Generac Power Systems PWRgenerator 9 kW Instruction sheet

Installation Guidelines
PWRgenerator™ Air-Cooled Generators
9 kW
SAVE THIS MANUAL FOR FUTURE REFERENCE
Register your Generac product at:
WWW.GENERAC.COM
1-888-GENERAC
(888-436-3722)
(000209b)
WARNING
Loss of life. This product is not intended to
be used in a critical life support application.
Failure to adhere to this warning could result
in death or serious injury.
®

ii Installation Guidelines for PWRgenerator Air-Cooled Generators
Use this page to record important information about this generator.
Record the information found on the unit data label on this
page. For the location of the unit data label, see the owner’s
manual. The unit has a label plate affixed to the inside parti-
tion, to the left of the control panel console.
Always supply the complete model and serial numbers of the
unit when contacting an Independent Authorized Service
Dealer (IASD) about parts and service.
Operation and Maintenance: Correct maintenance and
care of the generator ensures a minimum number of prob-
lems and keeps operating expenses at a minimum. It is the
operator’s responsibility to perform all safety inspections, to
verify all maintenance for safe operation is performed
promptly, and to have the equipment inspected periodically
by an IASD. Normal maintenance, service, and replacement
of parts are the responsibility of the owner/operator and are
not considered defects in materials or workmanship within
the terms of the warranty. Individual operating habits and
usage may contribute to the need for additional maintenance
or service.
When the generator requires servicing or repairs, Generac
recommends contacting an IASD for assistance. Authorized
service technicians are factory-trained and are capable of
handling all service needs. To locate the nearest IASD,
please visit the dealer locator at:
www.generac.com/Dealer-Locator.
Model:
Serial:
Prod Date Week:
Volts: 400VDC
Amps: 22.5A
Engine Speed: 2,300 rpm
Controller P/N:
(000393a)
WARNING
CANCER AND REPRODUCTIVE HARM
www.P65Warnings.ca.gov.

Table of Contents
Installation Guidelines for PWRgenerator Air-Cooled Generators iii
Section 1: Safety Rules & General
Information
Introduction ..................................................................1
Read This Manual Thoroughly ....................................1
Safety Rules .................................................................1
How to Obtain Service .................................................2
General Hazards ...........................................................2
Exhaust Hazards ..........................................................3
Electrical Hazards ........................................................3
Fire Hazards .................................................................3
Explosion Hazards .......................................................4
Battery Hazards ............................................................4
General Rules ...............................................................5
Before You Begin ........................................................5
Standards Index ..........................................................5
Section 2: Unpacking and Inspection
General ..........................................................................7
Required Tools .............................................................7
Unpacking .....................................................................7
Opening the Lid ...........................................................8
Enclosure Panel Removal ...........................................8
Front Access Panel Removal ......................................8
Intake Side Panel Removal .........................................9
Customer Connections and Loose Parts ...................9
Rear Connections ........................................................9
Generator Main Line Circuit Breaker
(Generator Disconnect) .............................................10
Parts Shipped Loose .................................................10
Auxiliary Shutdown Switch .......................................10
Section 3: Site Selection and Preparation
Site Selection .............................................................11
Carbon Monoxide .......................................................11
Carbon Monoxide Detectors ......................................11
Potential CO Entry Points ..........................................12
Protect the Structure .................................................12
Fire Prevention ...........................................................13
Distance Requirements .............................................13
Fire Codes, Standards, and Guidelines ....................14
Generator Maintenance .............................................14
Fresh Air for Ventilation and Cooling ......................14
Water Ingress Avoidance ..........................................14
Proximity to Utilities ..................................................14
Transportation Recommendations ..........................15
Suitable Mounting Surface ........................................15
Placement on Roofs, Platforms, and Other
Supporting Structures ...............................................15
Section 4: Generator Placement
Generator Placement .................................................17
Section 5: Fuel Conversion / Gas
Connections
Fuel Requirements and Recommendations ............19
BTU Content ..............................................................19
Fuel Pressure ............................................................19
Fuel Conversion .........................................................19
Fuel Consumption .....................................................20
Fuel Line Sizing ..........................................................20
Natural Gas Pipe Sizing ............................................21
LP Gas Pipe Sizing ...................................................21
Installing and Connecting Fuel Lines ......................22
Fuel Shutoff Valve .....................................................22
Flexible Fuel Line ......................................................22
Sediment Trap ...........................................................22
Checking Fuel Line Connections .............................23
Checking Fuel Pressure ............................................23
Performing Fuel System Leak Test ...........................23
Natural Gas Installation (Typical) .............................24
LP Gas (Vapor) Installation (Typical) .......................25
Section 6: Electrical Connections
Generator Connections .............................................27
Control Wiring ............................................................28
Main DC Wiring ..........................................................29
Service Entrance Decals ...........................................29
Battery Requirements ................................................29
Battery Installation .....................................................29
Connecting the Battery ..............................................30
Battery Disposal .........................................................30

