Generac Power Systems 5410, 5412, 5411 Test 5 Check Field Boost, Test 6 Test Stator DPE Winding

Page 41

Section 7

DIAGNOSTIC TESTS

1.11 Amp

VOLTAGE

REGULATOR

 

 

2

 

BLACK TEST LEAD

6

 

 

0

13

13

 

15

RED TEST LEAD

22S

 

11S

FUSE HOLDER (F1)

4

WIRES 4 REMOVED FROM

 

 

4VOLTAGE REGULATOR

Figure 7-6. – Fixed Excitation Test, Step D

7.Re-connect Wire 11S and Wire 22S to the Voltage Regulator.

8.Remove the jumper wire between Wire 4 and 12 volt supply.

9.Set the VOM to measure DC amps.

10.Connect one meter test lead to the 12 volt fused battery supply Wire 15, and connect the other meter test lead to Wire 4 (should still be discon- nected from the VR). See Figure 7-6.

11.Start the generator. Measure the DC current. Record the rotor amp draw.

12.Stop the generator. Re-connect Wire 4 to the Voltage Regulator.

Results:

 

AC Voltage across Wires 2 and 6 =

__________

AC Voltage across Wires 11S and 22S =_ _________

Proceed to “TEST 4 RESULTS” (top of page 40). Match all results to corresponding column in the chart. The column letter refers to the Problem 4 flow charts on pages 28 and 29.

Test 5 – Check Field Boost

DISCUSSION:

Field boost current is delivered to the Rotor only while the engine is being cranked. This current helps ensure that adequate “pickup” voltage is available to turn the Voltage Regulator on and build AC output voltage.

Loss of the field boost function may or may not result in a problem with AC output voltage. If the Rotor’s residual magnetism is sufficient to turn the Regulator on, loss of the function may go unnoticed. However, if the Rotor’s residual magnetism is not enough to turn the Regulator on, loss of field boost can result in fail- ure of the unit to generate an output voltage.

PROCEDURE:

1.Set VOM to measure DC voltage.

2.Disconnect Wire 4 from the Voltage Regulator and connect the positive (+) test lead to it. Connect the negative (-) test lead to a clean frame ground.

3.Set the Start-Stop Switch to “Start.” During cranking only, measure DC voltage. It should read 3-5 VDC. Reconnect Wire 4 to the Voltage Regulator.

Results:

1.If field boost checks good, replace the Voltage Regulator.

2.If voltage is not measured, replace the PCB.

11S 11S

22S 22S

4 4

0 0

6 6

2 2

VOLTAGE

REGULATOR

4

0

FIELD

BA

Figure 7-7. – The Field Boost Circuit

Test 6 – Test Stator DPE Winding

DISCUSSION:

An open circuit in the Stator excitation windings will result in a loss of unregulated excitation current to the Voltage Regulator. The flow of regulated excitation cur- rent to the Rotor will then terminate and the unit’s AC output voltage will drop to a value that is commensurate with the rotor’s residual magnetism (about 5 - 12 VAC).

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Electromagnetic Induction MagnetismElectromagnetic Fields 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 16 Check 7.5 Amp Fuse Test 17 Check Battery & CablesTest 18 Check Power Supply to Printed Circuit Board 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 ContactorTools for Starter Performance Test Checking the PinionPinion 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 Flywheel KEY Test 32 Check Valve AdjustmentChecking Flywheel Magnet 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

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