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Home My WebLink About46485-Z OS�FfOI,�� Town of Southold o� oG• 9/19/2021 a P.O.Box 1179 53095 Main Rd Southold,New York 11971 CERTIFICATE OF OCCUPANCY No: 42363 Date: 9/19/2021 THIS CERTIFIES that the building GENERATOR Location of Property: 270 North St,Cutchogue SCTM#: 473889 Sec/Block/Lot: 102.-5-18 Subdivision: Filed Map No. Lot No. conforms substantially to the Application for Building Permit heretofore filed in this office dated 6/24/2021 pursuant to which Building Permit No. 46485 dated 6/24/2021 was issued, and conforms to all of the requirements of the applicable provisions of the law. The occupancy for which this certificate is issued is: "as built"accessorygenerator as applied for. The certificate is issued to DRD LLC of the aforesaid building. SUFFOLK COUNTY DEPARTMENT OF HEALTH APPROVAL ELECTRICAL CERTIFICATE NO. 46485 9/7/2021 PLUMBERS CERTIFICATION DATED Au o ize Si ature CTOWN OF SOUTHOLD ago I� BUILDING DEPARTMENT TOWN CLERK'S OFFICE oy • (r SOUTHOLD, NY BUILDING PERMIT (THIS PERMIT MUST BE KEPT ON THE PREMISES WITH ONE SET OF APPROVED PLANS AND SPECIFICATIONS UNTIL FULL COMPLETION OF THE WORK AUTHORIZED) Permit#: 46485 Date: 6/24/2021 Permission is hereby granted to: DRD LLC 295 Kings Point Rd East Hampton, NY 11937 To: as built" accessory generator as applied for. At premises located at: 270 North St, Cutchogue SCTM #473889 Sec/Block/Lot# 102.-5-18 Pursuant to application dated 6/24/2021 and approved by the Building Inspector. To expire on 12/24/2022. Fees: ACCESSORY $200.00 CO-ACCESSORY BUILDING $50.00 ELECTRIC $180.00 otal: $430.00 Building Inspector Town Hall Annex ® Telephone(631)765-1802 54375 Main Road Fax(631)765-9502 P.O.Box 1179 ® sean.devlina-town.southold.ny.us Southold,NY 11971-0959 ®l�QUO,� BUILDING DEPARTMENT TOWN OF SOUTHOLD CERTIFICATE OF ELECTRICAL COMPLIANCE SITE LOCATION Issued To: DRD LLC Address: 270 North St City Cutchogue st: NY zip: 11935 Building Permit#: 46485 Section: 102 Block 5 Lot: 18 WAS EXAMINED AND FOUND TO BE IN COMPLIANCE WITH THE NATIONAL ELECTRIC CODE Contractor: DBA: AS BUILT License No: SITE DETAILS Office Use Only Residential X Indoor X Basement Generator X Commerical Outdoor X 1st Floor Pool New Renovation 2nd Floor Hot Tub Addition Survey X Attic Garage INVENTORY Service 1 ph Heat Duplec Recpt Ceiling Fixtures Bath Exhaust Fan Service 3 ph Hot Water GFCI Recpt Wall Fixtures Smoke Detectors Main Panel A/C Condenser Single Recpt Recessed Fixtures CO2 Detectors Sub Panel A/C Blower Range Recpt Ceiling Fan Combo Smoke/CO Transformer UC Lights Dryer Recpt Emergency Fixtures Time Clocks Disconnect Switches 4'LED Exit Fixtures Pump Other Equipment: 16kW Generac Generator w/200A Whole House Transfer Switch Notes. AS BUILT NO VISUAL DEFECTS " Generator Inspector Signature: Date: September 7, 2021 S.Devlin-Cert Electrical Compliance Form t � Y ( •�tR.. c '�'. r ®.e t "'.�i � �' �s �E � ��`�� jr,, � � � ry. r � ,. f ,, . . � � �� , �_L� �. ., I ,,,`, "�i1 ��. DRD L.L.C. 270 North Street Cutchogue, NY 11935 Generac Guardian 16KW f 3 •r i APE Of v �,�•4 � 111!!! DRD L.L.C. 270 North Street Cutchogue, NY 11935 Generac Guardian 16KW I �tirwt�vFuct. FUE INLET NA ruRAL GAS DIESEL ;iFRIN►30o1238043 MAX FLOW NA TU TE: NIA _ MIN INLET PS BTUMR MAX INLET ESSURE: 3.5 MAX FLOW RESSURE r In W.0 RATE 12000 In W.C. LP-VAPOR __ /HR MIN INLET PRESSURE 10 MAX INLET PRESSURE 12 In W C. MAX FLOW RA TE:290000 In W C F EXBTU/HR HOSE Ci BTU/HR OM.Y DRD L.L.C. 270 North Street Cutchogue, NY 11935 Generac Guardian 16KW 3 & 3 /r OF SOUIyO� eTq TOWN OF SOUTHOLD BUILDING DEPT. cou765-1802 = INSPECTION [ ] FOUNDATION 1ST- ' [ ] ROUGH PLBG. [ ] FOUNDATION 2ND [ ] INSULATION/CAULKING [ ] FRAMING /STRAPPING [ ] FINAL [ ] FIREPLACE & CHIMNEY [ ] FIRE SAFETY INSPECTION [ ] FIRE RESISTANT CONSTRUCTION [ ] FIRE RESISTANT PENETRATION [ ] EL ECTRICAL_(ROUGH) PoELECTRICAL (FINAL) - [ ] CODE VIOLATION [ ] PRE C/O REMARKS: DATE e07 INSPECTOR Li -- -- -- _� - -- hO�aOL F SOUIyo� �9 'f 6 2,77 0 f TOWN OF SOUTHOLD BUILDING DEPT. - �`ycourm 765-1802 INSPECTION [ '] FOUNDATION 1 ST [ ] ROUGH PLBG. [ ] FOUNDATION 2ND [ ] INSUL'ATIOWCAULKING [ ] FRAMING /STRAPPING [ ] FINAL [ " ] ----FIREPLACE & CHIMNEY [ ] FIRE SAFETY INSPECTION [ ] FIRE RESISTANT CONSTRUCTION [ ] FIRE RESISTANT PENETRATION [ ] ELECTRICAL (ROUGH) `r ELECTRICAL (FINAL) [ ] CODE VIOLATION [ ] PRE C/O REMARKS: DATE ISt -INSPECTOR . FIELD INSPECTION REPORT DATE COMMENTS FOUNDATION(1ST)_ „n y ------------------------------------ C FOUNDATION(2ND) z 0 �J H C3 ® ROUGH FRAMING& � v PLUMBINGLA y 00— INSULATION PER N.Y. y STATE ENERGY CODE of �t vl I t � tb FINAL ADDITIONAL COMMENTS Jai-� � ��.►� � --� Rl � nZ m _ � b �! o 7' z I _ x •may x _ b H TOWN OF SOUTHOLD—BUILDING DEPARTMENT Town Hall Annex 54375 Main Road P. O. Box 1179 Southold,NY 11971-0959 Telephone(631) 765-1802 Fax (631) 765-9502 https://www.southoldtomDu.gov Date Received APPLICATION FOR BUILDING PERMIT V Ll For Office Use Only PERMIT NO. ✓ Building Inspector: JUN 2 2 2021 ,Applications a n-dforms must be filled'6ut in-their entirety. lhornolet6"' B77;TTN PPIPT, appkations"Wfl_l n9t'lIbe acce �ZWhe'nI?t6-Analkant is np-ttheowre r,,.an, Owner's Authorization forMg shall be completed. Date: 23rd June, 2021 PW NEjR(S),P(PR0 PERTY: . Name: DRD L.L.C. SC-rM#1000-102-005-018 Project Address: 270 North Street,-Cutchoque, N.Y. 11935 Phone#: 631 .324.8080 Email: TCHamptgns.com Mailing Address: 295 Kings Point Road, East Hampton, N.Y. 11937 �,CONTACTPERSON Name: Nigel Robert Williamson Mailing Address: P.O. Box 1758, Southold, N.Y. 11971 -Phone#: 631 .834.9740 4 Email: nigel arch itecta-hotmai Lcom z% I DESIGN PR00,ESS' lbN4 'lN0,6RM' ATl Name: Mailing Address: Phone#: Email: � CCOWR' AC' T' 011�1114"ORMA-flON: . Name: Mailing Address: Phone#: Email: bE'S'tRiPfldN4- OF PROPOSEDCONSTRUchoh" EINewStructure ElAddition DAlteration EIRepair ElDemolition Estimated Cost of Project: li]OtherAs-built Generac Guardian 16KW propane generator Will WIII the lot be re-graded? E]Yes ®No Will excess fill be removed from premises? E]Yes! rf PROPERTY INFORMATION Existing use ofproperty:Single Family Dwelling Intended use of property:Single Family Dwelling Zone or use district in which premises is situated: Are there any covenants and restrictions with respect to this property? ❑Yes®No IF YES,PROVIDE A COPY- 9 Check Box After Reading. The owner/contractor/design professional is responsible for all drainage and storm water issues as provided by Chapter 736 ofthe Town Cade.APPLICATION IS t1EREBY-MADE to the Bulling Department forthe issuance of a Building Permit pursuantto the Building Zone Ordinance ofthe Town of Southold,Suffolk,County,New York and other applicable Laws,Ordinances or Regulations,for the construction of buildings, additions,alterations or for remoiral or demolition as herein described.The applicant agrees to comply with all applicable laws,ordinances,building code, housing code and regulations andto admit authorized-inspectors on premisesand in building(s)for necessary inspections.False statements made herein are punishable as a Dass A misdemeanor pursuant to Sec$oii 210.45 of the New YorkState Penal Law. Application Submitted By(print name): Nigel Robert WilliamSOrt ®Authorized Agent ❑Owner Signature of Applicant: - Date: 1-7 V- / 2,1 STATE OF NEW YORK) SS: COUNTY OF ) Nigel Robert Williamson being duly sworn,deposes and says that(s)he is the applicant (Name of individual signing contract)above named, (S)he is the Agent (Contractor,Agent,Corporate Officer,etc.) of said owner or owners,and is duly authorized to perform or have performed the said work and to make and file this application;that allstatements contained in this application are true to the best of his/her knowledge and belief;and that the work will be performed in the manner set forth in the application file therewith. Sworn before me this q LNOTARY of �� 20 AA./(D J.JANI�UfZ1 Notary Public BLIC,STATE OF NEW YORK ration No.02JAn052585ified in Suffolk County PROPERTYOWNER AUTHORIZATIO�Expires February 13, — (Where the applicant is not the owner) l Judi Desiderio (DRD L.L.C.) 295 Kings Point Road East Hampton, residing at � P , N.Y. 11937 do hereby authorizeNigel Robert Williamson to apply on I>;fy t0 the p of Southold Bu'ding Department for approval as descri ee l� d h "rein. L � ner's Sikriature � di. ®esiderio Date Print Owner's Name 2 BUILDING DEPARTMENT- Electrical Inspector TOWN OF SOUTHOLD Town Hall Annex- 54375 Main Road - PO Box 1179 h Southold, New York 11971-0959 Telephone (631) 765-1802 - FAX (631) 765-9502 rogerr(�southoldtownny.gov — seand@southoldtownny.gov APPLICATION FOR ELECTRICAL INSPECTION ELECTRICIAN INFORMATION (All Information Required) Date: Company Name: Name:Judi Desiderio (DRD L.L.C.) License No.: email: jd@TCHamptons.com Phone No: 631.324.8080 01 request an email copy of Certificate of Compliance Address.: 270 North Street, Cutchogue, N.Y. 11935 JOB SITE INFORMATION (All Information Required) Name: Judi Desiderio (DRD L.L.C.) Address: 270 North Street, Cutchogue, N.Y. 11935 Cross Street: Route 25 Phone No.: 631.324.8080 Bldg.Permit#: q&41Eemail: jd@TCHamptons.com Tax Map District: 1000 Section: 102 Block: 005 Lot: 018 BRIEF DESCRIPTION OF WORK (Please Print Clearly) As-built Generac Guardian 16KW propane generator As-built Generac Guardian 16KW propane generator As-built Generac Guardian 16KW propane generator Check All That Apply: Is job ready for inspection?: OYES ONO ❑Rough In OFinal Do you need a Temp Certificate?: ❑YES ❑✓ NO Issued On Temp Information: (All information required) Service Size ❑1 Ph ❑3 Ph Size: A # Meters Old Meter# ❑New Service ❑ Service Reconnect ❑ Underground ❑Overhead # Underground Laterals ❑1 ❑2 ❑H Frame ❑Pole Work done on Service? ❑Y ❑N Additional Information: PAYMENT DUE WITH APPLICATION Electrical Inspection Form 2020.xlsx f , 04 « µ GUARD IAN by Generac Power Systems,Inc. APPR,O ED AS NOT D DATE: P.# FEE: - BY: NOTIFY,',,BUILDING DEPARTMENT AT Installation a 765-1802 8-AM, TO 4 PM FOR-THE FOLLOWING INSPECTIONS: 1.'FOOATION = TWO REQUIRED Owner's Manual -FOR POURED CONCRETE 2. ROUGH'- FRAMING & PLUMBING 3. INSULATION 7, 10, 13 and 16kW Air-cooled, 4. FINAL'--CONSTRUCTION MUST BE COMPLETE FOR Co. Automatic Standby Generators ALL'-.CONSTRUCTION SHALL MEET THE REQUIREMENTS CODES OF NEW Models: 005240, 005280 (6 kW NG, 7 kW LP) YORK STATE. ES ONSIBLE FOR 005241, 005281 (9 kW NG, 10 kW LP) DESIGN OR G C IUS ERRORS. 