TP-5737 5/0152 Section 6 Decision-Makert 1 Controller Troubleshooting
6.2 Relay Controller
Use the following charts as a reference in
troubleshooting individual problems. Before beginning
any troubleshooting procedure, read all safety
precautions at the beginning of this manual and those
included in the text. Do not neglect these precautions.
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
WARNING
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving rotor.
WARNING
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Open the main circuit
breakers of all power sources before servicing the equipment.
Configure the installation to electrically ground the generator
set, transfer switch, and related equipment and electrical
circuits to comply with applicable codes and standards. Never
contact electrical leads or appliances when standing in water
or on wet ground because these conditions increase t he risk of
electrocution.
Use the following flowchart and Figure 6-9 and
Figure 6-10 as an aid in troubleshooting the main circuit
board and the generator set. If the prescribed remedy
does not correct the problem, replace the circuit board.
The controller circuit board includes light emitting
diodes (LEDs) indicating relay coil power and aids in
circuit board and generator fault detection. When the
K1, K2, K3, K4, or K5 relays receive power, the
corresponding LED lights. The LED does not indicate
whether the relay coil is energized. Determine if relay
coil is energized, by analyzing the generator faults and
performing a continuity test on the relay coil.
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