Bc Troubleshooting Manual

8/13/2019 Bc Troubleshooting Manual

1/16

ELECTRICAL TESTING

ND TROUBLESHOOTING GUIDE

Be GEN TORS

WESTER EKEWESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK150 JOHN HANCOCK ROAD TAUNTON MA 02780-7319 U.S.A.

TEL: 508)823-7677 FAX: 508)884-9688 WEBSITE: www.WESTERBEKE.COM

WESTERBEKE 65103 .tWA MI m1nr National MariM MW lujactu.rm As,rocialioll MARCH 2 2ND EDITION


2/16

T BLE OF CONTENTS

BC Generator Electrical Testing ............................2 Battery Charging Circuit/Bridge Rectifier ......... 10

Generator Troubleshooting Chart... : ................ 2 Testing the Bridge Rectifier .......................... 1 0

Internal Wiring Schematic 3 Integral Controller/Ballast Resistor ..................

C Terminal Board 3 Integral Controller LC.) ............................... 11

Low Voltage-Rotating Field Windings Tests ...... .4 Ballas t Resistor .......................... , .................. 11

Testing the Diodes ............................. .............. .4 Measuring Resistance ....................................11

Testing th Rotor Field Windings ..................... 5 Integral Controller/No-Load Voltage Adj . ............ 12

Residual Voltage Exciter Circuit Tests ................. 6 Testing the Integral Controller ...................... 12

Testing the Exciter Windings ........................... 6

Exciter Circuit Capacitor s) Tests 7

Fuse Protection .............................................. 12

Single/Dual Capacitor No-Load

Measuring Resistance ....................................... 7Voltage Adjustment ....................................... 12

Checking Continuity ......................................... 7 No-Load Voltage Adjustment Dual Exciter .......3

Testing the Capacitor s) .................................... 7 Dual Exciter Circuit Model ........................... 13

Exciting the Generator ...................................... 8 BC Generator Parts Identification ....................... 14

No Voltage Main Stator Windings Tests 8

Testing Residual Voltage .................................. 8

Checking Resistance ......................................... 8T Cstmg ontmlilty ............................................. 9

- . Y WESTER EKEngines Generators

1


3/16

BC GENER TOR ELECTRIC L TESTING

OESCRIPTION

The Be generator is a brushless, self-excited generator whichrequires only the driving force of the engine to produce anAC output. The stator houses two sets of windings; the mainstator windings and the exciter windings. When the generatoris started, residual magnetism in the four rotating polesinduces a voltage in the stator which then generates an evenlarger voltage n the exciter windings. This mutual build upof voltage n the four rotating poles and n the exciter windings quickly reaches the saturation point of the capacitor(s)and a regulated energy field is then maintained n the stator.At the same time, this regulated field produces a steady v o t ~age in the stator windings which can then be drawn off thegenerator s AC tenrunals to operate AC equipment. Thegenerator s a single-phase, reconnectable 120 volt ACtwo-wire or 115 voltAC two-wire or 230 voltAC two-wire,at 50 hertz.

The generator s dat a plate gives the voltage, current andfrequency rating of the generator. An AC wiring decal isaffixed to the inside of the louvered cove r at the generatorend. A diagram of the various AC voltage connections isprovided on the decal. An Integral Controller (IC) s mountedinside the generator and supplies a continuous DC charge tothe generators starting battery whe n the generator is running.

INTROOUCTION TO TROUBLESHOOTING

The following test procedures can be used to troubleshootWESTERBEKE S 4 POLE SINGLE ND DUAL CAPACI-TOR BRUSHLESS GENERATORS Due to the simplicityof the generator, troubleshooting is relatively easy.

Field testing and repairing can be accomplished with basictools and repair parts which should include the following:

A quality multimeter [muititesterj capable of readingless than one ohm and with a specific diode testingfunction.

Basic electrical tools including cutters, soldering iron,wire strapperlcrimper, terminals connectors, etc.

Repair parts such as diodes, fuses, bridge rectifier, etc.

PRELIMINARY CHECKING

Before electrical testing check for proper enginespeed/hertz adjustment. Low engine speed will cause lowAC voltage output, high engine s p e e ~ h i g hAC output.