005242 005282 13 kW NG 13 kW LP LISTED 005243, 005244,,(15 kW NG, 16 kW LP) 005283, 005284 COMPLY WITH ALL CODES OF NEW,YORK STATE & TOWN CODES OCCUPANCY OR AS REQUIRED AND CON # IS UNLAWFUL `3 t6G90A D WITHOUT CERTIR'AT so STEES OF CCUPANCY N. G�CnlAN' __ ELECTRICAL PECTION REQUIRED C3 0 Q Not intended for use as Primary Power in place of utility or in 0 life-support applications. ® A- DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY! INTRODUCTION The operator is responsible for proper and safe use Thank you for purchasing this model of the Guardian of the equipment. The manufacturer strongly recom- product line by Generac Power Systems Inc. This mends that the operator read this Owner's Manual model is a compact, high performance, air-cooled, and thoroughly understand all instructions before engine-driven generator designed to automatically using this equipment. The manufacturer also strong- supply trongsupply electrical power to operate critical loads dur- ly recommends instructing other users to properly ing a utility power failure. start and operate the unit. This prepares them if they This unit is factory installed in an all-weather, metal need to operate the equipment in an emergency. enclosure that is intended exclusively for outdoor installation. This generator will operate using either CONTENTS vapor withdrawn liquid propane (LP) or natural gas This manual contains pertinent owner's information, (NG). including warranty, electrical diagrams, exploded READ THIS MANUAL THOROUGHLY views and lists of repair parts, for these different models: If any portion of this manual is not understood,contact • 05240 & 05280- 6 kW NG, 7 kW LP single-cylin- the nearest Authorized Dealer for starting, operating der GH-410 Engine and servicing procedures. • 05241 & 05281 - 9.0 kW NG, 10 kW LP V twin Throughout this publication, and on tags and decals GT-530 Engine affixed to the generator, DANGER, WARNING, • 05242 & 05282- 13 kW NG, 13 kW LP V-twin GT- CAUTION and NOTE blocks are used to alert person- 990 Engine nel to special instructions about a particular opera- • 05243, 05244, 05283&05284- 15 kW NG, 16 kW tion that may be hazardous if performed.incorrectly LP V-twin GT-990 Engine or carelessly. Observe them carefully. Their defini- tions are as follows: * OPERATION AND MAINTENANCE ® A It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe After this heading, read instructions that, if not operation is performed promptly, and to have the strictly complied with,will result in serious person- equipment checked periodically by an Authorized al injury, including death, in addition to property Dealer.Normal maintenance service and replacement damage. of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials A WARNINGA- or workmanship within the terms of the warranty. After this heading, read instructions that, if not individual operating habits and usage contribute to strictly complied with, may result in serious person- the need for maintenance service. al injury or property damage. Proper maintenance and care of the generator ensures A CAUTIONA- a minimum number of problems and keep operating expenses at a minimum. See an Authorized Dealer After this heading, read instructions that, if not for service aids and accessories. strictly complied with,could result in damage to HOW TO OBTAIN SERVICE equipment and/or property. NOTE: When the generator requires servicing or repairs, contact an Authorized Dealer for assistance. Service After this heading, read explanatory statements technicians are factory-trained and are capable of that require special emphasis. handling all service needs. These safety warnings cannot eliminate the haz- When contacting an Authorized Dealer about parts ards that they indicate. Common sense and strict and service, always supply the complete model num- compliance with the special instructions while ber and serial number of the unit as given on its data performing the service are essential to preventing decal, which is located on the generator. See section accidents. "The Generator"for decal location. Four commonly used safety symbols accompany the Model No. Serial No. DANGER, WARNING and CAUTION blocks. The type of information each indicates follows: Qj This symbol points out important safety infor- mation that, if not followed, could endanger personal safety and/or property of others. DEALER LOCATION A This symbol points out potential explosion haz- To locate the nearest AUTHORIZED ard. DEALER,please call this number: ® This symbol points out potential fire hazard. 1-800-333-1322 DEALER LOCATION INFORMATION 0 This symbol points out potential electrical shock CAN BE OBTAINED AT THIS NUMBER or visit hazard. www.guardiangenerators.com. Table of Contents TABLE Air-cooled Generators OF CONTENTS Introduction........................Inside Front Cover Section 3 - Operation....................................15 Read This Manual Thoroughly........................IFC 3.1 Using the AUTO/OFF/MANUAL Switch........15 Contents..........................................................IFC Operation and Maintenance IFC 3.2 Automatic Transfer Operation.....................16 How to Obtain Service.....................................IFC 3.3 Sequence of Automatic Operation...............16 Authorized Dealer Locator Number...................IFC 3.4 Manual Transfer Operation.........................16 SafetyRules........................................................2 3.5 Setting the Exercise Timer..........................17 3.6 Protection Systems......................................18 Standards Index..................................................3 Section 4 - Maintenance...............................19 Section 1 - General Information...................4 4.1 Fuses...........................................................19 1.1 Unpacking/Inspection....................................4 4.2 Checking the Engine Oil Level.....................19 1.2 Protection Systems........................................4 4.3 Changing the Engine Oil...............................20 1.3 NEC Requirement for Arc Fault Circuit 4.4 Changing the Engine Air Cleaner.................21 Interruption Breaker for Bedrooms..............4 4.5 Spark Plug(s) ..............................................21 1.4 The Generator...............................................5 4.6 Battery Maintenance....................................22 1.5 Specifications................................................6 4.7 Adjusting GH-410/GT-530/990 1.6 System Set LED............................................7 Valve Clearance............................................22 1.7 Fuel Requirements and Recommendations ...7 4.8 Cooling System 23 1.8 Fuel Consumption.........................................7 4.9 Attention After Submersion.........................23 1.9 Reconfiguring the Fuel System......................8 4.10 Corrosion Protection 24 1.10 Location........................................................9 4.11 Out of Service Procedure.............................24 1.11 Battery Requirements..................................10 4.12 Service Schedule25 ......................................... 1.12 Battery Installation......................................10 1.13 The Battery.................................................11 Section 5 - Troubleshooting.........................26 5.1 Troubleshooting Guide................................26 Section 2 - Post Installation Start-up and Adjustments.......................12 Section 6 - Notes............................................27 2.1 Before Initial Startup...................................12 Section 7 - Mounting Dimensions.............30 2.2 Check Transfer Switch Operation...............12 Section 8 - Electrical Data........................... 31 2.3 Electrical Checks ........................................12 Section 9 - Exploded Views and 2.4 Generator Tests Under Load.......................13 Parts Lists...................................42 2.5 Checking Automatic Operation....................13 Section 10 - Warranty...................................68 2.6 Adjusting the Fuel Regulator- 7kW(Natural Gas Only)...............................13 2.7 Engine Governor Adjustment......................14 2.8 Voltage Regulator Adjustment......................15 SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS ' Air-cooled Generators QSAVE THESE INSTRUCTIONS-The manufacturer suggests that these rules for safe operation Q be copied and posted near the unit's installation site. Safety should be stressed to all opera tors and potential operators of this equipment. 0WARNING: A GENERAL HAZARDS 0 • The engine exhaust from this product contains chemicals known to the state For safety reasons, the manufacturer recommends of California to cause cancer,birth that the installation, initial startup and main- defects or other reproductive harm. tenance of this equipment is carried out by an Authorized Dealer. 0 WARNING: Qj The engine exhaust fumes contain carbon monox- ide, which can be DEADLY. This dangerous gas, if • This product contains or emits chemicals breathed in sufficient concentrations, can cause known to the state of California to cause unconsciousness or even death. This exhaust cancer, birth defects or other reproductive harm. system must be installed properly, in strict com- pliance with applicable codes and standards. Study these SAFETY RULES carefully before install- Following installation, do nothing that might ren- ing, operating or servicing this equipment. Become der the system unsafe or in noncompliance with familiar with this Owner's Manual and with the such codes and standards. unit. The generator can operate safely, efficiently and • Keep hands, feet, clothing, etc., away from drive reliably only if it is properly installed, operated and belts, fans, and other moving or hot parts. Never maintained. Many accidents are caused by failing to remove any drive belt or fan guard while the unit follow simple and fundamental rules or precautions. is operating. The manufacturer cannot anticipate every possible • Adequate, unobstructed flow of cooling and venti- circumstance that might involve a hazard. The warn- lating air is critical to correct generator operation. ings in this manual, and on tags and decals affixed Do not alter the installation or permit even partial to the unit are, therefore, not all-inclusive. If using blockage of ventilation provisions, as this can seri- a procedure, work method or operating technique ously affect safe operation of the generator. The the manufacturer does not specifically recommend, I generator MUST be installed outdoors. ensure that it is safe for others. Also make sure the • When working on this equipment, remain alert procedure, work method or operating technique uti- at all times. Never work on the equipment when lized does not render the generator unsafe. physically or mentally fatigued. A A • Inspect the generator regularly, and contact the nearest Authorized Dealer for parts needing repair i Despite the safe design of this generator, or replacement. operating this equipment imprudently,neglecting • Before performing any maintenance on the gen- its maintenance or being careless can cause erator, disconnect its battery cables to prevent possible injury or death. Permit only responsible accidental start up. Disconnect the cable from the and capable persons to operate or maintain this battery post indicated by a NEGATIVE, NEG or equipment. (-) first, then remove the POSITIVE, POS or (+) cable. When reconnecting the cables, connect the 0 Potentially lethal voltages are generated by POSITIVE cable first, the NEGATIVE cable last. these machines. Ensure all steps are taken to • Never use the generator or any of its parts as a render the machine safe before attempting to step. Stepping on the unit can stress and break work on the generator. parts, and may result in dangerous operating con- A Parts of the generator are rotating and/or hot ditions from leaking exhaust gases, fuel leakage, during operation. Exercise care near running oil leakage, etc. generators. 2 IMPORTANT SAFETY INSTRUCTIONS SAFETY RULES Air-cooled Generators ' 'h ELECTRICAL HAZARDS • Keep a fire extinguisher near the generator at all A times. Extinguishers rated `ABC" by the National • All generators covered by this manual produce Fire Protection Association are appropriate for dangerous electrical voltages and can cause fatal use on the standby electric system. Keep the extin- electrical shock. Utility power delivers extremely guisher properly charged and be familiar with its high and dangerous voltages to the transfer switch use. Consult the local fire department with any as does the standby generator when it is in opera- questions pertaining to fire extinguishers. tion. Avoid contact with bare wires, terminals, ® EXPLOSION HAZARDS connections, etc.,while the unit is running.Ensure all appropriate covers, guards and barriers are in place, secured and/or locked before operating the Do not smoke around the generator. Wipe up any generator. If work must be done around an oper- fuel or oil spills immediately. Ensure that no com- ating unit, stand on an insulated, dry surface to bustible materials are left in the generator com- reduce shock hazard. partment, or on or near the generator, as FIRE or • e not handle any kind of electrical device while EXPLOSION may result. Keep the area surround- standing in water,while barefoot,or while hands or ing the generator clean and free from debris. feet are wet. DANGEROUS ELECTRICAL SHOCK ' Gaseous fluids such as natural gas and liquid pro- MAY RESULT. pane (LP) gas are extremely EXPLOSIVE. Install • The National Electrical Code (NEC) requires the the fuel supply system according to applicable fuel-gas codes. Before placing the home standby frame and external electrically conductive parts of electric system into service, fuel system lines must the generator to be connected to an approved earth ground. Local electrical codes also may require be properly purged and leak tested according to papplicable code. After installation, inspect the fuel roper grounding of the generator electrical system. system periodically for leaks.No leakage is permit • After installing this home standby electrical sys- ted. tem, the generator may crank and start at any time without warning. When this occurs, load cir- ♦ STANDARDS INDEX cuits are transferred to the STANDBY (generator) power source. To prevent possible injury if such a In the absence of pertinent standards, codes, regu- start and transfer occur, always set the generator's lations and laws; the published information listed AUTO/OFF/MANUAL switch to its OFF position below may be used as installation guide for this before working on equipment and remove the 15A equipment. fuse from the generator control panel. 