installation manual - generac parts

INSTALLATION MANUAL

This manual should remain with the unit.

A new standard of reliability

Not intended for use in critical life support applications!! !

Generac® Power Systems, Inc.

INTRODUCTIONThank you for purchasing this model of the standbygenerator set product line by Generac PowerSystems.

Every effort was expended to make sure that theinformation and instructions in this manual are bothaccurate and current at the time the manual was writ-ten. However, the manufacturer reserves the right tochange, alter or otherwise improve this product(s) atany time without prior notice.

READ THIS MANUAL THOROUGHLYIf any portion of this manual is not understood, con-tact the nearest Generac Authorized Service Dealerfor 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 per-sonnel to special instructions about a particular serv-ice or operation that may be hazardous if performedincorrectly or carelessly. Observe them carefully.Their definitions are as follows:

After this heading, read instructions that, if notstrictly complied with, will result in personal injuryor property damage.

After this heading, read instructions that, if notstrictly complied with, may result in personalinjury or property damage.

After this heading, read instructions that, if notstrictly complied with, could result in damage toequipment and/or property.

NOTE:

After this heading, read explanatory statementsthat require special emphasis.

These safety warnings cannot eliminate the hazardsthat they indicate. Common sense and strict compli-ance with the special instructions while performingthe service are essential to preventing accidents.

Four commonly used safety symbols accompany theDANGER, WARNING and CAUTION blocks. The typeof information each indicates is as follows:

This symbol points out important safety infor-mation that, if not followed, could endangerpersonal safety and/or property of others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electricalshock hazard.

HOW TO OBTAIN SERVICEWhen the generator requires servicing or repairs,contact a Generac Authorized Service Dealer forassistance. Service technicians are factory-trainedand are capable of handling all service needs.

When contacting a Generac Authorized ServiceDealer about parts and service, always supply thecomplete model number of the unit as given on thefront cover of the Owner’s Manual.

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AUTHORIZED SERVICEDEALER LOCATION

To locate the nearest GENERAC AUTHORIZEDSERVICE DEALER, please call this number:

1-800-333-1322OR

Locate us on the web at:

www.generac.com

Table of ContentsGenerac Liquid-cooled Generators

Generac® Power Systems, Inc. 1

INTRODUCTION ................................................IFC

SAFETY RULES ....................................................2

Section 1 — GENERAL INFORMATION ............4

1.1 Generator Installation ..................................4

1.2 Before Installation ........................................4

1.3 Generator Location ......................................5

1.4 Generator Mounting and Support ................5

1.5 Unpacking ....................................................6

1.6 Lifting the Generator ....................................6

1.7 Muffler Extension Installtion ........................6

1.8 Fuel Systems ................................................6

1.9 Electrical Connections ................................11

1.10 Battery Installation ......................................11

Section 2 — INSTALLATION ..........................12

2.1 Transfer Switch ..........................................12

2.2 Unpacking ..................................................12

2.3 Mounting ....................................................12

Section 3 — OPERATION ................................13

3.1 Basic Standby Electric System ....................13

3.2 Standby Circuit Isolation Method................13

3.3 Total Circuit Isolation Method ....................13

3.4 Connection Diagrams ..................................13

3.5 Wire Recommendations/Sizing ....................15

Section 4 — NOTES ........................................17

2 Generac® Power Systems, Inc.

Study these SAFETY RULES carefully before installing,operating or servicing this equipment. Become familiarwith this Owner’s Manual and with the unit. The genera-tor can operate safely, efficiently and reliably only if it isproperly installed, operated and maintained. Many acci-dents are caused by failing to follow simple and funda-mental rules or precautions.

Generac cannot anticipate every possible circumstancethat might involve a hazard. The warnings in this man-ual, and on tags and decals affixed to the unit are, there-fore, not all-inclusive. If using a procedure, workmethod or operating technique that Generac does notspecifically recommend, ensure that it is safe for others.Also make sure the procedure, work method or operat-ing technique utilized does not render the generatorunsafe.

Despite the safe design of this generator, operating this equipment imprudently, neglectingits maintenance or being careless can cause possible injury or death. Permit only responsibleand capable persons to install, operate or main-tain this equipment.

Potentially lethal voltages are generated by thesemachines. Ensure all steps are taken to render themachine safe before attempting to work on thegenerator.

Parts of the generator are rotating and/or hotduring operation. Exercise care near running gen-erators.

GENERAL HAZARDS

• For safety reasons, Generac recommends that thisequipment be installed, serviced and repaired by aGenerac Authorized Service Dealer or other compe-tent, qualified electrician or installation technicianwho is familiar with applicable codes, standards andregulations. The operator also must comply with allsuch codes, standards and regulations.

• Installation, operation, servicing and repair of this(and related) equipment must always comply withapplicable codes, standards, laws and regulations.Adhere strictly to local, state and national electricaland building codes. Comply with regulations theOccupational Safety and Health Administration(OSHA) has established. Also, ensure that the gener-ator is installed, operated and serviced in accordancewith the manufacturer’s instructions and recommen-dations. Following installation, do nothing that mightrender the unit unsafe or in noncompliance with theaforementioned codes, standards, laws and regula-tions.

• The engine exhaust fumes contain carbon monoxidegas, which can be DEADLY. This dangerous gas, ifbreathed in sufficient concentrations, can causeunconsciousness or even death. For that reason, ade-quate ventilation must be provided. Exhaust gasesmust be piped safely away from any building orenclosure that houses the generator to an area wherepeople, animals, etc., will not be harmed. Thisexhaust system must be installed properly, in strictcompliance with applicable codes and standards.

• Keep hands, feet, clothing, etc., away from drive belts,fans, and other moving or hot parts. Never removeany drive belt or fan guard while the unit is operating.

• Adequate, unobstructed flow of cooling and ventilat-ing air is critical to prevent buildup of explosive gasesand to ensure correct generator operation. Do notalter the installation or permit even partial blockageof ventilation provisions, as this can seriously affectsafe operation of the generator.

