Generac 20 kW 0057440 Standby Generator Manual

Generac 20 kW 0057440 Standby Generator Manual
INSTALLATION
GUIDELINES
Air-cooled Generators
TABLE OF CONTENTS
Introduction ......................................................... Inside Front Cover
Read this Manual Thoroughly ..............................................IFC
Contents ................................................................................1
Operation and Maintenance ....................................................1
How to Obtain Service ............................................................1
Safety Rules...................................................................................1
Standards Index .....................................................................3
Unpacking/Inspection .....................................................................3
Protection Systems ........................................................................3
NEC Requirement for Arc Fault Circuit Interruption
Breaker for Bedrooms .................................................................3
Section 210.12 Arc Fault Circuit Interrupter Protection ............3
Emission Information .....................................................................4
Before You Begin ............................................................................4
Site Preparation and Generator Placement ......................................4
Coverting to LP Vapor ....................................................................5
Installing & Connecting Gas Lines ..................................................6
Battery Charger Installation.............................................................7
External Electrical Connections .......................................................8
Generator Connections - RTS Load Center Transfer Switch .............8
Appendix A - RTS Pre-wired Load Center Transfer
Switch Installation & Operational Testing ....................................10
Battery Installation................................................................11
Operational Testing ...............................................................12
Appendix B - RTSN Nd RTSE Transfer Switch
Installation & Operational Testing ...............................................14
Selected Circuit Coverage.....................................................15
Whole-house Circuit Coverage .............................................15
Battery Charger Installation...................................................16
Electrical Connections ..........................................................16
Operational Testing ...............................................................17
Appendix C - PowerMaster™ Load Controller
Installation and Operationa Testing .............................................19
Operational Testing ...............................................................20
Checking the Priority Load Controller ....................................23
Appendix D - PowerManager™ Load Shed Transfer
Switch Installation and Operational Testing.................................24
Battery Charger Installation...................................................25
Electrical Connections ..........................................................25
Operational Testing ...............................................................27
Verifying Load Shedding Operation .......................................28
Appendix E - GenReady™ Load Center Installation
and Operational Testing .............................................................31
Battery Charger Installation...................................................31
Electrical Connections ..........................................................32
Operational Testing ...............................................................33
Appendix F - Setting the Automatic Exercise Function....................35
Notes ...........................................................................................37
Electrical Data ..............................................................................40
INTRODUCTION
Thank you for purchasing this compact, high performance, aircooled, 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:
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.
‹ READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the
nearest Dealer for starting, operating and servicing procedures.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
operation that may be hazardous if performed incorrectly or
carelessly. Observe them carefully. Their definitions are as follows:
DANGER
After this heading, read instructions that, if not
strictly complied with, will result in serious personal injury, including death.
After this heading, read instructions that, if not
strictly complied with, could result in serious personal injury, including death.
After this heading, read instructions that, if not
strictly complied with, might result in minor or moderate injury.
NOTE:
After this heading, read instructions that, if not strictly complied with, may result in damage to equipment
and/or property.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the service are essential to
preventing accidents.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates follows:
SAFETY RULES
symbol points out important safety informa This
tion that, if not followed, could endanger per-
These Instructions – The manufacturer
 Save
suggests that these rules for safe operation be
sonal safety and/or property of others.

This symbol points out potential explosion
hazard.
 This symbol points out potential fire hazard.
symbol points out potential electrical shock
 This
hazard.
The operator is responsible for proper and safe use of the
equipment. The manufacturer strongly recommends that the
operator read this 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.
‹ CONTENTS
This manual contains pertinent owner’s information for these
models:
• 7 kW NG, 8 kW LP, single-cylinder GH-410 Engine
• 9 kW NG, 10 kW LP, V-twin GT-530 Engine
• 12 kW NG, 12 kW LP, V-twin GT-990 Engine
• 13 kW NG, 14 kW LP, V-twin GT-990 Engine
• 16 kW NG, 16 kW LP, V-twin GT-990 Engine
• 16 kW NG, 17 kW LP, V-twin GT-990 Engine
• 18 kW NG, 20 kW LP, V-twin GT-999 Engine
‹ OPERATION AND MAINTENANCE
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 a
Dealer. Normal maintenance service and replacement of parts
are the responsibility of the owner/operator and, as such, are not
considered defects in materials or workmanship within the terms
of the warranty. Individual operating habits and usage contribute to
the need for maintenance service.
Proper maintenance and care of the generator ensures a minimum
number of problems and keep operating expenses at a minimum.
See a Dealer for service aids and accessories.
‹ HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, contact a Dealer
for assistance. Service technicians are factory-trained and are
capable of handling all service needs.
When contacting a Dealer about parts and service, always supply
the complete model number and serial number of the unit as given
on its data decal, which is located on the generator. See section
“The Generator” for decal location.
Model No.__________________ Serial No. ______________
copied and posted near the unit’s installation
site. Safety should be stressed to all operators
and potential operators of this equipment.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this 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 warnings in this manual, and on
tags and decals affixed to the unit are, therefore, not all-inclusive.
If using a procedure, work method or operating technique the
manufacturer does not specifically recommend, ensure that it is
safe for others. Also make sure the procedure, work method or
operating technique utilized does not render the generator unsafe.
DANGER
the safe design of this generator,
 Despite
operating this equipment imprudently, neglect-
ing its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to install, operate and
maintain this equipment.
lethal voltages are generated by
 Potentially
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
of the generator are rotating and/or hot
 Parts
during operation. Exercise care near running
generators.
must always comply with applicable
 Installation
codes, standards, laws and regulations.
generator gives off carbon monoxide,
 Aandrunning
odorless, colorless poison gas. Breathing in
carbon monoxide can cause headaches, fatigue,
diziness, nausea, vomitting, confusion, fainting,
siezures or death.

WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.

WARNING:


This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
1
 GENERAL HAZARDS 
• For safety reasons, the manufacturer recommends that this
equipment be installed, serviced and repaired by a Service Dealer
or other competent, qualified electrician or installation technician
who is familiar with applicable codes, standards and regulations.
The operator also must comply with all such codes, standards
and regulations.
• Keep hands, feet, clothing, etc., away from drive belts, fans, and
other moving or hot parts. Never remove any drive belt or fan
guard while the unit is operating.
• When working on this equipment, remain alert at all times. Never
work on the equipment when physically or mentally fatigued.
• Inspect the generator regularly, and contact the nearest Dealer for
parts needing repair or replacement.
• Before performing any maintenance on the generator, disconnect
its battery cables to prevent accidental start up. Disconnect the
cable from the battery post indicated by a NEGATIVE, NEG or
(–) first, then remove the POSITIVE, POS or (+) cable. When
reconnecting the cables, connect the POSITIVE cable first, the
NEGATIVE cable last.
• Never use the generator or any of its parts as a step. Stepping on
the unit can stress and break parts, and may result in dangerous
operating conditions from leaking exhaust gases, fuel leakage, oil
leakage, etc.
 ELECTRICAL HAZARDS 
• All generators covered by this manual produce dangerous
electrical voltages and can cause fatal electrical shock. Utility
power delivers extremely high and dangerous voltages to the
transfer switch as does the standby generator when it is in
operation. Avoid contact with bare wires, terminals, connections,
etc., while the unit is running. Ensure all appropriate covers,
guards and barriers are in place, secured and/or locked before
operating the generator. If work must be done around an operating
unit, stand on an insulated, dry surface to reduce shock hazard.
• Do not handle any kind of electrical device while standing in water,
while barefoot, or while hands or feet are wet. DANGEROUS
ELECTRICAL SHOCK MAY RESULT.
