Attachment 2 - Installation Guidelines 60 Hz Air-Cooled Generators.pdf

SAVE THIS MANUAL FOR FUTURE REFERENCE

Installation Guidelines 60 Hz Air-Cooled Generators

10 kW to 26 kW

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

Register your Generac product at:

WWW.GENERAC.COM

1-888-GENERAC

(888-436-3722)

(000209b)

WARNING

Loss of life. This product is not intended to be used in a critical life support application.

Failure to adhere to this warning could result in death or serious injury.

http://www.generac.com/service-support/product-support-lookup http://www.generac.com/service-support/product-support-lookup ii Installation Guidelines for 60 Hz Air-Cooled Generators

Use this page to record important information about this generator.

Record the information found on the unit data label on this page. See General Information for the location of the unit data label. The unit has a label plate affixed to the inside partition, to the left of the control panel console as shown in Figure 2-1, Figure 2-2, or Figure 2-

3. See Operation for directions on how to open the top lid and remove the front panel.

Always supply the complete model and serial numbers of the unit when contacting an Inde-pendent Authorized Service Dealer (IASD) about parts and service.

Operation and Maintenance: Correct main-tenance and care of the unit ensures a mini-mum number of problems, and keeps operating expenses at a minimum. It is the operator’s responsibility to perform all safety inspections, to verify all maintenance for safe operation is performed promptly, and to have the equipment inspected 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 tech-nicians are factory-trained and are capable of handling all service needs. To locate the near-est IASD, please visit the dealer locator at:

www.generac.com/Dealer-Locator.

Model:

Serial:

Production Date:

Volts:

LPV Amps:

NG Amps:

Hz:

Phase:

Controller P/N:

STA MAC ID:

SSID:

(000393a)

WARNING

CANCER AND REPRODUCTIVE HARM

www.P65Warnings.ca.gov.

Installation Guidelines for 60 Hz Air-Cooled Generators iii

Table of Contents

Section 1: Safety Rules & General Information Introduction

Read This Manual Thoroughly Safety Rules

How to Obtain Service General Hazards Exhaust Hazards Electrical Hazards Fire Hazards Explosion Hazards Battery Hazards General Rules

Before You Begin NEC Requirements Standards Index

Section 2: Unpacking and Inspection General Required Tools Unpacking

Opening the Lid Enclosure Panel Removal

Front Access Panel Removal Intake Side Panel Removal

Customer Connections and Loose Parts Rear Connections Main Line Circuit Breaker (Generator Disconnect) Parts Shipped Loose Generator Emergency Shutdown Switch

Section 3: Site Selection and Preparation Site Selection Carbon Monoxide

Carbon Monoxide Detectors Potential CO Entry Points Protect the Structure

Fire Prevention Distance Requirements Fire Codes, Standards, and Guidelines Generator Maintenance

Fresh Air for Ventilation and Cooling

Water Ingress Avoidance Proximity to Utilities

Verify Wi-Fi Range Transportation Recommendations 17 Suitable Mounting Surface Placement on Roofs, Platforms, and Other Supporting Structures

Section 4: Generator Placement Generator Placement Fascia Installation (If Applicable) Base Plug Installation (If Applicable)

Section 5: Fuel Conversion / Gas Connections Fuel Requirements and Recommendations

BTU Content Fuel Pressure

Fuel Conversion Fuel Consumption Fuel Line Sizing

Flexible Fuel Line Extensions Natural Gas Pipe Sizing LP Gas Pipe Sizing

Installing and Connecting Fuel Lines

Fuel Shutoff Valve Flexible Fuel Line Sediment Trap

Checking Fuel Line Connections... 24 Checking Fuel Pressure Performing Fuel System Leak Test ...24

Natural Gas Installation (Typical) ..25 LP Gas (Vapor) Installation (Typical) iv Installation Guidelines for 60 Hz Air-Cooled Generators

Section 6: Electrical Connections Generator Connections Control Wiring Main AC Wiring Service Entrance Decals Common Alarm Relay (Option) Battery Requirements Battery Installation

Connecting the Battery Battery Disposal

Section 7: Control Panel Startup / Testing Control Panel Interface

Using the AUTO/OFF/MANUAL Buttons

Generator Setup Activation Cold Smart Start Setting The Exercise Timer

Before Initial Startup Install Wizard Interconnect System Self Test Feature Before starting, complete the following:

Checking Manual Transfer Switch Operation Electrical Checks Generator Tests Under Load Checking Automatic Operation Installation Summary Shutting Generator Down While Under Load or During a Utility Outage

