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Bryant ASPAS1BBA007, Diagnostic Repair Manual

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Bryant ASPAS1BBA007 Diagnostic Repair Manual Download Page 59

Page 59

SECTION 3.3

TROUBLESHOOTING FLOW CHARTS

INTRODUCTION TO TROUBLESHOOTING

The first step in troubleshooting is to correctly identify the problem. Once that is done, the cause of the problem
can be found by performing the tests in the appropriate flow chart.
Test numbers assigned in the flow charts are identical to test numbers in section 3.4, “Diagnostic Tests.” Section
3.4 provides detailed instructions for performance of each test.

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

PART 3

Summary of Contents for ASPAS1BBA007

Page 1: ...AUTOMATIC HOME STANDBY GENERATORS AIR COOLED MODELS ASPAS1BBA007 6 kW NG 7 kW LP ASPAS1BBA012 12 kW NG 12 kW LP ASPAS1BBA015 13 kW NG 15 kW LP DIAGNOSTIC REPAIR MANUAL www bryant com...

Page 2: ...12 Model ASPAS1BBA015 Type of Engine GH 410 GT 990 GT 990 Number of Cylinders 1 2 2 Rated Horsepower 14 5 3 600 rpm 26 3 600 rpm 30 3 600 rpm Displacement 410cc 992cc 992cc Cylinder Block Aluminum w C...

Page 3: ...ype Prepackaged Transfer Switches 4 DC Control 5 Operational Tests and Adjustments 6 Disassembly 7 Electrical Data DIAGNOSTIC REPAIR MANUAL Air cooled Prepackaged Automatic Standby Generators Models 6...

Page 4: ...Page 4 SPECIFICATIONS MOUNTING DIMENSIONS...

Page 5: ...Page 5 SPECIFICATIONS MOUNTING DIMENSIONS...

Page 6: ...Page 6 SPECIFICATIONS MAJOR FEATURES 12 kW and 15 kW V twin GT 990 Engine 7 kW Single Cylinder GH 410 Engine...

Page 7: ...re Use 1 4 Testing Cleaning and Drying 1 5 Engine Generator Protective Devices 1 6 Operating Instructions 1 7 Automatic Operating Parameters PART 1 GENERAL INFORMATION Air cooled Prepackaged Automatic...

Page 8: ...he manual has been divided into ten PARTS Each PART has been divided into SECTIONS Each SECTION consists of two or more SUBSECTIONS It is not our intent to provide detailed disassembly and reassembly...

Page 9: ...equire a vapor withdrawal type of fuel supply system when LP propane gas is used The vapor withdrawal system utilizes the gaseous fuel vapors that form at the top of the supply tank The pressure at wh...

Page 10: ...Page 10 PART 1 GENERAL INFORMATION SECTION 1 2 PREPACKAGED INSTALLATION BASICS Figure 1 Typical Prepackaged Installation...

Page 11: ...ugs T1 and T2 to the electrical load circuit Connect UTILITY STANDBY and LOAD neutral lines to the neutral block in the transfer switch SYSTEM CONTROL INTERCONNECTIONS Prepackaged home standby generat...

Page 12: ...uel If LP propane gas is to be used at the installation site adjustment of the generator fuel regulator will be required for best performance Refer to Test 63 Check Fuel Regulator for fuel regulator a...

Page 13: ...e value being measured by physically deflecting a needle across a graduated scale The scale used must be interpreted by the user Digital VOM s Figure 1 are also available and are generally very accura...

Page 14: ...e set slightly high to prevent excessive rpm and frequency droop under heavy electrical loading MEASURING CURRENT To read the current flow in AMPERES a clamp on ammeter may be used This type of meter...

Page 15: ...URE or the difference in electrical potential that causes electrons to flow Very few electrons will flow when voltage is weak More electrons will flow as voltage becomes stronger VOLTAGE may be consid...

Page 16: ...o obtain 0 12 Then add 1 to obtain 1 12 megohms Minimum Insulation resistance for a 120 VAC stator is 1 12 megohms If the stator insulation resistance is less than the calculated minimum resistance cl...

Page 17: ...e 1 second turn the tester switch OFF If the breakdown lamp comes on during the one second test the stator should be cleaned and dried After cleaning and drying repeat the insulation test If after cle...

