Protector™ Series
Installation Guidelines
For
Stationary Diesel Generators
Residential and Commercial
Model
RD015 RD020 RD030 RD048 -
15 kW
20 kW
30 kW
48 kW
60 Hz
60 Hz
60 Hz
60 Hz (Single Phase Only)
RD050 -
50 kW
60 Hz (Three Phase Only)
*
*
NOT INTENDED FOR USE IN CRITICAL
LIFE SUPPORT APPLICATIONS.
*
DEADLY EXHAUST FUMES! OUTDOOR
INSTALLATION ONLY!
ONLY QUALIFIED ELECTRICIANS OR
CONTRACTORS SHOULD ATTEMPT
INSTALLATION!
This manual should remain with the unit.
This manual must be used in conjunction
with the appropriate owner’s manual.
Forward
Purpose and Scope of This Manual
READ THIS MANUAL THOROUGHLY. This manual has been prepared to familiarize personnel involved with the
installation of generator sets with the manufacturer’s installation requirements. Information and instructions contained
herein are not intended to replace or supersede, local, state, or national safety, electrical, and building codes pertaining
to such installations. Applicable laws, codes, and standards must always take precedence over the recommendations
contained herein. Always check with the local Authority Having Jurisdiction (AHJ) for the codes or standards that apply.
Only authorized dealers or qualified, competent installation contractors or electricians thoroughly familiar with applicable codes, standards, and regulations should install this standby electric power system. The installation must be in strict
compliance with all codes, standards, and regulations. Start-up procedures must be performed by an Authorized Generac Service Dealer.
It is not intended that this manual be used by any unqualified person for the purpose of installing a generator set. Installation, inspection, and testing of the system should be attempted only by competent, qualified electricians or installation
contractors who are familiar with the equipment and with all installation codes and requirements.
It would be impossible to provide detailed coverage of every installation configuration. For this reason, much of the
information contained in this manual is general in nature. Illustrations of typical installations are not intended to serve
as detailed installation plans. Always have the drawings and manuals for the specific unit being installed before beginning the installation.
The information in this manual can be used in the planning and design process phase of selecting and purchasing a
generator set for a standby power application.
Sources of Information
Installation information and recommendations contained herein are derived from the following sources:
• Knowledgeable engineers, service technicians, and service representatives.
• The National Electric Code (NEC).
• National Fire Protection Association (NFPA) codes and standards.
• Other sources as listed in Subsection 1.7.
• Various manufacturing standards and best practices.
*
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 electric system from the utility distribution system when the generator is operating.
Failure to isolate an electrical system by such means may result in damage to the generator
and may also result in injury or even death to utility power workers due to backfeed of
electrical energy.
!
If an open bottom is used, the engine-generator is to be installed over non-combustible
materials and should be located such that combustible materials are not capable of
accumulating under the generator set.
•
After the system has been installed, do nothing that might render the installation in noncompliance with such codes, standards, and regulations.
Every effort was made to ensure the information in this manual was both accurate and current at the time it was
released. However, the manufacturer reserves the right to change, alter, or otherwise improve this product at any time
and without prior notice.
ii
Installation Guidelines for Stationary Diesel Generators
Table of Contents
Section 1 Safety
1.1 Introduction .......................................................................................................................... 1
1.2 Safety Rules .......................................................................................................................... 1
1.3 General Hazards ................................................................................................................... 2
1.4 Electrical Hazards ................................................................................................................ 3
1.5 Fire Hazards .......................................................................................................................... 3
1.6 Explosion Hazards ............................................................................................................... 3
1.7 Standards Index ................................................................................................................... 4
Section 2 Installation Planning
2.1 Protector Diesel Pre-Order Checklist ................................................................................. 5
2.2 Unit Drawings ....................................................................................................................... 7
2.2.1 Installation Drawings ................................................................................................................................. 7
2.2.2 Wiring Diagrams ......................................................................................................................................... 7
2.3 Receiving .............................................................................................................................. 7
2.3.1 Receiving and Unpacking .......................................................................................................................... 7
2.3.2 Inspection .................................................................................................................................................... 7
2.4 Storage Before Installation .................................................................................................. 8
2.4.1 Long Term Storage ..................................................................................................................................... 8
2.4.2 Short Term Storage .................................................................................................................................... 8
2.5 Lifting .................................................................................................................................... 8
2.6 Generator Location .............................................................................................................. 8
2.6.1 General Location Guidelines ..................................................................................................................... 9
2.6.2 Weather Considerations ............................................................................................................................ 9
2.7 Accessories .......................................................................................................................... 9
Section 3 Foundations & Mounting
3.1 Generator Foundations ...................................................................................................... 13
3.1.1 Concrete Pad ............................................................................................................................................ 13
3.1.2 Dimensions ............................................................................................................................................... 13
3.1.3 Unit Clearance .......................................................................................................................................... 13
3.1.4 Stub Up Area ............................................................................................................................................. 13
3.2 Mounting ............................................................................................................................. 14
3.2.1 Fixed Foundation ...................................................................................................................................... 14
3.2.2 Connections .............................................................................................................................................. 14
Section 4 Ventilation System
4.1 General ................................................................................................................................ 15
4.2 Outdoor Installation Only .................................................................................................. 15
4.2.1 Clearance .................................................................................................................................................. 15
Section 5 Diesel Fuel Systems
5.1 General Information ........................................................................................................... 17
5.2 Diesel Fuel Base Tank ....................................................................................................... 17
Installation Guidelines for Stationary Diesel Generators
iii
Table of Contents
5.3 Diesel Fuel Recommendations .........................................................................................18
5.3.1 Fuel Maintenance ...................................................................................................................................... 18
Section 6 Electrical System
6.1 General Information ...........................................................................................................19
6.2 Remove Rear Panel and Stub Up Cover ...........................................................................19
6.3 Wiring Installation Safety ...................................................................................................19
6.4 General Wiring Requirements ...........................................................................................19
6.5 High Voltage Connections .................................................................................................19
6.6 Control Wiring Connections ..............................................................................................22
6.7 Optional Accessory Power ................................................................................................24
6.8 Install Stub Up Cover and Rear Panel ..............................................................................24
6.9 Transfer Switch Location ...................................................................................................24
6.10 Battery ...............................................................................................................................25
6.10.1 General Cautions .................................................................................................................................... 25
6.10.2 Battery Size ............................................................................................................................................. 25
6.10.3 Battery Replacement .............................................................................................................................. 25
6.11 Operational Checks ..........................................................................................................27
6.11.1 Self Test ................................................................................................................................................... 27
6.11.2 Check Manual Transfer Switch Operation ............................................................................................ 28
6.11.3 Electrical Checks .................................................................................................................................... 28
6.11.4 Test Generator Under Load ................................................................................................................... 28
6.11.5 Check Automatic Operation .................................................................................................................. 29
6.12 Installation Summary .......................................................................................................29
Section 7 Installation Checklists
7.1 Safety Checklist ..................................................................................................................31
7.2 Installation Planning Checklist .........................................................................................31
7.3 Foundations & Mounting Checklist ..................................................................................32
7.4 Ventilation System Checklist ............................................................................................32
7.5 Diesel Fuel System Checklist ............................................................................................33
7.6 Electrical System Checklist ...............................................................................................33
WARNING!
California Proposition 65
Engine exhaust and some of its constituents are known to the state of California to cause cancer,
birth defects, and other reproductive harm.
WARNING!
