Honeywell 10 kW User manual

Owner's Manual
10,12,15 & 20kW Air-cooled,
Automatic Standby Generators
A DANGER!
NOT INTENDED FOR USE IN CRITICAL LIFE
.SUPPORT APPLICATIONS.
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
.SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES! OUTDOOR
INSTALLATION ONLY!
1-855-GEN-INFO
Honeywell
cQlLyus
LISTED

Table of Contents
Introduction 1
Read This Manual Thoroughly 1
Safety Rules 1
Contents 1
Operation and Maintenance 1
Howto Obtain Service 1
Standards Index 3
General Information 4
1.1 Unpacking/Inspection 4
1.2 Protection Systems 4
1.3
NEC Requirements 4
1.4
Emission Information 4
1.5 The
Generator 5
1.6 Specifications 5
1.7 Ready to Run 6
1.8 Fuel Requirements and Recommendations 6
1.9 Fuel Consumption 6
1.10 Reconfiguring the Fuel System 7
1.11 High Altitude Operation 7
1.12
Location 8
1.13 The Battery 9
1.14 Battery Requirements 11
1.15 Battery Installation 11
1.16 Battery Charger 11
Post Installation Start-up and
Adjustments 11
2.1 Activate the Generator 11
2.2 Before Initial Startup 11
2.3 Check Transfer Switch Operation 13
2.4 Electrical Checks 13
2.5
Generator Tests Under Load 13
2.6
Checking Automatic Operation 14
Operation 14
3.1 Control Panel Interface 14
3.2 Automatic Transfer Operation 15
3.3
Sequence of Automatic Operation 15
3.4 Manual Transfer Operation 16
3.5
Side Compartment 17
3.6
Protection Systems 18
Maintenance 19
4.1 Performing Scheduled Maintenance 19
4.2 Fuse 19
4.3 Checking the Engine Oil Level 19
4.4
Changing the Engine Oil 20
4.5
Changing the Engine Air Cleaner 21
4.6 Spark Plug(s) 21
4.7 Battery Maintenance 22
4.8
Adjusting GT-530/990/999 Valve Clearance 22
4.9 Cooling System 23
4.10 Attention After Submersion 23
4.11 Corrosion Protection 23
4.12
Out of Service Procedure 23
4.13
Service Schedule 25
Troubleshooting 26
5.1 Troubleshooting Guide 26
Appendix 27
6.1 Menu System Navigation 27
Notes 29
Installation Diagrams 30
Warranty 34
MANUAL DEL PROPIETARIO 39
MANUEL DE L'UTILISATEUR 75

INTRODUCTION
Thank you for purchasing this compact, high performance, air-cooled,
engine-driven generator. It is designed to automatically supply electrical
power to operate critical loads during a utility power failure.
This unit is factory installed in an all-weather, aluminum enclosure and is
intended exclusively for outdoor installation. This generator will operate
using either vapor withdrawn liquid propane (LP) or natural gas (NG).
NOTE:
This generator is suitable for supplying typical residential loads such
as Induction Motors (sump pumps, refrigerators, air conditioners,
furnaces, etc.), Electronic Components (computer, monitor, TV, etc.),
Lighting Loads and Microwaves.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Dealer
for starting, operating and servicing procedures.
SAFETY RULES
Throughout this publication, and ontags and decals affixed to the genera
tor, DANGER, WARNING, CAUTION and NOTE blocks are used to alert
personnel to special instructions about a particular operation that may be
hazardous if performed incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:
A DANGER!
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF
NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
A WARNING!
Indicates a hazardous situation or action which, if not
avoided, could result in death or serious injury.
A CAUTION!
Indicates a hazardous situation or action which, if not
avoided, could result in minor or moderate injury.
NOTE:
Notes contain additional information important to a procedure
and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the action or service are essential to
preventing accidents.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
This symbol points out important safety information that,
if not followed, couldendanger personal safety and/or
property of others.
This symbol points out potential explosion hazard.
Jk Ttos symbol points out potential fire hazard.
A This symbol pointsout potential electrical shock hazard.
Safety Rules
The operator is responsible for proper and safe use of the equipment. The
manufacturer strongly recommends that the operator read this Owner's
Manual and thoroughly understand all instructions before using this
equipment. The manufacturer also strongly recommends instructing other
users to properly start and operate the unit. This prepares them if they
needto operatethe equipment inan emergency.
CONTENTS
This manual contains pertinent owner's information for these models:
•9kWNG, 10 kWLR V-twin GT-530 Engine
• 12 kWNG, 12 kW LR V-twin GT-990 Engine
• 15 kWNG,15 kWLR V-twin GT-990 Engine
• 18 kWNG, 20 kWLR V-twin GT-999 Engine
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety checks, to make sure
that all maintenance forsafe operation is performed promptly, andto have
the equipment checked periodically by a Dealer. Normal maintenance ser
vice and replacement ofpartsarethe responsibility ofthe owner/operator
and, as such, are not considered defects in materials or workmanship
within the terms of the warranty. Individual operating habits and usage
contribute to the need for maintenance service.
Proper maintenance and care of the generator ensures a minimum number
of problems and keep operating expenses ata minimum. See a Dealer for
service aids and accessories.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs, contact a Dealer for
assistance. Service technicians are factory-trained and are capable of
handling all service needs.
When contacting a Dealer about parts and service, always supply the
complete model number and serial number of the unit as given on its data
decal, which is located onthe generator. See section "The Generator for
decal location.
Model No.
Serial No.
Data Label Sample
Honeywell
MODEL
SERIAL
VOLTS
AMPS
CONTROLLER
P/N
1 PH, 60 Hz. RPM 3600
RAINPROOF ENCLOSURE FITTED
CLASS H INSULATION
RATED AMBIENT TEMP - 25'C
FOR STANDBY SERVICE
KSEUTOM. IrLOATINQ
MAX LOAD UNBALANCE-50%
THE HONEYWELL TRADEMARK IS
USED UNDER LICENSE FROM
HONEYWELL INTERNATIONAL INC.
GENERAC POWER SYSTEMS
WHITEWATER. Wl
53190 U.S.A.