Refer to WESTERBEKE S operators manual or servicemanual for engine speed/hertz adjustment or for otherpossible engine related problems.

Before testing, get a clear explanation of the problem thatexists, be certain it relates to generator components.

A WARNING ACand DCcircuits often share the samedistributorpanel. Be certain to unplug ACpower cordsand shutdown DC/ACInverters. Simplyswitchingoffcircuit breakers will not do the Job since t will stilileave hot wires on the supply side o the panel.

GENERATOR TROUBLESHOOTING CHARTA, B, C, & 0 refer to the components of the INTERNAL WIRING

DIAGRAMand their test procedures in the followingpages.

NOTE: This fault finding chan is compiled assuming the engineis operating at the correct speed/henz

FAULT CAUSE TEST/CORRECTIONNo G Output Shorted stator B

Open stator BShorted diodes [two] A

Residual Voltage Faulty capacitor C4-6 V G (Hot N) Open exciter Bat no-load Shorted exciter B

Engine speed [hertz]is too low Adjust'Electrical connections Inspect wiringare faulty connections

High C Output Incorrect voltage tapat No-Load on capacitor C

Incorrect capacitor CIncorrect hertz tap;on capacitor CEngine speed [hertz]is too hiqh . Adjust'

Low C Output Faulty rotor winding A60-106V Faulty diode A

Faulty capacitor :I

Voltage Drop Faulty diode AUnder Load(or at No-Load) Faulty capacitor C

Engine speed [hertz]

is too low Adjust'No Battery Charge Faulty bridge rectifier DLow Battery Charge Faulty integral controller D

Blown fuse BFaulty winding B

High Voltage Engine speed [hertz]Output when Load . is too high Adjust'is appliedUnstable Voltage Electrical connections Inspect wiring

are faulty, loose connectionsNoisy Operation Faulty support bearing Inspect rear

bearing

Generator rotorconnection to engine Check rotoris loose security

Refer to th GENERATORS OPERATOR MANUAL**Refer to the GENERATORS SERVICE MANUAL

I 'fIIV'IWESTERBEKEI ngines & Generators

2


4/16

Be GENER TORS P RTS

INTEGR L CONTROLLER

GROUNDTERMINAl

\/ .

0ALLASTRESISTER[EARLYMODElSj

CURRENT MODELB C GENER TORS

CAPACITOR

30 AMP FUSE

INTEGRAL CONTROLLER_;y _


5/16

INTERNALWIRINGSCHEMATICDC BATTERY CHARGING CIRCUIT

FUSE - INTEGRALCONTROLLER _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

A - ROTOR WINDINGS8 - STATORWINDINGS

WINDING:NO TIME DELAY Dpn 43634 30A250V MDA-30.

I , C CAPACITOR WINDINGr------,I

;Dlooq~ ~ ; _______ ~- I I ,

I I B I

o BATIERY CHARGE WINDING

BALLAST RESISTEREARLY MODELS}I I ,A I 2 _ 6 0 .I I 3 I +

Ie

DC CHARGE

~ - ~ ~l r g-rn-u::-----1S-

J

CONNECTFOR THE 18 C :REQUIREDFREQUENCY I

AND OUTPUTVOLTAG;E L ~ 5 0 :

- t : f ~ O ~-JWINDINGRESISTANCEVALUESIN OHMSMODEL SINGLE ACAPACITOR B

C0

MODEL DUAL ACAPACITOR B

C0

ROTORSTATOREXCITER.CHARGER

ROTORSTATOREXCITERCHARGER

3 SDO 6D

1 9DO 14D

4 0DDAD2.2DD.14D

GND -=- GND -=--

r - - - - - - .. ,I 0 CHARGE

- - - - - - - : *

i tEli .-------:-'--------------I I JI f .J

: I : : CAPACITOR RATINGS: A : 28: 18MF 25MF 31_5MF

ffI' MAKECERTAINA REPLACEMEN: I : CAPACITORHAS THECORRECTI I I NUMBER.CHECK THEBODY OFI I I CAPACITORFOR THE RATiNG A

, I I I PART NUMBER.

