Generac Power Systems 5413, 5412, 5411 Effects of Dirt and Moisture, Insulation Resistance Testers

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Section 3

Insulation Resistance Tests

Effects of Dirt and Moisture

Moisture and dirt are detrimental to the continued good operation of any generator set.

If moisture is allowed to remain in contact with the Stator and Rotor windings, some of the moisture will be retained in voids and cracks of the winding insula- tion. This will result in a reduced Insulation resistance and, eventually, the unit’s AC output will be affected.

Insulation used in the generator is moisture resistant. However, prolonged exposure to moisture will gradu- ally reduce the resistance of the winding insulation.

Dirt can make the problem worse, since it tends to hold moisture Into contact with the windings. Salt, as from sea air, contributes to the problem since salt can absorb moisture from the air. When salt and moisture combine, they make a good electrical conductor.

Because of the detrimental affects of dirt and mois- ture, the generator should be kept as clean and as dry as possible. Rotor and Stator windings should be tested periodically with an insulation resistance tester (such as a megohmmeter or hi-pot tester).

If the Insulation resistance is excessively low, drying may be required to remove accumulated moisture. After drying, perform a second insulation resistance test. If resistance is still low after drying, replacement of the defective Rotor or Stator may be required.

Insulation Resistance Testers

Figure 3-1 shows one kind of hi-pot tester. The tester shown has a “Breakdown” lamp that will glow during the test procedure to indicate an insulation breakdown in the winding being tested.

Figure 3-1. – One Type of Hi-Pot Tester

*DANGER! INSULATION RESISTANCE TESTERS SUCH AS HI-POT TESTERS AND

MEGOHMMETERS ARE A SOURCE OF HIGH AND DANGEROUS ELECTRICAL VOLTAGE. FOLLOW THE TESTER MANUFACTURER’S INSTRUCTIONS CAREFULLY. USE COMMON SENSE TO AVOID DANGEROUS ELECTRICAL SHOCK

Drying the Generator

GENERAL:

If tests indicate the insulation resistance of a winding is below a safe value, the winding should be dried before operating the generator. Some recommended drying procedures include (a) heating units and (b) forced air.

HEATING UNITS:

If drying is needed, the generator can be enclosed in a covering. Heating units can then be installed to raise the temperature about 15°-18° F (8°-10° C) above ambient temperature.

FORCED AIR:

Portable forced air heaters can be used to dry the generator. Direct the heated air into the generator’s air intake openings. Remove the voltage regulator and run the unit at no-load. Air temperature at the point of entry into the generator should not exceed 150° F. (66° C.).

Cleaning the Generator

GENERAL:

The generator can be cleaned properly only while it is disassembled. The cleaning method used should be determined by the type of dirt to be removed. Be sure to dry the unit after it has been cleaned.

NOTE: A shop that repairs electric motors may be able to assist you with the proper cleaning of generator windings. Such shops are often expe- rienced in special problems such as a sea coast environment, marine or wetland applications, min- ing, etc.

USING SOLVENTS FOR CLEANING:

If dirt contains oil or grease a solvent is generally required. Only petroleum distillates should be used to clean electrical components. Recommended are safe- ty type petroleum solvents having a flash point greater than 100° F. (38° C.).

*CAUTION!: Some generators may use epoxy or polyester base winding varnishes. Use sol-

