Ge HOME GENERATOR 10000 Manual

GE Home Generator Systems

10,000 Watt

Home Generator System

Installation and

Reproduction
Start-Up Manual
Not	for

Thank you for purchasing this quality-built GE home generator. We’re pleased that you’ve placed your confidence in the GE brand. When operated and maintained according to the instructions in the operator’s manual, your home generator will provide many years of dependable service.

This manual contains safety information to make you aware of the hazards and risks associated with residential generator systems and how to avoid them. This generator system is designed and intended only for use as an optional home standby system that provides an alternate source of electric power and to serve loads such as heating, refrigeration systems, and communication systems that, when stopped during any power outage, could cause discomfort or inconvenience. Save these instructions for future reference.

This generator requires professional installation before use. The installer should follow the instructions completely.

Where to Find Us

You never have to look far to find support and service for your generator. For quick service when you need it most fill out the information below and keep your original receipt with this manual. You may contact Customer Service at [phone], or click on SERVICE & SUPPORT at www.homestandbygeneratorsystems.com, which provides a list of authorized dealers.

For Future Reference

Please fill out the information below andReproductionkeep with your receipt to assist in unit identification for future purchase issues. for

Date of PurchaseNot

Generator

Model Numb

Model evision

Serial Number

Engine

Model Number

2

Table of Contents

Important Safety Instructions . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . .             7

Home Owner Responsibilities . . . . . . . .	. . . .	.	.	. .	.		7
Installing Dealer/Contractor Responsibilities . . . . .		.	.	. .	.	.	. . . 7
Unpacking Precautions . . . . . . . . . . .	. . . .	.	.				7
Shipment Contents . . . . . . . . . . . . .	. . . .						8
Generator Location . . . . . . . . . . . . .	. . .	.					8
Electrical and Fuel Inlet Locations . . . . . .	. . . .	.	.	. .	.	.	. 10
The Gaseous Fuel System . . . . . . . . . .	. . . .	.	.	.         12
Reproduction
Fuel Consumption . . . . . . . . . . . . . .	. . .	14
Initial Start-up (No Load) . . . . . . . . . . .	for. . . . .		.	20
System Connectors . . . . . . . . . . . . .	. . . .			15
Grounding the Generator . . . . . . . . . .	. . . .	.	.	.         16
Final Installation Considerations . . . . . . .	. . .	. .	.	. .	.	.	19
Not	. . . .	21
Engine Adjustment . . . . . . . . . . . . .
Test Shutdown(s) Procedure . . . . . . . . .	. . . .	.	.	. .	22
Fuel Conversion . . . . . . . . . . . . . . .	. .				23
Schematic Diagram . . . . . . . . . . . . .	. . .	.			24
Wiring Diagram . . . . . . . . . . . . . . .	. .				25
Operation . . . . . . . . . . . . . .	. . .	26
Automatic Operation Sequence . . . . . . .	. . . .	.	.	. .	.	.	26
Setting Exercise Timer . . . . . . . . . . . .	. . .	. .					26
Installation Inspection . . . . . . . . . . . .	. . .	. .					27

3

Safety Rules

Important Safety Instructions

SAVE THESE INSTRUCTIONS - This manual contains

The manufacturer cannot possibly anticipate every possible

important instructions that should be followed during

circumstance that might involve a hazard. The warnings

installation and maintenance of the generator and batteries.

in this manual, and the tags and decals affixed to the unit

Safety Symbols and Meanings

are, therefore, not all-inclusive. If you use a procedure, work

method or operating technique that the manufacturer does

not specifically recommend, you must satisfy yourself that it

is safe for you and others. You must also make sure that the

procedure, work method or operating technique that you

Explosion

Fire

Electrical Shock

choose does not render the generator system unsafe.

WARNING Running engine gives off carbon monoxide, an

odorless, colorless, poison gas.

Breathing carbon mo

oxide can cause headache, fatigue,

Toxic Fumes

Rotating Parts

Hot Surface

dizz ness, v

m t g, co

fusion, seizures, nausea, fainting

or dea h.

•

Operate genera

r ONLY utdoors.

•

Install a ba ery operated carbon monoxide alarm near

the bedrooms.

for

Auto Start

Explosive Pressure

Chemical Burn

•

Keep exha st gas from entering a confined area through

win ows, doors, ventilation intakes, or other openings.

Not

WARNING The engine exhaust from this product contains

chemicals known to the State of California to cause cancer, birth

Lift Hazard

defects, or other reproductive harm.

Read Manual

The safety alert symbol indicates a potential rsonal

WARNING Certain components in this product and related

accessories contain chemicals known to the State of California

injury hazard. A signal word (DANGER, WA

NING, or

to cause cancer, birth defects, or other reproductive harm. Wash

CAUTION) is used with the alert symbol to designate a degree

hands after handling.

or level of hazard seriousness. A safety symbol may be used

Reproduction

to represent the type of hazard. The signal word NOTICE is

used to address practices not related to personal injury.

DANGER indicates a hazard which, if not avoided, will result in death or serious injury.

WARNING indicates a hazard which, if not avoided, could result in death or serious injury.

