Owner’s Manual
Air-cooled, Prepackaged
Automatic Standby Generators
Models:
C
US
ASPAS1CCA007 (6 kW NG, 7 kW LP)
ASPAS1CCA012 (12 kW NG, 12 kW LP)
ASPAS1CCA015 (13 kW NG, 15 kW LP)
L
ISTED
Not intended for use as Primary Power in place of utility or in
life-support applications.
!
!
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
Table of Contents
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
Introduction ........................Inside Front Cover
Section 3 – Maintenance ..............................12
Read This Manual Thoroughly ..............................IFC
Contents ................................................................IFC
Operation and Maintenance ..................................IFC
How to Obtain Service ..........................................IFC
3.1 Fuses ................................................................12
3.2 Checking the Engine Oil Level ..........................13
3.3 Changing the Engine Oil....................................13
3.4 Changing the Oil Filter ......................................14
3.5 Changing the Engine Air Cleaner......................14
3.6 Spark Plug(s) ....................................................14
3.7 Battery Maintenance..........................................15
3.8 Cooling System..................................................15
3.9 Corrosion Protection..........................................16
3.10 Attention After Submersion................................16
3.11 Out of Service Procedure ..................................16
Safety Rules ........................................................2
Standards Index ........................................................3
Section 1 – General Information ..................4
1.1 Unpacking/Inspection ..........................................4
1.2 Protection Systems..............................................4
1.3 NEC Requirement for Arc Fault Circuit
Interruption Breaker for Bedrooms ......................4
1.4 The Generator ....................................................5
1.5 Specifications ......................................................6
1.6 System Set LED ..................................................6
1.7 Fuel Requirements and Recommendations ........6
1.8 Fuel Consumption................................................7
1.9 Location ..............................................................7
1.10 Battery Installation ..............................................8
1.11 The Battery ..........................................................8
Section 4 – Service..........................................17
4.1 Service Schedule ..............................................17
Section 5 – Troubleshooting ........................18
5.1 Troubleshooting Guide ......................................18
Section 6 – Warranty ......................................19
Section 2 – Operation ......................................9
2.1 Break-in Procedure..............................................9
2.2 Using the Auto/Off/Manual Switch ......................9
2.3 Automatic Transfer Operation ..........................10
2.4 Sequence of Automatic Operation ....................10
2.5 Manual Transfer Operation................................11
2.6 Setting the Exercise Timer ................................11
2.7 Protection Systems............................................12
Carrier
1
IMPORTANT SAFETY INSTRUCTIONS
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted near the unit’s installation site. Safety should be stressed to all
operators and potential operators of this equipment.
!
!
!
!
!
!
GENERAL HAZARDS
WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
• For safety reasons, Carrier recommends that the
installation, initial start-up and maintenance of this
equipment is carried out by a Carrier Dealer.
• The engine exhaust fumes contain carbon monoxide,
which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust system
must be installed properly, in strict compliance with
applicable codes and standards. Following
installation, do nothing that might render the system
unsafe or in noncompliance with such codes and
standards.
• Keep hands, feet, clothing, etc., away from drive belts,
fans, and other moving or hot parts. Never remove any
drive belt or fan guard while the unit is operating.
• Adequate, unobstructed flow of cooling and ventilating
air is critical to correct generator operation. Do not
alter the installation or permit even partial blockage of
ventilation provisions, as this can seriously affect safe
operation of the generator. The generator MUST be
installed outdoors.
• When working on this equipment, remain alert at all
times. Never work on the equipment when physically
or mentally fatigued.
• Inspect the generator regularly, and contact the
nearest Carrier Dealer for parts needing repair or
replacement.
• Before performing any maintenance on the generator,
disconnect its battery cables to prevent accidental
start up. Disconnect the cable from the battery post
indicated by a NEGATIVE, NEG or (–) first. Reconnect
that cable last.
• Never use the generator or any of its parts as a step.
Stepping on the unit can stress and break parts, and
may result in dangerous operating conditions from
leaking exhaust gases, fuel leakage, oil leakage, etc.
!
!
WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar
with this Owner’s Manual and with the unit. The generator
can operate safely, efficiently and reliably only if it is
properly installed, operated and maintained. Many
accidents are caused by failing to follow simple and
fundamental rules or precautions.
Carrier
cannot
anticipate
every
possible
circumstance that might involve a hazard. The warnings
in this manual, and on tags and decals affixed to the unit
are, therefore, not all-inclusive. If using a procedure,
work method or operating technique Carrier does not
specifically recommend, ensure that it is safe for others.
Also make sure the procedure, work method or operating
technique chosen does not render the generator unsafe.
DANGER
Despite the safe design of this generator,
!
operating this equipment imprudently, neglecting
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
!
generators.
2
Carrier
IMPORTANT SAFETY INSTRUCTIONS
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
Extinguishers rated “ABC” by the National Fire
Protection Association are appropriate for use on the
standby electric system. Keep the extinguisher
properly charged and be familiar with its use. Consult
the local fire department with any questions pertaining
to fire extinguishers.
ELECTRICAL HAZARDS
• All generators covered by this manual produce
dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely high
and dangerous voltages to the transfer switch as does
the standby generator when it is in operation. Avoid
contact with bare wires, terminals, connections, etc.,
while the unit is running. Ensure all appropriate
covers, guards and barriers are in place before
operating the generator. If work must be done around
an operating unit, stand on an insulated, dry surface to
reduce shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• The National Electrical Code (NEC) requires the frame
and external electrically conductive parts of the
generator to be connected to an approved earth
ground. Local electrical codes also may require proper
grounding of the generator electrical system.
• After installing this home standby electrical system, the
generator may crank and start at any time without
warning. When this occurs, load circuits are
transferred to the STANDBY (generator) power
source. To prevent possible injury if such a start and
transfer occur, always set the generator’s
Auto/Off/Manual switch to its OFF position before
working on equipment and remove the 7.5A and 15A
fuses from the generator control panel.
• In case of accident caused by electric shock,
immediately shut down the source of electrical power. If
this is not possible, attempt to free the victim from the
live conductor. AVOID DIRECT CONTACT WITH THE
VICTIM. Use a nonconducting implement, such as a dry
rope or board, to free the victim from the live conductor.
If the victim is unconscious, apply first aid and get
immediate medical help.
EXPLOSION HAZARDS
• Do not smoke around the generator. Wipe up any fuel
or oil spills immediately. Ensure that no combustible
materials are left in the generator compartment, or on
or near the generator, as FIRE or EXPLOSION may
result. Keep the area surrounding the generator clean
and free from debris.
• Gaseous fluids such as natural gas and liquid propane
(LP) gas are extremely EXPLOSIVE. Install the fuel
supply system according to applicable fuel-gas codes.
Before placing the home standby electric system into
service, fuel system lines must be properly purged and
leak tested according to applicable code. After
installation, inspect the fuel system periodically for
leaks. No leakage is permitted.
STANDARDS INDEX
‹
In the absence of pertinent standards, codes, regulations
and laws, the published information listed below may be
used as installation guide for this equipment.
1. NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES, available from the
National Fire Protection Association, 470 Atlantic
Avenue, Boston, MA 02210.
