Generac Power Systems PowerPact 6561 Quick start guide

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INSTALLATION
Notes for Generac
Air-Cooled Generators
Date of Publication: November 1, 2015
© Better Power, Inc., 2015
DISCLAIMER: Only Generac’s official documents for the correct model and serial number of the equipment
you are installing should be relied upon. These technical notes are intended to be helpful as a secondary
source when you are out in the field.

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Table of Contents: Page Number
Permits & Applications 3
Generac Equipment and Accessories 4
Pick Up and Delivery 7
Site Selection and Preparation 8
Fuel Requirements & Pipe Sizing 20
Transfer Switches 32
Basics of How the System Works 34
How to Wire Switches 40
How to Wire the Genset 50
Activation 63
Initial System Tests 67
Loadshedding/SMM Smart Management Modules 73
Smart AC Modules 80
Load Shedding RTSY/T/W-R/P/C, RTSB, & I 81
Prolonged Outages 88
Accessories and Installations
Cold Weather Kit 89
MobileLink 90
Local Remote Monitor (Basic) 92
Utility Voltage Monitor Timer (Brown Out) 94
Warning Stickers 96
Bad Installs 97

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Do NOT modify any equipment.
Do NOT install anything that is not to code.
Any $$ you think you will save on your install by modifying equipment, NOT following the recommended
installation procedures, or going against local code, may be a safety issue for your customer, may void
warranties, and may not pass required inspections.
A Generator installation should be a very easy job. Just follow the  instructions, local
requirements, and you should have no problems.
Read ALL Manuals and Install Guides before attempting an install.
Permits and Applications
The Local Code Office has the final say on your install.
All Towns have different requirements. Check with the local code office before submitting a final quote
to your customer.
Brighton and Perinton are two of the more restrictive towns in our area.
Attached are examples of permit for the Town of Perinton and, if you have a NatGas installation
examples of the required RG&E Forms. NYSEG & Other Utilities may have different requirements.
Elevated Pressure Commitment Letter (RG&E) Residential You probably will not need this
because Generac Evolution Series Air-
Natural Gas Appliance Inventory (RG&E) Residential Generator Installation This should be filled
out for all NatGas installations
RG&E is looking to see that the total BTU  exceed
350,000 BTU.
If exceeded, they may have to increase the pressure to the residence. There is a co
usually between $150 - $350.
The Town may also ask for things like - 
generator placement, nameplate and spec sheet information.

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Equipment
Generators:
PowerPact Models - 6561, 6518, & 6519
6kW on NatGas, 7kW on LP.

We stock the PowerPact with an 8-circuit 50 Amp switch - NO whips. It is also available with a whip, and
without a switch.
Guardian Series Air-cooled Generators
Single Cylinder
Model 6245 - 7/8kW Steel
V Twin Engines
Model 6439/6720 - 10/11kW Steel and Aluminum
Models 6459/6721 - 16/16kW Steel and Aluminum
Model 6730 - 18/20kW Steel
Model 6552 –19.5/22kW Aluminum
They all have the NEW Evolution Controller
They all use the RTS Series transfer switches.
PrePack Models (packaged with a transfer switch) are available direct ship from the factory, we do not
stock them in Rochester.
Synergy Series Air-cooled Generator
Model 6055 18/20kW Aluminum Variable Speed 2700-3600RPM includes RTSB200A3 SE Switch w/Fast
Load Shed
Generac Air-cooled, QT, Protector Gaseous, and Protector Series Diesels are designed to work with
Generac RTS Switches.
QT, Protector Gaseous, and Protector Diesel Gensets

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Transfer Switches
The Whole-House Transfer Switch amperage must be equal to or greater than the generator output or
service amperage, whichever is greater.
Air-cooled Generators 6 to 22kW will put out 25 to 91.6 Amps.
s are smart generators with dumb switches.
That means all the line sensing is done on the generator control board; the generator tells the switch
when to transfer power.
On other brands, the switch has the brains and all the generator does is turn on or off.
If you absolutely have to use another switch, there is a super-secret code to punch into the controller
that will let the generator run on a 2- wire start, but it probably voids the warranty.
GenReady Panel
Used in New Construction or Service upgrades.
It replaces the Main Panel in the house.
It's a 200 Amp service with a 125 Amp Transfer Switch.
There is a built-in transfer switch in the middle of the panel.
You have 10 non-protected circuits on the top of the panel and 18 to 30 protected circuits
(with tandem breakers) on the bottom of the panel.
RTSY/RTST/RTSW /RTSB Switches –Whole House
The RTSY/T/W Switch comes in 100, 150, 200, 300, and 400A versions. RTSB is 200A only
(Synergy)
The RTSW switch will replace the Y/T switches Fall 2015. It will have built in Loadshedding
for four Air-conditioners.The RTSB comes with Fast Loadshed for Synergy Generator, all 9/10kW 2HP
loads must be shed.
The switches all have a service disconnect breaker in them.
RTG EZ Switches –Selected Circuits
10 and 12 Circuit 50A can be flush mounted.
16 Circuit 100A is panel mounted.
All have:
a 30-foot whip from the switch to the outside wall,
a 5-foot whip from the connection box to the Genset,
and a 2-foot whip to the main panel box.
There is a NEW RTG16EZA3 Nema-3R switch. It has no whips.
RTSR/RTSP/RTSC /RSTI Non Service Switches
The RTSC switch is the same as the RTSW switch except it does NOT have a Service Entrance
Breaker or internal cover. It will replace the R/P switches Fall 2015.
It comes in 100, 200, 400, 600, and 800 Amp Switches.
RTSI is 200A only (Synergy Canadian)

