®

DIAGNOSTIC
REPAIR
MANUAL

50 Hz and 60 Hz Air-Cooled Product

with Evolution™ or Nexus™ Control

S TA N D B Y G E N E R AT O R S
 Q: Can I use a fuel shut off valve that is not “Full
Flow Rated”?
WARNING
A: No, it must be a Full Flow Rated valve and must also
Operating, servicing and maintaining this
match the required fuel pipe ID dimensions.
equipment can expose you to chemicals
including engine exhaust, carbon monoxide, Q: Do pipe elbows, tees, sediment traps, etc., affect
phthalates, and lead, which are known to the gas pipe size and flow?
State of California to cause cancer and birth A: Yes, they are restrictions to gas flow. You must add
defects or other reproductive harm. To 2.5ft. (.76m) per each elbow, tee, etc. to the overall
minimize exposure, avoid breathing exhaust, calculated distance from the source to the generator.
do not idle the engine except as necessary, Q: Can I leave the unit on the shipping pallet and
service your equipment in a well-ventilated install it?
area and wear gloves or wash your hands A: No, it must be installed per local jurisdiction, code
frequently when servicing your equipment. and the instructions as outlined by Generac.
For more information go to
www.P65Warnings.ca.gov. Q: Can the generator be mounted indoors or in a
(000393)
structure?
A: No, it is designed, manufactured and sold for outdoor
Frequently Asked Questions use only!
Q: Do I have to supply the generator with the 100% Q: Can I run the Main AC and Control Wires in the
loaded BTU rated fuel supply and pipe size? same conduit?
A: Yes, the generator needs the 100% loaded BTU fuel A: Yes, this wiring can be run in the same conduit if the
rating to start, run and handle loads. The fuel pipe appropriate rated wire and insulation is used and it
must be sized for 100% load, regardless of the load. meets code.
Q: What distance does the gas regulator need to be Q: Can the Transfer Switch be mounted outdoors?
from the generator? A: Only if it’s a NEMA 3R rated transfer switch.
A: Distance is best practices per the regulator
manufacturer's instruction to assure proper operation
of the regulator and also to meet code.

Quick Reference Guide (Evolution Controllers)

Problem LED Things to Check Active Alarm Solution

Unit running in AUTO GREEN Check MLCB. NONE Check MLCB. If the MLCB
but no power in house. or is in the ON position contact
Flashing the servicing dealer.
GREEN
(2017
Units and
newer
with
Firmware
version
1.17 and
up.)

Unit shuts down during RED Check the LED’s/ HIGH Check ventilation around
operation. Screen for alarms. TEMPERATURE the generator, intake,
exhaust and rear of
generator. If no obstruction
contact serving dealer.

Unit shuts down during RED Check the LED’s/ OVERLOAD Clear alarm and remove
operation. Screen for alarms. REMOVE LOAD household loads from the
generator. Put back in
AUTO and restart.

ii Diagnostic Repair Manual

 Quick Reference Guide (Evolution Controllers)
Problem LED Things to Check Active Alarm Solution

Unit was running and RED Check the LED’s/ RPM SENSE LOSS Clear alarm and remove
shuts down, attempts to Screen for alarms. household loads from the
restart. generator. Put back in
AUTO and restart. It may be
a fuel issue so contact the
servicing dealer.

Unit will not start in NONE See if screen says NOT ACTIVATED Refer to activation section in
AUTO with utility loss. unit not activated. owners manual.

Unit will not start in GREEN Check screen for None If the start up delay is
AUTO with utility loss. start delay greater than expected,
countdown. contact servicing dealer to
adjust from 2 to 1500
seconds.

Unit will not start in RED Check the LED’s/ LOW OIL Check Oil Level/Add Oil Per
AUTO with utility loss. Screen for alarms. PRESSURE Owners Manual. If oil level
is correct contact servicing
dealer.

Unit will not start in RED Check the LED’s/ RPM SENSE LOSS Clear alarm. Check the
AUTO with utility loss. Screen for alarms. battery using the control
panel under the MAIN menu
using the BATTERY MENU
option. If it states battery is
GOOD contact servicing
dealer. If it states CHECK
BATTERY replace the
battery.

Unit will not start in RED Check the LED’s/ OVERCRANK Check fuel line shutoff valve
AUTO with utility loss. Screen for alarms. is in the ON position. Clear
alarm. Attempt to start the
unit in MANUAL. If it does
not start or starts and runs
rough, contact servicing
dealer.

Unit will not start in RED Check the LED’s/ OVERLOAD Clear alarm and remove
AUTO with utility loss. Screen for alarms. REMOVE LOAD household loads from the
generator. Put back in
AUTO and restart.

Unit will not start in RED Check the LED’s/ FUSE PROBLEM Check the 7.5 Amp fuse. If it
AUTO with utility loss. Screen for alarms. is bad replace it with an ATO
7.5 Amp fuse, if not contact
servicing dealer.

Unit will not start in RED Check the LED’s/ OVERSPEED Contact servicing dealer.
AUTO with utility loss. Screen for alarms.

Unit will not start in RED Check the LED’s/ UNDERVOLTAGE Contact servicing dealer.
AUTO with utility loss. Screen for alarms.

Diagnostic Repair Manual iii

 Quick Reference Guide (Evolution Controllers)
Problem LED Things to Check Active Alarm Solution

Unit will not start in RED Check the LED’s/ UNDERSPEED Contact servicing dealer.
AUTO with utility loss. Screen for alarms.

Unit will not start in RED Check the LED’s/ STEPPER Contact servicing dealer.
AUTO with utility loss. Screen for alarms. OVERCURRENT

Unit will not start in RED Check the LED’s/ MISWIRE Contact servicing dealer.
AUTO with utility loss. Screen for alarms.

Unit will not start in RED Check the LED’s/ OVERVOLTAGE Contact servicing dealer.
AUTO with utility loss. Screen for alarms.

Yellow LED illuminated YELLOW Check the screen for LOW BATTERY Clear alarm. Check the
in any state. additional battery using the control
information. panel under the MAIN menu
using the BATTERY MENU
option. If it states battery is
GOOD contact servicing
dealer. If it states CHECK
BATTERY replace the
battery.

Yellow LED illuminated YELLOW Check the screen for BATTERY Contact servicing dealer.
in any state. additional PROBLEM
information.

Yellow LED illuminated YELLOW Check the screen for CHARGER Contact servicing dealer
in any state. additional WARNING
information.

Yellow LED illuminated YELLOW Check the screen for SERVICE A Perform SERVICE A
in any state. additional maintenance, hit ENTER to
information. clear.

Yellow LED illuminated YELLOW Check the screen for SERVICE B Perform SERVICE B
in any state. additional maintenance, hit ENTER to
information. clear.

Yellow LED illuminated YELLOW Check the screen for Inspect Battery Inspect Battery, hit ENTER
in any state. additional to clear.
information.

iv Diagnostic Repair Manual

Safety first satisfy themselves that neither his nor the products
Throughout this publication and on tags and decals safety will be endangered by the service procedure
affixed to the generator, DANGER, WARNING, and selected.
CAUTION blocks are used to alert personnel to special All information, illustrations and specifications in this
instructions about a particular operation that may be manual are based on the latest product information
hazardous if performed incorrectly or carelessly. Observe available at the time of publication.
them carefully. Their definitions are as follows: When working on these products, remember that the
electrical system and engine ignition system are capable
DANGER of violent and damaging short circuits or severe electrical
shocks. If you intend to perform work where electrical
Indicates a hazardous situation which, if not avoided, terminals could be grounded or touched, the battery
will result in death or serious injury. cables should be disconnected at the battery.

(000001) Any time the intake or exhaust openings of the engine

are exposed during service, they should be covered to
prevent accidental entry of foreign material. Entry of such
WARNING materials will result in extensive damage when the
engine Is started.
Indicates a hazardous situation which, if not avoided,
During any maintenance procedure, replacement
could result in death or serious injury.
fasteners must have the same measurements and
(000002) strength as the fasteners that were removed. Metric bolts
and nuts have numbers that indicate their strength.
Customary bolts use radial lines to indicate strength
CAUTION while most customary nuts do not have strength
markings. Mismatched or incorrect fasteners can cause
Indicates a hazardous situation which, if not avoided, damage, malfunction and possible injury.
could result in minor or moderate injury.

(000003) Replacement Parts

When servicing this equipment, it is extremely important
NOTE: Notes provide additional information important to that all components be properly installed and tightened. If
a procedure or component. improperly installed and tightened, sparks could ignite
fuel vapors from fuel system leaks.
These safety alerts cannot eliminate the hazards they
indicate. Observing safety precautions and strict
compliance with the special instructions while performing Some of the terminology used in this manual may appear
the action or service are essential to preventing differently for product manufactured by the factory and
accidents. branded under another label.

Generac Name Honeywell Name

Read This Manual Thoroughly QuietTest WhisperCheck
This diagnostic manual has been written and published
by Generac to aid qualified Generac dealer technicians Nexus/Evolution Controller Sync 1.0/Sync 2.0 Controller
and company service personnel when servicing the Nexus Smart Switches Sync Transfer Switches with
products described herein. Load Shedding Capability
It is assumed that these personnel are familiar with the
Nexus Wireless Remote Sync Wireless Remote
servicing procedures for these products, or like or similar
Monitors Monitors
products manufactured and marketed by Generac, and
that they have been trained in the recommended Nexus Smart Switches Sync Smart Switches
servicing procedures for these products, including the
Service Rated Switches
use of common hand tools and any special Generac tools
or tools from other suppliers. Non-Service Rated Switches
Generac could not possibly know of and advise the
service trade of all conceivable procedures by which a
service might be performed and of the possible hazards
and/or results of each method. We have not undertaken
any such wide evaluation. Therefore, anyone who uses a
procedure or tool not recommended by Generac must

Diagnostic Repair Manual v

 This page intentionally left blank.

vi Diagnostic Repair Manual

 Table of Contents
Frequently Asked Questions ..................................... ii AC Troubleshooting ................................................37
Safety ........................................................................v Test 1 – Check AC Output Voltage .........................38
Read This Manual Thoroughly ..................................v Test 3 – Calibrate Voltage ......................................38
Replacement Parts ...................................................v Field Boost Circuit Tests .........................................39
Test FB1 – Test Wire 4 ...........................................39
Section 1 – General Information
Test FB2 – Test Wire 4A Evolution .........................39
Section 1.1 Generator Basics....................................1 Test FB3 – Diode Test Evolution ............................39
Introduction ...............................................................1 Test FB4 - Diode Test Nexus .................................40
Sections ....................................................................1 Test 4 – Fixed Excitation Test/Rotor Amp Draw Test .41
Specifications ............................................................2 Test 5 – Test Sensing Circuit Wires 11(S) and 44(S) .43
Section 1.2 Testing, Cleaning and Drying................7 Test 6 – Test Excitation Winding Circuit 2 and 6 ....44
Visual Inspection .......................................................7 Test 7 – Test the Stator with a DMM ......................44
Insulation Resistance ................................................7 Test 8 – Resistance Check of Rotor Circuit ............46
The Megohmmeter ...................................................7 Test 9 – Check Brushes and Slip Rings .................47
Testing Stator Insulation ...........................................7 Test 10 – Test Rotor Assembly ..............................48
Testing Rotor Insulation ............................................8 Test 11 – Check AC Output Frequency ..................48
Cleaning the Generator ............................................8 Test 12 – Check Stepper Motor Control .................48
Drying the Generator ................................................8 Test 14 – Check Voltage and Frequency Under Load 50
Test 15 – Check for an Overload Condition ............50
Section 1.3 Evolution Menu System Navigation......9
Test 16 – Check Engine Condition .........................50
Navigation Keys ........................................................9 Test 17 – Current Calibration ..................................51
Main Menu ................................................................9
Evolution Dealer Menu ...........................................10 Section 3 – Transfer Switch
Section 1.4 Nexus Menu System Navigation .........21 Section 3.1 Description and Major Components...53

Navigation Keys ......................................................21 Introduction .............................................................53

Main Menu ..............................................................21 Enclosure ................................................................53
Transfer Switch Contactor ......................................53
Section 2 – AC Generators Transfer Relay ........................................................54
Section 2.1 Operational Analysis............................25 Neutral Lug .............................................................54
Field Boost ..............................................................25 Manual Transfer Handle .........................................54
Operation ................................................................25 Customer Connections ...........................................54
Fuse Holder ............................................................55
Section 2.2 Troubleshooting Flow Charts.............29
Load Shed Module and Operation OPCB
Evolution™ Controller e-Codes ..............................29 LSM 120 Volt Only ..................................................57
Additional Codes For 8 and 9 kW Units Only ..........30 Load Shed Operation ..............................................57
Introduction .............................................................31 Load Shed Module Operation OPCB 24/
Preliminary Output Voltage Test (Evolution Only, 120 Volt Module ......................................................63
Non-Synergy, Firmware v1.12 and Above) .............31 Smart A/C Module (SACM) .....................................63
Field Boost Circuit Test - Evolution/Nexus.............. 32 Test Button .............................................................63
Problem 1 – Generator Shuts Down for Load Shed Operation ..............................................63
Under Voltage ......................................................... 33
OPCB Module Example ..........................................64
Problem 1 – Generator Shuts Down for
SACM .....................................................................69
Under Voltage (Continued) ..................................... 34
Power Supply Connections for Contactors .............69
Problem 2 – Generator Produces High Voltage...... 34
Power Management Module (PMM) .......................69
Problem 3 – Voltage and Frequency Drop
Excessively When Loads Are Applied .................... 35 Smart Management Module (SMM) ........................71
Problem 4 – Unstable Voltage or Incorrect Output SMM Features and Controls ...................................71
Which is Not Triggering a Shutdown....................... 35 Electrical Specifications ..........................................72
Enclosure Specifications .........................................72
Section 2.3 Diagnostic Tests...................................37
Connections ............................................................72
Introduction .............................................................37
Setting Priorities ......................................................73
Safety ......................................................................37
Setting Lockout .......................................................73

Diagnostic Repair Manual 1

Table of Contents

Tests ....................................................................... 73 Test 21 – Check Manual Transfer Switch Operation .. 98

Troubleshooting ...................................................... 74 Test 22 – Check Wire 23 and 194 Circuits ............. 98
Integrated SACM Module ....................................... 76 Test 23 – Test Transfer Relay ................................ 99
Section 3.2 Operational Analysis ........................... 79 Test 24 – Test Standby Control Circuit ................ 100
Test 25 – Check Wire 23 ...................................... 101
Utility Source Voltage Available ............................. 79
Test 26 – Test Utility Control Circuit ..................... 103
Utility Source Voltage Failure ................................. 80
Test 27 – Test Limit Switches .............................. 104
Transferring to Standby .......................................... 81
Test 28 – Check Fuses F1 and F2 ....................... 104
Transferred to Standby ........................................... 82
Test 29 – Check Fuse F3 ..................................... 105
Utility Restored ....................................................... 83
General Theory .................................................... 105
Utility Restored, Transferring Back to Utility ........... 84
Test 30 – Check Main Circuit Breaker ................. 105
Utility Restored, Transferred Back to Utility ............ 85
Test 32 – Check N1 and N2 Wiring ...................... 105
Transferred Back to Utility, Generator Shutdown ... 85
Test 33 – Check N1 and N2 Voltage .................... 106
Section 3.3 Troubleshooting Flowcharts............... 87 Test 34 – Check Utility Sensing Voltage
Evolution™ Controller e-Codes .............................. 87 at the Circuit Board .............................................. 106
Additional Codes For 8 and 9 kW Units Only ......... 88 Test 35 – Check Utility Sense Voltage ................. 106
Introduction ............................................................. 89 Test 36 – Check T1 Wiring ................................... 107
Problem 6 — With Controller in Automatic Mode Test 37 – Test SMM Contactor Line,
and Utility Failed, Generator Runs but Transfer to Load and Control .................................................. 107
Standby Does Not Occur........................................ 89
Section 4 – Engine/DC Control
Problem 7 – In Automatic Mode, Generator Starts
When Loss of Utility Occurs, Generator Shuts Section 4.1 Description and Major Components 109
Down When Utility Returns But There is No Introduction .......................................................... 109
Re-transfer to Utility Power
Customer Connection .......................................... 109
Or
Generator Transfers to Standby During Exercise Controller .............................................................. 110
or in Manual Mode.................................................. 89 LED Display ......................................................... 110
Problem 8 – Unit Starts and May or May Not Battery Charger .................................................... 111
Transfer When Utility Power is On ......................... 90 AUTO-OFF-MANUAL ........................................... 111
Problem 9 – Blown F1 or F2 Fuse.......................... 91 Fuse ..................................................................... 111
Problem 10 – Blown T1 Fuse ................................. 91 Starter Contactor Relay/Solenoid ......................... 112
SMM Problem 1 – Load Management Module Common Alarm Relay .......................................... 112
(SMM) LED is OFF, Load Not Powered ................. 91 Circuit Pin Descriptions ........................................ 112
SMM Problem 2 – Load Management Module Menu System Navigation ..................................... 113
(SMM) LED is ON, Load Not Powered................... 91
Section 4.2 Engine Protective Devices................ 123
SMM Problem 3 – Load Management Module
(SMM) LED is Flashing, Load Not Powered........... 92 Engine Protective Devices ................................... 123
SMM Problem 4 – Load Management Module Low Battery Warning ............................................ 123
(SMM) is Humming or Buzzing............................... 92 Low Oil Pressure
Integrated SACM Problem 1 – Generator starts (Evolution e-Code 1300) ...................................... 123
and runs in AUTO with Utility Present .................... 93 High Temperature Switch
Integrated SACM Problem 2 – Transfer to (Evolution e-Code 1400) ...................................... 123
Standby Does Not Occur in AUTO......................... 94 Overspeed ............................................................ 123
Integrated SACM Problem 3 – Transfer to Utility RPM Sensor Failure
Does Not Occur after Utility Returns ...................... 95 (Evolution e-Code 1501, 1505, 1511, 1515) ........ 123
Section 3.4 Diagnostic Tests .................................. 97 Overcrank
(Evolution e-Code 1100) ...................................... 123
Introduction ............................................................. 97
Under-Frequency ................................................. 124
Safety ..................................................................... 97
Clearing an Alarm ................................................ 125
Transfer Switch Troubleshooting ............................ 97
Test 20 – Check Voltage at Terminal Lugs E1 and E2 97

2 Diagnostic Repair Manual

 Table of Contents
Section 4.3 Operational Analysis – Evolution .....127 Test 43 – Test Auto Operations of Controller
Introduction ...........................................................127 (Evolution and Nexus) ..........................................164
Utility Source Voltage Available ............................127 Test 44 – Check 7.5 Amp Fuse (Evolution Alarm
Code 2400 Firmware 1.11 and Older) ..................164
Initial Dropout of Utility Source Voltage ................129
Test 45 – Check Battery and Cables ....................165
Utility Voltage Failure and Engine Cranking .........131
Test 46 – Check Wire 56 Voltage .........................167
Engine Startup and Running .................................133
Test 47 – Test Starter Contactor Relay
Transfer to Standby ..............................................135
(V-Twin Engine) ....................................................168
Utility Voltage Restored and Re-transfer to Utility .137
Test 48 – Test Starter Contactor ..........................168
Engine Shutdown ..................................................139
Test 49 – Test Starter Motor .................................169
Section 4.4 Operational Analysis – Nexus ...........141 Test 50 – Check Fuel Supply and Pressure .........170
Introduction ...........................................................141 Test 51 – Check Controller Wire 14 Outputs ........171
Utility Source Voltage Available ............................141 Test 52 – Check Fuel Solenoid .............................172
Initial Dropout of Utility Source Voltage ................143 Test 53 – Check Choke Solenoid (Nexus Only) ...172
Utility Voltage Failure and Engine Cranking .........145 Test 55 – Check for Ignition Spark .......................175
Engine Startup and Running .................................147 Test 57 – Check Condition of Spark Plugs ...........175
Transfer to Standby ..............................................149 Test 58 – Check Engine / Compression Test /
Utility Voltage Restored and Re-transfer to Utility .151 Cylinder Leak Down Test ......................................176
Engine Shutdown ..................................................153 Check Compression .............................................176
Cylinder Leak Down Test ......................................177
Section 4.5 Troubleshooting Flowcharts .............155
Test 59 – Check Shutdown Wire ..........................177
Evolution™ Controller e-Codes ............................155
Test 60 – Check and Adjust Ignition Magnetos ....178
Additional Codes For 8 and 9 kW Units Only ........156
Test 61 – Check Oil Pressure Switch and
Problem 14 – Shutdown Alarm/Fault Occurred Wire 86 (Evolution e-Code 1300) .........................181
During Crank Attempt, Start or Run ...................... 157
Test 62 – Check High Oil Temperature Switch
Problem 15 – Engine Will Not Crank When (e-Code 1400) .......................................................182
Utility Power Source Fails ..................................... 158
Test 63 – Check and Adjust Valves ......................183
Problem 16 – Engine Will Not Crank When
Test 64 – Check Wire 18 Continuity .....................184
Controller Switch is Set to MANUAL..................... 158
Test 65 – Test Exercise Function .........................185
Problem 17 – Engine Cranks but Will Not Start .... 159
Test 66 – Test Cranking and Running Circuits .....185
Problem 18 – Engine Starts Hard and/or Runs
Rough / Lacks Power / Backfires / Hunting / Test 67 – Test Run Circuit ....................................186
Erratic Operation................................................... 160 Test 68 – Test Crank Circuit .................................187
Problem 19 – 7.5 Amp Fuse (F1) Blown Test 70 – Check to See If Low Speed Function
(e-Code 2400)....................................................... 161 is Enabled (Available only on certain models) ......187
Problem 20 – Generator Will Not Exercise ........... 161 Test 71 – Check operation of the
Problem 21 – No Low Speed Exercise ................. 161 Choke Solenoid (Nexus Only) ..............................188
Problem 22 – Battery is Dead ............................... 161 Test 75 – Test 120 Volt Input (T1) 60 Hz
240 Volt Input (T1 - T2) 50 Hz ..............................188
Section 4.6 Diagnostic Tests.................................163 Test 76 – Verify DC Voltage Output
Introduction ...........................................................163 of the Controller ....................................................188
Safety ....................................................................163 Test 77 – Check Wire 13 and Wire 0 ....................188
Engine/DC Troubleshooting ..................................163 Test 78 – Test DC Charge Current to the Battery 189
Test 40 – Check position of Test 79 – Check T1 Voltage at
AUTO-OFF-MANUAL Mode .................................163 Customer Connections .........................................189
Test 41 – Try a Manual Start ................................164 Test 80 – Check T1 Voltage at Controller Connector 189
Test 42 – Test the Function of the Test 81 – Check T1/T2 Voltage in Transfer Switch ...190
AUTO-OFF-MANUAL Mode .................................164 Test 82 – Test F3 Fuse Circuit .............................190

Diagnostic Repair Manual 3

 Table of Contents

Section 5 – Disassembly
Section 5.1 Major Disassembly .............................191
2013 Front Engine Access ....................................191
2017 HSB Front Access .......................................197
Major Disassembly ................................................201
Torque Specifications ...........................................207
Section 6 – Electrical Data
Section 6.1 0L6822-B WD/SD Air-cooled
2017 HSB Evolution 9 kW 60 Hz............................209
Section 6.2 0L6823-B WD/SD Air-cooled
2017 HSB Evolution 60 Hz .....................................215
Section 6.3 0L6824-B WD/SD Air-cooled
2017 HSB Evolution 50 Hz .....................................221
Section 6.4 0K2945-E WD/SD Air-cooled
Pre 2017 HSB Evolution 8 kW 60 Hz .....................227
Section 6.5 0J9961-D WD/SD Air-cooled
Pre 2016 HSB Evolution 11-22 kW 60 Hz..............233
Appendix A Controller Identification.......................239
Probing and Pin Extraction ...................................239
Evolution 1.0 Controller ........................................240
Nexus Controller ...................................................242
Appendix B EcoGen Drawings ................................249
Eco Gen Oil Make-Up System (6 kW) ..................249
Electrical Formulas ..................................................253

Diagnostic Repair Manual 4

 Section 1.1 Generator Basics
Introduction Sections
This diagnostic repair manual has been prepared Section 1 – General Information – Provides the basic
especially for familiarizing service personnel with the understanding of the generator as well as basic
testing, troubleshooting and repair of air-cooled product installation information and operating instructions.
that utilizes the Evolution/Nexus controllers. Every effort Section 2 – AC Generators – Provides the basics of the
has been expended to ensure that the information and AC alternator design and the AC troubleshooting portion
instructions in the manual are accurate and current. of the manual.
However, the manufacturer reserves the right to change,
Section 3 – Transfer Switch – Provides the
alter or otherwise improve the product at any time without
troubleshooting and diagnostic testing procedure for:
prior notification.
This manual has been divided into SECTIONS and each
• Pre-packaged 10,12,14,16 circuit EZ Switch™
transfer switches.
section consists of SUBSECTIONS.
This manual is not intended to provide detailed • RTSY service and non service entrance rated
disassembly and reassembly of the entire Residential transfer switches with load management systems.
product line. This manual is intended to: Section 4 – Engine/DC Control – Provides the
• Provide the service technician with an troubleshooting and diagnostic testing procedure for
understanding of how the various assemblies and engine related problems on the Nexus™ and Evolution™
systems work. Controllers.
Section 5 – Disassembly – Provides detailed step-by-
• Assist the technician in finding the cause of
step instructions for the replacement of the rotor/stator
malfunctions.
and engine.
• Effect the expeditious repair of the equipment. Section 6 – Electrical Data – Illustrates all of the
electrical and wiring diagrams for the various kW ranges
and transfer switches.

Diagnostic Repair Manual 1

Section 1.1 Generator Basics

Specifications
Table 1-1. 60 Hz – Generator with Evolution Controller
Unit 8 kW 9 kW 11 kW 13 kW 14 kW 15 kW 16 kW 17 kW 20 kW 22 kW
Rated Voltage 240
Rated Max. Continuous
Load Current (Amps) 240 33.3/29.2 37.5/33.3 41.6/37.5 54.2/54.2 58.3/54.2 62.5/62.5 66.6/66.6 70.8/66.6 83.3/75.0 91.6/86.3
Volts (LP/NG)
Main Line Circuit Breaker 35 Amp 40 Amp 50 Amp 55 Amp 60 Amp 60 Amp 65 Amp 65 Amp 90 Amp 100 Amp
Main Line Circuit Breaker
35 Amp 40 Amp 50 Amp 55 Amp 60 Amp 60 Amp 70 Amp 70 Amp 100 Amp 100 Amp
(2017)
Phase 1
Rated AC Frequency 60 Hz
Battery Requirement Group 26R, 12 Volts and 525 CCA Minimum
Battery Requirement (2017) Group 26R, 12 Volts and 525 CCA Minimum or Group 35AGM, 12 Volts and 650 CCA Minimum
Steel/
Enclosure, Evolution Steel n/a Steel Steel Steel Steel Steel Aluminum Aluminum
Aluminum
Enclosure, Evolution (2017) Aluminum Steel Aluminum
This unit is tested in accordance to UL 2200 standards with an operating temperature of 20° F (-29° C) to 122°F. (50° C). For areas
Normal Operating Range where temperatures fall below 32° F (0° C), a cold weather kit is highly recommended. When operated above 77° F (25° C) there
may be a decrease in engine power. (Please reference the engine specifications section).

These generators are rated in accordance with UL 2200, Safety Standard for Stationary Engine Generator Assemblies and CSA-C22.2 No. 100-04 Standard for Motors
and Generators.
* Natural Gas ratings will depend on specific fuel Btu/joules content. Typical derates are between 10-20% off the LP gas rating.
** Circuits to be moved must be protected by same size breaker: For example, a 15 amp circuit in the main panel must be a 15 amp circuit in the transfer switch.

Table 1-2. 50 Hz – Generator with Evolution Controller

Unit 8 kVA 10 kVA 13 kVA
Rated Voltage 110/220
Rated Max. Continuous Load Current
36.4/31.8 45.5/45.5 59/59
(Amps) 220 Volts (LP/NG)
Main Line Circuit Breaker 35 Amp 50 Amp 65 Amp
Phase 1
Rated AC Frequency 50 Hz
Battery Requirement Group 26R, 12 Volts and 525 CCA Minimum
Battery Requirement (2017) Group 26R, 12 Volts and 525 CCA Minimum or Group 35AGM, 12 Volts and 650 CCA Minimum
Enclosure Steel Steel Steel
Enclosure (2017) Aluminum Aluminum Aluminum
This unit is tested in accordance to UL 2200 standards with an operating temperature of 20° F (-29° C) to
122°F. (50° C). For areas where temperatures fall below 32° F (0° C), a cold weather kit is highly
Normal Operating Range
recommended. When operated above 77° F (25° C) there may be a decrease in engine power. (Please
reference the engine specifications section).

These generators are rated in accordance with UL 2200, Safety Standard for Stationary Engine Generator Assemblies and CSA-C22.2 No. 100-04 Standard for Motors
and Generators.
* Natural Gas ratings will depend on specific fuel Btu/joules content. Typical derates are between 10-20% off the LP gas rating.
** Circuits to be moved must be protected by same size breaker: For example, a 15 amp circuit in the main panel must be a 15 amp circuit in the transfer switch.

Table 1-3. Generator Exercise Characteristics

Generator Size 8/9 kW 11 kW 16-20 kW 22 kW 50 Hz (8/10/13 kVA)
Low Speed Exercise n/a * n/a * ~ 2400 rpm 1950 rpm n/a *
Exercise Frequency Options Options Weekly/Bi-Weekly/Monthly
Exercise Time Length 12 minutes 12 minutes 5 minutes 5 minutes 5 minutes

* Exercises at 3600 rpm

~ Private label may vary
IMPORTANT NOTE: All unit specifications are subject to change.

2 Diagnostic Repair Manual

 Section 1.1 Generator Basics

Table 1-4. 60 Hz – Stator Winding Resistance Values / Rotor Resistance*

8 kW 9 kW 11 kW 13/14 kW 15 kW 16/17 kW 20 kW 22 kW
Power Windings 0.1584- 0.1580- 0.1584- 0.1227- 0.0758- 0.0720- 0.0421- 0.0361 -
Across 11 & 22 0.1840 0.1836 0.1840 0.1425 0.0881 0.0837 0.0489 0.0419
Power Windings 0.3168- 0.3160- 0.3168- 0.2454- 0.1050- 0.1440- 0.0824- 0.0722 -
Across 11&44 0.3680 0.3672 0.3680 0.2850 0.1220 0.1674 0.0978 0.0838
Power Windings 0.1584- 0.1580- 0.1584- 0.1227- 0.0758- 0.0720- 0.0421- 0.0361 -
Across 33 & 44 0.1840 0.1836 0.1840 0.1425 0.0881 0.0837 0.0489 0.0419
Sensing Windings 0.3712- 0.3538- 0.2824- 0.1050- 0.1526 -
0.3538-.4112 0.197-0.229 0.137-0.1594
Across 11 & 44 0.4314 0.4112 0.3280 0.1220 0.1772
Excitation Windings 0.5517- 1.0011- 0.5517- 0.8506- 0.7093- 0.7093- 0.6121- 0.6392 -
Across 2 & 6 0.6413 1.1634 0.6414 0.9885 0.8243 0.8243 0.7114 0.7429
Rotor Resistance 4.96-5.76 6.30-7.32 4.97-5.76 7.22-8.39 8.39-9.72 8.37-9.72 9.54-11.10 10.25 - 11.92

* Resistance values shown are based on new windings at 20 °C. Actual readings may vary based on type of meter used and any other components or connections
included in the circuit being tested.

Table 1-5. 50 Hz – Stator Winding Resistance Values / Rotor Resistance*

8 kVA 10 kVA 13 kVA
Power Windings: Across 11 & 22 0.1752 - 0.2036 0.0823 - 0.0957 0.0589 - 0.0685
Power Windings: Across 11&44 0.3504 - 0.4072 0.164 - 0.1914 0.1178 - 0.137
Power Windings: Across 33 & 44 0.1752 - 0.2036 0.0823 - 0.0957 0.0589 - 0.0685
Sensing Windings: Across 11 & 44 0.3504 - 0.4072 0.1646 - 0.1914 0.1178 - 0.1370
Excitation Windings: Across 2 & 6 0.6933 - 0.8057 0.7412 - 0.8614 0.6933 - 0.8057
Rotor Resistance 6.82 - 7.93 8.28 - 9.62 9.54 - 11.10

* Resistance values shown are based on new windings at 20 °C. Actual readings may vary based on type of meter used and any other components or connections
included in the circuit being tested.

Table 1-6. Engine with Evolution Controller

16/17kW (2017)
Model 8 kW 9 kW 11 kW 13/14/15/16/17 kW
20/22 kW
Type of Engine GH-410 GH-426 GT-530 GT-992 GT-999
Number of Cylinders 1 1 2 2 2
Displacement 410cc 426cc 530cc 992cc 999cc
Cylinder Block Aluminum w/Cast Iron Sleeve
Recommended Spark
RC14YC RC12YC BPR6HS / RL87YC RC14YC RC12YC
Plug
Spark Plug Gap 0.76 mm (0.030 inch) 0.508 mm (0.020 inch) 0.76 mm (0.030 inch) 1.02 mm (0.040 inch) 1.02 mm (0.040 inch)
0.05-0.1mm 0.05-0.1mm 0.05-0.1mm 0.05-0.1mm 0.05-0.1mm
Valve Clearance
(0.002-0.004 in) (0.002-0.004 in) (0.002-0.004 in) (0.002-0.004 in) (0.002-0.004 in)
Compression Pressure 190 psi +/- 10-15% Min 60 psi * 150 psi +/- 10-15% 165 psi +/- 10-15% 160 psi +/- 10-15%
Starter 12 VDC
Oil Capacity Including
Approx. 1.5 Qt/1.4L Approx. 1.1 Qt/1.03L Approx. 1.7 Qt/1.6L Approx. 1.9 Qt/1.8L Approx. 1.9 Qt/1.8L
Filter
Recommended Oil Filter Part # 070185F
Recommended Air Filter Part # 0E9371A 0E9371A Part # 0E9371A Part # 0J8478 Part # 0J8478
Engine power is subject to and limited by such factors as fuel Btu/joules content, ambient temperature and altitude. Engine power decreases about
3.5 percent for each 1000 feet (304.8 meters) above sea level and will decrease about 1 percent for each 6 ° C (10 ° F) above 15 ° C (60 ° F)
ambient temperature.

* 426 engine has a decompression system that will not allow full compression pressure while cranking. Can range from 60 to 110 psi.
IMPORTANT NOTE: All unit specifications are subject to change.

Diagnostic Repair Manual 3

Section 1.1 Generator Basics

Table 1-7. Fuel Consumption with Evolution Controller

Unit Natural Gas* LP Vapor**
1/2 Load Full Load 1/2 Load Full Load
7/8 kW 78/2.21 121/3.43 0.87/3.29 1.42/5.37
9 kW (2017) 109 / 3.09 133 / 3.77 1.00 / 3.79 1.50 / 5.66
10/11 kW 124/3.51 195/5.52 1.18/4.45 1.92/7.28
11 kW (2017) 123/3.48 166/5.64 1.19/4.49 2.01/7.62
13/13 kW 157/4.45 255/7.22 1.64/6.2 2.95/11.15
14/14 kW 177/5.01 279/7.9 1.85/6.99 3.07/11.61
15/15 kW 185/5.24 296/8.38 1.83/6.91 3.19/10.82
16/16 kW 193/5.47 296/8.38 1.9/7.2 3.19/12.07
16/16 kW (2017) 193/5.47 312/8.83 1.9/7.2 3.19/12.07
16/17 kW 193/5.47 312/8.83 1.99/7.53 3.57/13.53
17 kW (2017) 193/5.47 312/8.83 2.0/7.57 3.57/13.53
18/20 kW 205/5.8 308/8.72 2.08/7.87 3.85/14.57
20 kW (2017) 205/5.8 308/8.72 2.23/8.45 3.85/14.57
22 kW 184/5.21 281/7.96 2.16/8.16 3.68/13.94
22 kW (2017) 228/6.46 327/9.26 2.53/9.57 3.90/14.77
* Natural gas is in cubic feet per hour/cubic meters per hour **LP is in gallons per hour/liters per hour ***Values given are approximate

Table 1-8. 60 Hz – Generator with Nexus Controller

Unit 8 kW 10 kW 13 kW 14 kW 15 kW 16 kW 17 kW 20 kW
Rated Max. Continuous Power Capacity 7,000 NG 9,000 NG 13,000 NG 13,000 NG 15,000 NG 16,000 NG 16,000 NG 18,000 NG
(Watts*) 8,000 LP 10,000 LP 13,000 LP 14,000 LP 15,000 LP 16,000 LP 17,000 LP 20,000 LP
Rated Voltage 240
Rated Voltage at No-Load (NG)
Older controller P/N 0H6680A 250-254
Newer controller P/N 0H6680B 240-244
Rated Max. Continuous Load Current (Amps)
33.3/29.2 41.6/37.5 54.2/54.2 58.3/54.2 62.5/62.5 66.6/66.6 70.8/66.6 83.3/75.0
240 Volts (LP/NG)
Main Line Circuit Breaker 35 Amp 45 Amp 55 Amp 60 Amp 65 Amp 65 Amp 65 Amp 100 Amp
Circuits*** 50A, 240V - - 1 - 1 1 1 -
40A, 240V - 1 1 1 1 1 1 -
30A, 240V 1 1 - - - - - -
20A, 240V 1 - 1 1 1 1 1 -
20A, 120V 3 3 4 6 5 5 5 -
15A, 120V 3 5 4 4 5 5 5 -
Phase 1
Number of Rotor Poles 2
Rated AC Frequency 60 Hz
Power Factor 1
Battery Requirement Group 26R, 12 Volts and 525 CCA Minimum
Weight (unit only in lbs) 340 387/353 439 439 455/421 439 455/421 450
Steel/ Steel/ Steel/
Enclosure Steel Aluminum Steel Steel Aluminum Steel Aluminum Aluminum

This unit is tested in accordance to UL 2200 standards with an operating temperature of 20° F (-29° C)
Normal Operating Range to 122°F. (50° C). For areas where temperatures fall below 32° F (0° C), a cold weather kit is highly
recommended. When operated above 77° F (25° C) there may be a decrease in engine power. (Please
reference the engine specifications section).

IMPORTANT NOTE: All unit specifications are subject to change.

4 Diagnostic Repair Manual

 Section 1.1 Generator Basics

Table 1-9. 60 Hz – Stator Winding Resistance Values / Rotor Resistance*

8 kW 10 kW 13 kW 14 kW 15 kW 16 kW 17 kW 20 kW
Power Windings
0.1660-0.1930 0.1895-0.2203 0.1003-0.1165 0.1003-0.1165 0.0746-0.0866 0.0746-0.0866 0.0746-0.0866 0.0415-0.0483
Across 11 & 22
Power Windings
0.1660-0.1930 0.1895-0.2203 0.1003-0.1166 0.1003-0.1166 0.0746-0.0866 0.0746-0.0866 0.0746-0.0866 0.0415-0.0483
Across 33 & 44
Sensing Windings
0.378-0.4392 0.425-0.4938 0.2484-0.2887 0.2484-0.2888 0.197-0.229 0.197-0.229 0.197-0.229 0.137-0.1594
Across 11 & 44
Excitation Windings
1.0318-0.1930 1.0935-1.2708 0.876-1.017 0.876-1.018 0.780-0.906 0.780-0.906 0.780-0.906 0.7318-0.8504
Across 2 & 6
Rotor Resistance 6.30-7.32 6.30-7.32 7.58-8.80 7.58-8.81 8.37-9.72 8.37-9.72 8.37-9.72 9.54-11.10

Table 1-10. Engine with Nexus Controller

Model 8 kW 10 kW 13/14/15/16/17 kW 20 kW
Type of Engine GT-410 GT-530 GT-992 GT-999
Number of Cylinders 1 2 2 2
Rated Horsepower @ 3,600 rpm 14.8 18 32 36
Displacement 407cc 530cc 992cc 999cc
Cylinder Block Aluminum w/Cast Iron Sleeve
Valve Arrangement Overhead Valve
0.05-0.1mm 0.05-0.1mm 0.05-0.1mm 0.05-0.1mm
Valve Clearance
(0.002-0.004 in) (0.002-0.004 in) (0.002-0.004 in) (0.002-0.004 in)
Ignition System Solid-state w/Magneto
Recommended Spark Plug RC14YC BPR6HS RC14YC RC12YC
Spark Plug Gap 0.76 mm (0.030 inch) 0.76 mm (0.030 inch) 1.02 mm (0.040 inch) 0.76 mm (0.030 inch)
Compression Ratio 8.6:1 9.5:1 9.5:1 9.5:1
Starter 12 VDC
Oil Capacity Including Filter Approx. 1.5 Qt Approx. 1.7 Qt Approx. 1.9 Qt Approx. 1.9 Qt
Recommended Oil Filter Part # 070185F
Recommended Air Filter Part # 0G3332 Part # 0E9581 Part # 0C8127 Part # 0G5894
Operating RPM 3,600

* Resistance values shown are based on new windings at 20 °C. Actual readings may vary based on type of meter used and any other components or connections
included in the circuit being tested.

Table 1-11. Fuel Consumption with Nexus Controller

Unit Natural Gas* LP Vapor**
1/2 Load Full Load 1/2 Load Full Load
7/8 kW 77 140 0.94/34 1.68/62
9/10 kW 102 156 1.25/46 1.93/70
13/13 kW 156 220 1.55/57 2.18/80
13/14 kW 156 220 1.56/58 2.30/84
15/15 kW 171 244 1.49/54 2.35/85
16/16 kW 183 261 1.59/58 2.51/91
16/17 kW 183 261 1.61/59 2.57/94
18/20 kW 206 294 1.89/69 2.90/106

* Natural gas is in cubic feet per hour.

** LP is in gallons per hour / cubic feet per hour.

IMPORTANT NOTE: All unit specifications are subject to change.

Diagnostic Repair Manual 5

Section 1.1 Generator Basics

Table 1-12. 60 Hz – EcoGen™ Generator with Nexus Controller

Unit 6 kW
Rated Voltage 120 V (240V Capable with Conversion)
Rated Max. Continuous Load Current
50 (25 @ 240 VAC)
(Amps) 120 Volts (LP only)
Main Line Circuit Breaker 50 Amp (25 after conversion)
Phase 1
Rated AC Frequency 60 Hz
Battery Requirement Group 26R, 12 Volts and 525 CCA Minimum
Unit Weight - lbs (kg) 387 (175.5)
Enclosure Steel
This unit is tested in accordance to UL 2200 standards with an operating temperature of 20° F (-29° C) to
122°F. (50° C). For areas where temperatures fall below 32° F (0° C), a cold weather kit is highly
Normal Operating Range
recommended. When operated above 77° F (25° C) there may be a decrease in engine power. (Please
reference the engine specifications section).

Table 1-13. EcoGen™ with Nexus Controller - Stator Winding Resistance Values / Rotor Resistance
Power Windings: Across 11 & 22 0.2124 - 0.2468
Power Windings: Across 33 & 44 0.2124 - 0.2468
Sensing Windings: Across 11 & 44 0.4248 - 0.4936
Excitation Windings: Across 2 & 6 1.59 - 1.84
Rotor Resistance 10.81

Table 1-14. EcoGen™ Engine with Nexus Controller

Model 6 kW
Type of Engine Generac OHVI
Number of Cylinders 2
Displacement 530cc
Cylinder Block Aluminum w/Cast Iron Sleeve
Recommended Spark Plug BPR6HS
Spark Plug Gap 0.76 mm (0.030 inch)
Starter 12 VDC
Oil Capacity Including Filter Approx. 1.7 Qt/1.6L
Recommended Oil Filter Part # 070185F
Oil Reservoir Capacity 4.2 Qt./4.0L
Recommended Air Filter Part # 0E9371A
Operating RPM 2,600
Engine power is subject to and limited by such factors as fuel Btu/joules content, ambient temperature and altitude. Engine power decreases about
3.5 percent for each 1000 feet (304.8 meters) above sea level and will decrease about 1 percent for each 6 ° C (10 ° F) above 15 ° C (60 ° F)
ambient temperature.

IMPORTANT NOTE: All unit specifications are subject to change.

6 Diagnostic Repair Manual

 Section 1.2 Testing, Cleaning and Drying
Visual Inspection Testing Stator Insulation
Perform a thorough visual inspection before testing or See Figure 1-1. Isolate all stator leads and connect all
troubleshooting an alternator. Remove the access covers the stator leads together.
and look closely for any obvious problems. Look for the Use a Megohmmeter power setting of 500 volts. Connect
following: one Megohmmeter test lead to the junction of all the
• Burned or broken wires, broken wire connectors, stator leads. Connect the other test lead to a frame
damaged mounting brackets, etc. ground on the stator can. Read the number of megohms
• Loose or frayed wiring insulation, including loose or on the meter.
dirty connections.
• All wiring is well clear of rotating and hot parts.
22
• Generator output voltage rating matches utility 33
voltage. STATOR
44
• Foreign objects, loose nuts, bolts and other BA
4 11
fasteners.
0
• Area around the generator is clean and clear of 44
paper, leaves, snow, and other objects that might 11
2 6 44
blow against the generator and obstruct air flow.
11

6
Insulation Resistance
2
The insulation resistances of stator and rotor windings
are a measurement of the integrity of the insulating 4
material that separates the electrical windings from the 0
generator steel core. This resistance can degrade over 003004
time or due to such contaminates as dust, dirt, oil, grease Figure 1-1. Typical Stator Output Leads
and especially moisture. In most cases, failures of stator
and rotor windings are due to a break down in the To calculate the minimum acceptable Megohmmeter
insulation. In many cases, a low insulation resistance is readings use the following formula:
caused by moisture that collects while the generator is
shut down. When problems are caused by moisture Minimum Insulation Generator Rated Volts
buildup on the windings, this can usually be corrected by = +1
Resistance (In “Megohms”) 1000
drying the windings. Cleaning and drying the windings
can usually eliminate dirt and moisture that has built up in Example: Generator is rated at 120 VAC. Divide 120 by
the generator windings. 1000 to obtain 0.12. Then add 1 to obtain 1.12 megohms.
Minimum insulation resistance for a 120 VAC stator is
The Megohmmeter 1.12 megohms.

Introduction 120
+ 1 = 1.2 megohms
A Megohmmeter (often called a megger), consists of a 1000
meter calibrated in megohms and a power supply.
If the stator insulation resistance is less than the
IMPORTANT NOTE: When testing stators and rotors, calculated minimum resistance, clean and dry the stator.
set Megohmmeter to 500 volts and apply voltage for a Then, repeat the test. If resistance is still low, replace the
maximum of one second. Follow the Megohmmeter stator.
manufacturers instructions carefully. Do not exceed 500
Use the Megohmmeter to test for shorts between isolated
volts or apply voltage longer than 1 second.
windings as outlined in “Stator Insulation Tests.”
Megohmmeter HIGH voltages could cause damage to
other components on the generator. Take the proper
precautions before testing.

Diagnostic Repair Manual 7

Section 1.2 Testing, Cleaning and Drying

Testing Rotor Insulation Drying the Generator

Apply a voltage of 500 volts across the rotor positive slip The procedure for drying an alternator is as follows:
ring (nearest the rotor bearing), and a ground (i.e. the 1. Open the generator main circuit breaker.
rotor shaft).
NOTE: Generator should have no electrical loads
IMPORTANT NOTE: When testing stators and rotors, applied while drying.
set Megohmmeter to 500 volts and apply voltage for a
maximum of one second. Follow the Megohmmeter 2. Disconnect all wires in a manner that allows the
manufacturers instructions carefully. Do not exceed 500 alternator to be completed disconnected.
volts or apply voltage longer than 1 second. 3. Provide an external source to blow warm, dry air
Megohmmeter HIGH voltages could cause damage to through the generator interior (around the rotor and
other components on the generator. Take the proper stator windings.
precautions before testing.
NOTE: Do not exceed 185 ºF (85 ºC).
Rotor Minimum Insulation Resistance:
4. Connect stator lead.
1.5 Megohms
5. Start the generator and let it run for 2 or 3 hours.
6. Shutdown the generator and repeat the insulation
Cleaning the Generator resistance tests.
Caked or greasy dirt may be loosened with a soft brush
or a damp cloth. A vacuum system may be used to clean
up loosened dirt. Dust and dirt may also be removed
using dry, low-pressure air (25 psi maximum).
IMPORTANT NOTE: Do not use sprayed water to clean
the generator. Residual water on generator windings and
terminals could cause serious problems.

8 Diagnostic Repair Manual

 Section 1.3 Evolution Menu System Navigation
Navigation Keys Date/Time
There are four selection and navigation keys below the Selecting DATE/TIME displays current date and time.
display.
Battery
Escape Selecting BATTERY displays the battery condition.
The ESCAPE key will cause the display to move back
toward the main menu. Sub Menus
Selecting SUB MENUS displays the Sub Menu screen.
Enter
The ENTER key is used to activate a menu or accept a
value when it is changed. HISTORY MAINT

Up and Down
EDIT DEALER
The UP and DOWN triangle keys perform a number of 002463
functions depending on which screen of a menu is active.
Figure 1-4. Evolution Sub Menu
• Move to the next choice (the menu to be selected
will flash on and off). History
• Left and right arrows to move between the various The History Menu displays two history logs:
editable menus.
• Alarm Log: displays the last 50 alarm conditions.
• Increase or decrease a value or change a choice in They are in date and time order, numbered from 1
an editable menu (i.e. from Yes to No). to 50, with 1 being the most recent. Use the UP
and DOWN triangle keys to move from alarm to
alarm. Each alarm lists the date, time, and
description of the alarm.
• Run Log: displays the last 50 Run events. It will
display the date and time as well as a brief
description of the event; for instance Running –
Utility Lost; Stopped – Auto.

Figure 1-2. Evolution Display and Navigation Buttons History

Main Menu Alarm Log Run Log
002464
To get to the Main Menu from any other display, press the
Figure 1-5. History Menu
ESCAPE key one or more times. The Main Menu is
shown in Figure 1-3. The menu system diagram is
shown in Figure 1-12 and Figure 1-13.
There are four selections in the Main Menu: System, 1 09/15/10 04:55:22
Date/Time, Battery, Sub Menus.
Under Voltage
002465
SYSTEM DATE/TIME Figure 1-6. Alarm Log Display

Use the UP and DOWN triangle keys to move from the

BATTERY SUB MENUS most recent Alarm (1) to the oldest (50).
002462
Figure 1-3. Evolution Display Main Menu

System 1 09/15/10 04:55:22

Selecting SYSTEM returns to the Main Display.
Stopped
002466
Figure 1-7. Run Log Display.

Diagnostic Repair Manual 9

Section 1.3 Evolution Menu System Navigation

Use the UP and DOWN triangle keys to move from the Dealer
most recent Run event (1) to the oldest (50). The Dealer Menu displays three selections:
Maint • Display
The MAINT Menu displays three selections: Maint Log, • Dealer Edit
Run Hrs, and Scheduled. • Test

MAINT: Run Hrs Display

The Display Menu displays these selections:
Maint Log Scheduled • Battery Voltage
002467 • Charging Status
Figure 1-8. Maint Menu • Run Hours

Edit • Output Volts

Selecting the Edit Menu enables editing of the following • Output Frequency (Hz)
selections: • Engine Speed (RPM)
• Language • Utility Input Volts
• Fuel Selection • Ambient Temperature (ºF)
• Cold Smart Start (firmware 1.14 and above) • V Firmware Hardware
• Current Date/Time • Bootloader EEPROM
• Exercise Time • Command
• Exercise Frequency • Node Hz Volts
• Firmware Update Use the UP and DOWN triangle keys to move between
selections.
Table 1-15. Cold Smart Start Parameters
Dealer Edit
Node 8 - 20 kW 22 kW
The Dealer Edit Menu displays these selections:
Cold Smart Start (2015-02) • Startup Delay
and Ambient Temp display X X
• Run Hours
screen
• Util Volts Low Value
Temperature Threshold 50 ºF 20 ºF
• Util Recovery Volts
Default Setting Yes Yes • Calibrate Current 1
Transfer Time Delay 30 sec 30 sec • Calibrate Current 2
• Calibrate Volts
Run Hrs • 2-Wire Start Select
View the amount of actual run hours on the unit. • Reset Maintenance
These are editable selections within this menu selection.
Scheduled
View when the next scheduled maintenance is due. Test
Provides four test tools integral to the control panel:
Maint Log
Inputs, Outputs, Display, and QT-Test.
Review the history of maintenance recorded on the unit.
• INPUTS displays the status of the 8 input channels
monitored by the control panel. See Table 1-16.
Evolution Dealer Menu Each input represents an open or closed set of
contacts, and will display either a “0” or “1”. A “0”
DEALER: DISPLAY represents an open contact. A “1” represents a
closed contact. This screen also displays Utility
Voltage.
DEALER EDIT TEST • OUTPUTS displays the status of the output relays
002468
Figure 1-9. Evolution Dealer Menu used by the control panel to initiate commands (like

10 Diagnostic Repair Manual

 Section 1.3 Evolution Menu System Navigation

Crank and Run, or Transfer). See Table 1-16. Outputs

Each channel represents a relay with a either a “0” Outputs are numbered from left to right (1-8).
or “1”. A “0” represents a relay that is de-energized
(OFF). A “1” represents a relay that is energized 0 indicates the Output is OFF
(ON). This screen will also display the Generator 1 indicates the Output is ON
Output Voltage. For example, in Figure 1-11 there are no Outputs ON.
• Display provides two flashing bars that test the This indicates the unit is shut down.
display LEDs. As the bars flash on and off, bad
sectors will not turn on. If a sector does not turn on,
those LEDs are not working. The control panel OUTPUTS: Gen 0
requires replacement to correct a bad display.
NOTE: This will also flash the 3 LED's on the left side of 0 0 0 0 0 0 0 0
002470
the unit.
Figure 1-11. Test Outputs Display
• QT-Test is available when enabled on the unit. It
provides a way to test the Quiet Test mode of the
generator. When tested the generator will run at a Table 1-16. Digital Inputs and Outputs
lower speed (rpm) during the test. For the unit to
perform an actual Quiet Test Exercise, it must be Position Digital Inputs Digital Outputs
enabled in the Exercise Time editing menu. 1 Auxiliary Shutdown Not Used
NOTE: Utility must be present and the controller must be
2 Low Oil Pressure Not Used
in AUTO to unlock the Sub Test menu and perform the
QT-Test. 3 High Temperature Not Used

Inputs 4 Not Used Battery Charger Relay

Inputs are numbered from left to right (1-8). 5 Wiring Error Detect Fuel
0 indicates an Input is OFF
6 2-Wire Start Starter
1 indicates an Input is ON
7 Auto Ignition
For example, in Figure 1-10 Inputs 2 and 7 are ON (Low
Oil Pressure and the Auto switch). This indicates the unit 8 Manual Transfer
is shut down and in AUTO.
NOTE: On an Evolution controller, the 1 (ON) in Input 7
is only visible while the AUTO mode is depressed. When
the AUTO mode is released Utility 7 reverts to a 0 on the
display.

