Champion 100199, Installation Manual

Page 1: ...DANGER Not intended for use in critical life support application DANGER Generator must be installed and operated outdoors only ...

Page 2: ...ovement policy Thus information illustrations and or specifications to explain and or exemplify a product service or maintenance improvement may be changed at any time without notice ALL RIGHTS RESERVED No part of this publication may be reproduced or used in any form by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems ...

Page 3: ...sk of Fire 16 National Fire Protection Association NFPA Standard NFPA 37 Requirements and Testing 16 SPECIFICATIONS 17 Champion 439CC Engine 18 Champion 439CC Engine Torque Specifications 18 Master Mixing Assembly Jets Carburetor System 18 Alternator Overview 19 Rotor Assembly 19 Stator Assembly 19 Brush Holder and Brushes 19 UNPACKING 20 INSTALLATION 21 Generating Sizing 21 Site Selection Prepara...

Page 4: ...rcuits 45 Automatic Transfer Switch 46 Unpacking 46 Location and Mounting 46 Circuit Breakers for Utility Main Control Panel and ATS 46 Electrical Grommet s 47 Installation Wiring for ATS to Utility Main Control Panel 47 Installing Communication Wires 48 Commissioning the ATS 48 ATS Circuit Board Fuse Information 49 ATS Fuse Troubleshooting and Testing 49 Fuses F2 and F3 49 Fuses F4 and F5 49 Fuse...

Page 5: ...ch championpowerequipment com HOME STANDBY GENERATOR This home standby generator is intended exclusively for outdoor installation This generator will operate using either liquefied petroleum gas LPG Propane or natural gas NG This generator is designed to supply typical home load such as Induction motors sump pumps refrigerators air conditioners furnaces Electronic items televisions computers House...

Page 6: ...ight turns on if unit controller detects a fault code Automatic weekly exercise operates engine and generator between outage events system check On board battery charging and monitoring digital LED controller Engine and Generator monitoring digital LED controller Fast Tran ATS automatic transfer switch safe and simple extremely high speed switching system Flexible fuel line connector absorbs vibra...

Page 7: ...LE AND CONBUSTIBLE LIQUID CODE National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA NO 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES National Fire Protection Association 470 Atlantic Avenue Boston Ma 02210 NFPA NO 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES National Fire Protection Association 470 Atlantic Avenue Boston Ma 02210 NFPA NO 54 NATIONAL FUEL...

Page 8: ...CE Indicates a situation that can cause damage to the equipment personal property and or the environment or cause the equipment to operate improperly OTE N Indicates a procedure practice or condition that should be followed in order for the generator to function in the manner intended SAFETY SYMBOL DEFINITIONS Black hazard pictorial on yellow equilateral triangle enclosed by black triangular band ...

Page 9: ...tandards and regulations install and service the generator ALWAYS comply with local state and national electrical and building codes when installing the generator NEVER alter the recommended installation in a way that would render the unit noncompliant with these codes ALWAYS comply with regulations that Occupational Safety and Health Administration OSHA has established ENSURE the generator is ins...

Page 10: ...ly Contact your dealer if repairs are needed NEVER climb or step on any part or components of the generator Doing so may result in injury and cause leaking fuel and exhaust OPERATING HAZARDS WARNING ALWAYS operate the generator following the manufacturer s instructions Operating the generator imprudently neglecting maintenance or being careless can result in injury or possible death DO NOT allow c...

Page 11: ...Generator exhaust contains carbon monoxide a colorless odorless poisonous gas Breathing carbon monoxide will cause nausea dizziness fainting or death If you start to feel dizzy or weak get to fresh air immediately The generator must be installed and operated outdoors only NEVER install the generator where exhaust fumes could seep inside or be drawn into a potentially occupied building through wind...

Page 12: ...te and local codes for proper grounding may also apply Avoid direct contact with an electric shock victim Immediately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor using a nonconducting item such as a dry board or rope If the victim is unconscious apply first aid and call 911 immediately FIRE EXPLOSION HAZARDS WARNING NG and LPG...

