Briggs & Stratton 30000 User Manual

Installation & Start-Up Manual

30000 Series Liquid-Cooled Home Generator System

Manual No. 205052GS Rev. A (01/08/2008)

Thank you for purchasing this quality-built Briggs & Stratton home generator. We’re pleased that you’ve placed your confidence in the Briggs & Stratton brand. When operated and maintained according to the instructions in the operator’s manual, your Briggs & Stratton home generator will provide many years of dependable service.

This manual contains safety information to make you aware of the hazards and risks associated with home generator systems and how to avoid them. This home generator system is designed and intended only for use as an optional home standby system that provides an alternate source of electric power and to serve loads such as heating, refrigeration systems, and communication systems that, when stopped during any power outage, could cause discomfort or inconvenience. This product is not intended for any other purpose and does not qualify for emergency standby as defined by NFPA 70 (NEC).

This home generator requires professional installation before use. This installation manual provides full information. Follow the instructions completely. Save these instructions for future reference.

Where to Find Us

You never have to look far to find Briggs & Stratton support and service for your generator. Consult your Yellow Pages. There are thousands of Briggs & Stratton authorized service dealers worldwide who provide quality service. You can also contact Briggs & Stratton Customer Service by phone at (800) 743-4115, or use the Service Center Locator at BRIGGSandSTRATTON.COM, which provides a list of Briggs & Stratton Authorized Dealers.

Date of Purchase

Generator

Model Number

Model Revision

Serial Number

Engine

Model Number

Serial Number

Briggs & Stratton Power Products Group, LLC 900 North Parkway Jefferson, WI 53549

Copyright © 2008 Briggs & Stratton Power Products Group, LLC. All rights reserved. No part of this material may be reproduced or transmitted in any form by any means without the express written permission of Briggs & Stratton Power Products Group, LLC.

Table of Contents

Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installer Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Delivery Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Shipment Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Home Generator Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Access Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

The Gaseous Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

System Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Grounding the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Utility Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

System Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Final Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Initial Start-up (No Load). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Fuel Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Schematic/Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Automatic Operation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Setting Exercise Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Save These Instructions

Safety Rules

The safety alert symbol ( ) is used with a signal word (DANGER, CAUTION, WARNING), a pictorial and/or a safety message to alert you to hazards. DANGER indicates a hazard which, if not avoided, will result in death or serious injury. WARNING indicates a hazard which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury. NOTICE indicates a situation that could result in equipment damage. Follow safety messages to avoid or reduce the risk of injury or death.

This manual contains installation, startup and adjustment instructions for a home generator that supplies 120/240 Volt, single phase, 60Hz devices. The home generator may be operated on LP vapor or natural gas fuel. Separate engine and generator operator’s manuals are supplied that contain operating and maintenance instructions for this system.

Every effort has been made to ensure that the information in this manual is both accurate and current. However, the manufacturer reserves the right to change, alter or otherwise

improve the system at any time without prior notice.

Hazard Symbols and Meanings

WARNING

Storage batteries give off explosive hydrogen gas during recharging.

Slightest spark will ignite hydrogen and cause explosion.

Battery electrolyte fluid contains acid and is extremely caustic.

Contact with battery contents will cause severe chemical burns.

A battery presents a risk of electrical shock and high short circuit current.

DO NOT dispose of battery in a fire.

• DO NOT allow any open flame, spark, heat, or lit cigarette

• during and for several minutes after charging a battery.

DO NOT open or mutilate the battery.

• Wear protective goggles, rubber apron, and rubber

• gloves.

Remove watches, rings, or other metal objects.

• Use tools with insulated handles.

•

WARNING

Explosion

Toxic Fumes

Lift Hazard

Fire

Rotating Parts

Read Manual

Electrical Shock

Hot Surface

Chemical BurnExplosive PressureAuto Start

Running engine gives off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause headache, fatigue, dizziness, vomiting, confusion, seizures, nausea, fainting or death.

Operate generator ONLY outdoors.

• Install a battery operated carbon monoxide alarm near

• the bedrooms.

