Generac 13 kW NG, 9 kW NG, 8 kW LP, 16 kW NG, 14 kW LP User Manual

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diagnostic

repair

manual

Air-Cooled Product

MODELS:

7 kW NG, 8 kW LP

9 kW NG, 10 kW LP 13 kW NG, 14 kW LP 16 kW NG, 17 kW LP 18 kW NG, 20 kW LP

AUTOMATIC STANDBY GENERATORS

ElEctrical formulas

TO FIND KNOWN VALUES 1-PHASE 3-PHASE

KILOWATTS (kW)

KVA

AMPERES

WATTS

NO. OF ROTOR POLES

FREQUENCY

RPM

kW (required for Motor)

Volts, Current, Power Factor

Volts, Current

kW, Volts, Power Factor

Volts, Amps, Power Factor Volts x Amps E x I x 1.73 x PF

Frequency, RPM

RPM, No. of Rotor Poles

Frequency, No. of Rotor Poles

Motor Horsepower, Efficiency

E x I 1000

kW x 1000

2 x 60 x Frequency

RPM

RPM x Poles

2 x 60

2 x 60 x Frequency

Rotor Poles

HP x 0.746

Efficiency

E x I x 1.73 x PF

1000

E x I x 1.73

1000

kW x 1000

E x 1.73 x PF

2 x 60 x Frequency

RPM

RPM x Poles

2 x 60

2 x 60 x Frequency

Rotor Poles

HP x 0.746

Efficiency

RESISTANCE

VOLTS

AMPERES

E = VOLTS I = AMPERES R = RESISTANCE (OHMS) PF = POWER FACTOR

Volts, Amperes

Ohm, Amperes I x R I x R

Ohms, Volts

E R

specifications ..........................................................4

Generator ................................................................ 4

Engine ..................................................................... 5

Fuel Consumption ................................................... 5

Mounting Dimensions .............................................. 6

Mounting Dimensions .............................................. 7

Major Features ........................................................ 8

Part 1 - GENEral iNformatioN .......................9

1.1 Generator Identification ................................... 10

Introduction ......................................................10

1.2 Installation Basics ............................................11

Introduction ......................................................11

Selecting A Location ........................................11

Grounding The Generator ................................11

The Fuel Supply ...............................................11

The Transfer Switch / Load Center ...................11

Power Source And Load Lines .........................13

System Control Interconnections .....................13

Natural Gas Fuel Interconnections ..................13

1.3 Non-prepackaged Interconnections ................14

Connect a Pre-2008 Load Center Switch To a Current or Future

Air-Cooled Generator. ..................................14

Connect a 2008 And Later Load Center Switch to a Pre-2008

Air-Cooled Generator. ..................................15

1.4 Preparation Before Use ................................... 16

General ............................................................16

Fuel Requirements...........................................16

Fuel Consumption ............................................16

Reconfiguring The Fuel System .......................16

Engine Oil Recommendations .........................18

1.5 Testing, Cleaning and Drying........................... 19

Meters ............................................................19

The Vom ...........................................................19

Measuring AC Voltage .....................................19

Measuring DC Voltage .....................................19

Measuring AC Frequency ................................19

Measuring Current ...........................................20

Measuring Resistance .....................................20

Electrical Units .................................................21

Ohm’s Law .......................................................21

Visual Inspection ..............................................22

Insulation Resistance .......................................22

The Megohmmeter...........................................22

Stator Insulation Resistance Test (12-20 kW) .....23

Stator Insulation Resistance Test (8-10 kW) .......23

Rotor Insulation Resistance Test (8-10 kW) ........24

Rotor Insulation Resistance Test (12-20 kW) ......24

Cleaning The Generator...................................24

Drying The Generator ......................................24

1.6 Engine-Generator Protective Devices ............. 25

General ............................................................25

Low Battery ......................................................25

Low Oil Pressure Shutdown .............................25

High Temperature Switch .................................25

Overspeed Shutdown ......................................25

Rpm Sensor Failure .........................................25

Overcrank Shutdown .......................................26

1.7 Operating Instructions ..................................... 27

Control Panel ...................................................27

To Select Automatic Operation ........................28

Manual Transfer To “Standby”

and Manual Startup .....................................28

Manual Shutdown And

Retransfer Back To “Utility” ..........................28

1.8 Automatic Operating Parameters ....................29

Introduction ......................................................29

Automatic Operating Sequences .....................29

Part 2 - ac GENErators ..................................31

2.1 Description and Components .......................... 32

Introduction ......................................................32

Engine-Generator Drive System ......................32

The AC Generator ............................................32

Rotor Assembly ................................................32

Stator Assembly ...............................................33

Brush Holder And Brushes (12-20 kW) ...........34

Other AC Generator Components ...................34

2.2 Operational Analysis .......................................35

Rotor Residual Magnetism...............................35

Field Boost (12-20 kW) ....................................35

Operation (8/10 kW) .........................................36

Operation (12-20 kW) ......................................36

2.3 Troubleshooting Flowcharts ............................. 37

Problem 1 – Generator Produces Zero Voltage or Residual Voltage (12-20 kW) ...37-38

Problem 2 – Generator Produces Zero

Voltage or Residual Voltage (8/10 kW) ........38

Problem 3 – Generator Produces

Low Voltage at No-Load...............................39

Problem 4 – Generator Produces

High Voltage at No-Load ..............................39

Problem 5 – Voltage and Frequency Drop

Excessively When Loads are Applied ..........40

2.4 Diagnostic Tests .............................................. 41

Introduction ......................................................41

Safety ............................................................41

Test 1 – Check Main Circuit Breaker ................41

Test 2 – Check AC Output Voltage ...................41

Test 4 – Fixed Excitation Test/Rotor

Amp Draw Test ....................................42

Test 5 – Wire Continuity (12-20 kW) ................43

Test 6 – Check Field Boost (12-20 kW) ...........44

Page 1

Test 7 – Testing The Stator With A Vom

(12-20 kW)...........................................44

Test 8 – Test Brushless Stator..........................45

Test 9 – Check Capacitor .................................46

Test 10 – Test DPE Winding on

Brushless units ....................................47

Test 11 – Resistance Check Of Rotor Circuit

(12-20 kW)...........................................48

Test 12 – Check Brushes And Slip Rings

(12-20 kW)...........................................48

Test 13 – Test Rotor Assembly(12-20 kW) .......49

Test 14 – Check AC Output Frequency ............49

Test 15 – Check and Adjust Engine Governor

(Single Cylinder Units) .........................49

Test 16 – Check Stepper Motor Control

(V-twin Engine Units) ...........................50

Test 17 – Check And Adjust Voltage

Regulator (12-20 kW) ..........................51

Test 18 – Check Voltage And Frequency

Under Load..........................................52

Test 19 – Check F or Overload Condition ...........52

Test 20 – Check Engine Condition ...................52

Test 21 – Field Flash Alternator (8-10 kW) ......52

Part 3 - traNsfEr sWitcH ...............................55

3.1 Description and Components .......................... 56

General ............................................................56

Enclosure .........................................................56

Transfer Mechanism .........................................57

Transfer Relay ..................................................57

Neutral Lug ......................................................58

Manual Transfer Handle ..................................58

Terminal Block .................................................58

Fuse Holder .....................................................59

3.2 Operational Analysis .......................................60

Operational Analysis ........................................60

Utility Source Voltage Available .......................62

Utility Source Voltage Failure ..........................63

Transfer To Standby .........................................64

Transfer To Standby .........................................65

Utility Restored.................................................66

Utility Restored, Transfer Switch De-energized ...67

Utility Restored, Retransfer Back To Utility .......68

Transfer Switch In Utility ...................................69

3.3 – Troubleshooting Flowcharts .......................... 70

Introduction To Troubleshooting .......................70

Problem 7 – In Automatic Mode,

No Transfer to Standby ................................70

Problem 8 – In Automatic Mode, Generator Starts When Loss of Utility Occurs, Generator Shuts Down When Utility Returns But There Is No Retransfer To Utility Power / or Generator Transfers to Standby

During Exercise Or In Manual Mode............71

Problem 9 – Blown F1 or F2 Fuse ...............71

Problem 10 – Units Starts And Transfer

Occurs When Utility Power Is On .................72

Problem 11 – No Battery Charge

(Pre-Packed Load Center) ...........................73

Problem 12 – No Battery Charge

(RTSN & RTSE Transfer Switch) .................73

Problem 13 – No Battery Charge

(Gen-Ready Load Center) ...........................73

Problem 14 – No Battery Charge

(Load Shed Transfer Switch) ........................73

3.4 Diagnostic Tests .............................................. 74

General ............................................................74

Test 26 – Check Voltage at

Terminal Lugs E1, E2 ..........................74

Test 27 – Check Manual Transfer Switch

Operation .............................................75

Test 28 – Check 23 And 15B

Wiring/Connections .............................76

Test 29 – Test Transfer Relay TR ......................77

Test 30 – Standby Control Circuit ....................78

Test 31 – Check Wire 23 ..................................78

Test 32 – Utility Control Circuit .........................80

Test 33 – Test Limit Switch SW2 and SW3 ......82

Test 34 – Check Fuses F1 and F2 ...................82

Test 35 – Check N1 and N2 Wiring ..................83

Test 36 – Check N1 and N2 Voltage ................83

Test 37 – Check Utility Sensing Voltage

at the Circuit Board..............................84

Test 38 – Check Utility Sense Voltage .............84

Test 39 – Check Voltage at

Terminal Lugs N1, N2 ..........................84

Test 40 – Check Battery Charger Supply

Voltage “Pre-Wire Load Center” ..........86

Test 41 – Check Battery Charger Output

Voltage “Pre-Wire Load Center” ..........86

Test 42 – Check Wire 0 and Wire15B

“Pre-Wire Load Center” .......................86

Test 43 – Check Battery Charger

Supply Voltage

“RTSN & RTSE Transfer Switch” .........87

Test 44 – Check Battery Charger

Output Voltage

“RTSN & RTSE Transfer Switch” .........87

Test 45 – Check Wire 0/

“RTSN & RTSE Transfer Switch” ........87

Test 46 – Check Battery Charger

Supply Voltage

“GenReady Load Center” ....................90

Test 47 – Check Battery Charger

Output Voltage

“GenReady Load Center” ....................90

Test 48 – Check Wire 0/15B

“GenReady Load Center” ....................90

Test 49 – Check Battery Charger

Supply Voltage

“Load Shed Transfer Switch” ...............92

Test 50 – Check Battery Charger

Output Voltage

“Load Shed Transfer Switch” ...............92

Test 51 – Check Wire 0 and Wire 15B

“Load Shed Transfer Switch” ...............94

Page 2

Part 4 - Dc coNtrol ......................................... 95

4.1 Description and Components .......................... 96

General ............................................................96

Terminal Strip / Interconnection Terminal .........96

Circuit Board ....................................................96

Auto-Off-Manual Switch ...................................96

7.5 Amp Fuse...................................................96

Menu System Navigation ...............................102

4.2 Operational Analysis .....................................104

Introduction ....................................................104

Utility Source Voltage Available ......................104

Initial Dropout of Utility Source Voltage ..........106

Utility Voltage Dropout and

Engine Cranking ................................108

Engine Startup and Running ..........................110

Initial Transfer to the “Standby” Source ..........112

Utility Voltage Restored /

Re-transfer to Utility ...........................114

Engine Shutdown ...........................................116

4.3 Troubleshooting Flowcharts ........................... 118

Problem 15 – Engine Will Not Crank

When Utility Power Source Fails ................118

Problem 16 – Engine Will Not Crank When AUTO-OFF-MANUAL Switch

is Set to “MANUAL .....................................118

Problem 17 – Engine Cranks

but Won’t Start ...........................................119

Problem 18 – Engine Starts Hard and

Runs Rough / Lacks Power / Backfires ......120

Problem 19 – Shutdown Alarm /

Fault Occurred ...........................................121

Problem 20 – 7.5 Amp Fuse (F1) Blown ..... 122

Problem 21 – Generator Will Not Exercise ...122

Problem 22 – No Low Speed Exercise ........122

4.4 Diagnostic Tests ............................................ 123

Introduction ...................................................123

Test 56 – Check Position Of

Auto-Off- Manual Switch ..................123

Test 57 – Try a Manual Start .........................123

Test 58 – Auto-Off-Manual Switch

(V-Twin Only) .....................................123

Test 59 – Test Auto Operations ......................124

Test 60 – Check 7.5 Amp Fuse ......................124

Test 61 – Check Battery .................................124

Test 62 – Check Wire 56 Voltage ...................126

Test 63 – Test Starter Contactor Relay

(V-twin Only) ......................................126

Test 64 – Test Starter Contactor

(Single Cylinder Engine)....................127

Test 65 – Test Starter Motor ...........................128

Test 66 – Check Fuel Supply and Pressure ...130 Test 67 – Check Circuit Board

Wire 14 Output ..................................131

Test 68 – Check Fuel Solenoid ......................132

Test 69 – Check Choke Solenoid ...................132

Test 70 – Check for Ignition Spark .................134

Test 71 – Check Spark Plugs .........................136

Test 72 – Check Engine / Cylinder Leak

Down Test / Compression Test ..........136

Test 73 – Check Shutdown Wire ....................137

Test 74 – Check and Adjust

Ignition Magnetos ..............................138

Test 75 – Check Oil Pressure Switch

and Wire 86 .......................................141

Test 76 – Check High Oil

Temperature Switch ...........................142

Test 77 – Check and Adjust Valves ................142

Test 78 – Check Wire 18 Continuity ...............143

Test 79 – Test Exercise Function ...................144

Test 80 – Check Cranking and

Running Circuits ................................144

Test 81 – Check to see if Low Speed

Function is enabled ...........................146

Test 82 – Check operation of the

Choke Solenoid .................................146

Part 5 - oPEratioNal tEsts ........................147

5.1 System Functional Tests ................................ 148

Introduction ....................................................148

Manual Transfer Switch Operation .................148

Electrical Checks ...........................................148

Generator Tests Under Load ..........................149

Checking Automatic Operation ......................150

Setting The Exercise Timer ............................150

Part 6 - DisassEmBlY ..................................... 151

6.1 Major Disassembly ........................................ 152

Front Engine Access ......................................152

Major Disassembly .........................................156

Torque Requirements

(Unless Otherwise Specified) ............162

Part 7 - ElEctrical Data ..............................163

Wiring Diagram, 8 kW Home Standby ................. 164

Schematic, 8 kW Home Standby ......................... 166

Wiring Diagram, 10 kW Home Standby ............... 168

Schematic, 10 kW Home Standby ....................... 170

Wiring Diagram, 14 kW Home Standby ............... 172

Schematic, 14 kW Home Standby ....................... 174

Wiring Diagram, 17 kW Home Standby ............... 176

Schematic, 17 kW Home Standby ....................... 178

Wiring Diagram, 20 kW Home Standby ............... 180

Schematic, 20 kW Home Standby ....................... 182

Wiring Diagram, Home Standby Transfer Switch,

9/10/12/16 Circuit ................................................ 184

Schematic, Home Standby Transfer Switch,

9/10/12/16 Circuit ................................................ 186

Page 3

sPEcificatioNs

Generator

Unit

Rated Max. Continuous

Power Capacity (Watts*)

Rated Voltage 120/240

Rated Voltage at No-Load (NG) 220-235 247-249

Rated Max. Continuous Load

Current (Amps)

120 Volts** (NG/LP) 240 Volts (NG/LP)

Main Line Circuit Breaker

Circuits*** 50A, 240V - - - 1 1 1 -

40A, 240V - - 1 1 1 1 -

30A, 240V 1 1 1 - - - -

20A, 240V - 1 - 1 1 1 -

20A, 120V 1 3 3 4 5 5 -

15A, 120V 5 3 5 4 5 5 -

Phase 1

Number of Rotor Poles 2

Rated AC Frequency 60 Hz

Power Factor 1

Battery Requirement Group 26R, 12

Weight (unit only in lbs.)

Enclosure Steel Steel Steel Steel Steel Steel/Aluminum Aluminum

Normal Operating Range -20° F (-28.8° C) to 77° F (25° 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 the 240 volts.

*** Circuits to be moved must be protected by same size breaker. For example, a 15 amp circuit in the main panel must be a 15 amp circuit in the transfer switch.

8 kW 10 kW 12 kW 14 kW 16 kW 17 kW 20 kW

7,000 NG

8,000 LP

58.3/66.6

29.2/33.3

35 Amp 45 Amp 50 Amp 60 Amp 65 Amp 65 Amp 100 Amp

Volts and 350 CCA

Minimum

340 387 439 439 455 455/421 450

9,000 NG

10,000 LP

75.0/83.3

37.5/41.6

12,000 NG

12,000 LP

100.0/100.0

50.0/50.0

13,000 NG

14,000 LP

108.3/116.6

54.2/58.3

Group 26R, 12 Volts and 525 CCA Minimum

16,000 NG

16,000 LP

133.3/133.3

66.6/66.6

16,000 NG

17,000 LP

133.3/141.6

66.6/70.8

18,000 NG

20,000 LP

150.0/166.6

75.0/83.3

Power Winding: Across 11 & 22

Power Winding: Across 33 & 44

Excitation Winding: Across 2 & 6

Rotor Resistance

Page 4

Stator WindinG reSiStance ValueS / rotor reSiStance

8 kW 10 kW 12 kW 14 kW 16 kW 17 kW 20 kW

0.123-0.1439

0.776-0.902

3.01-3.49

0.090-0.105 0.100-0.116 0.100-0.116 0.074-0.086 0.074-0.086 0.0415-0.0483

0.511-0.594 0.876-1.018 0.876-1.018 0.780-0.906 0.780-0.906 0.731-0.850

3.22-3.74 7.96-9.25 7.96-9.25 8.79-10.21 8.79-10.21 10.02-11.65

engine

SpecificationS

Model

Type of Engine GH-410 GT-530 GT-990 GT-999

Number of Cylinders 1 2 2 2

Rated Horsepower @ 3,600 rpm 14.8 18 32 34

Displacement 407cc 530cc 992cc 999cc

Cylinder Block Aluminum w/Cast Iron Sleeve

Valve Arrangement Overhead Valves

Ignition System Solid-state w/Magneto

Recommended Spark Plug RC14YC BPR6HS RC14YCA RC12YC

Spark Plug Gap 0.76 mm (0.030 inch) 0.76 mm (0.030 inch) 1.02 mm (0.040 inch) 1.02 mm (0.040 inch)

Compression Ratio 9.4:1 9.5:1 9.5:1 9.5:1

Starter 12 VDC

Oil Capacity Including Filter Approx. 1.5 Qts Approx. 1.8 Qts Approx. 1.9 Qts Approx. 1.9 Qts

8 kW 10 kW 12/14/16/17 kW 20 kW

Recommended Oil Filter Part # 070185F

Recommended Air Filter Part # 0G3332 Part # 0E9581 Part # 0C8127 Part # 0G5894

Operating RPM 3,600

Fuel Consumption

Model # Natural Gas* LP Vapor**

1/2 Load Full Load 1/2 Load Full Load

7/8 kW 77 140 0.94/34 1.68/62

9/10 kW 102 156 1.25/46 1.93/70

12/12 kW 152 215 1.53/56 2.08/76

13/14 kW 156 220 1.56/58 2.30/84

16/16 kW 183 261 1.59/58 2.51/91

16/17 kW 183 261 1.61/59 2.57/94

18/20 kW 206 294 1.89/69 2.90/106

* Natural gas is in cubic feet per hour.

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

Values given are approximate.