Page 13: ...ecome caught BATTERY HAZARDS WARNING Always read and comply with the battery manufacturer s recommendations for procedures concerning proper battery use and maintenance WARNING Batteries contain sulfuric acid and generate explosive mixtures of hydrogen and oxygen gases Keep any device that may cause sparks or flames away from the battery to prevent explosion Always wear protective glasses or goggl...

Page 14: ...or may create sparks while operating Risque d incendie Nettoyez TOUJOURS la surface à proximité du groupe électrogène et enlevez les débris et ou la végétation sèche Le groupe électrogène peut générer des étincelles pendant son fonctionnement Riesgo de incendio SIEMPRE mantenga el área circundante cerca del generador limpia y libre de escombros y o vegetación seca El generador puede crear chispas ...

Page 15: ...ower Equipment Part No 101049 Rev B 6 2 1 4 5 3 A Serial number location B Nameplate A B SAFETY SERIAL MODEL NAMEPLATE LABEL LOCATIONS The safety labels have specific placement and must be replaced if they are unreadable damaged or missing ...

Page 16: ...materials outside the enclosure ANNEX A EXPLANATORY MATERIAL A 4 1 2 2 Means of demonstrating compliance are by means of full scale fire tests or by calculating procedures such as those given in NFPA 555 Guide on Methods for Evaluating Potential for Room Flashover To comply with condition 2 the weatherproof enclosure has been constructed of non combustible materials and full scale fire tests have ...

Page 17: ...ent 439cc Cylinder block Aluminum with cast iron sleeve Ignition system Solid state magneto Spark plug F7RTC NGK BPR7ES Governor Mechanical Starter Electric 24V DC Oil capacity 1 2 qt 1 1 L RPM 3600 Controls Mode switch auto Auto start on utility failure Mode switch manual Starts on demand Mode switch off Stops unit control and charger active Ready to run maintenance messages Standard Programmable...

Page 18: ...tive harden valves and seats Ignition System Solid state magneto Governor Mechanical Starter Electric 24V DC RPM 3 600 Oil Capacity 1 2 qt 1 1 L CHAMPION 439 CC ENGINE TORQUE SPECIFICATIONS Crankcase Cover Bolts 24 4 Nm 216 in lbs Connecting Rod Bolts 18 Nm 156 in lbs Rocker Cover Screws 5 4 Nm 48 in lbs Cylinder Head Bolts 39 Nm 29 ft lbs 348 in lbs Intake Manifold Screws 9 5 Nm 84 in lbs Carbure...

Page 19: ...engine mounting flange In combination with the rotor assembly they generate the electrical out put of the HSB BRUSH HOLDER AND BRUSHES The brush holder is a component that holds the brushes in a stationary position enabling them to maintain contact with the rotating surface commutator rings on the rotor The brush holder is attached to the rear bearing carrier by means of a M5 x 20 bolt and a locat...

Page 20: ...other trash 5 Remove plastic covering and discard 6 Remove 4 securing clamps Save if going to use anchor bolts to secure to concrete pad 7 Insert 2 lifting rods not supplied into lifting notches at each end of the base 8 Discard all shipping materials and recycle if possible NOTICE If you know length of run for wires you may want to install the ATS communication wires and voltage wires now before ...

Page 21: ...e output wattage or kW you have available to power your home The more output equals move devices or appliances you may power There is a HSB sizing guide on Champion web www championpowerequipment com Before installing the generator review SAFETY section starting on page 8 Have the generator installed by an authorized CPE dealer Install the equipment in compliance with the National Electrical Code ...

Page 22: ...t can be opened or other such home invasion points Use the same precautions when installing HSB at property line close to a neighbor s home or any building or structure that houses animals DANGER Running engines give off carbon monoxide an odorless colorless invisible poison gas Breathing carbon monoxide will cause fatigue headache dizziness vomiting and in prolonged conditions even death Carbon m...

Page 23: ...ood shipping pallet This pallet is for shipping transportation only and cannot be used as a mounting pad in any form Exercise caution when removing the HSB from the wood pallet dragging it off the wood pallet will damage the HSB base The HSB must be lifted from the wood pallet to separate Contact your natural gas NG supplier about the meter size Most meters must be replaced with a larger BTU size ...

