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Generac Power Systems 10 kW LP Portable Generator User Manual

1. T 1 a M 18 17 16 15 114 13 12 141 e 216115 4 21 987654321 2 2 J J2 CONNECTOR J1 CONNECTOR PCB END PCB END 411 10 11 12 13 14 15 16 17 18 1 2 111231415 6 7 8 J3 STEPPER MOTOR J1 CONNECTOR J2 CONNECTOR HARNESS END HARNESS END REMOTE WIRELESS CONNECTION N1 N2 CONNECTOR N1 N2 CONNECTOR PCB END HARNESS END Figure 6 12 14 kW Printed Circuit Board and J1 Connector 12 14 kW J1 Connector Pin Descriptions J1 1 85 High temperature shutdown J2 8 15B Provides an electrical connection for Shutdown occurs when Wire 85 is charge current to reach the battery grounded by contact closure in HTO from the battery charger Provides 12 J1 2 Low oil pressure shutdown Shutdown VDC to the Transfer Relay occurs when Wire 86 is grounded by J2 9 820 Positive voltage 5 VDC for status loss of oil pressure to the LOP LEDs 12 VDC source voltage for the circuit J2 10 gt Board J2 11 56 12 VDC output to starter contactor
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3. 0 69 5 8 158 gt 23 69 23 TS TO GENERATOR CONTROL PANEL N2 F1 240VAC NtH amp Ni OUTPUT WIRE WIRE BLACK BC 2 69 RED GENERATOR L NEUTRAL WHITE NEUTRAL m GROUND GREEN CONNECTION 62 INSIDE SWITCH 7 GROUND GREEN NEUTRAL WHITE RED MAIN 2 MAIN DISTRIBUTION BLACK MAIN 1 5 6 cIRCUIT14 6 CIRCUIT 13 6 CIRCUIT 10 CIRCUIT 9 E 4 5 CIRCUIT 6 4 6 CIRCUIT 5 c c m pen E E E 6 6 CIRCUIT 2 Z Z F3 B CY 2 11 T1 5 6 CIRCUIT 1 6 6 6 e 5 6 CIRCUIT 3 ES gt d 3 B Le 5 CIRCUIT 4 oO CIRCUIT 7 o LEGEND 4 5 o CIRCUIT 8 BC BATTERY CHARGER C1 UTILITY COIL amp RECTIFIER 4 9 CIRCUIT 11 C2 GENERATOR COIL amp RECTIFIER F1 F2 F3 5A 600V FUSE 4 5 o CIRCUIT 12 LC CIRCUIT BREAKER LOADS 16 CIRCUIT SHOWN FOR REFERENCE ONLY 4 5 6 CIRCUIT 15 N NEUTRAL xl SW1 AUTOMATIC TRANSFER SWITCH 6 6 CIRCUIT 16 SW2 SW3 LIMIT SWITCHES LC ui TB1 TERMINAL STRIP TR1 TRANSFER RELAY Figure 1 Schematic Page 60 SECTION 3 2
4. SLOAN 9 15 8321145 511124129 01 INSTALLATION BASICS SECTION 1 2 Figure 1 Typical Installation Page 12 GENERAL INFORMATION POWER SOURCE AND LOAD LINES The utility power supply lines the standby genera tor supply lines and electrical load lines must all be connected to the proper terminal lugs in the transfer switch The following rules apply In 1 phase systems with a 2 pole transfer switch connect the two utility source hot lines to Transfer Switch Terminal Lugs N1 and N2 Connect the standby source hot lines E1 E2 to Transfer Switch Terminal Lugs E1 and E2 Connect the load lines from Transfer Switch Terminal Lugs T1 and T2 to the electrical load circuit Connect UTILITY STANDBY and LOAD neutral lines to the neutral block in the transfer switch SECTION 1 2 INSTALLATION BASICS SYSTEM CONTROL INTERCONNECTIONS Home standby generators are equipped with a termi nal board identified with the following terminals a UTILITY 1 b UTILITY 2 c 23 and d 15B Load centers house an identically marked terminal board When these four terminals are properly interconnect ed dropout of utility source voltage below a preset value will result
5. GEN READY LOAD CENTER UTILITY METER SOCKET Figure 13 Test 46 47 and 48 GenReady Load Center Test Points Page 91 SECTION 3 4 DIAGNOSTIC TESTS 3 Measure across points G and H on the terminal strip 12VDC should be measured a If 12 VDC is measured the charger should be functioning b If 12 VDC is not measured proceed to Step 4 4 Remove Wire 0 and Wire 158 from generator terminal strip locations E and F 5 Wait five 5 minutes after removing wires 6 Measure across points E and F on the terminal strip 12 VDC should be measured a If 12 VDC is measured proceed to Step 8 b If 12 VDC is not measured proceed to Step 7 7 Measure across point H and ground lug 12 VDC should be measured a If 12 VDC is measured repair or replace Wire 0 between the generator terminal strip and the ground lug b If 12 VDC is not measured proceed to Step 8 8 Set VOM to measure resistance 9 Connect the meter test leads across the disconnected Wire 0 and Wire 15B Approximately 200 Ohms should be measured a If 200 Ohms is measured proceed to Step 11 b If zero resistance or CONTINUITY is measured connect the meter test leads a
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8. Figure 12A Test 43 44 and 45 HTSE Transfer Switch Test Points Page 89 SECTION 3 4 DIAGNOSTIC TESTS 6 Measure across points G and H on the terminal strip 12 VDC should be measured a If 12 VDC is measured proceed to Step 8 b If 12 VDC is not measured proceed to Step 7 7 Measure across point H and ground lug 12 VDC should be measured a If 12 VDC is measured repair or replace Wire 0 between the generator terminal strip and the ground lug b If 12 VDC is not measured proceed to Step 8 8 Set VOM to measure resistance 9 Connect the meter test leads across the disconnected Wire 0 and Wire 15B Approximately 115 Ohms should be measured a If 115 Ohms is measured proceed to Step 11 b If zero resistance or CONTINUITY is measured connect the meter test leads across Terminals A and B on the transfer relay TR1 zero resistance is measured a short exists Replace TR1 d If 115 Ohms is measured repair or replace Wire 15B between the generator and the transfer switch 10 Disconnect the J2 connector from the printed circuit board 11 Measure across point M and pin location J2 8 of the con nector just removed CONTINUITY should be measured a If CONTINUITY is not measured repair or replace Wire 15B between the J2 connector and the terminal strip b If CONTINUITY was measured a
9. OL f 1510 d3Wolsno 39018 WHLNAN D HOLIMS H3J3SNVH L SLY 1 LOANNOOSIG 39IAH3S AlddNS ALMILA Figure 12 Test 43 44 and 45 RTSN Transfer Switch Test Points Page 88 SECTION 3 4 DIAGNOSTIC TESTS TRANSFER SWITCH PANELBOARD B N2 fp SERVICE DISCONNECT ATS TO GROUNDING ELECTRODE UTILITY METER SOCKET
10. OPTIONAL BATTERY WARMER CONTROLLER PRINTED CIRCUIT BOARD 1 85 1 LED BOARD 86 J1 820 1 13mm 7 5 AMP FUSE PCB 817 2 L1 18 818 3 819 4 GOVERNOR J8 SELF RESETTING FUSE ACTUATOR J2 721312 gt lt 60 GROUND 5 BATTERY 12 VDC ALWAYS PRESENT t IM_ IGNITION MODULE Page 111 0 AC VOLTAGE GROUND FOR CONTROL PURPOSES LEGEND 12 VDC DURING CRANKING ONLY BRUSH ASSEMBLY LOW OIL PRESSURE SWITCH 12 VDC DURING ENGINE RUN NDITION CIRCUIT BREAKER MAIN OUTPUT SC STARTER CONTACTOR ENGINE RON CONDITIO CS CHOKE SOLENOID SCR STARTER CONTROL RELAY DC FIELD EXCITATION FS FUEL SOLENOID SM STARTER MOTOR HIGH TEMPERATURE SWITCH SP_ SPARK PLUG 5 VDC LED SECTION 4 2 DC CONTROL OPERATIONAL ANALYSIS EXON INITIAL TRANSFER TO THE STANDBY SOURCE The generator is running the circuit board s engine warm up timer is timing and generator AC output is avail able to transfer switch terminal lugs E1 and E2 and to the open contacts on the transfer relay Initial transfer to the STANDBY power supply may be briefly described as follows 12 volts DC output is delive
11. COIL 8 RECTIF IER COIL amp RECTIF 5 600V FUSI LC CIRCU C16 NCE N NE TRA J1 IM SW SW3 1 1 II NALI N Y Page 186 187 188 Generac Power Systems Inc Highway 59 amp Hillside Rd PO Box 8 Waukesha WI 53187 1 888 GENERAC MyGenerac com 2008 Generac Power Systems Inc All rights reserved Specifications are subject to change without notice Part No 0G9266 rev A Printed in USA 09 08
12. 86 Test 42 Check Wire 0 and Wire15B Pre Wire Load 86 Test 43 Check Battery Charger Supply Voltage RTSN RTSE Transfer Switch 87 Test 44 Check Battery Charger Output Voltage RTSN RTSE Transfer Switch 87 Test 45 Check Wire 0 8 RTSE Transfer Switch 87 Test 46 Check Battery Charger Supply Voltage GenReady Load 90 Test 47 Check Battery Charger Output Voltage GenReady Load 90 Test 48 Check Wire 0 15B GenReady Load 90 Test 49 Check Battery Charger Supply Voltage Load Shed Transfer 92 Test 50 Check Battery Charger Output Voltage Load Shed Transfer 92 Test 51 Check Wire 0 and Wire 15B Load Shed Transfer 94 SECTION 3 1 DESCRIPTION amp COMPONENTS GENERAL The W V Type transfer switch is rated 100 amps at 250 volts maximum It is available in 2 pole configura tion only and for that reason is usable with 1 phase systems only Transfer switches do not have an intelligence sys tem of their own Instead au
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15. 55 3 1 Description and Components 56 Gerleral 56 Enclosure ettet ade 56 Transfer 57 Transfer 2 57 Neutral ihe tte 58 Manual Transfer Handle 58 Terminal 58 Fuse 44444244 2 59 3 2 Operational Analysis 60 Operational 60 Utility Source Voltage Available 62 Utility Source Voltage Failure 63 Transfer To Standby 64 Transfer To Standby 65 Utility 22 66 Utility Restored Transfer Switch De energized 67 Utility Restored Retransfer Back To Utility 68 Transfer Switch In 69 3 3 Troubleshooting Flowcharts 70 Introduction To Troubleshooting 70 Problem 7 In Automatic Mode No Transfer to Standby 70 Problem 8 In Automatic Mode Generator Starts When Loss of Utility Occurs Generator Shuts Down When Utility Returns But There Is No Retransfer To Utility Power or Generator Transfers to Standby During Exe
16. 11 The 22 The Fuel Supply sees 11 Stator Insulation Resistance Test 12 20kW 23 The Transfer Switch Load Center 11 Stator Insulation Resistance Test 8 10kW 23 Power Source And Load Lines 13 Rotor Insulation Resistance Test 8 10kW 24 System Control Interconnections 13 Rotor Insulation Resistance Test 12 20kW 24 Natural Gas Fuel Interconnections 13 Cleaning The 24 1 3 Non prepackaged Interconnections 14 Drying The 24 Connect a Pre 2008 Load Center Switch 1 6 Engine Generator Protective Devices 25 To a Current or Future General 25 Air Cooled 14 Connect a 2008 And Later Load Center Low Battery aee ete recien idee 25 Switch to a Pre 2008 Low Oil Pressure Shutdown 25 Air Cooled 15 High Temperature Switch s 25 1 4 Preparation Before 5 16 Overspeed Shutdown 25 Generalized toe ONE MEE 16 Sensor 25 Fuel
17. 16 Overcrank Shutdown 26 Fuel Consumption eene 16 1 7 Operating 27 Reconfiguring The Fuel 5 16 Control Panel 27 Engine Oil Recommendations 18 To Select Automatic Operation 28 1 5 Testing Cleaning and Drying 19 Manual Transfer To Standby M IGIS 19 and Manual Startup 28 li m 19 Manual Shutdown And Measuring Voltage 19 Bar ie 22 2 Measuring DC Voltage 19 1 8 Automatic Operating Parameters 29 Measuring AC 19 Introduction alse ee estate 29 Measuring Current 20 Automatic Operating Sequences 29 1 1 GENERATOR IDENTIFICATION INTRODUCTION This Diagnostic Repair Manual has been prepared especially for the purpose of familiarizing service per sonnel with the testing troubleshooting and repair of air cooled automatic standby generators Every effort has been expended to ensure that information and instructions in the manual are both accurate and cur rent However changes alterations or other improve ments may be made to the product at any time w
18. es dn yoeq fay 39053 56944 283 31115 501 501 AHOLSIH 103 SECTION 4 2 DC CONTROL INTRODUCTION This Operational Analysis is intended to familiarize the service technician with the operation of the DC control system on units with air cooled engine A thorough understanding of how the system works is essential to sound and logical troubleshooting The DC control system illustrations on the following pages represent a 14 kW unit UTILITY SOURCE VOLTAGE AVAILABLE See Figure 1 below The circuit condition with the AUTO OFF MANUAL switch set to AUTO and with Utility source power available can be briefly described as follows 2 2 6 6 0 0 VOLTAGE 4 4 REGULATOR 4 POWER 22 22 WINDING ________ 44 6 STATOR 2 11 i POWER WINDING 4 m 12V Tscr 10 SECTION 4 2 OPERATIONAL ANALYSIS DC CONTROL Utility source voltage is available to transfer switch Terminal Lugs N1 N2 With the transfer switch main contacts at their Utility side this source voltage is available to Terminal Lugs T1 T2 and to the Load circuits Utility voltage is delivered to the Contro
19. 32 32 Engine Generator Drive System 32 AC 32 Rotor 32 Stator 33 Brush Holder And Brushes 12 20 kW 34 Other AC Generator Components 34 2 2 Operational 35 Rotor Residual Magnetism 35 Field Boost 12 20 KW Units 35 Operation 8 10 36 Operation 12 20 KW 36 2 3 Troubleshooting Flowcharts 37 Problem 1 Generator Produces Zero Voltage or Residual Voltage 12 20 kW 37 38 Problem 2 Generator Produces Zero Voltage or Residual Voltage 8 10 kW 38 Problem 3 Generator Produces Low Voltage at No Load 39 Problem 4 Generator Produces High Voltage at No Load 39 Problem 5 Voltage and Frequency Drop Excessively When Loads are Applied 40 2 4 Diagnostic Tests 41 41 Safety A 41 TABLE OF CONTENTS EZTA Description and Components 30 Analysis 33 233 Troubleshooting Flow Charts 2
20. 41 Safety dtc hae 41 Test 1 Check Main Circuit 41 Test 2 Check AC Output Voltage 41 Test 4 Fixed Excitation Test Rotor Amp Draw 42 Test 5 Wire Continuity 12 20 kW 43 Test 6 Check Field Boost 12 20 kW 44 Page 1 Test 7 19510 The Stator With Vom 12 20 kW aa 44 Test 8 Test Brushless 45 Test 9 Check 46 Test 10 Test DPE Winding on Brushless 47 Test 11 Resistance Check Of Rotor Circuit 12 20 KW ete aeterne 48 Test 12 s Brushes And Slip Rings 12 20 Test 13 Test Rotor Assembly 12 20 kW 49 Test 14 Check AC Output Frequency 49 Test 15 Check and Adjust Engine Governor Single Cylinder Units 49 Test 16 Check Stepper Motor Control V twin Engine 5 50 Test 17 Check And ep Voltage Regulator 12 20 kW 51 Test 18 Check Voltage And Frequency Under Load 52 Test 19 Check For Overload Condition 52 Test 20 Check Engine Condition 52 Test 21 Field Flash Alternator 8 10 kW 52 PART TRANSFER SWITCH
21. Figure 4 Brush Holder and Brushes 12 20 kW OTHER AC GENERATOR COMPONENTS Some AC generator components are housed in the generator control panel enclosure and are not shown in Figure 1 These are a a voltage regulator and b a main line circuit breaker VOLTAGE REGULATOR 12 20 KW A typical voltage regulator is shown in Figure 5 Unregulated AC output from the stator excitation winding is delivered to the regulators DPE terminals via Wire 2 and Wire 6 The voltage regulator rectifies that current and based on stator AC power winding sensing regulates it The rectified and regulated excitation current is then delivered to the rotor wind ings from the positive and negative regulator terminals via Wire 4 and Wire 0 Stator AC power winding sensing is delivered to the regulator SEN terminals via Wires 11 and 22 Page 34 The regulator provides over voltage protection but does not protect against under voltage On occur rence of an over voltage condition the regulator will shut down and complete loss Of excitation current to the rotor will occur Without excitation current the generator AC output voltage will drop to approximately one half or lower of the unit s rated voltage Figure 5 Typical Voltage Regulator A single red lamp LED glows during normal opera tion The lamp will become dim if excitation winding AC output diminishes It will go out on occurrence of an ope
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26. 28 1 8 Automatic Operating Parameters 29 29 Automatic Operating Sequences 29 PART 2 AC 31 2 1 Description and Components 32 oT me 32 Engine Generator Drive System 32 The AC Generator sss 32 Rotor 32 Stator 33 Brush Holder And Brushes 12 20 kW 34 Other AC Generator Components 34 2 2 Operational Analysis 35 Rotor Residual Magnetism 35 Field Boost 12 20 35 Operation 8 10 36 Operation 12 20 36 2 3 Troubleshooting Flowcharts 37 Problem 1 Generator Produces Zero Voltage or Residual Voltage 12 20 kW 37 38 Problem 2 Generator Produces Zero Voltage or Residual Voltage 8 10 kW 38 Problem 3 Generator Produces Low Voltage at No Load 39 Problem 4 Generator Produces High Voltage at No Load 39 Problem 5 Voltage and Frequency Drop Excessively When Loads are Applied 40 2 4 Diagnostic 41
27. T SPARK PLUG REMOVE LEADS Figure 35 Engine Ground Harness 12 Connect one meter test lead to one of the wires removed from the ignition magneto s Connect the other test lead to frame ground INFINITY should be measured CONTINUITY is measured replace the shutdown harness 13 Now check the flywheel magnet by holding a screwdriver at the extreme end of its handle and with its point down When the tip of the screwdriver is moved to within 3 4 inch 19mm of the magnet the blade should be pulled in against the magnet 14 For rough running or hard starting engines check the fly wheel key The flywheel s taper is locked on the crankshaft taper by the torque of the flywheel nut A keyway is provided for alignment only and theoretically carries no load Note If the flywheel key becomes sheared or even partially sheared ignition timing can change Incorrect timing can result in hard start ing or failure to start 15 As stated earlier the armature air gap is fixed for single cylinder engine models and is not adjustable Visually inspect the armature air gap and hold down bolts Page 139 SECTION 4 4 DIAGNOSTIC TESTS RESULTS If sparking still does not occur after adjusting the armature air gap testing the ground wires and performing the basic flywheel test replace the ignition magneto s PROCEDURE REPLACING MAGNETOS 1 Follow all steps of the Major Disassembly procedures that ar
28. 170 Wiring Diagram 14 kW Home 172 Schematic 14 kW Standby 174 Wiring Diagram 17 kW Home Standby 176 Schematic 17 kW Standby 178 Wiring Diagram 20 kW Home 180 Schematic 20 kW Home Standby 182 Wiring Diagram Home Standby Transfer Switch 9 10 12 16 Circuit 184 Schematic Home Standby Transfer Switch 9 10 12 16 cei 186 3 SPECIFICATIONS GENERATOR Unit 8 kW 10 kw 12 kW 14kW 16 kw 17 kW 20 kW Rated Max Continuous 7 000 NG 9 000 NG 12 000 NG 13 000 NG 16 000 NG 16 000 NG 18 000 NG Power Capacity Watts 8 000 LP 10 000 LP 12 000 LP 14 000 LP 16 000 LP 17 000 LP 20 000 LP Rated Voltage 120 240 Rated Voltage at No Load NG 220 235 247 249 Rated Max Continuous Load Current Amps 120 Volts NG LP 58 3 66 6 75 0 83 3 100 0 100 0 108 3 116 6 133 3 133 3 133 3 141 6 150 0 166 6 240 Volts NG LP 29 2 33 3 37 5 41 6 50 0 50 0 54 2 58 3 66 6 66 6 66 6 70 8 75 0 83 3 Main Line Circuit Breaker 35 Amp 45 Amp 50 Amp 60 Amp 65 Amp 65 Amp 100 Amp Circuits 50A 240V 1 1 1 40A 240V 1 1 1 1 30A 240V 1 1 1 20A 240V 1 1 1 1 20A 120V 1 3 3 4 5 5 15A 120V 5 3 5 4 5 5 Phase 1 Number of Rotor Poles 2 Rated AC Frequency 60 Hz Powe
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30. gt TEST 68 CHECK FUEL SUPPLY AND CIRCUIT BOARD SEE FUEL SOLENOID PRESSURE WIRE 14 OUTPUT BAD BAD Y REPLACE FUEL SOLENOID 9996 FIND AND CORRECT REPLACE CIRCUIT BOARD CAUSE OF NO FUEL OR LOW PRESSURE TEST 16 CHECK TEST 69 CHECK GOOD STEPPER MOTOR CE GOOD CHOKE SOLENOID CONTROL BAD BAD REPAIR OR REPLACE REPLACE CHOKE SOLENOID CHECK AIR FILTER REPLACE AS NEEDED TEST 70 CHECK FOR TEST 71 77 72 IGNITION GOOD CHECK SPARK CHECK AND coop gt CHECK ENGINE SPARK PLUGS ADJUST VALVES COMPRESSION BAD BAD D BAD BAD Y GOO CLEAN REGAP OR READJUST REPLACE REPLACE FUEL REGULATOR TEST 73 CHECK SHUTDOWN WIRE MAGNETOS BAD 4 BAD REPAIR OR ADJUST OR REFER TO ENGINE REPLACE SHORTED REPLACE SERVICE MANUAL WIRE 18 OR CIRCUIT BOARD Page 119 SECTION 4 3 TROUBLESHOOTING FLOW CHARTS DC CONTROL Problem 18 Engine Starts Hard and Runs Rough Lacks Power Backfires IF RECONFIGURED TO LP GAS TEST 66 CHECK FUEL SUPPLY AND GOOD gt gt VERIFY THAT PROPER a PRESSURE PROCEDURE WAS FOLLOWED REPLACE AS NEEDED REFER TO SECTION 1 3 BAD FIND AND CORRECT TEST 69 CHECK CAUSE OF NO FUEL CHOKE SOLENOID OR LOW PRESSURE BAD READJUST REPLACE CHOKE SOLENOID BAD TEST 77 71 TEST 70 GOOD CHECK SPARK BAD CHECK FOR UE ADJUST VALVES IGNITION
31. 5 os T 1 IN CN lt E E i Oe 9 i 25 85 89 lt EM NENNEN MM eee eee 179 lt a 4 lt H WIRING DIAGRAM 20 KW HOME STANDBY DRAWING 0G8186 i M 1926 2 Ol 57 ce m jal 2 LN z i 6 io zo i z we Os oS 58 0 e H e i Sa lt H i 5
32. 59 3 2 Operational Analysis sss 60 Operational 60 Utility Source Voltage Available 62 Utility Source Voltage Failure 63 Transfer To Standby Transfer To Standby Utility Restored e tertie Utility Restored Transfer Switch De energized Utility Restored Retransfer Back To Utility Transfer Switch In Utility eene 3 3 Troubleshooting Flowcharts Introduction To Troubleshooting Problem 7 In Automatic Mode No Transfer to 70 Problem 8 In Automatic Mode Generator Starts When Loss of Utility Occurs Generator Shuts Down When Utility Returns But There Is No Retransfer To Utility Power or Generator Transfers to Standby During Exercise Or In Manual tes materie eret erred rss 71 Problem 9 Blown F1 or F2 71 Problem 10 Units Starts And Transfer Occurs When Utility Power Is 72 Problem 11 No Battery Charge Pre Packed Load 73 Problem 12 No Battery Charge RTSN RTSE Transfer Switch 73 Problem 13 No Battery Charge Gen Ready Load 73 Pro
33. i Q OUTPUT 33 22 CONTROLLER DISPLAY 00 240 MES OPTIONAL BATTERY WARMER CONTROLLER PRINTED CIRCUIT BOARD 85 1 86 2 0 1 13 3 7 5 AMP FUSE A ve 2 18 t 818 3 L 4 819 SELF RESETTING FUSE ACTUATOR J2 6171819 13 14 15 16 17 18 0 G9 GROUND 5 BATTERY z TRANSFER 12 VDC ALWAYS PRESENT BOARD 0 AC VOLTAGE GROUND FOR CONTROL PURPOSES LEGEND 12 VDC DURING CRANKING ONLY BRUSH ASSEMBLY LOP LOW OIL PRESSURE SWITCH CE MAIN OLIBUT LOP AOW OIN PRESSURE 12 VDC DURING ENGINE RUN CONDITION CS CHOKE SOLENOID SCR STARTER CONTROL RELAY DC FIELD EXCITATION FS FUEL SOLENOID SM STARTER MOTOR HIGH TEMP
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35. BAD GOOD BAD 4 REPLACE PRINTED REPAIR OR REPLACE CHARGER CIRCUIT BOARD REPLACE Problem 12 No Battery Charge RTSN amp RTSE Transfer Switch TEST 44 CHECK GOOD 3 BATTERY CHARGER OUTPUT VOLTAGE TEST 45 CHECK NO BATTERY SUPPLY VOLTAGE p WIRE 0 15B GOOD BAD 1 REPLACE PRINTED REPAIR OR REPLACE CHARGER CIRCUIT BOARD REPLACE Problem 13 No Battery Charge GenReady Load Center TEST 47 CHECK GOOD 5 BATTERY CHARGER OUTPUT VOLTAGE TEST 48 CHECK WIRE 0 15B NO BATTERY b SUPPLY VOLTAGE Pa GOOD BAD 4 4 REPLACE PRINTED REPAIR OR REPLACE CHARGER CIRCUIT BOARD REPLACE Problem 14 No Battery Charge Load Shed Transfer Switch TEST 50 CHECK GOOD BATTERY CHARGER OUTPUT VOLTAGE TEST 51 CHECK WIRE 0 15B NO BATTERY SUPPLY VOLTAGE E GOOD BAD 4 REPLACE PRINTED REPAIR OR REPLACE CHARGER CIRCUIT BOARD REPLACE Page 73 SECTION 3 4 DIAGNOSTIC TESTS GENERAL Test numbers in this section correspond to the numbered tests in Section 3 3 Troubleshooting Flow Charts When troubleshooting first identify the problem Then perform the diagnostic tests in the sequence given in the flow charts TEST 26 CHECK VOLTAGE AT TERMINAL LUGS E1 DISCUSSION In automatic mode the standby closing coil C2 must be energized by standby generator output if transfer to the Standby
36. Check Engine Cylinder Leak Down Test Compression Test Test 73 Check Shutdown Wire Test 74 Check and Adjust Ignition Magnetos Test 75 Check Oil Pressure Switch and Wire 86 Test 76 Check High Oil Temperature Switch Test 77 Check and Adjust Valves Test 78 Check Wire 18 Continuity Test 79 Test Exercise Test 80 Check Cranking and Running Circuits Test 81 Check to see if Low Speed Function is Test 82 Check operation of the Choke 5 Page 95 SECTION 4 1 DESCRIPTION AND COMPONENTS GENERAL This section will familiarize the reader with the various components that make up the DC control system Major DC control system components that will be covered include the following A Terminal Strip Interconnection Terminal A Circuit Board An AUTO OFF MANUAL Switch A 7 5 Amp Fuse TERMINAL STRIP INTERCONNECTION TERMINAL The terminals of this terminal strip are connected to identically numbered terminals on a transfer switch terminal board The terminal board connects the transfer switch to the circuit board The terminal board provides the foll
37. Page 162 TORQUE REQUIREMENTS UNLESS OTHERWISE SPECIFIED STATOR 6 ft lbs 1 0 ROTOR BOLT nein ees 30 ft lbs ENGINE ADAPTOR siisii 25 ft lbs EXHAUST MANIFOLD 18 ft lbs 5 0 8 SCREW INTO ALUMINUM 25 50 in lbs 5 0 8 TAPTITE SCREW INTO PIERCED HOLE 25 50 in Ibs 6 1 0 TAPTITE SCREW INTO ALUMINUM 50 96 in lbs M6 1 0 TAPTITE SCREW INTO PIERCED HOLE 50 96 in Ibs M6 1 0 TAPTITE SCREW INTO WELDNUT 50 96 in lbs M8 1 25 TAPTITE SCREW INTO ALUMINUM 12 18 ft lbs M8 1 25 SCREW INTO PIERCED HOLE 12 18 ft lbs M6 1 0 NYLOK NUT ONTO WELD STUD 16 65 in Ibs M6 1 0 NYLOK NUT ONTO HINGE STUD 30 36 in Ibs Note torques are dynamic values with 10 toler ance unless otherwise noted 7 ELECTRICAL DATA 0G8514 SCHEMATIC 17 KW HSB 0G8186 WIRING DIAGRAM 20 KW HSB 068515 SCHEMATIC 20 KW HSB 9 10 12 16 CIRCUIT TRANSFER SWITCH Air cooled Automatic 067959 SCHEMATIC Stand by Ge nerators 9 10 12 16 CIRCUIT TRANSFER SWITCH Page 163 WIRING DIAGRAM 8 KW HOME STANDBY ELECTRICAL DATA DRAWING 0G7945
38. ROTOR CHECK AC TEST 21 OUTPUT FIELD FLASH STOP 4 coop VOLTAGE ALTERNATOR TESTING Page 38 SECTION 2 3 TROUBLESHOOTING FLOWCHARTS AC GENERATORS Problem 3 Generator Produces Low Voltage at No Load TEST 15 ADJUST SINGLE CYLINDER ENGINE GOVERNOR TEST 2 CHECK TEST 14 CHECK UNITS AC OUTPUT AC OUTPUT VOLTAGE FREQUENCY LOW TEST 16 CHECK V TWIN UNITS STEPPER MOTOR CONTROL NO VOLTAGE 12 20 kW UNITS gt GOTOTEST4 8 10 kW UNITS GO PROBLEM 2 TEST 9 CHECK e 810kW UNITS CAPACITOR FREQUENCY AND FREQUENCY O K VOLTAGE O K BUT VOLTAGE LOW TEST 17 ADJUST 20 kW UNIT VOLTAGE ar x REGULATOR STOP VOLTAGE AND FREQUENCY FREQUENCY GO TO PROBLEM 1 FLOW CHART BUT VOLTAGE IS 12 20 kW UNITS gt START AT TEST 4 STILL LOW 8 10 kW UNITS GO TO PROBLEM 2 Problem 4 Generator Produces High Voltage at No Load HIGH TEST 15 ADJUST SINGLE CYLINDER ENGINE GOVERNOR TEST 2 CHECK TEST 14 CHECK UNITS AC OUTPUT AC OUTPUT VOLTAGE FREQUENCY HIGH TEST 16 CHECK V TWIN UNITS STEPPER MOTOR CONTROL TEST 9 8 10 kW UNITS FREQUENCY AND CAPACITOR VOLTAGE O K FREQUENCY O K BUT VOLTAGE HIGH TEST 17 ADJUST VOLTAGE 12 20 kW UNITS REGULATOR STOP VOLTAGE AND FREQUENCY TESTS FREQUENCY O
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40. 5 If CONTINUITY was measured in Steps 5 and 6 proceed to Step 9 6 Disconnect Wire 0 and Wire 4 from the brush assembly Remove the brush assembly from the bearing carrier Inspect the brushes for excessive wear or damage 7 Inspect the rotor slip rings If they appear dull or tarnished they may be polished with fine sandpaper DO NOT USE METALLIC GRIT TO POLISH SLIP RINGS 8 If brush assembly and slip rings look good proceed to Test 13 Test Rotor Assembly 9 Wire 0 connects from the voltage regulator in the control panel ground lug Connect one meter test lead to Wire 0 atthe voltage regulator Connect the other meter test lead to the ground terminal in the control panel CONTINUITY should be measured If INFINITY is measured repair or replace Wire 0 between the voltage regulator and the ground terminal 10 Remove Wire 4 from the voltage regulator RESULTS 1 Repair replace or reconnect wires as necessary 2 Replace any damaged slip rings or brush holder 3 Clean and polish slip rings as required TEST 13 TEST ROTOR ASSEMBLY 12 20 KW DISCUSSION A rotor having completely open windings will cause loss of excitation current flow and as a result generator AC output voltage will drop to residual voltage A shorted rotor winding can result in a low voltage condition PROCEDURE Disconnect the brush wires or remove the brush holder to prevent interaction 2 Set a to measure re
41. 7 Repeat Test 70 and check for spark across the spark tester gap a A spark test may be conducted with unit dis sembled by following this procedure b Battery must be connected c J2 Connector must be connected to the printed circuit board d Remove Wire 56 from the SCR located beneath the printed circuit board Warning Make sure all debris is cleared from the engine compartment and all body parts are clear from flywheel before proceeding e Refer to Test 70 to check for spark f Utilizing a jumper wire connect a wire to the 15B terminal block Connect the other end to SECTION 4 4 DIAGNOSTIC TESTS where Wire 56 was disconnected in Step 7 The engine should crank once the jumper from 15B is connected 8 If spark was not indicated replace magnetos Note If gap is only adjusted ensure to properly test the magnetos by cranking the engine over before reassembly occurs Spark should be present on both cylinders before reassembly should be completed 9 If air gap was not out of adjustment test ground wires 10 Set a VOM to the measure resistance 11 Disconnect the engine wire harness from the ignition magnetos Figure 35 a On V twin generators remove Wire 18 from the stud located above the oil cooler See Figure 45 b On single cylinder generators disconnect Wire 18 at the bullet connector See Figure 44 ENGINE WIRE HARNESS STUD CONNECTOR SPARK PLUG a WIRE 18 CIRCUIT BOARD
42. TEST 43 CHECK BATTERY CHARGER SUPPLY VOLTAGE RTSN amp RTSE TRANSFER SWITCH DISCUSSION The battery charger is supplied with 120 VAC The output of the battery charger is 13 4 VDC 2 5A PROCEDURE Refer to Figure 12 or Figure 12A 1 Set VOM to measure AC voltage 2 Measure across points A and 240 should be measured a If 240 VAC is not measured verify load source voltage b If 240 VAC is measured proceed to Step 3 3 Measure across points A and C 240 VAC should be measured a If 240 VAC is not measured repair or replace wire between fuse block and T1 terminal b If 240VAC is measured proceed to Step 4 4 Measure across points and D 240 should be measured a If 240 VAC is not measured replace 5A fuse b If 240 VAC is measured proceed to Step 5 5 Measure across points E and F 120 VAC should be measured a If 120 VAC is not measured repair or replace supply wires BC line and BC 00 b If 120 VAC is measured refer to flow chart SECTION 3 4 DIAGNOSTIC TESTS TEST 44 CHECK BATTERY CHARGER OUTPUT VOLTAGE RTSN amp RTSE TRANSFER SWITCH DISCUSSION The battery charger is supplied with 120 VAC The output of the battery charger is 13 4 VDC 2 5A PROCEDURE Refer to Figure 12 or Figure 12A 1 Set VOM to measure DC voltage 2 Remove and isolate battery charger black and red leads from generator terminal strip points G and H 3 Measure across points G an
43. TRANSFER SWITCH OPERATIONAL ANALYSIS Figure 2 is a wiring diagram for a typical W V Type transfer switch RED RED BLK BLK BLK N2A RED 126 259 GRN GRN TR1 ES 13 N2A 46 79 905 1 15 23 L 4 N1A N1A N2A N2A BLK BLK RED RED N2A LEGEND BC BATTERY CHARGER C1 UTILITY COIL amp RECTIFIER C2 GENERATOR COIL amp RECTIFIER F1 F2 F3 5A 600V FUSE LC CIRCUIT BREAKER LOADS 16 CIRCUIT SHOWN FOR REFERENCE ONLY N NEUTRAL SW1 AUTOMATIC TRANSFER SWITCH SW2 SW3 LIMIT SWITCHES TB1 TERMINAL STRIP TR1 TRANSFER RELAY TO GENERATOR CONTROL PANEL Figure 2 Wiring Diagram Page 61 SECTION 3 2 OPERATIONAL ANALYSIS TRANSFER SWITCH UTILITY SOURCE VOLTAGE AVAILABLE Figure 3 is a schematic representation of the transfer switch with utility source power available The circuit condition may be briefly described as follows Utility source voltage is available to terminal lugs N1 and N2 of th
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45. 4 Record the highest reading obtained 5 Repeat the procedure for the remaining cylinder and record the highest reading RESULTS The difference in pressure between the two cylinders should not exceed 25 percent If the difference is greater than 25 percent loss of compression in the lowest reading cylinder is indicated Example 1 If the pressure reading of cylinder 1 is 165 psi and of cylinder 2 160 psi the difference is 5 psi Divide 5 by the highest reading 165 to obtain the percentage of 3 0 percent Example 2 No 1 cylinder reads 160 psi No 2 cylinder reads 100 psi The difference is 60 psi Divide 60 by 160 to obtain 37 5 percent Loss of compression in No 2 cylinder is indicated If compression is poor look for one or more of the fol lowing causes Loose cylinder head bolts Failed cylinder head gasket Burned valves or valve seats Insufficient valve clearance Warped cylinder head Warped valve stem Worn or broken piston ring s Worn or damaged cylinder bore Broken connecting rod Worn valve seats or valves Worn valve guides NOTE Refer to Engine Service manual for further engine service information TEST 73 CHECK SHUTDOWN WIRE DISCUSSION Circuit board action during shutdown will ground Wire 18 Wire 18 is connected to the Ignition Magneto s The grounded magneto will not be able to produce spark PROCEDURE 1 On V twin generators remove Wire 18 from the stu
46. DRAWING 0G8511 PAGE LEFT PLANK INTENTIONALLY Page 167 WIRING DIAGRAM 10 KW HOME STANDBY PART 7 NGINE COMPAR IMENT NTROL PAN CAPACITOR l e 6 99 ae STATOR m m N C NC 18 0 4 N1 N2 8 85 1 86 J1 CONTROLLER HTO M fh 2 8 5 7 158 g 825 1 2 8171 1 14 818 2 819 gt 90 Be Gouna 7 BLI 2 b SM SC 5 3 GND ENGINE FRAME O o oy 8 Page 168 WIRING DIAGRAM 10 KW HOME STANDBY lt a lt 9 o DRAWING 0G7946
47. Refer to flow chart TEST 68 CHECK FUEL SOLENOID DISCUSSION In Test 67 if battery voltage was delivered to Wire 14 the fuel solenoid should have energized open This test will verify whether or not the fuel solenoid is operating Fuel Solenoid FS1 Nominal Resistance 27 33 ohms Fuel Solenoid FS2 Nominal Resistance 29 ohms PROCEDURE 8 AND 12 20 kW UNITS 1 Install a manometer to Port 2 on the fuel regulator See Figure 18 or Figure 20 2 Setthe AUTO OFF MANUAL Switch to MANUAL 3 Proper gas pressure should be measured during cranking Page 132 If gas pressure is measured the fuel solenoid is operat ing If gas pressure is not measured repair or replace the fuel solenoid PROCEDURE 10 kW UNITS 1 Remove the hose from fuel solenoid FS2 and install a manometer to Port 2 on the fuel regulator See Figure 19 2 Set AUTO OFF MANUAL Switch to MANUAL 3 Proper gas pressure should be measured during crank ing If gas pressure is measured both fuel solenoids are operating Discontinue testing 4 f gas pressure was not measured in Step 3 remove fuel solenoid FS2 and install a manometer to the bottom port of the fuel regulator 5 Set AUTO OFF MANUAL Switch to MANUAL 6 Proper gas pressure should be measured during crank ing If gas pressure is measured fuel solenoid FS1 is operating Replace fuel solenoid FS2 If gas pressure is not measured repair or replace fuel solenoid FS
48. CONTROLLER PRINTED CIRCUIT BOARD LED BOARD 85 86 820 1 13 3 7 5 AMP FUSE EH 18 818 819 GOVERNOR SELF RESETTING FUSE ACTUATOR J2 1 J3 11218141516171819 17118 L1 1 2 3 L 4 69 GROUND 5 BATTERY nm TRANSFER 12 VDC ALWAYS PRESENT IGNITION MODULE Page 117 0 AC VOLTAGE GROUND FOR CONTROL PURPOSES LEGEND 12 VDC DURING CRANKING ONLY BA BRUSH ASSEMBLY LOP LOW OIL PRESSURE SWITCH 12 VDC DURING ENGINE RUN CONDITION CB CIRCUIT BREAKER MAIN OUTPUT SC STARTER CONTACTOR CURING ENG CONDITIO CS CHOKE SOLENOID SCR STARTER CONTROL RELAY pu DC FIELD EXCITATION FS FUEL SOLENOID SM STARTER MOTOR HIGH TEMPERATURE SWITCH SP_ SPARK PLUG 5 VDCTOLED SECTION 4 3 TROUBLESHOOTING FLOW CHARTS DC CONTROL Problem 15 Engine Will Not Crank When Utility Power Source Fails 8 kW system ready light will be flashing TEST 56 CHECK SWITCH IS TEST 57 TRY A VERIFY UTILITY 5 SOURCE IS OFF POSITION OF IN AUTO MANUAL START AUTO OFF MANUAL SWITCH ENGINE DOES ON NOT CRANK ENGINE SWITCH IS OFF CRANKS gt GO
49. If voltage is present proceed to Step 9 b If voltage is not present repair wiring between transfer switch and generator control panel 9 Remove the J2 connector from the circuit board 10 Set VOM to measure resistance 11 Connect one meter test lead to Wire 23 Pin Location J2 5 Connect the other meter test lead to Wire 15B Pin Location J2 8 Approximately 115 ohms should be measured see Figures 4 through 7 Section 4 1 If approximately 115 ohms is measured proceed to Step 12 b If infinity or an open is measured repair Wire 23 between PCB Connector J2 and the generator terminal strip resistance is not within specification to Test 29 Test Transfer Relay 12 Reconnect the J2 connector to the PCB 13 Set VOM to measure DC voltage 14 Connect the negative meter test lead to Wire 0 at the terminal strip in the generator Connect the positive meter test lead to Wire 23 at the terminal strip in the generator 12 VDC should be measured 15 Place generator AUTO OFF MANUAL switch to the AUTO position Turn off utility power supply to the transfer switch simulating a utility failure After the generator starts 10 seconds should elapse before transfer occurs At that time the VOM DC voltage should drop to zero This indicates the PCB energized the transfer relay a If DC voltage drops to zero refer to Flow Chart b If DC voltage remains constant at 12 VDC pro ceed to Step 16 16 With the g
50. J1 4 18 Ignition Shutdown Circuit board relay for V Twin engines fee ee PE 1212 NOTUSEO 42 12 NOT USED J2 13 2 board to turn on the ges 14 12 VDG output tar st di d conoi J2 15 Switched to ground for choke sole tion Used for fuel solenoid and choke noid operation solenoid operation Grounded by printed circuit board to 4216 INTERNAL USE ONLY turn on System Ready Green LED J2 17 USED Switched to ground for transfer relay J2 18 o NOT USED operation Control wires for Stepper Motor J26 NoTUSED Wired Plug 1 240 VAC sensing for control board J27 _ Wired Plug 2 240 VAC sensing for control board Page 100 DC CONTROL SECTION 4 1 DESCRIPTION AND COMPONENTS REMOTE WIRELESS CONNECTION NW 7 RUP 13 18 117 16 15 14 13 12 11 10 eee s 2 06 15 4 1370280 2 1 987654321 21 J2 Ji J2 CONNECTOR J1 CONNECTOR PCB END PCB END O O 3 4 10 11
51. Ne Maximum water column 12 inches 7 inches A primary regulator is required to ensure that proper fuel supply pressures are maintained DANGER LP AND NATURAL GAS ARE BOTH HIGHLY EXPLOSIVE GASEOUS FUEL LINES MUST BE PROPERLY PURGED AND TESTED FOR LEAKS BEFORE THIS EQUIPMENT IS PLACED INTO SERVICE AND PERIODICALLY THEREAFTER PROCEDURES USED IN GASEOUS FUEL LEAKAGE TESTS MUST COMPLY STRICTLY WITH APPLICABLE FUEL GAS CODES DO NOT USE FLAME OR ANY SOURCE OF HEAT TO TEST FOR GAS LEAKS NO GAS LEAKAGE IS PERMITTED LP GAS IS HEAVIER THAN AIR AND TENDS TO SETTLE IN LOW AREAS NATURAL GAS IS LIGHTER THAN AIR AND TENDS TO SETTLE IN HIGH PLACES EVENTHE SLIGHTEST SPARK CAN IGNITE THESE FUELS AND CAUSE AN EXPLOSION Use of a flexible length of hose between the genera tor fuel line connection and rigid fuel lines is required This will help prevent line breakage that might be caused by vibration or if the generator shifts or settles The flexible fuel line must be approved for use with gaseous fuels Flexible fuel line should be kept as straight as possi ble between connections The bend radius for flexible fuel line is nine 9 inches Exceeding the bend radius can cause the fittings to crack THE TRANSFER SWITCH LOAD CENTER A transfer switch is required by electrical code to pre vent electrical feedback between the utility and stand by power sources and to transfer electrical loads from one power supply to another safel
52. PROBLEM 16 SET TO AUTO RETEST REPLACE CONTROLLER ASSEMBLY TEST 59 CHECK TEST 58 TEST BAD AUTO OPERATION AUTO OFF MANUAL 10 kW 20 kW OF CONTROLLER SWITCH BAD REPLACE CONTROLLER 4 ASSEMBLY Problem 16 Engine Will Not Crank When AUTO OFF MANUAL Switch is Set to MANUAL 8 kW battery led should be off TEST 62 CHECK coop TEST 60 CHECK GOOD P WIRE 56 VOLTAGE 7 5 AMP FUSE BATTERY BAD 4 BAD BAD RELAY REPLACE V TWIN ONLY REPLACE CONTROLLER BAD ASSEMBLY 4 GOOD TEST 59 TEST 10 kW 20 kw AUTO OFF MANUAL WITCH gt NOTE If a starting problem is encountered the engine itself should be thoroughly TEST 64 checked to eliminate it as the cause of starting CHECK STARTER difficulty It is a good practice to check the CONTACTOR engine for freedom of rotation by removing the spark plugs and turning the crankshaft over slowly by hand to be sure it rotates freely TEST 65 TEST 4 GOOD STARTER MOTOR ENGINE WITH ELECTRIC STARTER WITH SPARK PLUGS REMOVED BAD gt REPLACE ARCING AT THE PLUG ENDS MAY IGNITE THE LP OR NG VAPOR EXITING THE SPARK PLUG HOLE WARNING DO ROTATE Page 118 DC CONTROL SECTION 4 3 TROUBLESHOOTING FLOW CHARTS Problem 17 Engine Cranks but Won t Start TEST 66 CHECK GOOD TEST 67 CHECK
