Your last generator Maintenance Run

[buickanddeere]

Operational temperatures for electric motors and generators

 

[RoyKing]

Most I'd plates on the Gen will quote an output at 20C and 40C. At 20C is the 100% duty cycle, the 40C is the max and is NOT 100% duty cycle. Most gas 3600 rpm gensets will run too hot, most contractors who run them a lot keep a box Fan on them for more cooling. If you can't keep your hand on it, it is too hot.

 

[buickanddeere]

Most I'd plates on the Gen will quote an output at 20C and 40C. At 20C is the 100% duty cycle, the 40C is the max and is NOT 100% duty cycle. Most gas 3600 rpm gensets will run too hot, most contractors who run them a lot keep a box Fan on them for more cooling. If you can't keep your hand on it, it is too hot.

I agree 100% . I’ve been trying to get people here to understand that a consumer grade generator should never be operated
Continuous at over 80% amperage .
Have to have the layman use amperage as they are unfamiliar with watts and volt amps .
The typical purchase is someone who adds up 3900watts in load and purchases a 4000W generator . Then they are baffled why the generator trips it’s breaker , motors won’t start and something somewhere burns out.

 

[Industrial Toys]

The only thing that matters is how many extension cords and powerbars they have available and how long the outage for them to employ them ALL! lol

As long as the thing is still running, all MUST be well.

 

[daugen]

4 inches of rain last night softened up the earth and 40mph gusts headed in shortly.
One friend had tree across road, had to walk a ways to get home last night. I expect a lot of pine trees down
and then the power goes out. Surprised it didn't quit last night.

After five years of sitting in hottest afternoon soon, the decals on my Generac 22kw are peeling off.
Otherwise case is in good condition, a little bleached but fine. Gen operation has been flawless. Mine goes through automatic cycle
Sat afternoons around 1pm, runs so quietly sometimes I don't know it's running.

These talks of temps are interesting, I'd like to IR gun my gen at the end of the maint. run, see if it actually gets hot enough after a short run at reduced rpms with no load.
My power goes out here at least once a month, so unit gets run under load plenty often. I'm in a humid area so I really want that moisture burned out when run.

 

[RjCorazza]

My Generac exl7000 just failed after 18 years
Having done monthly exercise at close to 50% load religiously, regular oil changes, and sheltered from weather, I am disappointed. It's putting out 170v on the 120v outlets and 340v on the 240v plug. Took out several surge protectors and an HVAC transformer.

I agree with the high load / low duty cycle comments about non commercial generators, which is why I got the 7k. Replaced with a Winco 15kw PTO generator, which now powers one complete panel.

 

[daugen]

My Generac exl7000 just failed after 18 years
Having done monthly exercise at close to 50% load religiously, regular oil changes, and sheltered from weather, I am disappointed. It's putting out 170v on the 120v outlets and 340v on the 240v plug. Took out several surge protectors and an HVAC transformer.

I agree with the high load / low duty cycle comments about non commercial fenders, which is why I got the 7k. Replaced with a Winco 15kw PTO generator, which now powers one complete panel.

you always hope it will be like a doctor, at least do no harm...

electronic components failed I assume, not motor. The part that doesn't seem to require maintenance.

 

[aczlan]

My Generac exl7000 just failed after 18 years
Having done monthly exercise at close to 50% load religiously, regular oil changes, and sheltered from weather, I am disappointed. It's putting out 170v on the 120v outlets and 340v on the 240v plug. Took out several surge protectors and an HVAC transformer.

I agree with the high load / low duty cycle comments about non commercial generators, which is why I got the 7k. Replaced with a Winco 15kw PTO generator, which now powers one complete panel.

Sounds like the voltage regulator has failed.

Aaron Z

 

[RjCorazza]

Sounds like the voltage regulator has failed.

Aaron Z

Alas, no. That was my first thought and replacing it did not change anything. I didn't check the frequency, but the engine is running at the same speed it has always run at over the past 18 years. I should probably check the frequency though.

 

[Chilliwack Murray]

Check for voltage at the AVR sensing terminals if it has separate power supply and sensing inputs. Sounds like the regulator is not seeing output voltage and trying to compensate.

 

[aczlan]

Check for voltage at the AVR sensing terminals if it has separate power supply and sensing inputs. Sounds like the regulator is not seeing output voltage and trying to compensate.

I agree, if it's not the AVR, it's probably the sensing input to the AVR.

