Guardian 4389 Diagnostic Repair Manual
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Guardian 4389 Diagnostic Repair Manual

Guardian 4389 Diagnostic Repair Manual

Automatic home standby generators
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AIR-COOLED
DIAGNOSTIC
DIAGNOSTIC
REPAIR MANUAL
REPAIR MANUAL
AUTOMATIC HOME STANDBY GENERATORS
Models:
4389, 4758 (6 kW NG, 7 kW LP)
4456, 4759 (12 kW NG, 12 kW LP)
4390, 4760 (13 kW, 15 kW LP)
Visit us online at
www.guardiangenerators.com

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  • Page 1 AIR-COOLED DIAGNOSTIC DIAGNOSTIC REPAIR MANUAL REPAIR MANUAL AUTOMATIC HOME STANDBY GENERATORS Models: 4389, 4758 (6 kW NG, 7 kW LP) 4456, 4759 (12 kW NG, 12 kW LP) 4390, 4760 (13 kW, 15 kW LP) Visit us online at www.guardiangenerators.com...

  • Page 2: Electrical Data

    DIAGNOSTIC REPAIR MANUAL Air-cooled, Prepackaged Automatic Standby Generators 04389, 04758 (6 kW NG, 7 kW LP) 04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 (13 kW NG, 15 kW LP) TABLE OF CONTENTS PART Specifications General Information AC Generators V-Type Prepackaged Transfer Switches DC Control Operational Tests and Adjustments...

  • Page 3: Electrical Formulas

    ELECTRICAL FORMULAS TO FIND KNOWN VALUES KILOWATTS (kW) Volts, Current, Power Factor Volts, Current AMPERES kW, Volts, Power Factor WATTS Volts, Amps, Power Factor NO. OF ROTOR Frequency, RPM POLES FREQUENCY RPM, No. of Rotor Poles Frequency, No. of Rotor Poles kW (required for Motor Horsepower, Efficiency Motor)

  • Page 4: Specifications

    Rated Max. Continuous Power Capacity (Watts*) Rated Voltage Rated Max. Continuous Load Current (Amps) 120 Volts** 240 Volts Main Line Circuit Breaker Phase Number of Rotor Poles Rated AC Frequency Power Factor Battery Requirement Weight Output Sound Level @ 23 ft (7m) at full load Normal Operating Range * Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc.

  • Page 5: Mounting Dimensions

    SPECIFICATIONS MOUNTING DIMENSIONS Page 3...
  • Page 6 SPECIFICATIONS MOUNTING DIMENSIONS Page 4...

  • Page 7: Major Features

    SPECIFICATIONS MAJOR FEATURES 7 kW, Single Cylinder GH-410 Engine 12 kW and 15 kW, V-twin GT-990 Engine Page 5...

  • Page 8: Part 1 General Information

    PART 1 GENERAL INFORMATION Air-cooled, Prepackaged Automatic Standby Generators 04389, 04758 (6 kW NG, 7 kW LP) 04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 (13 kW NG, 15 kW LP) TABLE OF CONTENTS PART Generator Identification Prepackaged Installation Basics Preparation Before Use Testing, Cleaning and Drying Engine-Generator Protective Devices...

  • Page 9: Generator Identification

    SECTION 1.1 GENERATOR IDENTIFICATION INTRODUCTION This Diagnostic Repair Manual has been prepared especially for the purpose of familiarizing service personnel with the testing, troubleshooting and repair of air-cooled, prepackaged automatic standby generators. Every effort has been expended to ensure that information and instructions in the manual are both accurate and current.

  • Page 10: Prepackaged Installation Basics

    PART 1 GENERAL INFORMATION INTRODUCTION Information in this section is provided so that the service technician will have a basic knowledge of installation requirements for prepackaged home standby systems. Problems that arise are often related to poor or unauthorized installation practices. A typical prepackaged home standby electric system is shown in Figure 1 (next page).
  • Page 11 SECTION 1.2 PART 1 GENERAL INFORMATION PREPACKAGED INSTALLATION BASICS Figure 1. Typical Prepackaged Installation Page 1.2-2...

  • Page 12: Power Source And Load Lines

    PART 1 GENERAL INFORMATION POWER SOURCE AND LOAD LINES The utility power supply lines, the standby (generator) 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.

  • Page 13: Preparation Before Use

    SECTION 1.3 PREPARATION BEFORE USE GENERAL The installer must ensure that the home standby generator has been properly installed. The system must be inspected carefully following installation. All applicable codes, standards and regulations pertaining to such installations must be strictly complied with.

  • Page 14: Testing, Cleaning And Drying

    PART 1 GENERAL INFORMATION 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.

  • Page 15: Measuring Ac Frequency

    SECTION 1.4 TESTING, CLEANING AND DRYING 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 readings are obtained. 3.

