Generac Power Systems Generator Bedienungsanleitung

POWER SYSTEMS, INC.

DANGER

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!

PowerMaster Technical Manual

This manual should remain with the unit.

INTRODUCTION

Thank you for purchasing the PowerMaster Assembly

by Generac Power Systems, Inc.

Every effort was expended to make sure that the

information and instructions in this manual were

both accurate and current at the time the manual was

written. However, the manufacturer reserves the right

to change, alter or otherwise improve this product(s)

at any time without prior notice.

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, con-

tact the nearest Authorized Service Dealer for start-

ing, operating and servicing procedures.

Throughout this publication, and on tags and decals

affixed to the generator, DANGER, WARNING,

CAUTION and NOTE blocks are used to alert person-

nel to special instructions about a particular service

or operation that may be hazardous if performed

incorrectly or carelessly. Observe them carefully.

Their definitions are as follows:

DANGER

After this heading, read instructions that, if not

strictly complied with, will result in personal injury

or property damage.

After this heading, read instructions that, if not

strictly complied with, may result in personal injury

or property damage.

After this heading, read instructions that, if not

strictly complied with, could result in damage to

equipment and/or property.

NOTE:

After this heading, read explanatory statements

that require special emphasis.

These safety warnings cannot eliminate the hazards

that they indicate. Common sense and strict compli-

ance with the special instructions while performing the

service are essential to preventing accidents.

Four commonly used safety symbols accompany the

DANGER, WARNING and CAUTION blocks. The type

of information each indicates is as follows:

This symbol points out important safety informa-

tion that, if not followed, could endanger personal

safety and/or property of others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock

hazard.



The operator is responsible for proper and safe use

of the equipment. The manufacturer strongly recom-

mends that the operator read this Owner's Manual

and thoroughly understand all instructions before

using this equipment. The manufacturer also strong-

ly recommends instructing other users to properly

start and operate the unit. This prepares them if they

need to operate the equipment in an emergency.

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety

checks, to make sure that all maintenance for safe

operation is performed promptly, and to have the

equipment checked periodically by an Authorized

Service Dealer. Normal maintenance service and

replacement of parts are the responsibility of the

owner/operator and, as such, are not considered

defects in materials or workmanship within the

terms of the warranty. Individual operating habits

and usage contribute to the need for maintenance

service.

Proper maintenance and care of the generator ensures

a minimum number of problems and keep operating

expenses at a minimum. See an Authorized Service

Dealer for service aids and accessories.

Operating instructions presented in this manual

assume that the standby electric system has been

installed by an Authorized Service Dealer or other

competent, qualified contractor. Installation of this

equipment is not a “do-it-yourself” project.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs,

contact an Authorized Service Dealer for assistance.

Service technicians are factory-trained and are capa-

ble of handling all service needs.

When contacting an Authorized Service Dealer about

parts and service, always supply the complete model

number of the unit as given on the front cover of this

manual or on the DATA LABEL affixed to the unit.



AUTHORIZED DEALER LOCATION

To locate the nearest AUTHORIZED

SERVICE DEALER, please call:

1-800-333-1322

or visit the website at:

www.generac.com

Table of Contents

PowerMaster Technical Manual

Introduction ........................Inside Front Cover

Read This Manual Thoroughly ........................ IFC

Operation and Maintenance ............................ IFC

How to Obtain Service..................................... IFC

Authorized Dealer Locator Number ................... IFC

Safety Rules ........................................................2

Section 1 – General Information...................4

1.1 Introduction ..................................................4

1.2 Equipment Description .................................4

1.3 Unpacking the Box ........................................4

1.4 Enclosure Details ..........................................4

Section 2 – Installation....................................4

2.1 Introduction to Installation............................. 4

2.2 Mounting the Enclosure ................................. 4

2.3 Connecting the Source Voltage(s)

and Load(s) .................................................... 5

2.3.1 Load #1 Connection Instructions ....... 5

2.3.2 Load #2 Connection Instructions ....... 5

2.4 Connecting the Control Circuits ..................... 5

2.4.1 Control Circuit #1 Connections.......... 5

2.4.2 Control Circuit #2 Connections.......... 5

2.5 Installing the Auxiliary Switches

to the Transfer Switch.................................... 6

2.6 Connecting the Auxiliary Switches.................. 6

2.6.1 Generator Side Auxiliary Switch ......... 6

2.6.2 Utility Side Auxiliary Switch................ 6

2.7 Restoring All Power Supplies ......................... 6

Section 3 – Operation ......................................7

3.1 Testing the PowerMaster Operation................ 7

Section 4 – Electrical Data ..............................8

Section 5 – Exploded Views &

Parts Lists................................... 10

Section 6 – Notes ........................................... 12

Section 7 – Warranty .....................Back Cover

Study these SAFETY RULES carefully before install-

ing, operating or servicing this equipment. Become

familiar with this Owner’s Manual and with the unit.

