Home Generator System - 18kW and 20kW
BRIGGS & STRATTON
SERVICE & TROUBLESHOOTING MANUAL
HOME GENERATOR SYSTEM - 18KW AND 20KW
Copyright Briggs & Stratton Corporation
Milwaukee, WI. All rights reserved.
277528GS
Revision C
Home Generator System - 18kW and 20kW
FORWARD
This manual was written to assist authorized technicians and service personnel with the repair and
maintenance procedures for Briggs & Stratton home standby generator systems. It assumes that persons
using this manual have been properly trained in and are familiar with the servicing procedures for these
products, including the proper use of required tools and safety equipment and the application of appropriate
safety practices. Persons untrained or unfamiliar with these procedures or products should not attempt to
perform such work.
Proper maintenance and repair is important to safe, reliable operation of the standby system. The
troubleshooting, testing, maintenance, and repair procedures described in this manual are appropriate for
the models described herein. Alternative methods or procedures may pose risk to personal safety and the
safety and/or reliability of the equipment and are not endorsed or recommended by Briggs & Stratton.
All information, illustrations, and specifications contained in this manual were based on the data available at
the time of publication. Briggs & Stratton Corporation reserves the right to change, alter, or otherwise
improve the product or the product manuals at any time without prior notice.
No part of this material may be reproduced or transmitted in any form or by any means, electronic or
mechanical, including photocopying or recording by any information storage and retrieval system, without
prior written permission from Briggs & Stratton Corporation.
TABLE OF CONTENTS
SECTION 1 - SAFETY, MAINTENANCE AND ADJUSTMENTS ...................................... 1
SAFETY MESSAGES .................................................................................................................. 1
ACCESS TO THE GENERATOR................................................................................................. 5
GENERATOR COMPONENTS.................................................................................................... 6
SYSTEM CONTROLS.................................................................................................................. 7
SYSTEM CONNECTIONS........................................................................................................... 8
GENERATOR CLEARANCES ..................................................................................................... 9
ENGINE MAINTENANCE ............................................................................................................ 10
FUEL SUPPLY............................................................................................................................. 11
SETTING THE EXERCISE TIMER .............................................................................................. 11
OERATIONAL TESTS.................................................................................................................. 12
SECTION 2 - TROUBLESHOOTING .................................................................................15
SYSTEM CONTROL PANEL (SCP) ............................................................................................ 15
AUTOMATIC VOLTAGE REGULATOR (AVR) ............................................................................ 16
FAULT CODE INDICATIONS ...................................................................................................... 17
STOPPING THE SYSTEM FOR MAINTENANCE....................................................................... 18
GENERATOR AC CONNECTION SYSTEM................................................................................ 18
(FAULT CODE_1) DEAD UNIT/LOW BATTERY VOLTAGE ....................................................... 19
(FAULT CODE_2) LOW OIL PRESSURE ................................................................................... 23
(FAULT CODE_3) LOW OUTPUT VOLTAGE ............................................................................. 27
(FAULT CODE_4) ENGINE FAILS TO START/FAILS TO CRANK............................................. 31
(FAULT CODE_5) UNDER FREQUENCY................................................................................... 39
(FAULT CODE_6) OVER FREQUENCY ..................................................................................... 42
(FAULT CODE_7) HIGH TEMPERATURE.................................................................................. 43
(FAULT CODE_8) TRANSFER SWITCH FAILURE .................................................................... 45
SECTION 3 - UNIT DISASSEMBLY ..................................................................................47
REMOVING THE ACCESS DOORS............................................................................................ 47
REMOVE THE ROOF ASSEMBLY.............................................................................................. 47
REMOVE THE EXHAUST BULKHEAD ....................................................................................... 47
REMOVE THE CONTROL PANEL BULKHEAD .......................................................................... 48
REMOVE THE MUFFLER ASSEMBLY ....................................................................................... 50
REMOVE COOLING DUCTS....................................................................................................... 50
REMOVE THE STATOR ASSEMBLY.......................................................................................... 50
REMOVING THE ROTOR ASSEMBLY ....................................................................................... 53
REMOVING THE ENGINE ADAPTOR......................................................................................... 54
SECTION 4 - SPECIFICATIONS & REFERENCE.............................................................55
SPECIFICATIONS........................................................................................................................ 55
SCHEMATIC ................................................................................................................................ 56
WIRING DIAGRAM ...................................................................................................................... 57
1
SECTION 1 - SAFETY,
MAINTENANCE AND
ADJUSTMENTS
In The Interest Of Safety
This repair manual contains safety information
that is designed to:
• Make you aware of hazards associated
with engines and generators.
