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Briggs & Stratton
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040204
User Manual
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Briggs & Stratton 40204, 40229, 40210, 40213, 40234 User Manual

Installation and
Start-Up Manual
Manual de Instalación y
Arranque
Manuel d'Installation et
Démarrage
Questions? Help is just a moment away!
Preguntas? La ayuda es justa un momento lejos!
besoin d'aller loin pour trouver de l'aide!
Call: Home Generator Helpline
Llamada: Línea Directa de Generador de Hogar
Appelez: Ligne Directe de Génératrice la Maison
1-800-743-4115 M-F 8-5 CT
BRIGGSandSTRATTON.com
Manual No. 199327GS Rev. - (11/20/06)
Models / Modelos / Modèles
040204 040210 040212 040213 040229 040234
12000 / 15000
Home Generator System

REFERENCE
2

TABLE OF CONTENTS 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 the like. This product DOES NOT qualify for emergency standby as defined by NFPA 70 (NEC).
This manual contains installation, startup and adjustment instructions for a Home Generator System that supplies 120/240 Volt, single phase, 60Hz devices. The Home Generator System may be operated on LP or natural gas fuel. A separate operator’s manual (part number 194689GS) contains operating and maintenance instructions for this model.
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.

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 System, as specified in the Operator’s Manual.

INSTALLER RESPONSIBILITIES

• Read and observe the safety rules.
• Refer to the list of recommended UL approved transfer switches that is compatible with the Home Generator System elsewhere in the carton.
• Read and follow the instructions given in this Installation and Start-up Manual.
IMPORTANT: If operating the generator below 40°F, it is recommended that a battery and oil warmer be installed. If operating the generator below 32°F, a battery and oil warmer MUST be installed. Both items are available at your
local servicing dealer.
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
EQUIPMENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 2
CUSTOMER RESPONSIBILITIES . . . . . . . . . . . . . . . . . . . . . 2
INSTALLER RESPONSIBILITIES . . . . . . . . . . . . . . . . . . . . . 2
IMPORTANT SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . 3
Hazard Symbols and Meanings. . . . . . . . . . . . . . . . . . . 3
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unpacking Precautions . . . . . . . . . . . . . . . . . . . . . . . . 6
Delivery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shipment Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Required Specialty Tools/Equipment . . . . . . . . . . . . . . 6
Home Generator System Location . . . . . . . . . . . . . . 6-7
Fuel and Electrical Inlet Dimensions . . . . . . . . . . . . . . 7
Lifting the Generator . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
THE GASEOUS FUEL SYSTEM . . . . . . . . . . . . . . . . . . . 9-10
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuel Pipe Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SYSTEM CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Generator AC Connection System . . . . . . . . . . . . . . . 13
Grounding the Generator . . . . . . . . . . . . . . . . . . . . . . 13
Utility Control Circuit Connection . . . . . . . . . . . . . . . . 13
Fault Detection System . . . . . . . . . . . . . . . . . . . . . . . . 13
System Control Panel . . . . . . . . . . . . . . . . . . . . . . . . 14
BEFORE INITIAL ENGINE START-UP . . . . . . . . . . . . . . . . 14
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . 14-15
Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FUEL SYSTEM SELECTION. . . . . . . . . . . . . . . . . . . . . . 15-16
INITIAL START-UP (NO LOAD) . . . . . . . . . . . . . . . . . . . . . 16
Engine Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 16-17
AUTOMATIC OPERATION SEQUENCE . . . . . . . . . . . . . . . . 18
SETTING EXERCISE TIMER . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . 18
Fuel Comparison Chart . . . . . . . . . . . . . . . . . . . . . . . 19
Size of Propane Tank Required at Various Temperatures
When Kept at Least Half Full . . . . . . . . . . . . 19
Copyright © 2006 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.