California Proposition 65
This product contains or emits chemicals known to the state of California to cause cancer,
birth defects, and other reproductive harm.
iv
Installation Guidelines for Stationary Diesel Generators
Section 1
Safety
1.1 — Introduction
Read this manual thoroughly. If any portion is not understood, contact the nearest Authorized Generac Service
Dealer for clarification. The manufacturer also requires having an Authorized Service Dealer oversee the installation of
any standby generator set. Trained/qualified service technicians familiar with the control systems and available options
have full access to drawings, publications, and other information required for a successful installation.
1.2 — Safety Rules
Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION, and
NOTE boxes are used to alert personnel to special instructions about a particular operation that may be hazardous if
performed incorrectly or carelessly. Observe them carefully. They indicate:
Indicates a hazardous situation or action that, if not avoided, will result in death or serious
injury.
Indicates a hazardous situation or action that, if not avoided, could result in death or serious injury.
Indicates a hazardous situation or action that, if not avoided, could result in minor or moderate injury.
NOTE: Notes provide additional information important to a procedure or component.
These safety warnings 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.
Four commonly used safety symbols accompany DANGER, WARNING, and CAUTION boxes and the type of information each indicates:
•
$
!
+
This symbol points out important safety information that, if not followed, could
endanger personnel and/or property.
This symbol represents the potential for an Explosion Hazard.
This symbol represents the potential for a Fire Hazard.
This symbol represents the potential for an Electrical Shock Hazard.
SAVE THESE INSTRUCTIONS. This manual contains important instructions that should be
followed during installation of the generator set and batteries. The manufacturer suggests
that these safety rules be copied and posted in potential hazard areas. Safety should
be stressed to all installers, operators, potential operators, and service and repair
technicians for this equipment.
Installation Guidelines for Stationary Diesel Generators
1
Safety
The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this
manual, and on tags and decals affixed to the unit, are not all-inclusive. If using a procedure, work method, or operating
technique the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method, or operating technique used does not render the generator unsafe.
• Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance, or
being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate, and maintain this equipment.
• Parts of the generator are rotating and/or hot during operation. Exercise care near running generators.
• If this generator is used to power electrical load circuits normally powered by a utility power source, install a
transfer switch. The transfer switch must effectively isolate the electrical system from the utility distribution system when the generator is operating. 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.
+ tor safe before operation or service.
Generators produce potentially lethal voltages. Ensure all steps are taken to make the genera-
1.3 — General Hazards
• For safety reasons, the manufacturer recommends that this equipment be installed, serviced, and repaired by an
Authorized Service Dealer or other competent, qualified electrician or installation technician who is familiar with
all applicable codes, standards, and regulations.
• Ensure that the generator is installed, operated, and serviced in accordance with the manufacturer’s instructions
and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance.
• The engine exhaust fumes contain carbon monoxide, which can be DEADLY. If breathed in sufficient concentrations, carbon monoxide can cause unconsciousness or even death. For this reason, adequate ventilation must
be provided. Exhaust gases must be piped safely away from any building or enclosure that houses the generator
to an area where people, animals, etc. will not be harmed.
• Keep hands, feet, clothing, etc. away from drive belts, fans, and other moving or hot parts. Never remove any
drive belt or fan guard while the unit is operating. Ensure that all guards, covers, and protective devices removed
during maintenance or service are reinstalled.
• Adequate, unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to
ensure correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can affect safe operation of the generator.
• Keep the area around the generator clean and uncluttered. Remove any materials that could become hazardous.
• When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.
• Inspect the generator regularly, and promptly repair or replace any worn or damaged components using only factory approved parts and procedures.
• Before performing any maintenance on the generator, always disconnect the battery cables to prevent accidental
startup. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG, or (–) first, then remove the
POSITIVE, POS, or (+) cable. When reconnecting the cables, connect the POSITIVE cable first, the NEGATIVE
cable last.
• Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may
result in exhaust, fuel, oil or coolant leaks.
2
Installation Guidelines for Stationary Diesel Generators
Safety
1.4 — Electrical Hazards
• All generators produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers
extremely high and dangerous voltages to the transfer switch as well as the generator when it is in operation.
Avoid contact with bare wires, terminals and other connections. Ensure all covers, guards, and barriers are in
place, and that they are properly secured and/or locked before operation. If work must be done around an operating unit, stand on an insulated, dry surface to reduce potential shock hazard.
• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
• If it is necessary to stand on metal or concrete while installing, operating, servicing, or repairing this equipment,
lay down a dry wooden platform and cover with insulated mats before beginning.
• Verify that the generator is properly grounded.
• Wire gauge sizes of electrical wiring, cables, and cord sets must be adequate to handle the maximum electrical
current (ampacity) to which it will be subjected.
• Before installing or servicing equipment, verify that all power voltage supplies are positively turned off at their
sources. Failure to do so can result in hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied by an electric utility is by means of a transfer switch
so as to isolate the generator electric system from the electric utility distribution system when the generator is
operating. Failure to isolate the two electric system power sources from each other by such means will result in
damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy.
• Generators installed with an automatic transfer switch will crank and start automatically when NORMAL (UTILITY) source voltage is removed or is below an acceptable preset level. To prevent automatic startup and possible
injury, disable the automatic start circuit (battery cables, etc.) before working on or around the unit. Place a “DO
NOT OPERATE” tag on the generator control panel and on the transfer switch.
• In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not
possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use
a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. If the victim is
unconscious, apply first aid and get immediate medical help.
• Do not wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock,
or may get caught in moving parts resulting in injury.
1.5 — Fire Hazards
• Keep a fire extinguisher near the generator at all times. Keep the extinguisher properly charged and be familiar
with its use. Direct any questions to the local fire department.
NOTE: DO NOT use any carbon tetra-chloride type fire extinguishers. These fire extinguishers emit toxic fumes
and the liquid can damage wiring insulation.
1.6 — Explosion Hazards
• Properly ventilate the room or building housing the generator to prevent buildup of explosive gas.
• Do not smoke around the generator. Immediately wipe up any fuel or oil spills. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result.
Keep the area surrounding the generator clean and free of debris.
• All types of fuels are potentially FLAMMABLE and/or EXPLOSIVE and must be handled with care. Inspect the
fuel system frequently and correct any leaks immediately. Be sure fuel supply lines are properly installed, purged,
and leak tested before placing the generator set into service.
Installation Guidelines for Stationary Diesel Generators
3
Safety
1.7 — Standards Index
Be sure the generator set is in strict compliance with all applicable local, state, and federal laws, codes, and regulations
pertaining to such installations. Always use the current version or edition of the applicable law, code, and regulation as
it applies to the local jurisdiction. In the absence of pertinent local laws and standards, use the following published
materials as a guide.
1.
National Fire Protection Association (NFPA) 70: The National Electric Code (NEC)*
2.
NFPA10: Standard for Portable Fire Extinguishers*
3.
NFPA 30: Flammable and Combustible Liquids Code*
4.
NFPA 37: Standard for Stationary Combustion Engines and Gas Turbines*
5.
NFPA 54: National Fuel Gas Code*
6.
NFPA 58: Standard for Storage and Handling of Liquefied Petroleum Gases*
7.
NFPA 68: Standard on Explosion Protection by Deflagration Venting*
8.
NFPA 70E: Standard for Electrical Safety in the Workplace*
9.
NFPA 99: Health Care Facilities Code*
10.
NFPA 101: Life Safety Code*
11.
NFPA 110: Standard for Emergency and Standby Power Systems*
12.
NFPA 211: Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances*
13.