Table of Contents
iv Installation Guidelines for PWRgenerator Air-Cooled Generators
Section 7: Control Panel Startup / Testing
Control Panel Interface ............................................. 31
Using the AUTO/MANUAL/OFF Buttons .................. 31
Generator Setup ........................................................ 31
Activation .................................................................. 31
Setting The Exercise Timer ....................................... 33
Before Initial Startup ................................................. 33
Install Wizard ............................................................ 33
Commissioning with PWRcell .................................. 35
Configuring PWRgenerator ....................................... 35
Verifying Island Mode is Enabled .............................. 35
Enabling PWRgenerator ........................................... 36
PWRgenerator States and Settings .......................... 36
Electrical Checks ....................................................... 37
Generator Tests Under Load .................................... 37
Checking Automatic Operation ................................ 38
Installation Summary ................................................ 38
Shutting Generator Down While Under Load
or During a Utility Outage ......................................... 38
Section 8: Troubleshooting
Generator Troubleshooting ...................................... 41
Section 9: Quick Reference Guide
System Diagnosis ...................................................... 43
Section 10: Accessories
Section 11: Diagrams
Installation Drawing (A0001919138 rev A—1 of 2) ... 47
Installation Drawing (A0001919138 rev A—2 of 2) ... 48

Safety Rules & General Information
Installation Guidelines for PWRgenerator Air-Cooled Generators 1
Section 1: Safety Rules & General Information
Introduction
Thank you for purchasing this PWRgenerator, a compact,
high performance, air-cooled, engine-driven generator. It
is designed to automatically supply direct current (DC)
electrical power to the Generac PWRcell Clean Energy
System for the purpose of charging storage batteries
during utility outages or periods of low solar output.
This unit is factory installed in an all-weather, metal
enclosure intended exclusively for outdoor installation.
This generator will operate using either vapor withdrawn
liquid propane (LP) or natural gas (NG).
NOTE: This unit is specifically designed as a backup
power source and to communicate with the PWRcell
inverter. PWRgenerator will charge PWRcell batteries
when solar cells through PVLink™ and utility power are
not sufficient to maintain minimum battery state of
charge.
NOTE: California Residents: This unit may only be uti-
lized as an emergency backup power source, use only
when grid power is unavailable.
The information in this manual is accurate based on
products produced at the time of publication. The manu-
facturer reserves the right to make technical updates,
corrections, and product revisions at any time without
notice.
Read This Manual Thoroughly
If any section of this manual is not understood, contact
the nearest Independent Authorized Service Dealer
(IASD) or Generac Customer Service at 1-888-436-3722
(1-888-GENERAC), or visit www.generac.com for start-
ing, operating, and servicing procedures. The owner is
responsible for correct maintenance and safe use of the
unit.
This manual must be used in conjunction with all other
supporting product documentation supplied with the
product.
SAVE THESE INSTRUCTIONS for future reference. This
manual contains important instructions that must be fol-
lowed during placement, operation, and maintenance of
the unit and its components. Always supply this manual
to any individual that will use this unit, and instruct them
on how to correctly start, operate, and stop the unit in
case of emergency.
Safety Rules
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The alerts in
this manual, and on tags and decals affixed to the unit,
are not all inclusive. If using a procedure, work method,
or operating technique that the manufacturer does not
specifically recommend, verify that it is safe for others
and does not render the equipment unsafe.
Throughout this publication, 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 that may be
hazardous if performed incorrectly or carelessly. Observe
them carefully. Alert definitions are as follows:
NOTE: Notes contain additional information important to
a procedure and will be found within the regular text of
this manual.
These safety alerts cannot eliminate the hazards that
they indicate. Common sense and strict compliance with
the special instructions while performing the action or
service are essential to preventing accidents.
(000100a)
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
WARNING
(000001)
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
(000002)
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
(000003)
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.

