Ge HOME GENERATOR SYSTEM 18000, HOME GENERATOR SYSTEM 20000 Manual

GE Home Generator Systems

18,000 and 20,000 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 888 575-8226 between 8:00 AM and 5:00 PM CT., 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

Installing Dealer/Contractor Responsibilities . . . . .				.		.	. .		.	.	. . . 7
Delivery Inspection . . . . . .	. . . . . . .	.	. . .								8
Generator Location . . . . . .	. . . . . . .	.	. .	.							8
The Gaseous Fuel System . . .	. . . . . . .	.	. . .	.		.	.				12
Fuel Consumption . . . . . . .	. . . . . . .	.	. .								14
System Connectors . . . . . .	. . . . . . .	.	. . .								15
Grounding the Generator . . .	. . . . . . .	.	. . .	.		.	.	16
System Control Panel . . . . .	Reproduction
	. . . . . . .	.	. . .	.		18
Test Shutdown(s) Procedure . .	. . . . . . .	.for. . . .				.	. .		22
Final Installation Considerations	. . . . . . .	.	. .	.	. .			.	.	. .	19
Initial Start-up (No Load) . . . .	. . . . . . .	.	. .	.	. .						20
Engine Adjustment . . . . . .	. . . . . . .	.	. . .	21
Fuel Conversion . . . . . . . .	Not	.	.                 24
	. . . . . . .
Schematic Diagram . . . . . .	. . . . . . .	.	. .	.             25
Wiring Diagram . . . . . . . .	. . . . . . .	.	.	26
Operation . . . . . . . .	. . . . . .	.	. .	27
Automatic Operation Sequence	. . . . . . .	.	. . .	.		.	. .		.	.	27
Setting Exercise Timer . . . . .	. . . . . . .	.	. .	.	.						27
Installation Inspection . . . . .	. . . . . . .	.	. .	.	.						28

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

dizziness, v

miti g, co

fusion, seizures, nausea, fainting

or death.

•

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. Asafety symbolRepmay beroductionused 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
					•	Use lifting pipes as described in Lifting the Generator. The unit
circuit current.
						may shift on the lifting pipes during movement, which can
•	DO NOT dispose of battery in a fire. Recycle battery.
						cause injury.
•	DO NOT allow any open flame, spark, heat, or lit cigarette during
					•	DO NOT lift unit by roof as damage to generator will occur.
	and for several minutes after charging a battery.
•	DO NOT open or mutilate the battery.
•	Wear protective goggles, rubber apron, rubber boots and					WARNING: Generator produces hazardous voltage.
	rubber gloves.			for			Failure to pr perly gr u d generator can result in
•	Remove watches, rings, or other metal objects.						elec rocu			n.
							Failure		s	late generator from power utility can result in
•	Use tools having insulated handles.
							dea h or njury to electric utility workers due to backfeed of
							ele ri		al energy.
							sing generator for backup power, notify utility company.
	WARNING: Propane and Natural Gas are extremely flammable				•	When
					•	DO NOT to ch bare wires or bare receptacles.
	and explosive.
	Fire or explosion can cause severe burns or death.				•	DO NOT use generator with electrical cords which are worn,
•	Install the fuel supply system according to FPA 37 and other					fraye	, bare or otherwise damaged.
	applicable fuel-gas codes.	Not			•	DO NOT handle generator or electrical cords while standing in
•						water, while barefoot, or while hands or feet are wet.
	Before placing the generator into service, the fuel system lines
	must be properly purged and leak tested.				•	If you must work around a unit while it is operating, stand on an
•	After the generator is installed, you should insp the fu l					insulated dry surface to reduce the risk of a shock hazard.
	system periodically.				•	DO NOT allow unqualified persons or children to operate or
•	NO leakage is permitted.					service generator.
•	DO NOT operate engine if smell of fuel is present or other				•	In case of an accident caused by electrical shock, immediately
	explosive conditions exist.					shut down the source of electrical power and contact the local
•	DO NOT smoke around the generator. Wipe up any oil spills					authorities. Avoid direct contact with the victim.
					•	Despite the safe design of the residential generator, operating
	immediately. Ensure that no combustible materialsReproductionare left in the
	generator compartment. Keep the area near the generator clean					this equipment imprudently, neglecting its maintenance or being
	and free of debris.					careless can cause possible injury or death.
					•	Remain alert at all times while working on this equipment.
						Never work on the equipment when you are physically or
						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					corrosive vapors.
	hands, 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.

