Powermate P3201, P2701, P2201 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: P2201

P2701 P3201

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:

200-2653 - Revision A - 9/07

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

200-26532

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

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

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

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

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

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

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

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

Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Main Line Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Utility Circuit Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Generator Start Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fuel Specifications & Consumption Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fuel Consumption Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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

Natural Gas Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Liquid Propane Vapor Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Battery Placement and Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Lubrication and Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

First Time Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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

Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Generator Control Panel Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Generator Control Panel Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Starting The Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Cyclic Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Run State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Low Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Not In Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Generator On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Generator Control Panel - Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Overcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

High Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Low Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Underspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-26

Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Engine Oil Level Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Engine Oil and Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Engine Air Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Battery Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25

Spark Plug Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Enclosure And Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Valve Clearance Check And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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

. . . . . . . . . 26

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-28

Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-30

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

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

TTTTAAAABBBBLLLLEEEE OOOOFFFF CCCCOOOONNNNTTTTEEEENNNNTTTTSS

3200-2653

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:

200-26534

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.

GGGGEEEENNNNEEEERRRRAAAALLLLSSSSAAAAFFFFEEEETTTTYYYYGGGGUUUUIIIIDDDDEEEELLLLIIIINNNNEEEESSSS ((((CC

Coooonnnnttttiiiinnnnuuuueeeedddd))))

WARNING:

CAUTION:

5200-2653

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 electricians and plumbers or gas technicians . Contact an authorized dealer for assistance with installation planning and referral to properly qualified, licensed installing contractors.

IIIINNNNTTTTRRRROOOODDDDUUUUCCCCTTTTIIIIOOOONN

UUUUNNNNPPPPAAAACCCCKKKKIIIINNNNGGGG IIIINNNNSSSSTTTTRRRRUUUUCCCCTTTTIIIIOOOONNNNSS

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 electricians, 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

IIIINNNNSSSSTTTTAAAALLLLLLLLAAAATTTTIIIIOOOONNNN PPPPLLLLAAAANNNNNNNNIIIINNNNGG

RISK OF INJURY

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

200-26536

GGGGEEEENNNNEEEERRRRAAAATTTTOOOORRRR SSSSPPPPEEEECCCCIIIIFFFFIIIICCCCAAAATTTTIIIIOOOONNNNSS

P2201 (22 KW) P2701 (27 KW) P3201 (32 KW)

Rated Wattage - (Standby) @1.0 PF LPG *

22,000 27,000 32,000

Rated Wattage - (Standby) @1.0 PF NG *

19,800 24,300 28,800

Voltage 120/240 volts 120/240 volts 120/240 volts Rated Current 184/92 amps LPG 224/112 amps LPG 255/133 amps LPG Frequency 60 HZ 60 HZ 60 HZ Power Factor 1.0 1.0 1.0 Max. Ambient Temp Rise 105°C 105°C 105°C Insulation class H H H Engine GM 3.0 L GM 3.0 L GM 3.0 L

Engine Type Water cooled inline (4 cyliners) Water cooled inline (4 cyliners) Water cooled inline (4 cyliners) RPM 1800 1800 1800

Displacement cc (c.i.d) 2966 (181) 2966 (181) 2966 (181) Bore X Stroke mm (inches) 101.60 x 91.44 (4.00 x 3.60) 101.60 x 91.44 (4.00 x 3.60) 101.60 x 91.44 (4.00 x 3.60) Compression Ratio 10:5:1 10:5:1 10:5:1 Valve arrangement Overhead valve Overhead valve Overhead valve Governor Electronic, Isochronous Electronic, Isochronous Electronic, Isochronous Ignition system Solid State Distributor Solid State Distributor Solid State Distributor Starter 12vdc, Solenoid Shift 12vdc, Solenoid Shift 12vdc, Solenoid Shift Alternator 12vdc 12vdc 12vdc Oil Capacity (w/o filter) 4 qts (3.8L) 4 qts (3.8L) 4 qts (3.8L) Oil Capacity (with filter) 5 qts (4.7L) 5 qts (4.7L) 5 qts (4.7L) Oil Filter PF-25 or equivalent PF-25 or equivalent PF-25 or equivalent

Radiator capacity

Shipped with 50/50 mix of

water and propylene glycol

antifreeze.

Shipped with 50/50 mix of

water and propylene glycol

antifreeze.

Shipped with 50/50 mix of

water and propylene glycol

antifreeze.

Spark plug AC Delco R45TS AC Delco R45TS AC Delco R45TS Battery

BCI Group 34, minimum

750 CCA

BCI Group 34, minimum

750 CCA

BCI Group 34, minimum 750

CCA

Air filter 019-0255 019-0255 019-0255 Minimum Content

Requirements for Natural Gas (NG) **

1000 BTU’s per cubic foot 1000 BTU’sper cubic foot 1000 BTU’sper cubic foot

Minimum Content Requirements for Liquid Propane Vapor (LPG) **

2520 BTU’sper cubic foot 2520 BTU’sper cubic foot 2520 BTU’s per cubic foot

Consumption at Full Load for Natural Gas (NG)

280 cubic feet per hour 304 cubic feet per hour 315 cubic feet per hour

Consumption at Full Load for Liquid Propane Vapor (LPG)

3.44 gallons per hour 3.71 gallons per hour 3.99 gallons per hour

Dimensions (see next page for installation drawing)

66”L x 35”W x 41”H 66”L x 35”W x 41”H 66”L x 35”W x 41”H

Shipping Weight 1300 1300 1300 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.

IIIINNNNSSSSTTTTAAAALLLLLLLLAAAATTTTIIIIOOOONNNN DDDDRRRRAAAAWWWWIIIINNNNGGGGSS

7200-2653

200-26538

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.

The generator should be installed with masonry anchor bolts on a level wire reinforced cement pad that is 4-6 inches thick and extends a minimum of 6” around all sides of the unit (see page 7 for anchor bolt locations).

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 lbin.

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.

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• 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.

9200-2653

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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• 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.

200-265310

Once the generator is anchored in its final position, it is ready for electrical connections. The generator is supplied with two terminal blocks for connection of three distinct electrical circuits; main line output power, utility power input and generator start signal. Main line output power is the electrical output of the generator, utility input powers the battery charger and optional block heater devices and the generator start signal is the interface with an Automatic Transfer Switch that allows the generator to operate automatically upon a utility power outage.

The output circuit of the generator is 4-wire, 240V, rated for the amperage as shown on the generator nameplate. Connection to the transfer switch requires two leads, commonly referred to as "hot" leads (L1 & L2), a neutral (N), and ground lead. Positions of these leads are labeled on the main line output terminal block, also shown in Fig. A. Select proper power output wire

sizes according to allowable ampacities given in Table 310-16 of the latest revision of The National Electric Code(NFPA 70). To connect the wires, strip

the insulation back approximately ½" from the end of the wire, insert the stripped end into the terminal block, then torque the terminal block screw to 35 in-lbs (4.0 N-m).

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• 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.

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• 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 and 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.

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Fig. A

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