Bryant ASPAS1BBA015 Manuale Utente

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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
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1 2 3 4 5 6 ... 143 144

Sommario

Pagina 1 - DIAGNOSTIC

AUTOMATIC HOME STANDBY GENERATORSAIR-COOLEDMODELS:ASPAS1BBA007(6 kW NG, 7 kW LP)ASPAS1BBA012(12 kW NG, 12 kW LP)ASPAS1BBA015(13 kW NG, 15 kW LP)DIAGNO

Pagina 2 - SPECIFICATIONS

Page 10PART 1GENERAL INFORMATIONSECTION 1.2PREPACKAGED INSTALLATION BASICSFigure 1. Typical Prepackaged Installation

Pagina 3 - REPAIR MANUAL

Page 100SECTION 4.4DIAGNOSTIC TESTSd. An average reading of 1.170 indicates thebattery is 25% charged. C. Test Battery Condition: 1.If the difference

Pagina 4

SECTION 4.4DIAGNOSTIC TESTS2. Connect the positive (+) meter test lead to the Wire 13connector. Connect the negative (-) meter test lead to aclean fra

Pagina 5

Page 102SECTION 4.4DIAGNOSTIC TESTSPART 4RESULTS:1. If battery voltage was indicated in Step 1, but not in Step2b, replace the starter contactor.2. If

Pagina 6

SECTION 4.4DIAGNOSTIC TESTSDC CONTROLFigure 11. Check Pinion Gear Operation (Single Cylinder)TOOLS FOR STARTER PERFORMANCE TEST:The following equipmen

Pagina 7 - INFORMATION

Page 104SECTION 4.4DIAGNOSTIC TESTSPART 4DC CONTROL4. A starter motor in good condition will be within thefollowing specifications:Single Cylinder V-t

Pagina 8 - SECTION 1.1

SECTION 4.4DIAGNOSTIC TESTSDC CONTROLTEST 52 - TEST FUEL SOLENOIDNote: This test is for fuel regulators equipped withidle circuit port only. See Figur

Pagina 9

Page 106SECTION 4.4DIAGNOSTIC TESTSPART 4connection and the Fuel Solenoid terminal. IfCONTINUITY was measured in Step 6, proceed to Test52 or test 54

Pagina 10 - SECTION 1.2

SECTION 4.4DIAGNOSTIC TESTSDC CONTROL3. Attach the spark plug lead to the spark tester terminal.4. Crank the engine while observing the spark tester.

Pagina 11

Page 108SECTION 4.4DIAGNOSTIC TESTSPART 4DC CONTROL3. Crank the engine until there is no further increase inpressure.4. Record the highest reading obt

Pagina 12 - SECTION 1.3

SECTION 4.4DIAGNOSTIC TESTSFigure 23. Setting Ignition Magneto (Armature) Air Gap7. Repeat Test 55 and check for spark across the sparktester gap.8. I

Pagina 13 - SECTION 1.4

Page 11SECTION 1.2PREPACKAGED INSTALLATION BASICSGENERAL INFORMATIONPOWER SOURCE AND LOAD LINESThe utility power supply lines, the standby (generator)

Pagina 14

Page 110SECTION 4.4DIAGNOSTIC TESTSPART 412.Now repeat Step 11 with the negative meter test leadconnected to Connector “C” (Figure 26).13.Now check th

Pagina 15

SECTION 4.4DIAGNOSTIC TESTSDC CONTROLa.Set a VOM to its "R x 1" scale and zero themeter.b.Connect the VOM test leads across the switchtermin

Pagina 16

Page 112SECTION 4.4DIAGNOSTIC TESTSDC CONTROLPART 49. Heat the oil in the container. When the thermometerreads approximately 274°-294° F. (134°-146° C

Pagina 17

SECTION 4.4DIAGNOSTIC TESTSDC CONTROLPART 4Page 1135. When the highest frequency is reached, maximumpower has been set. From this point turn the adjus

