Generac Power Systems 7 kW NG Repair Manual
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Generac Power Systems 7 kW NG Repair Manual

Standby generator air-cooled product with nexus control, 7 kw ng, 8 kw lp, 9 kw ng, 10 kw lp, 13 kw ng, 14 kw lp, 15 kw ng, 15 kw lp, 16 kw ng, 17 kw lp, 18 kw ng, 20 kw lp
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See also: Owner's Manual , Installation & Owner's Manual
®
DIAGNOSTIC
REPAIR
MANUAL
Air-Cooled Product with Nexus Control
MODELS:
7 kW NG, 8 kW LP
9 kW NG, 10 kW LP
13 kW NG, 14 kW LP
15 kW NG, 15 kW LP
16 kW NG, 17 kW LP
18 kW NG, 20 kW LP
S T A N D B Y G E N E R A T O R S

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Summary of Contents for Generac Power Systems 7 kW NG

  • Page 1 DIAGNOSTIC REPAIR MANUAL Air-Cooled Product with Nexus Control MODELS: 7 kW NG, 8 kW LP 9 kW NG, 10 kW LP 13 kW NG, 14 kW LP 15 kW NG, 15 kW LP 16 kW NG, 17 kW LP 18 kW NG, 20 kW LP...
  • Page 2 Generac tools or tools from other suppliers. with, will result in serious personal injury, including death. Generac could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results After this heading, read instructions that, if not strictly complied of each method.

  • Page 3: Table Of Contents

    Specifications ..............4 Cranking ............... 27 Generator ............... 4 Cranking Conditions ..........27 Engine ..............5 Load Transfer Parameters ........27 Fuel Consumption ........... 5 Utility Restored ............. 28 Mounting Dimensions ..........6 Section 1.8 – General Maintenance ........29 Major Features ............8 Introduction ............
  • Page 4 AC Troubleshooting..........47 Section 3.4 – Diagnostic Tests .......... 76 Test 1 – Check AC Output Voltage ......47 Introduction ............76 Test 3 – Calibrate Voltage ........48 Safety ..............76 Test 4 – Fixed Excitation Test/ Transfer Switch Troubleshooting ......76 Rotor Amp Draw Test .......
  • Page 5 Initial Dropout of Utility Source Voltage ....98 Test 65 – Test Exercise Function ......136 Utility Voltage Failure and Engine Cranking ... 100 Test 66 – Test Cranking and Running Circuits ..137 Engine Startup and Running ........ 102 Test 67 –...

  • Page 6: Specifications

    Specifications GENERATOR Unit 8 kW 10 kW 13 kW 14 kW 15 kW 16 kW 17 kW 20 kW Rated Max. Continuous Power Capacity 7,000 NG 9,000 NG 13,000 NG 13,000 NG 15,000 NG 16,000 NG 16,000 NG 18,000 NG (Watts*) 8,000 LP 10,000 LP...

  • Page 7: Engine

    Specifications ENGINE Model 8 kW 10 kW 13/14/15/16/17 kW 20 kW Type of Engine GH-410 GT-530 GT-990 GT-999 Number of Cylinders Rated Horsepower @ 3,600 rpm 14.8 Displacement 407cc 530cc 992cc 999cc Cylinder Block Aluminum w/Cast Iron Sleeve Valve Arrangement Overhead Valves Ignition System Solid-state w/Magneto...

  • Page 8: Mounting Dimensions

    Specifications MOUNTING DIMENSIONS Figure 1. Page 6...
  • Page 9 Specifications MOUNTING DIMENSIONS Page 7...

  • Page 10: Major Features

    Specifications MAJOR FEATURES Circuit Data Label Control Data Label Control Breaker Dipstick (see sample) Panel Dipstick (see sample) Panel Circuit Breaker Exhaust Exhaust Enclosure Enclosure Air Filter Filter Fuel Inlet Fuel Inlet (back) (back) Fuel Fuel Regulator Regulator Composite Base Oil Filter Battery Compartment Composite Base...

  • Page 11: Part 1 - General Information

    TABLE OF CONTENTS SECTION TITLE PAGE Generator Basics Installation Basics PART 1 Preparation Before Use GENERAL Measuring Electricity Testing, Cleaning and Drying INFORMATION Operating Instructions Automatic Operating Parameters General Maintenance Wireless Remote Control Panel Menu System 1.10 Navigation General Troubleshooting Air-cooled, Automatic 1.11 Guidelines...

  • Page 12: Section 1.1 - Generator Basics

    TEMP - FOR STANDBY SERVICE FOR STANDBY SERVICE NEUTRAL FLOATING NEUTRAL FLOATING Model Number - Serial Number - MAX LOAD UNBALANCE-50% MAX LOAD UNBALANCED - 50% GENERAC POWER SYSTEMS WHITEWATER, WI 53190 U.S.A. Figure 5. Typical Data Plates Page 10...

  • Page 13: Section 1.2 - Installation Basics

    Section 1.2 PART 1 GENERAL INFORMATION Installation Basics Annex A — Explanatory Material INTRODUCTION A4.1.4 (2) Means of demonstrating compliance are by means Information is provided in this section to ensure the service of full-scale fire test or by calculation procedures. technician will have a basic knowledge of installation requirements for home standby systems.
  • Page 14 60” Minimum 60” Recommended Minimum From Ends Generator 18 inches Minimum This drawing supersedes installation instructions in all Generac air-cooled installation and owner’s manuals dated previous to May 26, 2007. Figure 6. NFPA 37 Code Requirements Page 12...
  • Page 15 Section 1.2 PART 1 GENERAL INFORMATION Installation Basics Figure 7. A Typical Home Standby Electric System Page 13...

  • Page 16: Natural Gas Fuel Interconnections

    Section 1.2 PART 1 GENERAL INFORMATION Installation Basics vary considerably, depending on ambient temperatures. In Flexible fuel line should be kept as straight as possible between cold weather, supply pressures may drop to “zero”. In warm connections. The bend radius for flexible fuel lines is nine (9) weather, extremely high gas pressures may be encountered.

  • Page 17: System Control Interconnections

    Section 1.2 PART 1 GENERAL INFORMATION Installation Basics SYSTEM CONTROL INTERCONNECTIONS The system control wiring when properly connected monitors Utility source voltage for drop out below a preset value. When voltage drops below a preset level, the Generator will start in automatic and transfer electrical Loads to the “Standby”...

  • Page 18: Section 1.3 - Preparation Before Use

    Section 1.3 PART 1 GENERAL INFORMATION Preparation Before Use Table 2. Fuel Pipe Sizing INTRODUCTION It is the responsibility of the installer to ensure that the Generator Natural Gas installation was performed properly. A careful inspection Table values are maximum pipe run in feet must be performed when the installation is complete.

  • Page 19: Reconfiguring The Fuel System

    Section 1.3 PART 1 GENERAL INFORMATION Preparation Before Use 10, 13, 14, 15, 16, 17 and 20kw, V-twin Engines RECONFIGURING THE FUEL SYSTEM To reconfigure the fuel system from NG to LP , follow these 8kW, 410cc Engine steps: Note: The primary regulator for the propane supply is NOT To reconfigure the fuel system from NG to LP , follow these steps INCLUDED with the generator.
  • Page 20 Section 1.3 PART 1 GENERAL INFORMATION Preparation Before Use Close the roof. Reverse the procedure to convert back to natural gas. FUEL SELECTION LEVER - “IN” POSITION FOR NATURAL GAS Figure 12. 13, 14, 15, 16, 17, & 20kW, GT-990/GT-999 (Airbox Cover Removed) FUEL SELECTION LEVER - “OUT”...

  • Page 21: Section 1.4 - Measuring Electricity

    Section 1.4 PART 1 GENERAL INFORMATION Measuring Electricity METERS MEASURING AC VOLTAGE Devices used to measure electrical properties are called An accurate AC voltmeter or a VOM may be used to read the meters. Meters are available that allow one to measure (a) AC generator’s AC output voltage.

  • Page 22: Measuring Current

    Section 1.4 PART 1 GENERAL INFORMATION Measuring Electricity In-Line MEASURING CURRENT Alternatively, to read the current flow in AMPERES, an in-line Clamp-On ammeter may be used. Most Digital Volt Ohm Meters (VOM) will have the capability to measure amperes. To read the current flow, in AMPERES, a clamp-on ammeter may be used.

  • Page 23: Electrical Units

    Section 1.4 PART 1 GENERAL INFORMATION Measuring Electricity Component testing may require a specific resistance value or a test for INFINITY or CONTINUITY. Infinity is an OPEN The OHM is the unit of RESISTANCE. In every circuit there condition between two electrical points, which would read as is a natural resistance or opposition to the flow of electrons.

  • Page 24: Section 1.5 - Testing, Cleaning And Drying

    Section 1.5 PART 1 GENERAL INFORMATION Testing, Cleaning and Drying CONFIGURATION A VISUAL INSPECTION PIN # When it becomes necessary to test or troubleshoot an alternator, it is a good practice to complete a thorough visual inspection. Remove the access covers and look closely for any obvious problems.

  • Page 25: Cleaning The Generator

    Section 1.5 PART 1 GENERAL INFORMATION Testing, Cleaning and Drying 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).
  • Page 26 NOTES PART 1 GENERAL INFORMATION Page 24...

