AUTOMATIC HOME STANDBY GENERATORS DIAGNOSTIC REPAIR MANUAL AIR-COOLED MODELS: ASPAS1BBA007 (6 kW NG, 7 kW LP) ASPAS1BBA012 (12 kW NG, 12 kW LP) ASPAS1BBA015 (13 kW NG, 15 kW LP) www.bryant.
SPECIFICATIONS GENERATOR Rated Max. Continuous Power Capacity (Watts*) Rated Voltage Rated Max. Continuous Load Current (Amps) 120 Volts** 240 Volts Main Line Circuit Breaker Phase Number of Rotor Poles Rated AC Frequency Power Factor Battery Requirement Weight Output Sound Level @ 23 ft (7m) at full load Normal Operating Range Model ASPAS1BBA007 6,000 NG/7,000 LP 120/240 Model ASPAS1BBA012 12,000 NG/12,000 LP 120/240 Model ASPAS1BBA015 13,000 NG/15,000 LP 120/240 50.0 NG/58.3 LP 25.0 NG/29.
TABLE OF CONTENTS PART TITLE Specifications DIAGNOSTIC REPAIR MANUAL Air-cooled, Prepackaged Automatic Standby Generators Models: 6 kW NG, 7 kW LP 12 kW NG, 12 kW LP 13 kW NG, 15 kW LP 1 General Information 2 AC Generators 3 V-Type Prepackaged Transfer Switches 4 DC Control 5 Operational Tests and Adjustments 6 Disassembly 7 Electrical Data
SPECIFICATIONS MOUNTING DIMENSIONS Page 4
SPECIFICATIONS MOUNTING DIMENSIONS Page 5
SPECIFICATIONS MAJOR FEATURES 7 kW, Single Cylinder GH-410 Engine 12 kW and 15 kW, V-twin GT-990 Engine Page 6
TABLE OF CONTENTS PART PART 1 GENERAL INFORMATION Air-cooled, Prepackaged Automatic Standby Generators Models: 6 kW NG, 7 kW LP 12 kW NG, 12 kW LP 13 kW NG, 15 kW LP TITLE 1.1 Generator Identification 1.2 Prepackaged Installation Basics 1.3 Preparation Before Use 1.4 Testing, Cleaning and Drying 1.5 Engine-Generator Protective Devices 1.6 Operating Instructions 1.
SECTION 1.1 PART 1 GENERATOR IDENTIFICATION INTRODUCTION This Diagnostic Repair Manual has been prepared especially for the purpose of familiarizing service personnel with the testing, troubleshooting and repair of air-cooled, prepackaged automatic standby generators. Every effort has been expended to ensure that information and instructions in the manual are both accurate and current.
GENERAL INFORMATION PART 1 INTRODUCTION Information in this section is provided so that the service technician will have a basic knowledge of installation requirements for prepackaged home standby systems. Problems that arise are often related to poor or unauthorized installation practices. A typical prepackaged home standby electric system is shown in Figure 1 (next page). Installation of such a system includes the following: • Selecting a Location • Grounding the generator. • Providing a fuel supply.
SECTION 1.2 PREPACKAGED INSTALLATION BASICS PART 1 Figure 1.
GENERAL INFORMATION SECTION 1.2 PART 1 PREPACKAGED INSTALLATION BASICS POWER SOURCE AND LOAD LINES SYSTEM CONTROL INTERCONNECTIONS 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.
SECTION 1.3 PREPARATION BEFORE USE PART 1 GENERAL INFORMATION GENERAL ENGINE OIL RECOMMENDATIONS 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.
GENERAL INFORMATION SECTION 1.4 PART 1 TESTING, CLEANING AND DRYING VISUAL INSPECTION When it becomes necessary to test or troubleshoot a generator, it is a good practice to complete a thorough visual inspection. Remove the access covers and look closely for any obvious problems. Look for the following: • Burned or broken wires, broken wire connectors, damaged mounting brackets, etc. • Loose or frayed wiring insulation, loose or dirty connections. • Check that all wiring is well clear of rotating parts.
SECTION 1.4 TESTING, CLEANING AND DRYING PART 1 GENERAL INFORMATION 2. Before reading a DC voltage, always set the meter to a higher voltage scale than the anticipated reading. if in doubt, start at the highest scale and adjust the scale downward until correct readings are obtained. 3. The design of some meters is based on the "current flow" theory while others are based on the "electron flow" theory. a. b.
GENERAL INFORMATION PART 1 SECTION 1.4 TESTING, CLEANING AND DRYING If proper procedures are used, the following conditions can be detected using a VOM: • A "short-to-ground" condition in any stator or rotor winding. • Shorting together of any two parallel stator windings. • Shorting together of any two isolated stator windings. • An open condition in any stator or rotor winding. Component testing may require a specific resistance value or a test for INFINITY or CONTINUITY.
SECTION 1.4 PART 1 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.
GENERAL INFORMATION PART 1 parallel windings. Figure 2 is a pictorial representation of the various stator leads on units with air-cooled engine. TESTING ALL STATOR WINDINGS TO GROUND: 1. Disconnect stator output leads 11 and 44 from the generator main line circuit breaker. 2. Remove stator output leads 22 and 33 from the neutral connection and separate the two leads. 3. Disconnect C2 connector from the side of the control panel. The C2 connector is the closest to the back panel.
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. PART 1 GENERAL INFORMATION 6. Observe the breakdown lamp, then turn the tester switch OFF. DO NOT APPLY VOLTAGE LONGER THAN ONE (1) SECOND.
GENERAL INFORMATION PART 1 SECTION 1.5 ENGINE-GENERATOR PROTECTIVE DEVICES 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.
SECTION 1.6 PART 1 OPERATING INSTRUCTIONS CONTROL PANEL 2. OFF Position: GENERAL: See Figure 1. The front face of this panel mounts (a) an Auto-Off-Manual switch, (b) a 15 amp fuse, (c) a 7.5 amp fuse, (d) a set exercise switch and (e) the protection systems. 120 VAC GFCI OUTLET: The generator is equipped with an external, 15 amp, 120 volt, GFCI convenience outlet that is located in the right rear of the generator enclosure.
