Guardian 4721 Repair Manual Download | Manualshive

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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.

BAD

BAD

BAD

BAD

BAD

Problem 1 - In Automatic Mode, No Transfer to Standby

TEST 1 - CHECK
VOLTAGE AT
TERMINAL LUGS
E1 & E2

TEST 2 - CHECK
VOLTAGE AT
STANDBY CLOSING
COIL C2

TEST 3 - TEST
TRANSFER
RELAY (TR)

TEST 4 - CHECK
MANUAL TRANSFER
SWITCH OPERATION

TEST 5 - TEST LIMIT
SWITCH XB1

TEST 6 - CHECK
WIRING AND WIRING
CONNECTIONS

GOOD BUT NO
TRANSFER

FIND CAUSE OF NO AC
OUTPUT TO TRANSFER
SWITCH FROM GENERATOR

GOOD

GOOD

GOOD

REPLACE BAD SWITCH

REPLACE BAD RELAY

BAD

REPAIR, RECONNECT
OR REPLACE WIRING

GOOD

REPLACE STANDBY
CLOSING COIL C2

REPAIR OR REPLACE
DEFECTIVE TRANSFER
MECHANISM PART(S)

PART 3

Page 48

“V-TYPE” PREPACKAGED

TRANSFER SWITCHES

SECTION 3.3

TROUBLESHOOTING FLOW CHARTS

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Summary of Contents for 4721

Page 1: ...Models 4721 4722 4723 4724 4725 4726 1 5L HOME STANDBY GENERATORS www guardiangenerators com LIQUID COOLED DIAGNOSTIC REPAIR MANUAL...

Page 2: ...The manufacturer suggests that these rules for safe opera tion be copied and posted in potential hazard areas Safety should be stressed to all opera tors and potential operators of this equipment Impo...

Page 3: ...ure correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator Keep the area aroun...

Page 4: ...mediately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as...

Page 5: ...ged Liquid Cooled AC Generators 19 3 V Type Prepackaged Transfer Switches 39 4 DC Control Units with Liquid Cooled Engine 57 5 Operational Tests and Adjustments 95 6 Electrical Data 101 TABLE OF CONTE...

Page 6: ...ry depending on such variables as applied load ambient temperature engine conditions and other environmental factors Fuel pressure for a natural gas set up should be five inches to 14 inches of water...

Page 7: ...ion Basics 6 1 3 Preparation Before Use 9 1 4 Testing Cleaning and Drying 10 1 5 Engine Generator Protective Devices 13 1 6 Operating Instructions 15 1 7 Automatic Operating Parameters 17 TABLE OF CON...

Page 8: ...PLATE HOURMETER 15 AMP FUSE FAULT INDICATOR CIRCUIT BREAKER SET EXERCISE SWITCH AUTO OFF MANUAL SWITCH ALTERNATOR CARBURETOR MUFFLER RADIATOR ENGINE FUEL REGULATOR BATTERY DISTRIBUTOR CONTROL PANEL H...

Page 9: ...onsists of two or more SUBSECTIONS It is not the manufacturers intent to provide detailed disassembly and reassembly instructions in this man ual It is the manufacturers intent to a provide the servic...

Page 10: ...tive parts of the gen erator be property connected to an approved earth ground Local electrical codes may also require prop er grounding of the unit For that purpose a ground ing lug is attached to th...

Page 11: ...AIR AND TENDS TO SETTLE IN LOW AREAS NATURAL GAS IS LIGHTER THAN AIR AND TENDS TO SETTLE IN HIGH PLACES EVEN THE SLIGHTEST SPARK CAN IGNITE THESE FUELS AND CAUSE AN EXPLOSION Use of a flexible length...

Page 12: ...transfer of electrical loads to the Standby source On restoration of utility source voltage above a preset value will result in retransfer back to that source and generator shutdown System control wi...

Page 13: ...E OIL RECOMMENDATIONS For prepackaged generators with liquid cooled engine use a high quality detergent oil that meets or exceeds API Service SC SD SE or SF Detergent oils keep the engine cleaner and...

