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Giant Bicyle Bicycle User Manual

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3. DIAGRAM KEY BA BRUSH ASSEMBLY ENGINE WIRING BCR BATTERY CHARGE RELAY MAIN OUTPUT BREAKER CBe CIRCUIT BREAKER ALTERNATOR EXCITATION D DIODE DSW PCE MOUNTED DIP SWITCH FS FUEL SOLENOID Fl FUSE 15 AMP BATTERY Fe FUSE 5 CHARGER 2 GRD CONTROL PANEL GROUND i T HIGH OIL TEMPERATURE SWITCH 0 1 INLINE CONNECTOR INTERCONNECTION TERMINALS 225B IM IGNITION MODULE FS 2248 SC STARTER CONTACTOR 0 I SP SPARK PLUG SW1 AUTO Z OFF MANUAL SWITCH 0 ve SWe SET EXERCISE SWITCH SM STARTER MOTOR T INSULATED TERMINAL BLOCK TX TRANSFORMER 16 Voc 56 VA 14 amp 16 Vac 1 VA DUAL SEC 14 elole E T TB D 0 0 SP T 0 gt 6 0 18 gt 5 gt 14 85 gt 4 85 86 gt IC 0 13 gt 2 13 13 EMEN gt 1 gt C1 88 TC 18 LOP 56 56 PS 351 13 56 85 56 x 1 3 4 5 Je 4 Ji lt 23 SG 194 CONTROL xi 56 PRINTED CIRCUIT BOARD 7 18 66A BLACK RED DSW 239 d z 13A 16 C hk 5 F ON INDICATES 225 1 20 Vac Sense Transformer 2 224 TO q 2 Remote Not Auta 12V 3 50 Hz Operation BATTERY
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5. y 240VAC GENERATOR OUTPUT TO LOAD Figure 6 Circuit Condition Utility Voltage Restored SECTION 4 2 OPERATIONAL ANALYSIS DC CONTROL RE C2 1 sc Q BATTERY TRANSFER 12V RELAY o a SUPPLIED O 15 sc o 13 15A e 23 15 15 dia PUT 194 239 Res 17 j 13 EE i i Ti 1 240VAC PES gt GENERATOR IM2 gt SP2 OUTPUT 56VA i BLACK 14 BO 0 ba 1 SW1 3 CUSTOMER 225 224 17 225A 15A 0 Omm 1 1d 15 le CB1 224 23 194 l 15 B w 66A B 15 0 U 3 Gss 111 _ 225 POWER 120V WINDING STATOR 225A 11213 7 10 11 1 2 5 m UTILITY VOLTAGE C2 6 SENSING HTO C1 4 C2 L V 12VDC PCB SUPPLY ENGINE RUN WINDING 66 CONTROL 12VDC PRINTED CIRCUIT BOARD BATTERY CHARGE WINDING BATTERY CHARGER DIAGRAM KEY BA BRUSH ASSEMBLY BATTERY CHARGE RELAY DPE WINDING CB1 CIRCUIT BREAKER MAIN OUTPUT STATOR 2 CIRCUIT BREAKER ALT EXCITATION D DIODE FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 5 AMP HTO HIGH OIL TEMPERATURE SWITCH IM1 IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOP LOW GIL PRESSURE SWITCH SC STARTER CONTACTER SCR STARTER GONTACTOR RELAY EL
6. I WN VA 9i 9 WA 9 amp 29 9L AaS TUNIKA CALY ISN H SOLON 5314915 HS 0 HOLIAS 381038341 13 amp ZAS 21185 Z Z TAS 0 Sa 5 lds AWTSN 2 M3IMVIS NUR MDIOMINDI H3lHVWiS 25 AW 138 Hi 310W3H 21185 SESS aed TO AUT SD 0 HANI UI ACYIUM ZWI TH NH3GNITA2 3YWILDM MELLINSI STWMIMN31 NOLLIJNNOIJNHIUNI LM MD IZGMNHDUS ITNI 21 43 94 HH HH 3SBLW333431L qawa 7031405 qug 1535112 3 J3NVd D31NU2 T ves 5 GIONS OS Gnd 54 HZLIAS did A 1 112 3 MHULVNH31 TWW H3sv3HH LINISHI SEJ h 330938 IAD HIVM 189 AVTIH JAAHA AMELIE 38 783559 HAME AIA WS DT W to vir WIRING DIAGRAM 12 amp 15 KW HOME STANDBY DRAWING 0C7830 C MODEL 4456 0 amp 4390 0 Page7 1 3 2995 WG VA L 2A 9 9 VA 9G 9DA 91 MJ3NMOJSNVML
7. F1 126 Es N1 7 E1 E1 ET S205 N2A T T 4 T 240VAC GENERATOR OUTPUT p TO LOAD Figure 7 Circuit Condition Retransfer to Utility and Engine Shutdown DC CONTROL PART 4 SECTION 4 2 OPERATIONAL ANALYSIS C2 1 V SC Q BATTERY TRANSFER 12V RELAY 194 COIL BLACK S CUSTOMER SUPPLIED Q 15 13 gt mS 15A ES 23 15 15 xL ota 13 Gen 18 ga TTT GENERATOR OUTPUT 0 56VA 15 224 _ 225 17 7 13 18 225A 1 15A 0 1 CBI 24 13 15 T 225 239 POWER 120 WINDING STATOR 225A NEUTRAL 11213 5 7 10 11 12 13 14 15 16 17 2 5 UTILITY VOLTAGE SENSING 12VDC PCB SUPPLY ENGINE RUN WINDING 4 CONTROL 12VDC PRINTED CIRCUIT BOARD BATTERY CHARGE WINDING DIAGRAM KEY BATTERY CHARGER BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY CB1 CIRCUIT BREAKER MAIN OUTPUT DPE WINDING CB2 CIRCUIT BREAKER ALT EXCITATION STATOR D DIODE FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 5 AMP HTO HIGH OIL TEMPERATURE SWITCH M1 IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTER SCR STARTER CONTACTOR RELAY SP1 SP2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH REGULATOR SM STAR
8. vi d At LV ej dE Al un 1051409 AIHAdSSV HS W8 vg ABddLllva T T c dt 3 vi 9 gt 9 B56 AJM WVAOVIC vol Ae A Em JN i229 vl 11 v99 bn q3 gt I 6 2 M 7 S YSI 901915 gt DNIGNIM 999 zu T 7 LU bl cae 622 t Sg e T vo 98 y 9 19 291 ele 7 elle 9 RUE 77 622 5 MD LV 0938 399170 GIDIVIS 6 2 N O2IND312313 DNIQNIM X3JMOd E 61 907 x WS EN Ea I Tum 113 pest i 99 JOSHI AIL I GI r BuHT ple LL LL lt cr cr VET 52 8 1 o clo 61 6 7b y V BjOHVH2 ea 4931199 Voc IG ee CIN lt ans lt D u d O uU lt lt a lt O LL LL Page 7 1 4 WIRING DIAGRAM 7 KW HOME STANDBY MODEL 4389 1 DRAWING 0D9013 C 1 OF 2
9. RESULTS 1 If there is no evidence of binding sticking excessive force required replace the appropriate closing coil 2 f evidence of sticking binding excessive force required to move main contacts find cause of binding or sticking and repair or replace damaged part s TEST 25 TEST LIMIT SWITCH XB1 DISCUSSION Standby power source voltage must be available to the standby closing coil in order for a TRANSFER TO STANDBY action to occur To deliver that source voltage to the coil limit switch XB1 must be closed to the Standby power source side If the limit switch did not get actuated or has failed open the source voltage will not be available to the closing coil and transfer to Standby will not occur PROCEDURE With the generator shut down the generator main circuit breaker turned OFF and with the utility power supply to the transfer switch turned OFF test limit switch XB1 as follows 1 To prevent interaction disconnect Wire 205 and Wire B from the limit switch terminals 2 Set a VOM to its R x 1 scale and zero the meter 3 See Figure 1 Connect the VOM test probes across the two outer terminals from which the wires were disconnected 4 Manually actuate the main contacts to their Standby position The meter should read INFINITY 5 Manually actuate the main contacts to their UTILITY position The meter should read CONTINUITY 6 Repeat Steps 4 and 5 several times and verify the VOM read
10. 4 SPARE gg CUSTOMER SUPPLIED SEES L E D ALARM INDICATORS WIRING DIAGRAM REVISION F 9084 C 7 0 kW HSB DATE 1 21 03 DRAWING 0D9013 Page 7 1 5 WIRING DIAGRAM 7 KW HOME STANDBY MODEL 4389 1 DRAWING 0D9013 C 2 OF 2 ELECTRICAL DATA CUNTROUL PANEL BUX eoo 224 r 224 225A 224A CLOSEST TO BEARING 225A BA TX BCR 1 7 a a a a aaa ns Aa 4 EE O cao EE e 9 N1 N2 13A 66 Bil 77 162 5 T i 4 225B l 10 2248 0 lt 9 66 2 lt 8 lt 4 6 7 lt 4 0 77 6 t 6 e l 162 2 162 55 VOLTAGE REGULATOR 4 66A 0 0 0 66A 4 4 55 N1 33 13 22 225
11. 6 To connect Load terminal lugs to the Standby power source move the handle upward 7 To connect Load terminals to the Utility power source move the handle downward 8 Actuate the switch to Utility and to MANUAL several times Make sure no evidence of binding or interference is felt 9 When satisfied that manual transfer switch operation is correct actuate the main contacts to their Utility position Load connected to the Utility power supply ELECTRICAL CHECKS Complete electrical checks as follows 1 Set the generator main circuit breaker to its OFF or open position LOAD CONNECTED TO STANDBY POWER SOURCE TRANSFER SWITCH OPERATING LEVER MANUAL TRANSFER HANDLE Figure 1 Manual Operation V Type Switch Page 5 1 1 OPERATIONAL TESTS 2 Set the generator AUTO OFF MANUAL switch to the OFF position 3 Turn off all loads connected to the transfer switch terminals T1 and 2 4 Turn on the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker A A The transfer switch is now electrically hot Contact with hot parts will result in extremely hazardous and possibly fatal electrical shock Proceed with caution 5 Use an accurate AC voltmeter to check utility power source voltage across transfer switch terminals N1 and N2 Nominal line to line voltage should be 240 volts AC 6 Check util
12. Figure 12 Clamp On Ammeter TACHOMETER A tachometer is available from your Generac Power Systems source of supply Order as P N 042223 The tachometer measures from 800 to 50 000 RPM Figure 13 Figure 13 Tachometer TEST BRACKET A starter motor test bracket may be made as shown in Figure 14 A growler or armature tester is available from an automobile diagnostic service supplier Page 4 4 7 SECTION 4 4 DIAGNOSTIC TESTS METAL STOCK 1 4 THICK STEEL DRILL TWO HOLES 1 2 FOR STARTER MOUNTING BRACKET M DRILL TWO HOLES 1 2 FOR MOUNTING TACHOMETER TAP FOR 1 4 20 NC SCREWS Figure 14 Test Bracket REMOVE STARTER MOTOR It is recommended that the starter motor be removed from the engine when testing starter motor performance Assemble starter to test bracket and clamp test bracket in vise Figure 15 TESTING STARTER MOTOR 1 Afully charged 12 volt battery is required 2 Connect jumper cables and clamp on ammeter as shown in Figure 15 3 With the starter motor activated jump the terminal on the starter contactor to battery voltage note the reading on the clamp on ammeter and on the tachometer rpm Note Take the reading after the ammeter and tachometer are stabilized approximately 2 4 seconds Page 4 4 8 DC CONTROL DC CONTROL 4 A starter motor in good condition will be within the following specifications Single Cylinder V twin Minimum rpm 80
13. 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 L1 Check that all wiring is well clear of rotating parts L1 Verify that the Generator properly connected for the correct rated voltage This is especially important on new installations See Section 1 2 AC Connection Systems Look for foreign objects loose nuts bolts and other fasteners Clean the area around the Generator Clear away paper leaves snow and other objects that might blow against the generator and obstruct its air openings METERS Devices used to measure electrical properties are called meters Meters are available that allow one to measure a AC voltage b DC voltage c AC frequency and d resistance In ohms The following apply measure AC voltage use an AC voltmeter measure DC voltage use a DC voltmeter Use a frequency meter to measure AC frequency In Hertz or cycles per second L 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 Some VOM s are of the
14. 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 A INSTALLED CONJUNCTION WITH AUTOMATIC TRANSFER SWITCH ENGINE CRANKING AND STARTUP CAN OCCUR AT ANY TIME WITHOUT WARNING PROVIDING THE AUTO OFF MANUAL SWITCH IS SET TO AUTO TO PREVENT AUTOMATIC STARTUP AND POSSIBLE INJURY THAT MIGHT BE CAUSED BY SUCH STARTUP ALWAYS SET THE AUTO OFF MANUAL SWITCH TO ITS OFF POSITION BEFORE WORKING ON OR AROUND THIS EQUIPMENT 15 AMP FUSE This fuse protects the DC control circuit including the circuit board against overload If the fuse element has melted open due to an overload engine cranking or running will not be possible Should fuse replacement become necessary use only an identical 15 amp replacement fuse 5 AMP FUSE This fuse protects the battery charge circuit against overload If the fuse element has melted open due to an overload battery charge will not occur Should fuse replacement become necessary use only an identical 5 amp replacement fuse GENERAL INFORMATION THE SET EXERCISE SWITCH The air cooled prepackaged automatic standby generator will start and ex
15. 225A 224A o 11 a 44 224A C2 5 C2 6 BATTERY CHARGER GENERATOR 12 VDC ALWAYS PRESENT 12 VDC DURING CRANKING ONLY 15A 17 15A 13 15 0 RUN BATTERY CHARGE WINDING FIELD ELECTRONIC VOLTAGE REGULATOR AC VOLTAGE C2 3 ENGINE WINDING STATOR 15 13 17 4 SECTION 4 2 OPERATIONAL ANALYSIS C2 1 SC BATTERY 12V BLACK CUSTOMER SUPPLIED 16 Loa 0 i 13 18 18 C1 5 gt 0 SP2 0 L 17 18 56 0 15 B E SENSING 12VDC PCB SUPPLY CONTROL 12VDC PRINTED CIRCUIT BOARD 238 15A 23 194 239 66A DIAGRAM KEY bx BA BRUSH ASSEMBLY us BCR BATTERY CHARGE RELAY CB1 CIRCUIT BREAKER MAIN OUTPUT CB2 CIRCUIT BREAKER ALT EXCITATION D DIODE FS FUEL SOLENOID F1 FUSE 15 F2 FUSE 5 AMP HTQ HIGH GIL TEMPERATURE SWITCH IM1 IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTER SCA STARTER CONTACTOR RELAY SP1 8 2 SPARK PLUGS swi AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA 8 16 Vac 1 VA DUAL SEC DPE WINDING STATOR mum GROUND FOR CONTROL PURPOSES 12 VDC DURING ENGINE RUN CONDITION Page 4 2 6 SECTION 4 2 DC C
16. AIR COOLED REPAIR MANUAL AUTOMATIC HOME STANDBY GENERATORS Visit us online at www guardiangenerators com Models 4389 4758 6 kW NG 7 kW LP 4456 4759 12 KW NG 12 kW LP GUARDIAN 4390 4760 13 kW 15 kW LP TITLE Specifications General Information Generators 003 V Type Prepackaged Transfer Switches DC Control 225 Operational Tests and Adjustments Disassembly Electrical Data DIAGNOSTIC REPAIR MANUAL Air cooled Prepackaged Automatic Standby Generators Models 04389 04758 6 kW NG 7 kW LP 04456 04759 12 kW NG 12 kW LP 04390 04760 13 kW NG 15 kW LP ELECTRICAL FORMULAS TO FIND KNOWN VALUES 1 PHASE 3 PHASE KILOWATTS kW Volts Current Power Factor E x E x x 1 73 x PF 1000 1000 Volts Current E x x 1 73 1000 1000 AMPERES kW Volts Power Factor kW x 1000 kW x 1000 E E x 1 73x PF WATTS Volts Amps Power Factor Volts x Amps E xl x 1 73 x PF NO OF ROTOR Frequency RPM 2 x 60 x Frequency 2 x 60 x frequency POLES RPM RPM FREQUENCY RPM No of Rotor Poles RPM x Poles RPM x Poles 2 x 60 2 x 60 Frequency No of Rotor Poles 2 x 60 x Frequency 2 x 60 x Frequency Rotor Poles Rotor Poles kW required for Motor Horsepower Efficiency HP x 0 746 HP x 0 746 Motor Efficiency Efficiency R E VOLTS AMPERES R RESISTANCE OHMS PF POWER FACTOR 20 m Page 1 SPECIFICATION
17. B a lf meter Beeps once and displays voltage drop then the diode is good b If the meter makes a continuous tone the diode is bad shorted and the harness must be replaced c lf the meter displays OL the diode is defective open and the harness must be replaced ENGINE GROUND HARNESS POSITIVE METER TEST LEAD NEGATIVE METER TEST LEAD Figure 26 Engine Ground Harness Test Points 12 Now repeat Step 11 with the negative meter test lead connected to Connector C Figure 26 13 Now check the flywheel magnet by holding a screwdriver at the extreme end of its handle and with its point down When the tip of the screwdriver is moved to within 3 4 inch 19mm of the magnet the blade should be pulled in against the magnet 14 Now check the flywheel key The flywheel s taper is locked on the crankshaft taper by the torque of the flywheel nut A keyway is provided for alignment only and theoretically carries no load Note If the flywheel key becomes sheared or even partially sheared ignition timing can change Incorrect timing can result in hard starting or failure to start 15 As stated earlier the armature air gap is fixed for single cylinder engine models and is not adjustable Visually inspect the armature air gap and hold down bolts 16 Disconnect the shutdown ground wire from the armature and retest for spark Test 55 17 Perform Steps 13 and 14 RESULTS If sparking still does not occur
18. 4 Set your VOM to the R x 1 scale 5 Disconnect Wire N2A from the Utility Coil C1 and connect one test lead to it Connect the other test lead to terminal lug N2 of the transfer switch CONTINUITY should be read Reconnect Wire N2A 6 Disconnect Wire 126 from transfer relay TR and connect one test lead to it Connect the other test lead to limit switch XA1 bottom terminal Wire 126 CONTINUITY should be read Reconnect Wire 126 7 Disconnect Wire N1A from transfer relay TR terminal and connect one test lead to it Connect the other test lead to F1 top fuse terminal Wire N1A CONTINUITY should be read Reconnect Wire N1A RESULTS Repair any defective wiring that does not read Page 3 4 8 V TYPE PREPACKAGED CONTINUITY If wiring tests good proceed to Test 23 TEST 33 CONTINUITY TEST OF WIRING C2 DISCUSSION This test will ensure that all control wiring has continuity 1 See Test 32 Step 1 2 See Test 32 Step 2 3 See Test 32 Step 3 4 See Test 32 Step 4 5 Disconnect Wire E2 from the standby coil C2 and connect one test lead to it Connect the other test lead to Terminal Lug E2 of the transfer switch CONTINUITY should be read Reconnect Wire E2 6 Disconnect Wire 205 from transfer relay TR Terminal 6 and connect one test lead to it Connect the other test lead to limit switch XB1 top terminal Wire 205 CONTINUITY should be read Reconnect Wire 205 7 Disconnect Wire E1 from Transfer Rela
19. BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY DPE WINDING 7 STATOR CB1 CIRCUIT BREAKER MAIN OUTPUT CB2 CIRCUIT BREAKER ALT EXCITATION D DIODE F8 FUEL SOLENOID F1 FUSE 15 F2 FUSE S AMP HIGH OIL TEMPERATURE SWITCH KGNITION MODULE CYLINDER 1 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH S STARTER CONTACTER SCA STARTER CONTACTOR RELAY SP1 BP2 SPARK PLUGS ELECTRONIC SWH AUTO OFF MANUAL SWITCH VOLTAGE SW 2 SET EXERCISE SWITCH G E N E RATO R SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC 12 VDC ALWAYS PRESENT AC VOLTAGE ma GROUND FOR CONTROL PURPOSES Page 4 2 2 SECTION 4 2 OPERATIONAL ANALYSIS INITIAL DROPOUT OF UTILITY SOURCE VOLTAGE Refer to Figure 2 above Should a Utility power source failure occur circuit condition may be briefly described as follows The circuit board constantly senses for an acceptable Utility source voltage via transfer switch fuses F1 F2 transfer switch Utility 1 Utility 2 terminals connected wiring control panel Utility 1 Utility 2 terminals the sensing transformer TX and Wires 224 225 Should Utility voltage drop below approximately 60 percent of the nominal source voltage a 15 second timer on the circuit board will turn on In Figure 2 the 15 second timer is still timing and engine crankin
20. Figure 5 Circuit Condition Initial Transfer to Standby TRANSFER 23 RELAY COIL o 194 INPUT 240VAC 69 N1 UTILITY e N1 240VAC GENERATOR TX TPUT 56VA 1VA 225 224 225A 224A Omm POWER WINDING STATOR BATTERY CHARGER GENERATOR 12 VDC ALWAYS PRESENT 12 VDC DURING CRANKING ONLY 15 15A 23 194 239 17 13 15A C2 C2 3 66 BATTERY CHARGE WINDING DPE WINDING STATOR ELECTRONIC VOLTAGE REGULATOR mamam AC VOLTAGE 12VDC SECTION 4 2 OPERATIONAL ANALYSIS BATTERY 12V BLACK b uem CUSTOMER SUPPLIED 0 18 UTILITY i VOLTAGE SENSING CONTROL PRINTED CIRCUIT BOARD DIAGRAM KEY BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY CIRCUIT BREAKER MAIN OUTPUT CB2 CIRCUIT BREAKER ALT EXCITATION D DIODE FS FUEL SOLENOID F1 FUSE 15 F2 FUSE 5 HTQ HIGH OlL TEMPERATURE SWITCH IM1 IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOW OIL PRESSURE SWITCH SC STARTER CONTACTER SCR STARTER CONTACTOR RELAY SP1 SP2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC mam GROUND FOR CONTROL PURPOSES m 12 VDC DURING ENGINE RUN CONDITION Page 4 2 10
21. Remove Control Panel Cover Using a 10 mm socket remove the control panel cover Remove two nuts located on back panel using a 7mm socket Remove two control panel screws Disconnect Stator Leads Connectors Remove the Stator leads Wire 11 and Wire 44 from the main circuit breaker Remove the stator leads Wire 22 and Wire 33 from the neutral lug Unplug connectors C1 and C2 from the control panel For control panel removal only remove Wires N1 N2 and Wires 23 194 from the terminal strip and the ground and neutral wires from the control panel Disconnect Fuel Hoses Remove the two fuel hoses at the air box assembly Some models are equipped with an additional third fuel hose Remove it also if equipped Pull hoses back into the battery compartment For control panel removal only remove WireNos 0 and 14 from the fuel solenoid Remove Front and Back Exhaust Enclosure Covers Using a 10mm socket remove the five bolts and four nuts from the exhaust covers Remove the covers Remove the nut and bolt attaching to the roof left side folding support and bottom support bracket Remove Exhaust Side Enclosure Using a 10mm socket with a 2 1 2 extension remove the four 4 bottom enclosure bolts and six 6 side enclosure bolts Remove the enclosure Page 6 1 1 Figure 1 Exhaust Side Enclosure Removed 8 Remove Exhaust Pipe Using a 13mm socket loosen the exhaust clamp and remove the exhaust pipe 9 Remove F
22. f generator line to line voltage is NOT indicated in Procedure Step 7 proceed to Test 33 3 If generator line to line voltage is indicated in Procedure Step 7 proceed to Test 25 V TYPE PREPACKAGED TEST 23 TEST TRANSFER RELAY TR DISCUSSION In automatic operating mode the transfer relay must be energized by circuit board action or standby source power will not be available to the standby closing coil Without standby source power the closing coil will remain de energized and transfer to Standby will not occur This test will determine if the transfer relay is functioning normally PROCEDURE 1 See Figure 2 Disconnect all wires from the transfer relay to prevent interaction 2 Seta 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 DESIRED METER READING TEST LEADS ACROSS ENERGIZED DE ENERGIZED Terminals 6 and 9 Continuity Infinity Terminals 1 and 7 Infinity Continuity 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 The relay should energize and the VOM should read CONTINUITY LOAD CONNECTED TO UTILITY POWER SOURCE MANUAL TRANSFER HANDLE TRANSFER SWITCH OPERATING LEVER SECTION 3 4 DIAGNOSTIC TESTS Figure 2 Transfer Relay Test Points 5
23. o STOP TESTS FREQUENCY O K BUL VOLTAGE 0 FLOW CHART START AT TEST 4 GO TO PROBLEM 1 Problem 3 Generator Produces High Voltage at No Load TEST 2 CHECK TEST 11 CHECK TEST 12 CHECK AC OUTPUT AC OUTPUT ENGINE GOVERNOR VOLTAGE FREQUENCY FREQUENCY AND VOLTAGE O K FREQUENCY O K BUT VOLTAGE HIGH i DISCONTINUE TESTING TEST 13 ADJUST REQUENCY O ee BUT VOUAGE HIGH FREQUENCY O K REGULATOR DISCONTINUE TESTING FREQUENCY O K BUT VOLTAGE IS J3 VOLTAGE REGULATOR STILL HIGH REPLACE DEFECTIVE Page 2 3 3 SECTION 2 3 TROUBLESHOOTING FLOWCHARTS AC GENERATORS Problem 4 Voltage and Frequency Drop Excessively When Loads Are Applied TEST 14 CHECK TEST 15 CHECK TEST 12 CHECK AND BOTH VOLTAGE AND FOR OVERLAOD NOT OVERLOADED J3 ADJUST ENGINE FREQUENCY CONDITION GOVERNOR UNDER LOAD OVERLOADED GOOD GOOD 4 REDUCE LOADS TO DISCONTINUE TESTING UNIT S RATED CAPACITY ie ENGINE STARTS HARD AND RUNS ROUGH LACKS POWER PAGE 4 3 3 ENGINE CONDITION GOOD LOOK FOR A SHORTED TEST 7 CHECK CONDITION INA CONNECTED STATOR AC LOAD OR IN ONE OF THE LOAD POWER WINDINGS CIRCUITS BAD Y REPAIR OR REPLACE Page 2 3 4 AC GENERATORS PART2 INTRODUCTION This section is provided to familiarize the service technician with acceptable procedures for the testing and evaluation of various problems that could be enco
24. or Closed 2 Test for utility source line to line voltage across terminal lugs N1 and N2 see Figure 1 Normal utility source voltage should be indicated RESULTS 1 If low or no voltage is indicated find the cause of the problem and correct 2 lf normal utility source voltage is indicated go on to Test 28 3 For Problem 14 ONLY if voltage is good repair or replace Wire N1A N2A between Transfer Switch Lugs N1 N2 and Fuse Holder connections TEST 28 CHECK VOLTAGE AT UTILITY 1 AND UTILITY 2 TERMINALS The UTILITY 1 and UTILITY 2 terminals in the transfer switch deliver utility voltage sensing to a circuit board If voltage at the terminals is zero or low standby generator startup and transfer to the Standby source will occur automatically as controlled by the circuit board A zero or low voltage at these terminals will also prevent retransfer back to the Utility source PROCEDURE With utility source voltage available to terminal lugs N1 and N2 use an AC voltmeter or a VOM to test for utility source line to line voltage across terminal block Utility 1 and Utility 2 terminals Normal line to line utility source voltage should be indicated CN gt 2 Figure 4 Transfer Switch Terminal Block Page 3 4 6 V TYPE PREPACKAGED RESULTS 1 If voltage reading across the Utility 1 and Utility 2 terminals is zero go to Test 30 2 If voltage reading is good go to Test 29 3 For Prob
25. 90 seconds of crank rest cycles have been used up When the crank relay K1 is energized circuit board action delivers 12 volts DC to a starter contactor relay SCR via Wire 56 When the SCR energizes its contacts close and battery power is delivered to a starter contactor SC When the SC energizes its contacts close and battery power is delivered to the starter motor SM The engine cranks F2 Oy When the circuit board s run relay K2 energizes 12 volts DC is delivered to a fuel solenoid FS via Wire 14 The fuel solenoid FS energizes open and fuel is available to the engine Wire 14 also energizes the hourmeter for operation if so equipped Wire 14 energizes the battery charge relay BCR which will allow the BCR to power the battery charger TO LOAD Figure 3 Circuit Condition Engine Cranking As the engine cranks magnets on the engine flywheel induce a high voltage into the engine ignition modules IM1 IM2 A spark is produced that jumps the spark plug SP1 SP2 gap During cranking Wire 4 supplies 2 3 VDC 8 9 VDC isolated to the rotor for field flash With ignition and fuel flow available the engine can start Page 4 2 5 DC CONTROL 224 225 POWER WINDING STATOR 12VDC TRANSFER 69 RELAY COIL e 1 J 240vac N1 UTILITY INPUT 6 N2 TN 240 OUTPUT 56VA
26. CIRCUIT BREAKER ALT EXCITATION D DiODE FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE B AMP HIGH OIL TEMPERATURE SWITCH INi KGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOW CHL PRESSURE SWITCH SC STARTER CONTACTER STARTER CONTACTOUR RELAY SP1 SPP SPARK PLUGS SW AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC DPE WINDING STATOR mam GROUND FOR CONTROL PURPOSES Page 4 2 4 SECTION 4 2 DC CONTROL OPERATIONAL ANALYSIS UTILITY VOLTAGE DROPOUT AND ENGINE CRANKING After fifteen 15 seconds and when the circuit board s 15 second timer has timed out if Utility voltage is still below 60 percent of nominal circuit board action will energize the circuit board s crank and run relays K1 and K2 simultaneously The crank relay K1 will remain energized for about 15 seconds on the first crank cycle The relay will then de energize for 7 seconds and will again energize This time it will remain energized for 7 seconds Thus the engine will crank cyclically for 7 second crank rest K na N1 7 T E1 N2A Q2 240VAC GENERATOR OUTPUT cycles This cyclic cranking will continue until either the engine starts or until about ninety
27. INSULATION RESISTANCE TEST PAGE 1 4 4 TEST 9 CHECK BRUSHES amp SLIP RINGS TEST 5 WIRE CONTINUITY GOOD BAD REPAIR GOOD TEST 6 OR FIELD BOOST REPLACE REPAIR TEST 10 OR lt BAD TEST ROTOR BAD REPLACE ASSEMBLY REPAIR Lou REPLACE GOOD THEN GOOD RETEST PERFORM BAS INSULATION VOLTAGE RESISTANCE TEST REGULATOR PAGE 1 4 6 Page 2 3 1 SECTION 2 3 TROUBLESHOOTING FLOWCHARTS AC GENERATORS Problem 1 Generator Produces Zero Voltage or Residual Voltage Continued TEST 4 PERFORM FIXED EXCITATION ROTOR AMP DRAW TEST 7 TEST STATOR BAD GOOD TEST 10 BAD ASSEMBLY PERFORM STATOR INSULATION BAD RESISTANCE TEST GOOD PAGE 1 4 4 REPAIR PERFORM ROTOR GOOD OR INSULATION BAD REPLACE RESISTANCE TEST PAGE 1 4 6 TESTA TEST ROTOR BAD REPAIR GOOD OB ASSEMBLY REPLACE GOOD BAD PERFORM ROTOR INSULATION BAD RESISTANCE TEST PAGE 1 4 6 PERFORM STATOR INSULATION BAD RESISTANCE TEST GOOD PAGE 1 4 4 i RE TEST r TEST 4 RE TEST TEST 4 Page 2 3 2 AC GENERATORS PART 2 SECTION 2 3 TROUBLESHOOTING FLOWCHARTS Problem 2 Generator Produces Low Voltage at No Load TEST 2 CHECK TEST 11 CHECK AC OUTPUT AC OUTPUT VOLTAGE FREQUENCY TEST 12 ADJUST FREQUENCY AND ENGINE GOVERNOR VOLTAGE O K FREQUENCY O K BUT VOLTAGE LOW REGULATOR VOLTAGE AND FREQUENCY O K
28. If the unit is in an overheated condition the switch contacts will close at 284 F This will normally occur from inadequate airflow through the generator Page 4 4 16 PROCEDURE 1 Verify that the engine has cooled down engine block is cool to the touch This will allow the contacts in the High Oil Temperature Switch to close 2 Check the installation and area surrounding the generator There should be at least three feet of clear area around the entire unit Make sure that there are no obstructions preventing incoming and outgoing air 3 Disconnect Wire 85 and Wire 0 from the High Oil Temperature Switch 4 Set a VOM to measure resistance Connect the test leads across the switch terminals The meter should read INFINITY 5 If the switch tested good in Step 4 and a true over temperature condition has not occurred check Wire 85 for a short to ground Remove Connector J2 5 pin from the circuit board Set the VOM to measure resistance Connect one test lead to Wire 85 disconnected from High Oil Temperature Switch Connect the other test lead to a clean frame ground INFINITY should be measured TESTING HIGH OIL TEMPERATURE SWITCH 6 Remove the High Oil Temperature Switch 7 Immerse the sensing tip of the switch in oil as shown in Figure 28 along with a suitable thermometer Figure 28 Testing the Oil Temperature Switch 8 Set a VOM to measure resistance Then connect the VOM test leads across the switch
29. Remove Engine Divider Panel Using a 10mm socket remove the remove the two 2 nuts attached to the back enclosure Remove the two bolts attached to the Figure 7 Removing the Rotor 16 Remove Engine Using a 13mm socket remove the base enclosure Remove the engine divider panel Hs e mount nuts and ground wires Remove Intake manifolds Using a 6mm allen wrench c OV Wie ene remove the four 4 socket head cap screws from the 17 Reverse the previous steps to re assemble intake manifolds Remove the intake manifolds Remove the air intake snorkel 5 Remove Air Box Using a 5 32 allen wrench remove the four 4 air box allen head shoulder bolts While removing the air box remove the four rubber washers and disconnect the throttle linkage and anti lash spring 6 Unbolt Oil Cooler Using a 10mm socket remove the four 4 oil cooler bolts 7 Remove Blower Housing Using an 8mm socket remove the nine 9 bolts around the blower housing Remove the blower housing 8 Remove flywheel Use a 36mm socket a steering wheel puller two 2 M8x1 25 bolts and a 13 mm socket Remove the flywheel hex nut remove the fan FRONT ENGINE ACCESS plate and fan Install the puller using the M8x1 25 bolts and remove the flywheel Figure 8 Removing the Engine 1 Follow Stator Rotor Engine removal procedures Steps 1 5 TORQUE REQUIREMENTS UNLESS OTHERWISE SPECIFIED 2 Control Panel Removal Using a 7mm socket remove FLYWHEEL N
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31. on models with v twin engines or the starter contactor SC on models with single cylinder engines Connect the common test probe to frame ground 2 Observe the meter Then actuate the AUTO OFF MANUAL switch to MANUAL position a The circuit board crank and run relays should energize b The meter should indicate battery voltage 3 Insert the positive meter test lead into Pin 5 of the Page 4 4 4 DC CONTROL circuit board connector J1 Connect the common test lead to a clean frame ground Then repeat Step 2 a The circuit board s crank and run relays should energize b The meter should read battery voltage FIELD BOOST RESISTOR STARTER CONTACTOR Figure 4 The Wire 56 Circuit RESULTS 1 If battery voltage is indicated in Step 3 but NOT in Step 2 Wire 56 between the circuit board and starter contactor relay or starter contactor is open Repair or replace this wire as required 2 f battery voltage is NOT indicated in Step 3 go to Test 43 3 If battery voltage is indicated in both Steps 2 and 3 but engine does NOT crank go on to Test 49 TEST 48 TEST STARTER CONTACTOR RELAY V TWIN ONLY DISCUSSION The starter contactor relay SCR located in the control panel must be energized for cranking to occur Once the SCR is energized it s normally open contacts will close and battery voltage will be available to Wire 16 and to the starter contactor SC Figure 5 T
