Pacific scientific Redi-line da12l-1600a User manual

JL91374 99-4-5M PRINTED IN U.S.A.

Rugged, Reliable,

DC to AC Power Conversion

REDI-LINE

™

ELECTRIC GENERATORS

USER'S GUIDE

4301 Kishwaukee Street

P.O. Box 106

Rockford, Illinois 61105-0106

(815) 226-3100 Fax (815) 226-3080

LOCATIONS:

Rockford, IL

Wilmington, MA

Ennis, Ireland

PK91282

WARRANTY REGISTRATION

NAME ______________________________________________

ADDRESS ___________________________________________ PHONE ( ) ___________

CITY _______________________________ STATE ________ ZIP____________________

Where did you purchase your REDI-LINE Generator? __________________________________

Name of Business ______________________________________________________________

ADDRESS ____________________________________________________________________

Model # _______________________________ Purchase date _________________________

Generator application area: Medical RV Marine Construction Cable TV

Agriculture Utility Co. Consumer Other ___________________________________

How did you learn about the REDI-LINE Generator?

magazine ad previously owned one

newspaper ad salesperson

friend store demonstration

exhibit show other _______________________________________________

What device will the generator power primarily?

_____________________________________________________________________________

Thank you for your time in filling out this warranty card.

PACIFIC SCIENTIFIC MOTOR PRODUCTS DIVISION

Table of Contents

Page

Function................................................................................................................................................ 2

Features ................................................................................................................................................ 2

Specifications........................................................................................................................................ 2

Unpacking & Insertions ....................................................................................................................... 3

Installation Requirements.................................................................................................................... 3-4

Wiring Installation ...............................................................................................................................5-10

Maintenance.......................................................................................................................................... 11

Service................................................................................................................................................... 11

Warranty ............................................................................................................................................... 11

Mounting Templates ...........................................................................................................................12-13

REDI-LINE ELECTRIC GENERATOR

MODEL _______________________________________________________________

INPUT ACTUAL _________________________________________________________

OUTPUT ACTUAL _______________________________________________________

OUTPUT WATTS ________________________________________________________

SERIAL NO. ____________________________________________________________

PACIFIC SCIENTIFIC MOTOR PRODUCTS DIVISION ROCKFORD, IL 61109

Fill in Data for your permanent records.

The model and electrical data will be found on the body nameplate. Due to certain mounting applications, this data may become

obstructed. You should record information and keep in a safe place for future reference.

4301 Kishwaukee Street

P.O. Box 106

Rockford, IL 61105-0106

(815) 226-3100

Fax (815) 226-3148

User’s Guide

REDI-LINE®Electric Generator

The REDI-LINE Generator is a quality product, designed to be rugged, reliable and safe when installed

properly. Improper installation can cause damage to the unit and/or result in serious personal injury.

Read this entire manual before starting installation. If you have questions on installation or operation of the

generator, contact your REDI-LINE distributor for assistance. If you do not have a distributor contact, call Pacific

Scientific direct at (815) 226-3100.

Models DA12A-500A DA12L-1600A-GFI DA24A-800A DA24L-1600A DA36A-900A DA36L-1600A

Input Voltage (DC) 12 12 24 24 36 36

Nominal Input Voltage (DC) 12.6 12.6 25.2 25.2 37.8 37.8

Continuous Output Watts 500 1600 800 1600 900 1600

Surge Output Watts 750 2400 1200 2400 1350 2400

Output Voltage* (AC) 120 120 120 120 120 120

Output Frequency (Hz) 65 65 60 60 60 60

Continuous Output Current 4.5 14.5 7.3 12.8 8.2 14.5

Surge Output Current (Amps) 7 22 11 20 12 22

Wave Shape Sine Sine Sine Sine Sine Sine

Length (inches) 16.25 16.75 16.25 15.13 16.25 15.13

Height (inches) 5.5 9.13 5.5 9.13 5.5 9.13

Diameter (inches) 5.18 7.38 5.18 7.38 5.18 7.38

Weight (lbs.) 26 53 26 48 26 48

Ambient Temperature Range, all models: -30° to +130° F (-34° to +54° C)