Section 8: Troubleshooting Generator Troubleshooting

Section 9: Quick Reference Guide System Diagnosis

Section 10: Accessories

Section 11: Diagrams Installation Drawing (A0002360608 rev B—1 of 2) Installation Drawing (A0002360608 rev B—2 of 2)

Safety Rules & General Information

Installation Guidelines for 60 Hz Air-Cooled Generators 1

Section 1: Safety Rules & General Information

Introduction Thank you for purchasing this compact, high performance, air-cooled, engine-driven gen-erator. 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 intended exclusively for out-door 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 condi-tioners, furnaces, etc.), electronic components (computer, monitor, TV, etc.), lighting loads, and microwaves, when sized correctly. This unit is also equipped with a Wi-Fi® module, which allows the generator owner to monitor generator status from anywhere they have Internet access.

NOTE: Wi-Fi® is a registered trademark of Wi- Fi Alliance®.

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

If any section of this manual is not under-stood, contact the nearest Independent Authorized Service Dealer (IASD) or Gen-erac Customer Service at 1-888-436-3722 (1-888-GENERAC), or visit www.gen-erac.com for starting, operating, and servic-ing procedures. The owner is responsible for correct maintenance and safe use of the unit.

This manual must be used in conjunction with all other supporting product documentation supplied with the product.

SAVE THESE INSTRUCTIONS for future ref-erence. This manual contains important instructions that must be followed during placement, operation, and maintenance of the unit and its components. Always supply this manual to any individual that will use this unit, and instruct them on how to correctly start, operate, and stop the unit in case of emergency.

Safety Rules 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 that the manufacturer does not specifically recommend, verify that it is safe for others and does not render the equipment unsafe.

Throughout this publication, and on tags and decals affixed to the unit, DANGER, WARN- ING, CAUTION, and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be haz-ardous if performed incorrectly or carelessly.

Observe them carefully. Alert definitions are as follows:

NOTE: Notes contain additional information important to a procedure and will be found within the regular text of this manual.

These safety alerts cannot eliminate the haz-ards that they indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents.

How to Obtain Service When the unit requires servicing or repairs, contact Generac Customer Service at 1-888- GENERAC (1-888-436-3722) or visit www.generac.com for assistance.

(000100a)

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

WARNING

(000001)

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

(000002)

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

(000003)

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

www.generac.com www.generac.com http://www.generac.com http://www.generac.com http://www.generac.com http://www.generac.com

2 Installation Guidelines for 60 Hz Air-Cooled Generators

When contacting Generac Customer Service about parts and service, always supply the complete model and serial number of the unit as given on its data decal located on the unit.

Record the model and serial numbers in the spaces provided on the front cover of this manual.

General Hazards

• Inspect the generator regularly, and contact the nearest IASD for parts needing repair or replacement.

Exhaust Hazards

(000190)

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.

(000191)

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.

(000187)

WARNING

Electrocution. Potentially lethal voltages are generated by this equipment. Render the equipment safe before attempting repairs or maintenance. Failure to do so could result in death or serious injury.

(000209b)

WARNING

Loss of life. This product is not intended to be used in a critical life support application.

Failure to adhere to this warning could result in death or serious injury.

(000130)

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.

WARNING

(000182a)

WARNING

Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

(000247a)

Equipment damage. 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. Doing so could result in death, serious injury, and equipment damage.

WARNING

(000155a)

WARNING

Electric shock. 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 equipment or property damage.

(000115)

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.

WARNING

(000111)

WARNING

Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury.

(000108)

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.

(000146)

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.

Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to operate or service this equipment and could result in death or serious injury. (000215a)

WARNING

WARNING

(000228)

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.

(000216)

WARNING

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.

(000103)

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

DANGER

DANGER

Asphyxiation. Carbon monoxide can kill in minutes. Operate this unit outdoors only.

Failure to do so will cause death or serious injury. (000525)

Installation Guidelines for 60 Hz Air-Cooled Generators 3

Electrical Hazards

Fire Hazards

Comply with regulations the local agency for workplace health and safety has established.

Also, verify that the generator is installed in accordance with the manufacturer’s instruc-tions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in non-compliance with the aforementioned codes, standards, laws, and regulations.

Explosion Hazards

(000146)

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.

(000178a)

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.

(000144)

DANGER

Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury.

(000150)

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.

DANGER

(000237)

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.

(000152)

DANGER

Electrocution. Verify electrical system is properly grounded before applying power.

Failure to do so will result in death or serious injury.

