Champion 100199 User manual

DANGER: Not intended for use in critical life support application.
DANGER: Generator must be installed and operated outdoors only.

CALIFORNIA PROPOSITION 65 WARNING
Certain components in this product and its related accessories contain chemicals known to the state of California
to cause cancer, birth defects or other reproductive harm. Wash hands after handling.
CALIFORNIA PROPOSITION 65 WARNING
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth
defects or other reproductive harm.
DISCLAIMERS
All information, illustrations and specications in this manual are based on the latest information available at
the time of publishing. The illustrations used in this manual are intended as representative reference views only.
Products are under a continuous improvement policy. Thus, information, illustrations and/or specications to explain
and/or exemplify a product, service or maintenance improvement may be changed at any time without notice.
ALL RIGHTS RESERVED
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?
Do not return this product to the store!
WE ARE HERE TO HELP!
Visit our website:
www.championpowerequipment.com
for more info:
• Product Info & Updates
• Frequently Asked Questions
• Tech Bulletins
• Product Registration
– or –
Call our Customer Care Team Toll-Free at:
1-877-338-0999
*We are always working to improve our products. Therefore, the enclosed product may differ slightly from the image on the cover.

3
Model 100199
CONTENTS
© 2015 Champion Power Equipment Part No. 101049 Rev. B
CONTENTS
INTRODUCTION ..........................5
Home standby generator...................5
PartsIncluded ..........................5
HSB Models ............................6
Standard Features Tailor-Made Solutions . . . . . . .6
General Information, Standards and Codes......7
SAFETY ................................8
Safety Symbol Denitions..................8
Installation Hazards. . . . . . . . . . . . . . . . . . . . . . .9
Before Starting ..........................10
OperatingHazards.......................10
Accidental Starting .......................11
Carbon Monoxide Hazards..................11
Electrical Shock Hazards ...................12
Fire/Explosion Hazards . . . . . . . . . . . . . . . . . . . .12
Burn Hazards ...........................13
Entanglement Hazards . . . . . . . . . . . . . . . . . . . .13
BatteryHazards.........................13
Safety Labels ...........................13
SafetyLabelsonUnit....................... 14
Safety, Serial/Model, Nameplate Label Locations . . . 15
Placement and Installation Guidelines for
Champion 8,5kW Home Standby Generator
to Reduce the Risk of Fire . . . . . . . . . . . . . . . . .16
National Fire Protection Association (NFPA)
Standard NFPA 37 Requirements and Testing...... 16
SPECIFICATIONS .........................17
Champion 439CC Engine . . . . . . . . . . . . . . . . . .18
Champion 439CC Engine Torque Specications . .18
Master Mixing Assembly Jets
(Carburetor System) . . . . . . . . . . . . . . . . . . . . . .18
Alternator Overview . . . . . . . . . . . . . . . . . . . . . .19
RotorAssembly .........................19
Stator Assembly .........................19
Brush Holder and Brushes..................19
UNPACKING .............................20
INSTALLATION ...........................21
Generating Sizing ........................21
Site Selection, Preparation and Placement . . . . . .21
Site Selection............................. 21
Preparation.............................. 22
Placement............................... 23
Instalation Preparation . . . . . . . . . . . . . . . . . . . .24
Fuel Requirements and Recommendations........ 24
FuelConsumption ......................... 25
NG Pipe Sizing............................ 25
LPG Vapor Pipe Sizing . . . . . . . . . . . . . . . . . . . . . . 27
ConvertingtoLPG ......................... 28
Full Fuel Shut Off .......................... 29
Sediment Trap ............................ 29
Checking Pressure with a Manometer . . . . . . . . . . . 29
Batery Requirements, Installation & Service ....... 30
FlexibleFuelLine........................32
Wire Sizing.............................32
Identify/Select Standby Circuits . . . . . . . . . . . . . .33
Surge Protection.........................33
Hour Meter and Over Voltage Protection........33
HourMeter .............................. 33

4
Model 100199
CONTENTS
Part No. 101049 Rev. B
Over Voltage Protection . . . . . . . . . . . . . . . . . . . . . 33
Set Exercise Time ........................34
AVR=Automatic Voltage Regulator ............34
EngineRelayModuel .....................35
Top Row ................................ 35
Bottom Row.............................. 35
EngineController........................36
ModeSwitch............................. 36
Pin Locations............................. 38
ATS Control Module ......................38
Test/Auto/Off Switch. . . . . . . . . . . . . . . . . . . . . . . . 39
Pin Locations............................. 39
BatteryCharger.........................40
HSBTest ..............................41
Voltage Checks- No Load .................... 41
HSBTestUnderLoad....................... 42
Checking Automatic Operation...............43
Customer Familiarization Summary . . . . . . . . . . .43
HSB, ATS Model & Serial Reference
ATS Back-Up Circuits .....................45
Automatic Transfer Switch..................46
Unpacking ............................... 46
Location and Mounting...................... 46
Circuit Breakers for Utility
Main Control Panel and ATS . . . . . . . . . . . . . . . . . . 46
Electrical Grommet(s) ....................... 47
Installation Wiring for ATS
to Utility Main Control Panel . . . . . . . . . . . . . . . . . . 47
Installing Communication Wires. . . . . . . . . . . . . . . . 48
Commissioning the ATS . . . . . . . . . . . . . . . . . . . . . 48
ATS Circuit Board Fuse Information ...........49
ATS Fuse Troubleshooting and Testing .........49
FusesF2andF3.......................... 49
FusesF4andF5.......................... 49
Fuse F1................................. 49
Fuse F6................................. 50
Manual Transfer Switch....................50
TROUBLESHOOTING HSB ...................51
This manual must be used with Champion Power Equipment
(CPE) manuals:
• Operation Manual, Part No. 101048
• Transfer Switch Manual, Part No. 101111
It is also recommended to refer to the reference materials on page
7 of this manual.