• Inform you of the risk of injury
associated with those hazards.
• Tell you how to avoid or reduce the risk
of injury.
The Safety Alert Symbol
The safety alert symbol ( ) is used to identify
safety information about hazards that can result
in personal injury.
A signal word (
DANGER, WARNING, or CAUTION)
is used with the alert symbol to indicate the
likelihood and the potential severity of injury. In
addition, a hazard symbol may be used to
represent the type of hazard.
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.
CAUTION: When this signal word is used
without the alert symbol, it indicates a situation
that could result in damage to the equipment.
• Prior to work, read and understand the
section(s) of this manual that pertain to
the job. Follow all safety warnings.
• Wear suitable eye protection.
• When servicing engines or equipment,
prevent accidental starting by
disconnecting control panel fuse, spark
plug wire from the spark plug(s), and
disconnect negative battery cable.
• Disconnect all sources of supply
voltage before servicing the generator.
WARNING
Before attempting to service this equipment,
read and understand this manual and the
operating instructions of the equipment
Failure to follow instructions could result in
DEATH, SERIOUS INJURY (including
paralysis) or property damage.
Explosion
Fire Electrical
Shock
Toxic
Fumes
Rotating
Parts
Hot Surface
Auto Start
Explosive
Pressure
Chemical
Burn
Lift Hazard Read
Manual
HAZARD SYMBOLS AND MEANINGS
2
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
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 a 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
Running engine gives off carbon mon-
oxide, and 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 monox-
ide alarm near the bedrooms.
• Keep exhaust gas from entering a con-
fined area through windows, doors, venti-
lation intakes, or other openings.
WARNING
Generator produces hazardous volt-
age.
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 bare-
foot, or while hands or feet are wet.
• If you must work around a unit while it is
operating, stand on an insulated dry sur-
face to reduce shock hazard.
• DO NOT allow unqualified persons or chil-
dren to operate or service generator.
• In case of an accident caused by electri-
cal 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 gen-
erator, operating this equipment impru-
dently, 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 equip-
ment 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 work-
ing on the equipment.
3
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
NFPA 37 and other 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 the 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
Contact with muffler area can result in
serious burns.
Exhaust heat/gases can ignite com-
bustibles 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.
WARNING
Starter and other rotating parts can
entangle hands, hair, clothing, or
accessories.
• NEVER operate generator without protec-
tive housing or covers.
• DO NOT wear loose clothing, jewelry, or
anything that may be caught up in the
starter or other rotating parts.
• Tie up long hair and remove jewelry.
CAUTION
Installing the control panel’s 15A fuse could
cause the engine to start.
• DO NOT install this fuse until all plumbing
and wiring has been completed and
inspected.
CAUTION
Excessively high operating speeds increase
risk of injury and damage to the generator.
Excessive load will cause engine shutdown.
• DO NOT tamper with governed speed.
Generator supplies correct rated fre-
quency and voltage when running at gov-
erned speed.
• DO NOT modify the generator in any way.
CAUTION
Avoid prolonged or repeated skin contact with
used motor oil.
• Used motor oil has been shown to cause
skin cancer in certain laboratory animals.
• Thoroughly wash exposed areas with
soap and water.
4
Standby Safety Practices
• This manual contains important safety
messages. Read these carefully and
understand them before proceeding
with maintenance and repairs.
• Become familiar with the Home
Generator System. Know its
applications, its limitations, and any
hazards involved.
• This unit must not be modified for any
application other than that for which it
was designed. If you have any
questions about the Home Generator
System, ask the dealer or consult
Briggs and Stratton.
• Never handle any kind of electrical cord
or device while standing in the water,
while barefoot, or while hands and feet
are wet.
• Worn, bare, frayed, or otherwise
damaged electrical cord sets should
not be used with the Home Generator
System. Using a defective cord may
result is an electrical shock or damage
to the test equipment and/or the unit.
