Generator No Longer Powers Cool Cat w/ Soft Start

manyman297

I’ve had a SoftStart installed on our 2021 400 for three years and it has worked with no issues at all sorts of elevations. 

We just went on a weekend trip and I wanted to run the AC. I have a Westinghouse iGen2500 generator. My surge protector (hard wired) would trip and report that the voltage had dropped below 109 volts and wouldn’t allow the AC to start up.

I considered elevation (which was about 8k feet) to be an issue even though I’ve used it at higher elevation without issue. 

So back home where I know the generator will run the AC without the soft start I tried to run it and it also would trip the surge protector and cut power. 

So I’m wondering if the generator is the problem or the soft start? I can run the AC fine on a 20a circuit in my house. This is the first generator I’ve owned but I assume lack of maintenance could contribute to loss of power? It only has 50 hours on it and I’ve changed the oil annually. I have never cleaned the carb or anything like that. 

GatorEgg

Capacitors go bad.  Think your home airconditioning compressors.  Soft Start is a big capacitor.  YouTube videos on how to check a capacitor.

DaveAnna

You’ll also need a ground plug jumper for the genset if you have a surge protector. Most genset are open ground

manyman297

If the capacitor in the SoftStart was bad I don't think anything would work at all. The AC works on shore power (20a) just fine. SoftStart's green light glows indicating proper operation. 

I do have a ground plug jumper as the Watchdog won't even work without one. 

I keep thinking it has to be the generator that's the issue. 

DaveAnna

Load the genset up with hair dryer. They pull 1500 watts I think 

Mickerly

I think you are correct. If the system works plugged in, the only variable is the generator. A 2500watt generator should work with a soft start, but barely. It will loose power with altitude. New, it probably just worked. Maintenance may restore power and have it working well enough again.

Minimum sized equipment saves expense, weight, and space. The down side of minimum equipment is the need for it to work perfect all the time. I may suggest 3300 or 3500watt generator to have some head space when the world is not perfect. The advertised ratings are often surg rather than continuous power. 

Storage and motors don't like each other. If the generator hasn't been used for 2 or 3 months, it needed to have all the fuel drained before storage or cleaned out after. I normally do the after; although, following the manufacturer's procedures for storage is the better practice.

Loading the generator up with a space heater or hair dryer is a good idea too. But, you have already confirmed all the other parts are working. It's internal inverter may hide the brown out condition. A low voltage warning, working when on external power, plus a winter without maintenance makes me think the generator is at fault.

manyman297

Took the thing apart yesterday. Cleaned the carb, jet passages, etc. Still surging under load (I used a heat gun). I'm tempted to put a new carb on it. I admittedly am not the best at keeping it empty but I do use Stabil. In hindsight I thought a smaller genset matched with the softstart was perfect but a larger 3000 or 3500 watt genset would've been more reliable and quieter under load. They're just comparatively massive. 

Mickerly

Two things to think about. The 10% alcohol in the fuel will eat fuel lines and carburetor gaskets. Two options; expensive real gasoline or carb rebuild and change out the lines every other year for $5. I do the second on my lawn equipment.

Replace fuel lines, filter and the carburetor gasket(s). Clean or replace the spark plug. Most parts houses have a "Tune Up Kit" that has most of the parts for less cost than separate purchases.

Your Westinghouse 2550 is "2550 watts peak." It is only 1800 watts continuous at sea level, 1900w for the duel fuel model, when new (see owners manual). As you go higher in altitude, you loose about 3% per 1000ft. To get the power from a normal home extension cord at the altitudes you are camping, you need a bigger unit or spend a lot of time tinkering with the generator.

manyman297

Thanks @Mickerly. Still working on getting it going. I’ve cleaned the carb, new filter and fresh fuel. Nothing was really dirty. Cleaned out the tiny idle jet, all passages on the carb. 

Idle is fine. It’s once there’s a load applied that it starts to surge and struggle. 

This generator has worked well at all sorts of elevations (with the softstart). Even as high as 10k feet. 

At this point it is beyond my sklllset and I may need to have a real mechanic check it out. 

BridgerSunset

Once I had an issue with using a cheap pigtail for the generator to adapt to a 30 Amp cord.  Acted like you describe.  Have you tried starting up the genset without the surge device attached?

manyman297

@BridgerSunset Yeah. I’ve run it without anything and then applied a load from a heat gun to test it. That’s when it bogs down.

DaveAnna

turning eco mode off help any?

Mickerly

Your Westinghouse may have a "30amp" output. Plug directly into that to your trailer. The Soft start will make your AC use less power than the hair dryer. Test the generator on the trailer before you spend money for a repair.

Although the generator has a "30amp" plug, it only puts out 1800watts (about 16amp at 110v) minus the altitude loss. Your generator is just equal to an extension cord when perfect at sea level.

For keeping the battery charged, your rig is great. Camping in the heat of summer will get a little sketchy some days. I do understand the significant size and weight increase when you step up to the next level. We all make these decisions. My choice was "boondocking = no AC". I've gotten creative with a canopy for the trailer...

manyman297

@DaveAnna Nope.
@Mickerly No 30amp outlet but this is 100% a generator issue. I ordered a new carb and will see if that fixes it. I wasn’t the best about maintaining fresh fuel in it but the carb didn’t look particularly dirty.

DaveAnna

We use a 3300 watt generac because of altitude. No issues. Actually mounted on front of tab. Fits perfect and bolted from underneath. Removed spare tire and just keep it in truck bed

manyman297

Quick update. Replaced the carburetor and all is fine. Somewhere in that old carb is a clog but I can’t find it. Paid $37 for a new carb but I guess it’s cheaper than having a mechanic look at it…and now I know how to disassemble and work on it now. 

BridgerSunset

Well done.  Thanks for updating us.

Maxcamp

Glad you got it worked out.  Seems like it's not possible to own gas-powered equipment without replacing carburators every year or few.  In New England we cannot buy ethanol-free gas, I see it on trips south and west regularly.  Have three years on original carb in our 1800w genset that can run the Air8, just waiting for an issue.

gulfarea

I have a Honda 2200 and run it ONLY on propane with the propane coversion, so far no problems. Art

manyman297

So here’s the kicker…we have ethanol free gas just right outside of my neighborhood. But do I choose to use it…no. Why? I don’t have a good reason. I just tend to fill my gas can at wherever is convenient…and I guess a gas station right outside of my neighborhood isn’t convenient enough. From now on I’ll only get ethanol free gas.

Mickerly

If you put ethanol free in your truck, on the second tank you'll notice about 10% better gas mileage.

I'm glad its working.

manyman297

@Mickerly I really want to try that and see what happens. I do run a bottle of Techron through my truck every oil change but I’ll give the ethanol free a shot.

Mickerly

It takes at least one tank for the engine computer to figure out the difference.