16 Fault Finding

NEWAGE PRODUCT TRAINING
Lunch
Fault Finding - Basic machine and circuitry break
chaps?
SAFETY NOTICE !!
DANGER!
ELECTRIC SHOCK
[Live Terminals]
 The following tests should only be carried out by qualified and/or experienced
engineers who have received SAFETY TRAINING ON LIVE EQUIPMENT.
 All test instruments and their leads/connectors/ probes must be checked to ensure
that they are suitable for the voltage levels being tested, and are in good working
order.
 Never attempt to test a ‘LIVE’ generator without another competent person present
to shut down the engine or switchgear as necessary.
 Ensure that the work area is SAFE, other personnel in the area are advised of what
you are doing, warning notices and tapes are displayed to advise others of the
hazards.

Fault Finding - Basic machine and circuitry
AVR P2 -P3 -P4
output
A.C Power
D.C Into A.V.R
X+ (F1) & Sensing
Exciter 6-7-8 From
Stator XX- (F2)
Main Stator
Main Stator (2 or 3 Phase
Exciter sensing)
Rotor
& Stator
Bearing
Main Rotor
Shaft
PMG
Power
Supply Rectifier
To A.V.R Fan
(When Fitted).

A.V.R
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
 Fault finding can be simplified by breaking the generator down into three separate test
areas :-
 1. The windings, and main rectifier diode assembly
 2. The AVR and control circuit
 3. The Permanent magnet Generator ( PMG), when fitted.
FIRST CHECK THAT THE GENERATOR IS SAFE TO RUN, WITH AN INSULATION CHECK

Fault Finding - Testing the Main Stator Insulation
Connections shown in Series Star
EARTH
AVR Sensing W6
& Power supply N U6V6 Neutral
00
100
10 1
M
0.1
.01
from Main Stator 10
W5
6
W2 W W1
Test
V5
7
V2
V V1
3 Phase M  1KV
Output M 500V
U5
8
U2
U U1
EARTH MEGGER
FRAME
 1. Disconnect the AVR completely before carrying out this test.

 2. Disconnect any connections from Neutral to Earth.
 3. The Stator insulation should be checked with an Insulation tester.The test
instrument should be 500 or 1000 volts for low voltage Generators (up to 690V).
 4. For low voltage machines (up to 690V), the MINIMUM insulation value is 1.0 Meg-
Ohm to Earth (Ground). WINDINGS MUST BE DRIED OUT IF BELOW 1.0 MEG-OHM.

Fault Finding - Testing the Windings and Main rectifier
A.V.R
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
 TEST METHOD - Separately exciting the Generator with a 12V Battery

Output From
Battery into - +
Exciter Stator 12vA.V.R
BATTERY
Main Stator
Exciter
X+ XX- Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
 1. Stop the Generator Set and disable the Engine.

 2. Disconnect the AVR wiring.
 3. Replace the AVR with a 12 Volt battery
 4. Connect the battery to the Exciter Stator,(polarity must be correct).

Output From - +
Battery into 12vA.V.R
BATTERY
Exciter Stator
Main Stator
X+ XX- Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft

Rectifier
Fan
 1. Check all wiring is safe and secure before running Generator

 2. Start the Engine, and check that the speed is correct, (within 4% of nominal).
 3 Check the output voltage across the main stator terminals, with the Generator
running at NO LOAD.

 Connections shown in Series Star FLUKE 87
AVR Sensing W6
from Main Stator
W5 3 Phase
6 
W2 W W1
Output mV
mA
V5
7
V2
V V1 V
A
V
U5
8
U2
U U1 OFF
 1. Using a Multi-meter, CHECK ALL THREE PHASES.

