Generac Power Systems 65, 55, 75 manual Field Boost, Generator AC Connection System

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Section 1

GENERATOR FUNDAMENTALS

FIELD BOOST

When the engine is cranked during startup, the engine's starter contactor is energized closed. Battery current is then delivered to the starter motor and the engine cranks.

Closure of the starter contactor contacts also delivers battery voltage to Pin 13 of an Engine Controller cir- cuit board. The battery current flows through a 47 ohm, 2 watt resistor and a field boost diode, then to the Rotor via brushes and slip rings. This is called “Field Boost” current.

Field boost current is delivered to the Rotor only while the engine is cranking. The effect is to “flash the field” every time the engine is cranked. Field boost current helps ensure that sufficient “pickup” voltage is avail- able on every startup to turn the Voltage Regulator on and build AC output voltage.

NOTE: Loss of the Field Boost function may or may not result in loss of AC power winding out- put. If Rotor residual magnetism alone is suffi- cient to turn the Regulator on loss of Field Boost may go unnoticed. However, If residual magnet- ism alone Is not enough to turn the Regulator on, loss of the Field Boost function will result In loss of AC power winding output to the load. The AC output voltage will then drop to a value commen- surate with the Rotor's residual magnetism (about 7-12 VAC).

GENERATOR AC CONNECTION SYSTEM

These air-cooled generator sets are equipped with dual stator AC power windings. These two stator wind- ings supply electrical power to customer electrical loads by means of a dual 2-wire connection system.

You can use your generator set to supply electrical power for operating one of the following electrical loads:

QUIETPACT 55G & LP: 120 and/or 240 volts, sin- gle phase, 60 Hz electrical loads. These loads can require up to 5500 watts (5.5 kW) of total power, but cannot exceed 45.8 AC amperes of current at 120 volts or exceed 22.9 AC amperes at 240 volts.

QUIETPACT 65G & LP: 120 and/or 240 volts, sin- gle phase, 60 Hz electrical loads. These loads can require up to 6500 watts (6.5 kW) of total power, but cannot exceed 54.1 AC amperes of current at 120 volts or exceed 27 AC amperes at 240 volts.

QUIETPACT 75G & LP: 120 and/or 240 volts, sin- gle phase, 60 Hz electrical loads. These loads can require up to 7500 watts (7.5 kW) of total power, but cannot exceed 62.5 AC amperes of current at 120 volts or exceed 31.2 AC amperes at 240 volts.

CAUTION! Do not overload the generator. Some installations may require that electrical loads be alternated to avoid overloading. Applying exces- sively high electrical loads may damage the gen- erator and may shorten its life. Add up the rated watts of all electrical lighting, appliance, tool and motor loads the generator will power at one time. This total should not be greater than the wattage capacity of the generator. If an electrical device nameplate gives only volts and amps, multiply volts times amps to obtain watts (volts x amps = watts). Some electric motors require more watts of power (or amps of current) for starting than for continuous operation.

Generators may be installed to provide the following outputs:

1.120 VAC loads only — one load with a maximum total wattage requirement equal to the generator’s rated power output (in watts), and 120V across the generator output terminals. Figure 1.8, page 7, shows the generator lead wire connections for 120VAC ONLY.

2.120/240 VAC loads — one load with a maximum total wattage requirement equal to the generator’s rated power output, and 240V across the generator output terminals; or two separate loads, each with a maximum total wattage requirement equal to half of the generator’s rated power output (in watts), and 120V across the generator output terminals. Figure 1.9 on page 7, shows the generator lead wire connections for 120/240 VAC loads.