Keep exhaust gas from entering a confined area through

• windows, doors, ventilation intakes, or other openings.

WARNING

The engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth

defects, or other reproductive harm.

4 BRIGGSandSTRATTON.COM

WARNING

Generator produces hazardous voltage. Failure to properly ground generator can result

in electrocution. Failure to isolate generator from power utility

can result in death or injury to electric utility workers due to backfeed of electrical energy.

When using generator for backup power, notify utility

• company.

DO NOT touch bare wires or receptacles.

• DO NOT handle generator or electrical cords while

• standing in water, while barefoot, or while hands or feet are wet.

If you must work around a unit while it is operating,

• stand on an insulated dry surface to reduce shock hazard.

DO NOT allow unqualified persons or children to operate

• or service generator.

In case of an accident caused by electrical shock,

• immediately shut down the source of electrical power and contact the local authorities. Avoid direct contact

with the victim.

Despite the safe design of the home generator, operating

• this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death.

Remain alert at all times while working on this

• equipment. Never work on the equipment when you are physically or mentally fatigued.

Before performing any maintenance on the generator,

• disconnect the battery cable indicated by a NEGATIVE, NEG or (-) first. When finished, reconnect that cable last.

After your home generator is installed, the generator

• may crank and start without warning any time there is a power failure. To prevent possible injury, always set the generator’s system switch to OFF AND remove the 15 Amp fuse BEFORE working on the equipment.

Propane and Natural Gas are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

Install the fuel supply system according to applicable

• fuel-gas codes.

Before placing the home generator into service, the fuel

• system lines must be properly purged and leak tested.

After the generator is installed, you should inspect the

• fuel system periodically.

NO leakage is permitted.

• DO NOT operate engine if smell of fuel is present or other

• explosive conditions exist.

DO NOT smoke around the generator. Wipe up any oil

• spills immediately. Ensure that no combustible materials are left in the generator compartment. Keep the area near the generator clean and free of debris.

WARNING

Hazardous Voltage Contact with power lines can cause electric

shock or burn. Lifting Hazard / Heavy Object Can cause muscle strain or back injury.

DO NOT contact any power lines when using required

• lifting/hoisting equipment.

DO NOT lift or move generator without assistance.

• Use lifting pipes or straps as described in Lifting the

• Generator. The unit may shift during movement, which can cause injury.

DO NOT lift unit by roof as damage to generator will

• occur.

WARNING

Contact with muffler area can result in serious burns.

Exhaust heat/gases can ignite combustibles or structures causing a fire.

DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

• DO NOT install the generator closer than 5 feet (1.5m)

• from any combustibles or structures with combustible walls having a fire resistance rating of less than 1 hour.

Code of Federal Regulation (CFR) Title 36 Parks, Forests,

• and Public Property require equipment powered by an internal combustion engine to have a spark arrester, maintained in effective working order, complying to USDA Forest service standard 5100-1C or later revision. In the State of California a spark arrester is required under section 4442 of the California Public resources code. Other states may have similar laws.

WARNING

Starter and other rotating parts can entangle hands, hair, clothing, or accessories.

NEVER operate generator without protective housing or

• covers.

DO NOT wear loose clothing, jewelry or anything that

• may be caught in the starter or other rotating parts.

Tie up long hair and remove jewelry.

•

CAUTION

Excessively high operating speeds increase risk of injury and damage to generator.

Excessively low speeds impose a heavy load.

DO NOT tamper with governed speed. Generator supplies

• correct rated frequency and voltage when running at governed speed.

DO NOT modify generator in any way.

•

NOTICE

Exceeding generators wattage/amperage capacity can damage generator and/or electrical devices connected to it.

See Essential Circuits in Operator’s manual.

• Start generator and let engine stabilize before connecting

• electrical loads.

NOTICE

Improper treatment of generator can damage it and shorten its life.

Use generator only for intended uses.

• If you have questions about intended use, ask dealer or

• contact Briggs and Stratton.

Operate generator only on level surfaces.

• Adequate, unobstructed flow of cooling and ventilating

• air is critical to correct generator operation.

