This document provides a service manual for a generator set. It details possible causes and diagnoses for various alternator performance issues including low voltage, high voltage, poor response to load surges, and poor voltage regulation. For each issue, it lists potential causes such as engine speed problems, faulty regulators, wiring issues, and component failures. Diagnosis steps are provided to test components and adjust settings to identify and address the root cause.
This document provides a service manual for a generator set. It details possible causes and diagnoses for various alternator performance issues including low voltage, high voltage, poor response to load surges, and poor voltage regulation. For each issue, it lists potential causes such as engine speed problems, faulty regulators, wiring issues, and component failures. Diagnosis steps are provided to test components and adjust settings to identify and address the root cause.
This document provides a service manual for a generator set. It details possible causes and diagnoses for various alternator performance issues including low voltage, high voltage, poor response to load surges, and poor voltage regulation. For each issue, it lists potential causes such as engine speed problems, faulty regulators, wiring issues, and component failures. Diagnosis steps are provided to test components and adjust settings to identify and address the root cause.
This document provides a service manual for a generator set. It details possible causes and diagnoses for various alternator performance issues including low voltage, high voltage, poor response to load surges, and poor voltage regulation. For each issue, it lists potential causes such as engine speed problems, faulty regulators, wiring issues, and component failures. Diagnosis steps are provided to test components and adjust settings to identify and address the root cause.
Generator Set VTA28-G5 Engine with PowerCommand® 1.1 Control
C600 D6
English Original Instructions 6-2014 A047H770 (Issue 1) 7. Alternator Performance Troubleshooting 6-2014
• Run alternator again and check the excitation voltage across automatic voltage regulator output. If greater than 70 VDC, the protection circuit is operating correctly. 6. Main rectifier diodes short circuit • Check diodes. • Test diodes on the main rotating rectifier assembly with a multimeter. 7. Open circuit in exciter stator windings • Remove external leads from generator. Check the resistance value of the exciter stator across these two leads (approximately 18 to 30 ohms) with a multimeter. Refer to the procedure(s) in the troubleshooting and repair manual for the specific alternator for correct values. 8. Faulty automatic voltage regulator • Replace automatic voltage regulator and re-test. 9. Winding fault, open circuit, or short circuit • Remove external leads from the alternator. • Use appropriate metering equipment (Wheatstone bridge or Kelvin bridge). Measure the low resistance winding of the main rotor and stator.
7.2 Low Voltage (No Load)
Possible Causes: 1. Engine speed low, under frequency roll-off 2. Voltage sensing is faulty 3. Automatic voltage regulator voltage adjustment trim is configured incorrectly 4. Faulty automatic voltage regulator
7.2.1 Low Voltage (No Load) - Diagnosis and Repair
1. Engine speed low, under frequency roll-off • Under frequency roll-off protection is activated, indicating low engine speed. • Adjust or correct engine speed to an acceptable nominal. 2. Voltage sensing is faulty • Check and verify voltage at generator output terminals with a multimeter. 3. Automatic voltage regulator voltage adjustment trim is configured incorrectly • With the InPower service tool adjust nominal voltage parameter to the appropriate value for the application level. 4. Faulty automatic voltage regulator • Replace automatic voltage regulator and re-test.
7.3 High Voltage (No Load)
Possible Causes: 1. Automatic voltage regulator voltage adjustment trim is configured incorrectly
3. Non-linear loads causing interaction between dynamic closed loop control systems • The interaction of the alternator and the engine closed loop systems controls the load. • Instability is caused by oversensitive control settings. • Adjust automatic voltage regulator to high gain (stability) and load drive system to low gain. • Increase engine speed droop to stabilize engine. • Contact factory for further advice regarding non-linear loads. 4. Fluctuations in load current (motor starting or reciprocating loads) • Check the load current on a stable supply, i.e. mains or separately excite the machine. • A variable DC supply is required for on load separate excitation tests. 5. Automatic voltage regulator parameters configured incorrectly • With the InPower service tool adjust AVR control parameters, until voltage is stable.
