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Generac Power Systems PowerPact G0065201

Generac Power Systems PowerPact G0065201
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001036
Installation Guidelines
50 Hz Air-Cooled Generators
5.6 kVA PowerPact™
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Table of Contents

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Generac Power Systems PowerPact G0065201 Specifications

General IconGeneral
BrandGenerac Power Systems
ModelPowerPact G0065201
CategoryPortable Generator
LanguageEnglish

Summary

Installation Guidelines

Introduction

Overview of the compact, high-performance, air-cooled, engine-driven generator for critical loads.

Safety Warnings

Alerts personnel to special instructions about hazardous operations, defined as DANGER, WARNING, and CAUTION.

Section 1: Safety Rules & General Information

Introduction

Overview of the compact, high-performance, air-cooled, engine-driven generator for critical loads.

Safety Rules

Important guidelines and precautions for safe installation, operation, and maintenance of the generator.

How to Obtain Service

Guidance on contacting an Independent Authorized Service Dealer for assistance and locating a dealer.

General Hazards

Moving Parts Safety

Precautions regarding jewelry, clothing, hair, and appendages near moving parts for safety.

Hot Surfaces Warning

Caution against touching hot surfaces and keeping the machine away from combustibles.

Equipment and Property Damage

Warning against altering construction or blocking ventilation, which can cause unsafe operation or damage.

Injury and Equipment Damage

Warning against using the generator as a step, which can lead to injury or damage.

Qualified Service Personnel

Requirement for qualified personnel for installation, operation, and maintenance to prevent injury and damage.

Exhaust Hazards

Carbon Monoxide Hazard

Danger of asphyxiation from carbon monoxide, requiring indoor CO alarms and adequate ventilation.

Electrical Hazards

Contact with Bare Wires

Warning about electrocution risk from contact with bare wires, terminals, and connections while the generator is running.

Transfer Switch Requirement

Mandate for licensed electrician to install transfer switch to prevent electrocution and death.

Electrical Backfeed Warning

Warning about death, serious injury, and equipment damage from electrical backfeed without proper switchgear.

Grounding Verification

Importance of verifying proper grounding before applying power to prevent electrocution.

Fire Hazards

Ventilation Obstruction

Fire hazard from obstructing cooling and ventilating airflow, leading to potential fire or damage.

Code Compliance for Fire Safety

Requirement for compliance with codes for fire and explosion prevention during installation.

Fire Extinguisher Requirements

Recommendation to use only fully-charged fire extinguishers rated for electrical fires.

General Rules

Code and Regulation Compliance

Mandatory compliance with applicable codes, standards, laws, and regulations for installation.

Electrical Backfeed Prevention

Use of approved switchgear to isolate generator to prevent backfeed and ensure safety.

Qualified Personnel Requirement

Emphasis on qualified service personnel for installation and operation to prevent injury and warranty voidance.

Explosion Hazards

Fuel Flammability and Leakage

Warning about explosion and fire risk from flammable fuel and vapors; prohibition of fuel leakage.

Fuel Source Connection

Requirement for qualified technician for fuel source connection to prevent injury and damage.

Fuel Spill Handling

Caution to allow fuel spills to dry completely before starting the engine to prevent fire risk.

Hot Surfaces and Combustibles

Risk of fire from hot surfaces igniting combustibles, leading to severe injury or death.

Before You Begin

Permits and Inspections

Contacting local authorities for permits and inspections before starting the installation.

Manual Review

Thoroughly reading and understanding all manual sections and contacting support if unclear.

Code and Standard Compliance

Full compliance with NEC, NFPA, OSHA, and local codes for generator installation.

Fuel Capacity Verification

Verifying the capacity of the natural gas meter or LP tank for sufficient fuel supply.

NEC Requirements

Arc Fault Circuit Interrupters (AFCIs)

Information on local code requirements for AFCIs and compatible transfer switch panels.

Standards Index

NFPA and Building Codes

List of applicable NFPA and building codes for generator installation, with sources.

Section 2: Unpacking and Inspection

General Inspection Procedures

Guidelines for inspecting the unit for damage upon delivery and filing claims promptly.

Required Tools for Installation

List of essential tools needed for unpacking, installation, and maintenance of the generator.

Unpacking the Generator

Step-by-Step Unpacking

Detailed steps for removing the generator from its packaging and performing a visual inspection for damage.

Parts Shipped Loose

Inventory of Loose Parts

List of parts shipped loose with the generator, including their location and identification.