• Keep the area around the generator clean and unclut-tered. Remove any materials that could become haz-ardous.

• When working on this equipment, remain alert at alltimes. Never work on the equipment when physicallyor mentally fatigued.

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IMPORTANT SAFETY INSTRUCTIONSGenerac Liquid-cooled Generators

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to alloperators, potential operators, and service and repair technicians for this equipment.! !

SAVE THESE INSTRUCTIONS – This manual contains important instructions that should befollowed during installation of the generator and batteries.! !

The engine exhaust from this productcontains chemicals known to the state

of California to cause cancer, birthdefects or other reproductive harm.

WARNING:! !

This product contains or emits chemicalsknown to the state of California to cause

cancer, birth defects or other reproductive harm.

WARNING:! !


• Inspect the generator regularly, and promptly repairor replace all worn, damaged or defective parts usingonly factory-approved parts.

• Before performing any maintenance on the generator,disconnect its battery cables to prevent accidentalstart-up. Disconnect the cable from the battery postindicated by a NEGATIVE, NEG or (–) first.Reconnect that cable last.

• Never use the generator or any of its parts as a step.Stepping on the unit can stress and break parts, andmay result in dangerous operating conditions fromleaking exhaust gases, fuel leakage, oil leakage, etc.

ELECTRICAL HAZARDS• All generators covered by this manual produce dan-

gerous electrical voltages and can cause fatal electri-cal shock. Utility power delivers extremely high anddangerous voltages to the transfer switch as well asthe standby generator. Avoid contact with bare wires,terminals, connections, etc., on the generator as wellas the transfer switch, if applicable. Ensure all appro-priate covers, guards and barriers are in place beforeoperating the generator. If work must be done aroundan operating unit, stand on an insulated, dry surfaceto reduce shock hazard.

• Do not handle any kind of electrical device whilestanding in water, while barefoot, or while hands orfeet are wet. DANGEROUS ELECTRICAL SHOCKMAY RESULT.

• If people must stand on metal or concrete whileinstalling, operating, servicing, adjusting or repairingthis equipment, place insulative mats over a drywooden platform. Work on the equipment only whilestanding on such insulative mats.

• The National Electrical Code (NEC), Article 250requires the frame and external electrically conduc-tive parts of the generator to be connected to anapproved earth ground and/or grounding rods. Thisgrounding will help prevent dangerous electricalshock that might be caused by a ground fault condi-tion in the generator set or by static electricity. Neverdisconnect the ground wire.

• Wire gauge sizes of electrical wiring, cables and cordsets must be adequate to handle the maximum elec-trical current (ampacity) to which they will be sub-jected.

• Before installing or servicing this (and related) equip-ment, make sure that all power voltage supplies arepositively turned off at their source. Failure to do sowill result in hazardous and possibly fatal electricalshock.

• Connecting this unit to an electrical system normallysupplied by an electric utility shall be by means of atransfer switch so as to isolate the generator electricsystem from the electric utility distribution systemwhen the generator is operating. Failure to isolate the

two electric system power sources from each other bysuch means will result in damage to the generatorand may also result in injury or death to utility powerworkers due to backfeed of electrical energy.

• Generators installed with an automatic transferswitch will crank and start automatically when nor-mal (utility) source voltage is removed or is below anacceptable preset level. To prevent such automaticstart-up and possible injury to personnel, disable thegenerator’s automatic start circuit (battery cables,etc.) before working on or around the unit. Then,place a “Do Not Operate” tag on the generator controlpanel and on the transfer switch.

• In case of accident caused by electric shock, immedi-ately shut down the source of electrical power. If thisis not possible, attempt to free the victim from thelive conductor. AVOID DIRECT CONTACT WITHTHE VICTIM. Use a nonconducting implement, suchas a dry rope or board, to free the victim from the liveconductor. If the victim is unconscious, apply first aidand get immediate medical help.

• Never wear jewelry when working on this equipment.Jewelry can conduct electricity resulting in electricshock, or may get caught in moving componentscausing injury.

FIRE HAZARDS• Keep a fire extinguisher near the generator at all

times. Do NOT use any carbon tetra-chloride typeextinguisher. Its fumes are toxic, and the liquid candeteriorate wiring insulation. Keep the extinguisherproperly charged and be familiar with its use. If thereare any questions pertaining to fire extinguishers,consult the local fire department.

EXPLOSION HAZARDS• Do not smoke around the generator. Wipe up any fuel

or oil spills immediately. Ensure that no combustiblematerials are left in the generator compartment, oron or near the generator, as FIRE or EXPLOSIONmay result. Keep the area surrounding the generatorclean and free from debris.

• Generac generator sets may operate using one of sev-eral types of fuels. All fuel types are potentially FLAM-MABLE and/or EXPLOSIVE and should be handledwith care. Comply with all laws regulating the storageand handling of fuels. Inspect the unit’s fuel systemfrequently and correct any leaks immediately. Fuelsupply lines must be properly installed, purged andleak tested according to applicable fuel-gas codesbefore placing this equipment into service.

• Gaseous fluids such as natural gas and liquidpropane (LP) gas are extremely EXPLOSIVE. Naturalgas is lighter than air, and LP gas is heavier than air;install leak detectors accordingly.

IMPORTANT SAFETY INSTRUCTIONSGenerac Liquid-cooled Generators


1.1 GENERATOR INSTALLATIONThis equipment is a liquid-cooled, engine-driven gen-erator set. The generator is designed to supply elec-trical power that operates critical electrical loadsduring utility power failure. The unit has been facto-ry-installed in a weather resistant, all metal enclosureand is intended for outdoor installation only.

If this generator is used to power electrical loadcircuits normally powered by a utility powersource, it is required by code to install a trans-fer switch. The transfer switch must effectivelyisolate the electric system from the utility distri-bution system when the generator is operating(NEC 701). Failure to isolate an electrical systemby such means results in damage to the genera-tor and may also result in injury or even deathto utility power workers due to backfeed ofelectrical energy.

