Pacific Scientific Redi-Line DA12A Manual

INSTALLATION AND SERVICE
MANUAL
Models
DA12A DA12L
DA24A DA24L
DA36A DA36L

Warranty Policy Instruction and Service Manual
Pacific Scientific REDI-LINE Generators
Warranty Policy
Pacific Scientific warrants its REDI-LINE Generator to the original purchaser and in
the case of original equipment manufacturers or distributors, to their original
consumer, to be free from defects in material and workmanship. In no event,
however, shall Pacific Scientific be liable or have any responsibility under such
warranty if the products have been improperly stored, installed, used or maintained,
or if customer has permitted any unauthorized modifications, adjustments and/or
repairs to such products.
Pacific Scientific obligation hereunder is limited solely to repairing or replacing (at its
option), at its factory any products, or parts thereof, which prove to our satisfaction
to be defective as a result of defective materials or workmanship, in accordance
with our stated warranty, provided however, that the written notice of claimed
defects shall be given to Pacific Scientific within two (2) years after the date of the
product date code that is affixed to the product, and within thirty (30) days from the
date any such defect is first discovered. This warranty does not include brush or
commutator wear since wear is normal.
The products or parts claimed to be defective must be returned to Pacific Scientific,
or an Authorized REDI-LINE distributor, transportation prepaid by customer, with a
detailed written explanation of the claimed defect. Evidence acceptable to Pacific
Scientific must be furnished that the claimed defects were not caused by misuse.
abuse. or neglect by anyone other than Pacific Scientific.
The foregoing warranties are in lieu of all other warranties (except as to title),
whether expressed or implied, including without limitation, any warranty of
merchantability or of fitness for any particular purpose, and are in lieu of all other
obligations or liabilities on the part of Pacific Scientific. Pacific Scientific's maximum
liability with respect to these warranties, arising from any cause whatsoever,
including without limitation, breach of contract, negligence, strict liability, tort
warranty, patent or copyright infringement, shall not exceed the price specified of
the products giving rise to the claim, and in no event shall Pacific Scientific be liable
under these warranties or otherwise, even if Pacific Scientific has been advised of
the possibility of such damages, for special, incidental, or consequential damages,
including without limitation, damage or loss resulting from inability to use the
products, increased operating costs resulting from a loss of the products, loss of
anticipated profits, or other special, incidental, or consequential damages, whether
similar or dissimilar, of any nature arising or resulting from the purchase, installation,
removal, repair, operation, use or breakdown of the products, or any other cause
whatsoever, including negligence.
The forgoing shall also apply to products, or parts for the same which have been
repaired or replaced pursuant to such warranty, and within the period of time, in
accordance with Pacific Scientific's date of warranty.
No person, including any agent, distributor, or representative of Pacific Scientific, is
authorized to make any representation or warranty on behalf of Pacific Scientific
concerning any products or programs manufactured by Pacific Scientific, except to
refer purchases to this warranty.

Instruction and Service Manual Table of Contents
Pacific Scientific REDI-LINE Generators
TABLES OF CONTENTS
ABOUT THIS MANUAL.......................................................................................................................... 5
1. DESCRIPTION AND OPERATION ................................................................................................... 6
FEATURES.................................................................................................................................................... 6
2. GENERAL SPECIFICATIONS ........................................................................................................... 7
NAMEPLATE DATA...................................................................................................................................... 7
3. UNPACKING ......................................................................................................................................... 8
UNPACKING ................................................................................................................................................. 8
4. PREPARATION FOR INSTALLATION............................................................................................ 9
CHOOSING AN ACCEPTABLE LOCATION ................................................................................................... 9
DETERMINING INSTALLATION REQUIREMENTS..................................................................................... 10
BATTERY SELECTION ............................................................................................................................... 17
WIRING CONSIDERATIONS ....................................................................................................................... 18
5. INSTALLATION ................................................................................................................................. 19
BEFORE BEGINNING INSTALLATION........................................................................................................ 19
MOUNTING................................................................................................................................................. 19
INSTALLATION INTERCONNECTION......................................................................................................... 20
INSTALLATION CHECKOUT ...................................................................................................................... 23
6. MAINTENANCE ................................................................................................................................. 24
CLEANING.................................................................................................................................................. 24
MOUNTING AND ELECTRICAL CONNECTIONS ........................................................................................ 24
BRUSHES .................................................................................................................................................... 24
COMMUTATORS......................................................................................................................................... 24