(000188)

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.

(000104)

DANGER

Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.

(000145)

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.

WARNING

(000217)

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.

WARNING

(000218)

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.

WARNING

(000219)

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.

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)

(000147)

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.

(000192)

DANGER

Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury.

(000151a)

DANGER

Explosion and fire. Connection of fuel source must be completed by a qualified professional technician or contractor.

Incorrect installation of this unit will result in death, serious injury, and property and equipment damage.

(000174)

DANGER

Risk of fire. Allow fuel spills to completely dry before starting engine. Failure to do so will result in death or serious injury.

4 Installation Guidelines for 60 Hz Air-Cooled Generators

Battery Hazards

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 pro-cesses. For more information on battery recycling, visit the Battery Council Interna-tional website at: http://batterycouncil.org.

General Rules

• Follow all safety precautions in the owner’s manual, installation guidelines manual, and other documents included with the equipment.

• Never energize a new system without opening all disconnects and breakers.

• Always consult local code for additional requirements for where unit is being installed.

• Incorrect installation can result in personal injury and damage to the unit. It may also result in the warranty being suspended or voided. All instructions listed below must be followed including location clearances and pipe sizes.

Before You Begin

• Contact local inspector or city hall to be aware of all federal, state, and local codes which could impact installation. Secure all required permits before installing.

• Fully comply with all relevant NEC, NFPA, and OSHA standards, as well as all federal, state, and local building and electric codes.

This unit must be installed in accordance with current NFPA 37 and NFPA 70 standards, and any other federal, state, and local codes for minimum distances from other structures.

(000110)

WARNING

Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury.

(000188)

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.

(000162)

Explosion. Do not dispose of batteries in a fire.

Batteries are explosive. Electrolyte solution can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention.

WARNING

(000137a)

WARNING

Explosion. Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.

(000164)

WARNING

Electrical shock. Disconnect battery ground terminal before working on battery or battery wires. Failure to do so could result in death or serious injury.

(000138a)

WARNING

Risk of burns. Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.

(000163a)

Risk of burn. Do not open or mutilate batteries.

Batteries contain electrolyte solution which can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention.

WARNING

WARNING

(000228)

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.

(000190)

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.

(000237)

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.

(000182a)

WARNING

Equipment damage. Only qualified service personnel may install, operate, and maintain this equipment. Failure to follow proper installation requirements could result in death, serious injury, and equipment or property damage.

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)

(000100a)

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

WARNING

http://batterycouncil.org

Installation Guidelines for 60 Hz Air-Cooled Generators 5

• Verify capacity of NG meter or LP tank in regards to providing sufficient fuel for both the unit and other household and operating appliances.

NEC Requirements Local code enforcement may require Arc Fault Circuit Interrupters (AFCIs) to be incor-porated into the transfer switch distribution panel. The transfer switch provided with this generator has a distribution panel which 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

Strictly comply with all applicable national, state, and local laws, as well as codes or reg-ulations pertaining to the installation of this engine-generator 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 follow-ing publications may be used as a guide (these apply to localities which recognize NFPA and ICC).

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 *

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 follow-ing internet sources:

* www.nfpa.org ** www.iccsafe.org *** www.rerc.org Rural Electricity Resource Council P.O. Box 309 Wilmington, OH 45177- **** www.asabe.org American Society of Agricultural & Biological Engineers 2950 Niles Road, St. Joseph, MI 49085

(000209b)

WARNING

Loss of life. This product is not intended to be used in a critical life support application.

Failure to adhere to this warning could result in death or serious injury.

Cold Smart Start www.iccsafe.org www.rerc.org www.asabe.org

6 Installation Guidelines for 60 Hz Air-Cooled Generators

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Unpacking and Inspection

Installation Guidelines for 60 Hz Air-Cooled Generators 7

Section 2: Unpacking and Inspection

General NOTE: Carefully inspect contents for damage after unpacking. Unpack and inspect unit immediately upon delivery to identify any dam-age which may have occurred in transit. Any claims for shipping damage must be filed as soon as possible with freight carrier. This is especially important if unit will not be installed for a period of time.

• This standby generator is ready for installa-tion with a factory supplied and pre-mounted base pad and has a weather pro-tective enclosure intended for outdoor installation only.

• If any loss or damage is noted at time of delivery, have delivery person(s) note all damage on the freight bill, or affix their sig-nature under consignor’s memo of loss or damage.

• If a loss or damage is noted after delivery, separate damaged materials and contact freight carrier for claim procedures.