Page 18: ...ed The rotor must be completely isolated from other components before starting the test Attach all leads of all stator windings to ground 1 Connect the red tester lead to the positive slip ring neares...

Page 19: ...Should the AC frequency exceed approximately 72Hz 4320 rpm circuit board action will de energize a run relay mounted on the circuit board The relay s contacts will open to terminate engine ignition a...

Page 20: ...Set switch to MANUAL to crank and start unit manually b Engine will crank cyclically and start same as automatic startup but without transfer The unit will transfer if utility voltage is not available...

Page 21: ...ing Steps 1 through 4 completed a dropout in utility supply voltage below a preset level will result in automatic generator cranking and start up Following startup the prepackaged transfer switch will...

Page 22: ...NE STARTUP AND RUNNING The circuit board senses that the engine is running by receiving a voltage frequency signal from the engine run windings When generator AC frequency reaches approximately 30 Hz...

Page 23: ...tch transfer relay AC output voltage above and transfer to Standby occurs 50 nominal voltage 7 Engine running and load is No further action Circuit board voltage pickup powered by Standby power sensor...

Page 24: ...Page 24 NOTES PART 1 GENERAL INFORMATION...

Page 25: ...NTS PART TITLE 2 1 Description and Components 2 2 Operational Analysis 2 3 Troubleshooting Flow Charts 2 4 Diagnostic Tests Air cooled Prepackaged Automatic Standby Generators Models 6 kW NG 7 kW LP 1...

Page 26: ...controlled by a solid state circuit board in the generator control panel ENGINE GENERATOR DRIVE SYSTEM The generator revolving field is driven by an air cooled horizontal crankshaft engine The genera...

Page 27: ...he positive brush and slip ring The excitation and field boost current passes through the windings and to frame ground via the negative slip ring and brush and Wire 0 This current flow creates a magne...

Page 28: ...On occurrence of an over voltage condition the regulator will shut down and complete loss Of excitation current to the rotor will occur Without excitation current the generator AC output voltage will...

Page 29: ...is shown schematically in Figure 2 Manual and automatic engine cranking is initiated by circuit board action when that circuit board energizes a crank relay K1 Battery voltage is then delivered to fi...

Page 30: ...or windings the greater the voltage that is induced into the stator windings Initially the AC power winding voltage sensed by the regulator is low The regulator reacts by increasing the flow of excita...

Page 31: ...tion 2 4 Test numbers used in the flow charts correspond to the numbered tests in Section 2 4 The first step in using the flow charts is to correctly identify the problem Once that has been done locat...

Page 32: ...Page 32 SECTION 2 3 TROUBLESHOOTING FLOWCHARTS PART 2 AC GENERATORS...

Page 33: ...Page 33 SECTION 2 3 TROUBLESHOOTING FLOWCHARTS AC GENERATORS PART 2...

Page 34: ...Page 34 SECTION 2 3 TROUBLESHOOTING FLOWCHARTS PART 2 AC GENERATORS...

Page 35: ...st gases contain deadly carbon monoxide gas that can cause unconsciousness or even death Contact with moving parts can cause serious injury The list of hazards is seemingly endless When working on thi...

Page 36: ...stated limits go to Test 11 3 If a high voltage is indicated go on to Test 11 NOTE Residual voltage may be defined as the voltage that is produced by rotor residual magnetism alone The amount of volt...

Page 37: ...from the voltage regulator and connect one meter test lead to that wire Disconnect Wire 22 from the voltage regulator and connect the other meter test lead to that wire both wires are located at the...

Page 38: ...e test lead to one end of Wire 162 and the other test lead to the other end of Wire 162 The meter should read CONTINUITY RESULTS If CONTINUITY was not measured across each wire repair or replace the w...

Page 39: ...paper clip or similar metallic object to access pins in connector C2 Note Pins 9 10 11 12 are not used for this test 7 Connect one test lead to stator lead Wire 11 Connect the other test lead to stat...

Page 40: ...lead to Pin 6 of the C2 connector connect the other test lead to Wire 11 at the voltage regulator Continuity should be measured 35 Connect one meter test lead to Pin 7 of the C2 connector connect the...

Page 41: ...ITY is measured repair or replace wire 0 between the brush assembly and the C2 connector 6 Wire 4 from the positive brush terminal connects to Pin 10 of the C2 connector Test this wire for an open con...