• The Home Generator System requires
an adequate supply of cooling air for
continued proper operation. Never
allow the free flow of cooling air into or
out of the unit to be obstructed in any
way.
• Home Generator Systems produce
powerful voltages that can cause
extremely dangerous electrical shock.
Avoid contact with bare wires,
terminals, etc. Never permit an
untrained person to service or assist
with the procedures discussed in this
manual.
• Never manually start or stop this unit
with electrical loads connected to the
receptacles and turned ON. Start the
engine and allow it to stabilize before
connecting any electrical loads. Turn
OFF and disconnect all electrical loads
before shutting down the generator.
• The manufacturer cannot anticipate
every circumstance that might involve
or constitute a hazard. Warnings in
manuals, warnings on hang tags, and
labels affixed to the unit are NOT all-
inclusive.
CAUTION
Exceeding generators wattage/amperage
capacity can damage generator and/or
electrical devices connected to it.
•See Essential Circuits in the Operator’s
manual.
• Start generator and let engine stabilize
before connecting electrical loads.
CAUTION
Improper treatment of generator can damage
it and shorten its life, or result in personal
injury.
• 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 surface.
• Adequate, unobstructed flow of cooling
and ventilating air is critical to correct gen-
erator 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 gen-
erator, operating this equipment impru-
dently, neglecting its maintenance or
being careless can cause possible injury
or death.
• DO NOT start engine with air cleaner
removed.
• DO NOT insert any objects through the
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.
5
ACCESS TO THE GENERATOR
The 20kW Home Standby Generator System is
equipped with an enclosure that has three
access doors (Figure 1). The doors are named
for a significant component located behind them,
as follows:
• Oil Fill Door
• Control Panel Door
• Oil Drain Door
Each Home Generator System is equipped with
two identical keys. These keys fit all the doors.
Figure 1
Removing An Access Door
1. Insert a key into the lock of the access
door and turn one quarter turn
counterclockwise.
2. Open the latch with a quarter turn
counterclockwise.
3. Open the door enough to clear its jambs
and lift the door from its hinges.
NOTE: When removing more than one door at a
time, it’s a good idea to mark the doors for proper
fit when reinstalling.
Installing An Access Door
1. Mount the door hinge barrels on their
respective pins and close.
2. Turn latch a quarter turn clockwise.
3. Lock the door with the key.
CAUTION
Do not operate the standby generator for
extended periods without all the doors
installed and closed. Failure to do so will
cause overheating.
A
A
B
B
C
C
D
D
E
E
Oil Fill Door
Fuel Inlet Fitting
Lifting Holes
Control Panel Door
Oil Drain Door
6
GENERATOR COMPONENTS
Generator is pictured with access doors removed
for clarity.
A - Exhaust Port - High Performance muffler
lowers engine noise.
B - Oil Dip Stick - Used to check engine oil level.
C - Oil Fill Cap - Remove to add recommended
oil.
D - Air Cleaner - Protects engine by filtering dust
and debris out of air intake.
E - Oil Filter - Filters engine oil to prolong
system life.
F - Oil Drain Hose - Provided to facilitate oil
changing.
G - Oil Drain Door Opening - Provides access
for engine servicing.
H - Oil Fill Door Opening - Provides access for
engine servicing.
J - Engine Label - Identifies engine model and
type.
K - Fuel Inlet - Fuel supply is connected here.
L - Control Panel Door Opening - Provides
access to control panel and battery.
M - Unit Data Decal (located on base) -
Identifies unit by serial number.
N - Battery (installer supplied) - 12 Volt DC,
sealed battery provides power to start the
engine.
P - System Control Panel - Used for various
test, operation, and maintenance functions. See
System Control Panel on the next page.
7
SYSTEM CONTROLS
A - Set Exercise Switch - Used to set the
exercise cycle start time and day-of -the-week.
Exercise cycle only occurs in AUTO mode.
B - Manual Over-Ride Switch - With system
switch in AUTO position, push the manual over-
ride switch to start the generator. To turn off the
generator, push and hole the manual over-ride
switch again until engine stops.
C - 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, AUTO 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.
D - 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 15 Amp fuse.
E - Digital Display - Displays the total number of
hours the generator has been running and fault
codes. Used to schedule maintenance tasks and
for troubleshooting operational problems with the
home generator.
