PMG Assembly Line Testing

There is little excuse for wiring errors in Generators out of the box; but still I see it. This leads to a lot of calls, and "hand holding" on the telephone which is no fun for for Customers or Dealers

Here's the suggested assembly line Go-No Go test before they box the Generator.

Above: We start out with the simple connector block, note that the paired terminals are conductive, the top connections are where the stator windings will terminate. The bottom screw terminals are used to wire to the customer's distribution box.

Above: Here's the "Go-No Go test" Rig. that's a 12 volt light bulb like that found in an auto dome light at the bottom of the drawing. The red jumper must be in place between terminal two and three.

To PASS the test, you simply grab hold of the shaft and twist it sharply and the light will get bright!

If this test fails simply reverse either set of stator leads and try it again!

Note: The light bulb WILL light across 1 and 2, or 3 and 4, but not as bright.

Every generator should be delivered with a test tag, and the initials and date of this test.

In addition, the tester will double check all four screw terminals are tight.    

Note to Assemblers: We are the only people who can build job security for ourselves, a job well done is a job more secure.

 Note, if the above test passes, you can wire the generator for 120/240, 240 or 120 VAC only operation with predictable results.

 GB