Page 42: ...60 Hertz AC frequency at 3600 rpm The unit s AC output voltage is proportional to the AC frequency For example a unit rated 240 volts line to line will supply that rated voltage plus or minus 2 percen...

Page 43: ...pounds 4 Start unit and apply full load Use full load speed adjust screw Figure 11 to adjust frequency to 58 Hz 5 Remove load stop engine loosen the idle adjust screw and reconnect the idle spring 6...

Page 44: ...e engine let it stabilize and warm up 3 Apply electrical loads to the generator equal to the rated capacity of the unit 4 Check the AC frequency and voltage Frequency should not drop below approximate...

Page 45: ...Operational Analysis 3 3 Troubleshooting Flow Charts 3 4 Diagnostic Tests PART 3 V TYPE PREPACKAGED TRANSFER SWITCHES Air cooled Prepackaged Automatic Standby Generators Models 6 kW NG 7 kW LP 12 kW N...

Page 46: ...COVER 12 POSITION GTS LOAD CENTER 3 TRANSFER SWITCH HOME STANDBY 100A2P250V 4 SCREW TAPTITE M5 0 8 X 10 BP 5 SCREW TAPTITE 1 4 20 X 5 8 BP 6 LOCK WASHER SPECIAL 1 4 7 RELAY PANEL 12VDC DPDT 10A 240VA...

Page 47: ...y source side Energizing the coil moves the load contacts to an overcenter position limit switch action then opens the circuit and spring force will complete the transfer action to Standby This coil s...

Page 48: ...ansfer to Standby occurs 5 When the generator circuit board senses that utility source voltage has been restored above a preset level the board will open the Wire 23 circuit to ground a The transfer r...

Page 49: ...matic transfer to the standby source Utility source voltage is used to operate a battery trickle charge circuit which helps to maintain battery state of charge during non operating periods TERMINALS 2...

Page 50: ...ION 3 2 OPERATIONAL ANALYSIS PART 3 V TYPE PREPACKAGED TRANSFER SWITCHES OPERATIONAL ANALYSIS Figure 1 is a schematic and wiring diagram for a typical V Type transfer switch Figure 1 Wiring Diagram an...

Page 51: ...available to T1 T2 and customer load Utility source voltage is available to limit switch XA1 via the normally closed transfer relay contacts 1 and 7 and Wire 126 However XA1 is open and the Circuit t...

Page 52: ...hen initiate generator cranking and startup after a time delay circuit times out Figure 3 is a schematic representation of the transfer switch with generator power available waiting to transfer Genera...

Page 53: ...n generator startup an engine warm up timer on the generator circuit board starts timing When that timer has timed out circuit board action completes the Wire 23 circuit to ground The transfer relay t...

Page 54: ...towards the standby power source side the transfer switch mechanically snaps to the standby position On closure of the main contacts to the standby power source side limit switches XA1 and XB1 are me...

Page 55: ...D Utility voltage is restored and is available to terminals N1 and N2 The utility voltage is sensed by the generators circuit board If it is above a preset value for a preset time interval a transfer...

Page 56: ...e interval expires the circuit board will open the Wire 23 circuit to ground The transfer relay de energizes it s normally closed contacts close and utility source voltage is delivered to the utility...

Page 57: ...As the utility coil pulls the transfer switch to an OVER CENTER position the switch mechanically snaps to Utility On closure of the main contacts to the utility power source side Limit Switches XA1 a...

Page 58: ...L ANALYSIS PART 3 V TYPE PREPACKAGED TRANSFER SWITCHES TRANSFER SWITCH IN UTILITY When the transfer switch returns to the utility side generator shutdown occurs after approximately one 1 minute Figure...

Page 59: ...he problem Once that is done the cause of the problem can be found by performing the tests in the appropriate flow chart Test numbers assigned in the flow charts are identical to test numbers in secti...

Page 60: ...Page 60 SECTION 3 3 TROUBLESHOOTING FLOW CHARTS PART 3 V TYPE PREPACKAGED TRANSFER SWITCHES...

Page 61: ...has started automatically due to a utility power source outage and is running check the position of the generator main circuit breaker The circuit breaker must be set to its On or Closed position When...

Page 62: ...OR IS RUNNING AVOID CONTACT WITH HIGH VOLTAGE TERMINALS OR DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK MAY RESULT DO NOT PERFORM THIS VOLTAGE TEST WHILE STANDING ON WET OR DAMP GROUND WHILE BAREFOO...