• The National Electrical Code (NEC) requires the frame and external
electrically conductive parts of the generator to be connected to an
approved earth ground. Local electrical codes also may require proper
grounding of the generator electrical system.
• After installing this home standby electrical system, the generator
may crank and start at any time without warning. When this
occurs, load circuits are transferred to the STANDBY (generator)
power source. To prevent possible injury if such a start and
transfer occur, always set the generator’s AUTO/OFF/MANUAL
switch to its OFF position before working on equipment and
remove the 15A fuse from the generator control panel.
• In case of accident caused by electric shock, immediately shut
down the source of electrical power. If this is not possible, attempt
to free the victim from the live conductor. AVOID DIRECT CONTACT
WITH THE VICTIM. Use a nonconducting implement, such as a dry
rope or board, to free the victim from the live conductor. If the victim
is unconscious, apply first aid and get immediate medical help.
2
• Never wear jewelry when working on this equipment. Jewelry can
conduct electricity resulting in electric shock, or may get caught in
moving components causing injury.
 FIRE HAZARDS 
• For fire safety, the generator must be installed and maintained
properly. Installation must always comply with applicable
codes, standards, laws and regulations. Adhere strictly to local,
state and national electrical and building codes. Comply with
regulations the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the generator is
installed in accordance with the manufacturer’s instructions and
recommendations. Following proper installation, do nothing that
might alter a safe installation and render the unit in noncompliance
with the aforementioned codes, standards, laws and regulations.
• Keep a fire extinguisher near the generator at all times.
Extinguishers rated “ABC” by the National Fire Protection
Association are appropriate for use on the standby electric system.
Keep the extinguisher properly charged and be familiar with its use.
Consult the local fire department with any questions pertaining to
fire extinguishers.
 EXPLOSION HAZARDS 
• Do not smoke around the generator. Wipe up any fuel or oil spills
immediately. Ensure that no combustible materials are left in the
generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding the generator
clean and free from debris.
• Gaseous fluids such as natural gas and liquid propane (LP)
gas are extremely EXPLOSIVE. Install the fuel supply system
according to applicable fuel-gas codes. Before placing the home
standby electric system into service, fuel system lines must be
properly purged and leak tested according to applicable code.
After installation, inspect the fuel system periodically for leaks. No
leakage is permitted.
 EXHAUST HAZARDS 
• The engine exhaust fumes contain carbon monoxide, which
can be DEADLY. This dangerous gas, if breathed in sufficient
concentrations, can cause unconsciousness or even death. Do
NOT alter or add to the exhaust system or do anything that might
render the system unsafe or in noncompliance with applicable
codes and standards.
• Install a battery operated carbon monoxide alarm indoors,
according to manufacturer’s instructions/recommendations.
• Adequate, unobstructed flow of cooling and ventilating air is
critical to correct generator operation. Do not alter the installation
or permit even partial blockage of ventilation provisions, as this
can seriously affect safe operation of the generator. The generator
MUST be installed and operated outdoors only.
‹ STANDARDS INDEX
In the absence of pertinent standards, codes, regulations and
laws, the published information listed below may be used as
installation guide for this equipment.
1. NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS
TURBINES, available from the National Fire Protection Association,
470 Atlantic Avenue, Boston, MA 02210.
2. NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH
CARE FACILITIES, available same as Item 1.
3. NFPA No. 54, NATIONAL FUEL GAS CODE, available same as Item
1.
4. NFPA No. 58, AMERICAN NATIONAL STANDARD FOR STORAGE
AND HANDLING OF LIQUEFIED PETROLEUM GAS, available same
as Item 1.
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELECTRIC CODE,
available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available from the American
Insurance Association, 85 John Street, New York, N.Y. 10038.
7. AGRICULTURAL WIRING HANDBOOK, available from the Food and
Energy Council, 909 University Avenue, Columbia, MO 65201.
8. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARM
STANDBY ELECTRICAL SYSTEMS, available from the American
Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI
49085.
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE,
available same as Item 1.
DANGER
qualified electricians or contractors should
 Only
attempt such installations, which must comply
strictly with applicable codes, standards and regulations.
UNPACKING/INSPECTION
After unpacking, carefully inspect the contents for damage.
• This standby generator set is ready for installation with a
factory supplied and pre-mounted base pad and has a weather
protective enclosure that is intended for outdoor installation
only.
• This UL listed standby generator set may be packaged with
an automatic transfer switch with built in load center. The
combination transfer switch and load center is pre-wired with
a two foot and 30 foot conduit. Circuit breakers for emergency
circuit connections are included (if equipped).
• This UL listed, 2-pole switch is rated at 100 or 200 AC amperes
at 250 volts maximum. The 100 Amp transfer switch is for
indoor use only. The 200 Amp transfer switch is for indoor/
outdoor use (if equipped).
this generator is used to power electrical load
 Ifcircuits
normally powered by a utility power
source, it is required by code to install a transfer
switch. The transfer switch must effectively isolate
the electrical system from the utility distribution
system when the generator is operating (NEC 700,
701 & 702). Failure to isolate an electrical system
by such means will result in damage to the generator and also may result in injury or death to
utility power workers due to backfeed of electrical
energy.
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 in evidence at the time of
delivery, but is discovered later.
To properly open the roof, press down on the center top lip and
release the latch. If pressure is not applied from the top, the roof
may appear stuck. Always verify that the side lock is unlocked
before attempting to lift the roof.
PROTECTION SYSTEMS
Unlike an automobile engine, the generator may have to run for
long periods of time with no operator present to monitor engine
conditions. For that reason, the engine is equipped with the
following systems that protect it against potentially damaging
conditions:
1. Low Oil Pressure Sensor
2. High Temperature Sensor
3. Overcrank
4. Overspeed
5. RPM Sensor
6. Low Battery
There are readouts on the control panel to notify personnel that
one of these failures has occurred. There is also a System Set
LED (single cylinder) or a Status message on the display (V-twins)
that displays when all of the conditions described in the “System
Set LED” section are true.
NEC REQUIREMENT FOR ARC FAULT CIRCUIT
INTERRUPTION BREAKER FOR BEDROOMS
In 2001, the National Electric Code (NEC) introduced a
requirement for new construction. This new requirement indicates
the need for Arc Fault Circuit Interrupters to be used to protect the
complete branch circuit that feeds a dwelling bedroom. The actual
NEC requirement is indicated below.
‹ SECTION 210.12 ARC FAULT CIRCUIT INTERRUPTER
PROTECTION
1. Definition: An arc fault circuit interrupter is a device
intended to provide protection from the effects of arc faults
by recognizing characteristics unique to arcing and by
functioning to de-energize the circuit when an arc fault is
detected.
2. Dwelling Unit Bedrooms: All branch circuits that supply
125 volt, single-phase, 15 and 20 ampere outlets installed
in dwelling unit bedrooms shall be protected by an arc fault
circuit interrupter listed to provide protection of the entire
branch circuit.
3
Section 210.12 requires that AFCI protection be provided on
branch circuits that supply outlets (receptacle, lighting, etc.)
in dwelling bedrooms. The requirement is limited to 15 and 20
ampere, 125 volt circuits. There is no prohibition against providing
AFCI protection on other circuits or in locations other than
bedrooms. Because circuits are often shared between a bedroom
and other areas such as closets and hallways, providing AFCI
protection on the complete circuit would comply with 210.12.
If during the installation of the home standby system the decision
is made to provide back up power to a bedroom branch circuit,
then the circuit breaker in the transfer switch should be replaced
with an Arc Fault Circuit Interrupter.
It is most important that breakers only be switched like for like.
For instance, if replacing a 15A breaker, it MUST be replaced with
a 15A AFCI breaker. Likewise, a 20A breaker MUST be replaced
with a 20A AFCI.
These AFCI breakers are available at the nearest hardware store.