1.2 BEFORE INSTALLATIONBefore installing this equipment, check the ratings ofboth the generator and the transfer switch. Read“Emergency Isolation Method” and “Total CircuitIsolation Method” in Section 3.

The generator’s rated wattage/amperage capacitymust be adequate to handle all electrical loads thatthe unit will power. The critical (essential) loads mayneed to be grouped together and wired into a sepa-rate “emergency” distribution panel.

Connecting this generator to an electrical sys-tem normally supplied by an electric utilityshall be by means of a transfer switch, so as toisolate the electric system from the utility distri-bution system when the generator is operating.Failure to isolate the electric system by thesemeans will result in damage to the generatorand may also result in injury or death to utilityworkers due to backfeed of electrical energy.

If an open bottom is used, the engine-genera-tor is to be installed over non-combustiblematerials and should be located such that com-bustible materials are not capable of accumu-lating under the generator set.

Only qualified, competent installation contractors orelectricians thoroughly familiar with applicablecodes, standards and regulations should install thisstandby electric power system. The installation mustcomply strictly with all codes, standards and regula-tions pertaining to the installation.

After the system has been installed, do nothingthat might render the installation in noncompli-ance with such codes, standards and regula-tions.

1.2.1 NFPA STANDARDSThe following published standards booklets pertain-ing to standby electric systems are available form theNational Fire Protection Association (NFPA),Batterymarch Park, Quincy, MA 02269:

• NFPA No. 37, STATIONARY COMBUSTIONENGINES AND GAS TURBINES

• NFPA No. 54, NATIONAL FUEL GAS CODE• NFPA No. 58, LIQEEFIED PETROLEUM GAS

CODE• NFPA 70, NATIONAL ELECTRIC CODE (NEC)• NFPA 99, STANDARD FOR HEALTH CARE FACIL-

ITIES• NFPA 101, LIFE SAFETY CODE• NFPA 110, STANDARD FOR EMERGENCY AND

STANDBY POWER SYSTEMS• NFPA 220, STANDARD TYPES OF BUILDING

CONSTRUCTINNOTE:

It is essential to use the latest version of any stan-dard to ensure that the generator and its acces-sories comply with all the applicable standardsand local codes.

1.2.2 OTHER PUBLISHED STANDARDSIn addition to NFPA standards, the following infor-mation pertaining to the installation and use ofstandby electric systems is available:

• Article X, NATIONAL BUILDING CODE, availablefrom the American Insurance Association, 85 JohnStreet, New York, N.Y. 10038.

• AGRICULTURAL WIRING HANDBOOK, obtainablefrom the Food and Energy Council, 909 UniversityAvenue, Columbia, MO, 65201.

• ASAE EP-364.2, INSTALLATION AND MAINTE-NANCE OF FARM STANDBY ELECTRIC POWER,available from the American Society of AgriculturalEngineers, 2950 Niles Road, St. Joseph, MI 49085.

• A52.1, AMERICAN NATIONAL STANDARD FORCHIMNEYS, FIREPLACES AND VENTING SYS-TEMS, available from the American NationalStandard Institute, 1430 Broadway, New York, N.Y.10018.

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Section 1 - General InformationGenerac Liquid-cooled Generators


NOTE:

It is essential to use the latest version of any stan-dard to ensure that the generator and its acces-sories comply with all the applicable standardsand local codes.

The installer must comply with all applicable stateand local codes.

1.3 GENERATOR LOCATIONInstall the generator set, in its protective enclosureoutdoors, where adequate cooling and ventilating airalways is available. Consider these factors:

• Install the unit where air inlet and outlet openingswill not become obstructed by leaves, grass, snow,etc. If prevailing winds will cause blowing or drift-ing, consider using a windbreak to protect the unit.

• Install the generator on high ground where waterlevels will not rise and endanger it.

• This genset must be installed on a level surface.The base frame must be level within 1/2 inch allaround.

• Allow sufficient room on all sides of the generatorfor maintenance and servicing. A good rule is toallow five feet of space on all sides. Consult theinstallation drawing in the generator owner’s man-ual for exact clearance requirements.

• Where strong prevailing winds blow from onedirection, face the generator air inlet openings intothe prevailing winds.

• Install the generator as close as possible to thetransfer switch. This reduces the length of wiringand conduit.

• Install the generator as close as possible to the fuelsupply, to reduce the length of piping. HOWEVER,REMEMBER THAT LAWS OR CODES MAY REG-ULATE THE DISTANCE.

1.4 GENERATOR MOUNTING ANDSUPPORT

A CONCRETE BASE:

When designing a concrete base, some guidelines thatshould be followed are:

• The length and width of the concrete base shouldexceed the length and width of the generator by aminimum of at least 12 inches (0.305 meters) onall sides.

• The foundation depth should be sufficient to givethe concrete base a weight that is equal to theengine-generator set weight.

To calculate the depth of the concrete base, the fol-lowing formula may be used:

Suggested mixture of concrete (by volume) is 1:2:3 ofcement, sand and aggregate with a maximum fourinch (100mm) slump with a 28 day compressionstrength of 3000 psi (200 MPa).

The concrete base should be reinforced with No. 8gauge steel wire fabric, or equivalent, horizontallyplaced on 6 inch (150mm) centers.

An alternate reinforcement method is to place No. 6reinforcing bars on 12 inch (300mm) centers hori-zontally. Bars should clear the foundation surface aminimum of 3 inches (75mm).

Retain the generator compartment to the concreteslab with masonry bolts. Be sure the bolts are longenough to retain the compartment.

1.4.1 COMBUSTIBLE FLOOR AND ROOFPROTECTION

If the generator must be installed on any combustiblefloor or roof, comply with the following rules:

• Place a layer of non-combustible insulation, fol-lowed by a layer of sheet metal beneath the unit’smounting base rails (Figure 1.1).

• Both the layer of insulation and the sheet metalmust extend beyond the generator base to a dis-tance of at least 12 inches (30.5 cm) on all sides.

Figure 1.1 — Combustible Floor and RoofProtection


Depth of Base = W150xBxL

W = Total wet weight of engine-generator set inpounds (kg).

