INSTALLATION
GUIDELINES
Air-cooled Generators
INTENDED FOR USE IN CRITICAL LIFE SUPPORT
‹NOT
APPLICATIONS.
PRODUCT CAN BE INSTALLED BY THE HOMEOWNER.
‹THIS
HOWEVER, IF YOU ARE UNCOMFORTABLE WITH THE SKILLS
OR TOOLS REQUIRED, HAVE A QUALIFIED ELECTRICIAN OR
THIS MANUAL MUST BE USED IN CONJUNCTION
WITH THE APPROPRIATE OWNER’S MANUAL.
This manual should remain with the unit.
CONTRACTOR PERFORM THE INSTALLATION.
‹DEADLY EXHAUST FUMES! OUTDOOR INSTALLATION ONLY!
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.
Table of Contents
Section 1 — Safety Rules & General Information ..................................................................................................................................... 2
1.1 Introduction............................................................................................................................................................................. 2
1.2 Safety Rules ........................................................................................................................................................................... 3
1.3 General Rules ........................................................................................................................................................................ 4
Section 2 — Unpacking/Inspection/Familiarization ................................................................................................................................... 6
2.1 Required Tools ....................................................................................................................................................................... 6
2.2 Unpacking .............................................................................................................................................................................. 7
2.3 Parts Shipped Loose .............................................................................................................................................................. 9
Section 3 — Site Selection and Preparation ........................................................................................................................................... 10
3.1 Site Selection ....................................................................................................................................................................... 10
3.2 Site Preparation.................................................................................................................................................................... 12
Section 4 — Generator Placement .......................................................................................................................................................... 13
4.1 Generator Placement ........................................................................................................................................................... 13
Section 5 — Fuel Conversion/Gas Requirements/Connections .............................................................................................................. 15
5.1 Fuel Conversion ................................................................................................................................................................... 15
5.2 Fuel Requirements and Recommendations ......................................................................................................................... 16
5.3 Fuel Consumption ................................................................................................................................................................ 17
5.4 Fuel Line Sizing .................................................................................................................................................................... 17
5.5 Installing and Connecting Gas Lines .................................................................................................................................... 18
Section 6 — Electrical Connections ........................................................................................................................................................ 21
6.1 Generator Connections ........................................................................................................................................................ 21
6.2 Control Wiring....................................................................................................................................................................... 21
6.3 Main AC Wiring..................................................................................................................................................................... 22
6.4 Battery Requirements........................................................................................................................................................... 23
6.5 Battery Installation ................................................................................................................................................................ 23
Section 7 — Control Panel/Activation/Start-up/Testing ........................................................................................................................... 24
7.1 Control Panel Interface......................................................................................................................................................... 24
7.2 Generator Activation ............................................................................................................................................................. 25
7.3 Before Initial Start-up............................................................................................................................................................ 25
7.4 Check Manual Transfer Switch Operation ............................................................................................................................ 27
7.5 Electrical Checks .................................................................................................................................................................. 27
7.6 Generator Tests Under Load ................................................................................................................................................ 28
7.7 Checking Automatic Operation ............................................................................................................................................. 28
7.8 Installation Summary ............................................................................................................................................................ 29
Section 8 — Troubleshooting .................................................................................................................................................................. 30
Section 9 — Quick Reference Guide....................................................................................................................................................... 31
Section 10 — Accessories ....................................................................................................................................................................... 32
Section 11— Notes .................................................................................................................................................................................. 33
Section 12 — Interconnection Diagram ................................................................................................................................................... 34
Section 13 — Installation Diagram .......................................................................................................................................................... 36
1
Section 1
Safety Rules & General Information
1.1 INTRODUCTION
Thank you for purchasing this compact, high performance, air-cooled, engine-driven generator. It is designed to automatically supply electrical power
to operate critical loads during a utility power failure.
This unit is factory installed in an all-weather, metal enclosure that is intended exclusively for outdoor installation. This generator will operate using
either vapor withdrawn liquid propane (LP) or natural gas (NG).
NOTE:
When sized properly, this generator is suitable for supplying typical residential loads such as Induction Motors (sump pumps, refrigerators,
air conditioners, furnaces, etc.), Electronic Components (computer, monitor, TV, etc.), Lighting Loads and Microwaves.
1.1.1
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Dealer for starting, operating and servicing procedures.
Throughout this publication and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert
personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
Indicates a hazardous situation or action which, if not avoided, could result in death or serious injury.
Indicates a hazardous situation or action which, if not avoided, could result in minor or moderate injury.
NOTE: Notes contain additional information important to a procedure and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while
performing the action or service are essential to preventing accidents.
Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates is as
follows:
symbol points out important safety information that, if not followed, could endanger personal safety and/or property of
‹This
others.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock hazard.

This symbol points out potential explosion hazard.
The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recommends that if the operator is also the owner,
to read their Owner’s Manual and thoroughly understand all instructions before using this equipment. The manufacturer also strongly recommends
instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.
1.1.2
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, contact a Dealer for assistance. Service technicians are factory-trained and are capable of
handling all service needs. For assistance locating a dealer, call 1-888-436-3722.
When contacting a Dealer about parts and service, always supply the complete model number and serial number of the unit as given on its data decal,
which is located on the generator. See section “The Generator” for decal location.
Model No. ____________________ Serial No. _________________________
2
1.2 SAFETY RULES
These Instructions – The manufacturer suggests that these rules for safe operation be copied and posted near the unit’s
‹Save
installation site. Safety should be stressed to all operators and potential operators of this equipment.
Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Installation Manual and
with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are
caused by failing to follow simple and fundamental rules or precautions.
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, therefore, 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 utilized does not render the
generator unsafe.
the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can
‹Despite
cause possible injury or death. Permit only responsible and capable persons to install, operate and maintain this equipment.
ing to work on the generator.
Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempt-
‹Parts of the generator are rotating and/or hot during operation. Exercise care near running generators.
‹Installation must always comply with applicable codes, standards, laws and regulations.
running generator gives off carbon monoxide, an odorless, colorless poison gas. Breathing in carbon monoxide can cause head‹Aaches,
fatigue, dizziness, nausea, vomitting, confusion, fainting, siezures or death.
.
1.2.1 GENERAL HAZARDS
• For safety reasons, the manufacturer recommends that this equipment be installed by a Service Dealer or other competent, qualified electrician
or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes,
standards and regulations. Only an Authorized Service Dealer is allowed to perform warranty service on this unit.
• The engine exhaust fumes contain carbon monoxide, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can
cause unconsciousness or even death. Do NOT alter or add to the exhaust system or do anything that might render the system unsafe or in
noncompliance with applicable codes and standards.
• Install a battery-operated carbon monoxide alarm indoors, according to manufacturer’s instructions/recommendations.
• Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation. Do not alter the installation or permit even
partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator. The generator MUST be installed and
operated outdoors only.
• 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.
• 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 contact the nearest Dealer for parts needing repair or replacement.
• Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start up. 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 dangerous operating
conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.
3
1.2.2
ELECTRICAL HAZARDS
• All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer switch, as does the standby generator when it is in operation. Avoid contact with bare wires,
terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place, secured and/or locked
before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce 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.
• The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved
earth ground. Local electrical codes also may require proper grounding of the generator electrical system.
• After installing this home standby electrical system, the generator may crank and start at any time without warning. When this occurs, load circuits
are transferred to the STANDBY (generator) power source. To prevent possible injury if such a start and transfer occur, always set the generator
to the OFF mode, remove the 7.5 Amp fuse from the generator control panel, and disconnect the battery before working on equipment.
• 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.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving
components causing injury.
1.2.3
FIRE HAZARDS
• For fire safety, the generator must be installed and maintained properly. Installation must always comply with applicable codes, standards, laws
and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and
Health Administration (OSHA) has established. Also, ensure that the generator is installed in accordance with the manufacturer’s instructions
and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the
aforementioned codes, standards, laws and regulations.
• Keep a fire extinguisher near the generator at all times. Extinguishers rated “ABC” by the National Fire Protection Association are appropriate for
use on the standby electric system. Keep the extinguisher properly charged and be familiar with its use. Consult the local fire department with any
questions pertaining to fire extinguishers.
1.2.4
EXPLOSION HAZARDS
• Do not smoke around the generator. Wipe up any fuel or oil spills immediately. 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 from
debris.
• Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Install the fuel supply system according to applicable
fuel-gas codes. Before placing the home standby electric system into service, fuel system lines must be properly purged and leak tested according
to applicable code. After installation, inspect the fuel system periodically for leaks. No leakage is permitted.
1.3 GENERAL RULES
•
•
•
•
Follow all safety precautions in the Owner’s Manual, Installation Guidelines manual and other documents included with your equipment.
Refer to NFPA 70E for safety equipment required when working with a live system.
Never energize a new system without opening all disconnects and breakers.
Always consult your local code for additional requirements for the area in which the unit is being installed.
installation can result in personal injury and damage to the generator. It may also result in the warranty being suspended
or voided. All the instructions listed below must be followed including location clearances and pipe sizes.
‹Improper
1.3.1
BEFORE YOU BEGIN
Contact the local inspector or City Hall to be aware of all federal, state and local codes that could impact the installation. Secure all required permits
before starting the job.
Carefully read and follow all of the procedures and safety precautions detailed in the installation guide. If any portion of the installation manual,
technical manual or other factory-supplied documents is not completely understood, contact a dealer for assistance.
Fully comply with all relevant NEC, NFPA and OSHA standards as well as all federal, state and local building and electric codes. As with any
generator, this unit must be installed in accordance with current NFPA 37 and NFPA 70 standards as well as any other federal, state, and local codes
for minimum distances from other structures.
Verify the capacity of the natural gas meter or the LP tank in regards to providing sufficient fuel for both the generator and other household and
operating appliances.
4
1.3.2
NEC REQUIREMENTS
Local code enforcement may require that Arc Fault Circuit Interrupters (AFCIs) be incorporated into the transfer switch distribution panel. The
Transfer Switch provided with this generator has a distribution panel that will accept AFCIs (pre-wired transfer switches only).
Siemens Part No. Q115AF - 15A or Q120AF - 20A can be obtained from a local electrical wholesaler and will simply replace any of the single pole
circuit breakers supplied in the pre-wired transfer switch distribution panel.
1.3.3
STANDARDS INDEX
Applicable national, state or local laws, codes and regulations pertaining to the installation of engine-generator power systems must be strictly
complied with. Always use the current acceptable version or edition of the applicable code or standard which applies to your jurisdiction. In the
absence of pertinent local laws and standards, the following published booklets may be used as a guide (these apply to localities which recognize
NFPA and IBC):
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
National Fire Protection Association (NFPA) 70: The NATIONAL ELECTRIC CODE (NEC) *
NFPA 10: Standard for Portable Fire Extinguishers *
NFPA 30: Flammable And Combustible Liquids Code *
NFPA 37: Standard for Stationary Combustion Engines And Gas Turbines *
NFPA 54: National Fuel Gas Code *
NFPA 58: Standard for Storage And Handling Of Liquefied Petroleum Gases *
NFPA 68: Standard On Explosion Protection By Deflagration Venting *
NFPA 70E: Standard For Electrical Safety In The Workplace *
NFPA 99: Health Care Facilities Code *
NFPA 101: Life Safety Code *
NFPA 110: Standard for Emergency and Standby Power Systems *
NFPA 211: Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances *
NFPA 220: Standard on Types of Building Construction *
NFPA 5000: Building Code *
International Building Code **
Agricultural Wiring Handbook ***
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
your jurisdiction. 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 9085
‹
The installation of this product must comply strictly with applicable codes, standards and regulations. This product can be installed by
the homeowner. However, if you are uncomfortable with the skills or tools required, have a qualified electrician or contractor perform the
installation.
PERFORM THE INSTALLATION IN ONLY 6 STEPS!
STEP 1 - Unpacking / Inspection / Familiarization
STEP 2 - Site Selection and Preparation
STEP 3 - Generator Placement
STEP 4 - Gas Requirements Connections / Fuel Conversion
STEP 5 - Electrical Connections
STEP 6 - Control Panel Activation / Start-up / Testing
5
a transfer switch. The transfer switch must effectively isolate the electrical system from the utility distribution system when the
If this generator is used to power electrical load circuits normally powered by a utility power source, it is required by code to install
generator is operating (NEC 700, 701 & 702). Failure to isolate an electrical system by such means will result in damage to the generator and also may result in injury or death to utility power workers due to backfeed of electrical energy
Having reviewed SAFETY / GENERAL INFORMATION
proceed to Step 1:
SECTION 2 - UNPACKING / INSPECTION / FAMILIARIZATION
Section 2
Unpacking / Inspection / Familiarization
NOTE: After unpacking, carefully inspect the contents for damage. It is advised to unpack and inspect the unit immediately upon delivery to
detect any damage that may have occured in transit. Any claims for shipping damage need to be filed as soon as possible with the freight
carrier. This is especially important if the generator will not be installed for a period of time.
• This standby generator set is ready for installation with a factory supplied and pre-mounted base pad and has a weather protective enclosure that
is intended for outdoor installation only.
