Installation Guidelines
60 Hz Air-Cooled Generators
20 kW Synergy™
WARNING
This product is not intended to be used in
a critical life support application. Failure to
adhere to this warning could result in
death or serious injury.
(000209a)
Register your Generac product at:
WWW.GENERAC.COM
1-888-GENERAC
(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
Use this page to record important information about your generator set.
Model:
Serial:
Prod Date Week:
Volts:
LPV Amps:
NG Amps:
Hz:
Phase:
Controller P/N:
Record the information found on your unit data label on this
page. For the location of the unit data label, see your owner’s
manual. The unit has a label plate affixed to the inside partition, to the left of the control panel console.
When contacting an Independent Authorized Service Dealer
(IASD) about parts and service, always supply the complete
model and serial numbers of the unit.
Operation and Maintenance: Proper maintenance and care
of the generator ensures a minimum number of problems
and keeps operating expenses at a minimum. It is the
operator’s responsibility to perform all safety checks, to
make sure that all maintenance for safe operation is
performed promptly, and to have the equipment checked
periodically by an IASD. Normal maintenance, service, and
replacement of parts are the responsibility of the owner/
operator and are not considered defects in materials or
workmanship within the terms of the warranty. Individual
operating habits and usage may contribute to the need for
additional maintenance or service.
When the generator requires servicing or repairs, Generac
recommends contacting an IASD for assistance. Authorized
service technicians are factory-trained and are capable of
handling all service needs. Please visit the dealer locator at
www.generac.com/Service/DealerLocator/ to locate the
nearest IASD.
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.
(000004)
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.
(000005)
ii
Installation Guidelines For 60 Hz Synergy™ Generators
Table of Contents
Section 1: Safety Rules & General
Information
Section 5: Fuel Conversion / Gas
Connections
Introduction ..........................................................1
Fuel Requirements and Recommendations ... 17
Read This Manual Thoroughly ....................................1
Fuel Conversion ................................................ 17
Safety Alerts .........................................................1
Fuel Consumption ............................................. 18
How to Obtain Service .................................................1
Safety Rules .........................................................2
General Hazards .........................................................2
Exhaust Hazards .........................................................3
Electrical Hazards .......................................................3
Fire Hazards ................................................................4
Explosion Hazards ......................................................4
General Rules .......................................................5
Before You Begin ........................................................5
Fuel Line Sizing ................................................. 18
Natural Gas Pipe Sizing ............................................19
LP Vapor Pipe Sizing ................................................19
Installing and Connecting Gas Lines .............. 20
Shutoff Valve .............................................................20
Flexible Fuel Line ......................................................20
Sediment Trap ...........................................................20
Checking Gas Line Connections ..................... 21
NEC Requirements .....................................................5
Natural Gas Vapor Installation (typical) .......... 22
Standards Index ..........................................................5
LP Vapor Installation (typical) .......................... 23
Section 2: Unpacking and Inspection
Section 6: Electrical Connections
General .................................................................7
Generator Connections .................................... 25
Required Tools .....................................................7
Control Wiring ................................................... 26
Unpacking ............................................................7
Main AC Wiring .................................................. 27
Intake Side Panel Removal .........................................9
Rear Connections ................................................9
Generator Main Line Circuit Breaker ...............10
Parts Shipped Loose .........................................10
Section 3: Site Selection and Preparation
Site Selection .....................................................11
Installation Guidelines for Stationary Air-Cooled Generators ..........................................................................12
Service Entrance Decals ................................... 27
Common Alarm Relay (Option) ........................ 27
Load Shed Functionality ................................... 27
Automatic Voltage Regulator (AVR) Cooling
Fans .................................................................... 28
Battery Requirements ....................................... 28
Battery Installation ............................................ 28
Battery Disposal ................................................ 29
Annex A — Explanatory Material ..............................12
Site Preparation .................................................13
Section 7: Control Panel Start-Up/Testing
Material Sufficient for Level Installation .....................13
Control Panel Interface ..................................... 31
Transportation Recommendations ............................14
Using the AUTO/MANUAL/OFF Buttons ..................31
Placement on Roofs, Platforms, and Other Supporting Structures .............................................14
Generator Setup ................................................ 31
Activation ...................................................................31
Cold Smart Start ........................................................33
Section 4: Generator Placement
Setting The Exercise Timer .......................................33
Generator Placement .........................................15
Before Initial Start-up ........................................ 34
Fascia Installation ..............................................16
Installation Wizard .....................................................34
Installation Guidelines For 60 Hz Synergy™ Generators
Interconnect System Self Test Feature .....................34
iii
Table of Contents
Before starting, complete the following: .................... 34
Check Manual Transfer Switch Operation .......35
Electrical Checks ...............................................36
Generator Tests Under Load ............................36
Checking Automatic Operation ........................37
Installation Summary ........................................37
Shutting Generator Down While Under Load ..37
Section 8: Troubleshooting
System Diagnosis ..............................................39
Synergy Diagnostics .........................................40
Load Shed Troubleshooting .............................42
Section 9: Quick Reference Guide
System Diagnosis ..............................................43
Section 10: Accessories
Section 11: Diagrams
Installation Drawing (10000002490—1 of 2) ............. 47
Installation Drawing (10000002490—2 of 2) ............. 48
iv
Installation Guidelines For 60 Hz Synergy™ Generators
Safety Rules & General Information
Section 1: Safety Rules & General Information
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.
The information in this manual is accurate based on
products produced at the time of publication. The
manufacturer reserves the right to make technical
updates, corrections, and product revisions at any time
without notice.
Read This Manual Thoroughly
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000100a)
If any portion of this manual is not understood, contact
the nearest Independent Authorized Service Dealer
(IASD) for starting, operating, and servicing procedures.
This manual must be used in conjunction with the
appropriate owner’s manual.
SAVE THESE INSTRUCTIONS: The manufacturer
suggests that this manual and the rules for safe operation
be copied and posted near the unit installation site.
Safety should be stressed to all operators and potential
operators of this equipment.
Safety Alerts
Throughout this publication and on tags and decals
affixed to the generator, DANGER, WARNING, and
CAUTION 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:
Installation Guidelines For 60 Hz Synergy™ Generators
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
(000001)
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
(000002)
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
(000003)
NOTE: Notes provide additional information important to
a procedure or component.
Safety alerts cannot eliminate the hazards they indicate.
Observing safety precautions and strict compliance with
the special instructions while performing the action or
service are essential to preventing accidents.
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 the 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.
How to Obtain Service
When the generator requires servicing or repairs, contact
an IASD for assistance. Service technicians are factorytrained and are capable of handling all service needs.
Please visit the dealer locator at: www.generac.com/
Service/DealerLocator/ to locate the nearest IASD.
When contacting an IASD 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. Refer to owner’s manual for
decal location. Record the model and serial numbers in
the spaces provided on the inside front cover of this
manual.
1
Safety Rules & General Information
Safety Rules
Study these SAFETY RULES carefully before installing,
operating, or servicing this equipment. Become familiar
with this installation manual, the owner’s manual, and
with the unit. The generator can operate safely,
efficiently, and reliably only if it is properly installed,
operated, and maintained. Many accidents are caused by
failing to follow simple and fundamental rules or
precautions.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The alerts in
this manual and on tags and decals affixed to the unit are
not all-inclusive. If using a procedure, work method, or
operating technique the manufacturer does not
specifically recommend, verify that it is safe for others
and does not render the generator unsafe.
General Hazards
WARNING
Accidental Start-up. Disconnect the negative battery
cable, then the positive battery cable when working
on unit. Failure to do so could result in death
or serious injury.
(000130)
WARNING
(000182)
WARNING
This unit is not intended for use as a prime power
source. It is intended for use as an intermediate power
supply in the event of temporary power outage only.
See individual unit specifications for required
maintenance and run times pertaining to use.
(000247)
DANGER
Loss of life. Property damage. Installation must always
comply with applicable codes, standards, laws and
regulations. Failure to do so will result in death
or serious injury.
(000190)
DANGER
Automatic start-up. Disconnect utility power and
render unit inoperable before working on unit.
Failure to do so will result in death or serious injury.
(000191)
WARNING
WARNING
Only a trained and licensed electrician should perform
wiring and connections to unit. Failure to follow proper
installation requirements could result in death, serious
injury, and damage to equipment or property. (000155)
WARNING
Moving Parts. Do not wear jewelry when
starting or operating this product. Wearing
jewelry while starting or operating this product
could result in death or serious injury.
(000115)
WARNING
(000187)
WARNING
This product is not intended to be used in
a critical life support application. Failure to
adhere to this warning could result in
death or serious injury.
(000209a)
Moving Parts. Keep clothing, hair, and
appendages away from moving parts. Failure
to do so could result in death or serious injury.
(000111)
WARNING
Hot Surfaces. When operating machine, do not
touch hot surfaces. Keep machine away from
combustibles during use. Hot surfaces
could result in severe burns or fire.
(000108)
WARNING
Equipment and property damage. Do not alter
construction of, installation, or block ventilation for
generator. Failure to do so could result in unsafe
operation or damage to the generator.
(000146)
2
Installation Guidelines For 60 Hz Synergy™ Generators
Safety Rules & General Information
Electrical Hazards
WARNING
Risk of injury. Do not operate or service this
machine if not fully alert. Fatigue can impair the
ability to service this equipment and could result
in death or serious injury.
(000215)
WARNING
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death or serious injury.
(000228)
DANGER
Electrocution. Contact with bare wires,
terminals, and connections while generator
is running will result in death or serious injury.
(000144)
DANGER
Electrocution. Never connect this unit to the electrical
system of any building unless a licensed electrician
has installed an approved transfer switch. Failure to
do so will result in death or serious injury.
(000150)
WARNING
DANGER
Injury and equipment damage. Do not use
generator as a step. Doing so could result in falling,
damaged parts, unsafe equipment operation,
and could result in death or serious injury. (000216)
Electrical backfeed. Use only approved switchgear to
isolate generator from the normal power source.
Failure to do so will result in death, serious injury,
and equipment damage.
• Inspect the generator regularly, and contact the
nearest IASD
replacement.
for
parts
needing
repair
or
Exhaust Hazards
(000237)
DANGER
Electrocution. Verify electrical system is
properly grounded before applying power.
Failure to do so will result in death or serious
injury.