Siemens Item #
Description
Q115AF
15A Single Pole AFCI
Q120AF
20A Single Pole AFCI
EMISSION INFORMATION
The Environmental Protection Agency requires that this generator
complies with exhaust emission standards. This generator is
certified to meet the applicable EPA emission levels. Additional
information regarding the requirements set by the EPA is as
follows:
The generator is certified for use as a stationary engine for
standby power generation. Any other use may be a violation
of federal and/or local laws. It is important that to follow the
maintenance specifications in the “Maintenance” section to
ensure that the engine complies with the applicable emission
standards for the duration of the engine’s life. This engine is
certified to operate on Liquid Propane fuel and pipeline Natural
Gas. The emission control system on the generator consists of
the following:
• Fuel Metering System
• Carburetor/mixer assembly
• Fuel regulator
• Air Induction System
• Intake pipe/manifold
• Air cleaner
• Ignition System
• Spark plug
• Ignition module
The Emissions Compliance Period referred to on the Emissions
Compliance Label indicates the number of operating hours for
which the engine has been shown to meet Federal emission
requirements. See the table below to determine the compliance
period for the generator. The displacement of the generator is
listed on the Emissions Compliance Label.
4
Displacement
Category
Compliance Period
A
300 Hours
B
125 Hours
C
50 Hours
A
500 Hours
B
250 Hours
C
125 Hours
A
1000 Hours
B
500 Hours
C
250 Hours
< 66 cc
 66 cc < 225 cc
 225 cc
BEFORE YOU BEGIN
Contact the local inspector or City Hall to be aware of all federal,
state and local codes that could impact the installation. Secure all
required permits before starting the job.
Carefully read and follow all of the procedures and safety
precautions detailed in the installation guide. If any portion of the
installation manual, technical manual or other factory-supplied
documents is not completely understood, contact a dealer for
assistance.
Fully comply with all relevant NEC, NFPA and OSHA standards
as well as all federal, state and local building and electric codes.
As with any generator, this unit must be installed in accordance
with current NFPA 37 and NFPA 70 standards as well as any other
federal, state, and local codes for minimum distances from other
structures.
SITE PREPARATION AND GENERATOR
PLACEMENT
1. 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 (see the “Location” section in the
Owner’s Manual).
2. Place the unit so air vents won’t become clogged with leaves,
grass, snow or debris.
Make sure exhaust fumes will not enter the building through
eaves, windows, ventilation fans or other air intakes.
Dig a rectangular area approximately five inches deep and
about six inches longer and wider than the footprint of the
generator. Cover with polyurethane film and fill with pea gravel
or crushed stone. Compact and level the stone. A concrete
pad can be poured if desired.
5. Set the generator onto the pad so that the gravel bed extends
several inches beyond the generator on all sides.
Make sure the generator is level within ½ inch.
6. Connect an approved ground strap to the grounding lug on the
base frame and to an approved earth ground or grounding rod
as specified by local regulations.
7. Check the engine oil and, if necessary, add enough of the
recommended oil to bring the level up to the FULL mark on
the dipstick. Be careful not to overfill the crankcase.
3. Inspect the generator for shipping damage and if necessary,
file a claim with the shipper.
Remove the bands holding the generator to the wooden pallet.
CONVERTING TO LP VAPOR
4. Make sure the lifting equipment to be used has sufficient
capacity to safely handle the weight of the generator.
Use nylon lifting straps and connect them to the lifting eyes
on each corner of the base frame to avoid damaging the
enclosure.
1. The generator was configured for natural gas operation at the
factory. Switching over to LP Vapor is a simple procedure.
On models with a single cylinder engine, begin by
disconnecting and removing the battery if installed.
5
6. On all other models, simply remove the air cleaner cover and
slide the fuel selector pin outward from the natural gas to the
LP position.
INSTALLING & CONNECTING GAS LINES
2. Take the plastic T-handle fuel selector in the poly bag supplied
with the generator and locate the selector tab on the air box
cover. Insert the pin end into the hole in the selector tab
and pull outward to overcome spring pressure. Then twist
clockwise 90 degrees and allow the selector to return in once
aligned with the LP position.
1. Both natural gas and LP Vapor are highly volatile substances,
so strict adherence to all safety procedures, codes, standards
and regulations is essential.
Gas line connections should be made by a certified plumber
familiar with local codes. Always use AGA-approved gas pipe
and a quality pipe sealant or joint compound.
Verify the capacity of the natural gas meter or the LP tank in
regards to providing sufficient fuel for both the generator and
other operating appliances.
3. On 10 kW units, open the roof, loosen the forward clamp
on the air inlet hose, and slide the hose away from the hose
fitting.
2. Most applications will require an external manual shutoff valve
on the fuel line.
4. Slide the fuel selector pin on the carburetor out towards the
back of the enclosure.
5. Replace the inlet hose and tighten the clamp securely.
3. Where the gas line is to enter the generator, install a T-fitting
to allow for gas pressure monitoring. On one opening of the
fitting install a ¼” NPT nipple and threaded plug. In some
cases a sediment trap may also be installed.
6
4. When connecting the gas line to the generator, use the
provided section of UL Listed or AGA-approved flexible fuel
line in accordance with local regulations. The purpose of the
flexible fuel line is to ensure that vibration from the generator
does not cause a gas leak at one of the connection points, so
it’s important that the line be installed with as few bends as
possible.
5. Never bend the flexible fuel line to avoid using an elbow.
Bending the flexible line decreases its ability to absorb
vibrations and defeats its purpose as well as constricts the
actual fuel flow.
6. After checking for leaks, check the gas pressure at the
T-fitting installed earlier to make sure there’s enough pressure
for proper generator operation.
The local gas supplier is responsible for ensuring adequate
pressure, so if the pressure is too low, or if it’s greater than
14 inches of water column, contact the gas supplier.
7. When finished checking the gas pressure, close the manual
shutoff valve.
BATTERY CHARGER INSTALLATION
1. If the generator came with a separately packaged battery
charger, it may be necessary to install the charger, either in
the generator or in the transfer switch. Refer to documentation
included with the battery charger for installation and wiring of
the battery charger.
For applications with RTSN, RTSE and GenReady transfer
switches the charger needs to be mounted in the generator.
Refer to documentation included with the battery charger for
installation and wiring of the battery charger.
2. For applications with RTS Load Center switches and RTSS
Load Shed transfer switches the charger has already been
installed in the transfer switch. Discard the separately packed
battery charger that came with the generator.
7
EXTERNAL ELECTRICAL CONNECTIONS
1. Drill a 1 ¾ inch hole and feed the conduit through the hole.
5. For 10-20 kW models, locate the metal hasp that is packaged
in the owner’s manual bag. Insert the hasp in the slot located
on the left side of the external circuit breaker box. Be sure that
the clip of the hasp is facing toward the front of the generator.
If desired, lock the external box.
GENERATOR CONNECTIONS – RTS LOAD
CENTER TRANSFER SWITCH
2. Remove the knockout in the back of the connection box, feed
the wires through the back of the box and secure the conduit
with the lock nut.
Seal the hole with silicone caulk. Don’t forget to caulk the hole
inside the house as well.
3. Mount the connection box so that it completely covers the hole in
the wall. Caulk around the sides and top of the box to ensure a good
seal.
Connect all wires to the lugs in the connection box (black to black,
red to red and white to white). Attach the green ground wire to
the ground screw and connect the two small plugs to their mating
receptacle ends.
4. Replace the protective cover plate and retaining screw, and
lock the connection box.
8
1. If the generator comes with an external connection box and
5’ seal-tite whip pre-wired and connected to the generator, no
additional connections are necessary at the generator. Skip
the following section and proceed with Appendix A, RTS PreWired Load Center Transfer Switch Installation & Operational
Testing.