• This UL listed standby generator set may be packaged with an automatic transfer switch with built-in load center. The combination transfer switch
and load center is pre-wired with a two foot and 30 foot conduit. The pre-wired switch is rated for indoor use only. Circuit breakers for emergency
circuit connections are included (if equipped).
• This UL listed, 2-pole switch is rated at 50, 100 or 200 Amps, Service Rated at 250 volts maximum. The 200 Amp transfer switch is for indoor/
outdoor use (if equipped).
If any loss or damage is noted at time of delivery, have the person(s) making the delivery note all damage on the freight bill or affix their signature
under the consignor’s memo of loss or damage.
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 that is not evident at the time of delivery, but is discovered later.
2.1 REQUIRED TOOLS
• General SAE and Metric hand tools
– Wrenches
– Sockets
– Screwdrivers
• Standard electrician’s hand tools
– Drill and bits for mounting and routing conduits
• 4mm Allen wrench (for access to customer connections)
• 3/16 Allen wrench (test port on fuel regulator)
• Manometer (for fuel pressure checks)
• Meter capable of measuring AC/DC Voltage and Frequency
6
2.2 UNPACKING
1. With the box removed, you can see that this unit came with an automatic transfer switch. The transfer switch is an option and may not be
included.
2. Remove the wood frame and lift the transfer switch, if present, off the top of the generator.
Figure 2.1 — Crated Generator
3. Remove bolts and clamps. Exercise caution when removing the generator. Dragging it off the pallet WILL damage the base. The
generator must be lifted from the wooden pallet to remove.
LID
FRONT ACCESS
PANEL
REMOVE CRATING CLAMPS (4)
Figure 2.2 — Generator on Pallet
4. The lid will be locked. A set of keys is located behind the breaker door. Open the breaker door and cut the zip tie to remove the keys. Use the
keys to open the lid of the generator.
Figure 2.3 — Circuit Breaker Box and Keys (as shipped)
7
5. There are two locks securing the lid, one on each side. To properly open the lid, press down on the lid above the side lock and unlock the latch.
Repeat for the other side. If pressure is not applied from the top, the lid may appear stuck. NOTE: Always verify that the side locks are
unlocked before attempting to lift the lid.
6. Once the lid is open, remove the front access panel by lifting it up and out. Also remove the black panel over top of the customer connection
area.
7. Perform a visual inspection for any hidden freight damage.
Figure 2.4 — Inspecting for damage
8. Figure 2.5 illustrates the following:
– Customer connection area (underneath and behind the control panel)
– Fuel regulator
– Battery compartment
– Location of “Loose Shipped Parts”
CONNECTION AREA (UNDER CONTROL PANEL)
FUEL REGULATOR
LOOSE PARTS
BATTERY COMPARTMENT
Figure 2.5 — Customer Connection Area/Loose Parts Location
8
8-17 kW MAIN AC/CONTROL WIRING CONDUIT HOLE w/CAP PLUG
20 kW MAIN AC/CONTROL WIRING CONDUIT HOLE w/CAP PLUG
FUEL
CONNECTION
HOLE
BASE FASCIA (IF EQUIPPED)
Figure 2.6 — Generator Back View
2.3 PARTS SHIPPED LOOSE
• Rubber Mounts (only for units that include fascia)
• Flex Fuel Line
• Battery Terminal Cap
• Wire Shielding to separate AC from DC control wires
• Main Line Circuit Breaker (MLCB) Terminal Caps
• Wire Nuts (for pre-wired switches only)
• Main Line Circuit Breaker (MLCB) Locking Mechanism
• Install / Owner’s Manual (not shown) (CD if applicable)
• Keys
FLEX FUEL LINE
(tywrapped to battery cable or alternator bolt)
RUBBER MOUNTS
BATTERY
TERMINAL
CAP
WIRE SHIELDING
MLCB
TERMINAL CAPS
MLCB
LOCKING MECHANISM
WIRE NUTS
KEYS
Figure 2.7 — Loose Parts
With the UNPACKING / INSPECTION / FAMILIARIZATION
completed, proceed to Step 2:
SECTION 3 - SITE SELECTION and PREPARATION
9
Section 3
Site Selection and Preparation
3.1 SITE SELECTION
No operable windows or openings in the wall permitted
within 5 ft (1.52 m) from any point of the generator.
60 in (1524 mm) Existing Wall
36 in
(914 mm)
These guidelines are based upon fire
testing of the generator enclosure and
the manufacturer’s requirement for air
flow for proper operation. Local codes
may be different and more restrictive
than what is described here.
18 in (457 mm)
Minimum Distance
Top of Generator
36 in
(914 mm)
60 in (1524 mm)
36 in
(914 mm)
Clearance from operable
windows, doors or any
openings in the wall.
Clearance from the ends and front of the generator
must be 36 in (914 mm). This would include shrubs,
bushes or trees. Clearance at the top should be a
minimum of 60 in (1524 mm) from any structure,
overhang or projections from the wall. The generator
should not be placed under a deck or other structure
that is closed in and would limit or constrain air flow.
NOTE:
Removable fence panels for servicing cannot be
placed less than 18 in (457 mm) in front of the
generator.
60 in (1524 mm)
Minimum
60 in (1524 mm)
Recommended
Minimum From Ends
Generator
18 in
(457 mm)
Minimum
NOTE:
The generator can be placed under decks or structures as long as all clearances are met and local building codes are followed.
Figure 3.1 – Installation Guidelines
10
Install the generator set, in its protective enclosure, outdoors, where adequate cooling and ventilating air is always available (Figure 1.9). Consider
these factors:
• The installation of the generator must comply strictly with NFPA 37, NFPA 54, NFPA 58 and NFPA 70 standards.
• Install the unit where air inlet and outlet openings will not become obstructed by leaves, grass, snow, etc. If prevailing winds will cause blowing or
drifting, consider using a windbreak to protect the unit.
• Install the generator on high ground where water levels will not rise and endanger it. It should not operate in or be subjected to standing water.
• Allow sufficient room on all sides of the generator for maintenance and servicing. This unit must be installed in accordance with current applicable
NFPA 37 and NFPA 70 standards, as well as any other federal, state and local codes for minimum distances from other structures. DO NOT install
under wooden decks or structures unless there is at least 5 ft (1.52 m) of clearance above the generator, 3 ft (.91 m) of clearance on sides and
front, and a minimum of 18 in (457 mm) of clearance at the back of the unit.
• Install the unit where rain gutter down spouts, roof run-off, landscape irrigation, water sprinklers or sump pump discharge does not flood the unit or
spray the enclosure, including any air inlet or outlet openings.
• Install the unit where services will not be affected or obstructed, including concealed, underground or covered services such as electrical, fuel,
phone, air conditioning or irrigation. This could affect Warranty Coverage.
• Where strong prevailing winds blow from one direction, face the generator air inlet openings to the prevailing winds.
• Install the generator as close as possible to the fuel supply to reduce the length of piping. REMEMBER THAT LAWS OR CODES MAY
REGULATE THE DISTANCE AND LOCATION.
• Install the generator as close as possible to the transfer switch. REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE AND
LOCATION.
• The generator must be installed on a level surface. The generator must be level within a 0.5 in (13 mm) all around.
• The generator is typically placed on pea gravel, crushed stone or a concrete pad. Check local codes to see what type is required. If a concrete
pad is required, all federal, state and local codes should be followed.
3.1.1
INSTALLATION GUIDELINES FOR STATIONARY AIR-COOLED 8, 11, 13, 14, 15, 16, 17 AND 20 KW GENERATORS
The National Fire Protection Association has a standard for the installation and use of stationary combustion engines. That standard is NFPA 37, its
requirements limit the spacing of an enclosed generator set from a structure or wall (Figure 1.10).
NFPA 37, Section 4.1.4, Engines Located Outdoors: Engines, and their weatherproof housings if provided, that are installed outdoors shall be
located at least 5 ft (1.52 m) from openings in walls and at least 5 ft (1.52 m) from structures having combustible walls. A minimum separation shall
not be required where either of the following conditions exist:
1. The adjacent wall of the structure has a fire resistance rating of at least 1 hour.
2. The weatherproof enclosure is constructed of noncombustible materials and it has been demonstrated that a fire within the enclosure will not
ignite combustible materials outside the enclosure.
Annex A — Explanatory Material
A4.1.4 (2) Means of demonstrating compliance are by means of full scale fire test or by calculation procedures.
Because of the limited spaces that are frequently available for installation, it has become apparent that exception (2) would be beneficial for many
residential and commercial installations. With that in mind, the manufacturer contracted with an independent testing laboratory to run full scale fire
tests to assure that the enclosure will not ignite combustible materials outside the enclosure.
NOTE: Southwest Research Institute tesing approves 18 in (457 mm) installation minimum from structure. Southwest Research is a
nationally recognized third party testing and listing agency.
The criteria was to determine the worst case fire scenario within the generator and to determine the ignitability of items outside the engine enclosure
at various distances. The enclosure is constructed of non-combustible materials, and the results and conclusions from the independent testing lab
indicated that any fire within the generator enclosure would not pose any ignition risk to nearby combustibles or structures, with or without fire service
personnel response.
11
Figure 3.2 — Southwest Research Institute Decal (located inside the generator, next to the generator’s data decal)
http://www.swri.org/4org/d01/fire/listlab/listprod/director.htm
Based on this testing and the requirements of NFPA 37, Sec 4.1.4, the guidelines for installation of the generators listed above are
changed to 18 in (457 mm) from the back side of the generator to a stationary wall or building. For adequate maintenance and airflow
clearance, the area above the generator should be at least 5 ft (1.52 m) with a minimum of 3 ft (.91 m) at the front and ends of the enclosure. This
would include trees, bushes and shrubs. Vegetation not in compliance with these clearance parameters could obstruct air flow. In addition, exhaust
fumes from the generator could inhibit plant growth. See Figure 3.1 and the installation drawing within the owner’s manual for details.
Generator exhaust contains DEADLY carbon monoxide gas. This dangerous gas can cause unconsciousness or death. Do not place the unit near
windows, doors, fresh air intakes (furnaces, etc.) or any openings in the building or structure, including windows and doors of an attached garage.
supply is not turned off, sparking can occur at the battery posts and cause an explosion.
If the generator is not set to the OFF mode, it can crank and start as soon as the battery cables are connected. If the utility power
3.2 SITE PREPARATION
• Locate 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 that will provide adequate and unobstructed airflow.
• Place the unit so air vents won’t become clogged with leaves, grass, snow or debris. Make sure exhaust fumes will not enter the building through
eaves, windows, ventilation fans or other air intakes (see the “Site Selection” section).
• Select the type of base, gravel or concrete, as desired or as required by local laws or codes. Verify your local requirements before selecting.
3.2.1
CRUSHED STONE OR GRAVEL
• Dig a rectangular area approximately 5 in (127 mm) deep and about 6 in (152 mm) longer and wider than the footprint of the generator. Cover with
polyurethane film, if desired, and fill with pea gravel or crushed stone. Compact and level the stone. A concrete pad can be poured if desired or
required. The pad should be 4-5 in (102-127 mm) thick and extend 6 in (152 mm) beyond the outside of the generator in all directions.
NOTE: If a concrete pad is required, follow all applicable Federal, State or local codes.
12
Figure 3.3 — Compacted Gravel Site
Figure 3.4 — Concrete Pad Site
After completing your SITE SELECTION and PREPARATION,
time for Step 3:
SECTION 4 - GENERATOR PLACEMENT
Section 4
Generator Placement
4.1 GENERATOR PLACEMENT
With the Site Selection and Preparation performed, proceed with placement and installation of the generator itself.
All of the air-cooled generators come with a composite pad. The composite pad elevates the generator and helps prevent water from pooling around
the bottom of the generator (Figure 3.1). You can place the generator with a composite pad on 4 in (102 mm) of pea gravel that is compacted or on a
concrete pad. Check local codes to see what type of site base is required. If a concrete pad is required, all federal, state and local codes should be
followed. Place the generator on its mounting pad and position correctly as per the dimensional information given in Section 2.
NOTE: Generator must be level within 0.5 in (13 mm).
13
Figure 4.1 — Composite pad
When mounting the generator to concrete, there are four mounting holes available for securing the generator, if codes require (two holes inside the
front of the generator compartment and two holes in the back). See Figure 3.2.
Figure 4.2 — Mounting Hole Location
3.2.2
FASCIA INSTALLATION (IF APPLICABLE)
• Locate the four (4) threaded black rubber bumpers located in the Owner’s manual bag.
• Remove the four (4) bumpers from the bag and screw them into threaded holes located inside the end pieces of the fascia (two each) opposite
one another (A).
• Once the bumpers are installed, snap one of the end pieces into one of the front / rear pieces of fascia. Repeat this action with the other two
remaining pieces of fascia. NOTE: Do not assemble all four pieces together at this point (B).
• Place both assemblies at the base of the generator and fit the rubber bumpers into the lifting holes in the generator base (C).
• Once aligned, snap together the two remaining connection points.