Safety Rules & General Information
2 Installation Guidelines for PWRgenerator Air-Cooled Generators
How to Obtain Service
When the unit requires servicing or repairs, contact Gen-
erac Customer Service at 1-888-GENERAC (1-888-436-
3722) or visit www.generac.com for assistance.
When contacting Generac Customer Service about parts
and service, always supply the complete model and
serial number of the unit as given on its data decal
located on the unit. Record the model and serial numbers
in the spaces provided on the front cover of this manual.
General Hazards
(000750)
DANGER
Automatic start-up. Disconnect power and render
unit inoperable before working on unit. Failure to do
so will result in death or serious injury.
(000187)
WARNING
Electrocution. Potentially lethal voltages are generated
by this equipment. Render the equipment safe before
attempting repairs or maintenance. Failure to do so
could result in death or serious injury.
(000209b)
WARNING
Loss of life. This product is not intended to
be used in a critical life support application.
Failure to adhere to this warning could result
in death or serious injury.
(000130)
Accidental Start-up. Disconnect the negative battery
cable, then the positive battery cable when working
on unit. Failure to do so could result in death
or serious injury.
WARNING
(000182a)
WARNING
Equipment damage. Only qualified service personnel may
install, operate, and maintain this equipment. Failure to
follow proper installation requirements could result in death,
serious injury, and equipment or property damage.
(000247a)
Equipment damage. This unit is not intended for use as a prime
power source. It is intended for use as an intermediate power
supply in the event of temporary power outage only. Doing so
could result in death, serious injury, and equipment damage.
WARNING
(000155a)
WARNING
Electric shock. Only a trained and licensed electrician
should perform wiring and connections to unit. Failure to
follow proper installation requirements could result in death,
serious injury, and equipment or property damage.
(000115)
Moving Parts. Do not wear jewelry when
starting or operating this product. Wearing
jewelry while starting or operating this product
could result in death or serious injury.
WARNING
(000111)
WARNING
Moving Parts. Keep clothing, hair, and
appendages away from moving parts. Failure
to do so could result in death or serious injury.
(000108)
WARNING
Hot Surfaces. When operating machine, do not
touch hot surfaces. Keep machine away from
combustibles during use. Hot surfaces could
result in severe burns or fire.
(000146)
WARNING
Equipment and property damage. Do not alter
construction of, installation, or block ventilation for
generator. Failure to do so could result in unsafe
operation or damage to the generator.
Risk of injury. Do not operate or service this machine
if not fully alert. Fatigue can impair the ability to
operate or service this equipment and could result in
death or serious injury. (000215a)
WARNING
WARNING
(000228)
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death, or serious injury.
(000216)
WARNING
Injury and equipment damage. Do not use generator
as a step. Doing so could result in falling, damaged
parts, unsafe equipment operation, and could result
in death or serious injury.