	compatible with the generator.		(includes oil warmer and battery warmer) and a Model 6174
			Cold Weather Breather Kit (includes engine duct) be installed.
	• Read and follow the instructions given in this
			These items are available at your local servicing dealer.
	Home Owner Responsibilities
			If you need more information on this matter, please call
			[phone], between 8:00 AM and 5:00 PM CT.
	• Read and follow the instructions given in the		for
	operator’s manual.
	• Follow a regular schedule in maintaining, caring f r
	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
	• Install only an UL approved transfer switch that is		RECOMMENDED that a Model 6030 Cold Weather Kit
	installation and start-up manual.	Reproduction

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

Generator Location

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:			Not supplied:
•	Pre-attached mounting pad		•	Starting battery (see page 19)
•	Fully-serviced oil/lubricating system		•	Connecting wire a d co duit
• Flexible fuel hook-up hose			•	Fuel supply valves/plumbing
• Installation and start-up manual			•	Crane, l f ng straps, chains or cables
•	Operator’s manual		•	Two 48” leng hs of 1” pipe (NOT conduit)
•	Engine operator’s manual		for•	Hole pun hes for 16ga steel
•	Installation checklist		•	Torq screwdriver, 5 to 50 inch-pound range
•	Alternator cover		•	Voltage/frequency meter
		Not
• Spare access door keys		Reproduction
• Spare 15 Amp ATO-type fuse
• Two-pin control panel connector
• Ten-pin control panel connector
•	Touch up paint

• Remote LED indicator kit (LED/plate/screws)

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)

2’ (.62 m)

3’ (1 m)

B

5’ (1.5 m)				5’ (1.5 m)

D A

C

• Install the unit where it will not affect or obstruct
						5’ (1.5 m)
	Reproduction
any services (including covered, concealed and			for
underground), such as telephone, electric, fuel,				E				E
irrigation, air conditioning, and so forth.
• Install the unit where air inlet and outlet openings			A	Non-Combus	ble material with Fire Resistant Rating of
	Not
will not become obstructed by leaves, grass, snow,				1 hour or greater
etc. If prevailing winds will cause blowing or drif ing,
			B Home Standby Generator
you may need to construct a windbreak to pr ect
the unit.			C	Engine Exhaust
• Install the generator as close as possible to the			D Combustible Material or Structure with a Fire
transfer switch and fuel supply to reduce the length			f	Resistance Rating of less than 1 hour.
wiring, conduit, and piping.			E Any structure or material. DO NOT connect (A) and/or
Laws or local codes may regulate the distance to the				(D) to (E).
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

10

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

	Lifting the Generator				for
	The generator weighs more than 260 kg (575 unds). 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.
	•	Use lifting pipes as described in Lifting the Generator. The unit				D	C
		may shift on the lifting pipes during movement, which can
		cause injury.		Reproduction
	• DO NOT lift unit by roof as damage to generator will occur.				You may also lift the unit using a “hook and hoist” method
					attached to the lifting pipes, provided that you use a
	Two 48” lengths of 1” pipe (C), supplied by the installer, are				spreader bar to ensure that the chains or cables DO NOT
					touch the generator’s roof.
	required to lift the generator manually. Insert pipes through
					After unit is in place, fill the lifting holes with the supplied
	the lifting holes (D) located near the unit’s base.
					lifting hole plugs. Retouch any chipped paint with supplied
					touch-up paint.