CAUTION indicates a hazard which, if not avoided, could result in minor or moderate injury.

NOTICE addresses practices not related to personal injury.

4

	WARNING Storage batteries give off explosive hydrogen gas		WARNING Hazardous Voltage - Contact with power lines can
	during recharging.				cause electric shock or burn.
	Slightest spark will ignite hydrogen and				Lifting Hazard / Heavy Object - Can cause muscle
	cause explosion.				strain or back injury.
	Battery electrolyte fluid contains acid and is	•	If lifting or hoisting equipment is used, DO NOT contact any
	extremely caustic.		power lines.
	Contact with battery contents will cause severe chemical burns.	•	DO NOT lift or move generator without assistance.
	A battery presents a risk of electrical shock and high short
		•	DO NOT lift unit by roof as damage to generator will occur.
	circuit current.

• DO NOT dispose of battery in a fire. Recycle battery.

•	DO NOT allow any open flame, spark, heat, or lit cigarette during					WARNING Generator produces hazardous voltage.
	and for several minutes after charging a battery.						Failure to properly ground generator can result in
•	DO NOT open or mutilate the battery.						electrocution.
•	Wear protective goggles, rubber apron, rubber boots and						Failure to isolate ge erator from power utility can result in
							death r injury to electric utility workers due to backfeed of
	rubber gloves.
							electr cal energy.
•	Remove watches, rings, or other metal objects.
					•	When using generat r f r backup power, notify utility company.
•	Use tools having insulated handles.
					•	DO NOT		ou h bare wires or bare receptacles.
					•	DO NOT		se generator with electrical cords which are worn,
	WARNING Propane and Natural Gas are extremely flammable			for
						frayed, bare or otherwise damaged.
	and explosive.				•	DO NOT handle generator or electrical cords while standing in
	Fire or explosion can cause severe burns or death.					water, while barefoot, or while hands or feet are wet.
•	Install the fuel supply system according to FPA 37 and other				•	If you must work around a unit while it is operating, stand on an
	applicable fuel-gas codes.					insulated dry surface to reduce the risk of a shock hazard.
•	Before placing the generator into service, the fuelNotsystem lines				•	DO NOT allow unqualified persons or children to operate or
	must be properly purged and leak tested.					service generator.
•	After the generator is installed, you should insp the fu l				•	In case of an accident caused by electrical shock, immediately
	system periodically.					shut down the source of electrical power and contact the local
•	NO leakage is permitted.					authorities. Avoid direct contact with the victim.
•	DO NOT operate engine if smell of fuel is present or other				•	Despite the safe design of the residential generator, operating
	explosive conditions exist.					this equipment imprudently, neglecting its maintenance or being
•	DO NOT smoke around the generator. Wipe up any oil spills					careless can cause possible injury or death.
		Reproduction
	immediately. Ensure that no combustible materials are left in the				•	Remain alert at all times while working on this equipment.
	generator compartment. Keep the area near the generator clean					Never work on the equipment when you are physically or
	and free of debris.					mentally fatigued.
					•	Before performing any maintenance on the generator, disconnect
						the battery cable indicated by a NEGATIVE, NEG or (-) first. When
						finished, reconnect that cable last.
					•	After your system is installed, the generator may crank and start
						without warning any time there is a power failure. To prevent
						possible injury, always set the generator’s system switch to OFF,
						remove the service disconnect from the disconnect box AND
						remove the 15 Amp fuse BEFORE working on the equipment.

5

• Observe that the 15 Amp fuse has been removed from the control panel for shipping.

• DO NOT install this fuse until all plumbing and wiring has been completed and inspected.

