INSTALLATION MANUAL

A new standard of reliability

Not intended for use in critical life support applications! 
Outdoor installation only!

This manual should remain with the unit.

INTRODUCTION
Thank you for purchasing this model of the standby generator set product line by Generac Power Systems, Inc.. Every effort was expended to make sure that the information and instructions in this manual are 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.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance 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: symbol points out important safety infor This mation that, if not followed, could endanger personal safety and/or property of others. symbol points out potential explosion  This hazard.

‹ READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, 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 personnel 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:

 This symbol points out potential fire hazard.
symbol points out potential electrical shock  This hazard.

‹ 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 capable 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 the Owner’s Manual.

DANGER
After this heading, read instructions that, if not strictly complied with, will result in serious personal injury, including death, or property damage.

After this heading, read instructions that, if not strictly complied with, may result in personal injury or property damage.

AUTHORIZED SERVICE DEALER LOCATION
To locate the nearest AUTHORIZED SERVICE DEALER, please call this number:

1-800-333-1322
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. OR
Locate us on the web at:

www.generac.com

12 3....................................................12 Standby Circuit Isolation Method ..9.................... 4 1..........2 Load Wiring ..............3 Transfer Switch .....................2...........11 Unpacking .....4..4 Before Installation ......12 Connection Diagrams ...........8.........11 Section 2 — INSTALLATION ...............1 3...12 Section 3 — OPERATION ..7..................................4.....6 1...................11 Mounting ..................8 1.........4 1....7.................7 1.....1 Control Wiring ....2...1 1..............12 Total Circuit Isolation Method ............................................................4 1.....................5 Unpacking .....7....3 3...................6 1.....2 Generator Installation .........................2 Properties of Gaseous Fuels.............12 3...................................8 1.......Table of Contents Liquid-cooled Generators INTRODUCTION .............8 Electrical Connections............................................1 2......6 1.3 1....1 Introduction to Gaseous Fuel Systems.....................5...8 1..............................................1 Vented Batteries ......................14 3..................7...4 LP Gas Vapor Withdrawal System......1 Unpacking Precautions ..........6 1..................6 1..............................8.............4 Basic Standby Electric System .................5..2 3.5.........4 Generator Location .............5...................4 1.2 Battery Charger Connection .................................6 1..........................5 Gaseous Fuel System Piping ......2 Inspection .......................................13 3...........6 Fuel Systems ......14 3.................................. IFC SAFETY RULES ....................5 Wire Recommendations/Sizing ...............9 Battery Installation .....1 Grounding the Generator ..11 1..7.......8 1........................2 Section 1 — GENERAL INFORMATION .................3 The Natural Gas System ........1 R-series to RTS ......1 NFPA Standards .......2 2......................6 1.......... 11 2..2 Other Published Standards .....1 Combustible Floor and Roof Protection ............................................................5 Generator Mounting and Support ............14 Section 4 — NOTES......... 16 1 .......5 1.........5 1..............7 Lifting the Generator ..................................6 1.

If using a procedure. Exhaust gases must be piped safely away from any building or enclosure that houses the generator to an area where people.   GENERAL HAZARDS  • For safety reasons. • Keep hands. standards and regulations. standards and regulations. • Adequate. The manufacturer cannot anticipate every possible circumstance that might involve a hazard. do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes. Do not alter the installation or permit even partial blockage of ventilation provisions. feet. Never work on the equipment when physically or mentally fatigued. standards. Also. and other moving or hot parts. Adhere strictly to local. potential operators. will not be harmed. in strict compliance with applicable codes and standards. Never remove any drive belt or fan guard while the unit is operating. damaged or defective parts using only factory-approved parts. not all-inclusive. laws and regulations. of the generator are rotating and/or hot  Parts during operation. away from drive belts. etc. This exhaust system must be installed properly. work method or operating technique utilized does not render the generator unsafe. The operator also must comply with all such codes. Become familiar with this Owner’s Manual and with the unit. servicing and repair of this (and related) equipment must always comply with applicable codes. WARNING: The engine exhaust from this product contains chemicals known to the state of California to cause cancer. operated and serviced in accordance with the manufacturer’s instructions and recommendations. operating or servicing this equipment. ensure that the generator is installed. therefore. clothing. operation. etc. For that reason. Permit only responsible and capable persons to install. Remove any materials that could become hazardous. remain alert at all times. • The engine exhaust fumes contain carbon monoxide gas. birth defects or other reproductive harm. lethal voltages are generated by  Potentially these machines. • Inspect the generator regularly.  WARNING:  DANGER the safe design of this generator. Safety should be stressed to all operators. if breathed in sufficient concentrations. can cause unconsciousness or even death. fans. Following installation. work method or operating technique that the manufacturer does not specifically recommend. efficiently and reliably only if it is properly installed. which can be DEADLY.. operate or maintain this equipment. Also make sure the procedure. • Installation. unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to ensure correct generator operation. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. birth defects or other reproductive harm. Ensure all steps are taken to render the machine safe before attempting to work on the generator. qualified electrician or installation technician who is familiar with applicable codes. The warnings in this manual. • When working on this equipment. Many accidents are caused by failing to follow simple and fundamental rules or precautions.. and service and repair technicians for this equipment. ensure that it is safe for others. 2 . the manufacturer recommends that this equipment be installed. neglecting its maintenance or being careless can cause possible injury or death. state and national electrical and building codes. This dangerous gas.IMPORTANT SAFETY INSTRUCTIONS Liquid-cooled Generators   SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. animals. Exercise care near running generators. laws and regulations. operated and maintained. adequate ventilation must be provided.  Despite operating this equipment imprudently. and promptly repair or replace all worn. standards. Study these SAFETY RULES carefully before installing. This product contains or emits chemicals known to the state of California to cause cancer. and on tags and decals affixed to the unit are. • Keep the area around the generator clean and uncluttered. SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be    followed during installation of the generator and batteries. The generator can operate safely. as this can seriously affect safe operation of the generator. serviced and repaired by an Authorized Service Dealer or other competent.