Page 14: ...EADS WHILE THE GENERATOR IS SHUT DOWN OR WHEN THE POWER SUP PLY TO SUCH LEADS AND TERMINALS IS TURNED OFF THE USE OF INSULATIVE RUBBER MATS IS RECOMMENDED TAKE POWER VOLTAGE READINGS ONLY WHILE STANDI...

Page 15: ...Stator winding insulation tests consist of a testing all windings to ground b testing between iso lated windings and c testing between parallel wind ings Figure 3 represents the various stator AC outp...

Page 16: ...500 volts 5 Turn the tester switch ON and make sure the pilot light has turned on 6 Observe the breakdown lamp then turn the tester switch OFF DO NOT APPLY VOLTAGE LONGER THAN ONE 1 SECOND If the brea...

Page 17: ...ces work in conjunction with a control circuit board to protect the engine against such operating faults as a low engine oil pressure b high temperature c overspeed and d overcrank On occurrence of an...

Page 18: ...rcuit board will not initiate transfer of electrical loads to the Standby source until sensing voltage and fre quency is greater than 50 of the unit s rated values OVERCRANK SHUTDOWN Automatic engine...

Page 19: ...or more of the following engine fault condi tions should occur a low oil pressure b high coolant temperature c low coolant level d over speed and e overcrank 15 AMP FUSE This fuse protects the DC cont...

Page 20: ...2 Let the generator run at no load for a few minutes to cool 3 Set the generator s AUTO OFF MANUAL switch to OFF Wait for the engine to come to a complete stop 4 Turn OFF the Utility power supply to...

Page 21: ...enerator panel will illuminate If the engine starts cranking will terminate when gener ator AC output frequency reaches approximately 30 Hz PHASE 4 ENGINE STARTUP AND RUNNING The control board senses...

Page 22: ...ransfer switch Transfer switch transfer relay and transfer to Standby occurs 7 Engine running and load is No further action Control board s voltage pickup powered by Standby power sensor continues to...

Page 23: ...ATORS PART 2 PREPACKAGED LIQUID COOLED AC GENERATORS TEST DESCRIPTION PAGE 1 Check Main Circuit Breaker 30 2 Check AC Output Voltage 31 3 Test Excitation Circuit Breaker 31 4 Test Thermal Protector 32...

Page 24: ...g Brushes will ride on these slip rings The combination of slip rings and brushes allow rotor excitation current to be transmitted from stationary components into the rotating rotor windings The posi...

Page 25: ...TION AND MAJOR COMPONENTS PART 2 Page 21 STATOR To Blower Housing ROTOR BLOWER HOUSING FLEXIBLE DISK FAN AND RING GEAR ASSEMBLY BRUSH HOLDERS AND BRUSHES REAR BEARING CARRIER REAR BEARING CARRIER PLAT...

Page 26: ...al switch has failed in its open position it can be bypassed The Wire No 5 bypass lead is brought out of the stator and has a wire nut on its end Figure 4 The Thermal Protector EXCITATION CIRCUIT BREA...

Page 27: ...negative slip ring and brush and Wire No 1 The following apply The concentration of magnetic flux lines around the rotor will be proportional to the regulated excitation current flow through the roto...

Page 28: ...that circuit board energizes a crank relay Battery voltage is then delivered to field boost Wire 4 and to the rotor via a field boost resistor and diode The crank relay field boost resistor and diode...

Page 29: ...itive brush and slip ring This excitation current flows through the rotor windings and is direct ed to ground through the negative slip ring and brush and Wire 1 The greater the current flow through t...

Page 30: ...D EXCITATION ROTOR AMP DRAW PERFORM STATOR INSULATION RESISTANCE TEST PERFORM ROTOR INSULATION RESISTANCE TEST TEST 8 TEST STATOR TEST 6 WIRE CONTINUITY TEST 7 FIELD BOOST TEST 9 CHECK ROTOR CIRCUIT C...

Page 31: ...EST 11 TEST ROTOR ASSEMBLY REPAIR OR REPLACE BAD BAD BAD BAD GOOD GOOD GOOD GOOD GOOD GOOD GOOD GOOD BAD BAD BAD BAD RE TEST TEST 4 RE TEST TEST 4 REPAIR OR REPLACE Problem 1 Generator Produces Zero V...