 2. The voltage should be BALANCED PHASE TO PHASE , within 1% .

AVR Sensing W6
from Main Stator
W5 3 Phase
6 
W2 W W1
Output mV
mA
V5
7
V2
V V1 V
A
V
U5
8
U2
U U1 OFF


AVR Sensing W6
from Main Stator
W5 3 Phase
6 
W2 W W1
Output mV
mA
V5
7
V2
V V1 V
A
V
U5
8
U2
U U1 OFF

 3. The voltage should be WITHIN + OR - 10% OF THE NOMINAL VOLTAGE.
IF THE TESTS ARE WITHIN ABOVE LIMITS, THE WINDINGS AND DIODES ARE O.K.

AVR Sensing W6
from Main Stator
W5 3 Phase
6 
W2 W W1
Output mV
mA
V5
7
V2
V V1 V
A
V
U5
8
U2
U U1 OFF
 If the voltage is UNBALANCED PHASE TO PHASE, this indicated a fault in the

MAIN STATOR WINDINGS.

AVR Sensing W6
from Main Stator
W5 3 Phase
6 
W2 W W1
Output mV
mA
V5
7
V2
V V1 V
A
V
U5
8
U2
U U1 OFF


AVR Sensing W6
from Main Stator
W5 3 Phase
6 
W2 W W1
Output mV
mA
V5
7
V2
V V1 V
A
V
U5
8
U2
U U1 OFF

 DISCONNECT ALL EXTERNAL LEADS from the Generator and repeat tests.
IF THE VOLTAGES ARE STILL UNBALANCED, THE MAIN STATOR IS FAULTY

Fault Finding - Testing the Main Stator Windings
 What are the symptoms of a Main Stator fault ?
 1. The output voltage will be UNBALANCED, Phase to Phase or Neutral. In
Single phase connection, the unbalance should be checked from L - L to
Centre tap.
 2. When separately excited with a Battery, the engine will be ‘loaded’, by the
short circuit current in the fault.
 3. If the generator is run for a short period, the fault area in the windings area
will become VERY HOT. This can be detected by hand, or from insulation
burning (smell) .
THE MAIN STATOR WINDINGS WILL REQUIRE REPAIR OR REPLACEMENT.

AVR Sensing W6
from Main Stator
W5 3 Phase
6 
W2 W W1
Output mV
mA
V5
7
V2
V V1 V
A
V
U5
8
U2
U U1 OFF
 IF THE VOLTAGES PH - PH ARE BALANCED,THE MAIN STATOR IS O.K
 IF THE VOLTAGES ARE LOWER THAN 10% BELOW THE NOMINAL, THERE IS
A FAULT ON THE DIODES OR EXCITATION WINDINGS.

AVR Sensing W6
from Main Stator
W5 3 Phase
6 
W2 W W1
Output mV
mA
V5
7
V2
V V1 V
A
V
U5
8
U2
U U1 OFF

AVR Sensing W6
from Main Stator
W5 3 Phase
6 
W2 W W1
Output mV
mA
V5
7
V2
V V1 V
A
V
U5
8
U2
U U1 OFF
IMPORTANT : CHECK THAT THE ENGINE SPEED IS CORRECT.

Fault Finding - Testing the Main Rectifier Diodes
Output From - +
BATTERY
Exciter Stator
Main Stator
X+ XX- Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
 1. Stop the Generator Set and disable the Engine.

 2. Remove the Access covers from the Air Intake.
 3. Locate the Main Rectifier on the Shaft

Fault Finding - Testing the Rectifier Diodes
 What are the Symptoms of a Diode Failure ?
 THE VOLTAGE WILL BE LOW when separately exciting with a 12V battery.
 A SELF EXCITED AVR SYSTEM may not build up voltage on run up.
 A PMG AVR SYSTEM may trip on HIGH EXCITATION PROTECTION, when load is
applied, (depending on how many diodes have failed).
 Diodes usually become SHORT CIRCUIT when faulty.
 Two or more diodes short circuit may OVERHEAT THE EXCITER ROTOR.
 A SHORT CIRCUIT DIODE can sometimes melt its solder terminal.
! ALWAYS DISABLE ENGINE BEFORE WORKING INSIDE A GENERATOR !

DANGER !

