Powermate P1204 User Manual

Stationary Standby Electric Generator

IMPORTANT SAFETY INSTRUCTIONS – Please make certain that persons who are to install, operate and maintain this equipment thoroughly read and understand these instructions prior to operation. SAVE THESE INSTRUCTIONS — This manual contains important instructions that should be followed during installation and maintenance of the generator and battery.

Record the model and serial numbers of your generator below:

Model Number

____________________

Serial Number

____________________

Date Purchased

____________________

HELPLINE 1-866-769-3703

OWNERS MANUAL

MODEL SERIES: P1204

Read and understand all safety precautions in this manual and other manuals included with this product before installing, operating and maintaining this equipment. Failure to comply with instructions in this manual could result in personal injury, property damage, and/or voiding of your warranty. The manufacturer WILL NOT be liable for any damage because of failure to follow these instructions.

WARNING:

200-2667 - Revision A - 10/07

Product style and configuration may vary. Specifications are subject to change without notice.

200-26672

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unpacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Generator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Location and Generator Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Electrical Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Main Line Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Utility Circuit Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Generator Start Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fuel Specifications & Consumption Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fuel Consumption Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fuel Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Natural Gas Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Liquid Propane Vapor Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Battery Placement and Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

First Time Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Generator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Generator Control Panel Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Generator Control Panel Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Starting The Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Cyclic Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Run State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Low Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Engine Run. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Generator Control Panel - Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Overcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

High Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Low Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Loss Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-27

Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Engine Oil Level Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Engine Oil and Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Engine Oil Cooler Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Engine Air Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Battery Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-26

Spark Plug Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Enclosure And Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . 27

Valve Clearance Check And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Fuel System Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29

Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

TTTTAAAABBBBLLLLEEEE OOOOFFFF CCCCOOOONNNNTTTTEEEENNNNTTTTSS

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Do not attempt to install the generator yourself. Extremely high and dangerous electrical voltages are present in utility power source lines and in generator load leads when the unit is running. Therefore, be sure to turn OFF all power voltage supplies at their source before attempting to complete electrical connections. Only qualified installation contractors or electrician’s who are familiar with applicable codes, standards, regulations and procedures should install the system. Improper or unauthorized installation, operation, or service of this equipment is extremely hazardous and may result in serious personal injury or death.

It is NOT intended that the information in this manual be used by any unqualified persons for the purpose of installing a standby electric power system. This equipment must be installed, inspected, tested and adjusted only by qualified personnel. These people must be familiar with the equipment and installation requirements.

The installation of this unit must comply with the regulations of the United States National Electric Code (NEC) as well as state and local codes and Occupational Safety and Health Administration (OSHA) established in the United States.

This equipment, when installed as part of a standby electric power system, must be installed in conjunction with an approved transfer switch. The transfer switch serves to prevent both generator and utility power from being connected to the load

circuits at the same time. A properly connected transfer switch helps to prevent backfeed of generator power into commercial lines while the standby generator is operating.

This generator supplies extremely high and dangerous power voltages. Any contact with high voltage electrically "hot" components will result in extremely hazardous, and possibly LETHAL, electrical shock. Use care to avoid contact with live terminals, bare connectors, bare wires, etc. Disconnect all power before performing maintenance or service.

Generator exhaust air contains carbon monoxide, a deadly odorless, colorless and tasteless gas. Breathing carbon monoxide causes severe nausea, fainting or death. Install the generator set outdoors only. Do not use exhaust air to heat a room. Do not allow exhaust air to enter a building through windows, doors, air intakes or other means. Avoid breathing exhaust air while installing, operating or servicing generator set. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry, make sure clothing and shoes are dry and stand on a dry wooden platform while adjustments are made. Remove wristwatch, rings, and jewelry that can cause short circuits.

GGGGEEEENNNNEEEERRRRAAAALLLLSSSSAAAAFFFFEEEETTTTYYYYGGGGUUUUIIIIDDDDEEEELLLLIIIINNNNEEEESS

The following information relates to protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help you recognize this information, we use the following symbols. Please read the manual and pay attention to these sections. Also read and follow all safety labels on the engine/generator set. If labels are damaged or unreadable, contact product service for replacements.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Ground Location.

– A POTENTIAL HAZARD THAT WILL CAUSE SERIOUS INJURY OR LOSS OF LIFE.

– A POTENTIAL HAZARD THAT COULD CAUSE SERIOUS INJURY OR LOSS OF LIFE.

– A POTENTIAL HAZARD THAT MAY CAUSE MODERATE INJURY OR DAMAGE TO

EQUIPMENT.

