Briggs & Stratton 40213 Installation and operation manual

Installation and
Start-Up Manual
Manual de Instalación y
Arranque
Manuel d'Installation et
Démarrage
Questions? Help is just a moment away!
Preguntas? La ayuda es justa un momento
lejos!
Vous avez des questions?Vous n'avez pas
besoin d'aller loin pour trouver de l'aide!
Call: Home Generator Helpline
Llamada: Línea Directa de Generador de Hogar
Appelez: Ligne Directe de Génératrice la
Maison - 1-800-743-4115 M-F 8-5 CT
Web: www.homegeneratorsystems.com
Manual No. 194688GS Rev. 1 (12/20/05)
Models / Modelos / Modèles
040213
040234
15000 Rated Watts
Home Generator System

REFERENCE
2
TABLE OF CONTENTS EQUIPMENT
DESCRIPTION
This product is intended for use as an optional home
generator system which provides an alternate source of
electric power and to serve loads such as heating,
refrigeration systems, and communication systems that,
when stopped during any power outage, could cause
discomfort, or the like.This product DOES NOT qualify for
emergency standby as defined by NFPA 70 (NEC).
This manual contains installation, startup and adjustment
instructions for a Home Generator System that supplies
120/240 Volt, single phase, 60Hz devices.The Home
Generator System may be operated on LP or natural gas
fuel.A separate operator’s manual (part number 194689GS)
contains specifications, operating and maintenance
instructions for this model.
Every effort has been made to ensure that the information in
this manual is both accurate and current. However, the
manufacturer reserves the right to change, alter or otherwise
improve the system at any time without prior notice.
CUSTOMER
RESPONSIBILITIES
• Read and follow the instructions given in the Operator’s
Manual, especially the section regarding selecting essential
circuits.
• Follow a regular schedule in maintaining, caring for and
using your Home Generator System, as specified in the
Operator’s Manual.
INSTALLER
RESPONSIBILITIES
• Read and observe the safety rules.
• Refer to the list of recommended UL approved transfer
switches that is compatible with the Home Generator
System elsewhere in the carton.
• Read and follow the instructions given in this Installation
and Start-up Manual.
IMPORTANT: If operating the generator below 0°F,
a battery warmer and oil heater MUST be installed.
Both items are available at your local servicing dealer.
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
EQUIPMENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 2
CUSTOMER RESPONSIBILITIES . . . . . . . . . . . . . . . . . . . . 2
INSTALLER RESPONSIBILITIES . . . . . . . . . . . . . . . . . . . . 2
IMPORTANT SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . 3
Hazard Symbols and Meanings. . . . . . . . . . . . . . . . . . . 3
INSTALLATION PROCEDURES . . . . . . . . . . . . . . . . . . . . 4
Unpacking Precautions . . . . . . . . . . . . . . . . . . . . . . . . 4
Delivery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shipment Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Required Specialty Tools/Equipment . . . . . . . . . . . . . . 4
Home Generator System Location . . . . . . . . . . . . . 4-5
Fuel and Electrical Inlet Dimensions . . . . . . . . . . . . . . 5
Lifting the Generator . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
THE GASEOUS FUEL SYSTEM . . . . . . . . . . . . . . . . . . . 7-8
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel Pipe Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SYSTEM CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . 10
Generator AC Connection System . . . . . . . . . . . . . 11
Grounding the Generator . . . . . . . . . . . . . . . . . . . . . 11
Utility Control Circuit Connection . . . . . . . . . . . . . 11
Fault Detection System . . . . . . . . . . . . . . . . . . . . . . . 11
System Control Panel . . . . . . . . . . . . . . . . . . . . . . . . 12
BEFORE INITIAL ENGINE START-UP . . . . . . . . . . . . . . 12
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . 12-13
Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FUEL SYSTEM SELECTION . . . . . . . . . . . . . . . . . . . . 13-14
INITIAL START-UP (NO LOAD) . . . . . . . . . . . . . . . . . . 14
Engine Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 14-15
AUTOMATIC OPERATION SEQUENCE . . . . . . . . . . . . 15
SETTING EXERCISE TIMER . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . 16
Fuel Comparison Chart . . . . . . . . . . . . . . . . . . . . . . 17
Size of Propane Tank Required at Various Temperatures
When Kept at Least Half Full . . . . . . . . . . . 17
Copyright © 2005 Briggs & Stratton Power Products
Group, LLC. All rights reserved. No part of this material
may be reproduced or transmitted in any form by any
means without the express written permission of Briggs &
Stratton Power Products Group, LLC.