and LP gas is heavier than air. Ensure that no combustible materials are left in the generator compartment. If the victim is unconscious. Reconnect that cable last. etc. Never disconnect the ground wire. • Do not handle any kind of electrical device while standing in water. 3  EXPLOSION HAZARDS  . If this is not possible. Article 250 requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground and/or grounding rods.IMPORTANT SAFETY INSTRUCTIONS Liquid-cooled Generators • Before performing any maintenance on the generator. This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static electricity. • These generator sets may operate using one of several types of fuels. such as a dry rope or board. DANGEROUS ELECTRICAL SHOCK MAY RESULT. and the liquid can deteriorate wiring insulation. Failure to isolate the two electric system power sources from each other by such means will result  ELECTRICAL HAZARDS  in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy. fuel leakage. Work on the equipment only while standing on such insulative mats. Then. and may result in dangerous operating conditions from leaking exhaust gases. Wipe up any fuel or oil spills immediately. • Generators installed with an automatic transfer switch will crank and start automatically when normal (utility) source voltage is removed or is below an acceptable preset level. if applicable. NEG or (–) first. to free the victim from the live conductor. Fuel supply lines must be properly installed. Disconnect the cable from the battery post indicated by a NEGATIVE. AVOID DIRECT CONTACT WITH THE VICTIM. If there are any questions pertaining to fire extinguishers. immediately shut down the source of electrical power. • Do not smoke around the generator. place a “Do Not Operate” tag on the generator control panel and on the transfer switch. or while hands or feet are wet. oil leakage. Utility power delivers extremely high and dangerous voltages to the transfer switch as well as the standby generator. Keep the extinguisher properly charged and be familiar with its use. as FIRE or EXPLOSION may result. Its fumes are toxic. apply first aid and get immediate medical help. • Wire gauge sizes of electrical wiring. If work must be done around an operating unit. terminals. • Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE.) before working on or around the unit. Natural gas is lighter than air. cables and cord sets must be adequate to handle the maximum electrical current (ampacity) to which they will be subjected. or may get caught in moving components causing injury. disable the generator’s automatic start circuit (battery cables. disconnect its battery cables to prevent accidental start-up. Use a nonconducting implement. Stepping on the unit can stress and break parts. • Connecting this unit to an electrical system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the generator electric system from the electric utility distribution system when the generator is operating. stand on an insulated. dry surface to reduce shock hazard. while barefoot.. purged and leak tested according to applicable fuel-gas codes before placing this equipment into service. connections. • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. operating. Inspect the unit’s fuel system frequently and correct any leaks immediately. • The National Electrical Code (NEC). • If people must stand on metal or concrete while installing. etc. servicing. All fuel types are potentially FLAMMABLE and/or EXPLOSIVE and should be handled with care. Avoid contact with bare wires. Keep the area surrounding the generator clean and free from debris. • In case of accident caused by electric shock. make sure that all power voltage supplies are positively turned off at their source. • Never wear jewelry when working on this equipment. Comply with all laws regulating the storage and handling of fuels. Ensure all appropriate covers. Jewelry can conduct electricity resulting in electric shock. • Never use the generator or any of its parts as a step. • Before installing or servicing this (and related) equipment. install leak detectors accordingly. etc. Do NOT use any carbon tetra-chloride type extinguisher. consult the local fire department. adjusting or repairing this equipment. attempt to free the victim from the live conductor. place insulative mats over a dry wooden platform. or on or near the generator. Failure to do so will result in hazardous and possibly fatal electrical shock. To prevent such automatic start-up and possible injury to personnel. guards and barriers are in place before operating the generator.  FIRE HAZARDS  • Keep a fire extinguisher near the generator at all times. on the generator as well as the transfer switch.

