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Topic: Important caution when changing PowerTech voltage regulator (Read 1821 times) previous topic - next topic

Important caution when changing PowerTech voltage regulator

A few months ago, I mentioned that a Foretraveler smoked his generator immediately after installing a new voltage regulator, because they did not notice that the new regulator needed to be wired up differently.  The damaged generator required a new end pancake costing several thousand dollars.  In that write-up, I incorrectly noted he had a plug in regulator.
VERY IMPORTANT - 10KW Isuzu generator voltage regulator DESTRUCTIVE PROBLEM
 
I talked to Powertech today and got some more information on what generators need extra attention when changing voltage regulators.  Jeff Jones at Powertech is like our James Triana.  They have been around forever and know everything and are the number one contact for technical support.
 
Generators with plug-in voltage regulators are not affected.  To change these regulators, just unplug and replug.
 
Some older 10kw Powertech generators have wire terminals instead of plugs, and some cases connecting the new regulator requires wires to be connected differently.  The new regulator will come with instructions and wiring diagram that will explain the details and wire color codes.
 
If changing from an old VR63-4 voltage regulator to the newer AVC-64 voltage regulator, and if there is an "A" in the serial number of the generator, the regulator must be wired as shown in the diagram that is sent with every regulator.
 
If there is any questions at all, be sure to contact Jeff Jones BEFORE starting at 352-435-4416, JeffJ@ptse.net. 
 

Re: Important caution when changing PowerTech voltage regulator

Reply #1 –
I figured the post is only two months old so rather than cut and paste...........



Quote from: Barry & Cindy –

Generators with plug-in voltage regulators are not affected.  To change these regulators, just unplug and replug.

Some older 10kw Powertech generators have wire terminals instead of plugs, and some cases connecting the new regulator requires wires to be connected differently.  The new regulator will come with instructions and wiring diagram that will explain the details and wire color codes.

If changing from an old VR63-4 voltage regulator to the newer AVC-64 voltage regulator, and if there is an "A" in the serial number of the generator, the regulator must be wired as shown in the diagram that is sent with every regulator.


My generator has started to put out 140+ volts as measured on the Power Line Monitor. I finally got thru to Powertech (Jeff) who stated I needed the Basler AVC 63-4. I have not purchased the regulator yet.

My generator has a build date of 1999 (can't remember the month)
Today I removed the old regulator which is a "plug-in voltage regulator" as Barry mentioned above. I do not have wire terminals. Other than a very large letter  E on the flat side of the regulator there are no other markings. My generator serial number is ITA25DD91149SI. Third character is an  "A"

I sent Jeff photos of the old regulator via an email asking if I need to rewire. I just received his reply. He requested a photo of  "the end of the generator" before answering.

I'm not sure what he means by the end of the generator. I have a quiet box, I removed the front of the box and took pictures of the cylindrical case on the ?END? I hope he didn't want me to open that also before taking photos.

So I have a plug-in regulator but I also have an A in my serial number.

Ed


[fixed quote formatting - Michelle]
Ed and Michele
2000 U295  36'  (Build #5600)
8.3 ISC 350HP.
2012 Jeep Grand Cherokee (Toad)
2001 Lance Truck Camper (Sold)
2001 Lazy Daze (Class C). RK Floor Plan (Sold)

Re: Important caution when changing PowerTech voltage regulator

Reply #2 –
Ed, the end of the generator tells Jeff if the generator has brushes or is brushless.  Brush generators have a removable metal plate covering the end bearing & brush assembly.  Brush generators use a different voltage regulator than brushless units. 

Not sure how to examine the end with the quiet box.  Maybe there is an inspection cover on the quiet box that would be visible when generator is slid out. 

Periodic inspection of brushes may catch a badly wearing brush assembly that could cause thousands of dollars damage.  Also end bearing needs to be changed before it fails and destroys the whole generator end unit.  So preventatively changing bearing and brush assembly could be a good idea.  Generators like to be run and it will keep bearing rotating and not drying out.