53. Perform a load test on the Battery Maintenance Free Battery 1 Using a lead acid battery load tester test the load capability of the battery 2 Follow the load tester s manufacturer s instructions carefully Figure 3 A Typical Battery Load Tester C Test Battery State of Non Maintenance Free Battery 1 Use an automotive type battery hydrometer to test battery state of charge 2 Follow the hydrometer manufacturer s instructions carefully Read the specific gravity of the electrolyte fluid in all battery cells 3 If cells are low distilled water can be added to refill cell compartment 4 If the hydrometer does not have a percentage of charge scale compare the reading obtained to the following a An average reading of 1 260 indicates the battery is 10096 charged 1220 1230 Cell 1 LIQUID 7 LEVEL 1250 1260 _ 1270 a Charge Specific Gravity 1 255 1 260 1 235 1 250 1 240 1 225 SECTION 4 4 DIAGNOSTIC TESTS An average reading of 1 230 means the battery is 75 charged An average reading of 1 200 means the battery is 50 charged An average reading of 1 170 indicates the bat tery is 25 charged USE A TEMPERATURE COMPENSATED HYDROMETER CHECK EACH CELL AFTER CHARGING Figure 4 Using a Battery Hydrometer 5 Test Battery Condition a If the difference between the highest and lowest read
54. Refer to flow chart PROCEDURE SINGLE CYLINDER 1 Seta VOM to measure resistance 2 Remove Wire 18 from the in line bullet connector Disconnect the J1 Connector from the printed circuit board 3 Verify the continuity of Wire 18 Connect one meter test lead to Wire 18 removed from the stud connector or bullet connector Connect the other meter test lead to Pin Location J1 4 CONTINUITY should be measured If CONTINUITY is not measured repair or replace Wire 18 as needed RESULTS Refer to flow chart TEST 79 TEST EXERCISE FUNCTION DISCUSSION The following parameters must be met in order for the weekly exercise to occur AUTO OFF MANUAL switch set to AUTO PROCEDURE 8KW 1 Set the AUTO OFF MANUAL switch to MANUAL The generator should start Set AUTO OFF MANUAL switch back to AUTO Verify that AUTO OFF MANUAL switch has been in AUTO for weekly exercise to function 2 Hold the Set Exercise switch until the generator starts approximately 10 seconds and then release All of the red LEDs will flash for approximately 10 seconds and then stop The generator will start and run for approximately 12 minutes and then shutdown on it s own The exerciser will then be set to start and run at that time of that day each week If the unit does not start replace the circuit board PROCEDURE 10KW 20KW Note Make a record of the date and time the generator is set to exercise 1 Record the current date and time
55. Remove Fan Housing Cover Using a 10mm socket wrench remove the horizontal 10mm bolt that connects remove four bolts from the fan housing cover Remove the side panel to the back panel Using a 10mm socket the fan housing cover See Figure 30 remove three bolts from the base of the enclosure See Figure 28 Using a 10mm socket and wrench remove the top hinge bolt and loosen the bottom bolt See Figure 29 Holding the roof remove the bottom hinge bolt remove the side panel by sliding it forward then re install the hinge bolt Figure 30 8 Remove Rotor Bolt Using a 9 16 socket remove rotor bolt Figure 31 Figure 28 Page 158 n NEUE 10 Remove Brushes Using a 7mm socket remove brushes See Figure 33 Figure 31 9 Remove Fan Attach a steering wheel puller to the fan using two M8 x 1 25 bolts Remove the fan from the rotor Figure 32 11 Remove Alternator Divider Panel Using a 10mm socket remove two bottom base bolts Using a T27 torx driver remove one top rear bolt Remove the panel See Figure 34 Figure 33 Figure 32 Figure 34 Page 159 SECTION 6 1 MAJOR DISASSEMBLY PART 6 12 Remove Brush Wires Using a side cutters remove the tie wraps securing the brush wires to the outside of sta tor See Figure 35 VOLTAGE REGULATOR NEUTRAL amp GROUND LUGS Figure 37 15 Alternator Air Intake Bellows Removal Remove alterna tor intake bellows See Figure 38 Figure
56. Test 38 Check Utility Sense Voltage 84 Test 39 Check Voltage at Terminal Lugs 1 2 84 Test 40 Check Battery Charger Supply Voltage Pre Wire Load Center 86 Test 41 Check Battery Charger Output Voltage Pre Wire Load Center 86 Test 42 Check Wire 0 and Wire15B Pre Wire Load 86 Test 43 EPA Battery Charger RTSN amp RT E Transfer Switch 87 Test 44 Check Battery Charger Output Voltage RTSN amp RT E Transfer Switch 87 Test 45 Check Wire 0 RTSE Transfer Switch 87 Test 46 Check Battery Charger Supply Voltage GenReady Load Center 90 Test 47 Check Battery Charger Output Voltage GenReady Load Center 90 Test 48 Check Wire 0 15B GenReady Load Center 90 Test 49 Check Battery Charger Supply Voltage Load Shed Switch 92 Test 50 Check Battery Charger Output Voltage Load Shed Transfer Switch 92 Test 51 Check Wire 0 and Wire 15B Load Shed Transfer Switch 94 PART 4 DC CONTROL eene 95 4 1 Description and Components 96 General 96 Terminal Strip Interconnection Terminal 96 Gircuit Board ipm 96 Auto
57. Used for fuel solenoid J2 5 23 Switched to ground for transfer relay operation Page 98 PIN WIRE CIRCUIT FUNCTION J2 8 15B Provides an electrical connection for charge current to reach the battery from the battery charger Provides 12VDC to the Transfer Relay J2 11 56 12 VDC output to starter contactor for single cylinder engines 2 15 NOTUSED J216 NOTUSED J217 NOTUSED 248 NOTUSED Wired Plug 1 240 VAC sensing for control board Wired Plug 2 240 sensing for control board SECTION 4 1 DESCRIPTION AND COMPONENTS DC CONTROL 18 17 16 15 14 13 1211 10 43 N 18 17 16 15 14 13 12 11 10 FEE 9 9187 4 321 987654321 24 J2 J1 J2 CONNECTOR J1 CONNECTOR PCB END PCB END 9 1 3 14 J 10 11 112 113 114 15 16 17 18 1412 112 JL3 14 15 67 8 9 J3 STEPPER MOTOR J1 CONNECTOR J2 CONNECTOR HARNESS END HARNESS END REMOTE WIRELESS CONNECTION N1 N2 CONNECTOR N1 N2 CONNECTOR PCB END HARNESS END Figure 5
58. by increasing the flow of excitation current AC POWER WINDING OUTPUT A regulated voltage is induced into the stator AC power windings When electrical loads are connected across the AC power windings to complete the cir cuit current can flow in the circuit The regulated AC power winding output voltage will be in direct proportion to the AC frequency For example on units rated 120 240 volts at 60 Hz the regulator will try to maintain 240 volts line to line at 60 Hz This type of regulation system provides greatly improved motor starting capability over other types of systems GENERATORS SECTION 2 3 TROUBLESHOOTING FLOWCHARTS GENERAL Use the Flow Charts in conjunction with the detailed The first step in using the flow charts is to correctly instructions in Section 2 4 Test numbers used in identify the problem Once that has been done locate the flow charts correspond to the numbered tests in the problem on the following pages For best results Section 2 4 perform all tests in the exact sequence shown in the charts Problem 1 Generator Produces Zero Voltage or Residual Voltage 12 20 kW TEST 1 CHECK MAIN CIRCUIT BREAKER RESET TO ON OR REPLACE IF BAD TEST 4 PERFORM FIXED EXCITATION ROTOR AMP DRAW REPAIR OR REPLACE FUSES TEST 11 TIMOR a CHECK GOOD ROTOR RESISTANCE BAD ae PERFORM STATOR 5 WIRE IN
59. ing tornados hurricanes earthquakes and unstable ground for the flexibility and strength of piping and their connections Use an approved pipe sealant or joint compound on all threaded fitting Page 16 All installed gaseous fuel piping must be purged and leak tested prior to initial start up in accordance with local codes standards and regulations FUEL CONSUMPTION The fuel consumption rates are listed in the SPECIFICATIONS section at the front of this manual BTU FLOW REQUIREMENTS NATURAL GAS BTU flow required for each unit based on 1000 BTU per cubic foot 7 kW 140 000 BTU Hour 9 kW 156 000 BTU Hour 12kW 215 000 BTU Hour 13kW 220 000 BTU Hour 16kW 261 000 BTU Hour 18kW 294 000 BTU Hour A A Gaseous fuels such as natural gas and liquid propane LP gas are highly explosive Even the slightest spark can ignite such fuels and cause an explosion No leakage of fuel is per mitted Natural gas which is lighter than air tends to collect in high areas LP gas is heavi er than air and tends to settle in low areas NOTE A minimum of one approved manual shut off valve must be installed in the gaseous fuel supply line The valve must be easily accessible Local codes determine the proper location RECONFIGURING THE FUEL SYSTEM 8 kW 410CC ENGINE To reconfigure the fuel system from NG to LP follow these steps Figure 1 NOTE The primary regulator for the propane sup ply i
60. repair or replace Wire b If 240 VAC is measured proceed to Step 9 9 Measure across points A and D 240 VAC should be measured a If 240 VAC is not measured repair or replace Wire N1A b If 240 VAC is measured proceed to Step 10 10 Measure across points A and 240 should be measured a If 240 VAC is not measured repair or replace Wire N1A b If 240 VAC is measured proceed to Step 11 11 Measure across points A and F 240 VAC should be measured a If 240 VAC is not measured replace transfer relay b If 240 VAC is measured proceed to Step 12 12 Measure across points A and G 240 VAC should be measured a If 240 VAC is not measured repair or replace Wire 126 b If 240 VAC is measured proceed to Step 13 13 Measure across points A and H 240 VAC should be measured a If 240 VAC is not measured verify limit switch SW2 is wired correctly Proceed to Test 33 b If 240 VAC is measured proceed to Step 14 14 Measure across points A and 240 should be measured a If 240 VAC is not measured repair or replace Wire A b If 240 VAC is measured replace utility coil C1 Coil nominal resistance is 1 2 megohms Page 82 TEST 33 TEST LIMIT SWITCH SW2 AND SW3 DISCUSSION The limit switches are wired to the normally closed contacts When the switches are activated the contacts open PROCEDURE With the generator shut down the generator main circuit breaker
61. 1 4 L 13 10 r9 r6 r5 E E E E 2 z z o lt lt lt r3 bur 8 4 c o O 4 5 6 CIRCUIT 7 x e LEGEND 6 6 CIRCUIT 8 BC BATTERY CHARGER __ C1 UTILITY COIL amp RECTIFIER 5 CIRCUIT 11 C2 GENERATOR COIL amp RECTIFIER F1 F2 F3 5A 600V FUSE 4 5 5 CIRCUIT 12 LC CIRCUIT BREAKER LOADS 16 CIRCUIT SHOWN FOR REFERENCE ONLY CIRCUIT 15 N NEUTRAL SW1 AUTOMATIC TRANSFER SWITCH UTILITY 5 5 CIRCUIT 16 SW2 SW3 LIMIT SWITCHES LC TB1 TERMINAL STRIP TR1 TRANSFER RELAY GROUND ES GENERATOR Figure 4 Generator Power Available Waiting to Transfer Page 63 SECTION 3 2 OPERATIONAL ANALYSIS TRANSFER SWITCH TRANSFER TO STANDBY 12 VDC is delivered to the transfer relay via Wire 15B and back to the circuit board via Wire 23 However circuit board action holds the Wire 23 circuit open and the transfer relay remains de energized On generator startup an engine warm up timer on the generator circuit board starts timing When that timer has timed out circuit board action completes the Wire 23 circuit to ground The transfer relay then energizes its normally open contacts close and standby source voltage is delivered to the standby closing coil via Wires E1 and E2 the trans
62. 1 8 10110001 Figure 6 Home Page Debug Output Screens TEST 63 TEST STARTER CONTACTOR RELAY V TWIN ONLY DISCUSSION The starter contactor relay SCR located in the con trol panel must be energized for cranking to occur Once the SCR is energized it s normally open con tacts will close and battery voltage will be available to Wire 16 and to the starter contactor SC Figure 7 The Starter Contactor Relay PROCEDURE 1 to measure DC voltage 2 Remove Wire 13 from the Starter Contactor Relay located under the printed circuit board 3 Connect the positive meter test lead to the Wire 13 connector Connect the negative meter test lead to a Clean frame ground Battery voltage should be measured 4 Reconnect Wire 13 to the SCR 5 Remove Wire 16 from the SCR Connect the positive meter test lead to the SCR terminal from which Wire 16 was removed Connect the negative meter test lead to a clean frame ground 6 Set the AUTO OFF MANUAL switch to MANUAL Observe the meter reading Battery voltage should be measured If battery voltage is not measured proceed to Step 7 7 Set the VOM to measure resistance 8 Remove Wire 0 from the SCR Connect the positive meter test lead to the disconnected Wire 0 Connect the negative meter test lead to a clean frame ground CONTINUITY should be measured RESULTS 1 If battery voltage is not measured in Step 3
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64. 240 VAC should be measured a If 240 VAC is not measured repair or replace Wire E2 b If 240 VAC is measured proceed to Step 7 7 Measure across points A and D 240 VAC should be measured a If 240 VAC is not measured repair or replace Wire E1 b If 240 VAC is measured proceed to Step 8 8 Measure across points A and E 240 should be measured Page 78 a If 240 VAC is not measured replace transfer relay b If 240 VAC is measured proceed to Step 9 9 Measure across points A and F 240 VAC should be measured a If 240 VAC is not measured repair or replace Wire 205 b If 240 VAC is measured proceed to Step 10 10 Measure across points A and G 240 VAC should be measured a If 240 VAC is not measured verify limit switch SW3 is wired correctly Proceed to Test 33 b If 240 VAC is measured proceed to Step 11 11 Measure across points A and H 240 VAC should be measured a If 240 VAC is not measured repair or replace Wire B b If 240VAC is measured replace standby coil C2 Coil nominal resistance is 1 2 megohms TEST 31 CHECK WIRE 23 DISCUSSION Printed circuit board action controls grounding Wire 23 to initiate a transfer to standby When Wire 23 is grounded the transfer relay TR1 is energized To initiate a transfer back to utility the TR1 relay must be de energized If Wire 23 is grounded TR1 will always be energized PROCEDURE RESULTS 1 Set VOM to measure DC volt
65. 35 13 Remove Controls Cover Using a Torx T 27 socket remove two bolts and ground washer from the controls cover Remove the controls cover See Figure 36 Figure 38 16 Rear Bearing Carrier Removal Using a 13mm socket Figure 36 remove the two nuts from the alternator mounting brack et rubber mounts Lift the back end of the alternator up and place a 2 x 4 piece of wood under the engine See Figure 40 Using a 13mm socket remove the four stator hold down bolts See Figure 41 Using a small rubber mallet remove the rear bearing carrier See Figure 42 Remove stator See Figure 43 14 Remove Stator Wires Remove all wires from the voltage regulator remove the common and ground wires from landing lugs and remove N1 amp N2 wires from main bea kers See Figure 37 Page 160 17 Rotor Removal Cut 2 5 inches from the rotor bolt Slot the end of the bolt to suit a flat blade screwdriver Slide the rotor bolt back through the rotor and use a screw driver to screw it into the crankshaft Use a 3 M12x1 75 bolt to screw into rotor Apply torque to the 3 M12x1 75 bolt until taper breaks See Figure 43 Figure 42 11 Remove Engine Using a 13mm socket remove the two engine mount nuts with ground wires See Figure 43 Figure 43 Figure 41 Page 161 SECTION 6 1 MAJOR DISASSEMBLY 12 Remove Engine Using proper lifting equipment remove the engine See Figure 44 Figure 44
66. 4 Diagnostic Tests Test 1 Check Main Circuit 41 Test 2 Check AC Output 41 Test 4 Fixed Excitation Test Rotor Amp Draw 42 Test 5 Wire Continuity 12 20 kW 43 Test 6 Check Field Boost 12 20 kW 44 Test 7 Testing The Stator With A Vom 12 20 44 Test 8 Test Brushless Stator 45 Test 9 Check 46 Test 10 Test DPE Winding on Brushless 5 22 47 Test 13 Test Rotor Assembly 12 20 kW 49 Test 14 Check AC Output Frequency 49 Test 15 Check and Adjust Engine Governor Single Cylinder Units 49 Test 16 Check Stepper Motor Control V twin Engine 5 50 Test 17 Check And Adjust Voltage Regulator 12 20 51 Test 18 Check Voltage And Frequency Under Load sirsiran 52 Test 19 Check For Overload Condition 52 Test 20 Check Engine Condition 52 Test 21 Field Flash Alternator 8 10 kW 52 Page 31 SECTION 2 1 DESCRIPTION amp COMPONENTS INTRODUCTION The air cooled automatic standby system is an easy to install fully enclosed and self sufficient electric power system It is designed
67. 80 CHECK CRANKING AND RUNNING CIRCUITS FUSE BLOWS WHEN PLACED IN AUTO OR MANUAL Problem 21 Generator Will Not Exercise TEST 79 TEST EXERCISE FUNCTION Problem 22 No Low Speed Exercise TEST 81 CHECK TO SEE IF LOW SPEED FUNCTION DISABLED ENABLE IS ENABLED ENABLED Y TEST 82 CHECK HEBLAGE OPERATION OF GOOD gt CHOKE SOLENOID CONTROLLER OPERATING NORMALLY Y TEST 69 TEST SOLENOID Page 122 INTRODUCTION Perform these Diagnostic Tests in conjunction with the Troubleshooting Flow Charts of Section 4 3 The test procedures and methods presented in this section are not exhaustive The manufacturer could not possibly know of evaluate and advise the service trade of all conceivable ways in which testing and trouble diagnosis might be performed The manufacturer has not undertaken any such broad evaluation TEST 56 CHECK POSITION OF AUTO OFF MANUAL SWITCH DISCUSSION If the standby system is to operate automatically the generator AUTO OFF MANUAL switch must be set to AUTO That is the generator will not crank and start on occurrence of a Utility power outage unless that switch is at AUTO In addition the generator will not exercise every seven 7 days as programmed unless the switch is at AUTO MAIN FUSE 7 5 TO Figure 1 AUTO O
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69. BLACK RED upon NEUTRAL WHITE E2 NEUTRAL r GROUND GREEN E CONNECTION 52 INSIDE SWITCH LL GROUND GREEN NEUTRAL WHITE RED MAIN 2 MAR DISTRIBUTION BLACK MAIN 1 6 CIRCUIT 14 6 omes CIRCUIT 13 6 CIRCUIT 10 CIRCUIT 9 en 5 om CIRCUIT 6 6 CIRCUIT 5 c c c mc ui e E E omms CIRCUIT 2 i 2 o o o 5 omms CIRCUIT 1 a Q Q 5 6 6 CIRCUIT 3 E iM 5 5 5 5 2 6 CIRCUIT 4 O Z g R omm CIRCUIT 7 x LEGEND 5 omm CIRCUIT 8 BC BATTERY CHARGER C1 UTILITY COIL amp RECTIFIER 5 CIRCUIT 11 C2 GENERATOR COIL 3 RECTIFIER F1 F2 F3 5A 600V FUSE CIRCUIT 12 LC CIRCUIT BREAKER LOADS 16 CIRCUIT SHOWN FOR REFERENCE ONLY 6 CIRCUIT 15 N NEUTRAL L SW1 AUTOMATIC TRANSFER SWITCH ENEN UTILITY 6 CIRCUIT 16 SW2 SW3 LIMIT SWITCHES LC TB1 TERMINAL STRIP TR1 TRANSFER RELAY GROUND EN GENERATOR Figure 9 Utility Restored Retransfer Back to Utility Page 68 TRANSFER SWITCH SECTION 3 2 OPERATIONAL ANALYSIS TRANSFER SWITCH IN UTILITY When the transfer switch returns to the utility side generator shutdown occurs after approximately one 1 minute LEGEND N NEUTRAL
70. ESC until the main menu is reached Press the right arrow key until Debug is flashing Press Enter Press the right arrow key until Inputs is flashing Press Enter History Status Edit Debug TEST Inputs Outputs Displays INPUTS INPUTS 1 10110001 INPUT 1 Figure 41 Home Page Debug and Input Screens f Digital Input 1 is Wire 86 from the Low Oil Pressure switch to the board Refer to Figure 41 g Set the AUTO OFF MANUAL switch to the MANUAL position h Observe Input 1 for a change from 1 to 0 change from 1 to 0 indicates that the control board sensed the LOP switch change states the generator still shuts down replace printed circuit board i If the input did not change states proceed to Step 2 SECTION 4 4 DIAGNOSTIC TESTS 2 Check engine crankcase oil level a Check engine oil level b If necessary add the recommended oil to the dipstick FULL mark DO NOT OVERFILL ABOVE THE FULL MARK 3 With oil level correct try starting the engine a If engine still cranks and starts but then shuts down go to Step 4 b If engine cranks and starts normally discon tinue tests 4 Do the following a Disconnect Wire 86 and Wire 0 from the oil pressure switch terminals Remove the switch and install an oil pressure gauge in its place b Start the engine while observing the oil pres sure reading on gauge Note the oil p
71. F1 amp F2 N1 amp N2 WIRING PRINTED CIRCUIT BOARD GOOD BAD FINISH REPAIR OR REPLACE WIRING Page 71 SECTION 3 3 TRANSFER SWITCH TROUBLESHOOTING FLOW CHARTS PARTS menso Problem 10 Unit Starts and Transfer Occurs When Utility Power Is On 8 kW Green LED Flashes 10 20 kW Status Utility Lost TEST 36 37 REPLACE CHECK N1 amp 2 GOOD UTILITY SENSING GOOD CIRCUIT VOLTAGE VOLTAGE AT BOARD CIRCUIT BOARD REPAIR OR BAD BAD gt REPLACE WIRING TEST 38 CHECK TEST 39 CORRECT UTILITY SENSE TEST 34 GOOD CHECK VOLTAGE BAD UTILITY VOLTAGE CHECK FUSE AT TERMINAL SOURCE F1 amp F2 LUGS N1 amp N2 VOLTAGE GOOD BAD GOOD REPAIR N1 N2 OPEN WIRING REPAIR OR REPLACE WIRE BETWEEN TRANSFER N1A N2A BETWEEN N1 N2 SWITCH AND GENERATOR 7 LUGS AND FUSE HOLDER Page 72 TRANSFER SWITCH TEST 40 CHECK BATTERY CHARGER SUPPLY VOLTAGE BAD Y REPAIR OR REPLACE TEST 43 CHECK BATTERY CHARGER SUPPLY VOLTAGE BAD Y REPAIR OR REPLACE TEST 46 CHECK BATTERY CHARGER SUPPLY VOLTAGE BAD Y REPAIR OR REPLACE TEST 49 CHECK BATTERY CHARGER SUPPLY VOLTAGE BAD Y REPAIR OR REPLACE SECTION 3 3 TROUBLESHOOTING FLOW CHARTS Problem 11 No Battery Charge Pre Wire Load Center TEST 41 CHECK GOOD gt BATTERY CHARGER OUTPUT VOLTAGE TEST 42 CHECK WIRE 0 15B NO BATTERY SUPPLY VOLTAGE
72. INFINITY is indicated the winding is open or partially open Page 47 SECTION 2 4 DIAGNOSTIC TESTS 2 Testing for a grounded condition Any resistance reading indicated the winding is grounded 3 Testing for a shorted condition Any resistance reading indicated the winding is shorted 4 f stator tests good and wire continuity tests good refer back to flow chart TEST 11 RESISTANCE CHECK OF ROTOR CIRCUIT 12 20 KW DISCUSSION To verify the zero current draw reading and measure the rotor circuit PROCEDURE 1 Disconnect Wire 4 and Wire 0 from the voltage regulator located third and fourth terminals from the top of the voltage regulator 2 Set VOM to measure resistance 3 Connect one test lead to Wire 4 Connect the other test lead to a clean frame ground Note the resistance reading Compare to specifications in the front of this manual RESULTS 1 If the resistance reading is correct check the VOM meter fuse and repeat Test 4 2 If INFINITY or a high reading is measured on the VOM refer back to flow chart TEST 12 CHECK BRUSHES AND SLIP RINGS 12 20 KW DISCUSSION The function of the brushes and slip rings is to provide for passage of excitation current from stationary compo nents to the rotating rotor Brushes are made of a spe cial long lasting material and seldom wear out or fail However slip rings can develop a tarnish or film that can inhibit or offer a resistance to
73. If battery voltage is measured proceed to Step 4 4 Reconnect battery charger black and red lead wires previously removed in Step 2 5 Measure across points E and F 13 4 VDC should be measured If 13 4 VDC is not measured replace the battery charger b If 13 4 VDC is measured the charger is working NOTE Battery charger voltage will be higher than battery supply voltage TEST 48 CHECK WIRE 0 15B GENREADY LOAD CENTER DISCUSSION In order for the battery charger to function battery supply voltage must be available to the battery charger PROCEDURE Refer to Figure 13 1 Set VOM to measure DC voltage 2 Remove and isolate battery charger black and red leads from generator terminal strip points E and F SECTION 3 4 DIAGNOSTIC TESTS TRANSFER SWITCH ENGINE GENERATOR CONNECTION PANEL N1 EJEA DUPLEX BREAKER
74. LIQUID PROPANE 10 12 WATER COLUMN CABLE ACCESS HOLE T DO SSeS GROUNDING LUG K O RIGHT SIDE VIEW REAR VIEW Page 7 SPECIFICATIONS MAJOR FEATURES 8kW Single Cylinder GH 410 Engine door removed Data Label see sample Oil Dipstick Exhaust Enclosure Composite Base Oil Filter 10kW V twin GT 530 Engine door removed Circuit Control Breaker Oil Data Label Control Panel Dipstick see sample Panel Circuit Breaker Exhaust _ Encl Im i Air Filter sak m Ly _ Fuel Inlet F uel Inlet back Fuel Fuel M Regulator Regulator oll 1 m Battery Compartment Composite Base Oil Filter Battery Compartment Figure 1 3 12 14 16 17 and 20kW V twin GT 990 GT 999 E
75. Movement of the main contacts to UTILITY actuates limit switches XA1 XB1 opens and 1 actuates to its STANDBY source side The generator continues to run Figure 6 Circuit Condition Utility Voltage Restored 240 OUTPUT NEUTRAL CONTROLLER DISPLAY 00 240 UTILITY INPUT gt BATTERY WARMER CONTROLLER PRINTED CIRCUIT BOARD 85 1 LED BOARD 5 AMP FUSE 75 mE d a 18 818 3 819 4 i SELF RESETTING FUSE H ACTUATOR i 121314 i gt 14 14 GROUND 90 5 BATTERY 2 TRANSFER 12 VDC ALWAYS PRESENT 0 AC VOLTAGE GROUND FOR CONTROL PURPOSES LEGEND 12 VDC DURING CRANKING ONLY BRUSH ASSEMBLY LOW OIL PRESSURE SWITCH MIN GUTER PRESSURES 12 VDC DURING ENGINE RUN CONDITION CS CHOKE SOLENOID SCR STARTER CONTROL RELAY 177 DC FIELD EXCITATION FS FUEL SOLENOID SM STARTER MOTOR
76. Points Page 93 SECTION 3 4 DIAGNOSTIC TESTS 4 Reconnect battery charger black and red lead wires previously removed in Step 2 5 Measure across points G and H 13 4 VDC should be measured a If 13 4 VDC is not measured replace the battery charger b If 13 4 VDC is measured the charger is working NOTE Battery charger voltage will be higher than battery supply voltage TEST 51 CHECK WIRE 0 AND WIRE 158 LOAD SHED TRANSFER SWITCH DISCUSSION In order for the battery charger to function battery supply voltage must be available to the battery charger PROCEDURE Refer to Figure 14 1 Set VOM to measure DC voltage 2 Remove and isolate battery charger black and red leads from terminal strip points G and H 3 Measure across points and J on the terminal strip 12 VDC should be measured a If 12 VDC is measured the charger should be functioning b If 12 VDC is not measured proceed to Step 4 4 Remove Wire 0 and Wire 158 from generator terminal strip Refer to Figure 6 5 Wait five 5 minutes after removing wires 6 Measure across points J and K on the terminal strip Refer to Figure 6 12 VDC should be measured a If 12 VDC is measured proceed to Step 8 b If 12 VDC is not measured proceed to Step 7 Page 94 7 Inthe generator control panel measure across Wire 158 and Wire 0 at the customer connection 12 VDC should be measured a If 12 VDC is measured repair o
77. Problem 19 Shutdown Alarm Fa lt Occurred cic 121 Problem 20 7 5 Amp Fuse F1 Blown 122 Problem 21 Generator Will Not Exercise 122 Problem 22 No Low Speed Exercise 122 4 4 Diagnostic 123 Introduction 123 Test 56 Check Position Of Auto Off Manual Switch 123 TABLE OF CONTENTS Description and Components Troubleshooting Flow Charts Diagnostic Tests 41 42 Operational Analysis 43 44 Test 57 Try a Manual Start Test 58 Auto Off Manual Switch V Twin Test 59 Test Auto Operations Test 60 Check 7 5 Amp Fuse Test 61 Check Test 62 Check Wire 56 Voltage Test 63 Test Starter Contactor Relay V twin Only sees Test 64 Test Starter Contactor Single Cylinder Engine Test 65 Test Starter Motor Test 66 Check Fuel Supply and Pressure Test 67 Check Circuit Board Wire 14 Test 68 Check Fuel Solenoid Test 69 Check Choke Solenoid Test 70 Check for Ignition Spark Test 71 Check Spark Plugs Test 72
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79. SPARK BAD TEST 74 CHECK IGNITION MAGNETOS CLEAN REGAP GOOD GOOD OR REPLACE BAD Y TEST 15 CHECK AND ADJUST ADJUST OR READJUST BAD ENGINE REPLACE GOVERNOR TEST 16 CHECK STEPPER MOTOR V TWIN UNITS CONTROL TEST 72 CHECK TEST 78 CHECK BAD ENGINE FUEL REGULATOR COMPRESSION i GOOD BAD REPAIR OR BAD REPLACE REPAIR OR REFER TO ENGINE FLYWHEEL SERVICE MANUAL KEY Page 120 SECTION 4 3 TROUBLESHOOTING FLOW CHARTS DC CONTROL Problem 19 Shutdown Alarm Fault Occured CHECK FAULT LIGHTS OVERCRANK PROCEED TO PROBLEM 16 TEST 76 CHECK HIGH CHECK INSTALLATION FOR HIGH TEMP OIL TEMPERATURE PROPER AIRFLOW OR SWITCH REPLACE DEFECTIVE SWITCH REPAIR LINKAGE IF BINDING CHECK THROTTLE OPERATION OVERSEER AC OUTPUT AND AUS REFER TO ENGINE SERVICE FREQUENCY ENGINE GOVERNOR MANUAL TEST 16 CHECK STEPPER MOTOR CONTROL TEST 70 TEST 73 CHECK TEST 78 CHECK 5 WIBE y SHUTDOWN CONTINUITY IGNITION SPARK BAD GOOD REPAIR OR REPAIR OR REPLACE SHORTED REPLACE WIRE 18 OR CIRCUIT BOARD NO SIGNAL TEST 74 CHECK gt gt IGNITION MAGNETOS TEST 75 CHECK OIL LOW OIL PRESSURE SWITCH AND WIRE 86 LOW BATTERY PROCEED TO PROBLEMS 10 13 in Page 121 SECTION 4 3 DC CONTROL TROUBLESHOOTING FLOW CHARTS Problem 20 7 5 Amp Fuse F1 Blown TEST
80. SPARK PLUG 5 VDC TO LED IGNITION MODULE Page 109 SECTION 4 2 DC CONTROL OPERATIONAL ANALYSIS EXON ENGINE STARTUP AND RUNNING With the fuel solenoids open and ignition occurring the engine starts Engine startup and running may be briefly described as follows Voltage pulses from the ignition magnetos are delivered to the circuit board via Wire 18 Once the circuit board determines that the engine is running the circuit board a terminates cranking and b terminates the choke solenoid CS and c turns on an engine warm up timer VOLTAGE REGULATOR WINDING Ez 1 7 SECTION 4 2 OPERATIONAL ANALYSIS DC CONTROL The engine warm up timer will run for about 5 seconds When this timer finishes timing board action will initiate transfer to the STANDBY power source As shown in Figure 4 below the timer is still running and transfer has not yet occurred Generator AC output is available to transfer switch Terminal Lugs E1 E2 and to the normally open contacts of a transfer relay However the transfer relay is de energized and its contacts are open Figure 4 Circuit Condition Engine Startup and Running 240 VAC GENERATOR OUTPUT NEUTRAL CONTROLLER DISPLAY 00 W
81. The governed speed must be adjusted before any attempt to adjust the voltage regulator is made Page 49 SECTION 2 4 DIAGNOSTIC TESTS SECONDARY ADJUST SCREW GOVERNOR SHAFT GOVERNOR CLAMP BOLT PRIMARY ADJUST SCREW Figure 10 Engine Governor Adjustment Single Cylinder Engines PROCEDURE 8 kW UNITS WITH DUAL GOVERNOR SPRINGS 1 Loosen the governor clamp bolt Figure 10 2 Hold the governor lever at its wide open throttle position and rotate the governor shaft clockwise as far as it will go Then tighten the governor lever clamp bolt to 70 inch pounds 8 N m 3 Start the generator let it stabilize and warm up at no load 4 Connect a frequency meter across the generators AC output leads 5 Turn the primary adjust screw to obtain a frequency reading of 61 5 Hz Turn the secondary adjust screw to obtain a frequency reading of 62 5 Hz 6 When frequency is correct at no load check the AC voltage reading If voltage is incorrect the voltage regulator may require adjustment RESULTS 1 If after adjusting the engine governor frequency and voltage are good tests may be discontinued 2 If frequency is now good but voltage is high or low refer back to flow chart If engine was overspeeding check linkage and throttle for binding If no governor response is indicated refer to engine service manual 4 f engine appears to run rough and re
82. a wes ZZ 5 Hyva Cui FEM A OIII T 2 D N 4 4 a 00 0 m e E 2 2 5 E aS bn S xt o 5 0 5 1 0 ae is 4 o e L z En gt LI m lt d gt gt 2 5 ko SvD a 1 4 i ax lt po i O gt Foe 2 ow ON o 2 goor H lt l a o at OLIA Ty o x lt 1 1 4 M H 2 a N oz oz az oz oo amp v S gt 2 ro x E 5 2 Log 5 box x E Ve 2 oO 00 xX 166 7 SCHEMATIC 8 KW HOME STANDBY
83. alarm which will automatically clear if the battery voltage rises above 11 0 volts Battery voltage is NOT moni tored during the crank cycle LOW OIL PRESSURE SHUTDOWN See Figure 1 An oil pressure switch is mounted on the engine oil filter adapter This switch has normally closed contacts that are held open by engine oil pres sure during cranking and startup Should oil pressure drop below approximately 5 psi the switch contacts will close On closure of the switch contacts a Wire 86 circuit from the circuit board will be connected to ground Circuit board action will then de energize a run relay on the circuit board The run relay s normally open contacts will then open and a 12 volts DC power supply to a Wire 14 circuit will then be terminated This will result in closure of a fuel shutoff solenoid and loss of engine ignition HIGH TEMPERATURE SWITCH This switch s contacts Figure 1 close if the tempera ture should exceed approximately 144 C 293 F initiating an engine shutdown The generator will auto matically restart and the fault on the generator control panel will reset once the temperature has returned to a safe operating level SECTION 1 6 ENGINE GENERATOR PROTECTIVE DEVICES OVERSPEED SHUTDOWN During engine cranking and operation the circuit board receives AC voltage and frequency signals from the ignition magneto via Wire 18 Should the speed exceed approximately 72 Hz 4320 rpm circuit b
84. as follows 1 Set generator main circuit breaker to its OFF or open position 2 Turn OFF all loads connected to the Transfer Switch Terminals T1 and T2 3 Setthe generator AUTO OFF MANUAL switch to OFF 4 Turn off the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker WARNING amp DO NOT ATTEMPT MANUAL TRANSFER SWITCH OPERATION UNTIL ALL POWER VOLTAGE SUPPLIES TO THE TRANSFER SWITCH HAVE BEEN POSITIVELY TURNED OFF FAILURE TO TURN OFF ALL POWER VOLTAGE SUPPLIES WILL RESULT IN EXTREMELY HAZARDOUS AND POSSIBLY FATAL ELECTRICAL SHOCK 5 Manually set the transfer switch to the STANDBY posi tion i e load terminals connected to the generator E1 E2 terminals The transfer switch operating lever should be down 6 Set the generator AUTO OFF MANUAL switch to MANUAL The engine should crank and start immediately 7 Letthe engine stabilize and warm up for a few minutes 8 Set the generator main circuit breaker to its ON or closed position Loads are now powered by the standby generator 9 Turn ON electrical loads connected to transfer switch T1 and T2 Apply an electrical load equal to the full rated wattage amperage capacity of the installed generator 10 Connect an accurate AC voltmeter and a frequency meter across Terminal Lugs E1 and E2 a 7 8kW voltage should be greater than 230 volts and frequency should be greater than 58 Hz
85. b 10 20 kW voltage should be greater than 240 volts and frequency should be 60 Hz Page 149 SECTION 5 1 SYSTEM FUNCTIONAL TESTS 11 Let the generator run at full rated load for 20 30 minutes Listen for unusual noises vibration or other indications of abnormal operation Check for oil leaks evidence of overheating etc 12 When testing under load is complete turn off electrical loads 13 Set the generator main circuit breaker to its OFF or open position 14 Let the engine run at no load for a few minutes 15 Set the AUTO OFF MANUAL switch to OFF The engine should shut down CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation proceed as follows 1 Set generator main circuit breaker to its OFF or open position 2 Check that the AUTO OFF MANUAL switch is set to OFF 3 Turn off the utility power supply to the transfer switch using means provided such as a utility main line circuit breaker 4 Manually set the transfer switch to the UTILITY position i e load terminals connected to the utility power source side 5 Turn on the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker 6 Set the AUTO OFF MANUAL switch to AUTO The system is now ready for automatic operation 7 Turn off the utility power supply to the transfer switch With the AUTO OFF MANUAL switch at AUTO the engine should crank and start whe
86. be measured b Connect the negative meter lead to Wire 23 at the terminal strip INFINITY should be measured c Connect the negative meter lead to Wire 15B at the terminal strip INFINITY should be measured d Connect the negative meter lead to Wire 0 at the terminal strip INFINITY should be measured e Connect the negative meter lead to Wire N2 at the terminal block INFINITY should be measured f Connect the negative meter lead to the neutral connection INFINITY should be measured 7 Connect the positive meter test lead to Wire N2 at the terminal block in the control panel a Connect the negative meter lead to the ground lug INFINITY should be measured b Connect the negative meter lead to Wire 23 at the terminal strip INFINITY should be measured c Connect the negative meter lead to Wire 15B at the terminal strip INFINITY should be measured d Connect the negative meter lead to Wire at the terminal strip INFINITY should be measured e Connect the negative meter lead to the neutral connection INFINITY should be measured RESULTS If a short is indicated in Step 6 or Step 7 repair wiring and re test TEST 36 CHECK 1 AND N2 VOLTAGE DISCUSSION Loss of utility source voltage to the generator will initi ate a startup and transfer by the generator Testing at the control panel terminal block will divide the system in two thereby reducing troubleshooting time PROCEDURE 1 Set the A
87. engine service manuals TEST 21 FIELD FLASH ALTERNATOR 8 10 KW UNITS DISCUSSION The alternator utilizes residual magnetism within the windings to charge the capacitor If the generator has been sitting for a long period of time with no activity the residual magnetism could be lost within the rotor Field flashing the rotor while connected in parallel with the capacitor will force a charge of electricity through the DPE winding The voltage that is induced into the rotor will return and charge the capacitor enough to take over voltage regulation of the unit Note It is crucial that the generator exercise once a week to help maintain this residual magnetism Warning Please keep safety in mind while performing this test PROCEDURE 1 Construct an energizing cord that is similar to that shown in Figure 17 and connect it as shown in Figure 18 2 Set the AUTO OFF MANUAL switch to the OFF position Warning Do NOT energize the capacitor for more than 1 second at a time 3 Momentarily turn on the energizing cord one second 4 Disconnect the energizing cord from the capacitor 5 If the field flash was successful the generator should now be producing approximately 240 VAC at the main circuit breaker of the generator when the AUTO OFF MANUAL is set to the MANUAL position Warning Do not field flash alternator more than two times in sequence If the unit has not produced power after two attempts other issues exist a
88. especially for homeown ers but may be used in other applications as well On occurrence of a utility power failure this high performance system will a crank and start automati cally and b automatically transfer electrical loads to generator AC output The generator revolving field rotor is driven by an air cooled engine at about 3600 rpm The generator may be used to supply electrical power for the operation of 120 and or 240 volts 1 phase 60 Hz AC loads A 2 pole W V Type transfer switch is offered see Part 3 The transfer switch does not include an intel ligence circuit of it s own Instead automatic startup transfer running retransfer and shutdown operations are controlled by a solid state circuit board in the generator control panel ENGINE GENERATOR DRIVE SYSTEM The generator revolving field is driven by an air cooled horizontal crankshaft engine The generator is directly coupled to the engine crankshaft see Figure 8KW 10KW BRUSH HOLDER ASSEMBLY 12KW 20KW BEARING CARRIER 1 and mounted in an enclosure Both the engine and generator rotor are driven at approximately 3600 rpm to provide a 60 Hz AC output THE AC GENERATOR Figure 1 shows the major components of the AC generator ROTOR ASSEMBLY 12 20 KW The 2 pole rotor must be operated at 3600 rpm to supply a 60 Hertz AC frequency The term 2 pole means the rotor has a single north magnetic pole and a s
