Supplemental Generator Manual

Information contained within this document supersedes any written material included with your generator.

Welcome to our online supplemental generator manual. Information provided here should be followed and is intended to replace any dated printed material that may have been included with your generator. Please check back often for trouble shooting procedures, safety information and instructions on operation and required care for your generator products.

If you have any questions please contact us by e-mail at Support@EmergencyPower.com

Safety Information

(For safe operation please follow the instructions strictly)

RISK OF FIRE AND EXPLOSION

• Never use gasoline in a diesel engine or fire and explosion may result.
• Identify the correct fuel type and model before refueling.
• Always wipe off any spilled fuel and oil before using your generator.
• Keep Generator away from any flammable products and at least 3 feet clearance on every side. Never use it in an enclosure
• Refuel in a well-ventilated area with the engine stopped.
• Keep away from open fire, cigarettes, smoke, and sparks of any kind when refueling the generator or when near gasoline storage.

ACID WARNING

• Be careful when using any battery
• Batteries will exhaust hydrogen while charging.
• Only charge a battery in a well ventilated place
• Keepaway from open flame, heat or spark
• Avoid spilled battery acid. If contact with skin is made, wash immediately with water.

CARBON MONOXIDE WARNING

• Carbon monoxide poisoning occurs after the inhalation of carbon monoxide gas. Carbon monoxide (CO) is a product of combustion of organic matter under conditions of restricted oxygen supply, which prevents complete oxidation to carbon dioxide (CO2). Carbon monoxide is colorless, odorless, tasteless, and non-irritating, making it difficult for people to detect.
• Do not run the generator indoors, in confined spaces or in unventilated areas.
• The carbon monoxide gas produced by gas and diesel engines can kill you.

ELECTRICAL SHOCK WARNING

• Electricity can kill you.
• Installation should be preformed by a certified electrician. Improper installation can result in electrical shock and death.
• Follow all electrical safety code for your area. Consult an electrical safety inspector or electrician.
• Do NOT hook up any generator to a buildings electrical system without the proper use and installation of a transfer switch by a qualified electrician.
• Keep the generator dry. To reduce the risk of electrical shock do not use it in the rain or snow. Your generator should be protected from the elements.

OPERATOR RESPONSIBILITY

• Know how to stop the generator quickly in case of emergency
• Understand the proper operation and maintenance procedure before using it
• Be sure anyone using the generator receive proper instruction
• Keep away from children and animals

GENERATOR USE

CONNECTIONS TO A BUILDING’S ELECTRICAL SYSTEM

Connections for standby power to a building’s electrical system must be made by a qualified electrician. The connection must isolate the generator power from utility power, and must comply with all applicable laws and electrical codes. A CSA or UL approved transfer switch is recommended.

Improper connections to a building’s electrical system can allow electrical current from the generator to backfeed into the utility lines. Such backfeed may electrocute utility company workers or others who contact the lines during a power outage. When utility power is restored, the generator may explode, burn, or cause fires in the building’s electrical system. You are required to check local regulations for proper registration, use and procedures for generators.

The ground terminal can be used to earth the generator or bond the frame of the generator to the frame of a vehicle, but only if it is required by local law or electrical code. Before using the ground terminal consult a qualified electrician or electrical inspector for regulations in your area.

GENERATOR GROUND CIRCUITS

Bonding the neutral wire to ground is required on some construction sites. Industrial Generators provide neutral bonding.Some models are neutral bonded which allows the industrial generator to pass Occupational Safety and Health Administration job site inspections.

Portable generators have a system ground that connects generator frame components to the ground terminals in the AC output receptacles. The system ground may or may not be connected to the AC neutral wire. This is called “neutral bonding” Local regulations, codes or laws may require that the ground system be connected to the AC neutral wire depending on its use. Most of our products have a “neutral bonded” ground.

AC APPLICATIONS

Before connecting an appliance or power cord to the generator: Make sure that it is in good working order. Faulty appliances or power cords can create a potential for electrical shock.