NOTE: Improper installation can damage your electrical system and cause property damage, serious

personal injury or death. Installation MUST

be performed by a licensed electrician, plumber and gas technician. Installation MUST comply with all applicable building and electrical codes. Some areas may require building permits and/or detailed sight inspections prior to approving the

unit for operation.

NOTE: The important safety instructions appearing in this manual are not meant to cover all possible

conditions and situations that may occur. It must be understood that common sense, caution, and care are factors which are not built into a generator, but are supplied by the person(s) installing, maintaining, and operating it.

WARNING:

DANGER:

CAUTION:

WARNING:

200-26674

The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground.

Keep a fire extinguisher near the generator at all times. Extinguishers rated "ABC" by the National Fire Protection Association are appropriate for use on the standby electric system. Keep the extinguisher properly charged and be familiar with its use. If you have any question pertaining to fire extinguishers, consult your local fire department.

Generator/engine noise can cause hearing loss. Never operate the generator set without a muffler or with a faulty exhaust system. Always wear hearing protection when near or operating the generator.

DO NOT permit anyone to operate the standby electric system without proper instruction.

In case of accidents caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

Units with broken or missing parts, without

protective housing or covers should never be operated. Contact your service center for replacement parts.

Inspect the generator regularly, and contact your nearest Authorized Dealer for parts needing repair or replacement.

Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

Thoroughly read the OPERATORS MANUAL before operating the generator. Safe operation and top performance can be obtained only when equipment is operated and maintained properly.

Ensure that enclosure doors are closed and locked at all times other than during service.

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WARNING:

CAUTION:

5200-2667

The stationary standby electric generator is manufactured for our customers to supply reliable backup power. The generator is a compact unit, designed to supply the power for your critical needs when utility power fails.

The standby generator will run on Liquid Propane Gas or Natural Gas allowing flexibility for getting the power you need. Fuel lines should be installed by a licensed plumber or other qualified professionals or licensed gas technician.

•About the Owners Manual

Understanding the operation of the generator is important when using or maintaining your system. If there are any questions about the information supplied in this Owner’s Manuals, call our customer service helpline number shown on the manual cover.

•About Operation or Maintenance

All required safety checks that need to be performed are the responsibility of the operators. Listed within the Owners Manual are safety precautions that need to be followed to prevent personal injuries to persons around the unit and to prevent property damage.

Immediately inspect the generator carefully for freight loss or damage upon arrival. If loss or damage is noted at the time of delivery, require the person making the delivery to note the loss or damage on the freight bill, or affix his signature under the consignor’s memo of the loss or damage. Contact the carrier for claim procedures.

When loss or damage is noted after delivery, segregate the damaged material, and contact the carrier for claim procedures. Be sure to retain the packaging material for carrier inspection.

“Concealed Damage” is understood to mean damage to the contents of a package which is not evident at the time of delivery by the carrier, but which is discovered later. The carrier or carriers are responsible for merchandise lost or damaged in transit. The title to goods rests with the consignee when generators are shipped F.O.B. factory, and only the consignee can legally file a claim.

After inspecting the generator, engine and enclosure for physical damage, finish reading the Operating and Maintenance Instructions. These manuals contain important safety information.

Taking a few moments to pre-plan before beginning installation of the generator can provide significant savings in materials and labor and lower future maintenance. Some items to consider in planning generator installation are safe generator operation, use of an Automatic Transfer Switch, load requirements, generator location, fuel supply, environmental conditions and applicable local, regional or national codes. Some areas may require building permits and/or detailed site inspections prior to approving the unit for use. Check with local authorities before starting installation.

Installation of a standby engine/generator system is complex and should not be considered a Do-It-Yourself project. Safe installation requires the skill and knowledge of licensed electrician's and plumbers or gas technicians. Contact an authorized dealer for assistance with installation planning and referral to properly qualified, licensed installing contractors.

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RISK OF INJURY AND BEING CRUSHED

• HEAVY EQUIPMENT. Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage.

• When lifting the generator or using hoisting equipment, be careful not to touch overhead power lines. Proper tools and equipment and qualified personnel should be used in all phases of handling and unpacking.

WWAARRNNIINNGG

RISK OF ELECTROCUTION AND/OR INJURY

• The installation of this equipment must be done

by licensed electrician's, contractors and gas technicians or plumbers. Installation must be completed in conformance with NEC and local electrical and building codes. Some areas may require building permits and/or detailed sight inspections prior to approving the unit for operation.

