BenutzerhandbuchInhaltsverzeichnisElectrical Formulas2Contents3SPECIFICATIONS6Generator6Engine7Fuel Consumption7Mounting Dimensions8Major Features10PART 1 - GENERAL INFORMATION111.1 Generator Identification121.2 Installation Basics13Introduction13Selecting A Location13Grounding The Generator13The Fuel Supply13The Transfer Switch / Load Center13Power Source And Load Lines15System Control Interconnections15Natural Gas Fuel Interconnections151.3 Non-prepackaged Interconnections16Connect a Pre-2008 Load Center SwitchTo a Current or FutureAir-Cooled Generator16Connect a 2008 And Later Load CenterSwitch to a Pre-2008Air-Cooled Generator171.4 Preparation Before Use18General.18Fuel Requirements18Fuel Consumption18Reconfiguring The Fuel System18Engine Oil Recommendations201.5 Testing, Cleaning and Drying21Meters21The Vom21Measuring AC Voltage21Measuring DC Voltage21Measuring AC Frequency21Measuring Current22Measuring Resistance22Electrical Units23Ohm’s Law23Visual Inspection24Insulation Resistance24The Megohmmeter24Stator Insulation Resistance Test (12-20 kW)25Stator Insulation Resistance Test (8-10 kW)25Rotor Insulation Resistance Test (8-10 kW)26Rotor Insulation Resistance Test (12-20 kW)26Cleaning The Generator26Drying The Generator261.6 Engine-Generator Protective Devices27General.27Low Battery27Low Oil Pressure Shutdown27High Temperature Switch27Overspeed Shutdown27Rpm Sensor Failure27Overcrank Shutdown281.7 Operating Instructions29Control Panel29To Select Automatic Operation30Manual Transfer To “Standby”and Manual Startup30Manual Shutdown AndRetransfer Back To “Utility”301.8 Automatic Operating Parameters31Introduction31Automatic Operating Sequences31PART 2 - AC GENERATORS332.1 Description and Components34Introduction34Engine-Generator Drive System34The AC Generator34Rotor Assembly34Stator Assembly35Brush Holder And Brushes (12-20 kW)36Other AC Generator Components362.2 Operational Analysis37Rotor Residual Magnetism37Field Boost (12-20 kW)37Operation (8/10 kW)38Operation (12-20 kW)382.3 Troubleshooting Flowcharts39Problem 1 – Generator Produces ZeroVoltage or Residual Voltage (12-20 kW)39Problem 2 – Generator Produces ZeroVoltage or Residual Voltage (8/10 kW)40Problem 3 – Generator ProducesLow Voltage at No-Load41Problem 4 – Generator ProducesHigh Voltage at No-Load41Problem 5 – Voltage and Frequency DropExcessively When Loads are Applied422.4 Diagnostic Tests43Introduction43Safety43Test 1 – Check Main Circuit Breaker43Test 2 – Check AC Output Voltage43Test 4 – Fixed Excitation Test/RotorAmp Draw Test44Test 5 – Wire Continuity (12-20 kW)45Test 6 – Check Field Boost (12-20 kW)46Test 7 – Testing The Stator With A Vom(12-20 kW)46Test 8 – Test Brushless Stator47Test 9 – Check Capacitor48Test 10 – Test DPE Winding onBrushless units49Test 11 – Resistance Check Of Rotor Circuit(12-20 kW)50Test 12 – Check Brushes And Slip Rings(12-20 kW)50Test 13 – Test Rotor Assembly(12-20 kW)51Test 14 – Check AC Output Frequency51Test 15 – Check and Adjust Engine Governor(Single Cylinder Units)51Test 16 – Check Stepper Motor Control(V-twin Engine Units)52Test 17 – Check And Adjust VoltageRegulator (12-20 kW)53Test 18 – Check Voltage And FrequencyUnder Load54Test 19 – Check For Overload Condition54Test 20 – Check Engine Condition54Test 21 – Field Flash Alternator (8-10 kW)54PART 3 - TRANSFER SWITCH573.1 Description and Components58General58Enclosure58Transfer Mechanism59Transfer Relay59Neutral Lug60Manual Transfer Handle60Terminal Block60Fuse Holder613.2 