This post is a bit long but hang with me to the end. There is a point to be made.

Overview

As I’ve posted a few times, I have a Generac 20kw stand alone generator on our home. Recently, when I opted to do an oil change on the machine, I found the small keypad on the control panel didn’t want to function.



Without that input pad, you can’t access any of the data or capabilities in the controller. Not good. Since everything associated with this generator is expensive to fix, I began to worry I was on the hook for a big repair bill. Also, not good. With a little online searching, I found a new controller for the generator ran ~$400 with installation averaging around ~$200 (~$600 total). An additional downside to replacing the entire controller is that all the previous run and service data would be lost. I called two local generator guys who both told me they replace controllers fairly often, and that it was likely my only option to regain control of my generator. Not being content with that answer, I opted to explore further.

Troubleshooting

Since the generator was running its regular weekly exercise cycle, and I could cycle the unit on and off via the large main rocker switch, I began to suspect the problem wasn’t with the main computer board in the controller, but rather, might simply be a failure of a couple of the keys on the small keypad. Upon disassembly of the controller I found the front cover of the unit included the keypad, which was connected to the main computer board via a small ribbon cable.





Now I’m thinking maybe a $20 plastic replacement cover for the controller assembly might solve my problem. So back onto the phone I went to a couple local Generac resellers to see if I could order the part. The answer…Nope, Generac doesn’t sell that piece separately, I’d have to buy the entire controller (~$400+) to get it. That’s just stupid on steroids that a wear part, likely to break, and designed as a separate piece of the assembly, isn’t available for purchase. Annoyed but not deterred, I went back to the web and found a couple electrical company websites that specialize in generator sales and installs. After posting in their forums, a very nice guy in Idaho contacted me to let me know he had an old controller like mine, that was removed from a functioning system because the LCD screen got too dim to read. Since he was attempting to clean out his shop, he offered it to me for whatever the shipping cost would be to get it to me. I took him up on his offer and got his package yesterday. I disassembled his control panel assembly to remove the front cover, wiped it down a bit to clean it up (yes I am anal about cleanliness), and assembled it with my system control board and back panel. Then I reinstalled the control panel assembly back into the generator and powered everything up. And…….It worked flawlessly.

Summary

Ultimately, my hard headedness cost me a couple hours of time on the phone during the day and/or the computer at night to get to a solution. The control panel now works flawlessly, and because I didn’t replace the main system board in the controller, still contains all my run and service info. So what was my out of pocket cost? $11.20 USPS shipping cost.

So the moral of this story is simple. You can...

• Pick up the phone and call a Generac service tech, schedule with him to be home when he does the repair, lose all your run time and maintenance info, and shell out ~$600. Or,
• You can use that gray matter between your ears to learn a bit about how your generator works, perform the repair when it’s convenient for you, keep all your run time and service info intact, and save ~$589 in the process.

This is why I DIY.

quote:

You can learn a bit about how your generator works, perform the repair when it’s convenient for you, keep all your run time and service info, and save ~$589 in the process.

Good work, not only did you save $600 but you are now more familiar with your system. Win win!

Certainly is more sophisticated than the portable generator that I wheel from the garage and plug in to the socket on my house after power outages!

Thanks for the post. I am planning to put a Generac generator on the new home we are about to start building.

Some times stubbornness pay off.

I'm with you on troubleshooting to component level instead of just replacing at the module level but unfortunately companies find it cheaper to just replace at the module level. The higher cost of the module is all on the consumer.

Now you need to take apart the old cover and clean the contacts for those buttons so you can use it as a possible spare if you need to.

quote:

Originally posted by SpinZone:
I'm with you on troubleshooting to component level instead of just replacing at the module level but unfortunately companies find it cheaper to just replace at the module level. The higher cost of the module is all on the consumer.

Its also great for the service tech who can make $200 for 20 minutes (or less) of work installing a new control panel (not to mention whatever margin they make on the part).

quote:

Originally posted by Paten:
Now you need to take apart the old cover and clean the contacts for those buttons so you can use it as a possible spare if you need to.

I already explored that option, but the keypad is molded into the cover making it inaccessible.

Congrats on fixing it yourself. Now you can get that P226 you always wanted.

At first I thought you were going to have to replace the ribbon and warm up the soldering iron and have a flux pen ready. It was awesome for the dude in Idaho to send the part to you. Even better that it worked the first time you tried it.

Been there a few times myself. Had to repolarize an LCD screen because it was made in 1983 and long been out of production. That was... fun!
Rebuilding an automatic transmission isn't for everyone, doubt if I'll do that again. Converting an old truck to run projectors headlights is cheaper than hitting a deer.

