Section 7.2

ENGINE DC CONTROL SYSTEM / AC TROUBLESHOOTING

TEST 29 - 12 POSITION HARNESS

CONTINUITY TEST

1) Set VOM to measure Resistance.

2.Measure from pin location #1 on one end of the 12 position harness to pin location #1 on the opposite end of the harness. A reading of “Continuity” should be measured. Repeat proce- dure for each pin position on the 12-wire harness. If an open condition is detected, replace the defective harness as neces- sary.

3.If needed, check for continuity on the A6060 circuit board wire harness in the control panel. This connection is at location J1 on the circuit board. Follow the same procedure as steps 1 and 2 above.

TEST 30 - 12 POSITION HARNESS SIGNALS TEST

ASSUMPTION:

Engine runs

Inverter not connected

TEST PROCEDURE:

1.Disconnect the 12-wire cable from the inverter. Disconnect the Red-Black-Blue-Green DC Link wires from the inverter.

Note: Cap the DC Link wires with a wire nut for safety.

2.On units with A6060 circuit board revision “D” or higher soft- ware, jump pin #10 to pin #11 on the 12 position cable previ- ously removed from the inverter. The 12 position cable should be connected to the 12 position socket on the generator control panel. This will enable the generator to run with CB1 turned ON.

3.Turn CB1 to ON position. Start generator. The engine should run at approximately 3300rpm.

4.Set a DVOM to DC volts. Measure from the free end of the 12 position harness according to the chart below. Connect the negative and positive test leads as indicated in the chart.

(Note: Fluke 87 true RMS meter used in test.)

5.Set a DVOM to AC volts. Measure the the free end of the 9- Wire harness according to the chart below. Connect the nega- tive and positive test leads as indicated in the chart.

Figure 10 Free End of 12 Position Harness

 

Test With DVOM

 

 

 

 

Set At DC Volts

Connect negative lead to:

Connect positive lead to:

Reading should be:

 

 

 

 

 

 

Inverter Signals Ground

Pin 9 (0 v)

Pin 2 (En/Com)

< 0.10 vdc

 

 

 

 

 

 

Inverter Signal

Pin 2 (En/Com)

Pin 1 (PWM1)

2.5 v ± 0.15 vdc

 

 

 

 

 

 

Inverter Signal

Pin 2 (En/Com)

Pin 3 (PWM2)

2.5 v ± 0.15 vdc

 

 

 

 

 

 

Temperature Voltage

Pin 9 (0 v)

Pin 10 (TEMP)

5.0 v ± 0.1 vdc

 

 

 

 

 

 

Inverter Fan Voltage

Pin 9 (0 v)

Pin 4 (Wire #14)

12 v ± 1.0 vdc

 

 

 

 

 

 

Shield Wire

 

 

 

 

Test for Ground

Pin 12 (SHIELD)

Pin 4 (Wire #14)

12 v ± 1.0 vdc

 

 

 

 

 

 

 

 

 

 

 

Test With DVOM

 

 

 

 

Set At AC Volts

Connect negative lead to:

Connect positive lead to:

Reading should be:

 

 

 

 

 

 

Inverter Signal

Pin 2 (En/Com)

Pin 1 (PWM1)

2.5 v ± 2.0 vac*

 

 

 

 

 

 

Inverter Signal

Pin 2 (En/Com)

Pin 3 (PWM2)

2.5 v ± 2.0 vac*

 

 

 

 

 

* Tolerance is large because readings will vary, depending on type of meter used.

Page 7.2-17

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Generac Power Systems 941-2, 940-2 service manual Test 29 12 Position Harness Continuity Test, Assumption

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