Powermate PM400911 User Manual

Stationary Standby Electric Generator - 11,200 WATTS - MODEL PM401211 Stationary Standby Electric Generator - 9,7 00 WATTS - MODEL PM400911

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

____________________

OWNERS MANUAL

MODELS: PM401211

AND PM400911

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. Coleman Powermate WILL

NOT be liable for any damage because of failure to follow these instructions.

WARNING:

200-2341 - Revision C

2 200-2341

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

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

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

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

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

Generator location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Generator installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Generator placement and anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical hookup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Main line output power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

GFCI Circuit supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Generator start signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

12KW Wiring Diagram (CP200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fuel specifications and consumption requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fuel hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Natural gas (NG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Propane vapor (LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Battery requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Battery placement and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17

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

First time startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20

Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Generator feature identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Generator operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-24

Control panel features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Starting the generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Cyclic crank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Run state. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-33

Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-26

Engine oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Engine oil and oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Engine oil cooler inspection and cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Engine air filter change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Battery maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29

Spark plug check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Spark plug arrestor cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Enclosure and site maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Governor speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Valve clearance check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Fuel system inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Generator diode replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Generator varistor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-35

Parts drawings and lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-43

Warranty information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Service contact information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

TTTTAAAABBBBLLLLEEEE OOOOFFFF CCCCOOOONNNNTTTTEEEENNNNTTTTSS

200-2341 3

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 and licensed 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.

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:

4 200-2341

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.

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 form 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:

200-2341 5

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 needs when utility power fails.

The standby generator runs on Liquid Propane Vapor or Natural Gas allowing flexibility for getting the power you need. Fuel lines should be installed by a licensed plumber 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 cover of the manual.

•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 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, plumbers, and professional generator contractors. Contact an authorized dealer for assistance with installation planning and referral to properly qualified, licensed installing contractors.

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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 gas technicians and 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

DDAANNGGEERR

• 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.

6 200-2341

Proper location of the generator set is important to insure safe and reliable operation and can aid in the installation of the generator. When selecting a site for the generator, first ensure that the pad is outdoors in a well ventilated area to allow for proper cooling and proper removal of deadly exhaust fumes created during operation. Consider the direction of the engine exhaust exiting the cabinet and orient the generator on the site with the exhaust away from any windows, doors, ventilation intakes or other openings that can allow engine exhaust fumes to collect in a confined area. In addition, take into account any prevailing winds or other air currents that could carry engine exhaust fumes in unintended directions.

For minimum installation costs, plan to locate the generator outside at a position adjacent to the electrical service distribution panel and close to the intended fuel supply.

To assure adequate cooling air and access for maintenance, plan to locate the generator so that a minimum of three (3) feet of clear, unobstructed space is available on all sides of the cabinet, including above the lid. If landscaping is used to mask the generator from view or further control sound, leave enough room so that the mature plants still allow three feet of clear space around all sides. If necessary, place a screen style fence around the site to prevent grass, leaves or other combustible debris from gathering around the generator, creating a fire risk.

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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 open area around all sides of the unit. Do not plant trees or plants which may grow within three feet of the unit.

• Unit should be located to prevent combustible material from accumulating against the generator set.

• The generator MUST be installed outdoors.

DDAANNGGEERR

• 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 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 the generator. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

• Considerations for proper rooftop placement and weight distribution must be designed by a licensed engineer or architect.

WWAARRNNIINNGG

• 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 established by the Occupational Safety and Health Administration (OSHA) and National Electrical Code (NEC).

• 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.

• 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.

200-2341 7

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 an electrical sub-panel containing only the necessary circuits (see figure 1). 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 (see figure 2).

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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WWAARRNNIINNGG

• Hazardous "backfeed" voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent connection of standby to 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 remove power from all sources may result in extremely dangerous and possibly lethal electrical shock or arching.

Figure 2

Example of Alternative Transfer

Switch Installation

(Main Panel Load)

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

Figure 1

Example of Recommended Transfer

Switch Installation

(Essential Sub-panel Load)

A Utility Power B Standby Generator C Main Circuit Panel D Automatic Transfer Switch E Essential Loads Sub-panel

8 200-2341

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 electricians 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.