Page 5

FRONT VIEW

LEFT SIDE VIEW

"DO NOT LIFT BY ROOF"

Ø30.2 [Ø1.2]

LIFTING HOLES 4 CORNERS

642 [25.3]

731.9 [28.8]

637.6 [25.1]

1226 [48.3]

76.2 [3.0]

PEA GRAVEL

MINIMUM

1218 [47.9]

1079.5 [42.5]

747 [29.4]

698 [27.5]

TRANSFER

SWITCH

8KW - 17KW

(IF SUPPLIED)

207

[8.2]

299 [11.8]

997 [39.3]

508 [20.0]

TRANSFER

SWITCH

20KW

(IF SUPPLIED)

454

[17.9]

sPEcificatioNs

mountinG dimenSionS

Page 6

mountinG dimenSionS

AIR INTAKE

AIR OUTLET

FRONT OF UNIT

HOLE LOCATIONS FOR OPTIONAL MOUNTING TO A CONCRETE PAD

MINIMUM DISTANCE

AIR INTAKE

RIGHT SIDE VIEW

REAR VIEW

GROUNDING LUG

CABLE ACCESS HOLE

250.0 [9.8]

446.6 [17.6]

378.7 [14.9]

44.8 [1.8]

530.0 [20.9]

575.3 [22.7]

FUEL INLET - 12-20KW (1/2" NPT) 8 & 10KW (3/4" NPT) - USE SUPPLIED ADAPTER

REQUIRED FUEL PRESSURE: NATURAL GAS = 5-7" WATER COLUMN LIQUID PROPANE (VAPOR) = 10-12" WATER COLUMN

244.4 [9.6]

178.9 [7.0]

457.2 [18.0]

914 [36.0]

MINIMUM OPEN AREA

ON SIDES AND FRONT

sPEcificatioNs

Page 7

sPEcificatioNs

Data Label

(see sample)

Oil

Dipstick

Exhaust

Enclosure

Composite Base Oil Filter Battery Compartment

Fuel

Regulator

Fuel Inlet

(back)

Air Filter

Circuit

Breaker

Control

Panel

Data Label

(see sample)

Oil

Dipstick

Exhaust

Enclosure

Composite Base Oil Filter Battery Compartment

Fuel

Regulator

Fuel Inlet

(back)

Air Filter

Circuit Breakers

GFCI Outlet

(All 17 & 20kW)

Control

Panel

Data Label

(see sample)

Oil

Dipstick

Exhaust

Enclosure

Composite Base Oil Filter Battery Compartment

Fuel

Regulator

Fuel Inlet

(back)

Air

Filter

Circuit

Breaker

Control

Panel

major FeatureS

8kW, Single Cylinder, GH-410 Engine

(door removed)

10kW, V-twin, GT-530 Engine

(door removed)

Figure 1.3 – 12, 14, 16, 17 and 20kW, V-twin,

GT-990/GT-999 Engine (door removed)

Page 8

Part 1

GENEral

iNformatioN

air-cooled, automatic

standby Generators

taBlE of coNtENts

Part titlE PaGE

1.1 Generator identification 10

1.2 installation Basics 11

1.3 Non-Prepackaged interconnections

1.3 Preparation Before use 16

1.4 testing, cleaning and Drying 18

1.5 Engine-Generator Protective

Devices

1.6 operating instructions 27

1.7 automatic operating

Parameters

1.1 Generator Identification ................................... 10

Introduction ......................................................10

1.2 Installation Basics ............................................ 11

Introduction ......................................................11

Selecting A Location ........................................11

Grounding The Generator ................................11

The Fuel Supply ...............................................11

The Transfer Switch / Load Center ...................11

Power Source And Load Lines .........................13

System Control Interconnections .....................13

Natural Gas Fuel Interconnections ..................13

1.3 Non-prepackaged Interconnections ................14

Connect a Pre-2008 Load Center Switch To a Current or Future

Air-Cooled Generator. ..................................14

Connect a 2008 And Later Load Center Switch to a Pre-2008

Air-Cooled Generator. ..................................15

1.4 Preparation Before Use ................................... 16

General ............................................................16

Fuel Requirements...........................................16

Fuel Consumption ............................................16

Reconfiguring The Fuel System .......................16

Engine Oil Recommendations .........................18

1.5 Testing, Cleaning and Drying........................... 19

Meters ............................................................19

The Vom ...........................................................19

Measuring AC Voltage .....................................19

Measuring DC Voltage .....................................19

Measuring AC Frequency ................................19

Measuring Current ...........................................20

Measuring Resistance .....................................20

Electrical Units .................................................21

Ohm’s Law .......................................................21

Visual Inspection ..............................................22

Insulation Resistance .......................................22

The Megohmmeter...........................................22

Stator Insulation Resistance Test (12-20kW) ...23

Stator Insulation Resistance Test (8-10kW) .....23

Rotor Insulation Resistance Test (8-10kW) ......24

Rotor Insulation Resistance Test (12-20kW) ....24

Cleaning The Generator...................................24

Drying The Generator ......................................24

1.6 Engine-Generator Protective Devices ............. 25

General ............................................................25

Low Battery ......................................................25

Low Oil Pressure Shutdown .............................25

High Temperature Switch .................................25

Overspeed Shutdown ......................................25

Rpm Sensor Failure .........................................25

Overcrank Shutdown .......................................26

1.7 Operating Instructions ..................................... 27

Control Panel ...................................................27

To Select Automatic Operation ........................28

Manual Transfer To “Standby”

and Manual Startup .....................................28

Manual Shutdown And

Retransfer Back To “Utility” ..........................28

1.8 Automatic Operating Parameters ....................29

Introduction ......................................................29

Automatic Operating Sequences .....................29

Page 9

sEctioN 1.1

Item # 0055555

1234567 120/240 AC

108.3/108.3 13000

Serial

Volts

Watts

1 PH, 60 HZ, RPM 3600

NEUTRAL FLOATING

CLASS F INSULATION

MAX OPERATING AMBIENT

TEMP - 120F/49C

FOR STANDBY SERVICE

MAX LOAD UNBALANCED - 50%

Amps

MODEL # SERIAL #

WA TTS VOLTS AMPS

1PH, 60Hz, 3600 RPM, CLASS F INSULATION

RAINPROOF ENCLOSURE FITTED

RATED AMBIENT TEMP - 40°C

FOR STANDBY SERVICE, NEUTRAL FLOATING

0055555 1234567 120/240 AC

13000

108.3/108.3

Model Number - Serial Number -

GENErator iDENtificatioN

Part 1

GENERAL INFORMATION

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, automatic standby generators. Every effort has been expended to ensure that information and instructions in the manual are both accurate and current. However, changes, alterations or other improvements may be made to the product at any time without prior notification.

The manual has been divided into 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 reassemble 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.

ITEM 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.

Page 10

Figure 1. Typical Data Plates

GENERAL INFORMATION

Part 1

sEctioN 1.2

iNstallatioN Basics

introduction

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

A typical 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.

Control system interconnections between the transfer switch and generator consist of N1 and N2, and leads 23, 15B and 0. Control system interconnection leads must be run in a conduit that is separate from the AC power leads. Recommended wire gauge size depends on the length of the wire:

max. cable length recommended Wire size

35 feet (10.67m) No. 16 AWG.

60 feet (I8.29m) No. 14 AWG.

90 feet (27.43m) No. 12 AWG.

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.

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

lP NG

Minimum water column 10 inches 5 inches Maximum water column 12 inches 7 inches

A primary regulator is required to ensure that proper fuel supply pressures are maintained.

DaNGEr: lP aND Na tural Gas arE BotH

HiGHlY EXPlosiVE. GasEous fuEl liNEs

must BE ProPErlY PurGED aND tEstED for lEaKs BEforE tHis EQuiPmENt is PlacED iNt o sErVicE aND PErioDicallY tHErEaftEr. ProcEDurEs usED iN GasEous fuEl lEaKaGE tEsts must comPlY strictlY WitH aPPlicaBlE fuEl Gas coDEs. Do No t usE flamE or aNY sourcE of HEat to tEst for Gas lEaKs. No Gas lEaKaGE is PErmittED . lP Gas is HEa ViEr tHaN air aND tENDs to sEttlE iN loW arEas. Na tural Gas is liGHtEr tHaN air aND tENDs to sEttlE iN HiGH Pla cEs. EVEN tHE sliGHtEst sParK caN iGNitE tHEsE fuEls aND causE aN EXPlosioN.

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

Units with air-cooled engines 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.

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.

TRANSFER SWITCHES: Instructions and information on transfer switches may

be found in Part 3 of this manual.

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iNstallatioN Basics

Part 1

GENERAL INFORMATION

Page 12

Figure 1. Typical Installation

GENERAL INFORMATION

0000001

GAS MAIN

2-5 PSI

5-7” WC REGULATOR TO HOUSEHOLD

GAS METER CAPABLE

+HOUSEHOLD APPLIANCES

FUEL FLOW OF:

OF PROVIDING NATURAL GAS

SAFETY

SHUT OFF

VALVE

(BASED ON 1000 BTU/CU FT)

BTU/HOUR

140,000 (7 kW) 156,000 (9 kW) 215,000 (12 kW) 220,000 (13 kW) 261,000 (16 kW) 294,000 (18 kW)

Part 1

sEctioN 1.2

iNstallatioN Basics

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.

natural GaS Fuel interconnectionS

SyStem control interconnectionS

Home standby generators are equipped with a terminal board identified with the following terminals: (a) UTILITY 1, (b) UTILITY 2, (c) 23, and (d) 15B. 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.

Figure 2. Proper Fuel Installation

Page 13

Section 1.3

WIRE NUTS

N1 (BLU)

N2 (YEL)

23 (BRN)

194 (ORG)

N1 (YEL)

N2 (YEL)

23 (WHT)

15B (RED)

0 (BLK)

CONTROL WIRES FROM

ENGINE GENERATOR

CONTROL WIRES FROM

TRANSFER SWITCH

WIRE NUTS

N1 (BLU)

N2 (YEL)

23 (BRN)

194 (ORG)

N1 (YEL)

N2 (YEL)

23 (WHT)

15B (RED)

0 (BLK)

CONTROL WIRES FROM ENGINE GENERATOR

“08” & LATER HSB AIR-COOLED GENERATORS

SINGLE & V-TWIN ENGINES

PRE “08” LOAD CENTER

TRANSFER SWITCH

EXTERNAL CUSTOMER

CONNECTION BOX

INSTALL BATTERY CHARGER GENERAC P/N 0G8023

CONTROL WIRES FROM TRANSFER SWITCH

non-PrePackaged interconnectionS

Part 1

General information

Discussion: on the current model air-cooled generators Wire 194

was changed to 15B. Wire 15B is still utilized for positive voltage for the transfer relay and Wire 23 is still the control ground for transferring the generator. By following the procedures below it is possible to connect new product with Wire 15B to old or current product that still utilize Wire 194, such as an rts switch.

ConneCt a pre-2008 load Center switCh to a

Current or Future air-Cooled generator.

ProceDure:

1. Follow all instructions located in the Installation Manual that was supplied with the unit regarding mounting of the switch, junction box, and generator.

note: when installing a standalone 5500 series generator, the battery charger will be located in the generator on the side of the control assembly.

2. Inside the Junction box between the generator and the transfer switch there will be 5 wires coming from the generator and 4 wires from the transfer switch.

3. Using the following diagram and UL approved wire nuts connect the following wires together. Wire 0 will not be utilized for this setup.

Figure 1. Wire Connections

Page 14

Figure 2. Post 2008 HSB Interconnections

GENERAL INFORMATION

WIRE NUTS

N1 (BLU)

N2 (YEL)

23 (BRN)

194 (ORG)

N1 (YEL)

N2 (YEL)

23 (WHT)

15B (RED)

0 (BLK)

CONTROL WIRES FROM

ENGINE GENERATOR

CONTROL WIRES FROM

TRANSFER SWITCH

WIRE NUTS

N1 (BLU)

N2 (YEL)

23 (BRN)

194 (ORG)

N1 (YEL)

N2 (YEL)

23 (WHT)

15B (RED)

0 (BLK)

CONTROL WIRES FROM ENGINE GENERATOR

PRE “08” HSB AIR-COOLED GENERATORS

SINGLE & V-TWIN ENGINES

“08” & LATER LOAD CENTER

TRANSFER SWITCH

EXTERNAL CUSTOMER

CONNECTION BOX

CONTROL WIRES FROM TRANSFER SWITCH

Part 1

connect a 2008 and later load center SWitch

to a pre-2008 air-cooled Generator.

PROCEDURE:

1. Follow all instructions located in the Installation Manual that was supplied with the unit regarding mounting of the switch, junction box, and generator.

note: When installing a standalone pre-2008 generator, the battery charger will be located in the generator utilizing the 12 Vdc trickle charger.

2. Inside the Junction box between the generator and the transfer switch there will be 4 wires coming from the generator and 5 wires from the transfer switch.

3. Using the following diagram and UL approved wire nuts connect the following wires together. Wire 0 will not be utilized for this setup.

note: remove the battery charger from the transfer switch; it will not be utilized in the operation of the generator.

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NoN-PrEPacKaGED iNtErcoNNEctioNs

Figure 3. Wire Connections

Figure 4. Pre-2008 HSB Interconnections

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DANGER

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GENERAL INFORMATION

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

With LP gas, use only the vapor withdrawal system. This type of system uses the vapors formed above the liquid fuel in the storage tank.

The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air Resources Board for tamper-proof dual fuel systems. The unit will run on natural gas or LP gas, but it has been factory set to run on natural gas. Should the primary fuel need to be changed to LP gas, the fuel system needs to be reconfigured. See the Reconfiguring the Fuel System section for instructions on reconfiguration of the fuel system.

Recommended fuels should have a Btu content of at least 1,000 Btus per cubic foot for natural gas; or at least 2,520 Btus per cubic foot for LP gas. Ask the fuel supplier for the Btu content of the fuel.

Required fuel pressure for natural gas is 5 inches to 7 inches water column (0.18 to 0.25 psi); and for liquid propane, 10 inches to 12 inches of water column (0.36 to 0.43 psi).

note: all pipe sizing, construction and layout must comply with nFpa 54 for natural gas applications and nFpa 58 for liquid propane applications. once the generator is installed, verify that the fuel pressure neVer drops below four (4) inches water column for natural gas or 10 inches water column for liquid propane.

Prior to installation of the generator, the installer should consult local fuel suppliers or the fire marshal to check codes and regulations for proper installation. Local codes will mandate correct routing of gaseous fuel line piping around gardens, shrubs and other landscaping to prevent any damage.

Special considerations should be given when installing the unit where local conditions include flooding, tornados, hurricanes, earthquakes and unstable ground for the flexibility and strength of piping and their connections.

Use an approved pipe sealant or joint compound on all threaded fitting.

Page 16

All installed gaseous fuel piping must be purged and leak tested prior to initial start-up in accordance with local codes, standards and regulations.

Fuel conSumption

The fuel consumption rates are listed in the SPECIFICATIONS section at the front of this manual.

BTU FLOW REqUIREMENTS - NATURAL GAS: BTU flow required for each unit based on 1000 BTU

per cubic foot.

7 kW - 140,000 BTU/Hour 9 kW - 156,000 BTU/Hour 12 kW - 215,000 BTU/Hour 13 kW - 220,000 BTU/Hour 16 kW - 261,000 BTU/Hour 18 kW - 294,000 BTU/Hour

Gaseous fuels such as natural gas and liquid

propane (lP) gas are highly explosive. Even

the slightest spark can ignite such fuels and cause an explosion. No leakage of fuel is permitted. Natural gas, which is lighter than air, tends to collect in high areas. lP gas is heavier than air and tends to settle in low areas.

note: a minimum of one approved manual shutoff valve must be installed in the gaseous fuel supply line. the valve must be easily accessible. local codes determine the proper location.

reconFiGurinG the Fuel SyStem

8 kW, 410CC ENGINE: To reconfigure the fuel system from NG to LP, follow

these steps (Figure 1):

note: the primary regulator for the propane supply is not included with the generator. a fuel pressure of 10 to 12 inches of water column (0.36 to 0.43 psi) to the fuel inlet of the generator must be supplied.

1. Turn off the main gas supply (if connected).

2. Open the roof and remove the door.

3. Remove the battery (if installed).

4. Locate the plastic T-handle fuel selector in the poly bag supplied with the generator.

5. Locate the selector knob on the air box cover, behind the yellow air filter door and power bulge. The unit comes from the factory in the NG (Natural Gas) position. Grasping the T-handle, insert the pin end into the hole

GENERAL INFORMATION

FUEL SELECTION LEVER -

“IN” POSITION FOR NATURAL GAS

FUEL SELECTION LEVER -

“OUT” POSITION FOR LIQUID PROPANE (VAPOR) FUEL

FUEL SELECTION LEVER -

“IN” POSITION FOR NATURAL GAS

Part 1

in the selector knob and pull out to overcome spring pressure and then twist clockwise 90 degrees and allow the selector to return in once aligned with the LP (Liquid Propane) position.

6. Save this tool with the Owner's Manual.

7. Install the battery, door and close the roof.

8. Reverse the procedure to convert back to natural gas.

Figure 1. Demand Regulator

10, 12, 14, 16, 17 AND 20 kW, V-TWIN ENGINES: To reconfigure the fuel system from NG to LP, follow

these steps:

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Figure 3. 10 kW, GT-530 (Inlet Hose Slid Back)

1. Open the roof.

2. for 10 kW units: Loosen clamp and slide back the

air inlet hose.

• Slide fuel selector on carburetor out towards the

back of the enclosure (Figures 2 and 3).

• Returntheinlethoseandtightenclampsecurely.

for 12, 14, 16, 17 and 20 kW units: remove the air

cleaner cover.

• Slidetheselectorleverouttowardsthebackofthe

enclosure (Figures 4 and 5).

• Return the air cleaner cover and tighten the two

thumb screws.

3. Close the roof.

4. Reverse the procedure to convert back to natural gas.

Figure 2. 10 kW, GT-530 (Inlet Hose Slid Back)

Figure 4. 12/14/16/17/20 kW, GT-990/GT-999

(Airbox Cover Removed)

Page 17

FUEL SELECTION LEVER -

“OUT” POSITION FOR LIQUID PROPANE (VAPOR) FUEL

SAE 30

Synthetic 5W-30

10W-30

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Figure 5. 12/14/16/17/20 kW, GT-990/GT-999

(Airbox Cover Removed)

Part 1

GENERAL INFORMATION

enGine oil recommendationS

All oil should meet minimum American Petroleum Institute (API) Service Class SJ, SL or better. Use no special additives. Select the oil's viscosity grade according to the expected operating temperature.

• SAE30è Above 32° F

• 10W-30è Between 40° F and -10° F

• Synthetic5W-30è 10° F and below

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

any attempt to crank or start the engine before it has been properly serviced with

the recommended oil may result in an engine failure.

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GENERAL INFORMATION

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tEstiNG, clEaNiNG aND DrYiNG

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 VOMs 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).

meaSurinG ac VoltaGe

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

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

2. The generator’s 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.

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.

Figure 1. Digital VOM

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’s 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.

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1.00 A

BATTERY

RELAY

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Part 1

GENERAL INFORMATION

meaSurinG current

CLAMP-ON: 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.

IN-LINE: Alternatively, to read the current flow in AMPERES, an

in-line ammeter may be used. Most Digital Volt Ohm Meters (VOM) will have the capability to measure amperes.

This usually requires the positive meter test lead to be connected to the correct amperes plug, and the meter to be set to the amperes position. Once the meter is properly set up to measure amperes the circuit being measured must be physically broken. The meter will be in-line or in series with the component being measured.

In Figure 4 the control wire to a relay has been removed. The meter is used to connect and supply voltage to the relay to energize it and measure the amperes going to it.

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.

Page 20

Figure 4. A VOM as an In-line meter

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.

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.

GENERAL INFORMATION

amPErE - Unit measuring rate of

current flow (number of electrons past a given point)

oHm - Unit measuring resistance

or opposition to flow

Volt - Unit measuring force or

difference in potential causing current flow

Conductor of a Circuit

VOLTS

(E)

AMPS

(I)

OHMS

(R)

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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.

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. Electrical Units

Figure 6. Ohm’s Law

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

ohmS

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

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

ampereS

ampereS =

VoltS = ampereS x ohmS

ohmS

VoltS

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Part 1

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 obstr uct its air openings.

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 man y 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

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

MINIMUM INSULATION RESISTANCE = (in “Megohms”)

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 Windings” on next page.

TESTING ROTOR INSULATION (12-20kW): Apply a voltage of 500 volts across the rotor posi -

tive (+) 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:

TESTING ROTOR INSULATION (8-10kW):

No test available.

cautioN: Before attempting to measure insu-

lation resistance, first disconnect and isolate all leads of the winding to be tested. Electronic components, diodes, surge protectors, relays, voltage regulators, etc., can be destroy ed if subjected to high megger voltages.

GENERATOR RATED VOLTS

__________________________

1.5 megohms

1000

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 meg-

ger voltages must be disconnected before testing. Isolate all stator leads (Figure 8) 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.

Page 22

Figure 7. One Type of Hi-Pot Tester

GENERAL INFORMATION

11P

22S (12-20 kW)

22P

11S

(12-20 kW)

Part 1

sEctioN 1.5

tEstiNG, clEaNiNG aND DrYiNG

HI-POT TESTER: A “Hi-Pot” tester is shown in Figure 7. 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.

Stator inSulation reSiStance teSt

(12-20 kW)

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

dual stator AC power windings, and (b) excitation or DPE winding. Insulation tests of the stator consist of (a) testing all windings to ground, (b) testing between isolated windings, and (c) testing between parallel windings. Figure 8 is a pictorial representation of the various stator leads on units with air-cooled engines.

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 Wires 11 and 22 from Voltage Regulator. Ensure these wires are not touching any other components on the generator.

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 one-second 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. Proceed to the Voltage Regulator. Each winding will be individually tested for a short to ground. Refer to Steps 5a-5c and perform the same test on the following wires:

Wire

Number

22S Sense Lead Power 11S Sense Lead Power

6 Excitation 2 Excitation 0 Ground 4 Positive to Brush Ground

TEST BETWEEN WINDINGS:

Winding

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.

Figure 8. 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.

3. Disc onne ct Wir es 11, 22, 2, an d 6 from Volta ge Regulator. Ensure these wires are not touching any other components on the generator.

4. Connect the red tester probe to Wire 2. Connect the black tester probe to Stator Lead 11. Refer to Steps 5a through 5c of “TESTING ALL STATOR WINDINGS TO GROUND” on previous page.

5. Repeat Step 4 between Wire 2 and Stator Lead 33.

6. Repeat Step 4 between Stator Lead 11 and Stator Lead 33.

Stator inSulation reSiStance teSt

(8-10 kW)

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

Page 23

sEctioN 1.5

POSITIVE (+) TEST LEAD

tEstiNG, clEaNiNG aND DrYiNG

Part 1

GENERAL INFORMATION

TESTING ALL STATOR WINDINGS TO GROUND:

1. Disconnect Stator Output Leads 11 and 44 from the generator main line circuit breaker.

2. Disconnect Stator Output Leads 2 and 6 from the capacitor located on the end of the stator assembly.

3. Remove Stator Output Leads 22 and 33 from the neutral connection and separate the two 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.

6. Connect the terminal ends of Wires 2 and 6 together. Make sure the wire ends are not touching any part of the generator frame or any terminal.

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 9. Testing Rotor Insulation (12-20kW)

7. Repeat Step 5.

rotor inSulation reSiStance teSt

(8-10 kW)

No test available.

rotor inSulation reSiStance teSt

(12-20 kW)

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.

Page 24

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. O p e n t h e g e ne r a to r m a i n c i rc u it b r e ak e r. N O ELECTRICAL LOADS MUST BE APPLIED TO THE GENERATOR WHILE DRYING.

2. Disconnect all Wires 6 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.

GENERAL INFORMATION

OIL FILTER

OIL DRAIN HOSE

LOW OIL SWITCH

HIGH TEMP SWITCH

Part 1

sEctioN 1.6

ENGiNE-GENErator ProtEctiVE DEVicEs

General

Standby electric power generators will often run unattended for long periods of time. Such operating parameters as (a) battery voltage, (b) engine oil pressure, (c) engine temperature, (d) engine operating speed, and (e) 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.

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 battery, (b) low engine oil pressure, (c) high temperature, (d) overspeed, and (e) overcrank. On occurrence of any one or more of those operating faults, circuit board action will effect an engine shutdown.

loW Battery

The microprocessor will continually monitor the battery voltage and turn on the Low Battery Warning if the battery voltage falls below 10.8 volts for one (1) minute. No other action is taken on a low battery condition. Low battery voltage is a non-latching alarm which will automatically clear if the battery voltage rises above 11.0 volts. Battery voltage is NOT monitored during the crank cycle.

loW oil preSSure ShutdoWn

oVerSpeed ShutdoWn

During engine cranking and operation, the circuit board receives AC voltage and frequency signals from the ignition magneto, via Wire 18. Should the speed exceed approximately 72 Hz (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 rpm sensing to terminate engine cranking.

rpm SenSor Failure

During cranking, if the board does not see a valid RPM signal within three (3) seconds, it will shut down and latch out on RPM sensor loss.

During running, if the RPM signal is lost for one full second the board will shut down the engine, wait 15 seconds, then re-crank the engine.

• IfanRPMsignalisnotdetectedwithinthefirstthree

(3) seconds of cranking, the control board will shut the engine down and latch out on RPM sensor loss.

• If the RPM signal is detected the engine will start

and run normally. If the RPM signal is subsequently lost again, the control board will tr y one more recrank attempt before latching out and flashing the overspeed LED or RPM Sensor Failure.