	WARNING Contact with muffler area can result in					CAUTION Excessively high operating speeds increase risk of
	serious burns.				injury and damage to generator.
	Exhaust heat/gases can ignite combustibles or				Excessively low speeds impose a heavy load on generator.
	structures causing a fire.				•	DO NOT tamper with governed speed. Generator supplies correct
•	DO NOT touch hot parts and AVOID hot exhaust gases.					rated frequency and voltage when running at governed speed.
•	Allow equipment to cool before touching.				•	DO NOT modify generator in any way.
•	DO NOT install the generator closer than 5 feet (1.5m) from any
	combustibles or structures with combustible walls having a fire				NOTICE Exceeding generators wattage/amperage capacity can
	resistance rating of less than 1 hour.
					damage generator and/or electrical devices connected to it.
•	Keep at least minimum distances shown in General Location
					•	Start generator and let engine stabilize before connecting
	Guidelines to insure for proper generator cooling and
						electrical loads.
	maintenance clearances.
•	It is a violation of California Public Resource Code, Section 4442,				NOTICE Improper treatme t of generator can damage it and
	to use or operate the engine on any forest-covered, brush-
					sh ten its life.
	covered, or grass-covered land unless the exhaust system is
					•	Use genera	r nly f r intended uses.
	equipped with a spark arrester, as defined in Section 4442,
					•	If you have ques ns ab ut intended use, contact your
	maintained in effective working order. Other states or federal
	jurisdictions may have similar laws.					authorized dealer.
	Contact the original equipment manufacturer, retailer, r dealer				•	Operate generator only on level surfaces.
			for
	obtain a spark arrester designed for the exhaust system installed				•	Adeq ate,	nobstructed flow of cooling and ventilating air is
	on this engine.
						critical to correct generator operation.
•	Replacement parts must be the same and installed in the same
					•	The access panels/door must be installed whenever the unit
	position as the original parts.
						is running.
		Not			•	DO NOT expose generator to excessive moisture, dust, dirt, or
	WARNING Starter and other rotating parts can entangle hands,					corrosive vapors.
	hair, clothing, or accessories.				•	Remain alert at all times while working on this equipment.
						Never work on the equipment when you are physically or
						mentally fatigued.
•	NEVER operate generator without protective housings, cov rs, or				•	DO NOT start engine with air cleaner or air cleaner cover removed.
	guards in place.				•	DO NOT insert any objects through cooling slots.
•	DO NOT wear loose clothing, jewelry or anything that may be				•	DO NOT use the generator or any of its parts as a step. Stepping
	caught in the starter or other rotating parts.					the unit can cause stress and break parts. This may result in
•	Tie up long hair and remove jewelry.	Reproduction
						dangerous operating conditions from leaking exhaust gases, fuel
•	Before servicing, remove 15 Amp fuse from control panel and					leakage, oil leakage, etc.
	disconnect Negative (NEG or -) battery cable.				•	If connected devices overheat, turn them off and disconnect them
						from generator.
					•	Shut off generator if:
	CAUTION Installing the 15A fuse could cause the engine
						-electrical output is lost;
	to start.
						-equipment sparks, smokes, or emits flames;
						-unit vibrates excessively.

6

Installation

This product is intended for use as an optional home generator system which provides an alternate source of electric power and to serve loads such as heating, refrigeration systems, and communication systems that, when stopped during any power outage, could cause

discomfort or inconvenience. This product does not qualify for emergency standby as defined by NFPA 70 (NEC).

Every effort has been made to ensure that information in this manual is accurate and current. However, we reserve the right to change, alter, or otherwise improve the product and this document at any time without prior notice.

Only current licensed electrical and plumbing professionals should attempt home generator system installations. Installations must strictly comply with all applicable codes, industry standards and regulations.

	Reproduction
• Read and follow the instructions given in the		for
operator’s manual.
• Follow a regular schedule in maintaining, caring for
and using your home generator, as specified in the
operator’s manual.	Not
Installing Dealer/Contractor
	esponsibilities
• Read and observe the safety rules.		If operating the generator below 40°F (5°C), it is HIGHLY
		RECOMMENDED that a battery warmer be installed. This item

	• Install only an UL approved transfer switch that is
	Home Owner Responsibilities
	compatible with the generator.	is available at your local servicing dealer.
	• Read and follow the instructions given in this	If you need more information on this matter, please call
		[phone], between 8:00 AM and 5:00 PM CT.
	installation and start-up manual.

Unpacking Precautions

The unit is shipped bolted to its mounting pad, ready for installation. Avoid damage from dropping, bumping, collision, etc. Store and unpack carton with the proper side up, as noted on the shipping carton.

7

Delivery Inspection

After removing the carton, carefully inspect the generator for any damage that may have occurred during shipment.

If loss or damage is noted at time of delivery, have the person(s) making delivery note all damage on the freight bill and affix his signature under the consignor’s memo of loss or damage. If loss or damage is noted after delivery, separate the damaged materials and contact the carrier for claim procedures. Missing or damaged parts are not warranted.

Shipment Contents

The home generator system is supplied with:				•	Oil drain tray
•	Pre-attached mounting pad	Reproduction
				•	Touch up pai	t
•	Fully-serviced oil/lubricating system			•	Roof hardware
• Flexible fuel hook-up hose				•	Remote LED	dicat r kit (LED/plate/screws)
• Installation and start-up manual				N supplied:
•	Operator’s manual			•	Star ing ba ery (see page 19)
•	Engine operator’s manual		Not	for•	Conne ting wire and conduit
•	Installation checklist			•	F el s pply valves/plumbing
•	Access door keys			•	Crane, lifting straps, chains or cables
• Spare 15 Amp ATO-type fuse				•	Hole punches for 16ga steel
•	Two-pole control panel connector			•	Torque screwdriver, 5 to 50 inch-pound range
• Ten-pole control panel connector				•	Voltage/frequency meter

Generator Location

Before installing the generator, consult with the homeowner and convey the following guidelines, which may affect the desired installation location.

WARNING Exhaust heat/gases can ignite combustibles or structures causing a fire.

•DO NOT install the generator closer than 5 feet (1.5m) from any combustibles or structures with combustible walls having a fire resistance rating of less than 1 hour.

WARNING Running engine gives off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause headache, fatigue, dizziness, vomiting, confusion, seizures, nausea, fainting or death.

•Operate generator ONLY outdoors.

•Install a battery operated carbon monoxide alarm near the bedrooms.

•Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes, or other openings.

8

Install generator outdoors in an area which will not accumulate deadly exhaust gas. DO NOT install generator where exhaust gas could accumulate and enter inside or be drawn into a potentially occupied building. Ensure exhaust gas is kept away from windows, doors, ventilation intakes or other openings that can allow exhaust gas to collect in a confined area. Prevailing winds and air currents should be taken into consideration when positioning generator.