The Coolant Fill, Battery and Control Panel doors must be

• installed whenever the unit is running.

DO NOT expose generator to excessive moisture, dust,

• dirt, or corrosive vapors.

Despite the safe design of the home generator, operating

• this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death.

DO NOT start engine with air cleaner or air cleaner cover

• removed.

DO NOT insert any objects through cooling slots.

• DO NOT use the generator or any of its parts as a step.

• Stepping on the unit can cause stress and break parts. This may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

If connected devices overheat, turn them off and

• disconnect them from generator.

Shut off generator if:

•

-electrical output is lost;

-equipment sparks, smokes, or emits flames;

-unit vibrates excessively.

6 BRIGGSandSTRATTON.COM

Installation

Equipment Description

This product is intended for use as an optional home generator system which provides an alternate source of electric power and to serve loads such as heating, refrigeration systems, and communication systems that, when stopped during any power outage, could cause discomfort or inconvenience. This product does not qualify for emergency standby as defined by NFPA 70 (NEC).

Customer Responsibilities

• Read and follow the instructions given in the Operator’s Manual, especially the section regarding selecting essential circuits.

• Follow a regular schedule in maintaining, caring for and using your home generator, as specified in the Operator’s Manual.

Installer Responsibilities

• Read and observe the safety rules.

• Install only an UL approved transfer switches that is compatible with the home generator.

• Read and follow the instructions given in this Installation and Start-up Manual.

IMPORTANT: The system is equipped with a water heater that is activated when ambient temperature is less than 80°F AND utility power is present at the transfer switch.

Delivery Inspection

After removing the carton, carefully inspect the home generator for any damage that may have occurred during shipment.

IMPORTANT: If loss or damage is noted at time of delivery, have the person(s) making delivery note all damage on the freight bill and affix his signature under the consignor’s memo of loss or damage. If loss or damage is noted after delivery, separate the damaged materials and contact the carrier for claim procedures. Missing or damaged parts are not warranted.

Shipment Contents

The home generator system is supplied with:

• Home generator

• Fully-serviced coolant system

• Fully-serviced oil/lubricating system

• UL569/CSA8.3-listed flexible fuel hook-up

• Installation and start-up manual

• Operator’s manual

• Engine operator’s manual

• Installation checklist

• Two access door keys

• One spare 15A fuse

• 10 Pole control panel connector

• Remote LED indicator kit (red LED/plate/screws)

Unpacking Precautions

The unit is shipped ready for installation on a prepared reinforced cement slab or engineered base. Avoid damage from dropping, bumping, collision, etc. Store and unpack carton with the proper side up, as noted on the shipping carton.

Not Supplied:

• 650 CCA starting battery (NOT deep-cycle)

• Connecting wire and conduit

• Fuel supply valves/plumbing

Required Specialty Tools/Equipment

• Two 60” lengths of 2” Schedule 40 pipe (NOT conduit)

• Lifting straps, chains or cables

• Hole punches for 7 ga steel

• Torque screwdriver, 5 to 50 inch-pound range

• Ignition Timing Light

• Air Fuel Ratio Meter (O2 Sensor and Analyzer)

Home Generator Location

Before installing generator, consult with homeowner and convey the following guidelines which may affect the desired location.

WARNING

Exhaust heat / gasses can ignite combustibles or structures causing a fire.

DO NOT install the generator closer than 5 feet (1.5m)

• from any combustibles or structures with combustible walls having a fire resistance rating of less than 1 hour.

Generator Location

Install generator outdoors in an area which will not accumulate deadly exhaust gas. DO NOT install generator where exhaust gas could accumulate and enter inside or be drawn into a potentially occupied building. Ensure exhaust gas is kept away from any windows, doors, ventilation intakes or other openings that can allow exhaust gas to collect in a confined area. Prevailing winds and air currents should be

taken into consideration when positioning generator.

WARNING

• Install the generator as close as possible to the transfer switch and fuel supply to reduce the length of wiring, conduit, and piping.

IMPORTANT: Laws or local codes may regulate the distance to the fuel supply.

