Manual Part No. 79247 DIAGNOSTIC REPAIR Manual STANDBY/PRIME ELECTRIC POWER SYSTEMS All Series GENERAC CORPORATION . O. Box 8 Waukesha, WI 53187 Phone: (414) 544-4811 FAX: (414) 544-4851 Revision 4. (11/07/96) Printed in U.S.A,Proper service and repair is important to the safe, economocal and reliable operation of all standby electric power| systems. The troubleshooting, testing and servicing procedures recommended by Generac and described in this manu lal are effective methods of performing such operations. Some of these operations or procedures may require the use ot specialized equipment. Such equipment should be used when and as recommended {tis important to note that this manual contains various DANGER, CAUTION, and NOTE blocks. These should be read carefully in order to minimise the risk of personal injury or to prevent improper methods or practices from being lused. Use of improper or unauthorised practices may damage equipment or render it unsafe. The DANGER, CAUTION land NOTE blocks are not exhaustive. Generac could not possibly know, evaluate and advise the service trade of all conceivable ways in which operations described in this manual might be accomplished or of the possible hazardous consequences of each way. Consequently, Generac has not taken any such broad evaluation. Accordingly, anyone lwho uses any troubleshooting, testing or service procedure that is not recommended by Generac must first satisfy him self that neither his safety nor the equipments safety will be jeapordised by the procedure or the method he selects. LIST OF CHANGES CY This manual has been revised, corrected or changed as listed below. The manual's current revision date is located (on the lower left comer of the front cover. 1 Revision 1 (10/31/92): Added section 1.5, “Mechanical Engine Governors"; Section 1.6, “Electronic Engine Governors"; and Section 1.7, “Diesel Engine Governors” 0. Revision 2 (05/08/93): Revised Section 1.2, ‘Types of Stator Connection Systems” to reflect new Voltage codes. 1 Revision 3 (10/02/93): Added Sections 3.6, "Permenant Magnet Generators’, and 3.7 “Testing PMG Units’. Also added Section 11.7, “Inphase Monitor Control’ 1 Revision 4 (11/07/96): Added “Stepper Motor Governor’ to Section 1.6, updated Section 3.6 “PMG's", added Section 7.6 “18 Lamp Annunciator’, and updated Section 11.7 "Inphase Monitor Control’. NOTICE: ‘A "Technical Publications Catalog” PIN 91021 is available which lists other Diagnostic, Repair, and Parts manuals, including Engine Repair and Generator Installation information. This catalog and any other manuals can be ordered through your regular source of Generac Parts.DIAGNOSTIC REPAIR MANUAL STANDBY ELECTRIC POWER SYSTE All Series TABLE OF CONTENTS TITLE Introduction to Standby Electric Power Systems Direct Excited AC Generators Brushless AC Generators “Marathon@” AC Generators ‘Options A & B Control Consoles __| ‘Option C Control Console | ‘Generator Options & Accessories, “Type” Automatic Transfer Switches 9 “Wn Type Automatic Transfer Switches. 10 ‘The "CPU" Type Intelligence System 1" ‘The "Logic" Type Intelligence System 12 Transfer Switch Options NOTICE ‘A*WIRING DIAGRAMS & ELECTRICAL SCHEMATICS* manual {or standby electric power eystoms ls avaliable from Generac. To, ‘order, specify Manual Part No,87681.NOTES ¢Cr MNase) lenge) (Specs taa TO STANDBY : 3 4 5 6 7 Meat 6 os POWER | EYES STANDBY ELECTRIC POWER SYSTEMS Alll SeriesPART 1 SECTION 1.1 Page 1.1-1 Section 1.1 STANDBY GENERATOR IDENTIFICATION Introduction Generac standby generators are often unique products which have been engineered and designed to the specifications of a spectic buyer. Differences in design, ratings, attached options and accessories, etc., may exist between units To aid in the proper identification of each generator set, the following have been provided at the factory: + ADATA PLATE has been prominently atfixedto the ine or tore DATA CARDS have been shipped + One oF mor 'ave been shippe wih éach ont *P Data Plate See Figure 1. The typical data plate shown lists valu- able information pertaining to the standby generator, including Model Number, Serial Number, rated voltage, rated maximum continuous current (amperes), Kva rating, phase, rated AC frequency, rpm, and kilowatts. ALTERNATOR DATA move. ——}kva SERIAL puase————] vous (Hea) amps [ RPM PReih kw CLASS F WINDING INSULATION AT 40° C. WNERESEO MT MADEINUS.A, Figure 1. A Typical Data Plate GENERATOR IDENTIFICATION CODE §$G045 A 1 6 57 N 18 y Lop. arias MAIN CIRCUTT BREAKER + SHIPPED WITHAN, EXHAUST MUFFLER. + SHIPPED WITH ACOMPARTMENT + De DIRECT EXCITED B+ BRUSHLESS, + CONTROL CONSOLE ‘OPTION (A, B, CORP) + ROTOR RPMIN 100'S + Ne NATURAL GAS Le LP GAS (PROPANE) + DIESEL + ENGINE DISPLACEMENT INLITERS, + FREQUENCY 6 GO HERTZ SO HERTS, + PHASE (1 OR) + VOLTAGE CoE + RATED KILOWATTS + _GeGAS ENGINE Ds DIESEL ENGINE + SeSTANDBYPage 1.1-2 The Data Card One or more DATA CARDS are shipped with each standby generator set. When ordering parts or request- ing information, you may be asked to provide informa- tion from this card. ‘The card provides important information peculiar to each unit Included on the card are the following: The unit's MODEL NUMBER. The date of manufacture. A Generator Identication, Code. This_ code, is Sxplained by means of olagram on Page f.1-1 A, .Group-Descrption-Assembly, Number” isin the generator set The “assemply numpers ee {oie varus exploded views MM MaKe up Gach major assembly PART 1 SECTION 1.1 GENERAC CORP MODEL NO. 914012565 DATE S109/01 'SG012-A161,2N18COYNY GROUP DESCRIPTION ASSEMBLY NUMBERS. Generator 190000 00000 8 Cental Pane! 000090000 o9000 © Mounting Base 90000 00000 © Engine & Accy. 00000 & ——Fuelsystem 00000 G Wing Diagram 00000 90000 9000 Figure 2. A Typical Data CardPART 1 SECTION 1.2 PAGE 1.2-1 Section 1.2 TYPES OF STATOR CONNECTION SYSTEMS General Generac standby generators may be equipped with any ‘one of several diferent stator configurations. The electrician who installs a standby generator, as well as service technicians, must be familiar with these different stator con- figurations and the various stator connection systems. You may wish to review the “Generator Identification CCodet in Section 1.1. A *Voltage Code", which identifies the generators rated AC output voltage, Is part of that identit- catlon code. Also included in the Code are a *Phase” and a “Frequency” designator. NOTE: Stator connection system Information in this sec- tion applies to standby generators rated at up to 125 kW. Foruntts ratod 125 KW and higher, refer Part 4, “MAR ATHON AC GENERATORS". The Generator AC Connection Panel ‘Typically, the generator’s AC connection panel (Figure 1) is that enclosure directly