Generac Power Systems 7 kW PowerPact User manual

Reference all appropriate documentation.
This manual should remain with the unit.
nNOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS.
nONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT
INSTALLATION.
nDEADLY EXHAUST FUMES! OUTDOOR INSTALLATION ONLY!
LISTED
CUS
To locate in Spanish, go to http://www.generac.com/service-support/product-support-lookup
To locate in French, go to http://www.generac.com/service-support/product-support-lookup
Owner’s Manual
Automatic Standby Generator
7 kW PowerPact™

ii
WARNING!
California Proposition 65
Engine exhaust and some of its constituents are known to the state of California to cause cancer,
birth defects, and other reproductive harm.
WARNING!
California Proposition 65
This product contains or emits chemicals known to the state of California to cause cancer,
birth defects, and other reproductive harm.
Use this page to record important information about your generator set.
Record the information found on your unit data label on this page. The
generatorunitdatalabelplateisaffixedto theenginedivider panelinside
the enclosure. The unit data label provides the following information:
• Model Number
• Serial Number
• Control Panel Part Number
• Voltage Rating of the unit
• Maximum Current Rating of the unit (AMPS)
When contacting an Independent Authorized Service Dealer about parts
and service, always supply the complete model number and serial num-
ber of the unit.
Operation and Maintenance: Proper maintenance and care of the gen-
erator ensures a minimum number of problems and keeps operating
expenses at a minimum. It is the operator’s responsibility to perform all
safety checks, to make sure that all maintenance for safe operation is
performed promptly, and to have the equipment checked periodically by
anIndependentAuthorized ServiceDealer.Normalmaintenance,service
and replacement of parts are the responsibility of the owner/operator
and, as such, are not considered defects in materials or workmanship
within the terms of the warranty. Individual operating habits and usage
may contribute to the need for additional maintenance or service.
When the generator requires servicing or repairs, contact an
Independent Authorized Service Dealer for assistance. Authorized ser-
vice technicians are factory-trained and are capable of handling all ser-
vice needs.
For any Frequently Asked Questions (FAQs) for your product,
please go to: http://www.generac.com/service-support/faqs..
To find your Local Independent AUTHORIZED SERVICE DEALER
INDEPENDENT AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest INDEPENDENT
AUTHORIZED SERVICE DEALER,
please call this number:
1-800-333-1322
or, visit the dealer locator at:
www.generac.com/Service/Dealer Locator/