14
B
A
C
Figure 3.5 — Fascia Installation
After completing GENERATOR PLACEMENT, proceed to
Step 4:
SECTION 5 — FUEL CONVERSION / GAS REQUIREMENTS /
CONNECTIONS
Section 5
Fuel Conversion / Gas Requirements /
Connections
5.1 FUEL CONVERSION
The generator was configured for natural gas operation at the factory. Press and turn fuel knob 180° to switch over to LP Vapor.
NOTE: The orange fuel conversion knob is located on the top of the fuel mixer on the V-twin engine and under the fuel mixer on the single
cylinder engine.
Press and turn the fuel knob towards the marked fuel source arrow until it stops. Fuel knob will rotate 180° and slide into the mixer body when
converting to LP.
15
FUEL KNOB LOCATIONS SHOWN FROM GENERATOR AIR BOX SIDE VIEW
8 kW GENERATOR
FUEL KNOB
11-20 kW GENERATORS
ORANGE FUEL
CONVERSION KNOB
FUEL KNOB
Figure 5.1 — Fuel Conversion Knob Location for Single and Twin Cylinder Generators
5.2 FUEL REQUIREMENTS AND RECOMMENDATIONS
With LP gas, use only the vapor withdrawal system. This type of system uses the vapors formed above the liquid fuel in the storage tank.
The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air Resources Board for tamper-proof
dual fuel systems. The unit will run on natural gas or LP gas, but it has been factory set to run on natural gas. Should the primary fuel need to be
changed to LP gas, the fuel system needs to be reconfigured. See the Fuel Conversion section for instructions on converting the fuel system.
Recommended fuels should have a Btu content of at least 1,000 Btus per cubic foot (37.26 megajoules per cubic meter) for natural gas; or at least
2,500 Btus per cubic foot (93.15 megajoules per cubic meter) for LP gas. Ask the fuel supplier for the Btu content of the fuel.
Required fuel pressure for natural gas is 3.5-7” water column (7-13 mm mercury). Required fuel pressure for for liquid propane vapor is
10-12” water column (19-22 mm mercury). The primary regulator for the propane supply is NOT INCLUDED with the generator.
NOTE: All pipe sizing, construction and layout must comply with NFPA 54 for natural gas applications and NFPA 58 for liquid propane
applications. Once the generator is installed, verify that the fuel pressure NEVER drops below it’s required fuel pressure rating. For further information regarding NFPA requirements refer to their website at www.nfpa.org.
Prior to installation of the generator, the installer should consult local fuel suppliers or the fire marshal to check codes and regulations for proper
installation. Local codes will mandate correct routing of gaseous fuel line piping around gardens, shrubs and other landscaping to prevent any
damage.
Special considerations should be given when installing the unit where local conditions include flooding, tornados, hurricanes, earthquakes and
unstable ground for the flexibility and strength of piping and their connections.
Use an approved pipe sealant or joint compound on all threaded fittings.
All installed gaseous fuel piping must be purged and leak tested prior to initial start-up in accordance with local codes, standards and regulations.
16
5.3 FUEL CONSUMPTION
NOTE: Required fuel pressure for natural gas is 3.5-7 in water column (7-13 mm mercury). The required fuel pressure for LP Vapor is 10-12
in water column (19-22 mm mercury).
These are approximate values, use the appropriate spec sheet or owner’s manual for specific values.
Unit
Nat. Gas
LP Vapor
1/2 Load
Full Load
1/2 Load
Full Load
7 / 8 kW
78 / 2.21
121 / 3.43
0.87 / 3.29
1.42 / 5.37
10 / 11 kW
124 / 3.51
195 / 5.52
1.18 / 4.45
1.92 / 7.28
13 / 13 kW
157 / 4.45
255 / 7.22
1.64 / 6.2
2.95 / 11.15
14 / 14 kW
177 / 5.01
279 / 7.9
1.85 / 6.99
3.07 / 11.61
15 / 15 kW
185 / 5.24
296 / 8.38
1.83 / 6.91
2.86 / 10.82
16 / 16 kW
193 / 5.47
312 / 8.83
1.9 / 7.2
3.19 / 12.07
16 / 17 kW
193 / 5.47
312 / 8.83
1.99 / 7.53
3.57 / 13.53
18 / 20 kW
205 / 5.8
308 / 8.72
2.08 / 7.87
3.85 / 14.57
* Natural gas is in cubic feet per hour / cubic meters per hour.
** LP is in gallons per hour / liters per hour.
*** Values given are approximate.
Verify that gas meter is capable of providing enough fuel flow to include household appliances and all other loads.
cause an explosion. No leakage of fuel is permitted. Natural gas, which is lighter than air, tends to collect in high areas. LP gas
and
is heavier than air and tends to settle in low areas.
Gaseous fuels such as natural gas and liquid propane (LP) gas are highly explosive. Even the slightest spark can ignite such fuels

NOTE: A minimum of one approved full flow manual shut-off valve must be installed in the gaseous fuel supply line. The valve must be
easily accessible. Local codes determine the proper location.
NOTE: THE GAS SUPPLY AND PIPE MUST BE SIZED AT 100% LOAD BTU / MEGAJOULE RATING.
5.4 FUEL LINE SIZING
• First, determine what size pipe is required. Refer to NFPA 54 for NG or NFPA 58 for LP for further information.
• Always refer to the owner’s manual for the proper BTU / megajoule and required gas pressures. To calculate BTU or Megajoules:
– Natural Gas: BTU=Cubic feet / hour x 1000
Megajoules=Cubic meters / hour x 37.26
– Liquid Propane Vapor: BTU=Cubic feet / hour x 2500
Megajoules=Cubic meters / hour x 93.15
• Start by measuring the distance from the generator to the gas source. The generator should be plumbed directly from the source, not off the end
of an existing system.
• When measuring the pipe length, add 2.5 ft (.76 m) for every angle or bend in the pipe and add that to the overall pipe distance.
17
5.4.1
NATURAL GAS PIPE SIZING
To properly use this chart, find the kW rating of the generator in the left column, and trace to the right. The number to the right is the maximum length
(measured in feet / meters) allowed for the pipe sizes on top. The pipe sizes are measured by inside diameter (ID) to include any fittings, valves
(must be full flow), elbows, tees or angles. Add 2.5 ft (.76 m) per any bend, tee or angle in the pipe to the overall distance.
kW
7-8
11
13-14
16-17
20
.75 / 19
55 / 16.76
20 / 6.1
10 / 3.05
1 / 25
200 / 60.96
85 / 25.91
50 / 15.24
40 / 12.19
20 / 6.1
Pipe Size (in. / mm)
1.25 / 32
1.5 / 38
820 / 249.94
370 / 112.78
800 / 243.84
245 / 74.68
545 / 166.12
190 / 57.91
425 / 129.54
130 / 39.62
305 / 92.96
2 / 51
945 / 288.04
kW
7-8
11
13-14
16-20
.75 / 19
20 / 6.1
Pipe Size (in. / mm)
1 / 25
1.25 / 32
60 / 18.29
175 / 53.34
30 / 9.14
125 / 38.1
20 / 6.1
80 / 24.38
10 / 3.05
60 / 18.29
1.5 / 38
200 / 60.96
175 / 53.34
125 / 38.1
For pressures below 5" of water column (9mm mercury) down to 3.5” of water
column (7mm mercury)
For 5-7” of water column (9-13mm mercury)
5.4.2
LP VAPOR PIPE SIZING
To properly use this chart, find the kW rating of the generator in the left column, and trace to the right. The number to the right is the maximum length
(measured in feet / meters) allowed for the pipe sizes on top. The pipe sizes are measured by inside diameter (ID) to include any fittings, valves
(must be full flow), elbows, tees or angles. Add 2.5ft. (.76m) per any bend, tee or angle in the pipe to the overall distance.
NOTE: Pipe sizes are using a second stage regulator.
NOTE: The minimum LP tank size is 250 gallons (946 L), unless unit calculations dictate use of a larger tank. Vertical tanks, which
are measured in pounds (or kilograms), will not usually meet the minimum tank size requirement. A 1050 lb (476 kg) vertical tank size
minimum is required.
kW
7-8
11
13-14
16-17
20
5.4.3
.75 / 19
165 / 50.29
70 / 21.33
45 / 13.72
25 / 7.62
15 / 4.57
Pipe Size (in. / mm)
1 / 25
1.25 / 32
570 / 173.74
255 / 77.72
1000 / 304.8
170 / 51.82
690 / 210.31
130 / 39.62
540 / 164.59
115 / 35.05
480 / 146.3
GAS INSTALLATION SUMMARY
GAS PIPE SIZING IS ONE OF THE MOST COMMONLY MADE MISTAKES. A PROPERLY SIZED GAS PIPE IS CRITICAL TO THE PROPER OPERATION OF THE GENERATOR. THE GENERATOR INLET SIZE HAS NO BEARING ON
THE PROPER GAS PIPE SIZE.
NOTE: THE GAS SUPPLY AND PIPE MUST BE SIZED AT 100% LOAD BTU / MEGAJOULE RATING.
5.5 INSTALLING & CONNECTING GAS LINES
1. Both natural gas and LP Vapor are highly volatile substances, so strict adherence to all safety procedures, codes, standards and
regulations is essential.
Gas line connections should be made by a certified plumber familiar with local codes. Always use AGA-approved gas pipe and a quality
pipe sealant or joint compound.
Verify the capacity of the natural gas meter or the LP tank in regards to providing sufficient fuel for both the generator and other operating
appliances.
• Fuel Regulator installed per laws or regulator manufacturer’s specifications
• AGA approved gas pipe
• Flexible fuel line
– Do not bend!!!
– Do not attach directly to generator
– Check all connections for leaks
• Sediment trap near generator (if applicable or required by code)
• Full flow rated shut-off near generator per local jurisdiction or code
18
2. Most applications will require an external manual full flow shutoff valve on the fuel line.
Figure 5.2 — Full Flow Shutoff Valve
3. When connecting the gas line to the generator, use the provided section of UL Listed or AGA-approved flexible fuel line in accordance with
local regulations. The purpose of the flexible fuel line is to ensure that vibration from the generator does not cause a gas leak at one of the
connection points, so it’s important that the line be installed with as few bends as possible. Configure the sediment trap (if applicable or
required by code) as illustrated.
SEDIMENT TRAP
Figure 5.3 — Sediment Trap
Figure 5.4 — Incorrect Routing of Flexible Hose
19
4. Never bend the flexible fuel line to avoid using an elbow. Bending the flexible line decreases its ability to absorb vibrations and defeats its
purpose, as well as constricts the actual fuel flow. See Figure 5.5.
5. Check for leaks by spraying all connection points with a soap solution made of dishwashing soap and water. You should not see the solution be
“blown away” or form “bubbles”. Next, check the gas pressure at the regulator in the generator by following these steps.
– Close gas supply valve.
– Remove the top gas pressure test port from the regulator (see Figure 5.6) and install the gas pressure tester (manometer).
– Open the gas supply valve and ensure that the pressure is within the specified values.
NOTE: See owner’s manual or spec sheet for proper fuel pressure specifications. If the gas pressure is not within specifications, contact
the local gas supplier.
4) Close gas valve when completed.
Top Gas Pressure
Test Port
Fuel Regulator
Gas Pressure
Manometer
Figure 5.5 — Checking Pressure with Manometer
BTU and Pressure Decal
Check Distance with Gas Provider
Size Meter for Generator
Load Plus ALL
Appliances Loads
Flex Fuel Line
Safety Shut-off with Pressure Port
NG - BTU = Cubic feet/hour X 1000
Megajoules = Cubic meters/hour X 37.26
For Underground Installations, Verify
Piping System for Code Compliance
Size gas pipe with Pipe Sizing Guide or to local codes.
Figure 5.6 — Typical Natural Gas Vapor Installation
20
Primary Regulator Per LP Provider
BTU and Pressure Decal
Check Distance with LP Provider
Size tank Large Enough
to provide required BTUs
for Generator and ALL
Connected Appliance
Loads. Be sure to correct
for Weather Evaporation.
Check distance with
Regulator Manufacturer
Fuel Tank
Flex Fuel Line
High Pressure Pipe
sized per LP Provider
Full Flow Safety Shut-off
with Pressure Port
Secondary-vented Regulator
LP - BTU = Cubic feet/hour X 2500
Megajoules = Cubic meters/hour X 93.15
Size gas pipe from secondary regulator with Pipe Sizing Guide or to local codes.
Figure 5.7 — Typical LP Vapor Installation
NOTE: When sizing a secondary regulator for LP or high pressure natural gas applications be sure to note the maximum individual load
capabilities which will be lower than total capacity. This could impact generator starting performance if sized too small.
NOTE: It is not recommended to reduce the fuel pipe size exiting the secondary regulator unless necessary to accommodate the ½” or ¾”
flexible fuel line that is shipped with the generator. This may potentially cause starting or performance issues.
After completing GAS REQUIREMENTS / CONNECTIONS /
FUEL CONVERSION, it’s time for Step 5:
SECTION 6 — ELECTRICAL CONNECTIONS
Section 6
Electrical Connections
6.1 GENERATOR CONNECTIONS
NOTE: Control wiring may be already wired on pre-wired generators. If so, tighten the 5’ whip conduit inside of the enclosure. If not, wiring
must be in accordance with local jurisdiction and codes.