150 = Density of the concrete (pounds per cubicfoot).

2400 = Density of concrete (kilograms per cubicfoot).

B = Foundation width in feet (meters).L = Foundation length in feet (meters).


For rooftop or building structure mounting, it is rec-ommended that spring isolators be installed betweenthe engine frame and the mounting system. A mini-mum of six (6) isolators are required and must belocated at the front and rear cross members and thecenter of the frame.

Since the entire bottom of the genset is now exposed,it should be covered with a metal plate to keep outsmall animals and protect the integrity of the internalparts of the genset. Genset movement is more intensewith spring isolation, so flexible connections for thefuel and the electrcal conduits are also required.

NOTE:

Consult the local building codes which may vary.

1.5 UNPACKING1.5.1 UNPACKING PRECAUTIONS

Handle shipping cartons and crates with care. Usecare to avoid damage from dropping, bumping, colli-sion, etc. Store and unpack cartons with the properside up, as noted on the shipping carton.

1.5.2 INSPECTIONAfter unpacking, carefully inspect the generator forany damage that may have occurred during ship-ment. If loss or damage is noted at the time of deliv-ery, have the person(s) making delivery note all dam-age on the freight bill or affix their signature underthe consignor’s memo of loss or damage.

1.6 LIFTING THE GENERATOR

When lifting or hoisting equipment is used, becareful not to touch overhead power lines. Thegenerators weight of more than 900 poundsrequires proper tools, equipment, and qualifiedpersonnel to be used in all phases of handlingand unpacking.

1.7 MUFFLER EXTENSION INSTALLATION

The Quiet-Test model QT50, QT70, QT080, QT100,QT130 and QT150 have their external muffler(s)shipped loose to prevent damage during shipment.

Assembly Directions1. Slip item 3 over the exhaust pipe which extends

though the exhaust duct and secure with clamp(item 2) (see Figure 1.2).

2. Assemble item 5A to item 5B using six (6) screws(item 4).

3. Secure the item 5 assembly to the generator usingfour (4) screws (item 4).

4. Secure item 6 to the item 5 assembly using four(4) screws (item 4).

5. Slip item 1 over item 3 and tighten.

Figure 1.2 — Muffler Extension Installation

1.8 FUEL SYSTEMS

1.8.1 INTRODUCTION TO GASEOUS FUELSYSTEMS

The generator is equipped with a fuel system that uti-lizes liquefied petroleum (LP) or natural gas as a fuel.The fuel system used on the generator can be deter-mined from the 9th digit in the model number. An “N”in this position indicates a generator designed to runon natural gas. A “V” indicates that the generator isdesigned to run on LP Vapor. For example, the fol-lowing model indicates a natural gas generator:QT04039GUNSN. These fuels are highly volatile andcan be dangerous if handled or stored carelessly.

Gaseous fuels, such as LP and natural gas, arehighly volatile and their vapors are explosive.LP gas is heavier than air and will settle in lowareas. Natural gas is lighter than air and willsettle in high areas. Even the slightest sparkcan ignite these fuels and cause an explosion.For safety, all codes, standards and regulationspertaining to the installation and use ofgaseous fuels must be strictly complied with.

DANGER

5A

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5B

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Section 1 — General InformationGenerac Liquid-cooled Generators


Local fuel gas codes may vary widely. For that reason,it is recommended that a local gas distributor orinstaller be consulted when installing a gaseous fuelsupply system.

In the absence of local fuel gas codes and regulations,booklets published by the National Fire ProtectionAssociation (NFPA) may be used as sources of infor-mation.

1.8.2 PROPERTIES OF GASEOUS FUELS

Natural GasNatural gas is lighter than air. It is found in thegaseous state at normal ambient temperatures andpressures. It is highly explosive and can be ignited atthe slightest spark. For that reason, fuel lines mustbe free of leaks and adequate ventilation is absolute-ly essential.

Local fuel/gas codes usually dictate the maximumpressure at which natural gas can enter a structure.In order to reduce the gas pressure to that requiredby law, a PRIMARY REGULATOR is required.

LP GasLiquefied petroleum (LP) gas is heavier than air. Thegas vapors are explosive and, like natural gas, can beignited by the slightest spark.

LP tank pressure is dependent on the ambient tem-perature and can be as high as 200 psi. A primaryregulator is required at the tank to reduce the pres-sure to the required five to 14 inches of water columnfor units less than 70kW, or 11 to 14 inches of watercolumn for units 70kW and larger.

1.8.3 THE NATURAL GAS SYSTEMA typical natural gas system is shown in Figure 1.3,below. The maximum pressure at which the gas canenter a building is established by code and may varyfrom area to area. A primary regulator is required toreduce gas supply pressures to the required safe levelbefore the gas enters a structure.

The primary regulator may or may not be providedby the gas supplier. The gas distribution companywill usually provide piping from the main distribu-tion line to the generator site. It is the responsibilityof the gas supplier to ensure that sufficient gas pres-sure is available to operate the primary regulator.

From the primary regulator, gas flows to the genera-tor connection. A flexible length of gas line is requiredbetween rigid piping and the gas connection at thegenerator. The generator fuel system consists of anelectrical fuel shutoff valve/regulator assembly and agas actuator.

The secondary regulator reduces gas pressure toabout five inches of water column before the gas Isdelivered to the actuator.

NOTE:

Gas pressure from the primary regulator (suppliedby the installing contractor) to the generator's fuelshutoff valve should not exceed 14 inches of watercolumn. Units below 70kW can operate with thepressure as low as five inches of water column. Forunits 70kW and larger, the gas pressure should notbe below 11 inches of water column.


Gas ActuatorPrimary Regulator(Supplied byInstallingContractor)

11 - 14" Water Column (>= 70 kW)5 - 14" Water Column (< 70 kW)

Flex Fuel Line(Supplied byInstallingContractor)

Generator B ase

Fuel Shutoff/RegulatorAssembly

Manual ShutoffValve

Figure 1.3 — Typical Natural Gas System

Follow the local codes on selecting the required AGAapproved, and UL listed, for NG application flexibleportion of the fuel line (supplied by the installing con-tractor).

