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Generac Power Systems PowerPact 7.5 kW, Installation Manuallines

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Generac Power Systems PowerPact 7.5 kW Installation Manuallines Download Page 42

Quick Reference Guide

38

Installation Guidelines for 60 Hz PowerPact™

1 YEAR / 100 
HOUR 
MAINTENANCE 
DUE

Control panel indicates 
scheduled maintenance 
due.LED illuminates.

None

Perform scheduled maintenance. Clear Maintenance 
Due light.

NONE

Utility present. Generator 
running. Active mode 
LED (AUTO/MANUAL/
OFF) is flashing. 

Check utility sense 
lines / utility 
disconnect.

Contact IASD. Close utility disconnect.

Table 9-1. System Diagnosis (Continued)

Active Alarm

Problem

Things to Check

Solution

Summary of Contents for PowerPact 7.5 kW

Page 1: ...product support lookup Pour le français visiter http www generac com service support product support lookup Register your Generac product at WWW GENERAC COM 1 888 GENERAC 888 436 3722 000209b 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 ...

Page 2: ...of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage may contribute to the need for additional maintenance or service When the generator requires servicing or repairs Generac recommends contacting an IASD for assistance Authorized service technicians are factor...

Page 3: ...s Fuel Requirements and Recommendations 17 BTU Content 17 Fuel Pressure 17 Fuel Conversion 17 Fuel Consumption 18 Fuel Line Sizing 19 Natural Gas Pipe Sizing 19 LP Vapor Pipe Sizing 19 Summary 19 Installing and Connecting Gas Lines 20 Shutoff Valve 20 Flexible Fuel Line 20 Sediment Trap 20 Checking Gas Line Connections 21 Section 6 Electrical Connections Control Wiring 25 Main AC Wiring 26 Utility...

Page 4: ...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 44 Wiring Diagram 10000021282 A page 3 of 4 45 Wiring Diagram 10000021282 A page 4 of 4 46 ...

Page 5: ...dous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows NOTE Notes provide additional information important to a procedure or component These safety alerts cannot eliminate the hazards they indicate Observing safety precautions and strict compliance with the special instructions while performing the action or service are essential to preventing accidents...

Page 6: ...0 WARNING Accidental Start up Disconnect the negative battery cable then the positive battery cable when working on unit Failure to do so could result in death or serious injury 000182a WARNING Equipment damage Only qualified service personnel may install operate and maintain this equipment Failure to follow proper installation requirements could result in death serious injury and equipment or pro...

Page 7: ...m indoors and installed according to the manufacturer s instructions Failure to do so could result in death or serious injury WARNING 000144 DANGER Electrocution Contact with bare wires terminals and connections while generator is running will result in death or serious injury 000150 DANGER Electrocution Never connect this unit to the electrical system of any building unless a licensed electrician...

Page 8: ...guishers will not extinguish electrical fires in automatic standby generators 000100a WARNING Consult Manual Read and understand manual completely before using product Failure to completely understand manual and product could result in death or serious injury WARNING to use required safety equipment could result in death or serious injury 000257 Electrocution Refer to local codes and standards for...

Page 9: ...rolyte contacts skin or eyes flush with water and seek immediate medical attention 000137a WARNING Explosion Batteries emit explosive gases while charging Keep fire and spark away Wear protective gear when working with batteries Failure to do so could result in death or serious injury 000164 WARNING Electrical shock Disconnect battery ground terminal before working on battery or battery wires Fail...

Page 10: ...or power system Use the most current version of applicable codes or standards relevant to the local jurisdiction generator used and installation site NOTE Not all codes apply to all products and this list is not all inclusive In the absence of pertinent local laws and standards the following publications may be used as a guide these apply to localities which recognize NFPA and IBC 1 National Fire ...

Page 11: ...mage If a loss or damage is noted after delivery separate the damaged materials and contact the carrier for claim procedures Concealed damage is understood to mean damage to the contents of a package not evident at the time of delivery but discovered later Required Tools General SAE and Metric hand tools Wrenches Sockets Screwdrivers Standard electrician s hand tools Drill and bits for mounting an...

Page 12: ...nt Panel not shown B Controller Lid H Fuel Connection Hole O Air Box C Control Panel J Data Label P Spark Plug D Circuit Breaker K Battery Access Panel Q Exhaust Enclosure E Customer Connection Box L Oil Drain Hose R Alternator F Main AC Control Wiring Hole for 3 4 in Conduit M Oil Fill Dipstick S Starter Motor 005568 A B H G E C A J K L M N O P Q R S D F ...