3. Specifications

Models DA3179 DA3252 DA3272 DA3444

Input Voltage (DC) 12 12 24 24

Nominal Input Voltage (DC) 12.6 12.6 25.2 25.2

Continuous Output Watts 500 1600 800 1600

Surge Output Watts 750 2200 1200 2400

Output Voltage* (AC) 230 230 230 230

Output Frequency (Hz) 50 50 50 50

Continuous Output Current 2.3 7.3 3.6 7.3

Surge Output Current (Amps) 3.5 11 5.4 11

Wave Shape Sine Sine Sine Sine

Length (cm) 41.3 42.5 41.3 38.5

Height (cm) 19.4 23.2 19.4 23.2

Diameter (cm) 13.2 18.1 13.2 18.1

Weight (kg) 11.8 23.8 11.8 21.7

Ambient Temperature Range, all models: -30° to +130° F (-34° to +54° C)

* Variance from output voltage

and frequency is dependent

on load size and the DC

input voltage. Typical voltage

tolerance is ±15%. Typical

frequency tolerance is ±5%.

Carefully monitor any

equipment that is sensitive

to fluctuations in either

voltage or frequency.

1. Function

The REDI-LINE Generator is an electromechanical device

that converts DC to AC. The DC supply is one or more deep

cycle batteries that are typically added to the electrical

system of your vehicle.

Convenient, remote operation of most tools, appliances

and lighting is assured as long as their power consumption

is within the nameplate rating of the generator. Your

REDI-LINE generator is designed to supply true sine-wave

electrical power for years of trouble free service.

2. Features

• Built rugged and reliable with sturdy steel housing.

Two year warranty.

• Demand Start Circuitry extends battery life.

• Easily delivers peak output currents up to 1.5 times the

continuous output rating for extra starting power.

• Conveniently mounts in any position in a minimum of

space.

•True sine-wave output.

• Optional GFI outlet.

• Operates in ambient temperatures from -30°F to 130°F.

CAUTION

DA12L-1600A

4. Unpacking and Inspection

Open the top of the box and lift the Generator and the

insert out.

This generator is a heavy piece of equipment. Removing it

from the box may require more than one person to avoid

dropping the generator and prevent personal injury.

Inspect the unit for any damage that may have been

sustained during shipment. If you find damage, contact the

shipper immediately to file a claim.

5. Installation Requirements

Most REDI-LINE service requests result from improperly

installed units. Improper installation will affect generator

performance and may damage the unit. Generator damage

caused by improper installation is not covered under

warranty.

Battery Selection

Standard automotive batteries are designed to supply 300

to 500 amps of current over a relatively short period,

therefore, they are not the best power source for generator

operation. Deep cycle or marine batteries are designed to

deliver lower current levels for a longer time and are capable

of taking deep discharges without battery damage. For this

reason, a deep cycle battery is recommended for REDI-LINE

operation.

Batteries are rated in cold cranking amps (CCA). In

general, the higher the CCA the longer the battery will

operate a generator load. Length of run time depends on the

battery capacity, the size of the load (tool or appliance

connected to the generator), and how frequent the load is

operated.

Use the following formula to estimate how long a fully

charged deep cycle battery will keep the REDI-LINE

operating continuously before the battery needs recharging:

Hours = Cold Cranking Amps (CCA)

180 x AC Load Amps

Cold Cranking Amps are equal to the total of all batteries.

AC Load Amps is the AC current rating listed on the

nameplate of the tool or appliance.

For Example: Two batteries with a CCA rating of 675 are used to operate

a Generator. An AC load of 4 amps is required by the tool being operated.

Continuous run time is:

Hours = 675 + 675 = 1.87 Hours

180 x 4

To further extend the operating time of the generator, the

generator's battery system should be connected to the vehicle

charging system. With the vehicle running, the alternator

charges the generator battery bank which provides a longer

run time. If you plan to use the generator continuously, you

may need to install a larger alternator in your vehicle.

Consult your REDI-LINE distributor for more

information.

