Onan Mobile GenSet Service Manual
Onan Mobile GenSet empowers you with portable power at your fingertips. Whether you're embarking on an outdoor adventure, need backup power during outages, or seeking a reliable source of energy for your projects, this versatile device has got you covered.
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982-0001
9-2002
Safety Precautions
The following symbols in this manual highlight condi- tions potentially dangerous to service personnel, or equipment. Read this manual carefully. Know when these conditions can exist. Then take necessary steps to protect personnel as well as equipment.
If you must make adjustments while the unit is running, use extreme caution around hot manifolds, moving parts, etc.
Do
not work on this equipment when mentally or physi- cally fdigued.
This symbol if used warns of imme- diate hazards which will result in severe personal injury or death.
1 1
This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.
This symbol refers to a. hazard or unsafe practice which can result in personal injury or product or property damage.
PROTECT AGAINST MOVING PARTS
Avoid moving parts of the unit. Avoid use of loose jackets, shirts or sleeves due to danger of becoming caught in moving parts.
Make sure all nuts and bolts are secure. Keep power shields and guards in position.
GUARD AGAINST ELECTRIC SHOCK
Disconnect electric power before removing protective shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surfaces to be damp when handling electrical equipment.
Disconnect batteries to prevent accidental engine start.
Jewelry is a good conductor of electricity and should be removed before working on electrical equipment.
Use extreme caution when working on electrical com- ponents. High voltages cause injury or death.
Follow all state and local codes. To avoid possible per- sonal injury or equipment damage, a qualified electri- cian or an authorized service representative must per- form installation and all service.
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EXHAUST GAS IS DEADLY!
Exhaust gases contain carbon monoxide, an odorless and colorless gas formed during the combustion of hydrocarbon fuels. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning are the following:
0
0
0
Inability to Think Coherently
Vomiting
Muscular Twitching
0
Throbbing in Temples
0
Dizziness
Headache
Weakness and Sleepiness
If you or anyone else experience any of these symptoms, shut down the unit and get out into the fresh air immediately. If symptoms persist, seekmedicalattention.
DO NOT OPERATE THE UNIT UNTIL IT HAS BEEN INSPECTED AND REPAIRED.
The best protection against carbon monoxide inhalation is proper installation and regular, frequent visualandaudible inspections of the complete exhaust system.
Redistribution or publication of this document, by any means, is strictly prohibited.
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Table of Contents
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TITLE
SAFETY PRECAUTIONS
.................................................................
PAGE
Inside Front Cover
.....................................................................................
About this Manual
Test Equipment
.................................................................................. i
....................................................................................
How
to Obtain Service
i
.............................................................................. i
...................................... :
.......................................................................................
-I
................................................................................
...............................................................................
................................................................................
Current Transformers
Control Heater
.............................................................................
2-5
...................................................................................
2-6
.......................................................................................
................................................................................
...............................................................................
...........................................................................
.......................................................................................
..........................................................................
Time Delayed'Start/Stop and Preheat Module
Magnetic Pickup Interface Module
.......................................................
................................................................. 3-9
.
Over/Under Voltage Sensor Module
...............................................................
.........................................................................................
...............................................................................
...................................................................
.
......................................................................
....................................................................
..............................................................................
............................................................................
ENGINE CONTROL SERVICE ..........................................................................
....................................................................................
...........................................................................
Engine Cranks But Does Not Start
..................................................................
Engine Starts But Stops After Running Several Seconds
..............................................
Engine-Generator Is In Operation. Then a Fault Shutdown Occurs
.....................................
...............................................................................................
.................................................................................
...........................................................................
..............................................................................
...............................................................................
..................................................................................
...........................................................................
..........................................................................
WIRING DIAGRAMS
..................................................................................
5-1
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Redistribution or publication of this document, by any means, is strictly prohibited.
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Section
1
Introduction
ABOUT THIS MANUAL
This manual provides basic information regarding your
Onan GenSet AC/DC control options, internal compo- nent descriptions, and DC control troubleshooting. For the AC control troubleshooting, referto specific genera- tor service manual. For more DC servicing/trouble- shooting refer to specific engine service manual.
Study all manuals carefully and observe all warnings and cautions. Knowing your generator set, using it properly, and following a regular maintenance schedule can result in longer unit life, better performance, and safer operation.
Information for printed circuit board repair is not exten- sive because solid state printed circuit boards lend themselves more to replacement than repair. Applica- tion of meters or hot soldering irons to printed circuit boards by other than qualified personnel can cause unneGessary and expensive damage. Repair of the printed circuit boards is not recommended.
High voltage testing or high potential
(or Megder) testing of generator windings cae cause damage to solid state compo- nents. Isolate these components before testing.
TEST EQUIPMENT
Most of the test procedures in this manual can be per- formed with an AC-DC multimeter such as a Simpson
Model 260 VOM or a digital VOM. Some other instru- ments to have available are:
0
0
Onan Multitester
Jumper Loads
Onan Load Test Panel
AC Voltmeter
DC Voltmeter
HOW TO OBTAIN SERVICE
If the generator set/controis requires servicing beyond the scope of information given in this manual, contact an
Onan Distributor for assistance. Onan factory trained
Parts and Service representatives are ready to handle all your service needs.
When contacting an Onan Distributor, always supply the complete model number and serial number as shown on the Onan nameplate. The Onan nameplate is located on the side of the generator control box (Figure
1-1).
Incorrect service or replacement of l5iEWEl parts can result in severe personal injury and/or equipment damage. Service personnel must be qualified toperform electricaland/or mechan- ical service.
W Serial
NO.
W
FIGURE 1-1. ONAN NAMEPLATE
M-1641
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1 -1
Redistribution or publication of this document, by any means, is strictly prohibited.
CONTROLLER DESCRIPTIONS
The control configurations have been designed to accommodate both thevertical and horizontal style con- trol compartments. Although the controls on the exterior of the cabinets are similar, the interior component loca-
tions differ somewhat. Refer to the Figure 3-2 for exact
component locations of your control cabinet.
The control cabinet is separated into a DC panel for engine-related components on the right side, and an AC panel for generator-related components on the left side.
Depending on options ordered, the control groups can consist of the standard model Detector 2 DC control panel or with options as a Detector 12 control panel (can also include Detector AC meter control panel). The fol- lowing briefly describes each.
