Troubleshooting flowcharts | Generac Power Systems 13 kW NG instruction

AC generators

Part 2

Section 2.3

Troubleshooting flowcharts

Problem 3 - Generator Produces Low Voltage at No-Load

TEST 2 - CHECK
AC OUTPUT	LOW
VOLTAGE
NO VOLTAGE

12-20 kW UNITS

8/10 kW UNITS

TEST 9 -

CHECK

CAPACITOR

TEST 17 - ADJUST

VOLTAGE

REGULATOR

LOW -

SINGLE CYLINDER

TEST 14 - CHECK

UNITS

AC OUTPUT

FREQUENCY

LOW -

V-TWIN UNITS

GO TO TEST 4

GO TO “PROBLEM 2”

8/10 kW UNITS

FREQUENCY O.K.,

BUT VOLTAGE LOW

12-20 kW UNITS

TEST 15 - ADJUST

ENGINE GOVERNOR

TEST 16 - CHECK

STEPPER MOTOR

CONTROL

FREQUENCY AND

VOLTAGE O.K.

		STOP
	VOLTAGE AND FREQUENCY O.K.	STOP
	VOLTAGE AND FREQUENCY O.K.	TESTS
		TESTS

FREQUENCY O.K.,

BUT VOLTAGE IS

STILL LOW

			GO TO “PROBLEM 1” FLOW CHART -
12-20 kW UNITS			GO TO “PROBLEM 1” FLOW CHART -
12-20 kW UNITS			START AT “TEST 4 - F/E”
			START AT “TEST 4 - F/E”

8/10 kW UNITS GO TO “PROBLEM 2”

Problem 4 - Generator Produces High Voltage at No-Load

TEST 2 - CHECK

AC OUTPUT

VOLTAGE

HIGH

TEST 14 - CHECK

AC OUTPUT

FREQUENCY

HIGH -

SINGLE CYLINDER

UNITS

HIGH -

V-TWIN UNITS

TEST 15 - ADJUST

ENGINE GOVERNOR

TEST 16 - CHECK

STEPPER MOTOR

CONTROL

TEST 9 -

CHECK

CAPACITOR

TEST 17 - ADJUST

VOLTAGE

REGULATOR

8/10 kW UNITS

FREQUENCY O.K.,

BUT VOLTAGE HIGH

12-20 kW UNITS

VOLTAGE AND FREQUENCY O.K.

FREQUENCY AND

VOLTAGE O.K.

STOP

TESTS

FREQUENCY O.K.,

BUT VOLTAGE IS

STILL HIGH

		REPLACE DEFECTIVE
12-20 kW UNITS
		VOLTAGE REGULATOR

8/10 kW UNITS GO TO “PROBLEM 2”

Page 39

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Generac Power Systems 13 kW NG, 10 kW LP Troubleshooting flowcharts, Problem 3 Generator Produces Low Voltage at No-Load

