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Generac Power Systems 004988-4 Owner's Manual: Battery Installation; Preparation Before Start-up

Liquid-cooled, prepackaged standby generator.
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Control system interconnections consist of N1 and
N2, and leads 23 and 194. Control system intercon-
nection leads must be run in a conduit that is sepa-
rate from the AC power lead. Recommended wire
gauge sizes for this wiring depends on the length of
the wire, as recommended below:
460 feet (140m)
461 to 730 feet (223m)
731 to 1,160 feet (354m)
1,161 to 1,850 feet (565m)
If the generator is to be installed with an automatic
transfer switch, such as an engineered GTS-type
switch, it is necessary to connect the two-wire start
control system.
Connect the two-wire start signal from the automatic
transfer switch to the automatic start connection,
which is located in the middle, on the bottom, inside
the control panel. Match wires 178 and 183 in the
transfer switch to 178 and 183 on the terminal strip
in the control panel. The conductors for the two-
wire start circuit must be in their own conduit. (See
Section 3.1 for further explanation.)


Standby generators installed with automatic
transfer switches will crank and start automati-
cally when NORMAL (UTILITY) source voltage is
removed or is below an acceptable preset level.
To prevent such automatic start-up and possible
injury to personnel, ensure that the 15A and
4A fuses are removed from the control console,
the AUTO/OFF/MANUAL switch is set to OFF,
and the utility supply to the battery charger is
removed before removing or connecting battery
Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
around the battery for several hours after charg-
ing. The slightest spark can ignite the gas and
cause an explosion. Such an explosion can shat-
ter the battery and cause blindness or other
injury. Any area that houses a storage battery
must be properly ventilated. Do not allow smok-
ing, open flame, sparks or any spark producing
tools or equipment near the battery.
No. 18 AWG.
No. 16 AWG.
No. 14 AWG.
No. 12 AWG.
Section 2 — Installation
Liquid-cooled 30 kW Generators
Battery electrolyte fluid is an extremely caus-
tic sulfuric acid solution that can cause severe
burns. Do not permit fluid to contact eyes, skin,
clothing, painted surfaces, etc. Wear protective
goggles, protective clothing and gloves when
handling a battery. If fluid is spilled, flush the
affected area immediately with clear water.
Spilled electrolyte is to be washed down with
an acid neutralizing agent. A common practice
is to use a solution of one pound (500 grams)
bicarbonate of soda to one gallon (4 liters) of
water. The bicarbonate of soda solution is to be
added until the evidence of reaction (foaming)
has ceased. The resulting liquid is to be flushed
with water and the area dried.
Do not dispose of the battery in a fire. The
battery is capable of exploding.
Do not open or mutilate the battery. Released
electrolyte can be toxic and harmful to the skin
and eyes.
The battery represents a risk of high short circuit
current. When working on the battery, always
remove watches, rings or other metal objects,
and only use tools that have insulated handles.
When replacing batteries, use the same number
and type of battery. The recommended batteries are
Group 26, 12V negative ground 525 CCA/75 AH mini-
mum capacity, or Group 27F , 12V negative ground
600 CCA/90 AH minimum capacity. All batteries
must be at 100 percent state-of-charge before they
are installed on the generator.
When using maintenance-free batteries, it is not
necessary to check the specific gravity or electrolyte
level. Have these procedures performed at the inter-
vals specified in Section 4, "Maintenance." A nega-
tive ground system is used. Battery connections are
shown on the wiring diagrams. Make sure all batter-
ies are correctly connected and terminals are tight.
Observe battery polarity when connecting batteries to
the generator set.
Damage will result if the battery connections are
made in reverse.


The instructions in this section assume that the
standby generator has been properly installed, ser-
viced, tested, adjusted and otherwise prepared for
use by a competent, qualified installation contractor.
Be sure to read the "Safety Rules" on Pages 2 and 3,
as well as all other safety information in this manual,
before attempting to operate this (and related) equip-


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