  • Page 27: Section 1.6 - Operating Instructions

    Section 1.6 PART 1 GENERAL INFORMATION Operating Instructions CONTROL PANEL USER INTERFACE Exercise Time The Generator is equipped with an internal exercise timer. Once set, the Generator will start and exercise every seven days, on the day of the week and the time of day specified. During this exercise period, the unit runs for approximately 12 minutes and then shuts down.

  • Page 28: To Select Automatic Operation

    Section 1.6 PART 1 GENERAL INFORMATION Operating Instructions “ENTER” key to avoid setting up the exercise time. This MANUAL OPERATION will ensure that when the customer powers up the unit, the controller will prompt the consumer to enter the exercise Transfer to “Standby”...

  • Page 29: Section 1.7 - Automatic Operating Parameters

    Section 1.7 PART 1 GENERAL INFORMATION Automatic Operating Parameters INTRODUCTION CRANKING CONDITIONS When the Generator is installed in conjunction with a transfer The following notes apply during the crank cycle. switch, either manual or automatic operation is possible. Starter motor will not engage within 5 seconds of the See Section 5.1 for the manual transfer and engine startup, engine shutting down manual shutdown and re-transfer, and full automatic operation...

  • Page 30: Utility Restored

    Section 1.7 PART 1 GENERAL INFORMATION Automatic Operating Parameters Auto • Transfer to standby will occur if Utility fails (below 65% of nominal) for 10 consecutive seconds. • A five (5) second engine warm-up timer will initialize. • Transfer back to the “Utility” position if Utility subsequently returns.

  • Page 31: Section 1.8 - General Maintenance

    Section 1.8 PART 1 GENERAL INFORMATION General Maintenance • SAE 30  Above 32º F INTRODUCTION • 10W-30  Between 40ºF and -10ºF Performing proper maintenance on a Generator will ensure • Synthetic 5W-30  10ºF and below proper function during a Utility failure. Once a Generator has failed, it is already too late.

  • Page 32: Corrosion Protection

    Section 1.8 PART 1 GENERAL INFORMATION General Maintenance VALVE CLEARANCE Proper valve clearance is vital to ensuring longevity of the  The exhaust from this product gets extremely hot and engine. After the first 6 months of operation, check the engine remains hot after shutdown.
  • Page 33 Section 1.8 PART 1 GENERAL INFORMATION General Maintenance Table 7. Service Schedule SYSTEM/COMPONENT PROCEDURE FREQUENCY W = Weekly X = Action R = Replace as Necessary M = Monthly Inspect Change Clean * = Notify Dealer if Repair is Y = Yearly Needed.

  • Page 34: Section 1.9 - Wireless Remote

    Section 1.9 PART 1 GENERAL INFORMATION Wireless Remote WIRELESS MONITOR WIRELESS BASIC TROUBLESHOOTING. A small wireless device (about the size of a credit card) Pairing the Generator Transceiver with the Display Unit provides a basic approach to wireless monitoring; however, the device only provides three basic alerts.

  • Page 35: Wireless Advanced Module

    Section 1.9 PART 1 GENERAL INFORMATION Wireless Remote feet but this will be reduced if the signal has to go through walls, floors, etc. NOTE: Some building materials may completely block the passage of the signal. For example: steel beams, metal siding, foil radiant barrier insulation.
  • Page 36 Section 1.9 PART 1 GENERAL INFORMATION Wireless Remote Remove the large enclosure panel from the front of the enclosure. Locate the radio connector under the generator display panel. It is the closest one to you as you are facing the generator;...

  • Page 37: Section 1.10 - Control Panel Menu System Navigation

    Section 1.10 PART 1 GENERAL INFORMATION Nexus Control Panel Menu System Navigation To get to the Main Menu from any other display, press the “Esc” key one or more times. The Main Menu is shown in Figure 27. H i st or y There are four sub-menus, each with its own set of sub-menus.
  • Page 38 Section 1.10 PART 1 GENERAL INFORMATION Nexus Control Panel Menu System Navigation • TEST Output provides a way to see the status or the output relays the control panel uses to make things happen (like S TATUS : S tate Disp lay crank and run and transfer).

  • Page 39: High Temperature

    Section 1.10 PART 1 GENERAL INFORMATION Nexus Control Panel Menu System Navigation Table 8. Digital Inputs and Outputs Position Digital Inputs Digital Outputs Not Used Not Used Low Oil Pressure Not Used High Temperature Not Used Low Fuel Pressure Battery Charger Relay Wiring Error Detect Ignition Not Used...

  • Page 40: Section 1.11 - General Troubleshooting Guidelines

    Section 1.11 PART 1 GENERAL INFORMATION General Troubleshooting Guidelines For instance: If the unit shut down on ALARM - Low Oil INTRODUCTION Pressure, look to see what time it started. If it started at This section familiarizes the service technician with the 8/20/10 14:27:30 (2:27 pm), and shut down on low oil manufacturer recommended procedures for the testing and pressure on 8/30/10 10:15:22 (10:15 am), then the most likely...

  • Page 41: Part 2 - Ac Generators

    TABLE OF CONTENTS SECTION TITLE PAGE Description and Components Operational Analysis PART 2 Troubleshooting Flow Charts Diagnostic Tests AC GENERATORS Air-cooled, Automatic Standby Generators Section 2.1 – Description and Components ....... 40 Section 2.4 – Diagnostic Tests .......... 47 Introduction ............40 Introduction ............

  • Page 42: Section 2.1 - Description And Components

    Section 2.1 PART 2 AC GENERATORS Description and Components CONFIGURATION A INTRODUCTION PIN # The alternator contained within the Generator is a revolving field (rotor) type with a stationary armature (stator), and excitation to the field provided through brushes and slip rings (direct excitation).
  • Page 43 Section 2.1 PART 2 AC GENERATORS Description and Components Voltage Regulator Main Line Circuit Breaker The Automatic Voltage Regulator (AVR) is an integral component The main line circuit breaker protects the Generator against of the main controller. The AVR receives unregulated AC output electrical overload.

  • Page 44: Section 2.2 - Operational Analysis

    Section 2.2 PART 2 AC GENERATORS Operational Analysis ROTOR RESIDUAL MAGNETISM TO LOAD The Generators revolving field (rotor) provides the magnetic MLB = MAIN LINE CIRCUIT BREAKER flux required to induce voltage into the stator and excitation windings (DPE). Some “residual” magnetism is always present SENSING in the rotor.
  • Page 45 Section 2.2 PART 2 AC GENERATORS Operational Analysis 200 VAC STATOR ROTOR MAGNETIC FIELD Figure 45. Increased Excitation Voltage = Increased Magnetic Lines of Flux = Increased AC Output Voltage. The regulated excitation from the regulator is delivered to the rotor windings through Wire 4 and the positive brush and slip ring.

  • Page 46: Section 2.3 - Troubleshooting Flowcharts

    Section 2.3 PART 2 AC GENERATORS Troubleshooting Flow Charts INTRODUCTION 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. The first step in using the flow charts is to identify the correct problem on the following pages. For best results, perform all tests in the exact sequence shown in the flow charts.

  • Page 47: For High Voltage

    Section 2.3 PART 2 AC GENERATORS Troubleshooting Flow Charts Problem 1 – Generator Shuts Down for Under Voltage (Continued) TEST 4 – PERFORM TEST 7 – FIXED EXCITATION / TEST STATOR ROTOR AMP DRAW GOOD PERFORM STATOR TEST 10 – INSULATION TEST ROTOR RESISTANCE TEST...

  • Page 48: Excessively When Loads Are Applied

    Section 2.3 PART 2 AC GENERATORS Troubleshooting Flow Charts Problem 3 – Voltage and Frequency Drop Excessively When Loads Are Applied IF RECONFIGURED TO LP GAS, TEST 14 - CHECK TEST 15 - CHECK VERIFY THAT PROPER BOTH VOLTAGE AND FOR OVERLOAD OVERLOADED PROCEDURE WAS FOLLOWED...

  • Page 49: Section 2.4 - Diagnostic Tests

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests INTRODUCTION TEST 1 – CHECK AC OUTPUT VOLTAGE This section familiarizes the service technician with acceptable Discussion procedure for the testing and evaluation of various problems that can occur on the standby generators with air-cooled Use a Volt-Ohm-Milliammeter (VOM) to check the Generators engines.

  • Page 50: Test 3 - Calibrate Voltage

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests If the VOM indicated any other readings the voltage is Note: The Calibration Setting will reset to being a password protected option after the controller is left idle. BAD. Refer back to the flow chart. Note: “Residual”...
  • Page 51 Section 2.4 PART 2 AC GENERATORS Diagnostic Tests Required Tools Locate and disconnect the J5 connector from the controller. • A Volt-Ohm-Meter (VOM) equipped with a MIN/MAX feature • Meter test leads that are capable of measuring voltage inside Set VOM to measure AC voltage. a connector without damaging the socket.
  • Page 52 Section 2.4 PART 2 AC GENERATORS Diagnostic Tests controller; leave AUTO-OFF-MANUAL switch in the OFF position. 63 VAC Results Using the values recorded in the above procedure, PIN 5 compare the results to Table 10 “Results – Fixed Excitation Test/Rotor Amp Draw Test”. Determine the appropriate lettered column to use and refer back to the 14 13 12 11 PIN 14...

  • Page 53: Test 5 - Test Sensing Circuitwires 11 And 44

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests Table 10. TEST 4 Results – Fixed Excitation Test/Rotor Amp Draw Test (8-20kW) Results: Size Zero or Voltage Results Above 50 Above 50 Below 50 Below 50 Below 50 Above 50 Below 50 Residual Wire 2 &...

