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Diagnostic Repair Manual 5200 Series Air Cooled

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Diagnostic Repair Manual 5200 Series Air Cooled AUTOMATIC HOME STANDBY GENERATORS DIAGNOSTIC REPAIR MANUAL MODELS 6 kW NG, 7 kW LP 9 kW NG, 10 kW LP 13 kW NG, 13 kW LP 15 kW NG, 16 kW LP 16 kW NG, 18 kW LP ELECTRICAL FORMULAS TO FIND KNOWN VALUES 1-PHASE 3-PHASE E x I E x I x 1.73 x PF KILOWATTS (kW) Volts, Current, Power Factor 1000 1000 E x I E x I x 1.73 KVA Volts, Current 1000 1000 kW x 1000 kW x 1000 AMPERES kW, Volts, Power Factor E E x 1.73 x PF WATTS Volts, Amps, Power Factor Volts x Amps E x I x 1.73 x PF 2 x 60 x Frequency 2 x 60 x Frequency NO. OF ROTOR POLES Frequency, RPM RPM RPM RPM x Poles RPM x Poles FREQUENCY RPM, No. of Rotor Poles 2 x 60 2 x 60 2 x 60 x Frequency 2 x 60 x Frequency RPM Frequency, No. of Rotor Poles Rotor Poles Rotor Poles HP x 0.746 HP x 0.746 kW (required for Motor) Motor Horsepower, Efficiency Efficiency Efficiency E E RESISTANCE Volts, Amperes I I VOLTS Ohm, Amperes I x R I x R E E AMPERES Ohms, Volts R R E = VOLTS I = AMPERES R = RESISTANCE (OHMS) PF = POWER FACTOR Contents Overspeed Shutdown ......................................23 SPECIFICATIONS ..................................................... 4 RPM Sensor Failure .........................................23 Generator ................................................................ 4 Overcrank Shutdown .......................................24 Stator Winding Resistance Values/ 1.6 Operating Instructions ..................................... 25 Rotor Resistance ..................................................... 4 Control Panel ...................................................25 Engine ..................................................................... 5 To Select Automatic Operation ........................26 Fuel Consumption ................................................... 5 Manual Transfer To “Standby” And Mounting Dimensions ........................................... 6-7 Manual Startup ....................................26 Major Features ........................................................ 8 Manual Shutdown And Retransfer Back To “Utility” ....................................27 PART 1 - GENERAL INFORMATION ....................... 9 1.7 Automatic Operating Parameters .................... 28 1.1 Generator Identification ................................... 10 Introduction ......................................................28 1.2 Installation Basics ............................................ 11 Automatic Operating Sequences .....................28 Introduction ......................................................11 PART 2 - AC GENERATORS .................................. 29 Selecting A Location ........................................11 2.1 Description and Components .......................... 30 Grounding The Generator ................................11 Introduction ......................................................30 The Fuel Supply ...............................................11 Engine-generator Drive System .......................30 The Transfer Switch / Load Center ...................11 The AC Generator ............................................30 Power Source And Load Lines .........................13 Rotor Assembly ................................................30 System Control Interconnections .....................13 Stator Assembly ...............................................31 1.3 Preparation Before Use ................................... 14 Brush Holder And Brushes ..............................31 General ............................................................14 Other AC Generator Components ...................31 Fuel Requirements...........................................14 2.2 Operational Analysis ....................................... 33 Fuel Consumption ............................................14 Rotor Residual Magnetism...............................33 Reconfiguring The Fuel System .......................14 Field Boost .......................................................33 Engine Oil Recommendations .........................16 Operation .........................................................34 1.4 Testing, Cleaning and Drying........................... 16 2.3 Troubleshooting Flowcharts ............................. 35 Meters ............................................................17 Problem 1 – Generator Produces Zero The VOM ..........................................................17 Voltage or Residual Voltage .......... 