below the control panel. itis often called the “lower panel’. All of the stator’s AC output leads are routed into this panel. Electrical connections in the panel should be made in accordance with the appropriate ‘connec tion diagram’. Use the diagram that is appropriate for the umber of leads and the voltage range required. VOLTAGE, NO. OF COoE, WINDINGS ane staat TERMINALS. auneren TRANSFORMERS Siacur SREAKER, stator) (Enos: Figure 7. Generator AC Connection Panel (Typical) NOTE: The final voltage setting Is established within tho desired range by adjustment of the voltage regulator. ‘Some generators may have multiple, identically marked ‘cables for each lead. Connect all identically marked ca- bles together. TYPE OF STATOR CONNECTION SYSTEM z Dual voltege, wire, T-phase Tow (Parallel) Wye High eries) Wve ow (Parallel) Wye High (Series) Wye Dae High (Series) Wye soo Wye Connected Dual voltage, wire, t-phi Tier00 Tow (Parallel Wye T0020 ‘Dera ao | 7 High (Sorien) Wye * Voltage Codes “B" and *C* are obsolete but were used rior to 1968. Wye Connected * Stators with Voltage Code °D" can supply 1-phase output at up the fll rated capachy of the generator, But Gannot be reconnected to 277/480 volta (High Wye).PAGE 1.2-2 Dual Winding 1-Phase Stators See Figure 2. Units with Voltage Codes “A* and "M" are ‘equipped with stators having dual windings. Two leads are brought out of each winding and routed into the AC connec- tion (lower) panel, fora total of four (4) leads. The leads numbered 11, 22, 33 and 44. Leads 11 and 44 become the {wo "Hot" leads (E1 and E3). The junction of laads 22 and 33 forms the *Neutral* connection (00).. Each stator winding can supply a 120 volts AC output at 60 Hertz (or a 110 volts AC output at 50 Hertz). When the two windings are connected in series, a 240 volts, 60 Hertz (or 220 volts, 50 Hertz) AC output results. PART 1 SECTION 1.2 CONNECT ‘s10-S11-512 55-53 120 VOLTS Ll. 4 on tore Figure 2. Dual Winding, 1-Phase Stator System Parallel Wye or Low Wye Stator Low Wye or Parallel Wye type stators (Figure 3) have six windings and twelve (12) leads coming out into the AC. Connection (lower) panel. This type supply the 3-phase voltages indi stpsirsi2 ‘345556 si9-si1.s12 349586 High Wye or Series Wye Stator ‘See Figure 4. This type of stator has six (6) windings and twelve (12) leads brought out into the AC connection (lower) panel. This configuration is used in units with Voltage Codes. °C", “HY, “K* and ‘R" (see CHART on previous page). The {following CHART indicates how the 12 leads are connected toform Lt, L2, L3 and Neutral. 1-87 szsa so-89 Figure 3. Parallel Wye (Low Wye) Stator 4 aa 7% Series Wye (High Wye) Stator Delta Stators This type of stator has six (6) windings and twelve (12) leads coming out. See Figure 5. The stator can be used to ‘supply the voltages indicated in the following CHART, lonPART 1 SECTION 1.2 Ewell oe Wal | se em Figure &. High Delta Connection System NOTE: Units with Voltage Code "D" are equipped with a High Detta stator configuration, but are specially wound to supply the unit's full rated capacity when connected for a 120/240 volts, 1-phase AC output. Low Delta Connection System ‘The 12/lead generators can be reconnectedto orma‘Low Delta® connection system, shown in Figure 6. VOLTAGE: CONNECT SESTSESI2 'S2.S8-54-510 ‘355055511 The Zig Zag Connection System Units with twelve lead, reconnectable stators can be r@- connected to form a *Zig Zag" system, shown in Figure 7. CONNECT 3380 S1-86-87-512 S410 55.511 PAGE 1.2-3 Figure 7. Zig Zag Connection System Multi-Voltage Changeover Boards ‘On some generaior models, multivotage changeover boards are used for quicker changeover from one connection system to another. Refer to Part 7, “GENERATOR OPTIONS: & ACCESSORIES.PART 1 SECTION 1.3, PAGE 1.341 Section 1.3 STANDBY ELECTRIC SYSTEM FAMILIARIZATION Introduction ‘The purpose of a standby electric power system is to supply electrical power for the operation of critical electrical loads in the event of a utility power failure or dropout of that power source below an acceptable level. Standby electric power systems have long been used as sources of emergency electrical power in hospitals, schools, aiports and other public buildings. Use of stich systems is spreading rapidly, making it an absolute necessity that all who are involved with such systems be thoroughly familiar with standby system products and their application. The rapid increase in the use of such systems is primarily due to three factors. First, the increase in ‘dependence on electricity (coupled with costly electri- cal blackouts and brownouts) has dramatically in- creased the need for such systems. Second, the trend toward automation in manufacturing facilities has in- creased steadily. Any down time in such facilities means very expensive {oss of production. And third, such systems are being used more frequently in less critical appiications as building and safety codes be- come stricter (for example, the requirement that elevators in high rise buildings remain operable in the event of a fire). New developments in the design and application of standby electric systems are constantly surfacing. in addition, new problems are being created by the more sophisticated electrical systems of today. As standby generators, transfer switches, and other standby sys tem components are called upon to do more and more, and as accessories and components become more and more varied, selection of the proper components for any particular application becomes more dificult, Installation Manual ‘An “Installation Manual for Standby Electric Power Systems” is available from Generac Corporation. To order, specify Manual Part No. 46622. A Simple Standby Electric Power System A simple standby electric power system is shown schomaticaly in Figure 1. The UTILITY and STANOBY ower supplies are both connected to a transfer switch, as well as the LOAD circuits. Use of an approved transfer switch is required by electrical code. The trans- fer switch serves the following purposes: + When UTILITY source power is avaiable, the BSCR Must connegt that source to the aaa i] AB Siruits No be powered. Wnen URI! RBERL ESO avalible the Switch must Connect the PRANGEY power Suppiy to eriical electrical + The transter switch must positively prevent the UTI Pand STANGSY power supplies tromteed: ing the LOAD simutanedusty + The transfer switch must positively isolate the 9 wlecie Firing UYU uiaing slecieal creuls trom tne Wr Thesthile LOAD circails are being poweredby the ANDBY source # An tm ky zB oo 88 bs — 83 -~ 8 283 3% r Figure 1. Schematic- Simple Standby Electric System Methods of Isolation Either of two different isolation methods