Generac Power Systems 12.5kW Manuals

Manuals and User Guides for Generac Power Systems 12.5kW. We have 1 Generac Power Systems 12.5kW manual available for free PDF download: Diagnostic Repair Manual

Generac Power Systems 12.5kW Diagnostic Repair Manual (231 pages)

Home Standby Generators

Brand: Generac Power Systems | Category: Portable Generator | Size: 25.6 MB

Generator Specifications
5
Stator Winding Resistance Values
5
Air-Cooler V-Twin Engine Specifications
6
Liquid-Cooled 1.2 Liter Engine Specifications
6
The 8 KW, Air-Cooled Prepackaged Generator
7
Typical Prepackaged Generator with 1.2 Liter Engine
8
General Information
9
Table of Contents
9
Generator Identification
11
Units with Air-Cooled V-Twin Engine
11
Units with Liquid Cooled Engine
11
Voltage Codes
11
Generator Identification Code
12
Typical Data Plate
13
Typical Data Card
13
AC Connection Systems
15
Dual Stator Power Windings
15
Prepackaged Installation Basics
17
Selecting a Location
17
Mounting the Generator
17
Grounding the Generator
17
Lp/Natural Gas System (Air-Cooled Units)
18
LP Gas System
18
Natural Gas System-Liquid Cooled Units
18
The Transfer Switch
19
Power Source and Load Lines
19
System Control Interconnections
19
Installation with a GTS Transfer Switch
20
Preparation before Use
21
Fuel Requirements
21
Engine Oil Recommendations
21
Recommended Engine Coolant
22
Engine Governor Oiling
22
Visual Inspection
23
Measuring Voltages
23
Measuring Current
23
Measuring Resistance
23
Stator Insulation Tests-Air Cooled Units
24
Stator Insulation Tests - Liquid Cooled Units with 1-Phase Stator
25
Stator Insulation Tests - Liquid Cooled Units with 3-Phase Stator
26
Testing Rotor Insulation
26
Cleaning the Generator
27
Drying the Generator
27
Engine - Generator Protective Devices
29
Units with Air-Cooled Engine
29
Protective Devices on Liquid Cooled Engine
30
Operating Instructions
31
Control Panel - Units with Air-Cooled Engine
31
Control Panel - Units with Liquid Cooled Engine
31
To Select Automatic Operation
33
Manual Transfer to "Standby" and Manual Startup
33
Manual Shutdown and Retransfer Back to "Utility"
34
The Set Exercise Time Switch
34
Automatic Operating Parameters
35
Automatic Operating Sequences
35
Automatic Operating Sequences Chart
36
Prepackaged Air-Cooled AC Generators
37
Other AC Generator Components
39
Field Boost Circuit
40
Operational Analysis
41
Rotor Residual Magnetism
41
Field Boost
41
Operation
41
Troubleshooting Flow Charts
43
Generator Produces Zero or Residual Voltage
43
Generator Produces Low Voltage at No-Load
44
Generator Produces High Voltage at No-Load
44
Voltage and Frequency Drop Excessively When Loads and Applied
45
Description and Components
47
Engine-Generator Drive System
47
The AC Generator
47
Lower Bearing Carrier
47
Rotor Assembly
48
Stator Assembly
48
Upper Bearing Carrier
48
Brush Holder and Brushes
48
Diagnostic Tests
49
Safety
49
Check Main Circuit Breaker
49
Check AC Output Voltage
49
Test Excitation Circuit Breaker
50
Test Stator DPE Winding
50
Check Brushes and Slip Rings
51
Test Rotor Assembly
52
Check Field Boost
52
Check Voltage Regulator
53
Check AC Output Frequency
53
Check and Adjust Engine Governor
53
Check and Adjust Voltage Regulator
54
Check Voltage and Frequency under Load
54
Check for Overload Condition
54
Prepackaged Liquid-Cooled AC Generators
55
Description and Major Components