SAFETY RULES

3
IMPORTANT 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.
Hazard Symbols and Meanings
SAVE THESE INSTRUCTIONS
Explosion
Fire
Electrical Shock
Rotating Parts
Hot Surface
Toxic Fumes
Chemical BurnExplosive PressureAuto Start
Lift Hazard
Read Manual
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
WARNING
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
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
Hazardous Voltage Contact with power lines can cause electric shock
or burn. Lifting Hazard / Heavy Object Can cause muscle strain or back injury.
• If lifting or hoisting equipment is used, DO NOT contact any power lines.
• DO NOT lift or move generator without assistance.
• Use lifting pipes as described in the section “Lifting the Generator” in installation manual.
• The unit may shift on the lifting pipes during movement, which can cause injury.
• DO NOT lift unit by roof as damage to generator will occur.
SAFETY RULES
4
WARNING
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 System 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
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 use generator with electrical cords which are worn, frayed, bare or otherwise damaged.
• 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 System, 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 System 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, remove the service disconnect from the disconnect box AND remove the 15 Amp fuse BEFORE working on the equipment.
WARNING
Contact with muffler area can result in serious burns.
Exhaust heat/gases can ignite combustibles or structures causing a fire.
• DONOT 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.
• Keep at least 3 ft. (91 cm) clearance on all sides of generator including overhead.
• 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.
SAFETY RULES
5
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
Improper treatment of generator can damage it and shorten its life.
• Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation.
• 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, and so forth.
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
Installing the 15A fuse could cause the engine to start.
• Observe that the 15 Amp fuse has been removed from the control panel for shipping.
• DO NOT install this fuse until all plumbing and wiring has been completed and inspected.
INSTALLATION
6
INSTALLATION
Unpacking Precautions
The unit is shipped bolted to its mounting pad, ready for installation. Avoid damage from dropping, bumping, collision, etc. Store and unpack carton with the proper side up, as noted on the shipping carton.
Delivery Inspection
After removing the carton, carefully inspect the Home Generator System 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 System
• Pre-attached mounting pad
• One flexible hook-up hose
• This installation and start-up manual
• Operator’s manual
• Illustrated parts list manual
• Installation checklist
• Two access door keys
• Four lifting hole plugs
• Oil fill spout
• One spare 15A fuse
• 2 Pole connector - 240V from house
• 10 Pole connector - Sensing and control wires
• Air intake engine cover
• Alternator cover
• Diagnostic LED kit (red LED/plate/screws (2))
Required Specialty Tools/Equipment
• Two 48” lengths of 1” pipe (NOT conduit)
• Hole punches for 16ga steel
• Torque screwdriver, 5 to 50 inch-pound range
Home Generator System Location
Before installing generator, consult with homeowner and convey the following guidelines which may affect the desired location.
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 (Figure 1). Prevailing winds and air currents should be taken into consideration when positioning generator.
Figure 1 — Home Generator System Location
Exhaust Port
WARNING
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
Exhaust heat/gases 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.
• Keep at least 3 ft. (91 cm) clearance on all sides of generator including overhead.
CAUTION
Installing the 15A fuse could cause the engine to start.
• Observe that the 15 Amp fuse has been removed from the control panel for shipping.
• DO NOT install this fuse until all plumbing and wiring has been completed and inspected.
INSTALLATION
7
General Location Guidelines
• Install the unit outdoors ONLY.
• Place the unit in a prepared location that is flat 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 our 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.
• Install the generator as close as possible to the Transfer Switch to reduce the length of wiring and conduit.
• Install the generator as close as possible to the fuel supply to reduce length of pipes.
IMPORTANT: Laws or local codes may regulate the distance to the fuel supply.
The Home Generator System is shipped already attached to its mounting pad. Unless mandated by local code, a concrete slab is not required.
If mandated by local code, construct a concrete slab at least 3 inches thick and 6 inches longer and wider than the unit.
Attach unit to slab with 1/4” diameter (minimum) masonry anchor bolts long enough to retain the unit.
Fuel and Electrical Inlet Dimensions
Figure 2, below, depicts the location of the fuel piping connector. Also shown is the recommended location for punching holes for attaching the power conduit.
Lifting the Generator
The generator weighs more than 530 pounds. Proper tools, equipment and qualified personnel should be used in all phases of handling and moving the generator.
Figure 2 — Generator Fuel and Conduit Attachment Locations, Oil Fill Side of Unit
3/4” NPT
Fuel Piping
Connector
Recommended
Conduit Attachment
Area
WARNING
Hazardous Voltage Contact with power lines can cause electric shock
or burn. Lifting Hazard / Heavy Object Can cause muscle strain or back injury.
• If lifting or hoisting equipment is used, DO NOT contact any power lines.
• DO NOT lift or move generator without assistance.
• Use lifting pipes as described in the section “Lifting the Generator” in installation manual.
• The unit may shift on the lifting pipes during movement, which can cause injury.
• DO NOT lift unit by roof as damage to generator will occur.
INSTALLATION
8
Two 48” lengths of 1” pipe (supplied by the installer) are required to lift the generator manually. Insert pipes through the lifting holes located near the unit’s base, as shown in Figure 3.