GENERAL INFORMATION PART 1 PROTECTION SYSTEMS: Unlike an automobile engine, the generator may have to run for long periods of time with no operator present to monitor engine conditions. For that reason, the engine is equipped with the following systems that protect it against potentially damaging conditions: • Low Oil Pressure Sensor • High Temperature Sensor • Overcrank • Overspeed There are LED readouts on the control panel to notify you that one of these faults has occurred.
SECTION 1.7 AUTOMATIC OPERATING PARAMETERS INTRODUCTION When the prepackaged generator is installed in conjunction with a prepackaged transfer switch, either manual or automatic operation is possible. Manual transfer and engine startup, as well as manual shutdown and retransfer are covered in Section 1.6. Selection of fully automatic operation is also discussed in that section.
GENERAL INFORMATION SECTION 1.7 PART 1 AUTOMATIC OPERATING PARAMETERS AUTOMATIC OPERATING SEQUENCES CHART SEQ. CONDITION ACTION SENSOR, TIMER OR OTHER 1 Utility source voltage is available. No action Voltage Dropout Sensor on circuit circuit board. 2 Utility voltage dropout below 60% of rated voltage occurs. A 15-second timer on circuit board turns on. Voltage Dropout Sensor and 15 second timer on circuit board. 3 Utility voltage is still below 60% of rated voltage.
NOTES Page 24 PART 1 GENERAL INFORMATION
TABLE OF CONTENTS PART PART 2 AC GENERATORS Air-cooled, Prepackaged Automatic Standby Generators Models: 6 kW NG, 7 kW LP 12 kW NG, 12 kW LP 13 kW NG, 15 kW LP TITLE 2.1 Description and Components 2.2 Operational Analysis 2.3 Troubleshooting Flow Charts 2.
SECTION 2.1 DESCRIPTION & COMPONENTS INTRODUCTION The air-cooled, pre-packaged automatic standby system is an easy to install, fully enclosed and selfsufficient electric power system. It is designed especially for homeowners, but may be used in other applications as well. On occurrence of a utility power failure, this high performance system will (a) crank and start automatically, and (b) automatically transfer electrical loads to generator AC output.
AC GENERATORS PART 2 SECTION 2.1 DESCRIPTION & COMPONENTS Wire 4 connects to the positive (+) brush and Wire 0 to the negative (-) brush. Wire 0 connects to frame ground. Rectified and regulated excitation current, as well as current from a field boost circuit, are delivered to the rotor windings via Wire 4, and the positive (+) brush and slip ring. The excitation and field boost current passes through the windings and to frame ground via the negative (-) slip ring and brush, and Wire 0.
SECTION 2.1 DESCRIPTION & COMPONENTS PART 2 AC GENERATORS Figure 5. Excitation Circuit Breaker VOLTAGE REGULATOR: A typical voltage regulator is shown in Figure 6. Unregulated AC output from the stator excitation winding is delivered to the regulator's DPE terminals, via Wire 2, the excitation circuit breaker, Wire 162, and Wire 6. The voltage regulator rectifies that current and, based on stator AC power winding sensing, regulates it.
AC GENERATORS PART 2 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. 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.
SECTION 2.2 OPERATIONAL ANALYSIS OPERATION STARTUP: When the engine is started, residual plus field boost magnetism from the rotor induces a voltage into (a) the stator AC power windings, (b) the stator excitation or DPE windings, (c) the stator battery charge, and (d) engine run winding. In an "on-speed" condition, residual plus field boost magnetism are capable of creating approximately one-half the unit's rated voltage.
AC GENERATORS SECTION 2.3 PART 2 TROUBLESHOOTING FLOWCHARTS GENERAL Use the “Flow Charts” in conjunction with the detailed instructions in Section 2.4. Test numbers used in the flow charts correspond to the numbered tests in Section 2.4. The first step in using the flow charts is to correctly identify the problem. Once that has been done, locate the problem on the following pages. For best results, perform all tests in the exact sequence shown in the flow charts.
SECTION 2.
AC GENERATORS PART 2 SECTION 2.
SECTION 2.
AC GENERATORS SECTION 2.4 PART 2 INTRODUCTION This section is provided to familiarize the service technician with acceptable procedures for the testing and evaluation of various problems that could be encountered on prepackaged standby generators with air-cooled engine. Use this section of the manual in conjunction with Section 2.3, "Troubleshooting Flow Charts". The numbered tests in this section correspond with those of Section 2.3.
SECTION 2.4 PART 2 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 unit's DATA PLATE for rated line-to-line and line-to-neutral voltages. DANGER: USE EXTREME CAUTION DURING THIS TEST. THE GENERATOR WILL BE RUNNING. HIGH AND DANGEROUS VOLTAGES WILL BE PRESENT AT THE TEST TERMINALS.
SECTION 2.4 PART 2 MATCH RESULTS WITH LETTER AND REFER TO FLOW CHART IN SECTION 2.3 “Problem 1” 0.91-1.06A 0.80A 0.64A Above 1.5A Above 1.3A Above 1.1A Zero Current Draw Zero Current Draw 0.91-1.06A 0.80A 0.64A 0.91-1.06A 0.80A 0.64A Above 1.5A Above 1.3A Above 1.1A Above 1.5A Above 1.3A Above 1.1A Zero Current Draw Zero Current Draw 0.91-1.06A 0.80A 0.64A 0.91-1.06A 0.80A 0.64A 0.91-1.06A 0.80A 0.64A 0.91-1.06A 0.80A 0.64A 0.91-1.06A 0.80A 0.64A 0.91-1.06A 0.80A 0.
SECTION 2.4 PART 2 DIAGNOSTIC TESTS 8. Set the Auto-Off-Manual switch to MANUAL. Once the engine starts, record the AC voltage. 9. Set the Auto-Off-Manual switch to OFF. Reconnect Wire 11 and Wire 22. 10.Set VOM to DC amperage. 11.Remove jumper lead connected to Wire 4 and Wire 15. 12.Connect one meter test lead to battery positive twelvevolt supply Wire 15, located at the 15A fuse. Connect the other meter test lead to Wire 4 (still disconnected from previous tests).