57
Blower Housing
57
Fan and Ring Gear Assembly
57
Rear Bearing Carrier
57
Exploded View of AC Generator Components
58
The Excitation Circuit
59
AC Meters
60
Schematic Diagram of AC Generator
61
Block Diagram of AC Generator
62
Check Voltage-Phase Selector Switch Position
67
Check AC Voltmeter
67
Test Thermal Protector
68
Test Voltage Regulator
69
Check Leads 1 and 4
69
Test Rotor Windings
70
Test Voltage-Phase Selector Switch
70
"V-Type" Prepackaged Transfer Switches
75
Transfer Switch Major Components
77
Exploded View of V-Type Prepackaged Transfer Switch
77
Enclosure
78
Transfer Mechanism
78
Transfer Relay
79
Neutral Lug
79
Manual Transfer Handle
79
Terminal Block
79
Fuse Holder
80
Utility Source Voltage Available
81
Utility Source Voltage Dropout
81
Transfer to Standby
81
Retransfer Back to Utility
82
In Automatic Mode, no Transfer to Standby
83
In Automatic Mode, no Retransfer Back to Utility
83
In Automatic Mode, Generator Starts and Transfer to Standby Occurs When Utility Source Voltage Is Available
84
Check Voltage at Terminal Lugs E1, E2
85
Check Voltage at Standby Closing Coil C2
85
Test Transfer Relay TR
86
Check Manual Transfer Switch Operation
86
Test Limit Switch XB1
87
Check Voltage at Terminal Lugs N1, N2
87
Check Voltage at Utility 1 and Utility 2 Terminals
88
Check Voltage at Utility Closing Coil C1
88
Check Fuses F1 and F2
89
Test Limit Switch XA1
89
"Y-Type" Prepackaged Transfer Switches
91
Prepackaged Terminal Strip
96
3-Phase Power Monitor
97
Switch Enclosure
97
Utility Voltage Available (2-Pole Units)
99
Utility Voltage Available (3-Pole Units)
99
Utility Voltage Dropout (2-Pole Units)
100
Utility Power Outage (3-Pole Units)
100
Initial Transfer to Standby (2-Pole Units)
101
Initial Transfer to Standby (3-Pole Units)
101
Final Transfer to Standby (2-Pole Units)
102
Final Transfer to Standby (3-Pole Units)
102
Retransfer to Utility (2-Pole Units)
103
Retransfer to Utility (3-Pole Units)
103
In Automatic Mode, will Not Transfer to "Standby"
105
In Automatic Mode, will Not Retransfer to "Utility"
106
Genset Starts and Transfer Occurs When Utility Power Is Available (3-Phase Transfer Switches)
107
Test Automatic Operation
109
Check Voltage at Terminals E1/E2/E3
110
Check Voltage at Terminals B1/B2
110
Check Wiring
111
Test Limit Switch LS3
111
Test Limit Switch LS1
112
Test Limit Switch LS2
113
Test Bridge Rectifier
113
Test Solenoid Coil
115
Check Manual Operation
115
Inspect Main Contacts
115
Check Voltage at Terminals N1/N2/N3
116
Check Voltage at Terminals A1/A2
116
Check Voltage at Terminals N1A/N2 of Customer Terminal Strip
116
Test 3-Phase Power Monitor
116
Transfer Mechanism Removal
119
Electrical Section Disassembly
119
Stationary Main Contacts Removal
122
Moveable Main Contacts
122
Testing and Inspection
122
Reassembly
122
DC Control (Units with Air Cooled Engine)
123
Auto-Off-Manual Switch
125
15 Amp Fuse
125
Initial Dropout of Utility Source Voltage
128
Utility Voltage Dropout and Engine Cranking
129
Engine Startup and Running
130
Initial Transfer to the "Standby" Source
131
Utility Voltage Restored and Retransfer to "Utility"
132
Engine Shutdown
133
Engine will Not Crank When Utility Power Source Fails
135
Engine will Not Crank When Auto-Off-Manual Switch Is Set to "Manual"
135
Engine Cranks and Starts but no Transfer to Standby
137
