Manuals / Generac Power Systems / Lawn and Garden / Portable Generator

Generac Power Systems 7 kW NG, 10 kW LP Harness END Remote Wireless Connection N1/N2 Connector

Models: 18 kW NG 14 kW LP 16 kW NG 20 kW LP 17 kW LP 8 kW LP 9 kW NG 7 kW NG 13 kW NG 10 kW LP

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Page 102

Section 4.1

Description and components

Part 4

DC control

18 17 16 15 14 13 12 11 10									4	3
9	8	7	6	5	4	3	2	1	2	1

J2 J1

18	17	16	15	14	13	12	11	10
9	8	7	6	5	4	3	2	1

J2 CONNECTOR

(PCB END)

4	3
2	1

J1 CONNECTOR

(PCB END)

J3

(STEPPER MOTOR)

3	4	10	11	12	13	14	15	16	17	18
1	2	1	2	3	4	5	6	7	8	9
J1 CONNECTOR				J2 CONNECTOR
(HARNESS END)				(HARNESS END)

1

2

	REMOTE WIRELESS CONNECTION	N1/N2 CONNECTOR	N1/N2 CONNECTOR
		(PCB END)	(HARNESS END)

Figure 6. 12/14 kW Printed Circuit Board and J1 Connector

12/14 kW J1 Connector Pin Descriptions

PIN	WIRE	CIRCUIT FUNCTION

J1-1	85	High temperature shutdown:
		Shutdown occurs when Wire 85 is
		grounded by contact closure in HTO

J1-2	86	Low oil pressure shutdown: Shutdown
		occurs when Wire 86 is grounded by
		loss of oil pressure to the LOP

J1-3	13	12 VDC source voltage for the circuit
		board

J1-4	18	Ignition Shutdown: Circuit board
		action grounds Wire 18 for ignition
		shutdown.

J2-1		INTERNAL USE ONLY

J2-2		INTERNAL USE ONLY

J2-3	14	12 VDC output for engine run condi-
		tion. Used for fuel solenoid and choke
		solenoid operation.

J2-4	817	Grounded by printed circuit board to
		turn on System Ready (Green) LED.

J2-5	23	Switched to ground for transfer relay
		operation

J2-6		NOT USED

J2-7		NOT USED

PIN	WIRE	CIRCUIT FUNCTION

J2-8	15B	Provides an electrical connection for
		charge current to reach the battery
		from the battery charger. Provides 12
		VDC to the Transfer Relay

J2-9	820	Positive voltage (+5 VDC) for status
		LEDs.

J2-10	0	Common Ground

J2-11	56	12 VDC output to starter contactor
		relay for V-Twin engines

J2-12		NOT USED

J2-13	818	Grounded by board to turn on the
		Alarm (Red) LED.

J2-14		NOT USED

J2-15	90	Switched to ground for choke sole-
		noid operation

J2-16		INTERNAL USE ONLY

J2-17		NOT USED

J2-18		NOT USED

J3		Control wires for Stepper Motor

Wired Plug-1	N1	240 VAC sensing for control board.

Wired Plug-2	N2	240 VAC sensing for control board.

Page 100

Image 102

Generac Power Systems 7 kW NG, 10 kW LP manual Harness END Remote Wireless Connection N1/N2 Connector, PCB END Harness END

Contents

Air-Cooled Product Electrical formulas Automatic Operating Sequences Problem 12 No Battery Charge 147 Specifications Engine Fuel ConsumptionMounting Dimensions Right Side View Major Features Door removedPart General Information Neutral Floating Generator Identification PartIntroduction Rainproof Enclosure Fitted Rated Ambient Temp 40CSelecting a Location Installation basicsTransfer Switch / Load Center Grounding The GeneratorInstallation basics Part Typical InstallationPower Source And Load Lines System Control Interconnections Natural Gas Fuel InterconnectionsControl Wires from Transfer Switch Non-Prepackaged Interconnections PartNon-Prepackaged Interconnections PRE 08 HSB AIR-COOLED Generators Single & V-TWIN EnginesGeneral Reconfiguring The Fuel SystemPreparation Before Use Part Fuel RequirementsInstall the battery, door and close the roof Preparation before useEngine Oil Recommendations Measuring AC Voltage MetersVom Measuring DC VoltageTesting, cleaning and drying Part Measuring CurrentMeasuring Resistance Electrical Units Ohm’s LawVolts Amps Ohms Megohmmeter Visual InspectionInsulation Resistance ONE 1 SecondRepeat between Wire 2 and Stator Lead Stator Insulation Resistance Test 12-20 kWStator Insulation Resistance Test 10 kW Rotor Insulation Resistance Test 12-20 kW Cleaning The GeneratorRotor Insulation Resistance Test 10 kW Drying The GeneratorLow Oil Pressure Shutdown Low BatteryHigh Temperature Switch Overspeed ShutdownEngine-generator protective devices Part Overcrank ShutdownOperating Instructions Control PanelTo Select Automatic Operation KW Installation AssistantOperating instructions Part Manual Transfer To Standby Manual StartupAutomatic operating parameters Seconds then re-crank if additional crank cycles existAuto Automatic operating parameters PartManual ExercisePart AC Generators Rotor Assembly Engine-Generator Drive SystemAC Generator Stator Assembly Description & componentsOther AC Generator Components Description & components PartBrush Holder And Brushes 12-20 kW Main Line Circuit BreakerRotor Residual Magnetism Field Boost 12-20 KWOperation 12-20 kW Operational analysis PartOperation 8/10 kW StartupTroubleshooting flowcharts Troubleshooting flowcharts Part Troubleshooting flowcharts Problem 3 Generator Produces Low Voltage at No-LoadProblem 4 Generator Produces High Voltage at No-Load Units with Test 2 Check AC Output Voltage SafetyTest 1 Check Main Circuit Breaker ResultsProcedure Diagnostic tests PartRemove jumper lead connected to Wire 4 and Wire 15B Test 4 Fixed Excitation Test Rotor Amp Draw TestTest 5 Wire Continuity 12-20 kW Diagnostic testsExample Test 7 Testing The Stator With a Vom 12-20 kW Reconnect WireTest 6 Check Field Boost 12-20 kW Repeat using stator lead Wire Test Control Panel Wires for ContinuityTest 8 Test Brushless Stator Repeat using stator lead Repeat using WireTest 9 Check Capacitor Test 10 Test DPE Winding on Brushless units Meter lead to WireRepeat using Wires 2 MeasuredTest 12 Check Brushes And Slip Rings 12-20 kW Remove Wire 4 from the voltage regulatorTest 11 Resistance Check Rotor Circuit 12-20 kW If Continuity was measured in Steps 5 and 6 proceed to StepTest 13 Test Rotor Assembly 12-20 kW Test 14 Check AC Output FrequencyRemove air cleaner cover to access stepper motor Test 16 Check Stepper Motor Control V-twin Engine UnitsLoosen the governor clamp bolt Figure Test 17 Check And Adjust Voltage Regulator 12-20 kW Pull ARM this Direction to Close ThrottleTest 20 Check Engine Condition Refer back to flow chartTest 18 Check Voltage Frequency Under Load Test 21 Field Flash Alternator KW UnitsConstruction of Energizing Cord Page Transfer General Enclosure Item DescriptionTransfer Mechanism Transfer RelayTerminal Block Neutral LugManual Transfer Handle Utility N1 and N2Fuse Holder Fuses F1, F2Fuses F3 Is a schematic for a typical W/V-Type transfer switch Operational AnalysisIs a wiring diagram for a typical W/V-Type transfer switch Operational analysisUtility Source Voltage Available SW1Generator Power Available, Waiting to Transfer Utility Source Voltage FailureTransfer To Standby Transfer Action to Standby PositionGenerator Powering Load Utility Restored Utility Restored, Generator Still Providing Output to LoadUtility Restored, Transfer Switch De-energized Utility Restored, Transfer Relay De-energizedUtility Restored, Retransfer Back To Utility Utility Restored, Retransfer Back to UtilityTransfer Switch In Utility Transfer Switch in UtilityTroubleshooting flow charts Part Introduction To TroubleshootingProblem 7 In Automatic Mode, No Transfer to Standby Troubleshooting flow charts Problem 9 Blown F1 or F2 FuseCheck N1 & N2 Problem 13 No Battery Charge GenReady Load Center Problem 11 No Battery Charge Pre-Wire Load CenterProblem 12 No Battery Charge Rtsn & Rtse Transfer Switch Problem 14 No Battery Charge Load Shed Transfer SwitchTest 26 Check Voltage at Terminal Lugs E1, E2 If the generator has been shut down, proceed as followsTest 27 Check Manual Transfer Switch Operation Manual Transfer Switch OperationTest 28 Check 23 and 15B Wiring Reconnect the J2 connector to the PCBPROCEDURE/ Results Remove the J2 connector from the circuit board Test 29 Test Transfer Relay TrSet VOM to measure DC voltage Test 31 Check Wire Test 30 Standby Control CircuitSW1 Output Test 32 Utility Control CircuitN2A Test 33 Test Limit Switch SW2 and SW3 Test 34 Check Fuses F1 and F2Test 35 Check N1 and N2 Wiring Test 36 Check N1 and N2 VoltageReplace blown fuses as needed Test 37 Check Utility Sensing Voltage at the Circuit Board Test 38 Check Utility Sense VoltageTest 39 Check Voltage at Terminal Lugs N1, N2 Transfer Switch GeneratorMeasure across points a and C VAC should be measured Test 40 Check Battery ChargerTest 42 Check Wire 0 and Wire15B Pre-wire load center Measure across points M and N VDC should be measuredRtsn & Rtse Transfer Switch Test 45 Check Wire 0/15B Rtsn & Rtse Transfer SwitchMeasure across points E and F VAC should be measured 15B Test 43, 44, and 45 Rtse Transfer Switch Test Points Test 48 Check Wire 0/15B GenReady Load Center Disconnect the J2 connector from the printed circuit boardSection Load Shed Transfer Switch Measure across points C and D VAC should be measuredMeasure across points E and D VAC should be measured LSS ATSLSC Test 51 Check Wire 0 and Wire 15B Load Shed Transfer Switch Part DC Control Terminal Strip / Interconnection Auto-Off-Manual SwitchDescription and components Part Circuit BoardDescription and components Amp FuseKW Printed Circuit Boards and J1 Connector J2 Connector PCB END J1 Connector Stepper Motor Harness END Remote Wireless ConnectionHarness END Remote Wireless Connection N1/N2 Connector PCB END Harness END17 and 20 kW Printed Circuit Board and J1 Connector Choke Solenoid Connector Pin Number Identification Menu System NavigationDescription ComponentsStator Circuit Condition Utility Source Voltage Available Initial Dropout of Utility Source Voltage Circuit Condition Initial Dropout of Utility Source Voltage Utility Voltage Dropout and Engine Cranking Circuit Condition Engine Cranking Engine Startup and Running Circuit Condition Engine Startup and Running Initial Transfer to the Standby Source Circuit Condition Initial Transfer to Standby Utility Voltage Restored / Re-transfer to Utility Circuit Condition Utility Voltage Restored Engine Shutdown Circuit Condition Retransfer to Utility and Engine Shutdown Controller Switch BAD Replace Controller Assembly Problem 17 Engine Cranks but Won’t Start Readjust Replace Choke Solenoid BAD Problem 19 Shutdown Alarm/Fault Occured Problem 20 7.5 Amp Fuse F1 Blown Problem 21 Generator Will Not ExerciseProblem 22 No Low Speed Exercise Test 56 Check Position Of Auto-Off Manual Switch Test 58 Auto-Off-Manual Switch Twin OnlyTest 57 Try a Manual Start Test 61 Check Battery Test 59 Test Auto OperationsTest 60 Check 7.5 Amp Fuse Test Battery Condition Typical Battery Load TesterTest 63 Test Starter Contactor Relay V-twin Only Test 62 Check Wire 56 VoltageIf battery voltage is indicated in refer back to flow chart Set a VOM to measure DC voltageReconnect Wire 13 to the SCR Test 64 Test Starter Contactor Single Cylinder EngineChecking the Pinion Test 65 Test Starter MotorShorted, open or grounded armature PinionPinion Tools for Starter Performance TestTest 66 Check Fuel Supply Pressure PortSolenoid Removed Test 67 Check Circuit Board Wire Output 12-20 kW Gas Pressure Test pointDisconnect the C3 Connector Test 68 Check Fuel SolenoidTest 69 Check Choke Solenoid Approximately 3.7 ohms should be measured Solenoid De-Energized, Choke Closed KW UnitsDisconnect the C3 Connector Set a VOM to measure DC voltage Disconnect C3 Connector Set a VOM to measure resistanceTest 70 Check for Ignition Spark KW Choke Solenoid Test 71 Check Spark Plugs Repeat Steps 1 through 8 on remaining cylinder Test 73 Check Shutdown WireRemove a spark plug Check CompressionTest 74 Check and Adjust Ignition Magnetos Depending on engine type, do the followingSetting Ignition Magneto Armature Air Gap MagnetoCylinder One Back, Short Check engine crankcase oil level Test 75 Check Oil Pressure Switch WireNavigate to the Digital inputs display screen With oil level correct, try starting the engineReplace switch if it fails the test Test 76 Check High Oil Temperature SwitchTest 77 Check and Adjust Valves Remove the High Oil Temperature SwitchTest 78 Check Wire 18 Continuity Set the AUTO-OFF-MANUAL switch to the Manual positionBall Stud JAM NUT Test 79 Test Exercise Function Test 80 Check Cranking and Running CircuitsRecord the current date and time of the unit Choke Solenoid 8kWTest 82 Check operation Choke Solenoid Test 81 Check to see if Low Speed Function is enabledDisconnect Wire 4 and Wire 0 from the Voltage Regulator VR If the solenoid closed, replace the controllerPart Operational Tests Electrical Checks Manual Transfer Switch OperationSystem functional tests Part Set the generator main line circuit breaker to OFF or openSystem functional tests Generator Tests Under LoadSetting The Exercise Timer Verify that the AUTO-OFF-MANUAL switch is set to AutoChecking Automatic Operation Part Disassembly Major Disassembly Part Front Engine AccessRemove control harnesses Major Disassembly Section Section Major Disassembly Section Section Section Section Engine mount nuts with ground wires. See Figure Torque Requirements Unless Otherwise Specified Part Electrical Data Wiring Diagram, 8 kW Home Standby Part Drawing #0G7945Wiring Diagram, 8 kW Home Standby Schematic, 8 kW Home Standby Part Drawing #0G8511Part Schematic, 8 kW Home Standby Wiring Diagram, 10 kW Home Standby Part Drawing #0G7946Part Wiring Diagram, 10 kW Home Standby Schematic, 10 kW Home Standby Part Drawing #0G8512Part Schematic, 10 kW Home Standby Wiring Diagram, 14 kW Home Standby Part Drawing #0G7947Part Wiring Diagram, 14 kW Home Standby Schematic, 14 kW Home Standby Part Drawing #0G8513Part Schematic, 14 kW Home Standby Wiring Diagram, 17 kW Home Standby Part Drawing #0G7948Part Wiring Diagram, 17 kW Home Standby Schematic, 17 kW Home Standby Part Drawing #0G8514Part Schematic, 17 kW Home Standby Wiring Diagram, 20 kW Home Standby Part Drawing #0G8186Part Wiring Diagram, 20 kW Home Standby Schematic, 20 kW Home Standby Part Drawing #0G8515Part Schematic, 20 kW Home Standby Transfer Switch, 9/10/12/16 circuit Wiring Diagram, Home StandbyPart Wiring Diagram, Home Standby Schematic, Home Standby Drawing #0G7959Page Page Page MyGenerac.com