The critical (essential) loads may need to be grouped together and wired into a separate “emergency” distribution panel. 1430 Broadway. standards and regulations pertaining to the installation. the following information pertaining to the installation and use of standby electric systems is available: • Article X.Section 1 . Batterymarch Park. 58. obtainable from the Food and Energy Council. 10038. an open bottom is used. Quincy.2.General Information Liquid-cooled Generators 1. 10018. available from the American Insurance Association. competent installation contractors or electricians thoroughly familiar with applicable codes. The generator is designed to supply electrical power that operates critical electrical loads during utility power failure. available from the American National Standard Institute. it is required by code to install a transfer switch. Joseph. • A52. standards and regulations. 37. 85 John Street. Read “Emergency Isolation Method” and “Total Circuit Isolation Method”. MO. 909 University Avenue. available from the American Society of Agricultural Engineers. Only qualified. N. New York. 1. 65201. 4 . In addition to NFPA standards. check the ratings of both the generator and the transfer switch. LIQEEFIED PETROLEUM GAS CODE • NFPA 70. NATIONAL ELECTRIC CODE (NEC) • NFPA 99. ‹ 1. The unit has been factory-installed in a weather resistant. STANDARD FOR HEALTH CARE FACILITIES • NFPA 101. FIREPLACES AND VENTING SYSTEMS. all metal enclosure and is intended for outdoor installation only.Y. The installation must comply strictly with all codes. STANDARD FOR EMERGENCY AND STANDBY POWER SYSTEMS • NFPA 220. STATIONARY COMBUSTION ENGINES AND GAS TURBINES • NFPA No. • ASAE EP-364. NATIONAL FUEL GAS CODE • NFPA No. Columbia. The generator’s rated wattage/amperage capacity must be adequate to handle all electrical loads that the unit will power. Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy. so as to isolate the electric system from the utility distribution system when the generator is operating. Failure to isolate an electrical system by such means results in damage to the generator and may also result in injury or even death to utility power workers due to backfeed of electrical energy. 54.1 NFPA STANDARDS this generator is used to power electrical load  If circuits normally powered by a utility power source. the engine-generator  If is to be installed over non-combustible materials and should be located such that combustible materials are not capable of accumulating under the generator set.2 OTHER PUBLISHED STANDARDS  Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch. • AGRICULTURAL WIRING HANDBOOK. DANGER ‹ 1. St. AMERICAN NATIONAL STANDARD FOR CHIMNEYS. NATIONAL BUILDING CODE.2. This equipment is a liquid-cooled. New York. INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRIC POWER.1.2. engine-driven generator set. do nothing  After that might render the installation in noncompliance with such codes.2 BEFORE INSTALLATION Before installing this equipment. 2950 Niles Road. The transfer switch must effectively isolate the electric system from the utility distribution system when the generator is operating (NEC 701).Y. LIFE SAFETY CODE • NFPA 110. standards and regulations should install this standby electric power system.1 GENERATOR INSTALLATION the system has been installed. MA 02269: • NFPA No. STANDARD TYPES OF BUILDING CONSTRUCTION NOTE: It is essential to use the latest version of any standard to ensure that the generator and its accessories comply with all the applicable standards and local codes. MI 49085. The following published standards booklets pertaining to standby electric systems are available form the National Fire Protection Association (NFPA). N.

This reduces the length of wiring and conduit. face the generator air inlet openings into the prevailing winds. 1. • Install the generator as close as possible to the transfer switch. • Install the generator as close as possible to the fuel supply.3 GENERATOR LOCATION Install the generator set. grass. state and local codes for minimum distances from other structures. all federal. ‹ 1.1 COMBUSTIBLE FLOOR AND ROOF PROTECTION If the generator must be installed on any combustible floor or roof. • Both the layer of insulation and the sheet metal must extend beyond the generator base to a distance of at least 12 inches (30. NOTE: Consult the local building codes which may vary. to reduce the length of piping. where adequate cooling and ventilating air always is available. • Where strong prevailing winds blow from one direction.1).1 — Combustible Floor and Roof Protection For rooftop or building structure mounting. it is recommended that spring isolators be installed between the engine frame and the mounting system. Since the entire bottom of the genset is now exposed. state and local codes should be followed. HOWEVER. Figure 1. 5 . comply with the following rules: • Place a layer of non-combustible insulation. This unit must be installed in accordance with current applicable NFPA 37 and NFPA 70 standards. Special attention should be given to the concrete base slab which should exceed the length and width of the generator by a minimum of six (6) inches (0. in its protective enclosure outdoors. REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE. it should be covered with a metal plate to keep out small animals and protect the integrity of the internal parts of the genset. followed by a layer of sheet metal beneath the unit’s mounting base rails (Figure 1.General Information Liquid-cooled Generators NOTE: It is essential to use the latest version of any standard to ensure that the generator and its accessories comply with all the applicable standards and local codes. 1.4. • Allow sufficient room on all sides of the generator for maintenance and servicing. The base frame must be level within 1/2 inch all around. etc. consider using a windbreak to protect the unit. Consider these factors: • Install the unit where air inlet and outlet openings will not become obstructed by leaves. Genset movement is more intense with spring isolation. A minimum of six (6) isolators are required and must be located at the front and rear cross members and the center of the frame. so flexible connections for the fuel and the electrical conduits are also required.5 cm) on all sides. If prevailing winds will cause blowing or drifting. Retain the generator compartment to the concrete slab with masonry bolts. as well as any other federal. • This genset must be installed on a level surface.Section 1 .4 GENERATOR MOUNTING AND SUPPORT A CONCRETE BASE: When designing a concrete base slab. snow. • Install the generator on high ground where water levels will not rise and endanger it. The installer must comply with all applicable state and local codes.152 meters) on all sides.