No Automatic Retransfer Back to Utility
138
Unit Starts & Transfer Occurs When Utility Power Is Available
139
Generator Does Not Start and Exercise as Programmed
139
Check Position of Auto-Off-Manual Switch
141
Try a Manual Start
141
Test Auto-Off-Manual Switch
141
Check Wires 15A
142
Check 15 Amp Fuse
142
Check Battery
142
Check Wires 15/15A Voltage
143
Check Wire 56 Voltage
143
Test Starter Contactor
144
Test Starter Motor
144
Check Fuel Supply and Pressure
145
Check CMA Circuit Board Power Supply and Output to Wire 56
146
Check CMA Board Wire 14 Output
146
Check Fuel Solenoid
146
Check for Ignition Spark
147
Check Spark Plugs
147
Check Engine Compression
148
Check Engine I.S.D. Module
148
Check and Adjust Ignition Modules
149
Check Oil Pressure Switch
149
Check High Oil Temperature Switch
150
Check Wire 18
150
Check Generator Main Circuit Breakers
150
Test Stator Battery Charge Winding Output
150
Ground CMA Terminal 23
151
Test Terminals 23 and 194 Circuit
151
Test Sensing Transformer
152
Disconnect Wire 23 from CMA Terminal Strip
152
Check Utility Sensing Voltage at CMA Circuit Board
152
Check Transfer Switch Fuses F3 and F4
153
Check Voltage at CMA Utility 1 and 2 Terminals
153
Check Voltage at Transfer Switch Load 1 and Load 2 Terminals
153
Reset Exercise Timer
153
DC Control Liquid Cooled Engine Units
155
Control Module Assembly
157
Control Console Components
158
Engine Mounted Components
160
Transfer Switch
161
DC Control System Schematic
163
Circuit Condition-Utility Source Voltage Available
164
Circuit Condition - Initial Utility Voltage Dropout
166
Circuit Condition - Cranking and Initial Startup
168
Circuit Condition - Initial Transfer to Standby
170
Circuit Condition - Utility Voltage Restored
174
Circuit Condition - Initial Retransfer Back to Utility
176
Circuit Condition - Final Retransfer to Utility
178
Circuit Condition - Generator Shutdown
180
Check Auto-Off-Manual Switch Position
187
Try to Start Engine Manually
187
Inspect Auto-Off-Manual Switch to CMA Circuit Board Wiring
188
Check 30 Amp Fuse F1
188
Test Control Contactor CC
188
Test Starter Motor SM
189
Check CMA Circuit Board Power and Wire 56 Output
190
Check for Mechanical Damage
190
Check Fuel Supply
190
Check Wire 14 Output to Ignition
192
Test Ignition Coil
193
Test Ignition Condensor
193
Inspect Distributor Cap and Rotor Head
193
Inspect Contact Points
194
Check Governor Advance
194
Check Ignition Wires
194
Check Ignition Timing
195
Check DC Volts at Terminal 14 of TB1
195
Test Fuel Solenoid FS
195
Check Engine Compression and Condition
195
Check Generator Main Line Circuit Breaker
196
Check Sensing to CMA Circuit Board
196
Check Voltage at Terminal Lugs E1, E2, E3
197
Check Voltage at Terminal Lugs N1, N2, N3
197
Check Voltage at CMA Terminals N1A and N2
197
Operational Tests and Adjustments
199
Manual Transfer Switch Operation
201
System Voltage Tests
202
Generator Tests under Load
202
Testing Automatic Operation
203
The 7-Dat Exercise Cycle
205
Adjusting the Engine Governor
205
Voltage Regulator Checks and Adjustments
206
Load Block Adjustments
206
Adjusting Drive Belt Tension
208
Setting Weel;Y Exercise Cycle
209
Engine Governor Adjustment
209
Voltage Regulator Adjustment
210
Adjustment of 3-Phase Power Monitor
211
Electrical Data
213
Schematic Diagram
215
Wiring Diagram
216

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