If an appliance begins to operate abnormally, becomes sluggish or stops suddenly, turn it off immediately. Disconnect the appliance, and determine whether the problem is the appliance, or if the rated load capacity of the generator has been exceeded. Make sure that the electrical rating of the tool or appliance does not exceed that of the generator. Never exceed the maximum power rating of the generator. Power levels between rated and maximum may be used for no more than a few minutes.

Substantial overloading will open the circuit breaker. Exceeding the time limit for maximum power operation or slightly overloading the generator may not switch the circuit breaker OFF, but will shorten the service life of the generator.

Do not exceed the current limit specified for any one receptacle. If an overloaded circuit causes the AC circuit breaker to switch OFF, reduce the electrical load on the circuit, wait a few minutes and then reset the circuit breaker.

An overloaded DC circuit, excessive current draw by the battery, or a wiring problem will trip the DC circuit protector (PUSH button extends out). If this happens, wait a few minutes before pushing in the circuit protector to resume operation. If the circuit protector continues to go OFF, discontinue charging and see your authorized generator dealer.

DC OPERATION

The DC terminals may ONLY be used for charging 12 volt automotive-type batteries.

Do not start a vehicle while the battery charging cables are connected and the generator is running. The vehicle or the generator may be damaged.

Quick Setup Guide

ENGINE OIL

The main purpose of engine oil is to lubricate moving parts of the engine to reduce friction and wear and tear by providing smoothing, trouble free performance for increased length of time.

Just as there are different types of fuel there are different types of lubricants for gasoline and diesel engines.

The oil in an engine does more than just reduce friction between its moving parts. It also helps to seal the high-pressure combustion gases inside the cylinders, to impede the corrosion of metal parts, to absorb some of the harmful by-products of combustion, and to transfer heat from one part of the engine to another.

Combustion of rich air-fuel mixture during starting, idling and warm up form deposits. These deposits in the form of varnish, sludge, soot and carbon, interfere with proper engine operation.

The engine oil keeps all the deposit forming material in suspension and gets rid of them by oil filter, or draining out at proper intervals.

Engine oil is stored in the oil pan or sump at the bottom of the engine. A pump forces the oil through a filter and then through a series of passages and galleries to lubricate the engine’s moving parts. The flow of also cools these parts. Rapidly moving engine parts actually float on a thin film of oil and never make contact with one another. This is called hydrodynamic lubrication and usually begins when an engine reaches the idle speed. Most engine wear occurs when a cold engine is first started, before the oil reaches its normal operating pressure and flow.

Diesel Engine Lubricating Oil

The main function of lubricant for diesel engine is the same as mentioned for gasoline engine. As the load in diesel engine is much higher it should have adequate antiwear properties. Diesel fuel contains a high level of Sulphur which burns to form oxides of sulphur , which in turn in the presence of water, form sulphur acids resting in high corrosion of engine parts. Hence the need of alkalinity reserve in the oil which is represented by its TBN or Total Base Number. Generally, the higher TBN value more the alkalinity reserve or acid neutralizing capacity the oil contains.

Our diesel generators require 15W40 oil. The engine is designed in such a way that it is difficult to overfill it and as you can see in this issultration oil should be filled until it reaches the top of the oil filter neck.

Regardless of how little you may use your generator the oil on its own will break down losing some of its properties in 3 months. The same applies to your vehicle. You must replace it every 3 months.

If you use your generator within that time, the oil should be changed every 100 hours or earlier.

There is nothing you can do that will add more life to your engine then regular oil changes. This is very important and is the leading cause of engine failure.

Oil pressure sensor

Our engines all use an oil pressure sensor and they are designed to alert you when oil drops below a safe level. Some will automatically shut down your generator to prevent damage from happening. Our generators use a sensor in a pressurized engine oil system. If the oil pressure falls below the preset value during operation, the engine ignition is grounded out and the engine shuts down.

