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Battery not charging

 
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Paul M 383



Joined: 19 Mar 2012
Posts: 61
Location: United Kingdom

PostPosted: Thu Aug 09, 2018 11:06 am    Post subject: Battery not charging Reply with quote

I have just run my 912S (in a Europa) for the first time (with a Rotax engine specialist doing all the work!)

The problem is the battery is not charging.

I have researched the subject and found a good looking guide here: http://pointsforpilots.blogspot.com/2012/12/testing-rotax-912914-generator-and.html

These are the results:

Testing Generator
Result


Pull off the 2 yellow wires from G terminals.

With engine off and Master switch off, resistance between the two wires should be 0.1 - 0.8 Ohm.
0.5 - 0.8

Resistance between either wire and ground should be infinite; that is, there is an open circuit.

-1 (is this infinite?)

With engine running and the two wires still off the regulator, test AC voltage between the two wires.

It should be:

15 - 20 VAC during idle
14.6 (at) 2000 rpm (Almost 15!)

30 - 40 VAC during high rpm
24.4 (at) 3300 rpm (Almost 30!)

Testing Capacitor
Result

If the resistance between the plus and minus poles of the capacitor is not infinite, that is, it is not an open circuit, then the capacitor has failed and must be replaced.
-1 (is this infinite?)

Testing Regulator/Rectifier
Result

With Master switch on: Measure the voltage between ground and the wire on the R, B+ & C terminals in turn; it should be the battery voltage, about 12.5 VDC.

R 0.02
B+ 0.02
C 0.02


With Master switch off: The above test should show 0 voltage for all three cases.

R 0
B+ 0
C 0

Test that housing of regulator/rectifier is properly grounded:

Resistance between regulator housing and battery ground should be essentially 0.
0

If the wiring fails any of the above tests, the wiring problem needs to be isolated and fixed.

If the wiring passes the above tests, yet output voltage of the regulator/rectifier is not in the normal range, then the regulator/rectifier likely is faulty and should be replaced.

My understanding is that this is a wiring problem, no voltage is getting to the reg/rect... but I am worse than a novice at this – a little knowledge is a dangerous thing!

The aircraft is wired basically according to the Europa build manual (below or attached, depending how you are viewing this).

Any clues as to where I should begin looking?

Many thanks in advance,

Paul M
Europa XS 383
912S

[img]cid:image001.png(at)01D4301C.6E415560[/img]


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PostPosted: Thu Aug 09, 2018 12:29 pm    Post subject: Battery not charging Reply with quote

Hello Paul

It would appear that the AC part of your system is working ok. What DC voltage do you get when you put the positive probe on the Reg +B and and the black probe on system ground? This should be about 13.4 to about 14.2 VDC depending on the RPM of the engine, From you diagram, I do not see where the regulator is attached to system ground. Is the case of the regulator intended to be connected to system ground or was term L or R intended to be system ground?? Your capacitor is grounded but there is no indication of how the regulator ground circuit is completed??

Ted
Kitfox IV


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dashwoodlock(at)yahoo.ca
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PostPosted: Fri Aug 10, 2018 4:25 am    Post subject: Battery not charging Reply with quote

i also have a third item to check.. in doing all of the testing below... the battery voltage on r b ,c showed 2volt.
after much on and off with the master switch in testing the voltage gradually climbed on these terminals...... finally ended up after several hour with battery voltage...
turns out the master relay was failing or arc corroded . it was not open and had not seized and exciter coil was still working properly.. but was not contacting properly and was only letting 2 volts through... replaced it and everything checks below just fine...

On Thursday, August 9, 2018, 3:15:41 p.m. EDT, Paul Mansfield <europaul383(at)hotmail.com> wrote:





I have just run my 912S (in a Europa) for the first time (with a Rotax engine specialist doing all the work!)

The problem is the battery is not charging.

I have researched the subject and found a good looking guide here: http://pointsforpilots.blogspot.com/2012/12/testing-rotax-912914-generator-and.html

These are the results:

Testing Generator
Result


Pull off the 2 yellow wires from G terminals.


With engine off and Master switch off, resistance between the two wires should be 0.1 - 0.8 Ohm.
0.5 - 0.8


Resistance between either wire and ground should be infinite; that is, there is an open circuit.
-1
(is this infinite?)

With engine running and the two wires still off the regulator, test AC voltage between the two wires.

It should be:

15 - 20 VAC during idle
14.6
2000 rpm
Almost 15!

30 - 40 VAC during high rpm
24.4
3300 rpm
Almost 30!


Testing Capacitor
Result


If the resistance between the plus and minus poles of the capacitor is not infinite, that is, it is not an open circuit, then the capacitor has failed and must be replaced.
-1
(is this infinite?)

Testing Regulator/Rectifier
Result


With Master switch on: Measure the voltage between ground and the wire on the R, B+ & C terminals in turn; it should be the battery voltage, about 12.5 VDC.

R
0.02

B+
0.02

C
0.02


With Master switch off: The above test should show 0 voltage for all three cases.

R
0

B+
0

C
0


Test that housing of regulator/rectifier is properly grounded:

Resistance between regulator housing and battery ground should be essentially 0.
0


If the wiring fails any of the above tests, the wiring problem needs to be isolated and fixed.

