Powermate PM401211 manual

© Coleman Powermate, Inc. 10-06 St ationary St andby Electric Generator - 1 1,200 W A TTS - MODEL PM40121 1 St ationary St andby Electric Generator - 9,7 00 W A TTS - MODEL PM40091 1 I MPORT ANT SAFETY INSTRUCTIONS – Please make cert ain that persons who are to install, operate and maint ain this equipment thoroughly read and underst and these i[...]

2 200-2341 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Installation . . . . . . . . . [...]

200-2341 3 Do not attempt to install the generator yourself. Extremely high and dangerous electrical voltages are present in utility power source lines and in generator load leads when the unit is running. Therefore, be sure to turn OFF all power voltage supplies at their source before attempting to complete electrical connections. Only qualified i[...]

4 200-2341 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 ele[...]

200-2341 5 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 needs when utility power fails. The standby generator runs on Liquid Propane Vapor or Natural Gas allowing flexibility for getting the power you need. Fuel lin[...]

6 200-2341 Proper location of the generator set is important to insure safe and reliable operation and can aid in the installation of the generator. When selecting a site for the generator, first ensure that the pad is outdoors in a well ventilated area to allow for proper cooling and proper removal of deadly exhaust fumes created during operation.[...]

200-2341 7 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 w[...]

8 200-2341 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, loc[...]

200-2341 9 I I I I N N N N S S S S T T T T A A A A L L L L L L L L A A A A T T T T I I I I O O O O N N N N D D D D R R R R A A A A W W W W I I I I N N N N G G G G S S S S[...]

10 200-2341 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, GFCI power input and remote start signal. Main line output power is the electrical output of the generator, GFCI in[...]

200-2341 11 A ground fault circuit interrupting (GFCI) 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. [...]

12 200-2341 1 1 2 2 K K W W W W I I R R I I N N G G D D I I A A G G R R A A M M ( ( C C P P 2 2 0 0 0 0 C C O O N N T T R R O O L L L L E E R R ) ) R EL AY PI N W I RE NUM B ER 30 1 85 13 86 9 87 13 RELAY W I RI NG I NFORM AT I ON WIRE NO. WIRE NAME/ DE SCRIPTI ON WIRE NO. WIRE NAME/ DE SCRIPTI ON WIRE NO. WIRE NAME/ DESC RIPTION WIRE NO. WIRE NAME[...]

200-2341 13 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 is designed to operate on Liquefied Propane Vapor (LPG) with a minim[...]

14 200-2341 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 ½" NPT and is located adjacent to a fuel access hole in the lower engine end panel as illustrated in Fig E. To accommodate potential settling of the generator rel[...]

200-2341 15 In cases where liquefied propane vapor is selected as the fuel of choice, insure fuel delivery in the gaseous state, with a minimum energy content of 2500 BTU/ft 3 , at inlet pressures between 7" and 11" of water column (4 - 6 oz) . Fuel below these specifications may cause improper engine operation and/or failure to deliver r[...]

16 200-2341 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 en[...]

200-2341 17 To install the battery, begin by placing the battery ( A ) into the battery rack as shown in Fig G. Orientation of the battery terminals is according to installer preference as the supplied battery cables are of adequate length to reach terminals regardless of battery direction. Secure the battery to the rack using the J-bolts ( B ), nu[...]

18 200-2341 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 [...]

200-2341 19 G G G G E E E E N N N N E E E E R R R R A A A A T T T T O O O O R R R R S S S S P P P P E E E E C C C C I I I I F F F F I I I I C C C C A A A A T T T T I I I I O O O O N N N N S S S S E E E E N N N N G G G G I I I I N N N N E E E E S S S S P P P P E E E E C C C C I I I I F F F F I I I I C C C C A A A A T T T T I I I I O O O O N N N N S [...]

20 200-2341 E E E E L L L L E E E E C C C C T T T T R R R R I I I I C C C C A A A A L L L L S S S S P P P P E E E E C C C C I I I I F F F F I I I I C C C C A A A A T T T T I I I I O O O O N N N N S S S S F F F F U U U U E E E E L L L L S S S S P P P P E E E E C C C C I I I I F F F F I I I I C C C C A A A A T T T T I I I I O O O O N N N N S S S S A [...]