DIESEL FUEL

Diesel fuel only should be used. The regular diesel fuel you find at the gas station used for cars only. Not off road vehicles, farm or construction. Some Bio Diesels that are safe for cars are also safe for your generator however there are many different types and we can’t guarantee the quality or that it will not damage your engine. While a diesel engine can run on many different types of fuel such as vegetable oils and other bio diesels some can clog the fuel filter, fuel injector and fuel pump. A grain of sand is all it takes to plug a fuel injector! Do not use old fuel. Fuel does go bad over time.

Diesel Fuel is also used as a lubricant to lubricate the fuel pump, injector and fuel valves. Now with new low sulfur fuels on the market the sulfur that used to give diesel fuel some of its lubrication properties have been lost. For optimal performance we do suggest fuel additives be used especially in cold climates. This topic is covered on another page in more details.

Caution

• When filling from oil drums, ensure that no dirt or water enters the fuel tank.
• Contamination can cause serious fuel system problems.
• Never over fill the fuel tank.
• Filling should only be done in a well-ventilated area with the generator turned off.
• Never refill while the generator is running. Spilled fuel can ignite on a hot surface.
• Clean up all spills and ensure that area is dry before starting the generator.
• Do not use old fuel

FUEL VALVES

Under the fuel tank is a fuel valve. The valve should be in the open position when you are using your generator. Some people forget to open it and either can’t start the engine or cause air to be sucked into the fuel pump if it can’t get the fuel supply it requires.

If your generator has fuel filter make sure to check the fuel valve on it also.

Fuel Valve under fuel tank.

External Fuel Filter with Fuel Valve

PURGING AIR FROM THE FUEL SYSTEM

The engine fuel pump must be wet to work. If air enters the system from either running out of fuel or setting it up for the first time it will not be able to pump. Remove the rubber fuel line and let the fuel pour out until all the air is displaced by fuel then replace it. Once there is fuel in the inlet side of the pump it will be able to work once again.

Rough engine operation after air has entered the fuel system is normal. It may take a few moments for any air bubbles between the pump and the fuel injector to pass and normal fuel supply to resume. This process may take up to 15 min.

Fuel Pump shown without Solenoid

FUEL PUMP SOLENOID

To turn off a diesel engine you must cut off its fuel supply. One of the ways of doing this is either by releasing the throttle (run stop leaver) to cut the fuel supply or by closing an electric fuel valve. This valve is also known as a Magnetic Fuel Solenoid Valve.

When power is applied to this valve it creates a magnet that pulls open a plunger and its spring to permit fuel flow. When the power is removed it releases the spring and plunger closing off the fuel flow causing the engine to shut down.

This fuel valve is a very basic and simple device however it can get stuck by dirt in the fuel or burn out if the key is left on and the engine not running as it is kept cool by the fuel flow. Do not leave the key in to run position if the generator is not running.

Note:

If this solenoid does not work correctly it prevents fuel from going to the fuel pump. If it does not open fully it starves the engine of enough fuel to run properly. What users notice are erratic engine speeds, black smoke and difficulty keeping the engine running.

In an emergency if this fails the fix is simple. Users can unscrew it and remove the spring and plunger. Now to shut off the engine you will need to do so the traditional way, by releasing the throttles run stop leaver.

Photo showing the Magnetic Fuel Solenoid Valve. Fuel Pump shown with optional magnetic fuel solenoid valve.

GENERATOR BATTERY

You must fully charge your generator battery before use.

If the battery is too low you can cause damage to your starter. A low battery may have enough power to engage the starter but not enough to turn the engine. The result is possibly warned starter or flywheel gears if they do not mesh together.

A low battery may not have enough power to open the magnetic fuel solenoid on the fuel pump preventing fuel flow and starting.

Slow cranking causes low compression in the engine making starting difficult also.

If you plan on storing your generator and not using it for a period if time it is advised that you keep a small charger on it to prevent the battery from self discharging. We suggest buying a small trickle charger from an automotive store and leaving it hooked up to your battery when the generator is not in use.

* Deep discharges are the number one cause of battery failure.

