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Generac Power Systems G007144, Installation Manuallines

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Generac Power Systems G007144 Installation Manuallines Download Page 5

Table of Contents

Installation Guidelines For 50 Hz Air-Cooled Generator Sets

v

Section 1: Safety Information

Introduction ..........................................................1

Read This Manual Thoroughly ....................................1

Safety Messages ..................................................1

Safety and Informational Decals  ........................2

General Safety ......................................................5

Installation ............................................................6

Operation ..............................................................7

Maintenance .........................................................7

Hot Surfaces .........................................................9

Before You Begin ...............................................10

Standards Index .................................................10

Section 2: Unpacking and Inspection

General ...............................................................11

Required Tools ...................................................11

Unpacking ..........................................................11

Opening The Lid ........................................................12

Enclosure Panel Removal .................................12

Front Access Panel Removal  ....................................12
Intake Side Panel Removal  .......................................13

Customer Connections and Loose Parts  ........13

Rear Connections  ..............................................13

Generator Set Main Line Circuit Breaker 
(Generator Set Disconnect)  ..............................14

Parts Shipped Loose  .........................................14

Section 3: Site Selection and Preparation

Site Selection  .....................................................15

Carbon Monoxide  ..............................................15

Carbon Monoxide Detectors ......................................15
Potential CO Entry Points ..........................................16
Protect the Structure  .................................................16

Fire Prevention ...................................................17

Distance Requirements  .............................................17
Fire Codes, Standards, and Guidelines  ....................18
Generator Set Maintenance  ......................................18

Fresh Air for Ventilation and Cooling  ..............18

Water Ingress Avoidance ..................................18

Proximity to Utilities .......................................... 18

Verify Wi-Fi Range  ....................................................18

Transportation Recommendations .................. 19

Suitable Mounting Surface  ............................... 19

Placement on Roofs, Platforms, and Other 
Supporting Structures  ...................................... 19

Section 4: Generator Set Placement

Generator Set Weight ........................................ 21

Lifting Instructions ............................................ 21

Generator Set Placement .................................. 21

Section 5: Fuel Conversion / Gas 

Connections

Fuel Requirements and Recommendations  ... 23

BTU Content ..............................................................23
Fuel Pressure  ............................................................23

Fuel Conversion  ................................................ 23

Fuel Consumption ............................................. 24

Fuel Line Sizing  ................................................. 24

Natural Gas Pipe Sizing  ............................................25
LP Gas Pipe Sizing  ...................................................25

Installing and Connecting Fuel Lines .............. 26

Fuel Shutoff Valve  .....................................................26
Flexible Fuel Line  ......................................................26
Sediment Trap ...........................................................26

Checking Fuel Line Connections ..................... 27

Checking Fuel Pressure  ............................................27
Performing Fuel System Leak Test  ...........................27

Natural Gas Installation (Typical)  .................... 28

LP Gas (Vapor) Installation (Typical) ............... 29

Section 6: Electrical Connections

Generator Set Connections .............................. 31

Control Wiring  ................................................... 32

Main AC Wiring .................................................. 33

Common Alarm Relay (Option)  ........................ 33

Battery Requirements  ....................................... 33

Battery Installation  ............................................ 33

Connecting the Battery ..............................................34

Battery Disposal  ................................................ 34

Summary of Contents for G007144

Page 1: ...rator Sets 8 kVA to 13 kVA Original Instructions SAVE THIS MANUAL FOR FUTURE REFERENCE Register your Generac product at www activategen com 1 262 953 5155 ISO000209b This product is not intended to be...

Page 2: ...ps operating expenses at a minimum It is the operator s responsibility to perform all safety inspections to verify all maintenance for safe operation is performed promptly and to have the equipment in...

Page 3: ...for Outdoor Noise Emission Directive 2000 14 EC ISO 8528 10 1998 Reciprocating internal combustion engine driven alternating current generating sets EN ISO 3744 2010 Determination of sound power leve...

Page 4: ...iv Installation Guidelines For 50 Hz Air Cooled Generator Sets...