Contents

Air-Cooled Product Electrical formulas Automatic Operating Sequences Problem 12 No Battery Charge 147 Specifications Fuel Consumption Engine Mounting Dimensions Right Side View Door removed Major Features Part General Information Introduction Generator Identification PartNeutral Floating Rainproof Enclosure Fitted Rated Ambient Temp 40C Transfer Switch / Load Center Installation basicsSelecting a Location Grounding The Generator Typical Installation Installation basics Part Natural Gas Fuel Interconnections Power Source And Load Lines System Control Interconnections Non-Prepackaged Interconnections Part Control Wires from Transfer Switch PRE 08 HSB AIR-COOLED Generators Single & V-TWIN Engines Non-Prepackaged Interconnections Preparation Before Use Part Reconfiguring The Fuel SystemGeneral Fuel Requirements Preparation before use Install the battery, door and close the roof Engine Oil Recommendations Vom MetersMeasuring AC Voltage Measuring DC Voltage Measuring Resistance Testing, cleaning and drying PartMeasuring Current Volts Amps Ohms Electrical UnitsOhm’s Law Insulation Resistance Visual InspectionMegohmmeter ONE 1 Second Stator Insulation Resistance Test 10 kW Repeat between Wire 2 and Stator LeadStator Insulation Resistance Test 12-20 kW Rotor Insulation Resistance Test 10 kW Cleaning The GeneratorRotor Insulation Resistance Test 12-20 kW Drying The Generator High Temperature Switch Low BatteryLow Oil Pressure Shutdown Overspeed Shutdown Overcrank Shutdown Engine-generator protective devices Part Control Panel Operating Instructions Operating instructions Part KW Installation AssistantTo Select Automatic Operation Manual Transfer To Standby Manual Startup Seconds then re-crank if additional crank cycles exist Automatic operating parameters Manual Automatic operating parameters PartAuto Exercise Part AC Generators AC Generator Rotor AssemblyEngine-Generator Drive System Description & components Stator Assembly Brush Holder And Brushes 12-20 kW Description & components PartOther AC Generator Components Main Line Circuit Breaker Field Boost 12-20 KW Rotor Residual Magnetism Operation 8/10 kW Operational analysis PartOperation 12-20 kW Startup Troubleshooting flowcharts Troubleshooting flowcharts Part Problem 4 Generator Produces High Voltage at No-Load Troubleshooting flowchartsProblem 3 Generator Produces Low Voltage at No-Load Units with Test 1 Check Main Circuit Breaker SafetyTest 2 Check AC Output Voltage Results Remove jumper lead connected to Wire 4 and Wire 15B Diagnostic tests PartProcedure Test 4 Fixed Excitation Test Rotor Amp Draw Test Example Test 5 Wire Continuity 12-20 kWDiagnostic tests Test 6 Check Field Boost 12-20 kW Test 7 Testing The Stator With a Vom 12-20 kWReconnect Wire Test 8 Test Brushless Stator Repeat using stator lead WireTest Control Panel Wires for Continuity Test 9 Check Capacitor Repeat using stator leadRepeat using Wire Repeat using Wires 2 Meter lead to WireTest 10 Test DPE Winding on Brushless units Measured Test 11 Resistance Check Rotor Circuit 12-20 kW Remove Wire 4 from the voltage regulatorTest 12 Check Brushes And Slip Rings 12-20 kW If Continuity was measured in Steps 5 and 6 proceed to Step Test 14 Check AC Output Frequency Test 13 Test Rotor Assembly 12-20 kW Loosen the governor clamp bolt Figure Remove air cleaner cover to access stepper motorTest 16 Check Stepper Motor Control V-twin Engine Units Pull ARM this Direction to Close Throttle Test 17 Check And Adjust Voltage Regulator 12-20 kW Test 18 Check Voltage Frequency Under Load Refer back to flow chartTest 20 Check Engine Condition Test 21 Field Flash Alternator KW Units Construction of Energizing Cord Page Transfer Item Description General Enclosure Transfer Relay Transfer Mechanism Manual Transfer Handle Neutral LugTerminal Block Utility N1 and N2 Fuses F3 Fuse HolderFuses F1, F2 Operational Analysis Is a schematic for a typical W/V-Type transfer switch Operational analysis Is a wiring diagram for a typical W/V-Type transfer switch SW1 Utility Source Voltage Available Utility Source Voltage Failure Generator Power Available, Waiting to Transfer Transfer Action to Standby Position Transfer To Standby Generator Powering Load Utility Restored, Generator Still Providing Output to Load Utility Restored Utility Restored, Transfer Relay De-energized Utility Restored, Transfer Switch De-energized Utility Restored, Retransfer Back to Utility Utility Restored, Retransfer Back To Utility Transfer Switch in Utility Transfer Switch In Utility Problem 7 In Automatic Mode, No Transfer to Standby Troubleshooting flow charts PartIntroduction To Troubleshooting Problem 9 Blown F1 or F2 Fuse Troubleshooting flow charts Check N1 & N2 Problem 12 No Battery Charge Rtsn & Rtse Transfer Switch Problem 11 No Battery Charge Pre-Wire Load CenterProblem 13 No Battery Charge GenReady Load Center Problem 14 No Battery Charge Load Shed Transfer Switch If the generator has been shut down, proceed as follows Test 26 Check Voltage at Terminal Lugs E1, E2 Manual Transfer Switch Operation Test 27 Check Manual Transfer Switch Operation PROCEDURE/ Results Test 28 Check 23 and 15B WiringReconnect the J2 connector to the PCB Set VOM to measure DC voltage Remove the J2 connector from the circuit boardTest 29 Test Transfer Relay Tr