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Generac Power Systems
Portable Generator
7 kW NG
Generac Power Systems 7 kW NG User Manual
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APPENDIX A
SUPPLEMENT
AL
W
ORKSHEETS
Air
-cooled,
A
utomatic
Standb
y Generators
P
age 193
T
ABLE OF CONTENTS
PA
R
T
TITLE
PA
G
E
T
est 4 Results
194
T
est 7 Results
195
T
est 66 Results
196
Generator Failure Anal
ysis
197
194
196
Table of Contents
Default Chapter
3
Table of Contents
3
Specifications
6
Generator
6
Engine
7
Fuel Consumption
7
Mounting Dimensions
8
Major Features
10
PART 1 - General Information
11
Section 1.1 - Generator Basics
12
Introduction
12
Parts
12
Generator Identification
12
Section 1.2 - Installation Basics
13
Introduction
13
Selecting a Location
13
NFPA 37 Code Requirements
13
Grounding the Generator
13
The Fuel Supply
13
Natural Gas Fuel Interconnections
16
Transfer Switch / Load Center
16
Power Source and Load Lines
16
System Control Interconnections
17
Section 1.3 - Preparation before Use
18
Introduction
18
Reconfiguring the Fuel System
19
Section 1.4 - Measuring Electricity
21
Meters
21
The vom
21
Measuring AC Voltage
21
Measuring DC Voltage
21
Measuring AC Frequency
21
Measuring Current
22
Measuring Resistance
22
Electrical Units
23
Ohm's Law
23
Section 1.5 - Testing, Cleaning and Drying
24
Visual Inspection
24
The Megohmmeter
24
Cleaning the Generator
25
Drying the Generator
25
Section 1.6 - Operating Instructions
27
Control Panel
27
User Interface
27
To Select Automatic Operation
28
Manual Operation
28
Section 1.7 - Automatic Operating Parameters
29
Introduction
29
Utility Failure
29
Cranking
29
Cranking Conditions
29
Load Transfer Parameters
29
Utility Restored
30
Section 1.8 - General Maintenance
31
Introduction
31
Maintenance Message
31
Air Filter
31
Spark Plugs
31
Visual Inspection
31
Corrosion Protection
32
Valve Clearance
32
Battery
32
Section 1.9 - Wireless Remote
34
Wireless Monitor
34
Wireless Basic Troubleshooting
34
Wireless Advanced Module
35
Wireless Advanced Features
35
Wireless Advanced Troubleshooting
35
Section 1.10 - Control Panel Menu System Navigation
37
Main Menu
37
High Temperature
39
Section 1.11 - General Troubleshooting Guidelines
40
Introduction
40
Recommended Tools
40
Troubleshooting Reminders and Tips
40
Important Note Concerning Connectors
40
PART 2 - AC Generators
41
Section 2.1 - Description and Components
42
Introduction
42
Engine-Generator Drive System
42
Alternator Assembly
42
Other AC Generator Components
42
Section 2.2 - Operational Analysis
44
Rotor Residual Magnetism
44
Field Boost
44
Operation
44
Section 2.3 - Troubleshooting Flowcharts
46
Introduction
46
For Under-Voltage
46
Problem 1 - Generator Shuts down
46
For High Voltage
47
Excessively When Loads Are Applied
48
Problem 4 - Unstable Voltage or Incorrect Output Which Is Not Triggering a Shutdown
48
Problem 3 - Voltage and Frequency Drop
48
Section 2.4 - Diagnostic Tests
49
Introduction
49
Safety
49
AC Troubleshooting
49
Test 1 - Check AC Output Voltage
49
Test 3 - Calibrate Voltage
50
Rotor Amp Draw Test
50
Test 4 - Fixed Excitation Test
50
Test 5 - Test Sensing Circuitwires 11 and 44
53
Diagnostic Tests
53
Test 6 - Test Excitation Windingcircuit 2 and 6
54