Page 5: ...Generator Set Maintenance 18 Fresh Air for Ventilation and Cooling 18 Water Ingress Avoidance 18 Proximity to Utilities 18 Verify Wi Fi Range 18 Transportation Recommendations 19 Suitable Mounting Sur...

Page 6: ...ical Checks 41 Generator Set Tests Under Load 41 Checking Automatic Operation 42 Installation Summary 42 Shutting Generator Set Down While Under Load Or During A Mains Power Outage 42 Section 8 Troubl...

Page 7: ...TIONS for future reference This manual contains important instructions that must be fol lowed during placement operation and maintenance of the unit and its components Always supply this manual to any...

Page 8: ...es negative battery cable D Fuel Selection Step 1 Unit set for Natural Gas NG operation Step 2 Press and rotate fuel selector 180 to change fuel type Step 3 Unit set for Liquid Propane LPG operation N...

Page 9: ...the manual completely before installing or operating this equipment Do not smoke near this equipment Do not allow open flames near this equipment J Read Owner s Manual Read the manuals for an explana...

Page 10: ...Safety Information 4 Installation Guidelines For 50 Hz Air Cooled Generator Sets Figure 1 1 Safety and Informational Decals A B C E F H J K G D L E M2 M1 P N Q K K...

Page 11: ...llowing proper installation do nothing that might alter a safe installation and render the unit in noncompliance with locally applicable codes standards laws and regulations ISO000540 ISO000531a Follo...

Page 12: ...is properly grounded before applying power ISO000218 Installation must comply with all national and local electrical building codes ISO000147 Unit must be positioned in a manner that prevents combust...

Page 13: ...e atmospheres ISO000111 Keep clothing hair and appendages away from moving parts ISO000247a This unit is not intended for use as a prime power source It is intended for use as an intermediate power su...

Page 14: ...228 Always recycle batteries at an official recycling center in accordance with all local laws and regulations ISO000548 Batteries emit explosive gases while charging Keep fire and spark away ISO00016...

Page 15: ...or set shutdown procedure in Shut ting Generator Set Down While Under Load Or During A Mains Power Outage before opening the enclosure This allows adequate cooling to reduce the risk of exposure to ho...

Page 16: ...al laws and standards the following publications may be used as a guide these apply to localities which recognize NFPA and ICC 1 National Fire Protection Association NFPA 70 The NATIONAL ELECTRIC CODE...

Page 17: ...led damage is understood to mean dam age to contents of a package not evident at time of delivery but discovered later Required Tools General SAE and metric hand tools Wrenches Sockets Screwdrivers St...

Page 18: ...enerator set lid 2 See Figure 2 4 Two locks A secure lid one on each side Press down on lid above side lock and unlock latch to correctly open lid Figure 2 4 Opening The Lid 3 Repeat for other side Li...

Page 19: ...from enclosure before lifting up D Customer Connections and Loose Parts See Figure 2 7 and Figure 2 8 for customer connections and loose parts location Figure 2 10 illustrates parts shipped loose Figu...

Page 20: ...to relevant specifications Indicator B Identifier Green means OFF OPEN Red means ON CLOSED Figure 2 9 Generator Set Main Line Circuit Breaker MLCB Parts Shipped Loose Figure 2 10 Parts Shipped Loose A...

Page 21: ...nerator set exhaust contains carbon monoxide CO a poisonous potentially lethal gas that cannot be seen or smelled The generator set must be installed in a well ventilated area away from windows doors...

Page 22: ...fresh air into the structure B Garage door CO can leak into garage if door is open or does not seal correctly when closed C Attic vent Attic vents ridge vents crawl space vents and soffit vents can a...

Page 23: ...ront and ends of the generator set must be 0 91 m 3 ft This includes shrubs bushes and trees B Rear clearance Fuel and electrical connections are made here 457 mm 18 in minimum clearance per SwRI test...

Page 24: ...re This includes trees shrubs and bushes Vegetation not in compliance with these clearance parameters could obstruct air flow In addition exhaust fumes from the gen erator set could inhibit plant grow...

