Generac Power Systems 20 kW LP manual

dia gnostic rep air manu al AUT OMA TIC ST ANDBY GENERA T ORS Air - Cooled P roduct MODELS: 7 k W NG, 8 k W LP 9 k W NG, 10 k W LP 13 k W NG, 14 k W LP 16 k W NG, 17 k W LP 18 k W NG, 20 k W LP[...]

ElEctrical formulas TO FIND KNOWN V ALUES 1-PHASE 3-PHASE KILOW A TTS (kW) V olts, Current, Power Factor E x I 1000 E x I x 1.73 x PF 1000 KV A V olts, Current E x I 1000 E x I x 1.73 1000 AMPERES kW , V olts, Power Factor kW x 1000 E kW x 1000 E x 1.73 x PF W A TTS V olts, Amps, Power Factor V olts x Amps E x I x 1.73 x PF NO. OF ROTOR POLES Frequ[...]

P age 1 contents specifications .......................................................... 4 Generator ................................................................ 4 Engine ..................................................................... 5 Fuel Consumption ................................................... 5 Mounting Dimensions ..........[...]

T est 7 – T esting The Stator With A V om (12-20 kW)...........................................44 T est 8 – T est Brushless Stator..........................45 T est 9 – Check Capacitor .................................46 T est 10 – T est DPE Winding on Brushless units ....................................47 T est 11 – Resistance Check Of R[...]

P age 3 P art 4 - Dc coNtr ol ......................................... 95 4.1 Description and Components .......................... 96 General ............................................................96 T er minal Strip / Interconnection T er minal .........96 Circuit Board ....................................................96 A uto-Off-Manual[...]

P age 4 Genera t or Unit 8 kW 10 kW 12 kW 14 kW 16 kW 17 kW 20 kW Rated Max. Continuous P ower Capacity (W atts*) 7,000 NG 8,000 LP 9,000 NG 10,000 LP 12,000 NG 12,000 LP 13,000 NG 14,000 LP 16,000 NG 16,000 LP 16,000 NG 17,000 LP 18,000 NG 20,000 LP Rated V oltage 120/240 Rated V oltage at No-Load (NG) 220-235 247-249 Rated Max. Continuous Load Cu[...]

Specifica tionS P age 5 Fuel Consumption Model # Natural Gas* LP V apor** 1/2 Load Full Load 1/2 Load Full Load 7/8 kW 77 140 0.94/34 1.68/62 9/10 kW 102 156 1.25/46 1.93/70 12/12 kW 152 215 1.53/56 2.08/76 13/14 kW 156 220 1.56/58 2.30/84 16/16 kW 183 261 1.59/58 2.51/91 16/17 kW 183 261 1.61/59 2.57/94 18/20 kW 206 294 1.89/69 2.90/106 * Natural [...]

P age 6 sPEcifica tioNs mountinG dimenSionS AIR INT AKE AIR OUTLET FRONT OF UNIT HOLE LOCA TIONS FOR OPTIONAL MOUNTING TO A CONCRETE P AD MINIMUM DIST ANCE AIR INT AKE FRONT VIEW LEFT SIDE VIEW RIGHT SIDE VIEW REAR VIEW "DO NO T LIFT BY R OOF" GROUNDING LUG Ø30.2 [Ø1.2] LIFTING HOLES 4 CORNERS CABLE ACCESS HOLE 642 [25.3] 731.9 [28.8] 6[...]

P age 7 sPEcifica tioNs mountinG dimenSionS AIR INT AKE AIR OUTLET FRONT OF UNIT HOLE LOCA TIONS FOR OPTIONAL MOUNTING TO A CONCRETE P AD MINIMUM DIST ANCE AIR INT AKE FRONT VIEW LEFT SIDE VIEW RIGHT SIDE VIEW REAR VIEW "DO NO T LIFT BY R OOF" GROUNDING LUG Ø30.2 [Ø1.2] LIFTING HOLES 4 CORNERS CABLE ACCESS HOLE 642 [25.3] 731.9 [28.8] 6[...]

sPEcifica tioNs P age 8 major Fea tureS Data Label (see sample) Oil Dipstick Exhaust Enclosure Composite Base Oil Filter Battery Compar tment Fuel Regulator Fuel Inlet (back) Air Filter Circuit Breaker Control Panel Data Label (see sample) Oil Dipstick Exhaust Enclosure Composite Base Oil Filter Battery Compartment Fuel Regulator Fuel Inlet (back) [...]

P ar t 1 GENEral iNforma tioN air -cooled, a utomatic standb y Generators P age 9 t aBlE of coNtENts P art titlE P a GE 1.1 Generator identification 10 1.2 installation Basics 11 1.3 Non-Prepacka ged interconnections 14 1.3 Preparation Before use 16 1.4 t esting, cleaning and Dr ying 18 1.5 Engine-Generator Protective Devices 25 1.6 operating instr[...]

introduction This Diagnostic Repair Manual has been prepared especially for the pur pose of familiarizing ser vice per- sonnel with the testing, troubleshooting and repair of air-cooled, automatic standby generators. Every effor t has been expended to ensure that inf or mation and instructions in the manual are both accurate and cur- rent. How ev e[...]

P age 11 GENERAL INFORMA TION sEctioN 1.2 iNst alla tioN Basics introduction Inf or mation in this section is provided so that the ser vice technician will hav e a basic knowledge of installation requirements for home standby systems. Problems that ar ise are often related to poor or unau- thorized installation practices . A typical home standby el[...]

P art 1 P age 12 GENERAL INFORMA TION sEctioN 1.2 iNst alla tioN Basics Figure 1. T ypical Installation[...]

GENERAL INFORMA TION sEctioN 1.2 iNst alla tioN Basics po Wer Source and lo ad lineS The utility power supply lines, the standby (genera - tor) supply lines, and electrical load lines must all be connected to the proper terminal lugs in the transfer s witch. The following rules apply: In 1-phase systems with a 2-pole transf er switch, connect the t[...]

P age 14 P art 1 General informa tion Section 1.3 non-PreP a cka ged interconnectionS Discussion: on the current model air-cooled generators Wire 194 was changed to 15B. Wire 15B is still utilized for posi- tiv e voltage f or the transf er relay and Wire 23 is still the control ground f or transf err ing the generator . By follo w- ing the procedur[...]

GENERAL INFORMA TION sEctioN 1.3 NoN-PrEP a cKa GED iNtErcoNNEctioNs P art 1 connect a 2008 and la ter lo ad center SWitch t o a pre-2008 air-cooled Genera t or. PROCEDURE: 1. F ollow all instructions located in the Installation Manual that was supplied with the unit regarding mounting of the s witch, junction box, and gener ator . note: When insta[...]

General The installer must ensure that the home standby gen- erator has been proper ly installed. The system must be inspected carefully f ollowing installation. All appli- cable codes, standards and regulations per taining to such installations must be strictly complied with. In addition, regulations established by the Occupational Saf ety and Hea[...]

GENERAL INFORMA TION sEctioN 1.4 PrEP ara tioN BEforE usE in the selector knob and pull out to overcome spring pressure and then twist clockwise 90 degrees and allow the selector to retur n in once aligned with the LP (Liquid Propane) position. 6. Sav e this tool with the Owner's Manual. 7. Install the batter y , door and close the roof. 8. Re[...]

FUEL SELECTION LEVER - “OUT” POSITION FOR LIQUID PROP ANE (V APOR) FUEL Figure 5. 12/14/16/17/20 kW , GT -990/GT -999 (Airbo x Cov er Removed) enGine oil recommend a tionS All oil should meet minimum American P etroleum Institute (API) Ser vice Class SJ , SL or better . Use no special additives . Select the oil's viscosity grade according [...]

P age 19 GENERAL INFORMA TION sEctioN 1.5 tEstiNG, clEaNiNG aND Dr YiNG meterS De vices used to measure electr ical proper ties are called meters. Meters are av ailable that allow one to measure (a) A C voltage, (b) DC voltage , (c) AC frequency , and (d) resistance In ohms. The follo wing apply: • T omeasureACv oltage,useanA[...]

P art 1 meaSurinG current CLAMP-ON: T o read the current flow , in AMPERES, a clamp-on ammeter may be used. This type of meter indicates current flow through a conductor by measur ing the strength of the magnetic field around that conductor . The meter consists essentially of a current trans - f or mer with a split core and a rectifier type instrum[...]

GENERAL INFORMA TION sEctioN 1.5 tEstiNG, clEaNiNG aND Dr YiNG Component testing may require a specific resis - tance value or a test for INFINITY or CONT INUITY . Infinity is an OPEN condition between two electrical points, which would read as no resistance on a V OM. Continuity is a closed condition between two electrical points, which would be i[...]

P art 1 ViSu al inSpection When it becomes necessar y to test or troubleshoot a generator , it is a good practice to complete a thorough visual inspection. Remove the access cov ers and look closely f or any ob vious problems . Look f or the follo wing: • Bur ned or broken wires , broken wire connectors , damaged mounting [...]

GENERAL INFORMA TION sEctioN 1.5 tEstiNG, clEaNiNG aND Dr YiNG P art 1 HI-PO T TESTER: A “Hi-P ot” tester is shown in Figure 7. The model s ho w n i s on l y on e o f ma ny th a t ar e co m m e rc i a l l y av ailable. The tester shown is equipped with a voltage selector switch that per mits the power supply voltage to be selected. It also moun[...]

P art 1 GENERAL INFORMA TION sEctioN 1.5 tEstiNG, clEaNiNG aND Dr YiNG TESTING ALL ST A TOR WINDINGS T O GROUND: 1. Disconnect Stator Output Leads 11 and 44 from the generator main line circuit break er . 2 . Disconnect Stator Output Leads 2 and 6 from the capacitor located on the end of the stator assembly . 3. Remov e Stator Output Leads 22 and 3[...]

GENERAL INFORMA TION sEctioN 1.6 ENGiNE-GENEra tor Pr o tEctiVE DEVicEs General Standby electric power generators will often r un unattended for long periods of time. Such operating parameters as (a) batter y v oltage, (b) engine oil pres- su r e, ( c) e n gi n e te mp e ra tu r e, ( d) e n g in e o pe ra t in g speed, and (e) engine cranking and s[...]

P art 1 o Vercrank Shutdo Wn This feature prev ents the generator from damaging itself when it continually attempts to star t and another problem, such as no fuel supply , prev ents it from star t- ing. The unit will crank and rest for a preset time limit. Then, it will stop cranking, and the LCD screen or the LED on the generator control panel wil[...]