  • Page 54: Test 6 - Test Excitation Windingcircuit 2 And 6

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests Connect one-meter test lead to C1 Pin 1 (Wire 44) and Procedure the other meter test lead to the NEUTRAL connection, Remove the 7.5 amp fuse from the control panel. measure and record the resistance. Remove the controller and the cover to expose the lower harness connections.
  • Page 55 Section 2.4 PART 2 AC GENERATORS Diagnostic Tests Procedure: Resistance Test Test Windings for a Short to Ground Disconnect Wires 11 and 44 from the main line circuit Make sure all stator leads are isolated from each other breaker (MLCB). and are not touching the frame.

  • Page 56: Test 8 - Resistance Check Of Rotor Circuit

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests Note: Stator winding resistance values are very low If testing C1 Configuration A, locate and disconnect the and some VOM’s will not read such a low resistance, bulkhead C1 connector. If testing C1 Configuration B, and will simply indicate CONTINUITY.

  • Page 57: Test 10 - Test Rotor Assembly

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests Procedure • If the VOM indicated CONTINUITY, repair or replace Wire 4 between the positive slip ring and C1 Pin 6 (Configuration A) 1. Disassemble the Generator until the brushes and or J5 Pin 13 ( Configuration B). slip rings are exposed.

  • Page 58: Test 12 - Check Stepper Motor Control

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests Tools Required STEPPER MOTOR • A meter that is capable of measuring AC frequency Procedure See Figure 46, connect an accurate AC frequency meter across the Wires 11 and 44 Terminals of the generator main line circuit breaker (MLCB) Set the AUTO-OFF-MANUAL to the MANUAL position.

  • Page 59: Test 14 - Check Voltage And Frequency Under Load

    Section 2.4 PART 2 AC GENERATORS Diagnostic Tests Table 15. Stepper Motor Testing Apply electrical loads to the Generator equal to the rated capacity of the unit. Measure and record the frequency Test Point A Test Point B Resistance Value and the voltage.
  • Page 60 NOTES PART 2 AC GENERATORS Page 58...

  • Page 61: Part 3 - Transfer Switch

    TABLE OF CONTENTS SECTION TITLE PAGE Description and Components Operational Analysis Troubleshooting Flow Charts PART 3 Diagnostic Tests TRANSFER SWITCH Air-cooled, Automatic Standby Generators Section 3.1 – Description and Components ....... 60 Problem 8 – Unit Starts and Transfers When Utility Power is Available ....

  • Page 62: Section 3.1 - Description And Components

    Section 3.1 PART 3 TRANSFER SWITCH Description and Components INTRODUCTION ENCLOSURE The “V-Type” CONTACTOR is available in 100 and 200 Amp The transfer switch enclosure is a National Electrical ratings at 250 volts maximum. It is available in 2-pole Manufacture’s Association (NEMA) type 1. Based on NEMA configuration (single phase only).

  • Page 63: Transfer Switch Contactor

    Section 3.1 PART 3 TRANSFER SWITCH Description and Components Standby Closing Coil C2 TRANSFER SWITCH CONTACTOR The standby closing coil (C2) utilizes rectified Standby source The basic 2-pole CONTACTOR consists of a pair of moveable power to actuate the LOAD contacts to their “Standby” position. LOAD contacts, a pair of stationary UTILITY contacts, and Energizing the coil moves the LOAD contacts to an “over a pair of stationary STANDBY contacts.

  • Page 64: Neutral Lug

    Section 3.1 PART 3 TRANSFER SWITCH Description and Components b. The controller’s logic holds the Wire 23 circuit open b. When the normally closed relay contacts close, utility to ground (Normally Open circuit) and the relay is source voltage is delivered to the utility closing coil to de-energized.

  • Page 65: Fuse Holder

    Section 3.1 PART 3 TRANSFER SWITCH Description and Components Control 194, 23 Wire 194 and 23 provide control of the transfer relay by the controller. Wire 194 provides continuous DC voltage to the transfer switch. Wire 23 is held open from ground by the controller’s logic until a Utility failure is “sensed”.

  • Page 66: Section 3.2 - Operational Analysis

    Section 3.2 PART 3 TRANSFER SWITCH Operational Analysis UTILITY SOURCE VOLTAGE AVAILABLE Figure 66 is a schematic representation of the transfer switch with Utility source power available. The circuit condition is briefly described as follows: • Utility source voltage is available to terminal lugs N1 and N2 of the CONTACTOR; the transfer switch is in the “Utility” position and Utility voltage is available to T1 and T2, customer load.

  • Page 67: Utility Source Voltage Failure

    Section 3.2 PART 3 TRANSFER SWITCH Operational Analysis UTILITY SOURCE VOLTAGE FAILURE If Utility source voltage should drop below 65% of nominal voltage for ten seconds, the controller will initiate engine start. After the generator starts a five second engine warm-up timer is initiated. During this warm-up the generator is running at rated frequency and voltage.

  • Page 68: Transferring To Standby

    Section 3.2 PART 3 TRANSFER SWITCH Operational Analysis TRANSFERRING TO STANDBY 12 VDC is delivered to the transfer relay through Wire 194 and back to the controller through Wire 23. When the five second engine warm-up timer expires, the controller will take wire 23 to ground which will energize the Transfer Relay. The N.O. and N.C. relay contacts will change states.

  • Page 69: Transferred To Standby

    Section 3.2 PART 3 TRANSFER SWITCH Operational Analysis TRANSFERRED TO STANDBY When the standby coil (C2) energizes it pulls the CONTACTOR to an “over center” position towards the “Standby” position, the transfer switch mechanically snaps to that position. Upon closure of the main contacts to the “Standby” position limit switches SW2 and SW3 mechanically actuate to “arm”...

  • Page 70: Utility Restored

    Section 3.2 PART 3 TRANSFER SWITCH Operational Analysis UTILITY RESTORED Utility voltage is restored and available to terminals N1 and N2. The Utility voltage is “sensed” by the controller and, if it is above 75% of nominal for 15 consecutive seconds, a transfer back to Utility will occur. EXTERNAL CONNECTION BOX CONTROL TRANSFER...

  • Page 71: Utility Restored, Transferring Back To Utility

    Section 3.2 PART 3 TRANSFER SWITCH Operational Analysis UTILITY RESTORED, TRANSFERRING BACK TO UTILITY After the 15 second return to utility delay expires, the controller will open the Wire 23 circuit from ground. The transfer relay (TR1) de-energizes, the N.O. and N.C. contacts change state. Utility voltage is delivered to the utility closing coil (C1) through Wires N1A and N2A, the normally closed contacts (1 and 7) , Wire 126, and limit switch (SW2) .

  • Page 72: Utility Restored, Transferred Back To Utility

    Section 3.2 PART 3 TRANSFER SWITCH Operational Analysis UTILITY RESTORED, TRANSFERRED BACK TO UTILITY As the utility closing coil pulls the transfer switch to an “over center” position, the switch mechanically snaps to the “Utility” position. Upon closure of the contacts to Utility, the limit switches (SW2 and SW3) mechanically actuate to “arm” the circuit for the next transfer to Standby.

  • Page 73: Transferred Back To Utility, Generator Shutdown

    Section 3.2 PART 3 TRANSFER SWITCH Operational Analysis TRANSFERRED BACK TO UTILITY, GENERATOR SHUTDOWN When the transfer switch returns to the “Utility” position the controller will shut the generator down after the one minute engine cool- down timer expires. EXTERNAL CONNECTION BOX CONTROL TRANSFER TS TO...
  • Page 74 NOTES PART 3 TRANSFER SWITCH Page 72...

  • Page 75: Section 3.3 - Troubleshooting Flowcharts

    Section 3.3 PART 3 TRANSFER SWITCH Troubleshooting Flowcharts INTRODUCTION Use the “Flow Charts” in conjunction with the detailed instructions in Section 3.4. Test numbers used in the flow charts correspond to the numbered tests in Section 3.4. The first step in using the flow charts is to identify the correct problem on the following pages. For best results, perform all tests in the exact sequence shown in the flow charts.

  • Page 76: Standby During Exercise Or In Manual Mode With Utility Available

    Section 3.3 PART 3 TRANSFER SWITCH Troubleshooting Flowcharts Problem 7 – In Automatic Mode, Generator Starts When Loss of Utility Occurs, Generator Shuts Down When Utility Returns But There Is No Retransfer To Utility Power Generator Transfers to Standby During Excercise or in Manual Mode TEST 21 –...

  • Page 77: Problem 9 - Blown F1 Or F2 Fuse

    Section 3.3 PART 3 TRANSFER SWITCH Troubleshooting Flowcharts Problem 9 – Blown F1 or F2 Fuse TEST 28 – CHECK TEST 32 – CHECK INSPECT/REPLACE GOOD N1 & N2 WIRING FUSE F1 & F2 CONTROLLER GOOD FINISH REPAIR OR REPLACE WIRING Problem 10 –...

  • Page 78: Section 3.4 - Diagnostic Tests

    Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests INTRODUCTION TEST 20 – CHECK VOLTAGE AT TERMINAL This section familiarizes the service technician with acceptable LUGS E1 AND E2 procedure for the testing and evaluation of various problems that can occur on pre-packaged transfer switches. Use this Discussion section in conjunction with Section 3.3, “Troubleshooting Flow In automatic mode to transfer to the “Standby”...

