Thx for the helpful video, much appreciated !.i have a Honda gx5500 genny, runs sweet, no power , collecting info on here , even tho I’m a sparky , lots of ideas from great people like yourself is always a massive help. will get back with the diagnosis and fix
checkout james condons' youtube channel; he is the man, for GENERATORS ! '' Also, checkout Taryl Fixes all, on UA-cam. Steves' small engine saloon, donyboy, Bruces' workshop, all good !
You might to also use silver solder on all solder joints, it's stronger than lead based solder and will hold up better to the extreme centrifugal forces. Thanks for the great info.
Fix your alternator before its dead. I have 4 of the Unitedpower 1300 and 3 of the Champion same size, what I noticed on all of them is the alternator housing that bolts to the engine is on the wrong way. Looking at the opened case that bolts to the engine with the rotor removed there is a arrow symbol inside with the word UP however on all of the ones I have up is pointing side ways. This positions the case so it appears the hot air from the cylinder head is picked directly up by the intake air cooling ports of the alternator, take a look at yours. It isn't too hard to see this will cause the alternator to run much hotter then intended possibly causing burnouts of electronics or glues holding the diodes in place or prematurely degrade glues allowing the diodes to move with vibration & centrifugal force. My final comment comment, I believe there might have been a translation gap at the time of manufacturing, I hope what I've observed can help others out.
I just suscribed,,,bridge rectifiers have four legs,,input, +positive and - negative and two for. Output positive and negative,,,which. Ones are connected on. Both sides...
Hello sir. I know this video is from eight years ago, but if I am correct, that looks like a brushless generator armature is this correct? I don’t see the slip rings near the bearing that you would find on a brushed generator.
Nice observation, can you please tell me what guage wire do I need and how many turns on the coil if I need 50 amps and 24 volts from a single coil if I'm using N52 neodymium magnets 60mm by 200mm rotating at 7000 rpm
The cheaper generators are realible at about half rated watts when ran continually,,,and the charging capisator sometimes packs up ,,,,,,more often it's the wiring connectors being loose God Bless
I've got a generator similar to that one it's 2000 watts but the armature is made like that except where the bridge diodes are, it has the same holder but there's only a single resistor between the two sides..it has a gold stripe so I guess it needs to be about a certain size..anyways I worked at a small engine place and I got this thing the engine was junk so I cut part of the crankshaft off and left it sticking out of the generator...it wasn't long enough to put a pulley on but I drilled a 5/8 hole in it and inserted a piece of keyed shaft from a junk electric motor I had...tomorrow I'm getting batteries number 7 &8 for my solar setup so I'm going to weld the shaft piece tomorrow...it's for a backup generator thing I'm working on..it has two 110 legs...but with the resistor it let the crappy little motor they had wind up before it would start generating so I'm going to glue a little neodymium magnet to the back bearing because I'm gonna use an old 5 hp Briggs that's been put up for a long time..it has a centrifugal belt clutch so that'll let the motor get going. .yeah that's kinda crazy having those bridges flying around in there lol I never would have thought of that
Good man, David !. Consider, sealing anything up, with JB WELD. After your completely sure, it makes power consistently. GLUE THEM SOLID, so no more problems. IF i was a designer, engineer, i would put most all stuff, on armature, in epoxy cement. Modules, like in your alternator voltage regulator. No vibration, would destroy anything !
yes easy fix get a peice of pcb and make a lil board to mount said bridge rectifiers and mount it in there with nonconduct of adhesive double sided tape or past or silicone..
Why dont they start producing small three phase generators, with like 500 feet of line, because the 3 phase can actaully move along the line instead of developing a displacme t current after 100 feet or so , according to Eric Dollard
There are four primary ways that ferromagnetic materials can be magnetized. They include exposure to heat, using an external magnetic field, stroking or electromagnetism. With these methods, ferromagnetic objects will produce their own magnetic field Your welcome.
Wait! A rectifier in an AC generator? So it makes AC and converts it to DC and then controls the Hz with IGBTs? Then why does the Hz change with the RPM?
The reason those bridge rectifiers are on 2 posts are because they are acting as single diodes which can be had even cheaper. BTW, quit popping your dentures while filming man!
