Feature Archives | Feedback

In a column last January, called "Due Diligence in Y2K," I rationalized that there was no hurry to prepare for Y2K, as all preparations, except one, can probably be made during December, 1999. That one exception was standby electric power. Not wanting to face the possibility of a freezing house with bursting water pipes, I intended to obtain some kind of backup generator. That was in January. Time passed and so did my resolve to add a backup electrical system. When we lost power for eight hours in July and then again during Hurricane Floyd in September, I started to rethink the wisdom of backup power. What actually prompted me was the poor state of my village's power distribution system. The wires are all overhead and run through trees. The insulation on many cables is bare with age. It doesn't take much of a storm to produce a power outage on my street.

During "Floyd" there were reports of hundreds of thousands of people out of power for days, other news reports told of people being overcome by improperly exhausted generators. I sent an email to my cousin, Ron, in Virginia, asking how he survived. He replied that he had a 5KW backup generator that he used to power his lights, refrigerator and freezer. He would plug an extension cord into the generator and plug his appliances into the other side. The generator was kept on his front porch and operated on gasoline. A supply of twenty-five gallons of gasoline was kept on hand. The generator has a 5-gallon tank. Ron reported that he had to fill it about every five to ten hours. He also said that he starts the engine at least once a month to check it and maintain it.

I started to put together all this information and concluded that this was not going to be as easy as I thought. My concept of keeping a generator in the basement and simply jumping it to the power mains (after the input breakers are turned off, of course) by making up a double male extension cord and plugging one end into the generator and the other end into the wall, faded. Not to be a quitter, I concluded that the following would be necessary: 1. The generator should be kept outside the house to prevent any exhaust fumes from endangering the family. This also will reduce noise inside the house to a minimum. 2. The fuel available should be capable of at least two days of operation. 3. A minimum power rating of 5KW is necessary, if the furnace, refrigerator, freezer, office computer, and a projection TV (wouldn't want to be without comforts) are to be used. 4. Optional features might include an electric start and automatic transfer when power fails.

Research revealed the following.

Fuel: Generators can be bought to run off four types of fuel; Gasoline, Diesel, Propane and Natural Gas. If you heat with oil, diesel is for you. If you use natural gas a Propane/Natural Gas engine is recommended.

Consumption: Typical consumption in the 5KW generator range is one half to one gallon of gasoline (or diesel) per hour. Propane use is higher at about 1.5 gallons per hour. Natural gas has 10% less output than propane, meaning that a 5KW-rated generator will only produce 4.5KW when run on natural gas.

Finding the Generator:
I checked the web site northern-online (http://www.northern-online.com/) and decided that the generators for sale there were "construction" generators. They were meant to supply power to construction workers where there is none otherwise. They were not designed to operate for days at a time. Some specifications said that they should not be used with a transfer switch. The generators shown also would require a shed to keep them out of the elements. Next I went to http://www.grainger.com. Grainger is a large supplier of electrical equipment. There I saw just what I wanted, a Dayton, 8KW, "Standby Generator". This was perfect, it was a completely enclosed weather proof unit with engine, generator, battery, starter and control circuit contained inside. It had a Propane/Natural Gas engine with an electric starter. The control circuit included a battery charger for the internal battery, a self test that would active the generator for about 15 minutes once a week to maintain reliability, and a transfer switch command line for automatic start up and power transfer. The only drawback was the price, $5,238.00. Not including shipping! This was about twice what I had intended to spend, but it was an elegant design, and I am a fool for elegance. Still due diligence was necessary. A thorough trip through a number of search engines uncovered the web site called 2Kstore, (http://www.2Kstore.com). This web site has all the items a Y2K nut might desire. Food, stoves, lanterns and of course generators. I found the exact same 8KW Dayton generator at this site for only $4,469 and it included free shipping! Wow I thought, I just saved $769.00. What a bargain it was. It no longer mattered to me that I was about 80% over budget. Hey I thought, "If you are going to be a bear, be a grizzly".

I called the 2Kstore to order the Dayton 8KW Generator. When I spoke to the salesman, he asked me if I wanted a manual or an automatic transfer switch. He said that the automatic switch normally costs $800 but he could give it to me for $425 if I bought the Generator. Give me the automatic switch, I said. "Now I am saving $1,144, think grizzly," I thought.

