Clarke Power CP series Operating & Maintenance Instructions

0702

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Generator Set

CP Range

Operating & Maintenance

Instructions

- 2 -

Introduction

Thank you for purchasing this Clarke portable Generator set.

The set is powered by a Honda engine, a manual for which, is
provided separately. Please refer to that manual for all matters
relating to the engine, ...starting and stopping procedures,
maintenance etc.

Read these safety instructions before using the equipment.

Guarantee

This product is guaranteed against faults in manufacture for 12 months

from purchase date. Please keep your receipt as proof of purchase.

This guarantee is invalid if the product has been abused or tampered

with in any way, or not used for the purpose for which it is intended.

The reason for return must be clearly stated.

This guarantee does not affect your statutory rights.

Guarantee ...................................................................................................................... 2

Important General Notes .............................................................................................. 3

For your Own Safety ...................................................................................................... 3

Preparation for Use ........................................................................................................ 6

Electric Start Models ...................................................................................................... 6

Fuelling ........................................................................................................................... 6

Using Extension Cables ................................................................................................. 7

Before Use ......................................................................................................................7

Using your Generator ................................................................................................... 8

Shutting Down the Generator ....................................................................................... 9

Maintenance .................................................................................................................. 9

Troubleshooting.............................................................................................................. 9

Schematic Wiring Diagram .......................................................................................... 11

Parts and Service Contacts ......................................................................................... 11

Contents Page

Always

use in a well ventilated area.

Always

ensure the applied load does not exceed the
generator rating. Overloading the generator is
dangerous and could cause serious damage.

Always

disconnect the generator when carrying out any
maintenance.

Always

ensure the generator reaches operating speed

before connecting a load.

Always s

tart the engine BEFORE connecting appliances

to the ouput receptacles.

General Safety Precautions

For Your Own Safety

IMPORTANT General Notes

- 3 -

Never

allow children near the generator

Never

connect to a commercial or mains power supply,
or any other electrical source.

Never

allow the generator to run out of fuel when a load
is connected.

Never alter or tamper with the internal wiring of the

generator

• NEVER allow anyone, not fully familiar with generator sets, to use this equipment.

• This generator set is not suitable for use with electronic equipment such as
Televisions, hi-fi’s or computers etc.

• IMPORTANT! This generator does NOT require to be earthed.

• Connect ONLY those appliances that are in good working order.

Note: Most portable electric tools are Class II (double insulated)appliances. Always check
before connecting. Equipment that does not meet this standard (generally tools with
metallic casing) require a three conductor cable (with an earth conductor).

• DO NOT alter the engine settings....the voltage and frequency of the generator

output is directly linked to the engine speed. These settings are set at the factory.
Should they need recalibration - consult your Clarke dealer

• Connect ONLY those apppliances whose voltage, according to its data plate,
corresponds to that produced by the generator set.

- 4 -

Positioning the Generator for use

Always

leave a least a 1M gap between the
generator and any surrounding building or
structures.

Always

ensure the generator is on a solid, flat surface.

Always

ensure the surrounding area is free from any
material that could burn or be damaged by
heat.

Never

move or tilt generator whilst it is switched on.

Never

cover the generator or enclose it whilst in use.

1M (3ft) 1M (3ft)

]

Fire Prevention

Always

switch the engine OFF when refuelling.

Always

refuel away from any source of heat.

Always

refuel in a well ventilated area.

Never

overfill the tank, fill to the level specified.

Never

smoke whilst refuelling and avoid smoking
or using a naked flame near the generator.

Never

start the engine if there is spilled fuel. Any
spillage must be wiped clean and the
generator allowed to dry before attempting
to start the engine.

Prevention of Electric Shock

Always

store the generator undercover when not
in use away from damp or wet conditions.

Never

use the generator when it is raining or snowing
or in wet or damp conditions.

Never

operate the generator with wet hands.

Never

use water or any other liquids to clean the unit

Exhaust Gas Precautions

WARNING:

Exhaust fumes can be fatal

Always

ensure there is adequate ventilation when using
the generator.

Always

position the generator so that the exhaust is
pointed away from people or animals .

Never

use the generator indoors or in an enclosed area.
(i.e. in a warehouse, tunnel, well, hold.)

- 5 -

Preparation for Use

Electric Start Models

Electric start models are supplied with a 24AH dry charged battery, and a battery

acid pack. The battery must be prepared as follows:

Check to ensure the battery is in good condition, with no damage caused during
transit. Should there be any apparent damage, pleasse contact your Clarke
dealer immediately.

Disconnect the leads and remove the battery from the frame.

Remove the vent plugs and fill to 12mm (1/2” above the top of the separators).

Allow the battery to ‘soak’ for 30 minutes os so, then check the levels and
top up if necessary.

Replace the vent plugs.