A low battery also puts lot of strain on the engines generator charging system. (There is a small generator within the flywheel of the motor that is used to charge the battery. This is separate from the generator the engine turns to create power to the electric panel)

Inexpensive Trickle Charger

COLD WEATHER STARTING

Diesel fuel thickens in cold weather. It has a tendency to gel as it contains some naturally occurring paraffin (wax) and as the temperature drops, this paraffin crystallizes and affects the fluidity of the fuel and may cause hard starting and eventually lead to filter plugging. You can use a fuel additive to prevent this.

Regular diesel fuel is winterize or seasonally adjusted at the distributor before it is delivered to the pumps.

In cold weather fuel does not vaporize very well in the combustion chamber this makes staring difficult. Modern diesel engines designed for cold weather use a pre heater and glow plugs. Glow plugs are heating elements that work on a timed circuit or are manually activated just before the engine is started. The colder it gets, the longer those glow plugs need to stay on to preheat the combustion chamber for a smooth start.

Batteries that are weak may not crank the starter motor fast enough or long enough to start a cold engine. As the temperature goes down, so does battery capacity. A battery that has all of its power available at 80 degrees F will have only about 46% available power at 0 degrees F. Plus, the engine will be 2.5 times harder to start at 0 degrees due to thicker oil and resistance to movement of internal moving parts. In effect, an engine is about five times harder to start at 0 degrees F than at 80 degrees F.

Test weak or suspicious batteries under load before cold weather to help eliminate potential problems during busy times. If batteries need replacement, always replace with a battery equal to the original battery.

Two different types of preheat elements seen after air filter has been removed.

Before starting heater gets red hot warming up air.. Seconds later when the starter kicks in the generator pulls in this heated hear causing the diesel fuel to vaporize and ignite easier. If you can press and hold the decompression lever a second while cranking and let go, it will also help in the cold starting process.

Use glow plugs or block heaters on the engine for cold weather starts. Glow plugs heat the internal combustion chamber area or preheat the air intake to suitable temperatures for combustion. Otherwise, cold fuel sprayed into the chamber and onto the glow plugs can gel and adhere to these parts. Hard starting and inefficient combustion occur with potential for damage to plugs and cylinder heads.

Use Number 1 diesel fuel in cold weather. It is more volatile than Number 2 fuel and ignites more readily under cold conditions. Keep the fuel tank full to prevent condensation inside the tank. Water from condensation can freeze and plug fuel lines from the tank to the engine. Add winter diesel fuel additive to the fuel to lower the possibility of gelling and improve starting.

Store generators inside tool sheds, barns, garages or other suitable locations that are heated or warmer than outside temperatures. Only a few degrees warmer temperature can make starting faster and easier. The warmer the battery is, the more power it can provide to the starter motor to crank the engine. The warmer the engine oil is, the thinner it will be and have less resistance to moving engine parts. Make sure you are using the proper viscosity oil recommended for your engine for cold temperatures. If you cannot store engines inside or in a heated area, install a block heater on the engine. To save time and electricity, put the block heater on an electrical timer set to come on a couple of hours before you plan to start the generator.

After starting the generator on a cold day, allow the engine to warm up a few minutes before putting it under load. Proper engine operation temperatures assure more efficient fuel combustion and may prevent damage to cold engine parts. Engine oil flows more readily at operating temperatures and allows proper lubrication of engine parts and areas.

BREAK-IN PERIOD

Current technology provides the means of manufacturing engine parts with unimaginable precision however they still far short of achieving the near perfect fit that a proper break-in will provide.

Break-in, is the allowance of the machined parts in the engine engine to conform to each other. This conforming or mating specifically of the ring and cylinder surfaces is the ultimate goal of a proper break-in. Mating these two specific parts will produce a very tight seal in each cylinder. A tight seal is very important because of the intense pressure diesel engines operate under. Mating helps prevent the escape of unburned fuel and pressurized gasses into the crankcase, while further preventing crankcase oil from entering the cylinder above the top compression ring. The blow by also causes a loss of pressure and results in lack of power.

Friction causes heat and until the break in occurs extra heat and most of the ware and tear will happen during this period. Break in your engine before using it! Don’t forget oil will become contaminated faster because of combustion blow by fumes and metal that is ground away during the mating process. The oil should be changed at at the first 25 hours.