Test 30 Standby Control Circuit Test 31 Check Wire SW1 Test 32 Utility Control Circuit Output N2A Test 34 Check Fuses F1 and F2 Test 33 Test Limit Switch SW2 and SW3 Replace blown fuses as needed Test 35 Check N1 and N2 WiringTest 36 Check N1 and N2 Voltage Test 39 Check Voltage at Terminal Lugs N1, N2 Test 37 Check Utility Sensing Voltage at the Circuit BoardTest 38 Check Utility Sense Voltage Generator Transfer Switch Test 42 Check Wire 0 and Wire15B Pre-wire load center Test 40 Check Battery ChargerMeasure across points a and C VAC should be measured Measure across points M and N VDC should be measured Measure across points E and F VAC should be measured Rtsn & Rtse Transfer SwitchTest 45 Check Wire 0/15B Rtsn & Rtse Transfer Switch 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 Center Section Measure across points E and D VAC should be measured Load Shed Transfer SwitchMeasure across points C and D VAC should be measured LSC LSSATS Test 51 Check Wire 0 and Wire 15B Load Shed Transfer Switch Part DC Control Description and components Part Auto-Off-Manual SwitchTerminal Strip / Interconnection Circuit Board Amp Fuse Description and components KW Printed Circuit Boards and J1 Connector Harness END Remote Wireless Connection J2 Connector PCB END J1 Connector Stepper Motor PCB END Harness END Harness END Remote Wireless Connection N1/N2 Connector 17 and 20 kW Printed Circuit Board and J1 Connector Menu System Navigation Choke Solenoid Connector Pin Number Identification Components Description Stator 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 22 No Low Speed Exercise Problem 20 7.5 Amp Fuse F1 BlownProblem 21 Generator Will Not Exercise Test 57 Try a Manual Start Test 56 Check Position Of Auto-Off Manual SwitchTest 58 Auto-Off-Manual Switch Twin Only Test 60 Check 7.5 Amp Fuse Test 61 Check BatteryTest 59 Test Auto Operations Typical Battery Load Tester Test Battery Condition If battery voltage is indicated in refer back to flow chart Test 62 Check Wire 56 VoltageTest 63 Test Starter Contactor Relay V-twin Only Set a VOM to measure DC voltage Test 64 Test Starter Contactor Single Cylinder Engine Reconnect Wire 13 to the SCR Shorted, open or grounded armature Test 65 Test Starter MotorChecking the Pinion Pinion Tools for Starter Performance Test Pinion Solenoid Removed Test 66 Check Fuel Supply PressurePort 12-20 kW Gas Pressure Test point Test 67 Check Circuit Board Wire Output Test 69 Check Choke Solenoid Disconnect the C3 ConnectorTest 68 Check Fuel Solenoid Solenoid De-Energized, Choke Closed KW Units Approximately 3.7 ohms should be measured Test 70 Check for Ignition Spark Disconnect the C3 Connector Set a VOM to measure DC voltageDisconnect C3 Connector Set a VOM to measure resistance KW Choke Solenoid Test 71 Check Spark Plugs Remove a spark plug Test 73 Check Shutdown WireRepeat Steps 1 through 8 on remaining cylinder Check Compression Depending on engine type, do the following Test 74 Check and Adjust Ignition Magnetos Magneto Setting Ignition Magneto Armature Air Gap Cylinder One Back, Short Navigate to the Digital inputs display screen Test 75 Check Oil Pressure Switch WireCheck engine crankcase oil level With oil level correct, try starting the engine Test 77 Check and Adjust Valves Test 76 Check High Oil Temperature SwitchReplace switch if it fails the test Remove the High Oil Temperature Switch Ball Stud JAM NUT Test 78 Check Wire 18 ContinuitySet the AUTO-OFF-MANUAL switch to the Manual position Record the current date and time of the unit Test 79 Test Exercise FunctionTest 80 Check Cranking and Running Circuits 8kW Choke Solenoid Disconnect Wire 4 and Wire 0 from the Voltage Regulator VR Test 81 Check to see if Low Speed Function is enabledTest 82 Check operation Choke Solenoid If the solenoid closed, replace the controller Part Operational Tests System functional tests Part Manual Transfer Switch OperationElectrical Checks Set the generator main line circuit breaker to OFF or open Generator Tests Under Load System functional tests Checking Automatic Operation Setting The Exercise TimerVerify that the AUTO-OFF-MANUAL switch is set to Auto Part Disassembly Remove control harnesses Major Disassembly PartFront Engine Access 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 Part Wiring Diagram, 8 kW Home Standby Drawing #0G8511 Schematic, 8 kW Home Standby Part Part Schematic, 8 kW Home Standby Drawing #0G7946 Wiring Diagram, 10 kW Home Standby Part Part Wiring Diagram, 10 kW Home Standby Drawing #0G8512 Schematic, 10 kW Home Standby Part Part Schematic, 10 kW Home Standby Drawing #0G7947 Wiring Diagram, 14 kW Home Standby Part Part Wiring Diagram, 14 kW Home Standby Drawing #0G8513 Schematic, 14 kW Home Standby Part Part Schematic, 14 kW Home Standby Drawing #0G7948 Wiring Diagram, 17 kW Home Standby Part Part Wiring Diagram, 17 kW Home Standby Drawing #0G8514 Schematic, 17 kW Home Standby Part Part Schematic, 17 kW Home Standby Drawing #0G8186 Wiring Diagram, 20 kW Home Standby Part Part Wiring Diagram, 20 kW Home Standby Drawing #0G8515 Schematic, 20 kW Home Standby Part Part Schematic, 20 kW Home Standby Wiring Diagram, Home Standby Transfer Switch, 9/10/12/16 circuit Part Wiring Diagram, Home Standby Drawing #0G7959 Schematic, Home StandbyPage Page Page MyGenerac.com