(000152)
DANGER
Asphyxiation. Running engines produce
carbon monoxide, a colorless, odorless,
poisonous gas. Carbon monoxide, if not
avoided, will result in death or serious injury.
(000103)
DANGER
Electrocution. Do not wear jewelry while
working on this equipment. Doing so will
result in death or serious injury.
(000188)
WARNING
Equipment and property damage. Do not alter
construction of, installation, or block ventilation for
generator. Failure to do so could result in unsafe
operation or damage to the generator.
(000146)
WARNING
Asphyxiation. Always use a battery operated carbon
monoxide alarm indoors and installed according to
the manufacturer’s instructions. Failure to do so
could result in death or serious injury.
(000178a)
• The generator must be installed and operated
DANGER
Electrocution. Water contact with a power
source, if not avoided, will result in death
or serious injury.
(000104)
DANGER
Electrocution. In the event of electrical accident,
immediately shut power OFF. Use non-conductive
implements to free victim from live conductor. Apply
first aid and get medical help. Failure to do so will
result in death or serious injury.
(000145)
outdoors only.
Installation Guidelines For 60 Hz Synergy™ Generators
3
Safety Rules & General Information
Fire Hazards
Explosion Hazards
DANGER
WARNING
Fire hazard. Do not obstruct cooling and
ventilating airflow around the generator. Inadequate
ventilation could result in fire hazard, possible
equipment damage, death or serious injury. (000217)
(000192)
DANGER
WARNING
Fire and explosion. Installation must comply
with all local, state, and national electrical
building codes. Noncompliance could result in unsafe
operation, equipment damage, death or serious injury.
Connection of fuel source must be done by a qualified
professional technician or contractor. Incorrect installation
of this unit will result in death, serious injury, and damage
to equipment and property damage.
(000151)
(000218)
WARNING
Fire hazard. Use only fully-charged fire
extinguishers rated “ABC” by the NFPA. Discharged or
improperly rated fire extinguishers will not extinguish
electrical fires in automatic standby generators.
(000219)
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000100a)
DANGER
Risk of fire. Allow fuel spills to completely dry
before starting engine. Failure to do so will
result in death or serious injury.
(000174)
WARNING
Risk of Fire. Hot surfaces could ignite
combustibles, resulting in fire. Fire could
result in death or serious injury.
(000110)
WARNING
Electrocution. Refer to local codes and
standards for safety equipment required when
working with a live electrical system. Failure
to use required safety equipment could result
in death or serious injury.
(000257)
WARNING
Risk of Fire. Unit must be positioned in a
manner that prevents combustible material
accumulation underneath. Failure to do so
could result in death or serious injury. (000147)
• Comply with regulations the Occupational Safety
and
Health Administration
(OSHA)
has
established. Verify 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.
4
Installation Guidelines For 60 Hz Synergy™ Generators
Safety Rules & General Information
General Rules
• Fully comply with all relevant NEC, NFPA, and
DANGER
Loss of life. Property damage. Installation must always
comply with applicable codes, standards, laws and
regulations. Failure to do so will result in death
or serious injury.
(000190)
DANGER
Electrical backfeed. Use only approved switchgear to
isolate generator from the normal power source.
Failure to do so will result in death, serious injury,
and equipment damage.
(000237)
WARNING
(000182)
WARNING
Electrocution. Refer to local codes and
standards for safety equipment required when
working with a live electrical system. Failure
to use required safety equipment could result
in death or serious injury.
(000257)
• Follow all safety precautions in the owner’s
manual, installation guidelines manual, and other
documents included with your equipment.
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.
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.
Standards Index
WARNING
This product is not intended to be used in
a critical life support application. Failure to
adhere to this warning could result in
death or serious injury.
(000209a)
• 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.
• Improper 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.
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 install.
• 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 an IASD for
assistance.
• Strictly comply with all applicable national, state,
and local laws, as well as codes or regulations
pertaining to the installation of this enginegenerator power system. Use the most current
version of applicable codes or standards relevant
to the local jurisdiction, generator used, and
installation site.
NOTE: Not all codes apply to all products and this list is
not all-inclusive. In the absence of pertinent local laws
and standards, the following publications may be used as
a guide (these apply to localities which recognize NFPA
and IBC).
1. National Fire Protection Association (NFPA) 70:
The NATIONAL ELECTRIC CODE (NEC) *
2. NFPA 10: Standard for Portable Fire Extinguishers *
3. NFPA 30: Flammable and Combustible Liquids
Code *
4. NFPA 37: Standard for Stationary Combustion
Engines and Gas Turbines *
5. NFPA 54: National Fuel Gas Code *
6. NFPA 58: Standard for Storage and Handling Of
Liquefied Petroleum Gases *
Installation Guidelines For 60 Hz Synergy™ Generators
5
Safety Rules & General Information
7. NFPA 68: Standard On Explosion Protection By
Deflagration Venting *
8. NFPA 70E: Standard For Electrical Safety In The
Workplace *
9. NFPA 110: Standard for Emergency and Standby
Power Systems *
10. NFPA 211: Standard for Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances *
11. NFPA 220: Standard on Types of Building
Construction *
12. NFPA 5000: Building Code *
13. International Building Code **
14. Agricultural Wiring Handbook ***
15. Article X, NATIONAL BUILDING CODE
16. ASAE EP-364.2 Installation and Maintenance of
Farm Standby Electric Power ****
17. ICC:IFGC
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
49085
6
Installation Guidelines For 60 Hz Synergy™ Generators
Unpacking and Inspection
Section 2: Unpacking and Inspection
General
NOTE: Carefully inspect the contents for damage after
unpacking. It is advised to unpack and inspect the unit
immediately upon delivery to detect any damage that
may have occurred 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.
• 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.
Required Tools
• General SAE and Metric hand tools
– Wrenches
000427
Figure 2-1. Crated Generator
3. See Figure 2-2. Remove bolts and pallet brackets
(A). 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.
Bolts and pallet brackets are provided only for
shipping purposes and can be discarded after
removal.
– Sockets
– Screwdrivers
• Standard electrician’s hand tools
– Drill and bits for mounting and routing conduits
• 4 mm Allen wrench (for access to customer
connections)
• 3/16 in Allen wrench (test port on fuel regulator)
• Manometer (for fuel pressure checks)
• Meter capable of measuring AC/DC voltage and
frequency
• Torque wrenches
Unpacking
1. Remove cardboard carton.
A
000426
Figure 2-2. Generator on Pallet
2. Remove the wood frame.
Installation Guidelines For 60 Hz Synergy™ Generators
7
Unpacking and Inspection
NOTE: The enclosed keys provided with this unit are
intended for service personnel use only.
3. Two locks secure the lid; one on each side (A in
Figure 2-4). Press down on the lid above the side
lock, and unlock the latch to properly open the lid.
4. Repeat for the other side. The lid may appear stuck
if pressure is not applied from the top.
NOTE: Always verify that the side locks are unlocked
before attempting to lift the lid.
5. Remove the front access panel by lifting it straight
up and out once the lid is open.
001801
Figure 2-3. Keys As Shipped
The lid will be locked. A set of keys is attached to the
intake side of the generator. See Figure 2-3.
1. Cut the plastic bag to remove the keys.
NOTE: Always lift the front access panel straight up
before pulling away from enclosure (B and C in Figure 24). Do not pull the panel away from the enclosure before
lifting up (D in Figure 2-4).
2. Use the keys to open the lid of the generator.
A
A
B
C
D
001797
Figure 2-4. Side Lock Location and Front Panel Removal
8
Installation Guidelines For 60 Hz Synergy™ Generators
Unpacking and Inspection
Intake Side Panel Removal
3. Lift the intake panel up and away from the
generator.
See Figure 2-5. The intake side panel (A) must be
removed to access the battery compartment, fuel
regulator, and sediment trap.
NOTE: Always lift the intake side panel straight up
before pulling away from enclosure. Do not pull the panel
away from the enclosure before lifting up (D).
1. Raise the lid and remove the front panel.
2. Use an Allen wrench to remove two mounting
screws (B) and the L-bracket screw (C).
B
D
A
C
002961
Figure 2-5. Intake Side Panel Removal
4. Perform a visual inspection for any hidden freight
damage. Contact the freight carrier if damage is
present.
Rear Connections
5. See Figure 2-6 and Figure 2-7 for customer
connections and loose parts location. Figure 2-9
illustrates parts shipped loose.
A
B
E
C
001802
C
A
D
B
A
Customer electrical connection area
(behind the access panel)
B
Fuel regulator with sediment trap
C
Battery compartment (battery not supplied)
D
Positive (+) and negative (-) battery cables
E
Location of “Loose Shipped Parts”
A
Main AC/Control wiring hole for 1-1/4 in conduit
B
Main AC/Control wiring hole for 3/4 in conduit
C
Fuel Connection hole
Figure 2-7. Rear Connections
001800
Figure 2-6. Customer Connection Area and Loose
Parts Location
Installation Guidelines For 60 Hz Synergy™ Generators
9
Unpacking and Inspection
Generator Main Line Circuit
Breaker
Parts Shipped Loose
A
This is a 2-pole circuit breaker (generator disconnect)
rated according to relevant specifications. See (A) in
Figure 2-8.
E
B
C
D
001803
B
A
001810
Figure 2-8. Generator Main Line Circuit Breaker
The breaker can be locked in the OFF (OPEN) position
for security during maintenance or transfer switch
service. Use an appropriately-sized padlock (not
included) with a shackle long enough to pass through
both lock tabs (B).
NOTE: DO NOT leave the breaker disconnect locked in
the open (OFF) position during normal generator
operation. Leaving the breaker in the open position will
prevent the transfer of power to the generator from the
transfer equipment during normal generator operation.
10
A
Keys
B
Flexible fuel line
C
Battery terminal cap
D
Rubber mounts (only for units that include fascia)
E
Fascia (if applicable)
—
Decal—Service entrance warning (not shown)
—
Decal—Through conductors warning (not shown)
—
Decal—Service disconnect (not shown)
—
Owner’s and Install manual (not shown)
Figure 2-9. Parts Shipped Loose
Installation Guidelines For 60 Hz Synergy™ Generators
Site Selection and Preparation
Section 3: Site Selection and Preparation
Site Selection
D
5 ft (1.52 m)
B
3 ft
(0.91 m)
C
E
5 ft (1.52 m)
3 ft
(0.91 m)
A
B
3 ft (0.91 m)
B F
001751
G
D
001789
Figure 3-1. Installation Clearances
ID
Description
Comments
A
Top of generator
—
B
Front and end clearance
Minimum clear distances cannot include shrubs, bushes, or trees.