• “Concealed damage” is understood to mean damage to contents of a package not evident at time of delivery, but discovered later.

Required Tools

• General SAE and Metric hand tools

– Wrenches

– Sockets

– Screwdrivers

• Standard electrician’s hand tools

– Drill and bits for mounting and rout-ing conduits

• 4 mm hex key (for access to customer con-nections)

• 3/16 in hex key (test port on fuel regulator)

• Manometer (for fuel pressure checks)

• Meter capable of measuring AC/DC voltage and frequency

• Torque wrenches

Unpacking Proceed as follows to unpack the generator:

1. Remove outer shipping carton.

2. See Figure 2-1. Remove wood frame.

Figure 2-1. Crated Generator

3. See Figure 2-2. Lid will be locked. A set of keys is attached to the cardboard sheet on top of unit. An additional set is attached to the pallet bracket on the front intake end of unit. Remove keys from cardboard and pallet bracket.

Figure 2-2. Keys As Shipped

NOTE: The enclosed keys provided with this unit are intended for service personnel only.

(Part number 0G66240KEY)

000427

006729

8 Installation Guidelines for 60 Hz Air-Cooled Generators

IMPORTANT NOTE: DO NOT perform next step until generator has been transported to installation site.

4. See Figure 2-3. Remove bolts and pallet brackets (A). Exercise caution when removing generator. Dragging it off pallet will damage base. The unit must be lifted from wooden pallet to remove.

NOTE: Bolts and pallet brackets are provided only for shipping purposes and can be dis-carded after removal.

Figure 2-3. Pallet Bracket Locations

Opening the Lid Proceed as follows to open the generator lid:

1. Use keys to open generator lid.

2. See Figure 2-4. Two locks (A) secure lid;

one on each side. Press down on lid above side lock, and unlock latch to correctly open lid.

Figure 2-4. Opening the Lid

3. Repeat for other side. Lid may appear stuck if pressure is not applied from the top.

NOTE: Always verify side locks are unlocked before attempting to lift lid.

Enclosure Panel Removal Generator installation requires removal of front panel and intake side panel. Remove these panels when necessary. Proceed as fol-lows to remove the panels.

Front Access Panel Removal See Figure 2-5. Remove front access panel

(A) by lifting straight up and out once lid is open.

NOTE: Always lift front access panel straight up before pulling away from enclosure (B and C). Do not pull panel away from the enclosure before lifting up (D).

Figure 2-5. Remove Front Access Panel

000426A

009209

A

A

009210

B

C

D

A

Installation Guidelines for 60 Hz Air-Cooled Generators 9

Intake Side Panel Removal See Figure 2-6. The intake side panel (A) must be removed to access battery compart-ment, fuel regulator, and sediment trap.

1. Raise lid and remove front panel.

2. Use a hex key to remove two mounting screws (B) and the hex screw (C) on the L-bracket.

3. Lift intake panel up and away from generator.

4. Inspect for any hidden freight damage.

Contact freight carrier if damage is present.

NOTE: Always lift intake side panel straight up before pulling away from enclosure. Do not pull panel away from enclosure before lifting up (D).

Figure 2-6. Intake Side Panel Removal

Customer Connections and Loose Parts See Figure 2-7 and Figure 2-8 for customer connections and loose parts location. Figure 2-10 illustrates parts shipped loose.

Figure 2-7. Customer Connection Area and Loose Parts Location

Rear Connections

Figure 2-8. Rear Connections

NOTE: Generator is equipped with a Wi-Fi module. See Wi-Fi module owner’s manual for further instruction.

002961

B

C

D

A

A Customer electrical connection area (behind access panel)

B Fuel regulator with sediment trap

C Battery compartment (battery not supplied) (PN 0H3421S)

D Positive (+) and negative (-) battery cables

E Location of “Loose Shipped Parts”

A Wi-Fi module

B Main AC/Control wiring hole for 1-1/4 in conduit

C Main AC/Control wiring hole for 3/4 in conduit (if equipped)

D Fuel connection hole

E Generator emergency shutdown switch

001800

E

D

C

B

A

001360

B

C

D

E A

10 Installation Guidelines for 60 Hz Air-Cooled Generators

Main Line Circuit Breaker (Generator Disconnect) See Figure 2-9. The 2-pole main line circuit breaker (MLCB) (generator disconnect) (A) is rated according to relevant specifications.

Figure 2-9. Generator Main Line Circuit Breaker

Generator MLCB (generator disconnect) can be locked in 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 generator MLCB (gen-erator disconnect) locked in the OFF (OPEN) position during normal generator operation.