You may also lift the unit using a “hook and hoist” method attached to the lifting pipes, provided that you use a spreader bar to ensure that the chains or cables do not touch the generator’s roof.
After unit is in place, fill the lifting holes with the supplied lifting hole plugs.
Access Doors
The Home Generator System is equipped with an enclosure that has three access doors (Figure 4). The doors are named for a significant component located behind them. Starting with the side that has the fuel connection and proceeding clockwise, the doors are named:
• Oil Fill door
• Control Panel door
• Oil Drain door
Each Home Generator System 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 you wish to open and turn one quarter turn counterclockwise.
2. Grasp door’s handle and turn one quarter turn counterclockwise to open. Remove key.
To lift: Insert
pipe here
Installer-supplied pipe
Figure 3 — Location of Lifting Holes
Oil Fill Door
Fuel Inlet
Exhaust
Port
Control Panel Door
Oil Drain Door
Exhaust Bulkhead
Figure 4 — Enclosure Access Doors
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.
INSTALLATION
9
To Close an Access Door:
1. Close door and turn doors handle one quarter of a turn clockwise.
2. Insert key into lock of access door and turn one quarter turn clockwise. Remove key.
THE GASEOUS FUEL SYSTEM
TO THE INSTALLER: Consult with the Home Generator
System 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.
• Install the flexible, gaseous hose (supplied) between the Home Generator System 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.
• 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 an approved pipe sealant or joint compound 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.
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.
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.
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.
WARNING
Propane and Natural Gas are extremely flammable and explosive.
Fire or explosion can cause severe burns or death.
• Before placing the Home Generator System into service, the fuel system lines must be properly purged and leak tested.
• NO leakage is permitted.
INSTALLATION
10
Consider the following factors when planning to install the fuel supply system:
The Home Generator System engine is fitted with a fuel mixer system that meets the specifications of the California Air Resources Board for “tamper-proof” dual fuel systems. The unit will run on natural gas or liquefied propane (LP) vapor.
• 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 System. A union or flanged connection shall be provided downstream from this valve to permit removal of controls.
• Natural gas fuel supply pressure at the generator's fuel inlet port should be between 5 to 7 inches of water (in. W.C.) at full load. LP fuel supply pressure should be 11 to 14 inches of water (in. W.C.) at full load with all gas appliances turned on and operating.
The Home Generator System unit has been factory set to run on natural gas. If you need to change from natural gas
to LP gas, the unit will need to be reconfigured, as described on page 13.
It is recommended that the fuel connection incorporate the following components:
• 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 (Figure 5), to ensure that the engine receives the correct fuel pressure to operate efficiently throughout its operating range.
NOTE: A digital manometer, P/N 19495, is available at your local 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 in Figure 6.
Figure 6 — Completed Fuel Connections
Figure 5 — Temporary Manometer Installed
From Fuel
Supply Line
To Home Generator
System
INSTALLATION
11
Fuel Consumption
See Figure 7 for estimated fuel supply requirements at half and full load for both natural gas and LP vapor.
Fuel Pipe Sizing
Figures 8 and 9 provide the maximum capacity of pipe in cubic feet of gas per hour for gas pressures of 0.5 psi or less and a pressure drop of 0.3 in. water column. Specific gravity of gas is shown.
Listed values 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.
Natural Gas* LP Vapor**
1/2 Load Full Load 1/2 Load Full Load 12kW 102 195 41 79 15kW 140 218 66 96
* = Natural Gas is in cubic feet per hour ** = LP Vapor is in cubic feet per hour
Figure 7 — Fuel Supply Requirements
NPT 10ft 15ft 20ft 30ft 40ft 50ft 60ft 70ft 80ft 90ft 100ft
3/4” 346 293 240 192 163 145 132 120 113 106 99
1” 653 549 446 360 307 274 250 230 211 197 187
Natural Gas (sg=0.65)
NPT 10ft 15ft 20ft 30ft 40ft 50ft 60ft 70ft 80ft 90ft 100ft
3/4” 277 192 158 126 107 95 87 79 74 69 65
1” 428 360 293 236 202 180 164 151 139 129 123
Liquid Propane (LP) (sg=1.50)
Figure 8 — NATURAL GAS (NG) Pipe Size - Gas Flow Chart, in cubic feet per hour
Figure 9 — LIQUID PROPANE (LP) GAS Pipe Size - Gas Flow Chart, in cubic feet per hour
FEATURES AND CONTROLS
12
SYSTEM CONNECTIONS
Compare this illustration with your generator to familiarize yourself with the location of these important connections:
+12 Volt DC, .5 Amp Output
240 Volt Utility
Wiring for the 2 Pole Connector: 240 Volt Utility — Use to hook up the 240V utility leads from
the transfer switch to the generator.
Wiring for the 10 Pole Connector: Fault Contacts — Use NO, COM and NC to hook up a siren,
light, etc. to alert you in case of a fault. Contacts reverse state upon a fault condition.
Remote LED Output — Use this to hook up 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.
Transfer Switch Communication — Use TxRx and TxRx GND to transfer switch and optional wireless StatStation™ to monitor generator functions.
+12 Volt DC, .5 Amp Output — Internal power supply.
Remote LED Output
Transfer Switch Communication
Fault Contacts
10 Pole Connector
2 Pole Connector
INSTALLATION
13
Generator AC Connection System
A single-phase, three-wire AC connection system is used in the Home Generator System. The stator assembly consists of a pair of stationary windings with two leads brought out of each winding. The junction of leads 22 and 33 forms the neutral lead, as shown schematically and as wiring diagram in Figure 10. A complete schematic and wiring diagram can be found in the illustrated parts list manual.
NOTE: Neutral is not bonded to ground at generator.

