Bryant ASPAS1BBA015 User Manual

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AUTOMATIC HOME STANDBY GENERATORS

AIR-COOLED MODELS:

ASPAS1BBA007

(6 kW NG, 7 kW LP)

ASPAS1BBA012

(12 kW NG, 12 kW LP)

ASPAS1BBA015

(13 kW NG, 15 kW LP)

DIAGNOSTIC REPAIR MANUAL

www.bryant.com

SPECIFICATIONS

GENERATOR

Model ASPAS1BBA007 Model ASPAS1BBA012 Model ASPAS1BBA015

Rated Max. Continuous Power Capacity (Watts*) 6,000 NG/7,000 LP 12,000 NG/12,000 LP 13,000 NG/15,000 LP Rated Voltage 120/240 120/240 120/240 Rated Max. Continuous Load Current (Amps)

120 Volts** 50.0 NG/58.3 LP 100.0 NG/100.0 LP 108.3 NG/125.0 LP

240 Volts 25.0 NG/29.2 LP 50.0 NG/50.0 LP 54.2 NG/62.5 LP Main Line Circuit Breaker 30 Amp 50 Amp 70 Amp Phase 1 1 1 Number of Rotor Poles 2 2 2 Rated AC Frequency 60 Hz 60 Hz 60 Hz Power Factor 1 1 1 Battery Requirement Group 26/26R Group 26/26R Group 26/26R

12 Volts and 12 Volts and 12 Volts and

350 Cold-cranking 525 Cold-cranking 525 Cold-cranking

Amperes Minimum Amperes Minimum Amperes Minimum Weight 375 Pounds 470 Pounds 487 Pounds Output Sound Level @ 23 ft (7m) at full load 68 db (A) 70.5db (A) 71.5 db (A) Normal Operating Range -20°F (-28.8°C) to 104°F (40°C)

* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power

decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F) ambient temperature.

** Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value stated for 240 volts.

ENGINE

Model ASPAS1BBA007 Model ASPAS1BBA012 Model ASPAS1BBA015

Type of Engine GH-410 GT-990 GT-990 Number of Cylinders 1 2 2 Rated Horsepower 14.5 @ 3,600 rpm 26 @ 3,600 rpm 30 @ 3,600 rpm Displacement 410cc 992cc 992cc Cylinder Block Aluminum w/Cast Aluminum w/Cast Aluminum w/Cast

Iron Sleeve Iron Sleeve Iron Sleeve Valve Arrangement Overhead Valves Overhead Valves Overhead Valves Ignition System Solid-state w/Magneto Solid-state w/Magneto Solid-state w/Magneto Recommended Spark Plug RC12YC RC12YC RC12YC Spark Plug Gap 0.76 mm (0.030 inch) 0.5 mm (0.020 inch) 0.5 mm (0.020 inch) Compression Ratio 8.6:1 9.5:1 9.5:1 Starter 12 Vdc 12 Vdc 12Vdc Oil Capacity Including Filter Approx. 1.5 Qts Approx. 1.7 Qts Approx. 1.7 Qts Recommended Oil Filter Part # 070185 Part # 070185 Part # 070185 Recommended Air Filter Part # 0C8127 Part # 0C8127 Part # 0C8127 Operating RPM 3,600 3,600 3,600

FUEL CONSUMPTION

Model # Natural Gas* LP Vapor**

1/2 Load Full Load 1/2 Load Full Load ASAPAS1BBA007 66 119 0.82/30 1.47/54 ASAPAS1BBA012 152 215 1.53/56 2.08/76 ASAPAS1BBA015 156 220 1.58/58 2.40/88

* Natural gas is in cubic feet per hour. **LP is in gallons per hour/cubic feet per hour.

STATOR WINDING RESISTANCE VALUES / ROTOR RESISTANCE

Model ASPAS1BBA007 Model ASPAS1BBA012 Model ASPAS1BBA015

Power Winding: Across 11 & 22 0.223-0.259 ohms 0.115 ohms 0.08/0.08 ohms Power Winding: Across 33 & 44 0.223-0.259 ohms 0.115 ohms 0.08/0.08 ohms Excitation Winding: Across 2 & 6 1.53-1.77 ohms 0.745 ohms 0.705 ohms Engine Run Winding: Across 55 & 66A 0.100-0.169 ohms 0.109 ohms 0.087 ohms Battery Charge Winding: Across 66 & 77 0.146-0.169 ohms 0.164 ohms 0.130 ohms Rotor Resistance 11.88-13.76 ohms 15.9 ohms 19.8 ohms

PART TITLE

Specifications

1 General Information

2 AC Generators

3 V-Type Prepackaged Transfer Switches

4 DC Control

5 Operational Tests and Adjustments

6 Disassembly

7 Electrical Data

DIAGNOSTIC

REPAIR MANUAL

Air-cooled, Prepackaged

Automatic Standby

Generators

Models:

6 kW NG, 7 kW LP 12 kW NG, 12 kW LP 13 kW NG, 15 kW LP

TABLE OF CONTENTS

Page 4

SPECIFICATIONS

MOUNTING DIMENSIONS

Page 5

SPECIFICATIONS

MOUNTING DIMENSIONS

Page 6

SPECIFICATIONS

MAJOR FEATURES

12 kW and 15 kW, V-twin GT-990 Engine

7 kW, Single Cylinder GH-410 Engine

PART TITLE

1.1 Generator Identification

1.2 Prepackaged Installation Basics

1.3 Preparation Before Use

1.4 Testing, Cleaning and Drying

1.5 Engine-Generator Protective Devices

1.6 Operating Instructions

1.7 Automatic Operating Parameters

PART 1

GENERAL

INFORMATION

Air-cooled, Prepackaged

Automatic Standby Generators

Models:

6 kW NG, 7 kW LP 12 kW NG, 12 kW LP 13 kW NG, 15 kW LP

TABLE OF CONTENTS

Page 8

SECTION 1.1

GENERATOR IDENTIFICATION

GENERAL INFORMATION

PART 1

INTRODUCTION

This Diagnostic Repair Manual has been prepared especially for the purpose of familiarizing service personnel with the testing, troubleshooting and repair of air-cooled, prepackaged automatic standby generators. Every effort has been expended to ensure that information and instructions in the manual are both accurate and current. However, Generac reserves the right to change, alter or otherwise improve the product at any time without prior notification.

The manual has been divided into ten PARTS. Each PART has been divided into SECTIONS. Each SECTION consists of two or more SUBSECTIONS.

It is not our intent to provide detailed disassembly and reassembly instructions in this manual. It is our intent to (a) provide the service technician with an understanding of how the various assemblies and systems work, (b) assist the technician in finding the cause of malfunctions, and (c) effect the expeditious repair of the equipment.

MODEL NUMBER: Many home standby generators are manufactured to

the unique specifications of the buyer. The Model Number identifies the specific generator set and its unique design specifications.

SERIAL NUMBER: Used for warranty tracking purposes.

Figure 1. A Typical Data Plate

Page 9

SECTION 1.2

PREPACKAGED INSTALLATION BASICS

GENERAL INFORMATION

INTRODUCTION

Information in this section is provided so that the service technician will have a basic knowledge of installation requirements for prepackaged home standby systems. Problems that arise are often related to poor or unauthorized installation practices.

A typical prepackaged home standby electric system is shown in Figure 1 (next page). Installation of such a system includes the following:

• Selecting a Location

• Grounding the generator.

• Providing a fuel supply.

• Mounting the load center.

• Connecting power source and load lines.

• Connecting system control wiring.

• Post installation tests and adjustments.

SELECTING A LOCATION

Install the generator set as close as possible to the electrical load distribution panel(s) that will be powered by the unit, ensuring that there is proper ventilation for cooling air and exhaust gases. This will reduce wiring and conduit lengths. Wiring and conduit not only add to the cost of the installation, but excessively long wiring runs can result in a voltage drop.

GROUNDING THE GENERATOR

The National Electric Code requires that the frame and external electrically conductive parts of the generator be property connected to an approved earth ground. Local electrical codes may also require proper grounding of the unit. For that purpose, a grounding lug is attached to the unit. Grounding may be accomplished by attaching a stranded copper wire of the proper size to the generator grounding lug and to an earth-driven copper or brass grounding-rod (electrode). Consult with a local electrician for grounding requirements in your area.

THE FUEL SUPPLY

Prepackaged units with air-cooled engine were operated, tested and adjusted at the factory using natural gas as a fuel. These air-cooled engine units can be converted to use LP (propane) gas by making a few adjustments for best operation and power.

LP (propane) gas is usually supplied as a liquid in pressure tanks. Both the air-cooled and the liquid cooled units require a "vapor withdrawal" type of fuel supply system when LP (propane) gas is used. The vapor withdrawal system utilizes the gaseous fuel vapors that form at the top of the supply tank.

The pressure at which LP gas is delivered to the generator fuel solenoid valve may vary considerably, depending on ambient temperatures. In cold weather, supply pressures may drop to "zero". In warm weather, extremely high gas pressures may be encountered. A primary regulator is required to maintain correct gas supply pressures.

Recommended gaseous fuel pressure at the inlet side of the generator fuel solenoid valve is as follows:

LP NG

Minimum water column 11 inches 5 inches Maximum water column 14 inches 7 inches A primary regulator is required to ensure that proper

fuel supply pressures are maintained.

DANGER: LP AND NATURAL GAS ARE BOTH HIGHLY EXPLOSIVE. GASEOUS FUEL LINES MUST BE PROPERLY PURGED AND TESTED FOR LEAKS BEFORE THIS EQUIPMENT IS PLACED INTO SERVICE AND PERIODICALLY THEREAFTER. PROCEDURES USED IN GASEOUS FUEL LEAKAGE TESTS MUST COMPLY STRICTLY WITH APPLICABLE FUEL GAS CODES. DO NOT USE FLAME OR ANY SOURCE OF HEAT TO TEST FOR GAS LEAKS. NO GAS LEAKAGE IS PERMITTED. LP GAS IS HEAVIER THAN AIR AND TENDS TO SETTLE IN LOW AREAS. NATURAL GAS IS LIGHTER THAN AIR AND TENDS TO SETTLE IN HIGH PLACES. EVEN THE SLIGHTEST SPARK CAN IGNITE THESE FUELS AND CAUSE AN EXPLOSION.

Use of a flexible length of hose between the generator fuel line connection and rigid fuel lines is required. This will help prevent line breakage that might be caused by vibration or if the generator shifts or settles. The flexible fuel line must be approved for use with gaseous fuels.

Flexible fuel line should be kept as straight as possible between connections. The bend radius for flexible fuel line is nine (9) inches. Exceeding the bend radius can cause the fittings to crack.

THE TRANSFER SWITCH / LOAD CENTER

A transfer switch is required by electrical code, to prevent electrical feedback between the utility and standby power sources, and to transfer electrical loads from one power supply to another safely.

PREPACKAGED TRANSFER SWITCHES: Instructions and information on prepackaged transfer

switches may be found in Part 3 of this manual.

PART 1

Page 10

PART 1

GENERAL INFORMATION

SECTION 1.2

PREPACKAGED INSTALLATION BASICS

Figure 1. Typical Prepackaged Installation

Page 11

SECTION 1.2

PREPACKAGED INSTALLATION BASICS

GENERAL INFORMATION

POWER SOURCE AND LOAD LINES

The utility power supply lines, the standby (generator) supply lines, and electrical load lines must all be connected to the proper terminal lugs in the transfer switch. The following rules apply:In 1-phase systems with a 2-pole transfer switch, connect the two utility source hot lines to Transfer Switch Terminal Lugs N1 and N2. Connect the standby source hot lines (E1, E2) to Transfer Switch Terminal Lugs E1 and E2. Connect the load lines from Transfer Switch Terminal Lugs T1 and T2 to the electrical load circuit. Connect UTILITY, STANDBY and LOAD neutral lines to the neutral block in the transfer switch.

SYSTEM CONTROL INTERCONNECTIONS

Prepackaged home standby generators are equipped with a terminal board identified with the following terminals: (a) utility 1, (b) utility 2, (c) 23, and (d) 194. Prepackaged load centers house an identically marked terminal board. When these four terminals are properly interconnected, dropout of utility source voltage below a preset value will result in automatic generator startup and transfer of electrical loads to the "Standby" source. On restoration of utility source voltage above a preset value will result in retransfer back to that source and generator shutdown.

PART 1

Figure 2. Proper Fuel Installation

Page 12

PART 1

GENERAL INFORMATION

SECTION 1.3

PREPARATION BEFORE USE

GENERAL

The installer must ensure that the home standby generator has been properly installed. The system must be inspected carefully following installation. All applicable codes, standards and regulations pertaining to such installations must be strictly complied with. In addition, regulations established by the Occupational Safety and Health Administration (OSHA) must be complied with.

Prior to initial startup of the unit, the installer must ensure that the engine-generator has been properly prepared for use. This includes the following:

• An adequate supply of the correct fuel must be available for generator operation.

• The engine must be properly serviced with the recommended oil.

FUEL REQUIREMENTS

Generators with air-cooled engine have been factory tested and adjusted using natural gas as a fuel. If LP (propane) gas is to be used at the installation site, adjustment of the generator fuel regulator will be required for best performance. Refer to Test 63, "Check Fuel Regulator" for fuel regulator adjustment procedures.

• When natural gas is used as a fuel, it should be rated at least 1000 BTU's per cubic foot.

• When LP (propane) gas is used as a fuel, it should be rated at 2520 BTU's per cubic foot.

ENGINE OIL RECOMMENDATIONS

The primary recommended oil for units with aircooled, single cylinder or V-Twin engines is synthetic oil. Synthetic oil provides easier starts in cold weather and maximum engine protection in hot weather. Use high quality detergent oil that meets or exceeds API (American Petroleum Institute) Service class SG, SH, or SJ requirements for gasoline engines. The following chart lists recommended viscosity ranges for the lowest anticipated ambient temperatures.

Engine crankcase oil capacities for the engines covered in this manual can be found in the specifications section at the beginning of the book.

Use SAE 5W-30 Synthetic oil for all seasons.

Page 13

SECTION 1.4

TESTING, CLEANING AND DRYING

GENERAL INFORMATION

VISUAL INSPECTION

When it becomes necessary to test or troubleshoot a generator, it is a good practice to complete a thorough visual inspection. Remove the access covers and look closely for any obvious problems. Look for the following:

• Burned or broken wires, broken wire connectors, damaged mounting brackets, etc.

• Loose or frayed wiring insulation, loose or dirty connections.

• Check that all wiring is well clear of rotating parts.

• Verify that the Generator properly connected for the correct rated voltage. This is especially important on new installations. See Section 1.2, "AC Connection Systems".

• Look for foreign objects, loose nuts, bolts and other fasteners.

• Clean the area around the Generator. Clear away paper, leaves, snow, and other objects that might blow against the generator and obstruct its air openings.

METERS

Devices used to measure electrical properties are called meters. Meters are available that allow one to measure (a) AC voltage, (b) DC voltage, (c) AC frequency, and (d) resistance In ohms. The following apply:

• To measure AC voltage, use an AC voltmeter.

• To measure DC voltage, use a DC voltmeter.

• Use a frequency meter to measure AC frequency In "Hertz" or "cycles per second".

• Use an ohmmeter to read circuit resistance, in "ohms".

THE VOM

A meter that will permit both voltage and resistance to be read is the "volt-ohm-milliammeter" or "VOM".

Some VOM's are of the analog type (not shown). These meters display the value being measured by physically deflecting a needle across a graduated scale. The scale used must be interpreted by the user.

Digital VOM's (Figure 1) are also available and are generally very accurate. Digital meters display the measured values directly by converting the values to numbers.

NOTE: Standard AC voltmeters react to the AVERAGE value of alternating current. When working with AC, the effective value is used. For that reason a different scale is used on an AC voltmeter. The scale is marked with the effective or "rms" value even though the meter actually reacts to the average value. That is why the AC voltmeter will give an Incorrect reading if used to measure direct current (DC).

Figure 1. Digital VOM

MEASURING AC VOLTAGE

An accurate AC voltmeter or a VOM may be used to read the generator AC output voltage. The following apply:

1. Always read the generator AC output voltage only at the unit's rated operating speed and AC frequency.

2. The generator voltage regulator can be adjusted for correct output voltage only while the unit is operating at its correct rated speed and frequency.

3. Only an AC voltmeter may be used to measure AC voltage. DO NOT USE A DC VOLTMETER FOR THIS PURPOSE.

DANGER!: GENERATORS PRODUCE HIGH AND DANGEROUS VOLTAGES. CONTACT WITH HIGH VOLTAGE TERMINALS WILL RESULT IN DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK.

MEASURING DC VOLTAGE

A DC voltmeter or a VOM may be used to measure DC voltages. Always observe the following rules:

1. Always observe correct DC polarity.

a. Some VOM's may be equipped with a

polarity switch.

b. On meters that do not have a polarity

switch, DC polarity must be reversed by reversing the test leads.

PART 1

Page 14

SECTION 1.4

TESTING, CLEANING AND DRYING

PART 1

GENERAL INFORMATION

2. Before reading a DC voltage, always set the meter to a higher voltage scale than the anticipated reading. if in doubt, start at the highest scale and adjust the scale downward until correct readings are obtained.

3. The design of some meters is based on the "current flow" theory while others are based on the "electron flow" theory.

a. The "current flow" theory assumes that

direct current flows from the positive (+) to the negative (-).

b. The "electron flow" theory assumes that

current flows from negative (-) to positive (+).

NOTE: When testing generators, the "current flow" theory is applied. That is, current is assumed to flow from positive (+) to negative (-).

MEASURING AC FREQUENCY

The generator AC output frequency is proportional to rotor speed. Generators equipped with a 2-pole rotor must operate at 3600 rpm to supply a frequency of 60 Hertz. Units with 4-pole rotor must run at 1800 rpm to deliver 60 Hertz.

Correct engine and rotor speed is maintained by an engine speed governor. For models rated 60 Hertz, the governor is generally set to maintain a no-load frequency of about 62 Hertz with a corresponding output voltage of about 124 volts AC line-to-neutral. Engine speed and frequency at no-load are set slightly high to prevent excessive rpm and frequency droop under heavy electrical loading.

MEASURING CURRENT

To read the current flow, in AMPERES, a clamp-on ammeter may be used. This type of meter indicates current flow through a conductor by measuring the strength of the magnetic field around that conductor. The meter consists essentially of a current transformer with a split core and a rectifier type instrument connected to the secondary. The primary of the current transformer is the conductor through which the current to be measured flows. The split core allows the Instrument to be clamped around the conductor without disconnecting it.

Current flowing through a conductor may be measured safely and easily. A line-splitter can be used to measure current in a cord without separating the conductors.

Figure 2. Clamp-On Ammeter

Figure 3. A Line-Splitter

NOTE: If the physical size of the conductor or ammeter capacity does not permit all lines to be measured simultaneously, measure current flow in each individual line. Then, add the Individual readings.

MEASURING RESISTANCE

The volt-ohm-milliammeter may be used to measure the resistance in a circuit. Resistance values can be very valuable when testing coils or windings, such as the stator and rotor windings.

When testing stator windings, keep in mind that the resistance of these windings is very low. Some meters are not capable of reading such a low resistance and will simply read CONTINUITY.

Page 15

SECTION 1.4

TESTING, CLEANING AND DRYING

GENERAL INFORMATION

If proper procedures are used, the following conditions can be detected using a VOM:

• A "short-to-ground" condition in any stator or rotor winding.

• Shorting together of any two parallel stator windings.

• Shorting together of any two isolated stator windings.

• An open condition in any stator or rotor winding.

Component testing may require a specific resistance value or a test for INFINITY or CONTINUITY. Infinity is an OPEN condition between two electrical points, which would read as no resistance on a VOM. Continuity is a closed condition between two electrical points, which would be indicated as very low resistance or ZERO on a VOM.

ELECTRICAL UNITS

AMPERE: The rate of electron flow in a circuit is represented by

the AMPERE. The ampere is the number of electrons flowing past a given point at a given time. One AMPERE is equal to just slightly more than six thousand million billion electrons per second.

With alternating current (AC), the electrons flow first in one direction, then reverse and move in the opposite direction. They will repeat this cycle at regular intervals. A wave diagram, called a "sine wave" shows that current goes from zero to maximum positive value, then reverses and goes from zero to maximum negative value. Two reversals of current flow is called a cycle. The number of cycles per second is called frequency and is usually stated in "Hertz".

VOLT: The VOLT is the unit used to measure electrical

PRESSURE, or the difference in electrical potential that causes electrons to flow. Very few electrons will flow when voltage is weak. More electrons will flow as voltage becomes stronger. VOLTAGE may be considered to be a state of unbalance and current flow as an attempt to regain balance. One volt is the amount of EMF that will cause a current of 1 ampere to flow through 1 ohm of resistance.