Page 32: ...OLTAGE O K Problem 2 Generator Produces Low Voltage at No Load TEST 13 CHECK AND ADJUST GOVERNOR BOARD AND STEPPER MOTOR TEST 12 CHECK AC OUTPUT FREQUENCY TEST 2 CHECK AC OUTPUT VOLTAGE TEST 14 ADJUST...

Page 33: ...MOTOR GO TO SECTION 4 4 DIAGNOSTIC TESTS TEST 20 CHECK ENGINE COMPRESSION AND CONDITION BOTH LOW NOT OVERLOADED GOOD GOOD BAD GOOD ENGINE CONDITION GOOD DISCONTINUE TESTING REPAIR OR REPLACE LOOK FOR...

Page 34: ...consciousness or even death Contact with moving parts can cause serious injury The list of hazards is seemingly end less When working on this equipment use common sense and remain alert at all times N...

Page 35: ...r than the 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 mag netism alone The amo...

Page 36: ...ION Supplying a fixed DC current to the rotor will induce a magnetic field in the rotor With the generator run ning this should create a proportional voltage output from the stator windings PROCEDURE...

Page 37: ...nnect the other end of Wire 162 from the excitation circuit breaker Connect one 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 R...

Page 38: ...tween windings Note The resistance of stator windings is very low Some meters will not read such a low resis tance and will simply indicate CONTINUITY Recommended is a high quality digital type meter...

Page 39: ...N The function of the brushes and slip rings is to pro vide for passage of excitation current from stationary components to the rotating rotor Brushes are made of a special long lasting material and s...

Page 40: ...or low the engine speed governor may require adjustment PROCEDURE 1 Connect an accurate AC frequency meter across the Wires 11 and 44 terminals of the generator main line circuit breaker see Figure 1...

Page 41: ...e two Plug In connectors housed inside the connection boxes in the harness between the control module and the stepper motor Remove the covers from the boxes and carefully inspect the connections TEST...

Page 42: ...2 Start the 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...

Page 43: ...ABLE OF CONTENTS 1 5 LITER PREPACKAGED HOME STANDBY GENERATORS PART 3 V TYPE PREPACKAGED TRANSFER SWITCHES TEST DESCRIPTION PAGE 1 Check Voltage at Terminal Lugs E1 E2 50 2 Check Voltage at Standby Cl...

Page 44: ...ons TRANSFER SWITCH MAJOR COMPONENTS Figure 1 below shows the transfer switch compo nents Major components include the following ENCLOSURE The standard prepackaged V Type transfer switch enclosure is...

Page 45: ...ectified standby source power to actuate the load contacts to their Standby source side Energizing the coil moves the load con tacts to an overcenter position limit switch action then opens the circui...

Page 46: ...engine warm up timer has timed out control board action completes the Wire No 23 circuit to ground a The transfer relay then energizes b The relay s normally closed contacts open and its normally open...

Page 47: ...ltage is used by the control board to operate a battery trickle charge circuit which helps to maintain battery state of charge during non oper ating periods LOAD 1 AND 2 The control board is equipped...

Page 48: ...er NOTE Transfer switch terminals N1 and N2 Utility 1 and 2 must be properly connected to generator ter minals N1 and N2 Utility 1 and 2 by the installer TR RELAY TRANSFER TERMINAL STRIP CUSTOMER CONN...

Page 49: ...dby source voltage is delivered to the standby closing coil via Wires No E1 and E2 the transfer relay TR contacts limit switch XB1 Wire B and a bridge rectifier The standby closing coil energizes and...

Page 50: ...TB TR 194 TB6 TB7 194 23 23 B TR A A B B A 126 1 E1 N2A NOT USED WITH PREPACKAGED STANDBY GENERATORS TRANSFER SWITCH CONTACTOR SOLENOID COIL STANDBY CLOSING SOLENOID COIL UTILITY CLOSING LEGEND TR ATS...

