Guardian Technologies 4582 & 4987 Testing ALL Stator Windings to Ground, Test Between Windings

Section 3

DESCRIPTION & COMPONENTS

or DPE winding, (c) a center tapped battery charge winding and (d) a 10 Amp center tapped battery charge winding. Insulation tests of the stator con- sist of (a) testing all windings to ground, (b) testing between isolated windings, and (c) testing between parallel windings. Figure 3-9 is a pictorial representa- tion of the various stator leads on units with air-cooled engine.

TESTING ALL STATOR WINDINGS TO GROUND:

1.Disconnect stator output leads Wire 11 and Wire 44 from the generator 50A circuit breaker.

2.Remove stator output lead Wire 22 from the neutral terminal on the back of the 50A outlet.

3.Disconnect the C1 connector from the bottom of the control panel. See Figure 3-10. The C1 connector is on the right when facing the control panel.

11

44

22

11S

44S

55A

66A

77A

2

6

55

66

77

Figure 3-9. – Stator Winding Leads

4.Connect the terminal ends of Wires 11, 22, and 44 together. Make sure the wire ends are not touching any part of the gen- erator 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, and 44. Connect the black tester lead to a clean frame ground on the stator can. With tes- ter 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 sock- et 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-sec- ond 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 C1 connector ( Female side – Just removed). Each winding will be individually tested for a short to ground. Insert a large paper clip (or similar item) into the C1 connector at the following pin locations:

Pin	Wire	Winding
Location	Number
1	11S	Sense Lead Power
2	44S	Sense Lead Power
3	55A	Battery Charge
4	66A	Battery Charge
5	77A	Battery Charge
6	2	Excitation
7	6	Excitation
8	55	10 Amp Battery Charge
9	66	10 Amp Battery Charge
10	77	10 Amp Battery Charge
11	4	(Positive lead to Brush)
12	0	(Negative lead to Brush)

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

Example: Insert paper clip into Pin 1, Hi-Pot from Pin 1 (Wire 11S) to ground. Proceed to Pin 2, Pin 3, etc. through Pin 10.

	77A	55A		11S	PIN
		66A
PIN	2		44S		LOCATION

LOCATION	1
6

PIN					PIN
		55	77	0	LOCATION
LOCATION					12
7	6		66	4

Figure 3-10. – C1 Connector Pin Location Numbers (Female Side, Located to the Right When Facing the Control Panel)

TEST BETWEEN WINDINGS:

1.Insert a paper clip into Pin Location 3 (Wire 55A). Connect the red tester probe to the paper clip. Connect the black tes- ter probe to Stator Lead 11. Refer to Steps 5a through 5c of

“TESTING ALL STATOR WINDINGS TO GROUND”.

2.Repeat Step 1 at Pin Location 6 (Wire 2) and Stator Lead 11.

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