Test 7 - Test the Stator with a vom
54
Test 8 - Resistance Check of Rotor Circuit
56
Test 9 - Check Brushes and Slip Rings
56
Test 10 - Test Rotor Assembly
57
Test 11 - Check AC Output Frequency
57
Test 12 - Check Stepper Motor Control
58
Test 14 - Check Voltage and Frequency under Load
59
Test 15 - Check for an Overload Condition
59
Test 16 - Check Engine Condition
59
PART 3 - Transfer Switch
61
Section 3.1 - Description and Components
62
Introduction
62
Enclosure
62
Transfer Switch Contactor
63
Transfer Relay
63
Neutral Lug
64
Manual Transfer Handle
64
Customer Connections
64
Fuse Holder
65
Section 3.2 - Operational Analysis
66
Utility Source Voltage Available
66
Utility Source Voltage Failure
67
Transferring to Standby
68
Transferred to Standby
69
Utility Restored
70
Utility Restored, Transferring Back to Utility
71
Utility Restored, Transferred Back to Utility
72
Transferred Back to Utility, Generator Shutdown
73
Section 3.3 - Troubleshooting Flowcharts
75
Introduction
75
No Transfer to Standby
75
Problem 10 - Blown T1 Fuse
76
Problem 9 - Blown F1 or F2 Fuse
76
Standby During Exercise or in Manual Mode with Utility Available
76
Utility Power Is Available
76
Problem 9 - Blown F1 or F2 Fuse
77
Problem 10 - Blown T1 Fuse
77
Section 3.4 - Diagnostic Tests
78
Introduction
78
Safety
78
Transfer Switch Troubleshooting
78
Test 20 - Check Voltage at Terminal Lugs E1 and E2
78
Test 21 - Check Manual Transfer
79
Switch Operation
79
Test 22 - Check 23 and 194 Circuit
80
Test 23 - Test Transfer Relay
81
Test 24 - Test Standby Control Circuit
81
Test 25 - Check Wire 23
83
Test 26 - Utility Control Circuit
85
Test 27 - Test Limit Switches
85
Test 28 - Check Fuses F1 and F2
86
Test 29 - Check Fuse F3
86
Test 30 - Check Main Circuit Breaker
86
Test 32 - Check N1 and N2 Wiring
87
Test 33 - Check N1 and N2 Voltage
87
Test 34 - Check Utility Sensing Voltage
88
At the Circuit Board
88
Test 35 - Check Utility SENSE Voltage
88
Test 36 - Check T1 Wiring
88
PART 4 - Engine/DC Control
91
Section 4.1 - Description and Components
92
Introduction
92
Customer Connection
92
Controller
92
LED Display
92
Battery Charger
92
7.5 Amp Fuse
93
Starter Contactor Relay/Solenoid
93
Common Alarm Relay
94
Connector Pin Descriptions
94
Menu System Navigation
95
Section 4.2 - Engine Protective Devices
96
Introduction
96
Low Battery Warning
96
Low Oil Pressure
96
High Temperature Switch
96
Overspeed
96
RPM Sensor Failure
96
Overcrank
96
Under-Frequency
97
Clearing an Alarm
97
Section 4.3 - Operational Analysis
98
Introduction
98
Utility Source Voltage Available
98
Initial Dropout of Utility Source Voltage
100
Utility Voltage Failure and Engine Cranking
102
Engine Startup and Running
104
Transfer to Standby
106
Utility Voltage Restored and Re-Transfer to Utility
108
Engine Shutdown
110
Section 4.4 - Troubleshooting Flowcharts
112
Problem 14 - Engine will Not Crank
112
When Utility Voltage Fails
112
Problem 15 - Engine will Not Crank When
112
AUTO-OFF-MANUAL Switch
112
Is Set to MANUAL
112
Problem 16 - Engine Cranks but will Not Start
113
Problem 17 - Engine Starts Hard and Runs
114
Rough / Lacks Power / Backfires
114
Problem 18 - Shutdown Alarm/Fault Occurred
115
Problem 19 - 7.5 Amp Fuse (F1) Blown
116