Aaron Z

 

[Blaszer]

On Sunday, I was out with my brother and dad building the new greenhouse. At around 10 the generator started for its weekly run. Normally it is a smooth instant start, but this time is turned over for several seconds and wouldn't hold a smooth rpm for another 10 or so seconds. Went to check it out, and noticed the temp gauge wasn't even registering (<100F). Turns out, after 10 years, the coolant heater must have died (shorted) in the last week sometime (popped the GFCI). Ordered a new HotStart 1000W 120-140F and installed yesterday. Working like a charm after fixing a few leaks from the dry rotted hoses.

 

[RjCorazza]

Check for voltage at the AVR sensing terminals if it has separate power supply and sensing inputs. Sounds like the regulator is not seeing output voltage and trying to compensate.

Thank you both (Aaron Z) for the info.
This is probably out of my league, but in the diagram below do I check for voltage on #2 and #6 wires?
Of note, I did find a bad crimp on one of those wires where it connects to the regulator. The connector was repaired though.
I

 

[aczlan]

Thank you both (Aaron Z) for the info.
This is probably out of my league, but in the diagram below do I check for voltage on #2 and #6 wires?
Of note, I did find a bad crimp on one of those wires where it connects to the regulator. The connector was repaired though.
IView attachment 640546

Yes, check 2&6. I would also check 1&4.
As I read the schematic, 2&6 are the sensing input to the AVR to tell it how many volts it's putting out.
1&4 are the AVR output to feed into the rotor (via the brushes) and control the voltage of the field that 2&6 are driven off of.

Aaron Z

 

[Industrial Toys]

The various generator stories told, is why I opt to not have my generators run automatically, even though they could. I like to start them, listen to them and make sure there isn't a mouse nest in there or something. If they don't start, I was there and have a much better idea what happened, rather than just a diagnostic light or message. Trouble always comes out of nowhere it seems.

 

[Chilliwack Murray]

You should always be there to monitor the unit even if it’s an auto exercise. You will be able to track changes in starting, noises, instability and fix the root cause before it progresses to the point of failure and possible other damage.

I’ve spent over 20 years trying to convince people of this. Nobody thinks it important until it doesn’t work and they are on the 30th floor with no power to take the elevator to P3 where the generator is buried.

 

[buickanddeere]

My Generac exl7000 just failed after 18 years
Having done monthly exercise at close to 50% load religiously, regular oil changes, and sheltered from weather, I am disappointed. It's putting out 170v on the 120v outlets and 340v on the 240v plug. Took out several surge protectors and an HVAC transformer.

I agree with the high load / low duty cycle comments about non commercial generators, which is why I got the 7k. Replaced with a Winco 15kw PTO generator, which now powers one complete panel.

Simple swap out of the failed AVR and check the wiring to the AVR.

 

[buickanddeere]

On Sunday, I was out with my brother and dad building the new greenhouse. At around 10 the generator started for its weekly run. Normally it is a smooth instant start, but this time is turned over for several seconds and wouldn't hold a smooth rpm for another 10 or so seconds. Went to check it out, and noticed the temp gauge wasn't even registering (<100F). Turns out, after 10 years, the coolant heater must have died (shorted) in the last week sometime (popped the GFCI). Ordered a new HotStart 1000W 120-140F and installed yesterday. Working like a charm after fixing a few leaks from the dry rotted hoses.

Good Catch

 

[Industrial Toys]

Sometimes I am made aware of something, by sound, like dropping something, without knowing, and I realize how disadvantaged a person wih impaired hearing would be. Or you hear a retaining clip land on the far side of the shop AND have a good idea where to look.

 

[3930dave]

On Sunday, I was out with my brother and dad building the new greenhouse. At around 10 the generator started for its weekly run. Normally it is a smooth instant start, but this time is turned over for several seconds and wouldn't hold a smooth rpm for another 10 or so seconds. Went to check it out, and noticed the temp gauge wasn't even registering (<100F). Turns out, after 10 years, the coolant heater must have died (shorted) in the last week sometime (popped the GFCI). Ordered a new HotStart 1000W 120-140F and installed yesterday. Working like a charm after fixing a few leaks from the dry rotted hoses.

The more Training done in Peace...... :thumbsup:

Not familiar with your particular dzl, but at what I'd expect for "cold" your way, 10 seconds seems a bit long...... filters done lately ?

Rgds, D.