  • Page 16: Electrical Units

    PART 1 GENERAL INFORMATION If proper procedures are used, the following conditions 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.

  • Page 17: Insulation Resistance

    SECTION 1.4 TESTING, CLEANING AND DRYING 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.
  • Page 18 PART 1 GENERAL INFORMATION TESTING ALL STATOR WINDINGS TO GROUND: 1. Disconnect stator output leads 11 and 44 from the generator main line circuit breaker. 2. Remove stator output leads 22 and 33 from the neutral connection and separate the two leads. 3.

  • Page 19: Cleaning The Generator

    SECTION 1.4 TESTING, CLEANING AND DRYING 5. Insert a large paper clip into Pin Location No. 1 (Wire 77). Connect the red tester probe to the paper clip. Connect the black tester probe to Stator Lead 33. Refer to Steps 5a through 5c of “TESTING ALL STATOR WINDINGS TO GROUND”...

  • Page 20: Engine-Generator Protective Devices

    PART 1 GENERAL INFORMATION GENERAL Standby electric power generators will often run unattended for long periods of time. Such operating parameters as (a) engine oil pressure, (b) engine temperature, (c) engine operating speed, and (d) engine cranking and startup are not monitored by an operator during automatic operation.

  • Page 21: Operating Instructions

    SECTION 1.6 OPERATING INSTRUCTIONS CONTROL PANEL GENERAL: See Figure 1. The front face of this panel mounts (a) an hourmeter, (b) an AUTO-OFF-MANUAL switch ,(c) a 15 amp fuse, (d) a 5 amp fuse, (e) a set exercise switch and (f) the protection systems. HOURMETER: Equipped on some models only.

  • Page 22: Protection Systems

    PART 1 GENERAL INFORMATION THE SET EXERCISE SWITCH: The air-cooled, prepackaged automatic standby generator will start and exercise once every seven (7) days, on a day and at a time of day selected by the owner or operator. The set exercise time switch is provided to select the day and time of day for system exercise.
  • Page 23 SECTION 1.6 OPERATING INSTRUCTIONS 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 UTILITY loads back to the position, proceed as...

  • Page 24: Automatic Operating Parameters

    PART 1 GENERAL INFORMATION INTRODUCTION When the prepackaged generator is installed in conjunction with a prepackaged transfer switch, either manual or automatic operation is possible. Manual transfer and engine startup, as well as manual shutdown and retransfer are covered in Section 1.6. Selection of fully automatic operation is also discussed in that section.
  • Page 25 SECTION 1.7 AUTOMATIC OPERATING PARAMETERS AUTOMATIC OPERATING SEQUENCES CHART SEQ. CONDITION Utility source voltage is available. Utility voltage dropout below 60% of rated voltage occurs. Utility voltage is still below 60% of rated voltage. Utility voltage is still low after 15 seconds.
  • Page 26 PART 2 AC GENERATORS Air-cooled, Prepackaged Automatic Standby Generators 04389, 04758 (6 kW NG, 7 kW LP) 04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 (13 kW NG, 15 kW LP) TABLE OF CONTENTS PART Description and Components Operational Analysis Troubleshooting Flow Charts Diagnostic Tests...

  • Page 27: Section 2.1 Description & Components

    SECTION 2.1 DESCRIPTION & COMPONENTS INTRODUCTION The air-cooled, pre-packaged automatic standby system is an easy to install, fully enclosed and self- sufficient electric power system. It is designed especially for homeowners, 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 automatically, and (b) automatically transfer electrical loads to generator AC output.

  • Page 28: Stator Assembly

    PART 2 AC GENERATORS Figure 2. The 2-Pole Rotor Assembly STATOR ASSEMBLY The stator can houses and retains (a) dual AC power windings, (b) excitation winding, (c) battery charge winding and (d) engine run winding. A total of twelve (12) stator leads are brought out of the stator can as shown in Figure 3.

  • Page 29: Voltage Regulator

    SECTION 2.1 DESCRIPTION & COMPONENTS Figure 5. Excitation Circuit Breaker VOLTAGE REGULATOR: A typical voltage regulator is shown in Figure 6. Unregulated AC output from the stator excitation winding is delivered to the regulator’s DPE terminals, via Wire 2, the excitation circuit breaker, Wire 162, and Wire 6.

  • Page 30: Operational Analysis

    PART 2 AC GENERATORS ROTOR RESIDUAL MAGNETISM The generator revolving field (rotor) may be considered 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.

  • Page 31: Operation

    SECTION 2.2 OPERATIONAL ANALYSIS OPERATION STARTUP: When the engine is started, residual plus field boost magnetism from the rotor induces a voltage into (a) the stator AC power windings, (b) the stator excitation or DPE windings, (c) the stator battery charge, and (d) engine run winding.