2. If the RTS Load Center transfer switch was purchased
separately from the generator, the 5’ seal-tite whip will need
to be connected to the generator. To complete the wiring, run
the ¾” conduit for the power leads and control wires from the
external connection box to the generator.
3. Remove the two screws securing the connection area cover,
and remove the cover.
4. Feed the wires through the back of the generator and secure
the conduit with the lock nut.
8. Remove the plastic plugs inside the main breaker access area
to allow connection of the power leads to the circuit breaker.
9. Now connect the red and black power leads to the circuit
breaker. Since this is a single-phase application, it doesn’t
matter which wire is connected to which lug.
5. Run the power leads through the strain relief provided.
10. Connect the green equipment ground wire to the ground stud
and torque to 80 inch lbs.
6. On 8 kW units, the main breaker is located inside the
generator at the rear of the connection area.
11. Connect the white neutral wire to the neutral post and torque
to 100 inch lbs.
7. For all other models the circuit breaker is attached to the
exterior access panel.
12. Connect the control wires to the correct terminals. The
terminals are clearly marked N1, N2, 23 and 15B. If
connecting a pre-wired switch a 0 (zero) wire will also be
required.
9
13. If the battery charger was factory mounted in the transfer
switch, 0 (zero) will also need to be connected between the
generator and transfer switch.
14. An improperly connected control wire can damage the
generator control board.
3. Protect against impact and mount the switch vertically to
a rigid support structure. Make sure the switch is level and
plumb.
The transfer switch is an open transition switch. Open
transition switches prevent electrical feedback between the
generator and the utility by only allowing load circuits to be
connected to one power supply at a time.
APPENDIX A – RTS PRE-WIRED LOAD
CENTER TRANSFER SWITCH INSTALLATION &
OPERATIONAL TESTING
4. Each wire in the pre-wired transfer switch is color-coded to
easily match circuits in the main panel to their new breakers
in the transfer switch.
1. Before beginning any installation, make sure power is shut
OFF to the main distribution panel and carefully read the
Owner’s Manual that came with the transfer switch.
The distributed load center switch must be mounted close
enough to the main distribution panel to accommodate the
two-foot, pre-wired conduit. Make sure no water or corrosive
substances can drip onto the transfer switch enclosure.
2. Always inspect the switch for shipping damage. Never mount
a transfer switch that shows any evidence of damage.
10
5. When three-conductor wiring is used, two 120 volt circuits
will often share the same neutral wire. To avoid overloading
the neutral, either move BOTH of the circuits that share the
neutral or don’t move either of them.
6. When moving two circuits with a shared neutral, they should
be connected to adjacent positions (one above the other) in
the transfer switch. That will assure that the two hot wires
are on separate phases and will maintain their relationship to
neutral.
11. Install a 2-pole breaker in the distribution panel to protect
the transfer switch. The required amp rating of the breaker
depends on which transfer switch is used. If installing an
8-circuit, pre-wired load center switch, the breaker cannot
exceed 40 Amps. For all other pre-wired load center switches
the breaker cannot exceed 70 Amps. This breaker must be
compatible with the existing electrical distribution panel.
Install the breaker in two adjacent empty slots (one above the
other) in the main panel.
7. Choose a circuit to be backed up and remove the power lead
from the breaker.
8. Using UL Listed wire nuts, reconnect the power lead to a
matching breaker in the transfer switch.
9. Make sure each circuit moved is protected by the same
size breaker in the transfer switch. 15 Amp circuits must be
connected to 15 Amp breakers and 20 Amp circuits to 20
Amp breakers.
12. When all priority circuits have been moved to the transfer
switch, close the main breaker to restore utility power and
make sure utility voltage at the transfer switch is correct.
Refer to NFPA 70-E for the safety equipment required when
working inside a live transfer switch.
13. Before purchasing a battery for the generator, refer to
the generator Owner’s Manual for a list of recommended
batteries. Follow all of the procedures and safety precautions
in the Owner’s Manual when installing the battery.
‹ BATTERY INSTALLATION
10. Connect the provided large neutral to the neutral bar in the
distribution panel.
1. Before purchasing a battery for the generator, refer to the
Owner’s Manual for the recommended battery.
• 8 kW: Group 26R, 12 Volt, 350cca minimum
• 10-20 kW: Group 26R, 12 Volt, 525cca minimum
11
3. Battery Power-up: Interconnect system self test feature
checks for the presence of utility voltage on the DC circuits at
the control panel terminal blocks (see flow chart).
‹ OPERATIONAL TESTING
2. Follow all of the procedures and safety precautions in the
generator Owner’s Manual when installing the battery.
Verify the switch is in the off position. When preparing for
operational testing, DO NOT connect the battery until transfer
switch connections are complete.
POWER UP
UTILITY
CONNECTED?
No
WIRING
ERROR?
Yes
WIRING
ERROR?
Yes
CORRECT
WIRING ERROR
No
No
CONNECT UTILITY
Yes
ESCAPE
PRESSED?
CORRECT
WIRING ERROR
NO UTILITY
DETECTED
SELF TEST
OK
DELAY 3S
WIRING MAY BE
UNSAFE
DELAY 3S
RUN NORMAL
CODE
12
No
ESCAPE
PRESSED?
UNABLE TO PERFORM
WIRING TEST
DELAY 5S
1. Switch the generator’s main circuit breaker OFF and put the
mode switch in the OFF position.
models, if line-to-neutral voltage is not 120 volts, check the
neutral connection between the generator and transfer switch.
For 8 kW models check to be sure that the frequency from
the generator is correct. If the frequency is not approximately
60Hz, refer to the generator Owner’s Manual for the proper
adjustment procedure.
2. Make sure utility power is OFF and place all of the priority
circuit breakers in the transfer switch in the OFF position.
6. When finished checking the voltage, switch the generator’s
main circuit breaker OFF and put the mode switch in the OFF
position to shut down the generator.
3. Locate the transfer handle, insert the metal end into the slot
in the main contactor assembly and pull the handle DOWN to
move the main contacts to the standby power, or generator
position.
NEVER OPERATE THE TRANSFER SWITCH
MANUALLY WHEN LOADS ARE CONNECTED.
4. Put the generator’s mode switch in MANUAL to start the engine.
Allow the engine to warm up, then switch the generator’s
main breaker to the ON position. The generator is now
supplying electricity to the transfer switch but is not carrying
any load.
5. For all models except the 8 and 10kW check to be sure that
voltage and frequency from the generator is correct. If lineto-line voltage is not approximately 240 volts, refer to the
Owner’s Manual for the proper adjustment procedures. On all
7. Make sure the 2-pole circuit breaker installed in the main
distribution panel is in the OFF position.
8. Use the transfer handle to move the main contacts in the
transfer switch to the UP (utility position). Switch the 2-pole
breaker ON in the distribution panel.
9. Now switch the generator’s main breaker ON, and put the
mode switch in AUTO.
13
10. Shut OFF utility power and make sure the generator starts
automatically.
14. Switch the main breaker ON to restore utility power.
The generator will continue to run to allow the engine to cool
down before shutting itself off.
Shut off utility power again. The generator should start and the
entire priority load should transfer to the generator.
Close the main breaker to restore utility power and allow the
engine to cool down and shut itself off.
11. If everything worked properly, switch the main breaker to ON
and make sure that power is automatically transferred back to
the utility.
15. Operational tests are now complete. Refer to – Setting the
Automatic Exercise Function to complete the installation.
12. After the engine has completed its cool down cycle and shut
down, shut OFF utility power again.
When the generator is supplying power to the transfer switch,
move the breakers in the switch to the ON position, one at a
time, until the generator has accepted the entire priority load.