NOTE: Installation and wiring must conform to all applicable

codes, including the National Electric Code, state and local, or

other codes in effect at the time of installation.

Automotive and marine type batteries produce dangerous

current levels. Protect yourself when working around these

batteries and electrical systems. This includes the use of

safety goggles.

Mounting Guidelines

After reviewing your generator usage and selecting the

battery size and number of batteries, determine the best

location to mount your generator and its power supply.

When choosing a location, observe these guidelines:

• Keep the generator as close to the battery as possible to

reduce the length of the power cables. Long power cables

will reduce the amount of voltage to the generator and

decrease performance.

• Allow at least 2 inches of free air space around the

generator. Do not obstruct the ventilation as it can cause

the generator to overheat.

• Do not install the generator in areas with

direct exposure to water, or compartments containing

batteries or explosive fumes.

• Do not install in unventilated areas where

ignitable fumes can collect.

Mounting the Generator

The generator is not position sensitive and may be

mounted in whatever orientation best suits your application.

• Place the unit in the desired position or use the

templates on pages 12-13 to mark the location of the

mounting holes.

• Remove the generator or template. At the marked

location, drill 1/4" holes and fasten the generator using

four 1/4” flat washers, lock washers, bolts, and nuts

through the holes in the base flange.

Installation Wiring

Install additional batteries, fuses, and, if required, a

battery isolator. See Installation Illustrations (pages 5-11)

for specific instructions. Cable, connectors, fuses and

isolators may be available from your authorized REDI-LINE

distributor. Many also provide complete installation services.

Pacific Scientific recommends that the REDI-LINE

Generator always be installed using proper fuses or circuit

breakers. See the Installation Illustrations for suggested fuse

sizes and location. Place fuses no farther than 18” from the

battery.

It is important that the polarity (+ & -) be correctly

connected to the generator. Note polarity indications on

Installation Diagrams shown in this guide.

WARNING

CAUTION CAUTION

CAUTION

The connection between the supply battery and the REDI-

LINE Generator is one of the most critical installation steps.

Choose the correct supply cable size from the following

table. Using the wrong supply cable size will damage the

generator.

Do not ground the negative (-) REDI-LINE supply terminal

to the vehicle chassis. The negative REDI-LINE terminal

must be connected directly to the supply battery using the

proper size supply cable.

Recommended Supply Cable Size

Between Battery and REDI-LINE Generator

Less than 10 ft. #0 AWG Cable. More than 10 ft. #00 AWG Cable.

*Recommended minimum wire gauge for DA12L-1600A & DA3252

with one battery.

NOTE: Damage caused by incorrectly installing your

REDI-LINE generator is not covered by warranty.

Carefully plan the power supply cable route. Do not allow

the cables to rub against sharp surfaces which could cut the

cable insulation and cause a short against the vehicle frame.

NOTE: When attaching the power cables to the generator, a

spark at the connection may occur. This is normal and does

not mean the generator is defective.

The REDI-LINE generator will not run until the demand

start circuit senses a load. To turn on the generator plug a

load into the generator receptacle and turn on the device

switch. The generator should start. After the AC load is

removed the generator will stop in 2 to 10 seconds.

If the generator does not start, or cycles on and off, the

AC load may be too small or the AC device may not be

turned on. Verify the device is turned on or try adding more

load to the generator.

For Cable Length in Feet

Generator up to 3’ 3’ to 8’ 8’ to 10’ 10’ & over

DA3179

DA12A-500A #6 #4 #4 #4

DA24A-800A

DA3272 #6 #6 #6 #4

DA36A-900A

DA12L-1600A*

& DA32526 #2* #2* #2* #0*

DA24L-1600A

DA3444 & #6 #6 #6 #4

DA36-1600A

Recommended Wiring Installation

DA12A-500A and DA3179

Infrequent Use with Varying Loads

If the load requirement is not heavy (intermittent

hand tool use or light loads for a long period of

time) the vehicle battery and charging system

should handle both vehicle and additional

generator demand.