  • Page 32: Troubleshooting Flowcharts

    PART 2 AC GENERATORS Use the Flow Charts in conjunction with the detailed instructions in Section 2.4. Test numbers used in the flow charts correspond to the numbered tests in Section 2.4. TROUBLESHOOTING FLOWCHARTS GENERAL The first step in using the flow charts is to correctly identify the problem.
  • Page 33 SECTION 2.3 PART 2 AC GENERATORS TROUBLESHOOTING FLOWCHARTS Page 2.3-2...
  • Page 34 SECTION 2.3 PART 2 AC GENERATORS TROUBLESHOOTING FLOWCHARTS Page 2.3-3...
  • Page 35 SECTION 2.3 PART 2 AC GENERATORS TROUBLESHOOTING FLOWCHARTS Page 2.3-4...

  • Page 36: Diagnostic Tests

    PART 2 AC GENERATORS INTRODUCTION This section is provided to familiarize the service technician with acceptable procedures for the testing and evaluation of various problems that could be encountered on prepackaged standby generators with air-cooled engine. Use this section of the manual in conjunction with Section 2.3, "Troubleshooting Flow Charts".

  • Page 37: Test 2- Check Ac Output Voltage

    SECTION 2.4 DIAGNOSTIC TESTS 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 unit’s DATA PLATE for rated line-to-line and line-to-neutral voltages.

  • Page 38: Test 4- Fixed Excitation Test /Rotor Amp Draw Test

    PART 2 AC GENERATORS 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 39 SECTION 2.4 DIAGNOSTIC TESTS 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 15. 12.Connect one meter test lead to battery positive twelve- volt supply Wire 15, located at the 15A fuse.

  • Page 40: Test 7: Testing The Stator With A Vom

    PART 2 AC GENERATORS Figure 4. Field Boost Test Points TEST 7: TESTING THE STATOR WITH A VOM DISCUSSION: A Volt-OHM-Milliammmeter (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.

  • Page 41: Test 8 - Resistance Check Of Rotor Circuit

    SECTION 2.4 DIAGNOSTIC TESTS TEST WINDINGS FOR A SHORT TO GROUND: 13. Make sure all leads are isolated from each other and are not touching the frame. 14. Set a VOM to its "R x 10,000" or "R x 1K" scale and zero the meter 15.

  • Page 42: Test 9 - Check Brushes And Slip Rings

    PART 2 AC GENERATORS RESULTS: 1. If the resistance reading is correct, check your VOM meters fuse and repeat Test 4. 2. If INFINITY is measured on your VOM meter, go to Test 9. TEST 9 - CHECK BRUSHES AND SLIP RINGS DISCUSSION: The function of the brushes and slip rings is to provide for passage of excitation current from stationary components to the...

  • Page 43: Test 10 - Test Rotor Assembly

    SECTION 2.4 DIAGNOSTIC TESTS 14. Connect one meter test lead to Pin 10 (wire 4) of the C2 connector (male side). Connect the other meter test lead to Wire 4 removed from the Voltage regulator. CONTINUITY should be measured. If INFINITY is measured repair or replace wire 4 between the C2 connector and the voltage regulator.
  • Page 44 PART 2 AC GENERATORS generally proportional to AC frequency. A low or high governor speed will result in a correspondingly low or high AC frequency and voltage output. The governed speed must be adjusted before any attempt to adjust the voltage regulator is made. PROCEDURE (7KW UNITS): 1.

  • Page 45: Test 14 - Check Voltage And Frequency Under Load

    SECTION 2.4 DIAGNOSTIC TESTS TEST 13 - CHECK AND ADJUST VOLTAGE REGULATOR DISCUSSION: For additional information, refer to description and components Page 2.1-3. PROCEDURE: With the frequency between 61-62 Hertz, slowly turn the slotted potentiometer (Figure 12) until line voltage reads 244-252 volts.
  • Page 46 PART 3 V-TYPE PREPACKAGED TRANSFER SWITCHES Air-cooled, Prepackaged Automatic Standby Generators 04389, 04758 (6 kW NG, 7 kW LP) 04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 (13 kW NG, 15 kW LP) TABLE OF CONTENTS PART Description and Components Operational Analysis Troubleshooting Flow Charts Diagnostic Tests...

  • Page 47: Section 3.1 Description & Components

    SECTION 3.1 DESCRIPTION & COMPONENTS GENERAL The prepackaged, V-Type transfer switch is rated 100 amps at 250 volts maximum. It is available in 2- pole configuration only and, for that reason, is useable with 1-phase systems only. Prepackaged transfer switches do not have an intelligence system of their own.

  • Page 48: Transfer Mechanism

    V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES 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 contacts. The load contacts can be connected to the utility contacts by a utility closing coil;...