This is an important time for an engine. You should not subject the engine to significant loading for the first 25 hours or more however some load IS desirable since the heat and friction is also needed for the break in to occur. Excessive heat will burn oil and cause it to harden leaving an enamel like residue on the cylinder wall, commonly known as oil glazing and prevents the mating from occurring so small gaps between rings and cylinder surfaces will never seal. The same applies to use synthetic oil during the break in period. It will also prevent break in from happening. Only use synthetic oil after the break in period.

A moderate loading is the key to a proper break in. 1/2 the rated power may be ideal. While some manuals suggest decreasing the RPM it is not easy to do on generator motors since they have a fixed run or stop position that locks into place on the throttle. If you can, secure it for this process for a break in period so are running it at half the RPM you will benefit from it in the long run. Obviously you can not use the generator until the normal speed is restored.

“Wet Stacking” happens when a diesel engine operates below the rated output level the engine starts over-fuel or “wet stack”. Diesel engines are designed to operate with a load and operate more efficiently in the 70 to 80% range of rated output. When a diesel engine operates for a long period of time below 40% it begins to over fuel. This happens because the injection tips begins to carbonize and disrupt the fuel spray pattern.

The only way to correct a diesel engine if it has begun to wet stack is to load the engine for a couple of hours to burn off the excess fuel and clean up the engine. Diesel generator sets with electronically controlled engines or advance emission systems are less likely to wet stack. But all diesel engines will wet stack unfortunately, if operated for long periods of time below rated levels. This is the reason it is important to get the proper size and design of a diesel generator set.

GENERATOR CARE

When it comes to generators diesel wins hands down. The engines are simple, there is less maintenance. Diesel generators are built tougher to withstand the higher compression ratio diesel burns at compared to a gas engine. Less maintenance means more up time and more reliability when they are needed the most. There are many technical reasons why to chose diesel over gasoline however the point of this document is to help identify some important things necessary to truly befit from diesel and insure your generator continues to run long after its equivalent gasoline generator has died.

Diesel engines operate at twice the compression ratio of gasoline engines; create greater internal pressures and heat. Components are made to closer tolerances, therefore are more easily damaged by dirt, corrosion improper fuel and lubricants.

Diesel injectors are expensive precision parts that handle fuel pressures as high as 137,900 kPa. Using correct diesel fuel is essential because it not only runs the engine, but also lubricates and cools the fuel pump, injectors and spray tip.

Dripping or leaking injectors can cause rough engine operation, destructive unbalanced cylinder temperatures, crankcase oil dilution and incomplete combustion. Because of diesel fuel’s acid content, combustion byproducts are more corrosive. Greater diesel heat also converts combustion byproducts to varnish inside the engine more rapidly.

Dirt and water by passing fuel filters can badly score fuel pump and injectors, requiring replacement. Rust can cause sticking in pump pressure regulator valves. Water in fuel can also cause hard starting, uneven running and frequent stalling.

Because diesel engines breathe more air per hour than gasoline engines, air leaks through cracks, loose connections or holes in flexible hoses can cause serious and expensive engine damage. Clogged air filters reduce power.

Diesel engines make more use of oil as coolant because of greater heat and pressure. For example, the oil cools piston undersides. Improperly or inadequately filtered oil can cause scoring and damaging of engine parts. Inadequate circulation of oil and coolant can cause engine overheating and thermal distortion.

Poor quality fuel can cause hard starting, incomplete combustion withvarnish buildup, smoky exhaust, and plugged fuel filters in coldweather.

Don’t let the above scare you, there is a far greater list for the problems you can and often will encounter with a gasoline engine. Remember most of this is for information purposes and to help you get the maximum life out of a diesel generator.

OIL CHANGES

Engine oil has limited life – after a certain point it starts losing lubricating qualities and carbonizes. Once it happens, the engine gets contaminated with carbon deposits or sludge that significantly shorten engine’s life. When you change oil at or before manufacturer suggested interval, you change the oil before this “carbonizing” point, engine remains clean and once refilled with new oil ready to work hard again. If the engine oil has not been changed for long, carbon deposits start clogging the oil pickup screen decreasing oil supply and increasing friction. Compression decreases and engine start wearing much faster.