F - Circuit Breaker - Protects the system from
shorts and other over-current conditions. Must
be ON to supply power to the Automatic Transfer
Switch.
8
SYSTEM CONNECTIONS
Wiring For The 2-Pin Connector
240 Volt Utility - Use to hook up the 240V utility
leads from the transfer switch to the generator.
Wiring For The 10-Pin 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 to monitor
generator functions.
+12 Volt DC /.5 Amp Output - Power supply for
installer-supplied accessory.
Fault Contacts
Transfer Switch
Communications
Remote LED Output
+12VDC,.5Amp Output
240VAC Utility
10 Pin Connector
2 Pin Connector
9
GENERATOR CLEARANCES
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,
sand, 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 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 (B) to combustible (D) is and to non-
combustible (A) 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 (A) and/or (D) to (E).
• A roof cannot be used.
• Exhaust (C) must not be allowed to
accumulate.
A - Non-Combustible material with Fire Resistant
Rating of 1 hour or greater.
B - Home Standby Generator
C - Engine Exhaust
D - Combustible Material or Structure with a Fire
Resistance Rating of less that 1 hour.
E - Any structure or material. DO NOT connect
(A) and/or (D) to (E).
WARNING
Exhaust heat/gases can ignite com-
bustibles or structures, causing a fire.
• DO NOT install the generator closer to 5
feet (1.5m) from any combustibles or
structures with combustible walls having a
fire resistance rating of less than 1 hour.
WARNING
Running engine gives off carbon mon-
oxide, and 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 monox-
ide alarm near the bedrooms.
• Keep exhaust gas from entering a con-
fined area through windows, doors, venti-
lation intakes, or other openings.
A
B
C
D
E
E
5’ (1.5m)
5’ (1.5m)
5’ (1.5m)
5’ (1.5m)
3’
(1m)
2’
(62cm)
10
ENGINE MAINTENANCE
For detailed servicing information for the Briggs
& Stratton engine, please refer to the
VANGUARD™ V-Twin OHV Repair Manual
(#272144), available from your Briggs & Stratton
source of supply.
Checking the Oil Level
Before placing the standby generator in service,
and at each recommended maintenance interval,
check the engine oil level as follows:
1. Remove oil fill door. Clean area around oil
fill and dipstick locations.
2. Remove dipstick. Wipe with clean cloth.
3. Insert dipstick fully. Remove and check oil
level.
If oil level is low, remove oil fill cap and slowly
add recommended oil to bring level to the
Full
mark on the dipstick. A reusable oil spout is
supplied to make it easier to pour oil into the
engine.
Changing the Oil and Oil Filter
Oil capacity is approximately 2-1/2 quarts (80
ounces or 2.3 liters) when changing both the oil
and filter. Use only 5W-30 synthetic detergent
oil rated for service SJ or higher.
Change oil and oil filter after every 100 operating
hours. If the unit is run under dirty or dusty
conditions or in extremely hot weather, change
the oil more often.
Use the following instructions to change the oil
while the engine is still warm.
1. Set SYSTEM switch to OFF.
2. Remove the 15 Amp fuse.
3. Un-clip and wipe the oil drain hose clean
with a rag. Place the oil drain hose into a
suitable container. Push the oil drain fitting
in and rotate it counterclockwise to its
stop, and then pull the fitting outwards. Oil
will begin to flow out of the oil drain hose.
4. After the oil is drained, grasp the oil drain
fitting and rotate it clockwise until it locks
in place. Reposition the oil drain hose in
its storage clip.
5.
Place a suit
able container beneath the oil
filter and remove the filter.
6. Coat the gasket of the new filter with fresh
clean engine oil. Turn the new filter
clockwise by hand until the gasket
contacts the filter adapter, then tighten 1/2
to 3/4 turn more.
7.
Fill engine w
ith oil until level is at the
FULL
mark on the dipstick.
8. Install and tighten the oil fill cap.
9. Run the engine for one minute and check
for leaks. Recheck the oil level.
Replacing the Spark plugs
Replace the spark plugs every year. Use only the
recommended spark plugs and make sure they
are gapped to.030 in. (.76 mm).
1. Stop the engine and pull the wires from
the spark plugs.
2. Clean around the spark plugs and remove
them from the cylinder head.