NFPA 220: Standard on Types of Building Construction*
14.
NFPA 5000: Building Code*
15.
International Building Code**
16.
Agricultural Wiring Handbook***
17.
ASAE EP-364.2 Installation and Maintenance of Farm Standby Electric Power****
This list is not all inclusive. Check with the Authority Having Local Jurisdiction (AHJ) for any local codes or standards
which may be applicable to the jurisdiction where the generator is installed. The above listed standards are available
from the following internet sources:
* www.nfpa.org
** www.iccsafe.org
*** www.rerc.org Rural Electricity Resource Council; P.O. Box 309; Wilmington, OH 45177-0309
**** www.asabe.org American Society of Agricultural & Biological Engineers; 2950 Niles Road; St. Joseph, MI 49085
4
Installation Guidelines for Stationary Diesel Generators
Section 2
Installation Planning
2.1 — Protector Diesel Pre-Order Checklist
 The local fire marshal has confirmed that the generator must be located a minimum of ________ feet
from a house or other structure.
NOTE: Generac recommends a minimum clearance of five feet.
 The local AHJ has advised me regarding the requirements for electrical and/or building permits, as well
as those regulations relating to emissions and fuel storage.
 I have been advised of the local requirements for construction of a concrete base pad, and whether
anchoring requirements are needed for installation on a flood plain.
 I have confirmed with the appropriate authorities that the generator must be located a minimum of
________ feet from a property line.
 I have been advised whether the local fire marshal (or other third party) is required to be present at start
up.
 I have confirmed that the installation site is applicable to optional standby only and does not require an
NFPA 110 capable generator.
 The local fire marshal has confirmed that I am required to extend the fuel tank vents ________ feet above
the surrounding grade.
 The local fire marshal has confirmed that local codes require installation of the diesel product safety
accessories designated below.
Item
Description
Part Number
Emergency Stop
Switch
006510-0
 YES
 NO
90% Fuel Fill
Level Alarm
006504-0
 YES
 NO
Installation Guidelines for Stationary Diesel Generators
Required
5
Installation Planning
Item
Description
Part Number
Five Gallon Spill Box
006502-0
 YES
 NO
Spill Box Drain Back
006511-0
 YES
 NO
Fuel Fill Drop Tube
006507-0
 YES
 NO
Fuel Tank
Support Risers
Stainless Steel
Fuel Lines
6
006505-0 (15 & 20 kW)
006506-0 (30 & 50 kW)
006513-0 (15 & 20 kW)
006517-0
(30 kW)
006516-0
(50 kW)
Required
 YES  NO
 YES  NO
 YES  NO
 YES  NO
 YES  NO
Installation Guidelines for Stationary Diesel Generators
Installation Planning
2.2 — Unit Drawings
2.2.1— Installation Drawings
Installation drawings show weights, dimensions, clearances, exhaust details, connection locations, wiring stub-ups, lifting locations, and other information. Use the unit specific installation drawings when designing a site installation plan.
Thoroughly read the NOTES section of each drawing for important details.
Figure 2-1. Typical Installation Drawing
2.2.2— Wiring Diagrams
Wiring and schematic diagrams show the connection points for control wiring, load wiring, and any service power supply required for battery chargers, block heaters, etc. Always use the unit specific wiring diagrams during planning and
installation.
2.3 — Receiving
2.3.1— Receiving and Unpacking
Handle shipping cartons and crates with care to avoid damage. Store and unpack cartons with the correct side up, as
noted by the label on the shipping carton.
2.3.2— Inspection
Carefully inspect the generator set and all contents of cartons for any damage that may have occurred during shipment. See the shipping documentation for any provisions or guidance when damage is incurred. Correct all damage or
deficiencies before installation of the generator set.
Installation Guidelines for Stationary Diesel Generators
7
Installation Planning
2.4 — Storage Before Installation
2.4.1— Long Term Storage
If the unit is to be stored (or installed and not started-up) for six months or more, preserve in accordance with the manufacturer’s instructions. Contact the local Authorized Service Dealer to obtain the Long Term Preservation and Storage
Manual (Part No. 0G4018) and the Preservation Checklist (Part No. 0G4018A).
2.4.2— Short Term Storage
If the unit is to be stored (or installed and not started-up) for less than six months, proceed as follows:
• All units are provided with an enclosure.
• Place the unit on a smooth flat surface. Do not leave unit on the shipping pallet, as it leaves the bottom open for
entry of dirt, debris, insects, rodents, etc.
• Leave exhaust system openings covered.
• Leave plastic plugs in fuel connection points.
• Use anti-rodent plugs and other enclosure features to prevent entry of birds, small animals, and foreign objects.
2.5 — Lifting
To ensure personal safety and prevent damage to the unit, use only properly sized equipment intended for safe rigging,
lifting and moving of heavy machinery.
Use a spreader bar to prevent damage to the unit. Failure to use a spreader bar will result in scratches and damage to painted surfaces.
Installation drawings show the lifting points for rigging and lifting purposes. Always attach lifting and rigging devices at
the designated points only. Do not use the lifting points of the engine or alternator to move the generator set. See Figure 2-2.
Figure 2-2. Lifting Points (Four Places)
2.6 — Generator Location
Locate the generator set so that it is readily accessible for maintenance, repair, and firefighting purposes. Comply with
code requirements for minimum distance from combustible walls and building openings.
8
Installation Guidelines for Stationary Diesel Generators
Installation Planning
2.6.1— General Location Guidelines
Consider the following:
• The supporting structure must be adequate for the generator set and its accessories.
• Be sure the site is clean, dry, not subject to flooding, and provided with adequate drainage in the event of heavy
rains.
• Be sure the location permits noise and vibration to be effectively isolated.
• Verify that the site provides easy access to the generator set for maintenance, repair, and firefighting purposes.
• Keep a minimum of five feet of clearance around each side of the generator set to facilitate service or maintenance.
• Be sure the location permits engine exhaust gases to be safely evacuated from inhabited or occupied areas.
Consider the direction of prevailing winds to prevent exhaust gases from being carried back to the engine area or
to the fresh air intake vents of nearby buildings.
• The site must allow for the provision of an adequate fuel supply. Consider the ease of accessibility for refueling
purposes.
• Be sure the location permits sufficient air flow for cooling and ventilation. Consider the proximity of any walls,
fences, or other noise abatement or security barriers. Do NOT face the radiator discharge end of the enclosure
into the prevailing wind.
• Consider cold weather kit options and accessories for the generator in cold weather locations.
• Verify that the unit is securely fastened to the mounting pad to prevent movement caused by vibration.
• Verify that all electrical connections have flexible sections to isolate vibration.
NOTE: Failure to comply with the location guidelines can result in damage to the generator or surrounding area and
may cause the warranty to be suspended or voided. Extra repair labor or equipment may not be covered under the
warranty if service access is difficult or restricted.
2.6.2— Weather Considerations
Consider local weather conditions during installation. There are various accessories available to ensure fast, reliable
starting and operation regardless of local climatic conditions. Optional cold weather kits make starting of the engine
more dependable and reliable.
2.7 — Accessories
The following product accessories are available. See Figures 2-3 and 2-4. Contact a dealer for additional information.