SAFETY RULES
3
IMPORTANT SAFETY
RULES
The safety alert symbol ( ) is used with a signal word
(DANGER, CAUTION,WARNING), a pictorial and/or a
safety message to alert you to hazards. DANGER indicates
a hazard which, if not avoided, will result in death or serious
injury. WARNING indicates a hazard which, if not avoided,
could result in death or serious injury. CAUTION
indicates a hazard which, if not avoided, might result in
minor or moderate injury. CAUTION, when used
without the alert symbol, indicates a situation that could
result in equipment damage. Follow safety messages to
avoid or reduce the risk of injury or death.
Hazard Symbols and Meanings
• Adequate, unobstructed flow of cooling and ventilating air is
critical to correct generator operation.
• Despite the safe design of the Home Generator System,
operating this equipment imprudently, neglecting its maintenance
or being careless can cause possible injury or death.
• Remain alert at all times while working on this equipment.
NEVER work on the equipment when you are physically or
mentally fatigued.
• DO NOT use the generator or any of its parts as a step.
Stepping on the unit can cause stress and break parts.This
may result in dangerous operating conditions from leaking
exhaust gases, fuel leakage, oil leakage, and so forth.
Improper treatment of generator can damage it and
shorten its life.
CAUTION
• When using generator for backup power, notify utility
company.
• DO NOT touch bare wires or receptacles.
• DO NOT use generator with electrical cords which are worn,
frayed, bare or otherwise damaged.
• DO NOT handle generator or electrical cords while standing
in water, while barefoot, or while hands or feet are wet.
• If you must work around a unit while it is operating, stand on
an insulated dry surface to reduce shock hazard.
• DO NOT allow unqualified persons or children to operate or
service generator.
• In case of an accident caused by electrical shock, immediately
shut down the source of electrical power and contact the
local authorities. Avoid direct contact with the victim.
• Before performing any maintenance on the generator,
disconnect the battery cable indicated by a NEGATIVE,
NEG or (-) first.When finished, reconnect that cable last.
• After your Home Generator System is installed, the generator
may crank and start without warning any time there is a
power failure.To prevent possible injury, always set the
generator’s system switch to OFF, remove the service
disconnect from the disconnect box AND remove the
15 Amp fuse BEFORE working on the equipment.
Generator produces powerful voltage.
Failure to properly ground generator can result
in electrocution.
Failure to isolate generator from power utility
can result in death or injury to electric utility
workers due to backfeed of electrical energy.
WARNING
• Install the fuel supply system according to applicable fuel-gas
codes.
• Before placing the Home Generator System into service, the
fuel system lines must be properly purged and leak tested.
• After the generator is installed, you should inspect the fuel
system periodically.
• NO leakage is permitted.
• DO NOT operate engine if smell of fuel is present or other
explosive conditions exist.
• DO NOT smoke around the generator.Wipe up any oil spills
immediately. Ensure that no combustible materials are left in
the generator compartment. Keep the area near the generator
clean and free of debris.
Propane and Natural Gas are extremely
flammable and explosive.
Fire or explosion can cause severe burns or
death.
WARNING
• DO NOT tamper with governed speed. Generator supplies correct
rated frequency and voltage when running at governed speed.
• DO NOT modify generator in any way.
Excessively high operating speeds increase risk
of injury and damage to generator.
Excessively low speeds impose a heavy load.
CAUTION
SAVE THESE INSTRUCTIONS
Fire
Explosion Rotating Parts Electrical Shock