Exciter Rotor & Main Rectifier Connections
W
U
SHAFT
SHAFT SHAFT
SHAFT V
 Disconnect the 6 ends of the Exciter Rotor connections to the Rectifier Diodes

Checking the Rectifier Diodes
FLUKE 87
Diodes Negative Plate

Anode Stud
.--
mV
mA
V
SHAFT V
A
OFF
Diode Positive Plate

Cathode Stud
 Switch the Multi-meter to the position indicating ‘diode’ test position.

 With the Positive test lead on the Anode side of the diode, the meter should
give a reading, indicating electron flow

Checking the Rectifier Diodes
FLUKE 87
Diodes Negative Plate

Anode Stud
.--
mV
mA
V
SHAFT V
A
OFF
Diode Positive Plate

Cathode Stud
 Reverse the Multimeter leads, so that the Positive lead is on the Anode side of the
diode, the Multimeter should now read OL, (no electron flow).
 The positive plate diodes will give opposite polarity readings to above.
 A faulty diode will give a short circuit reading in both directions, or an open circuit readin
in both directions, (if the solder joint has melted).

Fault Finding - Testing the Varistor (Surge Suppressor)
 What are the Symptoms of a Varistor Failure?
 The Varistor is a High Voltage transient protection devise for the Diodes. The
Generator will function normally without it.
 Failure of the Varistor usually results in the device going SHORT CIRCUIT.
 The Varistor will often FAIL CATASTROPHICALLY (EXPLODE).
 On a Self Excited AVR system, a short circuit Varistor will prevent voltage build
up on initial start - up.
 On a PMG AVR system, the PMG may cause the varistor to EXPLODE.
IF THE VARISTOR, OR ONE OR MORE DIODES HAVE FAILED, THE WHOLE SET
SHOULD BE REPLACED WITH NEW COMPONENTS

Checking the Varistor (Surge Suppresser)
 UC & BC Type  HC/F8 Type
FLUKE 87
. --
mV
mA
V
A
SHAFT
V
OFF
 Switch the Multimeter to the position indicated for resistance ‘’ testing
 The Varistor should read Infinity in both directions, and has no polarity
 A faulty Varistor will be short circuit, or burnt (‘blown’) by fault current

Output From
- +
12vA.V.R
BATTERY
Battery into
Exciter Stator
Main Stator
X+ XX- Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft

Rectifier
Fan
 1. After changing DIODES or the VARISTOR, reconnect the battery, (if dis-connected)
 2. Run the Generator at nominal speed, and re-check the output voltage
IF THE VOLTAGE IS WITHIN 10% OF NOMINAL, THE FAULT IS NOW CORRECTED

Fault Finding - Testing the Windings and Main Rectifier
 Any fault found with the MAIN STATOR should now be corrected.
 Any fault with the DIODES or VARISTOR should now be corrected.
 The Output voltage from the main Main Stator should be balanced across phases and
within 10 % of the nominal Voltage.
IF CORRECT, THE WINDINGS AND DIODES ARE O.K 
 If the Output Voltage Is Balanced Phase to Phase, but is reading LOW, (MORE THAN
10% BELOW THE NOMINAL), there is a fault in the excitation winding.
 The EXCITER STATOR, ROTOR, AND MAIN ROTOR WINDINGS should be checked for
faults.
 The winding RESISTANCE VALUES must be checked against correct values given in
the Generator O & M manuals.

Fault Finding - Testing the Exciter Stator
Output From - +
BATTERY
Exciter Stator
Main Stator
X+ XX- Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
 1. Stop the Generator Set and disconnect the battery from X+ (F1), and XX- (F2).
 2. Check the Exciter Stator winding resistance across leads X+ (F1), and XX- (F2).
The correct values are given in the Generator O & M manual.