INPUTS: Utility 240

0 1 0 0 0 0 1 0
002469
Figure 1-10. Test Inputs Display

Diagnostic Repair Manual 11

Section 1.3 Evolution Menu System Navigation

EVOLUTION 1.0/SYNC 2.0 MENU MAP

EVOLUTION/SYNC2.0 HSB MENU MAP
READY TO RUN
Note: Menu functions and features may vary Hours of Protection
0 (H)
depending on unit model and firmware revision.

ESC
Running Manual
Running-Utility Lost
Running-Remote Start ENTER SYSTEM DATE/TIME
Running-2 Wire Start
Running - Exercise
Switched Off Battery Condition ENTER
Stopped - Auto BATTERY SUB MENUS
Stopped - Alarm “Good” “Inspect Battery” or “Check Battery” ESC

ENTER ESC

ENTER ENTER
- 1 thru 50 + - Run Log + “Run Log” ENTER
ESC ESC HISTORY
- 1 thru 50 + - Alarm Log + “Alarm Log” ESC
ENTER ENTER

Warning Message(s)
DEALER
Charger Warning
Charger Missing AC ENTER
Low Battery
Battery Problem
Exercise Set Error
USB Warning
Language ENTER Language Language Language
Download Failure + + +
ESC
FIRMWARE ERROR-9 Å English Æ + English - - + Espanol - - + Francais -
Overload Cooldown
SEEPROM ABUSE
Fuel Warning ESC
Fuel Selection ENTER Fuel Selection
ESC
Å NG or LP Æ + NG or LP -
Alarm Message(s)
High Temperature
Low Oil Pressure ESC
Cold Smart Start? ENTER Cold Smart Start?
Overcrank
ESC
Overspeed Å YES or NO Æ - YES or NO +
Overvoltage
Undervoltage
Overload ESC ESC
Underspeed
RPM Sensor Loss Time ENTER Current Date/Time ENTER Select Month (1-12) ENTER
Controller Fault ESC
Å Manual or AUTO Æ Å 2/13/16 13:00 Æ - 2 +
Wiring Error
Stepper Overcurrent
FIRMWARE ERROR-7
ESC ESC
Overload Remove Load
Low Volts Remove Load Exercise Time ENTER Select Frequency ENTER Quiet Test Mode ? ENTER
Stepper Over Current ESC
Å 14:00 Wednesday Æ - WEEKLY + - YES or NO +
Fuse Problem*
- BIWEEKLY +
- MONTHLY + Quiet Test Mode only
*“Fuse Problem” on Firmware on certain models
1.11 and older ONLY

Firmware Update ENTER Firmware Update

ESC
Å Press Enter Æ ESC Å Insert USB Æ

Figure 1-12. Main Menu Map

12 Diagnostic Repair Manual

 Section 1.3 Evolution Menu System Navigation

EVOLUTION 1.0/SYNC 2.0 MENU MAP

Current Date/Time UP ARROW = +

02/13/16 13:00

ESC

ENTER
DOWN ARROW = -
Run Hours (H)
0.0

ESC ENTER

MAINT: Run Hrs

ESC

ENTER
Maint. Log Scheduled

Access Requires Password ENTER ESC

ENTER ESC

- 1 thru 50 + EXAMPLE:
"Battery Maintained" Inspect Battery 200 RnHr or 12/27/13
"Schedule A Serviced"
and
+ Language + "Schedule B Serviced"
Next Maintenance 200 RnHr or 12/27/13
"Maintenance Reset"
- + Portuguese -
"Inspect Battery"
"Service Schedule A"
"Service Schedule B"

Select “Yes” then Press “Enter” to continue or Press “ESCAPE” to escape out of updating.
During update process the Blue “Manual” light flashes, then the Green “Auto” light flashes.
Sequence does this twice. When update is complete the unit returns to Install Wizard menu.
When the controller powers up the very first screen displays the version number for a few seconds.
When update is complete remove Thumb Drive, then follow the Install Wizard Menu.

ESC ESC ESC ENTER

Select Date (1-31) ENTER Select Year (0-99) ENTER Select Hour (0-23) ENTER Select Min (0-59)
- 13 + - 16 + - 13 + - 0 +

ESC ESC ESC

ENTER
Select Hour (0-23) ENTER Select Min (0-59) ENTER Select Day
- 14 + - 0 + - Wednesday +

Possible Message(s)
Corrupted File "Current:V XXXX " ENTER "Are You Sure?"
Invalid File
File Not Found "USB: V XXXX" ESC "- Yes or No +"
Unsupported Device 005615

Figure 1-13. Main Menu Map

Diagnostic Repair Manual 13

Section 1.3 Evolution Menu System Navigation

EVOLUTION 1.0/SYNC 2.0 HSB ACTIVATION

EVOLUTION/SYNC2.0 HSB ACTIVATION
AND
Note: INSTALL WIZARD
Menu functions MENU
and features MAP
may vary
depending on unit model and firmware revision.

Power Up Unit

FIRMWARE V 1.01
Use UP and DOWN arrows to select fuel type then press “ENTER”
HARDWARE V 1.05

ESC Fuel Selection

Activate me (ENT) or
Non Activated Unit Install Wizard
ESC to run in MANUAL + NG or LP -

ENTER
Activated Unit

ESC
Cold Smart Start? ENTER Cold Smart Start?

Å YES or NO Æ - YES or NO +
To activate go to
www.activategen.com
Note: If language was previously
programmed this goes directly to
“Select Hour”
Language + Language + L
Serial 1234567890
PASSCODE xxxxx + _______ - - + English - - +

ENTER
Use up and down arrows to change selection 0 Defaults to
thru 9. Press "Enter" to acccept selection and English if not
to move to the next digit. If passcode is correct selected.
goes to "Install Wizard." If not correct goes to
the message below.
Select Hour (0-23) ENTER Select Min (0-59) ENTER

- 14 + - 0 +

Wrong Passcode
* *
Try Again * Holding the Up or Down arrow
button for 2 seconds will speed dial
through the selections

Non Activated Unit

Select F
“NOT ACTIVATED!” Install Wizard ENTER Quiet Test Mode ? ENTER
- WEE
Hours of Protection
Set Exercise - YES or NO + - BIWE
0 (H)
- MON

Quiet Test Mode

To return to Activation Screen disconnect only on certain
battery and AC power to restart controller models

Figure 1-14. Activation and Install Wizard Menu Map

14 Diagnostic Repair Manual

 Section 1.3 Evolution Menu System Navigation

UP ARROW = +

DOWN ARROW = -

ESC

+ Language + Language + Language +

- + Espanol - - + Francais - - + Portuguese -

ENTER Select Month (1-12) ENTER Select Date (1-31) ENTER Select Year (0-99)
- 2 + - 13 + - 13 +
* * *

Select Frequency
ENTER Select Hour (0-23) ENTER Select Min (0-59) ENTER Select Day
- WEEKLY +
- BIWEEKLY + - 14 + - 0 + - Wednesday +
- MONTHLY +
* * *

Switched to “OFF” ENTER

Hours of Protection SYSTEM DATE/TIME
0 (H)

BATTERY SUB MENUS

000429

Figure 1-15. Activation and Install Wizard Menu Map

Diagnostic Repair Manual 15

Section 1.3 Evolution Menu System Navigation

EVOLUTION 1.0/SYNC 2.0 HSB FIRMWARE MENU MAP

EVOLUTION/SYNC2.0 HSB FIRMWARE MENU MAP
Note: Menu functions and features may vary Switched to “OFF”
depending on unit model and firmware revision. Hours of Protection
0 (H)

ESC

ENTER SYSTEM DATE/TIME

BATTERY SUB MENUS

ENTER ESC

HISTORY MAIN

EDIT DEALER

ENTER
- Language +
ESC
 English 

Fuel Selection
ESC
 NG or LP 

ESC - Current Date/Time +

 02/12/13 12:31 

Possible Message(s)
"Corrupted File"
"Invalid File"
EXERCISE TIME "File Not Found"
ESC "Unsupported Device"
 14:00 Wednesday 
"Insert USB"

Firmware Update ENTER Firmware Update ENTER

ESC
 Press Enter  ESC - Insert USB + ESC

Firmware Update
System not in the OFF position
Disabled Press OFF

Figure 1-16. Firmware Menu Map

16 Diagnostic Repair Manual

 Section 1.3 Evolution Menu System Navigation

UP ARROW = +

DOWN ARROW = -

Alternate Firmware Update Method:

Control unit at main screen and Insert Thumb drive with Firmware
Power the unit down completely. Disconnect AC power.
Repower the controller allow unit to complete the update process.
During update process the Blue “Manual” light flashes, then the Green “Auto” light
flashes. Sequence does this twice. When update is complete the unit returns to setup
menu.
When the controller powers up the very first screen displays the version number for a
few seconds.
When unit finishes update remove thumb drive then follow the Install Wizard menu.

Select “Yes” and Press “Enter” to continue or Press

“ESCAPE” to escape out of updating.
During update process the Blue “Manual” light flashes, then
the Green “Auto” light flashes. Sequence does this once for
firmware (single file) and twice for firmware and hardware
(two files)
When the controller powers up the very first screen displays
the version number for a few seconds.
When update is complete remove Thumb Drive, then follow
the Install Wizard Menu.

"Current:V XXXX " ENTER "Are You Sure?"

"USB: V XXXX" ESC "- Yes or No +"

000430

Figure 1-17. Firmware Menu Map

Diagnostic Repair Manual 17

Section 1.3 Evolution Menu System Navigation

EVOLUTION 1.0/SYNC 2.0 DEALER MENU MAP

EVOLUTION/SYNC2.0 HSB DEALER MENU MAP
Switched to “OFF”
Note: Menu functions and features may vary MAIN DISPLAY Hours of Protection
0 (H)
depending on unit model and firmware revision.

To access Dealer Menu enter Password from MAIN DISPLAY:

Up, Up, ESC, DN, Up, ESC, Up, ENTER

Note:Unit needs to be activated to access the Dealer Menu.

Press “ENTER” to modify. Use the

Startup Delay (sec)
*“Up” and “Down” arrows to change SYSTEM DATE/TIME
ESC
Å 2 to 1500 Æ
selection. Press “ENTER” to save.
* or BATTERY SUB MENUS
Press “ESCAPE” to return to previous
Run Hours (H) setting.
ESC ENTER ESC
Å 0.0 Æ

* 50 Hz Display
HISTORY MAINT

Util Volts Low Value Util Volts Low Value

ESC
Å 140 - 171 Æ Å 140 - 156 Æ
EDIT DEALER

*
ENTER ESC
Util Recovery Volts Util Recovery Volts
ESC
Å 190 - 216 Æ Å 175 - 198 Æ

* DEALER:

ENTER
Calibrate Current1 DEALER EDIT
Current 0.0
ESC
Å 1186 - 1780 Æ Å 1640 Æ
*
Calibrate Current 1, Calibrate Current 2,
Calibrate Current2 Current 0.0 Calibrate Volts. Special note: Press Enter
ESC to modify use the Up and Down arrows to
Å 1186 - 1780 Æ Å 1640 Æ make the change. Pressing Enter or ESC
* saves the changes. This is different from all
the others under Dealer Edit.
Calibrate Volts Calibrate Volts
ESC
Å 750 - 1280 Æ Å 1120 Æ
*
ENTER
(Performs Segment
2 Wire Start Select test of the display)
ESC
ESC
Å No or Yes Æ EcoGen Only
* Off Grid Mode
Yes or No
Reset Maintenance
ESC
Å No or Yes Æ UP ARROW = +
*
DOWN ARROW = -

Figure 1-18. Dealer Menu Map

18 Diagnostic Repair Manual

 Section 1.3 Evolution Menu System Navigation

“Battery Voltage”
ESC
0 - 13.7

“Charging Status”
ESC
“Charging” or “Not Charging”

Run Hours (H)

ESC
0

Output Volts”
ESC
0

“Output Frequency (Hz)”

ESC
0.0

Engine Speed (RPM)

ENTER ESC
0

DISPLAY
Utility Input Volts
ESC
T TEST 0

ENTER ESC Ambient Temperature (deg F)

ESC
INPUTS: Utility 0 V 0
ESC
0 0 0 0 0 0 0 0

FIRMWARE V 1.01
ESC
HARDWARE V 1.05
OUTPUTS:Gen. 0 V
ESC
0 0 0 0 0 0 0 0
Commands:
Bootloader V0.2
ESC “Running Manual”
EEPROM V1.01
To Test Displays “Running - Utility Loss”
ESC
Press Enter “Running - Remote Start”
COMMAND:
ESC “Running - 2-wire Start”
Switched Off
“Running - Exercise”
IN AUTO PRESS
ESC “Switched Off”
ENTER FOR QT-TEST
Node Hz Volts “Stopped - Auto”
ESC
15 KW 60 120/240 “Stopped - Alarm”
ENTER ESC or ENTER

PRESS ENTER TO Note: Units equipped with Quiet Test only. Unit
ESC
STOP Quiet Test must be in AUTO and have Utility available in order
to view this screen and test the Quiet Test function.
000431

Figure 1-19. Dealer Menu Map

Diagnostic Repair Manual 19

Section 1.3 Evolution Menu System Navigation

This page intentionally left blank.

20 Diagnostic Repair Manual

 Section 1.4 Nexus Menu System Navigation
Navigation Keys History
There are four selection and navigation keys below the The History Menu displays two history logs:
display. • Alarm Log: displays the last 50 alarm conditions.
They are in date and time order, numbered from 1
Escape to 50, with 1 being the most recent. Use the UP
The ESCAPE key will cause the display to move back and DOWN triangle keys to move from alarm to
toward the main menu. alarm. Each alarm lists the date, time, and
description of the alarm.
Enter
• Run Log: displays the last 50 Run events. It will
The ENTER key is used to activate a menu or accept a display the date and time as well as a brief
value when it is changed. description of the event; for instance Running –
Utility Lost; Stopped – Auto.
Up and Down
The UP and DOWN triangle keys perform a number of
functions depending on which screen of a menu is active.
• Move to the next choice (the menu to be selected
will flash on and off).
003046
• Left and right arrows to move between the various
Figure 1-22. History Menu
editable menus.
• Increase or decrease a value or change a choice in
an editable menu (i.e. from Yes to No).

003047
Figure 1-23. Alarm Log Display

Use the UP and DOWN triangle keys to move from the

most recent Alarm (1) to the oldest (50).

Figure 1-20. Nexus Display and Navigation Buttons

003048
Figure 1-24. Run Log Display.
Main Menu
To get to the Main Menu from any other display, press the Use the UP and DOWN triangle keys to move from the
ESCAPE key one or more times. The Main Menu is most recent Run event (1) to the oldest (50).
shown in Figure 1-21. The menu system diagram is
shown in Figure 1-30. Status

There are four selections in the Main Menu: History, The Status Menu displays four choices: State, Display,
Status, Edit, and Debug. Command, and Versions. Use the up and down triangle
keys to move:
• State displays the current state of the panel along
with the current date, time and day. See Figure 1-
30 for the complete list of possible Status
messages which will be displayed.
003044 • Display provides up to five generator parameters:
Figure 1-21. Nexus Display Main Menu Run Hours, RPM, Hz, Battery, and Hours Under
Load (if enabled)

Diagnostic Repair Manual 21

Section 1.4 Nexus Menu System Navigation

– Run Hours displays the total number of hours Generator starts and transfers. It is adjustable from
the generator has run (in 0.0 Hours format). 10 to 30 seconds.
– RPM displays the engine speed (in RPM). • Reset Maintenance will reset the Maintenance
– Hz displays the generator output frequency (in warning clock.
0.0 Hz format).
Debug
– Battery displays the battery voltage (i.e. 12.9).
Provides four test tools integral to the control panel:
– Hours Under Load displays the total number Inputs, Outputs, Display, and QT-Test.
of hours the unit has actually provided power.
• TEST Inputs displays the status of the 8 input
• Command displays the current command. See channels that the control panel monitors. See
Figure 1-30 for the list of possible commands Table 1-17. Each input represents an open or
which will be displayed. closed set of contacts, and will display either a “0”
• Versions displays the version of Software and or “1”. A “0” represents an open contact. A “1”
Hardware of the panel. represents a closed contact.

003061 003069

Figure 1-25. Nexus Status Menu Figure 1-27. Nexus Test Inputs Display

See Figure 1-27. Inputs are numbered from left to right

(1-8).
• 0 indicates an Input is OFF
• 1 indicates an Input is ON
003062
In this example Inputs 2 and 7 are ON (Low Oil Pressure
and the Auto switch). This indicates the unit is shut down
Figure 1-26. Nexus Display Menu and in Automatic.
Edit • TEST Output displays the status of the output
relays used by the control panel to initiate
Selecting the Edit Menu enables editing of the following: commands (like Crank and Run, or Transfer). See
Exercise Time, Current Time, Frequency, Language, Table 1-17. Each channel represents a relay with a
Startup Delay, and Reset Maintenance. To access the either a “0” or “1”. A “0” represents a relay that is
editing screens navigate to the Edit menu and press de-energized (OFF). A “1” represents a relay that is
ENTER. Either the STATUS or DISPLAY menu will energized (ON).
appear. Use the UP and DOWN triangle buttons to switch
between the menus. When the desired menu is displayed
press ENTER. Use the UP and DOWN triangle buttons to
change the value, then press ENTER. Press ESCAPE to
exit. If no changes are required, press ESCAPE to exit.
• Exercise Time displays four selections: Quiet Test 003070
Mode (Yes/No), Select Hour, Select Minute, and Figure 1-28. Nexus Test Outputs Display
Select Day. Once programmed the unit will perform
a weekly exercise. See Figure 1-28. Outputs are numbered from left to right
• Current Time displays five selections: Select Hour, (1-8).
Select Minute, Select Month, Select Date, Select • 0 indicates an Output is OFF
Year. The current time must be set to enable the • 1 indicates an Output is ON
exercise and maintenance functions of the panel.
In this example there are no Outputs ON which indicates
• Frequency is not enabled at this time. the unit is shut down.
• Language displays three choices: English, • TEST Display provides two flashing bars that test
Francais, and Espanol. the display LEDs. As the bars flash on and off, bad
• Startup Delay provides a way to change the time sectors will not turn on. If a sector does not turn on,
delay between when Utility fails and when the those LEDs are not working. The control panel
requires replacement to correct a bad display.

22 Diagnostic Repair Manual

 Section 1.4 Nexus Menu System Navigation

• TEST QT-Test is only available on 17-20 kW units.

It provides a way to test the Quiet Test mode of the Table 1-17. Digital Inputs and Outputs
generator. When tested the generator will run at a
lower speed (rpm) during the test. Position Digital Inputs Digital Outputs

NOTE: For the unit to perform an actual weekly Quiet 1 Not Used Not Used
Test Exercise, it must be enabled in the Exercise Time
2 Low Oil Pressure Not Used
editing menu.
3 High Temperature Not Used

4 Not Used Battery Charger Relay

5 Wiring Error Detect Fuel

6 Not Used Starter

003068
Figure 1-29. Nexus Status Menu 7 Auto Ignition

8 Manual Transfer

Diagnostic Repair Manual 23

24
PASSWORD Password is entered
“ESC, UP, UP ESC, DOWN, UP, ESC, UP, UP, ENTER” on this page. MAIN MENU
ESC

HISTORY STATUS EDIT DEBUG

ESC ESC ESC ESC

RESET
ALARM LOG RUN LOG STATE DISPLAY COMMAND VERSIONS MAINTENANCE
INPUTS OUTPUTS DISPLAYS QT TEST

EXERCISE If so equipped
ESC SOFTWARE
TIME
HARDWARE
Section 1.4 Nexus Menu System Navigation

Press the “ESCAPE” key IF APPLICABLE

ESC to jump back up through
the menu levels. ENGINE CURRENT
HOURS TIME
Use the “+/-” key
+/- to navigate through
the menu. EDIT WITH
ENGINE
FREQUENCY PASSWORD
RPM ESC
Use the “ENTER” key
ENTER to select items or
enter data.
GENERATOR START-UP
FREQUENCY LANGUAGE DELAY
The possible Status messages of the display
are as follows: BATTERY The possible commands START-UP LANGUAGE
• Switched Off/Time & Date VOLTAGE

Figure 1-30. Main Menu Map

on Line 2 of the display DELAY
• Ready to Run/Time & Date
are as follows:
• Utility Loss Delay/Pausing for X Seconds
• Switched Off
• Cranking/Attempt # X RESET
• Running Manually FREQUENCY MAINTENANCE
• Running in Exercise/Time & Date
• Stopped in Auto Mode
• Running/Cooling Down
• Running - Utility Lost
• Running - Warning/Warning Message
• Running in Exercise CURRENT REMOTE
• Running - Alarm/Alarm Message
• Running from Radio TIME START
• Stopped - Alarm/Alarm Message
• Stopped - Warning/Warning Message
• Cranking/Pausing for X Seconds
• Running/Time & Date EXERCISE CALIBRATE
Note: Some versions may have slightly different parameters. TIME VOLTS
• Running/Warming Up
• Cranking - Warning/Warning Message
• Cranking - Alarm/Alarm Message 003069

Diagnostic Repair Manual

 Section 2.1 Operational Analysis
Field Boost Firmware versions 1.12 and newer – Field boost turns
on at 2200 rpm. Field boost shuts off when system
During the engine's crank cycle, the control panel voltage reaches 80% of nominal (192 VAC on a 240V
provides battery voltage (12 VDC) on Wire 56 to energize generator). This firmware version allows the generator to
the starter contactor relay (SCR). run up to four additional minutes before shutting down on
See Figure 2-1. On a Nexus controller system, Wire 56 undervoltage. This will allow sufficient time for the unit to
also connects to Wire 4 (positive field voltage) through a make a positive connection between the brushes and slip
field boost diode. rings and build proper system voltage. The firmware also
See Figure 2-2. The Evolution controller has a dedicated allows for two to four* additional attempts of 15 seconds
field flash output on Wire 4A which flows through the field each following an unsuccessful four minute cycle.
boost diode to Wire 4. * Number of additional attempts depends on the unit.

Nexus Units A

Field boost voltage is available only while the crank relay B

is energized (i.e. during the engine crank cycle). D

A C
E
B
F
D G

C I
E H

F
G
K H J
I
003083
A. Evolution Controller F. Field Boost Diode
J
B. Field Excitation Ground Wire 0 G. 12 VDC
C. +VDC Gated Variable Wire 4 H. Wire 4A
L D. Rotor I. Field Boost Relay
003084 E. Wire 4 J. 12 VDC

A. Nexus Controller G. 12 VDC Wire 13 Figure 2-2. Evolution Field Boost Circuit
B. Field Excitation Ground Wire 0 H. Wire 56
C. +VDC Gated Variable Wire 4 I. To Starter
D. Rotor J. Starter Contactor Operation
E. Wire 4 K. Crank Relay
F. Field Boost Diode L. 12 VDC Engine Cranking
Figure 2-1. Nexus Field Boost Circuit See Figure 2-3. When the engine is cranking (Evolution
2200 rpm), field boost voltage causes the rotor to
Evolution Units magnetize. The rotor magnetic field induces a voltage
into the stator AC power windings, and the stator
Evolution units have a dedicated field flash relay with
excitation (DPE) windings. During cranking, field boost
logic that is separate from the start circuit. Depending on
magnetism is capable of creating approximately one-half
the firmware version, the field flash will turn on and off
the unit’s rated voltage.
depending on engine speed and system voltage.
Firmware versions up to 1.11 – Field boost turns on at
2200 rpm. Field boost shuts off after 10 seconds, or when
voltage is 88 VAC, whichever comes first.

Diagnostic Repair Manual 25

Section 2.1 Operational Analysis

A Initially, the AC power windings output voltage sensed by

the AVR is low. The AVR reacts by increasing the
B excitation voltage (and hence current flow) to the rotor
until AC output voltage increases to a preset level. The
A
AVR then maintains the voltage at this level. For
example, if voltage exceeds the desired level, the AVR
C C
G will decrease excitation. Conversely, if voltage drops
below the desired level, the AVR responds by increasing
D excitation.

E F

003085
100 VAC
A. To Load F. Rotor
STATOR
B. Main Line Circuit Breaker G. Field Boost Circuit
C. Stator Power Winding H. Voltage Regulator
D. Magnetic Field I. Stator Excitation Winding
E. Engine - Direct drive

Figure 2-3. Operating Diagram ROTOR

Field Excitation
AC voltage from the DPE winding provides power to the
MAGNETIC FIELD
AVR. The AVR gates and converts AC voltage to DC 002476
voltage, and provides regulated variable DC voltage to Figure 2-4. Low Field Excitation Voltage =
the rotor through Wires 4 and 0. When the starter Low Magnetic Lines of Flux = Low AC Output
disengages (cranking stopped), the AVR continues to
provide excitation voltage to the rotor.
The AVR senses the AC output voltage through Sensing
Wires 11 and 44 (11S & 44S for Evolution), which are
connected to the main power leads (11 and 44) in the
stator windings. The AVR will continue to increase
excitation voltage to the rotor until the desired AC output
voltage is reached. It will continue to regulate excitation 200 VAC
voltage as necessary to provide a constant AC output
voltage to the load. STATOR

Regulated excitation from the regulator is delivered to the

rotor windings through Wire 4 and the positive brush and
slip ring. This results in current flowing through the field
windings to the negative slip ring and brush, and then to
ROTOR
ground.
See Figure 2-4 and Figure 2-5. The greater the current
flow through the windings the more concentrated the
lines of flux around the rotor become. The more MAGNETIC FIELD

concentrated the lines of flux around the rotor, which cut 002477
Figure 2-5. Increased Field Excitation Voltage =
across the stationary stator windings, the greater the
Increased Magnetic Lines of Flux =
voltage induced into the stator.
Increased AC Output Voltage

26 Diagnostic Repair Manual

 Section 2.1 Operational Analysis

AC Power Winding Output affected during load changes. However, frequency is a

function of rotor speed (engine rpm); the engine
When electrical loads are connected across the AC electronic governor (integral to the control panel) and the
power windings to complete the circuit, current flows AVR will respond to any engine speed changes to
through the circuit powering the loads. maintain a stable, isochronous, frequency output based
Load changes will result in a corresponding change in on the specifications of the unit.
voltage. As load demand increases the voltage will The automatic voltage regulator and the electronic
decrease. As load demand decreases the voltage will governor work together to provide output voltage
increase. The AVR changes excitation to provide a regulation of +/- 1% voltage regulation and +/- 0.25%
constant output voltage with minimal increase or steady state, isochronous, frequency (speed) regulation.
decrease during load changes. Frequency is also

MLCB

240 VAC

44S Sensing

Evolution
Controller
44 Neutral 11 11S Sensing
33 22

120 VAC 120 VAC

Stator Power Stator Power 4A

Winding Winding

Field Boost
Diode

Rotor

4
Brushes

4 DC Field Excitation

Excitation 0 GND Field Excitation

“DPE” Winding
160 - 200 6
VAC
Power for Voltage Regulation
2
003081
Figure 2-6. Evolution Voltage Regulator Schematic

Diagnostic Repair Manual 27

Section 2.1 Operational Analysis

MLCB

240 VAC

44 Sensing

Nexus
Controller
44 Neutral 11 11 Sensing
33 22
To Starter
120 VAC 120 VAC Contactor

Stator Power Stator Power 56

Winding Winding

Field Boost
Diode

Rotor

4
Brushes

4 DC Field Excitation

Excitation 0 GND Field Excitation

“DPE” Winding
160 - 200 6
VAC Power for Voltage Regulation
2
003082
Figure 2-7. Nexus Voltage Regulator Schematic

28 Diagnostic Repair Manual

 Section 2.2 Troubleshooting Flow Charts

Evolution™ Controller e-Codes

Displayed Alarm/ e-Code
Description Action Step
Alarm Warning Breakdown
Controller Fault ALARM No E-code on HSB Replace Controller
Condition - Engine Cranks but will not Start (5 crank attempts)
Overcrank ALARM 1100 Problem 17
Unit turns over but will not start. Controller is receiving signal on Wire 18.
Prolonged (60 Hz on a 50 Hz unit, 72Hz on 60Hz unit)
Overspeed ALARM 1200 Over specified Hz for 3 seconds. Possible cause: Stepper motor/mixer body Test 12
assembly issue.
Instantaneous (62 Hz on a 50 Hz unit, 75Hz on 60Hz unit)
Overspeed ALARM 1205 Over specified Hz for 0.1 second (100 milliseconds). Possible cause: Stepper motor/ Test 12
mixer body assembly issue.
Monitors zero cross timing of the AVR to determine the alternator frequency which is
Overspeed ALARM 1207 a speed indicator. Set for 150 milliseconds of 4500 rpm or higher. Used if the normal Test 64 and Test 60
ignition pulse sequence(s) are not being seen by the controller.
Occurred while running
Low Oil Pressure ALARM 1300 Test 61
The default Extended alarm for low oil pressure. Check oil level and pressure.
High Condition - Air Flow Impeded / Flow Issue
ALARM 1400 Test 62
Temperature Check the inlet/outlet for debris. Check temperature sensor and wiring.
Twin Cylinder+Running
RPM Sensor ALARM 1501 Twin Cylinder Running faults to RPM Sensor Loss. Possible Causes: air pocket in fuel Test 50 and Test 64
line, dirty fuel, missing ignition pulse (loss of one of the primary coils).
Twin Cylinder+Cranking If engine cranks, Test 64.
RPM Sensor ALARM 1505 Twin Cylinder Cranking faults to RPM sensor loss Possible Cause: starter motor If engine does not crank,
issue, missing ignition pulse (loss of one of the primary coils). Problem 15.
Single Cylinder+Running
RPM Sensor ALARM 1511 Single Cylinder Running RPM sensor loss Possible Causes: air pocket in fuel line, Test 50 and Test 64
dirty fuel. Loss of ignition pulse.
Single Cylinder+Cranking If engine cranks, Test 64.
RPM Sensor ALARM 1515 Single Cylinder Cranking faults to RPM sensor loss Possible Cause: starter motor If engine does not crank,
and/or engine issue. Loss of ignition pulse. Problem 15.
Condition - Unit is Overloaded (55 Hz for 60 Hz for 30 sec, 40 Hz for 50 Hz unit Problem 3, or Test 50, or
Underspeed ALARM 1600
Unit is Overloaded slowing engine speed, fuel supply low or throttle control problem. Test 12
Underspeed Check fuel selection and
Underspeed ALARM 1603
The engine never comes up to 3600 RPM. fuel supply
Overvoltage ALARM 1800 Prolonged Over-Voltage Problem 2
*Preliminary Output
Voltage Test (firmware
Prolonged Under-Voltage
Undervoltage ALARM 1900 v1.12 and above).
Undervoltage due to loss of voltage. Below 80% for 10+ seconds)
Note: Update controller to
latest firmware.
*Preliminary Output
Voltage Test (firmware
Instantaneous
Undervoltage ALARM 1901 v1.12 and above).
Undervoltage due to sudden loss of voltage. (Voltage less than 15 sec 2 sec+)
Note: Update controller to
latest firmware.
*Preliminary Output
Both Zero Crosses missing
Voltage Test (firmware
Undervoltage due to faulty excitation winding, or zero cross circuit, or circuit in
Undervoltage ALARM 1902 v1.12 and above).
general. Possible cause: loose wiring, field boost hardware failure. (Both zero cross
Note: Update controller to
missing greater than 1.5 sec)
latest firmware.
NOTE: If an alarm code is displayed on the controller, use the diagnostic procedure listed in the action step.

Diagnostic Repair Manual 29

Section 2.2 Troubleshooting Flow Charts

Evolution™ Controller e-Codes

Displayed Alarm/ e-Code
Description Action Step
Alarm Warning Breakdown
*Preliminary Output
Single Zero Cross missing
Voltage Test (firmware
Undervoltage due to faulty excitation winding, zero cross circuit, or circuit in general.
Undervoltage ALARM 1906 v1.12 and above).
Possible cause: field boost hardware failure. (One zero cross missing greater than
Note: Update controller to
1.5 sec)
latest firmware.
Mis-wired Check customer
Wiring Error ALARM 2099
Customer connection low voltage and high voltage wires are crossed. connection in generator
Overloaded - Default (Output Current Method)
Overload
ALARM 2100 Unit is overloaded. One or both CT(s) detecting an overload condition. Check transfer Remove Load
Remove Load
switch loadshed functionality. (Change load dynamics or utilize loadshed).
Unit was overloaded and attempted to start with a large load connected. The unit can
Undervoltage
ALARM 2299 not ramp up the generator voltage to its normal target voltage value if it starts with a Remove Load
Overload
large load connected
Stepper
ALARM 2399 Current flow in stepper coil(s) above specification Test 12
Overcurrent
Missing / Damaged Fuse
Fuse Problem ALARM 2400* The 7.5 amp Controller Fuse is missing or blown (open). Test 44
*Firmware version 1.11 and older only
Check the continuity of
the harness and operation
Aux Shutdown ALARM 2800 External shut down circuit is open.
of the switch(es). Repair/
replace as needed.
Low Battery WARNING Condition->Battery less than 12.1 Volts for 60 seconds Test 45
Condition->More than 16 Volts of battery voltage or 600 milliamperes or more of
Battery Problem WARNING Test 45
charge current at the end of an 18 hour charge
Charger Warning WARNING Less than 12.5 volts of battery voltage at the end of a 18 hour charge Problem 22
Charger Missing
WARNING AC power is missing from the battery charger input Problem 22
AC
Service Service Schedule A 200hours 2 years
Perform Maintenance
Schedule Service Schedule B 400 Hours 4 years
NOTE: If an alarm code is displayed on the controller, use the diagnostic procedure listed in the action step.

Additional Codes For 8 and 9 kW Units Only

Displayed Alarm/ e-Code
Description Action Step
Alarm Warning Breakdown

If the engine has tried to

Engine/Starter Problem crank for 10 times
Overcrank ALARM 1101
Limiting number of cranking cycles to protect the starter motor. unsuccessfully, this will
trigger.

Check for Overloaded

Overloaded
Overload condition on unit.
ALARM 2102 Unit re-cranks 5 times when load is applied, engine dies (0 RPM) and has low
Remove Load Inspect stepper motor
voltage (< 180V)
operation.

Overloaded
Overload Check for Overloaded
ALARM 2103 Unit has run and attempted to accept load 10 times, could not accept due to
Remove Load condition on unit
overload condition

30 Diagnostic Repair Manual

 Section 2.2 Troubleshooting Flow Charts

Introduction Procedure
Use the “Flow Charts” in conjunction with the detailed 1. Set the Main Line Circuit Breaker (MLCB) to the
instructions in Section 2.3, Diagnostic Tests . Test CLOSED (ON) position.
numbers and/or verbiage used in the flow charts 2. Disconnect and isolate Wire 23 (from ground) in
correspond to the numbered tests and/or verbiage in the customer connection area of the generator or
Section 2.3. the transfer switch to ensure that the generator
The first step in using the flow charts is to identify the correct DOES NOT transfer power to the load (structure)
problem on the following pages. For best results, perform all during testing.
tests in the exact sequence shown in the flow charts. 3. Navigate to the voltage display using the dealer
menu map for the controller.
4. Set the controller to MANUAL. Allow generator to
Preliminary Output Voltage Test start and stabilize.
(Evolution Only, Non-Synergy, Firmware 5. Visually monitor the output volts displayed on the
v1.12 and Above) controller. Record the value indicated.

General Theory Voltage Indicated on the Controller: _________

When an Alarm of the 1900 group (Undervoltage) is 6. Set the digital multimeter (DMM) to measure AC
displayed on the controller, certain tests need to be voltage.
performed to determine the actual fault. With firmware 7. Connect one meter test lead to Wire 11 and the
v1.12 and above, up to four minutes (in Manual Mode) is other meter test lead to Wire 44 at the load side of
now available to measure output voltage before shutting the MLCB.
down on “Under Voltage”. Measuring output voltage as 8. Measure and record the voltage indicated on the
described in this test will help determine the next step in DMM.
troubleshooting. Refer to Table 2-1.
When measuring output voltage, it is important to look at Measured Voltage Output at MLCB: __________
the output voltage displayed on the control panel as well 9. Shut the unit down by pressing the OFF button on
as measuring actual output voltage of the generator. the controller.
NOTE: If the unit enters a shutdown during this 10. Connect Wire 23.
procedure, acknowledge the alarm by pressing the OFF
button and then ENTER. Restart unit if necessary to
complete the test.

Table 2-1. Preliminary Output Voltage Test Results

Controller Measured Flow Chart

Perform Test(s):
Voltage Voltage Path Begin:
0 140-180
C Test 6 – Test Excitation Winding Circuit 2 and 6
(+10%) (+ or – 10%)
140-180 140-180
FB1 Test FB1 – Test Wire 4
(+ or – 10%) (+ or – 10%)
0 0 Test FB2 – Test Wire 4A Evolution
FB2
(+20%) (+20%) if necessary, perform tests as defined in the standard flowchart.
~50% of
≥300 B Test 5 – Test Sensing Circuit Wires 11(S) and 44(S)
measured voltage

Table 2-2. Output Voltage Test Results

Voltage Voltage Voltage

Indicated Controller Indicated Controller Indicated Controller

Measured Output Measured Output Measured Output

Diagnostic Repair Manual 31

Section 2.2 Troubleshooting Flow Charts

Field Boost Circuit Test - Evolution/Nexus

TEST FB1 - TEST WIRE 4

GOOD
EVOLUTION/NEXUS

TEST FB2 -
BAD EVOLUTION TEST WIRE 4A
PROBLEM 1, TEST 4 –
PERFORM FIXED BAD
EXCITATION / ROTOR NEXUS
GOOD
AMP DRAW

PROBLEM 1, TEST 4 –
PERFORM FIXED
TEST FB4 - TEST FB3 - DIODE EXCITATION / ROTOR
GOOD DIODE TEST TEST EVOLUTION AMP DRAW
NEXUS

GOOD BAD BAD

BAD

REPLACE DIODE/HARNESS REPLACE DIODE/HARNESS GOOD

THEN RE-TEST THEN RE-TEST

PROBLEM 1, TEST 4 – PERFORM

PERFORM FIXED REPAIRS BASED
EXCITATION / ROTOR ON THE TEST 4
AMP DRAW RESULTS BEFORE
ADVANCING TO
THE NEXT STEP.

REPLACE CONTROLLER
003106

32 Diagnostic Repair Manual

 Section 2.2 Troubleshooting Flow Charts

IMPORTANT NOTE: Clear any faults in the controller before proceeding with any running diagnostic steps!
NOTE: Perform FBCT “Field Boost Circuit Test” PRIOR to performing Test 4. After performing “Field Boost Circuit Test”
in it's entirety, compare the results with the “Test 4 Results Table” to determine letter code result A through H on this
page and the next.

Problem 1 – Generator Shuts Down for Under Voltage

NOTE: If the generator is an Evolution (non-Synergy) and has Firmware version v1.12 or higher, perform the
Preliminary Output Voltage Test.

See Note above RE-TEST

TEST 4 – PERFORM
A FIXED EXCITATION /
ROTOR AMP DRAW G REPAIR
OR REPLACE
FUSES

B D
REPLACE CONTROLLER
Check GENservice bulletins on
C
IF NEXUS CONTROLLER-
controller replacement.
UTILIZE APPENDIX B CHECK
DMM
FUSES

TEST 8 –
TEST 6 – TEST
TEST 5 – TEST RESISTANCE GOOD
EXCITATION
SENSING CIRCUIT CHECK OF
WINDING CIRCUIT
WIRES 11 AND 44 ROTOR CIRCUIT
2 AND 6
BAD

GOOD GOOD
ROTOR CIRCUIT
FAILURE
BAD

REPAIR
OR TEST 7 – TEST
REPLACE STATOR TEST 9 –
GOOD REPAIR CHECK
OR BAD
BRUSHES &
REPLACE
SLIP RINGS
BAD PERFORM
STATOR GOOD
INSULATION BAD
RESISTANCE
TEST 10 –
BAD TEST ROTOR
ASSEMBLY
REPLACE TEST 10 –
STATOR GOOD TEST ROTOR
ASSEMBLY TEST 7 – TEST GOOD
ONLY GOOD
STATOR

BAD REPLACE BAD

ROTOR PERFORM ROTOR
ONLY INSULATION
REPLACE REPLACE RESISTANCE TEST
ROTOR AND ROTOR AND SECTION 1.2
STATOR STATOR

003107

IMPORTANT NOTE: Clear any faults in the controller before proceeding with any running diagnostic steps!

Diagnostic Repair Manual 33

Section 2.2 Troubleshooting Flow Charts

Problem 1 – Generator Shuts Down for Under Voltage (Continued)

NOTE: If the generator is an Evolution (non-Synergy) and has Firmware version v1.12 or higher, perform the
Preliminary Output Voltage Test.

TEST 4 – PERFORM
E FIXED EXCITATION / F TEST 7 –
TEST STATOR
BAD
ROTOR AMP DRAW

GOOD
H
PERFORM
TEST 10 –
STATOR
TEST ROTOR
INSULATION
ASSEMBLY BAD
RESISTANCE

GOOD

TEST 7 – TEST 10 –
TEST STATOR TEST ROTOR
PERFORM ROTOR ASSEMBLY
INSULATION
RESISTANCE TEST GOOD BAD
SECTION 1.2 BAD GOOD

GOOD REPLACE REPLACE

ROTOR ROTOR REPLACE REPLACE
ONLY AND ROTOR STATOR
STATOR AND ONLY
REPEAT STATOR
TEST 4 003108

Problem 2 – Generator Produces High Voltage

TEST 1 - CHECK TEST 11 - CHECK TEST 12 - CHECK

AC OUTPUT HIGH AC OUTPUT HIGH STEPPER MOTOR
VOLTAGE FREQUENCY CONTROL

FREQUENCY AND
VOLTAGE O.K.
VOLTAGE OUTPUT
REFER TO AT BREAKER IS
PROBLEM 1 BELOW 220 OR
ABOVE 270 VOLTS
FREQUENCY O.K.,
BUT VOLTAGE STOP
INCORRECT TESTS
VOLTAGE
TEST 3 -
OUTPUT AT
CALIBRATE
BREAKER IS
VOLTAGE
BETWEEN
003109
220-270 VAC

IMPORTANT NOTE: Clear any faults in the controller before proceeding with any running diagnostic steps!

34 Diagnostic Repair Manual

 Section 2.2 Troubleshooting Flow Charts

Problem 3 – Voltage and Frequency Drop Excessively When Loads Are Applied

TEST 14 - CHECK IF RECONFIGURED TO LP GAS,

TEST 15 - CHECK NOT
VOLTAGE AND BOTH VERIFY THAT PROPER
FOR OVERLOAD OVERLOADED
FREQUENCY LOW PROCEDURE WAS FOLLOWED
CONDITION
UNDER LOAD (REFER TO INSTALLATION
MANUAL)

GOOD OVERLOADED

TEST 12 - CHECK
DISCONTINUE REDUCE LOADS TO UNIT’S
STEPPER MOTOR
TESTING RATED CAPACITY
CONTROL GOOD

BAD

REPAIR OR REPLACE

TEST 16 - CHECK
ENGINE CONDITION

GOOD

GO TO “PROBLEM 18 -
TEST 7 - CHECK ENGINE ENGINE STARTS HARD
LOOK FOR A SHORTED CONDITION
GOOD STATOR AC CONDITION AND RUNS
IN A CONNECTED LOAD OR IN ONE
POWER WINDINGS GOOD ROUGH/LACKS POWER”
OF THE LOAD CIRCUITS
SECTION 4.5

BAD
REPAIR OR REPLACE 003110

Problem 4 – Unstable Voltage or Incorrect Output Which is Not Triggering a Shutdown

TEST 1 – CHECK
AC OUTPUT ERRATIC PROCEED TO PROBLEM 3
VOLTAGE

HIGH TEST 3 -
OR CALIBRATE
LOW VOLTAGE
003111

IMPORTANT NOTE: Clear any faults in the controller before proceeding with any running diagnostic steps!

Diagnostic Repair Manual 35

Section 2.2 Troubleshooting Flow Charts

This page intentionally left blank.

36 Diagnostic Repair Manual

 Section 2.3 Diagnostic Tests
Introduction AC Troubleshooting
This section familiarizes the service technician with It is always good practice to continue to ask questions
acceptable procedures for the testing and evaluation of during the troubleshooting process. When evaluating the
various problems that can occur on standby generators problem, asking some of these questions may help
with air-cooled engines. Use this section in conjunction identify the problem more quickly.
with Section 2.2, Troubleshooting Flow Charts. The • What is the generator supposed to do?
numbered tests in this section correspond with those of
Section 2.2. • What fault (Alarm) is shutting the generator down?
Some test procedures in this section require the use of • Is the fault a symptom of another problem?
specialized test equipment, meters or tools. Most tests • Does the generator have the same fault
can be performed with a Digital Multimeter (DMM). An consistently?
AC frequency meter is required where frequency • When does the fault occur?
readings must be taken. To measure AC loads it is
acceptable to use a clamp-on ammeter. • After the fault occurred what was displayed in the
LCD?
Testing and troubleshooting methods covered in this
section are not exhaustive. No attempt has been made to • Why would this happen?
discuss, evaluate and advise the home standby service • How would this happen?
trade of all conceivable ways in which service and trouble
• What type of test will either prove or disprove the
diagnosis must be performed. Accordingly, anyone who
cause of the fault?
uses a test method not recommended herein must first
satisfy himself that the procedure or method he has
selected will jeopardize neither his nor the product's safety.

Safety
Service personnel who work on this equipment should be
aware of the dangers of such equipment. Extremely high
and dangerous voltages are present that can kill or cause
serious injury. Gaseous fuels are highly explosive and
can ignite by the slightest spark. Engine exhaust gases
contain deadly carbon monoxide gas that can cause
unconsciousness or even death. Contact with moving
parts can cause serious injury. The list of hazards is
seemingly endless.
When working on this equipment, use common sense
and remain alert at all times. Never work on this
equipment while you are physically or mentally fatigued.
If you do not understand a component, device or system,
do not work on it.

Diagnostic Repair Manual 37

Section 2.3 Diagnostic Tests

Test 1 – Check AC Output Voltage NOTE: “Residual” voltage may be defined as the voltage
produced by rotor residual magnetism alone. The amount
General Theory of voltage induced into the stator AC power windings by
residual voltage alone will be approximately 2 to 16 VAC,
Use a DMM to check the generators output voltage. Test depending on the characteristics of the specific generator.
output voltages at the unit’s main circuit breaker (MLCB) If a unit is supplying residual voltage only, either excitation
terminals. Refer to the unit’s Data Plate for rated line-to- current is not reaching the rotor or the rotor windings are
line and line-to-neutral voltages. open and the excitation current cannot pass. On current
units with air-cooled engines, “field boost” current flow is
DANGER available to the rotor after the engine reaches 2200 rpm.
Electrocution. High voltage is present at
test terminals. Contact with live terminals Test 3 – Calibrate Voltage
will result in death or serious injury.
(000311) General Theory
IMPORTANT NOTE: The generator will be running. When voltage output is too high or too low, it is possible
Connect meter test clamps to the high voltage terminals to adjust voltage output of the generator. To access this
while the generator is shut down. Stay clear of power menu a password will be required to be entered into
terminals during the test. Make sure the meter clamps controller.
are securely attached and will not shake loose.
NOTE: Replacement controllers must be checked but
Procedure typically do not require calibration unless output is not
within the specifications. (Refer to the unit data decal and
1. Set the DMM to measure AC voltage. to the Specifications section in the front of this manual.)
2. See Figure 2-8. With the engine shut down,
connect the meter test leads across the load Procedure
terminals of the generator MLCB. This will 1. Set DMM to measure AC voltage.
measure line-to-line voltage. 2. Open the Main Line Circuit Breaker (MLCB) on the
generator.
3. Using appropriate back probes, measure output
voltage at the AVR connector (Wires 11S and 44S).
4. On the controller, press the ESC key until the main
menu is present. (Refer to the Menu Navigation
found in Section 1.10)
5. While at this screen proceed to enter the
appropriate password:
For Evolution:
UP, UP, ESC, DOWN, UP, ESC, UP, ENTER
Figure 2-8. MLCB Test Points For Nexus:
ESC, UP, UP, ESC, DOWN, UP, ESC, UP, UP, ENTER
3. Set the MLCB to the “Open” position. Verify that all 6. After the password has been entered, proceed to
electrical loads are disconnected from the the EDIT menu for Nexus controller, or to DEALER
generator. EDIT for Evolution controller.
4. Set the controller to MANUAL. 7. Press the down arrow key until the screen
indicates CALIBRATE VOLTAGE and press
NOTE: AC under and over-voltage shut downs have a ENTER.
10 second delay.
8. After pressing enter, a value will appear on the
5. Set the MLCB to the “Closed” position. Measure screen.
and record the voltage. NOTE: The default setting from the factory for calibration
6. Set the controller to OFF. is 1024. The Evolution controller is adjustable from 750-
1280.The Nexus controller is adjustable from 700-1300.
Results
Calibration factor must NOT be adjusted below 990 or
1. If the DMM indicated approximately 240-244 VAC, above 1040. Adjusting outside of this window could result
the output voltage is good. in damage to the generator.
2. If the DMM indicated any other readings the 9. Set controller to MANUAL.
voltage is bad. Refer back to the flow chart.

38 Diagnostic Repair Manual

 Section 2.3 Diagnostic Tests

10. While the unit is running, use the UP or DOWN Results

arrows to adjust the calibration setting. A higher 1. If approximately 12 VDC was measured field flash
value will create a lower voltage at the breaker. A is passing through the field boost diode. Test is
lower value will create a higher voltage at the good. Go back to flow chart for next test.
breaker.
2. If 0 volts was measured, test is bad, proceed back
11. Once a desired output voltage has been achieved, to the field boost circuit test flow chart.
press ENTER to save the new setting.
NOTE: The Calibration Setting will reset to being a Test FB2 – Test Wire 4A Evolution
password protected option after the controller is left idle.
General Theory
Verification
To verify that the field flash is working properly.
While the unit is running, verify that the output voltage at
the breaker is consistent within 5 volts of the value Procedure
displayed in the controller TEST menu (Evolution) or 1. Set DMM to measure DC voltage.
DEBUG menu (Nexus) under OUTPUTS in the TEST 2. Locate Wire 4A on back of control panel. Leave
section (Refer to Section 1.10 Menu Navigation). harness connector connected to control panel.
3. Insert Red back probe into connector that contains
Results Wire 4A.
1. If during the verification process the output voltage 4. Touch Black probe lead to the battery negative
at the breaker and the display match and the post.
calibration setting was not adjusted outside of the 5. Clear all faults on the control panel and place into
window, stop testing. manual mode.
6. Measure and record field flash voltage
2. If a correct voltage output was not achieved using
the window specified, perform the Field Boost Test NOTE: See Field Boost in Section 2.1 for analysis of
(FBT) and then refer to “Problem 1 – Test 4 Fixed Nexus and Evolution field boost parameters.
Excitation / Rotor Amp Draw Test.” 7. Record measurements.
Results
Field Boost Circuit Tests
1. If approximately 12 VDC (engine battery voltage)
was measured during field flash, the control board
Test FB1 – Test Wire 4 is good. Refer back to the flow chart.
2. If 0 VDC was measured during field flash, refer
General Theory back to the flow chart.
This test is to verify that Wire 4 is receiving field flash
voltage during startup of the generator. Test FB3 – Diode Test Evolution
NOTE: See Field Boost in Section 2.1 for analysis of
General Theory
Nexus and Evolution field boost parameters.
This test is to verify that the field flash diode is working
Procedure properly.
1. Locate Wire 4 on back of control panel. Disconnect
the wire harness connector from the control panel.
Procedure
1. Remove 7.5 amp fuse from control panel.
2. Insert the Red meter lead adapter into the back of
the wire harness on Wire 4 (on Nexus units 2. Set the DMM to the diode check function
(preferred). If the DMM does not have a diode
equipped with the Black AMP style connector, the
check selection, use the resistance or “Ohms”
connector must be disconnected to perform the test). selection.
3. Place Black lead on a good common ground or 3. Locate Wire 4A wire harness connector and
negative post on the engine battery. disconnect from control panel.
4. Clear all faults and place generator in the manual 4. With test probe, insert the Black lead into the back
mode and start engine. of the wire harness on Wire 4A.
5. Measure and record field flash voltage. 5. Locate Wire 4 wire harness connector and
disconnect from control panel.
NOTE: See Field Boost in Section 2.1 for analysis of 6. With test probe, insert the Red lead into the back of
Nexus and Evolution field boost parameters. the wire harness on Wire 4.
7. Record reading.