  • Page 49: Transfer Relay

    SECTION 3.1 DESCRIPTION & COMPONENTS 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.

  • Page 50: Fuse Holder

    V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES Figure 6. Transfer Switch Terminal Block Terminals used on the terminal block are identified as Utility 1 and 2; 23 and 194. UTILITY 1 AND 2: Interconnect with identically labeled terminals in the generator control panel assembly. This is the utility voltage signal to the circuit board.

  • Page 51: Section 3.2 Operational Analysis

    SECTION 3.2 OPERATIONAL ANALYSIS Figure 1 is a schematic and wiring diagram for a typical V-Type transfer switch. Page 3.2-1 OPERATIONAL ANALYSIS Figure 1. Wiring Diagram and Schematic V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES...

  • Page 52: Utility Source Voltage Available

    V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES Figure 2 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 the transfer mechanism, transfer switch is in the UTILITY position and source voltage is available to T1, T2 and customer load.

  • Page 53: Utility Source Voltage Failure

    SECTION 3.2 OPERATIONAL ANALYSIS If utility source voltage should drop below a preset value, the generator circuit board will sense the dropout. That circuit board will then initiate generator cranking and startup after a time delay circuit times out. Figure 3 is a schematic representation of the transfer switch with generator power available, waiting to transfer. Generator voltage available E1, E2.

  • Page 54: Transfer To Standby

    SECTION 3.2 V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES OPERATIONAL ANALYSIS TRANSFER TO STANDBY The generator circuit board delivers 12 volts DC to the transfer relay, via terminal 194 and back to the circuit board via terminal 23. However, circuit board action holds the Wire 23 circuit open and the transfer relay remains de-energized.
  • Page 55 SECTION 3.2 OPERATIONAL ANALYSIS 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 XA1 and XB1 are mechanically actuated to "arm" the circuit for re- transfer to utility power source side.

  • Page 56: Utility Restored

    SECTION 3.2 V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES OPERATIONAL ANALYSIS 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. Figure 6.
  • Page 57 SECTION 3.2 OPERATIONAL ANALYSIS UTILITY RESTORED, TRANSFER SWITCH DE-E E NERGIZED 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 coil (C1), via Wires N1A and N2A, closed Transfer Relay Contacts 1 and 7, and Limit Switch XA1.

  • Page 58: Utility Restored, Retransfer Back To Utility

    SECTION 3.2 V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES OPERATIONAL ANALYSIS 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 XA1 and XB1 are mechanically actuated to arm the circuit for transfer to STANDBY.

  • Page 59: Transfer Switch In Utility

    SECTION 3.2 OPERATIONAL ANALYSIS When the transfer switch returns to the UTILITY side, generator shutdown occurs after approximately one (1) minute. Page 3.2-9 TRANSFER SWITCH IN UTILITY Figure 9. Transfer Switch in UTILITY. V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES...

  • Page 60: Troubleshooting Flowcharts

    SECTION 3.3 V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES TROUBLESHOOTING FLOW CHARTS INTRODUCTION TO TROUBLESHOOTING The first step in troubleshooting is to correctly identify the problem. Once that is done, the cause of the problem can be found by performing the tests in the appropriate flow chart. Test numbers assigned in the flow charts are identical to test numbers in section 3.4, Diagnostic Tests.
  • Page 61 SECTION 3.3 V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES TROUBLESHOOTING FLOW CHARTS Page 3.3-2...