Grounding the Generator

Ground the Home Generator System per applicable codes, standards, and regulations. The generator GND lug is located inside the control panel door under the circuit breaker cover.
Utility Circuit Connection
"240V Utility" leads must be routed in conduit. Functions are briefly described as follows:
• "240V Utility" delivers power to the generator’s circuit board, optional battery and oil warmer, charge the battery and when utility is lost the generator will start.
Using provided 2 pole connector and installer-supplied minimum 300V, 14 AWG copper wire, connect each control circuit terminal in the generator to the Automatic Transfer Switch.
Fault Detection System
The generator's control panel has a digital display to show fault codes. It will display a fault code if certain faults are detected in the HGS. An extra LED and mounting plate is supplied so that it can be installed at a convenient indoor location. It will turn on and off in a series of blinks if certain faults are detected in the HGS. The owner will use it to observe the status of the HGS. Consult with the owner for a convenient location.
To install the remote LED panel:
• Push the LED through the mounting plate from the front until it snaps in place.
• Using provided 10 pole connector and installer-supplied minimum 18 AWG wire, connect the remote LED to the generator control board. Use wire nuts to attach wire to LED leads.
IMPORTANT: The LED is polarity sensitive.
• Attach mounting plate to installer-supplied electrical box.
Refer to the section “Fault Detection System” in the Operator’s Manual for operation.
Figure 10 — System AC Connections
INSTALLATION
14
System Control Panel
Figure 11 depicts the Home Generator System control panel, located inside the generator housing. Below are brief descriptions of the controls used during installation. More information may be found in the Operator’s Manual.
System Switch
This two-position switch is the most important control on the system 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 System 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.
BEFORE INITIAL START-UP

Engine Oil

This engine is shipped from the factory filled with the recommended oil. Before starting the engine, check oil level and ensure that engine is serviced as described in the engine operator’s manual.
Oil Considerations
Your Home Generator System is equipped with an engine that has been pre-run at the factory.
The system is filled with synthetic oil (API SJ/CF 5W-30W). This allows for system operation in the widest range of temperature and climate conditions.
NOTE: The use of synthetic oil DOES NOT alter the required oil change intervals described in the engine operator’s manual.