Page 24: ... the ADD mark on the dipstick doing so could damage the engine Check the oil level and add the appropriate viscosity and amount indicated on the oil dipstick full line Oil viscosity 5 w 30 full synthetic Refer to Owner s manual IN THE THIS SEGMENT INSTALLATION PREPARATION THE FOLLOWING WILL BE COVERED 1 Fuel Requirements and Recommendations 2 Fuel Consumption 3 NG Pipe Sizing flexible fuel line 4 ...

Page 25: ...c HSB model Fuel System Requirements LPG NG Fuel supply inlet 3 4 in NPT Fuel supply pressure 10 12 inch H20 2 5 3 0 kPa W C 5 7 inch H2O 1 2 1 7 kPa W C Maximum flow rate 8 5 kW 146 667 Btu hr 135 760 Btu hr Nominal Fuel Rating LPG 2500 Btu ft3 NG 1000 Btu ft3 Install the fuel system in accordance with NEC and local codes The HSB is EPA Phase 3 certified for LPG and NG fuels 2 FUEL CONSUMPTION Ai...

Page 26: ...ly line pipe and the fuel inlet pipe to the HSB The purpose of the flexible fuel line is to ensure that vibration from the HSB does not cause a gas leak at one of the connection points The flexible fuel line is not to be installed underground in contact with any enclosure parts or contact with the ground The entire flexible fuel line must be visible for periodic inspection and must not be conceale...

Page 27: ... tanks and existing LPG tanks already located at the installation site have a primary fuel regulator set and intended for home heating and cooking This regulator might not be properly sized to accommodate the addition of the HSB Contact the local LPG supplier to properly size the fuel regulator Make sure the tank is sized large enough to provide the required Btu s for the HSB and all connected app...

Page 28: ... m 1 in NPT 200 ft 61 m 1 in NPT Add 2 5 ft 0 76 m per bend tee or angle in the pipe line to overall distance for each 90 degree elbow add 8 feet 2 4 m to the overall measurement 5 CONVERTING TO LPG The engine is fitted with a dual Master Mixer Assembly carburetor system which allows the HSB to run on either NG or LPG It has been configured at the factory to run on NG If your installation requires...

Page 29: ...as Manometer measures gas pressure It s important to make sure the correct amount of fuel is being delivered to the HSB when it starts and at full load usage the Manometer provides the ability to check the fuel pressure throughout the operation of the HSB A Manometer port should be placed in the fuel supply pipe line CAUTION Remove the plug install the Manometer Open the gas supply valve check to ...

Page 30: ...combustion chamber ignition in all weather conditions especially in cold climate areas All 12 VDC batteries will lose a certain percentage of their charge while in storage It is important to test the battery voltage before it is installed in the generator and taken to the job site A fully charged battery must test at 12 5 13 0 volts DC at 70 degrees F Also the correct batteries must have lug termi...

Page 31: ...ries in a fire The battery is capable of exploding CAUTION Do not open or mutilate the battery or batteries Released electrolyte has been known to be harmful to the skin and eyes and can be toxic VENTED BATTERIES The installation of the engine generator shall provide enough ventilation to ensure that all gases generated by vented batteries during charging or caused by equipment malfunction are rem...

Page 32: ...is the responsibility of the installer to perform an installation that will pass the final electrical inspection Conductor wire sizes must be adequate to handle the maximum current to which they will be subjected The installation must comply fully with all applicable codes standards and regulations All power cables must enter the enclosure through the knockouts provided If not using knockouts cond...

Page 33: ...or multi outlet styles They re designed to protect against virtually all short duration voltage fluctuations HOUR METER OVER VOLTAGE PROTECTION HOUR METER The hour meter keeps track of all running time of the HSB This includes run time during a utility power outage and during the weekly exercise cycle This provides the owner with a record of operating time which is useful in keeping track of sched...