INSTALLATION
4
INSTALLATION
PROCEDURES
Unpacking Precautions
The unit is shipped bolted to its mounting pad, ready for
installation.Avoid damage from dropping, bumping, collision,
etc. Store and unpack carton with the proper side up, as
noted on the shipping carton.
Delivery Inspection
After removing the carton, carefully inspect the Home
Generator System for any damage that may have occurred
during shipment.
IMPORTANT: If loss or damage is noted at time of
delivery, have the person(s) making delivery note all damage
on the freight bill and affix his signature under the
consignor's memo of loss or damage. If loss or damage is
noted after delivery, separate the damaged materials and
contact the carrier for claim procedures. Missing or
damaged parts are not warranted.
Shipment Contents
The Home Generator System is supplied with:
• Home Generator System
• Pre-attached mounting pad
• One 24” flexible hook-up hose
• Installation and start-up manual
• Operator’s manual
• Illustrated parts list manual
• Installation checklist
• Two access door keys
• Four lifting hole plugs
• Oil fill spout
• One spare 15A fuse
• 2 Pole connector - 240V from house
• 10 Pole connector - Sensing and control wires
• Air intake engine cover
• Alternator cover
• Diagnostic LED kit (red LED/plate/screws (2))
Required Specialty Tools/Equipment
• Two 48” lengths of 1” OD pipe (NOT conduit)
• Hole punches for 16ga steel
• Torque screwdriver, 5 to 50 inch-pound range
Home Generator System Location
Before installing generator, consult with homeowner and
convey the following guidelines which may affect the
desired location.
Generator Clearances
Place generator in a well ventilated area, which will allow for
removal of deadly exhaust gas. DO NOT install generator
where exhaust gas could accumulate and enter inside or be
drawn into a potentially occupied building. Ensure exhaust gas
is kept away from any windows, doors, ventilation intakes or
other openings that can allow exhaust gas to collect in a
confined area (Figure 1). Prevailing winds and air currents
should be taken into consideration when positioning generator.
• Observe that the 15 Amp fuse has been removed from the
control panel for shipping.
• DO NOT install this fuse until all plumbing and wiring has
been completed and inspected.
Installing the 15A fuse could cause the engine to start.
CAUTION
• Operate generator ONLY outdoors.
• Keep exhaust gas from entering a confined area through
windows, doors, ventilation intakes or other openings.
Running generator gives off carbon monoxide,
an odorless, colorless, poison gas.
Breathing carbon monoxide will cause nausea,
fainting or death.
WARNING
• Keep at least 5 ft. (152 cm) clearance on all sides of generator
including overhead.
Exhaust heat/gases can ignite combustibles or
structures causing a fire.
WARNING
Figure 1 — Home Generator System Clearances
Exhaust port must be
5 ft (152 cm)
minimum distance
from building openings
Exhaust Port

INSTALLATION
5
General Location Guidelines
• Install the unit outdoors ONLY.
• Place the unit in a prepared location that is flat and has
provisions for water drainage.
• Install the unit where air inlet and outlet openings will
not become obstructed by leaves, grass, snow, etc. If
prevailing winds will cause blowing or drifting, you may
need to construct a windbreak to protect the unit.
• Install the generator as close as possible to the Transfer
Switch to reduce the length of wiring and conduit.
• Install the generator as close as possible to the fuel
supply to reduce length of pipes.
IMPORTANT: Laws or local codes may regulate the
distance to the fuel supply.
The Home Generator System is shipped already attached
to its mounting pad. Unless mandated by local code, a
concrete slab is not required.
If mandated by local code, construct a concrete slab at least
3 inches thick and 6 inches longer and wider than the unit.
Attach unit to slab with 1/4” diameter (minimum) masonry
anchor bolts long enough to retain the unit.
Fuel and Electrical Inlet Dimensions
Figure 2, below, depicts the location of the fuel piping
connector.Also shown is the recommended location for
punching holes for attaching the power conduit.
Lifting the Generator
The generator weighs more than 600 pounds. Proper tools,
equipment and qualified personnel should be used in all
phases of handling and moving the generator.
Two 48” lengths of 1” O.D. pipe (supplied by the installer)
are required to lift the generator manually. Insert pipes
through the lifting holes located near the unit’s base, as
shown in Figure 3 (next page).
Figure 2 — Generator Fuel and Conduit Attachment Locations, Oil Fill Side of Unit
3/4” NPT
Fuel Piping
Connector
Recommended
Conduit Attachment
Area
• If lifting or hoisting equipment is used, DO NOT contact any
power lines.
• DO NOT lift or move generator without assistance.
• Use lifting pipes as described in the section “Lifting the
Generator” in installation manual.
• The unit may shift on the lifting pipes during movement, which
can cause injury.
• DO NOT lift unit by roof as damage to generator will occur.
Hazardous Voltage
Contact with power lines can cause electric
shock or burn.
Lifting Hazard / Heavy Object
Can cause muscle strain or back injury.
WARNING

