Cleaning/disassembling the K1 AC Circuit Interrupter

[Browning1]

I'm in the process of cleaning/disassembling the K1 AC Circuit Interrupter. My question is how do I get to the inside to clean the part that moves up and down? I tried to pry the plastic top off but did not want to break it. I have taken all the contacts off the top and cleaned them already. TIA

 

[Light in the Dark]

There should be (4) corner screws that you remove, for the cover to pop off.

 

[Towbarman]

I'm trying to do the same thing. One of my steps was to unscrew P6 from J6. I have a PU 802A generator that when I hold the main switch it shows 120 volts and 60 Hz. When I release the switch to let it run voltage goes down same as the Hz

 

[kloppk]

... when I hold the main switch it shows 120 volts and 60 Hz. When I release the switch to let it run voltage goes down same as the Hz

Sounds like a bad AC Voltage Regulator. They fail a lot.
I'd suggest testing the AC Voltage Regulator per the -24 TM.
Post up your measurements for each step so we can help.

 

[Browning1]

There should be (4) corner screws that you remove, for the cover to pop off.

I have removed the top cover already. I trying to get to the part that has the three studs that move the copper contacts up and down.

 

[Towbarman]

I have taken a reading on my Alternator regulator. Any help here.
OHMS VAC
1. 6.2 1. 2.8
2. 4.7 2. 2.9
3. 4.7 3. 2.7
4. -4.7 4. 11.2
5. -.51 5. 11.3
6. 4.7 6. 2.6
7.1.5 7. 3.7
8. 56.5 8. 1.1
9. 57.5 9. 1.1
10. 4.5 10. 7.3
11.1.3 11. 8.1
12. 146.0 12. 1.1

 

[Guyfang]

People. to0 many folks, posting too many things, that do not all fit together. Towbarman, please start your own thread. And Kurt has pointed you in the right direction to start trouble shooting.

Browning. A K1 from a TQG? Or maybe a MEP-006A? Or a K1 from a 150 KW Turbine gen set? Makes a big difference.

 

[Browning1]

Mep 803a.

 

[Towbarman]

Guyfang
My apologizes for jumping into that thread. It sounded like the same thing going on with my gen. Again, I do apologize.

 

[Guyfang]

No problemo. It just gets everyone confused an its always better when you have your own thread, as it gets you the best viability.

 

[Guyfang]

Browning,

Have you gotten it apart yet? Normally its pretty easy. Show us a picture.

 

[Browning1]

Whats the easiest way to get to the three studs the move up and down

 

[Guyfang]

First apply 24 VDC to pins X&Y. See what happens. Then tap with a rubber headed hammer GENTLY where the top plastic meets the metal bottom of the case. It should just come apart.

You can see where there has been a bit of arcing on he contacts. Its not too bad. That normally happens when someone shuts the gen set off without shutting off the load first. or when the gen set runs under load and drops off line under load for a fault.

 

[Browning1]

Thanks. Here's the problem I have been having is with gen set under a 40amp load it drops offline in about 2 minutes. I reset the ac circuit interrupter switch and it ran fine under same load for about 2 mins and it drops offline again. I tried this with a 20amp load and it run for about 8 mins before dropping offline under load. When this happens there is no fault light that comes on.

 

[Ray70]

I assume the fault light is working?
I would not suspect K1 to be the problem, but you can test it by applying 24V to X and y with the machine running ( disconnect X and Y's wires before testing ) run under the same load and see if it disconnects.
That will tell you if K1 is the problem or if the problem is that 24V feeding X-Y is dropping out.

 

[Browning1]

Yes all the fault lights work when I press the test button. If it's not the K1 then where should I start looking/reading in the tech manual to figure out the issue?

 

[Guyfang]

I think the possibility of K1 being the problem is very small. In fact, I have never seen those symptoms when a K1 type relay had any kind of failure. Test the K1. Then put it back together. Ray, I think this sound more like he needs to clean S6 & S8 with some contact cleaner.

When it drops off line, what fault indicator light comes on?

 

[Browning1]

No fault indicator light comes on when it drops offline. I have clean S6 and S8 with contact cleaner but have not test unit yet. Now when I cleaned S6 and S8 I didn't remove them to clean them. I just sprayed them best I could and worked the switch back and forth a lot. I did notice a big difference in how the S6 switch was engaging the detents after I clean it.

 

[Mullaney]

No fault indicator light comes on when it drops offline. I have clean S6 and S8 with contact cleaner but have not test unit yet. Now when I cleaned S6 and S8 I didn't remove them to clean them. I just sprayed them best I could and worked the switch back and forth a lot. I did notice a big difference in how the S6 switch was engaging the detents after I clean it.

.
Yessir. More cleaner, possibly better contact cleaner...

 

[Browning1]

i have been using the WD-40 contact cleaner.