Page 1 Product MODELS: 7 kW NG, 8 kW LP 9 kW NG, 10 kW LP 13 kW NG, 14 kW LP 16 kW NG, 17 kW LP 18 kW NG, 20 kW LP a u t o m a t i c s t a n d b y g e n e r a t o r s 0G9266revA.indd 1...
Page 2: Electrical Formulas
ElEctrical formulas TO FIND KNOWN VALUES 1-PHASE 3-PHASE E x I E x I x 1.73 x PF KILOWATTS (kW) Volts, Current, Power Factor 1000 1000 E x I E x I x 1.73 Volts, Current 1000 1000 kW x 1000 kW x 1000 AMPERES kW, Volts, Power Factor...
Page 3: Table Of Contents
contents 1.6 Engine-Generator Protective Devices ..... 25 General ............25 specifications ............4 Low Battery ............25 Generator ..............4 Low Oil Pressure Shutdown ......25 Engine ..............5 High Temperature Switch .........25 Fuel Consumption ........... 5 Overspeed Shutdown ........25 Mounting Dimensions ..........6 Rpm Sensor Failure .........25 Mounting Dimensions ..........
Page 4 Test 7 – Testing The Stator With A Vom Problem 11 – No Battery Charge (12-20 kW)...........44 (Pre-Packed Load Center) ......73 Test 8 – Test Brushless Stator......45 Problem 12 – No Battery Charge (RTSN & RTSE Transfer Switch) ....73 Test 9 – Check Capacitor .........46 Problem 13 –...
Page 5 Part 4 - Dc coNtrol ......... 95 Test 68 – Check Fuel Solenoid ......132 4.1 Description and Components ......96 Test 69 – Check Choke Solenoid ....132 General ............96 Test 70 – Check for Ignition Spark ....134 Terminal Strip / Interconnection Terminal ..96 Test 71 –...
Page 6: Specifications
sPEcificatioNs Generator Unit 8 kW 10 kW 12 kW 14 kW 16 kW 17 kW 20 kW Rated Max. Continuous 7,000 NG 9,000 NG 12,000 NG 13,000 NG 16,000 NG 16,000 NG 18,000 NG Power Capacity (Watts*) 8,000 LP 10,000 LP 12,000 LP 14,000 LP 16,000 LP...
Page 7: Engine
sPEcificatioNs enGine Model 8 kW 10 kW 12/14/16/17 kW 20 kW Type of Engine GH-410 GT-530 GT-990 GT-999 Number of Cylinders 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 [ 1 1. 8 ] 1079.5 [42.5] [27.5] [39.3] [29.4] [8.2] [17.9] [20.0] TRANSFER Ø30.2 [Ø1.2] TRANSFER LIFTING HOLES 4 CORNERS SWITCH SWITCH 8KW - 17KW 20KW (IF SUPPLIED) (IF SUPPLIED) "DO NOT LIFT BY ROOF" 637.6 1218 [25.1] [47.9]...
Page 9: Mounting Dimensions
sPEcificatioNs mountinG dimenSionS AIR INTAKE 457.2 MINIMUM DISTANCE [18.0] 914 [36.0] MINIMUM OPEN AREA ON SIDES AND FRONT AIR OUTLET AIR INTAKE 250.0 575.3 [9.8] [22.7] 530.0 HOLE LOCATIONS FOR [20.9] OPTIONAL MOUNTING TO A CONCRETE PAD 446.6 378.7 44.8 [17.6] [14.9] [1.8]...
Page 10: Major Features
sPEcificatioNs major FeatureS 8kW, Single Cylinder, GH-410 Engine 10kW, V-twin, GT-530 Engine (door removed) (door removed) Circuit Data Label Control Breaker Data Label Control Dipstick (see sample) Panel Dipstick (see sample) Panel Circuit Breaker Exhaust Exhaust Enclosure Enclosure Air Filter Filter Fuel Inlet Fuel Inlet...
Page 11: Part 1 - General Information
taBlE of coNtENts Part titlE PaGE Generator identification installation Basics Part 1 Non-Prepackaged GENEral interconnections Preparation Before use iNformatioN testing, cleaning and Drying Engine-Generator Protective Devices operating instructions automatic operating Parameters air-cooled, automatic standby Generators 1.1 Generator Identification ........10 Measuring Resistance ........20 Introduction ............10 Electrical Units ..........21...
Page 12: Generator Identification
sEctioN 1.1 Part 1 GENERAL INFORMATION GENErator iDENtificatioN introduction It is not our intent to provide detailed disassembly and reassemble instructions in this manual. It is our intent to (a) provide the service technician with an under- This Diagnostic Repair Manual has been prepared standing of how the various assemblies and systems especially for the purpose of familiarizing service per- work, (b) assist the technician in finding the cause of...
Page 13: Installation Basics
sEctioN 1.2 Part 1 GENERAL INFORMATION iNstallatioN Basics introduction LP (propane) gas is usually supplied as a liquid in pressure tanks. Both the air-cooled and the liquid Information in this section is provided so that the cooled units require a “vapor withdrawal” type of fuel service technician will have a basic knowledge of supply system when LP (propane) gas is used.
Page 14: Installation Basics
sEctioN 1.2 Part 1 GENERAL INFORMATION iNstallatioN Basics Figure 1. Typical Installation Page 12 0G9266revA.indd 12 10/15/2008 11:26:40 AM...
Page 15: Power Source And Load Lines
sEctioN 1.2 Part 1 GENERAL INFORMATION iNstallatioN Basics poWer Source and load lineS SyStem control interconnectionS The utility power supply lines, the standby (genera- Home standby generators are equipped with a termi- tor) supply lines, and electrical load lines must all be nal board identified with the following terminals: (a) connected to the proper terminal lugs in the transfer UTILITY 1, (b) UTILITY 2, (c) 23, and (d) 15B.
Page 16: Non-Prepackaged Interconnections
sEctioN 1.3 Part 1 GENERAL INFORMATION NoN-PrEPacKaGED iNtErcoNNEctioNs 3. Using the following diagram and UL approved wire nuts DISCUSSION: connect the following wires together. Wire 0 will not be On the current model air-cooled generators Wire 194 utilized for this setup. was changed to 15B.
Page 17: Connect A 2008 And Later Load Center Switch To A Pre-2008 Air-Cooled Generator
sEctioN 1.3 Part 1 GENERAL INFORMATION NoN-PrEPacKaGED iNtErcoNNEctioNs connect a 2008 and later load center SWitch CONTROL WIRES FROM to a pre-2008 air-cooled Generator. ENGINE GENERATOR PROCEDURE: 1. Follow all instructions located in the Installation Manual N1 (BLU) N1 (YEL) that was supplied with the unit regarding mounting of the switch, junction box, and generator.
Page 18: Preparation Before Use
sEctioN 1.4 Part 1 GENERAL INFORMATION PrEParatioN BEforE usE General All installed gaseous fuel piping must be purged and leak tested prior to initial start-up in accordance with local codes, standards and regulations. The installer must ensure that the home standby gen- erator has been properly installed.
Page 19 sEctioN 1.4 Part 1 GENERAL INFORMATION PrEParatioN BEforE usE in the selector knob and pull out to overcome spring pressure and then twist clockwise 90 degrees and allow the selector to return in once aligned with the LP (Liquid Propane) position. FUEL SELECTION 6.
Page 20: Engine Oil Recommendations
sEctioN 1.4 Part 1 GENERAL INFORMATION PrEParatioN BEforE usE enGine oil recommendationS All oil should meet minimum American Petroleum FUEL SELECTION Institute (API) Service Class SJ, SL or better. Use LEVER - no special additives. Select the oil's viscosity grade “OUT”...
Page 21: Testing, Cleaning And Drying
sEctioN 1.5 Part 1 GENERAL INFORMATION tEstiNG, clEaNiNG aND DrYiNG meterS meaSurinG ac VoltaGe Devices used to measure electrical properties are An accurate AC voltmeter or a VOM may be used to read called meters. Meters are available that allow one the generator’s AC output voltage.
Page 22: Measuring Current
sEctioN 1.5 Part 1 GENERAL INFORMATION tEstiNG, clEaNiNG aND DrYiNG meaSurinG current IN-LINE: Alternatively, to read the current flow in AMPERES, an in-line ammeter may be used. Most Digital Volt Ohm CLAMP-ON: Meters (VOM) will have the capability to measure To read the current flow, in AMPERES, a clamp-on amperes.
Page 23: Electrical Units
sEctioN 1.5 Part 1 GENERAL INFORMATION tEstiNG, clEaNiNG aND DrYiNG Component testing may require a specific resis- OHM: tance value or a test for INFINITY or CONTINUITY. The OHM is the unit of RESISTANCE. In every circuit Infinity is an OPEN condition between two electrical there is a natural resistance or opposition to the flow points, which would read as no resistance on a VOM.
Page 24: Visual Inspection
sEctioN 1.5 Part 1 GENERAL INFORMATION tEstiNG, clEaNiNG aND DrYiNG ViSual inSpection The MINIMUM acceptable megger reading for stators may be calculated using the following formula: When it becomes necessary to test or troubleshoot a generator, it is a good practice to complete a thorough MINIMUM INSULATION GENERATOR RATED VOLTS __________________________...
