OWNERS MANUAL MODEL SERIES: P2201 P2701 P3201 Stationary Standby Electric Generator IMPORTANT SAFETY INSTRUCTIONS – Please make certain that persons who are to install, operate and maintain this equipment thoroughly read and understand these instructions prior to operation. SAVE THESE INSTRUCTIONS — This manual contains important instructions that should be followed during installation and maintenance of the generator and battery. Product style and configuration may vary.
TA B L E O F C O N T E N T S Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL SAFETY GUIDELINES The following information relates to protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help you recognize this information, we use the following symbols. Please read the manual and pay attention to these sections. Also read and follow all safety labels on the engine/generator set. If labels are damaged or unreadable, contact product service for replacements. This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
GENERAL SAFETY GUIDELINES (Continued) WARNING: CAUTION: The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. Units with broken or missing parts, without protective housing or covers should never be operated. Contact your service center for replacement parts. Keep a fire extinguisher near the generator at all times.
INTRODUCTION The stationary standby electric generator is manufactured for our customers to supply reliable backup power. The generator is a compact unit, designed to supply the power for your critical needs when utility power fails. The standby generator will run on Liquid Propane Gas or Natural Gas allowing flexibility for getting the power you need. Fuel lines should be installed by a licensed plumber or other qualified professionals or licensed gas technician.
G E N E R AT O R S P E C I F I C AT I O N S P2201 (22 KW) P2701 (27 KW) P3201 (32 KW) Rated Wattage - (Standby) @1.0 PF LPG * 22,000 27,000 32,000 Rated Wattage - (Standby) @1.0 PF NG * 19,800 24,300 28,800 120/240 volts 184/92 amps LPG 60 HZ 1.0 105°C H GM 3.0 L 120/240 volts 224/112 amps LPG 60 HZ 1.0 105°C H GM 3.0 L 120/240 volts 255/133 amps LPG 60 HZ 1.0 105°C H GM 3.0 L Voltage Rated Current Frequency Power Factor Max.
I N S TA L L AT I O N D R AW I N G S 200-2653 7
WARNING L O C AT I O N A N D G E N E R AT O R PLACEMENT For proper ventilation and maintenance, locate the generator outdoors in an area that will allow a minimum of three feet or more of clearance between the generator and any other structure. Note: Check your local building codes for clearance requirements for your area. When placing the generator, the direction of the exhaust should be pointing away from windows, doors and any ventilation system.
WARNING L O C AT I O N A N D G E N E R AT O R PLACEMENT (continued) WARNING • • For fire safety, the generator must be installed and maintained properly. Installation always must comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) and National Electrical Code (NEC) have established. This generator is designed to be installed outside only.
ELECTRICAL HOOKUP MAIN LINE OUTPUT POWER Once the generator is anchored in its final position, it is ready for electrical connections. The generator is supplied with two terminal blocks for connection of three distinct electrical circuits; main line output power, utility power input and generator start signal.
U T I L I T Y C I R C U I T S U P P LY G E N E R AT O R S TA R T S I G N A L A receptacle is provided with the generator to power the battery charger for reliable starting. It is also intended to power an optional block heater if that option is desired. Connection of this circuit to a power supply that is only present when normal utility power is supplied is recommended.
(9) (9) 30 (1) 85 86 START RELAY 87 (13) (9) (13) FUEL SHUTOFF SOLENOID (9) FUEL (2) SHUTOFF SOLENOID HIGH TEMP SWITCH OIL SWITCH LOW (9) (9) (9) (9) (9) STARTER SOLENOID (2) (22) (24) (9) (1) ENGINE START MOTOR ROTOR FIELD FIELD 12 EXCITATION 85 (1) 87 85 (2A) ENGINE ALTERNATOR (1) 30 (1) (3A) OIL PRESSURE RELAY 86 G L1 N L2 (13) (24) 5A FUSE (1) (1) (9) (9) ENGINE IGNITION ELECTRONIC GOVERNOR (13) (1) (22) (1) (1) BATTERY + - (9) (9A) (1C) (1A
WARNING F U E L S P E C I F I C AT I O N S A N D CONSUMPTION REQUIREMENTS The engine driving the generator is engineered to provide reliable power on either Liquefied Propane Vapor (LPG) or Natural Gas. For proper operation on these fuels, it is important to deliver gas with adequate energy content, at sufficient pressure and flow rate.
FUEL HOOKUP After electrical connections are complete, the next installation step is to connect a fuel supply to the unit. The fuel inlet fitting supplied with the generator is male 3/4" NPT. To accommodate potential settling of the generator relative to rigid supply pipeline, use of a flexible line, provided by manufacturer, in the supply line is suggested.
CAUTION B AT T E RY R E Q U I R E M E N T S To insure reliable starting in most weather conditions, it is important to properly match a battery to the requirements of the generator. The generator uses a 12 Volt, direct current, negative ground control system powered by an automotive style lead acid battery. Successful engine starting is dependent upon the cranking speed of the engine, which in turn is affected by the cranking capacity of the battery.
B AT T E RY P L A C E M E N T A N D CONNECTION (cont.) To install the battery, begin by placing the battery (A) into the battery rack as shown in Fig G. After the battery is in the rack, begin attaching the battery cables to the battery posts, starting with the positive (+), or red, cable (B). Loosen the bolt (C) on the post clamp slightly to allow the clamp to expand, then firmly push the clamp onto the battery post marked positive (+) until the top of the post extends past the top of the clamp.
