dhsvcs

Have an older generator 18-20 KW, model G0055060, 2007-2008 model with pre-nexus controller, serial 4995710.
Had customer purchase a new transfer switch with load shedding, Generac RXSC200A3, serial number 3002452955
and a new charger, 0G8023, both from Ziller. Customer has gas water heater, gas dryer and gas stove. I am an electrician with 30+
years experience and have been doing work at this residence for over 10 years, so I at least have a clue...

Client replaced his even older generator with this one. Load calc is under 70 amps (electric heat not used I live in Miami)., even though he has a 200 amp service with a 200 amp main breaker service disconnect. The original wiring to generator in 1" pvc only had 4 control wires, so I added 2 more.

There was no battery charger in original generator, he had it fed with an aux charger.
New transfer switch has a T1 wire going to generator, although there is no place to land it at the generator.

Am I better off
1. feeding the new battery charger from T1 in transfer switch and installing in new transfer switch enclosure and feeding  
    terminal 15B in generator and checking for charging voltage in run condition, ( I do have 0 grnd/common connected )

2. should I install the new charger in the generator assembly itself feeding 120 from T1 and neutral bus and placing 3/8        
    terminals on new group 26 battery to 12 v charger output , If so, should I disconnect/spare any existing connections
    ( see 3 )

3.  follow no 2 above and find / remove connections to original charger ( if there is one ) that is fed by generator windings
     ( if there working) that was used to maintain low voltage control power / battery charge while in running mode.
 
4. something different

Generator does work, auto starts on loss of utility power ( on newly charged battery ), with a load of 42 amps A phase,
32 amps B phase. I added time delay on energize relays to the 2 air conditioners, set at different times and added the best
hard starts that I could find, the adjustable Amrad TES5 Easy-start 5. Makes a HUGE difference in start up surge current.

Appreciate your advice / input on this endeavor
Thanking you in advance, dhsvcs






 






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78buckshot
I believe that generator has a field installed battery charger, it's a black plastic brick, two wires in at either 120 or 240 volts and two wires out at 14.0 volts dc. It could be mounted in the transfer switch and run the dc on two of the control conductors or it could be mounted in the generator and energized from the T1 side of the transfer switch. Look for it under the generator control panel, it may be stuck to a side panel with Velcro.
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Warren
If it is other than a matter of finding/replacing the plastic brick referenced by 78buckshot, see my post of 8 days ago in response to in2hockey's post of 9 days ago.  I think my solution will solve your problem, too.  The other posts on that thread may also be of interest to you.
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dhsvcs
Generator does not have a T1 terminal, but does have a 15B 12 v dc terminal. I will check to see if it is a feed or a load. There is no existing plastic battery charger.
My main concern is whether there is something I may damage if I connect a new charger directly to the battery if the generator starts due to a utility power loss.
I have attached what I found as being possible wiring schematics from Generac downloads along with a drawing showing the actual terminals in my first post.
Thanx, Tom
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UPS
dhsvcs wrote:
Generator does not have a T1 terminal, but does have a 15B 12 v dc terminal. I will check to see if it is a feed or a load. There is no existing plastic battery charger.
My main concern is whether there is something I may damage if I connect a new charger directly to the battery if the generator starts due to a utility power loss.
I have attached what I found as being possible wiring schematics from Generac downloads along with a drawing showing the actual terminals in my first post.
Thanx, Tom


The battery needs to be kept charged while the generator is running since it supplies power to the control circuitry.  Otherwise the voltage would eventually drop far enough that the generator would stop.
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78buckshot
dhsvcs, the serial number does not come up on Generac's records but given the model number that unit should have the black plastic field installed charger. Most I have seen are mounted in the generator but will work as well in the transfer switch. You have ordered a new one, it can run on 120vac or 240vac, the output can be wired directly to the battery if you like, I would just make sure another charger is not already wired in, if the machine has been working correctly all these years it has to have a charger somewhere.
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dhsvcs

Did not see any battery charger....client picked up this older generator to replace an even older one,,,
This generator was not transferring power on shut down, had to be done manually. I did not
originally install either generator.
This generator 0055060 was being charged by accessory battery charger clamped to batty terminals, fed by extension cord.
Older generator was removed by who ever installed this one. Only had 4 control wires between generator and original transfer switch.
Wire distance between generator and transfer switch approx 115 ft.
Old transfer switch was 16 circuits. New one is 200 amp rated Generac RXSC200A3 with load shedding to feed whole house with original 30/40 ckt panel.
I added 2 additt #12 control wires and changed 3/4" flex to 1" to allow full size conductors from " make up box" to generator.
I would prefer to place new 0G8023 charger in transfer switch fed by T1 and neutral in new transfer switch to keep charger out of
the heat and vibration of generator housing. Just wanted to be sure there was no existing wiring I should disconnect with 0055060
generator, and correct placement of charger output wires on new terminal block in new transfer switch. I can then spare the extra T1 wiire
going to generator as it has no place to land in generator and T1 from trans switch terminal block will now feed charger.

Confusing part is original 1st generator only had 4 control wires, and with 2 of them going to N1 and N2, that only left 2 remaining.
As i stated, I did not originally install either generator, Just trying to make it work now. Will eventually repull main run to upgrade 2 #4 hots, 1 #6 neut, 1 #8 grnd
with an 80 amp main at the generator. That way all the wires will fit in existing conduit. ( I did wire fill calc )
Thanx, dhsvcs

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dhsvcs
The 3 main feeds now are all #6 with a #8 ground..2 H, 1 N, 1 Grnd.
Since I have not measured over 40 amps continuous or 55 surge amps with new hard starts and time delays, I think this should be
more than adequate..
Thanx, DHSVCS
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78buckshot
Ok, now I understand your set-up, I thought the 2008 unit had been working ok and you were replacing just the xfer switch. Go ahead and mount the new battery charger in the switch and connect a wire to the zero terminal on the switch and generator, the -12 volt will go to zero and the +12 volt will go to 194/15B. The input side of the charger will be T1 and common ac.
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