Operational Analysis62Operational Analysis62Utility Source Voltage Available64Utility Source Voltage Failure65Transfer To Standby66Transfer To Standby67Utility Restored68Utility Restored, Transfer Switch De-energized69Utility Restored, Retransfer Back To Utility70Transfer Switch In Utility713.3 – Troubleshooting Flowcharts72Introduction To Troubleshooting72Problem 7 – In Automatic Mode,No Transfer to Standby72Problem 8 – In Automatic Mode, GeneratorStarts When Loss of Utility Occurs,Generator Shuts Down When UtilityReturns But There Is No Retransfer To UtilityPower / or Generator Transfers to StandbyDuring Exercise Or In Manual Mode73Problem 9 – Blown F1 or F2 Fuse73Problem 10 – Units Starts And TransferOccurs When Utility Power Is On74Problem 11 – No Battery Charge(Pre-Packed Load Center)75Problem 12 – No Battery Charge(RTSN & RTSE Transfer Switch)75Problem 13 – No Battery Charge(Gen-Ready Load Center)75Problem 14 – No Battery Charge(Load Shed Transfer Switch)753.4 Diagnostic Tests76General76Test 26 – Check Voltage atTerminal Lugs E1, E276Test 27 – Check Manual Transfer SwitchOperation77Test 28 – Check 23 And 15BWiring/Connections78Test 29 – Test Transfer Relay TR79Test 30 – Standby Control Circuit80Test 31 – Check Wire 2380Test 32 – Utility Control Circuit82Test 33 – Test Limit Switch SW2 and SW384Test 34 – Check Fuses F1 and F284Test 35 – Check N1 and N2 Wiring85Test 36 – Check N1 and N2 Voltage85Test 37 – Check Utility Sensing Voltageat the Circuit Board86Test 38 – Check Utility Sense Voltage86Test 39 – Check Voltage atTerminal Lugs N1, N286Test 40 – Check Battery Charger SupplyVoltage “Pre-Wire Load Center”88Test 41 – Check Battery Charger OutputVoltage “Pre-Wire Load Center”88Test 42 – Check Wire 0 and Wire15B“Pre-Wire Load Center”88Test 43 – Check Battery ChargerSupply Voltage“RTSN & RTSE Transfer Switch”89Test 44 – Check Battery ChargerOutput Voltage“RTSN & RTSE Transfer Switch"89Test 45 – Check Wire 0/“RTSN & RTSE Transfer Switch”89Test 46 – Check Battery ChargerSupply Voltage“GenReady Load Center"92Test 47 – Check Battery ChargerOutput Voltage“GenReady Load Center"92Test 48 – Check Wire 0/15B“GenReady Load Center"92Test 49 – Check Battery ChargerSupply Voltage“Load Shed Transfer Switch"94Test 50 – Check Battery ChargerOutput Voltage“Load Shed Transfer Switch"94Test 51 – Check Wire 0 and Wire 15B“Load Shed Transfer Switch"96PART 4 - DC CONTROL974.1 Description and Components98General98Terminal Strip / Interconnection Terminal98Circuit Board98Auto-Off-Manual Switch987.5 Amp Fuse99Menu System Navigation1044.2 Operational Analysis106Introduction106Utility Source Voltage Available106Initial Dropout of Utility Source Voltage108Utility Voltage Dropout andEngine Cranking110Engine Startup and Running112Initial Transfer to the “Standby” Source114Utility Voltage Restored /Re-transfer to Utility116Engine Shutdown1184.3 Troubleshooting Flowcharts120Problem 15 – Engine Will Not CrankWhen Utility Power Source Fails120Problem 16 – Engine Will Not Crank WhenAUTO-OFF-MANUAL Switchis Set to “MANUAL120Problem 17 – Engine Cranksbut Won’t Start121Problem 18 – Engine Starts Hard andRuns Rough / Lacks Power / Backfires122Problem 19 – Shutdown Alarm /Fault Occurred123Problem 20 – 7.5 Amp Fuse (F1) Blown124Problem 21 – Generator Will Not Exercise124Problem 22 – No Low Speed Exercise1244.4 Diagnostic Tests125Introduction125Test 56 – Check Position OfAuto-Off- Manual Switch125Test 57 – Try a Manual Start125Test 58 – Auto-Off-Manual