Page 25: Stator Insulation Resistance Test (12-20 Kw)
sEctioN 1.5 Part 1 GENERAL INFORMATION tEstiNG, clEaNiNG aND DrYiNG HI-POT TESTER: b. Plug the tester cord into a 120 volt AC wall socket and set its voltage selector switch to A “Hi-Pot” tester is shown in Figure 7. The model “1500 volts”.
Page 26: Rotor Insulation Resistance Test (8-10 Kw)
sEctioN 1.5 Part 1 GENERAL INFORMATION tEstiNG, clEaNiNG aND DrYiNG 4. Plug the tester into a 120 volts AC wall socket and set TESTING ALL STATOR WINDINGS TO GROUND: the voltage switch to “1500 volts”. 1. Disconnect Stator Output Leads 11 and 44 from the generator main line circuit breaker.
Page 27: Engine-Generator Protective Devices
sEctioN 1.6 Part 1 GENERAL INFORMATION ENGiNE-GENErator ProtEctiVE DEVicEs General oVerSpeed ShutdoWn Standby electric power generators will often run During engine cranking and operation, the circuit unattended for long periods of time. Such operating board receives AC voltage and frequency signals parameters as (a) battery voltage, (b) engine oil pres- from the ignition magneto, via Wire 18.
Page 28: Overcrank Shutdown
sEctioN 1.6 Part 1 GENERAL INFORMATION ENGiNE-GENErator ProtEctiVE DEVicEs oVercrank ShutdoWn CRANkING CONDITIONS: The following notes apply during cranking cycle. This feature prevents the generator from damaging 1. Starter motor will not engage within five (5) seconds of itself when it continually attempts to start and another the engine shutting down.
Page 29: Operating Instructions
sEctioN 1.7 Part 1 GENERAL INFORMATION oPEratiNG iNstructioNs control panel DaNGEr: WHEN tHE GENErator is iNstallED iN coNJuNctioN WitH aN automatic traNsfEr sWitcH, ENGiNE craNKiNG aND startuP caN occur at aNY timE WitHout WarNiNG (ProViDiNG tHE auto-off-maNual sWitcH is sEt to auto).
Page 30: To Select Automatic Operation
sEctioN 1.7 Part 1 GENERAL INFORMATION oPEratiNG iNstructioNs 10-20 kW – INSTALLATION ASSISTANT: manual tranSFer to “StandBy” and Upon first power up of the generator, the display inter- manual Startup face will begin an installation assistant. The assistant will prompt the user to set the minimum settings to To transfer electrical loads to the “Standby”...
Page 31: Automatic Operating Parameters
sEctioN 1.8 Part 1 GENERAL INFORMATION automatic oPEratiNG ParamEtErs introduction FAILURE TO START: This is defined as any of the following occurrences When the generator is installed in conjunction with during cranking. a transfer switch, either manual or automatic opera- 1.
Page 32 sEctioN 1.8 Part 1 GENERAL INFORMATION automatic oPEratiNG ParamEtErs load tranSFer The transfer of load when the generator is running is dependent upon the operating mode as follows: 1. Manual • Will not transfer to generator if utility is present. •...
Page 33: Part 2 - Ac Generators
taBlE of coNtENts Part titlE PaGE# 2.1. Description and components operational analysis Part 2 troubleshooting flow charts Diagnostic tests ac GENErators air-cooled, automatic standby Generators 2.1 Description and Components ......32 Test 1 – Check Main Circuit Breaker ....41 Introduction ............32 Test 2 –...
Page 34: Description And Components
sEctioN 2.1 Part 2 AC GENERATORS DEscriPtioN & comPoNENts introduction 1), and mounted in an enclosure. Both the engine and generator rotor are driven at approximately 3600 rpm, to provide a 60 Hz AC output. The air-cooled, automatic standby system is an easy to install, fully enclosed and self-sufficient electric power system.
Page 35: Stator Assembly
sEctioN 2.1 Part 2 AC GENERATORS DEscriPtioN & comPoNENts Stator aSSemBly The stator can houses and retains (a) dual AC power SLIP RINGS windings, and (b) excitation winding. A total of six (6) or eight (8) stator leads are brought out of the stator can as shown in Figure 4.
Page 36: Brush Holder And Brushes (12-20 Kw)
sEctioN 2.1 Part 2 AC GENERATORS DEscriPtioN & comPoNENts BruSh holder and BruSheS The regulator provides “over-voltage” protection, but does not protect against “under-voltage”. On occur- (12-20 kW) rence of an “over-voltage” condition, the regulator will “shut down” and complete loss Of excitation current The brush holder is retained to the rear bearing car- to the rotor will occur.
Page 37: Operational Analysis
sEctioN 2.2 Part 2 AC GENERATORS oPEratioNal aNalYsis rotor reSidual maGnetiSm Field boost voltage is reduced from that of battery voltage by the resistor action and, when read with a DC voltmeter, will be approximately 9 or 10 volts DC. The generator revolving field (rotor) may be consid- ered to be a permanent magnet.
Page 38: Operation (8/10 Kw)
sEctioN 2.2 Part 2 AC GENERATORS oPEratioNal aNalYsis operation (8/10 kW) FIELD EXCITATION: An AC voltage is induced into the stator excitation (DPE) windings. The DPE winding circuit is complet- STARTUP: ed to the voltage regulator, via Wire 2 and Wire 6. When the engine is started, residual magnetism from Unregulated alternating current can flow from the wind- the rotor induces a voltage into (a) the stator AC...
Page 39: Troubleshooting Flowcharts
sEctioN 2.3 Part 2 AC GENERATORS trouBlEsHootiNG floWcHarts General Use the “Flow Charts” in conjunction with the detailed The first step in using the flow charts is to correctly instructions in Section 2.4. Test numbers used in identify the problem. Once that has been done, locate the flow charts correspond to the numbered tests in the problem on the following pages.
Page 40: Problem 2 - Generator Produces Zero Voltage Or Residual Voltage (8/10 Kw)
sEctioN 2.3 Part 2 AC GENERATORS trouBlEsHootiNG floWcHarts Problem 1 - Generator Produces Zero Voltage or Residual Voltage (12-20 kW Continued) TEST 4 - PERFORM TEST 7 - TEST FIXED EXCITATION / STATOR ROTOR AMP DRAW GOOD PERFORM STATOR TEST 13 - INSULATION TEST ROTOR RESISTANCE TEST -...
Page 41: Problem 3 - Generator Produces Low Voltage At No-Load
sEctioN 2.3 Part 2 AC GENERATORS trouBlEsHootiNG floWcHarts Problem 3 - Generator Produces Low Voltage at No-Load LOW - TEST 15 - ADJUST SINGLE CYLINDER ENGINE GOVERNOR TEST 2 - CHECK TEST 14 - CHECK UNITS AC OUTPUT AC OUTPUT VOLTAGE FREQUENCY TEST 16 - CHECK...
Page 42: Problem 5 - Voltage And Frequency Drop Excessively When Loads Are Applied
sEctioN 2.3 Part 2 AC GENERATORS trouBlEsHootiNG floWcHarts Problem 4 - Voltage and Frequency Drop Excessively When Loads Are Applied IF RECONFIGURED TO LP GAS, TEST 18 - CHECK TEST 19 - CHECK VERIFY THAT PROPER BOTH VOLTAGE AND FOR OVERLOAD OVERLOADED PROCEDURE WAS FOLLOWED FREQUENCY...
Page 43: Diagnostic Tests
sEctioN 2.4 Part 2 AC GENERATORS DiaGNostic tEsts 1. Set a volt-ohm-milliammeter (VOM) to its “R x 1” scale introduction and zero the meter. This section is provided to familiarize the service 2. With the generator shut down, disconnect all wires from technician with acceptable procedures for the test- ing and evaluation of various problems that could be the main circuit breaker terminals, to prevent interaction.
Page 44: Test 4 - Fixed Excitation Test/Rotor
sEctioN 2.4 Part 2 AC GENERATORS DiaGNostic tEsts PROCEDURE: DaNGEr: usE EXtrEmE cautioN 1. Disconnect Wire 4 from the voltage regulator, 3rd DuriNG tHis tEst. tHE GENErator Will terminal from the top. See Figure 2. BE ruNNiNG. HiGH aND DaNGErous VoltaGEs Will BE PrEsENt at tHE 2.
Page 45: Test 5 - Wire Continuity (12-20 Kw)
sEctioN 2.4 Part 2 AC GENERATORS DiaGNostic tEsts Connect the other meter test lead to Wire 4 (still dis- connected from previous tests). Measure and record static rotor amp draw. 13. Set the AUTO-OFF-MANUAL switch to the MANUAL position. Once the engine starts, repeat Step 12. Measure and record running rotor amp draw with the engine running.
Page 46: Test 6 - Check Field Boost (12-20 Kw)
sEctioN 2.4 Part 2 AC GENERATORS DiaGNostic tEsts 6. Reconnect Wire 4. teSt 6 – check Field BooSt (12-20 kW) DISCUSSION: RESULTS: See “Field Boost Circuit” in Section 2.2. Field boost 1. If normal field boost voltage is indicated in Step 6, current (from the circuit board) is available to the replace the voltage regulator.
