Generator common faults and troubleshooting
methods
The generators with electric control
generator sets or electronic speed control generator sets have different oil
supply systems, but the generators of the two units are brushless excitation
generators, and the AVR regulator is used to stabilize the output voltage.
Generally, programmable or dedicated microprocessor controllers are used. The
basic principles of various types of generator sets are the same, and the
methods of fault handling have the same.
Common faults of the unit are: the unit
can't drive in the manual position; the unit can't drive in the automatic
position; the engine can drive but can't start, the display fails and alarms;
the engine runs, but can't reach the rated speed; the engine runs but the
burning is rough or Surge; engine output is low (ie load is limited or unable
to load or can not be fully loaded); voltage or frequency is unstable when
loading; generator no-load voltage is low; no load is no voltage; no AC output;
generator output voltage is too high Or too low; phase current imbalance;
controller failure; fault alarm or fault shutdown during operation. Below we
introduce the basic principles, methods and steps of modern generator set fault
handling.
Basic principles of fault diagnosis for modern generator sets
The modern generator set is a sophisticated and complicated system, and
its fault diagnosis is also difficult. The cause of the unit not working or
working abnormally may be the electronic control system or other parts of the
electronic control system. The difficulty of the inspection is also different.
If you can follow some basic principles of fault diagnosis, you can use the
simple method to find out the fault accurately and quickly.
The basic principles for troubleshooting
the unit fault diagnosis can be summarized as follows:
1) When the external unit fails, first
check the possible fault parts outside the electronic control system. This
avoids the fault that is not related to the electronic control system, but to
the system sensor, computer, actuator and line. Perform complex inspections
with time-consuming and laborious inspections, and real failures may be easier
to find but not found.
2) Check the possible fault locations that
can be checked in a simple way. For example, the visual inspection is the
simplest. You can use visual inspection methods such as watching, touching, and
listening to find out some of the more obvious faults quickly. The visual
inspection method will be introduced in the basic method below. When the visual
inspection does not find the fault and needs to be checked by instrumentation
or other special tools, it should be checked first.
3) Pre-cooked and born. Due to the
structure and environment, the fault phenomenon of the unit may be the most
common fault of some assemblies or components. These common fault locations
should be checked first. If the fault is not found, check other unusable
possible fault locations. This can often find faults quickly, saving time and
effort.
4) Code-prioritized electronic control
system generally has fault self-diagnosis function. When the electronic control
system has some kind of fault, the fault self-diagnosis system will immediately
detect the fault and alert the operator through warning lights such as “monitor
engine” or prompt. At the same time, the information of the fault is stored in code.
For some faults, before the fault self-diagnosis system is inspected, the fault
code should be read according to the method provided by the manufacturer, and
the fault location indicated by the code should be checked and excluded. After
the fault indicated by the fault code is eliminated, if the engine fault
phenomenon has not been eliminated, or if there is no fault code output at the
beginning, then the possible fault location of the engine is checked.
5) Think before you perform fault analysis
on the fault phenomenon of the generator set, and then perform fault check on
the basis of understanding the possible causes of the fault. In this way, the
blindness of the fault check can be avoided. It will not invalidate the parts
that are not related to the fault phenomenon, and can avoid the missed
detection of some related parts and cannot quickly eliminate the fault.
6) After use, the performance of some
components of the electronic control system is good or bad, and the electrical
circuit is normal or not, often judged by parameters such as voltage or
resistance value. Without these data, the system's failure detection will be
difficult, and often only new parts replacement methods can be adopted. These
methods sometimes cause maintenance costs to increase and labor and time. The
so-called after-use use means that when the type of unit is being overhauled,
the relevant maintenance data of the unit type should be prepared. In addition
to the maintenance data, another effective way is to use the fault-free unit to
measure the relevant parameters of the system and record it as a comparison
parameter for the inspection of the same unit in the future. If you usually pay
attention to doing this work, it will bring convenience to system fault
checking.
Special Note: Unit failures are not
necessarily in the electronic control system. If the generator set is found to
be faulty and the fault warning light is not lit (no fault code is displayed),
in most cases, the fault is checked according to the basic diagnostic procedures.
Otherwise, you may encounter a fault that was not related to the electronic
control system, but it takes a lot of time to check the sensors, actuators and
circuits of the electronic control system, but the real fault is not found.
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