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Generator Repair Tips 1

A generator converts mechanical power into electrical power. It has different components that work together, such as the exciter fields that provide excitation and the diodes in the bridge that rectify output into direct current. When repairing or rewinding a generator, it is important to properly identify auxiliary windings that provide voltage for components and ensure matching pole numbers between corresponding parts. Testing individual components helps identify issues.

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Yasir Mehmood
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90 views2 pages

Generator Repair Tips 1

A generator converts mechanical power into electrical power. It has different components that work together, such as the exciter fields that provide excitation and the diodes in the bridge that rectify output into direct current. When repairing or rewinding a generator, it is important to properly identify auxiliary windings that provide voltage for components and ensure matching pole numbers between corresponding parts. Testing individual components helps identify issues.

Uploaded by

Yasir Mehmood
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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GENERATOR REPAIR TIPS

Wayne Hall The number of exciter poles are normally more


Jenkins Electric Company than the main generator poles. This provides a
Charlotte, North Carolina higher frequency that when rectified gives a
cleaner dc. The exciter fields are dc fields and
A generator is a machine that converts can be voltage dropped just like a field in a dc
mechanical power to electrical power, either ac or motor. If you need to rewind the exciter rotor it
dc. The mechanical power can be provided by a must have the same number of poles as the
number of different sources; such as, a diesel or exciter fields.
gasoline engine, water wheel, windmill, or electric The diode bridge has a positive rectifier plate
motor. An alternator is a specific type of generator and a negative rectifier plate. There is usually a
that converts mechanical power to ac electrical suppressor across the rectifier plates that
power. We will be focusing on alternators in this protects the diodes as well as the main stator. A
paper. multimeter will read between 0.4 and 0.7 volts on
the diode scale with the positive lead on the
EXCITATION METHODS anode and negative lead on the cathode. If you
swap the leads it will read open. If it reads open
There are different options for excitation in both directions or shorted in both directions
methods. First is a self-excited system. The then the diode needs to be replaced.
output from the alternator provides the power for The best way to test the PMG is while it is in
the Automatic Voltage Regulator (AVR) as well as service on the generator. Find the tag on the AVR
the sensing voltage to the regulator. to find the sensing voltage required and the
The second form of excitation is the separately required PMG output. With a multimeter measure
excited method using a permanent magnet these voltages to verify that they are within range.
generator (PMG). This configuration has a small If the output from the PMG is too low then either
PMG mounted on the non-drive end that supplies the PMG is weak or there is a fault in the PMG
power for the AVR. The main generator output stator.
still supplies the sensing voltage. A variac with both a rectified dc output and ac
Another form of excitation uses an Auxiliary output is a very useful tool in testing a generator.
Winding. The auxiliary winding is a separate It can be used to voltage drop the main rotor and
single-phase winding which is inserted into the the exciter fields with the controlled ac supply.
main stator in the same slots as the main output The controlled dc supply can be used to bypass
winding. the AVR and separately excite the exciter field.
While applying dc directly to the exciter field of an
HOW DOES IT WORK? unloaded generator you can measure the
required dc input voltage and current to generate
In the case of the PMG method of excitation the full voltage. This can be useful in sourcing an
PMG rotor produces a high frequency ac voltage aftermarket AVR.
in the PMG stator which the AVR uses to supply A resistive load, such as an incandescent light
dc to the exciter fields. This generates three bulb, is required to test the AVR. Connect the light
phase ac power in the exciter rotor which is bulb to F+/F- of the AVR. Apply required supply
rectified and fed into the main rotating fields. The voltage and sensing voltage to the AVR. Use a dc
main dc fields generates ac output from the main voltmeter to measure the output across F+ and F-
stator which provides feedback to the AVR. . Adjust the pot to dim and brighten the bulb.
Using the PMG allows the AVR excitation to Return the pot to the original output voltage.
remain at full capacity when sudden loads are
applied to the generator, giving better motor If You Have to Rewind the Generator
starting performance.
Before burnout, identify the leads. If there are
Component Characteristics and Testing leads other than output power leads, they may be

5933 Brookshire Blvd. Charlotte, NC 28216 P (800) 438-3003 F (800) 392-2612 JenkinsElectric.com
taps or auxiliary windings to provide voltage for
the AVR. If there are taps or auxiliary windings
present it is best to burn out the stator without
cutting the coil end.
There can be more than one auxiliary winding.
Some manufacturers use a single-phase
transformer auxiliary winding and a load
dependent booster winding. For the auxiliary
windings it is all about location, location, location
just like in real estate. Mark a slot as #1, the main
lead #1 is a good reference. Draw a diagram of
the auxiliary windings in reference to the marked
slot. Insert the main windings and auxiliary
windings in the same slots. The main winding
acts as the primary of a transformer and the
auxiliary winding acts as the secondary. If the
coils are not placed back in the same orientation,
it may have incorrect voltage supplied to the AVR.
When there are taps, count the number of coils
to the main lead and to the non-output lead. A tap
may be within a coil so count the number of turns
to the tap.
It is best to maintain the original winding data.
It is common for a manufacturer to use a 2/3 pitch
to eliminate third harmonics in the output. Always
verify that the number of poles in the main stator
matches the number of poles in the main rotor.

Wayne Hall
Jenkins Electric Company
5933 Brookshire Blvd
Charlotte, NC 28216
whall@jenkins.com
www.jenkins.com

5933 Brookshire Blvd. Charlotte, NC 28216 P (800) 438-3003 F (800) 392-2612 JenkinsElectric.com

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