Document Outline

• Back to Main Menu
• Electrical Formulas
• Contents
• SPECIFICATIONS
  • Generator
  • Engine
  • Fuel Consumption
  • Mounting Dimensions
  • Major Features
• PART 1 - GENERAL INFORMATION
  • 1.1 Generator Identification
  • 1.2 Installation Basics
    • Introduction
    • Selecting A Location
    • Grounding The Generator
    • The Fuel Supply
    • The Transfer Switch / Load Center
    • Power Source And Load Lines
    • System Control Interconnections
    • Natural Gas Fuel Interconnections
  • 1.3 Non-prepackaged Interconnections
    • Connect a Pre-2008 Load Center SwitchTo a Current or FutureAir-Cooled Generator
    • Connect a 2008 And Later Load CenterSwitch to a Pre-2008Air-Cooled Generator
  • 1.4 Preparation Before Use
    • General.
    • Fuel Requirements
    • Fuel Consumption
    • Reconfiguring The Fuel System
    • Engine Oil Recommendations
  • 1.5 Testing, Cleaning and Drying
    • Meters
    • The Vom
    • Measuring AC Voltage
    • Measuring DC Voltage
    • Measuring AC Frequency
    • Measuring Current
    • Measuring Resistance
    • Electrical Units
    • Ohm’s Law
    • Visual Inspection
    • Insulation Resistance
    • The Megohmmeter
    • Stator Insulation Resistance Test (12-20 kW)
    • Stator Insulation Resistance Test (8-10 kW)
    • Rotor Insulation Resistance Test (8-10 kW)
    • Rotor Insulation Resistance Test (12-20 kW)
    • Cleaning The Generator
    • Drying The Generator
  • 1.6 Engine-Generator Protective Devices
    • General.
    • Low Battery
    • Low Oil Pressure Shutdown
    • High Temperature Switch
    • Overspeed Shutdown
    • Rpm Sensor Failure
    • Overcrank Shutdown
  • 1.7 Operating Instructions
    • Control Panel
    • To Select Automatic Operation
    • Manual Transfer To “Standby”and Manual Startup
    • Manual Shutdown AndRetransfer Back To “Utility”
  • 1.8 Automatic Operating Parameters
    • Introduction
    • Automatic Operating Sequences
• PART 2 - AC GENERATORS
  • 2.1 Description and Components
    • Introduction
    • Engine-Generator Drive System
    • The AC Generator
    • Rotor Assembly
    • Stator Assembly
    • Brush Holder And Brushes (12-20 kW)
    • Other AC Generator Components
  • 2.2 Operational Analysis
    • Rotor Residual Magnetism
    • Field Boost (12-20 kW)
    • Operation (8/10 kW)
    • Operation (12-20 kW)
  • 2.3 Troubleshooting Flowcharts
    • Problem 1 – Generator Produces ZeroVoltage or Residual Voltage (12-20 kW)
    • Problem 2 – Generator Produces ZeroVoltage or Residual Voltage (8/10 kW)
    • Problem 3 – Generator ProducesLow Voltage at No-Load
    • Problem 4 – Generator ProducesHigh Voltage at No-Load
    • Problem 5 – Voltage and Frequency DropExcessively When Loads are Applied
  • 2.4 Diagnostic Tests
    • Introduction
    • Safety
    • Test 1 – Check Main Circuit Breaker
    • Test 2 – Check AC Output Voltage
    • Test 4 – Fixed Excitation Test/RotorAmp Draw Test
    • Test 5 – Wire Continuity (12-20 kW)
    • Test 6 – Check Field Boost (12-20 kW)
    • Test 7 – Testing The Stator With A Vom(12-20 kW)
    • Test 8 – Test Brushless Stator
    • Test 9 – Check Capacitor
    • Test 10 – Test DPE Winding onBrushless units
    • Test 11 – Resistance Check Of Rotor Circuit(12-20 kW)