Safety Rules
SA VE THESE INSTRUCTIONS - The manufacturer suggests that these rules for safe operation be copied and posted near the unit's
.installation site. Safety should be stressed to all operators and potential operators of this equipment.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this Owner's
Manual and with the unit. The generator can operate safely, effi
ciently and reliably only if it is properly installed, operated and
maintained. Many accidents are caused by failing to follow simple
and fundamental rules or precautions.
The manufacturer cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this manual, and on
tags and decals affixed tothe unit are, therefore, not all-inclusive. If
using a procedure, work method or operating technique the manu
facturer does not specifically recommend, ensure that it is safe for
others. Also make sure the procedure, work method or operating
technique utilized does not render the generator unsafe.
Despite the safe design of this generator,
ioperating this equipment imprudently, neglect
ing its maintenance or being careless can
cause possible injury or death. Permit only
responsible and capable persons to install,
operate and maintain this equipment.
APotentially lethal voltages are generated by
these generators. Ensure all steps are taken
to render the generator safe before attempt
ing to work on the generator.
Parts of the generator are rotating and/or
.hot during operation. Exercise care near
running generators.
Installation must always comply with
applicable codes, standards, laws and
regulations.
A running generator gives off carbon
monoxide, an odorless, colorless poison
gas. Breathing in carbon monoxide can
cause headaches, fatigue, diziness, nausea,
vomitting, confusion, fainting, siezures or
death.
GENERAL HAZARDS
For safety reasons, the manufacturer recommends that this equip
ment be installed, serviced and repaired by a Service Dealer or
other competent, qualified electrician or installation technician who
is familiar with applicable codes, standards and regulations. The
operator also must comply with all such codes, standards and
regulations.
The engine exhaust fumes contain carbon monoxide, which
can be DEADLY. This dangerous gas, if breathed in sufficient
concentrations, can cause unconsciousness or even death.
Do NOT alter or add to the exhaust system or do anything that
might render the system unsafe or in noncompliance with appli
cable codes and standards.
Install a battery operated carbon monoxide alarm indoors,
according to manufacturer's instructions/recommendations.
Adequate, unobstructed flow of cooling and ventilating air is
critical to correct generator operation. Do not alter the instal
lation or permit even partial blockage of ventilation provisions,
as this can seriously affect safe operation of the generator. The
generator MUST be installed and operated outdoors only.
Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt or
fan guard while the unit is operating.
When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
Inspect the generator regularly, and contact the nearest Dealer
forparts needing repair or replacement.
Before performing any maintenance on the generator, discon
nect its battery cables to prevent accidental start up. Disconnect
the cable from the battery post indicated by a NEGATIVE, NEG
or(-) first, then remove the POSITIVE, POS or (+) cable. When
reconnecting the cables, connect the POSITIVE cable first, the
NEGATIVE cable last.
Hem use the generator or any of its parts as a step. Stepping
onthe unit can stress and break parts, and may result in dan
gerous operating conditions from leaking exhaust gases, fuel
leakage, oil leakage,etc.
EXHAUST HAZARDS
Generator engine exhaust contains DEADLY carbon monox
ide, an odorless, colorless poisonous gas. Breathing carbon
monoxide can cause: dizziness, throbbing temples, nausea,
muscular twitching, headache, vomiting, weakness and sleepi
ness, inability to think clearly, fainting, unconsciousness or
even death. If you experience any carbon monoxide poisoning
symptoms, move into fresh air and immediately seek medical
attention.
NEVER use inside a home ora garage EVEN IF doors and win
dows are open. Only use OUTSIDE and far away from windows,
doors and vents.
ELECTRICAL HAZARDS
All generators covered by this manual produce dangerous
electrical voltages and can cause fatal electrical shock. Utility
power delivers extremely high and dangerous voltages to the
transfer switch as does the standby generator when it is in
operation. Avoid contact with bare wires, terminals, connec
tions, etc., while the unit is running. Ensure all appropriate
covers, guards and barriersare in place, secured and/or locked
before operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface to reduce
shock hazard.
Do not handle any kind of electrical device while stand
ing in water, while barefoot, or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.

The National Electrical Code (NEC) requires the frame and external
electrically conductive parts of the generator to be connected to
an approved earth ground. Local electrical codes also may require
proper grounding of the generator electrical system.
After installing this home standby electrical system, the genera
tor may crank and startat any time without warning. When this
occurs, load circuits are transferred to the STANDBY (genera
tor) power source. To prevent possible injury if such a start and
transfer occur, always set the generator's AUTO/OFF/MANUAL
switch to its OFF position before working on equipment and
remove the 7.5A fuse from the generator control panel.
In case of accident caused by electric shock, immediately shut
down the source of electrical power. If this is not possible,
attempt to free the victim from the live conductor. AVOID DIRECT
CONTACT WITH THE VICTIM. Use a nonconducting implement,
such as a dry rope or board, to free the victim from the live
conductor. If the victim is unconscious, apply first aid and get
immediate medical help.
Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock, or may get
caught in moving components causing injury.
FIRE HAZARDS
For fire safety, the generator must be installed and maintained
properly. Installation must always comply with applicable
codes, standards, laws and regulations. Adhere strictly
to local, state and national electrical and building codes.
Comply with regulations the Occupational Safety and Health
Administration (OSHA) has established. Also, ensure that the
generator is installed in accordance with the manufacturer's
instructions and recommendations. Following proper installa
tion, do nothing that might alter a safe installation and render
fte unit in noncompliance with the aforementioned codes,
standards, laws and regulations.
• Keep a fire extinguisher near the generator at all times.
Extinguishers rated "ABC" by the National Fire Protection
Association are appropriate for use on the standby electric
system. Keep the extinguisher properly charged and be familiar
with its use. Consult the local fire department with any ques
tions pertaining to fire extinguishers.
EXPLOSION HAZARDS
' Do not smoke around the generator. Wipe up any fuel or oil
spills immediately. Ensure that no combustible materials are left
in the generator compartment, or on or near the generator, as
FIRE or EXPLOSION may result. Keep the area surroundingthe
generator cleanand free from debris.
• Gaseous fluids such as natural gas and liquid propane (LP)
gas are extremely EXPLOSIVE. Install the fuel supply system
according to applicable fuel-gas codes. Before placing the
home standby electric system into service, fuel system lines
must be properly purged and leaktested according to applica
ble code.
After installation, inspect the fuel system periodically
for leaks. No leakage is permitted.
Safety Rules
STANDARDS INDEX
In the absence of pertinent standards, codes, regulations and
laws, the published information listed below may be used for
installation guidance forthis equipment.
1. NFPA No. 37, STATIONARY COMBUSTION ENGINES AND
GAS TURBINES, available from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA 02210.
2. NFPA No. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR
HEALTH CARE FACILITIES, available same as Item 1.
3. NFPA No. 54, NATIONAL FUEL GAS CODE, available sameas
Item 1.
4 NFPA No. 58, AMERICAN NATIONAL STANDARD FOR
STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS,
available same as Item 1.
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELECTRIC
CODE, available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available from the
American Insurance Association, 85 John Street, New York,
N.Y 10038.
7. AGRICULTURAL WIRING HANDBOOK, available fromthe Food
and Energy Council, 909 University Avenue, Columbia, MO
65201.
8. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF
FARM STANDBY ELECTRICAL SYSTEMS, available from the
American Society of Agricultural Engineers, 2950 Niles Road,
St.Joseph, Ml 49085.
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS
CODE, available same as Item 1.
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and someofits constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product containsor emitschemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.

General Information
A DANGER!
Only qualified electricians or contractors
.should attempt such installations, which must
comply strictly with applicable codes, stan
dards and regulations.
TT UNPACKING/INSPECTION
After unpacking, carefully inspect the contents for damage.
• This standby generator set is ready for installation with a factory
supplied and pre-mounted base pad and has a weather protec
tive enclosure that is intended for outdoor installation only.
• This UL listed standby generator set may be packaged with an
automatic transfer switch with built in load center. The combi
nation transfer switch and load center is pre-wired with a two
foot and 30 foot conduit. Circuit breakers for emergency circuit
connections are included (if equipped).
• This UL listed, 2-pole switch is rated at 100 or 200 AC amperes
at 250 volts maximum. The 100 Amp transfer switch is for
indoor use only. The 200 Amp transfer switch is for indoor/
outdoor use (if equipped).
A WARNING!
Alt is required by code that generators used to
power electrical load circuits normally powered
by a utility power source have a transfer switch
installed. The transfer switch must effectively
isolate the electrical system from the utility dis
tribution system when the generator is operat
ing (NEC 700, 701 &702). Failure to isolate an
electrical system by such means will result in
damage to the generator and also may result in
injury or death to utility power workers due to
backfeed of electrical energy.
If any loss or damage is noted at time of delivery, have the
person(s) making the delivery note all damage on the freight bill
or affix their signature under the consignor's memo of loss or
damage.
If a loss or damage is noted after delivery, separate the damaged
materials and contact the carrier for claim procedures.
"Concealed damage" is understood to mean damage to the con
tents of a package that is not in evidence at the time of delivery,
but is discovered later.
To properly open the roof, press down on the center top lip and
release the latch. If pressure is not applied from the top, the roof
may appear stuck. Always verify that the side lock is unlocked
before attempting to lift the roof.
1.2 PROTECTION SYSTEMS
Unlike an automobile engine, the generator may have to run for
long periods of time with no operator present to monitor engine
conditions. For that reason, the engine is equipped with the fol
lowing systems that protect it against potentially damaging condi
tions:
1. Low Oil Pressure Sensor 6.
2. High Temperature Sensor 7.
3. Overcrank 8.
4. Overspeed 9.
5. RPM Sensor 10.
Low Battery
Under-frequency
Undervoltage
Overvoltage
Internal Failure
There are readouts on the control panel to notify personnel that
one of these failures has occurred. There isa Status message on
the display that displays when all ofthe conditions described in the
"Ready to Run" section are true.
T! NEC REQUIREMENTS
Local code enforcement may require that AFCI's be incorporated
into the transfer switch distribution panel. The Transfer Switch pro
vided with this generator has a distribution panel that will accept
AFCI's.
Siemens Part No. Q115AF -15Aor Q120AF - 20A canbe obtained
from a local electrical wholesaler and will simply replace any of
the single pole circuit breakers supplied in the Transfer Switch
distribution panel.
Ta emission information
The U.S. Environmental Protection Agency (EPA) requires that
this generator comply with exhaust emission standards. This
generator is certified to meetthe applicable EPA emission levels,
and is certified for use as a stationary engine for standby power
generation. Any otheruse maybe a violation of federal and/or local
laws. It is important to follow the maintenance specifications in the
Maintenance section to ensure that the engine complies with the
applicable emission standards for the duration of the engine's life.
This generator is certified to operate on Liquid Propane vapor luel
and pipeline Natural Gas.
For generators 10kW and below, the Emission Control System
consists ofthe following components:
•
Air Induction System
~ Intake Pipe/ Manifold
~ Air Cleaner
• Fuel Metering System
~Carburetor/ Mixer Assembly
~ Fuel Regulator
• Ignition System
~ Spark Plug
~ Ignition Module
• Exhaust System
~Exhaust Manifold
~Muffler/Catalyst