89. for LP gas Maximum gaseous fuel pressure at the generator fuel inlet connection is 7 inches water column for natural gas or 12 inches water column for LP gas When propane gas is used only a vapor withdrawal system may be used This type of system utilizes the gas that forms above the liquid fuel The vapor pressure must be high enough to ensure engine operation The gaseous fuel system must be properly tested for leaks following installation and periodically thereafter No leakage is permitted Leak test methods must comply strictly with gas codes DANGER GASEOUS FUELS ARE HIGHLY EXPLOSIVE DO NOT USE FLAME OR HEAT TO TEST THE FUEL SYSTEM FOR LEAKS NATURAL GAS IS LIGHTER THAN AIR AND Page 130 TENDS TO SETTLE IN HIGH PLACES LP PROPANE GAS IS HEAVIER THAN AIR AND TENDS TO SETTLE IN LOW AREAS EVEN THE SLIGHTEST SPARK CAN IGNITE THESE GASES AND CAUSE AN EXPLOSION PROCEDURE A water manometer or a gauge that is calibrated in ounces per square inch may be used to measure the fuel pressure Fuel pressure at the inlet side of the fuel solenoid valve should be between 5 7 inches water column for natural gas NG or 10 12 inches water column for LP gas 1 See Figures 18 19 or 20 for the gas pressure test point on the fuel regulator The fuel pressure can be checked at Port 1 on all fuel regulators and at Port on 12 20 kW units 2 With the manometer connected properly crank the engine Nominal fuel
90. insulation resistance test If the winding fails the insulation resistance test clean and dry the stator as outlined in Section 1 5 Then repeat the insulation resistance test If the winding fails the second resistance test after cleaning and drying replace the stator assembly TEST 8 TEST BRUSHLESS STATOR DISCUSSION The brushless stator has three internal windings two main power windings and a DPE winding This test will ensure that there are no shorts between the power windings or shorts to ground A VOM meter can be used to test the stator windings for the following faults Page 45 SECTION 2 4 DIAGNOSTIC TESTS An open circuit condition A short to ground condition A short circuit between windings Note The resistance of stator windings is very low Some meters will not read such a low resistance and will simply indicate CONTINUITY Recommended is a high quality digital type meter capable of read ing very low resistances PROCEDURE 8 KW 1 Disconnect Stator Leads 11 and 44 from the main circuit breaker 2 Disconnect Stator Leads 22 and 33 from the neutral connection separate the leads 3 Make sure all of the disconnected leads are isolated from each other and are not touching the frame during the test 4 Set a VOM to measure resistance 5 Connect one test lead to Stator Lead 11 Connect the other test lead to Stator Lead 22 Note the resistance reading and compare to the s
91. line circuit breaker 2 Remove Stator Output Leads 22 and 33 from the neutral connection and separate the two leads 3 Disconnect Wires 11 22 2 and 6 from Voltage Regulator Ensure these wires are not touching any other components on the generator 4 Connect the red tester probe to Wire 2 Connect the black tester probe to Stator Lead 11 Refer to Steps 5a through 5c of TESTING ALL STATOR WINDINGS TO GROUND on previous page 5 Repeat Step 4 between Wire 2 and Stator Lead 33 6 Repeat Step 4 between Stator Lead 11 and Stator Lead 33 STATOR INSULATION RESISTANCE TEST 8 10 KW GENERAL Units with air cooled engine are equipped with a dual stator AC power windings and b excitation or DPE winding Insulation tests of the stator consist of a testing all windings to ground b testing between isolated windings and c testing between parallel windings Figure 8 is a pictorial representation of the various stator leads on units with air cooled engines Page 23 SECTION 1 5 TESTING CLEANING AND DRYING TESTING ALL STATOR WINDINGS TO GROUND 1 Disconnect Stator Output Leads 11 and 44 from the generator main line circuit breaker 2 Disconnect Stator Output Leads 2 and 6 from the capacitor located on the end of the stator assembly 3 Remove Stator Output Leads 22 and 33 from the neutral connection and separate the two leads 4 Connect the terminal ends of Wires 11 22 33 and 44 together Make
92. minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle unless utility power is lost 8KW A switch on the control panel see Figure permits selection of the day and time for the system to exercise At the chosen time perform the following sequence to select the desired day and time of day the system will exercise Remember seasonal time changes affect the exercise settings 1 Verify that the AUTO OFF MANUAL switch is set to AUTO 2 Press and hold the Set Exercise switch for several seconds All the red LED s will stop flashing immediately and the generator will start 3 The generator will start and run for approximately 12 minutes and then shut down The exerciser is now set to run at this time of day each week Example If the Set Exercise pressed on Saturday afternoon at 2 00 p m the generator will start and exercise for approximately 12 minutes every Saturday at 2 00 p m NOTE The exerciser will only work in the AUTO mode and will not work unless this procedure is performed The exerciser will need to be reset every time the 12 Volt battery is disconnected and then reconnected and when the fuse is removed and or replaced Page 27 SECTION 1 7 OPERATING INSTRUCTIONS 10 20 KW INSTALLATION ASSISTANT Upon first power up of the generator the display inter face will begin an installation assistant The assistant will prompt the user to set the
93. need to be dis charged before testing A capacitor can be discharged by crossing the terminals with a metal insulated screw driver Danger Use proper protective equipment when dealing with a capacitor that has exploded PROCEDURE 1 Consult the owner s manual of the meter being used for directions on measuring capacitance Figure 7 shows a typical meter and how to check capacitance 2 Connect the meter leads directly across the terminals of the capacitor The rated pf micro farad of the capacitor is marked on the side of the canister The meter should display the correct pf reading 54 If anything other than the indicated rating is displayed replace the capacitor SET TO READ CAPACITANCE CAPACITOR Figure 7 Field Boost Test Points RESULTS 1 Refer back to flow chart 2 Common observations can be made by visually inspecting the capacitor SECTION 2 4 DIAGNOSTIC TESTS a A capacitor that has gone bad can have a tendency to explode Use caution when deal ing with an exploded capacitor the gel from inside a capacitor can cause skin irritation b A capacitor is defective if the terminal connec tions are loose on the canister capacitor is defective if it wobbles while sitting on a flat surface d If any of the above observations are observed replace the capacitor TEST 10 TEST DPE WINDING ON BRUSHLESS UNITS DISCUSSION A DPE winding or Displaced Phase Excitation wind ing is
94. on new or used spark plugs as follows Recommended RESULTS 1 Clean re gap or replace spark plugs as necessary 2 If spark plugs are good refer back to flow chart Page 136 MISFIRES NORMAL 2 DETONATION PRE IGNITION Figure 30 Spark Plug Conditions Figure 31 Checking Spark Plug Gap TEST 72 CHECK ENGINE CYLINDER LEAK DOWN TEST COMPRESSION TEST GENERAL Most engine problems may be classified as one or a combination of the following Will not start Starts hard Lack of power Runs rough Vibration Overheating High oil consumption DISCUSSION The Cylinder Leak Down Tester checks the sealing compression ability of the engine by measuring air leakage from the combustion chamber Compression loss can present many different symptoms This test is designed to detect the section of the engine where the fault lies before disassembling the engine PROCEDURE 1 Remove a spark plug 2 Gain access to the flywheel Remove the valve cover 3 Rotate the engine crankshaft until the piston reaches top dead center TDC Both valves should be closed 4 Lock the flywheel at top dead center 5 Attach cylinder leak down tester adapter to spark plug hole 6 Connect an air source of at least 90 psi to the leak down tester 7 Adjust the regulated pressure on the gauge to 80 psi 8 Read the right hand gauge on the tester for cylinder pressure 20 percent lea
95. pressure should be measured If pressure is not measured while cranking refer back to flow chart SOLENOID REMOVED Figure 19 10 kW Gas Pressure Test point DC CONTROL Figure 20 12 20 kW Gas Pressure Test point Note Where a primary regulator is used to estab lish fuel inlet pressure adjustment of that regula tor is usually the responsibility of the fuel supplier or the fuel supply system installer 12 20 kW UNITS ONLY Note The test port Port 3 below the fuel solenoid maybe used to take a fuel pressure reading before the fuel solenoid Consistent pressure should be measured at this port while the generator is run ning and when the generator is off RESULTS 1 If fuel supply and pressure are adequate but engine will not start refer back to flow chart 2 generator starts but runs rough or lacks power repeat the above procedure with the generator running and under load The fuel system must be able to maintain 10 12 inches water column at all load requirements for propane and 5 7 inches water column for natural gas If proper fuel supply and pressure is maintained refer to Problem 18 Flow Chart TEST 67 CHECK CIRCUIT BOARD WIRE 14 OUTPUT DISCUSSION During any cranking action the circuit board s crank relay and run relay both energize simultaneously When the run relay energizes it s contacts close and 12 VDC is del
96. probe to frame ground 3 Observe the meter Then set the AUTO OFF MANUAL switch to the MANUAL position The meter should indicate battery voltage If battery voltage is measured stop testing and refer back to flow chart 4 Navigate to the Digital output display screen Press ESC until the main menu is reached Press the right arrow key until Debug is flashing Press Enter Press the right arrow key until Outputs is flashing Press Enter Digital Output 6 is Wire 56 output from the board Refer to Figure 6 5 Actuate the AUTO OFF MANUAL switch to the MANUAL position and observe digital output Number 6 If the printed circuit board is working correctly output Number 6 will change from a 0 to a 1 If output did not change replace printed circuit board 0 9 6 Seta to measure resistance Note Remove 7 5 amp fuse before disconnecting J1 connector 7 Remove Wire 56 from the starter contactor relay V twin units or from the starter contactor single cylinder units Connect one meter test lead to disconnected Wire 56 Remove the J2 Connector from the printed circuit board Connect the other test lead to Wire 56 at J2 CONTINUITY should be measured If CONTINUITY is not measured repair or replace Wire 56 Page 126 RESULTS 1 If battery voltage is indicated in Step 3 refer back to flow chart History Status Edit Debug TEST Inputs Outputs Displays OUTPUTS
97. provided so that the service technician will have a basic knowledge of installation requirements for home standby systems Problems that arise are often related to poor or unau thorized installation practices A typical home standby electric system is shown in Figure 1 next page Installation of such a system includes the following Selecting a Location Grounding the generator Providing a fuel supply Mounting the load center Connecting power source and load lines Connecting system control wiring Post installation tests and adjustments SELECTING A LOCATION Install the generator set as close as possible to the electrical load distribution panel s that will be pow ered by the unit ensuring that there is proper ventila tion for cooling air and exhaust gases This will reduce wiring and conduit lengths Wiring and conduit not only add to the cost of the installation but excessively long wiring runs can result in a voltage drop Control system interconnections between the transfer switch and generator consist of N1 and N2 and leads 23 15B and 0 Control system interconnection leads must be run in a conduit that is separate from the AC power leads Recommended wire gauge size depends on the length of the wire GROUNDING THE GENERATOR The National Electric Code requires that the frame and external electrically conductive parts of the gen erator be property connected to an approved earth
98. repair or replace wiring between the starter contactor relay and the starter solenoid 2 If battery voltage is not measured in Step 6 and CONTINUITY is measured in Step 8 replace the starter contactor relay If battery voltage is measured in Step 6 refer back to flow chart TEST 64 TEST STARTER CONTACTOR SINGLE CYLINDER ENGINE DISCUSSION The starter contactor SC must energize and its heavy duty contacts must close or the engine will not crank This test will determine if the starter contactor is in working order PROCEDURE Carefully inspect the starter motor cable that runs from the battery to the starter motor Cable connec tions must be clean and tight If connections are dirty or corroded remove the cable and clean cable terminals and terminal studs Replace any cable that is defective or badly corroded Use a DC voltmeter or a VOM to perform this test Test the starter contactor as follows SECTION 4 4 DIAGNOSTIC TESTS 1 Connect the positive meter test lead to the starter contactor stud to which the red battery cable connects Connect the common meter test lead to a clean frame ground Battery voltage 12 VDC should be indicated 2 Connect the positive meter test lead to the starter contactor stud to which the starter motor cable attaches see Figure 8 or Figure 9 Connect the common test lead to frame ground a No voltage should be indicated initially b Set th
99. seemingly endless When working on this equipment use common sense and remain alert at all times Never work on this equipment while you are physically or mentally fatigued If you don t understand a component device or system do not work on it TEST 1 CHECK MAIN CIRCUIT BREAKER DISCUSSION Often the most obvious cause of a problem is over looked If the generator main line circuit breaker is set to OFF or Open no electrical power will be supplied to electrical loads If loads are not receiving power perhaps the main circuit breaker is open or has failed PROCEDURE The generator main circuit breaker is located on the control panel If loads are not receiving power make sure the breaker is set to On or Closed If you suspect the breaker may have failed it can be tested as follows see Figure 1 SECTION 2 4 DIAGNOSTIC TESTS 1 Set a volt ohm milliammeter VOM to its R x 1 scale and zero the meter 2 With the generator shut down disconnect all wires from the main circuit breaker terminals to prevent interaction 3 With the generator shut down connect one VOM test probe to the Wire 11 terminal of the breaker and the other test probe to the Wire E1 terminal 4 Set the breaker to its or Closed position The VOM should read CONTINUITY 5 Set the breaker to its OFF or Open position and the VOM should indicate INFINITY 6 Repeat Steps 4 and 5 with the VOM test probes con nect
100. source is to occur Transfer to Standby cannot occur unless that power supply is available to the transfer switch DANGER BE CAREFUL HIGH AND DANGEROUS VOLTAGES ARE PRESENT AT TERMINAL LUGS E1 AND E2 WHEN THE GENERATOR IS RUNNING AVOID CONTACT WITH HIGH VOLTAGE TERMINALS OR DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK MAY RESULT DO NOT PERFORM THIS VOLTAGE TEST WHILE STANDING ON WET OR DAMP GROUND WHILE OR WHILE HANDS OR FEET ARE WET BRIDGE RECTIFIER UTILITY CLOSING COIL C1 LIMIT SWITCH SW2 PROCEDURE 1 If the generator engine has started automatically due to a utility power source outage and is running check the position of the generator main circuit breaker The circuit breaker must be set to its On or Closed position After confirming that the generator main circuit breaker is set to ON or closed check the voltage at transfer mechanism Terminal Lugs E1 and E2 with an accurate AC voltmeter or with an accurate volt ohm milliammeter VOM The generator line to line voltage should be indicated 2 If the generator has been shut down proceed as follows a On the generator control panel set the AUTO OFF MANUAL switch to OFF b Turn off all power voltage supplies to the trans fer switch Both the utility and standby power supplies must be positively turned off before proceeding c Check the position of the transfer mechanism main co
101. sure the wire ends are not touching any part of the generator frame or any terminal 5 Connect the red test probe of the Hi Pot tester to the joined terminal ends of Stator Leads 11 22 33 and 44 Connect the black tester lead to a clean frame ground on the stator can With tester leads connected in this manner proceed as follows a Turn the Hi Pot tester switch OFF b Plug the tester cord into a 120 volt AC wall Socket and set its voltage selector switch to 1500 volts c Turn the tester switch ON and observe the breakdown lamp on tester DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND After one 1 second turn the tester switch OFF 6 Connect the terminal ends of Wires 2 and 6 together Make sure the wire ends are not touching any part of the generator frame or any terminal 7 Repeat Step 5 If the breakdown lamp came on during the one 1 second test cleaning and drying of the rotor may be necessary After cleaning and drying repeat the insu lation breakdown test If breakdown lamp comes on during the second test replace the rotor assembly ROTOR INSULATION RESISTANCE TEST 8 10 KW test available ROTOR INSULATION RESISTANCE TEST 12 20 KW Before attempting to test rotor insulation the brush holder must be completely removed The rotor must be completely isolated from other components before starting the test Attach all leads of all stator windings to ground 1 Connect the red tester lead t
102. test lead to stator lead Wire 33 a The meter should read INFINITY b Any reading other than INFINITY indicates a short circuit between windings 16 Repeat Step 15 using stator lead Wire 11 Wire 6 17 Repeat Step 15 using stator lead Wire 33 Wire 6 18 Repeat Step 15 using Wire 11 at the voltage regulator Wire 6 at the voltage regulator TEST CONTROL PANEL WIRES FOR CONTINUITY 19 Connect one test lead to Wire 11 at the voltage regulator and the other test lead at stator lead Wire 11 Continuity should be measured 20 Connect one test lead to Wire 22 at the voltage regulator and the other test lead at stator lead Wire 22 Continuity should be measured RESULTS 1 Stator winding resistance values is a test of winding conti nuity and resistance If a very high resistance or INFINITY is indicated the winding is open or partially open 2 Testing for a grounded condition Any resistance reading indicates the winding is grounded 3 Testing for a shorted condition Any resistance reading indicates the winding is shorted 4 the stator tests good and wire continuity tests good perform Insulation Resistance Test in Section 1 5 5 If any test of wire continuity failed in the control panel repair or replace the wire terminal or pin connectors for that associated wire as needed NOTE Read Section 1 5 Testing Cleaning and Drying carefully If the winding tests good per form an
103. the fuel solenoid drive the throttle open and continue the crank sequence 6 Starter motor will disengage when speed reaches starter dropout 7 If the generator does not reach 2200 RPM within 15 seconds re crank cycle will occur 8 If engine stops turning between starter dropout and 2200 RPM the board will go into a rest cycle for seven 7 seconds then re crank if additional crank cycles exist 9 Once started the generator will wait for a holdoff period before starting to monitor oil pressure and oil temperature refer to the Alarm Messages section for hold off times 10 During Manual start cranking if the Mode switch is moved from the Manual position the cranking stops immediately 11 During Auto mode cranking if the Utility returns the cranking cycle does NOT abort but continues until complete Once the engine starts it will run for one 1 minute then shut down Page 29 SECTION 1 8 AUTOMATIC OPERATING PARAMETERS LOAD TRANSFER The transfer of load when the generator is running is dependent upon the operating mode as follows 1 Manual Will not transfer to generator if utility is present Will transfer to generator if utility fails below 65 of nominal for 10 consecutive seconds Will transfer back when utility returns for 15 consec utive seconds The engine will continue to run until removed from the Manual mode 2 Auto Will start and run if Utility fails for 10 consecutive s
104. then continue to monitor utility source voltage 2 OFF Position a Set the switch to OFF to stop an operating engine b To prevent an automatic startup from occurring set the switch to OFF 3 MANUAL Position a Set switch to MANUAL to crank and start unit manually b Engine will crank cyclically and start same as automatic startup but without transfer The unit will transfer if utility voltage is not available SECTION 1 7 OPERATING INSTRUCTIONS DANGER WHEN THE GENERATOR IS INSTALLED IN CONJUNCTION WITH AN AUTOMATIC TRANSFER SWITCH ENGINE CRANKING AND STARTUP CAN OCCUR AT ANY TIME WITHOUT WARNING PROVIDING THE AUTO OFF MANUAL SWITCH IS SET TO AUTO PREVENT AUTOMATIC STARTUP AND POSSIBLE INJURY THAT MIGHT BE CAUSED BY SUCH STARTUP ALWAYS SET THE AUTO OFF MANUAL SWITCHTO ITS OFF POSITION BEFORE WORKING ON OR AROUND THIS EQUIPMENT 7 5 AMP FUSE This fuse protects the DC control circuit including the circuit board against overload If the fuse element has melted open due to an overload engine cranking or running will not be possible Should fuse replace ment become necessary use only an identical 7 5 amp replacement fuse SETTING THE EXERCISE TIMER This generator is equipped with an exercise timer Once it is set the generator will start and exercise every seven days on the day of the week and at the time of day specified During this exercise period the unit runs for approximately 12
105. turned OFF and with the utility power supply to the transfer switch turned OFF test limit switch SW2 SW3 as follows 1 To prevent interaction disconnect Wire 126 and Wire A from limit switch SW2 terminals 2 Seta VOM to its R x 1 scale and zero the meter 3 See Figure 1 Connect the VOM meter test leads across the two outer terminals from which the wires were disconnected 4 Manually actuate the main contacts to their Standby position The meter should read CONTINUITY 5 Manually actuate the main contacts to their Utility position The meter should read INFINITY 6 Repeat Steps 4 and 5 several times and verify the VOM reading at each switch position 7 To prevent interaction disconnect Wire 205 and Wire B from limit switch SW3 terminals 8 See Figure 1 Connect the VOM meter test leads across the two outer terminals from which the wires were disconnected 9 Manually actuate the main contacts to their Standby position The meter should read INFINITY 10 Manually actuate the main contacts to their Utility position The meter should read CONTINUITY 11 Repeat Steps 4 and 5 several times and verify the VOM reading at each switch position RESULTS 1 If Limit Switch SW2 or SW3 fails the test remove and replace the switch or adjust switch until it is actuated properly TEST 34 CHECK FUSES F1 AND F2 DISCUSSION Fuses F1 and F2 are connected in series with the N1 and 2 circuits respectively A b
106. 0 0 158 15B gt 23 23 TSTO GENERATOR CONTROL PANEL p i2 N2 ENG 240VAC NAP ps N1 OUTPUT 1 6 BLACK RED NEUTRAL WHITE E2 NEUTRAL GROUND GREEN 9 INSIDE SWITCH GROUND GREEN NEUTRAL WHITE BAVC TO RED MAIN 2 MAIN DISTRIBUTION PANEL BLACK MAIN 1 5 CIRCUIT 14 6 CIRCUIT 13 6 CIRCUIT 10 6 CIRCUIT 9 a 6 ome CIRCUIT 6 5 omes CIRCUIT 5 c c c E ge de 5 omms CIRCUIT 2 2 2 2 gt iu EN E CIRCUIT 1 Q Q Q 2 _ o 9 9 omms CIRCUIT 5 2 2 5 5 CIRCUIT 4 52222 5 o CIRCUIT 7 co S 5 omes CIRCUIT 8 BC BATTERY CHARGER C1 UTILITY COIL amp RECTIFIER 5 om CIRCUIT 11 C2 GENERATOR COIL amp RECTIFIER F1 F2 F3 5A 600V FUSE 5 o CIRCUIT 12 LC CIRCUIT BREAKER LOADS 16 CIRCUIT SHOWN FOR REFERENCE ONLY 6 CIRCUIT 15 SW1 AUTOMATIC TRANSFER SWITCH 6 o CIRCUIT 16 SW2 SW3 LIMIT SWITCHES LC TB1 TERMINAL STRIP EE Is TR1 TRANSFER RELAY GROUND IW GENERATOR Figure 10 Transfer Switch in UTILITY Page 69 SECTION 3 3 TRANSFER SWITCH TROUBLESHOOTING FLOW CHARTS PARTS eme INTRODUCTION TO TROUBLESHOOTING The first step in troubleshooting is to correctly identify the problem Once that is done the cause of the an be found by performing the tests in the appro
107. 0 850 Rotor Resistance 3 01 3 49 3 22 3 74 7 96 9 25 7 96 9 25 8 79 10 21 8 79 10 21 10 02 11 65 Page 4 SPECIFICATIONS ENGINE Model 8 kW 10 kw 12 14 16 17 kW 20 kW Type of Engine GH 410 GT 530 GT 990 GT 999 Number of Cylinders 1 2 2 2 Rated Horsepower 3 600 rpm 14 8 18 32 34 Displacement 407cc 530cc 992cc 999cc Oylinder Block Aluminum w Cast Iron Sleeve Valve Arrangement Overhead Valves Ignition System Solid state w Magneto Recommended Spark Plug RC14YC BPR6HS RC14YCA RC12YC Spark Plug Gap 0 76 mm 0 030 inch 0 76 mm 0 030 inch 1 02 mm 0 040 inch 1 02 mm 0 040 inch Compression Ratio 941 9 5 1 9 5 1 9 5 1 Starter 12 VDC Oil Capacity Including Filter Approx 1 5 Qts Approx 1 8 Qts Approx 1 9 Qts Approx 1 9 Qts Recommended Oil Filter Part 070185F Recommended Air Filter Part 003332 Part 0E9581 Part 008127 Part 065894 Operating RPM 3 600 FUEL CONSUMPTION Model Natural Gas LP Vapor 1 2 Load Full Load 1 2 Load Full Load 7 8 kW 77 140 0 94 34 1 68 62 9 10 kW 102 156 1 25 46 1 93 70 12 12 kW 152 215 1 53 56 2 08 76 13 14 kW 156 220 1 56 58 2 30 84 16 16 kW 183 261 1 59 58 2 51 91 16 17 kW 183 261 1 61 59 2 57 94 18 20 kW 206 294 1 89 69 2 90 106 Natural gas is in cubic feet per hour is in gallons per hour cubic feet per hour Values given are appr
108. 0 kw amp 3 22 225 12 20 kW amp 3 33 c3 Figure 8 Stator Winding Leads 4 Connect the terminal ends of Wires 11 22 33 and 44 together Make sure the wire ends are not touching any part of the generator frame or any terminal 5 Connect the red test probe of the Hi Pot tester to the joined terminal ends of stator leads 11 22 33 and 44 Connect the black tester lead to a clean frame ground on the stator can With tester leads connected in this manner proceed as follows a Turn the Hi Pot tester switch OFF SECTION 1 5 TESTING CLEANING AND DRYING b Plug the tester cord into a 120 volt AC wall socket and set its voltage selector switch to 1500 volts c Turn the tester switch ON and observe the breakdown lamp on tester DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND After one 1 second turn the tester switch OFF If the breakdown lamp comes on during the one sec ond test the stator should be cleaned and dried After cleaning and drying repeat the insulation test If after cleaning and drying the stator fails the second test the stator assembly should be replaced 6 Proceed to the Voltage Regulator Each winding will be individually tested for a short to ground Refer to Steps 5 and perform the same test on the following wires Sense Lead Power Sense Lead Power 4 TEST BETWEEN WINDINGS 1 Disconnect Stator Output Leads 11 and 44 from the generator main
109. 1 Page 182 SCHEMATIC 20 KW HOME STANDBY lt a lt 9 o DRAWING 0G8515 j I gt E x ac a 22 gt wo EET lt lt 5 lt gt gU E n gt 2 a Z gt 9 NITE gt oF 2 z zr i2 FES qOOo2 o m x 2 09 gt 2 lt 5 Www ae Eee Sania a Cultu tco 8 1 e aw od gt 900 Junna M CN MA d o Pow T 5 gt F a lt a i gt Su Liz p QU Luzgaz Qo us Neos nz 25 o o 4 2E BZz y lt GOIOTrU o m On m M gt o 1 rE N 2 gt
110. 1 RESULTS Refer to flow chart TEST 69 CHECK CHOKE SOLENOID DISCUSSION The automatic choke is active cyclically during crank ing and energized ON during running For low speed exercise the choke will be closed The 12 20 kW units utilize a plate that covers the throttle bores The choke is closed if the solenoid is not energized The 10 kW unit utilizes a throttle plate located in the choke housing and the choke is open when the solenoid is de energized The 8 kW unit has a choke solenoid that is closed during the entire crank cycle when the solenoid is energized and the engine is cranking PROCEDURE 10 20 kW UNITS 1 Operational Check Set the AUTO OFF MANUAL Switch to MANUAL While cranking the choke solenoid should pull the choke plate open cyclically The dura tion of the cycle will vary depending on it s position in the crank cycle sequence Refer to the Crank Cycle Sequence Table on the following page for crank cycle sequences and duration times If the choke solenoid does not pull in verify that the choke can be manually opened There should be no binding or interference 2 Disconnect the C3 Connector 5 Figure 22 Solenoid De Energized Choke Closed 12 20 kW Units _ CHOKE PLATE P Figure 23 Solenoid Energized Choke Open 12 20 kW Units 3 Set a VOM to measure DC voltage 4 Connect the positive test lead to Wire 14 Pin 1 of the C3 Connector going to the control panel Fe
111. 10 20 KW 10 LED DISPLAY SEL og B TO ENGINE DIVIDER PANEL TO ENGINE DIMDER PANEL Figure 3 Control Panel Component Identification Page 97 SECTION 4 1 DESCRIPTION AND COMPONENTS DC CONTROL 18 17 16 15 14 13 12 11 10 43 95151555 51515 987654321 J2 J2 CONNECTOR J1 CONNECTOR PCB END PCB END 1 3 4 11 12 13 1415 16 17 18 1 2 1 2 3 14 5 67 9 J1 CONNECTOR HARNESS END J2 CONNECTOR HARNESS END 09 N1 N2 CONNECTOR HARNESS END N1 N2 CONNECTOR PCB END Figure 4 8 KW Printed Circuit Boards and J1 Connector 8 kW J1 Connector Pin Descriptions J1 1 85 High temperature shutdown Shutdown occurs when Wire 85 is grounded by contact closure in HTO J1 2 Low oil pressure shutdown Shutdown occurs when Wire 86 is grounded by loss of oil pressure to the LOP J1 3 13 12 VDC source voltage for the circuit board J1 4 18 Ignition Shutdown Circuit board action grounds Wire 18 for ignition shutdown J2 3 14 12 VDC output for engine run condi tion
112. 10 kW Printed Circuit Board and J1 Connector 10 kW J1 Connector Pin Descriptions J1 1 85 High temperature shutdown J2 8 15B Provides an electrical connection for Shutdown occurs when Wire 85 is charge current to reach the battery grounded by contact closure in HTO from the battery charger Provides 12 J1 2 Low oil pressure shutdown Shutdown VDOC to the Transfer Relay occurs when Wire 86 is grounded by J2 9 820 Positive voltage 5 VDC for status loss of oil pressure to the LOP LEDs 12 VDC source voltage for the circuit J2 10 CommonGround 000 2 11 56 12 VDC output to starter contactor J1 4 18 Ignition Shutdown Circuit board relay for V Twin engines a 4212 NOTUSED 42 12 NOT USED J2 13 22 board to turn on the 23 b 12 VDC output for engine un condi J2 15 Switched to ground for choke sole tion Used for fuel solenoid and choke noid operation solenoid operation J2 4 817 Grounded by printed circuit board to ue 16 INTERNAL USE ONLY turn on System Ready Green LED J2 17 NOT USED ELI Switched to ground for transfer relay J2 18 NOT USED operation Control wires for Stepper Motor J26 NoT USED Wired Plug 1 240 VAC sensing for control board J27 Wired Plug 2 240 VAC sensing for control board Page 99 SECTION 4 1 DESCRIPTION AND COMPONENTS DC CONTROL
113. 11 12 13 14 115 16 117 18 1 2 1 2 13 14 15 16 7 8 9 J3 STEPPER MOTOR J1 CONNECTOR J2 CONNECTOR HARNESS END HARNESS END N N1 N2 CONNECTOR PCB END N1 N2 CONNECTOR HARNESS END Figure 7 16 17 and 20 kW Printed Circuit Board and J1 Connector 16 17 and 20 kW J1 Connector Pin Descriptions ELE CIRCUIT FUNCTION High temperature shutdown Shutdown occurs when Wire 85 is grounded by contact closure in HTO Low oil pressure shutdown Shutdown occurs when Wire 86 is grounded by loss of oil pressure to the LOP J1 3 13 12 VDC source voltage for the circuit board Ignition Shutdown Circuit board action grounds Wire 18 for ignition shutdown 12VDC output for engine run condi tion Used for fuel solenoid and choke Solenoid operation Grounded by printed circuit board to turn on System Ready Green LED Switched to ground for transfer relay operation Provides an electrical connection for J2 9 820 Positive voltage 5 VDC for status LEDs charge current to reach the battery from the battery charger Provides 12 VDC to the Transfer Relay J2 11 56 12 VDC output to starter contactor relay for V Twin engines J2 12 Field Boost output J2 13 Grounded by board to turn on the Alarm Red LED J2 14 Grounded by board to turn on the Maintenance Required Yellow LED J2 15 Switched to ground for choke sole noid operation J216 INTERNAL USE ONLY J217 NOTUSED J218 NOT
114. 20 Measuring Resistance 20 Electrical Units 21 Ohm s Pete aati 21 Visual Inspection eese 22 Insulation 22 The 22 Stator Insulation Resistance Test 12 20 kW 23 Stator Insulation Resistance Test 8 10 kW 23 Rotor Insulation Resistance Test 8 10 kW 24 Rotor Insulation Resistance Test 12 20 kW 24 Cleaning The 24 Drying The Generator 24 1 6 Engine Generator Protective Devices 25 General eei ee dedo 25 Low a 25 Low Pressure Shutdown 25 High Temperature Switch 25 Overspeed Shutdown 25 Sensor 25 Overcrank Shutdown 26 1 7 Operating Instructions 27 GontrolPanel reed 27 To Select Automatic Operation 28 Manual Transfer To Standby and Manual Startup 28 Manual Shutdown And Retransfer Back To Utility
115. 3 Test 56 Check Position Of Auto Off Manual Switch 123 Test 57 Try a Manual Start 123 Test 58 Auto Off Manual Switch V Twin 2 002 123 Test 59 Test Auto Operations 124 Test 60 Check 7 5 Amp Fuse 124 Test 61 Check 124 Test 62 Check Wire 56 Voltage 126 Test 63 Test Starter Contactor Relay V twin 126 Test 64 Test Starter Contactor Single Cylinder Engine 127 Test 65 Test Starter 128 Test 66 Check Fuel Supply and Pressure 130 Test 67 Check Circuit Board Wire 14 131 Test 68 Check Fuel Solenoid 132 Test 69 Check Choke 132 Test 70 Check for Ignition Spark 134 Test 71 Check Spark Plugs 136 Test 72 Check Engine Cylinder Leak Down Test Compression Test 136 Test 73 Check Shutdown Wire 137 Test 74 Check and Adjust Ignition 1 5 138 Test 75 Check Oil Pressure Switch and Wire 86 141 Test 76 Check High Oil Temperature Switch 142 Test 77 Check and Adjust Va
116. 7 Spark Tester SECTION 4 4 DIAGNOSTIC TESTS 7 Cy 2 2 y Figure 26 8KW Choke Solenoid Figure 28 Checking Ignition Spark To determine if an engine miss is ignition related connect the spark tester in series with the spark plug wire and the spark plug Figure 29 Then crank and start the engine A spark miss will be readily apparent If spark jumps the spark tester gap regularly but the engine miss continues the problem is in the spark plug or in the fuel system NOTE A sheared flywheel key may change ignition timing but sparking will still occur across the spark tester gap Page 135 SECTION 4 4 DIAGNOSTIC TESTS Figure 29 Checking Engine Miss RESULTS 1 If no spark or very weak spark occurs go to Test 73 2 If sparking occurs but engine still won t start go to Test 71 3 When checking for engine miss if sparking occurs at regular intervals but engine miss continues go to Test 20 4 When checking for engine miss if a spark miss is readily apparent go to Test 74 TEST 71 CHECK SPARK PLUGS DISCUSSION If the engine will not start and Test 70 indicated good ignition spark perhaps the spark plug s are fouled or otherwise damaged Engine miss may also be caused by defective spark plug s PROCEDURE 1 Remove spark plugs and clean with a penknife or use a wire brush and solvent 2 Replace any spark plug having burned electrodes or cracked porcelain 3 Set gap
117. 90 4 ohms should be measured If zero resistance was measured replace the Choke Solenoid c If coil resistance was measured in the Starter Contactor and Choke Solenoid Wire 56 is short ed to ground between the J2 Connector and SC or CS repair or replace the shorted wire 5 Disconnect Wire 56 from the Starter Contactor Relay SCR Disconnect the Choke Solenoid CS connector a Connect one meter test lead to the SCR terminal from which Wire 56 was removed Connect the other meter test lead to the ground terminal 4 ohms should be measured If zero resistance was measured replace the Starter Contactor Relay b Connect one meter test lead to the CS connec tor Wire 56 Connect the other meter test lead to the CS connector Wire 90 4 ohms should be measured If zero resistance was measured replace the Choke Solenoid If coil resistance was measured in SCR and CS Wire 56 is shorted to ground between J2 connector and SC or CS repair or replace the shorted wire 6 Disconnect Wire 14 from the Fuel Solenoid FS a Connect one meter test lead to the FS terminal from which Wire 14 was removed Connect the other meter test lead to the ground terminal 16 ohms should be measured If zero resistance was measured replace the Fuel Solenoid b If coil resistance was measured in FS Wire 14 is shorted to ground between J2 connector and FS repair or replace the shorted wire 7 Disconnect Wire 14 from the Fuel Solenoid FS F
118. AL switch to OFF 2 Remove the 7 5 amp main fuse See Figure 22 3 Remove the N1 and N2 fuse from the transfer switch Figure 22 Remove 7 5 Amp Fuse 4 Turn off fuel supply to the generator and remove the flex line from the fuel regulator 5 Remove utility power from the generator 6 Remove front door 7 Remove battery from the generator STATOR ROTOR ENGINE REMOVAL 1 Remove Top Exhaust Enclosure Covers Using a 10mm socket remove the nine bolts from the exhaust top cov ers Remove covers See Figure 23 Figure 25 4 Remove Exhaust Flex Pipe Using a 7 socket remove the front and rear muffler clamp Slide exhaust flex Figure 23 toward engine completely exposing the muffler flange See Figure 26 2 Remove Side Exhaust Enclosure Cover Using a 10mm socket remove the five bolts from the exhaust side cover Remove side covers See Figure 24 Figure 26 5 Remove Muffler and Tail Pipe Using a gt socket remove the muffler clamp and tail pipe Using a 10mm socket remove the four bolts from the muffler mounts and remove muffler See Figure 27 Figure 24 3 Remove Exhaust Flex Cover Using a 10mm socket remove the two bolts from the exhaust flex pipe cover Remove the cover See Figure 25 Page 157 SECTION 6 1 MAJOR DISASSEMBLY PART 6 E Figure 27 Figure 29 6 Remove Left side enclosure Using a 10mm ratchet 7
119. ANSFER SWITCH 7 6 BLU YEL YEL 4 T E 23 BRN 23 WHT H 9 194 ORG _ 158 RED li 0 BLK B cz caa cz ca 2 AY H 1 EXTERNAL CUSTOMER CONNECTION BOX U o Figure 4 Pre 2008 HSB Interconnections Page 15 SECTION 1 4 PREPARATION BEFORE USE GENERAL The installer must ensure that the home standby gen erator has been properly installed The system must be inspected carefully following installation All appli cable codes standards and regulations pertaining to such installations must be strictly complied with In addition regulations established by the Occupational Safety and Health Administration OSHA must be complied with Prior to initial startup of the unit the installer must ensure that the engine generator has been properly prepared for use This includes the following An adequate supply of the correct fuel must be available for generator operation The engine must be properly serviced with the rec ommended oil FUEL REQUIREMENTS With LP gas use only the vapor withdrawal system This type of system uses the vapors formed above the liquid fuel in the storage tank The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California A