  • Page 79: Test 21 - Check Manual Transfer

    Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests LOAD CONNECTED TO LOAD CONNECTED TO UTILITY POWER SOURCE STANDBY POWER SOURCE TRANSFER SWITCH OPERATING LEVER MANUAL TRANSFER MANUAL HANDLE TRANSFER HANDLE TRANSFER SWITCH OPERATING LEVER Figure 74. Manual Transfer Switch Operation Results Set the AUTO-OFF-MANUAL switch to the OFF position.

  • Page 80: Test 22 - Check 23 And 194 Circuit

    Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests b. If coil resistance is not measured, remove Wire 23 and TEST 22 – CHECK 23 AND 194 CIRCUIT Wire 194 from the TR1 relay. Measure across terminal A and terminal B of the TR1 relay. Discussion c.

  • Page 81: Test 23 - Test Transfer Relay

    Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests a. If voltage is present, repair Wire 194 between the Procedure Generator terminal strip and transfer switch terminal Disconnect all wires from the TR1 relay to prevent strip. interaction. See Figure 75. b.
  • Page 82 Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests Figure 76. Standby Control Circuit Test Points Page 80...

  • Page 83: Test 25 - Check Wire 23

    Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests Measure across points A and B, the VOM should indicate a. If 0 VDC was measured, proceed to Step 4. 240 VAC. b. If 12 VDC was measured, proceed to Step 13. a.
  • Page 84 Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests Figure 78. Utility Control Circuit Test Points Page 82...

  • Page 85: Test 26 - Utility Control Circuit

    Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests a. If transfer to Utility occurs, the transfer relay (TR1) was energized preventing a re-transfer to Utility. Proceed to Test 25 “Check Wire 23 Circuit”. b. If transfer to Utility does NOT occur, proceed to Step 7. Remove Wire N2A from the utility coil (C1).

  • Page 86: Test 28 - Check Fuses F1 And F2

    Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests CONTACTOR changes position, the limit switches contacts Procedure change state to become OPEN. On the generator panel, set the AUTO-OFF-MANUAL switch to the OFF position. Procedure Disconnect Utility from the transfer switch. With the AUTO-OFF-MANUAL switch in the OFF position, the generator main circuit breaker “Open”, and Utility Voltage Remove fuse F1 and F2 from the fuse holder.

  • Page 87: Test 32 - Check N1 And N2 Wiring

    Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests Set VOM to measure resistance. Connect the positive meter test lead to Wire N1 at the terminal block in the control panel. LINE SIDE a. Connect the negative meter lead to the ground lug. INFINITY should be measured.

  • Page 88: Test 34 - Check Utility Sensing Voltage

    Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests Procedure With utility source voltage available to terminal lugs N1 and N2, 240 VAC use a VOM to test for utility source line-to-line voltage across terminal locations N1 and N2 terminals. Normal line-to-line TEST POINTS utility source voltage should be indicated.
  • Page 89 Section 3.4 PART 3 TRANSFER SWITCH Diagnostic Tests d. Connect one meter test lead to T1 on the customer connection in the Generator and the other meter test lead to Wire N1. Measure and record the resistance. e. Connect one meter test lead to T1 on the customer connection in the Generator and the other meter test lead to Wire N2.
  • Page 90 NOTES PART 3 TRANSFER SWITCH Page 88...

  • Page 91: Part 4 - Engine/Dc Control

    TABLE OF CONTENTS SECTION TITLE PAGE Description and Components Engine Protective Devices PART 4 Operational Analysis ENGINE/DC Troubleshooting Flowcharts Diagnostic Tests CONTROL Air-cooled, Automatic Standby Generators Section 4.1 – Description and Components ...............90 Engine/DC Troubleshooting ..............115 Introduction ..................... 90 Test 40 –...

  • Page 92: Section 4.1 - Description And Components

    Section 4.1 PART 4 ENGINE/DC CONTROL Description and Components • Automatic voltage regulation (See Section 2.1 “Descriptions INTRODUCTION and Components) This section will familiarize the reader with the various • Starts and exercises the generator once every seven days. components that make up the Engine and DC Control • Automatic engine shutdown in the event of low oil pressure, systems.

  • Page 93: 7.5 Amp Fuse

    Section 4.1 PART 4 ENGINE/DC CONTROL Description and Components connection through a fuse (F3) in the transfer switch. This 120 7.5 AMP FUSE VAC source must be connected to the Generator in order to The fuse protects the controller against excessive current. If operate the charger.

  • Page 94: Common Alarm Relay

    Section 4.1 PART 4 ENGINE/DC CONTROL Description and Components Table 19. J4 Connector Pin Descriptions TO CONTROLLER WIRE CIRCUIT FUNCTION TO STARTER Switched to ground for choke solenoid operation Common Ground (DC) 12 VDC un-fused for the controller Grounded by the controller to turn on System Ready (Green) LED Grounded by the controller to turn on Alarm (Red) Grounded by the controller to turn on the...

  • Page 95: Menu System Navigation

    Section 4.1 PART 4 ENGINE/DC CONTROL Description and Components 240 VAC Generator Voltage Sensing 240 VAC Generator Voltage Sensing DC Field Excitation Ground DC (+) Field Excitation DPE Winding (AC Excitation power) MENU SYSTEM NAVIGATION To get to the MENU, use the “Esc” key from any page. It may 14 13 12 11 need to be pressed several times before getting to the menu page.

  • Page 96: Section 4.2 - Engine Protective Devices

    Section 4.2 PART 4 ENGINE/DC CONTROL Engine Protective Devices INTRODUCTION OVERSPEED Standby power generators will often run unattended for long During engine cranking and operation the controller receives periods. Such operating parameters as (a) battery voltage, AC voltage and frequency signals from the ignition magneto (b) engine oil pressure, (c) engine temperature, (d) engine via Wire 18.

  • Page 97: Under-Frequency

    Section 4.2 PART 4 ENGINE/DC CONTROL Engine Protective Devices The 410cc engines have a choke behind the air box that is UNDER-FREQUENCY automatically controlled by the electronic control board. After starting, if the generator stays under a set frequency for more than 30 seconds, it will shutdown.

  • Page 98: Section 4.3 - Operational Analysis

    Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis INTRODUCTION The “Operational Analysis” is intended to familiarize the service technician with the operation of the DC and AC control system. A through understanding of how the system works is essential to sound and logical troubleshooting. The control system illustrations on the following pages represent a 17kW unit.
  • Page 99 Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis POWER WINDING 240 VAC GENERATOR STATOR OUTPUT POWER 11 44 WINDING ROTOR EXCITATION OPTIONAL WINDING BATTERY WARMER 240Vac NEUTRAL CONNECT PIN # OPTIONAL OIL WARMER 240Vac 11 44 CONNECT 240 VAC UTILITY INPUT 120 VAC LOAD SUPPLY...

  • Page 100: Initial Dropout Of Utility Source Voltage

    Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis INITIAL DROPOUT OF UTILITY SOURCE VOLTAGE Refer to Figure 96. Should a Utility power failure occur, circuit condition may be briefly described as follows: • The controller continually monitors for acceptable Utility voltage via N1 and N2. Should Utility voltage drop below approximately 65% of the nominal source voltage, a programmable timer on the controller will turn on.
  • Page 101 Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis POWER WINDING 240 VAC GENERATOR STATOR OUTPUT POWER 11 44 WINDING ROTOR EXCITATION OPTIONAL WINDING BATTERY WARMER 240Vac NEUTRAL CONNECT PIN # OPTIONAL OIL WARMER 240Vac 11 44 CONNECT 240 VAC UTILITY INPUT 120 VAC LOAD SUPPLY...

  • Page 102: Utility Voltage Failure And Engine Cranking

    Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis UTILITY VOLTAGE FAILURE AND ENGINE CRANKING • After the controller’s 10-second timer has timed out, if Utility voltage is still below 65% of nominal, the controllers logic will energize the internal crank relay followed by the internal run relay. • When the internal crank relay energizes 12 VDC is delivered to the starter contactor relay (SCR) via Wire 56.
  • Page 103 Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis POWER WINDING 240 VAC GENERATOR STATOR OUTPUT POWER 11 44 WINDING ROTOR EXCITATION OPTIONAL WINDING BATTERY WARMER 240Vac NEUTRAL CONNECT PIN # OPTIONAL OIL WARMER 240Vac 11 44 CONNECT 240 VAC UTILITY INPUT 120 VAC LOAD SUPPLY...

  • Page 104: Engine Startup And Running

    Section 4.3 PART 4 ENGINE/DC CONTROL 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: • The ignition magnetos deliver a speed reference signal to the controller via Wire 18. Once the controller determines that the engine is running, the controller (a) terminates cranking, (b) continuously energizes the choke solenoid (open position), and (c) turns on an “engine warm-up timer”.
  • Page 105 Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis POWER WINDING 240 VAC GENERATOR STATOR OUTPUT POWER 11 44 WINDING ROTOR EXCITATION OPTIONAL WINDING BATTERY WARMER 240Vac NEUTRAL CONNECT PIN # OPTIONAL OIL WARMER 240Vac 11 44 CONNECT 240 VAC UTILITY INPUT 120 VAC LOAD SUPPLY...