Pagina 18

Page 114SECTION 4.4DIAGNOSTIC TESTSPART 4DC CONTROLTEST 65 - CHECK TRANSFORMER (TX)VOLTAGE OUTPUTDISCUSSION:The Transformer (TX) is a “step down” type

Pagina 19 - SECTION 1.5

SECTION 4.4DIAGNOSTIC TESTSFigure 33. Battery Charge Relay Test PointsTEST 67 - CHECK BATTERY CHARGE RELAY(BCR)DISCUSSION:The battery charge relay is

Pagina 20 - EXERCISER NOT SET

Page 116SECTION 4.4DIAGNOSTIC TESTSPART 4Figure 34. C2 Connector Pin Locations (MaleSide)4. Connect one test lead to Connector C2 Pin Location 1(Wire

Pagina 21 - SECTION 1.6

SECTION 4.4DIAGNOSTIC TESTSRESULTS:1. If CONTINUITY is not measured in Step 5, repair orreplace Wire 66A between Connector C2 andConnector J1 at the c

Pagina 22 - SECTION 1.7

Page 118SECTION 4.4DIAGNOSTIC TESTS6. Connect one meter test lead to Wire 351 (previouslyremoved from SW2). Connect the other meter test leadto Pin Lo

Pagina 23

SECTION 4.4DIAGNOSTIC TESTSJ1-4, Wire 194 If CONTINUITY was measured, goto Step 4. Average nominalresistance reading: 110-120 ohms.J1-5, Wire 56 If

Pagina 24 - GENERAL INFORMATION

Page 12PART 1GENERAL INFORMATIONSECTION 1.3PREPARATION BEFORE USEGENERALThe installer must ensure that the home standbygenerator has been properly ins

Pagina 25 - AC GENERATORS

Page 120SECTION 4.4DIAGNOSTIC TESTSPART 43. Hold the Set Exercise switch until the generator starts(approximately 10 seconds) and then release. Thegen

Pagina 26 - SECTION 2.1

PART TITLE5.1 System Functional TestsPART 5OPERATIONALTESTS Air-cooled, PrepackagedAutomatic Standby GeneratorsModels:6 kW NG, 7 kW LP12 kW NG, 12 kW

Pagina 27

Page 122SECTION 5.1SYSTEM FUNCTIONAL TESTSINTRODUCTIONFollowing home standby electric system installationand periodically thereafter, the system shoul

Pagina 28

Page 123SECTION 5.1SYSTEM FUNCTIONAL TESTSusing the means provided (such as a utility main linecircuit breaker).THE TRANSFER SWITCH IS NOWELECTRICALLY

Pagina 29 - SECTION 2.2

Page 124SECTION 5.1SYSTEM FUNCTIONAL TESTSOPERATIONAL TESTSAND ADJUSTMENTSPART 510.Connect an accurate AC voltmeter and a frequencymeter across termin

Pagina 30

PART TITLE6.1 Major DisassemblyPART 6DISASSEMBLYAir-cooled, PrepackagedAutomatic Standby GeneratorsModels:6 kW NG, 7 kW LP12 kW NG, 12 kW LP13 kW NG,

Pagina 31 - SECTION 2.3

Page 126MAJOR DISASSEMBLYSTATOR/ROTOR/ENGINE REMOVAL:For stator removal, follow Steps 1-14. For rotorremoval, follow Steps 1-15. For Engine removal fo

Pagina 32

Page 127SECTION 6.1MAJOR DISASSEMBLYDISASSEMBLYPART 6Remove the two bolts attaching the muffler side cover tothe back enclosure panel. They are locate

Pagina 33

Page 128SECTION 6.1MAJOR DISASSEMBLYPART 6DISASSEMBLYFigure 7. Removing the Rotor16.Remove Engine: Using a 13mm socket, remove thetwo engine mount nut

Pagina 34

DWG # TITLE0D9014-B WIRING DIAGRAM, 7 KW HSB0D9015-B SCHEMATIC, 7 KW HSB0D9016-B WIRING DIAGRAM, 12 & 15 KW HSB0D9017-B SCHEMATIC, 12 & 15 KW

