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Generac Power Systems G007144 Installation Manuallines

50 hz air-cooled generator sets
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Installation Guidelines
50 Hz Air-Cooled Generator Sets
8 kVA to 13 kVA
Original Instructions
This product is not intended to
be used in a critical life support
application.
ISO000209b
Register your Generac product at:
www.activategen.com
1-262-953-5155
SAVE THIS MANUAL FOR FUTURE REFERENCE

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  • Page 1 Installation Guidelines 50 Hz Air-Cooled Generator Sets 8 kVA to 13 kVA Original Instructions This product is not intended to be used in a critical life support application. ISO000209b Register your Generac product at: www.activategen.com 1-262-953-5155 SAVE THIS MANUAL FOR FUTURE REFERENCE...
  • Page 2 Use this page to record important information about this generator set. Record the information found on the unit data label on this page. See Safety and Informational Decals for the location Model: of the unit data label. The unit has a label plate affixed to the inside partition as shown in Figure 1-1.
  • Page 3 S45 W29290 Hwy 59 Waukesha, WI 53189 USA Generac Power Systems, Inc. hereby declares that the machinery described below fulfils all the relevant provisions of the Machinery Directive 2006/42/EC. The Machinery also conforms to the relevant provisions of Outdoor Noise Directive 2000/14/EC (as amended by Directive 2005/88/EC) Notified body: SNCH, 2a, Kalchesbruck L –...
  • Page 4 Installation Guidelines For 50 Hz Air-Cooled Generator Sets...

  • Page 5: Table Of Contents

    Table of Contents Section 1: Safety Information Proximity to Utilities .......... 18 Verify Wi-Fi Range ............18 Introduction ............1 Transportation Recommendations ....19 Read This Manual Thoroughly ........1 Suitable Mounting Surface ....... 19 Safety Messages ..........1 Placement on Roofs, Platforms, and Other Safety and Informational Decals ......2 Supporting Structures ........
  • Page 6 Table of Contents Section 7: Control Panel Startup / Testing Control Panel Interface ........35 Using the Control Panel Interface ....35 Control Panel Setup ..........35 Activation ..............35 Cold Smart Start ............37 Setting The Exercise Timer ........37 Before Initial Startup .........37 Install Wizard ............

  • Page 7: Section 1: Safety Information

    Safety Information Section 1: Safety Information Introduction Safety Messages Thank you for purchasing this compact, high perfor- The manufacturer cannot anticipate every possible cir- mance, air-cooled, engine-driven generator set. It is cumstance that might involve a hazard. The alerts in this designed to automatically supply electrical power to oper- manual, and on tags and decals affixed to the unit, are ate critical loads during a mains (utility) power failure.

  • Page 8: Safety And Informational Decals

    Safety Information Safety and Informational Decals This unit is equipped with safety and informational decals displaying pictorial symbols. These symbols and decals are described below. Locations are identified in Figure 1-1. Contact an IASD for a replacement if a decal is missing, damaged, or illegible.
  • Page 9 Safety Information • Activation Activate the generator set before putting the unit into operation. • Read the manual for details. WWW.ACTIVATEGEN.COM • No User Serviceable Electricity is present at various locations inside this Parts enclosure. • This equipment is designed for automatic operation and may start at any time.
  • Page 10 Safety Information Figure 1-1. Safety and Informational Decals Installation Guidelines For 50 Hz Air-Cooled Generator Sets...

  • Page 11: General Safety

    Safety Information General Safety Comply with regulations the local Hot surface. Keep equipment away from agency for workplace health and combustible materials during operation. Do not safety has established. touch hot surfaces when operating equipment. After equipment shutdown, allow sufficient time ISO000538 for surfaces to cool prior to contact.

  • Page 12: Installation

    Safety Information Installation Installation must comply with all national and local electrical building Installation must always comply with codes. applicable codes, standards, laws, and regulations. ISO000218 ISO000190 Unit must be positioned in a manner that prevents combustible material Only a trained and licensed electrician accumulation underneath.