OHM: The OHM is the unit of RESISTANCE. In every circuit

there is a natural resistance or opposition to the flow of electrons. When an EMF is applied to a complete circuit, the electrons are forced to flow in a single direction rather than their free or orbiting pattern. The resistance of a conductor depends on (a) its physical makeup, (b) its cross-sectional area, (c) its length, and (d) its temperature. As the conductor's temperature increases, its resistance increases in direct proportion. One (1) ohm of resistance will permit one (1) ampere of current to flow when one (1) volt of electromotive force (EMF) is applied.

Figure 4. Electrical Units

OHM'S LAW

A definite and exact relationship exists between VOLTS, OHMS and AMPERES. The value of one can be calculated when the value of the other two are known. Ohm's Law states that in any circuit the current will increase when voltage increases but resistance remains the same, and current will decrease when resistance Increases and voltage remains the same.

Figure 5.

If AMPERES is unknown while VOLTS and OHMS are known, use the following formula:

AMPERES = VOLTS

OHMS

If VOLTS is unknown while AMPERES and OHMS are known, use the following formula:

VOLTS = AMPERES x OHMS

If OHMS is unknown but VOLTS and AMPERES are known, use the following:

OHMS

VOLTS

AMPERES

PART 1

Page 16

SECTION 1.4

TESTING, CLEANING AND DRYING

PART 1

GENERAL INFORMATION

INSULATION RESISTANCE

The insulation resistance of stator and rotor windings is a measurement of the integrity of the insulating materials that separate the electrical windings from the generator steel core. This resistance can degrade over time or due to such contaminants as dust, dirt, oil, grease and especially moisture. In most cases, failures of stator and rotor windings is due to a breakdown in the insulation. And, in many cases, a low insulation resistance is caused by moisture that collects while the generator is shut down. When problems are caused by moisture buildup on the windings, they can usually be corrected by drying the windings. Cleaning and drying the windings can usually eliminate dirt and moisture built up in the generator windings.

THE MEGOHMMETER

GENERAL: A megohmmeter, often called a "megger", consists of

a meter calibrated in megohms and a power supply. Use a power supply of 500 volts when testing stators or rotors. DO NOT APPLY VOLTAGE LONGER THAN ONE (1) SECOND.

TESTING STATOR INSULATION: All parts that might be damaged by the high megger

voltages must be disconnected before testing. Isolate all stator leads (Figure 2) and connect all of the stator leads together. FOLLOW THE MEGGER MANUFACTURER'S INSTRUCTIONS CAREFULLY.

Use a megger power setting of 500 volts. Connect one megger test lead to the junction of all stator leads, the other test lead to frame ground on the stator can. Read the number of megohms on the meter.

The MINIMUM acceptable megger reading for stators may be calculated using the following formula:

EXAMPLE: Generator is rated at 120 volts AC. Divide "120" by "1000" to obtain "0.12". Then add "1" to obtain "1.12" megohms. Minimum Insulation resistance for a 120 VAC stator is 1.12 megohms.

If the stator insulation resistance is less than the calculated minimum resistance, clean and dry the stator. Then, repeat the test. If resistance is still low, replace the stator.

Use the Megger to test for shorts between isolated windings as outlined "Stator Insulation Tests”.

Also test between parallel windings. See "Test Between Parallel Windings" on next page.

TESTING ROTOR INSULATION: Apply a voltage of 500 volts across the rotor positive

(+) slip ring (nearest the rotor bearing), and a clean frame ground (i.e. the rotor shaft). DO NOT EXCEED 500 VOLTS AND DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND. FOLLOW THE MEGGER MANUFACTURER'S INSTRUCTIONS CAREFULLY.

ROTOR MINIMUM INSULATION RESISTANCE:

1.5 megohms

CAUTION: BEFORE ATTEMPTING TO MEASURE INSULATION RESISTANCE, FIRST DISCONNECT AND ISOLATE ALL LEADS OF THE WINDING TO BE TESTED. ELECTRONIC COMPONENTS, DIODES, SURGE PROTECTORS, RELAYS, VOLTAGE REGULATORS, ETC., CAN BE DESTROYED IF SUBJECTED TO HIGH MEGGER VOLTAGES.

HI-POT TESTER: A "Hi-Pot" tester is shown in Figure 1. The model

shown is only one of many that are commercially available. The tester shown is equipped with a voltage selector switch that permits the power supply voltage to be selected. It also mounts a breakdown lamp that will illuminate to indicate an insulation breakdown during the test.

Figure 1. One Type of Hi-Pot Tester

STATOR INSULATION RESISTANCE TEST

GENERAL: Units with air-cooled engines are equipped with (a)

dual stator AC power windings, (b) an excitation or DPE winding, (c) a battery charge winding and (d) an engine run winding. Insulation tests of the stator consist of (a) testing all windings to ground, (b) testing between isolated windings, and (c) testing between

MINIMUM INSULATION

GENERATOR RATED VOLTS

RESISTANCE =

__________________________

(in "Megohms")

1000

SECTION 1.4

TESTING, CLEANING AND DRYING

GENERAL INFORMATION

PART 1

Page 17

parallel windings. Figure 2 is a pictorial representation of the various stator leads on units with air-cooled engine.

TESTING ALL STATOR WINDINGS TO GROUND:

1. Disconnect stator output leads 11 and 44 from the

generator main line circuit breaker.

2. Remove stator output leads 22 and 33 from the neutral

connection and separate the two leads.

3. Disconnect C2 connector from the side of the control

panel. The C2 connector is the closest to the back panel. See Figure 9, page 128 for connector location.

Figure 2. Stator Winding Leads

4. Connect the terminal ends of Wires 11, 22, 33 and 44

together. Make sure the wire ends are not touching any part of the generator frame or any terminal.

5. Connect the red test probe of the Hi-Pot tester to the

joined terminal ends of stator leads 11, 22, 33 and 44. Connect the black tester lead to a clean frame ground on the stator can. With tester leads connected in this manner, proceed as follows:

a.Turn the Hi-Pot tester switch OFF. b.Plug the tester cord into a 120 volt AC wall

socket and set its voltage selector switch to "1500 volts".

c.Turn the tester switch "On" and observe the

breakdown lamp on tester. DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND. After one (1) second, turn the tester switch OFF.

If the breakdown lamp comes on during the onesecond test, the stator should be cleaned and dried. After cleaning and drying, repeat the insulation test. If, after cleaning and drying, the stator fails the second test, the stator assembly should be replaced.

6. Now proceed to the C2 connector. Each winding will be individually tested for a short to ground. Insert a large paper clip (or similar item) into the C2 connector at the following pin locations:

Pin Wire Winding

Location Number

1 77 Battery Charge 2 66 Battery Charge 3 66A Engine Run 4 55 Engine Run 5 22 Sense Lead Power 6 11 Sense Lead Power 7 6 Excitation 8 2 Excitation

Next refer to Steps 5a through 5c of the Hi-Pot procedure.

Example: Insert paper clip into Pin 1, Hi-Pot from Pin 1 (Wire 77) to ground. Proceed to Pin 2, Pin 3, etc. through Pin 8.

Figure 3. C2 Connector Pin Location Numbers

(Female Side)

TEST BETWEEN WINDINGS:

1. Insert a large paper clip into Pin Location 1 (Wire 77). Connect the red tester probe to the paper clip. Connect the black tester probe to Stator Lead 11. Refer to Steps 5a through 5c of “TESTING ALL STATOR WINDINGS TO GROUND” on the this page.

2. Repeat Step 1 at Pin Location 3 (Wire 66A) and Stator Lead 11.

3. Repeat Step 1 at Pin Location 7 (Wire 6). and Stator Lead 11.

4. Connect the red test probe to Stator Lead 33. Connect the black test probe to Stator Lead 11. Refer to Steps 5a through 5c of “TESTING ALL STATOR WINDINGS TO GROUND” on the this page.

Page 18

SECTION 1.4

TESTING, CLEANING AND DRYING

PART 1

GENERAL INFORMATION

5. Insert a large paper clip into Pin Location No. 1 (Wire

77). Connect the red tester probe to the paper clip. Connect the black tester probe to Stator Lead 33. Refer to Steps 5a through 5c of “TESTING ALL STATOR WINDINGS TO GROUND” on the previous page.

6. Repeat Step 5 at Pin Location 3 (Wire 66A) and Stator Lead 33.

7. Repeat Step 5 at Pin Location 7 (Wire 6) and Stator Lead 33.

For the following steps (8 through 10) an additional large paper clip (or similar item) will be needed:

8. Insert a large paper clip into Pin Location 1 (Wire 77). Connect the red tester probe to the paper clip. Insert the additional large paper clip into Pin Location 3 (Wire 66A). Connect the black tester probe to this paper clip. Refer to Steps 5a through 5c of “TESTING ALL STATOR WINDINGS TO GROUND” on the previous page.

9. Insert a large paper clip into Pin Location 1 (Wire 77). Connect the red tester probe to the paper clip. Insert the additional large paper clip into Pin Location 7 (Wire 6). Connect the black tester probe to this paper clip. Refer to Steps 5a through 5c of “TESTING ALL STATOR WINDINGS TO GROUND” on the previous page.

10.Insert a large paper clip into Pin Location 3 (Wire 66A). Connect the red tester probe to the paper clip. Insert the additional large paper clip into Pin Location 7 (Wire 6). Connect the black tester probe to this paper clip. Refer to Steps 5a through 5c of “TESTING ALL STATOR WINDINGS TO GROUND” on the previous page.

ROTOR INSULATION RESISTANCE TEST

Before attempting to test rotor insulation, the brush holder must be completely removed. The rotor must be completely isolated from other components before starting the test. Attach all leads of all stator windings to ground.

1. Connect the red tester lead to the positive (+) slip ring (nearest the rotor bearing).

2. Connect the black tester probe to a clean frame ground, such as a clean metal part of the rotor shaft.

3. Turn the tester switch OFF.

4. Plug the tester into a 120 volts AC wall socket and set the voltage switch to "1500 volts".

5. Turn the tester switch "On" and make sure the pilot light has turned on.

6. Observe the breakdown lamp, then turn the tester switch OFF. DO NOT APPLY VOLTAGE LONGER THAN ONE (1) SECOND.

If the breakdown lamp came on during the one (1) second test, cleaning and drying of the rotor may be necessary. After cleaning and drying, repeat the insulation breakdown test. If breakdown lamp comes on during the second test, replace the rotor assembly.

Figure 4. Testing Rotor Insulation

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).

CAUTION: DO NOT USE SPRAYED WATER TO CLEAN THE GENERATOR. SOME OF THE WATER WILL BE RETAINED ON GENERATOR WINDINGS AND TERMINALS, AND MAY CAUSE VERY SERIOUS PROBLEMS.

DRYING THE GENERATOR

To dry a generator, proceed as follows:

1. Open the generator main circuit breaker. NO ELECTRICAL LOADS MUST BE APPLIED TO THE GENERATOR WHILE DRYING.

2. Disconnect all Wires 4 from the voltage regulator.

3. Provide an external source to blow warm, dry air through the generator interior (around the rotor and stator windings. DO NOT EXCEED 185° F. (85° C.).

4. Start the generator and let it run for 2 or 3 hours.

5. Shut the generator down and repeat the stator and rotor insulation resistance tests.

Page 19

SECTION 1.5

ENGINE-GENERATOR PROTECTIVE DEVICES

GENERAL INFORMATION

GENERAL

Standby electric power generators will often run unattended for long periods of time. Such operating parameters as (a) engine oil pressure, (b) engine temperature, (c) engine operating speed, and (d) engine cranking and startup are not monitored by an operator during automatic operation. Because engine operation will not be monitored, the use of engine protective safety devices is required to prevent engine damage in the event of a problem.

Prepackaged generator engines mount several engine protective devices. These devices work in conjunction with a circuit board, to protect the engine against such operating faults as (a) low engine oil pressure, (b) high temperature, (c) overspeed, and (d) overcrank. On occurrence of any one or more of those operating faults, circuit board action will effect an engine shutdown.

LOW OIL PRESSURE SHUTDOWN: See Figure 1. An oil pressure switch is mounted on

the engine oil filter adapter. This switch has normally closed contacts that are held open by engine oil pressure during cranking and startup. Should oil pressure drop below approximately 10 psi, the switch contacts will close. On closure of the switch contacts, a Wire 86 circuit from the circuit board will be connected to ground. Circuit board action will then deenergize a "run relay" (on the circuit board). The run relay's normally open contacts will then open and a 12 volts DC power supply to a Wire 14 circuit will then be terminated. This will result in closure of a fuel shutoff solenoid and loss of engine ignition.

HIGH OIL TEMPERATURE SHUTDOWN: An oil temperature switch (Figure 1) is mounted on

the engine block. The thermal switch has normally open contacts that will close if oil temperature should exceed approximately 284° F (140° C). This will result in the same action as a low oil pressure shutdown.

OVERSPEED SHUTDOWN: During engine cranking and operation, the circuit

board receives AC voltage and frequency signals from the generator engine run windings, via Wire 66A. Should the AC frequency exceed approximately 72Hz (4320 rpm), circuit board action will de-energize a "run relay" (mounted on the circuit board). The relay's contacts will open, to terminate engine ignition and close a fuel shutoff solenoid. The engine will then shut down. This feature protects the engine-generator against damaging overspeeds.

NOTE: The circuit board also uses engine run winding output to terminate engine cranking at approximately 30 Hz (1800 rpm). In addition, the engine run winding output is used by the circuit board as an "engine running" signal The circuit board will not initiate transfer of electrical loads to the "Standby" source unless the engine is running at 30 Hz or above.

Figure 1. Engine Protective Switches on an

Air-Cooled Engine

OVERCRANK SHUTDOWN: Automatic engine cranking and startup normally

occurs when the circuit board senses that utility source voltage has dropped below approximately 60 percent of its nominal rated voltage and remains at that low level longer than fifteen (15) seconds. At the end of fifteen (15) seconds, circuit board action will energize a crank relay and a run relay (both relays are on the circuit board). On closure of the crank relay contacts, circuit board action will deliver 12 volts DC to a starter contactor relay (SCR, for v-twin models) or a starter contactor (SC, for single cylinder models). The control contactor will energize and battery power will be delivered to the starter motor (SM). The engine will then crank.

During a manual startup (Auto-Off-Manual switch at MANUAL), action is the same as during an automatic start, except that cranking will begin immediately when the switch is set to MANUAL.

Circuit board action (during both a manual and an automatic start) will hold the crank relay energized for 15 seconds on. The relay will then de-energize for 15 seconds off. It will then energize for seven (7) seconds on and de-energize for seven (7) seconds off. It will repeat this same cycle for another 45 seconds.

If the engine has not started after approximately 90 seconds of these crank-rest cycles, cranking will automatically terminate and shutdown will occur. The circuit board uses AC signals from the stator engine run winding as an indication that the engine has started.

PART 1

Page 20

CONTROL PANEL

GENERAL: See Figure 1. The front face of this panel mounts

(a) an Auto-Off-Manual switch, (b) a 15 amp fuse, (c) a 7.5 amp fuse, (d) a set exercise switch and (e) the protection systems.

120 VAC GFCI OUTLET: The generator is equipped with an external, 15 amp,

120 volt, GFCI convenience outlet that is located in the right rear of the generator enclosure. When the generator is running, in the absence of utility power, this outlet may be used to power items outside the home such as lights or power tools. This outlet may also be used when utility power is present by running the generator in manual mode. This oultlet does not provide power if the generator is not running. This outlet is protected by a 7.5 amp circuit breaker located in the generator control panel. (Figure 1).

Figure 1. Control Panel

AUTO-OFF-MANUAL SWITCH: Use this switch to (a) select fully automatic operation,

(b) to crank and start the engine manually, and (c) to shut the unit down or to prevent automatic startup.

1. AUTO position:

a.Select AUTO for fully automatic operation. b.When AUTO is selected, circuit board will

monitor utility power source voltage.

c. Should utility voltage drop below a preset level

and remain at such a low level for a preset time, circuit board action will initiate engine cranking and startup.

d.Following engine startup, circuit board action

will initiate transfer of electrical loads to the "Standby" source side.

e.On restoration of utility source voltage above a

preset level, circuit board action will initiate retransfer back to the "Utility Source" side.

f. Following retransfer, circuit board will shut the

engine down and will then continue to monitor utility source voltage.

2. OFF Position:

a.Set the switch to OFF to stop an operating

engine.

b.To prevent an automatic startup from occurring,

set the switch to OFF.

3. MANUAL Position:

a.Set switch to MANUAL to crank and start unit

manually.

b.Engine will crank cyclically and start (same as

automatic startup, but without transfer). The unit will transfer if utility voltage is not available.

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). TO PREVENT AUTOMATIC STARTUP AND POSSIBLE INJURY THAT MIGHT BE CAUSED BY SUCH STARTUP, ALWAYS SET THE AUTO-OFF-MANUAL SWITCH TO ITS OFF POSITION BEFORE WORKING ON OR AROUND THIS EQUIPMENT.

15 AMP FUSE: This fuse protects the DC control circuit (including the

circuit board) against overload. If the fuse element has melted open due to an overload, engine cranking or running will not be possible. Should fuse replacement become necessary, use only an identical 15 amp replacement fuse.

7.5 AMP FUSE:

This fuse protects the 12 VDC accessory socket against overload. If the fuse element has melted open due to an overload, the 12 VDC socket will not provide power to accessories. Should fuse replacement become necessary, use only an identical

7.5 amp replacement fuse.

THE SET EXERCISE SWITCH: The air-cooled, prepackaged automatic standby

generator will start and exercise once every seven (7) days, on a day and at a time of day selected by the owner or operator. The set exercise time switch is provided to select the day and time of day for system exercise.

See Section 5 ("The 7-Day Exercise Cycle") for instructions on how to set exercise time.

DANGER: THE GENERATOR WILL CRANK AND START WHEN THE SET EXERCISE TIME SWITCH IS SET TO "ON". DO NOT ACTUATE THE SWITCH TO "ON" UNTIL AFTER YOU HAVE READ THE INSTRUCTIONS IN PART 5.

PART 1

GENERAL INFORMATION

SECTION 1.6

OPERATING INSTRUCTIONS

MAN.

ACCESSORY

OUTLET 7.5A MAX

12 VDC

EXTERNAL

GFCI

CIRCUIT

BREAKER

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

FLASHING GREEN LED =

NO UTILITY SENSE

4 FLASHING RED LEDS=

EXERCISER NOT SET

OUTLET FUSE

7.5A

SYSTEM FUSE

15A

OFF

AUTO

SET

EXERCISE

TIME

SECTION 1.6

OPERATING INSTRUCTIONS

PROTECTION SYSTEMS: Unlike an automobile engine, the generator may have

to run for long periods of time with no operator present to monitor engine conditions. For that reason, the engine is equipped with the following systems that protect it against potentially damaging conditions:

• Low Oil Pressure Sensor

• High Temperature Sensor

• Overcrank

• Overspeed

There are LED readouts on the control panel to notify you that one of these faults has occurred. There is also a “System Set” LED that is lit when all of the following conditions are true:

1. The Auto-Off-Manual switch is set to the AUTO position.

2. The NOT IN AUTO dip switch is set to the OFF position on the control board.

3. No alarms are present.

TO SELECT AUTOMATIC OPERATION

The following procedure applies only to those installations in which the air-cooled, prepackaged automatic standby generator is installed in conjunction with a prepackaged transfer switch. Prepackaged transfer switches do not have an intelligence circuit of their own. Automatic operation on prepackaged transfer switch and generator combinations is controlled by circuit board action.

To select automatic operation when a prepackaged transfer switch is installed along with a prepackaged home standby generator, proceed as follows:

1. Check that the prepackaged transfer switch main contacts are at their UTILITY position, i.e., the load is connected to the utility power supply. If necessary, manually actuate the switch main contacts to their UTILITY source side. See Part 5 of this manual, as appropriate, for instructions.

2. Check that utility source voltage is available to transfer switch terminal lugs N1 and N2 (2-pole, 1-phase transfer switches).

3. Set the generator Auto-Off-Manual switch to its AUTO position.

4. Actuate the generator main line circuit breaker to its "On" or "Closed" position. With the preceding Steps 1 through 4 completed, a dropout in utility supply voltage below a preset level will result in automatic generator cranking and start-up. Following startup, the prepackaged transfer switch will be actuated to its "Standby" source side, i.e., loads powered by the standby generator.

MANUAL TRANSFER TO "STANDBY" AND

MANUAL STARTUP

To transfer electrical loads to the "Standby" (generator) source and start the generator manually, proceed as follows:

1. On the generator panel, set the Auto-Off-Manual switch to OFF.

2. On the generator, set the main line circuit breaker to it's OFF or "Open" position.

3. Turn OFF the utility power supply to the transfer switch, using whatever means provided (such as a utility source line circuit breaker).

4. Manually actuate the transfer switch main contacts to their “Standby” position, i.e., loads connected to the “Standby” power source side.