2. NFPA No. 76A, ESSENTIAL ELECTRICAL
SYSTEMS FOR HEALTH CARE FACILITIES,
available same as Item 1.
3. NFPA No. 54, NATIONAL FUEL GAS CODE,
available same as Item 1.
4. NFPA No. 58, AMERICAN NATIONAL STANDARD
FOR STORAGE AND HANDLING OF LIQUEFIED
PETROLEUM GAS, available same as Item 1.
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL
ELECTRIC CODE, available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85 John
Street, New York, N.Y. 10038.
• Never wear jewelry when working on this equipment.
Jewelry can conduct electricity resulting in electric
shock, or may get caught in moving components
causing injury.
FIRE HAZARDS
• 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) has established. Also, ensure that the
generator is installed in accordance with the
manufacturer’s instructions and recommendations.
Following proper installation, do nothing that might
alter a safe installation and render the unit in
noncompliance with the aforementioned codes,
standards, laws and regulations.
7. AGRICULTURAL WIRING HANDBOOK, available
from the Food and Energy Council, 909 University
Avenue, Columbia, MO 65201.
8. ASAE
EP-3634,
INSTALLATION
AND
MAINTENANCE
OF
FARM STANDBY
ELECTRICAL SYSTEMS, available from the
American Society of Agricultural Engineers, 2950
Niles Road, St. Joseph, MI 49085.
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE, available same as Item 1.
• Keep a fire extinguisher near the generator at all times.
Carrier
3
Section 1 — General Information
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
There are LED readouts on the control panel to notify
DANGER
personnel that one of these faults has occurred. There is
also a “System Set” LED that is lit when all of the
conditions describe in Section 1.3 are true.
Only qualified electricians or contractors should
attempt such installations, which must comply
strictly with applicable codes, standards and
regulations.
!
1.3 NEC REQUIREMENT FOR ARC
FAULT CIRCUIT INTERRUPTION
BREAKER FOR BEDROOMS
In 2001, the National Electric Code (NEC) introduced a
requirement for new construction. This new requirement
indicates the need for Arc Fault Circuit Interrupters to be
used to protect the complete branch circuit that feeds a
dwelling bedroom. The actual NEC requirement is
indicated below.
1.1 UNPACKING/INSPECTION
After unpacking, carefully inspect the contents
for damage.
• This standby generator set has been factory supplied
with a weather protective enclosure that is intended for
outdoor installation only.
• This UL listed standby generator set is packaged with
an automatic transfer switch with built in load center.
The combination transfer switch and load center is
pre-wired with a two foot and 30 foot conduit. Circuit
breakers for emergency circuit connections are
included.
‹
1.3.1 SECTION 210.12 ARC FAULT CIRCUIT
INTERRUPTER PROTECTION
1. Definition: An arc fault circuit interrupter is a device
intended to provide protection from the effects of arc
faults by recognizing characteristics unique to arcing
and by functioning to de-energize the circuit when an
arc fault is detected.
• This UL listed, 2-pole switch is rated at 100 AC
amperes at 250 volts maximum. This transfer switch
is for indoor use only.
2. Dwelling Unit Bedrooms: All branch circuits that
supply 125 volt, single-phase, 15 and 20 ampere
outlets installed in dwelling unit bedrooms shall be
protected by an arc fault circuit interrupter listed to
provide protection of the entire branch circuit.
Section 210.12 requires that AFCI protection be provided
on branch circuits that supply outlets (receptacle,
lighting, etc.) in dwelling bedrooms. The requirement is
limited to 15 and 20 ampere, 125 volt circuits. There is no
prohibition against providing AFCI protection on other
circuits or in locations other than bedrooms. Because
circuits are often shared between a bedroom and other
areas such as closets and hallways, providing AFCI
protection on the complete circuit would comply with
210.12.
If this generator is used to power electrical load
circuits normally powered by a utility power
source, it is required by code to install a
transfer switch. The transfer switch must
effectively isolate the electrical system from the
utility distribution system when the generator
is operating (NEC 700, 701 & 702). Failure to
isolate an electrical system by such means will
result in damage to the generator and also may
result in injury or death to utility power
workers due to backfeed of electrical energy.
If any loss or damage is noted at time of delivery, have
the person(s) making the delivery note all damage on the
freight bill or affix their signature under the consignor's
memo of loss or damage.
If during the installation of the Carrier Home Standby
system the decision is made to provide back up power to
a bedroom branch circuit, then the circuit breaker in the
Carrier Transfer Switch should be replaced with an Arc
Fault Circuit Interrupter.
If a loss or damage is noted after delivery, separate the
damaged materials and contact the Carrier for claim
procedures.
“Concealed damage” is understood to mean damage to
the contents of a package that is not in evidence at the
time of delivery, but is discovered later.
It is most important that breakers only be switched like for
like. For instance, if replacing a 15A breaker, it MUST be
replaced with a 15A AFCI breaker. Likewise, a 20A
breaker MUST be replaced with a 20A AFCI.
1.2 PROTECTION SYSTEMS
These AFCI breakers are available at the nearest
electrical wholesaler or hardware store.
Unlike an automobile engine, the generator may have to
run for long periods of time with no operator present to
monitor engine conditions. For that reason, the engine is
equipped with the following systems that protect it
against potentially damaging conditions:
Siemens Item #
Q115AF
Description
15A Single Pole AFCI
20A Single Pole AFCI
Q120AF
1. Low Oil Pressure Sensor
2. High Temperature Sensor
3. Overcrank
4. Overspeed
4
Carrier
Section 1 — General Information
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
1.4 THE GENERATOR
Figure 1.1 – 7 kW, Single Cylinder GH-410 Engine
Control
Panel
Oil
Dipstick
Data
Decal
GFCI
Outlet
Exhaust
Enclosure
Fuel
Regulator
Fuel
Inlet
Battery
Compartment
Oil Filter
Figure 1.2 – 12 kW and 15 kW, V-twin GT-990 Engine
Control
Panel
Oil
Dipstick
Data
Decal
GFCI
Outlet
Exhaust
Enclosure
Fuel
Regulator
Fuel
Inlet
Composite Base
Battery
Compartment
Oil Filter
Carrier
5
Section 1 — General Information
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
1.5 SPECIFICATIONS
1.5.1 GENERATOR
‹
Model
ASPAS1CCA007
6,000 NG/7,000 LP
120/240
ASPAS1CCA012
12,000 NG/12,000 LP
120/240
ASPAS1CCA015
13,000 NG/15,000 LP
120/240
Rated Max. Continuous Power Capacity (Watts*)
Rated Voltage
Rated Max. Continuous Load Current (Amps)
120 Volts**
50.0 NG/58.3 LP
100.0 NG/100.0 LP
108.3 NG/125.0 LP
240 Volts
25.0 NG/29.2 LP
50.0 NG/50.0 LP
54.2 NG/62.5 LP
Main Line Circuit Breaker
Phase
30 Amp
50 Amp
65 Amp
1
1
1
Number of Rotor Poles
Rated AC Frequency
Power Factor
2
2
2
60 Hz
1
60 Hz
1
60 Hz
1
Recommended Air Filter
Carrier Part # 0C8127
Carrier Part # 0C8127
Carrier Part # 0C8127
Battery Requirement
(At 0° F -17.8° C)
Group 26
12 Volts and
350 Cold-cranking
Amperes Minimum
Group 26
12 Volts and
525 Cold-cranking
Amperes Minimum
Group 26
12 Volts and
525 Cold-cranking
Amperes Minimum
Weight
375 Pounds
68 db (A)
470 Pounds
70.5 db (A)
487 Pounds
71.5 db (A)
Output Sound Level @ 23 ft (7m) at full load
Normal Operating Range
-20°F (-28.8°C) to 104°F (40°C)
* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power decreases about 3.5
percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F) ambient temperature.
** Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value stated for 240 volts.
1.5.2 ENGINE
‹
ASPAS1CCA007
GH-410
ASPAS1CCA012
GT-990
ASPAS1CCA015
GT-990
Type of Engine
Number of Cylinders
Rated Horsepower
Displacement
1
2
2
14.5 @ 3,600 rpm
410cc
30 @ 3,600 rpm
992cc
30 @ 3,600 rpm
992cc
Cylinder Block
Aluminum w/Cast
Iron Sleeve
Aluminum w/Cast
Iron Sleeve
Aluminum w/Cast
Iron Sleeve
Valve Arrangement
Ignition System
Recommended Spark Plug
Spark Plug Gap
Compression Ratio
Starter
Overhead Valves
Solid-state w/Magneto
RC14YC
0.76 mm (0.030 inch)
8.6:1
Overhead Valves
Solid-state w/Magneto
RC12YC
0.508 mm (0.020 inch)
9.5:1
Overhead Valves
Solid-state w/Magneto
RC12YC
0.508 mm (0.020 inch)
9.5:1
12 Vdc
12 Vdc
12Vdc
Oil Capacity Including Filter
Recommended Oil Filter
Recommended Air Filter
Operating RPM
Approx. 1.5 Qts
Carrier Part # 70185D
Carrier Part # 0C8127
3,600
Approx. 1.7 Qts
Carrier Part # 70185D
Carrier Part # 0C8127
3,600
Approx. 1.7 Qts
Carrier Part # 70185D
Carrier Part # 0C8127
3,600
4. No alarms are present, for example, low oil pressure,
high temperature, etc.
1.6 SYSTEM SET LED
The “System Set” LED is lit when all of the following
conditions are true:
1.7 FUEL REQUIREMENTS
1. The AUTO/OFF/MANUAL switch is set to the AUTO
position.
AND RECOMMENDATIONS
With LP gas, use only the vapor withdrawal
system. This type of system uses the vapors formed
above the liquid fuel in the storage tank. The engine has
been fitted with a fuel carburetion system that meets the
specifications of the 1997 California Air Resources Board
for tamper-proof dual fuel systems. The unit will run on
natural gas or LP gas, but it has been factory set to run
on natural gas.
2. The utility voltage being supplied to the unit is being
sensed by the PCB. If the utility sense voltage is not
connected to the unit or if it is below 168 volts AC,
then the system set light will flash rapidly. This
indicates that if the AUTO/OFF/ MANUAL switch is
placed in the Auto position, the generator will start.
3. The “Not In Auto” dip switch is set to the OFF position
on the control board.
6
Carrier
Section 1 — General Information
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
Should the primary fuel need to be changed to LP gas,
the fuel system needs to be reconfigured. See Section
1.9 for instructions on reconfiguration of the fuel system.
1.9.2 GENERATOR
Install the generator set, in its protective enclosure,
outdoors, where adequate cooling and ventilating air
is always available. Consider these factors:
◆
!
Recommended fuels should have a Btu content of at
least 1,000 Btus per cubic foot for natural gas; or at least
2,520 Btus per cubic foot for LP gas. Ask the fuel supplier
for the Btu content of the fuel.
• Install the unit where air inlet and outlet openings will
not become obstructed by leaves, grass, snow, etc. If
prevailing winds will cause blowing or drifting, consider
using a windbreak to protect the unit.
• Install the generator on high ground where water
levels will not rise and endanger it.
• Allow sufficient room on all sides of the generator for
maintenance and servicing. A good rule is to allow
three feet of space on all sides.
• Where strong prevailing winds blow from one direction,
face the generator air inlet openings to the prevailing
winds.
Required fuel pressure for natural gas is 5 inches to 7
inches water colum (0.18 to 0.25 psi); and for liquid
propane, 11 inches to 14 inches of water column (0.4
to 0.5 psi).
NOTE:
Any piping used to connect the generator to the fuel
supply should be of adequate size to ensure the fuel
pressure NEVER drops below 4 inches water colum
for natural gas or 10 inches water column for liquid
propane for all load ranges.
• Install the generator as close as possible to the fuel
supply, to reduce the length of piping.
• Install the generator as close as possible to the
transfer switch. HOWEVER, REMEMBER THAT
LAWS OR CODES MAY REGULATE THE
DISTANCE.
The genset must be installed on a level surface. The
base frame must be level within two (2) inches all around.
1.8 FUEL CONSUMPTION
*Natural gas is in cubic feet per hour.
**LP is in gallons per hour/cubic feet per hour.
*** Values given are approximate.
Model #
Nat. Gas (*)
1/2 Load Full Load
LP Vapor (**)
1/2 Load
Full Load
1.47/54
2.08/76
2.40/88
6/7 kW
12 kW
13/15 kW
66
152
156
119
215
220
0.82/30
1.53/56
1.58/58
1.9.3 TRANSFER SWITCH
◆
1.9.3.1 7 kW, 12 kW and 15 kW Units
DANGER
The transfer switch shipped with this generator is
enclosed in a NEMA 1 enclosure. This type of
enclosure is intended for indoor use only. Follow
these rules:
Gaseous fuels such as natural gas and liquid
propane (LP) gas are highly explosive. Even the
slightest spark can ignite such fuels and cause
an explosion. No leakage of fuel is permitted.
Natural gas, which is lighter than air, tends to
collect in high areas. LP gas is heavier than air
and tends to settle in low areas.
• Install the transfer switch indoors on a firm, sturdy
supporting structure.
• To prevent switch distortion, level the switch if
necessary. This can be done by placing washers
between the switch enclosure and mounting surface.
• Never install the switch where water or any corrosive
substance might drip onto the enclosure.
• Protect the switch at all times against excessive
moisture, dust, dirt, lint, construction grit and corrosive
vapors.
1.9 LOCATION
1.9.1 LIFTING THE GENERATOR
◆
To lift the generator, insert pipe having sufficient strength
and diameter through the lifting holes which are located
near the unit’s base (see Figure 1.1 and 1.2, page 5).
You may also lift the unit using a hook and hoist method
provided you utilize a spreader bar to ensure that the
lifting lines clear the roof panel.
If the AUTO/OFF/MANUAL switch is not set to
its OFF position, the generator can crank and
start as soon as the battery cables are
connected. If the utility power supply is not
turned off, sparking can occur at the battery
posts and cause an explosion.
DANGER
When lifting or hoisting equipment is used, be careful
not to contact overhead power lines.
The generator’s weight of more than 300 pounds
requires proper tools, equipment and qualified
!
personnel to be used in all phases of handling and
unpacking.