13. With the generator carrying the entire priority load, recheck
gas pressure to verify that it is at the same level it was before
the generator was started.
NOTE: Even if the generator is running smoothly at this point, a
drop in gas pressure indicates that the supply is barely adequate
to supply the generator’s needs. Changes in the generator load,
or additional gas demand by other appliances may affect the
generator’s performance. Verify gas pressure and pipe sizing.
Unhook the manometer and reinstall the port plug.
14
APPENDIX B – RTSN AND RTSE TRANSFER
SWITCH INSTALLATION & OPERATIONAL
TESTING
1. Before beginning any installation, make sure power is shut
OFF to the main distribution panel and carefully read the
Owner’s Manual that came with the transfer switch.
To simplify the installation process, the transfer switch
should be mounted as close to the main distribution panel as
possible. Make sure no water or corrosive substances can
drip onto the transfer switch enclosure.
2. Always inspect the switch for shipping damage. Never mount
a transfer switch that shows any evidence of damage.
6. The transfer switch being used is an open transition switch.
Open transition switches prevent electrical feedback between
the generator and the utility by only allowing load circuits to
be connected to one power supply at a time.
‹ SELECTED CIRCUIT COVERAGE
3. Protect against impact and mount the switch vertically to a rigid
support structure. Make sure the switch is level and plumb.
Check local codes before wiring the transfer switch. Some
jurisdictions require that wiring inside the switch be done by a
licensed electrician.
4. All wiring must be the correct size and type, and must
conform to all codes, standards and regulations. Refer to the
transfer switch Owner’s Manual and the National Electrical
Code for additional information.
5. As with any product, design changes can occur over time, so
always refer to the schematics in the transfer switch Owner’s
Manual for the required connections and safety precautions.
1. The generator powers only designated circuits that are grouped
together and wired into a separate priority distribution panel.
The transfer switch is installed between the main distribution
panel and the priority panel.
The amperage rating of the transfer switch must be equal to
or greater than the highest amperage rating of the utility and
generator breakers feeding the switch.
‹ WHOLE-HOUSE CIRCUIT COVERAGE
1. The generator will be backing up all electrical loads within the
panel, so the amperage rating of the transfer switch must be
equal to or greater than the amperage rating of the normal
utility service.
15
Unless a service entrance rated transfer switch is used, a
main service disconnect must be located before the transfer
switch. The transfer switch must be installed between the
utility service entrance and the building distribution panel.
2. A service entrance rated transfer switch is installed between
the service entrance and the main distribution panel. The
service entrance rated switch becomes the main service
so no service disconnect is needed. The existing main
distribution panel becomes a sub-panel.
‹ ELECTRICAL CONNECTIONS
1. Connect the power leads from both the generator and the
utility to the appropriate lugs in the transfer switch. The lugs
are clearly marked in the switch.
N = Normal Utility Supply
E = Generator Connection Panel
T = Load Distribution Panel
2. Neutral wires from both the utility and the generator are
connected to the same neutral lug in the switch.
3. The grounding that is normally in the main panel must be
accomplished in the service entrance rated switch and must
be disconnected in the existing distribution panel. Refer to the
National Electrical Code (NEC) for complete information on
grounding and bonding.
‹ BATTERY CHARGER INSTALLATION
1. The battery charger is to be installed in the generator when
using an RTSN or RTSE transfer switch. Refer to the Battery
Charger Installation Guide for details.
16
3. Connect the control wires from the generator to the terminal
block in the transfer switch. The terminals are marked N1, N2, 23
and (194 or 15B). If the fourth terminal in the transfer switch is
labeled 194, wire 15B from the generator will connect to terminal
194 in the transfer switch.
4. Complete the transfer switch wiring by connecting the
equipment ground wires from both the utility and the
generator to the ground lug.
3. Energize the utility and check line-to-line and line-to-neutral
voltage at terminals N1 and N2 on the transfer contactor. If
line-to-line voltage is not approximately 240 volts, de-energize
utility power and check the terminations between the utility
and N1 and N2.
If line-to-neutral voltage is not approximately 120 volts, deenergize utility power and check the neutral terminations.
Repeat the same voltage checks on terminals T1 and T2 to
make sure current is flowing properly through the contactor.
5. Being careful to support the lugs, torque the lugs in the
transfer switch to the specifications shown on the transfer
switch. Decal located on the inside of the switch door.
‹ OPERATIONAL TESTING
1. If installing the RTSE switch, the service was changed so make
sure the terminations are good before re-energizing the utility.
2
Switch the main utility breaker OFF. Refer to NFPA 70-E for the
safety equipment required when working inside a live transfer
switch.
4. Switch the generator’s main circuit breaker OFF and put the
mode switch in the OFF position.
5. Make sure utility power is OFF and place all of the individual
circuit breakers in the main distribution panel in the OFF position.
6. Locate the transfer handle, insert the metal end into the slot in
the main contactor assembly. Pull the handle DOWN to move
the main contacts to the standby power (generator) position.
NEVER OPERATE THE TRANSFER SWITCH MANUALLY WHEN
LOADS ARE CONNECTED.
17
7. Put the generator’s mode switch in MANUAL to start the engine.
Allow the engine to warm up, then switch the generator’s main
breaker to the ON position. The generator is now supplying
electricity to the transfer switch but is not carrying any load.
11. Close the main breaker to turn utility power ON.
8. For all models except the 8 and 10 kW check to be sure that
voltage and frequency from the generator is correct. If line-toline voltage is not approximately 240 volts, refer to the generator
Owner’s Manual for the proper adjustment procedures. On
all models, if line-to-neutral voltage is not approximately 120
volts, check the neutral connection between the generator and
transfer switch.
For 8 kW models check to be sure that the frequency from
the generator is correct. If the frequency is not approximately
60Hz, refer to the generator Owner’s Manual for the proper
adjustment procedure.
12. Switch the generator’s main breaker to the ON position and
put the mode switch in AUTO.
13. Shut OFF utility power and make sure the generator starts
automatically after the line interrupt delay.
9. Switch the generator’s main circuit breaker OFF and put the
mode switch in the OFF position to shut down the generator.
14. Switch the utility breaker to ON and make sure that power is
automatically transferred back to the utility.
10. With utility power still OFF, use the transfer handle to move the
main contacts to the UP (utility) position.
18
15. Shut OFF utility power again to automatically start the
generator. When power has transferred to the generator, close
each of the breakers in the distribution panel one at a time
until the generator has accepted the entire load.
16. With the generator carrying the entire load, recheck gas
pressure to verify that it’s at the same level it was before the
generator was started.
NOTE: Even if the generator is running smoothly at this point, a
drop in gas pressure indicates that the supply is barely adequate
to supply the generator’s needs. Changes in the generator load,
or additional gas demand by other appliances may affect the
generator’s performance. Verify gas pressure and pipe sizing.
Unhook the manometer and reinstall the port plug.
17. Switch the utility breaker ON to restore utility power to the
home.
20. Close the main breaker to restore utility power and allow the
engine to cool down and shut itself off.
Operational tests are now complete. Refer to – Setting the
Automatic Exercise Function to complete the installation.
APPENDIX C – POWERMASTER™ LOAD
CONTROLLER INSTALLATION AND
OPERATIONAL TESTING
1. The PowerMaster load controller should be mounted as
close to the main distribution panel as possible to avoid
splicing. Refer to the instructions and wiring diagram in
the PowerMaster Technical Manual before beginning the
installation.
18. The generator will continue to run to allow the engine to cool
down, then shut itself off.
19. Shut OFF utility power again. The generator should start and
the entire priority load should transfer to the generator.
2. After making sure that all power supplies are shut off, remove
the power leads from the 240 volt, 2-pole breaker that
controls the selected appliance.