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 5 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 de-energize 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 temperature SWitch

This switch’s contacts (Figure 1) close if the temperature should exceed approximately 144° C (293° F), initiating an engine shutdown. The generator will automatically restart and the fault on the generator control panel will reset once the temperature has returned to a safe operating level.

Figure 1. Engine Protective Switches on an

Air-Cooled Engine

Page 25

sEctioN 1.6

ENGiNE-GENErator ProtEctiVE DEVicEs

Part 1

GENERAL INFORMATION

oVercrank ShutdoWn

This feature prevents the generator from damaging itself when it continually attempts to start and another problem, such as no fuel supply, prevents it from starting. The unit will crank and rest for a preset time limit. Then, it will stop cranking, and the LCD screen or the LED on the generator control panel will light indicating an overcrank failure. The AUTO-OFF-MANUAL switch will need to be set to OFF and then back to AUTO to reset the generator control board.

note: if the fault is not repaired, the overcrank feature will continue to activate.

The system will control the cyclic cranking as follows: 16 second crank, seven (7) second rest, 16 second crank, seven (7) second rest followed by three (3) additional cycles of seven (7) second cranks followed by seven (7) second rests.

CHOkE OPERATION:

1. The 990/999cc engines have an electric choke in the air box that is automatically controlled by the electronic control board.

2. The 530cc engines have an electric choke on the divider panel air inlet hose that is automatically controlled by the electronic control board.

3. The 410cc engines have a choke behind the air box that is automatically controlled by the electronic control board.

FAILURE TO START: This is defined as any of the following occurrences

during cranking.

1. Not reaching starter dropout within the specified crank cycle. Starter dropout is defined as four (4) cycles at 1,500 RPM (1,800 RPM for 8 kW units).

2. Reaching starter dropout, but then not reaching 2200 RPM within 15 seconds. In this case the control board will go into a rest cycle for seven (7) seconds, then continue the rest of the crank cycle.

During a rest cycle the start and fuel outputs are deenergized and the magneto output is shorted to ground.

CRANkING CONDITIONS: The following notes apply during cranking cycle.

1. Starter motor will not engage within five (5) seconds of the engine shutting down.

2. The fuel output will not be energized with the starter.

3. The starter and magneto outputs will be energized together.

4. Once the starter is energized the control board will begin looking for engine rotation. If it does not see an RPM signal within three (3) seconds it will shut down and latch out on RPM sensor loss.

5. Once the control board sees an RPM signal it will energize the fuel solenoid, drive the throttle open and continue the crank sequence.

6. Star ter motor will disengage when speed reaches starter dropout.

7. If the generator does not reach 2200 RPM within 15 seconds, re-crank cycle will occur.

8. If engine stops turning between starter dropout and 2200 RPM, the board will go into a rest cycle for seven (7) seconds then re-crank (if additional crank cycles exist).

9. Once started, the generator will wait for a hold-off period before starting to monitor oil pressure and oil temperature (refer to the Alarm Messages section for hold-off times).

10. During Manual start cranking, if the Mode switch is moved from the Manual position, the cranking stops immediately.

11. During Auto mode cranking, if the Utility returns, the cranking cycle does NOT abort but continues until complete. Once the engine starts, it will run for one (1) minute, then shut down.

Page 26

GENERAL INFORMATION

SET

EXERCISE

SYSTEM READY

LOW BATTERY

LOW OIL PRESSURE

HIGH OIL TEMPERATURE

OVERSPEED

RPM SENSOR LOSS

OVERCRANK

ENTER

ECS

8 kW UNITS 10-20 kW UNITS

Part 1

sEctioN 1.7

oPEratiNG iNstructioNs

control panel

Figure 1. Generator 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 moni-

tor 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.

7.5 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 7.5 amp replacement fuse.

SETTING THE EXERCISE TIMER: This generator is equipped with an exercise timer.

Once it is set, the generator will start and exercise every seven days, on the day of the week and at the time of day specified. During this exercise period, the unit runs for approximately 12 minutes and then shuts down. Transfer of loads to the generator output does not occur during the exercise cycle unless utility power is lost.

8kW: A switch on the control panel (see Figure1) permits

selection of the day and time f or the system to exercise. At the chosen time, perform the following sequence to select the desired day and time of day the system will exercise. Remember seasonal time changes affect the exercise settings .

1. Verify that the AUTO-OFF-MANUAL switch is set to AUTO.

2. Press and hold the “Set Exercise” switch for several seconds. All the red LED’s will stop flashing immediately and the generator will start.

3. The generator will start and run for approximately 12 minutes and then shut down. The exerciser is now set to run at this time of day each week.

Example: If the “Set Exercise” pressed on Saturday afternoon at 2:00 p.m., the generator will start and exercise for approximately 12 minutes every Saturday at 2:00 p.m.

note: the exerciser will only work in the auto mode and will not work unless this procedure is performed. the exerciser will need to be reset every time the 12 Volt battery is disconnected and then reconnected, and when the fuse is removed and/or replaced.

Page 27

sEctioN 1.7

oPEratiNG iNstructioNs

Part 1

GENERAL INFORMATION

10-20 kW – INSTALLATION ASSISTANT: Upon first power up of the generator, the display inter-

face will begin an installation assistant. The assistant will prompt the user to set the minimum settings to operate. These settings are simply: Current Date/Time and Exercise Day/Time. The maintenance intervals will be initialized when the exercise time is entered for the first time (Figure 3.2).

The exercise settings can be changed at any time via the "EDIT" menu (see Appendix, "Menu System").

If the 12 Volt battery is disconnected or the fuse removed, the Installation Assistant will operate upon power restoration. The only difference is the display will only prompt the customer for the current Time and Date.

if the installer tests the generator prior to installation, press the “enter” key to avoid setting up the exercise time. this will ensure that when the customer powers up the unit, he will still be prompted to enter an exercise time.

note: the e x erciser will only work in the auto mode and will not work unless this procedure is performed. the current date/time will need to be reset every time the 12 Volt battery is disconnected and then reconnected, and/or when the fuse is removed.

to Select automatic operation

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

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

1. Check that the transfer switch main contacts are at their UTILITY position, i.e., the load is connected to the power supply. If necessary, manually actuate the switch main contacts to their UTILITY source side. See Part 3 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 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 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 transfer switches, see part 3.

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 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.

Page 28

GENERAL INFORMATION

Part 1

sEctioN 1.8

automatic oPEratiNG ParamEtErs

introduction

When the generator is installed in conjunction with a transfer switch, either manual or automatic operation is possible. Manual transfer and engine startup, as well as manual shutdown and re-transfer are covered in Section 1.7. 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.

utility Failure

Initial Conditions: Generator in Auto, ready to run, load being supplied by utility source. When utility fails (below 65% of nominal), a 10 second (optionally programmable on the 17 and 20 kW only) line interrupt delay time is started. If the utility is still gone when the timer expires, the engine will crank and start. Once started, a five (5) second engine warmup timer will be initiated.

When the warm-up timer expires, the control will transfer the load to the generator. If the utility power is restored (above 75% of nominal) at any time from the initiation of the engine start until the generator is ready to accept load (5 second warm-up time has not elapsed), the controller will complete the start cycle and run the generator through its normal cool down cycle; however, the load will remain on the utility source.

FAILURE TO START: This is defined as any of the following occurrences

during cranking.

1. Not reaching starter dropout within the specified crank cycle. Starter dropout is defined as four (4) cycles at 1,000 RPM.

During a rest cycle the start and fuel outputs are de-energized and the magneto output is shorted to ground.

CRANkING CONDITIONS: The following notes apply during cranking cycle.

1. Starter motor will not engage within five (5) seconds of the engine shutting down.

2. The fuel output will not be energized with the starter.

3. The starter and magneto outputs will be energized together.

crankinG

The system will control the cyclic cranking as follows: 16 second crank, seven (7) second rest, 16 second

crank, seven (7) second rest followed by three (3) additional cycles of seven (7) second cranks followed by seven (7) second rests.

CHOkE OPERATION:

1. The 990/999cc engines have an electric choke in the air box that is automatically controlled by the electronic control board.

2. The 530cc engines have an electric choke on the divider panel air inlet hose that is automatically controlled by the electronic control board.

3. The 410cc engines have a choke behind the air box that is automatically controlled by the electronic control board.

5. Once the control board sees an RPM signal it will energize the fuel solenoid, drive the throttle open and continue the crank sequence.

6. Starter motor will disengage when speed reaches starter dropout.

7. If the generator does not reach 2200 RPM within 15 seconds, re-crank cycle will occur.

8. If engine stops turning between starter dropout and 2200 RPM, the board will go into a rest cycle for seven (7) seconds then re-crank (if additional crank cycles exist).

9. Once started, the generator will wait for a holdoff period before starting to monitor oil pressure and oil temperature (refer to the Alarm Messages section for hold-off times).

10. During Manual start cranking, if the Mode switch is moved from the Manual position, the cranking stops immediately.

11. During Auto mode cranking, if the Utility returns, the cranking cycle does NOT abort but continues until complete. Once the engine starts, it will run for one (1) minute, then shut down.

Page 29

sEctioN 1.8

automatic oPEratiNG ParamEtErs

load tranSFer

The transfer of load when the generator is running is dependent upon the operating mode as follows:

1. Manual

• Willnottransfertogeneratorifutilityispresent.

• Willtransfertogeneratorifutilityfails(below65%of

nominal for 10 consecutive seconds.

• Willtransferbackwhenutilityreturnsfor15consecutive seconds. The engine will continue to run until removed from the Manual mode.

2. Auto

• Will start and run if Utility fails for 10 consecutive

seconds.

• Willstartafive(5)secondenginewarm-uptimer.

• Willnottransferifutilitysubsequentlyreturns.

• Willtransfertogeneratorifutilityisstillnotpresent.

• Willtransferbacktoutilityonceutilityreturns(above

75% of nominal) for 15 seconds.

• Will transfer back to utility if the generator is shut

down for any reason (such as the switch is in the OFF position or a shutdown alarm.

• After transfer, will shut down engine after one (1)

minute cool-down time.

3. Exercise

• Will not exercise if generator is already running in

either Auto or Manual mode.

• During exercise, the controller will only transfer if

utility fails during exercise for 10 seconds, and will switch to Auto mode.

Part 1

GENERAL INFORMATION

utility reStored

Initial Condition: Generator supplying power to customer load. When the utility returns (above 75% of nominal), a 15 second return to utility timer will start. At the completion of this timer, if the utility supply is still present and acceptable, the control will transfer the load back to the utility and run the engine through a one (1) minute cool down period and then shut down. If utility fails for three (3) seconds during this cool down period, the control will transfer load back to the generator and continue to run while monitoring for utility to return.

Page 30

Part 2

ac GENErators

air-cooled, automatic

standby Generators

taBlE of coNtENts

Part titlE PaGE#

2.1. Description and components 30

2.2 operational analysis 33

2.3 troubleshooting flow charts 35

2.4 Diagnostic tests 39

2.1 Description and Components .......................... 32

Introduction ......................................................32

Engine-Generator Drive System ......................32

The AC Generator ............................................32

Rotor Assembly ................................................32

Stator Assembly ...............................................33

Brush Holder And Brushes (12-20 kW) ...........34

Other AC Generator Components ...................34

2.2 Operational Analysis .......................................35

Rotor Residual Magnetism...............................35

Field Boost (12-20 kW Units) ..........................35

Operation (8/10 kW) .........................................36

Operation (12-20 kW) ......................................36

2.3 Troubleshooting Flowcharts ............................. 37

Problem 1 – Generator Produces Zero

Voltage or Residual Voltage 12-20 kW .... 37-38

Problem 2 – Generator Produces Zero

Voltage or Residual Voltage 8/10 kW ............38

Problem 3 – Generator Produces

Low Voltage at No-Load ................................39

Problem 4 – Generator Produces

High Voltage at No-Load ...............................39

Problem 5 – Voltage and Frequency Drop

Excessively When Loads are Applied ...........40

2.4 Diagnostic Tests .............................................. 41

Introduction ......................................................41

Safety ............................................................41

Test 1 – Check Main Circuit Breaker ................41

Test 2 – Check AC Output Voltage ...................41

Test 4 – Fixed Excitation Test/Rotor

Amp Draw Test ....................................42

Test 5 – Wire Continuity (12-20 kW) ................43

Test 6 – Check Field Boost (12-20 kW) ...........44

Test 7 – Testing The Stator With A Vom

(12-20 kW)...........................................44

Test 8 – Test Brushless Stator..........................45

Test 9 – Check Capacitor .................................46

Test 10 – Test DPE Winding on

Brushless units ....................................47

Test 11 – Resistance Check Of Rotor Circuit

(12-20 kW)...........................................48

Test 12 – Check Brushes And Slip Rings

(12-20 kW)...........................................48

Test 13 – Test Rotor Assembly(12-20 kW) .......49

Test 14 – Check AC Output Frequency ............49

Test 15 – Check and Adjust Engine Governor

(Single Cylinder Units) .........................49

Test 16 – Check Stepper Motor Control

(V-twin Engine Units) ...........................50

Test 17 – Check And Adjust Voltage

Regulator (12-20 kW) ..........................51

Test 18 – Check Voltage And Frequency

Under Load..........................................52

Test 19 – Check F or Overload Condition ...........52

Test 20 – Check Engine Condition ...................52

Test 21 – Field Flash Alternator (8-10 kW) ......52

Page 31

"C"

"B"

"C"

ROTOR

"B"

"C"

"D"

"B"

"C"

"D"

BEARING CARRIER

BRUSH HOLDER ASSEMBLY

ENGINE ADAPTOR

"8KW"

"8KW - 10KW"

ENGINE ADAPTOR

"10KW"

0.8

"D"

STATOR

"12KW - 20KW"

sEctioN 2.1 DEscriPtioN & comPoNENts

Part 2

AC GENERATORS

introduction

The air-cooled, automatic standby system is an easy to install, fully enclosed and self-sufficient 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, 1-phase, 60 Hz, AC loads.

A 2-pole, “W/V-Type” transfer switch is offered (see Part 3). The transfer switch does not include an “intelligence circuit” of it’s 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

12-20 kW: 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.

Page 32

Figure 1. AC Generator Exploded View

AC GENERATORS

SLIP RINGS

BEARING

11P

22S (12-20 kW)

22P

11S

(12-20 kW)

CATHODE

ANODE

DIODE B

CATHODE

DIODE A

COIL 2

ANODE

COIL 1

DIODE A

BEARING

Part 2

Figure 2. The 2-Pole Rotor Assembly 12-20 kW

8/10kW: Like the 12-20 kW rotor, the 8/10 kW 2-pole rotor must

be operated at 3600 rpm to supply a 60 Hertz AC frequency. However, the 8/10kW rotor uses no slip rings. As the rotor rotates in the generator voltage is induced from the Excitation winding using a capacitor that is in turn excited by the rotor. A continuous loop of charging and discharging of the capacitor is maintained that acts as a voltage regulation system. 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.

sEctioN 2.1

DEscriPtioN & comPoNENts

Stator aSSemBly

The stator can houses and retains (a) dual AC power windings, and (b) excitation winding. A total of six (6) or eight (8) stator leads are brought out of the stator can as shown in Figure 4.

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 4. Stator Assembly Leads

Figure 3. The 2-Pole Rotor Assembly 8/10kW

Page 33

sEctioN 2.1

DEscriPtioN & comPoNENts

Part 2

AC GENERATORS

BruSh holder and BruSheS

(12-20 kW)

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.

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 5. 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 frequency of 60 Hz

At the stated no-load frequency, adjust to obtain a line-to-line AC voltage of 247-249 volts.

Figure 4. Brush Holder and Brushes (12-20 kW)

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) a voltage regulator, and (b) a main line circuit breaker.

VOLTAGE REGULATOR (12-20 kW): A typical voltage regulator is shown in Figure 5.

Unregulated AC output from the stator excitation winding is delivered to the regulator’s DPE terminals, via Wire 2 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 0. Stator AC power winding “sensing” is delivered to the regulator “SEN” terminals via Wires 11 and 22.

Page 34

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

against electrical overload. See “Specifications” in front of manual for amp ratings.

AC GENERATORS

DIODE

PIN 5

PIN 1

BASE

TRANSISTOR

FIELD

BOOST

RESISTOR

FIELD

BOOST

DIODE

STARTER CONTACTOR

TO STARTER

+12 VDC

FIELD

BOOST

ROTOR

CRANk RELAY k1

CIRCUIT BOARD

STATOR

EXCITATION

WINDING

VOLTAGE

REGULATOR

FIELD BOOST FROM

CONTROL LOGIC

CIRCUIT BOARD

STATOR

POWER

WINDING

STATOR POWER

WINDING

MAGNETIC

FIELD

MAGNETIC

FIELD

MLB = MAIN LINE CIRCUIT BREAKER

ROTOR

SENSING

TO LOAD

MLB

ENGINE DIRECT DRIVE

12-20 kW Units

CAPACITOR

STATOR

EXCITATION

WINDING

STATOR

POWER

WINDING

STATOR POWER

WINDING

MAGNETIC

FIELD

MAGNETIC

FIELD

MLB = MAIN LINE CIRCUIT BREAKER

ROTOR

TO LOAD

MLB

ENGINE DIRECT DRIVE

8/10 kW Units

Part 2

sEctioN 2.2

oPEratioNal aNalYsis

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 (12-20 kW)

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. 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 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

Figure 1. Operating Diagram of AC Generator

Page 35

sEctioN 2.2

oPEratioNal aNalYsis

Part 2

AC GENERATORS

operation (8/10 kW)

STARTUP: When the engine is started, residual magnetism from

the rotor induces a voltage into (a) the stator AC power windings, and (b) the stator excitation or DPE windings. The capacitor on the DPE winding will be charged and then will discharge causing a voltage to be induced back into the rotor.

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

(DPE) windings. The DPE winding circuit is completed to the capacitor, via Wire 2 and Wire 6.

The capacitor will charge at a rate that is dependant on the amount of voltage that is being induced into it. Once the capacitor is fully charged the voltage that it discharges is a constant voltage and will in-turn increase the size of the magnetic field of the rotor.

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.

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.

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 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.

operation (12-20 kW)

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

magnetism from the rotor induces a voltage into (a) the stator AC power windings, and (b) the stator excitation or DPE windings. 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.

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.

Page 36

Use the “Flow Charts” in conjunction with the detailed

REPAIR

REPLACE

REPAIR

REPLACE

REPAIR

REPLACE

THEN

RETEST

REPLACE

VOLTAGE

REGULATOR

TEST 1 - CHECK

MAIN CIRCUIT

BREAKER

TEST 4 - PERFORM

FIXED EXCITATION /

ROTOR AMP DRAW

PERFORM STATOR

INSULATION

RESISTANCE TEST

SECTION 1.4

PERFORM ROTOR

INSULATION

RESISTANCE TEST

SECTION 1.4

TEST 7 - TEST

STATOR

TEST 5 - WIRE

CONTINUITY

TEST 6 -

FIELD BOOST

TEST 11 -

CHECK ROTOR

RESISTANCE

CHECK

VOM

FUSES

TEST 12 -

CHECK

BRUSHES &

SLIP RINGS

TEST 13 -

TEST ROTOR

ASSEMBLY

REPAIR

OR REPLACE

FUSES

RE-TEST

BAD

GOOD

Problem 1 - Generator Produces Zero Voltage or Residual Voltage

(12-20 kW)

GOOD

RESET TO

“ON”

OR REPLACE

IF BAD

instructions in Section 2.4. Test numbers used in the flow charts correspond to the numbered tests in Section 2.4.

AC GENERATORS

Part 2

sEctioN 2.3

trouBlEsHootiNG floWcHarts

General

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.

Page 37

STOP

TESTING

GOOD

REPLACE

BAD

REPLACE

STATOR

REPLACE

STATOR

REPLACE

ROTOR

TEST 1 - CHECK

MAIN CIRCUIT

BREAKER

TEST 8 - TEST

BRUSHLESS

STATOR

TEST 9 -

CHECK

CAPACITOR

REPLACE

CAPACITOR

TEST 10 - TEST

DPE WINDING

TEST 21 -

FIELD FLASH

ALTERNATOR

TEST 2 -

CHECK AC

OUTPUT

VOLTAGE

BAD

GOODON

GOOD

Problem 2 - Generator Produces Zero Voltage or Residual Voltage

(8/10 kW)

RESET TO

“ON”

OR REPLACE

IF BAD

BAD

TEST 4 - PERFORM

FIXED EXCITATION /

ROTOR AMP DRAW

TEST 7 - TEST

STATOR

TEST 7 - TEST

STATOR

TEST 13 -

TEST ROTOR

ASSEMBLY

TEST 13 -

TEST ROTOR

ASSEMBLY

REPAIR

REPLACE

BAD

GOOD

BAD

RE-TEST

TEST 4

RE-TEST

TEST 4

REPAIR

REPLACE

Problem 1 - Generator Produces Zero Voltage or Residual Voltage

(12-20 kW Continued)

PERFORM STATOR

INSULATION

RESISTANCE TEST -

SECTION 1.4

PERFORM STATOR

INSULATION

RESISTANCE TEST -

SECTION 1.4

PERFORM ROTOR

INSULATION

RESISTANCE TEST -

SECTION 1.4

PERFORM ROTOR

INSULATION

RESISTANCE TEST -

SECTION 1.4

sEctioN 2.3

trouBlEsHootiNG floWcHarts

Part 2

AC GENERATORS

Page 38

AC GENERATORS

STOP

TESTS

FREQUENCY O.K.,

BUT VOLTAGE LOW

TEST 14 - CHECK

AC OUTPUT

FREQUENCY

TEST 15 - ADJUST

ENGINE GOVERNOR

TEST 16 - CHECK

STEPPER MOTOR

CONTROL

TEST 2 - CHECK

AC OUTPUT

VOLTAGE

TEST 17 - ADJUST

VOLTAGE

REGULATOR

TEST 9 -

CHECK

CAPACITOR

LOW

LOW -

SINGLE CYLINDER

UNITS

LOW -

V-TWIN UNITS

FREQUENCY O.K.,

BUT VOLTAGE IS

STILL LOW

GO TO “PROBLEM 1” FLOW CHART START AT “TEST 4 - F/E”

GO TO “PROBLEM 2”

VOLTAGE AND FREQUENCY O.K.

8/10 kW UNITS

NO VOLTAGE

GO TO TEST 4

GO TO “PROBLEM 2”

8/10 kW UNITS

12-20 kW UNITS

FREQUENCY AND

VOLTAGE O.K.