Page 25: ...ider B than the generator set on all sides Figure 3 4 Pea Gravel or Crushed Stone Concrete pads must be appropriately sized in accor dance with national state or local building codes Verify surface wh...

Page 26: ...Site Selection and Preparation 20 Installation Guidelines For 50 Hz Air Cooled Generator Sets This page intentionally left blank...

Page 27: ...ting device The unit is now ready to be lifted Generator Set Placement See Figure 4 3 All air cooled generator sets come with a composite pad The composite pad elevates the genera tor set and helps pr...

Page 28: ...rator Sets 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 templat...

Page 29: ...ifica tion once the generator set is installed Always contact local fuel suppliers or fire marshal to ver ify codes and regulations for correct installation Local codes will mandate correct routing of...

Page 30: ...as Propane 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 7 62 2 01 2 07 13 kVA 4 02 142 6 48 229 5 58 1 47 1 52 8 8...

Page 31: ...B 3 2 in NFPA 54 or Table A 2 2 in the ICC IFGC Equivalent Lengths of Pipe Fittings and Valves for the correct values to be added to overall fuel piping length NOTE Pipe sizes are from the outlet of t...

Page 32: ...optional accessory fuel shutoff valve permits making pressure checks for diagnostic purposes without going into the generator set enclosure Figure 5 4 Fuel Shutoff Valve with Manometer Port Flexible F...

Page 33: ...cations contact local gas supplier 5 Close fuel valve when completed but keep man ometer connected for future tests of the generator set while starting running and under loads Performing Fuel System L...

Page 34: ...e pressure port optional Must be located no more than 1 83 m 6 ft away from fuel inlet D Pipe fittings E Flexible fuel line F Verify clearance with gas provider Regulator should be a minimum of 1 5 m...

Page 35: ...ated no more than 1 83 m 6 ft away from fuel inlet D Pipe fittings E Flexible fuel line F Verify minimum distance requirements for regulator vent according to local gas codes Regulator should be a min...

Page 36: ...Fuel Conversion Gas Connections 30 Installation Guidelines For 50 Hz Air Cooled Generator Sets This page intentionally left blank...

Page 37: ...or generator set control circuit wiring is prohibited Recommended wire gauge sizes for this wir ing depends on wire length as recommended in Table 6 3 Exception Conductors of AC and DC circuits rated...

Page 38: ...onnections F Ground stud C1 Wire tie for sense wires E1 Power lug E1 G Protective earth PE ground lug Table 6 2 Customer Wiring Connections Terminal Numbering Decal Wire Numbers ORANGE YELLOW TAG N1 F...

Page 39: ...er and in the Mobile Link Wi Fi app if used The controller is equipped with a common alarm relay providing contacts for an optional customer sup plied external alarm indicator The common alarm relay i...

Page 40: ...y cables were factory connected at generator set Figure 6 2 Battery Cable Connections Proceed as follows to connect battery cables to battery posts 1 Connect red positive battery cable A from starter...

Page 41: ...llow on screen instructions on the generator set along with Quick Start Guide supplied with the unit to connect generator set to home Wi Fi network 3 Wait for on line authentication of generator set a...

Page 42: ...see Wi Fi manual If NO continue Press ENTER to begin the activation process If ESCAPE is pressed instead of ENTER the generator set will only run in manual mode for test purposes and NOT ACTIVATED is...

Page 43: ...ill exercise on that day each month Transfer of loads to generator output does not occur during exercise cycle unless mains power is lost NOTE If installer tests generator set prior to installation pr...

Page 44: ...ontrol panel for this test to be performed and pass NOTE All appropriate panels must be in place during any operation of generator set This includes operation by a servicing technician while conductin...

Page 45: ...d DOWN arrows to select fuel type then press ENTER Fuel Selection NG or LP Follow setup process in Wi Fi manual Cold Smart Start YES or NO 006669 Default voltage 220V Use UP arrow to select output vol...

Page 46: ...uring update process the Blue Manual light flashes then the Green Auto light flashes Sequence does this twice When update is complete the unit returns to Install Wizard menu When the controller powers...

