Generac Power Systems 5415, 5412, 5411, 5413, 5414, 5410 manual Circuit Condition Cranking

Page 21

Section 5

ENGINE DC CONTROL SYSTEM

CIRCUIT CONDITION – CRANKING:

When the START-STOP SWITCH (SW1) or REMOTE PANEL START SWITCH is momentarily held in the “START” position and then released, Wire 17 from the Printed Circuit Board (PCB ) is connected to frame Ground. PCB action will then deliver battery voltage to a STARTER CONTACTOR RELAY (SCR) via Wire 56, and to an auto- matic CHOKE SOLENOID (CS) via Wire 14.

When battery voltage energizes the STARTER CONTACTOR RELAY (SCR), it’s contacts close and battery output is delivered to the STARTER CONTACTOR (SC) via Wire 16. When the STARTER CONTACTOR (SC) energizes, it’s contacts close, and battery out- put is delivered to the STARTER MOTOR (SM) via Wire 16. The STARTER MOTOR energizes and the engine cranks.

When the STARTER CONTACTOR RELAY (SCR) closes, battery voltage is also delivered to PCB Pin 13 . This voltage is reduced for use as field boost and is output from PCB Pin 13 to the rotor. While cranking, the CHOKE SOLENOID (CS) is energized by grounding Wire 90 cyclically by PCB action (two seconds on, two seconds off).

Also while cranking, PCB action energizes Pin 5, and delivers battery voltage to the Wire 14 circuit. This energizes the FUEL PUMP (FP) via a Red wire, FUEL SOLENOID (FS) via Wire 241 and CHOKE HEATER (CH) via Wire 14. Battery voltage is also delivered to an optional light or hour meter in the Remote Panel, if equipped.

PCB action now holds open Wire 18A to common ground, and the Magneto will induce a spark during cranking.

+

-

J2

56

16

 

 

GOVERNOR

 

 

 

 

 

 

ACTUATOR

 

 

SCR

 

 

 

 

 

 

 

 

 

 

 

CONTROL

 

 

 

 

 

 

PRINTED CIRCUIT BOARD

 

 

 

 

 

 

56

0

13

16

HTO

LOP

 

 

 

 

 

 

IM1

FS

FP

 

 

 

 

SP1

 

J1

 

 

 

 

 

 

 

 

 

 

1

2

3

4

5

6

7

8

9

10

11

12

13

14

 

 

 

 

 

 

 

 

 

IM2

 

 

 

17

 

14

 

85

 

56

 

0

 

4

 

 

 

 

 

 

 

 

 

SP2

 

 

 

18

 

15

 

86

 

712

 

90

 

 

 

18A

 

 

 

 

0

85

0

86

 

18A 0

241 BLK

RED

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

56

 

 

LED

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

712

 

 

712

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

18

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

17

 

 

 

18

 

 

 

14

CS

90

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

START 17

STOP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PRIME

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

14

 

 

712

 

 

 

 

 

 

 

 

 

SW1

0

 

CH

14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

13

16

0

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

0

0

 

 

 

0

0

0

SC

16

16

 

RED

13

 

 

 

 

 

 

15

 

 

 

 

 

 

 

 

REMOTE

 

F1

 

 

 

 

 

 

 

 

 

SC

 

PANEL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BATTERY

 

CONNECTOR

 

 

 

13

 

 

 

 

 

 

 

 

A

0

 

 

 

0

 

 

0

0

 

 

12V

 

H

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SM

 

B

18

 

 

 

18

 

 

 

 

 

 

 

 

G

 

 

 

 

 

 

 

 

 

 

 

712

C

17

 

 

 

17

 

 

 

 

 

 

 

F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

14

E

D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BLACK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

712

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WHITE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GREEN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11S

 

 

11S

11S

 

 

 

 

 

 

 

 

 

 

22S

 

 

22S

22S

 

 

 

 

 

44

 

 

 

 

 

 

 

4

4

+

 

 

 

 

22

 

 

 

 

 

 

0

0

0

-

 

 

 

 

 

 

 

 

 

 

 

 

6

6

 

 

 

 

 

 

 

 

 

CB1

 

 

 

2

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

44

 

 

CB2

 

 

 

 

 

 

 

VOLTAGE

 

 

CUSTOMER

22

 

 

 

 

 

 

 

 

 

REGULATOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AC CONNECTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NEUTRAL CONNECTION

 

 

 

 

11 11S

22S 22

44

33

6

2

4

0

 

 

BY CUSTOMER

 

 

 

 

 

 

WHITE

GREEN RED

 

BLACK

 

POWER WINDINGS

 

DPE WINDING

 

FIELD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BA

 

 

 

LEGEND

 

BA - BRUSH ASSEMBLY

IM2 - IGNITION MODULE, CYL. 2

CB 1 / CB 2 - SEE CHART

IMS - IGNITION MODULE STUD

CH - CHOKE HEATER

LED - ALARM INDICATOR

CS - CHOKE SOLENOID

LOP - LOW OIL PRESSURE SWITCH

F1 - FUSE, 7.5A

SC - STARTER CONTACTOR

FP - FUEL PUMP

SCR - STARTER CONTACTOR RELAY

FS - FUEL SOLENOID

SM - STARTER MOTOR

GRD1 - CONTROL PANEL GROUND

SP1 - SPARK PLUG, CYL. 1

GRD2 - UNIT GROUND STUD

SP2 - SPARK PLUG, CYL. 2

HTO - HIGH OIL TEMPERATURE SWITCH

SW1 - PRIME/START-RUN-OFF SWITCH

IM1 - IGNITION MODULE, CYL. 1

TB - TERMINAL BLOCK, 4 TAB

= 12 VOLTS DC

 

= AC VOLTAGE

 

= ALARM CONTROL (PCB)

 

= GROUND

 

= DC CONTROL VOLTAGE (PCB)

 

= GROUND CONTROL (PCB)

= SHUTDOWN CONTROL (PCB)

 

= FIELD BOOST

 

 

 

= VOLTAGE REGULATOR

 

 

DC OUTPUT

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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 IdentificationEffects of Dirt and Moisture Cleaning the GeneratorInsulation Resistance Testers Drying the GeneratorStator Insulation Resistance Testing Stator Insulation Testing Rotor InsulationTesting Rotor Insulation MegohmmeterVOM MetersMeasuring AC Voltage Measuring DC VoltageMeasuring Resistance Measuring CurrentOhm’s Law Electrical UnitsOperational Analysis IntroductionCircuit Condition Cranking Circuit Condition Running Circuit Condition Shutdown Recommended Battery BatteryBattery Cables Printed Circuit BoardAmp 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 BlowingTest 1 Check No-Load Voltage Frequency ProcedureTest 2 Check Stepper Motor Control DiscussionTest 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 11 Check Main Circuit Breaker SchematicTest 12 Check Load Voltage Frequency Test 13 Check Load Watts AmperageTest 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.
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