1. Fuel Maintenance Kit (Part No. 006576-0)
9. Touch-Up Paint Kit (Part No. 005704-0)
2. Scheduled Maintenance Kit (Part No. 006571-0; 15 & 20 kW)
10. Emergency Stop Switch (Part No. 006510-0)
3. Scheduled Maintenance Kit (Part No. 006572-0; 30 kW)
11. Lockable Fuel Fill Cap (Part No. 006512-0)
4. Scheduled Maintenance Kit (Part No. 006570-0; 50 kW)
12. Five Gallon Spill Box (Part No. 006502-0)
5. Fuel Fill Drop Tube (Part No. 006507-0)
13. 90% Fuel Fill Level Alarm (Part No. 006504-0)
6. Cold Weather Kit (Part No. 006558-0): 15/20 kW; Part No.
006559-0: 30 kW; Part No. 006560-0: 50 kW)
14. Fuel Tank Risers (Part No. 006505-0: 15/20 kW; Part
No. 006506-0: 30/50 kW)
7. Mobile Link Transmitter (Part No. 006463-0)
15. Spill Box Drain Back (Part No. 006511-0)
8. Mobile Link Adapter Harness (Part No. 006478-0)
16. Stainless Steel Fuel Lines (Part No. 006513-0:15/20 kW;
Part No. 006517-0: 30 kW; Part No. 006516-0:
50 kW)
Installation Guidelines for Stationary Diesel Generators
9
Installation Planning
1.
2.
3.
5.
6.
7.
8.
9.
10.
11.
12.
13.
4.
Figure 2-3. Product Accessories
10
Installation Guidelines for Stationary Diesel Generators
Installation Planning
14.
15.
16.
Figure 2-4. Product Accessories (Continued)
Installation Guidelines for Stationary Diesel Generators
11
Installation Planning
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12
Installation Guidelines for Stationary Diesel Generators
Section 3
Foundations & Mounting
3.1 — Generator Foundations
Install the generator set on a concrete pad or base slab able to support its weight and accessories. A proper foundation
is needed to resist dynamic loading and reduce transmitted noise and vibration. The exact composition of the mounting
pad must follow standard engineering practices for the required loading and application. Securely fasten the generator set to the foundation using suitable grade, size and style fasteners. Holes are provided in the base tank frame
for this purpose.
3.1.1— Concrete Pad
Seat the concrete pad or base slab on a prepared solid subsurface and use appropriate reinforcing bar or expanded
wire mesh. A common specification calls for 2500 psi concrete reinforced with 8 gauge wire mesh or number 6 reinforcing bars on 12 inch centers.
3.1.2— Dimensions
Extend the concrete pad beyond the frame of the unit at least 12 inches and above the surrounding surface by 6
inches. This provides a mounting surface for fuel line support, as well as space for maintenance and repair.
The base pad must be:
• Capable of supporting 125% of the unit wet weight for single unit applications. Wet weight is the dry weight plus
the weight of the fuel in the base tank.
• Flat and level to within 1/2 inch.
• Capable of withstanding severe torque reactions.
3.1.3— Unit Clearance
Verify that the site provides easy access to the generator set for maintenance, repair, and firefighting purposes. Keep a
minimum of five feet of clearance around each side of the generator set to facilitate service or maintenance.
3.1.4— Stub Up Area
For load conduit, auxiliary power conduit (high voltage), and control wiring conduit (low voltage), see the installation
drawings for the location and dimensions of the stub up areas. See Figure 3-1.
Installation Guidelines for Stationary Diesel Generators
13
Foundations & Mounting
Figure 3-1. Typical Installation Drawing Stub Up Detail
3.2 — Mounting
3.2.1— Fixed Foundation
Use mounting holes in the base frame to fasten the unit to the foundation. Always use hardware of a suitable grade,
size and style.
3.2.2— Connections
All electrical connections must have flexible sections where they connect to the unit to isolate vibration. Properly support and secure all piping before installing the flexible connection.
14
Installation Guidelines for Stationary Diesel Generators
Section 4
Ventilation System
4.1 — General
Adequate and unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to
ensure safe generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions.
Keep area around the generator clean and uncluttered, and remove any materials that may pose a hazard.
4.2 — Outdoor Installation Only
The installation design must ensure that there are no obstructions at any of the air intakes that may impede intake airflow. The unit is for outdoor installation only.
4.2.1— Clearance
Keep a minimum of five feet of clearance around the unit to facilitate service and maintenance, and to ensure adequate
air circulation for air intakes and cooling of exhaust discharges.
Installation Guidelines for Stationary Diesel Generators
15
Ventilation System
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16
Installation Guidelines for Stationary Diesel Generators
Section 5
Diesel Fuel Systems
5.1 — General Information
Since diesel fuels are less volatile than gasoline or gaseous fuels, they are sometimes considered safer. Due to this
perception, careless installation practices can occur, which may lead to serious problems with generator set performance and reliability.
Periodically inspect and test the system to ensure all components remain in good working order.
5.2 — Diesel Fuel Base Tank
Units provided are typically mounted on their own base/fuel tank. See Figure 5-1. These are plumbed at the factory.
The base tank is the main fuel tank and incorporates the following items:
• Fill Line – some are equipped with overflow containment.
• Vent Line – some applications require extending the vent line outside of an enclosure or to outside air along with
adequate spill containment.
• Fuel supply line to engine pump with in-line check valve.
• Fuel return line from engine, sometimes supplied with a check valve.
• Fuel level indication (electrical, mechanical or both).
• Double wall construction with rupture basin and level indicator switch.
• Emergency vent on main tank and rupture basin.
EMERGENCY
VENT FUEL FILL
FUEL LEVEL SENSOR
VENT
EMERGENCY
VENT
BAFFLE
FUEL RETURN
FUEL SUPPLY
LEAK CONTAINMENT AREA
BAFFLE
RUPTURE BASIN
LEAK DETECTOR
STUB UP AREA
Figure 5-1. Typical Integrated Diesel Fuel Base Tank
Installation Guidelines for Stationary Diesel Generators
17
Diesel Fuel Systems
5.3 — Diesel Fuel Recommendations
IMPORTANT! DO NOT use Home Heating Oil or Bio-Diesel Fuel.
Use No.1D diesel fuel when temperatures are below freezing. Use No. 2D diesel fuel when temperatures are above
freezing. Starting October 1, 2010, diesel fuel must also meet the following requirements:
• Sulfur content of 15 parts per million (ppm) maximum.
• Maximum Cetane index of 40 or a maximum aromatic content of 35 volume percent.
Allow at least 5 percent of the tank capacity for fuel expansion. DO NOT OVERFILL!
5.3.1— Fuel Maintenance
Diesel fuel must be treated for long term storage. Use approved fuel additive and water abatement material. Test
stored fuel every 90 days and add treatment as required. Periodically check and dry abatement as needed.
1
2
Fuel Maintenance Kit
(P/N 006576-0)
3
5
4
1
Diesel Fuel Additive
2
Tank Snake
3
Probe
4
Test Swabs
5
Snake Line
6
Tank Snake Tag
(Not Shown)
Figure 5-2. Diesel Fuel Maintenance Kit
18
Installation Guidelines for Stationary Diesel Generators
Section 6
Electrical System
6.1 — General Information
All wiring must be properly sized, routed, supported, and connected. All wiring must comply with NEC and local codes.
The generator uses Customer Connection Interface (CCI) panels to separate the high voltage and customer control
wiring connections. These two panels are clearly labeled. The wiring diagrams for each specific unit show the connection points in their corresponding sections. Terminal boards are clearly labeled and correspond to the same terminal
connections shown in the wiring diagrams. Always use the unit specific wiring diagrams when making wiring connections.
6.2 — Remove Rear Panel and Stub Up Cover
1.