The Minimum clearances from aerial view of generator (A) to combustible (C, D) materials is shown below.

• These distances are provided to give generator location guidance relative ONLY to combustibles, generator cooling, and maintenance.

• The minimum distances in the figure are as shown. All four sides of the generator cannot be enclosed or restricted, even if the minimum distances are maintained. DO NOT connect (C) to (D)

• A roof cannot be used.

• Exhaust (B) is directed out the top of the generator and must not be allowed to accumulate.

5’ (1.5m)

Running engine gives off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause headache, fatigue, dizziness, vomiting, confusion, seizures, nausea, fainting, or death.

Operate generator ONLY outdoors.

• Install a battery operated carbon monoxide alarm near

• the bedrooms.

Keep exhaust gas from entering a confined area through

• windows, doors, ventilation intakes, or other openings.

General Location Guidelines

• Install the unit outdoors ONLY.

• Place the unit on a prepared concrete slab that is flat, level, and has provisions for water drainage.

• Install the unit in a location where sump pump discharge, rain gutter down spouts, roof run-off, landscape irrigation, or water sprinklers will not flood the unit or spray the enclosure and enter any air inlet or outlet openings.

• Install the unit where the location of any services such as phone, electrical, fuel, air conditioning, irrigation, including covered, concealed and underground services will not be affected or obstructed.

• Install the unit where air inlet and outlet openings will not become obstructed by leaves, grass, snow, etc. If prevailing winds will cause blowing or drifting, you may need to construct a windbreak to protect the unit.

5’ (1.5m) 5’ (1.5m)

5’ (1.5m)

A Home Standby Generator B Engine Exhaust (exits vertically from enclosure) C Combustible Material or Structure with a Fire

Resistance Rating of less than 1 hour.

D Any structure or material. DO NOT connect (C) to (D).

8 BRIGGSandSTRATTON.COM

Concrete Slab

49”

14.25”

94”

78”

38”

9.5”

7”

7.38”

34.25”

10.5”

8”

At the appropriate location, construct a concrete slab (28 day compression strength of 3000 psi (200 MPa)) minimum 5 inches thick and 6 inches wider than the enclosure on all sides. Strengthen slab with No. 6 reinforcing bars (on 12” centers) or 8 ga. steel wire fabric (6” centers). Avoid placing reinforcement in entrance stub-up area.

Anchor bolt

position

(4 places)

Power Cable

Stub-in

location

Fuel Inlet

Port

Lifting the Generator

The generator weighs more than 1,700 pounds. Proper tools, equipment and qualified personnel should be used in all phases of handling and moving the generator.

WARNING

Hazardous Voltage Contact with power lines can cause electric

shock or burn. Lifting Hazard / Heavy Object Can cause muscle strain or back injury.

DO NOT contact any power lines when using required

• lifting/hoisting equipment.

DO NOT lift or move generator without assistance.

• Use lifting pipes or straps as described in Lifting the

• Generator. The unit may shift during movement, which can cause injury.

DO NOT lift unit by roof as damage to generator will

• occur.

Enclosure

Base

Exhaust

Opening

(shown for

reference)

Slab Top VIew

Attach unit to slab with 5/16” diameter (minimum) masonry anchor bolts long enough to retain the unit.

Electrical and Fuel Inlet Locations

A through-slab power cable stub-up is preferred (see above). If stub-up’s are not used, (A) indicates the recommended location for punching holes for attaching power conduit. The fuel inlet connector (B) is shown for reference.

Two 60” lengths of 2” Schedule 40 pipe (B), supplied by the installer, are required to lift the generator onto cement pad. Insert pipes through the lifting holes (A) located near the unit’s base.

Use a spreader bar to ensure that the chains, straps or cables DO NOT touch the generator’s roof.

1” Female NPT

Access Doors

The home generator is equipped with an enclosure that has three access doors, as shown above. The doors are named for a significant component located behind them, as follows:

A Fuel Inlet port (shown for reference) B Control Panel door C Exhaust opening (shown for reference) D Coolant Fill door E Battery door F Exhaust door (shown for reference)

WARNING

Contact with muffler area can result in serious burns.

DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

•

The Coolant Fill, Battery and Control Panel doors must be installed whenever the unit is running.

Each home generator is equipped with two identical keys. These keys fit the locks that secure the access doors.

To Open an Access Door:

1. Insert key into lock of access door handle you wish to open and turn one quarter turn counterclockwise. Remove key. Handle will remain unlocked until you relock it.

2. Grasp door’s handle and turn one quarter turn counterclockwise to open.

3. Coolant Fill door is unlocked in the same manner. It can be used for adding coolant or oil.

The Gaseous Fuel System

WARNING

Propane and Natural Gas are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

LP gas is heavier than air and will settle in low areas.

• Natural gas is lighter than air and will collect in high

• areas.

The slightest spark can ignite these fuels and cause an

• explosion.

DO NOT light a cigarette or smoke.

•

The information provided below is to assist gaseous fuel system technicians in planning installations. In no way should this information be interpreted to conflict with applicable fuel gas codes. Consult with your local fuel supplier or Fire Marshall if questions or problems arise.

TO THE INSTALLER: Consult with the home generator

owner(s) and convey any technical considerations that might affect their installation plans before applying these general guidelines.

The following general rules apply to gaseous fuel system piping:

• The piping should be of a material that conforms to federal and local codes, rigidly mounted and protected against vibration.

• Piping should be protected from physical damage where it passes through flower beds, shrub beds, and other cultivated areas where damage could occur.

To Close an Access Door:

1. Close door and turn handle one quarter turn clockwise.

2. Insert key into lock in handle and turn one quarter turn clockwise. Remove key.

10 BRIGGSandSTRATTON.COM

• Install the flexible, gaseous hose (supplied) between the home generator Fuel Inlet port and rigid piping to prevent thermal expansion or contraction from causing excessive stress on the piping material.

NOTE: Where local conditions include earthquake, tornado, unstable ground, or flood hazards, special consideration shall be given to increase strength and flexibility of piping supports and connections.

CAUTION

The supplied flexible gaseous pipe is not to be installed underground or in contact with the ground.

The entire flexible gaseous pipe must be visible for

• periodic inspection and must not be concealed within, contact, or run through any wall, floor, or partition.

• Piping must be of the correct size to maintain the required supply pressures and volume flow under varying generator load conditions with all gas appliances connected to the fuel system turned on and operating.

• Use a pipe sealant or joint compound approved for use with NG/LPG on all threaded fittings to reduce the possibility of leakage.

• Installed piping must be properly purged and leak tested, in accordance with applicable codes and standards.

WARNING

• Natural gas fuel supply pressure at the generator’s fuel inlet port should be between 7 to 11 inches of water (in. W.C.) at full load with all gas appliances turned on and operating.

The home generator unit has been factory set to run on natural gas. The unit can be converted from natural gas to LP gas or vice versa using two people and special tools. See Fuel Conversion, later in this manual.

It is recommended that the fuel connection incorporate the following components:

• A minimum 10 ft. (3 m) section of gas pipe between the primary fuel regulator and the generator fuel inlet connection (acts as accumulator for high block loads).

• A manual fuel shut-off valve located in the interior of the building.

• A manual fuel shut-off valve located outside the building, just before the generator unit.

• Where the formation of hydrates or ice is known to occur, piping should be protected against freezing. The termination of hard piping should include a sediment trap where condensate is not likely to freeze.

• A manometer port should be provided.

The manometer port permits temporary installation of a manometer to ensure that the engine receives the correct fuel pressure to operate efficiently throughout its operating range.

Propane and Natural Gas are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

Before placing the home generator into service, the fuel

• system lines must be properly purged and leak tested.

NO leakage is permitted.

•

Consider the following factors when planning to install the fuel supply system:

• A minimum of one accessible, approved manual shutoff valve shall be installed in the fuel supply line within 6 ft (1.8 m) of the home generator. A union or flanged connection shall be provided downstream from this valve to permit removal of controls.