If you don’t remember when you changed the oil last time – just check the oil on the dipstick. And every time you change the oil, the oil filter should be replaced as well.

We suggest you change your oil after the first 25 hours and then every 100 hours or sooner. The cost of the oil is far cheaper then the cost of a new engine. This is an area where you have great control over how long our generator will last.

Synthetic Oil

The advantage of synthetic oil is that it can withstand higher temperature and can work longer without losing its lubricating qualities. It doesn’t get thicker at below-zero temperatures providing good engine lubrication at a cold start. After your generators first oil change and initial break in period a good quality synthetic oil designed for diesel engines is recommended.  Mobil1 is one of the best ones you can get however make sure what you buy is specifically for a diesel engine.

What is Diesel Fuel

Diesel fuel is principally a blend of petroleum-derived compounds called middle distillates (heavier than gasoline but lighter than lube oil) and may or may not contain additional additives. Other middle distillates include kerosene and No. 2 Heating Oil. Diesel fuel is designed to operate in a diesel engine where it is injected into the compressed, high-temperature air in the combustion chamber and ignites spontaneously. This differs from gasoline, which is ignited in a gasoline engine by the spark plugs.

Low-Sulfur Diesel Fuel

Ultra-low sulfur diesel (ULSD) will begin replacing conventional diesel fuel starting in 2006. The new fuel will contain 97% less sulfur than conventional diesel—sulfur will be reduced from 500 parts per million (ppm) to 15 ppm. Sulfur was the main lubricating property of the fuel.

Since the removal of Sulfur from Diesel Fuel diesel shops have been flooded with work caused by lack of lubrication in the new fuels. Cars, Trucks and generators can all see the effects of this. Fuel Injector and Fuel pump failure can be common if the lubrication is not restored by some means.

Leading diesel manufactures now recommend using a fuel additive such as Stantadyne with every fill up to restore to restore the lost properties from removal of Sulfur from Diesel Fuel. You should also be using a fuel additive to avoid similar problems.

Stanadyne White Paper on Diesel Fuel* What is the difference between gasoline, kerosene, diesel fuel, etc? Visit the How Stuff Works web site.
* Vegetable Oil is Used as Fuel
* Exxon Diesel Fuel FAQ

Fuel Injection System Problems.

Most diesel engine problems are related to the injection system. As such diagnosing diesel engine problems requires knowledge of engine and injection system operation.

Excessive diesel smoke is due to incomplete combustion, normally caused by faulty injection system or other engine troubles. A small amount of exhaust smoke is normal during initial start-up or rapid acceleration.

Excessive black smoke is caused by a rich air-fuel mixture. This may result form problems with the injection pump or infection timing, which may in turn be clue to a choked air cleaner, worn fuel injectors, adulterated diesel fuel or the engine itself.

White smoke occurs mainly during cold starts, when the fuel tends to condense into liquid and does not burn due to cold engine parts. The most common reason for white smoke are in-operative glow plugs low engine compression, a bad injector spray pattern, late injection timing or injection pump problems.

Excessive blue smoke indicates problems from low engine compression and/or worn piston rings, scored cylinder walls or leaking valve stem seals The blue smoke is caused by crankcase oil entering the combustion chamber and being emitted after partial combustion through the exhaust

Lack of Lubrication

As fuel manufacturers remove sulfur from fuels in the refining processes, as well as blending with No. 1 diesel and kerosene, the lubrication properties of fuels are reduced. This leads to increased wear in the fuel injection system. after market additives help prevent this wear with extra strength lubricants. Do not use Alcohols.

Winter Gelling Problems

As temperatures drop, paraffin crystals precipitate from the fuel forming the waxy substance on the filters which blocks fuel flow. This “freeze-up” condition can be avoided by using a Wax Dispersant, which keeps wax crystals evenly distributed throughout the fuel, thus assisting in the prevention of wax clogging the fuel system. The Wax Modifier-Pour Point Depressant they use will lower the temperature at which fuel will continue to pour by up to 40° F. Also, there is a Freeze Depressant, which will lower the freeze-point of water in fuel. This can help to prevent damage from or the clogging of fuel lines with ice.

