®

Installation Guidelines
Spark-Ignited Stationary Generators
Protector Series 48 kW

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. (000209b)

Register your Generac product at:

WWW.GENERAC.COM
1-888-GENERAC
(888-436-3722)

Para español , visita: http://www.generac.com/service-support/product-support-lookup

Pour le français, visiter : http://www.generac.com/service-support/product-support-lookup

SAVE THIS MANUAL FOR FUTURE REFERENCE

Use this page to record important information about this generator.
Record the information found on the unit data label on this
Model: page. For location of the unit data label, see owner’s
manual. The unit has a label plate affixed to the back of the
control panel, inside the engine compartment.
Serial: Always supply the complete model and serial numbers of the
unit when contacting an Independent Authorized Service
Dealer (IASD) about parts and service.
Prod Date Week:
Operation and Maintenance: Correct maintenance and
care of the unit ensures a minimum number of problems, and
Volts: 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
LPV Amps: 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 consid-
NG Amps: ered defects in materials or workmanship within the terms of
the warranty. Individual operating habits and usage may con-
tribute to the need for additional maintenance or service.
Hz:
When the generator requires servicing or repairs, Generac
recommends contacting an IASD for assistance. Authorized
Phase: service technicians are factory-trained and are capable of
handling all service needs. To locate the nearest IASD,
please visit the dealer locator at:
Controller P/N: www.generac.com/Dealer-Locator.

WARNING
CANCER AND REPRODUCTIVE HARM
www.P65Warnings.ca.gov.
(000393a)

2 Installation Guidelines For Spark-Ignited Stationary Generators

 Table of Contents
Section 1: Safety Rules & General Proximity to Utilities .......................................... 17
Information Transportation Recommendations .................. 17
Introduction ..........................................................5 Site Preparation ................................................. 17
Safety Rules .........................................................5 Generator Foundation ...............................................17
How to Obtain Service .................................................5 Genpad LC ................................................................17
General Hazards .................................................6 Concrete Pad ............................................................17
Dimensions ................................................................17
Exhaust Hazards ..................................................7
Stub-Up Area ............................................................. 18
Electrical Hazards ................................................7
Mounting ............................................................ 18
Fire Hazards .........................................................7 Fixed Foundation .......................................................18
Explosion Hazards ...............................................8 Connections ..............................................................18
Lifting Hazards .....................................................8 Placement on Roofs, Platforms, and Other Sup-
porting Structures ............................................. 18
Battery Hazards ...................................................8
General Rules .......................................................9 Section 4: Gaseous Fuel Systems
Before You Begin ........................................................9
Fuel Requirements and Recommendations ... 19
Standards Index ........................................................10
BTU Content ..............................................................19
Fuel Pressure ............................................................19
Section 2: Installation Planning
Fuel System Conversion .................................. 19
Introduction ........................................................11
Gaseous Fuel Properties .................................. 19
Unit Drawings .....................................................11
Natural Gas ............................................................... 19
Installation Drawings .................................................11
Liquid Propane Gas ................................................... 20
Wiring Diagrams ........................................................11
Definitions .......................................................... 20
Receiving ............................................................11
Receiving and Unpacking ..........................................11 Gaseous Fuel Systems ..................................... 21
Inspection ..................................................................11 NG System ................................................................21
Flexible Fuel Line ......................................................21
Storage Before Installation ...............................11
Primary Regulator Outlet ...........................................21
Long Term Storage ...................................................11
LP Gas System .........................................................23
Short Term Storage ...................................................11
Sediment Trap ...........................................................23
Lifting ..................................................................11
Fuel Pressure Regulators ................................. 24
Generator Location ............................................12 General ...................................................................... 24
General Location Guidelines .....................................12 Best Practices ...........................................................24
Weather Considerations ............................................12 Operating Fuel Pressure ...........................................24
Engine Fuel Consumption .........................................24
Section 3: Site Selection and Preparation Fuel Pressure Regulator Sizing .................................25
Site Selection .....................................................13 Recommended Fuel Pressure Regulators ................ 25
Carbon Monoxide ..............................................13 Primary Fuel Pressure Regulator .............................. 25
Carbon Monoxide Detectors ......................................13 Pipe Sizing Considerations .............................. 26
Potential CO Entry Points ..........................................14 General ...................................................................... 26
Protect the Structure .................................................14
Sizing LP Tanks for LP Gas Withdrawal ......... 27
Fire Prevention ...................................................15
Final Operating Test .......................................... 30
Distance Requirements .............................................15
Fuel Shutoff Valve .....................................................30
Fire Codes, Standards, and Guidelines ....................16
Fuel Pressure Test Port Location .............................. 30
Generator Maintenance .............................................16
Final Test Procedure ................................................. 31
Fresh Air for Ventilation and Cooling ..............17
Water Ingress Avoidance ..................................17

Installation Guidelines For Spark-Ignited Stationary Generators 3

Section 5: Electrical System Ventilation System Checklist ........................... 48
General Information ...........................................33 Exhaust System Checklist ................................ 48
Connecting Generator Feeder Conductors .....33 Gaseous Fuel System Checklist ...................... 48
Connecting Control Circuit Wires ....................34 Electrical System Checklist .............................. 49
Removing Rear Panel and Stub-Up Cover ......34
Section 8: Troubleshooting/Quick Reference
Typical Load Leads and Control Wiring in Stub- Guide
Up ........................................................................34
Troubleshooting ................................................ 51
Customer Load Wiring ...................................... 34
Quick Reference Guide ..................................... 52
Control Wiring Connections .............................35
RTS Series Transfer Switch With T1 Fuse/Connection Section 9: Accessories
35
Two-Wire Start .......................................................... 36 Section 10: Installation Drawings
Optional Accessory Power ...............................37 A0000293718 Rev B Page 1 of 2 ....................... 57
Installing Stub-Up Cover and Rear Panel ........37 A0000293718 Rev B Page 2 of 2 ....................... 58
Transfer Switch Location ..................................37 Alternator AC Lead Connections ..................... 59
Battery ................................................................37 Four-Lead, Single-Phase Stator ............................... 59
General Safety Precautions ...................................... 37 Alternator Power Winding Connections ......... 59
Battery Requirements ............................................... 38 Three-Phase Alternators (“Y” Configuration) ............ 59
Battery Installation .................................................... 38 Three-Phase Alternators (“Delta” Configuration) ...... 60
Alternator Wiring Diagram ................................ 61
Section 6: Control Panel Startup / Testing
Control Panel Interface .....................................39
Using the AUTO/MANUAL/OFF Buttons .................. 39
Generator Setup ................................................. 39
Setting The Exercise Timer ....................................... 39
Before Initial Startup .........................................39
Install Wizard ............................................................ 39
Interconnect System Self Test Feature ..................... 39
Before starting, complete the following: .................... 40
Activate Unit .......................................................42
Checking Manual Transfer Switch Operation .43
Operational Checks ...........................................43
Electrical Checks ...................................................... 43
Testing Generator Under Load ................................. 43
Testing Auxiliary Shutdown Switch Operation .......... 44
Checking Automatic Operation ................................. 44
Installation Summary ........................................44
Shutting Generator Down While Under Load or
During a Utility Outage ...................................... 45

Section 7: Installation Checklists

Safety Checklist ................................................. 47
Installation Planning Checklist .........................47
Foundations and Mounting Checklist ..............47

4 Installation Guidelines For Spark-Ignited Stationary Generators

 Safety Rules & General Information

Section 1: Safety Rules & General Information

Introduction not all inclusive. If using a procedure, work method, or
operating technique that the manufacturer does not spe-
Thank you for purchasing this compact, high perfor- cifically recommend, verify that it is safe for others and
mance, liquid-cooled, engine-driven generator. It is does not render the equipment unsafe.
designed to automatically supply electrical power to oper-
ate critical loads during a utility power failure. Throughout this publication, and on tags and decals
affixed to the unit, DANGER, WARNING, CAUTION, and
This unit is factory installed in an all-weather enclosure NOTE blocks are used to alert personnel to special
intended exclusively for outdoor installation. This genera- instructions about a particular operation that may be haz-
tor will operate using either vapor withdrawn liquid pro- ardous if performed incorrectly or carelessly. Observe
pane (LP gas) or natural gas (NG). them carefully. Alert definitions are as follows:
NOTE: This generator is suitable for supplying typical
residential and commercial loads such as induction DANGER
motors (sump pumps, refrigerators, air conditioners, fur-
naces, etc.), electronic components (computer, monitor, Indicates a hazardous situation which, if not avoided,
TV, etc.), lighting loads, and microwaves, when sized cor- will result in death or serious injury.
rectly.
(000001)
The information in this manual is accurate based on
products produced at the time of publication. The manu-
facturer reserves the right to make technical updates, WARNING
corrections, and product revisions at any time without Indicates a hazardous situation which, if not avoided,
notice. could result in death or serious injury.
Read This Manual Thoroughly
(000002)
WARNING
Consult Manual. Read and understand manual CAUTION
completely before using product. Failure to Indicates a hazardous situation which, if not avoided,
completely understand manual and product could result in minor or moderate injury.
could result in death or serious injury. (000100a)
(000003)
If any section of this manual is not understood, contact
the nearest Independent Authorized Service Dealer NOTE: Notes contain additional information important to
(IASD) or Generac Customer Service at 1-888-436-3722 a procedure and will be found within the regular text of
(1-888-GENERAC), or visit www.generac.com for start- this manual.
ing, operating, and servicing procedures. The owner is
responsible for correct maintenance and safe use of the These safety alerts cannot eliminate the hazards that
unit. they indicate. Common sense and strict compliance with
the special instructions while performing the action or
This manual must be used in conjunction with all other service are essential to preventing accidents.
supporting product documentation supplied with the
product.
How to Obtain Service
SAVE THESE INSTRUCTIONS for future reference. This
manual contains important instructions that must be fol- When the unit requires servicing or repairs, contact Gen-
lowed during placement, operation, and maintenance of erac Customer Service at 1-888-GENERAC (1-888-436-
the unit and its components. Always supply this manual 3722) or visit www.generac.com for assistance.
to any individual that will use this unit, and instruct them When contacting Generac Customer Service about parts
on how to correctly start, operate, and stop the unit in and service, always supply the complete model and
case of emergency. serial number of the unit as given on its data decal
located on the unit. Record the model and serial numbers
Safety Rules in the spaces provided on the front cover of this manual.

The manufacturer cannot anticipate every possible cir-

cumstance that might involve a hazard. The alerts in this
manual, and on tags and decals affixed to the unit, are

Installation Guidelines For Spark-Ignited Stationary Generators 5

Safety Rules & General Information

General Hazards
WARNING
DANGER Moving Parts. Do not wear jewelry when
starting or operating this product. Wearing
Loss of life. Property damage. Installation must jewelry while starting or operating this product
always comply with applicable codes, standards, laws could result in death or serious injury. (000115)
and regulations. Failure to do so will result in death
or serious injury. (000190)
WARNING
DANGER Moving Parts. Keep clothing, hair, and
appendages away from moving parts. Failure
Automatic start-up. Disconnect utility power and
to do so could result in death or serious injury.
render unit inoperable before working on unit.
Failure to do so will result in death or serious injury. (000111)
(000191)
WARNING
WARNING Hot Surfaces. When operating machine, do not
touch hot surfaces. Keep machine away from
Loss of life. This product is not intended to combustibles during use. Hot surfaces could
be used in a critical life support application. result in severe burns or fire.
Failure to adhere to this warning could result (000108)
in death or serious injury. (000209b)
WARNING
WARNING Equipment and property damage. Do not alter
Equipment damage. This unit is not intended for use as a prime
construction of, installation, or block ventilation for
power source. It is intended for use as an intermediate power generator. Failure to do so could result in unsafe
supply in the event of temporary power outage only. Doing so operation or damage to the generator. (000146)
could result in death, serious injury, and equipment damage.
(000247a)
WARNING
WARNING Risk of injury. Do not operate or service this machine
if not fully alert. Fatigue can impair the ability to
Electrocution. Potentially lethal voltages are generated
by this equipment. Render the equipment safe before
service this equipment and could result in death or
attempting repairs or maintenance. Failure to do so serious injury. (000215)
could result in death or serious injury.
(000187)
WARNING
WARNING Injury and equipment damage. Do not use generator
as a step. Doing so could result in falling, damaged
Accidental Start-up. Disconnect the negative battery parts, unsafe equipment operation, and could result
cable, then the positive battery cable when working in death or serious injury.
on unit. Failure to do so could result in death (000216)
or serious injury. (000130) Inspect the generator regularly, and contact an IASD for
parts needing repair or replacement.
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.
(000182a)

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.
(000155a)

6 Installation Guidelines For Spark-Ignited Stationary Generators

 Safety Rules & General Information

Exhaust Hazards
DANGER
DANGER Electrocution. Verify electrical system is
properly grounded before applying power.
Asphyxiation. Carbon monoxide can kill in Failure to do so will result in death or serious
minutes. Operate this unit outdoors only. injury.
Failure to do so will cause death or serious (000152)
injury. (000525)
DANGER
DANGER Electrocution. Do not wear jewelry while
working on this equipment. Doing so will
Asphyxiation. Running engines produce carbon
monoxide, a colorless, odorless, poisonous
result in death or serious injury.
gas. Carbon monoxide, if not avoided, will (000188)
result in death or serious injury.
(000103)
DANGER
WARNING Electrocution. Water contact with a power
source, if not avoided, will result in death
Asphyxiation. Always use a battery operated carbon
monoxide alarm indoors and installed according to or serious injury.
the manufacturer’s instructions. Failure to do so (000104)
could result in death or serious injury.
(000178a)
DANGER
WARNING Electrocution. In the event of electrical accident,
immediately shut power OFF. Use non-conductive
Fire hazard. Do not obstruct cooling and ventilating implements to free victim from live conductor. Apply
airflow around the generator. Inadequate ventilation first aid and get medical help. Failure to do so will
could result in fire hazard, possible equipment result in death or serious injury. (000145)
damage, death or serious injury.
(000217)
WARNING
Electrical Hazards
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.
DANGER (000257)
Electrocution. Contact with bare wires,
Fire Hazards
terminals, and connections while generator
is running will result in death or serious injury.
(000144)
WARNING
DANGER Fire hazard. Do not obstruct cooling and ventilating
airflow around the generator. Inadequate ventilation
Electrocution. Never connect this unit to the electrical could result in fire hazard, possible equipment
system of any building unless a licensed electrician damage, death or serious injury.
has installed an approved transfer switch. Failure to (000217)
do so will result in death or serious injury.
(000150)
WARNING
DANGER Fire and explosion. Installation must comply with all
local, state, and national electrical building codes.
Electrical backfeed. Use only approved switchgear to Noncompliance could result in unsafe operation,
isolate generator from the normal power source. equipment damage, death, or serious injury.
Failure to do so will result in death, serious injury, (000218)
and equipment damage.
(000237)

Installation Guidelines For Spark-Ignited Stationary Generators 7

Safety Rules & General Information

WARNING WARNING
Fire hazard. Use only fully-charged fire extinguishers Risk of Fire. Hot surfaces could ignite
rated “ABC” by the NFPA. Discharged or improperly combustibles, resulting in fire. Fire could
rated fire extinguishers will not extinguish electrical
result in death or serious injury.
fires in automatic standby generators.
(000219) (000110)

WARNING Lifting Hazards

Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product DANGER
could result in death or serious injury. (000100a) Risk of electrocution. Avoid touching overhead
power lines when lifting or hoisting generator.
Failure to do so will result in death or serious
WARNING injury. (000245)
Risk of Fire. Unit must be positioned in a
manner that prevents combustible material
accumulation underneath. Failure to do so WARNING
could result in death or serious injury. (000147) Personal injury. Excessive weight. Use only
appropriate lifting eyes and lifting equipment to
Comply with regulations the Occupational Safety and lift unit. Improper lifting techniques could result in
Health Administration (OSHA) has established, or with equipment damage, death or serious injury. (000224)
equivalent standards. Also, verify that the unit is applied,
used, and maintained in accordance with the manufac-
turer's instructions and recommendations. Do nothing WARNING
that might alter safe application/usage and render the Personal injury. Failure to properly connect
unit in noncompliance with the aforementioned codes, lifting cables, chains, or straps could result in
standards, laws, and regulations. death, serious injury, or property damage.
(000346)
Explosion Hazards
WARNING
DANGER Personal Injury. Do not use lifting hook if there are
Explosion and fire. Fuel and vapors are extremely signs of damage or corrosion. Doing so could result
flammable and explosive. No leakage of fuel is in death, serious injury, or property damage.
permitted. Keep fire and spark away. Failure to do (000349)
so will result in death or serious injury.
(000192)
WARNING
DANGER Personal Injury. Do not use lifting eye if there are
Explosion and fire. Connection of fuel source must be signs of damage or corrosion. Doing so could result
completed by a qualified professional technician or contractor. in death, serious injury, or property damage.
Incorrect installation of this unit will result in death, serious
injury, and property and equipment damage.
(000433)
(000151a)