Diagnostic Repair Manual 39

Section 2.3 Diagnostic Tests

3. Locate Wire 56 at the SCR and disconnect from

the SCR. Also disconnect the controller harness
Table 2-3. Test Results connector containing Wire 56.
Test Point Results 4. Insert Red test lead probe to Wire 56 disconnected
Ohms Test Ohms from the SCR.
Diode Test VDC 5. Locate Wire 4 wire harness connector and
DISCONNECT from the control panel.
NOTE: Leave wire harness/harnesses unplugged. 6. With the test probe insert Black lead into Wire 4
connection of harness connector.
8. Locate Wire 4A.
NOTE: AMP style connectors must probed from the front
9. With test probe, insert the Red lead into the BACK
using the proper adapter. WHITE Molex connectors must
of the wire harness on Wire 4A.
be back probed using the proper probe adapter.
10. Locate Wire 4.
11. With test probe, insert the Black lead into the 7. Record reading.
BACK of the wire harness on Wire 4.
12. Record reading. Table 2-5. Test FB4 Results
Test Point Results
Table 2-4. Test Results Ohms Test Ohms

Test Point Results Diode Test VDC

Ohms Test Ohms

NOTE: Leave wire harness/harnesses unplugged.
Diode Test VDC
8. Locate Wire 56 – SCR connection.
9. With test probe connect Black lead into Wire 56 of
Results SCR connection.
1. If a reading of OL for Diode or OHMS test was 10. Locate Wire 4.
recorded in Step 7 and approximately 0.5 Volts (in
Diode setting) or approximately 2.07M OHMS (in 11. With the test probe insert Red lead into Wire 4
Ohms setting) was recorded in Step 12, the diode connection of harness connector.
is good. Replace 7.5 amp fuse and wire harness/ NOTE: AMP style connectors must be probed from the
harnesses into proper receptacles. Refer back to front using the proper adapter. WHITE Molex connectors
flow chart. must be back probed using the proper probe adapter.
2. If readings of INFINITY (OL) on Step 7 and
12. Record reading.
INFINITY on Step 12, Diode or wire is bad (open),
wire harness/diode needs to be repaired/replaced.
Table 2-6. Test FB4 Results
3. If readings of approximately 0.5 Volts (in Diode
setting) or CONTINUITY (Resistance in “Ohms” Test Point Results
setting) in Step 7 and Step 12, Diode is bad
Ohms Test Ohms
(shorted), diode needs to be repaired/replaced.
Diode Test VDC

Test FB4 - Diode Test Nexus

Results
General Theory 1. If the reading recorded at Step 7 for Ohms is
approximately 1.8M and for the Diode test is 0.5
This test is to verify that the field flash diode is working
VDC, and if the reading recorded at Step 12 for
properly.
Ohms is INFINITY (OL) and Diode test is INFINITY
(OL) the diode and wiring is good. Refer back to
Required Tools the flow chart.
DMM and meter lead adapters P/N 0J09460SRV. 2. If both OHMS and Diode readings of INFINITY
(OL) on Step 7 and INFINITY (OL) on Step 12,
Procedure Diode or wire is bad (open), wire harness/diode
needs to be repaired or replaced.
1. Remove 7.5 amp fuse from control panel.
3. If readings of approximately 0.5 Volts (in Diode
2. Set the DMM to the diode check function setting) or CONTINUITY (Resistance in “Ohms”
(preferred). If the DMM does not have a diode setting) in Step 7 and Step 12, the Diode is bad
check selection, use the resistance or “Ohms” (shorted) and needs to be repaired/replaced.
selection.

40 Diagnostic Repair Manual

 Section 2.3 Diagnostic Tests

Test 4 – Fixed Excitation Test/Rotor

Amp Draw Test
General Theory
003127
Supplying a fixed DC current to the rotor will induce a Figure 2-9. Narrow Test Probe
magnetic field in the rotor. With the generator running,
this should create a proportional voltage output from the
Procedure: Fixed Excitation Test
stator windings. With the use of the MIN/MAX feature of a
Digital Multimeter (DMM), it is possible to capture the IMPORTANT NOTE: DO NOT proceed to Step 1 until the
maximum output of a particular winding before faulting Field Boost Circuit Tests (FBCT) have been performed.
out on under-voltage.
1. Remove the 7.5 amp fuse from the controller.
Under-voltage Alarm – When the controller is set to
2. Locate and disconnect the appropriate harness
MANUAL the following logic is used to trigger an under- connector with Wires 2 and 6 from the controller.
voltage alarm:
IMPORTANT NOTE: During this procedure, DO NOT
• Cranking – If the starter disengages before a
reconnect this connector to the controller!
voltage has developed in the stator the controller
will initiate a shutdown alarm for “under-voltage.” 3. Set DMM to measure AC voltage.
NOTE: For further information about under-voltage 4. Using the scale feature of the DMM, set to the first
shutdowns, refer to the Air-cooled Reference Manual (P/N available scale greater than 100 (i.e. “600”).
10000020935). NOTE: Refer to the manufacturer’s owners manual for
Table 2-7 has been provided to record the results of the specific information on using manual scaling.
following procedure. These results may be required when 5. Set meter to MIN/MAX.
requesting factory support. Additional copies of Table 9
can be found in Appendix C “Supplemental Worksheets” NOTE: Refer to the manufacturer’s owners manual for
at the back of this manual. specific information on using the MIN/MAX feature.

Table 2-7. Test 4 Results

Test Point Results
003138
Wires 2 and 6 Voltage VAC
Figure 2-10.
Wires 11 and 44 Voltage VAC
6. Using approved meter test probes, connect one
Static Rotor Amp Draw Amps
meter test lead to the appropriate harness pin for
Running Rotor Amp Draw Amps Wire 6 and the other meter test lead to the
appropriate harness pin for Wire 2.
Column Identified
7. Install the 7.5 amp fuse.
8. Set the controller to MANUAL.
Required Tools
9. Measure and record the voltage indicated between
• A Digital Multimeter (DMM) equipped with a MIN/ Wires 2 and 6 as indicated by the DMM.
MAX feature
10. Acknowledge and reset the under-voltage alarm
• Meter test leads capable of measuring voltage present on the controller.
inside a connector without damaging the socket. A
11. Set the controller to OFF.
set of Black and Red test leads for this application
are available from the manufacturer. Contact your 12. Re-locate meter test probes to the appropriate
nearest servicing dealer for more information. harness pin for Wire 11 (11S on Evolution) and the
appropriate harness pin for Wire 44 (44S on
NOTE: It is not recommended to use any testing device Evolution).
other than the manufacturer's approved test lead
13. Set the controller to MANUAL.
adapters (P/N 0J09460SRV).
14. Measure and record the voltage indicated between
NOTE: These adapters are to be used on the Nexus Wire 11/11S and 44/44S as indicated by the DMM.
controller with AMP connectors (front socket test points)
15. Acknowledge and reset the under-voltage alarm
and The Nexus/Evolution controllers with white Molex
present on the controller.
connectors (back-probe only).
16. Set the controller to OFF.
Diagnostic Repair Manual 41
Section 2.3 Diagnostic Tests

Procedure: Rotor Amp Draw Results

1. Disengage the MIN/MAX feature and manual scale 1. Using the values recorded in the above procedure,
on the DMM. compare the results to Table 2-9. Determine the
2. Set DMM to measure DC amperage. appropriate lettered column to use and refer back to
the flow chart. The rotor amp draws are a calculated
3. Verify the connector (previously disconnected in
amp draw and actual amperage readings may vary
the Fixed Excitation Test) is disconnected.
depending on the resistance of the rotor.
NOTE: Consult the meters documentation for proper 12.9 VDC/12.3 Ohms = 1.05 DC Amps
setup procedure. See Section 1.4 “Measuring Current”
for further information. Table 2-8. Example
4. Connect the Black (negative) meter test lead to the Model 17 kW
appropriate harness pin for Wire 4 and the Red
(positive) test lead to the positive battery terminal. Wires 2 and 6 Voltage 53 VAC
5. Measure and record the static rotor amp draw. Wires 11 and 44 Voltage 31 VAC
6. Set the controller to MANUAL. Static Rotor Amp Draw 1.09 Amp
7. Measure and record the running rotor amp draw.
Running Rotor Amp Draw 1.10 Amp
8. Acknowledge and reset the under-voltage alarm
present on the controller.
These results match Column B in the chart. Refer back to
9. Set the controller to OFF. Problem 1 and follow letter “B”.

Table 2-9. TEST 4 Results – Fixed Excitation Test/Rotor Amp Draw Test (8-20 kW)

Results: Size A B C D E F G H

Voltage Results Above 50 Above 50 Below 50 Zero or Below 50 Below 50 Above 50 Below 50
ALL
Wire 2 & 6 VAC VAC VAC Residual Volts VAC VAC VAC VAC

Voltage Results Above 50 Below 50 Above 50 Zero or Below 50 Below 50 Above 50 Below 50
ALL
Wire 11 & 44 VAC VAC VAC Residual Volts VAC VAC VAC VAC

8 kW 1.76-2.05 1.76-2.05 1.76-2.05 Above 2.5A 1.76-2.05 1.76-2.05

10 kW 1.76-2.05 1.76-2.05 1.76-2.05 Above 2.5A 1.76-2.05 1.76-2.05
11 kW 1.76-2.05 1.76-2.05 1.76-2.05 Above 2.5A 1.76-2.05 1.76-2.05
12 kW 1.46-1.70 1.46-1.70 1.46-1.70 Above 2.3A 1.46-1.70 1.46-1.70

Static Rotor Amp 14 kW 1.46-1.70 1.46-1.70 1.46-1.70 Zero Current Above 2.3A 1.46-1.70 Zero Current 1.46-1.70
Draw 15 kW 1.33-1.54 1.33-1.54 1.33-1.54 Draw Above 2.3A 1.33-1.54 Draw 1.33-1.54
16 kW 1.33-1.54 1.33-1.54 1.33-1.54 Above 2.3A 1.33-1.54 1.33-1.54
17 kW 1.33-1.54 1.33-1.54 1.33-1.54 Above 2.3A 1.33-1.54 1.33-1.54
20 kW 1.16-1.36 1.16-1.36 1.16-1.36 Above 2.0A 1.16-1.36 1.16-1.36
22 kW 1.00-1.17 1.00-1.17 1.00-1.17 Above 2.0A 1.00-1.17 1.00-1.17
8 kW 1.76-2.05 1.76-2.05 1.76-2.05 Above 2.5A 1.76-2.05
10 kW 1.76-2.05 1.76-2.05 1.76-2.05 Above 2.5A 1.76-2.05
11 kW 1.76-2.05 1.76-2.05 1.76-2.05 Above 2.5A 1.76-2.05
12 kW 1.46-1.70 1.46-1.70 1.46-1.70 Above 2.3A 1.46-1.70

Running Rotor 14 kW 1.46-1.70 1.46-1.70 1.46-1.70 Zero Current Above 2.3A 1.46-1.70 Zero Current
Above 2.5A
Amp Draw 15 kW 1.33-1.54 1.33-1.54 1.33-1.54 Draw Above 2.3A 1.33-1.54 Draw

16 kW 1.33-1.54 1.33-1.54 1.33-1.54 Above 2.3A 1.33-1.54

17 kW 1.33-1.54 1.33-1.54 1.33-1.54 Above 2.3A 1.33-1.54
20 kW 1.16-1.36 1.16-1.36 1.16-1.36 Above 2.0A 1.16-1.36
22 kW 1.00-1.17 1.00-1.17 1.00-1.17 Above 2.0A 1.00-1.17
Note: Actual values measured may vary by as much as 0.5 amps; depending on the type and quality of meter used, the condition of the unit, and
how good the connection is between the test leads and test points.
MATCH RESULTS WITH LETTER AND REFER TO FLOW CHART IN SECTION 2.3 “Problem 1” 

42 Diagnostic Repair Manual

 Section 2.3 Diagnostic Tests

1.09 DC
Amps
Battery
Wire 4 In Appropriate
Wire Harness

12.9 VDC

0 1.09 A 11.83W

Rotor 11.83W OHM’S LAW

Digital Multimeter Positive Battery
Terminal
4 1.09 DC
Amps 12.9 VDC
Field Boost Diode

56/4A 003126
Figure 2-11. Rotor Amp Draw Test
NOTE: To calculate rotor amp draw take the battery voltage applied, divided by the actual resistance reading of the
rotor. Rotor resistance can be measured between Wires 4 and 0 in the appropriate harness.

Test 5 – Test Sensing Circuit Wires NOTE: Stator winding resistance values are very low
11(S) and 44(S) and some meters will not read such a low resistance, and
will simply indicate different ranges of resistance. The
General Theory manufacturer recommends a high quality digital type
meter capable of reading a very low resistance.
The voltage regulator (internal to the controller) requires a
reference voltage in order to regulate at a specific voltage 5. Connect one meter test lead to the appropriate
and to recognize if the alternator is producing voltage. The harness pin for Wire 11 on Nexus, or 11S on
alternator may be producing voltage, but if the voltage Evolution. Connect the other meter test lead to the
regulator cannot sense the voltage, it will fault out for under- NEUTRAL connection. Measure and record the
voltage. This test will verify the integrity of the sensing resistance.
circuit. 6. Connect one meter test lead to the appropriate
harness pin for Wire 44 on Nexus or 44S on
Required Tools Evolution. Connect the other meter test lead to the
• Meter test leads capable of measuring voltage NEUTRAL connection. Measure and record the
inside a connector without damaging the socket. A resistance.
set of Black and Red test leads for this application a. If the meter indicated a resistance value of less
are available from the manufacturer. Contact your than 0.2 ohms in Steps 5 and 6, stop testing
nearest servicing dealer for more information. See and refer back to the flow chart (Good).
Figure 2-9. b. If the meter indicated OPEN in Steps 5 or 6,
NOTE: It is not recommended to use any testing device proceed to Step 7.
other than the manufacturer's approved test lead adapters. 7. See Figure 2-12. Disconnect the lower bulkhead
C1 connector (if unit is equipped.)
Procedure 8. Connect one meter test lead to C1 (if unit is
1. Remove the 7.5 amp fuse from the control panel. equipped) to the appropriate harness pin with Wire
2. Remove the controller and the cover to expose the 11. Connect the other meter test lead to the
NEUTRAL connection, measure and record the
lower harness connections.
resistance.
3. Disconnect the appropriate harness connector
9. Connect one meter test lead to C1 (if unit is
from the controller.
equipped) to the appropriate harness pin for Wire 44.
4. Set the DMM to measure resistance. Connect the other meter test lead to the NEUTRAL
connection. Measure and record the resistance.

Diagnostic Repair Manual 43

Section 2.3 Diagnostic Tests

Procedure
1. Remove the 7.5 amp fuse from the control panel.
2. Expose the controller lower harness connections
by removing the controller mounting hardware.
3. Disconnect the harness connector containing
Wires 2 and 6 from the controller.
4. Set the DMM to measure resistance.
5. Connect one meter test lead to the harness pin for
Wire 2 and the other meter test lead to the harness
pin for Wire 6. Measure and record the resistance.
a. If the meter indicated a resistance value
Figure 2-12. C1 Connector (if unit is equipped) consistent with the values found in Section 1.1
Specifications, stop testing and refer back to
Results the flow chart (Good).
1. If the meter indicated a resistance value of less b. If the meter indicated an OPEN, proceed to
than 0.2 ohms in Steps 5 through 9, refer back to Step 6.
flow chart (Good).
6. See Figure 2-13 and Figure 2-14. Disconnect the
2. If the meter indicated a resistance value of OPEN lower bulkhead C1 connector (if unit is equipped).
in Step 5 and a value less than 0.2 ohms in Step 8, On Evolution units locate the STR connector and
repair or replace Wire 11 between the controller disconnect.
and the C1 connector (if unit is equipped). 7. On the harness connector (disconnected in Step 6)
3. If the meter indicated a resistance value of OPEN that leads to the stator, connect one meter test lead
in Step 6 and a value less than 0.2 ohms in Step 9, to Wire 2 and the other meter test lead to Wire 6.
repair or replace Wire 44 between the controller Measure and record the resistance.
and the C1 connector (if unit is equipped, see
Figure 2-12). Results
4. If the meter indicated OPEN in either Step 8 or Step 1. If the meter indicated a resistance value consistent
9, proceed to Test 7 – Test the Stator with a with the values found in the table in the front of the
DMM. manual, stop testing and refer back to the flow
chart (Good).
Test 6 – Test Excitation Winding 2. If the meter indicated a resistance value of OPEN
Circuit 2 and 6 in Step 5, but a resistance value consistent with the
values found in the table in the front of the manual
General Theory in Step 7, repair or replace Wire 2 and/or 6
between the controller and the connector (C1
The voltage regulator (internal to the controller) requires
Connector on Nexus, STR Connector on
unregulated voltage from the stator in order to supply
Evolution). Measure Ohms between Wire 2 and 2,
excitation power to the regulator. The regulator supplies
or Wire 6 and 6 to confirm which wire is open.
DC field excitation current to the rotor. The alternator may
be producing this voltage, but if the voltage is not being 3. If the meter indicated a resistance value of OPEN
supplied to the regulator, it will fault out for under-voltage. or a resistance value inconsistent with the values
This test will verify the integrity of the Excitation (DPE) found in the table in the front of the manual in Step
winding inside the stator and connections to the voltage 5 and Step 7, replace the stator.
regulator.
Test 7 – Test the Stator with a DMM
Required Tools
• Meter test leads capable of measuring voltage General Theory
inside a connector without damaging the socket. A This test will use a digital multimeter (DMM) to test the
set of Black and Red test leads for this application stator windings for the following faults:
are available from the manufacturer. Contact your
• An OPEN circuit condition
nearest servicing dealer for more information. See
Figure 2-9. • A “short-to-ground” condition
• A short circuit between windings
NOTE: It is not recommended to use any testing device
other than the manufacturer's approved test lead adapters. Table 2-13 has been provided to record the results of the
following procedure. These results may be required when
requesting factory support.

44 Diagnostic Repair Manual

 Section 2.3 Diagnostic Tests

NOTE: It is the recommendation of the factory to perform CONFIGURATION A

this test procedure using piercing probes on the wire side C1
PIN #
of the connector. Testing inside the connector itself can
44 1 44
cause unnecessary damage to the unit resulting in poor 11 2 11
or loose connections.
6 3 6
2 4 2
Procedure: Resistance Test 22
33 4 5 4
CLOSEST TO
1. Disconnect Wires 11 and 44 from the main line BEARING STATOR 0 6 0
44
circuit breaker (MLCB). BA
11
4
2. Disconnect Wires 22 and 33 from the NEUTRAL 0 CONFIGURATION B
44
connection and separate the leads. 11 C1
2 6 44 PIN #
3. Disconnect the stator connector or proper 11 44 1 44
controller connector on the harness (C1 Connector 6
11 2 11
on Nexus, STR Connector on Evolution). 2 6 3 6
2 4 2
NOTE: The C1 connector is not installed on all 4
0 5
generators. Do alternative testing on wire harness using
TO C1 SEE TABLE FOR PINOUT 6
specific wire numbers.
4 4
4. Make sure all of the disconnected leads are
0 0
isolated from each other and are not touching the
003149
frame during the test. Figure 2-15. Stator Lead Connections
5. Set the DMM to measure resistance.
6. Measure and record the resistance values for each Test Windings for a Short to Ground
set of windings between the A and B test points as 7. Make sure all stator leads are isolated from each
shown in Table 2-10. Record the results in other and are not touching the frame.
Table 2-13. 8. Measure and record the resistance values for each
set of windings between the A and B test points as
Table 2-10. Resistance Test Points shown in Table 2-11. Record the results in
Table 2-13.
Test Point A Test Point B
Stator Lead Wire 11 Stator Lead 22
Table 2-11. Short to Ground Test Points
Stator Lead Wire 33 Stator Lead 44
C1 Pin 2 Wire 11(S) Stator Lead 22
Test Point A Test Point B
C1 Pin 1 Wire 44(S) Stator Lead 33 Stator Lead Wire 11 Ground

C1 Pin 3 Wire 6 C1 Pin 4 Wire 2 Stator Lead Wire 44 Ground

C1 Pin 1 Wire 44 Ground
STR C1 Pin 2 Wire 11 Ground

44S C1 Pin 4 Wire 2 Ground

4 4
2 3 3
11S 2 2 Test For A Short Circuit Between Windings
6 1 1
9. Measure and record the resistance values for each
003147
set of windings between the A and B test points as
Figure 2-13. Stator Connector (STR) Pin Locations
shown in Table 2-12. Record the results in
(if unit is equipped)
Table 2-13.

Table 2-12. Short Between Windings Test Points

3 2 1 Test Point A Test Point B

C1 Pin 4 Wire 2 C1 Pin 2 Wire 11
C1 Pin 4 Wire 2 C1 Pin 1 Wire 44
6 5 4 C1 Pin 4 Wire 2 Stator Lead Wire 11
003148 C1 Pin 4 Wire 2 Stator Lead Wire 44
Figure 2-14. C1 Bulkhead Connector Pin Locations
(if unit is equipped) Stator Lead Wire 11 C1 Pin 1 Wire 44
Stator Lead Wire 11 Stator Lead Wire 44

Diagnostic Repair Manual 45

Section 2.3 Diagnostic Tests

Results Test 8 – Resistance Check of Rotor

1. Resistance Test: If the DMM indicated a very high Circuit
resistance or INFINITY, the windings are open or
partially open. General Theory
2. Grounded Condition: Any resistance value other During the rotor amp draw test in Test 4, if the amp draw
than INFINITY indicates a grounded winding. was zero, then an OPEN circuit should be present on
3. Shorted Condition: Any resistance value other Wires 4 and 0. This test will verify if the readings were
than INFINITY indicates a shorted winding. accurate and verify the field boost circuit.
• Identify C1 Connector (if unit is equipped) wiring
Table 2-13. Test 7 Stator Results configuration. Refer to Figure 2-12.
Test Point A Test Point B Results • Configuration A: follow Steps 1-11
• Configuration B: follow Steps 1-6
Resistance Tests
NOTE: if the unit does not have a C1 connector refer to
Stator Lead Wire 11 Stator Lead 22
the appropriate pin at the controller connector.
Stator Lead Wire 33 Stator Lead 44
Procedure
C1 Pin 2 Wire 11 Stator Lead 22
NOTE: For Evolution units perform Steps 1 - 6a.
C1 Pin 1 Wire 44 Stator Lead 33
1. Remove the 7.5 amp fuse from the control panel.
C1 Pin 3 Wire 6 C1 Pin 4 Wire 2
2. Remove the cover and controller to expose the
Shorts to Ground lower harness connections.
3. Disconnect the harness connector from the
Stator Lead Wire 11 Ground
controller
Stator Lead Wire 44 Ground 4. Set the DMM to measure resistance.

C1 Pin 1 Wire 44 Ground 5. Connect one meter test lead to the appropriate
harness pin for Wire 4 and connect the other meter
C1 Pin 2 Wire 11 Ground test lead to the appropriate harness pin for Wire 0.
Measure and record the resistance.
C1 Pin 4 Wire 2 Ground
6. Connect one meter test lead to the appropriate
Shorted Condition harness pin for Wire 4 and connect the other meter
test lead to a ground connection. Measure and
C1 Pin 4 Wire 2 C1 Pin 2 Wire 11
record the resistance.
C1 Pin 4 Wire 2 C1 Pin 1 Wire 44 a. If the meter indicated the correct rotor
resistance values as stated in the front of the
C1 Pin 4 Wire 2 Stator Lead Wire 11
manual, proceed to Step 9.
C1 Pin 4 Wire 2 Stator Lead Wire 44 b. If the meter indicated INFINITY, proceed to
Step 7.
Stator Lead Wire 11 C1 Pin 1 Wire 44
7. If testing C1 Configuration A (if unit is equipped),
Stator Lead Wire 11 Stator Lead Wire 44 locate and disconnect the bulkhead C1 connector.
If testing C1 Configuration B (if unit is equipped),
stop test and refer to Test 8 Results.
NOTE: Read Section 1.2, Testing, Cleaning and
Drying carefully. If the winding tests good, perform the 8. Connect one meter test lead to C1 (if unit is
insulation resistance test. If the winding fails the equipped) to the appropriate harness pin for Wire 4
and connect the other meter test lead to C1 (if unit
insulation resistance test (using a Megohmmeter), clean
is equipped) to the appropriate harness pin for
and dry the stator as outlined in Section 1.2 Testing,
Wire 0. Measure and record the resistance. If the
Cleaning and Drying. Then, repeat the insulation meter indicated INFINITY, stop testing and refer
resistance test. If the winding fails the second resistance back to flow chart (Rotor Circuit Failure).
test (after cleaning and drying), replace the stator
9. Locate the starter contactor relay (SCR) and
assembly. disconnect Wire 56 (blue wire).
NOTE: These results may be needed when requesting 10. Disconnect the harness connector from the
factory support. controller.
NOTE: Stator winding resistance values are very low. 11. Connect one meter test lead to the disconnected
Some meters will not read such a low resistance, and will Wire 56 and connect the other meter test lead to
the appropriate harness pin for Wire 4. Measure
simply indicate CONTINUITY. The manufacturer
and record the resistance.
recommends a high quality digital type meter capable of
reading a very low resistance.
46 Diagnostic Repair Manual
 Section 2.3 Diagnostic Tests

Results an OPEN condition, remove Wire 0 from the brush

assembly.
Refer to the front of this manual for correct Rotor
6. For C1 Configuration A (if unit is equipped)
resistance values.
disconnect the bulkhead connector C1 inside the
1. If the DMM indicated the correct resistance values control panel. For C1 Configuration B (if unit is
in Steps 5, 6, 8, and 11, refer back to flowchart equipped) disconnect the harness connector from the
(Good). controller and isolate Wire 0 from the ground stud.
2. If the DMM indicated INFINITY in Step 8, refer 7. Set the DMM to measure resistance.
back to flowchart (Rotor Circuit Failure).
8. For C1 Configuration A (if unit is equipped) connect
3. If the DMM indicated the correct resistance in Step
one meter test lead to Wire 0 at the brush
8 and indicated INFINITY in Step 5, repair or
assembly and connect the other meter test lead to
replace Wires 4 and 0 between the C1 (if unit is
C1 Pin 6. For C1 Configuration B (if unit is
equipped) and the J5 connector.
equipped) connect one meter test lead to Wire 0 at
4. If the DMM indicated the correct resistance in Step the brush assembly and connect the other meter
8 and indicated INFINITY in Step 5, but indicated test lead to the Wire 0 disconnected in Step 6.
the correct resistance in Step 6, repair or replace
Wire 0 between the J5 connector and the ground • If the DMM indicated INFINITY, repair or replace
connection. Wire 0 between the negative slip ring and C1 (if
unit is equipped) Pin 6 (Configuration A) or the
5. If the DMM indicated the correct resistance in Step
ground stud (Configuration B).
5 and indicated INFINITY in Step 11, replace the
harness (Field Boost Circuit Failure). • If the DMM indicated CONTINUITY, continue to Step
9.
Test 9 – Check Brushes and Slip Rings 9. Wire 4, located on the positive brush terminal,
provides an electrical connection for excitation
General Theory current to flow between the rotor and the voltage
regulator. To test this wire for an OPEN condition,
The brushes and slip rings function to provide an
remove Wire 0 from the brush assembly.
electrical connection for excitation current from the
stationary components to the rotating rotor. Made of a 10. For C1 Configuration A (if unit is equipped) connect
special long lasting material, brushes seldom wear out or one meter test lead to Wire 4 at the brush
fail. However, slip rings can develop a tarnish or film that assembly and connect the other meter test lead C1
can inhibit or offer resistance to the flow of current. Such (if unit is equipped) Pin 5. For C1 Configuration B
a non-conducting film usually develops during non- (if unit is equipped) connect one meter test lead to
operating periods. Broken or disconnected wiring can Wire 4 a the brush assembly and connect the other
also cause loss of excitation current to the rotor. meter test lead to appropriate controller connector.
Refer to Figure 2-12 to identify the C1 Connector (if unit • If the DMM indicated INFINITY, repair or replace
is equipped) wiring configuration of the unit being tested. Wire 4 between the positive slip ring and C1 (if unit
Follow steps for Configuration A or Configuration B is equipped) Pin 6 (Configuration A) or the
accordingly. appropriate controller connector (Configuration B).
• If the DMM indicated CONTINUITY, continue to Step
Procedure 11.
1. Disassemble the generator until the brushes and 11. Connect one meter test lead to Wire 4 at the brush
slip rings are exposed. Refer to Section 6.1 “Major assembly and connect the other meter test lead to
Disassembly.” frame ground.
2. Inspect the brush wires and verify they are secured • If the DMM indicated CONTINUITY, repair or
and properly connected. replace Wire 4 between the positive slip ring and
3. Inspect the brush assembly for excessive wear, or C1 Pin 6 (Configuration A) or Pin 13 (Configuration
damage. B).
4. Inspect the rotor slip rings. If their appearance is • If the DMM indicated INFINITY, continue to Step
dull or tarnished, polish with a fine grade abrasive 12.
material.
12. Connect one meter test lead to Wire 0 at the brush
IMPORTANT NOTE: Do not use metallic grit to polish assembly and connect the other meter test lead to
slip rings. This may cause irreversible damage to the rotor. a ground connection.
5. Wire 0, located on the negative brush terminal, • If the DMM indicated INFINITY, repair or replace
provides an electrical connection to ground for the Wire 0 between the positive slip ring and the
rotor and the voltage regulator. To test this wire for control panel ground connection.

Diagnostic Repair Manual 47

Section 2.3 Diagnostic Tests

• If the DMM indicated CONTINUITY, refer back to Terminals of the generator main line circuit breaker
flow chart. (MLCB).
2. Set the controller to MANUAL.
Results 3. Let engine stabilize. Measure and record the
1. Repair, replace, or reconnect wires as necessary. frequency.
2. Replace any damaged slip rings or brush holder. Results
3. Clean and polish slip rings as required.
1. If the meter indicated 59-61 Hertz, refer back to
flow chart.
Test 10 – Test Rotor Assembly 2. If the meter indicated a value outside the accepted
range, refer back to flow chart.
General Theory
A rotor having open windings will cause loss of excitation Test 12 – Check Stepper Motor Control
current flow and as a result generator AC output voltage
will drop to “residual” voltage. A “shorted” rotor winding Procedure: V-Twin and Single Cylinder
can result in a low voltage condition.
NOTE: For Nexus units follow only Steps 1-3 and 7-10.
Procedure 1. Remove air cleaner cover to access stepper motor
1. Remove the brush assembly from the slip rings to and/or visually see throttle plates.
prevent interaction. 2. Physically move the throttle and verify the stepper
2. Set a DMM to measure resistance. motor, linkage and throttle do not bind in any way. If
any binding is felt repair or replace components as
3. Connect one meter test lead to the positive slip ring
needed. The stepper motor will have resistance as
(nearest the rotor bearing) and the common test
it moves through its travel.
lead to the negative slip ring, measure and record
the resistance. 3. Physically and visually move the throttle to the
closed position by pulling the Stepper motor arm
4. Connect one meter test lead to the positive slip ring
towards the idle stop. See Figure 2-16, Figure 2-
and connect the other meter test lead to a ground
17, Figure 2-18, and Figure 2-19 for Evolution
connection. Measure and record the resistance.
units. See Figure 2-20, Figure 2-21, and Figure 2-
22 for Nexus units.
Results
4. Set the controller to MANUAL.
1. Compare the resistance measured in Step 3 with
Section 1.1 Specifications. Replace rotor as 5. Observe and record the stepper motor movement.
required. a. On Nexus units, it should open.
2. If the DMM indicated CONTINUITY in Step 4, b. On Evolution units the stepper motor will cycle
replace the rotor assembly. the mixer to a full open throttle position (which
opens both venturis), back to a closed position
and then to the starting position, which is a
Test 11 – Check AC Output Frequency slight opening of the throttle in the small venturi.
General Theory 6. Set the controller to OFF.
7. Physically move the throttle to the open position by
Generator AC frequency is proportional to the operating
pulling the stepper motor arm away from the idle stop.
speed of the rotor. The 2-pole rotor will supply a 60 Hertz
AC frequency at 3600 rpm. 8. Set the controller to MANUAL.
9. Observe and record the stepper motor movement.
NOTE: Engine Speed is in direct correlation to frequency
(Hertz). The controller monitors Wire 18 to maintain 10. Set the controller to OFF.
proper frequency. 11. If no movement was seen in Steps 5 or 9 remove
the controller and verify the six pin connector on
Tools Required the controller is seated properly. Remove the
• A meter that is capable of measuring AC connector and then connect it and test again. If
frequency. problems persist, proceed to Step 12.

Procedure
1. See Figure 2-8. Connect an accurate AC
frequency meter across the Wires 11 and 44

48 Diagnostic Repair Manual

 Section 2.3 Diagnostic Tests

Figure 2-16. Evolution Stepper Motor Starting Figure 2-19. Evolution Stepper Motor Mid-point =
Position and/or Mid-point Starting Point, Smaller Venturi Partially Open

NOTE: In Figure 2-20, Figure 2-21, and Figure 2-22 the

white arrow indicates the direction to pull the arm to close
the throttle.

Figure 2-17. Evolution Stepper Motor Wide Open =

Opens Both Venturis

Figure 2-20. Throttle Positions Nexus 8 kW Units

0

Figure 2-18. Evolution Stepper Motor Closed –

Closes Both Venturis

Figure 2-21. Throttle Positions Nexus 9/10 kW Units

Diagnostic Repair Manual 49

Section 2.3 Diagnostic Tests

excessively when electrical loads are applied. This

condition, in which voltage and frequency drop
excessively when loads are applied can be caused by (a)
overloading the generator, (b) loss of engine power or
performance, or (c) a shorted condition in the stator
windings or in one or more connected loads.

Procedure
1. Set a DMM to measure AC voltage.
2. Connect an accurate AC frequency meter and an
AC voltmeter across the stator AC power winding
leads.
3. Start the engine. Let it stabilize and warm-up.
4. Apply electrical loads to the generator equal to the
rated capacity of the unit. Measure and record the
frequency and the voltage.

Figure 2-22. Throttle Positions Nexus 12-20 kW Units Results

1. If the DMM indicated 60 Hz and approximately 248
12. Set the DMM to measure resistance.
VAC during full load, discontinue testing.
NOTE: Press down with the meter leads on the exposed 2. If the DMM indicated a frequency and voltage that
terminals of the connector. Do not probe into the dropped while under full load, refer back to flow chart.
connector.
13. Connect the meter test leads across points A and Test 15 – Check for an Overload
B as shown in Table 2-14 and compare to the Condition
specified value.
General Theory
Table 2-14. Stepper Motor Testing
An “overload” condition exists when the generator rated
Test Point A Test Point B Resistance Value wattage/amperage capacity has been exceeded. To test
Red wire Orange wire approx. 10-11Ω for an overload condition on an installed unit, the
Red wire Yellow wire approx. 10-11Ω recommended method is to use an ammeter. Refer to the
Air-cooled Reference Manual (P/N 10000020935).
Red wire Brown wire approx. 10-11Ω
Red wire Black wire approx. 10-11Ω Procedure
Red wire Ground INFINITY 1. Connect the clamp-on ammeter to the generator
according to the ammeter manufacturer’s
Results specifications.
1. If the stepper motor moved to the wide-open 2. Transfer all normal electrical loads to the
position in Step 5, and to the closed position in generator. Measure and record the amperage.
Step 9, and the DMM indicated appropriate
resistance values, refer back to flow chart. Results
2. If the stepper motor failed to change the throttle 1. If the ammeter indicated amperage readings that
position in Steps 5 or 9, replace stepper motor. were above the unit’s specified ratings, reduce
3. If the stepper motor moved to the wide-open loads to the rated capacity of the unit.
position in Step 5, and to the closed position in 2. If the ammeter indicated amperage readings that
Step 9, and the DMM indicated inappropriate were below the unit’s specified ratings, but rpm and
resistance values, replace Stepper motor. frequency dropped excessively refer back to
flowchart.
Test 14 – Check Voltage and
Frequency Under Load Test 16 – Check Engine Condition
General Theory General Theory
It is possible for generator AC output frequency and If engine speed and frequency drop excessively under
voltage to be good at no-load, but they may drop load, the engine may be underpowered. An

50 Diagnostic Repair Manual

 Section 2.3 Diagnostic Tests

underpowered engine can be the result of a dirty air generator and load bank to cool before shutting
cleaner, loss of engine compression, faulty fuel settings, down.
or incorrect ignition timing, etc. A decrease in available
horsepower will proportionally lead to a decrease in kW. Results

Procedure With loads applied, CT1 - Wires 398A/399A and CT2 -

Wires 398B/399B deliver approximately 0 to 1.5 VAC
For engine testing, troubleshooting, and repair based on percentage of Amps (load). Approximate
procedures refer to Section 4.6 Diagnostic Tests. For Values (when back-probed at connector):
further engine repair information, refer to the appropriate
engine service manual. 25 Amps = 0.380 mVAC

50 Amps = 0.755 mVAC

Test 17 – Current Calibration
75 Amps = 1.133 VAC
General Theory
100 Amps = 1.510 VAC
An Evolution unit monitors load (current) through two
Current Transformers (CT) mounted in the AC
connection box area. The CTs provide an AC output DANGER
signal proportional to the current flowing in the load leads
Electrocution. Lethal voltage may be present
11 and 44.
at current transformers (CTs). Do not touch
CT1 and CT2 have identical functions, diagnostic CTs while primary current is applied. Doing so
procedures and calibration process. CT1 wire circuits will result in death or serious injury. (000310)
398A and 399A monitor the current flow on Wire 11. CT2
wire circuits 398B and 399B monitor the current flow on
Wire 44. The CTs are calibrated using the Evolution
control panel. A password is required to access the
Dealer Edit menu when performing calibrations.
NOTE: Verify Wires 11 and 44 are fed through the side of
the CT with the green dot.

Procedure
1. Connect a load bank to the output circuit of the
generator. This should be done at the generator's
MLCB.
2. Place the Amp meter over the circuit being
checked. CT1 “Current Calibration1” – Wire 11 and
CT2 “Current Calibration2” – Wire 44.
3. Start the generator and allow it to warm up for 10
seconds.
4. Place a load on the generator that matches the
rated output of the generator.
5. Select the correct Current Calibration display menu
under the Dealer Edit menu.
6. Press ENTER to view generator output and the
calibration value of that CT.
7. Adjust up or down the generator display to match
the Amp meter’s calibrated reading. (Use the
controllers UP and DOWN arrows to make
adjustments)
8. Once the display panel reading matches the amp
meter, press the ENTER button to save the new
calibration. Repeat the process for CT2 Current
Calibrations.
9. When both calibration adjustments are correct,
remove the load from the generator and allow the

Diagnostic Repair Manual 51

Section 2.3 Diagnostic Tests

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52 Diagnostic Repair Manual

 Section 3.1 Description and Major Components
Introduction
STANDBY UTILITY
The “V-Type” Contactor is available in 100 through 200
Amp ratings at 250 volts maximum with a 2-pole
configuration (single phase only).
Automatic transfer operation of the transfer switch is
controlled by the generator. LOAD

Enclosure 002489

The transfer switch enclosure is either a National Figure 3-2. Load Connected to Standby Power Source
Electrical Manufacturer’s Association (NEMA) Type 1 or
a Type 3R. Based on NEMA Standard 250, the following Utility Closing Coil C1
standard applies: See Figure 3-3. The utility closing coil (C1) utilizes
NEMA 1 – Enclosures constructed for indoor use to rectified Utility source power to actuate the LOAD
provide a degree of protection against incidental contact contacts to the UTILITY position. When energized, the
with the enclosed equipment and to provide a degree of coil will move the LOAD contacts to an “over center”
protection against falling dirt. position. The coil and the spring force will complete the
Type 3R Enclosures constructed for either indoor or transfer to UTILITY. A bridge rectifier, which changes the
outdoor use to provide a degree of protection to Utility source alternating current (AC) to direct current
personnel against access to hazardous parts; to provide (DC), is sealed in the coil wrappings. If either coil or
a degree of protection of the equipment inside the bridge rectifier replacement becomes necessary, replace
enclosure against ingress of solid foreign objects (falling the coil assembly.
dirt); to provide a degree of protection with respect to
harmful effects on the equipment due to the ingress of
water (rain, sleet, snow); and that will be undamaged by
the external formation of ice on the enclosure. A

B
Transfer Switch Contactor
The basic 2-pole CONTACTOR consists of a pair of C
movable LOAD contacts, a pair of stationary UTILITY
contacts, and a pair of stationary STANDBY contacts.
The LOAD contacts connect to the UTILITY contacts by a D
utility closing coil or to the STANDBY contacts using the
standby closing coil. See Figure 3-1 and Figure 3-2. The E
LOAD contacts can be moved to either the UTILITY or
STANDBY position by means of a manual transfer
F
handle. The closing coils are energized and actuated by
the voltage source from the side to which the load is
being transferred. For example, if the CONTACTOR is in 002490
the UTILITY position, the standby closing coil will A. Utility Closing Coil C1 C. Limit Switch SW3
energize utilizing Standby voltage. B. Bridge Rectifier E. Bridge Rectifier
C. Limit Switch SW2 F. Standby Closing Coil C2
STANDBY UTILITY Figure 3-3. The “V-Type” Transfer Mechanism

Standby Closing Coil C2

The standby closing coil (C2) utilizes rectified Standby
source power to actuate the LOAD contacts to their
LOAD STANDBY position. Energizing the coil moves the LOAD
contacts to an “over center” position. The coil and the
002488
spring force will complete the transfer to STANDBY. If
Figure 3-1. Load Connected to Utility Power Source either the coil or the bridge rectifier replacement
becomes necessary replace the coil assembly.

Diagnostic Repair Manual 53

Section 3.1 Description and Major Components

Limit Switches SW2 and SW3

194
The LOAD contacts mechanically actuate the limit 8
switches. When the LOAD contacts connect to the
UTILITY contacts, the limit switch (SW2) opens the Utility
circuit to C1 and the limit switch (SW3) closes the 7
Standby circuit to standby closing coil (C2). The limit 23
switches “arm” the system for transfer back to the
opposite source. An open condition in SW2 will prevent 1 5
126 N1A
re-transfer to UTILITY. An open condition in SW3 will
prevent transfer to the STANDBY. 205 E2A
6 4

Transfer Relay 002491

Figure 3-4 shows the transfer relay electrical schematic. Figure 3-4. Typical Transfer Relay Schematic
Transfer relay operation is controlled by the generator
controller. The transfer relay operates as follows: 5. When the controller senses that utility source
1. Generator battery voltage (12 VDC) is available to voltage has been restored (nominal for 15
the transfer relay coil from the Evolution controller, seconds), the Wire 23 circuit will open from ground.
via Wire 194 to the relay. a. The transfer relay will de-energize, the
a. The 12 VDC circuit is completed through the normally closed contacts will close and the
transfer relay coil and back to the controller via normally open contacts will open.
Wire 23. b. When the normally closed relay contacts close,
b. Controller logic holds the Wire 23 circuit open utility source voltage is delivered to the utility
to ground (Normally Open circuit) and the relay closing coil to energize that coil.
is de-energized. c. Transfer back to UTILITY occurs.
c. When de-energized, the relay contacts are in
their normal condition (one set open, N.O.; and Neutral Lug
one set closed, N.C.)
The generator is equipped with an ungrounded neutral.
d. The normally closed relay contacts deliver The neutral lug in the transfer switch is isolated from the
utility source power to the utility closing circuit switch enclosure.
of the transfer switch.
e. The normally open relay contacts will deliver Manual Transfer Handle
standby source power to the transfer switch
standby closing circuit only when the transfer The manual transfer handle is retained in the transfer
relay is energized by the control panel. switch enclosure on a u-shaped bracket. Use the handle
to manually move the contactor to the UTILITY or
2. During automatic system operation, when the
“STANDBY position.
generator controller senses that Utility source
voltage has dropped out, the controller will initiate a
ten second “Line Interrupt Delay” timer. At the end Customer Connections
of the factory default ten second delay the See Figure 3-6. During system installation, the control
controller will crank and start the engine. wires must be properly landed between the generator
3. When the circuit board senses that the engine has and transfer switch.
started (via Wire 18 from the magneto circuit), the
controller will initiate a ten second “Engine Warm- Utility N1 and N2
up Timer.”
N1 and N2 provide the utility voltage-sensing signal to
4. When the “engine warm-up timer” has timed out, the controller. The controller utilizes the sensing circuit as
controller logic closes the Wire 23 circuit to ground. follows:
a. The transfer relay energizes. If utility source voltage drops below the set nominal value
b. The relay’s normally closed contacts open and for ten seconds (default), controller logic will initiate
the normally open contacts close. automatic cranking and startup. The controller will
c. When the normally open contacts close, transfer the switch to the STANDBY position after a five
standby source power is delivered to the second engine warm-up timer.
standby closing coil and transfer to STANDBY
occurs.

54 Diagnostic Repair Manual

 Section 3.1 Description and Major Components

Load T1
Wire T1, connected to the Load side of the contactor,
provides 120 VAC for the battery charging circuit (the
battery charger is an integral component of the
controller). The charger maintains battery voltage
anytime the load terminals have voltage available.

Control 194, 23
Wires 194 and 23 provide control of the transfer relay by
the controller. Wire 194 provides continuous DC voltage
to the transfer switch. Wire 23 is held open from ground
by controller logic until a utility failure is sensed.

Fuse Holder
The fuse holder holds three fuses, designated as fuses
F1, F2, and F3.

002509

Figure 3-5. Fuse Holder

Fuses F1, F2
These two fuses protects the N1 and N2 circuit against
overload.

Fuse F3
This T1 fuse protects the battery charger against
overload.

Fuse F4
This T2 fuse protects the battery charger against
overload (50 Hz only).

Diagnostic Repair Manual 55

56
OPTIONAL
(ALARM CONTACT)
CUSTOMER SUPPLIED SERVICE DISCONNECT ATS (RTSY - 2013 MODEL)
GENERATOR OUTPUT GROUND CONNECTION

WH
GRN

T
CIRCUIT BREAKER

UT
2 POLE

GN

NE
D
E1
E2
PANELBOARD
N1 N2
A BONDING JUMPER IS
PROVIDED BETWEEN
THE NEUTRAL LUG
AND ENCLOSURE
AT THIS LOCATION
N1 N2 T1
(FACTORY INSTALLED)
209 210 0 194 23

LOAD SHED
DEVICE
N1
GROUND BAR DISCONNECT N2
BONDING T1
BREAKER CONNECTION
Section 3.1 Description and Major Components

TO SUPPLY NEUTRAL BAR IN PANELBOARD

GFCI OUTLET UTILITY
(C1 & VR1)
(IF FITTED)
C

STANDBY
(C2 & VR2)
GROUND LUG
(LOCATED ON THE
REAR OF UNIT)
0

E1 T1 T2 E2
23
194

UTILITY
METER
SOCKET

TO GROUNDING
ELECTRODE

Figure 3-6. A Typical Interconnection Drawing

NOTE: INSTALLATION MUST MEET
ALL NATIONAL, STATE AND
LOCAL ELECTRICAL CODES.

002492

Diagnostic Repair Manual

 Section 3.1 Description and Major Components

Load Shed Module and Operation Load Shed Operation

OPCB LSM 120 Volt Only NOTE: The following sequence is for the LSM 120 volt
The Load Shed Module is designed to prevent an module ONLY.
overload on the generator when it is supplying customer The 4 green status LEDs will indicate when a load priority
loads. Up to six loads can be managed by the load shed level is enabled or disabled.
module; 2 air conditioner loads and 4 additional loads. All loads are enabled when the transfer signal is off. (ATS
The load shed module manages the loads by “shedding” in Utility position).
the connected loads in the event of a drop in generator If the transfer signal is pulled low (Active) all loads are
frequency (overload). Loads to be “shed” are grouped in enabled until an overload is detected.
4 priority levels on the load shed module.
When an overload is detected all loads are disabled.
Priority 1 and 2 each have connections for one air
conditioner and one contactor. Both an air conditioner A generator overload condition is determined by generator
and a contactor can be used at the same time if desired. frequency. Loads are shed when the frequency is <58 Hz
To control an air conditioner, no additional equipment is for 3 seconds or <50 Hz for ½ Second (For 60Hz).
required. Internal relays interrupt the thermostat 24 VAC • Priority 1 loads are enabled after 5 minutes.
control signal to disable the air conditioner load. • Priority 2 loads are enabled after 30 seconds.
Priority 3 and 4 have connections for one contactor only. • Priority 3 load is enabled after another 30 seconds.
Four LEDs located on the load shed module will indicate • Priority 4 load is enabled after another 30 seconds.
when a load priority level is enabled or disabled.
If an overload is detected within 30 seconds of a level
Any load, including a central air conditioner, can be
being enabled, all loads are disabled again and the
controlled via a contactor that must be purchased
sequence repeats. However, the level that caused the
separately. Up to four contactors can be controlled by the
overload and all levels higher will not be enabled again for
load shed module.
30 minutes. This process of testing will continue every 30
The LSM (120 volt only) supplies the 120 VAC to minutes. The faulting priority and all other higher levels
energize each contactor coil. will remain locked out until the overload for that priority is
Wire 194 from the HSB controller supplies 12 VDC to the lowered, or system is returned to utility, or reset button is
module. Wire 0 provides the ground for the logic side of pressed.
the module. Wire 23 is monitored by the module to Figures 3-8 through 3-17 follow the sequence of
identify when transfer to standby and back to utility has operation when an overload condition occurs on Priority
occurred. T1 and Neutral are used to monitor the Circuit 3. After a 30 minute timer expires, Priority 3 is
frequency of the generator for load control. activated. If the frequency is still OK, Priority 4 is enabled
Test Button after another 30 second timer expires.

The load shed modules and the OPCB modules have a

TEST button which forces the unit to act as if an overload
has occurred. This button operates even when the
transfer signal is inactive.

Figure 3-7. LSM TEST Button

Diagnostic Repair Manual 57

Section 3.1 Description and Major Components

Figure 3-8. Generator Running All Priorities Enabled

Figure 3-9. Generator Running Overload Detected, Waiting 5 Minutes

58 Diagnostic Repair Manual

 Section 3.1 Description and Major Components

Figure 3-10. LSM 120 Volt Generator Running Priority One Enabled, Waiting 30 Seconds

Figure 3-11. LSM 120 Volt Generator Running Priority Two Enabled, Waiting 30 Seconds

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Section 3.1 Description and Major Components

Figure 3-12. LSM 120 Volt Generator Running Enabling Priority Three, Overload

Figure 3-13. LSM 120 Volt Generator Running Overload Detected Waiting 5 Minutes

60 Diagnostic Repair Manual

 Section 3.1 Description and Major Components

Figure 3-14. LSM 120 Volt Generator Running Priority One Enabled, Waiting 30 Seconds

Figure 3-15. LSM 120 Volt Generator Running Holding At Priority 2, Waiting 30 Minutes

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Section 3.1 Description and Major Components

Figure 3-16. LSM 120 Volt Generator Running 30 Min Exp, Enabling Priority Three

Figure 3-17. LSM 120 Volt Generator Running All Priorities Restored

62 Diagnostic Repair Manual

 Section 3.1 Description and Major Components

Load Shed Module Operation 1. Turn on the utility supply to the ATS.
OPCB 24/120 Volt Module 2. Press and hold the TEST button on the OPCB for
approximately 1 second.
The Overload Prevention Control Board (OPCB) can
control an air conditioner (24 VAC) directly or a separate 3. Verify that all of the connected loads to be “shed”
contactor (24 VAC or 120 VAC operating coil) which can become disabled. The method of verification will
control any load connected to it. depend on the type of load.
4. After five (5) minutes verify A/C1 (Priority 1) are
The OPCB load contacts can be powered from either a energized. Status LED AC 1 and Load 1 is ON.
24 VAC or 120 VAC power supply. The 24 VAC supply is
from a Class 2 transformer which can be purchased from 5. After another 15 seconds, verify A/C2 (Priority 2) are
the manufacturer. energized. Status LED AC 2 and Load 2 are ON.
Wire 194 from the HSB controller supplies 12 VDC to the 6. After another 15 seconds, verify A/C3 (Priority 3) is
module. Wire 0 provides the ground for the logic side of energized. Status Load 3 is ON.
the module. Wire 23 is monitored by the module to identify 7. After another 15 seconds, verify A/C4 (Priority 4) is
when transfer to standby and back to utility has energized. Status Load 4 is ON.
occurred.T1 and Neutral are used to monitor the
frequency of the generator for load control.
NOTE: When utilizing the optional 24 VAC configuration,
the power supply transformer (Class 2) must have
connections to the LOAD and NEUTRAL connection at
the OPCB. Limit each output to 1 Amp.
NOTE: 120 volt contactors cannot be used in
conjunction with 24 volt contactors. The OPCB must be
wired with one or the other.
A generator overload condition is determined by generator
frequency. Loads are shed when the frequency is <58 Hz
for 3 seconds or <50 Hz for ½ Second (For 60Hz).
Figure 3-18. OPCB TEST Button
Smart A/C Module (SACM)
Up to four air conditioner loads can be managed by the Load Shed Operation
Smart A/C Module (SACM). The SACM manages the NOTE: The following sequence of operation is the same
loads by “shedding” the connected loads in the event of a for the SACM and the OPCB 24/120 modules.
drop in generator frequency (overload). Loads to be shed
The 4 green status LEDs will indicate when a load priority
are in 4 priority levels on the module.
level is enabled or disabled.
Priorities A/C 1-4 have connections for an air conditioner. All loads are enabled when the transfer signal is off. (ATS
To control an air conditioner, no additional equipment is in Utility position).
required. Internal normally closed relays interrupt the 24
When utility power is interrupted, T1 is de-activated. The
VAC thermostat control signal to disable the air
module remains powered via Wire 194 (12 VDC) and
conditioner load.
Wire 0. Wire 23 is not grounded (high, 12 VDC) at this
Four LEDs, located on the SACM, illuminate when a load time.
is connected and powered. The SACM has a test button
As the generator starts, runs, and transfers, Wire 23 is
used to simulate an overload condition. This button
pulled to ground (low, 0 VDC). Once the transfer switch
operates even when the transfer signal is inactive.
goes to the standby position, T1 is powered by the
A generator overload condition is determined by generator generator.
frequency. Loads are shed when the frequency is <58 Hz The module senses that the system is on standby and
for 3 seconds or <50 Hz for ½ Second (For 60Hz). disables all loads. A 5 minute timer is activated.
• A/C1 (Priority 1) load(s) are enabled after 5 minutes.
Test Button
• A/C2 (Priority 2) load(s) are enabled after 15 seconds.
The OPCB/SACM load shed module has a TEST button
which forces the unit to act as if an overload has • A/C3 (Priority 3) load is enabled after another 15
occurred. This button operates even when the transfer seconds.
signal is inactive. • A/C4 (Priority 4) load is enabled after another 15
The TEST button will work when the ATS is in the Utility seconds.
or the Generator position. When an overload is detected all loads are disabled.

Diagnostic Repair Manual 63

Section 3.1 Description and Major Components

Generator overload condition is determined by generator frequency drops below specifications, the OPCB/SACM
frequency. Loads are shed when the frequency is <58 Hz will disable again. This will continue until the frequency
for 3 seconds or <50 Hz for ½ second (For 60Hz). does not drop when the priority is enabled, the system is
If an overload is detected within 15 seconds of a priority returned to utility, or the TEST button is pressed.
being enabled, that load is then locked out. The When utility voltage returns, Wire 23 is released from
sequence will continue until all load levels have been ground (back to 12 VDC, high) and the transfer switch
checked (temporarily bypassing the faulting level). The returns to the utility position. The OPCB/SACM will
level that caused the overload will not be enabled/tested disable all loads, time out for 5 minutes and then enable
again for 30 minutes. The OPCB/SACM will attempt to all 4 priorities at the same time.
enable the load every 30 minutes. During enabling, if the

Figures 3-19 through 3-33 follow the sequence of operation when an overload condition occurs on example Priority Circuit
3. After a 30 minute timer expires, Priority 3 is activated. If the frequency is still OK then all priorities will remain active.