Access Ports

The home generator is equipped with an enclosure that has					Each home generator is supplied with a set of identical keys.
several access doors. The doors are named for a significant					These keys fit the locks that secure the access doors.
component located behind them, as follows:					To open access door:
A Control Panel door (shipped loose - to be attached
					1. Insert key into lock of access door handle and turn
	by installer)
					key one quarter turn counterclockwise.
B Fuel Inlet Port (shown for reference)
					2. Grasp door’s handle and turn one quarter turn
C	Oil Drain door
					counterclockwise to open. Remove key.
D Exhaust Port (cover to be attached by installer)
E	Oil Fill door				To close access door:
					1. Close door and turn door’s handle one quarter
	WARNING: Contact with muffler and engine parts can result in				turn clockwise.
	serious burns.				2. Insert key into lock of door handle and turn key one
					quarter turn clockwise. Remove key.
•	DO NOT touch hot parts and AVOID hot exhaust gases.				Additional force may be required to fully close and
•	Allow equipment to cool before touching.
					lock the doors because they create a pressurized seal
The oil and control panel doors must be installed whenever					for the generator	closure.
				for
the unit is running to assure proper cooling, reduce noise,
and for added safety.
			Not
			Reproduction
	A	B	C		D	E

11

• Use a pipe sealant or joint compound approved for use with NG/LPG on all threaded fittings to reduce the possibility of leakage.

• Installed piping must be properly purged and leak tested, in accordance with applicable codes and standards.

The Gaseous Fuel System

The information below is provided to assist gaseous fuel system technicians in planning installations. In no way should this information be interpreted to conflict with applicable fuel gas codes. Consult with your local fuel supplier or Fire Marshall if questions or problems arise.

WARNING: Propane and Natural Gas are extremely flammable

and explosive.

Fire or explosion can cause severe burns or death.

•LP gas is heavier than air and will settle in low areas.

•Natural gas is lighter than air and will collect in high areas.

•The slightest spark can ignite these fuels and cause an explosion.

•DO NOT light a cigarette or smoke.

WARNING: Propane and Natural Gas are extremely flammable

and explosive.

Fire or explosion can cause severe burns or death.

•Before placing the generator into service, the fuel system lines must be properly purged and leak tested.

•No leakage is permitted.

	TO THE INSTALLER: Consult with the generator owner(s) and		Consider the following factors when planning the fuel
	convey any technical considerations that might affect their		supply system installaton:
	installation plans before applying these general guidelines.		• Air density is less at high altitudes, resulting in less
	The following general rules apply to gaseous fuel
				available engi e power. Specifically, engine power
	system piping:			will decrease 3.5% for each 1,000 feet (300 meters)
	• The piping should be of a material that conforms			above sea level a d 1% for each 10° F (5.6°C) above
	to federal and local codes, rigidly mounted and			77°F (25°C). Make sure you and your installer consider
	protected against vibration.			these fac	rs when determining total generator load.
	• Piping should be protected from physical damage		•	The genera or engine is fitted with a fuel mixer system
	where it passes through flower beds, shrub beds, and for			that meets the specifications of the California Air
	other cultivated areas where damage c uld ccur.			Reso rces Board for “tamper-proof” fuel systems.
	CAUTION: The supplied flexible gaseous pipe is not to be		• A minimum of one accessible, approved manual
	installed underground or in contact with the ground.			shutoff valve shall be installed in the fuel supply line
	• The entire flexible gaseous pipe must be visible for periodic			within 6 ft (1.8 m) of the generator. A union or flanged
	inspection and must not be concealed within nor contact nor un			connection shall be provided downstream from this
	through any wall, floor, or partition.	Not
				valve to permit removal of controls.
	• Install the flexible, gaseous hose (suppli d) b tw n
			• Natural gas fuel supply pressure at the generator’s
	the generator fuel inlet port and rigid piping to
				fuel inlet port should be between 5 to 7 inches of
	prevent thermal expansion or contraction from
				water (in. W.C.) at full load with all gas appliances
	causing excessive stress on the piping material.
				turned	and operating.
		Reproduction
	Where local conditions include earthquake, tornado,		• LP gas fuel supply pressure should be 11 to 14 inches

	unstable ground, or flood hazards, special consideration	of water (in. W.C.) at full load with all gas appliances
	shall be given to increase strength and flexibility of piping
		turned on and operating.
	supports and connections.
		The generator has been factory set to run on natural gas. If
	• Piping must be of the correct size to maintain the
		you need to change from natural gas to LP gas, the unit will
	required supply pressures and volume flow under
		need to be reconfigured, as described in Fuel Conversion.
	varying generator load conditions with all gas
	appliances connected to the fuel system 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

	Fuel Pipe Sizing
Reproduction
	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 compensate 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 for 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
160 C		293 C	70.4 C	141.5 C
160,000 B		293,000 B	176,725 B	353,650 B
C = Cubic feet per hour
B = BTU’s per hour

Physical	LP Vapor	Natural
Properties		Gas
Normal Atmospheric	Gas	Gas
State
		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”.
† Weight is given in “Pounds 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-pin 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 because visual alignment with the decal can be misleading.