Page 47: Test 8 - Test Brushless Stator
sEctioN 2.4 Part 2 AC GENERATORS DiaGNostic tEsts 5. Turn the Main Breaker to the "ON" or CLOSED position. TEST FOR A SHORT CIRCUIT BETWEEN WINDINGS: 15. Connect one test lead to stator lead Wire 11 on the load 6. Set a VOM to measure resistance. side of the main circuit breaker.
Page 48: Test 9 - Check Capacitor
sEctioN 2.4 Part 2 AC GENERATORS DiaGNostic tEsts • An open circuit condition note: Wire 11 and Wire 44 could be switched on the main breaker. if an inFinity reading is indi- • A “short-to-ground” condition cated try putting the meter leads on the other •...
Page 49: Test 10 - Test Dpe Winding On
sEctioN 2.4 Part 2 AC GENERATORS DiaGNostic tEsts PROCEDURE: a. A capacitor that has gone bad can have a tendency to explode. Use caution when deal- 1. Consult the owner’s manual of the meter being used for ing with an exploded capacitor, the gel from directions on measuring capacitance.
Page 50: Test 11 - Resistance Check Of Rotor Circuit
sEctioN 2.4 Part 2 AC GENERATORS DiaGNostic tEsts 2. Testing for a “grounded” condition: Any resistance CONTINUITY should be measured. If INFINITY is reading indicated the winding is grounded. measured repair or replace Wire 0 between the brush assembly and the voltage regulator. 3.
Page 51: (12-20 Kw)
sEctioN 2.4 Part 2 AC GENERATORS DiaGNostic tEsts rotor if it fails that test. Then, repeat the test. If the rotor RESULTS: fails the second insulation resistance test, it should be 1. Repair, replace or reconnect wires as necessary. replaced. 2.
Page 52: Test 16 - Check Stepper Motor Control
sEctioN 2.4 Part 2 AC GENERATORS DiaGNostic tEsts teSt 16 – check Stepper motor SECONDARY control (V-tWin enGine unitS) ADJUST SCREW GOVERNOR PROCEDURE: SHAFT 1. Remove air cleaner cover to access stepper motor. 2. Physically grab the throttle and verify the stepper motor, linkage and throttle do not bind in any way, if any binding GOVERNOR is felt repair or replace components as needed.
Page 53: Test 17 - Check And Adjust Voltage
sEctioN 2.4 Part 2 AC GENERATORS DiaGNostic tEsts STEPPER MOTOR BLACK BROWN YELLOW ORANGE EMPTY PULL ARM THIS Figure 14. Six Pin Connector Wire Colors DIRECTION TO CLOSE THROTTLE teSt 17 – check and adjuSt VoltaGe reGulator (12-20 kW) Figure 11. Throttle Positions 9/10 kW Units DISCUSSION: STEPPER MOTOR For additional information, refer to description and...
Page 54: Test 18 - Check Voltage And Frequency
sEctioN 2.4 Part 2 AC GENERATORS DiaGNostic tEsts teSt 18 – check VoltaGe and teSt 20 – check enGine condition Frequency under load DISCUSSION: DISCUSSION: If engine speed and frequency drop excessively It is possible for the generator AC output frequency under load, the engine may be under-powered.
Page 55 sEctioN 2.4 Part 2 AC GENERATORS DiaGNostic tEsts CRIMP ON STANDARD FEMALE BLADE CONNECTORS 4 ft. 12 AWG MOMENTARY PUSHBUTTON ON/OFF SWITCH SINGLE POLE SWITCH ON LIVE SIDE 12 AWG  DO NOT SUBSTITUTE ANY OTHER DEVICE STANDARD MALE PLUG Figure 17.
Page 56 NotEs Page 54 0G9266revA.indd 54 10/15/2008 11:27:21 AM...
Page 57: Part 3 - Transfer Switch
taBlE of coNtENts Part titlE 3.1. Description and components Part 3 operational analysis troubleshooting flow charts traNsfEr Diagnostic tests sWitcH air-cooled, automatic standby Generators 3.1 Description and Components ..........56 Test 28 – Check 23 And 15B General Wiring/Connections ..........76 Enclosure ................
Page 58: Description And Components
sEctioN 3.1 Part 3 TRANSFER SWITCH DEscriPtioN & comPoNENts General encloSure The “W/V-Type” transfer switch is rated 100 amps at The “W/V-Type” transfer switch enclosure is a NEMA 250 volts maximum. It is available in 2-pole configura- 1 type (“NEMA” stands for “National Electrical tion only and, for that reason, is usable with 1-phase Manufacturer’s Association”).
Page 59: Transfer Mechanism
sEctioN 3.1 Part 3 TRANSFER SWITCH DEscriPtioN & comPoNENts tranSFer mechaniSm source side. Energizing the coil moves the load con- tacts to an overcenter position; limit switch action then opens the circuit and spring force will complete the The 2-pole transfer mechanism consists of a pair transfer action to “Standby”.
Page 60: Neutral Lug
sEctioN 3.1 Part 3 TRANSFER SWITCH DEscriPtioN & comPoNENts c. When de-energized, the relay’s normally open neutral luG contacts are open and its normally-closed contacts are closed. The standby generator is equipped with an UNGROUNDED neutral. The neutral lug in the transfer d.
Page 61: Fuse Holder
sEctioN 3.1 Part 3 TRANSFER SWITCH DEscriPtioN & comPoNENts TERMINALS 0, 15B AND 23: These terminals connect the transfer relay to the BLACK generator circuit board. See “Transfer Relay” in Section 3.1. FuSe holder The fuse holder holds three (3) fuses, designated as fuses F1, F2 and F3.
Page 62: Operational Analysis
sEctioN 3.2 Part 3 TRANSFER SWITCH oPEratioNal aNalYsis operational analySiS Figure 1 is a schematic for a typical “W/V-Type” transfer switch. CONTROL TRANSFER TS TO GENERATOR CONTROL PANEL UTILITY SENSING 240VAC OUTPUT BLACK WIRE WIRE TO GENERATOR OUTPUT NEUTRAL (WHITE) GROUND (GREEN) NEUTRAL CONNECTION...
Page 63 sEctioN 3.2 Part 3 TRANSFER SWITCH oPEratioNal aNalYsis Figure 2 is a wiring diagram for a typical “W/V-Type” transfer switch. GROUP G N1A N2A WIRE WIRE 0D4698-T LEGEND BC-BATTERY CHARGER C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER F1,F2,F3-5A, 600V FUSE LC-CIRCUIT BREAKER (LOADS) (16 CIRCUIT SHOWN FOR REFERENCE ONLY) N-NEUTRAL...
Page 64: Utility Source Voltage Available
sEctioN 3.2 Part 3 TRANSFER SWITCH oPEratioNal aNalYsis utility Source VoltaGe aVailaBle Figure 3 is a schematic representation of the transfer switch with utility source power available. The circuit condition may be briefly described as follows: • Utility source voltage is available to terminal lugs N1 and N2 of the transfer mechanism, transfer switch is in the UTILITY position and source voltage is available to T1, T2 and customer load.
Page 65: Utility Source Voltage Failure
sEctioN 3.2 Part 3 TRANSFER SWITCH oPEratioNal aNalYsis utility Source VoltaGe Failure If utility source voltage should drop below a preset value, the generator circuit board will sense the dropout. The circuit board will then initiate generator cranking and startup after a time delay circuit times out. Figure 4 is a schematic representation of the transfer switch with generator power available, waiting to transfer.
Page 66: Transfer To Standby
sEctioN 3.2 Part 3 TRANSFER SWITCH oPEratioNal aNalYsis tranSFer to StandBy 12 VDC is delivered to the transfer relay via Wire 15B and back to the circuit board via Wire 23. However, circuit board action holds the Wire 23 circuit open and the transfer relay remains de-energized. On generator startup, an “engine warm-up timer”...
Page 67: Transfer To Standby
sEctioN 3.2 Part 3 TRANSFER SWITCH oPEratioNal aNalYsis tranSFer to StandBy When the standby coil is energized it pulls the transfer switch mechanism to a overcenter position towards the standby power source side, the transfer switch mechanically snaps to the standby position. On closure of the main contacts to the standby power source side, limit switches SW2 and SW3 are mechanically actuated to “arm”...
Page 68: Utility Restored
sEctioN 3.2 Part 3 TRANSFER SWITCH 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. CONTROL TRANSFER TS TO...
Page 69: Utility Restored, Transfer Switch De-Energized
sEctioN 3.2 Part 3 TRANSFER SWITCH oPEratioNal aNalYsis utility reStored, tranSFer SWitch de-enerGized After the preset time interval expires the circuit board will open the Wire 23 circuit to ground. The transfer relay de-energizes, it’s normally closed contacts close, and utility source voltage is delivered to the utility closing coil (C1), via Wires N1A and N2A, closed Transfer Relay Contacts 1 and 7, and Limit Switch SW2.