For generators 12 kW and greater, the Emission Control System
code is EM (Engine Modification) and consists of the following
components:
• Air Induction System
~ Intake Pipe / Manifold
~ Air Cleaner
• Fuel Metering System
~ Carburetor/MixerAssembly
~ Fuel Regulator
• Ignition System
~ Spark Plug
~ Ignition Module
• ExhaustSystem
~ Exhaust Manifold
~Muffler
Ts THE generator
Figure 1.1 - 10kW, V-twin, GT-530 Engine
(door removed)
Exhaust
Enclosure
Composite Base Oil Filter Battery Compartment
Figure 1.2-12, 15and20kW, V-twin,
GT-990/GT-999 Engine (doorremoved)
Fuel
Regulator
Fuel Inlet
(back)
— Fuel
Regulator
Composite Base OilFilter Battery Compartment
General Information
1.6 SPECIFICATIONS
1.B.1 GENERATOR
Model
10 kW
12 kW
15 kW
20 kW
Rated Voltage
240
Rated MaximumLoad Current
(Amps) at240 Volts (LP)*
41.6
50.0
62.5
83.3
Main Circuit Breaker
45 Amp 50 Amp 65 Amp 100 Amp
Phase
1
Number ot Rotor Poles 2
Rated ACFrequency 60 Hz
BatteryRequirement
Group 26R, 12 Volts and525 CCA Minimum
Weight (unit onlyin lbs.)
353
439
421
450
Enclosure
Aluminum
Steel
Aluminum
Normal Operating Range
This unitis tested inaccordance to UL 2200 standards
with an operating temperature of 20 °F (-29 °C) to 122
°F. (50 °C). For areas where temperatures fall below 32
°F (0 °C), a cold weather kit is highly recommended.
When operated above 77°F (25° C) there may bea
decrease in engine power. (Please reference the engine
specifications section).
These generators are rated in accordance with UL2200, Safety Standard for Stationary
Engine Generator Assemblies; and CSA-C22.2 No. 100-04 Standard for Motors and
Generators.
* Natural Gas ratings will depend on specific fuel Btu content. Typical derates are
between 10-20%offthe LPgas rating.
** Circuits tobe moved must be protected by same size breaker. For example, a15 amp
circuit inthe main panel must bea 15 amp circuit inthe transfer switch.
1.6.2 ENGINE
Model
10 kW
12 kW
15 kW
20 kW
Type of Engine
GT-530
GT-990 GT-990 GT-999
Numberof Cylinders
2
Rated Horsepower @
3,600 rpm'
18
32 32 36
Displacement 530CC 992CC 992CC 999CC
Cylinder Block Aluminumw/Cast Iron Sleeve
ValveArrangement
Overhead Valves
Ignition System Solid-statew/Magneto
RecommendedSpark Plug BPR6HS RC14YC RC14YC RC12YC
SparkPlug Gap
0.76 mm
(0.030 inch)
1.02 mm
(0.040 inch)
1.02 mm
(0.040 inch)
0.76 mm
(0.030 inch)
Compression Ratio 9.5:1 9.5:1 9.5:1 9.5:1
Starter
12VDC
Oil Capacity Including Filter
Approx. 1.7
Qts
Approx.1.9
Qts
Approx.1.9
Qts
Approx.1.9
Qts
Recommended OilFilter
Part # 070185F
Recommended Air Filter
Part #
0E9581
Part #
0C8127
Part #
0C8127
Part#
0G5894
Operating RPM
3,600
• Engine power is subject toand limited bysuch factors as fuel Btu content, ambient
temperature and altitude. Engine power decreases about 3.5 percent for each 1,000 feet
abovesea level; and also will decrease about1 percentforeach 6 C(10 F)above16C
(60 F)ambient temperature.

General Information
1-7 READY TO RUN
The "Ready to Run" on the display is ready when all of the following
conditions are true:
3.
The AUTO/OFF/MANUAL switch is set to the AUTO position.
The utility voltage being supplied to the unit is being sensed
by the PCB. If the utility sense voltage is not connected to the
unit or if it is below approximately 150-160 volts AC, then
the system will display the message "No Utility Present". This
indicates that if the AUTO/OFF/MANUAL switch is placed in
the Auto position, the generator will start.
No alarms are present, for example, low oil pressure, high
temperature, etc.
1.8
FUEL REQUIREMENTS AND
RECOMMENDATIONS
With LP gas, use only the vapor withdrawal system. This type of
system uses the vapors formed above the liquid fuel in the storaqe
tank.
The engine has been fitted with a fuel carburetion system that
meets the specifications of the 1997 California Air Resources
Board for tamper-proof dual fuel systems. The unit will run on
natural gas or LP gas, but it has been factory set to run on natural
gas. Should the primary fuel need to be changed to LP gas, the
fuel system needs to be reconfigured. See the reconfiguring the
Fuel System section for instructions on reconfiguration of the fuel
system.
Recommended fuels should have a Btu content of at least 1,000
Btus per cubic foot for natural gas; or at least 2,520 Btus per
cubic foot for LP gas. Ask the fuel supplier for the Btu content of
the fuel.
Required fuel pressure for natural gas is five (5) inches to seven
(7) inches water column (0.18 to 0.25 psi); and for liquid pro
pane, 10 inches to 12 inches of water column (0.36 to 0.43 psi).
The primary regulator for the propane supply is NOT INCLUDED
with the generator.
NOTE:
All pipe sizing, construction and layout must comply with NFPA
54 for natural gas applications and NFPA 58 for liquid propane
vapor withdrawal applications. Once the generator is installed,
verify that the fuel pressure NEVER drops below five (5) inches
water column for natural gas or 10 inches water column for
liquid propane.
Prior to installation of the generator, the installer should consult
local fuel suppliers or the fire marshal to check codes and regula
tions for proper installation. Local codes will mandate correct rout
ing of gaseous fuel line piping around gardens, shrubs and other
landscaping to prevent any damage.
Special considerations should be given when installing the unit
where local conditions include flooding, tornados, hurricanes,
earthquakes and unstable ground for the flexibility and strength of
piping and theirconnections.
Use an approved pipe sealant or joint compound on all threaded
fitting.
All installed gaseous fuel piping must be purged and leak tested
prior to initial start-up in accordance with local codes, standards
and regulations.
1.9 FUEL CONSUMPTION
Unit
NG/LP
Nat. Gas
LPVapor
1/2 Load Full Load
1/2 Load Full
Load
9/10 kW
102
156
1.25/46
1.93/70
12/12 kW
149
224
1.68/59
2.67/94
15/15 kW
183
261
1.61/59
2.57/94
18/20 kW
206
294
1.89/69
2.90/106
• Natural gas isin cubic feet per hour.
"* LP is in gallons per hour/cubic feet per hour.
*** Values given are approximate.
NOTE:
Fuel piping "MUST" be based on full load consumption rates
regardless of actual load.
Verify that gas meter is capable of providing enough fuel flow to
include all gaseous household appliances running at maximum
capacity.
1.9.1 BTU FLOW REQUIREMENTS - NATURAL GAS
BTU flow required for each unit based on 1000 BTU per cubic foot.
• 9kW —156,000 BTU/Hour
• 12kW —224,000 BTU/Hour
• 15kW—-261,000 BTU/Hour
• 18kW— 294,000 BTU/Hour
A DANGER!
Gaseous fuels such as natural gas and liquid
^propane (LP) gas are highly explosive. Even
the slightest spark can ignite such fuels and
cause an explosion. No leakage of fuel is
permitted. Natural gas, which is lighter than
air, tends to collect in high areas. LP gas is
heavier than air and tends to settle in low
areas.
NOTE:
A minimum of one approved manual shut-off valve must be
installed in the gaseous fuel supply line. The valve mustbeeas
ily accessible. Local codes determine the proper location.

