Sometimes, a generator will stop working. A low electrical or mechanical input may have caused this and the only option available is to restart the generator by passing a current through it.
The reason for flashing a generator is to restart it after it stops and the process is quite easy and requires simple tools without any special skills. Follow the steps below for flashing your generator.
Why Does a Generator Run Without Producing Electricity?
Errors or blockages in the excitation circuit
Identify the error in the circuit wiring and correct it.
Locate and reconnect the blocked excitation winding with a multimeter for blocked circuits. When a poor connection is the cause, the oxide layer on the surface needs polishing until smooth. This will help the bolt and nut connect firmly.
Remove the brush assembly and examine it for damage, breaking, or sticking. Carbon brushes are rectangular components that insert into an assembly and pop in and out easily.
Discharge any remaining charge on the capacitor by removing it from the generator. Measure its charge with a multimeter. Capacitor readings must be within +/- 5uf of the rating indicated on the side. If not, contact a technician.
An excitation winding that has broken or grounded
Make sure the excitation winding is ground insulated by using a 500V ohmmeter. Identify the ground point, find and repair the broken winding using a multimeter.
A voltage regulator that does not work and needs replacing
The alternator cover of your generator needs removing. Unscrew the two spade connectors from the brush assembly.
Now, take out the screws securing the AVR in place. Detach the quick connector, attach the new AVR, and reassemble the unit as directed.
Lost magnetic residuals
The alternator has electromagnetic components that need a small amount of residual magnetism for priming to generate electricity.
There are several cases where residual magnetism becomes lost. For example, it ran out of gas with a load when left unused for a long time. Turning off the engine during a load can also be a cause
If connections are bad, clean any particles, debris, or obstructions, and secure everything.
Before starting the generator again, identify the cause of the breaker trip and remedy it.
If you have low or no voltage, you have a defective breaker. A defective breaker is suspected if the voltage isn’t responding to the loads.
How to Flash a Generator With a Battery?
Step 1: Remove exciter fields
Voltage regulator exciter leads F+ and F- must get disconnected. Flashing a regulator without removing the field lead causes regulators to become damaged.
Step 2: Get rid of the persistent winding
Using the F+ and F- leads, measure the excitation field resistance. A continuous winding should display some resistance when you measure it. A reading of zero resistance indicates an open exciter field. Make sure that there are no paths to the ground.
Step 3: Associate the F+
A positive battery pole connects to F+
Step 4: Contact the negative lead
Hold the F- wire by the insulated end of the lead wire F- against the negative terminal. Hold for about three to five seconds, before removing. If there is an arc, the F- wire should get disconnected.
Step 5: Reconnect F- and F+
F- and F+ need reconnecting to the regulator. If the generator doesn’t build voltage, repeat the procedure.