Service ·a ·i ;, [Q)®li®©u@[J GenSetCo'ntrol
982-0001 6-86
ES·1560
Safety Precautions part parts, s, etc. etc. call call
fati fatigu gued ed
in seve severe re pers person onal al inju injury ry or de th
ti
AWARNING
I.
is
l.
seve severe re pers person onal al inju injury ry or death.
ACAUTION
t.
ti
refe refe In
isco isconn nnec ec
atte atteri ries es to prev prev nt ac id nt
IN
ti
form form inst instal al at on an
IAWARNING/
ca caus caus tol/owing ing are the tol/ow
ll se vice vice
ngin ngin
st rt
TITLE
PAGE In id
SAFETY SAFETY PRECAU PRECAUTIO TIONS NS INTRODUCTION
ront ront
. . . . . . . . .. . . . . . .. . . . . . . . . .. . .. . . . . .. . . .. . . .. . . . .. . . .. . . . . . . .. . .. . .. . . . . . ... .. ... .. ... .. ... .. .. ... .. ... ... ... .. .. ... .. ... .. .. ... .. ... .. ... ... .. .. .. ..
AC CONT CONTRO RO
over over 1-1
2-1
... .... ... .. .... ... ... ..... .. .... ..... ... .... ... .. .... ... ... ... .... .... ... ...
3-1
DC CONT CONTRO RO
... .... .. ... ..... ... .... ..... ... .... .... .. ..... ... ... ... .. ... ..... ... ... .. ...• ... ... .. .. ... .. .. ... .. .. ... ... ... .. .. .. .. ... .. .. .. ... .. .. .. ... .. .. .. .. ..
.... ..... .... ....... ...... ...... ...... ......... ..... ....... .... ....... ....... ..... .... ... .... ... ..... ... ... .... ... ... ..... .. ... ... .... ... .. .... ... ... ..... ... ... .. t
S ... ... ... ..... ... ... ..•.... .•... ..... ... ... ... .. ... ... ... .. .... .... ... ... ..
ENGI ENGI
ONTR ONTROL OL
4-1
ERVI ERVI
.. ... .. .. .. ... .. .. .... .. ... ... .. .. .. ... ... .. .. ... ... .. .. .. ... .. ,. ... .... ... ... .•..... ... ..•... ... ..... .•.. ... .. .... ... ... .... ... ..... ... ... ... . . . . . . • •. . . . . . • . . . . . . . . . . . . . • •. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .... ... .... ... .... ... ..... ... .. .... ... ... .... ... .. ... .... ... .. ... .. .. . • . . . . . . . . . . . . . •. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ... ... ... ... .... ... ... ..... .... .. ... ... ... .. ... .... .... ... ... ... ... ...
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 6-1
ecti
.l trodu,cti.
fo Onan GenSet AC/OC contro ptions th AC co trol troubl shooting
intern
refe to sp cifi
to
pr perl
nd fo lowing
re ular maintenanc
compo-
th
Itrouble-
schedule 1-1).
fo
te
:AWARNING
te
injury d/ st be alifie ical service
CAUTIO nents. Isolat
tr
ener
safer operation In
to
High voltag
thes
testin
re
can
rvic
la In
ip en am ge rvic personne toperf rm lectri al ndI or chan
or high potentia of generator
components before testing.
TEST EQUIPMEN
ee
ol Catalo
00-0 19 M·1641
FI
1-1
CONTROLLER DESCRIPTIONS operating.
acco mo at ot th vertic an ho iz ntal tyle co tr compartm nts. Althou th co trol on th exteri
·.ture overcranking
':'hct
or overspee
condition.
to pane fo
enerator-related
th ts components on th Iertside
ff ti
to
to to
te
'indicator lamps:
selector
an voltag
adjustment
- -- - -- -- - -- - --
ACPANa
DC PANEl
M·1S90·2
TH ACPANEL
th
--....~
DC PANE
r--~-
'"
9E~~ c,....
~,
....-n~..
M.1590·1
TE
AC
IO
CONTRO
DESCRIPTIONS to
tr
ator.
AC Voltmeter Dual rang
indicato
Voltag
instrument indicating genera
Field Breaker: Pr vi es
Phas eter Indicate
ppro im te
ener to
xc te
generato
electo
witch:
lu
nd re ulat
output frequenc
ts tm Indicates
r/min r/min
fo
Wattmeter:
outp
rovi in
ight
Frequenc
r/min
heosta
voltage.
AC Ammeter:
tz
Adjust
kilo
ontinuousl tts.
iv
eading
th
ener to
UPPE
LOWE
INDICATO
AN
S CA L E
LAMP
ACAMMETER
WATTMETER
.....