  • Page 106: Transfer To Standby

    Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis TRANSFER TO STANDBY In Figure 102 the Generator is running, the controllers “engine warm-up” timer has expired and generator AC output is available to the transfer switch Terminal Lugs E1 and E2 and to the open contacts on the transfer relay. Transfer to Standby may be briefly described as follows: • 12 VDC is delivered to the transfer relay coil (TR1 - Terminal A) via Wire 194.
  • Page 107 Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis POWER WINDING 240 VAC GENERATOR STATOR OUTPUT POWER 11 44 WINDING ROTOR EXCITATION OPTIONAL WINDING BATTERY WARMER 240Vac NEUTRAL CONNECT PIN # OPTIONAL OIL WARMER 240Vac 11 44 CONNECT 240 VAC UTILITY INPUT 120 VAC LOAD SUPPLY...

  • Page 108: Utility Voltage Restored And Re-Transfer To Utility

    Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis UTILITY VOLTAGE RESTORED AND RE-TRANSFER TO UTILITY The Load is powered by Generator voltage. On restoration of Utility voltage, the following events will occur: • On restoration of Utility voltage above 75% of the nominal rated voltage, a “re-transfer time delay” on the controller starts timing. The timer will run for 15 seconds.
  • Page 109 Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis POWER WINDING 240 VAC GENERATOR STATOR OUTPUT POWER 11 44 WINDING ROTOR EXCITATION OPTIONAL WINDING BATTERY WARMER 240Vac NEUTRAL CONNECT PIN # OPTIONAL OIL WARMER 240Vac 11 44 CONNECT 240 VAC UTILITY INPUT 120 VAC LOAD SUPPLY...

  • Page 110: Engine Shutdown

    Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis ENGINE SHUTDOWN Following re-transfer back to the Utility source an “engine cool-down timer” on the controller starts timing. When the timer has expired (approximately one minute), the controller will de-energize the internal run relay removing fuel from the engine. The following events will occur: • The DC circuit to Wire 14 and the fuel solenoid will open.
  • Page 111 Section 4.3 PART 4 ENGINE/DC CONTROL Operational Analysis POWER WINDING 240 VAC GENERATOR STATOR OUTPUT POWER 11 44 WINDING ROTOR EXCITATION OPTIONAL WINDING BATTERY WARMER 240Vac NEUTRAL CONNECT PIN # OPTIONAL OIL WARMER 240Vac 11 44 CONNECT 240 VAC UTILITY INPUT 120 VAC LOAD SUPPLY...

  • Page 112: Section 4.4 - Troubleshooting Flowcharts

    Section 4.4 PART 4 ENGINE/DC CONTROL Troubleshooting Flowcharts Problem 14 – Engine Will Not Crank When Utility Power Source Fails TEST 40 – CHECK TEST 41 – TRY A SWITCH IS VERIFY UTILITY POSITION OF MANUAL START IN “AUTO” SOURCE IS “OFF” AUTO-OFF-MANUAL SWITCH ENGINE DOES...

  • Page 113: Problem 16 - Engine Cranks But Will Not Start

    Section 4.4 PART 4 ENGINE/DC CONTROL Troubleshooting Flowcharts Problem 16 – Engine Cranks but Will Not Start TEST 50 – CHECK TEST 51 – CHECK TEST 52 – CHECK GOOD GOOD FUEL SUPPLY AND CONTROLLER FUEL SOLENOID PRESSURE WIRE 14 OUTPUT GOOD REPLACE FUEL SOLENOID FIND AND CORRECT...

  • Page 114: Problem 17 - Engine Starts Hard And Runs

    Section 4.4 PART 4 ENGINE/DC CONTROL Troubleshooting Flowcharts Problem 17 – Engine Starts Hard and Runs Rough / Lacks Power / Backfires IF RECONFIGURED TO LP GAS, TEST 50 – CHECK CHECK AIR FILTER - VERIFY THAT PROPER FUEL SUPPLY AND GOOD GOOD REPLACE AS NEEDED...

  • Page 115: Problem 18 - Shutdown Alarm/Fault Occurred

    Section 4.4 PART 4 ENGINE/DC CONTROL Troubleshooting Flowcharts Problem 18 – Shutdown Alarm/Fault Occured GO TO PROBLEM 16 OVERCRANK CHECK INSTALLATION FOR TEST 62 – CHECK HIGH PROPER AIRFLOW OR OIL TEMPERATURE HIGH TEMP REPLACE DEFECTIVE SWITCH SWITCH TEST 16 – CHECK TEST 14 - CHECK REPAIR OR STEPPER MOTOR...

  • Page 116: Problem 19 - 7.5 Amp Fuse (F1) Blown

    Section 4.4 PART 4 ENGINE/DC CONTROL Troubleshooting Flowcharts Problem 19 – 7.5 Amp Fuse (F1) Blown FUSE BLOWS WHEN TEST 66 – CHECK PLACED IN “AUTO” CRANKING AND OR “MANUAL” RUNNING CIRCUITS Problem 20 – Generator Will Not Exercise TEST 65 – TEST EXERCISE FUNCTION Problem 21 –...

  • Page 117: Section 4.5 - Diagnostic Tests

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests When working on this equipment, use common sense and INTRODUCTION remain alert at all times. Never work on this equipment while This section familiarizes the service technician with acceptable you are physically or mentally fatigued. If you do not understand procedures for the testing and evaluation of various problems a component, device or system, do not work on it.

  • Page 118: Test 41 - Try A Manual Start

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Press the right arrow key until “Debug” flashes. Press TEST 41 – TRY A MANUAL START “Enter” and the following screen will appear. See Figure Discussion 108, Screen 2. The first step in troubleshooting for an “engine won’t crank” When “Inputs”...

  • Page 119: Test 44 - Check 7.5 Amp Fuse

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests If cable clamps or terminals are corroded, clean away all TEST 44 – CHECK 7.5 AMP FUSE corrosion. Note: Use the Alarm Log in the control panel to help troubleshoot various problems. For instance, if the unit Install battery cables, making sure all cable clamps are does not crank the control panel will display “Stopped- tight.

  • Page 120: Test 46 - Check Wire 56 Voltage

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests C. Test Battery State of Charge: If battery condition is good, refer back to flow chart. (Non-Maintenance Free Battery) 1. Use an automotive type battery hydrometer to test TEST 46 – CHECK WIRE 56 VOLTAGE battery state of charge.

  • Page 121: Test 47 - Test Starter Contactor Relay

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests DEBUG OUTPUTS OUTPUTS 1 - 8: 1 0 1 1 0 0 0 1 Figure 113. Starter Contactor Relay (V-twin Units) Connect the positive meter test lead to the SCR terminal OUTPUT 6 from which Wire 16 was removed and connect the negative meter test lead to a clean frame ground.

  • Page 122: Test 49 - Test Starter Motor

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Refer to Figure 114 and 115 for Test Points If battery voltage was indicated in Step 3, but not in Step 4, replace the starter contactor. Set Volt-Ohm-Milliammeter (VOM) to measure DC voltage. Connect the positive meter test lead to the positive post V-Twin Only of the battery and connect the negative meter test lead to...
  • Page 123 Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests If engine turns over slightly, go to Test 63 “Check and Adjust Valves.” If valve clearance is too loose the valves will not fully open which could slow down cranking of the engine. PINION Figure 119.

  • Page 124: Test 50 - Check Fuel Supply And Pressure

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests CLAMP ON AMP METER STARTER Figure 121. Tachometer CONTACTOR STARTER Test Bracket: MOTOR A starter motor test bracket may be made as shown in Figure 122. A growler or armature tester is available from an automobile diagnostic service supplier.

  • Page 125: Test 51 - Check Controller Wire 14 Outputs

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests (propane) gas is heavier than air, and tends to settle PORT 3 in low areas. Even the slightest spark can ignite these gases and cause an explosion. Procedure PORT 1 A water manometer or a gauge that is calibrated in “ounces per square inch”...

  • Page 126: Test 52 - Check Fuel Solenoid

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Disconnect Wire 14 from the fuel solenoid (FS). a. If the VOM indicated CONTINUITY repeat Step 5 and then retest. Connect the positive test lead to the disconnected Wire 14 b. If CONTINUITY is not measured, repair or replace Wire from Step 3 and connect the negative test lead to a clean 14 between the J4 Connector and the fuel solenoid.

  • Page 127: Test 53 - Check Choke Solenoid

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests TEST 53 – CHECK CHOKE SOLENOID CHOKE PLATE Discussion 12-20kW: The automatic choke cycles open and closed during cranking and stays energized (choke open) during running. For low speed exercise the choke will remain closed. A plate is utilized which covers the throttle bores.
  • Page 128 Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests CHOKE VALVE IN OPEN POSITION CHOKE SOLENOID AIR BOX CHOKE VALVE IN CLOSED POSITION Figure 130. 8kW Choke Solenoid Disconnect the choke solenoid. Set the AUTO-OFF-MANUAL switch to MANUAL. While cranking, the VOM should indicate battery voltage Set a Volt-Ohm-Milliammeter (VOM) to measure DC cyclically.

  • Page 129: Test 55 - Check For Ignition Spark

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests With the generator r unning at a rated speed of Connect one meter test lead to Pin 1(Wire 56) on the male approximately 60 Hz, verify that the choke is energized side of the CS connector and the other meter test lead to and holding the choke plate open.

  • Page 130: Test 57 - Check Condition Of Spark Plugs

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests system. TEST 57 – CHECK CONDITION OF SPARK PLUGS Discussion If the engine will not start and Test 55 indicated good ignition spark, some possible causes could be fouled or damaged electrodes. An engine miss may also be caused by defective spark plug(s).

