FAULT FIN D I N G GUI D E

BRU S H L E S S CAPA C IT O R TYPE ALTER N A T O R S

BEF O R E PRO C E E D I N G , IT IS IM P O R T A N T TO RE M E M B E R THAT CHEC K S AN D FAULT FIN D I N G SH O U L D ONL Y BE CAR R I E D OUT BY A CO M P E T E N T TRAI N E D ENGI N E E R, USI N G THE COR R E C T TOOL S AN D EQUIP M E N T .

NO VOLTA G E OUTPUT.
1) The voltage output of a brushless capacitor type alternator is dependant on the rotational speed of the engine. For a 50HZ generator this should be as follows; o! load; Full!load; "100 ! "150 rp# $ 51.5 ! 5%.5 h& ). o#inally "000 rp# $ 50h&).

'efore co##encing chec(s it is i#portant to verify that the engine rp# is correct. %) )hec( that circuit brea(ers have not tripped and that they are in wor(ing order. ") The alternator control bo* lid and non! drive end covers should now be re#oved+ allowing a visual inspection to be carried out. )hec( that all connections within the control bo* are secure+ and that there are no bro(en wires etc. ,a(e a visual chec( of the alternator windings for signs of burning. The discovery of a bro(en wire or burnt out winding at this stage+ can save a lot of ti#e and effort .) )hec( capacitor and if unserviceable+ replace with one of the sa#e voltage and #icro farad value. ote; dis! charge used capacitor by shorting ter#inals before handling. 5) Try to re!e*cite generator by applying a 1%vdc e*ternal supply $battery) across the capacitor ter#inals $with capacitor connected) for a few seconds. This should be done with the generator running at no#inal speed with no! load applied. /) )hec( continuity and value of alternator stator windings in accordance with #anufacturer0s data; a) )hec( continuity 1 resistance of au*iliary $capacitor) winding with capacitor disconnected. b) )hec( continuity 1 resistance of #ain stator winding. 2esistance of two halves of #ain winding should be e3ual to within 0.5 oh#. )ontinued.......

c) )hec( for a brea(down in winding insulation by carrying out following resistance tests; )hec( au*iliary winding to earth )hec( #ain winding halves to earth )hec( between both halves of #ain winding and au*iliary winding. 4deally+ insulation chec(s should be #ade with a high voltage tester $#eggar) at 500 volts. 5ll insulation resistance readings should be greater than 1 #ega oh#.

LOW VOLTA G E OUTP UT.

1) )hec( and verify correct rotational speed. %) )hec( and verify that generator is not being overloaded. 6verload 7 lower engine rp# 7 low voltage. ") )hec( that alternator shaft securing stud is tight and that rotor is not slipping on engine taper. .) )hec( rotating diodes for open or short circuit. This is done by un! soldering one end of the diode and chec(ing with an oh# #eter or diode tester for continuity in one direction only $refer to #anufacturer0s handboo(). ote; 4f a defective diode is found+ it is advisable to replace both co#ponents. 8hen replacing a diode ensure that it in inserted in the correct polarity. 5) 8ith diodes disconnected+ chec( rotor winding for continuity and resistance. 2efer to #anufacturer0s data for resistance values. /) 9ow voltage can also be caused if a capacitor of low #icro! farad value has been fitted.

UN ST A B L E VOLTA G E OUTP UT .
1) )hec( for constant engine speed. 5s we (now+ the voltage is dependant on rp# ! unstable or fluctuating rp# 7 unstable 1 fluctuating voltage output. %) )hec( for loose or poor connections within generator control bo* ") )hec( for loose or bro(en rotor securing stud.

REME M B E R !
IF IN DO U BT CONT A CT STEP H I L L GENER AT O R S LTD FOR FURTHER INF O R M A T I O N .