Champion aXis CONTROLLER Installation Manual Download Page 3

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aXis CONTROLLER HOME STANDBY GENERATOR

TABLE OF CONTENTS

Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Home Standby Generator

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Included

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Definitions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Symbols

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Important Safety Instructions

. . . . . . . . . . . . . . . . . . . . . . .

Installation Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Starting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accidental Starting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carbon Monoxide Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Shock Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire/Explosion Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Burn Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Entanglement Hazards

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Battery Hazards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Labels and Hang Tags

. . . . . . . . . . . . . . . . . . . . . . .

Safety, Serial/Model, Nameplate Label Locations

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Specifications

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14kW HSB Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion 754cc Engine

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Champion 754cc Engine Torque Specifications

. . . . . . . . . . . . . . . . .

Master Mixing Assembly Jets (Carburetor System)

. . . . . . . . . . . .

Alternator Overview

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unpacking

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Placement & Installation Guidelines for Champion Home Standby

Generators to Reduce the Risk of Fire

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intertek Group PLC Label

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Site Selection, Preparation and Placement

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Installation Preparation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Surge protection

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AVR = Automatic Voltage Regulator

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Engine Relay Module

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Exterior Warning LED

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Generator ON/OFF Switch

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aXis Controller™ Module

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Programming aXis Controller™

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Charger

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Transfer Switch (ATS)

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aXis Controller™ Module

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ATS Installation

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Commissioning the ATS

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HSB Test

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Checking Automatic Operation

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Installing Standby Generator to non-aXis Controller ™ ATS

. . .

Customer Familiarization Summary

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Troubleshooting HSB

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HSB, ATS Model & Serial Reference ATS Back-up Circuits

. . . . .

Summary of Contents for aXis CONTROLLER

Page 1: ...nd understood before operating the product Failure to do so could result in serious injury This manual should remain with the product 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 REGIST...

Page 2: ...quently Asked Questions or Call our Customer Care Team Toll Free at 1 877 338 0999 Tech Bulletins Product Registration This manual must be used with Champion Power Equipment CPE manuals Installation Manual Part No 101951 Transfer Switch Manual Part No 101948 We are always working to improve our products Therefore the enclosed product may differ slightly from the image on the cover ...

Page 3: ...15 Master Mixing Assembly Jets Carburetor System 15 Alternator Overview 16 Unpacking 16 Installation 17 Placement Installation Guidelines for Champion Home Standby Generators to Reduce the Risk of Fire 17 Intertek Group PLC Label 18 Site Selection Preparation and Placement 19 Installation Preparation 21 Surge protection 28 AVR Automatic Voltage Regulator 28 Engine Relay Module 29 Exterior Warning ...

Page 4: ...r maintenance this product should bring years of satisfying service Every effort has been made to ensure the accuracy and completeness of the information in this manual at the time of publication and we reserve the right to change alter and or improve the product and this document at any time without prior notice CPE highly values how our products are designed manufactured operated and serviced as...

Page 5: ...r warnings they give are not substitutes for proper accident prevention measures DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate i...

Page 6: ...injury user must read and understand operator s manual before using this product Eye protection Always wear eye protection with side shields marked to comply with ANSI Z87 1 Wear personal protective equipment Safety alert symbol Asphyxiation hazard Electrical shock hazard Entanglement hazard Fire hazard Fire Explosion Fuel and its vapors are extremely flammable and explosive Fire or explosion can ...

Page 7: ...aXis CONTROLLER HOME STANDBY GENERATOR SAFETY 7 SYMBOL MEANING Sever hazard rotating blade Crush hazard top ...

Page 8: ...cal equipment to live Inform your electrical provider immediately if a loss of power would cause you or anyone in your household to experience a medical emergency Installation Hazards WARNING Have only a qualified 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 elect...

Page 9: ...le first and then connect the NEGATIVE NEG or battery cable 2 Remove taped fuse from the panel and reinstall into the aXis Controller module Carbon Monoxide Hazards DANGER Generator must be installed and operated outdoors only NEVER allow exhaust fumes to enter a confined area through windows doors air intake vents or other openings of the building ALWAYS avoid breathing exhaust fumes when near an...