C
Rear clearance
18 in (45.7 cm) minimum clearance per NFPA testing, labeling, and listing, unless state or local codes
dictate otherwise.
D
Windows and openings
No operable windows, doors, or openings in the wall are permitted within 5 ft (1.52 m) from any point of
the generator.
E
Existing wall
One-hour fire rated walls allow closer placement of the generator set. Confirm before installation.
F
Removable fence
Removable fence panels for servicing cannot be placed less than 3 ft (0.91 m) in front of the generator.
G
Overhead clearance
5 ft (1.52 m) minimum distance from any structure, overhang, or projections from the wall.
DO NOT install under wooden decks or structures unless this distance is maintained.
Installation Guidelines For 60 Hz Synergy™ Generators
11
Site Selection and Preparation
Install the generator set, in its protective enclosure,
outdoors where adequate cooling and ventilating air is
always available (Figure 3-1). Consider these factors:
• The installation of the generator must comply
strictly with ICC IFGC, 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. This unit 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 any local, state, or
national codes for minimum distances from other
structures.
• Clearance from the ends and front of the generator
must be 3 ft (0.91 m). This includes shrubs,
bushes, and trees. Clearance from the back of the
generator must be a minimum of 18 in (457 mm).
Clearance at the top should be a minimum of 5 ft
(1.52 m) from any structure, overhang, or
projections from the wall.
• DO NOT install under wooden decks or structures
unless there is at least 5 ft (1.52 m) of clearance
above the generator.
• 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. In the absence of
local codes regarding placement or clearance, we
recommend following these guidelines:
– Install the generator as close as possible to the
transfer switch. REMEMBER THAT LAWS OR
CODES MAY REGULATE THE DISTANCE AND
LOCATION.
12
– 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,
compacted soil, crushed stone, or a concrete
pad. Check local codes to see what type is
required. If a concrete pad is required, all applicable codes should be followed.
Installation Guidelines for Stationary Air-Cooled
Generators
NFPA 37 is the The National Fire Protection
Association’s standard for the installation and use of
stationary combustion engines. Its requirements limit the
spacing of an enclosed generator set from a structure or
wall (Figure 3-1).
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 the following
conditions exist:
1. The adjacent wall of the structure has a fire
resistance rating of at least one 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 testing approves
18 in (457 mm) installation minimum from structure
(Figure 3-1, C). Southwest Research Institute 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
Installation Guidelines For 60 Hz Synergy™ Generators
Site Selection and Preparation
generator enclosure would not pose any ignition risk to
nearby combustibles or structures, with or without fire
service personnel response
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. Verify that
exhaust fumes will not enter any building through
eaves, windows, ventilation fans, or other air
intakes (see Site Selection).
002158a
• Select the type of base, such as—but not limited
Figure 3-2. Southwest Research Institute Marking
to—compacted soil, gravel, or concrete, as desired
or as required by local laws or codes. Verify your
local requirements before selecting.
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
(C). 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 (0.91 m) at the front and ends
of the enclosure. This includes trees, shrubs, and
bushes. 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.
Material Sufficient for Level Installation
• Prepare a rectangular area approximately 5 in (127
mm) deep (A) and approximately 6 in (152 mm)
longer and wider (B) than the footprint of the
generator. Verify that the surface where the
generator will be mounted is compacted, leveled,
and will not erode over time. A concrete pad can be
poured if desired or required.
DANGER
Automatic start-up. Disconnect utility power and
render unit inoperable before working on unit.
Failure to do so will result in death or serious injury.
(000191)
B
A
000856
DANGER
Asphyxiation. Running engines produce
carbon monoxide, a colorless, odorless,
poisonous gas. Carbon monoxide, if not
avoided, will result in death or serious injury.
(000103)
Figure 3-3. Compacted Soil or Gravel Pad
NOTE: If a concrete pad is required, follow all applicable
federal, state, or local codes.
NOTE: If the generator is not set to OFF, it can crank and
start as soon as the battery cables are connected. If the
utility power supply is not turned off, sparking can occur
at the battery posts and cause an explosion.
Installation Guidelines For 60 Hz Synergy™ Generators
13
Site Selection and Preparation
Transportation Recommendations
Use a suitable cart or equipment to carry the generator,
including the wooden pallet, to the installation site. Place
cardboard between the hand cart and the generator to
prevent any damage or scratches to the generator.
IMPORTANT NOTE: Do not lift, carry, or move the
generator by grasping the louvers. Doing so may bend or
damage the sheet metal.
Placement on Roofs, Platforms,
and Other Supporting Structures
Where required to place the generator on a roof,
platform, or other supporting structure, like a deck, the
generator shall be placed in accordance with the
requirements in NFPA 37, Section 4.1.3. The generator
can be located 18 in (45.7 cm) from structures having
combustible walls and 5 ft (1.52 m) from any operable
opening in the structure. The surface beneath the
generator and beyond shall be noncombustible to a
minimum distance of 12 in (30.5 cm). Consult with the
local Building Inspection Department or Fire Department
to determine which noncombustible materials are
approved for installation.
14
Installation Guidelines For 60 Hz Synergy™ Generators
Generator Placement
Section 4: Generator Placement
Generator Placement
All air-cooled generators come with a non-sinking direct
to dirt (DTD) composite base pad. The DTD pad elevates
the generator and helps prevent water from pooling
around the base. (Figure 4-1).
The DTD pad allows the generator to be placed on three
types of surfaces:
• directly on level, solid ground
• on 4 in (102 mm) of compacted pea gravel
• on a concrete pad
001377
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,
with the DTD pad attached, and position correctly as per
the dimensional information given in Site Selection.
Figure 4-2. Mounting Hole Location
NOTE: Generator must be level within 0.5 in (13 mm).
NOTE: See Figure 4-2. DO NOT remove the DTD pad
for mounting the generator to concrete. The pad is predrilled to accommodate mounting bolts.
000612
Figure 4-1. DTD Composite Pad
See Figure 4-2. Four mounting points are provided for
securing the generator to concrete—two holes at the
inside front of the enclosure and two outside rear
mounting brackets.
NOTE: Use the template at the top of the generator
carton to mark the concrete pad for drilling of the two
front mounting holes. For dimensions of the two rear
mounting
holes,
see
Installation
Drawing
(10000002490—2 of 2). DO NOT USE brackets from
shipping pallet. Use stainless steel brackets provided
with loose parts.
Installation Guidelines For 60 Hz Synergy™ Generators
15
Generator Placement
Fascia Installation
• Locate the four threaded black rubber bumpers
supplied with the loose parts.
• Remove the four rubber mounts 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 mounts 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 mounts into the lifting holes in the
generator base (C).
• Once aligned, snap together the two remaining
connection points.
A
B
C
000614
Figure 4-3. Fascia Installation
16
Installation Guidelines For 60 Hz Synergy™ Generators
Fuel Conversion / Gas Connections
Section 5: Fuel Conversion / Gas Connections
Fuel Requirements and
Recommendations
mandate correct routing of gaseous fuel line piping
around gardens, shrubs, and other landscaping.
Piping strength and connections should be given special
consideration when installation takes place in areas at
risk for flooding, tornadoes, hurricanes, earthquakes, and
unstable ground.
DANGER
(000192)
NOTE: Natural gas is lighter than air and will collect in
high areas. LP gas is heavier than air and will settle in
low areas.
LP gas should only use a vapor withdrawal system. This
type of system uses the vapors formed above the liquid
fuel in the storage tank.
The unit will run on natural gas or LP gas, but has been
configured at the factory to run on natural gas.
NOTE: Should the primary fuel need to be changed to
LP gas, the fuel system needs to be reconfigured. See
Fuel Conversion for instructions on converting the fuel
system.
Recommended fuels should have a BTU content of at
least 1,000 BTU/ft3 (37.26 MJ/m3) for natural gas; or at
least 2,500 BTU/ft3 (93.15 MJ/m3) for LP gas.
NOTE: BTU fuel content information is available from the
fuel supplier.
IMPORTANT NOTE: Use an approved pipe sealant or
joint compound on all threaded NPT fittings.
NOTE: All installed gaseous fuel piping must be purged
and leak tested prior to initial start-up in accordance with
local codes, standards, and regulations.
Fuel Conversion
See Figure 5-1. The orange fuel conversion knob is
located above the fuel mixer (A).
To convert from natural gas to LP vapor, turn the valve
toward the marked fuel source arrow until it stops. Fuel
knob will rotate 180° and slide into the mixer body when
converting to LP.
NOTE: The fuel selection (LP/NG) must be entered on
the controller during initial power up using the
Installation Wizard navigation menu, or in the EDIT
menu under “Fuel Selection.”
A
Required fuel pressure for natural gas is 3.5–7.0 in. water
column (7–13 mm Hg) at the generator fuel inlet.
Required fuel pressure for liquid propane vapor is 10–12
in. water column (19–22 mm Hg) at the generator fuel
inlet.
NOTE: 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 or ICC IFGC for liquid propane applications.
Verify fuel pressure NEVER drops below the required
specification once the generator is installed. See the
NFPA website at www.nfpa.org for further information
regarding NFPA requirements. Always consult local fuel
suppliers or the fire marshal to check codes and
regulations for proper installation. Local codes will
Installation Guidelines For 60 Hz Synergy™ Generators
003595
Figure 5-1. Fuel Conversion Knob Location
17
Fuel Conversion / Gas Connections
Fuel Consumption
Generator
20 kW Synergy™
Natural Gas
Propane
1/2 Load
Full Load
1/2 Load
Full Load
5.66/200
7.99 / 282
1.84 / 6.95 / 66.8
3.46 / 13.11 / 126
* Natural gas is in m3/h / ft3/h
** Propane is in gal/h / l/h (LP) / ft3/h (LPV)
*** Values given are approximate
These are approximate values. Use the appropriate spec sheet or owner’s manual for specific values.
Verify that gas meter is capable of providing enough fuel flow to include household appliances and all other loads.
NOTE: The gas supply and pipe MUST be sized at 100% load BTU / Megajoule rating.