Page 70: Utility Restored, Retransfer Back To Utility
sEctioN 3.2 Part 3 TRANSFER SWITCH 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 SW2 and SW3 are mechanically actuated to “arm”...
Page 71: Transfer Switch In Utility
sEctioN 3.2 Part 3 TRANSFER SWITCH oPEratioNal aNalYsis tranSFer SWitch in utility When the transfer switch returns to the utility side, generator shutdown occurs after approximately one (1) minute. CONTROL TRANSFER TS TO GENERATOR CONTROL PANEL UTILITY SENSING 240VAC OUTPUT BLACK WIRE WIRE...
Page 72: Troubleshooting Flowcharts
sEctioN 3.3 Part 3 TRANSFER SWITCH 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 an 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 73: During Exercise Or In Manual Mode
sEctioN 3.3 Part 3 TRANSFER SWITCH trouBlEsHootiNG floW cHarts Problem 8 – In Automatic Mode, Generator Starts When Loss of Utility Occurs, Generator Shuts Down When Utility Returns But There Is No Retransfer To Utility Power Generator Transfers to Standby During Excercise or in Manual Mode TEST 27 –...
Page 74: Problem 10 - Units Starts And Transfer Occurs When Utility Power Is On
sEctioN 3.3 Part 3 TRANSFER SWITCH trouBlEsHootiNG floW cHarts Problem 10 – Unit Starts and Transfer Occurs When Utility Power Is On 8 kW: Green LED Flashes 10-20 kW: Status – Utility Lost REPLACE TEST 36 – TEST 37 – CHECK GOOD CIRCUIT CHECK N1 &...
Page 75: Problem 11 - No Battery Charge (Pre-Packed Load Center)
sEctioN 3.3 Part 3 TRANSFER SWITCH trouBlEsHootiNG floW cHarts Problem 11 – No Battery Charge “Pre-Wire Load Center” TEST 40 – CHECK TEST 41 – CHECK TEST 42 – CHECK NO BATTERY BATTERY CHARGER GOOD BATTERY CHARGER WIRE 0/15B SUPPLY VOLTAGE SUPPLY VOLTAGE OUTPUT VOLTAGE GOOD...
Page 76: Diagnostic Tests
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts General PROCEDURE: 1. If the generator engine has started automatically (due to Test numbers in this section correspond to the a utility power source outage) and is running, check the numbered tests in Section 3.3, “Troubleshooting position of the generator main circuit breaker.
Page 77: Test 27 - Check Manual Transfer Switch Operation
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts e. Set the generator AUTO-OFF-MANUAL switch utility source voltage is available to the standby closing coil terminals, but transfer to Standby does not occur, to AUTO. the cause of the failure may be (a) a failed standby (1) The generator should crank and start.
Page 78: Test 28 - Check 23 And 15B Wiring/ Connections
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts b. Actuate the operating lever down to move the caution: after removing the fuse from the bat- load contacts against the standby contacts, i.e., tery charger, wait 5 minutes before proceeding. load connected to the Standby source. 6.
Page 79: Test 29 - Test Transfer Relay Tr
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts 13. Set VOM to measure DC voltage. caution: after installing the 7.5a fuse and dis- 14. Connect the (-) negative meter test lead to Wire 0 at the connecting Wire 15B from the generator termi- terminal strip in the generator.
Page 80: Test 30 - Standby Control Circuit
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts 4. Using jumper wires, connect the positive (+) post of a a. If 240 VAC is not measured, replace transfer 12 volt battery to relay Terminal “A” and the negative relay. (-) battery post to Relay Terminal “B”. The relay should b.
Page 81 sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts Figure 4. Standby Control Circuit Test Points Page 79 0G9266revA.indd 79 10/15/2008 11:27:32 AM...
Page 82: Test 32 - Utility Control Circuit
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts (2) Press the right arrow key until “Debug” is flashing. CUSTOMER SIDE (3) Press “Enter”. N1/N2 (4) Press the right arrow key until “Outputs” is CONTROL BOARD flashing. CONNECTION (5) Press “Enter”. N1 N2 (6) Digital Output 8 is Wire 23 output from the board.
Page 83 sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts Figure 7. Utility Control Circuit Test Points Page 81 0G9266revA.indd 81 10/15/2008 11:27:33 AM...
Page 84: Test 33 - Test Limit Switch Sw2 And Sw3
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts 5. Remove Wire N2A from the utility coil C1. teSt 33 – teSt limit SWitch SW2 and SW3 6. Turn on utility power supply to the transfer switch. DISCUSSION: a. If transfer to utility occurs, Wire 23 is grounded. The limit switches are wired to the normally closed Proceed to Test 31.
Page 85: Test 35 - Check N1 And N2 Wiring
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts 6. Connect the positive meter test lead to Wire N1 at the PROCEDURE: terminal block in the control panel. 1. On the generator panel, set the AUTO-OFF-MANUAL switch to OFF. a. Connect the negative meter lead to the ground lug.
Page 86: Test 37 - Check Utility Sensing Voltage At The Circuit Board
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts PROCEDURE: With utility source voltage available to terminal lugs N1 and N2, use a VOM to test for utility source line- 240 VAC to-line voltage across terminal locations N1 and N2 terminals. Normal line-to-line utility source voltage TEST POINTS should be indicated.
Page 87 sEctioN X.X sEctioN 3.4 Part 3 TRANSFER SWITCH XXXXXXXXXXXXXXXXXXXXXXXXXXX DiaGNostic tEsts TRANSFER SWITCH LEGEND BC-BATTERY CHARGER WIRE WIRE C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER F1,F2,F3-5A, 600V FUSE LC-CIRCUIT BREAKER (LOADS) (16 CIRCUIT SHOWN FOR REFERENCE ONLY) N-NEUTRAL SW1-AUTOMATIC TRANSFER SWITCH TB1-TERMINAL STRIP GENERATOR MAIN...
Page 88: Test 40 - Check Battery Charger Supply Voltage "Pre-Wire Load Center
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts 2. Test for utility source line-to-line voltage across Terminal PROCEDURE: Lugs N1 and N2 (see Figure 1). Normal utility source Refer to Figure 11. voltage should be indicated. 1. Set VOM to measure DC voltage. 2.
Page 89: Test 43 - Check Battery Charger Supply Voltage "Rtsn & Rtse Transfer Switch
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts a. If 115 Ohms is measured, proceed to Step 10. teSt 44 – check Battery charGer b. If zero resistance or CONTINUITY is measured, output VoltaGe connect the meter test leads across Terminals “rtSn &...
Page 90 sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts Figure 12. Test 43, 44, and 45 “RTSN Transfer Switch” Test Points. Page 88 0G9266revA.indd 88 10/15/2008 11:27:37 AM...
Page 91 sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts Figure 12A. Test 43, 44, and 45 “RTSE Transfer Switch” Test Points. Page 89 0G9266revA.indd 89 10/15/2008 11:27:39 AM...
Page 92: Test 46 - Check Battery Charger
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts 6. Measure across points G and H on the terminal strip. b. If 120 VAC is measured, proceed to Step 3. 12 VDC should be measured. 3. Measure across points C and D. 120 VAC should be measured.
Page 93 sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts Figure 13. Test 46, 47, and 48 “GenReady Load Center” Test Points. Page 91 0G9266revA.indd 91 10/15/2008 11:27:46 AM...
Page 94: Test 49 - Check Battery Charger Supply Voltage "Load Shed Transfer Switch
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts 3. Measure across points G and H on the terminal strip. PROCEDURE: 12VDC should be measured. Refer to Figure 14. 1. Set VOM to measure AC voltage. a. If 12 VDC is measured, the charger should be functioning.
Page 95 sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts Figure 14. Test 49, 50, and 51 “Load Shed Transfer Switch” Test Points. Page 93 0G9266revA.indd 93 10/15/2008 11:27:47 AM...
Page 96: Test 51 - Check Wire 0 And Wire 15B "Load Shed Transfer Switch
sEctioN 3.4 Part 3 TRANSFER SWITCH DiaGNostic tEsts 4. Reconnect battery charger black and red lead wires 7. In the generator control panel, measure across Wire 15B previously removed in Step 2. and Wire 0 at the customer connection. 12 VDC should be measured.
Page 97: Part 4 - Dc Control
taBlE of coNtENts Part titlE PaGE# 4.1. Description and components operational analysis Part 4 troubleshooting flow charts Dc coNtrol Diagnostic tests air-cooled, automatic standby Generators 4.1 Description and Components ........96 Test 57 – Try a Manual Start ......... 123 General ..............96 Test 58 –...
Page 98: Description And Components
sEctioN 4.1 Part 4 DC CONTROL DEscriPtioN aND comPoNENts General circuit Board This section will familiarize the reader with the various The circuit board controls all standby electric system components that make up the DC control system. operations including (a) engine startup, (b) engine running, (c) automatic transfer, (d) automatic retrans- Major DC control system components that will be fer, and (e) engine shutdown.
Page 99 sEctioN 4.1 Part 4 DC CONTROL DEscriPtioN aND comPoNENts 7.5 amp FuSe This fuse protects the circuit board against excessive current. If the fuse has blown, engine cranking and operation will not be possible. Should fuse replace- ment become necessary, use only an identical 7.5 amp replacement fuse.
