Generac 48kw generator: DOA, Generac unable to repair/not helpful

[CalG]

Most standby generators must have some kind of continuous charging method. You didn't say if it had one and simply wasn't doing it's job or the machine was relying on the excercise time for recharge.

Sorry to be unclear.

This unit has a built in charging system. I just don't know how it is supposed to work. But I do know that it doesn't work. ;-)

I also thought the exercise time would self charge the battery, but it fails to do so.

I was hoping the Generac knowledge base would aid in my learning. I have the schematics, but have no instructions on how to diagnose the system,

 

[CalG]

I dont know how old your generator is, but since you state a transformer, i assume its around 2008 era generator. i would need a serial number to cross reference it truly.
the older units have a transformer within the generator control panel area, and a relay. the relay swaps between utility supplying power to transformer and the generator windings while running powering the transformer. theres also a battery charge module. View attachment 670640

transformer should show 16 volts aprox at both sets of upper terminals. theres 2 set of 16 volt AC output on the transformer. since your getting voltage at transformer, i bet your issue is with the battery charger itself. ive had to replace quite a few of these over the years. you need the serial number of the generator to verify proper part.

It's very possible that the charger is bad. You can test for AC voltage on the input wires at the top of the charger (the smaller 2 wire connector) and should read around 19 VAC. The output is measured in DC voltage and will be the larger 3 wire connector that only has two wires (no wire in the middle spot). Output should be around 13.5 VDC on those 2 wires. If you have AC input and no DC output, the charger is bad. but, before you do this test you should start generator a few times to draw down on the battery reserve. if the battery is fully charged, i sometimes see no voltage at these terminals. best to be sure battery isnt fully charges. the battery charge module is a 2.5 amp trickle charger.

Great information
That picture is exactly what I saw with the panel open and poking around with the meter probes. I'll study it more!
I can get the numbers off the unit next time I'm over to the gals place. She frets over the electric power, stuff in the freezer etc.
It's a big place she has, Prior to this flu thing, she was running a B&B, But with her cancer and this disruption, now she only lets out to a single renter.

The battery was down to 12.2 V, After I installed it two weeks ago fully charged. So two auto run cycles (Wed at 1:30) it should have been asking for a charge. I did a manual start, and it kicked roared to life without cranking toooooo long. So, not dead yet.

Adding the battery maintainer is gonna complicate things I can tell.

Tusen tack!

Many thanks!

 

[ponytug]

It has been awhile, and I wanted to give you all an update when progress had been made.

Thanks for all of the helpful tips and advice. You all have managed to get my neighbor on to a working backup power solution. Many thanks!

So...what was done?

The primary fix was Generac coming out and they installed a new ECU version 280 and controller version 1.07. The surging problem under (partial) load issue was fixed.

We have had a couple of outages since the updates, and the generator has worked flawlessly, even texting the owner to let her know that it was online and producing power.

There are a few to dos: finish the re-piping to the recommended size, test under full load, and upgrade the propane tank from 500 to 2000 gallons.

Thanks again. It is always great to have such a supportive community here on TBN.

All the best,

Peter

 

[radios1]

It has been awhile, and I wanted to give you all an update when progress had been made.

Thanks for all of the helpful tips and advice. You all have managed to get my neighbor on to a working backup power solution. Many thanks!

So...what was done?

The primary fix was Generac coming out and they installed a new ECU version 280 and controller version 1.07. The surging problem under (partial) load issue was fixed.

We have had a couple of outages since the updates, and the generator has worked flawlessly, even texting the owner to let her know that it was online and producing power.

There are a few to dos: finish the re-piping to the recommended size, test under full load, and upgrade the propane tank from 500 to 2000 gallons.

Thanks again. It is always great to have such a supportive community here on TBN.

All the best,

Peter

WOW, Generac must have searched hard for a qualified tech, and finally found one!..

 

[grsthegreat]

glad you got it worked out. there is definitely a lot less liquid cooled techs out there....cause theres less liquid cooled units running. generac used to let non liquid cooled tech access files and order parts. that changed several years ago. now you have to spend big bucks and order lots of stock parts to service liquid cooled units. i did not want to sink 10 grand into classes and parts to take care of a few generators. in the lasty 10 years ive installed maybe 6 liquid cooled units. ive installed 100's and 100's of air cooled units. i dont mine keeping a stocked work truck for air cooled units. makes a good semi retired spending income.

 

[ultrarunner]

It has been awhile, and I wanted to give you all an update when progress had been made.

Thanks for all of the helpful tips and advice. You all have managed to get my neighbor on to a working backup power solution. Many thanks!

So...what was done?

The primary fix was Generac coming out and they installed a new ECU version 280 and controller version 1.07. The surging problem under (partial) load issue was fixed.

We have had a couple of outages since the updates, and the generator has worked flawlessly, even texting the owner to let her know that it was online and producing power.

There are a few to dos: finish the re-piping to the recommended size, test under full load, and upgrade the propane tank from 500 to 2000 gallons.

Thanks again. It is always great to have such a supportive community here on TBN.

All the best,

Peter

Great to here progress and positive too!