Carrier
7
Section 1 — General Information
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
A battery presents a risk of electrical shock
1.10 BATTERY INSTALLATION
Fill the battery with the proper electrolyte fluid if
necessary and have the battery fully charged before
installing it.
and high short circuit current. The following
precautions are to be observed when working
on batteries:
• Remove the 7.5A and 15A fuses from the
generator control panel.
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery; and
Before installing and connecting the battery, complete
the following steps:
1. Set the generator's AUTO/OFF/MANUAL switch to
OFF.
2. Turn off utility power supply to the transfer switch.
3. Remove the 7.5A and 15A fuses from the
generator control panel.
• Disconnect charging source prior to connecting or
disconnecting battery terminals.
Battery cables were factory connected at the generator
(Figure 1.5). Connect cables to battery posts as follows:
Figure 1.5 – Battery Cable Connections
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to
!
the skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
!
conductive and corrosive.
The following procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off
immediately with water;
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention; and
4. Connect the red battery cable (from starter contactor)
• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) of water. The
bicarbonate of soda solution is to be added until
the evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
to the battery post indicated by a positive, POS or
(+).
5. Connect the black battery cable (from frame ground)
to the battery post indicated by a negative, NEG or
(—).
NOTE:
Damage will result if battery connections are made in
Lead-acid batteries present a risk of fire
because they generate hydrogen gas. The
following procedures are to be followed:
reverse.
NOTE:
The generator is equipped with a battery trickle
charger that is active when the unit is set up for
automatic operation. With the battery installed and
utility power source voltage available to the transfer
switch, the battery receives a trickle charge while the
engine is not running, to prevent self-discharge. The
trickle charger is designed to help extend the life of
the battery by maintaining the battery when the unit
is not running. The trickle charge feature cannot be
used to recharge a discharged battery.
• DO NOT SMOKE when near the battery;
• DO NOT cause flame or spark in battery area; and
• Discharge static electricity from body before
touching the battery by first touching a grounded
metal surface.
Be sure the AUTO/OFF/MANUAL switch is set to
the OFF position before connecting the battery
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as
the battery cables are connected.
!
1.11 THE BATTERY
DANGER
Be sure the utility power supply is turned off
and the 7.5A and 15A fuses are removed from
the generator control panel, or sparking may
occur at the battery posts as the cables are
attached and cause an explosion.
Do not dispose of the battery in a fire. The
battery is capable of exploding.
8
Carrier
Section 2 — Operation
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
Servicing of the battery is to be performed or supervised
12. Drain the oil and remove the oil filter. Replace the oil
filter according to Section 3.4, “Changing the Oil
Filter”. Replace the oil with synthetic oil as
recommended in Section 3.3, “Changing the Engine
Oil”.
by personnel knowledgeable of batteries and the
required precautions. Keep unauthorized personnel
away from batteries.
When replacing the battery, use the following type of
battery: Group 26 12-volt DC, negative ground battery
with a rating of 350 cold-cranking amps minimum for 7
kW; 525 cold-cranking amps minimum for 12 and 15 kW
at -17.8° C (0° F) minimum. When using a maintenance-
free battery, it is not necessary to check the specific
gravity or electrolyte level. Have these procedures
performed at the intervals specified in the “Service
Schedule.” A negative ground system is used. Battery
connections are shown on the wiring diagrams. Make
sure the battery is correctly connected and terminals are
tight. Observe battery polarity when connecting the
battery to the generator set.
13. Reconnect the battery cables as outlined in “General
Hazards” (page 2) and insert the 7.5A and 15A fuses
into the generator control panel. The generator is
now ready for service.
2.2 USING THE AUTO/OFF/MANUAL
SWITCH (FIGURE 2.1)
2.2.1 “AUTO” POSITION
‹
Selecting this switch position activates fully automatic
system operation. It also allows personnel to start and
exercise the engine every seven days with the setting of
the exercise timer (see Section 2.6). This position also is
used for remote starting, when it is set up.
2.1 BREAK-IN PROCEDURE
Once the unit has been installed and all electrical checks
have been made, it is strongly recommended that the
following “Break-in Procedure” be completed to ensure
correct generator operation in the future.
2.2.2 “OFF” POSITION
‹
This switch position shuts down the engine. This position
also prevents automatic operation.
1. Set the generator’s AUTO/OFF/MANUAL switch to
AUTO.
2. Turn OFF the utility power supply to the transfer
switch using the means provided (such as a utility
main line circuit breaker).
Figure 2.1 – Generator Control Panel
EXTERNAL
OUTLET FUSE
GFCI
3. The unit will start, and the transfer switch will transfer
to standby.
4. Using the transfer switch’s built-in emergency load
center, turn on circuits to load the generator to
approximately 25% rated load and run the unit for
one hour.
5. Run the unit for one hour at 50% rated load.
6. Run the unit for one hour at 75% rated load.
7. Run the unit for one hour at 100% rated load.
8. Turn ON the utility power supply to the transfer
switch, which will allow the transfer switch to transfer
back to utility power. The unit will continue to run for
one minute and then shut down.
CIRCUIT
BREAKER
7.5A
AUTO
OFF MAN.
SYSTEM SET
LOW OIL
HIGH TEMP.
OVER SPEED
OVER CRANK
SYST
F
L
F
A
L
S
H
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D
SET
EXERCISE
TIME
N
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S
E
N
S
E
4
S
H
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S
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X
E
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S
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T
2.2.3 “MANUAL” POSITION
Set the switch to MANUAL to crank and start the engine.
Transfer to standby power will not occur unless there is a
utility failure.
‹
9. Allow the unit to cool.
10. Set the generator’s main circuit breaker to its OFF (or
OPEN) position.
11. Set the generator's AUTO/OFF/MANUAL switch to
OFF. Remove the 7.5A and 15A fuses from the
generator control panel. Disconnect the battery
cables as outlined in “General Hazards” (page 2).
With the switch set to AUTO, the engine may
!
crank and start at any time without warning.
Such automatic starting normally occurs when
utility power source voltage drops below a
preset level or during the normal exercise cycle.
To prevent possible injury that might be caused
by such sudden starts, always set the switch to
OFF and remove the fuses before working on
or around the generator or transfer switch.
Then, place a “DO NOT OPERATE” tag on the
generator panel and on the transfer switch.
Carrier
9
Section 2 — Operation
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
2.3 AUTOMATIC TRANSFER
2.4 SEQUENCE OF AUTOMATIC
OPERATION
OPERATION
To select automatic operation, do the following:
The generator’s control panel houses a control logic
circuit board. This board constantly monitors utility power
source voltage. Should that voltage drop below a preset
level, circuit board action will signal the engine to crank
and start. After the engine starts, the circuit board signals
the transfer switch to activate and connect load circuits to
the standby power supply (load terminal lugs T1/T2
connect to terminal lugs E1/E2).
1. Make sure the transfer switch main contacts are set
to their UTILITY position, i.e., loads connected to the
utility power source (Figure 2.2).
2. Be sure that normal UTILITY power source voltage is
available to transfer switch terminal lugs N1 and N2.
3. Set the generator’s AUTO/OFF/MANUAL switch to
AUTO.
