Generator

INSTALLATION
GUIDELINES
Air-Cooled Generators
Distributed Load Center Transfer Switch

OG 2697
This booklet and the accompanying video are designed to familiarize you with the installation
process for your air-cooled generator. Neither this booklet nor the accompanying video
replace or supersede any information contained in any of the written documents shipped with
your equipment. This booklet should only be used in conjunction with the Owner’s Manual,
Installation Guide and other technical documents shipped with your equipment.
Future product updates and/or modifications will be reflected in the written documentation
included with your equipment. Always read all accompanying documentation
carefully before attempting to install any generator, transfer switch or related equipment.
It is essential to comply with all regulations established by the Occupational Safety and Health
Administration (OSHA) and strict adherence to all local, state and national codes is mandatory.

Study the SAFETY RULES in the Owner’s your local dealer or other competent, qualified
Manual carefully before installing, electrician or installation technician who is
operating or servicing any equipment. Use familiar with applicable codes, standards and
this guide ONLY in conjunction with the regulations. The operator also must comply
Owner’s Manual and Installation Guide with all such codes, standards and regulations.
shipped with the generator. The generator Installation, operation, servicing and repair
can operate safely, efficiently and reliably of this (and related) equipment must always
only if it is properly installed, operated comply with applicable codes, standards, laws
and maintained. and regulations. Adhere strictly to local, state
The manufacturer cannot anticipate every and national electrical and building codes.
possible circumstance that might involve a Comply with regulations the Occupational
hazard. The warnings in this manual, and on Safety and Health Administration (OSHA)
tags and decals affixed to the unit are, has established. Also, ensure that the generator
therefore, not all-inclusive. is installed, operated and serviced in accordance
with the manufacturer’s instructions and
Despite the safe design of this generator,
recommendations. Following installation, do
operating this equipment imprudently,
nothing that might render the unit unsafe or
neglecting its maintenance or being careless
in non-compliance with the aforementioned
can cause possible injury or death.
codes, standards, laws and regulations.
Permit only responsible and capable persons
Engine exhaust fumes contain carbon
to install, operate or maintain this equipment.
monoxide gas, which can be DEADLY.
Potentially lethal voltages are generated by This dangerous gas, if breathed in sufficient
these machines. Ensure all steps are taken to concentrations, can cause unconsciousness
render the machine safe before attempting to or even death. For that reason, adequate
work on the generator. ventilation must be provided. Exhaust gases
General Hazards must be piped safely away from any building or
enclosure that houses the generator to
For safety reasons, the manufacturer
an area where people, animals, etc., will not
recommends that this equipment be
be harmed.
installed, serviced and repaired by


This exhaust system must be installed to isolate the electrical system from the utility
properly, in strict compliance with applicable distribution system when the generator is
codes and standards. operating. Failure to isolate the electrical
system by these means will result in damage
Keep hands, feet, clothing, etc., away from
to the generator and may also result in injury
drive belts, fans and other moving or hot
or death to utility workers due to backfeed of
parts. Never remove any drive belt or fan
electric energy.
guard while the unit is operating.
If an open bottom is used, the engine-generator
Adequate, unobstructed flow of cooling and
is to be installed over non-combustible
ventilating air is critical to prevent buildup of
materials and should be located such that
explosive gases and to ensure correct
combustible materials are not capable of
generator operation. Do not alter the
accumulating under the generator set.
installation or permit even partial blockage of
ventilation provisions, as this can seriously Only qualified, competent installation
affect safe operation of the generator. contractors or electricians thoroughly familiar
with applicable codes, standards and
Keep the area around the generator clean and
regulations should install this standby electric
uncluttered. Remove any materials that could
power system. The installation must comply
become hazardous.
strictly with all codes, standards and
When working on this equipment, regulations pertaining to the installation.
remain alert at all times. Never work
After the system has been installed,
on the equipment when physically or
do nothing that might render the
mentally fatigued.
installation in non-compliance with such
Generator Installation codes, standards and regulations.
These generators are air-cooled, engine- NFPA Standards
driven generator sets designed to supply
The following published standards
electric power that operates critical
booklets pertaining to standby electrical
electrical loads during utility power
systems are available from the National Fire
failure. Your generator was factory-installed
Protection Association (NFPA), Batterymarch
in a weather resistant, all metal enclosure and
Park, Quincy, MA 02269:
are intended for outdoor installation only.
NFPA 37, STATIONARY
Before Installation COMBUSTION ENGINES AND
The generator’s rated wattage/amperage GAS TURBINES
capacity must be adequate to handle all NFPA 54, NATIONAL FUEL
electrical loads that the unit will power. The GAS CODE
critical (essential) loads may need to be NFPA 58, LIQUIFIED
grouped together and wired into a separate PETROLEUM GAS CODE
“emergency” distribution panel.
NFPA 70, NATIONAL ELECTRIC
Connecting this generator to an electrical CODE (NEC)
system, normally supplied by an electric
NFPA 99, STANDARD FOR HEALTH
utility, shall be by means of a transfer switch,
CARE FACILITIES


