Trouble Shooting Pancake Generators

The Marathon PANCAKE is a 4 lead, brushless, AVR regulated generator. They are small, dedicated,
single phase generators between 8kW – 20kW. Normal output voltage is either 240Vac or 120Vac. A
complete listing of models and specifications is included at the end of this trouble shooting guide.

An PANCAKE generator is simple to trouble shoot with 6 main components: the exciter stator and
exciter rotor windings, a voltage regulator, a rectifier assembly, and the main stator and main
rotor windings. For tools you will need a good multi-meter – a Fluke works very well – a ratchet set,
and a set of screwdrivers. You can make an analog style meter work as well.

Figure 1

This trouble shooting guide is intended to address the most common causes of low or no output
voltage, usually 5V – 25V either Line-to-Line or Line-to-Neutral as measured at the generator output
terminal strip located in the connection box mounted on top of the generator.

If the generator has been sitting, unused, for 3 – 6 months, or longer it may have lost its residual
magnetic field required to build voltage. If you suspect this is the case, refer to the section on
Restoring Residual Magnetism near the end of this trouble shooting guide.

Start trouble shooting in the connection box mounted on the top of the generator. It gives easy access
to the exciter stator leads ( F+ & F- ) especially when the generator is mounted in a gen-set.

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 SAFETY NOTE – Dangerous Voltage May Be Present During Testing

Step 1 : Check Exciter Stator Continuity and Resistance

SAFETY NOTE –Testing the exciter stator must be done with the gen-set shut down.

Disconnect exciter stator leads F+ & F- from the voltage regulator – white leads in Figure 2.
Using digital multimeter or analog meter check continuity between F+ & F-. If you have NO
continuity between F+ & F- , you have a failed exciter stator winding.

Switch meter to auto-ranging Ohms setting check continuity between F+ and generator ground.
You should have at least 5-10 megOhms of resistance between the exciter stator and ground. A
new unit will have > 100 megOhms or more. If you HAVE continuity between F+ and
generator ground, or < 5 megOhms of resistance, you have a failed exciter stator
winding.

Figure 2

Using digital multimeter or analog meter, switch meter to auto-ranging Ohms setting and check
resistance between F+ & F-. Refer to Specifications Table for resistance by model.

If exciter stator resistance does not match table value within ± 5 Ohms, you have a failed
exciter stator winding.

Failed exciter stator cannot be repaired. Replace Exciter Stator

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Step 2 : Constant Excitation Test
SAFETY NOTE – The Constant Excitation test MUST be done with the gen-set running.

Disconnect exciter stator leads F+ & F- from the voltage regulator – white leads in Figure 1 and
observing polarity, connect to a 12V battery. The gen-set starting battery can be used as the
source of constant excitation.

Run the get-set, no-load with all breakers switched off. Measure output voltage at terminals 1 &
3 shown in Figure 1. A well-charged battery should give full output voltage – 240Vac or 120Vac
depending on generator connection – or possibly a bit more. Voltage should be equally
balanced L1 - N and L2 – N.

Possible Constant Excitation Test Results

Test Voltage Possible Corrective Action
216 – 252 Output voltage is within expected range. Exciter stator appears good.
Or Voltage Regulator has failed and must be replaced.
108 – 126
≤ 200 Output voltage is below expected range. Exciter stator appears good.
Or One or more diodes have failed. Replace Exciter Rotor and Integral
≤ 100 Rectifier Assembly.
≤ 50 Multiple component failures. Replace generator.
Unbalanced Voltage Main stator has failed. Replace generator.

Step 3 : Check the Main Stator Winding

The main stator windings are very low resistance which makes them difficult to test. Set meter
to the lowest possible Ohms scale. Connect one side to T1 and the other side to T3 – Black
Leads in Figure 1. You must have good continuity and should have a resistance reading
between .1 to .5 Ohms. Refer to Specifications Table for resistance by model.

If you have NO continuity or you have a significantly higher ohm reading – anything higher than
about 2 ohms you have a failed main stator winding.

Set meter to the highest possible Ohms scale. Check for continuity between T1 & T3 and the
ground terminal. Resistance should be greater than 2 megohms or infinite. If you have continuity
or < 2 megOhms resistance between the main stator leads and the ground terminal the main
stator is faulted to ground.

Failed main stator windings cannot be repaired. Replace generator.

If testing STEPS 1 - 3 have not found any faults or defects, move to the opposite drive end of the
generator to check the diodes on the rectifier assembly. You will need to remove the back cover to gain
access to the rectifier assembly which is integral with the exciter rotor. It is not necessary to remove
the exciter rotor.

