Generac Power Systems 5414, 5412, 5411 Testing Rotor Insulation, Megohmmeter, Positive + Test Lead

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Section 3

Insulation Resistance Tests

 

2

 

6

 

11

 

22

Stator

33

44

 

 

11S

 

22S

Leads 2 & 6 = Stator Excitation Winding Leads 11S & 22S = Voltage Sensing Leads Leads 11 & 22, 33 & 44 = AC Power Windings

Figure 3-2. – Stator Leads

Testing Rotor Insulation

To test the Rotor for insulation breakdown, proceed as follows:

1.Disconnect wires from the Rotor brushes or remove the brush holders with brushes.

2.Connect the tester positive (+) test lead to the positive (+) slip ring (nearest the Rotor bearing). Connect the tester negative (-) test lead to a clean frame ground (like the Rotor shaft).

POSITIVE (+)

TEST LEAD

Figure 3-3. – Rotor Test Points

3.Apply 1000 volts. DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND.

If an insulation breakdown is indicated, clean and dry the Rotor then repeat the test. Replace the Rotor if it fails the second test (after cleaning and drying).

The Megohmmeter

GENERAL:

A megohmmeter, often called a “megger”, consists of a meter calibrated in megohms and a power sup- ply. Use a power supply of 1500 volts when testing Stators; or 1000 volts when testing the Rotor. DO NOT APPLY VOLTAGE LONGER THAN ONE (1) SECOND.

TESTING STATOR INSULATION:

All parts that might be damaged by the high meg- ger voltages must be disconnected before testing. Isolate all Stator leads (Figure 3-2) and connect all of the Stator leads together. FOLLOW THE MEGGER MANUFACTURER’S INSTRUCTIONS CAREFULLY.

Use a megger power setting of 1500 volts. Connect one megger test lead to the junction of all Stator leads, the other test lead to frame ground on the Stator can. Read the number of megohms on the meter.

MINIMUM INSULATION

 

GENERATOR RATED VOLTS

 

RESISTANCE

=

__________________________

+1

1000

(in “Megohms”)

 

 

 

 

 

The MINIMUM acceptable megger reading for Stators may be calculated using the following formula:

EXAMPLE: Generator is rated at 120 volts AC. Divide “120” by “1000” to obtain “0.12”. Then add “1” to obtain “1.12” megohms. Minimum Insulation resistance for a 120 VAC Stator Is 1.12 megohms.

If the Stator insulation resistance is less than the cal- culated minimum resistance, clean and dry the Stator. Then, repeat the test. If resistance is still low, replace the Stator.

Use the Megger to test for shorts between isolated windings as outlined “Stator Insulation Resistance”.

Also test between parallel windings. See “Test Between Parallel Windings” on this page.

TESTING ROTOR INSULATION:

Apply a voltage of 1000 volts across the Rotor pos- itive (+) slip ring (nearest the rotor bearing), and a clean frame ground (i.e. the Rotor Shaft). DO NOT EXCEED 1000 VOLTS AND DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND. FOLLOW THE MEGGER MANUFACTURER’S INSTRUCTIONS CAREFULLY.

ROTOR MINIMUM INSULATION RESISTANCE:

1.5 megohms

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Electromagnetic Fields MagnetismElectromagnetic Induction 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 ComponentsCleaning the Generator Effects of Dirt and MoistureInsulation Resistance Testers Drying the GeneratorStator Insulation Resistance Testing Rotor Insulation Testing Stator InsulationTesting Rotor Insulation MegohmmeterMeters VOMMeasuring AC Voltage Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohm’s LawIntroduction Operational AnalysisCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Battery Recommended BatteryBattery Cables 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 YESProcedure Test 1 Check No-Load Voltage FrequencyTest 2 Check Stepper Motor Control 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 RingsSchematic Test 11 Check Main Circuit BreakerTest 12 Check Load Voltage Frequency Test 13 Check Load Watts AmperageTest 14 Try Cranking the Engine Test 15 Check Fuel PumpTest 18 Check Power Supply to Printed Circuit Board Test 17 Check Battery & CablesTest 16 Check 7.5 Amp Fuse 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 MotorPinion Checking the PinionTools for Starter Performance Test 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 Checking Flywheel Magnet Test 32 Check Valve AdjustmentFlywheel KEY 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

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