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Re: My generac 15kw generator went off on overcrank now...
It could be either your start capacitor or the contactor-relay. Or you could try cleaning the contacts of the relay with an emery board to see if there is a change.
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Turns out it was the Manual-off-Auto switch that was bad. My DVM showed a voltage drop across the switch. The controller wasn't getting enough power.
One good thing about it was it forced me to really study the schematics to understand how everything worked. I'm now in the process of designing my own esp32 based controller, with wifi connectivity, to replace the stock control board.
At 240v, a 15KW generator will produce appx 62A or 31A per 120V leg. Therefore allowing for some overload, a conductor sized for 35A per leg would be adequate, but you should verify local code requirements.
Overcrank means that it tried to start and couldn't. It will go through 5 crank cycles and then stop with this alarm. Switch to off, hit enter to clear fault and then try to start in manual. Check to make sure you have fuel and pressure is 11 to 14 in WC.
You can check for tanks being turned off and of course if there is fuel in the tanks. If further troublshooting is necessary you should likely ask for assistance.
I have a generator that did the same thing. It would start and then stop within a few seconds. The more expensive generators have an oil level safety switch to prevent the engine from burning up. There is usually a wire connecting to the switch on the outside of the engine near the oil fill hole. Remove this wire and try to start the generator. If it runs without a problem then it is the switch. You need to remove the switch and take it apart carefully and clean it. There is a small float inside the assembly. When the oil runs low the float allows the switch to short to ground which kills the spark to the spark plug. Hope that helps.
The 'overcrank' error simply means it tried to start but never actually started. It cranked for an extended period. Check the fuel and starting issues you would normally check to start the engine.
Typically caused by the fuel line (LP or Natural Gas) having a lot of air in it. Was your generator just installed, or was there any work done to the gas line of the building / generator? Consult local gas contractor / propane dealer / gas company for assistance in purging the fuel line.
A low battery can also cause this as well as the generator is not able to come up to starting speed quick enough. Try placing a stand alone battery charger on the generator and charge the battery. Also check the air filter as well.
OverCrank condition occurs when generator tries to start itself, or be manually started, and the starter spends too much time turning.
This can also indicate failure of the control board. This will need the expertise of generac technician. Call 1-888-GENERAC (1-888-436-3722)
M-F 7am-6pm Central
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