NOTE: For instructions on manual operation of prepackaged transfer switches, see Part 5.

5. On the generator panel, set the Auto-Off-Manual switch to MANUAL. The engine should crank and start.

6. Let the engine warm up and stabilize for a minute or two at no-load.

7. Set the generator main line circuit breaker to its "On" or "Closed" position. The generator now powers the electrical loads.

MANUAL SHUTDOWN AND RETRANSFER

BACK TO "UTILITY"

To shut the generator down and retransfer electrical loads back to the UTILITY position, proceed as follows:

1. Set the generator main line circuit breaker to its OFF or "Open" position.

2. Let the generator run at no-load for a few minutes, to cool.

3. Set the generator Auto-Off-Manual switch to OFF. Wait for the engine to come to a complete stop.

4. Turn off the utility power supply to the transfer switch using whatever means provided (such as a utility source main line circuit breaker)

5. Manually actuate the prepackaged transfer switch to its UTILITY source side, i.e., load connected to the utility source.

6. Turn on the utility power supply to the transfer switch, using whatever means provided.

7. Set the generator Auto-Off-Manual switch to AUTO.

GENERAL INFORMATION

PART 1

Page 21

Page 22

SECTION 1.7

AUTOMATIC OPERATING PARAMETERS

INTRODUCTION

When the prepackaged generator is installed in conjunction with a prepackaged transfer switch, either manual or automatic operation is possible. Manual transfer and engine startup, as well as manual shutdown and retransfer are covered in Section 1.6. Selection of fully automatic operation is also discussed in that section. This section will provide a step-by-step description of the sequence of events that will occur during automatic operation of the system.

AUTOMATIC OPERATING SEQUENCES

PHASE 1 - UTILITY VOLTAGE AVAILABLE: With utility source voltage available to the transfer

switch, that source voltage is sensed by a circuit board in the generator panel and the circuit board takes no action.

Electrical loads are powered by the utility source and the Auto-Off-Manual switch is set to AUTO.

PHASE 2- UTILITY VOLTAGE DROPOUT: If a dropout in utility source voltage should occur

below about 60 percent of the nominal utility source voltage, a 15 second timer on the circuit board will start timing. This timer is required to prevent false generator starts that might be caused by transient utility voltage dips.

PHASE 3- ENGINE CRANKING: When the circuit board's 15 second timer has finished

timing and if utility source voltage is still below 60 percent of the nominal source voltage, circuit board action will energize a crank relay and a run relay. Both of these relays are mounted on the circuit board.

If the engine starts, cranking will terminate when generator AC output frequency reaches approximately 30 Hz.

PHASE 4-ENGINE STARTUP AND RUNNING: The circuit board senses that the engine is running by

receiving a voltage/frequency signal from the engine run windings.

When generator AC frequency reaches approximately 30 Hz, an engine warm-up timer on the circuit board turns on. That timer will run for about ten (10) seconds.

The engine warm-up timer lets the engine warm-up and stabilize before transfer to the "Standby" source can occur.

NOTE: The engine can be shut down manually at any time, by setting the Auto-Off-Manual switch to OFF.

PHASE 5- TRANSFER TO "STANDBY": When the circuit board's engine warm-up timer has

timed out and AC voltage has reached 50 percent of the nominal rated voltage, circuit board action completes a transfer relay circuit to ground. The transfer relay is housed in the prepackaged transfer switch enclosure.

The transfer relay energizes and transfer of loads to the "Standby" power source occurs. Loads are now powered by standby generator AC output.

PHASE 6- "UTILITY" POWER RESTORED: When utility source voltage is restored above about

80 percent of the nominal supply voltage, a 15 second timer on the circuit board starts timing. If utility voltage remains sufficiently high at the end of 15 seconds, retransfer can occur.

PHASE 7- RETRANSFER BACK TO "UTILITY": At the end of the 15 second delay, circuit board action

will open a circuit to a transfer relay (housed in the transfer switch). The transfer relay will then deenergize and retransfer back to the utility source will occur. Loads are now powered by utility source power. On retransfer, an engine cool-down timer starts timing and will run for about one (1) minute.

PHASE 8- GENERATOR SHUTDOWN: When the engine cool-down timer has finished timing,

and if the minimum run timer has timed out, engine shutdown will occur.

PART 1

GENERAL INFORMATION

SECTION 1.7

AUTOMATIC OPERATING PARAMETERS

PART 1

Page 23

AUTOMATIC OPERATING SEQUENCES CHART

SEQ. CONDITION ACTION SENSOR, TIMER OR OTHER

1 Utility source voltage is No action Voltage Dropout Sensor on circuit

available. circuit board.

2 Utility voltage dropout below A 15-second timer on circuit Voltage Dropout Sensor and 15

60% of rated voltage occurs. board turns on. second timer on circuit board.

3 Utility voltage is still below 15-second timer runs for 15 Voltage Dropout Sensor and 15

60% of rated voltage. seconds, then stops. second timer.

4 Utility voltage is still low after Circuit board action energizes a Circuit board crank and run

15 seconds. crank relay and a run relay. relays.

See NOTE 1.

5 Utility voltage still low and Circuit board’s “engine warmup Engine Warmup Timer (10 seconds)

the engine has started. timer” runs for 10 seconds.

6 Engine running and “engine Circuit board action energizes a Circuit board transfer relay circuit

warmup timer” times out. transfer relay in transfer switch Transfer switch transfer relay. AC output voltage above and transfer to “Standby” occurs. 50% nominal voltage.

7 Engine running and load is No further action Circuit board voltage pickup

acceptable “Utility” voltage.

8 Utility source voltage is Circuit board “voltage pickup Voltage Pickup Sensor (80%)

restored above 80% of rated sensor” reacts and a “re-transfer Return to Utility Timer (15 seconds)

time delay” turns on.

9 Utility voltage still high after 15 “Return to Utility Timer” times out Return to Utility Timer

seconds.

10 Utility voltage still high. Circuit board action opens the Circuit board transfer relay circuit

transfer relay circuit to ground. Tra nsfer switch transfer relay. Transfer relay de-energizes and retransfer to “Utility” occurs.

11 Engine still running, loads are Circuit board “engine cool down Circuit board Engine Cool down

12 After 1 minute, “engine cool down Engine Cool down Timer

timer” stops and circuit board’s Circuit board Run Relay. run relay de-energizes. Engine shuts down.

13 Engine is shut down, loads are No action. Voltage Dropout Sensor on circuit

Page 24

NOTES

PART 1

GENERAL INFORMATION

PART 2

AC GENERATORS

TABLE OF CONTENTS

PART TITLE

2.1 Description and Components

2.2 Operational Analysis

2.3 Troubleshooting Flow Charts

2.4 Diagnostic Tests

Air-cooled, Prepackaged

Automatic Standby Generators

Models:

6 kW NG, 7 kW LP 12 kW NG, 12 kW LP 13 kW NG, 15 kW LP

Page 26

SECTION 2.1

DESCRIPTION & COMPONENTS

PART 2

AC GENERATORS

INTRODUCTION

The air-cooled, pre-packaged automatic standby system is an easy to install, fully enclosed and selfsufficient electric power system. It is designed especially for homeowners, but may be used in other applications as well. On occurrence of a utility power failure, this high performance system will (a) crank and start automatically, and (b) automatically transfer electrical loads to generator AC output.

The generator revolving field (rotor) is driven by an air-cooled engine at about 3600 rpm.

The generator may be used to supply electrical power for the operation of 120 and/or 240 volts, 1phase, 60 Hz, AC loads.

A 2-pole, "V-Type", prepackaged transfer switch is shipped with the unit (see Part 3). Prepackaged transfer switches do not include an "intelligence circuit" of their own. Instead, automatic startup, transfer, running, retransfer and shutdown operations are controlled by a solid state circuit board in the generator control panel.

ENGINE-GENERATOR DRIVE SYSTEM

The generator revolving field is driven by an aircooled, horizontal crankshaft engine. The generator is

directly coupled to the engine crankshaft (see Figure

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 AC GENERATOR

Figure 1 shows the major components of the AC generator.

ROTOR ASSEMBLY

The 2-pole rotor must be operated at 3600 rpm to supply a 60 Hertz AC frequency. The term "2-pole" means the rotor has a single north magnetic pole and a single south magnetic pole. As the rotor rotates, its lines of magnetic flux cut across the stator assembly windings and a voltage is induced into the stator windings. The rotor shaft mounts a positive (+) and a negative (-) slip ring, with the positive (+) slip ring nearest the rear bearing carrier. The rotor bearing is pressed onto the end of the rotor shaft. The tapered rotor shaft is mounted to a tapered crankshaft and is held in place with a single through bolt.

Figure 1. AC Generator Exploded View

Page 27

SECTION 2.1

DESCRIPTION & COMPONENTS

AC GENERATORS

PART 2

Figure 2. The 2-Pole Rotor Assembly

STATOR ASSEMBLY

The stator can houses and retains (a) dual AC power windings, (b) excitation winding, (c) battery charge winding and (d) engine run winding. A total of twelve (12) stator leads are brought out of the stator can as shown in Figure 3.

The stator can is sandwiched between an engine adapter and a rear bearing carrier. It is retained in that position by four stator studs.

Figure 3 Stator Assembly Leads

BRUSH HOLDER AND BRUSHES

The brush holder is retained to the rear bearing carrier by means of two #10-32 x 9/16 Taptite screws. A positive (+) and a negative (-) brush are retained in the brush holder, with the positive (+) brush riding on the slip ring nearest the rotor bearing.

Wire 4 connects to the positive (+) brush and Wire 0 to the negative (-) brush. Wire 0 connects to frame ground. Rectified and regulated excitation current, as well as current from a field boost circuit, are delivered to the rotor windings via Wire 4, and the positive (+) brush and slip ring. The excitation and field boost current passes through the windings and to frame ground via the negative (-) slip ring and brush, and Wire 0. This current flow creates a magnetic field around the rotor having a flux concentration that is proportional to the amount of current flow.

Figure 4. Brush Holder and Brushes

OTHER AC GENERATOR COMPONENTS

Some AC generator components are housed in the generator control panel enclosure, and are not shown in Figure 1. These are (a) an excitation circuit breaker, (b) a voltage regulator, and (c) a main line circuit breaker.

EXCITATION CIRCUIT BREAKER: The excitation circuit breaker (CB2) is housed in the

generator panel enclosure and electrically connected in series with the excitation (DPE) winding output to the voltage regulator. The breaker is self-resetting, i.e.; its contacts will close again when excitation current drops to a safe value.

If the circuit breaker has failed open, excitation current flow to the voltage regulator and, subsequently, to the rotor windings will be lost. Without excitation current flow, AC voltage induced into the stator AC power windings will drop to a value that is commensurate with the rotor residual magnetism (see Figure 5).

Page 28

SECTION 2.1

DESCRIPTION & COMPONENTS

PART 2

AC GENERATORS

Figure 5. Excitation Circuit Breaker

VOLTAGE REGULATOR: A typical voltage regulator is shown in Figure 6.

Unregulated AC output from the stator excitation winding is delivered to the regulator's DPE terminals, via Wire 2, the excitation circuit breaker, Wire 162, and Wire 6. The voltage regulator rectifies that current and, based on stator AC power winding sensing, regulates it. The rectified and regulated excitation current is then delivered to the rotor windings from the positive (+) and negative (-) regulator terminals, via Wire 4 and Wire 1. Stator AC power winding “sensing” is delivered to the regulator "SEN" terminals via Wires 11 and 22.

The regulator provides "over-voltage" protection, but does not protect against "under-voltage". On occurrence of an "over-voltage' condition, the regulator will "shut down" and complete loss Of excitation current to the rotor will occur. Without excitation current, the generator AC output voltage will drop to approximately one-half (or lower) of the unit's rated voltage.

Figure 6. Typical Voltage Regulator

A single red lamp (LED) glows during normal operation. The lamp will become dim if excitation winding AC output diminishes. It will go out on occurrence of an open condition in the sensing AC output circuit.

An adjustment potentiometer permits the stator AC power winding voltage to be adjusted. Perform this adjustment with the generator running at no-load, and with a 62 Hz AC frequency (62 Hz equals 3720 rpm). At the stated no-load frequency, adjust to obtain a line-to-line AC voltage of about 252 volts.

MAIN LINE CIRCUIT BREAKER: The main line circuit breaker protects the generator

against electrical overload. See “Specifications” on inside front cover of this manual for amp ratings.

Page 29

SECTION 2.2

OPERATIONAL ANALYSIS

AC GENERATORS

ROTOR RESIDUAL MAGNETISM

The generator revolving field (rotor) may be considered to be a permanent magnet. Some 'residual" magnetism is always present in the rotor. This residual magnetism is sufficient to induce a voltage into the stator AC power windings that is approximately 2-12 volts AC.

FIELD BOOST

FIELD BOOST CIRCUIT: When the engine is cranking, direct current flow is

delivered from a circuit board to the generator rotor windings, via Wire 4.

The field boost system is shown schematically in Figure 2. Manual and automatic engine cranking is initiated by circuit board action, when that circuit board energizes a crank relay (K1). Battery voltage is then delivered to field boost Wire 4 (and to the rotor), via a field boost resistor and diode. The crank relay, field boost resistor and diode are all located on the circuit board.

Notice that field boost current is available only while the crank relay (K1) is energized, i.e., while the engine is cranking.

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.

Figure 2. Field Boost Circuit Schematic

PART 2

Figure 1. Operating Diagram of AC Generator

Page 30

SECTION 2.2

OPERATIONAL ANALYSIS

PART 2

AC GENERATORS

OPERATION

STARTUP: When the engine is started, residual plus field boost

magnetism from the rotor induces a voltage into (a) the stator AC power windings, (b) the stator excitation or DPE windings, (c) the stator battery charge, and (d) engine run winding. In an "on-speed" condition, residual plus field boost magnetism are capable of creating approximately one-half the unit's rated voltage.

ON-SPEED OPERATION: As the engine accelerates, the voltage that is induced

into the stator windings increases rapidly, due to the increasing speed at which the rotor operates.

FIELD EXCITATION: An AC voltage is induced into the stator excitation

(DPE) windings. The DPE winding circuit is completed to the voltage regulator, via Wire 2, excitation circuit breaker, Wire 162, and Wire 6. Unregulated alternating current can flow from the winding to the regulator.

The voltage regulator "senses" AC power winding output voltage and frequency via stator Wires 11 and

22. The regulator changes the AC from the excitation

winding to DC. In addition, based on the Wires 11 and 22 sensing signals, it regulates the flow of direct current to the rotor.

The rectified and regulated current flow from the regulator is delivered to the rotor windings, via Wire 4, and the positive brush and slip ring. This excitation current flows through the rotor windings and is directed to ground through the negative (-) slip ring and brush, and Wire 0.

The greater the current flow through the rotor windings, the more concentrated the lines of flux around the rotor become.

The more concentrated the lines of flux around the rotor that cut across the stationary stator windings, the greater the voltage that is induced into the stator windings.

Initially, the AC power winding voltage sensed by the regulator is low. The regulator reacts by increasing the flow of excitation current to the rotor until voltage increases to a desired level. The regulator then maintains the desired voltage. For example, if voltage exceeds the desired level, the regulator will decrease the flow of excitation current. Conversely, if voltage drops below the desired level, the regulator responds by increasing the flow of excitation current.

AC POWER WINDING OUTPUT: A regulated voltage is induced into the stator AC

power windings. When electrical loads are connected across the AC power windings to complete the circuit, current can flow in the circuit. The regulated AC power winding output voltage will be in direct proportion to the AC frequency. For example, on units rated 120/240 volts at 60 Hz, the regulator will try to maintain 240 volts (line-to-line) at 60 Hz. This type of regulation system provides greatly improved motor starting capability over other types of systems.

BATTERY CHARGE WINDING OUTPUT: A voltage is induced into the battery charge windings.

Output from these windings is delivered to a battery charger, via Wires 66 and 77. The resulting direct current from the battery charger is delivered to the unit battery, via Wire 15, a 15 amp fuse, and Wire 13. This output is used to maintain battery state of charge during operation.

ENGINE RUN WINDING OUTPUT: A voltage is induced into the engine run winding and

delivered to a solid state circuit board , via Wire 66A. This output "tells" the circuit board that the engine has started and what its operating speed is. The circuit board uses these signals from the engine run winding to (a) terminate cranking, and (b) turn on various timing circuits that control automatic operation. See Part 4, "DC Control".

Page 31

SECTION 2.3

TROUBLESHOOTING FLOWCHARTS

AC GENERATORS

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 correctly identify the problem. Once that has been done, locate the problem on the following pages. For best results, perform all tests in the exact sequence shown in the flow charts.

PART 2

GENERAL

Page 32

SECTION 2.3

TROUBLESHOOTING FLOWCHARTS

PART 2

AC GENERATORS

Page 33

SECTION 2.3

TROUBLESHOOTING FLOWCHARTS

AC GENERATORS

PART 2

Page 34

SECTION 2.3

TROUBLESHOOTING FLOWCHARTS

PART 2

AC GENERATORS

Page 35

SECTION 2.4

DIAGNOSTIC TESTS

AC GENERATORS

INTRODUCTION

This section is provided to familiarize the service technician with acceptable procedures for the testing and evaluation of various problems that could be encountered on prepackaged standby generators with air-cooled engine. Use this section of the manual in conjunction with Section 2.3, "Troubleshooting Flow Charts". The numbered tests in this section correspond with those of Section 2.3.

Test procedures in this section do not require the use of specialized test equipment, meters or tools. Most tests can be performed with an inexpensive volt-ohmmilliammeter (VOM). An AC frequency meter is required, where frequency readings must be taken. A clamp-on ammeter may be used to measure AC loads on the generator.

Testing and troubleshooting methods covered in this section are not exhaustive. We have not attempted to discuss, evaluate and advise the home standby service trade of all conceivable ways in which service and trouble diagnosis might be performed. We have not undertaken any such broad evaluation. Accordingly, anyone who uses a test method not recommended herein must first satisfy himself that the procedure or method he has selected will jeopardize neither his nor the product's safety.

SAFETY

Service personnel who work on this equipment must be made aware of the dangers of such equipment. Extremely high and dangerous voltages are present that can kill or cause serious injury. Gaseous fuels are highly explosive and can be ignited by the slightest spark. Engine exhaust gases contain deadly carbon monoxide gas that can cause unconsciousness or even death. Contact with moving parts can cause serious injury. The list of hazards is seemingly endless.

When working on this equipment, use common sense and remain alert at all times. Never work on this equipment while you are physically or mentally fatigued. If you don't understand a component, device or system, do not work on it.

TEST 1- CHECK MAIN CIRCUIT BREAKER

DISCUSSION: Often the most obvious cause of a problem is

overlooked. If the generator main line circuit breaker is set to OFF or "Open", no electrical power will be supplied to electrical loads. If loads are not receiving power, perhaps the main circuit breaker is open or has failed.

PROCEDURE: The generator main circuit breaker is located on the

control panel. If loads are not receiving power, make sure the breaker is set to "On" or "Closed".

If you suspect the breaker may have failed, it can be tested as follows (see Figure 1):

1. Set a volt-ohm-milliammeter (VOM) to its "R x 1" scale and zero the meter.

2. With the generator shut down, disconnect all wires from the main circuit breaker terminals, to prevent interaction.

3. With the generator shut down, connect one VOM test probe to the Wire 11 terminal of the breaker and the other test probe to the Wire E1 terminal.

4. Set the breaker to its "On" or "Closed" position. The VOM should read CONTINUITY.

5. Set the breaker to its OFF or "Open" position and the VOMshould indicate INFINITY.

6. Repeat Steps 4 and 5 with the VOM test probes connected across the breaker's Wire 44 terminal and the E2 terminal.

RESULTS:

1. If the circuit breaker tests good, go on to Test 2.

2. If the breaker tests bad, it should be replaced.

Figure 1. Generator Main Circuit Breaker Test

Points

PART 2

Page 36

SECTION 2.4

DIAGNOSTIC TESTS

PART 2

AC GENERATORS

TEST 2- CHECK AC OUTPUT VOLTAGE

DISCUSSION: A volt-ohm-milliammeter (VOM) may be used to

check the generator output voltage. Output voltage may be checked at the unit's main circuit breaker terminals. Refer to the unit's DATA PLATE for rated line-to-line and line-to-neutral voltages.

DANGER: USE EXTREME CAUTION DURING THIS TEST. THE GENERATOR WILL BE RUNNING. HIGH AND DANGEROUS VOLTAGES WILL BE PRESENT AT THE TEST TERMINALS. CONNECT METER TEST CLAMPS TO THE HIGH VOLTAGE TERMINALS WHILE THE GENERATOR IS SHUT DOWN. STAY CLEAR OF POWER TERMINALS DURING THE TEST. MAKE SURE METER CLAMPS ARE SECURELY ATTACHED AND WILL NOT SHAKE LOOSE.