 What are the Symptoms of an Exciter Stator Failure ?
 If the winding is OPEN CIRCUIT, the Generator will produce very LOW voltage only,
(RESIDUAL VOLTAGE), irrespective of AVR type.
 The BATTERY TEST will also produce RESIDUAL VOLTS ONLY.
 SHORTS TO EARTH in the Exciter Stator can cause AVR INSTABILITY and may
OVERHEAT THE PMG STATOR WINDING.
 A SEVERE EARTH FAULT may cause the AVR POWER DIODES to fail, due to
excessive leakage current. This fault can BURN OUT THE PMG STATOR

HC Assembly BC/UC Assembly FLUKE 87
X+ (F1)
X+ F1)
XX- (F2)
XX- (F2)
. --
mV
mA
V
A
V
OFF
 Check the Exciter Stator resistance across X+ & XX- with a multi-meter set on the
 range.
 The correct resistance figures are given in the Operation and Maintenance Manual
supplied with the Generator.

HC Assembly BC/UC Assembly
X+ (F1)
X+ F1) M
10 1
100 0.1
00 .01
XX- (F2) 10
XX- (F2)
Test
M  1KV
M 500V
MEGGER
EARTH
 1. Check the Exciter Stator insulation with a 500V or 1000V Insulation tester,
 2.The MINIMUM insulation value should be 1.0 Megohm to Earth (Ground).
 3. Below 1 Megohm,The windings should be cleaned,dried, and re- coated with
anti-track varnish.

Fault Finding - Testing the Exciter Rotor
 What are the Symptoms of an Exciter Rotor Failure ?
 With a Self Excited AVR system, the Generator may not be able to build up Voltage on
start- up, (Residual Voltage is too low.)
 With a PMG powered AVR, a short in the exciter rotor may cause repeated tripping of
the AVR EXCITATION PROTECTION circuit on load. This is caused by HIGH
EXCITATION VOLTAGE.
 When separately excited with a 12 Volt battery, the VOLTAGE WILL BE LOW.
 An exciter rotor winding failure may be caused by SHORT CIRCUIT DIODES,

( POSITIVE and NEGATIVE diodes shorting across a phase group).

Fault Finding - Testing the Exciter Rotor
W
U
DUCTER Digital Ohmmeter
MILLIOHMS OHMS
V
SHAFT
V
 Visual inspection is recommended, any winding or insulation damage is usually

visible on the exciter rotor end windings, (burnt or blackened coils).
 A Low Resistance Bridge is required to accurately measure values below 0.5 .
 The correct resistance figures are given in the Operation and Maintenance Manual
supplied with the Generator.

Fault Finding - Testing the Main Rotor
- +
12vA.V.R
BATTERY
Main Stator
X+ XX- Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
 TESTING THE MAIN ROTOR WINDINGS
! ALWAYS DISABLE ENGINE BEFORE WORKING INSIDE A GENERATOR !

DANGER !

Fault Finding - Testing the Main Rotor
 What are the Symptoms of a Main Rotor Failure ?
 A Self Excited AVR system, may be unable to build up Voltage on start- up,
( from Residual Magnetism).
 A PMG powered AVR, may trip out repeatedly on AVR EXCITATION PROTECTION on
load, due to HIGH EXCITATION VOLTS.
 When separately excited with a 12 Volt battery, the VOLTAGE WILL BE LOW.
 The LOW VOLTAGE will be proportional to the LOSS OF WINDING TURNS, i.e, if
50% of the rotor windings are SHORT CIRCUIT, the RESISTANCE and the OUTPUT
VOLTAGE will be 50% OF THE NOMINAL VALUE.
 A rotor winding fault MAY NOT BE VISABLE, as the outer turns are cooled by the air-
flow, and may appear to be undamaged.