Leaving the generator MLCB (generator dis-connect) in OFF (OPEN) position will prevent generator from powering structure during a power outage when placed in AUTO mode.

Parts Shipped Loose

Figure 2-10. Parts Shipped Loose

001810

AB

A Keys

B Flexible fuel line

C Battery terminal cap

D Rubber mounts (only for units including fascia)

E Fascia (if applicable)

F Base plugs (if applicable)

G Decal—Service entrance warning (not shown)

H Decal—Through conductors warning (not shown)

J Decal—Service disconnect (not shown)

K Owner’s and installation manuals (not shown)

L Wi-Fi manual (not shown)

M Wi-Fi Quick Start Guide (not shown)

001803a

A

B

C

D

E

F

Installation Guidelines for 60 Hz Air-Cooled Generators 11

Generator Emergency Shutdown Switch

All generators are equipped with an external means of shutting down the generator which complies with the latest NEC code require-ment. The primary generator shutdown sequence is described in Control Panel Startup / Testing.

See Figure 2-11. An emergency shutdown switch (A) is located on the exterior of the gen-erator back panel. This switch shuts down the generator and disables restarts.

Figure 2-11. Emergency Shutdown Switch (all models)

NOTE: Whenever possible, perform primary shutdown procedure before disabling genera-tor with emergency shutdown switch.

See Figure 2-12. 14–26 kW generators have an emergency shutdown switch (B) located inside the generator.

Figure 2-12. Emergency Shutdown Switch (14–26 kW)

NOTE: Generator will not start if either switch is OPEN (O). Controller displays a “Shutdown Switch” alarm, and red LED “Alarm” light illu-minates and flashes until switch or switches are CLOSED (I) and alarm is cleared by pressing OFF mode button, and then ENTER.

Once cleared, generator can be placed back in AUTO or MANUAL.

Equipment Damage. The emergency shutdown switch is not to be used to power down the unit under normal operating circumstances. Doing so will result in equipment damage. (000399a)

CAUTION

005492

A

005491

B

12 Installation Guidelines for 60 Hz Air-Cooled Generators

Site Selection and Preparation

Installation Guidelines for 60 Hz Air-Cooled Generators 13

Section 3: Site Selection and Preparation

Site Selection Site selection is critical for safe generator operation. It is important to discuss these fac-tors with the installer when selecting a site for generator installation:

• Carbon monoxide

• Fire prevention

• Fresh air for ventilation and cooling

• Water ingress prevention

• Proximity to utilities

• Suitable mounting surface

• Readily accessible for maintenance, repair, and first responders The following pages describe each of these factors in detail.

NOTE: The term “structure” is used throughout this section to describe the home or building where generator is being installed.

Illustrations depict a typical residential home.

However, instructions and recommendations presented in this section apply to all structures regardless of type.

Carbon Monoxide

IMPORTANT NOTE: Move to fresh air immediately and seek medical attention if you feel sick, dizzy, or weak while the gen-erator is running or after it stops.

Generator exhaust contains carbon monox-ide (CO)—a poisonous, potentially lethal gas that cannot be seen or smelled. The genera-tor must be installed in a well ventilated area away from windows, doors, and openings.

The selected location should not allow exhaust gases to be drawn into structures where people or animals may be present.

Carbon Monoxide Detectors See Figure 3-1. CO detectors (K) must be installed and used to monitor for CO and to warn individuals about the presence of CO.

CO detectors must be installed and tested in accordance with the CO detector manufac-turer’s instructions and warnings. Contact local building inspection department for any applicable requirements concerning CO detectors. See NFPA 72, National Fire Alarm and Signaling Code, and Section R315 in the ICC International Residential Code for more information.

IMPORTANT NOTE: Common smoke alarms do NOT detect CO gas. Do not rely on smoke alarms to protect residents or animals from CO. The only way to detect CO is to have functioning CO alarms.

(000103)

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

DANGER

14 Installation Guidelines for 60 Hz Air-Cooled Generators

Potential CO Entry Points See Figure 3-1. Generator exhaust can enter a structure through large openings, such as windows and doors. However, exhaust and CO can also seep into the structure through smaller, less obvious openings.

Protect the Structure Verify structure itself is correctly caulked and sealed to prevent air from leaking in or out.

Voids, cracks, or openings around windows, doors, soffits, pipes, and vents can allow exhaust gas to be drawn into the structure.

Some examples of potential entry points are described and included in, but not limited to, the accompanying table.

