Generac Power Systems PowerPact G0069981 Bedienungsanleitung

Owner’s Manual

60 Hz Air-Cooled Generators

7.5 kW PowerPact™

SAVE THIS MANUAL FOR FUTURE REFERENCE

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1-888-GENERAC

(888-436-3722)

(000209b)

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.

ii Installation Guidelines For 60 Hz Air-Cooled Generators

Use this page to record important information about your generator set.

Record the information found on your unit data label on this

page. The unit has a label plate affixed to the inside partition,

above the battery access panel as shown in Figure 2-1. For

directions on how to open the top lid and remove the front

panel, see the Owner’s Manual.

When contacting an Independent Authorized Service Dealer

(IASD) about parts and service, always supply the complete

model number and serial number of the unit.

Operation and Maintenance: Proper maintenance and care

of the generator ensures a minimum number of problems

and keeps operating expenses at a minimum. It is the opera-

tor’s responsibility to perform all safety checks, to make sure

that all maintenance for safe operation is performed

promptly. Generac recommends that the equipment be

checked periodically by an IASD. Normal maintenance, ser-

vice 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 may contribute to the

need for additional maintenance or service.

When the generator requires servicing or repairs, Generac

recommends contacting an IASD for assistance. Authorized

service technicians are factory-trained and are capable of

handling all service needs.To locate the nearest IASD,

please visit the dealer locator at:

www.generac.com/Service/DealerLocator/.

Model:

Serial:

Prod Date Week:

Volts:

LPV Amps:

NG Amps:

Hz:

Phase:

Controller P/N:

(000393)

WARNING

Operating, servicing and maintaining this

equipment can expose you to chemicals

including engine exhaust, carbon monoxide,

phthalates, and lead, which are known to the

State of California to cause cancer and birth

defects or other reproductive harm. To

minimize exposure, avoid breathing exhaust,

do not idle the engine except as necessary,

service your equipment in a well-ventilated

area and wear gloves or wash your hands

frequently when servicing your equipment.

For more information go to

www.P65Warnings.ca.gov.

Owner’s Manual for 50 Hz Air-Cooled Generators iii

Section 1: Safety Information

Introduction ..........................................................1

Read This Manual Thoroughly ....................................1

How to Obtain Service .................................................1

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

General Hazards .........................................................2

Exhaust Hazards .........................................................3

Electrical Hazards .......................................................3

Fire Hazards ................................................................4

Explosion Hazards ......................................................4

Section 2: General Information

The Generator ......................................................5

Data Decals ..........................................................7

Protection Systems .............................................8

Emissions .............................................................8

Fuel Requirements ..............................................8

Battery Requirements .........................................8

Battery Charger ....................................................8

Engine Oil Requirements ....................................8

Section 3: Operation

Site Prep Verification .........................................11

Controller Lid .....................................................11

Main Line Circuit Breaker (Generator

Disconnect) ........................................................11

Control Panel .....................................................12

Alarm Response Procedures ............................13

Clearing an Alarm/Warning Condition .......................13

Setting the Exercise Timer ................................13

Battery Charger ..................................................13

Manual Transfer Operation ...............................13

Transfer to Generator Power Source ........................13

Transfer Back to Utility Power Source .......................14

Automatic Transfer Operation ..........................14

Automatic Sequence of Operation ...................15

Utility Failure ..............................................................15

Cranking ....................................................................15

Cold Smart Start ........................................................15

Load Transfer ............................................................15

Shutting Generator Down While Under Load Or

During A Utility Outage ..................................... 15

Auxiliary Shutdown Switch .............................. 16

Section 4: Maintenance

Maintenance ....................................................... 17

Performing Scheduled Maintenance ............... 17

Clearing a Maintenance Due Condition ........... 17

Service Schedule ............................................... 18

Checking Engine Oil Level ............................... 20

Engine Oil Recommendations ...................................20

Changing the Oil ................................................ 21

Changing the Engine Air Cleaner .................... 21

Spark Plug .......................................................... 22

Valve Clearance Adjustment ............................ 22

Check Valve Clearance .............................................22

Adjust Valve Clearance .............................................22

Battery Maintenance ......................................... 23

Attention After Submersion ............................. 24

Corrosion Protection ........................................ 24

Remove From, and Return To Service

Procedure ........................................................... 24

Remove From Service ...............................................24

Return to Service .......................................................24

Section 5: Troubleshooting

Section 6: Quick Reference Guide

System Diagnosis ............................................. 27

Table of Contents

iv Owner’s Manual for 50 Hz Air-Cooled Generators

This page intentionally left blank.

