DVR 2000E

DVR 2000EC

Troubleshooting

DVR2000E/EC Troubleshooting
- Section Overview This section will discuss basic troubleshooting for the DVR2000E/EC voltage regulator. Specific problems are detailed further in the DVR2000E Installation, Operation, and Maintenance (IOM) Manual (GPN019 03/06) on Pages 41 45. This section is separated into (2) parts: Troubleshooting a DVR2000E/EC installed on a generator in the field Troubleshooting a DVR2000E/EC on a test bench
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DVR2000E/EC Troubleshooting
- Field Testing Troubleshooting scenarios are provided in the DVR2000E Installation, Operation, and Maintenance (IOM) Manual (GPN019 03/06) beginning on page 41. This presentation will focus on basic troubleshooting methods for the DVR2000E/EC. Specific scenarios/problems can be discussed as a group as required.

NOTE: Marathon Electric recommends that testing discussed in this presentation be completed with NOLOAD on the generator.
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DVR2000E/EC Troubleshooting
- Field Testing NoteNOTE: It is recommended by Marathon Electric that, when possible, you utilize the Metering screen in the Marathon-DVR2000E-COMS Software for troubleshooting as this screen will provide you much insight into the the generator system including exciter field conditions and alarm status. See diagram below.
Exciter Field Voltage and Current Generator Output Voltage

Generator Output Current (if CT connected)

Additional System Information Generator Frequency (Calculated, not measured)

DVR2000E/EC Troubleshooting
- Field Testing NoteNOTE: Metering Button/Alarm/Status Tab. Any alarms displayed on this screen should also be seen on the Front Panel Display/LEDs.

DVR2000E/EC Troubleshooting
- Field Testing BasicsIn the event of a problem in which the DVR2000E/EC is suspect, confirm the following (10) items with NO-LOAD on the generator:
1. Check Front Panel/Metering Screen for Alarm Status. If an alarm is indicated, correct problem. These alarms are defined in the DVR2000E Installation, Operation, and Maintenance (IOM) Manual (GPN019 03/06) on Pages 23 24.

NOTE: If DVR2000E/EC latches-off , upon applying power to the DVR2000E/EC the function indicator LED on the front panel will flash rapidly for 5 seconds to indicate Latch-Off Mode prior to activating regulation. This is very useful in troubleshooting why the regulator is shutting down.
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DVR2000E/EC Troubleshooting
- Field Testing Basics (Contd) 2. Check the Integrity of All Connectors and Signal Wire Integrity. Correct as necessary. 3. Check Wiring Connections. The connection should be made as shown in the IOM on Pages 33 36. Correct as necessary. 4. Confirm Shaft Speed. It is always recommend to verify shaft speed with a tachometer or other equipment (i.e., not by the sound of the engine). Correct as necessary. 5. Check DVR2000E/EC Input Power (Terminals 3 & 4). This supplied by the PMG and should be nominally: a) 220 Vac, 300 Hz at 1800 RPM (60 Hz) b) 190 Vac, 250 Hz at 1500 RPM (50 Hz) 6. Check DVR2000E/EC On-Board Fuse. If failed replace with equivalent fuse.
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DVR2000E/EC Troubleshooting
- Field Testing Basics (Contd) 7. Review DVR2000E/EC Settings. Confirm that the settings are correct either using the Front Panel or MarathonDVR2000E-COMS Software. 8. Check Sensing Inputs (Terminal E1, E2, E3). Confirm that you are sensing the correct voltage and confirm that you are sensing on the proper generator terminals. 9. Constant Excitation (12V Battery) Test. This test is used to isolate the DVR2000E/EC and confirm that the regulator is the basis of the problem. Disconnect all DVR2000E/EC leads, isolating Leads 3, 4, E1, E2, and E3 which will have voltage on them. Follow instructions in your generator manual for performing this test. Compare generator output voltage to datasheet (available from the Marathon Electric website or your Regional Marathon Electric Representative) for your model generator.
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DVR2000E/EC Troubleshooting
- Field Testing Basics (Contd) 10a. Correct generator problem and repeat Steps #1 - #9. If there is a problem found with your generator, correct the generator problem and repeat these steps if your problem persists. Review IOM Pages 41 45. If there is no problem found with the generator, review the IOM for specific problem. If a problem not listed in the IOM is found, contact your Marathon Electric Regional Representative for assistance.

10b.

NOTE: If you find the problem is related to the DVR2000E/EC regulator, it is recommended that you perform a bench test on the regulator prior to contacting your Marathon Electric Regional Representative for a return authorization (AKA, RGA number).

