Champion 100199 Installation Manual
  1. Manuals
  2. Brands
  3. Champion Manuals
  4. Inverter
  5. 100199
  6. Installation manual

Champion 100199 Installation Manual

Home standby generator
Hide thumbs Also See for 100199:
Table of Contents

Advertisement

Quick Links

See also: Operator's Manual
DANGER: Not intended for use in critical life support application.
DANGER: Generator must be installed and operated outdoors only.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 100199 and is the answer not in the manual?

Questions and answers

Related Manuals for Champion 100199

Summary of Contents for Champion 100199

  • Page 1 DANGER: Not intended for use in critical life support application. DANGER: Generator must be installed and operated outdoors only.
  • Page 2 No part of this publication may be reproduced or used in any form by any means – graphic, electronic or mechanical, including photocopying, recording, taping or information storage and retrieval systems – without the written permission of Champion Power Equipment (CPE). Have questions or need assistance?

  • Page 3: Table Of Contents

    Surge Protection ......33 Champion 439CC Engine ....18 Hour Meter and Over Voltage Protection .
  • Page 4 Bottom Row ......35 This manual must be used with Champion Power Equipment Engine Controller .

  • Page 5: Introduction

    Model 100199 INTRODUCTION PARTS INCLUDED 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 Your HSB ships with the following: North American market. This engine-powered generator meets •...

  • Page 6: Hsb Models

    : Flexible fuel line connector, absorbs vibration when connected to rigid piping Champion Power Equipment is a market leader in power generation equipment. Champion has years of experience designing and manufacturing dependable and durable power products designed and engineered in the US to the exacting standards of the North American market.

  • Page 7: General Information, Standards And Codes

    470 Atlantic Avenue, Boston, Ma. 02210 NFPA NO. 58, AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUID PETROLEUM GAS National Fire Protection Association 470 Atlantic Avenue, Boston, Ma. 02210 © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 8: Safety

    Model 100199 SAFETY SAFETY SYMBOL DEFINITIONS 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 Black hazard pictorial on yellow possible injury or death.

  • Page 9: Installation Hazards

    Before welding components on the generator, contact CPE for recommended welding instructions. Wear eye protection WARNING Not intended for use in critical life support applications. Wear personal protective equipment Do not leave tools in the area © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 10: Before Starting

    Model 100199 SAFETY BEFORE STARTING OPERATING HAZARDS CAUTION WARNING Before starting, operating and ALWAYS operate the generator maintaining this generator, be sure following the manufacturer’s to read and understand the content instructions. Operating the generator and safety messages in this manual.

  • Page 11: Accidental Starting

    • Light-headedness, dizziness • Physical fatigue, weakness in joints and muscles • Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision • Stomachache, vomiting, nausea © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 12: Electrical Shock Hazards

    Model 100199 SAFETY FIRE/EXPLOSION HAZARDS 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 WARNING of carbon monoxide poisoning. If the affected person does not improve within minutes of breathing fresh air, call 911 immediately.

  • Page 13: Burn Hazards

    BATTERY HAZARDS WARNING Always read and comply with the battery manufacturer’s recommendations for procedures concerning proper battery use and maintenance. © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 14: Safety Labels On Unit

    Model 100199 SAFETY SAFETY LABELS ON UNIT Poisonous Gas Hazard Generator exhaust Fire Hazard ALWAYS keep the surrounding contains carbon monoxide. Breathing carbon Burn Hazard DO NOT area near generator clean and free of debris Burn Hazard DO NOT touch hot monoxide will cause nausea, dizziness, and and/or dry vegetation.

  • Page 15: Safety, Serial/Model, Nameplate Label Locations

    Model 100199 SAFETY SAFETY, SERIAL/MODEL, NAMEPLATE LABEL LOCATIONS The safety labels have specific placement and must be replaced if they are unreadable, damaged or missing. A) Serial number location B) Nameplate © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 16: Placement And Installation Guidelines For Champion 8,5Kw Home Standby Generator To Reduce The Risk Of Fire

    Based on this testing and the requirements of NFPA 37, Sec. noncombustible materials and has been demonstrated 4.1.4, the guidelines for installation of the Champion 8.5kW that a fire within the enclosure will not ignite combustible home standby generator are changed to 17.7 inches (45 cm) materials outside the enclosure.

  • Page 17: Specifications

    Engine start sequence Standard Starter lockout Standard Battery charger/low battery indicator Standard Charger fault Standard AVR over voltage protection Standard Low oil protection Standard Safety fused Standard Overcrank/overspeed/underspeed protection Standard © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 18: Champion 439Cc Engine

    Based on the engine’s power, performance and reliability, it was selected to power the 8.5kW Champion Home Stand by generator. This engine design has been used in production since 2008.

  • Page 19: Alternator Overview

    (+) brush and slip ring. The excitation and field boost current passes through the windings and to the frame ground via the negative (-) slip ring and brush, and the BLACK wire. © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 20: Unpacking

    Model 100199 UNPACKING UNPACKING WARNING The HSB weighs more than 300 lbs. (136 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.