GENERAL INFORMA TION sEctioN 1.7 oPEra tiNG iNstructioNs P art 1 P age 27 control p anel SET EXERCISE SYSTEM READY LOW BA TTERY LOW OIL PRESSURE HIGH OIL TEMPERATURE OVERSPEED RPM SENSOR LOSS OVERCRANK ENTER ECS 8 kW UNITS 10-20 kW UNITS Figure 1. Generator Control P anel A UT O-OFF-MANU AL SWITCH: Use this s witch to (a) select fully automatic ope[...]

P art 1 P age 28 GENERAL INFORMA TION sEctioN 1.7 oPEra tiNG iNstructioNs 10-20 kW – INST ALLA TION ASSIST ANT: Upon first pow er up of the generator , the displa y inter- f ace will begin an installation assistant. The assistant will prompt the user to set the minimum settings to operate . These settings are simply: Current Date/Time an d Exerc [...]

GENERAL INFORMA TION sEctioN 1.8 a ut oma tic oPEra tiNG P aramEtErs P art 1 P age 29 introduction When the generator is installed in conjunction with a transf er s witch, either manual or automatic opera- tion is possible . Manual transfer and engine star tup , as well as manual shutdown and re-transfer are cov ered in Section 1.7. Selection of fu[...]

P art 1 GENERAL INFORMA TION sEctioN 1.8 a ut oma tic oPEra tiNG P aramEtErs P age 30 lo ad tranSFer The transfer of load when the generator is r unning is dependent upon the operating mode as f ollows: 1. Manual • Willnottransf ertogeneratorifutilityispresent. • Willtransfertogeneratorif utilityf[...]

P age 31 air -cooled, a utomatic standb y Generators P ar t 2 a c GENEra t ors t aBlE of coNtENts P art titlE P a GE# 2.1. Description and components 30 2.2 operational analysis 33 2.3 t roubleshooting flo w char ts 35 2.4 Diagnostic t ests 39 2.1 Description and Components .......................... 32 Introduction ................................[...]

"C" "B" "C" ROTO R "B" "C" 9 "D" "B" "C" "D" BEARING CARRIER BR USH HOLDER ASSEMBL Y ENGINE AD APTOR "8KW" "8KW - 10KW" ENGINE AD APTOR "10KW" 0 .8 "D" "D" S TAT O R "12KW - 20KW" "12KW - 20KW&qu[...]

AC GENERA T ORS sEctioN 2.1 DEscriPtioN & comPoNENts P art 2 P age 33 SLIP RINGS BEARING Figure 2. The 2-P ole Rotor Assembly 12-20 kW 8/10kW: Like the 12-20 kW rotor , the 8/10 kW 2-pole rotor must be operated at 3600 r pm to supply a 60 Her tz AC fre- quency . Howe ver , the 8/10kW rotor uses no slip r ings. As the rotor rotates in the genera[...]

BruSh holder and Br uSheS (12-20 kW) The br ush holder is retained to the rear bearing car- rier by means of two #10-32 x 9/16 T aptite screws . A positive (+) and a negative (-) brush are retained in the brush holder , with the positive (+) br ush r iding on the slip ring nearest the rotor bear ing. Wire 4 connects to the positiv e (+) brush and W[...]

P age 35 AC GENERA T ORS sEctioN 2.2 oPEra tioNal aNal Ysis ro t or reSidu al ma GnetiSm The generator re volving field (rotor) may be consid - ered to be a per manent magnet. Some “residual” magnetism is alwa ys present in the rotor . This residual magnetism is sufficient to induce a voltage into the stator AC power windings that is approximat[...]

P art 2 opera tion (8/10 kW) ST ARTUP: When the engine is star ted, residual magnetism from th e r o t o r in d u ce s a vol ta g e i n t o (a ) t h e st a t or AC power windings, and (b) the stator excitation or DPE windings. The capacitor on the DPE winding will be charged and then will discharge causing a voltage to be induced back into the roto[...]

AC GENERA T ORS sEctioN 2.3 tr ouBlEsHoo tiNG flo WcHar ts Use the “Flow Char ts” in conjunction with the detailed instructions in Section 2.4. T est numbers used in the flow char ts correspond to the numbered tests in Section 2.4. The first step in using the flow char ts is to correctly identify the problem. Once that has been done, locate the[...]

P age 38 ST OP TESTING GOOD REPLACE BAD REPLACE S TAT OR REPLACE S TAT OR REPLACE R OTO R TEST 1 - CHECK MAIN CIRCUIT BREAKER TEST 8 - TEST BR USHLESS S TAT OR TEST 9 - CHECK CAP AC IT OR REPLACE CAP AC IT OR TEST 10 - TEST DPE WINDING TEST 21 - FIELD FLASH AL TERNA TO R TEST 2 - CHECK AC OUTPUT VO LT AG E BAD BAD GOOD ON GOOD GOOD Problem 2 - Gene[...]

AC GENERA T ORS sEctioN 2.3 trouBlEsHoo tiNG flo WcHar ts P art 2 P age 39 ST OP TESTS FREQUENCY O .K., BUT VO LT AG E LOW TEST 14 - CHECK AC OUTPUT FREQUENCY TEST 15 - ADJUST ENGINE GO VERNOR TEST 16 - CHECK STEPPER M OTO R CONTROL TEST 2 - CHECK AC OUTPUT VO LT AG E TEST 17 - ADJUST VO LTA GE REGULA TO R TEST 9 - CHECK CAP AC IT OR LOW LOW - SING[...]

P art 2 P age 40 AC GENERA T ORS sEctioN 2.3 trouBlEsHoo tiNG flo WcHar ts GOOD GOOD REP AIR OR REPLACE IF RECONFIGURED TO LP GAS, VERIFY THA T PROPER PROCEDURE W AS FOLLOWED (REFER TO SECTION 1.3) TEST 18 - CHECK VO LTA GE AND FREQUENCY UNDER LOAD TEST 19 - CHECK FOR O VERLOAD CONDITION TEST 15 - CHECK AND ADJUST ENGINE GO VERNOR GO TO “PROBLEM [...]

AC GENERA T ORS sEctioN 2.4 Dia GNostic tEsts introduction This section is provided to familiarize the ser vice technician with acceptable procedures f or the test - ing and ev aluation of various problems that could be encountered on standby generators with air-cooled engine. Use this section of the manual in conjunction with Section 2.3, “T rou[...]

* D aNGEr: usE EXtrEmE ca utioN DuriNG tHis tEst . tHE GENEra tor Will BE ruNNiNG. HiGH aND D aNGErous V ol t a GEs Will BE PrEsENt a t tHE tEst tErmiNals. coNNEct mEtEr tEst clamPs t o tHE HiGH V ol t a GE tErmiNals WHilE tHE GENEra t or is sHut Do WN. st a Y clEar of Po WEr tErmiNals DuriNG tHE tEst . maKE surE mEtEr clamPs arE sEcurEl Y a tt a c[...]

AC GENERA T ORS sEctioN 2.4 Dia GNostic tEsts Connect the other meter test lead to Wire 4 (still dis - co nn e ct ed f ro m p rev io us t es ts ) . M ea s ur e a nd r ec or d static rotor amp draw . 13 . Set the A UTO-OFF-MANU AL switch to the MANU AL position. Once the engine star ts, repeat Step 12. Measure and record r unning rotor amp draw with[...]

teSt 6 – check Field BooSt (12-20 kW) DISCUSSION: See “Field Boost Circuit” in Section 2.2. Field boost current (from the circuit board) is av ailable to the rotor only while the engine is cranking. Loss of field boost output to the rotor ma y or ma y not aff ect pow er winding A C output voltage . The follo wing facts apply: • A smal[...]

AC GENERA T ORS sEctioN 2.4 Dia GNostic tEsts 5. T urn the Main Breaker to the "ON" or CLOSED position. 6. Set a V OM to measure resistance. 7. Connect one meter test lead to Wire 11 on the load side of the main breaker . Connect the other meter test lead to Wire 22 (power winding). Note the resistance read - ing and compare to the specif[...]

• Anopencircuitcondition • A “shor t-to-ground” condition • Ashor t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 read- ing v[...]

AC GENERA T ORS sEctioN 2.4 Dia GNostic tEsts PROCEDURE: 1. Consult the owner’ s manual of the meter being used f or directions on measuring capacitance. Figure 7 shows a typical meter and how to chec k capacitance. 2. Connect the meter leads directly across the ter minals of the capacitor . The rated µf (micro farad) of the capacitor is marked [...]

2 . T esting for a “grounded” condition: Any resistance reading indicated the winding is grounded. 3. T esting for a “shor ted” condition: Any resistance reading indicated the winding is shor ted. 4. If stator tests good and wire continuity tests good, refer back to flo w char t. teSt 11 – reSiSt ance check oF ro t or circuit (12-20 kW) D[...]

AC GENERA T ORS sEctioN 2.4 Dia GNostic tEsts RESUL TS: 1. Repair , replace or reconnect wires as necessar y . 2. Replace any damaged slip rings or brush holder . 3. Clean and polish slip rings as required. teSt 13 – teSt ro t or aSSemBl y (12-20 kW) DISCUSSION: A rotor having completely open windings will cause loss of excitation current flow an[...]

P art 2 GO VERNOR SHAFT PRIMAR Y ADJUST SCREW GO VERNOR CLAMP BOL T SECOND AR Y ADJUST SCREW Figure 10. Engine Gov er nor Adjustment Single Cylinder Engines PROCEDURE (8 kW UNITS WITH DUAL GO VERNOR SPRINGS): 1. Loosen the gov er nor clamp bolt (Figure 10). 2. Hold the gov er nor lev er at its wide open throttle position, and rotate the gov ernor s[...]

STEPPER MO TO R PULL ARM THIS DIRECTION TO CLOSE TH RO TTLE Figure 11. Throttle P ositions 9/10 kW Units STEPPER MO TO R STEPPER MO TOR ARM PULL ARM THIS DIRECTION TO CLOSE TH RO TTLE Figure 12. Throttle P ositions 9/10 kW Units STEPPER MO TOR STEPPER MO TOR ARM PULL ARM THIS DIRECTION TO CLOSE THRO TTLE Figure 13. Throttle P ositions 12-20 kW Unit[...]

teSt 18 – check V ol t a Ge and Frequency under lo ad DISCUSSION: It is possible for the generator AC output frequency and voltage to be good at no-load, but they may drop e xcessively when electr ical loads are applied. This condition, in which voltage and frequency drop e xces- sively when loads are applied, can be caused by (a) ov er loading t[...]