5. Local fuel/gas codes usually dictate the maximum pressure at which natural gas can enter a structure. Store and unpack cartons with the proper side up. collision. A primary regulator is required at the tank to reduce the pressure to the required five to 14 inches of water column. A flexible length of gas line is required between rigid piping and the gas connection at the generator. From the primary regulator. like natural gas. In order to reduce the gas pressure to that required by law. LP Gas Liquefied petroleum (LP) gas is heavier than air. standards and regulations pertaining to the installation and use of gaseous fuels must be strictly complied with. 1. it is recommended that a local gas distributor or installer be consulted when installing a gaseous fuel supply system. have the person(s) making delivery note all damage on the freight bill or affix their signature under the consignor’s memo of loss or damage.Section 1 — General Information Liquid-cooled Generators 1. can be ignited by the slightest spark. A primary regulator is required to reduce gas supply pressures to the required safe level before the gas enters a structure. such as LP and natural gas. and qualified personnel to be used in all phases of handling and unpacking. It is the responsibility of the gas supplier to ensure that sufficient gas pressure is available to operate the primary regulator.2 INSPECTION After unpacking. The gas vapors are explosive and. If loss or damage is noted at the time of delivery.7 FUEL SYSTEMS INTRODUCTION TO GASEOUS FUEL SYSTEMS ‹ 1. a PRIMARY REGULATOR is required. Units below 70kW can operate with the pressure as low as five inches of water column.3 THE NATURAL GAS SYSTEM 1. The generator is equipped with a fuel system that utilizes liquefied petroleum (LP) gas or natural gas as a fuel. be  When careful not to touch overhead power lines.7. equipment.6 LIFTING THE GENERATOR lifting or hoisting equipment is used. Natural Gas Natural gas is lighter than air. LP tank pressure is dependent on the ambient temperature and can be as high as 200 psi. The secondary regulator reduces gas pressure to about five inches of water column before the gas Is delivered to the actuator. Local fuel gas codes may vary widely. The primary regulator may or may not be provided by the gas supplier. ‹ 1. For safety. NOTE: Gas pressure from the primary regulator (supplied by the installing contractor) to the generator's fuel shutoff valve should not exceed 14 inches of water column. The maximum pressure at which the gas can enter a building is established by code and may vary from area to area. booklets published by the National Fire Protection Association (NFPA) may be used as sources of information. bumping. DANGER fuels. carefully inspect the generator for any damage that may have occurred during shipment. etc. Natural gas is lighter than air and will settle in high areas. as noted on the shipping carton. Use care to avoid damage from dropping. all codes.2 PROPERTIES OF GASEOUS FUELS ‹ 1.1 UNPACKING PRECAUTIONS Handle shipping cartons and crates with care. are  Gaseous highly volatile and their vapors are explosive. ‹ 1. The gas distribution company will usually provide piping from the main distribution line to the generator site. It is highly explosive and can be ignited at the slightest spark. fuel lines must be free of leaks and adequate ventilation is absolutely essential. 6 .1 A typical natural gas system is shown in Figure 1. These fuels are highly volatile and can be dangerous if handled or stored carelessly. The generator fuel system consists of an electrical fuel shutoff valve/regulator assembly and a gas actuator. Even the slightest spark can ignite these fuels and cause an explosion. It is found in the gaseous state at normal ambient temperatures and pressures. In the absence of local fuel gas codes and regulations.7. For that reason.7.5 UNPACKING ‹ 1. gas flows to the generator connection. The generators weight of more than 900 pounds requires proper tools.2. For that reason. below. LP gas is heavier than air and will settle in low areas.5.

Gas pressure requirements for an LP vapor system at the frame of the generator are the Figure 1.4 LP GAS VAPOR WITHDRAWAL SYSTEM This type of system utilizes the vapors formed above the liquid fuel in the supply tank (see Figure 1. ‹ 1. The installer should be aware of the following: • When ambient temperatures are low and engine fuel consumption is high. for NG application flexible portion of the fuel line (supplied by the installing contractor).14" Water Column (>= 70 kW) 5 .2 — Typical Natural Gas System Primary Regulator (Supplied by Installing Contractor) Generator Base Gas Actuator Fuel Shutoff/Regulator Assembly Flex Fuel Line (Supplied with Unit) 11 .14" Water Column (< 70 kW) Fuel Tank 7 .14" Water Column (< 70 kW) Manual Shutoff Valve Follow the local codes on selecting the required AGA approved.7. the vapor withdrawal system may not function efficiently. Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state.3 — Typical LP Gas Vapor Withdrawal System Manual Shutoff Valves Generator Base Gas Actuator Fuel Shutoff/Regulator Assembly Flex Fuel Line (Supplied with Unit) Primary Regulator (Supplied by Installing Contractor) 11 .Section 1 — General Information Liquid-cooled Generators Figure 1.3).14" Water Column (>= 70 kW) 5 . See Table 1 for information regarding the vapor capacity of LP tanks. and UL listed. • Ambient temperatures around the supply tank must be high enough to sustain adequate vaporization or the system will not deliver the needed fuel volume. same as those listed for natural gas in "The Natural Gas System".

