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co614 Guide
User manual for co614
Here is the user manual for co614. You can read and download this user guide for free. User's manual, provided by the manufacturer, allows you to use properly your home appliances and electronics.
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Table of contents
Document Outline
Back to Main Menu
Electrical Formulas
Contents
SPECIFICATIONS
Generator
Engine
Fuel Consumption
Mounting Dimensions
Major Features
PART 1 - GENERAL INFORMATION
1.1 Generator Identification
1.2 Installation Basics
Introduction
Selecting A Location
Grounding The Generator
The Fuel Supply
The Transfer Switch / Load Center
Power Source And Load Lines
System Control Interconnections
Natural Gas Fuel Interconnections
1.3 Non-prepackaged Interconnections
Connect a Pre-2008 Load Center SwitchTo a Current or FutureAir-Cooled Generator
Connect a 2008 And Later Load CenterSwitch to a Pre-2008Air-Cooled Generator
1.4 Preparation Before Use
General.
Fuel Requirements
Fuel Consumption
Reconfiguring The Fuel System
Engine Oil Recommendations
1.5 Testing, Cleaning and Drying
Meters
The Vom
Measuring AC Voltage
Measuring DC Voltage
Measuring AC Frequency
Measuring Current
Measuring Resistance
Electrical Units
Ohm’s Law
Visual Inspection
Insulation Resistance
The Megohmmeter
Stator Insulation Resistance Test (12-20 kW)
Stator Insulation Resistance Test (8-10 kW)
Rotor Insulation Resistance Test (8-10 kW)
Rotor Insulation Resistance Test (12-20 kW)
Cleaning The Generator
Drying The Generator
1.6 Engine-Generator Protective Devices
General.
Low Battery
Low Oil Pressure Shutdown
High Temperature Switch
Overspeed Shutdown
Rpm Sensor Failure
Overcrank Shutdown
1.7 Operating Instructions
Control Panel
To Select Automatic Operation
Manual Transfer To “Standby”and Manual Startup
Manual Shutdown AndRetransfer Back To “Utility”
1.8 Automatic Operating Parameters
Introduction
Automatic Operating Sequences
PART 2 - AC GENERATORS
2.1 Description and Components
Introduction
Engine-Generator Drive System
The AC Generator
Rotor Assembly
Stator Assembly
Brush Holder And Brushes (12-20 kW)
Other AC Generator Components
2.2 Operational Analysis
Rotor Residual Magnetism
Field Boost (12-20 kW)
Operation (8/10 kW)
Operation (12-20 kW)
2.3 Troubleshooting Flowcharts
Problem 1 – Generator Produces ZeroVoltage or Residual Voltage (12-20 kW)
Problem 2 – Generator Produces ZeroVoltage or Residual Voltage (8/10 kW)
Problem 3 – Generator ProducesLow Voltage at No-Load
Problem 4 – Generator ProducesHigh Voltage at No-Load
Problem 5 – Voltage and Frequency DropExcessively When Loads are Applied
2.4 Diagnostic Tests
Introduction
Safety
Test 1 – Check Main Circuit Breaker
Test 2 – Check AC Output Voltage
Test 4 – Fixed Excitation Test/RotorAmp Draw Test
Test 5 – Wire Continuity (12-20 kW)
Test 6 – Check Field Boost (12-20 kW)
Test 7 – Testing The Stator With A Vom(12-20 kW)
Test 8 – Test Brushless Stator
Test 9 – Check Capacitor
Test 10 – Test DPE Winding onBrushless units
Test 11 – Resistance Check Of Rotor Circuit(12-20 kW)
Test 12 – Check Brushes And Slip Rings(12-20 kW)
Test 13 – Test Rotor Assembly(12-20 kW)
Test 14 – Check AC Output Frequency
Test 15 – Check and Adjust Engine Governor(Single Cylinder Units)
Test 16 – Check Stepper Motor Control(V-twin Engine Units)
Test 17 – Check And Adjust VoltageRegulator (12-20 kW)
Test 18 – Check Voltage And FrequencyUnder Load
Test 19 – Check For Overload Condition
Test 20 – Check Engine Condition
Test 21 – Field Flash Alternator (8-10 kW)
PART 3 - TRANSFER SWITCH
3.1 Description and Components
General
Enclosure
Transfer Mechanism
Transfer Relay
Neutral Lug
Manual Transfer Handle
Terminal Block
Fuse Holder
3.2 Operational Analysis
Operational Analysis
Utility Source Voltage Available
Utility Source Voltage Failure
Transfer To Standby
Transfer To Standby
Utility Restored
Utility Restored, Transfer Switch De-energized
Utility Restored, Retransfer Back To Utility
Transfer Switch In Utility
3.3 – Troubleshooting Flowcharts
Introduction To Troubleshooting
Problem 7 – In Automatic Mode,No Transfer to Standby
Problem 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 Mode
Problem 9 – Blown F1 or F2 Fuse
Problem 10 – Units Starts And TransferOccurs When Utility Power Is On
Problem 11 – No Battery Charge(Pre-Packed Load Center)
