06 - Voltage Regulation (VR) Maint (49 Slides - 1 WK)

FOR TRAINING PURPOSE ONLY
Malaysian Institute of Aviation Technology
TOPIC 6
VOLTAGE REGULATION
&
MAINTENANCE
Revision : Original Page No: 1 Subject Code AAB10403/AKD10203
Issue No : 001 Issue Date: 30 August 2006
BASIC GENERATOR THEORY

1. Generator – is an electrical machine that convert mechanical energy to
electrical energy

Over-Currents
An overcurrent is a condition which exists

in an electrical circuit when the normal load
current is exceeded.
The two basic forms of an overcurrent are
overloads and short circuits.

Overload
An overload is an overcurrent condition where the current
exceeds the normal full load-capacity of the circuit but where
no fault condition (short-circuit) is present.
A momentary overload condition (also known as “in-rush”

currents) may also occur when a circuit is first initialized due
to capacitor charging and/or motor-start-up.

INTERFERENCE SUPPRESSION
1. Sparking at brushes causes radio interference.
2. Radio interference can be

minimised by connecting
capacitor in parallel with the
generator output between
main terminal and earth known
as suppressor.

VOLTAGE REGULATION
1. The only practical way to control the generator output is by controlling the field
current by the use of voltage regulator.
2. This voltage regulator connected in series with generator field.
3. There are several types of voltage regulator (VR):
1. Voltage regulator using rheostat

2. Vibrating type VR
3. Carbon Pile VR
4. Three Unit Ctrl Panel

VOLTAGE REGULATION
1. Voltage regulator using rheostat

- assume the output voltage is 28V at
constant speed and the rheostat is at
mid position
* * * Point B-E  Terminal voltage

(1) Voltage Regulator using Rheostat
b. When generator voltage is

increased, let say 30V, the rheostat
has to increase its resistance
thus this will reduce current flow
to its shunt field.
c. Shunt field strength decrease

which will cause the generator
output to decrease.

(1) Voltage Regulator using Rheostat
d. When generator voltage drops

let say 26V, rheostat has to
decrease its resistance thus
more current flow to the shunt
field.
e. The strength of shunt field

increases thus increases the
generator output.
Note : Not suitable for aircraft use i.e. it is manually controlled to maintain its output

(2) Vibrating Type Voltage Regulator

4. Vibrating Type Voltage Regulator – it is automatically controlled to maintain
generator output
a. Construction :
- voltage coil connected in parallel
with generator output
- contact point which is normally

closed by spring tension
- shunt resistance connect across

the contact point

b. Operation :
- when generator voltage at 28V
the current will flow through
voltage coil and back to the
source
- current will also flow through
normally closed contact, to the
shunt field and back to the
source
- no current flow through the
shunt resistance

- when output voltage increases

say 30V, voltage coil has enough
strength to pull the contact
point to be opened
- now current must flow through
shunt resistance, shunt field
and back to source
- therefore less current flow to
the shunt field, field becomes
weak thus generator output will
slightly drop
- when generator output drops

say 26 V, voltage coil becomes
weak
- contact point closed by the
spring tension and shunt
resistance will be shorted out
- this allow more current to flow
to the shunt field to strengthen
its field
- therefore the generator output
will slightly increase, and this
cycle is repeated
- the contact will keep vibrating
Note : It is automatically controlled by the voltage coil to maintain its output at 28V

Note :
- To vary the output voltage is by
varying the spring tension
- Increase the spring tension will

increase the output voltage
- Decrease the spring tension will

decrease the output

(3) Carbon Pile Voltage Regulator

6. Carbon Pile Voltage Regulator : Used for heavy duty generator system which
requires a high field current
a. Construction :
- carbon stack; a series of
disks arranged in a stack
or pile, connected in
series with the field
- rheostat; controls
amount of current to
electromagnet coils