Table of Contents
iii
Section 1 — Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 — General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 — General Safety Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 — Exhaust Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 — Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 — Fire Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 — Explosion Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 2 — General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 — The Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 — Protection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 — Emission Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 — Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 — Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Section 3 — Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 — Controller Lid Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 — Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 — Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 — Alarm Response Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 — Automatic Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6 — Turning the Generator Off When Operating Under Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.7 — Manual Transfer Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.8 — Side Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.9 — Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.10 — Setting the Exercise Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Section 4 — Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 — Performing Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 — Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 — Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4 — Changing the Engine Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.5 — Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6 — Valve Lash Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.7 — Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.8 — Attention After Submersion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.9 — Corrosion Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.10 — Out of Service Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Section 5 — Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Section 6 — Quick Reference Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Automatic Standby Generator Owner’s Manual 1
Section 1 Safety
INTRODUCTION:Thank you for purchasing this compact, high performance, air-cooled, engine-driven stationary automatic standby generator
set. Every effort was madeto make sure that the information and instructions in this manual were both accurate and current at the time the man-
ual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product or manual at any time without
prior notice.
This generator 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 and is intended exclusively for outdoor installation. This generator will operate using either vapor
withdrawn liquid propane (LP) or natural gas (NG).
NOTE: When properly sized, 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: The operator is responsible for proper andsafe use of this equipment. The manufacturer strongly recom-
mends that the operator read and thoroughlyunderstand the instructions and contents of this owner’s manual before attempting touse the equip-
ment. If any portion of this publication is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing
procedures.
SAVE THESE INSTRUCTIONS: The manufacturer suggests that this manual and the rules for safe operation be copied and posted near the
unit’s installation site. Safety should be stressed to all operators and potential operators of this equipment.
SAFETY: Throughout this manual, and on tags and decals affixed to the unit, DANGER, WARNING, CAUTION and NOTE blocks are used to
alert personnel to special instructions about a particular operation, functionor service that may be hazardous if performed incorrectly or care-
lessly. Observe them carefully. Their definitions are as follows:
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS
INJURY.
Indicates a hazardous situation or action which, if not avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTE: Notes contain additional information important to an operation or procedure.
Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates is as
follows: This symbol points out important Safety Information that, if not followed, could endanger personal safety and/or
property of others.
This symbol points out a potential Explosion Hazard.
This symbol points out a potential Fire Hazard.
This symbol points out a potential Electrical Shock Hazard.
These “Safety Alerts” cannot eliminate the hazards that they signal. Strict compliance with these special instructions, plus common sense are
major accident prevention measures.
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2Automatic Standby Generator Owner’s Manual
1.1 — General Safety
Study these safety rules carefully before operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The
generator can operate safely, efficiently andreliably only if it is properly installed, operated andmaintained.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, ensure that itis safe for personnel. Also make surethe procedure, work methodoroperating technique utilizeddoes not
render the generator unsafe.
Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or
being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate
and maintain this equipment.
Potentially lethal voltages are generated by these machines. Ensure steps are taken to make the machine safe
before attempting to work on the generator.
Parts of the generator are rotating and/or hot during operation. Exercise care near a running generator.
The installation of this generator must always comply with applicable codes, standards, laws and regulations.
A running generator gives off DEADLY carbon monoxide, an odorless, colorless, poisonous gas. Breathing carbon
monoxide can cause dizziness, throbbing temples, nausea, muscular twitching, headache, vomiting, weakness,
sleepiness, inability to think clearly, fainting, unconsciousness or even death.
The control panel for this unit is intended to be operated by qualified service personnel only.
1.2 — General Safety Hazards
• For safety reasons, this equipment should only be installed, serviced and repaired by a Service Dealer or other competent, qualified electri-
cian or installation technician who is familiar with applicable codes, standards, regulations and product Installation Manual guidelines. The
operator also must comply with all such codes, standards, regulations and product Installation Manual guidelines.
• Theengineexhaustfumescontain carbonmonoxide, whichcanbe DEADLY.Thisdangerousgas,ifbreathedinsufficientconcentrations,can
cause unconsciousness or even death. DO NOT alter or add to the exhaust system or do anything that might render the system unsafe or in
noncompliance with applicable codes and standards.
• Install a carbon monoxide alarm indoors, according to manufacturer’s instructions/recommendations.
• Adequate,unobstructed flow ofcoolingand ventilating airis critical forcorrectgenerator operation.Donot alter theinstallationorpermit 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.
• Keep hands, feet, clothing,etc. away from drivebelts, fans, and othermoving or hot parts. Neverremove any drive beltor fanguardwhile the
unit is operating.
• When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.
• Inspect the generator regularly, and contact the nearest Dealer for parts needing repair or replacement.
• Before performing any maintenance on the generator, remove the control panel fuse and disconnect the Negative (—) battery cable to pre-
vent accidental startup. When disconnecting battery cables always remove the NEGATIVE (NEG or “—”) cable first, then remove the
POSITVE (POS, or “+”) cable. When reconnecting the cables, connect the POSITIVE cable first, and the NEGATIVE cable last.
• Never use the generator or any of its parts asa step. Stepping on the unit can stress and break parts,and may result in dangerous operating
conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.
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Automatic Standby Generator Owner’s Manual 3
1.3 — Exhaust Hazards
• Generator engine exhaust contains DEADLY carbon monoxide, an odorless, colorless, poisonous gas. Breathing carbon monoxide can
causedizziness, throbbingtemples,nausea, musculartwitching,headache,vomiting,weakness,sleepiness,inability tothink clearly, fainting,
unconsciousness or even death. If any carbon monoxide poisoning symptom is experienced, move into fresh air and immediately seek med-
ical attention.
• This generator is designed for OUTDOOR installation ONLY. Never operate the generator inside any garage or other enclosed space.
1.4 — Electrical Hazards
• All generators covered by this manual produce dangerous electrical voltages that can cause fatal electrical shock. Utility power delivers
extremely high and dangerous voltages to the transfer switch, as does the standby generator when it is in operation. Avoid contact with bare
wires, terminals, connections, etc. while the unit is running. Ensure all appropriate covers, guards and barriers are in place, secured and/or
locked before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce potential
shock hazard.
• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRI-
CAL SHOCK MAY RESULT.
• This is an Automatic StandbyGenerator, the generator may crankand start at any time whenutility is lost. When this occurs, load circuits are
transferred to the STANDBY (generator) power source. To prevent injury, before working on this generator (for inspection, service or mainte-
nance), always put the generator into the OFF mode and remove the 7.5 Amp ATO®fuse from the generator control panel.
• In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the
victimfromthe live conductor.AVOID DIRECT CONTACT WITHTHEVICTIM. Use a nonconductingimplement,such as adryrope or board,
to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving
components resulting in injury.
1.5 — Fire Hazards
• For fire safety, the generator must be installed and maintained properly. Installation MUST always comply with applicable codes, standards,
laws,regulationsand productInstallation Manual guidelines. Adhere strictly to local, state,and national electrical andbuilding codes.Comply
with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed in
accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe instal-
lation and render the unit in noncompliance with the aforementioned codes, standards, lawsand regulations.
• Keepa fireextinguishernear thegeneratorat alltimes.Extinguishers rated“ABC”bythe NationalFireProtection Associationareappropriate
for use on the standby generator. Keep the extinguisher properly charged and be familiar with its use. Consult the local fire department with
any questions pertaining to fire extinguishers.
1.6 — Explosion Hazards
• Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator
compartment, or on or near the generator as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from
debris.
• Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Install the fuel supply system according to appli-
cable fuel-gas codes. Before placing the home standby electric system into service, fuel system lines must be properly purged and leak
tested according to applicable code. After installation, inspect the fuel system periodically for leaks. No leakage can be permitted.

