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Generator Operation
05/20/12
Here are some simple rules to help you keep your portable generator running
smoothly and for a long time.
Most portable generator engines are engineered, designed and certified to run
on unleaded fuel. Use unleaded gasoline with a pump octane rating of 86 or higher.
Unleaded fuel will reduce deposit build-up on valves, spark arrestor, muffler
and spark plug.
Never use stale or contaminated gasoline or oil/gasoline mixture. Avoid getting
dirt or water in the fuel tank.
Gasoline blended with alcohol or ether is referred to as "oxygenated"
fuel. Before using oxygenated fuel, try to confirm the fuel’s contents
(refer to the owner’s manual). Some states (provinces of Canada) require
the information to be posted on the pump. If you notice any undesirable operating
symptoms, try another service station or switch to another brand of gasoline.
Refuel when the engine is off. Gasoline is extremely flammable and is explosive
under certain conditions. Refuel in a well-ventilated area with the engine stopped.
Do not over fill. Make sure that any spilled fuel has been wiped off before
starting the generator.
The fuel tank cap vents to the atmosphere. Don’t store the generator
below the deck of a boat. Gasoline fumes can collect and ignite. Store the generator
in a well-ventilated area.
Do not smoke or allow sparks in the area when refueling.
Never refuel while the engine/generator is running. Refuel the generator with
the engine stopped and the engine cool.
Wipe up spilled fuel before starting the generator. The engine produces enough
heat at the exhaust system, and the generator produces sufficient static electricity,
to ignite the fuel vapors.
PRE-OPERATION CHECKS
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Check Oil And Air Cleaner Before Use
Check the air cleaner before use.
Check the engine oil before use.
VOLTAGE SELECTOR SWITCH (if equipped)
The voltage selector switches the main power carrying windings of the generator
to produce "120V ONLY" or "120/240V". If a 240V appliance
is connected to the 4-prong receptacle, the switch must be in the "120/240V"
position. If a 120V appliance ONLY is being connected to any of the 120V 3-prong
receptacles, select the "120V ONLY" position. The benefit of this
is to get maximum power from the 120V 30A locking receptacle.
Check Switch Position Before You Start Up
If your generator has this switch then read carefully.
Honda and some other generators, with 120/240V capabilities, have two separate
main windings. Each winding is capable of the same output. The voltage selector
switch changes the two main windings from a PARALLEL connection for ("120V
ONLY") to a SERIES connection for the "120/240V" position.
In the "120V ONLY" position, the power of the two main windings are
connected in parallel (beyond the circuit breakers) and full power can be obtained
from the 30A 120V receptacle. When in the "120V ONLY" position, the
240V receptacle cannot be used.
With the voltage selector in the "120/240V" position, the power of
each main winding is evenly distributed to all the outlets. It is important
that the power connected to the different receptacles be applied equally to
avoid overloading any one main winding.
Voltage Selector Switch
Allows simultaneous use of 120V and 120/240V receptacles.
"120 ONLY" position: maximum power from locking plug.
"120/240V ONLY" position: simultaneous use.
BALANCE THE LOAD
The generator has two separate main power producing circuits. These two circuits
supply equal power to the receptacles shown when the voltage selector switch
is in the "120/240V" position. When two or more receptacles are used;
prevent overloading by dividing the loads between the two power circuits.
Example: (ES7500 rated current draw is 50A)
Receptacle 2 has a 15A load connected to it. Receptacle 3 has a 15A load connected
to it. Both receptacles are powered by the main power circuit 1. The equation
tells us that the total power draw on Circuit 1 is 30A (greater than 25A). This
is a substantial overload to this circuit. To eliminate the excess power draw
on circuit 1, the load from receptacle "3" should be switched to receptacle
"1". Now circuit 1 is powering a 15A load (less than 25A) and circuit
2 is powering a 15A load (less than 25A).
When the voltage selector is in the "120V ONLY" position, do not
exceed the rated capacity of any one receptacle. For all receptacles used, do
not exceed the rated load capacity of the generator.
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Balance The Load
"120/240V" position.
Connect loads to balance the two main windings.
AUTO-THROTTLE or IDLE CONTROL
The auto-throttle system automatically reduces engine speed when all loads
are turned off or disconnected. When appliances are turned on or reconnected,
the engine returns to the rated speed.
The auto-throttle system will not respond to electrical loads of less than
1 ampere.
The system is not effective for use with appliances that require only momentary
power. Leave the auto-throttle OFF if an appliance cycles on and off frequently.
To avoid extended warm-up periods, keep the switch OFF until the engine reaches
operating temperature.
Appliances with large start-up power demands may cause the engine to be overloaded
and keep it from reaching normal operating RPM. Turn the auto-throttle to the
OFF position and connect the appliance to the generator. If the engine is still
overloaded and cannot reach normal operating rpm, check that the appliance does
not exceed the rated load capacity of the generator.
If the generator is equipped with a pilot light or volt meter and the auto-throttle
is ON but no load is connected:
The pilot light will be dimmer.
The voltmeter will display less than the normal output voltage (120V or 240V).