- electromagnet; exert a pull on
the carbon stack to increase
resistance thus reduce field
current
- leaf spring; compress the carbon

stack to reduce the resistance
thus increase field current


b. Operation:
When generator
at constant speed

When generator
speed increases

When generator
speed decreases

- To adjust output voltage is by adjusting the rheostat

- Increase rheostat resistance, increase the output voltage
- Decrease rheostat resistance, decrease the output voltage
Note :
Advantages :
- no contact point thus no sparking
- no spring tension
- less maintenance but
high efficiency

(4) Three Unit Regulator Type/ Ctrl Panel

a. Construction :
-voltage regulator (VR)  to maintain output voltage constant by voltage coil
-current limiter (CL)  to limit the output current of the generator
-reverse current cutout relay (RCCR)  to prevent the battery from discharging through
the generator if output voltage falls below the battery voltage


(4) Three Unit Regulator Type

- gen warning light
illuminate 
indicate gen is off-
line
- extinguish warning
light indicate
gen is on-line
- voltage regulator
(VR) contact and
current regulator
(CL) contact are
normally closed
(n/c)
- reverse current
(RCCR) contact is
normally open
(n/o) : Original
Revision Page No: 23 Subject Code AAB10403/AKD10203

Operation :
At
stationary
When the generator at stationary, the generator warning light illuminates.

Normal
Operation
When generator reaches 14.25 volt, the reverse current cut out (RCC) contact is closed,
thus generator warning light is extinguished
Over Voltage
condition
When generator voltage above 14.25 volt, voltage regulator contact opens. Now the
resistance in series with the generator field thus less field current. The output voltage will
reduce.
Over Current
condition
When the load current exceeds the generator rating, the current coil contact opens. Now
two resistances in series with the generator field thus limit the generator output.
Under Voltage
Condition
During engine shuts down, the generator voltage is lower than battery voltage. The
reverse current from the battery through reverse current relay (RCCR) coil will oppose
the voltage coil thus weakening the field strength causes the contact to open.
When the generator voltage decreasing to zero, the generator warning light illuminates


Operation – RCCR
1a - When generator voltage is higher than the battery voltage.

a. When a generator rotate and cut the shunt field, emf is induced and will produced an
output voltage of 28V d.c.
b. This 28V dc. will flow to the shunt (voltage) winding and back to the generator.
c. The shunt (voltage) winding will energise the armature and overcome the spring tension
thus armature contact close.
d. When the armature contact close, the output voltage will flow to the series (current) coil
and to the bus bars. If the battery switch is close, the battery will be on charge.
e. In this condition, the series field will assist the shunt field (strengthen) to ensure the
armature contact remain tightly close.
1b – When the battery voltage is higher than the generator voltage.
a. During generator shut down or failure, generator output voltage will drop from 28V
toward zero.
b. When generator voltage is lower than battery voltage, there will be a reverse current
flow from the battery to the generator.
c. A reverse current flow from the battery, armature contact close, through series (current)
winding and shunt (voltage) winding and back to negative battery.
d. Therefore the magnetic field in series (current) windings will oppose the magnetic field
of the shunt (voltage) windings.
e. The overall field strength of reverse current relay weakened which cause the armature
contact open by the action of a spring. Therefore, the reverse current from the battery
will be disconnected thus prevent the generator from motoring.
DC GENERATOR MAINTENANCE
 Purpose is to keep the generator in good working order.
 Maintenance work is carried out at each check interval as specified in the
aircraft maintenance schedule.
 Inspection and servicing is carried out in accordance with manufacturer’s
instruction.
 Overhaul is often accomplished at the same time as engine overhaul thus
minimize aircraft down time.
 Routine Inspection and Servicing

 Generally, routine inspection and servicing is carried out as follows:
 Inspect for security of mounting.
 Inspect mounting flange for oil leaks.
 Inspect electrical connections for cleanliness and security of
attachments.
DC GENERATOR MAINTENANCE - cont

 Inspect area around the commutator and brush assemblies for any solder
particles. Loose solder particles indicate generator has overheated.
 Use compressed air to blow out accumulated dust around the brushes
and commutator.
 Inspect brushes for wear and freedom of movement.
 Troubleshooting – based on systematic analysis of the situation to

determine the cause of malfunction and remedial action:
 If Generator not charging battery:

Check the aircraft electrical system associated with the battery and
generator such as:
- every connection in the generator and battery circuit.
- condition of all fuses and circuit breakers.
- condition of all ground connections for battery, battery contacts, and
the generator control unit.