About one week later the generator and transfer switch arrived. When it came I realized that I had gotten into more than I bargained for. This was a serious piece of equipment, designed more to back up a small business than a house. The generator weighed 461 pounds and came in an enclosure 22" x 39" x 27". The transfer switch came in a large steel enclosure 19" x 14" x 6". What I imagined was going to be an install it yourself job, became a job for professionals. The installation instructions were quite clear. You must install the generator on a cement base that extends three inches past the perimeter on all sides. The instructions also defined what size wire to use, and demanded separate cables for control and power and grounding. When the installation is completed the instructions said that you must contact Dayton, and obtain a free inspection before powering the generator up. If this isn't done the warrantee is void.

Contracting the job out

It was now clear that I needed help. First a trip to the yellow pages produced a cement worker who came and laid the platform that the generator was to be bolted to. He charged $150 for the job and came and went in one morning, leaving me a cement platform next to my house. Next requirement was for the electrician to install both the transfer switch and the generator. I did due diligence and called four electricians to quote the job. Three came and quoted it. The first two quotes were from electricians intending to mount the transfer switch outside in a weatherproof enclosure. Their quotes were $2500 and $2200 respectively. The third quote was based on installing the transfer switch in the basement and was for $950. I accepted the third quote. Soon two electricians appeared and moved the generator onto the cement block and wired it as required. The wiring consisted of running the house mains into one side of the transfer switch and the generator output into the other side. The center arms of the transfer switch were connected to the various appliances and rooms I had specified. Each leg had a new circuit breaker in a box that was installed next to the transfer switch. In addition to the power wiring, a six-wire control cable was wired between the transfer switch and the generator, and a six-foot ground rod was buried into my soil and attached to the generator. Two electricians took about a day and a half to complete the installation.

Finally the plumber was called to connect the generator gas feed to my natural gas line. I had decided against propane, as it would involve using at least a 100-gallon tank and burying it. This would have added about an additional $1000. Two plumbers arrived one morning and connected the gas line to the generator through a flex hose. For two hours work it cost $475. Plumbers are really high paid. I was now ready for the inspection.

I called the phone number that came with the generator and made an appointment for an inspection. The person I spoke to, asked if I had installed the battery. I told him no, that I intended to buy one. He said that he would bring one with him ($60).

Evidentially many people screw up on the installation and blow out the generators. Dayton eliminates this problem by insisting on these inspections. On Friday morning, November 19, Lee arrived to inspect my installation and test it out. I was very excited. He inspected all the wiring, and plumbing and then installed the battery and started the generator. After setting up the frequency governor and the output voltage he shut it down and went to the main input panel and shut down the mains coming into the house. The loss of power caused the generator to start and once it was up to speed the transfer switch connected it to the house wiring. I ran around checking the appliances, furnace and office. It was all working as planned. I thought "Gee it is nice when a plan goes together." Lee then told me that from now on, the generator will "Exercise itself" every Friday at noon, for about 15 minutes. I missed it last Friday, but I will be listening this coming Friday.

Total cost was much above what I had originally budgeted. I had expected to spend about $3000 to $4000. Actually it cost a total of $6,529.00. But now I am Y2K compliant. This January when the lights go out in Amityville, I will sit in my warm house and watch the TV shows on the satellite or play Free Cell on my computer. Of course that is if the lights go out. My friend Larry told me he hopes the same thing happens to me that happened to him. Four years ago he bought a very expensive snow blower. It hasn't snowed since. Well whether the power fails or not, I will at least be able to hear my generator start up every Friday.

(Frank's new generator is pictured below.)

Frank Greenhalgh
December 1, 1999

Comments Frank's column hit a nerve and the responses we are receiving are proof of that. Read the comments as well as Frank's response

About the Author

Frank Greenhalgh has been working in power supplies and systems for 38 years. He has many impressive accomplishments and patents. Over the years he has made significant contributions to Trio Laboratories where he held the position of Chief Design Engineer and was then promoted to Vice President.