3. Inspect the spark plugs for wear or
damage - replace as necessary. Clean off
carbon deposits on the electrodes using a
wire brush or commercial solvent. Do not
blast clean.
4. Set the gap as specified above and install
the cleaned or new spark plugs into the
cylinder heads.
Torque to 15 lb.- ft.
Servicing the Air Cleaner
The engine air cleaner is one of the most
important areas to maintain. Use only genuine
Briggs & Stratton parts which meet UL
requirements for a standby generator. Clean the
foam pre-filter (if equipped) every 25 hours and
the filter cartridge every 100 hours of operation.
Clean or replace more often in dusty or dirty
conditions.
To service the air cleaner:
1. Remove fastener from top of air cleaner
cover.
2. Remove fastener from air filter retainer.
3. If equipped, remove foam pre-cleaner from
filter cartridge and wash in soapy water.
Rinse thoroughly and allow to air dry.
4. Clean filter cartridge by tapping gently on a
flat surface. Replace if very dirty or
damaged.
5. Place dry pre-cleaner on filter cartridge,
then re-install cartridge into air cleaner
housing.
6. Install the retainer and fastener, then the
cover and fastener.
NEVER use petroleum solvents or pressurized
air to clean the air filter cartridge. Solvents will
cause the cartridge to deteriorate; pressurized
air will perforate the media.
11
Adjusting the Valve Lash
Valve
lash must be checked every 100 hours of
operation when the engine is cold. Adjust if
necessary according to the VANGUARD™ V-
Twin OHV Repair Manual (#272144)
. The lash
for both intake and exhaust valves is.004 -.006
in. (.10 -.15 mm).
Cleaning the Cooling Fins
Periodically check to make sure the cylinder fins,
oil cooler, screens, and carburetor ducting are
free of leaves, grass, or other debris.
FUEL SUPPLY
The table below provides approximate fuel
supply requirements at half load and full load to
ensure effective generator operation (Figure 3).
For actual fuel requirements for the model you
are servicing, refer to the appropriate installation
manual.
NOTE: Air density is less at high altitudes,
resulting in less available engine power. Engine
power will decrease 3.5% for each 1,000 feet
(300 meters) above sea level and 1% for each
10°F (5.6°C) above 77°F (25°C). If the generator
does not output full rated power, make sure
these factors have been considered when
determining total generator load output.
SETTING THE EXERCISE TIMER
The Home Standby Generator System is
equipped with an exercise timer that will start
and run the system once every seven days.
During this exercise period, the unit runs for
approximately 20 minutes and then shuts down.
Electrical load transfer does not occur during the
exercise cycle (unless a utility power outage
occurs).
A switch on the control panel is labeled
SET
EXERCISE.
The day and time at which this switch is pressed
is retained by a memory chip on the Control
Module Assembly (SCP). Every seven days from
that day and time, the SCP will automatically
initiate the system exercise cycle.
For example, if you press the
SET EXERCISE
switch on Sunday morning at 10:00 AM, the unit
will run an exercise cycle every following Sunday
at 10:00 AM (± 30 minutes).
To perform the Set Exercise procedure:
1. Make sure the control panel fuse is
installed and the SYSTEM switch is set to
AUTO.
2. Press and hold down the
SET EXERCISE
switch for three seconds on the day and
time the Home Standby Generator System
is to exercise. The LED on the control
panel will flash until “SET EXERCISE” is
complete.
NOTE: Depending on the programming of the
SCP, some units may start when the exercise
switch is initially pressed.
3. Release the exercise switch.
If you want to change the day and time the unit
exercises, simply perform the set exercise
procedure on the exact day and time you want it
to take place.
NOTE: Set exercise will work only if the unit is in
AUTO mode. The feature will need to be re-set if
the battery is disconnected or the fuse is
removed.
Natural Gas
LP Vapor
1/2 Load Full Load
1/2 Load Full Load
160 CuFt/Hr
160,000 Btu/Hr
N/A
N/A
293 CuFt/Hr
293,000 Btu/Hr
N/A
N/A
N/A
N/A
70.4 CuFt/Hr
176,825 Btu/Hr
N/A
N/A
141.5 CuFt/Hr
353,650 Btu/Hr
18kW
20kW
Fuel Pressures:
NG = 5-7” wc
LP = 11-14” wc
These pressures are at FULL LOAD with all gas
appliances turned ON and operating.