4. Set the generator’s main circuit breaker to its ON (or
closed) position.
With the preceding steps complete, the generator will
start automatically when utility source voltage drops
below a preset level. After the unit starts, loads are
transferred to the standby power source. Refer to Section
2.4, “Sequence of Automatic Operation.”
Upon restoration of utility power supply, generator circuit
board action signals the transfer switch to transfer loads
back to the utility power supply. After retransfer, the
engine is signalled to shut down.
The actual sequence of operation is controlled by
sensors and timers on a control logic circuit board, as
follows:
A. Utility Voltage Dropout Sensor
‹
2.3.1 12 VDC ACCESSORY OUTLET
• This sensor monitors utility source voltage.
• If utility source voltage drops below about 70 percent
of the nominal supply voltage, the sensor energizes
a 15-second timer.
• Once the timer has expired, the engine will crank and
start.
Your generator is equipped with a 12 VDC accessory
outlet in the Generator Control Panel. (Figure 2.1) With
the generator running or in standby mode, this outlet may
be used to temporarily power low power accessories
such as a work light, cell phone, radio or any other
automotive style accessory. This outlet is capable of
delivering a MAXIMUM of 7.5 Amps. If the accessory to
be used through this circuit demands too much power,
the fuse that protects this circuit will melt open and the
circuit will not be functional.
B. Engine Warm-up Time Delay
• This mechanism lets the engine warm up for about
10 seconds before the load is transferred to the
standby source.
C.Standby Voltage Sensor
• This sensor monitors generator AC output voltage.
When the voltage has reached 50 percent of the
nominal rated voltage, transfer to standby can occur.
D.Utility Voltage Pickup Sensor
• This sensor monitors utility power supply voltage.
When that voltage is restored above 70 percent of
the nominal source voltage, a retransfer time delay
starts timing.
This 12 VDC outlet draws power from the
generator's starting battery and extended use
of this outlet may drain the battery and the
engine may not start. This outlet should NOT
be used for battery charging.
!
E. Retransfer Time Delay
‹
2.3.2 120 VAC GFCI OUTLET
• This timer runs for about 15 seconds.
• At end of a 15-second delay, circuit board action de-
energizes transfer relay in the transfer switch.
• Retransfer to utility power source then occurs.
F. Engine Cool-down Timer
• When the load is transferred back to utility power
source, the engine cool-down timer starts timing.
• The timer will run for about one minute, and the
generator will then shut down.
Your generator is equipped with an external, 15 amp, 120
volt, GFCI convenience outlet that is located in the right
rear of the generator enclosure. (Figures 1.1 and 1.2,
page 5) When the generator is running, in the absence of
utility power, this outlet may be used to power items
outside your home such as lights or power tools. This
outlet may also be used when utility power is present by
running the generator in manual mode. This oultlet does
not provide power if the generator is not running. This
outlet is protected by a 15-amp circuit breaker located in
the generator control panel. (Figure 3.1).
10 Carrier
Section 2 — Operation
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
2.5.2 TRANSFER BACK TO UTILITY POWER
‹
2.5 MANUAL TRANSFER OPERATION
SOURCE
2.5.1 TRANSFER TO GENERATOR
POWER SOURCE
‹
When utility power has been restored, transfer back to
that source and shut down the generator. This can be
accomplished as follows:
To start the generator and activate the transfer switch
manually, proceed as follows:
1. Set the generator’s main circuit breaker to its OFF (or
open) position.
2. Let the engine run for a minute or two at no-load to
stabilize the internal temperatures.
3. Set the generator’s AUTO/OFF/MANUAL switch to
its OFF (or open) position. The engine should
shut down.
4. Check that utility power supply to the transfer switch
is turned OFF.
1. Set the generator’s AUTO/OFF/MANUAL switch
to OFF.
2. Set the generator’s main circuit breaker to its OFF (or
open) position.
3. Turn OFF the utility power supply to the transfer
switch using the means provided (such as a
utility main line circuit breaker).
DANGER
DANGER
Do not attempt to activate the transfer switch
manually until all power voltage supplies to
the switch have been positively turned off.
Failure to turn off all power voltage supplies
may result in extremely hazardous and possibly
fatal electrical shock.
Do not attempt to activate the transfer switch
manually until all power voltage supplies
to the switch have been positively turned off.
Failure to turn off all power voltage supplies
may result in extremely hazardous and possibly
fatal electrical shock.
4. Use the manual transfer handle inside the transfer
switch to move the main contacts to their “Standby”
position, i.e., loads connected to the standby power
source (Figure 2.2).
5. Use the manual transfer handle inside the transfer
switch to move the main contacts back to their
UTILITY position, i.e., loads connected to the utility
power source (Figure 2.2).
6. Turn ON the utility power supply to the transfer
switch using the means provided.
Figure 2.2 – Manual Transfer Switch Operation
7. Set the system to automatic operation as outlined in
“Automatic Transfer Operation,” Section 2.3.
2.6 SETTING THE EXERCISE TIMER
This generator is equipped with an exercise timer. Once
it is set, the generator will start and exercise once every
seven days, on the day of the week and at the time of day
the following sequence is completed. During this
exercise period, the unit runs for approximately 12
minutes and then shuts down. Transfer of loads to the
generator output does not occur during the exercise
cycle.
A switch on the control panel (see Figure 2.1) permits
selection of the day and time for the system to exercise.
At the chosen time, perform the following sequence to
select the desired day and time of day the system will
exercise.
5. To crank and start the engine, set the
AUTO/OFF/MANUAL switch to MANUAL.
6. Let the engine stabilize and warm up for a few
minutes.
7. Set the generator’s main circuit breaker to its ON (or
closed) position. The standby power source now
powers the loads.
1. Verify that the AUTO/OFF/MANUAL switch is set
to AUTO.
2. Hold down the “Set Exercise Time” switch until the
generator starts (approximately 10 seconds) and
then release.
3. The generator will start and run for approximately 12
minutes and then shut down on its own. The
exerciser will then be set to run at that time of day
every week.
Carrier 11
Section 2 — Operation
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
NOTE:
2.7.3 OVER CRANK
‹
The exerciser will only work in the AUTO mode and
will not work unless this procedure is performed. The
exerciser will need to be reset every time the 12-volt
battery is disconnected and then reconnected.
This feature prevents the generator from damaging itself
when it continually attempts to start and another problem,
such as no fuel supply, prevents it from starting. The unit
will crank and rest for a preset time limit. Then, it will stop
cranking, and the Over Crank LED on the generator
control panel will light indicating an over crank failure.
The AUTO/OFF/MANUAL switch will need to be set to
OFF and then back to AUTO to reset the generator
control board.
The exerciser WILL NOT work if dip switch 2 on
the controller printed circuit board (Remote Not
!
Auto) is ON.
NOTE:
NOTE:
Damage will result if battery connections are made in
reverse.
If the fault is not repaired, the over crank feature will
continue to activate.
2.7.3.1 Approximate Crank Cycle Times
• 15 seconds ON
2.7 PROTECTION SYSTEMS
2.7.1 LOW OIL PRESSURE SWITCH
‹
• 7 seconds OFF
• 7 seconds ON
• 7 seconds OFF
• Repeat for 45 seconds
Approximately 90 seconds total
This switch (Figure 2.3) has normally closed contacts
that are held open by engine oil pressure during cranking
and operating. Should oil pressure drop below the 8 psi
limit, switch contacts close, and the engine shuts down.