1. NFPA No. 37, STATIONARY COMBUSTION • In case of accident caused by electric shock, imme- ENGINES AND GAS TURBINES, available from diately shut down the source of electrical power. If the National Fire Protection Association, 470 this is not possible, attempt to free the victim from Atlantic Avenue, Boston, MA 02210. the live conductor.AVOID DIRECT CONTACT WITH 2. NFPA No. 76A, ESSENTIAL ELECTRICAL THE VICTIM. Use a nonconducting implement, SYSTEMS FOR HEALTH CARE FACILITIES, such as a dry rope or board, to free the victim from available same as Item 1. the live conductor. If the victim is unconscious, 3. NFPA No. 54, NATIONAL FUEL GAS CODE, apply first aid and get immediate medical help. available same as Item 1. • Never wear jewelry when working on this equip- 4. NFPA No. 58,AMERICAN NATIONAL STANDARD ment. Jewelry can conduct electricity resulting in FOR STORAGE AND HANDLING OF LIQUEFIED electric shock, or may get caught in moving com- PETROLEUM GAS, available same as Item 1. ponents causing injury. 5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL AFIRE HAZARDS ® ELECTRIC CODE, available same as Item 1. 6. Article X, NATIONAL BUILDING CODE, available • For fire safety, the generator must be installed and from the American Insurance Association, 85 maintained properly. Installation must always John Street, New York, N.Y. 10038. comply with applicable codes, standards, laws 7. AGRICULTURAL WIRING HANDBOOK, avail- and regulations. Adhere strictly to local, state able from the Food and Energy Council, 909 and national electrical and building codes. Comply University Avenue, Columbia, MO 65201. with regulations the Occupational Safety and 8. ASAE EP-3634, INSTALLATION AND Health Administration (OSHA) has established. MAINTENANCE OFFARMSTANDBYELECTRICAL Also, ensure that the generator is installed in SYSTEMS, available from the American Society accordance with the manufacturer's instructions of Agricultural Engineers, 2950 Niles Road, St. and recommendations. Following proper installa- Joseph, MI 49085. tion, do nothing that might alter a safe installation 9, NFPA No. 30,FLAMMABLE AND COMBUSTIBLE and render the unit in noncompliance with the LIQUIDS CODE, available same as Item 1. aforementioned codes, standards, laws and regu- lations. 3 Section 1 — General Information GENERAL INFORMATION Air-cooled Generators A , A There are LED readouts on the control panel to notify personnel that one of these faults has occurred. There is also a System Set LED that is lit when all A Only qualified electricians or contractors should of the conditions described in section "System Set attempt such installations,which must comply LED" are true. (See the "Protection Systems" section strictly with applicable codes, standards and regu- for details.) lations. 1.1 UNPACKING/INSPECTION 1.3 NEC REQUIREMENT FOR ARC After unpacking, carefully inspect the contents for FAULT CIRCUIT INTERRUPTION damage. BREAKER FOR BEDROOMS • This standby generator set is ready for installa- In 2001, the National Electric Code (NEC) intro- tion with a factory supplied and pre-mounted base duced a requirement for new construction. This new pad and has a weather protective enclosure that is requirement indicates the need for Are Fault Circuit intended for outdoor installation only. Interrupters to be used to protect the complete • This UL listed standby generator set is packaged branch circuit that feeds a dwelling bedroom. The with an automatic transfer switch with built in actual NEC requirement is indicated below load center. The combination transfer switch and 1,3.1 SECTION 210.12 ARC FAULT CIRCUIT load center is pre-wired with a two foot and 30 foot conduit. Circuit breakers for emergency circuit INTERRUPTER PROTECTION connections are included (if equipped). 1. Definition: An are fault circuit interrupter is a • This UL listed, 2-pole switch is rated at 100 AC device intended to provide protection from the amperes at 250 volts maximum. This transfer effects of arc faults by recognizing characteristics switch is for indoor use only (if equipped). unique to arcing and by functioning to de-ener- AWARNING A gize the circuit when an arc fault is detected. 2. Dwelling Unit Bedrooms: All branch circuits that Alf this generator is used to power electrical load supply 125 volt, single-phase, 15 and 20 ampere circuits normally powered by a utility power outlets installed in dwelling unit bedrooms shall source, it is required by code to install a transfer be protected by an arc fault circuit interrupter switch.The transfer switch must effectively isolate listed to provide protection of the entire branch the electrical system from the utility distribution circuit. system when the generator is operating (NEC 700, Section 210.12 requires that AFCI protection be 701 &702). Failure to isolate an electrical system provided on branch circuits that supply outlets by such means will result in damage to the gen- (receptacle, lighting, etc.) in dwelling bedrooms. The erator and also may result in injury or death to requirement is limited to 15 and 20 ampere, 125 utility power workers due to backfeed of electrical volt circuits. There is no prohibition against provid- energy. ing AFCI protection on other circuits or in locations If any loss or damage is noted at time of delivery,have other than bedrooms. Because circuits are often the person(s) making the delivery note all damage shared between a bedroom and other areas such as on the freight bill or affix their signature under the closets and hallways, providing AFCI protection on consignor's memo of loss or damage. the complete circuit would comply with 210.12. If a loss or damage is noted after delivery, separate If during the installation of the home standby system the damaged materials and contact the carrier for the decision is made to provide back up power to a claim procedures. bedroom branch circuit, then the circuit breaker in "Concealed damage" is understood to mean damage the transfer switch should be replaced with an Arc to the contents of a package that is not in evidence at Fault Circuit Interrupter. the time of delivery, but is discovered later. It is most important that breakers only be switched 1 2 PROTECTION SYSTEMS like for like. For instance, if replacing a 15A breaker, it MUST be replaced with a 15A AFCI breaker. Unlike an automobile engine, the generator may have Likewise, a 20A breaker MUST be replaced with a to run for long periods of time with no operator pres- 20A AFCI. ent to monitor engine conditions. For that reason, the These AFCI breakers are available at the nearest engine is equipped with the following systems that hardware store. protect it against potentially damaging conditions: 1. Low Oil Pressure Sensor 4. Overspeed Siemens Item# Description 2. High Temperature Sensor 5. RPM Sensor Q115AF 15A Single Pole AFCI 3. Overcrank 6. Low Battery Q 120AF 20A Single Pole AFCI 4 Section 1 — General Information GENERAL Air-cooled Generators INFORMATION 1.4 THE GENERATOR Figure 1.1 -AW, Single Cylinder GH-410 Engine Figure 1.2- 10kW, V-twin GT-530 Engine Control Control Panel Data Panel Oil Data Air Filter Oil Decal Dipstick Decal Cover Dipstick Exhaust Exhaust EnclosureEnclosure Air Filter 0M Fuel Fuel Inlet Inlet oQo (Back) °O° '(Back) Fuel Fuel Regulator Regulator O O O O Composite Base Oil Filter Battery Compartment Composite Base Oil Filter Battery Compartment Figure 1.3- 13kW and 16kW, V-twin GT-990 Engine <Deca Filter Oil Dip Exhaust Enclosure Fuel Inlet (Back) Fuel Regulator O O Composite Base Oil Filter Battery Compartment 5 Section t — General Information GENERAL INFORMATION Air-cooled Generators 1.5 SPECIFICATIONS 1.5.1 GENERATOR Model 05240 &05280 05241 &05281 05242 &05282 05243&05244 05283&05284 Rated Max. Continuous 6,000 NG/7,000 LP 9,000 NG/10,000 LP 13,000 NG/13,000 LP 15,000 NG/16,000 LP Power Capacity(Watts* Rated Voltaj4c 120/240 120/240 120/240 120/240 Rated Max. Continuous Load Current(Amps) 120 Volts** 50.0 NG/58.3 LP 75.0 NG/83.3 LP 108.3 NG/108.3 LP 125 NG/133:3 LP 240 Volts 25.0 NG/29.2 LP 37.5 NG/41.7 LP 54.1 NG/54.1 LP 62.5 NG/66.6 LP Main Line Circuit Breaker 30 Amp 45 Amp 55 Amp 65 Am Circuits*** 50A, 240V - - - I 40A, 240V - - 1 1 30A, 240V 1 1 1 - 20A, 240V - 1 - 1 20A, 120V 1 3 3 5 15A, 120V 5 3 5 5 Phase 1 1 1 1 Number of Rotor Poles 2 2 2 2 Rated AC FrequencV 60 Hz 60 Hz 60 Hz 60 Hz Power Factor 1 1 1 1 Recommended Air Filter Part#OC8127 Part#OE9581 Part#OC8127 Part#OC8127 Battery Requirement Group 26 Group 26 Group 26 Group 26 12 Volts and 12 Volts and 12 Volts and 12 Volts and 350 Cold-cranking 525 Cold-cranking 525 Cold-cranking 525 Cold-cranking Amperes Minimum Amperes Minimum Amperes Minimum Amperes Minimum Battery Warming Blanket OF6148DSRV Weight Unit Only 336 Pounds—::_:[ 375 Pounds425.5 Pounds 445 &414 Pounds Enclosure Steel/Aluminum Normal Operating Range -20°F(-28.8°C) to 104°F(40°C) ' Maximum wattage and current are subject to and limited by such factors as fuel Btu content,ambient temperature,altitude,engine power and condition,etc.Maxunum power decreases about 3.5 percent for each 1,000 feet above sea level;and also will decrease about 1 percent for each W C(10°F)above 16°C(60°F)ambient temperature. " Load current values shown for 120 volts are maximum TOTAL values for two separate circuits.The maximum current in each circuit must not exceed the value stated for 240 volts. Circuits to be moved must be protected by same size breaker.For example,a 15 amp circuit in main panel must be a 15 amp circuit in transfer switch. 1.5.2 ENGINE Model 05240 &05280 05241 &05281 05242 &05282 05243&05244 05283 &05284 e of Engine GH-410 GT-530 GT-990 GT-990 Number of Cylinders 1 2 2 2 Rated Horsepower 14.5 @ 3,600 rpm 18 @ 3,600 rpm 30 @ 3,600 rpm 30 3,600 rpm Displacement 410cc 530cc 992cc 992cc Cylinder Block Aluminum w/Cast Aluminum w/Cast Aluminum w/Cast Aluminum w/Cast Iron Sleeve Iron Sleeve Iron Sleeve Iron Sleeve Valve Arrangement Overhead Valves Overhead Valves Overhead Valves Overhead Valves Ignition System Solid-state w/Magneto Solid-state w/Magneto Solid-state w/Magneto Solid-state w/Magneto Recommended Spark Plug RC14YC BPR6HS RC12YC RC12YC Spark Plug Gap 0.76 mm(0.030 inch) 0.76 mm(0.030 inch) 1.02 mm(0.040 inch) 1.02 mm(0.040 inch Compression Ratio 8.6:1 9.5:1 9.5:1 9.5:1 Starter 12 Vdc 12 Vdc 12 Vdc 12 Vdc Oil CapacitV Including Filter Approx. 1.5 Qts Approx. 1.7 Qts A rox. 1.7 Qts Approx. 