Page 63: ...ops below a preset level the engine should crank and start On engine startup an engine warm up timer on the generator circuit board should start timing When that timer has timed out about 15 seconds t...

Page 64: ...itch XB1 must be closed to the Standby power source side If the limit switch did not get actuated or has failed open the source voltage will not be available to the closing coil and transfer to Standb...

Page 65: ...2 DISCUSSION If retransfer to the Utility power source side is to occur utility source voltage must be available to terminal lugs N1 and N2 of the transfer mechanism In addition If that source voltage...

Page 66: ...LTAGE TEST WHILE STANDING ON WET OR DAMP GROUND WHILE BAREFOOT OR WHILE HANDS OR FEET ARE WET 5 Disconnect Wire N2A from the utility closing coil C1 Connect one meter test Lead to Wire N2A Use a suita...

Page 67: ...transfer switch using whatever means provided 3 To prevent interaction disconnect Wire 126 and Wire A from the limit switch terminals 4 Set a VOM to its R x 1 scale and zero the meter 5 Connect the VO...

Page 68: ...the interconnection terminal in the control panel or the terminal strip 5 Set your VOM to the R x 1 scale Connect the positive meter test lead to wire N1 a Connect the negative meter lead to the groun...

Page 69: ...ther test lead to TX terminal 9 Approximately 1 5 ohms should be measured 7 Connect one test lead tot TX terminal 7 Connect the other test lead to TX terminal 6 Approximately 0 3 ohms should be measur...

Page 70: ...Page 70 SECTION 3 4 DIAGNOSTIC TESTS PART 3 V TYPE PREPACKAGED TRANSFER SWITCHES...

Page 71: ...mponents 4 2 Operational Analysis 4 3 Troubleshooting Flow Charts 4 4 Diagnostic Tests PART 4 DC CONTROL Air cooled Prepackaged Automatic Standby Generators Models 6 kW NG 7 kW LP 12 kW NG 12 kW LP 13...

Page 72: ...type The line to line voltage from the Utility 1 Utility 2 terminals is delivered to the transformer s primary winding Transformer action then induces a reduced voltage about 12 to 16 volts into both...

Page 73: ...ter if equipped 8 66A AC input to the board for crank terminate and overspeed protection 9 239 B input when SW1 is in the MANUAL position 10 15A B input into the board for source voltage when SW1 is i...

Page 74: ...EAFTER ON THE DAY AND AT THE TIME OF DAY THE SWITCH WAS ACTUATED AUTO OFF MANUAL SWITCH This 3 position switch permits the operator to a select fully automatic operation b start the generator manually...

Page 75: ...TARTER CONTACTOR RELAY SCR V TWINS ONLY CIRCUIT BREAKER DPE CB2 GROUND TERMINAL NEUTRAL BLOCK TRANSFORMER TX VOLTAGE REGULATOR BATTERY CHARGE RELAY BCR 4 TAB TERMINAL BLOCK TB SET EXERCISE SWITCH SW2...

Page 76: ...10 CB2 4 0 22 6 BA FIELD 0 13 11 0 77 C2 1 3 1 2 C1 3 4 14 11 16 17 12 13 15 14 C2 3 PRINTED CIRCUIT 0 C1 6 C2 9 0 0 55 C2 4 4 0 WINDING ENGINE RUN STATOR 66 CONTROL BOARD 3 2 1 J2 3 7 9 4 6 5 J1 5 4...

Page 77: ...r Battery output is delivered to the circuit board with the Auto Off Manual switch SW1 set to AUTO as shown F1 SM C1 1 15 0 0 18 C1 5 56 18 17 15 17 15A SCR 0 0 0 15 16 239 15 14 0 194 23 13 18 D IM2...

Page 78: ...D 3 2 1 J2 3 7 9 4 6 5 J1 5 4 1 2 66A 66A 85 351 HTO C1 4 C2 2 0 0 SW2 17 225 15 224 0 66A 14 194 23 194 56 15A 66A 239 18 86 23 224 4 86 0 LOP 14 225 239 15A 23 194 13 225B BATTERY CHARGE WINDING 13...

Page 79: ...15A and Pin 10 of the circuit board connector F1 SM C1 1 15 0 0 18 C1 5 56 18 17 15 17 15A SCR 0 0 0 15 16 239 15 14 0 194 23 13 18 D IM2 IM1 SP2 SP1 23 16 0 13 SC 0 SW1 15 15A 239 194 FS 0 14 C2 1 WI...