Pagina 35 - SECTION 2.4

Page 13SECTION 1.4TESTING, CLEANING AND DRYINGGENERAL INFORMATIONVISUAL INSPECTIONWhen it becomes necessary to test or troubleshoot agenerator, it is

Pagina 36

Page 130WIRING DIAGRAM, 7 KW HOME STANDBYPART 7ELECTRICAL DATA+-CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATIONTX - TRANSFORMER, 16 Vac 56 VA & 16 Va

Pagina 37

WIRING DIAGRAM, 7 KW HOME STANDBYELECTRICAL DATAPART 794SWITCH CONTACTOR240V GENERATOROUTPUT TO TRANSFER82066A19401566A23915A231515AF21313140224225035

Pagina 38

Page 132SCHEMATIC, 7 KW HOME STANDBYPART 7ELECTRICAL DATATX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)CB2 - CIRCUIT BREAKER, ALT. EXCIT

Pagina 39

SCHEMATIC, 7 KW HOME STANDBY224A14185612VBATTERYSUPPLIEDCUSTOMER230C1-51517018018C1-60194239C1-11715A1700561315SC2315A15SW1SP0DIMBLACK3311144SMFS14C1-

Pagina 40

Page 134WIRING DIAGRAM, 12 & 15 KW HOME STANDBYPART 7ELECTRICAL DATA-+TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)BLACKCUSTOMER SU

Pagina 41

Page 135WIRING DIAGRAM, 12 & 15 KW HOME STANDBYELECTRICAL DATAPART 7DRAWING #0E9016 (2 OF 2)194224224225152242254224B225B142250013CLOSEST TO BEARI

Pagina 42

Page 136SCHEMATIC, 12 & 15 KW HOME STANDBYCHARGERBATTERYTX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)0DIAGRAM KEYBA - BRUSH ASSEMBL

Pagina 43

SCHEMATIC, 12 & 15 KW HOME STANDBYELECTRICAL DATAPART 7F1SMC1-115018C1-5561817151715ASCR000151623915140194231318DIM2IM1SP2SP123160130SW115A239194F

Pagina 44

PART 7ELECTRICAL DATAWIRING DIAGRAM, 8 CIRCUIT LOAD CENTERPage 138DRAWING #0E7687A

Pagina 45 - SWITCHES

ELECTRICAL DATASCHEMATIC, 8 CIRCUIT LOAD CENTERPART 7Page 139DRAWING #0E7815ASCHEMATIC DIAGRAMHSB X-FER SWITCH, 8 CIR.0E7815AF1BN2ABN2AABE2C1E2T1T2T2T

Pagina 46 - SECTION 3.1

Page 14SECTION 1.4TESTING, CLEANING AND DRYINGPART 1GENERAL INFORMATION2. Before reading a DC voltage, always set the meter to ahigher voltage scale t

Pagina 47

Page 140DRAWING #07687PART 7ELECTRICAL DATAWIRING DIAGRAM, 10 & 12 CIRCUIT LOAD CENTER

Pagina 48

Page 141DRAWING #0E7815NEUTRALCONNECTIONINSIDE SWITCHXBNOC1COMXANCNCCOMNOTR1942369F2CONNECTION15A/120V CIRCUIT 920A/120V CIRCUIT 10BLACK (MAIN 1)20A/1

Pagina 49

Page 142PART 7ELECTRICAL DATANOTES

Pagina 50 - SECTION 3.2

Page 143TO FIND KNOWN VALUES 1-PHASE 3-PHASEKILOWATTS (kW) Volts, Current, Power Factor E x I E x I x 1.73 x PF1000 1000KVA Volts, Current E x I E x I

Pagina 51

Part No. 0F4676 Revision * (02/25/05) Printed in U.S.A.Catalog No. DMASPAS.07.1

Pagina 52

Page 15SECTION 1.4TESTING, CLEANING AND DRYINGGENERAL INFORMATIONIf proper procedures are used, the followingconditions can be detected using a VOM:•