12 Volt

Battery

Vehicle Battery

+–

REDI-LINE Generator

To Vehicle

75 Amp

Fuse

Ground

–

Frequent Use with Varying Loads

If the load requirements are heavy (constant use

of hand tools or large loads) install one or more

auxiliary deep cycle batteries. The auxiliary

battery should be isolated from the vehicle

battery using a battery isolator. The battery

isolator is a one way path so both batteries are

charged by the vehicle but one battery cannot

discharge the other. This will ensure the vehicle

battery is always charged and you will be able to

start your vehicle.

To Vehicle

12 Volt

Battery

Auxiliary Battery

+–

REDI-LINE Generator

75 Amp

Fuse

Isolator*

Fuse

To The

Alternator

Ground

–

12 Volt

Battery

Isolator

Vehicle Battery

+–

*Use fuse size recommended

by isolator manufacturer

Recommended Wiring Installation

DA12L-1600A and DA 3252

Infrequent Use with Varying Loads

If the load requirement is not heavy (intermittent

hand tool use or light loads for a long period of

time) install one or more auxiliary deep cycle

batteries. The auxiliary battery should be isolated

from the vehicle battery using a battery isolator. The

battery isolator is a one way path so both batteries

are charged by the vehicle but one battery cannot

discharge the other. This will ensure the vehicle

battery is always charged and you will be able to

start your vehicle.

To Vehicle

12 Volt

Battery

Jumper

Cables

+– +–

REDI-LINE Generator

200 Amp

Fuse

To The

Alternator

Ground

–

–+

12 Volt

Battery

Isolator

Isolator*

Fuse

Frequent Use with Varying Loads

If the load requirements are heavy (constant use of

hand tools or large loads) install two or more

auxiliary deep cycle batteries. The auxiliary batteries

should be isolated from the vehicle battery using a

battery isolator. The battery isolator is a one way

path so both batteries are charged by the vehicle but

one battery cannot discharge the other. This will

ensure the vehicle battery is always charged and you

will be able to start your vehicle.

To Vehicle

12 Volt

Battery

Jumper

+–+–

REDI-LINE Generator

100 Amp

Fuse 100 Amp

Fuse

To The

Alternator

Ground

–

–+

12 Volt

Battery

Isolator

12 Volt

Battery

+–

Ground

Cables

Isolator*

Fuse

Isolator*

Fuse

*Use fuse size recommended

by isolator manufacturer

Recommended Wiring Installation

DA24A-800A and DA3272

Infrequent Use with Varying Loads

If the load requirement is not heavy

(intermittent hand tool use or light loads

for a long period of time) the vehicle

battery and charging system should handle

both the vehicle and additional generator

demand.

12 Volt

Battery

Vehicle Batteries

+–

12 Volt

Battery

+–

REDI-LINE Generator

To Vehicle

50 Amp

Fuse

Ground

–

Frequent Use with Varying Loads

If the load requirements are heavy

(constant use of hand tools or large loads)

install two or more deep cycle auxiliary

batteries. The auxiliary battery should be

isolated from the vehicle battery using a

battery isolator. The battery isolator is a

one way path so both batteries are charged

by the vehicle but one battery cannot

discharge the other. This will ensure the

vehicle battery is always charged and you

will be able to start your vehicle.

REDI-LINE Generator

50 Amp

Fuse

–

12 Volt

Battery

+–12 Volt

Battery

+–

Auxiliary Batteries Vehicle Batteries

To Vehicle

Ground

To The

Alternator

Isolator

12 Volt

Battery

+–12 Volt

Battery

+–

Isolator*

Fuse

*Use fuse size recommended

by isolator manufacturer

Recommended Wiring Installation

DA24L-1600A and DA3444

Infrequent Use with Varying Loads

If the load requirement is not heavy

(intermittent hand tool use or light loads

for a long period of time) the vehicle

battery and charging system should

handle both the vehicle and additional

generator demand.