 With engine cranked, check armature rotation
with engine running ; or on appropriate test stand:

 use voltmeter to check generator output by placing the probes
between‘G’terminal of voltage regulator and ground.
 performed in accordance with the manufacturer’s recommendations and

observe proper safety precautions.
check for residual voltage – around 1 or 2 volts.

 if no residual voltage – can be restored by an operation known as
‘flashing the field’.
 the operation is accomplished by momentarily passing current through
the field coils in the same way that is normally flows.


 if there is residual voltage but no output voltage – the trouble could be with th
generator or the regulator
operate the engine at a speed the generator can produce an output.

 bypass or short circuit the voltage regulator
- if generator produces
voltage depends on
speed, the problem is
at the regulator 
replace the regulator
-if there is no change

on generator voltage,
generator is bad 
replace generator

DC Generator Overhaul :
a. Disassemble – follow instruction i.a.w. manufacturer’s overhaul manual
- use proper tools and procedures to disassemble the parts


b. Cleaning – use proper solvent for cleaning as wrong solvent could remove the lacquer
type insulation used on field and armature coils resulting in short circuit
c. Inspection and Repair – use of Armature Growler

- Armature Growler is a test unit to test for DC generator
armature and motor armature for Open Circuit, Short
Circuit and Ground
- Growler consist of a laminated iron core as a primary and
armature armature being tested as secondary
- some include with a test lamp which illuminates if the circuit
Revision : Original
is completed (continuity)
Page No: 38 Subject Code AAB10403/AKD10203
Armature Coils Testing
i - Test for Open Circuit  Test lamp / Ohmmeter

ii - Test for Short Circuit  Growler
iii - Test for Ground  Test lamp / Ohmmeter
Field Coil Testing
i - Test for Open/ Short Circuit  Test lamp / Ohmmeter

ii - Test for Ground  Test lamp / Ohmmeter


i - Test for Open Circuit :

- use test lamp with both probes touch
the adjacent commutator segment
- if the test lamp illuminates, the coil is

not opened indicate it is good condition
- if the test lamp not illuminate, the coil
under test is open circuit
Test for Open Circuit
- if using ohmmeter, low resistance is of armature windings
good and infinity indicates open circuit

ii – Test for Short Circuit :

- use thin steel strip or a hacksaw blade
and placed slightly above the armature
and rotate armature slowly
- if the blade vibrates vigorously, it

indicate the armature is short circuited
(bad) Test for Short Circuit
- if the blade not vibrate, the armature is of armature windings
not short circuit (good)


Armature Testing
iii – Test for Ground :
- use test lamp or ohmmeter with one probe

touch the commutator segment and other
probe touch the armature shaft
- if the test lamp illuminates, the coil is

grounded (no good)
- if the test lamp not illuminates, the coil is Test for Ground
of armature
not grounded (good)

Field Coil Testing using Test Lamp or Ohmmeter:
i – Test for Open and Short Circuit :

- touch between both leads, if test lamp
illuminates indicate the field coil is not opened
(good) or ohmmeter indicate low
resistance
- if lamp not illuminate, indicate the coil is

open (bad) or ohmmeter indicate infinity
- shunt field resistance – between 2 to 30 ohms
Test for Open
- series field resistance – very low value of field coil


Field Coil Testing using Test Lamp
ii – Test for Ground :
- use test lamp with one probe

placed at field coil and the other at
generator frame to check for
ground
- test lamp illuminates indicate the

coil is grounded (bad)
Test for Ground

of field winding
Carbon brushes

f. Commutator Inspection :
- checked for irregularities and pitting.
- slight roughness can be smoothen by using number ‘000’ sandpaper.
- NEVER use emery cloth or other conductive material as these could cause
shorting.
- mica should be undercut about the same depth as mica’s thickness or
approximately 0.002 inch.
g. Brush Inspection :
- generally brushes is replaced at overhaul or when half worn
- ensure the new brush is seated or contoured to maximize the contact area
on the commutator
- accomplished by using no. 000 sandpaper inserted under the brush
between the commutator and pulled in the direction of rotation to shape the
brush contour.
- check the spring tension using spring scale.