Pagina 53

Page 16SECTION 1.4TESTING, CLEANING AND DRYINGPART 1GENERAL INFORMATIONINSULATION RESISTANCEThe insulation resistance of stator and rotor windingsis a

Pagina 54

SECTION 1.4TESTING, CLEANING AND DRYINGGENERAL INFORMATIONPART 1Page 17parallel windings. Figure 2 is a pictorial representationof the various stator

Pagina 55

Page 18SECTION 1.4TESTING, CLEANING AND DRYINGPART 1GENERAL INFORMATION5. Insert a large paper clip into Pin Location No. 1 (Wire77). Connect the red

Pagina 56

Page 19SECTION 1.5ENGINE-GENERATOR PROTECTIVE DEVICESGENERAL INFORMATIONGENERALStandby electric power generators will often rununattended for long per

Pagina 57

SPECIFICATIONSGENERATORModel ASPAS1BBA007 Model ASPAS1BBA012 Model ASPAS1BBA015Rated Max. Continuous Power Capacity (Watts*) 6,000 NG/7,000 LP 12,000

Pagina 58

Page 20CONTROL PANELGENERAL:See Figure 1. The front face of this panel mounts(a) an Auto-Off-Manual switch, (b) a 15 amp fuse,(c) a 7.5 amp fuse, (d)

Pagina 59 - SECTION 3.3

SECTION 1.6OPERATING INSTRUCTIONSPROTECTION SYSTEMS:Unlike an automobile engine, the generator may haveto run for long periods of time with no operato

Pagina 60

Page 22SECTION 1.7AUTOMATIC OPERATING PARAMETERSINTRODUCTIONWhen the prepackaged generator is installed inconjunction with a prepackaged transfer swit

Pagina 61 - SECTION 3.4

GENERAL INFORMATIONSECTION 1.7AUTOMATIC OPERATING PARAMETERSPART 1Page 23AUTOMATIC OPERATING SEQUENCES CHARTSEQ. CONDITION ACTION SENSOR, TIMER OR OTH

Pagina 62

Page 24NOTESPART 1GENERAL INFORMATION

Pagina 63

PART 2AC GENERATORSTABLE OF CONTENTSPART TITLE2.1 Description and Components2.2 Operational Analysis2.3 Troubleshooting Flow Charts2.4 Diagnostic Test

Pagina 64

Page 26SECTION 2.1DESCRIPTION & COMPONENTSPART 2AC GENERATORSINTRODUCTIONThe air-cooled, pre-packaged automatic standbysystem is an easy to instal

Pagina 65

Page 27SECTION 2.1DESCRIPTION & COMPONENTSAC GENERATORSPART 2Figure 2. The 2-Pole Rotor AssemblySTATOR ASSEMBLYThe stator can houses and retains (

Pagina 66

Page 28SECTION 2.1DESCRIPTION & COMPONENTSPART 2AC GENERATORSFigure 5. Excitation Circuit BreakerVOLTAGE REGULATOR:A typical voltage regulator is

Pagina 67

Page 29SECTION 2.2OPERATIONAL ANALYSISAC GENERATORSROTOR RESIDUAL MAGNETISMThe generator revolving field (rotor) may beconsidered to be a permanent ma

Pagina 68

PART TITLESpecifications1 General Information2 AC Generators3 V-Type Prepackaged Transfer Switches4 DC Control5 Operational Tests and Adjustments6 Dis

Pagina 69

Page 30SECTION 2.2OPERATIONAL ANALYSISPART 2AC GENERATORSOPERATIONSTARTUP:When the engine is started, residual plus field boostmagnetism from the roto

Pagina 70

Page 31SECTION 2.3TROUBLESHOOTING FLOWCHARTSAC GENERATORSUse the “Flow Charts” in conjunction with the detailedinstructions in Section 2.4. Test numbe