Page 80: ...e engine cranks CHARGER BATTERY 0 162 22 VOLTAGE REGULATOR ELECTRONIC 6 4 0 11 STATOR DPE WINDING C2 8 2 C2 7 C2 11 C2 10 CB2 4 0 22 6 BA FIELD 0 13 11 0 77 C2 1 3 1 2 C1 3 14 11 16 17 12 13 15 14 C2...

Page 81: ...ing Wire 4 supplies 2 3 VDC 8 9 VDC isolated to the rotor for field flash With ignition and fuel flow available the engine can start F1 SM C1 1 15 0 0 18 C1 5 56 18 17 15 17 15A SCR 0 0 0 15 16 239 15...

Page 82: ...224 0 66A 14 194 23 194 56 15A 66A 239 18 86 23 224 4 86 0 LOP 14 225 239 15A 23 194 13 225B BATTERY CHARGE WINDING 13 1 2 77 224B 11 22 1 6 66 3 4 225A 224A 9 9 7 7 7 7 9 9 BCR 0 14 13 13 13 0 0 224...

Page 83: ...0 0 18 C1 5 56 18 17 15 17 15A SCR 0 0 0 15 16 239 15 14 0 194 23 13 18 D IM2 IM1 SP2 SP1 23 16 0 13 SC 0 SW1 15 15A 239 194 FS 0 14 C2 1 WINDING STATOR POWER 22 44 11 CB1 33 56VA 1VA 13 225 225A 224...

Page 84: ...limit switch CHARGER BATTERY 0 162 22 VOLTAGE REGULATOR ELECTRONIC 6 4 0 11 STATOR DPE WINDING C2 8 2 C2 7 C2 11 C2 10 CB2 4 0 22 6 BA FIELD 0 13 11 0 77 C2 1 3 1 2 C1 3 4 11 16 17 12 13 15 14 C2 3 PR...

Page 85: ...wer is delivered to the Load terminals T1 T2 of the transfer switch F1 SM C1 1 15 0 0 18 C1 5 56 18 17 15 17 15A SCR 0 0 0 15 16 239 15 14 0 194 23 13 18 D IM2 IM1 SP2 SP1 23 16 0 13 SC 0 SW1 15 15A 2...

Page 86: ...r center CHARGER BATTERY 0 162 22 VOLTAGE REGULATOR ELECTRONIC 6 4 0 11 STATOR DPE WINDING C2 8 2 C2 7 C2 11 C2 10 CB2 4 0 22 6 BA FIELD 0 13 11 0 77 C2 1 3 1 2 C1 3 4 11 16 17 12 13 15 14 C2 3 PRINTE...

Page 87: ...7 15 17 15A SCR 0 0 0 15 16 239 15 14 0 194 23 13 18 D IM2 IM1 SP2 SP1 23 16 0 13 SC 0 SW1 15 15A 239 194 FS 0 14 C2 1 WINDING STATOR POWER 22 44 11 CB1 33 56VA 1VA 13 225 5 225A A 224A A 224 4 TX 17...

Page 88: ...0 55 C2 4 4 0 WINDING ENGINE RUN STATOR 66 CONTROL BOARD 3 2 1 J2 3 7 9 4 6 5 J1 5 4 1 2 66A 66A 85 351 HTO C1 4 C2 2 0 0 SW2 17 225 15 224 0 66A 14 194 23 194 56 15A 66A 239 18 86 23 224 4 86 0 LOP...

Page 89: ...down F1 SM C1 1 15 0 0 18 C1 5 56 18 17 15 17 15A SCR 0 0 0 15 16 239 15 14 0 194 23 13 18 D IM2 IM1 SP2 SP1 23 16 0 13 SC 0 SW1 15 15A 239 194 FS 0 14 C2 1 WINDING STATOR POWER 22 44 11 CB1 33 56VA 1...

Page 90: ...Page 90 SECTION 4 3 TROUBLESHOOTING FLOW CHARTS PART 4 DC CONTROL...

Page 91: ...Page 91 SECTION 4 3 TROUBLESHOOTING FLOW CHARTS DC CONTROL PART 4...