Problem 12 – No Battery Charge(RTSN & RTSE Transfer Switch)
Problem 13 – No Battery Charge(Gen-Ready Load Center)
Problem 14 – No Battery Charge(Load Shed Transfer Switch)
3.4 Diagnostic Tests
General
Test 26 – Check Voltage atTerminal Lugs E1, E2
Test 27 – Check Manual Transfer SwitchOperation
Test 28 – Check 23 And 15BWiring/Connections
Test 29 – Test Transfer Relay TR
Test 30 – Standby Control Circuit
Test 31 – Check Wire 23
Test 32 – Utility Control Circuit
Test 33 – Test Limit Switch SW2 and SW3
Test 34 – Check Fuses F1 and F2
Test 35 – Check N1 and N2 Wiring
Test 36 – Check N1 and N2 Voltage
Test 37 – Check Utility Sensing Voltageat the Circuit Board
Test 38 – Check Utility Sense Voltage
Test 39 – Check Voltage atTerminal Lugs N1, N2
Test 40 – Check Battery Charger SupplyVoltage “Pre-Wire Load Center”
Test 41 – Check Battery Charger OutputVoltage “Pre-Wire Load Center”
Test 42 – Check Wire 0 and Wire15B“Pre-Wire Load Center”
Test 43 – Check Battery ChargerSupply Voltage“RTSN & RTSE Transfer Switch”
Test 44 – Check Battery ChargerOutput Voltage“RTSN & RTSE Transfer Switch"
Test 45 – Check Wire 0/“RTSN & RTSE Transfer Switch”
Test 46 – Check Battery ChargerSupply Voltage“GenReady Load Center"
Test 47 – Check Battery ChargerOutput Voltage“GenReady Load Center"
Test 48 – Check Wire 0/15B“GenReady Load Center"
Test 49 – Check Battery ChargerSupply Voltage“Load Shed Transfer Switch"
Test 50 – Check Battery ChargerOutput Voltage“Load Shed Transfer Switch"
Test 51 – Check Wire 0 and Wire 15B“Load Shed Transfer Switch"
PART 4 - DC CONTROL
4.1 Description and Components
General
Terminal Strip / Interconnection Terminal
Circuit Board
Auto-Off-Manual Switch
7.5 Amp Fuse
Menu System Navigation
4.2 Operational Analysis
Introduction
Utility Source Voltage Available
Initial Dropout of Utility Source Voltage
Utility Voltage Dropout andEngine Cranking
Engine Startup and Running
Initial Transfer to the “Standby” Source
Utility Voltage Restored /Re-transfer to Utility
Engine Shutdown
4.3 Troubleshooting Flowcharts
Problem 15 – Engine Will Not CrankWhen Utility Power Source Fails
Problem 16 – Engine Will Not Crank WhenAUTO-OFF-MANUAL Switchis Set to “MANUAL
Problem 17 – Engine Cranksbut Won’t Start
Problem 18 – Engine Starts Hard andRuns Rough / Lacks Power / Backfires
Problem 19 – Shutdown Alarm /Fault Occurred
Problem 20 – 7.5 Amp Fuse (F1) Blown
Problem 21 – Generator Will Not Exercise
Problem 22 – No Low Speed Exercise
4.4 Diagnostic Tests
Introduction
Test 56 – Check Position OfAuto-Off- Manual Switch
Test 57 – Try a Manual Start
Test 58 – Auto-Off-Manual Switch(V-Twin Only)
Test 59 – Test Auto Operations
Test 60 – Check 7.5 Amp Fuse
Test 61 – Check Battery
Test 62 – Check Wire 56 Voltage
Test 63 – Test Starter Contactor Relay(V-twin Only)
Test 64 – Test Starter Contactor(Single Cylinder Engine)
Test 65 – Test Starter Motor
Test 66 – Check Fuel Supply and Pressure
Test 67 – Check Circuit BoardWire 14 Output
Test 68 – Check Fuel Solenoid
Test 69 – Check Choke Solenoid
Test 70 – Check for Ignition Spark
Test 71 – Check Spark Plugs
Test 72 – Check Engine / Cylinder LeakDown Test / Compression Test
Test 73 – Check Shutdown Wire
Test 74 – Check and AdjustIgnition Magnetos
Test 75 – Check Oil Pressure Switchand Wire 86
Test 76 – Check High OilTemperature Switch
Test 77 – Check and Adjust Valves
Test 78 – Check Wire 18 Continuity
Test 79 – Test Exercise Function
Test 80 – Check Cranking andRunning Circuits
Test 81 – Check to see if Low SpeedFunction is enabled
Test 82 – Check operation of theChoke Solenoid
PART 5 - OPERATIONAL TESTS
5.1 System Functional Tests
Introduction
Manual Transfer Switch Operation
Electrical Checks
Generator Tests Under Load
Checking Automatic Operation
Setting The Exercise Timer
PART 6 - DISASEMBLY
6.1 Major Disassembly
Front Engine Access
Major Disassembly
Torque Requirements(Unless Otherwise Specified)
PART 7 - ELECTRICAL DATA
Wiring Diagram, 8 kW Home Standby
Schematic, 8 kW Home Standby
Wiring Diagram, 10 kW Home Standby
Schematic, 10 kW Home Standby
Wiring Diagram, 14 kW Home Standby
Schematic, 14 kW Home Standby
Wiring Diagram, 17 kW Home Standby
Schematic, 17 kW Home Standby
Wiring Diagram, 20 kW Home Standby
Schematic, 20 kW Home Standby
Wiring Diagram, Home Standby Transfer Switch,9/10/12/16 Circuit
Schematic, Home Standby Transfer Switch,9/10/12/16 Circuit
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