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Generator Problem

06/22/2010 9:47 AM

I have a 7.5 kw single phase air cooled gen set kirloskar make, the engine is running fine but the alternator is not giving any output.the set is 6 yearsold.

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#1

Re: generator problem

06/22/2010 10:18 AM

It would not be surprising if this alternator has a field rotor, the excitation of which is controlled by a regulator. Brushes are used to feed the field. These could be worn out, or a brush spring may be hanging up on the brush holder. The continuity of the combination of brushes and field coil can be tested together -- resistance should be low from one brush lead, through the brushes and field coil, to the other brush lead. If there is continuity from brush lead to the armature shaft, then the field coil has probably failed (the wire insulation is not doing its job) although there are other grounding possibilities, so the rotor should be bench tested before replacing it. If you are familiar with such things, you can see what should be grounded and what should not. Otherwise, a wiring diagram of the alternator and regulator will help.

The field is often fed through diodes which can fail. They can be tested with an ohmmeter. They should conduct in one direction but not the other.

The regulator may have failed. It is possible to briefly bypass the regulator, but one should only do this if skilled in electrical work.

Other possibilities: open field winding (check with ohmmeter); open stator winding(s) (check with ohmmeter). The first of these is slightly more likely that the second. Highly unlikely, but possible, is a sheared key in the coupling between engine and generator.

Be careful.

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#2

Re: Generator Problem

06/22/2010 2:43 PM

Is the output overcurrent protection device correctly set and in good order?

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#3
In reply to #2

Re: Generator Problem

06/23/2010 1:05 AM

It may be a brushless design, so the diode and resistor, or thyristor, on the armature may be dead.

Alternately the capacitor has degraded. This fairly common.

This as well as - not instead of all else above.

But I'd start at the capacitor - it's a cheap item and no pull down is involved - if that's all it is.

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#4

Re: Generator Problem

06/23/2010 2:16 PM

If the unit was not used for over 6 years (?) then:

After checking all that MoronicBumble (#1) has suggested and found every thing OK (or not sure...) do the following:

1) identify the Field connections. They are normally marked X and XX or + & -

2) Check that they are coming from the Voltage regulator if there is one (electronic board) or it could be a simple transformer + rectifier diodes. This type of transformer system is called a compound system... Anyway, disconnect the two wires from the rectifier or voltage regulator and connect them to a battery (12V or 6V DC). Just For A Short time like 3seconds. You can do this several times at intervals of ~ 10 sec. (2 or 3 times). make sure you are connecting the field winding and not the voltage regulator.

Explanation: These generators rely on the remanent magnetism in the iron of the rotor. If for any reason this magnetism has gone, due to not being used or sometimes due to a heavy short / overload of the genset, there will be no generation of any voltage.

The short application of a DC current on the field coils will re-juvenate this magnetism and allow the unit to build up the required voltage on starting.

Try the unit and see if it starts to generate a voltage.

If not, you have a bigger problem and as #1 answered ....

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#5

Re: Generator Problem

06/25/2010 11:05 AM

Probably the remenant magnetism in the core is lost. Do "field-falshing" (i.e.) apply 24V Dc to the field terminals for a very brief period. The voltage would build up fast and the magnetism in the core would also build up.

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