  • Page 131: Test 58 - Check Engine / Cylinder Leak Down Test / Compression Test

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Results INLET GUAGE PRESSURE SET COMPRESSED POINT Clean, re-gap or replace plugs as necessary, re-test. AIR IN OUTLET GUAGE PRESSURE AIR PRESSURE If spark plugs are good, refer back to flow chart. REGULATOR TO SPARK PLUG HOLE...

  • Page 132: Test 59 - Check Shutdown Wire

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Note: Refer to Manufactures instructions for variations of this procedure. WIRE 18 CONNECTION Procedure Remove both spark plugs. Insert a compression gauge into either cylinder. Crank the engine until there is no fur ther increase in pressure.

  • Page 133: Test 60 - Check And Adjust Ignition Magnetos

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Results Note: It is recommended to replace Magnetos in pairs. If the VOM indicated CONTINUITY to ground in Step 6, Procedure: Adjusting Magneto Flywheel Gap repair or replace shorted ground Wire 18 between the Note: The air gap between the ignition magneto and the fly- engine and the J4 connector.
  • Page 134 Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests was disconnected in Step 7d. The engine should crank Procedure, Replacing Magnetos: once the jumper from 194 is connected. Follow all steps of the Major Disassembly procedures that If spark was not indicated, replace magnetos. are located in Section 6.

  • Page 135: Test 61 - Check Oil Pressure Switch And Wire 86

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Procedure Navigate to the Digital inputs display screen. a. Press “ESC” until the main menu is reached. b. Press the right arrow key until “Debug” is flashing. c. Press “Enter”. d. Press the right arrow key until “Inputs” is flashing. e.

  • Page 136: Test 62 - Check High Oil Temperature Switch

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests b. Star t the engine while observing the oil pressure (Wire 86). The VOM should indicate CONTINUITY. If reading on the gauge. CONTINUITY was not measured repair or replace Wire 86 between the LOP switch and the J5 connector. c.

  • Page 137: Test 63 - Check And Adjust Valves

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests test leads across the switch terminal and the switch body. stud with the allen wrench and tighten the rocker arm The meter should read INFINITY. jam nut. Torque the jam nut to 174 inch pounds. After tightening the jam nut, recheck the valve clearance to Heat the oil in the container.

  • Page 138: Ready To Run

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Disconnect the J4 connector from the controller. Adjust exercise time to 5 minutes ahead of the date and time noted in Step 1. Connect one meter test lead to a clean frame ground and connect the other meter test lead to J4 Pin 16 (Wire 18).

  • Page 139: Test 66 - Test Cranking And Running Circuits

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Press the right arrow key until “Debug” begins to flash. Procedure Press “Enter.” Set a Volt-Ohm-Milliammeter (VOM) to measure resistance. Press the right arrow key until “QT Test” beings to flash. Disconnect the J4 connector from the controller. Press “Enter.”...

  • Page 140: Test 68 - Test Crank Circuit

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests test lead to the ground terminal, measure and record the Disconnect Wire 14 from the fuel solenoid (FS) and the resistance. choke solenoid (CS). Connect one meter test lead to the FS terminal from Results which Wire 14 was removed.

  • Page 141: Test 69 - Test Transfer Relay Circuit

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests Disconnect Wire 56 and 0 from the starter contactor relay If the VOM indicated CONTINUITY in Step 3, replace the (SCR). TR1 relay. Connect one meter test lead to the SCR terminal from which Wire 56 was removed.

  • Page 142: Test 75 - Test 120 Volt Input (T1)

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests TEST 75 – TEST 120 VOLT INPUT (T1) TEST 77 – CHECK WIRE 13 AND WIRE 0 Discussion Discussion The controller requires 120 VAC supplied from the LOAD side The previous test indicated that battery voltage was not of the CONTACTOR in the transfer switch to function properly.

  • Page 143: Test 79 - Check T1 Voltage At Customer Connections

    Section 4.5 Section 4.5 PART 4 PART 4 ENGINE/DC CONTROL ENGINE/DC CONTROL Diagnostic Tests Diagnostic Tests Results TEST 80 – CHECK T1 VOLTAGE AT J5 If the VOM indicated positive DC amperage between CONNECTOR 50 milliamps to 2.5 amps, stop testing. The charger is If 120 VAC was available at T1 and neutral of the customer functioning properly.

  • Page 144: Test 82 - Test F3 Fuse Circuit

    Section 4.5 PART 4 ENGINE/DC CONTROL Diagnostic Tests TEST 82 – TEST F3 FUSE CIRCUIT Procedure Set a Volt-Ohm-Milliammeter (VOM) to measure AC voltage. Connect one meter test lead to the top side of the T1 fuse holder and connect the other test lead to the NEUTRAL connection.

  • Page 145: Part 5 - Operational Tests

    TABLE OF CONTENTS SECTION TITLE PAGE System Functional Tests Setup Procedures PART 5 OPERATIONAL TESTS Air-cooled, Automatic Standby Generators Section 5.1 – System Functional Tests ......144 Introduction ............144 Manual Transfer Switch Operation ....... 144 Electrical Checks ..........144 Generator Tests Under Load ........

  • Page 146: Section 5.1 - System Functional Tests

    Section 5.1 PART 5 OPERATIONAL TESTS System Functional Tests Remove the manual transfer handle from the enclosure. INTRODUCTION Following home standby electric system installation and Place open end of the manual transfer handle over transfer periodically thereafter, the system should be tested. Functional switch operating lever.

  • Page 147: Generator Tests Under Load

    Section 5.1 PART 5 OPERATIONAL TESTS System Functional Tests Turn OFF all loads connected to the Transfer Switch Terminals T1 and T2.  The transfer switch is now electrically “hot”, contact Set the generator AUTO-OFF-MANUAL switch to OFF. with “hot” parts will result in extremely hazardous and possibly fatal electrical shock.

  • Page 148: Checking Automatic Operation

    Section 5.1 PART 5 OPERATIONAL TESTS System Functional Tests CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation, proceed as follows: Set generator main circuit breaker to its OFF (or open) position. Check that the AUTO-OFF-MANUAL switch is set to OFF. Turn off the utility power supply to the transfer switch, using whatever means provided (such as a utility main line circuit breaker).

  • Page 149: Section 5.2 - Setup Procedures

    Section 5.2 PART 5 OPERATIONAL TESTS Setup Procedures SETTING THE EXERCISE TIME ACTIVATION PROCESS This Generator is equipped with an exercise timer. Once it is When battery power is applied to the Generator during the set, the Generator will start and exercise every seven days, on installation process, the controller will light up.

  • Page 150: Activation Chart

    Section 5.2 Setup Procedures Activation Chart CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Use ARROW keys to scroll to desired If the wrong language is chosen, it can language. Press ENTER to select. be changed later using the “edit” menu. Language English Escape Enter Display Reads:...

  • Page 151: Part 6 - Disassembly

    TABLE OF CONTENTS SECTION TITLE PAGE Major Disassembly PART 6 DISASSEMBLY Air-cooled, Automatic Standby Generators Section 6.1 – Major Disassembly ........150 Front Engine Access ........... 150 Major Disassembly ..........154 Torque Requirements .......... 160 Page 149...

  • Page 152: Section 6.1 - Major Disassembly

    Section 6.1 PART 6 DISASSEMBLY Major Disassembly Remove controller: Using a 10mm socket remove the FRONT ENGINE ACCESS three bolts holding the control panel in place. There are two Safety bolts on the side of the divider panel and the third directly Set the AUTO-OFF-MANUAL switch to OFF.
  • Page 153 Section 6.1 PART 6 DISASSEMBLY Major Disassembly Figure 167. Figure 169. 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 170. Figure 168.
  • Page 154 Section 6.1 PART 6 DISASSEMBLY Major Disassembly 11. Remove engine divider panel: Using a 10mm socket remove the rear 10mm bolt from the base of the enclosure. See Figure 174. Remove the front 10mm bolt from the base of the enclosure. See Figure 175. Figure 171.
  • Page 155 Section 6.1 PART 6 DISASSEMBLY Major Disassembly Figure 178. Figure 176. Figure 179. 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.

  • Page 156: Major Disassembly

    Section 6.1 PART 6 DISASSEMBLY Major Disassembly Figure 182. Figure 180. MAJOR DISASSEMBLY Safety: Set the AUTO-OFF-MANUAL switch to OFF. Remove the 7.5 amp main fuse. See Figure 183. Remove the N1 and N2 fuses from the transfer switch. Figure 181. Figure 183.
  • Page 157 Section 6.1 PART 6 DISASSEMBLY Major Disassembly Stator/Rotor/Engine Removal: Remove Top Exhaust Enclosure Covers: Using a 10mm socket, remove the nine bolts from the exhaust top covers. Remove covers. See Figure 184. Figure 186. Remove Exhaust Flex Pipe: Using a ½” socket remove the front and rear muffler clamp.
  • Page 158 Section 6.1 PART 6 DISASSEMBLY Major Disassembly Figure 188. Figure 190. Remove Left-side enclosure: Using a 10mm ratchet 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 the side panel to the back panel.
  • Page 159 Section 6.1 PART 6 DISASSEMBLY Major Disassembly Remove Rotor Bolt: Using a 9/16” socket, remove rotor 10. Remove Brushes: Using a 7mm socket remove brushes. bolt. Figure 192. See Figure 194. Figure 194. Figure 192. 11. Remove Alternator Divider Panel: Using a 10mm socket Remove Fan: Attach a steering wheel puller to the fan remove two bottom base bolts.
  • Page 160 Section 6.1 PART 6 DISASSEMBLY Major Disassembly 12. Remove Brush Wires: Using a side cutters remove the tie 14. Remove Stator Wires: Remove all connectors from wraps securing the brush wires to the outside of stator. the controller, remove all wires the common neutral and See Figure 196.
  • Page 161 Section 6.1 PART 6 DISASSEMBLY Major Disassembly 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 screwdriver to screw it into the crankshaft.

