How to Find The Basic Faults of The Audi ECP Series AC Generator?

This article introduces the program for testing the Audi Mecc Alte ECP AC generator. People without relevant qualifications are not suitable for this job. If you are not technically qualified to do so, you should not attempt to execute these programs as they may cause serious injury or death.

Main stator winding.

Remove the customer's output cable and disconnect any neutral wire connections.

Disconnect the AVR connection.

Disconnect the radio interference suppression unit (if installed).

The main stator winding of the megohmmeter is grounded. The insulation resistance must be greater than 1MW at 500 volts.

Test the continuity of the two red wires connected to the auxiliary stator winding and AVR. If the auxiliary equipment is open circuit, the machine can be operated by connecting the positive and negative terminals on the AVR. However, this will eliminate overload protection devices. If you have any questions, please consult Mecc Alte UK.

Please refer to the relevant manual for resistance (nominal value 1-1.5W).

If necessary, run the machine with the magnetic field leads disconnected or fuses removed, and check the voltage balance between phases or between phases and neutral wires. Any serious imbalance indicates that the stator is burnt out. The residual voltage should be greater than 50 volts. A lower voltage may indicate an open circuit in the exciter stator or a rotor fault, see paragraph 2/4.

Split neutral point and megohmmeter test phase to phase insulation.

Excitation magnetic field.

Check the continuity of the nominal resistance between 13-20W. (Yellow and blue leads)

Check the insulation resistance to ground.

AVR.

Test the AVR fuse. If necessary, excite the machine separately and remove the yellow and blue wires of the AVR. Using a 12 volt battery, connect the positive pole to the yellow wire of the excitation field and the negative pole to the blue wire of the excitation field. Remember, this way of running only requires a short amount of time. If long-term operation is required, connect a 33W resistor in series to limit the excitation current.

If the machine is running normally, excite it separately. AVR has a malfunction.

Ensure that the diesel engine speed is within an acceptable range of 1410 to 1560 rpm for proper operation

The rotor and exciter armature.

Disconnect the main rotor leads (marked with+red and - blue) from the rotating rectifier assembly.

Measure the rotor resistance (refer to the manual) as described above, using a megohmmeter to measure the ground resistance of the rotor winding.

Short circuit all rectifier boards together or disconnect the three-phase input from the exciter. The excitation machine winding of the megohmmeter is grounded.

Test the voltage drop on each diode, approximately 0.5 volts. Alternatively, the resistance meter should display continuity in one direction and very high resistance in the other direction.

Check the VDR (red button component on the main rotor lead). In normal operation, this should display a very high resistance.

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