 NFPA 101, LIFE SAFETY CODE Grounding the Generator
NFPA 110, STANDARD FOR A grounding lug is provided on the generator
EMERGENCY AND STANDBY mounting base for the purpose of grounding the
POWER SYSTEMS frame and the external electrically conductive
NFPA 220, STANDARD TYPES OF parts of this equipment to an approved earth
BUILDING CONSTRUCTION ground and/or grounding rods where required
NOTE: by the National Electrical Code. Grounding
It is essential to use the latest version of any procedures must meet local regulations.
standard to ensure that the generator and its Battery Installation
accessories comply with all the applicable
Standby generators installed with automatic
standards and local codes.
transfer switches will crank and start
Other Published Standards automatically when NORMAL (UTILITY)
In addition to NFPA standards, the source voltage is removed or is below an
following information pertaining to the acceptable preset level. To prevent such
installation and use of standby electric automatic start-up and possible injury to
systems is available: personnel, do not connect battery cables
until certain that normal source voltage at the
Article X, NATIONAL BUILDING CODE, transfer switch is correct and the system is
available from the American Insurance ready to be placed into operation.
Association, 85 John Street, New York,
NY 10038. Storage batteries give off explosive hydrogen
gas. This gas can form an explosive mixture
AGRICULTURAL WIRING around the battery for several hours after
HANDBOOK, obtainable from the Food charging. The slightest spark can ignite the
and Energy Council, 909 University gas and cause an explosion. Such an
Avenue, Columbia, MO 65201. explosion can shatter the battery and cause
ASAE EP-364.2, INSTALLATION blindness or other injury. Any area that houses
AND MAINTENANCE OF FARM a storage battery must be properly ventilated.
STANDBY ELECTRIC POWER, Do not allow smoking, open flame, sparks or
available from the American Society of any spark producing tools or equipment near
Agricultural Engineers, 2950 Niles Road, the battery.
St. Joseph, MI 49085. Battery electrolyte fluid is an extremely
A52.1, AMERICAN NATIONAL caustic sulfuric acid solution that can cause
STANDARDS FOR CHIMNEYS, severe burns. Do not permit fluid to contact
FIREPLACES AND VENTING eyes, skin, clothing, painted surfaces, etc.
SYSTEMS, available from the American Wear protective goggles, protective clothing
National Standards Institute, 1430 and gloves when handling a battery. If fluid
Broadway, New York, NY 10018. is spilled, flush the affected area immediately
The installer must comply with all with clear water.
applicable state and local codes. Do not dispose of the battery in a fire. The
battery is capable of exploding.


Do not open or mutilate the battery. Released Servicing of batteries is to be performed or
electrolyte can be toxic and harmful to the supervised by personnel knowledgeable of
skin and eyes. batteries and the required precautions. Keep
unauthorized personnel away from batteries.
The battery represents a risk of high
short-circuit current. When working on the For recommended batteries, see the
battery, always remove watches, rings or Installation Guide. All batteries must be at
other metal objects, and only use tools that 100 percent state of charge before they are
have insulated handles. installed on the generator.

