DANGER: Not intended for use in critical life support application. REV 100237-20180314 DANGER: Generator must be installed and operated outdoors only.
CALIFORNIA PROPOSITION 65 WARNING Certain components in this product and its related accessories contain chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. Wash hands after handling. CALIFORNIA PROPOSITION 65 WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
Model 100237 CONTENTS CONTENTS INTRODUCTION ............................................................ 5 Home Standby Generator ............................................ 5 HSB Models ............................................................... 6 Standard Features, Tailor-Made Solutions ..................... 6 SAFETY ........................................................................ 8 General Information, Standards and Codes ................... 7 Safety Symbol Definitions .....................
Model 100237 CONTENTS Checking Automatic Operation................................... 44 Customer Familiarization Summary ............................ 45 HSB, ATS model & Serial Reference ATS Back-up Circuits ....................................................... 46 Automatic Transfer Switch (ATS) Service Entrance Models .................................................................... 47 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Location and Mounting . . . . .
Model 100237 INTRODUCTION Congratulations on your purchase of a Champion Power Equipment (CPE) home standby generator. This generator is designed and engineered in the USA to exacting standards of the North American market. This engine-powered generator meets all Environmental Protection Agency (EPA) Phase 3 requirements and is approved by CETLUS as tested to UL2200 and CSA22.2 No. 100 in both the USA and Canada. With proper use and maintenance, this generator will provide years of satisfying service.
Model 100237 INTRODUCTION HSB MODELS 100237 14kW HSB Generator Only 100949 ATS Only 100A NEMA 1 (non-pre-wired switch) 100952 ATS Only 100A NEMA 3R (non-pre-wired switch) 100295 14kW HSB & 100A ATS NEMA 1 (non-pre-wired switch) 100292 14kW HSB & 100A ATS NEMA 3R (non-pre-wired switch) STANDARD FEATURES, TAILOR-MADE SOLUTIONS : Tested and approved by CARB, EPA and UL in both USA and Canada : HSB Designed and Engineered in the USA by Champion : Milwaukee Series Engine, Designed and Engineered in USA by Cham
Model 100237 INTRODUCTION GENERAL INFORMATION, STANDARDS AND CODES The following information related to General Information and Standards was gathered from the list of publications related to installing the HSB generator. A multitude of other materials related to generators were also used concerning common practice, knowledgeable installation practices, certified electrical experience and work related experiences.
Model 100237 SAFETY ! This is the safety alert symbol. It is used to alert you to potential physical injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. SAFETY SYMBOL DEFINITIONS Black hazard pictorial on yellow equilateral triangle enclosed by black triangular band The words DANGER, WARNING, CAUTION and NOTICE are used throughout this manual to highlight important information.
Model 100237 SAFETY INSTALLATION HAZARDS Explosion hazard Burn hazard ! ! WARNING Have only a qualified electrician or installation technician who is familiar with applicable codes, standards 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.
Model 100237 SAFETY BEFORE STARTING ! CAUTION Before starting, operating and maintaining this generator, be sure to read and understand the content and safety messages in this manual. The operator is responsible for safe operation and maintenance of the generator. Be sure all potential users of the generator also understand these instructions. If any portion of this manual is not understood, contact your dealer for assistance before operating the generator.
Model 100237 SAFETY ACCIDENTAL STARTING CARBON MONOXIDE HAZARDS WARNING ! ! ALWAYS prevent the generator from starting while the covers are open. The generator may crank and start at any time without notice. Follow these steps in order: 1. Turn the exercise switch to the OFF position. 2. Switch the main circuit breaker to the OFF position. 3. Turn the ATS control module to the OFF position. 4. Turn the engine control module switch to the OFF position. 5.
Model 100237 SAFETY Carbon monoxide poisoning is possible if someone is experiencing any of these symptoms. Seek fresh air immediately. DO NOT sit, lie down or fall asleep. Alert others to the possibility of carbon monoxide poisoning. If the affected person does not improve within minutes of breathing fresh air, call 911 immediately. ELECTRICAL SHOCK HAZARDS ! WARNING Use extreme caution when near the generator while it is operating. The generator produces dangerous voltage.
Model 100237 SAFETY BURN HAZARDS ! ! 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 allow hot surfaces to cool to the touch. Running engines produce heat. Severe burns can occur on contact. • DO NOT touch hot surfaces. Always wear protective glasses or goggles and protective clothing when working with batteries.