The Low Oil LED will light. The unit should not be
restarted until oil is added. The AUTO/OFF/MANUAL
switch must then be turned to OFF and then back to
AUTO to reset.
2.7.4 OVER SPEED
‹
This feature protects the generator from damage by
shutting it down if it happens to run faster than the preset
limit. This protection also prevents the generator from
supplying an output that could potentially damage
2.7.2 HIGH TEMPERATURE SWITCH
‹
appliances
connected
to
the
generator
This switch’s contacts (Figure 2.3) close if the
temperature should exceed approximately 140º C (284º
F), initiating an engine shutdown. The High Temp. LED
will light. The generator will automatically restart and the
LED on the generator control panel will reset once the
temperature has returned to a safe operating level.
circuit. If this protective shutdown should occur the Over
Speed LED will light. Contact the nearest Carrier Dealer
if this failure occurs.
3.1 FUSES
The generator panel's 15-amp fuse (Figure 2.1) protects
the DC control circuit and the battery charge circuit
against overload. This fuse is wired in series with the
battery output lead to the panel. If this fuse element has
melted open, the engine will not be able to crank or start.
The generator will also lose all battery charge
capabilities. Replace this fuse using only an identical 15-
amp replacement fuse. To replace the fuse, push the
fuse holder cap down and rotate it counterclockwise.
Figure 2.3 – Low Oil Pressure and
High Temperature Switches
Low Oil Switch
High Temp Switch
The generator panel's 7.5-amp fuse protects the 12 VDC
accessory socket. If the fuse element has melted open,
the 12 VDC socket will not be able to provide power to
any accessories. Replace this fuse using only an
identical 7.5-amp replacement fuse. To replace the fuse,
push the fuse holder cap down and rotate it
counterclockwise.
Oil
Drain
Hose
Oil Filter
12 Carrier
Section 3 — Maintenance
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
Figure 3.1 – Generator Control Panel
Figure 3.3 — Oil Dipstick and Fill,
12 kW and 15 kW
EXTERNAL
GFCI
OUTLET FUSE
Oil Dipstick
CIRCUIT
BREAKER
7.5A
AUTO
OFF MAN.
SYSTEM SET
LOW OIL
HIGH TEMP.
OVER SPEED
OVER CRANK
SYST
Oil Fill
F
L
F
A
L
S
H
I
N
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D
SET
EXERCISE
TIME
N
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S
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N
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4
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3.2 CHECKING THE ENGINE OIL LEVEL
For oil capacities, see “Specifications,” Section 1.5. For
engine oil recommendations, see Section 3.3.1. To
check the engine oil level, proceed as follows (Figures
3.2 and 3.3):
1. Start the generator by moving the AUTO/OFF/
MANUAL switch to the MANUAL position. Allow it to
run for a short while and then shut it down by moving
the switch to the OFF position.
2. Remove the dipstick and wipe it dry with a
clean cloth.
3. Install the dipstick; then, remove it again. The oil
level should be at the dipstick “Full” mark. If
necessary, add oil to the “Full” mark only. DO NOT
FILL ABOVE THE “FULL” MARK.
3.3 CHANGING THE ENGINE OIL
3.3.1 ENGINE OIL RECOMMENDATIONS
‹
Use oil of American Petroleum Institute (API) Service
Class SG, SH or SJ. Use all season SAE 5W-30
Synthetic oil. Organic break-in oil is required before
using synthetic oil.
NOTE:
The unit is supplied with organic “break-in” oil. See
the “Break-in Procedure,” Section 2.1, for the first
required oil change.
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
!
this could damage the engine.
4. Install the dipstick.
5. Reset the AUTO/OFF/MANUAL switch to its original
Any attempt to crank or start the engine before
it has been properly serviced with the
recommended oil may result in an engine
failure.
!
position.
NOTE:
3.3.2 OIL CHANGE PROCEDURE
To change the oil, proceed as follows:
‹
If the generator is to operate continuously for several
days the oil level should be monitored frequently. A
low oil shutdown can occur (Section 2.7.1) causing
loss of generator power to emergency circuits.
1. Run the engine until it is thoroughly warmed up then
shut OFF the engine.
2. Immediately after the engine shuts OFF, pull the oil
drain hose (Figure 3.4) free of its retaining clip.
Remove the cap from the hose and drain the oil into
a suitable container.
Figure 3.2 — Oil Dipstick and Fill, 7 kW
Oil Dipstick and Fill
3. After the oil has drained, replace the cap onto the end
of the oil drain hose. Retain the hose in the clip.
4. Refill with the proper recommended oil (see Section
3.3.1). See Section 1.5.2 for oil capacities.
Carrier 13
Section 3 — Maintenance
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
MAINTENENANCE
Figure 3.4 – Oil Drain Hose and Filter
Figure 3.5 — 7 kW, Engine Air Cleaner Location
Fuel
Regulator
Low Oil Switch
High Temp Switch
Air Cleaner
Screw
Oil
Drain
Hose
3/4” Hole
Oil Filter
Figure 3.6 — 12 kW and 15 kW Engine
Air Cleaner
3.4 CHANGING THE OIL FILTER
Screw
Change the engine oil filter as follows:
1. With the oil drained, remove the old oil filter by
turning it counterclockwise.
2. Apply a light coating of clean engine oil to the gasket
of the new filter. See Section 1.5.2 for recommended
filter.
3. Screw the new filter on by hand until its gasket lightly
contacts the oil filter adapter. Then, tighten the filter
an additional 3/4 to one turn (Figure 3.4).
4. Refill with the proper recommended oil (see Section
3.3.1). See Section 1.5.2 for oil capacities.
5. Start the engine and check for leaks.
Cover
Filter
3.5 CHANGING THE ENGINE
AIR CLEANER
3.5.1 7 KW, 12 KW AND 15 KW
GENERATORS
See Figures 1.1 and 1.2, for the location of the air
cleaner. Use the following procedure (Figures 3.5 & 3.6):
‹
3.6 SPARK PLUG(S)
Reset the spark plug(s) gap or replace the spark plug(s)
as necessary. See Section 4.1 for maintenance
requirements.
1. Turn the two screws counterclockwise to loosen.
2. Remove the cover and air filter.
3. Wipe away dust or debris from inside of the air box
and around edges.
4. Install the new air cleaner into the air box.
5. Install the cover. Turn the two cover screws
clockwise to tighten.
See the “Service Schedule,” Section 4.1, for air cleaner
maintenance. See Section 1.5.1 for air filter replacement
part number.
1. Clean the area around the base of the spark plug(s)
to keep dirt and debris out of the engine. Clean by
scraping or washing using a wire brush and
commercial solvent. Do not blast the spark plug(s) to
clean.
2. Remove the spark plug(s) and check the condition.
Replace the spark plug(s) if worn or if reuse is
questionable. See Section 4.1 for recommended
inspection.