Vented Batteries When using maintenance-free batteries, it is

not necessary to check the specific gravity
The electrolyte is a diluted sulfuric acid
or electrolyte level. Have these procedures
that is harmful to the skin and eyes. It is
performed at the intervals specified in the
electrically conductive and corrosive. The
“Maintenance” section in the Owner’s
following procedures are to be observed:
Manual. A negative ground system is used.
Wear full eye protection and Battery connections are shown on the wiring
protective clothing. diagrams. Make sure all batteries are correctly
If electrolyte contacts the skin, wash it connected and terminals are tight. Observe
off immediately with water. battery polarity when connecting batteries to
the generator set.
If electrolyte contacts the eyes, flush
thoroughly and immediately with water NOTE:
and seek medical attention. Damage could result if the battery
Spilled electrolyte is to be washed down connections are made in reverse.
with an acid-neutralizing agent. A common
practice is to use a solution of one pound
(500 grams) bicarbonate of soda to one gallon
(4 liters) of water. The bicarbonate of soda
solution is to be added until the evidence
of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water
and the area dried.
Lead acid batteries present a risk of fire
because they generate hydrogen gas. The
following procedures are to be followed:
DO NOT SMOKE when near batteries.
DO NOT cause flame or spark in battery area.
Discharge static electricity from body
before touching batteries by first touching a
grounded metal surface.


 Before You Begin
Carefully read and follow all of the procedures and safety precautions detailed in the installation
guide. If you do not completely understand any portion of the installation manual, technical manual
or other factory-supplied documents, contact an authorized dealer for assistance.
Fully comply with all relevant NEC, NFPA and OSHA standards as well as all federal, state and
local building and electric codes. As with any generator, this unit must be installed in accordance
with current NFPA 37 and NFPA 70 standards as well as any other federal, state, and local codes for
minimum distances from other structures.
Contact the local inspector or city hall to make sure you are aware of all state and local codes and
regulations that could impact installation. Secure all required permits before starting the job.

Site Preparation & Generator Placement

Locate the mounting pad as close as possible to
the transfer switch and fuel supply.
Leave adequate room around the pad for
service access (check local code) and place
the pad high enough to keep rising water from
reaching the generator.
Choose an open space that will provide
adequate and unobstructed airflow.

Place the unit so air vents won’t become

clogged with leaves, grass, snow or debris.
Make sure exhaust fumes will not enter the
building through eaves, windows, ventilation
fans or other air intakes.
Dig a rectangular area approximately five
inches deep and about six inches longer and
wider than the footprint of the generator. Cover
with polyurethane film and fill with pea gravel
or crushed stone. Compact and level the stone.

Inspect the generator for shipping damage and,

if necessary, file a claim with the shipper.
Remove the bolts holding the generator base
frame to the wooden pallet.


Make sure the lifting equipment you’ll be
using has sufficient capacity to safely handle
the weight of the generator.
Use nylon lifting straps and connect them
to the lifting eyes on each corner of the base
frame to avoid damaging the enclosure.

Set the generator onto the pad so that the

gravel bed extends several inches beyond the
generator on all sides.
Make sure the generator is level within ½ inch.

Some locations require the use of a poured

concrete mounting pad. If you’re using a
concrete pad, secure the base frame of the
generator to the pad with appropriately sized
masonry bolts or other fasteners specified by
local code.

Connect an approved ground strap to the

grounding lug on the base frame and to an
approved earth ground or grounding rod as
specified by local regulations.


 Check the engine oil, and if necessary, add
enough of the recommended oil to bring the
level up to the FULL mark on the dipstick. Be
careful not to overfill the crankcase.

Converting To LP Vapor
The generator was configured for natural gas
operation at the factory. Switching over to LP
vapor is a simple procedure.
On models with the V-Twin engine, simply flip
the fuel selection switch from natural gas to LP.