PROCEDURE:

1. With the engine shut down, connect the AC voltmeter test leads across the Wires 11 and 44 terminals of the generator main circuit breaker (see Figure 1). These connections will permit line-to-line voltages to be read.

2. Set the generator main circuit breaker to its OFF or "Open" position. This test will be conducted with the generator running at no-load.

3. Start the generator, let it stabilize and warm up for a minute or two.

4. Take the meter reading. On unit's having a rated line-toline voltage of 240 volts, the no-load voltage should be about 242-252 volts AC.

5. Shut the engine down and remove the meter test leads.

RESULTS:

1. If zero volts or residual voltage is indicated, go on to Test 3.

2. If the voltage reading is higher than residual, but is lower than the stated limits, go to Test 11.

3. If a high voltage is indicated, go on to Test 11.

NOTE: "Residual" voltage may be defined as the voltage that is produced by rotor residual magnetism alone. The amount of voltage induced into the stator AC power windings by residual voltage alone will be approximately 2 to 16 volts AC, depending on the characteristics of the specific generator. If a unit is supplying residual voltage only, either excitation current is not reaching the rotor or the rotor windings are open

and the excitation current cannot pass. On current units with air-cooled engine, "field boost" current flow is available to the rotor only during engine cranking.

TEST 3- TEST EXCITATION CIRCUIT

BREAKER

DISCUSSION: Unregulated excitation current is delivered to the

voltage regulator from the stator excitation (DPE) winding, via Wire 2, an excitation circuit breaker (CB2), Wire 162, and Wire 6. If the excitation circuit breaker has failed open, excitation current will not be available to the voltage regulator or to the rotor. Stator AC power winding output will then be reduced to a voltage that is the product of residual magnetism alone.

PROCEDURE:

1. With the generator shut down for at least two minutes, locate the excitation circuit breaker in the generator panel. Disconnect wires from the breaker, to prevent interaction.

2. Set a volt-ohm-milliammeter (VOM) to its "R x 1'scale and zero the meter.

3. Connect the VOM test probes across the circuit breaker terminals. The meter should read CONTINUITY.

RESULTS:

1. Replace circuit breaker if defective (meter reads “OPEN”). Then proceed to Test 4.

2. If circuit breaker is good, go on to Test 4.

Figure 2. Excitation Circuit Breaker

Page 37

SECTION 2.4

DIAGNOSTIC TESTS

AC GENERATORS

TEST 4- FIXED EXCITATION TEST

/ROTOR AMP DRAW TEST

DISCUSSION: Supplying a fixed DC current to the rotor will induce a

magnetic field in the rotor. With the generator running, this should create a proportional voltage output from the stator windings.

PROCEDURE:

1. Disconnect Wire 4 from the voltage regulator, 3rd terminal from the top. See Figure 3.

2. Connect a jumper wire to the disconnected Wire 4 and to the 12 volt fused battery supply Wire 15. (located at 15A fuse).

Figure 3. Voltage Regulator

3. Set VOM to AC volts.

4. Disconnect Wire 2 from the excitation circuit breaker (CB2) and connect one meter test lead to that wire. Disconnect Wire 6 from the voltage regulator and connect the other meter test lead to that wire. (5th terminal from top, double check wire number).

5. Set the AUTO-OFF-MANUAL switch to MANUAL. Once the engine starts, record the AC voltage.

6. Set the AUTO-OFF-MANUAL switch to OFF. Reconnect Wire 2 and Wire 6.

7. Disconnect Wire 11 from the voltage regulator and connect one meter test lead to that wire. Disconnect Wire 22 from the voltage regulator and connect the other meter test lead to that wire (both wires are located at the top two terminals of the voltage regulator, see Figure 3).

PART 2

TEST 4 RESULTS - FIXED EXCITATION TEST/ROTOR AMP DRAW TEST

Results: Size ABCDEFGH

Voltage Results ALL Above 60 VAC Above 60 VAC Below 60 VAC Zero or Below 60 VAC Below 60 VAC Above 60 VAC Below 60 VAC

Wire 2 & 6 Residual Volts

Voltage Results ALL Above 60 VAC Below 60 VAC Above 60 VAC Zero or Below 60 VAC Below 60 VAC Above 60 VAC Below 60 VAC

Wire 11 & 22 Residual Volts

Static Rotor 6 & 7 kW 0.91-1.06A 0.91-1.06A 0.91-1.06A Zero Above 1.5A 0.91-1.06A Zero 0.91-1.06A

Amp Draw 12 & 12 kW 0.80A 0.80A 0.80A Current Above 1.3A 0.80A Current 0.80A

13 & 15 kW 0.64A 0.64A 0.64A Draw Above 1.1A 0.64A Draw 0.64A

Running Rotor 6 & 7 kW 0.91-1.06A 0.91-1.06A 0.91-1.06A Zero Above 1.5A 0.91-1.06A Zero Above 1.5A

Amp Draw 12 & 12 kW 0.80A 0.80A 0.80A Current Above 1.3A 0.80A Current Above 1.3A

13 & 15 kW 0.64A 0.64A 0.64A Draw Above 1.1A 0.64A Draw Above 1.1A

MATCH RESULTS WITH LETTER AND REFER TO FLOW CHART IN SECTION 2.3 “Problem 1”

Page 38

SECTION 2.4

DIAGNOSTIC TESTS

PART 2

AC GENERATORS

8. Set the Auto-Off-Manual switch to MANUAL. Once the engine starts, record the AC voltage.

9. Set the Auto-Off-Manual switch to OFF. Reconnect Wire 11 and Wire 22.

10.Set VOM to DC amperage.

11.Remove jumper lead connected to Wire 4 and Wire 15.

12.Connect one meter test lead to battery positive twelvevolt supply Wire 15, located at the 15A fuse. Connect the other meter test lead to Wire 4 (still disconnected 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.

14.Set the Auto-Off -Manual switch to OFF. Reconnect Wire 4 to the voltage regulator.

RESULTS:

Refer to Chart on previous page : “Results - Fixed Excitation Test/Rotor Amp Draw Test.”.

TEST 5: WIRE CONTINUITY

DISCUSSION: The voltage regulator receives unregulated

alternating current from the stator excitation winding, via Wires 2, 6, and 162. It also receives voltage sensing from the stator AC power windings, via Wires 11 and 22. The regulator rectifies the AC from the excitation winding and based on the sensing signals, regulates the DC current flow to the rotor. The rectified and regulated current flow is delivered to the rotor brushes via Wires 4 (positive) and 0 (negative). This test will verify the integrity of Wires 0 and 162.

PROCEDURE:

1. Set VOM to its "R x 1" scale.

2. Remove Wire 0 from the voltage regulator, 4th terminal from the top. Also voltage regulator is labeled (-) next to terminal.

3. Connect one test lead to Wire 0, connect the other test lead to a clean frame ground. The meter should read CONTINUITY.

4. Disconnect Wire 162 from the voltage regulator, 6th terminal from the top. Disconnect the other end of Wire 162 from the excitation circuit breaker. Connect one test lead to one end of Wire 162, and the other test lead to the other end of Wire 162. The meter should read CONTINUITY.

RESULTS: If CONTINUITY was not measured across each wire,

repair or replace the wires as needed.

TEST 6 - CHECK FIELD BOOST

DISCUSSION: See "Field Boost Circuit" in Section 2.2. Field boost

current (from the circuit board) is available to the rotor only while the engine is cranking. Loss of field boost output to the rotor may or may not affect power winding AC output voltage. The following facts apply:

• A small amount of voltage must be induced into the DPE winding to turn the voltage regulator on.

• If rotor residual magnetism is sufficient to induce a voltage into the DPE winding that is high enough to turn the voltage regulator on, regulator excitation current will be supplied even if field boost has failed. Normal AC output voltage will then be supplied.

• If rotor residual magnetism has been lost or is not sufficient to turn the regulator on, and field boost has also been lost, excitation current will not be supplied to the rotor. Generator AC output voltage will then drop to zero or nearly zero.

PROCEDURE:

1. Locate Wire 4 that is routed from the circuit board and

connects to the voltage regulator terminal, third from the top (see Figure 3). Disconnect that wire from the voltage regulator terminal.

2. Set a VOM to read DC volts. Disconnect Connector C2

from the control panel (C2 is the closest to the back panel).

3. Connect the positive (+) VOM test probe to the terminal

end of disconnected Wire 4.

4. Connect the common (-) VOM test probe to the

grounding lug.

5. Crank the engine while observing the VOM reading. While

the engine is cranking, the VOM should read approximately 9-10 volts DC. When engine is not cranking, VOM should indicate "zero" volts (see Figure 4).

RESULTS:

1. If normal field boost voltage is indicated in Step 5,

replace the voltage regulator.

2. If normal field boost voltage is NOT indicated in Step 5,

check Wire 4 (between regulator and circuit board) for open or shorted condition. If wire is good, replace the circuit board.

Page 39

SECTION 2.4

DIAGNOSTIC TESTS

AC GENERATORS

Figure 4. Field Boost Test Points

TEST 7: TESTING THE STATOR WITH A VOM

DISCUSSION: A Volt-OHM-Milliammmeter (VOM) can be used to

test the stator windings for the following faults:

• An open circuit condition

• A "short-to-ground" condition

• A short circuit between windings

Note: The resistance of stator windings is very low. Some meters will not read such a low resistance, and will simply indicate CONTINUITY. Recommended is a high quality, digital type meter capable of reading very low resistances.

PROCEDURE:

1. Disconnect stator leads 11 and 44 from the main circuit breaker.

2. Disconnect stator leads 22 and 33 from the neutral connection separate the leads.

3. Disconnect Connector C2 from the side of the control panel (C2 is the closest to the back panel). See Figure 9, page 128 for connector location.

4. Make sure all off the disconnected leads are isolated from each other and are not touching the frame during the test.

5. Set a VOM to its "R x 1" scale and zero the meter.

6. Refer to Figure 5 for pin locations of Connector C2. Use a large paper clip or similar metallic object to access pins in connector C2.

Note: Pins 9, 10, 11 & 12 are not used for this test.

7. Connect one test lead to stator lead Wire 11. Connect the other test lead to stator lead Wire 22 (power winding). Note the resistance reading and compare to the specifications on inside front cover.

8. Connect one test lead to stator lead Wire 33. Connect the other test lead to stator lead Wire 44 (power winding). Note the resistance reading and compare to the specifications on inside front cover.

9. Connect one test lead to Pin 1. Connect the other test lead to Pin 2 (battery charge winding). Note the resistance reading, compare to specifications on inside front cover.

10.Connect one test lead to Pin 3. Connect the other test lead to Pin 4 (engine run winding). Note the resistance reading, compare to specification inside front cover.

11.Connect one test lead to Pin 5. Connect the other test lead to Pin 6 (power winding-sense leads). Note the resistance reading, compare to specification inside front cover.

12.Connect on test lead to Pin 7. Connect the other test lead to Pin 8 (excitation winding). Note the resistance reading, compare to specification inside front cover.

PART 2

Figure 5. C2

Connector Pin

Locations

(Female Side)

Figure 6. C2

Connector Pin

Locations

(Male Side)

Page 40

SECTION 2.4

DIAGNOSTIC TESTS

PART 2

AC GENERATORS

TEST WINDINGS FOR A SHORT TO GROUND:

13.Make sure all leads are isolated from each other and are not touching the frame.

14.Set a VOM to its "R x 10,000" or "R x 1K" scale and zero the meter

15.Connect one test lead to a clean frame ground. Connect the other test lead to stator lead Wire 11.

a.The meter should read INFINITY b.Any reading other than INFINITY indicates a

"short-to-ground" condition.

16. Repeat Step 15 using stator lead Wire 33.

17. Repeat Step 15 using Pin 1.

18. Repeat Step 15 using Pin 3

19. Repeat Step 15 using Pin 5

20. Repeat Step 15 using Pin 7

TEST FOR A SHORT CIRCUIT BETWEEN WINDINGS:

21. Set a VOM to its "R x 10,000" or "R x 1K" scale and zero the meter.

22. Connect one test lead to stator lead Wire 11. Connect the other test lead to stator lead Wire 33.

a.The meter should read infinity. b.Any reading other than INFINITY indicates a

short circuit between windngs.

23. Repeat Step 22 using stator lead Wire 11; Pin 1

24. Repeat Step 22 using stator lead Wire 11; Pin 3

25 Repeat Step 22 using stator lead Wire 11; Pin 7

26. Repeat Step 22 using stator lead Wire 33; Pin 1

27. Repeat Step 22 using stator lead Wire 33; Pin 3

28. Repeat Step 22 using stator lead Wire 33; Pin 7

29. Repeat Step 22 using Pin 1; Pin 3

30. Repeat Step 22 using Pin 1; Pin 7

31. Repeat Step 22 using Pin 3; Pin 7

TEST CONTROL PANEL WIRES FOR CONTINUITY:

32.Set a VOM to its "Rx1" scale.

33.Disconnect the C2 connector from the control panel. (C2 is the closest to the back panel). Refer to Figure 6 for pin locations.

33.Connect one meter test lead to Pin 5 of the C2 connector, connect the other test lead to Wire 22 at the voltage regulator. Continuity should be measured.

34. Connect one meter test lead to Pin 6 of the C2

connector, connect the other test lead to Wire 11 at the voltage regulator. Continuity should be measured.

35. Connect one meter test lead to Pin 7 of the C2 connector, connect the other test lead to Wire 6 at the voltage regulator. Continuity should be measured.

36. Connect one meter test lead to Pin 8 of the C2 connector, connect the other test lead to Wire 2 at CB2 (DPE circuit breaker). Continuity should be measured.

RESULTS:

1. Stator winding resistance values is a test of winding continuity and resistance. If a very high resistance or INFINITY is indicated, the winding is open or partially open.

2. Testing for a "grounded" condition: Any upscale movement of the meter needle or dial indicates the winding is grounded.

3. Testing for a "shorted" condition: Any upscale movement of the VOM needle or dial indicates the winding is shorted.

4. If the stator tests good and wire continuity tests good , perform “Insulation Resistance Test” in Section 1.4.

5. If any test of wire continuity failed in control panel failed, repair or replace the wire, terminal or pin connectors for that associated wire as needed.

NOTE: Read section 1.4, "Testing, Cleaning and Drying" carefully. If the winding tests good, perform an insulation resistance test. If the winding fails the insulation resistance test, clean and dry the stator as outlined in Section 1.4. Then, repeat the insulation resistance test. If the winding fails the second resistance test (after cleaning and drying), replace the stator assembly.

TEST 8 - RESISTANCE CHECK

OF ROTOR CIRCUIT

DISCUSSION: To verify the zero current draw reading and measure

the rotor circuit.

PROCEDURE:

1. Disconnect Wire 4 from the voltage regulator. It is located 3rd terminal from the top of the volt regulator.

2. Set VOM to the "Rx1" scale.

3. Connect one test lead to Wire 4. Connect the other test lead to a clean frame ground. Note the resistance reading. Compare to specifications on inside front cover.

Page 41

SECTION 2.4

DIAGNOSTIC TESTS

AC GENERATORS

RESULTS:

1. If the resistance reading is correct, check your VOM meters fuse and repeat Test 4.

2. If INFINITY is measured on your VOM meter, go to Test 9.

TEST 9 - CHECK BRUSHES

AND SLIP RINGS

DISCUSSION: The function of the brushes and slip rings is to

provide for passage of excitation current from stationary components to the rotating rotor. Brushes are made of a special long lasting material and seldom wear out or fail. However, slip rings can develop a tarnish or film that can inhibit or offer a resistance to the flow of electricity. Such a nonconducting film usually develops during non-operating periods. Broken or disconnected wiring can also cause loss of excitation current to the rotor.

Figure 7. Checking Brushes and Slip Rings

PROCEDURE:

1. Disconnect connector C2 (deutsch connector closest to the back panel). Refer to Figure 5 and Figure 6 in Section 2.4.

2. Set a VOM to measure resistance.

3. Connect one meter test lead to Pin 9 (Wire 0) of the C2 connector (female side). Connect the other meter test lead to Pin 10 (Wire 4) of the C2 connector (female side). Rotor resistance should be measured see specifications on inside front cover. If rotor resistance is not measured proceed to step 4. If rotor resistance is measured proceed to step 12.

4. See figure 7. Carefully inspect brush wires; make sure they are properly and securely connected.

5. Wire 0 from the negative (-) brush terminal connects to

Pin 9 of the C2 connector. Test this wire for an open condition. Remove wire 0 from the brush assembly. Connect one meter test lead to wire 0. Connect the other test lead to Pin 9 (wire 0) of the C2 connector ( female side). CONTINUITY should be measured. If INFINITY is measured repair or replace wire 0 between the brush assembly and the C2 connector.

6. Wire 4 from the positive (+) brush terminal connects to Pin 10 of the C2 connector.Test this wire for an open condition. Remove wire 4 from the brush assembly. Connect one meter test lead to Wire 4. Connect the other meter test lead to Pin 10 (wire 0) of the C2 connector (female side). CONTINUITY should be measured. If INFINITY is measured repair or replace wire 4 between the brush assembly and the C2 connector.

7. Connect one meter test lead to wire 4 Connect the other meter test lead to frame ground. INFINITY should be measured. If CONTINUITY is measured a short to ground exists on wire 4 repair or replace wire 4 between the brush assembly and the C2 connector.

8. If continuity was measured in steps 5 and 6 proceed to step 9.

9. Disconnect wires 0 and 4 from the brush assembly. Remove the brush assembly from the bearing carrier. Inspect the brushes for excessive wear,damage.

10.Inspect the rotor slip rings. If they appear dull or tarnished, they may be polished with a fine sandpaper. DO NOT USE METALLIC GRIT TO POLISH SLIP RINGS.

11.If brush assembly and slip rings look good proceed to Test 10 ( Test Rotor assembly)

12.Wire 0 connects from the C2 connector to the control panel ground lug. Connect one meter test lead to Pin 9 (Wire 0) of the C2 connector (male side). Connect the other meter test lead to the ground terminal in the control panel. CONTINUITY should be measured. If INFINITY is measured repair or replace wire 0 between the C2 connector and the ground terminal.

13.Remove wire 4 from the voltage regulator.

14.Connect one meter test lead to Pin 10 (wire 4) of the C2 connector (male side). Connect the other meter test lead to Wire 4 removed from the Voltage regulator. CONTINUITY should be measured. If INFINITY is measured repair or replace wire 4 between the C2 connector and the voltage regulator.

PART 2

Page 42

SECTION 2.4

DIAGNOSTIC TESTS

PART 2

AC GENERATORS

RESULTS:

1. Repair, replace or reconnect wires as necessary.

2. Replace any damaged slip rings or brush holder.

3. Clean and polish slip rings as required.

TEST 10 - TEST ROTOR ASSEMBLY

DISCUSSION: A rotor having completely open windings will cause

loss of excitation current flow and, as a result, generator AC output voltage will drop to "residual" voltage. A "shorted" rotor winding can result in a low voltage condition.

PROCEDURE:

1. Disconnect the brush wires or remove the brush holder, to prevent interaction.

2. Set a VOM to its "R x 1" scale and zero the meter.

3. Connect the positive (+) VOM test lead to the positive (+) rotor slip ring (nearest the rotor bearing); and the common (-) test lead to the negative (-) slip ring. The meter should read approximately 10-20 ohms. Compare to “Specifications,” inside front cover.

4. Now, set the VOM to a high resistance scale (such as "R x 10,000" or "R x 1K"). Again, zero the meter.

5. Connect the positive (+) VOM test lead to the positive (+) slip ring and the common (-) test lead to a clean frame ground. The meter should indicate infinity.

RESULTS:

1. Replace rotor assembly if it is open or shorted.

2. If rotor tests good, perform “Insulation Resistance Test” in Section 1.4.

NOTE: Be sure to read Section 1.4, "Testing, Cleaning and Drying", carefully. If the rotor tests good, try performing an insulation resistance test. Clean and dry the rotor if it fails that test. Then, repeat the test. If the rotor fails the second insulation resistance test, it should be replaced.

Figure 8. The Rotor Assembly

TEST 11 - CHECK AC OUTPUT FREQUENCY

DISCUSSION: The generator AC frequency is proportional to the

operating speed of the rotor. The 2-pole rotor will supply a 60 Hertz AC frequency at 3600 rpm. The unit's AC output voltage is proportional to the AC frequency. For example, a unit rated 240 volts (lineto-line) will supply that rated voltage (plus or minus 2 percent) at a frequency of 60 Hertz. If, for any reason, the frequency should drop to 30 Hertz, the line-to-line voltage will drop to a matching voltage of 120 volts AC. Thus, if the AC voltage output is high or low and the AC frequency is correspondingly high or low, the engine speed governor may require adjustment.

PROCEDURE:

1. Connect an accurate AC frequency meter across the Wires 11 and 44 terminals of the generator main line circuit breaker (see Figure 1, Section 2.4).