Switch(V-Twin Only)125Test 59 – Test Auto Operations126Test 60 – Check 7.5 Amp Fuse126Test 61 – Check Battery126Test 62 – Check Wire 56 Voltage128Test 63 – Test Starter Contactor Relay(V-twin Only)128Test 64 – Test Starter Contactor(Single Cylinder Engine)129Test 65 – Test Starter Motor130Test 66 – Check Fuel Supply and Pressure132Test 67 – Check Circuit BoardWire 14 Output133Test 68 – Check Fuel Solenoid134Test 69 – Check Choke Solenoid134Test 70 – Check for Ignition Spark136Test 71 – Check Spark Plugs138Test 72 – Check Engine / Cylinder LeakDown Test / Compression Test138Test 73 – Check Shutdown Wire139Test 74 – Check and AdjustIgnition Magnetos140Test 75 – Check Oil Pressure Switchand Wire 86143Test 76 – Check High OilTemperature Switch144Test 77 – Check and Adjust Valves144Test 78 – Check Wire 18 Continuity145Test 79 – Test Exercise Function146Test 80 – Check Cranking andRunning Circuits146Test 81 – Check to see if Low SpeedFunction is enabled148Test 82 – Check operation of theChoke Solenoid148PART 5 - OPERATIONAL TESTS1495.1 System Functional Tests150Introduction150Manual Transfer Switch Operation150Electrical Checks150Generator Tests Under Load151Checking Automatic Operation152Setting The Exercise Timer152PART 6 - DISASEMBLY1536.1 Major Disassembly154Front Engine Access154Major Disassembly158Torque Requirements(Unless Otherwise Specified)164PART 7 - ELECTRICAL DATA165Wiring Diagram, 8 kW Home Standby166Schematic, 8 kW Home Standby168Wiring Diagram, 10 kW Home Standby170Schematic, 10 kW Home Standby172Wiring Diagram, 14 kW Home Standby174Schematic, 14 kW Home Standby176Wiring Diagram, 17 kW Home Standby178Schematic, 17 kW Home Standby180Wiring Diagram, 20 kW Home Standby182Schematic, 20 kW Home Standby184Wiring Diagram, Home Standby Transfer Switch,9/10/12/16 Circuit186Schematic, Home Standby Transfer Switch,9/10/12/16 Circuit188Größe: 18,5 MBSeiten: 192Language: EnglishHandbuch öffnen
BenutzerhandbuchInhaltsverzeichnis1.6 Engine-Generator Protective Devices25Specifications4General25Generator4Low Battery25Engine5Low Oil Pressure Shutdown25Fuel Consumption5High Temperature Switch25Mounting Dimensions6Overspeed Shutdown25Mounting Dimensions7Rpm Sensor Failure25Major Features8Overcrank Shutdown26PART 1 - GENERAL INFORMATION91.7 Operating Instructions271.1 Generator Identification10Control Panel27Introduction10To Select Automatic Operation281.2 Installation Basics11and Manual Startup28Introduction11Selecting A Location11Retransfer Back To “Utility”28Grounding The Generator111.8 Automatic Operating Parameters29The Fuel Supply11Introduction29The Transfer Switch / Load Center11Automatic Operating Sequences29Power Source And Load Lines13PART 2 - AC GENERATORS31System Control Interconnections132.1 Description and Components32Natural Gas Fuel Interconnections13Introduction321.3 Non-prepackaged Interconnections14Engine-Generator Drive System32The AC Generator32Air-Cooled Generator14Rotor Assembly32Stator Assembly33Brush Holder And Brushes (12-20 kW)34Air-Cooled Generator15Other AC Generator Components341.4 Preparation Before Use162.2 Operational Analysis35General16Rotor Residual Magnetism35Fuel Requirements16Field Boost (12-20 kW)35Fuel Consumption16Operation (8/10 kW)36Reconfiguring The Fuel System16Operation (12-20 kW)36Engine Oil Recommendations182.3 Troubleshooting Flowcharts371.5 Testing, Cleaning and Drying19Meters.19The Vom19Measuring AC Voltage19Voltage or Residual Voltage (8/10 kW)38Measuring DC Voltage19Low Voltage at