Page 13: ...r the battery wires or the alternator can Flex Fuel Line A Battery Terminal Cap B LP Fuel Jet C Fuel Jet O ring D Decal Service Entrance Not Shown Decal Warning Not Shown MLCB Terminal Caps E Owner s and Installation Manual Not Shown Battery Bracket F M6 x 1 16mm Thread Forming Screw for Battery Bracket G 2 sets of Bolts Nuts and Washers for connecting battery cables H Reducer coupling FNPT 3 4 to...

Page 14: ...Unpacking and Inspection 10 Installation Guidelines for 60 Hz PowerPact This page intentionally left blank ...

Page 15: ...nimum clearance per SwRI testing labeling and listing unless state or local codes dictate otherwise D Windows and openings No operable windows doors or openings in the wall are permitted within 5 ft 1 52 m from any point of the generator E Existing wall One hour fire rated walls allow closer placement of the generator set Confirm before installation F Removable fence Removable fence panels for ser...

Page 16: ...of local codes regarding placement or clearance we recommend following these guidelines Install the generator as close as possible to the transfer switch REMEMBER LAWS OR CODES MAY REGULATE THE DISTANCE AND LOCATION The generator must be installed on a level surface The generator must be level within 0 5 in 13 mm all around The generator is typically placed on pea gravel compacted soil crushed sto...

Page 17: ...te the mounting area as close as possible to the transfer switch and fuel supply Leave adequate room around the area for service access check local code and place high enough to keep rising water from reaching the generator Choose an open space which provides adequate and unobstructed airflow Place the unit so air vents won t become clogged with leaves grass snow or debris Verify exhaust fumes wil...

Page 18: ... it off the pallet WILL damage the base 4 Unhook and remove the brackets from the generator Placement on Roofs Platforms and Other Supporting Structures Where required to place the generator on a roof platform or other supporting structure like a deck the generator shall be placed in accordance with the requirements in NFPA 37 Section 4 1 3 The generator can be located 18 in 45 7 cm from structure...

Page 19: ... pad is required all federal state and local codes should be followed Place the generator and position correctly as per the dimensional information given in Site Preparation NOTE Generator must be level within 0 5 in 13 mm Figure 4 1 Composite Pads NOTE When mounting the generator to concrete there are four mounting holes inside the generator enclosure for securing the generator DO NOT remove the ...

Page 20: ...Generator Placement 16 Installation Guidelines for 60 Hz PowerPact This page intentionally left blank ...

Page 21: ...ions for proper installation Local codes will mandate correct routing of gaseous fuel line piping around gardens shrubs and other landscaping Piping strength and connections should be given special consideration when installation takes place in areas at risk for flooding tornadoes hurricanes earthquakes and unstable ground IMPORTANT NOTE Use an approved pipe sealant or joint compound on all thread...

Page 22: ...iven are approximate Use the appropriate spec sheet or Owner s Manual for specific values Verify gas meter is capable of providing enough fuel flow to include household appliances and all other loads NOTE The gas supply and pipe MUST be sized at 100 load BTU Megajoule rating Always refer to the Owner s Manual for the proper BTU Megajoule and required gas pressures Natural Gas BTU ft3 h x 1000 Mega...

Page 23: ...the desired pipe size in the first row of the table The number below is the maximum length or run measured in meters feet allowed for the selected pipe size The pipe sizes are measured by inside diameter ID to include any fittings valves must be full flow elbows tees or angles NOTE Pipe sizes are using a second stage regulator NOTE Consult with the LP fuel provider to determine the minimum tank si...

Page 24: ...s This accessory valve permits making pressure checks without going into the generator enclosure Valves available through Generac and IASDs 1 2 ball valve part number 0K8752 3 4 ball valve part number 0K8754 1 ball valve part number 0K8184 1 1 4 ball valve part number 0L2844 Flexible Fuel Line When connecting the gas line to the generator use a listed assembly meeting the requirements of ANSI Z21 ...

Page 25: ... gas supply valve and verify the pressure is within the specified values NOTE Gas pressure can also be tested at the manometer port on the fuel shut off valve shown in Figure 5 2 NOTE SeeFuelRequirementsandRecommendations for proper fuel pressure specifications If the gas pressure is not within specifications contact the local gas supplier 4 Close gas valve when completed Figure 5 4 Checking Press...