WWAARRNNIINNGG

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RISK OF INJURY

• Improper installation can damage your electrical system and cause property damage, serious personal injury or death. Installation MUST be performed by a licensed electrician and plumber or gas technician. Installation MUST

comply with all applicable building and electrical codes. Some areas may require building permits and/or detailed sight inspections prior to approving the unit for operation.

DDAANNGGEERR

200-26676

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P120401 (12 KW)

Rated Wattage - (Standby) @1.0 PF LPG * 12,000 Rated Wattage - (Standby) @1.0 PF NG * 9,800 Voltage 120/240 volts Rated Current 100/50 amps LPG Frequency 60 HZ Power Factor 1.0 Max. Ambient Temp Rise 105°C Insulation class H Engine Subaru EH72 Engine Type Air cooled V-twin (2 cylinders) RPM 3600 Displacement cc (c.i.d) 43.9 cu. in. (720 cm³) Bore X Stroke mm (inches) 2 - 3.31 in. x 2.56 in. (84 mm x 65 mm) Compression Ratio 8:1 Valve arrangement Overhead valve Governor Centrifugal Flyweight Type Ignition system Flywheel Magneto (Solid State) Starter Electric Starter Alternator 12vdc Oil Capacity (w/o filter) 1.5 qts (1.42L) Oil Capacity (with filter) 1.8 qts (1.70L) Oil Filter See Engine Manual Cooling System Forced Air Spark plug NGK BPR6ES Battery BCI Group 26 or 26R, minimum 450 CCA Air filter See Engine Manual Minimum Content Requirements for Natural Gas (NG) ** 1000 BTU’sper cubic foot Minimum Content Requirements for Liquid Propane Vapor (LPG) ** 2520 BTU’s per cubic foot Consumption at Full Load for Natural Gas (NG) 315 cubic feet per hour Consumption at Full Load for Liquid Propane Gas (LPG) 3.99 gallons per hour Dimensions (see next page for installation drawing) 47”L x 29”W x 31”H Shipping Weight 550 Normal Operating Range -20°F (-28.8°C) to 104°F (40°C)

* Note: Rated wattage is specified at sea level, 60°F ambient temperature, and propane fuel (with 2500 BTU/cuft). Rated wattage decreases approximately 3.5% for each 1000ft above sea level and approximately 1% for each 10°F above 60°F ambient temperature.

** Fuel supply pressures must be between 4 oz (6” w.c.) and 6 oz (11” w.c.) at inlet to the unit.

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7200-2653

200-26678

Once installation planning is complete and all necessary local permits are granted, installation of the generator may begin. Within the following section general recommendations are given for installing the generator. However, installations are affected by local site conditions, regional construction practices, material availability, local or regional codes and/or other variables. Therefore, recommendations included in this manual are provided as a guide only and are not meant to serve as detailed installation plans. All decisions regarding installation and materials are at the discretion of the licensed electrician's and licensed plumbers performing the installation and/or the inspector performing the final inspection as required by local or regional code. Additionally, illustrations provided in this manual are subject to ongoing revisions and shall not be construed as blueprints.

For proper ventilation and maintenance, locate the generator outdoors in an area that will allow a minimum of three feet or more of clearance between the generator and any other structure. Note: Check your local

building codes for clearance requirements for your area.

When placing the generator, the direction of the exhaust should be pointing away from windows, doors and any ventilation system.

Insure that sufficient air flow is available to remove the exhaust fumes and cool the generator properly.

NOTE: It would be extremely difficult, if not impractical,

to attempt a detailed coverage of every installation possibility. For that reason, much of the information is general in nature. Plan the installation carefully. Information in this manual is provided as a guide only and is not meant to serve as a detailed installation plan. Illustrations provided in the manual must not be construed as blueprints.

NOTE: The generator has an engine fan that draws the

air in from the end panel slots, circulates it within the enclosure and forces the air through the side panels and the exhaust panel slots.

All local applicable codes, standards and regulations must be followed for the installation of the generator. Some areas may require building permits and/or detailed sight inspections prior to approving the unit for use.

NOTE: Utility wiring from the house to power the

battery charger and other start assisting components should be tightened on the identified terminal block at a torque of 20 lbin. The wire size is to be selected according to allowable ampacities given in Table 310-16 of the National Electric Code.

Signal wiring from the transfer switch is to be 18AWG multi-strand wire tightened on the identified terminal block to a torque of 20 lb-in.