Table Of Contents Instruction and Service Manual
4Pacific Scientific REDI-LINE Generators
7. FIELD TROUBLESHOOTING ......................................................................................................... 25
FIELD SERVICE.......................................................................................................................................... 25
USE OF FLOW CHARTS.............................................................................................................................. 25
CONDITIONAL BRANCHES ........................................................................................................................ 25
ADDITIONAL TROUBLESHOOTING AND REPAIR...................................................................................... 25
SHOULD YOU NEED TO RETURN THE UNIT............................................................................................. 26
FIELD TROUBLESHOOTING CHECKLIST FORM....................................................................................... 27
TROUBLESHOOTING FLOW CHARTS........................................................................................................ 28
OTHER TROUBLESHOOTING CHECKS...................................................................................................... 38
8. BENCH TROUBLESHOOTING ....................................................................................................... 39
USE OF FLOW CHARTS.............................................................................................................................. 39
CONDITIONAL BRANCHES ........................................................................................................................ 39
ASSEMBLY AND DISASSEMBLY................................................................................................................. 39
TROUBLESHOOTING FLOWCHARTS......................................................................................................... 40
TROUBLESHOOTING CHECKOUT PROCEDURES...................................................................................... 44
9. REPAIR PROCEDURES.................................................................................................................... 52
GENERAL ................................................................................................................................................... 52
RECOMMENDED TOOLS AND EQUIPMENT............................................................................................... 52
DISASSEMBLY OF SMALL FRAME UNITS................................................................................................. 53
RE-ASSEMBLY OF SMALL FRAME UNITS................................................................................................. 54
DISASSEMBLY OF LARGE FRAME UNITS................................................................................................. 55
RE-ASSEMBLY OF LARGE FRAME UNITS................................................................................................. 56
DC BRUSH REMOVAL AND REPLACEMENT............................................................................................. 57
CHECKOUT AFTER REPAIR....................................................................................................................... 58
10. PARTS LISTS..................................................................................................................................... 59
MODELS COVERED.................................................................................................................................... 59
PARTS LIST CONVENTIONS....................................................................................................................... 59
11. TECHNICAL DATA.......................................................................................................................... 92
PERFORMANCE CURVES........................................................................................................................... 92

Instruction and Service Manual About This Manual
Pacific Scientific REDI-LINE Generators 5
ABOUT THIS MANUAL
The purpose of this manual is twofold: first, to provide comprehensive installation
instructions for Pacific Scientific REDI-LINE generators; and second, to provide
comprehensive maintenance, troubleshooting, and repair procedures.
It is imperative that the installation instructions be followed closely. Successful
installation depends upon a number of factors, and ignoring any one factor can lead
to major problems with the unit.
Troubleshooting has been divided into three sections, the first for isolating
installation problems, the second for identifying problems with the unit itself while in
the field, and the third for isolating problems requiring bench repair. The owner or
installer should initially undertake troubleshooting. Careful troubleshooting can
eliminate installation problems and help avoid having to return the unit to the dealer.
Bench troubleshooting is for dealer or factory use, and should not be used in the
field.
Technical data contained in the manual is for dealer reference.