Detector 2 Group
This is the standard model DC control, which offers the minimum features required to operate and monitor the generator set. Its name refers to the two DC operating
'ndicator lamps:
AC PANEL
0
0
The green RUN lamp, which lights when unit operating.
is
The red FAULT lamp which lights in the event of shutdown for a
low oil
pressure, high engine temper- ature, overcranking, or overspeed condition.
Detector 12 Group
This model DC control group includes options to more effectively monitor the generator set during operation and identify the cause of a shutdown. It also includes pre-alarm monitoring to inform the operator that a shut- down circumstance might occur if attention is not given to an aspect of engine operation soon.
Detector
AC
Group
This AC control group enables generator monitoring and control at the genset and consists of meters, phase selector, and voltage adjustment.
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DC PANEL
0
-
Q
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FIGURE 1-2. STANDARD MODEL DETECTOR 2
WITH NO OPTIONS
AC PANEL
.-
DC PANEL
M-1590-2
1 z
M-1590-1
FIGURE 1-3.
DETECTOR 12 AND DETECTOR AC OPTIONS
Redistribution or publication of this document, by any means, is strictly prohibited.
1-2
DUAL RANGE
AC VOLTMETER
FREQUENCY
METER
FIELD
BREAKER
WATTMETER
Section
2,
AC Control
I
CONTROL DESCRIPTIONS
The following describes the optional Detector AC meter package for on-set control and monitoring of the gener- ator.
AC Voltmeter: Dual range instrument indicating genera- tor AC voltage. Measurement range in use shown on indicator light.
AC Ammeter: Dual range instrument indicating genera- tor AC voltage. Measurement range in use shown on indicator I ig ht.
Frequency Meter: Indicates generator output frequency in hertz. It can be used to check engine speed (Each hertz equals 30 r/min for 1800 r/min generator sets, 60 r/min for 3600 r/min generator sets.)
Waffmefer:Continuously gives reading
of
the generator output in kilowatts.
Voltage Adjust: Rheostat providing approximately plus or minus five percent adjustment of the rated output voltage.
Field Breaker: Provides generator exciter and regulator protection from overheating in the event of certain fail- ure modes of generator, exciter and voltage regulator.
Phase Selector Switch: Selects phases of generator outputto be measured by AC voltmeter and AC ammeter.
Upper and Lower Scale Indicator Lights: Indicates which scale to use on the AC voltmeter and ammeter.
VOLTAGE
ADJUSTING
RHEOSTAT
\
PHASE SELECTOR
SWITCH
/
UPPER AND
LOWER SCALE
INDICATOR LAMPS
\
/
"
AC PANEL
-
0
M-1590-1
FIGURE 2-1. CONTROLS
Redistribution or publication of this document, by any means, is strictly prohibited.
2-1
CONTROL PANEL INTERIOR
The following describes the internal components and their function.
Voltage Regulator
Because the voltage regulator circuit is directly con- nected to the AC generator, and because it does late excitation in response to generator output, this ser- vice information is covered with generator service. See the generator service manual for the voltage regulator information.
Current Transformers
.
For generator sets equipped with the optional ammeter, the generator output leads must be routed through the current trar;sfor,mers
for
proper meter operation. See
Figure 2-2. The current transformers are identified as
CT21, CT22, etc. on the AC wiring diagrams and electri-
' cal schematics.
Refer to the appropriate generator connection diagram to identify the output leads that must be routed through each current transformer. DeDendinn on model of generator set, it may be required to rouie the generator output leads through the current transformers a second or third winding to accomplish proper amplification for accurate meter movement readings. An output wire passing through a current transformer is considered one PrimaVtUrn. If passed through again, that would be two primary turns.
CURRENT
TRANSFORMER
I)_
OUTPUT WIRE
FROM GENERATOR
Ld
TWO PRIMARY TURNS
CURB
TRANSFl
CURRENT TRANSFORMERS
U
ONE PRIMARY TURN
ES-1566
2 - 2 CURRENTTRANSFORMERS
2-2
Redistribution or publication of this document, by any means, is strictly prohibited.
Control
Heafer
A control heater provides a meansof humidity/tempera- ture control
of
the control box interior to protect the components and ensure their effectiveness vJhen the generator set is subjected to varying ambient air condi- tions during extended periods
of
The element is controlled by an adjustable thermostat.
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TO VAC
SUPPLY
HEATER
ELEMENT
FIGURE 2-3. CONTROL HEATER
ES-1563-3
2-3
Redistribution or publication of this document, by any means, is strictly prohibited.
Section
3.
DC Control
CONTROL
DESCRIPTIONS
The following function and operation descriptions includes options. Refer to those applicable to your spe-
cific control group. See Figure 3-1.
Oil Pressure Gauge: Indicates pressure of lubricating oil in engine (wired to a sensor unit located on the engine).
Water Temperature Gauge: Indicates temperature of circulating coolant in engine (wired to a sensor unit located on the engine.
Battery Charge Rate DC Ammeter: Indicates the battery charging current.
Oil Temperature Gauge:Indicates temperature of lubri- cating oil in engine (wired to a sensor unit located on the engine).
Tachometer: Provides constant monitoring of engine r/min.
Speed Adjust Potentiometer: Operator control for adjusting engine r/min (used with electronic governor only).
Run-Stop-Remote Switch: Starts and stops the unit locally, or from a remote location wired to the control engine monitor board.
Reset, Lamp Test, Panel Lamp Switch: Resets the fault circuit only when the Run-Stop-Remote switch is in the
Stop (Reset) position. Tests fault lamps (except 2 light control) and turns on the control panel lamp.
Preheat Switch: Used with diesel engines to provide momentary warm-up of glow plugs.
Running Time Meter: Registers the total number of hours that the unit has run. Use it to keep a record for periodic servicing. Time is cumulative; meter cannot be reset.
Control Panel Lamp: Convenience light for operator. lndicator Lamps: Refer to the following control group descriptions.
Detector
2
Control
The standard control panel has two monitor system indicator lamps.