/.
.-
fIA----.... .-1590-1
AC COMTROLS
2-1
CONTRO
PANE
INTERI th
thei function
to
Voltage Regulator
tr it does re u-
tati
tw
information.
Curren Transformers to ts
tc ca schematics
ti
th
ti
th
te
tr
TW
RI
RY TURN
FROM GENERATO
URREN
TRA SFORMERS
ON
RI
RY TURN
ES·1566
FIGURE 2-
CURREN
2-2
TRANSFORMERS
Control Heate ontrol heater provides
ed
eans of hu dity Itempera
ng
tr
bl
HEATER ELEMENT THERMOSTAT ES-1563-2
TO 120V
SUPPLY
2-3
nt
nd er os
CONTRO
DESCRIPTIONS to In icat
ress re
lu ri atin
engine).
atte
arge
charging current.
at DC Ammeter: Indicate
Dete to
th batter
12 Contro
lamp fo th followin
Oi Temp rature Ga
e: In icat
temp rature
ubri te
engine). Tachometer:
r/min.
adjustin only).
engine rlmin
un-Stop-
ngin
mote
monito
(u ed
th
oard
ca se
time or on-tim down.)
te
descriptions.
indicato
ig
te perature
Switch
ntro Pane
Dete to
critically
Resets th faul
reset
In ic to
ve no
Sw tch:
t,
Prehea
lectroni
amp:
nv
ienc
ight fo
fo immediat
perator.
mps:
heater.
Contro
ally ow
lamps.
3-1
fo
faul (Normall se fo ti ed sh t-
shutdown.)
OIL PRESSURE GAUGE INDICATOR LAMPS
COOLANT TEMPERATURE GAUGE
DC AMMETE
RUNNIN TIME METER
-------~~,,-----------A NE L
----------
OIL TEMPERATUREGAUGE
TACHOMETER
AN
M-1590·1
ENGINE CONTROL MONITOR
All
"T-r------!.!--
MAGNETIC PICKUP A16
A13 OVER/UNDER VOLTAG SENSOR A17
NTERFACE RELA MODULES
VERTICAL CONTROllE
XES-1561
VOLTAGE REGULATOR VRAS-2
ENGINE CONTROL MONITOR
A1l
INTERFACE RELA MODULE A14
OVER/UNDER VOLTAG SENSOR A17 INDICATOR LAMPS
HORIZONTAL
FIGURE
CONTROLLER
3-2. CONTRO
3-3
INTERIOR
ONTROL he followin
describe
ANEL INTERIOR th engine contro components ta
fo
to
ts
A11 incl de
st rting, st pping,
nd faul system tr
peration
system.
ti
protection:
(216°F 11 it
ig
gine temperatur
CAUTION
ti L-.
fu ction.
Thehigh engin temperature shut..J
an to heat without protectio
Imin
1900 4000
nits
20
90
min.
Imin,
shutdown device result-
intain ad uate gi ol levels to ns re operational integrity cooling systeman engin coolan overheat shutdown protection
rI
ower
4p
response. sur function.
3-
- -
iZYl
()
300-2811
K2
c::J
C2
c:::=J
RS R6
IO
1'3 KI-4
KI8
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r._:,j
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~,
.
B LO C
D IA GR A
8LE
L O f UE L SW Of LE
PRE lOP PRE-HET
LO OS fLT-2 f'LT-1
UE
SI
DC
Z -Z & AR P2-Z:W7
OS HE HE
PRE
-lOP
T 82 -
tLT-1
L O F uE L
S l< U T e o W N W AT E
Oi 1 2 V AC !
AL
else
ST ART e l s e O i P RE S . . T E T Eu P OS tN O C D IS C RE
S TA A
T EM P
P RE S
"UN GNO
5"aa· RUN
GOO
S TA R
5wa-
AR WI
rLT-Z
5"
ST....
U NC T O N
SO
3-5
OD
T O S TA R S TA R
SE EC AB
O WS : N -
LOP ?H
l A W P T E S T" 'E S E T
STOP T E ST IR E SE T
S: GN
n.r-z n,T-I
sworr l A. P
SE
RU'
F U N C T IO N W2
~ OD E S E E CT AB L A S F O L OW S F UN e O N M O D E TI N O N -S H m O W N N O N H M E D S H U TD O W N ,N O N mlED N O N - S H U T D O W N , IMto S H U T D O W N , T I II E D
Ru Rela (K11 ta
st
connection).