Page 100 sEctioN 4.1 Part 4 DC CONTROL DEscriPtioN aND comPoNENts J2 CONNECTOR J1 CONNECTOR (PCB END) (PCB END) 10 11 12 13 14 15 16 17 18 J1 CONNECTOR J2 CONNECTOR (HARNESS END) (HARNESS END) N1/N2 CONNECTOR N1/N2 CONNECTOR (PCB END) (HARNESS END) Figure 4.
Page 101 sEctioN 4.1 Part 4 DC CONTROL DEscriPtioN aND comPoNENts J2 CONNECTOR J1 CONNECTOR (PCB END) (PCB END) 10 11 12 13 14 15 16 17 18 (STEPPER MOTOR) J1 CONNECTOR J2 CONNECTOR (HARNESS END) (HARNESS END) N1/N2 CONNECTOR N1/N2 CONNECTOR REMOTE WIRELESS CONNECTION (PCB END) (HARNESS END)
Page 102 sEctioN 4.1 Part 4 DC CONTROL DEscriPtioN aND comPoNENts J2 CONNECTOR J1 CONNECTOR (PCB END) (PCB END) 10 11 12 13 14 15 16 17 18 (STEPPER MOTOR) J1 CONNECTOR J2 CONNECTOR (HARNESS END) (HARNESS END) N1/N2 CONNECTOR N1/N2 CONNECTOR REMOTE WIRELESS CONNECTION (PCB END) (HARNESS END)
Page 103 sEctioN 4.1 Part 4 DC CONTROL DEscriPtioN aND comPoNENts J2 CONNECTOR J1 CONNECTOR (PCB END) (PCB END) 10 11 12 13 14 15 16 17 18 (STEPPER MOTOR) J1 CONNECTOR J2 CONNECTOR (HARNESS END) (HARNESS END) N1/N2 CONNECTOR N1/N2 CONNECTOR REMOTE WIRELESS CONNECTION (PCB END) (HARNESS END)
Page 104: Menu System Navigation
sEctioN 4.1 Part 4 DC CONTROL DEscriPtioN aND comPoNENts FEMALE SIDE MALE SIDE Figure 8. Choke Solenoid Connector Pin Number Identification menu SyStem naViGation CHANGING SETTINGS (EDIT MENU): To change a setting such as display contrast, go to To get to the MENU, use the "Esc" key from any page. the EDIT menu and use the +/- keys to navigate to It may need to be pressed many times before getting the setting to change.
Page 105 sEctioN 4.1 Part 4 DC CONTROL DEscriPtioN aND comPoNENts Page 103 0G9266revA.indd 103 10/15/2008 11:27:56 AM...
Page 106: Operational Analysis
sEctioN 4.2 Part 4 DC CONTROL oPEratioNal aNalYsis introduction This “Operational Analysis” is intended to familiarize the service technician with the operation of the DC control system on units with air-cooled engine. A thorough understanding of how the system works is essential to sound and logical troubleshooting.
Page 107 sEctioN 4.2 Part 4 DC CONTROL oPEratioNal aNalYsis • Utility source voltage is available to transfer switch Terminal Lugs N1/N2. With the transfer switch main contacts at their “Utility” side, this source voltage is available to Terminal Lugs T1/T2 and to the “Load” circuits. •...
Page 108: Initial Dropout Of Utility Source Voltage
sEctioN 4.2 Part 4 DC CONTROL oPEratioNal aNalYsis initial dropout oF utility Source VoltaGe Refer to Figure 2, below. Should a “Utility” power source failure occur, circuit condition may be briefly described as follows: • The circuit board constantly senses for an acceptable “Utility” source voltage, via transfer switch fuses F1/F2, transfer switch UTILITY 1 and UTILITY 2 terminals, connected wiring, control panel UTILITY 1 and UTILITY 2 terminals, and Wires N1/N2.
Page 109 sEctioN 4.2 Part 4 DC CONTROL oPEratioNal aNalYsis • Should utility voltage drop below approximately 65 percent of the nominal source voltage, a programmable timer on the circuit board will turn on. • In Figure 2, the 10-second timer is still timing and engine cranking has not yet begun. •...
Page 110: Utility Voltage Dropout And Engine Cranking
sEctioN 4.2 Part 4 DC CONTROL oPEratioNal aNalYsis utility VoltaGe dropout and enGine crankinG • After ten (10) seconds and when the circuit board’s 10-second timer has timed out, if utility voltage is still below 65 percent of nominal, circuit board action will energize the circuit board’s crank and run relays simultaneously. •...
Page 111 sEctioN 4.2 Part 4 DC CONTROL oPEratioNal aNalYsis • Printed circuit board action delivers 12 volts DC to the fuel solenoids (FS1 & FS2), via Wire 14. The fuel solenoids energize open and fuel is available to the engine. Wire 14 supplies power to the choke solenoid (CS). Circuit board action grounds Wire 90, energizing the choke solenoid cyclically during cranking and continuously while running.
Page 112: Engine Startup And Running
sEctioN 4.2 Part 4 DC CONTROL oPEratioNal aNalYsis enGine Startup and runninG With the fuel solenoids open and ignition occurring, the engine starts. Engine startup and running may be briefly described as follows: • Voltage pulses from the ignition magnetos are delivered to the circuit board via Wire 18. Once the circuit board determines that the engine is running, the circuit board (a) terminates cranking, and (b) terminates the choke solenoid (CS), and (c) turns on an “engine warm-up timer”.
Page 113 sEctioN 4.2 Part 4 DC CONTROL oPEratioNal aNalYsis • The “engine warm-up timer” will run for about 5 seconds. When this timer finishes timing, board action will initiate transfer to the STANDBY power source. As shown in Figure 4 (below), the timer is still running and transfer has not yet occurred.
Page 114: Initial Transfer To The "Standby" Source
sEctioN 4.2 Part 4 DC CONTROL 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 avail- able to transfer switch terminal lugs E1 and E2 and to the open contacts on the transfer relay. Initial transfer to the STANDBY power supply may be briefly described as follows: •...
Page 115 sEctioN 4.2 Part 4 DC CONTROL oPEratioNal aNalYsis • When the circuit board’s “engine warm-up timer” times out, circuit board action completes the Wire 23 circuit to ground. The transfer relay then energizes and its normally open contacts close. • Standby power is now delivered to the standby closing coil (C2), via Wires E1/E2, the normally open transfer relay contacts, Wire 205, limit switch XB1, Wire B, and a bridge rectifier.
Page 116: Re-Transfer To Utility
sEctioN 4.2 Part 4 DC CONTROL 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: •...
Page 117 sEctioN 4.2 Part 4 DC CONTROL oPEratioNal aNalYsis • The utility closing coil (C1) energizes and moves the main current carrying contacts to their NEUTRAL position. The main contacts move to an over center position past NEUTRAL and spring force closes them to their UTILITY side.
Page 118: Engine Shutdown
sEctioN 4.2 Part 4 DC CONTROL 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.
Page 119 sEctioN 4.2 Part 4 DC CONTROL oPEratioNal aNalYsis • Circuit board action will connect the engine’s ignition magnetos (IM1 & IM2) to ground, via Wire 18. Ignition will be terminated. • Without fuel flow and without ignition, the engine will shut down. Figure 7.
Page 120: Troubleshooting Flowcharts
sEctioN 4.3 Part 4 DC CONTROL trouBlEsHootiNG floW cHarts Problem 15 – Engine Will Not Crank When Utility Power Source Fails *8 kW system ready light will be flashing TEST 56 – CHECK TEST 57 – TRY A SWITCH IS VERIFY UTILITY POSITION OF MANUAL START...
Page 121: Problem 17 - Engine Cranks But Won't Start
sEctioN 4.3 Part 4 DC CONTROL trouBlEsHootiNG floW cHarts Problem 17 – Engine Cranks but Won’t Start TEST 66 – CHECK TEST 67 – CHECK TEST 68 – CHECK GOOD GOOD FUEL SUPPLY AND CIRCUIT BOARD FUEL SOLENOID PRESSURE WIRE 14 OUTPUT GOOD REPLACE FUEL SOLENOID FIND AND CORRECT...
Page 122: Problem 18 - Engine Starts Hard And Runs Rough / Lacks Power / Backfires
sEctioN 4.3 Part 4 DC CONTROL trouBlEsHootiNG floW cHarts Problem 18 – Engine Starts Hard and Runs Rough / Lacks Power / Backfires IF RECONFIGURED TO LP GAS, TEST 66 – CHECK CHECK AIR FILTER - VERIFY THAT PROPER FUEL SUPPLY AND GOOD GOOD REPLACE AS NEEDED...
Page 123: Problem 19 - Shutdown Alarm / Fault Occurred
sEctioN 4.3 Part 4 DC CONTROL trouBlEsHootiNG floW cHarts Problem 19 – Shutdown Alarm/Fault Occured CHECK FAULT LIGHTS PROCEED TO PROBLEM 16 OVERCRANK CHECK INSTALLATION FOR TEST 76 – CHECK HIGH PROPER AIRFLOW OR OIL TEMPERATURE HIGH TEMP REPLACE DEFECTIVE SWITCH SWITCH REPAIR LINKAGE IF BINDING.
