-

Bateman- KWG GEMA

Supplemental Troubleshooting Guide TSS-1C

1
IMPORTANT-Before Removing the Generator

Prior to removing the generator and controller from the diesel or hydraulic
power source, it is important to perform the trouble shooting tests and checks
that can only be completed with the generator spinning at the proper design
speed.

The Operator or Service Personnel must make note of what has occurred, that
causes the magnet from not working:

• Was the Magnet cable cut or pulled apart when snagged on the material
being processed?
• Did an Error light display on the HMI, and was there Short Circuit or OPEN
• Code displayed, along with an HW number displayed to the right of the
Value for Torque? (See page 12 for HW- codes)
• Once the generator is removed it is difficult to test, without the HMI, all
connecting Cables and magnet assembly.

2
Types and Sizes

3
 Components
Exciter Rotor: mounted beside main generator rotor on common shaft.
Provides the energy (+14 VDC) for the Main Rotor.

Exciter Stator: pressed into the Main generator body at fan end of extruded body.

Purpose: Creates Exciter 5-40 VDC Voltage which powers the Main Generator rotor.
Exciter Stator voltage is controlled by the DVR Digital Voltage Regulator
which controls the output voltage of the generator.

Main Rotor: Provides the Magnetization to produce the AC Voltage.

Main Stator: Provides the 3 Phase, 155-170 VAC to the Circuit Board in the Controller.

Rectifier: Integrated in the circuit board to convert the AC Voltage to DC Voltage.

Self Contained: The Generator requires no external voltage to function.

Maintenance Free: Brushless Design 4

 What size Generator do I need?
• What is the machine lifting capacity?
• What is the diameter of your magnet?
• What is the cold amp rating for your magnet?
• What is the condition of your magnet?
• What is the Ohm resistance measurement across conductors?
• Have you checked resistance from Conductors to ground at case?
• Match the Magnet to the Generator size.
• The Generator only produces the required current required for the magnet.
Example: 15kW - 4 Pole Max Output is 65 Amp’s., 48” Magnet draws 44 amps @
230 VDC and 10.1 kW.

5
 ELECTRICAL SAFETY!
• Only properly Trained Qualified
Electrical Personnel should
attempt internal tests.

• Wait 5 Minutes after using

Magnet for residual electricity to
dissipate before working on the
Cable, Plugs or Magnet.

• Magnet Cable and plug

installations and inspections
must be performed with the
generator and machine engine
turned off.

• Allow Magnet to cool before

servicing.
6
 My “Magnet” Quit Working!
Visually Check – Equipment Running
• Is Magnet connected?
• Is Generator Turning
• Is the HMI and Green LED Light
illuminated?
• Are the Performance Details; Gen Speed,
Voltage and kW output, etc. displayed on
Screen?
• Is the RED LED Error Light illuminated?
• Is the RED LED Error Light Illuminated and
“SC” displayed on right side of 230 Volt
Text ?
Possible Solutions
ü With equipment turned OFF, check magnet cable
plugs at rear of Controller and each plug for a
secure connection.
ü Verify solenoid control switch is turned on and
Control valve has shifted. Test for 24VDC at
solenoid plug.
ü Verify that the HMI Cable is securely connected at
Controller and HMI.
ü Turn Generator Off - Wait 15 Seconds, turn back
on, check for Error Light.
ü Turn system off wait 15 Seconds restart.
Check for Error light after restart and cycle.
ü Turn System off. Inspect Magnet Plugs for proper
connection and Magnet cables for crimped or cut
conductors.
ü Disconnect Magnet cable from rear of Controller,
start system, cycle and look for “OPEN” Code to
illuminate after 15-30 Seconds.
7
 My “Magnet” Quit Working!
Visually Check – Equipment Running
• Is the RED LED Error Light
Illuminated and “SC” displayed on
right side of 230 Volt Text ?
Turn Off Equipment and Test Magnet
• Is the Magnet Good?
Possible Solutions
ü With equipment turned OFF, remove
controller cover and remove RPD “Yellow
Box” from Controller by removing leads
and plug from positions on board.
ü Reconnect Magnet Cable to rear of
controller and restart and cycle
Generator. If the “SC” and “OPEN” error
code is no longer present, the RPD is
damaged and needs replacing.
ü Equipment Turned Off and Perform Test
ü Test the Magnet with an Ohm Meter.
ü Test each conductor to the magnet case
to see if the insulation has failed allowing
a short circuit.
8
 My “Magnet” Quit Working!
Turn Off Equipment and Test Magnet
• Is the Magnet Good?
Example: 48” Magnet is rated at
45 Cold Amps
230 VDC/5.11 Ohms = 45
Amps.
• Too big for a 9kW with 39 Amp
Output.
• Correct for a 15kW with 65 Amp
Output
ü Measure the Ohms
resistance between Magnet
conductor leads - record
the value.
ü Divide 230 Volts by the
Measured Ohms value =
Total Amp Draw of the
magnet.
ü Compare results with the
generator Output.
9
 My “Magnet” Quit Working!
ü Check the quick disconnect plugs for
• The HMI will not proper installation.
Illuminate and no ü Check the HMI cable that connects to
output values are the controller for cuts or damage.
ü Remove the Controller top cover and
displayed. check the power fuse for continuity.
If blown, replace with 5 amp x 20mm
Slow Blow DC fuse.
ü Measure resistance of Exciter
winding as described on page 14.
ü If Exciter Stator resistance is good,
test the generator operation again.
ü If the HMI is still inoperative, the DVR
is defective.