General Location Guidelines

•Install the unit outdoors ONLY.

•Place the unit in a prepared location that is flat and has provisions for water drainage.

•Install the unit in a location where sump pump discharge, rain gutter down spouts, roof run-off, landscape irrigation, or water sprinklers will not flood the unit or spray the enclosure and enter any air inlet or outlet openings.

5’ (1.5 m)

3’ (1 m)

3’ (1 m)

3’ (1 m)

B

5’ (1.5 m)

5’ (1.5 m)

D A

C

5’ (1.5 m)

• Install the unit where it will not affect or obstruct				E		E
	Reproduction
any services (including covered, concealed and			for
underground), such as telephone, electric, fuel,				A Non-Combust ble material with Fire Resistant Rating of
irrigation, air conditioning, and so forth.
• Install the unit where air inlet and outlet openings				1 hour	r greater
will not become obstructed by leaves, grass, snow,				B Home S andby Generator
	Not
etc. If prevailing winds will cause blowing		r drif ing,		C Engine Exhaust
you may need to construct a windbreak to pr ect				D Comb	stible Material or Structure with a Fire
the unit.				Resistance Rating of less than 1 hour.
• Install the generator as close as possible to the				E Any structure or material. DO NOT connect (A) and/or
transfer switch and fuel supply to reduce the length			f	(D) to (E).
wiring, conduit, and piping.
Laws or local codes may regulate the distance to the
fuel supply.
The minimum clearances from aerial view of g		rator (B) to

combustible (D), and non-combustible (A) mat rials is shown at right:

• These distances are provided to give generator location guidance relative ONLY to combustibles, generator cooling, and maintenance.

• The minimum distances in the figure are as shown.

All four sides of the generator cannot be enclosed or restricted, even if the minimum distances are maintained. DO NOT connect (A) and/or (D) to (E)

• A roof cannot be used.

• Exhaust (C) must not be allowed to accumulate.

9

Electrical and Fuel Inlet Locations

The 3/4 inch N.P.T. fuel inlet connector (A) and electrical inlet location (B) is shown at right.

The home generator is shipped already attached to its mounting pad. Unless mandated by local code, a concrete slab is not required.

If mandated by local code, construct a concrete slab at least 3 inches thick and 6 inches longer and wider than the unit. Attach unit to slab with 1/4” diameter (minimum) masonry anchor bolts long enough to retain the unit.

B

A

Lifting the Generator						for
The generator weighs more than 350 pounds (159 kg). Pr per
tools, equipment and qualified personnel should be used in
all phases of handling and moving the generator.
	WARNING Hazardous Voltage - Contact with power lines can
				cause electric shock or burn.	Not
				Lifting Hazard / Heavy Object - Can cause muscle
				strain or back injury.
•	If lifting or hoisting equipment is used, DO NOT contact any
	power lines.
•	DO NOT lift or move generator without assistance.
•	DO NOT lift unit by roof as damage to generator will occur.
					Reproduction

Lifting pockets are provided at each corner between the base of the generator and its mounting pad. Retouch any chipped paint with supplied touch-up paint.

10

Access Ports

The home generator is equipped with several access openings and a removable roof to permit simple oil and filter servicing.

To remove roof:

Remove the four screws and lift off. Replace roof in reverse order.

To remove access cover:

Remove the two screws, tilt cover out, and lift cover off panel. Replace cover in reverse order.

To remove side panel (if necessary):

1.Remove roof.

2.Remove screw(s) attaching side panel.

Each home generator is suppied with a set of identical keys. These keys fit the locks that secure the access door.

To open access door:

1.Insert key into lock of access door and turn key one quarter turn counterclockwise.

2.Grasp door’s handle and turn one quarter turn counterclockwise to open. Remove key.

To close access door:

1.Close door and turn doors handle one quarter of a turn clockwise.

2.Insert key into lock of access door and turn key one quarter turn clockwise. Remove key.

	WARNING Contact with muffler and engine parts can result in
		serious burns.	Reproduction
•	DO NOT touch hot parts and AVOID hot exhaust gases.				for
•	Allow equipment to cool before touching.
	3.			Not
		Pull panel outward (away) from unit while pulling
		panel upward and out of base.
To install side panel:
	1.	Guide bottom of side into base.
	2.	Push panel until it is flush with sides.
	3.	Replace panel screw(s).
	4.	Replace roof and screws.

11

The generator has been factory set to run on natural gas. If you need to change from natural gas to LP gas, the unit will need to be reconfigured, as described in Fuel Conversion.