1. Remove the appropriate Main AC/Control Wiring Knock-out Plug from the back of the generator.
2. Install the conduit and Main AC and Control Wires between the generator and the transfer switch. See Figure 2.6 for knockout locations (verify
specific transfer switch wiring/connections per model).
NOTE: These wiring connections may be present on pre-wired models.
NOTE: This wiring can be run in the same conduit if the appropriate insulation rated wire is used.
3. Seal the conduit at the generator and in compliance with any codes.
4. Strip the insulation from the ends of the wires. Do not remove excessive insulation.
5. To connect the control wires, push down on the spring loaded connection point with a flat head screwdriver, insert wire and release.
NOTE: No wire insulation should be in the connection point, only bare wire.
21
6.2 CONTROL WIRING
Control Wire Recommended Length and Size
Maximum Wire Length
Recommended Wire Size
1-115 ft (1-35 m)
No. 18 AWG
116-185 ft (36-56 m)
No. 16 AWG
186-295 ft (57-89 m)
No. 14 AWG
296-460 ft (90-140 m)
No. 12 AWG
CONTROL PANEL CONNECTIONS
Terminal Numbering Decal
Wire Numbers
A
YELLOW #1 & #2
N1 & N2 - 240 VAC - Sensing for Utility Dropout and Pickup
B
BLUE #3
T1 - Fused 120VAC for Battery Charger (see NOTE)
C
BLACK #3
0 - DC (-) Common Ground Wire
D
RED #4
194 - DC (+) 12 VDC for Transfer Controls
E
WHITE #5
23 - Transfer Control Signal Wire
SPRING LOADED CONNECTION POINTS
A
B*
(*see note below)
OPTIONAL ALARM
RELAY CONTACTS
(Normally Open)
LARGE NEUTRAL LUG TORQUE SPEC
2/0 TO 14AWG 120 IN-LB (13.56 N-M)
4-6 AWG 35 IN-LB (3.95 N-M),
8 AWG 25 IN-LB (2.82 N-M),
10-14 AWG 20 IN-LB (2.26 N-M)
C
D
E
LARGE GROUND LUG TORQUE SPEC
2/0 TO 14AWG 120 IN-LB (13.56 N-M)
Figure 6.1 — Control Wiring (found behind control board)
NOTE: *Wires 23, 194 and 0 must be run through the provided wire shielding provided in the manual bag to separate the low voltage from
the high voltage wires unless the requirement of 300.3(c)(1) of the NEC are met (see the Parts Shipped Loose section).
NOTE: Must be connected to keep battery charged whether unit is running or not.
6.3 MAIN AC WIRING
Figure 6.2 — Main AC Wiring
22
NOTE: Main AC wiring must be in accordance with local jurisdiction and codes.
6.
7.
8.
9.
Strip the insulation off the wire ends. Do not remove excessive insulation.
Remove the two cap plugs located behind the breaker door and to the right of the Main Breaker.
Loosen the lugs of the Main Breaker through the access holes.
Insert a power wire (E1 or E2) through the opening in the back cover and into the bottom lug. Torque to the proper specification.
NOTE: There are three (3) screws inside the top of the breaker panel (behind the breaker door). Removing these screws will allow the entire
breaker box to be carefully pulled out. When reinstalling, be certain that the tabs on the bottom lock into place.
10. Connect the Neutral wire to the Neutral Lug and torque to the required specification. See Figure 6.1.
11. Connect the Ground wire to the Ground Lug and torque to the required specification. See Figure 6.1.
NOTE: Neutral Bonding - For installations that require the neutral to be bonded to the 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 all wiring lugs, bus bars and connection points to the proper torque specifications. Torque specifications for the Main Line
Circuit Breaker (MLCB) can be found on a decal located on the inside of the Main Line Circuit Breaker Door.
6.4 BATTERY REQUIREMENTS
Group 26R, 12V, 525 CCA (Minimum CCA)
6.5 BATTERY INSTALLATION
Fill the battery with the proper electrolyte fluid if necessary and have the battery fully charged before installing it.
Before installing and connecting the battery, complete the following steps:
1. Verify that the generator has been turned OFF.
2. Turn off utility power supply to the transfer switch.
3. Remove the 7.5 Amp fuse from the generator control panel.
Battery cables were factory connected at the generator. See Figure 6.3. Connect cables to battery posts as follows:
4. Connect the red battery cable (from starter contactor) to the battery post indicated by a positive, POS or (+).
5. Connect the black battery cable (from frame ground) to the battery post indicated by a negative, NEG or (—).
6. Install the red battery post cover (included).
NOTE: Dielectric grease should be used on battery posts to aid in the prevention of corrosion.
NOTE: Damage will result if battery connections are made in reverse.
Figure 6.3 – Battery Cable Connections
NOTE: In areas where temperatures regularly fall below 32 °F (0 °C), it is recommended that a pad type battery heater be installed to aid
in cold climate starting. This is available as a cold weather kit through an authorized service dealer.
23
With the ELECTRICAL CONNECTIONS completed,
proceed to the final step - Step 6:
SECTION 7 — CONTROL PANEL / ACTIVATION /
START-UP / TESTING
Section 7
Control Panel / Activation / Start-up /
Testing
7.1
CONTROL PANEL INTERFACE
7.1.1
USING THE AUTO / MANUAL / OFF BUTTONS (FIGURE 7.1)
the AUTO button pushed in, the engine may crank and start at any time without warning. Such automatic starting occurs
when utility power source voltage droops below a preset level or during the normal exercise cycle. To prevent possible injury that
‹With
might be caused by such sudden starts, always push the OFF button, remove the fuses, and disconnect the battery before working
on or around the generator or transfer switch. Then, place a “DO NOT OPERATE” tag on the generator panel and on the transfer
switch.
1. “OFF” Button – This button shuts down the engine and prevents automatic operation.
2. “MANUAL” Button – This button cranks and starts the engine. Transfer to standby power will not occur unless there is a utility failure.
3. “AUTO” Button – Selecting this button activates fully automatic system operation. It also allows the unit to automatically start and exercise the
engine every seven days with the setting of the exercise timer (see the Setting the Exercise Timer section).
Figure 7.1 – 8/11/13/14/15/16/17/20 kW Generator Control Panel
24
Display Interface Menus
The LCD display is organized as detailed below:
• The “Home” page is the default page that will be displayed if no keys are pressed for five (5) minutes. This page normally shows the current
Status message and the current date and time. The highest priority active Alarm and/or Warning will be automatically posted on this page as well,
and the backlight will flash when such an event is detected. In the case of multiple Alarms or Warnings, only the first message will be displayed. To
clear an Alarm or Warning, press the OFF button and then press the ENTER key.
• The display backlight is normally off. If the user presses any key, the backlight will come on automatically and remain on for 30 seconds after the
last key was pressed.
• The “Main Menu” page will allow the user to navigate to all other pages or sub-menus by using the Up/Down and Enter keys. This page can
be accessed at any time with several presses of the Escape key. Each press of the Escape key takes you back to the previous menu until the
main menu is reached. This page displays the following options: HISTORY, STATUS, EDIT AND DEBUG. (See the Menu System Diagram in the
Owner’s Manual).)
7.2 GENERATOR ACTIVATION
When battery power is applied to the generator during the installation process, the controller will light up. However, the generator still needs to be
activated before it will automatically run in the event of a power outage.
Activating the generator is a simple, one-time process that is guided by the controller screen prompts. Once the product is activated, the
controller screen will not prompt you to activate again, even if you disconnect the generator battery.
After obtaining your activation code, please complete the following steps at the generator’s control panel in the Activation Chart.
Upon first power up of the generator, the display interface will begin an installation wizard. The installation wizard will prompt the user to set the
minimum settings to operate the generator. These settings are: Current Date/Time and Exercise Day/Time. The maintenance intervals will be
initialized when the exercise time is entered.
The exercise settings can be changed at any time via the “EDIT” menu.
If the 12 volt battery is disconnected or the fuse removed, the installation wizard will operate upon power restoration. The only difference is the
display will only prompt the customer for the current Time and Date.
7.2.1
SETTING THE EXERCISE TIMER
This generator is equipped with an exercise timer. Once it is set, the generator will start and exercise every seven days, on the day of the week and
at the time of day specified. During this exercise period, the unit runs for approximately 12 minutes and then shuts down. Transfer of loads to the
generator output does not occur during the exercise cycle unless utility power is lost.
IF THE INSTALLER TESTS THE GENERATOR PRIOR TO INSTALLATION, PRESS THE “ENTER” BUTTON TO SKIP SETTING UP THE
EXERCISE TIMER.
17 and 20 kW units can run at 2,400 rpm while exercising. While providing the necessary periodic exercise operation, the lower rpm also reduces
fuel consumption, engine wear and noise.
NOTE: The exerciser will operate only when the generator is placed in the AUTO mode and will not work unless this procedure is performed. The current date/time will need to be reset every time the 12 volt battery is disconnected and then reconnected, and/or when the
fuse is removed.
7.3 BEFORE INITIAL START-UP
NOTE: These units have been run and tested at the factory prior to being shipped and do not require any type of break-in.
‹Never operate the engine with the oil level below the “Add” mark on the dipstick. Doing this could damage the engine.
NOTE: This unit comes filled with 30 weight organic oil from the factory. Check the oil level and add the appropriate viscosity and amount
if necessary.
25
ACTIVATION CHART
TROUBLESHOOTING
Display Reads:
Language
English
Use ARROW keys to scroll to desired
language. Press ENTER to select.
If the wrong language is chosen, it can be
changed later using the “edit” menu.
Press ENTER to begin the activation process.
If ESCAPE is pressed instead of ENTER,
the generator will only run in manual mode
(for test purposes) and NOT ACTIVATED will
be displayed. You will need to remove the
7.5 Amp generator control panel fuse AND
disconnect the T1, N1 and N2 connector in
the external connection box (if equipped); or
disconnect utility input (main breaker) to the
transfer switch for 3-5 seconds and reconnect,
then begin with Step 1.
+
Display Reads:
Activate me (ENT) or
ESC to run in manual
Display Reads:
To Activate go to
www.activategen.com
If you do not have your activation code,
go to www.activategen.com or call
1-888-9ACTIVATE (922-8482 , US & CA only).
If you already have your activation code, wait
3-5 seconds for the next display.
Display Reads:
Serial 123456789
Passcode XXXXX +/-
Use ARROW keys to scroll and find the first
number of your Activation Code.
Press ENTER to select.
Repeat this step until all digits have been
entered.
Use ESCAPE to correct previous digits.
Display Reads:
Select Hour (0-23)
- 6 +
Figure 7.2 – Activation Sequence
26
Activation is complete when all digits are
entered above and your screen shows this
display.
What happens if “Wrong Passcode Try Again”
appears?
Reenter the activation code. If a second
Follow the controller prompts to continue
attempt is unsuccessful, check the number
setting the time function. Refer to your Owner’s against the code given on activategen.com. If
Manual with questions.
it is correct and the generator will not accept it,
contact 1-888-9ACTIVATE (922-8482 , US &
CA only).
7.3.1 Installation Assistant
Interconnect System Self Test Feature (follow the on-screen prompts)
Upon power up, this controller will go through a system self test which will check 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
will display a warning message and lock out the generator, preventing damage to the controller. Power to the controller must be removed 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.
NOTE: The generator is to be run with all appropriate panels in place, including during troubleshooting by a technician.
7.3.2 Before starting, complete the following:
1.
2.
3.
4.
5.
Ensure that the generator is OFF.
Set the generator’s main circuit breaker to the OFF (or OPEN) position.
Turn off all breakers that will be powered by the generator.
Check the engine crankcase oil level and, if necessary, fill to the dipstick FULL mark with the recommended oil. Do not fill above the FULL mark.
Check the fuel supply. Gaseous fuel lines must have been properly purged and leak tested in accordance with applicable fuel-gas codes. All fuel
shutoff valves in the fuel supply lines must be open.
During initial start up only, the generator may exceed the normal number of start attempts and experience an “overcrank” fault. This is due to
accumulated air in the fuel system during installation. Reset the control board by pushing the OFF button and ENTER key, and restart up to two
more times if necessary. If unit fails to start, contact a local dealer for assistance.
7.4 CHECK MANUAL TRANSFER SWITCH OPERATION
Refer to the “Manual Transfer Operation” section of the owner’s manual for procedures.
off. Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock.
Do not attempt manual transfer switch operation until all power voltage supplies to the transfer switch have been positively turned
7.5 ELECTRICAL CHECKS
Complete electrical checks as follows:
1.
2.
3.
4.
Ensure that the generator is OFF.
Set the generator’s main circuit breaker to the OFF (or OPEN) position.
Turn OFF all circuit breakers/electrical loads that will be supplied by the generator.
Turn on the utility power supply to the transfer switch using the means provided (such as a utility main line circuit breaker).
electrical shock. Proceed with caution.
