Generac Power Systems 5411, 5412, 5413, 5415, 5414, 5410 manual Generator Operating Diagram

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Section 1

GENERATOR FUNDAMENTALS

Figure 1-7. – Generator Operating Diagram

NOTE: AC output frequency at 3720 rpm will be about 60 Hertz. The “No-Load” is set slightly high to prevent excessive rpm, frequency and voltage droop under heavy electrical loading.

Generator operation may be described briefly as fol- lows:

1.Some “residual” magnetism is normally present in the Rotor and is sufficient to induce approximately 7 to 12 volts AC Into the STATOR’s AC power windings.

2.During startup, a Printed Circuit Board (PCB) delivers battery voltage to the ROTOR, via the brushes and slip rings.

a.The battery voltage is called “Field Boost”.

b.Flow of direct current through the ROTOR increases the strength of the magnetic field above that of “residual” magnetism alone.

3.“Residual” plus “Field Boost” magnetism induces a voltage into the Stator excitation (DPE) and AC Power windings.

4.Excitation winding unregulated AC output is deliv- ered to an electronic voltage regulator, via an excitation circuit breaker.

a.A “Reference” voltage has been preset into the Voltage Regulator.

b.An “Actual” (“sensing”) voltage is delivered to the Voltage Regulator via sensing leads from the Stator AC power windings.

c.The Regulator “compares” the actual (sens- ing) voltage to its pre-set reference voltage.

(1)If the actual (sensing) voltage is great- er than the pre-set reference voltage, the Regulator will decrease the regulated current flow to the Rotor.

(2)If the actual (sensing) voltage is less than the pre-set reference voltage, the Regulator will increase the regulated current flow to the Rotor.

(3)In the manner described, the Regulator maintains an actual (sensing) voltage that is equal to the pre-set reference voltage.

NOTE: The Voltage Regulator also changes the Stator excitation windings alternating current (AC) output to direct current (DC).

5.When an electrical load is connected across the Stator power windings, the circuit is completed and an electrical current will flow.

6.The Rotor’s magnetic field also induces a voltage into the Stator battery charge windings.

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Contents Diagnostic Repair Manual Safety Table of Contents Section Electrical Data 78-79 Electromagnetic Fields MagnetismElectromagnetic 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 18 Check Power Supply to Printed Circuit Board Test 17 Check Battery & CablesTest 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 ContactorPinion Checking the 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 Checking Flywheel Magnet Test 32 Check Valve AdjustmentFlywheel 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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