3. Check the spark plug gap using a wire feeler gauge.
Adjust the gap to 0.76 mm (0.030 inch) for 7 kW and
0.50 mm (0.020 inch) for 12 kW and 15 kW by
carefully bending the ground electrode (Figure 3.7).
14 Carrier
Section 3 — Maintenance
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
MAINTENENANCE
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off
immediately with water;
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention; and
Figure 3.7 – Setting the Spark Plug Gap
SET PLUG GAP AT 0.76 mm (.030 inch) - 7 kW
0.508 mm (.020 inch) - 12 kW & 15 kW
• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) of water. The
bicarbonate of soda solution is to be added until
the evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
Lead-acid batteries present a risk of fire
because they generate hydrogen gas. The
following procedures are to be followed:
3.7 BATTERY MAINTENANCE
The battery should be inspected per the “Service
Schedule,” Section 4.1. The following procedure should
be followed for inspection:
• DO NOT SMOKE when near the battery;
• DO NOT cause flame or spark in battery area; and
• Discharge static electricity from body before
touching the battery by first touching a grounded
metal surface.
1. Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
2. Check the battery fluid level of unsealed batteries
and, if necessary, fill with Distilled Water Only. Do
not use tap water in batteries.
3. Have the state of charge and condition checked. This
should be done with an automotive-type battery
hydrometer.
Be sure the AUTO/OFF/MANUAL switch is set to
the OFF position before connecting the battery
cables. If the switch is set to AUTO or MANUAL,
the generator can crank and start as soon as
the battery cables are connected.
!
Be sure the utility power supply is turned off
and the 7.5A and 15A fuses are removed from
the generator control panel, or sparking may
occur at the battery posts as the cables are
attached and cause an explosion.
DANGER
Do not dispose of the battery in a fire. The
battery is capable of exploding.
A battery presents a risk of electrical shock
and high short circuit current. The following
precautions are to be observed when working
on batteries:
3.8 COOLING SYSTEM
Air inlet and outlet openings in the generator
compartment must be open and unobstructed for
continued proper operation. This includes such
obstructions as high grass, weeds, brush, leaves and
snow.
• Remove the 7.5A and 15A fuses from the
generator control panel.
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery; and
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it to
quickly shut down. (See Figure 3.8 for vent locations.)
• Disconnect charging source prior to connecting or
disconnecting battery terminals.
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to
!
the skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
!
conductive and corrosive. The following
procedures are to be observed:
Carrier 15
Section 3 — Maintenance
MAINTENENANCE
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
5. Set the AUTO/OFF/MANUAL switch to OFF and turn
Figure 3.8 – Cooling Vent Locations
off the utility power to the transfer switch. Remove
the 7.5A and 15A fuses from the generator control
panel. Disconnect the battery cables as outlined in
“General Hazards” (page 2). Turn on the utility power
supply to the transfer switch in order to power the
emergency load centers circuits while utility power is
available.
6. While the engine is still warm from running, drain the
oil completely. Refill the crankcase with oil. See
”Engine Oil Recommendations,” Section 3.3.1.
7. Attach a tag to the engine indicating the viscosity and
classification of the oil in the crankcase.
8. Remove the spark plug(s) and spray fogging agent
into the spark plug(s) threaded openings. Reinstall
and tighten the spark plug(s).
9. Remove the battery and store it in a cool, dry room
on a wooden board. Never store the battery on any
concrete or earthen floor.
The exhaust from this product gets extremely
hot and remains hot after shutdown. High
grass, weeds, brush, leaves, etc. must remain
clear of the exhaust. Such materials may ignite
and burn from the heat of the exhaust system.
10. Clean and wipe the entire generator.
3.11.2 RETURN TO SERVICE
‹
To return the unit to service after storage, proceed
as follows:
The maximum ambient temperature for the
generator is 40° C (104° F).
1. Verify that utility power is turned off and that the
AUTO/OFF/MANUAL switch is set to OFF.
2. Check the tag on the engine for oil viscosity and
classification. Verify that the correct recommended
oil is used in the engine (see Section 3.3.1). If
necessary, drain and refill with the proper oil.
3. Check the state of the battery. Fill all cells of
unsealed batteries to the proper level with distilled
water. DO NOT USE TAP WATER IN THE
BATTERY. Recharge the battery to 100 percent
state of charge, or, if defective, replace the battery.
See “Specifications,” Section 1.5, for type and size.
4. Clean and wipe the entire generator.
!
3.9 CORROSION PROTECTION
Periodically wash and wax the enclosure using
automotive type products. Frequent washing is
recommended in salt water/coastal areas. Periodically
spray all engine linkage parts and brackets with corrosion
inhibiting spray such as WD-40 or a comparable product.
3.10 ATTENTION AFTER SUBMERSION
If the generator has been submerged in water,
it must not be started and operated. Following any
submersion in water, have a Carrier Dealer thoroughly
clean and dry the generator.
5. Remove the 7.5A and 15A fuses from the generator
control panel. Reconnect the battery. Observe
battery polarity. Damage may occur if the battery is
connected incorrectly.
3.11 OUT OF SERVICE PROCEDURE
6. Open the fuel shutoff valve.
7. Insert the 7.5A and 15A fuses into the generator
control panel. Start the unit by moving the
AUTO/OFF/MANUAL switch to MANUAL. Allow the
unit to warm up thoroughly.
8. Stop the unit by setting the AUTO/OFF/MANUAL
switch to OFF.
9. Turn on the utility power to the transfer switch.
10. Set the AUTO/OFF/MANUAL switch to AUTO.
11. The generator is now ready for service.
NOTE:
If the battery was dead or disconnected, the exercise
timer must be reset.
3.11.1 REMOVAL FROM SERVICE
If the generator cannot be exercised every seven days,
and will be out of service longer than 90 days, prepare
the generator for storage as follows:
‹
1. Start the engine and let it warm up.
2. Close the fuel shutoff valve in the fuel supply line and
allow the unit to shut down.
3. Once the unit has shut down, it will signal a low oil
fault.
4. Set the generator’s main circuit breaker to its OFF (or
open) position.
16 Carrier
Section 4 — Service Schedule
SERVICE
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
4.1 SERVICE SCHEDULE
ATTENTION: It is recommended that all service work
be performed by the nearest Carrier Dealer.
SYSTEM/COMPONENT
PROCEDURE
FREQUENCY
X = Action
Inspect
Change
Clean
W = Weekly
M = Monthly
Y = Yearly
R = Replace as Necessary
* = Notify Dealer
if Repair is Needed.
FUEL
Fuel lines and connections*
X
X
M
M
LUBRICATION
Oil level
Oil
X
X
AFTER BREAK-IN,
AND Y
Oil filter
AFTER BREAK-IN,
AND Y
COOLING
Enclosure louvers
BATTERY
X
X
W
Remove corrosion,
ensure dryness
X
X
X
X
M
M
Clean and tighten
battery terminals
Check charge state
X
X
R
R
EVERY 6 M
EVERY 6 M
Electrolyte level
(unsealed batteries only)*
ENGINE AND MOUNTING
Air cleaner
X
X
R
R
Y
Y
Spark plug(s)
GENERAL CONDITION
Vibration, Noise, Leakage,
Temperature*
X
M
Y
COMPLETE TUNE-UP*
TO BE COMPLETED BY A
CARRIER DEALER
Carrier 17
Section 5 — Troubleshooting
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
5.1 TROUBLESHOOTING GUIDE
PROBLEM
The engine will not crank.