32. 1A Above 1 3A Test 10 Below 60 VAC Below 60 VAC Above 1 5A Residual Volts Residual Volts Test 8 0 91 1 06A 0 91 1 06A 0 71 0 82A Test 7 Below 60 VAC Above 60 VAC Figure 3 Voltage Regulator 3 Set VOM to AC volts 4 Disconnect Wire 2 from the excitation circuit breaker CB2 and connect one meter test lead to that wire Disconnect Wire 6 from the voltage regulator and connect the other meter test lead to that wire 5th terminal from top double check wire number 5 Set the AUTO OFF MANUAL switch to MANUAL Once the engine starts record the AC voltage 6 Set the AUTO OFF MANUAL switch to OFF Reconnect Wire 2 and Wire 6 0 91 1 06A 0 71 0 82A 0 91 1 06A 0 71 0 82A Test 7 MATCH RESULTS WITH LETTER AND REFER TO FLOW CHART ON PAGE 2 3 1 amp 2 3 2 Problem 1 Above 60 VAC Below 60 VAC 7 C Q a O gt S i Q uj gt lt o 7 F Above 60 VAC Above 60 VAC 0 91 1 06A 0 91 1 06A 0 71 0 82A 4390 4760 4456 4759 4390 4760 7 Disconnect Wire 11 from the voltage regulator and connect one meter test lead to that wire Disconnect Wire 22 from the voltage regulator and connect the other meter test lead to that wire both wires are located at the top two terminals of the voltage regulator see Figure 3 Model 4389 4758 4679 4456 4759 4389 4758 4679 Voltage Results W
33. COIL VOLTAGE x TRANSFER SWITCH OPERATION COIL C2 TEST 22 CHECK VOLTAGE AT STANDBY CLOSING COIL C2 AND LIMIT SWITCH XB1 C2 COIL VOLTAGE BAD TEST 25 TEST REPLACE LIMIT SWITCH XB1 LIMIT SWITCH J BAD p LIMIT VOLTAGE GOOD XB1 SWITCH REPAIR C2 COIL VOLTAGE BAD u LIMIT SWITCH XB1 mu gt WIRE 8 VOLTAGE BAD TEST 33 CONTINUITY TEST OF WIRING C2 BAD i Pea s TEST 26 CHECK 23 AND 194 WIRING CONNECTIONS REPLACE Page 3 3 1 SECTION 3 3 PART 3 V TYPE PREPACKAGED TROUBLESHOOTING FLOW CHARTS Problem 6 In Automatic Mode Generator Starts When Loss of Utility Occurs Generator Shuts Down When Ulility Returns But There Is No Retransfer To Utility Power TEST 29 CHECK C1 COIL VOLTAGE TEST 24 CHECK REPLACE VOLTAGE ATUTILITY GOOD BUT NO gt MANUAL TRANSFER GOO0D 9 CLOSING COIL C1 AND TRANSFER SWITCH OPERATION oe LIMIT SWITCH XA1 C1 COIL VOLTAGE TEST 31 BAD LIMIT VOLTAGE GOOD SWITCH XA1 GOOD REPAIR wire A C1 COIL VOLTAGE BAD LIMIT SWITCH XA1 REPLACE VOLTAGE BAD BAD 9 LIMIT SWITCH TEST 32 CONTINUITY TEST OF WIRING C1 C1 BAD TEST 23 TEST TRANSFER RELAY BAD REPLACE TEST 26 CHECK 23 AND 194 WIRING CONNECTIONS Problem 7 Blown F1 or F2 Fuse TEST 30 CHECK TEST 34 CHECK TEST 35 CHECK GOOD gt FINISH FUSE F1 amp F2 N1 amp N2 WIRING TRANSFORMER TX GOOD B
34. E n Er wex lt H SLINOUIO oe WELAAN B z SLINOHIO 0L MPICL a SLINDYIO 9 NPIO Z x E mj 31Od 2 i o 3 2 LINOHIO MAE 09 e waym 5 T3NVd lt 931 2vH3N39 SLNN 3HIM a NZ qaorias SLINDYID HONVHS OL JO EX a Figure 1 Typical Prepackaged Installation 2 Page 1 2 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 neultral lines to the neutral block in the transfer switch ADDITIONAL 11 14 WC REGULATOR TO GENERATOR SAFETY SHUT OFF VALVE 0000001 SECTION 1 2 PREPACKAGED INSTALLATION BASICS SYSTEM CONTROL INTERCONNECTIONS Prepackaged home standby generators are equipped with a terminal board identified with the following terminals a UTILITY 1
35. Exercise TEST 77 TEST EXERCISE FUNCTION Page 4 3 7 INTRODUCTION Perform these Diagnostic Tests in conjunction with the Troubleshooting Flow Charts of Section 4 3 The test procedures and methods presented in this section are not exhaustive We could not possibly know of evaluate and advise the service trade of all conceivable ways in which testing and trouble diagnosis might be performed We have not undertaken any such broad evaluation TEST 41 CHECK POSITION OF AUTO OFF MANUAL SWITCH DISCUSSION If the standby system is to operate automatically the generator AUTO OFF MANUAL switch must be set to AUTO That is the generator will not crank and start on occurrence of a Utility power outage unless that switch is at AUTO In addition the generator will not exercise every seven 7 days as programmed unless the switch is at AUTO PROCEDURE With the AUTO OFF MANUAL switch set to AUTO test automatic operation Testing of automatic operation can be accomplished by turning OFF the Utility power supply to the transfer switch When the utility power is turned OFF the standby generator should crank and start Following startup transfer to the standby source should occur Refer to Section 1 8 in this manual An Automatic Operating Sequences Chart is provided on Page 1 7 2 Use the chart as a guide in evaluating automatic operation Following generator startup and transfer to the standby source turn O
36. FIND AND CORRECT FUEL SUPPLY CAUSE OF NO FUEL OR LOW PRESSURE AND PRESSURE PERFORM INSULATION RESISTANCE TEST GOOD TEST 70 CHECK TEST TEST ENGINE RUN STATOR GOOD WINDING BAD gt REPAIR OR REPLACE Page 4 3 4 SECTION 4 3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Problem 13 No Battery Charge TEST 64 CHECK BATTERY CHARGE OUTPUT UTILITY ON GENERATOR OFF GENERATOR RUNNING BATTERY CHARGE WORKING TEST 66 CHECK AC TEST 67 TEST VOLTAGE AT BAD BATTERY CHARGE BAD 1 TEST 65 TEST TRANSFORMER TX VOLTAGE OUTPUT RELAY BATTERY CHARGER VERIFY BATTERY CHARGE RELAY TEST 67 TEST WIRED BATTERY CHARGE lt 66 STEP 5 TEST 68 TEST 5 GOOD WINDING HARNESS INSULATION BAD GOOD J9 RESISTANCE TEST PAGE 1 4 1 REPLACE lt REwIRE lt BAD TEST 67 TEST TEST 66 CHECK AC TEST 65 TEST BATTERY CHARGE lt BAD VOLTAGE AT TRANSFORMER TX RELAY BATTERY CHARGER VOLTAGE OUTPUT BAD TEST 69 CHECK REPAIR OR BATTERY BAD gt REPLACE REPLACE CHARGER WIRING WIRING REPLACE BATTERY iad CHARGE REGULATOR Page 4 3 5 SECTION 4 3 DC CONTROL Problem 14 Unit Starts and Transfer Occurs When Utility Power Is Available TEST 71 TEST 65 TEST TEST 72 CHECK REPLACE CHECK N1 amp Goop 3 TRANSFORMER TX Goop UTILITY SENSI
37. Flow Chars DiagnosticTests _ _ SECTION 3 1 DESCRIPTION amp COMPONENTS GENERAL The prepackaged 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 useable with 1 phase systems only Prepackaged transfer switches do not have an intelligence system of their own Instead automatic operation of these transfer switches is controlled by a circuit board housed in the generator control panel ITEM DESCRIPTION BOX GTS LOAD CENTER COVER 12 POSITION GTS LOAD CENTER TRANSFER SWITCH HOME STANDBY 100A2P250V SCREW TAPTITE 5 0 8 X 10 BP SCREW TAPTITE 1 4 20 X 5 8 BP LOCK WASHER SPECIAL 1 4 RELAY PANEL 12VDC 10A 240VA BASE MOUNTING 12 CIRCUIT 125A 240V 9 SCREWTAPTITE M4 0 7X10 BP 10 RIVET POP 156 X 160 164 20 11 WASHER FLAT 1 4 ZINC 12 PLUG 13 HARNESS ADAPTER PLATE 14 PANEL SUB BREAKER BASE 15 TRIM VINYL BLACK 1 8GP 16 WASHERLOCK 10 35 17 NUT WING M6 1 0 18 HANDLE TRANSFER SWITCH HOME STANDBY 19 HOLDER CABLE TIE 21 LUG DIS QK NI S 10X45 DEG BRIT 22 SCREW PPHM 10 32 X 1 4 23 109510195 1 0 14 9 16 ALICU 24 BLOCK TERMINAL 20A 5 X 6 X 1100V 25 TIE WRAP 39 X 10 NATL UL 26 WASHER FLAT 8 ZINC 27 COVER RELAY amp TERM BLOCK 28 HARNESS GTS LOAD CENTER NOT SHOWN FOR CLARITY 29 FUSE HOLDER 30 ASSEMBLY FUSE 5A X BUSS HLDR73591 31 SUPPORT SNAP I
38. GENERATOR 00 23 r 1946 0 194 CONTROL PRINTED CIRCUIT BOARD TRANSFER SWITCH UTILITY restored Transfer mechanism and limit switches change position UTILITY is now providing power to the load Figure 8 Utility Restored Retransfer Back to Utility Page 3 2 8 SECTION 3 2 PART 3 V TYPE PREPACKAGED OPERATIONAL ANALYSIS TRANSFER SWITCH IN UTILITY When the transfer switch returns to the UTILITY side generator shutdown occurs after approximately one 1 minute GENERATOR 23 194 09 194 CONTROL PRINTED CIRCUIT BOARD TRANSFER SWITCH Transfer switch in UTILITY position UTILITY voltage available Generator shuts down Figure 9 Transfer Switch in UTILITY Page 3 2 9 V TYPE PREPACKAGED SECTION 3 3 TROUBLESHOOTING FLOW CHARTS INTRODUCTION TO TROUBLESHOOTING The first step in troubleshooting is to correctly identify the problem Once that is done the cause of the problem can be found by performing the tests in the appropriate flow chart Test numbers assigned in the flow charts are identical to test numbers in section 3 4 Diagnostic Tests Section Problem 5 In Automatic Mode No Transfer to Standby FIND CAUSE OF NO AC TEST 21 CHECK OUTPUT TO TRANSFER VOLTAGE AT p SWITCH FROM TERMINAL LUGS GENERATOR E1 amp E2 REPAIR OR BAD REPLACE GOOD TEST 24 CHECK REPLACE C2
39. SECTION 4 2 OPERATIONAL ANALYSIS UTILITY VOLTAGE RESTORED RE TRANSFER TO UTILITY The Load is powered by the Standby power supply The circuit board continues to seek an acceptable Utility source voltage On restoration of Utility source voltage the following events will occur On restoration of utility source voltage above 80 percent of the nominal rated voltage a retransfer time delay on the circuit board starts timing The timer will run for about fifteen 15 seconds At the end of fifteen 15 seconds the retransfer time delay will stop timing and circuit board action will open the Wire 23 circuit to ground The transfer relay TR will then de energize When the transfer relay TR de energizes its normally closed contacts close Utility source voltage is then delivered to the utility closing coil C1 via Wires N1A N2A the closed TR contacts Wire 126 limit switch XA1 and a bridge rectifier The utility closing coil C1 energizes and moves the main current carrying contacts to their Neutral position The main contacts move to an over center position past Neutral and spring force closes them to their Utility side Load terminals are now powered by the Utility source Movement of the main contacts to Utility actuates limit switches XA1 XB1 XA1 opens and XB1 actuates to its Standby source side The generator continues to run Page 4 2 11 DC CONTROL
40. 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 f transfer to Standby does NOT occur and no voltage is indicated across terminal lugs E1 E2 determine why generator AC output has failed 3 If transfer to Standby does NOT occur and voltage reading across terminal lugs E1 E2 is good go on to Test 22 TEST 22 CHECK VOLTAGE AT STANDBY CLOSING COIL C2 DISCUSSION Standby source voltage is used to energize the standby closing coil and actuate the main contacts to their Standby source side Standby source alternating current AC is changed to direct current DC by a bridge rectifier before reaching the closing coil This test will determine if standby voltage is available to the closing coil If normal standby source voltage is available to the terminals of the standby closing coil but transfer to Standby does NOT occur look for a binding or sticking in the transfer mechanism b a defective coil or c a bad bridge rectifier The coil and the bridge rectifier must be replaced as a unit PROCEDURE 1 Set the generator main line circuit breaker to the OFF or Open position Page 3 4 2 V TYPE PREPACKAGED 2 Set the generators AUTO OFF MANUAL switch to the OFF position 3 Set your
41. Stator Lead 33 Connect the black test probe to Stator Lead 11 Refer to Steps 5a through 5c of TESTING ALL STATOR WINDINGS TO GROUND on the previous page Page 1 4 5 SECTION 1 4 TESTING CLEANING AND DRYING 5 Insert a large paper clip into Pin Location No 1 Wire 77 Connect the red tester probe to the paper clip Connect the black tester probe to Stator Lead 33 Refer to Steps 5a through 5c of TESTING ALL STATOR WINDINGS TO GROUND on the previous page 6 Repeat Step 5 at Pin Location 3 Wire 66A and Stator Lead 33 7 Repeat Step 5 at Pin Location 7 Wire 6 and Stator Lead 33 For the following steps 8 through 10 an additional large paper clip or similar item will be needed 8 Insert a large paper clip into Pin Location 1 Wire 77 Connect the red tester probe to the paper clip Insert the additional large paper clip into Pin Location 3 Wire 66A Connect the black tester probe to this paper clip Refer to Steps 5a through 5c of TESTING ALL STATOR WINDINGS TO GROUND on the previous page 9 Insert a large paper clip into Pin Location 1 Wire 77 Connect the red tester probe to the paper clip Insert the additional large paper clip into Pin Location 7 Wire 6 Connect the black tester probe to this paper clip Refer to Steps 5a through 5c of TESTING ALL STATOR WINDINGS TO GROUND on the previous page 10 Insert a large paper clip into Pin Location 3 Wire 66A Connect the red tester
42. VOM to measure AC voltage DANGER BE CAREFUL HIGH AND A DANGEROUS VOLTAGES ARE PRESENT AT TERMINAL LUGS WHEN THE GENERATOR IS RUNNING AVOID CONTACT WITH HIGH VOLTAGE TERMINALS OR DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK MAY RESULT DO NOT PERFORM THIS VOLTAGE TEST WHILE STANDING ON WET OR DAMP GROUND WHILE BAREFOOT OR WHILE HANDS OR FEET ARE WET 4 Disconnect Wire E2 from the standby closing coil C2 Connect one meter test Lead to Wire E2 Use a suitable and safe connection to this wire such as an alligator clip that attaches to the meter test probe Isolate this wire and test probe from any other potential source or ground 5 f necessary repeat Step 2 under Procedure of Test 21 The system must be in automatic operating mode with engine running and standby source voltage available to terminal lugs E1 and E2 6 Locate on the standby closing coil the terminal that Wire B is connected to Figure 1 previous page Connect the other meter test lead to this terminal Generator line to line voltage should be indicated If generator voltage is NOT indicated proceed to Step 7 7 With Wire E2 still connected to one test probe connect the other meter test lead to Wire 205 on Limit Switch XB1 see Figure 1 on previous page Generator line to line voltage should be measured RESULTS 1 If generator line to line voltage is indicated in Procedure Step 6 but transfer does NOT occur proceed to Test 24 2
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44. a dual stator AC power windings b an excitation or DPE winding c a battery charge winding and d an engine run winding Insulation tests of the stator consist of a testing all windings to ground b testing between isolated windings and c testing between parallel windings Figure 2 is a pictorial representation of the various stator leads on units with air cooled engine _ TESTING ALL STATOR WINDINGS TO GROUND 1 Disconnect stator output leads 11 and 44 from the generator main line circuit breaker Remove stator output leads 22 and 33 from the neutral connection and separate the two leads Disconnect C2 connector from the side of the control panel The C2 connector is the closest to the back panel Figure 2 Stator Winding Leads 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 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
45. above a preset value for a preset time interval a transfer back to utility power will occur GENERATOR CONTROL PRINTED CIRCUIT BOARD TRANSFER SWITCH 1 F1 12 N1 7 UTILITY restored Waiting to retransfer Generator still providing output to load Figure 6 Utility Restored Generator Still Providing Output to Load Page 3 2 6 SECTION 3 2 PART 3 V TYPE PREPACKAGED OPERATIONAL ANALYSIS UTILITY RESTORED TRANSFER SWITCH DE ENERGIZED After the preset time interval expires the circuit board will open the Wire 23 circuit to ground The transfer relay de energizes it s normally closed contacts close and utility source voltage is delivered to the utility closing coil C1 via Wires N1A and N2A closed Transfer Relay Contacts 1 and 7 and Limit Switch XA1 GENERATOR C2 23 194 60 194 CONTROL PRINTED CIRCUIT BOARD TRANSFER SWITCH UTILITY restored Transfer relay is de energized and contacts reverse to normal position C1 is energized Figure 7 Utility Restored Transfer Relay De energized Page 3 2 7 OPERATIONAL ANALYSIS UTILITY RESTORED RETRANSFER BACK TO UTILITY As the utility coil pulls the transfer switch to an OVER CENTER position the switch mechanically snaps to UTILITY On closure of the main contacts to the utility power source side Limit Switches XA1 and XB1 are mechanically actuated to arm the circuit for transfer to STANDBY
46. an intelligence circuit of their own as do Generac GTS type transfer switches Instead automatic operation on prepackaged transfer switch and generator combinations is controlled by circuit board action SECTION 1 6 OPERATING INSTRUCTIONS To select automatic operation when a prepackaged transfer switch is installed along with a prepackaged home standby generator proceed as follows 1 Check that the prepackaged transfer switch main contacts are at their UTILITY position i e the load is connected to the utility power supply If necessary manually actuate the switch main contacts to their UTILITY source side See Part 5 of this manual as appropriate for instructions 2 Check that utility source voltage is available to transfer switch terminal lugs N1 and N2 2 pole 1 phase transfer switches 3 Set the generator AUTO OFF MANUAL switch to its AUTO position 4 Actuate the generator main line circuit breaker to its On or Closed position With the preceding Steps 1 through 4 completed a dropout in utility supply voltage below a preset level will result in automatic generator cranking and start up Following startup the prepackaged transfer switch will be actuated to its Standby source side i e loads powered by the standby generator MANUAL TRANSFER TO STANDBY AND MANUAL STARTUP To transfer electrical loads to the Standby generator source and start the generator manually proceed as follows 1 On th
47. 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 SECTION 1 4 TESTING CLEANING AND DRYING Figure 1 Digital VOM MEASURING AC VOLTAGE An accurate AC voltmeter or a VOM may be used to read the generator AC output voltage The following apply 1 Always read the generator AC output voltage only at the units rated operating speed and AC frequency 2 he generator voltage regulator can be adjusted for correct output voltage only while the unit is operating at its correct rated speed and frequency 3 Only an AC voltmeter may be used to measure AC voltage DO NOT USE A DC VOLTMETER FOR THIS PURPOSE DANGER GENERATORS PRODUCE HIGH AND DANGEROUS VOLTAGES CONTACT WITH HIGH VOLTAGE TERMINALS WILL RESULT IN DANGEROUS AND POSSIBLY LE
48. average reading of 1 260 indicates the battery is 100 charged b An average reading of 1 230 means the battery is 75 charged c An average reading of 1 200 means the battery is 50 charged d An average reading of 1 170 indicates the battery is 25 charged C Test Battery Condition 1 the difference between the highest and lowest reading cells is greater than 0 050 50 points battery condition has deteriorated and the battery should be replaced 2 However if the highest reading cell has a specific gravity of less than 1 230 the test for condition is questionable Recharge the battery to a 100 percent state of charge then repeat the test for condition RESULTS 1 Remove the battery and recharge with an automotive battery charger if necessary 2 f battery condition is bad replace the battery with a new one TEST 47 CHECK WIRE 56 VOLTAGE DISCUSSION During an automatic start or when starting manually a crank relay K1 on the circuit board should energize Each time the crank relay energizes the circuit board should deliver 12 volts DC to a starter contactor relay SCR and the engine should crank This test will verify a that the crank relay on the circuit board is energizing and b that circuit board action is delivering 12 volts DC to the starter contactor relay PROCEDURE 1 Connect the positive test probe of a DC voltmeter or VOM to the Wire 56 connector of the starter contactor relay SCR
49. b UTILITY 2 c 23 and d 194 Prepackaged load centers house an identically marked terminal board When these four terminals are properly interconnected dropout of utility source voltage below a preset value will result in automatic generator startup and transfer of electrical loads to the Standby source On restoration of utility source voltage above a preset value will result in retransfer back to that source and generator shutdown 4 8 WC REGULATOR TO HOUSEHOLD GAS METER CAPABLE _ OF PROVIDING FUEL FLOW 126 000 6kW 241 920 12kW 288 000 13kW HOUSEHOLD APPLIANCES BTU HOUR GAS MAIN 2 5 PSI Figure 2 Proper Fuel Installation Page 1 2 3 SECTION 1 3 PREPARATION BEFORE USE GENERAL The installer must ensure that the home standby generator has been properly installed The system must be inspected carefully following installation All applicable codes standards and regulations pertaining to such installations must be strictly complied with In addition regulations established by the Occupational Safety and Health Administration OSHA must be complied with Prior to initial startup of the unit the installer must ensure that the engine generator has been properly prepared for use This includes the following adequate supply of the correct fuel must be available for generator operation LiThe engine must be properly serviced with the recommended oil FUEL REQUIREM
50. boost system is shown schematically in Figure 2 Manual and automatic engine cranking is initiated by circuit board action when that circuit board energizes a crank relay K1 Battery voltage is then delivered to field boost Wire 4 and to the rotor via a field boost resistor and diode The crank relay field boost resistor and diode are all located on the circuit board Notice that field boost current is available only while the crank relay K1 is energized i e while the engine is cranking SECTION 2 2 OPERATIONAL ANALYSIS 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 FIELD STARTER BOOST RESISTOR PIN 1 2 STARTER RELAY K1 CONTACTOR TRANSISTOR CIRCUIT BOARD Figure 2 Field Boost Circuit Schematic TO LOAD MLB MAIN LINE CIRCUIT BREAKER BCR BATTERY CHARGE RELAY CB3 EXCITATION CIRCUIT BREAKER STATOR POWER WINDING AGNETIC ENGINE DIRECT DRIVE BATTERY CHARGER STATOR BATTERY CHARGE WINDING TO BATTERY SENSING STATOR POWER WINDING FIELD BOOST FROM re x CONTROL LOGIC x CIRCUIT BOARD VOLTAGE REGULATOR STATOR EXCITATION WINDING TO CONTROL LOGIC CIRCUITBOARD Figure 1 Operating Diagram of AC Generator Page 2 2 1 SECTION 2 2 OPERATIONAL ANALYSIS OPERATION STARTUP When the engine is started res
51. flow to the engine This test will determine if the circuit board is working properly PROCEDURE 1 Set the AUTO OFF MANUAL switch to OFF 2 Connect the positive test lead of a DC voltmeter or VOM into Pin 7 Wire 14 of the circuit board connector J1 Connect the common test lead to frame ground Page 4 4 10 3 While observing the meter set the AUTO OFF MANUAL switch to MANUAL a The circuit board s crank and run relays should energize and the engine should crank and start b The meter should indicate battery voltage C If battery voltage is indicated proceed to Step 4 If battery voltage is NOT indicated proceed to Test 53 results 4 Disconnect Wire 14 at the Fuel Solenoid FS a Connect the positive test lead to Wire 14 Connect the negative test lead to a clean frame ground Set the AUTO OFF MANUAL switch to MANUAL Battery voltage should be measured If battery voltage is indicated proceed to Step 5 b Connect the positive test lead to Wire 14 at the 4 tab terminal block in the control panel see Figure 17 Connect the negative test lead to frame ground While observing the meter set the AUTO OFF MANUAL switch to MANUAL Battery voltage should be measured Figure 17 4 Tab Terminal Block 5 Set the VOM to it s R x 1 scale 6 Disconnect Wire 0 from the Fuel Solenoid FS Connect one test lead to Wire 0 and the other test lead to a clean frame ground CONTINUITY should
52. lead to a clean frame ground Connect the other test lead to Pin location 13 Wire 0 at the J1 connector on the circuit board CONTINUITY should be measured RESULTS 1 No battery voltage in Step 2 Go to test 45 or repair replace Wire 15 from F1 to SW1 2 No battery voltage in Step 3 Go to Test 43 or repair or replace Wire 15A from Terminal 1 to Terminal 3 of SW1 3 No battery voltage in Step 4 Verify Step 2 and repair or replace wire 15 from SW1 to J1 connector 4 No battery voltage in Step 5 Go to Test 43 or repair or replace Wire 15A from SW1 to J1 connector 5 f battery voltage is available in Step 8 but NOT in Step 7 repair or replace Wire 17 from SW1 to J1 connector 6 If battery voltage is available in Step 7 but NOT in Step 6 go to Test 43 7 If CONTINUITY is NOT measured in Step 9 repair or replace Wire 0 between the J1 connector and the 8 tab ground terminal 8 If battery voltage is available in Steps 1 5 but NOT in Step 8 of Problem 2 flow chart replace or repair the circuit board 9 f battery voltage is available in Steps 1 5 for Problem 1 flow chart replace the circuit board Figure 3 Wires 15A SECTION 4 4 DIAGNOSTIC TESTS TEST 45 CHECK 15 AMP FUSE DISCUSSION The 15 amp fuse is located on the generator console A blown fuse will prevent battery power from reaching the circuit board with the same result as setting the AUTO OFF MANUAL switch to OFF PROCEDURE Hemove the 1
53. 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 SECTION 1 4 TESTING CLEANING AND DRYING 6 Now proceed to the C2 connector Each winding will be individually tested for a short to ground Insert a large paper clip or similar item into the C2 connector at the following pin locations Pin Wire Winding Location Number 1 77 Battery Charge 2 66 Battery Charge 3 66A Engine Run 4 55 Engine Run 5 22 Sense Lead Power 6 11 Sense Lead Power 7 6 Excitation 8 2 Excitation Next refer to Steps 5a through 5c of the Hi Pot procedure Example Insert paper clip into Pin 1 Hi Pot from Pin 1 Wire 77 to ground Proceed to Pin 2 Pin 3 etc through Pin 8 Figure 3 C2 Connector Pin Location Numbers Female Side TEST BETWEEN WINDINGS 1 Insert a large paper clip into Pin Location 1 Wire 77 Connect the red tester probe to the paper clip Connect the black tester probe to Stator Lead 11 Refer to Steps 5a through 5c of TESTING ALL STATOR WINDINGS TO GROUND on the previous page Repeat Step 1 at Pin Location 3 Wire 66A and Stator Lead 11 Repeat Step 1 at Pin Location 7 Wire 6 and Stator Lead 11 4 Connect the red test probe to
54. output will then be reduced to a voltage that is the product of residual magnetism alone PROCEDURE 1 With the generator shut down for at least two minutes locate the excitation circuit breaker in the generator panel Disconnect wires from the breaker to prevent interaction 2 Set a volt ohm milliammeter VOM to its R x 1 scale and zero the meter 3 Connect the VOM test probes across the circuit breaker terminals The meter should read CONTINUITY RESULTS 1 Replace circuit breaker if defective meter reads OPEN Then proceed to Test 4 2 lf circuit breaker is good go on to Test 4 Figure 2 Excitation Circuit Breaker AC GENERATORS SECTION 2 4 DIAGNOSTIC TESTS TEST 4 FIXED EXCITATION TEST ROTOR AMP DRAW TEST 2 2 BOP o o DISCUSSION amp 59958888 Supplying fixed current to the rotor will induce lt lt lt lt magnetic field in the rotor With the generator running this should create a proportional voltage output from the stator windings PROCEDURE 1 Disconnect Wire 4 from the voltage regulator 3rd terminal from the top See Figure 3 Above 60 VAC Above 60 VAC 2 Connect a jumper wire to the disconnected Wire 4 and to the 12 volt fused battery supply Wire 15 located at 15A fuse 0 91 1 06A Below 60 VAC Below 60 VAC 0 71 0 82A Test 7 Above 1 3A Above 1 1A Above 1 3A Above 1 5A Above 1 3A Above 1
55. probe to the paper clip Insert the additional large paper clip into Pin Location 7 Wire 6 Connect the black tester probe to this paper clip Refer to Steps 5a through 5c of TESTING ALL STATOR WINDINGS TO GROUND on the previous page ROTOR INSULATION RESISTANCE TEST Before attempting to test rotor insulation the brush holder must be completely removed The rotor must be completely isolated from other components before starting the test Attach all leads of all stator windings to ground 1 Connect the red tester lead to the positive slip ring nearest the rotor bearing 2 Connect the black tester probe to a clean frame ground such as a clean metal part of the rotor shaft 3 Turn the tester switch OFF 4 Plug the tester into a 120 volts AC wall socket and set the voltage switch to 1500 volts 5 Turn the tester switch On and make sure the pilot light has turned on Page 1 4 6 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 TEST LEAD Figure 4 Testing Rotor Insulation CLEANING THE GENERATOR Caked or greasy dirt may be loosened with a soft brush or a damp cloth A vacuum s
56. seconds on and 15 seconds off After the first crank rest cycle the remaining cycles will be In equal 7 9 second durations This cyclic cranking action continues until either a the engine starts or b approximately 90 seconds of the crank rest cycles have elapsed The run relay is energized by circuit board action at the same time as the crank relay to energize anq open a fuel solenoid valve DANGER THE GENERATOR ENGINE WILL CRANK AND START WHEN THE 7 DAY EXERCISER SWITCH IS ACTUATED THE UNIT WILL ALSO CRANK AND START EVERY 7 DAYS THEREAFTER ON THE DAY AND AT THE TIME OF DAY THE SWITCH WAS ACTUATED AUTO OFF MANUAL SWITCH This 3 position switch permits the operator to a select fully automatic operation b start the generator manually or c stop the engine and prevent automatic startup Switch terminals are shown pictorially and schematically in Figure 5 below IF EQUIPPED SCHEMATIC Figure 4 The AUTO OFF MANUAL Switch Page 4 1 3 15 AMP FUSE This fuse protects the circuit board against excessive current If the fuse has blown engine cranking and operation will not be possible Should fuse replacement become necessary use only an identical 15 amp replacement fuse 5 AMP FUSE This fuse protects the battery charger against excessive current If the fuse has blown battery charge operation will not be possible Should fuse replacement become necessary use only an identi
57. the meter 22 Connect one test lead to stator lead Wire 11 Connect the other test lead to stator lead Wire 33 a The meter should read INFINITY b Any reading other than INFINITY indicates a short circuit between windngs 23 Repeat Step 22 using stator lead Wire 11 Pin 1 24 Repeat Step 22 using stator lead Wire 11 Pin 3 25 Repeat Step 22 using stator lead Wire 11 Pin 7 26 Repeat Step 22 using stator lead Wire 33 Pin 1 27 Repeat Step 22 using stator lead Wire 33 Pin 3 28 Repeat Step 22 using stator lead Wire 33 Pin 7 29 Repeat Step 22 using Pin 1 Pin 3 30 Repeat Step 22 using Pin 1 Pin 7 31 Repeat Step 22 using Pin 3 Pin 7 TEST CONTROL PANEL WIRES FOR CONTINUITY 32 Set a VOM to its Rx1 scale 33 Disconnect the C2 connector from the control panel C2 is the closest to the back panel Refer to Figure 6 for pin locations 33 one meter test lead to Pin 5 of the C2 connector connect the other test lead to Wire 22 at the voltage regulator CONTINUITY should be measured 34 Connect one meter test lead to Pin 6 of the C2 connector connect the other test lead to Wire 11 at the voltage regulator CONTINUITY should be measured Page 2 4 6 35 Connect one meter test lead to Pin 7 of the C2 connector connect the other test lead to Wire 6 at the voltage regulator CONTINUITY should be measured 36 Connect one meter test lead to Pin 8 of the C2 connector connect the other test lead to Wire