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RTSJ200A3 Switch
This switch is basically a combination of the RTSY200A3 and the RTG16EZA1 switches.
It's a 200-Amp Whole House Service Entrance Switch that load sheds to a 16-circuit
priority load center. This Switch will become obsolete in 2015.
New 2015 "HomeLink" Upgradable Manual Transfer Switches
Manual version of the 8 Cir RTG Switch. It is 6 to 10 Circuit Manual Transfer
Switch they is upgradable to a fully Automatic Switch when the customer is ready to
upgrade from a portable generator to an Automatic Standby.
Optional and Other Items You Will Need for an Installation
GAS LINE ITEMS
Correct Gas Meter and Fuel Regulator,
AGA approved gas pipe,
Elbows,
Tees,
Full Flow Shut Off Valve.
ELECTRICAL ITEMS

Liquid Tite Conduit,
Approved Conduit for inside the building,
Appropriate-sized main AC Wire (Black, Red, White, Green),
Correct size control wire (2-Yellow, White, Red, Blue, Black),
(Generac has Installation cable and Control cable)
Wire Nuts, Fittings.
EZ Switch - 50A double Pole Breaker for the 8 and 11kws, or a 70A double-pole breaker for the 16kWs
15A single pole breaker for GenReady)
TOOLS NEEDED
General SAE and Metric hand tools,
Wrenches, Sockets, Screwdrivers,

Drill and Bits (for routing and mounting conduit),
4mm Allen Wrench,
3/16" Allen Wrench,
Manometer
Meter capable of measuring AC/DC Voltage and Frequency.
Level

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Optional Items You May Purchase from Better Power
Starting Battery,
Warning Stickers,
Cold Weather Kit,
Remote Monitors,
Brownout Kit,
PMM Kit and Modules, also SymCom Timers
SMM Smart Management Modules & Smart AC Modules
SoftStarts
Fascia Kit,
3" GenPad,
Generator Transport Cart.

for installs up to 113')
Also a Ground/ Neutral Bar Kit.
Delivery
You can pick up for free at our Rochester C&M Forwarding Warehouse, or have your system delivered.
There is a delivery charge from our Rochester Warehouse, or if we direct ship from the factory there
is no charge for delivery. If you are in the Rochester area we also have a cart to rent (if you are
local) -- try before you buy.
Safety Tip for the Generac Generator Cart - Use the long strap from a ratchet tie down. Hook the
end to the Generator Pad, when the unit is raised tie the other end off to the cart handle. This will
prevent the handle from flipping over accidently.
The PowerPact may be moved with a 2 wheeled cart. Leave it on the pallet & place cardboard
between the generator & cart. At the site the generator must be lifted off the pallet NOT dragged off.

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Site Selection and Preparation
This section can be found on page 10 of the Installation Guidelines for Air-cooled Generators.
Location of Generator
•Air-cooled generators should be located as close as possible to the transfer switch and fuel supply.
•There must be 5 feet of clearance around the gas meter.
•Leave adequate room around the area for service access (check local code),
•Place high enough to keep rising water from reaching the generator.
Air Circulation Requirements
•Choose an open space that will provide unobstructed air flow.
•Place the unit so air vents won't become clogged with leaves, grass, vegetation, snow, or debris.
•Make sure exhaust fumes will not enter the building through eaves, windows, ventilation fans, or other air
intakes.
•Install the generator, in its protective enclosure, outdoors, where adequate cooling and ventilating air is
always available.
Not only too close to a window but how about three windows! Maybe a few more plants and you wo
Mounting
•The generator comes with a composite pad.
•You can place the generator with the composite pad on pea gravel or a concrete pad.
•Check local codes to see what type of base is required.
Note: Whatever mounting you choose, the generator must be level within ½”.

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Generac doesn't recommend a wood box platform.
Why waste a perfectly good pallet?
HPS found this one - Nice Pad.