Page 124: Problem 20 - 7.5 Amp Fuse (F1) Blown
sEctioN 4.3 Part 4 DC CONTROL trouBlEsHootiNG floW cHarts Problem 20 – 7.5 Amp Fuse (F1) Blown FUSE BLOWS WHEN TEST 80 – CHECK PLACED IN “AUTO” CRANKING AND OR “MANUAL” RUNNING CIRCUITS Problem 21 – Generator Will Not Exercise TEST 79 –...
Page 125: Diagnostic Tests
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts 3. If engine cranks but won’t start, go to Problem 17 in introduction Section 4.3. Perform these “Diagnostic Tests” in conjunction with 4. If engine cranks and starts, but transfer to “Standby” the “Troubleshooting Flow Charts”...
Page 126: Test 59 - Test Auto Operations
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts PROCEDURE: 1. Simulate a power failure by disconnecting main breaker. 2. If the generator does not perform the sequence of events listed in the above discussion, replace the printed circuit board. DEBUG RESULTS: Refer back to flow chart teSt 60 –...
Page 127 sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts B. pe r fo r m a l o a d t e s t o n t h e B a t t e r y : b. An average reading of 1.230 means the battery (maintenance Free Battery) is 75% charged.
Page 128: Test 62 - Check Wire 56 Voltage
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts teSt 62 – check Wire 56 VoltaGe RESULTS: 1. If battery voltage is indicated in Step 3 refer back to flow chart. DISCUSSION: During an automatic start or when starting manually, a crank relay on the circuit board should energize. Each time the crank relay energizes, the circuit board should deliver 12 VDC to a starter contactor relay (SCR), or starter contactor (SC), and the engine...
Page 129: Test 64 - Test Starter Contactor
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts 1. Connect the positive (+) meter test lead to the starter PROCEDURE: contactor stud (to which the red battery cable connects). 1. Set a VOM to measure DC voltage. Connect the common (-) meter test lead to a clean frame 2.
Page 130: Test 65 - Test Starter Motor
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts teSt 65 – teSt Starter motor CONDITIONS AFFECTING STARTER MOTOR PERFORMANCE: 1. A binding or seizing condition in the starter motor bearings. 2. A shorted, open or grounded armature. a. Shorted armature (wire insulation worn and wires touching one another).
Page 131 sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts Figure 15. Tachometer PINION TEST BRACkET: A starter motor test bracket may be made as shown in Figure 16. A growler or armature tester is available from an automobile diagnostic service supplier. Figure 13.
Page 132: Test 66 - Check Fuel Supply And Pressure
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts tENDs to sEttlE iN HiGH PlacEs. lP (ProPaNE) Gas is HEaViEr tHaN air, aND tENDs to sEttlE iN loW arEas. EVEN tHE sliGHtEst sParK caN iGNitE tHEsE GasEs aND causE aN EXPlosioN. PROCEDURE: A water manometer or a gauge that is calibrated in CLAMP ON...
Page 133: Test 67 - Check Circuit Board
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts PROCEDURE: 12-20 kW UNITS 1. Set the AUTO-OFF-MANUAL switch to OFF. 2. Set a VOM to measure DC voltage. PORT 3 3. Disconnect Wire 14 from the fuel solenoid (FS). 4. Connect the positive test lead to the disconnected Wire 14 from Step 3.
Page 134: Test 68 - Check Fuel Solenoid
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts If gas pressure is measured, the fuel solenoid is operat- i. Set a VOM to measure resistance. ing. If gas pressure is not measured, repair or replace the j. Connect one meter test lead to Wire 14 that fuel solenoid.
Page 135 sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts 7. With the generator running at a speed of approximately 60 Hertz, verify that the choke is energized and hold- CHOKE PLATE ing the choke plate open. Repeat Step 2 procedure, however, once the unit starts, manually hold the choke open while taking the voltage measurement.
Page 136: Test 70 - Check For Ignition Spark
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts 2. Disconnect the C3 Connector. 2. If Choke Solenoid coil resistance is not measured in Step 8, replace the Choke Solenoid. 3. Set a VOM to measure DC voltage. 3. If battery voltage was not measured in Step 4, replace 4.
Page 137 sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts CHOKE VALVE IN OPEN POSITION CHOKE SOLENOID AIR BOX CHOKE VALVE IN CLOSED POSITION Figure 26. 8kW Choke Solenoid Figure 28. Checking Ignition Spark To determine if an engine miss is ignition related, connect the spark tester in series with the spark plug wire and the spark plug (Figure 29).
Page 138: Test 71 - Check Spark Plugs
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts NORMAL MISFIRES Figure 29. Checking Engine Miss RESULTS: 1. If no spark or very weak spark occurs, go to Test 73. PRE-IGNITION DETONATION 2. If sparking occurs but engine still won’t start, go to Test 71. 3.
Page 139: Test 73 - Check Shutdown Wire
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts DISCUSSION: PROCEDURE: 1. Remove both spark plugs. The Cylinder Leak Down Tester checks the sealing (compression) ability of the engine by measuring air 2. Insert a compression gauge into either cylinder. leakage from the combustion chamber. Compression loss can present many different symptoms.
Page 140: Test 74 - Check And Adjust Ignition Magnetos
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts RESULTS: WIRE 18 CONNECTION 1. If INFINITY was not measured in Step 4, repair or replace shorted ground Wire 18 between the J1 Connector from the circuit board to the stud or bullet connector. 2.
Page 141 sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts PROCEDURE, ADJUSTING MAGNETO FLYWHEEL GAP: where Wire 56 was disconnected in Step 7. The engine should crank once the jumper from 15B note: the air gap between the ignition magneto is connected. and the flywheel on single cylinder engines is not adjustable.
Page 142 sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts RESULTS: If sparking still does not occur after adjusting the armature air gap, testing the ground wires and performing the basic flywheel test, replace the ignition magneto(s). PROCEDURE, REPLACING MAGNETOS: 1. Follow all steps of the Major Disassembly procedures that are located in Section 6.
Page 143: Test 75 - Check Oil Pressure Switch
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts 2. Check engine crankcase oil level. teSt 75 – check oil preSSure SWitch and Wire 86 a. Check engine oil level. b. If necessary, add the recommended oil to the dipstick FULL mark. DO NOT OVERFILL DISCUSSION: ABOVE THE FULL MARk.
Page 144: Test 76 - Check High Oil Temperature Switch
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts short to ground. Remove J1 Connector from the circuit a. Disconnect the J1 Connector from the printed circuit board. board. Set the VOM to measure resistance. Connect one test lead to Wire 85 (disconnected from High Oil b.
Page 145: Test 78 - Check Wire 18 Continuity
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts 2. Connect one meter test lead to Wire 18 that is connected PROCEDURE: (INTAkE AND EXHAUST) to the bolt connector shown in Figure 46. Connect the Make sure that the piston is at Top Dead Center other meter test lead to a clean frame ground.
Page 146: Test 79 - Test Exercise Function
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts 10. Connect one meter test lead to Wire 18 removed from 3. Press the right arrow key till a line is present under “EDIT”. the stud connector. Connect the other meter test lead to 4.
Page 147 sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts PROCEDURE: a. Connect one meter test lead to the SC terminal from which Wire 56 was removed. Connect the 1. Set a VOM to measure resistance. other meter test lead to the ground terminal, 4 2.
Page 148: Test 81 - Check To See If Low Speed
sEctioN 4.4 Part 4 DC CONTROL DiaGNostic tEsts d. If coil resistance was measured in CS and FS, PROCEDURE: and FS2 Wire 14 is shorted to ground between 1. Press the “ESC” key till the main menu is reached. J2 connector and CS, FS, or FS2, repair or 2.
Page 149: Part 5 - Operational Tests
taBlE of coNtENts Part titlE 5.1. system functional tests Part 5 oPEratioNal tEsts air-cooled, automatic standby Generators 5.1 System Functional Tests ........ 148 Introduction ............148 Manual Transfer Switch Operation ....148 Electrical Checks ...........148 Generator Tests Under Load ......149 Checking Automatic Operation ......150 Setting The Exercise Timer ......150 Page 147 0G9266revA.indd 147...
Page 150: System Functional Tests
sEctioN 5.1 OPERATIONAL TESTS Part 5 AND ADJUSTMENTS sYstEm fuNctioNal tEsts introduction iN DaNGErous aND PossiBlY lEtHal ElEctrical sHocK. Following home standby electric system installation 4. Remove the manual transfer handle from the enclosure. and periodically thereafter, the system should be tested Functional tests of the system include the 5.
Page 151: Generator Tests Under Load
sEctioN 5.1 OPERATIONAL TESTS Part 5 AND ADJUSTMENTS sYstEm fuNctioNal tEsts Generally, if both ac frequency and voltage are DANGER high or low, the engine governor requires adjust- ment. if frequency is correct, but voltage is high or low, the generator voltage regulator requires tHE traNsfEr sWitcH is NoW ElEctri- adjustment.