MODEL DUAL A ROTOR

~ J n ~~ J N N E C: , 9 1 8 REQUIRED FREQUENCY4 0D , 0 1 AND OUTPUTVOLTAGE

EXCITER CIRCUIT BC

0

N

L1

STATOR O 3D IEXCITERCHARGER

b ~ s ~ m l w i n d i n g:50.~ r - JC 60,50.,:____________________ __ J

A C TERMINALBOARDCONNECTIONSWITHCIRCUITBREAKERCURRENT MODELS]

N

@

120V/60Hz 115V/50Hz

Engines & Generators

3

NOTE:When changing from 60Hz50Hz. make certai n lhe ground wirproperly repositioned accordingthese diagrams

n3EPQl230V/50Hz

L1 N


6/16

LOW VOLTAGE - ROTATING FIELD AUXILIARYWINDINGSTESTS

A WARNING:Some of the following tests require thegenerator to be running make certain the front pulleycover and timing belt covers are in place.

ROTATING FIELD/AUXILIARYWINDINGS

r ~

A~j i i i I Q ~

J

DescriptionTwo sets o windings are found in the rotor assembly. An ACvoltage is produced in two groups of windings as the rotorturns at rated rpm. The AC voltage passes through each of

the two diodes mounted on the isolated fixture just before therotor carrier bearing The AC sine wave is changed to a DCand tills DC voltage is passed through the two groups ofrotating field windings producing a DC field around thesewindings. This field affects the AC winding of the two mainstator groups inducing an AC voltage in these windings thatis available at the AC terminal block connections.

Testing The Windings Thru the DiodesTo check the resistance values, rotate the engine s crankshaftto position the diode(s) on the generator s shaft at 12 o clock.To make a quick check of these windings, presume thediode is OK and place one of the ohmmeter s leads on theconnection at the top of the diode and the other lead at the

connection at the base of the diode. Compare readings withthe figures below.STANDARDRESISTANCE VALUESROTATING FIELDI AUXILIARYWINDINGS

Single CapacitorDual Capacitor

3.8 Ohms4.0 Ohms

TESTINGTHE DIODESf a distinct difference is noted in the ohm value, carefully

unsolder the lead on the top of the diode and remove thediode from its isolated heat sink using a thin walled, deepwell 7/16 in II mm) socket.To check the diode, unsolder the connection from the top of

the diode. Place one ohmmeter lead on the connection at thetop of the diode and the other ohmmeter lead to the diode sbase Then reverse the position of the ohmmeter leads

lOW RESISTANCE .)

TESTING THE DIODES

A low resistance should be found with the leads in onedirection, and infinite resistance (blocking) in the otherdirectionDIODES 8 9.5 OHMS APPROXIMATELY)USING 260 SIMPSO/\ANALOG METER

NOTE: Different meter models may show different ohmvalues but should read the same j r both diodes.

DIODE RATING 1600 AMPS 6 AMPS

The diode s rating is far in excess o the circuit s requirementMost likely a diode failure will result from an overspeed orload surge.

A CAUTION:[ON SOL ERING]When soldering use alarge enough soldering iron to get the job done quickly.Excessive heat will damage the diodes.Also make certain no soldering splashes onto thewindings as it will melt the insulation.

~ WESTER EKEngines Generators

4


7/16

LOW VOLT GE ROT TING FIELD UXILI RY WINDINGS TESTS

Testing the Rotor Field Auxiliary WindingsWith the diode removed, both leads for the first group ofrotating field/auxiliary windings will be isolated with nointerference from a possibly faulty diode.Check the resistance value of the rotating windings byplacing the ohmmeter s probes across the two exposed

leads.ROTOR WINDINGSRESISTANCEVALUES

Single Capacitor 3 8 ohmsDual Capacitor 4 0 ohmsDual Exciter Circuit 4 0 ohms

TESTlNG THE WINDINGLE DS

Testing Continuityheck that no continuity exists between either of the wind

ing leads and the generator shaft. f continuity s found,there is a short n the windings.Repeat the above tests on the second set of windings onthe opposite side.

