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Old 07-10-17, 04:17 PM   #1
CSdiesel
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Default Honda 3.5kw alternator issues

Hi all. I have bought and taken out the alternator to run off my Wisconsin THD twin cylinder, I have fitted it all to the trolley and it was working fine before being tripped , I have taken to original control box off and have loose wires at the minute, so today I have fired it all up and run it up to speed but have no juice out the 110 volt or the 240 volt . however the 12volt dc side is working fine, can anyone explain please why there is no power out the main power cables ? Thanks Jon

And yes the generator is spinning fast enough also .

The alternator was off a Honda ES3500 belt drive unit
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Old 07-10-17, 05:31 PM   #2
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I've found a manual for the ES3500 and downloaded the wiring diagram as a pdf but it exceeds the forum attachment limit. Link to manual and wiring diagram is on pages 92 & 93.

Stuart.
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Old 07-10-17, 05:50 PM   #3
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No expert but sounds like it's not self exciting.
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Old 07-10-17, 05:54 PM   #4
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No expert but sounds like it's not self exciting.
The 12 volt side is exciting so the rotor is ok Steve.
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Old 07-10-17, 07:19 PM   #5
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The 12 volt side is exciting so the rotor is ok Steve.
Had that on my Stuart set, 12v side was fine 240 v side was dead. That was a user interface error that caused that fault
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Old 07-10-17, 08:39 PM   #6
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The 12 volt side is exciting so the rotor is ok Steve.
That's DC though isn't it? Or it all DC? Doesn't it use the DC to excite the AC circuit?
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Last edited by skankin_giant; 07-10-17 at 08:57 PM.
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Old 08-10-17, 07:15 AM   #7
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I thought the dc side was a seperate winding on the stator then rectified with a full wave bridge?
Gen sets I've worked on had an aux winding to provide the excitation juice via an avr......

I suspect a wiring error/broken or disconnected wire
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Old 08-10-17, 08:11 AM   #8
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I thought the dc side was a seperate winding on the stator then rectified with a full wave bridge?
Gen sets I've worked on had an aux winding to provide the excitation juice via an avr......

I suspect a wiring error/broken or disconnected wire
Looking at the wiring diagram that Stuart found that appears to be the case.

Martin P
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Old 08-10-17, 08:21 AM   #9
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Quote:
Originally Posted by Chippie View Post
I thought the dc side was a seperate winding on the stator then rectified with a full wave bridge?
Gen sets I've worked on had an aux winding to provide the excitation juice via an avr......

I suspect a wiring error/broken or disconnected wire
Gents. I have taken the control box off and the alternator is currently free standing albeit bolted to the sliders on the trolley and its all belted to the engine. the wires are all loose and not connected to anything , I ran the engine up to get a reading but only the 12v dc side was producing what I need to know is fom a simple view point, is how to link the 12v dc side to the 110 and 240 AC side to excite the windings to produce power without going through honda's control box as I don't want to use that in this set up but will be building a simpler control panel of my own . Thanks in advance Jon
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Old 08-10-17, 09:22 AM   #10
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Quote:
Originally Posted by Chippie View Post
I thought the dc side was a seperate winding on the stator then rectified with a full wave bridge?
Gen sets I've worked on had an aux winding to provide the excitation juice via an avr......

I suspect a wiring error/broken or disconnected wire
Didn't know that, not worked on them. If Jons not using the Control box then getting AC might be an issue.

Might take a look at the wiring diagram when I get 5 mins
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