Figure 3-1. Carbon Monoxide—Potential Entry Points

ID Entry Point Description / Comments

A Windows and doors

Architectural details which can be (or are) opened to admit fresh air into the structure.

B Garage door CO can leak into garage if door is open, or does not seal correctly when closed.

C Attic vent Attic vents, ridge vents, crawl space vents, and soffit vents can all admit generator exhaust.

D Basement windows Windows or hatches allowing ventilation to or from lower level of a structure.

E Furnace intake / exhaust vent Air intake and exhaust pipes for furnace.

F Wall cracks Includes (but not limited to) cracks in wall, foundation, mortar, or air gaps around doors, windows, and pipes. See Protect the Structure.

G Dryer vent Exhaust duct for clothes dryer.

H Airflow restrictions

Structural features, including but not limited to: corners, alcoves, fences, courtyards, and areas with heavy vegetation can restrict correct airflow around unit. Exhaust gases can be collected in these areas.

J HVAC

components

Do not direct generator discharge into HVAC components, including but not limited to: make up air systems, AC condensers, and window AC units.

IMPORTANT NOTE: Mechanical and gravity outdoor air intake openings for HVAC supply air systems shall be located according to Section 401 in the ICC Mechanical Code. See ICC Mechanical Code for any additional requirements.

008781

A

A

A A

J

A A

B

C C

D

E

F

G

H

J

K

Installation Guidelines for 60 Hz Air-Cooled Generators 15

Fire Prevention The generator must be installed at a safe dis-tance away from combustible materials.

Engine, alternator, and exhaust system com-ponents become very hot during operation.

Fire risk increases if unit is not correctly ven-tilated, is not correctly maintained, operates too close to combustible materials, or if fuel leaks exist. Also, accumulations of flamma-ble debris within or outside the generator enclosure may ignite.

Distance Requirements See Figure 3-2. Minimum clearances must be maintained around the generator enclo-sure. These clearances are primarily for fire prevention, but also to provide sufficient room for removing front and end panels for maintenance purposes.

Figure 3-2. Generator Distance Requirements

008782

A

A A

B

C C

C

C

D F

E

G

ID Description Definition

A Front and end clearance

Minimum clearance from the front and ends of generator must be 3 ft (0.91 m).

This includes shrubs, bushes, and trees.

B Rear clearance Fuel and electrical connections are made here. 18 in (457 mm) minimum clearance per SwRI testing, labeling, and listing, unless state or local codes dictate otherwise.

C Windows, vents, and openings

No operable windows, doors, vents, window wells, or openings in the wall are permitted closer to any point of the generator than what is permitted by locally adopted codes. See Fire Codes, Standards, and Guidelines for more information.

D Existing wall The generator should not be placed closer to existing walls than what is permitted by locally adopted codes, while abiding by the front, end, and rear clearances listed above.

E Removable fence

A removable barrier (non-permanent; without footings) installed as a visual surround.

Removable fence panels for servicing cannot be placed less than 3 ft (0.91 m) in front of the generator.

F Overhead clearance

5 ft (1.52 m) minimum distance from any structure, overhang, or projections from wall.

G Maintenance and servicing

Maneuvering space around generator for performing routine maintenance tasks such as battery replacement and engine service. Do not attempt to conceal generator with shrubs, bushes, or plants. See NEC Article 110.26 for more information.

16 Installation Guidelines for 60 Hz Air-Cooled Generators

Fire Codes, Standards, and Guidelines Generator installation must comply strictly with ICC IFGC, NFPA 37, NFPA 54, NFPA 58, and NFPA 70 standards. These stan-dards prescribe the minimum safe clear-ances around and above the generator enclosure.

NFPA 37

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 engine generator to a minimum of 5 ft (1.5 m) from an opening in a structure or a structure hav-ing combustible walls, and require the engine generator to be located where it is readily accessible for maintenance, repair, and first responders. The standard contains an excep-tion which allows an engine generator to be closer to a combustible wall when approved testing demonstrates a fire originating at the engine does not ignite the combustible struc-ture.

Figure 3-3. Southwest Research Institute Marking

NOTE: The Southwest Research Institute (SwRI) is a nationally recognized third party testing and listing agency. SwRI testing certifies a reduction of the minimum clearance from the engine generator to a structure having combustible walls.

The test 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 engine generator enclosure would not pose any ignition risk to nearby combustibles or structures.