  • Page 62: Section 3.4 Diagnostic Tests

    V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES 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 21- CHECK VOLTAGE AT TERMINAL LUGS E1, E2 DISCUSSION:...
  • Page 63 SECTION 3.4 DIAGNOSTIC TESTS d. Actuate the generator main line circuit breaker to its "On" or "Closed" position. The utility power supply to the transfer switch must be turned OFF. AUTO-OFF-MANUAL e. Set the generator AUTO. (1) The generator should crank and start. (2) When the generator starts, an "engine warm-up timer"...
  • Page 64 V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES TEST 23 - 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"...
  • Page 65 SECTION 3.4 DIAGNOSTIC TESTS DISCUSSION: In automatic operating mode, when utility source voltage 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.
  • Page 66 V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES TEST 26 - CHECK 23 AND 194 WIRING/CONNECTIONS DISCUSSION: An open circuit in the transfer switch control wiring can prevent a transfer action from occurring. In the auto mode, the circuit board supplies +12 VDC to Wire 194.
  • Page 67 SECTION 3.4 DIAGNOSTIC TESTS PROCEDURE: 1. Make sure that all main line circuit breakers in the utility line to the transfer switch are “On” or “Closed.” 2. Test for utility source line-to-line voltage across terminal lugs N1 and N2 (see Figure 1). Normal utility source voltage should be indicated.
  • Page 68 V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES 6. Set the generator main line circuit breaker to its "On" or "Closed" position. 7. Set the generator AUTO-OFF-MANUAL switch to AUTO. a. The generator should crank and start. b. About 15 seconds after engine startup, the transfer relay should energize and transfer to the ’Standby"...
  • Page 69 SECTION 3.4 DIAGNOSTIC TESTS 3. To prevent interaction, disconnect Wire 126 and Wire "A" from the limit switch terminals. 4. Set a VOM to its "R x 1 " scale and zero the meter. 5. Connect the VOM test leads across the two limit switch terminals from which Wires A and 126 were removed.
  • Page 70 V-TYPE PREPACKAGED PART 3 TRANSFER SWITCHES Connect the negative meter lead to the ground lug. INFINITY should be measured. Connect the negative meter lead to Wire 23 at ICT or terminal strip. INFINITY should be measured. Connect the negative meter lead to Wire 194 at ICT or terminal strip.
  • Page 71 SECTION 3.4 DIAGNOSTIC TESTS 12.Connect one test lead to TX terminal 1. Connect the other test lead to TX terminal 7. INFINITY should be measured. 13.Connect one test lead to TX terminal 10. Connect the other test lead t TX terminal 7. INFINITY should measured.

  • Page 72: Part 4 Dc Control

    PART 4 DC CONTROL Air-cooled, Prepackaged Automatic Standby Generators 04389, 04758 (6 kW NG, 7 kW LP) 04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 (13 kW NG, 15 kW LP) TABLE OF CONTENTS PART Description and Components Operational Analysis Troubleshooting Flow Charts Diagnostic Tests...

  • Page 73: Description And Components

    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 Transformer (TX) A Circuit Board.

  • Page 74: Circuit Function

    PART 4 DC CONTROL J1 PIN WIRE CIRCUIT FUNCTION Field boost current to rotor (about 9-10 volts DC). Low oil pressure shutdown. Automatic shutdown occurs when Wire 85 is grounded by loss of oil pressure to the LOP. Switched to ground for Transfer Relay (TR) operation. 12 VDC output from the circuit board for transfer relay, present in AUTO or MANUAL operation.
  • Page 75 SECTION 4.1 DESCRIPTION AND COMPONENTS The circuit board mounts a crank relay (K1) and a run relay (K2, see Figure 4). Crank relay (K1) is energized by circuit board action during both manual and automatic startup to crank the engine. Cranking is accomplished in crank-rest cycles, with the first cycle being 15 seconds on and 15 seconds off.
  • Page 76 SECTION 4.1 PART 4 DC CONTROL DESCRIPTION AND COMPONENTS Figure 6. Control Panel Component Identification Page 4.1-4...
  • Page 77 SECTION 4.2 OPERATIONAL ANALYSIS INTRODUCTION This "Operational Analysis" is intended to familiarize the service technician with the operation of the DC control system on prepackaged units with air-cooled engine. A thorough understanding of how the system works is essential to sound and logical troubleshooting.

  • Page 78: Operational Analysis

    SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS Page 4.2-2...

  • Page 79: Initial Dropout Of Utility Source Voltage

    SECTION 4.2 OPERATIONAL ANALYSIS INITIAL DROPOUT OF UTILITY SOURCE VOLTAGE Refer to Figure 2, above. 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/Utility 2"...
  • Page 80 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS Page 4.2-4...
  • Page 81 SECTION 4.2 OPERATIONAL ANALYSIS UTILITY VOLTAGE DROPOUT AND ENGINE CRANKING After fifteen (15) seconds and when the circuit board’s 15-second timer has timed out, if "Utility" voltage is still below 60 percent of nominal, circuit board action will energize the circuit board’s crank and run relays (K1 and K2) simultaneously.
  • Page 82 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS Page 4.2-6...

  • Page 83: Engine Startup And Running

    SECTION 4.2 OPERATIONAL ANALYSIS ENGINE STARTUP AND RUNNING With the fuel solenoid open and ignition occurring, the engine starts. Engine startup and running may be briefly described as follows: An AC voltage/frequency signal is delivered to the circuit board from the generator engine run winding, via Wire 66A.
  • Page 84 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS Page 4.2-8...

  • Page 85: Initial Transfer To The "Standby" Source

    SECTION 4.2 OPERATIONAL ANALYSIS 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 available to transfer switch terminal lugs E1 and E2 and to the open contacts on the transfer relay.
  • Page 86 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS Page 4.2-10...

  • Page 87: Utility Voltage Restored / Re- Transfer To Utility

    SECTION 4.2 OPERATIONAL ANALYSIS 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 80 percent of the nominal rated voltage, a "retransfer time delay"...
  • Page 88 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS Page 4.2-12...