Page 26: ... D E 006457 NG BTU ft3 h X 1000 Megajoules m3 h X 37 26 A Sediment Trap B Flexible Fuel Line C Manual Shut Off Valve With Pressure Port D BTU and Pressure Decal E Check Distance with Gas Provider F Fuel Pressure 5 7 in 9 13 mm Water Column G Size Gas Meter for Generator Load Plus All Appliance Loads H For Underground Installations Verify Piping System for Code Compliance J Gas Main ...

Page 27: ...sure decal C Minimum distance from side obstruction see Site Selection D Flexible fuel line E Manual shutoff valve pressure port optional F Check distance with gas provider G Reinforcing rod H Clamp J Secondary fuel pressure regulator K Manual shutoff valve pressure port optional L Primary fuel pressure regulator M Size fuel tank large enough to provide required BTUs for generator and ALL connecte...

Page 28: ...Fuel Conversion Gas Connections 24 Installation Guidelines for 60 Hz PowerPact This page intentionally left blank ...

Page 29: ...losing the panel back NOTE This wiring can be run in the same conduit if the appropriate insulation rated wire is used 4 Seal the conduit at the generator and in compliance with any codes 5 Strip the insulation from the ends of the wires Do not remove excessive insulation 6 To connect the control wires push down on the spring loaded connection point with a flat head screwdriver insert wire and rel...

Page 30: ...e ground this is to be done on the customer connections terminals inside the generator Connect a suitably sized wire from the neutral bar to the ground bar This is normally required when the generator is the source in a separately derived system It is not required when the generator is a backup source in a utility supplied electrical system with a 2 pole transfer switch See Figure 6 1 NOTE Torque ...

Page 31: ...heater is recommended to aid in cold climate starting This is available as a cold weather kit through an Independent Authorized Service Dealer 7 See Figure 6 4 Install the battery bracket A and screw B The installed bracket is shown on the right side of the figure 000137a WARNING Explosion Batteries emit explosive gases while charging Keep fire and spark away Wear protective gear when working with...

Page 32: ...socket screws and secure it in place Battery Disposal Always recycle batteries in accordance with local laws and regulations Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes For more information on battery recycling visit the Battery Council International website at http batterycouncil org 00 001134 134 A B WARNING Environmenta...

Page 33: ...anual Interface NOTE Loss of utility power will cause either the AUTO or OFF or MANUAL button to flash depending on which mode the generator is in at the time of utility loss Automatic start up Disconnect utility power and render unit inoperable before working on unit Failure to do so will result in death or serious injury 000191 DANGER 001052 A B C Button Description of Operation AUTO GREEN Selec...

Page 34: ...the activation code by pressing the AUTO OFF and SET EXERCISE buttons in the 6 press sequence you were given Example AUTO OFF OFF SET EXERCISE SET EXERCISE SET EXERCISE The yellow maintenance LED will blink each time a button is pressed 3 If the sequence is INCORRECTLY entered the AUTO OFF MANUAL buttons will flash 3 times together Return to Step 2 and continue 4 If the sequence is CORRECTLY enter...

Page 35: ...m the setting The exercise time must be established at the time you wish the exercise to take place 3 The exercise time is now established The generator will exercise each week at this time To CHANGE the exercise time once it has been set hold the SET EXERCISE button on the generator for three 3 seconds at the time you wish the new exercise time to take place Check Manual Transfer Switch Operation...

Page 36: ...ge should be approximately 240 volts and frequency should be 60 Hz If the voltage and frequency are rapidly dropping as the loads are applied the generator may be overloading or there may be a fuel issue Check amperage value of loads and or fuel pressure 10 Let the generator run at full rated load for 20 30 minutes Listen for unusual noises vibration or other indications of abnormal operation Chec...

Page 37: ...5 Remove the 7 5A fuse from the controller To turn the generator back ON 1 Install 7 5A fuse in controller 2 Confirm the generator MLCB generator disconnect is OFF OPEN 3 At the controller set the generator to AUTO mode 4 Generator will start and run Allow generator to run and warm up for a few minutes 5 Set the MLCB generator disconnect to ON CLOSED 6 Set the main utility disconnect to ON CLOSED ...

Page 38: ...Control Panel Start Up Testing 34 Installation Guidelines for 60 Hz PowerPact This page intentionally left blank ...

Page 39: ...sed 1 Check replace air cleaner 2 Clean re gap or replace plug s 3 Confirm fuel pressure to regulator is 10 12 in water column 19 22 mm mercury for LP and 5 7 in water column 9 13 mm mercury for natural gas 4 Change the fuel jet to the recommended part for the fuel used Generator is set to OFF but the engine continues to run 1 Controller wired incorrectly 2 Defective control panel 1 Repair wiring ...

