Error code 1505 after evolution controller replacement

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jfharrispe
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20 kw air cooled, natural gas fueled, Model 006250. unit was set to not exercise automatically and had been that way for a couple of months. when attempting to set on auto, Evolution LED was blank. Upon inspection found smoke residue near terminals 14, 15, 16 ,17 on J1 connector. and on Evolution controller at vicinity of those terminals. My assumption is a surge occurred on the utility sensing wiring, J! connector terminals 16, 17(N1,N2). Replaced(original) battery and Evolution controller. Unit attempted to start (cranked for about 3 seconds). two error messages: Error 1505 RPM sensor failure and something about battery. I read "Generac error code 1505 sense loss explained & how to fix". Reworked utility source connection at TB2. Electrician used stranded #12 which did not want to release from terminal board. Finally got N2 released and spliced in soild #14. Never could get N1 stranded wire to free up. Rechecked voltage and now have proper voltage on N1 and N2 where there was zero before. Rechecked J! terminals 14, 16,17. Now have 240 volts on 16, 17 and 12 volts on 14. Not certain what changed on 12 volt side; I have not found any bad connections.

Still have error code 1505 appear when trying manual start. cranks strong for 3 seconds. Since unit cranks strong, I have ruled out starting relay, solenoid and starter? I am suspecting the surge may have shorted an ignition module or both. Is there any way to verify? Are they both the same part. Is there any magic to replacing and getting correctly positioned? I have not looked for them yet; I assume I can access them without having to remove the other side and two ends of the housing?
Chris
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Many times a lightning strike shows these symptoms and almost always wipes out the ignition coils.

The new coil kit is here: https://shop.gentekpower.com/products/g ... generators

They get replaced in pairs, ALWAYS. Comes with directions once you get to them. It's a project though...
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jfharrispe
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I have ordered ignition coils

FYI
I have also installed tvss on utility sensing n1 & n2 on the load side of the fuses at the cutler hammer transfer switch
Chris
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I saw your order and it will go out today, should be there in 3 days. The surge suppressor is probably a good idea, T1 should also have protection since it's a 120V line to the controller for the charger. They may not protect against a lightning strike though if that's what happened. :sad:
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jfharrispe
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is there a path of least resistance to access flywheel. looks to me liketotal enclosure disassembly, gas and power disconnect, disconnect all control wires, and remove front engine cowl?
Chris
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You're pretty much right on with that :sad: It's not a pleasant repair, and some of the fasteners on the back side can be a real pain to access. It's basically done blind.
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jfharrispe
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replaced spark coils. yes it was a project. I am impressed with unit quality after disassembly and reassembly; that always reveals details you cannot otherwise determine. the only struggle was getting the engine cowl and intake manifold to cooperate. It is like both have to be installed simultaneously; I tried one first, then the other first; does not work; both have to be put in place loose, before bolts. unit started on first try. ran about two minutes, maybe more, then shut down with error 1902. controller is new; should have latest firmware already? what next?
Chris
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Well that is a different error all together, and leads me to believe that something didn't get reconnected is all. 1902 is for undervoltage and my guess is that the controller also said 'Warming Up' the entire time it was running before it shut down.

I would check to make sure that ALL of the little connectors made their way back together and into the control panel.

Sounds like you fixed the ignition coil issue and the fact that it runs is a great sign!
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jfharrispe
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your suggestion was right on. although I had already verified everything on the power and control compartment had been be connected, I have history with "details". I reopened the power control compartment. I did not open the engine/generator compartment because I was able to access the spark coils without disconnecting anything on that side. All I found on the power/control compartment, was a nut on the ground bus that was not as tight as I would expect. I tightened it, replaced fuse, restored utility sensing and reconnected battery. unit started and ran for 6 !/2 minutes in "manual" before I stopped it. MARK THIS AN "UNFORCED ERROR"...

I did not pick up load, because I was alone and did not want to open service main without someone present to call the coroner. when I get help, I will program exercise mode, put in "auto" and trip the main.

Assuming we are back to normal operation, I thank you for your analysis. I could not have otherwise resolved this problem.
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I would use a digital meter and confirm proper output voltage from the generator before switching the transfer switch over to the generator. Always good to double check!
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