Simplicity 040226A-0 User manual

Home Generator System - 18kW and 20kW

BRIGGS & STRATTON

SERVICE & TROUBLESHOOTING MANUAL

HOME GENERATOR SYSTEM - 18KW AND 20KW

Copyright Briggs & Stratton Corporation

277528GS

Revision C

Not for Reproduction

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.

Not for Reproduction

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

Not for Reproduction

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

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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

Not for Reproduction

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.

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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.

Not for Reproduction

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.

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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

B

C

D

E

Oil Fill Door

Fuel Inlet Fitting

Lifting Holes

Control Panel Door

Oil Drain Door

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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.

Not for Reproduction

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.

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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

Not for Reproduction

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

5’ (1.5m)

3’

(1m)

2’

(62cm)

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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 su

itable

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 wi

th 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.

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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

160 CuFt/Hr

160,000 Btu/Hr

N/A

293 CuFt/Hr

293,000 Btu/Hr

N/A

70.4 CuFt/Hr

176,825 Btu/Hr

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.

Not for Reproduction

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.

Not for Reproduction

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.

Not for Reproduction

14

Not for Reproduction

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

• Set Exercise Timer ( SET EXERCISE)

• Manual Start (MANUAL OVER-RIDE)

• Sensing Utility Voltage

• Automatic Start, in event of utility failure

• Automatic Engine Cool-Down Timer

• Fault Code (FC) Detection with

Automatic Shutdown

• Fault Indication Display (LED)

• Diagnostic Access Port (SERVICE

TOOL)

• Hour 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. Open 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 the SCP

board.

7. Remove the four mounting screws

(C,Figure 2) that secure the face of the

control panel, then carefully remove and

tilt 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

Not for Reproduction

16

The 8-pin connector (A) is wired to the internal

syst

ems 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

A

Not for Reproduction

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