19
7. The auxiliary switches that came with the controller must be
installed in the transfer switch. These switches ensure that the
controller will only disconnect the selected appliances when
utility power is off and the generator is running. Refer to the
Technical Manual for specific instructions for installing the
auxiliary switches.
3. Using the ring lugs provided and the wire specified in the
PowerMaster Technical Manual, connect one end of new
power leads to one of the contactors in the load controller.
8. Connect one end of two control wires to the COMMON and
NORMALLY OPEN pins on the generator side of the transfer
switch.
4. Connect the other end of the new power leads to the
appliance breaker in the distribution panel.
5. Connect the power leads that were removed from the
appliance breaker to the load terminals in the controller.
9. Connect the other ends of the control wires to the COMMON
and NORMALLY OPEN positions of the selected control circuit
in the controller.
If moving a second load to the controller, follow the same
procedure.
‹ OPERATIONAL TESTING
6. Now run 24 volt control wires from the air conditioning circuit
to the terminal strip in the controller.
1. Switch the generator’s main circuit breaker OFF and put the
mode switch in the OFF position.
20
2. If using a service entrance rated transfer switch, put the generator
disconnect switch in the ON position if applicable.
6. Check voltage and frequency from the generator. If line-to-line
voltage is not 240 volts, refer to the Installation Guide for the
proper adjustment procedures. If line-to-neutral voltage is not
120 volts, check the neutral connection between the generator
and transfer switch.
Switch the generator’s main circuit breaker OFF and put the
mode switch in the OFF position to shut down the generator.
3. Make sure utility power is OFF and place all of the individual
circuit breakers in the main distribution panel in the OFF
position.
7. With utility power still OFF, use the transfer handle to move the
main contacts to the UP (utility) position.
4. Locate the transfer handle and insert the metal end into the slot in the
main contactor assembly. Pull the handle DOWN to move the main
contacts to the standby power (generator) position.
NEVER OPERATE THE TRANSFER SWITCH MANUALLY WHEN
LOADS ARE CONNECTED.
8. Close the main breaker to turn utility power ON.
5. Put the generator’s mode switch in MANUAL to start the engine.
Allow the engine to warm up, then switch the generator’s
main breaker to the ON position. The generator is now
supplying electricity to the transfer switch but is not carrying
any load.
9. Switch the generator’s main breaker to the ON position an put
the mode switch in AUTO.
21
10. Shut OFF utility power and make sure the generator starts
automatically.
14. Switch the utility breaker ON to restore utility power to the
home.
11. Switch the utility breaker to ON and make sure that power is
automatically transferred back to the utility.
15. The generator will continue to run to allow the engine to cool
down before shutting itself OFF.
12. Shut OFF utility power again to automatically start the
generator. When power has transferred to the generator, close
each of the breakers in the distribution panel one at a time
until the generator has accepted the entire load.
16. Unhook the gas meter and reinstall the port plug on the
regulator.
13. With the generator carrying the entire load, re-check gas
pressure to verify that it’s at the same level it was before the
generator was started.
17. Shut OFF utility power again. The generator should start and
the entire emergency load should transfer to the generator.
Close the main breaker to restore utility power and allow the
engine to cool down and shut itself OFF. If everything worked
properly, the generator is now ready for automatic operation.
22
‹ CHECKING THE PRIORITY LOAD CONTROLLER
5. When the generator is carrying the entire load, check the
voltage on the load side of the contactors to be sure the
appliances connected to the controller are working properly.
1. With utility power ON, make sure the central air conditioner
will not start.
6. With the generator still carrying the load, start the central air
conditioner.
2. Using a multi-meter, make sure both the line and load sides of
the contactors in the controller register 240 volts, and that the
contactors are in the CLOSED position.
7. Check load side voltage again to be sure the selected
appliances will not operate. Shut OFF the central air
conditioner and re-check both line and load voltage to the
selected appliances to be sure they are working again.
3. Start the central air conditioner and make sure the appliances
selected are still working properly.
8. Turn the utility breaker back ON to restore utility power to the
home.
4. Make sure the central air conditioner will not start and
simulate a power outage by shutting OFF utility power.
23
9. The generator’s engine will continue to run through a cool
down period before shutting itself OFF.
If everything worked properly, the generator is now ready for
automatic operation.
APPENDIX D – POWER MANAGER LOAD SHED
TRANSFER SWITCH INSTALLATION AND
OPERATIONAL TESTING
5. All wiring must be the correct size and type, and must
conform to all codes, standards and regulations. Refer to the
transfer switch Owner’s Manual and the National Electrical
Code (NEC) for additional information.
As with any product, design changes can occur over time, so
always refer to the schematics in the transfer switch Owner’s
Manual for the required connections and safety precautions.
1. Before beginning any installation, make sure power is shut
OFF to the main distribution panel and carefully read the
Owner’s Manual that came with the transfer switch.
To simplify the installation process, the transfer switch
should be mounted as close to the main distribution panel as
possible. Make sure no water or corrosive substances can
drip onto the transfer switch enclosure.
2. Always inspect the switch for shipping damage. Never mount
a transfer switch that shows any evidence of damage.
6. The transfer switch being used is an open transition switch.
Open transition switches prevent electrical feedback between
the generator and the utility by only allowing load circuits to
be connected to one power supply at a time.
3. Protect against impact and mount the switch vertically to
a rigid support structure. Make sure the switch is level and
plumb.
7. Locate the dip switches on the transfer switch control board
and set them for the desired load shed delay as instructed in
the transfer switch owner’s manual.
4. Check local codes before wiring the transfer switch. Some
jurisdictions require that wiring inside the switch be done by a
licensed electrician.
24
8. The grounding that is normally in the main panel must be
accomplished in the Power Manager Load Shed transfer
switch and must be disconnected in the existing distribution
panel. Refer to the National Electrical Code (NEC) for
complete information on grounding and bonding.
‹ BATTERY CHARGER INSTALLATION
4. Be careful to support the lugs and torque the lugs in the
transfer switch to the specifications shown in the transfer
switch Owner’s Manual.
1. The battery charger is factory installed in the transfer switch.
‹ ELECTRICAL CONNECTIONS
5. Neutral wires from the utility, generator and shedding panel
are connected to the same neutral lug in the switch.
1. Connect the utility power leads from the meter to the Utility
circuit breaker in the transfer switch.
6. In this step, move priority load circuits, which will always
be backed up by the generator, from the existing electrical
distribution panel to the 16 circuit load center in the Power
Manager Load Shed switch.
2. Connect the generator power leads to the E1 and E2 terminals
on the transfer switch contactor.
3. Connect the customer non-priority load leads to the E1 and E2
terminals on the load shed contactor.
7. Select a priority circuit to be backed up and remove the power
lead from the breaker.
25
8. Reconnect the power lead to a matching breaker on the load
center.
9. Make sure each circuit moved is protected by the same
size breaker in the transfer switch. 15 Amp circuits must be
connected to 15 Amp breakers and 20 Amp circuits to 20
Amp breakers.
12. Remember that for every circuit moved from the main panel
to the load center, the neutral will need to be relocated to the
load center as well.
13. Connect the control wires from the generator to the terminal
block in the transfer switch. The terminals are marked N1, N2,
23, 15B, and 0.
10. When three-conductor wiring is used, two 120 volt circuits
will often share the same neutral wire. To avoid overloading the
neutral, either move BOTH of the circuits that share the neutral
or don’t move either of them.
14. Complete the transfer switch wiring by connecting the
equipment ground wire from the generator to the ground lug.
11. When moving two circuits with a shared neutral, they should
be connected to adjacent positions (one above the other) on
the load center. That will assure that the two hot wires are on
separate phases and will maintain their relationship to neutral.