A

B

C

D

	Reproduction
		E
		for
	Not	F
		G
A – Ten-pin Connector Plug		D - emote LED Output — Use this to hook up the remote
B - Fault Contacts — Use NO, COM and NC to hook up a		LED supplied with the generator. The remote LED will
siren, light, etc. to alert you in case of a fault. Contacts		turn on and off in a series of blinks if certain faults are
reverse state (NO goes to NC and vice versa) upon a		detected in the generator.
fault condition.		E - +12 Volt DC, .5 Amp Output — Internal auxiliary
C - Transfer Switch Communication — Connect to transfer		power supply.
switch control board for communication interface using		F - 240 Volt Utility — Use to hook up the 240V utility leads
18AWG copper twisted pair wire.		from the transfer switch to the generator.

G – Two-pin Connector Plug

•For power output connection, use #4 AWG minimum 300 volt 75°C-90°C copper wire

•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.	Power
Neutral is not bonded to ground at generator.
	Winding
			Circuit
			Breaker
	11
	44
Reproduction
Not	for	44	11
	0		Circuit
			Breaker
	Ground	Line 2	Line 1
		To Transfer Switch

Grounding the Generator

Ground the generator per applicable codes, standards, and regulations. The generator GND lug is located inside the control panel door under the circuit breaker cover.

Neutral

120V

120V

240V

22

Neutral

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 pin 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 an ACCM II or later control board only)
Using #18 AWG twisted pair conductors, no greater than
200 ft in length, connect Tx Rx and Tx Rx Ground from		for
the generator control panel (A) to the GND and T/R 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 pin 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 control			System Switch
	panel door, is shown below. Brief descriptions of the controls			This two-position switch is the most important control on the
	used during installation are:
				home generator and is used as follows:
	A - SET EXERCISE — Used to set the exercise cycle start time.
				• “AUTO” position is the normal operating position. If a
	B – MANUAL OVER-RIDE — Used to manually start and stop
					utility power outage is sensed, the system will start
	the generator.				the generator. When utility power is restored, lets the
	C - 15 Amp Fuse — Protects DC control circuits.				engine stabilize internal temperatures, shuts off the
	D - System Switch — Switches modes to OFF or AUTO.				generator, and waits for the next utility power outage.
				• “OFF” position turns off running generator, prevents
	E - Digital Display — Displays running time in hours or
					unit from starting and resets any detected faults.
	fault codes.
				15 Amp Fuse
	F - Circuit Breaker — Must be ON to supply power to the
	transfer switch.			Protects the generator DC control circuits. If the fuse has
	More information may be found in Controls in the			‘blown’ (melted open) or was removed, the engine cannot
	operator’s manual.			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
		Reproduction
			for
				timer (see Setting Exercise Timer).
		D	E		F
	C	Not
	B
	A

18

Final Installation Considerations

Alternator Cover	Battery
The unit’s alternator-end enclosure cover is shipped loose in	The installer must supply and install a valve-regulated
the carton. Attach the cover to the enclosure as follows:	rechargeable starting battery. The starting battery MUST
1. Position cover’s two locating pins over matching	conform to the specifications shown in this chart.