Model 100237 SAFETY SAFETY LABELS ON UNIT ! ! 1 Poisonous Gas Hazard Generator exhaust contains carbon monoxide. Breathing carbon monoxide will cause nausea, dizziness, and fainting, and it may cause death. ! Risque d’empoisonnement par le gaz Les gaz d’échappement de groupe électrogène contiennent du monoxyde de carbone. Si l’on respire du monoxyde de carbone, ceci peut provoquer des nausées, un évanouissement et une perte de conscience, et ceci peut provoquer la mort.
Model 100237 SAFETY SAFETY, SERIAL/MODEL, NAMEPLATE LABEL LOCATIONS The safety labels have specific placement and must be replaced if they are unreadable, damaged or missing. 4 1 ! (inner part of cover) 3 2 5 C A B 6 A) Serial number location B) Nameplate C) NFPA 37 Compliance Part No.
Model 100237 SAFETY PLACEMENT & INSTALLATION GUIDELINES FOR CHAMPION 14KW HOME STANDBY GENERATOR TO REDUCE THE RISK OF FIRE NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) STANDARD NFPA 37 REQUIREMENTS AND TESTING REQUIREMENTS: NFPA 37 2010, section 4.1.4, Engines Located Outdoors. Engines, and their weatherproof housings if provided, that are installed outdoors shall be located at least 1.5 m (5 ft.) from openings in walls and at least 1.5 m (5 ft.) from structures having combustible walls.
Model 100237 SAFETY INTERTEK GROUP PLC LABEL ID: 170800364HZH-001 Conforms to / Conforme à: NFPA 37 4.1.4 CL.
Model 100237 SPECIFICATIONS Home standby generator Maximum continuous power, LPG 14 kW Maximum continuous power, NG 12.5 kW Rated voltage 120/240 Amps Harmonic distortion 116.6/58.3 LPG, 104/52 NG Less than 5% Main line circuit breaker 65 amp Phase Single Frequency 60 Hz Unit weight 446.4 lb. (202.5 kg) Size (L x W x H) 49 x 28 x 28 in. (124.5 x 71 x 71 cm) Engine Type No.
Model 100237 SPECIFICATIONS CHAMPION 754CC ENGINE The 754cc engine was developed by Champion Engine Technology for use in Champion home standby generators. The V-Twin cylinder design provides high output, efficient operation, low maintenance and demonstrated long life. Based on the engine’s power, performance and reliability, it was selected to power the 14kW Champion Home Standby Generator. This engine design has been used in production since 2015.
Model 100237 SPECIFICATIONS ALTERNATOR OVERVIEW The alternator is made up with the following major components; 1. Brush holder assembly 2. Rear bearing carrier 3. 2 pole rotor (all copper wire) 4. Stator assembly (all copper wire) 5. Engine adapter ROTOR ASSEMBLY The alternator has a 2-pole rotor, which means the rotor has a single south magnetic pole and a single north magnetic pole.
Model 100237 UNPACKING UNPACKING ! WARNING The generator weighs more than 400 lb. (181 kg). Use the aid of additional assistants and exercise caution during installation. Inspect the generator for damaged or loose parts. DO NOT operate the generator if any components are damaged or loose. Contact your dealer for assistance. 1. Cut banding straps 2. Remove top lid 3. Remove center cardboard supporting rib 4. Lift cardboard housing and set aside with all other trash 5.
Model 100237 INSTALLATION GENERATOR SIZING Proper sizing is crucial to ensure that you purchase a model that will supply enough power to your home during a power outage. You need to determine the extent of the devices and appliances you need to power. Remember that when you have lost power (utility) at your home, you probably will not run every device or appliance. Understanding that each device or appliance has an electric consumption value generally referenced to as wattage or kilowatts.
Model 100237 INSTALLATION ponding or water sprinklers will not flood the unit or spray the enclosure entering any inlet or outlet opens. Position the unit in an area where prevailing winds will carry the exhaust gas away from any potentially occupied building or structure. Install the unit where leaves, grass, snow, etc., will not obstruct air inlet and outlet openings.