12 Volt

Battery

Vehicle Batteries

+–

12 Volt

Battery

+–

To Vehicle

100 Amp

Fuse

Ground

REDI-LINE Generator

–

Frequent Use with Varying Loads

If the load requirements are heavy

(constant use of hand tools or large loads)

install two or more deep cycle auxiliary

batteries. The auxiliary battery should be

isolated from the vehicle battery using a

battery isolator. The battery isolator is a

one way path so both batteries are

charged by the vehicle but one battery

cannot discharge the other. This will

ensure the vehicle battery is always

charged and you will be able to start your

vehicle.

100 Amp

Fuse

12 Volt

Battery

+–12 Volt

Battery

+–

Auxiliary Batteries Vehicle Batteries

To Vehicle

Ground

To The

Alternator

Isolator

12 Volt

Battery

+–12 Volt

Battery

+–

REDI-LINE Generator

–

Isolator*

Fuse

*Use fuse size recommended

by isolator manufacturer

Recommended Wiring Installation

DA36-900A

Infrequent Use with Varying Loads

If the load requirement is not heavy

(intermittent hand tool use or light loads for a

long period of time) the vehicle battery and

charging system should handle both the vehicle

and additional generator demand.

12 Volt

Battery

Vehicle Batteries

+–

12 Volt

Battery

+–

12 Volt

Battery

+–

REDI-LINE Generator

To Vehicle

50 Amp

Fuse

Ground

–

Frequent Use with Varying Loads

If the load requirements are heavy

(constant use of hand tools or large

loads) install two or more auxiliary deep

cycle batteries. The auxiliary batteries

should be isolated from the vehicle

battery using a battery isolator. The

battery isolator is a one way path so both

batteries are charged by the vehicle but

one battery cannot discharge the other.

This will ensure the vehicle battery is

always charged and you will be able to

start your vehicle.

12 Volt

Battery

+–12 Volt

Battery

+–12 Volt

Battery

+–

Auxiliary Batteries Vehicle Batteries

REDI-LINE Generator

To Vehicle

50 Amp

Fuse

Ground

–

12 Volt

Battery

+–12 Volt

Battery

+–12 Volt

Battery

+–

To The

Alternator

Isolator

Isolator*

Fuse

*Use fuse size recommended

by isolator manufacturer

Recommended Wiring Installation

DA36L-1600A

Infrequent Use with Varying Loads

If the load requirement is not heavy

(intermittent hand tool use or light loads for a

long period of time) the vehicle battery and

charging system should handle both the

vehicle and additional generator demand.

12 Volt

Battery

Vehicle Batteries

+–

12 Volt

Battery

+–

12 Volt

Battery

+–

REDI-LINE Generator

To Vehicle

100 Amp

Fuse

Ground

–

Frequent Use with Varying Loads

If the load requirements are heavy

(constant use of hand tools or large loads)

install two or more auxiliary deep cycle

batteries. The auxiliary batteries should be

isolated from the vehicle battery using a

battery isolator. The battery isolator is a

one way path so both batteries are charged

by the vehicle but one battery cannot

discharge the other. This will ensure the

vehicle battery is always charged and you

will be able to start your vehicle.

Auxiliary Batteries Vehicle Batteries

12 Volt

Battery

+–12 Volt

Battery

+–12 Volt

Battery

+–

To Vehicle

Ground

12 Volt

Battery

+–12 Volt

Battery

+–12 Volt

Battery

+–

To The

Alternator

Isolator

REDI-LINE Generator

100 Amp

Fuse –

Isolator*

Fuse

*Use fuse size recommended

by isolator manufacturer

6. Maintenance

Because the REDI-LINE generator contains long life

bearings and brushes, it is virtually maintenance free. A

periodic wipe down of the unit and inspection of all

mounting hardware for tightness is all that is needed. Cable

and battery connections should also be inspected regularly.

7. Service

If your REDI-LINE Generator should need service, contact

your nearest authorized REDI-LINE distributor. To obtain

the location of your nearest REDI-LINE distributor, contact

Pacific Scientific at 815-226-3100.