2. Start the engine, let it stabilize and warm up at no-load.

3. When engine has stabilized, read the frequency meter. The no-load frequency should be about 61-63 Hertz.

RESULTS:

1. If the AC frequency is high or low, go on to Test 12.

2. If frequency is good, but voltage is high or low, go to Test

13.

3. If frequency and voltage are both good, tests may be discontinued.

TEST 12 - CHECK AND ADJUST ENGINE

GOVERNOR

DISCUSSION: The generator AC frequency output is directly

proportional to the speed of the rotor. A two-pole rotor (having a single north and a single south magnetic pole) will produce an AC frequency of 60 hertz at 3600 RPM.

The generator is equipped with a "voltage over frequency" type AC voltage regulator. The units AC output voltage is

generally proportional to AC frequency. A low or high governor speed will result in a correspondingly low or high AC frequency and voltage output. The governed speed must be adjusted before any attempt to adjust the voltage regulator is made.

PROCEDURE (7KW UNITS):

1. Loosen the governor clamp bolt (Figure 9).

2. Hold the governor lever at its wide open throttle position, and rotate the governor shaft clockwise as far as it will go. Then, tighten the governor lever clamp bolt to 70 inch-pounds (8 N-m).

Page 43

SECTION 2.4

DIAGNOSTIC TESTS

AC GENERATORS

3. Start the generator; let it stabilize and warm up at noload.

4. Connect a frequency meter across the generators AC output leads.

5. Turn the primary adjust screw to obtain a frequency reading of 61.5 Hertz. Turn the secondary adjust screw to obtain a frequency of 62.5 Hz.

6. When frequency is correct at no load, check the AC voltage reading. If voltage is incorrect, the voltage regulator may require adjustment.

Figure 9. Engine Governor Adjustment Single

Cylinder Engines

Figure 10. Engine Governor Adjustment

V-twin Engines

PROCEDURE (12/15 KW UNITS):

1. Loosen governor clamp bolt (See Figure 10).

2. Completely remove the idle spring.

3. With governor arm at wide open throttle position, rotate governor shaft fully clockwise. Tighten clamp bolt to 84 inch-pounds.

4. Start unit and apply full load. Use full load speed adjust screw (Figure 11) to adjust frequency to 58 Hz.

5. Remove load, stop engine, loosen the idle adjust screw and reconnect the idle spring.

6. Using your hand, push the governor arm to the closed throttle position. Make sure the idle spring does not stretch at all.

7. Restart the unit.

8. Slowly turn the idle adjust screw to adjust the no-load idle speed to 62.5 Hz.

9. The governor is now set.

Figure 11. Full Load Speed Adjust

Screw V-twin Engines

RESULTS:

1. If, after adjusting the engine governor, frequency and voltage are good, tests may be discontinued.

2. If frequency is now good, but voltage is high or low, go to Test 13.

3. If engine was overspeeding, check linkage and throttle for binding. If no governor response is indicated refer to engine service manual.

4. If engine appears to run rough and results in low frequency, proceed to Problem 11, Section 4.3.

PART 2

SECONDARY

ADJUST SCREW

GOVERNOR

SHAFT

GOVERNOR

CLAMP

BOLT

PRIMARY

ADJUST

SCREW

Page 44

SECTION 2.4

DIAGNOSTIC TESTS

PART 2

AC GENERATORS

TEST 13 - CHECK AND ADJUST

VOLTAGE REGULATOR

DISCUSSION: For additional information, refer to description and

components Section 2.1.

PROCEDURE: With the frequency between 61-62 Hertz, slowly turn

the slotted potentiometer (Figure 12) until line voltage reads 244-252 volts.

NOTE: You must remove the access panel on top of the control panel to adjust the voltage regulator.

NOTE: The voltage regulator is housed above the generator control panel. The regulator maintains a voltage in direct proportion to frequency at a 2-to1 ratio. For example, at 62 Hertz, line-to-neutral voltage will be 124 volts.

Figure 12. Voltage Adjustment Potentiometer

RESULTS:

1. If the frequency and voltage are now good, discontinue tests.

2. If frequency is now good but voltage is high or low, go to Problem 1, Test 4.

TEST 14 - CHECK VOLTAGE AND

FREQUENCY UNDER LOAD

DISCUSSION: It is possible for the generator AC output frequency

and voltage to be good at no-load, but they may drop excessively when electrical loads are applied. This condition, in which voltage and frequency drop excessively when loads are applied, can be caused by (a) overloading the generator, (b) loss of engine power, or (c) a shorted condition in the stator windings or in one or more connected loads.

PROCEDURE:

1. Connect an accurate AC frequency meter and an AC

voltmeter across the stator AC power winding leads.

2. Start the engine, let it stabilize and warm-up.

3. Apply electrical loads to the generator equal to the rated capacity of the unit.

4. Check the AC frequency and voltage. Frequency should not drop below approximately 58-59 Hertz. Voltage should not drop below about 230 volts (plus or minus 2 percent).

RESULTS:

1. If frequency and voltage drop excessively under load, go to Test 15.

2. If frequency and voltage under load are good, discontinue tests.

TEST 15 - CHECK FOR OVERLOAD

CONDITION

DISCUSSION: An "overload' condition is one in which the generator

rated wattage/amperage capacity has been exceeded. To test for an overload condition on an installed unit, the best method is to use an ammeter. See "Measuring Current" in Section 1.4.

PROCEDURE: Use a clamp-on ammeter to measure load current

draw, with the generator running and all normal electrical loads turned on.

RESULTS:

1. If the unit is overloaded, reduce loads to the unit's rated capacity.

2. If unit is not overloaded, but rpm and frequency drop excessively when loads are applied, go to Test 16.

TEST 16 - CHECK ENGINE CONDITION

DISCUSSION: If engine speed and frequency drop excessively

under load, the engine may be under-powered. An under-powered engine can be the result of a dirty air cleaner, loss of engine compression, faulty carburetor settings, incorrect ignition timing, etc.

PROCEDURE: For engine testing, troubleshooting and repair

procedures refer to Problem 11 in Section 4.3. For further engine repair information refer to the following manuals:

• P/N 0C1103 - Service and Repair Manual for Single

Cylinder GN Engines.

• P/N 0E2081 - Service Manual for GTV-990/760 V-

Twin OHVI Engines.

PART TITLE

3.1 Description and Components

3.2 Operational Analysis

3.3 Troubleshooting Flow Charts

3.4 Diagnostic Tests

PART 3

“V-TYPE”

PREPACKAGED

TRANSFER

SWITCHES

Air-cooled, Prepackaged

Automatic Standby Generators

Models:

6 kW NG, 7 kW LP 12 kW NG, 12 kW LP 13 kW NG, 15 kW LP

TABLE OF CONTENTS

Page 46

SECTION 3.1

DESCRIPTION & COMPONENTS

PART 3

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

GENERAL

The prepackaged, “V-Type” transfer switch is rated 100 amps at 250 volts maximum. It is available in 2pole configuration only and, for that reason, is useable with 1-phase systems only.

Prepackaged transfer switches do not have an intelligence system of their own. Instead, automatic operation of these transfer switches is controlled by a circuit board housed in the generator control panel.

ENCLOSURE

The standard prepackaged, “V-Type” transfer switch enclosure is a NEMA 1 type ("NEMA" stands for "National Electrical Manufacturer's Association"). Based on NEMA Standard 250, the NEMA 1 enclosure may be defined as one that is intended for indoor use primarily to provide a degree of protection against contact with the enclosed equipment and where unusual service conditions do not exist.

The 2-pole transfer mechanism consists of a pair of moveable LOAD contacts, a pair of stationary

ITEM DESCRIPTION

1 BOX GTS LOAD CENTER 2 COVER, 12 POSITION GTS LOAD CENTER 3 TRANSFER SWITCH HOME STANDBY 100A2P250V 4 SCREW TAPTITE M5-0.8 X 10 BP 5 SCREW TAPTITE 1/4-20 X 5/8 BP 6 LOCK WASHER, SPECIAL-1/4" 7 RELAY PANEL 12VDC DPDT 10A@240VA 8 BASE, MOUNTING 12 CIRCUIT 125A/240V 9 SCREW TAPTITE M4-0.7X10 BP 10 RIVET POP .156 X .160-.164/#20 11 WASHER FLAT 1/4 ZINC 12 PLUG 13 HARNESS ADAPTER PLATE 14 PANEL-SUB BREAKER BASE 15 TRIM VINYL BLACK 1/8GP 16 WASHER LOCK #10 17 NUT WING M6-1.0 18 HANDLE, TRANSFER SWITCH HOME STANDBY 19 HOLDER CABLE TIE 21 LUG DIS QK NI-S 10X45 DEG BR/T 22 SCREW PPHM #10-32 X 1/4 23 LUG SLDLSS 1/0-#14X9/16 AL/CU 24 BLOCK TERMINAL 20A 5 X 6 X 1100V 25 TIE WRAP 3.9" X .10" NAT'L UL 26 WASHER FLAT #8 ZINC 27 COVER, RELAY & TERM BLOCK 28 WIRE HARNESS,GTS LOAD CENTER (NOT SHOWN FOR CLARITY) 29 FUSE HOLDER 30 ASSEMBLY FUSE 5A X BUSS HLDR73591 31 PCB SUPPORT SNAP-IN 1-3/8" 32 CIRCT BRK 20 X 1 HOM120 33 CIRCT BRK 20 X 2 HOM220 34 CIRCT BRK 15 X 1 HOM115 35 CIRCT BRK 30 X 2 HOM230 36 COVER - HARNESS ENTRY 37 HARNESS, GTS TO EXT CONN BOX 38 WASHER LOCK M4 39 SCREW SW 1/4-20X5/8 N WA JS500 40 SCREW SWAGE 1/4-20 X 1/2 ZINC 41 SCREW PPHM M4-0.7 X 10 42 HARNESS,GTS TO MAIN PANEL

Figure 1. Exploded View of V-Type Prepackaged Transfer Switch

Page 47

SECTION 3.1

DESCRIPTION & COMPONENTS

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

PART 3

UTILITY contacts, and a pair of stationary STANDBY contacts. The load contacts can be connected to the utility contacts by a utility closing coil; or to the standby contacts by a standby closing coil. In addition, the load contacts can be actuated to either the UTILITY or STANDBY side by means of a manual transfer handle. See Figures 2 and 3.

Figure 2. Load Connected to Utility Power Source

Figure 3. Load Connected to Standby Power

Source

UTILITY CLOSING COIL C1: See Figure 4. This coil is energized by rectified utility

source power, to actuate the load contacts to the UTILITY power source side. When energized, the coil will move the main contacts to an "overcenter" position. A limit switch will then be actuated to open the circuit and spring force will complete the retransfer to STANDBY. A bridge rectifier, which changes the utility source alternating current (AC) to direct current (DC), is sealed in the coil wrappings. If coil or bridge rectifier replacement becomes necessary, the entire coil and bridge assembly should be replaced.

STANDBY CLOSING COIL C2: Coil C2 is energized by rectified standby source

power, to actuate the load contacts to their "Standby" source side. Energizing the coil moves the load contacts to an overcenter position; limit switch action then opens the circuit and spring force will complete the transfer action to "Standby". This coil's bridge rectifier is also sealed in the coil wrappings. Replace the coil and bridge rectifier as a unit.

LIMIT SWITCHES XA1 AND XB1: Switches are mechanically actuated by load contacts

movement. When the load contacts are connected to the utility contacts, limit switch XA1 opens the utility circuit to utility closing coil C1 and limit switch XB1 closes the standby circuit to standby closing coil C2. The limit switches "arm" the system for retransfer back to UTILITY when the load contacts are connected to the STANDBY side. Conversely, when the load contacts are connected to the UTILITY side, the switches "arm" the system for transfer to STANDBY. An open condition in limit switch XA1 will prevent retransfer to "Utility". An open switch XB1 will prevent transfer to STANDBY.

Figure 4. The "V-Type" Transfer Mechanism

TRANSFER RELAY

Transfer relay operation is controlled by a circuit board. That circuit board is a part of a control panel assembly, mounted on the standby generator set.

Figure 5 shows the transfer relay pictorially and schematically. Relay operation may be briefly described as follows:

1. Generator battery voltage (12 volts DC) is available to the transfer relay coil from the generator circuit board, via Wire 194 and relay terminal A.

Page 48

SECTION 3.1

DESCRIPTION & COMPONENTS

a.The 12 volts DC circuit is completed through the

transfer relay coil and back to the generator circuit board, via Wire 23.

b.Circuit board action normally holds the Wire 23

circuit open to ground and the relay is deenergized.

c. When de-energized, the relay's normally open

contacts are open and its normally-closed contacts are closed.

d.The normally-closed relay contacts will deliver

utility source power to the utility closing circuit of the transfer mechanism.

e.The normally open relay contacts will deliver

standby source power to the transfer mechanism's standby closing circuit.

Figure 5. Transfer Relay Schematic

2. During automatic system operation, when the generator circuit board "senses" that utility source voltage has dropped out, the circuit board will initiate engine cranking and startup.

3. When the circuit board "senses" that the engine has started, an "engine warm-up timer" on the circuit board starts timing.

4. When the "engine warm-up timer" has timed out, circuit board action completes the Wire 23 circuit to ground.

a.The transfer relay then energizes. b.The relay's normally-closed contacts open and

its normally open contacts close.

c.When the normally open contacts close,

standby source power is delivered to the standby closing coil and transfer to "Standby" occurs.

5. When the generator circuit board "senses" that utility source voltage has been restored above a preset level, the board will open the Wire 23 circuit to ground.

a.The transfer relay will de-energize, its normally-

closed contacts will close and its normally open contacts will open.

b.When the normally-closed relay contacts close,

utility source voltage is delivered to the utility closing coil to energize that coil.

c. Retransfer back to UTILITY occurs.

NEUTRAL LUG

The standby generator is equipped with an UNGROUNDED neutral. The neutral lug in the transfer switch is isolated from the switch enclosure.

MANUAL TRANSFER HANDLE

The manual transfer handle is retained in the transfer switch enclosure by means of a wing stud. Use the handle to manually actuate the transfer mechanism load contacts to either the UTILITY or STANDBY source side.

Instructions on use of the manual transfer handle may be found in Part 5, "Operational Tests and Adjustments".

TERMINAL BLOCK

During system installation, this 5-point terminal block must be properly interconnected with an identically labeled terminal block in the generator control panel assembly.

Figure 6. Transfer Switch Terminal Block

Terminals used on the terminal block are identified as Utility 1 and 2; 23 and 194.

UTILITY 1 AND 2: Interconnect with identically labeled terminals in the

generator control panel assembly. This is the utility voltage signal to the circuit board. The signal is

PART 3

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

Page 49

SECTION 3.1

DESCRIPTION & COMPONENTS

delivered to a step-down transformer in the control module assembly and the resultant reduced voltage is then delivered to the circuit board. Utility 1 and 2 power is used by the circuit board as follows:

• If utility source voltage should drop below a preset level, circuit board action will initiate automatic cranking and startup, followed by automatic transfer to the standby source.

• Utility source voltage is used to operate a battery trickle charge circuit which helps to maintain battery state of charge during non-operating periods.

TERMINALS 23 AND 194: These terminals connect the transfer relay to the

generator circuit board. See "Transfer Relay" in Section 3.1.

FUSE HOLDER

The fuse holder holds two (2) fuses, designated as fuses F1 and F2. Each fuse is rated 5 amperes.

FUSES F1, F2: These two fuses protect the terminal board UTILITY 1

and 2 circuit against overload.

Figure 7. The Fuse Holder

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

PART 3

Page 50

SECTION 3.2

OPERATIONAL ANALYSIS

PART 3

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

OPERATIONAL ANALYSIS

Figure 1 is a schematic and wiring diagram for a typical “V-Type” transfer switch.

Figure 1. Wiring Diagram and Schematic

Page 51

SECTION 3.2

OPERATIONAL ANALYSIS

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

PART 3

UTILITY SOURCE VOLTAGE AVAILABLE

Figure 2 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.

• Utility source voltage is available to limit switch (XA1) via the normally-closed transfer relay contacts (1 and 7) and Wire 126. However, XA1 is open and the Circuit to the utility closing coil is open.

• Utility voltage "sensing" signals are delivered to a circuit board on the generator, via Wire N1A, a 5 amp fuse (F1), transfer switch terminal N1, generator terminal N1 and a sensing transformer. The second line of the utility voltage "sensing" circuit is via Wire N2A, a 5 amp Fuse (F2), transfer switch terminal N2, generator terminal N2, and the sensing transformer.

Figure 2. Utility Source Power Available

Page 52

SECTION 3.2

OPERATIONAL ANALYSIS

PART 3

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

UTILITY SOURCE VOLTAGE FAILURE

If utility source voltage should drop below a preset value, the generator circuit board will sense the dropout. That circuit board will then initiate generator cranking and startup after a time delay circuit times out.

Figure 3 is a schematic representation of the transfer switch with generator power available, waiting to transfer.

• Generator voltage available E1, E2.

• Circuit board action holding Wire 23 open to ground.

• Power available to standby coil C2, upon closure of TR, normally open contacts (9 & 6) will close and initiate a transfer.

Figure 3. Generator Power Available, Waiting to Transfer.

Page 53

SECTION 3.2

OPERATIONAL ANALYSIS

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

PART 3

TRANSFER TO STANDBY

The generator circuit board delivers 12 volts DC to the transfer relay, via terminal 194 and back to the circuit board via terminal 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" on the generator circuit board starts timing. When that timer has timed out, circuit board action completes the Wire 23 circuit to ground. The transfer relay then energizes, its normally open contacts close, and standby source voltage is delivered to the standby closing coil via Wires E1 and E2, the transfer relay (TR) contacts, limit switch (XB1), Wire "B". and a bridge rectifier. The standby closing coil energizes and the main contacts actuate to their "Standby" side.

Figure 4. Transfer Action to Standby Position

Page 54

SECTION 3.2

OPERATIONAL ANALYSIS

PART 3

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

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 XA1 and XB1 are mechanically actuated to "arm" the circuit for re- transfer to utility power source side.

Generator power from E1 and E2 is now connected to the customer load through T1 and T2.

Figure 5. Generator Powering Load.

Page 55

SECTION 3.2

OPERATIONAL ANALYSIS

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

PART 3

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.

Figure 6. Utility Restored, Generator Still Providing Output to Load.

Page 56

SECTION 3.2

OPERATIONAL ANALYSIS

PART 3

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

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 XA1.

Figure 7. Utility Restored, Transfer Relay De-energized.

Page 57

SECTION 3.2

OPERATIONAL ANALYSIS

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

PART 3

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 XA1 and XB1 are mechanically actuated to “arm” the circuit for transfer to standby.

Figure 8. Utility Restored, Retransfer Back to Utility.

Page 58

SECTION 3.2

OPERATIONAL ANALYSIS

PART 3

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

TRANSFER SWITCH IN UTILITY

When the transfer switch returns to the utility side, generator shutdown occurs after approximately one (1) minute.

Figure 9. Transfer Switch in Utility.

Page 59

SECTION 3.3

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 problem can 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.” Section

3.4 provides detailed instructions for performance of each test.

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

PART 3

Page 60

SECTION 3.3

TROUBLESHOOTING FLOW CHARTS

PART 3

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

Page 61

SECTION 3.4

DIAGNOSTIC TESTS

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

GENERAL

Test numbers in this section correspond to the numbered tests in Section 3.3, "Troubleshooting Flow Charts". When troubleshooting, first identify the problem. Then, perform the diagnostic tests in the sequence given in the flow charts.

TEST 21- CHECK VOLTAGE AT TERMINAL

LUGS E1, E2

DISCUSSION: In automatic mode, the standby closing coil (C2) must

be energized by standby generator output if transfer to the "Standby" source is to occur. Transfer to "Standby" cannot occur unless that power supply is available to the transfer switch.

DANGER: BE CAREFUL! HIGH AND DANGEROUS VOLTAGES ARE PRESENT AT TERMINAL LUGS E1 AND E2 WHEN THE GENERATOR IS RUNNING. AVOID CONTACT WITH HIGH VOLTAGE TERMINALS OR DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK MAY RESULT. DO NOT PERFORM THIS VOLTAGE TEST WHILE STANDING ON WET OR DAMP GROUND, WHILE BAREFOOT, OR WHILE HANDS OR FEET ARE WET.

PROCEDURE:

1. If the generator engine has started automatically (due to a utility power source outage) and is running, check the position of the generator main circuit breaker. The circuit breaker must be set to its "On" or "Closed" position. When you are sure the generator main circuit breaker is set to "On" or 'Closed", check the voltage at transfer mechanism terminal lugs E1 and E2 with an accurate AC voltmeter or with an accurate volt-ohm-milliammeter (VOM). The generator line-to line voltage should be indicated.