LINE BREAKERS (120 VOLTS ONLY):

Protects generator’s AC output circuit against overload, i.e., prevents unit from exceeding wattage/amperage capacity. The circuit breaker rat- ings are as follows:

 

Model

Circuit Breaker 1

Circuit Breaker 2

 

 

QuietPact 55

30A

20A

 

 

QuietPact 65

30A

30A

 

 

QuietPact 75

35A

35A

 

 

 

 

 

 

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Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents Section Specifications & Charts Section Exploded Views / Part NumbersElectromagnetic Induction MagnetismElectromagnetic Fields Simple AC Generator More Sophisticated AC GeneratorGenerator Operating Diagram Line Breakers 120 Volts only Field BoostGenerator AC Connection System Connection for 120 Volts Only Reconnection for Dual Voltage OutputRotor Assembly Stator AssemblyBattery Charge Components Brush HolderExcitation Circuit Components GeneralAdjustment Procedure Crankcase BreatherVoltage Regulator DescriptionInstall Breather Install oil vapor collector and retainerControl Panel Component Identification Check BreatherCleaning the Generator Effects of Dirt and MoistureInsulation Resistance Testers Drying the GeneratorBrushing and Vacuum Cleaning Stator Insulation ResistanceCloth or Compressed AIR Stator SHORT-TO-GROUND TestsTesting Rotor Insulation Testing Stator InsulationTesting Rotor Insulation MegohmmeterMeters VOMMeasuring AC Voltage Measuring DC VoltageMeasuring Resistance Measuring AC FrequencyMeasuring Current Electrical Units Ohms LAWAmpere VoltCircuit CONDITION- Rest IntroductionOperational Analysis Circuit CONDITION- Priming Circuit CONDITION- Cranking Circuit CONDITION-RUNNING Choke Heater CHCircuit CONDITION- Shutdown Circuit CONDITION- Fault Shutdown Sure Switch LOPBattery Recommended BatteryBattery Cables Engine Controller Circuit BoardAMP Fuse Fuel Primer SwitchSTART-STOP Switch Starter Contactor Relay Starter Motor Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Troubleshooting Flowcharts Procedure Test 1- Check NO-LOAD Voltage FrequencyTest 2- Check Engine Governor DiscussionGovernor Adjustment Test 3- Test Excitation Circuit BreakerTest 4- Fixed Excitation TEST/ROTOR AMP Draw If continuity was indicated, go to TestTest 5- Wire Continuity Re-connect Wire 11 and Wire 22 to the Voltage RegulatorSet the VOM to measure AC voltage Set a VOM to its Rx1 scaleIf field boost checks good, replace the Voltage Regulator Test 6- Check Field BoostTest 7 Test Stator DPE Winding Test 8- Check Sensing Leads / Power Windings Across Wires Ohms11S 22S Model OhmsTest 9- Check Brush Leads Test 10 Check Brushes & Slip RingsTest 11- Check Rotor Assembly Tance Tests ProcedureTest 12 Check Main Circuit Breaker Replace the Rotor if it fails the testTest 15 Check Battery Charge Output Test 16 Check Battery Charge RectifierBattery Charge Rectifier BCR is a full wave rectifier Test 13- Check Load Voltage Frequency10. Battery Charge Rectifier Short to GroundTest 19- Test Primer Switch Set a VOM to read battery voltage 12 VDCAlso see Fuel Primer Switch, Test 18 TRY Cranking the EngineTest 20- Check Fuel Pump 13. The LPG Fuel Solenoid FSTest 21- Check 7.5 AMP Fuse Test 22- Check Battery & CablesTest 23- Check Power Supply to Circuit Board Test 24 Check START-STOP Switch 17. Start-Stop SwitchTest 26- Check Starter Contactor Relay Set a VOM to measure DC voltage 12 VDCConditions Affecting Starter Motor Performance Test 26A Check Starter ContactorTest 27 Check Starter Motor Checking the Pinion Tools for Starter Performance TestMeasuring Current TachometerTesting Starter Motor Test 28- Check Fuel SupplyTest Bracket Remove Starter Motor28 LP Gas Carburetion Diagram Discussion LPG ModelsTest 29 Check Wire 14 Power Supply Test 30 Check WireBattery voltage is not measured, proceed to Step Crank the engine. The meter should indicate battery voltageTest 31 Check Fuel Solenoid Gasoline Models Test 32 Check Ignition SparkCylinder Balance Test Conclusion No cylinder is weakest of the two cylindersTest 34 Check and Adjust Ignition Magnetos Test 33 Check Spark Plugs37. Setting Ignition Magneto Armature Air Gap Test 35 Check Valve Adjustment Adjusting Valve ClearanceChecking Flywheel Magnet Flywheel KEYTest 37 Check Choke Solenoid Install Rocker ARM CoverTest 36 Check Carburetion 43. Connector Adjust the regulated pressure on the gauge to 80 psi Down Test / Compression TestRepeat Steps 1 through 8 on remaining cylinder Check CompressionIf all steps check GOOD, go to Test Test 39 Check OIL Pressure SwitchTest 40 Test OIL Temperature Switch Short to Ground Test 41 Test Choke HeaterTest 42 Check LPG Fuel Solenoid 49. Fuel Solenoid Major Disassembly ENCLOSURE/PANEL RemovalStator Removal Rotor RemovalStarter Removal Belt TensioningEngine Removal FLYWHEEL/MAGNETO Removal Page Section Exploded Views / Part Numbers Part NO. QTY Description Enclosure Drawing No E1011-B QTY Description Sheet Metal Drawing No E1012-E QTY Description Flywheel Assy GT-990Control Panel Drawing No E1013-A Wire ASM GRD STD Conn Switch Spdt ON-MOM-ONSwitch 6A Spdt Not Shown PANEL, TOP ControlTwin Engine Drawing No E1014-B ASSEMBLY, Crankcase RV ASSEMBLY, BreatherASSEMBLY, Head #1 ASSEMBLY, OIL Fill CAPLP Regulator Drawing No E1530 CASTING, Twin Regulator Housing Washer Flat M4SOLENOID, Twin Regulator SPRING-SOLENOID PlungerSpecifications & Charts Generator Specifications Nominal Resistances of Generator Windings AT 68FEngine Speeds and Voltage Specifications Page Electrical Data Electrical Data PO BOX 297 WHITEWATER, WI

