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Troubleshooting a Rotax generator

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txpilot

Joined: 26 Feb 2007
Posts: 87
Location: Houston, TX

Posted: Sat Sep 25, 2010 2:21 pm Post subject: Troubleshooting a Rotax generator

I have a Zenith CH-701 with a Rotax 912ULS.  My electrical system is based on the "Z-16" system diagram.



I'm getting set for my first flight when I noticed a generator failure.  I've double-checked all of my wiring and verified no fuselinks have been blown.  The alternator OV Disconnect relay is functioning fine.  It seems it's down to a bad generator or a bad rectifier-regulator.



I'm wondering what's the best way to proceed with the troubleshooting.  Could I connect a voltmeter to the generator cables and check for proper voltage?  What would I expect for a functioning generator?  (the installation manual indicates 250W AC output at full power).  Any other suggestions on how to troubleshoot without replacing the generator?



Thanks for any help.



Dan Ginty

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rickofudall

Joined: 19 Sep 2009
Posts: 1392
Location: Udall, KS, USA

Posted: Sat Sep 25, 2010 5:30 pm Post subject: Troubleshooting a Rotax generator

Dan, See the Rotax Heavy Maintenance Manual, Section 74-00-00, 3.7, page 16.



Rick Girard



On Sat, Sep 25, 2010 at 5:21 PM, txpilot <txpilot(at)consolidated.net (txpilot(at)consolidated.net)> wrote:

  	  Quote: 	
		  --> AeroElectric-List message posted by: "txpilot" <txpilot(at)consolidated.net (txpilot(at)consolidated.net)>

  

 I have a Zenith CH-701 with a Rotax 912ULS.  My electrical system is based on the "Z-16" system diagram.

 

 I'm getting set for my first flight when I noticed a generator failure.  I've double-checked all of my wiring and verified no fuselinks have been blown.  The alternator OV Disconnect relay is functioning fine.  It seems it's down to a bad generator or a bad rectifier-regulator.

  

 I'm wondering what's the best way to proceed with the troubleshooting.  Could I connect a voltmeter to the generator cables and check for proper voltage?  What would I expect for a functioning generator?  (the installation manual indicates 250W AC output at full power).  Any other suggestions on how to troubleshoot without replacing the generator?

  

 Thanks for any help.

 

 Dan Ginty

 

 

 

 

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user9253

Joined: 28 Mar 2008
Posts: 1921
Location: Riley TWP Michigan

Posted: Sun Sep 26, 2010 6:03 am Post subject: Re: Troubleshooting a Rotax generator

Dan,

How did you notice a generator failure?  Was the low voltage warning light on?  Did you verify low voltage with a voltmeter?  The low-voltage warning light could be lying.

 My Rotax Heavy Maintenance Manual gives the resistance of the generator windings on page 64.  With the master switch on and the engine off, remove the connector from the voltage regulator and check the resistance of the two generator yellow wires to ground.  There should be infinite resistance to ground.  Then measure the resistance between the two yellow generator wires.  It should be less than one ohm.  If more than one ohm, the relay contacts or generator winding is open.

 If the resistance checks are normal, chances are that the generator is OK.  You could also do an operational check.  With the voltage regulator connector still unplugged, connect a voltmeter and a high wattage lamp to the two yellow generator wires and start the engine.  The lamp should get brighter and the voltage should go up with RPM.

Joe

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