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- The shed that this generator is mounted in greatly reduces the noise level.
NO…..NO……NO!!!!!!!
Another one found by HPS - Needs more air flow
That's better

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Wood Deck- Not
recommended
Allow sufficient room on all sides of the generator for maintenance and servicing.
DO NOT install under wooden decks or structures unless there is at least four (4) feet of clearance
above the generator, three (3) feet of clearance on sides and front, and 18 inches of clearance at back
of unit.
Install the unit where rain gutter down spouts, roof run-off, landscape irrigation, water sprinklers or
sump pump discharge does not flood the unit or spray the enclosure, including any air inlet or outlet
openings.
This old style needs to 5 feet from the
house.

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I guess Koehler's don't need air flow.
DO NOT install under wooden decks or
structures unless there is at least four (4)
feet of clearance above the generator,
three (3) feet of clearance on sides and
front, and 18 inches of clearance at back of
unit. This would include trees, shrubs and
vegetation that could obstruct airflow.
And the internet say’s - Under a deck? ….
No No No!
This one may be ok
Entrance NEMA-3R Switch.

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•Install the unit
where rain gutter down
spouts, roof run-off,
landscape irrigation, water
sprinklers or sump pump
discharge does not flood
the unit or spray the
enclosure, including any air
inlet or outlet openings.
Here they used ceramic
floor tiles for a border,
gutter downspout, and a
window.
Install the generator as close as possible to the fuel supply, to reduce the length of piping.
Install the generator as close as possible to the transfer switch.
If you have to choose between Fuel & Switch, install closer to the Fuel.
REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE AND LOCATION.

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The genset must be installed on a level surface. The base frame must be level within 1/2 inch all

The generator is typically placed on pea gravel or crushed stone.
Pea gravel - must be 4" (102mm) deep, compacted and level. You may build a frame around the area
that you want to install the generator. Also, use something to inhibit weed growth through the gravel.
Check local codes if a concrete slab is required. If a concrete base slab is required.
Concrete base slab which should exceed the length and width of the generator by a minimum of six
(6) inches (0.152 meters) on all sides.
There are four mounting holes in the base of the generator to secure it to the concrete.
3" GenPad - Level and compact the ground where the pad will be placed. Lay the GenPad on the
ground. Bolt the generator to the pad.

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Looks nice but pavers eventually get out of level, and the
generator will walk if it’s not bolted down.
Not a good idea.
Wood deck and bolted down with shipping straps.

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Very small concrete pad.


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 PVC ??? And NEMA-3R Switch?
See the Generator Clearance handout for more details
18 inches (457mm) from the back side of the generator to a stationary wall or building.
For adequate maintenance and airflow clearance, the area above the generator should be at least 4
feet with a minimum of 3 feet at the front and ends of the enclosure. This would include trees, shrubs
and vegetation that could obstruct airflow.
Generator exhaust contains DEADLY carbon monoxide gas. This dangerous gas can cause
unconsciousness or death. Do not place the unit near windows, doors, fresh air intakes (furnaces,
etc.) or any openings in the building or structure, including windows and doors of an attached garage.
Note: Southwest Research Institute testing approves 18-in. (457mm) installation minimum from
structure. Southwest Research is a nationally recognized third party testing and listing agency.
Southwest Research Institute Decal (located inside the generator, next to the generator's data decal)
http://www.swri.org/4org/d01/fire/listlab/listproduct/director.htm

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DO NOT Install Inside the House!
Installing the Optional Fascia Kit
Screw the four rubber bumpers into the threaded holes on the inside ends of the fascia.
Snap one of the end pieces on to the front Fascia and the other end piece on to the rear fascia.
DO Not snap the front and rear together at this time. Next place both assemblies at the base of the
generator and fit the rubber bumpers into the lifting holes in the generator base.
Once aligned, snap the front and rear assemblies together.
Looks nice, also makes the generator critter proof.

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Gaseous Fuel Requirements and Installation
This section can be found in:
Page 16 thru 21 in the Installation Guidelines Air-cooled Generators
Page 7 thru 9 in the Generac Generator Sizing Guide
Most Generators using gaseous fuels have a higher kW rating on Propane vs Natural Gas.
Generac Guardian Series Air-Cooled (Evolution) generators require 3.5 to 7" of water column for
Natural Gas, and 10 - 12" Water column for Liquid Propane Vapor.
For NatGas, verify that the meter is capable of providing enough fuel flow to include all household
appliances and other loads.
Order New Gas Meter from the Utility if it needs to be upsized (Customer may have to place the
order)
LP Gas Requirements
With LP Gas, use only the vapor withdrawal system. This type of system uses the vapors formed
above the liquid fuel in the storage tank.
The minimum LP tank size is 250 gallons unless unit calculations dictate the use of a larger tank.
Vertical tanks which are measured in pounds will not usually meet the minimum requirements. A
1050LB vertical tank size is minimum required.