The generator(s) can operate safely, efficiently and

reliably only if it is properly installed, operated and

maintained. Many accidents are caused by failing to

follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible

circumstance that might involve a hazard. The warn-

ings in this manual, and on tags and decals affixed

to the unit are, therefore, not all-inclusive. If using

a procedure, work method or operating technique

the manufacturer does not specifically recommend,

ensure that it is safe for others. Also make sure the

procedure, work method or operating technique uti-

lized does not render the generator(s) unsafe.

DANGER

Despite the safe design of the generator(s),

operating this equipment imprudently, neglect-

ing its maintenance or being careless can cause

possible injury or death. Permit only responsible

and capable persons to operate or maintain this

equipment.

Potentially lethal voltages are generated by

these machines. Ensure all steps are taken to

render the machine safe before attempting to

work on the generator(s).

Parts of the generator(s) are rotating and/or hot

during operation. Exercise care near running

generators.

GENERAL HAZARDS 

For safety reasons, the manufacturer requires that

the installation, initial start-up and maintenance

of this equipment is carried out by an Authorized

Dealer.

The engine exhaust fumes contain carbon monox-

ide, which can be DEADLY. This dangerous gas, if

breathed in sufficient concentrations, can cause

unconsciousness or even death. This exhaust

system must be installed properly, in strict com-

pliance with applicable codes and standards.

Following installation, do nothing that might ren-

der the system unsafe or in noncompliance with

such codes and standards.

Keep hands, feet, clothing, etc., away from drive

belts, fans, and other moving or hot parts. Never

operate the unit with any drive belt or fan guard

removed.

Adequate, unobstructed flow of cooling and ventilat-

ing air is critical to correct generator(s) operation.

Do not alter the installation or permit even partial

blockage of ventilation provisions, as this can seri-

ously affect safe operation of the generator(s).

When working on this equipment, remain alert

at all times. Never work on the equipment when

physically or mentally fatigued.

Inspect the generator(s) regularly, and repair or

replace all damaged or defective parts immedi-

ately. Always use factory-authorized parts.

Turn off the AC power to the battery charger before

disconnecting the battery to minimize the chance

of equipment damage.

Before performing any maintenance on the

generator(s), disconnect its battery cables to pre-

vent accidental start-up. Remove control panel

fuse, then disconnect the cable from the battery

post indicated by a NEGATIVE, NEG or (–) first.

Reconnect that cable last, then reinstall control

panel fuse.

Never use the generator(s) or any of its parts as a

step. Stepping on the unit can stress and break

parts, and may result in dangerous operating con-

ditions from leaking exhaust gases, fuel leakage,

oil leakage, etc.

•

IMPORTANT SAFETY INSTRUCTIONS

PowerMaster Technical Manual

SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be

followed during installation and maintenance of the generator and batteries. The manufac-

turer suggests that these rules for safe operation be copied and posted in potential hazard

areas. Safety should be stressed to all operators and potential operators of this equipment.

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

•

WARNING:•





This product contains or emits chemicals

known to the state of California to cause

cancer, birth defects or other reproductive harm.

•

WARNING:•



ELECTRICAL HAZARDS 

All generators covered by this manual produce

dangerous electrical voltages and can cause fatal

electrical shock. Utility power delivers extremely

high and dangerous voltages to the transfer switch

as does the standby generator when it is in opera-

tion. Avoid contact with bare wires, terminals,

connections, etc., while the unit is running. Ensure

all appropriate covers, guards and barriers are in

place before operating the generator(s). If working

around an operating unit, stand on an insulated,

dry surface to reduce shock hazard.

Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or

feet are wet. DANGEROUS ELECTRICAL SHOCK

MAY RESULT.

The National Electrical Code (NEC) requires the

frame and external electrically conductive parts

of the generator to be connected to an approved

earth ground and/or grounding rods. Local electri-

cal codes also may require proper grounding of the

generator electrical system.

After installing this standby electrical system, the

generator(s) may crank and start at any time with-

out warning. When this occurs, load circuits are

transferred to the STANDBY (generator) power

source. To prevent possible injury if such a start

and transfer occur, always set the generator’s

AUTO/OFF/MANUAL switch to its OFF position

before working on equipment and remove the

negative battery lead.

In case of accident caused by electric shock, imme-

diately shut down the source of electrical power.