Pagina 71 - DC CONTROL

Page 32SECTION 2.3TROUBLESHOOTING FLOWCHARTSPART 2AC GENERATORS

Pagina 72 - SECTION 4.1

Page 33SECTION 2.3TROUBLESHOOTING FLOWCHARTSAC GENERATORSPART 2

Pagina 73

Page 34SECTION 2.3TROUBLESHOOTING FLOWCHARTSPART 2AC GENERATORS

Pagina 74

Page 35SECTION 2.4DIAGNOSTIC TESTSAC GENERATORSINTRODUCTIONThis section is provided to familiarize the servicetechnician with acceptable procedures fo

Pagina 75

Page 36SECTION 2.4DIAGNOSTIC TESTSPART 2AC GENERATORSTEST 2- CHECK AC OUTPUT VOLTAGEDISCUSSION:A volt-ohm-milliammeter (VOM) may be used tocheck the g

Pagina 76 - SECTION 4.2

Page 37SECTION 2.4DIAGNOSTIC TESTSAC GENERATORSTEST 4- FIXED EXCITATION TEST/ROTOR AMP DRAW TESTDISCUSSION:Supplying a fixed DC current to the rotor w

Pagina 77

Page 38SECTION 2.4DIAGNOSTIC TESTSPART 2AC GENERATORS8. Set the Auto-Off-Manual switch to MANUAL. Once theengine starts, record the AC voltage.9. Set

Pagina 78

Page 39SECTION 2.4DIAGNOSTIC TESTSAC GENERATORSFigure 4. Field Boost Test PointsTEST 7: TESTING THE STATOR WITH A VOMDISCUSSION:A Volt-OHM-Milliammmet

Pagina 79

Page 4SPECIFICATIONSMOUNTING DIMENSIONS

Pagina 80

Page 40SECTION 2.4DIAGNOSTIC TESTSPART 2AC GENERATORSTEST WINDINGS FOR A SHORT TO GROUND:13.Make sure all leads are isolated from each other and areno

Pagina 81

Page 41SECTION 2.4DIAGNOSTIC TESTSAC GENERATORSRESULTS:1. If the resistance reading is correct, check your VOMmeters fuse and repeat Test 4.2. If INFI

Pagina 82

Page 42SECTION 2.4DIAGNOSTIC TESTSPART 2AC GENERATORSRESULTS:1. Repair, replace or reconnect wires as necessary.2. Replace any damaged slip rings or b

Pagina 83

Page 43SECTION 2.4DIAGNOSTIC TESTSAC GENERATORS3. Start the generator; let it stabilize and warm up at no-load.4. Connect a frequency meter across the

Pagina 84

Page 44SECTION 2.4DIAGNOSTIC TESTSPART 2AC GENERATORSTEST 13 - CHECK AND ADJUST VOLTAGE REGULATORDISCUSSION:For additional information, refer to descr

Pagina 85

PART TITLE3.1 Description and Components3.2 Operational Analysis3.3 Troubleshooting Flow Charts3.4 Diagnostic TestsPART 3“V-TYPE”PREPACKAGEDTRANSFERSW

Pagina 86

Page 46SECTION 3.1DESCRIPTION & COMPONENTSPART 3“V-TYPE” PREPACKAGEDTRANSFER SWITCHESGENERALThe prepackaged, “V-Type” transfer switch is rated100

Pagina 87

Page 47SECTION 3.1DESCRIPTION & COMPONENTS“V-TYPE” PREPACKAGEDTRANSFER SWITCHESPART 3UTILITY contacts, and a pair of stationary STANDBYcontacts. T

Pagina 88

Page 48SECTION 3.1DESCRIPTION & COMPONENTSa.The 12 volts DC circuit is completed through thetransfer relay coil and back to the generatorcircuit b

Pagina 89

Page 49SECTION 3.1DESCRIPTION & COMPONENTSdelivered to a step-down transformer in the controlmodule assembly and the resultant reduced voltage ist

Pagina 90 - SECTION 4.3

Page 5SPECIFICATIONSMOUNTING DIMENSIONS

Pagina 91

Page 50SECTION 3.2OPERATIONAL ANALYSISPART 3“V-TYPE” PREPACKAGEDTRANSFER SWITCHESOPERATIONAL ANALYSISFigure 1 is a schematic and wiring diagram for a