in accordance with applicable codes and standards.4 – Generator Grounding Lug (typical) ‹ 1.5 GASEOUS FUEL SYSTEM PIPING The following general rules apply to piping used in gaseous fuel systems: • The piping should be of black iron. grounding helps dissipate static electricity that often builds up in ungrounded devices. Figure 1. In addition. NOTE: In the absence of local purging and leak test standards. 1.5 — Battery Charger Connection DANGER not connect the ground wire to any pipe  Do that carries a flammable or explosive substance – FIRE or an EXPLOSION may result. Grounding procedures must meet local regulations. GROUNDING LUG ‹ 1. to reduce the possibility of leakage. • Piping must be of the correct size to maintain the required supply pressures and volume flow under varying conditions (see Table 2). 54 may be used as a guide. NFPA No. The terminals will need to be supplied from a 120VAC.8. this connection is found in the control panel.5L engines.7.8 ELECTRICAL CONNECTIONS ‹ 1.2 BATTERY CHARGER CONNECTION The generator has been equipped with a 2 Amp battery charger installed in the control panel. the vaporization process itself provides an additional cooling effect.General Information Liquid-cooled Generators • In addition to the cooling effects of ambient air. • Installed piping must be properly purged and leaktested. rigidly mounted and protected against vibration. Consult a qualified electrician for grounding requirements in the area. Power leads for the charger have been run to the connection box (Figure 1.8.4). Proper grounding helps protect personnel against electrical shock in the event of a ground fault condition in the generator or in connected electrical devices. On units equipped with 2.Section 1 . • Use an approved pipe sealant or joint compound on all threaded fittings.1 GROUNDING THE GENERATOR A GROUNDING LUG is provided on the generator mounting base for the purpose of grounding the frame and the external electrically conductive parts of this equipment to an approved earth ground and/ or grounding rods where required by the National Electrical Code (Figure 1. Battery Charger Connection 8 . 15 Amp circuit. • Install an approved length of flexible hose between the generator connection point and rigid piping.5). Figure 1.

the LP temperature goes below the boiling point. Propane Conversions: 36. the pressure drops to zero and no vapor can be withdrawn. A primary regulator is also required at the tank to reduce the line pressure to the generator to 5-14 inches of water column. Inches 33 150 68 24 33 250 94 30 39 325 119 30 39 500 119 37 46 850 165 41 50 1000 192 41 50 Propane storage tanks can provide either a liquid or a vapor supply to the generator.38 ft3 = 90. The third column (tank capacity) will give the required tank size to continually produce the given fuel flow.500 btu = 8. If the withdrawal rate is too high. 20º or 0º F) that the generator would be operating in. Max kW Vapor 30 20 10 35 25 12 60 40 20 80 50 25 100 60 30 150 100 50 170 120 60 Minimum Temp 40 20 0 40 20 0 40 20 0 40 20 0 40 20 0 40 20 0 40 20 0 Operating Hours @ Max kW 24 35 67 26 36 72 26 38 74 26 40 77 31 51 100 35 53 105 36 51 103 Tank Capacity (Gallons) 120 Length Inches 57 Dia Inches 24 Overall Ht.500 btu = 1 gal • 1lb = 21.Section 1 — General Information Liquid-cooled Generators ‹ TABLE 1 — VAPOR CAPACITY OF PROPANE STORAGE TANKS To Use: Go to the First column and pick the required kW load and then pick the minimum ambient temperature ( 40º.56 ft3 Figure 1. The above chart is for vapor withdrawal only and provides the kW output or amount of vapor that can be withdrawn at a given temperature while keeping the temperature of the liquid above the boiling point.6 — Propane Storage Tank 9 .