If this is not possible, attempt to free the victim

from the live conductor. AVOID DIRECT CONTACT

WITH THE VICTIM. Use a nonconducting imple-

ment, such as a rope or board, to free the victim

from the live conductor. If the victim is uncon-

scious, apply first aid and get immediate medical

help.

Never wear jewelry when working on this equip-

ment. Jewelry can conduct electricity resulting in

electric shock, or may get caught in moving com-

ponents causing injury.

The enclosure door on this unit is grounded to the

chassis with a wire. The grounding wire must be

reconnected when the door is replaced to reduce

the risk of electric shock.

•

FIRE HAZARDS 

For fire safety, the generator(s) must be installed

and maintained properly. Installation always must

comply with applicable codes, standards, laws

and regulations. Adhere strictly to local, state and

national electrical and building codes. Comply

with regulations the Occupational Safety and

Health Administration (OSHA) has established.

Also, ensure that the generator(s) is installed in

accordance with the manufacturer’s instructions

and recommendations. Following proper installa-

tion, do nothing that might alter a safe installation

and render the unit in noncompliance with the

aforementioned codes, standards, laws and regu-

lations.

Keep a fire extinguisher near the generator(s) at all

times. Extinguishers rated “ABC” by the National

Fire Protection Association are appropriate for

use on the standby electric system. Keep the extin-

guisher properly charged and be familiar with its

use. If there are any questions pertaining to fire

extinguishers, consult the local fire department.

EXPLOSION HAZARDS 

Do not smoke around the generator(s). Wipe up

any fuel or oil spills immediately. Ensure that no

combustible materials are left in the generator(s)

compartment, or on or near the generator(s), as

FIRE or EXPLOSION may result. Keep the area

surrounding the generator(s) clean and free from

debris.

•

IMPORTANT SAFETY INSTRUCTIONS

PowerMaster Technical Manual

1.1 INTRODUCTION

This manual has been prepared especially for the

purpose of familiarizing personnel with the design,

application, installation, and operation of the appli-

cable equipment. Read the manual carefully and

comply with all instructions. This will help to prevent

accidents or damage to equipment that might other-

wise be caused by carelessness, incorrect applica-

tion, or improper procedures.

Every effort has been expended to make sure that the

contents of this manual are both accurate and cur-

rent. The manufacturer, however, reserves the right

to change, alter or otherwise improve the product at

anytime without prior notice.

1.2 EQUIPMENT DESCRIPTION

The PowerMaster assembly is used to automatically

disconnect selected loads from the generator output

when a high demand appliance, such as a central air

conditioning system, is started, easing the burden on

the generator. The selected loads will then be auto-

matically reconnected to the generator output once

the high demand appliance is turned off. The selected

loads will only be disconnected if the transfer switch

is in the generator position when the high demand

appliance is started.

A total of up to two 240V, 30Amp loads can be con-

nected to the system, and be controlled by a total of

up to two 24Vac control signals from various high

demand appliances.

Once installation is completed, the PowerMaster

assembly will operate automatically without any need

for user intervention or routine maintenance.

1.3 UNPACKING THE BOX

Carefully unpack the box and check for any damage

that may have occurred during shipping. Check to

make certain all the following items are included:

Qty. Part No. Description

1 0F9110 PowerMaster assembly

1 0G0734 Manual, installation and

operating instructions

2 084464 Auxiliary contact switches

4 027770 Screws for mounting the

auxiliary contact switches

4 043182 Washers for mounting the

auxiliary contact switches

4 059051 Lug, Ring, #8 screw, 10-

12AWG

4 079679 Lug, Fast-on, 3/16 inch, 18-

22AWG

1.4 ENCLOSURE DETAILS

The enclosure is a National Electrical Manufacturer’s

Association (NEMA) 1 type. NEMA 1 type enclosures

are suitable only for indoor mounting.

2.1 INTRODUCTION TO INSTALLATION

This equipment has been wired and tested at the fac-

tory.

Installing this assembly includes the following pro-

cedures:

Mounting the enclosure

Connecting the source voltage(s) and load(s)

Connecting the control circuit(s)

Installing the Auxiliary switches to the transfer

switch

Connecting the Auxiliary switches

Restoring all power supplies

Testing the PowerMaster operation

2.2 MOUNTING THE ENCLOSURE

Mounting dimensions for the enclosure are shown in

figure 1.

The enclosure should be wall mounted in an indoor

location only, preferably near the circuit breaker

load center. Mount the assembly vertically to a rigid

supporting structure. To prevent distortion, level all

mounting points. If necessary, use washers behind

the mounting holes to level the assembly.