AC GENERATORS SECTION 2.4 PART 2 DIAGNOSTIC TESTS 4. Make sure all off the disconnected leads are isolated from each other and are not touching the frame during the test. 5. Set a VOM to its "R x 1" scale and zero the meter. 6. Refer to Figure 5 for pin locations of Connector C2. Use a large paper clip or similar metallic object to access pins in connector C2. Note: Pins 9, 10, 11 & 12 are not used for this test. Figure 4.
SECTION 2.4 PART 2 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.
AC GENERATORS PART 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.
SECTION 2.4 PART 2 DIAGNOSTIC TESTS AC GENERATORS TEST 11 - CHECK AC OUTPUT FREQUENCY 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.
AC GENERATORS SECTION 2.4 PART 2 DIAGNOSTIC TESTS 3. Start the generator; let it stabilize and warm up at noload. 4. Connect a frequency meter across the generators AC output leads. 5. Turn the primary adjust screw to obtain a frequency reading of 61.5 Hertz. Turn the secondary adjust screw to obtain a frequency of 62.5 Hz. 6. When frequency is correct at no load, check the AC voltage reading. If voltage is incorrect, the voltage regulator may require adjustment. 3.
SECTION 2.4 PART 2 DIAGNOSTIC TESTS TEST 13 - CHECK AND ADJUST VOLTAGE REGULATOR DISCUSSION: For additional information, refer to description and components Section 2.1. PROCEDURE: With the frequency between 61-62 Hertz, slowly turn the slotted potentiometer (Figure 12) until line voltage reads 244-252 volts. NOTE: You must remove the access panel on top of the control panel to adjust the voltage regulator. NOTE: The voltage regulator is housed above the generator control panel.
TABLE OF CONTENTS PART 3 “V-TYPE” PREPACKAGED TRANSFER SWITCHES Air-cooled, Prepackaged Automatic Standby Generators Models: 6 kW NG, 7 kW LP 12 kW NG, 12 kW LP 13 kW NG, 15 kW LP PART TITLE 3.1 Description and Components 3.2 Operational Analysis 3.3 Troubleshooting Flow Charts 3.
SECTION 3.1 DESCRIPTION & COMPONENTS PART 3 “V-TYPE” PREPACKAGED TRANSFER SWITCHES GENERAL ENCLOSURE The prepackaged, “V-Type” transfer switch is rated 100 amps at 250 volts maximum. It is available in 2pole configuration only and, for that reason, is useable with 1-phase systems only. Prepackaged transfer switches do not have an intelligence system of their own. Instead, automatic operation of these transfer switches is controlled by a circuit board housed in the generator control panel.
“V-TYPE” PREPACKAGED TRANSFER SWITCHES PART 3 UTILITY contacts, and a pair of stationary STANDBY contacts. The load contacts can be connected to the utility contacts by a utility closing coil; or to the standby contacts by a standby closing coil. In addition, the load contacts can be actuated to either the UTILITY or STANDBY side by means of a manual transfer handle. See Figures 2 and 3. SECTION 3.
SECTION 3.1 DESCRIPTION & COMPONENTS a. The 12 volts DC circuit is completed through the transfer relay coil and back to the generator circuit board, via Wire 23. b. Circuit board action normally holds the Wire 23 circuit open to ground and the relay is deenergized. c. When de-energized, the relay's normally open contacts are open and its normally-closed contacts are closed. d. The normally-closed relay contacts will deliver utility source power to the utility closing circuit of the transfer mechanism. e.
“V-TYPE” PREPACKAGED TRANSFER SWITCHES PART 3 delivered to a step-down transformer in the control module assembly and the resultant reduced voltage is then delivered to the circuit board. Utility 1 and 2 power is used by the circuit board as follows: • If utility source voltage should drop below a preset level, circuit board action will initiate automatic cranking and startup, followed by automatic transfer to the standby source.
SECTION 3.2 PART 3 OPERATIONAL ANALYSIS OPERATIONAL ANALYSIS Figure 1 is a schematic and wiring diagram for a typical “V-Type” transfer switch. Figure 1.
“V-TYPE” PREPACKAGED TRANSFER SWITCHES PART 3 SECTION 3.2 OPERATIONAL ANALYSIS UTILITY SOURCE VOLTAGE AVAILABLE Figure 2 is a schematic representation of the transfer switch with utility source power available. The circuit condition may be briefly described as follows: • Utility source voltage is available to terminal lugs N1 and N2 of the transfer mechanism, transfer switch is in the UTILITY position and source voltage is available to T1, T2 and customer load.
SECTION 3.2 OPERATIONAL ANALYSIS PART 3 “V-TYPE” PREPACKAGED TRANSFER SWITCHES UTILITY SOURCE VOLTAGE FAILURE If utility source voltage should drop below a preset value, the generator circuit board will sense the dropout. That circuit board will then initiate generator cranking and startup after a time delay circuit times out. Figure 3 is a schematic representation of the transfer switch with generator power available, waiting to transfer. • Generator voltage available E1, E2.
“V-TYPE” PREPACKAGED TRANSFER SWITCHES SECTION 3.2 PART 3 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.
SECTION 3.2 PART 3 OPERATIONAL ANALYSIS “V-TYPE” PREPACKAGED TRANSFER SWITCHES TRANSFER TO STANDBY When the standby coil is energized it pulls the transfer switch mechanism to a overcenter position towards the standby power source side, the transfer switch mechanically snaps to the standby position. On closure of the main contacts to the standby power source side, limit switches XA1 and XB1 are mechanically actuated to "arm" the circuit for re- transfer to utility power source side.
“V-TYPE” PREPACKAGED TRANSFER SWITCHES SECTION 3.2 PART 3 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 above a preset value for a preset time interval a transfer back to utility power will occur. Figure 6. Utility Restored, Generator Still Providing Output to Load.