8. Warranty

Pacific Scientific warranties its REDI-LINE Generator

“Product(s)” to the original purchaser the “Customer”, and

in the case of original equipment manufacturers or

distributors to their original consumer the “Customer” to be

free from defects in material and workmanship and to be

made in accordance with Customer’s specifications which

have been accepted in writing by Pacific Scientific. In no

event, however, shall Pacific Scientific be liable or have any

responsibility under such warranty if the Products have

been improperly stored, installed, used or maintained, or if

Customer has permitted any unauthorized modifications,

adjustments and/or repairs to such Products. Pacific

Scientific’s obligation is limited solely to repairing or

replacing (at its option), at its approved repair facility, any

Products, or parts which prove to Pacific Scientific’s

satisfaction to be defective as a result of defective materials

or workmanship, in accordance with Pacific Scientific’s

stated warranty, provided, however, that written notice of

claimed defects shall have been given to Pacific Scientific

within two (2) years after the date of the product date code

that is affixed to the Product, and within thirty (30) days

from the date any such defect is first discovered. The

Products or parts claimed to be defective must be returned

to Pacific Scientific, or an Authorized Redi-Line distributor,

transportation prepaid by customer, with written

specifications of the claimed defect. Evidence acceptable to

Pacific Scientific must be furnished that the claimed defects

were not caused by misuse, abuse, or neglect by anyone

other than Pacific Scientific.

THE FOREGOING WARRANTIES ARE IN LIEU OF ALL

OTHER WARRANTIES (EXCEPT AS TO TITLE), WHETHER

EXPRESSED OR IMPLIED, INCLUDING WITHOUT

LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR

OF FITNESS FOR ANY PARTICULAR PURPOSE, AND ARE

IN LIEU OF ALL OTHER OBLIGATIONS OR LIABILITIES

ON THE PART OF PACIFIC SCIENTIFIC. PACIFIC

SCIENTIFIC’S MAXIMUM LIABILITY WITH RESPECT TO

THESE WARRANTIES, ARISING FROM ANY CAUSE

WHATSOEVER, INCLUDING WITHOUT LIMITATION,

BREACH OF CONTRACT, NEGLIGENCE, STRICT

LIABILITY, TORT WARRANTY, PATENT OR COPYRIGHT

INFRINGEMENT, SHALL NOT EXCEED THE PRICE

SPECIFIED OF THE PRODUCTS GIVING RISE TO THE

CLAIM, AND IN NO EVENT SHALL PACIFIC SCIENTIFIC

BE LIABLE UNDER THESE WARRANTIES OR

OTHERWISE, EVEN IF PACIFIC SCIENTIFIC HAS BEEN

ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, FOR

SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES,

INCLUDING WITHOUT LIMITATION, DAMAGE OR LOSS

RESULTING FROM INABILITY TO USE THE PRODUCTS,

INCREASED OPERATING COSTS RESULTING FROM A

LOSS OF THE PRODUCTS, LOSS OF ANTICIPATED

PROFITS, OR OTHER SPECIAL, INCIDENTAL, OR

CONSEQUENTIAL DAMAGES, WHETHER SIMILAR OR

DISSIMILAR, OF ANY NATURE ARISING OR RESULTING

FROM THE PURCHASE, INSTALLATION, REMOVAL,

REPAIR, OPERATION, USE OR BREAKDOWN OF THE

PRODUCTS, OR ANY OTHER CAUSE WHATSOEVER,

INCLUDING PACIFIC SCIENTIFIC’S NEGLIGENCE.

The forgoing shall also apply to Products, or parts for the

same which have been repaired or replaced pursuant to such

warranty.

No person,including any agent, distributor, or representative

of Pacific Scientific, is authorized to make any

representation or warranty on behalf of Pacific Scientific

concerning any Products manufactured by Pacific Scientific,

except to refer purchasers to this warranty.

3.812 ±.06

2.75

4.25

5.625 ±.06

4X .34

4X .88

+.05

–.00

DAI2A, DA24A, DA36A, DA3179 and DA3272 Mounting

All measurements in inches.

2.00.88 .88

.34

5.00

3.00

1.00

6.50

2.00

DAI2L, DA24L, DA36L, DA3252 and DA3444 Mounting

All measurements in inches.