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Installation Guidelines
60 Hz Air-Cooled Generators
7.5 kW PowerPact™
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 Generac product at:
WWW.GENERAC.COM
1-888-GENERAC
(888-436-3722)
WARNING
(000209b)
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Table of Contents
Related Manuals for Generac Power Systems PowerPact 7.5 kW
Summary of Contents for Generac Power Systems PowerPact 7.5 kW
- Page 1 Installation Guidelines 60 Hz Air-Cooled Generators 7.5 kW PowerPact™ 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...
- 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. The unit has a label plate affixed to the inside partition, Model: above the battery access panel as shown in Figure 2-2.
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Page 3: Table Of Contents
Table of Contents Section 1: Safety Rules & General Fuel Conversion ..........17 Information Fuel Consumption ..........18 Introduction ............1 Fuel Line Sizing ..........19 Read This Manual Thoroughly ........1 Natural Gas Pipe Sizing ..........19 Safety Messages ..........1 LP Vapor Pipe Sizing ..........19 How to Obtain Service ..........1 Summary ............ - Page 4 Table of Contents Section 9: Quick Reference Guide System Diagnosis ..........37 Section 10: Accessories Section 11: Diagrams Installation Drawing 10000022108-A, page 1 of 2 ..41 Installation Drawing 10000022108-A, page 2 of 2 ..42 Wiring Diagram 10000021282-A, page 1 of 4 ... 43 Wiring Diagram 10000021282-A, page 2 of 4 ...
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Page 5: Section 1: Safety Rules & General Information 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 WARNING DANGER Fire hazard. Do not obstruct cooling and Explosion and fire. Fuel and vapors are extremely ventilating airflow around the generator. Inadequate flammable and explosive. No leakage of fuel is ventilation could result in fire hazard, possible 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 comply with applicable codes, standards, laws and working on this equipment. Doing so will regulations. Failure to do so will result in death result in death or serious injury. -
Page 10: Before You Begin
Safety Rules & General Information Before You Begin National Fire Protection Association (NFPA) 70: The NATIONAL ELECTRIC CODE (NEC) * • Contact the local inspector or City Hall to be aware NFPA 10: Standard for Portable Fire Extinguishers * of all federal, state and local codes which could impact the installation. -
Page 11: Section 2: Unpacking And Inspection
Unpacking and Inspection Section 2: Unpacking and Inspection General Unpacking 1. Remove cardboard carton. NOTE: After unpacking, carefully inspect the contents for damage. It is advised to unpack and inspect the unit 2. If equipped, the optional transfer switch will be immediately upon delivery to detect any damage which visible on top of the generator. - Page 12 Unpacking and Inspection 005568 Figure 2-2. Features and Components Top Lid Auxiliary Engine Shutdown Front Panel (not shown) Switch Controller Lid Fuel Connection Hole Air Box Control Panel Data Label Spark Plug Circuit Breaker Battery Access Panel Exhaust Enclosure Customer Connection Box Oil Drain Hose Alternator Main AC/Control Wiring Hole...
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Page 13: Parts Shipped Loose
Unpacking and Inspection Parts Shipped Loose Figure 2-3. Parts shipped loose are located in a clear plastic bag inside the unit, in front of the engine or under the alternator. The flex fuel line (A) is tied to either the battery wires or the alternator can. •... - Page 14 Unpacking and Inspection This page intentionally left blank. Installation Guidelines for 60 Hz PowerPact™...
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Page 15: 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 16: Installation Guidelines For Stationary Air-Cooled Generators
Site Selection and Preparation Install the generator set, in its protective enclosure, – Install the generator as close as possible to the outdoors where adequate cooling and ventilating air is transfer switch. REMEMBER: LAWS OR CODES always available (Figure 3-1). Consider these factors: MAY REGULATE THE DISTANCE AND LOCATION. -
Page 17: Site Preparation
Site Selection and Preparation Site Preparation materials, and the results and conclusions from the independent testing lab indicated that any fire within the • Locate the mounting area as close as possible to generator enclosure would not pose any ignition risk to the transfer switch and fuel supply. -
Page 18: Transportation Recommendations
Site Selection and Preparation Transportation Recommendations 1. 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. -
Page 19: Section 4: Generator Placement
Generator Placement Section 4: Generator Placement Generator Placement NOTE: The top of the generator carton has a template which can be used to mark the concrete pad to pre-drill This generator comes with two composite pads. These the mounting holes. composite pads elevate the generator and help prevent water from pooling around the bottom of the generator (Figure... - Page 20 Generator Placement This page intentionally left blank. Installation Guidelines for 60 Hz PowerPact™...