No-Load39Measuring AC Frequency19Measuring Current20High Voltage at No-Load39Measuring Resistance20Electrical Units21Excessively When Loads are Applied40Ohm’s Law212.4 Diagnostic Tests41Visual Inspection22Introduction41Insulation Resistance22Safety.41The Megohmmeter22Test 1 – Check Main Circuit Breaker41Stator Insulation Resistance Test (12-20 kW)23Test 2 – Check AC Output Voltage41Stator Insulation Resistance Test (8-10 kW)23Amp Draw Test42Rotor Insulation Resistance Test (8-10 kW)24Test 5 – Wire Continuity (12-20 kW)43Rotor Insulation Resistance Test (12-20 kW)24Test 6 – Check Field Boost (12-20 kW)44Cleaning The Generator24Drying The Generator24(12-20 kW)44(Pre-Packed Load Center)73Test 8 – Test Brushless Stator45Test 9 – Check Capacitor46(RTSN & RTSE Transfer Switch)73Brushless units47(Gen-Ready Load Center)73(12-20 kW)48(Load Shed Transfer Switch)733.4 Diagnostic Tests74(12-20 kW)48General74Test 13 – Test Rotor Assembly(12-20 kW)49Test 14 – Check AC Output Frequency49Terminal Lugs E1, E274Operation75(Single Cylinder Units)49Wiring/Connections76(V-twin Engine Units)50Test 29 – Test Transfer Relay TR77Regulator (12-20 kW)51Test 30 – Standby Control Circuit78Test 31 – Check Wire 2378Under Load52Test 32 – Utility Control Circuit80Test 19 – Check For Overload Condition52Test 33 – Test Limit Switch SW2 and SW382Test 20 – Check Engine Condition52Test 34 – Check Fuses F1 and F282Test 21 – Field Flash Alternator (8-10 kW)52Test 35 – Check N1 and N2 Wiring83PART 3 - TRANSFER SWITCH55Test 36 – Check N1 and N2 Voltage833.1 Description and Components56General56at the Circuit Board84Enclosure56Test 38 – Check Utility Sense Voltage84Transfer Mechanism57Terminal Lugs N1, N284Transfer Relay57Neutral Lug58Voltage “Pre-Wire Load Center”86Manual Transfer Handle58Terminal Block58Voltage “Pre-Wire Load Center”86Fuse Holder59“Pre-Wire Load Center”863.2 Operational Analysis60Operational Analysis60Utility Source Voltage Available .62“RTSN & RTSE Transfer Switch”87Utility Source Voltage Failure63Transfer To Standby64“RTSN & RTSE Transfer Switch”87Transfer To Standby65Utility Restored66“RTSN & RTSE Transfer Switch”87Utility Restored, Retransfer Back To Utility68“GenReady Load Center”90Transfer Switch In Utility693.3 – Troubleshooting Flowcharts70“GenReady Load Center”90Introduction To Troubleshooting70“GenReady Load Center”90No Transfer to Standby70“Load Shed Transfer Switch”92During Exercise Or In Manual Mode71“Load Shed Transfer Switch”92Problem 9 – Blown F1 or F2 Fuse71“Load Shed Transfer Switch”94Occurs When Utility Power Is On72PART 4 - DC CONTROL95Test 68 – Check Fuel Solenoid1324.1 Description and Components96Test 69 – Check Choke Solenoid132General96Test 70 – Check for Ignition Spark134Terminal Strip / Interconnection Terminal96Test 71 – Check Spark Plugs136Circuit Board96Auto-Off-Manual Switch96Down Test / Compression Test1367.5 Amp Fuse96Test 73 – Check Shutdown Wire137Menu System Navigation102Ignition Magnetos1384.2 Operational Analysis104Introduction104and Wire 86141Utility Source Voltage Available104Initial Dropout of Utility Source Voltage106Temperature Switch142Test 77 – Check and Adjust Valves142Engine Cranking108Test 78 – Check Wire 18 Continuity143Engine Startup and Running110Test 79 – Test Exercise Function144Initial Transfer to the “Standby” Source112Running Circuits144Re-transfer to Utility114Engine Shutdown116Function is enabled1464.3 Troubleshooting Flowcharts118Choke Solenoid146When Utility Power Source Fails118PART 5 - OPERATIONAL