F I R S T T I M E S TA R T U P After completing all installation procedures, read and understand the operating instructions for the generator controller. Know how the control panel operates, what to expect when activating control panel switches and how to shut the generator off in the event of an emergency. Before starting the generator for the first time, check off all items on the following list, then follow the given procedure to verify correct operation of the generator.
G E N E R AT O R O P E R AT I O N A standby generator is an engine driven air cooled system to convert the energy contained in either liquid propane vapor or natural gas to electrical power. When coupled with an automatic transfer switch to monitor for failure of utility power, the unattended system can start, stop and transfer between sources to insure a nearly seamless supply of power. The generator is housed in a weather resistant, sound attenuated enclosure for outdoor installation only.
G E N E R AT O R C O N T R O L PA N E L O P E R AT I O N RUN MODES There are three run mode options: Run, Off and Auto. When the Run pushbutton is pressed the unit will immediately start and the “not in auto” light will illuminate. In Run mode, the generator will continue to run until the Off pushbutton is pressed to stop the unit. At this point the “not in auto” light will illuminate and the unit will not operate.
S TAT U S I N D I C AT O R S Status indicator lights relay conditions of generator function for user or service technician convenience. Illumination of these indicator lights communicate conditions that require generator service but are not severe enough to cause damage if the generator is allowed to operate. Contact a qualified service technician immediately for service if any of the listed lights are lit, even if the generator appears to function normally. A.
MAINTENANCE To ensure reliable generator operation, it is critical to periodically inspect all components. The following chart is provided as a guide for service check intervals. When the generator is operated under excessively hot, or dusty conditions, shorten service intervals according to the severity of the conditions encountered. To perform periodic inspections or maintenance, refer to the Maintenance Item Engine Oil Check procedures listed in the following sections.
• • • • • • • • • • • • 22 MAINTENANCE (cont.) ENGINE OIL LEVEL CHECK WARNING Prior to checking the oil level, start the generator by moving the Mode switch on the control panel to the RUN position. Allow the generator to run for one or two minutes, then shut it down by returning the switch to the OFF position. After the engine comes to a stop let the engine set for a couple of minutes before checking the oil level.
2. Place an oil drain pan capable of holding five (5) quarts under the oil drain plug (A). E N G I N E O I L A N D O I L F I LT E R CHANGE Selection of the correct grade and type of engine oil greatly affects the performance of the generator, especially when starting. Before selecting replacement oil for an oil change, consider the anticipated operating conditions the generator may be exposed to. Choose the appropriate weight of oil for anticipated temperatures from Chart C.
E N G I N E A I R F I LT E R C H A N G E The generator engine is equipped with a dry element air filter to block particles in the combustion air from getting into the engine and causing excessive engine wear. Over time this dirt builds-up on the filter, restricting the amount of combustion air available to the engine, in turn leading to a loss of generator power output.
B AT T E RY M A I N T E N A N C E ( c o n t . ) Table A Display Red Green Red Green Red Green Operating Condition •When the red LED is on, it indicates that your battery is discharged and the charger is recharging at the "BULK" rate of 6 Amps. •While the red LED is on, the voltage measured will be 11.8 to 14 volts. •If the red LED stays on for more than 24 hours, refer to the troubleshooting section of this manual.
VA LV E C L E A R A N C E C H E C K A N D ADJUSTMENT ENCLOSURE AND SITE Proper cooling of the generator is vital to maintain performance and prevent equipment failure. Blocked cabinet openings or other airflow obstructions are potential fire hazards and can cause failures. Periodically inspect generator cabinet openings and the engine oil cooler for blockages. Do not allow leaves, grass, dirt, snow or other objects to build up around the cabinet.
TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Loose battery cables • Check all battery cable connections. Defective battery • Test battery. Replace as necessary. • Ensure charger is plugged into receptacle. • Check for tripped main circuit. Reset if required. Engine does not crank Improper battery charger function • Check all charger cable connections for cleanness and tightness. • Check charger lights to verify correct operation. See Table A, Page 25.
TROUBLESHOOTING SYMPTOM Low generator output voltage POSSIBLE CAUSE Excitation capacitor failure CORRECTIVE ACTION • Contact a qualified generator dealer for service assistance. Generator diode or varistor • Contact a qualified generator dealer for service assistance. failure Shutdown due to high engine Overspeed light stays lit • Verify correct engine speed setting. speed Underspeed light stays Shutdown due to low engine • Reduce loads connected to generator.
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POWERSTATION® Automated Power System Limited Warranty Warranty: Powermate Corporation warrants to the original consumer purchaser in the U.S. or Canada that it will repair or replace any parts or components found to be defective in material or workmanship. The product must be properly installed and maintained in accordance with operator's manuals, and must be used solely as emergency stand-by power to a utility-supplied primary power system.
CONTACT THE POWERMATE PRODUCT SERVICE DEPARTMENT AT 1-866-769-3703 to obtain warranty service information or to order replacement parts or accessories. HOW TO ORDER REPLACEMENT PARTS Even quality built equipment such as the Powermate standby generator you have purchased, might need occasional replacement parts to maintain it in good condition over the years. To order replacement parts, please give the following information: 1. Model No. and Serial No. and all specifications shown on the Model No./Serial No.
