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Guardian Technologies 5209 User Manual

Page 3

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table of contents

Page 1

saFetY .................. insiDe FRont coveR (iFc)

NOTICE TO USERS OF THIS MANUAL ..............................IFC
REPLACEMENT PARTS .....................................................IFC

table oF contents ...................................... 1-2

section 1:

geneRatoR FunDaMentals ....................... 3-5

MAgNETISM ..................................................................... 3
ELECTROMAgNETIC FIELdS .............................................. 3
ELECTROMAgNETIC INdUCTION ...................................... 3
A SIMPLE AC gENERATOR ................................................ 4
A MORE SOPHISTICATEd AC gENERATOR ......................... 4

section 2:

MeasuRing electRicitY ............................. 6-8

METERS .......................................................................... 6
THE VOM ........................................................................ 6
MEASURINg AC VOLTAgE .............................................. 6
MEASURINg dC VOLTAgE .............................................. 6
MEASURINg AC FREqUENCy ......................................... 6
MEASURINg CURRENT .................................................... 7
MEASURINg RESISTANCE ................................................ 7
ELECTRICAL UNITS .......................................................... 8
OHM'S LAw .................................................................... 8

section 3:

DescRiption anD coMponents ............. 9-15

INTROdUCTION .............................................................. 9
ENgINE-gENERATOR dRIVE SySTEM ............................... 9
THE AC gENERATOR ....................................................... 9
ROTOR ASSEMbLy .......................................................... 9
STATOR ASSEMbLy ........................................................ 10
bRUSH HOLdER ANd bRUSHES ..................................... 10
OTHER AC gENERATOR COMPONENTS ........................ 10

EXCITATION CIRCUIT bREAKER .................................. 10
VOLTAgE REgULATOR .............................................. 11
AdJUSTMENT PROCEdURE ....................................... 11

CIRCUIT bREAKERS ................................................... 12

ROTOR RESIdUAL MAgNETISM ..................................... 12
FIELd bOOST CIRCUIT ................................................... 12
OPERATION ................................................................... 12

STARTUP ................................................................... 12

ON-SPEEd OPERATION .............................................. 12
FIELd EXCITATION ..................................................... 12
AC POwER wINdINg OUTPUT .................................. 12
bATTERy CHARgE wINdINg OUTPUT ....................... 12
10 AMP bATTERy CHARgE wINdINg OUTPUT .......... 12

INSULATION RESISTANCE .............................................. 13
THE MEgOHMMETER ................................................... 13

gENERAL .................................................................. 13
TESTINg STATOR INSULATION ................................... 13
TESTINg ROTOR INSULATION .................................... 13
HI-POT TESTER .......................................................... 13

STATOR INSULATION RESISTANCE TEST .......................... 13

gENERAL .................................................................. 13
TESTINg ALL STATOR wINdINgS TO gROUNd .......... 14
TEST bETwEEN wINdINgS: ....................................... 14

ROTOR INSULATION RESISTANCE TEST .......................... 15
CLEANINg THE gENERATOR ......................................... 15
dRyINg THE gENERATOR ............................................. 15

section 4:

engine Dc contRol sYsteM .................. 16-27

PRINTEd CIRCUIT bOARd .............................................. 16

gENERAL .................................................................. 16
CIRCUIT bOARd CONNECTIONS ............................... 16
dIP SwITCH POSITIONS ............................................. 16

bATTERy ....................................................................... 16

RECOMMENdEd bATTERy ........................................ 16

CONTROL PANEL COMPONENT IdENTIFICATION ...... 17-18
OPERATIONAL ANALySIS .......................................... 20-27

CIRCUIT CONdITION - REST ...................................... 20
CIRCUIT CONdITION - START .................................... 22
CIRCUIT CONdITION - RUN ....................................... 24
CIRCUIT CONdITION - STOP ...................................... 26
FAULT SHUTdOwN ................................................... 27

section 5:

tRoublesHooting FloWcHaRts .......... 28-36

INTROdUCTION ............................................................ 28
IF PRObLEM INVOLVES AC OUTPUT

............................... 28

PRObLEM 1 -

VOLTAgE & FREqUENCy ARE bOTH HIgH OR LOw .. 28

PRObLEM 2 -

gENERATOR PROdUCES ZERO VOLTAgE

OR RESIdUAL VOLTAgE (2-12 VAC) ...................... 29-30

PRObLEM 3 -

EXCESSIVE VOLTAgE/FREqUENCy

dROOP wHEN LOAd IS APPLIEd ............................... 30

PRObLEM 4 -

NO bATTERy CHARgE OUTPUT ................................. 31

PRObLEM 5 -

NO 10 AMP bATTERy CHARgE OUTPUT ................... 31

PRObLEM 6 -

ENgINE wILL NOT CRANK ........................................ 32

PRObLEM 7 -

ENgINE CRANKS bUT wILL NOT START ..................... 33

PRObLEM 8 -

ENgINE STARTS HARd ANd RUNS ROUgH ................ 34

PRObLEM 9 -

ENgINE STARTS THEN SHUTS dOwN ........................ 34

PRObLEM 10 -

10 AMP FUSE (F1) bLOwINg ..................................... 35

PRObLEM 11 -

UNIT OVERSPEEdS .................................................... 36

PRObLEM 12 -

IdLE CONTROL “RPM dOES NOT dECREASE” ........... 36

PRObLEM 13 -

IdLE CONTROL “RPM dOES NOT INCREASE

wHEN LOAd IS APPLIEd” .......................................... 36

PRObLEM 14 -

ENgINE “HUNTS” / ERRATIC IdLE .............................. 36

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