TESTING FORCONTINUITY[TEST BOTH LE

ngines Generators

5


8/16

RESIDU L VOLT GE - EXCITER CIRCUIT TESTS

TESTING THE EXCITER WINDINGS

AC voltage can be measured across the capacitor s) while thegenerator is operating. This voltage may be s high s 400 toS volts AC. This voltage buildup is accomplished s theexciter windings charge the capacitor(s) and the capacitor(s)discharge back into the exciter windings. This AC voltagereading is taken between the 60 Hertz connector and the

connection plugged into the capacitor(s) while the generatoris operating at its rated Hertz (60.S - 61.S for gasoline modelsand 61.S - 62.0 for diesel models). This flow o saturatingAC in the exciter windings produces a phase-imbalance typeo field that effects the auxiliary windings: a beneficial resultthat produces good motor starting characteristics for this typeo generator

ME SURINGCVOLT GE

GENER TORRUNNING

. SINGLE C P CITORc

DUAl EXCITER

DU L C P CITOR

ngines Generators


9/16

EXCITER CIRCUITCAPACITOR S) TESTSMeasuring ResistanceTo measure the resistance of the exciter winding locate the

9 and the 50 Hertz capacitor connections.

NOTE: Three numbered capacitor connections exist: #7, #8,and 9; and two Hertz connections 50 and 60.

Unplug any other connections from the capacitor noting

their position on the capacitor. Place one probe of the multimeter on plug connection 9 and the other probe on the50 Hertz lead. Measure the resistance value of the exciterwindings and compare to the figures below.

NOTE Lower residual voltage along with a lower windingresistance will confirm a/aulty winding.

EXCITER WINDINGSRESISTANCESingle Capacitor Dual Capacitor Dual Exciter 8CA Model

1.9 ohms 2.2 ohms 1.3 ohms 1.5 ohms

GENERATOR \ llCASE

CHECKING ORCONTINUITYBETWEENLEAD50Hz LEAO9 TO CASE GROUND

- , ~ ; : ; :-","'"

MEASURINGRESISTANCE I ~ ~ ~ : ~VALUEOF THHXCITERWINDINGSBETWEENLEAOS19 50Hz

Checking Continuity

CHECKINGFORCONTINUITYBETWEENLEAO50Hz ANOLEAO 9TO THEAC TERMINALLEAOS

Check to make sure there is no continuity to theground/generator case from either of the two leads. Alsocheck that no continuity exists between either the 50Hertz plug or the #9 plug and any of the main statorwinding leads on the AC output. If continuity is foundhere, a fault exists between these two winding groups.An AC voltage is induced in these windings by therotating field Checking the residual voltage output fromthis winding can determine the condition of the windingwhen troubleshooting. Test between leads 50 and #9 withleads lifted off the capacitor(s).RESIDUALVOLTAGESingle Capacitor Model:Dual Exciter Model:Dual CapaCitor Model:

10 -14 Volts AC from each winding7 -9 Volts AC from each winding14 16 Volts AC from each winding

TESTING THE CAPACITORS ~ :

_ - d:: - ~ l~ I . i

8 1 I i, ' .)J

DISCHARGINGTHE CAPACITOR

A WARNING CapaCitors must be discharged beforehandling as they store electricity and can pack a poten-tially lethal charge even when disconnected from theirpower source.

Discharge the capacitor by a bridging the terminals with aninsulated screwdriver.

Connect a multite ster (highest ohm scale) to the capacitor terminals. The meter should go to zero ohms and slowly return

to high. Discharge the capacitor again and reverse the leads,the same results should be obtained.

f the meter goes down and stays at zero ohms, the capacitoris faulty (shorted)

f the meter fails to go down to zero, the capacitor is fault(open circuited).

Indications of a defe ctive capacitor:D Infinite resistance, or no rise in resistance

(shorted capacitor)D Infinite resistance (open capacitor)

MEASURINGCAPACITORRESISTANCE

AC

TERMINALBOARD

CAPACITOR RATINGS

Single Capacitor ModelsDual Capacitor ModelsDual Exciter Models

CAPACITORCONNECTIONS

25.0 MFD Pn#03598531.5 MFD Pn#03597818.0 MFIl Pn#039556

NOTE The older single capaci tor models have 25.0 microfaradcapacitors. New models now have 31.5 microfarad capacitorsDual exciter models have Q 18.0 MFD capacity.

The capacitor rating is marked on the housing of the capaci

ngines Generators

7


10/16

NO VOLT GE OUTPUT M IN ST TOR WINDINGS TESTS

B

EXCITING THE GENER TOR

The generator may be excited using 12 volts DC takenfrom the engine's starting battery. This voltage is appliedacross the 50 and 9 leads of the exciter circuit windings(unplugged) with any other numbered leads unpluggedfrom the capacitors. The generator's reaction


11/16

NO VOLT GE OUTPUT - M IN ST TOR WINDINGS TESTS

Testing ContinuityThere should not be any continuity between these two wind-ing groups. Test between terminal 3 and tenninal 6. If con-tinuity exists, there is a short in the windings.

There also should be no continuity between the terminals andthe generator case (ground).

M IN ST TORWIN ING LE DS

TESTING CONTINUITYBETWEEN THE TWOWINDING GROUPS

TESTING CONTINUITYE CH TERMIN L TOC SE GROUND

I

I

IIIIII

j

. v WESTER EKEngines Generators

9


12/16

B TTERY CH RGING CIRCUIT BRIDGE RECTIFIER

TESTINGTHE BATTERY CHARGINGCIRCUIT

- - ~ - - - - - -DC CHARGE,

IL oJ

NOTE The battery charging circuit is totally separate from theC output afthe generator: The generator output affects the

circuits output but not the reverse.

Nonnal AC voltage running to the rectifier (while theengine is operating at 1800 rpm) is measured across thetwo AC connections on the bridge rectifier (shown below).AC VOLTAGE TO THE BRIDGE RECTIFIER (APPROXIMATELY):

No load 011 the generatorFull load 011 the generator

16.0 volts AC17.5 volts AC

Nonnal DC voltage running out of the rectifier (in voltsDC) is measured across the two DC connections of thebridge rectifier, th at is + and - as illustrated.DC VOLTAGEFROM THE BRIDGE RECTIFIER (APPROXIMATELY):

No load 011 the generatorFull load 011 the generator

17.0 volts DC18.5 volts DC

Lift the two AC wire leads off the bridge rectifier andmeasure the resistance between these two leads. It shouldmeasure 0.14 ohm. No continuity should exist betweenthese two leads and the ground or the main stator windings.

RESISTANCE BETWEENAC LEADS 0.14 OHMS

~

I . . . . . . . . . : . . ~, '''''

- ~ - - 7 - G

N TESTING. - . I ~ONTINUITY

: , BETWEEN . J \ ~ ~ ~ ~ < ?: : AC LEADS ,1i'

: : & CASE GROUND

V/ AC LEAD, , t _ a J l I::~ :

MEASURING AC RESISTANCEBETWEEN AC LEADS

ALSO TEST THESE TWO LEADSTO THE AC TERMINAL BLOCKSTUDS TO VERIFY NO CONTINUITY

TESTINGTHE ,BRIDGERECTIFIER

1. Set your multimeter's scale on RXI (+DC) and set theneedle to zero.

2. Connec t the (+) positive lead from the multimeter to po4. Taking the mullimeter's negative (-) probe, momentarily

touch points 1, 2, 3, and 5. The multimeter shouldregister no deflection for any of the points touched.

3. Remove the positive (+) probe from point 4 and connethe negative (-) probe, momentarily touch points 1,and 3. The multimete r's needle should deflect when e,point is touched.

4. Leaving the negative multimeter (-) probe on point 4,touch point 5 with the positive probe. No deflection shtake place.

5. Place the positive (+) probe on point 1 and the negativprobe (-) on point 3. The multimeter again should notregister any deflection (no deflection indicates infiniteresistance), Reverse these connections and the multimetershould again register no deflection.

IF THE BRIDGERECTIFIER FAILSANY OF THE ABOVETESTS IT SHOULD BEREPLACED

4

~ ~

5MOUNTING HOLE 3

BRIDGERECTIFtER

ngines & Generators

1


13/16

INTEGR L CONTROLLER I B LL ST RESISTOR

INTEGRALCONTROLLER OLT ADJ POT~ y y y y

VOLT

+ ACBRIDGE

+ - GND RECTIFIER0

/ AC - )BLACKYEllOW

~ INTEGR L CONTROLLER

GROUND

INTEGR L CONTROLLER I.C.)The Integral Controller I.e.) is an encapsulated, solid-stateunit that supplies a DC charging voltage to the generator sstarting battery while the generator is operating.

Charging Voltage: 13 0 -14.0 Yolts DC

Charging Amperage: 0 -10 amps DC [Early Models]Charging Amperage: 0 - 17 amps DC [Current Models]

A separate group of stator windings supplies AC voltage to abridge rectifier which converts the AC current to supply theI.C. unit. The I.e. unit senses the needs of the starting batteryand supplies a DC charge when one is needed. If you suspectthat the I.C. unit is faulty (that is, if the battery s charge islow), check the charging circuit and it s components asdescribed in the following steps. Check all connections forcleanliness and tightness including the ground before replacing the I.e. . unit.

NOTE When the generator is firs t started the I. C. unit willproduce a low charging rate. This charging rate will rise sthe generator is operated.

The Integral Controller is mounted inside the generator housing in the 12:00 position. There is a voltage output adjustment on the controller that will allow a DC voltage outputadjustment of 2 volts.

DC CHARGEISOLATORTERMINAL 1 : C I . . . . . l ; v ~ .

E RLIER MODELINTEGR L CONTROLLER

THIS CONTROLLER PERFORMS THESAME FUNCTION AS THE CURRENTMODEL CONTROLLERS.

THE DC CHARGE ISOLATDR TERMINAL IS

NO LONGER USEO THE DC CHARGE LEAO

TO GROUNO TERMINAL

GO S DIRECT LY TO THE BATTERY TERMINAL \ \ , d P \ i t ~ ~ON THE STARTER SOLENOIO. STRIPEO . _IIWIRES ARE NOW SOLID COLORS

i lo< _ r r YOIT. ADJ POT

B LL ST RESISTOR

Early model integral controllers have a ballast resistorinstalled along the DC( +) lead running from the bridge rectifier to the integral controller. This coil -type resistor functionsto suppress high amperage draw coming from the controllerwhen it is trying to charge a discharged starting battery.

BAllASTR E S I S T O ~

50HZ- r :::60Hz DC CHARGE~1 - - - - - . l L . . - - - ~

- =GNO

E RLIER MODEL

CAPACITOR- - - I > - I / /

BRIDGERECTIFIER

BALLASTRESISTOR0 3 OHM

Measuring ResistanceThe resistance value of the ballast coil is measured betweenthe lifted (+) lead at the bridge rectifier and the 60 Hertzconnection unplugged from the controller (that is, controllershaving plugs in the connector).

Controllers with three leads corning from the controllermeasure resistance between the unplugged 60 Hertzconnection at the bridge rectifier and the brown leadconnection on the coil resistor tenninal block.

NOTE New four wire controllers eliminate the ballast resistorcircuit since the ballast resistor s unction is now handledinternally. Whenever replacing an early style controller withthe newer four wire model remove the ballast resistor nd its

wiring.

~ WESTER EKEngines Generators


14/16

INTEGRAL CONTROLLER NO LOAD VOLTAGE ADJUSTMENT

TESTING THE INTEGRAL CONTROLLER

To test the battery charger, put a multimeter between thepositive (+) and negative (-) leads to the battery. It shouldindicate l3.5V to l4V with the engine running. f only thebattery voltage is indicated, check that the battery chargerterminal connections are tight. With the unit running, testbetween the (+) and (-) tenninals for l3.5V to l4Y. fnocharge is indicated, replace the charger.

f GROUNDCONNECTION INTEGR L CONTROLLER

FUSE PROTECTION - '-

A 30 amp fuse protects the windings from a failure of thebridge rectifier or integral controller (high amperage or ashort)

SINGLE AND DUAL CAPACITOR NO LOAD VOLT GEADJUSTMENT

}, Remove the louvered metal plate, at the back of thegenerator, covering tile AC terminal connections andthe capacitor(s).

2, Start the generator and allow it to run for approximatelyfive minutes so the engine can warm up. Make sure thegenerator is oper.ating without any equipment drawing ACcurrent from the generator (that is, shut off all electricalappliances). Make sure the engine 's speed (Hertz) iscorrect. Adjust the governor as needed to obtain thecorrect engine speed before proceeding.

3. Refer to the AC TERMINAL BOARD CONNECTIONSDIAGRAM for the correct configuration then chec k thegenerator's no-load voltage by measuring the voltageacross the neutral lead and the hot lead with a voltmeter.Make sure you reco rd this reading. The generator's noload voltage is lIS - 124 volts at 60.5 - 61.5 Hertz. I f hevoltage output is higher or lower than specified, proceed.

4 hut off he generator. Make sure the correct Hertz lead(60 Hertz 6, or 50 Hertz #5) is plugged into thecapacitor(s).

c DU L C P CITOR

A WARNING: Capacitors must be discharged beforehandling as they store electricity and can pack a potential y lethal charge even when disconnected from theirpower source_

NOTESimply cross the capacitor s wo tenninals with an insu-lated plastic handle) screwdriver. This will discharge any

excess electricity.

A WARNING: 00 not attempt to make a no-loadvoltage adjustment while the generator is operating.The capacitor can produce a 400-500 voltcharge.Touching any wiringcan produce a severe electricalshock. In addition, attemptingto make a no-load voltage adjustment while the generator is operating couldcause your fingers to be caught in the generator s rotor_

5. There are three plugs grouped for the right capacitortenninal, 7, 8, and 9. If the gene rator's no-load voltageis low, then disconnect the lower numbered plug andconnect the plug with the n ext higher number. If thegenerato r's no-load voltage is high, then disconnect thehigher numbered p lug and connect the plug with the nextlower number. Note that the plug presently connected tothis tenninal may.be anyone of the three plugs available.

6. If the generator's no-load voltage cannot be adjustedbecause the voltage ne eds to be increased and the highestnumbered plug is already connected to the right tenninal,or the voltage needs to be lowered and the lowest numberedplug is connected, refe r to HERTZ ADJUSTMENT in theoperators manual.

::i: : : ' i ': # 7 # 8 # 9o 0

TH CONNECTIONSSHOWN DEMONSTRATEHOW TH S AOJUSTMENTSCAN BEMADE

~ WBTERSEKE7 8 9 Engines & GeneratorsSUHz 60Hz

12


15/16

NO LOAD VOLTAGEADJUSTMENT DUAL EXCITER

DUAL EXCITER CIRCUIT MODEL

These generators have dual Hertz and no-load voltage adjust-ment connectors at each capacitor. There are five connectorsavailable for each capacitor. Two connectors are for Hertzselection, 60 Hertz or 50 Hertz and three connectors, 7, 8,and 9, are for no-load voltage adjustment.When making Hertz change or no-load voltage adjustmentsproceed as follows:1 Shut the generator down.2 Select the appropriate Hertz connection to plug into each

capacitor 60, 60 Hertz, 1800 RPM or 50 Hertz, 1500RPM. The three other connectors at each capacitor 7,8, and 9, will have an effect on the no-load voltage

produced by the generator. One connector from eachgroup can be plugged into each capacitor. No-load voltagewill increase or decrease approximately 8 - 10 voltsbetween connectors used in any pair combination toachieve the prescribed no-load voltage.

C

50Hz 7 8 9 50Hz 60Hz 8 9

~ t 1 ~ r lA WARNING Make certain the insulating covers onthe unused leads are in place and are NOTin contactwith each other or in contact with the generator shousing.

NOTE When changing Hertz produced by the generatOl; {engine speed adjustment at the governor mus t be made.

he C output connections on the terminal blocks must beselected for the voltage and em to be produced heHertzp ug connection at the capacitor must be changed/or50 em ( 5) or 60 e m ( 6). Theframe ground wiremust be moved when changing from 11 5 volts 50 em to230 volts 50 Hertz. Refer to the C TERMINAL BOARDCONNECTIONS.

3. On later model BC generators, a 50Hz/60Hz connectionis provided for the DC battery circuit. When changinghertz, connect the proper lead (50Hz or 60Hz) to thebridge rectifier.

BATTERY CIRCUITCONNECTIONS 5O/60Hz[CURRENT MODELS]

C CONNECTION

Engines Generators

13


16/16

ngines Generators

1033 WM DW 3 2000

Documents

Bc Troubleshooting Manual