4Automatic Standby Generator Owner’s Manual
If this generator is used to power electrical load circuits normally powered by a utility power source, it is
required by code to install a transfer switch. The transfer switch must effectively isolate the electrical system
from the utility distribution system when the generator is operating (NEC 702). Failure to isolate an electrical
system by such means will result in damage to the generator and also may result in injury or death to utility
power workers due to backfeed of electrical energy.
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Automatic Standby Generator Owner’s Manual 5
Section 2 General Information
2.1 — The Generator
Figure 2-1: GA-420 Engine 7 kW Unit
2.2 — Protection Systems
The generator may have to run for long periods of time with no operator present to monitor the engine/generator conditions. Therefore, the gen-
erator is equipped with a number of systems to automatically shut down the unit to protect it against potentially damaging conditions. Some of
these systems are as follows:
The control panel contains LEDs which alert the operator when a fault condition occurs. For more information about alarms and control panel
operation, see Section 3 Operation.
• Low Oil Level Sensor
• High Temperature Sensor
• Overcrank Detection
• Overspeed Detection
• RPM Sensor
• Underspeed Detection
• Charger Problem Detection
• Battery Problem Detection
• Fuse Problem Detection (missing or failed)
• Wiring Error Detection
Oil Fill/Dipstick
Control Panel/
Circuit Breaker
Spark Plug
Starter Motor
Alternator
Oil Drain Hose
Airbox

6Automatic Standby Generator Owner’s Manual
2.3 — Emission Information
TheU.S. EnvironmentalProtectionAgency(EPA) requiresthat thisgenerator complywith exhaustemissionstandards.Thisgeneratoris certified
to meet the applicable EPA emission levels, and is certified for use as a stationary engine for standby power generation. Any other use may be a
violation of federal and/or local laws. To ensure that the engine complies with the applicable emission standards for the duration of the engine’s
life, it is important to follow the maintenance specifications in the Section 4Maintenance. This generator is certified to operate on Liquid Propane
Vapor fuel or pipeline Natural Gas.
The Emission Control System on this generator consists of the following components:
• Air Induction System
• Airbox Assembly
• Air Cleaner
• Fuel Metering System
• Carburetor / Mixer Assembly
• Fuel Regulator
• Ignition System
• Spark Plug
• Ignition Module
• Exhaust System
• Exhaust Manifold
• Muffler

