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azpyroguy's avatar
azpyroguy
Explorer
Dec 03, 2014

Onan 5500 Marquis Gold - GAS, Generator Issue

Over Thanksgiving I took my toy hauler out to the dunes and got the chance to use my newly installed (replacement) secondary A/C unit, as a couple of the days got kinda warm.

The unit is supposed to be the same as the main "house" unit, just without the remote thermostat. We tested the new unit at the dealer on SHORE power, and it seemed OK.

I started the gen, let it run my normal 1 minute giving the transfer switch time to switch over from SHORE (even though I was dry camping - shore power is the default), then tested out the new A/C.

I flipped the switched and it ran for about 2-3 seconds, and shut down, at the same time shutting down pretty much half the power in my RV.

I checked all the breakers in the panel, and generator, all were on and switched. I turned off the gen, flipped the breakers a few times, and restarted no change.

I then turned it off again, and tested with a small 2000w external generator, I had power to all services in the rig (could not test A/C as the little gen would not run those, but I did have power them)

Shut off the little gen, and tested the big gen again, same issue... no power to half the rig.

Opened up the cover on the IOTA transfer switch, and measured the voltages, and found that 1 of the 2 HOT legs have no power despite all breakers being OK, and no codes being shown by the generator, I am unable to tell if that is incoming or outgoing from the transfer switch, but I THINK its the incoming HOT1 and HOT2 from Generator.

I also opened up the panel in side the rig, and tested the voltages there, and one side of the 50 amp 2 way circuit is dead.

When I got home, I opened up the generator circuit breaker cover, and checked them for continuity, and they both checked out. Did the same thing at the inside distribution panel as well.

I am not sure if there are further circuits behind the breakers at the generator, I would think they are in place to protect the genset itself.

I am thinking something went wonky inside the generator, or the IOTA transfer switch, via an overdraw with the newly installed A/C, as before it all was good.

Any thoughts?

9 Replies

  • The rig is down at the dealer now getting diagnosed, and they too think that since the ONAN is running good, and no codes that the transfer switch crapped out on me.
  • dougrainer wrote:
    NO RV Genset outputs 220. You CAN rewire some of them to output 220, but from Onan, they are ALL 120 output. Verify that at the transfer switch the each of the 2 HOT legs from the APU have 120 to the Neutral. If you have bthat then the APU wiring to the transfer is good. Then check the output wiring at the Transfer box. BOTH Hot legs to neutral should show 120. IF NOT, then your transfer switch is bad. Doug


    Knowing this, I think your right... the transfer switch seems to the culprit.
  • NO RV Genset outputs 220. You CAN rewire some of them to output 220, but from Onan, they are ALL 120 output. Verify that at the transfer switch the each of the 2 HOT legs from the APU have 120 to the Neutral. If you have bthat then the APU wiring to the transfer is good. Then check the output wiring at the Transfer box. BOTH Hot legs to neutral should show 120. IF NOT, then your transfer switch is bad. Doug
  • othertonka wrote:
    are both breakers right on the gen set itself turned ON? they are right above the start/stop button


    Yes, they are above the start/stop button, and both are on. I pulled that panel, and checked each one individually for continuity. I also flipped each one multiple times, and both seem to have the same amount of spring tension.

    Additionally both are tied together on one side by a bridge connector, so I believe its a 120v unit, as you would never tie a 240v together that way.
  • edatlanta wrote:
    Are you sure the transfer switch doesn't have some burned contacts? There was a recall of 50 amp IOTA transfer switches 3-4 years ago and IOTA no longer makes transfer switches as a result.


    I am unable to tell its in an odd location, the main contact bar with set screws is all tight, but the problem could be inside at the relay level. I had heard about that recall, but was never officially notified that my unit was specifically affected, however we all know how good RV and their parts makers are at alerting their owners of issues.... (sarcastically said)
  • I believe its a 120v gen, I was unable to check the voltage at the generator breakers, as there was no neutral for me to easily get to. The two larger gauge wires went back into the harness and into the generator. However when I inspected the breakers one side of the breakers had both tied together with a bridge connector so that is why I suspect its a 120v version.

    I am leaning towards the transfer switch developing a burned contact.


    islandvagabonds wrote:
    Does the gen output 220 volts or is it a 120 unit? If 120v one of the "hots" is neutral so will not show voltage.
    Did you check for voltage at the gen circuit breakers when you had the panel off. I have heard of output connectors burning off in the genset due to corrosion or being loose. If power at the gen breakers and no burnt connectors sound like the transfer switch may be the issue. Good Luck.
  • Are you sure the transfer switch doesn't have some burned contacts? There was a recall of 50 amp IOTA transfer switches 3-4 years ago and IOTA no longer makes transfer switches as a result.
  • are both breakers right on the gen set itself turned ON? they are right above the start/stop button
  • Does the gen output 220 volts or is it a 120 unit? If 120v one of the "hots" is neutral so will not show voltage.
    Did you check for voltage at the gen circuit breakers when you had the panel off. I have heard of output connectors burning off in the genset due to corrosion or being loose. If power at the gen breakers and no burnt connectors sound like the transfer switch may be the issue. Good Luck.

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