  • Page 13: Operation

    Safety Information Operation Do not wear jewelry when starting or operating this product. This product is not intended to be used in a critical life support application. ISO000115 ISO000209b Maintenance Hot surface. Keep equipment away from combustible materials during operation. Do not Batteries contain sulfuric acid and can touch hot surfaces when operating equipment.
  • Page 14 Safety Information Disconnect the negative battery cable, then the positive battery cable, when working on unit. ISO000130 Disconnect battery ground terminal before working on battery or battery wires. ISO000164 Always recycle batteries at an official recycling center in accordance with all local laws and regulations.

  • Page 15: Hot Surfaces

    Safety Information Hot Surfaces The enclosure provides protection against hot surfaces inside the generator set. Hot surfaces may be present if the generator set has been operating under a large load. Do not open the generator set enclosure while the generator set is running. ISO000533 The generator set enclosure provides protection against hot surfaces inside the enclosure.

  • Page 16: Before You Begin

    Safety Information Before You Begin 9. NFPA 110: Standard for Emergency and Standby Power Systems * • Incorrect installation can result in personal injury 10. NFPA 211: Standard for Chimneys, Fireplaces, and damage to the generator set. It may also result Vents, and Solid Fuel Burning Appliances * in the warranty being suspended or voided.

  • Page 17: 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. It is advised to unpack and inspect unit imme- 1. Remove outer shipping carton. diately upon delivery to detect any damage which may 2.

  • Page 18: Opening The Lid

    Unpacking and Inspection IMPORTANT NOTE: DO NOT perform this step until NOTE: Always verify side locks are unlocked before the generator set has been transported to the instal- attempting to lift the lid. lation site. See Transportation Recommendations. Enclosure Panel Removal 4.

  • Page 19: Intake Side Panel Removal

    Unpacking and Inspection Customer Connections and Loose Intake Side Panel Removal Parts Figure 2-6. Intake side panel (A) must be removed to access battery compartment, fuel regulator, and sedi- Figure 2-7 Figure 2-8 for customer connections ment trap. and loose parts location. Figure 2-10 illustrates parts shipped loose.

  • Page 20: Generator Set Main Line Circuit Breaker (Generator Set Disconnect)

    Unpacking and Inspection Generator Set Main Line Circuit Breaker (Generator Set Disconnect) Figure 2-9. This is a 2-pole main line circuit breaker (MLCB) (generator set disconnect) (A) rated according to relevant specifications. Indicator (B) Identifier—Green means OFF (OPEN). Red means ON (CLOSED). 006640 Figure 2-9.

  • Page 21: 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 set operation. It is important to discuss these factors with the installer Asphyxiating atmosphere. Carbon when selecting a site for generator set installation: monoxide, a colorless odorless poisonous •...

  • Page 22: Potential Co Entry Points

    Site Selection and Preparation Potential CO Entry Points Protect the Structure Figure 3-1. Generator set exhaust can enter a struc- Verify structure itself is correctly caulked and sealed to ture through large openings, such as windows and doors. prevent air from leaking in or out. Voids, cracks, or open- However, exhaust and CO can also seep into the struc- ings around windows, doors, soffits, pipes, and vents can ture through smaller, less obvious openings.

  • Page 23: Fire Prevention

    Site Selection and Preparation Fire Prevention The generator set must be installed at a safe distance Distance Requirements away from combustible materials. Engine, alternator, and Figure 3-2. Minimum clearances must be main- exhaust system components become very hot during tained around generator set enclosure. These clearances operation.

  • Page 24: Fire Codes, Standards, And Guidelines

    Site Selection and Preparation Fire Codes, Standards, and Guidelines Generator Set Maintenance Generator set 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 25: Transportation Recommendations

    Site Selection and Preparation Transportation Recommendations Placement on Roofs, Platforms, and Other Supporting Structures Use a suitable cart or equipment to carry the generator set, including wooden pallet, to the installation site. Place Where required to place generator on a roof, platform, cardboard between cart and generator set to prevent any deck, or other supporting structure, generator must be damage or scratches to generator set.
  • Page 26 Site Selection and Preparation This page intentionally left blank. Installation Guidelines For 50 Hz Air-Cooled Generator Sets...