The Gaseous Fuel System

The information below is provided to assist gaseous fuel							• Piping must be of the correct size to maintain the
system technicians in planning installations. In no way							required supply pressures and volume flow under
should this information be interpreted to conflict with							varying generator load conditions with all gas
applicable fuel gas codes. Consult with your local fuel							appliances connected to the fuel system turned on
supplier or Fire Marshall if questions or problems arise.							and operating.
	WARNING Propane and Natural Gas are extremely flammable
							WARNING Propane and Natural Gas are extremely flammable
	and explosive.
							and explosive.
	Fire or explosion can cause severe burns or death.
							Fire or explosion can cause severe burns or death.
•	LP gas is heavier than air and will settle in low areas.					•	Before placing the generator into service, the fuel system lines
•	Natural gas is lighter than air and will collect in high areas.						must be properly purged and leak tested.
•	The slightest spark can ignite these fuels and cause an explosion.					•	No leakage is permitted.
•	DO NOT light a cigarette or smoke.
							• Use a pipe sealant or joint compound approved for
TO THE INSTALLER: Consult with the home generator
							use with NG/LPG on all threaded fittings to reduce the
owner(s) and convey any technical considerations that							possibility of leakage.
might affect their installation plans before applying these							• Installed piping must be properly purged and
general guidelines.
							leak tested, in accordance with applicable codes
The following general rules apply to gaseous fuel
							and standards.
system piping:						C	nsider the f ll w g factors when planning the fuel
	• The piping should be of a material that conforms
						supply sys em ns allat n:
	to federal and local codes, rigidly mounted and						• Air dens y s less at high altitudes, resulting in
	protected against vibration.
							less available engine power. See Power Decrease
	• Piping should be protected from physical damage			for at High Altitude or High Temperature in the
	where it passes through flower beds, shrub beds, and						operator’s manual.
	other cultivated areas where damage c uld		ccur.				• The generator engine is fitted with a fuel mixer system
							that meets the specifications of the California Air
	CAUTION The supplied flexible gaseous pipe is not to be
							Resources Board for “tamper-proof” fuel systems.
installed underground or in contact with the ground.
		Not					• A minimum of one accessible, approved manual
• The entire flexible gaseous pipe must be visible for eriodic
	inspection and must not be concealed within nor contact nor			un			shutoff valve shall be installed in the fuel supply line
	through any wall, floor, or partition.						within 6 ft (1.8 m) of the generator. A union or flanged
	• Install the flexible, gaseous hose (suppli d) b		tw				connection shall be provided downstream from this
							valve to permit removal of controls.
	the generator Fuel Inlet port and rigid piping to

	prevent thermal expansion or contraction from	• Natural gas fuel supply pressure at the generator’s
		fuel inlet port should be between 5 to 7 inches of
	causing excessive stress on the piping material.
		water (in. W.C.) at full load with all gas appliances
	Reproduction
	Where local conditions include earthquake, tornado,	turned on and operating.
	unstable ground, or flood hazards, special consideration
		• LP gas fuel supply pressure should be 11 to 14 inches
	shall be given to increase strength and flexibility of piping
		of water (in. W.C.) at full load with all gas appliances
	supports and connections.
		turned on and operating.

12

It is recommended that the fuel connection incorporate the following components:

•A manual fuel shut-off valve located in the interior of the building.

•A manual fuel shut-off valve located outside the building, just before the generator unit.

•Where the formation of hydrates or ice is known to occur, piping should be protected against freezing. The termination of hard piping should include

a sediment trap where condensate is not likely to freeze.

•A manometer port should be provided.

The manometer port permits temporary installation of a manometer to ensure that the engine receives the correct fuel pressure to operate efficiently throughout its operating range.

When the initial test runs are completed, the manometer is removed and the port is plugged. A typical final fuel connection assembly is shown here, where (A) is the fuel supply and (B) goes to the home generator.

A B

Reproduction
	Fuel Pipe Sizing
	for
	The	a e numerous on-li e or otherwise-published
	efe ences for fuel pipe sizi g. For example, NFPA 54 -
	Nati	nal Fuel Gas C de, 2006 (Item #: 320-6031-06) is a
Not	mmon resource.
	The installer should consider the specific gravity of gas
	and	ompensate for a nominal amount of restriction from

bends, fittings, etc. If an unusual number of fittings, bends, or other restrictions are used, refer to federal and local codes

f r gui ance.

13

Fuel Consumption

Estimated fuel supply requirements at half and full load for natural gas and LP vapor fuels are shown here.

Natural Gas			LP Vapor
1/2 Load	Full Load	1/2 Load		Full Load
84 C	162 C	35 C		65 C
84,000 B	162,000 B	86,375 B		163,625 B
C = Cubic feet per hour
B = BTU’s per hour

Physical	LP Vapor	Natural
Properties		Gas
Normal Atmospheric	Gas	Gas
State
† Weight is given in “Pounds per	Gallon of Liquid”.	Reproduction
Boiling Point (in °F):			for
Initial	-44	-259
End	-44	-259
Heating Value:		Not
BTU per gallon (Net
LHV*)	83,340	63,310
BTU per gallon (gross**)	91,547
Cubic feet (gas)	2,500	1,000
Density***	36.39	57.75
Weight†	4.24	2.65
Octane Number:
Research	110+	110+
Motor	97
* LHV (Low Heat Value) is the more realistic rating.
** Gross heat value does not consider heat lost in the form of water during
combustion.
*** Density is given in “Cubic Feet of Gas per Gallon of Liquid”.

