PART 4
DC CONTROL
Air-cooled, Prepackaged
Automatic Standby Generators
Page 75
4.1 Description and Components ...............................................76
General 76
Terminal Strip / Interconnection Terminal ............................ 76
Transfor mer (TX) ................................................................. 76
Circuit Board ....................................................................... 76
AUTO-OFF-MANUAL Switch .............................................. 80
15 Amp Fuse ...................................................................... 80
4.2 Operational Analysis ............................................................. 82
Introduction ......................................................................... 82
Utility Source Voltage Available ........................................... 82
Initial Dropout Of Utility Source Voltage .............................. 84
Utility Voltage Dropout And
Engine Cranking ................................................. 86
Engine Startup And Running .............................................. 88
Initial Transfer To The “Standby” Source ............................. 90
Utility Voltage Restored /
Re-transfer To Utility ............................................ 92
Engine Shutdown .............................................................. 94
4.3 Troubleshooting Flow Charts ................................................96
Problem 8 - Engine Will Not Crank
When Utility Power Source Fails ......................... 96
Problem 9 - Engine Will Not Crank
When AUTO-OFF-MANUAL Switch
is Set to "MANUAL" ............................................. 96
Problem 10 - Engine Cranks
but Won't Start..................................................... 97
Problem 11 - Engine Starts Hard and
Runs Rough / Lacks Power .................................98
Problem 12 - Engine Starts and Runs,
Then Shuts Down ...............................................99
Problem 13 - No Battery Charge ...................................... 100
Problem 14 - Unit Starts and Transfer Occurs
When Utility Power is Available ........................101
Problem 15 - Generator Starts
Immediately in Auto - No Transfer to
Standby. Utility Voltage is Present ..................... 101
Problem 16 - 15 Amp Fuse (F1) Blown............................. 102
Problem 17 - Generator Will Not Exercise ........................ 102
Problem 18 - No Low Speed Exercise .............................. 102
4.4 Diagnostic Tests .................................................................. 103
Introduction ..................................................................... 103
Test 41 - Check Position Of
AUTO-OFF-MANUAL Switch .......................... 103
Test 42 - Try A Manual Start ........................................... 103
Test 43 - Test AUTO-OFF-MANUAL Switch .................... 103
Test 44 - Check Wire 15/15A/15B/239/0
Voltage .............................................................. 104
Test 45 - Check 15 Amp Fuse .......................................... 105
Test 46 - Check Battery ................................................... 105
Test 47 - Check Wire 56 Voltage ...................................... 106
Test 48 - Test Starter Contactor Relay
(V-twin Only)...................................................... 106
Test 49 - Test Starter Contactor ........................................ 106
Test 50 - Test Starter Motor .............................................. 107
Test 51 - Check Fuel Supply
And Pressure .................................................... 109
Test 52 - Check Circuit Board
Wire 14 Output .................................................. 110
Test 53 - Check Fuel Solenoid .......................................... 111
Test 54 - Check Choke Solenoid
(V-twins Units Only)........................................... 112
Test 55 - Check For Ignition Spark.................................... 113
Test 56 - Check Spark Plugs ............................................ 114
Test 57 - Check Engine / Cylinder Leak Down
Test / Compression Test ......... 114
Test 58 - Check Shutdown Wire ........................................ 115
Test 59 - Check And Adjust
Ignition Magnetos .............................................. 116
Test 60 - Check Oil Pressure Switch
And Wire 86 ...................................................... 117
Test 61 - Check High Oil
Temperature Switc
h .......................................... 118
Test 62 - Check And Adjust Valves ...................................119
Test 63 - Check Fuel Regulator
(7 Kw Natural Gas Units Only)
.......................... 117
Test 64 - Check Batter y Charge Output ............................ 120
Test 65 - Check Transformer (TX)
Voltage Output .................................................. 118
Test 66 - Check AC Voltage At
Battery Charger................................................. 121
Test 67 - Check Battery Charge
Relay (BCR) ...................................................... 122
Test 68 - Check Battery Charge
Winding Harness............................................... 122
Test 69 - Check Battery Charger Wiring .......................... 123
Test 70 - Check Wire 18 Continuity ................................... 123
Test 71 - Check N1 And N2 Voltage ..................................123
Test 72 - Check Utility Sensing Voltage
At The Circuit Board .......................................... 124
Test 73 - Test Set Exercise Switch .................................... 124
Test 75 - Check Battery Voltage Circuit ............................ 124
Test 76 - Check Cranking And
Running Circuits ................................................ 124
Test 77 - Test Exercise Function .......................................126
Test 78 - Check Dip Switch Settings ................................. 126
Test 79 - Check Idle Control Transformer
(V-twin Units Only) ............................................ 126
Test 80 - Check LC1 & LC2 Wiring ................................... 126
Test 81 - Check Idle Control Transformer
Primary Wiring .................................................. 127
TABLE OF CONTENTS
PART TITLE PAGE#
4.1. Description and Components 76
4.2 Operational Analysis 82
4.3 Troubleshooting Flow Charts 96
4.4 Diagnostic Tests 103
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