  We did find a great tech in Phoenix to repair our brush damage and swap our end bearing, that we would recommend.


Re: Important caution when changing PowerTech voltage regulator

Reply #3 –
Quote from: Barry & Cindy –
  We did find a great tech in Phoenix to repair our brush damage and swap our end bearing, that we would recommend.

Name, link, phone?  ^.^d
1993 U-240 "La Villa Grande"..CAT 3116 w/ Pacbrake PRXB...Allison 3060 6-speed..
Previous: 1983 Airstream 310 turbo diesel, 1979 Airstream 280 turbo diesel
                                      Build # 4297
                                      PNW natives
                      Home base:  'Cactus Hug' (Ajo, Arizona)
                        DW Judy & Chet the wonder dog
                        Full-Timers 'Sailing the asphalt sea'

Re: Important caution when changing PowerTech voltage regulator

Reply #5 –
Quote from: Barry & Cindy –
Phoenix Arizona recommended generator shop. .Important to check generator brushes... & have a good Phoenix generator shop. 

Thanks, Barry, will store the info.  ^.^d
1993 U-240 "La Villa Grande"..CAT 3116 w/ Pacbrake PRXB...Allison 3060 6-speed..
Previous: 1983 Airstream 310 turbo diesel, 1979 Airstream 280 turbo diesel
                                      Build # 4297
                                      PNW natives
                      Home base:  'Cactus Hug' (Ajo, Arizona)
                        DW Judy & Chet the wonder dog
                        Full-Timers 'Sailing the asphalt sea'

Re: Important caution when changing PowerTech voltage regulator

Reply #6 –
My generator saga is hopefully over. Installed a new voltage regulator purchased from a Powertech dealer in Michigan. The part number for my generator straight from the Powertech web site is

Voltage Regulator VR 2.4 (Exciter)
$280.95
Regulators

 Voltage Regulator 2.4 for Exciter generator end (brushless). PT# 06REG24


As mentioned above my generator serial number with the Isuzu 3LD1 engine is

/Users/edward/Desktop/Fred/IMG_3803.jpg
My link to photo did not post.  It was the label from the top of the generator.



A word of caution for anyone with a genny built around 1999-2000. Check and double check with Jeff at Powertech. When I gave him my serial number he told me I needed the Basler voltage regulator.

Basler Voltage Regulator 63-4 AVC
$327.36
Regulators

 Basler Voltage Regulator 63-4 AVC  PT# 06REG634AVC


After reading Barry's post above I removed my voltage regulator and emailed photos of the regulator to Jeff. He replied asking for photos of the generator end. I sent those along with the photo of my label with the Serial number.

Jeff replied  "this serial number does not match the unit  it takes  an 06reg2.4 please call me "

During our conversation he stated that my genny type was one of the first that PT built. Maybe that is why the serial number did not jive. Maybe it was correct at the time. Even the dealer in Michigan thought told me I should have a brush type generator. Even showed me another customer's similar genny.

Guys I don't know the answer but please be careful.
Ed and Michele
2000 U295  36'  (Build #5600)
8.3 ISC 350HP.
2012 Jeep Grand Cherokee (Toad)
2001 Lance Truck Camper (Sold)
2001 Lazy Daze (Class C). RK Floor Plan (Sold)

Re: Important caution when changing PowerTech voltage regulator

Reply #7 –
Powertech Dealer in Michigan

Graham Motor & Generator Service
1610 S. Airport Rd.
Traverse City, MI  48603
231-929-1829
Ph: 231-929-1829
Fx: 231-946-3734
Ed and Michele
2000 U295  36'  (Build #5600)
8.3 ISC 350HP.
2012 Jeep Grand Cherokee (Toad)
2001 Lance Truck Camper (Sold)
2001 Lazy Daze (Class C). RK Floor Plan (Sold)