Figure 1 — Mounting Dimensions

254

228.6

25.4 177.8

210

•

Section 1 — General Information

PowerMaster Technical Manual

2.3 CONNECTING THE SOURCE

VOLTAGE(S) AND LOAD(S)

The source voltage(s) are taken from the load center

and connected to the PowerMaster assembly as fol-

lows:

Refer to the system diagram and the wiring dia-

gram located in this manual.

Refer to the field wiring decal on the inside of

the enclosure cover for the contactor connection

points and required tightening torque.

DANGER

Make sure to turn OFF both the UTILITY (NOR-

MAL) and EMERGENCY (STANDBY) power sup-

plies before trying to connect the source volt-

ages and the loads. Supply voltages are high

and dangerous. Contact with such high power

supply lines will result in extremely hazardous,

possibly lethal, electrical shock.

Do not turn these supplies back on until the

PowerMaster installation has been completed in

it’s entirety.

2.3.1 LOAD #1 CONNECTION INSTRUCTIONS

1. Select a 240V load to be automatically discon-

nected by the PowerMaster assembly.

2. Remove the load connections from the 240V 2-

Pole circuit breaker in the load center controlling

the selected load.

3. Using a suitable wiring method, sized as 10AWG

stranded wire, route the wiring between the load

center and the load disconnect box. Using the ring

lugs provided, connect the 2-Pole circuit breaker

to the “Line 1A” and “Line 1B” connections on

contactor K1 in the PowerMaster assembly.

When making the connections to the contactor,

strip the 10AWG wire 0.312 inch (5/16”) and use

an appropriate crimping tool to crimp the ring

lugs.

4. Using the ring lugs provided, connect the load

connections removed in step #2 above to the

“Load 1A” and “Load 1B” connections on contac-

tor K1.

Strip the wire 0.312 inch (5/16”) and use an

appropriate crimping tool to crimp the ring lugs.

Tighten the terminal screws to 20-22 inch/

pounds.

2.3.2 LOAD #2 CONNECTION INSTRUCTIONS

If desired, a second load can be connected to contac-

tor K2 in the same manner.

•



2.4 CONNECTING THE CONTROL

CIRCUITS

The PowerMaster Load center is controlled by a

24Vac control voltage. The most common application

is to use the 24Vac control signal from a furnace or

central air conditioning system, but any 24Vac con-

trol signal may be used.

A total of two 24Vac control signals may be connected

to the PowerMaster load center. Any time either of the

two 24Vac control signals is active, both contactors

will be energized disconnecting both of the selected

loads.

The 24Vac control signals should be connected as

follows:

Refer to the system diagram and the wiring dia-

gram located in this manual.

Refer to the field wiring decal on the inside of the

enclosure cover for the control signal connection

points.

2.4.1 CONTROL CIRCUIT #1 CONNECTIONS

To prevent damage to the appliance control

circuitry, or possible electrical shock, be sure to

disconnect all power sources to the appliance

before making these connections.

Do not restore power to the appliance until the

PowerMaster installation has been completed in

it’s entirety.

Using a minimum of 18AWG wire, connect the 24Vac

control signal from the Air conditioner (or other

high demand appliance) to the two 24Vac control

circuit 1 connections on the terminal strip inside the

PowerMaster assembly.

The 18AWG wire should be stripped to ¼ inch length

before inserting into the terminal strip. Tighten the

terminal strip clamping screws to 7 inch pounds.

2.4.2 CONTROL CIRCUIT #2 CONNECTIONS

If desired, a second 24Vac control signal can be con-

nected to the PowerMaster assembly. The second

control signal should be connected to the two 24Vac

control circuit 2 connections on the terminal strip

inside the PowerMaster assembly.

•



Section 2 — Installation

PowerMaster Technical Manual

Section 2 — Installation

PowerMaster Technical Manual

2.5 INSTALLING THE AUXILIARY

SWITCHES TO THE TRANSFER

SWITCH

The included auxiliary switches need to be added to

the transfer switch to provide switch position sens-

ing to the PowerMaster assembly. This allows the

PowerMaster assembly to disconnect the selected

loads only when the transfer switch is in the genera-

tor position. These switches should be installed as

follows: Refer to figure 2.