Page 34: ...he AVR uses solid state semiconductor devices to smooth out variations in the flow of current The AVR monitors the output voltage and controls the input voltage to the exciter of the generator By increasing or decreasing the generator control voltage the output voltage of the generator increases or decreases accordingly The AVR calculates how much voltage has to be sent to exciter numerous times a...

Page 35: ...lity modes TOP ROW There are 12 wire land points in the top row the connection points are all the same size The following are the wire land points function and wire color this is viewed left to right 1 Position 1 Frequency R RED 2 Position 2 Frequency B BLACK 3 Position 3 ATS O ORANGE 4 Position 4 Exercise O B ORANGE BLACK 5 Position 5 High Engine Br BROWN Temp 6 Position 6 Low oil level Y YELLOW ...

Page 36: ...acity 4 Transfer load to HSB 5 In this position the HSB will also perform its weekly exercise cycle at the predetermined set time 6 The HSB will attempt up to 5 starting sequences to successfully start the HSB If the HSB fails to start after the 5th attempt the RED LED light Over Crank will be lit The exterior fault code indicator LED on the backside of the HSB will be activated and lit Should thi...

Page 37: ...ion Dealer The RED LED will remain lit until the failure has been corrected the HSB will not attempt to transfer or run LOW OIL LED The RED LED will be lit when the engine oil level drops below the safe operating level When this fault is detected the HSB will shut down and re start will be disabled RED LEDs on the module and enclosure exterior are lit Check the oil level The oil level should be at...

Page 38: ...e G B Green Black 5 Pin 5 Drives all fault lights L Blue 6 Pin 6 Ground stop L B Blue Black 7 Pin 7 Signal to alternator R B Red Black 8 Pin 8 Not Connected 9 Pin 9 Low Oil Level Y Yellow Pressure 10 Pin 10 Engine High Temp Br Brown 11 Pin 11 Exercise O B Orange Black 12 Pin 12 Signal to ATS O Orange 13 Pin 13 Frequency Over B Black Under 14 Pin 14 Frequency Over R Red Under DIP SWITCHES ON THE BA...

Page 39: ...tes the household is using Utility power source This position is the standby ready position OFF This position will not allow any power to be delivered or transferred to the ATS or the household when the engine HSB is running The UTILITY ATS active and LOAD LEDs will remain lit indicating the Utility power source is providing power to the household If the Utility power source is turned off main lin...

Page 40: ... adjustments are preset at the factory The automatic battery charger has five 5 built in LEDs that display the following view left to right NO CHARGE PAS DE CHARGE SIN CARGA AUTOMATIC BATTERY CHARGER CHARGE AUTOMATIQUE DE BATTERIE CARGADOR DE BATERÍA AUTOMÁTICO Output 24 Vdc 1 6 A Producción 24 V C C 1 6 A Sortie 24 V c c 1 6 A Power 80 125 Vac 1 0 A 50 60 Hz Potencia 80 125 V C A 1 0 A 50 60 Hz A...

Page 41: ...he correct voltage Single phase utility power supply Measure across the UTILITY SUPPLY ATS terminal lugs L1 and L2 Also check L1 to NEUTRAL and L2 to NEUTRAL 4 The utility supply voltage should be correct and compatible with the ATS ratings 5 Turn OFF the utility power supply to the ATS 6 The Control Panel MAIN CIRCUIT BREAKER must be in the OFF position 7 Set the ATS module in the test mode 8 Set...

Page 42: ...TO TURN OFF ANY CIRCUIT BREAKERS IN THE UTILITY MAIN DISTRIBUTION PANEL HSB CONTROL PANEL OR THE ATS This procedure will verify load Voltage and frequency output Prior to starting the test you can place a Manometer in line to check fuel flow when the HSB is under complete load 1 Set the Engine Control Module in the ATS position 2 Set the ATS Control Module in the TEST position 3 With the switch in...

Page 43: ...tic sequence of operation Turn on the Utility Main Circuit Breaker The ATS should automatically transfer from GENERATOR SUPPLY to UTILITY SUPPLY 8 The HSB will run through a cool down cycle shut off and be in standby ready mode 9 This check is now complete CUSTOMER FAMILIARIZATION SUMMARY It s important to educate the home owner on proper maintenance operation and service call procedures A properl...