See Figure 6-1. Remove six screws with nylon washers to release rear panel from enclosure. For best results,
rotate left side of panel outward away from enclosure before disengaging the right side.
2.
Remove four screws with nylon washers to release fascia from control panel.
3.
Remove six screws with flat washers to release stub up cover.
6.3 — Wiring Installation Safety
Review the safety rules at the beginning of this manual for specific dangers, cautions, and hazards associated with the
installation of industrial products.
When installing the generator set and connecting wiring, keep the generator and system de-energized and disabled. It
is common electrical safety practice to verify that wires are de-energized using appropriate safety gear and a meter
before handling. Disable the generator by placing the AUTO/OFF/MANUAL switch in the OFF position, de-energize the
battery charger, and disconnect the negative cable from the negative battery terminal. Also, make sure the 120/240,
120/208 auxiliary power circuit to the unit is de-energized.
6.4 — General Wiring Requirements
Consider the following general wiring requirements:
• Load Wiring - Properly size and select wiring.
• Control Wiring - Typically low DC voltage wiring (12-
24Vdc) that includes the 2-wire start and signal wiring.
Use multi-strand wire appropriately sized for the length of
run. Do not exceed #12 AWG when connecting to the
customer connection terminals.
A
• Accessory Power Wiring - Provides power for optional
user accessories (battery warmer and block heater). Size
and select wiring using the appropriate tables in the NEC
and per the connection requirements in the individual
control panel wiring diagram.
6.5 — High Voltage Connections
The customer connection area on the left side of the control
panel contains the terminals to connect all high voltage wiring.
These connections are as follows:
A = Rear Panel
B = Stub Up Cover
B
Figure 6-1. Remove Rear Panel
and Stub Up Cover
• MLCB - E1, E2, E3 (if three-phase), and Neutral for customer load wiring. These wires run from the main line circuit breaker to the transfer switch. They supply generator power to the transfer switch and are marked for easy
identification.
Installation Guidelines for Stationary Diesel Generators
19
Electrical System
NOTE: The following tables are provided for references purposes only. Refer to the latest NEC, state and local
AHJ requirements for proper sizing of power and control wires.
Table 6-1. Frame Breakers
Frame Breaker
Range
Wire Type
Wire
Temperature
Rating
Lug AWG Range
(Number of
Conductors)
Torque
to Wire
Generac 225 AF
2 Pole
125A-200A
Cu/Al
167º F (75º C)
6-350 kcmil (1)
375 in-lb
Generac 225 AF
3 Pole
50A-200A
Cu/Al
167º F (75º C)
6-350 kcmil (1)
375 in-lb
Generac 400 AF
2 Pole
225A-400A
Cu/Al
167º F (75º C)
1/0-250 kcmil (2)
or
4-600 kcmil (1)
375 in-lb
Generac 400 AF
3 Pole
225A-400A
Cu/Al
167º F (75º C)
1/0-250 kcmil (2)
or
4-600 kcmil (1)
375 in-lb
Table 6-2. Terminal Tightening Torques
Amperage
Rating
Description
Cable Screw
Torque
Wire Size Range
15-20 A
Load Side, Aluminum Body Lug
32 in-lb
#14 - #8 AWG Cu
#12 - #8 AWG Al
25-35 A
Load Side, Aluminum Body Lug
36 in-lb
#8 - #6 AWG Cu
#8 - #6 AWG Al
40-50 A
Load Side, Aluminum Body Lug
45 in-lb
#8 - #6 AWG Cu
#8 - #4 AWG Al
55-70 A
Load Side, Aluminum Body Lug
50 in-lb
#8 - #4 AWG Cu
#8 - #2 AWG Al
80-100 A
Load Side, Aluminum Body Lug
60 in-lb
#4 - #1/0 AWG Cu
#2 - #1/0 AWG Al
10-130 A
Line Side, Threaded Contact With Ring Lugs
72 in-lb
#14 - #2 AWG
NOTE: Refer to specific NEC article
for routing of control wires and
power wires. AHJ has final call on
single or dual conduit.
Load Leads
Control Wiring
NOTE: Stub up area shown is for
reference only. See installation
drawings for unit specific details.
Stub Ups
Figure 6-2. Typical Load Leads and Control Wiring in Stub Up
20
Installation Guidelines for Stationary Diesel Generators
Electrical System
Load Wiring
Connections
 E1
 E2
 Neutral
 Ground


 Knock Out Plug
NOTE: Single
phase shown.

NOTE: See Figure 6-4
for typical control wiring
connections.


Figure 6-3. Typical High Voltage Connections
Customer load wiring consists of single-phase or three-phase connections between the generator Main Line Circuit
Breaker (MLCB) and the transfer switch. The wiring connects to lugs E1, E2, E3 (if three phase on MLCB), neutral, and
equipment ground at the generator and runs to the corresponding lugs in the transfer switch. All load wires, neutral and
ground should be marked and terminated in the correct lugs in the transfer switch. Ensure all wiring is properly
mounted and terminated at the appropriate connection points in both the generator and transfer switch. For general
information regarding wire type, temperature rating, size range, and wire lug torque specifications, see Tables 6-1 and
6-2. Always refer to NEC tables for specific requirements.
NOTE: For three phase applications, use phase rotation meter to verify that the generator phase rotation
matches the rotation of the utility.
Installation Guidelines for Stationary Diesel Generators
21
Electrical System
6.6 — Control Wiring Connections
The Control Wire Customer Connection block is where all of the control wiring is connected. Depending on the type of
system, this wiring includes the following:
NOTE: The control wire customer connections typically use Class 1 Wiring Methods (verify with AHJ). Always follow
the standards and methods appropriate to the circuits being wired.
NOTE: Observe the maximum wire size for the terminal strip connections shown in the unit wiring diagram.
 For battery charging, connect neutral in TB2 to neutral in the transfer switch. See NOTE below for transfer switches
without T1.
 Connect T1 in TB2 to T1 in the transfer switch. This is 120 volt supply to the unit's battery charger (normal RTS
transfer switch).
  Connect N1, N2 sensing wires in TB2 to N1 and N2 in the transfer switch. These two wires are utility sensing
wires.
  Connect 23 in TB3 to 23 in the transfer switch. Connect 194 in TB3 to 194 in the transfer switch. These are the
transfer switch control wires.
NOTE: For non RTS series transfer switches, or RTS series transfer switches without T1, use a 120 volt circuit from the
load side of the transfer switch to power the battery charger (dedicated 15/20 amp circuit). Convert the generator control over to a two-wire start and use terminals 178 and 183 in TB3.
Control Wiring
Connections


NOTE: All wiring must comply
with NEC, state and local AHJ
requirements.


If Two-Wire
IMPORTANT: Control wiring must be
installed in the provided 600V rated
electrical sleeving. The sleeving is
shipped loose and can be found in
the manual bag attached to one of
the louvered panels of the enclosure.
If Two-Wire

NOTE: Wire colors are shown for
illustration purposes only.

