78buckshot
Gentlemen: I'm stumped as is generac tech support on an exercise issue. Model 0049160, 11kw nat. gas. Homeowner replaced battery and re-set exercise, unit started and ran 12 minutes, shut off by itself then flashed all LED's and re-started in exercise, ran 12 minutes shut down, then re-started again in exercise. Apparently it would continue this but he shut it off and called us. I checked all fuses, N1, N2, 23, 194 voltage and condition of connections, unit is very clean with no oxidation on terminals. I checked the molex connectors on the control board-all looks good. I then plugged in a jumper in place of the exercise switch and tested the unit, same action as before. Called tech support and we agree'd it's gotta' be the board. New board acts the same way. First time I have seen this problem, anyone run across this before?
Quote
Peddler
I have had that problem with that model several times. I have replaced boards, wiring harness, exercise switch and countless hours of time trouble shooting. Some of them do and some don't. The one I had the most problem with stopped doing it after a while but in that case I had a good customer who agreed that we had done everything imaginable and would just go out and shut it off when it did repeat exercise. In his case he said it would stop after 3 or 4 times. Good Luck, Peddler
Quote
78buckshot
Thanks peddler, I was able to bring up the control schematic on GenService, the Auto-off-manual switch looks like it is wired in reverse of the other air cooled models, but I think I found the culprit, if I remember right I think the exercise switch is closed in the rest position and opens when depressed, I bet it fell apart inside and is actually now making when released.
Quote
78buckshot
Update for anyone interested. I returned to this unit today with new exercise switch, new Auto-Off-manual switch, new board already in unit. So with all new parts listed above still has the same problem. Third call to tech support, they say look for RFI or anything that could wack out the control with flyback voltage or surges, also recommended checking to make sure it has resistor champion spark plugs. While checking the plugs I found the negative battery terminal cracked, then I found the culprit, a broken factory negative/ground wire that is supposed to be under the battery clamp bolt. Unit is now back in operation with all of the original parts other than a new battery terminal. Happy homeowner and I can stop fretting about this one.
Quote
MEC
Thanks for the update.
All too often there's people that come on here that have issues as you know and we never hear back from them.
Being a fellow tech you know that all too well.

Grounding issues can be recluse. For sure.
Quote
78buckshot
The backbone of a great technical forum is made from continuity and detail, I salute all who contribute their time and expertise.
Quote