Pagina 92

Page 51SECTION 3.2OPERATIONAL ANALYSIS“V-TYPE” PREPACKAGEDTRANSFER SWITCHESPART 3UTILITY SOURCE VOLTAGE AVAILABLE Figure 2 is a schematic representati

Pagina 93

Page 52SECTION 3.2OPERATIONAL ANALYSISPART 3“V-TYPE” PREPACKAGEDTRANSFER SWITCHESUTILITY SOURCE VOLTAGE FAILURE If utility source voltage should drop

Pagina 94

Page 53SECTION 3.2OPERATIONAL ANALYSIS“V-TYPE” PREPACKAGEDTRANSFER SWITCHESPART 3TRANSFER TO STANDBY The generator circuit board delivers 12 volts DC

Pagina 95

Page 54SECTION 3.2OPERATIONAL ANALYSISPART 3“V-TYPE” PREPACKAGEDTRANSFER SWITCHESTRANSFER TO STANDBY When the standby coil is energized it pulls the t

Pagina 96

Page 55SECTION 3.2OPERATIONAL ANALYSIS“V-TYPE” PREPACKAGEDTRANSFER SWITCHESPART 3UTILITY RESTOREDUtility voltage is restored and is available to termi

Pagina 97 - TEST 42 - TRY A MANUAL START

Page 56SECTION 3.2OPERATIONAL ANALYSISPART 3“V-TYPE” PREPACKAGEDTRANSFER SWITCHESUTILITY RESTORED, TRANSFER SWITCH DE-ENERGIZEDAfter the preset time i

Pagina 98 - DIAGNOSTIC TESTS

Page 57SECTION 3.2OPERATIONAL ANALYSIS“V-TYPE” PREPACKAGEDTRANSFER SWITCHESPART 3UTILITY RESTORED, RETRANSFER BACK TO UTILITYAs the utility coil pulls

Pagina 99

Page 58SECTION 3.2OPERATIONAL ANALYSISPART 3“V-TYPE” PREPACKAGEDTRANSFER SWITCHESTRANSFER SWITCH IN UTILITYWhen the transfer switch returns to the uti

Pagina 100 - (V-TWIN ONLY)

Page 59SECTION 3.3TROUBLESHOOTING FLOW CHARTSINTRODUCTION TO TROUBLESHOOTINGThe first step in troubleshooting is to correctly identify the problem. On

Pagina 101 - SECTION 4.4

Page 6SPECIFICATIONSMAJOR FEATURES12 kW and 15 kW, V-twin GT-990 Engine7 kW, Single Cylinder GH-410 Engine

Pagina 102

Page 60SECTION 3.3TROUBLESHOOTING FLOW CHARTSPART 3“V-TYPE” PREPACKAGEDTRANSFER SWITCHES

Pagina 103

Page 61SECTION 3.4DIAGNOSTIC TESTS“V-TYPE” PREPACKAGEDTRANSFER SWITCHESGENERALTest numbers in this section correspond to thenumbered tests in Section

Pagina 104

Page 62SECTION 3.4DIAGNOSTIC TESTSPART 3“V-TYPE” PREPACKAGEDTRANSFER SWITCHESe.Set the generator Auto-Off-Manual switch toAUTO.(1) The generator shoul

Pagina 105

Page 63SECTION 3.4DIAGNOSTIC TESTS3. Connect the VOM test leads across Relay Terminals 6and 9 with the relay de-energized. The VOM shouldread infinity

Pagina 106

Page 64SECTION 3.4DIAGNOSTIC TESTSPART 3“V-TYPE” PREPACKAGEDTRANSFER SWITCHESusing whatever means provided (such as a utility sourcemain line breaker)

Pagina 107

Page 65SECTION 3.4DIAGNOSTIC TESTS5. Connect the positive (+) test lead to Wire 23 at theterminal strip in the transfer switch.a.If voltage is present