P age 53 Figure 18. Energizing Cord Connection Figure 17. Construction of Energizing Cord GENERA TOR CAP ACIT OR WIRES 2 & 6 TO DPE WINDING DEPRESS SWITCH FOR ONE SECOND PLUG ENERGIZING CORD INT O AC OUTLET CAPICIT OR REMAINS CONNECTED T O GENERA TOR  Danger: The capacitor may need to be dis- charged before testing. A capacitor can be discha[...]

P age 54 No tEs[...]

P ar t 3 traNsfEr sWitcH air -cooled, a utomatic standb y Generators P age 55 3.1 Description and Components ............................................... 56 General 5 6 Enclosure ............................................................................ 56 T ransf er Mechanism ............................................................ 57 T r[...]

General The “W/V -T ype” transfer switch is rated 100 amps at 250 volts maximum. It is av ailable in 2-pole configura- tion only and, f or that reason, is usable with 1-phase systems only . T ransf er s witches do not hav e an intelligence sys - tem of their own. Instead, automatic operation of these transf er s witches is controlled by a circu[...]

TRANSFER SWITCH sEctioN 3.1 DEscriPtioN & comPoNENts P art 3 P age 57 tranSFer mechaniSm The 2-pole transf er mechanism consists of a pair of moveab le LOAD contacts, a pair of stationar y UTILITY contacts, and a pair of stationar y ST ANDBY contacts. The load contacts can be connected to the utility contacts by a utility closing coil; or to th[...]

c. When de-energized, the rela y’ s nor mally open contacts are open and its nor mally-closed contacts are closed. d. The nor mally-closed relay contacts will deliver utility source power to the utility closing circuit of the transf er mechanism. e . The nor mally open relay contacts will deliver standby source power to the transfer mecha - nism?[...]

TRANSFER SWITCH sEctioN 3.1 DEscriPtioN & comPoNENts P art 3 P age 59 TERMINALS 0, 15B AND 23: These ter minals connect the transfer rela y to the generator circuit board. See “T ransf er Relay” in Section 3.1. FuSe holder The fuse holder holds three (3) fuses, designated as fuses F1, F2 and F3. Each fuse is rated 5 amperes . FUSES F1, F2: [...]

opera tional anal ySiS Figure 1 is a schematic f or a typical “W/V -T ype” transfer s witch. Figure 1. Schematic P age 60 NEUTRAL CONNECTION SWITCH SW3 NO C1 COM SW2 VR1 NC NC COM C2 VR2 NO TR1 15B 23 1 7 4 7 9 3 6 9 F2 CIRCUIT 10 BLACK (MAIN 1) CONTROL TRANSFER RED (MAIN 2) NEUTRAL (WHITE) NEUTRAL (WHITE) 23 0 F1 N2 N1 15B 23 BLACK RED N2 N1 1[...]

TRANSFER SWITCH sEctioN 3.2 oPEra tioNal aNal Ysis P art 3 P age 61 Figure 2 is a wiring diagram f or a typical “W/V -T ype” transf er switch. Figure 2. Wir ing Diagram 205 N2A N1A RED BLK 10 CIRCUIT LOAD CENTER 12 CIRCUIT LOAD CENTER 14 CIRCUIT LOAD CENTER CIRCUIT 8 8 CIRCUIT LOAD CENTER CIRCUIT 1 CIRCUIT 3 CIRCUIT 10 CIRCUIT 12 CIRCUIT 14 CIR[...]

NEUTRAL CONNECTION SWITCH SW3 NO C1 COM SW2 VR1 NC NC COM C2 VR2 NO TR1 15B 23 1 7 4 7 9 3 6 9 F2 CIRCUIT 10 BLACK (MAIN 1) CONTROL TRANSFER RED (MAIN 2) NEUTRAL (WHITE) NEUTRAL (WHITE) 23 0 F1 N2 N1 15B 23 BLACK RED N2 N1 15B 240V AC T O TO GENERA TOR OUTPUT P ANEL MAIN DISTRIBUTION T1 T2 T1 T2 E2 E2 E2 E2 E1 E1 N1A N1A N2A N2A B B B B B E1 E1 E1 [...]

NEUTRAL CONNECTION SWITCH SW3 NO C1 COM SW2 VR1 NC NC COM C2 VR2 NO TR1 15B 23 1 7 4 7 9 3 6 9 F2 CIRCUIT 10 BLACK (MAIN 1) CONTROL TRANSFER RED (MAIN 2) NEUTRAL (WHITE) NEUTRAL (WHITE) 23 0 F1 N2 N1 15B 23 BLACK RED N2 N1 15B 240V AC T O TO GENERA TOR OUTPUT P ANEL MAIN DISTRIBUTION T1 T2 T1 T2 E2 E2 E2 E2 E1 E1 N1A N1A N2A N2A B B B B B E1 E1 E1 [...]

tranSFer t o St andBy 12 VDC is delivered to the transf er relay via Wire 15B and back to the circuit board via Wire 23. Howe ver , circuit board action holds the Wire 23 circuit open and the transf er relay remains de-energized. On generator star tup, an “engine warm-up timer” on the generator circuit board star ts timing. When that timer has [...]

tranSFer t o St andBy When the standby coil is energized it pulls the transf er switch mechanism to a ov ercenter position tow ards the standby power source side, the transfer s witch mechanical ly snaps to the standby position. On closure of the main contacts to the standby pow er source side, limit switches SW2 and SW3 are mechanically actuated t[...]

utility reSt ored Utility voltage is restored and is availab le to T erminals N1 and N2. The utility voltage is sensed by the generators circuit board. If it is abov e a preset value f or a preset time inter val a transf er back to utility pow er will occur . P age 66 NEUTRAL CONNECTION SWITCH SW3 NO C1 COM SW2 VR1 NC NC COM C2 VR2 NO TR1 15B 23 1 [...]

utility reSt ored, tranSFer SWitch de-enerGized After the preset time inter val expires the circuit board will open the Wire 23 circuit to ground. The transf er relay de-energizes , it’ s nor mally closed contacts close, and utility source voltage is delivered to the utility closing coil (C1), via Wires N1A and N2A, closed T ransfer Rela y Contac[...]

utility reSt ored, retranSFer B a ck t o utility As the utility coil pulls the transf er s witch to an O VER CENTER position, the switch mechanically snaps to Utility . On closure of the main contacts to the utility pow er source side, Limit Switches SW2 and SW3 are mechanically actuated to “ar m” the circuit for transf er to standby . P age 68[...]

tranSFer SWitch in utility When the transf er switch returns to the utility side, generator shutdo wn occurs after approximately one (1) min ute. P age 69 TRANSFER SWITCH sEctioN 3.2 oPEra tioNal aNal Ysis P art 3 NEUTRAL CONNECTION SWITCH SW3 NO C1 COM SW2 VR1 NC NC COM C2 VR2 NO TR1 15B 23 1 7 4 7 9 3 6 9 F2 CIRCUIT 10 BLACK (MAIN 1) CONTROL TRAN[...]

introduction to trouBleShoo tinG The first step in troubleshooting is to correctly identify the problem. Once that is done, the cause of the an be f ound by perf or ming the tests in the appropriate flow char t. T est numbers assigned in the flow char ts are identical to test numbers in Section 3.4, “Diagnostic T ests. ” Section 3.4 provides de[...]

TRANSFER SWITCH sEctioN 3.3 trouBlEsHoo tiNG flo W cHar ts P art 3 P age 71 Prob lem 8 – In A utomatic Mode, Generator Starts When Loss of Utility Occurs, Generator Shuts Down When Utility Returns But There Is No Retransfer T o Utility P ower OR Generator T ransfer s to Standby During Excer cise or in Manual Mode BAD BAD REP AIR OR REPLACE AS NEE[...]

REPLACE CIRCUIT BOARD CORRECT UTILITY SOURCE V OL T AGE REPLACE GO TO PR OBLEM 7 REP AIR OR REPLACE WIRING REP AIR OR REPLACE WIRE N1A/N2A BETWEEN N1/N2 LUGS AND FUSE HOLDER REP AIR N1/N2 OPEN WIRING BETWEEN TRANSFER SWITCH AND GENERA T OR Prob lem 10 – Unit Star ts and T ransfer Occur s When Utility P ower Is On 8 kW: Green LED Flashes 10-20 kW:[...]

REPLACE PRINTED CIRCUIT BOARD REP AIR OR REPLACE REPLACE CHARGER Prob lem 11 – No Batter y Charge “Pre-Wire Load Center” TEST 40 – CHECK BA TTER Y CHARGER SUPPL Y V OL T AGE TEST 41 – CHECK BA TTER Y CHARGER OUTPUT VOL T AGE TEST 42 – CHECK WIRE 0/15B GOOD GOOD BAD REP AIR OR REPLACE BAD BAD NO BA TTER Y SUPPL Y V OL T AGE REPLACE PRINT[...]

General T est numbers in this section correspond to the numbered tests in Section 3.3, “T roubleshooting Flow Char ts”. When troubleshooting, first identify the problem. Then, perform the diagnostic tests in the sequence given in the flo w char ts. teSt 26 – check V ol t a Ge a t terminal luGS e1, e2 DISCUSSION: In automatic mode, the standby[...]

TRANSFER SWITCH sEctioN 3.4 Dia GNostic tEsts P art 3 P age 75 e. Set the generator A UTO-OFF-MANU AL switch to A UT O . (1) The generator should crank and start. ( 2 ) When the generator starts, an “engine warm-up timer” should star t timing. After about 15 seconds, the transfer rela y should energize and transf er to the “Standby” source [...]

b . Actuate the operating le ver down to move the load contacts against the standby contacts, i.e., load connected to the Standby source . 6. Repeat Step 5 sev eral times. As the transfer switch operating lev er is mov ed slight force should be needed until the lev er reaches its center position. As the lev er mov es past its center position, an ov[...]

TRANSFER SWITCH sEctioN 3.4 Dia GNostic tEsts P art 3 P age 77 13. Set V OM to measure DC voltage . 14. Connect the (-) negative meter test lead to Wire 0 at the terminal strip in the generator . Connect the (+) positive meter test lead to Wire 23 at the ter minal str ip in the generator . 12 VDC should be measured. 1 5. Place generator A UT O-OFF-[...]