Automatic Standby Generator Owner’s Manual 7
2.4 — Specifications
2.4.1 — Generator
2.4.2 — Engine
The specification sheet for your generator was included in the documentation provided with the unit at the time of purchase. For additional
copies, consult your local Authorized Service Dealer for your specific generator model.
2.4.3 — Fuel Requirements
The engine has been fitted with a dual fuel carburetion system. The unit will run on natural gas or LP gas (vapor), but it has been factory set to
run on natural gas. The fuel system will be configured for the available fuel source during installation.
Recommended fuels should have a btu content of at least 1,000 Btus per cubic foot (37.26 megajoules per cubic meter) for natural gas, or at
least 2,500 Btus per cubic foot (93.15 megajoules per cubic meter) for LP gas (vapor).
NOTE: If converting to LP gas from natural gas, a minimum LP tank size of 250 gallons (946 liters) is recommended. See the Installation
Manual for complete procedures and details.
Output 7 kW
Rated Voltage 240
Rated Maximum Load
Current (Amps) at 240
Volts (LP)* 29.2
Main Circuit Breaker 30 Amp
Phase 1
Rated AC Frequency 60 Hz
Battery Requirement Group U1, 12 Volts and 300 CCA Minimum (Generac Part No. OD4575)
Weight (unit only in lbs./
kg) 280/127.3
Enclosure Galvanneal Steel
Normal Operating
Range This unit is tested in accordance to UL 2200 standards with anoperating temperature of -20 ºF (-29 ºC) to 122 ºF (50 ºC). For areas where temperaturesfall below 32 ºF (0 ºC) a cold weather kit isrequired. 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 Btu/joules content. Typical derates are between 10-20% off the LP gas rating.
** Circuits to be moved must be protectedby same size breaker. For example, a 15 Amp circuit in the main panel must be a 15 Amp circuit in the transfer switch.
Type of Engine GA-420
Number of Cylinders 1
Displacement 420 cc
Cylinder Block Aluminum w/Cast Iron Sleeve
Recommended Spark Plug F7TC/ Champion N9YC
Spark Plug Gap 0.76 mm (0.030 in)
Starter 12 VDC
Oil Capacity Including Filter Approx. 1.2 Qt/1.1 L
Recommended Air Filter Generac Part No. 0E9371A
Engine power is subject to and limited by such factors as fuel Btu/joules content, ambient temperature and altitude. Engine power decreases about
3.5 percent for each 1,000 feet (304.8 meters) above sea level, and also will decrease about 1 percent for each 10 ºF (6 ºC) above 60 ºF (15 ºC)
ambient temperature.

8Automatic Standby Generator Owner’s Manual
Gaseous fuels such as natural gas and liquid propane gas are highly explosive. Even the slightest
spark can ignite such fuels and cause an explosion. No leakage of fuel is permitted. Natural gas, which
is lighter than air, tends to collect in high areas. LP gas is heavier than air and tends to settle in low
areas.
2.4.4 — Battery Requirements
Group U1, 12V, minimum 300 CCA (Generac Part No. OD4575).
For proper battery maintenance procedures, see Section 4 Maintenance.
2.4.5 — Battery Charger
The battery charger is integrated into the control panel module in all models. Itoperates as a “Smart Charger” which ensures output charging lev-
els are safe and continuously optimized to promote maximum battery life.
2.5 — Accessories
There are performance enhancing accessories available for air-cooled generators.
Contact a Dealer for additional information on accessories.
Accessory Description
Cold Weather Kit Required in areas where temperatures regularly fall below 32 ºF (0 ºC).
Scheduled Maintenance Kit Includes all pieces necessary to perform maintenance on the generator along with oil recommendations.
Mobile Link™ Provides a personalized web portal that displays the generator’s status, maintenance schedule, event history and
much more. This portal is accessible via computer, tablet or smart phone. Sends emails and/or text notifications
when there is any change in the generator’s status. Notification settings can be customized to what type of alert is
sent and how often. For more information, visit www.standbystatus.com.
Wireless Local Monitor Completely wireless and battery powered, the Wireless Monitor provides you with instant status without ever leaving
the house. Status lights (red, yellow and green) alert owners when the generator needs attention. Magnetic backing
permits refrigerator mounting and gives a 600 foot line of sight communication.
Touch-Up Paint Kit Very important to maintain the look and integrity of the generator enclosure. This kit includes touch-up paint and
instructions.
Extended Warranty Coverage Extend your generator’s warranty coverage by purchasing the 5 year extended warranty coverage. Covers 5 years
of both parts and labor. Extended coverage can be purchased within 12 months of the end-users
purchase date. This extended coverage is applicable to registered units and end-user proof of purchase must be
available upon request.
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Section 3 Operation
Automatic Standby Generator Owner’s Manual 9
3.1 — Controller Lid Operation
• Lift lid from bottom to open. Lid will secure in place when opened.
Figure 3-1: Open Control Panel Lid
• Pull on lid slightly to close.
Figure 3-2: Close Control Panel Lid
OPEN
COVER
PULL THE COVER TO
UNLOCK AND CLOSE

