Generator Quick Startup Guide

SAFETY

NOTE: The information in this document is subject to change as generator feature requirements are revised and continue to be developed. In addition, some of the features described in this document may not apply to every generator model.

The information in this document is the property of Aurora Generators Inc. and its subsidiaries. Without written permission, any copying, transmission to others, and any use except that for which it is loaned is prohibited.

Before starting the generator, it is crucial to read and follow the manufacturer’s manual carefully. This quick guide is not a substitute for any other manual. You can find the manufacturers’ manuals in our Download section.

A generator is a significant piece of equipment, and the potential for physical injuries does exist. It’s important to recognize these potential dangers and take the necessary steps to prevent them.

It is important to note that certain parts of the generator engine, particularly the muffler, can become extremely hot. It is advised not to touch the muffler, even after the engine and generator have been turned off, as severe burns can occur. The engine can also become very hot with prolonged use, so it is essential to exercise caution before checking, moving or performing any maintenance on it.

Safe generator operation is crucial to avoid severe and fatal accidents. To ensure safe and proper use, it is essential to take extra time and follow the guidelines in the owner’s manual. Keeping the safety of yourself and others in mind, always observe these tips and guidelines.

Failure to follow proper procedures and instructions may result in severe injury or death. Generators are powerful equipment and can harm a negligent operator, innocent bystander, and property if misused. The good news is most accidents can be avoided by simply following basic safety rules or precautions.

Generators deserve as much safety consideration as any tool or machine on a job site or at home.

A generator can get you through a power outage, but it also poses safety hazards, including carbon monoxide poisoning, electric shock or electrocution and the risk of fire.

Carbon monoxide (CO) hazards

It is essential to never use a generator in an enclosed or partially enclosed space. Generators have the potential to produce high levels of carbon monoxide (CO), which is a colourless and odourless gas, very quickly. Even if you cannot smell exhaust fumes, you may still be exposed to CO. Therefore, it is essential to remember that the CO from generators can result in sickness, dizziness, or weakness and even cause complete incapacitation and death.

It is imperative to never use a generator indoors, including in homes, garages, basements, crawl spaces, and other enclosed or partially enclosed areas, even with ventilation. Simply opening doors and windows or using fans will not prevent carbon monoxide build-up in the home.

When installing generators outside, keeping a safe distance from doors, windows, and vents that could allow carbon monoxide to enter the building is essential.

Electrical Hazards

It is important to keep the electrical components of the generator dry. Anti-condensation heaters should be used to prevent moisture and condensation. Electrical components should not be exposed to wet conditions.

It is important to ensure that the connections to the generator are secure, free from any cuts or tears, and are properly grounded. If you are using extension cords, make sure to use only heavy-duty, outdoor-rated extension cords that are appropriately rated for the load and power they will be expected to carry.

Never try to power your home’s wiring by plugging the generator into a wall outlet. This practice is known as “backfeeding” and is extremely dangerous. It can put utility workers and neighbours who are served by the same utility transformer at risk of electrocution. Furthermore, backfeeding bypasses some of your home’s built-in circuit protection devices, making it an even more hazardous practice. It is recommended that you use a transfer switch installed by a licensed electrician to connect the generator to your home’s wiring safely.

Use an appropriate power transfer switch installed by a professional for best results.

Properly grounding the generator during setup is crucial, as generators can malfunction and accidents can happen even with safe practices. This safety practice is often overlooked, but only takes a few minutes.

It’s essential to take precautions against backfeeding when operating a generator. Backfeeding occurs when electrical power flows in the opposite direction as it usually does. This can pose a danger to utility workers and residents serviced by the same transformer. Because of this danger, it’s illegal to plug a generator into any public service line, including standard outlets in a home or garage. Even if a utility worker is repairing a power line miles away from the generator, they can still be electrocuted due to backfeeding if the generator is plugged into that line.

While many people may not be aware of backfeeding, the danger of electricity and water is more commonly understood. Even a tiny amount of moisture can be dangerous when dealing with anything electric. To operate a generator safely, ensure it is completely dry before use. If it’s raining or snowing, shelter the generator with a protective cover or tarp. Anyone touching the generator should ensure their hands are dry before contacting the unit.

It’s important to avoid direct contact between the generator and water, even when it’s shut off. Don’t dump water on a generator or use a pressure washer to clean it. If the engine and generator are filthy, use a non-petroleum-based degreaser and wipe it clean with a cloth or soft brush. A damp cloth may be used for minor spot cleanings, but dry the unit entirely before operating it again.

Most electrical problems can cause shock hazards, but severe ones can create sparks and start fires. To prevent generator-related fire hazards, follow these basic rules and use common sense.

