Carrier HOME STANDBY ASPAS1CCA007 User Manual

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
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F
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SET  
EXERCISE  
TIME  
N
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4
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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
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EXERCISE  
TIME  
N
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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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