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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Generac Power Systems 5410, 5412, 5411, 5413, 5415, 5414 manual Test 5 Check Field Boost, Test 6 Test Stator DPE Winding
Page 40 Page 42

5410, 5414, 5415, 5413, 5411 specifications

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