Using Power Cords

To prevent damage to equipment and a fire in the power cord, do not overload the generator. Every unit has a wattage output, which must not be exceeded by the total wattage draw of the powered equipment. Furthermore, hardwire all equipment directly into the generator if possible. However, in the event extension cords are required, be sure they are heavy-duty, outdoor-use rated and properly sized for the particular unit.

Fire Hazards

Please make sure to turn off the generator and let it cool down before refuelling it. Fuel spilled on hot engine parts might catch fire. To avoid any risk, never store fuel for your generator in your home. Always store flammable liquids in well-labelled fuel containers outside of living areas.

Moving Parts

When the generator is running, the engine cooling fan is spinning. Keep clear at all times. Make sure all loose articles, clothing or hair for example, are all safely kept away as to not contact or be sucked into the fan and any other moving parts.

Automatic Starting

If the generator is equipped, it may start automatically when the power is disconnected. Additionally, it can start via remote triggers, timer or regular exercising to recharge the battery. Before performing any service, disconnect all power sources.

Other Hazards

Aurora cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the generator are not all-inclusive. It would be best to ensure that all procedures and operating techniques are safe for you and others. You must make sure that the product will not be damaged and that the product will not be made unsafe by any procedures or techniques used in its installation, operation or maintenance.

Recognize potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to install, operate or perform any maintenance properly.

In many jurisdictions, you are required by law to have your installation approved and certified safe before it can be used. It is your responsibility to make sure you are not violating any rules or regulations in your area.

The information in this publication was based on current information at the time of publication. Check for the most current information before you start any job.

Shipping & Delivery

Great care is taken to make sure your generator arrives safely and in an environmentally sound shipping process. It is normal to find that oil and other fluids have been drained from your engine after it has been tested. This is to prevent leakage during shipment. A special absorbent material may be added to capture any spills during transportation and as a cushioned barrier. If used, it should be collected and disposed of in a safe manner.

Perform a brief visual check to identify any potential safety hazards. Look out for any loose, cut, or frayed wiring, as well as significant damage that may have occurred during the generator’s transportation. Prior to operating the generator, it is especially crucial to conduct a pre-operation inspection on job sites where the unit is frequently moved.

INSTALLATION

Installation should only be attempted by qualified electricians or contractors.
Aurora Generators are not intended for use in critical life support applications.

This information and instructions provided here are intended for general reference only and may not apply to all installation types. It is important to note that this guide should be used in conjunction with the detailed manuals provided by each significant component manufacturer. You can download those manuals as required from our website’s Downloads page.

It is important to comply with all necessary safety, electrical, and building codes as mandated by local, state, or national authorities. Please make sure to verify with the local Authority Having Jurisdiction to ensure that you are adhering to all the relevant codes and standards. The installation, inspection, and testing of the system should only be handled by experienced, qualified electricians or installation contractors who possess knowledge of the equipment and are familiar with all installation codes and requirements.

If you plan to use a generator for powering loads that are typically powered by a utility, you must install a generator transfer switch to isolate the generator power from the utility power. Failure to isolate an electrical system by such means may damage the generator. It may also lead to injury or death of utility power workers due to the backflow of electrical energy.

Concrete Pad

Installing a generator on a concrete pad is recommended for several reasons:

Stability and Support: Concrete pads provide a stable and level surface for the generator, which helps in proper alignment. It also reduces the risk of shifting or sinking, which could affect the generator’s efficiency and functioning.
Protection from Moisture: Concrete pads elevate the generator slightly off the ground, reducing the risk of water damage if placed directly on the soil. Moisture can lead to rust and corrosion, potentially impacting the generator’s lifespan and performance.
Ease of Maintenance: A concrete pad provides a clean and accessible surface for maintenance tasks, making it easier for technicians to service the generator without having to deal with mud or uneven ground.
Compliance with Regulations: In some regions or for specific types of installations, local building codes or regulations might require a concrete pad for safety and structural reasons.
Reduced noise and vibrations: The engine and generator heads rest on vibration isolators mounted to the frame. A stable surface lets the vibration isolators work correctly instead of transferring vibrations to the ground; they can absorb them, reducing noise levels.

Although a concrete pad isn’t always necessary, it’s highly recommended for ensuring the generator’s longevity, stability, and proper functioning.

Transfer Switch Installation

How it works

Automatic transfer switches (ATS) are commonly used in standby generator setups. They are designed to detect any power outage or disturbance in the primary power source. An ATS has a built-in mechanism that monitors the presence or absence of electricity from the primary source. When the primary power fails or drops below a certain threshold, the transfer switch sends a signal to the generator to start. Once the generator is stable, the transfer switch switches to the backup power source.