0
RUN(green)
0
FAULT(red)
The green RUN lamp comes on assoon as both primary and secondary starter disconnect circuits are opened after unit starting. The red FAULT lamp will come on when-an emergency shutdown of the generator set occurs from one of the following conditions:
0
0
0
0
Low oil pressure during unit operation
High engine temperature during unit operation
Overspeed of engine during unit operation
Overcrank condition during starting
Detector 12 Control
The twelve monitor system option features indicator lamps for the following:
0
RUN (green) lamp comes on when both starter dis- connect circuits are opened after unit starting.
0
PRE LO OIL PRES (yellow) indicates engine oil pres- sure is marginally low.
0
PRE HI ENG TEMP (yellow) indicates engine temper- ature is marginally high.
0
LO OIL PRES (red) indicates engine has shut down because of critically low oil pressure;
0
HI ENG TEMP (red) indicates engine has shut down because of critically high temperature.
0
OVERSPEED (red) indicates engine has shut down because of excessive speed.
0
OVERCRANK (red) indicates the starter has been locked out because of excessive cranking time.
0
FAULT 1 (red) an undedicated fault. Might be factory programmed as ashutdown or non-shutdown, and as a timed or non-timed fault. (Normally set for timed shut- down.)
0
FAULT 2 (red) same features as Fault 1. (Normally set for immediate shutdown.)
0
LO ENG TEMP (yellow) engine temperature is mar- ginally low for starting. Indicates inoperative coolant heater.
0
LOFUEL (yellow) indicates fuel supply is margi- nally low.
0
SWITCH OFF (flashing red) indicates generator set is not in automatic start operation mode.
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OILPRESSURE
GAUGE
B-
AC PANEL DC PANEL
~~~
FIGURE 3-1. DC CONTROL
INDICATOR
LAMPS
COOLANT
TEMPERATURE
GAUGE
PREHEAT SWITCH
DC AMMETER
RUNNING TIME
GAUGE
TACHOMETER
M-1590-1
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3-2
Redistribution or publication of this document, by any means, is strictly prohibited.
INDICATOR
/ /
RUNRELAY
K11
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PICKUP
0 A1 6
A I 3
-
A1 4
,.,.F,--,-.m-
IIY Cill-HClC
RE LAY MODULES
0
\
OVERIUNDER
‘ \
VOLTAGE SENSOR
XES-1561
VERTICAL CONTROLLER
VOLTAGE
REGULATOR
VRAS-2
INTERFACE
RELAY MODULE
I
A1 4
FIGURE
3-3
Redistribution or publication of this document, by any means, is strictly prohibited.
CONTROL PANEL INTERIOR
The following describesthe engine control components
and how they function (Figure 3-3). Depending on
options included on your control system, some of the following might not apply.
Engine Control Monitor (ECM)
(AI
1)
This solid state printed circuit board monitors basic
engine control system functions (Figure 3-3). This
includes starting, stopping, and fault system operation.
Terminal blocks are included for making remote con- nections and adding further control options.
The ECM provides the following functions or unit protection:
Overcrank
- limits engine cranking to 75 seconds. If engine fails to start, the module lights a fault lamp and opens the cranking circuit. The cycle cranking option allows three 15-second cranking cycles with two 15-second rest periods on 12-lamp controls.
Overspeed
- shuts down the engine immediately if overspeed occurs and lights a fault lamp. The sen- sor switch is mounted in the end bell on the genera-
, tor shaft. It is factory adjusted to shut down 1800
' r/min unitsat2200f100r/min,1500r/min unitsat
1900f100r/min,and3000and3600r/min unitsat
4000 f
Low Oil Pressure
- shuts down the engine imme- diately if oil pressure drops below, 14 psi- (97 kPa) and lights a fault lamp. The fault is time delayed about 10 seconds following starter disconnect and inhibited during cranking.Thedelayallowsoi1 pres- sure to rise to normal before the electronic control module monitors this system.
A pre-low oil pressure sensor and lamp (used with optional 12-lamp systems) provides an alarm that oil pressure is marginally low (20 psi/l38 kPa or less).
The cause should be found and corrected as soon as possible. This fault is delayed with low oil pres- sure function.
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High Engine Temperature
- shuts down the engine immediately if coolant temperature rises above
227°F or 108°C (above 222°F or 106" C for Onan
TechStar generator sets) and lights afault lamp. The fault is time delayed about 10 seconds following starter disconnect and inhibited during cranking.
This delay allows coolant in a hot engine time to circulate and return the water jacket to normal before the electronic control module monitors this system.
A pre-high engine temperature sensor and lamp used with optional 12-lamp systems, provides an alarm that engine temperature is marginally high
(216°F/1020C). The cause should be found and corrected as soon as possible. This fault is delayed with high engine temperature function.
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Thehigh engine temperature shut-
, down will shut down engine in an overheat condition only if coolant level is suf-
I ficiently high to physically contact shutdown switch. Loss of coolant will allow engine to over- heat withoutprotection of shutdown device, result- ing in severe damage to the engine. Therefore, maintain adequate engine coolant levels to ensure operationalintegrity of coolingsystemandenginecool- ant overheat shutdown protection.
A low engine temperature lamp lights when engine water jacket temperature is 70°F (21
Lighting of the lamp should be no cause for alarm, even during initial generator set operation, since the lamp goes out after the engine warms up.
If the generator set is in an application where it must accept load immediately after starting (such as emergency power standby operation) or when temperatures are so low that starting problems are encountered, Onan recommends the use of engine coolant heaters to ensure starting and proper response.
3-4
Redistribution or publication of this document, by any means, is strictly prohibited.
Y
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KI
TDZ
I
B L O C K D I A G R A M
PRE-HET
I_/B*
w 3 & w4 p c w r i u t i
A
B
I R E M O T E S T A R T S I G N A L
I GND TO S T A R T
B *
FLT.2
TB2
SW O F F 8'
5TOP
2
P4
LAMP TESTaESET +
HATER TEMP
-I d
FIGURE 3-3. ENGINE CONTROL MONITOR
3-5
Redistribution or publication of this document, by any means, is strictly prohibited.
Run Relay
(KII)
This relay, Figure
3-4,
for external functions
of
the site installation that are to be controlled by the starting and/or stopping of the genera- tor set such as ventilation air louvres, blowers, etc. The sets
of
contacts in the relay base provide for either closing a circuit or opening a circuit upon energizing and de-energizing the K11 relay (depending on the desired function wires to the base connections.) Run
Relay K11 is energized when the generator set starts when connected to the
ECM
at TB1-10 (switched B+ connection).