4. Using jumper wires, connect the positive (+) post of a 12 volt batter y to relay T er minal “A” and the negative (-) batter y post to Relay T er minal “B”. The relay should energize and the V OM should read CONTINUITY . 5. Now , connect the VOM test leads across Relay T er minals 1 and 7. a . Energize the relay and the meter should indic[...]

TRANSFER SWITCH sEctioN 3.4 Dia GNostic tEsts P art 3 P age 79 A B 7 9 4 6 1 3 TR1 SW1 205 C2 SW3 E1 SW2 C1 1 2 1 2 N1 N2 E1 E2 E2 T1 T2 B A G E F C D H Figure 4. Standby Control Circuit T est P oints[...]

(2 ) Press the r ight arrow ke y until “Debug” is flashing. (3) Press “Enter”. (4) Press the right arrow ke y until “Outputs” is flashing. (5) Press “Enter”. (6) Digital Output 8 is Wire 23 output from the board. Ref er to Figure 5. ( 7 ) If Output 8 shows a “1” then the control board is grounding Wire 23. Replace the printed ci[...]

Figure 7. Utility Control Circuit T est P oints TRANSFER SWITCH sEctioN 3.4 Dia GNostic tEsts P art 3 P age 81 N1A N1A A B 7 9 4 6 1 3 TR1 SW1 B C2 SW3 SW2 C1 A N2A N2A F1 F2 F3 A A A B B B 1 2 1 2 N1 N2 E1 E2 T1 T2 126 A B I G C D E F H[...]

5. Remov e Wire N2A from the utility coil C1. 6. T urn on utility power supply to the transf er switch. a. If transfer to utility occurs, Wire 23 is grounded. Proceed to T est 31. b . If transf er to utility does not occur , proceed to Step 7. 7. Measure across points A and B. 240 V A C should be measured. a. If 240 V A C is not measured, verify ut[...]

PROCEDURE: 1. On the generator panel, set the A UT O-OFF-MANUAL s witch to OFF . 2. T ur n off the utility power supply to the transf er s witch, using whate ver means pro vided. 3. Remov e fuses F1 and F2 from the fuse holder (s ee Figure 8). 4. Inspect and test fuses for blo wn condition. With a V OM set to measure resistance, CONTINUITY should b[...]

240 V A C N1 N2 TEST POINTS Figure 9. T er minal Block T est P oints teSt 37 – check utility SenSinG V ol t a Ge a t the circuit Bo ard DISCUSSION: If the generator star ts and transf er to ST ANDBY occurs in the automatic mode when acceptable UTILITY source voltage is availab le at the ter minal bloc k, the next step is to deter mine if sensing [...]

sEctioN X.X XXXXXXXXXXXXXXXXXXXXXXXXXXX P age 85 TRANSFER SWITCH sEctioN 3.4 Dia GNostic tEsts P art 3 23 TB1 A N LC B LEGEND TRANSFER SWITCH GENERA T OR LC-CIRCUIT BREAKER (LOADS) (16 CIRCUIT SHOWN FOR REFERENCE ONL Y) SW1-A UTOMA TIC TRANSFER SWITCH C2-GENERA TOR COIL & RECTIFIER C1-UTILITY COIL & RECTIFIER F1,F2,F3-5A, 600V FUSE TB1-TERM[...]

2. T est for utility source line-to-line voltage across T erminal Lugs N1 and N2 (see Figure 1). Nor mal utility source voltage should be indicated. RESUL TS: 1. If low or no voltage is indicated, find the cause of the problem and correct. 2. If nor mal utility source voltage is indicated, refer to Flow Chart. teSt 40 – check B a tter y charGer S[...]

P age 87 TRANSFER SWITCH sEctioN 3.4 Dia GNostic tEsts P art 3 a. If 115 Ohms is measured, proceed to Step 10. b . If zero resistance or CONTINUITY is measured, connect the meter test leads across T er minals A and B on the transf er relay (TR1) c. If zero resistance is measured, a shor t exists . Replace TR1. d. If 115 Ohms is measured, repair or [...]

P age 88 E2 WHITE GREEN 23 15B 0 N1 DET AIL DET AIL N2 BC 00 BC LINE E1 N2 N1 15B 23 N1 N2 23 194 UTILITY SUPPL Y FROM SER VICE DISCONNECT E2 T O GROUNDING ELECTRODE NEUTRAL BLOCK (DISTRIBUTION P ANEL) GROUND BC LINE BC 00 5 AMP FUSE T1 T2 CUST OMER LOAD RTS TRANSFER SWITCH T1 T2 E1 (C2 & VR2) ST ANDBY E1 E2 (C1 & VR1) UTILITY N1 N2 N2 N1 C[...]

P age 89 TRANSFER SWITCH sEctioN 3.4 Dia GNostic tEsts P art 3 WHITE GREEN 0 N1 N2 15B 23 BC 00 BC LINE TO GR OUNDING ELECTRODE SER VICE DISCONNECT A TS 23 E1 E2 BC LINE BC 00 FUSE N2 N1 5 AMP SOCKET METER UTILITY P ANELBOARD 15B T1 T2 E1 E2 N2 N1 C D E A B H G F DET AIL DET AIL 23 15B 0 N1 N2 H G Figure 12A. T est 43, 44, and 45 “R TSE T ransfer[...]

P age 90 6. Mea sure ac ross po int s G and H on the te r min al str ip. 12 VDC should be measured. a. If 12 VDC is measured, proceed to Step 8. b . If 12 VDC is not measured, proceed to Step 7. 7. Measure across point H and ground lug. 12 VDC should be measured. a. If 12 VDC is measured, repair or replace Wire 0 between the generator ter minal str[...]

P age 91 TRANSFER SWITCH sEctioN 3.4 Dia GNostic tEsts P art 3 CONNECTION P ANEL BC-LINE GEN-READ Y LOAD CENTER DUPLEX BREAKER BC-00 UTILITY SOCKET METER ENGINE GENERA T OR N1 WHITE GREEN BC 00 N2 15B 23 0 E1 E2 BC LINE C D E A B F DET AIL DET AIL DET AIL DET AIL BC 00 BC LINE N1 N2 15B 23 0 E F C D Figure 13. T est 46, 47, and 48 “GenReady Load [...]

3. Measure across points G and H on the ter minal str ip . 12VDC should be measured. a. If 12 VDC is measured, the charger should be functioning. b . If 12 VDC is not measured, proceed to Step 4. 4. Remove Wire 0 and Wire 15B from generator ter minal strip locations E and F . 5. W ait five (5) minutes after removing wires . 6. Measure across points[...]

P age 93 TRANSFER SWITCH sEctioN 3.4 Dia GNostic tEsts P art 3 FUSE, 2A F3 GROUND LUG LIMIT SWITCHES, A CTUA TOR RELA Y , TRANSFER UTILITY CIRCUIT BREAKER NB - NEUTRAL BLOCK LOAD SHED CONTROLLER RELA Y , LOAD SHED LOAD SHED TRANSFER SWITCH CONT ACTOR XA1,XB1 TR UCB GND LS LSC LSS NB SOLENOID COIL (LSS-OFF) SOLENOID COIL (LSS-ON) FUSE, 5A TRANSFER S[...]

P age 94 4. Reconnect batter y charger blac k and red lead wires pre viously remov ed in Step 2. 5. Measure across points G and H. 13.4 VDC should be measured. a. If 13.4 VDC is not measured, replace the batter y charger . b . If 13.4 VDC is measured, the charger is working. *no te: Battery char g er v oltage will be higher than battery supply v ol[...]

P ar t 4 Dc coNtr ol air -cooled, a utomatic standb y Generators P age 95 4.1 Description and Components .................................... 96 General ................................................................... 96 T er minal Str ip / Interconnection T er minal ................. 96 Circuit Board ............................................[...]

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 cov ered include the follo wing: • A T er minalStr ip/Interconnection T er minal • ACircuitBoard. • AnA UT O-OFF-MANU ALSwitch. • A7.5Am[...]

DIVIDER P ANEL DIVIDER P ANEL TO ENGINE TO ENGINE 6 7 9 8 3 5 4 1 2 10 1. CONTROL PANEL 2. 7.5 AMP FUSE 3. STARTER CONTACTOR RELAY (10-20 KW) 4. 4 POSITION TERMINAL BLOCK 5. TERMINAL BLOCK 6. CIRCUIT BREAKER (8KW) 7. 15 AMP GFCI DUPLEX OUTLET (17 & 20 KW) 8. CIRCUIT BREAKER (17 & 20 KW) 9. CIRCUIT BREAKER (10-20 KW) 10. LED DISPLAY Figure 3[...]

PiN WirE circuit fuNctioN J1-1 85 High temperature shutdown: Shutdown occurs when Wire 85 is grounded by contact closure in HT O J1-2 86 Low oil pressure shutdown: Shutdown occurs when Wire 86 is grounded by loss of oil pressure to the LOP J1-3 13 12 VDC source voltage f or the circuit board J1-4 18 Ignition Shutdown: Circuit board action grounds W[...]

DC CONTROL sEctioN 4.1 DEscriPtioN aND comPoNENts P art 4 PiN WirE circuit fuNctioN J1-1 85 High temperature shutdown: Shutdown occurs when Wire 85 is grounded by contact closure in HT O J1-2 86 Low oil pressure shutdown: Shutdown occurs when Wire 86 is grounded by loss of oil pressure to the LOP J1-3 13 12 VDC source voltage f or the circuit board[...]

P age 100 J2 J3 (STEPPER MO TOR) REMO TE WIRELESS CONNECTION J1 J2 CONNECT OR (HARNESS END) 10 11 12 13 14 15 16 17 18 1 2 3 4 1 2 3456789 10 11 12 13 14 15 16 17 18 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 1 2 3 4 5 6 7 8 9 J1 CONNECT OR (HARNESS END) J2 CONNECT OR (PCB END) J1 CONNECT OR (PCB END) N1/N2 CONNECT OR (HARNESS END[...]

P age 101 sEctioN 4.1 DEscriPtioN aND comPoNENts PiN WirE circuit fuNctioN J1-1 85 High temperature shutdown: Shutdown occurs when Wire 85 is grounded by contact closure in HT O J1-2 86 Low oil pressure shutdown: Shutdown occurs when Wire 86 is grounded by loss of oil pressure to the LOP J1-3 13 12 VDC source voltage f or the circuit board J1-4 18 [...]