14

System Connectors

Low Voltage connections to signal fault contacts, transfer switch communication, remote LED and auxiliary 12VDC power are made via a removable ten-pole connector plug. Compare this illustration with your generator to familiarize yourself with the location of these connections. Count down to the proper pin location on the control board since visual alignment with the decal can be misleading:

	Reproduction
			for
		B		D
		A	C	E	F	G
A - Fault Contacts — Use NO, COM and C to hook up a				D - +12 Volt DC, .5 Amp Output — Internal power supply.
siren, light, etc. to alert you in case of a fault. Contacts				E - 240 Volt Utility — Use to hook up the 240V utility leads
reverse state (NO goes to NC and vice versa) upon a fault				from the transfer switch to the generator.
condition.	Not
				F – Ten-pole Connector Plug
B - Transfer Switch Communication — Conn		to transfer
				G – Two-pole Connector Plug
switch control board for communication int		rface using

18AWG copper twisted pair wire.

C - Remote LED Output — Use this to hook up the remote

LED supplied with the generator. The remote LED will turn on and off in a series of blinks if certain faults are detected in the generator.

•For power output connection, use #8 AWG minimum 300 volt 75°C-90°C copper wire, (ref. NEC Table 310.16, 100 ft.

Use National Electric Code for correction factors and wire size calculations.)

•For Utility Circuit connection use #14 AWG minimum 300 volt 75°C-90°C copper wire

•For transfer switch communication use #18 AWG twisted pair conductors, no greater than 200 ft in length, 300 volt 75°C 90°C copper wire

•When connecting to the connector plugs, fasten only one wire to each connector screw.

•Torque connector plug screws to 7 in-lb (7.9 Newton meter).

15

Generator AC Connection System

	A single-phase, three-wire AC connection system is used in	33
	the home generator. The stator assembly consists of a pair
		22
	of stationary windings with two leads brought out of each
	winding. The junction of leads 22 and 33 forms the neutral
	lead, as shown schematically and as a wiring diagram. A
	complete schematic and wiring diagram can be found later
	in this manual.	Winding
	Neutral is not bonded to ground at generator.
		Power
		Circuit
		Breaker
		11
		44

Reproduction
Not	for	22	33	44		11
					Circuit
					Breaker
		Neutral		Line 2		Line 1
				To Transfer Switch

Grounding the Generator

Ground the home generator per applicable codes, standards, and regulations. The generator GND lug is located inside the control panel box.

Neutral

120V

120V

240V

0

Ground

16

Utility Circuit Connection

“240V Utility” leads must be routed in conduit. The “240V Utility” leads deliver power to the generator’s circuit board, optional battery warmer and optional oil warmer. This power also charges the battery. When power on these leads is lost, the generator will start.

Using provided 2 pole connector plug and installer-supplied minimum 300V, 14 AWG copper wire, connect each control circuit terminal in the generator to the two-amp fuse terminals in the automatic transfer switch.

When making connections, obey wire type and torque specifications printed on the circuit breaker and neutral/ ground connector.

Transfer Switch Communication

(Units with ACCM II or later transfer switch only)
Using #18 AWG twisted pair conductors, no greater than
200 ft in length, connect Tx Rx and Tx Rx GND from the		for
generator control panel (A) to T/R and GND on the transfer
switch control board (B).			A
	Not
				B
Fault Detection System
The generator may have to run for long periods of time with		T install the remote LED indicator:
	Reproduction
no operator present. For that reason, the system is equipped			1. Push the LED through the mounting plate from
with sensors that automatically shut down the generator			the front until it snaps in place. The LED is
in the event of potentially damaging conditions, such as			polarity sensitive.

	low oil pressure, high temperature, over speed, and other	2. Using provided 10 pole connector and installer-
	conditions. Refer to Fault Detection System in the operator’s
		supplied minimum 18AWG wire, connect the remote
	manual for more detailed information.
		LED to the generator control board +LED and GND
	The owner will use the remote LED indicator to observe
		connection. Use wire nuts to attach wire to LED leads.
	the status of the home generator system. The remote LED
		3. Attach mounting plate to installer-supplied
	will turn on and off in a series of blinks if certain faults are
		electrical box.
	detected in the generator system. Consult with the owner
	for a convenient location. Locate the electrical box in an
	area visible by the home owner such as near a garage door
	opener or security control panel.

17

System Control Panel

The home generator control panel, located inside the generator housing, is shown below.

C D E F

B

A

Brief descriptions of the controls used during installation are:

A - Set Exercise — Used to set the exercise cycle.

B - Circuit Breaker — Must be ON to supply power to the transfer switch.

C - 15 Amp Fuse — Protects DC control circuits.

D - System Switch — Switches modes to OFF or AUTO.

E – MANUAL OVER-RIDE — Used to manually start and stop the generator.

F - Digital Display — Displays running time in hours or fault codes.

More information may be found in Controls in the operator’s manual.