10 Automatic Standby Generator Owner’s Manual
3.2 — Circuit Breaker
The Main Line Circuit Breaker (MLCB) and control panel are located under the side panel cover. Open the side cover door to access both the
control panel and circuit breaker.
Figure 3-3: Control Panel / Circuit Breaker Location
Set to AUTO, the engine may crank and start at any time without warning. Such automatic starting
occurs
when utility power source voltage drops below a preset level or during the normal exercise
cycle. To prevent possible injury that might be caused by such suddenstarts, always set to OFF and
remove the fuse(s), disconnect the battery negative cable and shut off utility power at the MLCB
before work
ing on or around the generator or transfer switch. Then, place a “DO NOT OPERA TE” tag
on the
generator panel and on the trans fer switch.
NOTE: The generator is to be run with all appropriate panels in place, including during troubleshooting by a technician.
3.3 — Control Panel
Figure 3-4: Generator Control Panel and LEDs
NOTE: The control panel on this unit is intended to only be operated by qualified service personnel.
Circuit Breaker (MLCB) Control Panel
*
Operation
Mode
Buttons
and LEDs
Warning
LEDs
Alarm
LEDs

Automatic Standby Generator Owner’s Manual 11
3.3.1— Using the Auto/Off/Manual Buttons
NOTE: Damage caused by mis-wiring of the interconnect wires is not warrantable.
NOTE: Loss of utility power will cause either the AUTO or OFF or MANUAL button to flash. Whichever mode the generator is in at the
time of utility loss.
3.3.2— Using the LED Interface
The user interface includes seven (7) LEDs, to indicate the generator’s alarms, warnings, and maintenance actions due. See Figure 3-2 and the
following table for details on each indication.
The user interface also includes 3-mode LEDs to indicate the currentgenerator mode setting (AUTO, MANUAL, or OFF). The active LED is also
used to indicate whether the utility voltage is present. The active LED will be solid when utility is available. It will flash to indicate the loss of utility
power. For example; whenthe generator is in AUTO andUtility is present,the green AUTOLED will besolidON. When the generator is in AUTO
and utility is lost, the AUTO LED will flash.
3.4 — Alarm Response Procedures
The generator is protected by aseries of sensors that will detect anAlarm/Warning condition and alertthe owner/operator of thecondition via the
Control Panel display. When certain alarm conditions are detected, the generator will shut down.
NOTE: Unless properly trained to clear and correct Warning and Alarm conditions, contact the nearest Authorized dealer or Trained
Technician.
Button Description of Operation
AUTO (GREEN) Selecting this button activates fully automatic system operation. It also allows the unit to automatically start and exercise the engine every seven days with the setting of the exercise
timer (see the Setting the Exercise Timer section).
OFF (RED) This button shuts down the engine and also prevents automatic operation of the unit.
MANUAL (BLUE) This button will crank and start the generator. Transfer to standby power will not occur
unless there is a utility failure.
SET EXERCISE (GREY) Used to establish generator exercise time. Hold the button for 3 seconds at the new exercise time desired. NOTE: Exercise time can only be set at the time you wish exercise to
actually take place.
LED Alarm Description (LED Flashing) Description (LED Solid)
Temperature Alarm (Flashing)
Low Oil Level Alarm (Solid) *Temperature levels are excessive
------- ------- Engine oil level is insufficient
Charger Warning (Flashing)
Battery Problem Warning (Solid) *Charging problem exists
------- ------- Battery problem exists
RPM Sensor Alarm ------- RPM sensor problem exists
Overcrank Alarm ------- Overcranking condition exists
Speed Alarm Overspeed condition exists Underspeed condition exists
Break-in Maintenance Due (Flashing)
Regular Maintenance Due (Solid) *20 hour break-in maintenance due
------- ------- 1 year / 100 hour maintenance due
*These LEDs are shared with two alarm conditions. Solid light indicates one alarm. Flashing light indicates the other alarm condition.