OPCB Module Example

Figure 3-19. Generator Running All Priorities Enabled

64 Diagnostic Repair Manual

 Section 3.1 Description and Major Components

Figure 3-20. Generator Running Overload Detected, Waiting 5 Minutes

Figure 3-21. Generator Running Priority One Enabled, Waiting 15 Seconds

Diagnostic Repair Manual 65

Section 3.1 Description and Major Components

Figure 3-22. Generator Running Priority Two Enabled, Waiting 15 Seconds

Figure 3-23. Generator Running Enabling Priority Three, Overload

66 Diagnostic Repair Manual

 Section 3.1 Description and Major Components

Figure 3-24.

Figure 3-25. Generator Running Overload Detected Attempting Priority 4

Figure 3-26.

Figure 3-27. Generator Running Priority Four Enabled, Waiting 30 Minutes

Diagnostic Repair Manual 67

Section 3.1 Description and Major Components

Figure 3-28.

Figure 3-29. Generator Running Holding At Priority 3, Waiting 30 Minutes

Figure 3-30.

Figure 3-31. Generator Running All Priorities Restored after 30 Minutes

NOTE: After all priorities are enabled and the generator frequency is within limits all priorities will remain on. In this
example Priority 3 was the faulty circuit. The controller will lock out the priority for 30 minutes then attempt to enable
Priority 3. If not successful, the OPCB module would continue to lock out the faulting priority and continue to attempt to
enable it every 30 minutes until utility is restored or until unit is reset. If the unit is reset during generator operation, the
testing sequence would begin again.

68 Diagnostic Repair Manual

 Section 3.1 Description and Major Components

SACM

T1 THERMOSTAT 1
0 GROUND

194 +12V

T1 T1 AIR
23 TRANSFER
CONDITIONER 1
00 NEUTRAL 00
THERMOSTAT 2

A/C 1
23 AIR
194 CONDITIONER 2
0 A/C 2

A/C 1
A/C 3 THERMOSTAT 3
A/C 2

A/C 3

A/C 4 THERMOSTAT 4 AIR

A/C 4
CONDITIONER 3

0:00 AIR
CUSTOMER CONNECTION

Timer: CONDITIONER 4

DC VOLTAGE
(PCB) GROUND CONTROL
AC VOLTAGE
24VAC
NEUTRAL
GROUND

23 194 HZ

B
TR A 60.1
Figure 3-32. SACM

Power Supply Connections for 1. Mount the contactor module and connect the load
Contactors to the main contacts.

The Overload Prevention Control Board (OPCB) can be 2. Connect the contactor coil to the desired LSM
powered from either a 24 VAC or 120 VAC power supply. (Contactor 1, 2, 3 or 4) terminals on the terminal
The 24 VAC supply is from a class 2 transformer that can strip.
be purchased from the manufacturer. Mounting holes are 3. Connect additional load shedding contactors in a
provided in the enclosure subplate for mounting of the similar fashion.
transformer. The 120 VAC supply is fused at 5 amps and
is factory connected to OPCB terminals labeled “T1” and Power Management Module (PMM)
“Neutral”.
The PMM is for use with the Overload Prevention Control
24 VAC Supply Board (OPCB).
The Power Management Module (PPM) 24 VAC
Transformer connections are made as shown in Figure contactor is NOT supplied with the transfer switch. It can
3-36. be purchased separately from the manufacturer.
• Blue wire - OPCB “LOAD SUPPLY 1” terminal The OPCB is mounted in the transfer switch. The OPCB
• Black wire - OPCB “T1” terminal provides 24 VAC to the PMM contactor operating coil via
• White wire - OPCB “NEUTRAL” terminal the installed 24 VAC transformer. These PMM contactor
coil connections are made at the OPCB terminal strip.
• Yellow wire - OPCB “LOAD SUPPLY 2” terminal

120 VAC Supply

Install the following jumpers on the OPCB as shown in
Figure 3-37.
• Load Supply 1 to T1
• Load Supply 2 to Neutral
Control of a Separate Contactor
A separate contactor relay module can be purchased
from the manufacturer. If a different relay is used it must
have a 120 VAC coil voltage. The LSM supplies fused
Figure 3-33. Power Management Module
(5A) 120 VAC to energize the coils of the relay contactors
(contactor 1, 2, 3 or 4).
Diagnostic Repair Manual 69
Section 3.1 Description and Major Components

B C

A. Ground Stud
B. Line Connections Terminals L1 & L2
C. Load Connections Terminals T1 & T2
D. Contactor Control Connections
Figure 3-34. Power Supply Connections Figure 3-35. PMM Starter Kit

LOAD 1 C
0 Ground SUPPLY
A 194 +12V T1 D
B
23 Transfer NEUTRAL E
LOAD 2 F
A/C 1 SUPPLY

24V 1
LOAD 1
1A MAX 2
A/C 2
24V 1
LOAD 2
1A MAX 2
A/C 1 & LOAD 1
1
LOAD 3 G
A/C 2 & LOAD 2
1A MAX 2

LOAD 3 1
LOAD 4
LOAD 4 1A MAX 2

002521
A. Factory wiring E. White
B. Transformer leads Field installed F. Yellow
C. Blue G. Existing wiring
D. Black
Figure 3-36. 24 VAC Supply Connections

70 Diagnostic Repair Manual

 Section 3.1 Description and Major Components

LOAD 1 B
0 Ground SUPPLY
A D
194 +12V T1

23 Transfer NEUTRAL
E
LOAD 2
A/C 1 SUPPLY

24V 1
LOAD 1
1A MAX 2
A/C 2 C
24V 1
LOAD 2
1A MAX 2
A/C 1 & LOAD 1
1
LOAD 3
A/C 2 & LOAD 2
1A MAX 2

LOAD 3 1
LOAD 4
LOAD 4 1A MAX 2

003403
A. Factory wiring D. T1 (Factory)
B. Jumper Wire T1 to Load Supply 1 E. 00 (Factory)
C. Jumper Wire Neutral to Load Supply 2
Figure 3-37. 120 VAC Supply Connections

Smart Management Module (SMM)

Table 3-1. Priority Settings
Description
Priority Recovery Time
The Smart Power Management System is designed to
optimize the performance of a standby generator. The 1 5 minutes
system can consist of up to 8 individual Smart
2 5 minutes 15 seconds
Management Modules (SMM). Unlike other load
management systems that depend on another control 3 5 minutes 30 seconds
device, the SMM modules are actually self-aware and
4 5 minutes 45 seconds
operate autonomously.
5 6 minutes
Frequency is the true measure of generator engine
performance and does not need to factor in increased 6 6 minutes 15 seconds
ambient temperatures, elevation changes or generator
7 6 minutes 30 seconds
fuel type. The modules monitor the frequency (Hz) of the
power being produced by a standby generator and if it 8 6 minutes 45 seconds
falls below a certain threshold, the module will
automatically follow a power management algorithm to Lockout Switch (B) – Initial switch to generator power
ensure that the generator is not overloaded. will allow load to operate until an overload condition
Generator overload condition is determined by generator occurs. If overload happens the load will be locked out
frequency. Loads are shed when the frequency is <58 Hz until utility returns. See Table 3-2.
for 3.5 seconds or <50 Hz for 1 second. NOTE: Early Version: When lockout switch is engaged
The modules can be set to a load priority between 1 and 8 and running on generator, module will start in load shed
or be set in a lock out only mode for loads that do not need mode. After approximately 1 minute of run time the
to run during a power outage, which reduces the necessary module will enter lockout mode. When utility returns while
size of the generator for a more cost effective solution. in lockout mode, the module will delay for 2 minutes
before returning to load shed mode. After a 4 minute
SMM Features and Controls timer expires the load will be activated.
See Figure 3-38. Test Button (C) – Disables contactor output for a
Priority Dial (A) – Sets module priority. specified time.
LED (D) – Provides module status. See Table 3-3.
NOTE: PRIORITY MUST BE DIFFERENT for each
module in an installation. Priority sets the order in which Contactor (E) – Controlled by a smart controller in
loads recover from a load shed event. Recovery time module. Contactor remains CLOSED until generator
from a load shed event is five minutes for Priority 1. Each power is required. Upon generator activation, controller
priority after Priority 1 waits an additional 15 seconds moves to OPEN to handle overload conditions.
after the initial recovery time. See Table 3-1.
Diagnostic Repair Manual 71
Section 3.1 Description and Major Components

NOTE: When the system is on generator power, the Electrical Specifications

contactor is also opened during lockout switch ACTIVE
state. Input Voltage 240 VAC
Mounting Holes (F) – Internal enclosure mounting holes Current Rating 50A resistive, 40A inductive
provide clean and sturdy mounting.
Locked Rotor Amp Rating 240A
B C Motor Rating 3 HP
A D
Contactor Coil Voltage 240 VAC

Enclosure Specifications
UL Rating Type 3R
Temperature -30 to 50 deg C (-22 to 122 deg F)

F F
Connections
G H I

A C
000106 B D
Figure 3-38. SMM Features and Controls
J

Recovery time is based on priority dial settings. See E

Table 3-1.
F
.
.

000108

Table 3-2. Lockout Switch Settings Figure 3-39. Smart Management Module Connections

Lockout
Legend – Figure 3-39
Switch Mode Function
Position A Red (240 VAC - Line)
B Black (240 VAC - Line)
If overloaded, module sheds
load until utility returns. C Red (240 VAC - Load)
Contactor is OPEN. D Black (240 VAC - Load)
ON GENERATOR
NOTE: Early version goes into E White - Neutral (as required)
lockout mode. Load is never
activated until Utility returns. F Green - Ground (as required)
G Black - Factory (PCB)
Power is available on module
ON UTILITY output (contactor output). H Red - Factory (PCB)
Contactor is CLOSED. I Blue - Factory (PCB)

Module operates with standard J Blue - Factory (Jumper)

OFF GENERATOR load shed logic. Contactor is
OPEN or CLOSED per logic.

Power is available on module

OFF UTILITY output (contactor output).
Contactor is CLOSED.

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 Section 3.1 Description and Major Components

Table 3-3. LED States

State LED State Mode Note

Module detected an overload and shed its load. This state only
1 second flash
Shed Generator occurs in generator mode, or during a first time utility power up for
(1 On – 1 Off)
five minutes of initial operation.

Module detected an overload while trying to recover from a shed

Lockout 3 second flash situation. It identified the offending load and disabled operation for 30
Generator
(30 minutes) (3 On – 3 Off) minutes to allow other loads to operate. This state only occurs in
generator mode.

Lockout 6 second flash Module output is disabled and there is no power to the appliance
Generator
Switch Active (6 On – 6 Off) while in generator mode. Lockout switch must be ON. See Table 2.

Lockout Switch operates in generator mode only. It has no function in

Lockout
ON Utility utility mode. LED is solid, indicating contactor is CLOSED and load is
Switch Active
connected. Lockout switch must be ON. See Table 2.

Indicates contactor is CLOSED and appliance has power. This is the

Normal ON Generator or Utility default in utility mode. It is the normal operating state in generator
mode when an overload is not detected.

Test button triggers a typical shed condition and overrides all other
Test 1 second flash Generator or Utility
states except generator lockout switch ACTIVE state.

Setting Priorities 2. Apply priority decal in a suitable location on

electrical panel to record chosen priority
High priority 240 VAC loads should be set to the highest designations.
priorities so those loads recover first, in the event of
3. Record priorities on decal.
generator overload.
NOTE: The highest priority, and first load to activate is
Priority 1. The last load to activate is Priority 8. Setting Lockout
Most installations will require the lockout switch to be
Setting priority determines timing for 3 scenarios:
DISABLED. When performing a whole house backup
• Order in which loads recover with a generator not sized to manage all household
• Delay time until power returns during an outage loads, SMM's can be used to disable appliances or
• Delay time for post load shed recovery circuits during an outage. For non-essential loads that will
not be used on generator power, set lockout switch to
An example configuration is shown in Table 3-4. ENABLED.
Configurations will vary depending on customer
prioritization of loads.
Tests
Table 3-4. Typical SMM Configuration Utility Test
Priority 1 - Baseboard heat Priority 5 - Non-essential 1. Turn utility power ON and enable all module
circuits
feeding circuits.
Priority 2 - Air conditioner Priority 6 - Pool pump or hot 2. Verify LED begins to flash at one second intervals.
tub
3. All contactors will close after five minutes. LED will
Priority 3 - Range Priority 7 - Other circuits illuminate, and stay ON.
4. Wait 30 seconds after contactor closes, then press
Priority 4 - Dryer Priority 8 - Other circuits
TEST button and verify module load shed. LED will
flash at one second intervals.
1. Set the priority of each SMM module as desired
5. Wait five minutes, plus predefined priority set time
(using the example configuration for reference).
for module to recover.
6. Contactor will CLOSE and LED will illuminate, and
stay ON.

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Section 3.1 Description and Major Components

Generator Test Generator Test with Lockout Switch Enabled

(perform if Lockout Switch Enabled on any loads)
1. Simulate a utility loss by turning main line circuit
breaker (MLCB - service disconnect) OFF while 1. Simulate a utility loss by turning MLCB (service
generator is in AUTO. disconnect) to OFF while generator is in AUTO.
2. All modules will lose power and LEDs will disable. 2. All modules will lose power and LEDs will disable.
3. Generator will power on after preset delay. 3. Generator should power on after preset delay.
4. All LEDs will flash when generator transfers.
NOTE: For modules with lockout switch enabled, LEDs
5. Allow each module to enable output per its priority will flash at six second intervals and load will remain
setting. disabled while in generator power.
6. After predefined priority time elapses, each
contactor will CLOSE and LED will illuminate and Return to Utility Test
stay ON.
1. Return utility power by setting the MLCB (service
7. Once LED stays ON, press TEST button and verify
disconnect) to ON.
load shed occurs.
8. Once load shed occurs, LED will flash at one NOTE: All modules should begin flashing at one second
second intervals. intervals.
9. Allow time for each module to enable contactor NOTE: All modules will recover in five minutes (including
output per priority setting. units with lockout switch enabled).
10. After predefined priority set time, each contactor
will CLOSE and LED will illuminate and stay ON. Troubleshooting
NOTE: Depending on load size, the SMM module may See troubleshooting flowcharts.
immediately go into load shed mode or lockout during
test. In this event, remove one or more higher priority
loads to allow testing of each module.

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 SMM Functionality Flow Chart

Legend Contactor Open SMM Monitoring Contact Closed

Start Here
Utility Outage –
Contact opens

Diagnostic Repair Manual

Contact closes

Module powers up

Checks frequency

Checks power source

If <52Hz for 0.5s or Contact opens –
If <58Hz for 3s 30 minute lock out*†
Utility Generator
If frequency meets
acceptable levels
for 15 seconds
5 minute delay*
Checks power source

Lockout switch ON and

contactor OPEN Generator
5 minute delay

Monitors frequency**
Contact opens –
If <52Hz for 1s or
Load is shed for 5
If <58Hz for 3.5s minutes (Priority 1) or
Utility
more*
Contact closes
If frequency meets
acceptable levels

Note: When monitor frequency and Pressing the TEST button will
monitor power source levels are reached, immediately override all settings and

Figure iv-40. SMM Sequence of Operations

the system will remain in this state, during shed load. Loads will be established
Module returns to Checks power source
normal generator operation. If an again after five minutes, plus the
normal utility operation overload occurs during operation, loads pre-established priority setting time.
Generator Utility will shed according to set parameters.

Up to 5 minute delay
before contactor closes

* Each priority setting above Priority 1 will increase delay time in 15 second increments, starting with 15 seconds at Priority 2.
** If the frequency drops below acceptable levels for the pre-determined durations, all modules will shed.
† During lock out, the module will continuously monitor power source. If utility returns before the 30 minute lock out is satisfied, the module will allow five minutes to elapse from utility return time, and then close the contact.

Note 1: If the frequency is under 58 Hz when a module attempts to close the contactor after a shed, the module will wait another 5minutes plus Priority delay before attempting to enable.
Note 2: The "Checks power source" block monitors frequency and will change state, Generator or Utility, after it detects 1 minute of stable operation in the new state.
000105b

75
Section 3.1 Description and Major Components
Section 3.1 Description and Major Components

Integrated SACM Module

The integrated SACM module incorporates the following
components in one module:
• N1, N2 and T1 6.3 amp mini fuse.
• Transfer relay.
• Load shedding SACM that has the same operating
parameters as the non-integrated SACM.

Figure 3-41. Integrated SACM Module

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 Section 3.2 Operational Analysis
Utility Source Voltage Available
Figure 3-42 is a schematic representation of the transfer switch with utility source power available. The circuit condition
is briefly described as follows:
• Utility source voltage is available to terminal lugs N1 and N2 of the contactor; the transfer switch is in the
UTILITY position; and Utility voltage is available to T1 and T2, customer load.
• Utility source voltage is available to the limit switch (XA1) via the normally closed transfer relay contacts (1 and 5)
and Wire 126; however, XA1 is open and the circuit to the utility closing coil is open.
• Utility voltage sensing signals are delivered to controller on the generator, via Wire N1A, and a 5-amp fuse (F1).
The second line of the utility voltage sensing circuit is via Wire N2A, and a 5 amp fuse (F2).
NOTE: This is an example of Transfer Switch Operational Analysis. For troubleshooting use the operational analysis
with the appropriate wiring/schematic diagrams.

Figure 3-42. Utility Source Voltage Available

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Section 3.2 Operational Analysis

Utility Source Voltage Failure

If Utility source voltage drops below 65% of nominal voltage for five (5) seconds, the controller will initiate engine start.
After the generator starts, a five (5) second engine warm-up timer is initiated. During this warm-up the generator is
running at rated frequency and voltage. Figure 3-43 is a schematic representation of the transfer switch with the
Generator running with voltage available to the transfer switch.
Generator voltage available on contactor terminals E1 and E2.
• Controller logic is holding Wire 23 open from ground.
• Generator voltage from terminal E2 is available at the standby coil (C2); generator voltage from Terminal E1 is
available to the transfer relay at Pin 9. The transfer relay is not energized so E1 voltage will not go through the
N.O. contact (4 & 6) to Wire 205.
NOTE: This is an example of Transfer Switch Operational Analysis. For troubleshooting use the operational analysis
with the appropriate wiring/schematic diagrams.

Figure 3-43. Utility Source Voltage Failure

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 Section 3.2 Operational Analysis

Transferring to Standby
12 VDC is delivered to the transfer relay through Wire 194 and back to the controller through Wire 23. When the five
second engine warm-up timer expires, the controller will take Wire 23 to ground which will energize the Transfer Relay.
The N.O. and N.C. relay contacts will change states. This will connect generator voltage from E1 through wire 205 at
relay connector 6 to E2A relay connector 4. The voltage will go through the N.C contact of XB1. Voltage from both E1
and E2 will be available at the C2 coil. This voltage will pass through the rectifier in the coil and the coil will energize.
Generator voltage is now delivered to the standby closing coil (C2), via generator voltage E1 and E2, the now closed
TR1 contacts, Wire 205, the limit switch (XB1), Wire B, and a bridge rectifier. The standby closing coil energizes and
the main current carrying contacts of the transfer switch are actuated to the “Standby” position.
• As the main contacts move toward the “Standby” position, limit switch XA1 closes (Utility Coil). When the
contacts are in the “Standby” position, a mechanical interlock actuates XB1 to its open position. When SW3
opens the C2 coil de-energizes.
• Generator voltage is now available to the LOAD terminals (T1 and T2) of the transfer switch and 120 VAC is also
supplied to the controller on Wire T1 for the battery charger. (220 VAC on T1 and T2 50 Hz only.)
NOTE: This is an example of Transfer Switch Operational Analysis. For troubleshooting use the operational analysis
with the appropriate wiring/schematic diagrams. XA1 and XB1

Figure 3-44. Transferring to Standby

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Section 3.2 Operational Analysis

Transferred to Standby
When the standby coil (C2) energizes it pulls the contactor to an “over center” position towards the STANDBY position,
the transfer switch electronically/mechanically snaps to that position. Upon closure of the main contacts to the
STANDBY position limit switches XA1 and XB1 mechanically actuate to “arm” the circuit for re-transfer to the UTILITY
position. When XB1 changes, it opens the circuit providing voltage to the standby closing coil (C2). Voltage from the
generator, connected through T1 and T2, provides power to customer connected loads.
NOTE: This is an example of Transfer Switch Operational Analysis. For troubleshooting use the operational analysis
with the appropriate wiring/schematic diagrams.

Figure 3-45. Transferred to Standby

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 Section 3.2 Operational Analysis

Utility Restored
Utility voltage is restored and available to terminals N1 and N2. The Utility voltage is “sensed” by the controller and, if it
is above 75% of nominal for 15 consecutive seconds, a transfer back to UTILITY will occur.
NOTE: The TR1 open contacts 1 and 4 keep the switch from immediately transferring to the utility position.
NOTE: This is an example of Transfer Switch Operational Analysis. For troubleshooting use the operational analysis
with the appropriate wiring/schematic diagrams.

Figure 3-46. Utility Restored

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Section 3.2 Operational Analysis

Utility Restored, Transferring Back to Utility

After the 15 second return to utility delay expires, the controller will open the Wire 23 circuit from ground. The transfer
relay (TR1) de-energizes, the N.O. and N.C. contacts change state. Utility voltage is delivered to the utility closing coil
(C1) through Wires N1A and N2A, the normally closed contacts (1 and 5), Wire 126, and limit switch (XA1). With utility
voltage applied to both sides of the utility closing coil (C1), the rectifier in the coil causes the coil to energize.
When the TR1 relay de-energizes its utility side contacts close. Utility voltage is then delivered to the utility closing coil
(C1), via utility voltage from N1A and N2A, the closed TR1 contacts, Wire 126, limit switch (XA1), and a bridge rectifier.
• The C1 coil energizes and moves the main contacts to their “Utility” Position; the LOAD terminals are now
powered by Utility.
• Movement of the main contacts to the “Utility” position actuates the limit switches. XA1 opens and XB1 closes on
the Standby source side.
NOTE: This is an example of Transfer Switch Operational Analysis. For troubleshooting use the operational analysis
with the appropriate wiring/schematic diagrams.

Figure 3-47. Utility Restored, Transferring Back to Utility

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 Section 3.2 Operational Analysis

Utility Restored, Transferred Back to Utility

As the utility closing coil pulls the transfer switch to an “over center” position, the switch mechanically snaps to the
UTILITY position. Upon closure of the contacts to UTILITY, the limit switches (XA1 and XB1) mechanically actuate to
“arm” the circuit for the next transfer to STANDBY. When switch XA1 changes states, the circuit providing voltage to the
utility transfer coil is opened, and the coil de-energizes.

Figure 3-48. Utility Restored, Transferred Back to Utility

Transferred Back to Utility, Generator Shutdown

When the transfer switch returns to the UTILITY position the controller will shut the generator down after the one
minute engine cool-down timer expires.
NOTE: This is an example of Transfer Switch Operational Analysis. For troubleshooting use the operational analysis
with the appropriate wiring/schematic diagrams.

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Section 3.2 Operational Analysis

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 Section 3.3 Troubleshooting Flowcharts

Evolution™ Controller e-Codes

Displayed Alarm/ e-Code
Description Action Step
Alarm Warning Breakdown
Controller Fault ALARM No E-code on HSB Replace Controller
Condition - Engine Cranks but will not Start (5 crank attempts)
Overcrank ALARM 1100 Problem 17
Unit turns over but will not start. Controller is receiving signal on Wire 18.
Prolonged (60 Hz on a 50 Hz unit, 72Hz on 60Hz unit)
Overspeed ALARM 1200 Over specified Hz for 3 seconds. Possible cause: Stepper motor/mixer body Test 12
assembly issue.
Instantaneous (62 Hz on a 50 Hz unit, 75Hz on 60Hz unit)
Overspeed ALARM 1205 Over specified Hz for 0.1 second (100 milliseconds). Possible cause: Stepper motor/ Test 12
mixer body assembly issue.
Monitors zero cross timing of the AVR to determine the alternator frequency which is
Overspeed ALARM 1207 a speed indicator. Set for 150 milliseconds of 4500 rpm or higher. Used if the normal Test 64 and Test 60
ignition pulse sequence(s) are not being seen by the controller.
Occurred while running
Low Oil Pressure ALARM 1300 Test 61
The default Extended alarm for low oil pressure. Check oil level and pressure.
High Condition - Air Flow Impeded / Flow Issue
ALARM 1400 Test 62
Temperature Check the inlet/outlet for debris. Check temperature sensor and wiring.
Twin Cylinder+Running
RPM Sensor ALARM 1501 Twin Cylinder Running faults to RPM Sensor Loss. Possible Causes: air pocket in fuel Test 50 and Test 64
line, dirty fuel, missing ignition pulse (loss of one of the primary coils).
Twin Cylinder+Cranking If engine cranks, Test 64.
RPM Sensor ALARM 1505 Twin Cylinder Cranking faults to RPM sensor loss Possible Cause: starter motor If engine does not crank,
issue, missing ignition pulse (loss of one of the primary coils). Problem 15.
Single Cylinder+Running
RPM Sensor ALARM 1511 Single Cylinder Running RPM sensor loss Possible Causes: air pocket in fuel line, Test 50 and Test 64
dirty fuel. Loss of ignition pulse.
Single Cylinder+Cranking If engine cranks, Test 64.
RPM Sensor ALARM 1515 Single Cylinder Cranking faults to RPM sensor loss Possible Cause: starter motor If engine does not crank,
and/or engine issue. Loss of ignition pulse. Problem 15.
Condition - Unit is Overloaded (55 Hz for 60 Hz for 30 sec, 40 Hz for 50 Hz unit Problem 3, or Test 50, or
Underspeed ALARM 1600
Unit is Overloaded slowing engine speed, fuel supply low or throttle control problem. Test 12
Underspeed Check fuel selection and
Underspeed ALARM 1603
The engine never comes up to 3600 RPM. fuel supply
Overvoltage ALARM 1800 Prolonged Over-Voltage Problem 2
*Preliminary Output
Voltage Test (firmware
Prolonged Under-Voltage
Undervoltage ALARM 1900 v1.12 and above).
Undervoltage due to loss of voltage. Below 80% for 10+ seconds)
Note: Update controller to
latest firmware.
*Preliminary Output
Voltage Test (firmware
Instantaneous
Undervoltage ALARM 1901 v1.12 and above).
Undervoltage due to sudden loss of voltage. (Voltage less than 15 sec 2 sec+)
Note: Update controller to
latest firmware.
*Preliminary Output
Both Zero Crosses missing
Voltage Test (firmware
Undervoltage due to faulty excitation winding, or zero cross circuit, or circuit in
Undervoltage ALARM 1902 v1.12 and above).
general. Possible cause: loose wiring, field boost hardware failure. (Both zero cross
Note: Update controller to
missing greater than 1.5 sec)
latest firmware.
NOTE: If an alarm code is displayed on the controller, use the diagnostic procedure listed in the action step.

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Section 3.3 Troubleshooting Flowcharts

Evolution™ Controller e-Codes

Displayed Alarm/ e-Code
Description Action Step
Alarm Warning Breakdown
*Preliminary Output
Single Zero Cross missing
Voltage Test (firmware
Undervoltage due to faulty excitation winding, zero cross circuit, or circuit in general.
Undervoltage ALARM 1906 v1.12 and above).
Possible cause: field boost hardware failure. (One zero cross missing greater than
Note: Update controller to
1.5 sec)
latest firmware.
Mis-wired Check customer
Wiring Error ALARM 2099
Customer connection low voltage and high voltage wires are crossed. connection in generator
Overloaded - Default (Output Current Method)
Overload
ALARM 2100 Unit is overloaded. One or both CT(s) detecting an overload condition. Check transfer Remove Load
Remove Load
switch loadshed functionality. (Change load dynamics or utilize loadshed).
Unit was overloaded and attempted to start with a large load connected. The unit can
Undervoltage
ALARM 2299 not ramp up the generator voltage to its normal target voltage value if it starts with a Remove Load
Overload
large load connected
Stepper
ALARM 2399 Current flow in stepper coil(s) above specification Test 12
Overcurrent
Missing / Damaged Fuse
Fuse Problem ALARM 2400* The 7.5 amp Controller Fuse is missing or blown (open). Test 44
*Firmware version 1.11 and older only
Check the continuity of
the harness and operation
Aux Shutdown ALARM 2800 External shut down circuit is open.
of the switch(es). Repair/
replace as needed.
Low Battery WARNING Condition->Battery less than 12.1 Volts for 60 seconds Test 45
Condition->More than 16 Volts of battery voltage or 600 milliamperes or more of
Battery Problem WARNING Test 45
charge current at the end of an 18 hour charge
Charger Warning WARNING Less than 12.5 volts of battery voltage at the end of a 18 hour charge Problem 22
Charger Missing
WARNING AC power is missing from the battery charger input Problem 22
AC
Service Service Schedule A 200hours 2 years
Perform Maintenance
Schedule Service Schedule B 400 Hours 4 years
NOTE: If an alarm code is displayed on the controller, use the diagnostic procedure listed in the action step.

Additional Codes For 8 and 9 kW Units Only

Displayed Alarm/ e-Code
Description Action Step
Alarm Warning Breakdown

If the engine has tried to

Engine/Starter Problem crank for 10 times
Overcrank ALARM 1101
Limiting number of cranking cycles to protect the starter motor. unsuccessfully, this will
trigger.

Check for Overloaded

Overloaded
Overload condition on unit.
ALARM 2102 Unit re-cranks 5 times when load is applied, engine dies (0 RPM) and has low
Remove Load Inspect stepper motor
voltage (< 180V)
operation.

Overloaded
Overload Check for Overloaded
ALARM 2103 Unit has run and attempted to accept load 10 times, could not accept due to
Remove Load condition on unit
overload condition

88 Diagnostic Repair Manual

 Section 3.3 Troubleshooting Flowcharts

Introduction
Use the “Flow Charts” in conjunction with the detailed instructions in Section 3.4. Test numbers used in the flow charts
correspond to the numbered tests in Section 3.4. The first step in using the flow charts is to identify the correct problem
on the following pages. For best results, perform all tests in the exact sequence shown in the flow charts.
Problem 6 — With Controller in Automatic Mode and Utility Failed, Generator Runs but
Transfer to Standby Does Not Occur

TEST 20 – CHECK TEST 30 – CHECK FIND CAUSE OF NO AC OUTPUT

VOLTAGE AT BAD MAIN LINE CIRCUIT BAD TO TRANSFER SWITCH FROM
TERMINAL LUGS BREAKER GENERATOR
E1 & E2

GOOD

TEST 21 – CHECK
MANUAL TRANSFER BAD REPAIR OR REPLACE MECHANISM
SWITCH OPERATION

GOOD

TEST 22 – CHECK
23 AND 194 BAD REPAIR OR REPLACE AS NEEDED
CIRCUIT

GOOD

TEST 23 – TEST
TRANSFER BAD REPLACE
RELAY

GOOD

TEST 24 – CHECK
STANDBY CONTROL BAD REPAIR AS NEEDED
CIRCUIT

Diagnostic Repair Manual 89

Section 3.3 Troubleshooting Flowcharts

Problem 7 – In Automatic Mode, Generator Starts When Loss of Utility Occurs, Generator
Shuts Down When Utility Returns But There is No Re-transfer to Utility Power
Or
Generator Transfers to Standby During Exercise or in Manual Mode

TEST 21 – CHECK
MANUAL TRANSFER BAD REPAIR OR REPLACE MECHANISM
SWITCH OPERATION

GOOD

TEST 25 – CHECK
WIRE 23 BAD REPAIR OR REPLACE AS NEEDED

GOOD

TEST 23 – TEST
TRANSFER BAD REPLACE
RELAY

GOOD

TEST 26 – CHECK
UTILITY CONTROL BAD REPAIR OR REPLACE AS NEEDED
CIRCUIT

Problem 8 – Unit Starts and May or May Not Transfer When Utility Power is On

TEST 33 – TEST 34 – CHECK

CHECK N1 & N2 GOOD UTILITY SENSE BAD REPLACE CONTROLLER
VOLTAGE VOLTAGE

REPAIR N1/N2 OPEN WIRING

BAD GOOD BETWEEN TRANSFER
SWITCH AND GENERATOR

TEST 35 –
TEST 28 –
CHECK VOLTAGE CORRECT UTILITY
CHECK FUSE GOOD BAD
AT TERMINAL SOURCE VOLTAGE
F1 & F2
LUGS N1 & N2

BAD GOOD

REPLACE REPAIR OR REPLACE WIRE

GO TO PROBLEM 6 N1A/N2A BETWEEN N1/N2
LUGS AND FUSE HOLDER

90 Diagnostic Repair Manual

 Section 3.3 Troubleshooting Flowcharts

Problem 9 – Blown F1 or F2 Fuse

TEST 28 – CHECK TEST 32 – CHECK INSPECT/REPLACE

BAD GOOD
FUSE F1 & F2 N1 & N2 WIRING CONTROLLER

GOOD BAD

FINISH REPAIR OR REPLACE

WIRING

Problem 10 – Blown T1 Fuse

TEST 29 – CHECK TEST 36 – CHECK

BAD GOOD REPLACE CONTROLLER
FUSE F3 (T1) T1 WIRING

GOOD BAD

STOP TESTING REPAIR OR REPLACE

WIRING

SMM Problem 1 – Load Management Module (SMM) LED is OFF, Load Not Powered

SMM LED OFF – UTILTIY AVAILABLE DISTRIBUTION PANEL

LOAD NOT AND/OR YES CIRCUIT BREAKER NO
POWERED GENERATOR ON? ENABLED?

NO YES

ENABLE MLCB
AND/OR VERIFY LINE VOLTAGE ENABLE CIRCUIT
GENERATOR AVAILABLE? BREAKER
OPERATION

LINE VOLTAGE MUST

CHECK WIRING TO SMM CHECK METER
CONNECT TO THE LEFT
AND CONNECTIONS YES NO RETEST SETTINGS AND
SIDE OF THE CONTACTOR,
INSIDE SMM FUNTIONALITY
LOAD TO THE RIGHT SIDE.

SMM Problem 2 – Load Management Module (SMM) LED is ON, Load Not Powered

SMM LED ON – TEST 37 – CHECK

LOAD NOT VOLTAGE AT
POWERED CONTACTOR

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Section 3.3 Troubleshooting Flowcharts

SMM Problem 3 – Load Management Module (SMM) LED is Flashing, Load Not Powered

SMM LED FLASHING –

LOAD NOT POWERED

CORRECTIVE ACTION: THIS WILL ALSO OCCUR IF

GENERATOR WAS
WAIT 5 MINUTES PLUS UTILITY POWER WAS JUST
LED FLASHING – OVERLOADED, SHED
YES THE PRIORITY TIME APPLIED. (EXCEPT IF
1 SECOND INTERVAL OCCURED AND POWER
DELAY FOR SMM TO TRANSFERING FROM GEN
APPLIED TO SMM.
ENABLE OUTPUT. TO UTILITY)
NO

GENERATOR CORRECTIVE ACTION: REVIEW ALL ENABLED

OVERLOADED WHILE WAIT 30 MINUTES FOR LOADS. DISABLE SUSPECT
LED FLASHING –
YES ATTEMPTING PMM TO ATTEMPT LOADS TO PREVENT
3 SECOND INTERVAL
RECOVERY FROM LOAD REAPPLICAION. OVERLOAD FROM
SHEDDING. RECURRING.
NO
DURING INSTALLATION, IT
LOCKOUT SWITCH WAS DETERMINED THAT
CORRECTIVE ACTION:
LED FLASHING – ENABLED AND THE THIS LOAD WILL BE
YES REVIEW ATTACHED
6 SECOND INTERVAL UNIT IS ON DISABLED DURING
LOAD, IF NECESSARY.
GENERATOR POWER. GENERATOR OPERATION
TO PREVENT GENERATOR.

SMM Problem 4 – Load Management Module (SMM) is Humming or Buzzing

MOUNT SECURELY TO NOTE: A NORMAL 60 HZ

IMPROPER MOUNTING WALL OR VERTICAL
HUMMING SOUND HUM IS EXPECTED FROM
OR INCORRECT SURFACE WITH ARROWS
COMING FROM SMM THE NORMAILLY OPEN
CONNETIONS. POINTING UP ONLY. CONTACTOR.

LOUD BUZZING TEST 37 – CHECK NOTE: PMM MUST HAVE

SOUND COMING LOAD NOT POWERED VOLTAGE AT 240 VAC TO OPERATE
FROM SMM CONTACTOR CORRECTLY.

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 Section 3.3 Troubleshooting Flowcharts

Integrated SACM Problem 1 – Generator starts and runs in AUTO with Utility Present
NOTE: Verify the integrity of all wires and connections relative to the function of the Integrated SACM Board. AC
Voltage value must equal Generator Output voltage.
NOTE: This procedure will require SD/WD 100000060381.
1. Check for AC Voltage on N1 and N2 at the connection deck on the generator.

YES Test 34 – Check Utility Sensing Voltage at the Circuit Board

AC Voltage Present?
NO Go To Next Step

2. Check for AC Voltage on N1 and N2 at the 6 Pin Customer Control Connector.

YES Repair or Replace N1 and N2 interconnect wires

AC Voltage Present?
NO Go To Next Step

3. Check for AC Voltage at upper end of N1 and N2 Fuses.

YES Replace Integrated SACM Board

AC Voltage Present?
NO Go To Next Step

4. Check for AC Voltage at the lower end of N1 and N2 FusesAC Voltage Present?

YES Replace N1 and N2 fuses

AC Voltage Present?
NO Go To Next Step

5. Check for AC Voltage at pins 3 and 6 on the white Molex Connector.

YES Replace Integrated SACM Board

AC Voltage Present?
NO Go To Next Step

6. Check for AC Voltage on N1 and N2 at the lugs on the contactor.

YES Check N1A and N2A Wires

AC Voltage Present?
NO Reset Utility Breaker or Check Utility Service

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Section 3.3 Troubleshooting Flowcharts

Integrated SACM Problem 2 – Transfer to Standby Does Not Occur in AUTO

NOTE: Verify the integrity of all wires and connections relative to the function of the Integrated SACM Board. AC
Voltage value must equal Generator Output voltage. DC Voltage value should be at least 9 VDC.
NOTE: This procedure will require SD/WD 100000060381.
1. Check for AC Voltage on E1 and E2 at the connection deck on the generator.

YES Go To Step 3
AC Voltage Present?
NO Go To Next Step

2. Check for AC Voltage on Wire 11 and Wire 44 at the MLCB (Generator Circuit Breaker).

YES Is Breaker Closed? Go To Next Step

AC Voltage Present? Perform Preliminary Output Voltage Test (Evolution
NO
Only, Non-Synergy, Firmware v1.12 and Above)

3. Check for AC Voltage on E1 and E2 at the Transfer Switch Contactor.

YES Go To Next Step

AC Voltage Present?
NO Go to Step 1 in this Test

4. Check for DC Voltage across Wire 23 and Wire 194 at the Customer Control Connection on the Integrated SACM
board.

YES Go To Next Step

DC Voltage Present?
NO Go to Test 22 – Check Wire 23 and 194 Circuits

5. Check for AC Voltage at Pin 8 and Pin 4 on the white Molex Connector.

YES Go to Step 3 in this Test

AC Voltage Present?
NO Go To Next Step

6. Check for AC Voltage at Pin 8 of the white Molex Connector and Terminal 2 of the C2 Coil.

YES Replace C2 Coil

AC Voltage Present?
NO Go to Step 1 in this Test

7. Check for AC Voltage on Pin 8 and Terminal 1 of the XB1 Limit Switch.

YES Replace XB1 Limit Switch

AC Voltage Present?
NO Go to Test 23 – Test Transfer Relay

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 Section 3.3 Troubleshooting Flowcharts

Integrated SACM Problem 3 – Transfer to Utility Does Not Occur after Utility Returns
NOTE: Verify the integrity of all wires and connections relative to the function of the Integrated SACM Board. AC
Voltage value must equal Generator Output voltage. DC Voltage value should be at least 9 VDC.
NOTE: This procedure will require SD/WD 100000060381.
1. Check for AC Voltage at the Utility Connection (before Utility Main Circuit Breaker).

YES Go To Next Step

AC Voltage Present?
NO Check Utility Mains for AC Voltage

2. Check for AC Voltage on N1 and N2 (after Utility Main Circuit Breaker).

YES Go To Next Step

AC Voltage Present?
NO Go To Test 30 – Check Main Circuit Breaker

3. Check for DC Voltage across Wire 23 and Wire 194 at the Customer Control Connection on the Integrated SACM
board.

YES Go To Test 22 – Check Wire 23 and 194 Circuits

DC Voltage Present?
NO Go To Next Step

4. Check for AC Voltage at Pin 3 (N1A) and Pin 6 (N2A) on the white Molex Connector.

YES Go To Next Step

AC Voltage Present?
NO Go to Step 2 in this Test

5. Check for AC Voltage at Pin 3 (N1A) and Pin 5 (N2A) of the white Molex Connector.

YES Go To Next Step

AC Voltage Present?
NO Replace Integrated SACM board

6. Check for AC Voltage at Pin 3 (N1A) of the white Molex Connector and Terminal 2 of the C1 Coil.

YES Go To Next Step

AC Voltage Present?
NO Replace C1 Utility Coil

7. Check for AC Voltage on Pin 3 (N1A) on the white Molex Connector and Terminal 1 of the XA1 Limit Switch.

YES Replace the XA1 Limit Switch

AC Voltage Present?
NO Go To Next Step

8. Check for AC Voltage on Pin 3 (N1A) and Pin 2 (Wire 126) of the white Molex Connector.

YES Go to Test 23 – Test Transfer Relay

AC Voltage Present?
NO Go Step 3 in this Test

Diagnostic Repair Manual 95

Section 3.3 Troubleshooting Flowcharts

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96 Diagnostic Repair Manual

 Section 3.4 Diagnostic Tests
Introduction • How would this happen?
This section familiarizes the service technician with • What type of test will either prove or disprove the
cause of the fault?
acceptable procedures for the testing and evaluation of
various problems that can occur on pre-packaged
transfer switches. The numbered tests in this section Test 20 – Check Voltage at Terminal
correspond with the flow charts in Section 3.3: Lugs E1 and E2
Troubleshooting Flowcharts.
Some test procedures in this section may require the use General Theory
of specialized test equipment, meters or tools. Most tests While in AUTOMATIC mode, the standby closing coil
can be performed with a Digital Multimeter (DMM). An (C2) energizes utilizing generator output to transfer to the
AC frequency meter is required, where frequency STANDBY position. Transfer to STANDBY cannot occur
readings must be taken. To measure AC loads it is unless generator voltage is available to the transfer
acceptable to use a clamp-on ammeter. switch.
Testing and troubleshooting methods covered in this If the generator is not producing the correct voltage it will
section are not exhaustive. No attempt has been made to shutdown on an under or over-voltage alarm and thus will
discuss, evaluate and advise the home standby service not be running.
trade of all conceivable ways in which service and trouble
Two procedures have been provided for this test. The
diagnosis must be performed. Accordingly, anyone who
first procedure is performed in the event that the
uses a test method not recommended herein must first
generator is already running in a utility failure. The
satisfy himself that the procedure or method he has
second procedure is performed if the generator has
selected will jeopardize neither his nor the products safety.
already shutdown. It is not required to complete both
procedures.
Safety Be careful! Dangerously high voltages are present at
Service personnel who work on this equipment should be terminal lugs E1 and E2 when the generator is
aware of the dangers of such equipment. Extremely high running. Avoid contact with high voltage terminals or
and dangerous voltages are present that can kill or cause dangerous and possible lethal electrical shock may
serious injury. Gaseous fuels are highly explosive and result. Do not perform this voltage test while
can ignite by the slightest spark. Engine exhaust gases standing on wet or damp ground, while barefoot, or
contain deadly carbon monoxide gas that can cause while hands or feet are wet.
unconsciousness or even death. Contact with moving
parts can cause serious injury. The list of hazards is Procedure 1: Generator Running in Utility
seemingly endless. Failure, Switch did not Transfer
When working on this equipment, use common sense and 1. Set multimeter (DMM) to measure AC voltage.
remain alert at all times. Never work on this equipment while 2. If the generator engine has started automatically
physically or mentally fatigued. If you do not understand a (due to a utility failure) and is running, check the
component, device or system, do not work on it. position of the generator main line circuit breaker.
The circuit breaker must be set to its “Closed”
Transfer Switch Troubleshooting position. After confirming that the generator main
circuit breaker is set to the “Closed” position, verify
It is always good practice to continue to ask questions
the voltage at transfer switch contactor terminal
during the troubleshooting process. When evaluating the
lugs E1 and E2 with an accurate AC meter. The
problem, asking some of these questions may help
meter should indicate generator line-to-line voltage.
identify the problem more quickly.
• What is the transfer switch doing? Procedure 2: Generator Shutdown
• What was the transfer switch supposed to do? 1. Set the controller to OFF.
• Does the transfer switch have the same fault 2. Set DMM to measure AC voltage.
consistently, and when does it occur?
3. Disconnect Utility voltage from the transfer switch.
• Who is controlling it? 4. Verify the contactor is in the UTILITY position.
• Exactly what is occurring? 5. Verify the generator main line circuit breaker
• When is it happening? (MLCB) is in the “Closed” position.
• Why would this happen?
Diagnostic Repair Manual 97
Section 3.4 Diagnostic Tests

6. Set the controller to MANUAL. 5. See Figure 3-49. Insert the un-insulated end of the
7. If transfer to the STANDBY position does not occur, handle over the transfer switch-operating lever.
check the voltage across terminal lugs E1 and E2. 6. Manually actuate the contactor lever up to the
The DMM should indicate generator line-line UTILITY position.
voltage. 7. Actuate the operating lever down to the STANDBY
position.
Results
8. Repeat Step 5 several times. When the contactor
1. If normal transfer to the STANDBY position occurs, lever is moved, slight force should be needed until
discontinue testing. the lever reaches its center position. As the lever
2. If transfer to the STANDBY position did not occur moves past its “over center” position, an over-
but the Generator continued to run for longer than center spring should snap the movable LOAD
10 seconds, and the DMM did not indicate voltage contacts against the stationary STANDBY or
across E1 and E2, proceed to Test 1—Check AC UTILITY contacts.
Output Voltage. 9. Actuate the contactor to the UTILITY position.
3. If transfer to the STANDBY position did not occur
B
and the DMM indicated proper voltage across E1
and E2 this test is GOOD. Refer to back to flow A

chart.
4. If transfer to the STANDBY position did not occur D
and the generator faulted on under-voltage, refer to
Problem 1 – Generator Shuts Down for Under
Voltage.
C

Test 21 – Check Manual Transfer

Switch Operation
000260
General Theory A.Transfer switch-operating lever
In automatic operating mode, when Utility source voltage B.Manual transfer handle
drops below a preset level, the engine should crank and C.Load connected to utility power source
start. On engine startup, an “engine warm-up timer” on
the generator should start timing. After the timer has Figure 3-49. Manual Transfer Switch Operation
expired (about 15 seconds), the transfer relay (TR1)
energizes to deliver generator source voltage to the Results
standby closing coil terminals. If generator voltage is 1. If there is no evidence of binding, sticking, or
available to the standby closing coil terminals, but excessive force required the test is GOOD. Refer
transfer to STANDBY does not occur, the cause of the back to the flow chart.
failure may be (a) a failed standby closing coil and/or
2. If evidence of sticking, binding, excessive force is
bridge rectifier, or (b) a seized or sticking actuating coil or
required to move the contactor, find cause of
load contact. This test will help to evaluate whether any
binding or sticking and repair or replace damaged
sticking or binding is present in the contactor.
components.
Procedure
1. Set the generator main line circuit breaker (MLCB) Test 22 – Check Wire 23 and 194
to the “Open” position. Circuits
2. Set the controller to OFF.
General Theory
3. Disconnect Utility from the transfer switch.
An OPEN or improperly grounded circuit in either Wire 23
Do not attempt manual transfer switch operation or Wire 194 will prevent a transfer from occurring. This
until all voltage to the switch have been test assumes that battery voltage is sufficient (at least
disconnected. Failure to turn off all power voltage 12.2 VDC).
supplies may result in extremely hazardous and
NOTE: There are three variations of Transfer Relays
possibly lethal electrical shock.
(TR1) used in production. See Table 3-5, and Figure 3-
4. Locate the manual transfer handle inside the 50, Figure 3-51 and Figure 3-52 for proper pin
switch enclosure. identification.

98 Diagnostic Repair Manual

 Section 3.4 Diagnostic Tests

energizes, generator source voltage is available to

operate the standby closing coil. Without generator
Table 3-5. TR1 Relay Terminal Connections
source voltage available, the closing coil will remain de-
Clear Yellow energized and transfer to the STANDBY position will not
Relay Clear Square
Rectangle Rectangle occur. This test will determine if the TR1 relay is
Wire 194 A 7 13 functioning normally.

Wire 23 B 8 14 NOTE: There are three variations of Transfer Relays

(TR1) used in production. See the figures in Test 23 –
Wire N1A 7 5 9 Test Transfer Relay for identification.
Wire 126 1 1 1
Procedure
Wire E1 9 6 12
1. Disconnect all wires from the TR1 relay to prevent
Wire 205 6 4 8 interaction.
f003429

Procedure/Results 126 205

1. Check for DC voltage at Wire 194 on the TR1 relay
E1
in the transfer switch. 10-12 Volts DC is sufficient.
a. If DC voltage is not present at Wire 194 on the
TR1 Relay, check for DC Voltage at the
terminal block in the transfer switch and at the
terminal block in the generator. If not present at
either location, continue to Step 2.
b. If DC voltage is present at Wire 194 on the
N1A
TR1 relay, proceed to Step 3. 23

194
2. Disconnect Wire 194 from the transfer switch side COIL NOMINAL RESISTANCE = 120 Ohms
003429
of the terminal block in the generator, and then Figure 3-50. Clear Transfer Relay Test Points
check for DC voltage at this terminal block.
a. If DC voltage is now present but wasn’t before,
check for a short to ground between generator
and transfer switch. 205

b. If DC voltage is not present at the terminal 1 2

block, verify the presence of DC Voltage at the
controller and for connector/wire/pin integrity. 3 4
126
See Appendix A Controller Identification for E1
or
E2A

specific pin location. If okay, replace the 5 6

controller.
3. With the generator running (MANUAL or AUTO), N1A
8
7
connect a jumper wire from ground to Wire 23
23
located at the terminal block in the transfer switch.
Listen and visually watch for the energizing of the 194
COIL NOMINAL RESISTANCE = 160 Ohms 002523
TR1 Relay and for the transfer to Standby.
a. If the TR1 Relay visually and audibly energized Figure 3-51. Clear Transfer Relay Test Points
(clicked) and the contactor transferred to the
STANDBY position, proceed to Test 25 –
Check Wire 23. 205
b. If the CONTACTOR did not transfer to the 1 4
STANDBY position and the TR1 Relay DID or
DID NOT energize, proceed to Test 23 – Test 5 8
126
Transfer Relay. E1
or
E2A

9 12
Test 23 – Test Transfer Relay
N1A
13 14
General Theory
23
In automatic mode, transfer to standby will not occur until 194
COIL NOMINAL RESISTANCE = 163 Ohms 003430
the transfer relay (TR1) energizes. When TR1 relay
Figure 3-52. Yellow Transfer Relay Test Points
Diagnostic Repair Manual 99
Section 3.4 Diagnostic Tests

Table 3-7. Clear Transfer Relay (small) OMRON®

J2
Connect DMM Test Desired Meter Reading
1
2
A/C 1 A/C 1 E2A 205 Leads Across:
1 A/C 2 Energized De-Energized
A/C 2 N1A 00
2 A/C 3
1 Terminals 4 and 6 Continuity Infinity
A/C 3 A/C 4
2
1 4 8 Terminals 1 and 5 Infinity Continuity
2 A/C 4
3 7
J1
Terminals 7 and 8 (Coil) 160 Ohms
T1
2 6
CUSTOMER
N1 1 5
CONTROL
N2
MOLEX Table 3-8. Yellow Transfer Relay (small) IDEC®
0 GROUND
CONNECTIONS
194 +12V 4 8 126 N2A
23 TRANSFER 3 7 Connect DMM Test Desired Meter Reading
2 6 T1A N2A Leads Across:
1 5 Energized De-Energized

Terminals 8 and 12 Continuity Infinity

Terminals 1 and 9 Infinity Continuity

N2 N1 T1 Terminals 13 and 14 163 Ohms

Figure 3-53. Integrated SACM Test Points (Coil)

2. Set DMM to measure resistance. Table 3-9. Integrated SACM

3. See appropriate figure. With the wires
disconnected, connect the DMM test leads across Connect DMM Test Desired Meter Reading
Leads Across:
relay terminals where Wires 194 and 23 were Energized De-Energized
connected. Measure and record the resistance.
Pins 4 and 8 Continuity Infinity
4. See appropriate figure. Using jumper wires,
connect one fused jumper wire from the positive Pins 2 and 3 Infinity Continuity
post of the battery to the relay terminal that had
Wire 194 and connect the other jumper wire from Wires 23 and 194 339.5 Ohms
the negative post of the battery to the relay
terminal that had Wire 23. Results
5. Connect the DMM test leads across relay 1. Compare the results with the appropriate table. If
Terminals per Table 3-6, Table 3-7, and Table 3-8 the relay tests good, refer back to flow chart.
based on the TR1 relay being tested. Measure and 2. Replace relay if defective.
record the resistance while energized and de-
energized.
Test 24 – Test Standby Control Circuit
a. Energize the relay. The meter should indicate
either INFINITY or CONTINUITY according to General Theory
the appropriate table.
See Figure 3-54. The standby coil (C2) requires 240
b. De-energize the relay. The DMM should VAC to energize. When the transfer relay energizes, 240
indicate CONTINUITY or INFINITY according VAC is applied to the C2 coil. Once energized, the coil
to the appropriate table. will pull the contactor down to the STANDBY position.
6. Repeat Step 5 across relay Terminals 7 and 1. Once in the STANDBY position, the limit switch (SW3)
will open, removing AC voltage from the C2 coil.
Table 3-6. Clear Transfer Relay (Ice Cube) Procedure/Results
Connect DMM Test Desired Meter Reading 1. Set the DMM to measure AC voltage.
Leads Across: 2. Measure between the E2 terminal and Terminal 2
Energized De-Energized
of the C2 coil, the DMM should indicate 240 VAC.
Terminals 6 and 9 Continuity Infinity a. If 240 VAC was not measured, continue
Terminals 1 and 7 Infinity Continuity testing.
b. If 240 VAC was measured, replace the C2 coil.
Terminals A and B 120 Ohms
3. Verify the contactor is in the UTILITY position.