58. the standby source Li Utility source voltage is used to operate a battery trickle charge circuit which helps to maintain battery state of charge during non operating periods TERMINALS 23 AND 194 These terminals connect the transfer relay to the generator circuit board See Transfer Relay on Page 3 1 2 SECTION 3 1 DESCRIPTION amp COMPONENTS FUSE HOLDER The fuse holder holds two 2 fuses designated as fuses F1 and F2 Each fuse is rated 5 amperes FUSES F1 F2 These two fuses protect the terminal board UTILITY 1 and 2 circuit against overload Figure 7 The Fuse Holder Page 3 1 4 SECTION 3 2 V TYPE PREPACKAGED OPERATIONAL ANALYSIS OPERATIONAL ANALYSIS Figure 1 is a schematic and wiring diagram for a typical V Type transfer switch SCHEMATIC DIAGRAM LEGEND C1 SOLENOID COIL UTILITY CLOSING C2 SOLENOID COIL STANDBY CLOSING GTS TRANSFER SWITCH CONTACTOR TR RELAY TRANSFER TS TERMINAL STRIP CUSTOMER CONNECTION XA1 XB1 LIMIT SWITCHES ACTUATOR F1 F2 FUSE 5A SENSING VR1 VR2 VARISTOR 23 19469 194 NOTE ALL CONTACTS SHOWN WITH TRANSFER SWITCH IN UTILITY POSITION WIRING DIAGRAM N1 UTILITY 1 UTILITY 2 Figure 1 Wiring Diagram and Schematic Page 3 2 1 V TYPE PREPACKAGED PART 3 SECTION 3 2 2 EE OPERATIONAL ANALYSIS UTILITY SOURCE VOLTAGE AVAILABLE Figure 2 is a schematic representation of the transfer swit
59. the voltage regulator is made PROCEDURE 7KW UNITS 1 Loosen the governor clamp bolt Figure 9 2 Hold the governor lever at its wide open throttle position and rotate the governor shaft clockwise as far as it will go Then tighten the governor lever clamp bolt to 70 inch pounds 8 N m 3 Start the generator let it stabilize and warm up at no load 4 Connect an AC frequency meter across the generators AC output leads 5 Turn the speed adjust nut to obtain a frequency reading of 62 Hz 6 When frequency is correct at no load check the AC voltage reading If voltage is incorrect the voltage regulator may require adjustment GOVERNOR 7 SHAFT GOVERNOR 4y Figure 9 Engine Governor Adjustment Single Cylinder Engines IDLE SPRING GOVERNO Wo SHAFT ROTATE CLOCKWISE as NO LOAD IDLE ADJUSTMENT SCREW GOVERNOR CLAMP BOLT Figure 10 Engine Governor Adjustment V twin Engines SECTION 2 4 DIAGNOSTIC TESTS PROCEDURE 12 15 KW UNITS Loosen governor clamp bolt See Figure 10 2 Completely remove the idle spring 3 With governor arm at wide open throttle position rotate governor shaft fully clockwise Tighten clamp bolt to 84 inch pounds 4 Start unit and apply full load Use full load speed adjust screw Figure 11 to adjust frequency to 58 Hz 5 Remove load stop engine loose
60. timing and if utility source voltage is still below 60 percent of the nominal source voltage circuit board action will energize a crank relay and a run relay Both of these relays are mounted on the circuit board If the engine starts cranking will terminate when generator AC output frequency reaches approximately 30 Hz SECTION 1 7 AUTOMATIC OPERATING PARAMETERS The circuit board senses that the engine is running by receiving a voltage frequency signal from the engine run windings When generator AC frequency reaches approximately 30 Hz an engine warm up timer on the circuit board turns on That timer will run for about ten 10 seconds The engine warm up timer lets the engine warm up and stabilize before transfer to the Standby source can occur NOTE The engine can be shut down manually at any time by setting the AUTO OFF MANUAL switch to OFF PHASE 5 TRANSFER TO STANDBY When the circuit board s engine warm up timer has timed out and AC voltage has reached 50 percent of the nominal rated voltage circuit board action completes a transfer relay circuit to ground The transfer relay is housed in the prepackaged transfer switch enclosure The transfer relay energizes and transfer of loads to the Standby power source occurs Loads are now powered by standby generator AC output When utility source voltage is restored above about 80 percent of the nominal supply voltage a 15 second timer on the circuit board s
61. to TX terminal 1 Connect the other test lead to TX terminal 10 INFINITY should be measured Page 3 4 9 SECTION 3 4 DIAGNOSTIC TESTS 12 Connect one test lead to TX terminal 1 Connect the other test lead to TX terminal 7 INFINITY should be measured 13 Connect one test lead to TX terminal 10 Connect the other test lead t TX terminal 7 INFINITY should be measured RESULTS For steps 5 6 and 7 replace transformer if an open is indicated or if the resistance value indicated is zero If the resistance value is not within the approximate range proceed to test 65 For steps 8 through 13 replace the transformer if it fails any of these steps Figure 6 Transformer TX Page 3 4 10 PART 3 V TYPE PREPACKAGED TRANSFER SWITCHES PART 4 DC CONTROL Air cooled Prepackaged Automatic Standby Generators Models 04389 04758 6 kW NG 7 kW LP 04456 04759 12 kW NG 12 kW LP 04390 04760 13 kW NG 15 kW LP SECTION 4 1 DESCRIPTION AND COMPONENTS 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 LIA Terminal Strip Interconnection Terminal LIA Transformer TX LIA Circuit Board An AUTO OFF MANUAL Switch LIA 15 Amp Fuse LIA 5 Amp Fuse TERMINAL STRIP INTERCONNECTION TERMINAL The terminals of this terminal strip are connected to id
62. 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 inl If proper procedures are used the following conditions can be detected using a VOM LIA 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 L An open condition in any stator or rotor winding Component testing may require a specific resistance value or a test for INFINITY or CONTINUITY INFINITY is an OPEN condition between two electrical points which would read as no resistance on a VOM CONTINUITY is a CLOSED condition between two electrical points which would be indicated as very low resistance or ZERO on a VOM ELECTRICAL UNITS AMPERE The rate of electron flow in a circuit is represented by the AMPERE The ampere is the number of electrons flowing past a given point at a given time One AMPERE is equal to just slightly more than six thousand million billion electrons per second With alternating current AC the electrons flow first in one direction then reverse and move in the opposite direction They will repeat this cycle at regular intervals A wa
63. winding Note the resistance reading and compare to the specifications on Page 2 9 Connect one test lead to Pin 1 Connect the other test lead to Pin 2 battery charge winding Note the resistance reading compare to specifications on Page 2 10 Connect one test lead to Pin 3 Connect the other test lead to Pin 4 engine run winding Note the resistance reading compare to specification Page 2 11 Connect one test lead to Pin 5 Connect the other test lead to Pin 6 power winding sense leads Note the resistance reading compare to specification Page 2 12 Connect on test lead to Pin 7 Connect the other test lead to Pin 8 excitation winding Note the resistance reading compare to specification Page 2 Page 2 4 5 SECTION 2 4 DIAGNOSTIC TESTS TEST WINDINGS FOR A SHORT TO GROUND 13 Make sure all leads are isolated from each other and are not touching the frame 14 Set a VOM to its R x 10 000 or R x 1K scale and zero the meter 15 Connect one test lead to a clean frame ground Connect the other test lead to stator lead Wire 11 a The meter should read INFINITY b Any reading other than INFINITY indicates a short to ground condition 16 Repeat Step 15 using stator lead Wire 33 17 Repeat Step 15 using Pin 1 18 Repeat Step 15 using Pin 3 19 Repeat Step 15 using Pin 5 20 Repeat Step 15 using Pin 7 TEST FOR A SHORT CIRCUIT BETWEEN WINDINGS 21 Set a VOM to its R x 10 000 or R x 1K scale and zero
64. 0 351 224 0 194 23 N 66A T N1 23 11 id 13A 194 351 15A m 194 N1 0 a Fe F1 e39 1 n n 15 M Q 5 5 O 17 13 x 12 239 O 0 gt VY V m poc 15 eie Ae z gt T 15 co d AUTD 240V GENERATOR 2 BSG OUTPUT TO TRANSFER 6 m SWITCH CONTACTOR m CUSTUMER c WIRING DIAGRAM REVISION F 9084 C 7 0 kW HSB DATE 1 21 03 DRAWING 0D9013 Page 7 1 6 SCHEMATIC 7 KW HOME STANDBY DATA MODEL 4389 1 DRAWING 0D9014 B 1 OF 2 11 11 22 22 225A 2 l BATTERY 2258 Fe 224A 2248 13A 72 13 PER e A 224 1 7 7 9 9 kh BCR T 1 6713 4 13A gt 77 13 747 B BATTERY CHARGE o6 gt 14 WINDING oOo ee 66 lt 22 0 HE tg 0 0 0 2 4 amp 55 AAAA Ir LHP 11 EN INDI NG Cie 97 swe 22 gt FIELD sas C STATOR ERU 14 15 E AAA AAJ ELECTRONIC 2 9 Ce 3 VOLTAGE 4 4 REGULATOR 0 85 23 162 C2 11 86 194 9 i 351 225 1
65. 0 4500 Maximum Amps 9 50 CLAMP ON METER 12 VOLT BATTERY TACHOMETER OX VISE Figure 15 Testing Starter Motor Performance TEST 51 CHECK FUEL SUPPLY AND PRESSURE DISCUSSION The air cooled prepackaged generator was factory tested and adjusted using natural gas as a fuel If desired LP propane gas may be used However when changing over to propane some minor adjustments are required The following facts apply An adequate gas supply and sufficient fuel pressure must be available or the engine will not start Minimum recommended gaseous fuel pressure at the generator fuel inlet connection is 11 inches water column 6 38 ounces per square inch Maximum gaseous fuel pressure at the generator fuel inlet connection is 14 inches water column 8 ounces per square inch L1 When propane gas is used only a vapor withdrawal system may be used This type of system utilizes the gas that form above the liquid fuel the vapor pressure must be high enough engine operation SECTION 4 4 DIAGNOSTIC TESTS L1 The gaseous fuel system must be properly tested for leaks following installation and periodically thereafter No leakage is permitted Leak test methods must comply strictly with gas codes DANGER GASEOUS FUELS ARE HIGHLY A EXPLOSIVE DO NOT USE FLAME OR HEAT TO TEST THE FUEL SYSTEM FOR LEAKS NATURAL GAS IS LIGHTER THAN AIR TENDS TO SETTLE IN HIGH PLACES LP PROPANE GAS IS HEAVIER THAN
66. 0 INCH FOR SINGLE CYLINDER Figure 22 Checking Spark Plug Gap TEST 57 CHECK ENGINE COMPRESSION DISCUSSION Lost or reduced engine compression can result in a failure of the engine to start or b rough operation One or more of the following will usually cause loss of compression L1 Blown or leaking cylinder head gasket Improperly seated or sticking valves LiWorn Piston rings or cylinder This will also result in high oil consumption NOTE For the single cylinder engine the minimum allowable compression pressure for a cold engine is 60 psi NOTE It is extremely difficult to obtain an accurate compression reading without special equipment For that reason compression values are not published for the V Twin engine Testing has proven that an accurate compression indication can be obtained using the following method PROCEDURE 1 Remove both spark plugs 2 Insert a compression gauge into either cylinder 3 Crank the engine until there is no further increase in pressure 4 Record the highest reading obtained 5 Repeat the procedure for the remaining cylinder and record the highest reading RESULTS The difference in pressure between the two cylinders should not exceed 25 percent If the difference is greater than 25 percent loss of compression in the lowest reading cylinder is indicated Example 1 If the pressure reading of cylinder 1 is 65 psi and of cylinder 2 60 psi the differe
67. 19 224 D DIODE T FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 5 AMP HIO HIGH OIL TEMPERATURE SWITCH IM1 IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH SC STARTER SCR STARTER CONTACTOR RELAY SP1 5 2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 amp 16 Vac 1 VA DUAL SEC REVISION F 7994 B SCHEMATIC DIAGRAM DATE 09 11 02 DRAWING 0D8501 Page 7 1 11 SCHEMATIC 12 amp 15 KW HOME STANDBY MODEL 4456 1 amp 4390 1 DRAWING 0D8501 B 2 OF 2 ELECTRICAL DATA 11 lt 62 6 ee lt TX C2 5 225A N N1 240VAC UTILITY 56VA NB N2 INPUT 224A M 225 12Vde E e3 EO RELAY 194 o9 TED CUSTOMER CONNECTIONS 13 17 11 NEUTRAL 2 E 22 154 33 SW1 154 194 POWER 120V WINDING 120V 539 C STATOR 13 17 15 44 2 194 d 1 1 9 15 239 0 240 14 15 13 lt RED 9 071 13 2 1 lt 6 15 56 16 lt lt 16 14 18 C1 1 ln BATTERY 0 17 E sM 12 0 0 0 BLACK 1
68. 2 at CB2 DPE circuit breaker CONTINUITY should be measured RESULTS 1 Stator winding resistance values is a test of winding continuity and resistance lf a very high resistance or INFINITY is indicated the winding is open or partially open 2 Testing for a grounded condition Any upscale movement of the meter needle or dial indicates the winding is grounded 3 Testing for a shorted condition Any upscale movement of the VOM needle or dial indicates the winding is shorted 4 f the stator tests good and wire continuity tests good perform Insulation Resistance Test on page 1 4 4 5 f any test of wire continuity failed in control panel failed repair or replace the wire terminal or pin connectors for that associated wire as needed NOTE Read section 1 4 Testing Cleaning and Drying carefully If the winding tests good perform an insulation resistance test If the winding fails the insulation resistance test clean and dry the stator as outlined in Section 1 4 Then repeat the insulation resistance test If the winding fails the second resistance test after cleaning and drying replace the stator assembly TEST 8 RESISTANCE CHECK OF ROTOR CIRCUIT DISCUSSION To verify the zero current draw reading and measure the rotor circuit PROCEDURE 1 Disconnect Wire 4 from the voltage regulator It is located 3rd terminal from the top of the volt regulator 2 Set VOM to the Rx1 scale 3 Connect on
69. 320 rpm circuit board action will de energize a run relay mounted on the circuit board The relay s contacts will open to terminate engine ignition and close a fuel shutoff solenoid The engine will then shut down This feature protects the engine generator against damaging overspeeds NOTE The circuit board also uses engine run winding output to terminate engine cranking at approximately 30 Hz 1800 rpm In addition the engine run winding output is used by the circuit board as an engine running signal The circuit board will not initiate transfer of electrical loads to the Standby source unless the engine is running at 30 Hz or SECTION 1 5 ENGINE GENERATOR PROTECTIVE DEVICES above LOW OIL SWITCH HIGH TEMP SWITCH Figure 1 Engine Protective Switches on an Air Cooled Engine OVERCRANK SHUTDOWN Automatic engine cranking and startup normally occurs when the circuit board senses that utility source voltage has dropped below approximately 60 percent of its nominal rated voltage and remains at that low level longer than fifteen 15 seconds At the end of fifteen 15 seconds circuit board action will energize a crank relay and a run relay both relays are on the circuit board On closure of the crank relay contacts circuit board action will deliver 12 volts DC to a starter contactor relay SCR for v twin models or a starter contactor SC for single cyli
70. 35 TEST 35 CHECK TRANSFORMER TX DISCUSSION The transformer is a step down type and has two functions It supplies approximately 16VAC to the control board for utility sensing It also supplies approximately 16 VAC to the battery charger when utility is available for trickle charge A shorted transformer can result in fuse F1 or F2 blowing PROCEDURE 1 On the generator panel set the AUTO OFF MANUAL switch to OFF 2 Turn off the utility power supply to the transfer switch using whatever means is provided 3 See Figure 6 Disconnect Wires 1 N2 224 225 224A 225A from transformer TX 4 Seta VOM to the R x 1 scale 5 Connect one test lead to TX terminal 1 Connect the other test lead to TX terminal 5 Approximately 38 5 ohms should be measured 6 Connect one test lead to TX terminal 10 Connect the other test lead to TX terminal 9 Approximately 1 5 ohms should be measured 7 Connect one test lead tot TX terminal 7 Connect the other test lead to TX terminal 6 Approximately 0 3 ohms should be measured 8 Connect one test lead to TX terminal 1 Connect the other test lead to the transformer case INFINITY should be measured 9 Connect one test lead to TX terminal 7 Connect the other test lead to the transformer case INFINITY should be measured 10 Connect one test lead to TX terminal 9 Connect the other test lead to the transformer case INFINITY should be measured 11 Connect one test lead
71. 400 5 2 7 A 224 o 6 EDT 66A C2 8 2 DPE WINDING Life 31415 66A CSTATOR Ja 23 aoe 1 4 194 3 23 4 194 DIAGRAM KEY 5 6 18 7 BA BRUSH ASSEMBLY 8 m BCR BATIERY CHARGE RELAY PRINTED CIRCUIT 9 239 CB1 CIRCUIT BREAKER MAIN OUTPUT BOARD T CB2 CIRCUIT BREAKER ALT EXCITATION 15 D DIODE 13 0 FS FUEL SOLENOID a an F1 FUSE 15 AMP T F2 FUSE 5 AMP 17 HIGH OIL TEMPERATURE SWITCH HM HOUR RUN METER IM IGNITION MODULE LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTER SP SPARK PLUG SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC SCHEMATIC DIAGRAM REVISION F 7994 B DRAWING 0D9014 DATE 09 11 02 Page 7 1 7 SCHEMATIC 7 KW HOME STANDBY MODEL 4389 1 ELECTRICAL DATA DRAWING 0D9014 B 2 OF 2 11 lt Ce 6 ee TX 2 5 2250 N2 NI Q e40vac UTILITY 56 N2 N2 GO INPUT 224A 225 na e3 2 18V TRANSFER 1VA RELAY 7 CUSTOMER CONNECTIONS 17 11 NEUTRAL 17 23 28 33 5 0 O Sum 194 120V WINDI
72. 5 CUSTOMER 0 IML SUPPLIED 18 EE SPI D lt lt 18 C1 5 D gt E ire SCHEMATIC DIAGRAM REVISION F 7994 B DRAWING 0D8501 DATE 09 11 02 Page 7 1 12 Page 7 1 13 Page 7 1 14 Page 7 1 15 PO Box 297 Whitewater WI 53190 www guardiangenerators com GUARDIAN by Generac Power Systems Inc P N OE3586 Printed in the USA 1 03 Rev 3 04 XXXXXXXXXXXXXXXXXXXXXXXX P A RT X S E XXXXXXXXXXXXXXXXXXXXXXXXXXX RESULTS 1 Repair engine or replace defective part s or adjust as necessary 2 lf no engine problems are found go to Test 7 Page 149 S E CTI O N X X PART X XXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXX XO000000000000000000000X 3 4 provides detailed instructions for performance of each test XXXXXXXXXXXXXXXXXXXXXXXX P A RT X S E XXXXXXXXXXXXXXXXXXXXXXXXXXX PROCEDURE 1 Set the AUTO OFF MANUAL switch SW1 to MANUAL The generator should start Set SW1 back to AUTO Verify that SW1 has been in AUTO for weekly exercise to function 2 Verify that DIP Switch 2 REMOTE NOT AUTO on the circuit board is set to the OFF position see Figure 1 Page 1 6 1 3 Hold the Set Exercise switch until the generator starts approximately 10 seconds and then release The generator will start and run for approximately 12 minutes and then shutdown on it s own The exerciser will then be set to start and run at that time of
73. 5 amp fuse F1 by pushing in on fuse holder cap and turning the cap counterclockwise Inspect the fuse visually and with a VOM for an open condition RESULTS 1 If the fuse if good go on to Test 46 2 If the fuse is bad it should be replaced Use only an identical 15 amp replacement fuse If fuse continues to blow go to Problem 16 TEST 46 CHECK BATTERY DISCUSSION Battery power is used to a crank the engine and b to power the circuit board Low or no battery voltage can result in failure of the engine to crank either manually or during automatic operation PROCEDURE A Inspect Battery Cables 1 Visually inspect battery cables and battery posts 2 f cable clamps or terminals are corroded clean away all corrosion 3 Install battery cables making sure all cable clamps are tight The red battery cable from the starter contactor SC must be securely attached to the positive battery post the black cable from the frame ground stud must be tightly attached to the negative battery post B Test Battery State of Charge 1 Use an automotive type battery hydrometer to test battery state of charge 2 Follow the hydrometer manufacturer s instructions carefully Read the specific gravity of the electrolyte fluid in all battery cells 3 the hydrometer does not have a percentage of charge scale compare the reading obtained to the following Page 4 4 3 SECTION 4 4 DIAGNOSTIC TESTS a An
74. AD BAD FINISH REPAIR OR REPLACE REPLACE Page 3 3 2 V TYPE PREPACKAGED TRANSFER SWITCHES PART 3 GENERAL Test numbers in this section correspond to the numbered tests in Section 3 3 Troubleshooting Flow Charts When troubleshooting first identify the problem Then perform the diagnostic tests in the sequence given in the flow charts TEST 21 CHECK VOLTAGE AT TERMINAL LUGS 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 SECTION 3 4 DIAGNOSTIC TESTS PROCEDURE 1 If the generator engine has started automatically due to a utility power source outage and is running check the position of the generator main circuit breaker The circuit breaker must be set to its On or Closed position When you are sure the generator main circuit breaker is set to On or Closed check the voltage at transfer mechanism terminal lugs E1 and E2 with an accurate AC voltmeter or with an accurate volt ohm milliamm
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76. AIR TENDS TO SETTLE IN LOW AREAS EVEN THE SLIGHTEST SPARK CAN IGNITE THESE GASES AND CAUSE AN EXPLOSION PROCEDURE A water manometer or a gauge that is calibrated in ounces per square inch may be used to measure the fuel pressure Fuel pressure at the inlet side of the fuel solenoid valve should be between 11 14 inches water column as measured with a manometer or 6 38 8 00 ounces per square inch as measure with a pressure gauge The fuel pressure can be checked using a pressure tester kit Generac p n 0C7977 See Figure 16 for the gas pressure test point on the fuel regulator NOTE Where a primary regulator is used to establish fuel inlet pressure adjustment of that regulator is usually the responsibility of the fuel supplier or the fuel supply system installer RESULTS 1 If fuel supply and pressure are adequate but engine will not start go on to Test 53 2 f generator starts but runs rough or lacks power repeat the above procedure with the generator running and under load The fuel system must be able to maintain 11 14 water column at all load requirements If proper fuel supply and pressure is maintained go to Test 55 GAS PRESSURE TAP FUEL HOSE SMALL FUEL JET REGULATOR HOUSING PORT Figure 16 Air Cooled Engine Fuel System Page 4 4 9 SECTION 4 4 DIAGNOSTIC TESTS TEST 52 TEST FUEL SOLENOID Note This test is for fuel regulators equipped with idle circuit port only See Figur
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78. CESS HOLES REMOVE PLUG FOR ACCESS GROUNDING LUG 5 9 RIGHT SIDE VIEW REAR VIEW ALL DIMENSIONS IN MILLIMETERS INCHES HOME STANDBY GENERATOR INSTALLATION DIAGRAM Page 4 SPECIFICATIONS MAJOR FEATURES 7 kW Single Cylinder GH 410 Engine EXHAUST ENCLOSURE AIR FILTER FUEL REGULATOR BEHIND BATTERY COMPARTMENT OIL FILTER BATTERY COMPARTMENT 12 kW and 15 kW V twin GT 990 Engine AIR FILTER DATA CONTROL DECAL PANEL EXHAUST ENCLOSURE FUEL REGULATOR BEHIND BATTERY COMPARTMENT OIL FILTER BATTERY COMPARTMENT Page 5 PAR Generator Identification PART 1 GENERAL INFORMATION Air cooled Prepackaged Automatic Standby Generators Models 04389 04758 6 kW NG 7 kW LP 04456 04759 12 kW NG 12 kW LP 04390 04760 13 kW NG 15 kW LP SECTION 1 1 GENERATOR IDENTIFICATION INTRODUCTION This Diagnostic Repair Manual has been prepareq especially for the purpose of familiarizing service personnel with the testing troubleshooting and repair of air cooled prepackaged automatic standby generators Every effort has been expended to ensure that information and instructions in the manual are both accurate and current However Generac reserves the right to change alter or otherwise improve the product at any time without prior notification The manual has been divided into ten PARTS Each PART has been divided into SECTIONS Each SECTION consists of two or more SUBS
79. Connect one meter test Lead to Wire N2A Use a suitable and safe connection to this wire such as an alligator clip that attaches to the meter test probe Isolate this wire and test probe from any other potential source or ground V TYPE PREPACKAGED 6 Set the generator main line circuit breaker to its On or Closed position 7 Set the generator AUTO OFF MANUAL switch to AUTO a The generator should crank and start b About 15 seconds after engine startup the transfer relay should energize and transfer to the Standby source should occur 8 When you are certain that transfer to Standby has occurred turn ON the utility power supply to the transfer switch After a 15 seconds retransfer back to the Utility source should occur 9 Locate on the utility closing coil the terminal that Wire A is connected to see Figure 1 Page 3 4 1 Connect the other meter test lead to this terminal Generator line to line voltage should be indicated If generator voltage is NOT indicated proceed to Step 10 10 With Wire N24 still connected to one test probe connect the other meter test lead to Wire 126 on Limit Switch XA1 see Figure 1 Page 3 4 1 Generator line to line voltage should be measured RESULTS 1 In Step 7 if the generator does NOT crank or start refer to Part 4 DC Control 2 n Step 7 if transfer to the Standby source does NOT occur go to Problem 1 3 In Step 9 if normal utility source line to line
80. ECTIONS 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 1 1 1 Item 4 0055555 Serial 1234567 Volts 120 240 Amps 125 62 5 Watts 15000 1 PH 60 HZ RPM 3600 RAINPROOF ENCLOSURE FITTED CLASS F INSULATION MAX OPERATING AMBIENT TEMP 120F 49C FOR STANDBY SERVICE NEUTRAL FLOATING MAX LOAD UNBALANCED 50 GENERAC POWER SYSTEMS WAUKESHA WI MADE IN U S A Figure 1 A Typical Data Plate INTRODUCTION Information in this section is provided so that the service technician will have a basic knowledge of installation requirements for prepackaged home standby systems Problems that arise are often related to poor or unauthorized installation practices A typical prepackaged home standby electric system is shown in Figure 1 next page Installation of such a system includes the following Selecting a Location Grounding the generator L1 Providing a fue
81. ECTRONIC SP1 2 SPARK PLUGS VOLTAGE SW1 AUTO OFF MANUAL SWITCH REGULATOR SW SET EXERCISE SWITCH G E N E RATO R SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC mam 12 VDC ALWAYS PRESENT me AC VOLTAGE ma GROUND FOR CONTROL PURPOSES mu 12 VDC DURING CRANKING ONLY mamam 12 VDC DURING ENGINE RUN CONDITION Page 4 2 12 SECTION 4 2 OPERATIONAL ANALYSIS ENGINE SHUTDOWN Following retransfer back to the Utility source an engine cool down timer on the circuit board starts timing When that timer has timed out approximately one minute circuit board action will de energize the circuit board s run relay K2 The following events will then occur The DC circuit to Wire 14 and the fuel solenoid FS will be opened The fuel solenoid FS will de energize and close to terminate the engine fuel supply The hourmeter if equipped connected to Wire 14 will be opened and clock function of the hourmeter will stop The battery charge relay BCR connected to Wire 14 will be de energized This will cause transformer TX voltage to power the battery charger again Circuit board action will connect the engine s ignition shutdown module ISM to ground via Wire 18 circuit board Pin 13 and Wire 0 Ignition will be terminated Without fuel flow and without ignition the engine will shut down Page 4 2 13 DC CONTROL
82. ENTS Generators with air cooled engine have been factory tested and adjusted using natural gas as a fuel If LP propane gas is to be used at the installation site adjustment of the generator fuel regulator will be required for best performance Refer to Test 63 Check Fuel Regulator on Page 4 4 16 for fuel regulator adjustment procedures LiWhen natural gas is used as a fuel it should be rated at least 1000 BTU s per cubic foot When LP propane gas is used as a fuel it should be rated at 2520 BTU s per cubic foot Page 1 3 1 ENGINE OIL RECOMMENDATIONS The primary recommended oil for units with air cooled single cylinder or V Twin engines is synthetic oil Synthetic oil provides easier starts in cold weather and maximum engine protection in hot weather Use high quality detergent oil that meets or exceeds API American Petroleum Institute Service class SG SH or SJ requirements for gasoline engines The following chart lists recommended viscosity ranges for the lowest anticipated ambient temperatures Engine crankcase oil capacities for the engines covered in this manual can be found in the specifications section at the beginning of the book LOWEST ANTICIPATED AMBIENT TEMPERATURE Above 60 16 20 59 7 to 15 C AIR COOLED ENGINE RECOMMENDED OIL Use SAE 30 oil Use SAE 10W 30 oil SAE 5W 20 5W 30 oil Use SAE 5W 30 Synthetic oil Below 20 F 7 C For all seasons GENERAL INFORMATION
83. F2 terminal from which Wire 13A was removed The VOM should measure 50 milliamps to 2 5 amps depending upon the state of the charge of the battery 6 Repeat Step 5 This time set the AUTO OFF MANUAL switch to MANUAL Allow the generator to start and then measure the current again as in Step 5 RESULTS Follow the Flow Chart on Page 4 3 5 TEST 65 CHECK TRANSFORMER TX VOLTAGE OUTPUT DISCUSSION The Transformer TX is a STEP DOWN type and has two functions It supplies approximately 16 VAC to the control panel circuit board for utility sensing It also supplies approximately 16 VAC to the battery charger for trickle charging A defective transformer will a not supply AC to the battery charger and b not supply sensing voltage to the circuit board Figure 32 Transformer TX PROCEDURE 1 Set VOM to measure AC voltage 2 Connect one meter test lead to the Transformer TX Terminal 5 Wire N1 Connect the other meter test lead to the Transformer TX Terminal 1 Wire N2 Utility line to line voltage 240 VAC should be measured 3 Connect one meter test lead to the Transformer TX Terminal 6 with Wire 225A removed Connect the other meter test lead to the Transformer TX Terminal 7 with Wire 224A removed This output supplies power to the battery charger The VOM should measure approximately 16 VAC 4 Connect one meter test lead to the Transformer TX Terminal 9 with Wire 224 removed Connect the othe
84. H PLACES EVEN THE SLIGHTEST SPARK CAN IGNITE THESE FUELS AND CAUSE AN EXPLOSION Use of a flexible length of hose between the generator fuel line connection and rigid fuel lines is required This will help prevent line breakage that might be caused by vibration or if the generator shifts or settles The flexible fuel line must be approved for use with gaseous fuels Flexible fuel line should be kept as straight as possible between connections The bend radius for flexible fuel line is nine 9 inches Exceeding the bend radius can cause the fittings to crack THE TRANSFER SWITCH LOAD CENTER A transfer switch is required by electrical code to prevent electrical feedback between the UTILITY and STANDBY power sources and to transfer electrical loads from one power supply to another safely PREPACKAGED TRANSFER SWITCHES Instructions and information on prepackaged transfer switches may be found in Part 3 of this manual Page 1 2 1
