Generac Power Systems 5415, 5412, 5411, 5413, 5414, 5410 manual Stator Insulation Resistance

Page 15

Section 3 Insulation Resistance Tests

vents that will not attack such materials.

Use a soft brush or cloth to apply the solvent. Be careful to avoid damage to wire or winding insulation. After cleaning, dry all components thoroughly using moisture-free, low-pressure compressed air.

*DANGER!: DO NOT ATTEMPT TO WORK WITH SOLVENTS IN ANY ENCLOSED AREA. PROVIDE ADEQUATE VENTILATION WHEN WORKING WITH SOLVENTS. WITHOUT ADEQUATE VENTILATION, FIRE, EXPLOSION OR HEALTH HAZARDS MAY EXIST . WEAR EYE PROTECTION. WEAR RUBBER GLOVES TO PROTECT THE HANDS.

CLOTH OR COMPRESSED AIR:

For small parts or when dry dirt is to be removed, a dry cloth may be sufficient. Wipe the parts clean, then use low pressure air at 30 psi (206 Kpa) to blow dust away.

BRUSHING AND VACUUM CLEANING:

Brushing with a soft bristle brush followed by vacuum cleaning is a good method of removing dust and dirt. Use the soft brush to loosen the dirt, then remove it with the vacuum.

Stator Insulation Resistance

GENERAL:

Insulation resistance is a measure of the integrity of the insulating materials that separate electrical wind- ings from the generator’s steel core. This resistance can degrade over time due to the presence of con- taminants, dust, dirt, grease and especially moisture.

The normal insulation resistance for generator wind- ings is on the order of “millions of ohms” or “mego- hms”.

When checking the insulation resistance, follow the tester manufacturer’s Instructions carefully. Do NOT exceed the applied voltages recommended in this manual. Do NOT apply the voltage longer than one

(1) second.

*CAUTION!: DO NOT connect the Hi-Pot Tester or Megohmmeter test leads to any leads that are routed into the generator control panel.

Connect the tester leads to the Stator or Rotor leads only.

STATOR SHORT-TO-GROUND TESTS:

See Figure 3-2. To test the Stator for a short-to-ground condition, proceed as follows:

1.Disconnect and Isolate all Stator leads as follows:

a.Disconnect sensing leads 11S and 22S from the voltage regulator.

b.Disconnect excitation winding lead No. 6 from the voltage regulator.

c.Disconnect excitation lead No. 2 from the volt- age regulator (VR).

e.At the main circuit breakers, disconnect AC power leads No. 11 and 33.

f.At the 4-tab ground terminal (GRD2), discon- nect Stator power leads No. 22 and 44.

2.When all leads have been disconnected as out- lined in Step 1 above, test for a short-to-ground condition as follows:

a.Connect the terminal ends of all Stator leads together (11S, 22S, 11, 22, 33, 44, 2, & 6).

b.Follow the tester manufacturer’s instructions carefully. Connect the tester leads across all Stator leads and to frame ground on the Stator can. Apply a voltage of 1500 volts. Do NOT apply voltage longer than one (1) sec- ond.

If the test indicates a breakdown in insulation, the Stator should be cleaned, dried and re-tested. If the winding fails the second test (after cleaning and dry- ing), replace the Stator assembly.

TEST BETWEEN ISOLATED WINDINGS:

1.Follow the tester manufacturer’s instructions care- fully. Connect the tester test leads across Stator leads No. 11 and 2. Apply a voltage of 1500 volts-

DO NOT EXCEED 1 SECOND.

2.Repeat Step 1 with the tester leads connected across the following Stator leads:

a.Across Wires No. 33 and 2.

b.Across Wires No. 11 and 33.

c.Across Wires No. 11 and 2.

If a breakdown in the insulation between isolated windings is indicated, clean and dry the Stator. Then, repeat the test. If the Stator fails the second test, replace the Stator assembly.

TEST BETWEEN PARALLEL WINDINGS:

Connect the tester leads across Stator leads No. 11 and 33. Apply a voltage of 1500 volts. If an insula- tion breakdown is indicated, clean and dry the Stator. Then, repeat the test between parallel windings. If the Stator fails the second test, replace it.

Page 13

Page 14 Page 16
Image 15
Page 14 Page 16
Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Magnetism Electromagnetic FieldsElectromagnetic Induction More Sophisticated AC Generator Simple AC GeneratorGenerator Operating Diagram Generator AC Connection System Field BoostConnection for 120 Volts Only Stator Assembly Rotor AssemblyExcitation Circuit Components Brush HolderDescription Crankcase BreatherControl Panel Components Control Panel Component IdentificationDrying the Generator Cleaning the GeneratorEffects of Dirt and Moisture Insulation Resistance TestersStator Insulation Resistance Megohmmeter Testing Rotor InsulationTesting Stator Insulation Testing Rotor InsulationMeasuring DC Voltage MetersVOM Measuring AC VoltageMeasuring Resistance Measuring CurrentOhm’s Law Electrical UnitsOperational Analysis IntroductionCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Printed Circuit Board BatteryRecommended Battery Battery CablesAmp Fuse Start-Stop SwitchStarter Contactor Relay Starter Motor Start-Stop SwitchProblem 1 Voltage & Frequency Are Both High or Low If Problem Involves AC OutputTest 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 YES Problem 10 7.5A F1 Fuse BlowingDiscussion ProcedureTest 1 Check No-Load Voltage Frequency Test 2 Check Stepper Motor ControlTest 4 Fixed Excitation Test/Rotor Amp Draw Six Pin J2 Connector Wire ColorsFixed Excitation Test, Step B Test 6 Test Stator DPE Winding Test 5 Check Field BoostStator Excitation Winding Test 7 Check Sensing Leads / Power WindingsTest 8 Check Brush Leads Stator Power Winding LeadsTest 9 Check Brushes & Slip Rings Test 10 Check Rotor AssemblyTest 13 Check Load Watts Amperage SchematicTest 11 Check Main Circuit Breaker Test 12 Check Load Voltage FrequencyTest 15 Check Fuel Pump Test 14 Try Cranking the EngineTest 17 Check Battery & Cables Test 18 Check Power Supply to Printed Circuit BoardTest 16 Check 7.5 Amp Fuse Test 20 Check Start-Stop Switch Test 19 Check Continuity of WireTest 22 Check Starter Contactor Relay Test 21 Check Power Supply to WireTest 24 Check Starter Motor Test 23 Check Starter ContactorChecking the Pinion PinionTools for Starter Performance Test Minimum rpm 4500 Maximum Amps To Carburetor GAS Test 25 Check Fuel Supply29. Fuel Regulator Test 26 Check Wire 14 Power SupplyTest 28 Check Fuel Solenoid Gasoline Models Test 27 Check WireTools RequiredTwo Ignition Testers Generac P/N 0C5969 Test 29 Check Ignition SparkTest 30 Check Spark Plugs Test 31 Check and Adjust Ignition Magnetos37. Setting Ignition Magneto Armature Air Gap Test 32 Check Valve Adjustment Checking Flywheel MagnetFlywheel KEY Test 34 Check Choke Solenoid Test 33 Check CarburetionSolenoid Panel To ControlTest 36 Check Oil Pressure Switch Test 38 Test Oil Temperature Switch Test 37 Check Wire 86 for ContinuityTest 40 Test Choke Heater Test 39 Check Wire 85 for ContinuityTest 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 Nominal Resistances of Generator Windings at 68f Generator SpecificationsElectrical 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.
Top Page Image Contents