Always refer to the owner’s manual for the proper BTU, Megajoule and required gas pressures:
– Natural Gas:
BTU = ft3/h x 1000
Megajoules = m3/h x 37.26
– Liquid Propane Vapor:
BTU = ft3/h x 2500
Megajoules = m3/h / hour x 93.15
Fuel Line Sizing
Selecting the correct size fuel line is crucial to the proper
operation of the unit.
IMPORTANT NOTE: The generator inlet size does not
dictate the size of gas pipe to be used!
For further information refer to NFPA 54 for NG, or NFPA
58 or ICC IFGC for LP.
Measure the distance from the generator to the gas
source.
IMPORTANT NOTE: The generator should be plumbed
directly from the source, not off the end of an existing low
pressure system.
18
Installation Guidelines For 60 Hz Synergy™ Generators
Fuel Conversion / Gas Connections
Natural Gas Pipe Sizing
To determine correct gas pipe size, 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
meters / feet) allowed for the pipe sizes on top. Pipe
sizes are measured by inside diameter (ID) to include
any fittings, valves (must be full flow), elbows, tees, or
angles.
NOTE: Add 2.5 ft (0.76 m) per any bend, tee, or angle in
the pipe to the overall distance. Tables based on
schedule 40 black pipe. If installing any other piping
system, follow the pipe sizing charts for the selected
piping system.
Table 5-1. Natural Gas Pipe Sizing
For 5–7 in of water column
(9–13 mmHg)
For 3.5–5 in of water column
(7–9 mmHg)
Allowable Pipe Distances (feet / meters)
Pipe Size (in / mm)
0.75 / 19
1 / 25
1.25 / 32
1.5 / 38
2 / 51
1 / 25
1.25 / 32
1.5 / 38
20 kW Synergy
—
20 / 6.1
130 / 39.62
305 / 92.96
945 / 288.04
10 / 3.05
60 / 18.29
125 / 38.1
LP Vapor Pipe Sizing
To determine correct LP vapor pipe size, 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 meters / feet) 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 (0.76 m) 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 gal (946 L),
unless unit calculations dictate use of a larger tank.
Vertical tanks, which are measured in pounds (or
kilograms), are permitted if properly sized for the
generator.
Table 5-2. LP Vapor Pipe Sizing
For 10–12 in of water column (19–22 mmHg)
Allowable Pipe Distances (feet / meters)
Pipe Size (in / mm)
0.75 / 19
1 / 25
1.25 / 32
20 kW Synergy
15 / 4.57
115 / 35.05
480 / 146.3
Installation Guidelines For 60 Hz Synergy™ Generators
19
Fuel Conversion / Gas Connections
Installing and Connecting Gas Lines
Flexible Fuel Line
DANGER
(000192)
IMPORTANT NOTE: Natural gas and LP vapor are
highly volatile substances. Strictly adhere to all safety
procedures, codes, standards, and regulations.
Gas line connections should be made by a certified
contractor familiar with local codes. Always use AGAapproved gas pipe and a quality pipe sealant or joint
compound.
Verify the capacity of the natural gas meter or the LP tank
to provide sufficient fuel for both the generator and other
operating appliances.
Shutoff Valve
The generator will require an external manual shut-off
valve on the fuel line. The valve must be easily
accessible. See A in Figure 5-3.
When connecting the gas line to the generator, use a
listed assembly that meets the requirements of ANSI
Z21.75/ CSA 6.27—Connectors for Outdoor Gas
Appliances and Manufactured Homes or AGA-approved
flexible fuel line in accordance with local regulations.
The flexible fuel line shall not be connected directly to the
generator fuel inlet. Always connect the flexible fuel line
to an approved gas fitting.
The purpose of flexible fuel line is to isolate vibration from
the generator to reduce possibility of a gas leak at one of
the connection points. See B in Figure 5-3.
NOTE: Follow all installation instructions and warnings
provided with the flexible fuel line. Do not remove any
labels or tags.
Sediment Trap
Some local codes require a sediment trap. The fuel
regulator connection has an integrated sediment trap.
See C in Figure 5-3.
NOTE: Local codes determine the proper location.
A
B
C
001816
Figure 5-3. Sediment Trap, Fuel Shut-Off Valve with
Manometer Port, and Flexible Fuel Line
000743
Figure 5-2. Accessory Valve with Manometer Port
NOTE: Figure 5-2 illustrates a fuel shut-off valve with a
manometer port for making fuel pressure checks. This
optional accessory valve permits making pressure
checks for diagnostic purposes without going into the
generator enclosure.
The sediment trap must be cleaned periodically
according to local codes. See the owner’s manual for
more information.
Valves available through Generac and Independent
Authorized Service Dealers (IASD):
•
•
•
•
20
1/2” ball valve, part number 0K8752
3/4” ball valve, part number 0K8754
1” ball valve, part number 0K8184
1-1/4” ball valve, part number 0L2844
Installation Guidelines For 60 Hz Synergy™ Generators
Fuel Conversion / Gas Connections
Checking Gas Line Connections
1. Check for leaks by spraying all connection points
with a non-corrosive gas leak detection fluid. The
solution should not be blown away or form bubbles.
2. Check 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 5-4) and install the gas
pressure tester (manometer).
• Open the gas supply valve and verify the pressure
is within the specified values.
• Record static gas pressure:
NOTE: Gas pressure can also be tested at the
manometer port on the fuel shut-off valve shown in
Figure 5-3.
NOTE: See the owner’s manual or the spec sheet for
proper fuel pressure specifications. If the gas pressure is
not within specifications, contact the local gas supplier.
3. Close gas valve when completed, but keep
manometer connected for future tests of the
generator while starting, running and under loads.
001807
Figure 5-4. Checking Pressure with Manometer
Installation Guidelines For 60 Hz Synergy™ Generators
21
Fuel Conversion / Gas Connections
Natural Gas Vapor Installation (typical)
F
B
A
D
C
E
J
G
H
L
K
001808
NG BTU = ft3/h x 1000
Megajoules = m3/h / h x 37.26
A
BTU and pressure decal
B
Minimum distance from rear obstruction—see Site Selection
C
Manual shutoff valve (pressure port optional)
D
Pipe nipple (field supplied)
E
Flexible fuel line
F
Check distance with gas provider
G
Clamp
H
Reinforcing rod
J
Size gas meter for generator load plus all appliance loads
K
For underground installations, verify piping system for code compliance
L
Gas main
Figure 5-5. Natural Gas Vapor Installation (typical)
22
Installation Guidelines For 60 Hz Synergy™ Generators
Fuel Conversion / Gas Connections
LP Vapor Installation (typical)
F
G
B
C
A
D
J
K
M
E
H
L
001809
BTU = ft3/h X 2500
Megajoules = m3/h X 93.15
A
BTU and pressure decal
B
Minimum distance from rear obstruction—see Site Selection
C
Manual shutoff valve (pressure port optional)
D
Pipe nipple (field supplied)
E
Flexible fuel line
F
Check distance with gas provider
G
Reinforcing rod
H
Clamp
J
Secondary fuel pressure regulator
K
Manual shutoff valve
L
Primary fuel pressure regulator
M
Fuel tank—sized large enough to provide required BTUs for generator and
ALL connected appliance loads. Be sure to correct for weather evaporation.
Figure 5-6. LP Vapor Installation (typical)
Installation Guidelines For 60 Hz Synergy™ Generators
23
Fuel Conversion / Gas Connections
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24
Installation Guidelines For 60 Hz Synergy™ Generators
Electrical Connections
Section 6: Electrical Connections
Generator Connections
See Figure 6-1. The electrical wiring enclosure is located
behind an access panel on the intake end of the unit.
Remove the intake side panel as directed in Intake Side
Panel Removal, and then remove the access panel.
Connect wires according to the diagram and tables.
1. Remove the main AC / control wiring knock-out
plugs from the back of the generator.
2. Using the appropriate wiring hole, install the
conduit and main AC and control wires between
the generator and the transfer switch.
3. Close the unused hole with a NEMA 3R rated plug
(field-supplied).
NOTE: All conductors are to be rated for minimum 300V.
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 the
instruction manual of the specific engine generator for
wiring connection details. Recommended wire gauge
sizes for this wiring depends on the length of the wire, as
recommended in Table 6-3.
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).
4. Strip the insulation from the ends of the wires. Do
not remove excessive insulation. See Figure 6-1.
Route the sense wires through the supplied wire tie
(C1), and connect to the sense wire terminal block
(B). Push down on the spring loaded connection
point with a flat head screwdriver, insert wire, and
release.
5. Using the same process, route the control wires
through the second supplied wire tie (C2), and
connect to the control wire terminal block (A).
6. When all the wires are securely connected to the
proper terminals, tighten the wire ties and clip the
excess length.
NOTE: Only bare wire should be inserted into each
terminal. Do not insert any wire insulation into terminals.
Installation Guidelines For 60 Hz Synergy™ Generators
25
Electrical Connections
Control Wiring
C1
B
A
C2
E1
E2
001817
J
H
D
F
G
Figure 6-1. l Electrical Wiring Connections
Table 6-1. Electrical Wiring Connection Points
ID
Description
ID
Description
ID
Description
ID
Description
A
Control wire terminal block
C2
Wire tie for sense wires
E2
Power lug E2
H
Neutral stud
B
Sense wire terminal block
D
Neutral lug
F
Ground stud
J
Neutral bar
C1
Wire tie for control wires
E1
Power lug E1
G
Ground lug
—
—
Table 6-2. Customer Wiring Connections
Terminal Numbering
Decal
Wire Numbers
Table 6-3. Control Wire Recommended Length and Size
(Copper conductors only)
Maximum Wire Length
Recommended Wire Size
YELLOW
NO. 1 & NO. 2
N1 & N2 - 240 VAC - Sensing for utility
dropout and pickup
1–115 ft (1–35 m)
No. 18 AWG
115–185 ft (35–56 m)
No. 16 AWG
BLUE NO. 3 *
T1 - Fused 120 VAC for battery charger
185–295 ft (56–89 m)
No. 14 AWG
BLACK NO.3 **
0 - DC (-) Common ground wire
295–460 ft (89–140 m)
No. 12 AWG
RED NO. 4
194 - DC (+) 12 VDC for transfer controls
WHITE NO. 5
23 - Transfer control signal wire
* Must be connected to keep battery charged whether unit is running or not.
** Required if generator is paired with Generac Smart Power management transfer switch.
26
Installation Guidelines For 60 Hz Synergy™ Generators
Electrical Connections
.