TB2 Terminal Block
Terminal




Function
TB3 Terminal Block
Voltages
Terminal
Function
Voltages
Neutral
Neutral for T1 Battery Charger
Neutral
178
Two Wire Start Control [GTS]
5-12 VDC
T1
Power for T1 Battery Charger
120 VAC
183
Two Wire Start Control [GTS]
5-12 VDC
N2
Utility Sensing from Transfer Switch
208-277 VAC
23
Transfer Relay Control Wire
12-0 VDC
N1
Utility Sensing from Transfer Switch
208-277 VAC
194
Power for Transfer Relay


12 VDC
Figure 6-4. Typical Control Wiring Connections
22
Installation Guidelines for Stationary Diesel Generators
Electrical System
Figure 6-5. Typical Control Wiring Schematic
Installation Guidelines for Stationary Diesel Generators
23
Electrical System
NOTE: The following table is provided for references purposes only. Refer to the latest NEC, state and local
AHJ requirements for proper sizing.
Table 6-3. Control Wire Length/Size
Maximum
Wire Length
Recommended
Wire Size
1-115 ft (1-35m)
No. 18 AWG
116-185 ft (36-56m)
No. 16 AWG
186-295 ft (57-89m)
No. 14 AWG
296-460 ft (90-140m)
No. 12 AWG
6.7 — Optional Accessory Power
• Accessory power for optional items (battery warmer and block heater) should come from a customer utility supply
source (with appropriate sized breaker), which is also powered by emergency power during an outage.
• Optional user installed GFCI receptacles. Provides a place to plug in optional battery warmer and block heater.
NOTE: Remove knock out plug and route accessory wiring to customer supplied weather-proof junction box. See Figure 6-3. Verify that wires do not contact moving or vibrating engine parts, as abraded wires can result in electrical problems.
6.8 — Install Stub Up Cover and Rear Panel
1.
Install six screws with flat washers to secure stub up cover.
2.
Install four screws with nylon washers to fasten fascia over control panel.
3.
Install rear panel. For best results, first engage right side of panel and then rotate left side inward toward enclosure. Alternately work left and right sides in until slots are aligned with screw holes on both sides. Install six
screws with nylon washers and tighten until snug.
6.9 — Transfer Switch Location
The location of the transfer switch is important. Consider the following:
1.
Locate the transfer switch as close to the emergency load as practical to avoid interruptions of the emergency
power system due to natural disasters or equipment failures.
2.
Locate the transfer switch in a clean, dry, well ventilated location, away from excessive heat. When the ambient
air is above 104° F (40° C), fuses and circuit breakers must be derated. Allow adequate working space around
the transfer switch. Refer to the latest NEC, state and local AHJ requirements for details.
3.
Install a circuit breaker (or fuses) in the line between the generator and the transfer switch. Generator sets are
available with properly sized circuit breaker built into the generator control. The circuit breaker can be separately
mounted. In the case of very large circuit breakers, a separate floor mounted circuit breaker is easier to wire up
than a wall mounted breaker.
4.
Install power and control wires as per NEC requirements with flexible sections at the generator set. The flexible
sections prevent vibration from damaging the conduit. All power conduits from the generator set must contain all
three phases.
5.
Conduit, wire, circuit protective device sizes, insulation etc. must conform to applicable local and national codes
and regulations.
6.
Be certain to seal around conduits that penetrate the walls of the generator set room to reduce the amount of
noise that is transmitted to the surrounding areas of the building and maintain site fire code rating.
24
Installation Guidelines for Stationary Diesel Generators
Electrical System
6.10 — Battery
6.10.1— General Cautions
• Stationary emergency generators installed with automatic transfer switches will crank and start automatically when NORMAL (UTILITY) source voltage is removed or is below an acceptable preset level. To prevent automatic startup and possible injury to personnel, do not connect battery cables until NORMAL
source voltage at the transfer switch is correct and the system is ready to be placed into operation.
• Storage batteries give off EXPLOSIVE hydrogen gas. This gas can form an explosive mixture around the
battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion.
An explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage
battery must be properly ventilated. Do not allow smoking, open flame, sparks, or any spark producing
tools or equipment near the battery.
• When working on the battery, always remove watches, rings, or other metal objects, and only use tools
that have insulated handles.
• Discharge static electricity from the body before touching the battery by first touching a grounded metal
surface.
• Do not lay tools or metal parts on top of the battery.
• Wear full eye protection and protective clothing.
• Where electrolyte contacts the skin, wash it off immediately with water. If contact is with eyes, flush thoroughly and immediately with water and seek medical attention.
• Battery electrolyte fluid is an extremely caustic 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 1 pound (500 grams) bicarbonate of soda to 1 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.
6.10.2— Battery Size
The ability to start the engine depends upon battery capacity, ambient temperatures and coolant and oil temperatures.
The engine/generator set Data Sheet lists minimum recommended battery capacity at various ambient temperatures.
The recommended battery capacities are listed under cold cranking amps (CCA) at 0 °F (−18 °C). Battery capacities
decrease as ambient temperatures decrease, so it is important to specify batteries with the appropriate CCA rating at a
temperature no higher than the minimum ambient temperature for the application.
6.10.3— Battery Replacement
For battery replacement, consult the unit specification sheet for battery size. Battery cables are factory connected at
the generator connection points. Fill the battery with the proper electrolyte fluid if necessary and have the battery fully
charged before installing.
6.10.3.1— Preliminary Instructions
1.
Open the viewing window.
2.
Press the OFF button on the control panel keypad. The red LED above the button illuminates to confirm that the
system is in the OFF mode.
3.
Move the Main Circuit Breaker switch down to the OFF (Open) position.
4.
Pull up rubber flap covering fuse holder and remove 7.5 amp fuse.
5.
Turn off utility power supply to the battery charger circuit.
Installation Guidelines for Stationary Diesel Generators
25
Electrical System
6.10.3.2— Check Condition and Clean
1.
Verify that top of battery is clean and dry.
2.
Clean cable connectors and battery terminals using a wire brush, if necessary.
3.
Inspect battery screws, clamps and cables for breakage, loose connections and corrosion. Tighten and clean as
necessary.
4.
Inspect battery for discoloration, raised top or a warped or distorted case, which might indicate that the battery
has been frozen, overheated or overcharged.
5.
Inspect the battery case for cracks or leaks.
6.
Check the battery fluid level of unsealed batteries. See Subsection 6.10.3.3—Check Fluid Level.
7.
Check the battery state of charge. See Subsection 6.10.3.4—Check State of Charge.
6.10.3.3— Check Fluid Level
Check the fluid level of unsealed batteries. If necessary, fill with distilled water only. DO NOT use tap water.
6.10.3.4— Check State of Charge
Check the state of charge using a Digital Multimeter. If below the manufacturer's recommendations, recharge battery
and retest. Replace battery if necessary.
6.10.3.5— Removal/Installation
Removal
$
CAUTION: Always disconnect the negative battery cable first. If the positive cable should contact
ground with the negative cable installed, the resulting sparks may cause a battery explosion which
could result in serious injury.
2.3L Models
1.
Remove battery negative cable (black) from
battery negative (-) terminal.
2.
Remove battery positive cable (red) from battery positive (+) terminal.
3.
Install rubber protective cover over battery positive (+) terminal. See A of Figure 6-6.
4.
Loosen two screws with nylon washers to
release battery hold-down clamp from battery
tray.
5.
Grasp battery strap next to battery positive (+)
terminal, and lift battery. See B of Figure 6-6.
6.
When battery tilts sideways, remove from opening.
7.
Remove rubber protective cover from battery
positive (+) terminal.
B
A
2.4L/3.4L Models
1.
Remove battery negative cable (black) from
battery negative (-) terminal.
2.
Remove battery positive cable (red) from battery positive (+) terminal.
3.
Loosen two screws with nylon washers to
release battery hold-down clamp.
4.
Remove battery from tray.