100 Diagnostic Repair Manual

 Section 3.4 Diagnostic Tests

*Refer to the appropriate schematic

for the unit being worked on. 1 2
C1
E
A
TR1 N1 N2

1 2 F
3 4
SW2
5 6

SW1
7 8
B
SW3

H
E1 E2

D E1 205 T1 T2
C2
1 2
C

E2

G
002524

Figure 3-54. Typical Standby Control Circuit Test Points*

4. Remove Wire B from the C2 coil. 11. Measure between the E2 terminal and the bottom
5. Set the controller to AUTO mode. Turn off utility terminal of the SW3, the DMM should indicate 240
power supply to the transfer switch, simulating a VAC.
utility failure. The generator should start and the a. If 240 VAC was NOT measured, verify the limit
transfer relay should energize. switch (SW3) is wired correctly, proceed to
6. Measure across lugs E1 and E2, the DMM should Test 27 – Test Limit Switches.
indicate 240 VAC. b. If 240 VAC was measured, proceed to Step 12.
a. If 240 VAC was NOT measured, go back to 12. Measure between the E2 terminal and terminal 2 of
Test 20. the C2 coil, the DMM should indicate 240 VAC.
b. If 240 VAC was measured, proceed to Step 7. a. If 240 VAC was NOT measured, repair or
7. Measure for the voltage on Wire B from the lug to 1 replace Wire B.
of the C2 coil (Wire B previously removed from the b. If 240 VAC was measured, replace the C2 coil.
coil) and B, the DMM should indicate 240 VAC.
a. If 240 VAC was NOT measured, repair or Test 25 – Check Wire 23
replace Wire E2.
b. If 240 VAC was measured, proceed to Step 8. General Theory
8. Measure between the E2 lug and Terminal 9 on the The controller located in the generator is responsible for
TR1, the DMM should indicate 240 VAC. grounding Wire 23 in order to initiate a transfer. When
a. If 240 VAC was NOT measured, repair or Wire 23 closes to ground the transfer relay (TR1)
replace Wire E1. energizes. To initiate a transfer back to Utility the TR1
relay must de-energize. If the TR1 relay is staying
b. If 240 VAC was measured, proceed to Step 8. energized, a faulty Wire 23 could be the cause. This test
9. Measure between the E2 terminal and terminal 6 of assumes that battery voltage is sufficient (at least 12.2
the TR1, the DMM should indicate 240 VAC. VDC).
a. If 240 VAC was NOT measured, replace
transfer relay. Procedure/Results
1. Set the controller to OFF.
b. If 240 VAC was measured, proceed to Step 10.
2. Set the DMM to measure DC voltage.
10. Measure between the E2 terminal and the top
terminal of SW3 the DMM should indicate 240 3. See Figure 3-56 or Figure 3-57. Disconnect and
VAC. isolate Wire 23 from the transfer switch side of the
terminal block in the generator. Observe the
a. If 240 VAC was NOT measured, repair or transfer switch.
replace Wire 205.
a. If the transfer relay (TR1) DID NOT de-
b. If 240 VAC was measured, proceed to Step 11. energize and the Transfer Switch DID NOT
return to Utility, proceed to Step 7.
Diagnostic Repair Manual 101
Section 3.4 Diagnostic Tests

b. If the transfer relay (TR1) de-energized and the 9. If DC Voltage was measured, proceed to the next
Transfer Switch returned to Utility, proceed to step.
the next step.
4. Set the controller to the AUTO mode. Utility
Voltage must be present. Verify that Utility is
present at N1 and N2 Terminal Block in the
generator.
5. Using the appropriate menu map, access the
OUTPUTS display (Figure 3-55) via the DEALER
menu (Evolution) or DEBUG menu (Nexus) on the
controller. N1 N2 T1 0 194 23
6. See Figure 3-55. Digital Output 8 is the Wire 23
output from the controller (Figure 3-55)
a. If Output 8 is displaying a “1”, the control board
is grounding Wire 23. Replace the controller.
002525
b. If Output 8 is displaying a “0”, the control board A A.Terminal Block
is NOT grounding Wire 23, proceed to the next B
B.Terminal Strip - Customer Side
step.
Figure 3-57. Transfer Relay Test Points – Evolution

OUTPUTS: 1 - 8: 10. With Wire 23 removed from the terminal block in

the previous step (transfer switch side), check the
1 0 1 1 0 0 0 1 voltage between Wire 23 previously disconnected
and ground.
OUTPUT 8 a. If no DC Voltage was measured, an open
002522
exists on Wire 23 between the generator and
Figure 3-55. The Output Screen – Output 8
transfer switch.
7. See Figure 3-56 or Figure 3-57. Ensure that Wire b. If a low DC Voltage was measured, a short to
23 is disconnected from the transfer switch side of ground exists on Wire 23 between the
the terminal block on the generator. generator and transfer switch.
c. Repair or replace Wire 23 as needed between
the generator control panel and transfer switch
UT

GN
NE

relay (TR1).

B A

N1 N2 T1
209 210 0 194 23

003469
A A.Terminal Block B

B.Terminal Strip - Customer Side A.Terminal Block

Figure 3-56. Transfer Relay Test Points – Nexus B.Terminal Strip - Customer Side

8. Connect the positive meter test lead to Wire 194 at Figure 3-58. Transfer Relay Test Points – Evolution
the terminal block in the generator and connect the 2017
negative meter test lead to the ground lug. Verify
that DC Voltage is present.
a. If DC Voltage was not measured, refer back to
the flowchart (Test 22).

102 Diagnostic Repair Manual

 Section 3.4 Diagnostic Tests

Test 26 – Test Utility Control Circuit b. If 240 VAC is not measured proceed to Step 9.
7. Checking coil continuity:
General Theory a. If continuity is measured proceed to Step 8.
See Figure 3-59. The utility coil (C1) requires 240 VAC to b. If there is no continuity, replace the coil.
energize. When the transfer relay (TR1) de-energizes, 8. Measure the voltage across point C (Wire N2A
240 VAC is applied to the C1 coil. Once energized, the previously removed) and B, the DMM should
coil will pull the CONTACTOR up to the “Utility” position. indicate 240 VAC.
Once in the UTILITY position, the limit switch (SW2) will
a. If 240 VAC was NOT measured, repair or
open, removing AC voltage from the C1 coil.
replace Wire N2A.
Procedure b. If 240 VAC was measured, proceed to Step 9.
1. Set the controller to OFF. Disconnect Wire 194 9. Measure for voltage between the N2 lug and the
from the transfer switch terminal strip. F1 terminal A. The DMM should indicate 240 VAC.
2. Set DMM to measure AC voltage. a. If 240 VAC was NOT measured, repair or
replace Wire N1A.
3. Disconnect Utility supply voltage from the transfer
b. If 240 VAC was measured, proceed to Step 10.
switch.
10. Measure for voltage from the N2 lug and Terminal
4. Verify the transfer switch is in the STANDBY
7 of the TR1, the DMM should indicate 240 VAC.
position.
a. If 240 VAC was NOT measured, repair or
5. Turn on Utility supply voltage to the transfer switch.
replace Wire N1A.
a. If transfer to Utility occurs, the transfer relay
b. If 240 VAC was measured, proceed to Step 11.
(TR1) was energized preventing a re-transfer
to Utility. Proceed to Test 25 – Check Wire 23. 11. Measure for voltage between the N2 lug and
terminal 1 of the TR1, the DMM should indicate
b. If transfer to Utility does NOT occur, proceed to
240 VAC.
Step 7.
a. If 240 VAC was NOT measured, replace
6. Remove two wires from the utility coil and check for
transfer relay.
240 VAC.
b. If 240 VAC was measured, proceed to Step 12.
a. If 240 VAC is measured check utility coil for
continuity.

126
N2A H
A
F TR1 C
1 2
N2A
1 2
3 4 C1
5 6 A
E 7 8 I N1 N2

N1A
SW2 B
G
N1A SW1
SW3
D

E1 E2
A A A
B T1 T2
C2
F1 F2 F3 1 2
*Refer to the appropriate schematic
for the unit being worked on.
B B B

002526
Figure 3-59. Typical Utility Control Circuit Test Points

Diagnostic Repair Manual 103

Section 3.4 Diagnostic Tests

12. Measure for voltage between the N2 lug and the 10. Manually actuate the CONTACTOR to the “Utility”
bottom terminal of the SW2. The DMM should position. Measure and record the resistance.
indicate 240 VAC. 11. Repeat Step 4 and 5 several times and verify the
a. If 240 VAC was NOT measured, repair or DMM reading at each switch position.
replace Wire 126.
Coil Nominal Resistance: 480-520k ohms
b. If 240 VAC was measured, proceed to Step 13.
13. Measure for voltage between the N2 lug and the Results
top terminal of the SW2. The DMM should indicate 1. If the DMM indicated CONTINUITY in Step 4 and
240 VAC. 10 and INFINITY in Step 5 and 9 the limit switches
a. If 240 VAC was not measured, verify the limit are good. Refer back to flowchart.
switch (SW2) is wired correctly and proceed to 2. If the DMM did NOT indicate CONTINUITY in Step
Test 27 – Test Limit Switches. 4 or 10 and INFINITY in Step 5 or 9 the limit
b. If 240 VAC was measured, proceed to Step 14. switch(es) are bad. Repair or replace appropriate
14. Measure for voltage between the N2 lug and switch(es).
terminal 2 of the C1 coil. The DMM should indicate
240 VAC. Test 28 – Check Fuses F1 and F2
a. If 240 VAC was not measured, repair or
General Theory
replace Wire A.
b. If 240 VAC was measured, replace the C1 coil. Fuses F1 and F2 are connected in series with the N1 and
N2 circuits, respectively. A blown fuse will open the
applicable circuit and will result in (a) generator startup
Test 27 – Test Limit Switches and transfer to the “Standby”, or (b) failure to re-transfer
General Theory back to utility source.

Wired to the normally CLOSED contacts, the limit Procedure

switches provide a means to interrupt the transfer 1. On the generator panel, set the controller to OFF.
circuits. When the CONTACTOR changes position, the
2. Disconnect Utility from the transfer switch.
limit switch contacts change state to become OPEN.
3. See Figure 3-60. Remove fuse F1 and F2 from the
Procedure fuse holder.

With the controller set to OFF, the generator main circuit 4. Inspect and test fuses for an OPEN condition with
breaker “Open”, and Utility Voltage disconnected from the a DMM set to measure resistance. CONTINUITY
transfer switch, test limit switches SW2 and SW3 as follows. should be measured across the fuse.

1. To prevent interaction, disconnect Wire 126 and Results

Wire A from the limit switch (SW2) terminals.
1. Replace blown fuse(s) as needed.
2. Set the DMM to measure resistance.
N1A N2A T1A
3. Connect the DMM meter test leads across the two
outer terminals on SW2 from which the wires were
disconnected.
A A A
4. Manually actuate the CONTACTOR to the
“Standby” position. Measure and record the
resistance. F1 F2 F3

5. Manually actuate the CONTACTOR to the “Utility”

B B B
position. Measure and record the resistance.
6. Repeat Step 4 and 5 several times and verify the
DMM reading at each switch position.
N1 N2 T1 002633
7. To prevent interaction, disconnect Wire 205 and
Wire B from the limit switch (SW3) terminals. Figure 3-60. Transfer Switch Fuse Block
8. Connect the DMM meter test leads across the two
outer terminals on SW3 from which the wires were
disconnected.
9. Manually actuate the CONTACTOR to the
“Standby” position. Measure and record the
resistance.

104 Diagnostic Repair Manual

 Section 3.4 Diagnostic Tests

Test 29 – Check Fuse F3

B C

General Theory A

Connected in series with Load Wire T1, F3 provides 120

VAC to the generator to operate the battery charger. A
blown fuse will result in a possible dead battery situation.

Procedure
1. On the generator panel, set the controller to OFF.
2. Disconnect Utility from the transfer switch.
3. Remove fuse F3 from the fuse holder.
4. Inspect and test fuses for an OPEN condition with
a DMM set to measure resistance. CONTINUITY
D
should be measured across the fuse.
E F
002448
Results A. Line Side D. Load Side
1. Replace blown fuse as needed. B. 11 E. E1
C. 44 F. E2
Figure 3-61. Main Line Circuit Breaker
Test 30 – Check Main Circuit Breaker
General Theory Test 32 – Check N1 and N2 Wiring
Often the most obvious cause of a problem is over- General Theory
looked. If the generator main line circuit breaker (MLCB)
is set to “Open”, the electrical loads will not receive A shorted Wire N1 or N2 to ground can cause fuse F1 or
power. If the connected loads are not receiving voltage a F2 to blow.
possible cause could be, the MLCB has failed OPEN.
Procedure
Procedure 1. On the generator panel, set the controller to OFF.
The generator main line circuit breaker (MLCB) is located 2. Turn off the utility power supply to the transfer
underneath the control panel side cover. If loads are not switch, using whatever means provided.
receiving power, verify the breaker is set to the “Closed” 3. Remove fuses F1, F2, and F3 from the fuse holder.
position. If the beaker is suspected to have failed, test it 4. Remove the generator control panel cover.
as follows. Disconnect the connector that supplies the
1. Set the DMM to measure resistance. controller T1 located in the control panel.
2. With the generator shutdown, disconnect all wires 5. Set DMM to measure resistance.
from the MLCB terminals, to prevent interaction. 6. Connect the positive meter test lead to Wire N1 at
the terminal block in the control panel.
3. See Figure 3-61. Connect one meter test lead to
the Wire 11 terminal on the breaker and the other a. Connect the negative meter lead to the ground
test lead to the E1 terminal. lug. INFINITY should be measured.
4. Set the breaker to its “Closed” position; the DMM b. Connect the negative meter lead to Wire 23 at
should indicate CONTINUITY. the terminal strip. INFINITY should be
measured.
5. Set the breaker to its “Open” position; the DMM
c. Connect the negative meter lead to Wire 194
should indicate INFINITY.
at the terminal strip. INFINITY should be
6. Repeat Step 4 and 5 with the DMM meter leads measured.
connected across the Wire 44 terminal and the E2
d. Connect the negative meter lead to Wire 0 at
terminal.
the terminal strip. INFINITY should be
measured.
Results
e. Connect the negative meter lead to Wire N2 at
1. If the circuit breaker tests good, refer back to the
the terminal block. INFINITY should be
flow chart.
measured.
2. If the breaker failed Steps 4 or 5, replace the f. Connect the negative meter lead to the neutral
breaker. connection. INFINITY should be measured.

Diagnostic Repair Manual 105

Section 3.4 Diagnostic Tests

7. Connect the positive meter test lead to Wire N2 at Test 34 – Check Utility Sensing
the terminal block in the control panel. Voltage at the Circuit Board
a. Connect the negative meter lead to the ground
lug. INFINITY should be measured. General Theory
b. Connect the negative meter lead to Wire 23 at If the generator starts and transfer to STANDBY occurs in
the terminal strip. INFINITY should be automatic mode when acceptable UTILITY source
measured. voltage is available at the terminal block, the next step is
c. Connect the negative meter lead to Wire 194 to determine if sensing voltage is reaching the controller.
at the terminal strip. INFINITY should be
measured. NOTE: The System Ready LED will flash in AUTO or
UTILITY LOST will display on the panel.
d. Connect the negative meter lead to Wire 0 at
the terminal strip. INFINITY should be Procedure
measured.
1. Set the controller to OFF.
e. Connect the negative meter lead to the neutral
2. Disconnect the harness connector containing
connection. INFINITY should be measured.
Wires N1 and N2 from the controller.
Results 3. Set a DMM to measure AC voltage.
4. Connect one meter test lead to Wire N1. Connect
If a short is indicated in Step 6 or Step 7, repair wiring and
the other meter test lead to Wire N2. Approximately
repeat test.
240 VAC should be measured.

Test 33 – Check N1 and N2 Voltage Results

1. If voltage was measured in Step 4 and the pin con-
General Theory nections are good, replace the circuit board.
Loss of utility source voltage to the generator will initiate 2. If voltage was NOT measured in Step 4, repair or
a startup and transfer by the generator. Testing at the replace Wire N1/N2 between connector and
control panel terminal block will divide the system in two, terminal block.
thereby reducing troubleshooting time.
Test 35 – Check Utility Sense Voltage
Procedure
The N1 and N2 terminals in the transfer switch deliver
1. Set the controller to OFF.
utility voltage “sensing” to a circuit board. If voltage at the
2. Set a DMM to measure AC voltage. terminals is zero or low, standby generator startup and
3. See Figure 3-62. Connect one test lead to Wire N1 transfer to the “Standby” source will occur automatically
at the terminal block in the generator control panel. as controlled by the circuit board. Zero or low voltage at
Connect the other test lead to Wire N2. Utility line- these terminals will also prevent transfer back to the
to-line voltage should be measured. “Utility” source.

Results Procedure
Refer to Flow Chart. With utility source voltage available to terminal lugs N1 and
N2, use a DMM to test for utility source line-to-line voltage
across terminal locations N1 and N2 terminals. Normal
240 VAC line-to-line utility source voltage should be indicated.

Results
C 1. If voltage reading across the N1 and N2 terminals
is zero or low, refer to Flow Chart.
2. If voltage reading is good, refer to Flow Chart.

002527
A. N1
B. N2
C. Test Points
Figure 3-62. Terminal Block Test Points

106 Diagnostic Repair Manual

 Section 3.4 Diagnostic Tests

N1A N2A T1A Test 37 – Test SMM Contactor Line,

Load and Control
General Theory
A A A The SMM Load Shed Module (integral to load shedding)
requires line voltage from either the utility or the
generator for it to operate. If line voltage is present, but
F1 F2 F3
the SMM is still not operating, this test will confirm the
proper operation of the contactor.
B B B
Required Tools
• Meter test leads that are capable of measuring
voltage.
N1 N2 T1 002633 • Phillips screwdriver.
Figure 3-63. Transfer Switch Fuse Block
Procedure
Test 36 – Check T1 Wiring 1. Remove the four (4) screws securing the cover to
the SMM Load Shed Module.
General Theory
2. Verify the LED is ON, but not flashing.
If the T1 wiring is shorted to ground can cause the F3
a. If the LED is OFF or flashing in any interval,
fuse to blow.
return to the flowchart.
Procedure 3. Set the DMM to measure AC volts.
1. Set the controller to OFF. 4. Place the meter leads across the line (input)
2. Remove F1, F2, and F3 from the fuse holder in the terminals and record the voltage.
transfer switch. 5. Place the meter leads across the load (output)
3. Disconnect the proper controller harness terminals and record the voltage.
connector that has Wire T1 in it from the controller.
4. Set the DMM to measure resistance. Results
a. Connect one meter test lead to T1 on the 1. If the meter indicated less than approximately 240
customer connection in the generator and the VAC in Step 4, stop testing and check source volt-
other meter lead to ground. Measure and age coming from the circuit breaker.
record the resistance. 2. If the meter indicated approximately 240 VAC in
b. Connect one meter test lead to T1 on the Step 4, but not in Step 5, replace the contactor.
customer connection in the generator and the
other meter test lead to Wire 194. Measure
and record the resistance.
c. Connect one meter test lead to T1 on the
customer connection in the generator and the
other meter test lead to Wire 23. Measure and
record the resistance.
d. Connect one meter test lead to T1 on the
customer connection in the generator and the
other meter test lead to Wire N1. Measure and
record the resistance.
e. Connect one meter test lead to T1 on the
customer connection in the generator and the
other meter test lead to Wire N2. Measure and
record the resistance.

Results
1. If the DMM indicated INFINITY in Steps 4a -4e,
replace the controller.
2. If the DMM indicated CONTINUITY, repair or
replace the wiring in the appropriate circuit.

Diagnostic Repair Manual 107

Section 3.4 Diagnostic Tests

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108 Diagnostic Repair Manual

 Section 4.1 Description and Major Components
Introduction

UT

GN
NE

D
This section will familiarize the reader with the various
components that make up the Engine and DC Control
systems.
Topics covered in this section are:
• Customer Connections
• Controller
N1 N2 T1
• Menu System Navigation 209 210 0 194 23
• LED Display
• Battery Charger
• AUTO-OFF-MANUAL
• 7.5 Amp Fuse 209 210 0 194 23
003162
• Starter Contactor Relay
Figure 4-1. Nexus Customer Connections
• Common Alarm Relay
• Connector Pin Descriptions

Customer Connection
The terminals of this terminal strip connect to identically
numbered terminals in the transfer switch. The terminal
block provides the electrical connection for the controller
at the following connection points:
• UTILITY N1 (Utility Sensing)
• UTILITY N2 (Utility Sensing)
• LOAD T1 (Internal Battery Charger) - 60 Hz Unit 004920

• LOAD T2 (Internal Battery Charger) - 50 Hz Unit Figure 4-2. 2017 Evolution Customer Connections
• Wire 194 (Transfer Relay)
• Wire 23 (Transfer Relay)

Table 4-1. Control Panel Connections

Terminal Numbering
Wire Numbers
Decal
N1 & N2 - 240 VAC - Sensing for Utility Dropout and
A YELLOW #1 & #2
Pickup
1
B* BLUE #3 T1 - Fused 120 VAC for Battery Charger (*see NOTE)
N1
A UTILITY
SENSE
C BLACK #3 0 - DC (-) Common Ground Wire
A N2
UTILITY D RED #4 194 - DC (+) 12 VDC for Transfer Controls
B T1
VAC LOAD E WHITE #5 23 - Transfer Control Signal Wire
SUPPLY

F BLUE #1 & #2 Optional Alarm Relay Contacts (Normally Open)

209
F COMMOM Note: Must be connected to keep battery charged whether unit is running or not.
ALARM
3
210
F COMMON
ALARM

C 0
DC COMMON
Table 4-2. Ground and Neutral Connections

D 194 1 Large Neutral Lug Torque Spec 2/0 TO 14 AWG 120 in-lb (13.56 N-m)
+12 VDC

E 23 2 Large Ground Lug Torque Spec 2/0 TO 14 AWG 120 in-lb (13.56 N-m)
TRANSFER
Ground and Neutral Bus Bar Torque Specs:
2
4-6 AWG 35 in-lb (3.95 N-m)
3
8 AWG 25 in-lb (2.82 N-m)
10-14 AWG 20 in-lb (2.26 N-m)

Note: A 25 in-lb (2.82 Nm) torque should be applied to the ground wire
and neutral wire connection to the ground/neutral bar.
000914

Figure 4-3. Evolution Control Wiring - 60 Hz (found behind control board)

Diagnostic Repair Manual 109
Section 4.1 Description and Major Components

Table 4-3. Control Panel Connections

Terminal Numbering
Wire Numbers
Decal
N1 & N2 - 240 VAC - Sensing for Utility Dropout and
A YELLOW #1 & #2
Pickup
N1
A UTILITY 1 B* BLUE #3 T1 - Fused 120 VAC for Battery Charger (*see NOTE)
SENSE
A N2 C* WHITE #4 T2 - Fused 120 VAC for Battery Charger (*see NOTE)
UTILITY

B
T1 D BLACK #3 0 - DC (-) Common Ground Wire
VAC LOAD
SUPPLY
C T2 E RED #4 194 - DC (+) 12 VDC for Transfer Controls
VAC LOAD
SUPPLY
F WHITE #5 23 - Transfer Control Signal Wire

209 G BLUE #1 & #2 Optional Alarm Relay Contacts (Normally Open)

G COMMOM 3
ALARM
Note: Must be connected to keep battery charged whether unit is running or not.
210
G COMMON
ALARM
0
D DC COMMON
Table 4-4. Ground and Neutral Connections
E 194
+12 VDC 1 Large Neutral Lug Torque Spec 2/0 TO 14 AWG 120 in-lb (13.56 N-m)
F 23
TRANSFER 2 Large Ground Lug Torque Spec 2/0 TO 14 AWG 120 in-lb (13.56 N-m)
2
Ground and Neutral Bus Bar Torque Specs:
4-6 AWG—35 in-lb (3.95 N-m)
3
8 AWG—25 in-lb (2.82 N-m)
10-14 AWG—20 in-lb (2.26 N-m)

000620

Figure 4-4. Evolution Control Wiring - 50 Hz (found behind control board)

Controller
The controller is responsible for all standby electric Table 4-5. Digital Inputs and Outputs
system operations including (a) engine startup, (b)
Position Digital Inputs Digital Outputs
engine running, (c) automatic transfer, (d) automatic re-
transfer, and (e) engine shutdown. In addition, the 1 Not Used/Aux Shutdown* Not Used
controller performs the following functions:
2 Low Oil Pressure Not Used
• Automatic voltage regulation.
3 High Temperature Not Used
• Starts and exercises the generator once every
seven days. 4 Not Used Battery Charger Relay
• Automatic engine shutdown in the event of low oil 5 Wiring Error Detect Fuel
pressure, high oil temperature, over speed, no
RPM sense, over crank, or low battery. 6 2-Wire Start Starter

• Maintains proper battery charge. 7 Auto Ignition

The controller harness connectors are used to 8 Manual Transfer
interconnect the controller with the various circuits of the
DC and AC systems. Connector pin locations, numbers, * Evolution units only with 1.18 firmware and higher.
associated wires and circuit functions are listed in the
appropriate appendix in the back of this diagnostics IMPORTANT NOTE: The generator engine will crank
manual. and start when the 7-day exerciser is set. The unit will
To control the generator the controller utilizes digital also crank and start every 7 days thereafter, on the
inputs and outputs. See Table 4-5 for the specific programmed day and time.
position and function. See Menu System Navigation to IMPORTANT NOTE: If the controller was OFF during its
view state of output or input. scheduled exercise time it will immediately attempt to
exercise when the unit is set to AUTO.

LED Display
Located next to the right side lock cylinder on the
generator, the LED Display provides a visual indication
the generators status. The LED Display has three LEDs:
110 Diagnostic Repair Manual
 Section 4.1 Description and Major Components

• Red LED- Illuminates during an Alarm condition or AUTO-OFF-MANUAL

when the controller is set to OFF mode. This feature permits the operator to (a) select fully
• Yellow LED- Illuminates when the controller automatic operation, (b) start the generator manually, or
generates a Maintenance Alert and attention is (c) stop the engine and prevent the automatic startup.
required. The Nexus controller has a 3-position switch. The
• Green LED- Illuminates when the system is ready Evolution controller has OFF-MANUAL-AUTO Mode
to respond to a Utility failure. buttons. See Figure 4-5 or Figure 4-6 for the location of
the switch or push buttons.
NOTE: On 2017 Evolution units (Firmware 1.17 and
above) the Green LED will flash when unit has
transferred to standby and is carrying load.

Battery Charger
The charger operates at one of three battery charging
voltage levels depending on ambient temperature.
• 13.5 VDC at High Temperature
• 14.1 VDC at Normal Temperature
• 14.6 VDC at Low Temperature
The battery charger is powered from a 120 VAC Load
connection through a fuse (F3) in the transfer switch.
This 120 VAC source must be connected to the Figure 4-5. Nexus Auto-Off-Manual Switch
Generator in order to operate the charger.
NOTE: 50 Hz units use fuses F3 and F4 and a 220 VAC
supply to the battery charger.
During a Utility failure, the charger will momentarily be
turned off until the Generator is connected to the Load.
During normal operation, the battery charger supplies all
the power to the controller; the Generator battery is not
used to supply power.
The battery charger will begin its charge cycle when
battery voltage drops below approximately 12.6V. The
charger provides current directly to the battery dependent
on temperature, and the battery is charged at the
appropriate voltage level for 18 hours. At the end of the
18 hour charge period battery charge current is 000425
measured when the Generator is off. If battery charge
current at the end of the 18 hour charge time is greater Figure 4-6. Evolution controller Off-Manual-Auto
than a pre-set level, or the battery open-circuit voltage is Buttons
less than approximately 12.5V, an “Inspect Battery”
(Nexus) or “Charger Warning” (Evolution) warning is Fuse
raised. If the engine cranks during the 18 hour charge
The fuse protects the controller against excessive
period, then the 18 hour charge timer is restarted.
current. If the fuse has blown, engine cranking and
At the end of the 18 hour charge period the charger does operation will not be possible. Should fuse replacement
one of two things. If the temperature is less than become necessary, use only an equivalent 7.5 amp
approximately 40 ºF the battery is continuously charged replacement fuse.
at a voltage of 14.1V (i.e. the charge voltage is changed
from 14.6V to 14.1V after 18 hours). If the temperature is
above approximately 40 ºF then the charger will stop
charging the battery after 18 hours.
The battery has a similar role as that found in an
automobile application. It sits doing nothing until it either
self-discharges below 12.6V or an engine crank occurs 002438
(i.e. such as occurs during the weekly exercise cycle). If
Figure 4-7. Typical 7.5 Amp Fuse
either condition occurs the battery charge will begin its 18
hour charge cycle.
Diagnostic Repair Manual 111
Section 4.1 Description and Major Components

Starter Contactor Relay/Solenoid On 2017 Evolution units the connections are made to the
controller via Wires 209 and 210 by connecting to the
(V-Twins and units with 426cc Engine) dedicated wire connections.

See Figure 4-8. The starter contactor relay (SCR)

provides a safe and controlled method of energizing the Table 4-6. Specifications
solenoid located on the starter. The controller is
responsible for energizing the relay when the start Contact Rating: 200 mA at 12 VDC
command is given.
NOTE: Contact rating is for resistive load only
16
13
Circuit Pin Descriptions
Table 4-7 provides the physical wire identification and
circuit functions.
13 16
COM NO Table 4-7. Circuit Pin Description

Evolution Nexus Wire ID Circuit Function

56 Y Y 0 Common Ground (DC) DC Field
0 Excitation Ground
56 0 Y Y 00 Neutral Connection for T1 (battery
002407 charger)
Figure 4-8. Starter Contactor Relay (V-twin Units) Y Y 2 DPE Winding (AC Excitation power)

Y Y 4 DC (+) Field Excitation

(410cc Single Cylinder Engine Units Only)
Y N 4A DC (+) Field Excitation (Before Field
See Figure 4-9. The Starter Contactor (SC) is located in Boost Diode)
the engine compartment and is mounted against the Y Y 6 DPE Winding (AC Excitation power)
firewall. The SC provides the electrical connection to
safely engage the starter. N Y 11 240 VAC Generator Voltage Sensing

Y N 11S 240 VAC Generator Voltage Sensing

56 16 13 12 VDC un-fused for the controller
Y Y 14 12 VDC output for engine run
condition. Used for fuel solenoid on
all controller units and choke
solenoid operation on Nexus
13 13 controllers only
BATTERY
12V
SC Y Y 18 Ignition Shutdown: The controller
grounds Wire 18 for ignition
0 16
shutdown and receives a reference
SM signal for speed control while
cranking and running

0 13 Y Y 23 Switched to ground (internally) to

13 energize the Transfer Relay

003174 N Y 44 240 VAC Generator Voltage Sensing

Figure 4-9. The Starter Contactor (Single Cylinder Y N 44S 240 VAC Generator Voltage Sensing
Units)
Y Y 56 12 VDC output to starter contactor
relay/solenoid
Common Alarm Relay Y Y 85 High temperature shutdown:
Shutdown occurs when Wire 85 is
The common alarm relay provides a set of contacts to grounded by contact closure in the
drive a customer provided external alarm indication. oil temperature switch
When the control is powered up, if there are no Alarms, Y Y 86 Low oil pressure shutdown:
the relay contacts will be OPEN. Any ALARM (not Shutdown occurs when Wire 86 is
grounded by loss of oil pressure in
warning) will trigger the common alarm relay to operate, the LOP switch
closing the contacts.
N Y 90 Switched to ground for choke
On Nexus and Evolution (2013), the connections are made solenoid operation
to the generator customer connection terminal strip (or Y Y 178 Two-wire Start Return
WAGO block) at Terminals 1 and 2 (Wires 209 and 210).
Y Y 183 Two-wire Start Input

112 Diagnostic Repair Manual

 Section 4.1 Description and Major Components

Table 4-7. Circuit Pin Description Menu System Navigation

Evolution Nexus Wire ID Circuit Function To get to the menu page, press the ESCAPE key from
Y Y 194 Provides 12 VDC to the transfer any page. It may need to be pressed several times
relay (TR1) before getting to the menu page. The currently selected
Y Y 209 Common Alarm Relay Output menu is displayed as a flashing word. Navigate to the
desired menu item by using the up and down arrow keys.
Y Y 210 Common Alarm Relay Output
When the desired menu item is flashing, press ENTER.
Y Y 387 RS-232 Port 1 Rx Depending on the menu selected, a list of choices may
Y Y 387A RS-232 Port 2 Rx be presented. Use the same navigation method to select
the desired screen. Refer to Section 1.3 Evolution Menu
Y Y 388 RS-232 Port 1 Tx
System Navigation or Section 1.4 Nexus Menu System
Y Y 388A RS-232 Port 2 Tx Navigation for additional information.
Y Y 389 RS-232 Port 1 Gnd
Changing Settings (Edit Menu)
Y Y 389A RS-232 Port 2 Gnd

Y N 398A Generator Current Sense A2

To change a setting, such as display contrast, go to the
EDIT menu and use the up and down arrow keys to
Y N 398B Generator Current Sense B2 navigate to the setting to change. Once this setting is
Y N 399A Generator Current Sense A1 displayed (e.g. Contrast), press the ENTER key to go into
Y N 399B Generator Current Sense B1
the edit mode. Use the up and down arrow keys to
change the setting. Press the ENTER key to store the
Y Y 817 Grounded by the controller to turn on new setting.
System Ready (Green) LED

Y Y 818 Grounded by the controller to turn on NOTE: If the ENTER key is not pressed to save the new
Alarm (Red) LED setting, it will only be saved temporarily. The next time
Y Y 819 Grounded by the controller to turn on the battery is disconnected, the setting will revert back to
the Maintenance (Yellow) LED the old setting.
Y Y 820 Positive voltage (5VDC) for status
LEDs

N Y J1 Model ID Resistor

Y Y N1 240 VAC Utility sensing voltage

Y Y N2 240 VAC Utility sensing voltage

Y N R1 Model ID Resistor

Y N R3 Model ID Resistor

Y Y T1 120 VAC for Battery Charger

Y N T2 240 VAC for Battery Charger

Y Y Red Stepper Power

Y Y Orange Stepper Motor B2 coil

Y Y Yellow Stepper Motor B1 coil

Y Y Brown Stepper Motor A2 coil

Y Y Black Stepper Motor A1 coil

Diagnostic Repair Manual 113

Section 4.1 Description and Major Components

EVOLUTION 1.0/SYNC 2.0 MENU MAP

EVOLUTION/SYNC2.0 HSB MENU MAP
READY TO RUN
Note: Menu functions and features may vary Hours of Protection
0 (H)
depending on unit model and firmware revision.

ESC
Running Manual
Running-Utility Lost
Running-Remote Start ENTER SYSTEM DATE/TIME
Running-2 Wire Start
Running - Exercise
Switched Off Battery Condition ENTER
Stopped - Auto BATTERY SUB MENUS
Stopped - Alarm “Good” “Inspect Battery” or “Check Battery” ESC

ENTER ESC

ENTER ENTER
- 1 thru 50 + - Run Log + “Run Log” ENTER
ESC ESC HISTORY
- 1 thru 50 + - Alarm Log + “Alarm Log” ESC
ENTER ENTER

Warning Message(s)
DEALER
Charger Warning
Charger Missing AC ENTER
Low Battery
Battery Problem
Exercise Set Error
USB Warning
Language ENTER Language Language Language
Download Failure + + +
ESC
FIRMWARE ERROR-9 Å English Æ + English - - + Espanol - - + Francais -
Overload Cooldown
SEEPROM ABUSE
Fuel Warning ESC
Fuel Selection ENTER Fuel Selection
ESC
Å NG or LP Æ + NG or LP -
Alarm Message(s)
High Temperature
Low Oil Pressure ESC
Cold Smart Start? ENTER Cold Smart Start?
Overcrank
ESC
Overspeed Å YES or NO Æ - YES or NO +
Overvoltage
Undervoltage
Overload ESC ESC
Underspeed
RPM Sensor Loss Time ENTER Current Date/Time ENTER Select Month (1-12) ENTER
Controller Fault ESC
Å Manual or AUTO Æ Å 2/13/16 13:00 Æ - 2 +
Wiring Error
Stepper Overcurrent
FIRMWARE ERROR-7
ESC ESC
Overload Remove Load
Low Volts Remove Load Exercise Time ENTER Select Frequency ENTER Quiet Test Mode ? ENTER
Stepper Over Current ESC
Å 14:00 Wednesday Æ - WEEKLY + - YES or NO +
Fuse Problem*
- BIWEEKLY +
- MONTHLY + Quiet Test Mode only
*“Fuse Problem” on Firmware on certain models
1.11 and older ONLY

Firmware Update ENTER Firmware Update

ESC
Å Press Enter Æ ESC Å Insert USB Æ

Figure 4-10. Main Menu Map

114 Diagnostic Repair Manual

 Section 4.1 Description and Major Components

EVOLUTION 1.0/SYNC 2.0 MENU MAP

Current Date/Time UP ARROW = +

02/13/16 13:00

ESC

ENTER
DOWN ARROW = -
Run Hours (H)
0.0

ESC ENTER

MAINT: Run Hrs

ESC

ENTER
Maint. Log Scheduled

Access Requires Password ENTER ESC

ENTER ESC

- 1 thru 50 + EXAMPLE:
"Battery Maintained" Inspect Battery 200 RnHr or 12/27/13
"Schedule A Serviced"
and
+ Language + "Schedule B Serviced"
Next Maintenance 200 RnHr or 12/27/13
"Maintenance Reset"
- + Portuguese -
"Inspect Battery"
"Service Schedule A"
"Service Schedule B"

Select “Yes” then Press “Enter” to continue or Press “ESCAPE” to escape out of updating.
During update process the Blue “Manual” light flashes, then the Green “Auto” light flashes.
Sequence does this twice. When update is complete the unit returns to Install Wizard menu.
When the controller powers up the very first screen displays the version number for a few seconds.
When update is complete remove Thumb Drive, then follow the Install Wizard Menu.

ESC ESC ESC ENTER

Select Date (1-31) ENTER Select Year (0-99) ENTER Select Hour (0-23) ENTER Select Min (0-59)
- 13 + - 16 + - 13 + - 0 +

ESC ESC ESC

ENTER
Select Hour (0-23) ENTER Select Min (0-59) ENTER Select Day
- 14 + - 0 + - Wednesday +

Possible Message(s)
Corrupted File "Current:V XXXX " ENTER "Are You Sure?"
Invalid File
File Not Found "USB: V XXXX" ESC "- Yes or No +"
Unsupported Device 005615

Figure 4-11. Main Menu Map

Diagnostic Repair Manual 115

Section 4.1 Description and Major Components

EVOLUTION 1.0/SYNC 2.0 HSB ACTIVATION

EVOLUTION/SYNC2.0 HSB ACTIVATION
AND
Note: INSTALL WIZARD
Menu functions MENU
and features MAP
may vary
depending on unit model and firmware revision.

Power Up Unit

FIRMWARE V 1.01
Use UP and DOWN arrows to select fuel type then press “ENTER”
HARDWARE V 1.05

ESC Fuel Selection

Activate me (ENT) or
Non Activated Unit Install Wizard
ESC to run in MANUAL + NG or LP -

ENTER
Activated Unit

ESC
Cold Smart Start? ENTER Cold Smart Start?

Å YES or NO Æ - YES or NO +
To activate go to
www.activategen.com
Note: If language was previously
programmed this goes directly to
“Select Hour”
Language + Language + L
Serial 1234567890
PASSCODE xxxxx + _______ - - + English - - +

ENTER
Use up and down arrows to change selection 0 Defaults to
thru 9. Press "Enter" to acccept selection and English if not
to move to the next digit. If passcode is correct selected.
goes to "Install Wizard." If not correct goes to
the message below.
Select Hour (0-23) ENTER Select Min (0-59) ENTER

- 14 + - 0 +

Wrong Passcode
* *
Try Again * Holding the Up or Down arrow
button for 2 seconds will speed dial
through the selections

Non Activated Unit

Select F
“NOT ACTIVATED!” Install Wizard ENTER Quiet Test Mode ? ENTER
- WEE
Hours of Protection
Set Exercise - YES or NO + - BIWE
0 (H)
- MON

Quiet Test Mode

To return to Activation Screen disconnect only on certain
battery and AC power to restart controller models

Figure 4-12. Activation and Install Wizard Menu Map

116 Diagnostic Repair Manual

 Section 4.1 Description and Major Components

UP ARROW = +

DOWN ARROW = -

ESC

+ Language + Language + Language +

- + Espanol - - + Francais - - + Portuguese -

ENTER Select Month (1-12) ENTER Select Date (1-31) ENTER Select Year (0-99)
- 2 + - 13 + - 13 +
* * *

Select Frequency
ENTER Select Hour (0-23) ENTER Select Min (0-59) ENTER Select Day
- WEEKLY +
- BIWEEKLY + - 14 + - 0 + - Wednesday +
- MONTHLY +
* * *

Switched to “OFF” ENTER

Hours of Protection SYSTEM DATE/TIME
0 (H)

BATTERY SUB MENUS

000429

Figure 4-13. Activation and Install Wizard Menu Map

Diagnostic Repair Manual 117

Section 4.1 Description and Major Components

EVOLUTION 1.0/SYNC 2.0 HSB FIRMWARE MENU MAP

EVOLUTION/SYNC2.0 HSB FIRMWARE MENU MAP
Note: Menu functions and features may vary Switched to “OFF”
depending on unit model and firmware revision. Hours of Protection
0 (H)

ESC

ENTER SYSTEM DATE/TIME

BATTERY SUB MENUS

ENTER ESC

HISTORY MAIN

EDIT DEALER

ENTER
- Language +
ESC
 English 

Fuel Selection
ESC
 NG or LP 

ESC - Current Date/Time +

 02/12/13 12:31 

Possible Message(s)
"Corrupted File"
"Invalid File"
EXERCISE TIME "File Not Found"
ESC "Unsupported Device"
 14:00 Wednesday 
"Insert USB"

Firmware Update ENTER Firmware Update ENTER

ESC
 Press Enter  ESC - Insert USB + ESC

Firmware Update
System not in the OFF position
Disabled Press OFF

Figure 4-14. Firmware Menu Map

118 Diagnostic Repair Manual

 Section 4.1 Description and Major Components

UP ARROW = +

DOWN ARROW = -

Alternate Firmware Update Method:

Control unit at main screen and Insert Thumb drive with Firmware
Power the unit down completely. Disconnect AC power.
Repower the controller allow unit to complete the update process.
During update process the Blue “Manual” light flashes, then the Green “Auto” light
flashes. Sequence does this twice. When update is complete the unit returns to setup
menu.
When the controller powers up the very first screen displays the version number for a
few seconds.
When unit finishes update remove thumb drive then follow the Install Wizard menu.

Select “Yes” and Press “Enter” to continue or Press

“ESCAPE” to escape out of updating.
During update process the Blue “Manual” light flashes, then
the Green “Auto” light flashes. Sequence does this once for
firmware (single file) and twice for firmware and hardware
(two files)
When the controller powers up the very first screen displays
the version number for a few seconds.
When update is complete remove Thumb Drive, then follow
the Install Wizard Menu.

"Current:V XXXX " ENTER "Are You Sure?"

"USB: V XXXX" ESC "- Yes or No +"

000430

Figure 4-15. Firmware Menu Map

Diagnostic Repair Manual 119

Section 4.1 Description and Major Components

EVOLUTION 1.0/SYNC 2.0 DEALER MENU MAP

EVOLUTION/SYNC2.0 HSB DEALER MENU MAP
Switched to “OFF”
Note: Menu functions and features may vary MAIN DISPLAY Hours of Protection
0 (H)
depending on unit model and firmware revision.

To access Dealer Menu enter Password from MAIN DISPLAY:

Up, Up, ESC, DN, Up, ESC, Up, ENTER

Note:Unit needs to be activated to access the Dealer Menu.

Press “ENTER” to modify. Use the

Startup Delay (sec)
*“Up” and “Down” arrows to change SYSTEM DATE/TIME
ESC
Å 2 to 1500 Æ
selection. Press “ENTER” to save.
* or BATTERY SUB MENUS
Press “ESCAPE” to return to previous
Run Hours (H) setting.
ESC ENTER ESC
Å 0.0 Æ

* 50 Hz Display
HISTORY MAINT

Util Volts Low Value Util Volts Low Value

ESC
Å 140 - 171 Æ Å 140 - 156 Æ
EDIT DEALER

*
ENTER ESC
Util Recovery Volts Util Recovery Volts
ESC
Å 190 - 216 Æ Å 175 - 198 Æ

* DEALER:

ENTER
Calibrate Current1 DEALER EDIT
Current 0.0
ESC
Å 1186 - 1780 Æ Å 1640 Æ
*
Calibrate Current 1, Calibrate Current 2,
Calibrate Current2 Current 0.0 Calibrate Volts. Special note: Press Enter
ESC to modify use the Up and Down arrows to
Å 1186 - 1780 Æ Å 1640 Æ make the change. Pressing Enter or ESC
* saves the changes. This is different from all
the others under Dealer Edit.
Calibrate Volts Calibrate Volts
ESC
Å 750 - 1280 Æ Å 1120 Æ
*
ENTER
(Performs Segment
2 Wire Start Select test of the display)
ESC
ESC
Å No or Yes Æ EcoGen Only
* Off Grid Mode
Yes or No
Reset Maintenance
ESC
Å No or Yes Æ UP ARROW = +
*
DOWN ARROW = -

Figure 4-16. Dealer Menu Map

120 Diagnostic Repair Manual

 Section 4.1 Description and Major Components

“Battery Voltage”
ESC
0 - 13.7

“Charging Status”
ESC
“Charging” or “Not Charging”

Run Hours (H)

ESC
0

Output Volts”
ESC
0

“Output Frequency (Hz)”

ESC
0.0

Engine Speed (RPM)

ENTER ESC
0

DISPLAY
Utility Input Volts
ESC
T TEST 0

ENTER ESC Ambient Temperature (deg F)

ESC
INPUTS: Utility 0 V 0
ESC
0 0 0 0 0 0 0 0

FIRMWARE V 1.01
ESC
HARDWARE V 1.05
OUTPUTS:Gen. 0 V
ESC
0 0 0 0 0 0 0 0
Commands:
Bootloader V0.2
ESC “Running Manual”
EEPROM V1.01
To Test Displays “Running - Utility Loss”
ESC
Press Enter “Running - Remote Start”
COMMAND:
ESC “Running - 2-wire Start”
Switched Off
“Running - Exercise”
IN AUTO PRESS
ESC “Switched Off”
ENTER FOR QT-TEST
Node Hz Volts “Stopped - Auto”
ESC
15 KW 60 120/240 “Stopped - Alarm”
ENTER ESC or ENTER

PRESS ENTER TO Note: Units equipped with Quiet Test only. Unit
ESC
STOP Quiet Test must be in AUTO and have Utility available in order
to view this screen and test the Quiet Test function.
000431

Figure 4-17. Dealer Menu Map

Diagnostic Repair Manual 121

122
PASSWORD Password is entered
“ESC, UP, UP ESC, DOWN, UP, ESC, UP, UP, ENTER” on this page. MAIN MENU
ESC

HISTORY STATUS EDIT DEBUG

ESC ESC ESC ESC

RESET
ALARM LOG RUN LOG STATE DISPLAY COMMAND VERSIONS MAINTENANCE
INPUTS OUTPUTS DISPLAYS QT TEST

EXERCISE If so equipped
ESC SOFTWARE
TIME
HARDWARE

Press the “ESCAPE” key IF APPLICABLE

Section 4.1 Description and Major Components

ESC to jump back up through

the menu levels. ENGINE CURRENT
HOURS TIME
Use the “+/-” key
+/- to navigate through
the menu. EDIT WITH
ENGINE
FREQUENCY PASSWORD
RPM ESC
Use the “ENTER” key
ENTER to select items or
enter data.
GENERATOR START-UP
FREQUENCY LANGUAGE DELAY
The possible Status messages of the display
are as follows: BATTERY The possible commands START-UP LANGUAGE
• Switched Off/Time & Date VOLTAGE
on Line 2 of the display DELAY
• Ready to Run/Time & Date
are as follows:
• Utility Loss Delay/Pausing for X Seconds

Figure 4-18. Nexus Main Menu Map

• Switched Off
• Cranking/Attempt # X RESET
• Running Manually FREQUENCY MAINTENANCE
• Running in Exercise/Time & Date
• Stopped in Auto Mode
• Running/Cooling Down
• Running - Utility Lost
• Running - Warning/Warning Message
• Running in Exercise CURRENT REMOTE
• Running - Alarm/Alarm Message
• Running from Radio TIME START
• Stopped - Alarm/Alarm Message
• Stopped - Warning/Warning Message
• Cranking/Pausing for X Seconds
• Running/Time & Date EXERCISE CALIBRATE
Note: Some versions may have slightly different parameters. TIME VOLTS
• Running/Warming Up
• Cranking - Warning/Warning Message
• Cranking - Alarm/Alarm Message 003069

Diagnostic Repair Manual

 Section 4.2 Engine Protective Devices
Engine Protective Devices circuit will be terminated, followed by the grounding of the
ignition circuit. This will result in closure of the fuel shutoff
Standby power generators will often run unattended for solenoid and subsequent loss of engine ignition.
long periods. Such operating parameters as (a) battery
voltage, (b) engine oil pressure, (c) engine temperature, (d)
engine operating speed, and (e) engine cranking and High Temperature Switch
startup are not monitored by an operator during automatic (Evolution e-Code 1400)
operation. Because engine operation will not be monitored, All Evolution 2017 and Prior Models
the use of engine protective safety devices is required to
prevent engine damage in the event of a problem. There See Figure 4-19. The contacts of this switch are normally
are alarm codes programmed to display when certain open and will close if the temperature exceeds
conditions exist. These codes are displayed where they approximately 293 ºF (144 ºC), initiating an engine
apply in the headings below and elsewhere in this manual. shutdown. The generator will automatically restart and
the fault on the LCD display will reset once the
temperature has returned to a safe operating level.
Low Battery Warning
The controller will continually monitor the battery voltage Overspeed
and display a “Low Battery” message if the battery
voltage falls below 12.1 VDC. After a 60 second delay, a During engine cranking and operation the controller
warning will be set. The fault will remain until repaired. receives AC voltage and frequency signals from the ignition
magneto via Wire 18. If engine speed exceeds
No other action is taken on a low battery condition. The
approximately 72 Hz (4320 rpm), controller logic will de-
warning will automatically clear if the battery voltage rises
energize the “run relay” (internal to the controller). The relay
above 12.4 VDC.
contacts will open, terminating engine ignition and closing
A the fuel shutoff solenoid. The engine will then shut down.
This protects the engine and alternator against damaging
B
over speeds. During cranking, the rpm signal generated by
the magnetos is used to terminate engine cranking.

RPM Sensor Failure

(Evolution e-Code 1501, 1505, 1511, 1515)
During cranking, if the board does not see a valid rpm
signal within three (3) seconds it will shutdown and latch
out on “RPM Sensor Loss.”
If the rpm signal is lost for one full second during running,
002634 the controller will shutdown the engine, wait 15 seconds,
A.Low Oil Switch B.High Temp Switch then re-crank the engine.
Figure 4-19. Engine Protective Switches If an rpm signal is not detected within the first three (3)
seconds of cranking, the controller will shut down the
Low Oil Pressure engine and latch out on “RPM Sensor Loss.”
(Evolution e-Code 1300) If an rpm signal is detected the engine will start and run
normally. If the rpm signal is subsequently lost again, the
All Evolution 2017 and Prior Models
controller will try one re-crank attempt before latching out
See Figure 4-19. An oil pressure switch is mounted near and the LCD displays “RPM Sensor Loss.”
the oil filter. This switch has normally closed contacts that
are held open by engine oil pressure during cranking and NOTE: A common cause of RPM Sensor Loss fault is
startup. Should oil pressure drop below approximately 5 the lack of engine cranking. This could be due to a faulty
psi, the switch contacts will close. On closure of the crank circuit, a faulty starter, or a weak battery.
switch contacts, the Wire 86 circuit from the controller will
be connected to ground. The controller’s logic will then Overcrank
de-energize a “run relay” (internal to the controller). The (Evolution e-Code 1100)
run relay’s contacts will then open and the 12 VDC run This feature prevents the generator from damage when it
continually attempts to start and another problem, such as
no fuel supply, prevents it from starting. The unit will crank

Diagnostic Repair Manual 123

Section 4.2 Engine Protective Devices

and rest for a preset time limit. It will then stop cranking 5. Once the control board sees an rpm signal it will
and the LCD screen will indicate an “Overcrank” condition. energize the fuel solenoid, drive the throttle open
and continue the crank sequence.
NOTE: If the fault is not repaired, the overcrank fault will
6. Starter motor will disengage when speed reaches
continue to occur.
starter dropout.
Cyclic cranking is controlled as follows: 16 second crank, 7. If the generator does not reach 2200 rpm within 15
seven (7) second rest, 16 second crank, seven (7) second seconds, a rest and re-crank cycle will occur.
rest followed by three (3) additional cycles of seven (7)
8. If engine stops turning between starter dropout and
second cranks followed by seven (7) second rests.
2200 rpm, the board will go into a rest cycle for
Choke Operation (Nexus controller only) seven (7) seconds then re-crank (if additional
crank cycles exist).
This is defined as any of the following occurrences during
9. Once started, the generator will wait for a hold-off
cranking.
period before starting to monitor oil pressure and
1. The 990/999cc engines have an electric choke in oil temperature (refer to the Alarm Messages
the air box that is automatically controlled by the section for hold-off times).
electronic control board.
10. During cranking, if the controller is in the OFF
2. The 530cc engines have an electric choke on the mode, cranking stops immediately.
divider panel air inlet hose that is automatically
11. During Auto mode cranking, if the Utility returns,
controlled by the electronic control board.
the cranking cycle does NOT abort but continues
3. The 410cc engines have a choke behind the air until complete. Once the engine starts, it will run for
box that is automatically controlled by the one (1) minute, and then shut down.
electronic control board.
NOTE: Evolution and Evolution 2.0 units do not utilize a Under-Frequency
choke mechanism.
After starting, if the generator stays under a set
Failure to Start frequency for more than 30 seconds, it will shutdown.
This is defined as any of the following occurrences during
cranking. Table 4-8. Evolution Under-frequency Shutdown Settings
1. Not reaching starter dropout speed within the Unit Hertz Shutdown Frequency
specified crank cycle. Starter dropout speed is 50 Hz 40 Hz
defined as four (4) engine cycles at 1,500 rpm
60 Hz 55 Hz
(1,800 rpm for 8 kW units).
2. Reaching starter dropout speed, but then not
reaching 2200 rpm within 15 seconds. In this case
the control board will go into a rest cycle for seven (7)
seconds, then continue the rest of the crank cycle.
3. During a rest cycle the start and fuel outputs are
de-energized and the magneto output is shorted to
ground.