Problem 3 - Generator Produces Low Voltage at No-Load

STOP

TESTS

Problem 4 - Generator Produces High Voltage at No-Load

TEST 14 - CHECK

AC OUTPUT

FREQUENCY

TEST 15 - ADJUST

ENGINE GOVERNOR

TEST 16 - CHECK STEPPER MOTOR

CONTROL

TEST 2 - CHECK

AC OUTPUT

VOLTAGE

HIGH

HIGH -

SINGLE CYLINDER

UNITS

HIGH -

V-TWIN UNITS

REPLACE DEFECTIVE VOLTAGE REGULATOR

FREQUENCY AND

VOLTAGE O.K.

TEST 17 - ADJUST

VOLTAGE

REGULATOR

TEST 9 -

CHECK

CAPACITOR

8/10 kW UNITS

12-20 kW UNITS

FREQUENCY O.K.,

BUT VOLTAGE IS

STILL HIGH

FREQUENCY O.K.,

BUT VOLTAGE HIGH

VOLTAGE AND FREQUENCY O.K.

GO TO “PROBLEM 2”

8/10 kW UNITS

12-20 kW UNITS

Part 2

sEctioN 2.3

trouBlEsHootiNG floWcHarts

Page 39

sEctioN 2.3

GOOD

REPAIR OR REPLACE

IF RECONFIGURED TO LP GAS, VERIFY THAT PROPER PROCEDURE WAS FOLLOWED (REFER TO SECTION 1.3)

TEST 18 - CHECK

VOLTAGE AND

FREQUENCY

UNDER LOAD

TEST 19 - CHECK

FOR OVERLOAD

CONDITION

TEST 15 - CHECK AND

ADJUST ENGINE

GOVERNOR

GO TO “PROBLEM 18 -

ENGINE STARTS HARD

AND RUNS

ROUGH/LACKS POWER”

SECTION 4.3

TEST 20 - CHECK

ENGINE CONDITION

NOT

OVERLOADED

GOOD

ENGINE

CONDITION

GOOD

DISCONTINUE

TESTING

LOOK FOR A SHORTED

CONDITION IN A

CONNECTED LOAD OR

IN ONE OF THE LOAD

CIRCUITS

REDUCE LOADS TO UNIT’S

RATED CAPACITY

BAD

REPAIR OR REPLACE

OVERLOADED

Problem 4 - Voltage and Frequency Drop Excessively When Loads Are Applied

UNITS WITH

V-TWIN

ENGINES

UNITS WITH

SINGLE

CYLINDER

ENGINES

TEST 7 - CHECK

STATOR AC

POWER WINDINGS

BOTH

LOW

GOOD

BAD

GOOD

REPLACE

TEST 8 - TEST

BRUSHLESS

STATOR

TEST 10 - TEST

DPE WINDING

BAD

GOOD

TEST 16 - CHECK

STEPPER MOTOR

CONTROL

8/10 kW UNITS

12-20 kW UNITS

Part 2

AC GENERATORS

trouBlEsHootiNG floWcHarts

Page 40

AC GENERATORS

OFF

WIRE 11

TERMINAL

E1 TERMINAL

E2 TERMINAL

WIRE 44

TERMINAL

Part 2

sEctioN 2.4

DiaGNostic tEsts

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 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 voltohm-milliammeter (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.

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 VOM should 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.

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 over-

looked. 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):

Figure 1. Generator Main Circuit Breaker Test Points

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.

Page 41

sEctioN 2.4

DiaGNostic tEsts

Part 2

AC GENERATORS

DaNGEr: usE EXtrEmE cautioN

PROCEDURE:

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.

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.

PROCEDURE:

1. Disconnect Wire 4 from the voltage regulator, 3rd terminal from the top. See Figure 2.

2. Connect a jumper wire to the disconnected Wire 4 and to the 12 volt fused battery supply Wire 15B (located at TB1 terminal board).

3. Set VOM to AC volts.

4. Take the meter reading. On 12-20 kW units the no-load voltage should be between 249-247 VAC. On 8-10 kW units the no-load voltage should be between 220-235 VAC.

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

RESULTS:

1. If Step 4 indicated proper voltages, discontinue testing.

2. If any other readings were measured, refer back to flow chart.

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 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.

Page 42

Figure 2. Voltage Regulator

4. Disconnect Wire 2 from the voltage regulator 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. Wires 2 and 6 are located at the bottom two terminals of the voltage regulator (see Figure 2).

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 2).

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 15B.

12. Connect one meter test lead to battery positive 12 VDC supply Wire 15B, located at TB1 terminal board.

AC GENERATORS

Part 2

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 the chart on this page: “Results - Fixed

Excitation Test/Rotor Amp Draw Test”.

note: a calculated amp draw can be done by taking the battery voltage that is applied divided by the actual resistance reading of the rotor . a resistance reading can be taken by measuring ohms between Wires 4 and 0 at the voltage regulator.

EXAMPLE:

moDEl 5517

WIRE 2 & 6 VOLTAGE 87 VAC WIRE 11 & 22 VOLTAGE 31 VAC STATIC ROTOR AMP DRAW 1.0 AMP RUNNING ROTOR AMP DRAW 1.0 AMP

These results match Column B in the chart. Refer back to Problem 1 Flow Chart and follow Letter B.

1.75 - 1.17

Above 2.5A

Below 60 VAC Below 60 VAC Above 60 VAC Below 60 VAC

Volts

Zero or Residual

sEctioN 2.4

DiaGNostic tEsts

1.75 - 1.17

1.59 - 1.07

Zero

Draw

Current

1.75 - 1.17

1.59 - 1.07

Above 2.5A

Above 2.3A

Zero

Draw

Current

1.39 - 0.93

1.59 - 1.07

1.39 - 0.93

Above 2.3A

Above 2.0A

Zero

1.75 - 1.17

Above 2.5A

Zero

Above 2.5A

Current

1.59 - 1.07

Above 2.5A

Current

Draw

1.59 - 1.07

1.39 - 0.93

Above 2.5A

Draw

teSt 5 – Wire continuity (12-20 kW)

DISCUSSION: The voltage regulator receives unregulated alternating

current from the stator excitation winding, via Wires 2 and 6. 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 Wire 0.

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.

RESULTS: If CONTINUITY was not measured, repair or replace

the wire as needed.

teSt 4 results - Fixed excitation test/rotor amp draw test (12-20 kW)

ALL Above 60 VAC Below 60 VAC Above 60 VAC

ALL Above 60 VAC Above 60 VAC Below 60 VAC

Voltage Results

Wire 2 & 6

results: (model #) a B c D E f G H

1.75 - 1.17

12 kW

14 kW

Wire 11 & 22

1.59 - 1.07

1.39 - 0.93

1.59 - 1.07

1.39 - 0.93

1.59 - 1.07

1.39 - 0.93

16 kW

17 kW

20 kW

Static Rotor

Amp Draw

1.75 - 1.17

12 kW

14 kW

Running Rotor

1.59 - 1.07

16 kW

17 kW

Amp Draw

Page 43

1.39 - 0.93

match reSultS With letter and reFer to FloW chart in Section 2.3 “problem 1”

20 kW

5.54 VDC

LINE

WIRE 11 TEST POINT

WIRE 44 TEST POINT

LOAD

sEctioN 2.4

DiaGNostic tEsts

Part 2

AC GENERATORS

teSt 6 – check Field BooSt (12-20 kW)

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.

6. Reconnect Wire 4.

RESULTS:

1. If normal field boost voltage is indicated in Step 6, replace the voltage regulator.

2. If normal field boost voltage is NOT indicated in Step 6, check Wire 4 (between regulator and circuit board) for open or shorted condition. If wire is good, replace the circuit board.

teSt 7 – teStinG the Stator With a Vom

(12-20 kW)

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 Wire 4 from the voltage regulator, third terminal from the top (see Figure 3).

2. Set a VOM to read DC volts.

3. Connect the positive (+) VOM test probe to the terminal end of disconnected Wire 4.

4. C onnect the comm o n (- ) 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 4-6 Volts DC. When engine is not cranking, VOM should indicate “zero” volts (see Figure 3).

Page 44

Figure 3. Field Boost Test Points

Figure 4. Test 7 Test Points

PROCEDURE:

1. Isolate the generator from the transfer switch by disconnecting the load wires from the main breaker inside the generator.

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

3. Disconnect and isolate Wires 2 and 6 and Wires 11 and 22 from the voltage regulator.

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

AC GENERATORS

11P

22S (12-20 kW)

22P

11S (12-20 kW)

Part 2

sEctioN 2.4

DiaGNostic tEsts

5. Turn the Main Breaker to the "ON" or CLOSED position.

6. Set a VOM to measure resistance.

7. Connect one meter test lead to Wire 11 on the load side of the main breaker. Connect the other meter test lead to Wire 22 (power winding). Note the resistance reading and compare to the specifications in the front of this manual.

8. Connect one test lead to stator lead Wire 44 on the load side of the main breaker. Connect the other test lead to stator lead Wire 33 (power winding). Note the resistance reading and compare to the specifications in the front of this manual.

note: Wire 11 and Wire 44 could be switched on the main breaker. if an inFinity reading is indicated try putting the meter leads on the other output terminal of the breaker. if inFinity is still read then an actual fault may exist.

9. Connect one test lead to Wire 22 at the voltage regulator. Connect the other test lead to Wire 11 at the voltage regulator (power winding sense leads). Note the resistance reading and compare to the specifications in the front of this manual.

TEST WINDINGS FOR A SHORT TO GROUND:

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

11. Connect one test lead to a clean frame ground. Connect the other test lead to stator lead Wire 11 on the load side of the main circuit breaker.

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

“short-to-ground” condition.

12. Repeat Step 11 using stator lead Wire 33.

13. Repeat Step 11 using Wire 22 at the voltage regulator.

14. Repeat Step 11 using Wire 6 at the voltage regulator.

TEST FOR A SHORT CIRCUIT BETWEEN WINDINGS:

15. Connect one test lead to stator lead Wire 11 on the load side of the main circuit breaker. 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 windings.

16. Repeat Step 15 using stator lead Wire 11; Wire 6.

17. Repeat Step 15 using stator lead Wire 33; Wire 6.

18. Repeat Step 15 using Wire 11 at the voltage regulator; Wire 6 at the voltage regulator.

TEST CONTROL PANEL WIRES FOR CONTINUITY:

19. Connect one test lead to Wire 11 at the voltage regulator and the other test lead at stator lead Wire 11

should be measured.

. Continuity

20. Connect one test lead to Wire 22 at the voltage regulator and the other test lead at stator lead Wire 22

should be measured.

RESULTS:

. Continuity

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 resistance reading indicates the winding is grounded.

3. Testing for a “shorted” condition: Any reading

indicates the winding is shorted.

resistance

4. If the stator tests good and wire continuity tests good, perform “Insulation Resistance Test” in Section 1.5.

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

note: read Section 1.5, “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 1.5. then, repeat the insulation resistance test. if the winding fails the second resistance test (after cleaning and drying), replace the stator assembly.

Figure 5. Stator Assembly Leads

teSt 8 – teSt BruShleSS Stator

DISCUSSION: The brushless stator has three internal windings,

two main power windings and a DPE winding. This test will ensure that there are no shorts between the power windings or shorts to ground.

A VOM meter can be used to test the stator windings for the following faults:

Page 45

sEctioN 2.4

DiaGNostic tEsts

Part 2

AC GENERATORS

• Anopencircuitcondition

• A“short-to-ground”condition

• Ashortcircuitbetweenwindings

PROCEDURE, 8 kW:

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

4. Set a VOM to measure resistance.

5. Connect one test lead to Stator Lead 11. Connect the other test lead to Stator Lead 22. Note the resistance reading and compare to the specifications in the front of this manual.

6. Connect one test lead to Stator Lead 33. Connect the other test lead to Stator Lead 44. Note the resistance reading and compare to the specifications in the front of this manual.

PROCEDURE, 10 kW:

1. Isolate the generator from the transfer switch by disconnecting the load wires from the main breaker inside the generator.

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

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

TEST WINDINGS FOR A SHORT TO GROUND:

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

8. 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.

9. Repeat Step 7 using stator lead 44

TEST FOR A SHORT CIRCUIT BETWEEN WINDINGS:

10. Connect one test lead to stator lead 11. Connect the other test lead to stator lead 33.

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

short between windings.

11. Repeat Step 10 using Wire 44.

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 resistance reading indicated the winding is grounded.

3. Testing for a “shorted” condition: Any resistance reading indicated the winding is shorted.

4. If stator tests good and wire continuity tests good, refer back to flow chart.

teSt 9 – check capacitor

4. Turn the Main Breaker to the "ON" or CLOSED position.

5. Set a VOM to measure resistance.

6. See Figure 4 for proper testing points. Connect one

meter test lead to Wire 11 on the load side of the main breaker. Connect the other meter test lead to Wire 22 (power winding). Note the resistance reading and compare to the specifications in the front of this manual.

7. Connect one test lead to Stator Lead 44 on the load side of the main breaker. Connect the other test lead to Stator Lead 33 (power winding). Note the resistance reading and compare to the specifications in the front of this manual.

Page 46

DISCUSSION: The brushless rotor system relies on the charging and

discharging of a capacitor to induce voltage into the rotor and also to regulate voltage once 240 VAC is achieved. If the capacitor fails, only residual magnetism of the rotor will be measured at the Main Breaker .

Danger: the capacitor may need to be discharged before testing. a capacitor can be

discharged by crossing the terminals with a metal insulated screw driver.

Danger: use proper protective equipment when dealing with a capacitor that has

exploded.

AC GENERATORS

SET TO READ CAPACITANCE

CAPACITOR

59.0

µf

Part 2

sEctioN 2.4

DiaGNostic tEsts

PROCEDURE:

1. Consult the owner’s manual of the meter being used for directions on measuring capacitance. Figure 7 shows a typical meter and how to check capacitance.

2. Connect the meter leads directly across the terminals of the capacitor. The rated µf (micro farad) of the capacitor is marked on the side of the canister.

3. The meter should display the correct µf reading ± 5µf. If anything other than the indicated rating is displayed, replace the capacitor.

a. A capacitor that has gone bad can have a

tendency to explode. Use caution when dealing with an exploded capacitor, the gel from inside a capacitor can cause skin irritation.

b. A capacitor is defective if the terminal connec-

tions are loose on the canister.

c. A capacitor is defective if it wobbles while sitting

on a flat surface.

d. If any of the above observations are observed,

replace the capacitor.

teSt 10 – teSt dpe WindinG on

BruShleSS unitS

DISCUSSION: A DPE winding or Displaced Phase Excitation wind-

ing is used to charge a capacitor that discharges and charges releasing a voltage that is induced into the rotor. If the DPE winding fails, only residual magnetism of the rotor will be measured at the Main Breaker .

Figure 6. Capacitor

RESULTS:

Figure 7. Field Boost Test Points

1. Refer back to flow chart

2. C ommon ob ser vatio n s can be made by visu a lly inspecting the capacitor.

Warning: the capacitor may need to be

discharged before testing. a capacitor can

be discharged by crossing the terminals with a metal insulated screw driver.

PROCEDURE:

1. Disconnect Wire 2 and Wire 6 from the capacitor.

2. Set VOM to measure resistance.

3. Connect one meter lead to Wire 2 and connect the other meter lead to Wire 6.

a. Refer to the specifications in the front of this

manual for the correct resistance reading.

4. Connect one meter lead to Wire 2 and connect the other meter lead to a clean frame ground, INFINITY should be measured.

5. Disconnect Wires 11 and 44 from the main line circuit breaker.

6. Disconnect Wire 22 and Wire 33 from the neutral connection

note: isolate all main stator leads before proceeding.

7. Connect one meter lead to Wire 2 and connect the other meter lead to Wire 11. INFINITY should be measured.

8. Repeat Step 7 using Wires 2 and 44.

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.

Page 47

sEctioN 2.4

DiaGNostic tEsts

Part 2

AC GENERATORS

2. Testing for a “grounded” condition: Any resistance reading indicated the winding is grounded.

3. Testing for a “shorted” condition: Any resistance reading indicated the winding is shorted.

4. If stator tests good and wire continuity tests good, refer back to flow chart.

teSt 11 – reSiStance check oF

rotor circuit (12-20 kW)

DISCUSSION: To verify the zero current draw reading and measure

the rotor circuit. PROCEDURE:

1. Disconnect Wire 4 and Wire 0 from the voltage regulator, located third and fourth terminals from the top of the voltage regulator.

2. Set VOM to measure resistance.

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 in the front of this manual.

RESULTS:

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

2. If INFINITY or a high reading is measured on the VOM, refer back to flow chart.

teSt 12 – check BruSheS and Slip

rinGS (12-20 kW)

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 non-conducting film usually develops during non-operating per iods. Broken or disconnected wiring can also cause loss of excitation current to the rotor.

PROCEDURE:

1. See Figure 8. Carefully inspect brush wires; make sure they are properly and securely connected.

2. Wire 0 from the negative (-) brush terminal connects to Wire 0 at the voltage regulator. 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 Wire 0 at the voltage regulator.

Page 48

CONTINUITY should be measured. If INFINITY is measured repair or replace Wire 0 between the brush assembly and the voltage regulator.

Figure 8. Checking Brushes and Slip Rings

3. Wire 4 from the positive (+) brush terminal connects to Wire 4 at the voltage regulator. 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 Wire 4 at the voltage regulator. CONTINUITY should be measured. If INFINITY is measured repair or replace Wire 4 between the brush assembly and the voltage regulator.

4. 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 voltage regulator.

5. If CONTINUITY was measured in Steps 5 and 6 proceed to Step 9.

6. Disconnect Wire 0 and Wire 4 from the brush assembly. Remove the brush assembly from the bearing carrier. Inspect the brushes for excessive wear, or damage.

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

8. If brush assembly and slip rings look good proceed to Test 13 (Test Rotor Assembly)

9. Wire 0 connects from the voltage regulator in the control panel ground lug. Connect one meter test lead to Wire 0 at the voltage regulator. 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 voltage regulator and the ground terminal.

10. Remove Wire 4 from the voltage regulator.

AC GENERATORS

SLIP RINGS

BEARING

Part 2

sEctioN 2.4

DiaGNostic tEsts

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 13 – teSt rotor aSSemBly

(12-20 kW)

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:

I. Disconnect the brush wires or remove the brush holder,

to prevent interaction.

2. Set a VOM to measure resistance.

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 rotor resistance. Compare to “Specifications,” in the front of this manual.

4. 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 1.5.

rotor if it fails that test. Then, repeat the test. If the rotor fails the second insulation resistance test, it should be replaced.

teSt 14 – 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 (line-to-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 for single cylinder units should be about 62-63 Her tz. For V-Twin units, the no-load frequency should be about 60 Hertz.

RESULTS:

1. If the AC frequency is high or low, go on to Test 15 for single cylinder units, or Test 16 for V-Twin units.

2. If frequency is good, but voltage is high or low, go to Test 17.

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

Figure 9. The Rotor Assembly

NOTE: Be sure to read Section 1.5, “Testing, Cleaning and Drying”, carefully. If the rotor tests good, try performing an insulation resistance test. Clean and dry the

teSt 15 – check and adjuSt enGine

GoVernor (SinGle cylinder unitS)

DISCUSSION: The generator AC frequency output is directly pro-

portional 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.

Page 49

GOVERNOR

SHAFT

PRIMARY

ADJUST

SCREW

GOVERNOR

CLAMP

BOLT

SECONDARY

ADJUST SCREW

sEctioN 2.4

DiaGNostic tEsts

PROCEDURE (8 kW UNITS WITH DUAL GOVERNOR SPRINGS):

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

2. Hold the governor lever at its wide open throttle position,

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

4. Connect a frequency meter across the generators AC

5. Turn the primary adjust screw to obtain a frequency

6. When frequency is correct at no load, check the AC

RESULTS:

1. If, after adjusting the engine governor, frequency and

2. If frequency is now good, but voltage is high or low, refer

3. If engine was overspeeding, check linkage and throttle

4. If engine appears to run rough and results in low fre-

Page 50

Figure 10. Engine Governor Adjustment Single

Cylinder Engines

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).

no-load.

output leads.

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

voltage reading. If voltage is incorrect, the voltage regulator may require adjustment.

voltage are good, tests may be discontinued.

back to flow chart.

for binding. If no governor response is indicated refer to engine service manual.

quency, proceed to Problem 18, Section 4.3.

Part 2

AC GENERATORS

teSt 16 – check Stepper motor

control (V-tWin enGine unitS)

PROCEDURE:

1. Remove air cleaner cover to access stepper motor.

2. Physically grab the throttle and verify the stepper motor, linkage and throttle do not bind in any way, if any binding is felt repair or replace components as needed. Some resistance should be felt as the stepper motor moves through it’s travel.

3. Physically move the throttle to the closed position by pulling the stepper motor arm towards the idle stop. See Figures 11 and 12 (for 9/10 kW units) or Figure 13 (for 12-20 kW Units).

4. Place the AUTO-OFF-MANUAL switch to MANUAL and watch for stepper motor movement. It should move to the wide open position during cranking. Once the unit starts the stepper motor should move the throttle to a position to maintain 60 Hertz.

5. If no movement is seen in Step 4 remove the control panel cover. Verify the six pin connector on the printed circuit board is seated properly, remove the connector and then replace it and test again. Verify the switches are correctly set.

6. If problem continues the remove six pin connector from the printed circuit board. Set Volt meter to measure ohms. Carefully measure from the end of the six pin harness as follows:

note: press down with the meter leads on the connectors exposed terminals, do not probe into the connector.

a. Connect one meter lead to Red, connect the

remaining test lead to Orange, approximately 10 ohms should be measured.

b. Connect one meter lead to Red, connect the

remaining test lead to Yellow, approximately 10 ohms should be measured.

c. Connect one meter lead to Red, connect the

remaining test lead to Brown, approximately 10 ohms should be measured.

d. Connect one meter lead to Red, connect the

remaining test lead to Black, approximately 10 ohms should be measured.

e. Connect one meter lead to Red, connect the

remaining test to the stepper motor case. No resistance should be measured INFINITY or Open.

RESULTS:

1. If the stepper motor fails any part of Step 6 replace the stepper motor.

2. If the stepper motor passes all steps replace the Printed Circuit Board.

STEPPER MOTOR

PULL ARM THIS DIRECTION TO CLOSE THROTTLE

STEPPER MOTOR

STEPPER MOTOR ARM

PULL ARM THIS DIRECTION TO CLOSE THROTTLE

STEPPER MOTOR

STEPPER MOTOR ARM

PULL ARM THIS DIRECTION TO CLOSE THROTTLE

RED

EMPTY

YELLOW

BROWN

ORANGE

BLACK

AC GENERATORS

Part 2

Figure 11. Throttle Positions 9/10 kW Units

sEctioN 2.4

DiaGNostic tEsts

Figure 14. Six Pin Connector Wire Colors

teSt 17 – check and adjuSt VoltaGe

reGulator (12-20 kW)

DISCUSSION:

For additional information, refer to description and components Section 2.1.