Your battery is now ready for use, however, we recommend that you put it on
charge, at a rate of 2.5Amps ONLY, for a period of 4 hours. Should you do this,
remember to recheck the battery levels when completed, and top up if necessary
with distilled water (to BS4974).

Note: You may charge at a lower rate than that specified, but a longer charge
time will be necessary to achieve the same ampere hour input.

Before connecting to the generator, ensure the outside of the battery is completely dry

Connect the battery as follows:

Ensure the battery is firmly secured in its compartment within the frame

Connect the battery terminals to the battery posts, ensuring you connect the
POSITIVE connection FIRST. (When disconnecting, always disconnect the
positive terminal last).

NOTE: Smear the connections and the terminals with petroleum jelly.

a.

Fuelling

b.

Fill with unleaded petrol, according to the instructions within the engine manual.

Note that the ‘LR’ (Long Run) models are fitted with a three position fuel tap as
illustrated in Fig 1. These positions are ON - OFF - RESERVE.

• Ensure the tap is set to the required position.

• The fuel hose and connectors are intact and there is no leakage.

Note : Always use a funnel to fill the fuel tank so as to avoid accidental spillage of
fuel. If fuel is spilled it must be removed from the unit and surrounding area, before
attempting to start the engine.

- 6 -

Fig.1

WARNING !

• Observe all safety precautions when handling fuel. Always refuel in a
well ventilated area away from any heat sources.

• Ensure there is adequate fuel in the tank when using the generator.
Running out of fuel or stopping the engine suddenly with a load
connected could cause serious damage.

• Allow the unit to cool down before refuelling.

Extension Cables

All extension cables, from generator set to the appliance, must be carefully selected, fitted
and maintained. Cables in accordance with IEC 245-4 should be used.

Cables should be inspected regularly, and should be replaced, not repaired inthe event of
a defect.

The length and cross section of conductors should be selected according to the job to be
done. The table below is an indication of sizes which should be used.

IMPORTANT ! Ensure the Cable is fully unwound when in use to avoid overheating,
and the placing of extra load on the generator.

Conductor Max Length Current Single Phase

(mm2) (M) (Amps) (kW)

1.5 25 10 2.3

2.5 40 16 3.7

460286.5

With the engine running smoothly, connect the appliance to the appropriate

receptacle..... BLUE - 230V YELLOW - 115V

- 7 -

Using your Generator Set

IMPORTANT ! Ensure all precautions are taken, referring to this and the Honda engine
manual, before proceeding.

Start the Engine - (Refer to the Honda engine manual) and allow to run for a few

minutes at full speed in order for it to warm up.

IMPORTANT ! Ensure that no appliances are connected to the generator when starting
the engine.

Check the condition of the appliance, including the supply cable and the extension
cable if used, and ensue it is switched OFF. Ensure also that the operating voltage is
the same as the output from the generator.

For those generators with dual output, ensure the voltage selector switch, is set to
deliver the appropriate output - 115 or 230V, see Figs 2 and 3.

Depending upon the model, the switch is mounted as shown, or similar, to that in Figs
2 and 3.

BE AWARE

Some appliances draw more current on startup than their nominal running current

....electric motors and compressors are examples. If in doubt as to whether an

appliance is compatible or not, please contact your nearest Clarke dealer.

Additionally, please refer to the ‘Specifications’ sheet attached, to ensure the
machine is used under the correct operating conditions.

Fig.2

Fig.3

Reset
Button

Voltage Selector

Voltage Selector

Note : If the AC circuit is overloaded the circuit protection switch will trip. To reset the circuit, first
disconnect the appliance, and rectify the cause of the overload. Wait a short period then press the
appropriate reset button shown in Figs 2 & 3.

IMPORTANT ! Never switch off the engine whilst an electrical appliance is connected.

Switch off the electrical appliance.

Unplug the appliance from the generator.

Switch the Engine OFF (see engine manual).

Turn the Fuel OFF (see engine manual - for Long Run models...see page 7).

- 8 -

Shutting Down the Generator

Maintenance

If the generator is not going to be used for some time, the engine must be adequately
prepared. Please refer to the engine manual for details:

Always ensure the generator air vents are completely clear. Brush away any dust that may
have accumulated.

The engine requires periodic servicing. Please refer to the engine manual for details.

Troubleshooting : Electrical Fault finding

Remedy

1. Set selector switch

2. Reset AC safety trip

3. Check connection and
(or) replace lead

4. Contact Clarke Servicing

5. Contact Clarke Servicing

1. Set Engine RPM - Consult
your Clarke dealer

2. Contact Clarke Servicing

Problem

No AC Output

Erratic Supply

Possible Cause

Selector switch in wrong
position

Tripped Circuit Breaker

Poor connection or faulty
lead

Broken AC connector

Faulty Circuit Breaker

Incorrect engine RPM

Internal Alternator problem

Troubleshooting : Engine....consult the engine manual