35-36 Measuring AC Voltage .....................................17 Problem 2 – Generator Produces Measuring DC Voltage .....................................17 Low Voltage at No-Load ......................37 Measuring AC Frequency ................................17 Problem 3 – Generator Produces High Voltage at No-Load .....................37 Measuring Current ...........................................18 Problem 4 – Voltage and Frequency Drop Measuring Resistance .....................................18 Excessively When Loads are Applied .38 Electrical Units .................................................19 2.3 Diagnostic Tests .............................................. 39 Ohm’s Law .......................................................19 Introduction ......................................................39 Visual Inspection ..............................................20 Safety ............................................................39 Insulation Resistance .......................................20 Test 1 – Check Main Circuit Breaker ................39 The Megohmmeter...........................................20 Test 2 – Check AC Output Voltage ...................39 Stator Insulation Resistance Test .....................21 Test 4 – Fixed Excitation Test/Rotor Rotor Insulation Resistance Test ......................22 Amp Draw Test ....................................40 Cleaning The Generator...................................22 Test 5 – Wire Continuity ...................................41 Drying The Generator ......................................22 Test 6 – Check Field Boost ..............................42 1.5 Engine-Generator Protective Devices ............. 23 Test 7 – Testing The Stator With a VOM ...........42 General ............................................................23 Test 8 – Resistance Check of Rotor Circuit .....44 Low Battery ......................................................23 Test 9 – Check Brushes and Slip Rings ...........44 Low Oil Pressure Shutdown .............................23 Test 10 – Test Rotor Assembly .........................45 High Temperature Switch .................................23 Test 11 – Check AC Output Frequency ............45 Page 1 Test 12 – Check And Adjust Engine Governor Test 24 – Check Manual Transfer (Single Cylinder Units) .........................46 Switch Operation .................................68 Test 12A – Check Stepper Motor Control Test 25 – Test Limit Switch XB1 .......................69 (V-twin Engine Units) ...........................46 Test 26 – Check 23 And 194 Test 13 – Check And Adjust Wiring/Connections .............................69 Voltage Regulator ................................48 Test 27 – Check Voltage At Test 14 – Check Voltage And Terminal Lugs N1, N2 ..........................70 Frequency Under Load ........................48 Test 28 – Check Voltage At Utility 1 Test 15 – Check For Overload Condition .........48 And Utility 2 Terminals .........................70 Test 16 – Check Engine Condition ...................48 Test 29 – Check Voltage At Utility Closing Coil C1 ..........................71 PART 3 - “W/V-Type TRANSFER SWITCHES ....... 49 Test 30 – Check Fuses F1 And F2 ...................71 3.1 Description and Components .......................... 50 Test 31 – Test Limit Switch Xa1 .......................72 General ............................................................50 Test 32 – Continuity Test Of Wiring (C1) ..........72 Enclosure .........................................................50 Test 33 – Continuity Test Of Wiring (C2) ..........72 Transfer Mechanism .........................................51 Test 34 – Check N1 And N2 Wiring..................73 Transfer Relay .................................................51 Test 35 – Check Transformer (Tx) ....................73 Neutral Lug ......................................................52 PART 4 - DC CONTROL ......................................... 75 Manual Transfer Handle ..................................52 4.1 Description and Components .......................... 76 Terminal Block .................................................52 General ............................................................76 Fuse Holder .....................................................53 Terminal Strip / Interconnection Terminal .........76 3.2 Operational Analysis ....................................... 54 Transformer (TX) ..............................................76 Utility Source Voltage Available .......................56 Circuit Board ....................................................76 Utility Source Voltage Failure ..........................57 AUTO-OFF-MANUAL Switch ...........................80 Transfer To Standby ........................................58 15 Amp Fuse....................................................80 Utility Restored.................................................60 4.2 Operational Analysis ....................................... 82 Utility Restored, Transfer Switch De-energized .......................................61 Introduction ......................................................82 Utility
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