Figure 12. Throttle Positions 9/10 kW Units

PROCEDURE (V-TWIN ENGINE UNITS): With the frequency at 60 Hertz, slowly turn the

slotted potentiometer (Figure 15) until line voltage reads 247-249 volts.

note: the access panel on top of the control panel must be removed to adjust the voltage regulator.

note: the voltage regulator is housed in the back of the generator control panel. the regulator maintains a voltage in direct proportion to frequency at a 2-to-1 ratio. For example, at 60 hertz, line-to-neutral voltage will be 120 volts.

Figure 13. Throttle Positions 12-20 kW Units

Figure 15. 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, refer back to flow chart.

Page 51

sEctioN 2.4

DiaGNostic tEsts

Part 2

AC GENERATORS

teSt 18 – 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.

a. Single Cylinder Units: Frequency should not

drop below approximately 58 Hertz. Voltage should not drop below about 230 volts.

b. V-Twin Engine Units: Frequency should not drop

below approximately 60 Hertz. Voltage should not drop below about 240 volts.

RESULTS:

1. If frequency and voltage drop excessively under load, refer back to flow chart.

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

teSt 19 – 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 1.5.

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 20 – 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 fuel settings, incorrect ignition timing, etc.

PROCEDURE: For engine testing, troubleshooting and repair

procedures refer to Problem 11 in Section 4.3. For fur ther engine repair information refer to the appropriate engine service manuals

teSt 21 – Field FlaSh alternator

(8-10 kW unitS)

DISCUSSION: The alternator utilizes residual magnetism within the

windings to charge the capacitor. If the generator has been sitting for a long period of time with no activity the residual magnetism could be lost within the rotor. Field flashing the rotor while connected in parallel with the capacitor will force a charge of electricity through the DPE winding. The voltage that is induced into the rotor will return and charge the capacitor enough to take over voltage regulation of the unit.

note: it is crucial that the generator exercise once a week to help maintain this residual magnetism.

Warning:

performing this test.

PROCEDURE:

1. Construct an energizing cord that is similar to that shown in Figure 17 and connect it as shown in Figure 18.

2. Set the AUTO-OFF-MANUAL switch to the OFF position.

Warning:

more than 1 second at a time.

3. Momentarily turn on the energizing cord (one second).

4. Disconnect the energizing cord from the capacitor.

5. If the field flash was successful, the generator should now be producing approximately 240 VAC at the main circuit breaker of the generator when the AUTO-OFFMANUAL is set to the MANUAL position.

Warning:

than two times in sequence. if the unit has

not produced power after two attempts, other issues exist and need to be addressed.

RESULTS:

1. Refer back to flow chart.

Please keep safety in mind while

Do Not energize the capacitor for

Do not field flash alternator more

Page 52

GENERATOR

CAPACITOR

WIRES 2 & 6 TO

DPE WINDING

DEPRESS SWITCH FOR

ONE SECOND

PLUG ENERGIZING CORD

INTO AC OUTLET

CAPICITOR REMAINS CONNECTED

TO GENERATOR



Danger: The capacitor may need to be discharged before testing. A capacitor can be discharged by crossing the terminals with a metal insulated screw driver.



Danger: Use proper protective equipment when dealing with a capacitor that has exploded.

12 AWG

MOMENTARY PUSHBUTTON ON/OFF SWITCH

SINGLE POLE SWITCH ON LIVE SIDE

 DO NOT SUBSTITUTE ANY OTHER DEVICE

4 ft.

CRIMP ON STANDARD FEMALE BLADE CONNECTORS

STANDARD MALE PLUG

AC GENERATORS

Part 2

sEctioN 2.4

DiaGNostic tEsts

Figure 17. Construction of Energizing Cord

Figure 18. Energizing Cord Connection

Page 53

NotEs

Page 54

Part 3

taBlE of coNtENts

Part titlE PG#

3.1. Description and components 50

3.2 operational analysis 54

3.3 troubleshooting flow charts 64

traNsfEr

sWitcH

air-cooled, automatic

standby Generators

3.1 Description and Components ...............................................56

General 56

Enclosure ............................................................................56

Transfer Mechanism ............................................................57

Transfer Relay .....................................................................57

Neutral Lug .........................................................................58

Manual Transfer Handle .....................................................58

Terminal Block ...................................................................58

Fuse Holder ........................................................................59

3.2 Operational Analysis .............................................................60

Operational Analysis ...........................................................60

Utility Source Voltage Available ..........................................62

Utility Source Voltage Failure .............................................63

Transfer To Standby ............................................................64

Transfer To Standby ............................................................65

Utility Restored ...................................................................66

Utility Restored, Transfer Switch

De-energized ......................................................67

Utility Restored, Retransfer Back To Utility .........................68

Transfer Switch In Utility ......................................................69

3.3 – Troubleshooting Flowcharts ...............................................70

Introduction To Troubleshooting ..........................................70

Problem 7 – In Automatic Mode,

No Transfer to Standby ..................................................70

Manual Mode .................................................................71

Problem 9 – Blown F1 or F2 Fuse ................................. 71

Problem 10 – Units Starts And Transfer

Occurs When Utility Power Is On ..................................72

Problem 11 – No Battery Charge

(Pre-Packed Load Center) .............................................73

Problem 12 – No Battery Charge

(RTSN + RTSE Transfer Switch) ...................................73

Problem 13 – No Battery Charge

(Gen-Ready Load Center) .............................................73

Problem 14 – No Battery Charge

(Load Shed Transfer Switch) .........................................73

3.4 Diagnostic Tests ....................................................................74

General ............................................................................74

Test 26 – Check Voltage at

Terminal Lugs E1, E2 ..........................................74

Test 27 – Check Manual Transfer Switch Operation ...........75

3.4 Diagnostic tests 66

Test 28 – Check 23 And 15B

Wiring/Connections .............................................76

Test 29 – Test Transfer Relay TR ........................................77

Test 30 – Standby Control Circuit .......................................78

Test 31 – Check Wire 23 .....................................................78

Test 32 – Utility Control Circuit ............................................80

Test 33 – Test Limit Switch SW2 and SW3 .........................82

Test 34 – Check Fuses F1 and F2 ......................................82

Test 35 – Check N1 and N2 Wiring .....................................83

Test 36 – Check N1 and N2 Voltage ...................................83

Test 37 – Check Utility Sensing Voltage

at the Circuit Board .............................................84

Test 38 – Check Utility Sense Voltage ................................84

Test 39 – Check Voltage at

Terminal Lugs N1, N2 .........................................84

Test 40 – Check Battery Charger Supply

Voltage “Pre-Wire Load Center” ..........................86

Test 41 – Check Battery Charger Output

Voltage “Pre-Wire Load Center” ..........................86

Test 42 – Check Wire 0 and Wire15B

“Pre-Wire Load Center” .......................................86

Test 43 – Check Battery Charger

Supply Voltage

“RTSN & RTSE Transfer Switch” .........................87

Test 44 – Check Battery Charger

Output Voltage

“RTSN & RTSE Transfer Switch” .........................87

Test 45 – Check Wire 0/

“RTSN & RTSE Transfer Switch” ........................87

Test 46 – Check Battery Charger

Supply Voltage

“GenReady Load Center” ....................................90

Test 47 – Check Battery Charger

Output Voltage

“GenReady Load Center” ....................................90

Test 48 – Check Wire 0/15B

“GenReady Load Center” ....................................90

Test 49 – Check Battery Charger

Supply Voltage

“Load Shed Transfer Switch” ...............................92

Test 50 – Check Battery Charger

Output Voltage

“Load Shed Transfer Switch” ...............................92

Test 51 – Check Wire 0 and Wire 15B

“Load Shed Transfer Switch” ...............................94

Page 55

ITEMS 32-37

sEctioN 3.1

DEscriPtioN & comPoNENts

Part 3

TRANSFER SWITCH

General

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

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.

itEm DEscriPtioN

1 GTS LOAD CENTER ENCLOSURE 2 COVER GTS LOAD CTR 3 TRANSFER SWITCH HOME STANDBY 3A COIL UTILITY 3B COIL STANDBY 4 SCREW 5 SCREW 6 LOCK WASHER” 7 RELAY PANEL 12VDC DPDT 10A@240VAC 8 LOAD CENTER 9 SCREW 10 RIVET” 11 WASHER 12 PLUG 13 HARNESS ADAPTER PLATE 14 SUBPLATE GTS LOAD CENTER 15 U-CHANNEL 16 WASHER 17 GROMMET 18 ARM EXTENDER PIN 19 CABLE TIE SELF MOUNTING 4.3LG 20 HARNESS GTS-MAIN PANEL W/NEUTRAL 21 LUG QUICK DISCONNECT 22 SCREW 23 LUG 24 BLOCK TERMINAL 26 SCREW WITH WASHER 27 SCREW 28 HARNESS LOAD CENTER INT. CONN (NOT SHOWN) 29 FUSEBLOCK 30 FUSE 5A 31 BATTERY CHARGER 32-37 CIRCUIT BREAKERS 38 HARNESS ENTRY COVER 39 HARNESS GTS, EXTERNAL CONNECTION BOX

encloSure

The “W/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.

Page 56

Figure 1. Exploded View of W/V-Type Transfer Switch

TRANSFER SWITCH

STANDBY

LOAD

UTILITY

STANDBY

LOAD

UTILITY

UTILITY CLOSING COIL (C1)

STANDBY CLOSING COIL (C2)

BRIDGE RECTIFIER

MANUAL TRANSFER LEVER

LIMIT SWITCH (SW2)

LIMIT SWITCH (SW3)

N2A A

126

205

Part 3

sEctioN 3.1

DEscriPtioN & comPoNENts

tranSFer mechaniSm

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

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 SW2 AND SW3: Switches are mechanically actuated by load contacts

movement. When the load contacts are connected to the utility contacts, limit switch SW2 opens the utility circuit to utility closing coil C1 and limit switch SW3 closes the standby circuit to standby closing coil C2. The limit switches “ar m” 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 SW2 will prevent retransfer to “Utility”. An open switch SW3 will prevent transfer to STANDBY.

Figure 3. Load Connected to Standby Power Source

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

ity 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”

Figure 4. The “W/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 15B and Relay Terminal A.

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 de-energized.

Page 57

194

N1A E1

126

205

0 15B 23

sEctioN 3.1

DEscriPtioN & comPoNENts

Part 3

TRANSFER SWITCH

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.

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 3-point terminal block must be properly interconnected with an identically labeled terminal block in the generator control panel assembly.

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.

Page 58

Figure 6. Transfer Switch Terminal Block

Terminals used on the terminal block are identified as 0, 15B and 23.

UTILITY N1 AND N2: Interconnect with identically labeled terminals in the

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

TRANSFER SWITCH

BLACK

N1A N2A

Part 3

TERMINALS 0, 15B AND 23: These terminals connect the transfer relay to the

generator circuit board. See “Transfer Relay” in Section 3.1.

FuSe holder

The fuse holder holds three (3) fuses, designated as fuses F1, F2 and F3. Each fuse is rated 5 amperes.

FUSES F1, F2: These two fuses protect the UTILITY 1 and UTILITY 2

circuit against overload. FUSES F3:

This fuse protects the battery charger against overload.

sEctioN 3.1

DEscriPtioN & comPoNENts

Figure 7. The Fuse Holder

Page 59

NEUTRAL CONNECTION

SWITCH

SW3

COM

SW2

VR1

NC NC

COM

VR2

TR1

15B

174

7 9

3 6

CIRCUIT 10

BLACK (MAIN 1)

CONTROL TRANSFER

RED (MAIN 2)

NEUTRAL (WHITE)

15B

BLACK

RED

15B

240VAC TO

TO GENERATOR OUTPUT

PANEL

MAIN DISTRIBUTION

T1 T2

N1A

N2A

N1AN1A

N1A

15B

205

126

N1A

N2A

240VAC OUTPUT

GENERATOR

TS TO CONTROL PANEL

SW1

CIRCUIT 9

CIRCUIT 6

CIRCUIT 5

CIRCUIT 2

CIRCUIT 1

CIRCUIT 3

CIRCUIT 4

CIRCUIT 7

CIRCUIT 8

CIRCUIT 11

CIRCUIT 12

CIRCUIT 13

CIRCUIT 14

CIRCUIT 16

CIRCUIT 15

14 CIRCUIT LOAD CENTER

12 CIRCUIT LOAD CENTER

10 CIRCUIT LOAD CENTER

8 CIRCUIT LOAD CENTER

WIRE

BLK

+ RED

16 CIRCUIT LOAD CENTER

BC-BATTERY CHARGER

N-NEUTRAL

TR1-TRANSFER RELAY

SW2,SW3-LIMIT SWITCHES TB1-TERMINAL STRIP

F1,F2,F3-5A, 600V FUSE

C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER

SW1-AUTOMATIC TRANSFER SWITCH

(16 CIRCUIT SHOWN FOR REFERENCE ONLY)

LC-CIRCUIT BREAKER (LOADS)

LEGEND

SENSING

UTILITY

INSIDE

GROUND (GREEN)

sEctioN 3.2

oPEratioNal aNalYsis

operational analySiS

Figure 1 is a schematic for a typical “W/V-Type” transfer switch.

Part 3

TRANSFER SWITCH

Page 60

Figure 1. Schematic

TRANSFER SWITCH

205

N2A

N1A

RED

BLK

CONTROL PANEL

TO GENERATOR

15B

TB1

N1A

BLK RED

N1A N2A

15B

N2A

15B

N1A

A B

7 9

4 6

1 3

TR1

BLK RED

RED BLK

LEGEND

LC-CIRCUIT BREAKER (LOADS)

(16 CIRCUIT SHOWN FOR REFERENCE ONLY)

SW1-AUTOMATIC TRANSFER SWITCH

C2-GENERATOR COIL & RECTIFIER

C1-UTILITY COIL & RECTIFIER F1,F2,F3-5A, 600V FUSE

TB1-TERMINAL STRIP

SW2,SW3-LIMIT SWITCHES TR1-TRANSFER RELAY

N-NEUTRAL

BLK

RED

BLK

SW1

RED 205

205

SW3

126

BLKE1

N2A

N1A

SW2

126

N2A

RED

N2A

N1A

BLK

F1 F2 F3

A A A

B B B

0D4698-T

BLK WIRE

RED WIRE

15B

1 2 3

1 2

N1 N2

E1 E2

T1 T2

GRN

BC-BATTERY CHARGER

126

GROUP G

Part 3

Figure 2 is a wiring diagram for a typical “W/V-Type” transfer switch.

sEctioN 3.2

oPEratioNal aNalYsis

Figure 2. Wiring Diagram

Page 61

NEUTRAL CONNECTION

SWITCH

SW3

COM

SW2

VR1

NC NC

COM

VR2

TR1

15B

174

7 9

3 6

CIRCUIT 10

BLACK (MAIN 1)

CONTROL TRANSFER

RED (MAIN 2)

NEUTRAL (WHITE)

15B

BLACK

RED

15B

240VAC TO

TO GENERATOR OUTPUT

PANEL

MAIN DISTRIBUTION

T1 T2

N1A

N2A

N1AN1A

N1A

15B

205

126

N1A

N2A

240VAC OUTPUT

GENERATOR

TS TO CONTROL PANEL

SW1

CIRCUIT 9

CIRCUIT 6

CIRCUIT 5

CIRCUIT 2

CIRCUIT 1

CIRCUIT 3

CIRCUIT 4

CIRCUIT 7

CIRCUIT 8

CIRCUIT 11

CIRCUIT 12

CIRCUIT 13

CIRCUIT 14

CIRCUIT 16

CIRCUIT 15

14 CIRCUIT LOAD CENTER

12 CIRCUIT LOAD CENTER

10 CIRCUIT LOAD CENTER

8 CIRCUIT LOAD CENTER

WIRE

BLK

+ RED

16 CIRCUIT LOAD CENTER

BC-BATTERY CHARGER

N-NEUTRAL

TR1-TRANSFER RELAY

SW2,SW3-LIMIT SWITCHES TB1-TERMINAL STRIP

F1,F2,F3-5A, 600V FUSE

C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER

SW1-AUTOMATIC TRANSFER SWITCH

(16 CIRCUIT SHOWN FOR REFERENCE ONLY)

LC-CIRCUIT BREAKER (LOADS)

LEGEND

SENSING

UTILITY

INSIDE

GROUND (GREEN)

UTILITY

GENERATOR

GROUND

sEctioN 3.2

oPEratioNal aNalYsis

Figure 3 is a schematic representation of the transfer switch with utility source power available. The circuit condition may be briefly described as follows:

• UtilitysourcevoltageisavailabletoterminallugsN1andN2ofthetransfermechanism,transferswitchisinthe

UTILITY position and source voltage is available to T1, T2 and customer load.

• Utilitysourcevoltageisavailabletolimitswitch(SW2)viathenormally-closedtransferrelaycontacts(1and7)

and Wire 126. However, SW2 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). The second line of the utility voltage “sensing” circuit is via Wire N2A, a 5 amp Fuse (F2).

Page 62

Part 3

TRANSFER SWITCH

utility Source VoltaGe aVailaBle

Figure 3. Utility Source Power Available

NEUTRAL CONNECTION

SWITCH

SW3

COM

SW2

VR1

NC NC

COM

VR2

TR1

15B

174

7 9

3 6

CIRCUIT 10

BLACK (MAIN 1)

CONTROL TRANSFER

RED (MAIN 2)

NEUTRAL (WHITE)

15B

BLACK

RED

15B

240VAC TO

TO GENERATOR OUTPUT

PANEL

MAIN DISTRIBUTION

T1 T2

N1A

N2A

N1AN1A

N1A

15B

205

126

N1A

N2A

240VAC OUTPUT

GENERATOR

TS TO CONTROL PANEL

SW1

CIRCUIT 9

CIRCUIT 6

CIRCUIT 5

CIRCUIT 2

CIRCUIT 1

CIRCUIT 3

CIRCUIT 4

CIRCUIT 7

CIRCUIT 8

CIRCUIT 11

CIRCUIT 12

CIRCUIT 13

CIRCUIT 14

CIRCUIT 16

CIRCUIT 15

14 CIRCUIT LOAD CENTER

12 CIRCUIT LOAD CENTER

10 CIRCUIT LOAD CENTER

8 CIRCUIT LOAD CENTER

WIRE

BLK

+ RED

16 CIRCUIT LOAD CENTER

BC-BATTERY CHARGER

N-NEUTRAL

TR1-TRANSFER RELAY

SW2,SW3-LIMIT SWITCHES TB1-TERMINAL STRIP

F1,F2,F3-5A, 600V FUSE

C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER

SW1-AUTOMATIC TRANSFER SWITCH

(16 CIRCUIT SHOWN FOR REFERENCE ONLY)

LC-CIRCUIT BREAKER (LOADS)

LEGEND

SENSING

UTILITY

INSIDE

GROUND (GREEN)

UTILITY

GENERATOR

GROUND

TRANSFER SWITCH

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

Figure 4 is a schematic representation of the transfer switch with generator power available, waiting to transfer.

• GeneratorvoltageavailableE1,E2.

• CircuitboardactionholdingWire23opentoground.

• PoweravailabletostandbycoilC2,uponclosureofTR1,normallyopencontacts(9&6)willcloseandinitiatea

transfer.

Part 3

sEctioN 3.2

oPEratioNal aNalYsis

utility Source VoltaGe Failure

Page 63

Figure 4. Generator Power Available, Waiting to Transfer.

NEUTRAL CONNECTION

SWITCH

SW3

COM

SW2

VR1

NC NC

COM

VR2

TR1

15B

174

7 9

3 6

CIRCUIT 10

BLACK (MAIN 1)

CONTROL TRANSFER

RED (MAIN 2)

NEUTRAL (WHITE)

15B

BLACK

RED

15B

240VAC TO

TO GENERATOR OUTPUT

PANEL

MAIN DISTRIBUTION

T1 T2

N1A

N2A

N1AN1A

N1A

15B

205

126

N1A

N2A

240VAC OUTPUT

GENERATOR

TS TO CONTROL PANEL

SW1

CIRCUIT 9

CIRCUIT 6

CIRCUIT 5

CIRCUIT 2

CIRCUIT 1

CIRCUIT 3

CIRCUIT 4

CIRCUIT 7

CIRCUIT 8

CIRCUIT 11

CIRCUIT 12

CIRCUIT 13

CIRCUIT 14

CIRCUIT 16

CIRCUIT 15

14 CIRCUIT LOAD CENTER

12 CIRCUIT LOAD CENTER

10 CIRCUIT LOAD CENTER

8 CIRCUIT LOAD CENTER

WIRE

BLK

+ RED

16 CIRCUIT LOAD CENTER

BC-BATTERY CHARGER

N-NEUTRAL

TR1-TRANSFER RELAY

SW2,SW3-LIMIT SWITCHES TB1-TERMINAL STRIP

F1,F2,F3-5A, 600V FUSE

C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER

SW1-AUTOMATIC TRANSFER SWITCH

(16 CIRCUIT SHOWN FOR REFERENCE ONLY)

LC-CIRCUIT BREAKER (LOADS)

LEGEND

SENSING

UTILITY

INSIDE

GROUND (GREEN)

UTILITY

GENERATOR

GROUND

sEctioN 3.2

oPEratioNal aNalYsis

12 VDC is delivered to the transfer relay via Wire 15B and back to the circuit board via Wire 23. However, circuit board action holds the Wire 23 circuit open and the transfer relay remains de-energized. On generator startup, an “engine warm-up timer” 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 (TR1) contacts, limit switch (SW3), Wire “B”, and a bridge rectifier. The standby closing coil energizes and the main contacts actuate to their “Standby” side.