12 Automatic Standby Generator Owner’s Manual
3.4.1— Clearing an Alarm/Warning Condition
To clearanalarm orwarningcondition fromthe Control Panel,press theOFFbutton.PressOFF buttonagain.The flashingor solidindicatorLED
will turn off.
NOTE: Clearing a code will not correct the problem. It will simply turn off the LED indicating that told you that a problem occurred. The
problem indicated must be diagnosed and corrected to prevent a re-occurring alarm condition.
NOTE: Removing or failure of the 7.5 Amp ATO®fuse will turn off all the panel LEDs. Replacement of the fuse will initiate the LED self
test.
3.5 — Automatic Operation
To select automatic operation:
1. Make sure the transfer switch main contacts are set to their UTILITY position (loads connected to the utility power source).
2. Be sure that normal UTILITY power source voltage is available to transfer switch terminal lugs N1 and N2.
3. Press the AUTO button on the Control Panel Interface.
4. Set the Main Circuit Breaker (Generator Disconnect) to its ON (Closed) position.
Withthesesteps complete, thegenerator will startautomatically when utilitysourcevoltage dropsbelowa presetlevel. After theunit starts, loads
are transferred to the standby power source.
3.5.1— Automatic Sequence of Operation
3.5.1.1 — Utility Failure
With the generator set to AUTO, when the utility fails (below 65% of nominal) a 5 second line interrupt delay time is started. If the utility is still
gone when the timer expires, the engine will crank and start. Once started, a 6second engine warm-up timer will be initiated. When the warm-up
time expires, the Control Panel will transfer the load to the generator. If the utility power is restored (above 80% nominal) at any time from the ini-
tiationofthe enginestart untilthegenerator isreadyto acceptload (6 secondwarm-uptimehasnot elapsed),theControl Panelwillcomplete the
start cycle and run the generator through its normal cool down cycle, however, the load will remain on the utility source.
3.5.1.2 — Cranking
Most times the generator will start on the first crank cycle, but it is normal for it to cycle multiple times in order to start. The following is the crank-
ing sequence:
LED Condition Action 2nd Action 3rd Action
Clear Alarm / Warning or Maintenance LED Alarm(s) press OFF press OFF again -----
ClearMaintenanceLEDwhenAlarmorWarningLED
is also present press OFF press OFF again press OFF 3rd time
• 16 second engine cranking *
• 7 second pause
• 16 second engine cranking
• 7 second pause
• 7 second engine cranking
• 3 second pause
• 7 second engine cranking
• 3 second pause
• 7 second engine cranking
If the unit does not start during the crank sequence, the control panel Overcrank Alarm LED will light.
NOTE: The initial 16 second crank attempt may be repeated once if a proper crank was not detected. This may result in up to 6
crank attempts total. *

Automatic Standby Generator Owner’s Manual 13
3.5.1.3 — Load Transfer
The transfer of load when the generator is running is dependent upon the operating mode:
3.6 — Turning the Generator Off When Operating Under Load
NOTE: Important! To turn the generator off during prolonged utility outages to perform maintenance or conserve fuel, follow these sim-
ple, but important steps:
To turn the generator OFF (while running in AUTO and online):
1. Turn OFF (or OPEN) the main Utility disconnect.
2. Turn OFF (or OPEN) the Main Line Circuit Breaker (MLCB) on the generator.
3. Wait for 1 minute to allow the generator to cool. Turn the generator OFF.
To turn the generator back ON:
1. Put the generator back into AUTO and allow to start and warm-up for a few minutes.
2. Turn ON (or CLOSE) the MLCB on the generator.
The system will now be operating inits automatic mode. The main utility disconnect can be turned ON (or CLOSED), but to shut the unit off, this
complete process must be repeated.
3.7 — Manual Transfer Operation
DO NOT attempt to activate the transfer switch manually until all power voltage supplies to
the switch have been completely turned off. Failure to turn off all power voltage supplies may
result in extremely hazardous and possibly fatal electrical shock.
Prior to automatic operation, manually exercise the transfer switch to verify that there is no interference with proper operation of the mechanism.
Manual operation of the transfer switch is required if electronic operation should fail.
MANUAL
• Will not transfer to generator if utility is present.
• Will transfer to generator if utility fails (below 65% of nominal for 10 consecutive seconds).
• Will transfer back when utility returns for 15 consecutive seconds. The engine will continue to run
until removed from the MANUAL mode.
AUTO
• Will start and run if utility fails (below 65% of nominal for 5 consecutive seconds).
• Will start a 6 second engine warm-up timer.
• Will not transfer if utility subsequently returns.
• Will transfer to generator if utility is not present.
• Will transfer back to utility once utility returns (above 80% of nominal) for 15 seconds.
• Will not transfer back to utility unless utility returns. The generator will shut down if the OFF button is
pressed or a shutdown alarm is present.
• Once utility power is returned, the generator will shut down after 1 minute cool-down time.
EXERCISE • Will not exercise if generator is already running in either AUTO or MANUAL mode.
• During exercise, the control panel will only transfer if utility fails during exercise for 6 seconds, and
will operate as normal in AUTO mode.
+

