UPDATE #2 - I installed the hard start cap (SPP6) yesterday. Switched on the a/c and the gen overloaded again. I tried switching off all other breakers, but no luck. I connected to house power just to see if I shorted something on the roof, and the a/c fired right up. I shut it down and waited a few minutes and tried the gen again. This time the a/c started and the gen ran fine when resetting all the breakers. I did not add any more load except for the converter/charger. It was in the upper 80s outside and probably low 90s inside.
Now, will it work out in the field...or did running it on house power corrupt the test?