DVR2000E/EC Troubleshooting
- Bench Testing Basics -

In the event that you replace a DVR2000E/EC, it is recommended that you do the following tests prior to scrapping the unit or contacting your Marathon Electric Regional Representative for return authorization (if within warranty):
1. Confirm Internal Connections

2. Perform Light Bulb Test

3. Test on Known Working Generator (if possible)

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DVR2000E/EC Troubleshooting
- Internal Connection Test -

Measure the following to determine if regulator power stage is intact:

Terminals (F-) to (7): Using the diode setting of your meter. This should Open in one direction and 0.5 Vdc (approximately) in the other direction. Terminals (F+) to (F-): Using the diode setting of your meter. This should Open in one direction and 0.5 Vdc (approximately) in the other direction.

NOTE: If the values measured do not agree with the values discussed, the regulator is internally failed and cannot be repaired.

External Fuse: Using the resistance setting of your meter. If fuse is good meter should indicate minimal resistance. Replace fuse if bad.

Internal Fuse (Terminals (3) to (Rectifier Rivet)): Using the resistance setting of your meter. If this connection is intact meter should indicate minimal resistance.

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DVR2000E/EC Troubleshooting
- Light Bulb Test (Power Supply) NOTE 1: For the Light Bulb Test, Marathon Electric recommends that you use a 48 Vdc, equivalent to the Volgen SPN-50-48S, in order to limit the amount of current into the DVR2000E/EC which could further damage the unit. A separate power supply may be purchased which will limit the current into the regulator. The power should be equivalent to:
Volgen SPN-50-48S See Volgen Power Supply Specifications.pdf included on seminar compact disk for further details

Attach the wire terminals to Terminals 3 and 4 of DVR2000E/EC regulator. Be sure to attach a grounding wire prior to applying power.

NOTE: No matter what power source you choose, be sure that the DVR2000E/EC is hard-wired to earth ground with no smaller than 12 AWG copper wire attached to the ground terminal on the rear of the unit case.

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DVR2000E/EC Troubleshooting
- Light Bulb Test (Connection) -

Terminals (F+) & (F-): Connect 120 Volt, 100 Watt Light Bulb (recommended)

GROUND--Hard-wired GND Terminal to earth ground with no smaller than 12 AWG copper wire directly attached to terminal

Terminals 3 & 4: Connect power supply

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DVR2000E/EC Troubleshooting
- Light Bulb Test (Safety) Attached protective cover BEFORE applying power.

NOTE: It is highly recommended that the protective cover be installed on the DVR2000E / DVR2000EC whenever power is applied to the DVR2000E / DVR2000EC as the heat sinks on the rear-side of the DVR2000E / DVR2000EC are live when power is applied. Ref: IOM, Page 27 14

DVR2000E/EC Troubleshooting
- Light Bulb Test (Procedure) 1. Connect as shown. 2. Apply power to DVR2000E/EC and activate FCR/Manual Mode either through the Front Panel or the MarathonDVR2000E-COMS Software. LED #3 on the Front Panel should be blinking in either case. 3. Using the Front Panel (LED #4) or the Marathon-DVR2000ECOMS Software (Settings Button / Set point Tab), adjust the FCR Set point (A) up and down. a) If you see the light bulb illumination vary, your DVR2000E/EC is outputting current and may still be intact (confirm with generator testsee next slide) b) If you do not see a change in the illumination of the light bulb the DVR2000E/EC may be damaged and should not be used on another generator until fully evaluated by qualified personnel 15

DVR2000E/EC Troubleshooting
- Generator Connection 1. Program the DVR2000E/EC for the generator you will be using for this test, using either the Front Panel or the MarathonDVR2000E-COMS Software. 2. Connect the DVR2000E/EC regulator to a known working generator. 3. Run generator-set and check generator output: a) If generator is operating properly, do a load test on generator set to confirm. If load test passes, DVR2000E/EC is most likely intact and can be used on a generator b) If generator is not operating properly, contact your Marathon Electric Regional Representative for further assistance

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DVR2000E/EC Troubleshooting
- Summary -

In summary, prior to contacting your Marathon Electric Regional Representative to return a DVR2000E/EC voltage regulator, follow this troubleshooting sequence: 1. Confirm Internal Connections
2. Perform Light Bulb Test

3. Test on Known Working Generator (if possible)

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DVR2000E/EC Troubleshooting
- End of Section -

QUESTIONS?