Blink
Working on an older 1.5L model 4722. The generator starts immediately when placed in auto (does same when placed in manual- as it should). Utility voltage is present at N1 and N2 inside the generator and to the step down transformer. The transformer is sending the proper 18VAC to the board through the switches. It is not acting like it's sensing a loss in power, because there is no startup delay...it starts immediately. I checked the auto/off/manual switch itself and it is wired properly and operating correctly. I assumed the board was bad, but after replacing with a brand new one, same issue. I will say out of a dozen times starting, it didn't once... at which time I attempted to set the exercise and it started, but never turned off. I'm at a loss...any help much appreciated.
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MacL
If after starting immediately, if you turn it to "off" then back to "auto" will it start immediately again?
State your problem, not your diagnosis.
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Peddler
Check the set exerciser switch, some are normally open and others are normally closed depending on the model. These fail more often then I think they should. Once you determine which yours should be you can pull a wire off or jumper to check the switch. Good Luck
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78buckshot
Check every ground and common on the machine, ac and dc.
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CaptainRay
I'm having the same or similar problem. I have a core power 7kw genset that was wired to a Eaton ATS. Recently (Hurricane Florence) had a power outage and the genset did not start. 1st problem, old battery with shorted cell. Jump started with car batters and gen started fine. No power to the house. Opened the ATS and found a snake, crawled behind the circuit board, fried extra crispy, and blew our the board, along with one of the transfer solenoids. Was able to transfer it manually and power restored to house. Afterwards, bought a replacement, this time a Generac 100A ATS. wired it according to installation manual. So far so good, but due to blown fuses on N1, N2 and T, I had to replace them. ok, so now I have utility voltage present and N1, N2 and T. but the generator starts as though is sees no utility. I measured the voltage both at the ATS and at the Gen panel, and read 220 +. Every time I switch to AUTO the gen starts. So I tried following the setup procedure for the exercise. 1)removed the 7.5 A fuse, waited 10+ seconds, 2) reinstalled the fuse, [At this point all RED LED's were blinking.] I switched to AUTO and the led's went out, The System Ready was a steady Green. The gen started. 3)I held the Set Exercise for 5+ minutes. The gen ran for about 11 minutes, shut down, BUT started back up immediately.

Any advice?

Ray
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78buckshot
The last one I ran across with this issue had a bad ground, check and clean them all.
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CaptainRay
Thanks 78Buckshot, I did check, tighten or reset some of the grounds, ran resistance checks, etc. and gave it another try. So far, so good, it work according to the setup instructions this time, meaning that when I replaced the fuse the red lights continued to blink even after I moved the switch to AUTO. Pressing Set Exercise started the genset and after 12 minutes +/- it shut down and is still off. Before when I switched to auto it started immediately.

I appreciate the guidance!

Ray
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CaptainRay
Just when I thought it was fixed,,, same problem again. What's happening is that when I go to set up the exercise sequence in AUTO mode, it doesn't follow the procedure in the manual:

1) remove the 7.5A fuse
2) wait 10 sec
3) replace the 7.5A fuse - note that all the red lights begin to blink
4) move the Auto/Off?Manual switch to Auto
5) press the Set Exercise button
6) the genset starts, the red lights go out, and after 12 minutes it will shut down

What happens is that as soon as I move the switch to AUTO, the red lights go out, the genset starts, runs for 12 minutes, shuts down, BUT later (minutes to hours later) it restarts as if the grid sense drops.

I've checked and rechecked all the wiring, even checking the grid voltage (240v) at the connector to the control panel (yellow wires from N1 an N2) an get a good reading.

I'm now wondering if the Control Panel (0J0064) is the problem?

Any advice is appreciated before I go but a new Control Panel.

Ray
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Cobranut
Check to see if the exercise button is sticking or intermittent.
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CaptainRay
So I'm trying to figure out how to check the Set Exercise switch. I'm attaching a photo of the Controller circuit board and the top pad. It looks like the top pad is sealed to the frame, and I can "feel" the switch (membrane switch) depress and release though I don't know if it is making contact. The ribbon cable attached to the circuit board via a ribbon cable connector (in white) also shown in the photo. My question what is the pin-out configuration eg. the switch to the which of the 10 contacts. 7 of the contacts seem readily available to measure on the piggybacked circuit board.
Is there a better way to test the switch?

Ray


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Cobranut
Does the button "click" when you press it, or does it feel more like a plastic membrane?
The click style, has a small domed metal disk that makes contact when pressed, otherwise, it's just a printed circuit on a flexible plastic sheet.

Either way, if you cannot see the traces, it will be very difficult to test the switch for proper function.
These are often wired in a grid pattern, and each switch connects two or more traces to common, or to each other, and the processor determines which button is depressed.

I had a similar keypad on my microwave oven go bad a while back, likely due to moisture intrusion from the cooktop below. I found a new keypad on Amazon, peeled off the old one and replaced it pretty cheap.
No idea if the keypad for the genset is available though.
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CaptainRay
Yes, it's a "soft" press, certain and pretty sure it's a membrane. So I'm guessing my problem is connected to it either not sensing there is 240VAC (which is present), or keeps thinking/trying to set the Exercise interval. One more thing noticed. While they say to leave the 7.5A fuse out for 10 sec. leaving it out longer seems to be better in that with 10 sec as soon as you put the fuse back in the red lights blink, but stop as soon as the switch is switched to AUTO. Leaving it out longer (don't know exactly how much longer) when reinserted, the red lights blink, but do NOT go out when the switch is set to AUTO, like it says in the procedure..Now I don't know if it started when I pressed the Set Exercise button, or by itself (the problem) which I need to further investigate.

Thanks for the help!!

Ray
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CaptainRay
Another finding is when the 7.5A fuse in inserted, the Green "System Ready LED" is illuminated indicating the Utility Voltage is sensed by the controller, which is true in my case. So that leads me back to the "Set Exercise function" is malfunctioning or another malfunction in the controller. I hate to spend the $260 to find out, but will probably have to do that unless there is another test I can perform.

Ray
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Cobranut
This may or may not work, but try putting a piece of strong tape on the exercise button, and pull it out slightly, then put it in auto and see if it behaves normally.
If that works, it'll tell you the membrane switch is sticking. If it still malfunctions, you haven't really proved anything, but you haven't lost anything but a few minutes work.
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CaptainRay
Here's the latest, I didn't have anything to lose so I pulled up one corner of the control panel pad to expose the Set Exercise switch (photo 1), next I inserted the 7.5A fuse,(all lights blinking) put the mode into AUTO (all lights still blinking) then pressed the membrane Set switch (the gen started), and then I pulled back the pad and put a folded piece of electrical tape (photo 2) over the contact pattern. The gen ran for 12 minutes then shut down. I waited. About an hour and 10 minutes later it started again. So I'm ruling out a bad switch, and I think my next step is to replace the entire control assemble - ouch)


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Cobranut
Well, it was worth a try anyway.
Sorry that wasn't the problem.
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