P art 4 P age 102 DC CONTROL sEctioN 4.1 DEscriPtioN aND comPoNENts FEMALE SIDE MALE SIDE 2 1 1 2 C3 Figure 8. Choke Solenoid Connector Pin Number Identification menu SyStem na ViGa tion T o get to the MENU, use the "Esc" key from any page. It may need to be pressed many times before getting to the menu page. The currently selected menu i[...]

sEctioN 4.1 DEscriPtioN aND comPoNENts P age 103 MAIN MENU RUN LOG ALARM LOG HISTOR Y ST A TUS COMMAND S TAT E VERSIONS DISPLA Y GENERA TOR FREQUENCY ENGINE HOURS ENGINE RPM BA TTER Y V O LTA G E DEBUG INPUTS OUTPUTS DISPLA YS ST ARTUP DELA Y EDIT CONTRAST LANGU AGE FREQUENCY TIME/DA TE EXERCISE TIME * Low speed exer cise can be set in the EXERCISE[...]

CONTROLLER DISPLA Y Ready to Run = 12 VDC AL WA YS PRESENT = AC VOL T AGE = GROUND FOR CONTROL PURPOSES = 12 VDC DURING CRANKING ONL Y = 12 VDC DURING ENGINE RUN CONDITION = DC FIELD EXCIT A TION = 5 VDC T O LED 0 4 4 0 BA 6 11 22 6 2 2 REGULA TOR 11 2 6 0 4 22 VOL T AGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 13 12V BA TTERY SCR SM[...]

CONTROLLER DISPLA Y Ready to Run = 12 VDC AL WA YS PRESENT = AC VOL T AGE = GROUND FOR CONTROL PURPOSES = 12 VDC DURING CRANKING ONL Y = 12 VDC DURING ENGINE RUN CONDITION = DC FIELD EXCIT A TION = 5 VDC T O LED 0 4 4 0 BA 6 11 22 6 2 2 REGULA TOR 11 2 6 0 4 22 VOL T AGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 13 12V BA TTERY SCR SM[...]

CONTROLLER DISPLA Y Utility Loss Delay Pausing 10 sec CONTROLLER = 12 VDC AL WA YS PRESENT = AC VOL T AGE = GROUND FOR CONTROL PURPOSES = 12 VDC DURING CRANKING ONL Y = 12 VDC DURING ENGINE RUN CONDITION = DC FIELD EXCIT A TION = 5 VDC T O LED 0 4 4 0 BA 6 11 22 6 2 2 REGULA TOR 11 2 6 0 4 22 VOL T AGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO[...]

CONTROLLER DISPLA Y Utility Loss Delay Pausing 10 sec CONTROLLER = 12 VDC AL WA YS PRESENT = AC VOL T AGE = GROUND FOR CONTROL PURPOSES = 12 VDC DURING CRANKING ONL Y = 12 VDC DURING ENGINE RUN CONDITION = DC FIELD EXCIT A TION = 5 VDC T O LED 0 4 4 0 BA 6 11 22 6 2 2 REGULA TOR 11 2 6 0 4 22 VOL T AGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO[...]

CONTROLLER DISPLA Y Cranking Attempt #1 = 12 VDC AL WA YS PRESENT = AC VOL T AGE = GROUND FOR CONTROL PURPOSES = 12 VDC DURING CRANKING ONL Y = 12 VDC DURING ENGINE RUN CONDITION = DC FIELD EXCIT A TION = 5 VDC T O LED 0 4 4 0 BA 6 11 22 6 2 2 REGULA TOR 11 2 6 0 4 22 VOL T AGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 13 12V BA TTERY[...]

CONTROLLER DISPLA Y Cranking Attempt #1 = 12 VDC AL WA YS PRESENT = AC VOL T AGE = GROUND FOR CONTROL PURPOSES = 12 VDC DURING CRANKING ONL Y = 12 VDC DURING ENGINE RUN CONDITION = DC FIELD EXCIT A TION = 5 VDC T O LED 0 4 4 0 BA 6 11 22 6 2 2 REGULA TOR 11 2 6 0 4 22 VOL T AGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 13 12V BA TTERY[...]

CONTROLLER DISPLA Y Running - Utility Lost = 12 VDC AL WA YS PRESENT = AC VOL T AGE = GROUND FOR CONTROL PURPOSES = 12 VDC DURING CRANKING ONL Y = 12 VDC DURING ENGINE RUN CONDITION = DC FIELD EXCIT A TION = 5 VDC T O LED 0 4 4 0 BA 6 11 22 6 2 2 REGULA TOR 11 2 6 0 4 22 VOL T AGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 13 12V BA TT[...]

CONTROLLER DISPLA Y Running - Utility Lost = 12 VDC AL WA YS PRESENT = AC VOL T AGE = GROUND FOR CONTROL PURPOSES = 12 VDC DURING CRANKING ONL Y = 12 VDC DURING ENGINE RUN CONDITION = DC FIELD EXCIT A TION = 5 VDC T O LED 0 4 4 0 BA 6 11 22 6 2 2 REGULA TOR 11 2 6 0 4 22 VOL T AGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 13 12V BA TT[...]

CONTROLLER DISPLA Y Running - Utility Lost CONTROLLER = 12 VDC AL WA YS PRESENT = AC VOL T AGE = GROUND FOR CONTROL PURPOSES = 12 VDC DURING CRANKING ONL Y = 12 VDC DURING ENGINE RUN CONDITION = DC FIELD EXCIT A TION = 5 VDC T O LED 0 4 4 0 BA 6 11 22 6 2 2 REGULA TOR 11 2 6 0 4 22 VOL T AGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 1[...]

CONTROLLER DISPLA Y Running - Utility Lost CONTROLLER = 12 VDC AL WA YS PRESENT = AC VOL T AGE = GROUND FOR CONTROL PURPOSES = 12 VDC DURING CRANKING ONL Y = 12 VDC DURING ENGINE RUN CONDITION = DC FIELD EXCIT A TION = 5 VDC T O LED 0 4 4 0 BA 6 11 22 6 2 2 REGULA TOR 11 2 6 0 4 22 VOL T AGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 1[...]

CONTROLLER DISPLA Y Running / Cooling Down = 12 VDC AL WA YS PRESENT = AC VOL T AGE = GROUND FOR CONTROL PURPOSES = 12 VDC DURING CRANKING ONL Y = 12 VDC DURING ENGINE RUN CONDITION = DC FIELD EXCIT A TION = 5 VDC T O LED 0 4 4 0 BA 6 11 22 6 2 2 REGULA TOR 11 2 6 0 4 22 VOL T AGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 13 12V BA TT[...]

• The utility closing coil (C1) energizes and mov es the main current carr ying contacts to their NEUTRAL position. The main contacts mov e to an ov er center position past NEUTRAL and spr ing force closes them to their UTILITY side. LO AD ter minals are now powered b y the UTILITY source. •[...]

CONTROLLER DISPLA Y Ready to Run = 12 VDC AL WA YS PRESENT = AC VOL T AGE = GROUND FOR CONTROL PURPOSES = 12 VDC DURING CRANKING ONL Y = 12 VDC DURING ENGINE RUN CONDITION = DC FIELD EXCIT A TION = 5 VDC T O LED 0 4 4 0 BA 6 11 22 6 2 2 REGULA TOR 11 2 6 0 4 22 VOL T AGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 13 12V BA TTERY SCR SM[...]

CONTROLLER DISPLA Y Ready to Run = 12 VDC AL WA YS PRESENT = AC VOL T AGE = GROUND FOR CONTROL PURPOSES = 12 VDC DURING CRANKING ONL Y = 12 VDC DURING ENGINE RUN CONDITION = DC FIELD EXCIT A TION = 5 VDC T O LED 0 4 4 0 BA 6 11 22 6 2 2 REGULA TOR 11 2 6 0 4 22 VOL T AGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 13 12V BA TTERY SCR SM[...]

VERIFY UTILITY SOURCE IS “OFF”* TEST 56 – CHECK POSITION OF AU TO-OFF-MANU AL SWITCH TEST 58 – TEST AU TO-OFF-MANU AL SWITCH TEST 59 – CHECK AU TO OPERA TION OF CONTROLLER TEST 57 – TRY A MANU AL ST ART ON OFF SWITCH IS “OFF” SWITCH IS IN “A UT O” ENGINE DOES NO T CRANK ENGINE CRANKS BAD BAD SET TO “A UTO” - RETEST TURN “O[...]

P age 119 sEctioN 4.3 trouBlEsHoo tiNG flo W cHar ts BAD REPLACE CHOKE SOLENOID CLEAN, REGAP OR REPLACE REPLACE CIRCUIT BO ARD REPLACE FUEL SOLENOID TEST 66 – CHECK FUEL SUPPL Y AND PRESSURE REPLACE FUEL REGULA TO R TEST 70 – CHECK FOR IGNITION SP ARK TEST 69 – CHECK CHOKE SOLENOID TEST 74 – CHECK IGNITION MAGNET OS TEST 73 – CHECK SHUTDO[...]

P age 120 GOOD BAD GOOD GOOD GOOD READJUST REFER TO ENGINE SER VICE MANUAL REP AIR OR REPLACE ADJUST OR REPLACE CLEAN, REGAP OR REPLACE FIND AND CORRECT CA USE OF NO FUEL OR LOW PRESSURE READJUST TEST 78 – CHECK FUEL REGULA TO R GOOD GOOD GOOD GOOD BAD BAD BAD BAD BAD BAD BAD Problem 18 – Engine Starts Har d and Runs Rough / Lacks Po wer / Back[...]

sEctioN 4.3 trouBlEsHoo tiNG flo W cHar ts P age 121 BAD NO SIGNAL REP AIR OR REPLACE BAD PROCEED TO PROBLEM 16 PROCEED TO PROBLEMS 10-13 CHECK INST ALLA TION FOR PROPER AIRFLO W OR REPLACE DEFECTIVE SWITCH RE PA IR LINK AG E IF BINDING. CHECK THRO TTLE OPERA TION. REFER TO ENGINE SE RV ICE MANU AL TEST 15 – CHECK AND ADJUST ENGINE GO VERNOR TEST[...]