Exercising

Modern automatic transfer switches come with a pre-set schedule for exercising the generator. However, setting up a schedule for exercising the generator controller alone is not recommended. This is because the transfer switch will not connect your home to the generator running if there is no power failure. If you want to run the generator while having power, it is best to do so through the transfer switch. It can switch power over to the generator without any noticeable delay, allowing your generator to work during the test rather than just running without doing any work. Running generators under 30% load can result in long-term damage from deposits and varnishing of cylinder walls. It’s better to exercise the generator and have it work during that period.

ATS Wiring

Only two wires are required to signal the generator to start or stop. The transfer switches are responsible for opening or closing the connection between these two wires from the generator. The generator controller is configured to monitor the status of one of its inputs to determine whether it is grounded or ungrounded. The automatic transfer switch’s role is to establish or break that connection. Based on this open or closed connection, the generator controller knows whether to start or stop. These two lines are one ground and one sensor input, both DC and low voltage. They are also known as control wires.

Control wires must not be run in the same conduit as AC power lines from or to your generator.

Here are a few reasons why it’s often advised to keep AC and DC wires separate:

Interference: AC and DC currents can cause interference with each other when they run in the same conduit. This interference might lead to signal distortion or noise in the control circuits, affecting the proper functioning of the control systems.
Safety Concerns: Mixing AC and DC in the same conduit can increase safety risks. There’s a possibility of induction or induction heating in the wires due to the varying currents and voltages. This can create hazards like overheating, which might lead to electrical failures, insulation damage, or even fires.
Code Compliance: Electrical codes and regulations often specify the segregation of AC and DC wires for safety and performance reasons. Following these codes is crucial for ensuring a safe and compliant electrical installation.

Maintaining safety and preventing interference is advisable by keeping AC and DC wiring separate during installation. Different conduits or paths should be used for each type of wiring. In cases where they must cross paths or be nearby, appropriate shielding, insulation, or separation methods prescribed by electrical codes should be used to mitigate potential problems. It is essential to consult with a qualified electrician or follow local electrical codes and regulations when planning the installation of AC and DC wiring.

Electrical Hookup

Neutral Bonding

In certain scenarios, it is necessary to perform neutral bonding on a generator to ensure that the electrical system functions safely and correctly. The requirement for neutral bonding depends on the setup and electrical configuration used. Below are some examples of situations where neutral bonding on a generator may be needed:

Stand-Alone Generator: If the generator operates independently and is not connected to a larger electrical grid or utility system, it often requires neutral bonding. In this setup, the generator provides both the power and the grounding for the electrical system, and neutral bonding is necessary to ensure proper grounding and safety.
Floating Neutral Generators: Some generators have a “floating” neutral, meaning the neutral conductor is not connected to the generator’s frame or ground. In cases where this type of generator is used in a system that requires a bonded neutral (typically in certain residential or small-scale applications), an additional bonding jumper may need to be installed to connect the neutral to the generator frame or grounding point.
Specific Code Requirements: Local electrical codes and regulations might stipulate when neutral bonding is required based on the type of generator installation, the intended use, and the electrical system’s configuration. Compliance with these codes is essential for safety and legal reasons.

It is important to note that in certain situations, such as when connecting a generator to a larger electrical system or grid, neutral bonding may not be necessary or may even be prohibited. Under such circumstances, the generator’s neutral may need to be isolated or left ungrounded, and any required grounding and bonding should be handled at the main service entrance or distribution panel.

Ensuring the correct configuration for neutral bonding on a generator should be done in compliance with local electrical codes and guidelines. Consulting with a qualified electrician or an electrical engineer experienced in generator installations is highly recommended to determine the specific requirements for your setup.

Most Aurora Generators are designed for emergency standby and do NOT have the neutral bonded to the ground. Please check the product label and note the default electrical configuration.

Main Circuit Breaker

Aurora Generators include a main circuit breaker inside the generator control panel. This is sized to help protect the generator from overload and short circuits. When connecting your load to the generator, the connections are made to the circuit breaker load side, the neutral bar and ground to the chassis, panel or foot of the generator head are all acceptable bonding locations.

Additional Manuals

Your generator comes with a USB memory stick containing manuals for many system components and other relevant documents in PDF format. The memory stick is attached to the keys. Always ensure you have the latest document version, or check our downloads section for any updated documents.

Engine Storage

If you leave your engine unused for several weeks, the lubricating oil will drain from the cylinder walls and the piston rings. This can cause rust to form on the cylinder walls, which will increase engine wear and reduce the engine’s lifespan. To prevent corrosion, we suggest exercising your generator on a regular basis.