Deposits and Corrosion

Residual carbon deposits from combustion can build up in nozzles and around the orifices and can obstruct the atomization of the fuel into the air preventing complete combustion. Deposit Modifiers and Detergents soften the hard deposits allowing for their removal. The Detergent will clean the soft deposits and prevent additional deposit build-up. Also, they incorporate an Anti-Oxidant, which helps fuel maintain its potency and a Corrosion Inhibitor to help protect fuel injection parts from rust and corrosion.

Decompression Lever

A decompression lever on the engine enables the user to start the engine when it is extremely cold, when the battery is low, or when bleeding the fuel system.

Caution: The decompression lever must never be used to shop the engine except in emergencies such as a run away engine or throttle damage as serious damage can be done to the exhaust valves.

Decompression in most cases is not needed. The decompression lever is located on the top of the cylinder, accessible through the side inspection door or from the top of the generator depending on the model.

Pressing and holding the decompression lever down opens up the exhaust in the cylinder so no pressure is built up and it is easier to crank the engine. If you have an open frame generator access is simple and pulling the manual recoil starter is easy with no compression. If you open up the fuel line from the fuel pump at the fuel injector it makes purging air out easy without putting strain on the starter and battery.

Generator Batteries

Generator batteries are often required to be float charged for long periods of time and must be able to deliver high current when called upon. Generator batteries are often sealed and maintenance free.

Lead Acid batteries are often used however because the content is an acid it is considered a hazardous material and often can not be shipped. If your generator comes with a dry battery then you may be required to get it filled at Napa Auto Parts for example the charge is minimal.

Most generators sold here come with sealed maintenance free batteries and do not need to be filled.

How the battery works.

A lead-acid battery is composed of a series of plates immerse in a solution of sulfuric acid. Each plate consists of a grid upon which is attached the active material (lead dioxide on the negative plates, pure lead on the positive plates.) All of the negative plates are connected together, as are all of the positive plates.

When the battery is under load and being discharged, acid from the electrolyte combines with the active plate material. This releases energy and converts the plate material to lead sulfate. The electrolyte become less acidic in the process.When a battery is recharged, the opposite occurs: the lead sulfate reverts back to active material, and the electrolyte becomes more acidic with a higher specific gravity.

Battery Charging

To recharge a lead-acid battery, it is necessary to convert the lead sulfate material which attaches to the discharged areas of the plates back to active plate material.

If the battery has not remained discharged for long or has only been discharged slightly, this is a relatively easy process. However, when the battery has remained discharged for an extended period or has been subjected to repeated deep-discharges without charging fully between cycles, the sulfate material can harden into crystals which are more difficult to convert. Until the sulfate is converted, the sulfated portions of the plates are useless, and the battery can accept and hold only a partial charge. Eventually, sulfating can ruin a battery.

Sulfation is the number one cause of battery failure

Whenever possible, bring any batteries up to full charge as slowly as possible. This slow charging process is also known as equalization. Equalization allows the electrolyte time to diffuse into the less accessible areas of the plate grid and convert those areas from lead sulfate to active plate material.

Infrequently-used or stored batteries are also prone to sulfating if not kept fully-charged between uses. A battery loses approximately 1 percent of its charge per day (up to 2 percent in hotter climates) due to self-discharge. If self-discharge is not compensated for, a stored battery can become sulfated and will eventually be ruined.

The second most common cause of battery failure is overcharging. Many chargers on the market will damage your battery if left attached for extended periods by “boiling” the water out of the electrolyte solution. Eventually, water loss will destroy a battery. Checking the electrolyte level in a battery and adding distilled water when necessary is extremely important, especially when using fast chargers or many of the trickle chargers on the market

Maybe buy a small trickle charger and leave it on full time or hook up a small solar cell to keep the battery topped up when not in use.

