Alpha Technologies AlphaGen 3.5_5.0kW Kohler COM5 - Manual (Page 60)

TP-6482 8/06 60 Section 6 Controller Operation and Test
6.5.4 Ignition Circuits
Move the generator set master switch to the START
position. If the engine cranks but does not start, check
for voltage from lead 70 to ground at terminal B on the
ignition module and at the positive terminal of the
ignition coil. If no voltage is present during cranking,
replace the controller circuit board. If the ignition system
is receiving 12 VDC, check the spark plug and test the
other ignition system components.
6.6 Voltage Programming Shunt
Control board GM22402 uses a programming shunt for
voltage selection. See Figure 6-6 for the programming
shunt location. Set programming shunts JP1A through
JP1D to select the generator set kW and voltage as
shown in Figure 6-6 and Figure 6-7.
GM22402
3.5 5.0 7.5
R51 R52
D26
D27 D28
R53
SW1
D29 R43
MC1413BP
D7
D9 D8
D5
D6 17
P1 1 3
K110 12
D20
F1
D21
TYPE
12.5A 250V
FST1
K2 K3
P2
4
V1
20 R48
C24 R32
C19D23
D24 4
D22R45 R46 R47
Z1 R44
6
R3
R13
U1
R14 R15
R17 R16
D4 D3
C1
R11 R12
R10
R9
R8
R100
R7
R6 R5
R4
P4R2
+
D17
C4
C5
D16 D15
+
C3
D14 D13
+
+ U4
D18
C9
D19
74HC14 U574HC14
U3
LED1
D12 D11
Q1
FAIL GEN
R
C12 C8
87C196KB16
C18
U7
L293D
U8
R25
R28 R26 R27
R23 R24
R22
C16
C17
R30
R31
C23
L297/1
R42
LM2902N
C29
+
U9
R39 R40 R41
C28
JP1G 8
R21 R20
JP1H
R29
9
JP1B
JP1D JP1E JP1F
JP1C
1 JP1A JP1 16 U6
R33
R37
R38
R36 R35 R34
C21
Q2 R50 Q3Q4 D25
R49
D1
U2
R1 D2
C2
R18
C7
C6 R19 D10
C11
1
+ C10
Y1
C14
+
C15
C13
VR1
C20 +
R63
C37
R54
R55
1
R64
R65 P3
3 C36
+
LM2903N
C35
R62
D33
Z3 Z2
R61
D32 D31
D30
R60 C27 C34
C33
R56
R59
R58 R57 C26
U10
C25
+
C32 +
U11MAX680
C31
C30
BARCODE
+
JP1G
8 JP1H 9
JP1B
JP1D
JP1E
JP1F
JP1C
1 JP1A
JP1
16
Figure 6-6 Programming Shunt Location
Power Selection Jumpers
kW rating JP1A JP1B
3.5 OUT OUT
5.0 OUT IN
7.5 IN OUT
Voltage Selection Jumpers
Voltage Rating, VDC JP1C JP1D
24 OUT OUT
36 OUT IN
48 IN OUT
96 IN IN
Note: Jumpers JP1E and JP1F have no function.
Jumpers JP1G and JP1H are for factory use only.
Figure 6-7 Jumper Configurations
6.7 Control Board Replacement
NOTICE
Electrostatic discharge damage. Electrostatic discharge
(ESD)
damages electronic circuit boards. Prevent
electrostatic discharge damage by wearing an approved
grounding wrist strap when handling electronic circuit boards
or integrated circuits. An approved grounding wrist strap
provides a high resistance (about 1 megohm), not a direct
short, to ground.
If the controller tests in Section 6 or the troubleshooting
procedures in Section 4 indicate that the control board
needs to be replaced, follow these guidelines:
D Keep the new board in its protective wrapping until
installation.
D Wear a grounding strap while handling the circuit
board to prevent damage to the circuit board
components.
D Set the programming shunts for kW and voltage. See
Section 6.6.
D Check that all plug connections are secure.
D Calibrate the voltage after installing the board.
The new circuit board must be calibrated after
installation. Use the following procedure to calibrate the
board.
Installation Procedure
1. Place the generator set master switch in the OFF
position.
2. Disconnect the power to the battery charger, if
equipped.
3. Disconnect the generator set engine starting
battery(ies), negative (--) lead first.
4. Open the enclosure to access the control board.
5. Disconnect all connectors to the control board, and
remove the board from the enclosure.
6. Before installing replacement control board
GM22402, install the jumper(s) (294634) as shown
in Figure 6-7 to obtain the rated power (kW) and
voltage for the generator set. Zero (0) to three
jumpers are required, depending on the selected
voltage and power ratings. See Figure 6-6 for the
jumper locations.
Note: Verify that connector P2 is not connected to
the board during jumper installation or
removal.