Generac Power Systems PowerPact 6/7.5 kW 60 Hz Manuals

Manuals and User Guides for Generac Power Systems PowerPact 6/7.5 kW 60 Hz. We have 1 Generac Power Systems PowerPact 6/7.5 kW 60 Hz manual available for free PDF download: Diagnostic Repair Manual

Generac Power Systems PowerPact 6/7.5 kW 60 Hz Diagnostic Repair Manual (152 pages)

Home Standby Generator

Brand: Generac Power Systems | Category: Portable Generator | Size: 13 MB

Read this Manual Thoroughly
2
Replacement Parts
2
Table of Contents
3
Specifications
6
Generator
6
Engine
6
Fuel Consumption
7
Major Features - Corepower
7
Major Features - Powerpact
7
Interconnections - Corepower
8
Interconnections - Powerpact (60 Hz)
9
Interconnections - Powerpact (50 Hz)
10
Part 1 - General Information
11
Section 1.1 - Generator Basics
12
Introduction
12
Parts
12
Generator Identification
12
Section 1.2 - Measuring Electricity
13
Meters
13
The vom
13
Measuring AC Voltage
13
Measuring DC Voltage
13
Measuring AC Frequency
13
Measuring Current
14
Measuring Resistance
14
Electrical Units
15
Ohm's Law
15
Section 1.3 - Preparation before Use
16
Introduction
16
Fuel Consumption
16
Reconfigure the Fuel System
16
Section 1.4 - Operating Instructions
18
Control Panel
18
Before Initial Start-Up
18
Generator Activation
18
User Interface
19
Automatic Operation
19
Manual Operation
19
Shutting Generator down While under Load
20
Section 1.5 - Automatic Operating Parameters
21
Introduction
21
Utility Failure
21
Cranking
21
Cranking Conditions
21
Load Transfer Parameters
22
Cold Smart Start
22
Section 1.6 - General Maintenance
23
Introduction
23
Engine Oil
23
Engine Oil Recommendations
23
Air Filter
23
Spark Plugs
23
Visual Inspection
23
Corrosion Protection
23
Valve Clearance
23
Battery
24
Service Schedule - Corepower
24
Service Schedule - Powerpact
25
Section 1.7 - General Troubleshooting
26
Introduction
26
Recommended Tools
26
Troubleshooting Reminders and Tips
26
Connectors
26
Part 2 - AC Generators
27
Section 2.1 - Description and Components
28
Introduction
28
Engine-Generator Drive System
28
Alternator Assembly
28
Brush Holder and Brushes
29
Other AC Generator Components
29
Section 2.1 - Description and Components
29
Section 2.2 - Operational Analysis
30
On-Speed Operation
30
Field Excitation
30
Startup
30
AC Power Winding Output
30
Voltage Regulator
30
Section 2.3 - Troubleshooting Flowcharts
31
Introduction
31
Problem 1 - Generator Produces Zero Voltage or Residual Voltage
31
Problem 2 - Generator Produces Low Voltage at No-Load Problem 2 - Generator Produces Low Voltage at No-Load
32
At No-Load
32
Problem 3 - Generator Produces High Voltage
33
At No-Load
33
Problem 4 - Voltage and Frequency Drop Excessively When Loads Are Applied Problem 4 - Voltage and Frequency Drop Excessively When Loads Are Applied
33
Excessively When Loads Are Applied
33
Section 2.4 - Diagnostic Tests
34
Introduction
34
Safety
34
AC Troubleshooting
34
Test 1 - Check Main Circuit Breaker
34
Test 4 - Fixed Excitation /Rotor Amp Draw Test
34
Test 6 - Resistance Check of Rotor and Rotor Circuit
37
Test 7 - Check Brushes and Slip Rings
37
Test 9 - Test the Stator
37
Test 11 - Check AC Output Voltage
39
Test 12 - Check AC Output Frequency
40
Test 13 - Check and Adjust Engine Governor
40
Test 14 - Adjust Voltage Regulator
41
Test 15 - Check for Overload Condition
42
Test 16 - Check Voltage and Frequency under Load
42
Part 3 - Transfer Switch
43
Section 3.1 - Description and Components
44
General
44
Enclosure
44
EZ Transfer Operator (Genready Switch Only)
44
Fuse Holder
44
Load Management Options
44
Smart Management Module (SMM)
44
Understanding the Smart Management Module
45
Setting Priorities
46
Tests
46
Troubleshooting
47
Section 3.2 - Operational Analysis
48
Utility Voltage Present
48
Transfer to Standby
48
Transfer to Utility
48
Section 3.3 - Troubleshooting Flowcharts
49
Introduction
49
Problem 10 - in Automatic Mode, no Transfer to Standby Problem 10 - in Automatic Mode, no Transfer to Standby
49
Generator Transfers to Standby During Exercise or in Manual Mode
49
No Transfer to Standby
49
Problem 11- in Automatic Mode, Generator
49
Problem 12 - Blown F1 or F2 Fuse
50
Problem 13 - Blown T1 Fuse
50
Utility Power Is on
50
(SMM) LED Is Off, Load Not Powered
50
Smm Problem 2 - Load Management Module
51
(SMM) LED Is On, Load Not Powered
51
Smm Problem 3 - Load Management Module
51