1 (Butane) 10 .0 2. Length of Pipe (In Feet) 15 30 45 60 75 90 105 120 150 180 210 240 270 300 450 600 Iron Pipe Size (IPS Inches) 1-1/4” 1-1/2” 2” 2-1/2” 750 535 435 380 345 310 285 270 242 225 205 190 178 170 140 119 1220 850 700 610 545 490 450 420 380 350 320 300 285 270 226 192 2480 1780 1475 1290 1120 1000 920 860 780 720 660 620 580 545 450 390 3850 2750 2300 2000 1750 1560 1430 1340 1220 1120 1030 970 910 860 710 600 1/2” 76 52 43 38 3/4” 172 120 99 86 77 70 65 1” 345 241 199 173 155 141 131 120 109 100 92 3” 6500 4700 3900 3450 3000 2700 2450 2300 2090 1950 1780 1680 1580 1490 1230 1030 4” 13880 9700 7900 6800 6000 5500 5100 4800 4350 4000 3700 3490 3250 3000 2500 2130 6” 38700 27370 23350 19330 17310 15800 14620 13680 12240 11160 10330 9600 9000 8500 7000 6000 8” 79000 55850 45600 39500 35300 32250 29850 27920 25000 22800 21100 19740 18610 17660 14420 12480 ‹ CORRECTION FACTORS Specific Gravity 0.00 (specific gravity of air). The fuel’s specific gravity can be obtained from the fuel supplier.7 1.50 0. The 2 inch pipe is required at the given distance of 75 feet.707 0.83 2. a correction is required when the fuel used has a different specific gravity.60 0. Example: It is determined that a generator set running at 100% of rated load on natural gas requires 545 cubic feet of gas per hour.General Information Liquid-cooled Generators ‹ TABLE 2 — GAS FLOW-PIPE SIZE CHART This table is based on a specific gravity of 1.0 Multiplier 0.594 0. The table is also based on a pressure drop of 0. fittings.926 0.3 0. the fuel supplier will usually specify which multiplier is applicable.29 cubic feet of gas per hour.04 1. which allows for a nominal amount of restrictions from bends. it is apparent that a 1-1/2 inch pipe will deliver 524. etc.3.565 0.Section 1 .815 1.4 1.577 0. bends or other restrictions are used.90 1.962 0.65 (Natural Gas) 0.70 0.000 1.29 1.962).4 cubic feet per hour.633 0.1 0.08 0.5 1.9 2. will actually deliver 1077. when the correction factor is applied. For that reason. Pressure drop does not have to be considered unless an unusual number of fittings. An example of how to calculate pipe size follows the table.535 Pressure Drop 0.867 0.0 1. The unit is located 75 feet from the supply tank and will use gas having a specific gravity of 0.5 (Propane) Multiplier 0.775 0. The next larger pipe (2 inch) will deliver 1120 cubic feet per hour and.80 0. In such unusual cases.817 Specific Gravity 1.0 5.65 (multiplier is 0.00 0. From the table below.655 0.2 1.2 0.55 (Sewage Gas) Multiplier 1.10 1.58 4.

A common practice is to use a solution of one pound (500 grams) bicarbonate of soda to one gallon (4 liters) of water. flush thoroughly and immediately with water and seek medical attention.2 Carefully unpack the transfer switch. The following procedures are to be observed: • Wear full eye protection and protective clothing. Do not allow smoking. not open or mutilate the battery. always remove watches. open flame. protective clothing and gloves when handling a battery. 2. When using maintenance-free batteries. clothing.1 TRANSFER SWITCH The generator system may include a matched automatic transfer switch which is intended to be used in conjunction with the generator. sparks or any spark producing tools or equipment near the battery. electrolyte fluid is an extremely caus Battery tic sulfuric acid solution that can cause severe burns. This gas can form an explosive mixture around the battery for several hours after charging. do not connect battery cables until certain that normal source voltage at the transfer switch is correct and the system is ready to be placed into operation. • Spilled electrolyte is to be washed down with an acid-neutralizing agent. • Where electrolyte contacts the skin. Any area that houses a storage battery must be properly ventilated. Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. To prevent such automatic start-up and possible injury to personnel. If a transfer switch is not included. Do not permit fluid to contact eyes. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The slightest spark can ignite the gas and cause an explosion. If fluid is spilled. Observe battery polarity when connecting batteries to the generator set. Lead acid batteries present a risk of fire because they generate hydrogen gas.1 VENTED BATTERIES electrolyte is a dilute sulfuric acid that is  The harmful to the skin and eyes. NOTE: Damage will result if the battery connections are made in reverse. Have these procedures performed at the intervals specified in the “Maintenance” section in the Owner’s Manual.9 BATTERY INSTALLATION DANGER generators installed with automatic  Standby transfer switches will crank and start automatically when NORMAL (UTILITY) source voltage is removed or is below an acceptable preset level. Make sure all batteries are correctly connected and terminals are tight. • Where electrolyte contacts the eyes.Section 2 — Installation Liquid-cooled Generators 1. • DO NOT cause flame or spark in battery area. painted surfaces. Check that all packing material is completely removed from the switch prior to installation. The resulting liquid is to be flushed with water and the area dried. and 2. Battery connections are shown on the wiring diagrams. DO NOT LIFT THE SWITCH AT ANY OTHER POINT. and • Discharge static electricity from body before touching batteries by first touching a grounded metal surface. Wear protective goggles. Inspect closely for any damage that might have occurred during shipment. and only use tools that have insulated handles. one may be purchased separately from an Authorized Dealer. Attach any lifting device to the transfer switch mounting holes or brackets only. Released  Do electrolyte can be toxic and harmful to the skin and eyes. rings or other metal objects. It is electrically conductive and corrosive. The battery is capable of exploding.9. A negative ground system is used. it is not necessary to check the specific gravity or electrolyte level. It is supplied in a NEMA 3R enclosure.  Do not dispose of the battery in a fire. The purchaser must file with the carrier any claims for loss or damage incurred while in transit. battery represents a risk of high short circuit  The current.  For recommended batteries. ‹ 1. batteries give off explosive hydrogen  Storage gas. Such an explosion can shatter the battery and cause blindness or other injury. skin. When working on the battery. The following procedure are to be followed: • DO NOT SMOKE when near batteries. etc. All batteries must be at 100 percent state-of-charge before they are installed on the generator. flush the affected area immediately with clear water. 11 UNPACKING . The NEMA 3R enclosure is weather proof and can be used indoors or outdoors. wash it off immediately with water. see the “Specifications” section in the Owner’s Manual. Keep unauthorized personnel away from batteries.