Page 64

Part 3

TRANSFER SWITCH

tranSFer to StandBy

Figure 5. Transfer Action to Standby Position

NEUTRAL CONNECTION

SWITCH

SW3

COM

SW2

VR1

NC NC

COM

VR2

TR1

15B

174

7 9

3 6

CIRCUIT 10

BLACK (MAIN 1)

CONTROL TRANSFER

RED (MAIN 2)

NEUTRAL (WHITE)

15B

BLACK

RED

15B

240VAC TO

TO GENERATOR OUTPUT

PANEL

MAIN DISTRIBUTION

T1 T2

N1A

N2A

N1AN1A

N1A

15B

205

126

N1A

N2A

240VAC OUTPUT

GENERATOR

TS TO CONTROL PANEL

SW1

CIRCUIT 9

CIRCUIT 6

CIRCUIT 5

CIRCUIT 2

CIRCUIT 1

CIRCUIT 3

CIRCUIT 4

CIRCUIT 7

CIRCUIT 8

CIRCUIT 11

CIRCUIT 12

CIRCUIT 13

CIRCUIT 14

CIRCUIT 16

CIRCUIT 15

14 CIRCUIT LOAD CENTER

12 CIRCUIT LOAD CENTER

10 CIRCUIT LOAD CENTER

8 CIRCUIT LOAD CENTER

WIRE

BLK

+ RED

16 CIRCUIT LOAD CENTER

BC-BATTERY CHARGER

N-NEUTRAL

TR1-TRANSFER RELAY

SW2,SW3-LIMIT SWITCHES TB1-TERMINAL STRIP

F1,F2,F3-5A, 600V FUSE

C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER

SW1-AUTOMATIC TRANSFER SWITCH

(16 CIRCUIT SHOWN FOR REFERENCE ONLY)

LC-CIRCUIT BREAKER (LOADS)

LEGEND

SENSING

UTILITY

INSIDE

GROUND (GREEN)

UTILITY

GENERATOR

GROUND

TRANSFER SWITCH

When the standby coil is energized it pulls the transfer switch mechanism to a overcenter position towards the standby power source side, the transfer switch mechanically snaps to the standby position. On closure of the main contacts to the standby power source side, limit switches SW2 and SW3 are mechanically actuated to “arm” 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.

Part 3

sEctioN 3.2

oPEratioNal aNalYsis

tranSFer to StandBy

Page 65

Figure 6. Generator Powering Load.

NEUTRAL CONNECTION

SWITCH

SW3

COM

SW2

VR1

NC NC

COM

VR2

TR1

15B

174

7 9

3 6

CIRCUIT 10

BLACK (MAIN 1)

CONTROL TRANSFER

RED (MAIN 2)

NEUTRAL (WHITE)

15B

BLACK

RED

15B

240VAC TO

TO GENERATOR OUTPUT

PANEL

MAIN DISTRIBUTION

T1 T2

N1A

N2A

N1AN1A

N1A

15B

205

126

N1A

N2A

240VAC OUTPUT

GENERATOR

TS TO CONTROL PANEL

SW1

CIRCUIT 9

CIRCUIT 6

CIRCUIT 5

CIRCUIT 2

CIRCUIT 1

CIRCUIT 3

CIRCUIT 4

CIRCUIT 7

CIRCUIT 8

CIRCUIT 11

CIRCUIT 12

CIRCUIT 13

CIRCUIT 14

CIRCUIT 16

CIRCUIT 15

14 CIRCUIT LOAD CENTER

12 CIRCUIT LOAD CENTER

10 CIRCUIT LOAD CENTER

8 CIRCUIT LOAD CENTER

WIRE

BLK

+ RED

16 CIRCUIT LOAD CENTER

BC-BATTERY CHARGER

N-NEUTRAL

TR1-TRANSFER RELAY

SW2,SW3-LIMIT SWITCHES TB1-TERMINAL STRIP

F1,F2,F3-5A, 600V FUSE

C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER

SW1-AUTOMATIC TRANSFER SWITCH

(16 CIRCUIT SHOWN FOR REFERENCE ONLY)

LC-CIRCUIT BREAKER (LOADS)

LEGEND

SENSING

UTILITY

INSIDE

GROUND (GREEN)

UTILITY

GENERATOR

GROUND

sEctioN 3.2

oPEratioNal aNalYsis

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 7. Utility Restored, Generator Still Providing Output to Load.

Page 66

Part 3

TRANSFER SWITCH

utility reStored

NEUTRAL CONNECTION

SWITCH

SW3

COM

SW2

VR1

NC NC

COM

VR2

TR1

15B

174

7 9

3 6

CIRCUIT 10

BLACK (MAIN 1)

CONTROL TRANSFER

RED (MAIN 2)

NEUTRAL (WHITE)

15B

BLACK

RED

15B

240VAC TO

TO GENERATOR OUTPUT

PANEL

MAIN DISTRIBUTION

T1 T2

N1A

N2A

N1AN1A

N1A

15B

205

126

N1A

N2A

240VAC OUTPUT

GENERATOR

TS TO CONTROL PANEL

SW1

CIRCUIT 9

CIRCUIT 6

CIRCUIT 5

CIRCUIT 2

CIRCUIT 1

CIRCUIT 3

CIRCUIT 4

CIRCUIT 7

CIRCUIT 8

CIRCUIT 11

CIRCUIT 12

CIRCUIT 13

CIRCUIT 14

CIRCUIT 16

CIRCUIT 15

14 CIRCUIT LOAD CENTER

12 CIRCUIT LOAD CENTER

10 CIRCUIT LOAD CENTER

8 CIRCUIT LOAD CENTER

WIRE

BLK

+ RED

16 CIRCUIT LOAD CENTER

BC-BATTERY CHARGER

N-NEUTRAL

TR1-TRANSFER RELAY

SW2,SW3-LIMIT SWITCHES TB1-TERMINAL STRIP

F1,F2,F3-5A, 600V FUSE

C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER

SW1-AUTOMATIC TRANSFER SWITCH

(16 CIRCUIT SHOWN FOR REFERENCE ONLY)

LC-CIRCUIT BREAKER (LOADS)

LEGEND

SENSING

UTILITY

INSIDE

GROUND (GREEN)

UTILITY

GENERATOR

GROUND

TRANSFER SWITCH

After the preset time interval expires the circuit board will open the Wire 23 circuit to ground. The transfer relay de-energizes, it’s normally closed contacts close, and utility source voltage is delivered to the utility closing coil (C1), via Wires N1A and N2A, closed Transfer Relay Contacts 1 and 7, and Limit Switch SW2.

Part 3

utility reStored, tranSFer SWitch de-enerGized

Figure 8. Utility Restored, Transfer Relay De-energized.

sEctioN 3.2

oPEratioNal aNalYsis

Page 67

sEctioN 3.2

NEUTRAL CONNECTION

SWITCH

SW3

COM

SW2

VR1

NC NC

COM

VR2

TR1

15B

174

7 9

3 6

CIRCUIT 10

BLACK (MAIN 1)

CONTROL TRANSFER

RED (MAIN 2)

NEUTRAL (WHITE)

15B

BLACK

RED

15B

240VAC TO

TO GENERATOR OUTPUT

PANEL

MAIN DISTRIBUTION

T1 T2

N1A

N2A

N1AN1A

N1A

15B

205

126

N1A

N2A

240VAC OUTPUT

GENERATOR

TS TO CONTROL PANEL

SW1

CIRCUIT 9

CIRCUIT 6

CIRCUIT 5

CIRCUIT 2

CIRCUIT 1

CIRCUIT 3

CIRCUIT 4

CIRCUIT 7

CIRCUIT 8

CIRCUIT 11

CIRCUIT 12

CIRCUIT 13

CIRCUIT 14

CIRCUIT 16

CIRCUIT 15

14 CIRCUIT LOAD CENTER

12 CIRCUIT LOAD CENTER

10 CIRCUIT LOAD CENTER

8 CIRCUIT LOAD CENTER

WIRE

BLK

+ RED

16 CIRCUIT LOAD CENTER

BC-BATTERY CHARGER

N-NEUTRAL

TR1-TRANSFER RELAY

SW2,SW3-LIMIT SWITCHES TB1-TERMINAL STRIP

F1,F2,F3-5A, 600V FUSE

C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER

SW1-AUTOMATIC TRANSFER SWITCH

(16 CIRCUIT SHOWN FOR REFERENCE ONLY)

LC-CIRCUIT BREAKER (LOADS)

LEGEND

SENSING

UTILITY

INSIDE

GROUND (GREEN)

UTILITY

GENERATOR

GROUND

oPEratioNal aNalYsis

As the utility coil pulls the transfer switch to an OVER CENTER position, the switch mechanically snaps to Utility. On closure of the main contacts to the utility power source side, Limit Switches SW2 and SW3 are mechanically actuated to “arm” the circuit for transfer to standby.

Page 68

Part 3

utility reStored, retranSFer Back to utility

Figure 9. Utility Restored, Retransfer Back to Utility.

TRANSFER SWITCH

NEUTRAL CONNECTION

SWITCH

SW3

COM

SW2

VR1

NC NC

COM

VR2

TR1

15B

174

7 9

3 6

CIRCUIT 10

BLACK (MAIN 1)

CONTROL TRANSFER

RED (MAIN 2)

NEUTRAL (WHITE)

15B

BLACK

RED

15B

240VAC TO

TO GENERATOR OUTPUT

PANEL

MAIN DISTRIBUTION

T1 T2

N1A

N2A

N1AN1A

N1A

15B

205

126

N1A

N2A

240VAC OUTPUT

GENERATOR

TS TO CONTROL PANEL

SW1

CIRCUIT 9

CIRCUIT 6

CIRCUIT 5

CIRCUIT 2

CIRCUIT 1

CIRCUIT 3

CIRCUIT 4

CIRCUIT 7

CIRCUIT 8

CIRCUIT 11

CIRCUIT 12

CIRCUIT 13

CIRCUIT 14

CIRCUIT 16

CIRCUIT 15

14 CIRCUIT LOAD CENTER

12 CIRCUIT LOAD CENTER

10 CIRCUIT LOAD CENTER

8 CIRCUIT LOAD CENTER

WIRE

BLK

+ RED

16 CIRCUIT LOAD CENTER

BC-BATTERY CHARGER

N-NEUTRAL

TR1-TRANSFER RELAY

SW2,SW3-LIMIT SWITCHES TB1-TERMINAL STRIP

F1,F2,F3-5A, 600V FUSE

C1-UTILITY COIL & RECTIFIER C2-GENERATOR COIL & RECTIFIER

SW1-AUTOMATIC TRANSFER SWITCH

(16 CIRCUIT SHOWN FOR REFERENCE ONLY)

LC-CIRCUIT BREAKER (LOADS)

LEGEND

SENSING

UTILITY

INSIDE

GROUND (GREEN)

UTILITY

GENERATOR

GROUND

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

Part 3

sEctioN 3.2

oPEratioNal aNalYsis

tranSFer SWitch in utility

Page 69

Figure 10. Transfer Switch in UTILITy.

BAD

REPAIR OR REPLACE AS NEEDED

REPLACE

GOOD

FIND CAUSE OF NO AC OUTPUT TO TRANSFER SWITCH FROM GENERATOR

TEST 26 – CHECK

VOLTAGE AT

TERMINAL LUGS

E1 & E2

TEST 27 – CHECK

MANUAL TRANSFER

SWITCH OPERATION

TEST 28 – CHECK #23

AND #15B WIRING

CONNECTIONS

BAD

REPAIR AS NEEDED

TEST 30 – CHECK

STANDBY CONTROL

CIRCUIT

TEST 29 – TEST

TRANSFER

RELAY

BAD

GOOD

REPAIR OR REPLACE MECHANISM

Problem 7 – In Automatic Mode, No Transfer to Standby

sEctioN 3.3

Part 3

TRANSFER SWITCH

trouBlEsHootiNG floW cHarts

introduction to trouBleShootinG

The first step in troubleshooting is to correctly identify the problem. Once that is done, the cause of the an be found by performing the tests in the appropriate flow chart.

Test numbers assigned in the flow charts are identical to test numbers in Section 3.4, “Diagnostic Tests.” Section

3.4 provides detailed instructions for performance of each test.

Page 70

TRANSFER SWITCH

Problem 8 – In Automatic Mode, Generator Starts When Loss of Utility Occurs, Generator

Shuts Down When Utility Returns But There Is No Retransfer To Utility Power

Generator Transfers to Standby During Excercise or in Manual Mode

BAD

REPAIR OR REPLACE AS NEEDED

REPLACE

GOOD

TEST 27 – CHECK

MANUAL TRANSFER

SWITCH OPERATION

TEST 31 – CHECK

WIRE 23

BAD

TEST 32 – CHECK

UTILITY CONTROL

CIRCUIT

TEST 29 – TEST

TRANSFER

RELAY

BAD

REPAIR OR REPLACE MECHANISM

TEST 34 – CHECK

FUSE F1 & F2

TEST 35 – CHECK

N1 & N2 WIRING

GOOD

BAD

REPAIR OR REPLACE

WIRING

INSPECT/REPLACE PRINTED CIRCUIT BOARD

FINISH

Problem 9 – Blown F1 or F2 Fuse

Part 3

sEctioN 3.3

trouBlEsHootiNG floW cHarts

Page 71

REPLACE

CIRCUIT

BOARD

CORRECT

UTILITY

SOURCE

VOLTAGE

REPLACE

GO TO PROBLEM 7

REPAIR OR

REPLACE

WIRING

REPAIR OR REPLACE WIRE

N1A/N2A BETWEEN N1/N2 LUGS AND FUSE HOLDER

REPAIR N1/N2 OPEN WIRING

BETWEEN TRANSFER

SWITCH AND GENERATOR

Problem 10 – Unit Starts and Transfer Occurs When Utility Power Is On

8 kW: Green LED Flashes

10-20 kW: Status – Utility Lost

TEST 37 – CHECK UTILITY SENSING

VOLTAGE AT

CIRCUIT BOARD

TEST 36 –

CHECK N1 & N2

VOLTAGE

TEST 38 – CHECK

UTILITY SENSE

VOLTAGE

TEST 39 –

CHECK VOLTAGE

AT TERMINAL

LUGS N1 & N2

TEST 34 –

CHECK FUSE

F1 & F2

GOOD

BAD

sEctioN 3.3

trouBlEsHootiNG floW cHarts

Part 3

TRANSFER SWITCH

Page 72

REPLACE PRINTED

CIRCUIT BOARD

REPAIR OR REPLACE

REPLACE CHARGER

Problem 11 – No Battery Charge

“Pre-Wire Load Center”

TEST 40 – CHECK

BATTERY CHARGER

SUPPLY VOLTAGE

TEST 41 – CHECK

BATTERY CHARGER

OUTPUT VOLTAGE

TEST 42 – CHECK

WIRE 0/15B

GOOD

BAD

REPAIR OR

REPLACE

BAD

NO BATTERY

SUPPLY VOLTAGE

REPLACE PRINTED

CIRCUIT BOARD

REPAIR OR REPLACE

REPLACE CHARGER

Problem 12 – No Battery Charge

“RTSN & RTSE Transfer Switch”

TEST 43 – CHECK

BATTERY CHARGER

SUPPLY VOLTAGE

TEST 44 – CHECK

BATTERY CHARGER

OUTPUT VOLTAGE

TEST 45 – CHECK

WIRE 0/15B

GOOD

BAD

REPAIR OR

REPLACE

BAD

NO BATTERY

SUPPLY VOLTAGE

REPLACE PRINTED

CIRCUIT BOARD

REPAIR OR REPLACE

REPLACE CHARGER

Problem 13 – No Battery Charge

“GenReady Load Center”

TEST 46 – CHECK

BATTERY CHARGER

SUPPLY VOLTAGE

TEST 47 – CHECK

BATTERY CHARGER

OUTPUT VOLTAGE

TEST 48 – CHECK

WIRE 0/15B

GOOD

BAD

REPAIR OR

REPLACE

BAD

NO BATTERY

SUPPLY VOLTAGE

REPLACE PRINTED

CIRCUIT BOARD

REPAIR OR REPLACE

REPLACE CHARGER

Problem 14 – No Battery Charge

“Load Shed Transfer Switch”

TEST 49 – CHECK

BATTERY CHARGER

SUPPLY VOLTAGE

TEST 50 – CHECK

BATTERY CHARGER

OUTPUT VOLTAGE

TEST 51 – CHECK

WIRE 0/15B

GOOD

BAD

REPAIR OR

REPLACE

BAD

NO BATTERY

SUPPLY VOLTAGE

TRANSFER SWITCH

Part 3

sEctioN 3.3

trouBlEsHootiNG floW cHarts

Page 73

UTILITY CLOSING COIL (C1)

STANDBY CLOSING COIL (C2)

BRIDGE RECTIFIER

MANUAL TRANSFER LEVER

LIMIT SWITCH (SW2)

LIMIT SWITCH (SW3)

N2A A

126

205

sEctioN 3.4

DiaGNostic tEsts

Part 3

TRANSFER SWITCH

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 26 – 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. After confirming that 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 trans-

fer 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.

Page 74

Figure 1. The Transfer Mechanism

TRANSFER SWITCH

MANUAL TRANSFER HANDLE

TRANSFER SWITCH OPERATING LEVER

MANUAL TRANSFER HANDLE

TRANSFER SWITCH OPERATING LEVER

LOAD CONNECTED TO UTILITY POWER SOURCE

LOAD CONNECTED TO STANDBY POWER SOURCE

Part 3

sEctioN 3.4

DiaGNostic tEsts

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, refer to Flow Chart.

teSt 27 – check manual tranSFer

SWitch operation

DISCUSSION: In automatic operating mode, when utility source volt-

age drops below a preset level, the engine should crank and start. On engine startup, an “engine warm-up 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 AUTO-OFF-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, 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 2. 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.

Figure 2. Manual Transfer Switch Operation

Page 75

sEctioN 3.4

DiaGNostic tEsts

Part 3

TRANSFER SWITCH

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, or excessive force required, refer back to flow chart.

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 28 – check 23 and 15B WirinG/

connectionS

DISCUSSION: An open circuit in the transfer switch control wir-

ing can prevent a transfer action from occurring. Battery voltage +12 VDC is supplied on Wire 15B. 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 12 VDC is present on this also. Circuit board action will allow current to flow through the circuit and the (TR) is energized.

PROCEDURE/ RESULTS: Refer to Figure 3.

1. Remove transfer relay mounting screws so that contact movement can be visually observed.

2. Set the generator AUTO-OFF-MANUAL switch to the AUTO position. Turn off utility power supply to the transfer switch, simulating a utility failure. Visually watch the transfer relay for contact movement. The relay should be energized and contact movement seen approximately 10 seconds after the generator starts.

a. If the transfer relay energizes, discontinue

testing. Refer to flow chart.

b. If the transfer relay does not energize, continue

to Step 3.

3. Set the generator AUTO-OFF-MANUAL switch to the OFF position.

4. Remove the battery charger fuse (F3) from the transfer switch to disable the battery charge circuit.

Page 76

caution: after removing the fuse fr om the battery charger, wait 5 minutes before proceeding.

5. Set VOM to measure DC voltage.

6. Connect the negative (-) test lead to Wire 0 at the terminal strip in the transfer switch. Connect the positive (+) test lead to Wire 15B at the terminal strip in the transfer switch.

a. If voltage is present, proceed to Step 7. b. If voltage is not present proceed to Step 17.

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

a. If voltage is present, proceed to Step 8. b. If voltage is not present, set VOM to measure

resistance.

c. Remove Wire 23 and Wire 15B going to the

transfer relay from the transfer switch terminal strip. Connect the meter test leads across Wire 23 and Wire 15B.

d. Transfer coil resistance of approximately 115

ohms should be measured.

e. If coil resistance is not measured, remove

Wire 23 and Wire 15B from the transfer relay. Measure across Terminal A and Terminal B of the transfer relay.

f. If coil resistance is measured repair or replace

Wire 23 or Wire 15B between the terminal strip and the transfer relay.

g. If coil resistance is not measured replace trans-

fer relay and retest.

8. 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 terminal strip.

a. If voltage is present, proceed to Step 9. b. If voltage is not present, repair wiring between

transfer switch and generator control panel.

9. Remove the J2 connector from the circuit board.

10. Set VOM to measure resistance.

11. Connect one meter test lead to Wire 23 Pin Location J2-5. Connect the other meter test lead to Wire 15B Pin Location J2-8. Approximately 115 ohms should be measured. (see Figures 4 through 7, Section 4.1).

a. If approximately 115 ohms is measured proceed

to Step 12.

b. If infinity or an open is measured, repair Wire 23

between PCB Connector J2 and the generator terminal strip.

c. If resistance is not within specification, go to

Test 29 – Test Transfer Relay.

12. Reconnect the J2 connector to the PCB.

TRANSFER SWITCH

15B

COIL NOMINAL RESISTANCE = 120 Ohms

N1A

126

205

Part 3

sEctioN 3.4

DiaGNostic tEsts

13. Set VOM to measure DC voltage.

14. Connect the (-) negative meter test lead to Wire 0 at the terminal strip in the generator. Connect the (+) positive meter test lead to Wire 23 at the terminal strip in the generator. 12 VDC should be measured.

15. Place generator AUTO-OFF-MANUAL switch to the AUTO position. Turn off utility power supply to the transfer switch, simulating a utility failure. After the generator star ts 10 seconds should elapse before transfer occurs. At that time the VOM DC voltage should drop to zero. This indicates the PCB energized the transfer relay.

a. If DC voltage drops to zero, refer to Flow Chart. b. If DC voltage remains constant at 12 VDC, pro-

ceed to Step 16.

16. With the generator running and utility off, ground Wire 23 in the control panel at the terminal strip. If transfer relay energizes and or transfer occurs, replace the PCB.

17. Set VOM to measure DC voltage.

18. Connect the negative (-) test lead to the ground lug in the transfer switch. Connect the positive (+) test lead to Wire 15B at the terminal strip in the transfer switch.

a. If voltage is present repair or replace Wire 0

between transfer switch and generator ground lug.

b. If voltage is not present proceed to Step 19.

19. Connect the negative (-) test lead to the ground lug in the generator control panel. Connect the positive (+) test lead to Wire 15B at the terminal strip in the generator control panel.

a. If voltage is present, repair Wire 15B between

generator ter minal strip and transfer switch terminal strip.

b. If voltage is not present, proceed to Step 20.

20. Remove the J2 connector from the circuit board.

21. Set VOM to measure ohms. Connect one meter test lead to Wire 15B at the control panel terminal strip. Connect the other meter test lead to Wire 15B Pin Location J2-8. Continuity should be measured.

a. If continuity is not measured, repair pin connection

b. If continuity is measured proceed to Step 22.

and or Wire 15B between the J2 connector and terminal strip.

22. Remove the 7.5A fuse.

23. Reconnect J2 connector.

24. Install the 7.5A fuse.

25. Disconnect Wire 15B from the generator terminal strip.

26. Set VOM to measure DC voltage.

caution: after installing the 7.5a fuse and dis-

connecting Wire 15B from the generator termi-

nal strip, wait 5 minutes before proceeding.