h. Reassemble :
- prior assembly, ensure exterior paintwork is restored.
- ensure internal electrical connection is secured.
- checked pigtails on the brushes for freedom and ensure they do not restrict the
brushes free motion.
- after assemble, run the generator for a short period and reinspect to ensure no
sands are imbedded in the brush.
i - Operational Testing :
- accomplished on test benches built for the purpose.
- operated in accordance to manufacturer’s instruction.

THANK YOU FOR ATTENTION
YOUR NEXT LESSON WILL BE
D.C ALTERNATOR


06 - Voltage Regulation (VR) Maint (49 Slides - 1 WK)

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FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

BASIC GENERATOR THEORY

Revision : Original Page No: 2 Subject Code AAB10403/AKD10203

An overcurrent is a condition which exists

Revision : Original Page No: 3 Subject Code AAB10403/AKD10203

A momentary overload condition (also known as “in-rush”

Revision : Original Page No: 4 Subject Code AAB10403/AKD10203

1. Sparking at brushes causes radio interference.

2. Radio interference can be

Revision : Original Page No: 5 Subject Code AAB10403/AKD10203

1. Voltage regulator using rheostat

Revision : Original Page No: 6 Subject Code AAB10403/AKD10203

1. Voltage regulator using rheostat

* * * Point B-E  Terminal voltage

Revision : Original Page No: 7 Subject Code AAB10403/AKD10203

(1) Voltage Regulator using Rheostat

b. When generator voltage is

c. Shunt field strength decrease

Revision : Original Page No: 8 Subject Code AAB10403/AKD10203

(1) Voltage Regulator using Rheostat

d. When generator voltage drops

e. The strength of shunt field

Revision : Original Page No: 9 Subject Code AAB10403/AKD10203

(2) Vibrating Type Voltage Regulator

- contact point which is normally

- shunt resistance connect across

(2) Vibrating Type Voltage Regulator

Revision : Original Page No: 11 Subject Code AAB10403/AKD10203

(2) Vibrating Type Voltage Regulator

- when output voltage increases

(2) Vibrating Type Voltage Regulator

- when generator output drops

Revision : Original Page No: 13 Subject Code AAB10403/AKD10203

(2) Vibrating Type Voltage Regulator

varying the spring tension

- Increase the spring tension will

- Decrease the spring tension will

Revision : Original Page No: 14 Subject Code AAB10403/AKD10203

(3) Carbon Pile Voltage Regulator

Revision : Original Page No: 15 Subject Code AAB10403/AKD10203

(3) Carbon Pile Voltage Regulator

- leaf spring; compress the carbon

Revision : Original Page No: 16 Subject Code AAB10403/AKD10203

(3) Carbon Pile Voltage Regulator

Revision : Original Page No: 17 Subject Code AAB10403/AKD10203

(3) Carbon Pile Voltage Regulator

Revision : Original Page No: 18 Subject Code AAB10403/AKD10203

(3) Carbon Pile Voltage Regulator

Revision : Original Page No: 19 Subject Code AAB10403/AKD10203

(3) Carbon Pile Voltage Regulator

- To adjust output voltage is by adjusting the rheostat

Revision : Original Page No: 20 Subject Code AAB10403/AKD10203

(4) Three Unit Regulator Type/ Ctrl Panel

Revision : Original Page No: 21 Subject Code AAB10403/AKD10203

Revision : Original Page No: 22 Subject Code AAB10403/AKD10203

(4) Three Unit Regulator Type

(4) Three Unit Regulator Type

When the generator at stationary, the generator warning light illuminates.

Revision : Original Page No: 24 Subject Code AAB10403/AKD10203

(4) Three Unit Regulator Type

(4) Three Unit Regulator Type