Page 92: ...Page 92 SECTION 4 3 TROUBLESHOOTING FLOW CHARTS PART 4 DC CONTROL...

Page 93: ...Page 93 SECTION 4 3 TROUBLESHOOTING FLOW CHARTS DC CONTROL PART 4...

Page 94: ...Page 94 SECTION 4 3 TROUBLESHOOTING FLOW CHARTS PART 4 DC CONTROL...

Page 95: ...Page 95 SECTION 4 3 TROUBLESHOOTING FLOW CHARTS DC CONTROL PART 4...

Page 96: ...LE OF DELIVERING A MAXIMUM OF 7 5 AMPS IF THE ACCESSORY TO BE USED THROUGH THIS CIRCUIT DEMANDS TOO MUCH POWER THE FUSE THAT PROTECTS THIS CIRCUIT WILL OPEN CHECK FOR OVERLOAD CONDITION INSTALL NEW FU...

Page 97: ...off proceed to Test 42 3 If engine cranks but won t start go to Problem 10 in Section 4 3 4 If engine cranks and starts but transfer to Standby does not occur go to Problem 5 in Section 3 3 5 If trans...

Page 98: ...e 15 Connect the negative test lead to a clean frame ground Battery voltage should be measured See Figure 2 3 Connect the positive test lead to the Auto Off Manual switch terminal 1 Wire 15A Connect t...

Page 99: ...The 15 amp fuse is located on the generator console A blown fuse will prevent battery power from reaching the circuit board with the same result as setting the Auto Off Manual switch to OFF PROCEDURE...

Page 100: ...r contactor relay SCR on models with v twin engines or the starter contactor SC on models with single cylinder engines Connect the common test probe to frame ground 2 Observe the meter Then actuate th...

Page 101: ...must energize and its heavy duty contacts must close or the engine will not crank This test will determine if the starter contactor is in working order PROCEDURE Carefully inspect the starter motor c...

Page 102: ...a failure of the starter motor PROCEDURE The battery should have been checked prior to this test and should be fully charged Set a VOM to measure DC voltage 12 VDC Connect the meter positive test lea...

Page 103: ...chometer measures from 800 to 50 000 RPM Figure 13 Figure 13 Tachometer TEST BRACKET A starter motor test bracket may be made as shown in Figure 14 A growler or armature tester is available from an au...

Page 104: ...test methods must comply strictly with gas codes DANGER GASEOUS FUELS ARE HIGHLY EXPLOSIVE DO NOT USE FLAME OR HEAT TO TEST THE FUEL SYSTEM FOR LEAKS NATURAL GAS IS LIGHTER THAN AIR TENDS TO SETTLE IN...

Page 105: ...r or VOM into Pin 7 Wire 14 of the circuit board connector J1 Connect the common test lead to frame ground 3 While observing the meter set the Auto Off Manual switch to MANUAL a The circuit board s cr...

Page 106: ...nd on the Fuel Solenoid FS Cycle the Auto Off Manual switch from MANUAL to OFF You should be able to feel the solenoid actuate as well as hear it actuate If a small screwdriver is placed on the soleno...

Page 107: ...l not start and Test 55 indicated good ignition spark perhaps the spark plug s are fouled or otherwise damaged Engine miss may also be caused by defective spark plug s PROCEDURE 1 Remove spark plugs a...

Page 108: ...J1 from the circuit board 4 Set a VOM to measure resistance Connect one test lead to Wire 18 from the control panel Connect the other test lead to a clean frame ground INFINITY should be measured 5 R...

Page 109: ...An incomplete circuit open diode will be displayed as OL 10 Disconnect the engine wire harness from the ignition magnetos and stud connector Figure 24 Figure 24 Engine Ground Harness Figure 25 Diode...

Page 110: ...of the following Low engine oil level Low oil pressure A defective oil pressure switch If the oil pressure switch contacts have failed open or Wire 86 does not have continuity to ground at starting t...

Page 111: ...od for Problem 9 proceed to Test 44 2 Replace switch if it fails the test TEST 61 CHECK HIGH OIL TEMPERATURE SWITCH DISCUSSION If the temperature switch contacts have failed in a closed position the e...

Page 112: ...d the four 4 screws RESULTS Adjust valve clearance as necessary the retest TEST 63 CHECK FUEL REGULATOR DISCUSSION The fuel regulator is rarely the cause of a hard start or no start condition The most...