A
K11 RELAY
B
,
FIGURE 3-4. RUNRELAY
K11 BLOCK DIAGRAM
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Y5
ES-1577
3-6
Redistribution or publication of this document, by any means, is strictly prohibited.
,
Interface Relay
Modules
(Al3, A14)
T h e s e relay modules a r e used in conjunction with t h e
“Detector engine control monitor t o provide e&r- nal monitoring of t h e engine-generator at customers
control panel (Figure
As
add-on circuit boards, they interface with t h e remote annunciator signals from the engine control monitor a n d allow t h e u s e of either
AC
o r
DC
for alarm drives.The relays a r e configured for
low
side switching by t h e control a n d supply s e t s
of
contacts for external alarm connections.
BLOCK DIAGRAM
K3
1
6
I
PCB ASSM-ALARM RELAY l12Vl 300-2862 REV w
A i 3
6 \ e
- 3 ‘ )
7
8
E t
\
K6
K7
BLOCK DIAGRAM b 10 b 11 b 12 b 13 b 14
ES-1579 a P
1
1 i 4*4
5
1
10
E M 5 8 0
A I 4
FIGURE 3-5. INTERFACE RELAY MODULES
3-7
Redistribution or publication of this document, by any means, is strictly prohibited.
Time Delayed StaMStop, and Preheat Module
(AI
5)
This module provides time delays for starting and stop- ping the generator set
See Figure
Delayed Starting: The time delay start function is to preclude automatic start-up of the generator set for a determined amount of time (adjustable from
1
to
15
seconds) for installations that might experience power interruptions of short duration, and therefore not want the generator set starting.
De1ayedSfopping:The time delay stop function adjus- table from
1
to 15 minutes, is to provide for automatic cool-down running of the engine for prescribed amount of time (approximately
3
5 minutes is recommended).
Preheat: This function is included on the time delayed start/stop modules used on indirect injected diesel engine generator sets. It provides the engine glow plugs. a signal during the time delay start period and during cranking to activate
PCB A S S Y - T D ST8SP PklT I12V1
300-2898 R E V
WI t
C.W. TO
INCREASE
-
E i
A
KI n R l p ; r !
w2
-
A cI
STOP START
DELAY DELAY u u2 n u‘ n ‘
BLOCK DIAGRAM
R U N S I G N A L IN
TE1-5 TE1-4 TE16
R U N S I G N A L O U T
PREHEAT
GROUND
A
0
GND
B.
T O R U N
TO RUN
FIGURE 3-6. TIME DELAYED STARTlSTOP AND
PREHEAT MODULE
3-8
Redistribution or publication of this document, by any means, is strictly prohibited.
Magnetic
Pickup
Interface Module (Al6)
The magnetic pick-up module, Figure 3-7, senses
engine speed and provides a starter disconnect signal and an engine overspeed signal. Engine speed i s sensed using a magnetic pick-up and a toothed wheel mounted on the engine/generator. Asignal
LED (DSl)
is provided to indicate that a usable input signal is being received from the magnetic pick-up. There aretwo con- figurations of the magnetic pick-up interface module, a fixed setpoint or an adjustable setpoint.
The fixed setpoint version is designed to operate at the following output values:
0
0
Start Disconnect
-
51 0 -L. 60 r/min
Overspeed Trip Point
-
2200 r/min z t 8% for 4-pole, 50/60
-'4400 r/min f 50/60
The adjustable setpoint version has the following ranges of setpoint actuation: (clockwise adjustment increases values):
0
0
Start Disconnect
-
250 to 1000 r/min
Overspeed Trip Point
-
1000 to 2800 r/min on 4-pole, 50/60
-
2000 to 5600 r/rnin on 2-pole, 50160 Hz
On all versions, the starter reconnect value is from 0 to
30 r/min and the overspeed reconnect is 50 percent of the trip point.
BLOCK DIAGRAM
B+
DISCONNECT
MAGNETIC
PICKUP
GND
ES-1518
FIGURE 3-7.
3-9
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OverlUndet Voltage Sensor Module
(A17)
This module senses the applied generator voltage being controlled by the voltage regulator VRAS-2 and pro- vides two outputs for separate indication of over and
under voltage conditions (Figure
the AC inputs to the Over/UnderVoltage Sensor
(Al7)
receivedfrom t h e voltage regulator VRAS-2 indicate generator output is outside t h e limits of module Al7, a shutdown signal initiated to the
ECM.
Fault
1
on the 12-light ECM is is tied to undervoltage and Fault 2 is tied to overvoltage.
A
shutdown fault occuring through this module, might first indicate a failure of voltage regulator VRAS-2.
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The adjustments available on this module follovrs: are as
0
Undervoltage
-Dropout Range
-Time Delay
50 to 139 VAG
(R18)
0.5 to 30 seconds
0
overvoltage
-Limit Range
100
to 200 VAG
Time Delay
-
A
Function of the amount of overvoltage.
(%
Overvoltage of Limit Setting)
135 or above
120
110
100 or below
Time Delay
(Seconds)
0.5
maximum
2
5
8
to infinity
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Phase
Inputs
BLOCK DIAGRAM
TB1-4
B+
ADJUSTMENTS:
LIMIT SET POINT
1
ADJUSTMENTS:
DROPOUT SETPOINT
--
--
DROPOUT TIME DELAY
'
OVERVOLTAGE b 6
? 7
UNDERVOLTAGE b 8
ES-1581-1
TBI-10 GROUND (NEUTRAL)
FIGURE 3-8. OVEWUNDER VOLTAGE SENSOR MODULE
Redistribution or publication of this document, by any means, is strictly prohibited.
OPERATION
Because of varying control option combinations, the following operating descriptions will encompass a
“Detector 12” controller with full options (Figure 3-9).
Read the information through to Emergency Shutdown to gain afull understanding of the options and how they interact with the engine control monitor.
If you are reviewing this operation information for troub- leshooting purposes, ensure that you have eliminated all other malfunction checks external of the controls prior to troubleshooting the printed circuit board type components of the controller.
Regardless of the controller model you have, the engine control monitor includes theshutdown fault commands.