2. If the generator has been shut down, proceed as follows:

a.On the generator control panel, set the Auto-

Off-Manual switch to OFF.

b.Turn OFF all power voltage supplies to the

transfer switch. Both the utility and standby power supplies must be positively turned off before proceeding.

c. Check the position of the transfer mechanism

main contacts. The moveable LOAD contacts must be connected to the stationary UTILITY source contacts. If necessary, manually actuate the main contacts to the "Utility" power source side.

d.Actuate the generator main line circuit breaker

to its "On" or "Closed" position. The utility power supply to the transfer switch must be turned OFF.

PART 3

Figure 1. The “V-Type” Transfer Mechanism

Page 62

SECTION 3.4

DIAGNOSTIC TESTS

PART 3

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

e.Set the generator Auto-Off-Manual switch to

AUTO. (1) The generator should crank and start. (2) When the generator starts, an "engine

warm-up timer" should start timing. After about 15 seconds, the transfer relay should energize and transfer to the "Standby" source should occur.

f. If transfer to "Standby" does NOT occur, check the

voltage across transfer switch terminal lugs E1 and E2. The generator line-to-line voltage should be indicated.

RESULTS:

1. If normal transfer to "Standby" occurs, discontinue tests.

2. If transfer to "Standby" does NOT occur and no voltage is indicated across terminal lugs E1/E2, determine why generator AC output has failed.

3. If transfer to "Standby" does NOT occur and voltage reading across terminal lugs E1/E2 is good, go on to Test 22.

TEST 22 - CHECK VOLTAGE AT STANDBY

CLOSING COIL C2

DISCUSSION: Standby source voltage is used to energize the

standby closing coil and actuate the main contacts to their "Standby" source side. Standby source alternating current (AC) is changed to direct current (DC) by a bridge rectifier before reaching the closing coil. This test will determine if standby voltage is available to the closing coil.

If normal standby source voltage is available to the terminals of the standby closing coil but transfer to "Standby" does not occur, look for (a) binding or sticking in the transfer mechanism, (b) a defective coil, or (c) a bad bridge rectifier. The coil and the bridge rectifier must be replaced as a unit.

PROCEDURE:

1. Set the generator main line circuit breaker to the OFF or “Open” position.

2. Set the generators Auto-Off-Manual switch to the OFF position.

3. Set your VOM to measure AC voltage.

DANGER: BE CAREFUL! HIGH AND DANGEROUS VOLTAGES ARE PRESENT AT TERMINAL LUGS WHEN THE GENERATOR IS RUNNING. AVOID CONTACT WITH HIGH VOLTAGE TERMINALS OR DANGEROUS AND POSSIBLY LETHAL ELECTRICAL

SHOCK MAY RESULT. DO NOT PERFORM THIS VOLTAGE TEST WHILE STANDING ON WET OR DAMP GROUND, WHILE BAREFOOT, OR WHILE HANDS OR FEET ARE WET.

4. Disconnect Wire E2 from the standby closing coil (C2). Connect one meter test Lead to Wire E2. Use a suitable and safe connection to this wire, such as an alligator clip that attaches to the meter test probe. Isolate this wire and test probe from any other potential source or ground.

5. If necessary, repeat Step 2 under "Procedure" of Test

21. The system must be in automatic operating mode, with engine running, and standby source voltage available to terminal lugs E1 and E2.

6. Locate on the standby closing coil the terminal that Wire B is connected to. (Figure 1, previous page). Connect the other meter test lead to this terminal. Generator line to line voltage should be indicated. If generator voltage is not indicated, proceed to Step 7.

7. With Wire E2 still connected to one test probe, connect the other meter test lead to Wire 205 on Limit Switch XB1(see Figure 1 on previous page). Generator line to line voltage should be measured.

RESULTS:

1. If generator line-to-line voltage is indicated in “Procedure, Step 6,” but transfer does NOT occur, proceed to Test 24.

2. If generator line-to-line voltage is NOT indicated in “Procedure, Step 7,” proceed to Test 33.

3. If generator line-to-line voltage is indicated in “Procedure, Step 7,” proceed to Test 25.

TEST 23 - TEST TRANSFER RELAY TR

DISCUSSION: In automatic operating mode, the transfer relay must

be energized by circuit board action or standby source power will not be available to the standby closing coil. Without standby source power, the closing coil will remain de-energized and transfer to "Standby" will not occur. This test will determine if the transfer relay is functioning normally.

PROCEDURE:

1. See Figure 2. Disconnect all wires from the transfer relay, to prevent interaction.

2. Set a VOM to its "R x 1" scale and zero the meter.

Page 63

SECTION 3.4

DIAGNOSTIC TESTS

3. Connect the VOM test leads across Relay Terminals 6 and 9 with the relay de-energized. The VOM should read infinity.

4. Using jumper wires, connect the positive (+) post of a 12 volt battery to relay Terminal “A” and the negative (-) battery post to Relay Terminal "B". The relay should energize and the VOM should read CONTINUITY.

Figure 2. Transfer Relay Test Points

5. Now, connect the VOM test leads across Relay Terminals 1 and 7.

a.Energize the relay and the meter should

indicate infinity.

b.De-energize the relay and the VOM should read

CONTINUITY.

RESULTS:

1. Replace transfer relay if it is defective.

2. If transfer relay checks good go to Test 26.

TEST 24- CHECK MANUAL TRANSFER

SWITCH OPERATION

DISCUSSION: In automatic operating mode, when utility source

voltage drops below a preset level, the engine should crank and start. On engine startup, an "engine warmup timer" on the generator circuit board should start timing. When that timer has timed out (about 15 seconds), the transfer relay should energize to deliver utility source power to the standby closing coil terminals. If normal utility source voltage is available to the standby closing coil terminals, but transfer to Standby does not occur, the cause of the failure may be (a) a failed standby closing coil and/or bridge rectifier, or (b) a seized or sticking actuating coil or load contact. This test will help you evaluate whether any sticking or binding is present in the transfer mechanism.

PROCEDURE:

1. With the generator shut down, set the generator AutoOff-Manual switch to OFF.

2. Set the generator main circuit breaker to OFF or "Open".

3. Turn off the utility power supply to the transfer switch,

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

PART 3

Figure 3. Manual Transfer Switch Operation

126

N1A

194

205

Page 64

SECTION 3.4

DIAGNOSTIC TESTS

PART 3

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

using whatever means provided (such as a utility source main line breaker).

DANGER: DO NOT ATTEMPT MANUAL TRANSFER SWITCH OPERATION UNTIL ALL POWER VOLTAGE SUPPLIES TO THE SWITCH HAVE BEEN POSITIVELY TURNED OFF. FAILURE TO TURN OFF ALL POWER VOLTAGE SUPPLIES MAY RESULT IN EXTREMELY HAZARDOUS AND POSSIBLY LETHAL ELECTRICAL SHOCK.

4. In the transfer switch enclosure, locate the manual transfer handle. Handle is retained in the enclosure with a wing nut. Remove the wing nut and handle.

5. See Figure 3. Insert the un-insulated end of the handle over the transfer switch operating lever.

a.Move the transfer switch operating lever up to

actuate the load contacts to the Utility position, i.e., load connected to the utility source.

b.Actuate the operating lever down to move the

load contacts against the standby contacts, i.e., load connected to the Standby source.

6. Repeat Step 5 several times. As the transfer switch operating lever is moved slight force should be needed until the lever reaches its center position. As the lever moves past its center position, an over-center spring should snap the moveable load contacts against the stationary Standby or Utility contacts.

7. Finally, actuate the main contacts to their Utility power source side, i.e., load contacts against the Utility contacts (upward movement of the operating lever).

RESULTS:

1. If there is no evidence of binding, sticking, excessive force required, replace the appropriate closing coil.

2. If evidence of sticking, binding, excessive force required to move main contacts, find cause of binding or sticking and repair or replace damaged part(s).

TEST 25- TEST LIMIT SWITCH XB1

DISCUSSION: Standby power source voltage must be available to

the standby closing coil in order for a transfer to standby action to occur. To deliver that source voltage to the coil, limit switch XB1 must be closed to the "Standby" power source side. If the limit switch did not get actuated or has failed open, the source voltage will not be available to the closing coil and transfer to "Standby" will not occur.

PROCEDURE: With the generator shut down, the generator main

circuit breaker turned OFF, and with the utility power supply to the transfer switch turned OFF, test limit switch XB1 as follows:

1. To prevent interaction, disconnect Wire 205 and Wire B from the limit switch terminals.

2. Set a VOM to its "R x 1" scale and zero the meter.

3. See Figure 1. Connect the VOM test probes across the two outer terminals from which the wires were disconnected.

4. Manually actuate the main contacts to their "Standby" position. The meter should read infinity.

5. Manually actuate the main contacts to their Utility position. The meter should read CONTINUITY.

6. Repeat Steps 4 and 5 several times and verify the VOM reading at each switch position.

RESULTS:

1. If Limit Switch XB1 fails the test, remove and replace the switch or adjust switch until it is actuated properly.

2. If limit switch is good, repair or replace Wire B between limit switch and Standby Coil (C2).

TEST 26 - CHECK 23 AND 194

WIRING/CONNECTIONS

DISCUSSION: An open circuit in the transfer switch control wiring

can prevent a transfer action from occurring. In the auto mode, the circuit board supplies +12 VDC to Wire 194. This DC voltage is supplied to the transfer relay (TR) at Terminal Location “A”. The opposite side of the transfer relay (TR) coil (Terminal B) is connected to Wire 23. Positive 12VDC is present on this also. Circuit board action will allow current to flow through the circuit and the (TR) is energized.

PROCEDURE/RESULTS:

1. Set VOM to DC volts

2. Place generator Auto-Off-Manual switch to the AUTO position. Utility power should be present; the generator should not start.

3. Connect the negative (-) test lead to a suitable frame ground in the transfer switch.

4. Connect the positive (+) test lead to Wire 194 at the terminal strip in the transfer switch.

a.If voltage is present, proceed to Step 5. b.If voltage is not present, proceed to Step 9.

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SECTION 3.4

DIAGNOSTIC TESTS

5. Connect the positive (+) test lead to Wire 23 at the terminal strip in the transfer switch.

a.If voltage is present, proceed to Step 6. b.If voltage is not present, repair wiring between

terminal strip and transfer relay (TR).

6. Connect the negative (-) test lead to the ground lug in the generator control panel. Connect the positive (+) test lead to Wire 23 in the generator control panel at the interconnection terminals (ICT) or at the terminal strip.

a.If voltage is present, proceed to Step 7. b.If voltage is not present, repair wiring between

transfer switch and generator control panel.

7. Connect the positive (+) test lead to Wire 23 located in the J1 connector Pin Location 3, connected to the circuit board (see Figure 3, Section 4.1).

a.If voltage is present, proceed to Step 8. b.If voltage is not present, repair wiring between

(ICT and J1connector).

8. Turn off utility power to transfer switch, simulating a utility failure.

a.Generator starts and transfer occurs,

discontinue tests.

b.Generator starts and transfer does not occur.

With the generator running and utility off, ground Wire 23 in the control panel at interconnection terminals (ICT) or at the terminal strip. If transfer occurs replace circuit board.

9. Connect the negative (-) test lead to the ground lug in the generator control panel. Connect the positive (+) test lead to Wire 194 in the generator control panel at the interconnection terminals (ICT) or at the terminal strip.

a.If the voltage is present, repair wiring between

ICT (or terminal strip) and transfer switch

b.If voltage is not present, proceed to Step 10.

10.Connect the positive (+) test lead to Wire 194 located in the J1 connector Pin Location 4, connected to the circuit board (see Figure 3, Section 4.1).

a.If voltage is present, repair wiring between J1

connector and ICT (or terminal strip).

b.If voltage is not present, replace circuit board.

TEST 27- CHECK VOLTAGE AT TERMINAL

LUGS N1, N2

DISCUSSION: If retransfer to the "Utility" power source side is to

occur, utility source voltage must be available to

terminal lugs N1 and N2 of the transfer mechanism. In addition, If that source voltage is not available to NI/N2 terminals, automatic startup and transfer to "Standby" will occur when the generator manual-offauto switch is set to AUTO. This test will prove that "Utility" voltage is available to those terminals, or is not available. It is the first test in a series of tests that should be accomplished when (a) retransfer back to 'Utility" does not occur, or (b) startup and transfer occurs unnecessarily.

DANGER: PROCEED WITH CAUTION! HIGH AND DANGEROUS VOLTAGES ARE PRESENT AT TERMINAL LUGS N1/N2. CONTACT WITH HIGH VOLTAGE TERMINALS WILL RESULT IN DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK. DO NOT ATTEMPT THIS TEST WHILE STANDING ON WET OR DAMP GROUND, WHILE BAREFOOT, OR WHILE HANDS OR FEET ARE WET.

PROCEDURE:

1. Make sure that all main line circuit breakers in the utility line to the transfer switch are “On” or “Closed.”

2. Test for utility source line-to-line voltage across terminal lugs N1 and N2 (see Figure 1). Normal utility source voltage should be indicated.

RESULTS:

1. If low or no voltage is indicated, find the cause of the problem and correct.

2. If normal utility source voltage is indicated, go on to Test

28.

3. For Problem 14 ONLY, if voltage is good, repair or replace Wire N1A/N2A between Transfer Switch Lugs N1/N2 and Fuse Holder connections.

TEST 28 - CHECK VOLTAGE AT UTILITY 1 AND

UTILITY 2 TERMINALS

The Utility 1 and Utility 2 terminals in the transfer switch deliver utility voltage “sensing” to a circuit board. If voltage at the terminals is zero or low, standby generator startup and transfer to the “Standby” source will occur automatically as controlled by the circuit board. A zero or low voltage at these terminals will also prevent retransfer back to the “Utility” source.

PROCEDURE: With utility source voltage available to terminal lugs

N1 and N2, use an AC voltmeter or a VOM to test for utility source line-to-line voltage across terminal block

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

PART 3

Page 66

SECTION 3.4

DIAGNOSTIC TESTS

“Utility 1” and “Utility 2” terminals. Normal line-to-line utility source voltage should be indicated.

Figure 4. Transfer Switch Terminal Block

RESULTS:

1. If voltage reading across the "Utility I" and "Utility 2" terminals is zero, go to Test 30.

2. If voltage reading is good, go to Test 29.

3. For Problem 14 ONLY; if voltage is good, repair N1/N2 open wiring between Transfer Switch and Generator.

TEST 29- CHECK VOLTAGE AT UTILITY

CLOSING COIL C1

DISCUSSION: Utility source voltage is required to energize utility

closing coil C1 and effect retransfer back to the "Utility" source. This voltage is delivered to the utility closing coil via Wires N1A and N2A, the transfer relay's normally-closed contacts (relay de-energized), Wire 126, Limit Switch XA1, and a bridge rectifier.

PROCEDURE:

1. On the generator control panel, set the Auto-Off-Manual switch to OFF.

2. Turn OFF the utility power supply to the transfer switch, using whatever means provided (such as a utility source main line circuit breaker).

3. Set the generator main line circuit breaker to its OFF or "Open" position.

4. Check the position of the transfer mechanism main contacts. The moveable load contacts must be connected to the stationary utility contacts. If necessary, manually actuate the main contacts to their "Utility source side (load connected to the "Utility' source).

DANGER: BE CAREFUL! HIGH AND DANGEROUS VOLTAGES ARE PRESENT AT TERMINAL LUGS WHEN THE GENERATOR IS RUNNING. AVOID CONTACT WITH HIGH VOLTAGE TERMINALS OR DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK MAY RESULT. DO NOT PERFORM THIS VOLTAGE TEST WHILE STANDING ON WET OR DAMP GROUND, WHILE BAREFOOT, OR WHILE HANDS OR FEET ARE WET.

5. Disconnect Wire N2A from the utility closing coil (C1). Connect one meter test Lead to Wire N2A. Use a suitable and safe connection to this wire, such as an alligator clip that attaches to the meter test probe. Isolate this wire and test probe from any other potential source or ground.

6. Set the generator main line circuit breaker to its "On" or "Closed" position.

7. Set the generator Auto-Off-Manual switch to AUTO.

a.The generator should crank and start. b.About 15 seconds after engine startup, the

transfer relay should energize and transfer to the 'Standby" source should occur.

8. When you are certain that transfer to "Standby" has occurred, turn ON the utility power supply to the transfer switch. After a 15 seconds, retransfer back to the "Utility" source should occur.

9. Locate on the utility closing coil the terminal that Wire A is connected to (see Figure 1, Section 3.4). Connect the other meter test lead to this terminal. Generator line to line voltage should be indicated. If generator voltage is not indicated, proceed to Step 10.

10.With Wire N2A still connected to one test probe, connect the other meter test lead to Wire 126 on Limit Switch XA1 (see Figure 1, Section 3.4). Generator line to line voltage should be measured.

RESULTS:

1. In Step 7, if the generator does not crank or start, refer to Part 4, "DC Control".

2. In Step 7, if transfer to the "Standby" source does not occur, go to Problem 1.

3. In Step 9, if normal utility source line-to-line voltage is indicated but retransfer back to "Utility" does not occur, go to Test 24.

4. If normal utility source line-to-line voltage is not indicated in Step 9, but is indicated in Step 10, proceed to Test 31.

PART 3

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

Page 67

SECTION 3.4

DIAGNOSTIC TESTS

5. If normal utility source line-to-line voltage is NOT indicated in Step 8, and is NOT indicated in Step 9, proceed to Test 32.

TEST 30 - CHECK FUSES F1 AND F2

DISCUSSION: Fuses F1 and F2 are connected in series with the

Utility 1 and Utility 2 circuits, respectively. A blown fuse will open the applicable circuit and will result in (a) generator startup and transfer to "Standby", or (b) failure to retransfer back to the utility source.

Figure 5. Fuse Holder and Fuses

PROCEDURE:

1. On the generator panel, set the Auto-Off-Manual switch to OFF.

2. Turn off the utility power supply to the transfer switch, using whatever means provided.

3. Remove fuses F1 and F2 from the fuse holder (see Figure 5).

4. Inspect and test fuses for blown condition.

RESULTS:

1. Replace blown fuse(s) and proceed to Test 34.

2. For Problem 7 (DC Control section), go to Test 27.

TEST 31 - TEST LIMIT SWITCH XA1

DISCUSSION: When the transfer switch main contacts are actuated

to their "Utility" position, limit switch XA1 should be mechanically actuated to its open position. On

transfer to the "Standby" position, the limit switch should actuate to its closed position. If the switch does not actuate to its closed position, retransfer back to "Utility" will not occur.

PROCEDURE:

1. With the standby generator shut down, set its Auto-OffManual switch to OFF.

2. Turn OFF the utility power supply to the transfer switch, using whatever means provided.

3. To prevent interaction, disconnect Wire 126 and Wire "A" from the limit switch terminals.

4. Set a VOM to its "R x 1 " scale and zero the meter.

5. Connect the VOM test leads across the two limit switch terminals from which Wires A and 126 were removed.

6. Manually actuate the main contacts to their "Standby" position. The VOM should indicate CONTINUITY.

7. Manually actuate the main contacts to their "Utility" position. The VOM should read infinity.

RESULTS: Replace limit switch XA1 if it checks bad.

NOTE: Problems with transfer switch operation can also be caused by (a) defective wiring between the generator and transfer switch, or (b) a defective component in the generator circuit board. See Part 4, "DC Control".

TEST 32 - CONTINUITY TEST OF WIRING (C1)

DISCUSSION: This test will ensure that all control wiring has

continuity.

1. Set the Auto-Off-Manual switch to the OFF position.

2. Turn the generator main circuit breaker to the off position.

3. Turn off the utility power supply to the transfer switch using whatever means provided. (Such as utility source main line circuit breaker).

4. Set your VOM to the "R x 1" scale.

5. Disconnect Wire N2A from the Utility Coil C1 and connect one test lead to it. Connect the other test lead to terminal lug N2 of the transfer switch. CONTINUITY should be read. Reconnect Wire N2A.

6. Disconnect Wire 126 from transfer relay (TR) and connect one test lead to it. Connect the other test lead to limit switch XA1 bottom terminal Wire 126. CONTINUITY should be read. Reconnect Wire 126.

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

PART 3

Page 68

SECTION 3.4

DIAGNOSTIC TESTS

PART 3

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

7. Disconnect Wire N1A from transfer relay (TR) terminal and connect one test lead to it. Connect the other test lead to F1 top fuse terminal Wire N1A. CONTINUITY should be read. Reconnect Wire N1A.

RESULTS: Repair any defective wiring that does not read

CONTINUITY. If wiring tests good, proceed to Test

23.

TEST 33 - CONTINUITY TEST OF WIRING (C2)

DISCUSSION: This test will ensure that all control wiring has

continuity.

1. See Test 32, Step 1

2. See Test 32, Step 2

3. See Test 32, Step 3

4. See Test 32, Step 4

5. Disconnect Wire E2 from the standby coil (C2) and connect one test lead to it. Connect the other test lead to Terminal Lug E2 of the transfer switch. CONTINUITY should be read. Reconnect Wire E2.