Battery Hazards
DANGER
Risk of fire. Allow fuel spills to completely dry WARNING
before starting engine. Failure to do so will
result in death or serious injury. Personal Injury. Verify all fasteners are properly
tightened prior to lifting unit. Failure to do so could
(000174) result in death, serious injury, or property damage.
(000351)

8 Installation Guidelines For Spark-Ignited Stationary Generators

 Safety Rules & General Information

General Rules
DANGER
Electrocution. Do not wear jewelry while DANGER
working on this equipment. Doing so will
Loss of life. Property damage. Installation must
result in death or serious injury.
always comply with applicable codes, standards, laws
(000188) and regulations. Failure to do so will result in death
or serious injury. (000190)
WARNING
Explosion. Do not dispose of batteries in a fire.
Batteries are explosive. Electrolyte solution can cause
DANGER
burns and blindness. If electrolyte contacts skin or eyes, Electrical backfeed. Use only approved switchgear to
flush with water and seek immediate medical attention. isolate generator from the normal power source.
(000162) Failure to do so will result in death, serious injury,
and equipment damage.
(000237)
WARNING
Explosion. Batteries emit explosive gases while WARNING
charging. Keep fire and spark away. Wear protective
gear when working with batteries. Failure to do so Equipment damage. Only qualified service personnel may
could result in death or serious injury. install, operate, and maintain this equipment. Failure to
(000137a) follow proper installation requirements could result in death,
serious injury, and equipment or property damage.
(000182a)
WARNING
Electrical shock. Disconnect battery ground WARNING
terminal before working on battery or battery
Electrocution. Refer to local codes and standards for
wires. Failure to do so could result in death safety equipment required when working with a live
or serious injury. (000164) electrical system. Failure to use required safety
equipment could result in death or serious injury.
(000257)
WARNING
• Follow all safety precautions in the owner’s man-
Risk of burns. Batteries contain sulfuric acid and can
cause severe chemical burns. Wear protective gear
ual, installation guidelines, and other documents
when working with batteries. Failure to do so could included with the equipment.
result in death or serious injury. • See NFPA 70E for safety equipment required when
(000138a)
working with a live system.
• Never energize a new system without opening all
WARNING disconnects and breakers.
Risk of burn. Do not open or mutilate batteries. • Always consult local code for additional require-
Batteries contain electrolyte solution which can cause
burns and blindness. If electrolyte contacts skin or
ments for the area where unit is being installed.
eyes, flush with water and seek immediate medical • Incorrect installation can result in personal injury
attention. (000163a) and damage to the generator. It may also suspend
or void the warranty. All instructions listed below
WARNING must be followed including location clearances and
pipe sizes.
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local Before You Begin
laws and regulations. Failure to do so could result in
environmental damage, death, or serious injury. • Contact local inspector or city hall to be aware of all
(000228) federal, state, and local codes which could impact
Always recycle batteries in accordance with local laws installation. Secure all required permits before
and regulations. Contact your local solid waste collection installing.
site or recycling facility to obtain information on local • Fully comply with all relevant NEC, NFPA, and
recycling processes. For more information on battery OSHA standards, as well as all federal, state, and
recycling, visit the Battery Council International website local building and electric codes. This unit must be
at: http://batterycouncil.org installed in accordance with current NFPA 37 and
NFPA 70 standards, and any other federal, state,

Installation Guidelines For Spark-Ignited Stationary Generators 9

Safety Rules & General Information

and local codes for minimum distances from other This list is not all-inclusive. Check with the Authority Hav-
structures. ing Local Jurisdiction (AHJ) for any local codes or stan-
• Verify capacity of NG meter or LP tank in regards dards which may be applicable to your jurisdiction. The
to providing sufficient fuel for both the unit and above listed standards are available from the following
other household and operating appliances. internet sources:
* www.nfpa.org
Standards Index ** www.iccsafe.org
*** www.rerc.org Rural Electricity Resource Council P.O.
WARNING Box 309 Wilmington, OH 45177-0309
Loss of life. This product is not intended to **** www.asabe.org American Society of Agricultural &
be used in a critical life support application. Biological Engineers 2950 Niles Road, St. Joseph, MI
Failure to adhere to this warning could result 49085
in death or serious injury. (000209b)
Strictly comply with all applicable national, state, and
local laws, as well as codes or regulations pertaining to
the installation of this engine-generator power system.
Use the most current version of applicable codes or stan-
dards relevant to the local jurisdiction, generator used,
and installation site.
NOTE: Not all codes apply to all products and this list is
not all-inclusive. In the absence of pertinent local laws
and standards, the following publications may be used as
a guide (these apply to localities which recognize NFPA
and IBC).
1. National Fire Protection Association (NFPA) 70:
The NATIONAL ELECTRIC CODE (NEC) *
2. NFPA 10: Standard for Portable Fire Extinguishers *
3. NFPA 30: Flammable and Combustible Liquids
Code *
4. NFPA 37: Standard for Stationary Combustion
Engines and Gas Turbines *
5. NFPA 54: National Fuel Gas Code *
6. NFPA 58: Standard for Storage and Handling Of
Liquefied Petroleum Gases *
7. NFPA 68: Standard On Explosion Protection By
Deflagration Venting *
8. NFPA 70E: Standard For Electrical Safety In The
Workplace *
9. NFPA 211: Standard for Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances *
10. NFPA 220: Standard on Types of Building Con-
struction *
11. NFPA 5000: Building Code *
12. ICC IFGC: International Fuel Gas 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 ****

10 Installation Guidelines For Spark-Ignited Stationary Generators

 Installation Planning

Section 2: Installation Planning

Introduction Inspection
Carefully inspect generator and all contents of cartons for
DANGER any damage that may have occurred during shipment.
See shipping documentation for any provisions or guid-
Electrical backfeed. Use only approved switchgear to ance when damage is incurred. Correct all damage or
isolate generator from the normal power source.
deficiencies before installing generator.
Failure to do so will result in death, serious injury,
and equipment damage.
(000237)
Storage Before Installation
IMPORTANT NOTE: Connecting this generator to an Long Term Storage
electrical system normally supplied by an electric
utility shall be by means of a transfer switch, so as to If unit will be stored (or installed and not started) for six
isolate the electric system from the utility distribu- months or more, preserve in accordance with the manu-
tion system when the generator is operating. Failure facturer’s instructions. Contact an IASD to obtain the
to isolate the electric system by these means will Long Term Preservation and Storage Manual (Part No.
result in damage to generator and may also result in 0G4018) and the Preservation Checklist (Part No.
injury or death to utility workers due to backfeed of 0G4018A).
electrical energy.
Short Term Storage
NOTE: Only an IASD or qualified, competent installation
Proceed as follows if unit will be stored (or installed and
contractors, or electricians thoroughly familiar with appli-
not started) for less than six months:
cable codes, standards, and regulations should install
this standby electric power system. The installation must • All units are provided with an enclosure.
strictly comply with all codes, standards, and regulations • Place unit on a smooth flat surface. Do not leave
pertaining to installation. unit on shipping pallet, as it leaves the bottom open
for entry of dirt, debris, insects, rodents, etc.
Unit Drawings • If applicable, cover any exhaust system openings.
• Leave plastic plugs in fuel connection points.
Installation Drawings
• Use anti-rodent plugs and other enclosure features
See Installation Drawings. Installation drawings show to prevent entry of birds, small animals, and foreign
weights, dimensions, clearances, exhaust details, con- objects.
nection locations, wiring stub-ups, lifting locations, and
other information. Use the unit specific installation draw-
ings when designing a site installation plan. Thoroughly
Lifting
read NOTES section of each drawing for important
details. DANGER
Risk of electrocution. Avoid touching overhead
Wiring Diagrams
power lines when lifting or hoisting generator.
Wiring and schematic diagrams show connection points Failure to do so will result in death or serious
for control wiring, load wiring, and any service power sup- injury. (000245)
ply required for battery chargers, block heaters, etc.
Always use the unit specific wiring diagrams during plan-
ning and installation. WARNING
Personal injury. Excessive weight. Use only
Receiving appropriate lifting eyes and lifting equipment to
lift unit. Improper lifting techniques could result in
Receiving and Unpacking equipment damage, death or serious injury. (000224)
When applicable, handle shipping cartons and crates
with care to avoid damage. Store and unpack cartons Generators weighing more than 900 lbs (408 kg) require
with correct side up, as noted by label on shipping carton. the correct tools, equipment, and qualified personnel to
be used in all phases of handling and unpacking.
To verify personal safety and prevent damage to the unit,
use only correctly sized equipment intended for safe rig-
ging, lifting, and moving of heavy machinery.
Installation Guidelines For Spark-Ignited Stationary Generators 11
Installation Planning

Use a spreader bar to prevent damage to unit. Failure to • Verify installation site permits sufficient air flow for
use a spreader bar will result in scratches and dam- cooling and ventilation. Consider proximity of any
age to painted surfaces. walls, fences, or other noise abatement or security
See Figure 2-1. Installation drawings show lifting points barriers. Do NOT face radiator discharge end of
for rigging and lifting purposes. Always attach lifting and the enclosure into prevailing wind.
rigging devices at designated points only. Do not use lift- • Consider cold weather kit options and accessories
ing points of the engine or alternator to move generator. for generator in cold weather locations.
• Verify unit is securely fastened to mounting pad to
prevent movement caused by vibration.
• Verify all electrical connections have flexible sec-
tions to isolate vibration.
• Verify fuel pressure and pipe is sized correctly and
has the appropriate flex hose.
NOTE: Failure to comply with site selection guidelines
can result in damage to generator or surrounding area
and may cause warranty to be suspended or voided.
Extra repair labor or equipment may not be covered
under warranty if service access is difficult or restricted.
010038
Weather Considerations
Figure 2-1. Lifting Points (Four Places) Consider local weather conditions during installation.
There are various accessories available to promote fast,
Generator Location reliable starting and operation regardless of local climatic
conditions. Optional cold weather kits make engine start-
Locate generator so it is readily accessible for mainte- ing more dependable and reliable.
nance, repair, and firefighting purposes. Comply with
code requirements for minimum distance from combusti-
ble walls and building openings.

General Location Guidelines

Consider the following:
• The generator, in its protective enclosure, must be
installed outdoors.
• Supporting structure must be adequate for genera-
tor and its accessories.
• Verify installation site is clean, dry, not subject to
flooding, and provided with adequate drainage in
event of heavy rains.
• Verify installation site permits noise and vibration
to be effectively isolated.
• Verify installation site provides easy, ready access
to generator for maintenance, repair, and emer-
gency response purposes.
• See Figure 2-1. Keep a minimum clear working
space around each side of the generator to facili-
tate service or maintenance. See NEC Article
110.26 for clarification.
• Verify installation site permits engine exhaust
gases to be safely evacuated from inhabited or
occupied areas. Consider the direction of prevail-
ing winds to prevent exhaust gases from being car-
ried back to engine area or to fresh air intake vents
of nearby buildings.
• Installation site must allow for provision of an ade-
quate fuel supply.
12 Installation Guidelines For Spark-Ignited Stationary Generators
 Site Selection and Preparation

Section 3: Site Selection and Preparation

Site Selection Carbon Monoxide
Site selection is critical for safe generator operation. It is
important to discuss these factors with the installer when DANGER
selecting a site for generator installation:
Asphyxiation. Running engines produce carbon
• Carbon monoxide monoxide, a colorless, odorless, poisonous
• Fire prevention gas. Carbon monoxide, if not avoided, will
result in death or serious injury.
• Fresh air for ventilation and cooling (000103)
• Water ingress prevention IMPORTANT NOTE: Move to fresh air immediately
• Proximity to utilities and seek medical attention if you feel sick, dizzy, or
• Suitable mounting surface weak while the generator is running or after it stops.
• Servicing and periodic maintenance activities Generator exhaust contains carbon monoxide (CO)—a
The following pages describe each of these factors in poisonous, potentially lethal gas that cannot be seen or
detail. smelled. The generator must be installed in a well venti-
lated area away from windows, doors, and openings. The
NOTE: The term “structure” is used throughout this sec- selected location should not allow exhaust gases to be
tion to describe the home or building where generator is drawn into structures where people or animals may be
being installed. Illustrations depict a typical residential present.
home. However, instructions and recommendations pre-
sented in this section apply to all structures regardless of Carbon Monoxide Detectors
type. 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 pro-
tect residents or animals from CO. The only way to
detect CO is to have functioning CO alarms.

Installation Guidelines For Spark-Ignited Stationary Generators 13

Site Selection and Preparation

Potential CO Entry Points Protect the Structure

See Figure 3-1. Generator exhaust can enter a structure Verify structure itself is correctly caulked and sealed to
through large openings, such as windows and doors. prevent air from leaking in or out. Voids, cracks, or open-
However, exhaust and CO can also seep into the struc- ings around windows, doors, soffits, pipes, and vents can
ture through smaller, less obvious openings. 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.

C K

A A

A
H
D A
A F
A E
J
A
G
010044

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.
Furnace intake / Air intake and exhaust pipes for furnace.
E
exhaust vent
Includes (but not limited to) cracks in wall, foundation, mortar, or air gaps around doors,
F Wall cracks
windows, and pipes. See Protect the Structure.
G Dryer vent Exhaust duct for clothes dryer.
Structural corners and locations with heavy vegetation restrict airflow. Exhaust gases can collect
H Airflow restrictions
in such areas.
IMPORTANT NOTE: Mechanical and gravity outdoor air intake openings for HVAC supply
air systems shall be located not less than 10 feet (3048mm) horizontally from the
J Make up air system
generator enclosure. See Section 401 in the ICC Mechanical Code for any additional
requirements.
Semi-permanently mounted device that detects carbon monoxide within the living area of the
K CO detector
structure.

14 Installation Guidelines For Spark-Ignited Stationary Generators

 Site Selection and Preparation
Fire Prevention
The generator must be installed at a safe distance away Distance Requirements
from combustible materials. Engine, alternator, and See Figure 3-2. Minimum clearances must be main-
exhaust system components become very hot during tained around the generator enclosure. These clear-
operation. Fire risk increases if unit is not correctly venti- ances are primarily for fire prevention, but also to provide
lated, is not correctly maintained, operates too close to sufficient room for removing enclosure panels for mainte-
combustible materials, or if fuel leaks exist. Also, accu- nance purposes.
mulations of flammable debris within or outside the gen-
erator enclosure may ignite.

