTE: All installed gaseous fuel piping must be purged DANGER and leak tested prior to initial start-up in accordance with local codes, standards, and regulations.

  • Page 24: Fuel Consumption

    Fuel Conversion / Gas Connections Fuel Consumption Table 5-1. Fuel Consumption Chart Natural Gas Propane Generator 1/2 Load Full Load 1/2 Load Full Load 11 kW 3.03 / 107 4.50 / 159 1.22 / 4.62 / 44 1.97 / 7.45 / 72 20 kW 5.78 / 204 8.52 / 301...

  • Page 25: Natural Gas Pipe Sizing

    Fuel Conversion / Gas Connections Natural Gas Pipe Sizing To determine correct gas pipe size, find the kW rating of NOTE: Add 2.5 ft (0.76 m) per any bend, tee, or angle in the generator in the left column, and trace to the right. the pipe to the overall distance.

  • 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: Natural gas and LP vapor are highly volatile substances.

  • Page 27: Checking Fuel Line Connections

    Fuel Conversion / Gas Connections Checking Fuel Line Connections Perform Leak Test Check Fuel Pressure DANGER 1. Check fuel pressure at the regulator in the Explosion and fire. Fuel and vapors are extremely generator by following these steps. flammable and explosive. No leakage of fuel is •...

  • Page 28: Natural Gas Vapor Installation (Typical)

    Fuel Conversion / Gas Connections Natural Gas Vapor Installation (Typical) 001808 NG BTU/h = ft /h X 1000 Megajoules/h = m /h X 37.26 Fuel data decal Minimum distance from rear obstruction—see Site Selection Manual shutoff valve (pressure port optional) Pipe nipple (field supplied) Flexible fuel line Check distance with gas provider...

  • Page 29: Lp Vapor Installation (Typical)

    Fuel Conversion / Gas Connections LP Vapor Installation (Typical) 001809 LP BTU/h = ft /h X 2500 Megajoules/h = m /h X 93.15 Fuel data decal Minimum distance from rear obstruction—see Site Selection Manual shutoff valve (pressure port optional) Pipe nipple (field supplied) Flexible fuel line Check distance with gas provider Reinforcing rod...
  • Page 30 Fuel Conversion / Gas Connections This page intentionally left blank Installation Guidelines for 60 Hz Air-Cooled Generators...

  • 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 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.

  • Page 32: Control Wiring

    Electrical Connections Control Wiring UTILITY SENSE GROUND + 12 VDC VAC LOAD SUPPLY TRANSFER GROUND UTILITY SENSE + 12 VDC VAC LOAD TRANSFER SUPPLY 005810 Figure 6-1. Electrical Wiring Connections Table 6-1. Electrical Wiring Connection Points Description Description Description Description Control wire terminal block Wire tie for control wires Power lug E2...

  • Page 33: Main Ac Wiring

    Electrical Connections Conductors of AC and DC circuits, rated 1000 volts Table 6-4. Ground and Neutral Connections nominal or less, shall be permitted to occupy the same (Copper or Aluminum Conductors) equipment, cable, or conduit. All conductors shall have an insulation rating equal to at least the maximum circuit Refer to national and/or local codes to verify correct wire sizes.

  • Page 34: Battery Requirements

    Electrical Connections Battery Requirements Connect cables to battery posts as follows: 12 volts, Group 26R-540CCA minimum, or Group WARNING 35AGM-650CCA minimum. Explosion. Batteries emit explosive gases. NOTE: Do not use external battery chargers. Always connect positive battery cable first to avoid spark.

  • Page 35: Section 7: Control Panel Start-Up/Testing

    Control Panel Start-Up/Testing Section 7: Control Panel Start-Up/Testing Control Panel Interface Activation To receive the activation code, you must have the unit DANGER serial number and go to: www.activategen.com. You can also receive an activation code by calling 1-888- Automatic start-up. Disconnect utility power and 9ACTIVATE (1-888-922-8482).
  • Page 36 Control Panel Start-Up/Testing Table 7-1. Activation Chart 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 Enable Wi-Fi? Use arrow keys to either enable or disable Wi-Fi.