Pagina 108

Page 66SECTION 3.4DIAGNOSTIC TESTS“Utility 1” and “Utility 2” terminals. Normal line-to-lineutility source voltage should be indicated.Figure 4. Trans

Pagina 109

Page 67SECTION 3.4DIAGNOSTIC TESTS5. If normal utility source line-to-line voltage is NOTindicated in Step 8, and is NOT indicated in Step 9,proceed t

Pagina 110

Page 68SECTION 3.4DIAGNOSTIC TESTSPART 3“V-TYPE” PREPACKAGEDTRANSFER SWITCHES7. Disconnect Wire N1A from transfer relay (TR) terminaland connect one t

Pagina 111

Page 69SECTION 3.4DIAGNOSTIC TESTS“V-TYPE” PREPACKAGEDTRANSFER SWITCHESRESULTS:If a short is indicated in steps 5 through 9, repairwiring and re-test.

Pagina 112

PART TITLE1.1 Generator Identification1.2 Prepackaged Installation Basics1.3 Preparation Before Use1.4 Testing, Cleaning and Drying1.5 Engine-Generato

Pagina 113

Page 70SECTION 3.4DIAGNOSTIC TESTSPART 3“V-TYPE” PREPACKAGEDTRANSFER SWITCHES

Pagina 114

PART TITLE4.1 Description and Components4.2 Operational Analysis4.3 Troubleshooting Flow Charts4.4 Diagnostic TestsPART 4DC CONTROLAir-cooled, Prepack

Pagina 115

Page 72SECTION 4.1DESCRIPTION AND COMPONENTSPART 43DC CONTROLGENERALThis section will familiarize the reader with the variouscomponents that make up t

Pagina 116

Page 73SECTION 4.1DESCRIPTION AND COMPONENTSDC CONTROLPART 4J1 PIN WIRE CIRCUIT FUNCTION1 4 Field boost current to rotor (about 9-10 volts DC).2 86 Lo

Pagina 117

Page 74The circuit board mounts a crank relay (K1) and a runrelay (K2, see Figure 4). Crank relay (K1) isenergized by circuit board action during both

Pagina 118

Page 75SECTION 4.1DESCRIPTION AND COMPONENTSDC CONTROLPART 4FUSE HOLDER (F2)FUSE HOLDER (F1)GROUND TERMINALBATTERY CHARGERTERMINAL STRIPSTARTER CONTAC

Pagina 119

SECTION 4.2OPERATIONAL ANALYSISPART 4DC CONTROLINTRODUCTIONThis "Operational Analysis" is intended to familiarizethe service technician with

Pagina 120

Page 77SECTION 4.2OPERATIONAL ANALYSISDC CONTROLPART 4• "Utility" voltage is delivered to the primary windingof a sensing transformer (TX),

Pagina 121 - OPERATIONAL

Page 78SECTION 4.2OPERATIONAL ANALYSISPART 4DC CONTROLINITIAL DROPOUT OFUTILITY SOURCE VOLTAGERefer to Figure 2, above. Should a "Utility" p

Pagina 122 - SECTION 5.1

Page 79SECTION 4.2OPERATIONAL ANALYSISDC CONTROLPART 4• Should "Utility" voltage drop below approximately60 percent of the nominal source vo

Pagina 123

Page 8SECTION 1.1GENERATOR IDENTIFICATIONGENERAL INFORMATIONPART 1INTRODUCTIONThis Diagnostic Repair Manual has been preparedespecially for the purpos

Pagina 124

Page 80SECTION 4.2OPERATIONAL ANALYSISPART 4DC CONTROLUTILITY VOLTAGE DROPOUT / ENGINECRANKING• After fifteen (15) seconds and when the circuitboard&a

Pagina 125 - DISASSEMBLY

Page 81SECTION 4.2OPERATIONAL ANALYSISDC CONTROLPART 4• When the circuit board's run relay (K2) energizes,12 volts DC is delivered to a fuel sole