(SMM) LED Is Flashing, Load Not Powered
51
Smm Problem 4 - Load Management Module
51
(SMM) Is Humming or Buzzing
51
Section 3.4 - Diagnostic Tests
52
Introduction
52
Safety
52
Transfer Switch Troubleshooting
52
Test 26 - Check Manual Transfer Switch Operation
52
Test 27 - Check Generator Voltage at Transfer Switch
53
Test 28 - Test Transfer Operator
53
(Genready Switch Only)
53
Test 29 - Check 15B/194 Circuit
53
Test 30 - Check Wire 23 Circuit
53
Test 32 - Check Fuses F1 and F2
54
Test 33 - Check N1 and N2 Wiring
55
Test 35 - Check Fuse F3
55
Test 36 - Check T1 Wiring (60 Hz)
55
Test 36A - Check T1 and T2 Wiring (50 Hz)
55
Test 37 - Test SMM Contactor
56
Line, Load and Control
56
Test 38 - Check N1 and N2 Voltage
56
Test Points
56
Test 39 - Check Utility Sense Voltage
56
Test 40 - Check Utility Voltage at Transfer Switch
57
Test 41 - Check Utility Sensing Voltage
57
At the Controller
57
Part 4 - Engine/DC Control
61
Section 4.1 - Description and Components
62
General
62
Terminal Strip / Interconnection Terminal
62
(Corepower Only)
62
Controller
62
Auto-Off-Manual Control
62
7.5 Amp Fuse
62
Battery Charger (Corepower Only)
62
Section 4.2 - Engine Protective Devices
65
Alarms
65
Clear Alarms
65
Warnings
65
Section 4.3 - Operational Analysis
66
Utility Source Available - Corepower
66
Utility Failure and Engine Cranking - Corepower
66
Utility Failure and Engine Running - Corepower
68
Utility Source Available - Powerpact
69
Utility Failure and Engine Cranking - Powerpact
70
Utility Failure and Engine Running - Powerpact
71
Section 4.4 - Troubleshooting Flowcharts
72
Problem 20 - Engine will Not Crank When
72
Utility Power Source Fails
72
Problem 21 - Engine will Not Crank When Controller Is Set to "MANUAL" Mode
72
Controller Is Set to "Manual" Mode
72
Problem 22 - Engine Cranks but Won't Start
73
Problem 23 - Engine Starts Hard and Runs Rough / Lacks Power / Backfires
74
Problem 24 - Shutdown Alarm/Fault Occurred
75
Problem 25 - 7.5 Amp Fuse (F1) Blown
76
Problem 26 - Generator will Not Exercise
76
Problem 27 - no Battery Charge
76
Section 4.5 - Diagnostic Tests
77
Introduction
77
Safety
77
Engine/DC Troubleshooting
77
Test 52 - Check Controller Switch Position
77
Test 53 - Try a Manual Start
78
Test 54 - Test Auto Operations
78
Test 55 - Check 7.5 Amp Fuse
78
Test 56 - Check Battery and Cables
79
Test 57 - Check Wire 56 Voltage
80
Test 58 - Test Starter Contactor
81
Test Point
81
Test 59 - Test Starter Motor
81
Test 60 - Check Fuel Supply and Pressure
82
Test 61 - Check Controller Wire 14 Output
83
Test 62 - Check Fuel Solenoid
83
Test 63 - Check Choke Solenoid
83
Test 64 - Check for Ignition Spark
84
Test 65 - Check Spark Plugs
85
Test 66 - Check Engine / Cylinder Leak down Test
85
Compression Test
85
Cylinder Leak down Test
86
Check Compression
86
Test 67 - Check Ignition Coil
86
(Corepower Only)
87
Test 68A - Check Oil Pressure Switch and Wire
88
Test 68B - Check Oil Level Switch and Wire
88
(Powerpact Only)
88
Test 69 - Check High Oil Temperature Switch
88
Test 70 - Check and Adjust Valves
89
Test 71 - Check Wire 18 Continuity
90
Test 72 - Test Exercise Function
90
Test 73 - Test Cranking and Running Circuits
90
Test 74 - Check Battery Charger Supply Voltage
91
(Corepower Only)
91
Test 76 - Check Battery Charger out Voltage
92
(Powerpact Only)
92
Test 78 - Check Wire 0/15B
92
(Corepower Only)
92
Only)
92
Test 79 - Check Shutdown Wire
93
Part 5 - Disassembly
95
Section 5.1 - Major Disassembly - Corepower
95
Section 5.2 - Major Disassembly - Powerpact
95
Section 5.3 - Exploded Views
108
Part 6 - Electrical Data
131
Wiring Diagram - Drawing 0H7182-C (Corepower)
132
Wiring Diagram
132
Electrical Schematic
133
Drawing 0H7182-C (Corepower)
133
Drawing 0K7328-C (60 Hz Powerpact 1 of 4)
134
Drawing 0K7328-C (60 Hz Powerpact 2 of 4)
135
Electrical Schematic - Drawing 0K7328-C (60 Hz Powerpact 3 of 4)
136
Electrical Schematic - Drawing 0K7328-C (60 Hz Powerpact 4 of 4)
137
Drawing 0K7876-D (50 Hz Powerpact 1 of 4)
138
Drawing 0K7876-D (50 Hz Powerpact 2 of 4)
139
Drawing 0K7876-D (50 Hz Powerpact 3 of 4)
140
Drawing 0K7876-D (50 Hz Powerpact 4 of 4)
141
Wiring Diagram
142
Drawing 0K5879-B (50 Amp Transfer Switch)
142
Electrical Schematic - Drawing 0K5881-B (50 Amp Transfer Switch)
144
Electrical Formulas
146
Appendix A - Supplemental Worksheets
147

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