200-2341 21 Before installing, operating or maintaining the generator, take a few moments to become familiar with the features of the generator as illustrated. 1. CONTROL PANEL Controls the operation of the generator and communicates system status. 2. MAIN LINE CIRCUIT BREAKER Protects generator and connected loads from electrical faults. Used to i[...]

22 200-2341 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 seamles[...]

200-2341 23 Two methods are available to start the generator. The automatic, or AUTO mode is for use with an automatic transfer switch. With the control panel mode switch set to this position, the generator waits for an external signal to start. This signal is supplied by the transfer switch when utility power is of unacceptable quality. Since util[...]

24 200-2341 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 s[...]

200-2341 25 1. Perform first change at 25 hours. M M M M A A A A I I I I N N N N T T T T E E E E N N N N A A A A N N N N C C C C E E E E Every month or 15 hours Every 6 months or 100 hours Every year or 300 hours Every 2 years or 500 hours Engine Oil Check X Change X 1 Engine Oil Filter Change X Oil Cooler Check and Clean X Engine Air Filter Check [...]

26 200-2341 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 lev[...]

200-2341 27 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 [...]

28 200-2341 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. To avo[...]

200-2341 29 5. Insure the the battery charger is powered and functioning properly. A correctly operating battery charger displays lights on the face of the charger to relay the state of the charger. To locate the battery charger ( A ) and check the lights ( B ) (see note below) refer to Fig F. Refer to Table A to assess the mode the charger is oper[...]

30 200-2341 Engine spark plugs are an important part of the engine ignition system. Worn or incorrectly adjusted spark plugs can negatively affect engine starting and operation. Therefore, it is important to inspect and regap, or replace the engine spark plugs as indicated in the service interval table. The listed steps are recommended to access an[...]

200-2341 31 In some areas of the United States, a USDA Forest Service approved exhaust spark arrestor is legally required. This optional accessory is added to the generator during initial installation. To identify whether the generator is equipped with a spark arrestor, inspect the exhaust tailpipe opening for a screen. If a screen is present in th[...]

32 200-2341 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[...]

200-2341 33 Over time, normal engine operation leads to wear in the engine valve train which decreases generator output. To restore generator output, it is necessary to check and adjust the engine valve lash at regular intervals throughout the life of the engine. However, proper valve lash adjustments require specialized training and tools. Adjustm[...]

34 200-2341 T T T T R R R R O O O O U U U U B B B B L L L L E E E E S S S S H H H H O O O O O O O O T T T T I I I I N N N N G G G G S Y M P T O M P OS S I BL E CAUS E CORRECT I V E ACT I ON E ngi ne does not c rank Loos e bat t ery c abl es • Chec k al l bat t ery c abl e c onnec t ions Def ec t i v e bat t ery • T es t bat t ery . R epl ac e a[...]

200-2341 35 T T T T R R R R O O O O U U U U B B B B L L L L E E E E S S S S H H H H O O O O O O O O T T T T I I I I N N N N G G G G S Y M P T OM P OS S I BL E CAUS E CORRECT I V E ACT I ON Low generat or out put v ol t age Low engine s peed • V erify c orrec t engi ne s peed. Rem ov e ex c es s l oads or adj us t s peed as requi red. E x c i t at[...]

36 200-2341 P P A A R R T T S S D D R R A A W W I I N N G G - - E E X X H H A A U U S S T T S S Y Y S S T T E E M M P P A A R R T T S S L L I I S S T T Item Part No Qty Description 1 N/A 9 Screw, 10-16 x .50” lg 2 N/A 9 Star washer, #10 3 N/A 2 Rivet 4 Not replaceable 1 Label, hot, stamped steel 5 115-0262 1 Cover, muffler (includes items 3, 4, 6[...]