6. Disconnect Wire 205 from transfer relay (TR) Terminal 6 and connect one test lead to it. Connect the other test lead to limit switch XB1 top terminal Wire 205. CONTINUITY should be read. Reconnect Wire 205.

7. Disconnect Wire E1 from Transfer Relay (TR) Terminal 9 and connect one test lead to it. Connect the other test lead to terminal lug E1 of the transfer switch. CONTINUITY should be read. Reconnect Wire E1.

RESULTS: Repair any defective wiring that does not read

CONTINUITY. If wiring tests good, proceed to Test

23.

TEST 34 - CHECK N1 AND N2 WIRING

DISCUSSION: A shorted Wire N1 or N2 to ground can cause fuse F1

or F2 to blow.

PROCEDURE:

1. On the generator panel, set the Auto-Off-Manual switch to OFF.

2. Turn off the utility power supply to the transfer switch, using whatever means are provided.

3. Remove fuses F1 and F2 from the fuse holder (see Figure 5).

4. Remove the generator control panel cover. Disconnect wire N1 and wire N2 from the interconnection terminal in the control panel, or the terminal strip.

5. Set your VOM to the 'R x 1" scale. Connect the positive meter test lead to wire N1.

a.Connect the negative meter lead to the ground

lug. Infinity should be measured.

b.Connect the negative meter lead to Wire 23 at

ICT or terminal strip. Infinity should be measured.

c. Connect the negative meter lead to Wire 194 at

ICT or terminal strip. Infinity should be measured.

d.Connect the negative meter lead to the neutral

connection. Infinity should be measured.

6. Set your VOM to the 'R x 1" scale. Connect the positive meter test lead to wire N2.

a.Connect the negative meter lead to the ground

lug. Infinity should be measured.

b.Connect the negative meter lead to Wire 23 at

ICT or terminal strip. Infinity should be measured.

c. Connect the negative meter lead to Wire No.

194 at ICT or terminal strip. Infinity should be measured.

d.Connect the negative meter lead to the neutral

connection. Infinity should be measured.

7. Disconnect wire N1 and wire N2 from transformer TX.

8. Connect one test lead to wire N1 removed in step 7, and the other test lead to the ground terminal. INFINITY should be measured.

9. Connect one test lead to wire N2 removed in step 7, and the other test lead to the ground terminal. INFINITY should be measured.

10.If no short is indicated in steps 5 through 9, proceed with steps 11 through 15. If a short is indicated in steps 5 through 9, repair shorted wiring.

11.Reconnect wires N1 and N2 to the interconnection terminal or terminal strip.

12.Replace fuses F1 and F2 in the fuse holder.

13.Turn on the utility power supply to the transfer switch using whatever means is provided.

14.Set VOM to measure AC voltage. Connect one test lead to wire N1 and the other test lead to wire N2. Utility line to line voltage should be measured.

15.Turn off the utility power supply to the transfer switch using whatever means is provided.

Page 69

SECTION 3.4

DIAGNOSTIC TESTS

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

RESULTS: If a short is indicated in steps 5 through 9, repair

wiring and re-test. If utility line to line voltage is measured in Step 14, proceed to Test 35.

TEST 35 - CHECK TRANSFORMER (TX)

DISCUSSION: The transformer is a step down type and has two

functions. It supplies approximately 16VAC to the control board for utility sensing. It also supplies approximately 16 VAC to the battery charger when utility is available for trickle charge. A shorted transformer can result in fuse F1 or F2 blowing.

PROCEDURE:

1. On the generator panel, set the Auto-Off-manual switch to OFF.

2. Turn off the utility power supply to the transfer switch, using whatever means is provided.

3. See Figure 6. Disconnect Wires N1, N2, 224, 225, 224A, 225A from transformer (TX).

4. Set a VOM to the "R x 1" scale.

5. Connect one test lead to TX terminal 1. Connect the other test lead to TX terminal 5. Approximately 38.5 ohms should be measured

6. Connect one test lead to TX terminal 10. Connect the other test lead to TX terminal 9. Approximately 1.5 ohms should be measured.

7. Connect one test lead tot TX terminal 7. Connect the other test lead to TX terminal 6. Approximately 0.3 ohms should be measured.

8. Connect one test lead to TX terminal 1. Connect the other test lead to the transformer case. INFINITY should be measured.

9. Connect one test lead to TX terminal 7. Connect the other test lead to the transformer case. INFINITY should be measured.

10.Connect one test lead to TX terminal 9. Connect the other test lead to the transformer case. INFINITY should be measured.

11.Connect one test lead to TX terminal 1. Connect the other test lead to TX terminal 10. INFINITY should be measured.

12.Connect one test lead to TX terminal 1. Connect the other test lead to TX terminal 7. INFINITY should be measured.

13.Connect one test lead to TX terminal 10. Connect the other test lead t TX terminal 7. INFINITY should be measured.

RESULTS: For steps 5, 6, and 7, replace transformer if an open

is indicated, or if the resistance value indicated is zero. If the resistance value is not within the approximate range, proceed to test 65.

For steps 8 through 13, replace the transformer if it fails any of these steps.

Figure 6. Transformer (TX)

PART 3

Page 70

SECTION 3.4

DIAGNOSTIC TESTS

PART 3

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

PART TITLE

4.1 Description and Components

4.2 Operational Analysis

4.3 Troubleshooting Flow Charts

4.4 Diagnostic Tests

PART 4

DC CONTROL

Air-cooled, Prepackaged

Automatic Standby Generators

Models:

6 kW NG, 7 kW LP 12 kW NG, 12 kW LP 13 kW NG, 15 kW LP

TABLE OF CONTENTS

Page 72

SECTION 4.1

DESCRIPTION AND COMPONENTS

PART 4

3DC CONTROL

GENERAL

This section will familiarize the reader with the various components that make up the DC control system.

Major DC control system components that will be covered include the following:

o A Terminal Strip / Interconnection Terminal

• A Transformer (TX)

• A Circuit Board.

• An Auto-Off-Manual Switch.

• A 15 Amp Fuse.

• A 5 Amp Fuse.

TERMINAL STRIP / INTERCONNECTION

TERMINAL

The terminals of this terminal strip are connected to identically numbered terminals on a prepackaged transfer switch terminal board. The terminal board connects the transfer switch to the circuit board and transformer.

The terminal board provides the following connection points:

A. Utility 1 and Utility 2

1.Connect to identically marked terminals on a prepackaged transfer switch terminal board.

2.The circuit delivers "Utility" power source voltage to the transformer (TX) located in the control panel assembly.

B. 23 and 194

1.Connect to identically numbered terminals on the terminal board of the prepackaged transfer switch.

2.This circuit connects the circuit board to the transfer relay coil in the prepackaged transfer switch.

Figure 1. Terminal Board

TRANSFORMER (TX)

The control panel assembly's transformer is a stepdown type. The line-to-line voltage from the Utility 1/Utility 2 terminals is delivered to the transformer's primary winding. Transformer action then induces a reduced voltage (about 12 to 16 volts) into both secondary transformer windings. Reduced voltage from one secondary winding is delivered to the circuit board as "Utility" source sensing voltage. Reduced voltage from the other secondary winding is delivered to the battery charger for trickle charging.

• If the Utility sensing voltage drops below a preset value, circuit board action will initiate automatic generator startup and transfer to the "Standby" source side.

The sensing transformer is shown in Figure 2, both pictorially and schematically.

Figure 2. The Transformer

CIRCUIT BOARD

The circuit board controls all standby electric system operations including (a) engine startup, (b) engine running, (c) automatic transfer, (d) automatic retransfer, and (e) engine shutdown. In addition, the circuit board performs the following functions:

• Delivers "field boost" current to the generator rotor windings (see "Field Boost Circuit" in Section 2.2).

• Starts and "exercises" the generator once every seven days.

• Provides automatic engine shutdown in the event of low oil pressure, high oil temperature, or overspeed.

A 17-pin and a 5-pin connector are used to interconnect the circuit board with the various circuits of the DC systems. Connector pin numbers, associated wires and circuit functions are listed in the CHART on the next page.

Page 73

SECTION 4.1

DESCRIPTION AND COMPONENTS

DC CONTROL

PART 4

J1 PIN WIRE CIRCUIT FUNCTION

1 4 Field boost current to rotor (about 9-10 volts DC).

2 86 Low oil pressure shutdown. Automatic shutdown occurs when Wire 85 is grounded by loss of oil

pressure to the LOP.

3 23 Switched to ground for Transfer Relay (TR) operation.

4 194 12 VDC output from the circuit board for transfer relay, present in AUTO or MANUAL operation.

5 56 Energized (12 volts DC) by circuit board's crank relay (K1) to crank the engine.

6 18 Engine shutdown. Circuit is grounded by circuit board action to ground the engine

7 14 12 VDC output for engine run condition. Used for fuel solenoid (FS), battery charge relay (BCR),

and hourmeter if equipped.

8 66A AC input to the board for crank terminate and overspeed protection.

9 239 B+ input when SW1 is in the MANUAL position.

10 15A B+ input into the board for source voltage when SW1 is in the AUTO or MANUAL position.

11 17 B+ output to SW1 for manual start operation.

12 15 12VDC source voltage for the circuit board. Also runs timer for exerciser.

13 0 Common ground.

14 225 Transformer reduced "Utility" source sensing voltage.

15 224 Transformer reduced "Utility" source sensing voltage.

16 NOT USED

17 NOT USED

J2 PIN WIRE CIRCUIT FUNCTION

1 NOT USED

2 85 High temperature oil engine safety.

3 351 Input set exercise. Signal to ground to set.

4 NOT USED

5 NOT USED

Figure 3. Circuit Board

225194 151886 15A66A

239

15B

12345678 9 10 111213 141516 17

229

351

J2 CONNECTOR

J1 CONNECTOR

2244235614 17 0

OFF

SPARE 50 Hz OPERATION REMOTE NOT AUTO 20 VAC SENSE TRANSFORM

Page 74

The circuit board mounts a crank relay (K1) and a run relay (K2, see Figure 4). Crank relay (K1) is energized by circuit board action during both manual and automatic startup to crank the engine. Cranking is accomplished in crank-rest cycles, with the first cycle being 15 seconds on and 15 seconds off. After the first crank-rest cycle, the remaining cycles will be in equal 7-9 second durations. This cyclic cranking action continues until either (a) the engine starts, or (b) approximately 90 seconds of the crank-rest cycles have elapsed.

The run relay is energized by circuit board action at the same time as the crank relay, to energize and open a fuel solenoid valve.

DANGER: THE GENERATOR ENGINE WILL CRANK AND START WHEN THE 7-DAY EXERCISER SWITCH IS ACTUATED. THE UNIT WILL ALSO CRANK AND START EVERY 7 DAYS THEREAFTER, ON THE DAY AND AT THE TIME OF DAY THE SWITCH WAS ACTUATED.

AUTO-OFF-MANUAL SWITCH

This 3-position switch permits the operator to (a) select fully automatic operation, (b) start the generator manually, or (c) stop the engine and prevent automatic startup. Switch terminals are shown pictorially and schematically in Figure 5, below.

Figure 4. The Auto-Off-Manual Switch

15 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 replacement become necessary, use only an identical 15-amp replacement fuse.

7.5 AMP FUSE

7.5 amp replacement fuse.

Figure 5. 15 Amp Fuse

SW1

SECTION 4.1

DESCRIPTION AND COMPONENTS

PART 4

DC CONTROL

HEMATI

Page 75

SECTION 4.1

DESCRIPTION AND COMPONENTS

DC CONTROL

PART 4

Figure 6. Control Panel Component Identification

GROUND TERMINAL

NEUTRAL BLOCK

TERMINAL STRIP

STARTER CONTACTOR RELAY (SCR) (V-TWINS ONLY)

BATTERY CHARGER

CIRCUIT BREAKER "DPE" (CB2)

GROUND TERMINAL

SET EXERCISE SWITCH (SW2)

TRANSFORMER (TX)

VOLTAGE REGULATOR

BATTERY CHARGE RELAY (BCR)

4-TAB TERMINAL BLOCK (TB)

PRINTED CIRCUIT BOARD

FUSE HOLDER (F1)

FUSE HOLDER (F2)

AUTO-OFF-MANUAL SWITCH (SW1)

ACCESSORY OUTLET

EXTERNAL GFCI CIRCUIT BREAKER

SECTION 4.2

OPERATIONAL ANALYSIS

PART 4

DC CONTROL

INTRODUCTION

This "Operational Analysis" is intended to familiarize the service technician with the operation of the DC control system on prepackaged units with air-cooled engine. A thorough understanding of how the system works is essential to sound and logical troubleshooting. The DC control system illustrations on the following pages include a "V-Type" prepackaged transfer switch.

UTILITY SOURCE VOLTAGE AVAILABLE

See Figure 1, above. The circuit condition with the Auto-Off-Manual switch set to AUTO and with "Utility" source power available can be briefly described as follows:

• "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.

)

9413

)

SSU

Page 76

HARGE

BATTERY CHAR

WINDIN

2-1

DIAGRAM KE

RE SWIT

2-1

DPE WINDIN

STATOR

ELECTRONI

VOLTA

REGULAT

BA - BRUSH ASSEMBL

BCR - BATTERY CHARGE RELA CB1 - CIRCUIT BREAKER, MAIN OUTPU CB2 - CIRCUIT BREAKER, ALT. EXCITATIO CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PUL D - DIOD FS - FUEL SOLENOI F1 - FUSE 15 AM F2 - FUSE 7.5 AM HTO - HIGH OIL TEMPERATURE SWIT IM1 - IGNITION MODULE, CYLINDER # IM2 - IGNITION MODULE, CYLINDER # LOP - LOW OIL PRE

- STARTER CONTACT R - STARTER CONTACTOR RELA

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT W2 - SET EXERCISE SWIT M - STARTER MOT

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

= 12 VDC ALWAYS PRESEN

= AC VOLTA

= GROUND FOR CONTROL PURPOSE

PRINTED CIRCUI

NTR

BOAR

ENGINE R

WINDIN

STATOR

= 12 VDC DURING CRANKING ONL

= 12 VDC DURING ENGINE RUN CONDITI

Page 77

SECTION 4.2

OPERATIONAL ANALYSIS

DC CONTROL

PART 4

• "Utility" voltage is delivered to the primary winding of a sensing transformer (TX), via transfer switch wires N1/N2, fuses F1/F2, connected wiring, and Control Panel "Utility 1/Utility 2" terminals. A resultant voltage (about 16 volts AC) is induced into the transformer secondary windings and then delivered to the circuit board via Wires 224/225. The circuit board uses this reduced "Utility" voltage as sensing voltage. Wires 224A/225A supply 16 VAC to the battery charger.

• Battery output is delivered to the circuit board with the Auto-Off-Manual switch (SW1) set to AUTO, as shown.

313

)

SSO

SOCKET

Figure 1. Circuit Condition - Utility Source Voltage

Available

12VDC ACCE

240VA

TILITY

INP

12V

RANSFE

NNECTION

TOME

BLA

PPLIE

TOME

POWE

WINDIN

STATOR

TLE

Page 78

SECTION 4.2

OPERATIONAL ANALYSIS

PART 4

DC CONTROL

INITIAL DROPOUT OF

UTILITY SOURCE VOLTAGE

Refer to Figure 2, above. 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/Utility 2" terminals, connected wiring, control panel "Utility 1/Utility 2" terminals, the sensing transformer (TX), and Wires 224/225.

)

9413

)

SSU

HARGE

BATTERY CHAR

WINDIN

2-1

DIAGRAM KE

RE SWIT

2-1

DPE WINDIN

STATOR

ELECTRONI

VOLTA

REGULAT

BA - BRUSH ASSEMBL

- STARTER CONTACT R - STARTER CONTACTOR RELA

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT W2 - SET EXERCISE SWIT M - STARTER MOT

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

= 12 VDC ALWAYS PRESEN

= AC VOLTA

= GROUND FOR CONTROL PURPOSE

PRINTED CIRCUI

NTR

BOAR

ENGINE R

WINDIN

STATOR

= 12 VDC DURING CRANKING ONL

= 12 VDC DURING ENGINE RUN CONDITI

Page 79

SECTION 4.2

OPERATIONAL ANALYSIS

DC CONTROL

PART 4

• Should "Utility" voltage drop below approximately 60 percent of the nominal source voltage, a 15second timer on the circuit board will turn on.

• In Figure 2, the 15-second timer is still timing and engine cranking has not yet begun.

• The Auto-Off-Manual switch is shown in its AUTO position. Battery voltage is available to the circuit board, via Wire 13, 15 amp fuse (F1), Wire 15, the Auto-Off-Manual switch (SW1), Wire 15A, and Pin 10 of the circuit board connector.

313

)

SSO

SOCKET

Figure 2. Circuit Condition - Initial Dropout of

Utility Source Voltage

12VDC ACCE

240VA

TILITY

INP

12V

RANSFE

NNECTION

TOME

BLA

PPLIE

TOME

POWE

WINDIN

STATOR

TLE

Page 80

SECTION 4.2

OPERATIONAL ANALYSIS

PART 4

DC CONTROL

UTILITY VOLTAGE DROPOUT / ENGINE

CRANKING

• After fifteen (15) seconds and when the circuit board's 15-second timer has timed out, if "Utility" voltage is still below 60 percent of nominal, circuit board action will energize the circuit board's crank and run relays (K1 and K2) simultaneously.

• The crank relay (K1) will remain energized for about 15 seconds on the first crank cycle. The relay will then de-energize for 7 seconds and will again energize. This time it will remain energized for 7

seconds. Thus, the engine will crank cyclically for 7 second crank-rest cycles. This cyclic cranking will continue until either the engine starts or until about ninety (90) seconds of crank-rest cycles have elapsed.

• When the crank relay (K1) is energized, circuit board action delivers 12 volts DC to a starter contactor relay (SCR), via Wire 56. When the SCR energizes, its contacts close and battery power is delivered to a starter contactor (SC). When the SC energizes, its contacts close and battery power is delivered to the starter motor (SM).The engine cranks.

)

9413

)

SSU

HARGE

BATTERY CHAR

WINDIN

2-1

DIAGRAM KE

RE SWIT

2-1

DPE WINDIN

STATOR

ELECTRONI

VOLTA

REGULAT

BA - BRUSH ASSEMBL

- STARTER CONTACT R - STARTER CONTACTOR RELA

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT W2 - SET EXERCISE SWIT M - STARTER MOT

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

= 12 VDC ALWAYS PRESEN

= AC VOLTA

= GROUND FOR CONTROL PURPOSE

PRINTED CIRCUI

BOAR

NTR

ENGINE R

WINDIN

STATOR

= DC FIELD CONTROL VOLTA

= 12 VDC DURING CRANKING ONL

= 12 VDC DURING ENGINE RUN CONDITI

Page 81

SECTION 4.2

OPERATIONAL ANALYSIS

DC CONTROL

PART 4

• When the circuit board's run relay (K2) energizes, 12 volts DC is delivered to a fuel solenoid (FS), via Wire 14. The fuel solenoid (FS) energizes open and fuel is available to the engine. Wire 14 energizes the battery charge relay (BCR), which will allow the BCR to power the battery charger.

• As the engine cranks, magnets on the engine flywheel induce a high voltage into the engine ignition modules (IM1/IM2). A spark is produced that jumps the spark plug (SP1/SP2) gap.

• During cranking, Wire 4 supplies 2-3 VDC (8-9 VDC isolated) to the rotor for field flash.

• With ignition and fuel flow available the engine can start.

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Figure 3. Circuit Condition - Engine Cranking

12VDC ACCE

240VA

TILITY

INP

12V

RANSFE

NNECTION

TOME

BLA

PPLIE

TOME

POWE

WINDIN

STATOR

TLE

Page 82

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:

• An AC voltage/frequency signal is delivered to the circuit board from the generator engine run winding, via Wire 66A. When AC frequency reaches approximately 30 Hz, the circuit board (a) terminates cranking, and (b) turns on an "engine warm-up timer".

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SECTION 4.2

OPERATIONAL ANALYSIS

PART 4

DC CONTROL

HARGE

BATTERY CHAR

WINDIN

2-1

DIAGRAM KE

RE SWIT

2-1

DPE WINDIN

STATOR

ELECTRONI

VOLTA

REGULAT

BA - BRUSH ASSEMBL

- STARTER CONTACT R - STARTER CONTACTOR RELA

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT W2 - SET EXERCISE SWIT M - STARTER MOT

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

= 12 VDC ALWAYS PRESEN

= AC VOLTA

= GROUND FOR CONTROL PURPOSE

PRINTED CIRCUI

BOAR

NTR

ENGINE R

WINDIN

STATOR

= DC FIELD CONTROL VOLTA

= 12 VDC DURING CRANKING ONL

= 12 VDC DURING ENGINE RUN CONDITI

• The "engine warm-up timer" will run for about 15 seconds. When this timer finishes timing, board action will initiate transfer to the "Standby" power source. As shown in Figure 4 (above), the timer is still running and transfer has not yet occurred.