10
 HMI Operating and Error Messages
Display Indication Detail Responce Action Corrective Action
Green LED "ON" System Ready Ready to Operate
Yellow LED "ON" Magnet Energized Generator Functioning
Red LED "ON" Critical Fault Error Code Displayed Identify Displayed Code Refer to Troubleshooting Guide

"TEMP" Displayed Red LED "Off" Controller Temp Under Output reduced to 180 VDC Increases Automatically when
194F (90C) Temp. falls below 194F (90C)
"TEMP" Displayed Red LED "ON" Controller Temp Over System Turns "Off" Restart Generator System
212F (100C) Code 128
"OPEN" Displayed Magnet Cable Displays after 2-15 Sec. System Turns "Off" Reset after repair, Push Magnet
Disconnected of detection (Switch Off) "On- Off" Button
"OV" Displayed Overvoltage or Code HW64 Displayed System Turns "Off" Restart Generator System
Over Speed
"SC" Displayed Short- Circuit in Code HW32 System Turns "Off" Repair Mag Cable and
Magnet Cable Most Common Code Restart Generator System
"SC" Displayed Short Circuit in Code HW16 System Turns "Off" Restart Generator System
Controller Board
"SC" Displayed Protective Yellow Box Code HW32 System Turns "Off" Restart Generator System
has tripped
"SC" Displayed Short- Circuit in Codes: HW1, HW2 System Turns "Off" Restart Generator System
Controller Output Circuit HW4 or HW8

11
 HMI Error Codes
Error Code Error Type Remarks Possible Cause
HW-1 Internal Short- Circuit Output Transistor T-1 Output Circuit or Demagnitization circuit
HW-2 Internal Short- Circuit Output Transistor T-2 signals short circuit; possible caused by
HW-4 Internal Short- Circuit Output Transistor T-3 water in controller or defective regeneration
HW-8 Internal Short- Circuit Output Transistor T-4 resistor
HW-16 Internal Short- Circuit Output Transistor T-5
HW-32 Internal Short- Circuit Short Circuit in Magnet, Power Cable or
Magnet Plugs. Yellow Box Tripped
HW-64 Controller Overvoltage Protection against Overspeed, Regeneration
Controller Defect Resistor Defect
HW-128 Controller Over Temperature Protection against Air Supply: Cooling Air too Hot or
Controller Defect not enough. Possible fan failure

12
 HMI “ERROR” Code Examples
HMI indicating “HW-64” Error Code HMI indicating “Open” Code - Indicating
with RED Error Light Illuminated Open Magnet Cable connection

13
 Cable Connections

HMI Connection
AC Voltage Plug

DC Magnet Plug

14
 Generator Plug Test Points
For testing Main Stator and Exciter Stator Resistance from plug

Exciter Winding Test point Pin 1 to Pin 2 Main Stator Resistance Test Phase V to W
(See next page for Resistance values)
Test Both Pins 1 & 2 to Generator Case
No resistance value should be present.

Main Stator Resistance Test Phase V to U Main Stator Resistance Test V Winding
15
 Exciter Stator Winding Resistance Test:
Test Leads across Red and Grey conductors on plug

15kW-4 Pole Example

Generator Models Resistance

9 kW-2 Pole 28 Ohms
9 kW-4 Pole 28 Ohms
15 kW-2 Pole 28 Ohms
15 kW-4 Pole 14 Ohms
20 kW-2 Pole 14 Ohms
20 kW-4 Pole 14 Ohms
30 kW-2 Pole 10 Ohms
30 kW-4 Pole 10 Ohms
16
DVR (AVR) Digital Voltage Regulator
and RPD “Yellow Box” Mounted
Preliminary Yellow Box Test

• Disconnect All Leads from Yellow Box

• Check Continuity between PE (Ground)

terminal & M+ & M- (Power leads from
Magnet cable.
No Continuity should be recorder

17
18
19
DVR Plug Arrangement

20
 Exciter Section Voltage check: +10 to 35 VAC
Test Leads on Red w/ Fuse and Grey Conductors

21
DVR Protection: 5 Amp Fuse
Protection Fuse: 5 AMP x 20 mm Slow Blow DCV

22
 HMI Control Power Check: +12-15 VDC
Test Leads on Grey and Orange Conductors

LED’s

LED Indicators: Red: Over Temp Yellow: Out of Speed Range Green: DVR Current Low
23
 Main DC Output Terminal Position
Measure: 230 VDC at Operating Speed

24
Checking AC Phase to Phase Voltage: 170 VAC Energized
(150-155 VAC De-energized)
Test Leads: Check all Combinations of Yellow Conductors

25
Checking AC Phase to Phase at Terminal Posts: 170 VAC
(150-155 VAC De-energized)
Test Leads across all Three Lead Combinations

26
Temperature Sensor Leads: .62 Ohm’s resistance across plug disconnected.
Value is temperature sensitive, if zero resistance, Voltage Regulator reduces output
voltage to zero.

Temp Sensor Plug

27