The transfer switch is now electrically “hot.” Contact with “hot” parts will result in extremely hazardous and possibly fatal
5. Use an accurate AC voltmeter to check utility power source voltage across transfer switch terminals N1 and N2. Nominal line-to-line voltage
should be 240 volts AC. If it’s not, verify AC output and wiring from utility source to N1 and N2 lugs at transfer switch.
6. Check utility power source voltage across terminals N1 and the transfer switch neutral lug; then across terminal N2 and neutral. Nominal line-toneutral voltage should be 120 volts AC. If it’s not, verify AC output and wiring from utility source to N1 and N2 lugs at transfer switch.
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. On the generator panel, push the MANUAL button. The engine should crank and start.
9. Let the engine warm up for about five minutes to allow internal temperatures to stabilize. Then, set the generator’s main circuit breaker to its ON
(or CLOSED) position.
result in dangerous and possibly fatal electrical shock.
Proceed with caution! Generator power voltage is now supplied to the transfer switch. Contact with live transfer switch parts will
10. Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1 and E2. Voltage should be 238-242 at a
frequency of 59.5-60.5 Hertz. If it’s not, verify that the MLCB is closed and verify AC output and frequency (Hertz or Hz) at the MLCB. Also verify
wiring from generator to E1 and E2 lugs at transfer switch.
27
11. Connect the AC voltmeter test leads across terminal lugs E1 and neutral; then across E2 and neutral. In both cases, voltage reading should
be 119-121 volts AC. If it’s not, verify that the MLCB is closed and verify AC output between the E1 and E2 of the MLCB and Neutral at the
generator. Also, verify wiring from generator to E1, E2 ans Neutral lugs at transfer switch.
12. Set the generator’s main circuit breaker to its OFF (or OPEN) position.
13. Push the generator’s OFF button. The engine should shut down.
NOTE: It is important not to proceed until certain that generator AC voltage and frequency are correct and within the stated limits.
7.6 GENERATOR TESTS UNDER LOAD
To test the generator set with electrical loads applied, proceed as follows:
1. Ensure that the generator is OFF.
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).
off. Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock.
Do not attempt manual transfer switch operation until all power voltage supplies to the transfer switch have been positively turned
4. Manually set the transfer switch to the STANDBY position, i.e., load terminals connected to the generator’s E1/E2 terminals. The transfer switch
operating lever should be down.
5. Push the generator’s MANUAL button. The engine should crank and start immediately.
6. Let the engine stabilize and warm up for a few minutes.
7. Set the generator’s main circuit breaker to its ON (or CLOSED) position. Loads are now powered by the standby generator.
8. Turn ON the circuit breaker/electrical loads that are powered by the generator one by one.
9. Connect a calibrated AC voltmeter and a frequency meter across terminal lugs E1 and E2. Voltage 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. Check
for oil leaks, evidence of overheating, etc.
11. Verify gas pressure while under full load.
12. When testing under load is complete, turn OFF electrical loads.
13. Set the generator’s main circuit breaker to the OFF (or OPEN) position.
14. Let the engine run at no-load for 2-5 minutes.
15. Push the generator’s OFF button. The engine should shut down.
7.7 CHECKING AUTOMATIC OPERATION
To check the system for proper automatic operation, proceed as follows:
1. Ensure that the generator is OFF.
2. Install front cover of 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. Set the generator’s main circuit breaker to its ON (or CLOSED) position.
5. Push the generator’s AUTO button. 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 should crank and start when the utility source power is turned OFF after a 10 second
delay (factory default setting). After starting, the transfer switch should connect load circuits to the standby side after a five (5) second delay. 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 following should
occur:
• After approximately 15 seconds, the switch should transfer loads back to the utility power source.
• Approximately one minute after re-transfer, the engine should shut down.
28
7.8 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 end-user on the proper operation, maintenance and service call procedures.
Important! If the end user ever finds it necessary to turn the generator off during prolonged utility outages to perform maintenance or conserve fuel, educate them on these simple, but important steps:
To turn the generator OFF (while running in AUTO and online):
1. Turn OFF (or OPEN) the main Utility disconnect.
2. Turn OFF (or OPEN) the Main Line Circuit Breaker (MLCB) on the generator.
3. Turn the generator OFF.
To turn the generator back ON:
1. Put the generator back into AUTO and allow to start and warm-up for a few minutes.
2. Turn ON (or CLOSE) the MLCB on the generator.
The system will now be operating in its automatic mode. The main utility disconnect can be turned ON (or CLOSED), but to shut the unit off, this
complete process must be repeated.
29
Section 8
Troubleshooting
PROBLEM
CAUSE
CORRECTION
The engine will not crank.
1. Fuse blown.
1. Correct short circuit condition by replacing
7.5 Amp fuse in generator control panel.
2. Loose, corroded or defective battery cables.
2. Tighten, clean or replace as necessary.*
3. Defective starter contact.
3. *See #2.
4. Defective starter motor.
4. *See #2.
5. Dead Battery.
5. Charge or replace battery.
1. Out of fuel.
1. Replenish fuel / Turn on fuel valve.
2. Defective fuel solenoid (FS).
2. *
3. Open #14 wire from engine control board.
3. Repair wiring.
4. Defective spark plug(s).
4. Clean, re-gap or replace plug(s).
5. Valve lash out of adjustment.
5. Reset valve lash.
1. Air cleaner plugged or damaged.
1. Check / replace air cleaner.
2. Defective spark plug(s).
2. Clean, re-gap or replace plug(s).
3. Fuel pressure incorrect.
3. Confirm fuel pressure to regulator is 1012” water column (19-22 mm mercury) for
LP, and 3.5 - 7” water column (7 - 13 mm
mercury) for natural gas.
The engine cranks but will not start.
The engine starts hard and runs rough.
4. Fuel selector in wrong position.
4. Move selector to correct position..
The generator is set to OFF, but the engine
continues to run.
1. Controller wired incorrectly
1. Repair wiring or replace controller.
2. Defective control board.
2. *
There is no AC output from the generator.
1. Main line circuit breaker is in the OFF (or
OPEN) position.
1. Reset circuit breaker to ON (or CLOSED).
2. Generator internal failure.
2. *
1. Main line circuit breaker is in the OFF
(or OPEN position).
1. Reset circuit breaker to ON (or CLOSED).*
There is no transfer to standby after utility
source failure.
2. Defective transfer switch coil
3. Defective transfer relay
4. Transfer relay circuit open
5. Defective control logic board.
Unit consumes large amounts of oil.
3. *
3. *
5. *
1. Engine over filled with oil.
1. Adjust oil to proper level.
2. Engine breather defective.
2. *
3. Improper type or viscosity of oil.
3. See “Engine Oil Recommendations”.
4. Damaged gasket, seal or hose.
4. Check for oil leaks.
* Contact an Authorized Service Dealer for assistance.
30
2. *
Section 9
Quick Reference Guide
Problem
LED
Things to Check
Active Alarm
Solution
Unit running in AUTO but no
power in house.
GREEN
Check MLCB.
NONE
Check MLCB if the MLCB is in the ON position. If it is in
the ON position contact the servicing dealer.
Unit shuts down during
operation.
RED
Check the LED’s / Screen for
alarms.
HIGH TEMPERATURE
Check ventilation around the generator, intake, exhaust
and rear of generator. If no obstruction contact serving
dealer.
Unit shuts down during
operation.
RED
Check the LED’s / Screen for
alarms.
OVERLOAD REMOVE
LOAD
Clear alarm and remove household loads from the
generator. Put back in AUTO and restart.
Unit was running and shuts
down, attempts to restart.
RED
check the LED’s / Screen for
alarms.
RPM SENSE LOSS
Clear alarm and remove household loads from the
generator. Put back in AUTO and restart. It may be a fuel
issue so contact the servicing dealer.
Unit will not start in AUTO with NONE
utility loss.
See if screen says unit not
activated.
NOT ACTIVATED
Refer to activation section in owners manual.
Unit will not start in AUTO with GREEN
utility loss.
Check screen for start delay
countdown.
None
If the start up delay is greater than expected, contact
servicing dealer to adjust from 2 to 1500 seconds.
Unit will not start in AUTO with RED
utility loss.
Check the LED’s / Screen for
alarms.
LOW OIL PRESSURE
Check Oil Level / Add Oil Per Owners Manual. If oil level
is correct contact servicing dealer.
Unit will not start in AUTO with RED
utility loss.
Check the LED’s / Screen for
alarms.
RPM SENSE LOSS
Clear alarm. Check the battery using the control panel
under the MAIN menu using the BATTERY MENU
option. If it states battery is GOOD contact servicing
dealer. If it states CHECK BATTERY replace the battery.
Unit will not start in AUTO with RED
utility loss.
Check the LED’s / Screen for
alarms.
OVERCRANK
Check fuel line shutoff valve is in the ON position. Clear
alarm. Attempt to start the unit in MANUAL. If it does not
start or starts and runs rough, contact servicing dealer.
Unit will not start in AUTO with RED
utility loss.
Check the LED’s / Screen for
alarms.
LOW VOLTS REMOVE
LOAD
Clear alarm and remove household loads from the
generator. Put back in AUTO and restart.
Unit will not start in AUTO with RED
utility loss.
Check the LED’s / Screen for
alarms.
FUSE PROBLEM
Check the 7.5 Amp fuse. If it is bad replace it with an
ATO 7.5 Amp fuse, if not contact servicing dealer.
Unit will not start in AUTO with RED
utility loss.
Check the LED’s / Screen for
alarms.
OVERSPEED
Contact servicing dealer.
Unit will not start in AUTO with RED
utility loss.
Check the LED’s / Screen for
alarms.
UNDERVOLTAGE
Contact servicing dealer.
Unit will not start in AUTO with RED
utility loss.
Check the LED’s / Screen for
alarms.
UNDERSPEED
Contact servicing dealer.
Unit will not start in AUTO with RED
utility loss.
Check the LED’s / Screen for
alarms.
STEPPER
OVERCURRENT
Contact servicing dealer.
Unit will not start in AUTO with RED
utility loss.
Check the LED’s / Screen for
alarms.
MISWIRE
Contact servicing dealer.
Unit will not start in AUTO with RED
utility loss.
Check the LED’s / Screen for
alarms.
OVERVOLTAGE
Contact servicing dealer.
Yellow LED illuminated in any
state.
YELLOW
Check the screen for
additional information.
LOW BATTERY
Clear alarm. Check the battery using the control panel
under the MAIN menu using the BATTERY MENU
option. If it states battery is GOOD contact servicing
dealer. If it states CHECK BATTERY replace the battery.
Yellow LED illuminated in any
state.
YELLOW
Check the screen for
additional information.
BATTERY PROBLEM
Contact servicing dealer.
Yellow LED illuminated in any
state.
YELLOW
Check the screen for
additional information.
CHARGER WARNING
Contact servicing dealer
Yellow LED illuminated in any
state.
YELLOW
Check the screen for
additional information.
SERVICE A
Perform SERVICE A maintenance, hit ENTER to clear.
Yellow LED illuminated in any
state.
YELLOW
Check the screen for
additional information.
SERVICE B
Perform SERVICE B maintenance, hit ENTER to clear.
Yellow LED illuminated in any
state.
YELLOW
Check the screen for
additional information.
Inspect Battery
Inspect Battery, hit ENTER to clear.
31
Section 10
Accessories
There are performance enhancing accessories available for air-cooled generators.
Accessory
Description
Cold Weather Kit
Recommended in areas where temperatures regularly fall below 32 ºF (0 ºC).
Scheduled Maintenance Kit
Includes all pieces necessary to perform maintenance on the generator along with oil recommendations.
Auxiliary Transfer Switch Lockout
Enables any of the transfer switches to completely lock out one large electrical load by tying into its control
system.
Fascia Skirt Wrap
Standard on all 20 kW units. It is available for all other current production air-cooled units. It snaps together,
around the base of the generator, to provide a smoothing, contoured look as well as rodent / insect
protection.
Mobile Link™
Provides a personalized web portal that displays the generator’s status, maintenance schedule, event
history and much more. This portal is accessible via computer, tablet or smart phone. Sends emails and/
or text notifications the moment there is any change in the generator’s status. Notification settings can be
customized to what type of alert is sent and how often. For more information visit www.standbystatus.com.
Touch-Up Paint Kit
Very important to maintain the look and integrity of the generator enclosure. This kit includes touch-up paint
and instructions.
Contact a Dealer for additional information on accessories.
32
Section 11
Notes
33
34
T1
EVOLUTION
PANEL
GROUNDING ELECTRODE
CONNECTION
(LOCATED ON THE
REAR OF UNIT)
N1 N2
0
194 23
WHITE
T1
TOP
VIEW
N1 N2
0
194 23
GREEN
E1
E2
NOTE: INSTALLATION MUST MEET ALL
NATIONAL, STATE AND LOCAL
ELECTRICAL CODES.