Page 10: ...o properly purge the fuel lines and leak test according to applicable codes before placing the generator in service Be sure to regularly inspect the fuel system for leaks NEVER operate the generator if a fuel leak is present Install a fire extinguisher near the generator Keep it properly charged and be familiar with its use An ABC rated National Fire Protection extinguisher is appropriate for use ...

Page 11: ...ntacto con los componentes de escape y gases WARNING AVERTISSEMENT ADVERTENCIA Poison Burn and Fire Warning 2510 L SF B 2483 L SF A Burn Hazard DO NOT touch hot surfaces Allow the engine and alternator to cool to the touch before servicing Danger de brulure NE TOUCHEZ PAZ les surfaces chaudes Laissez le moteur et l alternateur devenir froid au toucher avant d intervenir Riesgo de quemaduras NO toq...

Page 12: ...tart any time without notice Prevent the generator from starting while the covers are open See the safety section of the operator s manual for further detail Risque au démarrage Le groupe électrogène peut tourner et démarrer à tout moment sans préavis Ne démarrez pas le groupe électrogène lorsque les capots sont ouverts Consultez la section sécurité du manuel d utilisation pour plus de détail Ries...

Page 13: ...FETY LABELS AND HANG TAGS 13 Safety Serial Model Nameplate Label Locations The safety labels have specific placement and must be replaced if they are unreadable damaged or missing C A B a Serial number location b Nameplate c NFPA 37 Compliance ...

Page 14: ...minum with cast iron sleeves Ignition system Solid state magneto Spark plug F7RTC NGK BPR7ES Governor Mechanical Starter Electric 24V DC Oil capacity 1 6 qt 1 5 L Oil Type 5W 30 Full Synthetic RPM 3600 Controls Mode switch auto Auto start on utility failure Mode switch manual Starts on demand Mode switch off Stops unit control and charger active Ready to run maintenance messages Standard Programma...

Page 15: ...sleeve Cylinder Head Automotive harden valves and seats Ignition System Solid state magneto Governor Mechanical Starter Electric 24V DC RPM 3 600 Oil Capacity 1 6 qt 1 5 L Champion 754cc Engine Torque Specifications Crankcase Cover Bolts 27 Nm 20 lbf ft Connecting Rod Bolts 12 Nm 9 lbf ft Rocker Cover Screws 10 Nm 7 lbf ft Cylinder Head Bolts 40 Nm 29 5 lbf ft Intake Manifold Screws 9 5 Nm 7 lbf f...

Page 16: ...are spring loaded to maintain contact A RED wire connects to the positive brush and a BLACK wire to the negative brush Rectified and regulated excitation current as well as current from the field boost circuit are delivered to the rotor windings via the RED wire and the positive brush and slip ring The excitation and field boost current passes through the windings and to the frame ground via the n...

Page 17: ... combustible materials outside the enclosure Annex A Explanatory Material A 4 1 2 2 Means of demonstrating compliance are by means of full scale fire tests or by calculating procedures such as those given in NFPA 555 Guide on Methods for Evaluating Potential for Room Flashover To comply with condition 2 the weatherproof enclosure has been constructed of non combustible materials and full scale fir...

Page 18: ... of the structure that are closer than 5 ft from the engine enclosure have a fire resistance rating of at least 1 hr or The weatherproof engine enclosure is constructed of noncombustible materials and it has been demonstrated that a fire within the enclosure will not ignite combustible materials outside the enclosure Intertek Group PLC performed a full scale fire test under a worst case fire scena...

Page 19: ...t openings If prevailing winds cause blowing or drifting you may consider building a windbreak planting trees or shrubs within the guidelines and codes applicable Watch out for roof overhangs Snow ice or rain shouldn t be permitted to accumulate on the roof and then cascade onto the unit DANGER Engine exhaust from the unit is hot poisonous and dangerous Exhaust must be allowed to dissipate into a ...

Page 20: ...heir 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 claims procedures Parts damaged in shipping are not covered under Champion warranty Unbox the unit by removing the exterior shipping carton The ATS is included remove the packaging and lift it out Remove the 4 shipping brackets 2 on each e...