Controllers with options provide delineation and pre- alarm of the shutdown faults, time delayed starting and stopping, and additional monitoring/control, but all engine operation commands through these options are still controlled through the engine control monitor
(ECM).
PHASE SELECTOR
PANEL
LAMP
AC PANEL
DC PANEL - / -
\
TACHOMETER
OIL TEMPERATURE
GAUGE
TIME DELAYED START/STOP INDICATOR
AND PREHEAT A15
.AMPS A12 VOLTAGE
M-1590-1
INTERFACE
RELAY MODULES
FIGURE 3-9. CONTROLLER
3-1 1
.MAGNETIC
PICKUP
A1 6
\
.
OVEWUNDER
VOLTAGE SENSOR
A1 7
XES-1561
Redistribution or publication of this document, by any means, is strictly prohibited.
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Starting Sequence
Manual:
For cold weather starting of diesel driven gensets, the Preheat switch (S13) is held in the preheat position for the necessary period of time (usually about
10 seconds).This energizes the glow plug solenoid.The starting sequence is initiated by placing the Run/Stop/
Remote switch
(SI
Placing switch S I 2 in the Run position energizes the
ECM Run Relay (K7). By energizing K7, B+ is supplied through the electrical circuits of the ECM to energize the engine run circuits (i.e. fuel solenoid) and front panel gauges and to the starter solenoid (through K3).
The engine cranking period is determined by the Over- crankTimer and Cycle Crank Driver (Ul), and the Cycle
Crank Relay (K12), which control energizing and de- energizing the Power Relays K2 and K3 that supply current to the on-set starter and fuel solenoids.
Automatic: With the Run/Stop/Remote switch (S12) in
Remote position, a start command to the genset con- t r o l l e r a c t i v a t e s t h e T i m e D e l a y e d S t a r t /
Stop and Preheat Module (AI 5), which initializes its time delay start period and the Preheat output.
Upon completion of the time delay start/preheat period of glow plugs, the ECM commenses the cranking and start-up by energizing Run Relay (K7) as described in manual start-up.
When engine successfully cranks and starter discon- nects, inputs signals from either start disconnect system of the ECM will activate the Start Disconnect Relay of module A I 5 (KI) which deactivates the preheat output and programs the module for Time Delayed Stop mode.
During generator set operation, all safety systems func- tion to protect and monitor set operation. At end of the generator set duty cycle, when generator output is dis- connected from load and the remote run signal is dis- continued, the time delayed stop function of module A1 5 will continue the engine-generator run time for the prescribed engine cool-down period of 5 minutes before deactivating the run circuits of the ECM.
Starter-Disconnect Parameters
This type of control requires two means of starter- disconnect in order to protect the starter in the case one means should fail. The first uses a DC relay (K14). A B+ signal taken from the battery charging alternator in most cases energizes this relay to disconnect the starter. The second method uses an AC relay (KlO). In this case, voltage from the generator energizes this relay to pro-
\We a back-up to the DC relay. The control uses this method to ensure uninterrupted generator set operation even if only one means of start disconnect is opera- tional. However, the local Run lamp does not light unless both start disconnect relays operate. If the generator set is equipped with a remote Run lamp, the operator can then determine which means of start dis- connect has failed for such an occurence. If the remote
Run lamp lights (and the local Run lamp does not), the
DC relay is not functioning.
All power paths leaving the ECM are protected by fuses so that the circuit board paths cannot be destroyed by excessive current
F1
-
Starter circuit fuse (20 ampere) to protect cir- cuit board paths, K3 and associated wiring.
F2 Switched B+ fuse (20 ampere) to protect cir- cuit board paths, K2 and associated wiring.
F3 - B+ out fuse (15 ampere) to protect circuit board paths.
F4
-
Main ECM circuit fuse (5 ampere) to protect circuit board paths and components on the
ECM.
F5
-
Gauge fuse (5 ampere) to protect circuit board paths, gauges on the front panel and all asso- ciated wiring.
High Engine Temperature (HET) and Low Oil Pressure
(LOP) faults are time delayed about 10 seconds follow- ing starter disconnect and inhibited during cranking.
This allows the coolant in a hot engine some time to circulate and return the water jacket to normal tempera- ture before the ECM begins to monitor this parameter. It also allows the oil pressure to build to normal before monitoring this system. Following thisdelay, these faults become immediate shutdowns for engine protection.
If conditions are correct, the engine will start and the starter will disconnect. If not, an overcrank fault occurs by U1 having cycled/timed out through drive transistor
U4 (pin 6 to 11) to energize Fault Relay K6, which opens the start circuit of the ECM. The Reset switch (S1 1) must be pushed to clear the fault before attempting a restart.
Start-Disconnect Sequence
When the generator set starts, output voltage from the
DC alternator, or from the Magnetic Pickup Module energizes Start-Disconnect relay K14. Energizing K14 then closes its normally-open contacts which illumi- nates the control panel RUN lamp. Also, when the generator set starts, output voltage from the generator stator energizes Starter-Disconnect relay K10. Energiz- ing K10 relay closes its normally-open contacts and illuminates a Remote Run lamp (if equipped).
After the starter disconnects, the LOP and HET fault shutdowns will remain inhibited for another 10 seconds to allow oil pressure and engine temperature to stabilize within the operating range.
Normal Operating Parameters
After a sucessful engine start-up, with all conditions satisfied, the engine will gain in r/min to governor con- trolled operation. Should the engine go into an over- speed condition, the Magnetic Pickup Module (AI 6) will reach the trip point and ground the overspeed input circuit to the ECM to cause a shutdown.
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If the genset is not equipped
with
the Magnetic Pickup
Module/toothed wheel speed sensing, the overspeed switch is a mechanical switch that grounds the over- speed circuit on the EGM if an overspeed condition exists. Either means of controlling overspeed activates the overspeed fault lamp. Afterthe problem is corrected, starting will not occur until the Reset switch is pressed.
Continuous operation of the genset also depends on the proper oil pressure and engine temperature being main- tained, and also any customer required fault conditions connected to the ECM.
Stopping Sequence
Placing the Run/Stop/Remote switch to the Stop posi- tion de-energizes Run Relay (K7) which opens the cur- rent supply through the ECM generator set mounted fuel solenoid (stops fuel flow which stops the engine).