Cranking Conditions
The following notes apply during the cranking cycle.
1. Starter motor will not engage within five (5)
seconds of the engine shutting down.
2. The fuel output will not be energized with the
starter.
3. The starter and magneto outputs will be energized
together.
4. Once the starter is energized the control board will
begin looking for engine rotation via the magnetos
and Wire 18 into the control panel. If it does not
see an rpm signal within three (3) seconds it will
shut down and latch out on “RPM Sensor Loss.”

124 Diagnostic Repair Manual

 Section 4.2 Engine Protective Devices

Clearing an Alarm
Table 4-9. Nexus Under-frequency Shutdown Settings When the generator is shut down due to a latching alarm,
Unit Hertz Shutdown Frequency the controller must be set to the OFF mode and the
“Enter” key pressed to unlatch any active fault and clear
50 Hz 40 Hz
the corresponding fault alarm message.
60 Hz with 0H6680A Controller 50 Hz
60 Hz with 0H6680B Controller 55 Hz

Table 4-10. Evolution Warnings and Alarm Parameters

Continuous
Description Hold-off Time Duration Time Upper threshold Lower threshold Lockout Type
or 2 looks

Low Oil Pressure 5 seconds 8 seconds 2 looks Digital input Digital input Hard Lockout
3 seconds 2 Re crank, Hard
RPM Sensor Loss 1.1 seconds Continuous Timed signal loss Timed signal loss
4 sec (8 kW only) Lockout

100 ms
Wiring error 0 seconds 7.5% of 100 ms sample 7.50% None Hard Lockout
periods

High temp. 10 seconds 1 second 2 looks Digital input Digital input Auto Reset
Underspeed 5 seconds 30 seconds Continuous None 55 Hz/3300 RPM Hard Lockout

Underspeed 50 Hz 5 seconds 30 seconds Continuous None 40 Hz/2400 RPM Hard Lockout

Overspeed Instant 50
0 seconds .1 second Continuous 62.5 Hz/3750 RPM None Hard Lockout
Hz

Overspeed Slow 50 Hz 0 seconds 3 seconds Continuous 60Hz/3600 RPM None Hard Lockout

Overspeed Instant 0 seconds .1 second Continuous 75 Hz/4500 RPM None Hard Lockout

Overspeed Slow 0 seconds 3 seconds Continuous 72 Hz/4320 RPM None Hard Lockout
15 Volts or no zero 2 Re crank, Hard
Undervoltage Fast* 10 seconds 2 seconds Continuous None
crosses detected Lockout

2 Re crank, Hard
Undervoltage Slow* 5 seconds 10 seconds Continuous None 80% of nominal
Lockout

Overvoltage fast * 5 seconds 1/5 second Continuous 130% nominal None Hard Lockout

Overvoltage slow * 5 seconds 3 seconds Continuous 110% nominal None Hard Lockout
Stepper Overcurrent 0 seconds Instant Continuous NA NA Hard Lockout

Fuse Problem 0 seconds 75% of 100ms Continuous NA NA Hard Lockout

Overload Alarm 0 seconds 20 seconds Continuous 102% rated current NA Hard Lockout

80% of nominal
Overload
5 seconds 10 seconds Continuous NA after Overload Hard Lockout
Undervoltage
Alarm
As long as battery
Low Battery 60 seconds Continuous NA 12.1 V or less Warning
is <12.1 VDC

> 16V immediate OR >

Battery Problem 0 seconds NA Continuous 600mA for 5 sec after Warning
18hr charge cycle

12.5 V at end of
Charger Warning 0 seconds NA Continuous NA Warning
charge cycle

Continuous
As long as AC is
Charger Missing AC 15 seconds except NA NA Warning
missing
cranking

Overcrank 0 seconds 5 attempts NA NA NA Hard Lockout

Diagnostic Repair Manual 125

Section 4.2 Engine Protective Devices

This page intentionally left blank.

126 Diagnostic Repair Manual

 Section 4.3 Operational Analysis – Evolution
Introduction
The “Operational Analysis” is intended to familiarize the service technician with the operation of the DC and AC control
system. A thorough understanding of how the system works is essential to sound and logical troubleshooting.

Utility Source Voltage Available

The circuit condition with the controller set to AUTO and with Utility source power available can be briefly described as
follows:
• Utility source voltage is available to the transfer switch Terminal Lugs N1 and N2 and the CONTACTOR is in the
“Utility” position.
• Utility voltage is available to the controller via Wire N1 and N2.
• Load voltage (120 VAC) is available to the controller via Wire T1 for Battery Charger. (220 VAC on T1 and T2 50
Hz only)
• The controller is shown in the AUTO mode. Battery voltage is available to the circuit board via Wire 13, the 7.5
amp fuse (F1). Wire 194 provides 12 VDC to the transfer relay in the transfer switch.
• Wire 820 supplies 5 VDC to the Tri-Light Annunciator and Wire 817 for the Green System Ready LED is gated to
ground.

N1 240VAC
UTILITY
N2 INPUT

120VAC
T1
LOAD SUPPLY
N1 220VAC
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
UTILITY
N1

J3 J2 INPUT
N2

N2
J8 T1

TO PCB
J9 T1
220VAC
MAIN LOAD SUPPLY
14 15 16
F1 CONTROLLER T2
J8 T1
Ready to Run J9 T2
J1
T1 and T2 220VAC for
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Battery Charger 50Hz only.
N1
N2
N1
N2

N2
N1
003213

Figure 4-20.
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

J3 J2 J8
TO PCB J9
MAIN
F1 CONTROLLER

Ready to Run
J1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
13
13

0
13

13
13

13

13
0

12V SCR
BATTERY
16

13
0

SC
16 SC SM 13
SC BATTERY
SM
003214
Figure 4-21.

Diagnostic Repair Manual 127

Section 4.3 Operational Analysis – Evolution

Figure 4-22. Utility Source Voltage Available

128 Diagnostic Repair Manual

 Section 4.3 Operational Analysis – Evolution

Initial Dropout of Utility Source Voltage

See Figure 4-24. Should a Utility power failure occur, circuit condition may be briefly described as follows:
• The controller continually monitors for acceptable Utility voltage via N1 and N2. Should Utility voltage drop below
approximately 65% (adjustable, see chart) of the nominal source voltage, a programmable timer on the controller
will turn on.
• The 5-second timer (factory default, but adjustable from 2-1500 seconds) is still timing and engine cranking has
not yet begun.

Utility Dropout

Factory Default Adjustable Dropout Voltage

60 Hz = 156 VAC 60 Hz = 140-171 VAC

50 Hz = 142 VAC 50 Hz = 140-156 VAC

N1 240VAC
UTILITY
N2 INPUT

120VAC
T1
LOAD SUPPLY
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
J3 J2

N1
N2
J8 T1

TO PCB
J9
MAIN
F1 CONTROLLER

Utility Loss Delay

J1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
N1
N2

N2
N1 003222

Figure 4-23.

Diagnostic Repair Manual 129

Section 4.3 Operational Analysis – Evolution

Figure 4-24. Initial Dropout of Utility Source Voltage

130 Diagnostic Repair Manual

 Section 4.3 Operational Analysis – Evolution

Utility Voltage Failure and Engine Cranking

• After the controller’s adjustable programmed timer has timed out, if Utility voltage is still below the programmed
utility drop out level, the controller's logic will energize the internal crank relay followed by the internal run relay.
• When the internal crank relay energizes, 12 VDC is delivered to the starter contactor relay (SCR) via Wire 56.
When the SCR energizes, its contacts close and battery voltage is delivered to a starter contactor (SC). When
the SC energizes, its contacts close and battery voltage is delivered to the starter motor (SM); the engine is now
cranking.
• A 12 VDC power supply is delivered to the stepper motor via the Red Wire and the other wires are gated to
ground by the controller to open the throttle position.
NOTE: The stepper motor will cycle the mixer to a full open throttle position (which opens both venturis), back to a
closed position and then to the starting position, which partially opens the small venturi.
• With the engine cranking, a pulsing AC speed reference signal is generated by the magneto(s) and is delivered
to the controller through Wire 18. If a valid signal is received, the controller will energize the internal run relay and
deliver 12 VDC on Wire 14. The fuel solenoid energizes (mechanically opens) and fuel is available to the engine.
NOTE: If the controller does not see a RPM signal, it will not energize Wire 14/Fuel Solenoid.
• With ignition and fuel flow available the engine RPM will begin to increase.
ROTOR
BA
0

4
0
4

FIELD
BOOST
DIODE
4A

18
4A
14
56
209

4A
18

18
14

14
56

56
6
0

2
4

1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

J3 J2 J8
J5 J9
TO PCB
GOVERNOR MAIN
ACTUATOR F1 CONTROLLER

Cranking
J1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
817

194
820
13
13

86
23

85

85
86
820
18

14
56

86
85

817
13

23

HOT LOP
SCR FS
0
0

0
0

0
18
13
0
13

13

13
0

194

SCR 23
12V
BATTERY
18 IM1 SP1
16

13
0

SC
SM 18 IM2 SP2

SC
16 SC SM 13
BATTERY
003223

Figure 4-25.

Diagnostic Repair Manual 131

Section 4.3 Operational Analysis – Evolution

Figure 4-26. Utility Voltage Failure and Engine Cranking

132 Diagnostic Repair Manual

 Section 4.3 Operational Analysis – Evolution

Engine Startup and Running

With the fuel solenoid open and ignition occurring, the engine starts. Engine startup and running may be briefly
described as follows:
• The ignition magneto(s) deliver a speed reference signal to the controller via Wire 18. Once the controller
determines that the engine is running, the controller:
a. terminates cranking by de-energizing Wire 56 at approximately 1500 RPM (V-twin) and 1800 RPM (single
cylinder).
b. energizes a field flash relay in the controller at 2200 RPM which delivers 12 VDC on Wire 4A through a field
boost diode and to the rotor via Wire 4. The field boost will continue for a pre-determined time, or until field
boost parameters are achieved, whichever occurs first.
NOTE: See “Field Boost” in Section 2.2 for analysis of Evolution field boost parameters.
c. also at 2200 RPM the hold off timers activate and the 5 second “warm-up timer” goes active.
• The “engine warm-up timer” will run for 5 seconds. When this timer finishes timing, the controller’s logic will
initiate a transfer to the “Standby” position. As shown in the next series, the timer is still running and transfer has
not yet occurred.
• Generator AC output is available to the transfer switch Terminal Lugs E1 and E2 and to the normally open
contacts of the transfer relay. However, the transfer relay is de-energized and its contacts are open.

44S
POWER CB1
WINDING
44 44 44
240VAC
GENERATOR
33 OUTPUT
STATOR 22 11 11

11 11 CB2
POWER
WINDING 11C
ROTOR 11S 33 33
BA EXCITATION 22 22
NEUTRAL
WINDING 00
11S 00
6
0

2
4

6
2
4
0
4

FIELD
BOOST
DIODE
4A

4A
11C
120VAC
ACCESSORY
00
POWER
OUTPUT
11S
44S
4A

00
6
0

2
4

1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 FOR APPLICABLE
MODELS ONLY
J3 J2 J8
J5 J9 00
TO PCB
GOVERNOR MAIN
ACTUATOR F1 CONTROLLER

Running/Warming Up
J1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
003224

Figure 4-27.

Diagnostic Repair Manual 133

Section 4.3 Operational Analysis – Evolution

Figure 4-28. Engine Startup and Running

134 Diagnostic Repair Manual

 Section 4.3 Operational Analysis – Evolution

Transfer to Standby
In Figure 4-30 the Generator is running, the controller's “engine warm-up” timer has expired and generator AC output
is available to the transfer switch Terminal Lugs E1 and E2 and to the open contacts on the transfer relay. Transfer to
Standby may be briefly described as follows:
• 12 VDC is delivered to the transfer relay coil (TR1 - Terminal A) via Wire 194. The 12 VDC circuit is completed
back to the controller via Wire 23 (TR1 - Terminal B). However, the controller’s logic holds Wire 23 open from
ground and the TR1 relay is de-energized.
• When the “engine warm-up timer” expires, the controller will take Wire 23 to ground. The TR1 relay energizes
and its normally open contacts close (standby position).
• While running, the pulsing AC speed reference from the ignition magneto(s) to the controller via Wire 18 will be
used for the following functions:
a. governor speed control to maintain frequency through different loads
b. overspeed
c. underspeed
• With no, or a light load, the stepper motor will control the throttle position of the smaller venturi. As the load
demand increases and with the smaller venturi nearly wide open, it will start to open the larger venturi as needed
for load/fuel demand.
• With loads applied, CT1 - Wires 398A/399A and CT2 - Wires 398B/399B deliver approximately 0- 1.5 VAC based
on percentage of Amps (load).
Approximate Values (when back-probed at connector):
25 Amps = 0.380 mVAC
50 Amps = 0.755 mVAC
75 Amps = 1.133 VAC
100 Amps = 1.510 VAC

DANGER
Electrocution. Lethal voltage may be present
at current transformers (CTs). Do not touch
CTs while primary current is applied. Doing so
will result in death or serious injury. (000310)

1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

J3 J2 J8
TO PCB
J9
MAIN
F1 CONTROLLER

Running
J1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
194
23

0
23

0 0 DC COMMON

194 194 +12VDC

TR
23 23 TRANSFER
003225

Figure 4-29.

Diagnostic Repair Manual 135

Section 4.3 Operational Analysis – Evolution

Figure 4-30. Transfer to Standby

136 Diagnostic Repair Manual

 Section 4.3 Operational Analysis – Evolution

Utility Voltage Restored and Re-transfer to Utility

The Load is powered by Generator voltage. On restoration of Utility voltage, the following events will occur:
• On restoration of Utility voltage above 75% (programmable, see chart for range) of the nominal rated voltage, a
“re-transfer time delay” on the controller starts timing. The timer will run for 15 seconds.
• At the end of the 15 seconds, the “re-transfer time delay” will stop timing. The controller will open the Wire 23
circuit from ground and the transfer relay (TR1) will de-energize.
• The generator continues to run in its cooling down mode.
NOTE: If utility fails during the cool-down timer cycle for 5 seconds, the controller will transfer back to standby.

Utility Pickup

Factory Default Adjustable Pickup Voltage

60 Hz = 190 VAC 60 Hz = 190-216 VAC

50 Hz = 175 VAC 50 Hz = 175-198 VAC

N1 240VAC
UTILITY
N2 INPUT

120VAC
T1
LOAD SUPPLY
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

N1
J3 J2

N2
J8 T1

TO PCB
J9
MAIN
F1 CONTROLLER

Running/Cooling Down
J1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
N1
N2
23

N2
N1

TRANSFER
003226

Figure 4-31.

Diagnostic Repair Manual 137

Section 4.3 Operational Analysis – Evolution

Figure 4-32. Utility Voltage Restored and Re-transfer to Utility

138 Diagnostic Repair Manual

 Section 4.3 Operational Analysis – Evolution

Engine Shutdown
Following re-transfer back to the Utility source an “engine cool-down timer” on the controller starts timing. When the
timer has expired (approximately one minute), the controller will de-energize the internal run relay removing fuel from
the engine. The following events will occur:
• Wire 14 (run circuit) will de-energize and the fuel solenoid will close to terminate the fuel supply to the engine.
• The controller’s logic will connect the engine’s ignition magnetos to ground via Wire 18. Ignition will terminate.
• Without fuel flow and without ignition the engine will shut down.
18

18
14

14
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

J3 J2 J8
TO PCB
J9
18

MAIN
FS F1 CONTROLLER

Stopping
J1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

18 IM1 SP1

18 IM2 SP2
003227

Figure 4-33.

Diagnostic Repair Manual 139

Section 4.3 Operational Analysis – Evolution

Figure 4-34. Engine Shutdown

140 Diagnostic Repair Manual

 Section 4.4 Operational Analysis – Nexus
Introduction
The “Operational Analysis” is intended to familiarize the service technician with the operation of the DC and AC control
system. A thorough understanding of how the system works is essential to sound and logical troubleshooting. The
control system illustrations on the following pages represent a 17 kW unit.

Utility Source Voltage Available

The circuit condition with the controller set to the AUTO mode and with Utility source power available can be briefly
described as follows:
• Utility source voltage is available to the transfer switch Terminal Lugs N1 and N2 and the contactor is in the
“Utility” position.
• Utility voltage is available to the controller via Wire N1 and N2.
• Battery voltage is available to the controller via Wire 13 when a Battery is installed.
OPTIONAL
BATTERY WARMER
1 240Vac 2 NEUTRAL
CONNECT
N1A N2A
OPTIONAL
OIL WARMER
N1B 1 240Vac 2 N2B
CONNECT 00 WHT
N1 N2
00
6
4
0 T1A
11 MOV
N1 N1 240 VAC
44 UTILITY
N2 N2 INPUT

120 VAC
T1 T1
LOAD SUPPLY
N1 00 2 44 0 6
T1 N2 11 4 BATTERY CHARGER
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Running - Utility Loss
J5

CONTROLLER
PRINTED CIRCUIT BOARD
J4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 003243

Figure 4-35.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Ready to Run
J5
TO PCB

CONTROLLER
PRINTED CIRCUIT BOARD
F1
J3

J4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

0 13

13 13 13

BATTERY
SCR

0 16
SC
SM

003244

Figure 4-36.

Diagnostic Repair Manual 141

Section 4.4 Operational Analysis – Nexus

Figure 4-37. Utility Source Voltage Available

142 Diagnostic Repair Manual

 Section 4.4 Operational Analysis – Nexus

Initial Dropout of Utility Source Voltage

See Figure 4-39. Should a Utility power failure occur, circuit condition may be briefly described as follows:
• The controller continually monitors for acceptable Utility voltage via N1 and N2. Should Utility voltage drop below
approximately 65% of the nominal source voltage, a programmable timer on the controller will turn on.
• In Figure 4-38, the 10-second timer is still timing and engine cranking has not yet begun.
• The controller is shown in the AUTO mode. Battery voltage is available to the circuit board via Wire 13, the 7.5
amp fuse (F1). Wire 194 provides 12 VDC to the transfer relay in the transfer switch.

OPTIONAL
BATTERY WARMER
1 240Vac 2 NEUTRAL
CONNECT
N1A N2A
OPTIONAL
OIL WARMER
N1B 1 240Vac 2 N2B
CONNECT 00 WHT
N1 N2
00
6
4
0 T1A
11 MOV
N1 N1 240 VAC
44 UTILITY
N2 N2 INPUT

120 VAC
T1 T1
LOAD SUPPLY
N1 00 2 44 0 6
T1 N2 11 4 BATTERY CHARGER
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Utility Dropout
J5
Pausing 10 seconds

CONTROLLER
PRINTED CIRCUIT BOARD
J4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 003246

Figure 4-38.

Diagnostic Repair Manual 143

Section 4.4 Operational Analysis – Nexus

Figure 4-39. Initial Dropout of Utility Source Voltage

144 Diagnostic Repair Manual

 Section 4.4 Operational Analysis – Nexus

Utility Voltage Failure and Engine Cranking

• After the controller’s 10-second timer has timed out, if Utility voltage is still below 65% of nominal, controller logic
will energize the internal crank relay followed by the internal run relay.
• When the internal crank relay energizes, 12 VDC is delivered to the starter contactor relay (SCR) via Wire 56.
When the SCR energizes its contacts close and battery voltage is delivered to a starter contactor (SC). When the
SC energizes its contacts close and battery voltage is delivered to the starter motor (SM). The engine is now
cranking.
• With the engine cranking a speed reference signal is generated by the magnetos and is delivered to the
controller through Wire 18. If a valid signal is received, the controller will energize the internal run relay and
deliver 12 VDC on Wire 14. The fuel solenoid energizes (opens) and fuel is available to the engine. The choke
solenoid (CS) (Nexus Only) begins to operate and the controller grounds Wire 90, energizing the choke solenoid
cyclically curing cranking, and continuously while running.
• During Cranking 3-5 VDC is supplied to the rotor for field flash via a field boost diode connected in parallel with
Wire 56.
• With ignition and fuel flow available the engine will start.
TO ROTOR

1 2 3 4 5 6 7 8 9 10 11 12 13 14
Crank Atempt # 1
J5

TO PCB
CONTROLLER
PRINTED CIRCUIT BOARD
4 0
GOVERNOR
F1
ACTUATOR
J3
FIELD BOOST
DIODE J4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
90 0 13 818 85 14 86 18 56 194
56 817 819 820 210 209 23

56 56

820
817
56 85 818
819
A
SCR HTO
86
B 14 CS
0 0
14
LOP FS
14
0 0
0
0 0
SP1
IM1 18
13 13 13

BATTERY
12V
SCR

0 16 SP2
SC
IM2 18
SM
003247

Figure 4-40.

Diagnostic Repair Manual 145

Section 4.4 Operational Analysis – Nexus

Figure 4-41. Utility Voltage Failure and Engine Cranking

146 Diagnostic Repair Manual

 Section 4.4 Operational Analysis – Nexus

Engine Startup and Running

With the fuel solenoid open and ignition occurring, the engine starts. Engine startup and running may be briefly
described as follows:
• The ignition magnetos deliver a speed reference signal to the controller via Wire 18. Once the controller
determines that the engine is running, the controller (a) terminates cranking, (b) continuously energizes the
choke solenoid (open position), and (c) turns on an “engine warm-up timer”.
NOTE: On 8 kW and 10 kW units the choke is de-energized to the open position (Wire 90 open from ground).
• The “engine warm-up timer” will run for 5 seconds. When this timer finishes timing the controller’s logic will
initiate a transfer to the “Standby” position. As shown in Figure 4-43, the timer is still running and transfer has not
yet occurred.
• Generator AC output is available to the transfer switch Terminal Lugs E1 and E2 and to the normally open
contacts of the transfer relay. However, the transfer relay is de-energized and its contacts are open.

CB1
POWER
WINDING
44 44
240 VAC
GENERATOR
STATOR 22
33
11
OUTPUT

CB2
11
11
POWER
WINDING 11 44
ROTOR 33
BA EXCITATION 22
0 4 2 6 WINDING
NEUTRAL
C1
PIN # 6 5 4 3 2 1

0 4 2 6 11 44
00 00 WHT
00
6 6
4 4
0 0 T1A
11 MOV
44

4
120 VAC
T1 T1
LOAD SUPPLY
0 00 2 44 0 6
FIELD BOOST T1 11 4 BATTERY CHARGER
DIODE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Running - Utility Loss
J5 11C

CONTROLLER 120 VAC

PRINTED CIRCUIT BOARD 00 ACCESSORY
POWER
GOVERNOR OUTPUT
0
ACTUATOR

J4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 003248

Figure 4-42.

Diagnostic Repair Manual 147

Section 4.4 Operational Analysis – Nexus

Figure 4-43. Engine Startup and Running

148 Diagnostic Repair Manual

 Section 4.4 Operational Analysis – Nexus

Transfer to Standby
In Figure 4-45 the Generator is running, the controller's “engine warm-up” timer has expired and generator AC output
is available to the transfer switch Terminal Lugs E1 and E2 and to the open contacts on the transfer relay. Transfer to
Standby may be briefly described as follows:
• 12 VDC is delivered to the transfer relay coil (TR1 - Terminal A) via Wire 194. The 12 VDC circuit is completed
back to the controller via Wire 23 (TR1 - Terminal B). However, the controller’s logic holds Wire 23 open from
ground and the TR1 relay is de-energized.
• When the “engine warm-up timer” expires, the controller will take Wire 23 to ground. The TR1 relay energizes
and its normally open contacts close (standby position).
• Generator voltage is now delivered to the standby closing coil (C2), via Wire E1 and E2, the now closed TR1
contacts, Wire 205, the limit switch (SW3), Wire B, and a bridge rectifier. The standby closing coil energizes and
the main current carrying contacts of the transfer switch are actuated to the “Standby” position.
• As the main contacts move to the “Standby” position, a mechanical interlock actuates SW3 to its open position
and limit switch (SW2) to the “Utility” position. When SW3 opens the C2 coil de-energizes.
• Generator voltage is now available to the LOAD terminals (T1 and T2) of the transfer switch.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Running - Utility Loss

CONTROLLER
PRINTED CIRCUIT BOARD

J4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

194
23

194 + BATTERY

TR1
23 TRANSFER 003249

Figure 4-44.

Diagnostic Repair Manual 149

Section 4.4 Operational Analysis – Nexus

Figure 4-45. Transfer to Standby

150 Diagnostic Repair Manual

 Section 4.4 Operational Analysis – Nexus

Utility Voltage Restored and Re-transfer to Utility

The Load is powered by Generator voltage. On restoration of Utility voltage, the following events will occur:
• On restoration of Utility voltage above 75% of the nominal rated voltage, a “re-transfer time delay” on the
controller starts timing. The timer will run for 15 seconds.
• At the end of the 15 seconds, the “re-transfer time delay” will stop timing. The controller will open the Wire 23
circuit from ground and the transfer relay (TR1) will de-energize.
• When the TR1 relay de-energizes its utility side contacts close. Utility voltage is then delivered to the utility
closing coil (C1), via Wire N1A and N2A, the closed TR1 contacts, Wire 126, limit switch (SW2), and a bridge
rectifier.
• The C1 coil energizes and moves the main contacts to their “Utility” Position; the LOAD terminals are now
powered by Utility.
• Movement of the main contacts to the “Utility” position actuates the limit switches. SW2 opens and SW3 moves
to the Standby source side.
• The generator continues to run.

OPTIONAL
BATTERY WARMER
1 240Vac 2 NEUTRAL
CONNECT
N1A N2A
OPTIONAL
OIL WARMER
N1B 1 240Vac 2 N2B
CONNECT 00 WHT
N1 N2
00
6
4
0 T1A
11 MOV
N1 N1 240 VAC
44 UTILITY
N2 N2 INPUT

120 VAC
T1 T1
LOAD SUPPLY
N1 00 2 44 0 6
T1 N2 11 4 BATTERY CHARGER
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Running / Cooldown
J5

CONTROLLER
PRINTED CIRCUIT BOARD
J4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 003250

Figure 4-46.

Diagnostic Repair Manual 151

Section 4.4 Operational Analysis – Nexus

Figure 4-47. Utility Voltage Restored and Re-transfer to Utility

152 Diagnostic Repair Manual

 Section 4.4 Operational Analysis – Nexus

Engine Shutdown
Following re-transfer back to the Utility source an “engine cool-down timer” on the controller starts timing. When the
timer has expired (approximately one minute), the controller will de-energize the internal run relay removing fuel from
the engine. The following events will occur:
• The DC circuit to Wire 14 and the fuel solenoid will open. The fuel solenoid will de-energize and close to
terminate the fuel supply to the engine.
• The controller’s logic will connect the engine’s ignition magnetos to ground via Wire 18. Ignition will terminate.
• Without fuel flow and without ignition the engine will shut down.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Utility Good –
Engine Shutdown

CONTROLLER
PRINTED CIRCUIT BOARD

J4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
18

SP1
IM1 18

SP2
IM2 18
003251

Figure 4-48.

Diagnostic Repair Manual 153

Section 4.4 Operational Analysis – Nexus

Figure 4-49. Engine Shutdown

154 Diagnostic Repair Manual

 Section 4.5 Troubleshooting Flowcharts

Evolution™ Controller e-Codes

Displayed Alarm/ e-Code
Description Action Step
Alarm Warning Breakdown
Controller Fault ALARM No E-code on HSB Replace Controller
Condition - Engine Cranks but will not Start (5 crank attempts)
Overcrank ALARM 1100 Problem 17
Unit turns over but will not start. Controller is receiving signal on Wire 18.
Prolonged (60 Hz on a 50 Hz unit, 72Hz on 60Hz unit)
Overspeed ALARM 1200 Over specified Hz for 3 seconds. Possible cause: Stepper motor/mixer body Test 12
assembly issue.
Instantaneous (62 Hz on a 50 Hz unit, 75Hz on 60Hz unit)
Overspeed ALARM 1205 Over specified Hz for 0.1 second (100 milliseconds). Possible cause: Stepper motor/ Test 12
mixer body assembly issue.
Monitors zero cross timing of the AVR to determine the alternator frequency which is
Overspeed ALARM 1207 a speed indicator. Set for 150 milliseconds of 4500 rpm or higher. Used if the normal Test 64 and Test 60
ignition pulse sequence(s) are not being seen by the controller.
Occurred while running
Low Oil Pressure ALARM 1300 Test 61
The default Extended alarm for low oil pressure. Check oil level and pressure.
High Condition - Air Flow Impeded / Flow Issue
ALARM 1400 Test 62
Temperature Check the inlet/outlet for debris. Check temperature sensor and wiring.
Twin Cylinder+Running
RPM Sensor ALARM 1501 Twin Cylinder Running faults to RPM Sensor Loss. Possible Causes: air pocket in fuel Test 50 and Test 64
line, dirty fuel, missing ignition pulse (loss of one of the primary coils).
Twin Cylinder+Cranking If engine cranks, Test 64.
RPM Sensor ALARM 1505 Twin Cylinder Cranking faults to RPM sensor loss Possible Cause: starter motor If engine does not crank,
issue, missing ignition pulse (loss of one of the primary coils). Problem 15.
Single Cylinder+Running
RPM Sensor ALARM 1511 Single Cylinder Running RPM sensor loss Possible Causes: air pocket in fuel line, Test 50 and Test 64
dirty fuel. Loss of ignition pulse.
Single Cylinder+Cranking If engine cranks, Test 64.
RPM Sensor ALARM 1515 Single Cylinder Cranking faults to RPM sensor loss Possible Cause: starter motor If engine does not crank,
and/or engine issue. Loss of ignition pulse. Problem 15.
Condition - Unit is Overloaded (55 Hz for 60 Hz for 30 sec, 40 Hz for 50 Hz unit Problem 3, or Test 50, or
Underspeed ALARM 1600
Unit is Overloaded slowing engine speed, fuel supply low or throttle control problem. Test 12
Underspeed Check fuel selection and
Underspeed ALARM 1603
The engine never comes up to 3600 RPM. fuel supply
Overvoltage ALARM 1800 Prolonged Over-Voltage Problem 2
*Preliminary Output
Voltage Test (firmware
Prolonged Under-Voltage
Undervoltage ALARM 1900 v1.12 and above).
Undervoltage due to loss of voltage. Below 80% for 10+ seconds)
Note: Update controller to
latest firmware.
*Preliminary Output
Voltage Test (firmware
Instantaneous
Undervoltage ALARM 1901 v1.12 and above).
Undervoltage due to sudden loss of voltage. (Voltage less than 15 sec 2 sec+)
Note: Update controller to
latest firmware.
*Preliminary Output
Both Zero Crosses missing
Voltage Test (firmware
Undervoltage due to faulty excitation winding, or zero cross circuit, or circuit in
Undervoltage ALARM 1902 v1.12 and above).
general. Possible cause: loose wiring, field boost hardware failure. (Both zero cross
Note: Update controller to
missing greater than 1.5 sec)
latest firmware.
NOTE: If an alarm code is displayed on the controller, use the diagnostic procedure listed in the action step.

Diagnostic Repair Manual 155

Section 4.5 Troubleshooting Flowcharts

Evolution™ Controller e-Codes

Displayed Alarm/ e-Code
Description Action Step
Alarm Warning Breakdown
*Preliminary Output
Single Zero Cross missing
Voltage Test (firmware
Undervoltage due to faulty excitation winding, zero cross circuit, or circuit in general.
Undervoltage ALARM 1906 v1.12 and above).
Possible cause: field boost hardware failure. (One zero cross missing greater than
Note: Update controller to
1.5 sec)
latest firmware.
Mis-wired Check customer
Wiring Error ALARM 2099
Customer connection low voltage and high voltage wires are crossed. connection in generator
Overloaded - Default (Output Current Method)
Overload
ALARM 2100 Unit is overloaded. One or both CT(s) detecting an overload condition. Check transfer Remove Load
Remove Load
switch loadshed functionality. (Change load dynamics or utilize loadshed).
Unit was overloaded and attempted to start with a large load connected. The unit can
Undervoltage
ALARM 2299 not ramp up the generator voltage to its normal target voltage value if it starts with a Remove Load
Overload
large load connected
Stepper
ALARM 2399 Current flow in stepper coil(s) above specification Test 12
Overcurrent
Missing / Damaged Fuse
Fuse Problem ALARM 2400* The 7.5 amp Controller Fuse is missing or blown (open). Test 44
*Firmware version 1.11 and older only
Check the continuity of
the harness and operation
Aux Shutdown ALARM 2800 External shut down circuit is open.
of the switch(es). Repair/
replace as needed.
Low Battery WARNING Condition->Battery less than 12.1 Volts for 60 seconds Test 45
Condition->More than 16 Volts of battery voltage or 600 milliamperes or more of
Battery Problem WARNING Test 45
charge current at the end of an 18 hour charge
Charger Warning WARNING Less than 12.5 volts of battery voltage at the end of a 18 hour charge Problem 22
Charger Missing
WARNING AC power is missing from the battery charger input Problem 22
AC
Service Service Schedule A 200hours 2 years
Perform Maintenance
Schedule Service Schedule B 400 Hours 4 years
NOTE: If an alarm code is displayed on the controller, use the diagnostic procedure listed in the action step.

Additional Codes For 8 and 9 kW Units Only

Displayed Alarm/ e-Code
Description Action Step
Alarm Warning Breakdown

If the engine has tried to

Engine/Starter Problem crank for 10 times
Overcrank ALARM 1101
Limiting number of cranking cycles to protect the starter motor. unsuccessfully, this will
trigger.

Check for Overloaded

Overloaded
Overload condition on unit.
ALARM 2102 Unit re-cranks 5 times when load is applied, engine dies (0 RPM) and has low
Remove Load Inspect stepper motor
voltage (< 180V)
operation.

Overloaded
Overload Check for Overloaded
ALARM 2103 Unit has run and attempted to accept load 10 times, could not accept due to
Remove Load condition on unit
overload condition

156 Diagnostic Repair Manual

 Section 4.5 Troubleshooting Flowcharts

Problem 14 – Shutdown Alarm/Fault Occurred During Crank Attempt, Start or Run

OVERCRANK - Nexus
GO TO PROBLEM 17
E-CODE 1100 - Evolution

HIGH TEMP - Nexus TEST 62 – CHECK HIGH CHECK INSTALLATION FOR

OIL TEMPERATURE PROPER AIRFLOW OR
E-CODE 1400 - Evolution SWITCH REPLACE DEFECTIVE SWITCH

TEST 12 – CHECK FOLLOW

OVERSPEED - Nexus
STEPPER MOTOR GOOD PROCEDURE IN
E-CODE 1200/1201/1205 - Evolution CONTROL APPENDIX B

NOTE: If the controller does not see an RPM

signal, it will not energize Wire 14/Fuel Solenoid.

RPM SENSE LOSS - Nexus RPM Sense Loss E-CODE -

ENGINE CRANKS 1511 - 8 kW EVOLUTION
E-CODE - 1505/1515 - Evolution
SINGLE CYLINDER

ENGINE DOES
NOT CRANK TEST 50 – CHECK
GOOD FUEL SUPPLY AND
PRESSURE

TEST 64 – CHECK WIRE 18 CONTINUITY TEST 55 – TEST 59 –

GOOD
CHECK FOR CHECK
RUNNING - Nexus GOOD OR
IGNITION SHUTDOWN
BAD
E-CODE - 1501/1511 - Evolution SPARK WIRE

BAD GOOD
BAD

REPAIR OR
REPAIR OR REPLACE SHORTED
REPLACE WIRE 18 OR CIRCUIT
BOARD
TEST 60 – CHECK
PROCEED TO PROBLEM 16
NO SIGNAL IGNITION
MAGNETOS

LOW OIL PRESSURE - Nexus TEST 61 – CHECK OIL PRESSURE

E-CODE 1300 - Evolution SWITCH AND WIRE 86

LOW BATTERY PROCEED TO TEST 45

IMPORTANT NOTE: Clear any faults in the controller before proceeding with any running diagnostic steps!

Diagnostic Repair Manual 157

Section 4.5 Troubleshooting Flowcharts

Problem 15 – Engine Will Not Crank When Utility Power Source Fails

TEST 40 – CHECK TEST 41 – TRY A

VERIFY UTILITY SWITCH IS
OFF POSITION OF MANUAL START
SOURCE IS “OFF” IN “AUTO”
AUTO-OFF-MANUAL
MODE

ON ENGINE DOES
NOT CRANK
SWITCH IS “OFF”

TURN “OFF” - ENGINE

RETEST GO TO PROBLEM 16 CRANKS
SET TO “AUTO” -
RETEST

TEST 43 – CHECK TEST 42 – TEST

REPLACE CONTROLLER AUTO-OFF-MANUAL
BAD AUTO OPERATION
ASSEMBLY MODE
OF CONTROLLER

BAD
REPLACE CONTROLLER
ASSEMBLY

Problem 16 – Engine Will Not Crank When Controller Switch is Set to MANUAL
TEST 46 – CHECK
TEST 45 – CHECK GOOD GOOD
TEST 44 – CHECK GOOD WIRE 56 VOLTAGE
7.5 AMP FUSE BATTERY

GOOD
BAD RECHARGE / BAD
BAD
REPLACE V-TWIN SINGLE
CYLINDER
UNITS
UNITS
REPLACE
REPLACE
CONTROLLER
ASSEMBLY TEST 47 – CHECK
BAD
STARTER
CONTACTOR
TEST 42 – TEST
RECHECK RELAY (SCR)
GOOD AUTO-OFF-MANUAL
TEST 46
MODE
BAD

NOTE: If a starting problem is encountered, GOOD

the engine itself should be thoroughly REPLACE
checked to eliminate it as the cause of starting
difficulty. It is a good practice to check the TEST 48 –
engine for freedom of rotation by removing the CHECK STARTER
spark plugs and turning the crankshaft over CONTACTOR
slowly by hand, to be sure it rotates freely.

WA R N I N G : D O N O T R O TAT E
GOOD TEST 49 – TEST GOOD
ENGINE WITH ELECTRIC STARTER
STARTER MOTOR
WITH SPARK PLUGS REMOVED.
ARCING AT THE PLUG ENDS MAY
IGNITE THE LP OR NG VAPOR BAD REPLACE BAD
EXITING THE SPARK PLUG HOLE.

IMPORTANT NOTE: Clear any faults in the controller before proceeding with any running diagnostic steps!

158 Diagnostic Repair Manual

 Section 4.5 Troubleshooting Flowcharts

Problem 17 – Engine Cranks but Will Not Start

IMPORTANT NOTE: Verify that the fuel selector is correct for the supplied fuel type.

TEST 50 – CHECK TEST 51 – CHECK TEST 52 – CHECK

GOOD GOOD GOOD
FUEL SUPPLY AND CONTROLLER FUEL SOLENOID
PRESSURE WIRE 14 OUTPUT

BAD
BAD BAD

REPLACE FUEL SOLENOID

FIND AND CORRECT REPLACE CONTROLLER
CAUSE OF NO FUEL Note: If the controller does not see an RPM
OR LOW PRESSURE signal, it will not energize Wire 14/Fuel Solenoid.
If reconfigured to LP gas, verify Check Wire 18 Signal and Magneto operation.
that proper procedure was If Wire 18 and Magnetos are OK and still no
followed. (refer to Section 1.3) output from controller, Replace Controller.

TEST 12 – CHECK TEST 53 – CHECK

GOOD STEPPER MOTOR GOOD CHOKE SOLENOID
CONTROL (NEXUS ONLY)

BAD BAD

REPAIR OR REPLACE REPLACE CHOKE

CHECK AIR FILTER - SOLENOID
REPLACE AS NEEDED

TEST 55 –
TEST 57 – TEST 63 – TEST 58 –
CHECK FOR
GOOD CHECK SPARK GOOD CHECK AND GOOD CHECK ENGINE
IGNITION
PLUGS ADJUST VALVES COMPRESSION
SPARK

BAD
BAD
GOOD BAD
BAD
CLEAN,
REGAP OR READJUST
REPLACE

CHECK
FLYWHEEL REPLACE FUEL
KEY REGULATOR

TEST 59 – CHECK TEST 60 – CHECK

SHUTDOWN WIRE GOOD
IGNITION
MAGNETOS

BAD
BAD

REPAIR OR ADJUST OR REFER TO ENGINE

REPLACE SHORTED REPLACE SERVICE MANUAL
WIRE 18 OR CIRCUIT
BOARD

IMPORTANT NOTE: Clear any faults in the controller before proceeding with any running diagnostic steps!

Diagnostic Repair Manual 159

Section 4.5 Troubleshooting Flowcharts

Problem 18 – Engine Starts Hard and/or Runs Rough / Lacks Power / Backfires / Hunting /
Erratic Operation

TEST 50 – CHECK IF RECONFIGURED TO LP GAS,

VERIFY THAT PROPER CHECK AIR FILTER -
FUEL SUPPLY AND GOOD GOOD REPLACE AS NEEDED
PRESSURE PROCEDURE WAS FOLLOWED.
(REFER TO SECTION 1.3)

BAD IMPORTANT NOTE: THE EVOLUTION CONTROLLED MODELS

MAY START AND RUN LIKE NORMAL WITH THE IMPROPER FUEL
SELECTED! VERIFY THE CORRECT FUEL IS SELECTED!

FIND AND CORRECT

CAUSE OF NO FUEL
OR LOW PRESSURE
TEST 53 – CHECK
CHOKE SOLENOID
(NEXUS ONLY)

BAD READJUST

REPLACE CHOKE SOLENOID BAD

TEST 55 – TEST 57 – TEST 63 –

CHECK FOR GOOD CHECK SPARK GOOD CHECK AND
BAD
IGNITION SPARK PLUGS ADJUST VALVES

BAD
TEST 60 – CHECK
IGNITION MAGNETOS
CLEAN, REGAP
OR REPLACE GOOD
BAD

ADJUST OR
REPLACE

CHECK TEST 58 – CHECK TEST 12 – CHECK

FLYWHEEL GOOD ENGINE GOOD STEPPER MOTOR
KEY COMPRESSION CONTROL

GOOD BAD BAD

CONTACT TECHNICAL REFER TO ENGINE REPAIR OR

SUPPORT SERVICE MANUAL REPLACE

IMPORTANT NOTE: Clear any faults in the controller before proceeding with any running diagnostic steps!

160 Diagnostic Repair Manual

 Section 4.5 Troubleshooting Flowcharts

Problem 19 – 7.5 Amp Fuse (F1) Blown

( (e-Code 2400) )
FUSE BLOWS WHEN TEST 66 – CHECK
PLACED IN “AUTO” CRANKING AND
OR “MANUAL” RUNNING CIRCUITS

Problem 20 – Generator Will Not Exercise

TEST 65 – TEST
EXERCISE
FUNCTION

Problem 21 – No Low Speed Exercise

TEST 70 – CHECK TO SEE TEST 71 – CHECK TEST 53 – TEST CHOKE

OPERATING
IF LOW SPEED FUNCTION ENABLED OPERATION OF CHOKE SOLENOID
NORMALLY
IS ENABLED SOLENOID (NEXUS ONLY) (NEXUS ONLY)

DISABLED GOOD BAD

ENABLE REPLACE CONTROLLER REPLACE

Problem 22 – Battery is Dead

TEST 75 – TEST TEST 76 – VERIFY DC TEST 78 – TEST DC

INPUT T1 60 Hz GOOD VOLTAGE OUTPUT OF GOOD CHARGE CURRENT
(T1 AND T2 50 Hz) THE CONTROLLER TO BATTERY

BAD TEST 77 – CHECK

BAD WIRE 13 AND
WIRE 0
TEST 80 – CHECK
TEST 79 – CHECK T1/T2 T1/T2 VOLTAGE AT GOOD
VOLTAGE AT BAD
GOOD CONTROLLER BAD
CUSTOMER CONNECTOR

REPLACE CONTROLLER
BAD BAD
GOOD
GOOD REPAIR
OR
TEST 81 – CHECK REPAIR REPLACE
T1/T2 VOLTAGE IN BAD OR
TRANSFER SWITCH REPLACE
REPLACE STOP TESTING. BATTERY
CONTROLLER CHARGER IS
GOOD FUNCTIONING PROPERLY

TEST 82 – TEST BAD

F3/F4 FUSE
VERIFY THAT VOLTAGE IS AVAILABLE TO
CIRCUIT GOOD THE LOAD SIDE OF THE CONTACTOR

IMPORTANT NOTE: Clear any faults in the controller before proceeding with any running diagnostic steps!

Diagnostic Repair Manual 161

Section 4.5 Troubleshooting Flowcharts

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162 Diagnostic Repair Manual

 Section 4.6 Diagnostic Tests
Introduction When working on this equipment, use common sense
and remain alert at all times. Never work on this
This section familiarizes the service technician with equipment while you are physically or mentally fatigued.
acceptable procedures for the testing and evaluation of If you do not understand a component, device or system,
various problems that can occur on standby generators do not work on it.
with air-cooled engines. The numbered tests in this
section correspond with the flow charts in Section 4.5,
Troubleshooting Flowcharts.
Engine/DC Troubleshooting
Some test procedures in this section require the use of It is always good practice to continue to ask questions
specialized test equipment, meters, or tools. Most tests during the troubleshooting process. When evaluating the
can be performed with a digital multimeter (DMM). An AC problem asking some of these questions may help
frequency meter is required where frequency readings identify the problem more quickly.
must be taken. • What is the generator doing?
Testing and troubleshooting methods covered in this • What is the fault that the generator is shutting
section are not exhaustive. No attempt has been made to down for?
discuss, evaluate and advise the home standby service
• After the fault occurred, what was the LCD
trade of all conceivable ways in which service and trouble
displaying?
diagnosis must be performed. Accordingly, anyone who
uses a test method not recommended herein must first • Is there another Alarm in the log just previous to
satisfy himself that the procedure or method he has the shutdown?
selected will jeopardize neither his nor the products safety. • Is the fault causing the shutdown a symptom of
Figure 4-50 shows the DMM in two different states. The another problem?
left DMM indicates an OPEN circuit or INFINITY. The • Does the generator have the same fault
right DMM indicates a dead short or CONTINUITY. consistently, and when does it occur?
Throughout the troubleshooting, refer back to Figure 4-
50 as needed to understand what the meter is indicating
• What was the generator supposed to do?
about the particular circuit that was tested. • Who is controlling it?
NOTE: CONTINUITY is equal to 0.01 ohms of resistance • Exactly what is occurring?
or a dead short. • When is it happening?
• Why would this happen?
• How would this happen?
• What type of test will either prove or disprove the
cause of the fault?

Test 40 – Check position of AUTO-

OFF-MANUAL Mode
General Theory
002397 If the system is to operate automatically, the generator's
Figure 4-50. INFINITY (Left) and CONTINUITY (Right) controller must be set to AUTO. The generator will not
Meter Readings crank and start on occurrence of a Utility failure unless
the switch is in AUTO. In addition, the generator will not
Safety exercise every seven (7) days as programmed unless the
switch is in AUTO.
Service personnel who work on this equipment should be
aware of the dangers of such equipment. Extremely high Procedure
and dangerous voltages are present that can kill or cause
serious injury. Gaseous fuels are highly explosive and With the controller set to AUTO, test automatic operation.
can ignite by the slightest spark. Engine exhaust gases Testing of automatic operation can be accomplished by
contain deadly carbon monoxide gas that can cause turning off the Utility power supply to the transfer switch.
unconsciousness or even death. Contact with moving When the Utility power is turned off the generator should
parts can cause serious injury. The list of hazards is crank and start. Following startup, transfer to the
seemingly endless. “Standby” position should occur.

Diagnostic Repair Manual 163

Section 4.6 Diagnostic Tests

Results 3. With the Inputs Screen displayed place the controller

1. If normal automatic operation is obtained, to MANUAL. If the controller reads an input from the
discontinue tests. Switch, Input 8 will change from “0” to “1”.
2. If the engine does not crank when Utility power is 4. With the controller set to OFF, both inputs will read
turned off refer back to the flow chart. zero.

Results
Test 41 – Try a Manual Start 1. If controller failed either Step 2 or Step 3, replace
General Theory the controller assembly.
2. If the controller passed Step 2 and Step 3, refer
The first step in troubleshooting for an “Engine Won’t
back to flow chart.
Crank” condition is to determine if the problem is related
to automatic operations only or if the engine will not crank
manually either. Test 43 – Test Auto Operations of
Controller (Evolution and Nexus)
Procedure
1. Set the controller to OFF.
General Theory
2. Set the main line circuit breaker (MLCB) to the Initial Conditions: The generator is in AUTO, ready to run,
“Open” position. and voltage is being supplied by Utility. When Utility fails
3. Set the controller set to MANUAL. (below 65% of nominal), a 10 second (optionally
a. The engine should crank cyclically through its programmable) line interrupt delay time is started. If the Utility
“crank-rest” cycles until it starts. is still gone when the timer expires, the engine will crank and
start. Once started a 10 second “engine warm-up timer” will
b. Let the engine stabilize and warm up for a few
be initiated. When the warm-up timer expires, the controller
minutes after it starts.
will transfer the load to the generator. If Utility voltage is
Results restored (75% of nominal) at any time from the initiation of the
engine start until the generator is ready to accept a load (5
1. If the engine cranks manually, but does not crank
second warm-up time has not elapsed), the controller will
automatically, refer back to flow chart.
complete the start cycle and run the generator through its
2. If the engine does not crank manually proceed to normal cool down cycle; however, the voltage will remain on
Problem 16. the Utility source.

Test 42 – Test the Function Of The Procedure

AUTO-OFF-MANUAL Mode 1. Set the generator controller to AUTO.
2. Simulate a power failure by opening the Utility
Procedure supply breaker. If the generator cranks and starts
1. See Figure 4-51. Navigate to the Input Screen and the switch transfers, close the Utility supply
using the menu system for the controller being breaker to return utility power. Within 15 seconds
worked on. the unit should transfer back to the Utility position
2. With the Inputs Screen displayed, set the controller and enter into a cool down mode for one minute,
to AUTO. If the controller reads the auto input from then shut down. If the generator performs this
the switch, Input 7 will change from “0” to “1”. See sequence of events the test is good; STOP.
Table 4-5 in Section 4.1 for a description of the 3. If the generator does not perform the sequence of
Inputs. events listed in the above discussion, diagnose
based on the symptom or Alarms displayed.

Results
Refer back to the flow chart.

Test 44 – Check 7.5 Amp Fuse

(Evolution Alarm Code 2400 Firmware 1.11 and Older)
NOTE: Use the Alarm Log in the control panel to help
troubleshoot various problems. For instance, if the unit
does not crank the control panel will display “Stopped-
002398 Alarm RPM Sensor Loss.” If the Fuse is bad and the unit
Figure 4-51. The Input Screens attempts to crank the alarm log will display “Inspect
Battery” first, and then “Stopped-Alarm RPM Sense Loss.”

164 Diagnostic Repair Manual

 Section 4.6 Diagnostic Tests

General Theory NOTE: Single Cylinder units have a bulkhead mounted

starter solenoid.
The 7.5 amp fuse is located on the generator control
console. A blown fuse will prevent battery power from 6. Set the controller to MANUAL. Measure and record
reaching the circuit board with the same result as setting the voltage.
the controller to OFF. The display and menus will remain 7. Record readings from test points V1, V2, V3 and
active but the unit will not be able to crank or run. V4 as depicted in Figure 4-52 and Figure 4-53.
Although resistance-free connections, wires and
Procedure cables would be ideal, most of them will contain at
Remove and inspect the 7.5 amp fuse (F1). Visually least some voltage drop. The maximum voltage
inspect the fuse and fuse element. If the fuse element readings you should see are as follows:
looks good, or if it cannot be visually inspected, test the a. 0.00-0.10 VDC across a connection (V4).
fuse for an open with a DMM or Continuity Tester. b. 0.10-0.20 VDC on a ground connection.
Results c. 0.20-0.30 VDC across a wire or cable (V1, V2).
1. If the fuse if good, refer back to the Flow Chart. d. 0.20-0.30 VDC across a switch or starter
contactor (V3).
2. If the fuse is bad, it should be replaced. Use only
an identical 7.5 amp replacement fuse. e. 0.40-0.50 VDC across the entire circuit.
3. If fuse continues to blow, proceed to Problem 19
Flow Chart. B
A

Test 45 – Check Battery and Cables

General Theory
Battery power is used to (a) crank the engine and (b) to
power the circuit board. Low or no battery voltage can
result in failure of the engine to crank, either manually or C
during automatic operation. The battery charger in the A. V1
control panel is not designed to recharge a dead battery. As B. V2
well, if there is a loose connection or corrosion associated C. V3
with a wire (positive or negative), battery voltage may be 002399
present, but because of the high resistance, will not allow Figure 4-52.
current to flow. Electrical voltage drop varies according to
current flow. Unless the circuit is operated so current flows
through it, voltage drop cannot be measured. To properly D
measure voltage drop, a crank attempt will need to be
performed. This test will determine whether the battery,
battery cables, or both are at fault.