Model 100237 INSTALLATION Contact your natural gas (NG) supplier about the meter size. Most meters must be replaced with a larger BTU size, due to a larger demand of BTU’s from the HSB and appliances during operation (utility outage). This also applies to HSB utilizing LPG. PLACEMENT The Site Selection has been completed, all federal, state and local codes have been reviewed and applied as mandated by the NFPA standards and all other related codes/standards.
Model 100237 INSTALLATION Once the HSB has been placed, check to make sure it is level. If it isn’t, make adjustments prior to installation procedures start. ! CAUTION The HSB is shipped without oil in the engine. Add oil to full capacity as stated in the specification section before starting the HSB. Never operate the HSB with the engine oil level below the “ADD” mark on the dipstick, doing so could damage the engine.
Model 100237 INSTALLATION ! Nominal Fuel Rating DANGER Gaseous fuels such as NG and LPG are highly explosive. Even the slightest spark can ignite such fuels and cause an explosion, which could cause burns, fire or explosion resulting in serious injury, property damage or even death. NO leakage is permitted. Recommended fuels should have a BTU content of at least 1,000 BTU’s per cubic foot for NG, or at least 2,500 Btu’s per cubic foot for LPG. Ask the fuel supplier for the Btu content of the fuel.
Model 100237 INSTALLATION Always use AGA approved gas pipe and a quality pipe sealant or joint compound. The piping should conform to federal and local codes, rigidly mounted and protected from vibration. Piping should be black iron or steel to avoid reacting with the sulfur in the fuel. ! DANGER NG is highly explosive. Even the slightest spark can ignite and cause an explosion, which could cause burns, fire or explosion resulting in serious injury, property damage or even death.
Model 100237 INSTALLATION *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. 4. LPG VAPOR PIPE SIZING The HSB leaves the factory set up for NG. If you are going to fuel the HSB with LPG you MUST change the Master Mixer Assembly (carburetor system) for LPG usage. The HSB will not perform on LPG if the carburetor system is not changed from NG to LPG.
Model 100237 INSTALLATION CAUTION ! Check for leaks by spraying all connection points with a soap solution made of dish washing soap and water. If you see soap bubbles, this would be an indication of a leak and it should be corrected. Check each connection point, there should not be a visible bubbling with the soap solution applied. Refer to the “Fuel Pipe Sizing Chart” contained in this manual or the Installation Manual for your specific HSB model.
Model 100237 INSTALLATION 4. 5. Install LPG jets and gasket (6) to fuel inlet chamber. Left side main jet: Size #410 (11) Right side main jet: #430 (12) Left side slow jet: Size #130* (13) Right side slow jet: #120* (14) Main Jet Tightening Torque: 34.7 lb.-in (3.92Nm) Slow Jet Tightening Torque: 17.3 lb.-in (1.96Nm) *No slow jet required for NG. 6. FULL FUEL SHUT OFF A minimum of one accessible, approved manual full fuel shutoff valve shall be installed in the fuel supply line of the HSB.
Model 100237 INSTALLATION 8. CHECKING PRESSURE WITH A MANOMETER Champion HSB units have been run and tested at the factory. They do not require any type of break-in period. This check should only be done when the HSB and ATS have been installed, properly inspected and ready for testing. 9. BATTERY REQUIREMENTS, INSTALLATION & SERVICE A Manometer is a general term for any device that measures pressure. A gas Manometer measures gas pressure.
Model 100237 INSTALLATION 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 °F. Also the correct batteries must have lug terminals to match lug battery cables, for a bolt-together connection. All cautions must be taken in accordance with the battery manufacturers recommendations.
Model 100237 INSTALLATION ! CAUTION Do not dispose of battery or batteries 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 removed.
Model 100237 INSTALLATION 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. IDENTIFY/SELECT STANDBY CIRCUITS All power cables must enter the enclosure through the knockouts provided. If not using knockouts, conduit entry into the enclosure must be at or below knockouts to maintain the Type 3R rating.
Model 100237 INSTALLATION 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 scheduled maintenance intervals. Refer to the scheduled maintenance chart in your Owner’s Manual for specific maintenance. The hour meter can’t be reset.
Model 100237 INSTALLATION of the generator increases or decreases accordingly. The AVR calculates how much voltage has to be sent to exciter numerous times a second, therefore stabilizing the output voltage to a predetermined set point. SLOTTED POTENTIOMETER is factory set to the correct voltage and should not require adjustment. There are 3 connectors that come from the AVR. For reference we have numbered them 1, 2 and 3 when viewed right to left.