CAUSE
1. Fuse blown.
CORRECTION
1. Replace 15A fuse in generator
control panel.
2. Loose, corroded or defective
battery cables.
2. Tighten, clean or replace
as necessary.
3. Defective starter contactor. (7 kW)
4. Defective starter motor.
5. Dead Battery.
3. *
4. *
5. Charge or replace battery.
The engine cranks but
will not start.
1. Out of fuel.
1. Replenish fuel.
2. *
3. *
2. Defective fuel solenoid (FS).
3. Open #14 wire from
engine control board.
4. Defective spark plug(s).
5. Valve lash out of adjustment.
4. Clean, re-gap or replace plug(s).
5. *
The engine starts hard
and runs rough.
1. Air cleaner plugged
or damaged.
1. Check, replace air cleaner.
2. Defective spark plug(s).
3. Fuel Regulator not set.
4. Fuel Pressure incorrect.
2. Clean, re-gap or replace plug(s).
3. Set Fuel Regulator.
4. Confirm fuel pressure to regulator
is 11-14” water column (0.4-0.5 psi)
for LP, and 5-7” water colum (0.18-
0.25 psi) for natural gas.
The Auto/Off/Manual switch
is set to OFF, but the engine
continues to run.
1. Defective switch.
2. Auto/Off/Manual switch
wired incorrectly.
1. *
2. *
3. Defective control board.
3. *
There is no AC output from
the generator.
1. Main line circuit breaker open.
2. Generator internal failure.
1. Reset circuit breaker
to ON (or closed).
2. *
There is no transfer to
standby after utility
source failure.
1. Defective transfer switch coil.
2. Defective transfer relay.
3. Transfer relay circuit open.
4. Defective control logic board.
1. *
2. *
3. *
4. *
Unit consumes large
amounts of oil.
Break-in procedure
not followed (see Section 2.1).
*
*Contact the nearest Carrier Dealer for assistance.
18 Carrier
Section 6 — Warranty
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
CARRIER "TWO YEAR" LIMITED WARRANTY FOR
"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"
For a period of two years from the date of original sale, warrants that its generator will be free from defects in material and
workmanship for the items and period set forth below. Carrier will, at its option, repair or replace any part which, upon examination,
inspection and testing by a Carrier Dealer, is found to be defective. All transportation costs under the warranty, including return to the
factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Carrier prepackaged emergency automatic
standby generators sold and rated for use in "Standby" applications.
WARRANTY SCHEDULE
YEARS ONE AND TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed.
ENGINE - All Components
ALTERNATOR - All Components
TRANSFER SYSTEM - All Components
Steel enclosures are warranted against rusting for the first year of ownership only. Damage caused after receipt of generator is the
responsibility of the owner and is not covered by this warranty. Nicks, scrapes, dents or scratches to the painted enclosure should be
repaired promptly by the owner.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
• Carrier generators that utilize non-Carrier replacement parts.
• Carrier generators utilizing non-Carrier automatic transfer switches.
• Any Carrier generators used as rental or trailer mounted applications.
• Units used for prime power in place of existing utility power where utility power is present or in place of utility power
where utility power service does not normally exist.
• Costs of normal maintenance, adjustments, installation and start-up.
• Steel enclosures that are rusting due to the improper installation, location in a harsh or saltwater environment or scratched where
integrity of paint applied is compromised.
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.
• Failures due, but not limited to, accident, misuse, abuse, negligence or improper installation. As with all mechanical devices, the
Carrier engines need periodic part(s) service and replacement to perform well.
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
• Damage related to rodent and/or insect infestation.
• Products that are modified or altered in a manner not authorized by Carrier in writing.
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or
replacement of the defective part(s).
• Failure due to misapplication.
• Telephone, cellular phone, facsimile, internet access or other communication expenses.
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty
period.
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.
• Rental equipment used while warranty repairs are being performed.
• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)
• Overnight freight costs for replacement part(s).
• Overtime labor.
• Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY,
CARRIER MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
CARRIER 'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL CARRIER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF CARRIER 'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
Revision (1.20.05)
Carrier 19
Section 6 – Warranty
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission
Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be designed,
built and equipped to meet the state’s stringent anti-smog standards. Carrier will warrant the emission control system on your engine
for the periods of time listed below provided there has been no abuse, neglect, unapproved modification or improper maintenance of
your engine.
Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Generac will repair your
engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted. If, during such
warranty period, any emission-related component or system on your engine is found to be defective in materials or workmanship,
repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.
PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:
As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory supplied
Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your engine.
However, Carrier cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled
maintenance.
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or
responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect , improper maintenance or unapproved
modifications, or the use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.
You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs. The
warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility. To
locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:
1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty (ECS
Warranty), which is provided to you by Generac pursuant to California law. See also the “Generac Limited Warranties for Generac,”
which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission
control system of your new engine. If there is any conflict in terms between the ECS Warranty and the Carrier Warranty, the ECS
Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period. Both the ECS
Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service,
evidence must be presented showing the date of the sale to the original purchaser/owner.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at one of the
following addresses:
For Air-cooled Product ...
For Liquid-cooled Product ...
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
211 MURPHY DRIVE
WHITEWATER, WI 53190
EAGLE, WI 53119
Part 1
20 Carrier
Section 6 – Warranty
Carrier Air-cooled 7 kW, 12 kW and 15 kW Generators
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines:
(a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the date
the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24
consecutive months thereafter.
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or
equipment and to each subsequent purchaser/owner that each of its engines is ...
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority, and
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a warranted
emissions-related part to fail to be identical in all material respects to the part as described in the engine manufacturer’s
application for certification.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s Manual
shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or
replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be
warranted for the remainder of the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual shall be
warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary”
shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for
the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s Manual shall
be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first
scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such
emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty
Period prior to the first scheduled replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the
owner at a Generac Authorized Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible for
diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a
failure under warranty of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet
the expected demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS Warranty
maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac ECS Warranty
obligations.
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac engine.
Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be
held liable hereunder for failures of any warranted parts of a Carrier engine caused by the use of such an unapproved, add-on,
modified, counterfeit and/or “grey market” part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1) Fuel Metering System:
3) Ignition System including:
a) Spark plug
b) Ignition module
1.2) LPG/Natural Gas carburetion assembly and its internal
components.
a) Fuel controller (if so equipped)
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
b) Mixer and its gaskets (if so equipped)
c) Carburetor and its gaskets (if so equipped)
d) Primary gas regulator (if so equipped)
e) LP liquid vaporizer (if so equipped)
5) Crankcase Breather Assembly including:
a) Breather connection tube
2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner
*Generac engine types covered by this warranty statement include the following:
1) Prepackaged Standby Generator
2) Auxiliary Power Unit (APU) Generator
3) Standby Generator
Part 2
Carrier 21
PART NO. 0F6902
CATALOG NO. OMASPAS07-2
REV. * (6/01/05)
PRINTED IN U.S.A.
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