Procedure A. Perform Starter Circuit Voltage

Drop Test
1. Remove the T1 fuse from the transfer switch.
2. Set a DMM to measure DC voltage. D. V4
005441
3. Connect the Red meter test lead to the positive
battery post and connect the Black meter test lead Figure 4-53.
to the negative battery post.
8. If voltage drop is greater than the above, based on
a. If battery voltage is 12.1 VDC or below, or if
the circuit or component, proceed to Procedure B.
engine does not crank (turn over), proceed to
If voltage drop is within the above, based on the
Procedure C or Procedure D.
circuit or component, proceed to Procedure C or D.
b. If battery voltage is 12.2 VDC or above,
proceed to next step. (For this test, battery Procedure B. Inspect Battery Cables, Terminals and
voltage should be at least 12.2 VDC) Connections
4. Turn off the fuel source and remove Wire 14 from 1. Inspect battery cables and battery posts.
the fuel solenoid to inhibit any possible startup.
2. If cable clamps or terminals are corroded, clean
5. Refer to battery post and starter connections in away all corrosion.
Figure 4-52 and Figure 4-53 and perform a
voltage drop test as indicated. NOTE: If corrosion cannot be cleaned or eliminated,
replace the component in question.
Diagnostic Repair Manual 165
Section 4.6 Diagnostic Tests

3. Verify all cable clamps are tight. The Red battery NOTE: Connect positive cable first.
cable from the starter contactor (SC) must be
securely attached to the positive (+) battery post. Procedure E.Test Battery State of Charge
The Black cable from the frame ground stud must (Non-Maintenance Free Battery Only)
be tightly attached to the negative (-) battery post. 1. Use an automotive type battery hydrometer to test
Procedure C. Perform a Conductance Test with a battery state of charge.
Conductance Type Battery Tester 2. Follow the hydrometer manufacturer’s instructions
1. Remove 7.5 amp fuse from the controller. carefully. Read the specific gravity of the
2. Remove the T-1 fuse from the Transfer Switch to electrolyte fluid in all battery cells.
disable the battery charger. 3. If cells are low, distilled water can be added to refill
3. Connect the test leads to the positive and negative cell compartment.
posts of the battery being tested, and follow the 4. If the hydrometer does not have a “percentage of
battery tester manufacturer’s instructions. Battery charge” scale, compare the reading obtained to the
Test results should not indicate anything lower than following:
60% of the battery’s rated CCA. a. An average reading of 1.260 indicates the
battery is 100% charged.
b. An average reading of 1.230 means the battery
is 75% charged.
c. An average reading of 1.200 means the battery
is 50% charged.
d. An average reading of 1.170 indicates the
battery is 25% charged.
I

Figure 4-54. A Typical Conductance Type Battery

Tester
Procedure D. Perform a load test on the Battery
(All Lead-Acid Type Batteries)
1. Remove 7.5 amp fuse from the controller.
2. Remove the T-1 fuse from the transfer switch.
3. Disconnect both negative and positive cables. 002410

NOTE: Disconnect negative cable first. Figure 4-56. Using a Battery Hydrometer
4. Test the load capability of the battery using a lead 5. Test Battery Condition:
acid battery load tester. a. If the difference between the highest and
lowest reading cells is greater than 0.050 (50
points), battery condition has deteriorated and
the battery should be replaced.
b. If the highest reading cell has a specific gravity
of less than 1.230, the test for condition is
questionable. Recharge the battery to a 100
percent state of charge, then repeat the test for
condition.

Results from Procedure C, Procedure D, or

Procedure E
002409
Figure 4-55. A Typical Battery Load Tester 1. If battery CCA is 60% or less in Procedure C,
IMPORTANT NOTE: To properly load test a battery, the replace battery with new.
battery must be fully charged and the load applied must 2. If the DMM indicated less than 10.5 VDC in
be 1/2 of the battery's CCA Rating. (i.e. 540/2=270) Procedure D, remove the battery and recharge
with an automotive battery charger.
5. Follow the load tester’s manufacturer’s instructions
3. If battery fails tests in Procedure E, replace with
carefully.
new battery.
6. Connect both positive and negative cables.
4. If battery condition is good, refer back to flow chart.
166 Diagnostic Repair Manual
 Section 4.6 Diagnostic Tests

002408
Figure 4-58. The Output Screens
002411 5. Navigate to the Digital Output Screen using the
A. Liquid Level menu system for the controller being worked on.
a. See Figure 4-58. Digital Output 6 is Wire 56
Cell # Specific Gravity output from the board.
1 1.255 6. Set the controller to MANUAL and observe digital
output Number 6. If the controller is working
2 1.260 HIGH READING correctly output Number 6 will change from a “0” to
3 1.235
 a “1”. Observe and record the change in state.
35 POINTS DIFFERENCE a. Nexus Controller - Move to MANUAL position
4 1.250
 to view change of state.
5 1.240 LOW READING b. Evolution Controller - Press MANUAL button
to view change of state.
6 1.225
c. If the controller indicated a “1” then proceed to
Figure 4-57. Reading a Battery Hydrometer the next step.
7. Nexus with Amp (black) connectors: go to step 9.
Test 46 – Check Wire 56 Voltage 8. Evolution and Nexus with Molex (white)
General Theory connectors: Set a DMM to measure DC volts. Use
one meter lead to back probe Wire 56 at the
During an automatic start or when starting manually, an controller connector, leaving the connector
internal crank relay energizes. Each time the crank relay connected to the controller. Connect the other
energizes, the controller should deliver 12 VDC to a starter meter lead to ground. Set the controller to
contactor relay (SCR), or starter contactor (SC) and the MANUAL and measure the voltage.
engine should crank. This test will verify (a) that the crank a. If battery voltage is measured go step 8.
relay on the controller is energizing, and (b) that the
b. If no voltage is measured replace the
controller is delivering 12 VDC to the SCR relay or the SC.
controller.
NOTE: If the unit does not crank the Alarm Log will 9. Set a DMM to measure resistance.
display, “Stopped-Alarm RPM Sense Loss.” 10. Remove 7.5 amp fuse.
Procedure 11. Disconnect the harness connector from the
controller.
1. Set the DMM to measure DC voltage.
12. Remove Wire 56 from the starter contactor relay
2. Locate and disconnect Wire 56 from the SCR on V-
(V-twin units) or from the starter contactor (single
Twin units and the SC on single cylinder units.
cylinder units).
3. Connect one meter test lead to Wire 56 and the
13. Connect one meter test lead to disconnected Wire
other meter test lead to the battery negative
56 and connect the other meter test lead to the
terminal.
controller side of the harness (Wire 56), measure
4. Set the controller to MANUAL. Observe the meter. and record the resistance.
The DMM should indicate battery voltage. If battery
voltage was measured, stop testing and refer back Results
to the flow chart. If voltage was NOT measured, 1. If the DMM indicated battery voltage in Step 4,
proceed to Step 5. refer back to the flow chart.
NOTE: If controller is in an Alarm State, digital output will 2. If the Digital Output in Step 5 did not change,
not change. Clear the fault prior to performing Step 5. replace the controller.
Diagnostic Repair Manual 167
Section 4.6 Diagnostic Tests

3. If the DMM did NOT indicate CONTINUITY in Step 10. Disconnect Wire 0 from the SCR.
13, repair or replace Wire 56 between the controller 11. Connect one meter test lead to Wire 0 and connect
side of the harness and the relay or contactor. the negative meter test lead to common ground,
4. If wire did have continuity and the controller measure and record the resistance.
indicated “1” in step 6 then replace controller.
Results
Test 47 – Test Starter Contactor Relay 1. If battery voltage was NOT measured in Step 3, repair
(V-Twin Engine) or replace Wire 13 between the SCR and the SC.
2. If battery voltage was NOT measured in Step 7 and
General Theory CONTINUITY was measured in Step 11, replace
The starter contactor relay (SCR) located in the control the SCR.
panel must energize for cranking to occur. Once 3. If CONTINUITY was NOT measured in Step 11,
energized the normally open contacts of the SCR will repair or replace Wire 0.
close and battery voltage will be available to Wire 16 and 4. If battery voltage was measured in Step 6, refer
to the starter contactor (SC). back to flow chart.

16
13 Test 48 – Test Starter Contactor
General Theory
The coil in the starter contactor (SC) must energize and
13 16
its normally open contacts close or the engine will not
COM NO
crank. This test will determine if the SC is working.

Procedure
56
0 Carefully inspect the starter motor cable that runs from the
56 0 battery to the starter motor. Cable connections must be
002407 clean and tight. If connections are dirty or corroded, remove
Figure 4-59. Starter Contactor Relay (V-Twin Engine) the cable and clean cable terminals and terminal studs.
Procedure Replace any cable that is defective or badly corroded.
1. Set a DMM to measure DC voltage. See Figure 4-60 and Figure 4-61 for Test Points.
2. Disconnect Wire 13 from the SCR located in the A A C
control panel.
3. Connect the positive meter test lead to Wire 13 and
B B
connect the negative meter test lead to a common
ground. Measure and record the voltage.
4. Connect Wire 13 to the SCR. D
5. Disconnect Wire 16 from the SCR.
6. Connect the positive meter test lead to the
002406
terminal on the SCR from which Wire 16 was A. Test Point A C. Starter Contactor
removed and connect the negative meter test lead B. Test Point B D. Starter Motor
to a common ground. Figure 4-60. Starter Contactor (V-Twins and units
with 426cc Engine)
IMPORTANT NOTE: Do not test wire.
56 16
7. Set the controller to MANUAL. Measure and record
the voltage.
a. If voltage is measured, stop testing and go to
B
the results of this test procedure.
b. If voltage is not measured, continue to the next
step.
A
8. Set the DMM to measure resistance.
9. Remove Wire 56 and Wire 0 from the SCR.
Measure and record the resistance at the terminals 13
A. Test Point A
where Wire 56 and Wire 0 were removed. If B. Test Point B
0
resistance was not measured replace the SCR. If 13
003270
resistance was measured go to Step 10. Figure 4-61. Starter Contactor (410cc Single Cylinder
Engine Units Only)
168 Diagnostic Repair Manual
 Section 4.6 Diagnostic Tests

1. Set DMM to measure DC voltage. • Starter drive dirty or binding.

2. Connect the positive meter test lead to the positive
post of the battery and connect the negative meter
test lead to the negative post of the battery. The DMM
should indicate battery voltage. This measurement
will be a reference during the testing procedure.
3. Connect the positive meter test lead to Test Point A
and connect the negative meter test lead to an
engine ground. Measure and record the voltage.
002405
4. Connect the positive meter test lead to Test Point B
Figure 4-62. Starter Motor (V-Twins and units with
and connect the negative meter test lead to an 426cc Engine)
engine ground.
5. Set the controller to MANUAL. Measure and record
the voltage at Test Point B. The contactor should
energize.

Results: V-Twin Engine

1. If the DMM did not indicate battery voltage in Step
5, measure the resistance on Wire 16 between the
SCR and the contactor. If no resistance is 003271
measured, repair or replace Wire 16 between the Figure 4-63. Starter Motor (410cc Single Cylinder
SCR and the contactor. Engine Units Only)

Results: 410cc Single Cylinder Engine Units Only General Theory

1. If battery voltage was indicated in Steps 3 and 5, Test 45 verified that the battery is fully charged and that
measure the resistance between Test Point B and the battery cables and connections are within the voltage
starter motor. If no resistance is measured, repair drop specifications. Test 46 verified that the circuit board
or replace Wire 16. If resistance is measured, refer is delivering DC voltage to the starter contactor relay
back to the flow chart. (SCR). Test 47 verified the operation of the SCR. Test 48
2. If battery voltage was indicated in Step 3, but not in verified the operation of the starter contactor (SC).
Step 5, replace the starter contactor. Another possible cause of an “Engine Won’t Crank”
problem is a failure of the starter motor itself.
Results: 426cc Single Cylinder Engine Units Only
1. If battery voltage was indicated in Steps 3 and 5, Procedure
stop testing and refer back to the flowchart. 1. Set a DMM to measure DC voltage (12 VDC).
2. If battery voltage was indicated in Step 3, but not in 2. Connect the meter positive (+) test lead to the
Step 5, measure the resistance between Test Point starter contactor stud which has the small jumper
B and Controller connection point for Wire 56 (Use wire or plate connected to the starter motor.
Appendix A for pin locations). If no resistance is 3. Connect the common (-) test lead to the starter
measured, repair or replace Wire 56. If resistance motor frame.
was measured, refer back to the flow chart. 4. Set the controller to MANUAL and observe the
meter. Meter should indicate battery voltage,
Test 49 – Test Starter Motor starter motor should operate and engine should
crank.
Conditions Affecting Starter Motor Performance
• A binding or seizing condition in the starter motor Results
bearings. 1. If battery voltage is indicated on the meter but
• A shorted, open or grounded armature. starter motor did not operate, remove and bench
– Shorted armature (wire insulation worn and wires test the starter motor.
touching one another). Indicated by low or no rpm. 2. If battery voltage was indicated and the starter
– Open armature (wire broken). Indicated by low or motor tried to engage (pinion engaged), but engine
no rpm and excessive current draw. did not crank, check for mechanical binding of the
– Grounded armature (wire insulation worn and wire engine or rotor.
touching armature lamination or shaft). Indicated 3. If engine turns over slightly, go to Test 63 – Check
by excessive current draw or no rpm.
and Adjust Valves. If valve clearance is too loose
• A defective starter motor switch. the valves will not fully open which could slow
• Broken, damaged or weak magnets. down cranking of the engine.

Diagnostic Repair Manual 169

Section 4.6 Diagnostic Tests

Checking The Pinion • The gaseous fuel system must be properly tested
for leaks following installation and periodically
When the starter motor is activated, the pinion gear
thereafter. No leakage is permitted. Leak test
should move and engage the flywheel ring gear. If the
methods must comply strictly with gas codes.
pinion does not move normally, inspect the pinion for
binding or sticking. DANGER
Explosion and fire. Fuel and vapors are extremely
flammable and explosive. No leakage of fuel is
permitted. Keep fire and spark away. Failure to do
so will result in death or serious injury.
(000192)
IMPORTANT NOTE: Verify that the fuel selector is
A properly set for the supplied fuel type.

002403
Procedure
A. Pinion
Figure 4-64. Check Pinion Gear Operation (V-Twins A water manometer or a gauge that is calibrated in
and units with 426cc Engine) “inches of water column” should be used to measure the
fuel pressure. Fuel pressure at the inlet side of the fuel
solenoid valve should be between 3.5-7 inches
A (Evolution) or 5-7 inches (Nexus) water column for natural
gas (NG), or 10-12 inches water column for LP gas.
1. See Figure 4-66, Figure 4-67, and Figure 4-68 for
the gas pressure test point on the fuel regulator. The
fuel pressure can be checked at Port 1 (A) on all fuel
regulators, and at Port 3 (B) on 12-20 kW units.
2. With the manometer connected properly, crank the
003272
A. Pinion
engine. Nominal fuel pressure should be
measured. If pressure is not measured while
Figure 4-65. Check Pinion Gear Operation (410cc cranking refer back to flow chart.
Single Cylinder Engine Units Only)
NOTE: Where a primary regulator is used to establish
Test 50 – Check Fuel Supply and fuel inlet pressure, adjustment of that regulator is usually
Pressure the responsibility of the fuel supplier or the fuel supply
system installer.
General Theory
NOTE: The static pressure port (before solenoid) is
The air-cooled generator was factory tested and adjusted ALWAYS closest to the solenoid, regardless of the
using natural gas as a fuel. If desired, LP (propane) gas demand regulator/plenum tank configuration.
may be used. However, when converting to propane,
some minor adjustments are required. The following Units with a Plenum Tank Only
conditions apply for a unit to operate correctly:
The Port 3 (B) below the fuel solenoid may be used to take a
• An adequate gas supply and sufficient fuel pressure fuel pressure reading before the fuel solenoid. Consistent
must be available or the engine will not start. pressure should be measured at this port both while the
• Minimum recommended gaseous fuel pressure at the generator is running and when the generator is off.
generator fuel inlet connection is 5 inches water
column (Nexus) or 3.5 inches (Evolution) for natural
Results
gas (NG) or 10 inches water column for LP gas on 1. If fuel supply and pressure are adequate, but
Nexus and Evolution. engine will not start refer back to the flow chart.
• Maximum gaseous fuel pressure at the generator 2. If generator starts but runs rough or lacks power,
fuel inlet connection is 7 inches water column for repeat the above procedure with the generator
natural gas or 12 inches water column for LP gas. running and under load. The fuel supply system must
be able to maintain between 3.5-7 inches (Evolution)
• When propane gas is used, only a “vapor or 5-7 inches (Nexus) water column for natural gas
withdrawal” system may be used. This type of (NG), or 10-12 inches water column for LP gas. If
system utilizes the gas that forms above the liquid proper fuel supply and pressure is maintained, refer
fuel. The vapor pressure must be high enough to to Problem 18 – Engine Starts Hard and/or Runs
ensure engine operation. Rough / Lacks Power / Backfires / Hunting /
Erratic Operation.

170 Diagnostic Repair Manual

 Section 4.6 Diagnostic Tests

NOTE: If pressure is above specifications correct/adjust Procedure

supply regulator to generator to maintain proper fuel 1. Set the controller to OFF.
pressure. On Nexus units no more than a 1" drop in fuel 2. Set a DMM to measure DC voltage.
pressure from No Load to Full Load operation while
3. Disconnect Wire 14 from the fuel solenoid (FS).
staying within specifications.
4. Connect the positive test lead to the disconnected
Wire14 from Step 3 and connect the negative test
lead to the negative battery post or an engine ground.
A 5. Set the controller to MANUAL. The meter should
indicate battery voltage once the engine rotates. If the
engine doesn't crank, refer to appropriate flow chart.
a. If battery voltage is indicated, refer back to flow
chart.
b. If battery voltage is not measured, proceed to
Step 6.
6. Navigate to the Digital Output display using the
003273 menu system for the controller.
Figure 4-66. Gas Pressure Test points (8 kW)

002414
Figure 4-69. The Output Screens
003274 7. Output 5 is Wire 14 out from the controller. If the
Figure 4-67. Gas Pressure Test points (10 kW) controller is functioning properly, Output 5 will
change from a “0” to a “1” while the unit is cranking.
a. If the DMM did NOT indicate voltage in Step 5
A
and output did not change in Step 7, replace
the controller.
b. If the DMM did NOT indicate voltage in Step 5
and the output in Step 7 changed, proceed to
Step 11.
B 8. Disconnect the 7.5 amp Fuse.
9. Disconnect the appropriate harness connector
from the controller.
10. Set a DMM to measure resistance.
002413 11. Connect one meter test lead to Wire 14

Figure 4-68. Gas Pressure Test points (12-20 kW) (disconnected in Step 3). Connect the other meter
test lead to Wire 14 at the controller side of the
Test 51 – Check Controller Wire 14 harness connector (Wire 14). See “Appendix A” for
proper wire and connector pin identification.
Outputs
a. If the DMM indicated CONTINUITY repeat
General Theory Step 5 and then retest.
During any crank attempt, the controllers crank relay and b. If CONTINUITY is not measured, repair or
run relays both are energized. When the run relay replace Wire 14 between the controller
energizes, its contacts close and 12 VDC is delivered to harness connector and the fuel solenoid.
the Wire 14 circuit and to the fuel solenoid. The solenoid Results
energizes open to allow fuel flow to the engine. This test
will determine if the controller is working properly. Refer back to flow chart.

Diagnostic Repair Manual 171

Section 4.6 Diagnostic Tests

Test 52 – Check Fuel Solenoid is de-energized, and closed when the choke solenoid is
energized.
General Theory
8 kW: See Figure 4-73. A choke solenoid (A), located on
In Test 51, if battery voltage was delivered to Wire 14, the the air box, energizes only during cranking to assist starting.
fuel solenoid should have energized open. This test will When energized the solenoid is closes the choke plate (B).
verify whether or not the fuel solenoid is operating.
6 kW EcoGen: A Choke Solenoid is located below the air
box and only energizes during cranking to assist starting.
Fuel Solenoid FS1 Nominal Resistance 15-16 ohms When energized, the solenoid is closed.
Fuel Solenoid FS2 Nominal Resistance 29 ohms
A
Procedure: 8 and 12-20 kW Units
1. See Figure 4-66 or Figure 4-68. Install a
manometer to Port 2 on the fuel regulator.
2. Set the controller to MANUAL.
3. Proper gas pressure should be measured during
cranking. If gas pressure is measured, the fuel B
solenoid is operating. If gas pressure is not
measured, repair or replace the fuel solenoid.

Procedure: 10 kW Units
1. See Figure 4-67. Remove the hose from fuel Figure 4-70. Solenoid De-Energized, Choke Closed
solenoid (FS2) and install a manometer to Port 2 12-20 kW Units
on the fuel regulator.
2. Set the controller to MANUAL.
3. Proper gas pressure should be measured during
cranking. If gas pressure is measured, both fuel
solenoids are operating. Discontinue testing.
4. If gas pressure was not measured in Step 3,
remove fuel solenoid FS2 and install a manometer A
to the bottom port of the fuel regulator.
5. Set the controller to MANUAL.
6. Proper gas pressure should be measured during
cranking. If gas pressure is measured, fuel B
solenoid FS1 is operating. Replace fuel solenoid
FS2. If gas pressure is not measured, repair or
replace fuel solenoid FS1. Figure 4-71. Solenoid Energized, Choke Open
12-20 kW Units
Results
If fuel pressure was measured in any of the preceding C
tests it indicates that the fuel solenoid is operating
properly. Refer back to the flow chart for the next test.

Test 53 – Check Choke Solenoid A

(Nexus Only)
General Theory B
12-20 kW: The automatic choke cycles open and closed
during cranking and stays energized (choke open) during
A.Choke Plate
running. For low speed exercise the choke will remain
B.Choke Housing
closed. See Figure 4-70. A choke plate (A) is utilized
C. Choke Solenoid
which covers the throttle bores. When the choke solenoid
003280
(B) is de-energized the choke is closed. Figure 4-72. Exploded View Showing Location of
10 kW: See Figure 4-72. A choke plate (A) located in the Choke Plate - 10 kW Units
choke housing (B) is open when the choke solenoid (C)

172 Diagnostic Repair Manual

 Section 4.6 Diagnostic Tests

b. If the DMM indicated a cyclical battery voltage

B proceed to Step 7.
7. Set a DMM to measure resistance.
8. Connect one meter test lead to Pin 1(Wire 14) on
the male side of the CS connector and the other
meter test lead to Pin 2 (Wire 90). Measure and
A record the resistance.
9. Connect the choke solenoid.
10. With the generator running at a rated speed of
approximately 60 Hz, verify that the choke is
energized and holding the choke plate open. (On
10 kW units de-energized is Open)
11. Repeat Step 3; however, once the unit starts,
manually hold the choke open while taking the
voltage measurement.
003281
Results
Figure 4-73. 8 kW Choke Solenoid
1. If the DMM did NOT indicate battery voltage in
Procedure: 10-20 kW / EcoGen 6 kW Step 6 and wire CONTINUITY was good, replace
the controller.
See Figure 4-72 for the 10 kW location. See Figure 4-70
and Figure 4-71 for the 12-20 kW Choke location and 2. If the DMM did NOT indicate approximately 3.7
operation. ohms (10 kW units) and 6-7 ohms (EcoGen 6 kW
units) in Step 8, replace the choke solenoid.
1. Turn off the fuel supply to the generator.
2. Set the controller to MANUAL. Procedure: 8 kW
NOTE: While cranking, the choke solenoid should pull See Figure 4-73 for location and function of choke
the choke plate open cyclically. The duration of the cycle solenoid.
will vary depending on its position in the crank cycle 1. Turn off the fuel supply to the generator.
sequence. See Table 4-11 for crank durations. If the
2. Set the controller to MANUAL.
choke solenoid does not pull in, verify that the choke can
be manually opened. There should be no binding or NOTE: While cranking, the choke solenoid should pull
interference. the choke plate closed. If the choke solenoid does not
pull in, verify that the choke can be manually opened.
3. Disconnect the choke solenoid.
There should be no binding or interference.
4. Set a DMM to measure DC voltage.
5. See Figure 4-74. Connect the positive meter test 3. Disconnect the choke solenoid.
lead to Pin 1 (Wire 14) of the female side of the CS 4. Set a DMM to measure DC voltage.
connector going to the control panel. Connect the 5. See Figure 4-75. Connect the positive meter test
negative meter test lead to Pin 2 (Wire 90). lead to Pin 1 (Wire 56) of the female side of the CS
connector going to the control panel and connect
90 14 14 90 the negative meter test lead to Pin 2 (Wire 90).

90 56 56 90

2 1 1 2
2 1 1 2
FEMALE SIDE MALE SIDE 003285
FEMALE SIDE MALE SIDE 003288
Figure 4-74. C3 Choke Solenoid Connector Figure 4-75. CS Choke Solenoid Connector
6. Set the controller to MANUAL. While cranking, the 6. Set the controller to MANUAL. While cranking, the
DMM should indicate battery voltage cyclically. DMM should indicate battery voltage.
a. If the DMM did NOT indicate battery voltage, a. If the DMM did NOT indicate battery voltage,
verify CONTINUITY of Wire 90 between the verify CONTINUITY of Wire 90 between the
connector and controller side of Wire 90 and connector Pin 1 J4 (Wire 90) and verify
verify CONTINUITY of Wire 14 between the CONTINUITY of Wire 14 between the
connector and controller side of Wire 14. connector Pin 9 J4 (Wire 56). Repair or replace
Repair or replace any wiring as needed. any wiring as needed.
Diagnostic Repair Manual 173
Section 4.6 Diagnostic Tests

b. If the DMM indicated battery voltage proceed 11. With the generator running at a rated speed of
to Step 7. approximately 60 Hz, verify that the choke is de-
7. Set the controller to MANUAL. While cranking, the energized and the choke plate is open.
DMM should indicate battery voltage.
Results
8. Set a DMM to measure resistance.
1. If the DMM did NOT indicate battery voltage in
9. Connect one meter test lead to Pin 1(Wire 56) on
Step 6 and wire CONTINUITY was good, replace
the male side of the CS connector and the other
the controller.
meter test lead to Pin 2 (Wire 90). Measure and
2. If the DMM did NOT indicate approximately 3.7
record the resistance.
ohms (10 kW units) and 6-7 ohms (EcoGen 6 kW
10. Connect the choke solenoid.
units) in Step 9, replace the choke solenoid.

Table 4-11. Crank Cycle Sequence

1=CHOKED
Note: The first second of each crank cycle is equal to two (2) revolutions of the engine.
0=OPEN

Seconds

Crank Cycle 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

10 kW/EcoGen 6 kW 0 1 1 1 1 1 1 1 0 0 1 1 1 1 1 1

12 kW-20 kW 0 1 1 0 0 1 1 1 0 0 0 1 1 1 1 1

Crank Cycle 2 Seconds

10 kW/EcoGen 6 kW 1 1 1 0 1 1 1 1 0 0 1 1 1 1 1 1

12 kW-20 kW 0 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1

Crank Cycle 3 Seconds

10 kW/EcoGen 6 kW 0 0 0 0 1 1 1

12 kW-20 kW 0 0 1 1 1 1 1

Crank Cycle 4 Seconds

10 kW/EcoGen 6 kW 0 1 1 1 1 1 1

12 kW-20 kW 0 1 0 0 0 0 0

Crank Cycle 5 Seconds

10 kW 0 1 1 1 1 0 0

12 kW-20 kW 0 0 0 0 1 1 1

174 Diagnostic Repair Manual

 Section 4.6 Diagnostic Tests

Test 55 – Check for Ignition Spark 7. See Figure 4-78. To determine if an engine miss is
ignition related, connect the spark tester in series
General Theory with the spark plug wire and spark plug. Then,
If the engine cranks but will not start, one cause might be crank and start the engine. A spark miss will be
that an ignition system failure has occurred. A special readily apparent. If spark jumps the spark tester
spark tester can be used to check for ignition spark. gap regularly, but the engine miss continues, the
problem is in the spark plug or in the fuel system.

V-Twin Only
8. Repeat Step 1 through 7 on the second cylinder.
NOTE: A sheared flywheel key may change ignition timing
but sparking will still occur across the spark tester gap.

Figure 4-76. Spark Tester

See Figure 4-76. When using this style spark tester the
adjustment screw must be set to the proper distance for the
type of ignition system being tested.
NOTE: For the magneto system used on the HSB
engines, set the distance of the adjustment screw tip at
the 10kV mark. When performing the test monitor the gap
for proper spark and color.
The cranking system and engine must be in proper
working order to insure accurate results.

Procedure Figure 4-78. Checking Engine Miss

1. Turn off the fuel supply to the generator. Results
2. Remove spark plug leads from the spark plugs. 1. If no spark or very weak spark occurs, proceed to
3. See Figure 4-77. Attach the clamp of the spark Test 59 – Check Shutdown Wire.
tester to the engine cylinder head. 2. If spark is present and the engine still will not start,
4. Attach the spark plug lead to spark tester terminal. proceed to Test 57 – Check Condition of Spark
5. Set the controller to MANUAL. Plugs.
6. While the engine is cranking, observe the spark 3. When checking for engine miss, if sparking occurs
tester. If spark jumps the tester gap, the engine at regular intervals, but an engine miss continues,
ignition system is operating satisfactorily. proceed to Test 57 – Check Condition of Spark
Plugs.
NOTE: The engine flywheel must rotate at 350 rpm (or
4. When checking for engine miss, if a spark miss is
higher) to obtain a good test of the solid-state ignition
readily apparent, proceed to Test 60 – Check and
system.
Adjust Ignition Magnetos.

Test 57 – Check Condition of Spark

Plugs
General Theory
If the engine will not start and Test 55 indicated good
ignition spark, a possible cause could be fouled or
damaged electrodes. An engine miss may also be
caused by defective spark plug(s).

Procedure
See Figure 4-79 for types of engine related spark plug
problems.
1. Remove spark plug(s) and inspect for any visible
damage.
Figure 4-77. Checking Ignition Spark

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Section 4.6 Diagnostic Tests

2. Replace any spark plug having burned electrodes NOTE: Always check the specifications of the unit you
or cracked porcelain. are working on for correct plug and settings.
3. See Figure 4-80. Using a wire feeler gauge set the
gap on new or used spark plugs as per Table 4-12. Test 58 – Check Engine / Compression
A C
Test / Cylinder Leak Down Test
Introduction
Performing the following test procedures will accurately
diagnose some of the most common problems:
• Will not start • Vibration
• Lack of power • Overheating
• Runs Rough • High Oil Consumption

Check Compression
B
General Theory
D
Lost or reduced engine compression can result in a failure
of the engine to start, or rough operation. One or more of
the following will usually cause loss of compression:
• Blown or leaking cylinder head gasket.
• Improperly seated or sticking-valves.
• Worn piston rings or cylinder (this will also result in
high oil consumption).
002418 For air-cooled engines, the minimum allowable
A. Normal C. Misfires
compression pressure for a cold engine is typically 150
PSI. Compression values are based on accurate process
B. Pre Ignition D. Detonation and proper procedure. However, testing has proven that
an accurate indication of compression in the cylinder can
Figure 4-79. Spark Plug Conditions
be obtained by using the following procedure.
Results
NOTE: Battery and starting system must be in good
1. Clean, re-gap or replace plugs as necessary, condition to get accurate results.
repeat test.
2. If spark plugs are good, refer back to flow chart. IMPORTANT NOTE: Valve adjustment is critical to
proper compression testing. Verify valve adjustment
is correct before proceeding with test.

Procedure
1. Shut off the fuel supply to the unit.
2. Remove both spark plugs.
3. Place a jumper wire from the spark plug boot wire
terminal to ground, OR ground Wire 18 at the
000211
magneto lead connects to harness connection to
Figure 4-80. Checking Spark Plug Gap disable spark.
4. Unplug the stepper motor connector from the
Table 4-12. Spark Plug Gap controller and open the throttle to wide open.
5. Insert a compression gauge into the cylinder.
Engine kW Recommended
Plug Gap Manufacturer 6. Crank the engine until there is no further increase
Size Rating Plug
in pressure.
410 cc 8 0.030 inch RC12YC Champion
7. Record the highest reading obtained.
426 cc 9 0.020 inch RC12YC Champion
8. Repeat the procedure for the remaining cylinder if
530 cc 10 0.030 inch BPR6HS NGK applicable and record the highest reading.
990 cc 12-17 0.040 inch RC14YC Champion NOTE: See Specifications in Section 1.1 for acceptable
999 cc 20 0.030 inch RC12YC Champion compression values.

176 Diagnostic Repair Manual

 Section 4.6 Diagnostic Tests

Results engine is not properly positioned at TDC the results

of the test may be inaccurate.
The difference in pressure between the two cylinders
5. Attach cylinder leak down tester adapter to spark
should not exceed 25 percent. If the difference in
plug hole.
compression is greater that 25 percent, loss of
compression in the lowest reading cylinder is indicated. 6. Connect an air source of 90 PSI to the cylinder leak
down tester.
Example 1: If the pressure reading of Cylinder #1 is 165
PSI and of Cylinder #2 is 160 PSI the difference is 5 PSI. NOTE: Refer to the Tool Manufacturer's instructions for
Divide “5” by the highest reading (165) to obtain the proper setting.
percentage of 3.0 percent.
7. Monitor the flywheel/generator fan for rotation from
top dead center as you apply air in the next step.
Cylinder Leak Down Test 8. Adjust the regulated pressure on the gauge to the
General Theory manufactures setting for the tool that you are using—
typically 90 psi. Verify flywheel/fan has not rotated.
The Cylinder Leak Down Tester checks the sealing
9. Read the gauge on the tester for cylinder percent
(compression) ability of the engine by measuring air
of leakage. A leakage of 20 percent is normally
leakage from the combustion chamber. Compression
acceptable. Use good judgment, and listen for air
loss can present many different symptoms. This test is
escaping at the carburetor (air intake), the exhaust,
designed to detect the section of the engine where the
the side of the head where head and block join,
fault lies before disassembling the engine. Figure 4-81
and the crankcase breather. This will help
represents a standard tester available on the market.
determine where the fault lies.
C
A 10. Repeat Steps 1 through 9 on remaining cylinder if
D
applicable.
B
0 0
E Results
• Air escapes at the carburetor (air intake)– check
F intake valve
H
• Air escapes through the exhaust – check exhaust
I valve
• Air escapes through the breather – check piston rings
G 0 J
• Air escapes between the cylinder head and block –
the head gasket should be replaced and check
both gasket surfaces.
002419
A. Compressed air in
B. Air pressure regulator Test 59 – Check Shutdown Wire
C. Inlet gauge pressure set point
D. Outlet gauge pressure General Theory
E. To spark plug hole
F. Regulator adjustment knob The controller uses Wire 18 for two purposes:
G. Outlet gauge
• to measure engine rpm.
H. Red range indicates unacceptable leakage
I. Needle indicates minimal air leakage • to shutdown the engine. During a shutdown,
J. Green range indicates acceptable leakage controller logic will apply a ground to Wire 18. Wire
Figure 4-81. Cylinder Leakdown Tester 18 is connected to the Ignition Magneto(s). The
grounded magneto will not be able to produce spark.
NOTE: Refer to the Tool Manufacturer's instructions for
variations of this procedure. Procedure
Procedure 1. Disconnect Wire 18.
1. Shut off the fuel supply. • Evolution Units and Nexus Single Cylinder
2. Remove the spark plug(s) from the cylinder. Units – See Figure 4-82, Figure 4-84 and Figure
4-85. Disconnect Wire 18 at the bullet connector.
3. Gain access to the flywheel or to the generator fan
assembly. Remove the valve cover. • Nexus V-twin units – See Figure 4-83. Remove
4. Rotate the engine crankshaft until the piston reaches Wire 18 from the stud located above the oil cooler.
top dead center (TDC) of the compression stroke on
the cylinder being tested. In this position, both the
intake and exhaust valves will be closed. If the

Diagnostic Repair Manual 177

Section 4.6 Diagnostic Tests

starter contactor relay (SCR). Utilizing a

jumper wire, jump 12 VDC from the positive
battery terminal to the terminal on the SCR
from which Wire 56 was removed. The
generator will start cranking. As it is cranking,
repeat Test 55 – Check for Ignition Spark.
Reconnect Wire 56 when done.
b. On single cylinder units, connect a jumper wire
from the stud to which Wire 56 is connected on
the starter contactor (SC) and 12 VDC from the
positive battery terminal. The generator will
Figure 4-82. Wire 18 Connection – Evolution V-Twin start cranking. As it is cranking, repeat Test 55
Units – Check for Ignition Spark. Reconnect Wire
56 when done.
3. If spark is now present with Wire 18 removed,
proceed to check for a short to ground (Steps 4
through 7).
4. Disconnect the harness connector from the
controller.
5. Set the DMM to measure resistance.
6. Connect one meter test lead to Wire 18
(disconnected in Step 1) and connect the other
meter test lead to an engine ground. Measure and
record the resistance.
Figure 4-83. Wire 18 Connection – Nexus V-Twin 7. Connect all disconnected wires and connectors.
Units
Results
1. If the DMM indicated CONTINUITY to ground in
Step 6, repair or replace shorted ground Wire 18
between the engine and the controller connector.
2. If the DMM indicated INFINITY to ground in Step 6,
replace the control board and re-test for spark.
3. If ignition (spark) was not present in Step 2 with
Wire 18 disconnected, proceed to Test 60 – Check
and Adjust Ignition Magnetos.

Test 60 – Check and Adjust Ignition

Figure 4-84. Wire 18 Connection – Evolution Single Magnetos
Cylinder Units
General Theory
In Test 55, a spark tester was used to check for engine
ignition. If sparking or weak spark occurred, one possible
cause might be the ignition magneto(s). This test
consists of checking values across the primary and
secondary windings of the magneto and adjusting the air
gap between the ignition magneto(s) and the flywheel.
The flywheel and flywheel key will also be checked
during this test.
NOTE: On V-Twin units a diode is installed in the primary
winding inside the coil. This is done to inhibit a spark
occurring on both magnetos at the same time.
Figure 4-85. Wire 18 Connection – Nexus Single
Cylinder Units Procedure: Testing Magnetos
2. Depending on engine type, do the following: 1. Depending on engine type, do the following:
a. On V-twin units, remove Wire 56 from the

178 Diagnostic Repair Manual

 Section 4.6 Diagnostic Tests

• Evolution Units and Nexus Single Cylinder Table 4-13.

Units – See Figure 4-82, Figure 4-84 and Figure
4-85. Disconnect Wire 18 at the bullet connector. Measurements with Wire 18 disconnected
• Nexus V-twin units – See Figure 4-83. Remove
Wire 18 from the stud located above the oil cooler. Magneto Wire Diagnostics V-Twins Single Cyl
2. Depending on engine type, disconnect spark plug
POS Test NEG Test
wires from the spark plugs on one or both Ohms Ohms
Lead Lead
cylinders.
3. Set DMM to measure resistance when performing To Plug Wire To Ground 7-14 K 9-16 K
resistance checks and to Diode function when
performing the Diode Test. Diode Test V-Twins Single Cyl
4. Follow the chart connections and record readings
POS Test NEG Test
on DMM to chart. VDC VDC
Lead Lead
NOTE: Readings are approximate.
To Magneto
To Ground 0.5-0.6 N/A
5. Secondary Resistance Check: Connect a meter Wire
lead to the spark plug wire and connect the other
To Magneto
meter lead to battery ground. Record the readings To Ground OL N/A
Wire
and compare to Table 4-13. Readings are
approximate. Measurements with Wire 18 connected
6. Primary Resistance and Diode Check: Connect
the meter lead to the bolt connector or bullet AC Voltage Wire 18
V-Twins Single Cyl
connector where Wire 18 was disconnected in Step Backprobed
1. Connect the other meter lead to the spark plug Cranking 3-5 VAC 1.5-2 VAC
wire or to ground following Table 4-13.
7. On V-twin generators, repeat Steps 5 and 6 on Running @ 3600 rpm 14-20 VAC 7-8.5 VAC
Cylinder Two. If readings are not measured, 11.5-16.5
replace the magnetos. Running @ 3000 rpm 5.8-7 VAC
VAC
NOTE: On V-twin generators it is recommended to
Frequency V-Twins Single Cyl
replace magnetos in pairs.
NOTE: Readings can change based on supplier Cranking 35-45 Hz 13-17 Hz
changes. Check GENservice or contact Generac for Running @ 3600 rpm 120 Hz 60 Hz
updates.
Running @ 3000 rpm 100 Hz 50 Hz
NOTE: Resistance values can vary depending on the
type and quality of meter being used.
Procedure: Adjusting Magneto Flywheel Gap
The air gap between the ignition magneto and the
Table 4-13. flywheel on single cylinder engines is not adjustable.
Proceed directly to Step 10 for single cylinder engines.
Measurements with Wire 18 disconnected
For V-twin engines, proceed as follows:
Magneto Wire Diagnostics V-Twins Single Cyl 1. See Figure 4-86. Rotate the flywheel (by hand)
until the magnet is under the module (armature)
POS Test NEG Test laminations.
Ohms Ohms
Lead Lead 2. Place a 0.008-0.012 inch (0.20-0.30mm) non
metallic thickness gauge between the flywheel
To Magneto
To Ground 1.5-2.5 M .5-1.0 magnet and the module laminations.
Wire
NOTE: A typical business card is approximately 0.010
To Magneto
To Ground OL 3.0 inch thick.
Wire
3. Loosen the mounting screws and let the magnet
To Magneto
To Plug Wire 1.5-2.5 M 10-11 K pull the magneto down against the thickness
Wire
gauge.
To Magneto 4. Tighten both mounting screws.
To Plug Wire OL 10-11 K
Wire

Diagnostic Repair Manual 179

Section 4.6 Diagnostic Tests

5. To remove the thickness gauge, rotate the flywheel 12. Connect one meter test lead to one of the wires
(manually). removed from the ignition magneto(s). Connect the
other test lead to an engine ground. INFINITY
A
should be measured. If CONTINUITY is measured,
replace the shutdown harness.
B
C

B
D

002422
A. 0.008-0.012” Gauge
B. Magneto A. Remove leads D. Wire 18 to circuit board
B. Engine wire harness E. Spark plug
Figure 4-86. Setting Ignition Magneto Air Gap C. Stud connector
6. Repeat the above procedure for the second Figure 4-87. Engine Ground Harness
magneto.
13. Check the flywheel magnet by holding a
7. Repeat Test 55 – Check for Ignition Spark and screwdriver at the extreme end of its handle and
check for spark across the spark tester gap. with its point down. When the tip of the screwdriver
a. A spark test may be conducted with unit is moved to within 3/4 inch (19 mm) of the magnet,
disassembled by following this procedure. the blade should be pulled in against the magnet.
b. Battery must be connected. 14. For rough running or hard starting engines check
c. The harness connector must be connected to the flywheel key. The flywheel's taper is locked on
the controller. the crankshaft taper by the torque of the flywheel
d. Remove Wire 56 from the SCR located nut. A keyway is provided for alignment only and
beneath the controller. theoretically carries no load.

NOTE: Verify all debris is cleared from the engine NOTE: If the flywheel key becomes sheared or even
compartment and all body parts are clear from flywheel partially sheared, ignition timing can change. Incorrect
before proceeding. timing can result in hard starting or failure to start.

e. Refer to Test 55 – Check for Ignition Spark. NOTE: As stated earlier, the armature air gap is fixed for
f. Connect a jumper wire to the 194 terminal single cylinder engine models and is not adjustable.
block. Connect the other end to where Wire 56 Visually inspect the armature air gap and hold down
was disconnected in Step 7d. The engine bolts.
should crank once the jumper from 194 is Results
connected.
8. If spark was not indicated, replace magnetos. If sparking still does not occur after adjusting the
armature air gap, testing the ground wires and
NOTE: If gap is only adjusted, properly test the performing the basic flywheel test, replace the ignition
magnetos by cranking the engine before reassembly. magneto(s).
Spark should be present on both cylinders.
Procedure, Replacing Magnetos:
9. If air gap was not out of adjustment, test ground
wires. 1. Follow all steps of the Major Disassembly
procedures that are located in Section 6.
10. Set a DMM to the measure resistance.
2. Once the magnetos are visible, make note of how
11. See Figure 4-87. Disconnect the engine wire
they are connected.
harness from the ignition magnetos.
• Evolution Units and Nexus Single Cylinder NOTE: Each magneto has its own part number. Verify
Units – See Figure 4-82, Figure 4-84 and Figure the part number prior to installation.
4-85. Disconnect Wire 18 at the bullet connector. 3. See Figure 4-88. Cylinder one is the back cylinder.
• Nexus V-twin units – See Figure 4-83. Remove 4. See Figure 4-89. Cylinder two is the front cylinder.
Wire 18 from the stud located above the oil cooler.

180 Diagnostic Repair Manual

 Section 4.6 Diagnostic Tests

5. See Figure 4-90. When installing new magnetos

there will be one with a short plug wire and one
with a longer plug wire.
NOTE: Magneto gap to flywheel needs to be 0.010 inch.
6. Short plug Wire will be installed on back cylinder
(Cylinder One).
7. Long plug wire (B) will be installed on front cylinder
(Cylinder Two).
8. Verify installation of magnetos correctly by
ensuring both spark plug wires point to the back of
the enclosure and shutdown terminals are nearest
cylinder head as shown in Figure 4-91 and Figure Figure 4-91. Cylinder One Shutdown Wire
4-92.

Figure 4-92. Cylinder Two Shutdown Wire

Figure 4-88. Cylinder One (Back, Short)
Test 61 – Check Oil Pressure Switch
and Wire 86 (Evolution e-Code 1300)
General Theory
If the engine cranks and starts, then shuts down within
about 5 (five) to 10 (ten) seconds with a Shutdown-Alarm
Low Oil Pressure, the cause may be one or more of the
following:
• Low engine oil level.
• Low oil pressure.
• A defective oil pressure switch.

Figure 4-89. Cylinder Two (Front, Long) Procedure

1. Navigate to the Digital inputs display screen of the
controller being worked on.
B A
a. See Figure 4-93. Digital Input 2 is Wire 86
from the Low Oil Pressure switch to the board.
D
b. Set the controller to MANUAL.
C
c. Observe Input 2 for a change from “1” to “0”. A
change from “1” to “0” indicates that the control
board sensed the LOP switch change states. If
E the generator still shuts down, replace controller.
d. If the input did change states, the oil pressure
A. Back Of Enclosure D. Cylinder One switch is good. An intermittent oil pressure
B. Long Spark Plug Wire E. Short Spark Plug Wire problem may still be present and should be
C. Cylinder Two checked with a mechanical gauge as in Step 4.
Figure 4-90. Magneto Positions

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Section 4.6 Diagnostic Tests

a. Set a DMM to measure resistance.

b. Connect the DMM test lead across the low oil
pressure (LOP) switch terminals. With the
engine shut down, the DMM should indicate
CONTINUITY. If INFINITY was measured,
replace the LOP switch.
c. With the DMM still connected to the LOP
switch, set the AUTO-OFF-MANUAL switch
MANUAL. The DMM should indicate INFINITY
after the engine has had a chance to build
pressure.
6. Set the DMM to measure DC voltage.
002430
Figure 4-93. The Input Screens a. Disconnect Wire 86 at the low oil pressure
switch.
2. Check engine crankcase oil level. If necessary, add
b. Connect the Black meter test lead to a good
the recommended oil to the dipstick FULL mark.
ground, and the Red meter test lead to Wire
DO NOT OVERFILL ABOVE THE FULL MARK.
86. Approximately 3.3 VDC should be
3. With oil level correct, try starting the engine. measured. If 3.3 VDC is not measured, go to
a. If engine still cranks and starts, but then shuts Step 7and check continuity on Wire 86 from
down, go to Step 4. the LOP switch back to the J4 connector.
b. If engine cranks and runs normally, discontinue 7. Keep the DMM set to measure resistance.
tests. a. Disconnect the appropriate harness connector
4. Do the following: from the controller and disconnect Wire 86 and
a. Disconnect Wire 86 and Wire 0 from the oil Wire 0 from the LOP switch.
pressure switch terminals. Remove the switch b. Connect one meter test lead to the
and install an oil pressure gauge in its place. disconnected Wire 86 and connect the other
b. Start the engine while observing the oil meter test lead to Wire 86. The DMM should
pressure reading on the gauge. indicate CONTINUITY. If CONTINUITY was
c. Note the oil pressure. not measured repair or replace Wire 86
(1) Normal oil pressure is approximately 35- between the LOP switch and the controller
40 psi with engine running. If normal oil harness connector.
pressure is indicated, go to Step 5 of this c. With Wire 86 still disconnected from the LOP
test. switch and the controller harness connector,
connect one meter test lead to disconnected
(2) If oil pressure is below about 4.5 psi, shut
Wire 86 and the other meter test lead to an
engine down immediately. A problem
engine ground. The DMM should indicate
exists in the engine lubrication system.
INFINITY. If CONTINUITY was measured a
NOTE: Note: The oil pressure switch is rated at 10 psi for short to ground exists on Wire 86. Repair or
V-twin engines, and 8 psi for single cylinder engines. replace as needed.

Results
1. If the switch operated properly and proper oil
pressure was measured, and Wires 86 and 0
tested good, and/or the Input would not change on
the controller, replace the controller.

Test 62 – Check High Oil Temperature

Switch (e-Code 1400)
General Theory
If the temperature switch contacts have failed in a closed
002431
position, the engine will fault out on “OVERTEMP”. If the
Figure 4-94. Oil Pressure Switch unit is in an overheated condition, the switch contacts will
5. Remove the oil pressure gauge and reinstall the oil close at 293 °F. This will normally occur from inadequate
pressure switch. Do NOT connect Wire 86 or Wire airflow through the generator.
0 to the switch terminals.

182 Diagnostic Repair Manual

 Section 4.6 Diagnostic Tests

Procedure Test 63 – Check and Adjust Valves

1. Verify that the engine has cooled down (engine block
is cool to the touch). This will allow the contacts in General Theory
the High Oil Temperature Switch to open. Improperly adjusted valves can cause various engine
2. Check the installation and area surrounding the related problems including, but not limited to, hard starting,
generator. There should be at least three feet of rough running and lack of power. The valve adjustment
clear area around the entire unit. Make sure that
procedures for single cylinder and V-twin engines are
there are no obstructions preventing cooling air
different and vary according to engine displacement.
from entering or exiting the enclosure.
3. Disconnect Wire 85 and Wire 0 from the High Oil Check Valve Clearance
Temperature Switch.
4. Set a DMM to measure resistance. Connect the DANGER
test leads across the switch terminals. The meter
should read INFINITY (0L). Automatic start-up. Disconnect utility power and
render unit inoperable before working on unit.
5. If the switch tested good in Step 4, and a true
Failure to do so will result in death or serious injury.
overtemperature condition has not occurred,
proceed to step 6. (000191)
6. Remove harness connector from the controller. NOTE: The engine should be cool before checking the
7. Set the DMM to measure resistance. valve clearance. Adjustment is not needed if valve
8. Connect one test lead to Wire 85 (disconnected clearance is within the dimensions provided in Section
from High Oil Temperature Switch). Connect the 1.1 Specifications.
other test lead to an engine ground. INFINITY
should be measured. Verify the piston is at Top Dead Center (TDC) of it’s
compression stroke (both valves closed). The cold valve
Testing High Oil Temperature Switch clearance specification is 0.05-0.1mm (0.002-0.004 in).
9. Remove the High Oil Temperature Switch.
NOTE: A small non-metallic object, such as a plastic straw,
10. See Figure 4-95. Immerse the sensing tip of the
can be inserted through the spark plug opening and rested
switch in oil, along with a suitable thermometer.
on the piston. Piston movement will cause the object to
11. Set a DMM to measure resistance. Then, connect move up and down, giving a visual indication of TDC.
the DMM test leads across the switch terminal and
the switch body. The meter should read INFINITY. Adjust Valve Clearance
12. Heat the oil in the container. When the See Figure 4-96 or Figure 4-97. Check and adjust the
thermometer reads approximately 283°-305° F. valve to rocker arm clearance as follows:
(139°-151° C.), the DMM should indicate 1. Remove the four screws attaching the valve cover
CONTINUITY. and remove valve cover.
Results 2. Discard valve cover gasket.
3. Loosen the rocker jam nut (C) using a 10 mm
1. If the switch fails Step 4, or Steps 11-12, replace
wrench (9-11 kW units) or 13 mm wrench (16-22
the switch.
kW units.)
2. If INFINITY was not measured in Step 8, repair or
4. Turn the pivot ball stud (D) using a 14 mm wrench
replace Wire 85 between the Circuit Board and the
(9 kW units), 8 mm wrench (11 kW units), or 10 mm
High Oil Temperature Switch.
Allen wrench (16-22 kW units) while checking
clearance between the rocker arm (E) and the
valve stem (F) with a feeler gauge. Adjust
clearance as per Section 1.1 Specifications.
.

F
E

002432 001812
Figure 4-95. Testing the Oil Temperature Switch Figure 4-96. Valve Clearance Adjustment (9 kW -
426cc engine)

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Section 4.6 Diagnostic Tests

3. Set the controller to MANUAL.

D 4. While unit is cranking measure and record the
E
voltage.
a. If the DMM indicated approximately 3-6 VAC
for V-twin or 2-3 VAC for single cylinder,
proceed to Step 6.
F
C b. If the DMM did NOT indicate the appropriate
voltage, go to the Step 5.

002380
Figure 4-97. Valve Clearance Adjustment (8 kW, 11-22
kW - 530cc through 999cc)

NOTE: Hold the rocker arm jam nut in place as the pivot
ball stud is turned.
5. When valve clearance is correct, hold the pivot ball
stud (D) in place with a wrench and tighten the rocker
arm jam nut. Tighten the jam nut according to the
Figure 4-98. Wire 18 Connection – Nexus V-Twin
following torque specifications: Units
7-8 kW 174 in-lbs (19.68 Nm)
9 kW 53 in-lbs (6.0 Nm)
11 kW 72 in-lbs (8.2 Nm)
16–22kW 174 in-lbs (19.68 Nm)
6. After tightening the jam nut, check valve clearance
again to verify it did not change.
7. Install new valve cover gasket.
8. Install the valve cover. Tighten fasteners in a cross
pattern to:
7-8 kW 48 in-lbs (5.4 Nm)
Figure 4-99. Wire 18 Connection Evolution V-Twin and
9 kW 80 in-lbs (9.0 Nm) Single Cylinder Units and Nexus Single Cylinder Units
11–22kW 60 in-lbs (6.8 Nm)
5. Disconnect Wire 18 from the stud on the Nexus V-
9. Repeat the process for the other cylinder if unit is a V- twin unit. On the Evolution V-twin and single
Twin. cylinder units, or Nexus single cylinder unit,
disconnect Wire 18 from magneto sensing lead.
Test 64 – Check Wire 18 Continuity a. Connect one meter test lead to an engine
ground and connect the other meter test lead
General Theory
to the magneto lead terminal.
During cranking and running, the controller receives a b. Set the controller to MANUAL and while unit is
pulse from the ignition magneto(s) via Wire 18. During cranking measure and record the voltage.
cranking, this signal has an AC voltage of approximately 3- c. If the DMM indicated approximately 3-6 VAC
6 Volts on V-twin engines, and approximately 2-3 Volts on for V-Twin and 2-3 VAC for single cylinder,
single cylinder engines. If the controller does not receive proceed to Step 6.
this signal, the unit will shut down due to no rpm sensing.
d. If the DMM did NOT indicate the appropriate
Procedure voltage, go back to the flow chart (Problem 14)
1. Set the DMM to measure AC voltage. and follow “No Signal” (Test 60).
2. See Figure 4-98 and Figure 4-99. 6. Set the DMM to measure resistance.
7. Disconnect the harness connector containing Wire
• On a Nexus V-twin unit, connect one meter test
18 from the controller.
lead to Wire 18 at the stud connector. Connect the
other meter test lead to an engine ground. 8. Connect one meter test lead to an engine ground
and connect the other meter test lead to Wire 18.
• On Evolution V-twin and single cylinder units and a. If the DMM indicated low resistance (.01),
the Nexus single cylinder units back probe the
check for a short to ground in the Wire 18
harness connector.
circuit.
184 Diagnostic Repair Manual
 Section 4.6 Diagnostic Tests

b. If the DMM indicated 0/L OPEN circuit proceed 4. Press ENTER.

to Step 9. 5. Press arrow key until “IN AUTO PRESS ENTER
9. Connect one meter test lead to harness side of Wire FOR QT-TEST” is displayed.
18 that went to the magneto and connect the other 6. Press ENTER.
meter test lead to Wire 18 at the controller connector. 7. The generator should start and run the low speed
a. If the DMM indicated CONTINUITY, refer back to exercise.
the flow chart (Problem 14, RPM Sense Loss). 8. To stop test press ENTER.
b. If the DMM indicated INFINITY repair or
replace Wire 18 between the magneto Nexus Procedure: 17-20 kW
connector and the controller connector. NOTE: Utility voltage must be present.