  • Page 162: Torque Requirements

    Section 6.1 PART 6 DISASSEMBLY Major Disassembly 19. Remove Engine: Using proper lifting equipment remove TORQUE REQUIREMENTS the engine. See Figure 206. (UNLESS OTHERWISE SPECIFIED) STATOR BOLTS ..........6 ft-lbs ( +1 / -0 ) ROTOR BOLT ..............30 ft-lbs ENGINE ADAPTOR ............
  • Page 163 NOTES PART 6 DISASSEMBLY Page 161...
  • Page 164 Section 6.1 PART 6 DISASSEMBLY Major Disassembly Control Panel Page 162...
  • Page 165 Section 6.1 PART 6 DISASSEMBLY Major Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION WASHER LOCK M6-1/4 SCREW REDUCED HH HI-LO M6X10MM SCREW HHC M6-1.0 X 30 C8.8 BLOCK TERM 5POS 20A SCREW HHFC M5-0.8X12 W/PATCH TERM BLOCK 3P UL 12-20AWG BRACKET CUSTOMER CONNECT EYE HASP CNTRL PANEL WASHER FLAT M6...
  • Page 166 Section 6.1 PART 6 DISASSEMBLY Major Disassembly Generator FUEL REGULATOR “8KW” “E” FUEL REGULATOR “C” “D” “F” “E” “C” “D” “F” “C” “B” 50 65 “D” “A” “G” “B” “E” “10KW” FUEL REGULATOR 46 47 “A” “E” “F” “C” “D” 29 (8KW),44 “F”...
  • Page 167 Section 6.1 PART 6 DISASSEMBLY Major Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION NUT LOCK HEX M8-1.25 NYLON INSERT SCREW PLASTITE 1/4-15 X 3/4” (8KW ONLY) WASHER FLAT M8-5/16 AIR IN SNORKEL (8KW ONLY) GASKET, EXHAUST (8KW) BAND HOSE CLAMP n35.05 (8KW ONLY) GASKET, EXHAUST (10KW) AIR FILTER (8KW ONLY) GASKET, EXHAUST...
  • Page 168 Section 6.1 PART 6 DISASSEMBLY Major Disassembly Enclosure Page 166...
  • Page 169 Section 6.1 PART 6 DISASSEMBLY Major Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION GASKET, DOOR SEAL BRACKET, CONTROL PNL FRONT ENCLOSURE FRONT PANEL ENCLOSURE END PANEL FOAM, FRONT PANEL ENCLOSURE SCREEN EXHAUST BAFFLE (13KW-20KW) U-CLIP , M6-1.00 SCREW HHFC M6-1.0 X 20 (8KW, 10KW) SCREW HHFC M6-1.0 X 14 PANEL, ENGINE DIVIDER FOAM, ENCLOSURE BACK PANEL...
  • Page 170 Section 6.1 PART 6 DISASSEMBLY Major Disassembly Engine, GN990/999 156 142 114 115 117,118 Page 168...
  • Page 171 Section 6.1 PART 6 DISASSEMBLY Major Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION WASHER FLAT M8 – 5/16 STARTER MOTOR HEAR REDUCED 1KW KNOB, AIR CLEANER ORG SCREW HHC M8 – 1.25 X 85 G8.8 COVER, AIRBOX NG/LP WASHER LOCK M8 – 5/16 ELEMENT, AIR CLEANER ASSEMBLY, GROUND WIRE ASSY, MIXER / AIRBOX 990...
  • Page 172 Section 6.1 PART 6 DISASSEMBLY Major Disassembly Engine, GN530 Page 170...
  • Page 173 Section 6.1 PART 6 DISASSEMBLY Major Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION WASHER LOCK M6-1/4 OIL FILTER INTAKE ADAPTER THERMAL SWITCH GASKET, AIRBOX TO CARB/MIXER SCREW PPHM M3-0.5 X 6 SEMS GASKET, MANIFOLD TO CARB/MIXER ASSY OIL DRAIN HOSE ORG BOLT, CARB MOUNT M6 –...
  • Page 174 Section 6.1 PART 6 DISASSEMBLY Major Disassembly Engine, GN410 Page 172...
  • Page 175 Section 6.1 PART 6 DISASSEMBLY Major Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION SCREW, TAPTITE M6-1.0X8 YELLOW SWITCH, OIL 5 PSI CHROME OIL FILTER HOUSING, BLOWER GH410 BLACK KEY, WOODRFF 4 X 19D TUBE 410GH OIL FILL/CHECK FLYWHEEL WITH RING GEAR 27 DEGREE GUARD, F AN WASHER,BELV-20 X 2.2 WRAPPER, BOTT OM...
  • Page 176 Section 6.1 PART 6 DISASSEMBLY Major Disassembly Page 174...

  • Page 177: Part 7 - Electrical Data

    TABLE OF CONTENTS DWG# TITLE 0H6912-B WD/SD 8KW 2010 AIR-COOLED HSB 0H7358-B WD/SD 10-14KW 2010 AIR-COOLED HSB PART 7 0H6198-C WD/SD 17KW 2010 AIR-COOLED HSB 0H7570-B WD/SD 20KW 2010 AIR-COOLED HSB ELECTRICAL DATA 0H6385-A WD HSB TRANSFER SWITCH 0H6386-B SD HSB TRANSFER SWITCH Air-cooled, Automatic Standby Generators Page 175...

  • Page 178: Wiring Diagram, 8 Kw Home Standby

    Section 7 PART 7 ELECTRICAL DATA 8KW 2010 AIR-COOLED HSB Wiring Diagram – Drawing 0H6912-B CONTROL PANEL ENGINE COMPARTMENT PIN # PIN # TABLE FOR C1 WIRING OPTIONS CLOSEST TO STATOR BEARING TABLE PINOUT GOVERNOR 2 3 4 9 10 12 13 14 ACTUATOR MAIN...
  • Page 179 Section 7 PART 7 ELECTRICAL DATA 8KW 2010 AIR-COOLED HSB Wiring Diagram – Drawing 0H6912-B OL PANEL CUSTOMER CONNECT AREA NEUT 240V GENERATOR OUTPUT TO TRANSFER SWITCH CONTACTOR LEGEND BA - BRUSH ASSEMBLY C1 - ALTERNATOR CONNECT - CIRCUIT BREAKER, MAIN OUTPUT L1: GREEN = SYSTEM READY GND - GROUND HTO - HIGH TEMPERATURE SWITCH...

  • Page 180: Electrical Schematic, 8 Kw Home Standby

    Section 7 PART 7 ELECTRICAL DATA 8KW 2010 AIR-COOLED HSB Electrical Schematic – 0H6912-B POWER WINDING 240 VAC GENERATOR STATOR OUTPUT POWER WINDING ROTOR EXCITATION WINDING NEUTRAL 11 44 11 44 11 44 1 PIN # PIN # SEE TABLE FOR PINOUT 11 44 2 6 11 44 11 44...

  • Page 181: Wiring Diagram, 10-14 Kw Home Standby

    Section 7 PART 7 ELECTRICAL DATA 10-14KW 2010 AIR-COOLED HSB Wiring Diagram – Drawing 0H7358-B NNECT AREA POWER WINDING 240 VAC GENERATOR STATOR OUTPUT POWER WINDING EXCITATION ROTOR WINDING NEUTRAL 11 44 11 44 11 44 1 PIN # PIN # SEE TABLE FOR PINOUT 11 44 2 6 11 44...

  • Page 182: Electrical Schematic, 10-14 Kw Home Standby

    Section 7 PART 7 ELECTRICAL DATA 10-14KW 2010 AIR-COOLED HSB Electrical Schematic – Drawing 0H7358-B CONTROL PANEL ENGINE COMPARTMENT PIN # PIN # TABLE FOR C1 WIRING OPTIONS CLOSEST TO STATOR BEARING TABLE PINOUT GOVERNOR 2 3 4 9 10 12 13 14 ACTUATOR MAIN...
  • Page 183 Section 7 PART 7 ELECTRICAL DATA 10-14KW 2010 AIR-COOLED HSB Electrical Schematic – Drawing 0H7358-B TROL PANEL CUSTOMER CONNECT AREA 240V GENERATOR NEUT OUTPUT TO TRANSFER SWITCH CONTACTOR LEGEND BA - BRUSH ASSEMBLY - CIRCUIT BREAKER, MAIN OUTPUT GND - GROUND HTO - HIGH TEMPERATURE SWITCH IM_ - IGNITON MODULE LOP - LOW OIL PRESSURE SWITCH...