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Auto-Throttle OR Idle Control
Lower fuel consumption
Reduced noise
GFCI APPLICATIONS
In certain applications, Honda industrial generators fall under OSHA regulations.
One such regulation is that 120V, 15 and 20 ampere receptacles be protected
by Ground Fault Circuit Interrupters (GFCI) automatically open the power circuit
in the event there is a current leakage in the tool or appliance plugged into
the GFCI receptacle. The GFCI will open the circuit protecting the operator
from ground faults. Examples of ground fault current is the current which would
flow through a person who is using an appliance with faulty insulation and,
at the same time, is in contact with an electrical ground such as a plumbing
fixture, wet floor, or earth.
The ground fault circuit interrupter receptacle will not protect against short
circuits or overloads. The circuit breaker or circuit protector in the control
panel, which supplies power to the circuit, provides that protection.
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GFCI
GFCI protection is required for certain applications.
Must protect all 15 and 20 ampere 120V receptacles.
GFCI OPERATION
Electric current (amperage) flow is the same in the wires going to and coming
from the load. When a ground fault occurs, electric current now has another
path and will take this path instead of returning to the source.
Current traveling in wires create magnetic fields around those wires. If the
current is the same coming and going, the magnetic fields cancel one another.
When there is a ground fault, the returning current has two paths. The returning
current through the GFCI is less than the going, there is now a magnetic field
difference through the transformer and the control unit will automatically open
the circuit.
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GFCI Operation
Detects ground faults in tools or appliances.
GFCI opens the power circuit.
TEST button creates ground fault situation for testing GFCI receptacle.
GFCI TESTING
Under normal operations, the GFCI should be tested monthly. There is a test
card located on the control panel to record the date of each test. If the generator
is stored outdoors, unprotected from the weather, test the GFCI receptacle before
each use.
Testing - You must test it to make sure it works!
Press the TEST button. The RESET button should extend with a click.
Press the RESET button. The RESET button should be flush with the TEST button.
If either of these tests fail on a Honda generator, contact an authorized Honda
generator servicing dealer.
.
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GFCI Testing
Test monthly normally.
Test before each use if stored outdoors.
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Honda and Other High Quality Makes
GFCI is standard on some models.
GFCI will protect 120V duplex receptacles.
20, 30 and 50 Amp 120V receptacle
Isolated ground system – no neutral bond with the frame.
NEUTRAL BONDING REQUIREMENTS
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
OSHA job site inspections.
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Neutral Bond
Required on certain job sites.
Neutral conductors bonded to ground.
Standard on some Honda & Pramac ES models.
SYSTEM GROUND
The power tool has a ground wire that connects the tool body to the generator
receptacle.
The generator ground terminal is connected to: the frame of the generator,
the metal non-current carrying parts of the generator, and the ground terminals
of each receptacle.
Before using the ground terminal, consult a qualified electrician, electrical
inspector or local agency having jurisdiction for local codes or ordinances
that apply.
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System Ground
Generator frame acts as system ground.
Local codes or agencies may require further generator grounding.
TURN THE CIRCUIT BREAKER OFF
SAFETY PRECAUTION!
Turn the circuit breaker OFF when starting the generator.
The generator starts producing power immediately after the engine starts. Start
the generator and wait 15 seconds to let it come up to speed and generate the
proper voltage, then turn the loads on. If there is a heavy load connected to
the generator, it may be strong enough to make the engine hard to start.
If the engine does not start, a heavy load may not allow the engine to reach
operating speed. Continuous operation of the generator below normal operating
speed may damage the load or the generator.
The circuit breaker should be switched OFF before stopping the engine. The
generator will produce power until the engine comes to a complete stop. AVR
generators will try to produce steady output as the generator winds down. This
may overload the AVR circuits, which could damage the AVR.
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STOPPING THE GENERATOR
Turn OFF the circuit breaker before starting the engine.
Turn OFF the circuit breaker before stopping the engine.
TURN OFF THE FUEL VALVE (if equipped)
Turn the fuel valve OFF when transporting or storing the generator. When the
generator is being transported, the carburetor inlet needle may unseat allowing
fuel to enter the engine crankcase. Gasoline will dilute the engine oil reducing
the lubrication properties and cause severe engine damage.
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Turn The Fuel Valve OFF
Turn OFF the fuel valve when transporting the generator.
Turn OFF the fuel valve when the generator is not in use.
STORE THE GENERATOR PROPERLY
The majority of the generator problems occur after the generator is removed
from prolonged storage. Gasoline has a very short shelf life. The fuel in the
carburetor bowl is vented to the atmosphere. Evaporation of the fuel occurs
quicker and will leave the heavier additives and water to plug and corrode the
carburetor passages.
If the generator is to be stored for more than 2 months:
Drain the fuel from the carburetor float bowl.
Drain the fuel from the sediment cup.
Add the correct proportion of fuel conditioner to the tank and top it off.
In addition, it is also recommended:
Add a tablespoon of oil through the spark plug hole. Lubricating the valves
and piston rings will help prevent corrosion during extended storage periods.
Change the engine oil. Engine oil oxidizes and breaks down like gasoline. Fresh
engine oil will ensure the oil will provide proper lubrication when the engine
is started after the storage period.
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STORAGE
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