INSTALLATION
6
You may also lift the unit using a “hook and hoist” method
attached to the lifting pipes, provided that you use a
spreader bar to ensure that the chains or cables do not
touch the generator’s roof.
After unit is in place, fill the lifting holes with the supplied
lifting hole plugs.
Access Doors
The Home Generator System is equipped with an
enclosure that has three access doors (Figure 4).The doors
are named for a significant component located behind
them. Starting with the side that has the fuel connection
and proceeding clockwise, the doors are named:
• Oil Fill door
• Control Panel door
• Oil Drain door
Each Home Generator System is equipped with two identical
keys.These keys fit the locks that secure the access doors.
To Open an Access Door:
1. Insert key into lock of access door you wish to open
and turn one quarter turn counterclockwise.
2. Grasp door’s handle and turn one quarter turn
counterclockwise to open. Remove key.
To Close an Access Door:
1. Close door and turn doors handle one quarter of a
turn clockwise.
2. Insert key into lock of access door and turn one
quarter turn clockwise. Remove key.
To lift: Insert
pipe here Installer-supplied pipe
Figure 3 — Location of Lifting Holes
Oil Fill Door
Fuel Inlet
Exhaust
Port
Control Panel Door
Oil Drain Door
Exhaust Bulkhead
Figure 4 — Enclosure Access Doors
• DO NOT touch hot surfaces.
• Allow equipment to cool before touching.
Running engines produce heat.Temperature of
exhaust port and nearby areas can reach or
exceed 600°F (316°C).
Severe burns can occur on contact.
WARNING

INSTALLATION
7
THE GASEOUS FUEL
SYSTEM
TO THE INSTALLER: Consult with the Home
Generator System owner(s) and convey any
technical considerations that might affect their
installation plans before applying these general
guidelines.
The following general rules apply to gaseous fuel system
piping:
• The piping should be of a material that conforms to
federal and local codes, rigidly mounted and protected
against vibration.
• Piping should be protected from physical damage where
it passes through flower beds, shrub beds, and other
cultivated areas where damage could occur.
• Install the flexible, gaseous hose (supplied) between the
Home Generator System Fuel Inlet port and rigid piping
to prevent thermal expansion or contraction from
causing excessive stress on the piping material.
NOTE: Where local conditions include earthquake,
tornado, unstable ground, or flood hazards, special
consideration shall be given to increase strength and
flexibility of piping supports and connections.
• Piping must be of the correct size to maintain the
required supply pressures and volume flow under varying
generator load conditions with all gas appliances
connected to the fuel system turned on and operating.
• Use an approved pipe sealant or joint compound on all
threaded fittings to reduce the possibility of leakage.
• Installed piping must be properly purged and leak tested,
in accordance with applicable codes and standards.
The information provided below is to assist
gaseous fuel system technicians in planning
installations. In no wayshould this information
be interpreted to conflict with applicable fuel gas
codes. Consult with your local fuel supplier or
Fire Marshall if questions or problems arise.
• The entire flexible gaseous pipe must be visible for periodic
inspection and must not be concealed within, contact, or run
through any wall, floor, or partition.
The supplied flexible gaseous pipe is not to be installed
underground or in contact with the ground.
CAUTION
• LP gas is heavier than air and will settle in low areas.
• Natural gas is lighter than air and will collect in high areas.
• The slightest spark can ignite these fuels and cause an explosion.
Propane and Natural Gas is extremely
flammable and explosive.
Fire or explosion can cause severe burns or
death.
WARNING
• Before placing the Home Generator System into service, the
fuel system lines must be properly purged and leak tested.
• NO leakage is permitted.
Propane and Natural Gas is extremely
flammable and explosive.
Fire or explosion can cause severe burns or
death.
WARNING