@@MrDoingEverything this has the AVR, and I believe that may be the issue. I ordered a new one, and it will be here tomorrow so I'm gonna change it and hope for the best.
How is the rotor being excited? It must be getting AC voltage from the stator and then brought back to the rotor while the full wave bridge rectifiers convert to DC voltage.
There's actually 3 sets of windings. First, the main output winding. Next a small set of excitation windings that create a small AC charge induced from residual magnetism of the main winding.This is then induced to a small set of field windings , which is converted to DC by the diodes, causing our main winding excitation and output.
I discovered. The rectifiers on my brushless Yamaha generator had been removed, can i put any diode as replacement,,,i now understant why there is no output power
Ok this might sound crazy but I’m gonna go ahead and ask anyways for any one that knows, couldn’t you just skip the bridge rectifier and just soldered the wires together to complete the circuit
Good Question! The rotor needs a DC voltage to create the magnetic field thus the diode is there. With a 2000 watt brushless unit here the bridge rectifier is just used as a Big diode. ie the two AC leads are cut off the plastic bridge diode package. The rotor here has the 2 rotor coils in parallel connected to the + and - terminals of the bridge.This affair has a 15 K ohm resistor across it for surges. When used this way you have two pairs of diodes in series, then the each is in parallel. So like 1.2 volts drop DC ie 2 diode drops instead of one. This is probably just done for cost and packaging, one has this tiny brick shaped diode box to fit in a hole and goop in place. Many diodes on brushless generators are a single diode on bigger generators. The brushless generator like in this video has also an extra winding in the stator that connects to a capacitor. My 2000 watt unit has a 20uF cap. When running and outputting 120 volts the cap voltage on mine is like 189 volts. If this cap is gone/removed you get about 4 volts across the cap wires and that too across the output wires ie AC jack. This 4 volts is from the base magnetism of the rotor. Adding the cap increases the voltage across the "cap coil" this "excites" the rotor coil. The rotor coil thus has DC with the diode thus the magnetism increases in the rotor. The voltage them builds up quickly.
Mine has a diode connected to the slip rings but tested fine with the multimeter! Should i replace as its producing 4 volts but at 50 hz to 90 hz! Any reply appreciated thanks from Australia!
I have a brushless petrol generator, I thought the capacitors were bad so changed them out, still doesn’t work. The 240 side produced 10volts, And the 110v produces 100 volts, what’s going on? Thoughts?
@@MrDoingEverything I’ll have to open it up and have a look for it, it’s not like the new generators it’s a Medusa petrol and it’s maybe 30 years old now, 13.5hp engine. I’ll try your suggestion, I’m new to generator repairs, this is my first attempt 😅
@@MrDoingEverything you’re not going to believe this, there isn’t a voltage regulator, or not one that looks modern day. All I see is copper wires, capacitors, or some tiny diodes. What do I do next? I’m so puzzled. It’s nothing like in people’s UA-cam videos
Mine one has both resistor blown in there. So there is only two diodes one on each side and two "other components" which are both missing so I'm not completely sure what they were so I only guess they were resistors. The generator rated 2kW continuous power output. Any ideas what was the Ohm-age of those resistors?
I have a Coleman Powermate 2500 that reads 1.5 to 2 volts at the receptacle. I checked the resistance in both the stator winding and the rotor windings and the show proper resistance of 1 ohm and 7 ohms (no open circuit wire). The diode is also ok. I tried the "drill spin" method to try to induce the field but no luck. Any other suggestions?
Perhaps the capacitor unless there are other types of electronics controlling it. Then the problem would be in there somewhere. Like a brain box of some sort.
there are a total of 4 electrical components in the entire generator - 2 windings, a 12 uf capacitor and a circuit breaker. both windings are to spec, the cap reads 12.35 uf and the circuit breaker shows continuity. when inserting probes into the receptacle, the ciol winding reads 1 ohm (to spec). the field excitation winding with the capacitor in the loop reads 1.75 uf (inductor-capacitor circuit). I don't know what else to check.....
Are you sure its spinning at needed rpm or maybe the keyway sheared were it joins to the motor. The motor may run good but where it connects to the armature it may have lost a solid connection and not spinning as fast or tight as it needs to be.
