Your last generator Maintenance Run

[Wakey]

I have a Generac 22kw with about 35 hours. About a month ago I noticed the light on the side was red. Turns out the battery failed, spectacularly! It burst on top and spewed a bit of its contents. NAPA gave me a partial warranty for their battery.

All appeared well until we lost power yesterday. As per usual the unit came on but there was no power inside.

It showed charger missing AC. All the fuses in the transfer switch were OK but I noticed none of the LED light were lit. I played around with it for a bit and then restarted the unit and within 2 minutes it gave me error code 1400. That made little sense because the unit had been off for at least 15 minutes.

I’d like to see if I can sort this out myself. I’m wondering if the battery was the cause or the effect of the issue at hand.

 

[daugen]

Wakey thankfully we have a resident expert here, GRS, but sounds like somehow you overcharged the battery. Which of course should have been regulated and not happened.
Good luck.

 

[3930dave]

I have a Generac 22kw with about 35 hours. About a month ago I noticed the light on the side was red. Turns out the battery failed, spectacularly! It burst on top and spewed a bit of its contents. NAPA gave me a partial warranty for their battery.

All appeared well until we lost power yesterday. As per usual the unit came on but there was no power inside.

It showed charger missing AC. All the fuses in the transfer switch were OK but I noticed none of the LED light were lit. I played around with it for a bit and then restarted the unit and within 2 minutes it gave me error code 1400. That made little sense because the unit had been off for at least 15 minutes.

I壇 like to see if I can sort this out myself. I知 wondering if the battery was the cause or the effect of the issue at hand.

22kw and low hours on yours, so likely too new..... I recall a discussion back aways about problem chargers on Generacs. GRS will know the vintage of those.....

If you do go poking around before/after g shows up, wear at least a good pair of safety-glasses. I know of a telecomm guy who still has sight because he had his reg-spec glasses on when he opened a cabinet door, the exact second a NiCd battery decided to blow apart.

Rgds, D.

 

[grsthegreat]

I have a Generac 22kw with about 35 hours. About a month ago I noticed the light on the side was red. Turns out the battery failed, spectacularly! It burst on top and spewed a bit of its contents. NAPA gave me a partial warranty for their battery.

All appeared well until we lost power yesterday. As per usual the unit came on but there was no power inside.

It showed charger missing AC. All the fuses in the transfer switch were OK but I noticed none of the LED light were lit. I played around with it for a bit and then restarted the unit and within 2 minutes it gave me error code 1400. That made little sense because the unit had been off for at least 15 minutes.

I’d like to see if I can sort this out myself. I’m wondering if the battery was the cause or the effect of the issue at hand.

if you have a battery warmer, get rid of it. I have had a few of these overheat and boil a battery. Then the battery explodes. If you dont have a heater, than it could have been something as simple as normal electrolyte evaporation and it exploded from escaping gas from battery. Newer generators with the evolution controllers generally do not have any overcharging issues. Now the fact that you had the error saying charger missing AC, that occurs normally when the power fails, but the message should go away when generator is running AND producing power into house. If the double pole breaker on the generator is turned off than the generator wont send power to house, and that error code will appear. What did you do to get unit to send power to house whenit didnt do it by itself? Error code 1400 refers to overheating or air blockage to air intake. You may just need to reset your controller due to battery problem. Easy to do. First turn off the generator. Then Pull the T1 fuse within the transfer switch (if switch is only a few years old you can simply unplug the molux connector near the load shed module/fuse holder unit ). Then unhook the ground wire on battery. In 30 seconds, reassemble in reverse order. You will have to scroll thru the startup programming again, but usually only the time of day needs adjusting. Then after you make sure generator is in automatic and generator breaker is turned on, simulate a power outage and check unit.

 

[Wakey]

22kw and low hours on yours, so likely too new..... I recall a discussion back aways about problem chargers on Generacs. GRS will know the vintage of those.....

If you do go poking around before/after g shows up, wear at least a good pair of safety-glasses. I know of a telecomm guy who still has sight because he had his reg-spec glasses on when he opened a cabinet door, the exact second a NiCd battery decided to blow apart.

Rgds, D.

Thanks Dave, good idea with the eye protection.

Model G0070431
Serial 3002147654
Production was 2017 09/29

 

[Wakey]

if you have a battery warmer, get rid of it. I have had a few of these overheat and boil a battery. Then the battery explodes. If you dont have a heater, than it could have been something as simple as normal electrolyte evaporation and it exploded from escaping gas from battery. Newer generators with the evolution controllers generally do not have any overcharging issues. Now the fact that you had the error saying charger missing AC, that occurs normally when the power fails, but the message should go away when generator is running AND producing power into house. If the double pole breaker on the generator is turned off than the generator wont send power to house, and that error code will appear. What did you do to get unit to send power to house whenit didnt do it by itself? Error code 1400 refers to overheating or air blockage to air intake. You may just need to reset your controller due to battery problem. Easy to do. First turn off the generator. Then Pull the T1 fuse within the transfer switch (if switch is only a few years old you can simply unplug the molux connector near the load shed module/fuse holder unit ). Then unhook the ground wire on battery. In 30 seconds, reassemble in reverse order. You will have to scroll thru the startup programming again, but usually only the time of day needs adjusting. Then after you make sure generator is in automatic and generator breaker is turned on, simulate a power outage and check unit.

I did your procedure as you explained and no joy..

I flipped off the breaker on the transfer switch a 2nd time and the generator started and the power did not come on inside.

The 200 amp breaker is on, it feels normal when you flip it.

To answer your question about sending generator power to the house manually, I flip the breaker on the transfer switch.

Thanks

 

[grsthegreat]

The next step is yo get a trusty electric test meter and check if you have 240 at the transfer switch when the generator is running. You place your test leads on the two wires clostest to the front, lower end of the Transfer mechanism. There labeled E1 and E2 on the diagram. You dont need to turn off the house power, just start generator. Make sure the 100 amp breaker on the generator itself is turned on.

 

[grsthegreat]

The next step is yo get a trusty electric test meter and check if you have 240 at the transfer switch when the generator is running. You place your test leads on the two wires clostest to the front, lower end of the Transfer mechanism. There labeled E1 and E2 on the diagram. You dont need to turn off the house power, just start generator. Make sure the 100 amp breaker on the generator itself is turned on. View attachment 671091 also, can you post a photo of the inside of your transfer switch, under the cover, so i can check wiring

 

[3930dave]

Thanks for the critical 411 g.

I'll play safety nanny today - Wakey, if you have a pair of green-patch (construction) boots, put them on. Not likely to break toes dropping a meter w/o them, but any decent approved boot should be dielectric rated.

Rgds, D.

 

[Wakey]

also, can you post a photo of the inside of your transfer switch, under the cover, so i can check wiring

I took a photo earlier, just in case. I’ll check for voltage in the morning. Do the AC1-AC4 lights only come on in a diagnostic mode? They’re unlit.

Dave, we’re good. I’m a lifelong low voltage tech.