26
A = Protective Cover
B = Battery Strap
Figure 6-6. Install Battery (2.3L Models)
Installation Guidelines for Stationary Diesel Generators
Electrical System
Installation
$
CAUTION: Always connect the positive battery cable first. If the positive cable should contact ground
with the negative cable installed, the resulting sparks may cause a battery explosion which could
result in serious injury.
2.3L Models
1.
Install rubber protective cover over battery positive (+) terminal.
2.
Grasp battery strap next to battery positive (+) terminal, and lift battery.
3.
When battery tilts sideways, insert into opening.
4.
Return battery to the horizontal position while sliding it onto battery tray.
5.
Tighten two screws with nylon washers to secure hold-down clamp to battery tray.
6.
Remove rubber protective cover from battery positive (+) terminal.
7.
Install battery positive cable (red) to battery positive (+) terminal.
8.
Install battery negative cable (black) to battery negative (-) terminal.
2.4L/3.4L Models
Installation
1.
Install battery onto tray.
2.
Tighten two screws with nylon washers to secure hold-down clamp to battery tray.
3.
Install battery positive cable (red) to battery positive (+) terminal.
4.
Install battery negative cable (black) to battery negative (-) terminal.
6.10.3.6— Final Instructions
1.
Pull up rubber flap covering fuse holder and install 7.5 amp fuse.
2.
Move the Main Circuit Breaker switch up to the ON (Closed) position.
3.
Turn on the utility power supply to the battery charger circuit.
4.
If the unit was previously operational, press the AUTO button on the control panel keypad. The green LED above
the button illuminates to confirm that the system is in the AUTO mode.
5.
Close the viewing window.
6.11 — Operational Checks
+
CAUTION: The following procedures require special tools and skills. Contact a Generac Dealer or an
authorized service provider to perform these tasks.
6.11.1— Self Test
Upon power up, the controller goes through a system self test which checks for the presence of utility voltage on the
DC circuits. This is done to prevent damage if the installer mistakenly connects AC utility power sense wires into the
DC terminal block. If utility voltage is detected, the controller displays a warning message and locks out the generator,
thereby preventing damage to the controller. Remove power to the controller to clear this warning.
Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test
to be performed and pass.
Before starting, complete the following:
1.
Verify that the generator is OFF. The red LED above the OFF key on the control panel keypad illuminates to confirm that the system is in the OFF mode.
2.
Verify that the Main Circuit Breaker switch on the generator control panel is in the OFF (Open) position.
3.
Turn off all circuit breakers/electrical loads that will be powered by the generator.
4.
Check the engine crankcase oil level, coolant level, and fuel level, if necessary.
Installation Guidelines for Stationary Diesel Generators
27
Electrical System
During initial start up only, the generator may exceed the normal number of start attempts and experience an “over
crank” fault. This is due to accumulated air in the fuel system during installation. Reset the control board and restart up
to two more times, if necessary. If unit fails to start, contact the local dealer for assistance.
6.11.2— Check Manual Transfer Switch Operation
Refer to the “Manual Transfer Operation” section of the owner’s manual for procedures.
NOTE: Also use the appropriate transfer switch owner’s manual for manual and automatic system test.
+
CAUTION: Do not attempt manual transfer switch operation until all power voltage supplies to the
transfer switch have been positively turned off. Failure to turn off all power voltage supplies will result
in extremely hazardous and possibly fatal electrical shock.
6.11.3— Electrical Checks
Complete electrical checks as follows:
1.
Verify that the generator is OFF. The red LED above the OFF key on the control panel keypad illuminates to confirm that the system is in the OFF mode.
2.
Verify that the Main Circuit Breaker switch on the generator control panel is in the OFF (Open) position.
3.
Turn OFF all circuit breakers/electrical loads that will be powered by the generator.
4.
Turn on the utility power supply to the transfer switch using the means provided (such as a utility main line circuit
breaker).
+
CAUTION: The transfer switch is now electrically “hot.” Contact with “hot” parts will result in extremely
hazardous and possibly fatal electrical shock.
5.
Use an accurate AC voltmeter to check utility power source voltage across transfer switch terminals N1, N2, and
N3 (if three phase). Normal line-to-line voltage should be equivalent to rated unit voltage.
6.
Check utility power source voltage across terminals N1, N2, and N3 (if three phase) and the transfer switch neutral lug.
7.
When certain that utility supply voltage is compatible with transfer switch and load circuit ratings, turn OFF the
utility power supply to the transfer switch.
8.
Press the MANUAL key on the control panel keypad to crank and start the engine.
9.
Allow the engine to warm up for about five minutes. Move the Main Circuit Breaker switch on the generator control panel up to the ON (Closed) position.
+
CAUTION: Generator power voltage is now supplied to the transfer switch. Contact with live transfer
switch parts will result in dangerous and possibly fatal electrical shock.
10.
Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1, E2, and E3 (if
three phase).
11.
Successively connect the AC voltmeter test leads across terminal lugs E1, E2, and E3 (if three phase) and neutral; then across E2 and neutral. Voltage reading in each case should match utility voltage reading. If system is
three phase, verify that generator phase rotation matches utility phase rotation.
12.
Move the Main Circuit Breaker switch on the generator control panel down to the OFF (Open) position.
13.
Press the OFF key on the control panel keypad to shut the engine down.
+
CAUTION: Do not proceed unless certain that generator AC voltage and frequency are correct and
within the stated limits.
6.11.4— Test Generator Under Load
To test the generator set with electrical loads applied, proceed as follows:
1.
28
Verify that the generator is OFF. The red LED above the OFF key on the control panel keypad illuminates to confirm that the system is in the OFF mode.
Installation Guidelines for Stationary Diesel Generators
Electrical System
2.
Turn OFF all breakers/electrical loads that will be powered by the generator.
3.
Turn OFF the utility power supply to the transfer switch, using the means provided (such as a utility main line circuit breaker).
+
CAUTION: Do not attempt manual transfer switch operation until all power voltage supplies to the
transfer switch have been positively turned off. Failure to turn off all power voltage supplies will result
in extremely hazardous and possibly fatal electrical shock.
4.
Manually set the transfer switch to the STANDBY position, i.e., load terminals connected to the generator’s E1,
E2, and E3 (if three phase) terminals. The transfer switch operating lever should be down.
5.
Press the MANUAL key on the control panel keypad. The engine should crank and start immediately.
6.
Allow the engine to warm up for a few minutes.
7.
Move the Main Circuit Breaker switch on the generator control panel up to the ON (Closed) position. Loads are
now powered by the standby generator.
8.
Turn ON the circuit breaker/electrical loads powered by the generator.
9.
Connect a calibrated AC voltmeter and a frequency meter across terminal lugs E1, E2, and E3 (if three phase).
Voltage should be approximately unit rated voltage.
10.
Let the generator run at full rated load for 20-30 minutes. Listen for unusual noises, vibration or other indications
of abnormal operation. Check for oil leaks, evidence of overheating, etc.
11.
When testing under load is complete, turn OFF electrical loads.
12.
Move the Main Circuit Breaker switch on the generator control panel down to the OFF (Open) position.
13.
Allow the engine to run at no-load for 2-5 minutes.
14.
Press the OFF key on the control panel keypad to shut the engine down.
6.11.5— Check Automatic Operation
To check the system for proper automatic operation, proceed as follows:
1.
Verify that the generator is OFF. The red LED above the OFF key on the control panel keypad illuminates to confirm that the system is in the OFF mode.
2.
Install front cover over the transfer switch.
3.