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Page 21: 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 when installation takes place in areas at Recommendations risk for; flooding, tornadoes, hurricanes, earthquakes, and unstable ground. DANGER IMPORTANT NOTE: Use an approved pipe sealant or Explosion and fire. -
Page 22: Fuel Consumption
Fuel Conversion/Gas Connections Fuel Consumption Generator Natural Gas LP Vapor 1/2 Load Full Load 1/2 Load Full Load 6 / 7.5 kW 73 / 2.07 117 / 3.31 0.87 / 3.29 / 31.6 1.42 / 5.37 / 51.6 * Natural gas is in ft /h / cm ** LP is in gal/h / l/h / ft *** Values given are approximate. -
Page 23: Fuel Line Sizing
Fuel Conversion/Gas Connections Fuel Line Sizing Selecting the correct size fuel line is crucial to the proper IMPORTANT NOTE: The generator should be plumbed operation of the unit. directly from the source, not off the end of an existing low pressure system. -
Page 24: Installing And Connecting Gas Lines
Fuel Conversion/Gas Connections Installing and Connecting Gas Flexible Fuel Line Lines When connecting the gas line to the generator, use a listed assembly meeting the requirements of ANSI Both natural gas and LP vapor are highly combustible Z21.75/ CSA 6.27—Connectors for Outdoor Gas substances, so strict adherence to all safety procedures, Appliances and Manufactured Homes or AGA-approved codes, standards and regulations is essential. -
Page 25: Checking Gas Line Connections
Fuel Conversion/Gas Connections Checking Gas Line Connections 1. Remove top lid and rear panel. 2. Check for leaks by spraying all connection points with a non-corrosive gas leak detection fluid. You should not see the solution be blown away or form bubbles. - Page 26 Fuel Conversion/Gas Connections Natural Gas Vapor Installation (typical) 006457 NG BTU = ft /h X 1000 Megajoules = m /h X 37.26 Sediment Trap Flexible Fuel Line Manual Shut Off Valve With Pressure Port BTU and Pressure Decal Check Distance with Gas Provider Fuel Pressure: 5–7 in.
- Page 27 Fuel Conversion/Gas Connections LP Vapor Installation (typical) 006458 LP BTU = ft /h X 2500 Megajoules = m /h X 93.15 Sediment trap BTU and pressure decal Minimum distance from side obstruction—see Site Selection Flexible fuel line Manual shutoff valve (pressure port optional) Check distance with gas provider Reinforcing rod Clamp...
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Page 29: Section 6: Electrical Connections
Electrical Connections Section 6: Electrical Connections Control Wiring 1. Remove the plug from the field connection box. 2. Remove the two hex socket screws to remove the electrical access panel. The access panel will hang Control Wire Recommended Length and Size off of the grounding wire. -
Page 30: Main Ac Wiring
Electrical Connections Main AC Wiring JUNCTION BOX JUNCTION BOX CUSTOMER SUPPLIED OMER SUPPLIED GENER GENERATOR CUS OR CUSTOMER OMER CONNECTION CONNECTION 8 CIRCUI 8 CIRCUIT T TRANSFER SWITCH TRANSFER SWITCH N1 N2 50A 2-POLE 2-POLE CIRCUI CIRCUIT 100A OR 200 OR 200A BREAKER BREAKER... -
Page 31: Battery Requirements
Electrical Connections Battery Requirements WARNING Group U1, 12V, minimum 300 CCA (Generac Part No. Explosion. Batteries emit explosive gases. 0D4575). Always connect positive battery cable first to avoid spark. Failure to do so could result in Battery Installation death or serious injury. (000133) WARNING 4. -
Page 32: Battery Disposal
Electrical Connections 001134 Figure 6-4. Battery Installation 8. Install the 7.5A fuse in the generator control panel. 9. Assemble the battery access panel with the two hex head screws and tighten securely. 10. Assemble the front door by hooking it to the base and aligning the slots to the hooks on the top of the enclosure. -
Page 33: Section 7: Control Panel/Start-Up/Testing
Control Panel/Start-Up/Testing Section 7: Control Panel/Start-Up/Testing Control Panel Interface Control Panel The Control Panel is located under the Controller Lid. DANGER Open the Controller Lid to access the control panel (F in Figure 2-2). Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. -
Page 34: Generator Set-Up
Control Panel/Start-Up/Testing Generator Set-Up Before Initial Start-Up When battery power is applied to the generator during NOTE: These units have been run and tested at the the installation process, the controller will light up. factory prior to being shipped. However, the generator still needs to be activated before it will automatically run in the event of a power outage. -
Page 35: Before Starting, Complete The Following
Control Panel/Start-Up/Testing Check Manual Transfer Switch Before starting, complete the following: Operation 1. Verify generator is OFF. 2. Set the generator main circuit breaker to OFF or Refer to the “Manual Transfer Operation” section of the OPEN. Owner’s Manual for procedures. 3. -
Page 36: Generator Tests Under Load
Control Panel/Start-Up/Testing 10. Connect accurate AC voltmeter 9. Connect a calibrated AC voltmeter and a frequency frequency meter across transfer switch terminal meter across terminal lugs E1 and E2. Voltage lugs E1 and E2. At no load, voltage should be 236– should be approximately 240 volts and frequency 240 at a frequency of 62–63 Hz. -
Page 37: Installation Summary
Control Panel/Start-Up/Testing With the generator running and loads powered by 1. Install 7.5A fuse in controller. generator AC output, turn ON the utility power supply to 2. Confirm the generator MLCB (generator disconnect) the transfer switch. The following should occur: is OFF (OPEN). - Page 38 Control Panel/Start-Up/Testing This page intentionally left blank. Installation Guidelines for 60 Hz PowerPact™...