D
F

C C C
A
G
A

E 010045

Figure 3-2. Generator Distance Requirements

ID Description Definition
End and side of Minimum clearance from the ends and side of generator must be 3 ft (0.91 m). This includes
A
enclosure shrubs, bushes, and trees.
For products NOT showing SWRI on the data plate:
• 5 ft (1.52 m) minimum distance if the wall is not fire rated.
• 3 ft (0.91 m) minimum distance if the wall is one hour fire rated.
Structure side of the If the data plate indicates the product is SWRI rated:
B
enclosure 18 in (47.7 cm) minimum distance from a combustible wall (Structure side of enclosure).
NOTE: Keep maintenance considerations in mind when installing less that 5 ft from a
wall or building. There may be items with periodic maintenance requirements located on
that side of the generator needing periodic access.
Windows, vents, and No operable windows, doors, vents, window wells, or openings in the wall are permitted near any
C
openings point of the generator. See Potential CO Entry Points for more information.
The generator should not be placed closer than 18 in (457 mm) from existing walls. See spacing
D Existing wall
requirements for structure side of generator (B) above.
A removable barrier (non-permanent; without footings) installed as a visual surround.
E Removable fence Removable fence panels for servicing cannot be placed less than 3 ft (0.91 m) in front of the
generator.
5 ft (1.52 m) minimum distance from any structure, overhang, or projections from wall. 60/80kW
F Overhead clearance
units should have no such structure above the generator set.
Maneuvering space around generator for performing routine maintenance tasks such as battery
Maintenance and
G replacement and engine service. Do not attempt to conceal generator with shrubs, bushes, or
servicing
plants. See NEC Article 110.26 for more information.
Installation Guidelines For Spark-Ignited Stationary Generators 15
Site Selection and Preparation

Fire Codes, Standards, and Guidelines generator enclosure would not pose any ignition risk to
nearby combustibles or structures, with or without fire
Generator installation must comply strictly with ICC
service personnel response.
IFGC, NFPA 37, NFPA 54, NFPA 58, and NFPA 70 stan-
dards. These standards prescribe the minimum safe
clearances around and above the generator enclosure.
NFPA 37
NFPA 37 is the The National Fire Protection Associa-
tion’s standard for the installation and use of stationary
combustion engines. Its requirements limit the spacing of
an enclosed generator set from a structure or wall, and
require generator to be located where it is readily acces-
sible for maintenance, repair, and first responders.
NFPA 37, Section 4.1.4, Engines Located Outdoors:
Engines, and their weatherproof housings if provided, 002158
installed outdoors shall be located at least 5 ft (1.52 m)
from openings in walls and at least 5 ft (1.52 m) from Figure 3-3. Southwest Research Institute Marking
structures having combustible walls. A minimum separa- http://www2.swri.org/www2/listprod/
tion shall not be required where either of the following DocumentSelection.asp?ProductID=973&IndustryID=2
conditions exist:
Based on this testing and the requirements of NFPA 37,
1. The adjacent wall of the structure has a fire resis- Sec 4.1.4, the guidelines for installation of the generators
tance rating of at least one hour. listed above are changed to 18 in (457 mm) from the
2. The weatherproof enclosure is constructed of non- structure side of generator to a stationary wall or building.
combustible materials and it has been demon-
NOTE: Keep maintenance considerations in mind when
strated that a fire within the enclosure will not ignite
installing less that 5 ft from a wall or building. There may
combustible materials outside the enclosure.
be items with periodic maintenance requirements located
Annex A—Explanatory Material on that side of the generator needing periodic access.
A4.1.4 (2) Means of demonstrating compliance are by For adequate maintenance and airflow clearance, the
means of full scale fire test or by calculation procedures. area above the generator should be at least 5 ft (60/
Because of the limited spaces frequently available for 80kW models should not have any obstructions directly
installation, it has become apparent that exception (2) above the generator for fire safety) with a minimum of 3 ft
would be beneficial for many residential and commercial (0.91 m) at the front and ends of the enclosure. This
installations. The manufacturer contracted with an inde- includes trees, shrubs, and bushes. Vegetation not in
pendent testing laboratory to run full scale fire tests. compliance with these clearance parameters could
obstruct air flow. In addition, exhaust fumes from the gen-
NOTE: The Southwest Research Institute (SwRI) is a
erator could inhibit plant growth. See Figure 3-2 and the
nationally recognized third party testing and listing
accompanying descriptions.
agency. SwRI testing approves 18 in (457 mm) installa-
tion minimum from the structure side of generator to an
Generator Maintenance
adjacent structure for fire protection.
Regular maintenance is crucial for minimizing exhaust
For products NOT showing SwRI on the data plate: emissions and reducing the risk of fire or equipment fail-
• 5 ft (1.52 m) minimum distance if the wall is not fire ure. For example:
rated. • A dirty air filter or low engine oil level may cause
• 3 ft (0.91 m) minimum distance if the wall is one engine to overheat.
hour fire rated. • Incorrect spark plug gaps may cause engine
If the data plate indicates the product is SwRI rated: backfiring and incomplete combustion.
• 18 in (47.7 cm) minimum distance from a IMPORTANT NOTE: See Maintenance section of gen-
combustible wall. erator owner’s manual to view a table of scheduled
The criteria was to determine the worst case fire scenario maintenance tasks and procedures. Perform all
within the generator and to determine the ignitability of maintenance tasks as directed.
items outside the engine enclosure at various distances.
The enclosure is constructed of non-combustible materi-
als, and the results and conclusions from the indepen-
dent testing lab indicated that any fire within the

16 Installation Guidelines For Spark-Ignited Stationary Generators

 Site Selection and Preparation
Fresh Air for Ventilation and Cooling Site Preparation
Install unit where air inlet and outlet openings will not
Generator Foundation
become obstructed by leaves, grass, snow, etc. If prevail-
ing winds will cause blowing or drifting, consider using a Install the generator on a concrete pad or base slab able
windbreak at a safe distance to protect the unit. to support its weight and accessories. A correct founda-
tion is needed to resist dynamic loading and reduce
transmitted noise and vibration. The exact composition of
Water Ingress Avoidance the mounting pad must follow standard engineering prac-
• Select a location on high ground where water tices for the required loading and application. Securely
levels will not rise and flood the generator. This unit fasten generator to the foundation using suitable
should not operate in, or be subjected to, standing grade, size, and style fasteners. Holes are provided in
water. the base frame for this purpose.
• Install unit where rain gutter downspouts, roof run-
off, landscape irrigation, water sprinklers, or sump
Genpad LC
pump discharge does not flood unit or spray Protector series generators can be installed on the pre-
enclosure, including any air inlet or outlet fabricated Genpad LC mounting pads designed for the
openings. particular generator product. The Genpad LC is a third-
• Excess moisture can cause excess corrosion and party product available exclusively for Protector series
decrease life expectancy of the unit. generators through Generac.

Concrete Pad
Proximity to Utilities Follow all federal, state, and local codes when designing
• Contact local utility providers and verify proposed a concrete pad or base slab.
site selection meets all required utility placement Seat concrete pad on a prepared solid subsurface and
requirements before installation. This could affect use appropriate reinforcing bar or expanded wire mesh.
warranty coverage. A common specification calls for 2,500 psi (17.24 MPa)
• Remember, laws and or codes may regulate concrete reinforced with 8 gauge wire mesh.
distance and location of unit to specific utilities.
Dimensions
• It is recommended to pick a location where the
generator is as close as possible to the transfer Extend concrete pad beyond the frame of the unit at least
switch and the fuel supply, while verifying the site 3 in (7.62 cm). A concrete pad extending 6 in (15.2 cm)
location conforms to the rest of the Site Selection beyond the frame of the unit is suggested to provide a
section. mounting surface for fuel line support, and space for
maintenance and repair.
Transportation Recommendations The base pad must be:
Use a suitable cart or equipment to carry generator, • Capable of supporting 125% of the unit wet weight
including wooden pallet, to installation site. Place card- for single unit applications.
board between cart and generator to prevent any dam- • Flat and level to within 0.5 in (13 mm).
age or scratches to generator. • Capable of withstanding severe torque reactions.
Do not lift, carry, or move generator by grasping the To calculate the depth of the concrete pad, the following
louvers. Doing so may bend or damage the sheet formula may be used:
metal.
W
Depth of Base =
Density x B x L
W = Total wet weight of generator set in pounds (kg)
Density = Density of the concrete:
• 150 pounds per ft3
• 2,400 kilograms per m3
B = Foundation width in ft (m)
L = Foundation length in ft (m)
Suggested mixture of concrete (by volume) is 1:2:3 of
cement, sand, and aggregate with a maximum 4 in (100
mm) slump with a 28 day compression strength of 3,000
psi (20.7 MPa).

Installation Guidelines For Spark-Ignited Stationary Generators 17

Site Selection and Preparation

Stub-Up Area Placement on Roofs, Platforms, and

For load conduit, auxiliary power conduit (high voltage), Other Supporting Structures
and control wiring conduit (low voltage), see unit installa- Where required to place generator on a roof, platform,
tion drawings for location and dimensions of the stub-up deck, or other supporting structure and an oil contain-
area. Figure 3-4 illustrates a typical stub opening (A). ment system consisting of a curb or dike shall be pro-
vided in accordance with the requirements in NFPA 37
chapter 4.1.3 and chapter 6. Contact local building
inspection department or fire department to determine
which noncombustible materials are approved for instal-
lation.
In. (mm)

A
4.1 (104.5)

1.9 (50) 0.4 (9) 2.0 (51)

3.9
(100)
002771
Figure 3-4. Installation Drawing Stub-Up Detail
(Typical)

Mounting
Fixed Foundation
Use mounting holes in the base frame to fasten unit to
foundation. Always use hardware of a suitable grade,
size, and style.

Connections
All electrical connections must have flexible sections to
isolate vibration if they connect to the unit base rails. Cor-
rectly support and secure all piping before installing the
flexible connection.
The surface beneath and beyond the engine and the oil
containment system must be noncombustible to a mini-
mum distance of 12 in (300 mm).

18 Installation Guidelines For Spark-Ignited Stationary Generators

 Gaseous Fuel Systems

Section 4: Gaseous Fuel Systems

Fuel Requirements and Piping strength and connections should be given special
consideration when installation takes place in areas at
Recommendations risk for; flooding, tornadoes, hurricanes, earthquakes,
and unstable ground.
DANGER NOTE: Use an approved pipe sealant or joint compound
Explosion and fire. Fuel and vapors are extremely on all threaded fittings.
flammable and explosive. No leakage of fuel is
permitted. Keep fire and spark away. Failure to do NOTE: All installed gaseous fuel piping must be purged
so will result in death or serious injury. and leak tested prior to initial startup in accordance with
(000192) local codes, standards, and regulations.
NOTE: NG is lighter than air and will collect in high
areas. LP gas is heavier than air and will settle in low Fuel System Conversion
areas. Commercial units are factory-configured and EPA certi-
LP gas should only use a vapor withdrawal system. This fied with the fuel system ordered. Units are factory-con-
type of system uses vapors formed above liquid propane figured for NG, and can be reconfigured for LP in the
in the storage tank. field.
The unit will run on NG or LP gas, but has been factory- Any one of the following gaseous fuel systems may be
configured to run on NG. installed:
• Natural Gas (NG)
NOTE: Should the primary fuel need to be changed to
LP gas, the fuel system needs to be reconfigured. See • LP Gas Vapor Withdrawal
Fuel System Conversion for instructions on converting To convert to a different fuel (for example, from NG to LP
fuel system. gas vapor), see owner's manual or contact an IASD.

BTU Content
Gaseous Fuel Properties
Recommended fuels should have a BTU content of at
least 1,000 BTU/ft3 (37.26 MJ/m3) for NG; or at least Natural Gas
2,500 BTU/ft3 (93.15 MJ/m3) for LP gas. NG is lighter than air. It is found in the gaseous state at
NOTE: BTU fuel content information is available from the normal ambient temperatures and pressures. It is highly
fuel supplier. explosive and can be ignited by the slightest spark. For
this reason, fuel lines must be free of leaks and adequate
Fuel Pressure ventilation is required. Local fuel/gas codes dictate maxi-
Required fuel pressure for NG is 3.5–14 in water column mum pressure under which NG can be delivered to a site
(0.87–3.48 kPa) and LP gas is 7–14 in water column or structure. Supply pressure from utility meter/regulator
(1.74–3.48 kPa). Always verify fuel pressure using the is usually not the same as required by generator, so a
appropriate specification sheet for the generator. separate primary regulator providing the correct pressure
and volume of fuel to generator is required. If local utility
NOTE: The primary regulator for LP gas supply is NOT source fuel pressure is less than required by generator, it
INCLUDED with generator. is up to local utility to provide volume of fuel at the
NOTE: All pipe sizing, construction, and layout must required pressure.
comply with ICC IFGC, NFPA 54 for NG applications, and
NFPA 58 for LP gas applications. Verify fuel pressure
NEVER drops below required specification once genera-
tor is installed. See the NFPA website at www.nfpa.org
for further information regarding NFPA requirements.
Always contact local fuel suppliers or fire marshal to ver-
ify codes and regulations for correct installation. Local
codes will mandate correct routing of gaseous fuel line
piping around gardens, shrubs, and other landscaping.

Installation Guidelines For Spark-Ignited Stationary Generators 19

Gaseous Fuel Systems

Liquid Propane Gas

LP gas is heavier than air. The LP gas vapors are explo- liquid volume in the tank, and can be over 200 psi (1,379
sive and can be ignited by the slightest spark. LP gas is kPa). A first-stage regulator at the tank reduces fuel pres-
supplied by liquid propane stored in tanks. Propane sure to a lower line pressure value. This line pressure is
exists in its liquid form at or below its boiling point (-44 º F then reduced to the correct operating pressure and vol-
[-42 °C]) as well as when stored under pressure. LP tank ume for the generator through the use of a second-stage
pressure is dependent on ambient temperature and the regulator included with the unit.

Definitions
The following definitions are provided for use in this manual:

Term Description

Allowable Pressure Design pressure loss in the system under maximum probable flow conditions, from point of delivery to
Drop inlet connection of generator, shall be such that supply pressure at the generator is greater than or equal
to the minimum pressure required by generator at its full load capacity.

Authority Having An organization, office, or individual responsible for enforcing requirements of a code or standard, or for
Jurisdiction (AHJ) approving equipment, materials, an installation, or a procedure.
(NFPA-54)

Cubic Foot (ft3) of Amount of gas that would occupy 1 ft3 (0.03 m3) when at a temperature of 600 °F (316 °C) saturated with
Gas (NFPA-54) water vapor and under a pressure equivalent to 30 in water column (7.47 kPa).

Generator Connection point for fuel supply system to generator is the end of the manufacturer supplied flexible fuel
Connection Point line fitting, which connects to fitting through base frame rail. An elbow and short nipple can be incorpo-
rated to allow the flexible fuel line to be positioned parallel to unit base frame. Size of fuel connection point
is shown in each unit’s installation drawing; size of the flexible fuel line (and any elbow and nipple) must
be equal to or larger than this connection point. Flexible fuel line must be installed straight without bend-
ing, twisting, or kinking.

psi & psig Measure of pressure in pounds per square inch and pounds per square inch gauge.

In of Water Measure of gaseous fuel pressure in inches of water column: 14 in water column = 3.48 kPa
Column

Primary Regulator A pressure regulator installed between the service regulator (NG) or first-stage regulator (LP gas) sized to
provide pressure and volume required by generator at its full rated load capacity.

Regulator (for LP gas)

First-Stage A pressure regulator for LP gas service designed to reduce pressure from a container to 10.0 psig or less.
Regulator

High-Pressure A pressure regulator for LP gas liquid or vapor service designed to reduce pressure from container to a
Regulator lower pressure in excess of 1.0 psig.

Second-Stage A pressure regulator for LP gas service designed to reduce first-stage regulator outlet pressure to 14 in
Regulator water column (3.48 kPa) or less. For generator purposes, this is also referred to as the primary regulator.

Regulator (for NG)

Pressure Regulator Device placed in a fuel line for reducing, controlling, and maintaining pressure in downstream piping.

Service Regulator A pressure regulator installed by the servicing fuel supplier to reduce and limit the service line fuel pres-
sure to delivery pressure.

20 Installation Guidelines For Spark-Ignited Stationary Generators

 Gaseous Fuel Systems

Gaseous Fuel Systems

NG System
The utility gas provider will provide the gas meter. Con-
Primary Regulator Outlet
tact utility gas provider to verify they offer a gas meter
that will deliver a sufficient fuel supply. Local utility is also Primary regulator outlet and generator connection point
responsible for providing fuel at sufficient volume and must be sized correctly to provide generator with
pressure to operate the primary regulator. Primary regu- required volume and pressure when it is operating at
lator can then provide the correct volume of fuel at the 100% of its rated load.
required pressure to generator. The unit-mounted regulator (it may be either a demand
The piping system between the primary pressure regula- regulator or a pressure regulator) and its associated
tor and generator must be correctly sized to provide fuel shutoff valves control flow and pressure to unit for correct
volume required at 100% load, while also staying within operation. The fuel pressure required for generator to
pressure range noted on unit specification sheet. operate is always measured at the primary fuel valve.
See Fuel Shutoff Valve for location of the pressure test
Follow regulator manufacturer's recommendation for
connection. Supply pressure and volume must meet
placement and mounting of regulator.
requirements described in unit specification sheet. If
A minimum of five (5) feet from the inlet of the generator specifications are not met, generator will not operate cor-
is recommended. A larger distance may be required by rectly and may display symptoms such as hard starting,
the regulator manufacturer or authority having jurisdic- rough running, inability to carry load, and erratic opera-
tion. tion.
Flexible Fuel Line Fuel pressure from primary regulator (supplied by install-
ing contractor) to generator's fuel shutoff valve should be
Flexible fuel line isolates vibration from generator to between 3.5–14 in water column (0.87–3.48 kPa).
reduce possibility of a fuel leak at one of the connection Always verify fuel pressure using the appropriate specifi-
points. cation sheet for the generator.
From the primary regulator, fuel flows to generator con-
nection point, which is the end of the manufacturer sup-
plied flexible fuel line. Flexible fuel line must not be
connected directly to generator connection point. Always
connect flexible fuel line to an approved gas fitting (per-
pendicular to frame rail, or by an elbow and short nipple
to fuel inlet itself (to run parallel to frame rail). The nipple
and elbow used must be the same pipe size as flexible
fuel line and generator connection point.
When connecting flexible fuel line to generator, use a
listed nonmetallic assembly meeting the requirements of
ANSI Z21.75/ CSA 6.27—Connectors for Outdoor Gas
Appliances and Manufactured Homes or AGA-approved
flexible fuel line in accordance with local regulations.
NOTE: Follow all installation instructions and warnings
provided with flexible fuel line. Do not remove any labels
or tags. Installation must always comply with applicable
codes, standards, laws, and regulations.
Additional flexible fuel line options can be ordered. Con-
tact an IASD for more information on sizes and availabil-
ity.

