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Commercial generator 20kv not working properly

Kohler fast response II, emergency generator for two building. 20KW diesel as two switch box for two building one is 800amp 480v and the second is a smaller , that right now i can't remeber. well we lost power recently and the trasfer-switch box did not send the command to the generator to start, both trasfer-switch box did't work . i check it the generator at the control and it run fine when it run manually. the board that is installed on the generator control as two realy k2 k3 that control the start of the generator. need some help .. 1st on how to test those board with out cut power to the building and too on not get fried while i work on the circuit board.
yes the board installed inside the control of the generator as a cpu date 1985 and the part number is g292806g1007022499 maybe this will help more. on pin number #3 #4 of this board is it used to start the generator remotly or not , is this the two port wher the signal from the trasfer switch come or not. i have some hold manual and they don't match with the board installed on the control.

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Troubleshoot like this:
1 - With the generator control in Auto, jumper from terminal 3 to 4 on the control board. Generator should start without transfer switch doing anything. If it won't you have a bad controller board.

2 - If the Generator started, remove the jumper - controller is OK. Next go to the 1st transfer switch and find the remote start terminals. These will be the same wires that were connected to controller terminals 3 and 4 at the generator. Use your jumper wire to connect them and see if the generator starts, if not there is something wrong between the switch and the generator, probably a broken wire.

3 - Don't forget to check the other switch, the remote start terminals of the switches connect in parallel across controller terminals 3 and 4 so that either switch can start the generator.

4 - Each switch should have some sort of a test button/switch, power down as much of the building as you can, then run the test function of each switch one at a time. Don't stand directly in front of the switch while you do this.


Posted on Nov 29, 2008

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