Section 3: Site Selection and Preparation

Site Selection Guidelines

Recommendations for generator placement, clearance, and environmental considerations for safe operation.

Generator Placement Requirements

Specific clearance requirements from structures, openings, and vegetation for airflow and maintenance.

Base Material and Leveling

Guidelines for selecting base material (gravel or concrete) and ensuring the generator is level.

Installation Guidelines for Stationary Air-Cooled Generators

NFPA 37 Compliance

Requirements from NFPA 37 for outdoor engine installation, including minimum separation distances.

Southwest Research Institute Decal

Information about the SwRI decal and its significance regarding fire safety testing.

Site Preparation

Location and Airflow

Tips for choosing a site that provides adequate airflow and avoids obstruction by debris or fumes.

Base Preparation

Detailed instructions for preparing a compacted gravel pad or a concrete pad for generator installation.

Material Sufficient for Level Installation

Gravel Pad Dimensions

Specifications for digging and filling a gravel pad to ensure a level installation base.

Transportation Recommendations

Moving the Generator

Instructions on how to safely move the generator using a hand cart or rails, with precautions against damage.

Section 4: Generator Placement

Composite Pad Usage

Information on the purpose and mandatory use of composite pads for elevating and protecting the generator.

Mounting to Concrete

Instructions for securing the generator to a concrete pad using lag bolts, emphasizing not removing the pads.

Section 5: Fuel ConversionGas Connections

Fuel Requirements and Recommendations

Guidelines for fuel types (NG/LP), BTU content, and pressure, with safety warnings.

Fuel Conversion Procedure

Step-by-step instructions for converting the generator from natural gas to liquid propane fuel.

Fuel Consumption Data

Natural Gas vs. LP Vapor Consumption

Table showing fuel consumption rates for natural gas and LP vapor at different load levels.

Fuel Line Sizing

Natural Gas Pipe Sizing

Chart for determining the correct pipe size based on kVA rating and maximum length for natural gas.

LP Vapor Pipe Sizing

Chart for determining the correct pipe size based on kVA rating and maximum length for LP vapor.

Summary of Gas Pipe Sizing

Critical Sizing Importance

Emphasis on correct gas pipe sizing for proper generator operation and 125% load rating.

Installing and Connecting Gas Lines

Gas Line Installation Safety

Adherence to safety procedures, codes, and regulations for combustible gas line connections.

Shutoff Valve Requirements

Mandatory installation of an accessible manual full flow shut-off valve on the fuel line.

Flexible Fuel Line Installation

Guidelines for using UL Listed/AGA-approved flexible fuel lines to isolate vibration and prevent leaks.

Sediment Trap Installation

Recommendation to install a sediment trap as required by local codes.

Checking Gas Line Connections

Leak Detection

Procedure for checking gas connections for leaks using non-corrosive leak detection fluid.

Gas Pressure Testing

Steps for checking gas pressure at the regulator using a manometer, referencing fuel requirements.

Natural Gas Vapor Installation (typical)

NG Installation Diagram Components

Labels and descriptions for components in a typical natural gas vapor installation diagram.

LP Vapor Installation (typical)

LP Vapor Installation Diagram Components

Labels and descriptions for components in a typical LP vapor installation diagram.

Section 6: Electrical Connections

Control Wiring

Guidelines for control wire length, size, and connection points to the generator control panel.

Control Panel Wiring Connections

Table detailing terminal numbering decals and corresponding wire numbers for control panel connections.

Main AC and Control Wire Installation

Instructions for installing conduit and routing wires through a NEMA 3 rated external connection box.

Main AC Wiring

AC Wiring Diagram

Diagram illustrating the main AC wiring connections between the generator, transfer switch, and panelboard.

Main AC Wiring Steps

Step-by-step instructions for connecting the main AC wiring, including torque specifications.

Neutral Bonding

Explanation of neutral bonding requirements for separately derived systems versus utility-supplied systems.

Battery Requirements

Battery Specifications

Details on the required battery type, voltage, and CCA rating for the generator.

Battery Installation Procedure

Battery Safety Precautions

Warnings regarding battery explosion, acid burns, and electrical shock hazards during installation.

Connecting Battery Cables

Step-by-step instructions for correctly connecting the positive and negative battery cables.

Battery Bracket Installation

Procedure for installing the battery bracket to secure the battery.

Section 7: Control PanelStart-upTesting

Control Panel Interface Overview

Description of the Auto/Off/Manual interface, including alarm LEDs, warning LEDs, and mode buttons.

Operation Mode Buttons

Explanation of the AUTO, MANUAL, and OFF buttons and their functions for generator operation.

