TP-6322 9/04 21Section 4 Troubleshooting
Exerciser Circuit Troubleshooting
1. Disconnect all power sources.
2. Disconnect the exerciser switch from connector P2
on the controller assembly.
3. Check the exerciser switch wiring harness for
loose, dirty, or corroded connections.
4. Check that connector J2 is wired to the correct
terminals on the exerciser switch according to
Figure 4-4.
5. Check the exerciser switch c ontinuity. If any of
these continuity readings is wrong, replace the
damaged exerciser switch.
a. Place the exerciser switch in the Enable
position and check for open circuits between
terminals J2-2 to J2-1 and J2-3.
b. Toggle the exerciser switch to the momentary
Set position and check that terminals J2-1 and
J2-2 are connected and terminals J2-2 to J2-3
are not connected.
c. Toggle the exerciser switch to the Disable
position and check that terminals J2-2 and J2-3
are connected and the terminals J2-1 to J2-2 is
are not connected.
6. See Sections 4.5 and 4.8 first, to verify that the
transfer switch is starting the generator set and the
ES LED c orrectly reflects the engine-start contact
status in the automatic operation sequence.
7. If the switch is correctly wired, and the switch
operates correctly, reconnect J2 to P2.
8. Review the instructions for exerciser operation. If
the exerciser is still not operating properly, replace
the controller assembly.
4.7 Contactor Operation
Follow this section when the switch fails to transfer or
transfers improperly when one source fails and the other
source is available and is indicated by the
corresponding source-available LED.
There may be both mechanical and electrical causes of
contactor operation problems. If the contactor is
binding, the contactor solenoid TS and other
components could be damaged.
4.7.1 Mechanical Check
Manually operate the contactor to check that it operates
smoothly without binding. If it does not, clean and
relubricate the contactor. See Section 3.1.2. Replace
the contactor assembly if cleaning or relubrication does
not solve the binding problem.
If the contactor assembly was replaced, check the
solenoid on the damaged contactor assembly before
reapplying power. See Section 4.7.5. If the solenoid
was damaged, follow the instructions in Section 4.7.3 to
check other system components not replaced with the
contactor assembly for damage.
4.7.2 Solenoid Troubleshooting
The solenoid coils on model G220 switches require
120 VAC for operation. The rectifier is sealed inside the
coil assembly and not accessible for testing. Refer to
Section 4.7.5 for instructions to check the coil voltage
and operation.
4.7.3 After Solenoid Replacement
A contactor solenoid is not designed to operate
continuously. When operated continuously the solenoid
coil windings first tend to short circuit, then eventually
burn up, and the solenoid becomes an open circuit.
Therefore, a damaged solenoid most likely indicates
that the contactor was mechanically binding or that
something in the control circuit failed and allowed the
solenoid to operate over a longer period than it should.
After Solenoid Replacement
1. Check that the contactor operates freely without
binding.
2. Check the coil-clearing contacts (SCN and SCE).
See Section 4.7.4.
3. Visually check other components for evidence of
overheating (discolored metal, burning odor or
melted plastic) and replace damaged components.
Check the wiring, coil-clearing contacts, bridge
rectifier BR, NR and ER relay contacts, and the
controller assembly.
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