Battery Connection

The Home Generator System is supplied with a 12 Volt DC, AGM type, 55 Amp-Hour, valve regulated battery. It is a sealed, lead-acid rechargeable battery. It is installed in the unit and the battery cables are connected at the factory. The unit’s 15 Amp fuse, which isolates the battery and prevents the unit from starting, has been removed for shipping. The battery will lose some charge charge prior to installation of the generator. If battery voltage is below 12 Volts, charge the battery.
IMPORTANT: If battery voltage is below 5 Volts, it may not take a charge and you will need a new battery.
Charging the Battery
If it is necessary to charge the battery, proceed as follows:
1. Set generator's system switch to OFF.
2. Remove 15 Amp fuse from control panel.
3. Disconnect negative battery cable to negative battery
terminal (indicated by NEGATIVE, NEG, or (-).
4. Charge battery with battery charger at 2 Amps until
battery holds 12 Volts.
NOTE: DO NOT exceed 13.7 Volts charging.
Manual Over-Ride
Switch
Set Exercise
Switch
System Switch
Digital Display
15 Amp Fuse
Service Tool
Circuit
Breaker
Figure 11 — Home Generator System Control Panel
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 engine manual for oil fill information.
• Damage to equipment resulting from failure to follow this instruction will void warranty.
NOTICE
Failure to disconnect negative battery cable will result in equipment failure.
• DO NOT attempt to jump start the battery.
• Damage to equipment resulting from failure to follow this instruction will void warranty.
INSTALLATION
15
NOTE: With the battery installed and utility power available to
the Automatic Transfer Switch, the battery receives a trickle charge whenever the engine is not running. This process may take up to 72 hours to fully charge a battery from 5 Volts. The trickle charge cannot be used to recharge a battery that is completely discharged.
5. Connect negative battery cable to negative battery terminal
(indicated by NEGATIVE, NEG, or (-)).
6. Ensure hardware on both positive and negative battery terminals is secure.
7. Reinstall 15 Amp fuse in control panel.
8. Set generator's system switch to AUTO.
Servicing the Battery
If it is necessary to service the battery, proceed as follows:
1. Open “Control Panel” access door.
2. Set generator's system switch to OFF.
3. Remove 15 Amp fuse from control panel.
4. Service or replace battery as required.
5. Connect red battery cable to battery positive terminal (indicated by POSITIVE, POS, or (+)).
6. Connect negative battery cable to negative battery terminal
(indicated by NEGATIVE, NEG, or (-).
7. Ensure hardware on both positive and negative battery terminals is secure.
8. Reinstall 15 Amp fuse in control panel.
9. Set generator's system switch to AUTO.
10. Close “Control Panel” access door.
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.
FUEL SYSTEM SELECTION
The engine of your Home Generator System is factory calibrated to run on natural gas (NG). It may also be operated on liquefied petroleum (LP) vapor. There is no additional hardware/equipment required to switch between either fuel. However, LP fuel inlet pressure must be between 11 and 14 inches water column.
To configure the fuel system for LP use:
1. Open control panel and oil fill access doors.
2. Set generator's system switch to OFF.
3. Remove 15 Amp fuse from control panel.
For a 12kW Home Generator System:
4. Connect the fuel select solenoid by joining the two-pin electrical connector shown in Figure 12.
5. Reinstall 15 Amp fuse in control panel.
6. Set generator's system switch to AUTO.
7. Close control panel and oil fill access doors.
The system is now ready to operate automatically using LP fuel. With a fixed main jet for LP gas, there is no need to perform any engine adjustments for LP operation.
Figure 12 — Fuel Select Solenoid Connection
Push two
connectors together
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.
CAUTION
Installing the 15A fuse could cause the engine to start.
• DO NOT install this fuse until all plumbing and wiring has been completed and inspected.
INSTALLATION
16
For a 15kW Home Generator System:
4. Remove cap from LP inlet on T-valve.
5. Remove fuel line from NG inlet.
6. Place cap from LP inlet onto NG inlet.
7. From oil fill access area, pull fuel line out of top hole and route it through bottom hole.
