Guardian Technologies 5308, 4582 & 4987, 4583 Megohmmeter, Stator Insulation Resistance Test

Page 15

Section 3

DESCRIPTION & COMPONENTS

The resulting direct current from the BCR is delivered to the 12 VDC receptacle, via Wire 13A, CB1, and Wire 15A. This receptacle allows the capability to recharge a 12 volt DC storage battery with provided battery charge cables.

Insulation Resistance

The insulation resistance of stator and rotor wind- ings is a measurement of the integrity of the insulat- ing materials that separate the electrical windings from the generator steel core. This resistance can degrade over time or due to such contaminants as dust, dirt, oil, grease and especially moisture. In most cases, failures of stator and rotor windings is due to a breakdown in the insulation. In many cases, a low insulation resistance is caused by moisture that collects while the generator is shut down. When problems are caused by moisture buildup on the windings, they can usually be corrected by drying the windings. Cleaning and drying the windings can usu- ally eliminate dirt and moisture built up in the genera- tor windings.

The Megohmmeter

GENERAL:

A megohmmeter, often called a “megger”, consists of a meter calibrated in megohms and a power supply. Use a power supply of 500 volts when testing stators or rotors. DO NOT APPLY VOLTAGE LONGER THAN ONE (1) SECOND.

TESTING STATOR INSULATION:

All parts that might be damaged by the high meg- ger voltages must be disconnected before testing. Isolate all stator leads (Figure 3-9) and connect all of the stator leads together. FOLLOW THE MEGGER MANUFACTURER’S INSTRUCTIONS CAREFULLY.

Use a megger power setting of 500 volts. Connect one megger test lead to the junction of all stator leads, the other test lead to frame ground on the stator can. Read the number of megohms on the meter.

The MINIMUM acceptable megger reading for stators may be calculated using the following formula:

MINIMUM INSULATION

 

GENERATOR RATED VOLTS

 

RESISTANCE

=

__________________________

+1

1000

(in “Megohms”)

 

 

 

 

 

 

 

 

 

EXAMPLE: Generator is rated at 120 volts AC. Divide “120” by “1000” to obtain “0.12”. Then add “1” to obtain “1.12” megohms. Minimum insulation resistance for a 120 VAC stator is 1.12 megohms.

If the stator insulation resistance is less than the cal- culated minimum resistance, clean and dry the stator. Then, repeat the test. If resistance is still low, replace the stator.

Use the Megger to test for shorts between isolated

windings as outlined “Stator Insulation Tests”.

Also test between parallel windings. See “Test Between Windings” on next page.

TESTING ROTOR INSULATION:

Apply a voltage of 500 volts across the rotor positive

(+)slip ring (nearest the rotor bearing), and a clean frame ground (i.e. the rotor shaft). DO NOT EXCEED 500 VOLTS AND DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND. FOLLOW THE MEGGER MANUFACTURER’S INSTRUCTIONS CAREFULLY.

ROTOR MINIMUM INSULATION RESISTANCE:

1.5megohms

* CAUTION: Before attempting to measure

Insulation resistance, first disconnect and Isolate all leads of the winding to be tested. Electronic components, diodes, surge protec- tors, relays, Voltage Regulators, etc., can be destroyed if subjected to high megger volt- ages.

HI-POT TESTER:

A“Hi-Pot” tester is shown in Figure 3-8. The model shown is only one of many that are commercially available. The tester shown is equipped with a voltage selector switch that permits the power supply voltage to be selected. It also mounts a breakdown lamp that will illuminate to indicate an insulation breakdown dur- ing the test.

Figure 3-8. – One Type of Hi-Pot Tester

Stator Insulation Resistance Test

GENERAL:

Units with air-cooled engines are equipped with (a) center tapped AC power windings, (b) an excitation