7.8 Poor Voltage Regulation (With Load)
Possible Causes: 1. Large speed droop on engine 2. Unbalanced load 3. Automatic voltage regulator parameters configured incorrectly 4. Voltage drop between alternator and load, caused by losses in supply cable (power losses) 5. Fault on main rectifier or excitation winding 6. Under frequency roll-off protection activated
7.8.1 Poor Voltage Regulation (With Load) - Diagnosis and
Repair 1. Large speed droop on engine • Check that the speed droop from no load to full load is no greater than 4%. 2. Unbalanced load • Check voltage and load current on all phases. • If unbalanced, redistribute the load more evenly across the phases. 3. Automatic voltage regulator parameters configured incorrectly • With the InPower service tool, adjust automatic voltage regulator control parameters until voltage is stable. 4. Voltage drop between alternator and load, caused by losses in supply cable (power losses) • Check the voltage at both ends of the cable run at full load. • Large differences in voltages indicate a large volts drop along the cable. • A larger diameter cable is required in severe cases.
• Check the no load excitation voltage across automatic voltage regulator X+ (F1) and XX- (F2). • Voltage should be no higher than 12 VDC. 6. Under frequency roll-off protection activated • Under frequency roll-off protection is activated, indicating low engine speed. • Adjust or correct engine speed to an acceptable nominal.
7.9 Poor Response to Load Surges or Motor Starting
(With Load) Possible Causes: 1. Engine performance 2. Load current surges significantly exceed the full load of the generator 3. Under frequency roll-off protection on automatic voltage regulator operational 4. Voltage drop between alternator and load, caused by power losses in supply cable. This will be worse during current surges (motor starting and etc) 5. Automatic voltage regulator stability controls incorrectly set 6. Fault on windings or rotating rectifier 7. Fault in automatic voltage regulator
7.9.1 Poor Response to Load Surges or Motor Starting (With
Load) - Diagnosis and Repair 1. Engine performance • Check performance of the engine during application of load. 2. Load current surges significantly exceed the full load of the generator • Check surges with clip-on ammeter. • Check with factory for advice on voltage dips for motor starting. 3. Under frequency roll-off protectio on automatic voltage regulator operational • Check engine speed dip on load application. • Low engine speed will activate under frequency roll-off protection circuit. 4. Voltage drop between alternator and load caused by power losses in supply cable. This will be worse during current surges (motor starting and etc) • Check the voltage at both ends of the cable run at full load. • Differences in voltages indicate a volts drop along the cable. • A larger diameter cable may be required in severe cases. • This will be worse during current surges (motor starting and etc). 5. Automatic voltage regulator stability controls incorrectly set • Automatic voltage regulator gain and/or damping trims to the appropriate value(s). • Check again when loaded.
Possible Causes: 1. Unbalanced load 2. Leading power factor 3. Faulty automatic voltage regulator
7.11.1 High Voltage (With Load) - Diagnosis and Repair
1. Unbalanced load • Check voltage on all three phases. If unbalanced, re-distribute loading over the three phases. 2. Leading power factor • Check for capacitive (leading) PF load (i.e. kVA correction fluorescent lights). • Apply motor (lagging) PF load, or switch off capacitors. • A leading power factor load will give abnormally low DC excitation volts across X+ (F1) and XX-(F2). 3. Faulty automatic voltage regulator • Replace automatic voltage regulator and re-test.
7.12 Low Voltage (With Load)
Possible Causes: 1. Engine speed droop greater than 4% 2. Under frequency roll-off protection circuit operational 3. Faulty permanent magnet generator stator or rotor 4. Automatic voltage regulator faulty 5. Fault on winding or rotating diodes 6. Voltage drop between alternator and load, due to power losses in the cable
7.12.1 Low Voltage (With Load) - Diagnosis and Repair
1. Engine speed droop greater than 4% • Check engine speed at no load and full load. • Engine speed droop should be within + 4% and –1% of nominal speed. • Reset as necessary. 2. Under frequency roll-off protection circuit operational • Under frequency roll-off protection is activated, indicating low engine speed. • Adjust or correct engine speed to an acceptable nominal. 3. Faulty permanent magnet generator stator or rotor • Disconnect the permanent magnet generator leads from automatic voltage regulator terminals P2, P3, and P4. • Check voltage across leads with a multimeter, with the set running at correct speed.
