Genny not generating, still sitting in the dark. . . any generator advice???

[Christyhicks]

So, early this morning, we started getting a flicker in the lights, seemed like the generator was running as smooth as ever, no voltage drop according to our digital meter, but had us concerned.  We ran to McDonalds for a sausage biscuit, swung up to the office to grab a few things and some oil for Genny, just in case, and when we got back to the house, the power was out.  Genny was running, but nothing coming out of her.

We shut her down and took her up to the shop, and we're getting no field voltage.  Larry suspects the Static Voltage Regulator, but we can't seem to come up with a wiring diagram for the generator.  The voltage regulator is a Basler vr 63.4, but that search pretty much comes up blank.  The generator puts out 125 amps @ 240. . .trying to remember the brand  . . . . . . Larry's drawing a blank  . . . .

(So I google "industrial air compressors" cause he's sure it was the same name as an industrial air compressor. . . after me naming about 50 different brands, I get a hit on a Sullair. . . yayyyyyy,) it's a Sullair generator. . not that this helps anyone tell us what is wrong, ha ha.  So, anyone have a clue where to start?  Thanks, Christy Hicks

P.S., Yes, we've been without real power since Monday, and just to kick a woman when she's down, today I get the mail and guess what it is in with it. . .yep, you guessed it, our UTILITY BILL!  hahahaha

[NJT 5573]

Maybe you need some brushes. It could be an easy fix.

[Christyhicks]

Um, this one doesn't have brushes. . . I wish, ha ha. Thanks anyway though! Christy

[tekebird]

http://www.basler.com/html/rscacc.htm

[Ncbob]

Christy, Try these folks.  They also rebuild Voltage regulators and might have a rebuilt in stock.   Good Luck.  http://www.flightsystems.com/bmk_regulators.html

Bob

[Christyhicks]

Yeah, I already checked the Basler site, but they don't list this voltage regulator in their downloads. . .I'm really trying to find out if there's anything we can check this weekend.  Come Monday, I imagine we can find out more info from local companies, but I was kind of hoping that someone on the board might have suggestions for troubleshooting or some wiring diagrams for this style of generator.  We don't even know if the voltage regulator is bad yet. . .we're just wondering where it gets it's power.  . .or, how to tell if it's the generator head itself.  . . that type of thing.  Thanks and please, keep swinging at it,    Christy

[ChuckMC9]

And the most unhelpful post in this thread...

We ran to McDonalds for a sausage biscuit

THAT was your first mistake!

(sorry 'bout that)

[DrivingMissLazy]

The alternator is probably a Lima or Kato or Marathon if the unit was manufactured in the US. According to your description it would be identified as a brushless, synchronous, revolving field alternator. This should be on the alternator name tag, along with the DC excitation voltage required.

The Basler 64.3 regulator, as I recall is a small beige colored plastic box a little larger than a pack of cigarettes. Its output is in the 10-50 volt range up to a maximum of about 60 volts I believe and its input excitation voltage is 120 volts. Probably only four connections. Two are AC input and two are DC output.

The engine must be running to accomplish these tests

First, disconnect all the loads or turn off the output circuit breaker if you have one.

Then remove the leads from the VR. Jumper a 12 volt battery to the DC output leads going to the alternator that you disconnected from the VR.

Can not remember the numbers unfortunately, but the regulator case should be marked. You should then get about the normal output from the genset. Somewhere in the 160 to 200 volt range. Might even be a little over the 240 volt rating of the genset, but not very much more. Polarity of the battery input is not really critical in this test. If you do not get any voltage then the problem is in the alternator.

If you get an AC output voltage, then the alternator is working properly. If you do get AC voltage from this test, then reconnect the VR leads.

The next test is to connect the same DC voltage to the DC terminals of the VR momentarily after you have re-connected them. Do not leave the is DC connected to the regulator for more than a couple or three seconds. This is flashing the field. You should then get an immediate AC output voltage and the unit should continue to output the proper AC voltage when you remove the external field flashing voltage. If you do not continue to get AC voltage when you remove the flashing voltage then the regulator is defective.

There are many regulators available to replace the VR 64.3. Any one that outputs 0-125 volts DC with 120 volt input will work directly. I know Marathon makes an exact duplicate of the Basler 64.3 under the Marathon name. 

It is truly a very simple system. If you need me to walk you thru it give me a call at
three zero four, nine two seven, four zero nine three.

Richard

[Len Silva]

Go back to the basler site here http://www.basler.com/php/download_page.php?section=regulation#VR634UL

You can download the product bulletin and the instruction manual.