Starter Battery

Most generators use a 12-volt starter battery. The engine’s alternator recharges the battery after the engine is running. However, running the motor or “exercising” the generator for only 15 minutes prevents the battery from recovering fully. We recommend using an optional battery maintainer from Aurora Generators to ensure your battery remains in optimal condition. This maintainer is designed to keep your battery from self-discharging over time, prevent it from freezing, and provide enough energy to start your engine under challenging conditions.

Your generator battery was fully charged before shipping but will self-discharge over time. The generator’s electronics will also drain the battery when it is in “standby mode” waiting to start unless you turn the power key “off” or use a battery maintainer.

It is crucial to have a reliable and powerful battery to ensure that the engine’s cold start glow plugs function correctly and have enough energy to crank the engine after that. In cold weather, it can be challenging to start an engine if the cranking is slow. Therefore, it is essential to have a good, strong battery to avoid any inconvenience. Do NOT jump start a dead battery while it is connected to the generator. This can overload the engine alternator or dangerous over voltages can cause other damage.

When connecting the battery to the generator, observe the proper polarity of the cables. Red is Battery + and Black is Battery Ground (-)

If you can turn any of the battery terminals by hand, it’s too loose and makes a poor connection that will affect starting. If you connect the red (+) terminal first and slip with a tool, the battery is less likely to shorten when you leave the ground (-) to the end. Never short the two battery terminals together!

Engine Oil

It is important to note that all fluids have been drained from the generator after factory testing before packaging and shipping, as per shipping regulations. Therefore, you must purchase engine oil and coolant locally to add to the generator. Please remember that capacities may vary from published volumes, as some residual fluids remain in the engine.

Typical engine oil used on diesel engines is SAE 15W40, but make sure it clearly says it is for “diesel engines.” Using engine oil designed for gas engines will damage your engine. SAE 15W40 covers a wide range of operating conditions, but there are better blends designed for different temperatures. Be sure to review the Perkins Engine Operation and Maintenance Manual “Fluid Recommendations” for complete details.

Oil Additives

Perkins does not recommend the use of aftermarket additives in oil. Using aftermarket additives is unnecessary to achieve the engine’s maximum service life or rated performance. Fully formulated, finished oils consist of base oils and commercial additive packages. These additive packages are blended into the base oils at precise percentages to help provide finished oils with performance characteristics that meet industry standards.

Coolant

The cooling system operates under pressure controlled by the radiator pressure cap. Removing the cap while the system is hot may allow the hot coolant and steam to escape, causing severe burns.

Before you remove the radiator cap, allow the system to cool. Use a thick cloth and slowly turn the radiator cap to the first stop to allow pressure to escape before removing the cap.

Avoid contact with coolant.

It is important to avoid using water alone as a coolant because it is corrosive and cannot protect against boiling or freezing. Instead, you should use glycol-based coolants that are explicitly designed for diesel engines. The ideal coolant is usually labelled ELC (Extended Life Coolant) and contains SCA (Supplement Coolant Additive). Commercial coolant/antifreeze that only meets the ASTM D3306 specification should not be used because it is intended for light automotive applications.

See Perkins Operation and Maintenance Manual “Fluids Recommendations” for complete details.

Fuel

Your engine can run on both on- and off-road diesel fuel, as long as it is Ultra Low Sulfur Diesel (ULSD). Since 2014, both on- and off-road diesel fuels have been ULSD in Canada and the USA. Off-road diesel fuel, used in farming equipment, backhoes, excavators, forklifts, and other heavy machinery, is dyed red and is also ULSD. The only difference is that off-road diesel fuel is not taxed in the same way, so it is cheaper. The red dye is used by authorities to detect if it is being used in a vehicle when it is not taxed.

Diesel fuel sold at stations in colder regions of the USA typically contains additives designed to prevent the fuel from gelling or thickening in low temperatures. These additives prevent clogs in fuel filters and make engines easier to start or run. However, the extent of treatment can vary based on region and anticipated weather conditions. In extremely cold climates, you may opt for specially treated winter diesel or use additives to further protect your engine in harsh conditions.

States in warmer climates, such as those in the southern United States (like Florida, Texas, Arizona, and parts of California), may not consistently winterize their diesel fuel since they don’t typically experience prolonged or extreme cold weather. However, some stations in these regions may still offer treated diesel during colder months due to transient weather conditions or to accommodate travellers heading to colder areas. It’s crucial to check fuel stations for specific winterized diesel options if you anticipate operation in colder climates.

To help prevent fuel gelling, improve cold flow, prevent wax formation, and enhance lubrication in cold weather, consider using diesel fuel additives.