Emergency Shutdown
The K6 fault relay is energized when fault sensors respond to one of the following fault conditions: over- crank, low oil pressure, high engine temperature, over- speed, over/under voltage output. Energizing the K6 fault relay opens its contacts and closes its normally- open contacts. Opening the normally-closed contacts disconnects
B+
from the Power Relays K3 and K2. stops cranking if the engine is being cranked and shuts off the fuel flow. Closing one of the contacts of K6, activates the K8 relay which breaks power to the fault interface relays so that only the indicator associated with the fault will activate. Closing the other normally- open contacts of K6 contacts connects
B+
to the remote alarm terminal.
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I
Section
4.
Engine Control Service
TROUBLESHOOTING
Regardless of the controller model a generator set has, the basics of problem analysis are fundamentally the same.
A. Engine does not crank.
B. Engine cranks, but does not start.
C. Engine starts, but stops after running several seconds.
D. Engine-generator is in operation, then a fault shutdown occurs.
Because the troubleshooting tables in this section include information about various control options, read through this section before a fault occurs to identify what is or is not applicable toyour genset. This will save troubleshooting time when the actual need arises.
Before starting a troubleshooting procedure, make a few simple checks that might expose the problem.
0
Review troubleshooting information as outlined in operator's manual before performing the proce- dures in this section.
,
0
Check all modifications, repairs, or parts replace- ments performed since the last satisfactory opera- tion of the generator set. A loose or otherwise incor- rect wire connection, an opened switch or circuit breaker, or a loose plug-in are all potential prob- lems that can be eliminated by a visual check.
0
Unless absolutely sure that panel instruments are accurate, use portable test meters for trouble- shooting.
When troubleshooting, remember to keep your problem solving a factual, methodical, and most of all a safe process. Hasty decisions can be costly and also harmful to your health.
The Detector 2 controller indicates a fault condition by illuminating only one FAULT lamp.
To
aid in identifying which of the four basic shutdown faults (LOP, HET,
Overcrank, or Overspeed) caused the shutdown, your initial problem analysis before reviewing the following tables should be as follows:
1. Was unit in operation?
Delete Overcrank condition.
2. Did shutdown occur within one minute after starter disconnect?
Possible Low Oil Pressure condition.
3. Was engine operation noticeably erratic with high r/min conditions.
Possible overspeed condition.
4. Perform start-up procedures and observe the following:
0
Oil pressure gauge reads within proper oper- ating range soon after starting.
0
Engine temperature gauge reads 175 to 21 2°F
(80 to 100' C) and stabilizes.
0
Engine starts, builds in speed, and stabilizes at proper r/min.
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SYMPTOM
1. SWITCH
OFF
indicator lamp flashing.
2. Other fault indicator lamps illuminated, but no fault exists.
3. No indication.
4. Time delay start is initiated, but starter solenoid does not energize after desired time delay period.
TABLE 4-1. ENGINE
DOES
.
CRANK
CAUSE CORRECTIVE ACTION
Press to desired, Run or Remote position.
Run/Stop/Remote switch in Stop position.
Lamp Reset switch not actuated after a previous fault was remedied.
Fuses blown on ECM board A1 1.
Starter'solenoid will not energize.
Possible defective
ECM board A I 1.
Broken wiring or poor connections between board A1 1 TBI -8 and starter solenoid.
Possible defective
Time Delayed Start/
Stop Module A15.
Press Lamp Reset switch to de-energize fault lamp relays of ECM, after
Run/Stop/Remote switch is pressed to Stop position.
Check fuses F1 and F4.
Replace if necesary with proper fuse:
F1
F4
-
20 Ampere
-
5 Ampere
Inspect starter solenoid per proper test procedure.
Check A I 1 board TBI -9 for B+ voltage in.
With S12 switch in Run position, check for voltage out to starter solenoid at TB1-8 of board A1 1.
Check and repair as necessary.
Check A I 5 board TBI -4 for constant B+ voltage in.
Check A I 5 board TBI -5 for
Run Signal In voltage.
Voltage at A I 5 board
TBI -6 should be at B+ at end of start delay period.
Check wiring and connections from A1 5 TBI -6 to ECM TBI -6.
Redistribution or publication of this document, by any means, is strictly prohibited.
SYMPTOM
1. Overcrank Fault shutdown lamp illuminated.
A. Low Fuel lamp
B. Fuel solenoid does not energize.
C. Fuel solenoid energizes, but no fuel flows.
D. Engine hard to start due to cold ambient air temperature.
BLE 4-2. ENGINE CRANKS BUT
I IES
NOT START
CAUSE CORRECTIVE ACTION
Insufficient fuel supply in tank.
Fuse blown on ECM board A1 1.
Possible defective
ECM board A1 1.
Broken, wiring or poor connections between board A1 1 TB1-10 and fuel solenoid.
Blockage of fuel supply system.
Heater system not keeping engine warm.
Engine glow plugs not being energized.
Time delayed Start/
Stop and Preheat module
A15 not energizing
Preheat solenoid for glow plugs.
Fill with correct fuel.
Check fuse F2. Replace if necessary with proper fuse. F2-20 Ampere.
Check for voltage out at
A1 1 TB1-10 when engine is cranking.
Check and rectify as necessary.
Check fuel supply system, fuel tank shutoff valves, fuel lines and connections, fuel filters and transfer pump.
Check heater system power supply, controls, etc., and correct as necessary.
Improper start-up procedures used. Depress
Preheat switch S i
3
to energize glow plugs.
Initiate a restart and check for voltage at
A1 5 TB1-7 to Preheat solenoid.
Depress Preheat switch
S i 3 to bypass A15. Check if Preheat solenoid energized.
Check Preheat solenoid per proper test procedure.
4-3
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SYMPTOM
TABLE 2. ENGINE CRANKS BUT
DOES
r IT START Continuedl
CAUSE CORRECTIVE ACTION
(Continued)
D. Engine hard to start due to cold ambient air temperature.
.
Check wiring and connections from switch
S13 and module
A1 5 to Preheat solenoid.
Fuel supply line freeze to engine.
Lamp burned out. 2. Fault shutdown occurs, but no fault lafflp indication.
Possible defective
ECM board A1 1. this table.
Depress Lamp Test switch
SI
1 to check fault lamps.
Refer to Symptom 3.