1.10 RECONFIGURING THE FUEL
SYSTEM
To reconfigure the fuel system from NG to LR follow these steps:
NOTE:
The primary regulator for the propane supply is NOT INCLUDED
vrith the generator. A fuel pressure of10to 12 inches of water
column (0.36 to 0.43 psi) MUST BE SUPPLIED to the fuel inlet
of the generator.
1. Open the roof.
2. For 10kW units: Loosen clamp and slide back the air inlet
hose.
• Slide fuel selectoron carburetor out towards the back ofthe
enclosure (Figures 1.3 and 1.4).
•
Return the inlet hoseand tighten clamp securely.
For 12,15 and 20kW units: remove the air cleaner cover.
• Slidethe selector lever out towards the back of the enclosure
(Figures 1.5 and 1.6).
• Return the air cleaner cover and tighten the two thumb
screws.
Close the roof.
Reverse the procedure to convert backto natural gas.
3.
4.
Figure 1.3 - WkW, GT-530 (Inlet Hose Slid Back)
Figure 1.4 - WkW, GT-530 (Inlet Hose Slid Back)
Fuel Selection
Lever - "Out'
Position for
Liquid Propane
(Vapor) Fuel
^5
General Information
Figure 1.5 -12, 15& 20kW,
GT-990/GT-999 (Airbox Cover Removed)
Figure 1.6-12, 15& 20kW,
GT-990/GT-999 (Airbox Cover Removed)
1.11 HIGH ALTITUDE OPERATION
The fuel system on this generator may be influenced by operation
at higher altitudes. Proper operation can be ensured by installing
an altitude kit when required. See the table below to determine
when an altitude kit is required. Operating this generator without
the proper altitude kit installed may increase the engine's emis
sions and decrease fuel economy and performance. Kits may be
obtained from any Dealer, and should be installed by a qualified
individual.

General Information
Unit
Fuel
Altitude Range*
Kit Part
Number
7/8 kW
LP Vapor 0 -
2600 ft Not Required
2600 - 6500 ft"
0J4931A
Nat. Gas
0 - 2000 ft Not Required
2000 - 4200 ft
0J4931A
4200 - 6500 ft"
0J4931B
9/10 kW
LP Vapor 0 -
2600 ft Not
Required
2600 - 6500 ft"
0J4930A
Nat. Gas
0-2000 ft Not
Required
2000 - 4200 ft
0J4930A
4200 - 6500 ft"
0J4930B
12-20 kW
LP Vapor
0 - 6500 ft"
Not Required
Nat. Gas
* Elevation above
**At elevations ab
performance
sea level
>ve 6500 ft, the
engine may experience
decreased
1.12 LOCATION
n.MJMdrli
A The engine exhaust fumes contain carbon
monoxide, which can be DEADLY. This dan
gerous gas, if breathed in sufficient con
centrations, can cause unconsciousness or
even death. This generator must be installed
properly, in strict compliance with applicable
codes and standards. Following installation,
do nothing
that might render the system
unsafe or in noncompliance with such codes
and standards.
Operate the generator outdoors ONLY.
• Keep exhaust gases from entering a confined
area through windows, doors, ventilation, crawl
spaces or other openings (Figure 1.7).
• It is highly recommended that carbon monox
ide detector(s) be installed indoors according
to the manufacturer's instructions/recommen
dations.
• The generator must be mounted safely per
applicable
codes and the manufacturer's speci
fications. Do NOT alter or add to the exhaust
system, or do anything that might render the
exhaust system unsafe or in noncompliance
with applicable codes and standards.
1.12.1 GENERATOR
Install the generator set, in its protective enclosure, outdoors,
where adequate cooling and ventilating air is always available
(Figure 1.7). Consider these factors:
• The installation of the generator must comply strictly with
NFPA 37, NFPA 54, NFPA 58, and NFPA 70 standards.
• Install the unit where air inlet and outlet openings will not
become obstructed by leaves, grass, snow, etc.. If prevailing
winds will cause blowing or drifting, consider using a wind
break to protect the unit.
• Install the generator on high ground where water levels will not
riseand endanger it.
Allow sufficient room on all sides of the generator for mainte
nance and servicing. This unit mustbe installed in accordance
with current applicable NFPA 37 and NFPA 70 standards; as
well as any other federal, state and local codes for minimum
distances from other structures. DO NOT install under wooden
decks or structures unless there is at least four (4) feet of clear
ance above the generator, three (3) feet of clearance on sides
and front, and 18 inchesofclearanceat back of unit.
Install the unit where rain gutter down spouts, roof run-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.
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.
Install the generator as close as possible to the fuel supply, to
reduce the length of piping.
Install the generator as close as possible tothe transfer switch.
REMEMBER THAT LAWS OR CODES MAY REGULATE THE
DISTANCE AND LOCATION.
The genset mustbe installed ona level surface. The base frame
must be level within two (2) inches all around.
The generator is typically placed on pea gravel or crushed
stone. Check local codes if a concrete slab is required. If a
concretebase slabis required, all federal, state and local codes
should be followed. Special attention should be given to the
concrete base slab which should exceed the length and width
of the generator by a minimum of six (6) inches (0.152 meters)
on all sides.
Figure 1.7-Generator Clearances