Page 51: ...ure 4 Final Retransfer to Utility TR RELAY TRANSFER TERMINAL STRIP CUSTOMER CONNECTION NB NEUTRAL BLOCK LIMIT SWITCHES ACTUATOR VARISTOR FUSE 5A VR1 VR2 F1 2 3 4 XA1 XB1 NB TB TR 194 TB6 TB7 194 23 23...

Page 52: ...tic Mode No Transfer to Standby TEST 1 CHECK VOLTAGE AT TERMINAL LUGS E1 E2 TEST 2 CHECK VOLTAGE AT STANDBY CLOSING COIL C2 TEST 3 TEST TRANSFER RELAY TR TEST 4 CHECK MANUAL TRANSFER SWITCH OPERATION...

Page 53: ...ITCH GOOD GOOD GOOD BAD BAD BAD REPLACE BLOWN FUSE S REPLACE BAD RELAY REPAIR RECONNECT OR REPLACE WIRING GOOD GOOD REPLACE UTILITY CLOSING COIL C1 REPAIR OR REPLACE DEFECTIVE TRANSFER MECHANISM PART...

Page 54: ...h the Utility and Standby power supplies must be positively turned off before proceeding c Check the position of the transfer mechanism main contacts The moveable LOAD contacts must be connected to th...

Page 55: ...if the transfer relay is functioning normally PROCEDURE 1 See Figure 2 Disconnect all wires from the transfer relay to prevent interaction 2 Set a VOM to its Rx1 scale and zero the meter 3 Connect th...

Page 56: ...til the lever reaches its center position As the lever moves past its center position an over center spring should snap the moveable load contacts against the stationary Standby or Utility contacts 7...

Page 57: ...ty source voltage must be available to Terminal Lugs N1 and N2 of the transfer mechanism In addition if that source voltage is not available to N1 N2 terminals automatic startup and transfer to Standb...

Page 58: ...y contacts If necessary manually actu ate the main contacts to their Utility source side load connected to the Utility source 5 Set the generator s main line circuit breaker to its ON or Closed positi...

Page 59: ...to Utility will not occur PROCEDURE 1 With the standby generator shut down set the AUTO OFF MANUAL switch to OFF 2 Turn OFF the utility power supply to the transfer switch using whatever means provide...

Page 60: ...PART 3 Page 56 V TYPE PREPACKAGED TRANSFER SWITCHES SECTION 3 4 DIAGNOSTIC TESTS...

Page 61: ...Check Engine Compression and Condition 90 21 Check Generator Main Line Circuit Breaker 91 22 Check Sensing to control Board 91 23 Ground control Board Terminal 23 91 24 Check Voltage at Terminal Lugs...

Page 62: ...ator once every seven days on a day and at a time of day selected by the installer C Terminals 23 and 194 1 The control board delivers a 12 volt DC signal to a transfer relay coil in the transfer swit...

Page 63: ...utdown 6 176 Negative side of fault indicator lamp circuit Circuit board action will complete this circuit to ground on occurrence of a fault shutdown Figure 3 Control Board Connector Terminals CONTRO...

Page 64: ...D BATTERY CHARGE SYSTEM See Figure 7 An alternator delivers a charging volt age to the battery during engine operation The charging voltage is regulated and rectified by the DC regulator The belt driv...

Page 65: ...The sensor is immersed in cooling sys tem liquid If coolant level drops below the level of the low coolant level sensor the device will complete a Wire 85 circuit to ground Engine shutdown will occur...

Page 66: ...n induces a reduced voltage about 14 volts AC into the transformer T1 secondary coil This reduced sensing voltage is delivered to the control board As long as the sensing voltage remains above 60 perc...

Page 67: ...T2 RED TRANSFER SWITCH CONNECTION TS3 INSULATE UNUSED WIRE YELLOW WIRE FOR 208V L L SYSTEMS USE BLUE WIRE FOR 240V L L SYSTEMS ACTUATOR GOV TO N2 PREPACKAGE T1 N1 194 YELLOW Y W BLACK BLACK T1 225A 19...

Page 68: ...d voltage is delivered to the control board as Utility sensing voltage If Utility source voltage drops below about 60 percent of rated voltage control board action will turn on a 15 second timer Volta...