  • Page 27: Section 4: Generator Set Placement

    Generator Set Placement Section 4: Generator Set Placement Generator Set Weight Generator Set Placement Figure 4-3. All air-cooled generator sets come with a 8 kVA 10 kVA 13 kVA composite pad. The composite pad elevates the genera- 154.7 kg (341 lb) 176.4 kg (389 lb) 192.8 kg (425 lb) tor set and helps prevent water from pooling around base.
  • Page 28 Generator Set Placement 005776 Figure 4-4. Mounting Hole Location Three M10 (or 3/8 in) lag bolts (not supplied) are recom- mended for securing generator set to a concrete pad. NOTE: The top of generator set carton has a template which can be used to mark concrete pad to pre-drill mounting holes.

  • Page 29: 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 and leak tested prior to initial startup in accordance with local codes, standards, and regulations.

  • Page 30: Fuel Consumption

    Fuel Conversion / Gas Connections Fuel Consumption Natural Gas Propane Generator Set Rating 1/2 Load Full Load 1/2 Load Full Load 8 kVA 2.21 / 78 3.62 / 128 3.29 / 0.87 / 0.89 6.16 / 1.63 / 1.68 10 kVA 3.51 / 124 5.30 / 187 4.79 / 1.26 / 1.30...

  • Page 31: Natural Gas Pipe Sizing

    Fuel Conversion / Gas Connections Natural Gas Pipe Sizing To determine correct NG pipe size, find the kVA rating of NOTE: See Table B.3.2 in NFPA 54 or Table A.2.2 in the the generator set in the left column, and trace to the right. ICC IFGC, Equivalent Lengths of Pipe Fittings and The number to the right is maximum length (measured in Valves for the correct values to be added to overall fuel...

  • Page 32: Installing And Connecting Fuel Lines

    Fuel Conversion / Gas Connections Installing and Connecting Fuel Lines Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. ISO000192 IMPORTANT NOTE: NG and LP gas are highly vola- tile substances. Strictly adhere to all safety proce- dures, codes, standards, and regulations.

  • Page 33: Checking Fuel Line Connections

    Fuel Conversion / Gas Connections Checking Fuel Line Connections Performing Fuel System Leak Test Checking Fuel Pressure Fuel and vapors are extremely Proceed as follows to check fuel pressure at the regulator flammable and explosive. No leakage in the generator: of fuel is permitted.

  • Page 34: Natural Gas Installation (Typical)

    Fuel Conversion / Gas Connections Natural Gas Installation (Typical) 008965 NG Megajoules/h = m /h X 37.26 BTU/h = ft /h X 1000 Fuel data decal Minimum distance from rear obstruction—see Distance Requirements Manual fuel shutoff valve (pressure port optional) Must be located no more than 1.83 m (6 ft) away from fuel inlet Pipe fittings Flexible fuel line...

  • Page 35: Lp Gas (Vapor) Installation (Typical)

    Fuel Conversion / Gas Connections LP Gas (Vapor) Installation (Typical) 008966 LPG Megajoules/h = m /h X 93.15 BTU/h = ft /h X 2500 Fuel data decal Minimum distance from rear obstruction—see Distance Requirements Manual fuel shutoff valve (pressure port optional) Must be located no more than 1.83 m (6 ft) away from fuel inlet.
  • Page 36 Fuel Conversion / Gas Connections This page intentionally left blank. Installation Guidelines For 50 Hz Air-Cooled Generator Sets...

  • Page 37: Section 6: Electrical Connections

    Electrical Connections Section 6: Electrical Connections Generator Set Connections NOTE: Only bare wire should be inserted into each ter- minal. Do not insert any wire insulation into terminals. NOTE: Damage caused by mis-wiring of interconnect wires is not warrantable. Installation must comply with all national and local electrical building codes.