and against construction grit and metal chips. In each case there are two types of interconnections. STANDBY CIRCUIT ISOLATION METHOD transfer switches carefully when install Handle ing. If the generator is powering only designated loads.” It is possible for the generator to be overloaded when this isolation method is employed.Section 3 — Operation Liquid-cooled Generators 2. Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker. level all mounting points. Such wiring must be properly supported. and connected. When a generator capable of powering all electrical loads in the circuit is to be installed. use the “Total Circuit Isolation Method. Mount the switch vertically to a rigid supporting structure. during utility power outages.1 – Basic Standby Electric System 3. Never install a transfer switch that has been damaged.1 BASIC STANDBY ELECTRIC SYSTEM TOTAL CIRCUIT ISOLATION METHOD Figure 3. within the wattage/amperage capacity.3 3. Install the transfer switch as close as possible to the electrical loads that are to be connected to it. standards and regulations. The connections between the generator and transfer switch will vary depending on the equipment ordered. Protect the switch against impact at all times. Figure 3. NOTE: Control wiring must always be run in a separate conduit from the load wiring. routed. 12 .3 MOUNTING 3. When this method is used.4 CONNECTION DIAGRAMS All wiring in the standby electric power system must be in strict compliance with applicable codes. Never install the switch where water or any corrosive substance might drip into the enclosure. Both the UTILITY power supply and the STANDBY (GENERATOR) output are connected to an approved transfer switch. consider using the emergency circuit isolation method.” Load circuits powered by that panel are within the wattage/amperage capacity of the generator set. wiring must be properly sized to carry the maximum load current to which is will be subjected. To prevent switch distortion. Enclosures are typically wall-mounted. If necessary. 3. • The transfer switch is installed between the utility service entrance and the building distribution panel. Do not drop the switch. The transfer switch is required by electrical code and serves the following functions: • Allows the LOAD circuits to be connected to only one power supply at a time. load wiring and control wiring. The following apply to the transfer switch in this type of system. This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator.1 shows a schematic diagram of a basic standby electric system. • Have it installed between the building’s main distribution panel and the standby distribution panel. Designated electrical loads are grouped together and wired into a separate “Standby Distribution Panel.2 Mounting dimensions for the transfer switch enclosure can be found in the transfer switch owner’s manual. The transfer switch must meet the following requirements: • It must have an ampere rating equal to the total amperage rating of the standby distribution panel circuit. Components are mounted in a standard NEMA 3R type enclosure. use washers behind mounting holes to level the unit. • Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service. In addition. • Prevents electrical backfeed between the generator and the UTILITY power circuits. it is difficult to overload the generator.

electrical shock.5L engines. and 23 and 194. electrical shock. a SET EXERCISE switch. See Figure 3. DANGER sure to turn OFF the NORMAL (UTILITY)  Make power supply before trying to connect the Utility 1 and Utility 2 control wires. In this configuration the control wires consist of Utility 1 and Utility 2 (N1 and N2). the control connections and main circuit breaker are found in the control panel. Supply voltages are extremely high and dangerous.2 for an interconnection diagram.4. which will consist of an AUTO/OFF/ MANUAL switch.  Make sure to turn OFF both the NORMAL (UTILITY) and STANDBY (EMERGENCY) power supplies before trying to connect power source and load lines to the transfer switch.Operation Liquid-cooled Generators DANGER ‹ 3. sure to maintain proper electrical clearances  Be between live electrical parts and grounded metal. This operation should only be performed by a trained electrician. N3 AND T3 WIRES ARE ONLY USED ON 3 PHASE SYSTEMS 13 . Contact with such high voltage power supply lines causes extremely hazardous. Supply voltages are extremely high and dangerous.2 — R-series to RTS UTILITY SUPPLY FROM SERVICE DISCONNECT QT SERIES ENGINE GENERATOR CONNECTION PANEL RTS TRANSFER SWITCH (N3) N2 N1 SINGLE PHASE 3 PHASE ON 0D7295 B E1 E1 N1 23 194 WIRE 178 7 E2 E2 (E3) E1 E2 (E3) T1 T1 T2 T2 T3 (T3) NEUTRAL BLOCK NEUTRAL BLOCK 8 CUST TOMER CONNECTION E WIRE WIRE WIRE WIRE 0F4034- GROUND N1 N2 057329-T NOTE: NOTE: 178 AND 183 CONNECTIONS ARE NOT USED IN THIS APPLICATION POWER LEADS AND TRANSFER SWITCH LEADS MUST BE RUN IN TWO DIFFERENT CONDUITS. CUSTOMER LOAD (DISTRIBUTION PANEL) NOTE: E3. and several fault indicator LEDs. See "Control Wiring" for control wire sizing recommendations.1 R-SERIES TO RTS An R-series generator is identified from the front of the control panel. possibly lethal. On units equipped with 2. possibly lethal. DANGER high and potentially lethal supply  Extremely voltages are present at the transfer switch when verifying phase rotation. Figure 3. Allow at least one-half inch of clearance circuits up to 400 amps. Contact with such high voltage power supply lines causes extremely hazardous.Section 3 .