@@off-gridhillbillystyle3735 Well not really because there are other components that work off the AC. So bypassing more then just that would need to be done. I never played around with it to figure out how to but i,m sure its pretty simple. I would guess if only the output leads from the generator were used it would be DC i mean the leads ahead of all the generator components but there would be no volt regulation happening either it would be full output power which could be to high to be able to be used for much. A Regulator would be needed to be used to give a good use able output voltage. I might play around with one beings i have a couple of them that i don.t need as a generator. If i do i will let you know back here on and through this message. If you play around with one let me know. I would play with a carefullness is how i would deal with it. High DC voltage can give a real hard shock.
That.s very hard to do it can be many reasons why. Tests of different things would need to be done to know for sure and maybe a lucky guess will find the issue faster. That's only a luckly guess though and they don't always work out. I have no way to know what could have went wrong. Sorry
2:30 time. MANUFACTURES; those 'engineers' ought to get a brain slap. GOING 3600 rpm, and NO JB WELD, to hold those wires/parts together ! Take a lesson, from aeronautics ! Build the electronics, and the bridge rectifier connections, IN A SOLID BLOCK, OF ceramic glue, or similar. Bolt into armature. ! dummies ! IF I HAD this gen problem, i would silver solder the connections, after twisting together; then, glue them in there, with JB WELD......no more 'design problems''' anymore ! MODERN junk Buy once, use once, (maybe) trash it >>> buy another new one,....repeat the cycle....the modern 'way'. I will keep my 1983 Yamaha ef2800 generator; built like a tank, starts right up, makes power even after sitting in the bush, for years at a garage sale. Freebie, had to redo carb completely, and de-rust tank.....this is a keeper !
A chain is only as strong as its weakest link...these little pieces of crap made crappily in a crap little factory in a crappy country, they will then work three times. But when you need them, they don't work and then you have to order parts, so you can get it to work when you don't need it to work.
Right the motors are not affected when the power heads stop working. If it was sitting to long sometime the only thing that need to be done is recharge the capacitor and some time also the capacitor will go bad and need changing. Really there is many reasons to why they stop working. There are the most common problems that I would check first. Which one of them is in the video and the other one I mentioned here with the capacitor. Best of luck to ya with it. TC
Thanks for explaining this - focus seemed pretty bad but you can see enough to understand.
This diagnosis did fix my problem with the rotor
Thx for the helpful video, much appreciated !.i have a Honda gx5500 genny, runs sweet, no power , collecting info on here , even tho I’m a sparky , lots of ideas from great people like yourself is always a massive help. will get back with the diagnosis and fix
checkout james condons' youtube channel; he is the man, for GENERATORS ! '' Also, checkout Taryl Fixes all, on UA-cam. Steves' small engine saloon, donyboy, Bruces' workshop, all good !
Problem finding is great thing, in time diagnosed it repaired soon , durability take s place, thanks for showing
You might to also use silver solder on all solder joints, it's stronger than lead based solder and will hold up better to the extreme centrifugal forces. Thanks for the great info.
Nice info left. Thank You
Bro you hit the head at the nail 🙃... much thanks 🙏
You have 1 new subscriber 👍
Fix your alternator before its dead.
I have 4 of the Unitedpower 1300 and 3 of the Champion same size, what I noticed on all of them is the alternator housing that bolts to the engine is on the wrong way.
Looking at the opened case that bolts to the engine with the rotor removed there is a arrow symbol inside with the word UP however on all of the ones I have up is pointing side ways.
This positions the case so it appears the hot air from the cylinder head is picked directly up by the intake air cooling ports of the alternator, take a look at yours.
It isn't too hard to see this will cause the alternator to run much hotter then intended possibly causing burnouts of electronics or glues holding the diodes in place or prematurely degrade glues allowing the diodes to move with vibration & centrifugal force.
My final comment comment, I believe there might have been a translation gap at the time of manufacturing, I hope what I've observed can help others out.
...drunk or stoned, assemblers, in either china or mexico, perhaps. SHODDY CRAPPY stuff....
I just suscribed,,,bridge rectifiers have four legs,,input, +positive and - negative and two for. Output positive and negative,,,which. Ones are connected on. Both sides...