Page 47: ...itch terminal lugs where E1 and E2 wires are terminated Volt age should be the output voltage selected during installation 2V e g 218 222 VAC at a frequency of 49 5 50 5 Hz If voltage is incorrect ver...

Page 48: ...switch 3 Turn on mains power supply to transfer switch using the means provided such as a mains MLCB NOTE Transfer switch will transfer to mains position 4 Set generator set MLCB generator set discon...

Page 49: ...enerator set MLCB generator set disconnect to OFF OPEN 6 Remove 7 5 amp fuse from control panel To turn generator set back ON 1 Install 7 5 amp fuse in control panel 2 Verify generator set MLCB genera...

Page 50: ...Control Panel Startup Testing 44 Installation Guidelines For 50 Hz Air Cooled Generator Sets This page intentionally left blank...

Page 51: ...lace spark plug s as needed Valve clearance out of adjustment Reset valve clearance Engine starts hard and runs rough Air cleaner plugged or damaged Inspect and clean air cleaner Faulty spark plug s C...

Page 52: ...ransfer relay circuit open Faulty control logic board Engine may be warming up See Cold Smart Start Check controller screen to verify status Unit consumes large amounts of oil Excessive engine oil Adj...

Page 53: ...will not start in AUTO with mains power loss Check screen for start delay countdown If startup delay is greater than expected contact an IASD to adjust from 2 to 1500 seconds LOW OIL PRESSURE RED Unit...

Page 54: ...isplays GOOD contact an IASD If control panel displays CHECK BATTERY replace battery BATTERY PROBLEM YELLOW Yellow LED illuminated in any state Check screen for additional information Contact an IASD...

Page 55: ...a base wrap snaps together around the bottom of the new air cooled generator set This offers a sleek contoured appearance as well as offering protection from rodents reptiles and insects by covering t...

Page 56: ...Accessories 50 Installation Guidelines For 50 Hz Air Cooled Generator Sets This page intentionally left blank...

Page 57: ...CONTROL WIRING HOLE FOR 1 1 4 CONDUIT FUEL INLET 1 2 NPT 8 13kVA 3 4 NPT 20kVA REQUIRED FUEL PRESSURE NATURAL GAS 0 87 1 74 kPa 3 5 7 WATER COLUMN LIQUID PROPANE VAPOR 2 49 2 99 kPa 10 12 WATER COLUM...

Page 58: ...GRAVEL PAD 127 5 0 914 36 0 MINIMUM OPEN AREA 914 36 0 MINIMUM OPEN AREA 457 18 0 MINIMUM OPEN AREA 914 36 0 MINIMUM OPEN AREA AIR OUTLET AIR INTAKE AIR INTAKE TOP VIEW FRONT VIEW RIGHT SIDE VIEW DO...

Page 59: ...Diagrams Installation Guidelines For 50 Hz Air Cooled Generator Sets 53 Wiring Diagram 10000007481 1 of 6...

Page 60: ...Diagrams 54 Installation Guidelines For 50 Hz Air Cooled Generator Sets Wiring Diagram 10000007481 2 of 6...

Page 61: ...Diagrams Installation Guidelines For 50 Hz Air Cooled Generator Sets 55 Wiring Diagram 10000007481 3 of 6...

Page 62: ...Diagrams 56 Installation Guidelines For 50 Hz Air Cooled Generator Sets Wiring Diagram 10000007481 4 of 6...

Page 63: ...Diagrams Installation Guidelines For 50 Hz Air Cooled Generator Sets 57 Wiring Diagram 10000007481 5 of 6...

Page 64: ...Diagrams 58 Installation Guidelines For 50 Hz Air Cooled Generator Sets Wiring Diagram 10000007481 6 of 6...

Page 65: ...Diagrams Installation Guidelines For 50 Hz Air Cooled Generator Sets 59 This page intentionally left blank...

Page 66: ...Diagrams 60 Installation Guidelines For 50 Hz Air Cooled Generator Sets This page intentionally left blank...

Page 67: ......

Page 68: ...nc All rights reserved Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Power Systems Inc Generac Power Systems Inc S4...

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