On models with a single-cylinder engine, start

by making sure the battery is disconnected.
Disconnect the two wires from the solenoid and
remove the fuel hose from the outlet port.

Remove the steel plug from the number one

outlet port and the brass fitting for the fuel hose
from the number two port.
Using a quality sealant on the threaded fittings,
install the brass fitting in port one and the steel
plug in port two.


 Replace the fuel hose and clamp. Then
reconnect the wires to the solenoid.

Finally, insert the plastic plug that came with

the generator into the hole on the bottom of the
air cleaner base.

Installing & Connecting Gas Lines

Both natural gas and LP vapor are highly
volatile substances, so strict adherence to all
safety procedures, codes, standards and
regulations is essential.
Gas line connections should be made by a
certified plumber familiar with local codes.
Always use AGA-approved gas pipe and a
quality pipe sealant or joint compound.

Most applications will require a manual shutoff

valve on the fuel line.


When connecting the gas line to the generator,
use a short section of UL Listed or AGA-
approved flexible fuel line in accordance with
local regulations. The purpose of the flexible
fuel line is to ensure that vibration from the
generator does not cause a gas leak at one of
the connection points, so it’s important that the
line be installed with as few bends as possible.

Never bend the flexible fuel line to avoid

using an elbow. Bending the flexible line
decreases its ability to absorb vibrations and
defeats its purpose.

Check the gas pressure at the secondary

regulator to make sure there’s enough pressure
for proper generator operation.
The local gas supplier is responsible for
ensuring adequate pressure, so if the pressure
is too low, or if it’s greater than 14 inches of
water column, contact the gas supplier.

When you’ve finished checking the gas

pressure, close the manual shutoff valve.


External Electrical Connections
Drill a 1¾ inch hole and feed the conduit
through the hole.

Remove the knockout in the back of the

connection box, feed the wires through the
back of the box and secure the conduit with
the lock nut.
Seal the hole with silicone caulk. Don’t forget
to caulk the hole inside the house as well.

Mount the connection box so that it completely

covers the hole in the wall.
Connect all wires to the lugs in the connection
box (black to black, red to red and white to
white). Attach the green ground wire to the
ground screw and connect the two ends of the
four-pin plug connector.

Replace the protective cover plate …

… and lock the connection box.

10
Installing The Automatic Transfer Switch
Before beginning any installation, make sure
power is shut OFF to the main distribution
panel and carefully read the Installation Guide
that came with your transfer switch.
The distributed load center switch must be
mounted close enough to the main distribution
panel to accommodate the two-foot, pre-wired
conduit. Make sure no water or corrosive
substances can drip onto the transfer switch
enclosure.
Always inspect the switch for shipping damage.
Never mount a transfer switch that shows any
evidence of damage.

Protect against impact and mount the switch

vertically to a rigid support structure. Make
sure the switch is level and plumb.
Your transfer switch is an open transition
switch. Open transition switches prevent
electrical feedback between the generator and
the utility by only allowing load circuits to be
connected to one power supply at a time.

Each wire in the pre-wired transfer switch is

color-coded so you can easily match circuits
in the main panel to their new breakers in the
transfer switch.

11
 When three-conductor wiring is used, two
120 volt circuits will often share the same neutral
wire. To avoid overloading the neutral, you
should either move BOTH of the circuits that
share the neutral or don’t move either of them.

When moving two circuits with a shared

neutral, they should be connected to adjacent
positions (one above the other) in the transfer
switch. That will assure that the two hot wires
are on separate phases and will maintain their
relationship to neutral.

Select a circuit you want to back up and

remove the power lead from the breaker.
Using UL Listed wire nuts, reconnect the
power lead to a matching breaker in the
transfer switch.

Make sure each circuit you move is protected

by the same size breaker in the transfer switch.
15 Amp circuits must be connected to 15 Amp
breakers and 20 Amp circuits to 20 Amp breakers.

For every circuit you move to the transfer

switch, connect the white neutral wire to the
neutral bar in the distribution panel.