Based on this testing and the requirements of NFPA 37, Sec 4.1.4, the guidelines for instal-lation of the generators listed above are changed to 18 in (457 mm) from the back side of the generator and 3 ft (914 mm) from the front and ends of the generator to a struc-ture having combustible walls. This offset reduction does not apply to clearances from openings in the structure. 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. Vegeta-tion not in compliance with these clearance parameters could obstruct air flow. In addi-tion, exhaust fumes from the generator could inhibit plant growth. See Figure 3-2 and the accompanying descriptions.

Generator Maintenance Regular maintenance is crucial for minimiz-ing exhaust emissions and reducing the risk of fire or equipment failure. For example:

• A dirty air filter or low engine oil level may cause engine to overheat.

• Incorrect spark plug gaps may cause engine backfiring and incomplete combustion.

IMPORTANT NOTE: See Maintenance sec-tion of generator owner’s manual to view a table of scheduled maintenance tasks and procedures. Perform all maintenance tasks as directed.

Fresh Air for Ventilation and Cooling Install unit where air inlet and outlet openings will not become obstructed by leaves, grass, snow, etc. If prevailing winds will cause blow-ing or drifting, consider using a windbreak at a safe distance to protect the unit.

Water Ingress Avoidance

• Select a location on high ground where water levels will not rise and flood the generator. This unit should not operate in, or be subjected to, standing water.

• Install unit where rain gutter downspouts, roof run-off, landscape irrigation, water sprinklers, or sump pump discharge does not flood unit or spray enclosure, including any air inlet or outlet openings.

• Excess moisture can cause excess corrosion and decrease life expectancy of the unit.

Proximity to Utilities

• Contact local utility providers and verify proposed site selection meets all required utility placement requirements before installation. This could affect warranty coverage.

002158

Installation Guidelines for 60 Hz Air-Cooled Generators 17

• Remember, laws and or codes may regulate distance and location of unit to specific utilities.

• It is recommended to pick a location where the generator is as close as possible to the transfer switch and the fuel supply, while verifying the site location conforms to the rest of the Site Selection section.

Verify Wi-Fi Range (If Applicable) See wireless communication accessory man-ual shipped with the unit if planning to use the Wi-Fi feature.

Transportation Recommendations Use a suitable cart or equipment to carry generator, including wooden pallet, to instal-lation site. Place cardboard between cart and generator to prevent any damage or scratches to generator.

Do not lift, carry, or move generator by grasping the louvers. Doing so may bend or damage the sheet metal.

Suitable Mounting Surface Select non-combustible base type as desired or as required by local laws or codes. The generator is typically approved to be placed on pea gravel, crushed stone, a concrete base pad, or an approved composite base pad. Follow all applicable codes if a concrete base pad is required. Verify any base pad meets or exceeds local codes and require-ments for wind ratings.

See Figure 3-4. Prepare a rectangular area approximately 5 in (127 mm) thick (A) and approximately 3 in (76.2 mm) longer and wider (B) than the footprint of the generator on all sides when using pea gravel or crushed stone.

Figure 3-4. Pea Gravel or Crushed Stone Concrete base pads must be appropriately sized in accordance with national, state, or local building codes.

Verify surface where generator will be mounted is compacted, leveled, and will not erode over time. Generator must be level within 0.5 in (13 mm) all around.

Recommended concrete base pads:

10000007852 – 3 in (76.2 mm), 10000007848 – 4 in (102 mm).

Placement on Roofs, Platforms, and Other Supporting Structures Where required to place generator on a roof, platform, deck, or other supporting structure, generator must be placed in accordance with the requirements in NFPA 37, Section 4.1.3.

See Fire Codes, Standards, and Guidelines for permissible clearance reductions. Surface beneath the generator and beyond must be noncombustible to a minimum distance of 12 in (30.5 cm). Contact local building inspection department or fire department to determine which noncombustible materials are approved for installation.

000856

Generator Placement

18 Installation Guidelines for 60 Hz Air-Cooled Generators

Section 4: Generator Placement

Generator Placement See Figure 4-1. All air-cooled generators come with an integrated composite pad. This integrated composite pad elevates the gener-ator and helps prevent water from pooling around base.

Figure 4-1. Integrated Composite Pad

The integrated composite pad allows the gen-erator to be placed on two types of manufac-turer approved surfaces:

• on 5 in (12.7 cm) of compacted pea gravel or crushed stone

• on a manufacturer approved composite or concrete base pad See local codes to verify what type of site base is required. If a concrete pad is required, all federal, state, and local codes must be fol-lowed. Place generator, with integrated com-posite pad attached, and position correctly as per dimensional information given in Site Selection and Preparation.