Table 6-4. Ground and Neutral Connections
(Copper or Aluminum Conductors)
Refer to national and/or local codes to verify correct wire sizes.
NOTE: Torque all wiring lugs, bus bars, and connection
points to the proper torque specifications.
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).
No.
Description
Recommended
Wire Size
Torque Spec
1
Power wire
terminals
2/0 to 8 AWG
120 in-lb (13.56 Nm)
2
Large neutral
lug
2/0 to 14 AWG
120 in-lb (13.56 Nm)
Service Entrance Decals
3
Large ground
lug
2/0 to 14 AWG
120 in-lb (13.56 Nm)
See Figure 2-6. Locate the service entrance-related
decals in the loose parts bag.
4
Neutral bus bar
4-6 AWG
8 AWG
10-14 AWG
35 in-lb (3.95 Nm)
25 in-lb (2.82 Nm)
120 in-lb (2.26 Nm)
Main AC Wiring
NOTE: Main AC wiring must be in accordance with local
jurisdiction and codes.
NOTE: The generator lugs are rated at 167 °F (75 °C),
copper or aluminum.
1. Strip the insulation off the wire ends. Do not remove
excessive insulation.
2. See Figure 6-1. Loosen the lugs at neutral (D),
ground (G), and power wire (mains) terminals (E1,
E2).
3. Connect the ground wire to the ground lug and torque
to the required specification. See Table 6-4.
4. Connect the neutral wire to the neutral lug if
applicable. Torque to the required specification. See
Table 6-4.
• Place the service disconnect decal next to the Main
Line Circuit Breaker (Generator Disconnect).
• Place the service entrance warning decal in an
appropriate location according to the instructions
printed on the decal.
Common Alarm Relay (Option)
Alarms relating to generator and engine performance
appear on the controller and in the Mobile Link™
application (if used). The controller is equipped with a
common alarm relay that provides contacts for an
optional customer-supplied external alarm indicator.
The common alarm relay is normally open until an alarm
occurs, triggering the relay to close the contacts.
Terminals for the common alarm relay are provided in the
wiring harness near the controller plug (Wires 209 and
210).
Contact rating is for resistive load only:
Contact rating
200 mA at 12 VDC
5. Insert the power wires (E1 and E2) into their
corresponding lugs. Torque to the proper specification.
Load Shed Functionality
6. Verify the factory-installed ground and neutral
connections are properly tightened to 25 in-lb (2.82
Nm).
The Synergy product Transfer Switch includes an
Overload Prevention Control Board (OPCB) to shed
critical loads.
NOTE: The neutral wire must remain connected to keep
the battery charged whether the generator is running or
not.
The OPCB, commonly referred to as the Load Shed
Board, has “Fast Load Shed” capability, which effectively
prevents large loads from stalling the engine. ALL
LOADS GREATER THAN 10 kW OR 2 HP (MOTORS)
MUST BE CONNECTED TO THE OPCB. If natural gas is
the selected fuel type, then all loads greater than 9kW
must be connected to the OPCB. Examples of a large
load are a 3T air conditioner, 3 HP well pump, 3 HP sump
pump, etc.
NOTE: Neutral bonding – Installations that require the
neutral to be bonded to the ground are done on the
customer connections terminals inside the generator.
See Figure 6-1. Connect a suitably sized wire from the
neutral bar (J) to the ground stud (F). Torque the nut on
the ground stud to 35 in-lbs (3.95 Nm). 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. The installation must be made in
accordance with NEC Articles 250.30 and 250.35(A) if
the generator will be installed as a separately derived
system.
Installation Guidelines For 60 Hz Synergy™ Generators
When the generator senses the application of a large
load (greater than 10 kW or 2HP) while the engine is at
low speed, the load is instantly shed (within milliseconds)
and the engine is instructed to run at 3600 RPM. This
action prevents stalling of the engine. The loads are then
reapplied when the engine is back up to speed. Normal
loads take about six seconds. Large loads, such as an air
27
Electrical Connections
conditioner, have specially designated connections on
the OPCB, and are only reapplied after five minutes (to
protect the air conditioner motor).
See the Transfer Switch Owner’s Manual for a complete
description.
Automatic Voltage Regulator
(AVR) Cooling Fans
The system is equipped with two fans to cool the AVR
electronics. The primary fan is powered by special power
supply via AC during operation. The secondary fan is
powered by 12V DC through the controller. The fans are
monitored during operation and if a failure occurs, an
alarm is displayed.
The secondary fan continues to operate for up to 80
minutes after the generator is shut down. Proper cooling
must occur before removing either battery connections or
7.5 amp fuse for maintenance or other service activity.
WARNING
Moving Parts. Avoid AVR fan housing for 80
minutes after generator shutdown. Fan
operates even if fuse is removed. Rotating fan
blades could result in death or serious injury.
(000222a)
NOTE: The AVR cooling air inlet includes a filter. Verify
the filter is installed and properly seated at time the unit is
installed. Check the filter at regular maintenance intervals
to verify proper airflow. See the Maintenance section of
the Owner’s Manual for details.
1. Verify that the generator is OFF.
2. Turn off utility power supply to the transfer switch.
3. Remove the 7.5A fuse from the generator control
panel.
Battery cables were factory connected at the generator.
See Figure 6-2. Connect cables to battery posts as
follows:
WARNING
Explosion. Batteries emit explosive gases.
Always connect positive battery cable first to
avoid spark. Failure to do so could result in
death or serious injury.
(000133)
4. Connect the red battery cable (A: from starter
contactor) to the battery post indicated by a
positive: POS or (+). Torque to 70 in-lbs (8 Nm).
5. Connect the black battery cable (B: from frame
ground) to the battery post indicated by a negative:
NEG, or (-). Torque to 70 in-lbs (8 Nm).
6. Install the red battery post cover (shipped with
loose parts).
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.
B
A
Battery Requirements
12 volts, Group 26R-540CCA minimum, or Group
35AGM-650CCA minimum.
–
+
Battery Installation
WARNING
001832
Figure 6-2. Battery Cable Connections
(000137a)
WARNING
NOTE: In areas where temperatures fall below 0°F
(-18°C), it is recommended that a pad type battery
warmer be installed to aid in cold climate starting. This is
available through an Independent Authorized Service
Dealer (IASD).
A battery warmer is not necessary for AGM-style
batteries.
(000138a)
• (Group 26R batteries only): Fill the battery with
the proper electrolyte fluid if necessary.
• Fully charge the battery before installing it.
Before installing and connecting the battery, complete the
following steps:
28
Installation Guidelines For 60 Hz Synergy™ Generators
Electrical Connections
Battery Disposal
WARNING
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death or serious injury.
(000228)
Always recycle batteries in accordance with local laws
and regulations. Contact your local solid waste collection
site or recycling facility to obtain information on local
recycling processes. For more information on battery
recycling, visit the Battery Council International website
at: http://batterycouncil.org.
Installation Guidelines For 60 Hz Synergy™ Generators
29
Electrical Connections
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30
Installation Guidelines For 60 Hz Synergy™ Generators
Control Panel Start-Up/Testing
Section 7: Control Panel Start-Up/Testing
Control Panel Interface
Generator Setup
DANGER
Automatic start-up. Disconnect utility power and
render unit inoperable before working on unit.
Failure to do so will result in death or serious injury.
(000191)
NOTE: Do not remove power from the unit until the AVR
has completed its cool down.
• Press the OFF button on the control panel, remove
fuses, and disconnect battery cables to prevent
accidental startup before performing any
maintenance on the generator.
• 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, and the NEGATIVE cable
last.
Using the AUTO/MANUAL/OFF Buttons
Description of Operation
AUTO
This button activates fully automatic system operation. Automatic operation allows the unit to automatically start and exercise the generator
according to the exercise timer settings (see Setting The Exercise Timer).
MANUAL
Activation
To receive the activation code, you must have the unit
serial number and go to: www.generac.com, “Service &
Support” tab, and then “Activate Your Home Standby”
under the “Generac Owners” list. You can also receive an
activation code by calling 1-888-9ACTIVATE (1-888-9228482).
Activating the generator is a simple, one-time process
that is guided by the controller screen prompts. The
controller screen will not prompt you to activate again
once the product is activated, even if you disconnect the
generator battery, fuse, and battery charge circuit. (T1)
Proceed as follows after obtaining your activation code:
1. The display interface will begin an installation wizard upon first power-up of the generator.
NOTE: If the unit has already been powered up, it is
necessary to disconnect the generator battery, fuse, and
battery charge circuit (T1).
Button
OFF
The controller will light up when battery power is applied
to the generator during the installation process. The
generator still needs to be activated before it will
automatically run in the event of a power outage.
This button shuts down the engine and also prevents automatic operation and exercise of the
unit.
This button will crank and start the generator.
Transfer to standby power will not occur unless
there is a utility failure.
2. The installation wizard prompts the user to set the
fuel type.* Chose fuel type and press ENTER. The
controller will display “Activate me (ENT) or ESC”.
Press ESC to run in MANUAL.
3. Press ENTER and use the up/down arrow keys
and the ENTER key to input the activation code.
NOTE: If you push ESC to run in MANUAL, the unit will
not function in AUTO. To enter the activation code at a
later time, it is necessary to disconnect the generator
battery, fuse, and battery charge circuit (T1).
The install wizard will only allow the user to change basic
operational settings if the unit is not activated. These
settings are: Current Date/Time and Exercise Day/Time.
“NOT ACTIVATED” will be displayed.
The installation wizard will allow further programming
parameters and AUTO operation if the unit is activated.
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 display will only prompt the customer for the current
Time and Date.
000425
Figure 7-1. Generator Control Panel
Installation Guidelines For 60 Hz Synergy™ Generators
* This is required in addition to setting the fuel selector
knob to the correct fuel for the generator to function
properly.
31
Control Panel Start-Up/Testing
Table 7-1. Activation Chart
Display Reads
Language
English
Troubleshooting
+
Use arrow keys to
scroll to desired
language.
Press ENTER to
select.
Language 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.
002227
Activate me (ENT) or
ESC to run in manual
002228
If you do not have your
activation code, go to
www.activategen.com
or call 1-8889ACTIVATE
(922-8482 US & CA
only).
If you already have
your activation code,
wait 3–5 seconds for
the next display.
To Activate go to
www.activategen.com
002229
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.