Generator Set-up

Pre-Start Checklist

Essential steps to complete before the initial start-up, including checking generator status and fuel supply.

Engine Oil Recommendations

Guidelines for selecting the appropriate engine oil viscosity based on operating temperature.

Setting The Exercise Timer

Exercise Timer Functionality

Explanation of the generator's exercise timer and how to set or change the weekly exercise time.

Check Manual Transfer Switch Operation

Manual Transfer Safety

Warning against manual transfer under load, emphasizing disconnecting power sources first.

Electrical Checks

Utility Power Checks

Steps to verify utility power voltage and compatibility before connecting the generator.

Generator Output Checks

Procedure for checking generator AC output voltage and frequency under no-load and load conditions.

Generator Tests Under Load

Full Load Testing Procedure

Steps for testing the generator at full rated load for 20-30 minutes, checking for abnormalities.

Checking Automatic Operation

Automatic Transfer Sequence

Procedure for verifying the generator's automatic start-up and transfer to standby during utility failure.

Installation Summary

Final Verification and User Education

Steps for verifying proper installation, testing operation, and educating the end user.

Shutting Generator Down While Under Load

Procedure for Generator Shutdown

Instructions for safely turning the generator off while it is running under load for maintenance or fuel conservation.

Section 8: Troubleshooting

Troubleshooting Guide Table

A table listing common problems, their causes, and recommended solutions for generator operation.

Engine Not Cranking

Troubleshooting steps for when the engine fails to crank, covering fuse, battery, and starter issues.

Engine Cranks But Wont Start

Troubleshooting steps for when the engine cranks but does not start, including fuel and spark issues.

Engine Runs Rough

Troubleshooting steps for an engine that starts hard or runs rough, addressing air cleaner, spark plugs, and fuel pressure.

No AC Output

Troubleshooting steps for when there is no AC output from the generator, checking the circuit breaker and internal failure.

No Transfer to Standby

Troubleshooting steps for when the generator fails to transfer to standby power after utility failure.

Unit Consumes Large Amounts of Oil

Troubleshooting steps for excessive oil consumption, including checking oil level and seals.

Section 9: Quick Reference Guide

System Diagnosis Table

A table for diagnosing system issues based on active alarms, LED indicators, problems, and checks.

Active Alarm: High Temperature

Troubleshooting steps for high temperature shutdown, focusing on ventilation and contacting service.

Active Alarm: Low Oil Pressure

Troubleshooting steps for low oil pressure issues, including checking oil level and contacting service.

Active Alarm: Overcrank

Troubleshooting steps for overcrank faults, checking fuel shutoff and starting in manual mode.

Active Alarm: Battery Problem

Troubleshooting steps for battery problems, checking the battery menu and contacting service.

System Diagnosis (Continued)

Active Alarm: Break-in Maintenance Due

Instructions for performing break-in maintenance and clearing the 'Maintenance Due' light.

Active Alarm: 1 Year 100 Hour Maintenance Due

Instructions for performing scheduled maintenance and clearing the 'Maintenance Due' light.

Active Alarm: Utility Present Flashing LED

Troubleshooting for flashing active mode LEDs when utility is present, checking utility sense lines.

Section 10: Accessories

Performance Enhancing Accessories

Description of accessories available for air-cooled generators, including their purpose and benefits.

Cold Weather Kit

Recommendation for the Cold Weather Kit in areas with temperatures below 32°F (0°C).

Scheduled Maintenance Kit

Information on the Scheduled Maintenance Kit for performing generator maintenance.

Wireless Local Monitor

Description of the Wireless Local Monitor for instant status updates and alerts.

Section 11: Diagrams

Generator Dimensional Views

Illustrations showing the left side and front views of the generator with key dimensions.

Generator Diagrams (Page 2)

Generator Side and Rear Views

Illustrations showing the right side and rear views of the generator with inlet/outlet and fuel connection details.

Wiring Diagram (Page 1)

Generator Wiring Schematic Components

Diagram detailing the electrical connections between the generator components, AVR, controller, and wiring legend.

Wiring Diagram (Page 2)

Generator Connection Points

Diagram illustrating dead front plate connections, generator output, utility sense, and AC load supply.

Wiring Diagram (Page 3)

Generator Schematics and Legend

Schematic diagram showing stator, rotor, controller, and battery connections with a detailed legend.

Wiring Diagram (Page 4)

AVR and Controller InputsOutputs

Diagram showing AVR and controller inputs and outputs, including utility and load supply connections.

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