Page 21: ...10 Wiring of the HSB 1 FUEL REQUIREMENTS AND RECOMMENDATIONS The following NG and LPG fuel information is provided to assist the fuel installer This information should not be deemed to be all inclusive or to conflict with local dry fuel codes Consult your local fuel supplier or Fire Marshall for guidance on proper local codes and installations Local codes will mandate correct routing of gaseous fu...

Page 22: ...be black iron or steel to avoid reacting with the sulfur in the fuel DANGER NG is highly explosive Even the slightest spark can ignite and cause an explosion which could cause burns fire or explosion resulting in serious injury property damage or even death NO leakage is permitted Safety is important Gas pipe sizing is critical to the proper operation of the HSB The HSB fuel inlet size has no bear...

Page 23: ...akage is permitted Safety is important Gas pipe sizing is critical to the proper operation of the HSB The HSB fuel inlet size has no bearing on the proper gas pipe size running to the HSB Gas supply and pipe MUST be sized at 100 load Btu rating Pipe sizes are measured by inside diameter ID to include any fittings valves elbows tees or angles Add 2 5 feet 76 m per any bend tee or angle in the pipe ...

Page 24: ...tion requires to run on LPG an orifice in the Master Mixer Assembly carburetor system must be changed The LPG orifices are shipped with the HSB Jet Change Procedures 1 Remove breather tube 1 by loosening breather tube clamp 2 2 Remove fuel inlet chamber screws 3 Remove fuel inlet chamber 4 along with fuel hose 5 and gasket 6 3 Remove left side main jet 7 right side main jet 8 left side slow jet 9 ...

Page 25: ...or joint compound approved for use with LPG NG on all threaded fittings to reduce the possibility of leakage Install a sediment trap downstream of the HSB shut off valve as close to the inlet as possible in accordance with local codes 8 CHECKING PRESSURE WITH A MANOMETER This check should only be done when the HSB and ATS have been installed properly inspected and ready for testing A Manometer is ...

Page 26: ... 0 degrees F can deliver for 30 seconds Starting cranking Cycle Battery is designed to deliver large bursts of power for a short time as needed to start an engine Starting batteries are intended to have a low depth of discharge on each use WARNING The starting system is a 24 volt DC system The two 12 volt batteries MUST be wired in series to achieve the correct voltage Damage will result if the ba...

Page 27: ...lled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbonate of soda to one gallon 4 liters of water The bicarbonate of soda is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried WARNING Lead acid batteries present a risk of fire because ...

Page 28: ...entary voltage fluctuations While there is no way to prevent voltage fluctuations you can take steps to protect sensitive electronic equipment Install UL1449 CSA listed plug in surge suppressors on the outlets feeding your sensitive equipment Surge suppressors come in single or multi outlet styles They re designed to protect against virtually all short duration voltage fluctuations AVR Automatic V...

Page 29: ...wo 2 fuses built into the board On the left side of the module there is a 250VAC 5A mini fuse protecting the system from an over voltage between the alternator and the relays The second fuse is an automotive style fuse 40A Orange which protects the system from an excessive transfer voltage output when the ATS relays transfer between Utility to Genset and Genset to Utility modes TOP ROW There are 1...

Page 30: ... and deactivate the aXis controller preventing future starts This switch should be used in instances where the HSB needs to stay off regardless of utility power presence When the switch is in the OFF position the HSB will not exercise or start for any reason OTE N If maintenance or service work is going to be performed on the generator or the home s electrical system it is required accidental star...

Page 31: ... BLUE icons will be lit when the HSB is performing the weekly exercise period Refer to Setting Exercise Time to establish the weekly exercise period When the exercise period is complete the icon will turn off and the HSB will resume its standby monitoring aXis CONTROLLER MODULE FAULT ICONS Low Oil The RED icon will be lit when the engine oil level drops below the safe operating level When this fau...

Page 32: ... charged or if they have failed It is extremely important to follow all cautions and warning per the battery manufacturer concerning installation service maintenance and replacement procedures Hz Over Speed Under Speed The RED icon will be lit if the engine was operating above or below its preset speed limits These limits are factory set to protect the HSB and the circuits connected to the generat...