Serial 123456789
Passcode XXXXX +/-
002230
32
Installation Guidelines For 60 Hz Synergy™ Generators
Control Panel Start-Up/Testing
Table 7-1. Activation Chart
Display Reads
Troubleshooting
Activation is complete
when all digits are
entered above and
your screen shows this
display.
Follow the controller
prompts to continue
setting the time
function. Refer to your
Owner’s Manual with
questions.
Select Hour (0-23)
- 6 +
What happens if “Wrong Passcode Try
Again” appears?
Re-enter the activation code. If a
second attempt is unsuccessful, check
the number against the code given on
activategen.com. If it is correct and the
generator will not accept it, contact 1888-9ACTIVATE (922-8482, US & CA
only).
002231
Cold Smart Start
The Cold Smart Start feature monitors the ambient
temperature and adjusts the warm-up delay upon start up
in AUTO mode based on prevailing conditions.
The generator will startup with the normal warm-up delay
of 5 seconds if the ambient temperature is at or above
the fixed temperature.
A check for proper output voltage build up will be
performed when the generator engine is started.
If some condition impedes normal voltage creation, such
as frost crystals or dust/dirt preventing a good electrical
connection, the start sequence will be interrupted so that
a cleaning cycle of the internal electrical connections can
be attempted.
The cleaning cycle is an extended warming up period
which lasts for several minutes while the normal
generator voltage output is determined to be low. During
this cycle, the generator controller will display “Warming
Up” on the display screen.
The generator controller display will show “Under
Voltage” if the cleaning cycle fails to clear the obstruction.
After several minutes, the alarm message can be
cleared, and the generator restarted.
the time of day specified. During this exercise
period, the unit runs for five to twelve minutes
depending on the model, and then shuts down.
• Exercise frequency (how often the exercise will
take place): Can be set to WEEKLY, BIWEEKLY,
or MONTHLY. If MONTHLY is selected, the day of
the month must be selected from 1–28. The
generator will exercise on that day each month.
Transfer of loads to the generator output does not
occur during the exercise cycle unless utility power
is lost.
NOTE: If the installer tests the generator prior to
installation, press the ENTER button to skip setting up
the exercise timer.
NOTE: The exercise feature 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.
NOTE: The exercise timer does not automatically adjust for
Daylight Savings Time.
If the problem persists, make no further attempts to start.
Contact an IASD.
Table 7-2. Cold Smart Start
Generator Size
Fixed Temperature
20 kW Synergy
50 °F (10 °C)
Setting The Exercise Timer
This generator is equipped with a configurable exercise
timer. There are two settings for the exercise timer:
• Day/Time: The generator will start and exercise for
the period defined, on the day of the week and at
Installation Guidelines For 60 Hz Synergy™ Generators
33
Control Panel Start-Up/Testing
Before Initial Start-up
NOTE: The unit has been run and tested at the factory
prior to being shipped and does not require any type of
break-in.
CAUTION
Engine damage. Verify proper type and quantity of
engine oil prior to starting engine. Failure to do so
could result in engine damage.
(000135)
shutoff valves in the fuel supply lines must be
open.
NOTE: 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 button, and restart up to two more times if
necessary. If unit fails to start, contact an Independent
Authorized Service Dealer (IASD) for assistance.
NOTE: The unit comes filled with 5W-30 weight organic
oil from the factory. Check the oil level and add the
appropriate viscosity and amount if necessary.
Installation Wizard
The installation wizard immediately appears upon powerup. It allows the user to input generator settings. See
Figure 7-2.
The installation wizard will start every time AC and DC
power are removed and reapplied to the generator.
Interconnect System Self Test Feature
This controller will go through a system self test at power
up, which will check for the presence of utility voltage on
the DC circuits. This is done to prevent damage if the
installer incorrectly connects AC utility power sense wires
into the DC terminal block. The controller will display a
warning message and lock out the generator, preventing
damage to the controller, if utility voltage is detected at
the DC terminal block. 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: All appropriate panels must be in place during
any operation of the generator. This includes operation
by
a
servicing
technician,
while
conducting
troubleshooting procedures.
Before starting, complete the following:
1. Verify that the generator is off.
2. Set the generator main circuit breaker to OFF
(OPEN).
3. Turn off all breakers that will be powered by the
generator.
4. Check the engine crankcase oil level and, if
necessary, fill to the dipstick FULL mark with the
recommended oil. Do not overfill.
5. Check the fuel supply. Gaseous fuel lines must
have been properly purged and leak tested in
accordance with applicable fuel-gas codes. All fuel
34
Installation Guidelines For 60 Hz Synergy™ Generators
Control Panel Start-Up/Testing
Power Up Unit
Note: If language was
previously programmed
this goes directly
to “Select Hour”
FIRMWARE V 1.01
HARDWARE V 1.05
UP ARROW =
Language
Install Wizard
+ English + Espanol + Francais + Portuguese -
+
Defaults to English if
not selected.
ENTER
DOWN ARROW =
Use UP and DOWN
arrows to select fuel
type then press
“ENTER”
Fuel Selection
+ NG or LP -
Select Hour (0-23)
- 14 +
-
ENTER
ENTER
Select Min (0-59)
- 0 +
*
Select Month (1-12)
- 2 +
*
ENTER
Select Date (1-31)
- 13 +
*
ENTER
Select Year (0-99)
- 13 +
*
Install Wizard
Set Exercise
ENTER
Select Quiet
Test Mode
ENTER
ENTER
Select Hour (0-23)
- 14 +
Yes / No
*
ENTER
* Holding the Up or Down arrow
button for 2 seconds will speed dial
through the selections
Select Min (0-59)
ENTER
- 0 +
*
ENTER
*
Select Day
Switched to “OFF”
Hours of Protection
0 (H)
ENTER
SYSTEM
DATE/TIME
- Wednesday +
If Frequency is
Monthly, Select Day
*
1–28
BAT-
SUB MENUS
003636
Figure 7-2. Installation Wizard Menu Map
Check Manual Transfer Switch
Operation
Refer to the Manual Transfer Operation section of the
owner’s manual for procedures.
DANGER
Electrocution. Do not manually transfer under load.
Disconnect transfer switch from all power sources
prior to manual transfer. Failure to do so will result
in death or serious injury, and equipment damage.
(000132)
Installation Guidelines For 60 Hz Synergy™ Generators
35
Control Panel Start-Up/Testing
Electrical Checks
DANGER
Electrocution. High voltage is present at
transfer switch and terminals. Contact with live
terminals will result in death or serious injury.
(000129)
Proceed as follows to complete electrical checks:
1. Verify that the generator is off.
2. Set the generator main circuit breaker to OFF
(OPEN).
3. Turn off all circuit breakers/electrical loads that will
be supplied by the generator.
4. Turn on the utility power supply to the transfer
switch using the means provided (such as a utility
main line circuit breaker).
5. Use a calibrated 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 voltage is not correct,
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 lineto-neutral voltage should be 120 volts AC (if wired
with a neutral). If voltage is not correct, verify AC
output and wiring from utility source to N1 and N2
lugs at transfer switch.
7. Turn off the utility power supply to the transfer
switch when certain that utility supply voltage is
compatible with transfer switch and load circuit
ratings.
8. Push the MANUAL button on the generator panel.
The engine will crank and start. Record cranking
gas pressure: ______________.
9. Let the engine warm up for approximately five
minutes to allow internal temperatures to stabilize.
Then set the generator MLCB (generator
disconnect) to ON (CLOSED). Record running gas
pressure: ______________.
10. Connect a calibrated 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 Hz. If voltage is not correct,
verify that the MLCB (generator disconnect) 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.
11. Connect the AC voltmeter test leads across
terminal lugs E1 and neutral; then across E2 and
neutral (if wired with a neutral). In both cases,
voltage reading should be 119–121 volts AC. If
voltage is not correct, verify that the MLCB
(generator disconnect) is closed and verify AC
output between the E1 and E2 of the MLCB
36
(generator disconnect) and neutral at the
generator.
12. Verify wiring from generator to E1, E2, and neutral
lugs at transfer switch.
13. Set the generator MLCB (generator disconnect) to
OFF (OPEN).
14. Push the generator OFF button. The engine will
shut down.
NOTE: It is important not to proceed until certain that the
generator AC voltage and frequency are correct and
within the stated limits.
Generator Tests Under Load
Proceed as follows to test the generator set with
electrical loads applied:
1. Verify 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
MLCB [generator disconnect]).
DANGER
Electrocution. Do not manually transfer under load.
Disconnect transfer switch from all power sources
prior to manual transfer. Failure to do so will result
in death or serious injury, and equipment damage.
(000132)
4. Manually set the transfer switch to STANDBY, i.e.,
load terminals connected to the generator’s E1/E2
terminals. The transfer switch operating lever
should be down.
5. Push the generator MANUAL button. The engine
will crank and start immediately.
6. Allow the engine to stabilize and warm up for a few
minutes.
7. Set the generator MLCB (generator disconnect) to
ON (CLOSED). Loads are now powered by the
standby generator.
8. Turn on the circuit breakers/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 approximately 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.
Installation Guidelines For 60 Hz Synergy™ Generators
Control Panel Start-Up/Testing
11. Verify gas pressure while under full load. Record
loaded gas pressure: ______________.
12. When testing under load is complete, turn off
electrical loads.
13. Set the generator MLCB (generator disconnect) to
OFF (OPEN).
14. Let the engine run at no-load for 2–5 minutes.
15. Push the generator OFF button. The engine will
shut down.
NOTE: If gas pressure under full load is below the
minimum operating pressure guideline, the generator may
not function properly. The pressure gauge needle should
also remain steady while testing. A fluctuating needle
indicates that gas piping may be undersized or restricted.
It may also indicate that a step-down gas regulator is too
small, or too close to the unit.
Checking Automatic Operation
Proceed as follows to check the system for proper
automatic operation:
1. Verify that the generator is off.
2. Install the 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
MLCB).
NOTE: Transfer switch will transfer to utility position.
4. Set the generator MLCB (generator disconnect) to
ON (CLOSED).
5. Push the generator AUTO button. The system is
now ready for automatic operation.
6. Turn off the utility power supply to the transfer
switch.
The generator is ready for automatic operation. The
engine will crank and start when the utility source power
is turned OFF after a 10 second delay (factory default
setting). After starting, the transfer switch will connect
load circuits to the standby side after a delay up to four
minutes. See Cold Smart Start. Allow the system to
operate through the entire automatic sequence of
operation.
connections or 7.5 amp fuse for maintenance or
other service activity.