1.12.2 INSTALLATION GUIDELINES FOR STATIONARY
AIR-COOLED 10. 12. 15 AND 20 KW GENERATORS
The National Fire Protection Association has a standard for the
installation and use of stationary combustion engines. That
standard is NFPA 37 and its requirements limit the spacing ofan
enclosed generator set from a structure or wall (Figure 1.8).
NFPA 37, Section 4.1.4, Engines Located Outdoors. Engines, and
their weatherproof housings if provided, that are installed outdoors
shall be located at least 5 ft. from openings in walls and at least5
ft. from structures having combustible walls. A minimum separa
tion shall not be required where the following conditions exist:
1. The adjacent wall of the structure hasa fire resistance rating
of at least 1 hour.
2. The weatherproof enclosure is constructed of noncombus-
tible materials and it has been demonstrated that a fire within
the enclosure will not ignite combustible materials outside the
enclosure.
Annex A— Explanatory Material
A4.1.4 (2) Means of demonstrating compliance are by means
of full scale fire test or by calculation procedures.
Because of the limited spaces that are frequently available for
installation, it has become apparent that exception (2) would be
beneficial for many residential and commercial installations. With
that in mind, the manufacturer contracted with an independent
testing laboratory to run full scale fire tests to assure that the
enclosure will not ignite combustible materials outside the enclo
sure.
The criteria was to determine the worst case fire scenario within
the generator and to determine the ignitability of items outside the
engine enclosure at various distances. The enclosure is construct
ed of non-combustible materials and the results and conclusions
from the independent testing lab indicated that any fire within the
generator enclosure would not pose any ignition risk to nearby
combustibles orstructures, with or without fire service personnel
response.
Based on this testing and the requirements of NFPA 37,Sec 4.1.4,
the guidelines for installation of the generators listed above are
changed to 18 inches (457mm) from the back side of the gen
erator to a stationary wall or building. For adequate maintenance
and airflow clearance, the area above the generator should be at
least 4 feet with a minimum of 3 feet at the front and ends of the
enclosure. This would include trees, shrubs and vegetation that
could obstruct airflow. Seethe diagram onthe reverse ofthis page
and the installation drawing within the owner's manual for details.
Generator exhaust contains DEADLY carbon monoxide gas. This
dangerous gascancause unconsciousness or death. Do not place
the unit near windows, doors, fresh air intakes (furnaces, etc.) or
any openings in the building or structure, including windows and
doors of an attached garage.
General Information
A WARNING!
If the AUTO/OFF/MANUAL switch is not set
to its OFF position, the generator can crank
and start as soon as the battery cables are
connected. If the utility power supply is not
turned off, sparking can occur at the battery
posts and cause an explosion.
1.13 THE BATTERY
A DANGER!
DO NOT dispose of the battery in a fire. The
battery is capable of exploding.
x Abattery presents a risk of electrical shock
iAand high short circuit current. The following
precautions are to be observed when work
ing on batteries:
• Remove the 7.5A fuse from the generator con
trol panel.
• Remove watches, rings or other metal objects.
• Use tools with insulated handles.
• Wear rubber gloves and boots.
• Do not lay tools or metal parts on top of the
battery.
• Disconnect charging source prior to connecting
or disconnecting battery terminals.
A
A WARNING!
DO NOT open or mutilate the battery.
.Released electrolyte has been known to
be harmful to the skin and eyes, and to be
toxic.
The electrolyte is a dilute sulfuric acid that
is harmful to the skin and eyes. It is electri
cally conductive and corrosive.
The following procedures are to be observed:
• Wear full eye protection and protective clothing.
•
Where electrolyte contacts the skin, wash it off
immediately with water.
• Where electrolyte contacts the eyes, flush thor
oughly and immediately with water and seek
medical attention.
•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 bicarbonate of soda solution is to
be added until the evidence of reaction (foam
ing) has ceased. The resulting liquid is to be
flushed with water and the area dried.
Lead-acid batteries present a risk of fire
because they generate hydrogen gas. The fol
lowing procedures are to be followed:
DO NOT SMOKE when near the battery.
DO NOT cause flame or spark in battery area.
Discharge static electricity from body before
touching the battery by first touching a ground
ed metal surface.
A

General Information
10
Figure 1.8- Installation Guidelines
Nowindowsor openings in the wallpermitted
within5 feet fromany point of the generator.
60 inches
7 1
Existing Wall 18 inches
Minimum Distance
4
•36 inches-
These guidelines are based upon fire
testing of the generator enclosure and
the manufacturer's requirement for air
flowfor proper operation. Local
codes
may be different and more restrictive
than what is described here.
Top of Generator
36 inches
60 inches
•36 inches-
\
Clearance from windows,
doors, any openings in the
wall,
shrubs or vegetation
over 12" in height
Clearance from the ends and front of the
generator should be 36 inches. This
would include shrubs, trees and any
kindof vegetation. Clearance at thetop
should be a minimum of 60 inches from
any structure, overhang or projections
from the wall. The generator should not
be placed under a deck or other
structure that is closed in and would limit
or contain air flow.

Post Installation Start-up and Adjustments
Be sure the AUTO/OFF/MANUAL switch is
.set to the OFF position before connecting
the battery cables. If the switch is set to
AUTO or MANUAL, the generator can crank
and start as soon as the battery cables are
connected.
Be sure the utility power supply is turned off
>and the 7.5A fuse is removed from the gener
ator control panel, or sparking may occur at
the battery posts as the cables are attached
and cause an explosion.
Servicing of the battery isto be performed or supervised by per
sonnel knowledgeable of batteries and the required precautions.
Keep unauthorized personnel away from batteries.
See the Specifications section for the correct size and rating when
replacing the battery. Have these procedures performed at the
intervals specified in the "Service Schedule." A negative ground
system is used. Battery connections are shown on the wiring dia
grams. Make sure the battery is correctly connected and terminals
are tight. Observe battery polarity when connecting the battery to
the generatorset.
1.14 BATTERY REQUIREMENTS
See the Specifications section for correct battery size and rating.
1.15 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 follow
ing steps:
1. Set the generator's AUTO/OFF/MANUAL switch to OFF.
2. Turn off utility power supply tothe transfer switch.
3. Remove the 7.5A fuse from the generator control panel.
Battery cables were factory connected at the generator (Figure
1.9). Connect cables to battery postsas follows:
4. Connect the red battery cable (from starter contactor) to the
battery post indicated by a positive, POS or (+).
5.
Connect the black battery cable (from frame ground) to the
battery post indicated by a negative, NEG or (—).
6. Install the battery post covers (included).
NOTE:
Dielectric grease should be used on battery poststo aid inthe
prevention of corrosion.
NOTE:
Damage will result if battery connections are made in reverse.
NOTE:
In areaswheretemperatures regularly fall below32° F (0° C) it
is recommended that a
pad type battery heater be installed to
aid in cold climate starting.
Figure 1.9- Battery Cable Connections
BLACK
BLACK LEAD
(FROM FRAME)
RED LEAD
(FROM STARTER
CONTACTOR)
RED
+
1.16 BATTERY CHARGER
NOTE:
The battery charger is integrated into the control module in all
models.
It operates as a "Smart Charger" which ensures output is continu
ally optimized to promote maximum battery life and charging levels
are at safe conditions.
NOTE:
There is a warning onthe LCD display when the battery needs
service.
2A ACTIVATE THE GENERATOR
When battery power is applied tothe generator during the installa
tion process, the controller will light up. However, the generator still
needsto be activated before it will automatically run in the eventof
a power outage (see Activation Chart).
Activating the generator isa simple one time process that is guided
by the controller screen prompts. Once the product is activated,
the controller screen will not prompt you again, even if you discon
nect the generator battery.
After obtaining your activation code, please complete the following
steps at the generator's control panel in the Activation Chart.
Z2 BEFORE INITIAL START-UP
NOTE:
These units have been run and tested at the factory prior to
being shipped and do not require any type of break-in.
NOTE:
This unit comes filled with oil from the factory. Check the oil
level and add the appropriate amount if necessary. See the
maintenance section for appropriate oil for yourlocation.
Before starting, complete the following:
1. Setthe generator's main circuit breaker to its OFF (or OPEN)
position.
ii

Post Installation Start-up and Adjustments
ACTIVATION CHAW
CHOOSE LANGUAGE TROUBLESHOOTING
Display Reads:
Use ARROW keys to scroll to desired lan
guage. Press ENTER to select.
If the wrong language is chosen,it can be
changed later using the "edit" menu.
[ Language |
I - English +J
Escaped A II ^ « Enlcr
L_ ^
Display
!Reads:
Press ENTER to begin the activation pro
cess.
If ESCAPE is pressed instead of ENTER,
your generator will onlyrun in manual mode
(for test purposes) and NOT ACTIVATED will
be displayed. You will needto remove the
generator control panel fuse and disconnect
the T1, N1, N2 connector inthe external
connection box (if equipped), or disconnect
utility input (main breaker) to the transfer
switch for 3-5 seconds and reconnect. Then
begin with Step 1.
CActivate me (ENT) or }
(ESCto run in manual J
Escape/f A II ^ \\ Enter
L_ ^
Display
Reads:
If you do not have your activation code,
go to www.activategen.com or call
1-888-9ACTIVATE (922-8482).
If you already have your activation code,
wait 3-5 seconds for the next display.
[To Activate go to ]
I www.activategen.com J
Escape// All ^ \\ Enter
v^_ _J
ENTER ACTIVATION CODE (Passcode)
TROUBLESHOOTING
Display
Reads:
Use ARROW keys to scroll and find the first
number ofyour Activation Code.
Press ENTER to select.
Repeat this step until all digits have been
entered.
Use ESCAPE to correct previous digits.
f Serial 123456789 ^
I Passcode XXXXX +/-J
Escape/) A • \\ Enlor
^_ j)
Display
Reads:
Activation is complete when all digits are
entered aboveand your screen shows this
display.
Follow the controller prompts to continue
setting the time function. Refer to your
Owner's Manual with questions.
What happens if "Wrong Passcode Try
Again" appears?
Reenter the activation code. Ifa second
attempt is unsuccessful, check the number
against the code given on activategen.com.
If itis correctand the generator will not
accept it, contact 1-888-9ACTIVATE (922-
8482).
(^'SELECT HOUR (0-23)^
I"' 6 +" )
Escape// A || T \\ Enler |
^_ j)
12