  • Page 37: Cold Smart Start

    Control Panel Start-Up/Testing Table 7-1. Activation Chart Display Reads Troubleshooting Use arrow keys to What happens if “Wrong Passcode Try Serial 123456789 scroll and find the first Again” appears? Passcode XXXXX +/- number of your Re-enter the activation code. If a activation code.

  • Page 38: Setting The Exercise Timer

    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.

  • Page 39: Before Initial Start-Up

    Control Panel Start-Up/Testing Before Initial Start-up Before starting, complete the following: 1. Verify generator is OFF. NOTE: The unit has been run and tested at the factory 2. Set generator main circuit breaker to OFF (OPEN). prior to being shipped and does not require any type of 3.
  • Page 40 Control Panel Start-Up/Testing Figure 7-2. Installation Wizard Menu Map Installation Guidelines for 60 Hz Air-Cooled Generators...
  • Page 41 Control Panel Start-Up/Testing Figure 7-3. Installation Wizard Menu Map Installation Guidelines for 60 Hz Air-Cooled Generators...

  • Page 42: Check Manual Transfer Switch Operation

    Control Panel Start-Up/Testing Check Manual Transfer Switch 10. Connect a calibrated accurate AC voltmeter and a frequency meter across transfer switch terminal Operation lugs E1 and E2. Voltage should be 238–242V at a frequency of 59.5–60.5 Hz. If voltage is not correct, DANGER verify the generator main line circuit breaker (generator disconnect) is closed and verify AC...

  • Page 43: Checking Automatic Operation

    Control Panel Start-Up/Testing Checking Automatic Operation 8. Verify gas pressure while running. Record running gas pressure:________ Proceed as follows to check the system for proper 9. Set the generator main line circuit breaker automatic operation: (generator disconnect) to ON (CLOSED). Loads 1.

  • Page 44: Shutting Generator Down While Under Load Or During A Utility Outage

    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.

  • Page 45: Section 8: Troubleshooting

    Troubleshooting Section 8: Troubleshooting Generator Troubleshooting Problem Cause Correction Correct short circuit condition by replacing 7.5 A fuse in generator control panel. Contact an Blown fuse. Independent Authorized Service Dealer (IASD) if fuse continues to blow. Engine will not Loose, corroded, or faulty battery cables. Tighten, clean, or replace as necessary.* crank.
  • Page 46 Troubleshooting Problem 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 No transfer to standby after utility Transfer relay circuit open. Contact an IASD for assistance source failure.

  • Page 47: Section 9: Quick Reference Guide

    Quick Reference Guide Section 9: Quick Reference Guide System Diagnosis To clear an active alarm, press the OFF mode button on the control panel, then the ENTER button, and finally the UTO mode button. Contact an IASD if the alarm reoccurs. Table 9-1.
  • Page 48 Quick Reference Guide Table 9-1. System Diagnosis (Continued) Active Alarm Problem Things to Check Solution Unit will not start in Check the LED’s / MISWIRE Contact an IASD. AUTO with utility loss. Screen for alarms. Unit will not start in Check the LED’s / OVERVOLTAGE Contact an IASD.

  • Page 49: 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). (Not necessary for use with AGM-style batteries) •...
  • Page 50 Accessories This page intentionally left blank. Installation Guidelines for 60 Hz Air-Cooled Generators...

  • Page 51: Section 11: Diagrams

    Diagrams Section 11: Diagrams Installation Drawing (10000010256 rev B—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 [2.7] [7.7] [18.0] [15.5]...

  • Page 52: Installation Drawing (10000010256 Rev B-2 Of 2)

    Diagrams Installation Drawing (10000010256 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" RIGHT VIEW INTAKE PANEL REMOVED LIFTING HOLES 4 CORNERS:...
  • Page 53 Diagrams This page intentionally left blank. Installation Guidelines for 60 Hz Air-Cooled Generators...
  • Page 54 Diagrams This page intentionally left blank. Installation Guidelines for 60 Hz Air-Cooled Generators...
  • Page 56 Part No. 10000027522 Rev. A 05/18/18 ©2018 DR Power Equipment 75 Meigs Road All rights reserved Post Office Box 25 Specifications are subject to change without notice. Vergennes, Vermont 05491 No reproduction allowed in any form without prior written consent...

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