INSTALLATION
8
Consider the following factors when planning to
install the fuel supply system:
The Home Generator System engine is fitted with a fuel
mixer system that meets the specifications of the California
Air Resources Board for “tamper-proof” dual fuel systems.
The unit will run on natural gas or liquefied propane.
• A minimum of one accessible, approved manual shutoff
valve shall be installed in the fuel supply line within 6 ft
(1.8 m) of the Home Generator System.A union or
flanged connection shall be provided downstream from
this valve to permit removal of controls.
• Natural gas fuel supply pressure at the generator's fuel
inlet port should be between 5 to 7 inches of water (in.
W.C.) at full load. LP fuel supply pressure should be 11 to
14 inches of water (in.W.C.) at full load.
The Home Generator System unit has been factory
set to run on natural gas. If you need to change from
natural gas to LP gas, the unit will need to be reconfigured,
as described on page 13.
It is recommended that the fuel connection incorporate
the following components:
• A manual fuel shut-off valve located in the interior of the
building.
• A manual fuel shut-off valve located outside the building,
just before the generator unit.
• Where the formation of hydrates or ice is known to
occur, piping should be protected against freezing.The
termination of hard piping should include a sediment trap
where condensate is not likely to freeze.
• A manometer port should be provided.
The manometer port permits temporary installation of a
manometer (Figure 5), to ensure that the engine receives
the correct fuel pressure to operate efficiently throughout
its operating range.
NOTE: A digital manometer, P/N 19495, is available at your
local Briggs and Stratton Power Products service center.
When the initial test runs are completed, the manometer is
removed and the port is plugged.A typical final fuel
connection assembly is shown in Figure 6.
Figure 6 — Completed Fuel Connections
Figure 5 — Temporary Manometer Installed
From Fuel
Supply Line
To Home
Generator System

INSTALLATION
9
Fuel Consumption
See Figure 7 for fuel supply requirements at half and full
load for both natural gas and LP vapor.
Fuel Pipe Sizing
Figures 8 and 9 provide the maximum capacity of pipe in
cubic feet of gas per hour for gas pressures of 0.5 psi or
less and a pressure drop of 0.3 in. water column. Specific
gravity of gas is shown.
Listed values compensate for a nominal amount of
restriction from bends, fittings, etc. If an unusual number of
fittings, bends, or other restrictions are used, please refer
to federal and local codes.
Models Natural Gas* LP Vapor**
1/2 Load Full Load 1/2 Load Full Load
040213-0 & 040234-0 120 233 49.62 +/- 5% 95.29 +/- 5%
* = Natural Gas is in cubic feet per hour
** = LP Vapor is in cubic feet per hour
Figure 7 — Fuel Supply Requirements
NPT 10ft 15ft 20ft 30ft 40ft 50ft 60ft 70ft 80ft 90ft 100ft
3/4” 346 293 240 192 163 145 132 120 113 106 99
1” 653 549 446 360 307 274 250 230 211 197 187
Natural Gas (sg=0.65)
NPT 10ft 15ft 20ft 30ft 40ft 50ft 60ft 70ft 80ft 90ft 100ft
3/4” 277 192 158 126 107 95 87 79 74 69 65
1” 428 360 293 236 202 180 164 151 139 129 123
Liquid Propane (LP) (sg=1.50)
Figure 8 — NATURAL GAS (NG) Pipe Size - Gas Flow Chart, in cubic feet per hour
Figure 9 — LIQUID PROPANE (LP) GAS Pipe Size - Gas Flow Chart, in cubic feet per hour

FEATURES AND CONTROLS
10
SYSTEM CONNECTIONS
Compare this illustration with your generator to familiarize yourself with the location of these important connections:
+12 Volt DC, .5 Amp Output
240 Volt Utility
Wiring for the 2 Pole Plug:
240 Volt Utility — Use to hook up the 240V utility leads
from the transfer switch to the generator.
Wiring for the 10 Pole Plug:
Fault Contacts — Use NO, COM and NC to hook up a
siren, light, etc. to alert you in case of a fault. Contacts
reverse state upon a fault condition.
Remote LED Output — Use this to hook up the
remote LED supplied with the generator.The remote LED
will turn on and off in a series of blinks if certain faults are
detected in the generator.
Transfer Switch Communication — Use TxRx and
TxRx GND to transfer switch and optional wireless
StatStation™ to monitor generator functions.
+12 Volt DC, .5 Amp Output — Internal power supply.
Remote LED Output
Transfer Switch
Communication
Fault Contacts