SECTION 3.2 OPERATIONAL ANALYSIS PART 3 “V-TYPE” PREPACKAGED TRANSFER SWITCHES UTILITY RESTORED, TRANSFER SWITCH DE-ENERGIZED After the preset time interval expires the circuit board will open the Wire 23 circuit to ground. The transfer relay de-energizes, it's normally closed contacts close, and utility source voltage is delivered to the utility closing coil (C1), via Wires N1A and N2A, closed Transfer Relay Contacts 1 and 7, and Limit Switch XA1. Figure 7.
“V-TYPE” PREPACKAGED TRANSFER SWITCHES PART 3 SECTION 3.2 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. Figure 8. Utility Restored, Retransfer Back to Utility.
SECTION 3.2 PART 3 OPERATIONAL ANALYSIS “V-TYPE” PREPACKAGED TRANSFER SWITCHES TRANSFER SWITCH IN UTILITY When the transfer switch returns to the utility side, generator shutdown occurs after approximately one (1) minute. Figure 9. Transfer Switch in Utility.
“V-TYPE” PREPACKAGED TRANSFER SWITCHES PART 3 SECTION 3.3 TROUBLESHOOTING FLOW CHARTS INTRODUCTION TO TROUBLESHOOTING The first step in troubleshooting is to correctly identify the problem. Once that is done, the cause of the problem can be found by performing the tests in the appropriate flow chart. Test numbers assigned in the flow charts are identical to test numbers in section 3.4, “Diagnostic Tests.” Section 3.4 provides detailed instructions for performance of each test.
SECTION 3.
“V-TYPE” PREPACKAGED TRANSFER SWITCHES SECTION 3.4 PART 3 GENERAL DIAGNOSTIC TESTS PROCEDURE: 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.
SECTION 3.4 PART 3 DIAGNOSTIC TESTS e. Set the generator Auto-Off-Manual switch to AUTO. (1) The generator should crank and start. (2) When the generator starts, an "engine warm-up timer" should start timing. After about 15 seconds, the transfer relay should energize and transfer to the "Standby" source should occur. f. If transfer to "Standby" does NOT occur, check the voltage across transfer switch terminal lugs E1 and E2. The generator line-to-line voltage should be indicated. RESULTS: 1.
“V-TYPE” PREPACKAGED TRANSFER SWITCHES SECTION 3.4 PART 3 DIAGNOSTIC TESTS 3. Connect the VOM test leads across Relay Terminals 6 and 9 with the relay de-energized. The VOM should read infinity. a. Energize the relay and the meter should indicate infinity. b. De-energize the relay and the VOM should read CONTINUITY. RESULTS: 1. Replace transfer relay if it is defective. 2. If transfer relay checks good go to Test 26. 4.
SECTION 3.4 PART 3 DIAGNOSTIC TESTS using whatever means provided (such as a utility source main line breaker). DANGER: DO NOT ATTEMPT MANUAL TRANSFER SWITCH OPERATION UNTIL ALL POWER VOLTAGE SUPPLIES TO THE SWITCH HAVE BEEN POSITIVELY TURNED OFF. FAILURE TO TURN OFF ALL POWER VOLTAGE SUPPLIES MAY RESULT IN EXTREMELY HAZARDOUS AND POSSIBLY LETHAL ELECTRICAL SHOCK. 4. In the transfer switch enclosure, locate the manual transfer handle. Handle is retained in the enclosure with a wing nut.
“V-TYPE” PREPACKAGED TRANSFER SWITCHES SECTION 3.4 PART 3 5. Connect the positive (+) test lead to Wire 23 at the terminal strip in the transfer switch. a. If voltage is present, proceed to Step 6. b. If voltage is not present, repair wiring between terminal strip and transfer relay (TR). 6. Connect the negative (-) test lead to the ground lug in the generator control panel.
SECTION 3.4 PART 3 DIAGNOSTIC TESTS “Utility 1” and “Utility 2” terminals. Normal line-to-line utility source voltage should be indicated. “V-TYPE” PREPACKAGED TRANSFER SWITCHES DANGER: BE CAREFUL! HIGH AND DANGEROUS VOLTAGES ARE PRESENT AT TERMINAL LUGS WHEN THE GENERATOR IS RUNNING. AVOID CONTACT WITH HIGH VOLTAGE TERMINALS OR DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK MAY RESULT. DO NOT PERFORM THIS VOLTAGE TEST WHILE STANDING ON WET OR DAMP GROUND, WHILE BAREFOOT, OR WHILE HANDS OR FEET ARE WET.
“V-TYPE” PREPACKAGED TRANSFER SWITCHES SECTION 3.4 PART 3 5. If normal utility source line-to-line voltage is NOT indicated in Step 8, and is NOT indicated in Step 9, proceed to Test 32. DIAGNOSTIC TESTS transfer to the "Standby" position, the limit switch should actuate to its closed position. If the switch does not actuate to its closed position, retransfer back to "Utility" will not occur.
SECTION 3.4 DIAGNOSTIC TESTS 7. Disconnect Wire N1A from transfer relay (TR) terminal and connect one test lead to it. Connect the other test lead to F1 top fuse terminal Wire N1A. CONTINUITY should be read. Reconnect Wire N1A. RESULTS: Repair any defective wiring that does not read CONTINUITY. If wiring tests good, proceed to Test 23. TEST 33 - CONTINUITY TEST OF WIRING (C2) DISCUSSION: This test will ensure that all control wiring has continuity. 1. See Test 32, Step 1 2. See Test 32, Step 2 3.
“V-TYPE” PREPACKAGED TRANSFER SWITCHES PART 3 RESULTS: If a short is indicated in steps 5 through 9, repair wiring and re-test. If utility line to line voltage is measured in Step 14, proceed to Test 35. TEST 35 - CHECK TRANSFORMER (TX) DISCUSSION: The transformer is a step down type and has two functions. It supplies approximately 16VAC to the control board for utility sensing. It also supplies approximately 16 VAC to the battery charger when utility is available for trickle charge.