Great video! David
Hello sir. I know this video is from eight years ago, but if I am correct, that looks like a brushless generator armature is this correct? I don’t see the slip rings near the bearing that you would find on a brushed generator.
Brushless is correct
Nice observation, can you please tell me what guage wire do I need and how many turns on the coil if I need 50 amps and 24 volts from a single coil if I'm using N52 neodymium magnets 60mm by 200mm rotating at 7000 rpm
ua-cam.com/video/J9wqTqh9Vzk/v-deo.html
Interesting video.
Thanks I was shocked to see such a thing on that. I never knew till then.
Sar good vedio
The cheaper generators are realible at about half rated watts when ran continually,,,and the charging capisator sometimes packs up ,,,,,,more often it's the wiring connectors being loose God Bless
I've got a generator similar to that one it's 2000 watts but the armature is made like that except where the bridge diodes are, it has the same holder but there's only a single resistor between the two sides..it has a gold stripe so I guess it needs to be about a certain size..anyways I worked at a small engine place and I got this thing the engine was junk so I cut part of the crankshaft off and left it sticking out of the generator...it wasn't long enough to put a pulley on but I drilled a 5/8 hole in it and inserted a piece of keyed shaft from a junk electric motor I had...tomorrow I'm getting batteries number 7 &8 for my solar setup so I'm going to weld the shaft piece tomorrow...it's for a backup generator thing I'm working on..it has two 110 legs...but with the resistor it let the crappy little motor they had wind up before it would start generating so I'm going to glue a little neodymium magnet to the back bearing because I'm gonna use an old 5 hp Briggs that's been put up for a long time..it has a centrifugal belt clutch so that'll let the motor get going. .yeah that's kinda crazy having those bridges flying around in there lol I never would have thought of that
Good man, David !. Consider, sealing anything up, with JB WELD. After your completely sure, it makes power consistently. GLUE THEM SOLID, so no more problems. IF i was a designer, engineer, i would put most all stuff, on armature, in epoxy cement. Modules, like in your alternator voltage regulator. No vibration, would destroy anything !
Excellent 👌😆
yes easy fix get a peice of pcb and make a lil board to mount said bridge rectifiers and mount it in there with nonconduct of adhesive double sided tape or past or silicone..
Why dont they start producing small three phase generators, with like 500 feet of line, because the 3 phase can actaully move along the line instead of developing a displacme t current after 100 feet or so , according to Eric Dollard
how does that amature gets magnetised? please explain the principle..I want to help myself out. thanks
There are four primary ways that ferromagnetic materials can be magnetized. They include exposure to heat, using an external magnetic field, stroking or electromagnetism. With these methods, ferromagnetic objects will produce their own magnetic field Your welcome.
Wait! A rectifier in an AC generator? So it makes AC and converts it to DC and then controls the Hz with IGBTs? Then why does the Hz change with the RPM?
Probably exciter winding and rectifier.
Yeah
Thanks sir nice post
Welcome
The reason those bridge rectifiers are on 2 posts are because they are acting as single diodes which can be had even cheaper. BTW, quit popping your dentures while filming man!
Yes.
I have a Generac gp3300 and it's producing low Voltage, like it will power a light bulb or drill but the bulb is dim and the drill spins slow as hell.
Hard to say what the problem is it matters to which type you have some have voltage regulator and some only use a capacitor.
@@MrDoingEverything this has the AVR, and I believe that may be the issue. I ordered a new one, and it will be here tomorrow so I'm gonna change it and hope for the best.
What I found on mine the fan spins backwards not crating enough flow to cool the rotor so the welds on rotor melt
Good point
How is the rotor being excited? It must be getting AC voltage from the stator and then brought back to the rotor while the full wave bridge rectifiers convert to DC voltage.
There's actually 3 sets of windings. First, the main output winding. Next a small set of excitation windings that create a small AC charge induced from residual magnetism of the main winding.This is then induced to a small set of field windings , which is converted to DC by the diodes, causing our main winding excitation and output.
I discovered. The rectifiers on my brushless Yamaha generator had been removed, can i put any diode as replacement,,,i now understant why there is no output power
no research them out
My generator seems to only put out half volts. like its only putting out 60 v instead o 120V
Any idea why?
Could be the same reason as in the video. Sounds like half the windings lost the connection which is giving half the voltage. My best guess.