Fault Finding - Main Rotor Assembly
Main Rectifier Main Rotor
SHAFT D.C
 Disconnect ONE lead of the Main Rotor connection to the Rectifier Assembly
 The main rotor resistance should be checked against values given in the Operation
and Maintenance Handbooks

Fault Finding - Main Rotor Assembly
FLUKE 87
Main Rotor
. --
mV
mA
V
A
V
OFF
 The Main Rotor resistance is checked with a multi-meter set on the  range.
 If the resistance readings are LOW, a further test to confirm results may be
necessary using a more accurate Low Resistance bridge meter.
 THE LOWER RESISTANCE will be PROPORTIONAL to the LOWER VOLTAGE

- +
12vA.V.R
BATTERY
X+ XX- Exciter
Rotor
& Stator
Main Stator

Bearing
Main Rotor
Shaft

Rectifier
Fan
 1. Reconnect the battery, (if disconnected)

 2. Run the Generator, and re-check the output voltage, if all faults found have
been corrected, the output Voltage should be
BALANCED PHASE TO PHASE AND WITHIN 10% OF THE NOMINAL
VOLTS.
Fault Finding - Loss of Residual Magnetism
 What are the Symptoms of Loss of Residual Magnetism?
 Residual magnetism is stored in the EXCITER STATOR CORE ONLY.
 Loss of residual magnetism effects SELF EXCITED AVR control systems ONLY.
 Loss of residual magnetism will PREVENTS VOLTAGE BUILD-UP ON RUN-UP.
 DECAY of residual magnetism may be caused by long storage periods.
 Residual magnetism may be DESTROYED by POLARITY REVERSAL of the Exciter

Stator ( crossed polarity when separately excited with a battery).
 PMG powered AVR system DO NOT rely upon residual magnetism for initial voltage
build -up

- +
12vA.V.R
BATTERY
Main Stator
X+ XX- Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
 1. Check the battery polarity to the Exciter Stator leads X+ (L1) and XX- (L2).
IF REVERSED, RECONNECT the battery,and try again with the A.V.R
 2. To CHECK RESIDUAL VOLTS, Stop the Generator,and disconnect the battery.

How to test for Residual Magnetism FLUKE 87
AVR Sensing W6
from Main Stator
W5 3 Phase
6 
W2 W W1
Output mV
mA
V5
7
V2
V V1 V
A
V
U5
8
U2
U U1 OFF
 1. With the Exciter Stator leads X+ and XX- OPEN CIRCUIT, run the Generator at
nominal speed, (without load).
 2. Check the output voltage across the AVR power supply terminals.
 3. The AVR requires a MINIMUM voltage of 3.5 VOLTS to begin excitation build up.
 4. If the Residual Voltage is lower than 3.5 Volts, the Residual magnetism must be
restored. NOTE : The residual magnetism can be as high as 10 - 15% of nominal volts !!.

How to Restore Residual Magnetism
X+ (F1)
Method 1
XX- (F2)
- +
24 V BATTERY
 METHOD 1 : ‘FLASH’ the Exciter Stator leads with a 12 or 24V Battery for 1-2 seconds. Run
the Generator and re-check the Residual Voltage, (Minimum 3.5V to the AVR power supply.
 If this does not restore residual, try METHOD 2

X+
XX-
Method 2
BLOCKING
DIODE

 RUN
+ - GENERATOR
12v BATTERY
 Run generator at NO LOAD, normal speed .

 Flash AVR terminals X+ (F1) & XX- (f2), for one second until AVR fires, and
voltage builds up. Shut down set, then check if AVR builds up normally.
 WARNING : NEVER FLASH AN AVR WITHOUT A BLOCKING DIODE IN THE BATTERY LEAD

X+ (F1) DANGER!
Method 3 ENGINE MUST
BE DISABLED
XX- (F2)
DIODE
120 VDC FUSE 240VAC

L693 5 AMP
BL 059-0112
 STOP THE SET, AND DISCONNECT THE EXCITER STATOR LEADS X+ AND XX_
 METHOD 2 : If the residual magnetism is totally lost, it can be fully re-charged by
‘FLASHING’ with 110 Volts D.C from a 240VAC supply rectified to half wave 120 VDC.
 Residual should be fully restored with 1 - 2 seconds flashing.

A.V.R
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft

Rectifier
Fan
 This completes the fault finding on the Excitation windings and main rectifier diode
assembly .
 The AVR should now be re-connected and the Generator run at nominal speed.
 Any further problems must now be in the AVR or the Permanent Magnet
Generator ( when fitted). The next tests check out the AVR SUPPLY CIRCUITS.