12
OPERATIONAL TESTS
Testing Manual Operation (No Load)
This test should be done without any electrical
loads connected, as follows:
1. Remove the oil drain and control panel
doors.
2. Remove the four screws that secure the
circuit breaker cover, if installed (Figure 2).
Figure 2
3. Connect voltage and frequency meters to
the load side of circuit breaker.
4. Set the generator’s main circuit breaker to
its
ON (closed) position.
5. Install the 15 Amp fuse in SCP.
6. Set the SYSTEM switch to
AUTO.
7. Make sure that all fuel shut-off valves are
open.
8. Push and hold the
MANUAL OVER-RIDE
button to start the engine. Do not crank
the engine for more than 10 seconds at a
time, and allow the starter motor to cool for
one minute between attempts.
9.
NOTE: If the unit has been idle for an
extended period or if the fuel system has
been serviced, air might get trapped in the
fuel lines. It may take a few minutes to
purge the air from the lines before the unit
will start.
If the unit fails to start:
Check for a Fault Code, if any, in the digital
display and follow the appropriate
troubleshooting to resolve. Then reset the fault
code detection system. Make sure fuel is
ON.
• Repeat step 8.
• Listen for unusual noises, vibration, or
other indications of abnormal
operation.
• Check for oil leaks, evidence of
overheating, or other problems that
may contribute to a no-start condition.
Let the engine warm up for about five minutes.
When you are satisfied with the operation of the
generator:
10. Check voltage and frequency across
wire
#11
and wire #44. Voltage should read
239VAC-264VAC and frequency should
read
62.0 Hz - 62.5 HZ.
11. Check the voltage across
wire #11
connection lug and
NEUTRAL and then
across
wire #44 connection lug and
NEUTRAL. Each reading should be
between
119VAC-131VAC.
If no-load voltage and frequency are correct,
push and hold the
MANUAL OVER-RIDE button to
shut down the unit.
If no-load voltage and frequency are NOT
correct, keep the unit running and slowly turn the
governor adjustment screw as required to obtain
a no-load frequency of
62.0 Hz - 62.5 Hz (Figure 3).
.
Figure 3
Set the SYSTEM switch to
OFF. The unit will shut
down.
13
Testing Auto Operation (Load Transfer)
1. Ensure that utility power is connected to
the UTILITY CONNECTION lugs of the
automatic transfer switch.
2. Ensure that the main line disconnect for
UTILITY POWER is set to
ON.
3. Set the generator SYSTEM switch to the
AUTO position. The unit is now set for
automatic operation.
4. Set the main line disconnect for UTILITY
POWER to
OFF.
The engine will crank and start when the utility
voltage drops and the (brown out) sensor has
timed out. After starting, the transfer switch will
transfer circuit loads to the generator. Let the
system go through its entire automatic operation
sequence.
5. Inspect protected loads and ensure that all
anticipated circuits are functioning.
6. With the generator supplying power, turn
ON the main line disconnect (UTILITY
POWER).
If the unit has run for 5 minutes or more, it will
transfer the load back to UTILITY POWER within
10 seconds. If the unit has run for less than 5
minutes, it will continue to run for approximately
5 to 6 minutes (to warm up the engine) and then
transfer the load back to UTILITY POWER.
Approximately one minute after the transfer
back, the engine will shut down.
This completes the testing procedures for
automatic operation. The unit will now start
automatically when UTILITY POWER is lost and
will supply STANDBY POWER to the protected
circuits in the home.
Testing Generator Load (Electrical Capacity
And Fuel Consumption)
1. Set the generator main circuit breaker to
ON.
2. Set the generator SYSTEM switch to
AUTO.
3. Set the main line disconnect (UTILITY
POWER) to
OFF.
4. The engine should crank and start
automatically. Let the engine stabilize and
warm up for about 5 minutes.
Standby power is now supplied to the
GENERATOR CONNECTION lugs of the
automatic transfer switch.
5. Turn
ON individual loads within the
protected circuits until unit is under full
load.
6. Turn on all gaseous fuel appliances in the
home before proceeding.