85. N 1 3 8 32 CIRCT BRK 20 X 1 HOM120 38 CIRCT BRK 20 X 2 HOM220 84 CIRCT BRK 15 X 1 HOM115 35 CIRCT BRK 30 X 2 HOM230 36 COVER HARNESS ENTRY 37 HARNESS GTS TO EXT CONN BOX 38 WASHER LOCK 39 SCREW SW 1 4 20 5 8 N WA JS500 40 SCREW SWAGE 1 4 20 X 1 2 ZINC 41 SCREW PPHM M4 07 X 10 42 HARNESS GTS TO MAIN PANEL O V TYPE PREPACKAGED TRANSFER SWITCHES ENCLOSURE The standard prepackaged V Type transfer switch enclosure is a NEMA 1 type NEMA stands for National Electrical Manufacturer s Association Based on NEMA Standard 250 the NEMA 1 enclosure may be defined as one that is intended for indoor use primarily to provide a degree of protection against contact with the enclosed equipment and where unusual service conditions do not exist 39 Figure 1 Exploded View of V Type Prepackaged Transfer Switch Page 3 1 1 V TYPE PREPACKAGED 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 STA
86. N the utility power supply to the transfer switch Retransfer back to the Utility source should occur After an engine cool down timer has timed out generator shutdown should occur RESULTS 1 If normal automatic operation is obtained discontinue tests 2 f engine does NOT crank when Utility power is turned off proceed to Test 42 3 If engine cranks but won t start go to Problem 10 in Section 4 3 4 f engine cranks and starts but transfer to Standby does NOT occur go to Problem 5 in Section 3 3 5 f transfer to Standby occurs but retransfer back to Utility does NOT occur when utility source voltage is restored go to Problem 6 in Section 3 3 SECTION 4 4 DIAGNOSTIC TESTS TEST 42 TRY A MANUAL START DISCUSSION The first step in troubleshooting for an engine won t crank condition is to determine if the problem is peculiar to automatic operations only or if the engine won t crank manually either PROCEDURE 1 On the generator panel set the AUTO OFF MANUAL switch to OFF 2 Set the generator main line circuit breaker to its OFF or open position 3 Set the generator AUTO OFF MANUAL switch to MANUAL a The engine should crank cyclically through it s crank rest cycles until it starts b Let the engine stabilize and warm up for a few minutes after it starts RESULTS 1 If the engine cranks manually but does NOT crank automatically go to Test 43 2 f the engine does NOT cran
87. NDBY UTILITY Figure 2 Load Connected to Utility Power Source STANDBY UTILITY Figure 3 Load Connected to Standby Power Source UTILITY CLOSING COIL C1 See Figure 4 This coil is energized by rectified utility source power to actuate the load contacts to the UTILITY power source side When energized the coil will move the main contacts to an overcenter position A limit switch will then be actuated to open SECTION 3 1 DESCRIPTION amp COMPONENTS the circuit and spring force will complete the retransfer to STANDBY A bridge rectifier which changes the utility source alternating current AC to direct current DC is sealed in the coil wrappings If coil or bridge rectifier replacement becomes necessary the entire coil and bridge assembly should be replaced STANDBY CLOSING COIL C2 Coil C2 is energized by rectified standby source power to actuate the load contacts to their Standby source side Energizing the coil moves the load contacts to an overcenter position limit switch action then opens the circuit and spring force will complete the transfer action to Standby This coil s bridge rectifier is also sealed in the coil wrappings Replace the coil and bridge rectifier as a unit LIMIT SWITCHES XA1 AND 1 Switches are mechanically actuated by load contacts movement When the load contacts are connected to the utility contacts limit switch XA1 opens the utility circuit to utility closing coil C1 an
88. NG 120V STATOR 239 23 Q M 1 5 194 15 240V B39 15A 15 uU LT 1 13 lt RED 1 0 17 0 SC 14 14 56 56 14 BATTERY T 12V GO G m 0 17 18 0 0 18 0 BLACK CUSTOMER 18 gt IM gt SUPPLIED Clr 5 D mm SP SCHEMATIC DIAGRAM REVISION F 7994 B DRAWING 0D9014 DATE 09 11 02 Page 7 1 8 WIRING DIAGRAM 12 amp 15 KW HOME STANDBY MODEL 4456 1 amp 4390 1 DRAWING 0D8500 B 1 OF 2 ELECTRICAL DATA DIAGRAM KEY BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY CB1 MAIN OUTPUT BREAKER D DIODE DSW PCB MOUNTED DIP SWITCH FS FUEL SOLENOID Fl FUSE 15 AMP Fe FUSE 3 AMP GRD CONTROL PANEL GROUND HIGH OIL TEMPERATURE SWITCH IC INLINE CONNECTOR CEZ CIRCUIT BREAKER ALTERNATOR EXCITATION ENGINE WIRING BATTERY CHARGER 2 224 INTERCONNECTI
89. NG GOOD CIRCUIT VOLTAGE VOLTAGE OUTPUT VOLTAGE AT CIRCUIT BOARD BOARD BAD BAD BAD gt REPAIR REPLACE REPLACE TURN TEST 28 CHECK TEST 27 CHECK UTILITY 1 amp TEST 30 CHECK UTILITY 2 FUSE F1 amp F2 BAD SOURCE TERMINALS VOLTAGE BAD ni REPAIR N1 N2 OPEN WIRING REPLACE REPAIR OR REPLACE WIRE BETWEEN TRANSFER SWITCH GO TO PROBLEM 7 N1A N2A BETWEEN N1 N2 LUGS AND FUSE HOLDER AND GENERATOR PAGE 3 3 2 Problem 15 Generator Starts Immediately in Auto No Transfer to Standby Utility Voltage is Present TEST 74 CHECK REPLACE REMOTE START GOOD CIRCUIT WIRING IF EQUIPPED BOARD TEST 73 TEST TEST 43 TEST GOOD gt AUTO OFF MANUAL SET EXERCISE SWITCH SWITCH BAD 4 BAD REWIRE OR REPLACE OR CORRECT WIRING REPAIR OR REPLACE REPLACE Page 4 3 6 SECTION 4 3 TROUBLESHOOTING FLOW CHARTS DC CONTROL Problem 16 15 Amp Fuse F1 Blown FUSE BLOWS TEST 75 CHECK REPLACED CIRCUIT FUSE BLOWS WHEN TEST 76 CHECK PLACED IN AUTO OR p CRANKING AND MANUAL RUNNING CIRCUITS Problem 17 5 Amp Fuse F2 Blown IF BATTERY SOURCE IS REVERSED THE 5A FUSE WILL OPEN IMMEDIATELY CHECK BATTERY CONNECTIONS FOR PROPER POLARITY INSTALL NEW 5A FUSE AND RETEST FUSE BLOWN Y TEST 66 CHECK AC REPLACE VOLTAGE AT GOOD gt BATTERY BATTERY CHARGER CHARGER BAD Y PROCEED WITH TEST 66 RESULTS Problem 18 Generator Will Not
90. 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 lf transfer relay checks good go to Test 26 TEST 24 CHECK MANUAL TRANSFER SWITCH OPERATION LOAD CONNECTED TO STANDBY POWER SOURCE TRANSFER SWITCH OPERATING LEVER MANUAL TRANSFER HANDLE Figure 3 Manual Transfer Switch Operation Page 3 4 3 SECTION 3 4 DIAGNOSTIC TESTS DISCUSSION In automatic operating mode when utility source voltage drops below a preset level the engine should crank and start On engine startup an engine 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 o
91. OHM Unit measuring resistance or opposition to flow AMPERE Unit measuring rate of current flow number of electrons past a given point VOLT Unit measuring force or difference in potential causing current flow Figure 4 Electrical Units OHM S LAW A definite and exact relationship exists between VOLTS OHMS and AMPERES The value of one can be calculated when the value of the other two are known Ohm s Law states that in any circuit the current will increase when voltage increases but resistance remains the same and current will decrease when resistance Increases and voltage remains the same Figure 5 If AMPERES is unknown while VOLTS and OHMS are known use the following formula _ VOLTS AMPERES OHMS If VOLTS is unknown while AMPERES and OHMS are known use the following formula VOLTS AMPERES x OHMS If OHMS is unknown but VOLTS and AMPERES are known use the following _ VOLTS OHMS AMPERES Page 1 4 3 SECTION 1 4 TESTING CLEANING AND DRYING INSULATION RESISTANCE The insulation resistance of stator and rotor windings is a measurement of the integrity of the insulating materials that separate the electrical windings from the generator steel core This resistance can degrade over time or due to such contaminants as dust dirt oil grease and especially moisture In most cases failures of stator and rotor windings is due to a breakdown in the insulation And in many cases a low insula
92. OM test probes connected across the breaker s Wire 44 terminal and the E2 terminal RESULTS 1 Ifthe circuit breaker tests good go on to Test 2 2 If the breaker tests bad it should be replaced E2 TERMINAL E1 TERMINAL WIRE 11 TERMINAL WIRE 44 TERMINAL Figure 1 Generator Main Circuit Breaker Test Points Page 2 4 1 SECTION 2 4 DIAGNOSTIC TESTS 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 units DATA PLATE for rated line to line and line to neutral voltages DANGER USE EXTREME CAUTION DURING A THIS TEST THE GENERATOR WILL BE RUNNING HIGH AND DANGEROUS VOLTAGES WILL BE PRESENT AT THE TEST TERMINALS CONNECT METER TEST CLAMPS TO THE HIGH VOLTAGE TERMINALS WHILE THE GENERATOR IS SHUT DOWN STAY CLEAR OF POWER TERMINALS DURING THE TEST MAKE SURE METER CLAMPS ARE SECURELY ATTACHED AND WILL NOT SHAKE LOOSE PROCEDURE 1 With the engine shut down connect the AC voltmeter test leads across the Wires 11 and 44 terminals of the generator main circuit breaker see Figure 1 These connections will permit line to line voltages to be read 2 Set the generator main circuit breaker to its OFF or Open position This test will be conducted with the generator running at no load 3 Start the generator let it stabilize and warm up for
93. ON TERMINALS i 13 IGNITION MODULE CYLINDER 1 0 0 IGNITION MODULE CYLINDER 2 B 2258 LOW PRESSURE SWITCH 2248 S STARTER CONTACTUR SCR STARTER CONTACTOR RELAY 14 SPARK PLUGS 0 0 SW1 AUTO OFF MANUAL SWITCH 14 SWe SET EXERCISE SWITCH SM STARTER MOTOR INSULATED TERMINAL BLOCK TX TRANSFORMER 16 Voc 56 VA 16 Voc 1 DUAL SEC IC folo L EL SP1 0 6 0 0 IM1 18 gt 5 14 85 4 gt 86 gt 3 13 gt 2 13 13 D 13 13 SP2 IC gt 1 16 C1 IC 16 0 SCR 13 351 18 A B 86 351 0 14 0 85 T 18 16 56 56 i 1 86 86 1 2 3 4 5 i Je 56 4 4 J1 fal 86 I 23 xd 194 SR CONTROL D 56 PRINTED CIRCUIT BHARD 18 14 66A RED eo 239 1234 184 3 ON 1E ON INDICATES E 225 SM 1 20 Vac Sense Transformer 5 2 4 E q 2 Remate Not Auto D 12V 3 5 Hz Operation B BATTERY 4 SPARE CUSTOMER SUPPLIED SC L E D ALARM INDICATORS REVISION F 7994 B DATE 09 11 02 Page 7 1 9 WIRING DIAGRAM HOME STANDBY DRAWING 0D8500 B WIRING DIAGRAM 12 amp 15 KW HOME STANDBY MODEL 4456 1 amp 4390 1 ELECTRICAL DATA DRAWING 0D8500 B 2 OF 2 CONTROL PANEL BUX
94. ONTROL OPERATIONAL ANALYSIS NE ENGINE STARTUP AND RUNNING With the fuel solenoid open and ignition occurring the engine starts Engine startup and running may be briefly described as follows An AC voltage frequency signal is delivered to the circuit board from the generator engine run winding via Wire 66A When AC frequency reaches approximately 30 Hz the circuit board a terminates cranking and b turns on an engine warm up timer GENERATOR OUTPUT engine warm up timer will run for about 15 seconds When this timer finishes timing board action will initiate transfer to the Standby power source shown in Figure 4 above the timer is still running and transfer has not yet occurred Generator output is available to transfer switch terminal lugs E1 E2 and to the normally open contacts of a transfer relay However the transfer relay is de energized and its contacts are open TO LOAD Figure 4 Circuit Condition Engine Startup and Running Page 4 2 7 DC CONTROL PART 4 SECTION 4 2 OPERATIONAL ANALYSIS CUSTOMER SUPPLIED 15A C2 1 SC 12VDC aa BATTERY TRANSFER 69 12V RELAY COIL 194 LT BLACK 23 15 15 dest 68 UTILITY ia 0 INPUT N2 194 239 16 IM1 SP1 17 N 13 TX 2 1 13 18 18 sus er rs 240VAC 2 SP2 GENE
95. P switch 6 Seta VOM to it s R x 1 scale a Connect one test lead to Wire 86 disconnected from LOP Connect the other test lead to Pin Location 2 Wire 86 of the J1 connector at the Circuit Board CONTINUITY should be measured If CONTINUITY is NOT measured repair or replace Wire 86 between the LOP switch and the J1 Connector b Connect one test lead to Wire 0 disconnected from LOP Connect the other test lead to a clean frame ground CONTINUITY should be measured If CONTINUITY is NOT measured repair or replace Wire 0 between the LOP and and the ground terminal connection on the engine mount 7 lf the LOP switch tests good in Step 4 and oil pressure is good in Step 3 but the unit still shuts down with a LOP fault check Wire 86 for a short to ground Set a VOM to its R x 1 scale Disconnect the J1 Connector from the circuit board Remove Wire 86 from the LOP switch Connect one test lead to Wire 86 Connect the other test lead to a clean frame ground INFINITY should be measured If CONTINUITY is measured repair or replace Wire 86 between the LOP switch and the J1 Connector RESULTS 1 If switch tests good for Problem 9 proceed to Test 44 2 Replace switch if it fails the test TEST 61 CHECK HIGH OIL TEMPERATURE SWITCH DISCUSSION If the temperature switch contacts have failed a closed position the engine will not crank or start If it tries to Start it will immediately fault outon OVERTEMP
96. RATOR 56VA 1VA a 15 E 225 224 i 18 225A 224A 15A 0 I I POWER WINDING STATOR T J 120V 66A UTILITY VOLTAGE SENSING 12VDC PCB SUPPLY ENGINE RUN WINDING 4 CONTROL 12VDC PRINTED CIRCUIT BOARD WINDING DIAGRAM KEY BATTERY CHARGE BATTERY CHARGER BA BRUSH ASSEMBLY BATTERY GHARGE RELAY CB1 CIRCUIT BREAKER MAIN OUTPUT CB2 CIRCUIT BREAKER ALT EXCITATION D MODE PPISTATOR FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 5 AMP HIGH TEMPERATURE SWITCH IM1 IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOP LOW GIL PRESSURE SWITCH SC STARTER SCR STARTER CONTACTOR RELAY SP1 2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH ELECTRONIC VOLTAGE SM STARTER MOTOR GENERATOR REGULATOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC 12 VDC ALWAYS PRESENT AC VOLTAGE GROUND FOR CONTROL PURPOSES 12 VDC DURING CRANKING ONLY mmm 12 VDC DURING ENGINE RUN CONDITION Page 4 2 8 SECTION 4 2 OPERATIONAL ANALYSIS INITIAL TRANSFER TO THE STANDBY SOURCE The generator is running the circuit board s engine warm up timer is timing and generator AC output is available to transfer switch terminal lugs E1 and E2 and to the open contacts on the transfer r
97. S GENERATOR Models 04389 04758 Models 04456 04759 Model 04390 04760 Rated Max Continuous Power Capacity Watts 6 000 NG 7 000 LP 12 000 NG 12 000 LP 13 000 NG 15 000 LP Rated Voltage 120 240 120 240 120 240 Rated Max Continuous Load Current Amps 120 Volts 50 0 NG 58 3 LP 100 0 NG 100 0 LP 108 3 NG 125 0 LP 240 Volts 25 0 NG 29 2 LP 50 0 NG 50 0 LP 54 2 NG 62 5 LP Main Line Circuit Breaker 30 Amp 50 Amp 60 Amp 70 Amp Phase 1 1 1 Number of Rotor Poles 2 2 2 Rated AC Frequency 60 Hz 60 Hz 60 Hz Power Factor 1 1 1 Battery Requirement Group 26 26R Group 26 26R Group 26 26R 12 Volts and 12 Volts and 12 Volts and 350 Cold cranking Amperes Minimum 550 Cold cranking Amperes Minimum 550 Cold cranking Amperes Minimum Weight 452 Pounds 470 Pounds 487 Pounds Output Sound Level 23 ft 7m at full load Normal Operating Range 68 db A 70 5db A 20 F 28 8 C to 104 F 40 C 71 5 db A 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 curre
98. S 1 Replace AUTO OFF MANUAL switch if defective 2 For Problem 8 Only If the switch passes the tests verify the REMOTE NOT AUTO dipswitch is set to OFF on the circuit board see Figure 3 page 4 1 2 then proceed to Test 44 3 For Problem 9 Only If the switch passes the tests proceed to Test 60 SCHEMATIC Figure 2 AUTO OFF MANUAL Switch Test Points Page 4 4 2 TEST 44 CHECK WIRE 15 15A 17 239 VOLTAGE DISCUSSION The circuit board will not turn on unless battery voltage is available to the board via wire 15 the AUTO OFF MANUAL switch and Wire 15A If battery voltage is not available automatic or manual operation will not be possible Battery voltage is available to wire 17 from pin location 11 of the J1 connector on the circuit board When the AUTO OFF MANUAL switch is in the MANUAL position wire 239 supplies battery voltage to pin location 9 of the circuit board and engine cranking occurs PROCEDURE For Problem 1 flow chart do Steps 1 5 and Step 9 only For Problem 2 flow chart do all steps Set a VOM to measure DC voltage 1 2 Connect the positive test lead to the AUTO OFF MANUAL switch Terminal 2 Wire 15 Connect the negative test lead to a clean frame ground Battery voltage should be measured See Figure 2 3 Connect the positive test lead to the AUTO OFF MANUAL switch terminal 1 Wire 15A Connect the negative test lead to a clean frame ground Set the AUTO OFF MAN
99. SCHEMATIC 12 amp 15 KW HOME STANDBY MODEL 4456 1 amp 4390 1 ELECTRICAL DATA DRAWING 0D8501 B 1 OF 2 11 22 225A 3 225A 2 224A l BATTERY 2258 8 CHARGER v e X RED mm s 224 iiis 11 0 134 3 7 13 77 Cl BATTERY CHARGE 66 0 14 WINDING 66 lt 2 2 ee 0 D 0 2 4 HTO O 0 pesti 0 lt lt 55 LOP C1 4 4 swe ee FIELD STATOR 9 i 14 15 C1 3 ELECTRONIC 4 C2 10 2 9 VOLTAGE 4 4 REGULATOR 0 85 23 162 C1 6 86 194 9 0 351 225 14 7 224 lt 66A DPE WINDING STATOR E us 23 239 194 66A 3 23 4 194 5 56 6 18 71 14 8 66A DIAGRAM KEY PRINTED CIRCUIT 9 39 BOARD 10 15A BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY n 0 CIRCUIT BREAKER MAIN OUTPUT 14 225 CIRCUIT BREAKER ALT EXCITATION
100. Sequence 1 Page 1 7 2 ACTION No action A 15 second timer on circuit board turns on 15 second timer runs for 15 seconds then stops Circuit board action energizes a crank relay and a run relay see NOTE 1 Circuit board s engine warmup timer runs for 10 seconds Circuit board action energizes a transfer relay in transfer switch and transfer to Standby occurs No further action Circuit board voltage pickup sensor reacts and a re transfer time delay turns on Return to Utility Timer times out Circuit board action opens the transfer relay circuit to ground Transfer relay de energizes and retransfer to Utility occurs Circuit board engine cool down timer starts running After 1 minute engine cool down timer stops and circuit board s run relay de energizes Engine shuts down No action SENSOR TIMER OR OTHER Voltage Dropout Sensor on circuit circuit board Voltage Dropout Sensor and 15 second timer on circuit board Voltage Dropout Sensor and 15 second timer Circuit board crank and relays run Engine Warmup Timer 10 seconds Circuit board transfer relay circuit Transfer switch transfer relay Circuit board voltage pickup sensor continues to seek an acceptable Utility voltage Voltage Pickup Sensor 8096 Return to Utility Timer 15 seconds Return to Utility Timer Circuit board transfer relay circuit Transfer switch transfer relay Circuit board Engine Cool down Tim
101. Step 10 10 Connect the positive test lead to Wire 194 located in the J1 connector Pin Location 4 connected to the circuit board see Figure 3 Page 4 1 2 a lf voltage is present repair wiring between J1 connector and ICT or terminal strip b If voltage is NOT present replace circuit board TEST 27 CHECK VOLTAGE AT TERMINAL LUGS 1 DISCUSSION If retransfer to the Utility power source side is to occur utility source voltage must be available to terminal lugs N1 and N2 of the transfer mechanism In addition If that source voltage is not available to NI N2 terminals automatic startup and transfer to Standby will occur when the generator manual off auto switch is set to AUTO This test will prove that Utility voltage is available to those terminals or is not available It is the first test in a series of tests that should be accomplished when a retransfer back to Utility does not occur or b startup and transfer occurs unnecessarily DANGER PROCEED WITH CAUTION HIGH A 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 Page 3 4 5 SECTION 3 4 DIAGNOSTIC TESTS PROCEDURE 1 Make sure that all main line circuit breakers in the utility line to the transfer switch are On
102. TER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC ELECTRONIC VOLTAGE GENERATOR mam 12 VDC ALWAYS PRESENT VOLTAGE mmm GROUND FOR CONTROL PURPOSES amm 12 VDC DURING CRANKING ONLY mam 12 VDC DURING ENGINE RUN CONDITION Page 4 2 14 SECTION 4 3 TROUBLESHOOTING FLOW CHARTS DC CONTROL Problem 8 Engine Will Not Crank When Utility Power Source Fails VERIFY UTILITY POSITION OF P TEST 42 SOURCE IS OFF MANUAL START SWITCH ON PM ENGINE DOES ENGINE SWITCH IS OFF NOT CRANK CRANKS TURN OFF RETEST SET TO AUTO RETEST GO TO PROBLEM 9 TEST 44 CHECK VERIFY REMOTE NOT AUTO TEST 43 TEST WIRE 15 15A 17 239 g SET TO OFF DIPSWITCH IS SET TO OFF AUTO OFF MANUA VOLTAGE SEE FIGURE 3 PAGE 4 1 2 SWITCH SET TO ON BAD SEE RESULTS OF 4 TEST 44 SET TO REPLACE RETEST Problem 9 Engine Will Not Crank When AUTO OFF MANUAL Switch is Set to MANUAL TEST 45 CHECK15 TEST 46 CHECK TEST 47 CHECK AMP FUSE WIRE 56 VOLTAGE BAD TEST 48 CHECK BAD BAD STARTER Y y CONTACTOR RELAY V TWIN ONLY REPLACE RECHARGE REPLACE EAE AUTO OFF MANUA TEST 60 CHECK GOOD SWITCH BAD REPAIR BAD PRESSURE SWITCH REPLACE AND WIRE 86 GOOD GOOD NOTE If a starting problem is encountered the engine itself should be thoroughly checked to eliminate it
103. THAL 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 Page 1 4 1 SECTION 1 4 TESTING CLEANING AND DRYING 2 Before reading a DC voltage always set the meter to a higher voltage scale than the anticipated reading if in doubt start at the highest scale and adjust the scale downward until correct readings are obtained 3 The design of some meters is based on the current flow theory while others are based on the electron flow theory a The current flow theory assumes that direct current flows from the positive to the negative b The electron flow theory assumes that current flows from negative to positive NOTE When testing generators the current flow theory is applied That is current is assumed to flow from positive to negative MEASURING AC FREQUENCY The generator AC output frequency is proportional to rotor soeed Generators equipped with a 2 pole rotor must operate at 3600 rpm to supply a frequency of 60 Hertz Units with 4 pole rotor must run at 1800 rpm to deliver 60 Hertz Correct engine and rotor speed is maintained by an engine speed governor For models rated 60 Hertz the gov
104. TS PART TITLE 51 System Functional Tests SECTION 5 1 SYSTEM FUNCTIONAL TESTS INTRODUCTION Following home standby electric system installation and periodically thereafter the system should be tested Functional tests of the system include the following L Manual transfer switch operation System voltage tests L Generator Tests Under Load Testing automatic operation Before proceeding with functional tests read instructions and information on tags or decals affixed to the generator and transfer switch Perform all tests in the exact order given in this section MANUAL TRANSFER SWITCH OPERATION V TYPE TRANSFER SWITCHES 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 such as a Utility main line circuit breaker 3 Set the generator main line circuit breaker to OFF or Open LOAD CONNECTED TO UTILITY POWER SOURCE MANUAL TRANSFER HANDLE TRANSFER SWITCH OPERATING LEVER OPERATIONAL TESTS DANGER BE SURE TO TURN OFF ALL A POWER VOLTAGE SUPPLIES TO THE TRANSFER SWITCH BEFORE ATTEMPTING MANUAL OPERATION FAILURE TO TURN OFF POWER VOLTAGE SUPPLIES TO THE TRANSFER SWITCH MAY RESULT IN DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK 4 Remove the manual transfer handle from the enclosure 5 Place open end of the manual transfer handle over transfer switch operating lever
105. UAL switch to MANUAL Battery voltage should be measured 4 Connect the positive test lead to Pin location 12 Wire 15 at the J1 connector on the circuit board Connect the negative test lead to a clean frame ground Battery voltage should be measured 5 Connect the positive test lead to pin location 10 wire 15A at the connector on the circuit board Connect the negative test lead to a clean frame ground Set the AUTO OFF MANUAL switch to the MANUAL position Battery voltage should be measured Repeat Step 5 This time set the AUTO OFF MANUAL switch to AUTO Battery voltage should be measured 6 Connect the positive test lead to pin location 9 wire 239 at the J1 connector on the circuit board Connect the negative test lead to a clean frame ground Set the AUTO OFF MANUAL switch to the MANUAL position Battery voltage should be measured If battery voltage is measured stop and proceed to results If battery voltage is NOT measured proceed to Step 7 7 Connect the positive test lead to the AUTO OFF MANUAL switch Terminal 4 Wire 17 178 Connect the negative test lead to a clean frame ground Battery voltage should be measured 8 Connect the positive test lead to Pin location 11 wire 17 at the J1 connector on the circuit board Connect the negative test lead to a clean frame ground Battery voltage should be measured 9 Set a VOM to measure resistance R x 1 scale Connect one meter test
106. UT 50 FT LBS the eight bolts from male connectors C1 and C2 STATOR BOLTS 12 FT LBS Remove connectors engine divider panel ROTOR BOLT 30 FT LBS ENGINE ADAPTER 25 FT LBS EXHAUST MANIFOLD 18 FT LBS INTAKE MANIFOLD TO CYLINDER HEAD 22 FT LBS 5 0 8 TAPTITE SCREW INTO ALUMINUM 25 50 IN LBS M5 0 8 TAPTITE SCREW INTO PIERCED HOLE 25 50 IN LBS M6 1 0 TAPTITE SCREW INTO ALUMINUM 50 96 IN LBS M6 1 0 TAPTITE SCREW INTO PIERCED HOLE 50 96 IN LBS M6 1 0 TAPTITE SCREW INTO 50 96 IN LBS TRE M8 1 25 TAPTITE SCREW INTO ALUMINUM 12 18 FT LBS E PIER V SS M6 1 0 NYLOK NUT ONTO STUD 16 65 IN LBS Figure 9 C1 and C2 Connectors Located on the Engine Divider Panel NOTE TORQUES ARE DYNAMIC VALUES WITH 10 TOLERANCE UNLESS OTHERWISE NOTED Page 6 1 3 TABLE OF CONTENTS DWG TITLE 0D5700 C WIRING DIAGRAM 7 KW HSB MODEL 4389 0 0D5701 C SCHEMATIC 7 KW HSB MODEL 4389 0 0C7830 C WIRING DIAGRAM 12 amp 15 KW HSB MODEL 4456 0 amp 4390 0 0C7836 C SCHEMATIC 12 amp 15 KW HSB MODEL 4456 0 amp 4390 0 0D9013 C WIRING DIAGRAM 7 KW HSB MODEL 4389 1 009014 SCHEMATIC 7 KW HSB MODEL 4389 1 008500 WIRING DIAGRAM 12 amp 15 KW HSB MODEL 4456 1 amp 4390 1 Air cooled Prepackaged 0D8501 B SCHEMATIC 12 amp 15 KW HSB MODEL 4456 1 amp 4390 1 Automatic Sta
107. Y REPLACE SHORTED m REFER TO ENGINE WIRE 18 OR SERVICE MANUAL CIRCUIT BOARD Page 4 3 2 SECTION 4 3 PART 4 DC CONTROL TROUBLESHOOTING FLOW CHARTS Problem 11 Engine Starts Hard and Runs Rough Lacks Power TEST 51 CHECK TEST 55 CHECK TEST 62 FUEL SUPPLY 6000 FOR IGNITION ee CHECK AND AND PRESSURE SPARK ADJUST VALVES BAD BAD BAD A L CLEAN REGAP READJUST TEST 59 CHECK OR REPLACE FIND AND CORRECT AND ADJUST CAUSE OF NO FUEL OR IGNITION MAGNETOS LOW PRESSURE BAD ADJUST OR REPLACE TEST 12 CHECK GOOD AND ADJUST q ENGINE GOVERNOR TEST 57 CHECK BAD n REFER TO ENGINE gt SERVICE MANUAL COMPRESSION READJUST GOOD TEST 63 CHECK CHECK FUEL REGULATOR Goop ao BAD Y REPAIR OR REPLACE Page 4 3 3 SECTION 4 3 DC CONTROL TROUBLESHOOTING FLOW CHARTS Problem 12 Engine Starts and Runs Then Shuts Down CHECK FAULT LIGHTS LOW OIL OVER TEMP OVERSPEED NO FAULT LIGHTS ILLUMINATED TEST 60 CHECK OIL ILLUMINATED PRESSURE SWITCH REFILL REPAIR OR REPLACE AND WIRE 86 TEST 61 CHECK HIGH ILLUMINATED gt OIL TEMPERATURE INSTALL CORRECTLY SWITCH OR REPLACE TEST 12 CHECK AND ADJUST REPAIR LINKAGE IF BINDING ILLUMINATED ENGINE CHECK THROTTLE OPERATION GOVERNOR REFER TO ENGINE SERVICE MANUAL GOOD TEST 70 CHECK TEST 7 TEST ENGINE RUN BAD kau sl WINDING ane TEST 51 CHECK
108. a minute or two 4 Take the meter reading On unit s having a rated line to line voltage of 240 volts the no load voltage should be about 242 252 volts AC 5 Shut the engine down and remove the meter test leads RESULTS 1 If zero volts or residual voltage is indicated go on to Test 3 2 lf the voltage reading is higher than residual but is lower than the stated limits go to Test 11 3 high voltage is indicated go on to Test 11 NOTE Residual voltage may be defined as the voltage that is produced by rotor residual magnetism alone The amount of voltage induced into the stator AC power windings by residual voltage alone will be approximately 2 to 16 volts AC depending on the characteristics of the specific generator If a unit is supplying residual voltage only either excitation current is not reaching the rotor or the rotor windings are open and the excitation current cannot pass On Page 2 4 2 current units with air cooled engine field boost current flow is available to the rotor only during engine cranking TEST 3 TEST EXCITATION CIRCUIT BREAKER DISCUSSION Unregulated excitation current is delivered to the voltage regulator from the stator excitation DPE winding via Wire 2 an excitation circuit breaker 2 Wire 162 and Wire 6 If the excitation circuit breaker has failed open excitation current will not be available to the voltage regulator or to the rotor Stator AC power winding
109. after adjusting the armature air gap testing the ground wires and performing the basic flywheel test replace the ignition magneto s TEST 60 CHECK OIL PRESSURE SWITCH AND WIRE 86 DISCUSSION If the oil pressure switch contacts have failed in their closed position the engine will probably crank and start However shutdown will then occur within about 5 five seconds If the engine cranks and starts then shuts down almost immediately with a LOP fault light the cause may be one or more of the following engine oil level L1 Low oil pressure LIA defective oil pressure switch If the oil pressure switch contacts have failed open or Wire 86 does not have continuity to ground at starting the engine will not crank If the engine does not crank the cause may be one of the following LIA defective oil pressure switch stuck open An open Wire 86 to Circuit Board SECTION 4 4 DIAGNOSTIC TESTS LOW OIL SWITCH HIGH TEMP SWITCH Figure 27 Oil Pressure Switch PROCEDURE Note For Problem 9 Flow Chart perform Steps 3a 4 and 5 only For Problem 12 Flow Chart perform all steps 1 Check engine crankcase oil level a Check engine oil level b If necessary add the recommended oil to the dipstick FULL mark DO NOT OVERFILL ABOVE THE FULL MARK 2 With oil level correct try starting the engine a lf engine still cranks and starts but then shuts down go to Step 3 b I
110. an Housing Cover Using a 10 mm socket remove the six 6 bolts from each side of the fan housing cover Remove the fan housing cover 10 Remove Rotor Bolt Using a 9 16 socket remove one rotor bolt 11 Remove Fan Attach a steering wheel puller to the fan using two 2 M8 X 1 25 bolts Remove fan from rotor Figure 2 Using a Steering Wheel Puller to Remove Fan From Rotor 12 Remove Muffler Box Side Cover and Alternator panel Divider Using a 10mm socket remove the three bolts from the top of the muffler box cover that attach to the muffler side cover and two bolts from the side of the muffler box cover that attach to the alternator divider plate Remove the muffler box cover Remove the four bolts that attach the alternator divider panel Three are connected on the left side to the back enclosure panel and one is connected to the enclosure base on the bottom right corner Remove the two bolts attaching the muffler side cover to the back enclosure panel They are located in the center of the back panel Remove the alternator panel and muffler side cover as an assembly Figure 3 13 Remove Muffler Using a 13mm socket remove the four muffler hold down bolts Remove the four exhaust manifold nuts Remove the muffler and muffler base panel 14 Stator Removal Using a 13mm socket remove the two nuts from the alternator mounting bracket rubber mounts Lift the back end of the alternator up and place a 2 x 4 piece