Page 33: ...toring and protection for the HSB AUTO MAN OFF MODE ARRÊT Power ON 24VDC After batteries are installed the engine control module will perform self diagnostic Hours will appear on screen Power save mode will dim then shut off the LCD after 1 minute with no input To turn the screen back on press the button MAN This button allows verification that the HSB power delivery circuit is functional The engi...

Page 34: ...e using the mode button 6b for next 7 Daylight Saving Time DST 7a Set DST on or off using the mode button 7b for next 8 Hours for maintenance reminder H 8a Set hours for maintenance using the mode button 8b for next 9 Exercise 9a Set exercise using mode button 9b for next 9c Exercise Schedule i 0 no exercise ii 1 1 time per month iii 2 2 times per month iv 3 4 times per month v 4 weekly 9d Week ex...

Page 35: ...iency is achieved This charger is a maintenance battery charger If the battery voltage falls below 6V the charger will not re change the batteries To properly maintain battery efficiency you must follow the battery manufacturers safety instructions warnings and proper maintenance procedures Feature benefits include reverse polarity protection short circuit protection overload protection over volta...

Page 36: ...quired for exterior installations by code The enclosure has knockouts on the bottom and side and requires water tight connections when installed outside per code This enclosure can also be used inside aXis Controller Module This standby generator is designed to communicate with the ATS using the integrated aXis Controller module In order to utilize features such as load management wifi programming...

Page 37: ... side for the enclosure requires water tight fasteners grommets when installed outside per code This enclosure can also be used inside HSB Test SPEED SETTING NO LOAD Do NOT move forward until the HSB generator AC output voltage and frequency are correct and within the stated limits 1 If the no load voltage is correct but no load frequency is incorrect the engine governed speed requires adjustment ...

Page 38: ...ow being delivered to the ATS and is electrically hot The feeder lines and terminals are now live Contact with these connections will result in extremely hazardous and possibly fatal electrical shock 9 With an AC voltmeter check the correct voltage Single phase generator supply 10 Measure across GENERATOR SUPPLY ATS lugs L1 and L2 Also check L1 to NEUTRAL These are factory pre set limits Frequency...

Page 39: ...Replace covers on ATS and HSB that were removed for HSB Test and Checking Automatic Operation This check is now complete Installing Standby Generator to non aXis Controller ATS OTE N This section is only for those looking to install their aXis Controller HSB to a non aXis Controller ATS that supports a two wire HSB start stop signal Please refer to the ATS installation manual for instructions on h...

Page 40: ...l not crank turn over 1 HSB set in OFF mode Place the HSB controllers in the AUTO position 2 Battery not connected or loose corroded posts or wires Connect the batteries according to owner s manual clean and tighten the battery connections 3 Battery s not charged or low charge Recharge or replace battery s 4 Check for active fault code Identify fault code correct and reset 5 Defective starter sole...

Page 41: ...Poor wiring connections 8 ATS problems LED Indicators In all cases when the GREEN icons are lit this is an indicator that the HSB is performing properly In all cases when the RED icons are lit this is an indicator that the HSB has registered a fault and must be corrected Only the LOW BATTERY and MAINTENANCE icons will not latch out or shut down the HSB All other RED icon faults will latch out shut...

Page 42: ...BLESHOOTING HSB 42 HSB ATS Model Serial Reference ATS Back up Circuits HSB Model Number HSB Serial Number Fuel Type LPG NG ATS Model Number ATS Serial Number ATS circuits powered Date Installed Dealer Installer Address Phone Cell Purchased from ...

Page 43: ...essful activation of the unit Unit should be Registered and Proof of Purchase and Maintenance must be available Warranty is transferable between ownership of original installation site Warranty only applies to permanently wired and mounted units Any and all warranty repairs and or concerns must be performed and or addressed by an Authorized Certified Champion Home Standby Service Dealer Repairs or...

Page 44: ...d is compromised 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 Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earth...

Page 45: ...ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF CHAMPION POWER EQUIPMENT S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitations may not apply to purchaser owner Purchaser owner agrees to make no claims against Champion Power Equipment based on negligence This warranty gives purchaser owne...

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