Page 13

Page 14 Page 16
Image 15
Page 14 Page 16
Contents Diagnostic Repair Manual Replacement Parts SafetyTable of Contents Section Disassembly and Exploded Views 66-71 Magnetism Electromagnetic FieldsElectromagnetic Induction STATORs AC power windings Simple AC GeneratorMore Sophisticated AC Generator Generator Operating Diagram Measuring DC Voltage MetersMeasuring AC Voltage VOMMeasuring Resistance Measuring CurrentOhms Law Electrical UnitsRotor Assembly Introduction AC GeneratorEngine-Generator Drive System Excitation Circuit Breaker Stator AssemblyBrush Holder and Brushes Other AC Generator ComponentsUnderfrequency Adjust 162Voltage Regulator Rotor Residual Magnetism Field Boost CircuitOperation Insulation Resistance MegohmmeterStator Insulation Resistance Test Test Between Windings Testing ALL Stator Windings to GroundCleaning the Generator Rotor Insulation Resistance TestDrying the Generator Circuit Board Connections BatteryRecommended Battery Printed Circuit BoardENGINE DC CONTROL Control Panel Component IdentificationC1 Female Side C1 Male Side C2 Female Side C2 Male SideTerminal Block Terminal BLOCKTB2 TB1 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 If Problem Involves AC Output Problem 1 Voltage & Frequency Are Both High or LowIntroduction Or Replace If BAD Load Watts Problem 5 No 10A Battery Charge Output Problem 4 No Battery Charge OutputProblem 6 Engine Will Not Crank Problem 7 Engine Cranks But Will Not Start Problem 9 Engine Starts Then Shuts Down Problem 8 Engine Starts Hard and Runs RoughProblem 10 10 Amp Fuse F1 Blowing Problem 11 Unit Overspeeds Problem 12 Idle Control RPM Does Not DecreaseProblem 14 Engine Hunts / Erratic Idle Results ProcedureTest 1 Check No-Load Voltage Frequency Test 2 Check Main Circuit BreakerTest 4 Fixed Excitation Test Rotor AMP Draw If circuit breaker is good, go on to TestSet voltmeter to measure AC voltage Refer to Test 4 Results chart AC Voltage across Wires 11S and 44S=Set a voltmeter to measure resistance Remove air cleaner cover to access stepper motorTest 7 Check Field Boost Test 6 Wire ContinuitySet volt meter to measure resistance Disconnect both wires from the Resistor R1Test 8 DIODE/RESISTOR Set volt meter to the diode test rangeTest 9 Test Stator From the 50 Amp receptacle disconnect WireTest 10 Sensing Leads Unplug the six pin connector at the Voltage RegulatorTest 13 Check Brushes & Slip Rings Test 11 Excitation WiringGain access to the brushes and slip rings Test 12 Check Brush LeadsIf the unit is overloaded, reduce the load Test 14 Check Rotor AssemblyTest 15 Check Load Voltage Frequency Test 16 Check Load Watts & AmperageTest 17 Check Battery Charge Output Test 19 Check Battery Charge Rectifier BCR2Disconnect all wires from the Battery Charge Rectifier Test 22- Check Battery & Cables Test 21- Check 10 Amp FuseBCR1BCR2 Test 25 Check Starter Motor Refer back to flow chartTest 23 Check Voltage at Starter Contactor SC Test 24 Check Starter Contactor SCTools for Starter Performance Test Checking the PinionSet voltmeter to measure DC voltage Test 26 Test Starter Contactor Relay SCRProcedure Set voltmeter to measure resistance Test 27 Check Start-Run-Stop Switch SW1Test 28 Check Start-Run-Stop Switch SW1 Wiring Reconnect all wires to the switchRefer back to the Flow Chart Test 29 Check Ignition SparkTest 30 Check Spark Plugs Test 32 Test Start Stop Relay SSR Test 31 Remove Wire 18 / Shutdown LeadRefer to Flow Chart SSR and the Battery Charge Rectifier 2 BCR2RUN Test 33 Test WireTest 34 Test Start Stop Relay Wiring Test 35 Check and Adjust IgnitionMagnetos Magneto Test 36 Test Fuel Shutoff Solenoid FSSTest 37 Test Fuel Shutoff Solenoid Voltage Test 38 Check Fuel PumpTest 40 Valve Adjustment Adjusting Valve ClearanceTest 39 Check Carburetion 52 Tightening the Jam Nut Adjust the regulated pressure on the gauge to 80 psiTest 43 Check Start Stop Relay SSR Test 42 Check Oil Pressure Switch WireTest 47 Check Fuel Shutoff Solenoid Test 45 Check Wire 15 CircuitTest 46 Check Wire 14 Circuit Test 44 Test Starter Contactor Relay SCRTest 48 Check Hourmeter Test 50 Check WireTest 49 Check Wire 15B Test 51 Check Wires 11S & 44STB2 Test 52 Check Idle Control SwitchTest 53 Check Idle Control Wiring SW2Test 54 Check Idle Control Transformers ICT Test 55 Check TR1 & TR2 WiringContinuity should be measured Test 56 Choke TestRemove air deflector Figure B, Item #45 from cross member Major DisassemblySupport 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 Rated Max DC Load Amperes Current @ 12 Volts Load %Frequency Hz 238-242 59-61 100 Trim Torque Specifications Torque SpecificationsPO BOX 297 WHITEWATER, WI

5308, 4583, 4451 & 4986, 4582 & 4987 specifications

Guardian Technologies has carved a niche in the market with its innovative air purification and UV-C sanitization products. The company's model numbers, including 4582, 4987, 4451, 4986, 4583, and 5308, represent a diverse range of solutions designed to enhance indoor air quality and safety in both residential and commercial settings.

The Guardian Technologies 4582 is equipped with a true HEPA filter that captures 99.97% of dust, pollen, smoke, and other particles as small as 0.3 microns. This model features a smart sensor that adjusts the fan speed according to the air quality in real-time. The UV-C light technology integrated into this device works to eliminate viruses and bacteria, providing an additional layer of protection against airborne pathogens.

The 4987 model follows suit with similar advanced features but adds a sleek design ideal for modern interiors. With multiple speed settings and a night mode, the 4987 is perfect for bedrooms or quiet spaces. Its energy-efficient operation coupled with an indicator that signals filter replacement ensures that users maintain optimal performance effortlessly.

The Guardian Technologies 4451 and 4986 models are particularly notable for their enhanced capacity and filtration efficiency. Both units incorporate a three-in-one filtration system that includes a pre-filter, activated charcoal filter, and HEPA filter. With their strategic design, these models not only purify the air but also trap common household odors, making them a popular choice for families with pets.

The 4583 model stands out with a unique combination of design and functionality. It features a low-profile design, making it easy to fit into any space. Its UV-C light technology not only disinfects air but can also sanitize surfaces, bridging the gap between air purification and direct sanitation.

Finally, the Guardian Technologies 5308 caters to larger spaces, offering impressive air circulation and filtration capabilities. Equipped with a high-efficiency particulate air (HEPA) filter and a powerful fan, it effectively cleans larger areas while maintaining whisper-quiet operation.

In summary, Guardian Technologies’ products exemplify a commitment to improving air quality and promoting health through innovative technology. With features like HEPA filtration, UV-C sanitization, smart sensors, and sleek designs, consumers can choose from a range of models that best fit their needs, ensuring cleaner, safer indoor environments.
Top Page Image Contents