LO
IA
_ _ I I
ES-1S77
3-6
Interf
Rela
dule
(A 3,
14
ontact
'-.-_
fo external alar
.....
onnect on
LOC
DIAGRA TBl
TB2
.r---r--l---r---l----"_
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I'
--
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11;;.
+ -~ 6
iii
.----+----+--
!:
ii
1 +
l:
+ + 1 0 1 + 1 2 13
....---+-- -
14
B+
,6.13 ES--1579
r -- -- -
- - - -- - _ .
.--"-=-...:..-.;.,;.. .
LOC
TIll
IN
.~=-_J
DIAGRA
l-=-l:I--~~-=;:::'-~~--.:::..,;,-·l--~-1
i.
ii
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SS
RU
V)
~--------------------------
ES-1580
A14
3-7
Ti Delaye (A1S)
St rt/Sto
re
Delaye
dule
Stopping
to Delaye
Preheat:
Starting
ta th
generato
th
mi
se starting
_ . _ -
SP c.e,
,Q
I~CR£'SE IF~~~~========
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T61-2 T6
~oo::
TER:..
T61-1
T6
T9
PREHEAT
Ii GROUND
PREHEA
MODULE
3-8
A S ; : _ _ cw CI
ag etic
ic
Inte fa
Mo ul
(A 6) follow ng output values
ou ed
gine en at
po nt or
dj
ab
60 r/mi
al LE
po nt increase
values): r/
to
r/
BLOC
DIAGRAM
MAGNETIC
--4I-!~-=:....J
GND ES-1578
FIGURE
3-7. M AG NE TI C
I CK U
3-9
I NT ER F C E M OD UL E
th ta
ta
follows: Undervoltage
ti ta
A1
fr
th
0t 5t verv ltag 0t
fa
Function of·the amount of overvoltage. im elay (Seconds)
Overvoltage Urnit Setting)
0. maximu
ab ve 120 110 100 or be ow 135
to infinity
'[EJ
..£IDCe
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'[]I)' I ( E I
emIl tatml~
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Ctm!J~
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BLOC
~[jD"'~'
DIAGRA TB1-4 B+ TB"t
TB1 ADJUSTMENTS: Phase
ATTEN.
IMIT
OI
Inputs
SELECT
OVERVOLTAGE
'----+-+ r -
ADJUSTMENTS: DROPOU SETPOINT OP UT TIME DE
TB1-10 GROUND (NEUTRAL
3-10
6'
+
UNDERVO TAGE \ _ . 8
ES-I581-1
OPERATION us
varyin
tr
ti
bi
ti
Regardless th tr ller de yo ve th en in co tro ito includes th shutd wn fault co ds tr ll rs with ti rovide deli ti re larm th shutdown faults ti delaye st rtin to g, it tori tr l, bu ll engin peratio co ds through thes ptio re
s, th
te to 2" tr ll with ll ti Figure ). Re th inform tio through to Emergency Shutd wn to gain afull understa di th ti th intera with th engi tr it r. Ifyou re reviewi this peratio inform tio fo troublesh ti ur ses, ensure th yo ve elimin te ll th lf ti ks xt th tr ls ri to tr bl ti th ri te ir bo ty co po ents the co troller
(ECM).
PANEL LAMP
UP ER LOWE SGAE INDIC TOR LAMP~,
VOLTMETER
101-159<1-1
IL THI, ER
TURE
G/"JGE
TI
DELAYE
ST RT 'STO
REHEA
15
INDICATO'" LA "'
12
ENGINE CO~JT"OL 1J10NITOR A7
MAGNETIC PICKUP 16
OVER UNDE VOLTAGE
SENSOR 17
13 INTERFACE REL
MODULES
FIGURE 3-9. CONTROLLER
3-11
XES-1S61
Startin
Seque ce
Manual:
excessiv
th
current.
th
ECM.
ciated wirinq Automatic:
Start!
A1 ,wh
ts
ti
monitoring th
manual start-up ects inputs signal
fr
it er star
isco nect
yste
A1 to
ta .b
fo
syst m.
llowin
fo
th
elay th se fa lt
.I
fa
6to
fe Start-Disco
ti
ec
Sequence
A15
Starter-Disco
fr
ec
ra eters
tt
to
te
ta
Energiz-
ta
th th
meth
to nsur
nint rrupte
generato
et peration
rm
Operatin
ra eters
A1
re ay
ot fu ctioning
3-12
Emergenc
Shutdown ss re
th
fa
ss
Stoppin
Sequence
ft
ct
tome
alar
th
3-13
terminal
ve
TROUBLESHOOTING en same.
to
ub esho ti g, ec
he
em
ou
ns
be
an
seconds. shutdown occurs nc ud
nformation abou
ab arious
ontrol options.read
ul
be
Delete Overcran disconnect?