27. Connect one meter test lead to Wire 15B. Connect the other meter test lead to Wire 0. 12 VDC should be measured.

a. If 12 VDC is not measured, replace the printed

circuit board.

b. If 12 VDC is measured, a short exists on Wire

15B or the transfer relay is shorted. Repair or replace as needed.

teSt 29 – 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.

Figure 3. Transfer Relay Test Points

PROCEDURE:

1. See Figure 3. Disconnect all wires from the transfer relay, to prevent interaction.

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

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

CONNECT VOM TEST

LEADS ACROSS

Terminals 6 and 9 Continuity Infinity

Terminals 1 and 7 Infinity Continuity

DESIRED METER READING

ENERGIZED DE-ENERGIZED

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Part 3

TRANSFER SWITCH

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.

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 31.

teSt 30 – StandBy control circuit

DISCUSSION: Refer to Figure 4. The standby coil (C2) requires 240

VAC to energize. When the transfer relay is energized, 240 VAC is applied to standby coil C2. Once energized, the coil will pull the transfer switch down to the standby position. Once in the standby position, limit switch SW3 will open, removing AC to standby coil C2.

PROCEDURE/ RESULTS:

1. Set VOM to measure AC voltage.

2. Verify the transfer switch is up in the utility position.

3. Remove Wire E2 from standby coil C2.

a. If 240 VAC is not measured, replace transfer

relay.

b. If 240 VAC is measured, proceed to Step 9.

9. Measure across points A and F. 240 VAC should be measured.

a. If 240 VAC is not measured, repair or replace

Wire 205.

b. If 240 VAC is measured, proceed to Step 10.

10. Measure across points A and G. 240 VAC should be measured.

a. If 240 VAC is not measured, verify limit switch

SW3 is wired correctly. Proceed to Test 33.

b. If 240 VAC is measured, proceed to Step 11.

11. Measure across points A and H. 240 VAC should be measured.

a. If 240 VAC is not measured, repair or replace

Wire B.

b. If 240VAC is measured, replace standby coil C2.

coil nominal resistance is 1-2 megohms.

teSt 31 – check Wire 23

DISCUSSION: Printed circuit board action controls grounding Wire

23 to initiate a transfer to standby. When Wire 23 is grounded the transfer relay (TR1) is energized. To initiate a transfer back to utility the TR1 relay must be de-energized. If Wire 23 is grounded, TR1 will always be energized.

4. Set the generator AUTO-OFF-MANUAL switch in the AUTO position. Turn off the utility power supply to the transfer switch, simulating a utility failure. The generator should start and the transfer relay should energize.

5. Measure across points A and B. 240 VAC should be measured.

a. If 240 VAC is not measured go back to Test 26. b. If 240 VAC is measured, proceed to Step 6.

6. Measure across points C (Wire E2 previously removed) and B. 240 VAC should be measured.

a. If 240 VAC is not measured, repair or replace

Wire E2.

b. If 240 VAC is measured, proceed to Step 7.

7. Measure across points A and D. 240 VAC should be measured.

a. If 240 VAC is not measured, repair or replace

Wire E1.

b. If 240 VAC is measured, proceed to Step 8.

8. Measure across points A and E. 240 VAC should be measured.

Page 78

PROCEDURE/ RESULTS:

1. Set VOM to measure DC voltage.

2. Set the generator AUTO-OFF-MANUAL switch in the OFF position.

3. Connect the positive (+) meter test lead to Wire 15B at the terminal strip in the transfer switch. Connect the negative (-) meter test lead to Wire 23 at the terminal strip in the transfer switch.

a. If 0 VDC is measured, proceed to Step 4. b. If 12 VDC is measured, proceed to Step 6.

4. Set the generator AUTO-OFF-MANUAL switch in the AUTO position.

5. Connect the positive (+) meter test lead to Wire 15B at the terminal strip in the transfer switch. Connect the negative (-) meter test lead to Wire 23 at the terminal strip in the transfer switch

a. If 12 VDC is measured, procced to Step b. b. Navigate to the Digital Output Display Screen

(see Figure 5).

(1) Press “ESC” until the main menu is reached.

TRANSFER SWITCH

A B

7 9

4 6

1 3

TR1

SW1

205

SW3

SW2

1 2

N1 N2

E1 E2

T1 T2

Part 3

sEctioN 3.4

DiaGNostic tEsts

Figure 4. Standby Control Circuit Test Points

Page 79

DEBUG

OUTPUTS

OUTPUT 8

OUTPUTS 1 - 8:

1 0 1 1 0 0 0 1

GENERATOR

TERMINAL STRIP

CUSTOMER SIDE

N1/N2

CONTROL BOARD

CONNECTION

15B

sEctioN 3.4

DiaGNostic tEsts

(2) Press the right arrow key until “Debug” is

flashing. (3) Press “Enter”. (4) Press the right arrow key until “Outputs” is

flashing. (5) Press “Enter”. (6) Digital Output 8 is Wire 23 output from the

board. Refer to Figure 5. (7) If Output 8 shows a “1” then the control

board is grounding Wire 23. Replace the

printed circuit board.

c. If 0 VDC is measured, the Wire 23 circuit is

good. Refer to flow chart.

Part 3

TRANSFER SWITCH

Figure 5. The Home Page, Debug and Output Screens

6. Locate the terminal strip in the generator control panel. Disconnect Wire 23 coming in from the transfer switch (customer connection, side-see Figure 6).

7. Connect the positive (+) meter test lead to Wire 15B at the terminal strip in the generator. Connect the negative (-) meter test lead to Wire 23 just removed from the terminal strip.

a. If 0 VDC is measured, proceed to Step 8. b. If 12 VDC is measured, a short to ground exists

on Wire 23 between the generator and transfer switch. Repair or replace Wire 23 as needed between generator control panel and transfer switch relay (TR1).

8. Locate the terminal strip in the generator control panel. Disconnect Wire 23 coming in from the transfer switch (customer connection, side - see Figure 6).

Page 80

Figure 6. Transfer Relay Test Points

9. Disconnect the J2 connector from the printed circuit board.

10. Set VOM to measure resistance.

11. Connect one meter test lead to Wire 23 connected at generator terminal strip. See Figure 6. Connect the other meter test lead to control panel ground.

a. If INFINITY or open is measured, replace the

printed circuit board

b. If continuity measured, Wire 23 is shorted to

ground. Repair or replace Wire 23 between the J2 connector and the generator terminal strip.

teSt 32 – utility control circuit

DISCUSSION: Printed circuit board action controls grounding Wire

PROCEDURE/ RESULTS: Refer to Figure 7.

1. Turn off utility supply voltage to the transfer switch.

2. Set VOM to measure AC voltage.

3. Set the generator AUTO-OFF-MANUAL switch in the OFF position. Remove Wire 15B from the transfer switch terminal strip.

4. Verify the transfer switch is down in the standby position.

TRANSFER SWITCH

N1A

A B

7 9

4 6

1 3

TR1

SW1

SW3

SW2

N2A

F1 F2 F3

A A A

B B B

1 2

N1 N2

E1 E2

T1 T2

126

Part 3

sEctioN 3.4

DiaGNostic tEsts

Figure 7. Utility Control Circuit Test Points

Page 81

sEctioN 3.4

DiaGNostic tEsts

Part 3

TRANSFER SWITCH

5. Remove Wire N2A from the utility coil C1.

6. Turn on utility power supply to the transfer switch.

a. If transfer to utility occurs, Wire 23 is grounded.

Proceed to Test 31.

b. If transfer to utility does not occur, proceed to

Step 7.

7. Measure across points A and B. 240 VAC should be measured.

a. If 240 VAC is not measured, verify utility source. b. If 240 VAC is measured, proceed to Step 8.

8. Measure across points C (Wire N2A previously removed) and B. 240 VAC should be measured.

a. If 240 VAC is not measured, repair or replace

Wire N2A.

b. If 240 VAC is measured, proceed to Step 9.

9. Measure across points A and D. 240 VAC should be measured.

a. If 240 VAC is not measured, repair or replace

Wire N1A.

b. If 240 VAC is measured, proceed to Step 10.

10. Measure across points A and E. 240 VAC should be measured.

a. If 240 VAC is not measured, repair or replace

Wire N1A.

b. If 240 VAC is measured, proceed to Step 11.

11. Measure across points A and F. 240 VAC should be measured.

a. If 240 VAC is not measured, replace transfer

relay.

b. If 240 VAC is measured, proceed to Step 12.

12. Measure across points A and G. 240 VAC should be measured.

a. If 240 VAC is not measured, repair or replace

Wire 126.

b. If 240 VAC is measured, proceed to Step 13.

13. Measure across points A and H. 240 VAC should be measured.

a. If 240 VAC is not measured, verify limit switch

SW2 is wired correctly. Proceed to Test 33.

b. If 240 VAC is measured, proceed to Step 14.

14. Measure across points A and I. 240 VAC should be measured.

a. If 240 VAC is not measured, repair or replace

Wire A.

b. If 240 VAC is measured, replace utility coil C1.

Coil nominal resistance is 1-2 megohms.

teSt 33 – teSt limit SWitch SW2 and SW3

DISCUSSION: The limit switches are wired to the normally closed

contacts. When the switches are activated the contacts open.

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 SW2/SW3 as follows:

1. To prevent interaction, disconnect Wire 126 and Wire A from limit switch SW2 terminals.

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

3. See Figure 1. Connec t the VOM meter test lea ds 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 CONTINUITY.

5. Manua lly actuate the main contacts to their Utility position. The meter should read INFINITY.

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

7. To prevent interaction, disconnect Wire 205 and Wire B from limit switch SW3 terminals.

8. See Figure 1. Connec t the VOM meter test lea ds across the two outer terminals from which the wires were disconnected.

9. Manually actuate the main contacts to their Standby position. The meter should read INFINITY.

10. Manually actua te the main contacts to their Utility position. The meter should read CONTINUITY.

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

RESULTS:

1. If Limit Switch SW2 or SW3 fails the test, remove and replace the switch or adjust switch until it is actuated properly.

teSt 34 – check FuSeS F1 and F2

DISCUSSION: Fuses F1 and F2 are connected in series with the N1

and N2 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.

Page 82

BLACK

N1A N2A

TRANSFER SWITCH

Part 3

sEctioN 3.4

DiaGNostic tEsts

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 8).

4. Inspect and test fuses for blown condition. With a VOM set to measure resistance, CONTINUITY should be measured across the fuse.

6. Connect the positive meter test lead to Wire N1 at the terminal block in the control panel.

a. Connect the negative meter lead to the ground

lug. INFINITY should be measured.

b. Connect the negative meter lead to Wire

23 at the terminal strip. INFINITY should be measured.

c. Connect the negative meter lead to Wire 15B at

the terminal strip. INFINITY should be measured.

d. Connect the negative meter lead to Wire 0 at the

terminal strip. INFINITY should be measured.

e. Connect the negative meter lead to Wire N2 at the

terminal block. INFINITY should be measured.

f. Connect the negative meter lead to the neutral

connection. INFINITY should be measured.

7. Connect the positive meter test lead to Wire N2 at the terminal block in the control panel.

a. Connect the negative meter lead to the ground

lug. INFINITY should be measured.

b. Connect the negative meter lead to Wire 23 at

the terminal strip. INFINITY should be measured.

c. Connect the negative meter lead to Wire 15B at

the terminal strip. INFINITY should be measured.

d. Connect the negative meter lead to Wire

0 at the terminal strip. INFINITY should be measured.

e. Connect the negative meter lead to the neutral

connection. INFINITY should be measured.

Figure 8. Fuse Holder and Fuses

RESULTS:

1. Replace blown fuse(s) as needed.

teSt 35 – 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 provided.

3. Remove fuses F1, F2, and F3 from the fuse holder (see Figure 7).

4. Remove the generator control panel cover. Disconnect the N1/N2 connector that supplies the printed circuit board located in the control panel (see Figure 6).

5. Set VOM to measure resistance.

RESULTS: If a short is indicated in Step 6 or Step 7, repair wiring

and re-test.

teSt 36 – check n1 and n2 VoltaGe

DISCUSSION: Loss of utility source voltage to the generator will initi-

ate a startup and transfer by the generator. Testing at the control panel terminal block will divide the system in two, thereby reducing troubleshooting time.

PROCEDURE:

1. Set the AUTO-OFF-MANUAL switch to OFF.

2. Set a VOM to measure AC voltage.

3. See Figure 9. Connect one test lead to Wire N1 at the terminal block in the generator control panel. Connect the other test lead to Wire N2. Utility line-to-line voltage should be measured.

RESULTS: Refer to Flow Chart

Page 83

240 VAC

TEST POINTS

N1A N2A

F1 F2 F3

A A A

B B B

sEctioN 3.4

DiaGNostic tEsts

Figure 9. Terminal Block Test Points

teSt 37 – check utility SenSinG

VoltaGe at the circuit Board

Part 3

PROCEDURE: With utility source voltage available to terminal lugs

N1 and N2, use a VOM to test for utility source lineto-line voltage across terminal locations N1 and N2 terminals. Normal line-to-line utility source voltage should be indicated.

TRANSFER SWITCH

DISCUSSION: If the generator starts and transfer to STANDBY

occurs in the automatic mode when acceptable UTILITY source voltage is available at the terminal block, the next step is to determine if sensing voltage is reaching the printed circuit board.

note: the System ready led will flash in auto or utility loSt will display on the panel.

PROCEDURE:

1. Set the AUTO-OFF-MANUAL switch to OFF.

2. Disconnect the N1/N2 connector in the control panel (see Figure 6).

3. Set a VOM to measure AC voltage.

4. Connect one meter test lead to Wire N1. Connect the other meter test lead to Wire N2. Approximately 240 VAC should be measured. See Figure 9.

RESULTS:

1. If voltage was measured in Step 4 and the pin connections are good, replace the circuit board.

2. If voltage was NOT measured in Step 4, repair or replace Wire N1/N2 between connector and terminal block.

teSt 38 – check utility SenSe VoltaGe

The N1 and N2 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.

Page 84

Figure 10. Transfer Switch Fuse Block

RESULTS:

1. If voltage reading across the N1 and N2 terminals is zero or low, refer to Flow Chart.

2. If voltage reading is good, refer to Flow Chart.

teSt 39 – check VoltaGe at terminal

luGS n1, n2

DISCUSSION: If source voltage is not available to N1/N2 terminals,

automatic startup and transfer to STANDBY will occur when the generator AUTO-OFF-MANUAL switch is set to AUTO. This test will prove that “Utility” voltage is available to those terminals, or is not available.

DaNGEr: ProcEED WitH cautioN! HiGH

PROCEDURE:

1. Make sure that all main line circuit breakers in the utility

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.

line to the transfer switch are “On” or “Closed.”

TRANSFER SWITCH

TB1

LEGEND

TRANSFER SWITCH

GENERATOR

LC-CIRCUIT BREAKER (LOADS)

(16 CIRCUIT SHOWN FOR REFERENCE ONLY)

SW1-AUTOMATIC TRANSFER SWITCH

C2-GENERATOR COIL & RECTIFIER

C1-UTILITY COIL & RECTIFIER F1,F2,F3-5A, 600V FUSE

TB1-TERMINAL STRIP

N-NEUTRAL

SW1

SW3

SW2

F1 F2 F3

A A A

B B B

BLK WIRE

RED WIRE

15B

1 2 3

1 2

N1 N2

E1 E2

T1 T2

BC-BATTERY CHARGER

1 52 3 4 76 8 119 10 12 13 14 15 16 17 18

MAIN

CONTROLLER

1 2 3 4

PANEL GND

GROUND

+ BATTERY

TRANS SIG

15B

Part 3

sEctioN X.X

sEctioN 3.4

XXXXXXXXXXXXXXXXXXXXXXXXXXX

DiaGNostic tEsts

Figure 11. Test 40, 41, and 42 “Pre-Wire Load Center” Test Points.

Page 85

sEctioN 3.4

DiaGNostic tEsts

Part 3

TRANSFER SWITCH

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, refer to Flow Chart.

teSt 40 – check Battery charGer

Supply VoltaGe

“pre-Wire load center”

DISCUSSION: The battery charger is supplied with 120 VAC. The

output of the battery charger is 13.4 VDC / 2.5A. PROCEDURE:

Refer to Figure 11.

1. Set VOM to measure AC voltage.

2. Measure across points A and B. 240 VAC should be measured.

a. If 240 VAC is not measured, verify load source

voltage.

b. If 240 VAC is measured go to Step 3.

3. Measure across points A and C. 240 VAC should be measured.

a. If 240 VAC is not measured, repair or replace

Wire T1.

b. If 240VAC is measured, proceed to Step 4.

4. Measure across points A and D. 240 VAC should be measured.

a. If 240 VAC is not measured, replace fuse F3. b. If 240VAC is measured, proceed to Step 5.

5. Remove Fuse F3. Measure across points D and C. 120 VAC should be measured.

a. If 120 VAC is not measured, verify neutral wire

is connected at point E. If good, replace battery charger, then retest.

b. If 120VAC is measured, refer to Flow Chart.

teSt 41 – check Battery charGer

output VoltaGe

“pre-Wire load center”

DISCUSSION: The battery charger is supplied with 120VAC. The out-

put of the battery charger is 13.4 VDC / 2.5A.

Page 86

PROCEDURE: Refer to Figure 11.

1. Set VOM to measure DC voltage.

2. Remove Wire 0 and Wire 15B from transfer switch terminal strip points F and G.

3. Measure across points H and I. Battery supply voltage (12 VDC) should be measured.

a. If battery voltage is not measured, wait 5 minutes

and repeat Step 3.

b. If battery supply voltage is still not available,

refer to Flow Chart.

c. If battery voltage is measured, proceed to Step 4.

4. Reconnect Wire 0 and Wire 15B previously removed in Step 2.

5. Measure across points H and I. 13.4 VDC should be measured.

a. If 13.4 VDC is not measured, replace the

battery charger

b. If 13.4 VDC is measured, the charger is working.

*note: Battery charger voltage will be higher than battery supply voltage.

teSt 42 – check Wire 0 and Wire15B

“pre-Wire load center”

DISCUSSION: In order for the battery charger to function, battery supply

voltage must be available to the battery charger. PROCEDURE:

Refer to Figure 11.

1. Set VOM to measure DC voltage.

2. Disconnect Wire 0 and Wire 15B from generator terminal strips, locations J and K.

3. Wait five (5) minutes after removing wires.

4. Measure across points L and M on the terminal strip. 12 VDC should be measured.

a. If 12 VDC is measured, proceed to Step 6. b. If 12 VDC is not measured, proceed to Step 5.

5. Measure across points M and N. 12 VDC should be measured.

a. If 12 VDC is measured, repair or replace Wire

0 between the generator terminal strip and the ground lug.

b. If 12 VDC is not measured, proceed to Step 8.

6. Set VOM to measure resistance.

7. Connect the meter test leads across the disconnected Wire 0 and Wire 15B. Approximately 115 Ohms should be measured.

TRANSFER SWITCH

Part 3

sEctioN 3.4

DiaGNostic tEsts

a. If 115 Ohms is measured, proceed to Step 10. b. If zero resistance or CONTINUITY is measured,

connect the meter test leads across Terminals A and B on the transfer relay (TR1)

c. If zero resistance is measured, a short exists.

Replace TR1.

d. If 115 Ohms is measured, repair or replace

Wire 15B between the generator and the transfer switch.

8. Set VOM to measure resistance.

9. Disconnect the J2 connector from the printed circuit board.

10. Measure across point M and pin location J2-8 of the connector just removed. Continuity should be measured.

a. If continuity is not measured, repair or replace

Wire 15B between the J2 connector and the terminal strip.

b. If continuity is measured and the pin connection

looks good, the internal fuse on the PCB has failed. Replace printed circuit board.

teSt 43 – check Battery charGer

Supply VoltaGe

“rtSn & rtSe tranSFer SWitch”

DISCUSSION: The battery charger is supplied with 120 VAC. The

output of the battery charger is 13.4 VDC/2.5A. PROCEDURE:

Refer to Figure 12 or Figure 12A.

1. Set VOM to measure AC voltage.

2. Measure across points A and B. 240 VAC should be measured.

a. If 240 VAC is not measured, verify load source

voltage.

b. If 240 VAC is measured, proceed to Step 3.

3. Measure across points A and C. 240 VAC should be measured.

a. If 240 VAC is not measured, repair or replace

wire between fuse block and T1 terminal.

b. If 240VAC is measured, proceed to Step 4.

4. Measure across points A and D. 240 VAC should be measured.

a. If 240 VAC is not measured, replace 5A fuse. b. If 240 VAC is measured, proceed to Step 5.

5. Measure across points E and F. 120 VAC should be measured.

a. If 120 VAC is not measured, repair or replace

supply wires BC line and BC 00.

b. If 120 VAC is measured, refer to flow chart.

teSt 44 – check Battery charGer

output VoltaGe

“rtSn & rtSe tranSFer SWitch”

DISCUSSION: The battery charger is supplied with 120 VAC. The

output of the battery charger is 13.4 VDC/2.5A. PROCEDURE:

Refer to Figure 12 or Figure 12A.

1. Set VOM to measure DC voltage.

2. Remove and isolate battery charger black and red leads from generator terminal strip points G and H.

3. Measure across points G and H. Battery supply voltage (12 VDC) should be measured.

a. If battery voltage is not measured, wait 5 minutes

and repeat Step 3. If battery supply voltage is still not available, refer to Flow Chart.

b. If battery voltage is measured, proceed to Step 4.

4. Reconnect battery charger black and red lead wires previously removed in Step 2.

5. Measure across points G and H. 13.4 VDC should be measured.

a. If 13.4 VDC is not measured, replace the

battery charger

b. If 13.4 VDC is measured, the charger is working.

*note : Battery charger voltage will be higher than battery supply voltage.

teSt 45 – check Wire 0/15B

“rtSn & rtSe tranSFer SWitch”

DISCUSSION: In order for the battery charger to function, battery supply

voltage must be available to the battery charger. PROCEDURE:

Refer to Figure 12 or Figure 12A.

1. Set VOM to measure DC voltage.

2. Remove and isolate battery charger black and red leads from generator terminal strip points G and H.

3. Measure across points G and H on the terminal strip. 12VDC should be measured.

a. If 12 VDC is measured, the charger should be

functioning.

b. If 12 VDC is not measured, proceed to Step 4.