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Page 39: Section 8: Troubleshooting
Troubleshooting Section 8: Troubleshooting Troubleshooting Guide Problem Cause Correction Engine will not crank. 1. Fuse blown. 1. Correct short circuit condition by replacing 7.5 A fuse in generator control panel. 2. Loose, corroded or defective battery 2. Tighten, clean or replace as necessary.* cables. - Page 40 Troubleshooting This page intentionally left blank. Installation Guidelines for 60 Hz PowerPact™...
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Page 41: Section 9: Quick Reference Guide
Quick Reference Guide Section 9: Quick Reference Guide System Diagnosis To clear an active alarm, press the OFF button twice and then press AUTO. If the alarm reoccurs, contact an Independent Authorized Service Dealer (IASD). Table 9-1. System Diagnosis Active Alarm Problem Things to Check Solution... - Page 42 Quick Reference Guide Table 9-1. System Diagnosis (Continued) Active Alarm Problem Things to Check Solution 1 YEAR / 100 Control panel indicates None Perform scheduled maintenance. Clear Maintenance HOUR scheduled maintenance Due light. MAINTENANCE due.LED illuminates. NONE Utility present. Generator Check utility sense Contact IASD.
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Page 43: Section 10: Accessories
Accessories Section 10: Accessories Performance enhancing accessories are available for air-cooled generators. Accessory Description Cold Weather Kit Recommended in areas where temperatures fall below 32 ºF (0 ºC). G006808-1 Scheduled Maintenance Kit Includes all pieces necessary to perform maintenance on the generator along G006806-0 with oil recommendations. - Page 44 Accessories This page intentionally left blank. Installation Guidelines for 60 Hz PowerPact™...
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Page 45: Section 11: Diagrams
Diagrams Section 11: Diagrams Installation Drawing 10000022108-A, page 1 of 2 WINDCHILL VERSION HOLE LOCATIONS FOR OPTIONAL MOUNTING TO A CONCRETE PAD 63.5 266.4 5/16 DIA MASONRY ANCHOR [2.5] [14.6] [10.5] BOLTS RECOMMENDED (DO NOT REMOVE MOUNTING FEET DURING CONCRETE PAD INSTALLATION) 292.1 400.6 [11.5]... -
Page 46: Installation Drawing 10000022108-A
Diagrams Installation Drawing 10000022108-A, page 2 of 2 WINDCHILL VERSION 457.2 [18.0] MINIMUM OPEN AREA AIR INLET 914 [36.0] MINIMUM OPEN AREA AIR OUTLET AIR INLET 914 [36.0] MINIMUM OPEN AREA 914 [36.0] MINIMUM OPEN AREA AUXILIARY SHUTDOWN SWITCH & DECAL FUEL INLET (3/4"... -
Page 47: Wiring Diagram 10000021282-A, Page 1 Of 4
Diagrams Wiring Diagram 10000021282-A, page 1 of 4 GROUP G WIRING - DIAGRAM REVISION: A 7.5KW AC POWER PACT 60HZ W/ AUX DRAWING #: 10000021282 09/08/17 PAGE 1 OF 4 Installation Guidelines for 60 Hz PowerPact™... -
Page 48: Wiring Diagram 10000021282-A
Diagrams Wiring Diagram 10000021282-A, page 2 of 4 GROUP G BATT LEGEND WIRING - DIAGRAM REVISION: A 7.5KW AC POWER PACT 60HZ W/ AUX DRAWING #: 10000021282 09/08/17 PAGE 2 OF 4 Installation Guidelines for 60 Hz PowerPact™... -
Page 49: Wiring Diagram 10000021282-A, Page 3 Of 4
Diagrams Wiring Diagram 10000021282-A, page 3 of 4 GROUP G SCHEMATIC - DIAGRAM REVISION: A 7.5KW AC POWER PACT 60HZ W/ AUX DRAWING #: 10000021282 09/08/17 PAGE 3 OF 4 Installation Guidelines for 60 Hz PowerPact™... -
Page 50: Wiring Diagram 10000021282-A, Page 4 Of 4
Diagrams Wiring Diagram 10000021282-A, page 4 of 4 GROUP G LEGEND SCHEMATIC - DIAGRAM REVISION: A 7.5KW AC POWER PACT 60HZ W/ AUX DRAWING #: 10000021282 09/08/17 PAGE 4 OF 4 Installation Guidelines for 60 Hz PowerPact™... - Page 52 ©2018 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.