Bulletin Number: TB084 Type of Bulletin: Informational Products Affected: Manual TracStars: 250/28, 412/618, 500 series II and III. Rolling 412/618 Date of Notification: October 22, 2012 Reason for Bulletin To provide our customers a detailed troubleshooting guide for 120V & 240V GFCIs installed on the machines specified in this technical bulletin. Action Required 1. ATTENTION! THIS TROUBLESHOOTING MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN. 2. Ensure that the Technical Bulletin TB078 Alternate GFCI Test Procedure has been properly followed. 3. Use the included drawings as a reference for their noted machines. GFCI and generator assembly for Manual TracStar 250/28, 412/618, and Rolling 412/618 Technical Bulletin: TB084 1
4. If your machine is a Manual TracStar 250/28, 412/618 or Rolling 412/618 continue to step 1. If it is a Manual TracStar 500 series II or III, proceed to step 5. i. Open generator cover and visually inspect all terminals and connections, paying close attention to the fuse holders. Look for any discoloration or signs of excessive heat, which indicates a poor connection or an overloaded circuit. If evidence of excessive heat exists, the circuit must be repaired to ensure a good connection and a sufficient current path. ii. If there are signs of excessive heat at the fuse holder terminals a new fuse holder kit (AT1217901) is available and should be installed. Figure 1 iii. Start machine and bring generator up to full operating speed. Measure generator voltage output to ensure that the values bellow are observed: iv. Terminals 1 to 4 should measure between 228V and 252V. v. Terminals 1 to 2, 2 to 4 and 3 to 4 should measure between 114V and 126V. vi. If any of these measurements is not correct, generator may be faulty. Term 3 Term 1 Term 2 Term 4 Figure 2 Technical Bulletin: TB084 2
5. If your machine is a Manual TracStar 500 series II or III, proceed as follows: i. TracStar 500 series II and III have a voltmeter installed on top of the generator so there is no need to open the generator box to measure the output voltage. ii. If the voltmeter indicates between 228V and 252V, proceed to step 6. iii. If not, check if circuit breaker (CB11) installed beside the generator box is tripped. iv. If CB11 is not tripped, then either voltmeter or generator is faulty. Figure 3 GFCI and generator assembly for Manual TracStar 500 series II GFCI and generator assembly for Manual TracStar 500 series III Technical Bulletin: TB084 3
6. For all machines covered by this troubleshooting: i. Make sure the wires passing through the loop in the GFCI sensing module are wrapped tightly against each other and tie-wrapped. ii. If not, correct it and try to reset GFCI per instructions on TB078. Figure 4 7. If all voltages at the generator terminals are correct and the electrical connections are good, follow the GFCI troubleshooting flow chart below. 8. Make sure the Technical Bulletin TB078 Alternate GFCI Test Procedure was properly followed. Technical Bulletin: TB084 4
GFCI will not reset IMPORTANT! GFCI will not reset if there is an electrical fault in either the machine or the heater. In order to isolate the problem, make sure the heater is not connected to machine s power outlet Start the machine and open the GFCI box. Check voltage between red and black wires on shunt trip breaker. See Fig.5 Check fuses Check wires between generator and GFCI Is voltage between 228V and 252V? Make sure the GFCI breaker lever is fully in the OFF position. Press the reset button on the sensor module. Turn off the machine. By using pliers, disconnect yellow wire from shunt breaker. See Fig.6 Start the machine, press the reset button on the sensor module and check voltage between black wire and yellow wire disconnected from shunt trip breaker. See Fig.7 Is the red light on the GFCI sensing module still blinking? Stop the machine and start again to power cycle GFCI. Try only once. Turn machine OFF. Connect yellow wire back to its terminal on shunt breaker Start machine. Is voltage between 228V and 252V? Replace GFCI sensing module If after power cycling If the red light will not reset after power cycling, replace GFCI sensing module. Press the ON side of the circuit breaker lever firmly to the ON position. Is the circuit breaker properly latched in the ON position? Replace shunt trip breaker Then, there must be nothing wrong. PERFORM GFCI TEST TO CERTIFY THE DEVICE IS WORKING PROPERLY 1- Press TEST button, GREEN LED should turn off, RED LED should start blinking, circuit breaker should trip to OFF position 2- Press RESET button, RED LED should turn OFF, GREE LED should turn ON 3- MANUALLY RESET circuit breaker to ON position PLUG THE HEATER TO MACHINE S POWER OUTLET IF GFCI TRIPS, HEATER IS FAULTY. Technical Bulletin: TB084 5
Yellow wire terminal is the top one RED BLACK Figure 5 Figure 6 Figure 7 Technical Bulletin: TB084 6