  • Page 184: Electrical Schematic, 17 Kw Home Standby

    Section 7 PART 7 ELECTRICAL DATA 17KW 2010 AIR-COOLED HSB Electrical Schematic – Drawing 0H6198-C CONTROL PANEL ENGINE COMPARTMENT PIN # PIN # TABLE FOR C1 WIRING OPTIONS CLOSEST TO STATOR BEARING TABLE PINOUT GOVERNOR 2 3 4 9 10 12 13 14 ACTUATOR MAIN...
  • Page 185 Section 7 PART 7 ELECTRICAL DATA 17KW 2010 AIR-COOLED HSB Electrical Schematic – Drawing 0H6198-C L PANEL CUSTOMER CONNECT AREA 240V GENERATOR NEUT OUTPUT TO TRANSFER SWITCH CONTACTOR 120V/15A DUPLEX LEGEND BA - BRUSH ASSEMBLY CB1 - CIRCUIT BREAKER, MAIN OUTPUT CB2 - CIRCUIT BREAKER, GFCI GND - GROUND L1: GREEN = SYSTEM READY...

  • Page 186: Wiring Diagram, 17 Kw Home Standby

    Section 7 PART 7 ELECTRICAL DATA 17KW 2010 AIR-COOLED HSB Wiring Diagram – Drawing 0H6198-C POWER WINDING 240 VAC GENERATOR STATOR OUTPUT POWER WINDING ROTOR EXCITATION WINDING NEUTRAL 11 44 11 44 11 44 1 PIN # PIN # SEE TABLE FOR PINOUT 11 44 11 44 2 6 11 44...
  • Page 187 Section 7 PART 7 ELECTRICAL DATA 20KW 2010 AIR-COOLED HSB Wiring Diagram – Drawing 0H7570-B ONNECT AREA POWER WINDING 240 VAC GENERATOR STATOR OUTPUT POWER WINDING ROTOR EXCITATION WINDING NEUTRAL 11 44 11 44 11 44 1 PIN # PIN # SEE TABLE FOR PINOUT 11 44 11 44...

  • Page 188: Electrical Schematic, 20 Kw Home Standby

    Section 7 PART 7 ELECTRICAL DATA 20KW 2010 AIR-COOLED HSB Electrical Schematic – Drawing 0H7570-B CONTROL PANEL ENGINE COMPARTMENT PIN # PIN # TABLE FOR C1 WIRING OPTIONS CLOSEST TO STATOR BEARING TABLE PINOUT GOVERNOR 2 3 4 9 10 12 13 14 ACTUATOR MAIN...
  • Page 189 Section 7 PART 7 ELECTRICAL DATA 20KW 2010 AIR-COOLED HSB Electrical Schematic – Drawing 0H7570-B ROL PANEL CUSTOMER CONNECT AREA 240V GENERATOR OUTPUT TO TRANSFER NEUT SWITCH CONTACTOR 120V/15A DUPLEX L1: GREEN = SYSTEM READY L2: YELLOW = MAINTENANCE REQ'D L3: RED = ALARM LED BOARD LEGEND...

  • Page 190: Electrical Schematic, Home Standby Transfer Switch

    Section 7 PART 7 ELECTRICAL DATA HSB TRANSFER SWITCH Electrical Schematic – Drawing 0H6385-A ALL CIRCUIT NEUTRAL CONDUCTORS NOT SHOWN FOR CLARITY 16 CIRCUIT LOAD CENTER 14 CIRCUIT LOAD CENTER 12 CIRCUIT LOAD CENTER EXTER EXTERNAL CONNEC CONNECTION 10 CIRCUIT LOAD CENTER 8 CIRCUIT LOAD CENTER TO GENERATOR OUTPUT...
  • Page 191 Section 7 PART 7 ELECTRICAL DATA HSB TRANSFER SWITCH Electrical Schematic – Drawing 0H6385-A F1 F2 0D4698-T LEGEND C1-UTILITY COIL & RECTIFIER EXTERNAL RNAL C2-GENERATOR COIL & RECTIFIER CONNECTION CTION F1,F2,F3-5A, 600V FUSE LC-CIRCUIT BREAKER (LOADS) (16 CIRCUIT SHOWN FOR REFERENCE ONLY) N-NEUTRAL SW1-AUTOMATIC TRANSFER SWITCH TO GENERATOR...

  • Page 192: Wiring Diagram, Home Standby Transfer Switch

    Section 7 PART 7 ELECTRICAL DATA HSB TRANSFER SWITCH Electrical Schematic – Drawing 0H6386-B EXTERNAL CONNECTION CONTROL TRANSFER TS TO LOAD SENSING GENERATOR 120VAC CONTROL OUTPUT PANEL UTILITY SENSING 240VAC OUTPUT BLACK OUTPUT GENERATOR NEUTRAL (WHITE) GROUND (GREEN) NEUTRAL CONNECTION INSIDE GROUND (GREEN) SWITCH...
  • Page 193 Section 7 PART 7 ELECTRICAL DATA HSB TRANSFER SWITCH Page 191...

  • Page 194: Electrical Formulas

    Electrical Formulas TO FIND KNOWN VALUES 1-PHASE E x I KILOWATTS (kW) Volts, Current, Power Factor 1000 E x I Volts, Current 1000 kW x 1000 AMPERES kW, Volts, Power Factor WATTS Volts, Amps, Power Factor Volts x Amps 2 x 60 x Frequency NO.

  • Page 195: Appendix A Supplemental Worksheets

    TABLE OF CONTENTS PART TITLE PAGE Test 4 Results Test 7 Results APPENDIX A Test 66 Results SUPPLEMENTAL Generator Failure Analysis WORKSHEETS Air-cooled, Automatic Standby Generators Page 193...
  • Page 196 Table 9 APPENDIX A SUPLEMENTAL WORKSHEETS Test 4 Results Test 4 Results, Serial #_________________________ Test 4 Results, Serial #_________________________ Test Point Results Test Point Results Wires 2 and 6 Voltage Wires 2 and 6 Voltage Wires 11 and 44 Voltage Wires 11 and 44 Voltage Static Rotor Amp Draw Static Rotor Amp Draw...
  • Page 197 Table 14 SUPLEMENTAL WORKSHEETS APPENDIX A Test 7 Stator Results Test 7 Stator Results, Serial #_______________________ Test 7 Stator Results, Serial #_______________________ Test Point A Test Point B Results Test Point A Test Point B Results Resistance Tests Resistance Tests Stator Lead Wire 11 Stator Lead 22 Stator Lead Wire 11 Stator Lead 22 Stator Lead Wire 33 Stator Lead 44...
  • Page 198 Table 26 APPENDIX A SUPLEMENTAL WORKSHEETS Test 66 Results Test 66 Results, Serial #___________________________ Test 66 Results, Serial #___________________________ Test Point Pin Location Circuit Result Test Point Pin Location Circuit Result J4 Pin 9 Wire 14 J4 Pin 9 Wire 14 J4 Pin 17 Wire 56 J4 Pin 17...
  • Page 199 Generator Failure Analysis SUPLEMENTAL WORKSHEETS APPENDIX A Date: Serial #: Failed Part #: Describe the symptoms of the fault: Fill in the test number performed during troubleshooting and indicate if it passed or failed. If it failed the test, describe what part of the test failed. Problem # 1.) Test # 2.) Test #...
  • Page 200 Generator Failure Analysis APPENDIX A SUPLEMENTAL WORKSHEETS Date: Serial #: Failed Part #: Describe the symptoms of the fault: Fill in the test number performed during troubleshooting and indicate if it passed or failed. If it failed the test, describe what part of the test failed. Problem # 1.) Test # 2.) Test #...
  • Page 201 Generator Failure Analysis SUPLEMENTAL WORKSHEETS APPENDIX A Date: Serial #: Failed Part #: Describe the symptoms of the fault: Fill in the test number performed during troubleshooting and indicate if it passed or failed. If it failed the test, describe what part of the test failed. Problem # 1.) Test # 2.) Test #...
  • Page 202 Generator Failure Analysis APPENDIX A SUPLEMENTAL WORKSHEETS Date: Serial #: Failed Part #: Describe the symptoms of the fault: Fill in the test number performed during troubleshooting and indicate if it passed or failed. If it failed the test, describe what part of the test failed. Problem # 1.) Test # 2.) Test #...
  • Page 203 Generator Failure Analysis SUPLEMENTAL WORKSHEETS APPENDIX A Date: Serial #: Failed Part #: Describe the symptoms of the fault: Fill in the test number performed during troubleshooting and indicate if it passed or failed. If it failed the test, describe what part of the test failed. Problem # 1.) Test # 2.) Test #...
  • Page 204 Page 202...

  • Page 205: Appendix B Index Of Figures And Tables

    TABLE OF CONTENTS PART TITLE PAGE Index of Figures Index of Tables APPENDIX B INDEX OF FIGURES AND TABLES Air-cooled, Automatic Standby Generators Page 203...

  • Page 206: Index Of Figures

    Index of Figures APPENDIX B INDEX OF FIGURES AND TABLES Figure # Page # Figure # Page # Figure # Page # Figure # Page # Figure # Page # Figure 1 Figure 42 Figure 83 Figure 124 Figure 165 Figure 2 Figure 43 Figure 84...

  • Page 207: Index Of Tables

    Index of Tables INDEX OF FIGURES AND TABLES APPENDIX B Table # Page Table # Page Table # Page Table # Page Table 1 Table 9 Table 15 Table 24 Table 2 Table 10 Table 17 Table 25 Table 3 Table 11 Table 19 Table 26...
  • Page 208 NOTES Page 206...
  • Page 210 ©2011 Generac Power Systems, Inc. All rights reserved. Specifications are subject to change without notice g e n e r a c . c o m No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc.

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