Safety Rules & General Information
Installation Guidelines for PWRgenerator Air-Cooled Generators 3
•Inspect generator regularly, and contact the near-
est IASD for parts needing repair or replacement.
Exhaust Hazards
•Generator must be installed and operated outdoors
only.
Electrical Hazards
Fire Hazards
(000103)
Asphyxiation. Running engines produce carbon
monoxide, a colorless, odorless, poisonous
gas. Carbon monoxide, if not avoided, will
result in death or serious injury.
DANGER
(000146)
WARNING
Equipment and property damage. Do not alter
construction of, installation, or block ventilation for
generator. Failure to do so could result in unsafe
operation or damage to the generator.
(000178a)
WARNING
Asphyxiation. Always use a battery operated carbon
monoxide alarm indoors and installed according to
the manufacturer’s instructions. Failure to do so
could result in death or serious injury.
(000144)
DANGER
Electrocution. Contact with bare wires,
terminals, and connections while generator
is running will result in death or serious injury.
(000753)
Electrocution. Never connect this unit to the electrical
system of any building unless a licensed electrician
has installed a PWRcell inverter. Failure to do so will
result in death or serious injury.
DANGER
(000152)
DANGER
Electrocution. Verify electrical system is
properly grounded before applying power.
Failure to do so will result in death or serious
injury.
(000188)
DANGER
Electrocution. Do not wear jewelry while
working on this equipment. Doing so will
result in death or serious injury.
(000104)
DANGER
Electrocution. Water contact with a power
source, if not avoided, will result in death
or serious injury.
(000145)
DANGER
Electrocution. In the event of electrical accident,
immediately shut power OFF. Use non-conductive
implements to free victim from live conductor. Apply
first aid and get medical help. Failure to do so will
result in death or serious injury.
WARNING
(000217)
Fire hazard. Do not obstruct cooling and ventilating
airflow around the generator. Inadequate ventilation
could result in fire hazard, possible equipment
damage, death or serious injury.
WARNING
(000218)
Fire and explosion. Installation must comply with all
local, state, and national electrical building codes.
Noncompliance could result in unsafe operation,
equipment damage, death, or serious injury.
WARNING
(000219)
Fire hazard. Use only fully-charged fire extinguishers
rated “ABC” by the NFPA. Discharged or improperly
rated fire extinguishers will not extinguish electrical
fires in automatic standby generators.
WARNING
Electrocution. Refer to local codes and standards for
safety equipment required when working with a live
electrical system. Failure to use required safety
equipment could result in death or serious injury.
(000257)

Safety Rules & General Information
4 Installation Guidelines for PWRgenerator Air-Cooled Generators
Comply with regulations the Occupational Safety and
Health Administration (OSHA) has established, or with
equivalent standards. Also, verify that the unit is applied,
used, and maintained in accordance with the manufac-
turer's instructions and recommendations. Do nothing
that might alter safe application/usage and render the
unit in noncompliance with the aforementioned codes,
standards, laws, and regulations.
Explosion Hazards
Battery Hazards
Always recycle batteries in accordance with local laws
and regulations. Contact your local solid waste collection
site or recycling facility to obtain information on local
recycling processes. For more information on battery
recycling, visit the Battery Council International website
at: http://batterycouncil.org.
(000147)
WARNING
Risk of Fire. Unit must be positioned in a
manner that prevents combustible material
accumulation underneath. Failure to do so
could result in death or serious injury.
(000192)
DANGER
Explosion and fire. Fuel and vapors are extremely
flammable and explosive. No leakage of fuel is
permitted. Keep fire and spark away. Failure to do
so will result in death or serious injury.
(000151a)
DANGER
Explosion and fire. Connection of fuel source must be
completed by a qualified professional technician or contractor.
Incorrect installation of this unit will result in death, serious
injury, and property and equipment damage.
(000174)
DANGER
Risk of fire. Allow fuel spills to completely dry
before starting engine. Failure to do so will
result in death or serious injury.
(000110)
WARNING
Risk of Fire. Hot surfaces could ignite
combustibles, resulting in fire. Fire could
result in death or serious injury.
(000188)
DANGER
Electrocution. Do not wear jewelry while
working on this equipment. Doing so will
result in death or serious injury.
(000162)
Explosion. Do not dispose of batteries in a fire.
Batteries are explosive. Electrolyte solution can cause
burns and blindness. If electrolyte contacts skin or eyes,
flush with water and seek immediate medical attention.
WARNING
(000137a)
WARNING
Explosion. Batteries emit explosive gases while
charging. Keep fire and spark away. Wear protective
gear when working with batteries. Failure to do so
could result in death or serious injury.
(000164)
WARNING
Electrical shock. Disconnect battery ground
terminal before working on battery or battery
wires. Failure to do so could result in death
or serious injury.
(000138a)
WARNING
Risk of burns. Batteries contain sulfuric acid and can
cause severe chemical burns. Wear protective gear
when working with batteries. Failure to do so could
result in death or serious injury.
(000163a)
Risk of burn. Do not open or mutilate batteries.
Batteries contain electrolyte solution which can cause
burns and blindness. If electrolyte contacts skin or
eyes, flush with water and seek immediate medical
attention.
WARNING
WARNING
(000228)
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death, or serious injury.

