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PART 4
DC CONTROL
Air-cooled, Prepackaged
Automatic Standby Generators
4.1 Description and Components ...............................................76
General 76
Terminal Strip / Interconnection Terminal ............................ 76
Transformer (TX) ................................................................. 76
Circuit Board ....................................................................... 76
AUTO-OFF-MANUAL Switch .............................................. 80
15 Amp Fuse ...................................................................... 80
4.2 Operational Analysis .............................................................82
Introduction ......................................................................... 82
Utility Source Voltage Available ........................................... 82
Initial Dropout Of Utility Source Voltage .............................. 84
Utility Voltage Dropout And
Engine Cranking ................................................. 86
Engine Startup And Running .............................................. 88
Initial Transfer To The "Standby" Source ............................. 90
Utility Voltage Restored /
Re-transfer To Utility ............................................ 92
Engine Shutdown .............................................................. 94
4.3 Troubleshooting Flow Charts ................................................96
Problem 8 - Engine Will Not Crank
When Utility Power Source Fails ......................... 96
Problem 9 - Engine Will Not Crank
Problem 10 - Engine Cranks
but Won't Start..................................................... 97
Problem 11 - Engine Starts Hard and
Runs Rough / Lacks Power ................................. 98
Problem 12 - Engine Starts and Runs,
Then Shuts Down ............................................... 99
Problem 13 - No Battery Charge ...................................... 100
Problem 14 - Unit Starts and Transfer Occurs
When Utility Power is Available ........................ 101
Problem 15 - Generator Starts
Standby. Utility Voltage is Present ..................... 101
Problem 16 - 15 Amp Fuse (F1) Blown............................. 102
Problem 17 - Generator Will Not Exercise ........................ 102
Problem 18 - No Low Speed Exercise .............................. 102
4.4 Diagnostic Tests ..................................................................103
Introduction ..................................................................... 103
Test 41 - Check Position Of
AUTO-OFF-MANUAL Switch .......................... 103
Test 42 - Try A Manual Start ........................................... 103
Test 43 - Test AUTO-OFF-MANUAL Switch .................... 103
Voltage .............................................................. 104
Test 45 - Check 15 Amp Fuse .......................................... 105
Test 46 - Check Battery ................................................... 105
Test 47 - Check Wire 56 Voltage ...................................... 106
TABLE OF CONTENTS
PART
TITLE
4.1.
Description and Components
4.2
Operational Analysis
4.3
Troubleshooting Flow Charts
4.4
Diagnostic Tests
(V-twin Only)...................................................... 106
Test 49 - Test Starter Contactor ........................................ 106
Test 50 - Test Starter Motor .............................................. 107
Test 51 - Check Fuel Supply
And Pressure .................................................... 109
Test 52 - Check Circuit Board
Wire 14 Output .................................................. 110
Test 53 - Check Fuel Solenoid .......................................... 111
(V-twins Units Only)........................................... 112
Test 55 - Check For Ignition Spark.................................... 113
Test 56 - Check Spark Plugs ............................................ 114
Test 58 - Check Shutdown Wire ........................................ 115
Test 59 - Check And Adjust
Ignition Magnetos .............................................. 116
And Wire 86 ...................................................... 117
Test 61 - Check High Oil
Temperature Switch .......................................... 118
Test 62 - Check And Adjust Valves ................................... 119
(7 Kw Natural Gas Units Only) .......................... 117
Test 64 - Check Battery Charge Output ............................ 120
Voltage Output .................................................. 118
Test 66 - Check AC Voltage At
Battery Charger................................................. 121
Test 67 - Check Battery Charge
Relay (BCR) ...................................................... 122
Winding Harness............................................... 122
Test 69 - Check Battery Charger Wiring .......................... 123
Test 70 - Check Wire 18 Continuity ................................... 123
Test 71 - Check N1 And N2 Voltage .................................. 123
At The Circuit Board .......................................... 124
Test 73 - Test Set Exercise Switch .................................... 124
Test 75 - Check Battery Voltage Circuit ............................ 124
Test 76 - Check Cranking And
Running Circuits ................................................ 124
Test 77 - Test Exercise Function ....................................... 126
Test 78 - Check Dip Switch Settings ................................. 126
(V-twin Units Only) ............................................ 126
Test 80 - Check LC1 & LC2 Wiring ................................... 126
Primary Wiring .................................................. 127
PAGE#
76
82
96
103
Page 75
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Table of Contents
Troubleshooting