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. 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.
Shutting Generator Down While
Under Load
IMPORTANT NOTE: To avoid equipment damage,
follow these steps, in order, when shutting the generator
down during utility outages. Shutdowns may be required
during outages to perform routine maintenance or to
conserve fuel.
To turn the generator OFF (while running in AUTO
and online):
1. Turn the main utility disconnect off.
2. Turn the generator MLCB (generator disconnect)
to OFF (OPEN).
3. Run the generator for approximately one minute for
proper cooling.
4. Turn the generator OFF.
To turn the generator back ON:
1. Put the generator into AUTO. Start generator and
warm-up for a few minutes.
2. Set the MLCB (generator disconnect) to ON
(CLOSED).
The system now operates in automatic mode. The main
utility disconnect can be turned ON (CLOSED). To shut
the unit off, repeat this complete process.
With the generator running and loads powered by
generator AC output, turn on the utility power supply to
the transfer switch. The following will occur:
• After approximately 15 seconds, the switch will
transfer loads to the utility power source.
• Approximately one minute after re-transfer, the
engine will shut down.
• AVR will now go through its cool down. The
secondary fan continues to operate for up to 80
minutes after the generator is shut down. Proper
cooling must occur before removing either battery
Installation Guidelines For 60 Hz Synergy™ Generators
37
Control Panel Start-Up/Testing
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38
Installation Guidelines For 60 Hz Synergy™ Generators
Troubleshooting
Section 8: Troubleshooting
System Diagnosis
Table 8-1. System Diagnosis
Problem
Engine will not crank.
Cause
1. Blown fuse.
2. Loose, corroded, or defective battery
cables.
3. Defective starter contact.
4. Defective starter motor.
5. Discharged battery.
Correction
1. Correct short circuit condition by replacing
7.5 amp fuse in generator control panel. If
fuse continues to blow, contact an IASD for
assistance.
2. Tighten, clean, or replace as necessary.*
3. *See #2.
4. *See #2.
5. Charge or replace battery.
Engine cranks but will not start.
1. No fuel
2. High fuel pressure.
3. Fuel selector in wrong position.
4. Defective fuel solenoid (FS).
5. Open Wire 14 from engine control board.
6. Defective spark plug(s).
7. Valve clearance out of adjustment.
1. Replenish fuel / turn on fuel valve.
2. Check and adjust fuel pressure.
3. Turn fuel conversion knob to correct position.
4. *
5. *
6. Clean; check gap; replace plug(s) as
needed.
7. Reset valve clearance.
Engine starts hard and runs
rough.
1. Plugged or damaged air cleaner.
2. Defective spark plug(s).
3. Incorrect fuel pressure.
5. Internal engine issue.
1. Check / replace air cleaner.
2. Clean; check gap; replace plug(s) as
needed.
3. Confirm fuel pressure to regulator is 10–12 in.
water column (19–22 mm Hg) for LP, and 3.5–7
in. water column (7–13 mm Hg) for NG.
4. Turn fuel conversion knob to correct position,
and program controller for fuel type.
5. *
Generator is set to OFF, but the
engine continues to run.
1. Controller wired incorrectly.
2. Defective control board.
1. *
2. *
No AC output from generator.
1. MLCB (generator disconnect) is OFF
(OPEN).
2. Generator internal failure.
3. Engine may be warming up. Refer to Cold
Smart Start.
1. Reset circuit breaker to ON (CLOSED).
1. MLCB (generator disconnect) is OFF
(OPEN).
2. Defective transfer switch coil.
3. Defective transfer relay.
4. Transfer relay circuit open.
5. Defective control logic board.
6. Engine may be warming up.Refer to Cold
Smart Start.
1. Reset circuit breaker to ON (CLOSED).
1. Excessive engine oil.
2. Defective engine breather.
3. Improper type or viscosity of oil.
4. Damaged gasket, seal, or hose.
5. Restricted air filter.
1. Adjust oil to proper level.
2. *
3. See “Engine Oil Recommendations”.
4. Check for oil leaks.
5. Replace air filter.
4. Fuel selector in wrong position.
No transfer to standby after utility source failure.
Unit consumes large amounts
of oil.
2. *
3. Check controller screen to verify status.
2. *
3. *
4. *
5. *
6. Check controller screen to verify status.
* Contact an Independent Authorized Service Dealer or visit www.generac.com for assistance.
Installation Guidelines For 60 Hz Synergy™ Generators
39
Troubleshooting
Synergy Diagnostics
Table 8-2. Synergy Diagnostics
Ecode/Active
Alarm
LED
Problem
Things to
Check
Possible Causes/Solution
1048 VSCF Overload RED
Unit shuts down
during operation.
Check the
LEDs/Screen
for alarms.
Alternator, AVR or wiring is damaged.
Contact Independent Authorized Servicing Dealer.
1049 VSCF Overload RED
Unit shuts down
during operation.
Check the
LEDs/Screen
for alarms.
Generator output is shorted or severely overloaded.
Identify and clear the overload, and then restart.
1051 VSCF High
Battery
YELLOW
Yellow LED
illuminated in any
state.
Check the
LEDs/Screen
for alarms.
Voltage supply to the AVR is high. If an external battery
charger is in use, contact installing dealer to correct
installation. If an external battery charger is NOT in use,
contact Independent Authorized Servicing Dealer.
1052 VSCF DC
Overvoltage
RED
Unit shuts down
during operation.
Check the
LEDs/Screen
for alarms.
Probable causes are:
1) The generator was temporarily overloaded.
2) The output was temporarily shorted. Try to restart the
unit.
1053 VSCF Gate
Fault
RED
Unit shuts down
during operation
or starting.
Check the
LEDs/Screen
for alarms.
AVR is damaged. Contact Independent Authorized
Servicing Dealer.
1054 VSCF IGBT
Overtemp.
RED
Unit shuts down
during operation
or starting.
Check the
LEDs/Screen
for alarms.
Probable causes are:
1) Replace AVR filter. Inspect fan.
2) Intake or exhaust air path is blocked. Check intake and
exhaust.
3) The BIG fan is not running (only runs when the engine
is running). KEEP FINGERS AWAY FROM FAN
HOUSING- PERSONAL INJURY CAN OCCUR IF FAN IS
RUNNING. Contact Independent Authorized Servicing
Dealer.
4) Air leak in AVR enclosure. Contact Independent
Authorized Servicing Dealer.
5) Engine running too hot. Inspect air intake and exhaust.
6) Ambient temperature has risen above 60º F (15.5°C).
Derate the generator output per specifications.
1055 VSCF Phase
Error
RED
Unit shuts down
during starting.
Check the
LEDs/Screen
for alarms.
An incorrect voltage and frequency has been detected
during starting. Probable causes are:
1) Alternator damage. Contact Independent Authorized
Servicing Dealer.
2) Generator has started into a severe load. Manually
operate transfer switch back to utility position and try to
restart unit. If problem persists, remove load and attempt
to restart unit again.
3) The engine may not be reaching its prescribed speed.
Proceed as follows:
• Verify stepper motor is moving and linkage is free.
• Verify stepper motor is plugged in.
• Verify gas pressure is within specified limits.
1056 VSCF
Undervoltage
40
RED
Unit shuts down
during operation
or starting.
Check the
LEDs/Screen
for alarms.
The generator output voltage is too low. Probable causes
are:
1) The load is too large. Remove load and attempt to
restart unit.
2) Alternator or AVR damage. Contact Independent
Authorized Servicing Dealer.
Installation Guidelines For 60 Hz Synergy™ Generators
Troubleshooting
Table 8-2. Synergy Diagnostics (Continued)
Ecode/Active
Alarm
LED
Problem
Things to
Check
Possible Causes/Solution
1057 VSCF
Overvoltage
RED
Unit shuts down
during operation
or starting.
Check the
LEDs/Screen
for alarms.
Probable causes are:
1) The generator has been overloaded. Remove load and
attempt to restart unit.
2) Generator has started into a severe load. Manually
operate transfer switch back to utility position and try to
restart unit. If problem persists, remove load and attempt
to restart unit again.
1058 VSCF DC
Undervoltage
RED
Unit shuts down
during operation
or starting.
Check the
LEDs/Screen
for alarms.
The DPE winding supplies this voltage.
1) Alternator or brush damage. Contact Independent
Authorized Servicing Dealer.
1059 VSCF
Field Loss
RED
Unit shuts down
during starting.
Check the
LEDs/Screen
for alarms.
Unit detects no output voltage while starting.
1) Alternator or brush damage. Contact Independent
Authorized Servicing Dealer.
1061 VSCF
Field Loss
RED
Unit shuts down
during operation.
Check the
LEDs/Screen
for alarms.
Unit detects loss of output voltage while running.
1) Alternator or brush damage. Contact Independent
Authorized Servicing Dealer.
1060 Big Fan Failure RED
Unit shuts down
during operation.
Check the
LEDs/Screen
for alarms.
This alarm occurs when the AVR electronics temperature
exceeds 158°F (70°C). Possible causes are:
1) AVR filter faulty. Replace AVR filter.
2) Intake or exhaust air path is blocked. Check intake and
exhaust.
3) The BIG fan is not running (only runs when the engine
is running). KEEP FINGERS AWAY FROM FAN
HOUSING- PERSONAL INJURY CAN OCCUR IF FAN IS
RUNNING. Contact Independent Authorized Servicing
Dealer.
4) Air leak in AVR enclosure. Contact Independent
Authorized Servicing Dealer.
5) Engine running too hot. Inspect air intake and exhaust.
6) Ambient temperature has risen above 60º F (15.5°C).
Derate the generator output per specifications.
If message is displayed when generator is stopped, also
check SMALL fan. Small fan RUNS for 80 minutes after
generator is stopped and keeps electronics cool during
heat soak.
1065 Overfrequency
Unit shuts down
during operation.
Check the
LEDs/Screen
for alarms.
Probable causes are:
1) Overload. Remove load and attempt to restart unit.
2) RPM sensor has failed. Contact Independent
Authorized Servicing Dealer.
3) Stepper motor problem. Contact Independent
Authorized Servicing Dealer.
RED
Installation Guidelines For 60 Hz Synergy™ Generators
41
Troubleshooting
Table 8-2. Synergy Diagnostics (Continued)
Ecode/Active
Alarm
LED
Problem
Things to
Check
Possible Causes/Solution
1066 VSCF Speed
mismatch
RED
Unit shuts down
during Operation
or starting.