  • Page 89: Engine Shutdown

    SECTION 4.2 OPERATIONAL ANALYSIS 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 (K2).
  • Page 90 SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS Page 4.2-14...

  • Page 91: Troubleshooting Flowcharts

    SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Page 4.3-1...
  • Page 92 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Page 4.3-2...
  • Page 93 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Page 4.3-3...
  • Page 94 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Page 4.3-4...
  • Page 95 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Page 4.3-5...
  • Page 96 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Page 4.3-6...
  • Page 97 SECTION 4.3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Page 4.3-7...

  • Page 98: Manual Switch

    PART 4 DC CONTROL 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. We could not possibly know of, evaluate and advise the service trade of all conceivable ways in which testing and trouble diagnosis might be performed.
  • Page 99 SECTION 4.4 DIAGNOSTIC TESTS PROCEDURE: Disconnect all wires from switch terminals, to prevent interaction. Then, use a volt-ohm-milliammeter (VOM) to test for continuity across switch terminals as shown in the following chart. Reconnect all wires and verify correct positions when finished. TERMINALS SWITCH POSITION 2 and 3...
  • Page 100 PART 4 DC CONTROL 7. Connect the positive (+) test lead to the AUTO-OFF- MANUAL switch Terminal 4, Wire 17/178. Connect the negative (-) test lead to a clean frame ground. Battery voltage should be measured. 8. Connect the positive (+) test lead to Pin location 11, wire 17 at the J1 connector on the circuit board.
  • Page 101 SECTION 4.4 DIAGNOSTIC TESTS An average reading of 1.260 indicates the battery is 100% charged. 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 battery is 25% charged.
  • Page 102 PART 4 DC CONTROL Figure 5. The Starter Contactor Relay PROCEDURE: 1 Set a VOM to measure DC voltage. 2. Connect the positive (+) meter test lead to the Wire 13 connector. Connect the negative (-) meter test lead to a clean frame ground.
  • Page 103 SECTION 4.4 DIAGNOSTIC TESTS Figure 7. The Starter Contactor (V-twin 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, go on to Test 50.

  • Page 104: Tools For Starter Performance Test

    PART 4 DC CONTROL Figure 10. Check Pinion Gear Operation (V-Twin) Figure 11. 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: A clamp-on ammeter. A tachometer capable of reading up to 10,000 rpm.

  • Page 105: Testing Starter Motor

    SECTION 4.4 DIAGNOSTIC TESTS Figure 14. Test Bracket REMOVE STARTER MOTOR: It is recommended that the starter motor be removed from the engine when testing starter motor performance. Assemble starter to test bracket and clamp test bracket in vise, Figure 15. TESTING STARTER MOTOR: 1.
  • Page 106 PART 4 DC CONTROL 4. A starter motor in good condition will be within the following specifications: Single Cylinder Minimum rpm Maximum Amps Figure 15. Testing Starter Motor Performance TEST 51 - CHECK FUEL SUPPLY AND PRESSURE DISCUSSION: The air-cooled prepackaged generator was factory tested and adjusted using natural gas as a fuel.
  • Page 107 SECTION 4.4 DIAGNOSTIC TESTS TEST 52 - TEST FUEL SOLENOID Note: This test is for fuel regulators equipped with idle circuit port only. See Figure 16. These units have an additional 1/4” fuel hose. DISCUSSION: When the Fuel Solenoid (FS) is energized, gas pressure is available internally to the on demand Fuel Regulator.