Page 69: ...S USE BLUE WIRE FOR 240V L L SYSTEMS ACTUATOR GOV TO N2 PREPACKAGE T1 T2 N1 23 194 YELLOW W BLACK BLACK T1 225A 194 23 176 176 194 BLUE RED T2 BLUE 23 F 183 178 EC EC 8 EC 5 EC 4 EC 3 EC 6 AR 1 85 EC...

Page 70: ...ts or has cycled through six 6 crank cycles If the engine has not started in approximately 90 seconds cranking will end and the fault indicator lamp will light overcrank condition When the engine is c...

Page 71: ...L SYSTEMS USE BLUE WIRE FOR 240V L L SYSTEMS ACTUATOR GOV TO N2 PREPACKAGE T1 T2 N1 23 194 YELLOW W BLACK BLACK T1 225A 194 23 176 176 194 BLUE RED T2 BLUE 23 F 183 178 EC EC 8 EC 5 EC 4 EC 3 EC 6 AR...

Page 72: ...s the Wire 23 circuit open When the engine warm up timer has timed out control board action closes the Wire 23 circuit to ground The transfer relay TR energizes its normally closed contacts 1 7 open i...

Page 73: ...EMS USE BLUE WIRE FOR 240V L L SYSTEMS ACTUATOR GOV TO N2 PREPACKAGE T1 T2 N1 23 194 YELLOW W BLACK BLACK T1 225A 194 23 176 176 194 BLUE RED T2 BLUE 23 F 183 178 EC EC 8 EC 5 EC 4 EC 3 EC 6 AR 1 85 E...

Page 74: ...s With coil C de energized spring force closes the main contacts to their Standby power source side Load connected to the Standby source As the main contacts close to the Standby side a mechanical int...

Page 75: ...EMS USE BLUE WIRE FOR 240V L L SYSTEMS ACTUATOR GOV TO N2 PREPACKAGE T1 T2 N1 23 194 YELLOW W BLACK BLACK T1 225A 194 23 176 176 194 BLUE RED T2 BLUE 23 F 183 178 EC EC 8 EC 5 EC 4 EC 3 EC 6 AR 1 85 E...

Page 76: ...ge is then delivered from the transformer s secondary winding to the control board It the Utility sensing voltage is above about 80 percent of the nominal rated voltage the control board will react On...

Page 77: ...SYSTEMS USE BLUE WIRE FOR 240V L L SYSTEMS ACTUATOR GOV TO N2 PREPACKAGE T1 N1 194 YELLOW Y W BLACK BLACK T1 225A 194 23 176 176 194 BLUE RED T2 BLUE 23 F 183 178 EC EC 8 EC 5 EC 4 EC 3 EC 6 AR 1 85 E...

Page 78: ...Utility source power is now delivered to the main contacts actuating coil C via Wires N1 N2 the closed TR contacts transfer mechanism terminals A1 A2 limit switches XA1 XB1 and the bridge rectifier A...

Page 79: ...1 T2 RED TRANSFER SWITCH CONNECTION TS3 INSULATE UNUSED WIRE YELLOW WIRE FOR 208V L L SYSTEMS USE BLUE WIRE FOR 240V L L SYSTEMS ACTUATOR GOV TO N2 PREPACKAGE T1 N1 194 YELLOW Y W BLACK BLACK T1 225A...

Page 80: ...Load connect ed to the Utility supply Loads are now powered by the Utility power source The standby generator is still running and generator AC output voltage is still available to transfer mechanism...

Page 81: ...1 T2 RED TRANSFER SWITCH CONNECTION TS3 INSULATE UNUSED WIRE YELLOW WIRE FOR 208V L L SYSTEMS USE BLUE WIRE FOR 240V L L SYSTEMS ACTUATOR GOV TO N2 PREPACKAGE T1 N1 194 YELLOW Y W BLACK BLACK T1 225A...

Page 82: ...t control board action will de energize the board s run relay With the run relay de energized its contacts open and the 12 volts DC power supply to Wire 14 is terminated The Wire 14 circuit is now dea...