111. ard 4 If the remote start connections have been used disconnect the customer wires from the terminal connector at Wire 178 and Wire 183 5 Connect one meter test lead to Wire 178 at the terminal connector Connect the other meter test lead to Wire 183 at the terminal connector INFINITY should be measured 6 If the remote start connections have been used connect the meter test leads across customer supplied wiring If CONTINUITY is measured customer supplied circuit is causing startup SECTION 4 4 DIAGNOSTIC TESTS RESULTS 1 If CONTINUITY was measured in Step 5 a short exists between Wire 178 and Wire 183 Repair or replace Wire 178 and or Wire 183 between terminal connector and SW1 TEST 75 CHECK BATTERY VOLTAGE CIRCUIT DISCUSSION If the 15 amp fuse blows immediately after replacement Wire 15 should be checked for a fault PROCEDURE 1 Set the AUTO OFF MANUAL switch to OFF 2 Disconnect the 17 pin connector J1 from the circuit board 3 Set a VOM to measure resistance 4 Disconnect Wire 15 from the fuse holder F1 5 Connect one meter test lead to Wire 15 removed from fuse holder in previous step Connect the other meter test lead to the ground terminal INFINITY should be measured RESULTS 1 If CONTINUITY was measured in Step 5 repair or replace Wire 15 between the fuse holder F1 and SW1 or between SW1 and Connector J1 2 If INFINITY was measured in Step 5 replace the circuit b
112. ard 6 Set a VOM to measure resistance Connect one test lead to Wire 18 from the control panel Connect the other test lead to a clean frame ground Set the AUTO OFF MANUAL switch to MANUAL During cranking the meter should read INFINITY RESULTS 1 If INFINITY was NOT measured in Step 4 repair or replace shorted ground Wire 18 between the J1 connector from the circuit board to the stud or bullet connector 2 If INFINITY was NOT measured in Step 6 during cranking replace the circuit board and retest for spark 3 If ignition spark still has not occurred proceed to Test 59 TEST 59 CHECK AND ADJUST IGNITION MAGNETOS DISCUSSION In Test 55 a spark tester was used to check for engine ignition If sparking or weak spark occurred one possible cause might be the ignition magneto s This test consists of adjusting the air gap between the ignition magneto s and the flywheel The flywheel and flywheel key will also be checked during this test PROCEDURE Note The air gap between the ignition magneto and the flywheel on single cylinder engines is non adjustable Proceed directly to Steps 15 16 and 17 for single cylinder engines For V twin engines proceed as follows 1 See Figure 23 Rotate the flywheel until the magnet is under the module armature laminations 2 Place a 0 008 0 012 inch 0 20 0 30mm thickness gauge between the flywheel magnet and the module laminations 3 Loosen the mounting screws and
113. as the cause of starting difficulty It is a good practice to check the engine for freedom of rotation by removing the spark plugs and turning the crankshaft over slowly by hand to be sure it rotates freely REPLACE TEST 44 CHECK SEE RESULTS OF WIRE 15 15A 17 239 TEST 44 VOLTAGE TEST 49 CHECK STARTER CONTACTOR WARNING DO NOT ROTATE ENGINE WITH ELECTRIC STARTER WITH SPARK PLUGS REMOVED ARCING amp GOOD A AT THE PLUG ENDS MAY IGNITE THE STARTER MOTOR LP OR NG VAPOR EXITING THE SPARK PLUG HOLE L BAD REPLACE BAD Page 4 3 1 SECTION 4 3 TROUBLESHOOTING FLOW CHARTS DC CONTROL Problem 10 Engine Cranks but Won t Start TEST 51 CHECK TEST 53 CHECK TEST 52 CHECK FUEL SOLENOID FUEL SUPPLY GOOD CIRCUIT BOARD GOOD UNITS EQUIPPED WITH IDLE PORT AND PRESSURE WIRE 14 OUTPUT OF FUEL REGULATOR TEST 54 CHECK FUEL SOLENOID BAD BAD BAD FIND AND CORRECT CAUSE OF NO FUEL OR REPLACE CIRCUIT BOARD LOW PRESSURE REPLACE FUEL SOLENOID TEST 55 CHECK TEST 56 CHECK IE TEST 57 CHECK FOR IGNITION CHECK AND GOOD SPARK PLUGS ENGINE SPARK ADJUST VALVES COMPRESSION BAD BAD BAD GOOD BAD CLEAN REGAP READJUST OR REPLACE CHECK FLYWHEEL KEY 4 TEST 63 CHECK TEST 59 FUEL REGULATOR BAD TEST 58 CHECK TEST 59 CHECK REPAIR OR SHUTDOWN WIRE GOOD i AND ADJUST REPLACE IGNITION MAGNETOS BAD REPAIR OR
114. asured 5 Verify that the battery charge relay BCR is wired correctly Figure 33 6 Connect one meter test lead to Terminal 1 Wire 224A on the BCR Connect the other test lead to Terminal 3 Wire 225A Approximately 16 VAC should be measured RESULTS 1 If voltage was NOT measured in Step 6 but was measured in Test 65 repair or replace Wire 224A and Wire 225B between the transformer TX and the battery charge relay BCR 2 f voltage was not measured in Step 4 go to Test 67 Page 4 4 19 SECTION 4 4 DIAGNOSTIC TESTS Figure 33 Battery Charge Relay Test Points TEST 67 CHECK BATTERY CHARGE RELAY BCR DISCUSSION The battery charge relay is used to switch the AC source delivered to the battery charger When the BCR is de energized the Normally Closed NC contacts deliver AC power from the transformer When the BCR is energized by Wire 14 the Normally Open NO contacts close and battery charge winding AC source is delivered to the battery charger PROCEDURE 1 See Figure 33 Disconnect all wires from the battery charge relay to prevent interaction 2 Seta VOM to its R x 1 scale and zero the meter 3 Follow the chart below and test each set of contacts Connect the VOM test leads to the relay terminals indicated in the chart provided below 4 To energize or de energize the relay Connect a jumper wire 10 positive 12VDC source and to relay Terminal A Connec
115. be measured RESULTS 1 If the engine cranks but does not start and battery voltage was NOT measured in Step 8 replace the circuit board 2 If the engine cranks and battery voltage was measured in Step 3 but there was no battery voltage in Step 4 repair or replace Wire 14 between 4 tab terminal block and the Fuel Solenoid FS 3 If the engine cranks and battery voltage was measured in step 3 and no battery voltage is measured in step 4b repair or replace Wire 14 between the J1 connector on the circuit board and the 4 tab terminal block 4 f the engine cranks but does not start and battery voltage was measured in Steps 2 3 and 4 and CONTINUITY was NOT measured in Step 6 repair or replace Wire 0 between the Control Panel ground connection and the Fuel Solenoid terminal If CONTINUITY was measured in Step 6 proceed to Test 52 or test 54 depending on the model TEST 54 CHECK FUEL SOLENOID DISCUSSION In Test 53 if battery voltage was delivered to Wire 14 the fuel solenoid should have energized open This test will verify whether or not the fuel solenoid is operating Fuel Solenoid Nominal Resistance 27 33 ohms FUEL REGULATOR Figure 18 The Fuel Solenoid FS PROCEDURE 1 Disconnect Wire 56 from the starter contactor relay SCR This will disable the unit from cranking For single cylinder units disconnect from the starter contactor SC and isolate it from ground 2 Place one hand on the Fuel S
116. breaker 5 Manually actuate the prepackaged transfer switch to its UTILITY source side i e load connected to the utility source 6 Turn on the utility power supply to the transfer switch using whatever means provided 7 Set the generator AUTO OFF MANUAL switch to AUTO Page 1 6 3 INTRODUCTION When the prepackaged generator is installed in conjunction with a prepackaged transfer switch either manual or automatic operation is possible Manual transfer and engine startup as well as manual shutdown and retransfer are covered in Section 1 6 Selection of fully automatic operation is also discussed in that section This section will provide a step by step description of the sequence of events that will occur during automatic operation of the system AUTOMATIC OPERATING SEQUENCES With utility source voltage available to the transfer switch that source voltage is sensed by a circuit board in the generator panel and the circuit board takes no action Electrical loads are powered by the utility source and the AUTO OFF MANUAL switch is set to AUTO If a dropout in utility source voltage should occur below about 60 percent of the nominal utility source voltage a 15 second timer on the circuit board will start timing This timer is required to prevent false generator starts that might be caused by transient utility voltage dips PHASE 3 ENGINE CRANKING When the circuit board s 15 second timer has finished
117. cal 5 amp replacement fuse Figure 5 15 Amp Fuse DC CONTROL PART 4 SECTION 4 1 DESCRIPTION AND COMPONENTS GROUND TERMINAL TERMINAL STRIP NEUTRAL BLOCK STARTER CONTACTOR RELAY SCR V TWINS ONLY TRANSFORMER TX VOLTAGE REGULATOR BATTERY CHARGER BATTERY CHARGE RELAY BCR GROUND TERMINAL 4 TAB TERMINAL BLOCK TB CIRCUIT BREAKER DPE CB2 PRINTED CIRCUIT BOARD FUSE HOLDER F1 FUSE HOLDER F2 SET EXERCISE SWITCH SW2 AUTO OFF MANUAL SWITCH SW1 Figure 6 Control Panel Component Identification Page 4 1 4 SECTION 4 2 OPERATIONAL ANALYSIS INTRODUCTION This Operational Analysis is intended to familiarize the service technician with the operation of the DC control system on prepackaged units with air cooled engine A thorough understanding of how the system works is essential to sound and logical troubleshooting The DC control system illustrations on the following pages include a V Type prepackaged transfer switch UTILITY SOURCE VOLTAGE AVAILABLE See Figure 1 above The circuit condition with the AUTO OFF MANUAL switch set to AUTO and with Utility source power available can be briefly described as follows Utility source voltage is available to transfer switch terminal lugs N1 N2 With the transfer switch main contacts at their Utility side this source voltage is available to terminal lugs T1 T2 and to the Load circuits Utility voltage is delivered
118. ch with utility source power available The circuit condition may be briefly described as follows L1 Utility source voltage is available to terminal lugs 1 N2 of the transfer mechanism transfer switch is in the UTILITY position and source voltage is available to T1 T2 and customer load L1 Utility source voltage is available to limit switch XA1 via the normally closed transfer relay contacts 1 and 7 and Wire 126 However XA1 is open and the Circuit to the utility closing coil is open LI Utility voltage sensing signals are delivered to a circuit board on the generator via Wire N1A a 5 amp fuse F1 transfer switch terminal N1 generator terminal N1 and a sensing transformer The second line of the utility voltage sensing circuit is via Wire N2A a 5 amp Fuse F2 transfer switch terminal N2 generator terminal N2 and the sensing transformer GENERATOR Z 23 194 194 i CONTROL PRINTED CIRCUIT BOARD TRANSFER SWITCH Transfer Switch in Utility Position Utility Voltage Available 1 2 Figure 2 Utility Source Power Available Page 3 2 2 SECTION 3 2 PART 3 V TYPE PREPACKAGED OPERATIONAL ANALYSIS UTILITY SOURCE VOLTAGE FAILURE If utility source voltage should drop below a preset value the generator circuit board will sense the dropout That circuit board will then initiate generator cranking and startup after a time delay circuit times out Figure 3 is a schemat
119. ct brush wires make sure they are properly and securely connected SECTION 2 4 DIAGNOSTIC TESTS 5 Wire 0 from the negative brush terminal connects to Pin 9 of the C2 connector Test this wire for an open condition Remove wire 0 from the brush assembly Connect one meter test lead to wire 0 Connect the other test lead to Pin 9 wire 0 of the C2 connector female side CONTINUITY should be measured If INFINITY is measured repair or replace wire 0 between the brush assembly and the C2 connecior 6 Wire 4 from the positive brush terminal connects to Pin 10 of the C2 connector Test this wire for an open condition Remove wire 4 from the brush assembly Connect one meter test lead to Wire 4 Connect the other meter test lead to Pin 10 wire 0 of the C2 connector female side CONTINUITY should be measured If INFINITY is measured repair or replace wire 4 between the brush assembly and the C2 connecior 7 Connect one meter test lead to wire 4 Connect the other meter test lead to frame ground INFINITY should be measured If CONTINUITY is measured a short to ground exists on wire 4 repair or replace wire 4 between the brush assembly and the C2 connector 8 lf continuity was measured in steps 5 and 6 proceed to Step 9 9 Disconnect wires 0 and 4 from the brush assembly Remove the brush assembly from the bearing carrier Inspect the brushes for excessive wear damage 10 Inspect the rotor slip rings If they appear
120. ct one meter test lead to Wire 0 at the three pin connector Connect the other test lead to the ground terminal CONTINUITY should be measured RESULTS 1 If CONTINUITY was NOT measured in Step 4 repair or replace Wire 13A between the battery charger and fuse F2 2 II CONTINUITY was NOT measured in Step 5 repair or replace Wire 0 between the battery charger and frame ground TEST 70 CHECK ENGINE RUN WINDING DISCUSSION The engine run winding provides an AC input through Wire 66A to the circuit board This input is used for overspeed sensing If the input is not received by the circuit board immediate shutdown will occur PROCEDURE 1 Set the AUTO OFF MANUAL switch to OFF 2 Set a VOM to measure resistance 3 Disconnect Connector C2 from the side of the control panel 4 Disconnect Connector J1 from the circuit board 5 Connect one meter test lead to Connector C2 Pin Location 3 Wire 66A Connect the other test lead to Connector J1 Pin Location 8 Wire 66A CONTINUITY should be measured 6 Connect one test lead to Connector C2 Pin Location 4 Wire 55 Connect the other test lead to a clean frame ground CONTINUITY should be measured 7 Re connect connector C2 to the control panel and re connect connector J1 to the circuit board 8 Set a VOM to measure AC Voltage 9 Connect the positive meter test lead to Pin Location 8 Wire 66A of the J1 Connector on the circuit board Connect the negative met
121. d condition LI A short circuit between windings Note The resistance of stator windings is very low Some meters will not read such a low resistance and will simply indicate CONTINUITY Recommended is a high quality digital type meter capable of reading very low resistances PROCEDURE 1 Disconnect stator leads 11 and 44 from the main circuit breaker 2 Disconnect stator leads 22 and 33 from the neutral connection separate the leads 3 Disconnect Connector C2 from the side of the control panel C2 is the closest to the back panel 4 Make sure all off the disconnected leads are isolated SECTION 2 4 DIAGNOSTIC TESTS from each other and are not touching the frame during the test 5 Seta VOM to its R x 1 scale and zero the meter 6 Refer to Figure 5 for pin locations of Connector C2 Use a large paper clip or similar metallic object to access pins in connector C2 Note Pins 9 10 11 amp 12 are not used for this test Figure 5 C2 Connector Pin Locations Female Side Figure 6 C2 Connector Pin Locations Male Side 7 Connect one test lead to stator lead Wire 11 Connect the other test lead to stator lead Wire 22 power winding Note the resistance reading and compare to the specifications on Page 2 8 Connect one test lead to stator lead Wire 33 Connect the other test lead to stator lead Wire 44 power
122. d limit switch XB1 closes the standby circuit to standby closing coil C2 The limit switches arm the system for retransfer back to UTILITY when the load contacts are connected to the STANDBY side Conversely when the load contacts are connected to the UTILITY side the switches arm the system for transfer to STANDBY An open condition in limit switch XA1 will prevent retransfer to Utility An open switch XB1 will prevent transfer to STANDBY UTILITY CLOSING LIMIT SWITCH XA1 MANUAL TRANSFER LEVER COIL C2 BRIDGE RECTIFIER Figure 4 The V Type Transfer Mechanism Page 3 1 2 SECTION 3 1 DESCRIPTION amp COMPONENTS TRANSFER RELAY Transfer relay operation is controlled by a circuit board That circuit board is a part of a control panel assembly mounted on the standby generator set Figure 5 shows the transfer relay pictorially and schematically Relay operation may be briefly described as follows 1 Generator battery voltage 12 volts DC is available to the transfer relay coil from the generator circuit board via Wire 194 and relay terminal A 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 c When de energized the relay s normally open contacts are open and its normally closed contacts a
123. dirty or corroded remove the cable and clean cable terminals and terminal studs Replace any cable that is defective or badly corroded Use a DC voltmeter or a VOM to perform this test Test the starter contactor as follows 1 Connect the positive meter test lead to the starter contactor stud to which the red battery cable connects Connect the common meter test lead to a clean frame SECTION 4 4 DIAGNOSTIC TESTS ground Battery voltage 12 volts DC should be indicated Now connect the positive meter test lead to the starter contactor stud to which the starter motor cable attaches see Figure 6 or 7 Connect the common test lead to frame ground a No voltage should be indicated initially b Set the AUTO OFF MANUAL switch to MANUAL The meter should now indicate battery voltage as the starter contactor energizes TO STARTER STEP 2 TEST POINT STEP 1 TEST POINT STARTER SWITCH CONNECTING DIAGRAM STARTER TEST CONTACTOR O STEP 2 T TEST POINT STARTER 4 4 5 SECTION 4 4 DIAGNOSTIC TESTS Figure 7 The Starter Contactor V twin Units RESULTS 1 If battery voltage was indicated in Step 1 but NOT in Step 2b replace the starter contactor 2 f battery voltage was indicated in Step 2b but the engine did NOT crank go on to Test 50 TEST 50 TEST STARTER MOTOR CONDITIONS AFFECTING STARTER MOTOR PERFORMANCE 1 A binding
124. dull or tarnished they may be polished with a fine sandpaper DO NOT USE METALLIC GRIT TO POLISH SLIP RINGS 11 If brush assembly and slip rings look good proceed to Test 10 Test Rotor assembly 12 Wire 0 connects from the C2 connector to the control panel ground lug Connect one meter test lead to Pin 9 Wire 0 of the C2 connector male side Connect the other meter test lead to the ground terminal in the control panel CONTINUITY should be measured If INFINITY is measured repair or replace wire 0 between the C2 connector and the ground terminal 13 Remove wire 4 from the voltage regulator Page 2 4 7 SECTION 2 4 DIAGNOSTIC TESTS 14 Connect one meter test lead to Pin 10 wire 4 of the C2 connector male side Connect the other meter test lead to Wire 4 removed from the Voltage regulator CONTINUITY should be measured If INFINITY is measured repair or replace wire 4 between the C2 connector and the voltage regulator RESULTS 1 Repair replace or reconnect wires as necessary 2 Replace any damaged slip rings or brush holder 3 Clean and polish slip rings as required TEST 10 TEST ROTOR ASSEMBLY DISCUSSION A rotor having completely open windings will cause loss of excitation current flow and as a result generator AC output voltage will drop to residual voltage A shorted rotor winding can result in a low voltage condition PROCEDURE Disconnect the brush wires or remove the brush holder to
125. e calculated minimum resistance clean and dry the stator Then repeat the test If resistance is still low replace the stator Use the Megger to test for shorts between isolated windings as outlined Stator Insulation Tests Also test between parallel windings See Test Between Parallel Windings on this page Page 1 4 4 TESTING ROTOR INSULATION Apply a voltage of 500 volts across the rotor positive slip ring nearest the rotor bearing and a clean frame ground i e the rotor shaft DO NOT EXCEED 500 VOLTS AND DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND FOLLOW THE MEGGER MANUFACTURER S INSTRUCTIONS CAREFULLY ROTOR MINIMUM INSULATION RESISTANCE 1 5 megohms CAUTION Before attempting to measure Insulation resistance first disconnect and Isolate all leads of the winding to be tested Electronic components diodes surge protectors relays voltage regulators etc can be destroyed if subjected to high megger voltages HI POT TESTER A Hi Pot tester is shown in Figure 1 The model shown is only one of many that are commercially available The tester shown is equipped with a voltage selector switch that permits the power supply voltage to be selected It also mounts a breakdown lamp that will illuminate to indicate an insulation breakdown during the test Figure 1 One Type of Hi Pot Tester STATOR INSULATION RESISTANCE TEST GENERAL Units with air cooled engines are equipped with
126. e 16 These units have an additional 1 4 fuel hose DISCUSSION When the Fuel Solenoid FS is energized gas pressure is available internally to the on demand Fuel Regulator Gas pressure will then be available to the idle circuit port of the Fuel Regulator PROCEDURE 1 Disconnect Wire 56 from the starter contactor relay SCR This will disable the unit from cranking For single cylinder units disconnect from the starter contactor SC and isolate it from ground 2 Remove the fuel hose from the idle circuit port barbed fitting 3 Attach a manometer Generac P N 0C7977 to the idle circuit port barbed fitting 4 Set the AUTO OFF MANUAL switch to MANUAL The engine will not crank but gas pressure should be observed on the manometer at 11 14 of water column 5 Set the AUTO OFF MANUAL switch to OFF Remove the manometer Re attach the fuel hose to the idle circuit port barbed fitting Re connect Wire 56 to the starter contactor relay or starter contactor RESULTS 1 If gas pressure was measured proceed to Test 55 2 f gas pressure was NOT measured replace the fuel solenoid FS TEST 53 CHECK CIRCUIT BOARD WIRE 14 OUTPUT DISCUSSION During any cranking action the circuit board s crank relay K1 and run relay K2 both energize simultaneously When the run relay energizes its contacts close and 12 volts DC is delivered to Wire 14 and to a fuel solenoid The solenoid energizes open to allow fuel
127. e No Load Frequency with the roof open and the door off is set to 63 63 5 Hz Transfer load to emergency circuits 4 Turn on appliances lights pumps etc that are on the emergency circuits in an attempt to fully load the generator Be cautious not to overload the generator Use the following chart as a guide Unit 120 Volts 240 Volts 7 kW 50 0 amps 25 0 amps 12 kW 100 0 amps 50 0 amps 15 kW 108 3 amps 54 1 amps 5 When full load has been achieved connect a frequency Page 4 4 17 SECTION 4 4 DIAGNOSTIC TESTS meter to the output lugs of the generator main line circuit breaker The fuel regulator is fitted with one 7 kW or two 12 amp 15 kW adjustment screws While watching the frequency meter slowly turn the adjustment screw s clockwise or counterclockwise one at a time until highest frequency is read on the meter Note Only limited adjustment is available between the set pins on 7 kW fuel regulators Under no circumstance should any of the pins be removed see Figures 30 amp 31 6 When the highest frequency is reached maximum power has been set From this point turn the adjustment screw s 1 4 turn counterclockwise The regulator is now set V TWIN 12 amp 15 KW SINGLE CYLINDER ADJUSTMENT SCREW r ADJUSTMENT BOTH SIDES SCREW ONE SIDE ONLY ARAM ARA NAR NAR 590000000 5 Figure 31 4 4 18 7 Turn utility power to the mai
128. e continuity of Wire 66 and Wire 77 between Connector C2 and the battery charge relay PROCEDURE 1 Disconnect Connector C2 from the side of the control panel 2 Disconnect Wire 66 from Terminal 6 and Wire 77 from Terminal 4 of the BCR 3 Set a VOM to measure resistance a Figure 34 C2 Connector Pin Locations Male Side 4 Connect one test lead to Connector C2 Pin Location 1 Wire 77 Connect the other test lead to the end of Wire 77 which was previously removed from the BCR CONTINUITY should be measured 5 Connect one test lead to Connector C2 Pin Location 2 Wire 66 Connect the other test lead to the end of Wire 66 which was previously removed from the BCR CONTINUITY should be measured RESULTS If CONTINUITY was NOT measured in Step 4 or Step 5 repair or replace defective wiring between Connector C2 and the battery charge relay TEST 69 CHECK BATTERY CHARGER WIRING DISCUSSION The three pin connector on the battery charger connects the charger to ground and to battery power PROCEDURE 1 Set the AUTO OFF MANUAL switch to OFF 2 Disconnect the three pin connector from the battery charger 3 Seta VOM to measure resistance 4 Connect one meter test lead to Wire 13A at the three pin connector Connect the other test lead to Wire 13A at Fuse F2 CONTINUITY should be measured SECTION 4 4 DIAGNOSTIC TESTS 5 Conne
129. e generator panel set the AUTO OFF MANUAL switch to OFF 2 On the generator set the main line circuit breaker to it s OFF or Open position 3 Turn OFF the utility power supply to the transfer switch using whatever means provided such as a utility source line circuit breaker 4 Manually actuate the transfer switch main contacts to their Standby position i e loads connected to the Standby power source side NOTE For instructions on manual operation of prepackaged transfer switches see Part 5 5 On the generator panel set the AUTO OFF MANUAL switch to MANUAL The engine should crank and start 6 Let the engine warm up and stabilize for a minute or two at no load Page 1 6 2 SECTION 1 6 PART 4 GENERAL INFORMATION OPERATING INSTRUCTIONS 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
130. e test lead to Wire 4 Connect the other test lead to a clean frame ground Note the resistance reading Compare to specifications on Page 2 RESULTS 1 If the resistance reading is correct check your VOM meters fuse and repeat Test 4 2 If INFINITY is measured on your VOM meter go to Test 9 TEST 9 CHECK BRUSHES AND SLIP RINGS DISCUSSION The function of the brushes and slip rings is to provide for passage of excitation current from stationary components to the rotating rotor Brushes are made of a special long lasting material and seldom wear out or fail However slip rings can develop a tarnish or film that can inhibit or offer a resistance to the flow of electricity Such a non conducting film usually develops during non operating periods Broken or disconnected wiring can also cause loss of excitation current to the rotor Figure 7 Checking Brushes and Slip Rings PROCEDURE 1 Disconnect connector C2 deutsch connector closest to the back panel Refer to figure 5 and figure 6 on page 2 4 5 2 Seta VOM to measure resistance 3 Connect one meter test lead to Pin 9 Wire 0 of the C2 connector female side Connect the other meter test lead to Pin 10 Wire 4 of the C2 connector female side Rotor resistance should be measured see specifications on page 2 If rotor resistance is not measured proceed to step 4 If rotor resistance is measured proceed to step 12 4 See figure 7 Carefully inspe
131. elay Initial transfer to the Standby power supply may be briefly described as follows The circuit board delivers a 12 volts DC output to the transfer relay TR actuating coil via Wire 194 and terminal A of the transfer relay TR in the transfer switch This 12 volts DC circuit is completed back to the board via transfer relay terminal B and Wire 23 However circuit board action holds the Wire 23 circuit open to ground and the transfer relay TR is de energized When the circuit board s engine warm up timer times out circuit board action completes the Wire 23 circuit to ground The transfer relay then energizes and its normally open contacts close Standby power is now delivered to the standby closing coil C2 via Wires E1 E2 the normally open transfer relay contacts Wire 205 limit switch XB1 Wire B and a bridge rectifier The standby closing coil energizes and the main current carrying contacts of the transfer switch are actuated to their Standby source side As the main contacts move to their Standby source side a mechanical interlock actuates limit switch XB1 to its open position and limit switch XA1 to its Utility side position When XB1 opens standby closing coil C2 3 de energizes Standby power is delivered to the Load terminals 1 2 of the transfer switch Page 4 2 9 DC CONTROL ee 240VAC GENERATOR OUTPUT TRANSFER SWITCH TO LOAD
132. energizes and the main contacts actuate to their Standby side GENERATOR 2 23 194 0 194 CONTROL PRINTED CIRCUIT BOARD TRANSFER SWITCH Transfer action to STANDBY position RL 3 energized Transfer relay is energized and contacts reverse C2 is energized Figure 4 Transfer Action to Standby Position Page 3 2 4 SECTION 3 2 PART 3 V TYPE PREPACKAGED OPERATIONAL ANALYSIS TRANSFER TO STANDBY When the standby coil is energized it pulls the transfer switch mechanism to a overcenter position towards the standby power source side the transfer switch mechanically snaps to the STANDBY position On closure of the main contacts to the standby power source side limit switches XA1 and XB1 are mechanically actuated to arm the circuit for re transfer to utility power source side Generator power from E1 and E2 is now connected to the customer load through T1 and T2 GENERATOR 00 23 1946 0 194 CONTROL PRINTED CIRCUIT BUARD TRANSFER SWITCH Transfer action to STANDBY position Transfer mechanism and limit switches change position Generator is now powering load T1 amp T2 Figure 5 Generator Powering Load Page 3 2 5 V TYPE PREPACKAGED PART 3 SECTION 3 2 2 EE OPERATIONAL ANALYSIS UTILITY RESTORED Utility voltage is restored and is available to terminals N1 and N2 The utility voltage is sensed by the generators circuit board If it is
133. entically numbered terminals on a prepackaged transfer switch terminal board The terminal board connects the transfer switch to the circuit board and transformer The terminal board provides the following connection points A Utility 1 and Utility 2 1 Connect to identically marked terminals on a prepackaged transfer switch terminal board 2 circuit delivers Utility power source voltage to the transformer TX located in the control panel assembly B 23 and 194 1 Connect to identically numbered terminals on the terminal board of the prepackaged transfer switch 2 This circuit connects the circuit board to the transfer relay coil in the prepackaged transfer switch Figure 1 Terminal Board Page 4 1 1 TRANSFORMER TX The control panel assembly s transformer is a step down type The line to line voltage from the Utility 1 Utility 2 terminals is delivered to the transformer s primary winding Transformer action then induces a reduced voltage about 12 to 16 volts into both secondary transformer windings Reduced voltage from one secondary winding is delivered to the circuit board as Utility source sensing voltage Reduced voltage from the other secondary winding is delivered to the battery charger for trickle charging If the Utility sensing voltage drops below a preset value circuit board action will initiate automatic generator startup and transfer to the Standby source side The sensing trans