120. C CONTROL OPERATIONAL ANALYSIS EXON UTILITY VOLTAGE RESTORED RE TRANSFER TO UTILITY The Load is powered by the standby power supply The circuit board continues to seek an acceptable utility source voltage On restoration of utility source voltage the following events will occur On restoration of utility source voltage above 75 percent of the nominal rated voltage a retransfer time delay on the circuit board starts timing The timer will run for about fifteen 15 seconds At the end of fifteen 15 seconds the retransfer time delay will stop timing and circuit board action will open the Wire 23 circuit to ground The transfer relay TR will then de energize When the transfer relay TR de energizes its normally closed contacts close Utility source voltage is then delivered to the utility closing coil C1 via Wires N1A N2A the closed TR contacts Wire 126 limit switch and a bridge rectifier VOLTAGE REGULATOR WINDING Ez 1 7 SECTION 4 2 OPERATIONAL ANALYSIS DC CONTROL The utility closing coil C1 energizes and moves the main current carrying contacts to their NEUTRAL position The main contacts move to an over center position past NEUTRAL and spring force closes them to their UTILITY side LOAD terminals are now powered by the UTILITY source
121. CIRCUIT 4 9 amp amp amp o 5 CIRCUIT 7 co o e LEGEND 6 CIRCUIT 8 BC BATTERY CHARGER C1 UTILITY COIL amp RECTIFIER 6 CIRCUIT 11 C2 GENERATOR COIL RECTIFIER F1 F2 F3 5A 600V FUSE 6 CIRCUIT 12 LC CIRCUIT BREAKER LOADS 16 CIRCUIT SHOWN FOR REFERENCE ONLY 5 CIRCUIT 15 N NEUTRAL A SW1 AUTOMATIC TRANSFER SWITCH UTILITY 5 oe CIRCUIT 16 SW2 SW3 LIMIT SWITCHES LC no TB1 TERMINAL STRIP TR1 TRANSFER RELAY GROUND GENERATOR Figure 7 Utility Restored Generator Still Providing Output to Load Page 66 SECTION 3 2 OPERATIONAL ANALYSIS TRANSFER SWITCH UTILITY RESTORED TRANSFER SWITCH DE ENERGIZED After the preset time interval expires the circuit board will open the Wire 23 circuit to ground The transfer relay de energizes it s normally closed contacts close and utility source voltage is delivered to the utility closing coll C1 via Wires N1A and N2A closed Transfer Relay Contacts 1 and 7 and Limit Switch SW2 CONTROL 158 gt TRANSFER 23 TSTO GENERATOR CONTROL PANEL N2 UTILITY SENSING 240 N1 OUTPUT BLACK RED NEUTRAL WHITE NEUTRAL r GROUND GREEN CONNECTION 6 INSIDE SWITCH LL GROUND GREEN NEUTRAL WHITE RED MAIN 2 MAIN DISTRIBUTION PANEL BLACK MAIN 1 5 CIRCUIT 14 6 CIRC
122. CTIFIER F1 F2 F3 5A 600V FUSE 5 o CIRCUIT 12 LC CIRCUIT BREAKER LOADS 16 CIRCUIT SHOWN FOR REFERENCE ONLY 6 CIRCUIT 15 N NEUTRAL L SW1 AUTOMATIC TRANSFER SWITCH UTILITY 5 CIRCUIT 16 LC SW2 SW3 LIMIT SWITCHES TB1 TERMINAL STRIP EN TR1 TRANSFER RELAY MEE GROUND GENERATOR Figure 3 Utility Source Power Available Page 62 SECTION 3 2 OPERATIONAL ANALYSIS TRANSFER SWITCH UTILITY SOURCE VOLTAGE FAILURE If utility source voltage should drop below a preset value the generator circuit board will sense the dropout The circuit board will then initiate generator cranking and startup after a time delay circuit times out Figure 4 is a schematic representation of the transfer switch with generator power available waiting to transfer Generator voltage available E1 E2 Circuit board action holding Wire 23 open to ground Power available to standby coil C2 upon closure of TR1 normally open contacts 9 amp 6 will close and initiate a transfer 0 0 15849 158 gt TRANSFER 23 23 TS GENERATOR CONTROL PANEL 8 6 OUTPUT Ef BLACK Em earner NEUTRAL WHITE NEUTRAL GROUND GREEN CONNECTION INSIDE SWITCH 2 GROUND GREEN NEUTRAL WHITE E RED MAIN 2 MAIN DISTRIBUTION PANEL BLACK MAIN
123. DIAGNOSTIC REPAIR MANUAL geheBve MODELS 7 KW NG 8 KW LP 9 KW NG 10 KW LP 13 KW NG 14 KW LP 16 KW NG 17 KW LP 18 KW NG 20 KW LP AUTOMATIC STANDBY GENERATORS ELECTRICAL FORMULAS TO FIND KNOWN VALUES 1 PHASE 3 PHASE ExI ExIx 1 73x PF 1000 1000 ExI ExIx 1 73 KVA Volts Current 1000 1000 kW x 1000 kW x 1000 AMPERES kW Volts Power Factor 1 73 x PF WATTS Volts Amps Power Factor Volts x Amps 1 73 x PF 2 x 60 x Frequency 2 x 60 x Frequency RPM RPM KILOWATTS kW Volts Current Power Factor NO OF ROTOR POLES Frequency RPM RPM x Poles RPM x Poles FREQUENCY RPM No of Rotor Poles 2 60 2 60 2 x 60 x Frequency 2 x 60 x Frequency RPM Frequency No of Rotor Poles EIER Rotor Poles Rotor Poles HP x 0 746 HP x 0 746 Efficiency Efficiency kW required for Motor Motor Horsepower Efficiency RESISTANCE Volts Amperes VOLTS Ohm Amperes AMPERES Ohms Volts VOLTS 1 AMPERES RESISTANCE OHMS POWER FACTOR Contents Specifications eese 4 Generator st 4 ENGINE ive ag e aii enone 5 Fuel 5 Mounting 6 Mounting 7 Major Features 8 PART 1 GENERAL INFORMATION 9 1 1 Generator 10 Introduc
124. DISCUSSION The 7 5 amp fuse is located on the generator control console A blown fuse will prevent battery power from reaching the circuit board with the same result as setting the AUTO OFF MANUAL switch to OFF PROCEDURE Remove the 7 5 amp fuse F1 by pushing the fuse RESULTS 1 If the fuse if good refer back to Flow Chart 2 If the fuse is bad it should be replaced Use only an identical 7 5 amp replacement fuse 3 If fuse continues to blow proceed to Problem 20 Flow Chart TEST 61 CHECK BATTERY DISCUSSION Battery power is used to a crank the engine and b to power the circuit board Low or no battery voltage can result in failure of the engine to crank either manually or during automatic operation The trickle charger that is included in the generator will not recharge a dead battery PROCEDURE A Inspect Battery Cables 1 Visually inspect battery cables and battery posts 2 If cable clamps or terminals are corroded clean away all corrosion 3 Install battery cables making sure all cable clamps are tight The red battery cable from the starter contactor SC must be securely attached to the positive battery post the black cable from the frame ground stud must be tightly attached to the negative battery post 4 Disconnect both negative and positive cables Note Disconnect negative battery cable first 5 Using a DC Volt meter measure DC volts on the battery DC CONTROL B
125. EGEND 8 BC BATTERY CHARGER C1 UTILITY COIL 8 RECTIFIER CIRCUIT 11 L 2 COIL amp RECTIFIER F1 F2 F3 5A 600V FUSE 6 CIRCUIT 12 LC CIRCUIT BREAKER LOADS 16 CIRCUIT SHOWN FOR REFERENCE ONLY Stee CIRCUIT 15 N NEUTRAL 1 SW1 AUTOMATIC TRANSFER SWITCH EE UTILITY Stes CIRCUIT 16 SW2 SW3 LIMIT SWITCHES TB1 TERMINAL STRIP m TR1 TRANSFER RELAY GROUND IW GENERATOR Figure 6 Generator Powering Load Page 65 SECTION 3 2 OPERATIONAL ANALYSIS TRANSFER SWITCH UTILITY RESTORED Utility voltage is restored and is available to Terminals N1 and N2 The utility voltage is sensed by the generators circuit board If it is above a preset value for a preset time interval a transfer back to utility power will occur CONTROL 158 gt TRANSFER 23 TS GENERATOR CONTROL PANEL N2 UTILITY SENSING 240VAC N1 OUTPUT BLACK RED NEUTRAL WHITE NEUTRAL GROUND GREEN CONNECTION go INSIDE SWITCH GROUND GREEN NEUTRAL WHITE RED MAIN 2 MAIN DISTRIBUTION BLACK MAIN 1 5 CIRCUIT 14 om CIRCUIT 13 5 CIRCUIT 10 5 CIRCUIT 9 Mes CIRCUIT 6 6 CIRCUIT 5 m c c c c ui ui E E E E o CIRCUIT 2 2 2 2 6 CIRCUIT 1 a Q Q 55505 5 CIRCUIT 3 E E 3 3 o
126. ERATURE SWITCH SP_ SPARK PLUG 5 VDC LED IGNITION MODULE Page 107 SECTION 4 2 DC CONTROL UTILITY VOLTAGE DROPOUT AND ENGINE CRANKING After ten 10 seconds and when the circuit board s 10 second timer has timed out if utility voltage is still below 65 percent of nominal circuit board action will energize the circuit board s crank and run relays simultaneously Printed circuit board action delivers 12 volts DC to a starter contactor relay SCR via Wire 56 When the SCR energizes its contacts close and battery power is delivered to a starter contactor SC When the SC energizes its contacts close and battery power is delivered to the starter motor SM The engine cranks VOLTAGE REGULATOR 16 1 OB SECTION 4 2 OPERATIONAL ANALYSIS DC CONTROL Printed circuit board action delivers 12 volts DC to the fuel solenoids FS1 amp FS2 via Wire 14 The fuel solenoids energize open and fuel is available to the engine Wire 14 supplies power to the choke solenoid CS Circuit board action grounds Wire 90 energizing the choke solenoid cyclically during cranking and continuously while running As the engine cranks magnets on the engine flywheel induce a high voltage into the engine ignition magnetos IM1 IM2 A spark is produced that jumps the spark plug SP1 SP2 gap During cranking Wire 4 supplies 3 5 VDC 9 10 VDC isolate
127. FF MANUAL Switch Positions PROCEDURE With the AUTO OFF MANUAL switch set to AUTO test automatic operation Testing of automatic opera tion can be accomplished by turning off the Utility power supply to the transfer switch When the utility power is turned off the standby generator should crank and start Following startup transfer to the standby source should occur Refer to Section 1 8 in this manual Following generator startup and transfer to the standby source turn ON the utility power supply to the transfer switch Retransfer back to the Utility source should occur After an engine cooldown timer has timed out generator shutdown should occur RESULTS 1 If normal automatic operation is obtained discontinue tests 2 If engine does not crank when utility power is turned off proceed to Problem 15 Flow Chart Section 4 3 SECTION 4 4 DIAGNOSTIC TESTS 3 If engine cranks but won t start go to Problem 17 in Section 4 3 4 engine cranks and starts but transfer to Standby does NOT occur go to Problem 7 in Section 3 3 5 If transfer to Standby occurs but retransfer back to Utility does NOT occur when utility source voltage is restored go to Problem 8 in Section 3 3 TEST 57 TRY A MANUAL START DISCUSSION The first step in troubleshooting for an engine won t crank condition is to determine if the problem is peculiar to automatic operations only or if the engine won t crank manually eit
128. H 51 GND ve 3504 vs 3504 2414 557 1109 dION310S Veo LHM 89 0 NOILOANNOO YAWOLSND c 230 881 100 GIONS IOS VIO ONISO19 A8QNVIS 109 GION310S ONISO19 ALMILA GION310S t9 HOLIMS H3JSNVHI 51 9 QN3931 le x 55 s LHM 9 24 e 2S1 00 12 H3TIOHINOO T 16 er 21 ir nd 1 mH 20 51 19 Tei gt ooo ooo ooo ooo ooo 89 ooo ooo an ZZ 551 8 SIV 000 ooo ooo 000 ooo S 9 vX 9 IvX V V n H 19 Figure 14 Test 49 50 and 51 Load Shed Transfer Switch Test
129. H OPERATION W V TYPE TRANSFER SWITCHES 1 On the generator panel set the AUTO OFF MANUAL Switch to OFF 2 Turn OFF the utility power supply to the transfer switch using whatever means provided such as a Utility main line circuit breaker 3 Set the generator main line circuit breaker to OFF or open DANGER BE SURE TO TURN OFF ALL IN POWER VOLTAGE SUPPLIES TO THE TRANSFER SWITCH BEFORE ATTEMPTING MANUAL OPERATION FAILURE TO TURN OFF POWER VOLTAGE SUPPLIES TO THE TRANSFER SWITCH MAY RESULT LOAD CONNECTED TO UTILITY POWER SOURCE MANUAL TRANSFER HANDLE TRANSFER SWITCH OPERATING LEVER OPERATIONAL TESTS IN DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK 4 Remove the manual transfer handle from the enclosure 5 Place open end of the manual transfer handle over transfer switch operating lever 6 To connect LOAD terminal lugs to the utility power source move the handle upward 7 To connect LOAD terminals to the standby power source move the handle downward 8 Actuate the switch to UTILITY and to MANUAL several times Make sure no evidence of binding or interference is felt 9 When satisfied that manual transfer switch operation is correct actuate the main contacts to their UTILITY position Load connected to the utility power supply ELECTRICAL CHECKS Complete electrical checks as follows 1 Set the generator main circuit break
130. HIGH TEMPERATURE SWITCH SP_ SPARK PLUG 5 VDCTOLED IM_ IGNITION MODULE SECTION 4 2 DC CONTROL ENGINE SHUTDOWN Following retransfer back to the utility source an engine cool down timer on the circuit board starts timing When that timer has timed out approximately one minute circuit board action will de energize the circuit board s run relay The following events will then occur The DC circuit to Wire 14 and the fuel solenoids FS1 amp FS2 will be opened The fuel solenoids will de energize and close to terminate the engine fuel supply VOLTAGE REGULATOR POWER 22 WINDING 11 LTN im STATOR POWER WINDING 13 13 BATTERY 12V o Page 116 SECTION 4 2 OPERATIONAL ANALYSIS DC CONTROL Circuit board action will connect the engine s ignition magnetos IM1 amp IM2 to ground via Wire 18 Ignition will be terminated Without fuel flow and without ignition the engine will shut down Figure 7 Circuit Condition Retransfer to Utility and Engine Shutdown 240 i GENERATOR Q OUTPUT 33 NEUTRAL 22 CONTROLLER DISPLAY 00 UTILITY INPUT OPTIONAL BATTERY WARMER
131. HOCK DO NOT ATTEMPT THIS TEST WHILE STANDING ON WET OR DAMP GROUND WHILE BAREFOOT OR WHILE HANDS OR FEET ARE WET PROCEDURE 1 Make sure that all main line circuit breakers in the utility line to the transfer switch are or Closed SECTION 3 4 DIAGNOSTIC TESTS TRANSFER SWITCH TRANSFER SWITCH le f 1 F2 U 5 1 5 U LJ IJ LEGEND ee BLK RED BC BATTERY CHARGER WIRE i C1 UTILITY COIL amp RECTIFIER C2 GENERATOR COIL 8 RECTIFIER 15B F1 F2 F3 5A 600V FUSE LC CIRCUIT BREAKER LOADS 16 CIRCUIT SHOWN FOR REFERENCE ONLY 0 N NEUTRAL SW1 AUTOMATIC TRANSFER SWITCH TB1 TERMINAL STRIP GENERATOR MAIN J1 CONTROLLER 5 o 46 J3 112131415161 7 8 91 10 11112 13 14 15 16 17 18 afoje BA
132. K REPLACE DEFECTIVE BUT VOLTAGE 15 12 20 kW UNITS gt VOLTAGE REGULATOR STILL HIGH 8 10 kW UNITS i PROBLEM 2 Page 39 SECTION 2 3 TROUBLESHOOTING FLOWCHARTS AC GENERATORS Problem 4 Voltage and Frequency Drop Excessively When Loads Are Applied IF RECONFIGURED TO LP GAS TEST 18 CHECK VOLTAGE AND BOTH VERIFY THAT PROPER FREQUENCY LOW OVERLOADED PROCEDURE WAS FOLLOWED UNDER LOAD REFER TO SECTION 1 3 GOOD OVERLOADED UNITS WITH UNITS WITH SINGLE V TWIN CYLINDER DISCONTINUE REDUCE LOADS TO UNIT S ENGINES ENGINES TESTING RATED CAPACITY TEST 16 CHECK STEPPER MOTOR CONTROL Y TEST 15 CHECK AND ADJUST ENGINE REPAIR OR REPLACE GOVERNOR GOOD TEST 20 CHECK ENGINE CONDITION gt REPLACE BAD BAD TEST 8 TEST TEST 10 TEST BRUSHLESS GOOD DPE WINDING STATOR 8 10 kW UNITS GO TO PROBLEM 18 GOOD ENGINE STARTS HARD CONDITION ROUGH LACKS POWER GOOD SECTION 4 3 12 20 kW UNITS LOOK FOR A SHORTED TEST 7 CHECK CONDITION IN A STATOR 4 D CONNECTED LOAD OR 999 IN ONE OF THE LOAD CIRCUITS POWER WINDINGS BAD REPAIR OR REPLACE Page 40 AC GENERATORS INTRODUCTION This section is provided to familiarize the service technician with acceptable procedures for the test ing and evaluation of various problems that could be encountered on standby generators wi
133. OFF MANUAL Switch to MANUAL While cranking the choke solenoid should energize and pull the choke plate closed If the choke solenoid does not pull in verify that the choke can be manually closed There should be no binding or interference Page 133 SECTION 4 4 DIAGNOSTIC TESTS PART 4 2 Disconnect the C3 Connector 2 If Choke Solenoid coil resistance is not measured in Step 8 replace the Choke Solenoid 3 If battery voltage was not measured in Step 4 replace the printed circuit board 3 Set a to measure DC voltage 4 Connect the positive test lead to Wire 56 Pin 1 of C3 Connector going to the control panel Female Side Connect the negative test lead to Wire 0 Pin 2 5 Set the AUTO OFF MANUAL Switch to MANUAL While TEST 70 CHECK FOR IGNITION SPARK cranking battery voltage should be measured If battery voltage was not measured verify continuity of Wire DISCUSSION 0 between C3 Connector and a clean frame ground If the engine cranks but will not start perhaps an Verify continuity of Wire 56 between the C3 Connector ignition system failure has occurred A special spark and Wire 56 connector and J2 Connector Pin Location tester can be used to check for ignition spark J2 11 Repair or replace any wiring as needed PROCEDURE 6 Disconnect C3 Connector 1 Remove spark plug leads from the spark plugs 7 Seta VOM to measure resistance Figure 28 8 Connect the positive test lead to Wire 56
134. Off Manual 96 7 5 Amp 96 Menu System Navigation 102 4 2 Operational Analysis 104 Introd ctlon x cete octets 104 Utility Source Voltage Available 104 Initial Dropout of Utility Source Voltage 106 Utility Voltage Dropout and Engine 108 Engine Startup and Running 110 Initial Transfer to the Standby Source 112 Utility Voltage Restored Re transfer to Utility 114 Engine 5 116 4 3 Troubleshooting Flowcharts 118 Problem 15 Engine Will Not Crank When Utility Power Source Fails 118 Problem 16 Engine Will Not Crank When AUTO OFF MANUAL Switch is Set to 118 Problem 17 Engine Cranks but Won t Start 119 Problem 18 Engine Starts Hard and Runs Rough Lacks Power Backfires 120 Problem 19 Shutdown Alarm Fault Occurred 121 Problem 20 7 5 Amp Fuse F1 Blown 122 Problem 21 Generator Will Not Exercise 122 Problem 22 Low Speed Exercise 122 4 4 Diagnostic Tests 123 Introduction esse 12
135. PLIES MAY RESULT IN EXTREMELY HAZARDOUS AND POSSIBLY LETHAL ELECTRICAL SHOCK DANGER DO ATTEMPT MANUAL 4 In the transfer switch enclosure locate the manual transfer handle Handle is retained in the enclosure with a wing nut Remove the wing nut and handle 5 See Figure 2 Insert the un insulated end of the handle over the transfer switch operating lever a Move the transfer switch operating lever up to actuate the load contacts to the Utility position i e load connected to the utility source LOAD CONNECTED TO STANDBY POWER SOURCE TRANSFER SWITCH OPERATING LEVER MANUAL TRANSFER HANDLE Figure 2 Manual Transfer Switch Operation Page 75 SECTION 3 4 DIAGNOSTIC TESTS b Actuate the operating lever down to move the load contacts against the standby contacts i e load connected to the Standby source 6 Repeat Step 5 several times As the transfer switch operating lever is moved slight force should be needed until the lever reaches its center position As the lever moves past its center position an over center spring should snap the moveable load contacts against the stationary STANDBY or UTILITY contacts 7 Finally actuate the main contacts to their UTILITY power source side i e load contacts against the UTILITY contacts upward movement of the operating lever RESULTS 1 If there is no evidence of binding sticking or excessive force required r
136. PM sensing PROCEDURE V TWIN ONLY 1 Seta to measure AC voltage SECTION 4 4 DIAGNOSTIC TESTS 2 Connect one meter test lead to Wire 18 that is connected to the bolt connector shown in Figure 46 Connect the other meter test lead to a clean frame ground 3 Set the AUTO OFF MANUAL switch to the MANUAL position 4 When the generator comes up to rated speed measure and record the voltage reading 4 6 VAC should be measured 5 If the correct voltage was not measured in Step 4 refer back to flow chart If the correct voltage was measured proceed to Step 6 WIRE 18 CONNECTION Figure 46 Wire 18 Connection 10 20 kW Units 6 Set a VOM to measure resistance 7 Disconnect the J1 Connector from the printed circuit board 8 Verify the continuity of Wire 18 Connect one meter test lead to a clean frame ground Connect the other meter test lead to Pin Location J1 4 for all models A reading of 275K 325K ohms should be measured If CONTINUITY is measured 0 1 ohms a short to ground could be present 9 Disconnect Wire 18 from the stud connector Continue to leave J1 disconnected from Step 7 Page 143 SECTION 4 4 DIAGNOSTIC TESTS 10 Connect one meter test lead to Wire 18 removed from the stud connector Connect the other meter test lead to a clean frame ground INFINITY should be measured If CONTINUITY is measured repair or replace Wire 18 between the stud connector and the J1 Connector RESULTS
137. PREPARATION BEFORE USE _ FUEL SELECTION VER QUT POSITION FOR LIQUID PROPANE VAPOR FUEL ELO Figure 3 10 kW GT 530 Inlet Hose Slid Back 1 Open the roof 2 For 10 kW units Loosen clamp and slide back the air inlet hose Slide fuel selector on carburetor out towards the back of the enclosure Figures 2 and 3 Return the inlet hose and tighten clamp securely For 12 14 16 17 and 20 kW units remove the air cleaner cover Slide the selector lever out towards the back of the enclosure Figures 4 and 5 Return the air cleaner cover and tighten the two thumb screws 3 Close the roof 4 Reverse the procedure to convert back to natural gas IN POSITION FOR NATURAL mw NN S Figure 4 12 14 16 17 20 kW GT 990 GT 999 Airbox Cover Removed Page 17 SECTION 1 4 PREPARATION BEFORE USE OUT POSITION FC LIQUID PROPANE VAPOR FUEL Figure 5 12 14 16 17 20 kW GT 990 GT 999 Airbox Cover Removed Page 18 ENGINE OIL RECOMMENDATIONS All oil should meet minimum American Petroleum Institute API Service Class SJ SL or better Use no special additives Select the oil s viscosity grade according to the expected operating temperature e SAE 30 Above 32 F e 10W 30 gt Between 40 F and 10 F Synthetic 5W 30 3 10 F and below Engine crankcase oil capacities for the engines cov ered in this manual can be found in the spec
138. Pin 1 of 2 Attach the clamp of the spark tester to the engine C3 Connector going to the choke solenoid Male Side cylinder head Connect the negative test lead to Wire 0 Pin 2 3 Attach the spark plug lead to the spark tester terminal 4 Crank the engine while observing the spark tester If RESULTS spark jumps the tester gap you may assume the engine 1 If Battery voltage was not measured in Step 5 and wire continuity is good replace the printed circuit board NOTE The engine flywheel must rotate at 350 rpm or higher to obtain a good test of the solid state ignition system Crank Cycle Sequence Table 1 CHOKED 0 Note The first second of each crank cycle is equal to two 2 revolutions of the engine a 12 13 pog ron ue EARS 1 Crank Cycle 1 12 kW 20 kW ENENKN ww 71919191 EA 2 __ o i 12 kW 20 1 14 15 EAEN 1 1 1 1 3 10 kW 12 kW 20 k po i 011 Crank Cycle 4 ww i2kw2okw o 1 1 5 ow fo 7 i2kw 20kw 1 Page 134 AIR BOX CHOKE VALVE IN CLOSED POSITION Figure 2
139. S FOR A SHORT TO GROUND 7 Make sure all leads are isolated from each other and are not touching the frame 8 Connect one test lead to a clean frame ground Connect the other test lead to stator lead Wire 11 a The meter should read INFINITY b Any reading other than INFINITY indicates a short to ground condition 9 Repeat Step 7 using stator lead 44 TEST FOR A SHORT CIRCUIT BETWEEN WINDINGS 10 Connect one test lead to stator lead 11 Connect the other test lead to stator lead 33 a The meter should read INFINITY b Any reading other that INFINITY indicates a short between windings 11 Repeat Step 10 using Wire 44 RESULTS 1 Stator winding resistance values is a test of winding conti nuity and resistance If a very high resistance or INFINITY is indicated the winding is open or partially open 2 Testing for a grounded condition Any resistance reading indicated the winding is grounded 3 Testing for a shorted condition Any resistance reading indicated the winding is shorted 4 f stator tests good and wire continuity tests good refer back to flow chart TEST 9 CHECK CAPACITOR DISCUSSION The brushless rotor system relies on the charging and discharging of a capacitor to induce voltage into the rotor and also to regulate voltage once 240 VAC is achieved If the capacitor fails only residual magnetism of the rotor will be measured at the Main Breaker Danger The capacitor may
140. SP_ SPARK PLUG EN 5 VDCTOLED SECTION 4 2 um OPERATIONAL ANALYSIS INITIAL DROPOUT OF UTILITY SOURCE VOLTAGE Refer to Figure 2 below Should a Utility power source failure occur circuit condition may be briefly described as follows The circuit board constantly senses for an acceptable Utility source voltage via transfer switch fuses F1 F2 transfer switch UTILITY 1 and UTILITY 2 terminals connected wiring control panel UTILITY 1 and UTILITY 2 terminals and Wires N1 N2 2 2 6 6 0 m 0 VOLTAGE 4 4 REGULATOR POWER 22 22 WINDING 11 11 44 33 Le 22 2 11 POWER WINDING 4 Turo 13 13 m 13 BATTERY 1 w Tscr 0 16 SM 106 SECTION 4 2 OPERATIONAL ANALYSIS DC CONTROL Should utility voltage drop below approximately 65 percent of the nominal source voltage a programmable timer on the circuit board will turn on In Figure 2 the 10 second timer is still timing and engine cranking has not yet begun The AUTO OFF MANUAL switch is shown in its AUTO position Battery voltage is available to the circuit board via Wire 13 a 7 5 amp fuse F1 and Wire 15B Figure 2 Circuit Condition Initial Dropout of Utility Source Voltage 240
141. SULATION CONTINUITY RESISTANCE TEST TEST 12 5 1 4 BEUSHES GOOD BAD SLIP RINGS BAD REPAIR GOOD TEST 6 OR FIELD BOOST REPLACE REPAIR TEST 13 OR lt BaD TEST ROTOR REPLACE ASSEMBLY REPAIR GOOD OR REPLACE GOOD THEN RETEST PERFORM ROTOR BAD INSULATION REPLACE VOLTAGE RESISTANCE TEST REGULATOR SECTION 1 4 Page 37 SECTION 2 3 TROUBLESHOOTING FLOWCHARTS AC GENERATORS Problem 1 Generator Produces Zero Voltage or Residual Voltage 12 20 kW Continued TEST 4 PERFORM TEST 7 TEST FIXED EXCITATION STATOR ROTOR AMP DRAW PERFORM STATOR ROTOR INSULATION BAD ASSEMBLY RESISTANCE TEST SECTION 1 4 ace REPAIR GOOD OR REPLACE PERFORM ROTOR INSULATION TEST 13 RESISTANCE TEST TEST ROTOR EAD SECTION 1 4 ASSEMBLY REPAIR GOOD OR BAD PERFORM ROTOR STATOR INSULATION 0 1 4 GOOD PERFORM STATOR 4 INSULATION BAD RESISTANCE TEST RETES SECTION 1 4 RE TEST COOP Problem 2 Generator Produces Zero Voltage or Residual Voltage 8 10 kW TEST 9 CHECK CAPACITOR TEST 1 CHECK TEST 8 TEST MAIN CIRCUIT ON gt BRUSHLESS BREAKER STATOR TEST 10 TEST DPE WINDING GOOD BAD SAD REPLACE OR REPLACE EPLACI We PE REPLACE STATOR REPLACE CAPACITOR REPLACE
142. Screens 6 Locate the terminal strip in the generator control panel Disconnect Wire 23 coming in from the transfer switch customer connection side see Figure 6 7 Connect the positive meter test lead to Wire 158 at the terminal strip in the generator Connect the nega tive meter test lead to Wire 23 just removed from the terminal strip a If 0 VDC is measured proceed to Step 8 b If 12 VDC is measured a short to ground exists on Wire 23 between the generator and transfer switch Repair or replace Wire 23 as needed between generator control panel and transfer switch relay TR1 8 Locate the terminal strip in the generator control panel Disconnect Wire 23 coming in from the transfer switch customer connection side see Figure 6 Page 80 TRANSFER SWITCH CUSTOMER SIDE N1 N2 CONTROL BOARD CONNECTION GENERATOR TERMINAL STRIP Figure 6 Transfer Relay Test Points 9 Disconnect the J2 connector from the printed circuit board 10 Set VOM to measure resistance 11 Connect one meter test lead to Wire 23 connected at generator terminal strip See Figure 6 Connect the other meter test lead to control panel ground a If INFINITY or open is measured replace the printed circuit board b If continuity measured Wire 23 is shorted to ground Repair or replace Wire 23 between the J2 conne
143. Solenoid and FS Wire 14 is shorted to ground between the J2 Connector and CS or FS repair or replace the shorted wire 9 Disconnect Wire 4 and Wire 0 from the Voltage Regulator VR a At the J2 connector connect one meter test lead to Wire 4 Connect the other meter test lead to a clean frame ground Note the resistance reading and compare to the rotor resistance in the front of this manual If zero resistance was measured test Wire 4 for a short to ground Check brushes slip rings and rotor TEST 81 CHECK TO SEE IF LOW SPEED FUNCTION IS ENABLED DISCUSSION The Low speed exercise function when it is enabled allows the generator to exercise at 2400 rpm If it is disabled it will exercise at its 3600 rpm during exercise Page 146 PROCEDURE 1 Press the ESC key till the main menu is reached 2 Press the right arrow key until Edit is flashing 3 Press Enter 4 Press the right arrow key until Exercise Time appears on the controller Press Enter 6 Press the right arrow key until the Low speed exercise option is displayed 7 Ensure that it is enabled RESULTS Refer back to flow chart TEST 82 CHECK OPERATION OF THE CHOKE SOLENOID DISCUSSION The choke solenoid should be closed when it is in low speed exercise PROCEDURE 1 Remove the air box cover and filter from the engine 2 Refer to test 79 for Test Exercise Function 3 When the generator starts and the
144. TR1 TRANSFER RELAY ME GROUND GENERATOR Figure 5 Transfer Action to Standby Position Page 64 SECTION 3 2 OPERATIONAL ANALYSIS TRANSFER SWITCH TRANSFER TO STANDBY When the standby coil is energized it pulls the transfer switch mechanism to a overcenter position towards the standby power source side the transfer switch mechanically snaps to the standby position On closure of the main contacts to the standby power source side limit switches SW2 and SW3 are mechanically actuated to arm the circuit for re transfer to utility power source side Generator power from E1 and E2 is now connected to the customer load through T1 and T2 0 0 CONTROL 158 158 gt TRANSFER 236 23 TS CONTROL PANEL 2 UTILITY SENSING 240 69 OUTPUT Ete BLACK TO GENERATOR E2 RED OUTPUT NEUTRAL WHITE NEUTRAL GROUND GREEN CONNECTION INSIDE SWITCH GROUND GREEN NEUTRAL WHITE RED MAIN 2 MAIN DISTRIBUTION PANEL BLACK MAIN 1 T 14 T 13 T 10 c cc gt _ 2 gt 2 2 2 2 o lt lt lt lt 6 T3 2 a 2 2 8 8 4 g o O L
145. TTERY TRANS SIG D 0 0 PANEL GND S4 E Figure 11 Test 40 41 42 Pre Wire Load Center Test Points Page 85 SECTION 3 4 DIAGNOSTIC TESTS 2 Test for utility source line to line voltage across Terminal Lugs N1 and see Figure 1 Normal utility source voltage should be indicated RESULTS 1 If low or no voltage is indicated find the cause of the problem and correct 2 If normal utility source voltage is indicated refer to Flow Chart TEST 40 CHECK BATTERY CHARGER SUPPLY VOLTAGE PRE WIRE LOAD CENTER DISCUSSION The battery charger is supplied with 120 VAC The output of the battery charger is 13 4 VDC 2 5A PROCEDURE Refer to Figure 11 1 Set VOM to measure AC voltage 2 Measure across points A and 240 should be measured a If 240 VAC is not measured verify load source voltage b If 240 VAC is measured go to Step 3 3 Measure across points A and C 240 VAC should be measured a If 240 VAC is not measured repair or replace Wire T1 b If 240 is measured proceed to Step 4 4 Measure across points A and D 240 VAC should be measured a If 240 VAC is not measured replace fuse F3 b If 240 is measured proceed to Step 5 5 Remove Fuse Measure across points D and 120 VAC
146. UIT 13 6 CIRCUIT 10 5 CIRCUIT 9 5 CIRCUIT 6 5 CIRCUIT 5 c c c ui E E E omm CIRCUIT 2 2 t e 6 om CIRCUIT 1 Q Q agag 5 om CIRCUIT 3 E E E 55 8 om CIRCUIT 4 Q amp amp O O 6 om CIRCUIT 7 co o 57 LEGEND 5 om CIRCUIT 8 BC BATTERY CHARGER C1 UTILITY COIL amp RECTIFIER 6 CIRCUIT 11 C2 GENERATOR COIL amp RECTIFIER F1 F2 F3 5A 600V FUSE 5 CIRCUIT 12 LC CIRCUIT BREAKER LOADS 16 CIRCUIT SHOWN FOR REFERENCE ONLY 5 CIRCUIT 15 N NEUTRAL al SW1 AUTOMATIC TRANSFER SWITCH UTILITY 5 CIRCUIT 16 SW2 SW3 LIMIT SWITCHES LC TB1 TERMINAL STRIP TR1 TRANSFER RELAY GROUND GENERATOR Figure 8 Utility Restored Transfer Relay De energized Page 67 SECTION 3 2 OPERATIONAL ANALYSIS TRANSFER SWITCH UTILITY RESTORED RETRANSFER BACK TO UTILITY As the utility coil pulls the transfer switch to an OVER CENTER position the switch mechanically snaps to Utility On closure of the main contacts to the utility power source side Limit Switches SW2 and SW3 are mechanically actuated to arm the circuit for transfer to standby CONTROL 158 gt TRANSFER TSTO GENERATOR CONTROL PANEL N2 UTILITY SENSING 240VAC N1 OUTPUT
147. USED Control wires for Stepper Motor Wired Plug 1 240 VAC sensing for control board Wired Plug 2 240 VAC sensing for control board Page 101 SECTION 4 1 DESCRIPTION AND COMPONENTS DC CONTROL Figure 8 Choke Solenoid Connector Pin Number Identification MENU SYSTEM NAVIGATION To get to the MENU use the Esc key from any page It may need to be pressed many times before getting to the menu page The currently selected menu is displayed as a flashing word Navigate to the menu required by using the keys When the menu required is flashing press the ENTER key Depending on the menu selected there may be a list of choices pre sented Use the same navigation method to select the desired screen refer to the Menu System diagram Page 102 CHANGING SETTINGS EDIT MENU To change a setting such as display contrast go to the EDIT menu and use the keys to navigate to the setting to change Once this setting is displayed e g Contrast press the ENTER key to go into the edit mode Use the keys to change the setting press the ENTER key to store the new setting NOTE If the ENTER key is not pressed to save the new setting it will only be saved temporarily The next time the battery is disconnected the setting will revert back to the old setting SECTION 4 1 DESCRIPTION AND COMPONENTS tc 2 a 35129 24
148. UTO OFF MANUAL switch to OFF 2 Set to measure AC voltage 3 See Figure 9 Connect one test lead to Wire N1 at the terminal block in the generator control panel Connect the other test lead to Wire N2 Utility line to line voltage should be measured RESULTS Refer to Flow Chart Page 83 SECTION 3 4 DIAGNOSTIC TESTS 3 5 Figure 9 Terminal Block Test Points TEST 37 CHECK UTILITY SENSING VOLTAGE AT THE CIRCUIT BOARD DISCUSSION the generator starts and transfer to STANDBY occurs in the automatic mode when acceptable UTILITY source voltage is available at the terminal block the next step is to determine if sensing voltage is reaching the printed circuit board Note The System Ready LED will flash in AUTO or UTILITY LOST will display on the panel PROCEDURE 1 Set the AUTO OFF MANUAL switch to OFF 2 Disconnect the N1 N2 connector in the control panel see Figure 6 3 to measure AC voltage 4 Connect one meter test lead to Wire N1 Connect the other meter test lead to Wire N2 Approximately 240 VAC should be measured See Figure 9 RESULTS 1 If voltage was measured in Step 4 and the pin connec tions are good replace the circuit board 2 If voltage was NOT measured Step 4 repair or replace Wire N1 N2 between connector and terminal block TEST 38 CHECK UTILITY SENSE VOLTAGE The N1 and N2 terminals in the transfer switch deliver
149. Y Use a megger power setting of 500 volts Connect one megger test lead to the junction of all stator leads the other test lead to frame ground on the sta tor can Read the number of megohms on the meter Page 22 The MINIMUM acceptable megger reading for stators may be calculated using the following formula MINIMUM INSULATION RATED VOLT RESISTANCE GENERATOR OLTS 1000 in Megohms EXAMPLE Generator is rated at 120 volts AC Divide 120 by 1000 to obtain 0 12 Then add 1 to obtain 1 12 megohms Minimum Insulation resistance for 120 VAC stator is 1 12 megohms If the stator insulation resistance is less than the cal culated minimum resistance clean and dry the stator Then repeat the test If resistance is still low replace the stator Use the Megger to test for shorts between isolated windings as outlined Stator Insulation Tests Also test between parallel windings See Test Between Windings on next page TESTING ROTOR INSULATION 12 20kW Apply a voltage of 500 volts across the rotor posi tive slip ring nearest the rotor bearing and a clean frame ground i e the rotor shaft DO NOT EXCEED 500 VOLTS AND DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND FOLLOW THE MEGGER MANUFACTURER S INSTRUCTIONS CAREFULLY ROTOR MINIMUM INSULATION RESISTANCE 1 5 megohms TESTING ROTOR INSULATION 8 10kW No test available CAUTION Before attempting to meas
150. a za a o oz n 9 00 2 5 1 1 x 2 H Del 19 i m e T i T 2p V vi 1 a H 2 LE M E o gt lt lt gt lt x I H o Page 170 PART 7 SCHEMATIC 10 KW HOME STANDBY PAGE LEFT BLANK INTENTIONALLY Page 171 lt lt H WIRING DIAGRAM 14 KW HOME STANDBY DRAWING 0G7947 6 amp C 1956 SNVULIG G 2 9 61 981 9 fe gt 9 9 gt D amp 60 2 lt IN lt lt lt e Z 2 zo A xu zt ze o 55 E 1 5 Ku ao 98 cere i
151. age 2 Set the generator AUTO OFF MANUAL switch in the OFF position 3 Connect the positive meter test lead to Wire 158 at the terminal strip in the transfer switch Connect the negative meter test lead to Wire 23 at the terminal strip in the transfer switch a 0 is measured proceed to Step 4 b If 12 VDC is measured proceed to Step 6 4 Set the generator AUTO OFF MANUAL switch in the AUTO position 5 Connect the positive meter test lead to Wire 158 at the terminal strip in the transfer switch Connect the negative meter test lead to Wire 23 at the terminal strip in the transfer switch a If 12 VDC is measured procced to Step b b Navigate to the Digital Output Display Screen see Figure 5 1 Press ESC until the main menu is reached PARIS Figure 4 Standby Control Circuit Test Points Page 79 SECTION 3 4 DIAGNOSTIC TESTS 2 Press the right arrow key until Debug is flashing 3 Press Enter 4 Press the right arrow key until Outputs is flashing 5 Press Enter 6 Digital Output 8 is Wire 23 output from the board Refer to Figure 5 7 If Output 8 shows a 1 then the control board is grounding Wire 23 Replace the printed circuit board c If 0 VDC is measured the Wire 23 circuit is good Refer to flow chart History Status Edit Debug TEST Inputs Outputs Displays OUTPUTS 1 8 10110001 Figure 5 The Home Page Debug and Output
152. age will drop to a matching voltage of 120 volts AC Thus if the AC voltage output is high or low and the AC frequency is correspondingly high or low the engine speed governor may require adjustment PROCEDURE 1 Connect an accurate AC frequency meter across the Wires 11 and 44 terminals of the generator main line circuit breaker see Figure 1 Section 2 4 2 Start the engine let it stabilize and warm up at no load 3 When engine has stabilized read the frequency meter The no load frequency for single cylinder units should be about 62 63 Hertz For V Twin units the no load frequency should be about 60 Hertz RESULTS 1 If the AC frequency is high or low go on to Test 15 for single cylinder units or Test 16 for V Twin units 2 If frequency is good but voltage is high or low go to Test 17 3 If frequency and voltage are both good tests may be discontinued TEST 15 CHECK AND ADJUST ENGINE GOVERNOR SINGLE CYLINDER UNITS DISCUSSION The generator AC frequency output is directly pro portional to the speed of the rotor A two pole rotor having a single north and a single south magnetic pole will produce an AC frequency of 60 hertz at 3600 RPM The generator is equipped with a voltage over fre quency type AC voltage regulator The units AC output voltage is generally proportional to AC fre quency A low or high governor speed will result in a correspondingly low or high AC frequency and voltage output
153. al shutdown and re transfer are covered in Section 1 7 Selection of fully automatic operation is also discussed in that section This section will provide a step by step description of the sequence of events that will occur during automatic operation of the system UTILITY FAILURE Initial Conditions Generator in Auto ready to run load being supplied by utility source When utility fails below 6596 of nominal a 10 second optionally programmable on the 17 and 20 kW only line inter rupt delay time is started If the utility is still gone when the timer expires the engine will crank and start Once started a five 5 second engine warmup timer will be initiated When the warm up timer expires the control will transfer the load to the generator If the utility power is restored above 75 of nominal at any time from the initiation of the engine start until the generator is ready to accept load 5 second warm up time has not elapsed the controller will complete the start cycle and run the generator through its normal cool down cycle however the load will remain on the utility source CRANKING The system will control the cyclic cranking as follows 16 second crank seven 7 second rest 16 second crank seven 7 second rest followed by three 3 additional cycles of seven 7 second cranks followed by seven 7 second rests CHOKE OPERATION 1 The 990 999cc engines have an electric choke in the air box that is a