	System Switch
	This two-position switch is the most important control on the
	home generator and is used as follows:
Reproduction
	for	• “AUTO” position is the ormal operating position. If a
		utility wer	utage is sensed, the system will start
		the generat	r. When utility power is restored, lets the
		engine s ab l ze internal temperatures, shuts off the
Not		genera or, and waits for the next utility power outage.
		• “OFF” position turns off running generator, prevents
		nit from starting and resets any detected faults.
	15 Amp F se
	Pr tects the home generator DC control circuits. If the fuse
	has ‘blown’ (melted open) or was removed, the engine cannot
	crank or start. Replace the fuse using only an identical

ATO 15A fuse. One spare fuse is supplied with the unit. If fuse was blown or removed, you will need to reset the exercise timer (see Setting Exercise Timer).

18

Final Installation Considerations

Engine Oil			Battery
NOTICE Any attempt to crank or start the engine before it has			The installer must supply and install a valve-regulated
been properly serviced with the recommended oil will result in			rechargeable 12 volt starting battery. The starting battery
equipment failure.			MUST conform to the specifications shown in this chart.
•	Refer to Maintenance in the operator’s manual and engine
			Battery Specifications
	manual for oil fill information.
•	Damage to equipment resulting from failure to follow this		Volts		12 Volt DC
	instruction will void engine and generator warranty.
			Amps (MIN)		350 CCA (cold cranking amps)
This engine is shipped from the factory pre-run and filled with			Type		AGM (Absorbent glass mat)
			Terminal Hardware		M8
synthetic oil (SAE 5W-30). This allows for system operation in
			Dimensions (MAX):
a wide range of temperature and climate conditions. Before
			Width		5.325 inches (135mm)
starting the engine, check oil level and ensure that engine is
serviced as described in the engine operator’s manual.			Length		7.875 inches (200mm)
The use of synthetic oil does not alter the required oil change			Height		6.875 inches (175mm)
intervals described in the engine operator’s manual.			Install the battery as described in Servicing the Battery in
			the Maintenance section of the operator’s manual. Always
			make sure the NEGATIVE cable is connected last and that
			the ed POSITIVE term		al sulator is fully in place.
			WARNING Ba ery p		sts, terminals and related accessories
			contain lead and lead compounds, chemicals known to the State
			of California to ause cancer and reproductive harm. Wash hands
	Not	for
			after handling.

Fuel Supply System

Ensure that all fuel pipe connections areReproductiontight, secure and without leaks.

Ensure that all gas line shutoff valves are OPEN and that adequate fuel pressure is available whenever automatic operation is desired.

19

7. Listen for unusual noises, vibration or other indications of abnormal operation. Check for oil leaks while engine runs.

Initial Start-up (No Load)

Unit has been set-up for NG operation at the factory. Fuel conversion, if needed, must be completed prior to performing these steps. See Fuel Conversion later in this section.

5. Set generator’s system switch to AUTO.
	Reproduction
6. Push and hold MANUAL OVER-RIDE button on control		DO NOT proceed until you are certain that generator AC
		voltage and freque cy are correct and within the stated
panel for about six seconds. Engine will start.		for
When the generator is started for the very first time, it will		limits. To obtain the pr per ge erator frequency, see
		Engine Adjustment.
Before operating the home generator or placing it into		8. Let engine warm up for about five minutes to allow
service, inspect the entire installation carefully. Then begin		internal temperatures to stabilize.
testing the system without any electrical loads connected,		9. Check generator output at load side of circuit breaker.
as follows:		Voltage should be 239   262 Volts, frequency should
1. Remove four screws that secure control panel to		be 62.0   62.5 Hz.
enclosure to expose unit’s circuit breaker.		If either parameter is outside these ranges, perform Engine
2. Connect an accurate frequency meter to line side of		Adjustment described later in this section.
generator’s main circuit breaker.		10. Check generator output between one generator
3. Set generator’s main circuit breaker to ON		connection lug and neutral lug, then between
(closed) position.		other generator connection lug and neutral lug.
4. Install 15 Amp fuse in control panel.		In both cases, voltage reading should be between
		119 and 131 Volts.
require that air in the gaseous fuel lines be purged. This may		11.	Push and h ld MANUAL OVER-RIDE button on
take a few minutes.	Not		rol panel until engine stops.
		12.	Reinstall ontrol panel into enclosure.

20

Engine Adjustment

	There are regional variances in the composition of natural			8. Turn service disconnect to transfer switch OFF.
	gas. Each home generator unit leaves the factory set for			After a short time delay, transfer switch will connect
	NG operation. If the generator output voltage or frequency			to generator.
	measured during Initial Start-Up is outside the listed ranges,			9. Load generator to full load.
	the combustibility of the gas supplied at the installtion
				10. After load stabilizes, frequency should be
	site may be substantially different from the fuel used at
				above 57.0 Hz.
	the factory.
				11. If frequency is below 57.0 Hz, slowly adjust the
	To adjust the engine for this difference, proceed as follows.
				governor until frequency is above 57.0 Hz.
	1. Remove four screws that secure control panel to
				12. Turn service disconnect to transfer switch ON.
	enclosure to expose unit’s circuit breaker.
				Transfer switch will connect to utility power after
	2. Connect an accurate frequency meter to line side of
				five minutes.
	generator’s main circuit breaker.
				13. Push and hold MANUAL OVER-RIDE button on
	3. Ensure that the 15 Amp fuse is installed.
				control panel until engine stops.
	4. Set the generator’s main circuit breaker ON.
				14. After the engine has stopped:
	5. Set the generator’s system switch to AUTO.
				• If an adjustment was made in step 11, repeat steps
	6. Push MANUAL OVER-RIDE button control panel.
				2 through 7.
	When the engine starts, allow it to warm up for			• If an adjustme	t was ot made in step 11, proceed
	five minutes.
				to step 15.
	7. Normal no load frequency is 62.0 to 62.5 Hz. If
			If no load frequency falls		ut of the no load range shown
	adjustment is needed at no load, slowly rota he
			in step 7 af er full load adjustment is made, contact an
	governor adjustment knob (A) clockwise and/or
			authorized servi e center.
	counterclockwise until frequency is 62.0 to 62.5 Hz.
			for	15. Reinstall control panel into enclosure.
		Not
		Reproduction