may be used in a standby electric system. These may be called (a) the emergency circu, or (b) the total circuit isolation ‘methods. EMERGENCY CIRCUIT ISOLATION METHOD: ‘See Figure 2. This method of isolation employs both a MAIN and an EMERGENCY distribution panel. Cri cal, essential electrical loads within the wat tage/amperage capacity of the generator are grouped together and wired into the emergency distribution panel. Only those electrical loads that are fed by the emergency panel are supplied when the standby gen- erator is running. Use of this type of isolation method will help avoid overloading the standby generator. The installed transter switch must meet the following re- ‘quirements: + The transfer switch must have. an ampere satin ual fo oF greater than the total ampere rating o ‘emergeficy distribution panel {oad circuits. + The transfer switch must be installed between the Duigling’s main aisioution panel and the emerger- ey distribution panel TOTAL CIRCUIT ISOLATION METHOD: ‘Only one electrical distribution panel is use type of installation. To prevent overloading the standby generator, non-essential electrical loads ‘must be {urned of. The folowing rules apply: + The ampere rating of the installed transfer switch must edual of extsed the ampore Taing of the formal incoming uly service + Switch must be installed between the tity power Supply service entrance and disinoution panelPAGE 1.3-2 PART 1 SECTION 1.3 Methods of Isolation (Continued) Hy yoPoweR une TREY 77 mage rane LR a tT =! ' =. 7 owes 1 Saas mana ier geen [Reet eit or way pole aera revs A t= HEmoeesron as rovons Sf Ho sours St TA Benccrren rouons = forme rouans SOE EE Bante t Sted 4 rot0ns wens ene ase om 0 on natn ewe ety COTTER Reece Figure 2. Schemalic- Emergency Circuit Isolation Figure 3. Schematic. Total Circuit Isolation DANGER: CONNECTION OF ANY GENERATOR SET TO AN ELECTRICAL SYSTEM NORMALLY SUP- PLIED BY AN ELECTRIC UTILITY MUST BE DONE BY MEANS OF A DOUBLE THROW TRANSFER ‘SWITCH, SO AS TO ISOLATE THE ELECTRIC SYSTEM FROM THE UTILITY DISTRIBUTION SYSTEM WHILE THE GENERATOR IS OPERATING (NEC 701). FAILURE TO ISOLATE THE ELECTRIC SYSTEM BY SUCH MEANS WILL RESULT IN DAMAGE TO THE GENERATOR OR POSSIBLE INJURY OR DEATH TO UTILITY POWER WORKERS DUE TO BACKFEED OF ELECTRICAL ENERGY.PART 1 SECTION 1.4 PAGE 1.41 Section 1.4 GENERATOR MAINTENANCE AND TESTING Effects of Dirt and Moisture Hf dust or dt particles are allowed to accumulate on generator parts, they will conduct electrical energy between points of different electrical potential. f mois- ture is allowed to accumulate with the dirt and dust, the problem will be worsened. The combination of dust, dit and moisture on generator windings can result in a breakdown of the winding insulation. Normally, moisture builSup on windings is not a problem sitcg interna neat tends to cy the windings. lowever, moisture may accumulate while the unit is idle. Problems with moisture will become worse in very humid environments, or where rapid temperature chan ges can cause condensation. In addition to causing insulation breakdown, dirt and moisture can increase internal generator temperatures, by restricting air low through the unit or by blocking the dissipation of heat. Such materials as talc, lint, rock dust, and cement dust will seriously obstruct ventilation openings in an operating unt. Such materials ascarbon lack, metallic dust, metal chips, and similar materials are probably the most harmful. The latter materials will ‘ot only impede ventilation, but will form a conductive film over the insulation. Generators that operate in very dusty or dirty areas should be disassembled and cleaned periodically. in addition, the condition af the insulation should be tested by measuring the insulation resistance Drying the Generator tests indicate that the insulation resistance of stator ings is below a safe value, such electrical components should be dried before operating the unit. ‘Some recommended drying methods inciude the use of (a) heating units, and (b) forced air. HEATING UNITS: The generator can be enclosed in a covering and heating units can be installed to raise the temperature about 15'-18" F. (8"-10" C.) above the temperature outside the covering. FORCED AIR: Portable forced air heaters can be used to dry the ‘generator. Direct the heat into the generators air inlet Openings ‘and run the unit at no-load and with the voltage regulator removed. The heat at the point of entry should not exceed 150° F. (66° C.). Cleaning the Generator ‘The generator can be cleaned properly only when it is disassembled. The methods used for cleaning should be determined by the kind of dir. Be sure to dry the generator after it has been cleaned. A shop that repairs electric motors in your area may be able to assist you with proper cleaning of generator windings. Such shops are often experienced in special problems that may be peculiar to a certain area (such as a sea coast, marine applications, mining, oil rigs, ete.). USING SOLVENTS FOR CLEANING: ‘A solvent is usually required when dirt contains oil or ‘grease. Only petroleum distilates should be used to ‘lean electrical components. Recommended are safety type petroleum solvents having a flash point greater than 100" F. (38° C.).. Use a soft brush or cloth to apply solvent. Be careful 10 avoid damaging magnet wire of insulation on wind- ings. After cleaning, be sure to dry all components thoroughly with moisture free, low pressure, com- pressed air. DANGER: WHEN USING SOLVENTS, ALWAYS PROVIDE ADEQUATE VENTILATION. IF SUFFI- CIENT VENTILATION IS NOT PROVIDED, FIRE, EXPLOSION OR HEALTH HAZARDS MAY EXIST. WEAR EYE PROTECTION. ALSO WEAR RUBBER GLOVES OR OTHER SUITABLE PROTECTION FOR THE HANDS WHEN USING SOLVENTS. CAUTION: Many generators use epoxy or polyester base winding varnishes. Use only sol- Vents that do not attack such materials. CLOTH AND COMPRESSED AIR FOR CLEANING: When cleaning small components or # only dry dirt is to be removed, cleaning with a dry cloth may prove satisfactory. After wiping such components clean with the cloth, use low pressure air at 30 psi (206 Kpa) to blow the dirt away. BRUSHING AND VACUUM CLEANING: Brushing with a bristle brush followed by vacuuming may be used to remove dry dust and dint: Loosen the dust first, then remove it with the vacuum. Checking Insulation Resistance Insulation resistance is a measurement of the in- tegrity of the insulating materials that separate the electrical windings from the generator's steel core. This resistance can degrade over time, due to contaminants, such as dust, dirt, grease and ‘especially moisture. Tests of insulation resistance are usually done with a “megohmmeter" or