SIDE VIEW
GFCI
BREAKER
E1
E2
GENERATOR OUTPUT
CIRCUIT BREAKER
2 POLE
TO GROUNDING
ELECTRODE
GROUND
LOAD SHED
DEVICE
UTILITY SUPPLY FROM
SERVICE DISCONNECT
PRIORITY 4
PRIORITY 3
PRIORITY 2
PRIORITY 1
AIR 2
AIR 1
23 TRANSFER
15B +12V
0 GROUND
NEUTRAL BLOCK
4
CONTACTOR
3
CONTACTOR
2
CONTACTOR
1
CONTACTOR
NEUTRAL
T1
N1 N2 T1
E2
T1 E1 E2 T2
T2
E1
T1
N2
N2
N1
N1
CUSTOMER LOAD
(DISTRIBUTION PANEL)
STANDBY
(C2 & VR2)
UTILITY
(C1 & VR1)
RTSR TRANSFER SWITCH - 2013 MODEL
0
194
23
Section 12
Interconnection Diagram
12.1 INTERCONNECTION DRAWING 0K2516-B
35
T1
0
EVOLUTION
PANEL
GROUNDING ELECTRODE
CONNECTION
(LOCATED ON THE
REAR OF UNIT)
N1 N2
194 23
WHITE
T1
TOP
VIEW
N1 N2
0
194 23
GREEN
E1
E2
NOTE: INSTALLATION MUST MEET ALL
NATIONAL, STATE AND LOCAL
ELECTRICAL CODES.
SIDE VIEW
GFCI
BREAKER
E1
E2
GENERATOR OUTPUT
CIRCUIT BREAKER
2 POLE
NEUTRAL BAR
GROUND BAR
PANELBOARD
UTILITY
METER
SOCKET
DISCONNECT
BONDING
CONNECTION
IN PANELBOARD
LOAD SHED
DEVICE
TO GROUNDING
ELECTRODE
N1
N2
T1
C
0D9618-TO
STANDBY
(C2 & VR2)
UTILITY
(C1 & VR1)
E1 T1
N1
RTSY TRANSFER SWTICH - 2013 MODEL
A BONDING JUMPER IS
PROVIDED BETWEEN
THE NEUTRAL LUG
AND ENCLOSURE
AT THIS LOCATION
(FACTORY INSTALLED)
GROUND CONNECTION
0
194
23
T2 E2
N2
Section 13
Installation Diagram
13.1 INSTALLATION DRAWING 0J9945-D
36
37
© 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.
Internal Use Only – Not for Distribution
Part No. 0J9944
Revision K (10/08/14)
Generac Power Systems, Inc.
S45 W29290 Hwy. 59
Waukesha, WI 53189
1-888-GENERAC (1-888-436-3722)
generac.com
Printed in U.S.A.
Owner’s Manual
For
Automatic Transfer Switch
50 & 100 Amp
Model Number
RTG10EZA1
RTG12EZA1
RTG16EZA1
MODEL NUMBER: _________________________
SERIAL NUMBER: _________________________
DATE PURCHASED:________________________
Register your Generac product at:
WWW.GENERAC.COM
888-436-3722
Para español , visita: http://www.generac.com/service‐support/product‐support‐lookup
Pour le français, visiter : http://www.generac.com/service‐support/product‐support‐lookup
SAVE THIS MANUAL FOR FUTURE REFERENCE
:$51,1*
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ii
Automatic Transfer Switch Owner’s Manual
Table of Contents
Section 1 Introduction and Safety
Section 4 Operation
1.1 Introduction ............................................................1
4.1 Functional Tests and Adjustments ......................9
1.2 Safety Rules ...........................................................1
4.2 Manual Operation ...................................................9
4.2.1 Transfer Mechanism Manual Operation .............9
1.3 Safety Symbols and Meanings .............................2
Section 2 General Information
4.2.2 Close to Generator Source Side ......................10
4.2.3 Return to Utility Source Side ............................10
2.1 Unpacking ...............................................................3
4.3 Voltage Checks ....................................................10
4.3.1 Utility Voltage Checks ......................................10
2.2 Equipment Description ..........................................3
2.2.1 Transfer Switch Mechanism ...............................3
4.3.2 Generator Voltage Checks ...............................10
2.2.2 Circuit Breakers Listed for Use ...........................4
2.3 Transfer Switch Data Decal ...................................4
2.4 Transfer Switch Enclosure ....................................4
2.5 Safe Use of Transfer Switch .................................4
2.6 Load Management Options ...................................4
Section 3 Installation
3.1 Mounting the Transfer Switch ...............................5
3.2 Mounting the Outdoor
Connection Box ...........................................................5
4.4 Generator Tests Under Load ..............................10
4.5 Checking Automatic Operation ..........................11
4.6 Installation Summary ...........................................11
4.7 Shutting Generator Down While Under Load ....11
Section 5 Drawings and Diagrams
5.1 Installation Drawing (USA) ..................................13
5.1.1 Drawing No. 0H6447-A ....................................13
5.2 Installation Drawing (Canada) ............................14
5.2.1 Drawing No. 0L3138-A .....................................14
3.3 Routing the Flexible Conduit ................................6
5.3 Interconnection Drawing .....................................15
5.3.1 Drawing No. 0H6453-B (Part 1 of 2) ................15
3.4 Connecting Power Source and Load Lines .........6
5.3.2 Drawing No. 0H6453-B (Part 2 of 2) ................16
3.5 Connecting Generator Control Wiring .................6
5.3.3 Drawing No. 0H6454-B ....................................17
3.6 Installing Branch Circuit Conductors
– USA Installations ................................................7
3.7 Installing Branch Circuit Conductors
– Canadian Installations ........................................7
3.8 Installing Breakers .................................................8
Automatic Transfer Switch Owner’s Manual
iii
This page intentionally left blank.
iv
Automatic Transfer Switch Owner’s Manual
Introduction and Safety
Section 1 Introduction and Safety
1.1 — Introduction
Thank you for purchasing a Generac Power Systems
Inc. product. This unit has been designed to provide
high-performance, efficient operation, and years of
use when maintained properly.
Read this manual thoroughly and understand all of
the instructions, cautions, and warnings before
using this equipment. If any section of the manual is
not understood, contact your nearest authorized
dealer, or contact Generac Customer Service at 1888-436-3722, or www.generac.com with any questions or concerns.
The owner is responsible for proper maintenance
and safe use of the equipment. Before operating or
servicing this transfer switch:
• Study all warnings in this manual and on the product carefully.
• Become familiar with this manual and the unit
before use.
• Refer to the Assembly section of the manual for
instructions on final assembly procedures. Follow
the instructions completely.
Save these instructions for future reference.
ALWAYS supply this manual to any individual that
will use this machine.
THE INFORMATION CONTAINED HEREIN WAS
BASED ON MACHINES IN PRODUCTION AT THE
TIME OF PUBLICATION. GENERAC RESERVES THE
RIGHT TO MODIFY THIS MANUAL AT ANY TIME.
1.2 — Safety Rules
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NOTE: Notes contain additional information important to
a procedure and will be found within the regular text of
this manual.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compliance with the special instructions while performing
the action or service are essential to preventing accidents.
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, therefore, not all inclusive. If using a
procedure, work method or operating technique that
the manufacturer does not specifically recommend,
verify that it is safe for others. Also make sure the
procedure, work method or operating technique utilized does not render the equipment unsafe.
Throughout this publication, and on tags and decals
affixed to the transfer switch, DANGER, WARNING,
CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly
or carelessly. Observe them carefully. Their definitions are as follows:
Automatic Transfer Switch Owner’s Manual
1
Introduction and Safety
1.3 — Safety Symbols and Meanings
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• Any voltage measurements should be performed
with a meter that meets UL3111 safety standards,
and meets or exceeds overvoltage class CAT III.
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2
Automatic Transfer Switch Owner’s Manual
General Information
Section 2 General Information
2.1 — Unpacking
The conductor size range is as follows:
Carefully unpack the transfer switch. Inspect closely for
any damage that might have occurred during shipment.
The purchaser must file with the carrier any claims for
loss or damage incurred while in transit.
Switch
Rating
Check that all packing material is completely removed
from the switch prior to installation.
100A
The pre-wired switch includes:
• 30 foot, five foot, and two foot pre-wired conduits
for making all required wiring runs.
• An outdoor junction box for making connections
between outdoor and indoor pre-wired conduits.
• UL listed wire nuts for reconnecting standby circuits within the main distribution panel.
The pre-wired limited circuit automatic transfer switch
can be installed along with an 8, 11, 16, kW Air-cooled
Standby Generator, or can be used to pre-wire a home or
small business in advance of generator installation. In
either case, the provided wiring saves installation time
and cost, since the majority of labor involved in installing
a standby power system is in wiring the generator, automatic transfer switch and standby circuit subpanel.
50A
Wire Range
Conductor
Tightening
Torque
Lug
Temp.
Rating
#14-1/0 AWG
(Cu/Al)
50 in-lbs
(5.6 Nm)
167°F (75°C)
This transfer switch is suitable for control of motors, electric discharge lamps, tungsten filament and electric heating equipment where the sum of motor full load ampere
ratings and the ampere ratings of other loads do not
exceed the ampere rating of the switch and the tungsten
load does not exceed 30 percent of the switch rating.
This transfer switch is suitable for use on a circuit capable of 10,000 (100A) symmetrical amperes, 240 VAC
maximum.
C
A
D
2.2 — Equipment Description
The automatic transfer switch is used for transferring
electrical load from a UTILITY (NORMAL) power source
to a GENERATOR (STANDBY) power source. Such a
transfer of electrical loads occurs automatically when the
UTILITY power source has failed or is substantially
reduced and the GENERATOR source voltage and frequency have reached an acceptable level. The transfer
switch prevents electrical feedback between two different
power sources (such as the UTILITY and GENERATOR
sources) and, for that reason, codes require it in all
standby electric system installations.
The transfer switch consists of a transfer mechanism, a
control relay, fuses, terminal strip, and fuse holder for
connection of sensing wires.
The transfer switch is listed for use on optional standby
systems only (NEC 702).
B
E
Figure 2-1. Typical Single-Phase ATS
Transfer Mechanism
A
Utility Closing Coil
B
Generator Closing Coil
C
Utility Lugs (N1 & N2)
D
Generator Lugs (E1 & E2)
E
Load Lugs (T1 & T2)
2.2.1— Transfer Switch Mechanism
These switches (Figure 2-1) are used with a single-phase
system, when the single-phase NEUTRAL line is to be
connected to a neutral lug and is not to be switched.
Solderless, screw-type terminal lugs are standard.
Automatic Transfer Switch Owner’s Manual
3
General Information
2.2.2— Circuit Breakers Listed for Use
This switch is listed for use with the following one inch
breakers:
• Siemens*
• Murray*
Publications that outline the safe installation and manufacturing of transfer switches are the following:
• NFPA 70; National Electrical Code
• UL 1008, STANDARD FOR SAFETY-AUTOMATIC
TRANSFER SWITCHES
*Including GFCI, AFCI and tandem breakers up to 50
amps.
NOTE: For branch circuits over 50 amps, only listed
Siemens or Murray circuit breakers (16EZ only) shall be
used.
2.3 — Transfer Switch Data Decal
A data decal is permanently affixed to the transfer switch
enclosure. Use this transfer switch only with the specific
limits shown on the data decal and on other decals and
labels that may be affixed to the switch. This will prevent
damage to equipment and property.
• UL67 Panel boards
NOTE: It is essential to use the latest version of any
standard to ensure correct and current information.
2.6 — Load Management Options
Loads can be managed using a smart power
management system. The system can accommodate up
to eight individual Smart Management Modules (SMM).*
NOTE: The SMM modules are self-contained and have
individual built-in controllers.
*See SMM Module (available separately)
When requesting information or ordering parts for this
equipment, make sure to include all information from the
data decal.
For future reference, record the Model and Serial numbers in the space provided on the front cover of this manual
2.4 — Transfer Switch Enclosure
The standard switch enclosure is a National Electrical
Manufacturer’s Association (NEMA) 1 type, rated for
indoor use only.
2.5 — Safe Use of Transfer Switch
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Before installing, operating or servicing this equipment,
read the SAFETY RULES carefully. Comply strictly with
all SAFETY RULES to prevent accidents and/or damage
to the equipment. The manufacturer recommends that a
copy of the SAFETY RULES be posted near the transfer
switch. Also, be sure to read all instructions and information found on tags, labels and decals affixed to the equipment.
4
Automatic Transfer Switch Owner’s Manual
Installation
Section 3 Installation
3.1 — Mounting the Transfer Switch
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Mounting dimensions for the transfer switch enclosure
are in this manual. Enclosures are typically wallmounted. See the Drawings and Diagrams section.
This transfer switch is mounted in a NEMA 1 enclosure. It
can be mounted indoors only and should be based on the
layout of installation, convenience and proximity to the
utility supply and load center.
IMPORTANT: Always adhere to local electrical codes
during installation.
1.
Locate transfer switch where the proper equipment
and clear working space can be maintained.
2.
Hold transfer switch against the mounting surface.
IMPORTANT: To eliminate the possibility of debris
contamination, never drill inside the enclosure.
Figure 3-1. Transfer Switch Mounting
3.2 — Mounting the Outdoor
Connection Box
1.
Lift cover.
2.
Remove internal cover plate screw and internal
cover.
3.