Page 44: ...ording to the manufacturer s instructions A CO monitor is an electric device that detects hazardous levels of CO When there is a buildup of CO the monitor will alert the occupants by flashing a visual light indicator and an audible alarm Smoke alarms cannot detect CO gas CO gas is odorless colorless and tasteless and is unlikely to be noticed until a person is overcome Standby generators emit carb...

Page 45: ...__ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ Date Installed _____________________________________ Dealer Installer ________...

Page 46: ...3R This type of enclosed ATS is similar to the indoor box except that it is a weatherproof enclosure and required for exterior installations by code The enclosure only has knockouts on the bottom side for the enclosure requires water tight fasteners grommets when installed outside per code This enclosure can also be used inside The ATS is also equipped with manual transfer switch operation which i...

Page 47: ...ough the sheathing and siding 3 In compliance with all local electrical codes route the conduit along ceiling floor joists and wall studs to the location where the conduit will pass through the wall to the exterior of the house Once the conduit is pulled through the wall and in proper position to attach to the HSB generator place silicone caulk around the conduit on both side of the hole inside an...

Page 48: ...er terminal block in the ATS Strip the wires inch and connect each wire to the terminal block in the sequence from left to right starting with 1 in the left most position Each wire is connected by pushing the nylon release lever backward to open the terminal clamp Inserting the stripped wire into the terminal opening releasing the terminal clamp Care should be taken not to overstress the nylon rel...

Page 49: ...L2 out 3 F3 Utility L1 out 4 F4 Load Buss L2 out 5 F5 Load Buss L1 out 6 F6 Generator solenoid ATS FUSE TROUBLESHOOTING AND TESTING FUSES F2 AND F3 1 If the systems controller shows that load voltage is available Fuses F2 and F3 are functional 2 If not disconnect the wires that are connected to terminals 9 and 10 on the 12 position terminal block 3 With the Utility power on verify the fact that al...

Page 50: ...nal 3 5 FOR NO MORE THAN 1 SECOND press the positive lead of the 24 VDC power supply to terminal 2 6 If the solenoid clicks and the mechanism transfers fuse F2 is functional 7 Disconnect the 24 VDC power supply and reconnect the wires that were installed in terminals 1 2 and 3 in the correct order MANUAL TRANSFER SWITCH WARNING A manual switch is NOT approved by code when used with a stationary or...

Page 51: ...m fuel pressure to fuel regulator 4 Weak battery s Recharge or replace battery s 5 Low oil level Check for oil leaks Check the oil level and add oil if necessary 6 Spark plug wire is disconnected Connect spark plug wire 7 Defective fuel solenoid regulator ENGINE STARTS RUNS ROUGH 1 Fuel pressure insufficient Manometer check confirm fuel pressure to fuel regulator 2 Wrong fuel jets Check jets for N...

Page 52: ...rected Only the LOW BATTERY LED will not latch out or shut down the HSB All other RED LED faults will latch out shut down disable starting and light the RED LEDS on the Engine Control Module and the exterior fault code light on the backside of the HSB RESET FAULT CODE S There is an exterior fault code indicator light located on the back of the enclosure This should be checked weekly to make sure t...

Page 53: ...Champion Power Equipment 12039 Smith Ave Santa Fe Springs CA 90670 USA Made in China ...

Page 54: ...ted comprehensive coverage on engine short block and alternator rotor and stator parts only GUIDELINES Warranty begins upon the successful activation of the unit Unit should be Registered and Proof of Purchase and Maintenance must be available Warranty is transferable between ownership of original installation site Warranty only applies to permanently wired and mounted units Any and all warranty r...

Page 55: ...wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Champion engines need periodic part s service and fluid replacement to perform as designed 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 to...

Page 56: ...PART S AS STATED ABOVE IN NO EVENT SHALL CHAMPION POWER EQUIPMENT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF CHAMPION POWER EQUIPMENT S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitations may not apply to purchaser owner Purchaser owner agrees to make no claims against...