Safety Information

Owner’s Manual for 7.5 kW PowerPact™ 1

Section 1: Safety Information

Introduction

Thank you for purchasing this compact, high

performance, air-cooled, engine-driven generator. It is

designed to automatically supply electrical power to

operate critical loads during a utility power failure.

This unit is factory installed in an all-weather, metal

enclosure intended exclusively for outdoor installation.

This generator will operate using either vapor withdrawn

liquid propane (LP) or natural gas (NG).

NOTE: When sized properly, this generator is suitable for

supplying typical residential loads such as induction

motors (sump pumps, refrigerators, air conditioners,

furnaces, etc.), electronic components (computer,

monitor, TV, etc.), lighting loads and microwaves.

Read This Manual Thoroughly

If any portion of this manual is not understood, contact

the nearest Independent Authorized Service Dealer

(IASD) for starting, operating and servicing procedures.

This manual must be used in conjunction with the

appropriate Installation Manual.

SAVE THESE INSTRUCTIONS: The manufacturer

suggests that this manual and the rules for safe operation

be copied and posted near the unit installation site.

Safety should be stressed to all operators and potential

operators of this equipment.

The information in this manual is accurate based on

products produced at the time of publication. The

manufacturer reserves the right to make technical

updates, corrections, and product revisions at any time

without notice.

Safety Messages

Throughout this publication and on tags and decals

affixed to the generator, DANGER, WARNING, and

CAUTION blocks are used to alert personnel to special

instructions about a particular operation that may be

hazardous if performed incorrectly or carelessly. Observe

them carefully. Their definitions are as follows:

NOTE: Notes provide additional information important to

a procedure or component.

These safety alerts cannot eliminate the hazards they

indicate. Observing safety precautions and strict

compliance with the special instructions while performing

the action or service are essential to preventing accidents.

The operator is responsible for proper and safe use of

the equipment. The manufacturer strongly recommends

that if the operator is also the owner, to read the Owner’s

Manual and thoroughly understand all instructions before

using this equipment. The manufacturer also strongly

recommends instructing other users to properly start and

operate the unit. This prepares them if they need to

operate the equipment in an emergency.

How to Obtain Service

When the generator requires servicing or repairs, Generac

recommends contacting an

IASD

for assistance. Service

technicians are factory-trained and are capable of handling

all service needs. For assistance locating an IASD, go to

www.generac.com/Service/DealerLocator/.

When contacting an IASD about parts and service, always

supply the complete model number and serial number of

the unit as given on its data decal, which is located on the

generator. Refer to

Figure 2-1

for decal location. Record

the model number and serial numbers in the spaces

provided on the inside front cover of this manual.

(000100a)

WARNING

Consult Manual. Read and understand manual

completely before using product. Failure to

completely understand manual and product

could result in death or serious injury.

(000001)

DANGER

Indicates a hazardous situation which, if not avoided,

will result in death or serious injury.

(000002)

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

(000003)

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

Safety Information

2Owner’s Manual for 7.5 kW PowerPact™

Safety Rules

Study these SAFETY RULES carefully before installing,

operating or servicing this equipment. Become familiar

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

generator 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 warnings 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, verify that it is safe for others.

Also, make sure the procedure, work method or operating

technique utilized does not render the generator unsafe.

General Hazards

(000190)

DANGER

Loss of life. Property damage. Installation must always

comply with applicable codes, standards, laws and

regulations. Failure to do so will result in death

or serious injury.

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)

DANGER

(000209b)

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.

WARNING

Equipment damage. This unit is not intended for use as a

prime power source. It is intended for use as an intermediate

power supply in the event of temporary power outage only.

Doing so could result in death, serious injury, and

equipment damage. (000247a)

(000187)

WARNING

Electrocution. Potentially lethal voltages are generated

by this equipment. Render the equipment safe before

attempting repairs or maintenance. Failure to do so

could result in death or serious injury.