P art 4 P age 122 DC CONTROL sEctioN 4.3 trouBlEsHoo tiNG flo W cHar ts FUSE BLOWS WHEN PLACED IN “A UT O” OR “MAN UA L” Problem 20 – 7.5 Amp Fuse (F1) Blo wn TEST 80 – CHECK CRANKING AND R UNNING CIRCUITS Problem 21 – Generator Will Not Exer cise TEST 79 – TEST EXERCISE FUNCTION GOOD BAD Problem 22 – No Lo w Speed Exer cise TEST [...]

P age 123 sEctioN 4.4 Dia GNostic tEsts introduction P erform these “Diagnostic T ests” in conjunction with the “T roubleshooting Flow Charts” of Section 4.3. The test procedures and methods presented in this section are not exhaustiv e. The manuf acturer could not pos sib ly kn ow of , e v alu ate and a dvi se th e se rvice t rad e of all [...]

P age 124 INPUT 7 INPUT 8 DEBUG 1 2 3 INPUTS Figure 2. The Home P age, Deb ug and Input Screens 5. With the Inputs Screen displa yed place the A UT O-OFF- MANU AL switch to the MANUAL P osition. If the control- ler reads an input from the switch input 8 will change from “0” to “1”. 6. W i t h t h e AU TO - O F F - M A N U A L S w i t c h i [...]

sEctioN 4.4 Dia GNostic tEsts P age 125 B . p erform a load test on the Batter y: (maintenance Free Battery) 1 . Using a lead acid batter y load tester test the load capability of the batter y . 2. F ollow the load tester’ s manuf acturer’ s instr uctions carefully . Figure 3. A T ypical Batter y Load T ester c . t est Batter y State of char ge[...]

P age 126 teSt 62 – check Wire 56 V ol t a Ge DISCUSSION: During an automatic star t or when star ting manually , a crank rela y on the circuit board should energize . Each time the crank relay energizes, the circuit board should deliver 12 VDC to a star ter contactor rela y (SCR), or star ter contactor (SC), and the engine should crank. This tes[...]

sEctioN 4.4 Dia GNostic tEsts P age 127 PROCEDURE: 1. Set a VOM to measure DC v oltage. 2. Rem ov e Wir e 13 fr om t he St arter Con tacto r Rel a y lo cate d under the printed circuit board. 3. Connect the positive (+) meter test lead to the Wire 13 connector . Connect the negative (-) meter test lead to a clean frame ground. Battery voltage shoul[...]

P age 128 teSt 65 – teSt St arter mo t or CONDITIONS AFFECTING ST ARTER MO T OR PERFORMANCE: 1. A binding or seizing condition in the starter motor bear ings. 2. A shor ted, open or grounded armature. a . Shor ted ar mature (wire insulation wor n and wires touching one another). Will be indicated by lo w or no RPM. b . Open ar mature (wire broken[...]

sEctioN 4.4 Dia GNostic tEsts P age 129 PINION Figure 13. Check Pinion Gear Oper ation (Single Cylinder) T OOLS FOR ST AR TER PERFORMANCE TEST: The follo wing equipment may be used to complete a perf or mance test of the star ter motor : • Aclamp-onammeter . • Atachometercapableofreadingupto10,000rpm. • [...]

P age 130 ST ARTER CONT AC TO R ST ARTER M OTO R TA CHOMETER 12 VO LT BA TTER Y CLAMP ON AMP METER VISE Figure 17. T esting Star ter Motor P erformance teSt 66 – check Fuel Suppl y and preSSure DISCUSSION: The air-cooled generator was factory tested and adjusted using natural gas as a fuel. If desired, LP (propane) gas may be used. Howe ver , whe[...]

sEctioN 4.4 Dia GNostic tEsts P age 131 POR T 3 POR T 1 POR T 2 Figure 20 (12-20 kW) Gas Pressure T est point note: Where a primary regulator is used to estab- lish fuel inlet pressure, adjustment of that regula- tor is usually the responsibility of the fuel supplier or the fuel supply system installer . 12-20 kW UNITS ONL Y : note: the test port ([...]

P age 132 i. Set a V OM to measure resistance. j. Connect one meter test lead to Wire 14 that was disconnected in Step 3. k. Connect the other meter test lead to Wire 14 at J2-3. See Figures on P ages 92-95. l . CONTINUITY should be measured. If CONTINUITY is measured, repeat Step 5 and then retest. m . If CONTINUITY is not measured, repair or repl[...]

sEctioN 4.4 Dia GNostic tEsts P age 133 CHOKE SOLENOID CHOKE PLA TE Figure 22. Solenoid De-Energized, Chok e Closed 12-20 kW Units CHOKE SOLENOID CHOKE PLA TE Figure 23. Solenoid Energized, Chok e Open 12-20 kW Units 3. Set a VOM to measure DC v oltage. 4. Connect the positive (+) test lead to Wire 14 (Pin 1) of the C3 Connector going to the contro[...]

P age 134 2. Disconnect the C3 Connector . 3. Set a VOM to measure DC v oltage. 4. Connect the positive (+) test lead to Wire 56 (Pin 1) of C3 Connector going to the control panel (Female Side) Connect the negative (-) test lead to Wire 0 (Pin 2). 5. Set the A UT O-OFF-MANU AL Switch to MANUAL. While cranking, battery voltage should be measured. If[...]

sEctioN 4.4 Dia GNostic tEsts P age 135 Figure 27. Spark T ester Figure 28. Checking Ignition Spark T o deter mine if an engine miss is ignition related, connect the spark tester in series with the spar k plug wire and the spark plug (Figure 29). Then, crank and star t the engine. A spark miss will be readily apparent. If spark jumps the spar k tes[...]

P age 136 Figure 29. Checking Engine Miss RESUL TS: 1. If no spark or very weak spark occurs, go to T est 73. 2. If sparking occurs but engine still won’t start, go to T est 71. 3. When checking f or engine miss, if spar king occurs at regular inter vals b ut engine miss continues, go to T est 20. 4. When checking f or engine miss, if a spark mis[...]

sEctioN 4.4 Dia GNostic tEsts P age 137 DISCUSSION: The Cylinder Leak Down T ester checks the sealing (compression) ability of the engine by measuring air leakage from the combustion chamber . Compression loss can present many diff erent symptoms. This test is designed to detect the section of the engine where the f ault lies bef ore disassembling [...]

P age 138 WIRE 18 CONNECTION Figure 32. Wire 18 Connection 10-20 kW Units 2. Depending on engine type, do the f ollowing: a . On V -twin units , remov e Wire 56 from the Star ter Contactor Relay (SCR). Using a jumper lead, jump 12 VDC from Wire 15B at TB1 (Customer Connection) to the ter minal on the SCR from which Wire 56 was remov ed. The generat[...]

sEctioN 4.4 Dia GNostic tEsts P age 139 PROCEDURE, ADJUSTING MA GNET O FL YWHEEL GAP: note: the air gap between the ignition magneto and the flywheel on single cylinder engines is not adjustable. proceed directly to Step 10 for single cylinder engines. For V -twin engines, proceed as follo ws. 1. See Figure 34. Rotate the flywheel until the magnet [...]

P age 140 RESUL TS: If spar king still does not occur after adjusting the ar mature air gap , testing the ground wires and perf or ming the basic flywheel test, replace the ignition magneto(s). PROCEDURE, REPLA CING MAGNET OS: 1. F ol lo w a ll ste ps of th e Ma jor Di sa sse mb ly pr oce dur es that are located in Section 6. 2. Once the magnetos a[...]

sEctioN 4.4 Dia GNostic tEsts P age 141 teSt 75 – check oil preSSure SWitch and Wire 86 DISCUSSION: If the oil pressure s witch contacts have failed in their closed position, the engine will probably crank and star t. How ev er , shutdown will then occur within about 5 (five) seconds. If the engine cranks and star ts, then shuts down almost immed[...]

P age 142 a. Disconnect the J1 Connector from the pr inted circuit board. b . Connect one test lead to Wire 86 (disconnected from LOP). Connect the other test lead to Pin Location 4 (Wire 86) of the J1 Connector at the Circuit Board (for all models). CONTINUITY should be measured. If CONTINUITY is not measured, repair or replace Wire 86 between the[...]

sEctioN 4.4 Dia GNostic tEsts P age 143 PROCEDURE: (INT AkE AND EXHA UST) Make sure that the piston is at T op Dead Center (TDC) of it’ s compression stroke (both v alves closed). The valv e clearance should be 0.05-0.1mm (0.002-0.004 in.) cold. Check and adjust the v alve to rocker arm clearance as f ollows: 1. Remov e the f our (4) screws from [...]

P age 144 10. Connect one meter test lead to Wire 18 removed from the stud connector . Connect the other meter test lead to a clean frame ground. INFINITY should be measured. If CONTINUITY is measured, repair or replace Wire 18 between the stud connector and the J1 Connector . RESUL TS: Ref er to flow char t. PROCEDURE: (SINGLE CYLINDER) 1. Set a V[...]

PROCEDURE: 1. Set a VOM to measure resistance . 2. Disconnect the J2 Connector from the controller . 3. Connect one meter test lead to the ground ter minal. Connect the other meter test lead to each of the f ollow- ing J2 connector pin locations. J2-11 Wire 56 8kW If CONTINUITY was measured, go to Step 4. A verage nominal resistance reading is 4 oh[...]

d. If coil resistance was measured in CS and FS, and FS2 Wire 14 is shor ted to ground between J2 connector and CS, FS, or FS2, repair or replace the shor ted wire. 8. Disconnect Wire 14 from the Fuel Solenoid (FS) and Choke Solenoid (CS). a. Connect one meter test lead to the FS ter minal from which Wire 14 was remov ed. Connect the other meter te[...]

P ar t 5 oPEra tioNal tEsts air -cooled, a utomatic standb y Generators P age 147 t aBlE of coNtENts P art titlE 5.1. system functional t ests 5.1 System Functional T ests ................................ 148 Introduction ....................................................148 Manual T ransf er Switch Operation .................148 Electrical Check[...]

introduction F ollowing home standby electric system installation and per iodically thereafter , the system should be tested Functional tests of the system include the f ollowing: • Manualtransf erswitchoper ation. • Systemvoltagetests . • Generator T estsUnderLoad. • T estingautomaticoperation. Bef[...]

OPERA TIONAL TESTS AND ADJUSTMENTS sEctioN 5.1 sYstEm fuNctioNal tEsts P art 5 P age 149 D ANGER + tHE traNsfEr sWitcH is No W ElEctri- call Y “Ho t”, coNt act WitH “Hot” P arts Will rEsul t iN EXtrEmEl Y HaZarDous aND PossiBl Y f a t al ElEctrical sHocK. ProcEED WitH ca utioN. 5. Use an accurate AC voltmeter to check utility power source v[...]