IMPORTANT: Failure to route fuel line through bottom hole may cause the fuel line to kink. When tightening fuel hose fittings make certain the fuel hose does not twist or kink. If the fuel line kinks, the generator may start but will not operate properly.
8. Connect fuel line to LP inlet (Figure 13).
9. Reinstall 15 Amp fuse in control panel.
10. Set generator's system switch to AUTO.
11. Close control panel and oil fill access doors.
The system is now ready to operate automatically using LP fuel.
INITIAL START-UP (NO LOAD)
Begin testing the system without any electrical loads connected, as follows:
1. Set generator’s main circuit breaker to its ON (closed) position.
2. Install 15 Amp fuse in control panel.
3. Set generator’s system switch to AUTO.
4. Push MANUAL OVER-RIDE switch on control panel.
NOTE: When the Home Generator System 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 10 seconds, then pause for 10 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 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. Voltage should be 239-262 Volts, frequency should be
62.0 - 62.5 Hz.
NOTE: If either parameter is outside these ranges, perform the Engine Adjustments described 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 121-131 Volts.
11. Push and hold MANUAL OVER-RIDE switch on control panel again until engine stops.
IMPORTANT: DO NOT proceed until you are certain that generator AC voltage and frequency are correct and within the stated limits. To obtain the proper generator frequency, see Engine Adjustments.
Engine Adjustment
There are regional variances in the composition of natural gas. Each HGS unit is adjusted at the factory for NG operation. If the generator output voltage or frequency measured during Initial Start-Up (paragraph #9) is outside the listed ranges, the combustibility of the gas supplied at the installation site may be substantially different.
To adjust the engine for this difference, proceed as follows.
1. Open the oil drain and control panel access doors.
2. Remove the four screws that hold the circuit breaker cover to the air intake guard (Figure 14).
Figure 14 — Accessing Back of Circuit Breaker
Figure 13 — T - Valve
INSTALLATION
17
3. Connect an accurate frequency meter to the line side of the generator’s main circuit breaker.
4. Ensure that the 15 Amp fuse is installed.
5. Set the generator’s main circuit breaker ON.
6. Set the generator’s system switch to AUTO.
7. Push MANUAL OVER-RIDE switch on control panel. When the engine starts, allow it to warm up for five minutes.
8A. For a 12kW generator, normal no load frequency is 62.0
to 62.5 Hz. If adjustment is needed at no load, slowly rotate the governor adjustment nut (Figure 15) clockwise and/or counterclockwise until frequency is 62.0 to
62.5 Hz.
8B. For a 15kW generator, normal no load frequency is 62.0
to 62.5 Hz. If adjustment is needed at no load, slowly rotate the governor adjustment screw (Figure 16) clockwise and/or counterclockwise until frequency is
62.0 to 62.5 Hz.
9. Push and hold MANUAL OVER-RIDE switch on control panel again until engine stops.
10. Turn the service disconnect to the transfer switch off. After a short time delay, the transfer switch will connect to the generator.
11. Load generator to full load.
12. Connect an accurate frequency meter to the load side of the generator’s main circuit breaker. Frequency should be above 57.0 Hz.
13. If frequency is below 57.0 Hz, slowly rotate the governor adjustment nut or screw clockwise and/or counterclockwise until frequency is above 57.0 Hz.
14. Turn the service disconnect to the transfer switch on. The transfer switch will connect to the utility after five minutes.
15. After the engine has stopped running,
• If an adjustment was made in step 13, repeat steps
3 through 9.
• If an adjustment was not made in step 13, proceed
to step 16.
IMPORTANT: If the no load frequency falls out of the no load parameter after full load adjustment is made, contact an authorized service center.
16. Reinstall the circuit breaker cover to the air intake guard.
17. Close the oil drain and control panel access doors.
Figure 15 — Governor Adjustment Nut
Governor Adjustment Nut
Figure 16 — Governor Adjustment Screw
Governor Adjustment Screw
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