Generac Power Systems 7 kW PowerPact Owner's Manual
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Generac Power Systems 7 kW PowerPact Owner's Manual

Automatic standby generator
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Owner's Manual
Automatic Standby Generator
NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT
INSTALLATION.
DEADLY EXHAUST FUMES! OUTDOOR INSTALLATION ONLY!
To locate in Spanish, go to
To locate in French, go to
Reference all appropriate documentation.
This manual should remain with the unit.
http://www.generac.com/service-support/product-support-lookup
http://www.generac.com/service-support/product-support-lookup
7 kW PowerPact™

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Summary of Contents for Generac Power Systems 7 kW PowerPact

  • Page 1 Owner’s Manual Automatic Standby Generator 7 kW PowerPact™ NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION. DEADLY EXHAUST FUMES! OUTDOOR INSTALLATION ONLY! To locate in Spanish, go to http://www.generac.com/service-support/product-support-lookup To locate in French, go to http://www.generac.com/service-support/product-support-lookup...
  • 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 generator unit data label plate is affixed to the engine divider panel inside the enclosure. The unit data label provides the following information: •...

  • Page 3: Table Of Contents

    Table of Contents Section 1 — Safety ................1 1.1 —...
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  • Page 5: Section 1 - Safety

    Safety Section 1 INTRODUCTION: Thank you for purchasing this compact, high performance, air-cooled, engine-driven stationary automatic standby generator set. Every effort was made to make sure that the information and instructions in this manual were both accurate and current at the time the man- ual was written.

  • Page 6: General Safety

    1.1 — General Safety Study these safety rules carefully before operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

  • Page 7: Exhaust Hazards

    1.3 — Exhaust Hazards • Generator engine exhaust contains DEADLY carbon monoxide, an odorless, colorless, poisonous gas. Breathing carbon monoxide can cause dizziness, throbbing temples, nausea, muscular twitching, headache, vomiting, weakness, sleepiness, inability to think clearly, fainting, unconsciousness or even death. If any carbon monoxide poisoning symptom is experienced, move into fresh air and immediately seek med- ical attention.
  • Page 8 If this generator is used to power electrical load circuits normally powered by a utility power source, it is required by code to install a transfer switch. The transfer switch must effectively isolate the electrical system from the utility distribution system when the generator is operating (NEC 702). Failure to isolate an electrical system by such means will result in damage to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy.

  • Page 9: Section 2 - General Information

    General Information Section 2 2.1 — The Generator Spark Plug Airbox Control Panel/ Circuit Breaker Starter Motor Oil Drain Hose Alternator Oil Fill/Dipstick Figure 2-1: GA-420 Engine 7 kW Unit 2.2 — Protection Systems The generator may have to run for long periods of time with no operator present to monitor the engine/generator conditions. Therefore, the gen- erator is equipped with a number of systems to automatically shut down the unit to protect it against potentially damaging conditions.

  • Page 10: Emission Information

    2.3 — Emission Information The U.S. Environmental Protection Agency (EPA) requires that this generator comply with exhaust emission standards. This generator is certified to meet the applicable EPA emission levels, and is certified for use as a stationary engine for standby power generation. Any other use may be a violation of federal and/or local laws.

  • Page 11: Specifications

    2.4 — Specifications 2.4.1 — Generator Output 7 kW Rated Voltage Rated Maximum Load Current (Amps) at 240 29.2 Volts (LP)* Main Circuit Breaker 30 Amp Phase Rated AC Frequency 60 Hz Battery Requirement Group U1, 12 Volts and 300 CCA Minimum (Generac Part No. OD4575) Weight (unit only in lbs./ 280/127.3 Enclosure...

  • Page 12: Accessories

    Gaseous fuels such as natural gas and liquid propane gas are highly explosive. Even the slightest spark can ignite such fuels and cause an explosion. No leakage of fuel is permitted. Natural gas, which is lighter than air, tends to collect in high areas. LP gas is heavier than air and tends to settle in low areas.

  • Page 13: Section 3 - Operation

    Operation Section 3 3.1 — Controller Lid Operation • Lift lid from bottom to open. Lid will secure in place when opened. OPEN COVER Figure 3-1: Open Control Panel Lid • Pull on lid slightly to close. PULL THE COVER TO UNLOCK AND CLOSE Figure 3-2: Close Control Panel Lid Automatic Standby Generator Owner’s Manual...

  • Page 14: Circuit Breaker

    3.2 — Circuit Breaker The Main Line Circuit Breaker (MLCB) and control panel are located under the side panel cover. Open the side cover door to access both the control panel and circuit breaker. Circuit Breaker (MLCB) Control Panel Figure 3-3: Control Panel / Circuit Breaker Location Set to AUTO, the engine may crank and start at any time without warning.

  • Page 15: Alarm Response Procedures

    3.3.1— Using the Auto/Off/Manual Buttons Button Description of Operation Selecting this button activates fully automatic system operation. It also allows the unit to AUTO (GREEN) automatically start and exercise the engine every seven days with the setting of the exercise timer (see the Setting the Exercise Timer section).

  • Page 16: Automatic Operation

    3.4.1— Clearing an Alarm/Warning Condition To clear an alarm or warning condition from the Control Panel, press the OFF button. Press OFF button again. The flashing or solid indicator LED will turn off. NOTE: Clearing a code will not correct the problem. It will simply turn off the LED indicating that told you that a problem occurred. The problem indicated must be diagnosed and corrected to prevent a re-occurring alarm condition.