Post Installation Start-up and Adjustments
2. Set the generator's AUTO/OFF/MANUAL switch to the OFF
position.
3. Turn OFF all breakers onthe load centerofthetransfer box (T1
and T2).
4. Turn OFF all loads connected to the transfer switch terminals
T1 and T2.
5. Check the engine crankcase oil level and, if necessary, fill to
the
dipstick FULL mark with the recommended oil. Do not fill
above the FULL mark.
6. Check the fuel supply. Gaseous fuel lines must have been
properly purged and leak tested in accordance with applicable
fuel-gas codes. All fuel shutoff valves in the fuel supply lines
must be open.
During initial start up only, the generator may exceed the normal
number of start attempts and experience an "over crank" fault (See
the "Overcrank" section). This is due to accumulated air in the fuel
system during installation. Reset the control board and restart up
to two more times, if necessary. If unit fails to start, contact the
local dealer for assistance.
A CAUTION!
Never operate the engine with the oil level
.below the "Add" mark on the dipstick. Doing
this could damage the engine.
15 CHECK TRANSFER SWITCH
OPERATION
Refer to the "Manual Transfer Operation" section, of the owner's
manual for procedures.
A DANGER!
DO NOT attempt manual transfer switch oper
ation until all power voltage supplies to the
transfer switch have been positively turned
off. Failure to turn off all power voltage sup
plies will result in extremely hazardous and
possibly fatal electrical shock.
A
2.4 ELECTRICAL CHECKS
Complete electrical checks as follows (voltages and frequencies
will be approximate):
1. Set the generator's main circuit breaker to its OFF (or OPEN)
position.
2. Set the generator's AUTO/OFF/MANUAL switch to the OFF
position.
3. Turn OFF all breakers on the load center ofthe transfer box (T1
and T2).
4. Turn onthe utility power supply to the transfer switch using
the means provided (such as a utility main line circuit break
er).
A DANGER!
The transfer switch is now electrically
"hot." Contact with "hot" parts will result in
extremely hazardous and possibly fatal
electrical shock. Proceed with caution.
A
5. Use an accurate AC voltmeter to check utility power source
voltage across transfer switch terminals N1 and N2. Nominal
line-to-line voltage should be 240 volts AC.
6. Check utility power source voltage across terminals N1 and
the transfer switch neutral lug; then across terminal N2 and
neutral. Nominal line-to-neutral voltage should be 120 volts
AC.
7. When certain that utility supply voltage is compatible with
transfer switch and load circuit ratings, turn OFF the utility
power supply to the transfer switch.
8. On the generator panel, set the Auto/Off/ Manual switch to
MANUAL. The engine should crankand start.
9. Let the engine warm up for about five minutes to allow inter
nal temperatures to stabilize. Then, set the generator's main
circuit breaker to its ON (orclosed) position.
BBEEB13
A Proceed with caution! Generator power volt
age is now supplied to the transfer switch.
Contact with live transfer switch parts will
result in dangerous and possibly fatal electri
cal shock.
10. Connect an accurate AC voltmeter and a frequency meter
across transfer switch terminal lugs E1 and E2. Voltage
should be 240-244at a frequency of59.5-60.5 Hertz.
11. Connect the AC voltmeter test leads across terminal lugs E1
and neutral; thenacross E2 and neutral. In both cases, voltage
reading should be 120-122 volts AC.
12. Set the generator's main circuit breaker to its OFF (or OPEN)
position.
13. Set the generator's AUTO/OFF/MANUAL switch to OFF. The
engine shouldshut down.
NOTE:
It is important not to proceed until certain that generator AC
voltage and frequency are correct and within the stated limits.
2.5 GENERATOR TESTS UNDER
LOAD
To test the generator set with electrical loads applied, proceed as
follows:
1. Set generator's main circuit breaker to its OFF (or OPEN) posi
tion.
2. Turn OFF all breakers onthe load centerofthetransfer box (T1
and T2).
3. Setthe generator's AUTO/OFF/MANUAL switch to OFF.
4. Turn OFF the utility power supply to the transfer switch,
using the means provided (such as a utility main line circuit
breaker).
A WARNING!
Do not attempt manual transfer switch opera
tion until all power voltage supplies to the
transfer switch have been positively turned
off. Failure to turn off all power voltage sup
plies will result in extremely hazardous and
possibly fatal electrical shock.
13
A

Operation
5.
6.
7.
9.
6.
7.
14
Manually set the transfer switch to the STANDBY position, i.e.,
load terminals connected to the generator's E1/E2 terminals.
The transfer switch operating lever should be down.
Set the generator's AUTO/OFF/MANUAL switch to MANUAL.
The engine should crank and start immediately.
Let the engine stabilize and warm up for a few minutes.
Set the generator's main circuit breaker to its ON (or CLOSED)
position. Loads are now powered by the standby generator.
Turn ON the load center of the transfer switch (T1 and T2).
10. Connect an accurate AC voltmeter and a frequency meter
across terminal lugs E1 and E2.
• Voltage should be greater than 240 volts and frequency
should be 60 Hz.
11. Let the generator run at full rated load for 20-30 minutes.
Listen for unusual noises, vibration or other indications of
abnormal operation. Check for oil leaks, evidence of overheat
ing, etc.
12. When testing under load is complete, turn OFF electrical
loads.
13. Set the generator's main circuit breaker to its OFF (or OPEN)
position.
14. Let the engine run at no-load for a few minutes.
15. Set the AUTO/OFF/MANUAL switch to OFF. The engine should
shut down.
£!i CHECKING AUTOMATIC
OPERATION
To check the system for proper automatic operation, proceed as
follows:
1.
Set generator's main circuit breaker to its OFF (or OPEN) posi
tion.
Checkthat the AUTO/OFF/MANUAL switch is set to OFF.
Turn OFF the utility power supply to the transfer switch, using
means provided (such asa utility main line circuit breaker).
Manually set the transfer switch to the UTILITY position, i.e.,
load terminals connected to the utility power source side.
Turn ON the utility power supply to the transfer switch,
using the means provided (such as a utility main line circuit
breaker).
Set the generator's main circuit breaker to its ON (or CLOSED)
position.
Set the AUTO/OFF/MANUAL switch to AUTO. The system is
now readyfor automatic operation.
8. Turn OFF the utility power supply tothe transfer switch.
With the AUTO/OFF/MANUAL switch at AUTO, the engine should
crank and start when the utility source power is turned OFF after a
10 second delay. After starting, the transfer switch should connect
load circuits to the standby side after a five (5) second delay. Let
the system go through its entire automatic sequence of operation.
With the generator running and loads powered by generator AC
output, turn ON the utility power supply tothe transfer switch. The
following should occur:
•
After about 15 seconds, the switch should transfer loads back
to the
utility power source.
• About one minute after re-transfer, the engine should shut
down.
3/i CONTROL PANEL INTERFACE
3.1.1 USING THE AUTO/OFF/MANUAL SWITCH
(FIGURE 3.1)
1.
2.
3.
A WARNING!
With the switch set to AUTO, the engine may
.crank and start at any time without warning.
Such automatic starting occurs when utility
power source voltage droops below a preset
level or during the normal exercise cycle. To
prevent possible injury that might be caused
by such sudden starts, always set the switch
to OFF and remove the fuses before work
ing on or around the generator or transfer
switch. Then, place a "DO NOT OPERATE"
tag on the generator panel and on the trans
fer switch.
"AUTO" Position - Selecting this switch activates fully auto
matic system operation. It also allows the unit to automati
cally start and exercise the engine every seven days with the
setting of the exercise timer (see the Setting the Exercise
Timer section).
"OFF" Position -This switch position shuts down the engine.
This position also prevents automatic operation.
"MANUAL' Position - Set the switch to MANUAL to crank
and startthe engine. Transfer to standby power will not occur
unlessthere is a utility failure.
Figure 3.1 - 10, 12, 15 &20kW
Generator Control Panel
AUTO OFF MANUAL