Ok this might sound crazy but I’m gonna go ahead and ask anyways for any one that knows, couldn’t you just skip the bridge rectifier and just soldered the wires together to complete the circuit
In this case you need to include an AVR circuit with rectifier stage to stabilize the power output and prevent peaks or drops i guess.
Good Question! The rotor needs a DC voltage to create the magnetic field thus the diode is there.
With a 2000 watt brushless unit here the bridge rectifier is just used as a Big diode. ie the two AC leads are cut off the plastic bridge diode package. The rotor here has the 2 rotor coils in parallel connected to the + and - terminals of the bridge.This affair has a 15 K ohm resistor across it for surges.
When used this way you have two pairs of diodes in series, then the each is in parallel. So like 1.2 volts drop DC ie 2 diode drops instead of one. This is probably just done for cost and packaging, one has this tiny brick shaped diode box to fit in a hole and goop in place. Many diodes on brushless generators are a single diode on bigger generators.
The brushless generator like in this video has also an extra winding in the stator that connects to a capacitor. My 2000 watt unit has a 20uF cap. When running and outputting 120 volts the cap voltage on mine is like 189 volts. If this cap is gone/removed you get about 4 volts across the cap wires and that too across the output wires ie AC jack. This 4 volts is from the base magnetism of the rotor. Adding the cap increases the voltage across the "cap coil" this "excites" the rotor coil. The rotor coil thus has DC with the diode thus the magnetism increases in the rotor. The voltage them builds up quickly.
@@3beltwesty
Thanks bro 🤙
You sound like Evo from Thundermist Lure Company. Or is this Evo?
Mine has a diode connected to the slip rings but tested fine with the multimeter! Should i replace as its producing 4 volts but at 50 hz to 90 hz! Any reply appreciated thanks from Australia!
It is a brush type or brushless. Brush check voltage regulator. Brushless check capacity.
I have a brushless petrol generator, I thought the capacitors were bad so changed them out, still doesn’t work.
The 240 side produced 10volts,
And the 110v produces 100 volts, what’s going on? Thoughts?
Have you thought about the voltage regulator
@@MrDoingEverything I’ll have to open it up and have a look for it, it’s not like the new generators it’s a Medusa petrol and it’s maybe 30 years old now, 13.5hp engine.
I’ll try your suggestion, I’m new to generator repairs, this is my first attempt 😅
@@MrDoingEverything you’re not going to believe this, there isn’t a voltage regulator, or not one that looks modern day. All I see is copper wires, capacitors, or some tiny diodes. What do I do next? I’m so puzzled. It’s nothing like in people’s UA-cam videos
@@belsayshootingground Have you checked the diodes.
@@MrDoingEverything there’s 2 of them on the rotor, they look fine visually, but I don’t know what tests to run?
Mine one has both resistor blown in there. So there is only two diodes one on each side and two "other components" which are both missing so I'm not completely sure what they were so I only guess they were resistors. The generator rated 2kW continuous power output. Any ideas what was the Ohm-age of those resistors?
No idea sorry
Great! Thank you very much!
Thanks
Welcome
How did you get the armature out of the generator?
Slow and carefully are always the best methods
I have a Coleman Powermate 2500 that reads 1.5 to 2 volts at the receptacle. I checked the resistance in both the stator winding and the rotor windings and the show proper resistance of 1 ohm and 7 ohms (no open circuit wire). The diode is also ok. I tried the "drill spin" method to try to induce the field but no luck. Any other suggestions?
Perhaps the capacitor unless there are other types of electronics controlling it. Then the problem would be in there somewhere. Like a brain box of some sort.
there are a total of 4 electrical components in the entire generator - 2 windings, a 12 uf capacitor and a circuit breaker. both windings are to spec, the cap reads 12.35 uf and the circuit breaker shows continuity. when inserting probes into the receptacle, the ciol winding reads 1 ohm (to spec). the field excitation winding with the capacitor in the loop reads 1.75 uf (inductor-capacitor circuit). I don't know what else to check.....
Are you sure its spinning at needed rpm or maybe the keyway sheared were it joins to the motor. The motor may run good but where it connects to the armature it may have lost a solid connection and not spinning as fast or tight as it needs to be.