Description and Operation Instruction and Service Manual
6Pacific Scientific REDI-LINE Generators
1. DESCRIPTION AND OPERATION
The REDI-LINE Generator is an electromechanical device that converts DC battery
power to AC power. The DC supply consists of one or more deep cycle batteries
typically added to a vehicle electrical system. Convenient, remote operation of most
tools, appliances and lighting is assured as long as power consumption is within the
nameplate rating of the generator. The REDI-LINE generator is designed to supply
unregulated, true sine-wave electrical power for years of trouble free service.
The REDI-LINE Generator consists of a DC motor and an AC generator on a
common armature assembly. Speed of the DC motor, and, therefore, frequency of
the AC generator varies within limits as the load and battery power levels vary. The
unit starts automatically when an electrical load is applied.
Figure 1. The Two Basic Versions of REDI-LINE Generators
Features
The following features recommend the REDI-LINE DC to AC generator to users
who have need of reliable AC power on service and recreational vehicles, or at
remote sites.
•Built rugged and reliable with sturdy steel housing.
•Two year warranty.
•Patented Demand Start Circuitry extends battery life.
•Easily delivers peak output currents up to 1.5 times the continuous output rating
for extra starting power.
•Conveniently mounts in any position in a minimum of space.
•True sine-wave output.
•Optional GFI outlet.
•Operates in ambient temperatures from -30°F to 104°F

Instruction and Service Manual General Specifications
Pacific Scientific REDI-LINE Generators 7
2. GENERAL SPECIFICATIONS
Nameplate Data
The generator nameplate provides the operational specifications of the generator.
The beginning letter designations of the catalog listing describe the generator type.
Additional data given on the nameplate includes the generator part number, input
data, output data, insulation class, and serial number.
Table 1.1 General Specifications
Models DA12A-500A DA12L-1600A DA24A-800A DA24L-1600A DA36A-900A DA36L-1600A
Input Voltage (DC) 12 12 24 24 36 36
Nominal Input Voltage (DC) 12.6 12.6 25.2 25.2 37.8 37.8
Continuous Output Watts 500 1600 800 1600 900 1600
Surge Output Watts 750 2400 1200 2400 1350 2400
Output Voltage* (AC) 120 120 120 120 120 120
Output Frequency (Hz) 65 65 60 60 60 60
Continuous Output Current (Amps) 4.5 14.5 7.3 12.8 8.2 14.5
Surge Output Current (Amps) 722 11 20 12 22
Wave Shape Sine Sine Sine Sine Sine Sine
Length (inches) 16.25 16.75 16.25 15.13 16.25 15.13
Height (inches) 5.5 9.13 5.5 9.13 5.5 9.13
Diameter (inches) 5.18 7.38 5.18 7.38 5.18 7.38
Weight (lbs.) 26 53 26 48 26 48
** Variance from output voltage and frequency is dependent on load size and the
DC input voltage. Typical voltage tolerance is ±15%. Typical frequency tolerance
is ±5%. Carefully monitor any equipment that is sensitive to fluctuations in either
voltage or frequency.

Unpacking Instruction and Service Manual
Pacific Scientific REDI-LINE Generators
3. UNPACKING
Unpacking
Open the box and lift out the Generator and the insert.
CAUTION: The generator is a piece of heavy equipment. Removing it from the
box may require more than one person to avoid dropping the generator and
prevent personal injury.
Inspect the unit for any damage that may have been sustained during shipment. If
you find damage, contact the shipper immediately to file a claim.