TESTS .1475.1 System Functional Tests148Introduction148is Set to “MANUAL118Manual Transfer Switch Operation148but Won’t Start119Electrical Checks148Generator Tests Under Load149Runs Rough / Lacks Power / Backfires120Checking Automatic Operation150Setting The Exercise Timer150Fault Occurred121PART 6 - DISASSEMBLY151Problem 20 – 7.5 Amp Fuse (F1) Blown1226.1 Major Disassembly152Front Engine Access152Problem 22 – No Low Speed Exercise122Major Disassembly1564.4 Diagnostic Tests123Introduction123(Unless Otherwise Specified)162PART 7 - ELECTRICAL DATA163Auto-Off- Manual Switch123Wiring Diagram, 8 kW Home Standby164Test 57 – Try a Manual Start123Schematic, 8 kW Home Standby166Wiring Diagram, 10 kW Home Standby168(V-Twin Only)123Test 59 – Test Auto Operations124Schematic, 10 kW Home Standby170Test 60 – Check 7.5 Amp Fuse124Wiring Diagram, 14 kW Home Standby172Test 61 – Check Battery124Schematic, 14 kW Home Standby174Test 62 – Check Wire 56 Voltage126Wiring Diagram, 17 kW Home Standby176Schematic, 17 kW Home Standby178(V-twin Only)126Wiring Diagram, 20 kW Home Standby180Schematic, 20 kW Home Standby182(Single Cylinder Engine)127Test 65 – Test Starter Motor1289/10/12/16 Circuit1849/10/12/16 Circuit186Wire 14 Output1311.1 Generator Identification10Measuring Resistance20Introduction10Electrical Units211.2 Installation Basics11Ohm’s Law21Introduction11Visual Inspection22Selecting A Location11Insulation Resistance22Grounding The Generator11The Megohmmeter22The Fuel Supply11The Transfer Switch / Load Center11Stator Insulation Resistance Test (8-10kW)23Power Source And Load Lines13Rotor Insulation Resistance Test (8-10kW)24System Control Interconnections13Rotor Insulation Resistance Test (12-20kW)24Natural Gas Fuel Interconnections13Cleaning The Generator241.3 Non-prepackaged Interconnections14Drying The Generator241.6 Engine-Generator Protective Devices25General25Air-Cooled Generator14Low Battery25Low Oil Pressure Shutdown25Air-Cooled Generator15High Temperature Switch251.4 Preparation Before Use16Overspeed Shutdown25General16Rpm Sensor Failure25Fuel Requirements16Overcrank Shutdown26Fuel Consumption161.7 Operating Instructions27Reconfiguring The Fuel System16Control Panel27Engine Oil Recommendations18To Select Automatic Operation281.5 Testing, Cleaning and Drying19Meters.19and Manual Startup28The Vom19Retransfer Back To “Utility”28Measuring AC Voltage191.8 Automatic Operating Parameters29Measuring DC Voltage19Introduction29Measuring AC Frequency19Automatic Operating Sequences29Measuring Current202.1 Description and Components32Test 1 – Check Main Circuit Breaker41Introduction32Test 2 – Check AC Output Voltage41Engine-Generator Drive System32The AC Generator32Amp Draw Test42Rotor Assembly32Test 5 – Wire Continuity (12-20 kW)43Stator Assembly33Test 6 – Check Field Boost (12-20 kW)44Brush Holder And Brushes (12-20 kW)34(12-20 kW)44Other AC Generator Components34Test 8 – Test Brushless Stator452.2 Operational Analysis35Test 9 – Check Capacitor46Rotor Residual Magnetism35Field Boost (12-20 KW Units)35Brushless units47Operation (8/10 kW)36Operation (12-20 kW)36(12-20 kW)482.3 Troubleshooting Flowcharts37(12-20 kW)48Voltage or Residual Voltage 12-20 kW37Test 13 – Test Rotor Assembly(12-20 kW)49Test 14 – Check AC Output Frequency49Voltage or Residual Voltage 8/10 kW38(Single Cylinder Units)49Low Voltage at No-Load39(V-twin Engine Units)50High Voltage at No-Load39Regulator (12-20 kW)51Excessively When Loads are Applied402.4 Diagnostic