    • Test 12 – Check Brushes And Slip Rings(12-20 kW)
    • Test 13 – Test Rotor Assembly(12-20 kW)
    • Test 14 – Check AC Output Frequency
    • Test 15 – Check and Adjust Engine Governor(Single Cylinder Units)
    • Test 16 – Check Stepper Motor Control(V-twin Engine Units)
    • Test 17 – Check And Adjust VoltageRegulator (12-20 kW)
    • Test 18 – Check Voltage And FrequencyUnder Load
    • Test 19 – Check For Overload Condition
    • Test 20 – Check Engine Condition
    • Test 21 – Field Flash Alternator (8-10 kW)
• PART 3 - TRANSFER SWITCH
  • 3.1 Description and Components
    • General
    • Enclosure
    • Transfer Mechanism
    • Transfer Relay
    • Neutral Lug
    • Manual Transfer Handle
    • Terminal Block
    • Fuse Holder
  • 3.2 Operational Analysis
    • Operational Analysis
    • Utility Source Voltage Available
    • Utility Source Voltage Failure
    • Transfer To Standby
    • Transfer To Standby
    • Utility Restored
    • Utility Restored, Transfer Switch De-energized
    • Utility Restored, Retransfer Back To Utility
    • Transfer Switch In Utility
  • 3.3 – Troubleshooting Flowcharts
    • Introduction To Troubleshooting
    • Problem 7 – In Automatic Mode,No Transfer to Standby
    • Problem 8 – In Automatic Mode, GeneratorStarts When Loss of Utility Occurs,Generator Shuts Down When UtilityReturns But There Is No Retransfer To UtilityPower / or Generator Transfers to StandbyDuring Exercise Or In Manual Mode
    • Problem 9 – Blown F1 or F2 Fuse
    • Problem 10 – Units Starts And TransferOccurs When Utility Power Is On
    • Problem 11 – No Battery Charge(Pre-Packed Load Center)
    • Problem 12 – No Battery Charge(RTSN & RTSE Transfer Switch)
    • Problem 13 – No Battery Charge(Gen-Ready Load Center)
    • Problem 14 – No Battery Charge(Load Shed Transfer Switch)
  • 3.4 Diagnostic Tests
    • General
    • Test 26 – Check Voltage atTerminal Lugs E1, E2
    • Test 27 – Check Manual Transfer SwitchOperation
    • Test 28 – Check 23 And 15BWiring/Connections
    • Test 29 – Test Transfer Relay TR
    • Test 30 – Standby Control Circuit
    • Test 31 – Check Wire 23
    • Test 32 – Utility Control Circuit
    • Test 33 – Test Limit Switch SW2 and SW3
    • Test 34 – Check Fuses F1 and F2
    • Test 35 – Check N1 and N2 Wiring
    • Test 36 – Check N1 and N2 Voltage
    • Test 37 – Check Utility Sensing Voltageat the Circuit Board
    • Test 38 – Check Utility Sense Voltage
    • Test 39 – Check Voltage atTerminal Lugs N1, N2
    • Test 40 – Check Battery Charger SupplyVoltage “Pre-Wire Load Center”
    • Test 41 – Check Battery Charger OutputVoltage “Pre-Wire Load Center”
    • Test 42 – Check Wire 0 and Wire15B“Pre-Wire Load Center”
    • Test 43 – Check Battery ChargerSupply Voltage“RTSN & RTSE Transfer Switch”
    • Test 44 – Check Battery ChargerOutput Voltage“RTSN & RTSE Transfer Switch"
    • Test 45 – Check Wire 0/“RTSN & RTSE Transfer Switch”
    • Test 46 – Check Battery ChargerSupply Voltage“GenReady Load Center"
    • Test 47 – Check Battery ChargerOutput Voltage“GenReady Load Center"
    • Test 48 – Check Wire 0/15B“GenReady Load Center"
    • Test 49 – Check Battery ChargerSupply Voltage“Load Shed Transfer Switch"
    • Test 50 – Check Battery ChargerOutput Voltage“Load Shed Transfer Switch"