7. Check generator frequency across the
GENERATOR CONNECTION lugs in the
transfer switch. Frequency should read
above
57.0 Hz.
If the frequency is below this value, slowly turn
the governor adjustment screw as required to
obtain a full-load frequency above
57.0 Hz.
Once the frequency is correct, allow the unit to
run at full rated load for an additional 5 minutes.
Then remove load and check the no-load
frequency again.
8. Set the main line disconnect (UTILITY
POWER) to ON. The unit will transfer the
load back to UTILITY POWER within 10
seconds.
Approximately one minute after the transfer
back, the engine will shut down.
9. Set the generator main circuit breaker to
OFF.
10. Set the generator SYSTEM switch to
OFF.
11. Remove all test equipment and reinstall
the circuit breaker cover.
12. Set the generator main circuit breaker to
ON.
13. Set the generator SYSTEM switch to
AUTO.
14. Install the access doors.
The generator is now in standby configuration.
14
15
SECTION 2 -
TROUBLESHOOTING
SYSTEM CONTROL PANEL (SCP)
The System Control Panel (SCP) is a printed
circuit board that is integrated with the control
panel of the Home Standby System. It contains
all the logic circuits, operator controls, and
system displays necessary to operate, program,
and protect the generator. The SCP interprets
and monitors electrical inputs from all related
circuits throughout the standby installation.
Before replacing the SCP, all other circuits must
be tested to ensure proper operation. When a
failure has been traced to the SCP, the board
must be replaced as a complete assembly.
Functions of the SCP:
• Battery Trickle Charge
• S
et Exercise Timer ( SET EXERCISE)
• Man
ual Start (MANUAL OVER-RIDE)
• S
ensing Utility Voltage
•
Automatic Start, in event of utility failure
• Automatic Engine Cool-Down Timer
•
Fault Code (FC) Detection w
ith
A
utomatic Shutdown
• F
ault Indication Display (LED)
• D
iagnostic Access Port (SERVIC
E
TO
OL)
• H
our Meter
Power During SCP Fault Conditions
When the Home Generator System experiences
a fault condition, the Automatic Transfer Switch
automatically defaults to UTILITY POWER. This
ensures that utility power is available to all
circuits in the home until the fault is corrected.
If the unit fails to exercise at its prescribed time,
check for a fault code on the generator system
control panel display. If no fault code is shown,
perform the SET EXERCISE procedure.
How to Access the SCP
The SCP is mounted behind the face of the
control panel (A,Figure 1).
1.
Op
en and/or remove the SCP door.
Figure 1
2.
Set SYSTEM switch to OFF.
3.
Remove the 15 Amp fuse from the SCP.
4. Disconnect the negative (-) battery cable.
5.
Remove the circuit breaker cover
(B,Figure 1).
6.
Disconnect the 2-pin and the 10-pin
connectors from the edge of th
e SCP
bo
ard.
7.
Remove the four mounting screw
s
(C,Figu
re 2) that secure the face of the
control panel, then carefully remove an
d
t
ilt down the panel to expose the board.
Figure 2
The SCP is connected to its various circuits
through three connectors that are mounted
directly to the board (Figure 3), shown tilted
down.
B
A
C
16
The 8-pin connector (A) is
wired to the internal
systems of the unit and is the primary point of
measurement for troubleshooting. The 2-pin
connector (B) supplies 240VAC from UTILITY
power. The 10-pin connector (C) is used for
optional generator features. In addition, the SCP
also has connections for E1 and E2 (D), which
sense 240VAC on the generator, and four
terminals (E), which are used for optional battery
and engine warmers.
Figure 3
To show probe locations for troubleshooting with
a test meter, an arrow from a connector/pin
illustration will be shown against the exposed
SCP board (Figure 4). Note that the board will be
shown upside down in relation to the actual
schematic in the manual.
Figure 4
The functions of the 8-pin connector is shown
below (Figure 5).
Figure 5
AUTOMATIC VOLTAGE
REGULATOR (AVR)
The Automatic Voltage Regulator (AVR) is
mounted on the bulkhead (A,Figure 6) behind
the SCP.
Figure 6
A
B
C
D
E
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
Battery Trickle Charge (Wire #13)
Ground (Wire #0)
Start Circuit (Wire #56)
Fuel Solenoid (Wire #14)
High Temperature (Wire #95)
Oil Pressure (Wire #85)
Vacant
Vacant
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
A
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