  • Page 38: Control Wiring

    Electrical Connections Control Wiring 005967 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 Neutral lug Alternator winding junction Sense wire terminal block No service connections Ground stud —...

  • Page 39: Main Ac Wiring

    Electrical Connections Table 6-4. Ground and Neutral Connections (Copper or Aluminum Conductors) See national and/or local codes to verify correct wire sizes. Recommended Wire Size Description Tool Size Torque Spec Power wire (mains) terminals 2/0 to 8 AWG 3/16 in Hex Key 13.56 Nm (120 in-lb) Neutral lug terminal 2/0 to 8 AWG...

  • Page 40: Connecting The Battery

    Electrical Connections Strictly observe the following precautions when working on batteries. – ISO000535 • Do not place tools or metallic objects on top of bat- tery. • Remove all jewelry, including watches, rings, and other metal objects. 001832 001832 • Use tools with insulated handles.

  • Page 41: Section 7: Control Panel Startup / Testing

    Control Panel Startup / Testing Section 7: Control Panel Startup / Testing Control Panel Interface Control Panel Setup Figure 7-1. The control panel interface (A) is located Activation under the lid of the enclosure. Verify both left and right To activate the generator set, go to www.activate- side locks are unlocked before attempting to lift lid.
  • Page 42 Control Panel Startup / Testing Display Reads Troubleshooting Language English Use arrow keys to scroll to desired lan- Language can be changed later using guage. the EDIT menu. Press ENTER to select. 002227 Enable Wi-Fi? Use arrow keys to either enable or disable Wi-Fi (if equipped).

  • Page 43: Cold Smart Start

    Control Panel Startup / Testing Display Reads Troubleshooting Select Hour (0-23) - 6 + Activation is complete when this screen is displayed. Follow controller prompts to complete installation. 002231 Cold Smart Start NOTE: When using the Wi-Fi module, exercise time will be set at random.

  • Page 44: Install Wizard

    Control Panel Startup / Testing Install Wizard Figure 7-3 Figure 7-4. The Install Wizard imme- diately appears upon startup. It allows user to input gen- erator set settings. NOTE: Install Wizard will start every time AC and DC power are removed and reapplied to generator set. Interconnect System Self Test Feature This controller goes through a system self test at startup, which checks for mains voltage on DC circuits.
  • Page 45 Control Panel Startup / Testing Figure 7-3. Install Wizard Menu Map Installation Guidelines For 50 Hz Air-Cooled Generator Sets...
  • Page 46 Control Panel Startup / Testing Figure 7-4. Install Wizard Menu Map Installation Guidelines For 50 Hz Air-Cooled Generator Sets...

  • Page 47: Checking Manual Transfer Switch Operation

    Control Panel Startup / Testing Checking Manual Transfer Switch 8. Push MANUAL button on generator set control panel. Engine will crank and start. Record cranking Operation fuel pressure: ______________. 9. Allow engine to warm up for approximately five minutes to allow internal temperatures to stabilize. Do not manually transfer under load.

  • Page 48: Checking Automatic Operation

    Control Panel Startup / Testing 8. Allow engine to stabilize and warm up for a few 6. Turn off mains power supply to transfer switch minutes. using the means provided (such as a mains MLCB). 9. Verify fuel pressure while running. Record running fuel pressure: ___________.
  • Page 49 Control Panel Startup / Testing – Allow generator set to run for five minutes at no load. – After five minutes, use emergency stop button to shut down generator set. – Wait 15 minutes to allow internal temperature to stabilize. NOTE: Failure to follow this procedure may expose user to hot surfaces.
  • Page 50 Control Panel Startup / Testing This page intentionally left blank. Installation Guidelines For 50 Hz Air-Cooled Generator Sets...