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, position the generator directly on the pad (A), 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 (C). Lower the pallet to the pad, then pry the other end up and remove the skid from that end (D). 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.

PPPPLLLLAAAACCCCEEEEMMMMEEEENNNNTTTT AAAANNNNDDDD AAAANNNNCCCCHHHHOOOORRRRIIIINNNNGG

GGGGEEEENNNNEEEERRRRAAAATTTTOOOORRRR IIIINNNNSSSSTTTTAAAALLLLLLLLAAAATTTTIIIIOOOONN

200-2341 9

IIIINNNNSSSSTTTTAAAALLLLLLLLAAAATTTTIIIIOOOONNNN DDDDRRRRAAAAWWWWIIIINNNNGGGGSSSS

10 200-2341

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, GFCI power input and remote start signal. Main line output power is the electrical output of the generator, GFCI input powers the battery charger and optional block heater devices and the remote start signal is the interface with an Automatic Transfer Switch that allows the generator to operate automatically upon a utility power outage.

To access the wiring connection terminal blocks, open the generator lid (A) and place the lid prop rod (B) into the slot (C) on the underside of the lid. Remove the three screws (D) from the access panel, then open the hinged access panel (E) as shown in Fig A. The access panel is removable by pulling the pins from the panel hinges. Locate the two terminal blocks (F) on the lower right corner of the engine partition panel.

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. B. 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).

EEEELLLLEEEECCCCTTTTRRRRIIIICCCCAAAALLLLHHHHOOOOOOOOKKKKUUUUPP

DDAANNGGEERR

MMMMAAAAIIIINNNN LLLLIIIINNNNEEEE OOOOUUUUTTTTPPPPUUUUTTTT PPPPOOOOWWWWEEEERR

FIG . A

FIG. B

L2 NEUTRAL

L1 GROUND

MAIN

LINE OUTPUT

(CONNECT TO

AUTOMATIC

TRANSFER

SWITCH)

DDAANNGGEERR

• 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.

200-2341 11

A ground fault circuit interrupting (GFCI) receptacle is provided with the generator to power the battery charger for reliable starting. It is also intended to power an optional block heater if that option is desired. Connection of this circuit to a power supply that is only present when normal utility power is supplied is recommended. By connecting the GFCI in this fashion, it is possible to insure that neither the battery charger or block heater are on while the engine is running. Precautions are engineered into the generator to prevent these occurances but connection of the circuit in this fashion provides an additional fail-safe method of engine and battery protection.

Input to the GFCI circuit is 3-wire, 120V, 15A. Connections include a "hot" lead (L1), neutral (N) and ground lead. Positions of the incoming wire connections are labeled at the auxiliary connection block, shown in Fig.C. Select proper GFCI supply wire size

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 ¼" from the end of the wire, insert the stripped end under the screw and washer on the terminal block, then torque the terminal block screw to 20 in-lbs (2.3 N-m).

When the control panel mode switch is placed in the AUTO position, generator starting and stopping is controlled by the opening or closing of a set of voltage free contacts. Two wires from those contacts are connected to the generator through the auxiliary connection block shown in Fig. D. Use of a twisted pair of stranded copper wire no smaller than AWG 18 gage is recommended. To insure proper operation of the auto start feature, use a transfer switch offering “close-to-run control contacts. To connect the wires, strip the insulation back approximately ¼" from the end of the wire, insert the stripped end under the screw and washer on the terminal block, then torque the terminal block screw to 20 in-lbs (2.3 N-m).