154. alling a standalone 5500 series generator the battery charger will be located in the generator on the side of the control assembly 2 Inside the Junction box between the generator and the transfer switch there will be 5 wires coming from the generator and 4 wires from the transfer switch 08 amp LATER HSB AIR COOLED GENERATORS SINGLE amp V TWIN ENGINES CONTROL WIRES FROM ENGINE GENERATOR N1 YEL N2 YEL 23 ama 23 BRN 15B RED 3 Using the following diagram and UL approved wire nuts connect the following wires together Wire 0 will not be utilized for this setup CONTROL WIRES FROM TRANSFER SWITCH CONTROL WIRES FROM ENGINE GENERATOR WIRE NUTS Figure 1 Wire Connections PRE 08 LOAD CENTER TRANSFER SWITCH WIRE CONTROL WIRES FROM TRANSFER SWITCH BLU N2 YEL 194 ORG X EXTERNAL CUSTOMER CONNECTION BOX INSTALL BATTERY CHARGER GENERAC P N 0G8023 Figure 2 Post 2008 HSB Interconnections Page 14 GENERAL INFORMATION SECTION 1 3 NON PREPACKAGED INTERCONNECTIONS CONNECT A 2008 AND LATER LOAD CENTER SWITCH CONTROL WIRES FROM TO A PRE 2008 AIR COOLED GENERATOR Seda ag GENERA UR PROCEDURE 1 Follow all instructions located in the Installation Manual that was supplied w
155. and Wire 6 The capacitor will charge at a rate that is dependant on the amount of voltage that is being induced into it Once the capacitor is fully charged the voltage that it discharges is a constant voltage and will in turn increase the size of the magnetic field of the rotor The greater the current flow through the rotor windings the more concentrated the lines of flux around the rotor become The more concentrated the lines of flux around the rotor that cut across the stationary stator windings the greater the voltage that is induced into the stator windings POWER WINDING OUTPUT A regulated voltage is induced into the stator AC power windings When electrical loads are connected across the AC power windings to complete the circuit current can flow in the circuit OPERATION 12 20 KW STARTUP When the engine is started residual plus field boost magnetism from the rotor induces a voltage into a the stator AC power windings and b the sta tor excitation or DPE windings In an on speed condition residual plus field boost magnetism are capable of creating approximately one half the unit s rated voltage ON SPEED OPERATION As the engine accelerates the voltage that is induced into the stator windings increases rapidly due to the increasing speed at which the rotor operates Page 36 FIELD EXCITATION An AC voltage is induced into the stator excitation DPE windings The DPE wind
156. ator terminal strips locations J and K 3 Wait five 5 minutes after removing wires 4 Measure across points L and M on the terminal strip 12 VDC should be measured a If 12 VDC is measured proceed to Step 6 b If 12 VDC is not measured proceed to Step 5 5 Measure across points M and N 12 VDC should be measured a If 12 VDC is measured repair or replace Wire 0 between the generator terminal strip and the ground lug b If 12 VDC is not measured proceed to Step 8 6 Set VOM to measure resistance 7 Connect the meter test leads across the disconnected Wire 0 and Wire 15B Approximately 115 Ohms should be measured If 115 Ohms is measured proceed to Step 10 b If zero resistance or CONTINUITY is measured connect the meter test leads across Terminals A and B on the transfer relay TR1 zero resistance is measured a short exists Replace TR1 d If 115 Ohms is measured repair or replace Wire 15B between the generator and the transfer switch 8 Set VOM to measure resistance 9 Disconnect the J2 connector from the printed circuit board 10 Measure across point M and pin location J2 8 of the con nector just removed Continuity should be measured a continuity is not measured repair or replace Wire 15B between the J2 connector and the terminal strip b If continuity is measured and the pin connection looks good the internal fuse on the PCB has failed Replace printed circuit board
157. attery supply Wire 15B located at TB1 terminal board 3 Set VOM to AC volts Figure 2 Voltage Regulator 4 Disconnect Wire 2 from the voltage regulator and con nect one meter test lead to that wire Disconnect Wire 6 from the voltage regulator and connect the other meter test lead to that wire Wires 2 and 6 are located at the bottom two terminals of the voltage regulator see Figure 2 5 Set the AUTO OFF MANUAL switch to MANUAL Once the engine starts record the AC voltage 6 Set the AUTO OFF MANUAL switch to OFF Reconnect Wire 2 and Wire 6 7 Disconnect Wire 11 from the voltage regulator and con nect one meter test lead to that wire Disconnect Wire 22 from the voltage regulator and connect the other meter test lead to that wire both wires are located at the top two terminals of the voltage regulator see Figure 2 8 Set the AUTO OFF MANUAL switch to MANUAL Once the engine starts record the AC voltage 9 Set the AUTO OFF MANUAL switch to OFF Reconnect Wire 11 and Wire 22 10 Set VOM to DC amperage 11 Remove jumper lead connected to Wire 4 and Wire 158 12 Connect one meter test lead to battery positive 12 VDC supply Wire 15B located at TB1 terminal board GENERATORS Connect the other meter test lead to Wire 4 still dis connected from previous tests Measure and record static rotor amp draw 13 5 the AUTO OFF MANUAL switch to the MANUAL position Once the engine starts repeat Ste
158. blem 14 No Battery Charge Load Shed Transfer Switch 73 3 4 Diagnostic Tests rne tr e iei ree t 74 Gehetall 74 Test 26 Check Voltage at Terminal Lugs E1 2 Test 27 Check Manual Transfer Switch Operation TABLEOFCONTENTS 13 1 Description and Components 50 3 2 Operational Analysis 54 33 Troubleshooting Flow Charts 64 34 Diagnostic Tests 66 Test 28 Check 23 And 158 76 Test 29 Test Transfer Relay TR 77 Test 30 Standby Control Circuit 78 Test 31 Check Wire 23 78 Test 32 Utility Control Circuit 80 Test 33 Test Limit Switch SW2 and SW3 82 Test 34 Check Fuses F1 and 2 82 Test 35 Check 1 and 2 Wiring 83 Test 36 Check 1 N2 83 Test 37 Check Utility Sensing Voltage at the Circuit 9 84 Test 38 Check Utility Sense Voltage 84 Test 39 Check Voltage at Terminal Lugs N1 84 Test 40 Check Battery Charger Supply Voltage Pre Wire Load 86 Test 41 Check Battery Charger Output Voltage Pre Wire Load
159. by position i e loads connected to the Standby power source side NOTE For instructions on manual operation of transfer switches see Part 3 5 On the generator panel set the AUTO OFF MANUAL switch to MANUAL The engine should crank and start 6 Let the engine warm up and stabilize for a minute or two at no load 7 Set the generator main line circuit breaker to its On or Closed position The generator now powers the electrical loads MANUAL SHUTDOWN AND RETRANSFER BACK TO UTILITY To shut the generator down and retransfer electrical loads back to the UTILITY position proceed as follows 1 Set the generator main line circuit breaker to its OFF or Open position 2 Let the generator run at no load for a few minutes to cool 3 Set the generator AUTO OFF MANUAL switch to OFF Wait for the engine to come to a complete stop 4 Turn off the utility power supply to the transfer switch using whatever means provided such as a utility source main line circuit breaker 5 Manually actuate the transfer switch to its UTILITY source side i e load connected to the utility source 6 Turn on the utility power supply to the transfer switch using whatever means provided 7 Setthe generator AUTO OFF MANUAL switch to AUTO INTRODUCTION When the generator is installed in conjunction with a transfer switch either manual or automatic opera tion is possible Manual transfer and engine startup as well as manu
160. cations in the front of this manual Note Wire 11 and Wire 44 could be switched on the main breaker If an INFINITY reading is indi cated try putting the meter leads on the other output terminal of the breaker If INFINITY is still read then an actual fault may exist 9 Connect one test lead to Wire 22 at the voltage regula tor Connect the other test lead to Wire 11 at the voltage regulator power winding sense leads Note the resis tance reading and compare to the specifications in the front of this manual TEST WINDINGS FOR A SHORT TO GROUND 10 Make sure all leads are isolated from each other and are not touching the frame 11 Connect one test lead to a clean frame ground Connect the other test lead to stator lead Wire 11 on the load side of the main circuit breaker a The meter should read INFINITY b Any reading other than INFINITY indicates a short to ground condition 12 Repeat Step 11 using stator lead Wire 33 13 Repeat Step 11 using Wire 22 at the voltage regulator 14 Repeat Step 11 using Wire 6 at the voltage regulator 6 11 3 115 12 20 kw amp 3 22P 225 12 20 kW amp 3 33 44 amp 3 Figure 5 Stator Assembly Leads SECTION 2 4 DIAGNOSTIC TESTS TEST FOR A SHORT CIRCUIT BETWEEN WINDINGS 15 Connect one test lead to stator lead Wire 11 on the load side of the main circuit breaker Connect the other
161. cover Remove the controls cover See Figure 2 Figure 4 Figure 2 Page 152 4 Remove Stator Wires Remove all wires from the voltage regulator remove the neutral and ground wires from landing lugs and remove N1 amp N2 wires from main bea kers See Figure 5 5 Remove Control Wires Remove Wires N1 N2 0 158 23 GFCI Outlet and unit status lights from the control box See Figure 6 Figure 8 7 Remove engine intake baffle Using a 10mm socket remove the two bolts from the engine intake baffle Pull baffle toward you carefully there are tabs holding the backside of the baffle to the divider panel See Figure 9 Figure 6 6 Remove controller mounting box Using an 8mm socket remove the two screws from the rear of the control ler mounting box See Figure 7 Using a 10mm socket remove the two bolts from under the front of the control ler mounting box See Figure 8 Figure 9 Page 153 SECTION 6 1 MAJOR DISASSEMBLY PART 6 8 Loosen side panel Using a 10mm socket remove the 10 Remove fuel regulator Remove the two fuel hoses at two bolts from the base of the enclosure side panel See the top of the regulator Using a 10mm socket remove Figure 10 one 10mm bolt from the base of the plenum and one 10mm bolt from the base of the fuel regulator Flex the enclosure side out to allow for room to remove the regulator assemble See Figure 12 9 Unbolt enclosure side panel mou
162. cross BAT and XFER on the load center motor zero resistance is measured a short exists Replace the load center motor d If 200 Ohms to INFINITY is measured repair or replace Wire 15B between the generator and the load center 10 Disconnect the J2 connector from the printed circuit board 11 Measure across point M and pin location J2 8 of the connector just removed CONTINUITY should be measured a If CONTINUITY is not measured repair or replace Wire 15B between the J2 connector and the terminal strip b If CONTINUITY is measured and the pin con nection looks good the internal fuse on the PCB has failed Replace the printed circuit board TEST 49 CHECK BATTERY CHARGER SUPPLY VOLTAGE LOAD SHED TRANSFER SWITCH DISCUSSION The battery charger is supplied with 120 VAC The output of the battery charger is 13 4 VDC 2 5A Page 92 PROCEDURE Refer to Figure 14 1 Set VOM to measure AC voltage 2 Measure across points A and B 240 VAC should be measured a If 240 VAC is not measured verify load source voltage at ATS b If 240 VAC is measured proceed to Step 3 3 Measure across points A and C 240 VAC should be measured a If 240 VAC is not measured repair or replace Wire T1 between LSS and J3 terminal of load shed controller b If 240VAC is measured proceed to Step 4 4 Measure across points C and D 120 VAC should be measured a If 120 VAC is not measured repair or rep
163. ct the remaining test lead to Orange approximately 10 ohms should be measured b Connect one meter lead to Red connect the remaining test lead to Yellow approximately 10 ohms should be measured c Connect one meter lead to Red connect the remaining test lead to Brown approximately 10 ohms should be measured d Connect one meter lead to Red connect the remaining test lead to Black approximately 10 ohms should be measured e Connect one meter lead to Red connect the remaining test to the stepper motor case No resis tance should be measured INFINITY or Open RESULTS 1 If the stepper motor fails any part of Step 6 replace the Stepper motor 2 If the stepper motor passes all steps replace the Printed Circuit Board PULL ARM THIS DIRECTION TO CLOSE THROTTLE PULL ARM THIS DIRECTION TO THROTTLE STEPPER MOTOR STEPPER MOTOR ARM Figure 13 Throttle Positions 12 20 kW Units SECTION 2 4 DIAGNOSTIC TESTS BLACK BROWN YELLOW ORANGE RED EMPTY Figure 14 Six Pin Connector Wire Colors TEST 17 CHECK AND ADJUST VOLTAGE REGULATOR 12 20 KW DISCUSSION For additional information refer to description and components Section 2 1 PROCEDURE V TWIN ENGINE UNITS With the frequency at 60 Hertz slowly turn the slotted potentiometer Figure 15 until line voltage reads 247 249 volts NOTE The access panel on top of the co
164. ctor and the generator terminal strip TEST 32 UTILITY CONTROL CIRCUIT DISCUSSION Printed circuit board action controls grounding Wire 23 to initiate a transfer to standby When Wire 23 is grounded the transfer relay TR1 is energized To initiate a transfer back to utility the TR1 relay must be de energized If Wire 23 is grounded TR1 will always be energized PROCEDURE RESULTS Refer to Figure 7 1 Turn off utility supply voltage to the transfer switch 2 Set VOM to measure AC voltage 3 Set the generator AUTO OFF MANUAL switch in the OFF position Remove Wire 15B from the transfer switch terminal strip 4 Verify the transfer switch is down in the standby position PART 3 A 9 lt 2 Figure 7 Utility Control Circuit Test Points Page 81 SECTION 3 4 DIAGNOSTIC TESTS 5 Remove Wire from the utility coil C1 6 Turn on utility power supply to the transfer switch a If transfer to utility occurs Wire 23 is grounded Proceed to Test 31 b If transfer to utility does not occur proceed to Step 7 7 Measure across points A and 240 should be measured a If 240 VAC is not measured verify utility source b If 240 VAC is measured proceed to Step 8 8 Measure across points C Wire N2A previously removed and B 240 VAC should be measured a If 240 VAC is not measured
165. cts The load contacts can be connected to the utility contacts by a utility closing coil or to the standby contacts by a standby closing coil In addi tion the load contacts can be actuated to either the UTILITY or STANDBY side by means of a manual transfer handle See Figures 2 and 3 STANDBY UTILITY Figure 3 Load Connected to Standby Power Source UTILITY CLOSING COIL C1 See Figure 4 This coil is energized by rectified util ity source power to actuate the load contacts to the UTILITY power source side When energized the coil will move the main contacts to an overcenter posi tion A limit switch will then be actuated to open the circuit and spring force will complete the retransfer to STANDBY A bridge rectifier which changes the utility source alternating current AC to direct current DC is sealed in the coil wrappings If coil or bridge rectifier replacement becomes necessary the entire coil and bridge assembly should be replaced STANDBY CLOSING COIL C2 Coil C2 is energized by rectified standby source power to actuate the load contacts to their Standby SECTION 3 1 DESCRIPTION amp COMPONENTS source side Energizing the coil moves the load con tacts to an overcenter position limit switch action then opens the circuit and spring force will complete the transfer action to Standby This coil s bridge rectifier is also sealed in the coil wrappings Replace the c
166. d located above the oil cooler On single cylinder gen erators disconnect Wire 18 at the bullet connector See Figures 32 or 33 Page 137 SECTION 4 4 DIAGNOSTIC TESTS 2 5 WIRE 18 CONNECTION Figure 32 Wire 18 Connection 10 20 kW Units Depending on engine type do the following a On V twin units remove Wire 56 from the Starter Contactor Relay SCR Using a jumper lead jump 12 VDC from Wire 15B at TB1 Customer Connection to the terminal on the SCR from which Wire 56 was removed The generator will start cranking As it is cranking repeat Test 70 Reconnect Wire 56 when done b On single cylinder units connect a jumper lead from the stud to which Wire 56 is connected on the Starter Contactor SC and 12 VDC Wire 15B at TB1 Customer Connection The generator will start cranking As it is cranking repeat Test 70 WIRE 18 CONNECTION Figure 33 Wire 18 Connection 8 kW Units If spark now occurs with Wire 18 removed check for a short to ground Remove the J1 Connector from the circuit board Seta VOM to measure resistance Connect one test lead to Wire 18 disconnected in Step 1 Connect the other test lead to a clean frame ground INFINITY should be measured Reconnect the J1 Connector to the circuit board Page 138 RESULTS 1 2 3 If INFINITY was not measured in Step 4 repair or replace shorted ground Wire 18 between the J1 Connector from the circuit board t
167. d to the rotor for field flash With ignition and fuel flow available the engine can start Figure 3 Circuit Condition Engine Cranking 69 240 Q OUTPUT NEUTRAL CONTROLLER DISPLAY 00 em OPTIONAL BATTERY WARMER H CONTROLLER i PRINTED CIRCUIT BOARD 85 1 LED BOARD 86 2 J1 1 820 1 i 3 7 5 AMP FUSE Hm 3 Li 18 5 818 3 L 819 4 GOVERNOR b SELF RESETTING FUSE ACTUATOR J2 TTI2TI3 T4 TS T6 L7 T8 9 To T T2 834 55 36 7 16 0 56 lt 60 GROUND 5 BATTERY 2 TRANSFER 12 VDC ALWAYS PRESENT 0 AC VOLTAGE GROUND FOR CONTROL PURPOSES LEGEND 12 VDC DURING CRANKING ONLY E BA BRUSH ASSEMBLY LOP LOW OIL PRESSURE SWITCH 12 VDC DURING ENGINE RUN CONDITION CB CIRCUIT BREAKER MAIN OUTPUT SC STARTER CONTACTOR C DU G G col CS CHOKE SOLENOID SCR STARTER CONTROL RELAY DC FIELD EXCITATION FS FUEL SOLENOID SM STARTER MOTOR HIGH TEMPERATURE SWITCH SP_
168. d H Battery supply voltage 12 VDC should be measured a If battery voltage is not measured wait 5 minutes and repeat Step 3 If battery supply voltage is still not available refer to Flow Chart b If battery voltage is measured proceed to Step 4 4 Reconnect battery charger black and red lead wires previously removed in Step 2 5 Measure across points G and H 13 4 VDC should be measured a If 13 4 VDC is not measured replace the battery charger b If 13 4 VDC is measured the charger is working NOTE Battery charger voltage will be higher than battery supply voltage TEST 45 CHECK WIRE 0 15B RTSN amp RTSE TRANSFER SWITCH DISCUSSION In order for the battery charger to function battery supply voltage must be available to the battery charger PROCEDURE Refer to Figure 12 or Figure 12A 1 Set VOM to measure DC voltage 2 Remove and isolate battery charger black and red leads from generator terminal strip points G and H 3 Measure across points G and H on the terminal strip 12VDC should be measured a If 12 VDC is measured the charger should be functioning b If 12 VDC is not measured proceed to Step 4 4 Remove Wire 0 and Wire 15B from generator terminal strip locations G and H 5 Wait five 5 minutes after removing wires Page 87 T o E 7 oc LL 2 lt oc SECTION 3 4 DIAGNOSTIC TESTS
169. d circuit board 4 DC CONTROL Air cooled Automatic Standby Generators 4 1 Description and 96 General 96 Terminal Strip Interconnection Terminal 96 Circuit Board 96 Auto Off Manual 96 7 5 AMP FUSO ie eroosio r eo 96 Menu System 102 4 2 Operational Analysis 104 Introduction 104 Utility Source Voltage Available 104 Initial Dropout of Utility Source Voltage 106 Utility Voltage Dropout and Engine Cranking 108 Engine Startup and Running 110 Initial Transfer to the Standby Source 112 Utility Voltage Restored Re transfer to Utility 114 Engine Shutdown esee 116 4 3 Troubleshooting 118 Problem 15 Engine Will Not Crank When Utility Power Source Fails 118 Problem 16 Engine Will Not Crank When AUTO OFF MANUAL Switch is Set to 118 Problem 17 Engine Cranks but Won t Start 119 Problem 18 Engine Starts Hard and Runs Rough Lacks Power Backfires 120
170. d to hard starting rough running and lack of power The valve adjustment procedure for both the single cylinder and the V twin engines is the same PROCEDURE INTAKE AND EXHAUST Make sure that the piston is at Top Dead Center TDC of it s compression stroke both valves closed The valve clearance should be 0 05 0 1 0 002 0 004 in cold Check and adjust the valve to rocker arm clearance as follows 1 Remove the four 4 screws from the rocker cover 2 Remove the rocker cover and rocker cover gasket 3 Loosen the rocker arm jam nut Use a 10mm allen wrench to turn the pivot ball stud and check the clearance between the rocker arm and the valve stem with a flat feeler gauge see Figure 44 4 When the valve clearance is correct hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut Torque the jam nut to 174 inch pounds After tightening the jam nut recheck the valve clearance to make sure it did not change Figure 44 5 Re install the rocker cover gasket rocker cover and the four 4 screws RESULTS Adjust valve clearance as necessary then retest TEST 78 CHECK WIRE 18 CONTINUITY DISCUSSION During cranking and running the printed circuit board receives a pulse from the ignition magnetos via Wire 18 This signal has an AC voltage of 4 6 volts on V Twin engines only If this signal is not received by the printed circuit board the unit will shut down due to no R
171. d with the effective or rms value even though the meter actually reacts to the average value That is why the AC voltmeter will give an Incorrect reading if used to measure direct current DC Figure 1 Digital VOM SECTION 1 5 TESTING CLEANING AND DRYING MEASURING AC VOLTAGE An accurate AC voltmeter or a VOM may be used to read the generator s AC output voltage The following apply 1 Always read the generator s AC output voltage only at the unit s rated operating speed and AC frequency 2 The generator s Voltage Regulator can be adjusted for correct output voltage only while the unit is operating at its correct rated speed and frequency 3 Only an AC voltmeter may be used to measure AC voltage DO NOT USE A DC VOLTMETER FOR THIS PURPOSE DANGER GENERATORS PRODUCE HIGH AND DANGEROUS VOLTAGES CONTACT WITH HIGH VOLTAGE TERMINALS WILL RESULT IN DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK MEASURING DC VOLTAGE A DC voltmeter or a VOM may be used to measure DC voltages Always observe the following rules 1 Always observe correct DC polarity a Some VOM s may be equipped with a polarity switch b On meters that do not have a polarity switch DC polarity must be reversed by reversing the test leads 2 Before reading a DC voltage always set the meter to a higher voltage scale than the anticipated reading If in doubt start at the highest scale and adjust the scale downward until correct rea
172. dings are obtained 3 The design of some meters is based on the current flow theory while others are based on the electron flow theory a The current flow theory assumes that direct current flows from the positive to the nega tive b The electron flow theory assumes that current flows from negative to positive NOTE When testing generators the current flow theory is applied That is current is assumed to flow from positive to negative MEASURING AC FREQUENCY The generator s AC output frequency is proportional to Rotor speed Generators equipped with a 2 pole Rotor must operate at 3600 rpm to supply a frequency of 60 Hertz Units with 4 pole Rotor must run at 1800 rpm to deliver 60 Hertz Page 19 SECTION 1 5 TESTING CLEANING AND DRYING MEASURING CURRENT CLAMP ON To read the current flow in AMPERES a clamp on ammeter may be used This type of meter indicates current flow through a conductor by measuring the strength of the magnetic field around that conductor The meter consists essentially of a current trans former with a split core and a rectifier type instrument connected to the secondary The primary of the cur rent transformer is the conductor through which the current to be measured flows The split core allows the Instrument to be clamped around the conductor without disconnecting it Current flowing through a conductor may be mea sured safely and easily A line sp
173. display reflects that it is exercising confirm that the choke solenoid is fully closed over one port RESULTS 1 If the solenoid did not close confirm that utility voltage is present If the generator believes that there is a power outage it will run at full speed until utility is returned 2 If the solenoid closed replace the controller TABLE OF CONTENTS TITLE PART 5 E p __ OPERATIONAL _ 7 TESTS Air cooled Automatic Standby Generators 5 1 System Functional 148 148 Manual Transfer Switch Operation 148 Electrical Checks 148 Generator Tests Under Load 149 Checking Automatic Operation 150 Setting The Exercise Timer 150 Page 147 5 1 SYSTEM FUNCTIONAL TESTS INTRODUCTION Following home standby electric system installation and periodically thereafter the system should be tested Functional tests of the system include the following Manual transfer switch operation System voltage tests Generator Tests Under Load Testing automatic operation Before proceeding with functional tests read instruc tions and information on tags or decals affixed to the generator and transfer switch Perform all tests in the exact order given in this section MANUAL TRANSFER SWITC
174. e AUTO OFF MANUAL switch to MANUAL The meter should now indicate battery voltage as the starter contactor energizes 16 TO STARTER STEP 2 TEST POINT STEP 1 TEST POINT 13 TO FUSE F1 TO GROUND 1 TO BATTERY Figure 8 The Starter Contactor Single Cylinder Units RESULTS 1 If battery voltage was indicated in Step 1 but NOT in Step 2b replace the starter contactor 2 If battery voltage was indicated in Step 2b but the engine did NOT crank refer back to flow chart STEP 1 STARTER POINT CONTACTOR STEP 2 TEST POINT MOTOR Figure 9 The Starter Contactor V twin Units Page 127 SECTION 4 4 DIAGNOSTIC TESTS TEST 65 TEST STARTER MOTOR CONDITIONS AFFECTING STARTER MOTOR PERFORMANCE 1 A binding or seizing condition in the starter motor bearings 2 Ashorted open or grounded armature a Shorted armature wire insulation worn and wires touching one another Will be indicated by low or no RPM b Open armature wire broken will be indicated by low or no RPM and excessive current draw c Grounded armature wire insulation worn and wire touching armature lamination or shaft Will be indicated by excessive current draw or no RPM 3 A defective starter motor switch 4 Broken damaged or weak magnets 5 Starter drive dirty or binding DISCUSSION Test 62 verified that circuit board action i
175. e located in Section 6 2 Once the magnetos are visible make note to how they are connected Note Each magneto has its own part number Verify the part number prior to installation 3 Cylinder one is the back cylinder Figure 36 and cylinder two is the front cylinder Figure 37 Figure 37 Cylinder Two Front Long 4 When installing new magnetos there will be one with a short plug wire and one with a longer plug wire Figure 38 Page 140 Figure 38 Note Magneto gap between flywheel needs to be 0 010 inch 5 Long plug wire B will be installed on front cylinder number two 6 Short plug Wire A will be installed on back cylinder number one 7 Verify installation of magnetos correctly by ensuring both spark plug wires point to the back of the enclosure and shutdown terminals are nearest cylinder head as shown in Figures 39 and 40 Figure 40 TEST 75 CHECK PRESSURE SWITCH AND WIRE 86 DISCUSSION If the oil pressure switch contacts have failed in their closed position the engine will probably crank and start However shutdown will then occur within about 5 five seconds If the engine cranks and starts then shuts down almost immediately with a LOP fault light the cause may be one or more of the following Low engine oil level Low oil pressure A defective oil pressure switch PROCEDURE 1 Navigate to the Digital inputs display screen Press
176. e transfer mechanism transfer switch is in the UTILITY position and source voltage is available to T1 T2 and customer load Utility source voltage is available to limit switch SW2 via the normally closed transfer relay contacts 1 and 7 and Wire 126 However SW2 is open and the Circuit to the utility closing coil is open Utility voltage sensing signals are delivered to a circuit board on the generator via Wire N1A a 5 amp fuse F1 The second line of the utility voltage sensing circuit is via Wire N2A a 5 amp Fuse F2 158 gt TRANSFER 23 TSTO GENERATOR CONTROL PANEL N2 UTILITY SENSING 240VAC N1 OUTPUT BLACK RED NEUTRAL WHITE E2 NEUTRAL r GROUND GREEN CONNECTION A INSIDE SWITCH GROUND GREEN NEUTRAL WHITE RED MAIN 2 MAIN DISTRIBUTION BLACK MAIN 1 5 omm E2 5 omes CIRCUIT 13 5 omms CIRCUIT 10 omms CIRCUIT 9 Bs omms CIRCUIT 6 5 omes CIRCUIT 5 coc c omms CIRCUIT 2 z A 2 o o o 5 o CIRCUIT 1 a Q Q Q Q 5 B 5 omm CIRCUIT 3 Bh n 2 4 5 5 5 5 5 E2 5 CIRCUIT 4 9 5 CIRCUIT 7 N 5 CIRCUIT 8 CHARGER C1 UTILITY RECTIFIER 5 o CIRCUIT 11 C2 GENERATOR COIL RE
177. econds Will start a five 5 second engine warm up timer Will not transfer if utility subsequently returns Will transfer to generator if utility is still not present Will transfer back to utility once utility returns above 75 of nominal for 15 seconds Will transfer back to utility if the generator is shut down for any reason such as the switch is in the OFF position or a shutdown alarm After transfer will shut down engine after one 1 minute cool down time 3 Exercise Will not exercise if generator is already running in either Auto or Manual mode During exercise the controller will only transfer if utility fails during exercise for 10 seconds and will switch to Auto mode UTILITY RESTORED Initial Condition Generator supplying power to cus tomer load When the utility returns above 75 of nominal a 15 second return to utility timer will start At the completion of this timer if the utility supply is still present and acceptable the control will transfer the load back to the utility and run the engine through a one 1 minute cool down period and then shut down If utility fails for three 3 seconds during this cool down period the control will transfer load back to the generator and continue to run while monitoring for utility to return Page 30 PART 1 GENERAL INFORMATION 2 GENERATORS Air cooled Automatic Standby Generators 2 1 Description and Components
178. ecting the J2 connector h If voltage was not measured in Step 5 and out put changed in Step 5f remove the J1 connec tor from the printed circuit board See Figures on Pages 92 95 Page 131 SECTION 4 4 DIAGNOSTIC TESTS i Seta VOM to measure resistance j Connect one meter test lead to Wire 14 that was disconnected in Step 3 k Connect the other meter test lead to Wire 14 at J2 3 See Figures on Pages 92 95 CONTINUITY should be measured If CONTINUITY is measured repeat Step 5 and then retest m If CONTINUITY is not measured repair or replace Wire 14 between the J2 Connector and the fuel solenoid PROCEDURE 8 kW UNITS 1 Set AUTO OFF MANUAL switch to OFF 2 Seta VOM to measure DC voltage 3 Disconnect Wire 14 from the fuel solenoid 4 Connect the positive test lead to disconnected Wire 14 and the negative test lead to a clean frame ground 5 Set the AUTO OFF MANUAL switch to the MANUAL position 6 Battery voltage should be measured If battery voltage is measured refer back to flow chart Note Disconnect the 7 5 amp fuse before discon necting the J2 connector 7 Disconnect the J2 connector from printed circuit board 8 Set VOM to measure resistance 9 Connect the positive test lead to disconnected Wire 14 and the negative test lead to J2 Pin 3 10 CONTINUITY should be measured If CONTINUITY is not measured repair or replace Wire 14 between J2 Pin 3 and the fuel solenoid RESULTS
179. ed across the breaker s Wire 44 terminal and the E2 terminal RESULTS 1 If the circuit breaker tests good go on to Test 2 2 If the breaker tests bad it should be replaced E2 TERMINAL E1 TERMINAL WIRE 11 TERMINAL WIRE 44 TERMINAL Figure 1 Generator Main Circuit Breaker Test Points TEST 2 CHECK AC OUTPUT VOLTAGE DISCUSSION A volt ohm milliammeter VOM may be used to check the generator output voltage Output voltage may be checked at the unit s main circuit breaker terminals Refer to the units DATA PLATE for rated line to line and line to neutral voltages Page 41 SECTION 2 4 DIAGNOSTIC TESTS DANGER USE EXTREME CAUTION DURING THIS TEST THE GENERATOR WILL BE RUNNING HIGH AND DANGEROUS VOLTAGES WILL BE PRESENT AT THE TEST TERMINALS CONNECT METER TEST CLAMPS TO THE HIGH VOLTAGE TERMINALS WHILE THE GENERATOR 15 SHUT DOWN STAY CLEAR OF POWER TERMINALS DURING THE TEST MAKE SURE METER CLAMPS ARE SECURELY ATTACHED AND WILL NOT SHAKE LOOSE PROCEDURE 1 With the engine shut down connect the AC voltmeter test leads across the Wires 11 and 44 terminals of the generator main circuit breaker see Figure 1 These connections will permit line to line voltages to be read 2 Set the generator main circuit breaker to its OFF or Open position This test will be conducted with the generator running at no load 3 Start the generator let it s
180. efer back to flow chart 2 If evidence of sticking binding excessive force required to move main contacts find cause of binding or sticking and repair or replace damaged part s TEST 28 CHECK 23 AND 15B WIRING CONNECTIONS DISCUSSION An open circuit in the transfer switch control wir ing can prevent a transfer action from occurring Battery voltage 12 is supplied on Wire 15B This DC voltage is supplied to the transfer relay TR at Terminal Location A The opposite side of the transfer relay TR coil Terminal B is connected to Wire 23 Positive 12 VDC is present on this also Circuit board action will allow current to flow through the circuit and the TR is energized PROCEDURE RESULTS Refer to Figure 3 1 Remove transfer relay mounting screws so that contact movement can be visually observed 2 Set the generator AUTO OFF MANUAL switch to the AUTO position Turn off utility power supply to the transfer switch simulating a utility failure Visually watch the transfer relay for contact movement The relay should be energized and contact movement seen approximately 10 seconds after the generator starts a If the transfer relay energizes discontinue testing Refer to flow chart b If the transfer relay does not energize continue to Step 3 3 Set the generator AUTO OFF MANUAL switch to the OFF position 4 Remove the battery charger fuse F3 from the transfer switch to disable the battery cha
181. efer to Flow Chart TEST 27 CHECK MANUAL TRANSFER SWITCH OPERATION DISCUSSION In automatic operating mode when utility source volt age drops below a preset level the engine should crank and start On engine startup an engine warm up timer on the generator circuit board should start timing When that timer has timed out about 15 seconds the transfer relay should energize to deliver utility source power to the standby closing coil terminals If normal LOAD CONNECTED TO UTILITY POWER SOURCE x MANUAL TRANSFER HANDLE TRANSFER SWITCH OPERATING LEVER SECTION 3 4 DIAGNOSTIC TESTS utility source voltage is available to the standby closing coil terminals but transfer to Standby does not occur the cause of the failure may be a a failed standby closing coil and or bridge rectifier or 0 a seized or sticking actuating coil or load contact This test will help you evaluate whether any sticking or binding is present in the transfer mechanism PROCEDURE 1 With the generator shut down set the generator AUTO OFF MANUAL switch to OFF 2 Set the generator main circuit breaker to OFF or Open 3 Turn off the utility power supply to the transfer switch using whatever means provided such as a utility source main line breaker TRANSFER SWITCH OPERATION UNTIL ALL POWER VOLTAGE SUPPLIES TO THE SWITCH HAVE BEEN POSITIVELY TURNED OFF FAILURE TO TURN OFF ALL POWER VOLTAGE SUP
182. enerator running and utility off ground Wire 23 in the control panel at the terminal strip If transfer relay energizes and or transfer occurs replace the PCB 17 Set VOM to measure DC voltage 18 Connect the negative test lead to the ground lug in the transfer switch Connect the positive test lead 10 Wire 15B at the terminal strip in the transfer switch a If voltage is present repair or replace Wire 0 between transfer switch and generator ground lug b If voltage is not present proceed to Step 19 19 Connect the negative test lead to the ground lug in the generator control panel Connect the positive test lead to Wire 15B at the terminal strip in the generator control panel a If voltage is present repair Wire 15B between generator terminal strip and transfer switch terminal strip b If voltage is not present proceed to Step 20 20 Remove the J2 connector from the circuit board 21 Set VOM to measure ohms Connect one meter test lead to Wire 15B at the control panel terminal strip Connect the other meter test lead to Wire 15B Pin Location J2 8 Continuity should be measured a If continuity is not measured repair pin connection and or Wire 15B between the J2 connector and terminal strip b If continuity is measured proceed to Step 22 22 Remove the 7 5A fuse 23 Reconnect J2 connector 24 Install the 7 5A fuse 25 Disconnect Wire 15B from the generator terminal strip 26 Set VOM to measure DC
183. er to its OFF or open position 2 Set the generator AUTO OFF MANUAL switch to the OFF position 3 Turn off all loads connected to the transfer switch Terminals T1 and T2 4 Turn on the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker LOAD CONNECTED TO STANDBY POWER SOURCE TRANSFER SWITCH OPERATING LEVER MANUAL TRANSFER HANDLE Figure 1 Manual Operation V Type Switch Page 148 OPERATIONAL TESTS DH A THE TRANSFER SWITCH IS NOW ELECTRI A CALLY HOT CONTACT WITH HOT PARTS WILL RESULT IN EXTREMELY HAZARDOUS AND POSSIBLY FATAL ELECTRICAL SHOCK PROCEED WITH CAUTION 5 Use an accurate AC voltmeter to check utility power source voltage across transfer switch Terminals N1 and N2 Nominal line to line voltage should be 240 volts AC 6 Check utility power source voltage across Terminals N1 and the transfer switch neutral lug then across Terminal N2 and neutral Nominal line to neutral voltage should be 120 volts AC 7 When certain that utility supply voltage is compatible with transfer switch and load circuit ratings turn off the utility power supply to the transfer switch 8 On the generator panel set the AUTO OFF MANUAL switch to MANUAL The engine should crank and start 9 Let the engine warm up for about five minutes to allow internal temperat