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Electromagnetic Induction MagnetismElectromagnetic Fields Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Field Boost Generator AC Connection SystemConnection for 120 Volts Only Rotor Assembly Stator AssemblyBrush Holder Excitation Circuit ComponentsCrankcase Breather DescriptionControl Panel Component Identification Control Panel ComponentsInsulation Resistance Testers Cleaning the GeneratorEffects of Dirt and Moisture Drying the GeneratorStator Insulation Resistance Testing Rotor Insulation Testing Rotor InsulationTesting Stator Insulation MegohmmeterMeasuring AC Voltage MetersVOM Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohm’s LawIntroduction Operational AnalysisCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Battery Cables BatteryRecommended Battery Printed Circuit BoardStart-Stop Switch Amp FuseStart-Stop Switch Starter Contactor Relay Starter MotorIf Problem Involves AC Output Problem 1 Voltage & Frequency Are Both High or LowTest Troubleshooting Flowcharts Proble 5 Priming Function Does Not Work Gasoline Models Problem 6 Engine Will Not Crank Test 26 Check Test 20 Check Check Fuel Wire 14 Power Good Troubleshooting Flowcharts Problem 8 Engine Starts Hard and Runs Rough Gasoline Units Problem 8 Engine Starts Hard and Runs Rough LP Units LOW OIL Pressure Flashes on SW1 LED Problem 10 7.5A F1 Fuse Blowing YESTest 2 Check Stepper Motor Control ProcedureTest 1 Check No-Load Voltage Frequency DiscussionSix Pin J2 Connector Wire Colors Test 4 Fixed Excitation Test/Rotor Amp DrawFixed Excitation Test, Step B Test 5 Check Field Boost Test 6 Test Stator DPE WindingTest 7 Check Sensing Leads / Power Windings Stator Excitation WindingStator Power Winding Leads Test 8 Check Brush LeadsTest 10 Check Rotor Assembly Test 9 Check Brushes & Slip RingsTest 12 Check Load Voltage Frequency SchematicTest 11 Check Main Circuit Breaker Test 13 Check Load Watts AmperageTest 14 Try Cranking the Engine Test 15 Check Fuel PumpTest 16 Check 7.5 Amp Fuse Test 17 Check Battery & CablesTest 18 Check Power Supply to Printed Circuit Board Test 19 Check Continuity of Wire Test 20 Check Start-Stop SwitchTest 21 Check Power Supply to Wire Test 22 Check Starter Contactor RelayTest 23 Check Starter Contactor Test 24 Check Starter MotorTools for Starter Performance Test Checking the PinionPinion Minimum rpm 4500 Maximum Amps Test 25 Check Fuel Supply To Carburetor GASTest 26 Check Wire 14 Power Supply 29. Fuel RegulatorTest 27 Check Wire Test 28 Check Fuel Solenoid Gasoline ModelsTest 29 Check Ignition Spark Tools RequiredTwo Ignition Testers Generac P/N 0C5969Test 31 Check and Adjust Ignition Magnetos Test 30 Check Spark Plugs37. Setting Ignition Magneto Armature Air Gap Flywheel KEY Test 32 Check Valve AdjustmentChecking Flywheel Magnet Test 33 Check Carburetion Test 34 Check Choke SolenoidTo Control Solenoid PanelTest 36 Check Oil Pressure Switch Test 37 Check Wire 86 for Continuity Test 38 Test Oil Temperature SwitchTest 39 Check Wire 85 for Continuity Test 40 Test Choke HeaterTest 41 Check LPG Fuel Solenoid Section Exploded Views QTY Description Enclosure Drawing No G3881-C Enclosure Door Views Screw Plastite HI-LOW #10X3/8 Engine Accessories Drawing No G7718-B QTY Description 48,49 Square Head Plug Rotor & Stator Drawing No G3953-b NUT TOP Lock FL M8-1.25 Charts Generator Specifications Nominal Resistances of Generator Windings at 68fElectrical Data Electrical Data OG7515 REV. a

5410, 5414, 5415, 5413, 5411 specifications

Generac Power Systems has established itself as a leading manufacturer of backup power solutions, particularly known for its range of generators designed for both residential and commercial use. Among their noteworthy products are the Generac models 5412, 5411, 5413, 5415, and 5414. Each of these generators showcases innovative technologies and features that enhance reliability, efficiency, and ease of use.

The Generac 5412 is a versatile model equipped with a robust 10 kW output, making it suitable for powering essential home appliances during outages. It operates using a 1.0 L engine that runs on natural gas or propane, providing flexibility in fuel options. The Quiet-Test feature is a notable characteristic, as it allows for a self-test at a reduced volume, minimizing noise disruptions during routine checks.

Moving to the Generac 5411, this generator offers a higher output capacity of 13 kW. It integrates advanced load management technology, which ensures that power is allocated efficiently among connected devices. This model also features a Mobile Link remote monitoring system, enabling users to check generator status and performance from anywhere via a smartphone app.

The Generac 5413 is tailored for larger residential needs, delivering an impressive 16 kW output. It boasts a durable all-weather aluminum enclosure designed for longevity against the elements. The 5413's integrated wifi connectivity allows for real-time monitoring and alerts, ensuring that homeowners are always informed of their generator's operating status.

For those seeking a balance of power and efficiency, the Generac 5415 offers 20 kW of output while maintaining a compact design. This model is enriched with the patented G-Flex technology, allowing it to adjust engine speed based on the load requirements, thereby conserving fuel and reducing noise levels. Additionally, the 5415 comes with an intuitive user interface for effortless operation and programming.

Finally, the Generac 5414 rounds out the lineup with its strong 24 kW capability. This model is particularly known for its Smart Management modules, which facilitate the safe and efficient distribution of power. Its intuitive design also includes a user-friendly control panel for straightforward operation, ensuring that homeowners, regardless of technical expertise, can utilize the system effectively.

In summary, Generac Power Systems’ 5412, 5411, 5413, 5415, and 5414 generators exemplify advanced power technology, tailored for reliability and user convenience. Whether for essential home functions or more extensive power needs, these models provide effective solutions to ensure that homes remain powered during outages.
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