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Powermate P1204 manual

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Table of contents for the manual

  • Page 1

    © 2007 Powermate Corporation S t ationary S t andby Electric Generator I MPORT ANT SAFETY INSTRUCTIONS – Please make cert ain that persons who are to inst all, operate and maint ain this equipment thoroughly read and underst and these instructions prior to operation. SA VE THESE INSTRUCTIONS — This manual cont ains import ant instructions that[...]

  • Page 2

    200-2667 2 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Introduction . . . . . . [...]

  • Page 3

    3 òÿå Do not attempt to install the generator yourself. Extremely high and dangerous electrical voltages are present in utility power source lines and in generator load leads when the unit is running. Therefore, be sure to turn OFF all power voltage supplies at their source before attempting to complete electrical connections. Only qualified ins[...]

  • Page 4

    200-2667 4 The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. Keep a fire extinguisher near the generator at all times. Extinguishers rated "ABC" by the National Fire Protection Association are appropriate for use on the standby ele[...]

  • Page 5

    5 200-2667 The stationary standby electric generator is manufactured for our customers to supply reliable backup power. The generator is a compact unit, designed to supply the power for your critical needs when utility power fails. The standby generator will run on Liquid Propane Gas or Natural Gas allowing flexibility for getting the power you nee[...]

  • Page 6

    200-2667 6 G G G G E E E E N N N N E E E E R R R R A A A A T T T T O O O O R R R R S S S S P P P P E E E E C C C C I I I I F F F F I I I I C C C C A A A A T T T T I I I I O O O O N N N N S S S S P120401 (12 KW) Rated Wattage - (Standby) @1.0 PF LPG * 12,000 Rated Wattage - (Standby) @1.0 PF NG * 9,800 Voltage 120/240 volts Rated Current 100/50 amps[...]

  • Page 7

    I I I I N N N N S S S S T T T T A A A A L L L L L L L L A A A A T T T T I I I I O O O O N N N N D D D D R R R R A A A A W W W W I I I I N N N N G G G G S S S S 7 200-2653[...]

  • Page 8

    200-2667 8 Once installation planning is complete and all necessary local permits are granted, installation of the generator may begin. Within the following section general recommendations are given for installing the generator. However, installations are affected by local site conditions, regional construction practices, material availability, loc[...]

  • Page 9

    9 200-2667 The generator is supplied with an integral molded plastic base for use as an installation pad. Use of this base is intended to minimize installation cost by eliminating the need for a poured concrete pad. A pad of crushed gravel a minimum of three inches thick is recommended as a base to set the generator on. Compact the gravel and ensur[...]

  • Page 10

    200-2667 10 When connecting the generator to a building electrical distribution system, use of a transfer switch is recommended to isolate the normal utility source from the generator supply. By preventing backfeed of the generator power into the utility lines during a utility power outage, the switch provides a level of safety for electrical line [...]

  • Page 11

    11 200-2667 Once the generator is anchored in its final position, it is ready for electrical connections. The generator is supplied with two terminal blocks for connection of three distinct electrical circuits; main line output power, utility power input and generator start signal. Main line output power is the electrical output of the generator, u[...]

  • Page 12

    200-2667 12 A receptacle is provided with the generator to power the battery charger for reliable starting. It is also intended to power an optional block heater if that option is desired. Connection of this circuit to a power supply that is only present when normal utility power is supplied is recommended. By connecting the receptacle in this fash[...]

  • Page 13

    13 200-2667 W W I I R R I I N N G G D D I I A A G G R R A A M M[...]

  • Page 14

    200-2667 14 The engine driving the generator is engineered to provide reliable power on either Liquefied Propane Vapor (LPG) or Natural Gas. For proper operation on these fuels, it is important to deliver gas with adequate energy content, at sufficient pressure and flow rate. This generator is designed to operate on Liquefied Propane Vapor (LPG) wi[...]

  • Page 15

    15 200-2667 Units are tested with natural gas before they leave the factory. If natural gas is to be used, no adjustments are required. When supplying natural gas as the operating fuel, provide fuel with a minimum of 1000 BTU/ft 3 at inlet pressures between 6" and 11" of water column (4 - 6 oz) . Failure to meet these minimums will cause [...]

  • Page 16

    200-2667 16 To insure reliable starting in most weather conditions, it is important to properly match a battery to the requirements of the generator. The generator uses a 12 Volt, direct current, negative ground control system powered by an automotive style lead acid battery. Successful engine starting is dependent upon the cranking speed of the en[...]

  • Page 17

    17 200-2667 To access the battery and charger, remove the front and back panels by inserting the key into the locks located on top of the panel. and turn 1/4 turn counterclockwise to unlock. Lift the panels up and out of the base and set it aside. Place the battery ( A ) on the base as shown in Fig G. After the battery is set, begin attaching the b[...]