Page 113: ...e to the generator or if the generator is running The system consists of a transformer TX battery charge relay BCR battery charger BC and a battery charge winding The BCR contacts allow AC voltage to...

Page 114: ...to Problem 7 Section 3 3 2 If correct voltage was measured in Step 2 and no voltage was measured in Step 3 replace the Transformer 3 If correct voltage was measured in Step 2 and no voltage was measu...

Page 115: ...e battery charge relay if it fails any of the steps in this chart 2 If the BCR tests good but still does not function during generator operation check Wire 14 and Wire 0 connected to the BCR a Set a V...

Page 116: ...tep 4 repair or replace Wire 13A between the battery charger and fuse F2 2 If CONTINUITY was not measured in Step 5 repair or replace Wire 0 between the battery charger and frame ground TEST 70 CHECK...

Page 117: ...ANDBY occurs in the automatic mode even though an acceptable UTILITY source voltage is available from the Transformer TX the next step is to determine if that sensing voltage is reaching the circuit b...

Page 118: ...nect the other meter test lead to Wire 183 at the terminal connector INFINITY should be measured 6 If the remote start connections have been used connect the meter test leads across customer supplied...

Page 119: ...or SC terminal from which Wire 56 was removed Connect the other meter test lead to the ground terminal If CONTINUITY or zero resistance was measured replace the SCR or SC Coil resistance for the SCR...

Page 120: ...own on it s own The exerciser will then be set to start and run at that time of that day each week If the unit does not start go to Test 73 Retest after performing Test 73 If the generator still will...

Page 121: ...PART TITLE 5 1 System Functional Tests PART 5 OPERATIONAL TESTS Air cooled Prepackaged Automatic Standby Generators Models 6 kW NG 7 kW LP 12 kW NG 12 kW LP 13 kW NG 15 kW LP TABLE OF CONTENTS...

Page 122: ...ING MANUAL OPERATION FAILURE TO TURN OFF POWER VOLTAGE SUPPLIES TO THE TRANSFER SWITCH MAY RESULT IN DANGEROUS AND POSSIBLY LETHAL ELECTRICAL SHOCK 4 Remove the manual transfer handle from the enclosu...

Page 123: ...n at no load for a few minutes to stabilize internal engine generator temperatures 13 Set the generator Auto Off Manual switch to OFF The engine should shut down NOTE It is important that you do not p...

Page 124: ...ource power is turned off After starting the transfer switch should connect load circuits to the standby side Let the system go through its entire automatic sequence of operation With the generator ru...

Page 125: ...PART TITLE 6 1 Major Disassembly PART 6 DISASSEMBLY Air cooled Prepackaged Automatic Standby Generators Models 6 kW NG 7 kW LP 12 kW NG 12 kW LP 13 kW NG 15 kW LP TABLE OF CONTENTS...

Page 126: ...sing a 10mm socket remove the five bolts and four nuts from the exhaust covers Remove the covers Remove the nut and bolt attaching to the roof left side folding support and bottom support bracket 7 Re...

Page 127: ...pter Figure 4 Engine Adapter Supported by 2 x4 Piece of Wood Using a 1 4 socket remove Wire 0 and Wire 4 from the brush assembly Remove the two brush assembly hold down bolts Remove the brushes Using...

Page 128: ...panel 4 Remove Intake manifolds Using a 6mm allen wrench remove the four 4 socket head cap screws from the intake manifolds Remove the intake manifolds Remove the air intake snorkel 5 Remove Air Box U...

Page 129: ...12 15 KW HSB 0E7687A WIRING DIA 8 CIRCUIT LOAD CENTER 0E7815A SCHEMATIC 8 CIRCUIT LOAD CENTER 0E7687 WIRING DIA 10 12 CIRC LOAD CENTER 0E7815 SCHEMATIC 12 12 CIRC LOAD CENTER PART 7 ELECTRICAL DATA Ai...

Page 130: ...NOID HTO HIGH OIL TEMPERATURE SWITCH IC INLINE CONNECTOR ICT INTERCONNECTION TERMINALS SC STARTER CONTACTOR DIAGRAM KEY L E D ALARM INDICATORS 1 20 Vac Sense Transformer 3 50 Hz Operation 2 Remote Not...