  • Page 21: Installation

    This additional compensation is also for differing wattage ratings among devices or appliances. Most devices or Champion HSB units are run and tested at the factory prior to appliances carry tags that reflect wattage usage and you could being shipped.

  • Page 22: Preparation

    This unit shouldn’t be operated in standing water. Champion recommends using a mixture of pea gravel and sand or crushed stone for placement of the mounting pad. The DO NOT place HSB waterproof enclosure under a deck or other mounting pad MUST be level.

  • Page 23: Placement

    Parts damaged in shipping are not covered under Champion warranty. Two (2) 5 foot (1.5 m) lengths of ¾ “steel pipe (supplied by the installer), are required to lift the HSB. Insert the steel pipes Unbox the unit, by removing the exterior shipping carton.

  • Page 24: Instalation Preparation

    LED controllers. NG is lighter than air and will collect in high areas. LPG is heavier Champion HSB units have been run and tested at the factory than air and will settle in low areas. prior to being shipped. They do not require any type of break-in period.

  • Page 25: Fuel Consumption

    Consult your local fuel supplier or Fire Marshall for guidance on proper local codes and installations. All piping must comply with NFPA 54 © 2015 Champion Power Equipment Part No. 101049 Rev. B...
  • Page 26 NG on all threaded fittings to assure zero leakage. Refer to the “Fuel Pipe Sizing Chart” contained in this manual or the Installation manual for your specific HSB model. Champion A dedicated NG fuel supply line pipe and primary gas regulator is HSB units have been run and tested at the factory prior to mandatory for proper operation.

  • Page 27: Lpg Vapor Pipe Sizing

    HSB pad and the ridged gas Use a pipe sealant or joint compound for use with LPG/NG on all supply piping. threaded fitting to assure zero leakage. © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 28: Converting To Lpg

    Loosen the clamp, disconnect the fuel delivery hose from the bottom of the mixing valve. Champion HSB units have been run and tested at the factory Use a flat-head screwdriver to remove the idle/low speed prior to shipment. They do not require any type of break-in orifice (jet) counter clockwise and main orifice (jet) from period.

  • Page 29: Full Fuel Shut Off

    Recheck you initial calculations to ensure where the problem might exist. Champion HSB units have been run and tested at the factory. They do not require any type of break-in period. © 2015 Champion Power Equipment...

  • Page 30: Batery Requirements, Installation & Service

    Model 100199 INSTALLATION 9. BATTERY REQUIREMENTS, F. Also the correct batteries must have lug terminals to match lug battery cables, for a bolt-together connection. All cautions INSTALLATION & SERVICE must be taken in accordance with the battery manufacturers recommendations. Battery sizing is a topic that is discussed and debated for a number of reasons.

  • Page 31: 2015 Champion Power Equipment

    3. Discharge static electricity from body before touching batteries by first touching a grounded metal surface. Do not dispose of battery or batteries in a fire. The battery is capable of exploding. © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 32: Flexible Fuel Line

    No. 14 AWG 296 – 460 ft. (90 – 140m) No. 12 AWG Champion HSB units have been run and tested at the factory prior to shipment. They do not require any type of break-in Utility Circuit and Generator Power Connections period.

  • Page 33: Identify/Select Standby Circuits

    HSB by referring to the sizing guide provided by Champion, www.championpowerequipment.com or call 1 has a 3 point connector, top is B = Black wire (Gen-AC, L1), Champion 1-877-338-0999.

  • Page 34: Set Exercise Time

    Model 100199 INSTALLATION SET EXERCISE TIME of the generator increases or decreases accordingly. The AVR calculates how much voltage has to be sent to exciter numerous To set the exercise time, times a second, therefore stabilizing the output voltage to a predetermined set point.

  • Page 35: Engine Relay Moduel

    Position #1 Frequency R (RED) Position #2 Frequency B (BLACK) Position #3 O (ORANGE) Position #4 Exercise O/B (ORANGE/BLACK) © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 36: Engine Controller

    Model 100199 INSTALLATION Position #5 High Engine Br (BROWN) ATS POSITION – In this position the system is ready for full Temp automatic operation. Position #6 Low oil level/ Y (YELLOW) Monitors constant utility power source voltage, if the pressure...

  • Page 37: 2015 Champion Power Equipment

    DO NOT overfill. Inspect the unit for a possible procedures contained in the manuals specific to your model to oil leak, if a leak is discovered, contact Champion or your nearest clear or correct. Authorized Champion Dealer. Follow the reset procedures HIGH ENGINE TEMP.

  • Page 38: Pin Locations

    Model 100199 INSTALLATION LED INDICATORS Pin 2 G (Green) Pin 3 Motor start signal B/W (Black/White) In all cases when the LED is GREEN, this is an indicator that the HSB is performing properly. Pin 4 Fuel valve G/B (Green/Black)

  • Page 39: Test/Auto/Off Switch

    P (Pink) transferred to the ATS or the household when the engine (HSB) 14. Pin 14 Load AC Detect Br (Brown) is running. 15. Pin 15 Gen AC Detect B (Black) © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 40: Battery Charger

    Model 100199 INSTALLATION 16. Pin 16 Gen AC Detect R (Red) NO CHARGE / PAS DE CHARGE / DIP SWITCHES on the backside of the control, between the 2 SIN CARGA POWER ALIMENTATION rows of pin connectors POTENCIA RECOGNIZED COMPONENT The Dip Switches set parameters of the controller for delay sequences.

