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®
POWER SYSTEMS, INC.
Installation and
Owner’s Manual
Air-cooled Automatic
Standby Generators
Models:
04673-2 (6 kW NG, 7 kW LP)
04674-2 (12 kW NG, 12 kW LP)
04675-3 (13 kW NG, 15 kW LP)
R
GENERAC
POWER SYSTEMS, INC.
R
*This manual should remain with the unit.*
Not intended for use as Primary Power in place of utility
!
!
or in life-support applications.
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
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The operator is responsible for proper and safe use INTRODUCTION of the equipment. Generac strongly recommends that Thank you for purchasing this model by Generac the operator read this Owner's Manual and thor- Power Systems Inc.. This model is a compact, high oughly understand all instructions before using this performance, air-cooled, engine-driven generator equipment. Generac also strongly recommends designed to automatically supply electrical power to instructing other users to properly sta
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Table of Contents Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 3.2.2 “Off” Position....................................14 Introduction ........................Inside Front Cover Read This Manual Thoroughly ........................IFC 3.2.3 “Manual” Position ............................14 Contents ..........................................................IFC 3.3 Automatic Transfer Operation ....................14 Operation and Maintenance ............................IFC 3.4 Sequence of Aut
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IMPORTANT SAFETY INSTRUCTIONS Generac Air-cooled 7 kW, 12 kW and 15 kW Generators SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit’s installation site. Safety should be stressed to ! ! all operators and potential operators of this equipment. ! ! WARNING: The engine exhaust from this product Please read all hazards carefully! ! contains chemicals known to the state of California to cause cancer, birth defects or other repr
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IMPORTANT SAFETY INSTRUCTIONS Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Keep a fire extinguisher near the generator at all times. Extinguishers rated “ABC” by the National ELECTRICAL HAZARDS Fire Protection Association are appropriate for use on the standby electric system. Keep the extin- All generators covered by this manual produce dangerous electrical voltages and can cause fatal guisher properly charged and be familiar with its use. If there are any questions pertaining to fir
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Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 1.2 PROTECTION SYSTEMS DANGER Unlike an automobile engine, the generator may have Only qualified electricians or contractors should to run for long periods of time with no operator pres- ! attempt such installations, which must comply ent to monitor engine conditions. For that reason, the strictly with applicable codes, standards and engine is equipped with the following systems that regulations. protect it again
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Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 1.4 THE GENERATOR Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine Control Panel Oil Data Dipstick Decal GFCI Outlet Exhaust Enclosure Fuel Regulator Fuel Inlet Battery Oil Filter Compartment Figure 1.2 – 12 kW/15 kW, V-twin GT-990/760 Engine Control Panel Oil Data Dipstick Decal GFCI Outlet Exhaust Enclosure Fuel Regulator Fuel Inlet Composite Base Battery Oil Filter Compartment ® Generac Power Systems, Inc. 5
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Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 1.5 SPECIFICATIONS 1.5.1 GENERATOR Model 04673 Model 04674 Model 04675 Rated Max. Continuous Power Capacity (Watts*) 6,000 NG/7,000 LP 12,000 NG/12,000 LP 13,000 NG/15,000 LP Rated Voltage 120/240 120/240 120/240 Rated Max. Continuous Load Current (Amps) 120 Volts + 50.0 NG/58.3 LP 100 NG/100.0 LP 108.3 NG/125.0 LP 240 Volts 25.0 NG/29.2 LP 50 NG/50.0 LP 54.2 NG/62.5 LP Main Line Circuit Breaker 30 Amp 50 Amp 60
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Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 3. Remove the battery (if installed). 1.6 FUEL REQUIREMENTS 4. Disconnect wire #0 and wire #14 from the gas AND RECOMMENDATIONS solenoid on top of the demand regulator. With LP gas, use only the vapor withdrawal 5. Remove the carburetor fuel hose from the outlet system. This type of system uses the vapors formed port of the demand regulator. above the liquid fuel in the storage tank. 6. Remove the demand regula
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Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 4. Remove the engine air in baffle located on the left- 14. It may be necessary to make minor adjustments hand side of the battery compartment. Two M6 to the preset adjustment screw settings to achieve screws are located on top of the baffle and two maximum power, particularly at higher altitudes. M6 screws are located on the inside of the baffle If experiencing problems with the unit producing towards the back.