Fault Finding - Testing the AVR Supply Circuits
 What are the Symptoms of AVR supply failure ?
 HIGH VOLTAGE - This can also be caused by loss of signal (sensing supply), from
the main stator.
 NO VOLTAGE - This can also be caused by loss of power supply to the AVR.
 UNSTABLE VOLTAGE - This can also be caused by loose wiring or corroded
terminals from the AVR to the Generator.
 Run the Generator, with the 12 Volt battery connected to the Exciter Stator,
and check the AVR supply terminals.
MAKE SURE ALL WIRING IS SAFELY

SECURED BEFORE TESTING

Fault Finding - AVR Supply Circuits
TEST
P2 -P3 -P4 6-7-8
- + A.C Sensing
PMG 12v BATTERY and Power
Power Supply from
Supply Main Stator Main Stator
To A.V.R Exciter (2 or 3 Phase)
(when fitted) Rotor
& Stator
XX- (F2)
X+ (F1) Bearing
Main Rotor
Shaft
Rectifier
Fan
 Check that the AVR is receiving the correct POWER AND SENSING SUPPLIES

Fault Finding - AVR Sensing and Power Supply from the Main Stator
Power supply for Self-Excited AVR Control systems Only
FLUKE 87
AVR Sensing W6
from Main Stator
W5
6

W2 W W1
mV
V5 3 Phase
mA
7
V2 V V1 Output
V
A U5
V 8
U2
U U1
OFF
 1. Check all three sensing leads into the AVR, using a Multi-meter on AC Volts.
 2. The Sensing and Power supply should be Half Line - Line Volts in Series Star.
 3. For Single phase and 240 Volt 3 Phase Machines, the Sensing and Power supply
should be the identical to the Line - Line Voltage.
 Also check supply at the A.V.R terminals to ensure continuity of wiring.

Wound Main Stator 6 Ends Out
Sensing Supply in SERIES STAR connection FLUKE 87
Examples - 6 ends Stators

Winding 312 U 8
380 to 440 V @ 50 HZ
416 to 480 V @ 60 HZ U1
Single Phase
(N) = 3 of L-L 
U2 Isolation transformer mV
Winding 26
660 - 690 Volts @ 50 HZ 8 mA
N V
W2 V2
A
V
7
W1 V1 7 OFF
w v
6 6
 1. Using a Multimeter set on A.C volts, check all three sensing leads into the AVR.
To ensure continuity of wiring, check the leads at the A.V.R terminals.
 2. The Sensing supply should be 190- 240 Volts, when the line voltage is at its
correct nominal level. This is determined by turns ratio of the sensing transformer.

Fault Finding - AVR Sensing Supply - 6 Ends Out Stator
Typical Isolation Transformer Assembly
U V W
P1
P1 P2 P2
S1 S2 S1 S2
8 7 6
 Primary and Secondary turns ratio is determined by the Primary (input) Voltage.
The Secondary output must be 170 - 240 V to the A.V.R sensing input 6, 7,
8.

Fault Finding - AVR Power Supply - PMG
FLUKE 87
P2 P3 P4
P2, P3, P4 Power Supply To A.V.R

mV
mA
V
A
V
OFF
 Generator Drive Shaft (Non-Drive -End)
 Run the Generator at nominal speed, and set the Multi-meter to read A.C Volts. ,
 Check the Permanent Magnet Stator output Voltage across the 3 input terminals to
the AVR. The Voltage across P2,P3,P4, should be 170 VAC to 220 VAC, and balanced
across phases.

A.V.R
Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Shaft
Rectifier
Fan
 This completes the testing of the windings, Main rectifier and AVR supplies.
 The final tests are to CHECK if the AVR IS FAULTY

Fault Finding - Testing the AVR
 What are the Symptoms of AVR failure
 HIGH VOLTAGE
 NO VOLTAGE
 LOW VOLTAGE.
 UNSTABLE VOLTAGE

Fault Finding - Testing the AVR
 Testing the AVR for faults
 Check that the AVR is not being affected by adverse environmental conditions :-
 Excessive temperature ( Limits - 40º to +70º C.)