Pagina 126 - SECTION 6.1

Page 82ENGINE STARTUP AND RUNNINGWith the fuel solenoid open and ignition occurring, theengine starts. Engine startup and running may bebriefly descri

Pagina 127

• The "engine warm-up timer" will run for about 15seconds. When this timer finishes timing, boardaction will initiate transfer to the "

Pagina 128

Page 84SECTION 4.2OPERATIONAL ANALYSISPART 4DC CONTROLINITIAL TRANSFER TO THE "STANDBY"SOURCEThe generator is running, the circuit board&apo

Pagina 129 - ELECTRICAL

SECTION 4.2OPERATIONAL ANALYSISDC CONTROLPART 4Page 85XB1, Wire B, and a bridge rectifier. The standbyclosing coil energizes and the main current carr

Pagina 130 - DRAWING #0E9014 (1 OF 2)

Page 86SECTION 4.2OPERATIONAL ANALYSISPART 4DC CONTROLUTILITY VOLTAGE RESTORED / RE-TRANSFER TO UTILITYThe "Load" is powered by the "St

Pagina 131 - DRAWING #0E9014 (2 OF 2)

SECTION 4.2OPERATIONAL ANALYSISDC CONTROLPART 4Page 87position past "Neutral" and spring force closes themto their "Utility" side.

Pagina 132 - SCHEMATIC, 7 KW HOME STANDBY

Page 88SECTION 4.2OPERATIONAL ANALYSISPART 4DC CONTROLENGINE SHUTDOWNFollowing retransfer back to the "Utility" source, an"engine cool-

Pagina 133

Page 89SECTION 4.2OPERATIONAL ANALYSISDC CONTROLPART 4• The battery charge relay (BCR) connected to Wire14 will be de-energized. This will cause trans

Pagina 134 - DRAWING #0E9016 (1 OF 2)

Page 9SECTION 1.2PREPACKAGED INSTALLATION BASICSGENERAL INFORMATIONINTRODUCTIONInformation in this section is provided so that theservice technician w

Pagina 135 - DRAWING #0E9016 (2 OF 2)

Page 90SECTION 4.3TROUBLESHOOTING FLOW CHARTSPART 4DC CONTROL

Pagina 136 - DRAWING #0E9017 (1 OF 2)

Page 91SECTION 4.3TROUBLESHOOTING FLOW CHARTSDC CONTROLPART 4

Pagina 137 - DRAWING #0E9017 (2 OF 2)

Page 92SECTION 4.3TROUBLESHOOTING FLOW CHARTSPART 4DC CONTROL

Pagina 138 - DRAWING #0E7687A

Page 93SECTION 4.3TROUBLESHOOTING FLOW CHARTSDC CONTROLPART 4

Pagina 139 - DRAWING #0E7815A

Page 94SECTION 4.3TROUBLESHOOTING FLOW CHARTSPART 4DC CONTROL

Pagina 140 - DRAWING #07687

Page 95SECTION 4.3TROUBLESHOOTING FLOW CHARTSDC CONTROLPART 4

Pagina 141 - DRAWING #0E7815

Page 96SECTION 4.3TROUBLESHOOTING FLOW CHARTSPART 4DC CONTROLProblem 17 - 7.5 Amp Fuse (F2) BlownTHE 12 VDC ACCESSORY OUTLET IS CAPABLE OF DELIVERING

Pagina 142 - Page 142

SECTION 4.4DIAGNOSTIC TESTSINTRODUCTION Perform these "Diagnostic Tests" in conjunction withthe "Troubleshooting Flow Charts" of S

Pagina 143 - ELECTRICAL FORMULAS

Page 98SECTION 4.4DIAGNOSTIC TESTSPART 4DC CONTROLPROCEDURE: Disconnect all wires from switch terminals, to preventinteraction. Then, use a volt-ohm-m

Pagina 144

SECTION 4.4DIAGNOSTIC TESTSswitch Terminal 4, Wire 17/178. Connect the negative (-)test lead to a clean frame ground. Battery voltageshould be measur

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