A

21

Test Shutdown(s) Procedure

The installer will test the system to verify that diagnostic messages are correctly shown on the system control panel digital display, as follows:

three seconds the generator will shut down and FC_5 will be displayed on the system control panel. Turn the system switch to OFF for 30 seconds to clear the fault.

FC_1 - Low Battery

No test procedure required for this fault.

FC_2 - Low Oil Pressure:

Locate wire #85 connected to the oil pressure switch (A):

A

FC_6 - Engine Overspeed

With the system switch in AUTO position, push and hold MANUAL OVER-RIDE to start the generator. Locate the governor lever and SLOWLY raise engine speed. Do NOT change engine speed using the governor adjustment. When the generator output frequency is 65-70 Hz after three seconds the generator will shut down and FC_6 will be displayed on the system control panel. If the generator output frequency is greater than 70 Hz the generator will shut down immediately. Turn the system switch to OFF for 30 seconds to clear the fault.

FC_7 - High Temperature

Connect an installer-supplied jumper wire to wire #85.			Locate wire #95 connected to the temperature switch (B):
With the system switch in AUTO position, push the manual		for
over-ride switch to start the generator. With the generator
running, connect other end of jumper to a good ground
location such as the engine block. The generator will shut
down and FC_2 will be displayed on the system con rol
panel. Remove the jumper wire. Turn the system swi ch				B
OFF for 30 seconds to clear the fault.
FC_3 - Low Voltage
With the system switch in AUTO position, push and hold
MANUAL OVER-RIDE to start the generator. With the
	Not
generator running at no load, turn the generator circuit			C nnect an installer-supplied jumper wire to wire #95. With
breaker to OFF. The generator should shut down and FC 3
			the system switch in AUTO position, push and hold MANUAL
will be displayed on the system control panel. Turn the
			OVER-RIDE to start the generator. With the generator
system switch to OFF for 30 seconds to clear the fault. Turn
			running, connect other end of jumper to a good ground
the circuit breaker to ON position.
			location such as the engine block. The generator should
FC_4 - Engine Does Not Start
			shut down and display FC 7 on the system control panel.
With the generator not running, turn the installer supplied			Remove the jumper wire. Turn the system switch to OFF for
manual fuel valve to the OFF position. With the system			30 seconds to clear the fault.
	Reproduction
switch in AUTO, turn off utility power. The engine will crank,			FC_8 - Transfer Switch Fault

	attempting to start. After approximately a two-minute	Verify that utility power is present at the Automatic Transfer
	start attempt (10 seconds of crank, 10 seconds of rest) the
		Switch. With the system switch in AUTO position, remove
	generator should terminate the start attempt and FC_4 will
		one of the fuses from the transfer switch. FC_8 will display
	be displayed on the system control panel. Turn the system
		on the system control panel. Carefully reinstall the fuse in
	switch to OFF for 30 seconds to clear the fault. Turn the
		the transfer switch, then turn the system switch to OFF for
	installer supplied fuel valve to the ON position.
		30 seconds to clear the fault
	FC_5 - Low Frequency
		Analyze Test Results
	With the system switch in AUTO position, push and hold
		If any test procedure above does not cause the generator
	MANUAL OVER-RIDE to start the generator. Locate the
		to shut down and display the indicated fault, repair the fault
	governor lever and SLOWLY lower engine speed. Do NOT
		condition before putting the unit into service.
	change engine speed using the governor adjustment.
	When the generator reaches a speed slower than 55 Hz for

22

Fuel Conversion

The engine of your home generator system is factory calibrated to run on natural gas (NG). It may also be operated on liquefied petroleum (LP) vapor. There is no additional hardware/equipment required to switch between either

fuel. However, LP fuel inlet pressure must be between 11 and 14 inches water column at full load with all gas appliances turned on and operating.

To configure the fuel system for LP use:

1.Set generator’s system switch to OFF.

2.Remove 15 Amp fuse from control panel.

3.Open oil fill access panel.

4.Connect the fuel select solenoid by joining the two-pin electrical connector (C).

			Reproduction
		C		for
			Not
5.	Reinstall 15 Amp fuse in control panel.
6.	Set generator’s system switch to AUTO.
7.	Close access panels.

The system is now ready to operate automatically using

LP vapor fuel.

23

Schematic Diagram

Not	for
Reproduction

24