a “hi-pot” tester.PAGE 1.42 Checking Insulation Resistance (Con- tinued) Most failures of generator windings are caused by a breakdown in the insulation system. In some cases, a reduced insulation resistance can be caused by mois- ture that has collected on the windings while the unit is shut down. This problem can usually be corrected by ‘drying the generator windings. ‘The normal insulation resistance for generator wind- ings is on the order of "millions of ohms". It can be measured using a device called a “megohmmeter’, or with a "hi-pot tester”. One type of hi-pot tester is shown in Figure 1 below. CAUTION: When using insulation resistance testers, follow the manufacturer's Instructions Carefully. Improper use of such testers can result In’ serious damage to generator com- ponents. DO NOT APPLY VOLTAGES IN EX- CESS OF THOSE RECOMMENDED FOR GEN- ERATOR WINDINGS. Apply voltage for a maxl- mum time limit of one (1) second only. When applying voltage, terminal ends of winding leads must NOT be In contact with any part of the generator. Figure 1. One Kind of Hi-Pot Tester Testing Stator Insulation GENERAL: Stator winding leads are routed out of the stator can and into the generator’s AC connection (lower) panel. The following procedure utlizes the hi-pot tester shown in Figure 1 to test the insulation resistance. #f using another type of insulation resistance tester, be sure to follow the manufacturer's instructions carefully. Follow the instructions carefully when performing tests. You may wish to review the information in Section 1.2, “Types of Stator Connection Systems”. PART 1 SECTION 1.4 ‘CAUTION: Connect the tester probes onlytothe stator leads. DO NOT connect the test probes to any leads that are routed into the generator control console. ‘TESTING STATOR INSULATION TO GROUND: 1. Disconnect and isolate all stator output leads in the AAC connection (ower) pa 2, Connect the terminal nds ofall stator output leads together. '2. On 1-phase units with dual stator windings, con- ect leads 11, 22, 33, 44, 2 and 6A (or 6B) together. 'b. On"broad range” units with 12-Iead reconnectable stator, connect leads $1 through S12 and leads 2 and 6 together. ¢. Make sure none of the lead terminal ends are in contact with the generator frame. 3. Connect the red test probe of the hi-pot tester to the joined stator lead terminal ends. 4. Connect the black tester probe to a clean frame ground on the stator can. 5. Tur the hi-pot tester switch to "Ott 6. Set the tester’s voltage selector switch to "500 volts”, 7, Tum the tester switch "On" and check thatthe plot lamp is lighted. 8. Observe the breakdown lamp on the tester, wait one ‘second, then tum the hi-pot tester switch to "Off Ifthe tester breakcovn lamp iluminates during the 1 second test, clean and dry the stator. After cleaning and crying, rept the test the breakdown lamp comes on:during the second test (after cleaning and drying), replace the stator assembly. ‘TEST BETWEEN ISOLATED STATOR WINDINGS: (On 1 Phase Units: Test between isolated windings as (ol 1, Connect the red hi-pot tester probe to terminal end oi statoriead 11, the black tester probe to terminal end of Wire #2. 2, Turn the tester switch "On" and check thatthe tester Bilt amp is lighted Set the testers voltage selector switch to 1500 volts ‘APPLY VOLTAGE FOR ONE SECOND ONLY. Ob: serve the tester breakdown lamp, then turn the tester switch to “Ott 4. Reset the tester voltage selector switch to "500 volts”. Connect the red tester probe to terminal end of stator lead 33, the black test probe to terminal end of Wire #2. 5, Tur the tester switch “On* and make sure the tester pilot lamp is lighted. 6. Set the tester's voltage selector switch to “1500 volts". APPLY VOLTAGE FOR ONE SECOND ONLY, Observe the tester breakdown lamp, then set the tesier switch to “Of, 7. Reset the tester’s voltage selector switch to “500 volts”. NOTE: Figures 2, 3 and 4 are schematic illustrations of a Yephase stator, a S-phase Wye connected stator and a 3- Delta connected stator, respectively. ~~PART 1 SECTION 1.4 Testing Stator Insulation (Continued) On 3-Phase Units: To test the insulation resistance between isolated windings on 3-phase stators, proceed as follows: 1. Make sure all twelve stator leads are completed isolated from one another. 2. Connect the red tester probe to terminal end of stator lead $3; the biack tester probe to erminal end of stator lead 8, Tum tha tater switch "On and check thatthe pot is lighted, et the voitage selector switch to “1500 vols". APPLY VOLTAGE FOR ONE SECOND ONLY. Ob- serve the tester breakdown lamp, then turn the tester ‘switch to “Of”. 5. Reset the voltage selector switch to "500 volts”. 6. Repeat Steps 1 through 5, with the black tester probe connected to stator lead 5’ and the red tester probe connected to each of the following stator leads, one at atime: a. Lead $9. b, Lead $7. ¢. Lead $1 d. Lead $2. e. Lead $8. It the tester breakdown lamp comes on during any of the one second tests, clean and dry the stator, then repeat the tests. It (alter cleaning and drying), ‘stator fails the second test, replace the stator assembly. ‘TEST BETWEEN PARALLEL WINDING: 1-Phase Stators: To test for insulation breakdown between parallel windings on 1-phase stators, proceed as follows: 4. Connect the red tester probe to terminal endof stator lead 11; the black probe to terminal end of stator lead 3. 2. Sethe tester's voltage selector switch to "500 volts" 3. Tum the tester switch “On* and check that the pilot iampis lighted. APPLY VOLTAGE FOR ONE SECOND ONLY. 4, Observe the breakdown lamp, then tum the tester switch to “Of ‘3Phase Stators: To test insulation resistance be- {ween parallel windings on 3-phase stator, proceed as follows: 1, Connect red tester probe to terminal end of stator lead $3; blacktester probe to terminal endo statorlead 8. 2. Set the voltage selector switch to "500 volts” 3. Tum the tester switch "On" and check that the pilot lampis lighted. APPLY VOLTAGE FOR ONE SECOND ONLY. Observe the breakdown lamp, then tum the tester switch “Of”, 4. Repeat Steps 1 through 3 wit the red tester probe connected to stator lead 83; the black probe connected to the following eads one at atime: S9- $11- S5- S1- 5. Repeat Steps 1 through 3 with red probe connected to stator lead S9 anhd with blacxk probe connected to PAGE 1.43 the folowing stator leads, one at time: S11- $5- S1- 5. Repeat Steps 1 through 3 with red probe connected, to stator lead 11 and black probe connected to the following leads, one at a time: S5- S1- $7. 