Instruction and Service Manual Preparation for Installation
Pacific Scientific REDI-LINE Generators 9
4. PREPARATION FOR INSTALLATION
Most REDI-LINE service requests result from improperly installed units. Improper
installation will affect generator performance and may damage the unit.
NOTE: Damage caused by incorrectly installing your REDI-LINE generator is
not covered by warranty.
Successful installation calls for proper planning, as well as the use of proper
materials during the installation process. Follow the procedures outlined below in
preparing for installation of your generator.
Choosing an Acceptable Location
Observe these guidelines when choosing a location to mount your generator and it’s
battery system.
Cable Routing
Keep the generator as close to the battery as possible to reduce the length of the
power cables. Long power cables will reduce the amount of voltage to the
generator and decrease performance.
Carefully plan the power supply cable route. Do not allow the cables to rub against
sharp surfaces, which could cut the cable insulation and cause a short against the
vehicle frame.
Accessibility
Be sure both the REDI-LINE generator and the battery system are located so that
they are easily accessible for servicing.
Protection from Moisture
Do not install the generator or battery system in areas with direct exposure to water.
Do not use a steam cleaner or a high-pressure washer around the generator unless
it is totally protected against water intrusion.
Protection from Damage
Be sure both the REDI-LINE generator and the battery system are installed in areas
where they are not subject to damage.
Ventilation Considerations
Allow at least 2 inches of free air space around the REDI-LINE generator. Do not
obstruct the ventilation as it can cause the generator to overheat. Install the battery
system in an area that is ventilated, so that battery fumes can be readily dissipated.

Preparation For Installation Instruction and Service Manual
10 Pacific Scientific REDI-LINE Generators
CAUTION: Do not install the REDI-LINE generator and it’s supply
batteries in the same compartment.
CAUTION: Do not install the REDI-LINE generator in a compartment that
could contain explosive fumes.
Determining Installation Requirements
Determine how frequently and at what loads you plan to use your generator. Find
the Redi-Line generator series you purchased and choose the correct installation
diagram based on your usage and loads. Use this diagram as a guide when it
comes time to do the system installation.

Instruction and Service Manual Preparation for Installation
Pacific Scientific REDI-LINE Generators 11
DA12A Series
If the load requirement is not heavy (intermittent hand tool use or light loads for a
long period of time) the vehicle battery and charging system should handle both
vehicle and additional generator demand.
If the load requirements are heavy (constant use of hand tools or large loads) install
one or more auxiliary deep cycle batteries. The auxiliary battery should be isolated
from the vehicle battery using a battery isolator. The battery isolator is a one way
path so the vehicle charges both batteries but one battery cannot discharge the
other. This will ensure the vehicle battery is always charged and you will be able to
start your vehicle.
Figure 4-1. Infrequent Use with Varying Loads
*Use fuse size recommended by isolator manufacturer
Figure 4-2. Frequent Use with Varying Loads

Preparation For Installation Instruction and Service Manual
12 Pacific Scientific REDI-LINE Generators
DA12L Series
If the load requirement is not heavy (intermittent hand tool use or light loads for a
long period of time) install one or more auxiliary deep cycle batteries. The auxiliary
battery should be isolated from the vehicle battery using a battery isolator. The
battery isolator is a one way path so the vehicle charges both batteries but one
battery cannot discharge the other. This will ensure the vehicle battery is always
charged and you will be able to start your vehicle.
If the load requirements are heavy (constant use of hand tools or large loads) install
two or more auxiliary deep cycle batteries. The auxiliary batteries should be isolated
from the vehicle battery using a battery isolator. The battery isolator is a one way
path so the vehicle charges both batteries but one battery cannot discharge the
other. This will ensure the vehicle battery is always charged and you will be able to
start your vehicle.
Figure 4-3. Infrequent Use with Varying Loads
Figure 4-4. Frequent Use with Varying Loads

Instruction and Service Manual Preparation for Installation
Pacific Scientific REDI-LINE Generators 13
DA24A Series
If the load requirement is not heavy (intermittent hand tool use or light loads for a
long period of time) the vehicle battery and charging system should handle both the
vehicle and additional generator demand.
If the load requirements are heavy (constant use of hand tools or large loads) install
two or move deep cycle auxiliary batteries. The auxiliary battery should be isolated
from the vehicle battery using a battery isolator. The battery isolator is a one way
path so the vehicle charges both batteries but one battery cannot discharge the
other. This will ensure the vehicle battery is always charged and you will be able to
start your vehicle.
Figure 4-5. Infrequent Use with Varying Loads
Figure 4-6. Frequent Use with Varying Loads