134. er 1 minute Engine Cool down Timer Circuit board Run Relay Voltage Dropout Sensor on circuit circuit board PART 2 AC GENERATORS Air cooled Prepackaged Automatic Standby Generators Models 04389 04758 6 kW NG 7 kW LP 04456 04759 12 kW NG 12 kW LP 04390 04760 13 kW NG 15 kW LP Description and Components 22 operational Analysis 2 Troubleshooting Flow Chars _ 24 Diagnostic Tess I SECTION 2 1 DESCRIPTION amp COMPONENTS INTRODUCTION The air cooled pre packaged 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 1phase 60 Hz AC loads A 2 pole V Type prepackaged transfer switch is shipped with the unit see Part 3 Prepackaged transfer switches do not include an intelligence circuit of their own Instead automatic startup transfer running retransfer and shutdown operations are controlled by a solid state circuit board in the generator control pane
135. er on at startup via the same Wire 14 circuit that powers the engine ignition system and the fuel shutoff solenoid WITH HOURMETER Co LT HOUR METER AUTO OFF MAN GENERAC Power SYSTEMS SYSTEM SET FUSE LOW OIL 15 OVER icu WITHOUT HOURMETER AUTO OFF MAN FUSE GENERAC Power SYSTEMS SYSTEM SET LOW OIL HIGH TEMP OVER SPEED OVER CRANK SET 4 FLASHING RED LEDS EXERCISER NOT SET EXERCISE TIME Figure 1 Control Panel AUTO OFF MANUAL SWITCH Use this switch to a select fully automatic operation b to crank and start the engine manually and c to shut the unit down or to prevent automatic startup 1 AUTO position a Select AUTO for fully automatic operation b When AUTO is selected circuit board will monitor utility power source voltage c Should utility voltage drop below a preset level and remain at such a low level for a preset time Page 1 6 1 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 restoration of utility source voltage above 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
136. er test lead to the ground terminal Set the AUTO OFF MANUAL switch to MANUAL When the generator starts observe the voltage output on the VOM AC voltage should be 8 12 VAC 10 Set VOM to measure frequency 62 63 HZ should be measured Page 4 4 21 SECTION 4 4 DIAGNOSTIC TESTS RESULTS 1 If CONTINUITY is not measured in Step 5 repair or replace Wire 66A between Connector C2 and Connector J1 at the circuit board 2 If CONTINUITY was not measured in Step 6 repair replace Wire 55 between Connector C2 and the ground terminal 3 If CONTINUITY was measured in both Step 5 and Step 6 go to Test 7 4 f AC voltage is not correct in Step 9 proceed to Test 7 If frequency is not correct adjust no load frequency and re test TEST 71 CHECK N1 AND N2 VOLTAGE DISCUSSION Loss of utility source voltage to the generator will initiate a startup and transfer by the generator Testing at the control panel terminal strip will divide the system in two thereby reducing troubleshooting time PROCEDURE Note Verify that Utility Source Voltage is present 1 Setthe AUTO OFF MANUAL switch to OFF 2 Set a VOM to measure AC voltage 3 Connect one test lead to Wire N1 at the terminal strip in the generator control panel Connect the other test lead to Wire N2 Utility line to line voltage should be measured RESULTS 1 If voltage was measured in Step 3 go to Test 65 2 f voltage was not measured in Step 3 go to Te
137. erate remove and bench test the starter motor see following test 2 f battery voltage was indicated and the starter motor tried Page 4 4 6 DC CONTROL to engage pinion engaged but engine did NOT crank check for mechanical binding of the engine or rotor If engine turns over slightly go to Test 62 Check and Adjust Valves Compression release on single cylinder engines may not be working or mechanical binding is occurring Figure 8 Starter Motor V Twin Engines Figure 9 Starter Motor Single Cylinder Engines CHECKING THE PINION When the starter motor is activated the pinion gear should move and engage the flywheel ring gear If the pinion does not move normally inspect the pinion for binding or sticking PINION Figure 11 Check Pinion Gear Operation Single Cylinder TOOLS FOR STARTER PERFORMANCE TEST The following equipment may be used to complete a performance test of the starter motor LIA clamp on ammeter tachometer capable of reading up to 10 000 rpm LIA fully charged 12 volt battery MEASURING CURRENT To read the current flow in AMPERES a clamp on ammeter may be used This type of meter indicates current flow through a conductor by measuring the strength of the magnetic field around that conductor SECTION 4 4 DIAGNOSTIC TESTS CONDUCTOR CLAMP ON AMMETER ATTACHMENT Nes m M 7 p _ 22
138. ercent 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 Page 2 4 1 2 Start the engine let it stabilize and warm up at no load 3 When engine has stabilized read the frequency meter The no load frequency should be about 61 63 Hertz RESULTS 1 If the AC frequency is high or low go on to Test 12 2 If frequency is good but voltage is high or low go to Test 13 3 If frequency and voltage are both good tests may be discontinued TEST 12 CHECK AND ADJUST ENGINE GOVERNOR DISCUSSION The generator AC frequency output is directly proportional to the speed of the rotor A two pole rotor having a single north and a single south magnetic pole will produce an AC frequency of 60 hertz at 3600 RPM The generator is equipped with a voltage over frequency type AC voltage regulator The units AC output voltage is generally proportional to AC frequency A low or high governor speed will result in a correspondingly low or high AC frequency and voltage output The governed speed must be adjusted before any attempt to adjust
139. ercise once every seven 7 days on a day and at a time of day selected by the owner or operator The set exercise time switch is provided to select the day and time of day for system exercise See Page 5 1 3 The 7 Day Exercise Cycle for Instructions on how to set exercise time DANGER THE GENERATOR WILL CRANK AND START WHEN THE SET EXERCISE TIME SWITCH IS SET TO ON DO NOT ACTUATE THE SWITCH TO ON UNTIL AFTER YOU HAVE READ THE INSTRUCTIONS IN PART 5 PROTECTION SYSTEMS Unlike an automobile engine the generator may have to run for long periods of time with no operator present to monitor engine conditions For that reason the engine is equipped with the following systems that protect it against potentially damaging conditions L Low Oil Pressure Sensor L1 High Temperature Sensor 1 Overcrank Overspeed There are LED readouts on the control panel to notify you that one of these faults has occurred There is also a System Set LED that is lit when all of the following conditions are true 1 The AUTO OFF MANUAL switch is set to the AUTO position 2 The NOT IN AUTO dip switch is set to the OFF position on the control board 3 No alarms are present TO SELECT AUTOMATIC OPERATION The following procedure applies only to those installations in which the air cooled prepackaged automatic standby generator is installed in conjunction with a prepackaged transfer switch Prepackaged transfer switches do not have
140. erminal strip and transfer relay TR 6 Connect the negative test lead to the ground lug in the generator control panel Connect the positive test lead to Wire 23 in the generator control panel at the interconnection terminals ICT or at the terminal strip lf voltage is present proceed to Step 7 b If voltage is NOT present repair wiring between transfer switch and generator control panel 7 Connect the positive test lead to Wire 23 located in the J1 connector Pin Location 3 connected to the circuit board see Figure 3 Page 4 1 2 If voltage is present proceed to Step 8 b If voltage is NOT present repair wiring between ICT and J1connector 8 Turn off utility power to transfer switch simulating a utility failure SECTION 3 4 DIAGNOSTIC TESTS a Generator starts and transfer occurs discontinue tests b Generator starts and transfer does NOT occur With the generator running and utility OFF ground Wire 23 in the control panel at interconnection terminals ICT or at the terminal strip If transfer occurs replace circuit board 9 Connect the negative test lead to the ground lug in the generator control panel Connect the positive test lead to Wire 194 in the generator control panel at the interconnection terminals ICT or at the terminal strip the voltage is present repair wiring between ICT or terminal strip and transfer switch b If voltage is NOT present proceed to
141. ernor is generally set to maintain a no load frequency of about 62 Hertz with a corresponding output voltage of about 124 volts AC line to neutral Engine speed and frequency at no load are set slightly high to prevent excessive rpm and frequency droop under heavy electrical loading MEASURING CURRENT To read the current flow in AMPERES a clamp on ammeter may be used This type of meter indicates current flow through a conductor by measuring the strength of the magnetic field around that conductor The meter consists essentially of a current transformer with a split core and a rectifier type instrument connected to the secondary The primary of the current transformer is the conductor through which the current to be measured flows The split core allows the Instrument to be clamped around the conductor without disconnecting it Current flowing through a conductor may be measured safely and easily A line splitter can be used to measure current in a cord without separating the conductors Page 1 4 2 CONDUCTOR s 2 MIX N CLAMP ON AMMETER ATTACHMENT Figure 2 Clamp On Ammeter SPLITTER Figure 3 A Line Splitter NOTE If the physical size of the conductor or ammeter capacity does not permit all lines to be measured simultaneously measure current flow in each individual line Then add the Individual readings MEASURING RESISTANCE The volt ohm milliammeter may be used
142. essure 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 SECTION 1 2 PREPACKAGED INSTALLATION BASICS 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 Hecommended gaseous fuel pressure at the inlet side of the generator fuel solenoid valve is a a minimum of 11 inches water column 6 38 ounces per square inch and b a maximum of 14 inches water column 8 ounces per square inch A primary regulator is required to ensure that proper fuel supply pressures are maintained DANGER LP AND NATURAL GAS ARE BOTH A HIGHLY EXPLOSIVE GASEOUS FUEL LINES MUST BE PROPERLY PURGED AND TESTED FOR LEAKS BEFORE THIS EQUIPMENT IS PLACED INTO SERVICE AND PERIODICALLY THEREAFTER PROCEDURES USED IN GASEOUS FUEL LEAKAGE TESTS MUST COMPLY STRICTLY WITH APPLICABLE FUEL GAS CODES DO NOT USE FLAME OR ANY SOURCE OF HEAT TO TEST FOR GAS LEAKS NO GAS LEAKAGE IS PERMITTED LP GAS IS HEAVIER THAN AIR AND TENDS TO SETTLE IN LOW AREAS NATURAL GAS IS LIGHTER THAN AIR AND TENDS TO SETTLE IN HIG
143. eter 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 Turn OFF all power voltage supplies to the transfer switch Both the utility and standby power supplies must be positively turned off before proceeding 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 WHILE BAREFOOT OR WHILE HANDS OR side FEET ARE WET BRIDGE UTILITY CLOSING LY COIL C1 LIMIT lt SWITCH a XA1 1 es MANUAL 205 TRANSFER AH oe IG LEVER P LIMIT a SWITCH 1 7 STANDBY CLOSING n COIL C2 T2 BRIDGE RECTIFIER Figure 1 The V Type Transfer Mechanism Page 3 4 1 SECTION 3 4 DIAGNOSTIC TESTS 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 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
144. f engine does not crank go to Step 6 c If engine cranks and starts normally discontinue tests 3 Do the following Disconnect Wire 86 and Wire 0 from the oil pressure switch terminals Remove the switch and install an oil pressure gauge in its place b Connect Wire 86 to Wire O for starting purposes only After engine starts remove Wire 86 from Wire O c Start the engine while observing the oil pressure reading on gauge d Note the oil pressure 1 Normal oil pressure is approximately 35 40 psi with engine running lf normal oil pressure is indicated go to Step 4 of this test 2 If oil pressure is below about 4 5 psi shut engine down immediately A problem exists in the engine lubrication system Note The oil pressure switch is rated at 10 psi for v twin engines and 8 psi for single cylinder engines 4 Remove the oil pressure gauge and reinstall the oil pressure switch Do NOT connect Wire 86 or Wire 0 to Page 4 4 15 SECTION 4 4 DIAGNOSTIC TESTS the switch terminals a Set a VOM to its R x 1 scale and zero the meter b Connect the VOM test leads across the switch terminals With engine shut down the meter should read CONTINUIT Y c Connect Wire 86 to Wire 0 for starting purposes only After engine starts remove Wire 86 from Wire 0 d Crank and start the engine The meter should read INFINITY 5 Perform Steps 4a and 4b If INFINITY is measured with the engine shutdown replace the LO
145. former is shown in Figure 2 both pictorially and schematically 50 60Hz SCHEMATIC Figure 2 The Transformer CIRCUIT BOARD The circuit board controls all standby electric system operations including a engine startup b engine running c automatic transfer d automatic retransfer and e engine shutdown In addition the circuit board performs the following functions Delivers field boost current to the generator rotor windings see Field Boost Circuit on Page 2 2 1 LiStarts and exercises the generator once every seven days L1 Provides automatic engine shutdown in the event of low oil pressure high oil temperature or overspeed A 17 pin and a 5 pin connector are used to interconnect the circuit board with the various circuits of the DC systems Connector pin numbers associated wires and circuit functions are listed in the CHART on the next page SECTION 4 1 DESCRIPTION AND COMPONENTS DC CONTROL CIRCUIT FUNCTION Field boost current to rotor about 9 10 volts DC Low oil pressure shutdown Automatic shutdown occurs when Wire 85 is grounded by loss of oil pressure to the LOP Switched to ground for Transfer Relay TR operation 12 VDC output from the circuit board for transfer relay present in AUTO or MANUAL operation Energized 12 volts DC by circuit board s crank relay K1 to crank the engine Engine shutdown Circuit is grounded by circuit board action to g
146. g has not yet begun The AUTO OFF MANUAL switch is shown in its AUTO position Battery voltage is available to the circuit board via Wire 13 15 amp fuse F1 Wire 15 the AUTO OFF MANUAL switch SW1 Wire 15A and Pin 10 of the circuit board connector Page 4 2 3 DC CONTROL L 240VAC GENERATOR OUTPUT I O A F2 TO LOAD Figure 2 Circuit Condition Initial Dropout of Utility Source Voltage DC CONTROL 12VDC 69 5 EH RELAY col 69 1 a SW1 5 15 240 G9 N1 UTILITY INPUT N2 17 1 13 240VAC m GENERATOR TA OUTPUT 56VA 1VA 225 224 17 13 225A 224 15 o 11 POWER WINDING STATOR C2 3 ENGINE RUN WINDING STATOR 4 BATTERY CHARGE WINDING BATTERY CHARGER ELECTRONIC VOLTAGE REGULATOR GENERATOR 12 VDC ALWAYS PRESENT mamam AC VOLTAGE SECTION 4 2 OPERATIONAL ANALYSIS BATTERY CUSTOMER SUPPLIED 18 18 z 0 E D 13 UTILITY i VOLTAGE SENSING CONTROL PRINTED CIRCUIT BOARD 12VDC DIAGRAM KEY BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY CB1 CIRCUIT BREAKER MAIN OUTPUT
147. gass is in cubic feet per hour LP is in gallons per hour cubic feet per hour STATOR WINDING RESISTANCE VALUES ROTOR RESISTANCE Model 04692 Models 04389 Models 04456 Models 04390 04679 04758 04759 04760 Power Winding Across 11 amp 22 0 190 0 208 ohms 0 223 0 259 ohms 0 115 ohms 0 08 0 08 ohms Power Winding Across 33 amp 44 0 190 0 208 ohms 0 223 0 259 ohms 0 115 ohms 0 08 0 08 ohms Excitation Winding Across 2 amp 6 1 442 1 670 ohms 1 53 1 77 ohms 0 745 ohms 0 705 ohms Engine Run Winding Across 55 amp 66A 0 104 0 120 ohms 0 100 0 169 ohms 0 109 ohms 0 087 ohms Battery Charge Winding Across 66 amp 77 0 137 0 158 ohms 0 146 0 169 ohms 0 164 ohms 0 130 ohms Rotor Resistance 15 42 17 85 ohms 11 88 13 76 ohms 15 9 ohms 19 8 ohms Page 2 SPECIFICATIONS 743 704 29 25 207 207 8 14 TRANSFER SWITCH IF SUPPLIED 604 23 5 716 28 622 24 5 LEFT SIDE VIEW 76 2mm 3 00 PEA GRAVEL MINUMUM Page 3 MOUNTING DIMENSIONS LIFTING HOLES 4 CORNERS DO NOT LIFT BY THE ROOF 1193 47 1232 48 5 VIEW ALL DIMENSIONS IN MILLIMETERS INCHES HOME STANDBY GENERATOR INSTALLATION DIAGRAM SPECIFICATIONS MOUNTING DIMENSIONS 914mm 36 0 MINIMUM OPEN AREA ALL AROUND UNIT A co per L AIR INTAKE 1172 3 46 2 3 4 NPT FUEL INLET GAS PRESSURE OF 11 14 WATER COLUMN REQUIRED CABLE AC
148. generator main circuit breaker to its ON or closed position Loads are now powered by the standby generator 9 Turn ON electrical loads connected to transfer switch T1 Page 5 1 2 SECTION 5 1 SYSTEM FUNCTIONAL TESTS and T2 Apply an electrical load equal to the full rated wattage amperage capacity of the installed generator 10 Connect an accurate AC voltmeter and a frequency meter across terminal lugs E1 and E2 Voltage should be greater than 230 volts frequency should be greater than 58 Hertz 11 Let the generator run at full rated load for 20 30 minutes Listen for unusual noises vibration or other indications of abnormal operation Check for oil leaks evidence of overheating etc 12 When testing under load is complete turn OFF electrical loads 13 Set the generator main circuit breaker to its OFF or open position 14 Let the engine run at no load for a few minutes 15 Set the AUTO OFF MANUAL switch to OFF The engine should shut down CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation proceed as follows 1 Set generator main circuit breaker to its OFF or open position 2 Check that the AUTO OFF MANUAL switch is set to OFF 3 Turn off the utility power supply to the transfer switch using means provided such as a utility main line circuit breaker 4 Manually set the transfer switch to the UTILITY position load terminals connected to the utility power so
149. gulator 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 Page 2 1 3 AC GENERATORS Figure 6 Typical Voltage Regulator A single red lamp LED glows during normal operation The lamp will become dim if excitation winding AC output diminishes It will go out on occurrence of an open condition in the sensing AC output circuit An adjustment potentiometer permits the stator AC power winding voltage to be adjusted Perform this adjustment with the generator running at no load and with a 62 Hz AC frequency 62 Hz equals 3720 rpm At the stated no load frequency adjust to obtain a line to line AC voltage of about 252 volts MAIN LINE CIRCUIT BREAKER The main line circuit breaker protects the generator against electrical overload See Specifications on Page 1 for amp ratings AC GENERATORS ROTOR RESIDUAL MAGNETISM The generator revolving field rotor may be considered to be a permanent magnet Some residual magnetism is always present in the rotor This residual magnetism is sufficient to induce a voltage into the stator AC power windings that is approximately 2 12 volts AC FIELD BOOST FIELD BOOST CIRCUIT When the engine is cranking direct current flow is delivered from a circuit board to the generator rotor windings via Wire 4 The field
150. he Starter Contactor Relay PROCEDURE 1 Seta VOM to measure DC voltage 2 Connect the positive meter test lead to the Wire 13 connector Connect the negative meter test lead to a clean frame ground Battery voltage should be measured 3 Connect the positive meter test lead to the Wire 16 connector Connect the negative meter test lead to a clean frame ground 4 Set the AUTO OFF MANUAL switch to MANUAL Observe the meter reading Battery voltage should measured If battery voltage is NOT measured proceed to Step 5 5 Set the VOM to it s R x 1 scale to measure ohms 6 Connect one test lead to the Wire 0 connector Connect the other test lead to a clean frame ground CONTINUITY should be measured RESULTS 1 If battery voltage is NOT measured in Step 2 repair or replace wiring between starter contactor relay and fuse F2 2 f battery voltage is NOT measured in Step 4 and CONTINUITY is measured in Step 6 replace the starter contactor relay If battery voltage is measured in Step 4 proceed to Test 49 TEST 49 TEST STARTER CONTACTOR DISCUSSION The starter contactor SC must energize and its heavy duty contacts must close or the engine will not crank This test will determine if the starter contactor is in working order PROCEDURE Carefully inspect the starter motor cable that runs from the battery to the starter motor Cable connections must be clean and tight If connections are
151. he stator can as shown in Figure 3 The stator can is sandwiched between an engine adapter and a rear bearing carrier It is retained in that position by four stator studs Figure 3 Stator Assembly Leads BRUSH HOLDER AND BRUSHES The brush holder is retained to the rear bearing carrier by means of two 10 32 x 9 16 Taptite screws A positive and a negative brush are retained in the brush holder with the positive brush riding on the slip ring nearest the rotor bearing SECTION 2 1 DESCRIPTION amp COMPONENTS Wire 4 connects to the positive brush and Wire 0 to the negative brush Wire O connects to frame ground Rectified and regulated excitation current as well as current from a field boost circuit are delivered to the rotor windings via Wire 4 and the positive brush and slip ring The excitation and field boost current passes through the windings and to frame ground via the negative slip ring and brush and Wire 0 This current flow creates a magnetic field around the rotor having a flux concentration that is proportional to the amount of current flow Figure 4 Brush Holder and Brushes OTHER AC GENERATOR COMPONENTS Some AC generator components are housed in the generator control panel enclosure and are not shown in Figure 1 These are a an excitation circuit breaker b a voltage regulator and c a main line circuit breaker EXCITATION CIRCUIT BREAKER The excitation circ
152. ic representation of the transfer switch with generator power available waiting to transfer L Generator voltage available E1 E2 Circuit board action holding Wire 23 open to ground L1 Power available to standby coil C2 upon closure of TR normally open contacts 9 amp 6 will close and initiate a transfer GENERATOR oM 23 194 00 194 CONTROL PRINTED CIRCUIT BOARD TRANSFER SWITCH 1 F1 126 7 N1A N1 Utility Failure A Transfer Switch in Duty Position eges Generator Running amp Generator Voltage Available E1 E2 Waiting to Transfer Figure 3 Generator Power Available Waiting to Transfer Page 3 2 3 ss din OPERATIONAL ANALYSIS TRANSFER TO STANDBY The generator circuit board delivers 12 volts DC to the transfer relay via terminal 194 and back to the circuit board via terminal 23 However circuit board action holds the Wire 23 circuit open and the transfer relay remains de energized On generator startup an engine warm up timer on the generator circuit board starts timing When that timer has timed out circuit board action completes the Wire 23 circuit to ground The transfer relay then energizes its normally open contacts close and standby source voltage is delivered to the standby closing coil via Wires E1 and E2 the transfer relay TR contacts limit switch XB1 Wire B and a bridge rectifier The standby closing coil
153. idual plus field boost magnetism from the rotor induces a voltage into a the stator AC power windings b the stator excitation or DPE windings c the stator battery charge and d engine run winding In an 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 induceq Into the stator windings increases rapidly due to the Increasing speed at which the rotor operates FIELD EXCITATION An AC voltage is induced into the stator excitation DPE windings The DPE winding circuit is completed to the voltage regulator via Wire 2 excitation circuit breaker Wire 162 and Wire 6 Unregulated alternating current can flow from the winding to the regulator The voltage regulator senses AC power winding output voltage and frequency via stator Wires 11 and 22 The regulator changes the AC from the excitation winding to DC In addition based on the Wires 11 and 22 sensing signals it regulates the flow of direct current to the rotor The rectified and regulated current flow from the regulator is delivered to the rotor windings via Wire 4 and the positive brush and slip ring This excitation current flows through the rotor windings and is directed to ground through the negative slip ring and brush and Wire 0 The greater the current flow through the rotor windings the more co
154. ily power source voltage across terminals N1 and the transfer switch neutral lug then across terminal N2 and neutral Nominal line to neutral voltage should be 120 volts AC 7 When certain that utility supply voltage is compatible with transfer switch and load circuit ratings turn OFF the utility power supply to the transfer switch 8 On the generator panel set the AUTO OFF MANUAL switch to MANUAL The engine should crank and start 9 Let the engine warm up for about five minutes to allow internal temperatures to stabilize Then set the generator main circuit breaker to its or closed position A A Proceed with caution Generator power voltage is now supplied to the transfer switch Contact with live transfer switch parts will result in dangerous and possibly fatal electrical shock 10 Connect an accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1 and E2 Voltage should be 242 252 volts frequency should read about 61 63 Hertz 11 Connect the AC voltmeter test leads across terminal lug 1 and neutral then across 2 and neutral In both cases voltage reading should be 121 126 volts AC 12 Set the generator main circuit breaker to its OFF or open SECTION 5 1 SYSTEM FUNCTIONAL TESTS position Let the engine run at no load for a few minutes to stabilize internal engine generator temperatures 13 Set the generator AUTO OFF MANUAL switch to OFF The engine
155. ime for system exercise To select the desired day and time of day you must perform the following sequence at that time 1 Verify that the AUTO OFF MANUAL switch is set to AUTO 2 Hold down the set timer switch until the generator starts approximately 10 seconds and then release 3 The generator will start and run for approximately 12 minutes and then shut down on its own The exerciser will then be set to run at that time of day every week 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 The exerciser WILL NOT work if dip switch 2 REMOTE NOT AUTO on the controller printed circuit board is ON TABLE OF CONTENTS PART TITLE 61 Major Disassembly Torque Specifications PART 6 DISASSEMBLY Air cooled Prepackaged Automatic Standby Generators Models 04389 04758 6 kW NG 7 kW LP 04456 04759 12 kW NG 12 kW LP 04390 04760 13 kW NG 15 kW LP SECTION 6 1 MAJOR DISASSEMBLY MAJOR DISASSEMBLY STATOR ROTOR ENGINE REMOVAL For stator removal follow Steps 1 14 For rotor removal follow Steps 1 15 For Engine removal follow Steps 1 16 1 2 Remove door Set the AUTO OFF MANUAL switch to OFF Disconnect battery cables Remove Fuse F1 Remove the utility power source to the generator Turn off fuel supply to the generator
156. ine against such operating faults as a low engine oil pressure b high temperature c overspeed and d overcrank On occurrence of any one or more of those operating faults circuit board action will effect an engine shutdown LOW OIL PRESSURE SHUTDOWN See Figure 1 An oil pressure switch is mounted on the engine oil filter adapter This switch has normally closed contacts that are held open by engine oil pressure during cranking and startup Should oil pressure drop below approximately 10 psi the switch contacts will close On closure of the switch contacts a Wire 86 circuit from the circuit board will be connected to ground Circuit board action will then 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 OIL TEMPERATURE SHUTDOWN An oil temperature switch Figure 1 is mounted on the engine block The thermal switch has normally open contacts that will close if oil temperature should exceed approximately 284 F 140 C This will result in the same action as a low oil pressure shutdown OVERSPEED SHUTDOWN During engine cranking and operation the circuit board receives AC voltage and frequency signals from the generator engine run windings via Wire 66A Should the AC frequency exceed approximately 72Hz 4
157. ing at each switch position RESULTS 1 If Limit Switch XB1 fails the test remove and replace the switch or adjust switch until it is actuated properly 2 f limit switch is good repair or replace Wire B between limit switch and Standby Coil C2 V TYPE PREPACKAGED TEST 26 CHECK 23 AND 194 WIRING CONNECTIONS DISCUSSION An open circuit in the transfer switch control wiring can prevent a transfer action from occurring In the auto mode the circuit board supplies 12 VDC to Wire 194 This DC voltage is supplied to the transfer relay TR at Terminal Location A The opposite side of the transfer relay TR coil Terminal B is connected to Wire 23 Positive 12VDC is present on this also Circuit board action will allow current to flow through the circuit and the TR is energized PROCEDURE RESULTS 1 Set VOM to DC volts 2 Place generator AUTO OFF MANUAL switch to the AUTO position Utility power should be present the generator should not start 3 Connect the negative test lead to a suitable frame ground in the transfer switch 4 Connect the positive test lead to Wire 194 at the terminal strip in the transfer switch lf voltage is present proceed to Step 5 b If voltage is NOT present proceed to Step 9 5 Connect the positive test lead to Wire 23 at the terminal strip in the transfer switch lf voltage is present proceed to Step 6 b If voltage is NOT present repair wiring between t
158. ire 2 amp 6 Voltage Results Wire 11 amp 22 Static Rotor Running Rotor Page 2 4 3 SECTION 2 4 DIAGNOSTIC TESTS 8 Setthe AUTO OFF MANUAL switch to MANUAL Once the engine starts record the AC voltage 9 Set the AUTO OFF MANUAL switch to OFF Reconnect Wire 11 and Wire 22 10 Set VOM to DC amperage 11 Remove jumper lead connected to Wire 4 and Wire 15 12 Connect one meter test lead to battery positive twelve volt supply Wire 15 located at the 15A fuse Connect the other meter test lead to Wire 4 still disconnected from previous tests Measure and record static rotor amp draw 13 Set the AUTO OFF MANUAL switch to the MANUAL position Once the engine starts repeat step 12 Measure and record running rotor amp draw with the engine running 14 Set the Auto Off Manual switch to OFF Reconnect Wire 4 to the voltage regulator RESULTS Refer to Chart on Page 2 4 3 Results Fixed Excitation Test Rotor Amp Draw Test TEST 5 WIRE CONTINUITY DISCUSSION The voltage regulator receives unregulated alternating current from the stator excitation winding via Wires 2 6 and 162 It also receives voltage sensing from the stator AC power windings via Wires 11 and 22 The regulator rectifies the AC from the excitation winding and based on the sensing signals regulates the DC current flow to the rotor The rectified and regulated current flow is delivered to the rotor brushes via Wires 4 positive and 0 nega