    • Test 51 – Check Wire 0 and Wire 15B“Load Shed Transfer Switch"
• PART 4 - DC CONTROL
  • 4.1 Description and Components
    • General
    • Terminal Strip / Interconnection Terminal
    • Circuit Board
    • Auto-Off-Manual Switch
    • 7.5 Amp Fuse
    • Menu System Navigation
  • 4.2 Operational Analysis
    • Introduction
    • Utility Source Voltage Available
    • Initial Dropout of Utility Source Voltage
    • Utility Voltage Dropout andEngine Cranking
    • Engine Startup and Running
    • Initial Transfer to the “Standby” Source
    • Utility Voltage Restored /Re-transfer to Utility
    • Engine Shutdown
  • 4.3 Troubleshooting Flowcharts
    • Problem 15 – Engine Will Not CrankWhen Utility Power Source Fails
    • Problem 16 – Engine Will Not Crank WhenAUTO-OFF-MANUAL Switchis Set to “MANUAL
    • Problem 17 – Engine Cranksbut Won’t Start
    • Problem 18 – Engine Starts Hard andRuns Rough / Lacks Power / Backfires
    • Problem 19 – Shutdown Alarm /Fault Occurred
    • Problem 20 – 7.5 Amp Fuse (F1) Blown
    • Problem 21 – Generator Will Not Exercise
    • Problem 22 – No Low Speed Exercise
  • 4.4 Diagnostic Tests
    • Introduction
    • Test 56 – Check Position OfAuto-Off- Manual Switch
    • Test 57 – Try a Manual Start
    • Test 58 – Auto-Off-Manual Switch(V-Twin Only)
    • Test 59 – Test Auto Operations
    • Test 60 – Check 7.5 Amp Fuse
    • Test 61 – Check Battery
    • Test 62 – Check Wire 56 Voltage
    • Test 63 – Test Starter Contactor Relay(V-twin Only)
    • Test 64 – Test Starter Contactor(Single Cylinder Engine)
    • Test 65 – Test Starter Motor
    • Test 66 – Check Fuel Supply and Pressure
    • Test 67 – Check Circuit BoardWire 14 Output
    • Test 68 – Check Fuel Solenoid
    • Test 69 – Check Choke Solenoid
    • Test 70 – Check for Ignition Spark
    • Test 71 – Check Spark Plugs
    • Test 72 – Check Engine / Cylinder LeakDown Test / Compression Test
    • Test 73 – Check Shutdown Wire
    • Test 74 – Check and AdjustIgnition Magnetos
    • Test 75 – Check Oil Pressure Switchand Wire 86
    • Test 76 – Check High OilTemperature Switch
    • Test 77 – Check and Adjust Valves
    • Test 78 – Check Wire 18 Continuity
    • Test 79 – Test Exercise Function
    • Test 80 – Check Cranking andRunning Circuits
    • Test 81 – Check to see if Low SpeedFunction is enabled
    • Test 82 – Check operation of theChoke Solenoid
• PART 5 - OPERATIONAL TESTS
  • 5.1 System Functional Tests
    • Introduction
    • Manual Transfer Switch Operation
    • Electrical Checks
    • Generator Tests Under Load
    • Checking Automatic Operation
    • Setting The Exercise Timer
• PART 6 - DISASEMBLY
  • 6.1 Major Disassembly
    • Front Engine Access
    • Major Disassembly
    • Torque Requirements(Unless Otherwise Specified)
• PART 7 - ELECTRICAL DATA
  • Wiring Diagram, 8 kW Home Standby
  • Schematic, 8 kW Home Standby
  • Wiring Diagram, 10 kW Home Standby
  • Schematic, 10 kW Home Standby
  • Wiring Diagram, 14 kW Home Standby
  • Schematic, 14 kW Home Standby
  • Wiring Diagram, 17 kW Home Standby
  • Schematic, 17 kW Home Standby
  • Wiring Diagram, 20 kW Home Standby
  • Schematic, 20 kW Home Standby
  • Wiring Diagram, Home Standby Transfer Switch,9/10/12/16 Circuit
  • Schematic, Home Standby Transfer Switch,9/10/12/16 Circuit