  • Page 17: Turning The Generator Off When Operating Under Load

    3.5.1.3 — Load Transfer The transfer of load when the generator is running is dependent upon the operating mode: • Will not transfer to generator if utility is present. • Will transfer to generator if utility fails (below 65% of nominal for 10 consecutive seconds). MANUAL •...

  • Page 18: Side Compartment

    3.7.1— Transfer to Generator Power Source Press the Control Panel OFF button. Set the Main Circuit Breaker (Generator Disconnect) to its OFF (OPEN) position. LOAD CONNECTED TO STANDBY POWER SOURCE Turn off the utility power supply to the transfer LOAD CONNECTED TO UTILITY POWER SOURCE switch using the means provided (such as a utility main line circuit breaker).

  • Page 19: Battery Charger

    3.8.1— Main Circuit Breaker (Generator Disconnect) This is a 2-pole breaker rated according to relevant specifications. 3.9 — Battery Charger NOTE: The battery charger is integrated into the control panel. Battery Problem LED is illuminated when battery needs service. The battery charger operates as a “Smart Charger” that ensures: •...
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  • Page 21: Section 4 - Maintenance

    Maintenance Section 4 NOTE: Proper maintenance and proper and safe operation is crucial to the life of the generator. Genuine Generac parts MUST be used to ensure warranty coverage. NOTE: All service to this generator must be performed by a qualified service person only. 4.1 —...

  • Page 22: Service Schedule

    4.2 — Service Schedule ATTENTION: All service work must be performed by a qualified service person only. System Component Procedure Frequency X = Action W = Weekly Change R= Replace as Necessary Inspect Clean M = Monthly * = Notify Dealer if Repair is Needed Y = Yearly Fuel Fuel lines and connections*...

  • Page 23: Checking Engine Oil Level

    Valve Adjustment (recommended after the first 20 hours of operation and then after every 300 hours of operation) Dates Performed: 4.3 — Checking Engine Oil Level When power outages necessitate running the generator for extended periods, the oil level should be checked daily. To check the engine oil level: If the generator is running during a utility outage, first turn OFF all associated loads running in the residence using the electrical panel's main disconnect.
  • Page 24 Figure 4-2: Recommended Oil Based on Temperature • SAE 30 above 32 ºF (0 ºC) • 10W-30 between 40 ºF and -10 ºF (4 ºC and -23 ºC) • Synthetic 5W-30 for all temperature ranges* NOTE: *Synthetic oil should only be used after 100 hours of operation. Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure.

  • Page 25: Changing The Engine Air Cleaner

    Oil Drain Hose Cap Drain Hose Retaining Clamp Oil Drain Hose Oil Fill Cap/Dipstick Battery Battery Access Panel Figure 4-3: Oil Drain Location 4.4 — Changing the Engine Air Cleaner With the generator shut down, remove the top lid. Disengage the wire clip and remove the air cleaner access cover. See Figure 4-4. Remove the old air filter and discard.

  • Page 26: Valve Lash Adjustment

    Clean the plug by scraping or washing with a wire brush and commercial solvent. Do not blast the plug to clean. Check the spark plug gap using a wire feeler gauge. See Figure 4-5. Adjust the gap by carefully bending the ground electrode to: •...

  • Page 27: Battery Maintenance

    Install the rubber plug into the fan screen. 10. Install the spark plug and attach the spark plug wire. 11. Install the back panel. Ensure that the alternator intake bellow is captured by the frame on back panel securely with out any kinks. Install enclosure top lid.
  • Page 28 Lead-acid batteries present a risk of fire because they generate hydrogen gas. Strictly observe the following pre- cautions: • DO NOT smoke when near the battery. • DO NOT cause flame or spark in the battery area. • Discharge static electricity from the body before touching the battery by first touching a grounded metal surface. Be sure the utility power supply is turned off and the 7.5 Amp ATO fuse is removed from the generator Control ®...

  • Page 29: Attention After Submersion

    Black Lead to Red Lead from Engine Block (-) Starter Contactor (+) Figure 4-8: Battery Location and Terminals Check the battery fluid level of unsealed batteries, and if necessary, fill with distilled water only. DO NOT use tap water. Also, have the Dealer or a qualified Service Technician check the state of charge and condition.
  • Page 30 4.10.2 — Return to Service To return the unit to service after storage: Verify that utility power is turned off. Check the tag on the engine for oil viscosity and classification. If necessary, drain and refill with proper oil. Check the state of the battery. Fill all cells of unsealed batteries to the proper level with distilled water. DO NOT use tap water. Recharge the battery to 100% state of charge.

  • Page 31: Section 5 - Troubleshooting

    Troubleshooting Section 5 Problem Cause Correction Engine will not crank. 1. Fuse blown. 1. Correct short circuit condition by replacing 7.5 Amp fuse in generator control panel. 2. Loose, corroded or defective battery 2. Tighten, clean or replace as necessary.* cables.
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  • Page 33: Section 6 - Quick Reference Guide

    Quick Reference Guide Section 6 Problem Things to Check Active Alarm Solution Unit running in AUTO but no Check MLCB. Contact servicing dealer if Check MLCB NONE power in house. MLCB is in the ON position. Check ventilation around the generator, Unit shuts down during HIGH Check for alarms...
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  • Page 36 Part No. 0K6020 Rev. A 07/29/2014 Printed in USA 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 1-888-GENERAC (1-888-436-3722) consent from Generac Power Systems, Inc.

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