SECTION 3.
TABLE OF CONTENTS PART 4 DC CONTROL Air-cooled, Prepackaged Automatic Standby Generators Models: 6 kW NG, 7 kW LP 12 kW NG, 12 kW LP 13 kW NG, 15 kW LP PART TITLE 4.1 Description and Components 4.2 Operational Analysis 4.3 Troubleshooting Flow Charts 4.
SECTION 4.1 DESCRIPTION AND COMPONENTS PART 4 3DC CONTROL GENERAL TRANSFORMER (TX) This section will familiarize the reader with the various components that make up the DC control system. Major DC control system components that will be covered include the following: o A Terminal Strip / Interconnection Terminal • A Transformer (TX) • A Circuit Board. • An Auto-Off-Manual Switch. • A 15 Amp Fuse. • A 5 Amp Fuse. The control panel assembly's transformer is a stepdown type.
SECTION 4.1 PART 4 DC CONTROL DESCRIPTION AND COMPONENTS J1 PIN WIRE 1 4 Field boost current to rotor (about 9-10 volts DC). CIRCUIT FUNCTION 2 86 Low oil pressure shutdown. Automatic shutdown occurs when Wire 85 is grounded by loss of oil pressure to the LOP. 3 23 Switched to ground for Transfer Relay (TR) operation. 4 194 12 VDC output from the circuit board for transfer relay, present in AUTO or MANUAL operation.
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 seconds on and 15 seconds off. After the first crank-rest cycle, the remaining cycles will be in equal 7-9 second durations.
DC CONTROL PART 4 SECTION 4.1 DESCRIPTION AND COMPONENTS GROUND TERMINAL NEUTRAL BLOCK TRANSFORMER (TX) TERMINAL STRIP STARTER CONTACTOR RELAY (SCR) (V-TWINS ONLY) VOLTAGE REGULATOR BATTERY CHARGER BATTERY CHARGE RELAY (BCR) CIRCUIT BREAKER "DPE" (CB2) 4-TAB TERMINAL BLOCK (TB) GROUND TERMINAL PRINTED CIRCUIT BOARD SET EXERCISE SWITCH (SW2) ACCESSORY OUTLET FUSE HOLDER (F1) EXTERNAL GFCI CIRCUIT BREAKER FUSE HOLDER (F2) AUTO-OFF-MANUAL SWITCH (SW1) Figure 6.
SECTION 4.2 PART 4 OPERATIONAL ANALYSIS DC CONTROL INTRODUCTION UTILITY SOURCE VOLTAGE AVAILABLE 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. See Figure 1, above.
SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • "Utility" voltage is delivered to the primary winding of a sensing transformer (TX), via transfer switch wires N1/N2, fuses F1/F2, connected wiring, and Control Panel "Utility 1/Utility 2" terminals. A resultant voltage (about 16 volts AC) is induced into the transformer secondary windings and then delivered to the circuit board via Wires 224/225. The circuit board uses this reduced "Utility" voltage as sensing voltage.
SECTION 4.2 PART 4 OPERATIONAL ANALYSIS INITIAL DROPOUT OF UTILITY SOURCE VOLTAGE DC CONTROL • 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. Refer to Figure 2, above.
SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • Should "Utility" voltage drop below approximately 60 percent of the nominal source voltage, a 15second timer on the circuit board will turn on. • In Figure 2, the 15-second timer is still timing and engine cranking has not yet begun. • The Auto-Off-Manual switch is shown in its AUTO position.
SECTION 4.2 PART 4 OPERATIONAL ANALYSIS UTILITY VOLTAGE DROPOUT / ENGINE CRANKING DC CONTROL seconds. Thus, the engine will crank cyclically for 7 second crank-rest cycles. This cyclic cranking will continue until either the engine starts or until about ninety (90) seconds of crank-rest cycles have elapsed. • When the crank relay (K1) is energized, circuit board action delivers 12 volts DC to a starter contactor relay (SCR), via Wire 56.
SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • When the circuit board's run relay (K2) energizes, 12 volts DC is delivered to a fuel solenoid (FS), via Wire 14. The fuel solenoid (FS) energizes open and fuel is available to the engine. Wire 14 energizes the battery charge relay (BCR), which will allow the BCR to power the battery charger. • As the engine cranks, magnets on the engine flywheel induce a high voltage into the engine ignition modules (IM1/IM2).
SECTION 4.2 PART 4 OPERATIONAL ANALYSIS ENGINE STARTUP AND RUNNING DC CONTROL • 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". With the fuel solenoid open and ignition occurring, the engine starts.
SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • The "engine warm-up timer" will run for about 15 seconds. When this timer finishes timing, board action will initiate transfer to the "Standby" power source. As shown in Figure 4 (above), the timer is still running and transfer has not yet occurred. • Generator AC output is available to transfer switch terminal lugs E1/E2 and to the normally open contacts of a transfer relay. However, the transfer relay is de-energized and its contacts are open.
SECTION 4.2 PART 4 OPERATIONAL ANALYSIS INITIAL TRANSFER TO THE "STANDBY" SOURCE DC CONTROL 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.
SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS 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.
SECTION 4.2 PART 4 OPERATIONAL ANALYSIS UTILITY VOLTAGE RESTORED / RETRANSFER TO UTILITY DC CONTROL • 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.
SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS 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.
SECTION 4.2 PART 4 OPERATIONAL ANALYSIS ENGINE SHUTDOWN DC CONTROL • The DC circuit to Wire 14 and the fuel solenoid (FS) will be opened. The fuel solenoid (FS) will deenergize and close to terminate the engine fuel supply. • The hourmeter (if equipped) connected to Wire 14 will be opened and clock function of the hourmeter will stop. Following retransfer back to the "Utility" source, an "engine cool-down timer" on the circuit board starts timing.
SECTION 4.2 PART 4 DC CONTROL OPERATIONAL ANALYSIS • 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.
SECTION 4.
DC CONTROL PART 4 SECTION 4.