6. Repeat Steps 1 through 3 with red tester probe connected to stator lead S1; black probe connected to, stator lead S7. {tthe breakdown lamp comes on during any one second test, clean and dry the stator. Then, retest stator insula tion resistance. If stator fails the second test (atter cleaning and drying), replace the stator assembly. Le vous 120 [| a ro Figure 2. Schematic. 1-Phase Stator “my oS ‘ Figure 3. Schematic- 3-Phase Wye Connected Stator Figure 4- Schematic 3-Phase Delta ConnectedPAGE 1.44 Testing Stator Insulation with a Megohmmeter GENERAL: ‘A megohmmeter, often called a “megger", consists of a meter calibrated in megohms and a power supply. The most common power supply is 500 volts. Use of any magger voltage n excess of 800 volts sna recom- mended. TESTING STATOR INSULATION: ‘All parts that might be damaged by high megger voltages must be disconnected from the circuit before starting the test. Isolate all of the stator leads from ground and connect all stator lead terminal ends together. Connect one megger test lead to the stator leads; the other to frame ground. Follow the megger ‘manufacturer's instructions carefully. Take the megger reading. The minimum acceptable value can be calcu- lated using rhe following formula: Generator Rated Volts "| (in Megohms) 1000 Example: For a generator ated 240 volts, divide "240" 1900" to obtain “0.24". Then, add “1" to obtain “{.24" megohms. In this case the minimum allowable insulation resistance for the stator is 1.24 megohms. Testing Rotor insulation on Direct Ex- cited Units Direct excited generators are those which utilize brushes and slip rings to deliver excitation current from ‘the ‘stationary voltage regulator to the rotating rotor assembly, Test the rotor insulation for breakdown with a hicpot tester, as follows: 41. Gain access to the rotor’s brushes and slip rings. 2. Disconnect all wires from the brushes, or remove the brush holders with brushes. 3. Connect the red hi-pot tester probe to the positive (+) slip ring (nearest the rotor bearing). 4. Connect the black tester probe to a clean frame ound. ‘Turn the hi-pot tester switch to "Off. 6. Plug the tester into a 120 volts AC wall socket. 7. Setthe tester’s voltage selector switch to "S00 volts”. 8. Tum the tester switch “On” and check that the pilot lamp Is lighted. 8. Set the volage selector switch to “1250 vols" and observe the tester breakdown lamp. Then, turn the tester switch “Orr. lf the breakdown lamp comes on in Step 9, drying of the generator may be necessary. After cleaning and drying, repeat the test. If rotor fails the second test (after, cleaning and drying), it should be replaced. PART 1 SECTION 1.4 BLACK TEST LEAD "RED TEST LEAD. Figure 5. Testing Rotor Resistance (Typical) Insulation Resistance Tests on Brush- Jess Generators GENERAL: ‘Stator windings on brushless generators are identi- cal to those used on direct excited units and may be tested in the same manner. However, as the name implies, brushless units do not have brushes and s! rings. instead, excitation currents suppliedto the main rotor windings by means of (a) an exciter stator, (b) an exciter rotor, and (c) the main rotor self, Each ot these windings canbe tested separately for insulation break- n. ‘TESTING WITH A HI-POT TESTER: Disconnect the appropriate winding leads (main rotor, excter stator, of exciter rotor) and isolate them from ground. Connéct all of the winding leads together. ‘Then, connect the red tester probe to the winding leads; the black probe to frame ground. Set the voltage selec- tor switch to "500 volts’. DO NOT EXCEED 500 VOLTS. Turn the tester switch "On", observe the break- down lamp, then turn the tester switch "Off. It the breakdown lamp comes on during the test, clean and dry the winding(s) and retest. i'a winding falls the second test (after cleaning and drying), replace the defective winding. TESTING WITH A MEGOHMMETER: Use a megger having a rated voltage of $00 vot, DO NOT EXCEED 500 VOLTS. Disconnect the ap- propriate leads (main rotor, exciter stator or exciter rotor) and isolate them from ground. Connect the leads. ‘of the winding to be tested together. Connect the meg- ger test probes across the junction of all winding leads and frame ground. Read the meter, then disconnect the meter quickly. The minimum allowable resistance read- ing is 1.5 megohms. aPART 1 SECTION 1.4 Insulation Resistance Tests on Brush- less Generators (Continued) Figure 6. Exciter Rotor (Typical Brushless Uni PAGE 1.45 Measuring Voltages ‘AC VOLTAGES: When reading generator AC output voltage, the gen- erator must be running at its rated operating speed. In addition, some of its protective guards and covers may bbe removed. PROCEED WITH CAUTION. Keep your- self and the meter test leads well clear of moving parts. Stay clear of power voltage terminals and wire terminal ends, DANGER: STANDBY GENERATORS PRODUCE EXTREMELY HIGH AND DANGEROUS VOLT- AGE. CONTACT WITH HIGH VOLTAGE TER- MINALS MAY RESULT IN HAZARDOUS AND EVEN DEADLY ELECTRICAL SHOCK. USE EX- TREME CARE WHEN CHECKING ELECTRICAL VOLTAGES. ‘The generator's AC output voltage can be read at the transfer switch terminal lugs. The following rules apply: + On1-phase generators, line-to-line voltage may be ag separa Naa re votage ype Agural yotag across line E1 to 00 or across line + One 3-phase units, line-to-line voltage can be re aefoss ling Et to Ez: £2 fo ES: and ES fo Bt ine-to-neutral voltage can be read across line E1 10.00; ine E2 to 00; or line E3 t0 00. ‘Some standby generators will have an AC voltmeter ‘mounted on their control console, along with a voltage- phase selector switch that allows the operator to select, the line being read on the meter. These console mounted voltmeters are generally very reliable and accurate. Most Generac standby generators are equipped with a solid state "Voltage over frequency” type vottage regulator. This type of regulation maintains an AC ‘oulput voitage that is proportional to the unit's operating speed and AC frequency. Thus, if operating speed and frequency are high or low, generator AC output voltage will be correspondingly high or low. For that reason, wen checking AC vallage fi a good idea to check AC trequency as well. The voltage regulator can be adjusted to maintain the correct rated AC age, but such adjustment should be accomp| when AC frequency is correct. ut valt- ied only OC VOLTAGES: Use an accurate DC voltmeter to measure these voltages. Always observe correct DC polarity. Some ‘meters will be equipped with a polarity switch; on other ‘meters, polarity is reversed by reversing the meter test leads. The meter must be set to a higher scale than the anticipated voltage reading. When in doubt, start with the highest available voltage scale and adjust the scale downward until he correct reading is observed. Some DC vokmeters are designed with a positive (+) to nega- tive (-) current flow; some with a negative (-) to positive (+) current flow.PAGE 1.46 Measuring Current The generators AC output curent can usually be taken witha “clamp-on’ type ammeter. Mast clamy-on lammeters will not measure direct current (Oc). When measuring current, the following rules apply: + Some generators may have more tan one lead or ach ne or phage, When checting, current laimperes mde sure, the clarnp‘gn metas ua stl fo aan tn or phase. + ithe physical size of the conductors orthe capaci al ind akamater wil not stow al ince of cahos Row each logo cablsraviualy ther, sat he individual readings Together to obtXin he fota + Compare the reasings obtained fo the unit's DATA foneerete hai: eanedie eu PATA SHOE URE Relators oe Measuring Resistance MAIN STATOR WINDINGS RESISTANC! The resistance of stator AC power windings is typi- cally very low. Some meters will not be capable of treading such a low resistance and will simply indicate “continuity”. However, a standard volt-ohm-milliam- ‘meter (VOM) can be used to test the stator windings for (a) continuity, (b) shorts, or (c) grounded condition STATOR EXCITATION WINDINGS: Stator excitation windings can be tested for either a shorted or grounded condition. "Marathon®* gener- ators are not equipped with an excitation winding. ROTOR WINDING RESISTANCE: ‘On direct excited units, the rotor can be tested with a volt-ohm-milliammeter (VOM) to determine i it is ‘grounded or shorted. Always connect the meter's posi- tive (+) test lead to the positive (+) slip ring: the common (test lead to the negative (-) slip ring. The positive (+) slip ring is usually the slip ring nearest the rotor bearing (On brushless generators, the exciter stator, exciter rotor and main rotor can ali be tested for an open or shorted condition, using a volt-ohm-milliammeter. Measuring AC Frequency ‘The operating speed and AC frequency of a gener- ator are directly proportional. The following rules apply + Units having a 4-pote rotor will supaly a 60 Hertz AAC‘outpul Hequepey at 1800 roma 80 Wertz AC requericy at 1500 mpri + Units with 2-pale rotor will deliver a 60 Hertz AC fGageney at Se8d rom’ a 90 Men frequency Gnerat standby generators are typically equipped with 2 solid state voltage regulator, often called a “voltage-over-trequency”of "VIF" type regulator. These valage regulators maintain avotage that proporton- alto Ac frequency. For example, aunt rated 240 vots, 0 Hertz will supply that volage at 60 Hertz. frequen: cy (and rpm) decrease, output voltage will decrease proportionally PART1 SECTION 1.4 When testing for proper AC voltage, both voltage and frequency readings should be taken. The voltage regulator should never be adjusted for correct voltage until AC frequency is correct. Frequency and rpm are adjusted at the engine speed governor. —~PART 1 SECTION 1.5 PAGE 1.5-1 Section 1.5 MECHANICAL ENGINE GOVERNORS Introduction Governor AC output frequency is directly proportion- alto the driven speed of the rotor. In order to maintain a specific AC output frequency, rotor speed must be precisely controlled. Rotor speed can be maintained by ‘governing the operating speed of the driving engine. Many spark ignited (gas fueled) engines employ a fixed speed, mechanical engine governor. Because proper generator operation is so dependent on a cor- rectly adjusted and maintained governor, some of the adjustment procedures for mechanical governors will be discussed in this section. How a Mechanical Governor Works See Figure 1. Engine and govemor speed will decrease i the load on the engine is increased even htly. In response to the decrease in engine speed, governor flyweights (2) are forced inward by governor Spring force. Flyweight (2) movement is transmitted through a sleeve (3) and a shaft (4) to a governor lever (6). The governor lever (5) then moves a link (6) which actuates the carburetor throttle valve to a more open position. Engine speed then increases. ‘As engine speed increases, flyweight (2) centrifugal force overcomes governor spring force and the flyweights move outward. Flyweight movement is then transmitted through a sleeve (3), a shaft (4) and to a governor lever (5). This actuates a link (6) to a reduced {uel flow position and engine speed decreases. ‘An equilibrium will be reached when tlyweight centrifugal force becomes equal to governor spring force. This type of govemor actually never reaches a state of equilibrium. That is, governing action consists of a series of very small and brief accelerations and decelerations. Sueiden dumping ofa load willeause a rapid increase in engine speed. The governor must be able to recover very quickly, to prevent an overspeed condition. Some Typical Mechanical Governors Governors currently in use on spark ignited (gas) engines include (a) Fart No. 65934 and (b)Part No. 68985. The latter (68985) is used on 1.0 and 1.2 liter gas/gasoline engines. Governor 65834 is used on most other spark ignited engines. NOTE: Starting in September 1991, Generac bagan to -@ tha mechanical governor (65934) with the new Ganerac electronic govemor. The 1.0, 1.2 and 2.3 liter on- gines wil continue to use a mechanical governor. For infor- ‘mation and instructions on the new electronic governer, refer to Section 1.6. Adjustment procedures on diesel engine govemors are discussed in Section 1.7. Figure 1. Governor Operating Diagram Adjustment of 65934 Governor GENERAL: ‘The following adjustment procedure applies to en- gines that are NOT equipped with a vacuum operated dashpot system. Some 2.6 liter, 5.7 liter and 7.4 liter engines are equipped with a vacuum operated dashpot system. These systems were installed to alleviate rpm su that might occur at mid-power ranges on the applicat engines. Kits were made available for field installation of the dashpot system on early production units. Ad- justment procedures for units with dashpot system are Not included in this manual, but may be found in the following manuals which are available from Generac: + Instructions and Parts, “Vacuum Operated Gover- nor Dashpot Kits for 5:7 & 7.4 Liter Gas Engines” Order Manual Part No. 78915. + Instructions and Parts, "Vacuum Operated Gover- nor Dashpot Kits for 2.6 Liter Gas Engines". Order Manual Part No. 78916. INITIAL (PRESTART) ADJUSTMENTS: 1. Find the length of the throttle linkage rod by observ- ing the position of the governor arm and the throttle plate arm. a. The governor arm should be in alignment with the spring fension arm. b. The throttle arm should be between one and two O'clock. cc. With the relationship between (a) and (b) above established, no drag or binding should be present and full travel of the entire linkage assembly should be obtained.PAGE 1.5-2 Adjustment of 65934 Governor (Con- tinued) 2. Adjust the OROOP ADJUSTMENT SCREW so that ‘approximately 9/4 inch of thread is showing above the upper lock nut. Then, tighten the upper and lower DROOP ADJUSTMENT SCREW lock nuts. 3. Tum the BUMPER SCREW cut (counterclockwise) Until approximately 3 or 4 threads are engaged. Then, tighten the BUMPER SCREW lock nut. CAUTION: The bumper screw locknut must be tightened before startup or oil will leak from the jovernor. 