5
Model 100199
INTRODUCTION
© 2015 Champion Power Equipment Part No. 101049 Rev. B
Congratulations on your purchase of a Champion Power
Equipment (CPE) home standby generator. This generator is
designed and engineered in the USA to exacting standards of the
North American market. This engine-powered generator meets
all Environmental Protection Agency (EPA) Phase 3 requirements
and is approved by CETLUS as tested to UL2200 and CSA22.2 No.
100 in both the USA and Canada.
With proper use and maintenance, this generator will provide
years of satisfying service.
The Champion Staff,
Champion Power Equipment
12039 Smith Ave.
Santa Fe Springs, CA 90670
Toll-free: 1-877-338-0999
Mon-Fri 8:30 AM – 5:00 PM (PST/PDT)
www.championpowerequipment.com
[email protected]
HOME STANDBY GENERATOR
This home standby generator is intended exclusively for outdoor
installation. This generator will operate using either liqueed
petroleum gas (LPG, Propane) or natural gas (NG).
This generator is designed to supply typical home load such as:
• Induction motors – sump pumps, refrigerators, air
conditioners, furnaces
• Electronic items – televisions, computers
• Household lighting
• Microwaves
• This generator is not intended for use in critical life
support applications.
Proper sizing of the generator is required to ensure proper
operation of appliances. Some appliances require additional
wattage to start and must be considered.
PARTS INCLUDED
Your HSB ships with the following:
• Operators Manual
• Installation Manual
• Oil Drain Pan
• Flexible Fuel Line
• HSB Enclosure Keys
• Battery Cable Connection
• LPG Low-speed and Main Converting Jets
• Jet Change Tool
• Lock Nut M6, Flange
• Washer, Ø6
• Flange bolt, M6 x 20

6
Model 100199
INTRODUCTION
Part No. 101049 Rev. B
HSB MODELS
100199 8.5kW HSB Generator Only
100947 ATS Only 50A NEMA 1 (non-pre-wired switch)
100950 ATS Only 50A ATS NEMA 3R (non-pre-wired switch)
100174 8.5kW HSB & 50A ATS NEMA 1 (non-pre-wired switch)
100177 8.5kW HSB & 50A ATS NEMA 3R (non-pre-wired switch)
STANDARD FEATURES, TAILOR-MADE SOLUTIONS
: Tested and approved by CARB, EPA and UL in both USA and Canada
: HSB Designed and Engineered in the USA by Champion
: Milwaukee Series Engine, Designed and Engineered in USA by Champion
: 5 year, 2000 hour limited warranty
: Easy access, all weather steel, sound attenuated enclosure, Gull Wing door design, quite operation
: Composite Mounting Pad, eliminates the need of concrete pad unless required by code
: Natural Gas (NG) or LP gas (propane) operation
: Exterior LED fault light (turns on if unit controller detects a fault code)
: Automatic weekly exercise, operates engine and generator between outage events, system check
: On board battery charging and monitoring, digital LED controller
: Engine and Generator monitoring, digital LED controller
: Fast/Tran ATS (automatic transfer switch), safe and simple, extremely high speed switching system
: 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. All our residential standby products are designed in conformance with Environmental Protection Agency (EPA)
requirements, California Air Resource Board (CARB) regulations and are approved by Underwriters Laboratory (UL) in both the USA and
Canada. When the power goes out you’ll want a Champion by your side.