Model 100237 INSTALLATION 3. Position #3 ATS O (ORANGE) 4. Position #4 Exercise O/B (ORANGE/BLACK) 5. Position #5 High Engine Temp Br (BROWN) 6. Position #6 Low oil level/ pressure Y (YELLOW) 7. Position #7 NOT CONNECTED EMPTY 8. Position #8 Fuel supply valve G/B (GREEN/BLACK) Starter B/W (BLACK/WHITE) 10. Position #10 Stop L/B (BLUE/BLACK) 11. Position #11 B+ W (WHITE) 12. Position #12 B- G (GREEN) 9.
Model 100237 INSTALLATION ATS POSITION – In this position the system is ready for full automatic operation. the battery voltage rises above 21.1 volts, the LED will turn off. Battery voltage is NOT monitored when the engine is cranking, just when the engine is running. If the RED LED comes on it will not shut the HSB off, it will remain lit until the battery condition meets the required output. 1.
Model 100237 INSTALLATION 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 the FULL mark, if necessary, add oil. DO NOT overfill. Inspect the unit for a possible oil leak, if a leak is discovered, contact Champion or your nearest Authorized Champion Dealer.
Model 100237 INSTALLATION 2. Pin 2 B- G (Green) 3. Pin 3 Motor start signal B/W (Black/White) 4. Pin 4 Fuel valve 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/ Pressure Y (Yellow) 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.
Model 100237 INSTALLATION 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 line breaker is turned “OFF”) or if a Utility power source failure occurs, NO LEDs will be lit if the ATS Control Module is in the “OFF” position.
Model 100237 INSTALLATION POWER ALIMENTATION POTENCIA RECOGNIZED COMPONENT NO CHARGE / PAS DE CHARGE / SIN CARGA E. O. AUTOMATIC BATTERY CHARGER / CHARGE AUTOMATIQUE DE BATTERIE / CARGADOR DE BATERÍA AUTOMÁTICO Conforms to UL Std. 1236 MODEL / MODÈLE / MODELO : 100482 Power: 80-125 Vac 1.0 A 50 / 60 Hz Output: 24 Vdc 1.6 A Alimentation : 80-125 V c.a. 1,0 A 50 / 60 Hz Sortie : 24 V c.c. 1,6 A Potencia: 80 - 125 V C.A. 1,0 A 50 / 60 Hz Producción: 24 V C.C.
Model 100237 INSTALLATION HSB TEST 7. Set the ATS module in the test mode. 8. Set the Engine Control Module in the MANUAL mode. The HSB will crank and start. Let the HSB warm up at no load for 5 minutes to stabilize performance. 9. Set the Control Panel MAIN CIRCUIT BREAKER in the ON position. VOLTAGE CHECKS – NO LOAD ! DANGER ! Proceed with caution. Once the Utility Power is turned ON, the ATS is now electrically hot. The feeder lines and terminals are now live.
Model 100237 INSTALLATION driver, to bend the spring anchor on the fixed speed controls. i. To increase engine speed HSNL bend the spring anchor tang on the fixed speed controls away from the governor lever to increase spring tension. ii. To decrease engine speed HSNL bend the spring anchor tang on the fixed speed controls toward the governor lever to decrease spring tension. 2. Set the ATS Control Module in the TEST position. 3.
Model 100237 INSTALLATION CHECKING AUTOMATIC OPERATION To check the HSB system for proper automatic operation, proceed as follows: 4. ATS Module and LED indicators 5. Battery Charger and LED indicators 6. Exterior fault code indicator LED on the backside of the HSB 7. ATS operation 8. Exercise scheduled time of operation 9. Scheduled Maintenance 1. Ensure the HSB is set in the OFF positions on both the Engine Control Module and the ATS Module. 2. Install front cover of the ATS. 3.
Model 100237 INSTALLATION HSB, ATS MODEL & SERIAL REFERENCE ATS BACK-UP CIRCUITS HSB Model Number _____________________________________ HSB Serial Number _____________________________________ Fuel Type LPG_____________ NG_________________ ATS Model Number ______________________________________ ATS Serial Number ______________________________________ ATS circuits powered ______________________________________ ____________________________ ____________________________ ____________________________
Model 100237 INSTALLATION AUTOMATIC TRANSFER SWITCH (ATS) SERVICE ENTRANCE MODELS Refer to the Reliance instruction guide enclosed with each unit for information related to installation, operation, service, trouble shooting and warranty (Champion part number 101949). The most reliable and convenient method to transfer power is with an automatic transfer switch (ATS). The ATS will automatically disconnect the home from the utility power prior to the HSB functioning (see NEC 700, 701 and 702).