Len

[boogiethecat]

If it turns out that you need a regulator and you don't like basler's prices, consider getting one of these: AVR12 from Solesco
http://www.solesco.com/AVRmenu.html

They are cheap ($75-80) and I LOVE them.  I've used 5-6 now on various generators and they seem to be truly universal, super simple to install and reliable.  There is a hitch, they need to have 208-240 coming in to them to work.  If your genset has 208-240 connections it's easy, otherwise it'd require a small step up transformer to create 240 out of your 120 volts, probably in the 300 watt range.

[DrivingMissLazy]

She stated it is connected for 240 volt output, so it should be OK.

If anyone has her phone number, call her and ask her to call me. I do not know if she has power to monitor the computer or not. I can probably work her thru a temporary fix it the regulator is bad.

Richard

[Christyhicks]

Finally got back online for a few mins. . .got your messages, thanks a million Richard. . .I've got your number written down, will print your post out for Larry and we'll attack it in the morn.  Your description was so good, I wondered if maybe you were looking over our shoulder or something earlier today! 

Len, thanks for the link.   Thanks again everyone, and will let you know what happens in the morn.  We think the utility guys will have us going in the morn  . . .they were so close and worked for at least two hours after dark. . poor guys. . .it sure was cold and windy today. . .not pleasant at all for these guys, especially the ones who came up here from the gulf coast. . leaving 80 degree weather to work up here in the 30's!

Oh, and ahem, Chuck, hahaha, you kill me you goof.

The good news is, well, we cheat  .  We started the 3200 watt portable genny, (we're currently running off a 4.5 Onan from our old motorhome), while Larry worked his end, I worked mine. . .we took a long piece of SO cord, he wired up a short piece of romex on his end, while I did mine, he shoved his into the 240v outlet on the genny right after I tied my end to the well wires, I plugged the water heater into another cord, and we jumped into the shower. 

Guess I wasted that bottle of wine we drank. . .cause I smell pretty anyway.  (for those of you who missed the earlier chat room, I explained that I was chilling a bottle of wine outside, was going to ply Larry with wine so he didn't realize how much I smelled without taking a shower tonight.  Couldn't cook, so wrapped some cheese up inside some luncheon meat and tried to convince him it was fancy hor-de-vours ). 

Anyway, thanks all. . . going to call it a night. . .will let you know what we find out tomorrow.  Christy Hicks

[Prather]

Check all your wire connections, Over the years all my generator failures have been broken wires. Trouble shooting will give you all types of indicated failures but in my experience it has always been a broken wire some where. Sometimes they are hard  to find. Maybe you will get lucky

Prather

[larryh]

OK Christy, guess I'm feeling sorry for Larry so I'm going out and start the fans headed East and will start them blowing heat up to you two you probably wish you had come SW by now don't feel too bad it was 37 here this morning up to 42 but by the time it gets to you two it should be low 70's enjoy.

Larry Have fun

LarryH should be there by wednesday this week.

[DrivingMissLazy]

Finally got back online for a few mins. . .got your messages, thanks a million Richard. . .I've got your number written down, will print your post out for Larry and we'll attack it in the morn.  Your description was so good, I wondered if maybe you were looking over our shoulder or something earlier today! 

Len, thanks for the link.   Thanks again everyone, and will let you know what happens in the morn.  We think the utility guys will have us going in the morn  . . .they were so close and worked for at least two hours after dark. . poor guys. . .it sure was cold and windy today. . .not pleasant at all for these guys, especially the ones who came up here from the gulf coast. . leaving 80 degree weather to work up here in the 30's!

Oh, and ahem, Chuck, hahaha, you kill me you goof.

The good news is, well, we cheat  .  We started the 3200 watt portable genny, (we're currently running off a 4.5 Onan from our old motorhome), while Larry worked his end, I worked mine. . .we took a long piece of SO cord, he wired up a short piece of romex on his end, while I did mine, he shoved his into the 240v outlet on the genny right after I tied my end to the well wires, I plugged the water heater into another cord, and we jumped into the shower. 

Guess I wasted that bottle of wine we drank. . .cause I smell pretty anyway.  (for those of you who missed the earlier chat room, I explained that I was chilling a bottle of wine outside, was going to ply Larry with wine so he didn't realize how much I smelled without taking a shower tonight.  Couldn't cook, so wrapped some cheese up inside some luncheon meat and tried to convince him it was fancy hor-de-vours ). 

Anyway, thanks all. . . going to call it a night. . .will let you know what we find out tomorrow.  Christy Hicks

Hope I was some help. As you can tell I have spent quite a bit of time over the past 50 years on those beasts. I tried to cover the highlights but I have a lot more information that can help, depending on what you find out from the preliminary data I supplied including how to convert to manual voltage regulation if the VR is bad.

Richard