2 LOAD WIRING  Terminals 178 and 183 in the generator AC connection box are not used in this application. and a neutral wire. 14 AWG. Tighten terminals to the specified torque value. Cable Length 460 feet (140m) 461 to 730 feet (223m) 731 to 1. and load lines remove surface oxides from stripped ends of conductors with a wire brush.1 CONTROL WIRING Control system interconnections on an R-series controlled generator consist of N1 and N2. source. No. See "Wire Recommendations Sizing" for load wire sizing information. 12 AWG. No. Recommended wire gauge size depends on the length of the wire: Max. No. Control system interconnection leads must be run in a conduit that is separate from the AC power leads. of approved insulative qualities. Power source and load line conductors must be properly supported. 16 AWG. Recommended wire gauge size depends on the current rating of the generator main circuit breaker.Section 3 — Operation Liquid-cooled Generators ‹ 3. Connection of any wires to these terminals may result in unwarrantable damage to the control board.161 to 1850 feet (565m) Recommended Wire Size No.5 WIRE RECOMMENDATIONS/ SIZING (SEE TABLE 3) ‹ 3. and of the correct wire gauge size. Apply joint compound to stripped ends of conductors.160 feet (354m) 1.5. When connecting power. as given in the owner's manual for the transfer switch. 18 AWG. 3. and leads 23 and 194.5. 14 . The load wires consist of wires run between the generator main circuit breaker and the transfer mechanism.

Section 3 . SA TW¥ RH¥. 14. ZW¥ USE2. THHW¥ FEPB¥ THW¥ THHN¥ THW¥ RHH¥. ZW2 XHHW2. 20 amperes for No. the overcurrent protection for conductor types marked with an ¥ shall not exceed 15 amperes for No. SIS. and 30 amperes for No. RHW¥ SIS. RHW2 USE¥. BASED ON AMBIENT TEMPERATURE OF 30° C (86° F) (REFERENCE NEC TABLE 310-16) SIZE 60° C (140° F) TYPES TW¥. 12 and 25 amperes for No. 60° TO 90° C (140° TO 194° F). TBS. FEP¥ UF¥ THHW¥ SA. UF¥ AWG kcmil TEMPERATURE RATING OF CONDUCTOR SIZE 75° C 90° C 60° C 75° C 90° C (167° F) (194° F) (140° F) (167° F) (194° F) TYPES TYPES TYPES TYPES TYPES FEPW¥ TA. RHW2 THWN¥ THHW¥ THWN¥ THHN¥. 15 . 10 aluminum and copper-clad aluminum after any correction factors for ambient temperature and number of conductors have been applied. THWN2 USE¥ RHH¥. or 15 amperes for No. RHW¥ TA. TBS RH¥. NOT MORE THAN THREE CONDUCTORS IN RACEWAY OR CABLE OR EARTH (DIRECTLY BURIED). 10 copper. 12. THHW¥ XHHW¥ THW2.Operation Liquid-cooled Generators ‹ TABLE 3 — ALLOWABLE AMPACITIES OF INSULATED CONDUCTORS RATED 0-2000 VOLTS. XHHW XHHW2. XHH USE2 XHHW¥ XHH. ZW2 COPPER ALUMINUM OR COPPER CLAD ALUMINUM — 14 — — — — 18 — — — 20¥ 25¥ — — — 25¥ 30¥ 20¥ 20¥ 25¥ 35¥ 40¥ 25 30¥ 35¥ 50 55 30 40 45 65 75 40 50 60 85 95 55 65 75 100 110 65 75 85 115 130 75 90 100 160 150 85 100 115 150 170 100 120 135 175 195 115 135 150 200 225 130 155 175 230 260 150 180 205 255 290 170 205 230 285 320 190 230 255 310 350 210 250 280 335 380 225 270 305 380 430 260 310 350 42 475 285 340 385 460 520 310 375 420 475 535 320 385 435 490 555 330 395 450 520 585 355 425 480 545 615 375 445 500 590 665 405 485 545 625 705 435 520 585 650 735 455 545 615 665 750 470 560 630 AWG 18 16 14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000 1250 1500 1750 2000 — — 20¥ 25¥ 30 40 55 70 85 95 110 125 145 165 195 215 24 260 280 320 355 385 400 410 435 455 495 520 545 560 — — — 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000 1250 1500 1750 2000 ¥ Unless otherwise specifically permitted in the NEC. THWN2 XHHW¥ THW2.

Notes Liquid-cooled Generators 16 .Section 4 .

Notes Liquid-cooled Generators 17 .Section 4 .

S. .P.O. 0F9849 Revision B (06/08/06) Printed in U.A. WI 53187 Phone: 262-544-4811 Part No. Box 8 • Waukesha.