15. Close the Utility circuit breaker to restore utility power and
make sure utility voltage at the transfer switch is correct.
Refer to NFPA 70E for the safety equipment required when
working inside a live transfer switch.
26
‹ OPERATIONAL TESTING
1. Before energizing utility power to the service, make sure the
main breaker is in the open (OFF) position.
2. Next, make sure all of the individual circuit breakers in both
the priority load center and in the non-priority sub-panel, are
in the OFF position. If the sub-panel has a primary breaker,
make sure it is in the OFF position as well.
5. With the main breaker OFF, energize the utility and check the
voltage at terminals N1 and N2 on the transfer contactor. If
utility voltage is not approximately 240 volts, de-energize
utility power and check all of the terminations between the
utility and N1 and N2.
6. Check line-to-neutral voltage on N1 and N2. If voltage is not
approximately 120 volts, de-energize utility power and check
all of the neutral terminations between the utility and N1 and
N2.
3. Locate the yellow transfer handle, insert the metal end into the
slot for the transfer switch contactor assembly and move it
UP into the UTILITY position.
7. With all branch circuit breakers still OFF, close the main
breaker by switching it to the ON position.
4. Next, insert the transfer handle into slot in the non-essential
load shed switch assembly and move the contactor DOWN
into the closed position.
NEVER OPERATE THE TRANSFER SWITCH MANUALLY WHEN
LOADS ARE CONNECTED.
8. Check line-to-line voltage on terminals T1 and T2. If line-toline voltage is not approximately 240 volts at any point in the
system, switch the main breaker OFF and check terminations.
27
9. Next, make sure line-to-neutral voltage at T1 and T2 is
approximately 120 volts. If line-to-neutral voltage is not
approximately 120 volts at any point in the system, check
neutral terminations.
13. Now check the terminations in the sub-panel. If there is a
primary breaker in the sub-panel, make sure it is in the OFF
position. Then check line-to-line and line-to-neutral voltage at
the primary breaker.
‹ VERIFYING LOAD SHEDDING OPERATION
10. Make sure there is no voltage on terminals E1 and E2 at the
transfer switch contactor. If voltage is present, switch the
main breaker OFF and check the terminations.
11. Next, check the voltage to the load shedding switch.
12. Check both line-to-line and line-to-neutral voltage on terminals
E1 and E2. Terminations to T1 and T2 were made at the
factory, but still make sure that voltage is correct at these
terminals.
28
1. Switch the main breaker OFF. If there is a primary breaker in
the sub-panel, make sure it is in the closed (ON) position.
2. Make sure the transfer switch contactor is still in the UP
(UTILITY) position, and use the transfer handle to move the
non-essential load shed contactor UP to the open (SHED)
position. To move the non-essential load shed contactor UP to
the open (SHED) position.
3. With all branch circuit breakers still OFF, switch the main
breaker ON. The load shed contactor should automatically
move DOWN to the closed position, verifying that the load
shedding switch is working properly.
7. For all models except the 8 and 10kW check to be sure that
output voltage from the generator is correct. If line-to-line
voltage is not approximately 240 volts, refer to the generator
Owner’s Manual for the proper adjustment procedure. On all
models, if line-to-neutral voltage is not 120 volts, check the
neutral connection between the generator and transfer switch.
For 8 kW models check to be sure that the frequency from
the generator is correct. If the frequency is not approximately
60Hz, refer to the generator Owner’s Manual for the proper
adjustment procedure.
8. On all models, make sure line-to-line voltage on the control
wires ( N1 and N2) is correct.
4. If not, switch OFF the main breaker, make sure all breakers
and both contactors are in their correct positions and repeat
the test.
9. Using the mode switch, place the generator in AUTO. If utility
power is still present, the generator will shut down.
5. Make sure that both the main breaker and the primary subpanel breaker are closed (ON), all branch circuit breakers
are open (OFF) and that the contactors for both the transfer
switch and non-essential load shed switch are in the UTILITY
position.
10. Switch the generator’s main breaker ON. The generator is now
ready for automatic operation.
6. With the generator’s main breaker OFF, place the mode switch
in MANUAL to start the engine.
11. Shut OFF utility power at the transfer switch. The generator
should start, and after a brief delay, the transfer contactor
should move to the generator position.
29
NOTE: Even if the generator is running smoothly at this point, a
drop in gas pressure indicates that the supply is barely adequate
to supply the generator’s needs. Changes in the generator load,
or additional gas demand by other appliances may affect the
generator’s performance. Verify gas pressure and pipe sizing.
Unhook the manometer and reinstall the port plug.
12. Switch the main breaker ON and make sure that power
transfers back to the utility. The generator should shut down
and go through a short cool-down cycle.
16. Switch the utility breaker ON to restore utility power to the
home.
13. Shut OFF utility power again to automatically start the
generator. When power has transferred to the generator, close
each of the breakers in the priority load center, one at a time,
until the generator has accepted the entire priority load.
14. Now close each of the breakers in the non-priority sub-panel
one at a time until the generator has accepted the entire
non-priority load. Be aware that should the generator become
overloaded in the process, the Load Shed contactor will
automatically move UP to the disconnect position, removing
power from the non-priority loads. If this happens, it simply
confirms that the load shedding switch is working properly.
Close the remainder of the non-priority breakers.
17. The generator will continue to run to allow the engine to cool
down before shutting itself OFF.
18. Shut OFF utility power again. The generator should start
and the entire load should transfer to the generator. If the
load is too large, the non-essential load shed switch will
automatically shed the non-priority loads.
15. With the generator carrying either the entire load (or the
priority loads if the non-priority loads were shed) re-check
gas pressure to the generator to verify that it’s at the same
level it was before the generator was started.
19. Close the main breaker to restore utility power and allow the
engine to cool down and shut itself OFF.
Operational tests are now complete. Refer to Appendix F
– Setting the Automatic Exercise Function to complete the
installation.
30
APPENDIX E – GENREADY LOAD CENTER
INSTALLATION AND OPERATIONAL TESTING
1. Before beginning any installation, make sure power is shut
OFF and carefully read the Owner’s Manual that came with the
load center.
When choosing a location for the load center, make sure no
water or corrosive substances can drip onto the enclosure.
2. Always inspect the load center for shipping damage. Never
mount a load center that shows any evidence of damage.
5. All wiring must be the correct size and type, and must
conform to all codes, standards and regulations. Refer to the
load center Owner’s Manual and the National Electrical Code
(NEC) for additional information.
As with any product, design changes can occur over time,
so always refer to the schematics in the load center Owner’s
Manual for the required connections and safety precautions.
6. The load center being used contains, or will contain, an
open transition operator. Open transition prevents electrical
feedback between the generator and the utility by only
allowing load circuits to be connected to one power supply at
a time.
3. Check local codes before wiring the load center. Some
jurisdictions require that wiring inside the load center be done
by a licensed electrician.
7. If the load center will serve as the service entrance for the
house, install the ground to neutral bond. Refer to the National
Electrical Code (NEC) for complete information on grounding
and bonding.
‹ BATTERY CHARGER INSTALLATION
4. Protect against impact and mount the load center vertically to
a rigid support structure. Make sure the load center is level
and plumb.
1. The generator battery charger is to be installed in the
generator when using a GenReady load center. Refer to the
Battery Charger Installation Guide for details.
31
‹ ELECTRICAL CONNECTIONS
1. Connect the utility power leads from the meter to the main
Utility circuit breaker in the load center.
During installation, be careful to torque the lugs on all circuit
breakers to the specifications listed in the load center Owner’s
Manual.
2. If the load center is being installed with a generator, locate
and install the load center operator. Refer to the installation
instructions packed with the operator for installation details.