enclosure holes.			Battery Specifications
2. Press in on cover until it snaps in place.
			Volts	12 Volt DC
3. Using supplied self-drill screws, fasten cover to
			Amps (MIN)	600 CCA (cold cranking amps)
enclosure at six places.
			Type	AGM (absorbent glass mat)
Engine Oil
			Terminal Hardware	M6
notice: Any attempt to crank or start the engine before it has
			Dimensions (MAX):
been properly serviced with the recommended oil will result in
			Width	5.5 inches (140mm)
equipment failure.
			Length	9.0 inches (230mm)
• Refer to Maintenance in the operator’s manual and engine
manual for oil fill information.			Height	8.25 inches (210mm)
• Damage to equipment resulting from failure to follow this
			Install the battery as described in Servicing the Battery in
instruction will void engine and generator warranty.
This engine is shipped from the factory pre-run and filled			the Maintenance section of the operator’s manual. Installer
			must connect battery charge wire (wire #13) to positive
with synthetic oil (API SJ/CF 5W-30). This allows for system
			batte y term nal! Always make sure the NEGATIVE cable is
operation in a wide range of temperature and climate
			nnected last.
conditions. Before starting the engine, check oil level and
ensure that engine is serviced as described in the engine			WARNING: Ba ery posts, terminals and related accessories
operator’s manual.			contain lead and lead compounds, chemicals known to the State
		for
The use of synthetic oil does not alter the required il change			of California to ause cancer and reproductive harm. Wash hands
			after handling.
intervals described in the engine operator’s manual.
	Not
Fuel Supply System
Ensure that all fuel pipe connections are tight, secure and
without leaks.	Reproduction

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

19

Initial Start-up (No Load)

Before operating the generator or placing it into service, inspect the entire installation carefully. Then begin testing the system without any electrical loads connected, as follows:

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.

1.Remove four screws that hold circuit breaker cover to air intake guard.

When the generator is started for the very first time, it will require that air in the gaseous fuel lines be purged. This may take a few minutes.

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

8.Let engine warm up for about five minutes to allow internal temperatures to stabilize.

9.No-load voltage should be 239   262 Volts, frequency should be 62.0   62.5 Hz.

If either parameter is outside these ranges, perform Engine Adjustment described later in this section.

10. Check generator output between one generator

					connection lug and neutral lug, then between
					other generator connection lug and neutral lug.
					In both cases, voltage reading should be between
	Reproduction
					119 and 131 Volts.
				DO NOT proceed u til y u are certain that generator AC
				v ltage and frequency are correct and within the stated
2.	Connect an accurate AC voltmeter and a frequency			limits. To ob a n he pr per generator frequency, see
	meter to line side of generator’s circuit breaker.			Engine Adjus ment.
		Not		11. P sh and hold MANUAL OVER-RIDE button on
3.	Set generator’s circuit breaker to ON (cl sed)		si i	n.for	ontrol panel until engine stops.
4.	Install 15 Amp fuse in control panel.			12. Reinstall circuit breaker cover.
5.	Set generator’s system switch to AUTO.
6.	Push and hold MANUAL OVER-RIDE button		contr	l
	panel for about six seconds. Engine will start.

20

Engine Adjustment

There are regional variances in the composition of natural gas. Each home generator unit leaves the factory set for NG operation. If the generator output voltage or frequency measured during Initial Start-Up is outside the listed ranges, the combustibility of the gas supplied at the installtion

site may be substantially different from the fuel used at the factory.

To adjust the engine for this difference, proceed as follows.

1.Remove four screws that hold circuit breaker cover to air intake guard.

2.Connect an accurate frequency meter to line side of generator’s circuit breaker.

3.Ensure that the 15 Amp fuse is installed.

4.Set the generator’s circuit breaker ON.

8.Turn service disconnect to transfer switch OFF. After a short time delay, transfer switch will connect to generator.

9.Load generator to full load.

10.After load stabilizes, frequency should be above 57.0 Hz.

11.If frequency is below 57.0 Hz, slowly rotate the governor adjustment nut or screw clockwise and/or counterclockwise until frequency is above 57.0 Hz.

12.Turn service disconnect to transfer switch ON. Transfer switch will connect to utility power after five minutes.

13.Push and hold MANUAL OVER-RIDE button on control panel until engine stops.

5. Set the generator’s system switch to AUTO.				14. After the engine has stopped:
	Reproduction
6. Push MANUAL OVER-RIDE button control panel.		for			• If an adjustme	t was made in step 11, repeat steps
When the engine starts, allow it to warm up for					2 through 7.
five minutes.					• If an adjustme	t was ot made in step 11, proceed
7. Normal no load frequency is 62.0 to 62.5 Hz. If					to s ep 15.
	Not
adjustment is needed at no load, slowly rota he			If no load frequency falls out of the no load range shown
governor adjustment screw (B) clockwise and/or			in step 7 after full load adjustment is made, contact an
counterclockwise until frequency is 62.0 to 62.5 Hz.			a	thorized servi e center.