4. Tum the SPEED ADJUSTING SCREW in (clock- wise) until a slight tension is felt on the governor spring. This should provide low speed operation on initial star- tup. FINAL ADJUSTMENT (ENGINE RUNNING): 1. Connect an accurate AC frequency meter to the generator’s AC output leads. 2. Start the engine and let it warm up at no-load. 3. Turn the. SPEED ADJUSTING SCREW clockwise to increase speed and AC frequency. Siowiy increase engine speed until the frequency meter reads 62 Hertz at no-load. NOTE: At this point govar jon may be somewhat Unstable. You may wish to stabilize the governor by placir ‘your hand on the GOVERNOR ARM as a dampanor. This wil help stabilize rpm and frequency and allow you to complete adjustments. 4. Loosen the lock nut on the BUMPER SCREW. a. Tap the governor arm to make it go into an un- stable condition, b. Tum the BUMPER SCREW clockwise until the ‘governor begins to stabilize. . Continue fo turn the BUMPER SCREW clockwise until frequency starts to increase. Then, tum the BUMPER SCREW counterclockwise unti irequency reads 62 Hertz at no-load. 4. Tighten the BUMPER SCREW lock nut. CAUTION: If the BUMPER SCREW is turned Clockwise too far, speed adjustment may be adversely affected. If any governor setting (speed, bumper, droop) Is changed, the other settings must be rechecked. 5, When settings are complete, tighten all locknuts. ‘Then, check to make sure settings have not changed, 6. Apply an electrical load equal to the unit's rated wattage/amperage capacity. Frequency should not droop more than four (4) Hertz a. I excessive rpm and frequency droop occurs, increase tension on the DROOP SPRING. b. After changing DROOP SPRING tension, reset the SPEED ADJUSTING SCREW to 62 no-load, PART1 SECTION 1.5 Buuren scmew Figure 2. Governor Part No. 65934 Adjusting Governor 68985 GENERAL: This governor is used on some 1.0 and 1.2 liter spark ignited, gas engines. It consists of (a) a fixed speed Mechanical govemor, and (b) a battery charge alter- nator. See Figure 4. ADJUSTMENT PROCEDURE: 1. The length ofthe governor lever to carburetor nk, ‘as measured between ball joint centerlines, should be 4-3/8 inches. Figure 3. Governor Lever to Carburetor Link 2, Connect an accurate AC frequency meter to the generators AC output leads. Start the engine, let it warm up at no-load. 4, Adjust the NO-LOAD SPEED ADJUST SCREW to obtain a frequency reading as close as possible to 61.5 Hertz for 60 Hertz units; or 50 Hertz for 50 Hertz units, 5. Adjust the NO-LOAD BUMPER SCREW to obtain a fo-load speed of 62 Hertz for 60 Hertz units (51 Hertz for 50 Hertz units). 6. Apply an electrical load to the generator as close as possible to the unit's rated wattage/amperage capacity,PART1 SECTION 1.5 Adjusting Governor 68985 4a. Check the AC frequency with load applied. D. If frequency droops below about 58 Heitz (60 Hertz units) or 49 Hertz (50 Hertz units), adjust the DROOP ADJUSTMENT downward, ¢. Adjust the DROOP ADJUSTMENT until applica- tion of the load results in the smallest possible AC frequency droop. NOTE: I surging occurs when electrical loads are removed, ‘adjust the NO-LOAD BUMPER SCREW inward. I BUMPER SCREW aqustment changes the AC requency, back the BUMPER SCREW out until no-load frequency returns to 62 Hertz (60 Hartz units) or to 51 Hertz (50 Hert? units). Figure 4. Governor Part No. 68985 PAGE 1.5-3PART 1 SECTION 1.6 PAGE 1.6-1 Section 1.6 ELECTRONIC ENGINE GOVERNORS Introduction ‘This section provides information on the compo- ents and adjustment of electronic engine governor systems used with Generac standby generators. The standby generator engine may be equipped with either, (a) a Barber-Colman governor or (b) a Generac elec- tronic govemor. BARBER-COLMAN GOVERNORS: ‘These governor systems are manufactured bythe Precision Dynamics Division of the Barber-Colman Company, headquartered at 1354 Clifford Avenue, P. ©. Box 2540, Loves Park, llinois 61132-2840. The following governors may be used: 1 The "DYNA-MASTER’ governor system. Oi The *DYNA-8000" govemor system. GENERAC ELECTRONIC GOVERNOR: ‘Operation and adjustment of Generac’s electronic governor system will be discussed in this section. The “DYNA 8000" Governor GENERAL: ‘The "DYNA 8000" system is an all electric governor which provides precise isochronous or droop speed Conta of medium size engines, depending on the ype Of el system used. The basic system consists of (2) a controller, (b) an actuator and (c) a magnetic pickup. THE ACTUATOR: ‘The actuator is basically a simple, proportional, ‘electric solenoid with a sliding armature. The solenoic's ‘magnetic force is proportional to the input coil current. Balanced between the force of its return spring and the ‘magnetic force, the armature slides on ant-friction bearings, providing a hysteresis-free linear movement. ‘The linear motion is converted to output shatt rotation by a boll crank. ‘The following differences may exist between actuators (see ELECTRONIC GOVERNOR: APPLICATION CHART in this section). D Direction of shatt rotation (CW or CCW). system voltage (12 or 24 volts DC). Davailable torque (Dyna 8000 actuator is rated at about 1.0 foot-pound) ‘THE CONTROLLER: ‘he contrllor receives engine speed (requency) signals from a magnetic pickup. Its powered by Dt voltage from the generator battery (12 or 24 volts OC). Adjustment pots are provided on the controller for the adjustment of (a) governed speed, (b) gain, and (c) droop. DYNA 8000 specifications are as follows: MAGNETIC PICKUP: ‘The magnetic pickup i installed so that its mag- netic tip is directly over the engine flywhee''s ring gear teeth. The device will emit a pulse or cycle of electricity each time a gear tooth passes the magnetic tip. The pulse is delivered to the govemor controller as an indication of actual engine speed. ‘The input signal frequency delivered from the mag- netic pickup to the controller can be calculated using the following formula, where “A* is the input signal frequency in Hertz, "RPM" is engine speed, and ‘Nis the number of gear teeth on the flywheel. A = RPMXN 60 ISOCHRONOUS OPERATION: Isochronous operation is obtained by setting the DROOP potentiometer fully counterclockwise. The ‘governor is all electric and is