Check the Voltage Regulator. I find that after they fail they may produce a small amount of voltage.
The wires separate because of the excessive centrifugal force.
They must run at 3600 RPM to produce the 60 hertz.
60 x 60 = 3600
If I decide to recoil the rotar how do I figure out how many windings I need
@@musicitt -- just use the old wire to determine the exact measurement for the replacement wire. imo 🤔
it can't exceed a thousand feet 😆
@@Texaca Sounds like an 160 meter Beverage antenna to Me. Yeah
Windings look like a hobby motor!
Its not a very big generator that's for sure. 1000 watt.
What happens if you don't have the rectifier? Could you just hook the coils togeather?
output current would be DC with out the rectifier. Then its no longer a AC generator.
@@MrDoingEverything so technically we can bypass those and make it a strictly DC output generator?
@@off-gridhillbillystyle3735 Well not really because there are other components that work off the AC. So bypassing more then just that would need to be done. I never played around with it to figure out how to but i,m sure its pretty simple. I would guess if only the output leads from the generator were used it would be DC i mean the leads ahead of all the generator components but there would be no volt regulation happening either it would be full output power which could be to high to be able to be used for much. A Regulator would be needed to be used to give a good use able output voltage. I might play around with one beings i have a couple of them that i don.t need as a generator. If i do i will let you know back here on and through this message. If you play around with one let me know. I would play with a carefullness is how i would deal with it. High DC voltage can give a real hard shock.
@@MrDoingEverything I need a low rpm high voltage generator.... Any idea where I could find or scavenge one?
@@off-gridhillbillystyle3735 No other then keep looking.
Hello Sir I want see Power Man Honda Generator Rotar Removes Videos
I can definitely hear a wee bit of Scottish in your speech
Comment tester ce rectifier ?
My gas welder won't put out a full 240 volts only 189.help.
Its hard to say why. It could be as simple a brush is dirty or wore down to much and lost spring pressure. I would check that first anyway.
Check for correct spec RPM of the welder/generator
my generator does not produce electricity . i have change avr and Corbin but it cant produce electricity kindly help
That.s very hard to do it can be many reasons why. Tests of different things would need to be done to know for sure and maybe a lucky guess will find the issue faster. That's only a luckly guess though and they don't always work out. I have no way to know what could have went wrong. Sorry
My generator produce power for 2 min and then it cut the power what is the possible problem ?
Could be the same as in the video.
@@MrDoingEverything it was from the AVR
@@marwans4018 That's it when these type things fail it's never going to mean the same issues for all of them. Best of luck.
2:30 time. MANUFACTURES; those 'engineers' ought to get a brain slap. GOING 3600 rpm, and NO JB WELD, to hold those wires/parts together ! Take a lesson, from aeronautics ! Build the electronics, and the bridge rectifier connections, IN A SOLID BLOCK, OF ceramic glue, or similar. Bolt into armature. ! dummies ! IF I HAD this gen problem, i would silver solder the connections, after twisting together; then, glue them in there, with JB WELD......no more 'design problems''' anymore ! MODERN junk Buy once, use once, (maybe) trash it >>> buy another new one,....repeat the cycle....the modern 'way'. I will keep my 1983 Yamaha ef2800 generator; built like a tank, starts right up, makes power even after sitting in the bush, for years at a garage sale. Freebie, had to redo carb completely, and de-rust tank.....this is a keeper !
I have 4 kw generator with the same windings
A chain is only as strong as its weakest link...these little pieces of crap made crappily in a crap little factory in a crappy country, they will then work three times. But when you need them, they don't work and then you have to order parts, so you can get it to work when you don't need it to work.
Better
my wolf xxl petrol generator will run find but no power out put
Right the motors are not affected when the power heads stop working. If it was sitting to long sometime the only thing that need to be done is recharge the capacitor and some time also the capacitor will go bad and need changing. Really there is many reasons to why they stop working. There are the most common problems that I would check first. Which one of them is in the video and the other one I mentioned here with the capacitor. Best of luck to ya with it. TC
Residual magnetism is lost. Magnetic field, conductor and relative motion that's how generators produce power
Maybe learn how to focus camera?
Thats a poor Design!
Cheap is all fast and cheap and not long lasting.