1.8.4 LP GAS VAPOR WITHDRAWAL SYSTEMThis type of system utilizes the vapors formed abovethe liquid fuel in the supply tank (see Figure 1.4).Approximately 10 to 20 percent of the tank capacityis needed for fuel expansion from the liquid to thevapor state. Gas pressure requirements for an LPvapor system at the frame of the generator are thesame as those listed for natural gas in Section 1.8.3.See Table 1 for information regarding the vaporcapacity of LP tanks. The installer should be aware ofthe following:

• When ambient temperatures are low and enginefuel consumption is high, the vapor withdrawalsystem may not function efficiently.

• Ambient temperatures around the supply tankmust be high enough to sustain adequate vapor-ization or the system will not deliver the neededfuel volume.

• In addition to the cooling effects of ambient air, thevaporization process itself provides an additionalcooling effect.

1.8.5 GASEOUS FUEL SYSTEM PIPINGThe following general rules apply to piping used ingaseous fuel systems:

• The piping should be of black iron, rigidly mount-ed and protected against vibration.

• Install an approved length of flexible hose betweenthe generator connection point and rigid piping.

• Piping must be of the correct size to maintain therequired supply pressures and volume flow undervarying conditions (see Table 2).

• Installed piping must be properly purged and leak-tested, in accordance with applicable codes andstandards.

• Use an approved pipe sealant or joint compoundon all threaded fittings, to reduce the possibility ofleakage.

NOTE:

In the absence of local purging and leak test stan-dards, NFPA No. 54 may be used as a guide.


Gas Actuator

Primary Regulator(Supplied byInstallingContractor)

11 - 14" Water Column (>= 70 kW)5 - 14" Water Column (< 70 kW)

Flex Fuel Line(Supplied byInstallingContractor)

Generator B ase

Fuel Shutoff/RegulatorAssembly

Manual Shutoff Valves

FuelTank

Figure 1.4 — Typical LP Gas Vapor Withdrawal System



TABLE 1 — VAPOR CAPACITY OF PROPANE STORAGE TANKSTo Use: Go to the First column and pick the required kW load and then pick the minimum ambient temperature( 40º, 20º or 0º F) that the generator would be operating in. The third column (tank capacity) will give the requiredtank size to continually produce the given fuel flow.

Propane storage tanks can provide either a liquid or a vapor supply to the generator. The above chart is for vaporwithdrawal only and provides the kW output or amount of vapor that can be withdrawn at a given temperaturewhile keeping the temperature of the liquid above the boiling point. If the withdrawal rate is too high, the LP tem-perature goes below the boiling point, the pressure drops to zero and no vapor can be withdrawn. A primary reg-ulator is also required at the tank to reduce the line pressure to the generator to 5-14 inches of water column forunits less than 70kW or 11-14 inches of water column for units 70kW and above.

Propane Conversions: 36.38 ft3 = 90,500 btu = 1 gal • 1lb = 21,500 btu = 8.56 ft3

Figure 1.5 — Propane Storage Tank

OperatingMax kW Minimum Hours @ Tank Capacity Length Dia OverallVapor Temp Max kW (Gallons) Inches Inches Ht. Inches

30 40 2420 20 35 120 57 24 3310 0 6735 40 2625 20 36 150 68 24 3312 0 7260 40 2640 20 38 250 94 30 3920 0 7480 40 2650 20 40 325 119 30 3925 0 77100 40 3160 20 51 500 119 37 4630 0 100150 40 35100 20 53 850 165 41 5050 0 105170 40 36120 20 51 1000 192 41 5060 0 103



TABLE 2 — GAS FLOW-PIPE SIZE CHARTThis table is based on a specific gravity of 1.00 (specific gravity of air). For that reason, a correction is requiredwhen the fuel used has a different specific gravity. The fuel’s specific gravity can be obtained from the fuel suppli-er. The table is also based on a pressure drop of 0.3, which allows for a nominal amount of restrictions frombends, fittings, etc. An example of how to calculate pipe size follows the table.

Example: It is determined that a generator set running at 100% of rated load on natural gas requires 545 cubicfeet of gas per hour. The unit is located 75 feet from the supply tank and will use gas having a specific gravity of0.65 (multiplier is 0.962). From the table below, it is apparent that a 1-1/2 inch pipe will deliver 524.29 cubic feetof gas per hour. The next larger pipe (2 inch) will deliver 1120 cubic feet per hour and, when the correction fac-tor is applied, will actually deliver 1077.4 cubic feet per hour. The 2 inch pipe is required at the given distance of75 feet. Pressure drop does not have to be considered unless an unusual number of fittings, bends or other restric-tions are used. In such unusual cases, the fuel supplier will usually specify which multiplier is applicable.

Length of Pipe Iron Pipe Size (IPS Inches)(In Feet) 1/2” 3/4” 1” 1-1/4” 1-1/2” 2” 2-1/2” 3” 4” 6” 8”

15 76 172 345 750 1220 2480 3850 6500 13880 38700 7900030 52 120 241 535 850 1780 2750 4700 9700 27370 5585045 43 99 199 435 700 1475 2300 3900 7900 23350 4560060 38 86 173 380 610 1290 2000 3450 6800 19330 3950075 77 155 345 545 1120 1750 3000 6000 17310 3530090 70 141 310 490 1000 1560 2700 5500 15800 32250105 65 131 285 450 920 1430 2450 5100 14620 29850120 120 270 420 860 1340 2300 4800 13680 27920150 109 242 380 780 1220 2090 4350 12240 25000180 100 225 350 720 1120 1950 4000 11160 22800210 92 205 320 660 1030 1780 3700 10330 21100240 190 300 620 970 1680 3490 9600 19740270 178 285 580 910 1580 3250 9000 18610300 170 270 545 860 1490 3000 8500 17660450 140 226 450 710 1230 2500 7000 14420600 119 192 390 600 1030 2130 6000 12480

