JonEQuest
Last year my internal battery charger went out in my 16kw air cooled 2007 Generac. I disconnected it internally and installed a nice battery charger/tender in its place. To power the charger I added an outdoor outlet by grabbing power from an outlet in my kitchen and running some wire right through the wall to the outside of my house. The last couple of time power went out I have had a couple of weird problems. One time the generator started but put out no power. I was not home but had my wife reset the 65amp breaker and that was it. This time (2 weeks later) my house lost power and my generator started right up and powered the house but during the 45 minutes it ran it hiccupped a couple times and power in at least one room blinked. after one hiccup the power was out. The main breaker was on but I flipped it off and back on and power was back on again. I just never had any issues until lately and wonder if there is an AC feedback issue with me using house power to power the battery charger that in turn comes back from the generator while it is running?
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78buckshot
Give us a few details about the original charger, was it a separate black plastic brick or was it the potted square with aluminum heat sink. Either one is powered from ac produced by the generator while it is in emergency mode although the potted one gets its power from a step down transformer. I don't think your issue stems from the charger, my first thought is an overloaded or possible short in one of your house circuits or a heavy load starting and tripping the breaker. Can you describe the "hiccup"?
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Peddler
Main generator Breaker could be failing or you have dirty slip rings and it is taking high amperage to drive the dc to the rotor and the DPE breaker is opening. I don't think it is the battery charger at all.
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JonEQuest
My model# is 0052430 and my serial # is 4452856.

I had the potted square on the inside. Mine is the 2007 model and I had to change the main control board to make it work with my newer load shed transfer switch. I am thinking of changing the main breaker since I am suspecting it may be just getting old and worn. It doesn't actually trip or feel soft but it could still be a bad breaker I guess.
How do I check the slip rings for dirt? Hopefully it is not too deep inside. I have no fear of taking things apart but it is 95 degrees lately with a heat index over 100.
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Peddler
The brushes are in the end of the generator opposite the engine. The easiest way to test them would be to pull the #4 wire off the voltage regulator and ohm it to ground. If it is in the 30+ ohms range they need to be cleaned. It takes about an hour to disassemble, remove/clean the brushes and slip rings and then reassemble. The model generator you have will run even if there is no Ac output so you need to check for AC on both sides of the breaker to be sure but I do see these not allow power across one leg from time to time.
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