Lo
ws condition.
es
conditions. Possible over peed condition.
r/min
du
th
ec n.
following: an
ft and stabilizes.
proper r/min. shooting.
4-1
di
ar
AB
4~1. EN IN
DOES NQ CRAN CORRECTIVE ACTION
Run/Stop/Remote n S
indicator p l
indicato
lamp
es
sw tc od
ap wa remedied
·no faul'texists.
3.
Lamp
r R
te tc Stop position.
indication. boardA11.
Replace if necesary with pr pe fuse - 2 Ampere - 5 Ampere
wi no energize
pe
ro er te
pr ce ur
1b r B
ou to starte solenoid A11 -8
A11 starte solenoid
is initiated,bu
ti
Time Delaye
Startl
ft
A1 fo constant 8+
ta
Ru Signal In vo tage A1
~od.
Check wiring and
connections from 1\15
4-2
TABLE 4-2. CORRECTIVE ACTION
illuminated.
ar fu e. F2 20 Possible defectiv
connection
pere
A1 is cranking.
betwee
necessary.
fuel solenoid
energize bu no ow
ff supply system
fuel tank shutof va es fuel ines an onnect ons. fuel fi te an transfer pump. heck heater yste powe supply controls
ea
necessary.
temperature.
bein
Ti
Improper start-up procedures used Depres
energized.
dela ed
".
tart
A15 no energizing
te A1 solenoid.
glow plugs. Depres
reheat sw tc
if Prehea solenoid energized.
proper test procedure.
4-3
TABLE 4-2.
ntin CORRECTIVE ACTION
CAUSE
SYMPTOM
.'
fr
,.
,A1 to Pr heat so enoi
cold ambien air temperature.
C' to engine
this table.
",
indication. Possible defectiv
A1 to to 15
seconds. A1
15 seconds.
4-
A1
sp
Manual fo adjustment
.s adjustment Magnetic Pickup Module A16 initialize shutdown.
Review functional descriptio A1 adjustable setpoint
engine spee shutdown. Fixe
to over peed
Setpoint
Adjustable Setpoint desire no
setp int, read us
orre
faul
ondition
ou of adjustment governor operatio contac Replenis
an Onan representative as necessary.
is faulty Replace.
4-5
in engine/generator
SYMPTOM
CORRECTIVE ACTION
CAUSE
Replenis
High Eng1ne "Temperature.
as necessary.
in engine tc rest rt an temperatur
monito en in gaug Ml2. If
faulty Re lace Thermostat detective. Fa belt slipping
,..
Replac
thermosta fa
t.
Intermittent contro irin conn ct ons. terminal connections.
4-6
CORRECTIVE ACTION 1.
au nd cato lamp illuminated. , H Overspeed
s i
As required illuminated.
customer.
solenoid.
solenoid etc.
shutof valves
is defective. Replace. Refe to installation refe ence ateria or ontact an Onan representative
Othe customer required shutdown command.
4-7.
TESTS
tr
ts
fr s,
s, /g
(J1, J2 J3 or J4 from th boar
Refe to th appr priate
Solenoi
Checkou
Battery Checkou 1.260
BO°F (27°C)
replac
bracket. So enoi
it
su
:ACAUTION Do
If not,
should activate
th
fJ~ses
ot sm ke whil servic ng
ta ti
Relay Checkou
aNerie
r. Alternator Checkout
Batter Cabl
contacts.
Checkout
cy
k,
fr
closed contacts
te
Fuel Solenoid Checkout (Diese Only ti
Alternato Checkou replaced.
se
t,
Contro Switch Checkout
ti
(+)
mi ut
to llow th voltag
to stabilize.
cl
rope operat
between 13.B and 14.B volts.
4-8
sh
ty
SectionS. W i
Dl
TITLE Cont ol
ms NUMBER
re Diag am
DC Contro ir Diagra DC Contro Wire Diagra
Horizontal
w/Detector
(Hor ontal, Dete to 2) .•.................. (Vertical, Detector 2)•......................
DC Cont ol re Diagra (Verti al Detector 12 •................... CM P.C. Asse bl 11 (Detecto 2, 12 ......•................. EC P.C. Asse bl A11 (Detecto 2, 24V) .•...................... CM P.C. Asse bl A11 (Detecto 12 12 ....•.......•......... . A - A 1 ( , 2
5-1
300-2808 ...........•• 300-281
...•.........
PAGE 5-2 5-4 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13
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