Installation Guidelines For Spark-Ignited Stationary Generators 21

Gaseous Fuel Systems

B C
A
D

009908

A Manual fuel shutoff valve C Primary regulator

B Sediment trap D Flexible fuel line
Figure 4-1. Typical NG System

22 Installation Guidelines For Spark-Ignited Stationary Generators

 Gaseous Fuel Systems

LP Gas System
See Figure 4-2. LP gas uses vapors formed above liquid Fuel pressure from the primary regulator (supplied by
propane in fuel supply tank (A). The maximum fuel tank installing contractor) to generator's fuel shutoff valve (B)
fill capacity is 80% and a minimum of approximately 20% should be between 7–14 in water column (1.74–3.48
of fuel tank capacity is needed for fuel expansion from liq- kPa). Always verify fuel pressure using the appropriate
uid to vapor state. Fuel pressure and volume require- specification sheet for the generator.
ments for a LP gas system at the connection point of the The piping system connecting outlet of the first-stage
generator are listed on the unit specification sheet. regulator to the connection point on the second-stage
Pressure regulation for vapor withdrawal systems is typi- regulator must be correctly sized to provide fuel volume
cally a two-step process. First, by reducing high tank required by unit at 100% load.
pressure to a lower line pressure with a first-stage regula- The piping system between outlet of second-stage regu-
tor (C), then reducing line pressure to pressure required lator and generator connection point must be sized to
by unit with a second-stage regulator (E). Both regulators provide fuel volume required by generator at 100% load,
and associated system piping and valves need to be while also staying within pressure range noted on the unit
sized correctly to provide generator with the required vol- specification sheet.
ume and pressure of fuel at the generator connection Follow regulator manufacturer's recommendation for
point. placement and mounting of the regulator.
A minimum of five (5) feet from the inlet of the generator
is recommended. A larger distance may be required by
the regulator manufacturer or authority having jurisdic-
tion.

B A
E
B C

D
F

009909

A Fuel supply tank D Sediment trap

B Manual fuel shutoff valve E Second-stage regulator
C First-stage regulator with relief valve and pressure tap F Flexible fuel line
Figure 4-2. Typical LP Gas Withdrawal Fuel System

Sediment Trap
Some local codes require a sediment trap (D). The sedi-
ment trap must be installed downstream of the generator
fuel shutoff valve, and as close as practical to the inlet of
the generator. Sediment trap must be either a tee fitting
having a capped nipple installed vertically in the lowest
opening of the tee fitting, or a device approved for use as
an effective sediment trap.

Installation Guidelines For Spark-Ignited Stationary Generators 23

Gaseous Fuel Systems

Fuel Pressure Regulators • Seasonal supply pressure changes to primary

pressure regulator can affect correct operation of
General the generator. Fuel supply pressure to unit must
remain within specified operating parameters as
A common cause of a generator not operating correctly is
stated in the unit specification sheet. Contact local
incorrect sizing and installation of gaseous fuel supply
utility to find out what can be done to correct sea-
system between gas meter (utility source) and generator
sonal changes.
connection. The fuel supply system consists of a primary
regulator to regulate flow and volume from fuel source • Use sediment traps.
(utility supply) to generator, and all of the associated pip- • Generator must have its own dedicated fuel supply.
ing, fittings, and shutoff valves, both upstream (feeding Do not connect any other loads to the outlet of the
main meter/regulator) and downstream (between meter primary pressure regulator.
and primary regulator), which connect fuel source to con- For LP gas systems, due to the nature of the conversion
nection point on generator. Fuel supply system must be process from LP liquid to LP vapor, consider the follow-
capable of supplying the correct volume of fuel within the ing:
correct pressure range to connection point on generator.
• Vaporization rate of a given LP tank is dependent
The volume of fuel and operating pressure required are
on the liquid level in tank (wetted surface area),
listed in the technical specifications for the applicable
ambient temperature around tank, and relative
generator. Fuel pressure at unit must remain within spec-
humidity.
ified operating range and not drop below minimum pres-
sure specified. • When ambient temperatures are below 40 °F (4
°C), engine fuel consumption is high, and sufficient
Best Practices humidity is present, condensation can occur result-
ing in frosting of the tank at the liquid level. This
These are the manufacturer recommended best prac-
condition can lead to a reduced rate of vaporiza-
tices for configuring and sizing fuel supply piping to gen-
tion. See LP tank sizing section for more informa-
erators. These best practices have been developed
tion.
specifically for the manufacturer’s product and may not
represent conventional gaseous fuel system sizing meth- Operating Fuel Pressure
ods, particularly those used frequently with low volume
appliance installations. Compliance with these best prac- The unit specification sheet lists operating fuel pressure
tices will help to verify the generator engine will operate range, as well as 100% load fuel consumption rate. Pres-
correctly under dynamic conditions. sure range is minimum and maximum acceptable pres-
sures for correct operation of the unit under all operating
• Minimum distance from primary pressure regulator
conditions. Maximum fuel system pressure drop at each
outlet to generator connection point is covered in
condition, that is, static, cranking, running at no load, and
the pressure regulator manufacturer's installation
running at full load, is 1–2 in water column (0.25–0.50
instructions. Do not connect pressure regulator
kPa) as measured at primary fuel pressure regulator. See
directly to flexible fuel line on generator. Piping
Final Test Procedure for definitions of each condition.
between primary pressure regulator and connec-
tion point on the generator acts as a reservoir Engine Fuel Consumption
(accumulator) which stores fuel and, therefore, can
minimize or maximize changes in delivery pressure Volume of gaseous fuel consumed at various loads is
that the generator sees during cranking and load listed in the unit specification sheet. Both NG and LP gas
changes. values are provided in cubic feet per hour (CFH). Interna-
tional units of measure are also provided.
• See Fuel Shutoff Valve. Required fuel pressure to
unit is measured before the fuel shutoff solenoids Use the following formulas if it becomes necessary to
at the inlet to the unit mounted regulator. A 1/8 in convert CFH to BTUs per hour:
pipe port in the pressure regulator body, or in the
piping just before the pressure regulator, is pro-
vided for this purpose.

• Natural Gas: CFH x 1000 = BTU per hour • LP Vapor: CFH x 2500 = BTU per hour
• Natural Gas: CMH x 37.26 = MJ per hour • LP Vapor: CMH x 93.15 = MJ per hour
NG Operating Range: 3.5–14 in water column (0.87– LP Operating Range: 7–14 in water column (1.74–3.48
3.48 kPa) kPa)

24 Installation Guidelines For Spark-Ignited Stationary Generators

 Gaseous Fuel Systems

Fuel Pressure Regulator Sizing increases. It is stated as a percent, in inches of water col-
umn, or in kPa, and indicates the difference between out-
Fuel pressure regulators are designed to automatically
let pressure at low flow rates and outlet pressure at the
adjust flow to meet downstream demand at a required
published maximum flow rate. Droop is also called offset
pressure. The typical regulator installed as the primary
or proportional band. For correct generator operation, a
regulator for a generator is of the direct acting, internally
maximum of 1–2 in water column (0.25–0.50 kPa) droop
registered design. “Direct acting” means the pressure
is required at each operating condition; static, cranking,
sensing element acts directly to open the fuel valve and
running at no load, and running at full load.
control flow to load while maintaining desired pressure.
The pressure sensing element is typically a diaphragm 2. Verify generator has a dedicated fuel supply which
which is opposed by a combination of spring pressure is not shared with any other appliances (furnace,
and atmospheric pressure. The valve is the restricting water heaters, ranges, etc.).
element and consists of some type of variable restriction 3. Verify inlet fuel pressure measured at pressure
(cone, poppet, disc) which closes against a fixed seat. regulator body inlet connection when pressure reg-
Internal registration means the pressure used for sensing ulator appears unable to pass published flow rate.
comes from within the valve body, usually through a pas- Supply piping up to regulator can cause significant
sage from the secondary side (outlet) to the sensing dia- flowing pressure losses.
phragm.
4. Verify pressure regulator is flowing at least 5% of
The primary regulator must be sized to provide required normal operating flow when adjusting pressure set
flow at rated pressure to generator at its full load capac- point.
ity. Generator fuel consumption values and required
5. Expect approximately a 1 °F (0.5 °C) drop in fuel
operating pressures are listed on unit specification sheet.
temperature for every 15 psid (differential) across
The manufacturer recommends primary pressure regula- regulator due to natural refrigeration effect.
tor be sized for at least 110% of generator’s required fuel
consumption at 100% load, and pressure regulator pro- NOTE: Freezing is often a problem when ambient tem-
vide no more than a 1–2 in water column (0.25–0.50 kPa) perature is between 30–45 °F (-1–7 °C), particularly with
pressure drop at each operating condition; static, crank- LP gas systems.
ing, running at no load, and running at full load. 6. Point vents down to help avoid accumulation of
Various regulator manufacturers provide sizing tables, water condensation or other materials in spring
flow capacity, pressure drop tables, and distributors who case.
will help size a regulator correctly to a system. 7. Keep vents open. Do not use long, small diameter
vent lines. Follow the rule-of-thumb: use the next
Recommended Fuel Pressure Regulators nominal pipe size for every 10 ft (3 m) of vent line,
Use only fuel pressure regulators marked as “direct act- and use 3 ft (0.9 m) of vent line for every elbow in
ing.” the line.
8. The connection point on generator is the end of
Primary Fuel Pressure Regulator manufacturer supplied flexible fuel line. The flexible
The following are the manufacturer’s recommendations fuel line is the same size as the connection point
for specifying, sizing, and installing the primary fuel pres- through base frame rail (see installation drawings).
sure regulator. It is permissible to install one elbow (90º) and a
1. Verify regulator: short nipple between flexible fuel line and fuel con-
nection point to allow flexible fuel line to parallel
• is sized to have a fuel flow delivery rating equal to
generator for installation purposes.
fuel consumption requirements of generator.
NOTE: The recommended selection for orifice diameters
is to use smallest orifice that will still provide a CFH fuel
flow rate at least 1.1 times greater than the required full
load CFH rating of generator.
• is approved for a mechanized engine application.
• has a spring rating within range of fuel pressure
listed in the generator specification sheet.
• has an accuracy rating of 1% or less and/or have a
maximum allowable pressure droop rate of 1–2
water column (0.25–0.50 kPa).
NOTE: “Droop” is reduction of outlet pressure experi-
enced by pressure-reducing regulators as flow rate

Installation Guidelines For Spark-Ignited Stationary Generators 25

Gaseous Fuel Systems

Pipe Sizing Considerations

General • Install supplied or recommended length of flexible
Contact a local fuel distributor or licensed installer when fuel line between generator connection point and
sizing and installing piping for any gaseous fuel supply the rigid supply piping. Do not install flexible fuel
system. When using a local fuel distributor or installer, line underground or in contact with the ground.
verify they have correct documentation to support their NOTE: Some manufacturers offer flexible fuel line spe-
recommendations. Fuel system requirements and best cifically designed to permit bends. Do not allow any
practices conveyed in this manual must be provided to bends, twists, or kinks in the installation unless certain
the representative responsible for sizing fuel system. The the flexible fuel line is approved for that purpose. Contact
final test of the system is measuring fuel pressure as flexible fuel line manufacturer for specifications.
described in Fuel Shutoff Valve. The fuel supply system
is not correct if pressure requirements are not met.
• Correctly size piping to maintain required supply
pressure and volume under varying load condi-
There are several pipe sizing programs available for use tions.
on the Internet and from various manufacturers. If used, it
is highly recommended that minimum pressure drop
• Correctly purge and leak test installed piping.
value always be used (0.5 in water column [0.12 kPa] or • Use an approved pipe sealant or joint compound
less). This verifies piping system is sized correctly to han- on all threaded fittings to reduce possibility of leak-
dle generator volume at full load, and during cranking age.
and load transients, while also remaining above minimum • Make provision for a fuel shutoff valve near unit.
operating fuel pressure. Verify fuel shutoff valve is installed correctly and
The following general rules apply to piping of gaseous works correctly.
fuel systems: • Inspect entire pipe run for leaks using suitable
• Use black iron piping or other approved fuel line. methods.
Fuel line must be rigidly mounted and protected
against vibration.
Table 4-1. NG Pipe Sizing
NG 3.5–14 in of Water Column (0.87–3.48 kPa)
Table values are maximum pipe run in ft (m)
kW 0.75 in 1 in 1.25 in 1.5 in 2 in 2.5 in 3 in
(1.9 cm) (2.5 cm) (3.2 cm) (3.8 cm) (5.1 cm) (6.4 cm) (7.7 cm)
48 — — 40 (12.2) 90 (27.4) 300 (91.4) 750 (228.6) —
Note: Size the fuel pipe to the sizing charts or to local codes. When installing other than Sch. 40 black pipe, see manufacturer’s sizing charts.
The liquid-cooled generator is not a constant flow appliance. The fuel pipe was sized large enough to supply at least 100% of the generator BTU/
hr rating.
Natural Gas Note:
• 1 ft3 (28.31 L) = 1,000 BTU (1.055 MJ) • Pipe sizing is based on 0.5 in water column (0.12 kPa) pressure
• 1 therm = 100,000 BTU (105.5 MJ) drop.
• Fuel consumption = 13,000–16,000 BTU per kW/hr • Sizing includes a nominal number of elbows and tees.
• Please verify adequate service and meter sizing.
Pressure • Tables based on black pipe.
1 in mercury = 13.61 in water column
1 in water column = 0.036 psi
3.5–14 in water column = 0.126 psi to 0.50 psi

26 Installation Guidelines For Spark-Ignited Stationary Generators

 Gaseous Fuel Systems

Table 4-2. LP Gas Pipe Sizing

LP Gas 7–14 in of Water Column (1.74–3.48 kPa)
Table values are maximum pipe run in ft (m)
kW 0.75 in 1 in 1.25 in 1.5 in 2 in 2.5 in 3 in
(1.9 cm) (2.5 cm) (3.2 cm) (3.8 cm) (5.1 cm) (6.4 cm) (7.7 cm)
48 — — 125 (38.1) 300 (91.4) 900 (274.3) — —
Note: Size fuel pipe to the sizing charts or to local codes. When installing other than Sch. 40 black pipe, see manufacturer’s sizing charts.
The liquid-cooled generator is not a constant flow appliance. The fuel pipe was sized large enough to supply at least 100% of the generator BTU/
hr rating.
LPG Note:
• 8.55 ft3/lb (548.02 L/kg) • Pipe sizing is based on 0.5 in water column (0.12 kPa) pressure drop.
• 4.24 lbs/gal (0.51 kg/L) • Sizing includes a nominal number of elbows and tees.
• 2500 BTU/ft3 (93.2 kJ/L) • Verify adequate service and meter sizing.
• 36.3 ft3 = 1 gal (0.272 m3/L) • Tables based on black pipe.

Pressure
1 in water column = 0.25 kPa
7–14 in water column = 1.74–3.48 kPa

Sizing LP Tanks for LP Gas Withdrawal

The manufacturer recommends the installer contact a tank capacity to be used to calculate run time. Most
reputable LP gas supplier when sizing LP gas storage tank sizing tables provide vaporization rate of LP
tanks and the associated pressure regulators and piping gas tank at lowest allowable level (20%); any tank
systems. Many factors come into play when working with level above this point will have a higher vaporiza-
LP in either its vapor or liquid form. tion rate.
The operation of an LP gas system depends on vaporiza- • Lowest normal temperature expected. Typical tank
tion of liquid propane stored in the tanks. As vapor above tables provide vaporization rates at 40 °F, 20 °F,
liquid propane level is withdrawn, pressure in LP gas tank and 0 °F (4 °C, -7 °C, and -18 °C). For tempera-
decreases. This change in pressure causes LP gas to tures below 0 °F (-18 °C), contact a reputable LP
“boil” in order to restore pressure equilibrium. The liquid gas dealer for options.
propane in the tank uses the temperature difference • Mean relative humidity.
between its boiling point (-44 °F [-42 °C] for propane) and
The following information is required to size an LP tank
the outside temperature to extract enough heat to enable
for a desired run time:
vaporization (boiling). Only liquid in contact with LP gas
tank wall absorbs heat from outside. The area of LP gas • Maximum vapor consumption of generator (in BTU/
tank where liquid is in contact with LP gas tank wall is hr) at 100% load. The specification sheet for the
referred to as the “wetted surface area”. Cold weather generator will list fuel consumption rate, usually in
results in a reduced tank vaporization capacity because ft3/hr. To convert CFH to BTU/hr, multiply by 2,520.
there is less heat energy available to boil off liquid pro- • Fuel consumption rate in gallons per hour (gph)
pane into vapor. The wetted surface area of LP gas tank with generator at 100% load. To convert CFH (pro-
must be large enough to sustain vaporization rate pane vapor) to gph, divide by 36.38. To convert
required by generator. Depending on relative humidity BTU/hr to gph, divide by 91,502.
and ambient temperature, frosting can occur on outside • Desired run time.
of LP gas tank when it is in use. This condition further
• Minimum operating temperature expected.
inhibits the heat transfer required to sustain vaporization.
The most important thing to consider when sizing LP gas
Several factors affect rate of vaporization for LP gas
tanks for vapor withdrawal is the vaporization rate of LP
tanks:
gas tank at minimum temperature expected, and at mini-
• Size of tank (wetted surface area). As wetted sur- mum fuel level tank will be allowed to reach. Vaporization
face area decreases, rate of vaporization de- rates shown in Table 4-3 are based on the tank at 20%
creases. fill capacity.
• Lowest liquid level tank will be allowed to reach 1. Multiply gph fuel consumption rate of generator at
(relates directly to wetted surface area). Typical 100% load by longest run time expected/desired.
maximum fill level for LP gas tanks is 80%, and
2. Determine fuel consumption in BTU/hr with gener-
lowest recommended operating level is 20%. This
ator at 100% load.
provides a volume equivalent to 60% of LP gas
3. Determine lowest expected operating temperature.