Starter Motors

During starting of the generator a small amount of power is given to the solenoid above the starter. This causes the solenoid plunger to move the starter gears forward, bringing it in gear and meshing it with the engines crankshaft flywheel. At the same time a larger contact is made inside directing power from the battery to the starter motor. The motor then spins, and the engine turns by the gears spinning the crankshaft flywheel until power is removed from the solenoid.

During staring there is a delay before the generators control box or other electronics check to see that the engine is running and that there is oil pressure.

A slow cranking speed is a common cause for starting problem. Being a compression ignition engine, a diesel engine must crank fast enough to produce sufficient heat for combustion. Make sure your battery is fully charged and all connections are tight.

UPS and Generators

It is strongly recommended if are going to run a computer off a generator that you use a UPS power supply. UPS power supplies will insure 100% clean power to your computer and protect it from spikes and brownouts. There is a catch though. UPS power supplies do not like generators and that’s because most generators do not produce perfect power.

If the engine speed is off, the frequency of the generator output will be off. A UPS wants to see 60 Hz and chances are your not bang on if your having problems. The UPS needs 60 Hz not 63 or 57 Hz so adjust the RPM until your UPS is happy. Consider buying a Power Meter. You can check frequency, power usage, voltage and current.

Keep in mind that too many times people adjust the engine RPM for correct voltage rather then frequency. The frequency is more important.

The second issue is generator voltage. It should be within the tolerance of the UPS, say 110 to 130 volts. This is controlled by the generators field voltage. The field voltage is determined by the running capacitor or in the case of a generator with a AVR its a pot you adjust to change the field voltage as seen in the image on the left. The AVR is located in the back of the generator.

The third situation is with spikes on the output wave form, caused by the output voltage regulators such as generators with AVRs and or Brushes.

Some have reported excellent results using a motors start capacitor across the ac terminals to help reduce spikes. Generally about 10 uF (microFarad) is enough. This does upset the power factor and will reduce the output capacity of the generator but it will help smooth out the wave form. We do not suggest doing this as its high voltage you are playing with and there is a risk of electrical shock and damage to the generator. There is lots of information on the Internet, we suggest doing a search for “generators and ups

Turning on and off devices hooked up to the generator

Before you turn off the generator make sure there is no load connected to it. This will help prevent damage to the voltage regulator.

Shutting down your generator with large loads connected is very tough on the voltage regulator. When the voltage drops all of a sudden the generator increases the current to the generators fields to increase the output voltage. This sudden discharge of the capacitor and the reverse EMF caused by the magnetic fields sudden collapse can also create a huge voltage spike that can damage your generator. The replacement AVR or Capacitor is an inconvenience and this kind of damage may not be covered by warranty.

Your electric company can not turn everything on or off at the same time without damage occurring. Give your generator a chance to catch up. Motors and Fridge Compressors and air conditioners are some of the largest killers of generators.

Hooking Up To Your Home

A manual transfer switch is the key to safe and convenient operation of portable generators for standby power. By isolating those circuits using generator power, a transfer switch eliminates the risk of back feeding the electrical utility, which can cause injury to workers and property damage.

By installing a transfer switch at your breaker box and connecting a portable generator to the transfer switch, you can run selected circuits for appliances such as a furnace, well pump sump pump, refrigerator, television, computer, printer or lighting circuit during a power outage, depending on the capacity of your generator. Since many portable generators cannot handle all of these loads at the same time, the transfer switch allows you to manually transfer each of these loads separately whenever you need them.

Determining which circuits you will require during a power outage is the first step in selecting the proper wattage generator and transfer switch. Since most home appliances operate intermittently, a 3000 watt generator can provide adequate power to circuits for the most common appliances, such as furnace, lights, refrigerator, freezer, microwave oven, and TV.

If your home has a deep well pump with up to 1 HP motor, a 5000 watt generator will be required to provide the starting capacity for the pump. Larger wattage units can be selected for simultaneous starting and operation of multiple appliances.

We carry a huge selection of transfer switches, electrical cables, plugs and outlet boxes. See what we have to offer that will help make your installation one that will get the job done right.