12
 Install a 2-pole breaker in the distribution panel
to protect the transfer switch. The required Amp
rating of the breaker depends on which transfer
switch you’re using, so refer to the Installation
Guide before purchasing the breaker.
Install the breaker in two adjacent empty slots
(one above the other) in the main panel.

When all emergency circuits have been moved

to the transfer switch, close the main breaker
to restore utility power and make sure utility
voltage at the transfer switch is correct. Refer
to NFPA 70E for the safety equipment required
when working inside a live transfer switch.

Before purchasing a battery for the

generator, refer to the Installation Guide for a
list of recommended batteries. Follow all of
the procedures and safety precautions in the
Installation Guide when installing the battery.

Operational Tests
Switch the generator’s main circuit
breaker OFF and put the mode switch in
the OFF position.

Make sure utility power is OFF and place all of

the emergency circuit breakers, in the transfer
switch, in the OFF position.

13
 Locate the transfer handle and insert the metal
end into the slot in the main contactor
assembly. Pull the handle DOWN to move the
main contacts to the standby power
(generator) position.
NEVER OPERATE THE TRANSFER
SWITCH MANUALLY WHEN LOADS
ARE CONNECTED.

Put the generator’s mode switch in MANUAL

to start the engine.
Allow the engine to warm up, then switch the
generator’s main breaker to the ON position.
The generator is now supplying electricity to
the transfer switch but is not carrying any load.

Check to be sure that voltage and frequency

from the generator is correct. If line-to-line
voltage is not 240 volts, refer to the Installation
Guide for the proper adjustment procedures. If
line-to-neutral voltage is not 120 volts, check
the neutral connection between the generator
and transfer switch.
When finished checking the voltage, switch the
generator’s main circuit breaker OFF and put
the mode switch in the OFF position to shut
down the generator.

Make sure the 2-pole circuit breaker you

installed in the main distribution panel is in the
OFF position.

14
Use the transfer handle to move the main
contacts in the transfer switch to the UP
(utility) position. Switch the 2-pole breaker ON
in the distribution panel.

Now switch the generator’s main breaker ON

and put the mode switch in AUTO.

Shut OFF utility power and make sure the

generator starts automatically.

If everything worked properly, switch the main

breaker to ON and make sure that power is
automatically transferred back to the utility.

15
 After the engine has completed its cool
down cycle and shut down, shut OFF utility
power again.
When the generator is supplying power to the
transfer switch, move the breakers in the
switch to the ON position one at a time
until the generator has accepted the entire
emergency load.
With the generator carrying the entire emergency
load, re-check gas pressure to verify that it
is at the same level it was before you started
the generator.

Switch the main breaker ON to restore

utility power.

The generator will continue running to

allow the engine to cool down before
shutting itself OFF.

Unhook the gas meter and reinstall the port

plug on the regulator.

16
 Shut OFF utility power again. The generator
should start and the entire emergency load
should transfer to the generator.
Close the main breaker to restore utility power
and allow the engine to cool down and shut
itself OFF.

Setting The Automatic Exercise Function

With the mode switch in AUTO, press the
EXERCISER switch. Hold it down for at least
10 seconds and release. The generator should
start within a few seconds. The unit will run
for about 12 minutes before shutting itself
down automatically.
Once set, the generator will exercise each week
at the same time. Be sure to show the owner
how to set the exercise function on the day and
time he/she wants the unit to exercise.

If the battery is ever disconnected for any reason,

the exercise function will have to be reset.
If your generator is equipped with the low
speed exercise feature, it was enabled at the
factory and no adjustment is needed.

As you can see, this installation is not difficult.

Simply follow all of the instructions that come
with the generator and observe all safety
procedures, applicable codes and regulations.

17
Notes

18
Every installation has its own unique set of circumstances and requirements. This booklet
provides guidelines for basic installations only and is not intended to cover all applications. If
you have any questions or concerns after carefully reading all documentation received with the
equipment, contact your local dealer for assistance.

Part# 0G2697 Printed in USA 08/06

©2006 Generac Power Systems, Inc. All rights reserved.