  • Page 18

    200-2667 18 After completing all installation procedures, read and understand the operating instructions for the generator controller. Know how the control panel operates, what to expect when activating control panel switches and how to shut the generator off in the event of an emergency. Before starting the generator for the first time, check off [...]

  • Page 19

    19 200-2667 A . MODE BUTTONS (AUTO, MANUAL AND OFF) B. AUTO LED C . STATUS INDICATOR LED’s D. UTILITY POWER MONITOR LED E. TRANSFER SWITCH MONITOR LED F. GENERATOR POWER MONITOR LED G . HOUR METER A. Mode Buttons The Mode Buttons are used to set the operating state of the generator. Pressing the OFF button prevents engine operation or stops the e[...]

  • Page 20

    200-2667 20 RUN MODES There are three run mode options: Off, Manual and Auto . When the Manual pushbutton is pressed the unit will immediately start and the run indicator light will illuminate. In Manual mode, the generator will continue to run until the Off pushbutton is pressed to stop the unit. At this point the “not in auto” light will illu[...]

  • Page 21

    21 200-2667 Status indicator LED’s relay conditions of generator function for user or service technician convenience. Illumination of these indicator LED’s communicate conditions that require generator service but are not severe enough to cause damage if the generator is allowed to operate. Contact a qualified service technician immediately for[...]

  • Page 22

    200-2667 22 M M M M A A A A I I I I N N N N T T T T E E E E N N N N A A A A N N N N C C C C E E E E To ensure reliable generator operation, it is critical to periodically inspect all components. The following chart is provided as a guide for service check intervals. When the generator is operated under excessively hot, or dusty conditions, shorten [...]

  • Page 23

    23 200-2667 Prior to checking the oil level, start the generator by pressing the MANUAL Mode button on the control panel. Allow the generator to run for one or two minutes, then shut it down by pressing the OFF button on the control panel. After the engine comes to a stop let the engine set for a couple of minutes before checking the oil level. Beg[...]

  • Page 24

    200-2667 24 Selection of the correct grade and type of engine oil greatly affects the performance of the generator, especially when starting. Before selecting replacement oil for an oil change, consider the anticipated operating conditions the generator may be exposed to. Choose the appropriate weight of oil for anticipated temperatures from Chart [...]

  • Page 25

    25 200-2667 The generator engine is equipped with a dry element air filter to block particles in the combustion air from getting into the engine and causing excessive engine wear. Over time this dirt builds-up on the filter, restricting the amount of combustion air available to the engine, in turn leading to a loss of generator power output. To avo[...]

  • Page 26

    200-2667 26 Engine spark plugs are an important part of the engine ignition system. Worn or incorrectly adjusted spark plugs can negatively affect engine starting and operation. Therefore, it is important to inspect and regap, or replace the engine spark plugs as indicated in the service interval table. The listed steps are recommended to access an[...]

  • Page 27

    27 200-2667 Proper cooling of the generator is vital to maintain performance and prevent equipment failure. Blocked cabinet openings or other airflow obstructions are potential fire hazards and can cause failures. Periodically inspect generator cabinet openings and the engine oil cooler for blockages. Do not allow leaves, grass, dirt, snow or other[...]

  • Page 28

    200-2667 28 T T T T R R R R O O O O U U U U B B B B L L L L E E E E S S S S H H H H O O O O O O O O T T T T I I I I N N N N G G G G SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Engine does not crank Loose battery cables • Check all battery cable connections. Defective battery • Test battery. Replace as necessary. Improper battery charger function ?[...]

  • Page 29

    29 200-2667 T T T T R R R R O O O O U U U U B B B B L L L L E E E E S S S S H H H H O O O O O O O O T T T T I I I I N N N N G G G G SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Low generator output voltage Excitation capacitor failure • Contact a qualified generator dealer for service assistance. Generator diode or varistor failure • Contact a qual[...]

  • Page 30

    200-2667 30 N N N N O O O O T T T T E E E E S S S S[...]

  • Page 31

    31 200-2667 POWERST A TION ® Automated Power System Limited W arranty Warranty: Powermate Corporation warrants to the original consumer purchaser in the U.S. or Canada that it will repair or replace any parts or components found to be defective in material or workmanship. The product must be properly installed and maintained in accordance with ope[...]

  • Page 32

    CONT ACT THE POWERMA TE PRODUCT SERVICE DEP ARTMENT A T 1-866-769-3703 to obt ain warranty service information or to order replacement p art s or accessories. HOW TO ORDER REPLACEMENT P ARTS Even quality built equipment such as the Powermate standby generator you have purchased, might need occasional replacement part s to maintain it in good condit[...]