Page 152: Checking Automatic Operation
sEctioN 5.1 OPERATIONAL TESTS Part 5 AND ADJUSTMENTS sYstEm fuNctioNal tEsts 11. Let the generator run at full rated load for 20-30 minutes. the unit runs for approximately 12 minutes and then shuts down. Transfer of loads to the generator output Listen for unusual noises, vibration or other indications does not occur during the exercise cycle unless utility of abnormal operation.
Page 153: Part 6 - Disassembly
taBlE of coNtENts Part titlE 6.1. major Disassembly Part 6 DisassEmBlY air-cooled, automatic standby Generators 6.1 Major Disassembly ........152 Front Engine Access ........152 Major Disassembly .........156 Torque Requirements (Unless Otherwise Specified) ....162 Page 151 0G9266revA.indd 151 10/15/2008 11:28:23 AM...
Page 154: Major Disassembly
sEctioN 6.1 Part 6 DISASSEMBLY maJor DisassEmBlY 2. Remove controller: Using a Phillips screwdriver remove the Front enGine acceSS four mounting screws from the controller. See Figure 3. SAFETY: 1. Set the AUTO-OFF-MANUAL switch to OFF. 2. Remove the 7.5 amp main fuse. See Figure 1. 3.
Page 155: Major Disassembly
sEctioN 6.1 Part 6 DISASSEMBLY maJor DisassEmBlY 4. Remove Stator Wires: Remove all wires from the voltage regulator, remove the neutral and ground wires from landing lugs, and remove N1 & N2 wires from main bea- kers. See Figure 5. 5.
Page 156 sEctioN 6.1 Part 6 DISASSEMBLY maJor DisassEmBlY 8. Loosen side panel: Using a 10mm socket remove the 10. Remove fuel regulator: Remove the two fuel hoses at two bolts from the base of the enclosure side panel. See the top of the regulator. Using a 10mm socket remove Figure 10.
Page 157 sEctioN 6.1 Part 6 DISASSEMBLY maJor DisassEmBlY Figure 16. 13. Unbolt Oil Cooler: Using a 10mm socket remove the two 10mm bolts from the front of the oil cooler. See Figure 17. Remove the two 10mm bolts from the rear of the oil cooler.
Page 158: Major Disassembly
sEctioN 6.1 Part 6 DISASSEMBLY maJor DisassEmBlY 14. Remove Blower Housing: Using a 4mm allen wrench remove one button head cap screw from top of blower housing. Using a 10mm socket remove one 10mm bolt from the top of the blower housing. See Figure 19. Using a 10mm socket remove four 10mm bolts from the right- side of the blower housing, (see Figure 20) and four 10mm bolts from the left-side of the blower housing.
Page 159 sEctioN 6.1 Part 6 DISASSEMBLY maJor DisassEmBlY STATOR/ROTOR/ENGINE REMOVAL: 1. Remove Top Exhaust Enclosure Covers: Using a 10mm socket, remove the nine bolts from the exhaust top cov- ers. Remove covers. See Figure 23. Figure 25. 4. Remove Exhaust Flex Pipe: Using a ½” socket remove the front and rear muffler clamp.
Page 160 sEctioN 6.1 Part 6 DISASSEMBLY maJor DisassEmBlY Figure 27. Figure 29. 6. Remove Left-side enclosure: Using a 10mm ratchet 7. Remove Fan Housing Cover: Using a 10mm socket wrench remove the horizontal 10mm bolt that connects remove four bolts from the fan housing cover. Remove the side panel to the back panel.
Page 161 sEctioN 6.1 Part 6 DISASSEMBLY maJor DisassEmBlY 10. Remove Brushes: Using a 7mm socket remove brushes. See Figure 33. Figure 31. 9. Remove Fan: Attach a steering wheel puller to the fan Figure 33. using two M8 x 1.25 bolts. Remove the fan from the rotor.
Page 162 sEctioN 6.1 Part 6 DISASSEMBLY maJor DisassEmBlY 12. Remove Brush Wires: Using a side cutters remove the tie wraps securing the brush wires to the outside of sta- tor. See Figure 35. Figure 37. 15. Alternator Air Intake Bellows Removal: Remove alterna- tor intake bellows.
Page 163 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 screw- driver to screw it into the crankshaft.
Page 164: Torque Requirements
sEctioN 6.1 Part 6 DISASSEMBLY maJor DisassEmBlY 12. Remove Engine: Using proper lifting equipment remove torque requirementS the engine. See Figure 44. (unleSS otherWiSe SpeciFied) STATOR BOLTS ..........6 ft-lbs ( +1 / -0 ) ROTOR BOLT ..............30 ft-lbs ENGINE ADAPTOR ............
Page 165: Part 7 - Electrical Data
taBlE of coNtENts DWG# titlE 0G7945 WiriNG DiaGram, 8 KW HsB 0G8511 scHEmatic, 8 KW HsB Part 7 0G7946 WiriNG DiaGram, 10 KW HsB ElEctrical 0G8512 scHEmatic, 10 KW HsB 0G7947 WiriNG DiaGram, 14 KW HsB Data 0G8513 scHEmatic, 14 KW HsB 0G7948 WiriNG DiaGram, 17 KW HsB 0G8514...
Page 166: Wiring Diagram, 8 Kw Home Standby
WiriNG DiaGram, 8 KW HomE staNDBY Part 7 ELECTRICAL DATA DraWiNG #0G7945 GROUP G CONTROL PANEL ENGINE COMPARTMENT CAPACITOR STATOR N1 N2 MAIN CONTROLLER 2 3 4 9 10 12 13 14 15 16 17 18 CHOKE SOLENOID PANEL GND ENGINE FRAME WIRING - DIAGRAM...
Page 167 Part 7 WiriNG DiaGram, 8 KW HomE staNDBY ELECTRICAL DATA DraWiNG #0G7945 GROUP G CUSTOMER CONNECT AREA 240V GENERATOR OUTPUT TO TRANSFER SWITCH CONTACTOR LEGEND CB - CIRCUIT BREAKER, MAIN OUTPUT GND - GROUND HTO - HIGH TEMPERATURE SWITCH IM1 - IGNITON MODULE LOP - LOW OIL PRESSURE SWITCH SC - STARTER CONTACTOR SM - STARTER MOTOR...
Page 168: Schematic, 8 Kw Home Standby
scHEmatic, 8 KW HomE staNDBY Part 7 ELECTRICAL DATA DraWiNG #0G8511 GROUP G EXCITATION WINDING CAPACITOR 240 VAC GENERATOR OUTPUT POWER WINDING NEUTRAL STATOR POWER WINDING 240 VAC UTILITY INPUT OPTIONAL BATTERY WARMER CONTROLLER PRINTED CIRCUIT BOARD GROUND + BATTERY TRANSFER BATTERY LEGEND...
Page 169 Part 7 scHEmatic, 8 KW HomE staNDBY ELECTRICAL DATA DraWiNG #0G8511 GROUP G PAGE LEFT PLANK INTENTIONALLY SCHEMATIC - DIAGRAM REVISION: -A- 2008 AIR COOLED DRAWING #: 0G8511 DATE: Page 167 0G9266revA.indd 167 10/15/2008 11:28:35 AM...
Page 170: Wiring Diagram, 10 Kw Home Standby
WiriNG DiaGram, 10 KW HomE staNDBY Part 7 ELECTRICAL DATA DraWiNG #0G7946 GROUP G CONTROL PANEL ENGINE COMPARTMENT CAPACITOR STATOR N.C. N.C. N1 N2 MAIN CONTROLLER 2 3 4 9 10 12 13 14 15 16 17 18 CHOKE SOLENOID GOVERNOR ACTUATOR PANEL GND...
Page 171 Part 7 WiriNG DiaGram, 10 KW HomE staNDBY ELECTRICAL DATA DraWiNG #0G7946 GROUP G CUSTOMER CONNECT AREA 240V GENERATOR OUTPUT TO TRANSFER SWITCH CONTACTOR LEGEND CB - CIRCUIT BREAKER, MAIN OUTPUT GND - GROUND HTO - HIGH TEMPERATURE SWITCH IM_ - IGNITON MODULE LOP - LOW OIL PRESSURE SWITCH SC - STARTER CONTACTOR SCR - STARTER CONTROL RELAY...
Page 172: Schematic, 10 Kw Home Standby
scHEmatic, 10 KW HomE staNDBY Part 7 ELECTRICAL DATA DraWiNG #0G8512 GROUP G EXCITATION WINDING CAPACITOR 240 VAC GENERATOR OUTPUT POWER WINDING NEUTRAL STATOR POWER WINDING 240 VAC UTILITY INPUT OPTIONAL BATTERY WARMER LED BOARD CONTROLLER PRINTED CIRCUIT BOARD 1 2 3 4 GOVERNOR ACTUATOR GROUND...
Page 173 Part 7 scHEmatic, 10 KW HomE staNDBY ELECTRICAL DATA DraWiNG #0G8512 GROUP G PAGE LEFT BLANK INTENTIONALLY SCHEMATIC - DIAGRAM REVISION: -A- 2008 AIR COOLED DRAWING #: 0G8512 DATE: Page 171 0G9266revA.indd 171 10/15/2008 11:28:38 AM...