normally operated in the isochronous mode, That is, engine spe (plus or minus 0.25%) under steady state load condi tions, up to the engine's maximum capability, regard- less of load on the engine. DROOP OPERATION Droop operation is obtained by setting the DROOP. potentiometer clockwise to increase droop. The amount of droop for a given setting depends on the ‘magnetic pickup frequency and the no-load to full-load actuator shaft rotation. A droop potentiometer setting ‘of 10 o'clock will give about 4% droop, no-load to fullload, when pickup frequency is 4260 Hz and actu- ator shaft rotation js approximately 20 degrees from no-load to full-load. A lower pickup frequency or a smallr shat rotation results in less droop forthe sys- fem, MAGNETIC PICKUP INSTALLATION: f the magnetic pickup is removed for any reason, it must be installed property. Rotate the ring gear unti ‘a gear tooth face is directly in the center of the pickup tapped hole. See Figure 1, on next page. Gently tum ‘the magnetic pickup clockwise into the tapped hole until itjust bottoms on the gear tooth. Then, back off 1/4 turn. nd tighten the am nut securely. ‘CAUTION: DO NOT rotate ring gear until after the magnetic pickup has been properly In- stalled or damage to equipment will resulPAGE 1.6-2 PART1 SECTION 1.6 The "DYNA-8000" Governor (Continued) J ‘Soeee Sensor Engane Gao Houeng 4 a7 = 127 mm pr Up [018 = 005}, ing Gear Figure 1. Magnetic Pickup Installation OPTIONAL REMOTE SPEED ADJUSTMENT: ‘An optional remote speed selector is available for adjusting engine speed from up to 300 feet (30 meters) from the unit. See terminals 6, 7 and 9 in Figure 2. DYNA 8000 CALIBRATION AND ADJUSTMENTS: A. Initial Settings: With engine shut down, complete ial potentiometer adjustments as follows: 1. Sat the “I” adjustment one division from zero and the "GAIN" at the third division from zero. 2. Select either isochronous or droop operation as follows: a. For isochronous operation, set OROOP coun- terlocise ois minimum positon as shown in igure : For droop operation, set the OROOP potentiom- ter clockwise to obtain desired amount of droop from no-load to full-load. Tum the adjustment clockwise to increase droop. NOTE: Ifthe full 35° rotation of the actuator shaft is used and the linkage adjusted to use only the active fuel range, maxi- mum obtainable droop would be approximately 12% at ful load. [O79 7 eae oe ares coe ERS Que @ bync actuator ly 8 { T Pelee] orl 3 ceboas cue hs 9 waster 8 4 i manecn | @ lla own pe De Bc Fower _ sev Some 7 cune—| C4 5 Sinmoneis’ ated ow Figure 2. DYNA 8000 Governor SystemPART1 SECTION 1.6 The "DYNA 8000 Governor (Continued) 3. Set switches S1 and S2 as follows: a, Switch S1 selects one of two integrating rate ranges. The diesel version integrates at twice the rate of the gas version, . Switch $2 selects the point at which actuator coil current level causes the intergator limit to be actuated. This level is normally 6.3 amperes for the DYNA 8000., ¢. Set switches S1 and $2 as follows: (1) Sot Switch $1 to OFF for ciesel engines; to for gas engines. (2) Set switch $2 to OFF for the "8000" actuator. NOTE: Figure 3 below should claty any confusion about ‘wilch settings. The easiest way tosot the swilches isto apply Gownward pressure wih a small painted object (as Shown) Uni the switch clicks ino postion. ol Seevew Sen ew “on! “or Figure 3. Setting Switches ST and S2 4. If a remote speed potentiometer is used, set it to mid-range. ‘NOTE: If tha remote speed potentiometer is connected to terminals 6, 7 and9, the resistor ‘Rin the wire is notrequired. This wil provide approximately a plus or minus 5% adjustable speed range. B. Adjustment with Engine Running: After all initial settings are completed, start the engine. Let it stabilize and warm up {or a few minutes. Then, proceed as follows 1, Adjust the controller "SPEED" potentiometer until the engine is running at the desired speed. Turn the adjustment clockwise to increase rpm and AC fre- quency, - 2. I the governor system is unstable, slightly reduce the "I" and "GAIN" settings. NOTE: Excopt forthe *SPEED" adustment, tho potenti tors have toma stops at her and 100% postions 3. with the generator running at no-load, finalize the Settings of “It and "GAIN" as follows: fum the GAIN adjustment slowly clockwise until the actuator lever oscillates. This will be a faster oscillation than was observed when "I" was ad- justad. When oscillation occurs, tum GAIN slowly counterclockwise until the lever stabilizes. Upset the lever with your hand. Ifthe lever oscillates 3 to 5 diminishing oscillations and stops, the setting is correct, PAGE 1.6-3 b. If system performance to load changes is salis- factory, omit Step 4. 4, Reduce the GAIN setting counterclockwise one division. Next, tum the “I* adjustment fully clockwise while observing the actuator lever. If the lever soes, not become uynstable, upset it by hand. When the lever slowly oscillates, tum the GAIN adjustment slowly counterclockwise until the lever is stable, Upset the lever again: it should oscillate 3 to 5 times, and then become stable for optimum response. NOTE: Use the settings of Step 3 or Step 4, whichever provides the best performance, The unit is now calibrated. The "DYNA-MASTER" Governor GENERAL: Engine speed is controlled by an all-alectric gover- or assembly consisting of an actuator and a controller. ‘The actuator output is connected to the fuel control lever via a linkage rod. The speed signal from the enginais obtained roma magnetic pickup inthe engine flywheel housing. ACTUATOS ‘The actuator consists of an electro-magnet with an iton armature rotating on a center shaft. The actuator | provided with a return spring which’ balances the magnetic forces of the armature. When DC current is flowing in the coil, the magnetic force tends to rotate the armature in the stator. CONTROLLER: ‘The electronic controller is the information process- ing unit of the govemor assembly. Itcontains electronic components which process the input signal from the magnetic pickup. Extemal adjustments are available on the controller for field adjustment of the unit, if neces- sary. POWER SOURCE: ‘The govemor system is energized by the generator battery which supplies either 12 volts DC of 24 volts 'DC, depending on the specific unit. Average operating cutrent is about 2 to 3 amperes. Highest current flow is about 10 amperes, during startup oF during largo load change. ISOCHRONOUS OPERATION: Droop operation is normally available only on DYN1 10614 series units only. In isochronous opera- tion, engine speed is constant (plus 0.35%) under steady state load conditions, up to the engine's maxi- mum capabilities, regardless of load on engine.