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Step 4 : Checking Diodes / Rectifier Assembly
The diodes may be tested in place. The White leads connect to three FORWARD stud type
diodes, and the Black leads connect to three REVERSE stud type diodes.

Remove each of the exciter rotor leads from the quick-connect diode terminals and remove the
mail rotor leads from the main rotor terminals – note location of each for proper reassembly.

Figure 3

Multimeter Diode Test : Switch multimeter to diode test mode, place one lead on the top of a
diode, the other lead in contact with corresponding main terminal post. Test each of the three
FORWARD diodes in turn. Reverse test leads and repeat. A good diode will have no voltage
reading in one direction and 0.4 – 0.5Vdc in the other.

Repeat testing procedure for the three REVERSE diodes.

No voltage in either direction or voltage in both directions indicates a failed diode.

OR
Analog Meter: Place one lead on top of a diode, the other lead in contact with corresponding
main terminal post. Test each of the three FORWARD diodes in turn. Reverse test leads and
repeat. A good diode will have much greater resistance in one direction. Typical forward
resistance is under 100 Ohms. Typical resistance in the reverse direction is over 30,000 ohms.

Repeat testing procedure for the three REVERSE diodes.

Continuity with little or no resistance in both directions or very high resistance in both
directions indicates a failed diode.

Failed diodes must be replaced. Replace Integral Rectifier Assembly.

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Field Flashing / Restoring Residual Magnetism
If the generator has been sitting, unused, for 3 – 6 months, or longer it may have lost its residual
magnetic field required to build voltage.

12V Dynamic Field Flash

SAFETY NOTE – The Dynamic Field Flash MUST be done with the gen-set running.
Disconnect sensing & power leads 3 & 4 from the voltage regulator – black leads in Figure 4.
Insulate and isolate leads for safety.
Disconnect exciter stator leads F+ & F- from the voltage regulator – white leads in Figure 4 and
observing polarity, connect to a 12V battery. The gen-set starting battery can be used.

Run the get-set, no-load with all breakers switched off. Measure output voltage at terminals 1 &
3 shown in Figure 4. A well-charged battery should give full output voltage – 240Vac or 120Vac
depending on generator connection – or possibly a bit more.
If output voltage comes up to normal range, run generator for 15 minutes to build residual
magnetism.

Figure 4

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 Pancake Generator Connections

SINGLE PHASE CONNECTION - DUAL VOLTAGE SERIES

VOLTAGE

L-L L-N

60 HZ 240 120

SINGLE PHASE CONNECTION - SINGLE VOLTAGE PARALLEL

VOLTAGE

L-L

60 HZ 120

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 Pancake Generator Specifications

Current Production Models - 3/2/16

Exciter Exciter Main Stator

Standard Main
Model No kW Hz Stator Rotor
AVR L-L Res. Ω Rotor Ω
Ω Ω
(Series)
331CSA / CSB3018 SE350EL 8 60 23.7 0.49 0.50 1.48
332CSA / CSB3020 SE350EL 10 60 24.5 0.49 0.395 1.58
333CSA / CSB3024 SE350EL 15 60 28 0.55 0.20 1.88
334CSA / CSB3027 SE350EL 17.5 60 27 0.55 0.162 2.08
334CSA / CSB3028 SE350EL 20 60 27 0.55 0.162 2.08
334CDA3028 SE350EL 20 60 27 0.55 0.162 2.08

Legacy Models - 3/2/16

Exciter Exciter Main Stator

Standard Main
Model No kW Hz Stator Rotor
AVR L-L Res. Ω Rotor Ω
Ω Ω
(Series)
331RSA / RSB3002 VR63-4A 8 60 23.7 0.49 0.50 1.48
332RSA / RSB3004 VR63-4A 10 60 24.5 0.49 0.395 1.58
333RSA / RSB3008 VR63-4A 15 60 28 0.55 0.20 1.88
334RSA / RSB3010 VR63-4A 17.5 60 31.7 0.55 0.162 2.08
334RDA3028 VR63-4A 20 60 31.7 0.55 0.162 2.08
332CSA5204 VR63-4A 10 60 24.1 0.47 0.39 1.61
333CSA / CSB5205 VR63-4A 15 60 28 0.55 0.202 1.94
334CSA / CSB5207 VR63-4A 17.5 60 28 0.54 0.169 2.08
337CSB5209 VR63-4A 20 60 28.6 0.56 0.143 2.36
332RSA5017 VR63-4A 10 60 24.1 0.47 0.39 1.61
333RSA / RSB5048 VR63-4A 15 60 28 0.55 0.202 1.94
334RSA5003 VR63-4A 17.5 60 28 0.54 0.169 2.08
337RSB5012 VR63-4A 20 60 28.6 0.56 0.143 2.36

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