Remove the knock out in the lower right corner of
the external connection box and feed wires, 4-pin
and 2-pin plugs into box.
4.
Slip the lock nut over wires and plugs and tighten
securely onto conduit coupling.
5.
Using appropriate fasteners, mount external connection box over area where conduits will enter
through the back of the box.
6.
Connect wires to lugs; black to black, white to
white, and red to red.
7.
Tighten screws to 35 in-lbs (4 Nm).
8.
Snap together the 4-pin and 2-pin plug connector.
9.
Terminate grounding electrode conductor to the
equipment grounding terminal.
10.
Tighten lug to specification below.
3.
Drill the appropriate size holes for mounting hardware at marked hole locations.
4.
Mount transfer switch to mounting surface with
appropriate fasteners.
45 in-lbs (5 Nm)
NOTE: The 2’ whip and conduit can be installed on
either side of the box through a removable plate.
35 in-lbs (4 Nm)
NOTE: Transfer switch must be mounted vertically as
shown in Figure 3-1.
Automatic Transfer Switch Owner’s Manual
Ground Lug Torque Specifications
40 in-lbs (4.5 Nm)
11.
No. 4-6 AWG.
No. 8 AWG.
No. 10-14 AWG.
Close cover.
5
Installation
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3.3 — Routing the Flexible Conduit
1.
Determine where the flexible conduit will pass
through the building from inside to outside.
2.
While adhering to all local electrical codes, route
the 30 foot conduit along ceiling/floor joists and
wall studs to the location where the conduit will
pass through the wall to the exterior of the building.
NOTE: The 30 foot whip can be shortened to any length
or lengthened up to 70 additional feet. It can also be
removed and replaced with field wiring.
NOTE: The two foot pre-wire whip can be shortened if
needed or removed and replaced with field wiring. The
factory installed branch circuits and circuit breakers can
also be modified if needed. Follow all applicable electrical
codes for any field modification.
IMPORTANT: Follow all applicable NEC codes for the
installed wiring methods.
3.
From inside the building, feed the end of the 30foot conduit (INCLUDED and pre-wired from transfer switch) through the wall to the outside.
4.
Remove the threaded lock nut from the conduit
connector.
3.4 — Connecting Power Source and
Load Lines
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Conductor sizes must be adequate to handle the maximum current to which they will be subjected, based on
the 75°C column of tables, charts, etc. used to size conductors. The installation must comply fully with all applicable codes, standards and regulations.
NOTE: If aluminum conductors are used, apply corrosion
inhibitor to conductors. After tightening terminal lugs,
carefully wipe away any excess corrosion inhibitor.
Tighten terminal lugs to the torque values as noted on the
inside of the door.
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Connect power source and load conductors to clearly
marked terminal lugs on transfer mechanism as follows:
1.
Install a 2-pole, 50 Amp breaker for 8kW units and
a 70 Amp double-pole breaker for 11-16kW units,
in the home’s main distribution panel. This will be
the utility (normal) power source for transfer switch.
2.
Customer LOAD leads are pre-wired at the factory.
NOTE: Conductors must be properly supported, of
approved insulative qualities, protected by approved conduit, and of the correct wire gauge size in accordance
with applicable codes.
3.5 — Connecting Generator Control
Wiring
Control system interconnections may consist of N1, N2,
and T1, and leads 23 and 194. The generator control wiring is a Class 1 signaling circuit. Reference instruction
manual of specific engine generator for wiring connection
details. Recommended wire gauge sizes for this wiring
depends on the length of the wire, as recommended in
the following chart:
Maximum Wire Length
Recommended Wire Size
Installation and interconnection diagrams are provided in
the Drawings and Diagrams section of this manual.
1-115 ft (1-35m)
116-185 ft (36-56m)
No. 16 AWG.
NOTE: All installations must comply with national, state
and local codes. It is the responsibility of the installer to
perform an installation that will pass the final electrical
inspection.
186-295 ft (57-89m)
No. 14 AWG.
296-460 ft (90-140m)
No. 12 AWG.
The utility supply, generator, and customer load connections are made at the transfer switch mechanism, inside
the switch enclosure.
6
No. 18 AWG.
Exception: Conductors of AC and DC circuits, rated
1000 volts nominal, or less, shall be permitted to occupy
the same equipment, cable, or conduit. All conductors
shall have an insulation rating equal to at least the maximum circuit voltage applied to any conductor within the
equipment, cable, or conduit. See NEC 300.3(C)(1).
Automatic Transfer Switch Owner’s Manual
Installation
3.6 — Installing Branch Circuit
Conductors – USA Installations
1.
Select which branch circuits will be protected by
the generator in the normal power panel board.
2.
Turn the circuit breaker in the normal power panel
board to the off position.
3.
Remove the ungrounded (hot) conductor from the
circuit breaker and neutral conductor from the neutral terminal bar in the normal power panel board.
NOTE: Multi-wire branch circuits must be connected to
circuit breakers that are adjacent to each other. If the circuit to be protected is part of a multi-wire branch circuit,
the entire multi-wire branch circuit must be relocated to
the transfer switch panel board (See NEC 210.4). The
branch circuit wiring can be removed from the normal
power panel board and installed in the transfer switch
panel board, or spliced onto new branch circuit wiring
originating from the transfer switch panel board.
4.
5.
If the normal power panel board is being used as a
junction box for the protected branch circuit conductors, install the 2 foot conduit, raceway(s), or
other approved wiring method between the transfer
switch panel board and normal power panel board.
Install properly sized branch circuit conductors
between the transfer switch panel board to the
branch circuit conductors to be protected by the
transfer switch, if not using factory supplied wiring.
6.
Use listed wire nuts or any other approved termination device to connect the branch circuit conductors.
7.
Install the provided label on the existing panel
board that indicates the location of the disconnecting means for the pass through conductors.
8.
If the generator protected branch circuit conductors
are being re-installed into the transfer switch panel
board, punch the required sized hole(s) for the
cable, conduit, or raceway.
9.
Route the branch circuit conductors into the transfer switch and terminate the equipment ground
conductor on the equipment ground terminal bar,
the neutral on the neutral terminal bar, and the
ungrounded (hot) on the circuit breaker terminal.
10.
Size all conductors, raceways, conduits, and junction boxes, if required, to the applicable NEC code
articles and follow the NEC installation requirements for the wiring method(s) selected.
3.7 — Installing Branch Circuit
Conductors – Canadian
Installations
1.
Select which branch circuits will be protected by
the generator in the normal power panel board.
Turn the circuit breaker in the normal power panel
board to the off position.
2.
Remove the ungrounded (hot) conductor from the
circuit breaker and neutral conductor from the neutral terminal bar in the normal power panel board.
NOTE: If the circuit to be protected is part of a multi-wire
branch circuit, the entire multi-wire branch circuit must be
relocated to the transfer switch panel board.
3.
The Canadian Electric Code prohibits the use of
the normal power panel board as a junction box,
the generator protected branch circuit wiring must
be relocated to a properly sized junction box, or
reinstalled into the transfer switch panel board.
4.
Punch the required sized hole(s) for the cable, conduit, or raceway into the transfer switch.
5.
Route the branch circuit conductors into the transfer switch and terminate the equipment ground
conductor on the equipment ground terminal bar,
the neutral on the neutral terminal bar, and the
ungrounded (hot) on the circuit breaker terminal.
6.
Size all conductors, raceways, conduits, and junction boxes, if required, to the applicable CEC code
articles and follow the CEC installation requirements for the wiring method(s) selected.
NOTE: The two foot pre-wire whip can be shortened if
needed or removed and replaced with field wiring. The
factory installed branch circuits and circuit breakers can
also be modified if needed. Follow all applicable electrical
codes for any field modification.
NOTE: The two foot pre-wire whip can be shortened if
needed or removed and replaced with field wiring. The
factory installed branch circuits and circuit breakers can
also be modified if needed. Follow all applicable electrical
codes for any field modification.
Automatic Transfer Switch Owner’s Manual
7
Installation
3.8 — Installing Breakers
IMPORTANT: AFCI and GFCI circuit breakers are not
provided by the factory. If the circuits to be protected
require AFCI or GFCI protection, or both, then listed
protection shall be provided by the installer.
The factory supplied breakers can be changed by the
installer. Install listed and labeled circuit breakers that are
compatible with the transfer switch (See Circuit Breakers
Listed for Use ). Follow all applicable NEC and CEC code
articles for any field modifications.
Insert the tab on the breaker (A) into the hook on the bus
(B). Push the breaker into the bus until it snaps into place.
B
A
Figure 3-2. Installing Breakers
8
Automatic Transfer Switch Owner’s Manual
Operation
Section 4 Operation
4.1 — Functional Tests and
Adjustments
• Manual operation handle in the DOWN position LOAD terminals (T1, T2) are connected to
STANDBY terminals (E1, E2).
Following transfer switch installation and interconnection,
inspect the entire installation carefully. A competent,
qualified electrician should inspect it. The installation
should comply strictly with all applicable codes, standards, and regulations. When absolutely certain the
installation is proper and correct, complete a functional
test of the system.
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IMPORTANT: Before proceeding with functional
tests, read and make sure all instructions and information in this section is understood. Also read the
information and instructions of labels and decals
affixed to the switch. Note any options or accessories that might be installed and review their operation.
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4.2.1— Transfer Mechanism Manual Operation
Before proceeding, verify the position of the switch by
observing the position of manual operation handle in
Figure 4-1. If the handle is UP, the contacts are closed in
the NORMAL (UTILITY) position, no further action is
required. If the handle is DOWN, proceed with Step 1.
1.
With the handle inserted into the movable contact
carrier arm, move handle UP. Be sure to hold on to
the handle as it will move quickly after the center of
travel.
2.
Remove manual operating handle from movable
contact carrier arm. Return handle to storage
bracket.
4.2 — Manual Operation
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A
A manual handle is shipped with the transfer switch. See
Figure 4-1. Manual operation must be checked BEFORE
the transfer switch is operated electrically. To check manual operation, proceed as follows:
1.
Verify the generator is OFF.
2.
Turn OFF both UTILITY (service disconnect circuit
breaker) and STANDBY (generator main line circuit
breaker) power supplies to the transfer switch.
3.
Note position of transfer mechanism main contacts
by observing the movable contact carrier arm. This
can be viewed through the long narrow slot in the
inside cover of the ATS. The top of the movable
contact carrier arm is yellow to be easily identified.
Figure 4-1. Transfer Mechanism Manual
Operation
A
B
Utility Position
Generator Position
• Manual operation handle in the UP position - LOAD
terminals (T1, T2) are connected to UTILITY terminals (N1, N2).
Automatic Transfer Switch Owner’s Manual
9
Operation
4.2.2— Close to Generator Source Side
3.
Before proceeding, verify the position of the switch by
observing the position of the manual operation handle in
Figure 4-1. If the handle is DOWN, the contacts are closed
in the GENERATOR (STANDBY) position. No further
action is required. If the handle is UP, proceed with Step
1.
1.
2.
With the handle inserted into the movable contact
carrier arm, move the handle DOWN. Be sure to
hold on to the handle as it will move quickly after
the center of travel.
Set the generator's main circuit breaker (CB1) to its
ON or CLOSED position.
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4.
Remove manual operating handle from movable
contact carrier arm. Return handle to storage
bracket.
With an accurate AC voltmeter and frequency
meter, check the no-load, voltage and frequency.
Measure across ATS terminal lugs E1 to E2; E1 to
NEUTRAL and E2 to NEUTRAL.
Frequency
4.2.3— Return to Utility Source Side
1.
Manually actuate switch to return manual operating
handle to the UP position.
Remove manual operating handle from movable
contact carrier arm. Return handle to storage
bracket.
60-62 Hz
Terminals E1 to E2
240-246 VAC
Terminals E1 to NEUTRAL
120-123 VAC
Terminals E2 to NEUTRAL
120-123 VAC
5.
When certain that generator supply voltage is correct and compatible with transfer switch ratings,
turn OFF the generator supply to the transfer
switch.
4.3 — Voltage Checks
6.
Set the generator main circuit breaker (CB1) to
OFF or OPEN.
4.3.1— Utility Voltage Checks
7.
On the generator panel, select the OFF mode to
shut down the generator.
2.
1.
Turn ON the UTILITY power supply to the transfer
switch using the breaker in main distribution panel.
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2.
With an accurate AC voltmeter, check for correct
voltage. Measure across ATS terminal lugs N1 and
N2; N1 to NEUTRAL and N2 to NEUTRAL.
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4.3.2— Generator Voltage Checks
10
NOTE: Do NOT proceed until generator AC output
voltage and frequency are correct and within stated
limits.
4.4 — Generator Tests Under Load
1.
Set the generator main circuit breaker to OFF or
OPEN.
2.
Set the utility service disconnect circuit breaker to
OFF or OPEN.
3.
Manually actuate the transfer switch main contacts
to the Standby position. See Manual Operation.
4.
To start the generator, select the MANUAL mode of
operation. When engine starts, let it stabilize for a
few minutes.
5.
Set the generator main circuit breaker to ON or
CLOSED. The generator now powers all LOAD circuits. Check generator operation under load as follows:
• Turn on electrical loads to the full rated wattage/
1.