Preparation For Installation Instruction and Service Manual
14 Pacific Scientific REDI-LINE Generators
DA24L Series
If the load requirement is not heavy (intermittent hand tool use or light loads for a
long period of time) the vehicle battery and charging system should handle both the
vehicle and additional generator demand.
If the load requirements are heavy (constant use of hand tools or large loads) install
two or move deep cycle auxiliary batteries. The auxiliary battery should be isolated
from the vehicle battery using a battery isolator. The battery isolator is a one way
path so the vehicle charges both batteries but one battery cannot discharge the
other. This will ensure the vehicle battery is always charged and you will be able to
start your
Figure 4-7. Infrequent Use with Varying Loads
Figure 4-8. Frequent Use with Varying Loads

Instruction and Service Manual Preparation for Installation
Pacific Scientific REDI-LINE Generators 15
DA36A Series
If the load requirement is not heavy (intermittent hand tool use or light loads for a
long period of time) the vehicle battery and charging system should handle both the
vehicle and additional generator demand.
If the load requirements are heavy (constant use of hand tools or large loads) install
two or more auxiliary deep cycle batteries. The auxiliary batteries should be isolated
from the vehicle battery using a battery isolator. The battery isolator is a one way
path so the vehicle charges both batteries but one battery cannot discharge the
other. This will ensure the vehicle battery is always charged and you will be able to
start your vehicle.
Figure 4-9: Infrequent Use with Varying Loads
Figure 4-10. Frequent Use with Varying Loads

Preparation For Installation Instruction and Service Manual
16 Pacific Scientific REDI-LINE Generators
DA36L Series
If the load requirement is not heavy (intermittent hand tool use or light loads for a
long period of time) the vehicle battery and charging system should handle both the
vehicle and additional generator demand.
If the load requirements are heavy (constant use of hand tools or large loads) install
two or more auxiliary deep cycle batteries. The auxiliary batteries should be isolated
from the vehicle battery using a battery isolator. The battery isolator is a one way
path so the vehicle charges both batteries but one battery cannot discharge the
other. This will ensure the vehicle battery is always charged and you will be able to
start your vehicle.
Figure 4-11. Infrequent Use with Varying Loads
Figure 4-12. Frequent Use with Varying Loads

Instruction and Service Manual Preparation for Installation
Pacific Scientific REDI-LINE Generators 17
Battery Selection
Standard automotive batteries are designed to supply 300 to 500 amps of current
for a relatively short period; therefore they are not the best power source for REDI-
LINE generators. Deep cycle or marine batteries are designed to deliver lower
current levels for a longer time, and are capable of taking deep discharges without
battery damage. For this reason, a deep cycle battery is recommended for REDI-
LINE operation.
Batteries are rated in cold cranking amps (CCA). In general, the higher the CCA the
longer the battery will operate a generator load. The length of the duty cycle
depends on the battery capacity, the size of the load (tool or appliance connected to
the generator), and how frequent the load is applied.
Use the following formula to estimate how long a fully charged deep cycle battery
will keep the REDI-LINE operating continuously before the battery needs
recharging:
Hours = Cold Cranking Amps (CCA)
180 X AC Load Amps
Where:
•Cold Cranking Amps is equal to the sum of all the battery CCAs.
•AC Load Amps is the AC current rating listed on the nameplate of the
largest tool or appliance to be powered by the REDI-LINE generator.
For Example:
•Two batteries with a CCA rating of 675 are used to operate a Generator.
•The tool being operated requires an AC load of 4 amps.
•Continuous run time is:
Hours = 675 + 675
180 X 4 = 1.87 Hours
To extend the operating time of the generator further, connect the generator’s
battery system to the vehicle charging system. With the vehicle running, the
alternator charges the generator battery bank, thereby providing a longer run time.
If the charging system is not powerful enough, the batteries may still ultimately
become discharged after a long operating time. If that is the case, you may need to
install a larger alternator in your vehicle. Consult your REDI-LINE distributor for
more information

