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Power Genera... Master
Re: no voltage out
Here is a simple test. With engine off apply 12v ac 1 amp to 110v outlet plug on generator. This will energize the field windings and cause the armature to produce dc voltage at the brushes and produce a nice magnet if all is well. If dc voltage is present at comutater, remove 12v ac and start engine to check for output. enjoy
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Capacitors typically fail due to overloading and large current inrushes like HVAC motors compressors etc. Or shorted wiring / windings. Diode? Are you referring to diodes in the exciter? Often fail due to over current
There are a few more components to check in the system. From the information provided this is not a Kohler generator as Kohler makes all their own AC alternators under 350KW, seems you may have just a Kohler engine (probably a CH25). Cannot find any info on the voltage regulator which leads me to believe it may be integrated into the main controller. Curious to know who the manufacturer is. If the capacitors are good, try checking the diodes. A volt/ohm meter with a diode check will do. Voltage reading on one side and nothing on the other. If you have no access to a diode check feature, try reading it through a battery NOT SHORTED TO BATTERY hook a meter to a battery and put the diode between one of the leads to the positive, one way will read voltage the other will read open, no voltage, or OL. Look for any fuses or breakers blown / tripped. 6 VAC on the output is about residual voltage meaning voltage the alternator makes without any help from a voltage regulator or field voltage. This usually means the alternator / rotor windings are still good. This alternator is brushless so you could seperately excite this unit via a 12V battery through your field. Look for your exciter field winding, it should have some kind of label on it saying F+ and F-, apply 12V here momentarily on + & - respectively with the unit running and you should see your output voltage spike. This tests the alternator. If this tests ok, then check to make sure your wiring / fuses from the alternator to the controller or voltage regulator (voltage sensing leads) are ok. If all these check ok, it is likely you have a bad voltage regulator.
According to the parts pdf, there is no voltage regulator. Voltage is adjusted by the rpm of the engine. If your have a meter that reads hertz (Hz), you can set the engine rpm by adjusting hertz to 60 cycles (Hz). At 60 cycles the engine is running at about 3600 rpm. Most engines develop their max horsepower at this rpm. If you are loosing power/voltage and the engine speed is not dropping below 3600, than most likely could be problem with capacitor, brushes or diode (bridge diode). The diode converts ac voltage from stator to direct current to power the magnet (rotor). Check for brush wear and test capacitor for value printed on part. It should test with 5% of stated value. Diode can also be easily tested with meter. Good holidays
High no-load voltage Capacitor with high capacity
Check and replace.
Low no-load voltage Speed to low Check and adjust rpm
Faulty rotary diodes Check and replace
Breakdown in windings Check winding resistance
Capacitor with low capacity Check and replace.
Proper no-load but low loaded voltage Capacitor with low capacity Check and replace.
if wires are connected start with the Diodes first electronics parts stores will have these in stock as well as cheeper.
hope this helps
Usually a power surge (short) or sometimes an overload will take out the diodes. Like you have suggested I would say that you have just knocked out one... Test them and replace the bad one and you should be good to go.
I hope that this will help you to solve your problem!
Hi there, Yes it is very possible that you blew 1 or more diodes in the rotor when you overrevved the generator. You also likely shorted the MOV devices that go across the diodes as well. What happened is that the over speed of the rotor caused it to make a much higher voltage than it was designed for and something had to give. I'd suggest that you also look at the capacitor that connects to the stator windings (it's a little like a voltage regulator), you've probably exceeded its voltage rating. This is pretty much why there are governor mechanisms on generators, much more than 20% or so overspeed makes nasty things happen.