SECTION 4.
DC CONTROL PART 4 SECTION 4.
SECTION 4.
DC CONTROL PART 4 SECTION 4.
SECTION 4.3 TROUBLESHOOTING FLOW CHARTS PART 4 Problem 17 - 7.5 Amp Fuse (F2) Blown THE 12 VDC ACCESSORY OUTLET IS CAPABLE OF DELIVERING A MAXIMUM OF 7.5 AMPS. IF THE ACCESSORY TO BE USED THROUGH THIS CIRCUIT DEMANDS TOO MUCH POWER, THE FUSE THAT PROTECTS THIS CIRCUIT WILL OPEN. CHECK FOR OVERLOAD CONDITION. INSTALL NEW FUSE AND RETEST. IF FUSE STILL MELTS OPEN CHECK WIRE 15 BETWEEN 7.5A(F2) FUSE HOLDER AND THE 12 VDC ACCESSORY SOCKET FOR A SHORT TO GROUND.
DC CONTROL SECTION 4.4 PART 4 DIAGNOSTIC TESTS INTRODUCTION Perform these "Diagnostic Tests" in conjunction with the "Troubleshooting Flow Charts" of Section 4.3. The test procedures and methods presented in this section are not exhaustive. We could not possibly know of, evaluate and advise the service trade of all conceivable ways in which testing and trouble diagnosis might be performed. We have not undertaken any such broad evaluation.
SECTION 4.4 PART 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.
DC CONTROL SECTION 4.4 PART 4 switch Terminal 4, Wire 17/178. Connect the negative (-) test lead to a clean frame ground. Battery voltage should be measured. 8. Connect the positive (+) test lead to Pin location 11, wire 17 at the J1 connector on the circuit board. Connect the negative (-) test lead to a clean frame ground. Battery voltage should be measured. 9. Set a VOM to measure resistance "R x 1" scale. Connect one meter test lead to a clean frame ground.
SECTION 4.4 PART 4 DIAGNOSTIC TESTS d. DC CONTROL An average reading of 1.170 indicates the battery is 25% charged. C. Test Battery Condition: 1. If the difference between the highest and lowest reading cells is greater than 0.050 (50 points), battery condition has deteriorated and the battery should be replaced. 2. However, if the highest reading cell has a specific gravity of less than 1.230, the test for condition is questionable.
DC CONTROL PART 4 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. SECTION 4.4 DIAGNOSTIC TESTS attaches (see Figure 6 or 7). Connect the common (-) test lead to frame ground. a. No voltage should be indicated initially. b.
SECTION 4.4 DIAGNOSTIC TESTS RESULTS: 1. If battery voltage was indicated in Step 1, but not in Step 2b, replace the starter contactor. 2. If battery voltage was indicated in Step 2b, but the engine did not crank, go on to Test 50. PART 4 DC CONTROL 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.
DC CONTROL PART 4 SECTION 4.4 DIAGNOSTIC TESTS Figure 13. Tachometer 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: • A clamp-on ammeter. • A tachometer capable of reading up to 10,000 rpm. • A fully charged 12-volt battery. TEST BRACKET: A starter motor test bracket may be made as shown in Figure 14.
SECTION 4.4 PART 4 DIAGNOSTIC TESTS 4. A starter motor in good condition will be within the following specifications: Minimum rpm Maximum Amps Single Cylinder 800 9 V-twin 4500 50 DC CONTROL • 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 EXPLOSIVE. DO NOT USE FLAME OR HEAT TO TEST THE FUEL SYSTEM FOR LEAKS.
DC CONTROL SECTION 4.4 PART 4 TEST 52 - TEST FUEL SOLENOID Note: This test is for fuel regulators equipped with idle circuit port only. See Figure 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).
SECTION 4.4 PART 4 DIAGNOSTIC TESTS 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. DC CONTROL 2. Replace the solenoid if it does not actuate.
DC CONTROL SECTION 4.4 PART 4 DIAGNOSTIC TESTS 3. Attach the spark plug lead to the spark tester terminal. PROCEDURE: 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. 1. Remove spark plugs and clean with a penknife or use a wire brush and solvent. NOTE: The engine flywheel must rotate at 350 rpm (or higher) to obtain a good test of the solid state ignition system.
SECTION 4.4 PART 4 DIAGNOSTIC TESTS 3. Crank the engine until there is no further increase in pressure. DC CONTROL other test lead to a clean frame ground. INFINITY should be measured. 4. Record the highest reading obtained. 5. Reconnect the J1 connector to the circuit board. 5. Repeat the procedure for the remaining cylinder and record the highest reading. 6. Set a VOM to measure resistance. Connect one test lead to Wire 18 from the control panel.
DC CONTROL PART 4 SECTION 4.4 DIAGNOSTIC TESTS Figure 25. Diode Failure Diagnosis 11.Connect the positive (+) test lead to Connector ”A” (as shown in Figure 26). Connect the negative (-) test lead to Connector “B.” Figure 23. Setting Ignition Magneto (Armature) Air Gap 7. Repeat Test 55 and check for spark across the spark tester gap. 8. If air gap was not out of adjustment, test ground wires. a. If meter “Beeps” once and displays voltage drop, then the diode is good. b.
SECTION 4.4 DIAGNOSTIC TESTS PART 4 DC CONTROL 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.
DC CONTROL SECTION 4.4 PART 4 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 CONTINUITY. 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 LOP switch. 6. Set a VOM to it’s “R x 1” scale.
SECTION 4.4 PART 4 DIAGNOSTIC TESTS 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. DC CONTROL stud with the allen wrench and tighten the rocker arm jam nut. Torque the jam nut to 174 inch pounds.
DC CONTROL SECTION 4.4 PART 4 5. 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. DIAGNOSTIC TESTS 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 Figure 30 DISCUSSION: The battery charging system is a two amp trickle charge.
SECTION 4.4 PART 4 DIAGNOSTIC TESTS 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. DC CONTROL RESULTS: 1.