3. Connect the generator power leads to the generator feed
breaker. This is the 2 pole breaker directly below the operator
on the right side of the load center.
4. Connect the neutral wire from the utility and generator to the
neutral bar on the right side of the load center panel and the
generator equipment ground wire to the ground bar on the left
side of the load center panel.
32
5. Connect the customer loads to the load center. The breakers
above the operator are used for loads which will not be
backed up during a power outage. Connect these loads to the
appropriate sized breakers in the load center. When selecting
circuits, note that the breakers immediately above and below
the operator are dedicated for use by the generator and load
center, and may not be used for customer loads.
6. Next, connect the loads which are to be backed up. The
breakers below the operator will be backed up by the
generator during a power outage. Connect these loads to the
appropriate sized breakers in the load center.
7. If the generator is not being installed at this time, loads can
still be connected to the lower breakers. Simply make sure
the utility feed breaker, the 2 pole breaker directly below the
operator on the left side of the load center, is switched ON.
8. Connect the control wires from the generator to the load
center operator. Connect the 23 wire to the XFER terminal,
15B to the BAT+ terminal, and 0 to the BAT- terminal.
9. Connect the voltage sensing wires to the sense breaker. This
is the 2 pole breaker directly above the operator on the right
side of the load center. Connect N1 to one pole of the breaker,
and N2 to the other.
10. Switch ON the main utility breaker if not already on and switch
on the utility supply breaker for the priority circuits. Make sure
utility voltage at the load center is correct. Refer to NFPA 70E
for the safety equipment required when working inside a live
load center.
2. Switch the generator’s main circuit breaker OFF and put the
mode switch in the OFF position.
3. Switch the main utility breaker OFF and place all of the
individual protected branch circuit breakers (located below the
transfer operator) in the OFF position.
4. Manually switch the generator circuit breaker (just below the
transfer operator) to the ON position. This will also move the
utility feed circuit breaker to the OFF position.
NEVER MOVE THE LOAD CENTER FEED BREAKERS
MANUALLY WHEN LOADS ARE CONNECTED.
‹ OPERATIONAL TESTING
5. With the generator’s main breaker OFF, put the mode switch in
MANUAL to start the engine.
1. The following operational tests are meant to be performed
with a fully installed system. If the GenReady panel
was installed without a generator, these tests cannot be
performed.
6. Allow the engine to warm up, then switch the generator’s
main breaker to the ON position. The generator is now
supplying electricity to the lower half of the load center but is
not carrying any load.
33
7. For all models except the 8 and 10 kW check to be sure that
voltage from the generator is correct. If line-to-line voltage is not
approximately 240 volts, refer to the generator Owner’s Manual
for the proper adjustment procedure. On all models, if line-toneutral voltage is not 120 volts, check the neutral connection
between the generator and load center.
11. Switch the main utility breaker ON to restore utility power.
12. Switch the generator’s main breaker ON and put the mode
switch in AUTO.
8. For 8 kW models check to be sure that the frequency from
the generator is correct. If the frequency is not approximately
60Hz, refer to the generator Owner’s Manual for the proper
adjustment procedure.
13. Shut OFF utility power at the main utility breaker and make
sure the generator starts automatically.
9. Switch the generator’s main circuit breaker OFF and put the
mode switch in the OFF position to shut down the generator.
14. Switch the main utility breaker to ON and make sure that power
on the lower half on the load center is automatically transferred
back to the utility. This can be verified by noting the position of
the utility feed and generator feed breakers.
10. With utility power still OFF, switch the utility feed breaker
(below the transfer operator on the left side of the load center)
ON. This will also move the generator feed breaker to the OFF
position.
34
15. Shut OFF utility power again to automatically start the
generator. When power on the lower half of the load center
has transferred to the generator, turn ON each of the branch
circuit breakers in the lower half of the load center, one at a
time, until the generator has accepted the entire priority load.
16. With the generator carrying the entire priority load, re-check
gas pressure to verify that it’s at the same level it was before
the generator was started.
2. On all other models, the display will enter an Installation Assistant
mode when battery power is first connected. The assistant will
prompt to first enter the current date and time, followed by the
exercise day and time.
If the battery is ever disconnected and reconnected, or fuse
removed and replaced, the Installation Assistant will be displayed
again, but only the current date and time will need to be entered.
3. If the exercise time or day ever needs to be changed, press
the escape key to access the main menu.
NOTE: Even if the generator is running smoothly at this point, a
drop in gas pressure indicates that the supply is barely adequate
to supply the generator’s needs. Changes in the generator load,
or additional gas demand by other appliances may affect the
generator’s performance. Verify gas pressure and pipe sizing.
Unhook the manometer and reinstall the port plug.
APPENDIX F - SETTING THE AUTOMATIC
EXERCISE FUNCTION
4. Press the left or right arrow key until ‘Edit’ is flashing and press
enter.
1. To set the exercise on 8 kW models, make sure with the mode
switch is in AUTO. Press and hold down the EXERCISER switch
for at least 10 seconds and release. The generator should
start within a few seconds. The unit will run for about 12
minutes before shutting itself down automatically.
If the battery is ever disconnected or the fused is removed for
any reason, the exercise function will have to be reset.
5. Press the right or left arrow key until the exercise time is
displayed and press enter.
6. Using the arrow and enter keys first set the exercise hour in
24 hour format, followed by the minute, and finally the day.
35
7. Once set, the generator will exercise each week at the same
time. Be sure to show the owners how to set the exercise
function for the day and time they want the unit to exercise.
8. If the generator is equipped with the low speed exercise feature,
it was enabled at the factory and no adjustment is needed.
Every installation has its own unique set of circumstances
and requirements. This booklet provides guidelines for basic
installations only and is not intended to cover all applications.
If there are any questions or concerns after carefully reading all
documentation received with the equipment, contact the nearest
dealer for assistance.
36
NOTES
37
NOTES
38
NOTES
39
Electrical Data
Wiring Diagram - 8kW – Drawing No. 0G7945-A
40
Electrical Data
Wiring Diagram - 8kW – Drawing No. 0G7945-A
41
Electrical Data
Electrical Schematic - 8kW – Drawing No. 0G8511-A
42
Electrical Data
Electrical Schematic - 10kW – Drawing No. 0G8512-A
43
Electrical Data
Wiring Diagram - 10kW – Drawing No. 0G7946-A
44
Electrical Data
Wiring Diagram - 10kW – Drawing No. 0G7946-A
45
Electrical Data
Wiring Diagram - 12 & 14kW – Drawing No. 0G7947-A
46
Electrical Data
Wiring Diagram - 12 & 14kW – Drawing No. 0G7947-A
47
Electrical Data
Electrical Schematic - 12 & 14kW – Drawing No. 0G8513-A
48
Electrical Data
Electrical Schematic - 12 & 14kW – Drawing No. 0G8513-A
49
Electrical Data
Wiring Diagram - 16 & 17kW – Drawing No. 0G7948-A
50
Electrical Data
Wiring Diagram - 16 & 17kW – Drawing No. 0G7948-A
51
Electrical Data
Electrical Schematic - 16 & 17kW – Drawing No. 0G8514-A
52
Electrical Data
Electrical Schematic - 16 & 17kW – Drawing No. 0G8514-A
53
Electrical Data
Wiring Diagram - 20kW – Drawing No. 0G8186-A
54
Electrical Data
Wiring Diagram - 20kW – Drawing No. 0G8186-A
55
Electrical Data
Electrical Schematic - 20kW – Drawing No. 0G8515-A
56
Electrical Data
Electrical Schematic - 20kW – Drawing No. 0G8515-A
57
Part No. 0G8679
Revision F (10/09/09)
Catalog No. IM-ASPCA-S-01
Printed in U.S.A.
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement