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manual router netgear onoDO NOT attempt to work on live equipment if you are not qualified or experienced in this work. Before testing the generating set, read the generating set Installation Manual, and this Fault Finding Manual, and become familiar with it and the equipment.Ensure installation meets all applicable safety and local electrical codes. Have all installations performed by qualified Installation technicians. Do not operate the generator with protective covers, access covers or terminal box covers removed. Disable engine starting circuits before carrying out maintenance. Observe all IMPORTANT, CAUTION, WARNING, and DANGER notices, defined as: Important. Important refers to hazard or unsafe method or practice, which can result in product damage or related equipment damage. Caution! Caution refers to hazard or unsafe method or practice, which can result in product damage or personal injury. Warning refers to a hazard or unsafe method or practice, which CAN result in severe personal injury or possible death. Danger refers to immediate hazards, which WILL result in severe personal injury or death. Due to our policy of continuous improvement, details in this manual which were correct at time of printing may now be due for amendment. Information included must not therefore be regarded as binding. 2 Automatic Voltage Regulator is powered from the Generator Output. SECTION 5 Fault Finding method B, for Separately Excited Generators Automatic Voltage Regulator is powered from the Permanent Magnet Generator. SECTION 6 Parallel Operation and Fault Finding for All Generators 3 The following lists detail the basic requirements in this respect. It should be noted that in addition to these instruments a comprehensive kit of tools is also essential. For fault finding purposes this need not include any specialised tools. Item 1 - Multimeter The Multimeter is a comprehensive test instrument for measuring voltage, current and resistance.http://freeorden.com/media/conair-blender-manual.xml
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It should be capable of measuring the following ranges:- Voltage A C Voltage D C Amperes D C D C Resistance Volts Volts 0-10 Amps 0-10k (ohms) or 0-2k (ohms) 0-100k (ohms) or 0-20k (ohms) 0-1M (ohms) or 0-200k (ohms) It is essential that all test instruments be regularly checked for safety, and any connection leads, probes or clips checked to ensure that they are suitable for the voltage levels being tested. Make sure you have made all other persons in the immediate area fully aware of what you are doing. Item 2 Tachometer or Frequency meter This instrument is for measuring the shaft speed of the alternator and should be capable of measuring speeds between 0 and 5000 revolutions per minute, (RPM). An alternative to the tachometer is the frequency meter (see Section 2 on Frequency and Speed, for details). However the Generator must be operating at its normal output voltage for this instrument to be accurate. Item 3 Megger (Insulation test meter) MEDIUM AND HIGH VOLTAGE GENERATORS 3.3 kvolt to 13.6 kvolt Do not attempt to carry out tests on high voltage Generators without using specialised instruments and probes. Suitable protection equipment and safety procedures for grounding, (earthing), must be carried out before working on the Generator. This instrument generates a voltage of 500V or 1000V, and is used to measure the resistance value of the insulation to earth (ground). It may be an electronic push button type, or a hand cranked generator type. Item 4 - Clip-On Ammeter (Clampmeter) Used to measure A C current, it consists of a pair of callipers, which are clamped around the conductor, and by means of a transformer action, gives an indication of the amperes flowing in the conductor. Useful ranges to have on this meter are:- A C Amps Item 5 Kelvin Bridge low resistance meter This instrument is used to measure resistance values below 1.0 ohm.http://www.consili.nl/userfiles/conair-bts1-manual.xml They are bulky, and expensive, but are the only means of accurately measuring very low resistances, such as main stator and exciter rotor windings. However, there are other simple methods of testing low resistance windings, which are included in the various test procedures, i.e. Test Method A (Section 3). This procedure enables the main generator, (stator), and windings to be tested while running the generator at normal speed, without load. 4 The Generator control circuits are designed to automatically maintain this voltage level as the load is increased or decreased. Sudden large changes in loading will produce temporary changes in the voltage. The Automatic Voltage Regulator (AVR) is designed to recover to a stable condition as quickly as possible. The current drawn from the AC Generator is determined by the amount of load connected to it. Current creates a temperature rise in the windings, hence the requirement for drawing air through the AC Generator by means of the cooling fan. If the full load rated current is exceeded on any phase of the main stator windings, it will result in overheating in this winding. Similarly, any restriction in the flow of air through the machine will result in a rapid increase in the temperature of the windings. Kilowatts (kw) kilo Volt Amperes (kva) and Power Factors (pf.) For an AC Generator to supply power for a load of 1kW, the prime mover (engine) driving the alternator must produce approximately 1.5 horsepower. Frequency (Hz) and Speed (RPM) An AC Generator is a constant speed device, and should not be operated at speeds above 4 of the rated speed, or more than 1 below the rated speed. Load changes will create temporary changes in the speed, but the engine must be capable of returning to the steady state condition within a few seconds. Power Factor The Power Factor (pf), is a measure of wasted current, which is a product of inductive loads such as motors, transformers, (magnetic circuits), and some forms of lighting.https://congviendisan.vn/vi/bose-mb4-panaray-subwoofer-manual An AC Generator will deliver continuously the rated full load current at any power factor between pf1 (unity) and 0.8. However, the prime mover, (engine), is greatly affected by the power factor. At pf1, the kva and kw are equal; therefore the engine is supplying 20 more kw load at pf1, than at pf 0.8. It is important, therefore, that this is taken into consideration, when approaching 75 to 100 load current of the Generator, with a power factor higher than A reduction in the full load (kva), rating is required for a continuous lagging pf lower than 0.8. Leading Power Factors Capacitive load e.g. some fluorescent lighting, and power factor correction capacitor banks, produce leading power factor current. The latter is required by the Electricity authorities to improve the customers lagging power factor. The capacitor bank size is measured in kvar (reactive). A purely Capacitive load can cause the Generator control system, (AVR), to loose control, creating voltage instability, and possible high voltage from the Generator. This is due to the fact that, unlike most loads, which are pf1, (unity) or lagging pf, a leading pf load current will cause the Generator excitation voltage to decrease, as the load current increases. Eventually the control system will be unable to control the Generator excitation level, and voltage instability will occur. The degree of instability is determined by the kvar size of the capacitors, relative to the kva size of the alternator. Capacitive load can present a problem for mains failure (standby) Generators. When the mains electricity supply fails, all motor, (inductive), load is disconnected by the individual contactors. Subsequently, when the Generator is connected to the system, the load will mainly consist of lighting, and possibly power factor correction capacitors. In order to prevent this situation, it is advisable to ensure that the power factor correction capacitors are switched OFF when the generator takes the initial load.http://erptrends.com/images/canon-eos-rebel-g11-manual.pdf Further advice in this respect may be obtained from Cummins Generator Technologies if required. Resistances - measuring component values Very low resistance values (below 0.5 ohm) Main stators and exciter rotors are included in this category. These values can only be measured accurately with a special instrument, such as a Kelvin bridge test meter. The test leads are equipped with special spiked probes, which penetrate the surface of the contact, ensuring accurate reading. The generators main stator windings can also be tested by means of separately exciting the machine (see, Section 3, Test Method A), thus partly eliminating the need to have this specialised type of instrument when fault finding in the field. When fault finding it is necessary to measure the resistance values of components and windings, and compare them with known normal values, in order to identify a faulty winding. The normal resistances of the windings are given in the winding resistance charts, in the generator installation and maintenance handbooks, service and maintenance section. Resistance values above 10 ohms can be measured accurately with a multimeter. Between 0.5 and 5 ohms a multimeter has a limited accuracy, and other test methods may be adopted. Resistances between 0.5 And 5 Ohms The resistance value of a winding such as a brushless main rotor will be between 0.5 and 3 ohms. A multimeter may not give an accurate enough reading at these levels. If a Wheatstone Bridge Resistance Meter is not available, an accurate measurement can be obtained by means of a battery supply, using a Multimeter in series on the 10 Amps D.C. range. Most Multimeters have this current range, or alternatively, a battery charging Ammeter could be used instead). 6 An arrow printed on the diode body identifies the positive side of a diode. The forward resistance is being measured in Fig. A with the positive meter lead connected to the forward side of the diode. In Figure 'B' the meter leads have been reversed, and the reverse resistance is being measured. A good diode will light the bulb in only one direction. It should not light when test leads are reversed on the diode pin and base. A faulty diode will light the bulb in both forward and reverse directions (short circuit diode), or no light in either direction, (open circuit diode). If one or more diodes are found to be faulty, always change the complete set of diodes. An electronic digital instrument will read true electron flow, hence the resistance polarity readings will be reverse to conventional current flow, i.e. forward and reverse readings will be reversed. A Digital Multimeter usually has a semiconductor test scale on the selector switch, marked as shown:- This measures true electron flow, and will give a forward, (indication reading only), or reverse (no reading) indication. Using an analogue meter on resistance scale, the forward resistance varies considerably, depending on the internal impedance of the Multimeter, and the diode type. A typical reading would be between 20 and 100 ohms. The reverse resistance must be very much higher, usually in excess of 100k ohms, (100,000 ohms ). A faulty diode will give a reading in both forward and reverse directions (short circuit), or no reading in either direction, (open circuit). 7 Note When conducting high voltage test to earth, it is advisable to either disconnect or short out any electronic devices, such as the Automatic Voltage Regulator, (AVR), and Main rotor diodes. Short circuiting the terminals can be achieved with a piece of fuse wire, which must be removed immediately after the tests are completed. Caution: Running the Generator before removing the short circuit connection could seriously damage the Generator. When Megger testing a machine, failure to protect the voltage control unit and diodes could result in permanent damage to one or more of the electronic components. Insulation Resistance to Earth cont. Medium to High voltage Generators, 1k Volt or higher High voltage generators are capable of storing a dielectric (capacitive) charge in the main stator windings, following a high voltage insulation test. Any testing of the main stator must be followed by a discharge to earth or ground for at least 1 minute. Do not attempt to touch the main output terminals until all residual charge has been discharged. Insulation testing of Medium and High voltage generators. The effectiveness of a particular on-site test will depend to a large extent on the machine application. In many situations, measurements of insulation resistance and polarisation index only will be appropriate. More detailed testing involving loss tangent, dielectric loss analysis, partial discharge measurement, is undertaken at intervals in order to establish the extent of deterioration of insulation condition. Other tests such as high voltage withstand tests are particularly effective for investigative work in order to identify the onset of fault conditions. Polarisation Index Test (P.I.) The P.I. test is used as a guide to the dryness, cleanliness, and safety of the winding insulation system. A special motorised insulation tester is required, which can maintain a test voltage of 1-2.5kV, (medium voltages), or 5kV, (high voltage), for a period of 10 minutes. The high voltage causes a current to leak through the insulation system. This current produces an output reading on the Insulation tester ( Megger ), which is measured in Megohms (resistance to earth or ground). A normal value for a low voltage Generator winding should be higher than 1 Megohm to earth. Generators with an output voltage of between 100V to 600V should be tested as above. If the output winding (stator) is lower than 1 Megohm to earth, the windings should be cleaned, dried, or removed to a workshop for complete refurbish. Caution! Do not test any winding other than the Main Stator with the P.I Index method. 8 Make sure you have made all other persons in the immediate area fully aware of what you are doing. 2. Check the Exciter Stator Resistance Check the resistance value of the exciter stator across these two leads (approximately ohms) with a Multimeter. Caution! Testing Insulation Resistance to Earth Before conducting the following tests, the Insulation of the Main Stator windings should be checked, in the methods described in Section 2, Insulation Resistance to Earth. Minimum Insulation to Earth for the Main Stator is 1.0 Megohm. Fault Finding Method A Success with this method depends upon each test being completed before proceeding to the next, unless otherwise stated. Ensure that the speed is within 4 of the nominal. The engine speed must be correct, to avoid misleading test results. 5. Excitation Voltage at No Load It is essential that ALL LOAD is disconnected from the machine, and that the speed is correct. Check the Battery Voltage after connecting to the Exciter Stator, a minimum of 12 VDC is required. Note Ensure that the correct two exciter leads are identified, by physically tracing them back to the exciter stator windings, fitted inside the non-drive end bracket of the Generator. When testing with a fixed battery supply, any difference between the figures below, and the actual battery voltage, will affect the test results, and should be taken into account. For example, if your battery voltage is 10 higher or lower than the figures shown, you can expect the Generator voltage to be equally 10 higher or lower than expected. 9. If the output voltage from the main stator is within 10 of the nominal, or higher than the nominal, and is also balanced across the phases within 1., this indicates that the main stator, the main rotor, exciter stator, exciter rotor, and main rectifier diodes, are all functioning correctly. Proceed directly to Test Number Voltage is Balanced but reading Low If the output voltage is more than 10 below the nominal voltage, but is balanced within 1 Phase to Phase, (and Phase to Neutral), the main stator is good, but there is a fault elsewhere in the Excitation system. First check that the D.C. battery supply is not lower than the figures given in Paragraph 5, and that the engine speed is correct. The flexible leads connected to each diode should be disconnected at the terminal end, and the forward and reverse resistance checked. (See section 2, diode testing). The rectifier assembly is split into two plates, positive and negative, and the main rotor is connected across these plates. Each plate carries 3 diodes, the negative plate carries the negative based diodes, and the positive plate carries the positive based diodes. Care must be taken to ensure that three identical polarity diodes are fitted to each plate. When fitting the diodes to the plates they must be tight enough to ensure a good mechanical and electrical contact, but should not be over tightened. If the output is unbalanced phase to phase, or more than 10 below the nominal, this indicates that a fault exists in one of the above components, and the following tests must be conducted, 7. Checking the Main Stator Winding The voltages between phases, and each phase to neutral, should be balanced, to within 1 of the nominal voltage. On a single-phase machine the voltage between L1-L4, and L2- L4 or U-N and W-N, must be balanced. If the voltage is 10 or more below the nominal voltage, but is balanced within 1 phase to phase, the Main Stator is good. Proceed to test number 9. If the ph ph voltage is unbalanced by more than 1, this indicates that the main stator windings are faulty. This test should be repeated with all external connections removed from the Generator terminals, to eliminate the possibility of external shorts in the output cables, or the circuit breaker. Further tests may be made on the resistance values of the main stator windings with a Kelvin Bridge resistance test meter. (refer to the Operation and Maintenance manual for main stator winding resistance values). 8. Symptoms of a Main Stator Fault A fault in the main stator windings will produce short circuit currents between turns in the main stator coil windings. When separately exciting with a battery, the current will also create heat in the damaged winding, which may also be heard as a slight loading of the engine. A faulty stator winding must be repaired or replaced. Rectifier Components 1. A.C Connection Stud 2. Rectifier Plates 3. Diodes - 3 X Negative 4. Diodes - 3 X Positive 5. Surge Suppressor (Varistor) 6. Main Rotor Leads 7. Rectifier Hub 10 High Voltage transients are created by fault conditions in the distribution system. The transient returns to the Generator via the output terminals, enters the main stator windings, and by mutual inductance, (transformer reaction), is transferred to the main rotor windings, and then the main rectifier assembly. The Surge Suppressor can be tested with a Multimeter on the megohms range. A good Surge Suppressor should have a very high resistance, (more than 100 megohms in either direction). A faulty Surge Suppressor will be either open circuit (usually showing signs of damage) or short circuit in both directions. The Main Rectifier will still work normally with this device removed. However, it should be replaced as soon as possible, to avoid diode failure in the event of further transient fault conditions. Occasionally, a very high transient will totally destroy the Surge Suppressor. This could result from extreme fault conditions, such as lightening, (electric storms), striking close to overhead distribution lines, or out of phase synchronisation of the Generator, when paralleled to multiple Generator systems, or embedded systems connected to the Mains, (Grid, Utility) supply. In the event of a Surge Suppressor failure, all rectifier diodes should also be replaced, including any which appear to test OK. 11. Testing the Excitation Windings After establishing and correcting any fault on the rectifier assembly, the battery test should be repeated, from paragraph 6, and the output voltage checked. If the output voltage is still more than 10 below the nominal voltage when separately excited, this indicates that the fault must be in one of the excitation windings. To test the main rotor, exciter stator and exciter rotor winding, the resistance values must be checked against correct values, which are given in the Operation and Maintenance handbook, supplied with the generator. Refer to the Service and Maintenance section, for the winding resistance charts, specific to each Generator type and size. Note. The charts require identification of the frame size, number of rotor poles, followed by the main stator and rotor core length (A, B, C G, H, J etc). The Main Stator core length and winding number are given on the Generator nameplate. If in doubt, refer to the factory, with the Generator serial number or machine identification number. A standard Multimeter, set on the lowest resistance range, will be suitable for this test. The exciter Stator winding Insulation to earth should also be tested with a Megger. As a low insulation can affect the AVR performance. Minimum value to earth 1 megohm. (See section 2 for details).Alternatively, a visual inspection will usually identify any burnt or damaged windings. Main Rotor The main Rotor leads are connected to the main rectifier plates. Disconnect one of the leads to check the resistance value. A good quality Multimeter will measure resistances of 0.5 to 2 ohms with reasonable accuracy, however if the resistance is found to be lower than the quoted figure, it should be verified with a more accurate measurement. 12. Testing the AVR Sensing Supply (feedback). Caution! A fault in the AVR sensing supply could result in high excitation when the AVR is re-connected, which will produce a high voltage output on the Generator terminals. Checking the sensing supply from the main stator is the final test, which can be carried out while separately exciting the Generator with a battery supply. Make sure the output voltage is approximately correct, I.e. within 10 of the nominal voltage). The previous tests should have cleared any fault in the windings or rectifier assembly and the correct output obtained from the main stator with the battery. With the Generator running at nominal voltage, the sensing supply should be between 190 and 240 volts. If the supply is incorrect, or unbalanced, the fault should be traced back via the wiring circuit to the Main Stator connections. Two phase sensed AVR s, MK11A, SX440, MX341, SX460, SA465, AS440, AS480. The sensing supply is across AVR terminals 2 and 3, (AVR types MX341 and SX440), or 7 and 8, (all other AVR types). Note. Generators supplied before The parallel droop CT, and close regulation CT, (when fitted), is connected into the sensing supply via a burden resistor, fitted in the terminal box. Refer to the Operation and Maintenance manual supplied with the Generator for details. Three phase sensed AVR s, MX321, MA325, MA327,329,330. The sensing supply is connected to the AVR terminals marked 6, 7, and 8. Note 1. The Sensing Supply is connected via an isolation transformer, or an encapsulated isolation module, (PCB), fitted in the Generator terminal box. Check primary and secondary of transformer, or input and output of PCB. Note 2. Generators supplied before The parallel droop CT, and close regulation CT, (when fitted), is connected into the sensing supply via a burden resistor, fitted in the terminal box. Exciter Rotor The exciter rotor is connected to the 6 X AC connection studs on the Main Rectifier assembly. Disconnect the 6 leads from the AC connection studs, and check the resistance value across three of the leads, which were connected to the same polarity diodes, (fitted to the same 11 This system cannot suffer loss of residual problems as it does not rely upon residual magnetism for voltage build up. 4) Very low insulation resistance to earth (ground), on exciter stator or main stator. 5) Surge suppressor on main rotating rectifier short circuit. 6) Main rectifier diode(s) short circuit. 7) Winding fault. Open circuit or short circuit on any winding in the machine. 8) Exciter stator polarity reversed by battery tests. Check and verify voltage at Generator terminals with a multimeter. Check all auxiliary terminals. Check the AVR push on terminals for tightness. Repair or renew where necessary. See diagram left. Maximum connection time 1 second.In most cases this will destroy the AVR power devices. Battery polarity MUST be correct. Check the insulation resistance value with a Megger (see section 2). (Disconnect AVR during this test, and remove any Neutral earth connection). Check surge suppressor resistance (see Section 3 Test Method A). Carry out Test Method A, Section 3. Replace where necessary. Check diodes (See Section 2) Carry out all tests as listed in Test Method A. Check winding resistance values. Re-connect battery to exciter stator ensuring that polarity is correct, and retest. Restore residual magnetism as Item 3 above. 9) Fault in AVR. Replace the AVR and re-test machine. 10) Load applied to machine during run up of engine. 11) Open circuit power supply from main stator to AVR terminals P2, P3, P4. (SX440), or 7 and 8 (SX460 and SA465). The voltage may not build up until the load is disconnected from the machine. Open circuit breaker and re-test.Under frequency protection (UFRO) circuit activated. 2) AVR 'VOLTS' adjust, or external hand trimmer control incorrectly set. 3) Voltmeter faulty or sticking. Check AVR LED. If lit, UFRO is activated, indicating low speed. Check speed with tachometer. Adjust voltage on AVR 'volts' trim, or remote trimmer. Ensure that speed is correct, and UFRO is OFF. (See above). Check and verify voltage across machine output terminals, with a Multimeter. 4) Fault in AVR. Replace AVR and re- test. HIGH VOLTAGE (NO LOAD) 5) Loose broken or corroded connections. 6) Fault on power supply from main stator. 1) Sensing supply from Main Stator to AVR open circuit or too low. 2) AVR 'VOLTS' control or hand trimmer incorrectly set. 3) Sensing supply transformer or sensing module (PCB), faulty. 4) Burden resistor, fitted in AVR sensing supply, corroded or open circuit. (Pre 1987 Generators only.) Check the wiring for poor connections. Repair or replace where necessary. Check sensing supply voltage, as per Test Method A, Section 3, (item 13). Adjust as necessary. Ensure that the engine speed is correct first. AVR sensing supply circuit via dropper transformer, (4 or 6 wire Generators), or sensing PCB. Check sensing supply as per Test Method A, Section 3, (item 13). A fault on the burden resistor can create a high voltage condition. Normal resistance value 215 ohms. 5) AVR faulty. Replace AVR and re-test. Check connections on auxiliary terminal board and AVR terminals. Repair or replace if necessary. Check for speed instability with a frequency meter, or tachometer. Sometimes this problem will clear when a load is applied to the engine. Check AVR stability links, adjust stability potentiometer. Intermittent voltage fluctuations can be created by poor connections. Check auxiliary and AVR terminals. Megger all windings, (see section 2), including Exciter Stator, low insulation resistance can effect the AVR. Check AVR for corrosion or broken components. Replace AVR and re-test Panel mounted voltmeters are sensitive to vibration. Check and verify readings. Disconnect all external leads to Generator and re-test. Separately excite, (Test Method A Section 3). A winding short will get hot, and engine will sound slightly loaded. Shut down set and check by hand for hot spots. 13 Check current in each phase with clip-on ammeter. The full load rated current must NOT be exceeded on any individual phase. Re-distribute load if necessary. Check with a frequency meter or tachometer for speed variations due to governor 'hunting', or cyclic irregularities in the engine. Isolate the power factor correction capacitors until sufficient inductive load has been applied. (See Power Factors, Section 2). Check the load current on a stable supply, i.e. mains, or separately excite the machine. A variable D.C. supply is required for on load separate excitation tests. (See test method A, section 3). 4) Non linear load creating waveform distortion. (Contact factory for further information on non-linear loads). Use Permanent Magnet Generator (PMG), powered AVR control system. 5) AVR stability incorrectly adjusted. Adjust AVR, until voltage stabilises. HIGH VOLTAGE (ON LOAD) POOR VOLTAGE REGULATION (ON LOAD) 1) Unbalanced load. 2) Leading Power Factor load (capacitor banks). 3) Parallel droop current transformers reversed. 4) Burden resistor incorrectly set across improved regulation transformer. (Pre 1989 machines only). 1) Large speed droop on engine. AVR UFRO protection activated. 2) Unbalanced load. 3) Parallel droop circuit incorrectly adjusted, or requires shorting switch for single running. 4) Voltage drop between machine and load, due to I 2 R losses in supply cable. (This will be made worse by high motor starting current surges, etc). 5) Improved regulation equipment reversed. (Pre 1989 machines only). Check voltages on all phases. If unbalanced, re-distribute loading over three phases. A leading power factor will give an abnormally LOW DC excitation. Remove power factor correction capacitors from system at low load (see Power Factors Section 2). Check for droop reversal. (See section 6, parallel operation).