159. k manually proceed to Problem 9 in the Troubleshooting Flow Charts TEST 43 TEST AUTO OFF MANUAL SWITCH DISCUSSION When the AUTO OFF MANUAL switch is set to AUTO position battery voltage 12 volts DC is delivered to the circuit board via Wire 15A the closed switch terminal Wire 15A and Pin 10 of the circuit board connector This voltage is needed to operate the circuit board Setting the switch to its Manual position delivers battery voltage to the circuit board for its operation In addition when the switch is set to Manual 12 volts DC is supplied to the circuit board via Pin 11 of the board Wire 239 the closed switch contacts Wire 17 and Pin 9 of the circuit board connector A Set to Auto B Set to Manual 183 178 17 IF EQUIPPED Figure 1 Schematic of AUTO OFF MANUAL Switch Page 4 4 1 SECTION 4 4 DIAGNOSTIC TESTS PROCEDURE Disconnect all wires from switch terminals to prevent interaction Then use a volt ohm milliammeter VOM to test for continuity across switch terminals as shown in the following chart Reconnect all wires and verify correct positions when finished TERMINALS 2 and 3 SWITCH POSITION AUTO CONTINUITY MANUAL INFINITY OFF INFINITY AUTO INFINITY MANUAL CONTINUITY OFF INFINITY AUTO CONTINUITY MANUAL INFINITY OFF INFINITY AUTO INFINITY MANUAL CONTINUITY OFF INFINITY READING 2 1 5 and 6 5 and 4 RESULT
160. l ENGINE GENERATOR DRIVE SYSTEM The generator revolving field is driven by an air cooled horizontal crankshaft engine The generator is STATOR BRUSH HOLDER ASSEMBLY directly coupled to the engine crankshaft see Figure 1 and mounted in an enclosure Both the engine and generator rotor are driven at approximately 3600 rpm to provide a 60 Hz AC output THE AC GENERATOR Figure 1 shows the major components of the AC generator ROTOR ASSEMBLY The 2 pole rotor must be operated at 3600 rpm to supply a 60 Hertz AC frequency The term 2 pole means the rotor has a single north magnetic pole and a single south magnetic pole As the rotor rotates its lines of magnetic flux cut across the stator assembly windings and a voltage is induced into the stator windings The rotor shaft mounts a positive and a negative slip ring with the positive slip ring nearest the rear bearing carrier The rotor bearing is pressed onto the end of the rotor shaft The tapered rotor shaft is mounted to a tapered crankshaft and is held in place with a single through bolt ENGINE ADAPTOR CARRIER Figure 1 AC Generator Exploded View Page 2 1 1 AC GENERATORS PART2 Figure 2 The 2 Pole Rotor Assembly STATOR ASSEMBLY The stator can houses and retains a dual AC power windings b excitation winding c battery charge winding and d engine run winding A total of twelve 12 stator leads are brought out of t
161. l magnetism has been lost or is not sufficient to turn the regulator on and field boost has also been lost excitation current will not be supplied to the rotor Generator AC output voltage will then drop to zero or nearly zero PROCEDURE 1 Locate Wire 4 that is routed from the circuit board and connects to the voltage regulator terminal third from the top see Figure 3 Disconnect that wire from the voltage regulator terminal 2 Set a VOM to read DC volts Disconnect Connector C2 from the control panel C2 is the closest to the back panel 3 Connect the positive VOM test probe to the terminal end of disconnected Wire 4 4 Connect the common VOM test probe to the grounding lug 5 Crankthe engine while observing the VOM reading While the engine is cranking the VOM should read approximately 9 10 volts DC When engine is not cranking VOM should indicate zero volts see Figure 4 RESULTS 1 If normal field boost voltage is indicated in Step 5 replace the voltage regulator 2 f normal field boost voltage is NOT indicated in Step 5 check Wire 4 between regulator and circuit board for open or shorted condition If wire is good replace the circuit board TO GROUND Figure 4 Field Boost Test Points TEST 7 TESTING THE STATOR WITH A VOM DISCUSSION A Volt OHM Milliammmeter VOM can be used to test the stator windings for the following faults 4 An open circuit condition 4 A short to groun
162. l supply Mounting the load center Connecting power source and load lines Connecting system control wiring L1 Post installation tests and adjustments SELECTING A LOCATION Install the generator set as close as possible to the electrical load distribution panel s that will be powered by the unit ensuring that there is proper ventilation for cooling air and exhaust gases This will reduce wiring and conduit lengths Wiring and conduit not only add to the cost of the installation but excessively long wiring runs can result in a voltage drop GROUNDING THE GENERATOR The National Electric Code requires that the frame and external electrically conductive parts of the generator be property connected to an approved earth ground Local electrical codes may also require proper grounding of the unit For that purpose a grounding lug is attached to the unit Grounding may be accomplished by attaching a stranded copper wire of the proper size to the generator grounding lug and to an earth driven copper or brass grounding rod electrode Consult with a local electrician for grounding requirements in your area THE FUEL SUPPLY Prepackaged units with air cooled engine were operated tested and adjusted at the factory using natural gas as a fuel These air cooled engine units can be converted to use LP propane gas by making a few adjustments for best operation and power LP propane gas is usually supplied as a liquid in pr
163. lem 14 ONLY if voltage is good repair N1 N2 open wiring between Transfer Switch and Generator TEST 29 CHECK VOLTAGE AT UTILITY CLOSING COIL C1 DISCUSSION Utility source voltage is required to energize utility closing coil C1 and effect retransfer back to the Utility source This voltage is delivered to the utility closing coil via Wires N1A and N2A the transfer relay s normally closed contacts relay de energized Wire 126 Limit Switch XA1 and a bridge rectifier PROCEDURE 1 On the generator control panel set the AUTO OFF MANUAL switch to OFF 2 Turn OFF the utility power supply to the transfer switch using whatever means provided such as a utility source main line circuit breaker 3 Set the generator main line circuit breaker to its OFF or Open position 4 Check the position of the transfer mechanism main contacts The moveable load contacts must be connected to the stationary utility contacts If necessary manually actuate the main contacts to their Utility source side load connected to the source DANGER BE CAREFUL HIGH AND A DANGEROUS VOLTAGES ARE PRESENT AT TERMINAL LUGS WHEN THE GENERATOR IS RUNNING AVOID CONTACT WITH HIGH VOLTAGE TERMINALS OR DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK MAY RESULT DO NOT PERFORM THIS VOLTAGE TEST WHILE STANDING ON WET OR DAMP GROUND WHILE BAREFOOT OR WHILE HANDS OR FEET ARE WET 5 Disconnect Wire N2A from the utility closing coil C1
164. let the magnet pull the magneto down against the thickness gauge Page 4 4 13 SECTION 4 4 DIAGNOSTIC TESTS 4 Tighten both mounting screws 5 To remove the thickness gauge rotate the flywheel 6 Repeat the above procedure for the second magneto Figure 23 Setting Ignition Magneto Armature Air Gap 7 Repeat Test 55 and check for spark across the spark tester gap 8 lf air gap was not out of adjustment test ground wires 9 Set the VOM to the diode test position The meter will display forward voltage drop across the diode If the voltage drop is less than 0 7 volts the meter will Beep once as well as display the voltage drop A continuous tone indicates CONTINUITY shorted diode An incomplete circuit open diode will be displayed as OL 10 Disconnect the engine wire harness from the ignition magnetos and stud connector Figure 24 SPARK PLUG WIRE 18 TO CIRCUIT BOARD ENGINE WIRE HARNESS Figure 24 Engine Ground Harness Page 4 4 14 DC CONTROL SWITCH ON TURNED OFF CAUSE Engine Runs Shuts Off OK 1 Closed Diode On One Cylinder Engine Runs Only One Cylinder 1 Open Diode Both Cylinders Shuts Off Won t Run 2 Closed Diodes No Spark Engine Runs Engine Won t 2 Open Diodes Both Cylinders Shut Off Figure 25 Diode Failure Diagnosis 11 Connect the positive test lead to Connector as shown in Figure 26 Connect the negative test lead to Connector
165. m the transfer switch terminal strip Connect the other meter test lead to the ground terminal If CONTINUITY was measured Wire 194 is shorted to ground between the generator and the transfer switch 1 If INFINITY was measured disconnect Wire 194 from the transfer relay TR Connect one meter test lead to the transfer relay terminal from which Wire 194 was previously removed Connect the other test lead to Wire 23 at the transfer switch terminal strip If CONTINUITY ZERO RESISTANCE was measured replace the transfer relay Normal coil resistance is approximately 113 ohms 2 If coil resistance of 113 ohms was measured the short is in Wire 194 between the transfer relay and the terminal strip Repair or replace Wire 194 6 O 155 ohms Coil resistance for the SC is 4 ohms If coil resistance was measured Wire 56 is shorted to ground between Connector J1 and the SCR or SC Repair or replace the shorted wire Disconnect and isolate each Wire 14 from the 4 tab insulated terminal block Repeat Step 3 for Pin Location J1 7 If CONTINUITY was measured repair or replace Wire 14 between Connector J1 and the 4 tab terminal block If INFINITY was measured proceed as follows a Disconnect Wire 14 from the following fuel solenoid FS battery charge relay BCR and hourmeter HM if equipped b Connect the negative meter test lead to the ground terminal Connect the positive meter test lead to each of the listed comp
166. n distribution panel back This can be done by switching the service main breaker to the ON or closed position Allow the generator to shut down WARNING A Do not make any unnecessary adjustments Factory settings are correct for most applications However when making adjustments be careful to avoid overspeeding the engine TEST 64 CHECK BATTERY CHARGE OUTPUT DISCUSSION The battery charging system is a two amp trickle charge It is capable of maintaining a charge on a functional battery It is not intended to nor capable of charging a completely dead battery The system will charge when utility source power is available to the generator or if the generator is running The system consists of a transformer TX battery charge relay BCR battery charger BC and a battery charge winding The BCR contacts allow AC voltage to the battery charger When the BCR is de energized voltage from the TX is available to the battery charger When the generator starts Wire 14 energizes the BCR This allows battery charge winding AC output to power the battery charger PROCEDURE 1 Check the 5 amp fuse F2 2 Set the AUTO OFF MANUAL switch to OFF Note Utility source voltage MUST be available to the generator 3 Set a VOM to measure DC amps 4 Disconnect Wire 13A purple from the 5 amp fuse F2 5 Connect the positive test lead to Wire 13A and connect the negative test lead to the fuse
167. n the idle adjust screw and reconnect the idle spring 6 Using your hand push the governor arm to the closed throttle position Make sure the idle spring does not Stretch at all 7 Restart the unit 8 Slowly turn the idle adjust screw to adjust the no load idle speed to 62 5 Hz 9 The governor is now set FULL LOAD SPEED ADJUST SCREW ONT Figure 11 Full Load Speed Adjust Screw V twin Engines RESULTS 1 If after adjusting the engine governor frequency and voltage are good tests may be discontinued 2 If frequency is now good but voltage is high or low go to Test 13 3 If engine was overspeeding check linkage and throttle for binding If no governor response is indicated refer to engine service manual 4 f engine appears to run rough and results in low frequency proceed tp Problem 11 Page 4 3 3 Page 2 4 9 SECTION 2 4 DIAGNOSTIC TESTS TEST 13 CHECK AND ADJUST VOLTAGE REGULATOR DISCUSSION For additional information refer to description and components Page 2 1 3 PROCEDURE With the frequency between 61 62 Hertz slowly turn the slotted potentiometer Figure 12 until line voltage reads 244 252 volts NOTE You must remove the access panel on top of the control panel to adjust the voltage regulator NOTE The voltage regulator is housed above the generator control panel The regulator maintains a voltage in direct proportion to frequency at a 2 to 1 ratio For example at 62 Hert
168. nce is 5 psi Divide 5 by the highest reading 65 to obtain the percentage of 7 6 percent Example 2 No 1 cylinder reads 75 psi No 2 cylinder reads 55 psi The difference is 20 psi Divide 20 by 75 to obtain 26 7 percent Loss of compression in No 2 cylinder is indicated If compression is poor look for one or more of the following Loose cylinder head bolts Failed cylinder head gasket Burned valves or valve seats Insufficient valve clearance Warped cylinder head Warped valve stem Worn or broken piston ring s Worn or damaged cylinder bore Broken connecting rod Worn valve seats or valves TEST 58 CHECK SHUTDOWN WIRE DISCUSSION Circuit board action during shutdown will ground Wire 18 Wire 18 is connected to the Ignition Magneto s The grounded magneto will not be able to produce spark PROCEDURE 1 On v twin generators remove Wire 18 from the stud located above the oil cooler On single cylinder generators disconnect Wire 18 at the bullet connector 2 Perform Test 55 SECTION 4 4 DIAGNOSTIC TESTS If spark now occurs with Wire 18 removed check for short to ground Set the AUTO OFF MANUAL switch to OFF Remove the 17 pin connector J1 from the circuit board 4 Set a VOM to measure resistance Connect one test lead to Wire 18 from the control panel Connect the other test lead to a clean frame ground INFINITY should be measured 5 Reconnect the J1 connector to the circuit bo
169. ncentrated 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 Page 2 2 2 Initially the AC power winding voltage sensed by the regulator is low The regulator reacts by increasing the flow of excitation current to the rotor until voltage increases to a desired level The regulator then maintains the desired voltage For example if voltage exceeds the desired level the regulator will decrease the flow of excitation current Conversely if voltage drops below the desired level the regulator responds by increasing the flow of excitation current AC POWER WINDING OUTPUT A regulated voltage is induced into the stator AC power windings When electrical loads are connected across the AC power windings to complete the circuit current can flow in the circuit The regulated AC power winding output voltage will be in direct proportion to the AC frequency For example on units rated 120 240 volts at 60 Hz the regulator will try to maintain 240 volts line to line at 60 Hz This type of regulation system provides greatly improved motor starting capability over other types of systems BATTERY CHARGE WINDING OUTPUT A voltage is induced into the battery charge windings Output from these windings is delivered to a battery charger via Wires 66 and 77 The resulting direct cur
170. ndby Generators Models 04389 04758 6 kW NG 7 kW LP 04456 04759 12 kW NG 12 kW LP 04390 04760 13 kW NG 15 kW LP PART 7 ELECTRICAL DATA N90 Z INVHOVIO lt lt
171. nder models The control contactor will energize and battery power will be delivered to the starter motor SM The engine will then crank During a manual startup AUTO OFF MANUAL switch at MANUAL action is the same as during an automatic start except that cranking will begin immediately when the switch is set to MANUAL Circuit board action during both a manual and an automatic start will hold the crank relay energized for 15 seconds on The relay will then de energize for 15 seconds off It will then energize for seven 7 seconds on and de energize for seven 7 seconds off It will repeat this same cycle for another 45 seconds If the engine has not started after approximately 90 seconds of these crank rest cycles cranking will automatically terminate and shutdown will occur The circuit board uses AC signals from the stator engine run winding as an indication that the engine has started Page 1 5 1 SECTION 1 6 OPERATING INSTRUCTIONS CONTROL PANEL GENERAL See Figure 1 The front face of this panel mounts a an hourmeter b an AUTO OFF MANUAL switch c 15 amp fuse d 5 amp fuse e a set exercise switch and f the protection systems HOURMETER Equipped on some models only The hourmeter indicates engine generator operating time in hours and tenths of hours Use the meter in conjunction with the periodic maintenance schedule for the applicable generator set circuit board action turns the hourmet
172. nt in each circuit must not exceed the value stated for 240 volts 15 000 watt with upgrade kit 04578 0 Kit includes power hamesses and 70 amp 2 pole circuit breaker ENGINE Models 04389 04758 Models 04456 04759 Models 04390 04760 Type of Engine GH 410 GT 990 GT 990 Number of Cylinders 1 2 2 Rated Horsepower 14 5 3 600 rpm 26 3 600 rpm 30 3 600 rpm Displacement 410cc 992cc 992cc Cylinder Block Aluminum w Cast Aluminum w Cast Aluminum w Cast Iron Sleeve Iron Sleeve Iron Sleeve Valve Arrangement Overhead Valves Overhead Valves Overhead Valves Ignition System Solid state w Magneto Solid state w Magneto Solid state w Magneto Recommended Spark Plug RC12YC RC12YC RC12YC Spark Plug Gap 0 76 mm 0 030 inch 0 5 mm 0 020 inch 0 5 mm 0 020 inch Compression Ratio 8 6 1 9 5 1 9 5 1 Starter 12 Vdc 12 Vdc 12Vdc Oil Capacity Including Filter Approx 1 5 Qts Approx 1 7 Qts Approx 1 7 Qts Recommended Oil Filter Generac Part 070185 Generac Part 070185 Generac Part 070185 Recommended Air Filter Generac Part 0C8127 Generac Part 0C8127 Generac Part 0C8127 Operating RPM 3 600 3 600 3 600 FUEL CONSUMPTION Model Natural Gas LP Vapor 1 2 Load Full Load 1 2 Load Full Load 04389 04758 74 105 0 91 33 1 21 44 1 04556 04759 114 185 1 34 48 9 2 17 79 0 04390 04760 148 5 240 1 73 63 2 2 80 102 3 Natural
173. oard and retest TEST 76 CHECK CRANKING AND RUNNING CIRCUITS DISCUSSION This test will check all of the circuits that are HOT with battery voltage and which could cause the F1 Fuse to blow PROCEDURE 1 Seta VOM to measure resistance 2 Disconnect the 17 pin connector J1 from the circuit board 3 Connect one meter test lead to the ground terminal Connect the other meter test lead to each of the following J1 Connector pin locations Page 4 4 23 SECTION 4 4 DIAGNOSTIC TESTS J1 4 Wire 194 If CONTINUITY was measured go to Step 4 Average nominal resistance other meter test lead to the ground terminal If CONTINUITY or zero resistance was measured replace the SCR or SC Coil resistance for the SCR is reading 110 120 ohms J1 5 Wire 56 If CONTINUITY was measured go to Step 5 Average nominal resistance reading V twin SCR 150 160 ohms Single Cylinder SC 4 ohms J1 10 Wire 15A If CONTINUITY was measured repair or replace shorted to ground Wire 15A between Connector J1 and switch SW1 J1 7 Wire 14 If CONTINUITY was measured go to Step 6 4 Disconnect Wire 194 from the terminal strip Repeat Step 3 at Pin Location J1 4 a lf CONTINUITY was measured Wire 194 is shorted to ground between Connector J1 and terminal strip b If INFINITY was measured disconnect Wire 194 from the transfer switch terminal strip Connect one meter test lead to the end of Wire 194 which was removed fro
174. of wood under the engine adapter Figure 4 Engine Adapter pm by 2 x4 Piece of Wood Using a 1 4 socket remove Wire 0 and Wire 4 from the brush assembly Remove the two brush assembly hold down bolts Remove the brushes Using a 13mm socket remove the four stator hold down bolts Using a small rubber mallet remove the rear bearing carrier Remove the stator SECTION 6 1 MAJOR DISASSEMBLY Figure 6 Removing the Stator 15 Rotor Removal Cut 2 5 inches from the rotor bolt Slot the end of the bolt to suit a flat blade screwdriver Slide the rotor bolt back through the rotor and use a screwdriver to screw it into the crankshaft Use a 3 M12x1 75 bolt to screw into rotor Apply torque to the 3 M12x1 75 bolt until taper breaks If necessary when torque is applied to 3 M12x1 75 bolt use a rubber mallet on the end of the rotor shaft to break taper Page 6 1 2 SECTION 6 1 DISASSEMBLY Using a 10mm socket remove the six 6 nuts attaching the control panel to the side back enclosure and the engine divider panel Remove the two 2 nuts connected to the back enclosure located on the top side of control panel Remove the two 2 nuts located underneath the middle of the control panel connecting to the back side enclosure and the engine divider panel Remove the two 2 nuts from the front top side of the control panel connecting to the back side enclosure and the engine divider panel Remove the control panel 3
175. oil c Retransfer back to UTILITY occurs NEUTRAL LUG The standby generator is equipped with an UNGROUNDED neutral The neutral lug in the transfer switch is isolated from the switch enclosure MANUAL TRANSFER HANDLE The manual transfer handle is retained in the transfer switch enclosure by means of a wing stud Use the handle to manually actuate the transfer mechanism load contacts to either the UTILITY or STANDBY source side Instructions on use of the manual transfer handle may be found in Part 5 Operational Tests and Adjustments TERMINAL BLOCK During system installation this 5 point terminal block must be properly interconnected with an identically labeled terminal block in the generator control panel assembly V TYPE PREPACKAGED 2 2 Figure 6 Transfer Switch Terminal Block Terminals used on the terminal block are identified as Utility 1 and 2 23 and 194 UTILITY 1 AND 2 Interconnect with identically labeled terminals in the generator control panel assembly This is the utility voltage signal to the circuit board The signal is 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 utility source voltage should drop below a preset level circuit board action will initiate automatic cranking and startup followed by automatic transfer to
176. olenoid FS Cycle the AUTO OFF MANUAL switch from MANUAL to OFF You should be able to feel the solenoid actuate as well as hear it actuate If a small screwdriver is placed on the solenoid and then gently pulled away a magnetic field should be felt 3 Set the AUTO OFF MANUAL switch to OFF Reconnect Wire 56 to starter contactor relay or starter contactor SECTION 4 4 DIAGNOSTIC TESTS RESULTS 1 If solenoid actuates go to Test 55 2 Replace the solenoid if it does not actuate TEST 55 CHECK FOR IGNITION SPARK DISCUSSION If the engine cranks but will not start perhaps an ignition system failure has occurred A special spark tester Generac P N 0C5969 can be used to check for ignition spark Figure 19 Spark Tester PROCEDURE 1 Remove spark plug leads from the spark plugs Figure 20 2 Attach the clamp of the spark tester to the engine cylinder head 2 Y LITT TTE Figure 20 Checking Ignition Spark Page 4 4 11 SECTION 4 4 DIAGNOSTIC TESTS 3 Attach the spark plug lead to the spark tester terminal 4 Crank the engine while observing the spark tester If spark jumps the tester gap you may assume the engine ignition system is operating satisfactorily NOTE The engine flywheel must rotate at 350 rom or higher to obtain a good test of the solid state ignition system To determine if an engine miss is ignition related connect the spark tester in series
177. onents at the terminal from which Wire 14 was removed If CONTINUITY or zero resistance was measured the component has shorted to ground Replace the component The average nominal resistance value that should be measured for each component is Battery Charge Relay BCR 112 ohms Fuel Solenoid FS 31 ohms Hourmeter HM 2 Mega ohms to infinity each component tests good there is no short to ground The fault exists in one of the Wire 14 wires Connect one meter test lead to the ground terminal Connect the other meter test lead to each Wire 14 individually on the end removed from the BCR FS or HM The Wire 14 which measures CONTINUITY is shorted to ground Repair or replace the affected wire between the component and the 4 tab terminal block TEST 77 TEST EXERCISE FUNCTION DISCUSSION The following parameters must be met in order for the weekly exercise to occur LIAUTO OFF MANUAL switch SW1 set to AUTO L1 Circuit board DIP Switch 2 REMOTE NOT AUTO set to OFF 5 Disconnect Wire 56 From the starter contactor relay SCR on V twin or the starter contactor SC on single cylinder Connect one meter test lead to the SCR or SC terminal from which Wire 56 was removed Connect the Page 4 4 24 PART 5 OPERATIONAL TESTS Air cooled Prepackaged Automatic Standby Generators Models 04389 04758 6 kW NG 7 kW LP 04456 04759 12 kW NG 12 kW LP 04390 04760 13 kW NG 15 kW LP TABLE OF CONTEN
178. or seizing condition in the starter motor bearings 2 A shorted open or grounded armature a Shorted armature wire insulation worn and wires touching one another Will be indicated by low or no RPM b Open armature wire broken will be indicated by low or no RPM and excessive current draw c Grounded armature wire insulation worn and wire touching armature lamination or shaft Will be indicated by excessive current draw or no RPM 3 A defective starter motor switch 4 Broken damaged or weak magnets 5 Starter drive dirty or binding DISCUSSION Test 47 verified that circuit board action is delivering DC voltage to the starter contactor relay SCR Test 48 verified the operation of the SCH Test 49 verified the operation of the starter contactor SC Another possible cause of an engine won t crank problem is a failure of the starter motor PROCEDURE The battery should have been checked prior to this test and should be fully charged Set a VOM to measure DC voltage 12 VDC Connect the meter positive test lead to the starter contactor stud which has the small jumper wire connected to the starter Connect the common test lead to the starter motor frame Set the Start Stop Switch to its START position and observe the meter Meter should Indicate battery voltage starter motor should operate and engine should crank RESULTS 1 If battery voltage is indicated on the meter but starter motor did NOT op
179. prevent interaction NO Seta VOM to its R x 1 scale and zero the meter Co Connect the positive VOM test lead to the positive rotor slip ring nearest the rotor bearing and the common test lead to the negative slip ring The meter should read approximately 10 20 ohms Compare to Specifications Page 1 4 Now set the VOM to a high resistance scale such as 10 000 or R x 1K Again zero the meter 5 Connect the positive VOM test lead to the positive slip ring and the common test lead to a clean frame ground The meter should indicate INFINITY RESULTS 1 Replace rotor assembly if it is open or shorted 2 f rotor tests good perform Insulation Resistance Test on Page 1 4 6 NOTE Be sure to read Section 1 4 Testing Cleaning and Drying carefully If the rotor tests good try performing an insulation resistance test Clean and dry the rotor if it fails that test Then repeat the test If the rotor fails the second insulation resistance test it should be replaced Page 2 4 8 Figure 8 The Rotor Assembly TEST 11 CHECK AC OUTPUT FREQUENCY DISCUSSION The generator AC frequency is proportional to the operating speed of the rotor The 2 pole rotor will supply a 60 Hertz AC frequency at 3600 rpm The unit s AC output voltage is proportional to the AC frequency For example a unit rated 240 volts line to line will supply that rated voltage plus or minus 2 p
180. r 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 A TRANSFER SWITCH OPERATION UNTIL ALL POWER VOLTAGE SUPPLIES TO THE SWITCH HAVE BEEN POSITIVELY TURNED OFF FAILURE TO TURN OFF ALL POWER VOLTAGE SUPPLIES MAY RESULT IN EXTREMELY HAZARDOUS AND POSSIBLY LETHAL ELECTRICAL SHOCK 4 In the transfer switch enclosure locate the manual transfer handle Handle is retained in the enclosure with a wing nut Remove the wing nut and handle 5 See Figure 3 Insert the un insulated end of the handle over the transfer switch operating lever a Move the transfer switch operating lever up to actuate the load contacts to the UTILITY position i e load connected to the utility source b Actuate the operating lever down to move the load contacts against the standby contacts i e load connected to the STANDBY source 6 Repeat Step 5 several times As the transfer switch operating lever is moved slight force should be needed until the lever reaches its center position As the lever moves past its center position an over center spring should snap the moveable load contacts against the stationary STANDBY or UTILITY contacts Page 3 4 4 V TYPE PREPACKAGED 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
181. r meter test lead to the Transformer TX Terminal 10 with Wire 224 removed This AC output is used as utility sensing and is supplied to the circuit board The VOM should measure approximately 16 VAC SECTION 4 4 DIAGNOSTIC TESTS RESULTS 1 If line to line voltage was NOT measured in Step 2 go to Problem 7 Page 3 3 2 2 If correct voltage was measured in Step 2 and no voltage was measured in Step 3 replace the Transformer 3 If correct voltage was measured in Step 2 and no voltage was measured in Step 4 replace the Transformer 4 f voltage output was correct for Step 3 and for Step 4 refer back to the Flow Chart Page 4 3 5 TEST 66 CHECK AC VOLTAGE AT BATTERY CHARGER DISCUSSION The battery charger needs to be supplied with approximately 16 VAC When the generator is not running and utility source power is available the battery charger still receives voltage from the Transformer TX When the generator is running voltage is supplied to the battery charger from the battery charge winding PROCEDURE 1 Set the AUTO OFF MANUAL switch to OFF Note Utility source voltage MUST be available to the generator 2 Set a VOM to measure AC voltage 3 Disconnect the two pin connector Wire 224B and Wire 225B at the battery charger 4 Connect one meter test lead to Wire 224B at the two pin connector Connect the other test lead to Wire 225B at the two pin connector Approximately 16 VAC should be me
182. re closed d The normally closed relay contacts will deliver utility source power to the utility closing circuit of the transfer mechanism e The normally open relay contacts will deliver standby source power to the transfer mechanism s standby closing circuit Figure 5 Transfer Relay Schematic 2 During automatic system operation when the generator circuit board senses that utility source voltage has dropped out the circuit board will initiate engine cranking and startup 3 When the circuit board senses that the engine has started an engine warm up timer on the circuit board starts timing Page 3 1 3 V TYPE PREPACKAGED 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 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 c