3.1.2 SETTING THE EXERCISE TIMER
This generator is equipped with an exercise timer. Once it is set,
the generator will start and exercise every seven days, on the day
of the week and atthe time of day specified. During this exercise
period, the unit runs for approximately 12 minutes and then shuts
down. Transfer of loads to the generator output does not occur
during the exercise cycle unless utility power is lost.
INSTALLATION ASSISTANT
Interconnect System Self Test Feature (follow the on-screen
prompts)
Upon power up, this controller will go through a system self test
which will check for the presence of utility voltage on the DC
circuits. This is done to prevent damage if the installer mistakenly
connects AC utility power sense wires into the DC terminal block.
If utility voltage is detected, the controller will display a warning
message and lock out the generator, preventing damage to the
controller. Power to the controller must be removed to clear this
warning.
Utility voltage must be turned on and present at the N1 and N2
terminals inside the generator control panel for this test to be
performed and pass.
NOTE:
DAMAGE CAUSED BY MISWIRING OF THE INTERCONNECT
WIRES IS NOT WARRANTABLE!
This test will be performed each time the controller is powered
up.
Upon first power up of the generator, the display interface will
begin an installation assistant. The assistant will prompt the user
to set the minimum settings to operate. These settings are sim
ply: Current Date/Time and Exercise Day/Time. The maintenance
intervals will be initialized whenthe exercise time is entered (Figure
3.1).
The exercise settings can be changed at any time via the "EDIT"
menu (see Appendix, "Menu System").
If the 12 volt battery is disconnected or the fuse removed, the
Installation Assistant will operate upon power restoration. The
only difference is the display will only prompt the customer for the
current Time and Date.
IF THE INSTALLER TESTS THE GENERATOR PRIOR TO
INSTALLATION, PRESS THE "ENTER" KEY TO AVOID SETTING
UP THE EXERCISE TIME. THIS WILL ENSURE THAT WHEN
THE CUSTOMER POWERS UP THE UNIT, HE WILL STILL BE
PROMPTED TO ENTER AN EXERCISE TIME.
NOTE:
The exerciser will only work inthe AUTO mode and will not work
unless this procedure is performed. The current date/time will
need to be reset every time the 12 volt battery is disconnected
andthen reconnected, and/or when the fuse is removed.
Low Speed Exercise
15 and 20kW units will run at 2,400 RPM on Low Speed
Exercize.
Operation
Display Interface Menus
The LCD display is organized as detailed below:
• The "Home" page, this page is the default page which will be
displayed if no keys are pressed for 30 seconds. This page
normally shows the current Status message and the current
date and time. The highest priority active Alarm and/or Warning
will be automatically posted on this page as well as flashing
the backlight when such an event is detected. In the case of
multiple Alarms or Warnings, only the first message will be
displayed. To clear an Alarm or Warning, see the Protection
Systems section - Clear Alarm.
• The display backlight is normally off. If the user presses any
key, the backlight will come on automatically and remain on for
30 seconds afterthe last keywas pressed.
• The "Main Menu" page will allow theuserto navigate to all other
pages or sub-menus by using the Left/Right and Enter keys.
This page can be accessed at any time with several presses of
the dedicated Escape key. Each pressofthe Escape key takes
you back to the previous menu until the main menu is reached.
This page displays the following options: HISTORY; STATUS;
EDIT; AND DEBUG. (See the Appendix - "Menu System".)
3^2 AUTOMATIC TRANSFER
OPERATION
To select automatic operation, do the following:
1. Make sure the transfer switch main contacts are set to their
UTILITY position, i.e., loads connected to the utility power
source (Figure 3.1).
2. Be sure that normal UTILITY power source voltage is avail
ableto transferswitch terminal lugs N1 and N2 (Refer to the
Electrical Datasection).
3. Set the generator's AUTO/OFF/MANUAL switch to AUTO.
4. Set the generator's main circuit breaker to its ON (or CLOSED)
position.
With the preceding steps complete, the generator will start auto
matically when utility source voltage drops below a preset level.
After the unit starts, loads are transferred to the standby power
source. Refer to the Sequence of Automatic Operation section.
3!5 SEQUENCE OF AUTOMATIC
OPERATION
3.3.1 UTILITY FAILURE
Initial Conditions: Generatorin Auto, ready to run, load being sup
plied by utility source. When utility fails (below 60% of nominal),
a 10 second (optionally programmable) line interrupt delay time is
started. If the utility is still gone when the timer expires, the engine
will crankandstart. Oncestarted, a five (5) second engine warm-
up timer will be initiated. When the warm-up timer expires, the
control will transferthe load to the generator. If the utility power is
restored (above 80% of nominal) at any time from the initiation of
the engine start until the generator is ready to accept load (5sec
ond warm-up time has not elapsed), the controller will complete
thestart cycle and run the generator through its normal cool down
cycle; however, the load will remain onthe utility source.
15

3.3.2 CRANKING
The system will control the cyclic cranking as follows: 16 second
crank, seven (7) second rest, 16 second crank, seven (7) second
rest followed by three (3) additional cycles of seven (7) second
cranks followed by seven (7) second rests.
Choke Operation
1. The 990/999cc engines have an electric choke in the air
box that is automatically controlled by the electronic control
board.
2. The 530cc engines have an electric choke on the divider panel
air inlet hose that is automatically controlled by the electronic
control board.
Failure to Start
This is defined as any of the following occurrences during crank
ing:
1.
2.
2.
3.
4.
5.
6.
7.
9.
16
Not reaching starter dropout within the specified crank cycle.
Starter dropout is defined as four (4) cycles at 1,000 RPM.
Reaching starter dropout, but then not reaching 2200 RPM
within 15 seconds. In this case the control board will go into
a rest cycle for seven (7) seconds, then continue the restof
the crank cycle.
During a rest cycle the start and fuel outputs are de-energized and
the magneto output is shorted to ground.
Cranking Conditions
The following notes apply during cranking cycle.
I. Starter motor will not engage within five (5) seconds of the
engine shutting down.
The fuel output will not be energized with the starter.
The starter and magneto outputs will be energized together.
Once the starter is energized the control board will begin look
ing for engine rotation. If it does not see an RPM signal within
three (3) seconds it will shut down and latch out on RPM
sensor loss.
Once the control board sees an RPM signal it will energize the
fuel solenoid, drive the throttle open and continue the crank
sequence.
Starter motor will disengage when speed reaches starter
dropout.
If the generator does not reach 2200 RPM within 15 seconds,
re-crank cycle will occur.
If engine stops turning between starter dropout and 2200
RPM, the board will go into a rest cycle for seven (7) seconds
then re-crank (if additional crank cycles exist).
Once started, the generator will wait for a hold-off period
before starting to monitor oil pressure and oil temperature
(refer to the Alarm Messages section for hold-off times).
10. During Manual start cranking, if the Mode switch is moved
from the Manual position, the cranking stops immediately.
II. During Auto mode cranking, if the Utility returns, the cranking
cycle does NOT abort but continues until complete. Once the
engine starts, it will run for one (1) minute, then shut down.
3.3.3 LOAD TRANSFER
The transfer of load when the generator is running is dependent
upon the operating modeas follows:
1. Manual
• Will not transfer to generator if utility is present.
• Will transfer to generator if utility fails (below 65% of nominal
for 10 consecutive seconds.
• Will transfer back when utility returns for 15 consecutive
seconds. The engine will continue to run until removed from
the Manual mode.
2. Auto
• Will start and run if Utility fails for 10 consecutive seconds.
• Will start a five (5) second engine warm-up timer.
• Will not transfer if utility subsequently returns.
• Will transfer to generator if utility is still not present.
• Will transfer back to utility once utility returns (above 75% of
nominal) for 15 seconds.
• Will transfer back to utility if the generator is shut down for
any reason (such as the switch is in the OFF position ora
shutdown alarm.
• After transfer, will shut down engine after one (1) minute
cool-down time.
3. Exercise
• Will not exercise if generator is already running in either Auto
or Manual mode.
• During exercise, the controller will only transfer if utility fails
during exercise for 10 seconds, and will switch to Auto
mode.
3.3.4 UTILITY RESTORED
Initial Condition: Generator supplying power to customer load.
When the utility returns (above 80% of nominal), a 15 second
return to utility timer will start. At the completion of this timer, if
the utility supply is still present and acceptable, the control will
transfer the load back to the utility and run the engine through a
one (1) minute cool down period and then shut down. If utility tails
for three (3) seconds during this cool down period, the control
will transfer load back to the generator and continue to run while
monitoring for utility to return.
3A MANUAL TRANSFER
OPERATION
3.4.1 TRANSFER TO GENERATOR POWER SOURCE
To start the generator and activate the transfer switch manually,
proceed as follows:
1.
2.
3.
Set the generator's AUTO/OFF/MANUAL switch to OFF.
Set the generator's main circuit breaker to its OFF (or OPEN)
position.
Turn OFF the utility power supply to the transfer switch
using the means provided (such as a utility main line circuit
breaker).