184. erconnect with identically labeled terminals in the generator control panel assembly This is the utility voltage signal to the circuit board The signal is deliv ered to a step down transformer in the control module assembly and the resultant reduced voltage is then delivered to the circuit board Utility 1 and 2 power is used by the circuit board as follows If utility source voltage should drop below a pre set level circuit board action will initiate automatic cranking and startup followed by automatic transfer to the standby source Utility source voltage is used to operate a battery trickle charge circuit which helps to maintain battery state of charge during non operating periods e e TERMINALS 0 158 23 These terminals connect the transfer relay to the generator circuit board See Transfer Relay in Section 3 1 FUSE HOLDER The fuse holder holds three 3 fuses designated as fuses F1 F2 and F3 Each fuse is rated 5 amperes FUSES F1 F2 These two fuses protect the UTILITY 1 and UTILITY 2 circuit against overload FUSES This fuse protects the battery charger against overload SECTION 3 1 DESCRIPTION amp COMPONENTS Figure 7 The Fuse Holder Page 59 SECTION 3 2 OPERATIONAL ANALYSIS TRANSFER SWITCH OPERATIONAL ANALYSIS Figure 1 is a schematic for a typical W V Type transfer switch
185. fer relay TR1 contacts limit switch SW3 Wire and a bridge rectifier The standby closing coil energizes and the main contacts actuate to their Standby side 0 o i64 gt FONE 23 23 CONTROL PANEL 1 240VAC 6 OUTPUT BLACK ndis NEUTRAL WHITE NEUTRAL r GROUND GREEN P CONNECTION INSIDE SWITCH GROUND GREEN WHITE RED MAIN 2 MAIN DISTRIBUTION PANEL BLACK MAIN 1 5 6 circuitia 4 5 5 CIRCUIT 13 6 5 CIRCUIT 10 4 5 6 CIRCUIT 9 4 5 CIRCUIT 6 6 6 CIRCUIT 5 c c c c 5 CIRCUIT 2 2 2 2 gt tu ul E o e 5 6 CIRCUIT 1 2 Q 8 8 8 5 6 CIRCUIT 3 E 5 5 5 6 6 CIRCUIT 4 Q amp 2 z amp o 4 5 CIRCUIT 7 o x LEGEND 1 6 6 CIRCUIT 8 BC BATTERY CHARGER __ C1 UTILITY COIL RECTIFIER 5 o CIRCUIT 11 C2 GENERATOR COIL amp RECTIFIER F1 F2 F3 5A 600V FUSE 4 6 6 CIRCUIT 12 LC CIRCUIT BREAKER LOADS 16 CIRCUIT SHOWN FOR REFERENCE ONLY CIRCUIT 15 N NEUTRAL L SW1 AUTOMATIC TRANSFER SWITCH UTILITY CIRCUIT 16 SW2 SW3 LIMIT SWITCHES LC TB1 TERMINAL STRIP
186. ground Local electrical codes may also require prop er grounding of the unit For that purpose a ground ing lug is attached to the unit Grounding may be accomplished by attaching a stranded copper wire of the proper size to the generator grounding lug and to an earth driven copper or brass grounding rod elec trode Consult with a local electrician for grounding requirements in your area THE FUEL SUPPLY Units with air cooled engines were operated tested and adjusted at the factory using natural gas as a fuel These air cooled engine units can be converted to use LP propane gas by making a few adjustments for best operation and power SECTION 1 2 INSTALLATION BASICS LP propane gas is usually supplied as a liquid in pressure tanks Both the air cooled and the liquid cooled units require a vapor withdrawal type of fuel supply system when LP propane gas is used The vapor withdrawal system utilizes the gaseous fuel vapors that form at the top of the supply tank The pressure at which LP gas is delivered to the generator fuel solenoid valve may vary considerably depending on ambient temperatures In cold weather supply pressures may drop to zero In warm weath er extremely high gas pressures may be encountered A primary regulator is required to maintain correct gas supply pressures Current recommended gaseous fuel pressure at the inlet side of the generator fuel solenoid valve is as follows iP
187. her PROCEDURE 1 On the generator panel set the AUTO OFF MANUAL switch to OFF 2 Set the generator main line circuit breaker to its OFF or open position 3 Setthe generator AUTO OFF MANUAL switch to MANUAL a The engine should crank cyclically through it s crank rest cycles until it starts b Let the engine stabilize and warm up for a few minutes after it starts RESULTS 1 If the engine cranks manually but does not crank automatically go to Problem 15 Section 4 3 2 If the engine does not crank manually proceed to Problem 16 in the Troubleshooting Flow Charts TEST 58 AUTO OFF MANUAL SWITCH V TWIN ONLY PROCEDURE 1 Press the ESC key on the controller until the home page is reached 2 Press the right arrow key until Debug flashes Press Enter and the following screen will appear See Figure 2 Screen 2 3 Press Enter when Inputs is flashing 4 With the Inputs Screen displayed place the AUTO OFF MANUAL switch to the AUTO Position If the controller reads an input from the switch Input 7 will change from 0 to 1 Page 123 SECTION 4 4 DIAGNOSTIC TESTS History Status Edit Debug TEST Inputs Outputs Displays INPUTS INPUTS V 1271999 10110001 1 8 INPUT 7 INPUT 8 Figure 2 The Home Page Debug and Input Screens 5 With the Inputs Screen displayed place the AUTO OFF MANUAL switch to the MANUAL Position If the control ler reads an input from the swi
188. hould be measured This reading is the secondary winding of both coils in parallel If INFINITY or a low or high ohm reading is measured replace the magnetos Connect the negative black meter lead to the bolt connector where Wire 18 was disconnected in Step 1 Connect the positive red meter lead to the spark plug wire on cylinder number two The meter should indicate INFINITY This step is testing the diodes in both magnetos to ensure they are still functioning Repeat Step 6 on cylinder two If INFINITY is not measured replace the magnetos Note It is recommended to replace Magnetos in pairs PROCEDURE ADJUSTING MAGNETO FLYWHEEL Note The air gap between the ignition magneto and the flywheel on single cylinder engines is not adjustable Proceed directly to Step 10 for single cylinder engines For V twin engines proceed as follows 1 See Figure 34 Rotate the flywheel until the magnet is under the module armature laminations 2 Place a 0 008 0 012 inch 0 20 0 30mm thickness gauge between the flywheel magnet and the module laminations Note A business card is approximately 0 010 inch thick 3 Loosen the mounting screws and let the magnet pull the magneto down against the thickness gauge 4 Tighten both mounting screws 5 To remove the thickness gauge rotate the flywheel 6 Repeat the above procedure for the second magneto Figure 34 Setting Ignition Magneto Armature Air Gap
189. ide an external source to blow warm dry air through the generator interior around the rotor and stator wind ings DO NOT EXCEED 185 85 4 Start the generator and let it run for 2 or 3 hours 5 Shut the generator down and repeat the stator and rotor insulation resistance tests GENERAL INFORMATION GENERAL Standby electric power generators will often run unattended for long periods of time Such operating parameters as a battery voltage b engine oil pres sure engine temperature d engine operating speed and e engine cranking and startup are not monitored by an operator during automatic operation Because engine operation will not be monitored the use of engine protective safety devices is required to prevent engine damage in the event of a problem Generator engines mount several engine protec tive devices These devices work in conjunction with a circuit board to protect the engine against such operating faults as a low battery low engine oil pressure c high temperature d overspeed and e overcrank On occurrence of any one or more of those operating faults circuit board action will effect an engine shutdown LOW BATTERY The microprocessor will continually monitor the bat tery voltage and turn on the Low Battery Warning if the battery voltage falls below 10 8 volts for one 1 minute No other action is taken on a low battery condition Low battery voltage is a non latching
190. ifications section at the beginning of the book Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure Temperature Range of Expected Use Devices used to measure electrical properties are called meters Meters are available that allow one to measure a AC voltage b DC voltage c AC frequency and d resistance In ohms The following apply To measure AC voltage use an AC voltmeter To measure DC voltage use a DC voltmeter Use a frequency meter to measure AC frequency In Hertz or cycles per second Use an ohmmeter to read circuit resistance in ohms THE VOM A meter that will permit both voltage and resistance to be read is the volt ohm milliammeter or VOM Some VOMs are of the analog type not shown These meters display the value being measured by physically deflecting a needle across a graduated scale The scale used must be Interpreted by the user Digital VOM s Figure 1 are also available and are generally very accurate Digital meters display the measured values directly by converting the values to numbers NOTE Standard AC voltmeters react to the AVERAGE value of alternating current When working with AC the effective value is used For that reason a different scale is used on an AC voltmeter The scale is marke
191. in automatic generator startup and transfer of electrical loads to the Standby source On restoration of utility source voltage above a preset value will result in retransfer back to that source and generator shutdown NATURAL GAS FUEL INTERCONNECTIONS 5 7 WC REGULATOR TO HOUSEHOLD GAS METER CAPABLE OF PROVIDING NATURAL GAS FUEL FLOW OF 140 000 7 kW 156 000 9 kW 215 000 12 kW 220 000 13 kW 261 000 16 kW 294 000 18 kW HOUSEHOLD APPLIANCES BASED ON 1000 BTU CU FT BTU HOUR GAS MAIN 2 5 PSI Figure 2 Proper Fuel Installation Page 13 SECTION 1 3 NON PREPACKAGED INTERCONNECTIONS DISCUSSION On the current model air cooled generators Wire 194 was changed to 15B Wire 15B is still utilized for posi tive voltage for the transfer relay and Wire 23 is still the control ground for transferring the generator By follow ing the procedures below it is possible to connect new product with Wire 15B to old or current product that still utilize Wire 194 such as an RTS switch CONNECT A PRE 2008 LOAD CENTER SWITCHTO A CURRENT OR FUTURE AIR COOLED GENERATOR PROCEDURE 1 Follow all instructions located in the Installation Manual that was supplied with the unit regarding mounting of the switch junction box and generator Note When inst
192. ing cells is greater than 0 050 50 points battery condition has deteriorated and the bat tery should be replaced However if the highest reading cell has a specific gravity of less than 1 230 the test for condition is questionable Recharge the battery to a 100 percent state of charge and then repeat the test for condition RESULTS 1 Remove the battery and recharge with an automotive battery charger if necessary 2 If battery condition is bad replace with a new battery HIGH READING 35 POINTS DIFFERENCE LOW READING Figure 5 Reading a Battery Hydrometer Page 125 SECTION 4 4 DIAGNOSTIC TESTS TEST 62 CHECK WIRE 56 VOLTAGE DISCUSSION During an automatic start or when starting manually a crank relay on the circuit board should energize Each time the crank relay energizes the circuit board should deliver 12 VDC to a starter contactor relay SCR or starter contactor SC and the engine should crank This test will verify a that the crank relay on the circuit board is energizing and b that circuit board action is delivering 12 VDC to the starter contactor relay or starter contactor PROCEDURE 1 to measure DC voltage 2 Connect the positive test probe of a DC voltmeter or VOM to the Wire 56 connector of the starter contactor relay SCR on models with V twin engines or the starter contactor SC on models with single cylinder engines Connect the common test
193. ing circuit is complet ed to the voltage regulator via Wire 2 and Wire 6 Unregulated alternating current can flow from the wind ing to the regulator The voltage regulator senses AC power winding out put voltage and frequency via stator Wires 11 and 22 The regulator changes the AC from the excitation winding to DC In addition based on the Wires 11 and 22 sensing signals it regulates the flow of direct current to the rotor The rectified and regulated current flow from the regu lator is delivered to the rotor windings via Wire 4 and the positive brush and slip ring This excitation current flows through the rotor windings and is directed to ground through the negative slip ring and brush and Wire 0 The greater the current flow through the rotor windings the more concentrated the lines of flux around the rotor become The more concentrated the lines of flux around the rotor that cut across the stationary stator windings the greater the voltage that is induced into the stator windings Initially the AC power winding voltage sensed by the regulator is low The regulator reacts by increasing the flow of excitation current to the rotor until volt age increases to a desired level The regulator then maintains the desired voltage For example if voltage exceeds the desired level the regulator will decrease the flow of excitation current Conversely if voltage drops below the desired level the regulator responds
194. ingle south magnetic pole As the rotor rotates its lines of magnetic flux cut across the stator assem bly windings and a voltage is induced into the stator windings The rotor shaft mounts a positive and a negative slip ring with the positive slip ring nearest the rear bearing carrier The rotor bearing is pressed onto the end of the rotor shaft The tapered rotor shaft is mounted to a tapered crankshaft and is held in place with a single through bolt ENGINE ADAPTOR Figure 1 AC Generator Exploded View Page 32 SECTION 2 1 AC GENERATORS DESCRIPTION amp COMPONENTS STATOR ASSEMBLY SLIP RINGS The stator can houses and retains a dual AC power windings and b excitation winding A total of six 6 or eight 8 stator leads are brought out of the stator can as shown in Figure 4 The stator can is sandwiched between an engine adapter and a rear bearing carrier It is retained in that position by four stator studs BEARING 11 Figure 2 The 2 Pole Rotor Assembly 12 20 kW 115 12 20 kw amp 3 8 10KW 7 22P lt Like the 12 20 kW rotor the 8 10 kW 2 pole rotor must be operated at 3600 rpm to supply a 60 Hertz AC fre quency However the 8 10kW rotor uses no slip rings As the rotor rotates in the generator voltage is induced from the Excitation winding using a capacitor that is in turn excited by the rotor A continuous loop of charging and discharging of the capacitor is ma
195. intained that acts as CEA rf Eu nd is pressed onto the end of the rotor shaft The tapere rotor shaft is mounted to a tapered crankshaft and is Figure 4 Stator Assembly Leads held in place with a single through bolt 225 12 20 kW amp 3 33 BEARING DIODE B DIODE A ANODE CATHODE Figure 3 The 2 Pole Rotor Assembly 8 10kW Page 33 SECTION 2 1 DESCRIPTION amp COMPONENTS BRUSH HOLDER AND BRUSHES 12 20 KW The brush holder is retained to the rear bearing car rier by means of two 10 32 x 9 16 Taptite screws A positive and a negative brush are retained in the brush holder with the positive brush riding on the slip ring nearest the rotor bearing Wire 4 connects to the positive brush and Wire 0 to the negative brush Wire 0 connects to frame ground Rectified and regulated excitation current as well as current from a field boost circuit are delivered to the rotor windings via Wire 4 and the positive brush and slip ring The excitation and field boost cur rent passes through the windings and to frame ground via the negative slip ring and brush and Wire 0 This current flow creates a magnetic field around the rotor having a flux concentration that is proportional to the amount of current flow
196. ir Resources Board for tamper proof dual fuel systems The unit will run on natural gas or LP gas but it has been factory set to run on natural gas Should the primary fuel need to be changed to LP gas the fuel system needs to be reconfigured See the Reconfiguring the Fuel System section for instruc tions on reconfiguration of the fuel system Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask the fuel supplier for the Btu content of the fuel Required fuel pressure for natural gas is 5 inches to 7 inches water column 0 18 to 0 25 psi and for liq uid propane 10 inches to 12 inches of water column 0 36 to 0 43 psi NOTE All pipe sizing construction and layout must comply with NFPA 54 for natural gas applica tions and NFPA 58 for liquid propane applications Once the generator is installed verify that the fuel pressure NEVER drops below four 4 inches water column for natural gas or 10 inches water column for liquid propane Prior to installation of the generator the installer should consult local fuel suppliers or the fire marshal to check codes and regulations for proper installation Local codes will mandate correct routing of gaseous fuel line piping around gardens shrubs and other landscaping to prevent any damage Special considerations should be given when install ing the unit where local conditions include flood
197. is available to the transfer relay coil from the generator circuit board via Wire 15B and Relay Terminal A a The 12 volts DC circuit is completed through the transfer relay coil and back to the generator circuit board via Wire 23 b Circuit board action normally holds the Wire 23 circuit open to ground and the relay is de energized Page 57 SECTION 3 1 DESCRIPTION amp COMPONENTS c When de energized the relay s normally open contacts are open and its normally closed contacts are closed d The normally closed relay contacts will deliver utility source power to the utility closing circuit of the transfer mechanism e The normally open relay contacts will deliver standby source power to the transfer mecha nism s standby closing circuit Figure 5 Transfer Relay Schematic 2 During automatic system operation when the genera tor circuit board senses that utility source voltage has dropped out the circuit board will initiate engine cranking and startup 3 When the circuit board senses that the engine has started an engine warm up timer on the circuit board starts timing 4 When the engine warm up timer has timed out circuit board action completes the Wire 23 circuit to ground a The transfer relay then energizes b The relay s normally closed contacts open and its normally open contacts close c When the normally open contacts close standby source power is delivered to
198. ith out prior notification The manual has been divided into PARTS Each PART has been divided into SECTIONS Each SECTION consists of two or more SUBSECTIONS Item 0055555 Serial 1234567 Volts 120 240 AC is not our intent to provide detailed disassembly and reassemble instructions in this manual It is our intent to a provide the service technician with an under standing of how the various assemblies and systems work b assist the technician in finding the cause of malfunctions and c effect the expeditious repair of the equipment ITEM NUMBER Many home standby generators are manufactured to the unique specifications of the buyer The Model Number identifies the specific generator set and its unique design specifications SERIAL NUMBER Used for warranty tracking purposes Amps 108 3 108 3 Watts 13000 1 PH 60 HZ RPM 3600 RAINPROOF ENCLOSURE FITTED CLASS F INSULATION MAX OPERATING AMBIENT TEMP 120F 49C FOR STANDBY SERVICE MODEL SERIAL FOR STANDBY SERVICE NEUTRAL FLOATING S 0055555 WATTS 13000 1234567 VOLTS 120 240 AC AMPS 10831083 1PH 60Hz 3600 RPM CLASS F INSULATION RAINPROOF ENCLOSURE FITTED RATED AMBIENT TEMP 40 C NEUTRAL FLOATING MAX LOAD UNBALANCED 50 Model Number Serial Number Figure 1 Typical Data Plates Page 10 GENERAL INFORMATION INTRODUCTION Information in this section is
199. ith the unit regarding mounting of the switch junction box and generator Note When installing a standalone pre 2008 gen erator the battery charger will be located in the generator utilizing the 12 VDC trickle charger 2 Inside the Junction box between the generator and the transfer switch there will be 4 wires coming from the 4 generator and 5 wires from the transfer switch 0 BLK 3 Using the following diagram and UL approved wire nuts connect the following wires together Wire 0 will not be Ep E m CONTROL WIRES FROM utilized for this setup WRENS TRANSFER SWITCH Note Remove the battery charger from the trans Fi 2 Wire C fi fer switch it will not be utilized in the operation of igure 3 vvire 5 the generator PRE 08 HSB AIR COOLED GENERATORS 08 amp LATER LOAD CENTER SINGLE amp V TWIN ENGINES TRANSFER SWITCH CONTROL WIRES FROM ENGINE GENERATOR WIRE p NUTS CONTROL WIRES FROM TR
200. ivered to Wire 14 and to a fuel solenoid The solenoid energizes open to allow fuel flow to the engine This test will determine if the circuit board is working properly SECTION 4 4 DIAGNOSTIC TESTS PROCEDURE 12 20 kW UNITS 1 Set AUTO OFF MANUAL switch to OFF 2 Seta VOM to measure DC voltage 3 Disconnect Wire 14 from the fuel solenoid FS 4 Connect the positive test lead to the disconnected Wire 14 from Step 3 Connect the negative test lead to a clean frame ground 5 Set AUTO OFF MANUAL switch to the MANUAL position The meter should indicate battery voltage a If battery voltage is indicated refer back to flow chart b If battery voltage is not measured navigate to the Digital Output display c Press ESC until the display screen is present d Press the right arrow key until Debug is flashing Press Enter e Press the right arrow key until Outputs is flashing Press Enter History Status Edit Debug TEST Inputs Outputs Displays OUTPUTS OUTPUTS 1 8 1011000 1 Figure 21 The Page Debug and Output Screens f Output 5 is Wire 14 out from the printed circuit board If the printed circuit board is functioning properly Output 5 will change from 0 to a 1 while the unit is cranking 9 If voltage was not measured in Step 5 and output did not change in Step 5f replace the printed circuit board Note Disconnect the 7 5 amp Fuse before dis conn
201. kage is normally acceptable Use good judgement and listen for air escaping at the carburetor the exhaust and the crankcase breather This will determine where the fault lies 9 Repeat Steps 1 through 8 on remaining cylinder RESULTS Air escapes at the carburetor check intake valve Air escapes through the exhaust check exhaust valve Air escapes through the breather check piston rings Air escapes from the cylinder head the head gasket should be replaced CHECK COMPRESSION Lost or reduced engine compression can result in a failure of the engine to start or b rough operation One or more of the following will usually cause loss of compression Blown or leaking cylinder head gasket Improperly seated or sticking valves Worn Piston rings or cylinder This will also result in high oil consumption NOTE For the single cylinder engine the minimum allowable compression pressure for a cold engine is 60 psi NOTE It is extremely difficult to obtain an accu rate compression reading without special equip ment For that reason compression values are not published for the V Twin engine Testing has proven that an accurate compression indication can be obtained using the following method SECTION 4 4 DIAGNOSTIC TESTS PROCEDURE 1 Remove both spark plugs 2 Insert a compression gauge into either cylinder 3 Crank the engine until there is no further increase in pressure
202. l Board Wires N1 N2 fuses F1 F2 connected wiring and Control Panel UTILITY 1 and UTILITY 2 terminals A voltage of 240 AC is delivered to the circuit board Battery output is delivered to the circuit board via Wire 13 when the Battery is installed Figure 1 Circuit Condition Utility Source Voltage Available CB Q 240 VAC GENERATOR T OUTPUT NEUTRAL 22 CONTROLLER DISPLAY 00 AM Q 240 VAC UTILITY Es OPTIONAL V BATTERY WARMER N1 N2 NI CONTROLLER PRINTED CIRCUIT BOARD 85 1 LED BOARD 86 2 41 TO 820 gum 1 3 13 7 5 817 2 18 818 3 qu 819 111 GOVERNO SELF RESETTING FUSE ACTUATOR J2 0 69 GROUND 5 BATTERY s TRANSFER 12 VDC ALWAYS PRESENT IGNITION MODULE Page 105 0 AC VOLTAGE GROUND FOR CONTROL PURPOSES LEGEND 12 VDC DURING CRANKING ONLY BRUSH ASSEMBLY LOP LOW OIL PRESSURE SWITCH CB CIRCUIT BREAKER MAIN GUTBUT OW OII FRESSURE 12 VDC DURING ENGINE RUN CONDITION CS CHOKE SOLENOID SCR STARTER CONTROL RELAY DC FIELD EXCITATION FS FUEL SOLENOID SM STARTER MOTOR HIGH TEMPERATURE SWITCH
203. lace Wire 00 between J3 terminal and neutral block NB b If 120 VAC is measured proceed to Step 5 5 Measure across points E and D 120 VAC should be measured a If 120 VAC is not measured replace fuse F3 on load shed controller b If 120 VAC is measured proceed to Step 6 6 Measure across points E and F 120 VAC should be measured a If 120 VAC is not measured replace load shed controller b If 120 VAC is measured refer to Flow Chart TEST 50 CHECK BATTERY CHARGER OUTPUT VOLTAGE LOAD SHED TRANSFER SWITCH DISCUSSION The battery charger is supplied with 120 VAC The output of the battery charger is 13 4 VDC 2 5A PROCEDURE Refer to Figure 14 1 Set VOM to measure DC voltage 2 Remove and isolate battery charger black and red leads from generator terminal strip points G and H 3 Measure across points G and H Battery supply voltage 12 VDC should be measured a If battery voltage is not measured wait 5 min utes and repeat Step 3 If battery supply voltage is still not available refer to Flow Chart b If battery voltage is measured proceed to Step 4 SECTION 3 4 DIAGNOSTIC TESTS x a oc LL 2 lt oc YOLWNLOV S3HOLIMS gon YJJSNYYL AV T3H ul 39018 IVH LO3N HOLOVINOO HOLIMS 46 CJHS QVOT 561 H3TIOH LNOO Q3HS QVOT 057 0385 AV 13
204. led along with a home standby generator proceed as follows 1 Check that the transfer switch main contacts are at their UTILITY position i e the load is connected to the power supply If necessary manually actuate the switch main contacts to their UTILITY source side See Part 3 of this manual as appropriate for instructions 2 Check that utility source voltage is available to transfer Switch terminal lugs N1 and 2 2 pole 1 phase transfer switches 3 Set the generator AUTO OFF MANUAL switch to its AUTO position 4 Actuate the generator main line circuit breaker to its On or Closed position With the preceding Steps 1 through 4 completed a dropout in utility supply voltage below a preset level will result in automatic generator cranking and start up Following startup the transfer switch will be actuated to its Standby source side i e loads powered by the standby generator Page 28 MANUAL TRANSFER TO STANDBY AND MANUAL STARTUP To transfer electrical loads to the Standby generator source and start the generator manually proceed as follows 1 On the generator panel set the AUTO OFF MANUAL switch to OFF 2 On the generator set the main line circuit breaker to it s OFF or Open position 3 Turn OFF the power supply to the transfer switch using whatever means provided such as a utility source line circuit breaker 4 Manually actuate the transfer switch main contacts to their Stand
205. litter can be used to measure current in a cord without separating the conductors CONDUCTOR MAGNETIC FIELD CLAMP ON AMMETER ATTACHMENT LINE SPLITTER Figure 3 A Line Splitter NOTE If the physical size of the conductor or ammeter capacity does not permit all lines to be measured simultaneously measure current flow in each individual line Then add the Individual readings Page 20 IN LINE Alternatively to read the current flow in AMPERES an in line ammeter may be used Most Digital Volt Ohm Meters VOM will have the capability to measure amperes This usually requires the positive meter test lead to be connected to the correct amperes plug and the meter to be set to the amperes position Once the meter is properly set up to measure amperes the circuit being measured must be physically broken The meter will be in line or in series with the component being measured In Figure 4 the control wire to a relay has been removed The meter is used to connect and supply voltage to the relay to energize it and measure the amperes going to it BATTERY Figure 4 A VOM as In line meter MEASURING RESISTANCE The volt ohm milliammeter may be used to measure the resistance in a circuit Resistance values can be very valuable when testing coils or windings such as the Stator and Rotor windings When testing Stator windings keep in mind that the resistance of these windings is ve
206. lity returns the cranking cycle does NOT abort but continues until complete Once the engine starts it will run for one 1 minute then shut down CONTROL PANEL system READY Low Battery tow ol PRESSURE HIGH OIL TEMPERATURE oversPeeD EXERCISE rpm sensor Loss overcrank eee E NER 8 kW UNITS 10 20 kW UNITS Figure 1 Generator Control Panel AUTO OFF MANUAL SWITCH Use this switch to a select fully automatic operation b to crank and start the engine manually and c to shut the unit down or to prevent automatic startup 1 AUTO position a Select AUTO for fully automatic operation b When AUTO is selected circuit board will moni tor utility power source voltage c Should utility voltage drop below a preset level and remain at such a low level for a preset time circuit board action will initiate engine cranking and startup d Following engine startup circuit board action will initiate transfer of electrical loads to the Standby source side e On restoration of utility source voltage above a preset level circuit board action will initiate retransfer back to the Utility Source side f Following retransfer circuit board will shut the engine down and will
207. lown fuse will open the applicable circuit and will result in a generator startup and transfer to Standby or b failure to retransfer back to the utility source PROCEDURE 1 On the generator panel set the AUTO OFF MANUAL switch to OFF 2 Turn off the utility power supply to the transfer switch using whatever means provided 3 Remove fuses F1 and F2 from the fuse holder see Figure 8 4 Inspect and test fuses for blown condition With a VOM set to measure resistance CONTINUITY should be measured across the fuse Figure 8 Fuse Holder and Fuses RESULTS 1 Replace blown fuse s as needed TEST 35 CHECK N1 AND WIRING DISCUSSION A shorted Wire 1 or N2 to ground can cause fuse 1 or F2 to blow PROCEDURE 1 On the generator panel set the AUTO OFF MANUAL switch to OFF 2 Turn off the utility power supply to the transfer switch using whatever means provided 3 Remove fuses F1 F2 and F3 from the fuse holder see Figure 7 4 Remove the generator control panel cover Disconnect the N1 N2 connector that supplies the printed circuit board located in the control panel see Figure 6 5 Set VOM to measure resistance SECTION 3 4 DIAGNOSTIC TESTS 6 Connect the positive meter test lead to Wire N1 at the terminal block in the control panel a Connect the negative meter lead to the ground lug INFINITY should
208. lt lt lt lt 19 zm 0 DOSTOQUVVNHHHS oo 5 C a lt 60650 e Q moorztomn ou i oc E 55 2 HO E H lt 5 7 0E lt ic z T lt E 5 20 1 vio d a i 2 gt 22 5 RP 5 me ru OEE nr ME ma zu a 24 5 D 55 8 4 e a i H 1 o VAS Y 1 8 i i Nece 00 00 0 i 00 i i avanan 22 i lt z 8 annoya lt T i H i i amp 1 i SCHEMATIC 14 KW HOME STANDBY ELECTRICAL DATA DRAWING 0G8513 2 2 6 6 0 0 VOLTAGE 4 4 4 REGULATOR 22 WINDING 11 33 Po _____2 1 WINDING 0 4 0 4 lt 2 18 5 2
209. ltage should not drop below about 230 volts b V Twin Engine Units Frequency should not drop below approximately 60 Hertz Voltage should not drop below about 240 volts RESULTS 1 If frequency and voltage drop excessively under load refer back to flow chart 2 If frequency and voltage under load are good dis continue tests TEST 19 CHECK FOR OVERLOAD CONDITION DISCUSSION An overload condition is one in which the generator rated wattage amperage capacity has been exceed ed To test for an overload condition on an installed unit the best method is to use an ammeter See Measuring Current in Section 1 5 PROCEDURE Use a clamp on ammeter to measure load current draw with the generator running and all normal electrical loads turned on RESULTS 1 If the unit is overloaded reduce loads to the unit s rated capacity 2 If unit is not overloaded but rpm and frequency drop excessively when loads are applied go to Test 16 Page 52 TEST 20 CHECK ENGINE CONDITION DISCUSSION If engine speed and frequency drop excessively under load the engine may be under powered An under powered engine can be the result of a dirty air cleaner loss of engine compression faulty fuel set tings incorrect ignition timing etc PROCEDURE For engine testing troubleshooting and repair procedures refer to Problem 11 in Section 4 3 For further engine repair information refer to the appropriate
210. lts and other fasteners Clean the area around the Generator Clear away paper leaves snow and other objects that might blow against the generator and obstruct its air openings INSULATION RESISTANCE The insulation resistance of stator and rotor windings is a measurement of the integrity of the insulating materials that separate the electrical windings from the generator steel core This resistance can degrade over time or due to such contaminants as dust dirt oil grease and especially moisture In most cases failures of stator and rotor windings is due to a break down in the insulation And in many cases a low insu lation resistance is caused by moisture that collects while the generator is shut down When problems are caused by moisture buildup on the windings they can usually be corrected by drying the windings Cleaning and drying the windings can usually eliminate dirt and moisture built up in the generator windings THE MEGOHMMETER GENERAL A megohmmeter often called a megger consists of a meter calibrated in megohms and a power supply Use a power supply of 500 volts when testing stators or rotors DO NOT APPLY VOLTAGE LONGER THAN ONE 1 SECOND TESTING STATOR INSULATION parts that might be damaged by the high meg ger voltages must be disconnected before testing Isolate all stator leads Figure 8 and connect all of the stator leads together FOLLOW THE MEGGER MANUFACTURER S INSTRUCTIONS CAREFULL
211. lves 142 Test 78 Check Wire 18 Continuity 143 Test 79 Test Exercise Function 144 Test 80 Check Cranking and Running Circuits 144 Test 81 Check to see if Low Speed Function is enabled 146 Test 82 Check operation of the Choke 146 PART 5 OPERATIONAL TESTS 147 5 1 System Functional 15 148 Introduction 148 Manual Transfer Switch Operation 148 Electrical 148 Generator Tests Under Load 149 Checking Automatic Operation 150 Setting The Exercise Timer 150 PART 6 DISASSEMBLY 151 6 1 Major 152 Front Engine 22 152 Major 156 Torque Requirements Unless Otherwise 162 PART 7 ELECTRICAL DATA 163 Wiring Diagram 8 kW Home Standby 164 Schematic 8 KW Home Standby 166 Wiring Diagram 10 kW Standby 168 Schematic 10 kW Home Standby
212. male Side Connect the negative test lead to Wire 90 Pin 2 5 Set the AUTO OFF MANUAL Switch to MANUAL While cranking battery voltage should be measured cyclically If battery voltage was not measured verify continuity of Wire 90 between the C3 Connector and the printed circuit board J1 Connector Pin Location J1 23 Verify continuity of Wire 14 between the C3 Connector and J2 connector Pin Location J2 3 Repair or replace any wiring as needed 6 Disconnect C3 Connector Set a VOM to measure resis tance Connect the positive test lead to Wire 14 Pin 1 of C3 Connector going to the choke solenoid Male Side Connect the negative test lead to Wire 90 Pin 2 Approximately 3 7 ohms should be measured SECTION 4 4 DIAGNOSTIC TESTS 7 With the generator running at a speed of approximately 60 Hertz verify that the choke is energized and hold ing the choke plate open Repeat Step 2 procedure however once the unit starts manually hold the choke open while taking the voltage measurement Figure 24 Exploded View Showing Location of Choke Plate 10 kW Units MALE SIDE FEMALE SIDE Figure 25 Choke Solenoid Connector RESULTS 1 If Battery voltage was not measured in Step 5 and wire continuity is good replace the printed circuit board 2 If Choke Solenoid coil resistance is not measured Step 6 replace the Choke Solenoid PROCEDURE 8 kW UNITS 1 Operational Check Set the AUTO
213. mediately and the generator will start 3 The generator will start and run for approximately 12 minutes and then shut down The exerciser is now set to run at this time of day each week Example If the Set Exercise is pressed on Saturday afternoon at 2 00 p m the generator will start and exercise for approximately 12 minutes every Saturday at 2 00 p m 10 20 kW INSTALLATION ASSISTANT Upon first power up of the generator the display inter face will enter an installation assistant The assistant will prompt the user to set the minimum settings to operate These settings are simply Current Date Time and Exercise Day Time The maintenance intervals will be initialized when the exercise time is entered The exercise settings can be changed at any time via the EDIT menu see Appendix Menu System If the 12 volt battery is disconnected or the fuse removed the Installation Assistant will operate upon power restoration The only difference being that the display will only prompt the customer for the current Time and Date ALL UNITS Note If the installer tests the generator prior to installation press the ENTER key to avoid set ting the exercise time This will ensure that the customer will still be prompted to enter an exercise time when the unit is first powered up NOTE The exerciser will only work in the AUTO mode and will not work unless this procedure is performed The current date time will need t
214. minimum settings to operate These settings are simply Current Date Time and Exercise Day Time The maintenance intervals will be initialized when the exercise time is entered for the first time Figure 3 2 The exercise settings can be changed at any time via the EDIT menu see Appendix Menu System If the 12 Volt battery is disconnected or the fuse removed the Installation Assistant will operate upon power restoration The only difference is the display will only prompt the customer for the current Time and Date If the installer tests the generator prior to instal lation press the ENTER key to avoid setting up the exercise time This will ensure that when the customer powers up the unit he will still be prompted to enter an exercise time NOTE The exerciser will only work in the AUTO mode and will not work unless this procedure is performed The current date time will need to be reset every time the 12 Volt battery is disconnected and then recon nected and or when the fuse is removed TO SELECT AUTOMATIC OPERATION The following procedure applies only to those instal lations in which the air cooled automatic standby generator is installed in conjunction with a transfer Switch Transfer switches do not have an intelligence circuit of their own Automatic operation on transfer switch and generator combinations is controlled by circuit board action To select automatic operation when a transfer switch is instal
215. n Initial Transfer to Standby OUTPUT 1 p 44 SO io 33 NEUTRAL CONTROLLER DISPLAY 00 Slee BATTERY WARMER H CONTROLLER PRINTED CIRCUIT BOARD N2 85 1 LED BOARD 86 2 41 1 820 1 13 m 3 7 5 AMP FUSE os 2 Li 818 3 i 819 4 GOVERNOR B SELF RESETTING FUSE J2 1 2 3 4 0 14 _ ij 14 lt 60 GROUND 90 5 BATTERY 2 TRANSFER 12 VDC ALWAYS PRESENT VOLTAGE GROUND FOR CONTROL PURPOSES LEGEND 12 VDC DURING CRANKING ONLY BRUSH ASSEMBLY LOW OIL PRESSURE SWITCH PA PRUSH MN GUTER LOP lt LOWLOIL PRESSURE 12 VDC DURING ENGINE RUN CONDITION CS CHOKE SOLENOID SCR STARTER CONTROL RELAY DC FIELD EXCITATION i FS FUEL SOLENOID SM STARTER MOTOR HIGH TEMPERATURE SWITCH SP_ SPARK PLUG 5 VDC LED IM_ IGNITION MODULE 113 SECTION 4 2 D