7
Model 100199
INTRODUCTION
© 2015 Champion Power Equipment Part No. 101049 Rev. B
GENERAL INFORMATION,
STANDARDS AND CODES
The following information related to General Information and
Standards was gathered from the list of publications related
to installing the HSB generator. A multitude of other materials
related to generators were also used concerning common
practice, knowledgeable installation practices, certied
electrical experience and work related experiences. This
information is not all inclusive and the manufacturer strongly
recommends the owner and installer become familiar with all
pertinent codes, standards and regulations. Always check for
the latest publications date to ensure you are current. Have
only a qualied/certied electrician or installation technician
who is knowledgeable about applicable codes, standards and
regulations install and service the generator.
NFPA NO. 30, FLAMMABLE AND CONBUSTIBLE LIQUID
CODE
National Fire Protection Association
470 Atlantic Avenue, Boston, MA. 02210
NFPA NO.37, STATIONARY COMBUSTION ENGINES AND
GAS TURBINES
National Fire Protection Association
470 Atlantic Avenue, Boston, Ma. 02210
NFPA NO. 76A, ESSENTIAL ELECTRICAL SYSTEMS FOR
HEALTH CARE FACILITIES
National Fire Protection Association
470 Atlantic Avenue, Boston, Ma. 02210
NFPA NO.54, NATIONAL FUEL GAS CODE
National Fire Protection Association
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
NFPA NO.70, NFPA HANDBOOK OF ELECTRIC CODE
National Fire Protection Association
470 Atlantic Avenue, Boston, Ma. 02210
ARTICLE X, NATIONAL BUILDING CODE
American Insurance Association
85 John Street, New York, N.Y. 10038
AGRICULTURAL WIRING HANDBOOK
Food and Energy Council
909 University Avenue, Columbia, Mo. 65201
ASAE EP-3634, INSTALLATION AND MAINTENANCE OF
FARM STANDBY ELECTRICAL SYSTEMS
American Society of Agricultural Engineers
2950 Niles Road, St. Joseph, Mi. 49085

8
Model 100199
SAFETY
Part No. 101049 Rev. B
!
This is the safety alert symbol. It is used to alert
you to potential physical injury hazards. Obey all
safety messages that follow this symbol to avoid
possible injury or death.
The words DANGER, WARNING, CAUTION and NOTICE are used
throughout this manual to highlight important information.
!
DANGER
Indicates a hazardous situation that, if not avoided, will
result in death or serious injury.
!
WARNING
Indicates a hazardous situation that, if not avoided,
could result in death or serious injury.
!
CAUTION
Indicates a hazardous situation that, if not avoided,
could result in minor or moderate injury.
NOTICE
Indicates a situation that can cause damage to the
equipment, personal property and/or the environment, or
cause the equipment to operate improperly.
OTE:NIndicates a procedure, practice or condition that
should be followed in order for the generator to
function in the manner intended.
SAFETY SYMBOL DEFINITIONS
Black hazard pictorial on yellow
equilateral triangle enclosed by black
triangular band
Warns that hazard exists and describes
its nature and/or consequences
Black hazard pictorial on white circle
enclosed by red circular band with red
diagonal bar
Depicts action NOT to be taken or
action to be stopped in order to avoid
hazard
White hazard pictorial on blue circle
Depicts action to be taken in order to
avoid hazard
WARNINGS
!
Safety alert symbol
Asphyxiation hazard
Electrical shock hazard
Entanglement hazard
Fire hazard

9
Model 100199
SAFETY
© 2015 Champion Power Equipment Part No. 101049 Rev. B
Explosion hazard
Burn hazard
Sever hazard (rotating blade)
Crush hazard (top)
MANDATORY ACTIONS
Read manufacturer’s instructions
Wear eye protection
Wear personal protective equipment
Do not leave tools in the area
INSTALLATION HAZARDS
!
WARNING
!
Have only a qualied electrician
or installation technician who is
familiar with applicable codes,
standards and regulations install
and service the generator.
ALWAYS comply with local, state
and national electrical and building
codes when installing the generator.
NEVER alter the recommended
installation in a way that would
render the unit noncompliant with
these codes.
ALWAYS comply with regulations
that Occupational Safety and
Health Administration (OSHA) has
established.
ENSURE the generator is installed
following the manufacturer’s
instructions.
NOTICE
Before welding components on the generator, contact CPE
for recommended welding instructions.
!
WARNING
!
Not intended for use in critical life
support applications.

10
Model 100199
SAFETY
Part No. 101049 Rev. B
BEFORE STARTING
!
CAUTION
Before starting, operating and
maintaining this generator, be sure
to read and understand the content
and safety messages in this manual.
The operator is responsible for safe
operation and maintenance of the
generator. Be sure all potential users
of the generator also understand
these instructions. If any portion
of this manual is not understood,
contact your dealer for assistance
before operating the generator.
The operator is responsible for
performing all safety checks, making
sure all maintenance is properly
performed and making sure the
generator is periodically checked by
the dealer.
Inspect the generator regularly.
Contact your dealer if repairs are
needed.
NEVER climb or step on any part or
components of the generator. Doing
so may result in injury and cause
leaking fuel and exhaust.
OPERATING HAZARDS
!
WARNING
!
ALWAYS operate the generator
following the manufacturer’s
instructions. Operating the generator
imprudently, neglecting maintenance
or being careless can result in injury
or possible death.
DO NOT allow children or unqualied
persons to operate or service the
generator.
NEVER operate the generator
with the covers open. Operate the
generator only with the covers
closed and secured in place. NEVER
leave the covers unlocked.
Remain alert at all times when
working on the generator. NEVER
work on the generator when
physically or mentally fatigued.
Never operate the generator while
under the inuence of alcohol
or drugs. Their effects on vision
and judgment make operating a
generator dangerous.