65, 75, 55 specifications

Generac Power Systems has established itself as a leader in power generation, offering a range of high-performance generators suited for residential and commercial applications. Among its lineup, the Generac 55, 65, and 75 kW generators stand out for their reliability, efficiency, and advanced features.

The Generac 55 kW generator is designed to provide a powerful backup solution for medium to large homes or small businesses. It features a robust engine that delivers dependable performance while maintaining fuel efficiency. One of its key characteristics is the True Power Technology, which produces clean and stable power, ensuring that sensitive electronic devices run smoothly without risk of damage. This generator is equipped with a fully automatic transfer switch, allowing for seamless power transition during outages, with minimal disruption.

Moving to the 65 kW model, it offers increased capacity while retaining the fundamental qualities of the 55 kW version. This unit is particularly suited for larger homes or commercial applications that require greater power demands. The 65 kW generator utilizes Generac’s G-Force engine, known for its durability and reduced maintenance needs. Advanced features such as remote monitoring capabilities allow users to check the generator's status from anywhere, providing peace of mind and convenience.

The 75 kW generator takes performance to the next level, making it ideal for even more significant power needs. It is engineered for both quiet operation and enhanced performance, accommodating a wide range of requirements from residential to larger commercial operations. The 75 kW model includes a full-load voltage regulation system that maintains stable power output under varying loads, safeguarding appliances and equipment.

All three models incorporate advanced air-cooled technology, which enhances their efficiency and operational lifespan. Additionally, their corrosion-resistant enclosures ensure durability even in harsh weather conditions, making them suitable for diverse environments. The intuitive LCD display on each unit provides critical information, including runtime hours and maintenance reminders, empowering users with easy access to the generator's performance data.

Overall, Generac Power Systems' 55, 65, and 75 kW generators represent a commitment to quality, reliability, and innovation in backup power solutions. They are designed to meet the demands of modern power consumption while ensuring peace of mind through robust engineering and advanced technology. Whether for home use or commercial applications, these generators provide an effective means to stay prepared for unexpected power outages.