Preparation For Installation Instruction and Service Manual
18 Pacific Scientific REDI-LINE Generators
Wiring Considerations
Installation and wiring must conform to all applicable codes, including the National
Electric Code, state and local, or other codes in effect at the time of installation.
Pacific Scientific recommends that the REDI-LINE Generator always be installed
using proper fuses or circuit breakers. Refer to the appropriate Installation figure
(Figures 4-1 through 4-12) for fuse sizes and locations. Place fuses no farther than
18" from the battery.
The connection between the supply battery and the REDI- LINE Generator is one of
the most critical installation steps. Using the wrong supply cable size could damage
the generator. Choose the correct supply cable size from the Table 4-1 below.
Table 4-1. Supply Cable Size Between Battery and REDI-LINE Generator
Cable Length in Feet
Generator up to 3’ 3’ to 8’ 8’ to 10’ 10’ +
DA12A-500A
Figure 4-1 and 4-2 No. 6 No. 4 No. 4 No. 4
DA24A-800A
DA36A-900A
Figure 4-5, 4-6, 4-9and 4-10
No. 6 No. 6 No. 6 No. 4
DA12L-1600A
Figure 4-3 No. 0 No. 0 No. 0 No. 00
DA12L-1600A
Figure 4-4 No. 2 No. 2 No. 2 No. 0
DA24L-1600A
DA36L-1600A
Figure 4-7, 4-8, 4-11, and 4-12
No. 6 No. 6 No. 6 No. 4

Instruction and Service Manual Installation
Pacific Scientific REDI-LINE Generators 19
5. INSTALLATION
Before Beginning Installation
The REDI-LINE Generator is a quality product, designed to be rugged, reliable and
safe when installed properly. Improper installation can cause damage to the unit
and/or result in serious personal injury. Damage caused by incorrectly installing your
REDI-LINE generator is not covered by warranty. Read the entire installation
procedure before you start to install the generator. If you have questions on
installation or operation of the generator, contact your REDI-LINE distributor for
assistance. If you do not have a distributor contact, call Pacific Scientific direct at
[phone].
To prevent damage to the generator, insure that it is sized properly for the
application. Excessive AC current draw, above the rating stated on the nameplate,
may cause overheating of the generator.
Be sure that all the preparation for installation provisions described in Section 4
have been carried out.
CAUTION: Automotive and marine type batteries produce dangerous current
levels. Protect yourself when working around batteries and associated
electrical systems. This includes the use of safety goggles.
Mounting
The generator is not position sensitive and may be mounted in whatever orientation
best suits your application.
1. Place the unit in the desired position or use the templates in Figures 5-1 or 5-
2 to mark the location of the mounting holes.
2. Remove the generator or template. At the marked location, drill 1/4" holes.
3. Attach the generator using four 1/4" flat washers, lock washers, bolts, and
nuts through the holes in the base flange. Mounting hardware is not included.
4. Install and secure the batteries in accordance with instructions provided by
the battery manufacturer.

Installation Instruction and Service Manual
20 Pacific Scientific REDI-LINE Generators
Installation Interconnection
Install your REDI-LINE generator according to the interconnection shown in the
appropriate installation figure (Figures 4-1 through 4-12). Use the correct cable size
(Table 4-1) between the battery and generator. Be sure all electrical connections
are securely made.
WARNING
It is important that the polarity (+ and - ) be correctly connected to the generator. Note
polarity indications on the installation figure (Figures 4-1 through 4-12) you are using.
Do not ground the negative (-) REDI-LINE supply terminal to the vehicle chassis. The
negative REDI-LINE terminal must be connected directly to the supply battery using the
proper size supply cable.
NOTE: Cable, connectors, fuses and isolators may be available from your
authorized REDI-LINE distributor. Many also provide complete installation
services.
NOTE: When attaching power cables to the generator; a spark at the
connection may occur. This is normal and does not mean the generator is
defective.