1.7 Qts Recommended Oil Filter Part#070185B Part#070185B Part#070185B Part#070185B Recommended Air Filter Part#OC8127 Part#OE9581 Part#OC8127 Part#OC8127 Operating RPM 3,600 3,600 3,600 39600 6 Section 1 — General Information GENERAL Air-cooled Generators INFORMATION 1.6 SYSTEM SET LED Special considerations should be given when install- The "System Set" LED is lit when all of the following ing the unit where local conditions include flooding, conditions are true: tornados, hurricanes, earthquakes and unstable ground for the flexibility and strength of piping and 1. The AUTO/OFF/MANUAL switch is set to the their connections. AUTO position. 2. The utility voltage being supplied to the unit is all Use an approved pipe sealant or joint compound on being sensed by the PCB. If the utility sense volt- age olt threaded fitting. age is not connected to the unit or if it is below All installed gaseous fuel piping must be purged and approximately 150-160 volts AC, then the system leak tested prior to initial start-up in accordance with set light will flash rapidly. This indicates that if local codes, standards and regulations. the AUTO/OFF/ MANUAL switch is placed in the Auto position, the generator will start. 1.8 FUEL CONSUMPTION 3. No alarms are present, for example, low oil pres- Unit Nat.Gas * LP Va or ** sure, high temperature, etc. 1/2 Load Full Load 1/2 Load Full Load 6/7 kW 66 1,19 0.82/30 1.47/54 1.7 FUEL REQUIREMENTS 9/10 kW- 102 156 1.25/46 1.93/70 13/13 kW 156 _ 220 1.55/57 2.18/80 AND RECOMMENDATIONS 15/16 kW 173 245 1.59/59 2.51/92 With LP gas, use only the vapor Withdrawal sys- *Natural gas is in cubic feet per hour. tem. This type of system uses the vapors formed "LP is in gallons per hour/cubic feet per hour. above the liquid fuel in the storage tank. "'Values given are approximate. The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 1.8.1 BTU FLOW REQUIREMENTS - California Air Resources Board for tamper-proof dual NATURAL GAS fuel systems. The unit will run on natural gas or LP BTU flow required for each unit based on 1000 BTU gas, but it has been factory set to run on natural gas. per cubic foot. Should the primary fuel need to be changed to LP gas, the fuel system needs to be reconfigured. See the • 6kW— 119,000 BTU/Hour Reconfiguring the Fuel System section for instruc- • 9kW— 156,000 BTU/Hour tions on reconfiguration of the fuel system. • 13kW— 220,000 BTU/Hour Recommended fuels should have a Btu content of at • 15kW— 245,000 BTU/Hour least 1,000 Btus per cubic foot for natural gas; or at A A least 2,520 Btus per cubic foot for LP gas. Ask the fuel supplier for the Btu content of the fuel. ® Gaseous fuels such as natural gas and liquid Required fuel pressure1or natural gas is 5 inches propane(LP) gas are highly explosive. Even the to 7 inches water column (0.18 to 0.25 psi); and slightest spark can ignite such fuels and cause for liquid propane, 10 inches to 12 inches of water an explosion. No leakage of fuel is permitted. column (0.36 to 0.43 psi). Natural gas, which is lighter than air,tends to collect in high areas. LP gas is heavier than air NOTE: and tends to settle in low areas. All pipe sizing, construction and layout must com- NOTE: ply with NFPA 54 for natural gas applications and NFPA 58 for liquid propane applications. Once the A minimum of one approved manual shut-off valve generator is installed, verify that the fuel pressure must be installed in the gaseous fuel supply line. The valve must NEVER drops below four (4) inches water column easily accessible. Local codes for natural gas or 10 inches water column for liq- uid propane. Prior to installation of the generator, the installer should consult local fuel suppliers or the fire mar- shall to check codes and regulations for proper installation. Local codes will mandate correct routing of gaseous fuel line piping around gardens, shrubs and other landscaping to prevent any damage. 7 Section 1 — General Information GENERAL Air-cooled Generators INFORMATION 1.9 RECONFIGURING THE NOTE: FUEL SYSTEM Use an approved pipe sealant or joint compound on all threaded fittings to reduce the possibility 1.9.1 7 KIN, 41OCC ENGINE of leakage. To reconfigure the fuel system from NG to LP follow 9• Reverse procedure steps 1-6 to reinstall demand these steps (Figure 1.4): regulator. NOTE: 10.Take the plastic plug supplied in the poly-bag • with the generator and press it into the 3/4" hole The primary regulator for the propane supply is on the bottom of the air cleaner base (Figure NOT INCLUDED with the generator. A fuel pres- 4.6). sure of 10 to 12 inches of water column (0.36 to 11.Reverse the procedure to convert back to natural 0.43 psi) to the fuel inlet of the generator MUST gas. BE SUPPLIED. 12.Check for gas leakage at the pipe plug; hose con- t. 71zrn off the main gas supply (if connected). nection and fittings. 2. Open the roof and remove the door. ♦ 1.9.2 10. 13 AND 16KW,V TWIN ENGINES 3. Remove the battery(if installed). th reconfigure the fuel system from NG to LP, follow 4. Disconnect wire #0 and wire #14 from the gas solenoid on top of the demand regulator. these steps: NOTE: 5. Remove the carburetor fuel hose from the outlet port of the demand regulator. The primary regulator for the propane supply is 6. Remove the demand regulator by removing the NOT INCLUDED with the generator. A fuel pres- fastener that retains the regulator mounting sure of 10 to 12 inches of water column (0.36 to bracket. 0.43 psi) to the fuel inlet of the generator MUST 7. Remove the square headed steel pipe plug from BE SUPPLIED. outlet -port #1 and the brass hose barb fitting 1. Open the roof. from outlet port#2. 2. For 10kW units: Loosen clamp and slide back 8. Refit the brass hose barb fitting to outlet port#1 the air inlet hose. and the square headed steel pipe plug to outlet • Slide fuel selector on carburetor out towards the port#2. back of the enclosure (Figures 1.5 and 1.6). Figure 1.4—Demand Regulator • Return the inlet hose and tighten clamp secure- 9 9 1y. HOSE&RUG For 13 and 16kW units: remove the air cleaner SMCHEUS ES cover. FUEL HOSE` M • Slide the selector lever out towards the back of PIPE MELROSE the enclosure (Figures 1.7 and 1.8). BflAS5,I05E PLUG �HGSE • Return the air cleaner cover and tighten the two FRPNG FUTM thumb screws. OunEr ADIUSTMENf PORT 3. Close the roof. SCREW Q miff 4. Reverse the procedure to convert back to natural 0 0 O gas. 0 0 0 0 0 ° 0 0 ° 0 0 0 0 0 NG FUEL SYSTEM LP FUEL SYSTEM SUMC ■ PRESSURE TAP 0 0 RUNNING PRESSURE TAP S Section 1 — General Information Air-cooled Generators GENERAL INFORMATION Figure 1.5 - 10M,, GT-530 (inlet Hose Slid Back) Figure 1,8- 13/16kW, GT-990 (Airbox Cover Removed) ->< < Fuel Selection Lever-"Out°Position for Liquid Propane - .,A;n;;!t z4 (Vapor)Fuel Fuel Selection Lever- In Position for Natural Gas =K � '„>•� << f* tt Jh Sx'rr.n Fuel :gin q_ _01 � kn , �,•,'r' �4 ��1 "� „jri�<� <,3<`�v={;�J<tzv '�^�rt'” . � "�. ,`'1;5 ky��t��,Ni}�r t:zi' ��i>r;a''"'�;;�i°�<,oto„r',;.'S, 'i�•��,� '��ti ,� 22 1Gh Figure 1.6 - 10kW, GT-530 (Inlet Hose Slid Back) .� 1.10 LOCATION � b 1.10.1 GENERATOR Install a generator set, in its protective enclosure, Fuel Selection %3 '`` x ' sr k outdoor,., where adequate cooling and ventilating air Lever-"Out” is alwayE available (Figure 1.9). Consider these fac- Position for � .- �:r� ��R'r "'° tors: Liquid Pro anek�-_rq" t'= � , The installation of the generator must comply (Vapor)Fuel`, �;:.:r, Y strict] with NFPA 37, NFPA 54, NFPA 58, and ;fi;:°"; 3 r,`;;fir;f`•S':`,;t•':: ;' hM NFPA 70 standards. ��,„:�•f,T, � � Install the unit where� � ':.,•.%-�` �`"' . =. e air inlet and outlet open- mix � 'rs ``';,- ;`;, ings will not become obstructed by leaves, grass, Ilk" snow, Ac.. If prevailing winds will cause blowing or drff1hngl consider using a windbreak to protect the unit. Y • Install the generator on high ground where water Figure 1.7 - 13/16M, GT-990 (Airbox Cover levels"I not rise and endanger it. Removed) • Allow sufficient room on all sides of the generator for maintenance and servicing. This unit must be Fuel Selection Lever-"Ing Position for Natural Gas Fuel installd in accordance with current applicable ,, $r NFPA :37 and NFPA 70 standards; as well as any "w other ederal, state and local codes for minimum ;mow} distances from other structures. DO NOT install under wooden decks or structures. w. Install the unit where rain gutter down spouts, roof fun-off, landscape irrigation,water sprinklers or sump pump discharge does not flood the unit or spray the enclosure, including any air inlet or outlet openings. t y Install the unit where services �, .; ;.{��.,``"�" �• �� will not be affected or obstructed, including concealed, underground or covered services such as electrical, fuel, phone, air conditioning or irrigation. Where strong prevailing winds blow from one direction, face the generator air inlet openings to " the prevailing winds. 9 Section 1 — General Information GENERAL INFORMATION Air-cooled Generators • Install the generator as close as possible to the fuel • Install the transfer switch indoors on a firm, sturdy supply, to reduce the length of piping. supporting structure. • Install the generator as close as possible to the • To prevent switch distortion, level the switch if transfer switch. REMEMBER THAT LAWS OR necessary. This can be done by placing washers CODES MAY REGULATE THE DISTANCE AND between the switch enclosure and mounting sur- LOCATION. face. • The genset must be installed on a level surface. • Never install the switch where water or any corro- The base frame must be level within two (2)inches sive substance might drip onto the enclosure. all around. • Protect the switch at all times against excessive • The generator is typically placed on pea gravel or moisture, dust, dirt, lint, construction grit and crushed stone.Check local codes if a concrete slab corrosive vapors. is required. If a concrete base slab is required, all A WARNING A federal, state and local codes should be followed. Special attention should be given to the concrete A If the AUTO/OFF/MANUAL switch is not set to its base, slab which should exceed the length and OFF position,the generator can crank and start width of the generator by a minimum of six (6) as soon as the battery cables are connected. If inches (0.152 meters) on all sides. the utility.power supply is not turned off, spark- Figure 9.9— Generator Clearances ing can occur at the battery posts and cause an explosion. ® � 1.11 BATTERY REQUIREMENTS I �u1 See the Specifications section for correct battery size and rating. g ® 1.12 BATTERY INSTALLATION Fill the battery with the proper electrolyte fluid if necessary and have the battery fully charged before installing it. Before installing and connecting the battery, complete the following steps: 1. Set the generator's AUTO/OFF/MANUAL switch to OFF. 2. 'ffirn off utility power supply to the transfer ® WARNING A switch. 3. Remove the 15A fuse from the generator control Q The engine exhaust fumes contain carbon mon- panel. oxide,which can be DEADLY.This dangerous Battery cables were factory connected at the genera- gas, if breathed in sufficient concentrations, for (Figure 1.10). Connect-cables to battery posts as can cause unconsciousness or even death.This follows: exhaust system must be installed properly, in 4. Connect the red battery cable (from starter con- strict compliance with applicable codes and stan- tactor) to the battery post indicated by a positive, dards. Following installation, do nothing that POS or M. might render the system unsafe or in noncompli- ance with such codes and standards. 