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INPUT 7 INPUT 8
DEBUG
1
2
3
INPUTS
Figure 2. The Home Page, Debug and Input Screens
5. With the Inputs Screen displayed place the AUTO-OFF-
MANUAL switch to the MANUAL Position. If the control-
ler reads an input from the switch input 8 will change
from “0” to “1”.
6. With the AUTO-OFF-MANUAL Switch in the OFF
position, both inputs will read zero.
RESULTS:
1. If controller failed either Step 4 or Step 5 ,replace the
controller assembly.
2. If the controller passed Step 4 and Step 5, refer back
to flow chart.
TEST 59 – TEST AUTO OPERATIONS
DISCUSSION:
Initial Conditions: The generator is in AUTO, ready
to run, and load is being supplied by the utility source.
When utility fails (below 65% of nominal), a 10 second
(optionally programmable) line interrupt delay time is
started. If the utility is still gone when the timer expires,
the engine will crank and start. Once started, a five (5)
second engine warm-up timer will be initiated. When
the warm-up timer expires, the control will transfer the
load to the generator. If the utility power is restored
(above 75% of nominal) at any time from the initiation
of the engine start until the generator is ready to accept
a load (5 second warm-up time has not elapsed), the
controller will complete the start cycle and run the
generator through its normal cool down cycle; however,
the load will remain on the utility source.
PROCEDURE:
1. Simulate a power failure by disconnecting main breaker.
2. If the generator does not perform the sequence of
events listed in the above discussion, replace the
printed circuit board.
RESULTS:
Refer back to flow chart
TEST 60 – CHECK 7.5 AMP FUSE
DISCUSSION:
The 7.5 amp fuse is located on the generator control
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:
Remove the 7.5 amp fuse (F1) by pushing the fuse.
RESULTS:
1. If the fuse if good, refer back to Flow Chart.
2. If the fuse is bad, it should be replaced. Use only an
identical 7.5 amp replacement fuse.
3. If fuse continues to blow, proceed to Problem 20
Flow Chart.
TEST 61 – CHECK BATTERY
DISCUSSION:
Battery power is used to (a) crank the engine and
(b) to power the circuit board. Low or no battery
voltage can result in failure of the engine to crank,
either manually or during automatic operation. The
trickle charger that is included in the generator will not
recharge a dead battery.
PROCEDURE:
A. Inspect Battery Cables:
1. Visually inspect battery cables and battery posts.
2. If cable clamps or terminals are corroded, clean away all
corrosion.
3. Install battery cables, making sure all cable clamps are
tight. The red battery cable from the starter contactor (SC)
must be securely attached to the positive (+) battery post;
the black cable from the frame ground stud must be tightly
attached to the negative (-) battery post.
4. Disconnect both negative and positive cables.
*Note: Disconnect negative battery cable first.
5. Using a DC Volt meter, measure DC volts on the battery.
PART 4
DC CONTROL
SECTION 4.4
DIAGNOSTIC TESTS