• LP gas fuel supply pressure should be 7 to 11 inches of water (in. W.C.) at full load with all gas appliances turned on and operating.

NOTE: A digital manometer, P/N 19495, is available at your Briggs & Stratton service center.

When the initial test runs are completed, the manometer is removed and the port is plugged. A typical final fuel connection assembly is shown here, where (A) is the fuel supply and (B) goes to the home generator.

Fuel Consumption

Estimated fuel supply requirements at half and full load for natural gas and LP vapor fuels are shown below.

Natural Gas LP Vapor

1/2 Load Full Load 1/2 Load Full Load

27kW 259 C 420 C N/A N/A

Fuel Pipe Sizing

There are numerous on-line or otherwise-published references for fuel pipe sizing. The installer should consider the specific gravity of gas and compensate for a nominal amount of restriction from bends, fittings, etc. If an unusual number of fittings, bends, or other restrictions are used, please refer to federal and local codes.

259,000 B 420,000 B N/A N/A

30kW N/A N/A 92 C 150 C

N/A N/A 228,800 B 373,000 B

C = Cubic feet per hour B = BTU’s per hour

Physical Properties LP Vapor Natural

Gas

Normal Atmospheric State Gas Gas Boiling Point (in °F):

Initial End

Heating Value: BTU per gallon (Net LHV*) BTU per gallon (gross**) Cubic feet (gas)

Density*** 36.39 57.75 Weight† 4.24 2.65 Octane Number:

Research Motor

* LHV (Low Heat Value) is the more realistic rating. ** Gross heat value does not consider heat lost in the form of water

during combustion. *** Density is given in “Cubic Feet of Gas per Gallon of Liquid”. † Weight is given in “Pounds per Gallon of Liquid”.

-44

83,340 91,547

2,500

110+

-259

63,310

1,000

110+

12 BRIGGSandSTRATTON.COM

System Connectors

LV connections to signal fault contacts, transfer switch communication, remote LED and auxiliary 12VDC power are made to a removable ten-pin connector plug. Compare this illustration with your generator to familiarize yourself with the location of these important connections:

A - 10 Pole Connector Plug B - Fault Contacts — Use NO, COM and NC for operating a

siren, light, optional GenAlert, etc. to alert you in case of a fault. Contacts reverse state (NO goes to NC and vice versa) upon a fault condition.

C - Transfer Switch Communication — Connect to transfer

switch control board for communication interface.

D - Remote LED Output — Used to connect to the remote

LED supplied with the generator. The remote LED will turn on and off in a series of blinks if certain faults are detected in the generator.

E - +12 Volt DC, .5 Amp Output — Internal auxiliary power

supply.

Generator AC Connection System

10 A

240 VAC

120 V

240 V

A single-phase, three-wire AC connection system is used in the home generator. The stator assembly consists of a pair of stationary windings with two leads brought out of each winding. The junction of leads T2 and T3 forms the neutral lead, as shown schematically and as wiring diagram below. A complete schematic and wiring diagram can be found later in this manual.

NOTE: Neutral is not bonded to ground at generator.

Grounding the Generator

Ground the home generator per applicable codes, standards and regulations. There are two generator GND lug locations. The one inside the alternator junction box next to the circuit breaker is the primary lug and should meet most applications. The second generator GND lug is located on the frame below the generator circuit breaker cover, and should ONLY be used for a ground rod located at the generator, if required by local codes. See Controls for location.

Power Winding

Neutral

Utility Circuit Connection

“240V Utility” leads must be routed in conduit. The “240V Utility” leads deliver power to the generator’s circuit board and water heater. This power also charges the battery. When power on these leads is lost, the generator will start.

Using installer-supplied minimum 300V, 14 AWG copper wire, connect each ten-amp fuse terminal in the alternator junction box to the ten-amp fuse terminals in the automatic transfer switch.

Fault Detection System

The generator may have to run for long periods of time with no operator present. For that reason, the system is equipped with sensors that automatically shut down the generator in the event of potentially damaging conditions, such as low oil pressure, high water temperature, over speed, and other conditions. Refer to Fault Detection System in the Operator’s Manual for more detailed information.