5. Connect the black battery cable (from frame • Operate the generator outdoors ONLY. ground) to the battery post indicated by a nega- • Keep exhaust gases from entering a confined area tive, NEG or (—). through windows, doors,ventilation or other NOTE: openings(Figure 1.9). Dielectric grease should be used on battery posts 1.10.2 TRANSFER SWITCH to aid in the prevention of corrosion. NOTE: 1.10.2.1 7, 10, 13, and 16 kW Units (if equipped) Damage will result if battery connections are made The transfer switch shipped with this generator is in reverse. enclosed in a NEMA 1 enclosure. This type of enclo- sure is intended for indoor use only. Follow these rules: 10 Section 1 — General Information Air-cooled Generators GENERAL INFORMATION Figure 1.10-Battery Cable Connections A WARNING BLACK LEAD Qj Do not open or mutilate the battery. Released (FROM FRAME) electrolyte has been known to be harmful to the skin and eyes, and to be toxic. RED LEAD Q The electrolyte is a dilute sulfuric acid that is x (FROM STARTER harmful to the skin and eyes. It is electrically CONTACTOR) conductive and corrosive. RED The following procedures are to be observed: + • Wear full eye protection and protective clothing; + • Where electrolyte contacts the skin,wash it off BATTERY immediately with water; • Where electrolyte contacts the eyes,flush thor- oughly and immediately with water and seek BLACK medical attention; and • Spilled electrolyte is to be washed down with an acid neutralizing agent.A common practice is to NOTE: use a solution of 1 pound (500 grams) bicarbonate In areas where temperatures regularly fall below of soda to 1 gallon (4 liters) of water.The bicar- 10° F (-12° C) it is recommended that a pad type bonate of soda solution is to be added until the battery heater be installed to aid in cold climate evidence of reaction (foaming) has ceased.The resulting liquid is to be flushed with water and the starting (see Specifications). area dried. NOTE: A Lead-acid batteries present a risk of fire because The generator is equipped with a battery trickle they generate hydrogen gas.The following charger that is active when the unit is set up for procedures are to be followed: automatic operation. With the battery installed • DO NOT SMOKE when near the battery; and utility power source voltage available to the • DO NOT cause flame or spark in battery area; and transfer switch, the battery receives a trickle • Discharge static electricity from body before touch- charge while the engine is not running, to prevent ing the battery by first touching a grounded metal self-discharge. The trickle charger is designed to surface. help extend the life of the battery by maintain- Qj Be sure the AUTO/OFF/MANUAL switch is set to ing the battery when the unit is not running. The the OFF position before connecting the battery trickle charge feature cannot be used to recharge cables. If the switch is set to AUTO or MANUAL, a discharged battery. the generator can crank and start as soon as the battery cables are connected. 1.13 THE BATTERY A Be sure the utility power supply is turned off A A and the 15A fuse is removed from the generator control panel, or sparking may occur at the bat- ® Do not dispose of the battery in a fire. The tery posts as the cables are attached and cause battery is capable of exploding. an explosion. A battery presents a risk of electrical shock Servicing of the battery is to be performed or super- and high short circuit current.The following pre- vised by personnel knowledgeable of batteries and cautions are to be observed when working on the required precautions. Keep unauthorized person- batteries: nel away from batteries. • Remove the 15A fuse from the generator control See the Specifications section for the correct size panel. and rating when replacing the battery. When using a • Remove watches, rings or other metal objects; maintenance-free battery, it is not necessary to check • Use tools with insulated handles; the specific gravity or electrolyte level. Have these • Wear rubber gloves and boots; procedures performed at the intervals specified in • Do not lay tools or metal parts on top of the the "Service Schedule." A negative ground system is battery; and used. Battery connections are shown on the wiring • Disconnect charging source prior to connecting or diagrams. Make sure the battery is correctly connect- disconnecting battery terminals. ed and terminals are tight. Observe battery polarity when connecting the battery to the generator set. 1'I POST C:�� Section 2 — Post Installation Start-up and Adjustments INSTALLATION Air-cooled Generators STARTUP ADJUSTMENTS 2.1 BEFORE INITIAL START-UP A , NOTE: These units have been run and tested at the fac- 0 The transfer switch is now electrically"hot." tory prior to being shipped and do not require any Contact with "hot" parts will result in extremely type of break-in. hazardous and possibly fatal electrical shock. Proceed with caution. Before starting, complete the following: 5. Use an accurate AC voltmeter to check utility 1. Set the generator's main circuit breaker to its power source voltage across transfer switch ter- OFF (or OPEN) position. minals N1 and N2. Nominal line-to-line voltage 2. Set the generator's AUTO/OFF/MANUAL switch to should be 240 volts AC. the OFF position. 6. Check utility power source voltage across termi- 3. Turn OFF all breakers on the load center of the nals N1 and the.transfer switch neutral lug; then transfer box(T1 and T2). across terminal N2 and neutral. Nominal line-to- 4. Turn OFF all loads connected to the transfer neutral voltage should be 120 volts AC. switch terminals TI and T2. 7. When certain that utility supply voltage is compat- 5. Check the engine crankcase oil level and,if neces- ible with transfer switch and load circuit ratings, sary, fill to the dipstick FULL mark with the rec- turn OFF the utility power supply to the transfer ommended oil. Do not fill above the FULL mark. switch. 6. Check the fuel supply. Gaseous fuel lines must 8• On the generator panel, set the AUTO/OFF/ have been properly purged and leak tested in MANUAL switch to MANUAL. The engine should accordance with applicable fuel-gas codes. All crank and start. fuel shutoff valves in the fuel supply lines must 9• Let the engine warm up for about five minutes to be open. allow internal temperatures to stabilize.Then,set the generator's main circuit breaker to its ON (or A CAUTIONA— CLOSED) position. 0 Never operate the engine with the oil level A A below the"Add" mark on the dipstick. Doing 0 this could damage the engine. Proceed with caution! Generator power voltage Is now supplied to the transfer switch. Contact 2 2 CHECK TRANSFER SWITCH with live transfer switch parts will result in dan- gerous and possibly fatal electrical shock. OPERATION 10. Connect an accurate AC voltmeter and a frequen- Refer to the "Manual Transfer Operation" section, of cy meter across transfer switch terminal lugs E1 the owner's manual for procedures. and E2. 7kW voltage should be 242-252 volts at a frequency of 61-63 Hertz. 10, 13, and 16kW A . A voltage should be 247-249 volts at a frequency of 57.5-59.5 Hertz. ADO not attempt manual transfer switch opera- 11. Connect the AC voltmeter test leads across ter- tion until all power voltage supplies to the minal lugs E1 and neutral; then across E2 and transfer switch have been positively turned off. neutral. In both cases, voltage reading should be Failure to turn off all power voltage supplies 121-126 volts AC (7M, and 125-126 volts AC will result in extremely hazardous and possibly (10, 13 and 16kW). fatal electrical shock. 12.Set the generator's main circuit breaker to its OFF(or OPEN)position. Let the engine run at no- 2.3 ELECTRICAL CHECKS load for a few minutes to stabilize internal engine generator temperatures. Complete electrical checks as follows: 13. Set the generator's AUTO/OFF/MANUAL switch to 1. Set the generator's main circuit breaker to its OFF. The engine should shut down. OFF (or OPEN) position. NOTE: 2. Set the generator's AUTO/OFF/MANUAL switch to It is important not to proceed until certain that the OFF position. generator AC voltage and frequency are correct 3. Mirn OFF all breakers on the load center of the and within the stated limits. Generally, if both AC transfer box (T1 and T2). frequency and voltage are high or low, the engine 4. Thin on the utility power supply to the transfer governor requires adjustment* (*GH410 only). If switch using the means provided(such as a utility frequency is correct, but voltage is high or low, the main line circuit breaker). generator's voltage regulator requires adjustment. 12 Section 2 — Post Installation Start-up and Adjustments POST G� Air-cooled Generators INSTALLATION START-UP ADJUSTMENTS 2.4 GENERATOR TESTS UNDER LOAD 2.5 CHECKING AUTOMATIC To test the generator set with electrical loads applied, OPERATION proceed as follows: To check the system for proper automatic operation, 1. Set generator's main circuit breaker to its OFF proceed as follows: (or OPEN) position. 2. Tun OFF all breakers on the load center of the 1. Set generator's main circuit breaker to its OFF transfer box (T1 and T2). (or OPEN) position. 2 3. Set the generator's AUTO/OFF/MANUAL switch to . Check that the AUTO/OFF/MANUAL switch is set OFF. to OFF. 4. Turn OFF the utility power supply to the transfer 3. Turn OFF the utility power supply to the transfer switch, using the means provided (such as a util- switch, using means provided (such as a utility main line circuit breaker). ity main line circuit breaker). 4. Manually set the transfer switch to the UTILITY AWARNING A position,i.e.,load terminals connected to the util- ity power source side. 0 Do not attempt manual transfer switch opera- 5. Turn ON the utility power supply to the transfer tion until all power voltage supplies to the switch, using the means provided (such as a util- transfer switch have been positively turned off. ity main line circuit breaker). Failure to turn off all power voltage supplies 6. Set the generator's main circuit breaker to its ON will result in extremely hazardous and possibly (or CLOSED)) position. fatal electrical shock. 7. Set the AUTO/OFF/MANUAL switch to AUTO. The 5. Manually set the transfer switch to the STANDBY system is now ready for automatic operation. position, i.e., load terminals connected to the 8. Turn OFF the utility power supply to the transfer generator's El/E2 terminals. The transfer switch switch. operating lever should be down. With the AUTO/OFF/MANUAL switch at AUTO, the 6. Set the generator's AUTO/OFF/MANUAL switch engine should crank and start when the utility source to MANUAL. The engine should crank and start power is turned OFF after a 10 second delay. After immediately. starting, the transfer switch should connect load cir- 7. Let the engine stabilize and warm up for a few cuits to the standby side after a 15 second delay. Let minutes. the system go through its entire automatic sequence 8. Set the generator's main circuit breaker to its ON of operation. (or closed) position. Loads are now powered by With the generator running and loads powered by the standby generator. generator AC output,turn ON the utility power supply 9. Turn ON the load center of the transfer switch to the transfer switch. The following should occur: (T1 and T2). 10. Connect an accurate AC voltmeter and a frequen- • After about 15 seconds, the switch should transfer cy meter across terminal lugs E1 and E2. loads back to the utility power source. • 7kW voltage should be greater than 230 volts and • About one minute after retransfer, the engine frequency should be greater than 58 Hz. should shut down. • 10, 13 & 1,6kW voltage should be greater than 240 volts and frequency should be greater than 2.6 ADJUSTING THE FUEL REGULATOR 60 Hz. - 7KW (NATURAL GAS ONLY) 11.Let the generator run at full rated load for 20-30 NOTE: minutes. Listen for unusual noises, vibration or other indications of abnormal operation. Check All V twin engine units DO NOT require a fuel reg- for oil leaks, evidence of overheating, etc. ulator adjustment due to the fuel system design. 12.When testing under load is complete, turn OFF Although the-generator has been factory set to pro- electrical loads. vide maximum power, it may be necessary in some 13. Set the generator's main circuit breaker to its areas to adjust this setting. If experiencing engine OFF (or OPEN) position. problems at high or full load conditions, follow these 14. Let the engine run at no-load for a few minutes. steps. It will require a frequency meter to perform 15. Set the AUTO/OFF/MANUAL switch to OFF. The this procedure. engine should shut down. 13 POST Section 2 — Post Installation Start-up and Adjustments INSTALLATION Air-cooled Generators STARTUP ADJUSTMENTS 1. Turn off utility power to the main distribution panel in the house. This can be done by switching A WARNING A the service main breaker to the off or open posi- tion. 0 Do not make any unnecessary adjustments. 