183. rent from the battery charger is delivered to the unit battery via Wire 15 a 15 amp fuse and Wire 13 This output is used to maintain battery state of charge during operation ENGINE RUN WINDING OUTPUT A voltage is induced into the engine run winding and delivered to a solid state circuit board via Wire 66A This output tells the circuit board that the engine has started and what its operating speed is The circuit board uses these signals from the engine run winding to a terminate cranking and b turn on various timing circuits that control automatic operation See Part 4 DC Control SECTION 2 3 AC GENERATORS TROUBLESHOOTING FLOWCHARTS GENERAL Use the Flow Charts in conjunction with the detailed The first step in using the flow charts is to correctly Instructions in Section 2 4 Test numbers used in the identify the problem Once that has been done locate flow charts correspond to the numbered tests in the problem on the following pages For best results Section 2 4 perform all tests in the exact sequence shown in the flow charts Problem 1 Generator Produces Zero Voltage or Residual Voltage TEST 1 CHECK TEST 3 TEST GOOD PROCEED MAIN CIRCUIT EXCITATION BAD PROCEED REPLACE AFTER TESTS CIRCUIT BREAKER CONCLUDE BREAKER RESET TO ON OR REPLACE IF BAD TEST 4 PERFORM FIXED EXCITATION ROTOR AMP REPAIR OR REPLACE FUSES TEST 8 CHECK ROTOR CIRCUIT PERFORM STATOR
184. rious injury The list of hazards is seemingly endless When working on this equipment use common sense and remain alert at all times Never work on this equipment while you are physically or mentally fatigued If you don t understand a component device or system do not work on it TEST 1 CHECK MAIN CIRCUIT BREAKER DISCUSSION Often the most obvious cause of a problem is overlooked If the generator main line circuit breaker is set to OFF or Open no electrical power will be supplied to electrical loads If loads are not receiving power perhaps the main circuit breaker is open or has failed SECTION 2 4 DIAGNOSTIC TESTS PROCEDURE The generator main circuit breaker is located on the control panel If loads are not receiving power make sure the breaker is set to On or Closed If you suspect the breaker may have failed it can be tested as follows see Figure 1 1 Set a volt ohm milliammeter VOM to its R x 1 scale and zero the meter 2 With the generator shut down disconnect all wires from the main circuit breaker terminals to prevent interaction 3 With the generator shut down connect one VOM test probe to the Wire 11 terminal of the breaker and the other test probe to the Wire E1 terminal 4 Set the breaker to its On or Closed position The VOM should read CONTINUITY 5 Set the breaker to its OFF or Open position and the VOM should indicate INFINITY 6 Repeat Steps 4 and 5 with the V
185. round the engine 12 VDC output for engine run condition Used for fuel solenoid FS battery charge relay BCR and hourmeter if equipped AC input to the board for crank terminate and overspeed protection B input when SW1 is in the MANUAL position B input into the board for source voltage when SW1 is in the AUTO or MANUAL position B output to SW1 for manual start operation 12VDC source voltage for the circuit board Also runs timer for exerciser Common ground Transformer reduced Utility source sensing voltage Transformer reduced Utility source sensing voltage NOT USED NOT USED CIRCUIT FUNCTION NOT USED High temperature oil engine safety Input set exercise Signal to ground to set Output for remote alarm relay optional Output for remote alarm relay optional 56 1e 66 54 15 29 NIG 14 ED r7 12 34 5 6 7 B 9 1011 12 13 14 1516 17 41 CONNECTOR 229 O 5 J2 CONNECTOR SPARE 50 Hz OPERATION Figure 3 Circuit Board Page 4 1 2 SECTION 4 1 DESCRIPTION AND COMPONENTS The circuit board mounts a crank relay K1 and a run relay K2 see Figure 4 Crank relay K1 is energized by circuit board action during both manual and automatic startup to crank the engine Cranking is accomplished in crank rest cycles with the first cycle being 15
186. s 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 on Page 1 4 2 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 lf unit is not overloaded but rpm and frequency drop excessively when loads are applied go to Test 16 TEST 16 CHECK ENGINE CONDITION DISCUSSION If engine speed and frequency drop excessively under load the engine may be under powered An under powered engine can be the result of a dirty air cleaner loss of engine compression faulty carburetor settings incorrect ignition timing etc PROCEDURE For engine testing troubleshooting and repair procedures refer to Problem 11 on Page 4 3 3 For further engine repair information refer to the following manuals e P N 0C1108 Service and Repair Manual for Single Cylinder GN Engines e P N 0E2081 Service Manual for GTV 990 760 V Twin OHVI Engines PART 3 V TYPE PREPACKAGED TRANSFER SWITCHES Air cooled Prepackaged Automatic Standby Generators Models 04389 04758 6 kW NG 7 kW LP 04456 04759 12 kW NG 12 kW LP 04390 04760 13 kW NG 15 kW LP Description and Components 32 operational Analysis 33 Troubleshooting
187. should shut down NOTE It is important that you do not proceed until you are certain that generator AC voltage and frequency are correct and within the stated limits Generally if both AC frequency and voltage are high or low the engine governor requires adjustment If frequency is correct but voltage is high or low the generator voltage regulator requires adjustment GENERATOR TESTS UNDER LOAD To test the generator set with electrical loads applied proceed as follows 1 Set generator main circuit breaker to its OFF or open position 2 Turn OFF all loads connected to the Transfer Switch Terminals T1 and T2 3 Set the generator AUTO OFF MANUAL switch to OFF 4 Turn off the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker wanNiNG A Do not attempt manual transfer switch operation until all power voltage supplies to the transfer switch have been positively turned off Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock 5 Manually set the transfer switch to the STANDBY position i e load terminals connected to the generator E1 E2 terminals The transfer switch operating lever should be down 6 Set the generator AUTO OFF MANUAL switch to MANUAL The engine should crank and start immediately 7 Letthe engine stabilize and warm up for a few minutes 8 Set the
188. st 28 TEST 72 CHECK UTILITY SENSING VOLTAGE AT THE CIRCUIT BOARD DISCUSSION If the generator starts and transfer to STANDBY occurs in the automatic mode even though an acceptable UTILITY source voltage is available from the Transformer TX the next step is to determine if that sensing voltage is reaching the circuit board PROCEDURE 1 Set the AUTO OFF MANUAL switch to OFF 2 Disconnect Connector J1 from the circuit board 3 Set a VOM to measure AC voltage Page 4 4 22 4 Connect one meter test lead to Pin Location J1 14 Wire 225 Connect the other test lead to Pin Location J1 15 Wire 224 Approximately 14 16 VAC should be measured RESULTS 1 If voltage was measured in Step 4 replace the circuit board 2 f voltage was NOT measured in Step 4 repair replace Wire 224 and or No Wire 225 between Transformer TX and Circuit Board Connector J1 TEST 73 TEST SET EXERCISE SWITCH DISCUSSION If the Set Exercise Switch SW2 fails closed the unit will start when in AUTO In normal operation the Normally Open contacts close when the switch is depressed This will ground Wire 351 and reset the exercise time PROCEDURE 1 Set a VOM to measure resistance 2 Disconnect Wire 351 and Wire 0 from the Set Exercise Switch SW2 3 Connect one meter test lead to one terminal of SW2 Connect the other test lead to the remaining terminal of SW2 The meter should read INFINITY 4 With the meter tes
189. sured b Connect the negative meter lead to Wire 23 at ICT or terminal strip INFINITY should be measured c Connect the negative meter lead to Wire No 194 at ICT or terminal strip INFINITY should be measured d Connect the negative meter lead to the neutral connection INFINITY should be measured 7 Disconnect wire N1 and wire N2 from transformer TX 8 Connect one test lead to wire 1 removed in step 7 and the other test lead to the ground terminal INFINITY should be measured 9 Connect one test lead to wire N2 removed in step 7 and the other test lead to the ground terminal INFINITY should be measured 10 If no short is indicated in steps 5 through 9 proceed with steps 11 through 15 If a short is indicated in steps 5 through 9 repair shorted wiring 11 wires 1 and N2 to the interconnection terminal or terminal strip 12 Replace fuses F1 and F2 in the fuse holder 13 Turn on the utility power supply to the transfer switch using whatever means is provided 14 Set VOM to measure AC voltage Connect one test lead to wire 1 and the other test lead to wire N2 Utility line to line voltage should be measured 15 Turn off the utility power supply to the transfer switch using whatever means is provided SECTION 3 4 DIAGNOSTIC TESTS RESULTS If a short is indicated in steps 5 through 9 repair wiring and re test If utility line to line voltage is measured in Step 14 proceed to Test
190. t a jumper wire to the negative 12VDC source and to relay Terminal The relay will ENERGIZE Disconnect the positive jumper from Terminal of the relay and the relay will DE ENERGIZE Page 4 4 20 DESIRED METER READING CONNECT VOM TEST LEADS ACROSS ENERGIZED DE ENERGIZED Terminals 6 and 9 Continuity Infinity Terminals 3 and 9 Infinity Continuity Terminals 4 and 7 Continuity Infinity Terminals 1 and 7 Infinity Continuity RESULTS 1 Replace the battery charge relay if it fails any of the Steps in this chart 2 f the BCR tests good but still does not function during generator operation check Wire 14 and Wire 0 connected to the BCR a Set a VOM to measure DC volts Disconnect Wire 14 from BCR Terminal A Connect the positive test lead to Wire 14 Connect the negative test lead to a clean frame ground Set the AUTO OFF MANUAL switch to MANUAL Battery voltage should be measured If battery voltage is not measured repair or replace Wire 14 between the BCR and the 4 tab terminal block b If voltage was measured a set the VOM to measure resistance Disconnect Wire 0 from BCR Terminal B Connect one test lead to Wire 0 Connect the other test lead to a clean frame ground CONTINUITY should be measured If CONTINUITY was not measured repair or replace Wire 0 between the BCR and the ground terminal TEST 68 CHECK BATTERY CHARGE WINDING HARNESS DISCUSSION This test will check th
191. t leads connected to SW2 depress and hold the switch activated The meter should read CONTINUITY c 351 Figure 35 Set Switch 5 Disconnect the five connector 2 from the circuit board 6 Connect one meter test lead to Wire 351 previously removed from SW2 Connect the other meter test lead to Pin Location J3 Wire 351 CONTINUITY should be measured 7 Connect one meter test lead to Wire 351 previously removed from SW2 Connect the other meter test lead to the ground terminal INFINITY should be measured 8 Connect one meter test lead to Wire 0 previously removed from SW2 Connect the other meter test lead to the ground terminal CONTINUITY should be measured RESULTS 1 If the Set Exercise Switch SW2 fails Step 3 or Step 4 replace the switch 2 If CONTINUITY was NOT measured Step 6 OR if it WAS measured in Step 7 repair or replace Wire 351 between SW2 and Connector J2 3 If CONTINUITY was NOT measured in Step 8 repair or replace Wire 0 between SW2 and the ground terminal TEST 74 CHECK REMOTE START WIRING IF EQUIPPED DISCUSSION On some earlier models a remote start connection was available If these two wires are connected together while the generator is in AUTO the generator will start PROCEDURE 1 Set the AUTO OFF MANUAL switch to OFF 2 Seta VOM to measure resistance 3 Disconnect the 17 pin connector J1 from the circuit bo
192. tarts timing If utility voltage remains sufficiently high at the end of 15 seconds retransfer can occur At the end of the 15 second delay circuit board action will open a circuit to a transfer relay housed in the transfer switch The transfer relay will then de energize and retransfer back to the utility source will occur Loads are now powered by utility source power On retransfer an engine cool down timer starts timing and will run for about one 1 minute PHASE 8 GENERATOR SHUTDOWN When the engine cool down timer has finished timing and if the minimum run timer has timed out engine shutdown will occur Page 1 7 1 SECTION 1 7 AUTOMATIC OPERATING PARAMETERS AUTOMATIC OPERATING SEQUENCES CHART SEQ CONDITION 1 Utility source voltage is available 2 Utility voltage dropout below 60 of rated voltage occurs 3 Utility voltage is still below 60 of rated voltage 4 Utility voltage is still low after 15 seconds 5 Utility voltage still low and the engine has started 6 Engine running and engine warmup timer times out AC output voltage above 50 nominal voltage 7 Engine running and load is powered by Standby power 8 Utility source voltage is restored above 80 of rated 9 Utility voltage still high after 15 seconds 10 Utility voltage still high 11 Engine still running loads are powered by Utility source 13 Engine is shut down loads are powered by Utility source Return to
193. terminal and the switch body The meter should read INFINITY 9 Heat the oil in the container When the thermometer reads approximately 274 294 F 134 146 C the VOM should indicate CONTINUITY RESULTS 1 If the switch fails Step 4 or Steps 8 9 replace the switch 2 If INFINITY was NOT measured in Step 5 repair or replace Wire 85 between the Circuit Board and the High Oil Temperature Switch TEST 62 CHECK AND ADJUST VALVES DISCUSSION Improperly adjusted valves can cause various engine related problems including but not limited to hard starting rough running and lack of power The valve adjustment procedure for both the single cylinder and the V twin engines is the same PROCEDURE INTAKE AND EXHAUST Make sure that the piston is at Top Dead Center TDC of it s compression stroke both valves closed The valve clearance should be 0 05 0 1 0 002 0 004 in cold Check and adjust the valve to rocker arm clearance as follows 1 Remove the four 4 screws from the rocker cover 2 Remove the rocker cover and rocker cover gasket IB Tex STUD ies V 0 076 mm 9 0 003 SHIM Figure 29 3 Loosen the rocker arm jam nut Use a 10mm allen wrench to turn the pivot ball stud and check the clearance between the rocker arm and the valve stem with a flat feeler gauge see Figure 29 SECTION 4 4 DIAGNOSTIC TESTS 4 When
194. that day each week If the unit does not start go to Test 73 Retest after performing Test 73 If the generator still will not start replace the circuit board If the generator does not start after depressing the Set Exercise switch wait one week and watch for exercise operation If exercise fails to operate replace the circuit board Page 151 S E CTI O N X X PART X XXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXXXXX XO000000000000000000000X
195. the valve clearance is correct hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut Torque the jam nut to 174 inch pounds After tightening the jam nut recheck the valve clearance to make sure it did not change 5 Re install the rocker cover gasket rocker cover and the four 4 screws RESULTS Adjust valve clearance as necessary the retest TEST 63 CHECK FUEL REGULATOR DISCUSSION The fuel regulator is rarely the cause of a HARD START or NO START condition The most common causes are insufficient fuel pressure supplied to the unit or the adjustment screws on the fuel regulator being out of adjustment The fuel regulator is an ON DEMAND type During cranking and running negative pressure from the airbox or carburetor unseats the fuel regulator diaphragms and allows fuel flow through the regulator PROCEDURE Note Step 1 of this procedure pertain to V twin engines only Single cylinder engines begin at Step 2 1 If the adjustment screw settings are in question reset as follows Turn adjustment screws clockwise all the way in then turn out counterclockwise two and one half full turns This will provide a starting point for further adjustment 2 Turn off utility power to the main distribution panel in the house This can be done by switching the service main breaker to the OFF or Open position 3 Allow the generator to start Before loading the generator confirm that th
196. tion If the switch does not actuate to its closed position retransfer back to Utility will not occur PROCEDURE 1 With the standby generator shut down set its AUTO OFF MANUAL switch to OFF 2 Turn OFF the utility power supply to the transfer switch using whatever means provided Page 3 4 7 SECTION 3 4 DIAGNOSTIC TESTS 3 To prevent interaction disconnect Wire 126 and Wire A from the limit switch terminals 4 Seta VOM to its R x 1 scale and zero the meter 5 Connect the VOM test leads across the two limit switch terminals from which Wires A and 126 were removed 6 Manually actuate the main contacts to their Standby position The VOM should indicate CONTINUITY 7 Manually actuate the main contacts to their Utility position The VOM should read INFINITY RESULTS Heplace limit switch XA1 if it checks bad NOTE Problems with transfer switch operation can also be caused by a defective wiring between the generator and transfer switch or b a defective component in the generator circuit board See Part 4 DC Control TEST 32 CONTINUITY TEST OF WIRING C1 DISCUSSION This test will ensure that all control wiring has continuity 1 Set the AUTO OFF MANUAL switch to the OFF position 2 Turn the generator main circuit breaker to the off position 3 Turn off the utility power supply to the transfer switch using whatever means provided Such as utility source main line circuit breaker
197. tion resistance is caused by moisture that collects while the generator is shut down When problems are caused by moisture buildup on the windings they can usually be corrected by drying the windings Cleaning and drying the windings can usually eliminate dirt and moisture built up in the generator windings THE MEGOHMMETER GENERAL A megohmmeter often called a megger consists of a meter calibrated in megohms and a power supply Use a power supply of 500 volts when testing stators or rotors DO NOT APPLY VOLTAGE LONGER THAN ONE 1 SECOND TESTING STATOR INSULATION All parts that might be damaged by the high megger voltages must be disconnected before testing Isolate all stator leads Figure 2 and connect all of the stator leads together FOLLOW THE MEGGER MANUFACTURER S INSTRUCTIONS CAREFULLY Use a megger power setting of 500 volts Connect one megger test lead to the junction of all stator leads the other test lead to frame ground on the stator can Read the number of megohms on the meter The MINIMUM acceptable megger reading for stators MINIMUM INSULATION RESISTANCE _ GENERATOR RATED VOLTS 1000 in Megohms may be calculated using the following formula EXAMPLE Generator is rated at 120 volts AC Divide 120 by 1000 to obtain 0 12 Then add 1 to obtain 1 12 megohms Minimum Insulation resistance for a 120 VAC stator is 1 12 megohms If the stator insulation resistance is less than th
198. tive This test will verify the integrity of Wires 0 and 162 PROCEDURE 1 Set VOM to its R x 1 scale 2 Remove Wire 0 from the voltage regulator 4th terminal from the top Also voltage regulator is labeled next to terminal 3 Connect one test lead to Wire 0 connect the other test lead to a clean frame ground The meter should read CONTINUITY 4 Disconnect Wire 162 from the voltage regulator 6th terminal from the top Disconnect the other end of Wire 162 from the excitation circuit breaker Connect one test lead to one end of Wire 162 and the other test lead to the other end of Wire 162 The meter should read CONTINUITY Page 2 4 4 RESULTS It CONTINUITY was NOT measured across each wire repair or replace the wires as needed TEST 6 CHECK FIELD BOOST DISCUSSION See Field Boost Circuit on Page 2 2 1 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 o A small amount of voltage must be induced into the DPE winding to turn the voltage regulator on o 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 o If rotor residua
199. to the primary winding of a sensing transformer TX via transfer switch wires N1 N2 fuses F1 F2 connected wiring and Control Panel Utility 1 Utility 2 terminals A resultant voltage about 16 volts AC is induced into the transformer secondary windings and then delivered to the circuit board via Wires 224 225 The circuit board uses this reduced Utility voltage as sensing voltage Wires 224A 225A supply 16 VAC to the battery charger Battery output is delivered to the circuit board with the AUTO OFF MANUAL switch SW1 set to AUTO as shown Page 4 2 1 DC CONTROL 240VAC GENERATOR OUTPUT TO LOAD Figure 1 Circuit Condition Utility Source Voltage Available SECTION 4 2 OPERATIONAL ANALYSIS DC CONTROL TRANSFER 12VDC BATTERY 12 A COIL e bi CUSTOMER SUPPLIED UTILITY 0 14 N2 194 239 17 i Lug mu TS 240VAC 0 GENERATOR OUTPUT 0 56VA 15 E 225 224 17 225A 18 56 15 1 13 teh 4 L 225 239 23 194 POWER WINDING STATOR ELE 112131415 7 10 11 12 13 14 15 16 17 2 5 UTILITY VOLTAGE C2 6 SENSING HTO C1 4 12VDC PCB SUPPLY C2 3 ENGINE CONTROL 12VDC PRINTED CIRCUIT BOARD BATTERY CHARGE WINDING BATTERY CHARGER DIAGRAM KEY C2 1 BA
200. uit breaker CB2 is housed in the generator panel enclosure and electrically connected in series with the excitation DPE winding output to the voltage regulator The breaker is self resetting i e its contacts will close again when excitation current drops to a safe value If the circuit breaker has failed open excitation current flow to the voltage regulator and subsequently to the rotor windings will be lost Without excitation current flow AC voltage induced into the stator AC power windings will drop to a value that is commensurate with the rotor residual magnetism See Figure 5 Page 2 1 2 SECTION 2 1 DESCRIPTION amp COMPONENTS Figure 5 Excitation Circuit Breaker VOLTAGE REGULATOR A typical voltage regulator is shown in Figure 6 Unregulated AC output from the stator excitation winding is delivered to the regulators DPE terminals via Wire 2 the excitation circuit breaker Wire 162 and Wire 6 The voltage regulator rectifies that current and based on stator AC power winding sensing regulates it The rectified and regulated excitation current is then delivered to the rotor windings from the positive and negative regulator terminals via Wire 4 and Wire 1 Stator AC power winding sensing is delivered to the regulator SEN terminals via Wires 11 and 22 The regulator provides over voltage protection but does not protect against under voltage On occurrence of an over voltage condition the re
201. untered on prepackaged standby generators with air cooled engine Use this section of the manual in conjunction with Section 2 3 Troubleshooting Flow Charts The numbered tests in this section correspond with those of Section 2 3 Test procedures in this section do not require the use of specialized test equipment meters or tools Most tests can be performed with an inexpensive volt ohm 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 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 se
202. urce side 5 Turn ON the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker 6 Set the AUTO OFF MANUAL switch to AUTO The system is now ready for automatic operation 7 Turn OFF the utility power supply to the transfer switch With the AUTO OFF MANUAL switch at AUTO the engine should crank and start when the utility source power is turned off After starting the transfer switch should connect load circuits to the STANDBY side Let the system go through its entire automatic Page 5 1 3 OPERATIONAL TESTS AND ADJUSTMENTS sequence of operation With the generator running and loads powered by generator AC output turn ON the utility power supply to the transfer switch The following should occur After about six seconds the switch should transfer loads back to the utility power source LiAbout one minute after retransfer the engine should shut down SETTING THE EXERCISE TIMER Your generator is equipped with an exercise timer Once it is set the generator will start and exercise once every seven days on the day of the week and at the time of day you complete the following sequence 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 A switch on the control panel see Figure 1 Page 1 6 1 allows you to select the day and t
203. ve 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 SECTION 1 4 TESTING CLEANING AND DRYING Conductor of a Circuit
204. voltage is indicated but retransfer back to Utility does NOT occur go to Test 24 4 f normal utility source line to line voltage is NOT indicated in Step 9 but is indicated in Step 10 proceed to Test 31 5 f normal utility source line to line voltage is NOT indicated in Step 8 and is NOT indicated in Step 9 proceed to Test 32 TEST 30 CHECK FUSES F1 AND F2 DISCUSSION Fuses F1 and F2 are connected in series with the Utility 1 and Utility 2 circuits respectively A blown fuse will open the applicable circuit and will result in a generator startup and transfer to Standby or b failure to retransfer back to the UTILITY source SECTION 3 4 DIAGNOSTIC TESTS lt Z IER il Figure 5 Fuse Holder and Fuses PROCEDURE 1 On the generator panel set the AUTO OFF MANUAL switch to OFF 2 Turn off the utility power supply to the transfer switch using whatever means provided 3 Remove fuses F1 and F2 from the fuse holder see Figure 5 4 Inspect and test fuses for blown condition RESULTS 1 Replace blown fuse s and proceed to Test 34 2 For Problem 7 DC Control section go to Test 27 TEST 31 TEST LIMIT SWITCH XA1 DISCUSSION When the transfer switch main contacts are actuated to their Utility position limit switch XA1 should be mechanically actuated to its open position On transfer to the Standby position the limit switch should actuate to its closed posi
205. with the spark plug wire and the spark plug Figure 21 Then crank and start the engine A spark miss will be readily apparent If spark jumps the spark tester gap regularly but the engine miss continues the problem is in the spark plug or in the fuel system NOTE A sheared flywheel key may change ignition timing but sparking will still occur across the spark tester gap Figure 21 Checking Engine Miss RESULTS 1 If no spark or very weak spark occurs go to Test 58 2 If sparking occurs but engine still won t start go to Test 56 3 When checking for engine miss if sparking occurs at regular intervals but engine miss continues go to Test 16 4 When checking for engine miss if a spark miss is readily apparent go to Test 59 TEST 56 CHECK SPARK PLUGS DISCUSSION If the engine will not start and Test 55 indicated good ignition spark perhaps the spark plug s are fouled or otherwise damaged Engine miss may also be caused Page 4 4 12 by defective spark plug s PROCEDURE 1 Remove spark plugs and clean with a penknife or use a wire brush and solvent 2 Replace any spark plug having burned electrodes or cracked porcelain 3 Set gap on new or used spark plugs to 0 030 inch for single cylinder engines and 0 020 inch for v twin engines RESULTS 1 Clean re gap or replace spark plugs as necessary 2 lf spark plugs are good go to Test 62 SET GAP TO 0 020 INCH FOR V TWINS SET GAP TO 0 03
206. y TR Terminal 9 and connect one test lead to it Connect the other test lead to terminal lug E1 of the transfer switch CONTINUITY should be read Reconnect Wire E1 RESULTS Repair any defective wiring that does not read CONTINUITY If wiring tests good proceed to Test 23 TEST 34 CHECK 1 AND 2 WIRING DISCUSSION A shorted Wire 1 or N2 to ground can cause fuse 1 or F2 to blow PROCEDURE 1 On the generator panel set the AUTO OFF MANUAL switch to OFF 2 Turn off the utility power supply to the transfer switch using whatever means are provided 3 Remove fuses F1 and F2 from the fuse holder see Figure 5 4 Remove the generator control panel cover Disconnect wire 1 and wire N2 from the interconnection terminal in the control panel or the terminal strip 5 Set your VOM to the R x 1 scale Connect the positive meter test lead to wire N1 V TYPE PREPACKAGED a Connect the negative meter lead to the ground lug INFINITY should be measured b Connect the negative meter lead to Wire 23 at ICT or terminal strip INFINITY should be measured c Connect the negative meter lead to Wire 194 at ICT or terminal strip INFINITY should be measured d Connect the negative meter lead to the neutral connection INFINITY should be measured 6 Set your VOM to the R x 1 scale Connect the positive meter test lead to wire N2 a Connect the negative meter lead to the ground lug INFINITY should be mea
207. ystem may be used to clean up loosened dirt Dust and dirt may also be removed using dry low pressure air 25 psi maximum CAUTION Do not use sprayed water to clean the generator Some of the water will be retained on generator windings and terminals and may cause very serious problems DRYING THE GENERATOR To dry a generator proceed as follows 1 Open the generator main circuit breaker NO ELECTRICAL LOADS MUST BE APPLIED TO THE GENERATOR WHILE DRYING 2 Disconnect all Wires 4 from the voltage regulator 3 Provide an external source to blow warm dry air through the generator interior around the rotor and stator windings DO NOT EXCEED 185 F 85 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 GENERAL Standby electric power generators will often run unattended for long periods of time Such operating parameters as a engine oil pressure b engine temperature c engine operating speed and d engine cranking and startup are not monitored by an operator during automatic operation Because engine operation will not be monitored the use of engine protective safety devices is required to prevent engine damage in the event of a problem Prepackaged generator engines mount several engine protective devices These devices work in conjunction with a circuit board to protect the eng
208. z line to neutral voltage will be 124 volts SCREWDRIVER SLOTTED POTENTIOMETER VOLTAGE REGULATOR Figure 12 Voltage Adjustment Potentiometer RESULTS 1 If the frequency and voltage are now good discontinue tests 2 If frequency is now good but voltage is high or low go to Problem 1 Test 4 TEST 14 CHECK VOLTAGE AND FREQUENCY UNDER LOAD DISCUSSION It is possible for the generator AC output frequency and voltage to be good at no load but they may drop excessively when electrical loads are applied This condition in which voltage and frequency drop excessively when loads are applied can be caused by a overloading the generator b loss of engine power or c a shorted condition in the stator windings or in one or more connected loads Page 2 4 10 PROCEDURE 1 Connect an accurate AC frequency meter and an AC voltmeter across the stator AC power winding leads 2 Start the engine let it stabilize and warm up 3 Apply electrical loads to the generator equal to the rated capacity of the unit 4 Check the AC frequency and voltage Frequency should not drop below approximately 58 59 Hertz Voltage should not drop below about 230 volts plus or minus 2 percent RESULTS 1 If frequency and voltage drop excessively under load go to Test 15 2 If frequency and voltage under load are good discontinue tests TEST 15 CHECK FOR OVERLOAD CONDITION DISCUSSION An overload condition i

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