Figure 2 — Auxiliary Switch Installation

SWITCH SHOWN IN THE

UTILITY POSITION

SIDE VIEW

MOUNTING THE AUXILIARY SWITCHES

AUXILIARY SWITCH

MOUNTING LOCATION

32 3

GENERATOR UTILITY

1 = COMMON

2 = NC

3 = NO

UTILITY AUX SWITCH

CONNECT TO

PINS 1 AND 2

GENERATOR AUX SWITCH

CONNECT TO

PINS 1 AND 3

There are multiple voltage sources present inside

the transfer switch enclosure. Make sure to turn

OFF both the UTILITY (NORMAL) and the EMER-

GENCY (STANDBY) power sources before install-

ing the auxiliary switches. Failure to do so could

result in an extremely hazardous, possibly lethal,

electrical shock.

Do not turn these supplies back on until the

PowerMaster installation has been completed in

it’s entirety.

Mount the two auxiliary switches (provided) to the

transfer switch using the four screws and four wash-

ers (provided) as shown in figure 2.

2.6 CONNECTING THE AUXILIARY

SWITCHES

The auxiliary switches need to be connected to the

PowerMaster assembly using a minimum of 18AWG

wire as follows: Refer to figure 2.

2.6.1 GENERATOR SIDE AUXILIARY SWITCH

1. Connect one end of each of the two 18AWG wires

to the generator auxiliary switch.

Strip the 18AWG wire 0.234 inch (15/64") and

use an appropriate crimping tool to crimp the

3/16” fast on lugs (provided).

The two wires should be connected to pins 1 and

3 on the generator auxiliary switch.

2. Connect the other end of the two wires to the

Control Circuit 1 COM and N.O. positions on the

terminal strip inside the PowerMaster assembly.

These wires are not polarity sensitive.

These wires should be stripped 0.25 inch (¼")

before being inserted into the terminal strip.

The terminal strip clamping screws should be

tightened to 7 inch pounds.

2.6.2 UTILITY SIDE AUXILIARY SWITCH

1. Connect one end of each of the two 18AWG wires

to the utility auxiliary switch.

Strip the 18AWG wire 0.234 inch (15/64") and

use an appropriate crimping tool to crimp the

3/16" fast on lugs (provided).

The two wires should be connected to pins 1 and

2 on the utility auxiliary switch.

2. Connect the other end of the two wires to the

Control Circuit 2 COM and N.O. positions on the

terminal strip inside the PowerMaster assembly.

These wires are not polarity sensitive.

These wires should be stripped 0.25 inch (¼")

before being inserted into the terminal strip.

The terminal strip clamping screws should be

tightened to 7 inch pounds.

2.7 RESTORING ALL POWER

SUPPLIES

Now that the PowerMaster installation is completed:

1. Restore power to the appliance(s) disconnected

in section 2.4.

2. Turn the UTILITY (NORMAL) and EMERGENCY

(STANDBY) power supplies back ON.



•



•

3.1 TESTING THE POWERMASTER

OPERATION

The PowerMaster assembly can be functionally tested

using the following steps:

Note: the following steps will reference a central air

conditioner being used as the high demand appliance

controlling the PowerMaster assembly.

1. Ensure the Utility supply is available and the

transfer switch is in the utility position.

Ensure the Central air conditioner is not run-

ning.

Check for proper operation of the load(s) con-

nected to the PowerMaster assembly.

2. Run the Central air conditioner.

Check for proper operation of the load(s) con-

nected to the PowerMaster assembly.

3. Stop the central air conditioner.

Check for proper operation of the load(s) con-

nected to the PowerMaster assembly.

4. Simulate a utility loss.

Wait for the generator to start and run.

Wait for the transfer switch to transfer to the

Standby position.

Ensure the Central air conditioner is still not

running.

Check for proper operation of the load(s) con-

nected to the PowerMaster assembly.

5. Run the central air conditioner.

Contactors K1 and K2 should both energize

disconnecting the load(s) connected to the

PowerMaster assembly.

Verify the load(s) connected to the PowerMaster

assembly no longer operate.

6. Stop the central air conditioner.

Contactors K1 and K2 should both de-ener-

gize reconnecting the load(s) connected to the

PowerMaster assembly.

Check for proper operation of the load(s) con-

nected to the PowerMaster assembly.

7. Return the utility supply.

Wait for the transfer switch to return to the utility

position.

Wait for the generator to go through it’s cool down

period and shut off.

Check for proper operation of the load(s) con-

nected to the PowerMaster assembly.

Testing completed.

•

Figure 3 — System Diagram

Customer

Selected

Load #1

Customer

Load #2

Selected

Control circuit

Connections

Control

Circuit #1

Control

Circuit #2

OWER aster

Load

Center

Transfer

Switch

Auxiliary

Contacts

Aux2Aux1

Section 3 — Operation

PowerMaster Technical Manual

Section 4 — Electrical Data

Electrical Schematic - Drawing No. 0F8146-A

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