BC
GENERATOR
ELECTRICAL
TESTING
DESCRIPTION
The BC generator is a brushless, self-excited generator which
requires only the driving force
of
the engine to produce an
AC output. The stator houses two sets
of
windings; the main
stator windings and the exciter windings. When the generator
is
started, residual magnetism in the four rotating poles
induces a voltage in the stator which then generates an even
larger voltage in the exciter windings. This mutual build up
of
voltage in the four rotating poles and in the exciter wind-
ings quickly reaches the saturation point
of
the capacitor(s)
and a regulated energy field is then maintained in the stator.
At the same time, this regulated field produces a steady volt-
age
in
the stator windings which can then be drawn off the
generator's AC terminals to operate AC equipment. The
generator is a single-phase, reconnectable
120 volt AC
two-wire or
115
volt AC two-wire
or
230 volt AC two-wire,
at
50
hertz.
The generator's data plate gives the voltage, current and
frequency rating
of
the generator. An
AC
wiring decal is
affixed to the inside
of
the louvered cover at the generator
end. A diagram
of
the various
AC
voltage connections is
provided on the decal.
An Integral Controller (IC) is mounted
inside the generator and supplies a continuous DC charge to
the generators. starting battery when the generator is running.
INTRODUCTION
TO
TROUBLESHOOTING
The following test procedures can be used to troubleshoot
WES'IERBEKE'S 4
POLE
SINGLE
AND
DUAL CAPACI-
TOR BRUSHLESS GENERATORS.
Due
to the simplicity
of
the generator, troubleshooting is relatively easy.
Field testing and repairing
can
be
accomplished with basic
tools and repair parts which should include the following:
A
quality
multimeter
[multitester]
capable
of
reading
less than one ohm and with a
specific diode testing
function.
Basic electrical tools including cutters, soldering iron,
wire strapper/crimper, terminals connectors, etc.
Repair
parts
such as diodes, fuses, bridge rectifier, etc.
PRELIMINARY
CHECKING
.
Before electrical testing
check
for proper engine
speedlhertz adjustment.
Low
engine speed will cause low
AC voltage output, high engine speed-high AC output.
Refer to
WES'IERBEKE'S
operators manual or service
manual for engine speedlhertz adjustment
or
for other
possible engine related problems.
Before testing, get a clear explanation
of
the problem that
exists, be certain it relates to generator components.
A
WARNING:
AC
and
DC
circuits
often
share
the
same
distributor
panel.
Be
certain
to
unplug
AC
power
cords
and
shutdown
DC/AC
inverters.
Simply
switching
off
circuit
breakers
will
not
do
the
job
since
it
will still
leave
hot
wires
on
the
supply
side
of
the
panel.
GENERATOR
TROUBLESHOOTING
CHART
A,
B,
C,
& D
refer
to
the
components
of
the
INTERNAL
WIRING
DIAGRAM
and
their
test
procedures
in
the
following
pages.
NOTE:
This fault finding chart is compiled assuming the engine
is operating
at
the correct
speed/hem
FAULT
No
AC
Output
Residual
Voltage
4-6
VAC
(Hot
N)
at
no-load
High
AC
Output
at
No-Load
Low
AC
Output
60-106V
Voltage
Drop
Under
Load
(or
at
No-Load)
No
Battery
Charge
Low
Battery
Charge
High
Voltage
Output
when
Load
is
applied
Unstable
Voltage
Noisy
Operation
CAUSE
TEST/CORRECTION
Shorted
stator
B
Open
stator
B
Shorted
diodes
[two]
. A
Faulty
capacitor
C
Open
exciter
B
Shorted
exciter
B
Engine
speed
[hertz]
is
too
low
Adjust*
Electrical
connections
Inspect
wiring
are
faulty
connections
Incorrect
voltage
tap
on
capacitor
C
Incorrect
capacitor
C
Incorrect
hertz
tap
on
capacitor
C
Engine
speed
[hertz]
is
too
high
Adjust*
Faulty-
rotor
winding
A
Faulty
diode
A
Faulty
capacitor
B
Faulty
diode
A
Faulty
capaCitor
C
Engine
speed
[hertz]
is
too
low
Adjust*
Faulty
bridge
rectifier
0
Faulty
integral
controller
0
Blown
fuse
B
Faulty
winding
B
Engine
speed
[hertz]
is
too
high
Adjust*
Electrical
connections
are
faulty,
loose
Faulty
support
bearing
Generator
rotor
Inspect
wiring
connections
Inspect
rear
bearing
* *
connection
to
engine
Check
rotor
is
loose
security**
* Refer to the GENERATORS OPERATOR MANUAL
**
Refer to the GENERATORS SERVICE MANUAL
Engines & Generators
:59
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