When utility power goes out, generator won't start on auto setting, but will start on manual. Then if it is shut off and switched to auto it will start. Sounds like the starter relay is sticking. Will contact cleaner help this?

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.

• The completely automatic transfer switch monitors incoming voltage from the utility line, around the clock.
• When utility power is interrupted, the automatic transfer switch immediately senses the problem and signals the generator to start.
• Once the generator is running at proper speed, the automatic transfer switch safely shuts off the utility line and simultaneously opens the generator power line from the generator.
• Within seconds, your generator system begins supplying electricity to the critical emergency circuits of your home or business. The transfer switch continues to monitor the utility line conditions.
• When the automatic transfer switch senses the utility line voltage has returned at a steady state, it re-transfers the electrical load back to the utility line and resumes monitoring for subsequent utility loss. The generator will continue to run for an engine cool-down period of several minutes while the entire system stands ready for the next power outage.

https://www.dieselgeneratortech.com/generator-sets/Information-of-Starting-Battery-in-Diesel-Generator-Set.html

do you think that you might have installed the power source for the gas shut off solinoid incorrectly ???

is the auto transfer switch rated to handle a 60 kva gen set cus you can use a larger auto switch on a smaller gen set but it don't work the other way cus you'll be burning up wires and contactors and have a fire !

The transfer switch is responsible for starting / stopping the generator. Check your auto - start circuit. It is 2 wires that go between the genset and ATS. They are generally normally open. When the genset is to shut down this circuit needs to change state.

Are you overiding the auto switch by putting it in remote position then closing the start contacts with 173 and 184 wires ?

If you are using a Manual transfer switch, then you should manually operate the system. Why don't you use the switch it came with? Why would you use a 200a manual transfer switch on a 17kw generator? The idea is to move your critical circuits into the transfer switch panel. Then it would operate in auto.

http://www.homegeneratorsystems.com/service_support/manuals/index.cfm?rd=1

This link will take you to their site where you can download their manual.

Setting Exercise Timer
The Home Standby Generator is equipped with an exercise
timer that will start and exercise the system once every
seven days. During this exercise period, the unit runs for
approximately 20 minutes and then shuts down. Electrical
load transfer DOES NOT occur during the exercise cycle
(unless an utility power outage occurs).
A switch on the control panel is labeled “Set Exercise”
(depicted on page 10).The specific day and the specific time
of day this switch is pressed is programmed into the
control board memory.This date and time is then used to
automatically initiate the system exercise cycle.
To perform the Set Exercise procedure:
1. Choose the day and time you want your Home
Standby Generator to exercise.
2. On that day and time, set the AUTO/OFF/MANUAL
switch to OFF.
3. Press and hold down the “Set Exercise” switch for two
seconds.
4. Set the AUTO/OFF/MANUAL switch to AUTO.“Set
Exercise” is complete.
For example, if you press the “Set Exercise” switch on
Sunday morning at 10:00 AM, the unit will run an exercise
cycle the following Sunday at 10:00 AM (+/- 1/2 hour).
NOTE: “Set Exercise” will only work if the unit is in the
Automatic mode and this exact procedure is followed.The
exerciser does not need to be re-set if the 15 Amp fuse is
removed or changed.The exerciser will need to be re-set if
the 12 Volt DC battery is disconnected.
If you want to change the day and time the unit exercises,
simply perform the “Set Exercise” procedure at the exact
weekday and time you want it to take place.
• To prevent possible injury that might be caused by such sudden
starts, always set the AUTO/OFF/MANUAL switch to OFF.
• Remove the 15 Amp fuse before working on or around the
generator or transfer switch.

DO U HAV POWER FROM GEN ?

I install and work on these everyday. If you hooked up the transfer switch you probable have a control wire wrong. check the utility power sense wire. That lets it no when to start in auto. it could be a relay or fuses. or a control board.