Guardian Technologies 4583, 4582 & 4987 Rotor Residual Magnetism, Field Boost Circuit, Operation

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Section 3

DESCRIPTION & COMPONENTS

with a 62 Hz AC frequency (62 Hz equals 3720 rpm). At the stated no-load frequency, adjust to obtain a line-to-line AC voltage of about 252 volts.

Circuit Breakers:

Each individual outlet on the generator is protected by a circuit breaker to prevent overload.

Rotor Residual Magnetism

The generator revolving field (rotor) may be consid- ered to be a permanent magnet. Some “residual” magnetism is always present in the rotor. This residu- al magnetism is sufficient to induce a voltage into the stator AC power windings that is approximately 2-12 volts AC.

Field Boost Circuit

When the engine is cranked during start-up, the START/STOP RELAY (SSR) will be energized. The normally open contacts of the SSR will close and Wire 15 will supply 12 VDC to Wire 14. Connected to Wire 14 is a resistor (R1) and a diode (D1). The resistor will limit current flow, and the diode will block Voltage Regulator DC output. Once through the resistor and diode it becomes Wire 4, and Wire 4 then connects to the positive brush. The effect is to “flash the field” every time the engine is cranked. Field boost current helps ensure that sufficient “pickup” voltage is avail- able on every startup to turn the Voltage Regulator on and build AC output voltage.

Notice that field boost current is always available dur- ing cranking and running, this is because the SSR is energized the whole time. The diode (D1) prevents or blocks the Voltage Regulators higher DC output from reaching the Wire 14 run circuit.

Field boost voltage is reduced from that of battery voltage by the resistor (R1), and when read with a DC voltmeter will be approximately 9 or 10 volts DC.

Operation

STARTUP:

When the engine is started, residual plus field boost magnetism from the rotor induces a voltage into (a) the stator AC power windings, (b) the stator excitation or DPE windings, (c) the stator battery charge wind- ings. In an “on-speed” (engine cranking) condition, residual plus field boost magnetism are capable of creating approximately one-half the unit’s rated volt- age.

ON-SPEED OPERATION:

As the engine accelerates, the voltage that is induced into the stator windings increases rapidly, due to the increasing speed at which the rotor operates.

FIELD EXCITATION:

An AC voltage is induced into the stator excitation (DPE) windings. The DPE winding circuit is completed to the Voltage Regulator, via Wire 2, Excitation Circuit Breaker, Wire 162, and Wire 6. Unregulated alternat- ing current can flow from the winding to the regulator.

The Voltage Regulator “senses” AC power winding output voltage and frequency via stator Wires 11S and 44S.

The regulator changes the AC from the excitation winding to DC. In addition, based on the Wires 11S and 44S sensing signals, it regulates the flow of direct current to the rotor.

The rectified and regulated current flow from the regu- lator is delivered to the rotor windings, via Wire 4, and the positive brush and slip ring. This excitation current flows through the rotor windings and is directed to ground through the negative (-) slip ring and brush, and Wire 0.

The greater the current flow through the rotor wind- ings, the more concentrated the lines of flux around the rotor become.

The more concentrated the lines of flux around the rotor that cut across the stationary stator windings, the greater the voltage that is induced into the stator windings.

Initially, the AC power winding voltage sensed by the regulator is low. The regulator reacts by increasing the flow of excitation current to the rotor until volt- age increases to a desired level. The regulator then maintains the desired voltage. For example, if voltage exceeds the desired level, the regulator will decrease the flow of excitation current. Conversely, if voltage drops below the desired level, the regulator responds by increasing the flow of excitation current.

AC POWER WINDING OUTPUT:

A regulated voltage is induced into the stator AC power windings. When electrical loads are connected across the AC power windings to complete the cir- cuit, current can flow in the circuit. The regulated AC power winding output voltage will be in direct propor- tion to the AC frequency. For example, on units rated 120/240 volts at 60 Hz, the regulator will try to main- tain 240 volts (line-to-line) at 60 Hz. This type of regu- lation system provides greatly improved motor starting capability over other types of systems.

BATTERY CHARGE WINDING OUTPUT:

A voltage is induced into the battery charge winding. Output from these windings is delivered to a Battery Charge Rectifier (BCR2), via Wires 55A, 66A and 77A. The resulting direct current from the BCR is delivered to the unit battery, via Wire 15, a 10 amp fuse, and Wire 13. This output is used to maintain bat- tery state of charge during operation.

10 Amp BATTERY CHARGE WINDING OUTPUT:

A voltage is induced into the battery charge winding. Output from these windings is delivered to a Battery Charge Rectifier (BCR1), via Wires 55, 66 and 77.

