Guardian Technologies 4456, 4390 Testing ALL Stator Windings to Ground, Test Between Windings

GENERAL INFORMATION

PART 1

SECTION 1.4

TESTING, CLEANING AND DRYING

TESTING ALL STATOR WINDINGS TO GROUND:

1.Disconnect stator output leads 11 and 44 from the generator main line circuit breaker.

2.Remove stator output leads 22 and 33 from the neutral connection and separate the two leads.

3.Disconnect C2 connector from the side of the control panel. The C2 connector is the closest to the back panel.

Figure 2. Stator Winding Leads

4.Connect the terminal ends of Wires 11, 22, 33 and 44 together. Make sure the wire ends are not touching any part of the generator frame or any terminal.

5.Connect the red test probe of the Hi-Pot tester to the joined terminal ends of stator leads 11, 22, 33 and 44. Connect the black tester lead to a clean frame ground on the stator can. With tester leads connected in this manner, proceed as follows:

a.Turn the Hi-Pot tester switch OFF.

b.Plug the tester cord into a 120 volt AC wall socket and set its voltage selector switch to "1500 volts".

c.Turn the tester switch "On" and observe the breakdown lamp on tester. DO NOT APPLY VOLTAGE LONGER THAN 1 SECOND. After one (1) second, turn the tester switch OFF.

If the breakdown lamp comes on during the one- second test, the stator should be cleaned and dried. After cleaning and drying, repeat the insulation test. If, after cleaning and drying, the stator fails the second test, the stator assembly should be replaced.

6.Now proceed to the C2 connector. Each winding will be individually tested for a short to ground. Insert a large paper clip (or similar item) into the C2 connector at the following pin locations:

Pin	Wire	Winding
Location	Number
1	77	Battery Charge
2	66	Battery Charge
3	66A	Engine Run
4	55	Engine Run
5	22	Sense Lead Power
6	11	Sense Lead Power
7	6	Excitation
8	2	Excitation

Next refer to Steps 5a through 5c of the Hi-Pot procedure.

Example: Insert paper clip into Pin 1, Hi-Pot from Pin 1 (Wire 77) to ground. Proceed to Pin 2, Pin 3, etc. through Pin 8.

Figure 3. C2 Connector Pin Location Numbers

(Female Side)

TEST BETWEEN WINDINGS:

1.Insert a large paper clip into Pin Location 1 (Wire 77). Connect the red tester probe to the paper clip. Connect the black tester probe to Stator Lead 11. Refer to Steps 5a through 5c of “TESTING ALL STATOR WINDINGS TO GROUND” on the previous page.

2.Repeat Step 1 at Pin Location 3 (Wire 66A) and Stator Lead 11.

3.Repeat Step 1 at Pin Location 7 (Wire 6). and Stator Lead 11.

4.Connect the red test probe to Stator Lead 33. Connect the black test probe to Stator Lead 11. Refer to Steps 5a through 5c of “TESTING ALL STATOR WINDINGS TO GROUND” on the previous page.

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