Installation Guidelines For Spark-Ignited Stationary Generators 27

Gaseous Fuel Systems

4. See Table 4-3. Using both Minimum Operating

Temperature and Tank Vaporization Capacity col-
umns, find the BTU/hr vaporization rate of the gen-
erator at 100% load corresponding to the lowest
expected operating temperature.
5. See column 2, and note the Available Tank Capac-
ity. If it is greater than total run time fuel consump-
tion, see column 1 – this is the correct size tank
required. If it is less than total run time fuel con-
sumption, see next larger tank size. Verify lowest
operating temperature and tank vaporization
capacity.

28 Installation Guidelines For Spark-Ignited Stationary Generators

 Gaseous Fuel Systems

Table 4-3. Vaporization Rates

Total Tank Available Tank Minimum Tank Vaporization

Capacity Capacity Operating Capacity Length Diameter
gal (L) gal (L) Temperature BTU/hr (MJ/hr) in (cm) in (cm)
See Note 1 See Note 2 °F (°C) See Note 3

250 (946.4) 150 (567.8) 40 (4.4) 507,600 (535.5) 94 (238.8) 30 (76.2)

20 (-6.6) 338,400 (357)
0 (-17.8) 169,200 (178.5)

325 (1,230.3) 195 (768.2) 40 (4.4) 642,600 (683.3) 119 (302.3) 30 (76.2)
20 (-6.6) 428,400 (452)
0 (-17.8) 214,200 (226)

500 (1,892.7) 300 (1,135.6) 40 (4.4) 792,540 (836.2) 119 (302.3) 37 (93.9)
20 (-6.6) 528,360 (557.4)
0 (-17.8) 264,180 (278.7)

850 (3,217.6) 510 (1,930.6) 40 (4.4) 1,217,700 (1,284.7) 165 (419.1) 41 (104.1)
20 (-6.6) 811,800 (856.5)
0 (-17.8) 405,900 (428.2)

1,000 (3,785.4) 600 (2,271.2) 40 (4.4) 1,416,960 (1,495) 192 (487.7) 41 (104.1)
20 (-6.6) 944,640 (996.6)
0 (-17.8) 472,620 (498.6)

Note 1: Minimum tank size should be sized large enough to provide correct fuel capacity to generator at full load. Contact a LP
gas provider for correct tank sizing.
Note 2: Available tank capacity is approximately 60% of total fill capacity. This is based on a maximum fill level of 80% and a min-
imum operating level of 20% (80% - 20% = 60%).
Note 3: Vaporization capacity shown is based on a tank level of 20%. This represents the smallest allowable wetted surface area
of the liquid in the tank. As liquid propane level goes up, wetted surface area and vaporization rate increases.

Length

Height
Propane Diameter

Figure 4-3. Typical Propane Tank Dimensions

Propane conversion figures:

• 36.38 ft3 = 90,500 BTU = 1 gal • 1 lb = 21,500 BTU = 8.56 ft3 • 2500 BTU = 1 ft3
• 0.001 m3 = 21 MJ = 1 L • 1 kg = 10.3 MJ = 0.11 m3 • 1.13 MJ = 1 m3

Installation Guidelines For Spark-Ignited Stationary Generators 29

Gaseous Fuel Systems

Final Operating Test Fuel Pressure Test Port Location

A correctly configured and sized fuel system provides the 1. See Figure 4-5. Using a suitable pressure gauge
fuel volume and fuel pressure required for the generator or water manometer, measure fuel pressure to the
set to operate correctly in all modes of operation. To ver- generator at a test port located at the fuel solenoid
ify correct fuel system operation, a series of tests must shutoff valve(s).
be performed as described below. NOTE: Take necessary readings as quickly as possible.
Severe deformation of valves may occur if gauge adapter
Fuel Shutoff Valve probe is left in test port plug for a period of hours or days.
Most applications will require an external manual fuel NOTE: Below 45 °F (7 °C), the neoprene core of the plug
shutoff valve on the fuel line. The fuel shutoff valve must does not recover its original shape as rapidly as it would
be readily accessible. Local codes determine correct at higher temperatures. Upon removal of gauge adapter
location. probe, valves may not close fully and immediately, or
they may remain slightly open until operating tempera-
ture is above 45 °F (7 °C). Lower pressures and the
length of time gauge adapter probe is inserted can also
affect valve closing rate. The protective cap is provided to
eliminate the small amount of leakage that might occur
following removal of the gauge adapter probe.
2. Tighten protective cap to prevent tampering.

000743

Figure 4-4. Fuel Shutoff Valve with Manometer Port

NOTE: Figure 4-4 illustrates a fuel shutoff valve with a

manometer port for making fuel pressure checks. This
accessory fuel shutoff valve permits making pressure
checks without going into the generator enclosure.
Valves available through Generac and IASD’s:
• 1-1/4 in pressure rated ball valve; part number
0L2844
• 1-1/2 in ball valve; part number 0L2856
• 2 in ball valve; part number 0L2846

30 Installation Guidelines For Spark-Ignited Stationary Generators

 Gaseous Fuel Systems

Stator Attachment Rod

Gauge Adapter
1/8 Inch Diameter Probe
Part No. 0K2341

Cross-member
at Rear of Stator Test Port

011291

Figure 4-5. Fuel Pressure Test Point

Final Test Procedure

The following test must be performed at startup to docu- incorrectly sized, or mounted too close to the gen-
ment and validate fuel system operation. It requires a erator connection point. Unit may experience hard
load bank connected to the unit, or a combination of load starting, or will not perform as expected at full load
bank and system load, to bring unit to its full rated kW or during load transients.
load capacity. 3. Running—No Load Pressure: Fuel supply pres-
Measure fuel supply pressure under each of the following sure when unit is running at rated frequency and
conditions: voltage with no load. Must be at or slightly below
1. Static Pressure: Fuel supply pressure when unit is maximum pressure as listed in the unit specifica-
not running. Must not exceed maximum pressure tion sheet.
listed in the unit specification sheet. 4. Running—Full Load Pressure: Fuel supply pres-
2. Cranking Pressure: Fuel supply pressure when sure when unit is running with full rated load
unit is cranking. Must not drop more than 1 in water applied (kW). Fuel supply pressure should not drop
column (0.25 kPa) below Static Pressure or below more than 1–2 in water column (0.25–0.50 kPa)
minimum pressure listed in the unit specification from the Running—No Load Pressure and must
sheet. If it does, it may indicate fuel supply piping is NEVER drop below minimum pressure listed in the
not correctly sized, or primary fuel regulator is unit specification sheet.

Installation Guidelines For Spark-Ignited Stationary Generators 31

Gaseous Fuel Systems

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32 Installation Guidelines For Spark-Ignited Stationary Generators

 Electrical System

Section 5: Electrical System

General Information Tighten terminal lugs to torque values noted on decal
located on the inside of the door. Carefully wipe away
All wiring must be correctly sized, routed, supported, and any excess corrosion inhibitor after tightening terminal
connected. All wiring must comply with NEC and local lugs.
codes.
Proceed as follows to connect generator conductors to
The generator uses Customer Connection Interface marked terminal lugs in generator:
(CCI) panels to separate high voltage and customer con-
trol wiring connections. These two panels are clearly 1. See Figure 5-1. Connect generator conductors to
labeled. Wiring diagrams for each specific unit show con- disconnect circuit breaker.
nection points in their corresponding sections. Terminal
boards are labeled and correspond to the same terminal 1 2
connections shown in the wiring diagrams. Always use
unit specific wiring diagrams when making wiring connec-
tions.
NOTE: See Alternator AC Lead Connections.

Connecting Generator Feeder

Conductors

DANGER
Electrocution. Turn utility and emergency 3
power supplies to OFF before connecting
power source and load lines. Failure to do so
will result in death or serious injury. (000116) 4

5
CAUTION
Equipment damage. Verify all conductors are tightened
to the factory specified torque value. Failure to do so
could result in damage to the switch base.
(000120)

NOTE: Installation and interconnection diagrams are

provided at the back of this manual. 001758

NOTE: All installations must comply with national, state,

and local codes. It is the responsibility of the installer to Load Wiring Connections
perform an installation that will pass final electrical 1 E1 4 Ground
inspection. 2 E2 Knock Out Plug
5
Generator supply connection is made at the generator 3 Neutral (Cold Weather Kit)
disconnect circuit breaker terminals. Conductor sizes Notes:
must be adequate to handle the maximum current to Single-phase installation shown.
which they will be subjected, based on the 75 °C column See Figure 5-4 for typical control wiring connections.
of tables, charts, etc., used to size conductors. Installa-
tion must comply fully with all applicable codes, stan- Figure 5-1. High Voltage Connections (Typical)
dards, and regulations. 2. Connect generator neutral to neutral terminal bar.
All power cables can enter enclosure through knockouts 3. Connect equipment ground to equipment ground
provided. lug.
NOTE: Apply corrosion inhibitor to conductors if alumi-
num conductors are used. Carefully wipe away any
excess corrosion inhibitor after tightening terminal lugs.

Installation Guidelines For Spark-Ignited Stationary Generators 33

Electrical System

Connecting Control Circuit Wires Table 5-1. Frame Breakers

Control system interconnections may consist of N1, N2, Frame Generac 225 Generac 225 Generac 400 AF Generac 400 AF
Breaker AF 2 Pole AF 3 Pole 2 Pole 3 Pole
and T1, and leads 23 and 194. The generator control wir-
ing is a Class 1 signaling circuit. See instruction manual Range 125A-200A 50A-200A 225A-400A 225A-400A
of specific engine generator for wiring connection details. Wire type Cu/Al
Recommended wire gauge sizes for wiring depends on Wire temp. 167 °F
length of wire, as recommended in the following chart: rating (75 °C)
Lug AWG 6-350 kcmil (1) 1/0 -250 kcmil (2) 1/0-250 kcmil (2)
Maximum Wire Length Recommended Wire Size range or or
(number of 4-600 kcmil (1) 4-600 kcmil (1)
1–115 ft (0.30–35 m) No. 18 AWG conductors)
116–185 ft (36–56 m) No. 16 AWG Lug torque 375 in-lbs (42.37 Nm)

186–295 ft (57–89 m) No. 14 AWG NOTE: Generac frame breakers are rated at an 80%
296–460 ft (90–140 m) No. 12 AWG continuous load rating. Frame breaker torque specs are
on the breaker data tag.
Exception: Conductors of AC and DC circuits, rated
1,000 volts nominal or less, shall be permitted to occupy Typical Load Leads and Control
the same equipment, cable, or conduit. All conductors
shall have an insulation rating equal to at least the maxi-
Wiring in Stub-Up
mum circuit voltage applied to any conductor within the Figure 5-3 is for reference only. See installation drawings
equipment, cable, or conduit. See NEC 300.3(C)(1). for unit-specific details.
NOTE: See 300.3(C) and Article 725 in the NEC for rout-
Removing Rear Panel and Stub-Up ing of control wires and power wires.
Cover NOTE: A single conduit is permitted.
1. See Figure 5-2. Remove six screws with nylon
washers to release rear panel (A) from enclosure.
A B
For best results, rotate left side of panel outward
away from enclosure before disengaging right side. D

C
000385

C 010039 A Load leads C Stub-ups

Figure 5-2. Remove Rear Panel and Stub-Up Cover B Control wiring D Concrete pad
Figure 5-3. Typical Load Leads and Control Wiring in
2. Remove four screws with nylon washers to release
Stub-Up
fascia from control panel.
3. The stub-up cover (B) and five screws with flat
washers are shipped loose and found inside the
Customer Load Wiring
enclosure. An optional knock-out (C) is provided. Customer load wiring consists of single-phase or three-
phase connections between generator main line circuit
breaker (MLCB) and transfer switch. The wiring connects
to lugs E1, E2, (and E3, if three-phase on MLCB), neu-
tral, and equipment ground at generator, and runs to cor-
responding lugs in transfer switch. All load wires, neutral,
and ground should be marked and terminated in the cor-
rect lugs in transfer switch. Verify all wiring is correctly
mounted and terminated at appropriate connection points

34 Installation Guidelines For Spark-Ignited Stationary Generators

 Electrical System

in both generator and transfer switch. For general infor- (5) (6) Connect 23 in TB3 to 23 in transfer switch. Con-
mation regarding wire type, temperature rating, size nect 194 in TB3 to 194 in transfer switch. These are
range, and wire lug torque specifications, see Table 5-1 transfer switch control wires.
and Table 5-2. Always see NEC tables for specific
NOTE: RTS Series Transfer Switch Without T1 Fuse/
requirements.
Connection: Use a 120 volt generator protected circuit
NOTE: For three-phase applications, use phase rotation from the panel board to power the battery charger circuit
meter to verify generator phase rotation matches rotation (dedicated 15/20 amp circuit).
of the utility.
NOTE: For three-phase, delta configured alternators
(voltage code J) and the second leg (N2) must be 1
bonded to all second legs in the entire system. 2
See Alternator AC Lead Connections for more infor-
mation.

Control Wiring Connections 3

The control wire customer connection block is where all
4
of the control wiring is connected.
IMPORTANT NOTE: All wiring must comply with
NEC, state, and local AHJ requirements. Control wir-
ing shall be installed per the requirements of NEC
Articles 300.3(C) and 725.46. If installing conductors A
with different voltage insulation ratings, a 600V rated
electrical sleeve is provided and can be found in the
B
manual bag.
See Figure 5-4. Depending on the system type, control 5
wiring includes the following. (Wire colors shown for illus-
tration purposes only):
6
RTS Series Transfer Switch With T1 Fuse/
Connection
NOTE: Control wire customer connections typically use
009122
Class 1 Wiring Methods (verify with AHJ). Always follow
the standards and methods appropriate to the circuits TB2 Terminal Block
being wired. Terminal Function Voltages
NOTE: T1 is the 120 VAC power supply for the control 1 Neutral Neutral for T1 Battery Charger Neutral
panel battery charger. This circuit must be powered
whether transfer switch is in utility or generator mode. If 2 T1 Power for T1 Battery Charger 120 VAC
circuit loses power, control board will generate a warning 3 N2 Utility Sensing from Transfer Switch 208-277 VAC
(Battery Charge AC Fail).
4 N1 Utility Sensing from Transfer Switch 208-277 VAC
NOTE: Observe maximum wire size for terminal strip
TB3 Terminal Block
connections shown in the unit wiring diagram.
Terminal Function Voltages
(1) For battery charging, connect neutral in TB2 to neutral
in transfer switch. See NOTE below for transfer switches A 178 Two Wire Start Control [GTS] 5 VDC
without T1. B 183 Two Wire Start Control [GTS] 5 VDC
(2) Connect T1 in TB2 to T1 in transfer switch. This is 5 23 Transfer Relay Control Wire 12-0 VDC
120 volt supply to the unit's battery charger (normal RTS
transfer switch). 6 194 Power for Transfer Relay 12 VDC

(3) (4) Connect N1, N2 sensing wires in TB2 to N1 and Figure 5-4. Control Wiring Connections (Typical)
N2 in transfer switch. These two wires are utility sensing
wires.

Installation Guidelines For Spark-Ignited Stationary Generators 35

Electrical System

Two-Wire Start
To convert control panel to two-wire start transfer switch
mode of operation, see dealer for panel conversion and
connection of terminals 178 and 183 in TB3. Use a 120
volt generator protected circuit from the panel board to
power the battery charger circuit (dedicated 15/20 amp
circuit).
The generator controller will have to be programmed for
two-wire start by an IASD.