15. Reinstall circuit breaker cover.

B

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:

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. Shown here is the oil pressure switch (A) and the oil filter location (B):

FC_3 - Low Voltage

With the system switch in AUTO position, push and hold MANUAL OVER-RIDE to start the generator. With the generator running at no load, turn the generator circuit breaker to OFF. The generator should shut down and FC_3 will be displayed on the system control panel. Turn the system switch to OFF for 30 seconds to clear the fault. Turn the circuit breaker to ON position.

FC_4 - Engine Does Not Start

		With the generator not running, turn the installer supplied
		manual fuel valve to the OFF position. With the system
		switch in AUTO, turn off utility power. The engine will crank,
	A	attempting to start. After approximately a two-minute
		start attempt (10 seconds of crank, 10 seconds of rest) the
	B	generator should terminate the start attempt and FC_4 will
		be displayed on the system control panel. Turn the system
		switch to OFF for 30 seco ds to clear the fault. Turn the
		installer supplied fuel valve to the ON position.
		FC 5 - Low Freque cy
		With the sys em sw ch in AUTO position, push and hold
		MANUAL OVER-RIDE to start the generator. Locate the
	Connect an installer-supplied jumper wire to wire #85.	forgovernor lever and SLOWLY lower engine speed. Do NOT
		change engine speed using the governor adjustment nut.
	With the system switch in AUTO position, push the manual	When the generator reaches a speed slower than 55 Hz for
	over-ride switch to start the generator. With the generator	three seconds the generator will shut down and FC_5 will
	running, connect other end of jumper to a good ground	be isplayed the system control panel. Turn the system
	location such as the engine block. The generator will shut	switch to OFF for 30 seconds to clear the fault.

OFF for 30 seconds to clear the fault.

down and FC_2 will be displayed on the ReproductionsystemNotcontrol panel. Remove the jumper wire. Turn the system switch to

22

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 nut. 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

Locate wire #95 connected to the temperature switch.

Shown here is the temperature switch (C) and the oil filter location (D):

Connect an installer-supplied jumper wire to wire #95.

With the system switch in AUTO position, push and hold MANUAL OVER-RIDE 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 should shut down and display FC_7 on the system control panel. Remove the jumper wire. Turn the system switch to OFF for 30 seconds to clear the fault.

FC_8 - Transfer Switch Fault

Verify that utility power is present at the Automatic Transfer Switch. With the system switch in AUTO position, remove one of the fuses from the transfer switch. FC_8 will display on the system control panel. Carefully reinstall the fuse in the transfer switch, then turn the system switch to OFF for 30 seconds to clear the fault.

Analyze Test Results

	If any test procedure above does not cause the generator
	to shut down and display the indicated fault, repair the fault
Reproduction
	condition before putti g the it into service.
D	for
C
Not

23

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 generator fuel system for LP use:

1.Open control panel and oil fill access doors.

2.Set generator’s system switch to OFF.

3.Remove 15 Amp fuse from control panel.

4.Remove cap from LP inlet on T-valve (G).

	F
	G		for
5.	Remove fuel line from NG inlet.
6.	Place cap from LP inlet onto NG inlet.
7.		Not
	From oil fill access area, pull fuel line (F) out of top h le
	and route it through bottom hole.
Failure to route fuel line through bottom hole may cause
the fuel line to kink. When tightening fuel hose fittings make
certain the fuel hose does not twist or kink. If the fuel line
kinks, the generator may start but will not operate properly.
8.	Connect fuel line (F) to T-valve’s LP inlet.
9.		Reproduction
	Reinstall 15 Amp fuse in control panel.

10. Set generator’s system switch to AUTO.

11. Close control panel and oil fill access doors.

The system is now ready to operate automatically using LP fuel. With a fixed main jet for LP gas, there is no need to perform any engine adjustments for LP operation.

24

Schematic Diagram

Reproduction
Not	for

25

Wiring Diagram

Reproduction
Not	for

26