Check the
LEDs/Screen
for alarms.
1) Fuel problem (pressure loss). Check fuel supply and
attempt to restart unit.
2) A large load is not wired through the Loadshed module.
Contact installing dealer to correct installation.
3) Large overload. Remove load and attempt to restart
unit.
4) Throttle or engine problem. Contact Independent
Authorized Servicing Dealer.
1070 Small fan
failure
YELLOW
“Small fan failure” Check the
is displayed. If
LEDs/Screen
unit was running
for alarms.
in AUTO and
utility returns, it
will continue to
run for 80 minutes
to cool electronics
without fan.
Small fan current incorrect. Probable causes are:
1) Fan wiring or mechanical problem. Contact
Independent Authorized Servicing Dealer.
2) Air path is blocked. Check AVR filter.
KEEP FINGERS AWAY FROM FAN HOUSINGPERSONAL INJURY CAN OCCUR IF FAN IS RUNNING.
Load Shed Troubleshooting
Table 8-3. Load Shed Troubleshooting
Symptom
Possible Causes
Generator stalls when large load is
supplied.
1) Total load is too big for the generator and fuel type. Contact installing dealer to correct
installation.
2) A large load is not wired through the load shed module. Contact installing dealer to
correct installation.
Large loads keep getting shed and
locked out (load LED goes out for 30
minutes).
Total load is too big for generator. Contact installing dealer to correct installation.
Output voltage is low/high.
Voltage calibration incorrect. Contact Independent Authorized Servicing Dealer.
Generator does not pull full power.
Current calibration incorrect. Contact Independent Authorized Servicing Dealer.
42
Installation Guidelines For 60 Hz Synergy™ Generators
Quick Reference Guide
Section 9: Quick Reference Guide
System Diagnosis
To clear an active alarm, press the OFF button, ENTER button, then press AUTO. Contact an Independent Authorized
Service Dealer (IASD) if the alarm reoccurs.
Table 9-1. System Diagnosis
Active Alarm
LED
NONE
FLASHING
GREEN
HIGH
TEMPERATURE
OVERLOAD
REMOVE LOAD
Problem
Things to Check
Solution
Check MLCB
Unit running in AUTO but
(generator
no power in house.
disconnect).
Check MLCB (generator disconnect). If it is
ON, contact an IASD.
RED
Unit shuts down during
operation.
Check the LED’s /
screen for alarms.
Check ventilation around the generator,
intake, exhaust, and rear of generator. If no
obstructions are present, contact an IASD.
RED
Unit shuts down during
operation.
Check the LED’s /
screen for alarms.
Clear alarm and remove household loads
from the generator. Put into AUTO and
restart.
RPM SENSE
LOSS
RED
Unit was running and
shut down, attempts to
restart.
Check the LED’s /
screen for alarms.
Clear alarm and remove household loads
from the generator. Put into AUTO and
restart. If generator does not start, contact
an IASD.
NOT ACTIVATED
NONE
Unit will not start in
AUTO with utility loss.
See if screen says unit
See Activation.
not activated.
NONE
GREEN
Unit will not start in
AUTO with utility loss.
If the startup delay is greater than
Check screen for start
expected, contact an IASD to adjust
delay countdown.
between 2 to 1500 seconds.
LOW OIL
PRESSURE
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
screen for alarms.
Check oil level and add oil as needed. If oil
level is correct, contact an IASD.
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
screen for alarms.
Clear alarm. Using the control panel, check
the battery by navigating to the BATTERY
MENU option from the MAIN MENU. If
battery condition displays GOOD, contact
an IASD. If control panel displays CHECK
BATTERY, replace the battery.
OVERCRANK
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
screen for alarms.
Check fuel line shutoff valve is ON. Clear
alarm. Start the unit in MANUAL. If it does
not start, or starts and runs rough, contact
an IASD.
LOW VOLTS
REMOVE LOAD
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
screen for alarms.
Clear alarm and remove household loads
from the generator. Put into AUTO and
restart.
FUSE PROBLEM
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
screen for alarms.
Check the 7.5 amp fuse. If blown, replace it
with an ATO 7.5 amp fuse. If the fuse is
intact, contact an IASD.
OVERSPEED
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
screen for alarms.
Contact an IASD.
UNDERVOLTAGE
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
screen for alarms.
Contact an IASD.
RPM SENSE
LOSS
Installation Guidelines For 60 Hz Synergy™ Generators
43
Quick Reference Guide
Table 9-1. System Diagnosis (Continued)
Active Alarm
LED
UNDERSPEED
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
screen for alarms.
Contact an IASD.
STEPPER
OVERCURRENT
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
screen for alarms.
Contact an IASD.
MISWIRE
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
screen for alarms.
Contact an IASD.
OVERVOLTAGE
RED
Unit will not start in
AUTO with utility loss.
Check the LED’s /
screen for alarms.
Contact an IASD.
44
Problem
Things to Check
Solution
LOW BATTERY
YELLOW
Clear alarm. Using the control panel, check
the battery by navigating to the BATTERY
Yellow LED illuminated in Check the screen for MENU option from the MAIN MENU. If
any state.
additional information. battery condition displays GOOD, contact
an IASD. If control panel displays CHECK
BATTERY, replace the battery.
BATTERY
PROBLEM
YELLOW
Yellow LED illuminated in Check the screen for
Contact an IASD.
any state.
additional information.
CHARGER
WARNING
YELLOW
Yellow LED illuminated in Check the screen for
Contact an IASD.
any state.
additional information.
SERVICE A
YELLOW
Yellow LED illuminated in Check the screen for Perform SERVICE A maintenance. Press
any state.
additional information. ENTER to clear.
SERVICE B
YELLOW
Yellow LED illuminated in Check the screen for Perform SERVICE B maintenance. Press
any state.
additional information. ENTER to clear.
INSPECT BATTERY
YELLOW
Yellow LED illuminated in Check the screen for
Inspect battery. Press ENTER to clear.
any state.
additional information.
Installation Guidelines For 60 Hz Synergy™ Generators
Accessories
Section 10: Accessories
Performance enhancing accessories are available for air-cooled generators.
Accessory
Cold Weather Accessories*—
• Battery Pad Warmer
Description
• Recommended in areas where temperatures fall below 0 °F (-18 °C).
(Not necessary for use with AGM-style batteries)
• Oil Warmer
• Breather Warmer
• Recommended in areas where temperatures fall below 0 °F (-18 °C).
• Recommended in areas where heavy icing occurs.
* each sold separately
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 Base Wrap
The fascia base wrap snaps together around the bottom of the generator. This
offers a sleek, contoured appearance as well as offering protection from
rodents, reptiles, and insects by covering the lifting holes located in the base.
Requires use of the mounting pad shipped with the generator.
Touch-Up Paint Kit
Very important to maintain the look and integrity of the generator enclosure.
This kit includes touch-up paint and instructions.
Wireless Local Monitor
The Wireless Local Monitor is completely wireless and battery powered, and
provides owners with instant status without ever leaving the house. Status
lights (red, yellow, and green) alert owners when the generator needs
attention. Magnetic backing permits refrigerator mounting and gives a 600 ft
line of sight communication.
Extended Warranty Coverage
Extend the generator warranty coverage by purchasing extended warranty
coverage. Covers both parts and labor. Extended coverage can be purchased
within 12 months of the end-users purchase date.
This extended coverage is applicable to registered units and end-user proof of
purchase must be available upon request.
Available for Generac® and Guardian® products.
Not available for Corepower™, PowerPact™, and EcoGen™ products or all
international purchases.
NOTE: Contact an Independent Authorized Service Dealer or visit www.generac.com for additional information on
accessories and extended warranties.
Installation Guidelines For 60 Hz Synergy™ Generators
45
Accessories
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46
Installation Guidelines For 60 Hz Synergy™ Generators
Diagrams
Section 11: Diagrams
Installation Drawing (10000002490—1 of 2)
AIR INTAKE
457.2
[18.0]
914 [36.0]
MINIMUM OPEN AREA
ON SIDES AND FRONT
AIR OUTLET
AIR INTAKE
TOP VIEW
"DO NOT LIFT BY ROOF"
RIGHT VIEW
INTAKE PANEL REMOVED
30.2 [ 1.2]
LIFTING HOLES 4 CORNERS
1218.0
[48.0]
76.2 [3.0]
PEA GRAVEL
MINIMUM
1232.0
[48.5]
Installation Guidelines For 60 Hz Synergy™ Generators
RIGHT SIDE VIEW
47
Diagrams
Installation Drawing (10000002490—2 of 2)
510.3
[20.1]
768.3
[30.2]
438.0
[17.2]
679.5
[26.8]
318.0
[12.5]
371.8
[14.6]
266.7
[10.5]
SERVICE ENTRANCE
CSA TRANSFER SWITCH
355.8
[14.0]
MOUNTING TO CONCRETE PAD
SERVICE ENTRANCE
TRANSFER SWITCH
1154.0
[45.43]
340.7
[13.4]
HOLE LOCATIONS FOR
OPTIONAL MOUNTING TO
A CONCRETE PAD
10.0 [3/8] DIA. CLEARANCE
HOLE (4) PLACES,
3/8 DIA. MASONRY ANCHOR
BOLTS RECOMMENDED
536.8
[21.13]
MAIN AC/CONTROL WIRING HOLE FOR 1 1/4" CONDUIT
MAIN AC/CONTROL WIRING HOLE FOR 3/4" CONDUIT
FUEL INLET - 3/4" NPT
456.6
[17.98]
392.7
[15.5]
68.0
[2.7]
FRONT OF UNIT
REQUIRED FUEL PRESSURE: NATURAL GAS : 3.5-7" WATER COLUMN
LIQUID PROPANE (VAPOR) : 10-12" WATER COLUMN
635.0
[25.0]
732.5
[28.8]
345.3
[13.59]
218.0
[8.58]
REAR VIEW
648.0
[25.5]
LEFT SIDE VIEW
48
Installation Guidelines For 60 Hz Synergy™ Generators
Diagrams
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Installation Guidelines For 60 Hz Synergy™ Generators
49
Diagrams
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50
Installation Guidelines For 60 Hz Synergy™ Generators
Part No. 0L6632
Rev. A
09/1/16
©2016 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