GGGGEEEENNNNEEEERRRRAAAATTTTOOOORRRR SSSSTTTTAAAARRRRTTTT SSSSIIIIGGGGNNNNAAAALL

FIG. C

GGGGFFFFCCCCIIII CCCCIIIIRRRRCCCCUUUUIIIITTTT SSSSUUUUPPPPPPPPLLLLYY

FIG. D

NEUTRAL L1

GFCI CIRCUIT SUPPLY

(CONNECT TO

120V UTILITY

POWER)

ATS1 ATS2

GENERATOR

START SIGNAL

(CONNECT TO

AUTOMATIC

TRANSFER

SWITCH)

12 200-2341

1122KKWW WWIIRRIINNGG DDIIAAGGRRAAMM ((CCPP220000 CCOONNTTRROOLLLLEERR)

)

RELAY PIN WIRE NUMBE R

30 1

85 13

86 9

87 13

RELAY WIRING INFORMAT ION

WIRE

NO.

WIRE NAME/ DESCRIPTION

WIRE

NO.

WIRE NAME/ DESCRIPTION

WIRE

NO.

WIRE NAME/ DESCRIPTION

WIRE

NO.

WIRE NAME/ DESCRIPTION

1 BATTERY POSITIVE 11 IGNITION TIMING INPUT 21 NOT ASSIGNED 31 NOT ASSIGNED

2 SWITCHED BATTERY POSITIVE 12 REMOTE START + 22

HIGH TEMPERATURE SENDER

32 120V UTILITY HOT

3 GENERATOR GROUND 13 STARTER SHIFT SIGNAL 23 LOW OIL SENDER 33 120V UTILITY NEUTRAL

4 CONTROLLER START SIGNAL 14 MODE SWITCH AUTO 24 NOT ASSIGNED 34 CT 1

5 GENERATOR LINE 1 15 MODE SWITCH RUN 25 NOT ASSIGNED 35 CT 1 COMMON

6 GENERATOR LINE 2 16 MODE SWITCH COMMON 26 NOT ASSIGNED 36 CT 2

7 GENERATOR LINE 3 17 LED TEST 27 NOT ASSIGNED 37 CT 2 COMMON

8 GENERATOR NEUTRAL 18 NOT ASSIGNED 28 NOT ASSIGNED 38 CT 3

9 BATTERY GROUND 19 NOT ASSIGNED 29 NOT ASSIGNED 39 CT 3 COMMON

10 IGNITION SPARK SIGNAL 20 NOT ASSIGNED 30 NOT ASSIGNED

WIRE NUMBER LEGEND

200-2341 13

The engine driving the generator is engineered to provide reliable power on either Liquefied Propane Vapor (LPG) or Natural Gas. For proper operation on these fuels, it is important to deliver gas with adequate energy content, at sufficient pressure and flow rate. This is designed to operate on Liquefied Propane Vapor (LPG) with a minimum energy content of 2500 BTU per cubic foot or Natural Gas with a minimum energy content of 1000 BTU per cubic foot. This generator is designed to operate with a fuel pressure at the inlet of the unit between 7 and 11 inches of water column (4-6 ounces).

Required fuel flow rates for specific models are given in the table below. To insure correct sizing of the piping supplying fuel to the generator set, provide the flow and pressure requirements of this section to a fuel supplier or licensed plumber during the installation planning stage. If the fuel supplier cannot guarantee delivery of fuel with these properties, the generator may not perform as advertised.

Due to differences in the energy content of fuel used, it is necessary to derate the output of the generator when connected to Natural Gas. Additionally, regional and/or seasonal variations in the makeup of the fuel can further affect output of the engine/generator system. When using Natural Gas fuel with minimum properties as defined, engine output can fall approximately 10% below that of the same set using Propane Vapor.

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WWAARRNNIINNGG

• Natural gas (NG) is highly explosive.

• Natural gas (NG) is lighter than air and collects in high places.

• Liquid propane vapor (LPG) is highly explosive.

• Liquid propane vapor (LPG) is heavier than air and collects in lower places.

• Extreme caution should be taken when working on a new installation or while performing general maintenance.

• Do not smoke when near the unit.

• Keep flames, sparks, pilot lights, arc-producing equipment, switches and all other sources of ignition well away. Keep a type ABC fire extinguisher handy.

• Potential for fire or explosion always exist when using natural gas (NG) or liquid propane vapor (LPG) as a fuel source. Install this unit in compliance with all local fuel codes.