Test 65 – Test Exercise Function 1. Set the controller to AUTO.

2. Press the “ESC” key until the main menu is
General Theory displayed.
The following parameters must be met in order for the 3. Press the right arrow key until “Debug” begins to
weekly exercise to occur: flash.
• Exercise Time set in controller. 4. Press “Enter.”
5. Press the right arrow key until “QT Test” beings to
• Controller set to AUTO.
flash.
6. Press “Enter.”
7. The generator should start and run its normal
exercise period.

Results
1. In all models, if the unit starts in MANUAL, but fails
002434
to exercise without any ALARMS present, replace
Figure 4-100. The Exercise Screen the controller.
Procedure: 8 kW-14 kW
NOTE: Utility voltage must be present.
Test 66 – Test Cranking and Running
Circuits
Make a record of the date and time the generator is set to
exercise. General Theory
1. Record the current date and time of the unit. This test will check all of the circuits that are “Hot” with
2. Navigate to the Exercise settings screen of the battery voltage and which could cause the Main Fuse to
controller being worked on. blow. Refer to Table 4-14 throughout the procedure for
3. Press “Enter”. the known resistance values of components.
4. Adjust exercise time to 5 minutes ahead of the date Figure 4-101 shows the DMM in two different states. The
and time noted in Step 1. left DMM indicates an OPEN circuit or INFINITY. The
5. Return to the Main Display where “READY TO right DMM indicates a dead short or CONTINUITY.
RUN” is displayed. The controller must be in AUTO Throughout the troubleshooting, refer to Figure 4-101 as
mode for the unit to exercise. needed to understand what the meter is indicating about
6. Watch the generator display and note the time. the circuit being tested.
When the date and time reaches the time that was
programmed for exercise the unit should crank and
run. “Running in Exercise” will display if the
exercise feature is working properly.

Evolution Procedure: 15-20 kW (11-20 kW

Honeywell™)
NOTE: Utility voltage must be present.
1. Set the controller to AUTO.
2. Enter the Dealer Password to enter the Dealer Edit 002397
Menu. Figure 4-101. INFINITY (Left) and CONTINUITY (Right)
3. Select “Test.” Meter Readings

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Section 4.6 Diagnostic Tests

NOTE: CONTINUITY is equal to 0.01 ohms of resistance Results

or a dead short. 1. If the DMM indicated less than 15 ohms in Step 3,
replace the FS solenoid.
Table 4-14. Component Resistance Values 2. Refer to Table 4-15 and if the DMM indicated the
correct resistance for the component, a short to
Starter Contactor 8Ω ground exists on Wire 14. Repair and replace Wire
14 as needed.
Starter Contactor Relay 155 - 158Ω
Procedure: 10 kW
Fuel Solenoid(s) 15 - 16Ω 1. Set a DMM to measure resistance.
2. Disconnect Wire 14 from the fuel solenoid (FS),
Choke Solenoid (Nexus only) 3 - 4Ω
fuel solenoid 2 (FS2, if equipped), and the choke
solenoid (CS).
Procedure
3. Connect one meter test lead to the FS terminal
1. Set a DMM to measure resistance.
from which Wire 14 was removed. Connect the
2. Disconnect the harness from the controller. other meter test lead to the ground terminal.
3. Connect one meter lead to battery negative Measure and record the resistance.
(ground) and connect the other meter test lead to 4. Connect one meter test lead to the FS2 terminal
each of the tests points in Table 4-15. Measure from which Wire 14 was removed. Connect the
and record the resistance. other meter test lead to the ground terminal.
Measure and record the resistance.
Table 4-15. Resistance Measurements 5. See Figure 4-102. Connect one meter test lead to
Pin 1 on the male side of the CS connector.
Test Point Pin Location Circuit 20 kW Connect the other meter test lead to Pin 2.
Measure and record the resistance.
1 * Wire 14 16Ω
90 14 14 90
2 * Wire 56 155Ω
* Use Appendix A for pin locations

Results
2 1 1 2
1. Compare the results of Step 3 with Table 4-15.
a. If the DMM indicates less than the value in table FEMALE SIDE MALE SIDE 003285
4-16 at Test Point 1 proceed to Test 67 – Test Figure 4-102. C3 Choke Solenoid Connector
Run Circuit.
b. If the DMM indicates less than the value in Results
table 4-16 at Test Point 2 proceed to Test 68 – 1. If the DMM indicated less than 15 ohms in Step 3,
Test Crank Circuit. replace the FS solenoid.
c. If the DMM indicated proper resistance values 2. If the DMM indicated less than 30 ohms in Step 4,
at all Test Points, refer to FB3 (Evolution) or replace the FS2 solenoid.
FB4 (Nexus) Diode Test. 3. If the DMM indicated less than 3 ohms in Step 5,
replace the CS solenoid.
Test 67 – Test Run Circuit 4. Refer to Table 4-15 and if the DMM indicated the
correct resistance for the component, a short to
General Theory ground exists on Wire 14. Repair or replace Wire
Wire 14 provides 12 VDC during cranking and running. If the 14 as needed.
DMM indicated less than 15 Ohms in the previous test, one
possible cause could be a faulty harness or solenoid.
Procedure: 12 kW - 20 kW
1. Set a DMM to measure resistance.
Procedure: 8 kW 2. Disconnect Wire 14 from the fuel solenoid (FS) and
1. Set a DMM to measure resistance. the choke solenoid (CS).
2. Disconnect Wire 14 from the fuel solenoid (FS). 3. Connect one meter test lead to the FS terminal
3. Connect one meter test lead to the FS terminal from which Wire 14 was removed. Connect the
from which Wire 14 was removed. Connect the other meter test lead to the ground terminal.
other meter test lead to the ground terminal. Measure and record the resistance.
Measure and record the resistance.
186 Diagnostic Repair Manual
 Section 4.6 Diagnostic Tests

4. See Figure 4-102. Connect one meter test lead to 2. Disconnect Wire 56 and 0 from the starter
Pin 1 on the male side of the CS connector. contactor relay (SCR).
Connect the other meter test lead to Pin 2. 3. Connect one meter test lead to the SCR terminal
Measure and record the resistance. from which Wire 56 was removed. Connect the
other meter test lead to the terminal from which
Results Wire 0 was removed. Measure and record the
1. If the DMM indicated less than 15 ohms in Step 3, resistance.
replace the FS solenoid. 4. See Figure 4-103. Connect one meter test lead to
2. If the DMM indicated less than 30 ohms in Step 4, Pin 1 on the male side of the CS connector.
replace the FS2 solenoid. Connect the other meter test lead to Pin 2.
3. Refer to Table 4-15 and if the DMM indicated the Measure and record the resistance.
correct resistance for the component, a short to
ground exists on Wire 14. Repair and replace Wire Results
14 as needed. 1. If the DMM indicated less than 155 ohms in Step 3,
replace the SCR relay.
Test 68 – Test Crank Circuit 2. If the DMM indicated less than 3 ohms in step 4
replace the CS solenoid.
General Theory 3. Refer to Table 4-14 and if the DMM indicated the
Wire 56 provides 12 VDC during cranking only. If the correct resistance for the component, a short to
DMM indicated less than 8 ohms (8 kW) at the starter ground exists on Wire 56. Repair and replace Wire
contactor or less than 155 ohms (10-20 kW) at the starter 56 as needed.
contactor relay in the previous test, one possible cause
could be a faulty relay or solenoid. Test 70 – Check to See If Low Speed
Function is Enabled
Procedure: 8 kW (Available only on certain models)
1. Set a DMM to measure resistance.
2. Disconnect Wire 56 from the starter contactor (SC)
General Theory
and on Nexus units disconnect the choke solenoid Some generators are equipped with a low speed
(CS). exercise function. When enabled, the low speed exercise
3. Connect one meter test lead to the SC terminal function allows the generator to exercise at 2400 rpm.
from which Wire 56 was removed. Connect the When low speed exercise is disabled the generator will
other meter test lead to the ground terminal. exercise at 3600 rpm.
Measure and record the resistance. Procedure – Evolution (If equipped)
4. See Figure 4-103. Connect one meter test lead to 1. From the main display enter the Edit Menu using
Pin 1 on the male side of the CS connector. the menu map.
Connect the other meter test lead to Pin 2.
2. Press UP or DOWN Arrow key until “Exercise
Measure and record the resistance.
Time” is displayed.
90 56 56 90 3. Press ENTER.
4. “Quiet Test Mode? Yes or No” will be displayed.
Press UP or DOWN Arrow key until “Yes” is
displayed.
2 1 1 2 5. Press ENTER to save change.
FEMALE SIDE MALE SIDE 003288 6. Return to Main Display.
Figure 4-103. CS Choke Solenoid Connector
Procedure – Nexus
Results 1. Navigate to the Set Exercise display screen of the
1. If the DMM indicated less than 8 ohms of controller being worked on and check to see if the
resistance in Step 3, a short exists. Repair or exercise function is enabled.
replace as needed.
Results
2. If the DMM indicated less than 3 ohms in step 4
replace the CS solenoid. Enable the exercise function if it is not already enabled.
Refer back to flow chart.
Procedure: 10 kW-20 kW
1. Set a DMM to measure resistance.

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Section 4.6 Diagnostic Tests

Test 71 – Check operation of the Test 76 – Verify DC Voltage Output of

Choke Solenoid (Nexus Only) the Controller
General Theory General Theory
The choke solenoid should be closed during low speed The battery voltage of the unit can be viewed within the
exercise. “Display” (Evolution) or “Status” (Nexus) menu of the
controller. This test procedure will verify battery voltage
Procedure to the controller.
1. Remove the air box cover and air filter from the
engine. Procedure
2. Refer to Test 65 – Test Exercise Function. 1. Use the Navigation Menu Map for the controller
3. When the generator starts and the display being serviced.
indicates that unit is exercising, confirm that the Results
choke solenoid is fully closed over one port.
1. If the battery voltage indicated on the display is
Results greater than 12 VDC, the connections to the
1. If the solenoid did not close, confirm that utility controller from the battery are good. Refer back to
voltage is present. If the generator believes that flow chart.
there is a power outage it will run at full speed until 2. If the battery voltage indicated on the display is 0
utility is returned. VDC, the connections to the controller are bad.
2. If the solenoid did not close during low speed (quiet Refer back to flow chart.
test) exercise, and Utility power was available, 3. If the battery voltage indicated on the display is
refer back to Test 53 – Check Choke Solenoid between 1 VDC to 11 VDC, check cables and
(Nexus Only). connections, or charge or replace the battery.

Test 75 – Test 120 Volt Input (T1) 60 Hz Test 77 – Check Wire 13 and Wire 0
240 Volt Input (T1 - T2) 50 Hz General Theory
General Theory The previous test indicated that battery voltage was not
The controller requires 120 VAC (60 HZ Unit) or 240 VAC available to the controller and it was operating only off of
(50 HZ Unit) supplied from the LOAD side of the the 120 VAC input from T1.
contactor in the transfer switch to function properly. When Procedure
the circuit is supplied to the controller it will allow the
1. Set DMM to measure DC voltage.
controller to remain ON, but in a disabled mode where it
will not crank or function properly. 2. Remove the 7.5 Amp fuse from the controller.
3. Connect one meter lead to the left side of the fuse
Procedure holder where the fuse was previously connected.
NOTE: “Inspect Battery” alarm may appear while Connect the other meter test lead to battery
performing this test procedure. Ignore this alarm, it is a negative (ground). Measure and record the
symptom of the test procedure. voltage.
4. Disconnect the appropriate harness connector
1. Locate the 7.5 amp fuse on the controller. from the controller.
2. Remove the fuse and observe the LCD screen. 5. Connect one meter test lead to harness connector
Results pin for Wire 13 and the other meter test lead to
harness connector pin for Wire 0. Measure and
1. If the controller remained illuminated or continued
record the voltage.
to show its status after the fuse was removed, the
120 VAC (60 Hz) or 240 VAC (50 Hz) input is good. Results
2. If the controller powered down when the fuse was 1. If the DMM indicated battery voltage in Steps 3 and
removed, the controller is not getting the 120 VAC 5, replace the controller.
(60 Hz) or 240 VAC (50 HZ) input. Return to the 2. If the DMM indicated battery voltage in Step 3, but
flow chart (Test 79). did NOT indicate battery voltage in Step 5, repair or
replace Wire 0 between the harness connector and
the ground stud.

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 Section 4.6 Diagnostic Tests

Test 78 – Test DC Charge Current to Test 79 – Check T1 Voltage at

the Battery Customer Connections
General Theory Procedure
Previous testing has verified the 120 VAC input 1. Set a DMM to measure AC Voltage.
connection and the battery connection. This test 2. Connect one meter test lead to the T1 Terminal
procedure will determine if there is a negative draw on block at the customer connections in the generator.
the battery or a positive one, which will indicate Connect the other meter test lead to the NEUTRAL
successful operation of the charger. connection. Measure and record the voltage.

Procedure Results
1. If the DMM indicated 120 VAC, proceed to check
NOTE: A “Low Battery” or “Inspect Battery” alert may be
voltage at the J5 connector, refer back to flow
generated during this test procedure. It will not effect the
chart.
results of the test and can be acknowledged when testing
is complete. 2. If the DMM indicated less than 120 VAC or 0, refer
back to flow chart.
1. Set the controller to MANUAL and crank the engine
for 2 -3 seconds. Test 80 – Check T1 Voltage at
2. Set the controller to OFF. Controller Connector
3. Disconnect the negative cable battery.
4. Set the DMM to measure DC amperage. General Theory
NOTE: Consult the meters owner’s manual to ensure If 120 VAC was available on the customer connection
proper setup of meter and that the internal fuse is good block between T1 and neutral for 60 Hz units, or 240 VAC
before proceeding. between T1 and T2 for 50 Hz units, the problem may be
an open wire or bad connector at the controller harness
5. Connect the positive (Red) meter test lead to the connection.
negative battery post and connect the negative
(Black) meter test lead to disconnected negative Procedure
battery cable. Measure and record the amperage. 1. Disconnect the controller connector at the control
panel.
Results
2. Set the DMM to measure AC voltage.
1. If the DMM indicated positive DC amperage
between 50 milliamps to 2.5 amps, stop testing. a. For 60 Hz units check the voltage at the
The charger is functioning properly. controller harness connector pin between Wire
T1 and the neutral connection on the customer
2. If the DMM indicated negative DC amperage,
connection block. If Voltage is present,
replace the controller.
proceed to Step 3. If voltage is not present
check the T1 wire from the customer
connection block to the controller harness
connector.
b. For 50 Hz units check the voltage at the
controller harness connector pins between T1
002435 and the neutral connection, then between T2
Figure 4-104. Positive DC Amps and the neutral connection on the customer
connection block. If voltage is not present
check the T1/T2 wires from the customer
connection block to the controller harness
connector. If Voltage is present, replace the
controller.
3. For 60 Hz units only, check the voltage between
002436 Wire 00 of the controller harness connector pin and
Figure 4-105. Negative DC Amps T1 at the customer connection block. If voltage is
present inspect and repair the connection pins at
controller harness connector. If voltage is not
available, check the 00 wire from the customer
connection block to the controller harness
connector.

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Section 4.6 Diagnostic Tests

4. If 120 VAC is present between T1 and 00 of the Test 82 – Test F3 Fuse Circuit
controller harness connector, and the pins are in
good condition, then the fault is in the controller. Procedure
Replace the controller. 1. Set a DMM to measure AC voltage.
2. Connect one meter test lead to the top side of the
Test 81 – Check T1/T2 Voltage in T1 fuse holder and connect the other test lead to
Transfer Switch the NEUTRAL connection. Measure and record the
voltage.
General Theory a. If the DMM indicated 120 VAC, proceed to Step 3.
If voltage was not present in the generator, the most b. If the DMM indicated less than 120 VAC or 0,
likely cause is a blown T1/T2 fuse or an open wire. verify that Load voltage is available to the
LOAD side of the CONTACTOR.
Procedure 3. Set the controller to OFF.
1. Set the DMM to measure AC voltage.
4. Disconnect Utility from the transfer switch.
2. Connect one meter test lead to the bottom side of
5. See Figure 4-106. Remove fuse F3 from the fuse
the T1 fuse holder (T1/T2 for 50 Hz units) and the
holder.
other meter test lead to the NEUTRAL connection.
6. Inspect and test fuses for an OPEN condition with
Measure and record the voltage.
a DMM set to measure resistance. CONTINUITY
Results should be measured across the fuse.
1. If the DMM indicated proper voltage, repair or Results
replace faulty wire between the generator and the
1. Replace blown fuse as needed and proceed to
fuse holder.
Problem 10 “Blown T1 Fuse.”
2. If the DMM indicated less than proper voltage or 0,
refer back to the flow chart. N1A N2A T1A N1A N2A T1A T2A

A A A A A A A

F1 F2 F3 F1 F2 F3 F3

B B B B B B B

N1 N2 T1 N1 N2 T1 T2
60 Hz Units 50 Hz Units 003304
Figure 4-106. Transfer Switch Fuse Block

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 Section 5.1 Major Disassembly
2013 Front Engine Access Front Engine Access
1. Remove Controls Cover: See Figure 5-3 or
Safety Figure 5-4. Depending on unit, use a Torx T-27
1. Set the controller to OFF. socket or 5/32” (4 mm) Hex Allen socket to remove
2. See Figure 5-1. Remove the 7.5 amp main fuse. screws and ground washer from the controls cover.
Remove the controls cover.
3. Remove the N1 and N2 fuses from the transfer
switch.

Figure 5-1. Remove 7.5 Amp Fuse (Nexus)

Figure 5-3.

005459

Figure 5-2. Remove 7.5 Amp Fuse (Evolution)

005460
4. Turn off fuel supply to the generator and remove
the flex-line from the fuel regulator. Figure 5-4.
5. Remove Utility power from the generator.
2. Remove Nexus Controller: See Figure 5-5. Use
6. Remove the front door. a 10 mm socket to remove the three bolts holding
7. Remove battery from the generator. the control panel in place. There are two bolts on
the side of the divider panel and the third directly
underneath the support bracket.

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Section 5.1 Major Disassembly

Figure 5-5.

3. Remove Evolution Controller: See Figure 5-6.

Use a 1/4” socket to remove the screw that is
directly underneath the support bracket and then
slide the controller back to line up the tabs on the
controller with the openings on the divider wall.

005461

Figure 5-8. Evolution Controller Connections

5. Remove Stator Wires: See Figure 5-9. Remove

all wires from the main circuit breaker, remove the
neutral and ground wires from landing lugs.

Figure 5-6. Tabs on Controller

4. Remove Control Harnesses: See Figure 5-7 or

Figure 5-8. Disconnect all connectors and remove
the controller.

Figure 5-9.

6. Remove Control Wires: See Figure 5-10.

Remove Wires N1, N2, T1, 0, 194, 23, GFCI
Outlet, and unit status lights from the control box.
Figure 5-7. Nexus Controller Connections

192 Diagnostic Repair Manual

 Section 5.1 Major Disassembly

Figure 5-10. Figure 5-12.

7. Remove Controller Mounting Box On Nexus 9. Loosen Side Panel: See Figure 5-11. Using a 10
Controllers: See Figure 5-11. On units with Nexus mm socket remove the two bolts from the base of
controllers, use an 8 mm socket to remove the two the enclosure side panel.
screws from the rear of the controller mounting 10. Unbolt Enclosure Side Panel Mounting
box. Use a 10 mm socket to remove the two bolts Bracket: See Figure 5-11. Using a 10 mm socket
from under the front of the controller mounting box. remove the two bolts from the enclosure side panel
mounting bracket.

Figure 5-11.
Figure 5-13.
8. Remove Engine Intake Baffle: See Figure 5-11.
Use a 10 mm socket to remove the two bolts from
the engine intake baffle. Pull baffle out carefully,
there are tabs holding the backside of the baffle to
the divider panel.

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Section 5.1 Major Disassembly

002644

Figure 5-14. Figure 5-16.

11. Remove Fuel Regulator: See Figure 5-15.

Remove the two fuel hoses at the top of the
regulator. Use a 10 mm socket to remove one 10
mm bolt from the base of the plenum and one 10
mm bolt from the base of the fuel regulator. Flex
the enclosure side out to allow for room to remove
the regulator assembly.

002643

Figure 5-15.
002645

12. Remove Engine Divider Panel: See Figure 5-16. Figure 5-17.
Use a 10 mm socket to remove the rear 10 mm bolt
from the base of the enclosure. See Figure 5-17. 13. Remove Air Box on Nexus units: See Figure 5-
Remove the front 10 mm bolt from the base of the 18. Use a 6 mm Allen wrench to remove the four
enclosure. intake manifold socket head cap screws. See
Figure 5-19. Use a 4 mm Allen wrench to remove
the four airbox Allen head shoulder bolts. While
removing the airbox remove the four rubber
washers.

194 Diagnostic Repair Manual

 Section 5.1 Major Disassembly

Figure 5-21. Evolution Air Box

14. Unbolt Oil Cooler: See Figure 5-22. Use a 10 mm

socket to remove the two 10 mm bolts from the
front of the oil cooler. See Figure 5-23. Remove
the two 10 mm bolts from the rear of the oil cooler.

Figure 5-18. Nexus Intake Manifold

Figure 5-22.

Figure 5-19. Nexus Air Box

Figure 5-20. Evolution Intake Manifold 002649

Figure 5-23.

Diagnostic Repair Manual 195

Section 5.1 Major Disassembly

15. Remove Blower Housing: See Figure 5-24. Use

a 4 mm Allen wrench to remove one button head
cap screw from top of blower housing. Use a 10
mm socket to remove one 10 mm bolt from the top
of the blower housing.

002651

Figure 5-25.

Figure 5-24.

16. See Figure 5-25 and Figure 5-26. Use a 10 mm

socket to remove four 10 mm bolts from the right-
side of the blower housing, and four 10 mm bolts
from the left-side of the blower housing.
17. Remove blower housing.

002652
Figure 5-26.

196 Diagnostic Repair Manual

 Section 5.1 Major Disassembly

2017 HSB Front Access 7. Remove Controls Cover: Use a 4mm Hex Allen
1. Set the controller to OFF. socket to remove the bolts and ground washer
from the controls cover.
2. Remove the 7.5 amp main fuse.
8. Remove the controls cover.
9. Remove the controller.

005459

Figure 5-27.

3. Remove the N1 and N2 fuses from the transfer

switch.
4. Turn off fuel supply to the generator.
5. Remove the front door and the right side access
panel
005463
6. Remove battery.
Figure 5-29.

10. Remove control harnesses.

11. Disconnect all connectors and remove the
controller.

005465

Figure 5-30.

12. Remove right side support panel from divider

panel.
005462
Figure 5-28.

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Section 5.1 Major Disassembly

005467

005464 Figure 5-33.

Figure 5-31.
15. Remove circuit breaker mounting plate.
13. Remove engine intake baffle.
14. Use a 10 mm socket to remove the two bolts from
the engine intake baffle. Pull baffle out carefully.
There are tabs holding the back of the baffle to the
divider panel.

005468

Figure 5-34.

16. Remove cap screw located above the electrical

connection pad in the customer connection area.

005466

Figure 5-32.

198 Diagnostic Repair Manual

 Section 5.1 Major Disassembly

19. Swing breaker with tray out of the way leaving the
wires on the outlet side of breaker connected.
20. Remove air cleaner cover and rubber inlet duct.

005469
005472
Figure 5-35.
Figure 5-38.
17. Remove the 2 inside cap screws under the breaker
tray connecting to the divider panel. 21. Remove the 2 brass colored mounting screws from
the divider panel to the base.

005470

Figure 5-36.

18. Disconnect wires from breaker.

005473

Figure 5-39.

22. Remove two cap screws from the back of the

divider panel (located on the engine side).

005471

Figure 5-37.

Diagnostic Repair Manual 199

Section 5.1 Major Disassembly

005476

Figure 5-42.

25. Remove the blower housing (front engine cover)

per Engine Service manual procedures.

005474

Figure 5-40.

23. Remove Allen screw back side of divider panel to

back panel of generator.

005477

Figure 5-43.

26. Reassemble in reverse order.

005475

Figure 5-41.

24. Pivot panel out for access to front of engine.

200 Diagnostic Repair Manual

 Section 5.1 Major Disassembly

Major Disassembly
Safety
1. Set the controller to OFF.
2. See Figure 5-44. Remove the 7.5 amp main fuse.
3. Remove the N1 and N2 fuses from the transfer
switch.

Figure 5-46.

2. Remove Side Exhaust Enclosure Cover: See

Figure 5-47. Use a 10 mm socket to remove the
five bolts from the exhaust side cover. Remove
side covers.
IF

Figure 5-44. Remove 7.5 Amp Fuse (Nexus)

Figure 5-47.

3. Remove Exhaust Flex Cover: See Figure 5-48.

005459 Use a 10 mm socket to remove the two bolts from
Figure 5-45. Remove 7.5 Amp Fuse (Evolution) the exhaust flex pipe cover. Remove the cover.

4. Turn off fuel supply to the generator and remove

the flex-line from the fuel regulator.
5. Remove Utility power from the generator.
6. Remove the front door.
7. Remove battery from the generator.

Stator/Rotor/Engine Removal
1. Remove Top Exhaust Enclosure Covers: See
Figure 5-46. Use a 10 mm socket to remove the
nine bolts from the exhaust top covers. Remove
covers.
002658
Figure 5-48.

Diagnostic Repair Manual 201

Section 5.1 Major Disassembly

4. Remove Exhaust Flex Pipe: See Figure 5-49. 10. Remove the side panel by sliding it forward then
Use a ½” socket to remove the front and rear re-install the hinge bolt.
muffler clamp. Slide exhaust flex toward engine to
NOTE: The muffler has been removed for better view of
completely expose the muffler flange.
the bolts.
f

Figure 5-49.
002661
002661
5. Muffler Assembly: See Figure 5-50. Depending Figure 5-51.
on the clamp, use a ½” or 10 mm socket to remove
the muffler clamp and flex pipe. Leave muffler
attached to the divider panel.

002662

Figure 5-52.

11. Remove Fan Housing Cover: See Figure . Use a

Figure 5-50. 10 mm socket to remove four bolts from the fan
housing cover (if equipped).
6. Remove Left-side Enclosure: See Figure 5-51.
12. Remove the fan housing cover.
Use a 10 mm ratchet wrench to remove the
horizontal 10 mm bolt that connects the side panel
to the back panel.
7. Use a 10 mm socket to remove three bolts from the
base of the enclosure.
NOTE: The muffler is shown removed for better view of
the bolts.
8. See Figure 5-52. Use a 10 mm socket and wrench
to remove the top hinge bolt and loosen the bottom
bolt.
9. While holding the roof, remove the bottom hinge
bolt.

202 Diagnostic Repair Manual

 Section 5.1 Major Disassembly

14. Remove Rotor Fan: See Figure 5-56. Attach a

vibration dampener or suitable puller to the fan
using two M8 x 1.25 bolts.
15. Remove the fan from the rotor.

Figure 5-53.

13. Remove Rotor Bolt: See Figure 5-54. Use a 9/ 003157

16” socket to remove rotor bolt. Figure 5-56.
NOTE: See Figure 5-55. After removing the rotor bolt,
install a 12 mm x 1.75 mm cap screw in the end of the 16. Remove Alternator Divider Panel: See Figure 5-
rotor shaft. This will be used in conjunction with the puller 57. Depending on the unit, use a 10 mm socket or 4
in the following step. mm Allen wrench to remove two bottom base bolts.
NOTE: Muffler assembly remains attached to the
alternator divider panel during removal.
17. Use a T27 torx driver to remove one top rear bolt.
18. Remove the panel.

Figure 5-54.

003159
Figure 5-57.

19. Remove Brushes: See Figure 5-58 and Figure 5-

59. Use a 7 mm socket to remove brushes.

003156
Figure 5-55.

Diagnostic Repair Manual 203

Section 5.1 Major Disassembly

remove two bolts and ground washer from the

controls cover. Remove the controls cover.

003160
Figure 5-58. Brushes on Nexus Unit

Figure 5-61.

22. Remove Stator Wires: See Figure 5-62. Remove

all connectors from the controller, remove all wires
the common neutral and ground wires from landing
lugs, and remove wires from main beakers.

003163

Figure 5-59. Brushes on Evolution Unit

20. Remove Brush Wires: See Figure 5-58. Use a

side cutters to remove the tie wraps securing the
brush wires to the outside of stator.

Figure 5-62.

23. Alternator Air Intake Bellows Removal: See

Figure 5-63. Remove alternator intake bellows.

003164
Figure 5-60.

21. Remove Controls Cover: See Figure 5-61. Use a

Torx T-27 socket or 5/32” Hex Allen socket to

204 Diagnostic Repair Manual

 Section 5.1 Major Disassembly

Figure 5-65.
003165

Figure 5-63.

24. Rear Bearing Carrier Removal: See Figure 5-62.

Use a 13 mm socket to remove the two nuts from
the alternator mounting bracket rubber mounts.

003166 Figure 5-66.

Figure 5-64.
26. Use a 13 mm socket to remove the four stator hold
25. See Figure 5-66. Lift the back end of the alternator down bolts.
up and place a 2”x 4” piece of wood under the 27. Use a small rubber mallet to remove the rear
engine*. bearing carrier.
NOTE: *See Figure 5-65. On Evolution product there is 28. See Figure 5-67. Remove stator.
a center engine mount and clamping screw. This
clamping screw must be loosened before lifting the
alternator up to set the wood block in place.

Diagnostic Repair Manual 205

Section 5.1 Major Disassembly

Figure 5-67.

29. Rotor Removal: 003171

NOTE: Each model uses a specific rotor bolt. Verify the Figure 5-69.
correct bolt is being used for the rotor being serviced.
31. See Figure 5-70. Using proper lifting equipment
a. Cut 0.5 inches from the rotor bolt. Slot the end remove the engine.
of the bolt to suit a flat blade screwdriver.
b. Slide the rotor bolt back through the rotor and
use a screwdriver to screw it into the crankshaft.
Be sure to thread in a minimum of 3/8” to
ensure enough threads for puller cap screw.
c. Screw a 3” M12x1.75 cap screw into rotor.
d. Apply torque to the 3” M12x1.75 cap screw
until taper breaks free from crankshaft.

Figure 5-70.

Figure 5-68.

30. Remove Engine: See Figure . Using a 13 mm

socket, remove the two engine mount nuts with
ground wires.

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 Section 5.1 Major Disassembly

Torque Specifications

Stator Bolts 6 ft-lbs (+1 / -0)

Rotor Bolt 30 ft-lbs

Engine Adapter 25 ft-lbs

Exhaust Manifold 18 ft-lbs

M5-0.8 Taptite Screw Into Aluminum 25-50 in-lbs

M5-0.8 Taptite Screw Into Pierced Hole 25-50 in-lbs

M6-1.0 Taptite Screw Into Aluminum 50-96 in-lbs

M6-1.0 Taptite Screw Into Pierced Hole 50-96 in-lbs

M6-1.0 Taptite Screw Into Weldnut 50-96 in-lbs

M8-1.25 Taptite Screw Into Aluminum 12-18 ft-lbs

M8-1.25 Taptite Screw Into Pierced Hole 12-18 ft-lbs

M6-1.0 Nylok Nut Onto Weld Stud 16-65 in-lbs

M6-1.0 Nylok Nut Onto Hinge Stud 30-36 in-lbs

NOTE: Torques values are dynamic, with ±10%

tolerance unless otherwise noted.

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Section 6.1 0L6822-B WD/SD Air-cooled 2017 HSB Evolution 9 kW 60 Hz

Introduction
The diagrams in this section are provided for general reference only. For unit specific diagrams refer to the Service and
Support page at the manufacturer’s website.

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Section 6.2 0L6823-B WD/SD Air-cooled 2017 HSB Evolution 60 Hz

Introduction
The diagrams in this section are provided for general reference only. For unit specific diagrams refer to the Service and
Support page at the manufacturer’s website.

Diagnostic Repair Manual 215

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Section 6.3 0L6824-B WD/SD Air-cooled 2017 HSB Evolution 50 Hz

Introduction
The diagrams in this section are provided for general reference only. For unit specific diagrams refer to the Service and
Support page at the manufacturer’s website.

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Section 6.3 0L6824-B WD/SD Air-cooled 2017 HSB Evolution 50 Hz

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Section 6.4 0K2945-E WD/SD Air-cooled Pre 2017 HSB Evolution 8 kW 60 Hz

Introduction
The diagrams in this section are provided for general reference only. For unit specific diagrams refer to the Service and
Support page at the manufacturer’s website.

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Section 6.4 0K2945-E WD/SD Air-cooled Pre 2017 HSB Evolution 8 kW 60 Hz

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Section 6.5 0J9961-D WD/SD Air-cooled Pre 2016 HSB Evolution 11-22 kW 60 Hz

Introduction
The diagrams in this section are provided for general reference only. For unit specific diagrams refer to the Service and
Support page at the manufacturer’s website.

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238 Diagnostic Repair Manual

 Appendix A Controller Identification
Important Note
For Nexus Menu System Navigation refer to Section
1.4.
Use wire numbers only and disregard any specific
“J” Connector references. Utilize the wire numbers
and controller pin out chart in this appendix per
specific connector styles!

Probing and Pin Extraction

Use the special tool (P/N 0J09460SRV) to back probe
the connector.
NOTE: DO NOT front probe Molex Connectors.
Diagnostic procedures in this manual do not call out the Figure A-3. Probing AMP Connector
connector or pin number, only the wire number.
This section (Appendix A) is to be used as a resource to
identify the correct pin location and connector on the
controller being diagnosed.
NOTE: If probing and/or back-probing results in a “BAD”
condition, before condemning the controller, remove the
pin/plug in question and verify the pin/plug is not
distorted, bent and/or not making electrical contact!
Repair as needed! 002452
Figure A-4. Molex Pin Extractor Tool Part# 0K4445

Figure A-1. Special Tool (P/N 0J09460SRV) Back

Probe 002453

Figure A-5. Using Molex Pin Extractor Tool

Figure A-2. Back-Probing Molex Connector

Diagnostic Repair Manual 239

Appendix A Controller Identification

Evolution 1.0 Controller

See Figure A-6 – Evolution 1.0 Air-cooled Panel has 3 Molex style connectors on the back (J1, J2, & J3), one actuator
connector (J5), a battery charger connector (J8 & J9), and a connector socket for a remote annunciator (optional
accessory).

Note: View is from

2 1 J8-J9 harness side of connectors.

3 1
4 2
J3

1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8
11 12 13 14 15 16 17 18 19 20
J1 J2 9 10 11 12 13 14 15 16

NOTE: Ribs on connector indicate pin

number, starting with pin 1, then pin 2
Remote Annunciator
and pin 3, etc. Connector

10 9 8 7 6 5 4 3 2 1 J5

003483
Figure A-6. Evolution 1.0 Air-cooled Panel and Connectors (Harness End)

J1 Connector J1 Connector
Pin Wire Circuit Function Pin Wire Circuit Function
J1-1 13 12 VDC un-fused for the controller J1-11 85 High temperature shutdown: Shutdown
occurs when Wire 85 is grounded by
J1-2 13 12 VDC un-fused for the controller
contact closure in the oil temperature switch
J1-3 820 Positive voltage (5VDC) for status LEDs
J1-12 86 Low oil pressure shutdown: Shutdown
J1-4 23 Switched to ground (internally) to energize occurs when Wire 86 is grounded by loss
the Transfer Relay of oil pressure in the LOP switch
J1-5 178 Not Used, Optional - 2-Wire Start (return) J1-13 0 Common Ground (DC) DC Field Excitation
J1-6 819 Grounded by the controller to turn on the Ground
Maintenance (Yellow) LED J1-14 194 Provides 12 VDC to the transfer relay
J1-7 818 Grounded by the controller to turn on (TR1)
Alarm (Red) LED J1-15 - Not Used - UL Required Spacing
J1-8 817 Grounded by the controller to turn on J1-16 N1 240 VAC Utility sensing voltage
System Ready (Green) LED
J1-17 N2 240 VAC Utility sensing voltage
J1-9 398A Generator Current Sense A2
J1-18 - Not Used - UL Required Spacing
J1-10 399A Generator Current Sense A1
J1-19 11S 240 VAC Generator Voltage Sensing
J1-20 44S 240 VAC Generator Voltage Sensing

240 Diagnostic Repair Manual

 Appendix A Controller Identification

J2 Connector J3 Connector
Pin Wire Circuit Function Pin Wire Circuit Function
J2-1 J3-1 0 Common Ground (DC) DC Field Excitation
Ground
J2-2 209 Common Alarm Relay Output
J3-2 4 DC (+) Field Excitation
J2-3 56 12 VDC output to starter contactor relay/
solenoid J3-3 2 DPE Winding (AC Excitation power)
J2-4 14 12 VDC output for engine run condition. J3-4 6 DPE Winding (AC Excitation power)
Fuel solenoid supply voltage.
J5 Connector
J2-5 4A DC (+) Field Excitation (Before Field Boost
Diode) Pin Wire Circuit Function
J2-6 398A Generator Current Sense B2 J5-1 - Not Used
J2-7 18 Ignition Shutdown: The controller grounds J5-2 - Not Used
Wire 18 for ignition shutdown and receives
J5-3 - Not Used
a reference signal for speed control while
cranking and running J5-4 - Not Used
J2-8 R1 Model ID Resistor J5-5 - Not Used
J2-9 - Not Used J5-6 Red Stepper Power
J2-10 - Not Used J5-7 Orange Stepper Motor B2 Coil
J2-11 183 Not Used, Optional - 2-Wire Start J5-8 Yellow Stepper Motor B1 Coil
J2-12 210 Common Alarm Relay Output J5-9 Brown Stepper Motor A2 Coil
J2-13 - Not Used J5-10 Black Stepper Motor A1 Coil
J2-14 399B Generator Current Sense B1
J8-J9 Connector
J2-15 R3 Model ID Resistor
Pin Wire Circuit Function
J2-16 R2 Model ID Resistor
1 T1 120 VAC Power for the Battery Charger
2 00 Neutral Connection for T1 (battery
charger)

Diagnostic Repair Manual 241

Appendix A Controller Identification

Nexus Controller
There are currently three styles of Nexus Air-cooled control panel. The difference in the styles is how the wires are
connected to the panel. The different panel part numbers, connection types, and images of each are shown on the
following pages.
See Figure A-7 – Nexus Air-cooled Panel part number 0H6680 (A) or (B) has two Amp-Seal style connectors on the
back (J4 & J5), one actuator connector (J3), and a connector socket for the remote wireless annunciator (optional
accessory).

J5

This view is showing the "Pin side" of the connector,

opposite of the wire harness side

BLACK

BROWN

YELLOW
J3
ORANGE

RED J4
EMPTY

Remote Annunciator
Connector
003484

Figure A-7. Nexus Air-cooled Panel Part Number 0H6680 (A) or (B), and Connectors (Harness End)

J3 Connector J4 Connector
Pin Wire Circuit Function Pin Wire Circuit Function
J3-1 Black Stepper Motor A1 Coil J4-1 90 Switched to ground for choke solenoid
operation
J3-2 Brown Stepper Motor A2 Coil
J4-2 0 Common Ground (DC)
J3-3 Yellow Stepper Motor B1 Coil
J4-3 13 12 VDC un-fused for the controller
J3-4 Orange Stepper Motor B2 Coil
J4-4 817 Grounded by the controller to turn on
J3-5 Red Stepper Power
System Ready (Green) LED
J3-6 Empty
J4-5 818 Grounded by the controller to turn on
Alarm (Red) LED
J4-6 819 Grounded by the controller to turn on the
Maintenance (Yellow) LED
J4-7 85 High temperature shutdown: Shutdown
occurs when Wire 85 is grounded by
contact closure in the oil temperature
switch
J4-8 820 Positive voltage (5VDC) for status LED's

242 Diagnostic Repair Manual

 Appendix A Controller Identification

J4 Connector (Continued)
J5 Connector
Pin Wire Circuit Function
Pin Wire Circuit Function
J4-9 14 12 VDC output for engine run condition.
Used for fuel solenoid and choke solenoid J5-1 N1
operation on V-Twin Models J5-2 T1
J4-10 210 Common Alarm Relay Output J5-3 00
J4-11 Not used J5-4 Not Used
J4-12 Not used J5-5 2 DPE Winding (AC excitation power)
J4-13 86 Low oil pressure shutdown: Shutdown J5-6 N2 240VAC Utility sensing voltage
occurs when Wire 86 is grounded by loss
of oil pressure in the LOP switch J5-7 Not Used

J4-14 Not used J5-8 Not Used

J4-15 JMP 1 Installed in series with a resistor to identify J5-9 Not Used
the kW to the controller J5-10 44 240VAC Generator voltage sensing
J4-16 18 Ignition Shutdown: The controller grounds J5-11 11 240VAC Generator voltage sensing
Wire 18 for ignition shutdown and receives
J5-12 0 DC Field excitation ground
a reference signal for speed control while
cranking and running J5-13 4 DC (+) Field excitation voltage
J4-17 56 12 VDC output to starter contactor relay/ J5-14 6 DPE Winding (AC excitation power)
solenoid
J4-18 209 Common Alarm Relay Output
J4-19 194 Provides 12 VDC to the transfer relay
(TR1)
J4-20 23 Switched to ground (internally) to energize
the Transfer Relay
J4-21 Not used
J4-22 Not used
J4-23 JMP 1 Installed in series with a resistor to identify
the kW to the controller

Diagnostic Repair Manual 243

Appendix A Controller Identification

See Figure A-8 – Nexus Air-cooled Panel part number 0H6680 (D) has 4 Molex/ETC style connectors on the back (J5,
J8, J9 & J10), one actuator connector (J3), the battery charger connector (J11 & J12), and a connector socket for the
remote wireless annunciator (optional accessory).

J11-J12 2 1

J9 3 4
4 5 6
J10 1 2
1 2 3

This view is showing the "Pin side" of the

connector, opposite of the wire harness side

BLACK

BROWN

YELLOW
J3
ORANGE 10 11 12 13 14 15 16 17 18
RED
J8
EMPTY J5 1 2 3 4 5 6 7 8 9

1 2 3 4 5

Remote Annunciator
Connector
003485

Figure A-8. Nexus Air-cooled Panel Part Number 0H6680 (D), and Connectors (Harness End)

J3 Connector J5 Connector
Pin Wire Circuit Function Pin Wire Circuit Function
J3-1 Black Stepper Motor A1 Coil J5-1 209 Common Alarm Relay Output
J3-2 Brown Stepper Motor A2 Coil J5-2 194 Provides 12 VDC to the transfer relay
(TR1)
J3-3 Yellow Stepper Motor B1 Coil
J5-3 23 Switched to ground (internally) to energize
J3-4 Orange Stepper Motor B2 Coil
the Transfer Relay
J3-5 Red Stepper Power
J5-4 Not used
J3-6 Empty
J5-5 Not used

244 Diagnostic Repair Manual

 Appendix A Controller Identification

J8 Connector J9 Connector
Pin Wire Circuit Function Pin Wire Circuit Function
J8-1 820 Positive voltage (5VDC) for status LED's J9-1 6 DPE Winding (AC excitation power)
J8-2 LMP 1 Installed in series with a resistor to identify J9-2 11 240 VAC Generator voltage sensing
the kW to the controller
J9-3 2 DPE Winding (AC excitation power)
J8-3 85 Low oil pressure shutdown: Shutdown
J9-4 44 240 VAC Generator voltage sensing
occurs when Wire 86 is grounded by loss
of oil pressure in the LOP switch
J8-4 0 Common Ground (DC) J10 Connector

J8-5 JMP 1 Installed in series with a resistor to identify Pin Wire Circuit Function
the kW to the controller J10-1 T1 120 VAC power for the battery charger
J8-6 56 12 VDC output to starter contactor relay/ J10-2 00 Neutral Connection for T1 (battery
solenoid charger)
J8-7 14 12 VDC output for engine run condition.
Used for fuel solenoid and choke solenoid
operation on V-Twin Models
J8-8 18 Ignition Shutdown: The controller grounds
Wire 18 for ignition shutdown and receives
a reference signal for speed control while
cranking and running
J8-9 90 Switched to ground for choke solenoid
operation
J8-10 85 High temperature shutdown: Shutdown
occurs when Wire 85 is grounded by
contact closure in the oil temperature
switch
J8-11 Not used
J8-12 819 Grounded by the controller to turn on the
Maintenance (Yellow) LED
J8-13 818 Grounded by the controller to turn on
Alarm (Red) LED
J8-14 817 Grounded by the controller to turn on
System Ready (Green) LED
J8-15 Not used
J8-16 210 Common Alarm Relay Output
J8-17 Not used
J8-18 13 12 VDC un-fused for the controller

Diagnostic Repair Manual 245

Appendix A Controller Identification

See Figure A-9 – Nexus Air-cooled Panel part number 0H6680 (T) has 3 Amp/Tyco style connectors on the back (J4,
J5 & J6) the actuator connector (J3), and a connector socket for the remote wireless annunciator (optional accessory).

J6

J4
BLACK

BROWN

YELLOW
J3
ORANGE

RED J5
EMPTY

Remote Annunciator
Connector
003486

Figure A-9. Nexus Air-cooled Panel Part Number 0H6680 (T), and Connectors (Harness End)

J5 Connector (Continued)
J3 Connector
Pin Wire Circuit Function
Pin Wire Circuit Function
J5-6 819 Grounded by the controller to turn on the
J3-1 Black Stepper Motor A1 Coil Maintenance (Yellow) LED
J3-2 Brown Stepper Motor A2 Coil J5-7 85 High temperature shutdown: Shutdown
J3-3 Yellow Stepper Motor B1 Coil occurs when Wire 85 is grounded by
contact closure in the oil temperature
J3-4 Orange Stepper Motor B2 Coil switch
J3-5 Red Stepper Power J5-8 820 Positive voltage (5VDC) for status LED's
J3-6 Empty J5-9 14 12 VDC output for engine run condition.
Used for fuel solenoid , and choke
J5 Connector solenoid operation on V-Twin Models

Pin Wire Circuit Function J5-10 210 Common Alarm Relay Output

J5-1 90 Switched to ground for choke solenoid J5-11

operation J5-12
J5-2 0 Common Ground (DC) J5-13 86 Low oil pressure shutdown: Shutdown
J5-3 13 12 VDC un-fused for the controller occurs when Wire 86 is grounded by loss
of oil pressure in the LOP switch
J5-4 817 Grounded by the controller to turn on
System Ready (Green) LED J5-14

J5-5 818 Grounded by the controller to turn on J5-15

Alarm (Red) LED

246 Diagnostic Repair Manual

 Appendix A Controller Identification

J5 Connector J6 Connector
Pin Wire Circuit Function Pin Wire Circuit Function
J5-1 JMP 1 Installed in series with a resistor to identify J6-1 N1 240 VAC Utility sensing voltage
the kW to the controller
J6-2 T1 120 VAC power for the battery charger
J5-2 18 Ignition Shutdown: The controller grounds
J6-3 00 Neutral Connection for T1 (battery
Wire 18 for ignition shutdown and receives
charger)
a reference signal for speed control while
cranking and running J6-4 2 DPE Winding (AC excitation power)
J5-3 56 12 VDC output to starter contactor relay/ J6-5 N2 240 VAC Utility sensing voltage
solenoid J6-6 44 240 VAC Generator voltage sensing
J5-4 209 Common Alarm Relay Output J6-7 11 240 VAC Generator voltage sensing
J5-5 19423 Provides 12 VDC to the transfer relay J6-8 0 DC (-) Field excitation voltage
(TR1)
J6-9 4 DC (+) Field excitation voltage
J5-6 23 Switched to ground (internally) to energize
the Transfer Relay J6-10 6 DPE Winding (AC excitation power)

J5-7 J6-11

J5-8 J6-12

J5-9 JMP 1 Installed in series with a resistor to identify

the kW to the controller

Diagnostic Repair Manual 247

Appendix A Controller Identification

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248 Diagnostic Repair Manual

 Appendix B EcoGen Drawings
Eco Gen Oil Make-Up System (6 kW)
355.6mm
VENT LINE [14"]

355.6mm
[14"]
700mm
AIR FILTER BOX
ENGINE [27 5/8"]

177.8mm
[7"]

OIL
FILL
38.1mm
VALVE [1 1/2"] 203.2mm
COVER [8"]
279.4mm
980mm
[11"]
[38 5/8"] OIL
TANK
50.8mm 177.8mm
[2"] [7"]
CHECK
VALVE SCAVANGER 350mm
PROBE [13 3/4"]
MAX OIL
LEVEL PROBE

SUMP

003493
Figure B-1. Eco Gen Oil Make-Up System

Pump 1 Pump 2

Figure B-3. Pump 2 – 0F6263 (New Style)

Figure B-2. Pump 1 – 0H7726
• Draws oil from reservoir tank to replenish sump
• Pulse is controlled by the scavenger probe and the
max oil probe
IMPORTANT NOTE: Incorrect routing of the hoses in the
oil make-up circuit can cause the crankcase to fill with
excessive amounts of oil. Inspect for proper hose routing to
the pumps and if necessary, follow the procedures identified
in the Service information bulletin (SIB13-09-EcoGen).
Figure B-4. Pump 2 – 0C4147 (Old Style)

• Draws oil from engine crankcase to the reservoir

tank
• Scavenger probe must be submerged to operate
properly

Diagnostic Repair Manual 249

Appendix B EcoGen Drawings

Pump 1 Operation
OIL =
VENT =
PULSE = 355.6mm
VENT LINE [14"]

355.6mm
[14"]
700mm
AIR FILTER BOX
ENGINE [27 5/8"]

177.8mm
PUMP 1 [7"]

OIL
FILL
38.1mm
VALVE [1 1/2"] 203.2mm
COVER [8"]
279.4mm
980mm
[11"]
[38 5/8"] OIL
TANK
50.8mm
50 8 177.8mm
177 8
[2"] [7"]
CHECK
VALVE SCAVANGER 350mm
PROBE [13 3/4"]
MAX OIL
LEVEL PROBE

SUMP

003494
Figure B-5. Eco Gen Oil Make-Up System – Pump 1 Operation
Pump 1 draws oil from reservoir tank to replenish sump with the pulse being controlled by the scavenger probe and the
max oil level probe. When the scavenger and max oil probes are submersed in oil, the pulse to pump 1 is stopped.

Pump 2 Operation
OIL = 355.6mm
VENT LINE [14"]
VENT =
PULSE = 355.6mm
PUMP 2 [14"]
700mm
AIR FILTER BOX
ENGINE [27 5/8"]

177.8mm
[7"]

OIL
FILL
38.1mm
VALVE [1 1/2"] 203.2mm
COVER [8"]
279.4mm
980mm
[11"]
[38 5/8"] OIL
TANK
50.8mm 177.8mm
[ ]
[2"] [7"]
CHECK
VALVE SCAVANGER 350mm
PROBE 3/4 ]
[13 3/4"]
MAX OIL
LEVEL PROBE

SUMP

003495
Figure B-6. Eco Gen Oil Make-Up System – Pump 2 Operation
Pump 2 draws oil from engine crankcase to the reservoir tank, essentially keeping the crankcase full. The scavenger
probe must be submerged in the crankcase oil for it to pull oil from the crankcase. This stops the flow of oil from the
reservoir tank to the engine crankcase.
250 Diagnostic Repair Manual
 Appendix B EcoGen Drawings

Figure B-7. Eco Gen Installation Diagram

Diagnostic Repair Manual 251

Appendix B EcoGen Drawings

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252 Diagnostic Repair Manual

Electrical Formulas
To Find Known Values 1-phase 3-phase
EXI E x I x 1.73 x PF
Kilowatts (kW) Volts, Current, Power Factor
1000 1000
ExI E x I x 1.73
KVA Volts, Current
1000 1000
kW x 1000 kW x 1000
Amperes kW, Volts, Power Factor
E E x 1.73 x PF
Watts Volts, Amps, Power Factor Volts x Amps E x I x 1.73 x PF
2 x 60 x Frequency 2 x 60 x Frequency
No. of Rotor Poles Frequency, RPM
RPM RPM
RPM x Poles RPM x Poles
Frequency RPM, No. of Rotor Poles
2 x 60 2 x 60
2 x 60 x Frequency 2 x 60 x Frequency
RPM Frequency, No. of Rotor Poles
Rotor Poles Rotor Poles
HP x 0.746 HP x 0.746
kW (required for Motor) Motor Horsepower, Efficiency
Efficiency Efficiency
E E
Resistance Volts, Amperes
I I
Volts Ohm, Amperes IxR IxR
E E
Amperes Ohms, Volts
R R
E = Volts I = Amperes R = Resistance (Ohms) PF = Power Factor

Term Symbol Measurement Constant Shift Result

Current I Amps
Voltage Resistance Current
Wattage P Watts E Increase
 Decrease

Voltage E Volts
Voltage Resistance Current
Resistance R Ohms
E Decrease
 Increase

Resistance Voltage Current
R Decrease
 Decrease

E P Resistance Voltage

Current

R Increase Increase

I R I E Current Resistance

Voltage

003003 I Decrease Decrease

Current Resistance Voltage

I Increase
 Increase

Power Voltage Power
P Increase
 Increase

Power Voltage Power
P Decrease
 Decrease

Power Current Power
P Increase
 Increase

Power Current Power
P Decrease
 Decrease

Part No. 0H9172 Rev. M 09/25/2017
©2017 Generac Power Systems, Inc. Generac Power Systems, Inc.
All rights reserved S45 W29290 Hwy. 59
Specifications are subject to change without notice. Waukesha, WI 53189
No reproduction allowed in any form without prior written 1-888-GENERAC (1-888-436-3722)
consent from Generac Power Systems, Inc. www.generac.com