Problem 20 - Generator will Not Exercise
116
Problem 21 - no Low Speed Exercise
116
Problem 22 - Battery Is Dead
116
Section 4.5 - Diagnostic Tests
117
Introduction
117
Safety
117
Engine/DC Troubleshooting
117
Test 40 - Check Position of AUTO-OFF-MANUAL Switch
117
AUTO-OFF-MANUAL Switch
117
Test 41 - Try a Manual Start
118
Test 42 - Test the AUTO-OFF-MANUAL Switch
118
Test 43 - Test Auto Operations of Controller
118
Test 44 - Check 7.5 Amp Fuse
119
Test 45 - Check Battery
119
Test 46 - Check Wire 56 Voltage
120
Test 47 - Test Starter Contactor Relay
121
(V-Twin Only)
121
Test 48 - Test Starter Contactor
121
Test 49 - Test Starter Motor
122
Test 50 - Check Fuel Supply and Pressure
124
Test 51 - Check Controller Wire 14 Outputs
125
Test 52 - Check Fuel Solenoid
126
Test 53 - Check Choke Solenoid
127
Test 55 - Check for Ignition Spark
129
Test 57 - Check Condition of Spark Plugs
130
Test 58 - Check Engine / Cylinder Leak down Test / Compression Test
131
Test 59 - Check Shutdown Wire
132
Test 60 - Check and Adjust Ignition Magnetos
133
Test 61 - Check Oil Pressure Switch and Wire 86
135
Test 62 - Check High Oil Temperature Switch
136
Test 63 - Check and Adjust Valves
137
Test 64 - Check Wire 18 Continuity
137
Ready to Run
138
Test 65 - Test Exercise Function
138
Test 66 - Test Cranking and Running Circuits
139
Test 67 - Test Run Circuit
139
Test 68 - Test Crank Circuit
140
Function Is Enabled
141
Speed Function Is Enabled
141
Test 69 - Test TRANSFER RELAY Circuit
141
Test 70 - Check to See if Low Speed
141
Test 71 - Check Operation of the Choke Solenoid
141
Of the Controller
142
Test 75 - Test 120 Volt Input (T1)
142
Test 76 - Verify DC Voltage Output of the Controller
142
Test 77 - Check Wire 13 and Wire 0
142
Test 78 - Test DC Charge Current to the Battery
142
Test 79 - Check T1 Voltage at Customer Connections
143
Test 80 - Check T1 Voltage at J5 Connector
143
Test 81 - Check T1 Voltage in Transfer Switch
143
Test 82 - Test F3 Fuse Circuit
144
PART 5 - Operational Tests
145
Section 5.1 - System Functional Tests
146
Introduction
146
Manual Transfer Switch Operation
146
Electrical Checks
146
Generator Tests under Load
147
Checking Automatic Operation
148
Section 5.2 - Setup Procedures
149
Setting the Exercise Time
149
Activation Process
149
Activation Chart
150
PART 6 - Disassembly
151
Section 6.1 - Major Disassembly
152
Front Engine Access
152
Major Disassembly
156
Torque Requirements
162
PART 7 - Electrical Data
177
Wiring Diagram, 8 Kw Home Standby
178
Electrical Schematic, 8 Kw Home Standby
180
Wiring Diagram, 10-14 Kw Home Standby
181
Electrical Schematic, 10-14 Kw Home Standby
182
Electrical Schematic, 17 Kw Home Standby
184
Wiring Diagram, 17 Kw Home Standby
186
Electrical Schematic, 20 Kw Home Standby
188
Electrical Schematic, Home Standby Transfer Switch
190
Wiring Diagram, Home Standby Transfer Switch
192
Electrical Formulas
194
Appendix A Supplemental Worksheets
195
Appendix B Index of Figures and Tables
205
Index of Figures
206
Index of Tables
207
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Generac Power Systems 7 kW NG Specifications
General
Brand
Generac Power Systems
Model
7 kW NG
Category
Portable Generator
Language
English
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