216. n condition in the sensing AC output circuit An adjustment potentiometer permits the stator AC power winding voltage to be adjusted Perform this adjustment with the generator running at no load and with a frequency of 60 Hz At the stated no load frequency adjust to obtain a line to line AC voltage of 247 249 volts MAIN LINE CIRCUIT BREAKER The main line circuit breaker protects the generator against electrical overload See Specifications in front of manual for amp ratings AC GENERATORS PART2 ROTOR RESIDUAL MAGNETISM The generator revolving field rotor may be consid ered to be a permanent magnet Some residual magnetism is always present in the rotor This residual magnetism is sufficient to induce a voltage into the stator AC power windings that is approximately 2 12 volts AC FIELD BOOST 12 20 KW FIELD BOOST CIRCUIT When the engine is cranking direct current flow is delivered from a circuit board to the generator rotor windings via Wire 4 The field boost system is shown schematically in Figure 2 Manual and automatic engine cranking is initiated by circuit board action when that circuit board energizes a crank relay Battery voltage is then delivered to field boost Wire 4 and to the rotor via a field boost resistor and diode The crank relay field aud resistor and diode are all located on the circuit oard Notice that field boost current is available only while the crank relay is e
217. n the utility source power is turned off After starting the transfer switch should connect load circuits to the standby side Let the system go through its entire automatic sequence of operation With the generator running and loads powered by generator AC output turn ON the utility power supply to the transfer switch The following should occur After about fifteen seconds the switch should transfer loads back to the utility power source About one minute after retransfer the engine should shut down SETTING THE EXERCISE TIMER This generator is equipped with an exercise timer Once it is set the generator will start and exercise every seven days on the day of the week and at the time of day specified During this exercise period Page 150 OPERATIONAL TESTS the unit runs for approximately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle unless utility power is lost PROCEDURE 8 KW UNITS A switch on the control panel see Figure 3 1 permits selection of the day and time for the system to exercise At the chosen time perform the following sequence to select the desired day and time of day the system will exercise Remember seasonal time changes affect the exercise settings 1 Verify that the AUTO OFF MANUAL switch is set to AUTO 2 Press and hold the Set Exercise switch for several seconds All the red LED s will stop flashing im
218. nd need to be addressed RESULTS 1 Refer back to flow chart SECTION 2 4 DIAGNOSTIC TESTS AC GENERATORS CRIMP ON STANDARD FEMALE BLADE CONNECTORS MOMENTARY PUSHBUTTON ON OFF SWITCH SINGLE POLE SWITCH ON LIVE SIDE 12 AWG DO NOT SUBSTITUTE ANY OTHER DEVICE STANDARD MALE PLUG Figure 17 Construction of Energizing Cord DEPRESS SWITCH FOR ONE SECOND PLUG ENERGIZING CORD INTO AC OUTLET CAPACITOR 7 WIRES 2 amp 6 TO DPE WINDING CAPICITOR REMAINS CONNECTED TO GENERATOR Danger The capacitor may need to be dis charged before testing A capacitor can be discharged by crossing the terminals with a metal insulated screw driver Danger Use proper protective equipment when dealing with a capacitor that has exploded GENERATOR Figure 18 Energizing Cord Connection Page 53 5 54 3 TRANSFER SWITCH Air cooled Automatic Standby Generators 3 1 Description and Components 56 General 6 suere 56 Transfer 57 Transfer Relay aniio ree cit teo rers 57 Ne ttr l EUg dnce ee tec 58 Manual Transfer Handle 58 Terminal 1 58 giz Malr
219. nd the pin con nection looks good the internal fuse on the PCB has failed Replace the printed circuit board TEST 46 CHECK BATTERY CHARGER SUPPLY VOLTAGE GENREADY LOAD CENTER DISCUSSION The battery charger is supplied with 120VAC The output of the battery charger is 13 4 VDC 2 5A PROCEDURE Refer to Figure 13 1 Set VOM to measure AC voltage 2 Measure across points A and B 120 VAC should be measured a If 120 VAC is not measured verify that load source voltage is available and that the duplex circuit breaker in ON Page 90 b If 120 VAC is measured proceed to Step 3 3 Measure across points C and D 120 VAC should be measured a If 120 VAC is not measured repair or replace Wire BC LINE or BC 00 between the load cen ter and the generator b If 120 VAC is measured refer to Flow Chart TEST 47 CHECK BATTERY CHARGER OUTPUT VOLTAGE GENREADY LOAD CENTER DISCUSSION The battery charger is supplied with 120VAC The output of the battery charger is 13 4 VDC 2 5A PROCEDURE Refer to Figure 13 1 Set VOM to measure DC voltage 2 Remove and isolate battery charger black and red leads from generator terminal strip points E and F 3 Measure across points E and Battery supply voltage 12 VDC should be measured a battery voltage is not measured wait 5 min utes and repeat Step 3 If battery supply voltage is still not available refer to Flow Chart b
220. nergized i e while the engine is cranking TO LOAD MLB MAIN LINE CIRCUIT BREAKER STATOR POWER STATOR POWER WINDING ENGINE DIRECT DRIVE SECTION 2 2 OPERATIONAL ANALYSIS Field boost voltage is reduced from that of battery voltage by the resistor action and when read with a DC voltmeter will be approximately 9 or 10 volts DC TO STARTER FIELD l BOOST RESISTOR PIN 1 STARTER CONTACTOR Figure 2 Field Boost Circuit Schematic TO LOAD MLB MAIN LINE CIRCUIT BREAKER SENSING STATOR POWER WINDING FIELD BOOST FROM CONTROLLOGIC CIRCUIT BOARD STATOR POWER WINDING ve stator c gt 8 10 kW Units Figure 1 ENGINE DIRECT DRIVE VOLTAGE REGULATOR STATOR EXCITATION WINDING 12 20 kW Units Operating Diagram of AC Generator Page 35 SECTION 2 2 OPERATIONAL ANALYSIS OPERATION 8 10 KW STARTUP When the engine is started residual magnetism from the rotor induces a voltage into a the stator AC power windings and b the stator excitation or DPE windings The capacitor on the DPE winding will be charged and then will discharge causing a voltage to be induced back into the rotor FIELD EXCITATION An AC voltage is induced into the stator excitation DPE windings The DPE winding circuit is completed to the capacitor via Wire 2
221. ng voltage drops below a preset value circuit board action will initiate automatic generator startup and transfer to the Standby Source side The crank relay and fuel solenoid valve are energized by circuit board action at the same time DIGITAL INPUT OUTPUT FUNCTIONS Postion Digital inputs Digital Outputs 6 Not Used waa DANGER THE GENERATOR ENGINE WILL CRANK AND START WHEN THE 7 DAY EXERCISER SWITCH IS ACTUATED THE UNIT WILL ALSO CRANK AND START EVERY 7 DAYS THEREAFTER ON THE DAY AND AT THE TIME OF DAY THE SWITCH WAS ACTUATED AUTO OFF MANUAL SWITCH This 3 position switch permits the operator to a select fully automatic operation b start the generator manually or c stop the engine and prevent automatic startup Switch terminals are shown pictorially and schematically in Figure 6 below SECTION 4 1 DESCRIPTION AND COMPONENTS 7 5 AMP FUSE This fuse protects the circuit board against excessive current If the fuse has blown engine cranking and operation will not be possible Should fuse replace ment become necessary use only an identical 7 5 amp replacement fuse Figure 2 A Typical 7 5 Amp Fuse 1 CONTROL PANEL 7 5 AMP FUSE STARTER CONTACTOR RELAY 10 20 KW 4 POSITION TERMINAL BLOCK TERMINAL BLOCK CIRCUIT BREAKER 8KW 15 AMP GFCI DUPLEX OUTLET 17 amp 20 KW 8 CIRCUIT BREAKER 17 amp 20 KW 9 CIRCUIT BREAKER
222. ngine door removed 8 Data Label Oil see sample Control Dipstick Panel Air Filter a Circuit Breakers GFCI Outlet All 17 amp 20kW Em nclosure _ 5 i Fuel Inlet 6 N j 0 JI d Fuel 6 Sf Regulator LU Composite Base Oil Filter Battery Compartment Page 8 TABLE OF CONTENTS Pear me Generator Identification Installation Basics Non Prepackaged Interconnections PART 1 GENERAL INFORMATION Engine Generator Protective Devices Operating Instructions 1 7 Automatic Operating Parameters PAGE EXN 19 fen ul 13 Preparation Before Use 16 ul 16 Air cooled Automatic Standby Generators 1 1 Generator Identification 10 Measuring Resistance 20 Introduction 10 Electrical Units sss 21 1 2 Installation 11 Ohm 5 LAW tei feted ties 21 Introduction eese 11 Visual 22 Selecting A Location 11 Insulation 22 Grounding The
223. nspect the pinion for binding or sticking PINION Figure 12 Check Pinion Gear Operation V Twin DC CONTROL PINION Figure 13 Check Pinion Gear Operation Single Cylinder TOOLS FOR STARTER PERFORMANCE TEST The following equipment may be used to complete a performance test of the starter motor Aclamp on ammeter A tachometer capable of reading up to 10 000 rpm A fully charged 12 volt battery MEASURING CURRENT To read the current flow in AMPERES a clamp on ammeter may be used This type of meter indicates current flow through a conductor by measuring the strength of the magnetic field around that conductor CONDUCTOR MAGNETIC lt lt CLAMP ON C AMMETER Figure 14 Clamp On Ammeter TACHOMETER A tachometer is available from your parts source The tachometer measures from 800 to 50 000 rpm see Figure 15 SECTION 4 4 DIAGNOSTIC TESTS Figure 15 Tachometer TEST BRACKET A starter motor test bracket may be made as shown in Figure 16 A growler or armature tester is available from an automobile diagnostic service supplier METAL STOCK 2 1 4 THICK STEEL i DRILL TWO HOLES 1 2 FOR STARTER MOUNTING BRACKET DRILL TWO HOLES 1 2 FOR MOUNTING TACHOMETER TAP FOR 1 4 20 NC SCREWS Figure 16 Test Bracket REMOVE STARTER MOTOR It is recommended that the starter mot
224. ntacts The moveable LOAD contacts must be connected to the stationary UTILITY source contacts If necessary manually actuate the main contacts to the Utility power source side d Actuate the generator main line circuit breaker to its or Closed position The utility power supply to the transfer switch must be turned off MANUAL TRANSFER LEVER LIMIT SWITCH CLOSING Eu UE STANDBY COIL C2 BRIDGE RECTIFIER T2 T1 Figure 1 The Transfer Mechanism Page 74 Set the generator AUTO OFF MANUAL switch to AUTO 1 The generator should crank and start 2 When the generator starts an engine warm up timer should start timing After about 15 seconds the transfer relay should energize and transfer to the Standby source should occur f If transfer to Standby does NOT occur check the voltage across transfer switch Terminal Lugs E1 and E2 The generator line to line voltage should be indicated RESULTS 1 If normal transfer to Standby occurs discontinue tests 2 If transfer to Standby does NOT occur and no voltage is indicated across Terminal Lugs E1 E2 determine why generator AC output has failed 3 If transfer to Standby does NOT occur and voltage reading across Terminal Lugs E1 E2 is good r
225. nting bracket Using a 10mm socket remove the two bolts from the enclosure side panel mounting bracket See Figure 11 Figure 12 11 Remove engine divider panel Using a 10mm socket remove the rear 10mm bolt from the base of the enclosure See Figure 13 Remove the front 10mm bolt from the base of the enclosure See Figure 14 Figure 11 Figure 13 Page 154 Figure 16 13 Unbolt Oil Cooler Using 10mm socket remove the two 10mm bolts from the front of the oil cooler See Figure 17 Remove the two 10mm bolts from the rear of the oil cooler See Figure 18 Figure 14 12 Remove Air Box Using a 6mm allen wrench remove the four intake manifold socket head cap screws See Figure 15 Using a 4mm allen wrench remove the four airbox allen head shoulder bolts While removing the airbox remove the four rubber washers See Figure 16 Figure 15 Figure 18 Page 155 SECTION 6 1 MAJOR DISASSEMBLY 14 Remove Blower Housing Using a 4mm allen wrench remove one button head cap screw from top of blower housing Using a 10mm socket remove one 10mm bolt from the top of the blower housing See Figure 19 Using a 10mm socket remove four 10mm bolts from the right side of the blower housing see Figure 20 and four 10mm bolts from the left side of the blower housing See Figure 21 Remove blower housing Figure 20 Page 156 Figure 21 MAJOR DISASSEMBLY SAFETY 1 Set the AUTO OFF MANU
226. ntrol panel must be removed to adjust the voltage regulator NOTE The voltage regulator is housed in the back of the generator control panel The regula tor maintains a voltage in direct proportion to frequency at a 2 to 1 ratio For example at 60 Heriz line to neutral voltage will be 120 volts SCREWDRIVER ____ VOLTAGE POTENTIOMETER REGULATOR Figure 15 Voltage Adjustment Potentiometer RESULTS 1 Ifthe frequency and voltage are now good discontinue tests 2 If frequency is now good but voltage is high or low refer back to flow chart Page 51 SECTION 2 4 DIAGNOSTIC TESTS TEST 18 CHECK VOLTAGE AND FREQUENCY UNDER LOAD DISCUSSION It is possible for the generator AC output frequency and voltage to be good at no load but they may drop excessively when electrical loads are applied This condition in which voltage and frequency drop exces sively when loads are applied can be caused by a overloading the generator b loss of engine power or c a shorted condition in the stator windings or in one or more connected loads PROCEDURE 1 Connect an accurate AC frequency meter and an AC voltmeter across the stator AC power winding leads 2 Start the engine let it stabilize and warm up 3 Apply electrical loads to the generator equal to the rated capacity of the unit 4 Check the AC frequency and voltage a Single Cylinder Units Frequency should not drop below approximately 58 Hertz Vo
227. o motive force EMF is applied OHM S LAW A definite and exact relationship exists between VOLTS OHMS and AMPERES The value of one can be calculated when the value of the other two are known Ohm s Law states that in any circuit the current will increase when voltage increases but resistance remains the same and current will decrease when resistance Increases and voltage remains the same Figure 6 Ohm s Law If AMPERES is unknown while VOLTS and OHMS are known use the following formula VOLTS AMPERES OHMS If VOLTS is unknown while AMPERES and OHMS are known use the following formula VOLTS z AMPERES x OHMS If OHMS is unknown but VOLTS and AMPERES are known use the following _ VOLTS 5 AMPERES 21 SECTION 1 5 TESTING CLEANING AND DRYING VISUAL INSPECTION When it becomes necessary to test or troubleshoot a generator it is a good practice to complete a thorough visual inspection Remove the access covers and look closely for any obvious problems Look for the following Burned or broken wires broken wire connectors damaged mounting brackets etc Loose or frayed wiring insulation loose or dirty connections Check that all wiring is well clear of rotating parts Verify that the Generator properly connected for the correct rated voltage This is especially important on new installations See Section 1 2 AC Connection Systems Look for foreign objects loose nuts bo
228. o be reset every time the 12 volt battery is discon nected and then reconnected and or when the fuse is removed 6 DISASSEMBLY Air cooled Automatic Standby Generators 6 1 Major 152 Front Engine 152 Major 156 Torque Requirements Unless Otherwise Specified 162 TABLE OF CONTENTS 61 Major Disassembly Epl a Page 151 SECTION 6 1 MAJOR DISASSEMBLY PART 6 FRONT ENGINE ACCESS 2 Remove controller Using a Phillips screwdriver remove the four mounting screws from the controller See Figure 3 SAFETY 1 Set the AUTO OFF MANUAL switch to OFF 2 Remove the 7 5 amp main fuse See Figure 1 3 Remove the N1 and N2 fuse from the transfer switch Figure 3 3 Remove control harnesses a Remove engine wiring harness at the J1 port Figure 1 Remove 7 5 Amp Fuse b Remove control wiring harness at the J2 port c Remove stepper motor wiring harness at the J3 port See Figure 4 4 Turn off fuel supply to the generator and remove the flex line from the fuel regulator 5 Remove utility power from the generator 6 Remove front door 7 Remove battery from the generator FRONT ENGINE ACCESS 1 Remove Controls Cover Using a Torx T 27 socket remove two bolts and ground washer from the controls
229. o the positive slip ring nearest the rotor bearing 2 Connect the black tester probe to a clean frame ground such as a clean metal part of the rotor shaft 3 Turn the tester switch OFF Page 24 4 Plug the tester into a 120 volts AC wall socket and set the voltage switch to 1500 volts 5 Turn the tester switch On and make sure the pilot light has turned on 6 Observe the breakdown lamp then turn the tester switch OFF DO NOT APPLY VOLTAGE LONGER THAN ONE 1 SECOND If the breakdown lamp came on during the one 1 second test cleaning and drying of the rotor may be necessary After cleaning and drying repeat the insu lation breakdown test If breakdown lamp comes on during the second test replace the rotor assembly TEST LEAD Figure 9 Testing Rotor Insulation 12 20kW CLEANING THE GENERATOR Caked or greasy dirt may be loosened with a soft brush or a damp cloth A vacuum system may be used to clean up loosened dirt Dust and dirt may also be removed using dry low pressure air 25 psi maximum CAUTION Do not use sprayed water to clean the generator Some of the water will be retained on generator windings and terminals and may cause very serious problems DRYING THE GENERATOR To dry a generator proceed as follows 1 Open the generator main circuit breaker NO ELECTRICAL LOADS MUST BE APPLIED TO THE GENERATOR WHILE DRYING 2 Disconnect all Wires 6 from the voltage regulator 3 Prov
230. o the stud or bullet connector If INFINITY was measured in Step 4 replace the circuit board and retest for spark If ignition spark still has not occurred proceed to Test 74 TEST 74 CHECK AND ADJUST IGNITION MAGNETOS DISCUSSION In Test 70 a spark tester was used to check for engine ignition If sparking or weak spark occurred one possible cause might be the ignition magneto s This test consists of checking ohm values across the primary and secondary windings of the magneto and adjusting the air gap between the ignition magneto s and the flywheel The flywheel and flywheel key will also be checked during this test A diode is installed before the primary winding inside the coil This is done to inhibit a spark occurring on both magnetos at the same time PROCEDURE TESTING MAGNETOS V TWIN ONLY 1 Disconnect the J1 connector from the printed circuit board Disconnect spark plug wires from the spark plugs on cylinder one and two Set VOM to measure resistance Connect the positive red meter lead to the bolt connec tor where Wire 18 was disconnected in Step 1 Connect the negative black meter lead to a clean frame ground A resistance of approximately 300K 10K ohms should be measured This reading is the primary winding of both coils in parallel Connect the positive meter lead to the spark plug wire and connect the negative meter lead to a clean frame ground Approximately 14K 3 ohms s
231. oard action will de energize a run relay mounted on the circuit board The relay s contacts will open to terminate engine ignition and close a fuel shutoff solenoid The engine will then shut down This feature protects the engine generator against damaging overspeeds NOTE The circuit board also uses rpm sensing to terminate engine cranking RPM SENSOR FAILURE During cranking if the board does not see a valid RPM signal within three 3 seconds it will shut down and latch out on RPM sensor loss During running if the RPM signal is lost for one full second the board will shut down the engine wait 15 seconds then re crank the engine f an RPM signal is not detected within the first three 3 seconds of cranking the control board will shut the engine down and latch out on RPM sensor loss f the RPM signal is detected the engine will start and run normally If the RPM signal is subsequently lost again the control board will try one more re crank attempt before latching out and flashing the overspeed LED or RPM Sensor Failure LOW OIL SWITCH HIGH TEMP SWITCH Figure 1 Engine Protective Switches on an Air Cooled Engine Page 25 SECTION 1 6 ENGINE GENERATOR PROTECTIVE DEVICES OVERCRANK SHUTDOWN This feature prevents the generator from damaging itself when it continually attempts to start and another problem such as no fuel supply prevents it from start ing The
232. of the unit 2 Press the ESC key till the main menu is displayed Page 144 3 Press the right arrow key till a line is present under EDIT 4 Press Enter 5 Press the right arrow key until EXERCISE is displayed 6 Press Enter READY TO RUN 12 10 08 09 30 Mon DATE AND TIME History Status Edit Debug Status History Edit Debug Figure 47 The Date and Time and Main Menu Screens 7 Adjust exercise time to about 3 to 4 minutes ahead of the date and time noted in Step 1 8 Press ESC until READY TO RUN is displayed The AUTO OFF MANUAL switch must be in AUTO for the unit to exercise 9 Watch the generator display and note the time When the date and time reaches the time that was programmed for exercise the unit will display Running in Exercise if the exercise feature is working properly RESULTS 1 In all models if the unit starts in MANUAL but fails to exercise without any ALARMS present replace the printed circuit board TEST 80 CHECK CRANKING AND RUNNING CIRCUITS DISCUSSION This test will check all of the circuits that are HOT with battery voltage and which could cause the Main Fuse to blow PROCEDURE 1 Set a to measure resistance 2 Disconnect the J2 Connector from the controller 3 Connect one meter test lead to the ground terminal Connect the other meter test lead to each of the follow ing J2 connector pin locati
233. oil and bridge rectifier as a unit LIMIT SWITCHES SW2 AND 5 3 Switches are mechanically actuated by load contacts movement When the load contacts are connected to the utility contacts limit switch SW2 opens the utility circuit to utility closing coil C1 and limit switch SW3 closes the standby circuit to standby closing coil C2 The limit switches arm the system for retransfer back to UTILITY when the load contacts are con nected to the STANDBY side Conversely when the load contacts are connected to the UTILITY side the switches arm the system for transfer to STANDBY An open condition in limit switch SW2 will prevent retransfer to Utility An open switch SW3 will prevent transfer to STANDBY BRIDGE RECTIFIER UTILITY CLOSING m COIL C1 LIMIT SWITCH SW2 MANUAL TRANSFER LEVER STANDBY CLOSING COIL C2 S BRIDGE RECTIFIER Figure 4 The W V Type Transfer Mechanism TRANSFER RELAY Transfer relay operation is controlled by a circuit board That circuit board is a part of a control panel assembly mounted on the standby generator set Figure 5 shows the transfer relay pictorially and schematically Relay operation may be briefly described as follows 1 Generator battery voltage 12 volts DC
234. ons J2 11 Wire 56 If CONTINUITY was measured go to Step 4 Average nominal resistance reading is 4 ohms Single Cylinder Starter Contactor SC 4 ohms Choke Solenoid CS is 4 ohms If CONTINUITY was measured go to Step 5 Average nominal resistance reading is 150 160 ohms V twin Starter Contact Relay SCR 150 160 ohms Choke Solenoid CS 4 ohms J2 3 Wire 14 If CONTINUITY was measured go to Step 6 Average nominal resistance reading is 16 ohms Fuel Solenoid FS 16 ohms If CONTINUITY was measured go to Step 8 Average nominal resistance reading is 16 ohms Fuel Solenoid FS 16 ohms Choke Solenoid CS 4 ohms If CONTINUITY was measured go to Step 7 Average nominal resistance reading is 16 ohms Fuel Solenoids FS 16 ohms FS2 7 ohms Choke Solenoid CS 4 ohms J2 12 Wire 4 If RESISTANCE was measured go to Step 9 For average nominal resistance reading of the rotor refer to the front of the manual 4 Disconnect Wire 56 and Wire 0 from the Starter Contactor SC Disconnect the Choke Solenoid CS connector SECTION 4 4 DIAGNOSTIC TESTS a Connect one meter test lead to the SC terminal from which Wire 56 was removed Connect the other meter test lead to the ground terminal 4 ohms should be measured If zero resistance was measured replace the SC b Connect one meter test lead to the CS connec tor Wire 56 Connect the other meter test lead to the CS connector Wire
235. or be removed from the engine when testing starter motor perfor mance Assemble starter to test bracket and clamp test bracket in vise Figure 17 TESTING STARTER MOTOR 1 A fully charged 12 volt battery is required 2 Connect jumper cables and clamp on ammeter as shown in Figure 17 3 With the starter motor activated jump the terminal on the starter contactor to battery voltage note the reading on the clamp on ammeter and on the tachometer rpm Note Take the reading after the ammeter and tachometer are stabilized approximately 2 4 seconds 4 A starter motor in good condition will be within the fol lowing specifications Page 129 SECTION 4 4 DIAGNOSTIC TESTS CLAMP ON STARTER AMP METER CONTACTOR STARTER MOTOR 12 VOLT BATTERY Figure 17 Testing Starter Motor Performance TEST 66 CHECK FUEL SUPPLY AND PRESSURE DISCUSSION The air cooled generator was factory tested and adjusted using natural gas as a fuel If desired LP propane gas may be used However when convert ing to propane some minor adjustments are required The following facts apply An adequate gas supply and sufficient fuel pressure must be available or the engine will not start Minimum recommended gaseous fuel pressure at the generator fuel inlet connection is 5 inches water column for natural gas NG or 10 inches water column
236. owing connection points A UTILITY 1 and UTILITY 2 1 Connect to identically marked terminals on a transfer switch terminal board B 23 and 15B 1 Connect to identically numbered terminals on the terminal board of the transfer switch 2 This circuit connects the circuit board to the transfer relay coil in the transfer switch TERMINAL STRIP Figure 1 Terminal Strip Page 96 CIRCUIT BOARD The circuit board controls all standby electric system operations including a engine startup b engine running c automatic transfer d automatic retrans fer and e engine shutdown In addition the circuit board performs the following functions Delivers field boost current to the generator rotor windings see Field Boost Circuit in Section 2 2 Starts and exercises the generator once every seven days Provides automatic engine shutdown in the event of low oil pressure high oil temperature overspeed no RPM sense overcrank or low battery An 18 pin and a 4 pin connector are used to inter connect the circuit board with the various circuits of the DC systems Connector pin numbers associated wires and circuit functions are listed in the CHART on the next page If the Utility sensi
237. oximate Page 5 SPECIFICATIONS IS 299 MOUNTING DIMENSIONS 1079 5 25 698 DE 997 93 747 t4 zu CYA r 732 1 ag 508 200 TRANSFER 0802012 SWITCH TRANSFER LIFTING HOLES 4 CORNERS 8KW 17KW SWITCH IF SUPPLIED 20KW IF SUPPLIED DO NOT LIFT BY ROOF p 1 d u SSS ESSE 2 _ t T n 642 M 54 762840 1226 PEA GRAVEL 83 MINIMUM LEFT SIDE VIEW FRONT VIEW Page 6 SPECIFICATIONS MOUNTING DIMENSIONS AIR INTAKE dur MINIMUM DISTANCE 914 36 0 MINIMUM OPEN AREA ON SIDES AND FRONT AIROUTLET 2500 575 3 08 T 227 HOLE LOCATIONS FOR ma OPTIONAL MOUNTING TO A CONCRETE PAD 446 6 378 7 L 448 78 149 13 FRONT OF UNIT FUEL INLET 12 20KW 1 2 NPT 8 amp 10KW 3 4 NPT USE SUPPLIED ADAPTER REQUIRED FUEL PRESSURE NATURAL GAS 5 7 WATER COLUMN
238. p 12 Measure and record running rotor amp draw with the engine running 14 Set the AUTO OFF MANUAL switch to OFF Reconnect Wire 4 to the voltage regulator RESULTS Refer to the chart on this page Results Fixed Excitation Test Rotor Amp Draw Test Note A calculated amp draw can be done by taking the battery voltage that is applied divided by the actual resistance reading of the rotor A resistance reading can be taken by measuring ohms between Wires 4 and 0 at the voltage regulator EXAMPLE MODEL 5517 WIRE 2 amp 6 VOLTAGE 87 VAC WIRE 11 amp 22 VOLTAGE 31 VAC STATIC ROTOR AMP DRAW 1 0 AMP RUNNING ROTOR AMP DRAW 1 0 AMP These results match Column B in the chart Refer back to Problem 1 Flow Chart and follow Letter B TEST 5 WIRE CONTINUITY 12 20 KW DISCUSSION The voltage regulator receives unregulated alternating current from the stator excitation winding via Wires 2 and 6 It also receives voltage sensing from the sta tor AC power windings via Wires 11 and 22 The regulator rectifies the AC from the excitation winding and based on the sensing signals regulates the DC current flow to the rotor The rectified and regulated current flow is delivered to the rotor brushes via Wires 4 positive and O negative This test will verify the integrity of Wire O PROCEDURE 1 Set to its x 1 scale 2 Remove Wire 0 from the voltage regulator 4th terminal from the top Also voltage
239. pecifications in the front of this manual 6 Connect one test lead to Stator Lead 33 Connect the other test lead to Stator Lead 44 Note the resistance reading and compare to the specifications in the front of this manual PROCEDURE 10 KW 1 Isolate the generator from the transfer switch by dis connecting the load wires from the main breaker inside the generator 2 Disconnect Stator Leads 22 and 33 from the neutral connection and separate the leads 3 Make sure all of the disconnected leads are isolated from each other and are not touching the frame during the test 4 Turn the Main Breaker to the ON or CLOSED position 5 Set a to measure resistance 6 See Figure 4 for proper testing points Connect one meter test lead to Wire 11 on the load side of the main breaker Connect the other meter test lead to Wire 22 power winding Note the resistance reading and com pare to the specifications in the front of this manual 7 Connect one test lead to Stator Lead 44 on the load side of the main breaker Connect the other test lead to Stator Lead 33 power winding Note the resistance reading and compare to the specifications in the front of this manual Page 46 Note Wire 11 and Wire 44 could be switched on the main breaker If an INFINITY reading is indi cated try putting the meter leads on the other output terminal of the breaker If INFINITY is still read then an actual fault may exist TEST WINDING
240. priate flow chart Test numbers assigned in the flow charts are identical to test numbers in Section 3 4 Diagnostic Tests Section 3 4 provides detailed instructions for performance of each test Problem 7 In Automatic Mode No Transfer to Standby TEST 26 CHECK VOLTAGE AT BAD FIND CAUSE OF NO AC OUTPUT TERMINAL LUGS TRANSFER SWITCH FROM GENERATOR E1 amp E2 GOOD TEST 27 CHECK MANUAL TRANSFER BAD REPAIR OR REPLACE MECHANISM SWITCH OPERATION TEST 28 CHECK 23 AND 15B WIRING BAD REPAIR OR REPLACE AS NEEDED CONNECTIONS TEST 29 TEST TRANSFER BAD P9 REPLACE TEST 30 CHECK STANDBY CONTROL BAD REPAIR AS NEEDED CIRCUIT Page 70 SECTION 3 3 TROUBLESHOOTING FLOW CHARTS TRANSFER SWITCH Problem 8 In Automatic Mode Generator Starts When Loss of Utility Occurs Generator Shuts Down When Utility Returns But There Is No Retransfer To Utility Power OR Generator Transfers to Standby During Excercise or in Manual Mode TEST 27 CHECK MANUAL TRANSFER BAD gt REPAIR OR REPLACE MECHANISM SWITCH OPERATION GOOD TEST 31 CHECK WIRE 23 BAD gt REPAIR OR REPLACE AS NEEDED TEST 29 TEST TRANSFER BAD REPLACE RELAY GOOD TEST 32 CHECK UTILITY CONTROL BAD REPAIR OR REPLACE AS NEEDED CIRCUIT Problem 9 Blown or F2 Fuse TEST 34 CHECK TEST 35 CHECK IL gt INSPECT REPLACE FUSE
241. r Factor 1 Battery Requirement Group 26R 12 Volts and 350 CCA Group 26R 12 Volts and 525 CCA Minimum Minimum Weight unit only in 165 340 387 439 439 455 455 421 450 Enclosure Steel Steel Steel Steel Steel Steel Aluminum Aluminum Normal Operating Range 20 F 28 8 C to 77 F 25 C Maximum wattage and current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine power and condition etc Maximum power decreases about 3 5 percent for each 1 000 feet above sea level and also will decrease about 1 percent for each 6 C 10 F above 16 C 60 F ambient temperature Load current values shown for 120 volts are maximum TOTAL values for two separate circuits The maximum current in each circuit must not exceed the value stated for the 240 volts Circuits to be moved must be protected by same size breaker For example a 15 amp circuit in the main panel must be a 15 amp circuit in the transfer switch STATOR WINDING RESISTANCE VALUES ROTOR RESISTANCE 8 kW 10 kW 12 kW 14 kW 16 kW 17 kW 20 kW Power Winding Across 11 amp 22 0 123 0 1439 0 090 0 105 0 100 0 116 0 100 0 116 0 074 0 086 0 074 0 086 0 0415 0 0483 Power Winding Across 33 amp 44 0 123 0 1439 0 090 0 105 0 100 0 116 0 100 0 116 0 074 0 086 0 074 0 086 0 0415 0 0483 Excitation Winding Across 2 amp 6 0 776 0 902 0 511 0 594 0 876 1 018 0 876 1 018 0 780 0 906 0 780 0 906 0 731
242. r replace Wire 0 or Wire 15B between the generator terminal strip and the ground lug b If 12 VDC is not measured proceed to Step 5 8 Set VOM to measure resistance 9 Connect the meter test leads across the disconnected Wire 0 and Wire 15B Approximately 115 Ohms should be measured a If 115 Ohms is measured proceed to Step 11 b If zero resistance or CONTINUITY is measured connect the meter test leads across locations J and K on the load shed controller Figure 12 C zero resistance is measured a short exists Replace the transfer relay TR d If 200 115 is measured repair or replace Wire 15B between the generator and the transfer switch 10 Disconnect the J2 connector from the printed circuit board 11 In the generator control panel measure across Wire 15B at the customer connection and pin location J2 8 of the connector just removed CONTINUITY should be measured a If CONTINUITY is not measured repair or replace Wire 15B between the J2 connector and the terminal strip b IF CONTINUITY is measured proceed to Step 12 12 In the generator control panel measure across Wire 0 at the customer connection and the ground lug CONTINUITY should be measured a If CONTINUITY is not measured repair or replace Wire 0 between the customer connection and the ground lug b If CONTINUITY is measured and the pin con nection of J2 looks good the internal fuse on the PCB has failed Replace the printe
243. rcise Or In Manual 71 Problem 9 Blown F1 or F2 Fuse 71 Problem 10 Units Starts And Transfer Occurs When Utility Power Is 72 Page 2 Problem 11 No Battery Charge Pre Packed Load Center 73 Problem 12 No Battery Charge amp RTSE Transfer Switch 73 Problem 13 No Battery Charge Gen Ready Load Center 73 Problem 14 No Battery Charge Load Shed Transfer Switch 73 3 4 Diagnostic Tests 74 Generale cedet 74 Test 26 Check Voltage at Terminal Lugs 2 74 Test 27 Check Manual Transfer Switch 75 1 28 23 158 Wiring Connections 76 Test 29 Test Transfer Relay TR 77 Test 30 Standby Control Circuit 78 Test 31 Check Wire 23 78 Test 32 Utility Control Circuit 80 Test 33 Test Limit Switch SW2 and SW3 82 Test 34 Check Fuses F1 and F2 82 Test 35 Check N1 and Wiring 83 Test 36 Check N1 Voltage 83 Test 37 Check Utility Sensing Voltage at the Circuit 84
244. red to the transfer relay TR actuating coil via Wire 15B and terminal A of the transfer relay TR in the transfer switch This 12 volts DC circuit is completed back to the board via transfer relay terminal B and Wire 23 However circuit board action holds the Wire 23 circuit open to ground and the transfer relay TR is de energized VOLTAGE REGULATOR WINDING Ez 1 7 SECTION 4 2 OPERATIONAL ANALYSIS DC CONTROL When the circuit board s engine warm up timer times out circuit board action completes the Wire 23 circuit to ground The transfer relay then energizes and its normally open contacts close Standby power is now delivered to the standby closing coil C2 via Wires E1 E2 the normally open transfer relay contacts Wire 205 limit switch XB1 Wire B and a bridge rectifier The standby closing coil energizes and the main current carrying contacts of the transfer switch are actuated to their STANDBY source side As the main contacts move to their STANDBY source side a mechanical interlock actuates limit switch XB1 to its open position and limit switch to its Utility side position When XB1 opens standby closing coil C2 3 de energizes Standby power is delivered to the LOAD terminals T1 T2 of the transfer switch Figure 5 Circuit Conditio
245. regulator is labeled next to terminal 3 Connect one test lead to Wire 0 connect the other test lead to a clean frame ground The meter should read CONTINUITY RESULTS If CONTINUITY was not measured repair or replace the wire as needed TEST 4 Results Fixed Excitation Test Rotor Amp Draw Test 12 20 kW SECTION 2 4 DIAGNOSTIC TESTS Above 2 5A Above 2 5 Above 2 5A Above 2 3A Above 2 3A Above 2 0A Above 2 5A Above 2 5 Above 2 5A Above 2 5A Above 2 5A lt MATCH RESULTS WITH LETTER AND REFER TO FLOW CHART IN SECTION 2 3 Problem 1 gt Below 60 VAC Below 60 VAC Above 60 VAC Below 60 VAC Below 60 VAC Below 60 VAC Above 60 VAC Below 60 VAC Zero or Residual Above 60 VAC Zero or Residual Below 60 VAC Above 60 VAC 60 60 Below 60 Voltage Results Wire 2 amp 6 Voltage Results Wire 11 amp 22 Static Rotor Running Rotor Page 43 SECTION 2 4 DIAGNOSTIC TESTS TEST 6 CHECK FIELD BOOST 12 20 KW DISCUSSION See Field Boost Circuit in Section 2 2 Field boost current from the circuit board is available to the rotor only while the engine is cranking Loss of field boost output to the rotor may or may not affect power winding AC output voltage The following facts apply small amount of voltage must be induced into the DPE winding to turn the voltage regulator on If rotor residual magne
246. ressure 1 Normal oil pressure is approximately 35 40 psi with engine running If normal oil pres sure is indicated go to Step 4 of this test 2 If oil pressure is below about 4 5 psi shut engine down immediately A problem exists in the engine lubrication system Note The oil pressure switch is rated at 10 psi for V twin engines and 8 psi for single cylinder engines zx LOW OIL PRESSURE SWITCH OIL TEMPERATURE LS Figure 42 Oil Pressure Switch 5 Remove the oil pressure gauge and reinstall the oil pressure switch Do NOT connect Wire 86 or Wire 0 to the switch terminals a Set a VOM to measure resistance b Connect the VOM test leads across the switch terminals With engine shut down the meter should read CONTINUITY If INFINITY is measured with the engine shutdown replace the LOP switch c Crank and start the engine The meter should read INFINITY 6 Set a VOM to measure resistance Page 141 SECTION 4 4 DIAGNOSTIC TESTS a Disconnect the J1 Connector from the printed circuit board b Connect one test lead to Wire 86 disconnected from LOP Connect the other test lead to Pin Location 4 Wire 86 of the J1 Connector at the Circuit Board for all models CONTINUITY should be measured If CONTINUITY is not measured repair or replace Wire 86 between the LOP switch and the J1 Connector c Connect one test lead to Wire 0 disconnected from LOP Connect the other tes