3. Short cranking period.
A. Controller ECM (A1 1 is equipped to perforn cycle crGnking, but stops cranking before
15 f seconds.
B. Controller ECM (A1 1) is equipped to provide constant cranking to fault limit, but stops cranking before 75 f 15 seconds.
Defective ECM board A1 1
Defective ECM board A1 1
Replace ECM (A1 1).
Replace ECM (A1 1).
4-4 Redistribution or publication of this document, by any means, is strictly prohibited.
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1.
A.
TABLE 4-3. ENGINE STARTS BUT STOPS AFTER RUNNING SEVERAL SECONDS.
SYMPTOM CAUSE CORRECTIVE ACTION
Fault lamp illuminated:
Overspeed
Mechanical Switch, or
Magnetic Pickup overspeed sensing faulty or out of adjustment.
Magnetic Pickup
Module A16 initialized shutdown.
Refer to Generator Service
Manual for adjustment specifications.
B. Low Oil Pressure
Engine governor faulty or out of adjustment.
Low oil level in engine.
LOP switch
SI
faulty.
Review functional description of Mag Pickup Module Al6, and limits of fixed setpoint or adjustable setpoint.
Perform start-up and monitor engine speed to overspeed shutdown.
Fixed Setpoint
If shutdown occurs before limit, replace A I 6 module.
Adjustable Setpoint
If shutdown occurs before desired setpoint, readjust module Al6. If adjustment does not correct fault conditions, replace module A16.
If shutdown occurs within module A I 6 limits, refer to governor operation in enginelgenerator service manual, or contact an Onan representative.
Replenish as necessary.
Check oil level, perform restart, and monitor oil pressure gauge M I If gauge reading is within normal range, switch S i is faulty. Replace.
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4-5
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TABLE 4-3. ENGINE STARTS BUT STOPS RUNNING A n
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SYMPTOM CAUSE
-~
~
C. High Engine' Low coolant level in engine. Temperature.
R SRlERAL SECONDS.
IContinuedl
CORRECTIVE ACTION
Replenish as necessary.
HET switch
S2
Check coolant level, perform restart, and monitor engine temperature gauge M12. If gauge reading is within normal range, switch
S2
faulty. Replace.
Thermostat defective. Rep I ace therm
osiagt.
Tighten fan belt.
2. No fault condition.
Fan belt slipping,
Intermittent control wiring connections.
Check condition of all con'trol wiring to ensure correct and secure terminal connections.
-
-
-
4-6
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TABLE 4-4. ENGINE GENERATOR
IS
IN OPERATION, THEN A FAULT SHUTDOWN
OCCURS
SYMPTOM CAUSE CORRECTIVE ACTION
1. Fault indicator
' lamp illuminated.
A. LOP, HET,
Overs peed
B. Auxiliary lamp illuminated.
2. No fault lamp indication.
As indicated.
As dedicated by customer.
'
Possible defective
ECM board A1 1.
Refer to Table 4.
As required.
Other customer required shutdown command.
Check fuses F4 and F2 of
ECM board A1 1.
F4-(Main)
-
5 Ampere
F2- (Fuel solerioid or ignition)
-
20 ampere
Perf0r.m restart and check for
B+ vqltage in at TBI -9 and voltsge out at TBl-10 to fuel solenoid.
I! there is voltage out at
TI31 -1 0, check fuel supply solenoid, shutoff valves, etc.
If there is no voltage out at TBl-10, ECM board A1 1 is defective. Replace.
Refer to installation reference material, or contact an Onan representative.
4-7
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TESTS
Refer to the following checkout tests when isolating circuit problems caused by faulty engine control com- ponents.
Follov~
instruments and components from permanent damage.
All external engine control components such as leads, switches, relays, indicator lights, senders, and gauges, plug into the engine monitor board. When testing exter- nal components, disconnect the corresponding jack
(Jl, 32, J3, or J4)from the board. Refer to the appropriate wiring diagram to determine the jack number.
Battery Checkout
Check charge condition of the battery with a hydrome- ter. The electrolyte specific gravity should be about
1.260 for a fully charged battery at 8OoF (27OC). If not, add approved water to keep electrolyte at proper level and recharge the battery. If battery will not recharge, replace it.
Ignition of explosive battery gases can cause severe personalinjury. Do not smoke while servicing batteries.
If the battery loses excess water, the alternator charge may be too high. Likewise, if battery state of charge
is
not maintained, the charge rate may be too low. Refer to
Alternator Checkout.
Battery Cable Checkout
With the starter motor operating, check the voltage drops (1) from the battery negative post (not the cable clamp) to the cylinder block, (2)from the battery positive post to the battery terminal stud on the solenoid. Nor- mally, each of these should be less than 0.3 volt. If extra long battery cables are used, slightly higher voltage drops may result. Thoroughly clean all connections in any part of the circuit showing excessive voltage drop.
Alternator Checkout
With the engine running, check the battery charge rate
DC ammeter. If the alternator is operating properly, the ammeter should show a slight charge, gradually taper- ing to zero as the battery becomes fully charged. If the ammeter shows a constant discharge or aconstant high rate of charge, stop the generator set and check for a loose or slipping drive belt, poor terminal connections, or broken lead wires. Repair or replace as required.
If
everything checks out, use a voltmeter to determine the alternator output voltage. Connect the positive (+) lead to the output terminal and connect the negative (-) lead to ground. Start the generator set and run for a few minutes to allow thevoltage to stabi1ize.A proper operat- ing system will have a nominal output voltage of between 13.8 and 14.8 volts.
If the output voltage is high (over 15 volts), check for loose or corroded voltage regulator leads. If this does not correct the problem, the regulator is probably shorted and should be replaced.
If the output voltage is low (equals battery voltage), the problem could be worn or broken brushes, an open regulator, or an open field diode. Refer to appropriate engine/generator service manual for more detailed test and service procedures.
Solenoid Checkout
1. Apply battery positive (B+) to the terminal marked S.
2. Jumper a ground wire to the solenoid mounting bracket. Solenoid should activate.
3. If the contacts are good, 12 volts should be read between terminal I and ground. The voltage drop measured across the contacts should never exceed one volt in circuit application.
Relay Checkout
Connect 12 volts across relay coil terminals. Relay should activate if coil is okay.