11. Let the generator r un at full rated load for 20-30 minutes . Listen for unusual noises, vibration or other indications of abnor mal operation. Check for oil leaks, evidence of ov erheating, etc. 12. When testing under load is complete, tur n off electr ical loads. 13 . Set the generator main circuit breaker to its OFF (or open) position. 14. L[...]

P ar t 6 DisassEmBl Y air -cooled, a utomatic standb y Generators P age 151 t aBlE of coNtENts P art titlE 6.1. major Disassembl y 6.1 Major Disassembly ........................................ 152 F ront Engine Access ......................................152 Major Disassembly .........................................156 T orque Requirements (Unle[...]

Front enGine a cceSS SAFETY : 1. Set the A UTO-OFF-MANU AL switch to OFF . 2. Remov e the 7.5 amp main fuse. See Figure 1. 3. Remov e the N1 and N2 fuse from the transf er switch. Figure 1. Remov e 7.5 Amp Fuse 4. T urn off fuel supply to the generator and remov e the flex- line from the fuel regulator . 5. Remov e utility power from the gener ator[...]

DISASSEMBL Y sEctioN 6.1 maJor DisassEmBl Y P art 6 P age 153 4. Remov e Stator Wires: Remove all wires from the voltage regulator , remove the neutral and ground wires from landing lugs, and remov e N1 & N2 wires from main bea- kers . See Figure 5. 5. Remov e Control Wires: Remov e Wires #N1,#N2, #0, #15B, #23, GFCI Outlet, and unit status lig[...]

8. Loo sen si de pan el: U sin g a 1 0mm so cket r emove t he two bolts from the base of the enclosure side panel. See Figure 10. 9. Unbolt enclosure side panel mounting brack et: Using a 10mm socket remov e the two bolts from the enclosure side panel mounting brac ket. See Figure 11. Figure 10. Figure 11. 10. Remove fuel regulator : Remov e the tw[...]

Figure 14. 12. Remove Air Box: Using a 6mm allen wrench remov e the f our intake manif old sock et head cap screws. See Figure 15. Using a 4mm allen wrench, remove the four airbox allen head shoulder bolts. While removing the airbox remov e the f our rubber washers. See Figure 16. Figure 15. Figure 16. 13. Unbolt Oil Cooler : Using a 10mm sock et r[...]

P age 156 P art 6 DISASSEMBL Y sEctioN 6.1 maJor DisassEmBl Y 14 . Remov e Blower Housing: Using a 4mm allen wrench remov e one button head cap screw from top of blower housing. Using a 10mm sock et remov e one 10mm bolt from the top of the blower housing. See Figure 19. Using a 10mm socket remove f our 10mm bolts from the right- side of the blower[...]

ST A TOR/R OT OR/ENGINE REMO V AL: 1. Remov e T op Exhaust Enclosure Cov ers: Using a 10mm sock et, remove the nine bolts from the exhaust top cov- ers. Remov e covers . See Figure 23. Figure 23. 2. Remov e Side Exhaust Enclosure Cov er : Using a 10mm sock et, remov e the five bolts from the exhaust side cov er . Remove side cov ers. See Figure 24.[...]

Figure 27. 6 . Remove Left-side enclosure: Using a 10mm ratchet wrench remove the hor izontal 10mm bolt that connects the side panel to the back panel. Using a 10mm sock et, remov e three bolts from the base of the enclosure. See Figure 28. Using a 10mm sock et and wrench remove the top hinge bolt and loosen the bottom bolt. See Figure 29. Holding [...]

Figure 31. 9. Remove Fan: Attach a steering wheel puller to the fan us in g tw o M8 x 1. 25 b ol ts . R em ove th e fan f ro m th e rotor . Figure 32. Figure 32. 10. Remove Br ushes: Using a 7mm sock et remov e br ushes. See Figure 33. Figure 33. 11 . Remove Alter nator Divider P anel: Using a 10mm socket remov e two bottom base bolts. Using a T27 [...]

12. Remove Br ush Wires: Using a side cutters remove the tie wraps securing the brush wires to the outside of sta- tor . See Figure 35. Figure 35. 1 3. Remov e Controls Cover: Using a T orx T -27 socket remov e two bolts and ground washer from the controls cov er . Remove the controls cov er . See Figure 36. Figure 36. 14. Remove Stator Wires: Remo[...]

Figure 39. Figure 40. Figure 41. 17. 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 screw- driver 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 bre[...]

12. Remove Engine: Using proper lifting equipment remov e the engine. See Figure 44. Figure 44. t orque requirementS (unleSS o ther WiSe SpeciFied) ST A T OR BOL TS ................................................ 6 ft-lbs ( +1 / -0 ) RO TOR BOL T ................................................................ 30 ft-lbs ENGINE AD APT OR ..........[...]

P ar t 7 ElEctrical D ata air -cooled, a utomatic standb y Generators P age 163 t aBlE of coNtENts D WG# titlE 0G7945 WiriNG DiaGram, 8 KW HsB 0G8511 scHEma tic, 8 KW HsB 0G7946 WiriNG Dia Gram, 10 KW HsB 0G8512 scHEma tic, 10 KW HsB 0G7947 WiriNG Dia Gram, 14 KW HsB 0G8513 scHEma tic, 14 KW HsB 0G7948 WiriNG Dia Gram, 17 KW HsB 0G8514 scHEma tic, [...]

2 6 44 22 33 11 STATOR ENGINE COMPARTMENT CONTROL PANEL 1 5 2 3 4 7 6 8 11 9 10 12 13 14 15 16 17 18 J1 J2 MAIN CONTROLLER SP1 IM1 HTO 85 LOP 86 0 0 1 2 3 4 85 86 13 18 CHOKE SOLENOID RED 1 2 BLK FRAME GND 0 ENGINE GND 0 18 10 10 10 10 N1 N2 1 2 N1 N2 6 6 PANEL GND 0 0 0 0 0 0 GROUND + BATTERY TRANS SIG 0 15B 23 15B 23 0 14 0 N1 CUSTOMER SUPPLIED B[...]

2 6 44 22 33 11 STATOR ENGINE COMPARTMENT CONTROL PANEL 1 5 2 3 4 7 6 8 11 9 10 12 13 14 15 16 17 18 J1 J2 MAIN CONTROLLER SP1 IM1 HTO 85 LOP 86 0 0 1 2 3 4 85 86 13 18 CHOKE SOLENOID RED 1 2 BLK FRAME GND 0 ENGINE GND 0 18 10 10 10 10 N1 N2 1 2 N1 N2 6 6 PANEL GND 0 0 0 0 0 0 GROUND + BATTERY TRANS SIG 0 15B 23 15B 23 0 14 0 N1 CUSTOMER SUPPLIED B[...]

P art 7 ELECTRICAL DA T A scHEma tic, 8 KW HomE st aNDBY P age 166 OUTPUT GENERATOR 240 VAC NEUTRAL INPUT UTILITY 240 VAC TRANSFER + BATTERY GROUND 56 0 15B 23 23 0 0 0 0 56 56 FS 16 13 SC 0 0 86 85 HTO LOP 18 BATTERY WARMER OPTIONAL N1 00 22 33 11 44 CB 15B 14 0 13 0 12V BATTERY SC 0 CS IM SP EXCITATION WINDING 2 6 CAPACITOR 44 11 POWER WINDING 33[...]

ELECTRICAL D A T A scHEma tic, 8 KW HomE st aNDBY P art 7 P age 167 OUTPUT GENERATOR 240 VAC NEUTRAL INPUT UTILITY 240 VAC TRANSFER + BATTERY GROUND 56 0 15B 23 23 0 0 0 0 56 56 FS 16 13 SC 0 0 86 85 HTO LOP 18 BATTERY WARMER OPTIONAL N1 00 22 33 11 44 CB 15B 14 0 13 0 12V BATTERY SC 0 CS IM SP EXCITATION WINDING 2 6 CAPACITOR 44 11 POWER WINDING 3[...]

P age 168 2 6 44 22 33 11 STATOR ENGINE COMPARTMENT CONTROL PANEL 1 5 2 3 4 7 6 8 11 9 10 12 13 14 15 16 17 18 J3 J1 J2 MAIN CONTROLLER SP1 IM1 SP2 IM2 HTO 85 LOP 86 0 0 1 2 3 4 85 86 13 18 CHOKE SOLENOID RED 1 2 BLK ACTUATOR GOVERNOR SC SM FRAME GND 0 ENGINE GND 0 18 13 14 90 0 0 56 A 0 B SCR 16 13 16 10 10 10 10 1 2 N1 N2 0 6 6 PANEL GND 0 0 0 0 [...]

P age 169 2 6 44 22 33 11 STATOR ENGINE COMPARTMENT CONTROL PANEL 1 5 2 3 4 7 6 8 11 9 10 12 13 14 15 16 17 18 J3 J1 J2 MAIN CONTROLLER SP1 IM1 SP2 IM2 HTO 85 LOP 86 0 0 1 2 3 4 85 86 13 18 CHOKE SOLENOID RED 1 2 BLK ACTUATOR GOVERNOR SC SM FRAME GND 0 ENGINE GND 0 18 13 14 90 0 0 56 A 0 B SCR 16 13 16 10 10 10 10 1 2 N1 N2 0 6 6 PANEL GND 0 0 0 0 [...]

P age 170 P art 7 ELECTRICAL DA T A scHEma tic, 10 KW HomE st aNDBY 820 817 818 819 ACTUATOR J3 GOVERNOR 14 0 14 FS 90 13 18 SP2 IM2 OUTPUT GENERATOR 240 VAC NEUTRAL INPUT UTILITY 240 VAC TRANSFER + BATTERY GROUND 56 0 15B 23 23 0 0 FS 16 13 SCR 0 0 86 85 HTO LOP 18 BATTERY WARMER OPTIONAL N1 00 22 33 11 44 CB 15B 14 0 13 0 12V BATTERY SCR 0 CS SM [...]

P age 171 ELECTRICAL D A T A scHEma tic, 10 KW HomE st aNDBY P art 7 820 817 818 819 ACTUATOR J3 GOVERNOR 14 0 14 FS 90 13 18 SP2 IM2 OUTPUT GENERATOR 240 VAC NEUTRAL INPUT UTILITY 240 VAC TRANSFER + BATTERY GROUND 56 0 15B 23 23 0 0 FS 16 13 SCR 0 0 86 85 HTO LOP 18 BATTERY WARMER OPTIONAL N1 00 22 33 11 44 CB 15B 14 0 13 0 12V BATTERY SCR 0 CS SM[...]