Safety Rules & General Information
Installation Guidelines for PWRgenerator Air-Cooled Generators 5
General Rules
•Follow all safety precautions in the owner’s man-
ual, installation guidelines manual, and other docu-
ments included with the equipment.
•Never energize a new system without opening all
disconnects and breakers.
•Always consult local code for additional require-
ments for where unit is being installed.
•Incorrect installation can result in personal injury
and damage to the unit. It may also result in the
warranty being suspended or voided. All instruc-
tions listed below must be followed including loca-
tion clearances and pipe sizes.
Before You Begin
•Contact local inspector or city hall to be aware of all
federal, state, and local codes which could impact
installation. Secure all required permits before
installing.
•Fully comply with all relevant NEC, NFPA, and
OSHA standards, as well as all federal, state, and
local building and electric codes. This unit must be
installed in accordance with current NFPA 37 and
NFPA 70 standards, and any other federal, state,
and local codes for minimum distances from other
structures.
•Verify capacity of NG meter or LP tank in regards
to providing sufficient fuel for both the unit and
other household and operating appliances.
Standards Index
Strictly comply with all applicable national, state, and
local laws, as well as codes or regulations pertaining to
the installation of this engine-generator power system.
Use the most current version of applicable codes or stan-
dards relevant to the local jurisdiction, generator used,
and installation site.
NOTE: Not all codes apply to all products and this list is
not all-inclusive. In the absence of pertinent local laws
and standards, the following publications may be used as
a guide (these apply to localities which recognize NFPA
and ICC).
1. National Fire Protection Association (NFPA) 70:
The NATIONAL ELECTRIC CODE (NEC) *
2. NFPA 10: Standard for Portable Fire Extinguishers
*
3. NFPA 30: Flammable and Combustible Liquids
Code *
4. NFPA 37: Standard for Stationary Combustion
Engines and Gas Turbines *
5. NFPA 54: National Fuel Gas Code *
6. NFPA 58: Standard for Storage and Handling Of
Liquefied Petroleum Gases *
7. NFPA 68: Standard On Explosion Protection By
Deflagration Venting *
8. NFPA 70E: Standard For Electrical Safety In The
Workplace *
9. NFPA 110: Standard for Emergency and Standby
Power Systems *
10. NFPA 211: Standard for Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances *
11. NFPA 220: Standard on Types of Building Con-
struction *
12. NFPA 5000: Building Code *
13. International Building Code **
14. Agricultural Wiring Handbook ***
15. Article X, NATIONAL BUILDING CODE
16. ASAE EP-364.2 Installation and Maintenance of
Farm Standby Electric Power ****
17. ICC:IFGC
(000190)
DANGER
Loss of life. Property damage. Installation must
always comply with applicable codes, standards, laws
and regulations. Failure to do so will result in death
or serious injury.
(000182a)
WARNING
Equipment damage. Only qualified service personnel may
install, operate, and maintain this equipment. Failure to
follow proper installation requirements could result in death,
serious injury, and equipment or property damage.
WARNING
Electrocution. Refer to local codes and standards for
safety equipment required when working with a live
electrical system. Failure to use required safety
equipment could result in death or serious injury.
(000257)
(000100a)
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
WARNING
(000209b)
WARNING
Loss of life. This product is not intended to
be used in a critical life support application.
Failure to adhere to this warning could result
in death or serious injury.

Safety Rules & General Information
6 Installation Guidelines for PWRgenerator Air-Cooled Generators
This list is not all-inclusive. Check with the Authority Hav-
ing Local Jurisdiction (AHJ) for any local codes or stan-
dards which may be applicable to your jurisdiction. The
above listed standards are available from the following
internet sources:
* www.nfpa.org
** www.iccsafe.org
*** www.rerc.org Rural Electricity Resource Council P.O.
Box 309 Wilmington, OH 45177-0309
**** www.asabe.org American Society of Agricultural &
Biological Engineers 2950 Niles Road, St. Joseph, MI
49085