Connect a 12-volt source to one side of relay contacts.
Connect a voltmeter to other side of relay contact and 12-volt source. If 12 volts appear when relay is energized, contact is okay. The 12-volt reading appears in reverse order when checking normally closed contacts.
Fuel Solenoid Checkout (Diesel Only)
If there is fuel to the injection pump, but no fuel at injection nozzle, the fuel solenoid might be defective.
To
check fuel solenoid operation, remove the B+ lead connection from the solenoid, and jumper a separate B+ connection to this terminal. The injection pump should click. If no click is heard, the fuel solenoid must be replaced.
Control Switch Checkout
1.
2.
3.
Remove battery B+ cable.
Place ohmmeter leads across switch.
Open and close switch while observing the ohmme- ter. A normally open switch should indicate infinite resistance when open and continuity when closed.
A normally closed switch should indicate continuity
4. when closed and infinite resistance when open.
Replace switch if defective.
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Wiring Diagrams
TITLE NUMBER PAGE
AC Control Wire Diagram (Horizontal, w/Detector AC) . . . . . . . . . . . . . . . . . . . . . . . 612-6267 . . . . 5-2
AC Control Wire Diagram (Vertical, w/Detector AC) . . . . . . . . . . . sheet 1 of 3 . . . 612-6269 . . . . 5-3
AC Control Wire Diagram (Vertical, w/Detector AC) . . . . . . . . . . sheet 2 of 3 . . . 612-6269
DC Control Wire Diagram (Horizontal, Detector 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 612-6280
. . . . 5-4
AC Control Wire Diagram (Vertical, w/Detector AC) . . . . . . . . . . . sheet 3 of 3 . . . 612-6269 . . . . 5-5
. . . . 5-6
DC Control Wire Diagram (Vertical, Detector 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612-6283
DC Control Wire Diagram (Horizontal, Detector 12) . . . . . . . . . . . . . . . . . . . . . . . . . . 612-6278
. . . . 5-7
. . . . 5-8
DC Control Wire Diagram (Vertical, Detector 12)
EMC P.C.B. Assembly - A11 (Detector 2, 12V)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 612-6281
. . . . . . . . . . . . . . . sheet 2 . . . . . . . 300-2807
EMC P.C.B. Assembly - A11 (Detector 2, 24V) . . . . . . . . . . . . . . . sheet 2 . . . . . . . 300-2808
EMC P.C.B. Assembly - A11 (Detector 12, 12V)
EMC P.C.B. Assembly - A11 (Detector 12, 24V)
. . . . . . . . . . . . . . sheet 2 . . . . . . . 300-2811
. . . . . . . . . . . . . . sheet 2 . . . . . . . 300-2812
. . . .
. . . .
. . . .
5-9
5-10
5-11
. . . . 5-12
. . . . 5-13
5−1
Redistribution or publication of this document, by any means, is strictly prohibited.
AC Control Wire Diagram (Horizontal, w/Detector AC)
Redistribution or publication of this document, by any means, is strictly prohibited.
AC Control Wire Diagram (Vertical, w/Detector AC) Sheet 1 of 3
Redistribution or publication of this document, by any means, is strictly prohibited.
AC Control Wire Diagram (Vertical, w/Detector AC) Sheet 2 of 3
Redistribution or publication of this document, by any means, is strictly prohibited.
AC Control Wire Diagram (Vertical, w/Detector AC) Sheet 3 of 3
Redistribution or publication of this document, by any means, is strictly prohibited.
DC Control Wire Diagram (Horizontal, w/Detector 2)
Redistribution or publication of this document, by any means, is strictly prohibited.
DC Control Wire Diagram (Vertical, w/Detector 2)
Redistribution or publication of this document, by any means, is strictly prohibited.
DC Control Wire Diagram (Horizontal, Detector 12)
Redistribution or publication of this document, by any means, is strictly prohibited.
DC Control Wire Diagram (Vertical, Detector 12)
Redistribution or publication of this document, by any means, is strictly prohibited.
EMC P.C.B. Assembly - A11 (Detector 2, 12V)
Redistribution or publication of this document, by any means, is strictly prohibited.
EMC P.C.B. Assembly - A11 (Detector 2, 24V)
Redistribution or publication of this document, by any means, is strictly prohibited.
EMC P.C.B. Assembly - A11 (Detector 12, 12V)
Redistribution or publication of this document, by any means, is strictly prohibited.
EMC P.C.B. Assembly - A11 (Detector 12, 24V)
Redistribution or publication of this document, by any means, is strictly prohibited.
5−14
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Section 6. Engine Sensor Location
I
COOLANT HIGH COOLANT
TEMPERATURE TEMPERATURE
PRE-LOW OIL
PRESSURE
(OPTL)
LOW OIL
PRESSURE
VIEW 0 - 6
LOW ENGINE
TEMPERATURE
(OPTL)
MODEL DVA, DVB GENSETS
OIL PRESSURE
PRE-LOW OIL
HIGH COOLANT
TEMPERATURE.
E*
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BETAIL A
HIGH COOLANT
TEMPERATURE COOLANT TEMPERATURE
SENDER
PRE-HIGH
COOLANT TEMPERATURE
(OPTL)
MODEL DVC, DVD, DVE GENSETS
6-1
'DVC ONLY. SEE
DETAIL A FOR
DVD AND DVE.
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LOW OIL
PREsSURE HIGH
COOLANT
TEEJPEFWTURE
PRE-HIGH
COOLANT
PRE-LOW OIL
~
PRESSURE
(OPTL)
'
I OIL PRESSURE
SENDER i
1
MODEL DVF, DVG GENSETS '
COOLANT dEMPERATURE L
\
LOW ENGINE
TEMPERATURE
(OPTL) i
MODEL DVH, DVJ GENSETS
LOW ENGINE
TEMPERATURE
(OPTL)
M-1644
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6-2
Onan Corporation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
Telex 275477
612-574-8087
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Advertisement
Key features
- Portable design for effortless transportation and use on the go
- Robust construction ensures durability and longevity
- Comprehensive control panel provides intuitive operation and monitoring
- Advanced voltage regulation ensures stable power output
- Current transformers enable precise monitoring of electrical parameters
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- Comprehensive safety features safeguard against electrical hazards and exhaust gas exposure