2. Allow the generator to start. Before loading the Factory settings are correct for most applica- generator, confirm that the No Load Frequency, tions. However,when making adjustments, be with the roof open and door off, is set to 63-63.5 careful to avoid overspeeding the engine. Hz. Transfer load to emergency circuits. If this procedure or the test equipment is not avail- 3. Turn on appliances, lights, pumps, etc., that are able, locate the nearest Dealer and they can perform on the emergency circuits in an attempt to fully the adjustments. load the generator. Be cautious not to overload NOTE: the generator. Use the following chart as a guide: A service fee may be charged for this adjustment. Unit 120 Volts 240 Volts 7 kW 50.0 amps 25.0 amps 2,7 ENGINE GOVERNOR ADJUSTMENT If both AC frequency and voltage are correspondingly 4. When 3/4 load has been achieved. Connect a fre- high or low, adjust the engine governor as follows: quency meter to the output lugs of the generator's main line circuit breaker. A 2.7.1 7 KIN UNITS 5. The fuel regulator is fitted with one adjustment screw.While watching the frequency meter,slowly A WARNING A turn the adjustment screw clockwise or counter- clockwise until the highest frequency is read on Qj The engine must be OFF to perform steps 1 and the meter. Only limited adjustment is available 2. because of the set pin. Under no circumstances 1. Loosen the governor clamp bolt (Figures 2.2). should any of the pins be removed (Figure 2.1): 2. Hold the governor lever at its wide open throttle Figure 2.1 —AIN Fuel Regulator position (clockwise), and rotate the governor shaft clockwise as far as it will go. Then, tighten the governor lever'clamp bolt to 70 inch-pounds 410cc Engine (8 N-m). 3. Start the generator; let it stabilize and warm up at no-load. Figure 2.2—Engine Governor Adjustment O Single Cylinder Engines Adjustment SECONDARY Screw Set ADJUST SCREW (One Side 0 Pin Only) GOVERNOR SHAFT GOVERNOR ® 1 CLAMP/ PRIMARY 6. When the highest frequency is reached maximum BOLT SCREW power has been set. From this point turn the adjustment screw 1/4 turn counterclockwise.The regulator is now set. 7. Turn utility power to the main distribution panel back on. This can be done by switching the ser- vice main breaker to the on or closed position. I C) U Allow the generator to shut down. 14 Section 3 — Operation OPERATION Air-cooled Generators 4. Connect a frequency meter across the generators NOTE: AC output leads. The access panel on top of the control panel must 5. Turn the primary adjust screw to obtain a fre- be removed to adjust the voltage regulator. quency reading of 61.5 Hertz.Turn the secondary adjust screw to obtain a frequency of-62.5 Hz. NOTE: 6. When frequency is correct at no load, check the The voltage regulator is housed above the gen- AC voltage reading.If voltage is incorrect,the volt- erator's control panel. The regulator maintains a age regulator may require adjustment (See the voltage in direct proportion to frequency at a 2-to- Voltage Regulator Adjustment section). 1 ratio. For example, at 62 Hertz, line-to-neutral voltage will be 124 volts. ♦ 2.7.2 13 KW AND 16 KW UNITS NOTE: 3.1 USING THE AUTO/OFF/MANUAL All V twin units DO NOT require an engine gover- SWITCH (FIGURE 3.1) nor adjustment due to their design. ♦ 3.1.1 "AUTO" POSITION ♦ 2.7.3 ADDITIONAL CORROSION Selecting this switch position activates fully automatic PROTECTION system operation. It also allows the unit to automati- Periodically spray all engine linkage parts and brack- cally start and exercise the engine every seven days ets with corrosion inhibiting spray such as WD-40 or with the setting of the exercise timer (see the Setting a comparable product. the Exercise Timer section). 2.8 VOLTAGE REGULATOR ♦ 3.1.2 "OFF" POSITION ADJUSTMENT This switch position shuts down the engine. This position also prevents automatic operation. ♦ 2.8.1 7KW UNITS Figure 3.1 - Generator Control Panel With the frequency between 62-63 Hertz at no-load, slowly turn the slotted potentiometer (Figure 2.3) CONTROLAND INFORMATION CENTER until line voltage reads 248-252 volts. SYSTEM SET ♦ LOW BATTERY 2.8.2 10. 13.AND 16KW UNITS AUTO. OFF MAN. -LOWOIL OIL HIGHTEMP With the frequency between 58-59 Hertz at no-load SYSTEM FUSE OVER SPEED , O El NO RPM SENSE IF FLASHING slowly turn the slotted potentiometer (Figure 2.3) OVER CRANK until line voltage reads 247-249 volts. SET 0000,1k , ISA D(ERCISE TIME Figure 2.3— Voltage Adjustment Potentiometer ♦ 3.1.3 "MANUAL" POSITION ® ® Set the switch to MANUAL to crank and start the __ engine. Transfer to standby power will not occur r ® unless there is a utility failure. L--- -_ A WARNING A Turn to A With the switch set to AUTO,the engine may O O crank and start at any time without warning. adjust voltage. Such automatic starting normally occurs when utility power source voltage drops below a pre- set level or during the normal exercise cycle.To El O prevent possible injury that might be caused by such sudden starts, always set the switch to OFF and remove the fuses before working on or ® ® around the generator or transfer switch.Then, place a "DO NOT OPERATE"tag on the genera- tor panel and on the transfer switch. 15 OPERATION Section 3 — Operation Q-- Air-cooled Generators ♦ 3.1.4 CHOKE OPERATION A. Utility Voltage Dropout Sensor 1. 990 engines have an electric choke in the air box • This sensor monitors utility source voltage. that is automatically controlled by the electronic • If utility source voltage drops below about 65 control board. percent of the nominal supply voltage, the sensor 2. 530 engines have an electric choke on the divider energizes a 10 second timer. panel air inlet hose that is automatically con- • Once the timer has expired, the engine will crank trolled by the electronic control board. and start if utility is still low. 3. 410 engines do not have a choke. B. Engine Warm-up Time Delay • This mechanism lets the engine warm up for 3.2 AUTOMATIC TRANSFER about five (5) seconds before the load is trans- ferred to the standby source. OPERATION C. Standby Voltage Sensor To select automatic operation, do the following: • This sensor monitors generator AC output volt- 1. olt1. Make sure the transfer switch main contacts are age. When the voltage has reached 50 percent of set to their UTILITY position, i.e., loads con- the nominal rated voltage, transfer to standby nected to the utility power source (Figure 3.2). - can occur. 2. Be sure that normal UTILITY power source volt D. Utility Voltage Pickup Sensor age is available to transfer switch terminal lugs • This sensor monitors utility power supply volt- N1 and N2 (Refer to the Electrical Data section). age. When that voltage is restored above 75 per- 3. Set theenerator's AUTO/OFF/MANUAL switch to cent of the nominal source voltage, a retransfer g time delay starts timing. AUTO. E. Retransfer Time Delay 4. Set the generator's main circuit breaker to its ON • This timer runs for about 15 seconds. (or CLOSED) position. • At end of a 15-second delay, circuit board action With the preceding steps complete, the generator will de-energizes transfer relay in the transfer switch start automatically when utility source voltage drops if utility is still present. below a preset level. After the unit starts, loads are • Retransfer to utility power source then occurs. transferred to the standby power source. Refer to the Sequence of Automatic Operation section. F. Engine Cool-down Timer • When the load is transferred back to utility power source, the engine cool-down timer starts tim- 3.3 SEQUENCE OF AUTOMATIC ing. • The timer will run for about one minute, and the OPERATION generator will then shut down. The generator's control panel houses a control logic circuit board. This board constantly monitors util- 3.4 MANUAL TRANSFER OPERATION ity power source voltage. Should that voltage drop below a preset level, circuit board action will signal ♦ 3.4.1 TRANSFER TO GENERATOR the engine to crank and start.After the engine starts, POWER SOURCE the circuit board signals the transfer switch to acti- vate and connect load circuits to the standby power To start the generator and activate the transfer switch supply(load terminal lugs T1/T2 connect to terminal manually, proceed as follows: lugs E1/E2). Refer to the Electrical Data section. 1. Set the generator's AUTO/OFF/MANUAL switch to The generator must run at 50 Hz or greater for the OFF. transfer output to be activated. Once activated, it will 2. Set the generator's main circuit breaker to its remain active even if the frequency dips below 50 OFF (or OPEN) position. Hz. 3. Turn OFF the utility power supply to the transfer Upon restoration of utility source voltage above a switch using the means provided(such as a utility preset level,generator circuit board action signals the main line circuit breaker). transfer switch to transfer loads back to that power A supply.After retransfer,the engine is signalled to shut A1971,"[114:1 down. The actual sequence of operation is controlled by Q Do not attempt to activate the transfer switch manually until all power voltage supplies to the sensors and timers on a control logic circuit board, as follows: switch have been positively turned off. Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal elec- trical shock. 16 Section 3 — Operation OPERATION Air-cooled Generators :CE 4. Use the manual transfer handle inside the trans- 5. Use the manual transfer handle inside the trans- fer switch to move the main contacts to their fer switch to move the main contacts back to their STANDBY position, i.e., loads connected to the UTILITY position,i.e.,loads connected to the util- standby power source (Figure 3.2). ity power source (Figure 3.2). 5. To crank and start the engine, set the AUTO/OFF/ 6. nU-n ON the utility power supply to the transfer MANUAL switch to MANUAL. switch using the means provided. 6. Let the engine stabilize and warm up for a few 7. Set the system to automatic operation as outlined minutes. in Automatic Transfer Operation section. 7. Set the generator's main circuit breaker to its ON (or CLOSED)position.The standby power source 3.5 SETTING THE EXERCISE TIMER now powers the loads. This generator is equipped with an exercise timer. Figure 3.2—Manual Transfer Switch Operation Once it is set, the generator will start and exercise 9 P once every seven days, on the day of the week and at the time of day the following sequence is completed. During this exercise period, the unit runs for approx- imately, 12 minutes and then shuts down.Transfer of LOAD CONNECTED TO UTILITY POWER SOURCE loads to the generator output does not occur during LOAD CONNECTED TO STANDBY POWER SOURCE the exercise cycle unless utility power is lost. A switch on the control panel (see Figure 3.1) per- 0 o mits selection of the day and time for the system to exercise. At the chosen time, perform the following \ sequence to select the desired day and time of day MANUAL TRANSFER the system will exercise. Remember seasonal time ® HANDLE changes affect the exercise time settings. 