  • Page 108: Test 55 - Check For Ignition Spark

    PART 4 DC CONTROL 4. If the engine cranks but does not start and battery voltage was measured in Steps 2, 3 and 4, and CONTINUITY was NOT measured in Step 6, repair or replace Wire 0 between the Control Panel ground connection and the Fuel Solenoid terminal.
  • Page 109 SECTION 4.4 DIAGNOSTIC TESTS 3. Attach the spark plug lead to the spark tester terminal. 4. Crank the engine while observing the spark tester. If spark jumps the tester gap, you may assume the engine ignition system is operating satisfactorily. NOTE: The engine flywheel must rotate at 350 rpm (or higher) to obtain a good test of the solid state ignition system.
  • Page 110 PART 4 DC CONTROL 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. 4. Record the highest reading obtained. 5. Repeat the procedure for the remaining cylinder and record the highest reading.
  • Page 111 SECTION 4.4 DIAGNOSTIC TESTS 4. Tighten both mounting screws. 5. To remove the thickness gauge, rotate the flywheel. 6. Repeat the above procedure for the second magneto. Figure 23. Setting Ignition Magneto (Armature) Air Gap 7. Repeat Test 55 and check for spark across the spark tester gap.
  • Page 112 PART 4 DC CONTROL 12.Now repeat Step 11 with the negative meter test lead connected to Connector “C” (Figure 26). 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.
  • Page 113 SECTION 4.4 DIAGNOSTIC TESTS the switch terminals. a. Set a VOM to its "R x 1" scale and zero the meter. b. Connect the VOM test leads across the switch terminals. With engine shut down, the meter should read CONTINUITY. c.
  • Page 114 PART 4 DC CONTROL 9. Heat the oil in the container. When the thermometer reads approximately 274°-294° F. (134°-146° C.), the VOM should indicate CONTINUITY. 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.
  • Page 115 SECTION 4.4 DIAGNOSTIC TESTS meter to the output lugs of the generator main line circuit breaker. The fuel regulator is fitted with one (7 kW), or two (12 & 15 kW) adjustment screws. While watching the frequency meter, slowly turn the adjustment screw(s) clockwise or counterclockwise one at a time until highest frequency is read on the meter.
  • Page 116 PART 4 DC CONTROL TEST 65 - CHECK TRANSFORMER (TX) VOLTAGE OUTPUT DISCUSSION: The Transformer (TX) is a STEP DOWN type and has two functions. It supplies approximately 16 VAC to the control panel circuit board for utility sensing. It also supplies approximately 16 VAC to the battery charger for trickle charging.
  • Page 117 SECTION 4.4 DIAGNOSTIC TESTS Figure 33. Battery Charge Relay Test Points TEST 67 - CHECK BATTERY CHARGE RELAY (BCR) DISCUSSION: The battery charge relay is used to switch the AC source delivered to the battery charger. When the BCR is de-energized, the Normally Closed (NC) contacts deliver AC power from the transformer.
  • Page 118 PART 4 DC CONTROL Figure 34. C2 Connector Pin Locations (Male Side) 4. Connect one test lead to Connector C2 Pin Location 1 (Wire 77). Connect the other test lead to the end of Wire 77 which was previously removed from the BCR. CONTINUITY should be measured.
  • Page 119 SECTION 4.4 DIAGNOSTIC TESTS RESULTS: 1. If CONTINUITY is not measured in Step 5, repair or replace Wire 66A between Connector C2 and Connector J1 at the circuit board. 2. If CONTINUITY was not measured in Step 6, repair or replace Wire 55 between Connector C2 and the ground terminal.
  • Page 120 PART 4 DC CONTROL 6. Connect one meter test lead to Wire 351 (previously removed from SW2). Connect the other meter test lead to Pin Location J3 (Wire 351). CONTINUITY should be measured. 7. Connect one meter test lead to Wire 351 (previously removed from SW2).
  • Page 121 SECTION 4.4 DIAGNOSTIC TESTS J1-4, Wire 194 CONTINUITY measured, go to Step 4. Average nominal resistance reading: 110-120 ohms. J1-5, Wire 56 CONTINUITY measured, go to Step 5. Average nominal resistance reading V-twin (SCR): 150- 160 ohms, Single Cylinder (SC): 4 ohms. J1-10, Wire 15A CONTINUITY measured, repair or replace...

  • Page 122: Part 5 Operational Tests

    TABLE OF CONTENTS PART TITLE System Functional Tests PART 5 OPERATIONAL TESTS Air-cooled, Prepackaged Automatic Standby Generators Models: 04389, 04758 (6 kW NG, 7 kW LP) 04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 (13 kW NG, 15 kW LP)

  • Page 123: System Functional Tests

    SECTION 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 instructions and information on tags or decals affixed to the generator and transfer switch.

  • Page 124: Generator Tests Under Load

    OPERATIONAL TESTS PART 5 AND ADJUSTMENTS 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).

  • Page 125: Setting The Exercise Timer

    SECTION 5.1 SYSTEM FUNCTIONAL TESTS 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. Voltage should be greater than 230 volts; frequency should be greater than 58 Hertz.
  • Page 126 PART 6 DISASSEMBLY Air-cooled, Prepackaged Automatic Standby Generators 04389, 04758 (6 kW NG, 7 kW LP) 04456, 04759 (12 kW NG, 12 kW LP) 04390, 04760 (13 kW NG, 15 kW LP) TABLE OF CONTENTS PART Major Disassembly Torque Specifications Models: TITLE...

  • Page 127: Major Disassembly

    SECTION 6.1 MAJOR DISASSEMBLY MAJOR DISASSEMBLY STATOR/ROTOR/ENGINE REMOVAL: For stator removal, follow Steps 1-14. For rotor removal, follow Steps 1-15. For Engine removal follow Steps 1-16. 1. Remove door. 2. Set the AUTO-OFF-MANUAL switch to OFF. Disconnect battery cables. Remove Fuse F1. Remove the utility power source to the generator.
  • Page 128 PART 6 DISASSEMBLY Figure 3 13.Remove Muffler: Using a 13mm socket, remove the four muffler hold down bolts. Remove the four exhaust manifold nuts. Remove the muffler and muffler base panel. 14.Stator Removal: Using a 13mm socket, remove the two nuts from the alternator mounting bracket/rubber mounts.