247. rest of the crank cycle During a rest cycle the start and fuel outputs are de energized and the magneto output is shorted to ground Page 26 CRANKING CONDITIONS The following notes apply during cranking cycle 1 Starter motor will not engage within five 5 seconds of the engine shutting down 2 The fuel output will not be energized with the starter 3 The starter and magneto outputs will be energized together 4 Once the starter is energized the control board will begin looking for engine rotation If it does not see an RPM signal within three 3 seconds it will shut down and latch out on RPM sensor loss 5 Once the control board sees an RPM signal it will energize the fuel solenoid drive the throttle open and continue the crank sequence 6 Starter motor will disengage when speed reaches starter dropout 7 If the generator does not reach 2200 RPM within 15 seconds re crank cycle will occur 8 If engine stops turning between starter dropout and 2200 RPM the board will go into a rest cycle for seven 7 seconds then re crank if additional crank cycles exist 9 Once started the generator will wait for a hold off period before starting to monitor oil pressure and oil temperature refer to the Alarm Messages section for hold off times 10 During Manual start cranking if the Mode switch is moved from the Manual position the cranking stops immediately 11 During Auto mode cranking if the Uti
248. rge circuit Page 76 PART3 TRANSFER SWITCH Caution After removing the fuse from the bat tery charger wait 5 minutes before proceeding 5 Set VOM to measure DC voltage 6 Connect the negative test lead to Wire 0 at the termi nal strip in the transfer switch Connect the positive test lead to Wire 15B at the terminal strip in the transfer switch a If voltage is present proceed to Step 7 b If voltage is not present proceed to Step 17 7 Connect the positive test lead to Wire 23 at the termi nal strip in the transfer switch a If voltage is present proceed to Step 8 b If voltage is not present set VOM to measure resistance c Remove Wire 23 and Wire 15B going to the transfer relay from the transfer switch terminal strip Connect the meter test leads across Wire 23 and Wire 15B d Transfer coil resistance of approximately 115 ohms should be measured e If coil resistance is not measured remove Wire 23 and Wire 15B from the transfer relay Measure across Terminal A and Terminal B of the transfer relay f If coil resistance is measured repair or replace Wire 23 or Wire 15B between the terminal strip and the transfer relay g If coil resistance is not measured replace trans fer relay and retest 8 Connect the negative test lead to the ground lug in the generator control panel Connect the positive test lead to Wire 23 in the generator control panel at the terminal strip a
249. ry low Some meters are not capable of reading such a low resistance and will simply read CONTINUITY If proper procedures are used the following condi tions can be detected using a VOM A short to ground condition in any Stator or Rotor winding Shorting together of any two parallel Stator windings Shorting together of any two isolated Stator windings An open condition in any Stator or Rotor winding Component testing may require a specific resis tance value or a test for INFINITY or CONTINUITY Infinity is an OPEN condition between two electrical points which would read as no resistance on a VOM Continuity is a closed condition between two electrical points which would be indicated as very low resis tance or ZERO on a VOM ELECTRICAL UNITS AMPERE The rate of electron flow in a circuit is represented by the AMPERE The ampere is the number of elec trons flowing past a given point at a given time One AMPERE is equal to just slightly more than six thou sand million billion electrons per second With alternating current AC the electrons flow first in one direction then reverse and move in the oppo site direction They will repeat this cycle at regular intervals A wave diagram called a sine wave shows that current goes from zero to maximum positive value then reverses and goes from zero to maximum negative value Two reversals of current flow is called a cycle The number of cycle
250. s NOT INCLUDED with the generator A fuel pressure of 10 to 12 inches of water column 0 36 to 0 43 psi to the fuel inlet of the generator must be supplied 1 Turn off the main gas supply if connected 2 Open the roof and remove the door 3 Remove the battery if installed 4 Locate the plastic T handle fuel selector in the poly bag supplied with the generator 5 Locate the selector knob on the air box cover behind the yellow air filter door and power bulge The unit comes from the factory in the NG Natural Gas position Grasping the T handle insert the pin end into the hole GENERAL INFORMATION in the selector knob and pull out to overcome spring pressure and then twist clockwise 90 degrees and allow the selector to return in once aligned with the LP Liquid Propane position 6 Save this tool with the Owner s Manual 7 Install the battery door and close the roof 8 Reverse the procedure to convert back to natural gas Figure 1 Demand Regulator 10 12 14 16 17 AND 20 KW V TWIN ENGINES To reconfigure the fuel system from NG to LP follow these steps NOTE The primary regulator for the propane sup ply is NOT INCLUDED with the generator A fuel pressure of 10 to 12 inches of water column 0 36 to 0 43 psi to the fuel inlet of the generator MUST BE SUPPLIED FUEL SELECTION LEVER IN POSITION FOR NATURAL GAS Figure 2 10 kW GT 530 Inlet Hose Slid Back SECTION 1 4
251. s delivering DC voltage to the starter contactor relay SCR Test 63 verified the operation of the SCR Test 64 verified the operation of the starter contactor SC Another possible cause of an engine won t crank problem is a failure of the starter motor PROCEDURE The battery should have been checked prior to this test and should be fully charged Set a VOM to measure DC voltage 12 VDC Connect the meter positive test lead to the starter contactor stud which has the small jumper wire connected to the starter Connect the common test lead to the starter motor frame Set the AUTO OFF MANUAL Switch to its MANUAL position and observe the meter Meter should indicate battery voltage starter motor should operate and engine should crank RESULTS 1 If battery voltage is indicated on the meter but starter motor did NOT operate remove and bench test the starter motor see following test 2 If battery voltage was indicated and the starter motor tried to engage pinion engaged but engine did NOT crank check for mechanical binding of the engine or rotor If engine turns over slightly go to Test 77 Check and Adjust Valves Page 128 Figure 11 Starter Motor Single Cylinder Engines CHECKING THE PINION When the starter motor is activated the pinion gear should move and engage the flywheel ring gear If the pinion does not move normally i
252. s per second is called frequency and is usually stated in Hertz VOLT The VOLT is the unit used to measure electrical PRESSURE or the difference in electrical potential that causes electrons to flow Very few electrons will flow when voltage is weak More electrons will flow as voltage becomes stronger VOLTAGE may be consid ered to be a state of unbalance and current flow as an attempt to regain balance One volt is the amount of EMF that will cause a current of 1 ampere to flow through 1 ohm of resistance Conductor of a Circuit OHM Unit measuring resistance or opposition to flow AMPERE Unit measuring rate of current flow number of electrons past a given point VOLT Unit measuring force or difference in potential causing current flow Figure 5 Electrical Units SECTION 1 5 TESTING CLEANING AND DRYING OHM The OHM is the unit of RESISTANCE In every circuit there is a natural resistance or opposition to the flow of electrons When an EMF is applied to a complete circuit the electrons are forced to flow in a single direction rather than their free or orbiting pattern The resistance of a conductor depends on a its physical makeup b its cross sectional area c its length and d its temperature As the conductor s tempera ture increases its resistance increases in direct pro portion One 1 ohm of resistance will permit one 1 ampere of current to flow when one 1 volt of electr
253. should be measured a If 120 VAC is not measured verify neutral wire is connected at point E If good replace battery charger then retest b If 120VAC is measured refer to Flow Chart TEST 41 CHECK BATTERY CHARGER OUTPUT VOLTAGE PRE WIRE LOAD CENTER DISCUSSION The battery charger is supplied with 120VAC The out put of the battery charger is 13 4 VDC 2 5A Page 86 PROCEDURE Refer to Figure 11 1 Set VOM to measure DC voltage 2 Remove Wire 0 and Wire 15B from transfer switch terminal strip points F and G 3 Measure across points H and l Battery supply voltage 12 VDC should be measured a If battery voltage is not measured wait 5 minutes and repeat Step 3 b If battery supply voltage is still not available refer to Flow Chart C If battery voltage is measured proceed to Step 4 4 Reconnect Wire 0 and Wire 15B previously removed in Step 2 5 Measure across points and 13 4 VDC should be measured a If 13 4 VDC is not measured replace the battery charger b If 13 4 VDC is measured the charger is working NOTE Battery charger voltage will be higher than battery supply voltage TEST 42 CHECK WIRE 0 AND WIRE15B PRE WIRE LOAD CENTER DISCUSSION In order for the battery charger to function battery supply voltage must be available to the battery charger PROCEDURE Refer to Figure 11 1 Set VOM to measure DC voltage 2 Disconnect Wire 0 and Wire 15B from gener
254. sistance 3 Connect the positive VOM test lead to the posi tive rotor slip ring nearest the rotor bearing and the common test lead to the negative slip ring The meter should read rotor resistance Compare to Specifications in the front of this manual 4 Connect the positive VOM test lead to the positive slip ring and the common test lead to a clean frame ground The meter should indicate INFINITY RESULTS 1 Replace rotor assembly if it is open or shorted 2 rotor tests good perform Insulation Resistance Test in Section 1 5 SLIP RINGS BEARING Figure 9 The Rotor Assembly NOTE Be sure to read Section 1 5 Testing Cleaning and Drying carefully If the rotor tests good try per forming an insulation resistance test Clean and dry the SECTION 2 4 DIAGNOSTIC TESTS rotor if it fails that test Then repeat the test If the rotor fails the second insulation resistance test it should be replaced TEST 14 CHECK AC OUTPUT FREQUENCY DISCUSSION The generator AC frequency is proportional to the operating speed of the rotor The 2 pole rotor will sup ply a 60 Hertz AC frequency at 3600 rpm The unit s AC output voltage is proportional to the AC frequency For example a unit rated 240 volts line to line will supply that rated voltage plus or minus 2 percent at a frequency of 60 Hertz If for any reason the frequency should drop to 30 Hertz the line to line volt
255. sults in low fre quency proceed to Problem 18 Section 4 3 Page 50 TEST 16 CHECK STEPPER MOTOR CONTROL V TWIN ENGINE UNITS PROCEDURE 1 Remove air cleaner cover to access stepper motor 2 Physically grab the throttle and verify the stepper motor linkage and throttle do not bind in any way if any binding is felt repair or replace components as needed Some resistance should be felt as the stepper motor moves through it s travel 3 Physically move the throttle to the closed position by pulling the stepper motor arm towards the idle stop See Figures 11 and 12 for 9 10 kW units or Figure 13 for 12 20 kW Units 4 Place the AUTO OFF MANUAL switch to MANUAL and watch for stepper motor movement It should move to the wide open position during cranking Once the unit starts the stepper motor should move the throttle to a position to maintain 60 Hertz 5 no movement is seen in Step 4 remove the control panel cover Verify the six pin connector on the printed circuit board is seated properly remove the connector and then replace it and test again Verify the switches are correctly set 6 If problem continues the remove six pin connector from the printed circuit board Set Volt meter to measure ohms Carefully measure from the end of the six pin harness as follows NOTE Press down with the meter leads on the connectors exposed terminals do not probe into the connector a Connect one meter lead to Red conne
256. t Wire 85 and Wire 0 from the High Oil Temperature Switch 4 Set a VOM to measure resistance Connect the test leads across the switch terminals The meter should read INFINITY 5 If the switch tested good in Step 4 and a true overtem perature condition has not occurred check Wire 85 for a Page 142 short to ground Remove J1 Connector from the circuit board Set the VOM to measure resistance Connect one test lead to Wire 85 disconnected from High Oil Temperature Switch Connect the other test lead to a clean frame ground INFINITY should be measured TESTING HIGH OIL TEMPERATURE SWITCH 6 Remove the High Oil Temperature Switch 7 Immerse the sensing tip of the switch in oil as shown in Figure 43 along with a suitable thermometer 8 Set a VOM to measure resistance Then connect the VOM test leads across the switch terminal and the switch body The meter should read INFINITY 9 Heat the oil in the container When the thermometer reads approximately 283 305 139 151 C the VOM should indicate CONTINUITY Figure 43 Testing the Oil Temperature Switch RESULTS 1 If the switch fails Step 4 or Steps 8 9 replace the switch 2 If INFINITY was NOT measured in Step 5 repair or replace Wire 85 between the Circuit Board and the High Oil Temperature Switch TEST 77 CHECK AND ADJUST VALVES DISCUSSION Improperly adjusted valves can cause various engine related problems including but not limite
257. t lead to a clean frame ground CONTINUITY should be measured If CONTINUITY is NOT measured repair or replace Wire 0 between the LOP and the ground terminal connection on the engine mount 7 If the switch tests good in Step 5 and oil pressure is good in Step 4 but the unit still shuts down with a LOP fault check Wire 86 for a short to ground Set a VOM to measure resistance Disconnect the J1 Connector from the circuit board Remove Wire 86 from the LOP switch Connect one test lead to Wire 86 Connect the other test lead to a clean frame ground INFINITY should be measured If CONTINUITY is measured repair or replace Wire 86 between the LOP switch and the J1 Connector RESULTS 1 Replace switch if it fails the test TEST 76 CHECK HIGH OIL TEMPERATURE SWITCH DISCUSSION If the temperature switch contacts have failed in a closed position the engine will fault out on OVERTEMP If the unit is in an overheated condition the switch contacts will close at 293 F This will normally occur from inadequate airflow through the generator PROCEDURE 1 Verify that the engine has cooled down engine block is cool to the touch This will allow the contacts in the High Oil Temperature Switch to close 2 Check the installation and area surrounding the generator There should be at least three feet of clear area around the entire unit Make sure that there are no obstructions preventing incoming and outgoing air 3 Disconnec
258. tabilize and warm up for a minute or two 4 Take the meter reading On 12 20 kW units the no load voltage should be between 249 247 VAC On 8 10 kW units the no load voltage should be between 220 235 VAC 5 Shut the engine down and remove the meter test leads RESULTS 1 If Step 4 indicated proper voltages discontinue testing 2 If any other readings were measured refer back to flow chart NOTE Residual voltage may be defined as the voltage that is produced by rotor residual mag netism alone The amount of voltage induced into the stator AC power windings by residual volt age alone will be approximately 2 to 16 volts AC depending on the characteristics of the specific generator If a unit is supplying residual voltage only either excitation current is not reaching the rotor or the rotor windings are open and the exci tation current cannot pass On current units with air cooled engine field boost current flow is available to the rotor only during engine cranking TEST 4 FIXED EXCITATION TEST ROTOR AMP DRAW TEST DISCUSSION Supplying a fixed DC current to the rotor will induce a magnetic field in the rotor With the generator running this should create a proportional voltage output from the stator windings Page 42 PROCEDURE 1 Disconnect Wire 4 from the voltage regulator 3rd terminal from the top See Figure 2 2 Connect a jumper wire to the disconnected Wire 4 and to the 12 volt fused b
259. tch input 8 will change from 0 to 1 6 With the AUTO OFF MANUAL Switch in the OFF position both inputs will read zero RESULTS 1 If controller failed either Step 4 or Step 5 replace the controller assembly 2 If the controller passed Step 4 and Step 5 refer back to flow chart TEST 59 TEST AUTO OPERATIONS DISCUSSION Initial Conditions The generator is in AUTO ready to run and load is being supplied by the utility source When utility fails below 65 of nominal a 10 second optionally programmable line interrupt delay time is started If the utility is still gone when the timer expires the engine will crank and start Once started a five 5 second engine warm up timer will be initiated When the warm up timer expires the control will transfer the load to the generator If the utility power is restored above 7596 of nominal at any time from the initiation of the engine start until the generator is ready to accept a load 5 second warm up time has not elapsed the controller will complete the start cycle and run the generator through its normal cool down cycle however the load will remain on the utility source Page 124 PROCEDURE 1 Simulate a power failure by disconnecting main breaker 2 If the generator does not perform the sequence of events listed in the above discussion replace the printed circuit board RESULTS Refer back to flow chart TEST 60 CHECK 7 5 AMP FUSE
260. ter VOM can be used to test the stator windings for the following faults An open circuit condition A short to ground condition A short circuit between windings Note The resistance of stator windings is very low Some meters will not read such a low resis tance and will simply indicate CONTINUITY Recommended is a high quality digital type meter capable of reading very low resistances GFCI BREAKER Figure 4 Test 7 Test Points PROCEDURE 1 Isolate the generator from the transfer switch by dis connecting the load wires from the main breaker inside the generator 2 Disconnect Stator Leads 22 and 33 from the neutral connection and separate the leads 3 Disconnect and isolate Wires 2 and 6 and Wires 11 and 22 from the voltage regulator 4 Make sure all of the disconnected leads are isolated from each other and are not touching the frame during the test GENERATORS 5 Turn the Main Breaker to the CLOSED position 6 Set a VOM to measure resistance 7 Connect one meter test lead to Wire 11 on the load side of the main breaker Connect the other meter test lead to Wire 22 power winding Note the resistance read ing and compare to the specifications in the front of this manual 8 Connect one test lead to stator lead Wire 44 on the load side of the main breaker Connect the other test lead to stator lead Wire 33 power winding Note the resistance reading and compare to the specifi
261. th air cooled engine Use this section of the manual in conjunction with Section 2 3 Troubleshooting Flow Charts The numbered tests in this section correspond with those of Section 2 3 Test procedures in this section do not require the use of specialized test equipment meters or tools Most tests can be performed with an inexpensive volt ohm milliammeter VOM An AC frequency meter is required where frequency readings must be taken A clamp on ammeter may be used to measure AC loads on the generator Testing and troubleshooting methods covered in this section are not exhaustive We have not attempted to discuss evaluate and advise the home standby ser vice trade of all conceivable ways in which service and trouble diagnosis might be performed We have not undertaken any such broad evaluation Accordingly anyone who uses a test method not recommended herein must first satisfy himself that the procedure or method he has selected will jeopardize neither his nor the product s safety SAFETY Service personnel who work on this equipment must be made aware of the dangers of such equipment Extremely high and dangerous voltages are present that can kill or cause serious injury Gaseous fuels are highly explosive and can be ignited by the slightest spark Engine exhaust gases contain deadly carbon monoxide gas that can cause unconsciousness or even death Contact with moving parts can cause seri ous injury The list of hazards is
262. the flow of electric ity Such a non conducting film usually develops during non operating periods Broken or disconnected wiring can also cause loss of excitation current to the rotor PROCEDURE 1 See Figure 8 Carefully inspect brush wires make sure they are properly and securely connected 2 Wire 0 from the negative brush terminal connects to Wire 0 at the voltage regulator Test this wire for an open condition Remove Wire 0 from the brush assem bly Connect one meter test lead to Wire 0 Connect the other test lead to Wire 0 at the voltage regulator Page 48 CONTINUITY should be measured If INFINITY is measured repair or replace Wire 0 between the brush assembly and the voltage regulator Figure 8 Checking Brushes and Slip Rings 3 Wire 4 from the positive brush terminal connects to Wire 4 at the voltage regulator Test this wire for an open condition Remove Wire 4 from the brush assembly Connect one meter test lead to Wire 4 Connect the other meter test lead to Wire 4 at the voltage regula tor CONTINUITY should be measured If INFINITY is measured repair or replace Wire 4 between the brush assembly and the voltage regulator 4 Connect one meter test lead to Wire 4 Connect the other meter test lead to frame ground INFINITY should be measured If CONTINUITY is measured a short to ground exists on Wire 4 repair or replace Wire 4 between the brush assembly and the voltage regulator
263. the standby closing coil and transfer to Standby occurs 5 When the generator circuit board senses that utility source voltage has been restored above a preset level the board will open the Wire 23 circuit to ground a The transfer relay will de energize its normally closed contacts will close and its normally open contacts will open b When the normally closed relay contacts close utility source voltage is delivered to the utility closing coil to energize that coil c Retransfer back to UTILITY occurs Page 58 NEUTRAL LUG The standby generator is equipped with an UNGROUNDED neutral The neutral lug in the transfer switch is isolated from the switch enclosure MANUAL TRANSFER HANDLE The manual transfer handle is retained in the transfer switch enclosure by means of a wing stud Use the handle to manually actuate the transfer mechanism load contacts to either the UTILITY or STANDBY source side Instructions on use of the manual transfer handle may be found in Part 5 Operational Tests and Adjustments TERMINAL BLOCK During system installation this 3 point terminal block must be properly interconnected with an identically labeled terminal block in the generator control panel assembly Figure 6 Transfer Switch Terminal Block Terminals used on the terminal block are identified as 0 15B and 23 UTILITY 1 AND 2 Int
264. tion 10 1 2 Installation 11 Introduction 11 Selecting A 11 Grounding The Generator 11 The Fuel 11 The Transfer Switch Load Center 11 Power Source And Load 13 System Control Interconnections 13 Natural Gas Fuel Interconnections 13 1 3 Non prepackaged Interconnections 14 Connect a Pre 2008 Load Center Switch To a Current or Future Air Cooled 14 Connect a 2008 And Later Load Center Switch to a Pre 2008 Air Cooled 15 1 4 Preparation Before 5 16 General Lee i ete tuts 16 Fuel 16 Fuel 16 Reconfiguring The Fuel 16 Engine Oil Recommendations 18 1 5 Testing Cleaning and Drying 19 Meters uas eet 19 Leinen eee 19 Measuring AC Voltage 19 Measuring DC 22 4 022422 19 Measuring AC Frequency 19 Measuring
265. tism is sufficient to induce a voltage into the DPE winding that is high enough to turn the voltage regulator on regulator excitation current will be supplied even if field boost has failed Normal AC output voltage will then be supplied If rotor residual magnetism has been lost or is not sufficient to turn the regulator on and field boost has also been lost excitation current will not be supplied to the rotor Generator AC output voltage will then drop to zero or nearly zero 7j Figure 3 Field Boost Test Points PROCEDURE 1 Disconnect Wire 4 from the voltage regulator third terminal from the top see Figure 3 2 Set a to read DC volts 3 Connect the positive test probe to the terminal end of disconnected Wire 4 4 Connect the common VOM test probe to the grounding lug 5 Crank the engine while observing the VOM reading While the engine is cranking the VOM should read approximately 4 6 Volts DC When engine is not crank ing VOM should indicate zero volts see Figure 3 Page 44 6 Reconnect Wire 4 RESULTS 1 If normal field boost voltage is indicated in Step 6 replace the voltage regulator 2 normal field boost voltage is NOT indicated in Step 6 check Wire 4 between regulator and circuit board for open or shorted condition If wire is good replace the circuit board TEST 7 TESTING THE STATOR WITH A VOM 12 20 KW DISCUSSION A Volt OHM Milliammme
266. tive post of a 12 volt battery to relay Terminal and the negative battery post to Relay Terminal B The relay should energize and the VOM should read CONTINUITY 5 Now connect the VOM test leads across Relay Terminals 1 and 7 a Energize the relay and the meter should indicate INFINITY b De energize the relay and the VOM should read CONTINUITY RESULTS 1 Replace transfer relay if it is defective 2 If transfer relay checks good go to Test 31 TEST 30 STANDBY CONTROL CIRCUIT DISCUSSION Refer to Figure 4 The standby coil C2 requires 240 VAC to energize When the transfer relay is energized 240 VAC is applied to standby coil C2 Once energized the coil will pull the transfer switch down to the standby position Once in the standby position limit switch SW3 will open removing AC to standby coil C2 PROCEDURE RESULTS 1 Set VOM to measure AC voltage 2 Verify the transfer switch is up in the utility position 3 Remove Wire E2 from standby coil C2 4 Set the generator AUTO OFF MANUAL switch in the AUTO position Turn off the utility power supply to the transfer switch simulating a utility failure The generator should start and the transfer relay should energize 5 Measure across points A and B 240 VAC should be measured a If 240 VAC is not measured go back to Test 26 b If 240 VAC is measured proceed to Step 6 6 Measure across points C Wire E2 previously removed and B
267. tomatic operation of these transfer switches is controlled by a circuit board housed in the generator control panel ITEM DESCRIPTION GTS LOAD CENTER ENCLOSURE COVER GTS LOAD CTR TRANSFER SWITCH HOME STANDBY COIL UTILITY COIL STANDBY SCREW SCREW LOCK WASHER RELAY PANEL 12VDC 10A 9240VAC LOAD CENTER SCREW RIVET WASHER PLUG HARNESS ADAPTER PLATE SUBPLATE GTS LOAD CENTER U CHANNEL WASHER GROMMET ARM EXTENDER PIN CABLE TIE SELF MOUNTING 4 3LG HARNESS GTS MAIN PANEL W NEUTRAL LUG QUICK DISCONNECT SCREW LUG BLOCK TERMINAL SCREW WITH WASHER SCREW HARNESS LOAD CENTER INT CONN NOT SHOWN FUSEBLOCK FUSE 5A BATTERY CHARGER CIRCUIT BREAKERS HARNESS ENTRY COVER HARNESS GTS EXTERNAL CONNECTION BOX TRANSFER SWITCH ENCLOSURE The W V Type transfer switch enclosure is a NEMA 1 type stands for National Electrical Manufacturer s Association Based on NEMA Standard 250 the NEMA 1 enclosure may be defined as one that is intended for indoor use primarily to provide a degree of protection against contact with the enclosed equipment and where unusual service conditions do not exist ITEMS 32 37 Figure 1 Exploded View of W V Type Transfer Switch Page 56 TRANSFER SWITCH TRANSFER MECHANISM The 2 pole transfer mechanism consists of a pair of moveable LOAD contacts a pair of stationary UTILITY contacts and a pair of stationary STANDBY conta
268. uel Solenoid 2 FS2 and Choke Solenoid CS a Connect one meter test lead to the FS terminal from which Wire 14 was removed Connect the other meter test lead to the ground terminal 16 ohms should be measured If zero resistance was measured replace the Fuel Solenoid b Connect one meter test lead to the FS2 termi nal from which Wire 14 was removed Connect the other meter test lead to the ground terminal 7 ohms should be measured If zero resistance was measured replace Fuel Solenoid 1 c At the CS connector connect one meter test lead to Wire 14 connect the other meter test lead to Wire 90 4 ohms should be measured If zero resistance was measured replace the Choke Solenoid Page 145 SECTION 4 4 DIAGNOSTIC TESTS d coil resistance was measured in CS and FS and FS2 Wire 14 is shorted to ground between J2 connector and CS FS FS2 repair or replace the shorted wire 8 Disconnect Wire 14 from the Fuel Solenoid FS and Choke Solenoid CS a Connect one meter test lead to the FS terminal from which Wire 14 was removed Connect the other meter test lead to the ground terminal 16 ohms should be measured If zero resistance was measured replace the FS b At the CS connector connect one meter test lead to Wire 14 Connect the other meter test lead to Wire 90 4 ohms should be measured If zero resistance was measured replace the Choke Solenoid c If coil resistance was measured in the Choke
269. unit will crank and rest for a preset time limit Then it will stop cranking and the LCD screen or the LED on the generator control panel will light indicating an overcrank failure The AUTO OFF MANUAL switch will need to be set to OFF and then back to AUTO to reset the generator control board NOTE If the fault is not repaired the overcrank feature will continue to activate The system will control the cyclic cranking as follows 16 second crank seven 7 second rest 16 second crank seven 7 second rest followed by three 3 additional cycles of seven 7 second cranks followed by seven 7 second rests CHOKE OPERATION 1 The 990 999cc engines have an electric choke in the air box that is automatically controlled by the electronic control board 2 The 530cc engines have an electric choke on the divider panel air inlet hose that is automatically controlled by the electronic control board 3 The 410cc engines have a choke behind the air box that is automatically controlled by the electronic control board FAILURE TO START This is defined as any of the following occurrences during cranking 1 Not reaching starter dropout within the specified crank cycle Starter dropout is defined as four 4 cycles at 1 500 RPM 1 800 RPM for 8 kW units 2 Reaching starter dropout but then not reaching 2200 RPM within 15 seconds In this case the control board will go into a rest cycle for seven 7 seconds then con tinue the
270. ure insu lation resistance first disconnect and isolate all leads of the winding to be tested Electronic components diodes surge protectors relays voltage regulators etc can be destroyed if subjected to high megger voltages Figure 7 One Type of Hi Pot Tester HI POT TESTER A Hi Pot tester is shown in Figure 7 The model shown is only one of many that are commercially available The tester shown is equipped with a voltage selector switch that permits the power supply voltage to be selected It also mounts a breakdown lamp that will illuminate to indicate an insulation breakdown dur ing the test STATOR INSULATION RESISTANCE TEST 12 20 KW GENERAL Units with air cooled engine are equipped with a dual stator AC power windings and b excitation or DPE winding Insulation tests of the stator consist of a testing all windings to ground b testing between isolated windings and c testing between parallel windings Figure 8 is a pictorial representation of the various stator leads on units with air cooled engines TESTING ALL STATOR WINDINGS TO GROUND 1 Disconnect stator output leads 11 and 44 from the gen erator main line circuit breaker 2 Remove stator output leads 22 and 33 from the neutral connection and separate the two leads 3 Disconnect Wires 11 and 22 from Voltage Regulator Ensure these wires are not touching any other compo nents on the generator 11P lt 115 12 2
271. ures to stabilize Then set the generator main circuit breaker to its ON or closed position A Dita A PROCEED WITH CAUTION GENERATOR POWER VOLTAGE IS NOW SUPPLIED TO THE TRANSFER SWITCH CONTACT WITH LIVE TRANSFER SWITCH PARTS WILL RESULT IN DANGEROUS AND POSSIBLY FATAL ELECTRICAL SHOCK 10 Connect an accurate AC voltmeter and a frequency meter across transfer switch Terminal Lugs E1 and E2 Voltage should be 242 252 volts frequency should read about 61 63 Hertz 7 8 kW units and about 60 Hertz on 10 20 kW units 11 Connect the AC voltmeter test leads across Terminal Lug E1 and neutral then across E2 and neutral In both cases voltage reading should be 121 126 volts AC 12 Set the generator main circuit breaker to its OFF or open position Let the engine run at no load for a few minutes to stabilize internal engine generator temperatures 13 Set the generator AUTO OFF MANUAL switch to OFF The engine should shut down NOTE It is important that you do not proceed until you are certain that generator AC voltage and fre quency are correct and within the stated limits SECTION 5 1 SYSTEM FUNCTIONAL TESTS Generally if both AC frequency and voltage are high or low the engine governor requires adjust ment If frequency is correct but voltage is high or low the generator voltage regulator requires adjustment GENERATOR TESTS UNDER LOAD To test the generator set with electrical loads applied proceed
272. used to charge a capacitor that discharges and charges releasing a voltage that is induced into the rotor If the DPE winding fails only residual magnetism of the rotor will be measured at the Main Breaker Note The resistance of stator windings is very low Some meters will not read such a low resis tance and will simply indicate CONTINUITY Recommended is a high quality digital type meter capable of reading very low resistances Warning The capacitor may need to be discharged before testing A capacitor can be discharged by crossing the terminals with a metal insulated screw driver PROCEDURE 1 Disconnect Wire 2 and Wire 6 from the capacitor 2 Set VOM to measure resistance 3 Connect one meter lead to Wire 2 and connect the other meter lead to Wire 6 a Refer to the specifications in the front of this manual for the correct resistance reading 4 Connect one meter lead to Wire 2 and connect the other meter lead to a clean frame ground INFINITY should be measured 5 Disconnect Wires 11 and 44 from the main line circuit breaker 6 Disconnect Wire 22 and Wire 33 from the neutral connection Note Isolate all main stator leads before proceeding 7 Connect one meter lead to Wire 2 and connect the other meter lead to Wire 11 INFINITY should be measured 8 Repeat Step 7 using Wires 2 and 44 RESULTS 1 Stator winding resistance values is a test of winding conti nuity and resistance If a very high resistance or
273. utility voltage sensing to a circuit board If voltage at the terminals is zero or low standby generator startup and transfer to the Standby source will occur auto matically as controlled by the circuit board A zero or low voltage at these terminals will also prevent retransfer back to the Utility source Page 84 PROCEDURE With utility source voltage available to terminal lugs N1 and N2 use a VOM to test for utility source line to line voltage across terminal locations N1 and N2 terminals Normal line to line utility source voltage should be indicated N2A H e A 2 Figure 10 Transfer Switch Fuse Block RESULTS 1 If voltage reading across the N1 and N2 terminals is zero or low refer to Flow Chart 2 If voltage reading is good refer to Flow Chart TEST 39 CHECK VOLTAGE AT TERMINAL LUGS N1 N2 DISCUSSION If source voltage is not available to N1 N2 terminals automatic startup and transfer to STANDBY will occur when the generator AUTO OFF MANUAL switch is set to AUTO This test will prove that Utility voltage is available to those terminals or is not available DANGER PROCEED WITH CAUTION HIGH AND DANGEROUS VOLTAGES PRESENT AT TERMINAL LUGS N1 N2 CONTACT WITH HIGH VOLTAGE TERMINALS WILL RESULT IN DANGEROUS AND POSSIBLY LETHAL ELECTRICAL S
274. utomatically controlled by the electronic control board 2 The 530cc engines have an electric choke on the divider panel air inlet hose that is automatically controlled by the electronic control board 3 The 410cc engines have a choke behind the air box that is automatically controlled by the electronic control board SECTION 1 8 AUTOMATIC OPERATING PARAMETERS FAILURE TO START This is defined as any of the following occurrences during cranking 1 Not reaching starter dropout within the specified crank cycle Starter dropout is defined as four 4 cycles at 1 000 RPM 2 Reaching starter dropout but then not reaching 2200 RPM within 15 seconds In this case the control board will go into a rest cycle for seven 7 seconds then continue the rest of the crank cycle During a rest cycle the start and fuel outputs are de energized and the magneto output is shorted to ground CRANKING CONDITIONS The following notes apply during cranking cycle 1 Starter motor will not engage within five 5 seconds of the engine shutting down 2 The fuel output will not be energized with the starter 3 The starter and magneto outputs will be energized together 4 Once the starter is energized the control board will begin looking for engine rotation If it does not see an RPM signal within three 3 seconds it will shut down and latch out on RPM sensor loss 5 Once the control board sees an RPM signal it will energize
275. voltage SECTION 3 4 DIAGNOSTIC TESTS Caution After installing the 7 5A fuse and dis connecting Wire 15B from the generator termi nal strip wait 5 minutes before proceeding 27 Connect one meter test lead to Wire 158 Connect the other meter test lead to Wire 0 12 VDC should be measured a If 12 VDC is not measured replace the printed circuit board b If 12 VDC is measured a short exists on Wire 15B or the transfer relay is shorted Repair or replace as needed TEST 29 TEST TRANSFER RELAY TR DISCUSSION In automatic operating mode the transfer relay must be energized by circuit board action or standby source power will not be available to the standby closing coil Without standby source power the closing coil will remain de energized and transfer to Standby will not occur This test will determine if the transfer relay is functioning normally COIL NOMINAL RESISTANCE 120 Ohms Figure 3 Transfer Relay Test Points PROCEDURE 1 See Figure 3 Disconnect all wires from the transfer relay to prevent interaction 2 Seta VOM to its R x 1 scale and zero the meter 3 Connect the VOM test leads across Relay Terminals 6 and 9 with the relay de energized The VOM should read INFINITY CONNECT VOM TEST DESIRED METER READING LEADS ACROSS Page 77 SECTION 3 4 DIAGNOSTIC TESTS 4 Using jumper wires connect the posi
276. y TRANSFER SWITCHES Instructions and information on transfer switches may be found in Part 3 of this manual Page 11 NIML A ii M Iu y LA GENERAL INFORMATION T N T NOILOSNNOD JVNN31X3 OL L NODIS INNO 201943439 30 lt SNDLS3NNU NDILO3NNDJ 310150 WNN31X3 CHOLIAS LINDSID 91 MD vl 8 gt 3Nvd 831511 30 avaa 0319207 1 NULL23NND2 300419373 1 431113 30 aava 1 340812313 1949 1 39835 NIYW 3SNOH 9002 9001 53 19 3 142 319 15 HLIM 401943 39 3709 1119812 1084110 01 9 1119812 3709 904 80 vor 51112419

Generac Power Systems 10 kW LP Portable Generator User Manual

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