• Do Not operate engine if smell of fuel is present or other explosive conditions exist.

Per the National Gas Code (NFPA 54 - ANSI

2223.1), a manual shutoff valve in the fuel supply line to the generator is recommended.

LP Vapor

(ft 3/hr)

LP Vapor

(Gal/hr)

Natural Gas

(ft 3/hr)

PM401211 81 2.2 186 PM409011 79 2.1 176

DDAANNGGEERR

• All fuel system installations MUST BE done by a licensed plumber or licensed gas technician and must comply with all applicable codes, standards and regulations.

FUEL CONSUMPTION TABLE

All values reflect consumption at 100% rated output.

14 200-2341

After electrical connections are complete, the next installation step is to connect a fuel supply to the unit. The fuel inlet fitting supplied with the generator is male ½" NPT and is located adjacent to a fuel access hole in the lower engine end panel as illustrated in Fig E. To accommodate potential settling of the generator relative to rigid supply pipeline, use of a flexible line to make the final connection in the supply line is suggested. When making flexible connections, use only materials rated for the fuel supplied and approved for use by local, regional or national codes and/or regulatory agencies.

When supplying natural gas as the operating fuel,

provide fuel with a minimum of 1000 BTU/ft3at inlet

pressures between 7" and 11" of water column (4 - 6 oz). Failure to meet these minimums will cause the

generator to run poorly and/or may limit output to values below nameplate value. If fuel with these qualities is not available, a low calorific fuel system kit may be required, at additional cost. Contact the customer service center to determine if a kit is required in cases of inadequate fuel quality.

Refer to the Fuel Consumption Table on page 13 for fuel flow requirements for the unit installed. Size all feeding piping to deliver sufficient flow above the minimum pressure of 7" water column (4 oz).

Per the National Gas Code (NFPA 54 - ANSI

2223.1), a manual shutoff valve in the fuel supply line to the generator is recommended.

Once all external connections are complete, check the position of the flexible engine supply hose, as shown in Fig F. When configuring a generator to run on a specific fuel, it is necessary to verify correct positioning of the hose on the fuel pressure regulator outlet. The factory default position is for natural gas (NG), as indicated in Fig F. If the fuel hose is not in the proper position, move it to the tee branch labeled NG, making sure the brass cap is placed securely on the opposite branch. With fuel supply attached and the flexible engine supply hose on the proper branch of the regulator output, the fuel hookup is complete. The generator is supplied with a fixed orifice tuned to provide proper fuel flow and no further adjustment of the fuel system is possible or required.

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Natural Gas (NG)

FIG. E

DDAANNGGEERR

• All fuel system installations MUST BE done by a licensed plumber or licensed gas technician and must comply with all applicable codes, standards and regulations.

WWAARRNNIINNGG

• Natural Gas and Propane Vapor are highly explosive gases. Check ALL fuel system connections for leaks before starting engine/generator set.

• DO NOT use a flame to check for leaks.

• Use approved equipment and methods to check for leaks.

200-2341 15

In cases where liquefied propane vapor is selected

as the fuel of choice, insure fuel delivery in the gaseous state, with a minimum energy content of 2500 BTU/ft3,

at inlet pressures between 7" and 11" of water column (4 - 6 oz). Fuel below these specifications may

cause improper engine operation and/or failure to deliver rated generator output. Size all fuel system plumbing to provide fuel flow as given in the Fuel Consumption Table on page 13, at a minimum pressure of 7" water column (4 oz).

After completing external supply connections, verify proper positioning of the flexible engine supply hose on the fuel pressure regulator output, as shown in Fig F. The factory default position is for natural gas (NG), requiring a change for liquefied propane vapor (LPG) operation. If the fuel hose is not in the proper position, move it to the tee branch labeled LPG, making sure the brass cap is placed securely on the opposite branch. With fuel supply attached and the flexible engine supply hose on the proper branch of the regulator output, the fuel hookup is complete. The generator is supplied with a fixed orifice tuned to provide proper fuel flow and no further adjustment of the fuel system is possible or required.

Propane Vapor (LPG)

FIG. F

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