Page 40: ...Troubleshooting 36 Installation Guidelines for 60 Hz PowerPact This page intentionally left blank ...

Page 41: ...ct an IASD NOT ACTIVATED Unit will not start in AUTO with utility loss Observe if all six Alarm and Warning LEDs are blinking simultaneously Refer to Generator Activation LOW OIL PRESSURE Unit will not start in AUTO with utility loss Check the Controller for alarms Check oil level add oil per Owners Manual If oil level is correct contact an IASD OVERCRANK Unit will not start in AUTO with utility l...

Page 42: ...ntenance due LED illuminates None Perform scheduled maintenance Clear Maintenance Due light NONE Utility present Generator running Active mode LED AUTO MANUAL OFF is flashing Check utility sense lines utility disconnect Contact IASD Close utility disconnect Table 9 1 System Diagnosis Continued Active Alarm Problem Things to Check Solution ...

Page 43: ...low and green alert owners when the generator needs attention Magnetic backing permits refrigerator mounting and gives a 600 foot 183 m line of sight communication Extended Warranty Coverage Available only in U S and Canada Extend your generator warranty coverage by purchasing extended warranty coverage Covers both parts and labor Extended coverage can be purchased within 12 months of the end user...

Page 44: ...Accessories 40 Installation Guidelines for 60 Hz PowerPact This page intentionally left blank ...

Page 45: ...GRAVEL MINIMUM 152 4 6 0 152 4 6 0 152 4 6 0 152 4 6 0 TITLE INSTALLATION DRAWING PPACT W AUX SW SIZE CAGE NO DWG NO 10000022108 REV A N A A SCALE NTS WT KG N A SHEET 1 of 2 SH 1 2 REV A WINDCHILL VERSION A 7 LEFT SIDE VIEW FRONT VIEW HOLE LOCATIONS FOR OPTIONAL MOUNTING TO A CONCRETE PAD 5 16 DIA MASONRY ANCHOR BOLTS RECOMMENDED DO NOT REMOVE MOUNTING FEET DURING CONCRETE PAD INSTALLATION CLEAR F...

Page 46: ... OPEN AREA TITLE INSTALLATION DRAWING PPACT W AUX SW SIZE CAGE NO DWG NO 10000022108 REV A N A A SCALE NTS WT KG N A SHEET 2 of 2 SH 2 2 REV A WINDCHILL VERSION A 7 FUEL INLET 3 4 NPT RIGHT SIDE VIEW REAR VIEW AIR INLET AIR OUTLET AIR INLET REQUIRED FUEL PRESSURE NATURAL GAS 9 13mm HG 5 7 WATER COLUMN LIQUID PROPANE VAPOR 19 22mm HG 10 12 WATER COLUMN AUXILIARY SHUTDOWN SWITCH DECAL ALL DIMENSIONS...

Page 47: ...elines for 60 Hz PowerPact 43 Wiring Diagram 10000021282 A page 1 of 4 PAGE 1 OF 4 GROUP G WIRING DIAGRAM 7 5KW AC POWER PACT 60HZ W AUX DRAWING 10000021282 REVISION A 09 08 17 CS HOT SM SC FS LOL MAG IM SP AVR 1 2 R BA J4 J5 AS ...

Page 48: ...llation Guidelines for 60 Hz PowerPact Wiring Diagram 10000021282 A page 2 of 4 PAGE 2 OF 4 GROUP G WIRING DIAGRAM 7 5KW AC POWER PACT 60HZ W AUX DRAWING 10000021282 REVISION A 09 08 17 LEGEND BATT 1 TB1 GND NEU TB2 CB ...

Page 49: ...uidelines for 60 Hz PowerPact 45 Wiring Diagram 10000021282 A page 3 of 4 PAGE 3 OF 4 GROUP G SCHEMATIC DIAGRAM 7 5KW AC POWER PACT 60HZ W AUX DRAWING 10000021282 REVISION A 09 08 17 SC SM SP IM HOT SC CS FS LOL R J4 J5 BA CB ...

Page 50: ...s 46 Installation Guidelines for 60 Hz PowerPact Wiring Diagram 10000021282 A page 4 of 4 PAGE 4 OF 4 GROUP G SCHEMATIC DIAGRAM 7 5KW AC POWER PACT 60HZ W AUX DRAWING 10000021282 REVISION A 09 08 17 AS LEGEND ...

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Page 52: ...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 S45 W29290 Hwy 59 Waukesha WI 53189 1 888 GENERAC 1 888 436 3722 www generac com ...

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