CORRECTION FACTORS

Specific Specific PressureGravity Multiplier Gravity Multiplier Drop Multiplier

0.50 1.10 1.0 0.775 0.1 0.5770.55 1.04 1.2 0.707 0.2 0.815

(Sewage Gas)

0.60 1.00 1.4 0.655 0.3 1.0000.65 0.962 1.5 0.633 0.5 1.29

(Natural Gas) (Propane)

0.70 0.926 1.7 0.594 1.0 1.830.80 0.867 1.9 0.565 2.0 2.580.90 0.817 2.1 0.535 5.0 4.08

(Butane)



1.9 ELECTRICAL CONNECTIONS

1.9.1 GROUNDING THE GENERATORA GROUNDING LUG is provided on the generatormounting base for the purpose of grounding theframe and the external electrically conductive parts ofthis equipment to an approved earth ground and/orgrounding rods where required by the NationalElectrical Code (Figure 1.6). Consult a qualified elec-trician for grounding requirements in the area.Groudning procedures must meet local regulations.

Do not connect the ground wire to any pipethat carries a flammable or explosive substance– FIRE or an EXPLOSION may result.

Proper grounding helps protect personnel againstelectrical shock in the event of a ground fault condi-tion in the generator or in connected electricaldevices. In addition, grounding helps dissipate staticelectricity that often builds up in ungroundeddevices.

Figure 1.6 – Generator Grounding Lug (typical)

1.9.2 BATTERY CHARGER CONNECTIONThe generator has been equipped with a 2 Amp bat-tery charger installed in the control panel. Powerleads for the charger have been run to the connectionbox (Figure 1.7). On units equipped with 2.5Lengines, this connection is found in the control panel.The terminals will need to be supplied from a120VAC, 15 Amp circuit.

Figure 1.7 — Battery Charger Connection

1.10 BATTERY INSTALLATION

Standby generators installed with automatictransfer switches will crank and start automati-cally when NORMAL (UTILITY) source voltage isremoved or is below an acceptable preset level.To prevent such automatic start-up and possibleinjury to personnel, do not connect batterycables until certain that normal source voltageat the transfer switch is correct and the systemis ready to be placed into operation.

Storage batteries give off explosive hydrogengas. This gas can form an explosive mixturearound the battery for several hours aftercharging. The slightest spark can ignite the gasand cause an explosion. Such an explosion canshatter the battery and cause blindness orother injury. Any area that houses a storagebattery must be properly ventilated. Do notallow smoking, open flame, sparks or any sparkproducing tools or equipment near the battery.

Battery electrolyte fluid is an extremely causticsulfuric acid solution that can cause severeburns. Do not permit fluid to contact eyes, skin,clothing, painted surfaces, etc. Wear protectivegoggles, protective clothing and gloves whenhandling a battery. If fluid is spilled, flush theaffected area immediately with clear water.

Do not dispose of the battery in a fire. The bat-tery is capable of exploding.Do not open or mutilate the battery. Releasedelectrolyte can be toxic and harmful to the skinand eyes.

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DANGER

Battery Charger Connection

GROUNDINGLUG

DANGER



The battery represents a risk of high short cir-cuit current. When working on the battery,always remove watches, rings or other metalobjects, and only use tools that have insulatedhandles.

1.10.1 VENTED BATTERIES

The electrolyte is a dilute sulfuric acid that isharmful to the skin and eyes. It is electricallyconductive and corrosive. The following proce-dures are to be observed:

• Wear full eye protection and protective clothing,• Where electrolyte contacts the skin, wash it off

immediately with water,• Where electrolyte contacts the eyes, flush thor-

oughly and immediately with water and seek med-ical attention, and

• Spilled electrolyte is to be washed down with anacid-neutralizing agent. A common practice is touse a solution of one pound (500 grams) bicarbon-ate of soda to one gallon (4 liters) of water. Thebicarbonate of soda solution is to be added untilthe evidence of reaction (foaming) has ceased. Theresulting liquid is to be flushed with water and thearea dried.

Lead acid batteries present a risk of firebecause they generate hydrogen gas. The fol-lowing procedure are to be followed:

• DO NOT SMOKE when near batteries,• DO NOT cause flame or spark in battery area, and• Discharge static electricity from body before touch-

ing batteries by first touching a grounded metalsurface.

Servicing of batteries is to be performed or super-vised by personnel knowledgeable of batteries andthe required precautions. Keep unauthorized person-nel away from batteries.

For recommended batteries, see the “Specifications”section in the Owner’s Manual. All batteries must beat 100 percent state-of-charge before they areinstalled on the generator.

When using maintenance-free batteries, it is not nec-essary to check the specific gravity or electrolyte level.Have these procedures performed at the intervalsspecified in the “Maintenance” section in the Owner’sManual. A negative ground system is used. Batteryconnections are shown on the wiring diagrams. Makesure all batteries are correctly connected and termi-nals are tight. Observe battery polarity when con-necting batteries to the generator set.

NOTE:

Damage will result if the battery connections aremade in reverse.

2.1 TRANSFER SWITCHThe generator system may include a matched auto-matic transfer switch which is intended to be used inconjunction with the Generac generator. It is suppliedin either a NEMA 1 enclosure or a NEMA 3R enclo-sure. The NEMA 1 enclosure is intended for indooruse only. The NEMA 3R enclosure is weather proofand can be used indoors or outdoors.

If a transfer switch is not included, one may be pur-chased separately from a Generac Authorized Dealer.

2.2 UNPACKINGCarefully unpack the transfer switch. Inspect closelyfor any damage that might have occurred duringshipment. The purchaser must file with the carrierany claims for loss or damage incurred while in tran-sit.

Check that all packing material is completelyremoved from the switch prior to installation.

Attach any lifting device to the transfer switch mount-ing holes or brackets only. DO NOT LIFT THESWITCH AT ANY OTHER POINT.

2.3 MOUNTINGMounting dimensions for the transfer switch enclo-sure can be found in the transfer switch owner’smanual. Enclosures are typically wall-mounted.Components are mounted in a standard NEMA 12-type enclosure.

