Generator Troubleshooting

8/12/2019 Generator Troubleshooting

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It is essential that all test instruments areregularly checked for safety, and any connectionleads, probes, or clips, are checked to ensurethat they are suitable for the voltage levels beingtested.

Never attempt to test a "LIVE" generator unlessthere is another competent person present whocan switch off the power supply or shut down theengine in an emergency.

Never expose "LIVE" connections unless youhave created a safe working area around you.

Make sure you have made all other persons in theimmediate area fully aware of what you are doing.


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Item 1 Multimeter

The Multimeter is a comprehensive test instrument for measuringvoltage, current and resistance. It should be capable ofmeasuring the following ranges:-Voltage A C 0-250-500-1000 VoltsVoltage D C 0-25-100-250 Volts

Amperes D C 0-10 AmpsD C Resistance 0-10k (ohms) or 0-2k (ohms)

0-100k (ohms) or 0-20k (ohms)0-1M (ohms) or 0-200k (ohms)

MEDIUM AND HIGH VOLTAGEGENERATORS3.3 kVolt to 13.6 kVoltDo not attempt to carry out tests on highvoltage Generators without usingspecialisedinstruments and probes.Suitable protection equipment and safety


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Item 2 Tachometer or Frequency meter

This instrument is for measuring the shaft speed of the alternatorand should be capable of measuring speeds between 0 and 5000revolutions per minute, (RPM).

An alternative to the tachometer is the frequency meter (seeSection 2 on Frequency and Speed, for details). However theGenerator must be operating at its normal output voltage for thisinstrument to be accurate.



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Item 3 Megger (Insulation test meter)

This instrument generates a voltage of 500V or 1000V, and isused to measure the resistance value of the insulation to earth(ground). It may be an electronic push button type, or a handcranked generator type.



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Voltage and Current (Amperes)

Current creates a temperature rise in the windings, hence the requirement fordrawing air through the AC Generator by means of the cooling fan. If the full loadrated current is exceeded on any phase of the main stator windings, it will result inoverheating in this winding. Similarly, any restriction in the flow of air through themachine will result in a rapid increase in the temperature of the windings.


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Frequency (Hz) and Speed (RPM)

An AC Generator is a constant speed device, and should not be operated atspeeds 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 becapable of returning to the steady state condition within a few seconds.The shaft speed requirements for the AC Generator are determined by:-

(a) The frequency, (Hz), requirements of the load(b) The number of poles,( main rotors), in the generator


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Frequency (Hz) and Speed (RPM)

( ) = ( )60 ( )

This can be shown more clearly in a chart: -

Frequency(Hz) Speed(R.P.M.) No. of Poles(rotor coils)

50 1500 4

60 1800 4

50 1000 660 1200 6

50 3000 2

60 3600 2

From this chart, a simple formula isproduced to calculate the speed from thefrequency, or vice versa.

4 pole machine 1 cycle (Hz) = 30 R.P.M.




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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 1.5horsepower.


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Kilowatts (kW) kilo Volt Amperes (kVA) and Power Factors (pf.)

Kilowatts are calculated by the formula: -

kVA (kilo Volt Amperes), are calculated by theformula:-

=

1000

Both equations are multiplied by 3 (1.732) for a 3 phase machine.


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Power Factor

The Power Factor (pf), is a measure of wasted current, which is a productof inductive loads such as motors, transformers, (magnetic circuits), andsome forms of lighting.

The formula for calculating the Power Factor is:-

pf =


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Unity Power Factor (pf 1)

Purely resistive load, i.e. heating, tungsten filament lighting, has a powerfactor of one, (pf1), and contains very little Wattless (inductive) load, whichis power factor zero, (pf 0).

An AC Generator will deliver continuously the rated full load current at anypower 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 areequal; therefore the engine is supplying 20% more kW load at pf1, than atpf 0.8. It is important, therefore, that this is taken into consideration, whenapproaching 75% to 100% load current of the Generator, with a power

factorhigher than 0.8.


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Lagging Power Factors

A Generator is designed to deliver the full load current at any power factorbetween unity and 0.8 lagging. Certain loads have a power factor lowerthan 0,8 lag, e.g. welding transformers; autotransformer, motor starting,

gas discharge lighting. A reduction in the full load (kVA), rating is requiredfor a continuous lagging pf lower than 0.8.


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Leading Power Factors

Capacitive load e.g. some fluorescent lighting, and power factor correctioncapacitor banks, produce leading power factor current. The latter isrequired 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 fromthe 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.


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Eventually the control system will be unable to control the Generatorexcitation level, and voltage instability will occur. The degree of instability isdetermined by the kVAr size of the capacitors, relative to the kVA size ofthe 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 loadwill mainly consist of lighting, and possibly power factor correctioncapacitors. In this situation the AC Generator will see a very low, (leading ),power factor, and may become unstable, and/or generate high voltage.


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In order to prevent this situation, it is advisable to ensure that thepower factor correction capacitors are switched OFF when thegenerator takes the initial load.Further advice in this respect may be obtained from CumminsGenerator Technologies if required.


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Resistances - measuring component values

When fault finding it is necessary to measure the resistance values ofcomponents and windings, and compare them with known normal values,in order to identify a faulty winding. The normal resistances of the windingsare given in the winding resistance charts, in the generator installation andmaintenance handbooks, service and maintenance section. Resistancevalues above 10 ohms can be measured accurately with a multimeter.Between 0.5 and 5 ohms a multimeter has a limited accuracy, and othertest methods may be adopted.


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Resistances between 0.5 And 5 Ohms

The resistance value of a winding such as a brushless main rotor will bebetween 0.5 and 3 ohms. A multimeter may not give an accurate enoughreading at these levels. If a Wheatstone Bridge Resistance Meter is notavailable, an accurate measurement can be obtained by means of abattery supply, using a Multimeter in series on the 10 Amps D.C. range.Most Multimeters have this current range, or alternatively, a batterycharging Ammeter could be used instead).


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Resistances between 0.5 And 5 Ohms

Using 6 volt battery cells the resistance of the winding can becalculated i.e.

Generator Troubleshooting

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