Page 83: ...IRE FOR 208V L L SYSTEMS USE BLUE WIRE FOR 240V L L SYSTEMS ACTUATOR GOV TO N2 PREPACKAGE T1 N1 194 YELLOW Y W BLACK BLACK T1 225A 194 23 176 176 194 BLUE RED T2 BLUE 23 F 183 178 EC EC 8 EC 5 EC 4 EC...

Page 84: ...R MOTOR TEST 7 TEST CONTROL CONTACTOR CC TEST 3 TEST AUTO OFF MANUAL SWITCH BAD POWER SUPPLY TO BOARD O K BUT WIRE 56 OUTPUT IS BAD POWER SUPPLY TO BOARD AND WIRE 56 OUTPUT ARE BOTH BAD ENGINE GENERAT...

Page 85: ...E Problem 3 Engine Cranks but Won t Start REPLACE CONTROL BOARD BAD BAD BAD BAD REPLACE BAD WIRES TEST 16 CHECK IGNITION WIRES TEST 17 CHECK IGNITION TIMING GOOD BAD GOOD TEST 21 CHECK GENERATOR MAIN...

Page 86: ...to Problem 3 in Section 4 3 4 If engine cranks and starts but transfer to Standby does not occur go to Problem 4 in Section 4 3 5 If transfer to Standby occurs but retransfer back to Utility does not...

Page 87: ...3 e Wire 239 between Terminal 1 and the circuit board Wire 178 between Terminal 3 and TB3 f Wire 178 between Terminal 3 and the circuit board RESULTS Repair reconnect or replace any bad wiring TEST 5...

Page 88: ...olts DC to the coil of a control contactor The control contactor energizes its contacts close and battery power is delivered to the starter motor SM to crank the engine A defective control contactor C...

Page 89: ...ust be available to the control board or the board will not operate A 2 volt DC output must be delivered from the circuit board to Wire 56 or engine cranking cannot occur In this test you will check t...

Page 90: ...K FUEL SUPPLY DISCUSSION Often the most obvious cause of a problem is over looked If the engine cranks but will not start per haps the fuel supply is exhausted or fuel pressure is too low The followin...

Page 91: ...d a run relay on the control board are energized simultaneously See Figure 9 When the engine is cranking battery voltage is deliv ered to the positive terminal of the distributor via Wire 14 On startu...

Page 92: ...F 20 C 3 To test power input terminals measure across the exter nal power connection terminals with an ohmmeter The reading across the two internal connector terminals should be 1 3 ohms 10 at 68 F 2...

Page 93: ...20 29 N m Figure 13 Checking Spark Plug Gap NOTE Use Champion RN11YC4 replacement spark plugs RESULTS 1 Replace bad spark plugs 2 If spark plugs are good go to Test 19 TEST 16 CHECK IGNITION WIRES DI...

Page 94: ...te battery voltage The fuel solenoid should energize RESULTS 1 If battery voltage is indicated but the fuel solenoid does not energize replace the solenoid 2 If the fuel solenoid is good go on to Test...

Page 95: ...5 S16 signal is lost transfer will not occur This test will determine if the line to neutral sensing signal is available to the control board PROCEDURE 1 Set the AUTO OFF MANUAL switch to OFF 2 Turn O...

Page 96: ...SWITCH TERMINAL LUGS CONTACT WITH THESE HIGH VOLTAGE TERMINALS WILL RESULT IN EXTREMELY DANGEROUS AND POSSIBLY DEADLY ELECTRICAL SHOCK PROCEDURE 1 Start the generator engine manually let it stabilize...

Page 97: ...s this voltage to approximately 14 volts AC The reduced sensing voltage is then delivered to the control board This is a test of the control board transformer PROCEDURE 1 See Figure 16 Connect an AC v...

Page 98: ...PART 4 Page 94 DC CONTROL LIQUID COOLED ENGINE UNITS SECTION 4 4 DIAGNOSTIC TESTS...

Page 99: ...Page 95 PART TITLE PAGE 5 1 System Functional Tests 96 5 2 Adjustments Liquid Cooled Units 99 TABLE OF CONTENTS 1 5 LITER PREPACKAGED HOME STANDBY GENERATORS PART 5 OPERATIONAL TESTS AND ADJUSTMENTS...