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Contents Diagnostic Repair Manual Safety Replacement PartsTable of Contents Section Disassembly and Exploded Views 66-71 Electromagnetic Induction MagnetismElectromagnetic Fields More Sophisticated AC Generator STATORs AC power windingsSimple AC Generator Generator Operating Diagram VOM MetersMeasuring AC Voltage Measuring DC VoltageMeasuring Current Measuring ResistanceElectrical Units Ohms LawEngine-Generator Drive System Rotor AssemblyIntroduction AC Generator Other AC Generator Components Stator AssemblyBrush Holder and Brushes Excitation Circuit BreakerVoltage Regulator Underfrequency Adjust162 Operation Rotor Residual MagnetismField Boost Circuit Stator Insulation Resistance Test Insulation ResistanceMegohmmeter Testing ALL Stator Windings to Ground Test Between WindingsDrying the Generator Cleaning the GeneratorRotor Insulation Resistance Test Printed Circuit Board BatteryRecommended Battery Circuit Board ConnectionsControl Panel Component Identification ENGINE DC CONTROLTerminal Block Terminal BLOCKTB2 TB1 C1 Female Side C1 Male SideC2 Female Side C2 Male Side Page Circuit Condition Rest = 12 VDC Control Circuit Condition Start IM1 SP1 IM2 SP2 RED Black Battery Circuit Condition RUN = Idle Control Transformer Output CIRcUIT Condition Stop Fault Shutdown Introduction If Problem Involves AC OutputProblem 1 Voltage & Frequency Are Both High or Low Or Replace If BAD Load Watts Problem 4 No Battery Charge Output Problem 5 No 10A Battery Charge OutputProblem 6 Engine Will Not Crank Problem 7 Engine Cranks But Will Not Start Problem 8 Engine Starts Hard and Runs Rough Problem 9 Engine Starts Then Shuts DownProblem 10 10 Amp Fuse F1 Blowing Problem 14 Engine Hunts / Erratic Idle Problem 11 Unit OverspeedsProblem 12 Idle Control RPM Does Not Decrease Test 2 Check Main Circuit Breaker ProcedureTest 1 Check No-Load Voltage Frequency ResultsSet voltmeter to measure AC voltage Test 4 Fixed Excitation Test Rotor AMP DrawIf circuit breaker is good, go on to Test AC Voltage across Wires 11S and 44S= Refer to Test 4 Results chartRemove air cleaner cover to access stepper motor Set a voltmeter to measure resistanceTest 6 Wire Continuity Test 7 Check Field BoostSet volt meter to the diode test range Disconnect both wires from the Resistor R1Test 8 DIODE/RESISTOR Set volt meter to measure resistanceFrom the 50 Amp receptacle disconnect Wire Test 9 Test StatorUnplug the six pin connector at the Voltage Regulator Test 10 Sensing LeadsTest 12 Check Brush Leads Test 11 Excitation WiringGain access to the brushes and slip rings Test 13 Check Brushes & Slip RingsTest 16 Check Load Watts & Amperage Test 14 Check Rotor AssemblyTest 15 Check Load Voltage Frequency If the unit is overloaded, reduce the loadDisconnect all wires from the Battery Charge Rectifier Test 17 Check Battery Charge OutputTest 19 Check Battery Charge Rectifier BCR2 BCR1BCR2 Test 22- Check Battery & CablesTest 21- Check 10 Amp Fuse Test 24 Check Starter Contactor SC Refer back to flow chartTest 23 Check Voltage at Starter Contactor SC Test 25 Check Starter MotorChecking the Pinion Tools for Starter Performance TestTest 26 Test Starter Contactor Relay SCR Set voltmeter to measure DC voltageReconnect all wires to the switch Test 27 Check Start-Run-Stop Switch SW1Test 28 Check Start-Run-Stop Switch SW1 Wiring Procedure Set voltmeter to measure resistanceTest 30 Check Spark Plugs Refer back to the Flow ChartTest 29 Check Ignition Spark SSR and the Battery Charge Rectifier 2 BCR2 Test 31 Remove Wire 18 / Shutdown LeadRefer to Flow Chart Test 32 Test Start Stop Relay SSRTest 33 Test Wire RUNMagnetos Test 34 Test Start Stop Relay WiringTest 35 Check and Adjust Ignition Test 38 Check Fuel Pump Test 36 Test Fuel Shutoff Solenoid FSSTest 37 Test Fuel Shutoff Solenoid Voltage MagnetoTest 39 Check Carburetion Test 40 Valve AdjustmentAdjusting Valve Clearance Adjust the regulated pressure on the gauge to 80 psi 52 Tightening the Jam NutTest 42 Check Oil Pressure Switch Wire Test 43 Check Start Stop Relay SSRTest 44 Test Starter Contactor Relay SCR Test 45 Check Wire 15 CircuitTest 46 Check Wire 14 Circuit Test 47 Check Fuel Shutoff SolenoidTest 51 Check Wires 11S & 44S Test 50 Check WireTest 49 Check Wire 15B Test 48 Check HourmeterSW2 Test 52 Check Idle Control SwitchTest 53 Check Idle Control Wiring TB2Test 55 Check TR1 & TR2 Wiring Test 54 Check Idle Control Transformers ICTTest 56 Choke Test Continuity should be measuredMajor Disassembly Remove air deflector Figure B, Item #45 from cross memberSupport Alternator 3317 3026 20 22 25 QTY Description Detail of Battery Tray QTY. Description ELECTRICAL DATA RED Battery Charge Winding BA Brush Assembly Governor Actuator 167 229 15B Power Winding DPE Winding SCR Wiring Diagram 17.5 kW Drawing No G0731 Stator Closest to Bearing Electrical Schematic 17.5 kW Drawing No G0733 Circuit 11 ORG Circuit 13 DRK BLU Circuit 15 PNK ELECTRICAL DATA Page Frequency Hz 238-242 59-61 100 Rated Max DC Load Amperes Current @ 12 VoltsLoad % Torque Specifications Trim Torque SpecificationsPO BOX 297 WHITEWATER, WI

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