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Section 1 — General Information Generac Air-cooled 7 kW, 12 kW and 15 kW Generators NOTE: 1.10 BATTERY INSTALLATION Fill the battery with the proper electrolyte fluid if nec- The generator is equipped with a battery trickle essary and have the battery fully charged before charger that is active when the unit is set up for installing it. automatic operation. With the battery installed and utility power source voltage available to the Before installing and connecting the battery, complete transfer
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Section 2 — Post Installation Start-up and Adjustments Generac Air-cooled 7 kW, 12 kW and 15 kW Generators The following procedures are to be observed: 2.2 CHECK TRANSFER SWITCH Wear full eye protection and protective clothing; OPERATION Where electrolyte contacts the skin, wash it off Refer to Section 3.5 of the owner’s manual for manu- immediately with water; al operation procedures. Where electrolyte contacts the eyes, immediately flush thoroughly with water and seek medical DANGER att
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Section 2 — Post Installation Start-up and Adjustments Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 8. Connect an accurate AC voltmeter and a frequen- 8. Turn ON electrical loads. Apply an electrical load cy meter across transfer switch terminal lugs E1 equal to the full rated wattage/amperage capacity and E2. Voltage should be 242-252 volts; fre- of the installed generator. quency should read about 61-63 Hertz. 9. Connect an accurate AC voltmeter and a frequen- 9. Connect the AC voltmete
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Section 2 — Post Installation Start-up and Adjustments Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 6. When the highest frequency is reached maximum 2.6 ADJUSTING THE REGULATOR power has been set. Then turn both adjustment (NATURAL GAS ONLY) screws 1/4 turn counterclockwise. Regulator is Although the generator has been factory set to pro- now set. vide maximum power, it may be necessary in some Figure 2.2 — Placement of Regulator areas to adjust this setting. Because natural gas has diffe
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Section 2 — Post Installation Start-up and Adjustments Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 6. When frequency is correct at no load, check the 7. Restart the unit. AC voltage reading. If voltage is incorrect, the volt- 8. Slowly turn the idle adjust screw to adjust the no- age regulator may require adjustment. load idle frequency to 63-63.5 Hz. 9. The governor is now set. Figure 2.3 — Single Cylinder Engine Governor Adjustment Figure 2.5 — V-twin Full Load Speed Adjust Screw Full
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Section 3 — Operation Generac Air-cooled 7 kW, 12 kW and 15 kW Generators NOTE: Figure 3.1 – Generator Control Panel The voltage regulator is housed above the genera- FUSE R tor's control panel. The regulator maintains a volt- Loc at e y our near es t dealer at : age in direct proportion to frequency. For example, R POWER SYSTEMS, INC. at 62 Hertz, line-to-neutral voltage will be 124 volts. 5A AUTO OFF MAN. SYSTEM SET LOW OIL HIGH TEMP. FUSE 3.1 BREAK-IN PROCEDURE OVER SPEED Once the unit has be
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Section 3 — Operation Generac Air-cooled 7 kW, 12 kW and 15 kW Generators Upon restoration of utility source voltage above a pre- DANGER set level, generator circuit board action signals the transfer switch to transfer loads back to that power Do not attempt to activate the transfer switch supply. After retransfer, the engine is signalled to shut manually until all power voltage supplies to down. the switch have been positively turned off. The actual sequence of operation is controlled by Failu
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n e s o o L Section 3 — Operation Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 3.7 PROTECTION SYSTEMS DANGER 3.7.1 LOW OIL PRESSURE SWITCH Do not attempt to activate the transfer switch manually until all power voltage supplies This switch (Figure 3.3) has normally closed contacts to the switch have been positively turned off. that are held open by engine oil pressure during crank- Failure to turn off all power voltage supplies ing and operating. Should oil pressure drop below the may r
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Section 4 — Maintenance Generac Air-cooled 7 kW, 12 kW and 15 kW Generators 3. Install the dipstick; then, remove it again. The oil 3.7.3.1 Approximate Crank Cycle Times level should be at the dipstick “Full” mark. If nec- 15 seconds ON essary, add oil to the “Full” mark only. DO NOT 7 seconds OFF FILL ABOVE THE “FULL” MARK. 7 seconds ON 7 seconds OFF Repeat for 45 seconds Never operate the engine with the oil level Approximately 90 seconds total ! below the “Add” mark on the dipstic
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n e s o o L Section 4 — Maintenance Generac Air-cooled 7 kW, 12 kW and 15 kW Generators NOTE: 4.5 CHANGING THE ENGINE The unit is supplied with “break-in” oil. See the AIR CLEANER “Break-in Procedure,” Section 3.1, for the first required oil change. 4.5.1 7 KW, 12 KW AND 15 KW GENERATORS See Figures 1.1 and 1.2, for the location of the air Any attempt to crank or start the engine before cleaner. Use the following procedure (Figure 4.6): ! it has been properly serviced with the recom- 1. Turn t