Engine speed low. Test speed with tachometer. Adjust governor control to nominal speed. Under frequency protection (UFRO) Inspect UFRO LED at AVR. If lit, circuit activated. UFRO is activated, indicating low speed. Adjust engine speed, to within -1% to +4% of nominal. AVR volts control, or external hand trimmer incorrectly set. 1. Test engine speed is correct with tachometer, and UFRO is OFF. LOW VOLTAGE 2. Adjust voltage by AVR volts (NO LOAD) control, or remote trimmer. Panel voltmeter faulty or sticking. Test voltage at alternator terminals with a multimeter. AVR fault. Replace AVR and re-test. Loose broken or corroded connections. Inspect the wiring for poor connections. Repair or replace where necessary. Faulty power to AVR from main stator. Test the AVR sensing supply feedback in Faultfinding without AVR (see on page 91) Voltage sensing input to AVR is open Test the AVR sensing supply feedback circuit or too low. in Faultfinding without AVR (see on page 91) AVR volts control or external hand trimmer incorrectly set. 1. Test engine speed is correct with tachometer. 2. Adjust voltage by AVR volts HIGH VOLTAGE control, or remote trimmer. (NO LOAD) Faulty sensing supply circuit Test the AVR sensing supply feedback transformer (4 or 6 wire alternators) or in Faultfinding without AVR (see on sensing module (PCB). page 91) AVR fault. Replace AVR and re-test. Connections loose, broken or corroded. Inspect all auxiliary board terminals. Inspect AVR push-on terminals. Repair or renew where necessary. Engine governor unstable (hunting). Test engine speed stability with a frequency meter or tachometer. Sometimes this problem will clear when load is applied. AVR stability control incorrectly set. Inspect AVR stability links, adjust stability potentiometer. Connections loose or corroded. Inspect all auxiliary board terminals. UNSTABLE VOLTAGE Inspect AVR push-on terminals. (NO LOAD) Repair or renew where necessary. Intermittent earth (low resistance of Test the insulation resistance of all windings insulation). windings in Faultfinding without AVR (see on page 91) AVR components broken or corroded. Replace AVR and re-test Panel voltmeter faulty or vibrating. Test voltage at alternator terminals with a multimeter. UNBALANCED Fault on main stator windings. Test the main stator windings in VOLTAGE Faultfinding without AVR (see on page (NO LOAD) 91)
4. The diodes on the main rectifier assembly can be checked with a multimeter. The flexible leads connected to each diode should be disconnected at the terminal end, and the forward and reverse resistance checked. A healthy diode will indicate a very high resistance (infinity) in the reverse direction, and a low resistance in the forward direction. A faulty diode will give a full deflection reading in both directions with the test meter on the 10,000 Ohms scale, or an infinity reading in both directions. On an electronic digital meter a healthy diode will give a low reading in one direction, and a high reading in the other. Replace diode(s) if faulty. 7. The base board is faulty. a. If the previous steps did not identify a faulty component, replace the control.
13.66 Code 1448 - Underfrequency
Logic: The frequency has dropped below the “Underfrequency Threshold" for the time set in the “Underfrequency Delay" parameter.
Possible Causes: 1. Fault simulation is enabled. 2. Underfrequency threshold is set too high. 3. There are fuel or air delivery problems. 4. Overload. 5. See page 26 Fuel system issue(s). 6. Refer to Generator troubleshooting. Type your text
Diagnosis and Repair:
1. Fault simulation is enabled. a. Connect with InPower and ensure that the Fault simulation for Low Frequency is not enabled. If InPower is not available, cycle power to the control: 1. Depress the Emergency Stop button and wait 30 seconds. 2. Disconnect/disable the battery charger. 3. Disconnect the battery (disconnect negative first). 4. Leave the controller without power for 1 minute. 5. Reconnect the battery, enable the battery charger, pullout the E-Stop button, and reset the control (in this order). 2. Underfrequency threshold is set too high. A. To access the Underfrequency configuration menu on the operator panel go to Setup > OEM Setup > OEM ALT Setup > Underfrequency Threshold and set the “Underfrequency Threshold" Parameter appropriately for the application. Refer to the parameter list to see the default value for Underfrequency. 3. Check to see if there are any fuel or defect in fuel system problems. a. Refer to the Engine Service Manual.