1. Verify that the AUTO/OFF/MANUAL switch is set TRANSFER SWITCH to AUTO. OPERATING LEVER 2. Press and hold the"Set Exercise Time"switch for 0 o several seconds, then release. All the red LED's will flash for approximately 10 seconds and then stop. 3. Once the red LED's stop flashing, the generator will start and run for approximately 12 minutes ♦ 3.4.2 TRANSFER BACK TO UTILITY POWER and then shut down. The exerciser is now set to SOURCE run at this time of day each week. Example: If the "Set Exercise Time" switch is When utility power has been restored, transfer back pressed on Saturday afternoon at 2:00 p.m., the to that source and shut-down the generator. This can generator will start and exercise for approximate- be accomplished as follows: ly 12 minutes every Saturday at 2:00 p.m.. 1. Set the generator's main circuit breaker to its NOTE: OFF (or OPEN) position. The exerciser will only work in the AUTO mode 2. Let the engine run for a minute or two at no-load and will not work unless this procedure is per- to stabilize the internal temperatures. formed. The exerciser will need to be reset every 3. Set the generator's AUTO/OFF/MANUAL switch to time the 12-volt battery is disconnected and then its OFF (or OPEN) position. The engine should reconnected, and when the 15A fuse is removed. shut down. The 16kW unit has a low speed exercise option. Dip 4. Check that utility power supply to the transfer switch 1 on the control board is factory set to OFF. switch is turned OFF. This allows the engine to run at a slower speed dur- A , A ing weekly exercise periods for quieter operation. If this Dip switch is set to ON, the generator will exer- t Do not attempt to activate the transfer switch cise at it's normal speed. manually until all power voltage supplies This DIP switch position is only read at board power to the switch have been positively turned off. up. If the DIP switch position is changed, power to Failure to turn off all power voltage supplies the board must be cycled for the micro controller to may result in extremely hazardous and possibly recognize the new DIP switch position. fatal electrical shock. 17 OPERATION Section 3 — Operation Air-cooled Generators Low speed exercise will be handled as follows: ♦ 3.6.3 OVERCRANK 1. The standard start sequence will be initiated. This feature prevents the generator from damaging 2. The unit will run at 2,400 RPM. itself when it continually attempts to start and anoth- 3. If utility is lost during exercise, the controller will er problem, such as no fuel supply, prevents it from do the following: starting. The unit will crank and rest for a preset • Wait 10 seconds for utility to return. time limit. Then, it will stop cranking, and the LED • If utility returns within 10 seconds, continue to on the generator control panel will light indicating an exercise at 2,400 RPM. overcrank failure. The AUTO/OFF/MANUAL switch • If utility is still lost after 10 seconds, run the will need to be set to OFF and then back to AUTO to engine up to 3600 RPM and transfer the load. reset the generator control board. At this time the controller will exit the exercise NOTE: routine and,assume full automatic operation. If the fault is not repaired, the overcrank feature 3.6 PROTECTION SYSTEMS will continue to activate. ♦ 3.6.1 LOW OIL PRESSURE SWITCH 3.7.3.1 Approximate Crank Cycle Times 7kW Units: This switch (Figure 3.3) has normally closed con- . 15 seconds ON tacts that are held open by engine oil pressure dur- . 7 seconds OFF ing cranking and operating. Should oil pressure drop below the 8 psi range, switch contacts close, • 7 seconds ON and the engine shuts down. The unit should not be • 7 seconds OFF restarted until oil is added. The AUTO/OFF/MANUAL • 7 seconds ON switch must then be turned to OFF and then back to • 7 seconds OFF AUTO. • 7 seconds ON • 7 seconds OFF ♦ 3.6.2 HIGH TEMPERATURE SWITCH • 7 seconds ON This switchs contacts (Figure 3.3) close if the tem- • 7 seconds OFF perature should exceed approximately 144° C (2930 • 7 seconds ON F), initiating an engine shutdown. The generator will If the unit fails to start, the overcrank alarm LED will automatically restart and the LED on the generator be illuminated. control panel will reset once the temperature has IOkW, 13kW and 16kW Units: returned to a safe operating level. • 16 seconds ON Figure 3.3—Low Oil Pressure and • 7 seconds OFF High Temperature Switches • 16 seconds ON • 7 seconds OFF Low Oil Switch High Temp Switch • 7 seconds ON • 7 seconds OFF • 7 seconds ON • 7 seconds OFF • 7 seconds ON 0 • 7 seconds OFF If the unit fails to start, the overcrank alarm LED will be illuminated. a-—Lour P7 Oil Filter ♦ 3.6.4 OVERSPEED This feature protects the generator from damage by Oil shutting it down if it happens to run faster than the Drain preset limit. This protection also prevents the gen- Hose erator from supplying an output that could poten- tially damage appliances connected to the generator circuit. Contact the nearest Authorized Dealer if this failure occurs. 18 Section 4 — Maintenance Air-cooled Generators MAINTENANCE ♦ 3.6.5 RPM SENSOR FAILURE 4.2 CHECKING THE ENGINE During cranking, if the board does not see a valid OIL LEVEL RPM signal within three (3) seconds, it will shut For oil capacities, see the Specifications section. down and latch out on RPM sensor loss. For engine oil recommendations, see the Engine Oil During running, if the RPM signal is lost for one full Recommendations section. To check the engine oil second the board will shut down the engine, wait 15 level, proceed as follows (Figures 4.2, 4:3 and 4.4): seconds, then re-crank the engine. 1. Move the AUTO/OFF/MANUAL switch to the OFF • If an RPM signal is not detected within the first position. three (3) seconds of cranking, the control board 2. Remove the dipstick and wipe it dry with a clean will shut the engine down and latch out on RPM cloth. sensor loss. 3. Completely insert the dipstick; then, remove it • If the RPM signal is detected the engine will start again.The oil level should be at the dipstick"Full' and run normally. If the RPM signal is subsequent mark. If necessary, add oil to the "Rill' mark ly lost again, the control board will try one more only. DO NOT FILL ABOVE THE "FULIT MARK. re-crank attempt before latching out and flashing the overspeed LED. A CAUTION A. ♦_3.6.6 LOW BATTERY 0 Never operate the engine with the oil level The microprocessor will continually monitor the below the"Add" mark on the dipstick. Doing battery voltage and turn on the Low Battery LED if this could damage the engine. the battery voltage falls below 11.0 volts for one (1) 4. Install the dipstick. minute. No other action is taken on a low battery 5. Reset the AUTO/OFF/MANUAL switch to its origi- condition.Low battery voltage is a non-latching alarm nal position. which will automatically clear if the battery voltage rises above 11.0 volts. Battery voltage is NOT moni- Figure 4,2—Oil Dipstick and Fill, 7kW tored during the crank cycle. 4.1 FUSES Oil Dipstick and Fill The 15-amp fuse on the generator panel protects the DC control circuit against overload (Figure 4.1). This fuse is wired in series with the battery output lead O to the panel. If this fuse element has melted open, o the engine will not be able to crank or start. Replace this fuse using only an identical 15-amp replacement fuse. To replace the fuse, push the fuse holder cap down and rotate it counterclockwise. Whenever the fuse is removed or replaced, the exercise timer needs to be reset. 0 Figure 4.1 — Generator Control Panel ®I CONTROL AND INFORMATION CENTER SYSTEM SET LOW BATTERY AUTO OFF MAN LOW OIL HIGHTEMP SYSTEM FUSE OVER SPEED O F-1 ��OVER CRANK IF FLASHING 15A SET 00 murrses� EXERCISE TIME 19 Section 4 — Maintenance MAINTENANCE Air-cooled Generators Figure 4.3— Oil Dipstick and Fill, 10kW ♦ 4.3.3 OIL & OIL FILTER CHANGE PROCEDURE To change the oil, proceed as follows: Oil Dipstick 1. Start the engine by moving the AUTO/OFF/ MANUAL switch to MANUAL and run until it ° is thoroughly warmed up. Then shut OFF the engine by moving the switch to the OFF position. 2. Immediately after the engine shuts OFF, pull the oil drain hose (Figure 4.5) free of its retaining O HO clip. Remove the cap from the hose and drain the OD - oil into a suitable container. 3. After the oil has drained, replace the cap onto the end of the oil drain hose. Retain the hose in the clip. Oil Fill Figure 4.5- Oil Drain Hose and Filter o` Low Oil Switch High Temp Switch Figure 4.4— Oil Dipstick and Fill, 13kW and 16kW 0 Oil Dipstick d Oil Filter - Oil Fill I Oil Drain ® / Hose I� Change the engine oil filter as follows: 1. With the oil drained, remove the old oil filter by turning it counterclockwise. 2. Apply a light coating of clean engine oil to the gas- ket of the new filter.See the Specifications section 4.3 CHANGING THE ENGINE OIL for recommended filter. 3. Screw the new filter on by hand until its gasket ♦ 4.3.1 OIL CHANGE INTERVALS lightly contacts the oil filter adapter.Then, tighten See the "Service Schedule" section. the filter an additional 3/4 to one turn (Figure 4.4). 4. Refill with the proper recommended oil (see the ♦ 4.3.2 ENGINE OIL RECOMMENDATIONS Engine oil Recommendations section). See the Use all season SAE 5W-30 synthetic oil or use SAE Specifications section for oil capacities. 30 oil of American Petroleum Institute (API) Service 5. Start the engine, run for one (1) minute, and Class SG, SH, SJ or SL. check for leaks. 6. Shutdown and recheck oil level, add as needed. A CAUTION A DO NOT OVER FILL. I Any attempt to crank or start the engine before 7• Reset the AUTO/OFF/MANUAL switch to the it has been properly serviced with the recom- AUTO position. mended oil may result in an engine failure. 20 Section 4 — Maintenance Air-cooled Generators MAINTENANCE 4.4 CHANGING THE ENGINE Figure 4.7— 10kW Engine Air Cleaner AIR CLEANER 4.4.1 7,_13, AND 1.6KW GENERATORS Control See Figures 1.1 and 1.2, for the location of the air cleaner. Use the following procedures (Figure 4.6, Panel 7kW, Figure 4.8, 13/16kW): 1. Lift the roof and remove the door. 2. Turn the two screws counterclockwise to loosen. . 3. Remove the cover and air filter. -,,Air Filter 4. Wipe away dust or debris from inside of the air box and around edges. 5. Install the new air cleaner into the air box. 6. Install the cover. Turn the two cover screws clock- wise to tighten. See the Service Schedule section for air cleaner main- tenance. See the Specifications section for air filter O n O replacement part number. Figure 4.8— 13 kW and 16 kW Engine Figure 4.6—7 kW, Engine Air Cleaner Location Air Cleaner Screw i Air Cleaner Cover s Filter 3/4" Hole a O ♦ 4.4.2 10KW GENERATORS 4.5 SPARK PLUG(S) See Figure 1.2 for the location of the air cleaner. Use Reset the spark plug(s) gap or replace the spark the following procedure (Figure 4.7): plug(s)as necessary. See the Service Schedule section for maintenance requirements. 1. Lift the roof and remove the door. 1. Clean the area around the base of the spark 2. Turn the worm gear clamp screw counterclock- plug(s) to keep dirt and debris out of the engine. wise to loosen. 2. Remove the spark plug(s) and check the condi- 3. Pull the old filter off the divider panel hub. tion. Replace the spark plug(s) if worn or if reuse 4. Wipe away dust or debris from the panel hub. is questionable. See the Service Schedule section 5. Install the new air cleaner onto the hub. for recommended inspection. Clean by scraping 6. Turn the worm gear clamp screw clockwise to or washing using a wire brush and commercial tighten. solvent. Do not blast the spark plug(s) to clean. 