4. Remove Wire 0 and Wire 15B from generator terminal strip locations G and H.

5. Wait five (5) minutes after removing wires.

Page 87

WHITE

GREEN

15B

DETAIL

BC 00

BC LINE

N2 N1

15B

194

UTILITY SUPPLY FROM

SERVICE DISCONNECT

TO GROUNDING

ELECTRODE

NEUTRAL BLOCK

(DISTRIBUTION PANEL)

GROUND

BC LINE

BC 00

5 AMP

FUSE

T1 T2

CUSTOMER LOAD

RTS TRANSFER SWITCH

T1 T2

(C2 & VR2)

STANDBY

E1 E2

(C1 & VR1)

UTILITY

N1 N2

15B

sEctioN 3.4

DiaGNostic tEsts

Part 3

TRANSFER SWITCH

Page 88

Figure 12. Test 43, 44, and 45 “RTSN Transfer Switch” Test Points.

TRANSFER SWITCH

WHITE

GREEN

15B

BC 00

BC LINE

TO GROUNDING

ELECTRODE

SERVICE DISCONNECT ATS

BC LINE BC 00

FUSE

N2 N1

5 AMP

SOCKET

METER

UTILITY

PANELBOARD

15B

T1 T2

E1E2

N2N1

DETAIL

15B

Part 3

sEctioN 3.4

DiaGNostic tEsts

Figure 12A. Test 43, 44, and 45 “RTSE Transfer Switch” Test Points.

Page 89

sEctioN 3.4

DiaGNostic tEsts

Part 3

TRANSFER SWITCH

6. Measure across points G and H on the terminal strip. 12 VDC should be measured.

a. If 12 VDC is measured, proceed to Step 8. b. If 12 VDC is not measured, proceed to Step 7.

7. Measure across point H and ground lug. 12 VDC should be measured.

a. If 12 VDC is measured, repair or replace Wire

0 between the generator terminal strip and the ground lug.

b. If 12 VDC is not measured, proceed to Step 8.

8. Set VOM to measure resistance.

9. Connect the meter test leads across the disconnected Wire 0 and Wire 15B. Approximately 115 Ohms should be measured.

a. If 115 Ohms is measured, proceed to Step 11. b. If zero resistance or CONTINUITY is measured,

connect the meter test leads across Terminals A and B on the transfer relay (TR1)

c. If zero resistance is measured, a short exists.

Replace TR1.

d. If 115 Ohms is measured, repair or replace

Wire 15B between the generator and the transfer switch.

10. Disconnect the J2 connector from the printed circuit board.

11. Measure across point M and pin location J2-8 of the connector just removed. CONTINUITY should be measured.

a. If CONTINUITY is not measured, repair or

replace Wire 15B between the J2 connector and the terminal strip.

b. If CONTINUITY was measured and the pin con-

nection looks good, the internal fuse on the PCB has failed. Replace the printed circuit board.

teSt 46 – check Battery charGer

Supply VoltaGe

“Genready load center”

b. If 120 VAC is measured, proceed to Step 3.

3. Measure across points C and D. 120 VAC should be measured.

a. If 120 VAC is not measured, repair or replace

Wire BC LINE or BC 00 between the load center and the generator.

b. If 120 VAC is measured, refer to Flow Chart.

teSt 47 – check Battery charGer

output VoltaGe

“Genready load center”

DISCUSSION: The battery charger is supplied with 120VAC. The

output of the battery charger is 13.4 VDC / 2.5A. PROCEDURE:

Refer to Figure 13.

1. Set VOM to measure DC voltage.

2. Remove and isolate battery charger black and red leads from generator terminal strip points E and F.

3. Measure across points E and F. Battery supply voltage (12 VDC) should be measured.

a. If battery voltage is not measured, wait 5 min-

utes and repeat Step 3. If battery supply voltage is still not available, refer to Flow Chart.

b. If battery voltage is measured, proceed to Step 4.

4. Reconnect battery charger black and red lead wires previously removed in Step 2.

5. Measure across points E and F. 13.4 VDC should be measured.

a. If 13.4 VDC is not measured, replace the

battery charger.

b. If 13.4 VDC is measured, the charger is working.

*note: Battery charger voltage will be higher than battery supply voltage.

DISCUSSION: The battery charger is supplied with 120VAC. The

output of the battery charger is 13.4 VDC / 2.5A. PROCEDURE:

Refer to Figure 13.

1. Set VOM to measure AC voltage.

2. Measure across points A and B. 120 VAC should be measured.

a. If 120 VAC is not measured, verify that load

source voltage is available, and that the duplex circuit breaker in ON.

Page 90

teSt 48 – check Wire 0/15B

“Genready load center”

DISCUSSION: In order for the battery charger to function, battery supply

voltage must be available to the battery charger. PROCEDURE:

Refer to Figure 13.

1. Set VOM to measure DC voltage.

2. Remove and isolate battery charger black and red leads from generator terminal strip points E and F.

TRANSFER SWITCH

CONNECTION PANEL

BC-LINE

GEN-READY

LOAD CENTER

DUPLEX BREAKER

BC-00

UTILITY

SOCKET

METER

ENGINE GENERATOR

WHITE

GREEN

BC 00

15B

BC LINE

DETAIL

BC 00

BC LINE

15B

Part 3

sEctioN 3.4

DiaGNostic tEsts

Figure 13. Test 46, 47, and 48 “GenReady Load Center” Test Points.

Page 91

sEctioN 3.4

DiaGNostic tEsts

Part 3

TRANSFER SWITCH

3. Measure across points G and H on the terminal strip. 12VDC should be measured.

a. If 12 VDC is measured, the charger should be

functioning.

b. If 12 VDC is not measured, proceed to Step 4.

4. Remove Wire 0 and Wire 15B from generator terminal strip locations E and F.

5. Wait five (5) minutes after removing wires.

6. Measure across points E and F on the terminal strip. 12 VDC should be measured.

a. If 12 VDC is measured, proceed to Step 8. b. If 12 VDC is not measured, proceed to Step 7.

7. Measure across point H and ground lug. 12 VDC should be measured.

a. If 12 VDC is measured, repair or replace Wire

0 between the generator terminal strip and the ground lug.

b. If 12 VDC is not measured, proceed to Step 8.

8. Set VOM to measure resistance.

9. Connect the meter test leads across the disconnected Wire 0 and Wire 15B. Approximately 200 Ohms should be measured.

a. If 200 Ohms is measured, proceed to Step 11. b. If zero resistance or CONTINUITY is measured,

connect the meter test leads across BAT- and XFER on the load center motor.

c. If zero resistance is measured, a short exists.

Replace the load center motor.

d. If 200 Ohms to INFINITY is measured, repair

or replace Wire 15B between the generator and the load center.

10. Disconnect the J2 connector from the printed circuit board.

11. Measure across point M and pin location J2-8 of the connector just removed. CONTINUITY should be measured.

a. If CONTINUITY is not measured, repair or

replace Wire 15B between the J2 connector and the terminal strip.

b. If CONTINUITY is measured and the pin con-

nection looks good, the internal fuse on the PCB has failed. Replace the printed circuit board.

PROCEDURE: Refer to Figure 14.

1. Set VOM to measure AC voltage.

2. Measure across points A and B. 240 VAC should be measured.

a. If 240 VAC is not measured, verify load source

voltage at ATS.

b. If 240 VAC is measured, proceed to Step 3.

3. Measure across points A and C. 240 VAC should be measured.

a. If 240 VAC is not measured, repair or replace

Wire T1 between LSS and J3 terminal of load shed controller.

b. If 240VAC is measured, proceed to Step 4.

4. Measure across points C and D. 120 VAC should be measured.

a. If 120 VAC is not measured, repair or replace

Wire 00 between J3 terminal and neutral block (NB).

b. If 120 VAC is measured, proceed to Step 5.

5. Measure across points E and D. 120 VAC should be measured.

a. If 120 VAC is not measured, replace fuse F3 on

load shed controller.

b. If 120 VAC is measured, proceed to Step 6.

6. Measure across points E and F. 120 VAC should be measured.

a. If 120 VAC is not measured, replace load shed

controller.

b. If 120 VAC is measured, refer to Flow Chart.

teSt 50 – check Battery charGer

output VoltaGe

“load Shed tranSFer SWitch”

DISCUSSION: The battery charger is supplied with 120 VAC. The

output of the battery charger is 13.4 VDC/2.5A. PROCEDURE:

Refer to Figure 14.

1. Set VOM to measure DC voltage.

teSt 49 – check Battery charGer

Supply VoltaGe

“load Shed tranSFer SWitch”

DISCUSSION: The battery charger is supplied with 120 VAC. The

output of the battery charger is 13.4 VDC/2.5A.

Page 92

2. Remove and isolate battery charger black and red leads from generator terminal strip points G and H.

3. Measure across points G and H. Battery supply voltage (12 VDC) should be measured.

a. If battery voltage is not measured, wait 5 min-

utes and repeat Step 3. If battery supply voltage is still not available, refer to Flow Chart.

b. If battery voltage is measured, proceed to Step 4.

TRANSFER SWITCH

FUSE, 2AF3

GROUND LUG

LIMIT SWITCHES, ACTUATOR

RELAY, TRANSFER

UTILITY CIRCUIT BREAKER

NB - NEUTRAL BLOCK

LOAD SHED CONTROLLER

RELAY, LOAD SHED

LOAD SHED TRANSFER SWITCH CONTACTOR

XA1,XB1

UCB

GNDLSLSC

LSS

SOLENOID COIL (LSS-OFF)

SOLENOID COIL (LSS-ON)

FUSE, 5A

TRANSFER SWITCH CONTACTOR

SOLENOID COIL (UTILITY CLOSING)

SOLENOID COIL (STANDBY CLOSING)

BATTERY CHARGER

F1,F2

C1A

C2A

ATS

LEGEND

(C2A)

T2 T1

XB1

XA1

(C1A)

LSS

E2 E1

N2 N1

(C2)

T1 T2

ATS

XB1

(C1)

XA1

WHT

CONNECTION

CUSTOMER

15B

321

1 2

LSC

OUTPUT

RED

BLK

6 565 4 4

8 7

9 8

2 13

1 432

13 2

6 75

CONTROLLER

LOAD SHED

INPUT

WHT

BLK

NON-ESSENTIAL

LOAD CONNECTION

OUTPUT CONNECTION GENERATOR

E1A

A A

1 2 3 54 6

Part 3

sEctioN 3.4

DiaGNostic tEsts

Figure 14. Test 49, 50, and 51 “Load Shed Transfer Switch” Test Points.

Page 93

sEctioN 3.4

DiaGNostic tEsts

Part 3

TRANSFER SWITCH

4. Reconnect battery charger black and red lead wires previously removed in Step 2.

5. Measure across points G and H. 13.4 VDC should be measured.

a. If 13.4 VDC is not measured, replace the

battery charger.

b. If 13.4 VDC is measured, the charger is working.

*note: Battery charger voltage will be higher than battery supply voltage.

teSt 51 – check Wire 0 and Wire 15B

“load Shed tranSFer SWitch”

DISCUSSION: In order for the battery charger to function, battery supply

voltage must be available to the battery charger. PROCEDURE:

Refer to Figure 14.

1. Set VOM to measure DC voltage.

2. Remove and isolate battery charger black and red leads from terminal strip points G and H.

3. Measure across points I and J on the terminal strip. 12 VDC should be measured.

a. If 12 VDC is measured, the charger should be

functioning.

b. If 12 VDC is not measured, proceed to Step 4.

4. Remove Wire 0 and Wire 15B from generator terminal strip. Refer to Figure 6.

5. Wait five (5) minutes after removing wires.

6. Measure across points J and K on the terminal strip. Refer to Figure 6. 12 VDC should be measured.

a. If 12 VDC is measured, proceed to Step 8. b. If 12 VDC is not measured, proceed to Step 7.

7. In the generator control panel, measure across Wire 15B and Wire 0 at the customer connection. 12 VDC should be measured.

a. If 12 VDC is measured, repair or replace Wire

0 or Wire 15B between the generator terminal strip and the ground lug.

b. If 12 VDC is not measured, proceed to Step 5.

8. Set VOM to measure resistance.

9. Connect the meter test leads across the disconnected Wire 0 and Wire 15B. Approximately 115 Ohms should be measured.

a. If 115 Ohms is measured, proceed to Step 11. b. If zero resistance or CONTINUITY is measured,

connect the meter test leads across locations J and k on the load shed controller, Figure 12.

c. If zero resistance is measured, a short exists.

Replace the transfer relay (TR).

d. If 200 115 is measured, repair or replace Wire

15B between the generator and the transfer switch.

10. Disconnect the J2 connector from the printed circuit board.

11. In the generator control panel, measure across Wire 15B at the customer connection and pin location J2-8 of the connector just removed. CONTINUITY should be measured.

a. If CONTINUITY is not measured, repair or

replace Wire 15B between the J2 connector and the terminal strip.

b. If CONTINUITY is measured, proceed to Step 12.

12. In the generator control panel, measure across Wire 0 at the customer connection and the ground lug. CONTINUITY should be measured.

a. If CONTINUITY is not measured, repair or

replace Wire 0 between the customer connection and the ground lug.

b. If CONTINUITY is measured and the pin con-

nection of J2 looks good, the internal fuse on the PCB has failed. Replace the printed circuit board.

Page 94

Part 4

Dc coNtrol

air-cooled, automatic

standby Generators

taBlE of coNtENts

Part titlE PaGE#

4.1. Description and components 76

4.2 operational analysis 82

4.3 troubleshooting flow charts 96

4.4 Diagnostic tests 103

4.1 Description and Components ....................................96

General ...................................................................96

Terminal Strip / Interconnection Terminal .................96

Circuit Board ............................................................96

Auto-Off-Manual Switch ........................................... 96

7.5 Amp Fuse ...........................................................96

Menu System Navigation ....................................... 102

4.2 Operational Analysis ...............................................104

Introduction ............................................................104

Utility Source Voltage Available ..............................104

Initial Dropout of Utility Source Voltage ..................106

Utility Voltage Dropout and

Engine Cranking ......................................108

Engine Startup and Running ..................................110

Initial Transfer to the “Standby” Source ..................112

Utility Voltage Restored /

Re-transfer to Utility .................................114

Engine Shutdown ...................................................116

4.3 Troubleshooting Flowcharts .....................................118

Problem 15 – Engine Will Not Crank

When Utility Power Source Fails .......................118

Problem 16 – Engine Will Not Crank When AUTO-OFF-MANUAL Switch

is Set to “MANUAL ............................................ 118

Problem 17 – Engine Cranks

but Won’t Start ...................................................119

Problem 18 – Engine Starts Hard and

Runs Rough / Lacks Power / Backfires .............120

Problem 19 – Shutdown Alarm /

Fault Occurred ...................................................121

Problem 20 – 7.5 Amp Fuse (F1) Blown ........... 122

Problem 21 – Generator Will Not Exercise ........122

Problem 22 – No Low Speed Exercise ..............122

4.4 Diagnostic Tests ......................................................123

Introduction ...........................................................123

Test 56 – Check Position Of

Auto-Off- Manual Switch ......................... 123

Test 57 – Try a Manual Start .................................123

Test 58 – Auto-Off-Manual Switch

(V-Twin Only) ............................................123

Test 59 – Test Auto Operations ..............................124

Test 60 – Check 7.5 Amp Fuse ..............................124

Test 61 – Check Battery .........................................124

Test 62 – Check Wire 56 Voltage ...........................126

Test 63 – Test Starter Contactor Relay

(V-twin Only) ............................................126

Test 64 – Test Starter Contactor

(Single Cylinder Engine) ..........................127

Test 65 – Test Starter Motor ...................................128

Test 66 – Check Fuel Supply and Pressure ...........130

Test 67 – Check Circuit Board

Wire 14 Output .........................................131

Test 68 – Check Fuel Solenoid ..............................132

Test 69 – Check Choke Solenoid ...........................132

Test 70 – Check for Ignition Spark ......................... 134

Test 71 – Check Spark Plugs .................................136

Test 72 – Check Engine / Cylinder Leak

Down Test / Compression Test .................136

Test 73 – Check Shutdown Wire ............................137

Test 74 – Check and Adjust

Ignition Magnetos .....................................138

Test 75 – Check Oil Pressure Switch

and Wire 86 ..............................................141

Test 76 – Check High Oil

Temperature Switch .................................142

Test 77 – Check and Adjust Valves ........................142

Test 78 – Check Wire 18 Continuity .......................143

Test 79 – Test Exercise Function............................144

Test 80 – Check Cranking and

Running Circuits .......................................144

Test 81 – Check to see if Low Speed

Function is enabled ..................................146

Test 82 – Check operation of the

Choke Solenoid ........................................146

Page 95

TERMINAL STRIP

15B

sEctioN 4.1

DEscriPtioN aND comPoNENts

Part 4

DC 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:

• ATerminalStrip/InterconnectionTerminal

• ACircuitBoard.

• AnAUTO-OFF-MANUALSwitch.

• A7.5AmpFuse.

terminal Strip / interconnection

terminal

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

The terminal board provides the following connection points:

A. UTILITY 1 and UTILITY 2

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

B. 23 and 15B

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

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

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, overspeed, no RPM sense, overcrank, or low battery.

An 18-pin and a 4-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.

If the Utility sensing voltage drops below a preset value, circuit board action will initiate automatic generator star tup and transfer to the “Standby” source side.

The crank relay and fuel solenoid valve are energized by circuit board action at the same time.

DIGITAL INPUT/OUTPUT FUNCTIONS:

Postion Digital inputs Digital outputs

1 Low Oil Pressure Not Used 2 High Temperature Not Used 3 Internal Use Not Used 4 Internal Use Not Used 5 Internal Use Fuel 6 Not Used Starter 7 Auto Ignition 8 Manual Transfer

Page 96

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

Figure 1. Terminal Strip

manually, or (c) stop the engine and prevent automatic startup. Switch terminals are shown pictorially and schematically in Figure 6, below.

DIVIDER PANEL

TO ENGINE

1. CONTROL PANEL

2. 7.5 AMP FUSE

3. STARTER CONTACTOR RELAY (10-20 KW)

4. 4 POSITION TERMINAL BLOCK

5. TERMINAL BLOCK

6. CIRCUIT BREAKER (8KW)

7. 15 AMP GFCI DUPLEX OUTLET

(17 & 20 KW)

8. CIRCUIT BREAKER (17 & 20 KW)

9. CIRCUIT BREAKER (10-20 KW)

10. LED DISPLAY

DC CONTROL

Part 4

7.5 amp FuSe

This fuse protects the circuit board against excessive current. If the fuse has blown, engine cranking and operation will not be possible. Should fuse replacement become necessary, use only an identical 7.5 amp replacement fuse.

sEctioN 4.1

DEscriPtioN aND comPoNENts

Figure 2. A Typical 7.5 Amp Fuse

Figure 3. Control Panel Component Identification

Page 97

J2 J1

J2 CONNECTOR (HARNESS END)

N1/N2 CONNECTOR

(HARNESS END)

N1/N2 CONNECTOR

(PCB END)

10 11 12 13 14 15 16 17 18

1 2

3 4 1 2 3 4 5 6 7 8 9

101112131415161718

123456789

101112131415161718

34 12

3456789

J1 CONNECTOR (HARNESS END)

J2 CONNECTOR

(PCB END)

J1 CONNECTOR

(PCB END)

1 2

sEctioN 4.1

DEscriPtioN aND comPoNENts

Part 4

DC CONTROL

PiN WirE circuit fuNctioN

J1-1 85 High temperature shutdown:

J1-2 86 Low oil pressure shutdown: Shutdown

J1-3 13 12 VDC source voltage for the circuit

J1-4 18 Ignition Shutdown: Circuit board

J2-1 0 INTERNAL USE J2-2 0 INTERNAL USE J2-3 14 12 VDC output for engine run condi-

J2-5 23 Switched to ground for transfer relay

J2-6 NOT USED

Shutdown occurs when Wire 85 is grounded by contact closure in HTO

occurs when Wire 86 is grounded by loss of oil pressure to the LOP

Figure 4. 8 kW Printed Circuit Boards and J1 Connector

8 kW J1 connector Pin Descriptions

board

action grounds Wire 18 for ignition shutdown.

tion. Used for fuel solenoid.

operation

PiN WirE circuit fuNctioN

J2-7 NOT USED J2-8 15B Provides an electrical connection for

J2-9 NOT USED

J2-10 0 Common Ground J2-11 56 12 VDC output to starter contactor for

J2-15 NOT USED J2-16 NOT USED J2-17 NOT USED

J2-18 NOT USED Wired Plug 1 N1 240 VAC sensing for control board. Wired Plug 2 N2 240 VAC sensing for control board.

charge current to reach the battery from the battery charger. Provides 12VDC to the Transfer Relay

single cylinder engines.

Page 98

Generac 13 kW NG, 9 kW NG, 8 kW LP, 16 kW NG, 14 kW LP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ElEctrical formulas

contents

sPEcificatioNs

Generator

engine

Fuel Consumption

mountinG dimenSionS

major FeatureS

GENErator iDENtificatioN

iNstallatioN Basics

introduction

SelectinG a location

GroundinG the Generator

the Fuel Supply

the tranSFer SWitch / load center

poWer Source and load lineS

natural GaS Fuel interconnectionS

SyStem control interconnectionS

non-PrePackaged interconnectionS

PrEParatioN BEforE usE

Fuel requirementS

Fuel conSumption

reconFiGurinG the Fuel SyStem

enGine oil recommendationS

tEstiNG, clEaNiNG aND DrYiNG

meterS

the Vom

meaSurinG ac VoltaGe

meaSurinG dc VoltaGe

meaSurinG ac Frequency

meaSurinG current

meaSurinG reSiStance

electrical unitS

ohm’S laW

ViSual inSpection

inSulation reSiStance

the meGohmmeter

cleaninG the Generator

dryinG the Generator

ENGiNE-GENErator ProtEctiVE DEVicEs

loW Battery

loW oil preSSure ShutdoWn

oVerSpeed ShutdoWn

rpm SenSor Failure

hiGh temperature SWitch

oVercrank ShutdoWn

oPEratiNG iNstructioNs

control panel

to Select automatic operation

automatic oPEratiNG ParamEtErs

introduction

introduction

enGine-Generator driVe SyStem

the ac Generator

rotor aSSemBly

Stator aSSemBly

other ac Generator componentS

oPEratioNal aNalYsis

rotor reSidual maGnetiSm

Field BooSt (12-20 kW)

operation (8/10 kW)

operation (12-20 kW)

trouBlEsHootiNG floWcHarts

DiaGNostic tEsts

introduction

SaFety

teSt 1 – check main circuit Breaker

teSt 2 – check ac output VoltaGe

teSt 5 – Wire continuity (12-20 kW)

teSt 6 – check Field BooSt (12-20 kW)

teSt 8 – teSt BruShleSS Stator

teSt 9 – check capacitor

teSt 14 – check ac output Frequency

teSt 20 – check enGine condition

General

encloSure