  • Page 41: Hsb Test

    The manufacturer recommends Also check L1 to NEUTRAL and L2 to NEUTRAL. These are that a licensed electrician or an factory pre-set limits. individual with complete knowledge of electricity perform these procedures. © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 42: Hsb Test Under Load

    Model 100199 INSTALLATION Frequency 63 Hertz Terminals L1 to L2 230 VAC Terminals L1 to NEUTRAL 115 VAC HSB TESTS UNDER LOAD Terminals L2 to NEUTRAL 115 VAC DURING THIS TEST YOU DO NOT NEED TO TURN OFF ANY 12. Set the HSB generator MAIN CIRCUIT BREAKER to its OFF CIRCUIT BREAKERS IN THE UTILITY MAIN DISTRIBUTION position.

  • Page 43: Checking Automatic Operation

    HSB and ATS for the customer’s reference. The HSB will run through a cool down cycle, shut off and be in standby ready mode. This check is now complete. © 2015 Champion Power Equipment Part No. 101049 Rev. B...
  • Page 44 Model 100199 INSTALLATION NOTICE By law it is required in many states to have a Carbon Monoxide (CO) detector in operating condition in your home. Carbon Monoxide detector(s) must be installed and maintained indoors according to the manufacturer’s instructions. A CO monitor is an electric device that detects hazardous levels of CO.

  • Page 45: Hsb, Ats Model & Serial Reference Ats Back-Up Circuits

    ATS circuits powered ______________________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ Date Installed _____________________________________ Dealer/Installer _____________________________________________________ Address _____________________________________________________ _____________________________________________________ Phone _____________________________________________________ Cell _____________________________________________________ Purchased from _____________________________________________________ © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 46: Automatic Transfer Switch

    ATS, proper installation and conduit is required by code. Mount the ATS vertically to a rigid supporting structure. The Champion Fast/Tran is an automatic transfer switch (ATS) To prevent the ATS or enclosure box from distortion, level all...

  • Page 47: Electrical Grommet(S)

    Conductors must be properly circuit breaker. Repeat for each of the selected circuits. supported, of approved insulation materials, protected by © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 48: Installing Communication Wires

    Model 100199 INSTALLATION The branch conductors must be connected to the same ampacity (size) breakers as they were when they were in the main panel. Make sure that the total ampacity of the selected circuits does not exceed the maximum capacity of the generator.

  • Page 49: Ats Circuit Board Fuse Information

    F4 Load Buss L2 out of the 24 VDC power supply to terminal 1. If the solenoid clicks and the mechanism transfers, fuse F1 is functional. F5 Load Buss L1 out F6 Generator solenoid © 2015 Champion Power Equipment Part No. 101049 Rev. B...

  • Page 50: Fuse F6

    HSB generator by code. All applicable codes must be followed. The manufacturer of the switch provides detailed instructions that must be followed (Champion manual part number 101271). The Champion HSB requires the installation of a Champion approved ATS.

  • Page 51: Troubleshooting Hsb

    Turn off standby circuits for house, reset fault, place unit back into AUTO and ATS mode. Turn on standby circuits for house. If problem returns contact Champion or Champion service dealer*. Engine high/over temperature shut down Check all intake and exhaust ventilation around the HSB, remove all debris.

  • Page 52: Troubleshooting

    This will reset fault LED, however if a fault code(s) re-occurs it must be addressed. BATTERY(S) NO OR LOW LEVEL CHARGED, BATTERY(S) DEAD, NEEDS REPLACEMENT, THE EXERCISE TIME MUST BE RESET ONCE THE BATTERY(S) HAVE BEEN DISCONNECTED. *Contact Champion Power Equipment, Technical Service toll free 1-877-338-0999, tech@championpowerequipment.com or your nearest Champion dealer. www.championpowerequipment.com...
  • Page 53 Champion Power Equipment 12039 Smith Ave. Santa Fe Springs, CA 90670 USA Made in China...

  • Page 54: Year Limited Warranty

    A Champion approved Transfer Switch is highly recommended to be used in conjunction with the generator • set. If a Non-Champion approved Transfer Switch is substituted for use and directly causes damage to the generator set, no warranty coverage shall apply.
  • Page 55 Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all mechanical devices, the Champion engines need periodic part(s) service and fluid replacement to perform as designed.
  • Page 56 Purchaser/owner also may have other rights that vary from state to state. To obtain warranty service or your nearest Champion Home Standby Dealer call Champion Power Equipment Customer Service toll free 1-877-338-0999, Monday - Friday from 8:30 AM - 5:00 PM (PST/PDT).

Table of Contents

Save PDF