Power leads from the generator/circuit breaker being wired to the transfer switch should be tightened in the identified terminal block to 120 lb-in. The wire size is to be selected according to allowable ampacities given in Table 310-16 of the National Electric Code.

Field wiring of this unit must be conducted by a licensed electrician.

CCAAUUTTIIOONN

• Covering or restricting the air passages on the generator will cause the unit to overheat and may create a fire hazard. Do not allow snow or leaves to cover enclosure openings.

• Leave a three foot or greater open area around all sides of the unit. Check your local building

codes for clearance requirements for your area.

Do not plant trees or plants close to the unit.

• Unit should be located such that it prevents combustible material from accumulating under the generator set.

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• Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open the main circuit breaker of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

• The exhaust from this product is extremely hot and remains hot after shutdown. High grass, weeds, brush, leaves, or other combustible materials, must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system.

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• The generator engine exhaust fumes contain carbon monoxide, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. The generator must be installed properly, in strict compliance with applicable codes and standards. Following installation, you must do nothing that might render the generator unsafe or in noncompliance with such codes and standards.

9200-2667

The generator is supplied with an integral molded plastic base for use as an installation pad. Use of this base is intended to minimize installation cost by eliminating the need for a poured concrete pad.

A pad of crushed gravel a minimum of three inches thick is recommended as a base to set the generator on. Compact the gravel and ensure that the pad is level in all directions, making sure that the overall pad height is greater than the surrounding grade with a slope to carry water away from all sides of the pad. Pad dimensions at least six inches larger than the base size in all directions are recommended.

It is possible to use a standard concrete pad if desired. When using this method, a lightly steel reinforced pad a minimum of 2 inches thick, poured to local codes is recommended. Ensure the pad extends past the generator pallet and is high enough to promote drainage of water away from the generator.

After preparing the base pad (C), position the generator (A) directly on the pad , complete with the wooden skids supplied for shipping. Remove the lag bolts (B) fastening the wood to the pallet from all six positions. Using a pry bar with a block of wood as a pivot, carefully lift one end of the pallet and remove the wooden skids from both that end and the center of the pallet (D). Lower the pallet to the pad, then pry the other end up and remove the skid from that end (E). Check the generator with a level in all directions, placing material under the base as required.

Although the weight of the generator is adequate to prevent movement during normal operation, anchoring of the generator is recommended. To anchor the generator on a gravel pad, drive a minimum of four (4) spikes through the anchoring tabs located on the outside corners of the pallet. If a concrete pad is used, anchor the pallet at the same points using appropriate concrete fasteners.

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• For fire safety, the generator must be installed and maintained properly. Installation always must comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) and National Electrical Code (NEC) have established.

• This generator is designed to be installed outside only. Never install this unit inside any room, enclosure, or basement. The generator needs adequate cooling and ventilation for continued proper and safe operation.

200-266710

When connecting the generator to a building electrical distribution system, use of a transfer switch is recommended to isolate the normal utility source from the generator supply. By preventing backfeed of the generator power into the utility lines during a utility power outage, the switch provides a level of safety for electrical line workers. An automatic transfer switch listed to Underwriters Laboratories Standard 1008 performs this function while also supplying a method to automatically start and stop the generator set and transfer power to the building electrical system from an appropriate source.

When planning for a transfer switch/generator installation, it is necessary to know the method of interconnection to the building system. As illustrated, it is recommended to connect the generator to power only circuits that are necessary during a power outage. When following this method, the transfer switch feeds only the necessary circuits. Another option is to connect the transfer switch directly to the entire building electrical distribution system. In this case, all circuits or loads must be controlled to avoid overloading and possibly damaging the generator set.

Switch selection is based on factors such as the size of the building distribution system, available generator power and required generator control system. Due to the

complex nature of electrical distribution systems, the sizing, selection and installation of a switch is best handled by a licensed electrician or qualified standby generator dealer. Any switch installation must be performed by a licensed electrician to the instructions of the switch manufacturer and any applicable local, regional or national codes.

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Example of Recommended Transfer

Switch Installation

(Main Panel Load)

A Utility Power B Standby Generator C Main Circuit Panel D Automatic Transfer Switch

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• Hazardous "backfeed" voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause serious injury or death to utility personnel working on transmission lines.

• Do not try MANUAL operation of the transfer switch until all power supplied to the switch has been positively turned OFF. Failure to turn OFF power supplied may result in extremely dangerous and possibly lethal electrical shock or arching.

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