(000130)

WARNING

Accidental Start-up. Disconnect the negative battery

cable, then the positive battery cable when working

on unit. Failure to do so could result in death

or serious injury.

(000182a)

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.

(000155a)

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.

(000115)

WARNING

Moving Parts. Do not wear jewelry when

starting or operating this product. Wearing

jewelry while starting or operating this product

could result in death or serious injury.

(000111)

WARNING

Moving Parts. Keep clothing, hair, and

appendages away from moving parts. Failure

to do so could result in death or serious injury.

(000108)

WARNING

Hot Surfaces. When operating machine, do not

touch hot surfaces. Keep machine away from

combustibles during use. Hot surfaces could

result in severe burns or fire.

(000146)

WARNING

Equipment and property damage. Do not alter

construction of, installation, or block ventilation for

generator. Failure to do so could result in unsafe

operation or damage to the generator.

Safety Information

Owner’s Manual for 7.5 kW PowerPact™ 3

Inspect the generator regularly. Generac recommends

contacting the nearest Independent Authorized Service

Dealer for parts needing repair or replacement.

Exhaust Hazards

•Adequate, unobstructed flow of cooling and

ventilating air is critical to correct generator

operation. Do not alter the installation or permit

even partial blockage of ventilation provisions, as

this can seriously affect safe operation of the

generator. The generator must be installed and

operated outdoors only.

Electrical Hazards

WARNING

Risk of injury. Do not operate or service this machine

if not fully alert. Fatigue can impair the ability to service

this equipment and could result in death or serious

injury. (000215)

WARNING

Injury and equipment damage. Do not use generator

as a step. Doing so could result in falling, damaged

parts, unsafe equipment operation, and could result

in death or serious injury. (000216)

Asphyxiation. Running engines produce

carbon monoxide, a colorless, odorless,

poisonous gas. Carbon monoxide, if not

avoided, will result in death or serious injury.

(000103)

DANGER

(000178a)

Asphyxiation. Always use a battery operated carbon

monoxide alarm indoors and installed according to

the manufacturer’s instructions. Failure to do so

could result in death or serious injury.

WARNING

(000144)

DANGER

Electrocution. Contact with bare wires,

terminals, and connections while generator

is running will result in death or serious injury.

(000150)

DANGER

Electrocution. Never connect this unit to the electrical

system of any building unless a licensed electrician

has installed an approved transfer switch. Failure to

do so will result in death or serious injury.

(000237)

DANGER

Electrical backfeed. Use only approved switchgear to

isolate generator from the normal power source.

Failure to do so will result in death, serious injury,

and equipment damage.

(000152)

DANGER

Electrocution. Verify electrical system is

properly grounded before applying power.

Failure to do so will result in death or serious

injury.

(000188)

DANGER

Electrocution. Do not wear jewelry while

working on this equipment. Doing so will

result in death or serious injury.

(000104)

DANGER

Electrocution. Water contact with a power

source, if not avoided, will result in death

or serious injury.

(000144)

DANGER

Electrocution. Contact with bare wires,

terminals, and connections while generator

is running will result in death or serious injury.

(000145)

DANGER

Electrocution. In the event of electrical accident,

immediately shut power OFF. Use non-conductive

implements to free victim from live conductor. Apply

first aid and get medical help. Failure to do so will

result in death or serious injury.

Safety Information

4Owner’s Manual for 7.5 kW PowerPact™

Fire Hazards

Comply with regulations the Occupational Safety and

Health Administration (OSHA) has established. Also,

verify that the generator is installed in accordance with

the manufacturer’s instructions and recommendations.

Following proper installation, do nothing that might alter a

safe installation and render the unit in noncompliance

with the aforementioned codes, standards, laws and

regulations.

Explosion Hazards

WARNING

Fire hazard. Do not obstruct cooling and

ventilating airflow around the generator. Inadequate

ventilation could result in fire hazard, possible

equipment damage, death or serious injury. (000217)

WARNING

Fire and explosion. Installation must comply

with all local, state, and national electrical

(000218)

building codes. Noncompliance could result in unsafe

operation, equipment damage, death or serious injury.