200-2341 37 P P A A R R T T S S L L I I S S T T P P A A R R T T S S D D R R A A W W I I N N G G - - E E N N C C L L O O S S U U R R E E Item Part No Qty Description 1 N/A 14 Screw, 10-16 x .50” lg 2 N/A 14 Star washer, #10 3 115-0264 1 Side panel, left side (includes item 16) 4 S115-0242 1 Prop arm, lid 5 S115-0240 1 Lid assembly, complete (see p[...]

38 200-2341 P P A A R R T T S S D D R R A A W W I I N N G G - - L L I I D D A A S S S S E E M M B B L L Y Y P P A A R R T T S S L L I I S S T T Item Part No Qty Description 1 0056765 1 Lock (includes 1A, 1B, 1C & 1D) 1A 146-0023 1 Key 1B Order item # 1 1 Washer 1C Order item #1 1 Bolt 1D Order item #1 1 Nut 2 0056761 1 Handle 3 S115-0251 1 Lid [...]

200-2341 39 P P A A R R T T S S D D R R A A W W I I N N G G - - G G E E N N E E R R A A T T O O R R P P A A R R T T S S L L I I S S T T Item Part No Qty Description 1 0056629 1 Discharge louvered cover 2 0056623 1 Engine adapter 3 160-0311 1 Rotor assembly 4 100-0003 2 Diode/varistor assembly 5 059-0348 1 Rotor bolt 6 160-0312 1 Stator assembly 7 1[...]

40 200-2341 P P A A R R T T S S D D R R A A W W I I N N G G - - H H 2 2 X X B B R R E E A A K K D D O O W W N N P P A A R R T T S S L L I I S S T T Item Part No Qty Description 1 094-0091 1 Insulation 2 115-0268 1 Panel, left side (includes item 1) 3 N/A 4 Screw, 10-32 x .50” lg 4 N/A 1 Bolt, 5/16 NC x 1.25” lg 5 N/A 1 Lock washer, 5/16” 6 N/[...]

200-2341 41 P P A A R R T T S S D D R R A A W W I I N N G G - - E E N N G G I I N N E E P P A A N N E E L L E E N N D D A A S S S S E E M M B B L L Y Y P P A A R R T T S S L L I I S S T T Item Part No Qty Description 1 094-0096 1 Insulation 2 N/A 6 Hose clamp, 23/32” I.D. 3 S012-0106 1 Hose, high temp oil, 3/8” x 26.5” lg 4 N/A 10 Nut, 1/4-20[...]

42 200-2341 P P A A R R T T S S D D R R A A W W I I N N G G - - C C O O N N T T R R O O L L P P A A N N E E L L B B R R E E A A K K D D O O W W N N P P A A R R T T S S L L I I S S T T Item Part No Qty Description 1 N/A 2 Screw #8-32 x .75 phillips hd 2 034-0161 1 Switch, toggle 3 032-0067 1 Hourmeter, 120V AC 60HZ 4 (see #8) 1 Not available separat[...]

200-2341 43 P P A A R R T T S S D D R R A A W W I I N N G G - - B B A A T T T T E E R R Y Y H H O O L L D D D D O O W W N N P P A A R R T T S S L L I I S S T T Item Part No Qty Description 1 N/A 2 Nut, 1/4-20 2 S114-0563 1 Bracket, battery hold down 3 026-0480 1 Battery cable, positive 4 026-0481 1 Battery cable, negative 5 N/A 1 Battery, BCI Group[...]

44 200-2341 N N O O T T E E S S[...]

200-2341 45 N N O O T T E E S S[...]

46 200-2341 Coleman PowerSt ation™ St ationary St andby 3-Y ear or 1500 Hour Limited W arranty Your Coleman PowerStation™ emergency back up power system generator has been manufactured to stringent guidelines & standards for years of dependable operation & service. Coleman Powermate warrants this product to the original consumer against[...]

200-2341 47 COMUNÍQUESE CON EL DEP ART AMENTO DE SER VICIO DE PRODUCTOS COLEMAN POWERMA TE EN EL TELÉFONO 1-800-445-1805 p ara obtener información sobre servicios de garantía o p ara pedir piezas de repuesto o accesorios. CÓMO PEDIR PIEZAS DE REPUESTO Incluso los equipos de calidad como el generador de emergencia Coleman Powermate que ha compr[...]

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