On the generator panel, select the MANUAL mode
of operation. The generator should crank and start.
amperage capacity of the generator. DO NOT
OVERLOAD.
2.
Let the generator stabilize and warm up at no-load
for at least five minutes.
• With maximum rated load applied, check voltage
and frequency across transfer switch terminals E1
and E2. Voltage should be greater than 230 VAC
(240 VAC system); frequency should be greater
than 59 Hz.
Automatic Transfer Switch Owner’s Manual
Operation
• Verify that the gas pressure remains within acceptable parameters (see the generator Installation
Guidelines manual).
• Let the generator run under rated load for at least
30 minutes. With unit running, listen for unusual
noises, vibration, overheating, etc., that might indicate a problem.
6.
When checkout under load is complete, set main
circuit breaker of the generator to the OFF or
OPEN position.
7.
Let the generator run at no-load for several minutes. Then, shut down by selecting the OFF mode.
8.
Move the main switch contacts back to the utility
position.
9.
Place the manual handle in its storage bracket.
NOTE: See Manual Operation. Handle and operating lever
of transfer switch should be in up position.
10.
11.
Turn ON the utility power supply to transfer switch,
using whatever means provided (such as a utility
main line circuit breaker). The utility power source
now powers the loads.
The system is now set for fully automatic operation.
4.5 — Checking Automatic Operation
To check the system for proper automatic operation, proceed as follows:
With the generator in the AUTOMATIC mode, the system
is now set for fully automatic operation.
4.6 — Installation Summary
1.
Verify the installation has been properly performed
as outlined by the manufacturer and that it meets
all applicable laws and codes.
2.
Verify proper operation of the system as outlined in
the appropriate installation and owner’s manuals.
3.
Educate the end-user on the proper operation,
maintenance and service call procedures.
4.7 — Shutting Generator Down While
Under Load
IMPORTANT: To turn the generator off during utility
outages to perform maintenance, or conserve fuel,
follow these important steps:
To turn the generator OFF (while running in AUTO
and Online):
1.
Turn the main utility disconnect OFF.
2.
Turn the main line circuit breaker (MLCB) on the
generator to OFF (OPEN).
3.
Turn the generator OFF.
NOTE: If turning the unit off for longer than 24 hours,
remove the F1 fuse from the generator controller.
To turn the generator back ON:
1.
Verify generator is OFF.
2.
Verify switch is de-energized.
1.
Reinstall F1 fuse if necessary.
3.
Install front cover of the transfer switch.
2.
4.
Turn the utility power supply to the transfer switch
ON, using the utility main line circuit breaker.
Put the generator back into AUTO and allow to
start and warm-up for a few minutes.
3.
Set the MLCB on the generator to On.
5.
Set the generator main circuit breaker to ON.
6.
On the generator panel, select AUTO. The system
is now ready for automatic operation.
7.
Turn utility power supply to the transfer switch OFF.
The system will now be operating in automatic mode.
The main utility disconnect can be turned ON (CLOSED).
NOTE: To shut the unit off, this complete process must
be repeated.
With the generator ready for automatic operation, the
engine should crank and start when the utility source
power is turned OFF after a ten second delay (factory
default setting). After starting, the transfer switch should
connect load circuits to the standby side after the engine
warm-up delay. 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 following should occur:
• After approximately 15 seconds, the switch should
transfer loads back to the utility power source.
• Approximately one minute after re-transfer, the
engine should shut down.
Automatic Transfer Switch Owner’s Manual
11
Operation
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12
Automatic Transfer Switch Owner’s Manual
Drawings and Diagrams
Section 5 Drawings and Diagrams
5.1 — Installation Drawing (USA)
5.1.1— Drawing No. 0H6447-A
Automatic Transfer Switch Owner’s Manual
13
14
N2
T1
CONNECTION OF GENERATOR
TO EXTERNAL CONNECTION BOX
N2
T1
E1
E2
0
19423
SIDE VIEW
GENERATOR OUTPUT
CIRCUIT BREAKER
2 POLE
GREEN GROUND
19423
TOP VIEW
N1
WHITE/NEUTRAL
GROUNDING ELECTRODE
CONNECTION
(LOCATED ON THE
REAR OF UNIT)
EVOLUTION
PANEL
N1
E1
E2
GFCI RECEPTACLE BREAKER
(IF EQUIPPED)
NEUTRAL
BAR
40A OR 70A 2-POLE
CIRCUIT BREAKER
GROUND
BAR
4 PIN
CONNECTORS
2 PIN
CONNECTORS
EXTERNAL CUSTOMER
CONNECTION BOX
100A OR 200A
HOUSE MAIN
SERVICE
REMOVE FROM PANELBOARD
ROUTE TO JUNCTION BOX
EXISTING
HOUSE
WIRING
(CIRCUITS TO
BE SUPPLIED
BY GENERATOR)
NEUTRAL BAR
FOR
INDIVIDUAL
CIRCUITS
EMERGENCY
CIRCUITS
GROUNDED AND
UNGROUNDED
0D4698-T
UL LISTED
PANEL BOARD
(10, 12, 14 OR 16 CIRCUIT
TRANSFER SWITCH)
TO HOUSE BRANCH
CIRCUITS SPLICED
USING WIRE NUTS
(OPTIONAL)
GROUND BAR
KIT# 006612-0
FOR
INDIVIDUAL
CIRCUITS
GROUND
CUSTOMER SUPPLIED
JUNCTION
BOX
Drawings and Diagrams
5.2 — Installation Drawing (Canada)
5.2.1— Drawing No. 0L3138-A
Automatic Transfer Switch Owner’s Manual
Drawings and Diagrams
5.3 — Interconnection Drawing
5.3.1— Drawing No. 0H6453-B (Part 1 of 2)
WHT
WHT
N
LC
A
B
16 CIRCUIT LOAD CENTER
14 CIRCUIT LOAD CENTER
12 CIRCUIT LOAD CENTER
10 CIRCUIT LOAD CENTER
8 CIRCUIT LOAD CENTER
NEUTRAL
MAIN 2
MAIN 1
GRD
240VAC TO MAIN
DISTRIBUTION
PANEL
CIRCUIT 16
CIRCUIT 14
CIRCUIT 12
CIRCUIT 10
CIRCUIT 8
CIRCUIT 6
CIRCUIT 4
CIRCUIT 2
CIRCUIT 1
CIRCUIT 3
CIRCUIT 5
CIRCUIT 7
CIRCUIT 9
CIRCUIT 11
CIRCUIT 13
CIRCUIT 15
WHT
RED
BLK
GRN
ALL CIRCUIT
NEUTRAL
CONDUCTORS NOT
SHOWN FOR
CLARITY
RED
WHT
GRN
BLK
RED
WHT
BLK
RED
BLK
BLK
RED
WHT
GRN
BLK
RED
WHT
EXTERNAL
CONNECTION
BOX
TO GENERATOR
OUTPUT
CIRCUIT BREAKER
Automatic Transfer Switch Owner’s Manual
15
Drawings and Diagrams
5.3.2— Drawing No. 0H6453-B (Part 2 of 2)
RED
BLK
BLK
RED
N1A
BLK
N2A
RED
126
GRN
GRN
126
N2A
N1A
TR1
2 4 6
1 3 5
1
C1
A
N2A
2
126 A
7
8
E1
23
N1A
N2A
205
194
N1A
N2A
E1 BLK
RED
205
1
T1A
C2
E2
A
B
B
23
F3
194
T1
TB1
194
23
T1
N2
B
E1
E2
T1A
0D4698-T
N1
T2
BLK
RED
BLK
RED
E1
B
N1 N2
B
2
205
A
F1 F2
E2
T1
SW3
205
A
E1
SW1
BLK
RED
N1A N2A
N2
SW2
N1A
N2A
BLK
RED
N1
EXTERNAL
CONNECTION
BOX
LEGEND
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
TR1-TRANSFER RELAY
TO GENERATOR
CONTROL PANEL
16
Automatic Transfer Switch Owner’s Manual
Drawings and Diagrams
5.3.3— Drawing No. 0H6454-B
EXTERNAL
CONNECTION
BOX
T1A
E1
N1A
5 6
5
E1
6
1 3 2
4
194
23
23
TR1
205
T1A
7
N1A
126
194
8
N2A
23
N1A
N1A
F3
F2
F1
194
23
T1
T1
N2
N2
N1
N1
CONTROL
TRANSFER
LOAD SENSING
120VAC
OUTPUT
TS TO
GENERATOR
CONTROL
PANEL
UTILITY
SENSING
240VAC
OUTPUT
N1A
N2A
E1
E1
BLACK
E2
RED
E1
E2
B
NEUTRAL
CONNECTION
INSIDE
SWITCH
N2A
126
NC
205
N2A
NC
VR2
C1
C2
CIRCUIT 10
CIRCUIT 9
T1A
SW1
T2
T1
CIRCUIT 6
CIRCUIT 5
N2A
B E2
CIRCUIT 2
T1A
B
T1
CIRCUIT 1
T2
CIRCUIT 3
CIRCUIT 4
E2
CIRCUIT 7
LEGEND
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2,F3-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
(16 CIRCUIT SHOWN FOR REFERENCE ONLY)
N-NEUTRAL
SW1-AUTOMATIC TRANSFER SWITCH
SW2,SW3-LIMIT SWITCHES
TB1-TERMINAL STRIP
TR1-TRANSFER RELAY
Automatic Transfer Switch Owner’s Manual
16 CIRCUIT LOAD CENTER
VR1
14 CIRCUIT LOAD CENTER
A
CIRCUIT 13
E2
SW3
COM
12 CIRCUIT LOAD CENTER
N2A
CIRCUIT 14
E2
10 CIRCUIT LOAD CENTER
B
240VAC TO
MAIN DISTRIBUTION
PANEL
BLACK (MAIN 1)
E1
NO
SW2
COM
N1A
GROUND (GREEN)
NEUTRAL (WHITE)
RED (MAIN 2)
8 CIRCUIT LOAD CENTER
NO
B
NEUTRAL (WHITE)
GROUND (GREEN)
TO
OUTPUT
GENERATOR
CIRCUIT 8
CIRCUIT 11
CIRCUIT 12
CIRCUIT 15
CIRCUIT 16
LC
17
Drawings and Diagrams
18
Automatic Transfer Switch Owner’s Manual
Part No. 0H6448 Rev. G 06/16/15 Printed in USA
©2015 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
8
7
6
5
4
3
SH
1/1
REV
F
WINDCHILL VERSION
1
F.3
AIR INTAKE
457.2
[18.0]
D
D
914 [36.0]
MINIMUM OPEN AREA
ON SIDES AND FRONT
597
660
[26.0] [23.5]
768.3
[30.2]
679.5
[26.8]
AIR OUTLET
AIR INTAKE
211
[8.3]
TOP VIEW
308
[12.1]
266.7
[10.5]
PRE-WIRED TRANSFER SWITCH
(IF SUPPLIED)
349.3
[13.8]
C
250.0
[9.8]
30.2 [ 1.2]
LIFTING HOLES 4 CORNERS
575.3
[22.7]
C
SERVICE ENTRANCE
TRANSFER SWITCH
(IF SUPPLIED)
HOLE LOCATIONS FOR
OPTIONAL MOUNTING TO
A CONCRETE PAD
"DO NOT LIFT BY ROOF"
530.0
[20.9]
16.0 [5/8] DIA. CLEARANCE
HOLE (4) PLACES,
3/8 DIA. MASONRY ANCHOR
BOLTS RECOMMENDED
558.8 477.4
[22.0] [18.8]
446.6
[17.6]
44.8
[1.8]
378.7
[14.9]
FRONT OF UNIT
FUEL INLET - 3/4" NPT
266.7
[10.5]
366.0
[14.4]
B
REQUIRED FUEL PRESSURE: NATURAL GAS : 3.5-7" WATER COLUMN
LIQUID PROPANE (VAPOR) : 10-12" WATER COLUMN
637.6
[25.1]
1229.5
[48.4]
B
MAIN AC/CONTROL WIRING HOLE FOR 3/4" CONDUIT
MAIN AC/CONTROL WIRING HOLE FOR 1 1/4" CONDUIT
732.5
[28.8]
300.4
[11.8]
642
[25.3]
A
LEFT SIDE VIEW
RIGHT SIDE VIEW
1226
[48.3]
76.2 [3.0]
PEA GRAVEL
MINIMUM
179.0
[7.0]
A
FRONT VIEW
TITLE
DRAWING CREATED FROM PRO/ENGINEER
3D FILE. ECO MODIFICATION TO BE
APPLIED TO SOLID MODEL ONLY.
HSB INSTALL GENERATOR
FIRST USE: 2013 HSB
ISSUE DATE:
SIZE
ELECTRONICALLY APPROVED
INSIDE WINDCHILL
8
**ALL DIMENSIONS IN:
MILLIMETERS [INCHES]
REAR VIEW
7
6
5
4
3
2
B
SCALE
11/27/12
CAGE NO
DWG NO
N/A
NTS
WT-KG
0J9945
N/A
SHEET
1
REV
1 of 1
F