 Excessive vibration ( Limits- 50 mm/sec Velocity @ 20 - 100 Hz)
 Excessive Humidity :- ( Limits 0 - 60 º C, 95% )
 If all operating conditions appear normal, the AVR should be changed with a new
replacement unit.
 The defective unit can be returned to Newage for test and report.
 Being an encapsulated unit the AVR is not repairable.
THIS COMPLETES THE FAULT FINDING SECTION. ANY QUESTIONS?

16 Fault Finding

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NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

 1. Disconnect the AVR completely before carrying out this test.

NEWAGE PRODUCT TRAINING

 TEST METHOD - Separately exciting the Generator with a 12V Battery

NEWAGE PRODUCT TRAINING

 1. Stop the Generator Set and disable the Engine.

NEWAGE PRODUCT TRAINING

 1. Check all wiring is safe and secure before running Generator

NEWAGE PRODUCT TRAINING

 Connections shown in Series Star FLUKE 87

 1. Using a Multi-meter, CHECK ALL THREE PHASES.

NEWAGE PRODUCT TRAINING

 Connections shown in Series Star FLUKE 87

 1. Using a Multi-meter, CHECK ALL THREE PHASES.

NEWAGE PRODUCT TRAINING

 Connections shown in Series Star FLUKE 87

 1. Using a Multi-meter, CHECK ALL THREE PHASES.

NEWAGE PRODUCT TRAINING

 Connections shown in Series Star FLUKE 87

 If the voltage is UNBALANCED PHASE TO PHASE, this indicated a fault in the

NEWAGE PRODUCT TRAINING

 Connections shown in Series Star FLUKE 87

 If the voltage is UNBALANCED PHASE TO PHASE, this indicated a fault in the

NEWAGE PRODUCT TRAINING

 Connections shown in Series Star FLUKE 87

 If the voltage is UNBALANCED PHASE TO PHASE, this indicated a fault in the

IF THE VOLTAGES ARE STILL UNBALANCED, THE MAIN STATOR IS FAULTY

NEWAGE PRODUCT TRAINING

 1. The output voltage will be UNBALANCED, Phase to Phase or Neutral. In

Single phase connection, the unbalance should be checked from L - L to

short circuit current in the fault.

THE MAIN STATOR WINDINGS WILL REQUIRE REPAIR OR REPLACEMENT.

NEWAGE PRODUCT TRAINING

 Connections shown in Series Star FLUKE 87

 IF THE VOLTAGES PH - PH ARE BALANCED,THE MAIN STATOR IS O.K

NEWAGE PRODUCT TRAINING

 Connections shown in Series Star FLUKE 87

 IF THE VOLTAGES PH - PH ARE BALANCED,THE MAIN STATOR IS O.K

NEWAGE PRODUCT TRAINING

 Connections shown in Series Star FLUKE 87

 IF THE VOLTAGES PH - PH ARE BALANCED,THE MAIN STATOR IS O.K

IMPORTANT : CHECK THAT THE ENGINE SPEED IS CORRECT.

NEWAGE PRODUCT TRAINING

 1. Stop the Generator Set and disable the Engine.

NEWAGE PRODUCT TRAINING

 Diodes usually become SHORT CIRCUIT when faulty.

 A SHORT CIRCUIT DIODE can sometimes melt its solder terminal.

! ALWAYS DISABLE ENGINE BEFORE WORKING INSIDE A GENERATOR !

NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

Diodes Negative Plate

Diode Positive Plate

 Switch the Multi-meter to the position indicating ‘diode’ test position.

NEWAGE PRODUCT TRAINING

Diodes Negative Plate

Diode Positive Plate

NEWAGE PRODUCT TRAINING

 What are the Symptoms of a Varistor Failure?

 The Varistor will often FAIL CATASTROPHICALLY (EXPLODE).

NEWAGE PRODUCT TRAINING