Generac Power Systems 5412, 5411, 5413 Printed Circuit Board, Battery, Circuit Board Connections

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Section 5

ENGINE DC CONTROL SYSTEM

Printed Circuit Board

GENERAL:

The Printed Circuit Board (PCB) mounted inside the generator control panel is responsible for crank- ing, startup, running and shutdown operations. The board interconnects with other components of the DC control system to turn them on and off at the proper times. It is powered by fused 12 VDC power from the unit battery.

CIRCUIT BOARD CONNECTIONS:

The circuit board mounts a 14-pin receptacle (J1) and a six pin terminal (J2, see Figure 5-2). Figure 5-1 shows the 14-pin receptacle (J1), the associated wires and the function(s) of each pin and wire.

PIN

WIRE

FUNCTION

 

 

 

1

N/A

NOT USED

 

 

 

2

18

To Start-Stop switch. When grounded

 

 

by setting Start-Stop switch to “STOP”

 

 

engine shuts down

 

 

 

3

17

To Start-Stop switch. When grounded by

 

 

setting the Start-Stop switch to “START”

 

 

the engine start cycle begins.

 

 

 

4

15

Delivers fused 12 VDC to PCB

 

 

 

5

14

PCB control. During cranking and running,

 

 

supplies 12 VDC to fuel pump, choke

 

 

solenoid, choke heater, fuel solenoid

 

 

 

6

86

Low Oil Pressure switch / Safety shut-

 

 

down

 

 

 

7

85

High Temperature switch / Safety shut-

 

 

down

 

 

 

8

712

PCB control/Alarm led

 

 

 

9

56

Delivers 12 VDC to Starter Contactor

 

 

(SC) (cranking only)

 

 

 

10

90

To Choke Solenoid. When grounded by

 

 

the PCB the choke operates at two sec-

 

 

onds ON , two second OFF intervals

 

 

(cranking only)

 

 

 

11

0

Common Ground

 

 

 

12

N/A

Not Used

 

 

 

13

4

Field Boost DC to the Voltage Regulator

 

 

and to the Rotor Winding

 

 

 

14

18A

Ground to Magneto for Shutdown

 

 

 

Figure 5-1. – Receptacle J1

CIRCUIT BOARD Dip Switches:

The circuit board mounts a pair of dip switches which are factory set in the “OFF” (down) position. These dip switches should remain in the factory setting.

J1 CONNECTOR

DIP SWITCH

 

 

 

1 2

1 2

 

SIX PIN

 

J2 CONNECTOR

 

 

 

DIP SWITCHES ARE FACTORY

 

SET IN THE “OFF” (DOWN) POSITION

Figure 5-2. – Printed Circuit Board

1

6

10

2

7

11

3

8

12

4

9

13

5

 

14

Figure 5-3. – J1 Connector, Harness End

Battery

RECOMMENDED BATTERY:

When anticipated ambient temperatures will be con- sistently above 32° F (0° C), use a 12 volts automotive type storage battery rated 70 amp-hours and capable of delivering at least 400 cold cranking amperes.

If ambient temperatures will be below 32° F (0° C), use a 12 volt battery rated 95 amp-hours and having a cold cranking capacity of 400 amperes.

BATTERY CABLES:

Use of battery cables that are too long or too small in diameter will result in excessive voltage drop. For best

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Magnetism Electromagnetic FieldsElectromagnetic 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 17 Check Battery & Cables Test 18 Check Power Supply to Printed Circuit BoardTest 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 MotorChecking the Pinion 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 Test 32 Check Valve Adjustment Checking Flywheel MagnetFlywheel 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

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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