COMPONENTS LOCATED IN CUSTOMER CONNECTION BOX

LOW VOLTAGE CONNECTIONS

NOTE: ALL WIRES ON THIS

PAGE ARE 600V RATED

60HZ/50HZ
CAR
J1-8 209/210
COMMON ALARM
J1-15

ES
14/14A (ORANGE)

CUSTOMER CONNECTIONS
J1-9
SPLICE E
J1-3 56/56A (WHITE)
E-STOP
COP1-7
J2-8 395/396 (BLACK)
J2-4

X TB3 Y

4 178
J1-14 178
REMOTE START OPTION
3 183
J1-5 183

2 23 TRANSFER RELAY COIL

J1-7 23

1 194 TRANSFER RELAY

J1-6 194

COMPONENTS LOCATED IN CUSTOMER CONNECTION BOX

HIGH VOLTAGE CONNECTIONS

60HZ UNITS 50HZ (M-VOLTAGE, 110/220VAC & R-VOLTAGE, 231/400VAC)

X TB2 Y X TB2 Y

CUSTOMER CONNECTIONS
FUSED 220VAC(M) OR
4 NEU FUSED 120VAC 4 N2 200VAC(R) SOURCE FOR
BCH2-2 NEU BCH2-2 NEU
SOURCE FOR BATTERY CHARGER
3 T1 BATTERY CHARGER 3 N1 (PRE-CONNECTED WITH
BCH2-1 T1 BCH2-1 T1 JUMPERS AS SHOWN)
2 N2 2 N2
J4-6 N2 UTILITY FROM J4-6 N2 UTILITY FROM
TRANSFER SWITCH TRANSFER SWITCH
1 N1 1 N1
J4-3 N1 J4-3 N1

240VAC MAX
NOTE:
FOR FIELD WIRING TO CUSTOMER CONNECTIONS
(TERMINAL BLOCKS)
WIRE SIZE 18-12 GAUGE 000378

Figure 5-5. Typical Control Wiring Schematic

36 Installation Guidelines For Spark-Ignited Stationary Generators

 Electrical System

NOTE: The following table is provided for reference pur- See latest NEC, state, and local AHJ requirements
poses only. See latest NEC, state, and local AHJ require- for details.
ments for correct sizing. • Install power and control wires as per NEC require-
Table 5-2. Control Wire Length/Size ments. In a three-phase system, all power conduits
from the generator must contain all three phases.
Maximum Recommended • Conduit, wire, circuit protective device sizes, insu-
Wire Length Wire Size lation, etc. must conform to applicable local and
national codes and regulations.
1–115 ft (0.30–35 m) No. 18 AWG

116–185 ft (36–56 m) No. 16 AWG Battery

186–295 ft (57–89 m) No. 14 AWG
General Safety Precautions
296–460 ft (90–140 m) No. 12 AWG
DANGER
Optional Accessory Power Automatic start-up. Disconnect utility power and
render unit inoperable before working on unit.
• Accessory power for optional items (battery Failure to do so will result in death or serious injury.
warmer and block heater) should come from a cus-
tomer utility supply source (with appropriate sized (000191)
breaker), which is also powered by emergency
power during an outage. DANGER
• Optional user installed GFCI receptacles. Provides Electrocution. Do not wear jewelry while
a place to plug in optional battery warmer and working on this equipment. Doing so will
block heater. result in death or serious injury.
NOTE: See Figure 5-2. Remove knockout plug and (000188)
route accessory wiring to customer supplied weather-
proof junction box. Verify wires do not contact moving or
vibrating engine parts, as abraded wires can result in
WARNING
electrical problems. Accidental Start-up. Disconnect the negative battery
cable, then the positive battery cable when working
Installing Stub-Up Cover and Rear on unit. Failure to do so could result in death
or serious injury.
Panel (000130)

1. Install five screws with flat washers to secure stub-

up cover. WARNING
2. Install four screws with nylon washers to fasten Explosion. Batteries emit explosive gases while
charging. Keep fire and spark away. Wear protective
fascia over control panel.
gear when working with batteries. Failure to do so
3. Install rear panel. For best results, first engage could result in death or serious injury.
right side of panel and then rotate left side inward (000137a)
toward enclosure. Alternately work left and right
sides in until slots are aligned with screw holes on WARNING
both sides. Install six screws with nylon washers
Risk of burns. Batteries contain sulfuric acid and can
and tighten until snug.
cause severe chemical burns. Wear protective gear
when working with batteries. Failure to do so could
Transfer Switch Location result in death or serious injury.
(000138a)
The location of the transfer switch is important. Consider
the following:
WARNING
• Locate transfer switch as close to emergency load
as practical, to avoid interruptions of emergency Explosion. Batteries emit explosive gases.
power system due to natural disasters or equip- Always connect positive battery cable first to
ment failures. avoid spark. Failure to do so could result in
death or serious injury.
• Locate transfer switch in a clean, dry, well venti- (000133)
lated location, away from excessive heat. Allow
adequate working space around transfer switch.

Installation Guidelines For Spark-Ignited Stationary Generators 37

Electrical System

1. See Figure 5-6. Install rubber protective cover (A)

WARNING over positive (+) battery terminal.
Environmental Hazard. Always recycle batteries at an 2. Grasp battery strap (B) and lift battery.
official recycling center in accordance with all local 3. Set battery onto battery tray.
laws and regulations. Failure to do so could result in
4. Tighten two screws with nylon washers to secure
environmental damage, death, or serious injury.
(000228) hold-down clamp to battery tray, or fasten strap
over top of battery.
Always recycle batteries in accordance with local laws
5. Remove rubber protective cover from positive (+)
and regulations. Contact your local solid waste collection
battery terminal.
site or recycling facility to obtain information on local
recycling processes. For more information on battery 6. Install positive battery cable (C) (red) on positive
recycling, visit the Battery Council International website (+) battery terminal.
at: http://batterycouncil.org 7. Install negative battery cable (D) (black) on nega-
• Stationary generators installed with automatic tive (-) battery terminal.
transfer switches will crank and start automatically NOTE: The unit is equipped with a internal battery char-
when NORMAL, UTILITY source voltage is ger. The internal battery charger is powered by the T1
removed or is below an acceptable preset level. To wire. Verify power supply (T1 wire) has been safely dis-
prevent automatic startup and possible injury to connected before performing any work on the battery.
personnel, do not connect battery cables until
NORMAL source voltage at transfer switch is cor-
rect and system is ready to be placed into opera-
tion.
• When working on battery, only use tools with insu- B
lated handles. Do not rest tools or metal parts on
top of battery. A
• Discharge static electricity from the body before
touching battery by first touching a grounded metal
surface.
• Immediately wash down spilled electrolyte with an
acid neutralizing agent. Use a solution of 1 lb (500
g) bicarbonate of soda to 1 gal (4 L) of water. Add
the bicarbonate of soda solution until evidence of
reaction (foaming) has ceased. Flush resulting liq-
uid with water.

Battery Requirements 001499

The ability to start the engine depends upon battery

capacity, ambient temperatures, and coolant and oil tem-
peratures. The engine/generator set data sheet lists mini-
C
mum recommended battery capacity at various ambient
temperatures. Recommended battery capacities are
listed under cold cranking amps (CCA) at 0 °F (−18 °C).
Battery capacities decrease as ambient temperatures
decrease, so it is important to specify batteries with the D
appropriate CCA rating at a temperature no higher than
+
the minimum ambient temperature for the application. -
Battery Installation
000621
NOTE: Battery is not included with the 48 kW unit only.
Figure 5-6. Battery Cable Connections
Fill battery with correct electrolyte fluid as necessary and
have battery fully charged before installing it. NOTE: At temperatures of 32 °F (0 °C) and below, it is
recommended that a pad type battery heater be installed
Use appropriate tools when working with battery termi-
to aid in cold climate starting. This is available as a cold
nals. The use of terminal pullers, expansion pliers, and
weather kit through an IASD.
terminal cleaning brushes will greatly extend the life of
the battery terminals.

38 Installation Guidelines For Spark-Ignited Stationary Generators

 Control Panel Startup / Testing

Section 6: Control Panel Startup / Testing

Control Panel Interface to generator output does not occur during exercise
cycle unless utility power is lost.
The control panel interface is located behind the door on
the alternator end of the enclosure. NOTE: If installer tests generator prior to installation,
press ENTER button to skip setting up exercise timer.
Using the AUTO/MANUAL/OFF Buttons
NOTE: Exercise feature will operate only when genera-
tor is placed in AUTO, and will not work unless this pro-
Button Description of Operation cedure is performed. Current date/time will need to be
reset every time the 12 volt battery is disconnected and
Activates fully automatic system operation. Auto- then reconnected, and/or when the fuse is removed.
matic operation allows unit to automatically start
AUTO
and exercise generator according to exercise timer
settings (see Setting The Exercise Timer). Before Initial Startup
Shuts down engine and also prevents automatic
OFF
operation and exercise of unit. CAUTION
Cranks and starts generator. Transfer to standby Engine damage. Verify proper type and quantity of
MANUAL
power will not occur unless there is a utility failure. engine oil prior to starting engine. Failure to do so
could result in engine damage.
(000135)

NOTE: This unit has been run and tested at the factory
prior to being shipped and does not require any type of
break-in.
NOTE: This unit comes factory-filled with 30 weight
organic oil. Verify oil level and add the appropriate vis-
cosity and amount of oil if necessary.

Install Wizard
See Figure 6-2. Upon initial startup, Install Wizard imme-
000425
diately appears. It allows user to input generator settings.
Figure 6-1. Generator Control Panel The Install Wizard starts every time AC and DC power
are removed and reapplied to generator.
Generator Setup Interconnect System Self Test Feature
Controller will light up when battery power is applied to This controller goes through a system self test at startup,
generator during the installation process. Generator still which checks for utility (AC) voltage on DC circuits. This
needs to be activated before it will automatically run in check prevents damage if installer incorrectly connects
event of a power outage. See Activate Unit. AC utility power sense wires into DC terminal block. Con-
troller will display a warning message and lock out the
Setting The Exercise Timer
generator if utility voltage is detected, preventing damage
This generator is equipped with a configurable exercise to controller. Power to controller must be removed to
timer. There are two settings for the exercise timer. clear this warning.
• Day/Time: Once set, generator will start and exer- Utility voltage must be turned on and present at the N1
cise for period defined, on day of week and at time and N2 terminals inside generator control panel for this
of day specified. During this exercise period, unit test to be performed and pass.
runs for approximately 12 minutes at 1,800 rpm,
and then shuts down. NOTE: All appropriate panels must be in place during
any operation of the generator. This includes operation
• Exercise frequency (how often exercise will by a servicing technician, while conducting troubleshoot-
take place): It can be set to Weekly, Biweekly, or ing procedures.
Monthly. If MONTHLY is selected, day of month
must be selected from 1–28. Generator will exer-
cise on selected day each month. Transfer of loads

Installation Guidelines For Spark-Ignited Stationary Generators 39

Control Panel Startup / Testing

Before starting, complete the following:

1. Verify generator is OFF.
2. Set generator MLCB (generator disconnect) to
OFF (OPEN).
3. Turn off all breakers supplied by generator.
4. Check engine crankcase oil level and, if necessary,
fill to oil dipstick FULL mark with recommended oil.
Do not fill above FULL mark.
5. Inspect fuel supply. Gaseous fuel lines must have
been correctly purged and leak tested in accor-
dance with applicable fuel-gas codes. All fuel shut-
off valves in the fuel supply lines must be open.
6. Verify both auxiliary shutdown switches are ON (I).
During initial startup only, generator may exceed normal
number of start attempts and experience an “OVER-
CRANK” fault. This is due to accumulated air in the fuel
system during installation. Reset control board by press-
ing OFF button and ENTER button, and restart up to two
more times if necessary. If unit fails to start, contact an
IASD for assistance.

40 Installation Guidelines For Spark-Ignited Stationary Generators

 Power Up Unit

FIRMWARE V 1.01
Use UP and DOWN
arrows to select fuel HARDWARE V 1.05
type then press
“ENTER”
UP ARROW = +
GUI FW V XXX
SEEPROM V XXX

Language
Install Wizard DOWN ARROW = -
+ English -
+ Espanol -
+ Francais -
Note: If language was previously programmed this goes directly to “Select Hour”
+ Portuguese -
Defaults to English if not selected.

Product Registration
(if not already
registered)

Installation Guidelines For Spark-Ignited Stationary Generators

ENTER

Select Hour (0-23) ENTER Select Min (0-59) ENTER Select Month (1-12) ENTER Select Date (1-31) ENTER Select Year (0-99)
- 14 + - 0 + - 2 + - 13 + - 13 +
* * * * *
* Holding the Up or Down arrow
button for 2 seconds will speed dial
through the selections

Figure 6-2. Install Wizard Menu Map

Select Frequency

Install Wizard ENTER Quiet Test Mode Select Hour (0-23) ENTER ENTER - WEEKLY +
ENTER Select Min (0-59)
+ yes - - BIWEEKLY +
Set Exercise + no - - 14 + - 0 + - MONTHLY +
* * ENTER

Select Day
Switched to “OFF” ENTER - Wednesday +
Hours of Protection SYSTEM DATE/TIME
0 (H)
ENTER Fuel Selection ENTER
- LP +
- NG +
BAT- SUB MENUS
Control Panel Startup / Testing

41
010124
Control Panel Startup / Testing

Activate Unit

Display Reads: Generator Active is displayed on If the wrong language is selected, it may be
Up Arrow = (+) the LCD screen when the unit is first changed later using the Edit menu.
powered up. After displaying
Language firmware and hardware version
- English + codes, as well as other system
information, the Install Wizard is
launched, and the Language screen
is displayed.

Use UP ARROW or DOWN ARROW

to scroll to desired language.
Down Arrow = (-)
Press ENTER.

Display Reads: Press ENTER. Press ESCAPE to abort the activation sequence.
NOT ACTIVATED is displayed and the generator
will run in manual mode only. Disconnect and
Activate me (ENT) or
reconnect the negative battery cable to restart the
ESC to run in manual activation routine. If power is removed after a
successful activation, no data is lost, but the time
and date must be updated.

Display Reads: Go to www.activategen.com or call 1-

888-9ACTIVATE (922-8482, US &
Canada only) if activation passcode
To Activate go to is not available.
www.activategen.com
If activation passcode is available,
wait a few seconds for the next
display.

Display Reads: Use UP ARROW or DOWN ARROW Press ESCAPE to return to preceding digits if a
to increment or decrement the digit to correction becomes necessary.
correspond to the first number of the
SN 1234567890
passcode. If attempts to enter the activation code are
PASS CODE XXXXX unsuccessful, check the number against the
Press ENTER. passcode given on activategen.com. If it is
correct, contact 1-888-9ACTIVATE (922-8482,
Repeat step to enter remaining US & Canada only).
digits.

42 Installation Guidelines For Spark-Ignited Stationary Generators

 Control Panel Startup / Testing

Checking Manual Transfer Switch 7. Turn off utility power supply to transfer switch when
Operation utility supply voltage is compatible with transfer
switch and load circuit ratings.
8. Verify both auxiliary shutdown switches are ON (I).
DANGER
9. Press MANUAL on control panel keypad to crank
Electrocution. High voltage is present at and start engine.
transfer switch and terminals. Contact with live
10. Allow engine to warm up for approximately five
terminals will result in death or serious injury.
minutes. Set generator MLCB (generator discon-
(000129) nect) to ON (CLOSED).
See Manual Transfer Operation section of owner’s man- 11. Connect an accurate AC voltmeter and a fre-
ual for procedures. quency meter across transfer switch terminal lugs
E1 and E2 (and E3 if three-phase).
12. Successively connect the AC voltmeter test leads
Operational Checks across terminal lugs E1, E2, (and E3 if three-
NOTE: The following procedures require special tools phase) and neutral. Voltage reading in each case
and skills. Contact an IASD to perform these tasks. should match utility voltage reading. If system is
three-phase, verify generator phase rotation
Electrical Checks matches utility phase rotation.
13. Set generator MLCB (generator disconnect) to
DANGER OFF (OPEN).
Electrocution. High voltage is present at 14. Press OFF on control panel to shut engine down.
transfer switch and terminals. Contact with live
IMPORTANT NOTE: Do not proceed unless generator
terminals will result in death or serious injury.
AC voltage and frequency are correct and within
(000129) stated limits.
NOTE: Verify all power and control wiring is correctly ter- Testing Generator Under Load
minated in the generator and corresponding location in
transfer switch. For three-phase applications, verify gen-
erator phase rotation matches utility phase rotation L1- DANGER
L2-L3 or L3-L2-L1. Validate phase rotation L1-L2-L3 or Electrocution. Do not manually transfer under load.
L3-L2-L1 with an phase rotation tester (if three-phase). Disconnect transfer switch from all power sources
prior to manual transfer. Failure to do so will result in
NOTE: To correct phase rotation, interchange any two death or serious injury, and equipment damage.
leads. (000132)

Proceed as follows to complete electrical checks: Proceed as follows to test generator with electrical loads
applied:
1. Verify generator is in OFF mode. Red LED above
OFF on control panel illuminates to verify system is 1. Verify generator is in OFF mode. Red LED above
OFF. OFF on control panel illuminates to verify system is
OFF.
2. Verify generator MLCB (generator disconnect) is
OFF (OPEN). 2. Turn off all breakers/electrical loads to be supplied
by generator.
3. Turn off all circuit breakers/electrical loads to be
supplied by generator. 3. Turn off utility power supply to transfer switch,
using the means provided (such as a utility MLCB).
4. Turn on utility power supply to transfer switch using
the means provided (such as a utility MLCB). 4. Manually set transfer switch to STANDBY, i.e., load
terminals connected to generator’s E1 and E2 (and
5. Use an accurate AC voltmeter to verify utility power
E3 if three-phase) terminals. Transfer switch oper-
source voltage across transfer switch terminals N1
ating lever should be down in standby position.
and N2 (and N3 if three-phase). Normal line-to-line
voltage should be equivalent to rated unit voltage. 5. Verify both auxiliary shutdown switches are ON (I).
Validate (if three-phase) phase rotation L1-L2-L3 or 6. Press MANUAL on control panel. Engine should
L3-L2-L1 with a phase rotation tester. crank and start immediately.
6. Verify utility power source voltage across terminals 7. Allow engine to warm up for approximately five
N1 and N2 (and N3 if three-phase) and transfer minutes.
switch neutral lug. 8. Set generator MLCB (generator disconnect) to ON
(CLOSED).

