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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.
Specifications are subject to change without notice.
WARNING:
Read and understand all safety precautions in this manual and other manuals
included with this product before installing, operating and maintaining this equipment. Failure to
comply with instructions in this manual could result in personal injury, property damage, and/or
voiding of your warranty. The manufacturer WILL NOT be liable for any damage because of
failure to follow these instructions.
© 2007 Powermate Corporation
Record the model and serial numbers of your generator below:
Model Number
____________________
____________________
Date Purchased
____________________
HELPLINE 1-866-769-3703
Serial Number
OWNERS MANUAL
MODEL SERIES: P1204
200-2667 - Revision A - 10/07
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Table of Contents
Related Manuals for PowerStation P1204
Summary of Contents for PowerStation P1204
- Page 1 The manufacturer WILL NOT be liable for any damage because of failure to follow these instructions. Record the model and serial numbers of your generator below: © 2007 Powermate Corporation Model Number ____________________ Serial Number...
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Page 2: Table Of Contents
Table of Contents ..............2 General Safety Instructions . -
Page 3: General Safety Instructions
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. - Page 4 WARNING: The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. Keep a fire extinguisher near the generator at all times. Extinguishers rated "ABC" by the National Fire Protection Association are appropriate for use on the standby electric system.
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Page 5: 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. -
Page 6: Specifications
Rated Wattage - (Standby) @1.0 PF LPG * Rated Wattage - (Standby) @1.0 PF NG * Voltage Rated Current Frequency Power Factor Max. Ambient Temp Rise Insulation class Engine Engine Type Displacement cc (c.i.d) Bore X Stroke mm (inches) Compression Ratio Valve arrangement Governor Ignition system... -
Page 7: Installation Drawing
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Page 8: Generator Installation
Once installation planning is complete and all necessary local permits are granted, installation of the generator may begin. Within the following section general recommendations are given for installing the generator. However, installations are affected by local site conditions, regional construction practices, material availability, local or regional codes and/or other variables. - Page 9 The generator is supplied with an integral molded plastic base for use as an installation pad. Use of this base is intended to minimize installation cost by eliminating the need for a poured concrete pad. A pad of crushed gravel a minimum of three inches thick is recommended as a base to set the generator on.
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Page 10: Automatic Transfer Switch
When connecting the generator to a building electrical distribution system, use of a transfer switch is recommended to isolate the normal utility source from the generator supply. By preventing backfeed of the generator power into the utility lines during a utility power outage, the switch provides a level of safety for electrical line workers. -
Page 11: Electrical Hookup
Once the generator is anchored in its final position, it is ready for electrical connections. The generator is supplied with two terminal blocks for connection of three distinct electrical circuits; main line output power, utility power input and generator start signal. Main line output power is the electrical output of the generator, utility input powers the battery charger and optional block heater devices and the generator start signal is the interface... -
Page 12: Utility Circuit Supply
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. -
Page 13: Wiring Diagram
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Page 14: Fuel Specifications & 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. This generator is designed to operate on Liquefied Propane Vapor (LPG) with a minimum energy content of 2500 BTU per cubic foot or Natural Gas with a minimum... -
Page 15: Natural Gas Settings
Natural Gas (NG) Units are tested with natural gas before they leave the factory. If natural gas is to be used, no adjustments are required. When supplying natural gas as the operating fuel, provide fuel with a minimum of 1000 BTU/ft pressures between 6"... -
Page 16: Battery Requirements
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. -
Page 17: Lubrication
To access the battery and charger, remove the front and back panels by inserting the key into the locks located on top of the panel. and turn 1/4 turn counterclockwise to unlock. Lift the panels up and out of the base and set it aside. Place the battery (A) on the base as shown in Fig G. -
Page 18: First Time Startup
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. -
Page 19: Circuit Breaker
A. MODE BUTTONS (AUTO, MANUAL AND OFF) B. AUTO LED C. STATUS INDICATOR LED’s D. UTILITY POWER MONITOR LED E. TRANSFER SWITCH MONITOR LED F. GENERATOR POWER MONITOR LED G. HOUR METER A. Mode Buttons The Mode Buttons are used to set the operating state of the generator. -
Page 20: Run State
RUN MODES There are three run mode options: Off, Manual and Auto. When the Manual pushbutton is pressed the unit will immediately start and the run indicator light will illuminate. In Manual mode, the generator will continue to run until the Off pushbutton is pressed to stop the unit. At this point the “not in auto”... -
Page 21: Status Indicators
Status indicator LED’s relay conditions of generator function for user or service technician convenience. Illumination of these indicator LED’s communicate conditions that require generator service but are not severe enough to cause damage if the generator is allowed to operate. Contact a qualified service technician immediately for service if any of the listed LED’s are lit, even if the generator appears to function normally. -
Page 22: 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. -
Page 23: Upper Limit
W W A A R R N N I I N N G G • Before performing any maintenance, make sure the controller mode is in the OFF position, the circuit breaker is in the OFF position and the positive (red) battery cable is disconnected. •... -
Page 24: Engine Oil And Oil Filter 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. -
Page 25: Engine Air Filter Change
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. -
Page 26: Spark Plug Check
Table A Display 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. Green •If the red LED stays on for more than 24 hours, refer to the troubleshooting section... -
Page 27: 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. -
Page 28: Troubleshooting
SYMPTOM POSSIBLE CAUSE Loose battery cables Defective battery Improper battery charger Engine does not crank function Fault in starter signal circuit Blown control circuit fuse Low battery Engine cranks without starting Poor fuel supply Low oil pressure Engine starts then immediately shuts down High engine temperature Main line circuit breaker... - Page 29 SYMPTOM POSSIBLE CAUSE Excitation capacitor failure Low generator output voltage Generator diode or varistor failure Shutdown due to high engine Overspeed LED stays lit speed Shutdown due to low engine Low Speed LED stays lit speed Overcrank light stays lit Failure to start Low oil pressure LED Shutdown due to low engine stays lit...
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Page 30: Notes
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Page 31: Limited Warranty
Powermate-authorized service center or with parts other than Powermate-approved parts, or (ii) where the generator is used as a primary power source or as back up for solar, wind-power or other alternative power system. -
Page 32: How To Order Replacement Parts
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.
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