Handle transfer switches carefully wheninstalling. Do not drop the switch. Protect theswitch against impact at all times, and againstconstruction grit and metal chips. Never installa transfer switch that has been damaged.

Install the transfer switch as close as possible to theelectrical loads that are to be connected to it. Mountthe switch vertically to a rigid supporting structure.To prevent switch distortion, level all mountingpoints. If necessary, use washers behind mountingholes to level the unit. Never install the switch wherewater or any corrosive substance might drip into theenclosure.

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Section 2 — InstallationGenerac Liquid-cooled Generators


3.1 BASIC STANDBY ELECTRICSYSTEM

Figure 3.1 shows a schematic diagram of a basicstandby electric system. Both the UTILITY powersupply and the STANDBY (GENERATOR) output areconnected to an approved transfer switch. The trans-fer switch is required by electrical code and servesthe following functions:

• Allows the LOAD circuits to be connected to onlyone power supply at a time.

• Prevents electrical backfeed between the generatorand the UTILITY power circuits.

Figure 3.1 – Basic Standby Electric System

Notice that both the STANDBY and the UTILITYpower supplies to the transfer switch are protectedagainst overload by a main line circuit breaker.

3.2 STANDBY CIRCUIT ISOLATIONMETHOD

This prevents overloading the generator by keepingelectrical loads below the wattage/amperage capacityof the generator. If the generator is powering only des-ignated loads, within the wattage/amperage capacity,during utility power outages, consider using theemergency circuit isolation method.

Designated electrical loads are grouped together andwired into a separate “Standby Distribution Panel.”Load circuits powered by that panel are within thewattage/amperage capacity of the generator set. Whenthis method is used, it is difficult to overload the gen-erator. The transfer switch must meet the followingrequirements:

• It must have an ampere rating equal to the totalamperage rating of the standby distribution panelcircuit.

• Have it installed between the building’s main dis-tribution panel and the standby distribution panel.

3.3 TOTAL CIRCUIT ISOLATIONMETHOD

When a generator capable of powering all electricalloads in the circuit is to be installed, use the “TotalCircuit Isolation Method.” It is possible for the gener-ator to be overloaded when this isolation method isemployed. The following apply to the transfer switchin this type of system.

• Ampere rating of the transfer switch must equalthe ampere rating of the normal incoming utilityservice.

• The transfer switch is installed between the utilityservice entrance and the building distributionpanel.

3.4. CONNECTION DIAGRAMSAll wiring in the standby electric power system mustbe in strict compliance with applicable codes, stan-dards and regulations. Such wiring must be properlysupported, routed, and connected. In addition,wiring must be properly sized to carry the maximumload current to which is will be subjected.

The connections between the generator and transferswitch will vary depending on the equipmentordered. In each case there are two types of intercon-nections, load wiring and control wiring.

NOTE:

Control wiring must always be run in a separateconduit from the load wiring.

Make sure to turn OFF both the NORMAL (UTIL-ITY) and STANDBY (EMERGENCY) power sup-plies before trying to connect power sourceand load lines to the transfer switch. Supplyvoltages are extremely high and dangerous.Contact with such high voltage power supplylines causes extremely hazardous, possiblylethal, electrical shock.

Be sure to maintain proper electrical clearancesbetween live electrical parts and groundedmetal. Allow at least one-half inch of clearancecircuits up to 400 amps.

On 3 phase installations the phase rotation ofthe Generator power lines MUST match thephase rotation of the Utility power lines at thetransfer switch. Failure to do so may result indamage to equipment and/or property.

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DANGER

Section 3 - OperationGenerac Liquid-cooled Generators


Extremely high and potentially lethal supplyvoltages are present at the transfer switchwhen verifying phase rotation. This operationshould only be performed by a trained electri-cian.

3.4.1 R-100 TO RTSAn R-100 generator is identified from the front of thecontrol panel, which will consist of an AUTO/OFF/MANUAL switch, a SET EXERCISE switch, and sev-eral fault indicator LEDs. See Figure 3.2 for an inter-connection diagram. On units equipped with 2.5Lengines, the control connections and main circuitbreaker are found in the control panel. In this con-figuration the control wires consist of Utility 1 andUtility 2 (N1 and N2), and 23 and 194. See Section3.5.1 for control wire sizing recommendations.

Make sure to turn OFF the NORMAL (UTILITY)power supply before trying to connect theUtility 1 and Utility 2 control wires. Supply volt-ages are extremely high and dangerous.Contact with such high voltage power supplylines causes extremely hazardous, possiblylethal, electrical shock.

Terminals 178 and 183 in the generator AC con-nection box are not used in this application.Connection of any wires to these terminals mayresult in unwarrantable damage to the controlboard.

The load wires consist of wires run between the gen-erator main circuit breaker and the transfer mecha-nism, and a neutral wire. See Section 3.5 for loadwire sizing information.

3.4.2 H-100 TO HTSAn H-100 controlled generator is identified from thefront of the control panel, which consists of a controlpanel with integrated dual LCD display and tactilekeypad. See Figure 3.3 for an interconnection dia-gram. In this configuration the control wires consistof RS485 + and RS485 - communication wires runin a shielded cable. See Section 3.5 for communica-tion wire sizing and type recommendations.

NOTE:

RS485 communication wiring MUST consist of a 2wire, twisted pair cable with overall screen.

NOTE:

The shield wire of the RS485 communicationcable MUST be connected on one end only.