Turn ON the utility power supply to the transfer switch, using the means provided (such as a utility main line circuit breaker).
NOTE: Transfer Switch will transfer back to utility position.
4.
Move the Main Circuit Breaker switch on the generator control panel up to the ON (Closed) position.
5.
Press the AUTO key on the control panel keypad. The system is now ready for automatic operation.
6.
Turn OFF the utility power supply to the transfer switch.
With the generator ready for automatic operation, the engine will crank and start when the utility source power is turned
OFF after a 10 second delay (factory default setting). After starting, the transfer switch connects load circuits to the
standby side. Let the system operate through its entire automatic sequence of operation.
With the generator running and loads powered by generator AC output, turn ON the utility power supply to the transfer
switch. The system transfers back to the utility position and then runs through the cool down cycle and shuts down.
6.12 — Installation Summary
1.
Ensure that the installation has been properly performed as outlined by the manufacturer and that it meets all
applicable laws and codes.
2.
Test and confirm proper operation of the system as outlined in the appropriate installation and owner’s manuals.
3.
Educate the customer on the proper operation, maintenance and service call procedures.
IMPORTANT! If the customer ever finds it necessary to turn the generator off during prolonged utility outages
to conserve fuel or perform maintenance, alert them to these important steps:
Installation Guidelines for Stationary Diesel Generators
29
Electrical System
To turn the generator OFF (while running in AUTO and online):
1.
Turn OFF (or open) the main Utility disconnect.
2.
Move the Main Circuit Breaker switch on the generator control panel down to the OFF (Open) position.
3.
Press the OFF key on the control panel keypad. The red LED above the button illuminates to confirm that the
system is in the OFF mode.
To turn the generator back ON:
1.
Press the AUTO key on the control panel keypad. Allow the unit to start and warm-up for a few minutes.
2.
Move the Main Circuit Breaker switch on the generator control panel up to the ON (Closed) position.
The system will now be operating in the automatic mode. The main utility disconnect can be turned ON (Closed), but to
shut the unit off, this complete process must be repeated.
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Installation Guidelines for Stationary Diesel Generators
Section 7
Installation Checklists
7.1 — Safety Checklist
NOTE: See Section 1 for more information.
 Are manuals, wiring diagrams and other documentation readily available?
 Is there any evidence of freight damage?
 Does the enclosure have scratches or damage to painted surfaces (which would indicate lifting without a spreader
bar)?
 Are all guards, covers, insulation blankets and other protective devices in place?
 Are any parts or components worn, damaged or missing?
 Is the generator properly grounded?
 Is a fire extinguisher kept near the generator?
 Is there any evidence of fuel, oil or coolant leaks?
 Are any combustible materials left in the generator compartment?
 Is the area surrounding the generator clean and free of debris?
 Do these parameters meet all applicable codes and local jurisdiction?
7.2 — Installation Planning Checklist
NOTE: See Section 2 for more information.
 Is the generator set readily accessible for maintenance, repair, and firefighting purposes?
 Is the site clean and dry? Is the site provided with adequate drainage?
 Is there a minimum of five feet of clearance around the generator set to facilitate the repair or replacement of major
components?
 Have adequate provisions been made for delivery of a fuel supply?
 Do these parameters meet all applicable codes and local jurisdiction?
Installation Guidelines for Stationary Diesel Generators
31
Installation Checklists
7.3 — Foundations & Mounting Checklist
NOTE: See Section 3 for more information.
 Is the generator set installed on a concrete pad capable of supporting its weight and accessories?
 Is the generator securely fastened to the concrete pad using suitable grade, size and style fasteners?
 Is the concrete pad seated on a prepared solid subsurface using appropriate reinforcing bar or expanded wire
mesh?
 Does the concrete pad extend beyond the frame rails at least 18 inches and above the surrounding surface by 3-8
inches?
 Is the concrete pad flat and level to within 1/2 inch?
 Is a containment dike provided for fuel and oil spillage?
 Is the bottom of the generator set enclosed?
 Do all fuel, coolant, exhaust, and electrical lines have flexible sections where they connect to the generator?
 Is all piping properly supported and secured?
 Do these parameters meet all applicable codes and local jurisdiction?
7.4 — Ventilation System Checklist
NOTE: See Section 4 for more information.
 Is there sufficient air flow for cooling and ventilation?
 Does the air inlet face the direction of prevailing winds?
 Has system been properly protected from freeze up and corrosion?
 Have standby equipment heaters been specified?
 Have all electrically driven devices been connected to load side of EPS connection points?
 Does the air outlet face noise sensitive areas without noise attenuating devices?
 Does the installation appear to have the necessary accessories to enable fast, reliable starting and operation in
adverse weather conditions (such as engine jacket water heaters, battery warmers, etc.)?
 Do these parameters meet all applicable codes and local jurisdiction?
32
Installation Guidelines for Stationary Diesel Generators
Installation Checklists
7.5 — Diesel Fuel System Checklist
NOTE: See Section 5 for more information.
 Is black iron or steel piping used from the fuel source to the flexible connection at the generator?
 Is any galvanized pipe used for diesel fuel applications?
 Are any pipe or fittings constructed of cast iron or aluminum?
 Is there evidence of leakage or damage at any hoses, clamps or fittings?
 Has the fuel system been primed (bled of air)?
 Do these parameters meet all applicable codes and local jurisdiction?
7.6 — Electrical System Checklist
NOTE: See Section 6 for more information.
 Is all wiring correctly sized for load and length of run?
 Is all wiring correctly routed?
 Is all wiring correctly supported?
 Is all wiring correctly connected?
 Are wire lugs fastened to buss bars using appropriate hardware? Is hardware properly tightened to specified
torque?
 Are all other terminals correctly tightened using the specified torque?
 Are batteries correctly sized?
 Are batteries correctly installed?
 Are the battery fluid levels correct?
 Are battery cables and connections clean and free of corrosion?
 Are the battery cables correctly connected? Are the terminal lugs correctly tightened?
 Is the battery condition and state of charge acceptable?
 Is area housing storage battery properly ventilated?
 Are batteries located near a source of flame or spark?
 Are AC wire sizes and connections correct?
 Are DC and communication wire sizes and connections correct?
 Are DC and communication wires routed separately from AC wires?
Installation Guidelines for Stationary Diesel Generators
33
Installation Checklists
 Are block heaters, battery charger, etc. properly matched with utility supply voltage?
 Are battery charger and block heater properly connected?
 If used, are remote start Wires 0 & 183 pulled and connected inside lower control panel of generator and inside
transfer switch?
 Is the AUTO/OFF/MANUAL switch in the “OFF” position?
 Is the grounding rod installed?
 Is the block heater operational?
 Is the battery charger operational?
 Are all AC electrical connections tight at the circuit breaker and transfer switch?
 Are all electrical connections (wiring, wire ties, clamps, terminal ends, connectors) on the generator tight?
 Are all electrical plugs throughout the generator seated correctly and fully inserted into their receptacles?
 Is there proper voltage and phase rotation at the transfer switch?
 Is manual operation of the transfer switch smooth and non-binding?
 Are dip switch settings in transfer switch OK?
 Do these parameters meet all applicable codes and local jurisdiction?
34
Installation Guidelines for Stationary Diesel Generators
Part No. 0K4465 Rev. A 08/14/2013
Printed in USA
© Generac Power Systems, Inc. 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.
S45 W29290 Hwy. 59
Waukesha, WI 53189
1-888-GENERAC (1-888-436-3722)
generac.com
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