WARNING

Fire hazard. Use only fully-charged fire

(000219)

extinguishers rated “ABC” by the NFPA. Discharged or

improperly rated fire extinguishers will not extinguish

electrical fires in automatic standby generators.

(000100a)

WARNING

Consult Manual. Read and understand manual

completely before using product. Failure to

completely understand manual and product

could result in death or serious injury.

WARNING

to use required safety equipment could result

in death or serious injury. (000257)

Electrocution. Refer to local codes and

standards for safety equipment required when

working with a live electrical system. Failure

(000147)

WARNING

Risk of Fire. Unit must be positioned in a

manner that prevents combustible material

accumulation underneath. Failure to do so

could result in death or serious injury.

(000192)

DANGER

Explosion and fire. Fuel and vapors are extremely

flammable and explosive. No leakage of fuel is

permitted. Keep fire and spark away. Failure to do

so will result in death or serious injury.

(000151a)

DANGER

Explosion and fire. Connection of fuel source must be

completed by a qualified professional technician or

contractor. Incorrect installation of this unit will result in

death, serious injury, and property and equipment damage.

(000174)

DANGER

Risk of fire. Allow fuel spills to completely dry

before starting engine. Failure to do so will

result in death or serious injury.

(000110)

WARNING

Risk of Fire. Hot surfaces could ignite

combustibles, resulting in fire. Fire could

result in death or serious injury.

General Information

Owner’s Manual for 7.5 kW PowerPact™ 5

Section 2: General Information

The Generator

Figure 2-1. Features and Components

A. Top Lid G. Fuel Connection Hole N. Air Box

B. Controller Lid H. Data Label O. Spark Plug

C. Control Panel J. Battery Access Panel P. Exhaust Enclosure

D. Circuit Breaker K. Oil Drain Hose Q. Alternator

E. Customer Connection Box L. Oil Fill / Dipstick R. Starter Motor

F. Auxiliary Engine Shutdown Switch M. Front Panel (not shown)

005568

NOP

General Information

6Owner’s Manual for 7.5 kW PowerPact™

Specifications

Generator

Engine

A detailed specification sheet for your particular generator is available from your local Independent Authorized Service

Dealer (IASD).

Model 7.5 kW

Rated Voltage 240

Rated Maximum Load Current

(Amps) at Rated Volts (LP)* 31.25

Main Line Circuit Breaker

(Generator Disconnect) 35 Amp

Phase 1

Rated AC Frequency 60 Hz

Battery Requirement Group U1, 12 Volts and 300 CCA Minimum (see Replacement Parts)

Enclosure Galvanneal Steel

Unit Weight 280 lb (127.3 kg)

Normal Operating Range This unit is tested in accordance to UL 2200 standards with an operating temperature of -20 ºF

(-29 ºC) to 122 ºF (50 ºC). For areas where temperatures fall below 32 ºF (0 ºC) a cold weather kit is

recommended. When operated above 77 ºF (25 ºC) there may be a decrease in engine power.

(Please reference the engine specifications section.)

These generators are rated in accordance with UL 2200, Safety Standard for Stationary Engine Generator Assemblies, and CSA-C22.2 No. 100-04

Standard for Motors and Generators.

* Natural Gas ratings will depend on specific fuel joules/Btu content. Typical derates are between 10-20% off the LP gas rating.

** Circuits to be moved must be protected by same size breaker. For example, a 15 amp circuit in the main panel must be a 15 amp circuit in the

transfer switch.

Model 7.5 kW

Type of Engine GA-420

Number of Cylinders 1

Displacement 25.6 in3(420 cc)

Cylinder Block Aluminum w/ cast iron sleeve

Recommended Spark Plug see Replacement Parts

Spark Plug Gap

0.030 in (0.76 mm)

Valve Clearance 0.002 - 0.004 in

(0.05 - 0.1 mm)

Starter 12 VDC

Oil Capacity

Approx. 1.2 qt (1.1 L)

Recommended Air Filter see Replacement Parts

Engine power is subject to and limited by such factors as fuel Btu/joules, ambient temperature and altitude. Engine power decreases about 3.5 percent

for each 1000 feet (304.8 meters) above sea level, and also will decrease about 1 percent for each 10 °F (6 ºC) above 60 ºF (15 ºC) ambient temperature.

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