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DANGER

DANGER

Section 3 — OperationGenerac Liquid-cooled Generators

DIFFERENT CONDUITS.RUN IN TWO LEADS MUST BETRANSFER SWITCHPOWER LEADS AND

NOTE:

SINGLE PHASE

UTILITY SUPPLY FROMSERVICE DISCONNECT

23

USED ON 3 PHASE SYSTEMSNOTE: E3, N3 AND T3 WIRES ARE ONLY

NOTE:

178 AND 183

APPLICATION

NOT USED IN THIS

CONNECTIONS ARE

194

CONNECTIONE

WIRE 178

CUSTOMERT

8

7

NEUTRAL BLOCK

CONNECTION PANELQT SERIES ENGINE GENERATOR

E1N1

E2 (E3)

ON

3 PHASE

E1 E2

(T3)T2T1

0F40

34-

(DISTRIBUTION PANEL)

WIR

E

WIR

E

N1

N2

WIR

E

WIR

E

057329-T

CUSTOMER LOAD

NEUTRAL BLOCK

GROUND

RTS TRANSFER SWITCH

(E3)E2E1

T1

B0D7295

T3T2

(N3)

N1N2

Figure 3.2 — R-100 to RTS


Terminals 0 and 183 in the generator AC con-nection box are not used in this application.Connection of any wires to these terminals mayresult in unwarrantable damage to the controlboard.

The load wires consist of wires run between the gen-erator main circuit breaker and the transfer mecha-nism, and a neutral wire. See Section 3.5 for loadwire sizing information.

3.5 WIRE RECOMMENDATIONS/SIZING (SEE TABLE 3)

3.5.1 CONTROL WIRINGControl system interconnections on an R-100 con-trolled generator consist of N1 and N2, and leads 23and 194. Control system interconnection leads mustbe run in a conduit that is separate from the ACpower leads. Recommended wire gauge size dependson the length of the wire:

3.5.2 COMMUNICATION WIRINGControl system interconnections on an H-100 con-trolled generator consist of RS485 + and RS485 -wires in a 2 wire, twisted pair cable with overallscreen. Communication interconnection cables mustbe run in a conduit that is separate from the ACpower leads. Recommended wire gauge size dependson the length of the cable:

3.5.3 LOAD WIRINGPower source and load line conductors must be prop-erly supported, of approved insulative qualities, andof the correct wire gauge size.

When connecting power, source, and load linesremove surface oxides from stripped ends of conduc-tors with a wire brush. Apply joint compound tostripped ends of conductors. Tighten terminals to thespecified torque value, as given in the owner's manu-al for the transfer switch.

Recommended wire gauge size depends on the cur-rent rating of the generator main circuit breaker.

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Figure 3.3 — H-100 to HTS

Max. Cable Length Recommended Wire Size

460 feet (140m) No. 18 AWG.

461 to 730 feet (223m) No. 16 AWG.

731 to 1,160 feet (354m) No. 14 AWG.

1,161 to 1850 feet (565m) No. 12 AWG.

Max. Cable Length Recommended Wire Size0 - 250 feet (76m) No. 24 AWG (Belden

8641 or equivalent)0 - 1200 feet (366m) No. 18 AWG (Belden

8760 or equivalent)

Section 3 - OperationGenerac Liquid-cooled Generators


SIZE TEMPERATURE RATING OF CONDUCTOR SIZE60° C 75° C 90° C 60° C 75° C 90° C

(140° F) (167° F) (194° F) (140° F) (167° F) (194° F)TYPES TYPES TYPES TYPES TYPES TYPES

TW¥, UF¥ FEPW¥ TA, TBS, SA TW¥ RH¥, RHW¥ TA, TBSRH¥, RHW¥ SIS, FEP¥ UF¥ THHW¥ SA, SIS,

AWG THHW¥ FEPB¥ THW¥ THHN¥ AWGkcmil THW¥ RHH¥, RHW2 THWN¥ THHW¥

THWN¥ THHN¥, THHW¥ XHHW¥ THW2, THWN2XHHW¥ THW2, THWN2 USE¥ RHH¥, RHW2

USE¥, ZW¥ USE2, XHH USE2XHHW¥ XHH, XHHW

XHHW2, ZW2 XHHW2, ZW2COPPER ALUMINUM OR COPPER CLAD ALUMINUM

18 — — 14 — — — —16 — — 18 — — — —14 20¥ 20¥ 25¥ — — — —12 25¥ 25¥ 30¥ 20¥ 20¥ 25¥ 1210 30 35¥ 40¥ 25 30¥ 35¥ 108 40 50 55 30 40 45 86 55 65 75 40 50 60 64 70 85 95 55 65 75 43 85 100 110 65 75 85 32 95 115 130 75 90 100 21 110 160 150 85 100 115 1

1/0 125 150 170 100 120 135 1/02/0 145 175 195 115 135 150 2/03/0 165 200 225 130 155 175 3/04/0 195 230 260 150 180 205 4/0250 215 255 290 170 205 230 250300 24 285 320 190 230 255 300350 260 310 350 210 250 280 350400 280 335 380 225 270 305 400500 320 380 430 260 310 350 500600 355 42 475 285 340 385 600700 385 460 520 310 375 420 700750 400 475 535 320 385 435 750800 410 490 555 330 395 450 800900 435 520 585 355 425 480 9001000 455 545 615 375 445 500 10001250 495 590 665 405 485 545 12501500 520 625 705 435 520 585 15001750 545 650 735 455 545 615 17502000 560 665 750 470 560 630 2000

¥ Unless otherwise specifically permitted in the NEC, the overcurrent protection for conductor types marked with an ¥ shallnot exceed 15 amperes for No. 14, 20 amperes for No. 12, and 30 amperes for No. 10 copper; or 15 amperes for No. 12and 25 amperes for No. 10 aluminum and copper-clad aluminum after any correction factors for ambient temperature andnumber of conductors have been applied.

TABLE 3 — ALLOWABLE AMPACITIES OF INSULATED CONDUCTORS RATED 0-2000 VOLTS, 60° TO 90° C(140° TO 194° F). NOT MORE THAN THREE CONDUCTORS IN RACEWAY OR CABLE OR EARTH(DIRECTLY BURIED), BASED ON AMBIENT TEMPERATURE OF 30° C (86° F) (REFERENCE NECTABLE 310-16)

Section 3 — OperationGenerac Liquid-cooled Generators


Section 4 - NotesGenerac Liquid-cooled Generators

Part No. 0F6618 Revision A (06/06/05) Printed in U.S.A.

P.O. Box 8 • Waukesha, WI 53187Phone: 262-544-4811

installation manual - generac parts

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