Installation Guidelines For Spark-Ignited Stationary Generators 43

Control Panel Startup / Testing

9. Turn on circuit breaker/electrical loads to be sup- • If engine does not stop, auxiliary shutdown switch
plied by generator. Loads are now powered by is not functioning correctly. Stop generator through
standby generator. control panel, and inspect wiring installation. Con-
10. Connect a calibrated AC voltmeter and a frequency tact Generac Technical Support if problem cannot
meter across terminal lugs E1 and E2 (and E3 if be identified or if assistance is needed.
three-phase). Voltage should be approximately unit Auxiliary shutdown switches are not intended to be a pri-
rated voltage. mary means to shut down generator under normal oper-
11. Allow generator to run at full rated load for 20–30 ating conditions. Accidental activation of an auxiliary
minutes. Listen for unusual noises, vibration, or shutdown switch will prevent generator from operating
other indications of abnormal operation. Inspect for during a power outage.
oil leaks, evidence of overheating, etc.
12. Turn off electrical loads when utility supply voltage Checking Automatic Operation
is compatible with transfer switch and load circuit Proceed as follows to check system for correct automatic
ratings. operation:
13. Set generator MLCB (generator disconnect) to 1. Verify generator is in OFF mode. Red LED above
OFF (OPEN). OFF on control panel illuminates to verify system is
14. Allow engine to run at no-load for 2–5 minutes. OFF.
15. Press OFF on control panel to shut engine down. 2. Install front cover over transfer switch.
3. Turn on utility power supply to transfer switch,
Testing Auxiliary Shutdown Switch Operation using the means provided (such as a utility MLCB).
NOTE: Transfer switch will transfer to utility position.
CAUTION
4. Set generator MLCB (generator disconnect) to ON
Equipment Damage. The auxiliary shutdown switch (CLOSED).
is not to be used to power down the unit under
normal operating circumstances. Doing so will 5. Verify both auxiliary shutdown switches are ON (I).
result in equipment damage. (000399) 6. Press AUTO on control panel. System is now
ready for automatic operation.
Proceed as follows to test auxiliary shutdown switches to 7. Turn off utility power supply to transfer switch.
verify correct operation:
With generator ready for automatic operation, engine will
1. Verify auxiliary shutdown switches (A, B) are ON crank and start when utility source power is turned OFF
(I). after a 10 second delay (factory default setting). After
starting, transfer switch connects load circuits to standby
side. Allow system to operate through entire automatic
ON
ENGINE
sequence of operation.
SHUTDOWN

OFF
With generator running and loads powered by generator
AC output, turn ON utility power supply to transfer switch.
System transfers to UTILITY, and then runs through the
A cool down cycle and shuts down.

B
Installation Summary
1. Verify installation has been performed correctly as
outlined by the manufacturer and that it meets all
applicable laws and codes.
004900

Figure 6-3. Auxiliary Shutdown Switch Locations 2. Test and verify correct operation of the system as
outlined in the appropriate installation and owner’s
2. Press MANUAL on control panel to start engine.
manuals.
3. With engine running, set one auxiliary shutdown
3. Educate end-user on correct operation, mainte-
switch to OFF (O). Engine will shut down immedi-
nance, and service call procedures.
ately.
• If engine stops, set auxiliary shutdown switch to
ON (I), clear alarm on controller, and restart engine
to verify generator is operating normally. After veri-
fying normal operation of first auxiliary shutdown
switch, verify operation of second auxiliary shut-
down switch.
44 Installation Guidelines For Spark-Ignited Stationary Generators
 Control Panel Startup / Testing

Shutting Generator Down While

Under Load or During a Utility Outage

DANGER
Automatic start-up. Disconnect utility power and
render unit inoperable before working on unit.
Failure to do so will result in death or serious injury.
(000191)

IMPORTANT NOTE: If user finds it necessary to turn

generator OFF during prolonged utility outages to
conserve fuel or perform maintenance, alert them to
these important steps:
To turn generator OFF (while running in AUTO and
online):
1. Turn main utility disconnect OFF (OPEN).
2. Set generator MLCB (generator disconnect) to
OFF (OPEN).
3. Allow unit to run for a few minutes to cool, and then
press OFF on control panel. Red LED illuminates
to verify system is OFF.
To turn generator back ON:
1. Press AUTO on control panel. Allow unit to start
and warm up for a few minutes.
2. Set generator MLCB (generator disconnect) to ON
(CLOSED).
System is now operating in AUTO. The main utility dis-
connect can be turned ON (CLOSED), but to shut unit
down, this complete process must be repeated.

Installation Guidelines For Spark-Ignited Stationary Generators 45

Control Panel Startup / Testing

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46 Installation Guidelines For Spark-Ignited Stationary Generators

 Installation Checklists

Section 7: Installation Checklists

Safety Checklist Foundations and Mounting Checklist
NOTE: See Safety Rules & General Information for NOTE: See Site Selection and Preparation for more
more information. information.
 Are manuals, wiring diagrams, and other documenta-  Is generator installed on a concrete pad capable of
tion readily available? supporting its weight and accessories?
 Is there any evidence of freight damage?  Is generator securely fastened to concrete pad using
suitable grade, size, and style fasteners?
 Does the enclosure have scratches or damage to
painted surfaces (which would indicate lifting without  Is concrete pad seated on a prepared solid subsur-
a spreader bar)? face using appropriate reinforcing bar or expanded
 Are all guards, covers, insulation blankets, and other wire mesh?
protective devices in place?  Does concrete pad extend beyond the frame rails at
 Are any parts or components worn, damaged, or least 3 in (7.62 cm) on all sides?
missing?  Is concrete pad flat and level to within 0.5 in (13 mm)?
 Is generator correctly grounded?  Are plugs installed in the tie-down holes of frame rail?
 Is a fire extinguisher kept near generator?  If installed on a roof or combustible floor, is generator
seated on a layer of sheet metal and non-combustible
 Is there any evidence of oil or coolant leaks?
insulation? Do the sheet metal and insulation extend
 Are any combustible materials left in generator com- beyond generator base at least 12 in (300 mm) on all
partment? sides?
 Is area surrounding generator clean and free of  Is base frame stub-up cover plate installed?
debris?  Do all fuel, coolant, exhaust, and electrical lines have
 Do these parameters meet all applicable codes and flexible sections where they connect to generator?
local jurisdiction?  Is all piping correctly supported and secured?
Installation Planning Checklist  Do these parameters meet all applicable codes and
local jurisdiction?
NOTE: See Installation Planning for more information.
 Is generator readily accessible for maintenance,
repair, and firefighting purposes?
 Is installation site clean, dry, and provided with ade-
quate drainage?
 Is there minimum clearance around the generator to
facilitate repair or replacement of major components?
 Have adequate provisions been made for installation
of the fuel supply?
 Do these parameters meet all applicable codes and
local jurisdiction?

Installation Guidelines For Spark-Ignited Stationary Generators 47

Installation Checklists

Ventilation System Checklist  Is fuel regulator sized to have a fuel flow delivery rat-
NOTE: See Site Selection and Preparation for more ing (CFH) at least 10% greater than the 100% rated
information. kW fuel consumption requirement of the generator?
 Is fuel pressure regulator approved for a mechanized
 Is there sufficient air flow for cooling and ventilation? engine application?
 Are all bushes, shrubs, and other vegetation a mini-  Does fuel pressure regulator have an accuracy rating
mum of 3 ft (1 m) away? of 1% or less, and/or have a maximum allowable fuel
 Does the air inlet face the direction of prevailing pressure drop of 1–2 in water column (0.25–0.50 kPa)
winds? under all operating conditions; that is, static, cranking,
running at no load, and running at full load (as mea-
 Is system piping correctly sized? Have all gas loads
sured at the primary fuel pressure regulator)?
been taken into consideration?
 Does fuel pressure regulator have a spring rating
 Is system correctly protected from freeze up and cor- appropriate for the required fuel pressure as listed in
rosion? the unit specification sheet?
 Have standby equipment heaters been specified?  Does fuel system use black iron piping or other
 Have system drain valves and air eliminators been approved fuel line?
installed?  Is fuel line rigidly mounted and protected against
 Does air outlet face noise sensitive areas without vibration?
noise attenuating devices?  Is a length of flexible fuel line installed between gener-
 Does installation appear to have the necessary acces- ator connection point and rigid fuel supply piping? Is
sories to promote fast, reliable starting and operation the flexible fuel line straight without bends, twists, or
in adverse weather conditions (such as engine block kinks?
heaters, battery warmers, etc.)?
 Is fuel piping correctly sized to maintain required fuel
 Do these parameters meet all applicable codes and supply pressure and volume under varying load con-
local jurisdiction? ditions?
 Was an approved pipe sealant or joint compound
Exhaust System Checklist used on all threaded fittings?
NOTE: See Gaseous Fuel Systems for more informa-  Is a fuel shutoff valve installed near unit? Was correct
tion. operation of fuel shutoff valve verified?
 Are exhaust discharges directed away from combusti-  Was Final Operating Test performed to verify system
ble surfaces and inhabited areas? operates correctly in all modes of operation?
 Is exhaust piping kept clear of fuel supply, fuel lines,  Is there any evidence of leakage at any hoses,
etc.? clamps, or fittings?
 Is off-engine exhaust piping covered with high tem-  Do these parameters meet all applicable codes and
perature insulation blankets where necessary? local jurisdiction?
 Do these parameters meet all applicable codes and
local jurisdiction?

Gaseous Fuel System Checklist

NOTE: See Gaseous Fuel Systems for more informa-
tion.
 Are fuel supply lines correctly sized and installed?
Were fuel supply lines purged and leak tested?
 Is fuel pressure regulator correctly sized?
 Is a fuel pressure test port installed before fuel shutoff
solenoids at the fuel inlet?
 Does generator have a dedicated fuel line which is not
shared with any other appliances?

48 Installation Guidelines For Spark-Ignited Stationary Generators

 Installation Checklists

Electrical System Checklist  Is manual operation of transfer switch smooth and

NOTE: See Electrical System for more information. non-binding?
 Do these parameters meet all applicable codes and
 Is all wiring correctly sized for load and length of run? local jurisdiction?
 Is all wiring correctly routed?
 Is all wiring correctly connected?
 Are wire lugs fastened to bus bars using appropriate
hardware? Is hardware correctly tightened to speci-
fied torque?
 Are all other terminals correctly tightened using the
specified torque?
 Are batteries correctly sized?
 Are batteries correctly installed?
 Are battery fluid levels correct?
 Are battery cables and connections clean and free of
corrosion?
 Are battery cables correctly connected? Are terminal
lugs correctly tightened?
 Is battery condition and state of charge acceptable?
 Is area housing storage battery correctly ventilated?
 Are batteries located near a source of flame or spark?
 Are AC wire sizes and connections correct?
 Are DC and communication wire sizes and connec-
tions correct?
 Are block heaters, battery charger, etc. correctly
matched with utility supply voltage?
 Are battery charger and block heater correctly con-
nected?
 Are remote start Wires 178 & 183 pulled and con-
nected inside lower control panel of generator and
inside transfer switch?
 Is generator set to OFF?
 Is block heater operational?
 Is battery charger operational?
 Are all AC electrical connections tight at the circuit
breaker and transfer switch?
 Are two auxiliary shutdown switches ON (I)?
 Are all electrical connections (wiring, wire ties,
clamps, terminal ends, connectors) on generator
tight?
 Are all electrical plugs throughout generator seated
correctly and fully inserted into their receptacles?
 Is voltage and phase rotation correct at the transfer
switch?

Installation Guidelines For Spark-Ignited Stationary Generators 49

Installation Checklists

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50 Installation Guidelines For Spark-Ignited Stationary Generators

 Troubleshooting/Quick Reference Guide

Section 8: Troubleshooting/Quick Reference Guide

Troubleshooting

Problem Cause Correction

Correct short circuit condition by replacing 7.5

Blown fuse.
amp fuse in generator control panel.

Loose, corroded, or faulty battery cables.

Tighten, clean, or replace as necessary. Con-
Faulty starter contact.
Engine will not crank tact an IASD for assistance.
Faulty starter motor.

Discharged battery. Charge or replace battery.

One (or both) auxiliary shutdown switches is

Set both auxiliary shutdown switches to ON (I).
OFF (O).

No fuel. Verify fuel source / turn on fuel shutoff valve.

Faulty fuel solenoid (FS). Contact an IASD for assistance.

Engine cranks but will not start
Faulty spark plug(s). Clean, re-gap, or replace plug(s).

Valve lash out of adjustment. Reset valve lash.

Air cleaner plugged or damaged. Inspect / replace air cleaner.

Faulty spark plug(s). Clean, inspect gap, replace plug(s) if needed.

Engine starts hard and runs Verify fuel pressure to regulator is 3.5–14 in
rough Incorrect fuel pressure. water column (0.87–3.48 kPa) for NG or 7–14
in water column (1.74–3.48 kPa) for LP gas.

Fuel selection in controller is incorrect. Program controller with correct fuel type.

Unit is set to OFF, but engine Controller wired incorrectly.

Contact an IASD for assistance.
continues to run Faulty control board.

MLCB (generator disconnect) is OFF Set MLCB (generator disconnect) to ON

No AC output from generator (OPEN). (CLOSED).

Generator internal failure. Contact an IASD for assistance.

MLCB (generator disconnect) is OFF Set MLCB (generator disconnect) to ON

(OPEN). (CLOSED).

Faulty transfer switch coil.

No transfer to standby after
utility source failure Faulty transfer relay.
Contact an IASD for assistance.
Transfer relay circuit open.

Faulty control logic board.

Excessive engine oil. Adjust oil to correct level.

Faulty engine breather. Contact an IASD for assistance.

Unit consumes large amounts
of oil See Engine Oil Recommendations in owner’s
Incorrect type or viscosity of oil.
manual.

Damaged gasket, seal, or hose. Inspect for oil leaks.

Installation Guidelines For Spark-Ignited Stationary Generators 51

Troubleshooting/Quick Reference Guide

Quick Reference Guide

To clear an active alarm, press the ENTER button twice and then press AUTO. If the alarm reoccurs, contact an IASD.

Active Alarm LED Problem Action Solution

Unit running in AUTO but Check MLCB (genera- Check MLCB. If MLCB is ON, contact an
NONE GREEN
no power in house. tor disconnect). IASD for assistance.

Inspect ventilation around generator,

HIGH Unit shuts down during Check LED’s / Screen intake, exhaust, and rear of generator. If no
RED
TEMPERATURE operation. for alarms. obstruction, contact an IASD for assis-
tance.

Clear alarm and remove household loads

OVERLOAD Unit shuts down during Check LED’s / Screen
RED from generator. Put back in AUTO and
REMOVE LOAD operation. for alarms.
restart.

Clear alarm and remove household loads

Unit was running and
Check LED’s / Screen from generator. Put back in AUTO and
RPM SENSE LOSS RED shuts down, attempts to
for alarms. restart. If generator does not start, contact
restart.
an IASD for assistance.

Unit will not start in Verify if screen says See Checking Manual Transfer Switch
NOT ACTIVATED NONE
AUTO with utility loss. unit not activated. Operation.

Unit will not start in Check screen for start If startup delay is greater than expected,
NONE GREEN
AUTO with utility loss. delay countdown. contact an IASD for assistance.

LOW OIL Unit will not start in Check LED’s / Screen Check oil level / add oil per owners man-
RED
PRESSURE AUTO with utility loss. for alarms. ual. If oil level is correct, contact an IASD.

Clear alarm. Check battery option in con-

Unit will not start in Check LED’s / Screen trol menu. If it states battery is GOOD, con-
RPM SENSE LOSS RED
AUTO with utility loss. for alarms. tact an IASD. If it states CHECK BATT-
ERY, replace battery.

Verify fuel line shutoff valve is ON. Clear

Unit will not start in Check LED’s / Screen alarm. Attempt to start unit in MANUAL. If it
OVERCRANK RED
AUTO with utility loss. for alarms. does not start or starts and runs rough,
contact an IASD for assistance.

Clear alarm and remove household loads

LOW VOLTS Unit will not start in Check LED’s / Screen
RED from generator. Put back in AUTO and
REMOVE LOAD AUTO with utility loss. for alarms.
restart.