  • Page 51: Section 8: Troubleshooting

    Troubleshooting Section 8: Troubleshooting Generator Set Troubleshooting Problem Cause Correction Engine will not crank Blown fuse. Correct short circuit condition by replacing 7.5 amp fuse in generator set control panel. Con- tact an IASD for assistance if fuse continues to blow.
  • Page 52 Troubleshooting Problem Cause Correction No transfer to standby Generator set MLCB (generator set Set generator set MLCB (generator set after mains power disconnect) is OFF (OPEN). disconnect) to ON (CLOSED). source failure Faulty transfer switch coil. Faulty transfer relay. Contact an IASD for assistance. Transfer relay circuit open.

  • Page 53: Section 9: Quick Reference Guide

    Quick Reference Guide Section 9: Quick Reference Guide Quick Reference Guide To clear an active alarm, press the OFF mode button and then the ENTER button on the control panel. Then press the AUTO mode button. If the alarm reoccurs, contact an IASD. Active Alarm Problem Action...
  • Page 54 Quick Reference Guide Active Alarm Problem Action Solution Unit will not start in AUTO Check LEDs / screen WIRING ERROR Contact an IASD. with mains power loss. for alarms. Unit will not start in AUTO Check LEDs / screen OVERVOLTAGE Contact an IASD.

  • Page 55: Section 10: Accessories

    Accessories Section 10: Accessories Performance enhancing accessories are available for air-cooled generator sets. Accessory Description Cold Weather Accessories*— • • Battery Pad Warmer Recommended in areas where temperatures fall below -18 °C (0 °F). (Not necessary for use with AGM-style batteries) •...
  • Page 56 Accessories This page intentionally left blank. Installation Guidelines For 50 Hz Air-Cooled Generator Sets...

  • Page 57: Section 11: Diagrams

    Diagrams Section 11: Diagrams Installation Drawing (10000010676—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] [2.7] [18.0] [15.5] FRONT OF UNIT -REMOVE FACTORY PLUGS AND DISCARD...

  • Page 58: Installation Drawing (10000010676-2 Of 2)

    Diagrams Installation Drawing (10000010676—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:...

  • Page 59: Wiring Diagram (10000007481-1 Of 6)

    Diagrams Wiring Diagram (10000007481—1 of 6) Installation Guidelines For 50 Hz Air-Cooled Generator Sets...

  • Page 60: Wiring Diagram (10000007481-2 Of 6)

    Diagrams Wiring Diagram (10000007481—2 of 6) Installation Guidelines For 50 Hz Air-Cooled Generator Sets...

  • Page 61: Wiring Diagram (10000007481-3 Of 6)

    Diagrams Wiring Diagram (10000007481—3 of 6) Installation Guidelines For 50 Hz Air-Cooled Generator Sets...

  • Page 62: Wiring Diagram (10000007481-4 Of 6)

    Diagrams Wiring Diagram (10000007481—4 of 6) Installation Guidelines For 50 Hz Air-Cooled Generator Sets...

  • Page 63: Wiring Diagram (10000007481-5 Of 6)

    Diagrams Wiring Diagram (10000007481—5 of 6) Installation Guidelines For 50 Hz Air-Cooled Generator Sets...

  • Page 64: Wiring Diagram (10000007481-6 Of 6)

    Diagrams Wiring Diagram (10000007481—6 of 6) Installation Guidelines For 50 Hz Air-Cooled Generator Sets...
  • Page 65 Diagrams This page intentionally left blank. Installation Guidelines For 50 Hz Air-Cooled Generator Sets...
  • Page 66 Diagrams This page intentionally left blank. Installation Guidelines For 50 Hz Air-Cooled Generator Sets...
  • Page 68 ©2021 Generac Power Systems, Inc. Generac Power Systems, Inc. All rights reserved. S45 W29290 Hwy. 59 Specifications are subject to change without notice. Waukesha, WI 53189 No reproduction allowed in any form without prior written 1-262-544-4811 consent from Generac Power Systems, Inc. www.generac.com...

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