NOTE: Generator must be level within 0.5 in (13 mm).

NOTE: See Figure 4-2. DO NOT remove inte-grated composite pad for mounting generator to concrete. The integrated composite pad is pre-drilled to accommodate mounting bolts.

Figure 4-2. Mounting Hole Locations

Three mounting holes are available if codes require securing generator to concrete.

Mounting holes are located inside the genera-tor compartment—two in front and one in back.

Three 3/8 in (or M10) lag bolts (not supplied) are recommended for securing generator to a concrete pad.

NOTE: The top of the generator carton has a template which can be used to mark concrete pad to pre-drill the mounting holes.

Fascia Installation (If Applicable)

1. Locate the four threaded black rubber bumpers supplied with loose parts. (See Parts Shipped Loose.)

2. See Figure 4-3. Remove rubber bumpers from bag and screw them into threaded holes located inside the end pieces of the fascia (two each) opposite one another (A).

Figure 4-3. Fascia Installation

3. 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 (B).

NOTE: Do not assemble all four pieces together at this point.

4. Place both assemblies at generator base and fit the rubber mounts into the lifting holes in the generator base (C).

5. Once aligned, snap together the two remaining connection points.

000612a

001804

000614

C

Generator Placement

Installation Guidelines for 60 Hz Air-Cooled Generators 19

Base Plug Installation (If Applicable) Proceed as follows to install base plugs:

1. Locate the four base plugs supplied with the loose parts. (See Parts Shipped Loose.)

2. Locate the four holes in the corners of the generator base.

3. See Figure 4-1. Install base plugs into generator base.

Figure 4-1. Installing Base Plugs

013381

Fuel Conversion / Gas Connections

20 Installation Guidelines for 60 Hz Air-Cooled Generators

Section 5: Fuel Conversion / Gas Connections

Fuel Requirements and Recommendations

NOTE: NG 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 vapors formed above liquid propane in the storage tank.

The unit will run on NG or LP gas, but has been factory-configured to run on NG.

NOTE: Should the primary fuel need to be changed to LP gas, the fuel system must be reconfigured. See Fuel Conversion for instruc-tions on converting the fuel system.

BTU Content Recommended fuels should have a BTU con-tent of at least 1,000 BTU/ft3 (37.26 MJ/m3) for NG; or at least 2,500 BTU/ft3 (93.15 MJ/ m3) for LP gas.

NOTE: BTU fuel content information is avail-able from fuel supplier.

Fuel Pressure Required fuel pressure for NG is 3.5–7.0 in water column (0.87–1.74 kPa) at generator fuel inlet. Required fuel pressure for LP gas is 10–12 in water column (2.49–2.99 kPa) at generator fuel inlet.

NOTE: The primary regulator for LP gas sup-ply is NOT INCLUDED with generator.

NOTE: All pipe sizing, construction, and lay-out must comply with NFPA 54 for NG applica-tions and NFPA 58 or ICC IFGC for LP gas applications. Verify fuel pressure NEVER drops below required specification once gen-erator is installed. See the NFPA website at www.nfpa.org for further information regard-ing NFPA requirements.

Always contact local fuel suppliers or fire mar-shal to verify codes and regulations for correct installation. Local codes will mandate correct routing of gaseous fuel line piping around gar-dens, shrubs, and other landscaping.

Piping strength and connections should be given special consideration for installations in areas at risk for flooding, tornadoes, hurri-canes, earthquakes, and unstable ground.

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 startup in accordance with local codes, stan-dards, and regulations.

Fuel Conversion Proceed as follows to convert from NG config-uration to LP gas.

See Figure 5-1 for fuel conversion knob (A) locations. Orange fuel conversion knob is located beneath fuel mixer on 10 kW units (B) and above fuel mixer on 14 kW–26 kW units (C).

To select fuel type, turn fuel conversion knob towards marked fuel source arrow until it stops. Fuel conversion knob will rotate 180° and slide into mixer body when converting to LP gas.

NOTE: It may be necessary to remove intake snorkel to access fuel conversion knob on 26 kW units.

NOTE: The fuel selection (LP/NG) must be entered on the controller during initial startup using the Install Wizard navigation menu, or in EDIT menu under “Fuel Selection.”

Figure 5-1. Fuel Conversion Knob Locations

(000192)

DANGER

Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury.

014655

CB

www.nfpa.org

Installation Guidelines for 60 Hz Air-Cooled Generators 21

Fuel Consumption

Fuel Line Sizing Selecting the correct…