The owner will use the remote LED indicator to observe the status of the home generator system. Consult with the owner for a convenient location. Locate the electrical box in an area visible by the home owner such as near a garage door opener or security control panel.

To Transfer Switch

Line 1

To install the remote LED indicator:

1. Push the LED through the mounting plate from the front until it snaps in place.

Circuit

Breaker

Line 2

IMPORTANT: The LED is polarity sensitive.

2. Using provided 10 pole connector and installer-supplied minimum 18AWG wire, connect the remote LED to the generator control board +LED and GND connection. Use wire nuts to attach wire to LED leads.

Ground

3. Attach mounting plate to installer-supplied electrical box.

To Transfer Switch

Connection

Utility Fuse

14 BRIGGSandSTRATTON.COM

Control

Board

Water

Heater

System Control Panel

The home generator control panel, located inside the generator housing, is shown below.

System Switch

This two-position switch is the most important control on the home generator and is used as follows:

• “AUTO” position is the normal operating position. If a utility power outage is sensed, the system will start the generator. When utility power is restored, lets the engine stabilize internal temperatures, shuts off the generator, and waits for the next utility power outage.

• “OFF” position turns off running generator, prevents unit from starting and resets any detected faults.

15 Amp Fuse

Protects the home generator DC control circuits. If the fuse has ‘blown’ (melted open) or was removed, the engine cannot crank or start. Replace the fuse using only an identical ATO 15A fuse. One spare fuse is supplied with the unit. If fuse was blown or removed, you will need to reset the exercise timer (see Setting Exercise Timer).

Final Installation Considerations

Engine Oil

Brief descriptions of the controls used during installation are: A Removable Panel — To assist with conduit connection. B Circuit Breaker — Must be ON to supply power to the

transfer switch.

C Set Exercise Switch — Used to set time of the exercise

cycle.

D Manual Over-Ride Switch — Used to manually start

and stop the generator. E 15 Amp Fuse — Protects the DC control circuits. F System Switch — Switches modes to OFF and AUTO. G Digital Display — Displays running time in hours, and

fault codes. More information may be found in Controls in the Operator’s

Manual.

NOTICE

Any attempt to crank or start the engine before it has been properly serviced with the recommended oil will result in equipment failure.

Refer to Maintenance and engine manual for oil fill

• information.

Damage to equipment resulting from failure to follow this

• instruction will void engine and generator warranty.

This engine is shipped from the factory pre-run and filled with non-synthetic oil (API SL 10W-30W). This allows for system operation in a wide range of temperature and climate conditions. Before starting the engine, check oil level and ensure that engine is serviced as described in the engine operator’s manual.

Coolant System

This engine is shipped from the factory filled with a 5050 mix of automotive (Dex-Cool™ orange) anti-freeze and water. This will provide optimum year round protection against freezing, boiling and corrosion. The coolant system incorporates a water heater that operates when ambient temperature is below 80ºF AND utility power is present at the transfer switch. Before starting the engine, check coolant level as described in the engine operator’s manual.

Battery

UNDER-FREQ.

ADJUST

STABILITY

ADJUST

VOLTAGE

ADJUST

The installer must supply a sealed, rechargeable 12 Volt DC, 650 Cold Cranking Amps (CCA) 55 amp hour starting battery. The battery may not be at full charge when installed. If battery voltage is below 12 Volts, charge the battery. See Battery in Maintenance for details.

NOTE: DO NOT use a deep-cycle type battery.

Fuel Supply System

Ensure that all fuel pipe connections are tight, secure and without leaks.

Ensure that all gas line shutoff valves are OPEN and that adequate fuel pressure is available whenever automatic operation is desired.

Initial Start-up (No Load)

Before operating the home generator or placing it into service, inspect the entire installation carefully.

Then begin testing the system without any electrical loads connected, as follows:

NOTE: Unit has been set-up for natural gas operation at the factory. Fuel conversion, if needed, must be completed prior to performing these steps.

1. Set generator’s main circuit breaker to its ON (closed)

position.