14 Automatic Standby Generator Owner’s Manual
3.7.1— Transfer to Generator Power Source
1. Press the Control Panel OFF button.
2. Set the Main Circuit Breaker (Generator
Disconnect) to its OFF (OPEN) position.
3. Turn off the utility power supply to the transfer
switch using the means provided (such as a utility
main line circuit breaker).
4. Use the manual transfer handle inside the transfer
switch to move the main contacts to their STANDBY
positions (loads connected to the standby power
source).
5. To crank and start the engine, press the Control
Panel MANUAL button.
6. Allow the engine to stabilize and warm up for a few
minutes.
7. Set the Main Circuit Breaker (Generator
Disconnect) to its ON (CLOSED) position. The
standby power source now powers the loads.
Figure 3-5: Manual Transfer Switch Operation
NOTE: This is an example, actual switch may vary. Follow directions in the appropriate manual.
3.7.2— Transfer Back to Utility Power Source
When utility power has been restored, transfer back to utility source and shut down the generator. To manually transfer back to utility power and
shut down the generator:
1. Set the Main Circuit Breaker (Generator Disconnect) to its OFF (OPEN) position.
2. Allow the engine to run for 2 minutes at no-load to stabilize the internal temperatures.
3. Press the Control Panel OFF button. The engine should shut down.
4. Ensure that utility power supply to the transfer switch is turned off.
5. Usethemanual transferhandleinside the transferswitch to movethemain contactsbackto their UTILITYpositions(loads connected tothe
utility power source).
6. Turn on the utility power supply to the transfer switch using the means provided.
7. Press the Control Panel AUTO button.
3.8 — Side Compartment
Local codes may require this compartment to be locked. A hasp is provided so the owner/operator can secure the compartment with his or her
own padlock. Check local codes for side compartment locking requirements.
Figure 3-6: Open Side Compartment
LOAD CONNECTED TO STANDBY POWER SOURCE
LOAD CONNECTED TO UTILITY POWER SOURCE
TRANSFER SWITCH
OPERATING LEVER
MANUAL
TRANSFER
HANDLE
LID OPEN LID CLOSED
HASP

Automatic Standby Generator Owner’s Manual 15
3.8.1— Main Circuit Breaker (Generator Disconnect)
This is a 2-pole breaker rated according to relevant specifications.
3.9 — Battery Charger
NOTE: The battery charger is integrated into the control panel. Battery Problem LED is illuminated when battery needs service.
The battery charger operates as a “Smart Charger” that ensures:
• Output is continually optimized to promote maximum battery life.
• Charging levels are safe.
3.10 — Setting the Exercise Timer
This generator is equipped with an exercise timer. Once it is set, the generator will star t and exercise every seven days, on the day of the week
andatthe time ofdayspecified. Duringthisexercise period,the unit runs forapproximately 12 minutes and then shuts down. Transferofloads to
the generator output does not occur during the exercise cycle unless utility power is lost.
1. Place the generator in the AUTO mode.
2. Hold the “SET EXERCISE” Button for 3 seconds. The generator will start, run an exercise cycle and confirm the setting.
3. The exercise time is now established. The generator will exercise each week at this time.
To CHANGEthe exercisetimeonce ithas beenset, holdthe “SETEXERCISE”buttononthegeneratorfor three(3) secondsat thetime youwish
the new exercise time to take place. The exercise timer does not correct for daylight savings time.
NOTE:
Theexerciser will only work in the AUTOmode and will default to exercise weekly at the time the Control Panel was last powered ON
unless this procedure is performed.
The exercise function will need to be reset every time the 12 volt battery and T1 power to the generator are
disconnected and then reconnected, and/or when the fuse is removed and T1 power is removed from the generator.
NOTE: If the unit is equipped with Mobile Link™, the exercise time can be remotely set for any desired day or time.

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