Page 100: ...ITCH BEFORE ATTEMPTING MANUAL OPERATION FAILURE TO TURN OFF POWER VOLTAGE SUPPLIES TO THE TRANSFER SWITCH MAY RESULT IN DAN GEROUS AND POSSIBLY LETHAL ELECTRI CAL SHOCK 4 Remove the manual transfer ha...

Page 101: ...eed until generator AC output voltage and frequency are correct If no load volt age and frequency are both correspondingly high or low the engine governor may require adjust ment If AC frequency is go...

Page 102: ...warm up timer has timed out transfer of Load circuits to the Standby power supply should occur 8 Wait about 10 15 minutes then turn ON the Utility power supply to the transfer switch a After about si...

Page 103: ...tion Wait 30 seconds then place the AUTO OFF MANUAL switch at AUTO The generator will exercise every seven 7 days at the selected time NOTE Failure to wait 30 seconds before placing the AUTO OFF MANUA...

Page 104: ...o the pre selected speed 50 or 60 Hz based on unit Observe performance of system when loads are applied and removed Increasing stability will decrease recovery time but may result in damped oscillatio...

Page 105: ...ng Diagram 1 Phase Liquid Cooled Generator 106 0E1525 Schematic 1 Phase Liquid Cooled Generator 107 0E0343 B Wiring Diagram 1 5 Liter Liquid Cooled Engine 108 0A7182 C Schematic 1 5 Liter Liquid Coole...

Page 106: ...CK LIMIT SWITCHES ACTUATOR VARISTOR FUSE 5A VR1 VR2 F1 2 3 4 XA1 XB1 NB TB TR 194 TB6 TB7 194 23 23 B TR A A B B A 126 1 E1 N2A NOT USED WITH PREPACKAGED STANDBY GENERATORS TRANSFER SWITCH CONTACTOR S...

Page 107: ...23 N2A N1A N2A E2 TR N1A N1A 194 B A 9 7 6 3 1 23 N2A B N2A N1A N1A A N2 N1 T1 F2 F1 F3 T2 F4 23 T1A 194 T2A E2 205 E2 B T1A E1 E2 N2A N2A N1A N2A N2A N1A A 126 NEUTRAL BLOCK 00 00 NB C2 XB1 ATS C1 XA...

Page 108: ...Page 104 PART 9 ELECTRICAL DATA V TYPE TRANSFER SWITCH 100 200 AMP 2 POLE DRAWING 0F0015 A 1 of 2...

Page 109: ...ELECTRICAL DATA V TYPE TRANSFER SWITCH 100 200 AMP 2 POLE PART 9 Page 105 DRAWING 0F0015 A 2 of 2...

Page 110: ...7 8 9 10 11 12 13 14 15 16 17 18 5 1 2 4 3 6 13 15 15 178 239 0 14 176 15A T1 T2 225A 0 15C 239 15E 178 14 56 194 23 85 4 S15 S16 229 S16 176 4 229 56 162 S16 E1 TO E2 240 E1 TO 00 120V E2 TO 00 OUTP...

Page 111: ...00 E2 CUSTOMER CONNECTION 120 240V 1 PHASE TRANSFER SWITCH CONNECTION TS3 EC AR ALTERNATOR ROTOR AS ALTERNATOR STATOR CB1 2 CIRCUIT BREAKERS DPE EXCITATION WINDING F FUSE 15 AMPS GCU GOVERNOR CONTROL...

Page 112: ...PART 9 Page 108 ELECTRICAL DATA WIRING DIAGRAM 1 5 LITER LIQUID COOLED ENGINE DRAWING 0E0343 B...

Page 113: ...OVERNOR ACTUATOR CC DC A 14 TO CONTROL PANEL TERMINAL STRIP 85 13 0 56 14 56 85 14 0 14 CC 12V BATTERY RED 16 SM 0 ISC LEGEND BLACK GRD 0 FS WTS LOS WLS 0 0 0 NOTE ENGINE HEATERS ARE NOT AVAILABLE ON...

Page 114: ...requency 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 60 x Frequ...

Page 115: ......

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