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

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

E x I
1000

kW x 1000

E

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

I

E
R

E

I

E
R

contents

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

0.123-0.1439

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

0.090-0.105 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

14

25

29

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.

Page 11

sEctioN 1.2

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.

sEctioN 1.3

NoN-PrEPacKaGED iNtErcoNNEctioNs

Figure 3. Wire Connections

Figure 4. Pre-2008 HSB Interconnections

Page 15

DANGER

sEctioN 1.4

PrEParatioN BEforE usE

Part 1

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:

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.

sEctioN 1.4

PrEParatioN BEforE usE

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

sEctioN 1.4

PrEParatioN BEforE usE

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.

Page 18

GENERAL INFORMATION

Part 1

sEctioN 1.5

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.

Page 19

1.00 A

BATTERY

+-

RELAY

sEctioN 1.5

tEstiNG, clEaNiNG aND DrYiNG

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)

Part 1

sEctioN 1.5

tEstiNG, clEaNiNG aND DrYiNG

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

VoltS

=

Page 21

sEctioN 1.5

tEstiNG, clEaNiNG aND DrYiNG

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

+1

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

2

6

11P

44

33

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)

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.

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.

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.

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

L

O

O

S

E

N

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.

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