A DANGER!
ADO NOT attempt to activate the transfer
switch manually until all power voltage sup
plies to the switch have been positively
turned off. Failure to turn off all power volt
age supplies may result in extremely hazard
ous and possibly fatal electrical shock.
4. Use the manual transfer handle inside the transfer switch to
move the main contactstotheir STANDBY position, i.e., loads
connected tothe standby power source (Figure 3.2).
Figure 3.2- Manual Transfer Switch Operation
1
LOAD CONNECTED TO UTILITY POWER SOURCE
LOAD CONNECTED TO STANDBYPOWER SOURCE
5.
6.
7.
MANUALTRANSFER
HANDLE
TRANSFER SWITCH
OPERATING LEVER
To crank and start the engine, set the AUTO/OFF/MANUAL
switch to MANUAL.
Let the engine stabilize and warm up for a few minutes.
Setthe generator's main circuit breaker to its ON (or CLOSED)
position. The standby power source now powers the loads.
3.4.2 TRANSFER BACK TO UTILITY POWER SOURCE
When utility power has been restored, transfer back to that source
and shut down the generator. This can be accomplished as fol
lows:
1. Set the generator's main circuit breaker to its OFF (or OPEN)
position.
2. Let the engine run for a minute or two at no-load to stabilize
the internal temperatures.
3. Set the generator's AUTO/OFF/MANUAL switch to its OFF (or
OPEN) position. The engine should shut down.
4. Check that utility power supply tothe transfer switch is turned
OFF.
ADO NOT attempt to activate the transfer
switch manually until all power voltage sup
plies to the switch have been positively
turned off. Failure to turn off all power volt
age supplies may result in extremely hazard
ous and possibly fatal electrical shock.
Operation
5. Use the manual transfer handle inside the transfer switch to
move the main contacts back to their
UTILITY position, i.e.,
loads connected to the utility power source (Figure 3.2).
6. Turn ON the utility power supply to the transfer switch using
the means provided.
7. Set the system to automatic operation as outlined in Automatic
Transfer Operation section.
3.5 SIDE COMPARTMENT
(FIGURES 3.3 &3.4)
Local codes may require this compartment to be locked. A hasp is
provided so the owner can secure the compartment with their own
padlock. Check local codes in the area.
3.5.1 MAIN CIRCUIT BREAKER
This isa 2-pole breaker rated according to the Specifications sec
tion.
3.5.2 EXTERIOR READY LIGHTS
• Green LED 'Ready' light ison when utility is present and switch
is in AUTO indicating the generator is ready and when the gen
erator is running.
• Red LED 'Alarm' light is on when the generator is OFF or a fault
is detected. (See the Protections Systems section.)
• Yellow LED 'Maintenance' light (See the Protections Systems
section.)
3.5.3 120 VAC GFCI OUTLET & 15 AMP BREAKER
Some models are equipped with an external, 15 amp, 120 volt,
GFCI convenience outlet that is located in acompartment on the
right side of generator (Figure 1.3).
When the generator is running, in the absence of utility power, this
outlet may also be used to power items outside your home such
as lights or power tools. This outlet may also be used when utility
power is present by running the generator in manual mode. This
outlet does not provide power if the generator is not running. This
outlet is protected by a 15 amp circuit breaker in the same com
partment as the outlet. (Do not use when the generator is running
in exercise mode.)
Figure 3.3- Side Compartment
17

Operation
Figure 3.4- Open Side Compartment
120V GFJCJ Outlet 15 Amp Qutlat Bmfllror
3.6 PROTECTION SYSTEMS
3.6.1 ALARMS
Highest Priority (Latching) Displayed on the control panel and the
external red LED. They must be cleared before the alarm message
goes away. The alarm log records each occurrence (see Appendix
- "Menu System").
Low Oil Pressure (Shutdown Alarm)
A five (5) second delay on start-up and seven (7) second delay
oncethe engine is running.
This switch (Figure 3.5) has normally closed contacts that are
held open by engine oil pressure during operation. Should the oil
pressure drop below the five (5) PSI range, switch contacts close
and the engine shuts down. The unit should not be restarted until
oil level is verified.
High Engine Temperature (Shutdown Alarm - Auto Reset)
A 10 second delay on start-up and one (1) second delay before
shutdown. Auto reset when the condition clears and restart the
engine if a valid start signal is still present.
This switch's contacts (Figure 3.5) close if the temperature should
exceed approximately 144° C (293° F), initiating an engine shut
down. Once the oil temperature drops toa safe level the switch's
contacts open again.
Over Crank (Shutdown Alarm)
This occurs if the engine has not started within the specified crank
cycle. (See "Cranking" section.)
NOTE:
The oil drain hose may be routed in the opposite direction as
shown in figure.
IS
Figure 3.5- LowOilPressure and
High Temperature Switches
Low Oil Switch
High TempSwitch
Over Speed (Shutdown Alarm)
4320 RPM for three (3) seconds or 4500 RPM immediately. This
feature protects the generator from damage by shutting it down
if it happens to run faster than the preset limit. This protection
also prevents the generator from supplying an output that could
potentially damage appliances connected to the generator circuit.
Contact the nearest Dealer ifthis failure occurs.
RPM Sense Loss (Shutdown Alarm)
During cranking, if the Control Board does not see a valid RPM
signal within three (3) seconds, it will shut down and lock out on
RPM sense loss. While engine is running, if RPM signal is lost for
one (1) second the Control Board will shut the engine down, wait
15 seconds, then re-crank the engine. If no RPM signal is detected
within the first three (3) seconds of cranking, the Control Board
will shutthe engine down and latch outon RPM sensor loss. If the
RPM signal is detected, the engine will start and run normally. If
the RPM signal is subsequently lost again, the Control Board will
try one more re-crank attempt before latching out and displaying
the RPM sensor failure message.
Under-frequency (Shutdown Alarm)
After starting, if the generator stays under frequency for more
than 30 seconds it will shut down. The under-frequency settinq is
55 Hz.
Internal Fault (Shutdown Alarm)
This alarm cannotbe cleared, call service dealer.
Undervoltage (Shutdown Alarm)
If the generator voltage falls below 85% of nominal for more than
10 seconds, it shuts down.