P age 172 ENGINE COMPARTMENT CONTROL PANEL 1 5 2 3 4 7 6 8 11 9 10 12 13 14 15 16 17 18 J3 J1 J2 MAIN CONTROLLER SP1 IM1 SP2 IM2 HTO 85 LOP 86 0 0 1 2 3 4 85 86 13 18 CHOKE SOLENOID RED 1 2 BLK ACTUATOR GOVERNOR SC SM FRAME GND 0 ENGINE GND 0 18 13 0 14 4 90 0 0 56 A 0 B SCR 16 13 16 N1 N2 1 2 N1 N2 0 6 6 PANEL GND 0 0 0 0 0 0 0 0 GROUND + BATTERY [...]

P age 173 ENGINE COMPARTMENT CONTROL PANEL 1 5 2 3 4 7 6 8 11 9 10 12 13 14 15 16 17 18 J3 J1 J2 MAIN CONTROLLER SP1 IM1 SP2 IM2 HTO 85 LOP 86 0 0 1 2 3 4 85 86 13 18 CHOKE SOLENOID RED 1 2 BLK ACTUATOR GOVERNOR SC SM FRAME GND 0 ENGINE GND 0 18 13 0 14 4 90 0 0 56 A 0 B SCR 16 13 16 N1 N2 1 2 N1 N2 0 6 6 PANEL GND 0 0 0 0 0 0 0 0 GROUND + BATTERY [...]

P age 174 P art 7 ELECTRICAL DA T A scHEma tic, 14 KW HomE st aNDBY 0 4 4 0 BA 6 11 22 6 2 2 REGULATOR 11 2 6 0 4 22 VOLTAGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 13 12V BATTERY SCR SM IM1 SP1 44 11 POWER WINDING 33 22 WINDING POWER STATOR 4 0 56 0 SC 820 817 818 819 819 818 817 820 L2 L1 LED BOARD 4 3 2 1 4 ACTUATOR J3 GOVERNOR 1[...]

P age 175 ELECTRICAL D A T A scHEma tic, 14 KW HomE st aNDBY P art 7 0 4 4 0 BA 6 11 22 6 2 2 REGULATOR 11 2 6 0 4 22 VOLTAGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 13 12V BATTERY SCR SM IM1 SP1 44 11 POWER WINDING 33 22 WINDING POWER STATOR 4 0 56 0 SC 820 817 818 819 819 818 817 820 L2 L1 LED BOARD 4 3 2 1 4 ACTUATOR J3 GOVERNOR [...]

P age 176 CLOSEST TO BEARING BA 0 4 6 22 11 44 22 33 11 STATOR 2 0 6 VOLTAGE REGULATOR 4 11 22 2 2 6 22 11 ENGINE COMPARTMENT CONTROL PANEL 1 5 2 3 4 7 6 8 11 9 10 12 13 14 15 16 17 18 J3 J1 J2 MAIN CONTROLLER SP1 IM1 SP2 IM2 4 HTO 85 LOP 86 0 0 1 2 3 4 85 86 13 18 CHOKE SOLENOID RED 1 2 BLK ACTUATOR GOVERNOR SC SM FRAME GND 0 ENGINE GND 0 18 13 0 [...]

P age 177 CLOSEST TO BEARING BA 0 4 6 22 11 44 22 33 11 STATOR 2 0 6 VOLTAGE REGULATOR 4 11 22 2 2 6 22 11 ENGINE COMPARTMENT CONTROL PANEL 1 5 2 3 4 7 6 8 11 9 10 12 13 14 15 16 17 18 J3 J1 J2 MAIN CONTROLLER SP1 IM1 SP2 IM2 4 HTO 85 LOP 86 0 0 1 2 3 4 85 86 13 18 CHOKE SOLENOID RED 1 2 BLK ACTUATOR GOVERNOR SC SM FRAME GND 0 ENGINE GND 0 18 13 0 [...]

P age 178 P art 7 ELECTRICAL DA T A scHEma tic, 17 KW HomE st aNDBY 0 4 4 0 BA 6 11 22 6 2 2 REGULATOR 11 2 6 0 4 22 VOLTAGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 13 0 12V BATTERY SCR SM IM1 SP1 44 11 POWER WINDING 33 22 WINDING POWER STATOR 18 13 86 85 4 0 0 SC 13 0 0 00 00 11C L3 820 817 818 819 819 818 817 820 L2 L1 LED BOARD 4[...]

P age 179 ELECTRICAL D A T A scHEma tic, 17 KW HomE st aNDBY P art 7 0 4 4 0 BA 6 11 22 6 2 2 REGULATOR 11 2 6 0 4 22 VOLTAGE 4 0 0 13 13 18 SP2 IM2 16 13 SCR 0 0 86 85 HTO LOP 18 0 13 0 12V BATTERY SCR SM IM1 SP1 44 11 POWER WINDING 33 22 WINDING POWER STATOR 18 13 86 85 4 0 0 SC 13 0 0 00 00 11C L3 820 817 818 819 819 818 817 820 L2 L1 LED BOARD [...]

P age 180 CLOSEST TO BEARING BA 0 4 6 22 11 44 22 33 11 STATOR 2 0 6 VOLTAGE REGULATOR 4 11 22 2 2 6 22 11 ENGINE COMPARTMENT CONTROL PANEL 1 5 2 3 4 7 6 8 11 9 10 12 13 14 15 16 17 18 J3 J1 J2 MAIN CONTROLLER SP1 IM1 SP2 IM2 4 HTO 85 LOP 86 0 0 1 2 3 4 85 86 13 18 CHOKE SOLENOID RED 1 2 BLK ACTUATOR GOVERNOR SC SM FRAME GND 0 ENGINE GND 0 18 13 0 [...]

P age 181 CLOSEST TO BEARING BA 0 4 6 22 11 44 22 33 11 STATOR 2 0 6 VOLTAGE REGULATOR 4 11 22 2 2 6 22 11 ENGINE COMPARTMENT CONTROL PANEL 1 5 2 3 4 7 6 8 11 9 10 12 13 14 15 16 17 18 J3 J1 J2 MAIN CONTROLLER SP1 IM1 SP2 IM2 4 HTO 85 LOP 86 0 0 1 2 3 4 85 86 13 18 CHOKE SOLENOID RED 1 2 BLK ACTUATOR GOVERNOR SC SM FRAME GND 0 ENGINE GND 0 18 13 0 [...]

P age 182 P art 7 ELECTRICAL DA T A scHEma tic, 20 KW HomE st aNDBY 0 0 00 00 11C L3 0 4 4 0 BA 6 11 22 6 2 2 REGULATOR 11 2 6 0 4 22 VOLTAGE 820 817 818 819 819 818 817 820 L2 L1 LED BOARD 4 3 2 1 4 4 0 0 ACTUATOR J3 GOVERNOR 14 14 90 13 13 13 18 SP2 IM2 OUTPUT GENERATOR 240 VAC NEUTRAL INPUT UTILITY 240 VAC TRANSFER + BATTERY GROUND 56 0 15B 23 2[...]

P age 183 ELECTRICAL D A T A scHEma tic, 20 KW HomE st aNDBY P art 7 0 0 00 00 11C L3 0 4 4 0 BA 6 11 22 6 2 2 REGULATOR 11 2 6 0 4 22 VOLTAGE 820 817 818 819 819 818 817 820 L2 L1 LED BOARD 4 3 2 1 4 4 0 0 ACTUATOR J3 GOVERNOR 14 14 90 13 13 13 18 SP2 IM2 OUTPUT GENERATOR 240 VAC NEUTRAL INPUT UTILITY 240 VAC TRANSFER + BATTERY GROUND 56 0 15B 23 [...]

P art 7 P age 184 ELECTRICAL D A T A WiriNG Dia Gram, HomE st aNDBY traNsfEr sWitcH, 9/10/12/16 circuit 205 N2A N1A RED BLK 10 CIRCUIT LOAD CENTER 12 CIRCUIT LOAD CENTER 14 CIRCUIT LOAD CENTER CIRCUIT 8 8 CIRCUIT LOAD CENTER CIRCUIT 1 CIRCUIT 3 CIRCUIT 10 CIRCUIT 12 CIRCUIT 14 CIRCUIT 16 CIRCUIT 5 CIRCUIT 7 CIRCUIT 9 CIRCUIT 11 CIRCUIT 15 CIRCUIT 1[...]

205 N2A N1A RED BLK 10 CIRCUIT LOAD CENTER 12 CIRCUIT LOAD CENTER 14 CIRCUIT LOAD CENTER CIRCUIT 8 8 CIRCUIT LOAD CENTER CIRCUIT 1 CIRCUIT 3 CIRCUIT 10 CIRCUIT 12 CIRCUIT 14 CIRCUIT 16 CIRCUIT 5 CIRCUIT 7 CIRCUIT 9 CIRCUIT 11 CIRCUIT 15 CIRCUIT 13 PANEL OUTPUT TO GENERATOR DISTRIBUTION 240VAC TO MAIN CIRCUIT BREAKER CIRCUIT 6 CIRCUIT 2 CIRCUIT 4 MA[...]

P age 186 P art 7 ELECTRICAL DA T A scHEma tic, HomE st aNDBY traNsfEr sWitcH, 9/10/12/16 circuit NEUTRAL CONNECTION SWITCH SW3 NO C1 COM SW2 VR1 NC NC COM C2 VR2 NO TR1 15B 23 1 7 4 7 9 3 6 9 F2 CIRCUIT 10 BLACK (MAIN 1) CONTROL TRANSFER RED (MAIN 2) NEUTRAL (WHITE) NEUTRAL (WHITE) 23 0 F1 N2 N1 15B 23 BLACK RED N2 N1 15B 240VAC TO TO GENERATOR OU[...]

P age 187[...]

P age 188[...]

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Generac Power Systems, Inc. Highway 59 & Hillside Rd. P .O . Box 8 Waukesha, WI 53187 1-888-GENERAC MyGenerac.com ©2008 Generac Power Systems, Inc. All rights reserved. Specifications are subject to change without notice. Part No. 0G9266 rev . A / Printed in USA 09.08[...]