If the wiring passes the above tests, yet output voltage of the regulator/rectifier is not in the normal range, then the regulator/rectifier likely is faulty and should be replaced.


My understanding is that this is a wiring problem, no voltage is getting to the reg/rect... but I am worse than a novice at this – a little knowledge is a dangerous thing!

The aircraft is wired basically according to the Europa build manual (below or attached, depending how you are viewing this).

Any clues as to where I should begin looking?

Many thanks in advance,

Paul M
Europa XS 383
912S

[img]cid:2J9GLr3T9NlqIV1nwv3q[/img]





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Paul M 383



Joined: 19 Mar 2012
Posts: 61
Location: United Kingdom

PostPosted: Fri Aug 10, 2018 8:44 am    Post subject: Battery not charging Reply with quote

Thanks for the reply Ted,

I didn't test the VDC with the engine running - I will do that tomorrow and report back.

Yes, the regulator case is grounded (I shall update the wiring diag).

Thanks again,

Paul

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Paul M 383



Joined: 19 Mar 2012
Posts: 61
Location: United Kingdom

PostPosted: Fri Aug 10, 2018 10:12 am    Post subject: Battery not charging Reply with quote

Thanks Dash,
 
I’ll take a look at that...
 
From: owner-rotaxengines-list-server(at)matronics.com <owner-rotaxengines-list-server(at)matronics.com> On Behalf Of Dashwoodlock
Sent: 10 August 2018 13:25
To: rotaxengines-list(at)matronics.com
Subject: Re: RotaxEngines-List: Battery not charging


 
i also have a third item to check.. in doing all of the testing below... the battery voltage on r b ,c showed 2volt.

after much on and off with the master switch in testing the voltage gradually climbed on these terminals...... finally ended up after several hour with battery voltage...

turns out the master relay was failing or arc corroded . it was not open and had not seized and exciter coil was still working properly.. but was not contacting properly and was only letting 2 volts through... replaced it and everything checks below just fine...

 


On Thursday, August 9, 2018, 3:15:41 p.m. EDT, Paul Mansfield <europaul383(at)hotmail.com (europaul383(at)hotmail.com)> wrote:

 

 

I have just run my 912S (in a Europa) for the first time (with a Rotax engine specialist doing all the work!)
 
The problem is the battery is not charging.
 
I have researched the subject and found a good looking guide here: http://pointsforpilots.blogspot.com/2012/12/testing-rotax-912914-generator-and.html
 
These are the results:
 
Testing Generator
Result
 
 
Pull off the 2 yellow wires from G terminals.
 
 
With engine off and Master switch off, resistance between the two wires should be 0.1 - 0.8 Ohm.
0.5 - 0.8
 
 
Resistance between either wire and ground should be infinite; that is, there is an open circuit.
-1
(is this infinite?)
 
With engine running and the two wires still off the regulator, test AC voltage between the two wires.
 
It should be:
 
15 - 20 VAC during idle
14.6
2000 rpm
Almost 15!
 
30 - 40 VAC during high rpm
24.4
3300 rpm
Almost 30!
 
 
Testing Capacitor
Result
 
 
If the resistance between the plus and minus poles of the capacitor is not infinite, that is, it is not an open circuit, then the capacitor has failed and must be replaced.
-1
(is this infinite?)
 
Testing Regulator/Rectifier
Result
 
 
With Master switch on: Measure the voltage between ground and the wire on the R, B+ & C terminals in turn; it should be the battery voltage, about 12.5 VDC.
 
R
0.02
 
B+
0.02
 
C
0.02
 
 
With Master switch off: The above test should show 0 voltage for all three cases.
 
R
0
 
B+
0
 
C
0
 
 
Test that housing of regulator/rectifier is properly grounded:
 
Resistance between regulator housing and battery ground should be essentially 0.
0
 
 
If the wiring fails any of the above tests, the wiring problem needs to be isolated and fixed.
 
If the wiring passes the above tests, yet output voltage of the regulator/rectifier is not in the normal range, then the regulator/rectifier likely is faulty and should be replaced.
 
 
My understanding is that this is a wiring problem, no voltage is getting to the reg/rect... but I am worse than a novice at this – a little knowledge is a dangerous thing!
 
The aircraft is wired basically according to the Europa build manual (below or attached, depending how you are viewing this).
 
Any clues as to where I should begin looking?
 
Many thanks in advance,
 
Paul M
Europa XS 383
912S
 
[img]cid:image001.png(at)01D430D3.2AF8D410[/img]







 

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PostPosted: Fri Aug 10, 2018 10:12 am    Post subject: Battery not charging Reply with quote

Paul your test results show you are not connecting the battery to C B+ R on the regulator you need to check why has fuse blown or is master switch contact faulty some circuits I have seen use a seperate contact to connect alternator the led connected to L should light with engine stopped if battery supply is connected to regulator.

Clive


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From: Paul Mansfield

Sent: Friday, 10 August, 17:49

Subject: RE: Battery not charging

To: rotaxengines-list(at)matronics.com



--> RotaxEngines-List message posted by: Paul Mansfield Thanks for the reply Ted, I didn't test the VDC with the engine running - I will do that tomorrow and report back. Yes, the regulator case is grounded (I shall update the wiring diag). Thanks again, Paul --


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