DC CONTROL SECTION 4.4 PART 4 DIAGNOSTIC TESTS RESULTS: 1. Replace the battery charge relay if it fails any of the steps in this chart. 2. If the BCR tests good, but still does not function during generator operation, check Wire 14 and Wire 0 connected to the BCR. 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.
SECTION 4.4 PART 4 DIAGNOSTIC TESTS DC CONTROL 5. Connect 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. If 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 Figure 34.
DC CONTROL SECTION 4.4 PART 4 DIAGNOSTIC TESTS RESULTS: 3. Set a VOM to measure AC voltage. 1. If CONTINUITY is not measured in Step 5, repair or replace Wire 66A between Connector C2 and Connector J1 at the circuit board. 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. 2.
SECTION 4.4 PART 4 DIAGNOSTIC TESTS DC CONTROL 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. 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. 7. Connect one meter test lead to Wire 351 (previously removed from SW2).
DC CONTROL J1-4, Wire 194 If CONTINUITY was measured, go to Step 4. Average nominal resistance 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 J1-7, Wire 14 SECTION 4.4 PART 4 If CONTINUITY was measured, repair or replace shorted to ground Wire 15A between Connector J1 and switch SW1. If CONTINUITY was measured, go to Step 6.
SECTION 4.4 DIAGNOSTIC TESTS 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 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.
TABLE OF CONTENTS PART PART 5 OPERATIONAL TESTS Air-cooled, Prepackaged Automatic Standby Generators Models: 6 kW NG, 7 kW LP 12 kW NG, 12 kW LP 13 kW NG, 15 kW LP 5.
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: • Manual transfer switch operation. • System voltage tests. • 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.
OPERATIONAL TESTS AND ADJUSTMENTS PART 5 using the means provided (such as a utility main line circuit breaker). DANGER THE TRANSFER SWITCH IS NOW ELECTRICALLY “HOT.” CONTACT WITH “HOT” PARTS WILL RESULT IN EXTREMELY HAZARDOUS AND POSSIBLY FATAL ELECTRICAL SHOCK. PROCEED WITH CAUTION. SECTION 5.1 SYSTEM FUNCTIONAL TESTS 13.Set the generator Auto-Off-Manual switch to OFF. The engine should shut down.
SECTION 5.1 SYSTEM FUNCTIONAL TESTS 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.
TABLE OF CONTENTS PART 6.
SECTION 6.1 MAJOR DISASSEMBLY PART 6 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. Remove door. 2. 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. 3. Remove Control Panel Cover: Using a 10 mm socket, remove the control panel cover.
DISASSEMBLY PART 6 SECTION 6.1 MAJOR DISASSEMBLY 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 5. Rear Bearing Carrier Removed 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.
SECTION 6.1 MAJOR DISASSEMBLY PART 6 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.
TABLE OF CONTENTS DWG # PART 7 ELECTRICAL DATA Air-cooled, Prepackaged Automatic Standby Generators Models: 6 kW NG, 7 kW LP 12 kW NG, 12 kW LP 13 kW NG, 15 kW LP 0D9014-B 0D9015-B 0D9016-B 0D9017-B 0E7687A 0E7815A 0E7687 0E7815 TITLE WIRING DIAGRAM, 7 KW HSB SCHEMATIC, 7 KW HSB WIRING DIAGRAM, 12 & 15 KW HSB SCHEMATIC, 12 & 15 KW HSB WIRING DIA., 8 CIRCUIT LOAD CENTER SCHEMATIC, 8 CIRCUIT LOAD CENTER WIRING DIA., 10/12 CIRC. LOAD CENTER SCHEMATIC, 12/12 CIRC.
WIRING DIAGRAM, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA DRAWING #0E9014 (1 OF 2) DIAGRAM KEY BA - BRUSH ASSEMBLY BCR - BATTERY CHARGE RELAY CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL D - DIODE DSW - PCB MOUNTED DIP SWITCH FS - FUEL SOLENOID F1 - FUSE 15 AMP F2 - FUSE 7.
WIRING DIAGRAM, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA DRAWING #0E9014 (2 OF 2) CONTROL PANEL BOX 225 224 224A 225A 224A 225A TX 4 BCR CB2 STATOR N1 9 N2 66 13 162 77 2 224B 0 225B 224B 14 4 0 4 66 14 4 11 11 1 2 8 6 7 11 1 6 2 0 9 11 6 22 55 66A 22 13 225 4 4 0 0 66A 11 3 44 6 162 N1 224 66 4 0 6 N2 77 0 162 1 77 55 VOLTAGE REGULATOR C2 66A 4 22 33 22 33 0 0 0 4 44 4 0 0 0 11 55 N1 1 0 13 225 0 224 GRD 0 0 0 G 0 0 351 194
SCHEMATIC, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA DRAWING #0E9015 (1 OF 2) 11 1 11 1 22 0 3 225A 224A 1 11 22 0 22 225A BATTERY CHARGER 13 224A 225 225B 13 224B 2 1 225A 224 9 1 3 224A 13 77 C2-1 77 BCR 66 0 14 13 BATTERY CHARGE WINDING 77 66 C2-2 0 0 0 C2-4 55 11 1 BA 0 22 ELECTRONIC VOLTAGE REGULATOR FIELD HTO 0 0 LOP ENGINE RUN WINDING (STATOR) 0 C2-9 4 0 SW2 C1-4 14 C1-3 C2-3 4 4 0 66A 0 23 6 162 194 C2-11 6 CB2 0 C2-7 C2-8 351 85 86 225
SCHEMATIC, 7 KW HOME STANDBY PART 7 ELECTRICAL DATA DRAWING #0E9015 (2 OF 2) 11 1 11 1 C2-6 22 22 C2-5 TX N2 2 225A N1 1 56VA N2 UTILITY INPUT N2 224A 225 N1 12Vdc TRANSFER RELAY COIL 23 1VA 194 N1 1 224 + F1 F2 15B 15 22 15 11 CUSTOMER CONNECTIONS 15 12VDC ACCESSORY SOCKET 13 0- 13 23 194 22 13 N 17 22 15 0 33 17 0 13 15A 15 15 120V POWER WINDING (STATOR) SW1 120V N 239 44 CB1 23 11 1 194 11 1 239 240V N G G CB3 15 13 RED L C1-2 15A 17 15 S
WIRING DIAGRAM, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA DRAWING #0E9016 (1 OF 2) DIAGRAM KEY ENGINE WIRING BCR - BATTERY CHARGE RELAY CB1 - MAIN OUTPUT BREAKER CB3 D DSW FS - 3 2 1 BATTERY CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL DIODE PCB MOUNTED DIP SWITCH FUEL SOLENOID CHARGER F2 - FUSE 7.