7. Replace door and roof. 21 Section 4 — Maintenance MAINTENANCE Air-cooled Generators 3. Check the spark plug gap using a wire feeler gauge.Adjust the gap to 0.76 mm(0.030 inch)for Q The electrolyte is a dilute sulfuric acid that is 7 and l0kW; and 1.02 mm(0.040 inch)for 13/16 harmful to the skin and-eyes. It is electrically kW by carefully bending the ground electrode conductive and corrosive.The following (Figure 4.9). procedures are to be observed: • Wear full eye protection and protective clothing; Figure 4.9—Setting the Spark Plug Gap • Where electrolyte contacts the skin,wash it off immediately with water; SET PLUG GAP AT 0.76 mm(.030 inch)-7&10kW; • Where electrolyte contacts the eyes,flush 1.02 mm(.040 inch)-13 &16kW thoroughly and immediately with water and seek medical attention; and • Spilled electrolyte is to be washed down with an acid neutralizing agent.A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) of water.The bicar- bonate of soda solution is to be added until the evidence of reaction (foaming) has ceased.The \ \ resulting liquid is to be flushed with water and the area dried. A Lead-acid batteries present a risk of fire because 4.6 BATTERY MAINTENANCE they generate hydrogen gas.The The battery should be inspected per the "Service following procedures are to be followed: Schedule"section.The following procedure should be • DO NOT SMOKE when near the battery; followed for inspection: • DO NOT cause flame or spark in battery area; and 1. Inspect the battery posts and cables for tightness • Discharge static electricity from body before touch- and corrosion. Tighten and clean as necessary. ing the battery by first touching a grounded metal 2. Check the battery fluid level of unsealed batteries surface. and,if necessary, ffi1 with Distilled Water Only. Do 0 Be sure the AUTO/OFF/MANUAL switch is set to not use tap water in batteries. the OFF position before connecting the battery 3. Have the state of charge and condition checked. cables. If the switch is set to AUTO or MANUAL, This should be done with an automotive-type bat the generator can crank and start as soon as the tery hydrometer. battery cables are connected. A m n A A Be sure the utility power supply is turned off and the 15A fuse is removed from the generator A Do not dispose of the battery in a fire.The control panel, or sparking may occur at the bat- battery is capable of exploding. tery posts as the cables are attached and cause AA battery presents a risk of electrical shock an explosion. and high short circuit current. The following pre- cautions are to be observed when working on 4.7 ADJUSTING GH-410/GT-530/990 batteries: VALVE CLEARANCE • Remove the I SA fuse from the generator control Atter the first six (6) months of operation, check panel, the valve clearance in the engine, adjust if neces- • Remove watches, rings or other metal objects; sem, • Use tools with insulated handles; • Wear rubber gloves and boots; Important: If feeling uncomfortable about doing • Do not lay tools or metal parts on top of the this procedure or the proper tools are not available, battery; and please contact the Authorized Dealer for service • Disconnect charging source prior to connecting or assistance. This is a very important step to insure disconnecting battery terminals. longest life for the engine. AWARNING To check valve clearance: • The engine should be cool before checking. If 0 Do not open or mutilate the battery. Released valve clearance is 0.002" - 0.004" (0.05 - 0.1mm), electrolyte has been known to be harmful to the adjustment is not needed. skin and eyes, and to be toxic. 22 Section 4 — Maintenance Air-cooled Generators MAINTENANCE • Remove spark plug wires and position wires away • Install spark plugs. from plugs. • Re-attach the spark plug wire to the spark plug. • Remove spark plugs. • On the GT-530 and GT-990, repeat the process for • Make sure the piston is at Top Dead Center (TDC) the other cylinder. of its compression stroke (both valves closed). To get the piston at TDC, remove the intake screen at 4.8 COOLING SYSTEM the front of the engine to gain access to the flywheel Air inlet and outlet openings in the generator com- nut. Use a large socket and socket wrench to rotate partment must be open and unobstructed for con- the nut and hence the engine in a clockwise direc- tinued proper operation. This includes such obstruc- tion. While watching the piston through the spark tions as high grass, weeds, brush, leaves and snow plug hole. The piston should move up and down. The piston is at TDC when it is at its highest point Without sufficient cooling and ventilating air flow,the of travel. engine/generator quickly overheats, which causes it To adjust valve clearance (if necessary): to quickly shut down. (See Figure 4.11 for vent loca- • Make sure the engine is at 60°to 80°F tions.) • Make sure that the spark plug wire is removed Make sure the doors and roof are in place dur- from the spark plug and out of the way. ing operation as running the generator with them • Remove the four screws attaching the valve cover removed can effect cooling air movement. with a#2 or #3 Phillips screwdriver. Figure 4.11 — Cooling Vent Locations • Loosen the rocker jam nut. Use an 10mm allen wrench to turn the pivot ball stud while checking AIR clearance between the rocker arm and the valve OUTLET ? ? AIR INTAKE stem with a feeler gauge. Correct clearance is 0.002-0.004 inch (0.05-0.1 mm). 41o . ❑ � NOTE: Hold the rocker arm jam nut in place as the pivot 401 EI4-1 ball stud is turned. O N When valve clearance is correct, hold the pivot ball 0 stud in place with the allen wrench and tighten the 41 rocker arm jam nut. Tighten the jam nut to 174 in/lbs. torque. After tightening the jam nut, recheck o valve clearance to make sure it did not change. Figure 4.10 - Valve Clearance Adjustment A WARNING A ®The exhaust from this product gets extremely Rocker hot and remains hot after shutdown. High grass, Pivot Bail Arm weeds, brush, leaves, etc. must remain clear of .lam Nut stud the exhaust. Such materials may ignite and burn Valve from the heat of the exhaust system. Stem A CAUTION A © The maximum ambient temperature for the gen- erator is 40°C(104° F). ® 4.9 ATTENTION AFTER SUBMERSION If the generator has been submerged in water,it must not be started and operated. Following any submer- • Install new valve cover gasket. sion in water, have an Authorized Dealer thoroughly • Re-attach the valve cover. clean, dry and inspect the generator. If the structure NOTE: (ex. home) has been flooded, it should be inspected by a certified electrician to ensure there won't be any Start all four screws before tightening or it will not electrical problems during generator operation or be possible to get all the screws in place. Make when utility is returned. sure the valve cover gasket is in place. 23 Section 4 — Maintenance MAINTENANCE Air-cooled Generators 4.10 CORROSION PROTECTION 1 4.11.2 RETURN TO SERVICE Periodically wash and wax the enclosure using auto- To return the unit to service after storage, proceed motive type products. Frequent washing is recom- as follows: mended in salt water/coastal areas. Spray engine 1. Ver that utilityower is turned off and that the linkages with a light oil such as WD-40. AUTO/OFF/MANUAL switch is set to OFF. 4.11 OUT OF SERVICE PROCEDURE 2. Check the tag on the engine for oil viscosity and classification.Verify that the correct recommend- ed oil is used in the engine (see the Engine Oil ♦ 4.11.1 REMOVAL FROM SERVICE Recommendations section). If necessary, drain If the generator cannot be exercised every seven days, and refill with-the proper oil. and will be out of service longer than 90 days, pre- 3. Check the state of the battery. Fill all cells of pare the generator for storage as follows: unsealed batteries to the proper level with dis- tilled water. DO NOT USE TAP WATER IN THE 1. Start the engine and let it warm up. BATTERY. Recharge the battery to 100 percent 2. Close the fuel shutoff valve in the fuel supply line state of charge, or,if defective,replace the battery. and allow the unit to shut down. See "Specifications," for type and size. 3. Once the unit has shut down, 'it will signal a low 4. Clean and wipe the entire generator. oil fault. 5. Make sure the 15A fuse is removed from the 4. Set the generator's main circuit breaker to its generator control panel. Reconnect the battery. OFF (or OPEN) position. Observe battery polarity.Damage may occur if the 5. Set the AUTO/OFF/MANUAL switch to OFF and battery is connected incorrectly. turn off the utility power to the transfer switch. 6. Open the fuel shutoff valve. Remove the 15A fuse from the generator control 7. Insert the 15A fuse into the generator control panel. Disconnect the battery cables as outlined panel. Start the unit by moving the AUTO/OFF/ in "General Hazards". MANUAL switch to MANUAL. Allow the unit to 6. While the engine is still warm from running, warm up thoroughly. drain the oil completely. Refill the crankcase with 8. Stop the unit by setting the AUTO/OFF/MANUAL oil. See "Engine Oil Recommendations". switch to OFF. 7. Attach a tag to the engine indicating the viscosity 9. Mirn on the utility power to the transfer switch. and classification of the oil in the crankcase. 10. Set the AUTO/OFF/MANUAL switch to AUTO. 8. Remove the spark plugs) and spray fogging 11. The generator is now ready for service. agent into the spark plug(s) threaded openings. NOTE: Reinstall and tighten the spark plug(s). 9. Remove the battery and store it in a cool, dry If the battery was dead or disconnected, the eger- room on a wooden board. Never store the battery cise timer must be reset. on any concrete or earthen floor. 10. Clean and wipe the entire generator. 24 Section 4 — Maintenance Air-cooled Generators MAINTENANCE 4.12 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Authorized Dealer. SYSTEWCOMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly * = Notify Dealer Y = Yearly if Repair is Needed. FUEL Fuel lines-and connections* X M LUBRICATION Oil level X M Oil X EVERY 100 HOURS**, AND Y Oil filter X EVERY 100 HOURS**, AND Y COOLING Enclosure louvers X X W BATTERY Remove corrosion, X X M ensure dryness Clean and tighten X X M batterV terminals Check charge state X R EVERY 6 M Electrolyte level X R EVERY 6 M (unsealed batteries only)* ENGINE AND MOUNTING Air cleaner X R Y Spark plug(s) X R Y GENERAL CONDITION Vibration, Noise,Leakage, X M Temperature* COMPLETE TUNE-UP* TO BE COMPLETED BY AN Y AUTHORIZED DEALER * Contact the nearest Authorized Dealer for assistance if necessary. ** Change oil and filter after first eight(8) hours of operation and then every 100 hours thereafter. Change sooner when operating under a heavy load or in a dusty or dirty environment or in high ambient temperatures. 25 TROUBLESHOOTING Section 5 -Troubleshooting Air-cooled Generators 5.1 TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown. 1. Correct short circuit condition, replace 15A fuse in generator control panel. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables. as necessary. 3. Defective starter contactor. (7 kW) 3. * 4. Defective starter motor. 4. * 5. Dead Battery. 5. Charge or replace battery. The engine cranks but 1. Out of fuel. 1. Replenish fuel/Turn on fuel valve. will not start. 2. Defective fuel solenoid (FS). 2. * 3. Open #14 wire from 3. * engine control board. 4. Defective spark plug(s). 4. Clean, re-gap or replace plug(s). 5. Valve lash out of adjustment. 5. Reset valve lash. 6. Choke not operating. 6. Verify choke plate moves freely. The engine starts hard 1. Air cleaner plugged 1. Check, replace air cleaner. and runs rough. or damaged. 2. Defective spark plug(s). 2. Clean, re-gap or replace plug(s). 3. Fuel regulator not set. 3. Set Fuel Regulator. 4. Fuel pressure,incorrect. 4. Confirm fuel pressure to regulator is 10-12"water column (0.36-0.43 psi) for LP and 5-7"water column (0.18-0.25 psi) for natural gas. 5. Fuel selector in wrong position. 5. Move selector to correct position. 6. Choke remains closed. 6. Verify choke plate moves freely. The AUTO/OFF/MANUAL switch 1. Defective switch. 1. * is set to OFF, but the engine 2. AUTO/OFF/MANUAL switch 2. * continues to run. wired incorrectly. 3. Defective control board. 3. * There is no AC output from 1. Main line circuit breaker is in 1. Reset circuit breaker the generator. the OFF (or OPEN) position. to ON (or CLOSED). 2. Generator internal failure. 2. * There is no transfer to 1. Defective transfer switch coil. 1. * standby after utility 2. Defective transfer relay. 2. * source failure. 3. Transfer relay circuit open. 3. * 4. Defective control logic board. 4. * Unit consumes large 1. Engine over filled with oil. 1. Adjust oil to proper level. amounts of oil. 2. Engine breather defective. 2. * *Contact the nearest Authorized Dealer for assistance. 26