Inspect 7.5 amp fuse. If it is bad, replace

Unit will not start in Check LED’s / Screen
FUSE PROBLEM RED with an ATO 7.5 amp fuse. If fuse is good,
AUTO with utility loss. for alarms.
contact an IASD for assistance.

Unit will not start in Check LED’s / Screen

OVERSPEED RED Contact an IASD for assistance.
AUTO with utility loss. for alarms.

Unit will not start in Check LED’s / Screen

UNDERVOLTAGE RED Contact an IASD for assistance.
AUTO with utility loss. for alarms.

Unit will not start in Check LED’s / Screen

UNDERSPEED RED Contact an IASD for assistance.
AUTO with utility loss. for alarms.

STEPPER Unit will not start in Check LED’s / Screen

RED Contact an IASD for assistance.
OVERCURRENT AUTO with utility loss. for alarms.

Unit will not start in Check LED’s / Screen Verify wiring is installed and landed cor-
WIRING ERROR RED
AUTO with utility loss. for alarms. rectly.

Unit will not start in Check LED’s / Screen

OVERVOLTAGE RED Contact an IASD for assistance.
AUTO with utility loss. for alarms.

52 Installation Guidelines For Spark-Ignited Stationary Generators

 Troubleshooting/Quick Reference Guide

Active Alarm LED Problem Action Solution

Clear alarm. Check battery option in con-

Yellow LED illuminated in See screen for addi- trol menu. If it states battery is GOOD, con-
LOW BATTERY YELLOW
any state. tional information. tact an IASD. If it states CHECK BAT-
TERY, replace battery.

BATTERY Yellow LED illuminated in See screen for addi-

YELLOW Contact an IASD for assistance.
PROBLEM any state. tional information.

CHARGER Yellow LED illuminated in See screen for addi-

YELLOW Contact an IASD for assistance.
WARNING any state. tional information.

Yellow LED illuminated in See screen for addi- Perform SERVICE A maintenance. Press
SERVICE A YELLOW
any state. tional information. ENTER to clear.

Yellow LED illuminated in See screen for addi- Perform SERVICE B maintenance. Press
SERVICE B YELLOW
any state. tional information. ENTER to clear.

Yellow LED illuminated in See screen for addi-

INSPECT BATTERY YELLOW Inspect battery. Press ENTER to clear.
any state. tional information.

AC input to battery char-

Inspect connections at
CHARGER ger circuit missing for
YELLOW transfer switch, fuses Contact an IASD for assistance.
MISSING AC greater than 5 minutes
in transfer switch.
during charging cycle.

Unit either shuts down or Clear alarm and verify both auxiliary shut-
AUXILIARY does not start when one See screen for addi- down switches are ON (I). See Testing
RED
SHUTDOWN or both switches are OFF tional information. Auxiliary Shutdown Switch Operation
(O). for more information.

Installation Guidelines For Spark-Ignited Stationary Generators 53

Troubleshooting/Quick Reference Guide

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54 Installation Guidelines For Spark-Ignited Stationary Generators

 Accessories

Section 9: Accessories
Performance enhancing accessories are available for liquid-cooled generators.
Item Description Part Number
Cold Weather Kit G0079920
Recommended in areas where temperatures fall below
32 °F (0 °C).

Extreme Cold Weather Kit G0079900

Engine block heater. Used in conjunction with the
appropriate Cold Weather Kit.
NOTE: Engine oil must be replaced with synthetic oil.

Scheduled Maintenance Kit G0079910

Includes all pieces necessary to perform routine main-
tenance on the generator along with oil recommenda-
tions (oil not included).

Mobile Link™ 4G LTE Cellular Accessory G006463-4

(USA only)
Mobile Link 4G LTE Cellular Accessory allows the user
to monitor the status of the generator from anywhere in
the world, using a smartphone, tablet, or PC. Easily
access information such as the current operating status
and maintenance alerts. Users can connect an account
with an authorized service dealer for fast, friendly, and
proactive service. With Mobile Link, the user is taken
care of before the next power outage.
Touch-Up Paint Kit G005703-0—Bisque
If the generator enclosure is scratched or damaged, it is
important to touch-up the paint to protect from future
corrosion. The touch-up paint kit includes the necessary
paint to correctly maintain or touch-up a generator
enclosure.

Wireless Local Monitor G006664-0

Completely wireless and battery powered, the Wireless
Local Monitor provides users with instant status without
ever leaving the house. Status lights (red, yellow, and
green) alert users when the generator needs attention.
Magnetic backing permits refrigerator mounting and
gives a 600 ft (183 m) line of sight communication.

Extended Warranty Coverage

Ultrasonic Cleaner Solution A0000018981
An ultra-concentrated anti-corrosive cleaning solution
engineered to reach the smallest cavities to clean the
toughest contaminants. This water based formula is
non-toxic, biodegradable, safe for both metal and plas-
tic surfaces and is superior in rinsibility
All Surface Protectant A0000019001
All Surface Protectant for vinyl, rubber, plastics creates
a barrier that seals & protects surfaces from water, UV
rays while renewing the look of the surface.
Contact an IASD or visit www.generac.com for additional information on accessories and extended warranties.

Installation Guidelines For Spark-Ignited Stationary Generators 55

Accessories

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56 Installation Guidelines For Spark-Ignited Stationary Generators

 Installation Drawings

Section 10: Installation Drawings

A0000293718 Rev B Page 1 of 2
WEIGHT DATA SERVICE ITEM 4.5L NOTES:
WEIGHT WEIGHT OIL FILL CAP LEFT SIDE
ENCLOSURE SHIPPING WEIGHT
ENGINE/KW GENSET ONLY SHIPPING SKID OIL DIP STICK LEFT SIDE 1. MINIMUM RECOMMENDED CONCRETE PAD SIZE IS 6" OFFSET OF OVERALL LENGTH
MATERIAL KG [LBS]
KG [LBS] KG [LBS]
OIL FILTER LEFT SIDE AND WIDTH OF GENERATOR. {1193.8 (47") WIDE X 2423.2 (95.4") LONG}. REFERENCE
4.5L/48KW AL 808 [1781] 51 [112] 859 [1893]
OIL DRAIN HOSE RIGHT SIDE INSTALLATION GUIDE SUPPLIED WITH THE UNIT FOR CONCRETE PAD GUIDELINES.
RADIATOR DRAIN HOSE RIGHT SIDE REFERENCE MANUFACTURER'S SPECIFICATIONS IF USING ENGINEERED, PREFABRICATED SLABS.
COOLANT RECOVERY BOTTLE RIGHT SIDE 2. ALLOW SUFFICIENT ROOM ON ALL SIDES OF THE GENERATOR FOR MAINTENANCE
RADIATOR/EXHAUST AIR INTAKE
RADIATOR FILL CAP ROOF TOP AND SERVICING. THIS UNIT MUST BE INSTALLED IN ACCORDANCE WITH CURRENT
DISCHARGE AIR (BOTH SIDES)
AIR CLEANER ELEMENT LEFT SIDE APPLICABLE NFPA 37 AND NFPA 70 STANDARDS AS WELL AS ANY OTHER FEDERAL,
(BOTH SIDES)
SPARK PLUGS LEFT SIDE STATE, AND LOCAL CODES.
REMOVE COVER
3. CONTROL PANEL / CIRCUIT BREAKER INFORMATION:
FOR ACCESS TO MUFFLER SEE NOTE 11
- SEE SPECIFICATION SHEET OR OWNERS MANUAL
RADIATOR FILL DRIVE BELT EITHER SIDE
- ACCESSIBLE THROUGH CUSTOMER ACCESS ASSEMBLY DOOR ON REAR OF GENERATOR.
CAP BATTERY LEFT SIDE
4. REMOVE THE REAR ENCLOSURE COVER PANEL TO ACCESS
THE STUB-UP AREAS AS FOLLOWS:
REFERENCE OWNERS MANUAL - HIGH VOLTAGE CONNECTION INCLUDING AC LOAD LEAD CONDUIT CONNECTION
FOR PERIODIC REPLACEMENT NEUTRAL CONNECTION, BATTERY CHARGER 120 VOLT AC (0.5 AMP MAX) CONNECTION.
PARTS LIST - LOW VOLTAGE CONNECTION INCLUDING TRANSFER SWITCH CONTROL WIRES.
5. CENTER OF GRAVITY AND WEIGHT MAY CHANGE DUE TO UNIT OPTIONS.
6. BOTTOM OF GENERATOR SET MUST BE ENCLOSED TO PREVENT PEST INTRUSION AND
RECIRCULATION OF DISCHARGE AIR AND/OR IMPROPER COOLING AIR FLOW.
7. REFERENCE OWNERS MANUAL FOR LIFTING WARNINGS.
8. MOUNTING BOLTS OR STUDS TO MOUNTING SURFACE SHALL BE 5/8-11 GRADE 5
(USE STANDARD SAE TORQUE SPECS)
9. MUST ALLOW FREE FLOW OF INTAKE AIR, DISCHARGE AIR AND EXHAUST. SEE SPEC
SHEET FOR MINIMUM AIR FLOW AND MAXIMUM RESTRICTION REQUIREMENTS.
843 [33] 10. GENERATOR MUST BE INSTALLED SUCH THAT FRESH COOLING AIR IS AVAILABLE
TOP VIEW CENTER OF GRAVITY BATTERY 12V AND THAT DISCHARGE AIR FROM RADIATOR IS NOT RECIRCULATED.
(SEE NOTE 5) GROUP 27F 11. EXHAUST MUFFLER ENCLOSED WITHIN GENERATOR ENCLOSURE,
NEGATIVE GROUND REMOVE FRONT PANEL TO ACCESS.
P/N G058665
1212 [47.7]
VICE ACTION LATCH
EXHAUST MUFFLER DOOR TYP
REAR ENCLOSURE ONE PER DOOR
ENCLOSED WITHIN CIRCUIT BREAKER COVER PANEL ONE LIFT OFF DOOR PER
GENERATOR ENCLOSURE SEE NOTE 3 SEE NOTE 4 SIDE OF GENERATOR

1168 [46.0]
RADIATOR/EXHAUST
DISCHARGE AIR
OVERALL
HEIGHT

65
[2.6]

47 2026 [79.8] TYP FUEL LINE CONNECTION

58 318 1-1/4" NPT FEMALE TEE
[2.3] [1.8] 888 [35.0] [12.5] THROUGH BASEFRAME OPENING
TYP OVERALL WIDTH
2119 CUSTOMER ACCESS
[83.4] ASSEMBLY, CONTROL RIGHT SIDE VIEW
REAR VIEW
OVERALL LENGTH PANEL ACCESS
BATTERY CHARGER
LEFT SIDE VIEW LOCATED WITHIN
SEE NOTE 4

Installation Guidelines For Spark-Ignited Stationary Generators 57

Installation Drawings

A0000293718 Rev B Page 2 of 2

13.5 X 29.5
[.53] [1.2]
MOUNTING SLOTS *NOTE:
4X STUB-UP AREA FOR HIGH AND LOW
VOLTAGE CONNECTIONS, CIRCUIT BREAKER,
NEUTRAL AND CUSTOMER CONNECTION OPENING.

HIGH AND LOW

VOLTAGE
STUB-UP AREA 786
[30.9]

162
[6.4]
STUB-UP
AREA

42 162 9
[1.7] [6.4] 51
[.4] [2.0]
STUB-UP
1872 243 AREA
[73.7] [9.5] REMOVABLE
STUB-UP COVER
TOP VIEW
850
[33.5]

100 1919 [75.5] 838.1 [33.00]

[3.94] MOUNTING SLOT CENTERS MOUNTING SLOT CENTERS

2119
[83.4]
REAR VIEW
LEFT SIDE VIEW

58 Installation Guidelines For Spark-Ignited Stationary Generators

 Installation Drawings

Alternator AC Lead Connections Alternator Power Winding

The electrical wires in the unit’s AC connection (lower) Connections
panel should be installed according to number of leads
and voltage/phase required for the application. The volt- Three-Phase Alternators (“Y” Configuration)
age and phase are described on the generator data label. The Stationary Emergency Generator is designed to sup-
The number of lead wires can be identified using the ply three-phase electrical loads. Electric power is pro-
Specifications section and power output rating on the duced in the alternator power windings. These windings
generator data label. For example, if generator produces were factory-connected to the main circuit breaker with a
130kW, 277/480 volt, three-phase power, generator has “Y” configuration as shown in Figure 10-2 through Fig-
12 alternator output leads. Figure 10-3 describes the sta- ure 10-6.
tor power winding connection for the generator. Rated voltage between circuit breaker terminals E1–E2,
E1–E3 and E2–E3 is 480V, 208V or 600V depending on
Four-Lead, Single-Phase Stator model.
See Figure 10-1. Four-lead alternators are designed to Rated voltage between each circuit breaker terminal and
supply electrical loads with voltage code “A” (240V, sin- the neutral point 00 is 277V, 120V, or 346V depending on
gle-phase, 60 Hz). Electrical power is produced in the model.
stator power windings. These windings were factory-con-
nected to the main circuit breaker as shown. E1
S1

44 E3
B

A 120 VAC
L-L
33 S4
00 240 VAC
S6
00 A
S5
22

120 VAC S3 S2

E3 L-N E2

11 E1 006478
B 006477 A Neutral B Internal connections
A Neutral B Circuit breaker Figure 10-2. Stator Power Winding Connections—
Three-Phase, 277/480V (6 Lead)
Figure 10-1. Four-Lead, Single-Phase Stator

Rated voltage between each circuit breaker terminal is E1

240V. The rated voltage between each circuit breaker ter- S1

minal and the neutral point 00 is 120V.

S4
S7

L-L
S12 S10

S9 S11 S8
S6 S5

S3 S2

E3 E2 006479
L-N

Figure 10-3. Stator Power Winding Connections—

Three-Phase, 277/480V (12 Lead)

Installation Guidelines For Spark-Ignited Stationary Generators 59

Installation Drawings

Three-Phase Alternators (“Delta” Configuration)

B E1
S1 S1 The Stationary Emergency Generator is designed to sup-
ply three-phase electrical loads. Electric power is pro-
duced in the alternator power windings. These windings
were factory-connected to the main circuit breaker with a
S4 S4
L-L “Delta” configuration as shown in Figure 10-7 and Fig-
00 A ure 10-8.
S6 S5
Rated voltage between circuit breaker terminals E1–E2,
S3 S6 S5 S2 E1–E3 and E2–E3 is 240V.
Rated voltage between E2 and the neutral point 00 is
E3 E2
S3 S2
006480
208V. The rated voltage E1–00 and E3–00 is approxi-
L-N
mately 120V.
A Neutral B Internal connections NOTE: Voltage measured from E2 to 00 can greatly vary
when single-phase load is placed on alternator.
Figure 10-4. Stator Power Winding Connections—
Three-Phase, 120/208V (6 Lead)

E1
S7 S1

B
L-L
S10 S4
S12 S5

S9 S6 S11 S2
006483
E3 E2
S3 S8
006481 B Internal connections
L-N
Figure 10-5. Stator Power Winding Connections—
Figure 10-7. Stator Power Winding Connections—
Three-Phase, 120/208V (12 Lead)
Three-Phase, 120/240V (6 Lead)
E1
S1 E2
S2 S12
B
S5 S9
240 VAC
S8 S6 240 VAC
L-L
S4 208 VAC
S6
00 A S11 NB S3
S5
E1 S1 S10 E3
240 VAC

S3 S2
120 VAC
E3 E2 120 VAC
L-N 006482 006484

A Neutral B Internal connections Figure 10-8. Stator Power Winding Connections—

Three-Phase, 120/240V (12 Lead)
Figure 10-6. Stator Power Winding Connections—
Three-Phase, 346/600V (6 Lead)

60 Installation Guidelines For Spark-Ignited Stationary Generators

 Installation Drawings

Alternator Wiring Diagram

(1 of 4)

Installation Guidelines For Spark-Ignited Stationary Generators 61

Installation Drawings

Alternator Wiring Diagram

(2 of 4)

62 Installation Guidelines For Spark-Ignited Stationary Generators

 Installation Drawings

Alternator Wiring Diagram

(3 of 4)

Installation Guidelines For Spark-Ignited Stationary Generators 63

Installation Drawings

Alternator Wiring Diagram

(4 of 4)

64 Installation Guidelines For Spark-Ignited Stationary Generators

 Installation Drawings

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Installation Guidelines For Spark-Ignited Stationary Generators 65

Installation Drawings

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66 Installation Guidelines For Spark-Ignited Stationary Generators

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 ®

Part No. A0000253470 Rev. B 8/3/2020

©2020 Generac Power Systems, Inc. Generac Power Systems, Inc.
All rights reserved. S45 W29290 Hwy. 59
Specifications are subject to change without notice. Waukesha, WI 53189
No reproduction allowed in any form without prior written 1-888-GENERAC (1-888-436-3722)
consent from Generac Power Systems, Inc. www.generac.com