  • Page 129: Front Engine Access

    SECTION 6.1 MAJOR DISASSEMBLY Figure 7. Removing the Rotor 16.Remove Engine: Using a 13mm socket, remove the two engine mount nuts, and ground wires. Remove the engine. 17. Reverse the previous steps to re-assemble. Figure 8. Removing the Engine FRONT ENGINE ACCESS 1.

  • Page 130: Table Of Contents

    0D8500-B WIRING DIAGRAM, 12 & 15 KW HSB 0D8501-B Models: TITLE WIRING DIAGRAM, 7 KW HSB MODEL 4389-0 SCHEMATIC, 7 KW HSB MODEL 4389-0 MODEL 4456-0 & 4390-0 SCHEMATIC, 12 & 15 KW HSB MODEL 4456-0 & 4390-0 WIRING DIAGRAM, 7 KW HSB...

  • Page 131: Model 4389-0

    WIRING DIAGRAM, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4389-0 DRAWING #0D5700-C Page 7.1-1...

  • Page 132: Model 4389-0

    SCHEMATIC, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4389-0 DRAWING #0D5701-C Page 7.1-2...
  • Page 133 WIRING DIAGRAM, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4456-0 & 4390-0 DRAWING #0C7830-C Page7.1-3...
  • Page 134 SCHEMATIC, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4456-0 & 4390-0 DRAWING #0C7836-C Page 7.1-4...

  • Page 135: Model 4389-1

    WIRING DIAGRAM, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4389-1 DRAWING #0D9013-C (1 OF 2) Page 7.1-5...

  • Page 136: Model 4389-1

    WIRING DIAGRAM, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4389-1 DRAWING #0D9013-C (2 OF 2) Page 7.1-6...
  • Page 137 SCHEMATIC, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4389-1 DRAWING #0D9014-B (1 OF 2) Page 7.1-7...
  • Page 138 SCHEMATIC, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4389-1 DRAWING #0D9014-B (2 OF 2) Page 7.1-8...
  • Page 139 WIRING DIAGRAM, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4456-1 & 4390-1 DRAWING #0D8500-B (1 OF 2) Page 7.1-9...
  • Page 140 WIRING DIAGRAM, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4456-1 & 4390-1 DRAWING #0D8500-B (2 OF 2) Page 7.1-10...
  • Page 141 SCHEMATIC, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4456-1 & 4390-1 DRAWING #0D8501-B (1 OF 2) Page 7.1-11...
  • Page 142 SCHEMATIC, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA MODEL 4456-1 & 4390-1 DRAWING #0D8501-B (2 OF 2) Page 7.1-12...
  • Page 143 NOTES PART 7 ELECTRICAL DATA Page 7.1-13...
  • Page 144 NOTES PART 7 ELECTRICAL DATA Page 7.1-14...
  • Page 145 NOTES PART 7 ELECTRICAL DATA Page 7.1-15...
  • Page 147 PO Box 297 Whitewater, WI 53190 www.guardiangenerators.com P/N OE3586/Printed in the USA/1.03/Rev. 3.04...
  • Page 148 XXXXXXXXXXXXXXXXXXXXXXXX PART X XXXXXXXXXXXXXXXXXXXXXXXX RESULTS: 1. Repair engine, or replace defective part(s), or adjust as necessary. 2. If no engine problems are found, go to Test 7. SECTION X.X XXXXXXXXXXXXXXXXXXXXXXXXXXX Page 149...
  • Page 149 SECTION X.X XXXXXXXXXXXXXXXXXXXXXXXXXXX 3.4 provides detailed instructions for performance of each test. XXXXXXXXXXXXXXXXXXXXXXXX PART X XXXXXXXXXXXXXXXXXXXXXXXX...
  • Page 150 XXXXXXXXXXXXXXXXXXXXXXXX PART X XXXXXXXXXXXXXXXXXXXXXXXX PROCEDURE: 1. Set the AUTO-OFF-MANUAL switch (SW1) to MANUAL. The generator should start. Set SW1 back to AUTO. Verify that SW1 has been in AUTO for weekly exercise to function. 2. Verify that DIP Switch 2 (REMOTE NOT AUTO) on the circuit board is set to the OFF position ( Page 1.6-1 3.
  • Page 151 SECTION X.X XXXXXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXX PART X XXXXXXXXXXXXXXXXXXXXXXXX...

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