WIRING DIAGRAM, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA DRAWING #0E9016 (2 OF 2) 225 224 CONTROL PANEL BOX 224A 225A 224A 225A CLOSEST TO BEARING TX BCR B CB2 4 N1 0 N2 13 66 0 224B 224B 225B 225B STATOR 162 77 2 4 2 66 14 6 0 2 14 4 0 13 0 N2 N1 225 6 22 11 11 1 11 1 6 22 22 22 5 4 4 0 0 77 66 6 162 77 66 11 44 1 0 VOLTAGE REGULATOR 66A 4 0 55 3 6 162 224 11 8 0 55 C2 0 66A 0 0 0 0 33 55 4 0 0 0 0 22 N1 1 13 15 GRD 0 0 351 1 0
SCHEMATIC, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA DRAWING #0E9017 (1 OF 2) 11 1 11 1 22 22 225A 3 225A 224A 1 BATTERY CHARGER 13 11 224A 225 225B 13 224B 2 1 224 7 9 7 1 0 6 9 3 BCR 4 13 13 0 77 C2-1 77 0 0 BATTERY CHARGE WINDING 66 66 22 0 0 HTO C2-11 11 1 4 0 0 FIELD 0 LOP ENGINE RUN WINDING (STATOR) 0 C2-9 C2-10 4 0 55 BA 22 ELECTRONIC VOLTAGE REGULATOR 13 14 SW2 C1-4 14 C2-3 C1-3 15A 4 0 66A 0 85 6 162 23 86 C1-6 6 CB2 C2-8 13 194
SCHEMATIC, 12 & 15 KW HOME STANDBY PART 7 ELECTRICAL DATA DRAWING #0E9017 (2 OF 2) 11 1 C2-6 22 C2-5 TX 225A N2 240VAC UTILITY INPUT N1 1 56VA N2 N2 224A 225 N1 12Vdc TRANSFER RELAY COIL 23 1VA 194 224 N1 + - 0 12VDC ACCESSORY SOCKET 194 23 15B 11 CUSTOMER CONNECTIONS 22 13 22 17 13 0 15B N F1 15 F2 22 15 33 0 15 15A SW1 15A 15 120V POWER WINDING 239 120V N 17 15 44 23 23 194 194 11 CB 11 1 13 0 11 239 239 14 14 N 240V CB3 15 0 13 17 L RED C2-1
WIRING DIAGRAM, 8 CIRCUIT LOAD CENTER DRAWING #0E7687A Page 138 PART 7 ELECTRICAL DATA
SCHEMATIC, 8 CIRCUIT LOAD CENTER PART 7 ELECTRICAL DATA DRAWING #0E7815A E1 1 N1A 194 194 23 23 9 E1 6 N1A 126 194 12Vdc TRANSER COIL 194 A 23 TR TS TO GENERATOR CONTROL PANEL OPEN B 23 F2 205 N2A N2 N2 N1 1 N1 E1 1 BLACK E2 RED 240VAC OUTPUT F1 N1A N1A N1A E1 1 E1 E2 B NEUTRAL CONNECTION INSIDE SWITCH NEUTRAL (WHITE) NEUTRAL (WHITE) N2A 126 B RED (MAIN 2) 205 N1A N2A TO GENERATOR OUTPUT CIRCUIT BREAKER 240VAC TO MAIN DISTRIBUTION PANEL BLACK (MAIN 1) E1 1 NO N
WIRING DIAGRAM, 10 & 12 CIRCUIT LOAD CENTER DRAWING #07687 Page 140 PART 7 ELECTRICAL DATA
SCHEMATIC, 10 & 12 CIRCUIT LOAD CENTER PART 7 ELECTRICAL DATA DRAWING #0E7815 E1 N1A 194 194 23 23 9 E1 6 N1A 126 194 12Vdc TRANSER COIL 194 A 23 TR TS TO GENERATOR CONTROL PANEL OPEN B 23 F2 205 N2A N2 N2 N1 N1 E1 BLACK E2 RED 240VAC OUTPUT F1 N1A N1A N1A E1 E1 E2 B NEUTRAL CONNECTION INSIDE SWITCH NEUTRAL (WHITE) NEUTRAL (WHITE) N2A 126 B RED (MAIN 2) 205 N1A N2A TO GENERATOR OUTPUT CIRCUIT BREAKER 240VAC TO MAIN DISTRIBUTION PANEL BLACK (MAIN 1) E1 NO NC NC
NOTES Page 142 PART 7 ELECTRICAL DATA
ELECTRICAL FORMULAS TO FIND KNOWN VALUES 1-PHASE 3-PHASE KILOWATTS (kW) Volts, Current, Power Factor ExI 1000 E x I x 1.73 x PF 1000 KVA Volts, Current ExI 1000 E x I x 1.73 1000 AMPERES kW, Volts, Power Factor kW x 1000 E kW x 1000 E x 1.73 x PF WATTS Volts, Amps, Power Factor Volts x Amps E x I x 1.73 x PF NO. OF ROTOR POLES Frequency, RPM 2 x 60 x Frequency RPM 2 x 60 x frequency RPM FREQUENCY RPM, No. of Rotor Poles RPM x Poles 2 x 60 RPM x Poles 2 x 60 RPM Frequency, No.
Part No. 0F4676 Revision * (02/25/05) Catalog No. DMASPAS.07.1 Printed in U.S.A.