Model 100237 INSTALLATION ! ! WARNING The manufacturer recommends that a licensed electrician or an individual with complete knowledge of electricity perform these procedures. Be certain that the power from the main panel is turned “OFF” and all backup sources are locked out prior to removal of the cover or removal of any wiring of the utility main electrical distribution panel. Failure to do so could result in serious injury or death.
Model 100237 INSTALLATION 4. Replace the deadfront by sliding it from the bottom into the cabinet underneath the door latch protrusions. Secure it to the deadfront brackets with the screws removed earlier. of backup power to the utility lines. The extremely high speed switching system avoids the electrical appliance shutdowns that can occur with other transfer switches when transitioning from back-up power to utility power. 5. Close and latch the door 6.
Model 100237 INSTALLATION CIRCUIT BREAKERS FOR UTILITY MAIN CONTROL PANEL AND ATS The Utility Main Control Panel requires a double-pole circuit breaker as a feeder for the ATS. Refer to inside label/decal on the ATS enclosure front panel for recommendations. ! Consult all local and National electric codes for proper wiring methods for all wiring. 1. Conductor sizes must be adequate to handle the maximum current to which they will be subjected.
Model 100237 INSTALLATION in the main panel board through the conduit into the ATS. Install the branch circuit breakers in the ATS panel for those branch circuits to be powered by the generator. The ATS is UL listed for a number of 1 inch interchangeable breakers (see label on the inside cover of the ATS).
Model 100237 INSTALLATION 7. To test the ATS performance, simply disable utility mains power. Your HSB generator should start, and your ATS will automatically switch to the “GENERATOR SUPPLY” source. When utility mains power is re-established, your ATS will automatically switch back to the “UTILITY SUPPLY” source, your HSB generator will cool down, turn off and then be placed into standby ready position. 8.
Model 100237 INSTALLATION 3. With utility power on, verify the fact that all circuits connected to the ATS are energized. Connect the negative lead of the 24 VDC power supply to terminal 3. 4. FOR NO MORE THAN 1 SECOND, press the positive lead of the 24 VDC power supply to terminal 1. If the solenoid clicks and the mechanism transfers, fuse F1 is functional. 5. Disconnect the 24 VDC power supply and reconnect the wires that were installed in terminals 1, 2 and 3, in the correct order. FUSE F6 1.
Model 100237 TROUBLESHOOTING TROUBLESHOOTING HSB The number one problem which relates to starting, output and performance is “Fuel Pressure Insufficient”. Utility fuel regulator and pipe sized to small which can be compounded by pipe run distance to long for the size of pipe installed. Confirm fuel pressure to the fuel regulator during No-load and Load operation. ENGINE WILL NOT CRANK/TURN OVER 1. HSB set in “OFF” mode. Place the HSB controllers in the proper AUTO and ATS start positions. 2.
Model 100237 TROUBLESHOOTING NO AC OUTPUT 1. Engine control set in “OFF” mode Place HSB ATS mode. 2. Circuit breaker in “OFF” position Turn on breaker. 3. ATS control in “OFF” mode Place ATS module in ATS mode. 4. Main circuit breaker in “OFF” position. Turn on breaker. 5. Transfer switch breaker in “OFF” position. Turn on breaker. 6. Standby breakers set in “OFF” position. Turn on breaker. 7. Line circuit tripping breaker because of short circuit * 8.
Champion Power Equipment 12039 Smith Ave.
10 Year Limited Warranty* Basic Warranty Provisions Champion Air-Cooled 8.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING: Original installation or start-up costs Champion Home Standby generators that utilize non-Champion Power Equipment replacement parts Costs of normal maintenance (i.e.
Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.: cranes, hoists, lifts, etc.) Planes, ferries, railroad, buses, helicopters, snowmobiles, snow-cats, off-road vehicles or any other mode of transport deemed abnormal Starting batteries, fuses, light bulbs, engine fluids, and spark plugs THIS WARRANTY AND THE ATTACHED U.S.