Page 131: ...55 55 22 6 11 1 0 1 C2 4 3 6 7 CONTROL PANEL BOX 224B 224A 225B 224B 0 13 224 225 N2 N1 224A 66 TX 225A 66 BCR 225A CB2 162 0 77 2 4 9 2 N2 NEUTRAL CONNECTION 12Vdc TRANSFER RELAY COIL 22 N 23 194 240...

Page 132: ...22 162 0 4 6 4 0 11 1 22 11 2 85 0 PRINTED CIRCUIT BOARD CONTROL C2 4 C2 7 STATOR 6 0 FIELD 6 BA C2 9 C2 11 0 0 1 STATOR WINDING ENGINE RUN C2 3 4 55 0 66 66A C2 2 HTO C1 4 15A 10 225 224 17 17 7 15...

Page 133: ...G 22 SC RED 240V CB1 120V 120V N1 22 225A 56VA 1VA 225 224 17 N1 1 TX 11 1 N2 C2 6 C2 5 11 194 23 N1 1 N2 UTILITY 12Vdc INPUT RELAY COIL TRANSFER CONNECTIONS CUSTOMER 22 N 15 15A 22 11 1 N2 2 13 14 15...

Page 134: ...LINE CONNECTOR SC STARTER CONTACTOR SP1 SP2 SPARK PLUGS FS FUEL SOLENOID F2 FUSE 7 5 AMP SM STARTER MOTOR D DIODE 14 SCR ON 2 Remote Not Auto 1 20 Vac Sense Transformer PRINTED CIRCUIT BOARD 4 SPARE 3...

Page 135: ...O SW1 1b 1a 1 0 0 CONNECTION CUSTOMER SWITCH CONTACTOR 240V GENERATOR 23 351 N1 1 N2 194 0 66A 55 77 44 11 55 0 C2 3 1 CONTROL PANEL BOX N1 N2 225B 13 66 TX 224 225 224A 225A 11 1 11 BCR 0 66 77 224A...

Page 136: ...5 AMP D DIODE F1 FUSE 15 AMP 162 22 VOLTAGE REGULATOR ELECTRONIC 6 4 0 11 1 STATOR DPE WINDING C2 8 2 C2 7 C2 11 C2 10 CB2 4 0 22 6 BA FIELD 0 13 11 0 77 C2 1 3 1 C1 3 4 14 11 1 16 6 17 7 13 3 15 5 14...

Page 137: ...6VA 1VA 13 225 225A 224A 224 TX 17 N1 N2 11 1 22 C2 5 N2 N1 C2 6 11 194 23 N1 1 N2 CUSTOMER SUPPLIED BATTERY 12V BLACK RED SC 240V 120V 120V CUSTOMER CONNECTIONS COIL 12Vdc UTILITY INPUT 240VAC RELAY...

Page 138: ...PART 7 ELECTRICAL DATA WIRING DIAGRAM 8 CIRCUIT LOAD CENTER Page 138 DRAWING 0E7687A...

Page 139: ...20V CIRCUIT 5 20A 120V CIRCUIT 2 30A 240V CIRCUIT 1 15A 120V CIRCUIT 6 YLW WHT BRN WHT PNK GRY BRN YLW CUSTOMER CIRCUIT CIRCUIT BREAKER CONTROL PANEL MAIN DISTRIBUTION NEUTRAL WHITE NEUTRAL WHITE RED...

Page 140: ...Page 140 DRAWING 07687 PART 7 ELECTRICAL DATA WIRING DIAGRAM 10 12 CIRCUIT LOAD CENTER...

Page 141: ...1 194 23 BLACK RED N2 N1 194 240VAC TO TO GENERATOR OUTPUT PANEL MAIN DISTRIBUTION LC CIRCUIT BREAKER LOADS F1 F2 5A 600V FUSE XA XB LIMIT SWITCHES TS TERMINAL STRIP TR TRANSFER RELAY C2 GENERATOR COI...

Page 142: ...Page 142 PART 7 ELECTRICAL DATA NOTES...

Page 143: ...OF ROTOR Frequency RPM 2 x 60 x Frequency 2 x 60 x frequency POLES RPM RPM FREQUENCY RPM No of Rotor Poles RPM x Poles RPM x Poles 2 x 60 2 x 60 RPM Frequency No of Rotor Poles 2 x 60 x Frequency 2 x...

Page 144: ...Part No 0F4676 Revision 02 25 05 Printed in U S A Catalog No DMASPAS 07 1...

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