Section 4.1 - Description And Components; Introduction; Customer Connection; Controller - Generac Power Systems 7 kW NG Repair Manual

Section 4.1
Description and Components

INTRODUCTION

This section will familiarize the reader with the various
components that make up the Engine and DC Control
systems.
Topics covered in this section are:
• Customer Connections

• Controller

• Menu System Navigation

• LED Display

• Battery Charger

• AUTO-OFF-MANUAL
• 7.5 Amp Fuse
• Starter Contactor Relay
• Common Alarm Relay
• Connector Pin Descriptions

CUSTOMER CONNECTION

The terminals of this terminal strip connect to identically
numbered terminals in the transfer switch. The terminal block
provides the electrical connection for the controller.
The terminal block provides the following connection points:
• UTILITY N1 (Utility Sensing)
• UTILITY N2 (Utility Sensing)
• LOAD T1 (Internal Battery Charger)
• Wire 194 (Transfer Relay)
• Wire 23 (Transfer Relay)
N1 N2 T1
209 210 0 194 23
TERMINAL BLOCK
Figure 83. Customer Connections

CONTROLLER

The controller is responsible for all standby electric system
operations including (a) engine startup, (b) engine running,
(c) automatic transfer, (d) automatic re-transfer, and (e) engine
shutdown. In addition, the controller performs the following
functions:
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TERMINAL STRIP
CUSTOMER SIDE
PART 4
• Automatic voltage regulation (See Section 2.1 "Descriptions
and Components)
• Starts and exercises the generator once every seven days.
• Automatic engine shutdown in the event of low oil pressure,
high oil temperature, over speed, no RPM sense, over crank,
or low battery.
• Maintains proper battery charge
A 23-pin and a 14-pin connector are used to interconnect the
controller with the various circuits of the DC and AC systems.
Connector pin locations, numbers, associated wires and circuit
functions are listed in Tables 19 and 20.
To control the Generator the controller utilizes digital inputs and
outputs. See Table 17 for the specific position and function.
See "Menu Navigation" to view state of output or input.
Table 17. Digital Inputs and Outputs
Position Digital Inputs
1 Not Used
2 Low Oil Pressure
3 High Temperature
4 Low Fuel Pressure
5 Wiring Error Detect
6 Not Used
7 Auto
8 Manual
 The Generator engine will crank and start when the
7-day exerciser is set. The unit will also crank and
start every 7 days thereafter, on the day and at the time
the exerciser was set for.

LED DISPLAY

Located next to the circuit breaker access panel on the
generator, the LED Display provides a visually annunciating the
Generators status. The LED Display has three LED, a red, a
yellow, and a green.
• Red LED- Illuminates during an Alarm condition or when the
AUTO-OFF-MANUAL is set to OFF.
• Yellow LED- Illuminates when the controller generates a
Maintenance Alert and attention is required.
• Green LED- Illuminates when the system is ready to respond
to a Utility failure.

BATTERY CHARGER

The charger operates at one of three battery charging voltage
levels depending on ambient temperature.
• 13.5Vdc at High Temperature
• 14.1Vdc at Normal Temperature
• 14.6Vdc at Low Temperature
The battery charger is powered from a 120 VAC Load
ENGINE/DC CONTROL
Digital Outputs
Not Used
Not Used
Not Used
Battery Charger Relay
Ignition
Starter
Fuel
Transfer