• Generator AC output is available to transfer switch terminal lugs E1/E2 and to the normally open contacts of a transfer relay. However, the transfer relay is de-energized and its contacts are open.

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SECTION 4.2

OPERATIONAL ANALYSIS

DC CONTROL

PART 4

Page 83

Figure 4. Circuit Condition - Engine Startup and

Running

12VDC ACCE

240VA

TILITY

INP

12V

RANSFE

NNECTION

TOME

BLA

PPLIE

TOME

POWE

WINDIN

STATOR

TLE

Page 84

SECTION 4.2

OPERATIONAL ANALYSIS

PART 4

DC CONTROL

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 available 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:

• The circuit board delivers a 12 volts DC output to the transfer relay (TR) actuating coil, via Wire 194, and terminal A of the transfer relay (TR) in the

transfer switch. This 12 volts DC circuit is completed back to the board, via transfer relay terminal B, and Wire 23. However, circuit board action holds the Wire 23 circuit open to ground and the transfer relay (TR) is de-energized.

• 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

)

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SSU

HARGE

BATTERY CHAR

WINDIN

2-1

DIAGRAM KE

RE SWIT

2-1

DPE WINDIN

STATOR

ELECTRONI

VOLTA

REGULAT

BA - BRUSH ASSEMBL

- STARTER CONTACT R - STARTER CONTACTOR RELA

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT W2 - SET EXERCISE SWIT M - STARTER MOT

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

= 12 VDC ALWAYS PRESEN

= AC VOLTA

= GROUND FOR CONTROL PURPOSE

PRINTED CIRCUI

BOAR

NTR

ENGINE R

WINDIN

STATOR

= DC FIELD CONTROL VOLTA

= 12 VDC DURING CRANKING ONL

= 12 VDC DURING ENGINE RUN CONDITI

SECTION 4.2

OPERATIONAL ANALYSIS

DC CONTROL

PART 4

Page 85

XB1, Wire B, and a bridge rectifier. The standby closing coil energizes and the main current carrying contacts of the transfer switch are actuated to their 'Standby" source side.

• As the main contacts move to their "Standby" source side, a mechanical interlock actuates limit switch XB1 to its open position and limit switch XA1 to its "Utility" side position. When XB1 opens, standby closing coil C2 3 de-energizes.

• "Standby" power is delivered to the "Load" terminals (T1/T2) of the transfer switch.

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Figure 5. Circuit Condition - Initial Transfer to

Standby

240VA

TILITY

INP

12V

RANSFE

12VDC ACCE

POWE

WINDIN

STATOR

TOME

NNECTION

BLA

TOME

PPLIE

TLE

Page 86

SECTION 4.2

OPERATIONAL ANALYSIS

PART 4

DC CONTROL

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:

• On restoration of utility source voltage above 80 percent of the nominal rated voltage, a "retransfer time delay" on the circuit board starts timing. The timer will run for about fifteen (15) seconds.

• At the end of fifteen (15) seconds, the "retransfer time delay" will stop timing and circuit board action will open the Wire 23 circuit to ground. The transfer relay (TR) will then de-energize.

• When the transfer relay (TR) de-energizes, its normally-closed contacts close. "Utility" source voltage is then delivered to the utility closing coil (C1), via Wires N1A/N2A, the closed TR contacts, Wire 126, limit switch XA1, and a bridge rectifier.

• 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

)

9413

)

SSU

HARGE

BATTERY CHAR

WINDIN

2-1

DIAGRAM KE

RE SWIT

2-1

DPE WINDIN

STATOR

ELECTRONI

VOLTA

REGULAT

BA - BRUSH ASSEMBL

- STARTER CONTACT R - STARTER CONTACTOR RELA

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT W2 - SET EXERCISE SWIT M - STARTER MOT

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

= 12 VDC ALWAYS PRESEN

= AC VOLTA

= GROUND FOR CONTROL PURPOSE

PRINTED CIRCUI

BOAR

NTR

ENGINE R

WINDIN

STATOR

= DC FIELD CONTROL VOLTA

= 12 VDC DURING CRANKING ONL

= 12 VDC DURING ENGINE RUN CONDITI

SECTION 4.2

OPERATIONAL ANALYSIS

DC CONTROL

PART 4

Page 87

position past "Neutral" and spring force closes them to their "Utility" side. "Load" terminals are now powered by the "Utility" source.

• Movement of the main contacts to 'Utility" actuates limit switches XA1/XB1. XA1 opens and XB1 actuates to its "Standby" source side.

• The generator continues to run.

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225

225A

SSO

SOCKET

Figure 6. Circuit Condition - Utility Voltage

Restored

240VA

TILITY

INP

12V

RANSFE

12VDC ACCE

POWE

WINDIN

STATOR

TOME

NNECTION

BLA

TOME

PPLIE

TLE

Page 88

SECTION 4.2

OPERATIONAL ANALYSIS

PART 4

DC CONTROL

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 (K2). The following events will then occur:

• The DC circuit to Wire 14 and the fuel solenoid (FS) will be opened. The fuel solenoid (FS) will deenergize and close to terminate the engine fuel supply.

• The hourmeter (if equipped) connected to Wire 14 will be opened and clock function of the hourmeter will stop.

)

9413

)

SSU

HARGE

BATTERY CHAR

WINDIN

2-1

DIAGRAM KE

RE SWIT

2-1

DPE WINDIN

STATOR

ELECTRONI

VOLTA

REGULAT

BA - BRUSH ASSEMBL

- STARTER CONTACT R - STARTER CONTACTOR RELA

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT W2 - SET EXERCISE SWIT M - STARTER MOT

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

= 12 VDC ALWAYS PRESEN

= AC VOLTA

= GROUND FOR CONTROL PURPOSE

PRINTED CIRCUI

NTR

BOAR

ENGINE R

WINDIN

STATOR

= 12 VDC DURING CRANKING ONL

= 12 VDC DURING ENGINE RUN CONDITI

Page 89

SECTION 4.2

OPERATIONAL ANALYSIS

DC CONTROL

PART 4

• The battery charge relay (BCR) connected to Wire 14 will be de-energized. This will cause transformer (TX) voltage to power the battery charger again.

• Circuit board action will connect the engine's ignition shutdown module (ISM) to ground, via Wire 18, circuit board Pin 13, and Wire 0. Ignition will be terminated.

• Without fuel flow and without ignition, the engine will shut down.

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SOCKET

Figure 7. Circuit Condition - Retransfer to “Utility”

and Engine Shutdown

240VA

TILITY

INP

12V

RANSFE

12VDC ACCE

POWE

WINDIN

STATOR

TOME

NNECTION

BLA

TOME

PPLIE

TLE

Page 90

SECTION 4.3

TROUBLESHOOTING FLOW CHARTS

PART 4

DC CONTROL

Page 91

SECTION 4.3

TROUBLESHOOTING FLOW CHARTS

DC CONTROL

PART 4

Page 92

SECTION 4.3

TROUBLESHOOTING FLOW CHARTS

PART 4

DC CONTROL

Page 93

SECTION 4.3

TROUBLESHOOTING FLOW CHARTS

DC CONTROL

PART 4

Page 94

SECTION 4.3

TROUBLESHOOTING FLOW CHARTS

PART 4

DC CONTROL

Page 95

SECTION 4.3

TROUBLESHOOTING FLOW CHARTS

DC CONTROL

PART 4

Page 96

SECTION 4.3

TROUBLESHOOTING FLOW CHARTS

PART 4

DC CONTROL

Problem 17 - 7.5 Amp Fuse (F2) Blown

THE 12 VDC ACCESSORY OUTLET IS CAPABLE OF DELIVERING A MAXIMUM OF

7.5 AMPS. IF THE ACCESSORY TO BE USED THROUGH THIS CIRCUIT DEMANDS TOO MUCH POWER, THE FUSE THAT PROTECTS THIS CIRCUIT WILL OPEN.

CHECK FOR OVERLOAD CONDITION.

INSTALL NEW FUSE AND RETEST.

IF FUSE STILL MELTS OPEN CHECK WIRE 15 BETWEEN 7.5A(F2) FUSE HOLDER

AND THE 12 VDC ACCESSORY SOCKET FOR A SHORT TO GROUND.

SECTION 4.4

DIAGNOSTIC TESTS

INTRODUCTION

Perform these "Diagnostic Tests" in conjunction with the "Troubleshooting Flow Charts" of Section 4.3.

The test procedures and methods presented in this section are not exhaustive. We could not possibly know of, evaluate and advise the service trade of all conceivable ways in which testing and trouble diagnosis might be performed. We have not undertaken any such broad evaluation.

TEST 41 - CHECK POSITION OF AUTO-OFF-

MANUAL SWITCH

DISCUSSION: If the standby system is to operate automatically, the

generator Auto-Off-Manual switch must be set to AUTO. That is, the generator will not crank and start on occurrence of a "Utility" power outage unless that switch is at AUTO. In addition, the generator will not exercise every seven (7) days as programmed unless the switch is at AUTO.

PROCEDURE: With the Auto-Off-Manual switch set to "Auto,” test

automatic operation. Testing of automatic operation can be accomplished by turning OFF the Utility power supply to the transfer switch. When the utility power is turned OFF, the standby generator should crank and start. Following startup, transfer to the standby source should occur. Refer to Section 1.8 in this manual. An "Automatic Operating Sequences Chart" is provided in Section 1.7. Use the chart as a guide in evaluating automatic operation.

Following generator startup and transfer to the standby source, turn ON the utility power supply to the transfer switch. Retransfer back to the "Utility" source should occur. After an "engine cool down timer" has timed out, generator shutdown should occur.

RESULTS:

1. If normal automatic operation is obtained, discontinue

tests.

2. If engine does not crank when "Utility" power is turned

off, proceed to Test 42.

3. If engine cranks but won't start, go to Problem 10 in

Section 4.3.

4. If engine cranks and starts, but transfer to "Standby"

does not occur, go to Problem 5 in Section 3.3.

5. If transfer to "Standby" occurs, but retransfer back to

"Utility" does not occur when utility source voltage is restored, go to Problem 6 in Section 3.3.

TEST 42 - TRY A MANUAL START

DISCUSSION: The first step in troubleshooting for an "engine won't

crank" condition is to determine if the problem is peculiar to automatic operations only or if the engine won't crank manually either.

PROCEDURE:

1. On the generator panel, set the Auto-Off-Manual switch to OFF.

2. Set the generator main line circuit breaker to its OFF or open position.

3. Set the generator Auto-Off-Manual switch to MANUAL.

a.The engine should crank cyclically through it’s

"crank-rest" cycles until it starts.

b.Let the engine stabilize and warm up for a few

minutes after it starts.

RESULTS:

1. If the engine cranks manually but does not crank automatically, go to Test 43.

2. If the engine does not crank manually, proceed to Problem 9 in the "Troubleshooting Flow Charts".

TEST 43- TEST AUTO-OFF-MANUAL SWITCH

DISCUSSION: When the Auto-Off-Manual switch is set to AUTO

position, battery voltage (12 volts DC) is delivered to the circuit board via Wire 15A, the closed switch terminal, Wire 15A, and Pin 10 of the circuit board connector. This voltage is needed to operate the circuit board.

Setting the switch to its "Manual" position delivers battery voltage to the circuit board for its operation. In addition, when the switch is set to "Manual", 12 volts DC is supplied to the circuit board via Pin 11 of the board, Wire 239, the closed switch contacts, Wire 17 and Pin 9 of the circuit board connector.

Figure 1. Schematic of Auto-Off-Manual Switch

DC CONTROL

PART 4

Page 97

A. Set to "Auto

B. Set to "Manual

Page 98

SECTION 4.4

DIAGNOSTIC TESTS

PART 4

DC CONTROL

PROCEDURE: Disconnect all wires from switch terminals, to prevent

interaction. Then, use a volt-ohm-milliammeter (VOM) to test for continuity across switch terminals as shown in the following chart. Reconnect all wires and verify correct positions when finished.

RESULTS:

1. Replace Auto-Off-Manual switch, if defective.

2. For Problem 8 Only: If the switch passes the tests, verify the remote not auto dip switch is set to OFF on the circuit board (see Figure 3, Section 4.1) then proceed to Test 44.

3. For Problem 9 Only: If the switch passes the tests, proceed to Test 60.

Figure 2. Auto-Off-Manual Switch Test Points

TEST 44- CHECK WIRE 15/15A/17/239

VOLTAGE

DISCUSSION: The circuit board will not turn on unless battery

voltage is available to the board via wire 15, the AutoOff-Manual switch and Wire 15A. If battery voltage is not available, automatic or manual operation will not be possible.

Battery voltage is available to wire 17 from pin location 11 of the J1 connector on the circuit board. When the Auto-Off-Manual switch is in the MANUAL position, wire 239 supplies battery voltage to pin location 9 of the circuit board, and engine cranking occurs.

PROCEDURE: (For Problem 1 flow chart, do Steps 1-5 and Step 9

only) (For Problem 2 flow chart, do all steps)

1. Set a VOM to measure DC voltage.

2. Connect the positive (+) test lead to the Auto-Off-Manual switch Terminal 2, Wire 15. Connect the negative (-) test lead to a clean frame ground. Battery voltage should be measured (See Figure. 2).

3. Connect the positive (+) test lead to the Auto-Off-Manual switch terminal 1, Wire 15A. Connect the negative (-) test lead to a clean frame ground. Set the Auto-Offmanual switch to MANUAL. Battery voltage should be measured.

4. Connect the positive (+) test lead to Pin location 12 Wire 15 at the J1 connector on the circuit board. Connect the negative (-) test lead to a clean frame ground. Battery voltage should be measured.

5. Connect the positive (+) test lead to pin location 10, wire 15A at the J1 connector on the circuit board. Connect the negative test lead to a clean frame ground. Set the Auto-Off-Manual switch to the MANUAL position. Battery voltage should be measured. Repeat Step 5. This time set the Auto-Off-Manual switch to AUTO. Battery voltage should be measured.

6. Connect the positive (+) test lead to pin location 9, wire 239 at the J1 connector on the circuit board. Connect the negative (-) test lead to a clean frame ground. Set the Auto-Off-Manual switch to the MANUAL position. Battery voltage should be measured. If battery voltage is measured, stop and proceed to results. If battery voltage is not measured, proceed to Step 7.

7. Connect the positive (+) test lead to the Auto-Off-Manual

TERMINALS SWITCH POSITION READING 2 and 3 AUTO C

ONTINUITY

MANUAL I

NFINITY

OFF I

NFINITY

2 and 1 AUTO I

NFINITY

MANUAL C

ONTINUITY

OFF I

NFINITY

5 and 6 AUTO C

ONTINUITY

MANUAL I

NFINITY

OFF I

NFINITY

5 and 4 AUTO I

NFINITY

MANUAL C

ONTINUITY

OFF I

NFINITY

AUT

MANUA

HEMATI

SECTION 4.4

DIAGNOSTIC TESTS

switch Terminal 4, Wire 17/178. Connect the negative (-) test lead to a clean frame ground. Battery voltage should be measured.

8. Connect the positive (+) test lead to Pin location 11, wire 17 at the J1 connector on the circuit board. Connect the negative (-) test lead to a clean frame ground. Battery voltage should be measured.

9. Set a VOM to measure resistance "R x 1" scale. Connect one meter test lead to a clean frame ground. Connect the other test lead to Pin location 13, Wire 0 at the J1 connector on the circuit board. Continuity should be measured.

RESULTS:

1. No battery voltage in Step 2. Go to test 45 or repair/replace Wire 15 from F1 to SW1.

2. No battery voltage in Step 3. Go to Test 43 or repair or replace Wire 15A from Terminal 1 to Terminal 3 of SW1.

3. No battery voltage in Step 4. Verify Step 2 and repair or replace wire 15 from SW1 to J1 connector.

4. No battery voltage in Step 5. Go to Test 43 or repair or replace Wire 15A from SW1 to J1 connector.

5. If battery voltage is available in Step 8 but not in Step 7, repair or replace Wire 17 from SW1 to J1 connector.

6. If battery voltage is available in Step 7 but not in Step 6, go to Test 43.

7. If continuity is not measured in Step 9, repair or replace Wire 0 between the J1 connector and the 8-tab ground terminal.

8. If battery voltage is available in Steps 1-5 but not in Step 8 of Problem 2 flow chart, replace or repair the circuit board.

9. If battery voltage is available in Steps 1-5 for Problem 1 flow chart, replace the circuit board.

Figure 3. Wires 15A

TEST 45- CHECK 15 AMP FUSE

DISCUSSION: The 15 amp fuse is located on the generator console.

A blown fuse will prevent battery power from reaching the circuit board, with the same result as setting the Auto-Off-Manual switch to OFF.

PROCEDURE: Remove the 15 amp fuse (F1) by pushing in on fuse

holder cap and turning the cap counterclockwise. Inspect the fuse visually and with a VOM for an open condition.

RESULTS:

1. If the fuse if good, go on to Test 46.

2. If the fuse is bad, it should be replaced. Use only an identical 15 amp replacement fuse.

3. If fuse continues to blow, go to Problem 16.

TEST 46- CHECK BATTERY

DISCUSSION: Battery power is used to (a) crank the engine and (b)

to power the circuit board. Low or no battery voltage can result in failure of the engine to crank, either manually or during automatic operation.

PROCEDURE:

A. Inspect Battery Cables:

1.Visually inspect battery cables and battery posts.

2.If cable clamps or terminals are corroded, clean away all corrosion.

3.Install battery cables, making sure all cable clamps are tight. The red battery cable from the starter contactor (SC) must be securely attached to the positive (+) battery post; the black cable from the frame ground stud must be tightly attached to the negative (-) battery post.

B. Test Battery State of Charge:

1.Use an automotive type battery hydrometer to test battery state of charge.

2.Follow the hydrometer manufacturer's instructions carefully. Read the specific gravity of the electrolyte fluid in all battery cells.

3.If the hydrometer does not have a "percentage of charge" scale, compare the reading obtained to the following:

a. An average reading of 1.260 indicates the

battery is 100% charged.

b. An average reading of 1.230 means the

battery is 75% charged.

c. An average reading of 1.200 means the

battery is 50% charged.

DC CONTROL

PART 4

Page 99

Page 100

SECTION 4.4

DIAGNOSTIC TESTS

d. An average reading of 1.170 indicates the

battery is 25% charged.

C. Test Battery Condition:

1.If the difference between the highest and lowest reading cells is greater than 0.050 (50 points), battery condition has deteriorated and the battery should be replaced.

2.However, if the highest reading cell has a specific gravity of less than 1.230, the test for condition is questionable. Recharge the battery to a 100 percent state of charge, then repeat the test for condition.

RESULTS:

1. Remove the battery and recharge with an automotive battery charger, if necessary.

2. If battery condition is bad, replace the battery with a new one.

TEST 47 - CHECK WIRE 56 VOLTAGE

DISCUSSION: During an automatic start or when starting manually,

a crank relay (K1) on the circuit board should energize. Each time the crank relay energizes, the circuit board should deliver 12 volts DC to a starter contactor relay(SCR) and the engine should crank. This test will verify (a) that the crank relay on the circuit board is energizing, and (b) that circuit board action is delivering 12 volts DC to the starter contactor relay.

PROCEDURE:

1. Connect the positive (+) test probe of a DC voltmeter (or VOM) to the Wire 56 connector of the starter contactor relay (SCR, on models with v-twin engines) or the starter contactor (SC, on models with single cylinder engines). Connect the common (-) test probe to frame ground.

2. Observe the meter. Then, actuate the Auto-Off-Manual switch to MANUAL position.

a.The circuit board crank and run relays should

energize.

b.The meter should indicate battery voltage.

3. Insert the positive (+) meter test lead into Pin 5 of the circuit board connector J1. Connect the common (-) test lead to a clean frame ground. Then, repeat Step 2.

a.The circuit board's crank and run relays should

energize.

b.The meter should read battery voltage.

Figure 4. The Wire 56 Circuit

RESULTS:

1. If battery voltage is indicated in Step 3, but not in Step 2, Wire 56 (between the circuit board and starter contactor relay or starter contactor) is open. Repair or replace this wire as required.

2. If battery voltage is not indicated in Step 3, go to Test

43.

3. If battery voltage is indicated in both Steps 2 and 3, but engine does not crank, go on to Test 49.

TEST 48- TEST STARTER CONTACTOR RELAY

(V-TWIN ONLY)

DISCUSSION: The starter contactor relay (SCR) located in the

control panel must be energized for cranking to occur. Once the SCR is energized, it’s normally open contacts will close and battery voltage will be available to Wire 16 and to the starter contactor (SC).

Figure 5. The Starter Contactor Relay

PROCEDURE:

1 Set a VOM to measure DC voltage.

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PART 4

DC CONTROL

Bryant ASPAS1BBA015 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual