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

Generac Power Systems 9 kW NG, 10 kW LP, 13 kW NG and 20 kW Printed Circuit Board and J1 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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DC control

Part 4

Section 4.1

Description and components

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 7. 16, 17 and 20 kW Printed Circuit Board and J1 Connector

16, 17 and 20 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	12VDC 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	4	Field Boost output

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

J2-14	819	Grounded by board to turn on the
		Maintenance Required (Yellow) LED.

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.

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Image 103

Generac Power Systems 9 kW NG, 10 kW LP, 13 kW NG, 7 kW NG, 8 kW LP, 17 kW LP and 20 kW Printed Circuit Board and J1 Connector

Contents

Air-Cooled Product Electrical formulas Automatic Operating Sequences Problem 12 No Battery Charge 147 Specifications Fuel Consumption EngineMounting Dimensions Right Side View Door removed Major FeaturesPart General Information Rainproof Enclosure Fitted Rated Ambient Temp 40C Generator Identification PartIntroduction Neutral FloatingGrounding The Generator Installation basicsTransfer Switch / Load Center Selecting a LocationTypical Installation Installation basics PartNatural Gas Fuel Interconnections Power Source And Load Lines System Control InterconnectionsNon-Prepackaged Interconnections Part Control Wires from Transfer SwitchPRE 08 HSB AIR-COOLED Generators Single & V-TWIN Engines Non-Prepackaged InterconnectionsFuel Requirements Reconfiguring The Fuel SystemPreparation Before Use Part GeneralPreparation before use Install the battery, door and close the roofEngine Oil Recommendations Measuring DC Voltage MetersVom Measuring AC VoltageMeasuring Current Testing, cleaning and drying PartMeasuring Resistance Ohm’s Law Electrical UnitsVolts Amps Ohms ONE 1 Second Visual InspectionInsulation Resistance MegohmmeterStator Insulation Resistance Test 12-20 kW Repeat between Wire 2 and Stator LeadStator Insulation Resistance Test 10 kW Drying The Generator Cleaning The GeneratorRotor Insulation Resistance Test 10 kW Rotor Insulation Resistance Test 12-20 kWOverspeed Shutdown Low BatteryHigh Temperature Switch Low Oil Pressure ShutdownOvercrank Shutdown Engine-generator protective devices PartControl Panel Operating InstructionsManual Transfer To Standby Manual Startup KW Installation AssistantOperating instructions Part To Select Automatic OperationSeconds then re-crank if additional crank cycles exist Automatic operating parametersExercise Automatic operating parameters PartManual AutoPart AC Generators Engine-Generator Drive System Rotor AssemblyAC Generator Description & components Stator AssemblyMain Line Circuit Breaker Description & components PartBrush Holder And Brushes 12-20 kW Other AC Generator ComponentsField Boost 12-20 KW Rotor Residual MagnetismStartup Operational analysis PartOperation 8/10 kW Operation 12-20 kWTroubleshooting flowcharts Troubleshooting flowcharts Part Problem 3 Generator Produces Low Voltage at No-Load Troubleshooting flowchartsProblem 4 Generator Produces High Voltage at No-Load Units with Results SafetyTest 1 Check Main Circuit Breaker Test 2 Check AC Output VoltageTest 4 Fixed Excitation Test Rotor Amp Draw Test Diagnostic tests PartRemove jumper lead connected to Wire 4 and Wire 15B ProcedureDiagnostic tests Test 5 Wire Continuity 12-20 kWExample Reconnect Wire Test 7 Testing The Stator With a Vom 12-20 kWTest 6 Check Field Boost 12-20 kW Test Control Panel Wires for Continuity Repeat using stator lead WireTest 8 Test Brushless Stator Repeat using Wire Repeat using stator leadTest 9 Check Capacitor Measured Meter lead to WireRepeat using Wires 2 Test 10 Test DPE Winding on Brushless unitsIf Continuity was measured in Steps 5 and 6 proceed to Step Remove Wire 4 from the voltage regulatorTest 11 Resistance Check Rotor Circuit 12-20 kW Test 12 Check Brushes And Slip Rings 12-20 kWTest 14 Check AC Output Frequency Test 13 Test Rotor Assembly 12-20 kWTest 16 Check Stepper Motor Control V-twin Engine Units Remove air cleaner cover to access stepper motorLoosen the governor clamp bolt Figure Pull ARM this Direction to Close Throttle Test 17 Check And Adjust Voltage Regulator 12-20 kWTest 21 Field Flash Alternator KW Units Refer back to flow chartTest 18 Check Voltage Frequency Under Load Test 20 Check Engine ConditionConstruction of Energizing Cord Page Transfer Item Description General EnclosureTransfer Relay Transfer MechanismUtility N1 and N2 Neutral LugManual Transfer Handle Terminal BlockFuses F1, F2 Fuse HolderFuses F3 Operational Analysis Is a schematic for a typical W/V-Type transfer switchOperational analysis Is a wiring diagram for a typical W/V-Type transfer switchSW1 Utility Source Voltage AvailableUtility Source Voltage Failure Generator Power Available, Waiting to TransferTransfer Action to Standby Position Transfer To StandbyGenerator Powering Load Utility Restored, Generator Still Providing Output to Load Utility RestoredUtility Restored, Transfer Relay De-energized Utility Restored, Transfer Switch De-energizedUtility Restored, Retransfer Back to Utility Utility Restored, Retransfer Back To UtilityTransfer Switch in Utility Transfer Switch In UtilityIntroduction To Troubleshooting Troubleshooting flow charts PartProblem 7 In Automatic Mode, No Transfer to Standby Problem 9 Blown F1 or F2 Fuse Troubleshooting flow chartsCheck N1 & N2 Problem 14 No Battery Charge Load Shed Transfer Switch Problem 11 No Battery Charge Pre-Wire Load CenterProblem 12 No Battery Charge Rtsn & Rtse Transfer Switch Problem 13 No Battery Charge GenReady Load CenterIf the generator has been shut down, proceed as follows Test 26 Check Voltage at Terminal Lugs E1, E2Manual Transfer Switch Operation Test 27 Check Manual Transfer Switch OperationReconnect the J2 connector to the PCB Test 28 Check 23 and 15B WiringPROCEDURE/ Results Test 29 Test Transfer Relay Tr Remove the J2 connector from the circuit boardSet VOM to measure DC voltage Test 30 Standby Control Circuit Test 31 Check WireSW1 Test 32 Utility Control Circuit OutputN2A Test 34 Check Fuses F1 and F2 Test 33 Test Limit Switch SW2 and SW3Test 36 Check N1 and N2 Voltage Test 35 Check N1 and N2 WiringReplace blown fuses as needed Test 38 Check Utility Sense Voltage Test 37 Check Utility Sensing Voltage at the Circuit BoardTest 39 Check Voltage at Terminal Lugs N1, N2 Generator Transfer SwitchMeasure across points M and N VDC should be measured Test 40 Check Battery ChargerTest 42 Check Wire 0 and Wire15B Pre-wire load center Measure across points a and C VAC should be measuredTest 45 Check Wire 0/15B Rtsn & Rtse Transfer Switch Rtsn & Rtse Transfer SwitchMeasure across points E and F VAC should be measured 15B Test 43, 44, and 45 Rtse Transfer Switch Test Points Disconnect the J2 connector from the printed circuit board Test 48 Check Wire 0/15B GenReady Load CenterSection Measure across points C and D VAC should be measured Load Shed Transfer SwitchMeasure across points E and D VAC should be measured ATS LSSLSC Test 51 Check Wire 0 and Wire 15B Load Shed Transfer Switch Part DC Control Circuit Board Auto-Off-Manual SwitchDescription and components Part Terminal Strip / InterconnectionAmp Fuse Description and componentsKW Printed Circuit Boards and J1 Connector Harness END Remote Wireless Connection J2 Connector PCB END J1 Connector Stepper MotorPCB END Harness END Harness END Remote Wireless Connection N1/N2 Connector17 and 20 kW Printed Circuit Board and J1 Connector Menu System Navigation Choke Solenoid Connector Pin Number IdentificationComponents DescriptionStator 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 21 Generator Will Not Exercise Problem 20 7.5 Amp Fuse F1 BlownProblem 22 No Low Speed Exercise Test 58 Auto-Off-Manual Switch Twin Only Test 56 Check Position Of Auto-Off Manual SwitchTest 57 Try a Manual Start Test 59 Test Auto Operations Test 61 Check BatteryTest 60 Check 7.5 Amp Fuse Typical Battery Load Tester Test Battery ConditionSet a VOM to measure DC voltage Test 62 Check Wire 56 VoltageIf battery voltage is indicated in refer back to flow chart Test 63 Test Starter Contactor Relay V-twin OnlyTest 64 Test Starter Contactor Single Cylinder Engine Reconnect Wire 13 to the SCRPinion Test 65 Test Starter MotorShorted, open or grounded armature Checking the PinionTools for Starter Performance Test PinionPort Test 66 Check Fuel Supply PressureSolenoid Removed 12-20 kW Gas Pressure Test point Test 67 Check Circuit Board Wire OutputTest 68 Check Fuel Solenoid Disconnect the C3 ConnectorTest 69 Check Choke Solenoid Solenoid De-Energized, Choke Closed KW Units Approximately 3.7 ohms should be measuredDisconnect C3 Connector Set a VOM to measure resistance Disconnect the C3 Connector Set a VOM to measure DC voltageTest 70 Check for Ignition Spark KW Choke Solenoid Test 71 Check Spark Plugs Check Compression Test 73 Check Shutdown WireRemove a spark plug Repeat Steps 1 through 8 on remaining cylinderDepending on engine type, do the following Test 74 Check and Adjust Ignition MagnetosMagneto Setting Ignition Magneto Armature Air GapCylinder One Back, Short With oil level correct, try starting the engine Test 75 Check Oil Pressure Switch WireNavigate to the Digital inputs display screen Check engine crankcase oil levelRemove the High Oil Temperature Switch Test 76 Check High Oil Temperature SwitchTest 77 Check and Adjust Valves Replace switch if it fails the testSet the AUTO-OFF-MANUAL switch to the Manual position Test 78 Check Wire 18 ContinuityBall Stud JAM NUT Test 80 Check Cranking and Running Circuits Test 79 Test Exercise FunctionRecord the current date and time of the unit 8kW Choke SolenoidIf the solenoid closed, replace the controller Test 81 Check to see if Low Speed Function is enabledDisconnect Wire 4 and Wire 0 from the Voltage Regulator VR Test 82 Check operation Choke SolenoidPart Operational Tests Set the generator main line circuit breaker to OFF or open Manual Transfer Switch OperationSystem functional tests Part Electrical ChecksGenerator Tests Under Load System functional testsVerify that the AUTO-OFF-MANUAL switch is set to Auto Setting The Exercise TimerChecking Automatic Operation Part Disassembly Front Engine Access Major Disassembly PartRemove 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 Drawing #0G7945 Wiring Diagram, 8 kW Home Standby PartWiring Diagram, 8 kW Home Standby Drawing #0G8511 Schematic, 8 kW Home Standby PartPart Schematic, 8 kW Home Standby Drawing #0G7946 Wiring Diagram, 10 kW Home Standby PartPart Wiring Diagram, 10 kW Home Standby Drawing #0G8512 Schematic, 10 kW Home Standby PartPart Schematic, 10 kW Home Standby Drawing #0G7947 Wiring Diagram, 14 kW Home Standby PartPart Wiring Diagram, 14 kW Home Standby Drawing #0G8513 Schematic, 14 kW Home Standby PartPart Schematic, 14 kW Home Standby Drawing #0G7948 Wiring Diagram, 17 kW Home Standby PartPart Wiring Diagram, 17 kW Home Standby Drawing #0G8514 Schematic, 17 kW Home Standby PartPart Schematic, 17 kW Home Standby Drawing #0G8186 Wiring Diagram, 20 kW Home Standby PartPart Wiring Diagram, 20 kW Home Standby Drawing #0G8515 Schematic, 20 kW Home Standby PartPart Schematic, 20 kW Home Standby Wiring Diagram, Home Standby Transfer Switch, 9/10/12/16 circuitPart Wiring Diagram, Home Standby Drawing #0G7959 Schematic, Home StandbyPage Page Page MyGenerac.com