Tests41Under Load52Introduction41Test 19 – Check For Overload Condition52Safety.41Test 20 – Check Engine Condition52Test 21 – Field Flash Alternator (8-10 kW)523.1 Description and Components56Wiring/Connections76Enclosure56Test 29 – Test Transfer Relay TR77Transfer Mechanism57Test 30 – Standby Control Circuit78Transfer Relay57Test 31 – Check Wire 2378Neutral Lug58Test 32 – Utility Control Circuit80Manual Transfer Handle58Test 33 – Test Limit Switch SW2 and SW382Terminal Block58Test 34 – Check Fuses F1 and F282Fuse Holder59Test 35 – Check N1 and N2 Wiring833.2 Operational Analysis60Test 36 – Check N1 and N2 Voltage83Operational Analysis60Utility Source Voltage Available62at the Circuit Board84Utility Source Voltage Failure63Test 38 – Check Utility Sense Voltage84Transfer To Standby64Transfer To Standby65Terminal Lugs N1, N284Utility Restored66Voltage “Pre-Wire Load Center”86De-energized67Utility Restored, Retransfer Back To Utility68Voltage “Pre-Wire Load Center”86Transfer Switch In Utility693.3 – Troubleshooting Flowcharts70“Pre-Wire Load Center”86Introduction To Troubleshooting70No Transfer to Standby70“RTSN & RTSE Transfer Switch”87“RTSN & RTSE Transfer Switch”87“RTSN & RTSE Transfer Switch”87Manual Mode71Problem 9 – Blown F1 or F2 Fuse71“GenReady Load Center”90Occurs When Utility Power Is On72(Pre-Packed Load Center)73“GenReady Load Center”90(RTSN + RTSE Transfer Switch)73“GenReady Load Center”90(Gen-Ready Load Center)73“Load Shed Transfer Switch”92(Load Shed Transfer Switch)733.4 Diagnostic Tests74General.74“Load Shed Transfer Switch”92Terminal Lugs E1, E274“Load Shed Transfer Switch”94Test 27 – Check Manual Transfer Switch Operation754.1 Description and Components96Test 57 – Try a Manual Start123General.96(V-Twin Only)123Terminal Strip / Interconnection Terminal96Test 59 – Test Auto Operations124Circuit Board96Test 60 – Check 7.5 Amp Fuse124Auto-Off-Manual Switch96Test 61 – Check Battery1247.5 Amp Fuse96Test 62 – Check Wire 56 Voltage126Menu System Navigation1024.2 Operational Analysis104(V-twin Only)126Introduction104Utility Source Voltage Available104(Single Cylinder Engine)127Initial Dropout of Utility Source Voltage106Test 65 – Test Starter Motor128Test 66 – Check Fuel Supply and Pressure130Engine Cranking108Engine Startup and Running110Wire 14 Output131Initial Transfer to the “Standby” Source112Test 68 – Check Fuel Solenoid132Test 69 – Check Choke Solenoid132Re-transfer to Utility114Test 70 – Check for Ignition Spark134Engine Shutdown116Test 71 – Check Spark Plugs1364.3 Troubleshooting Flowcharts118Down Test / Compression Test136When Utility Power Source Fails118Test 73 – Check Shutdown Wire137Ignition Magnetos138is Set to “MANUAL118and Wire 86141but Won’t Start119Temperature Switch142Runs Rough / Lacks Power / Backfires120Test 77 – Check and Adjust Valves142Fault Occurred121Test 78 – Check Wire 18 Continuity143Problem 20 – 7.5 Amp Fuse (F1) Blown122Test 79 – Test Exercise Function144Problem 21 – Generator Will Not Exercise122Running Circuits144Problem 22 – No Low Speed Exercise1224.4 Diagnostic Tests123Function is enabled146Introduction123Choke Solenoid146Auto-Off- Manual Switch1235.1 System Functional Tests148Introduction148Manual Transfer Switch Operation148Electrical Checks148Generator Tests Under Load149Checking Automatic Operation150Setting The Exercise Timer1506.1 Major Disassembly152Front Engine Access152Major Disassembly156(Unless Otherwise Specified)162Größe: 17,7 MBSeiten: 192Language: EnglishHandbuch öffnen