Page 174: Wiring Diagram, 14 Kw Home Standby
WiriNG DiaGram, 14 KW HomE staNDBY Part 7 ELECTRICAL DATA DraWiNG #0G7947 GROUP G CONTROL PANEL ENGINE COMPARTMENT VOLTAGE REGULATOR STATOR CLOSEST TO BEARING N1 N2 MAIN CONTROLLER 2 3 4 9 10 12 13 14 15 16 17 18 CHOKE SOLENOID GOVERNOR...
Page 175 Part 7 WiriNG DiaGram, 14 KW HomE staNDBY ELECTRICAL DATA DraWiNG #0G7947 GROUP G CUSTOMER CONNECT AREA 240V GENERATOR OUTPUT TO TRANSFER SWITCH CONTACTOR LEGEND BA - BRUSH ASSEMBLY CB - CIRCUIT BREAKER, MAIN OUTPUT GND - GROUND HTO - HIGH TEMPERATURE SWITCH IM_ - IGNITON MODULE LOP - LOW OIL PRESSURE SWITCH SC - STARTER CONTACTOR...
Page 176: Schematic, 14 Kw Home Standby
scHEmatic, 14 KW HomE staNDBY Part 7 ELECTRICAL DATA DraWiNG #0G8513 GROUP G VOLTAGE REGULATOR POWER WINDING STATOR POWER WINDING BATTERY SCHEMATIC - DIAGRAM REVISION: -A- 2008 AIR COOLED DRAWING #: 0G8513 DATE: Page 174 0G9266revA.indd 174 10/15/2008 11:28:41 AM...
Page 177 Part 7 scHEmatic, 14 KW HomE staNDBY ELECTRICAL DATA DraWiNG #0G8513 GROUP G 240 VAC GENERATOR OUTPUT NEUTRAL 240 VAC UTILITY INPUT OPTIONAL BATTERY WARMER LED BOARD CONTROLLER PRINTED CIRCUIT BOARD GOVERNOR ACTUATOR GROUND + BATTERY TRANSFER LEGEND BA - BRUSH ASSEMBLY LOP - LOW OIL PRESSURE SWITCH SC - STARTER CONTACTOR CB - CIRCUIT BREAKER, MAIN OUTPUT...
Page 178: Wiring Diagram, 17 Kw Home Standby
WiriNG DiaGram, 17 KW HomE staNDBY Part 7 ELECTRICAL DATA DraWiNG #0G7948 GROUP G CONTROL PANEL ENGINE COMPARTMENT VOLTAGE REGULATOR STATOR CLOSEST TO BEARING N1 N2 MAIN CONTROLLER 2 3 4 9 10 12 13 14 15 16 17 18 CHOKE SOLENOID GOVERNOR...
Page 179 Part 7 WiriNG DiaGram, 17 KW HomE staNDBY ELECTRICAL DATA DraWiNG #0G7948 GROUP G CUSTOMER CONNECT AREA 240V GENERATOR OUTPUT TO TRANSFER SWITCH CONTACTOR LED BOARD 120V/15A DUPLEX L1: GREEN = SYSTEM READY LEGEND L2: YELLOW = MAINTENANCE REQ'D L3: RED = ALARM BA - BRUSH ASSEMBLY CB - CIRCUIT BREAKER, MAIN OUTPUT GND - GROUND...
Page 180: Schematic, 17 Kw Home Standby
scHEmatic, 17 KW HomE staNDBY Part 7 ELECTRICAL DATA DraWiNG #0G8514 GROUP G VOLTAGE REGULATOR POWER WINDING STATOR POWER WINDING BATTERY SCHEMATIC - DIAGRAM REVISION: -A- 2008 AIR COOLED DRAWING #: 0G8514 DATE: Page 178 0G9266revA.indd 178 10/15/2008 11:28:45 AM...
Page 181 Part 7 scHEmatic, 17 KW HomE staNDBY ELECTRICAL DATA DraWiNG #0G8514 GROUP G 240 VAC GENERATOR OUTPUT NEUTRAL 240 VAC UTILITY INPUT OPTIONAL BATTERY WARMER 120 VAC ACCESSORY POWER CONTROLLER OUTPUT PRINTED CIRCUIT BOARD GOVERNOR ACTUATOR LED BOARD GROUND + BATTERY TRANSFER LEGEND BA - BRUSH ASSEMBLY...
Page 182: Wiring Diagram, 20 Kw Home Standby
WiriNG DiaGram, 20 KW HomE staNDBY Part 7 ELECTRICAL DATA DraWiNG #0G8186 GROUP G CONTROL PANEL ENGINE COMPARTMENT VOLTAGE REGULATOR STATOR CLOSEST TO BEARING N1 N2 MAIN CONTROLLER 2 3 4 9 10 12 13 14 15 16 17 18 CHOKE SOLENOID GOVERNOR...
Page 183 Part 7 WiriNG DiaGram, 20 KW HomE staNDBY ELECTRICAL DATA DraWiNG #0G8186 GROUP G CUSTOMER CONNECT AREA 240V GENERATOR OUTPUT TO TRANSFER SWITCH CONTACTOR LED BOARD 120V/15A DUPLEX L1: GREEN = SYSTEM READY LEGEND L2: YELLOW = MAINTENANCE REQ'D L3: RED = ALARM BA - BRUSH ASSEMBLY CB - CIRCUIT BREAKER, MAIN OUTPUT GND - GROUND...
Page 184: Schematic, 20 Kw Home Standby
scHEmatic, 20 KW HomE staNDBY Part 7 ELECTRICAL DATA DraWiNG #0G8515 GROUP G VOLTAGE REGULATOR POWER WINDING STATOR POWER WINDING BATTERY SCHEMATIC - DIAGRAM REVISION: -A- 2008 AIR COOLED DRAWING #: 0G8515 DATE: Page 182 0G9266revA.indd 182 10/15/2008 11:28:49 AM...
Page 185 Part 7 scHEmatic, 20 KW HomE staNDBY ELECTRICAL DATA DraWiNG #0G8515 GROUP G 240 VAC GENERATOR OUTPUT NEUTRAL 240 VAC UTILITY INPUT OPTIONAL BATTERY WARMER 120 VAC ACCESSORY POWER OUTPUT CONTROLLER PRINTED CIRCUIT BOARD GOVERNOR ACTUATOR LED BOARD GROUND + BATTERY TRANSFER LEGEND BA - BRUSCH ASSEMBLY...
Page 186: Wiring Diagram, Home Standby Transfer Switch, 9/10/12/16 Circuit
WiriNG DiaGram, HomE staNDBY Part 7 ELECTRICAL DATA traNsfEr sWitcH, 9/10/12/16 circuit DraWiNG #0G7958 GROUP G ALL CIRCUIT GROUNDED CONDUCTORS NOT SHOWN FOR CLARITY 16 CIRCUIT LOAD CENTER 14 CIRCUIT LOAD CENTER 12 CIRCUIT LOAD CENTER 10 CIRCUIT LOAD CENTER 8 CIRCUIT LOAD CENTER WIRING - DIAGRAM REVISION: "A"...
Page 187 WiriNG DiaGram, HomE staNDBY Part 7 ELECTRICAL DATA traNsfEr sWitcH, 9/10/12/16 circuit DraWiNG #0G7958 GROUP G N1A N2A WIRE WIRE 0D4698-T LEGEND BC-BATTERY CHARGER C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER F1,F2,F3-5A, 600V FUSE LC-CIRCUIT BREAKER (LOADS) (16 CIRCUIT SHOWN FOR REFERENCE ONLY) N-NEUTRAL SW1-AUTOMATIC TRANSFER SWITCH SW2,SW3-LIMIT SWITCHES...
Page 188: Schematic, Home Standby Transfer Switch, 9/10/12/16 Circuit
scHEmatic, HomE staNDBY Part 7 ELECTRICAL DATA traNsfEr sWitcH, 9/10/12/16 circuit DraWiNG #0G7959 GROUP G CONTROL TRANSFER TS TO GENERATOR CONTROL PANEL UTILITY SENSING 240VAC OUTPUT BLACK WIRE WIRE TO GENERATOR OUTPUT NEUTRAL (WHITE) GROUND (GREEN) NEUTRAL CONNECTION INSIDE GROUND (GREEN) SWITCH NEUTRAL (WHITE) 240VAC TO...
Page 189 Page 187 0G9266revA.indd 187 10/15/2008 11:28:53 AM...
Page 190 Page 188 0G9266revA.indd 188 10/15/2008 11:28:53 AM...
Page 191 0G9266revA.indd 189 10/15/2008 11:28:53 AM...
Page 192 CAC / BDP 7310 W. Morris Street Indianapolis, IN 46231 Catalog No. ASPDS-Y-1DM Printed in USA 01.09 Specifications are subject to change without notice. 0G9266revA.indd 190 10/15/2008 11:28:53 AM...

CAC / BDP 7 kW NG Diagnostic Repair Manual

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