2. Confirm 15 Amp fuse is installed in control panel.

3. Set generator’s system switch to AUTO.

4. Push MANUAL OVER-RIDE button on control panel. NOTE: When the generator is started for the very first time, it

will require that air in the gaseous fuel lines be purged. This may take a few minutes.

5. DO NOT crank engine for more than 15 seconds, then pause for 15 seconds to reduce heat in the starter.

6. Repeat process until engine starts.

7. Listen for unusual noises, vibration or other indications of abnormal operation. Check for oil or coolant leaks while engine runs.

8. Let engine warm up for about five minutes to allow internal temperatures to stabilize.

9. Connect an accurate AC voltmeter and a frequency meter to check generator output at load side of circuit breaker. No-load voltage should be 239-244 Volts, frequency should be 59.8 - 60.2 Hz.

NOTE: If AC voltage is outside these ranges, perform the generator adjustment, Steps 13 and 14 below.

10. Check generator output between one of the generator connection lugs and the neutral lug, then between the other generator connection lug and the neutral lug. In both cases, voltage reading should be between 117-123 Volts.

11. Push and hold MANUAL OVER-RIDE button on control

panel again until engine stops.

IMPORTANT: DO NOT proceed until you are certain that generator AC voltage is correct and within the stated limits. Generator frequency is fixed and not adjustable

12. If voltage and frequency values are correct, proceed to step 15.

13. Connect voltmeter as described in step 9 above.

14. While observing voltmeter, adjust alternator voltage control (A) for 240 volts. DO NOT adjust either of the other alternator controls.

15. Install alternator circuit breaker enclosure cover.

16. Close all enclosure access doors.

Fuel Conversion

The unit is shipped from the factory calibrated for NG

operation. To convert the engine from NG to LP vapor operation, follow these steps:

1. Disconnect NEGATIVE battery cable from battery.

2. Set the generator’s main circuit breaker OFF.

3. Set the control panel System switch to OFF.

4. Install O2 sensor into exhaust manifold.

NOTE: Avoid leaving O2 sensor attached for lengthy period.

5. After purging fuel supply line, push MANUAL OVER- RIDE button on control panel. When the engine starts, allow it to warm up for a few minutes under no load.

6. Attach a timing light to engine. Loosen distributor hold-down clamp. While one person observes timing indicator, a second person adjusts distributor for 20º before top dead center. Tighten distributor holddown.

NOTE: If converting from LP to NG, use 32º before top dead center.

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7. While observing O2 Analyzer readout, adjust zero

pressure regulator [ZPR] (A) and main adjustment screw [MAS] (B) to obtain stoichiometric value shown in table below. Select table value that corresponds to your O2 measurement system. Shaded table line is target value.

A B

Voltage Phi Lamda

2.40 1.000 1.000

2.45 1.012 0.988

2.50 1.024 0.977

2.55 1.036 0.966

2.60 1.048 0.955

2.65 1.060 0.944

2.70 1.071 0.933

11. Set generator’s main circuit breaker ON (resume full load). Reverify sensor value remains in target area. Adjust MAS (B) as necessary.

12. Set generator’s main circuit breaker OFF (no load). Reverify sensor value remains in target area. Adjust ZPR (A) as necessary.

13. Set the generator’s main circuit breaker OFF.

14. Push and hold the MANUAL OVER-RIDE button on control panel. When the engine stops, allow it to cool for a few minutes before proceeding.

15. Remove O2 sensor from exhaust manifold and reinstall plug. Disconnect timing light from engine.

16. Complete emissions statement and send with installation checklist.

8. Set generator’s main circuit breaker ON.

9. Apply full load to generator. Adjust MAS (B) to achieve

target value. Clockwise rotation of MAS will cause airfuel mixture to become more lean.

10. Set generator’s main circuit breaker OFF (no load). Adjust ZPR (A) to achieve target value. Clockwise rotation of ZPR will cause mixture to become more rich. Make sure ZPR tower cap is reinstalled prior to final reading.

Schematic/ Wiring Diagram

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