This is why I change the oil in my truck, change filters in my ac, mow my own yard, fix my dishwasher...some people call it frugal...I call it being cheap

This is why I DIY - on the left is the pad in Mrs. Lee's car that was perfectly within spec and not close to tripping the warning sensor.

Another one. Saved $400 by DIY'ing the replacement of a $4 odometer gear on my last 911. Dicey job, but totally DIY'able.

I had a WINCO generator installed back in 1990, before generators became popular. It had an automatic transfer switch- small unit --7,500 watts. Great unit--back then , there was no trickle charger for the battery-so I always kept a spare battery on hand (small lawnmower battery). The muffler rusted out after 10 or 12 years. Replaced with an factory muffler. That required a little bit of McGivering to make it fit. Forward another 10 years-the transfer switch went-called WINCO --spoke with a very knowledgeable , older gentleman that told me that part was history--replaced with a newer "electronic" gizmo. I would have to replace the entire transfer switch--no parts for the older, obsolete switch. The wealth of knowledge that he had impressed me- ultimately he recommended replacing the whole transfer switch. The external panels of the generator were rusting. It was time for a new generator--I did get my money's worth out of it.

quote:

Originally posted by SpinZone:
Some times stubbornness pay off.

I'm with you on troubleshooting to component level instead of just replacing at the module level but unfortunately companies find it cheaper to just replace at the module level. The higher cost of the module is all on the consumer.

Yep. No way in hell I would have spent the time to do that.

Option 1). I spend three hours researching find pieces of used parts and bill you $200 to install and 3*175 to research it.

Total = $525 + $200 no warranty

Option 2). I order part for $400 and install for $200

Total = $400 +$200 with warranty

For business they have to pay employee for time to hunt for a used part and hope it pays off. If they can't find it or it doesn't fix your problem, they can't bill you for it.

Simple smart business decision.

As a homeowner you value your time at x dollars and may be willing to spend three hours in hopes of possibly saving some money. Depends on how much your time is worth and the odds of success. Simple business decision.

Bigdeal, I may have extra troubleshooting manual in my basement from taking refresher factory training class. If I find it, it's yours.

One of the key steps in your trouble shooting was research. I have found there is an Internet forum for just about everything. It may take a little searching to find the best forum but you will find a wealth of information.

Or you could start by asking a question here. If there was a post listing each forum members trade/background, it would be a multiple page thread.

quote:

Originally posted by Skins2881:

quote:

Originally posted by SpinZone:
Some times stubbornness pay off.

I'm with you on troubleshooting to component level instead of just replacing at the module level but unfortunately companies find it cheaper to just replace at the module level. The higher cost of the module is all on the consumer.

Yep. No way in hell I would have spent the time to do that.

Option 1). I spend three hours researching find pieces of used parts and bill you $200 to install and 3*175 to research it.

Total = $525 + $200 no warranty

Option 2). I order part for $400 and install for $200

Total = $400 +$200 with warranty

For business they have to pay employee for time to hunt for a used part and hope it pays off. If they can't find it or it doesn't fix your problem, they can't bill you for it.

Simple smart business decision.

As a homeowner you value your time at x dollars and may be willing to spend three hours in hopes of possibly saving some money. Depends on how much your time is worth and the odds of success. Simple business decision.

Yeah, I wouldn't expect an electrician or generator tech to do what I did because it would be counter productive to them. For them, replacing the entire controller assembly makes much more sense from a time and money standpoint. However, for me this is both a good way to learn more about my equipment (that generator ain't rocket science) and save a chunk of change in the process. I value both of those more than the three hours or so I spent chasing a solution.

quote:

(that generator ain't rocket science)

Shhhhh, don't let anyone know...

I'll check for spare troubleshooting book, makes it even easier. Is that a Nexus unit?

I prefer to DIY. The internet and youtube are a tremendous resource.

I’ve done several small projects that could have been more costly if I didn’t take the time to find out what’s involved with the repair.

These are simple tasks for many here but I am always pleased when I fix the problem.

Some items were:

Troubleshoot half full washer and replace lid switch.

Move Mac OS and data to external drive

Replace heating element on broiler of stove.

troubleshoot garage door issue and replace gear set.

Troubleshoot dishwasher and repair.

All simple stuff, I know, but saved quite a bit on unnecessary service call charges.

I scanned the thread, but have you now made a paper copy of the service information?

Internet is great for hacks and codes to get into settings menus.

Also great for washers/dryers etc troubleshooting.

I try to do as much as I can as DIY but age sometimes gets the better of me...and I call in a pro.

Good on you!i have been a DYI since a kid and these days anyone who does this is a relative rarity. I couldn’t afford my hobbies without this approach - .i.e.. this weekend changed out my cars suspension (setting up for AutoX), began a repair/rebuild on my dock and started sourcing parts for a generator hookup.

We learn so much and become independent doing dyi