Professional Documents
Culture Documents
INSTALLATION,
OPERATION, AND
MAINTENANCE
MANUAL
INDEX
Section
Safety
1
General I nformation
. .
2, 3
I nstallation ...... . . . . . .. .. . . . . . . . . . . . .. 4-1 3
Operati on .
, . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance . . . . . .. . . . . . . . . . . .. . . . . . 1 5- 1 7
Service
.
..
1 8-31
Troubleshooti ng
..
32-35
.
. . . . . . . .
. . . . . . .
. . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . .
. . . . . . .
. . . . . . . . . . . . . .
Section
!il
Generator Testi ng .
Parts List & Recommended
Spare Parts
Special Tools . .
P reparation For Shipment
Specifications a n d Data
Generator Formulas
.
36-39
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
40-4 1
42
. . 43
. 44-47
48
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . .
SAFETY$
Whenever the generator i s running, always assume
and proceed as if voltage is present. Resi d ual
voltage is present at th e generator leads and at the
reg ulator panel connections, even with the regulator
fuse removed. Caution must be observed, o r s.e r
personal i nj ury or death can result.
'
The hazards associated with liftin g or movIng the
MagnaPLUS generator are pOinted out i n the i nstalla
tion and servi ce sections; i n c orrect lifti ng or movi ng
can result in personal i nj u ry o r property damage to
the u n it.
mucheasleTf6handfefhan'durilbrilisliikes:
"GENERAL INFORMATION
I EC, and a l l popular mari n e agencies are avai lable).
All standard prod ucts have 2/3 pitch main wi ndings
to eliminate the third harmonic. This serves to lower
operating temperatures, give lower harmo n i c con
tent and better wave form , and extend the overa l l life
of the generator.
MECHANICAL DESIGN
General
All single and two bearing units are man ufactured
with cast iron end brackets and adapters, and
fabricated steel frames. Flexi ble d rive discs and SAE
adapters are machined to SAE standards. Pre
l u b ri c ated , sealed b a l l b e a rin g s are used o n
MagnaPLUS generators. Standard units are fully
guarded. Dripp roof shields are available as an
opti o n .
Standby Generator
Synchronous generators used on emergency backup
power ca n have tem perature ri ses up to 25" C above
those for conti n uous operation. ( N EMA M G 1 -22.40
and MG 1 -22.84).
Co nduit Box
Premium Insulation System
The large front end mounted conduit box is con
structed of formed sheet steel w h i c h wi l l allow the
addition of top m o u nted control packages. Refer to
Marathon Electric for top mounted controls of more
than 240 Ibs. The cond uit box cover properly d i rects
outside venti lating air through the generator.
Power Factor
All stan dard generators are designed for operation
at rated kVA at 0.8 power factor but can be operated
at rated kVA over the 0.8 to 1 .0 power factor range.
--------2--
'
GENERAL INFORMATION
FIGURE 2-1
Arrangement
A
B
E
F
H
J
K
L
M
N
0
S
43 2 S
CD
1 268
CD
3286 A A- F A
@@
CD 43 - 430 Frame
0 -4-Pole
1 - 6-Pole
2 - 4-Pole, extra length
3 - 6-Pole, extra length
S - SE R Generator
M - MAC Generator
R - Synchronous Motor
0- DOD Generator
Adaptor
SAE Size
Drive Disc
SAE Size
3
2
3
1
1 1 -1/2
1 1-11 2
10
1 1 -112
14
Delco
14
10
Delco
14
Small Delco
None
Delco
1
112
2
112
0
2
N one
0
INSTALLATION
If the machine has been exposed t o damp, h urnie]
c o n d i t i o n s the i n s u l atio n resistance s h ould be
checked . Refer to section 8.
WARN ING
WARN I N G
DO N OT A P P L Y ANY F O R C E T O G E N ERA
TOR FAN F O R L IF T I N G OR ROTA T I N G
G E N ERATOR R OTOR. DISREG A R D I N G
THESE INSTRUCTIONS MAY CAUSE PER
SONAL INJURY O R E Q U I PM ENT DAMAGE.
STORAGE
In the event that the generator is not to be i nstalled
on the prime mover i m mediately, it is recommended
that it be sto red in a clean, dry area which i s not
s u bject to r a p i d c h a n g e s i n t e m p e ra t u re a n d
h umidity.
I'(';"lMAAAI
HDN'
...::: L_=_=:....... _=_._=:
-------
INSTALLATION
BELT DRIVE
430 frame, two bea ring generators can be belt
dri ven. Please refer to Marathon Electric for appli
cation assistance involving belt d riven installations.
Sheave diameters should be c h osen according to
the table below.
60 Hz
6.6
7.3
8.3
9.8
1 1 .7
1 3.80
1 6.90
1 6.70
2 1 .30
50 Hz
5.5
5.6
6.5
7.6
9.2
1 0.8
1 2.4
1 3.2
1 4.6
Min. Sheave
Dia. i n
Inches@
20,000 Hr.
B-10 LifeCD
60 Hz
8.6
9.4
1 0.8
1 2.8
1 5.30
1 8.10
22.40
22.20
28.60
Max.
Sheave
Width
50 Hz Inches
7.3
7.5
8.8
1 0.2
1 2.4
1 4.60
1 7.00
1 8.00
20.1CD
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
CD Assumptions:
A. Belting factor is 1 .3.
B. The drive and the driven sheaves are the same
diameter.
C. The sheave load is located a the center of the
shaft extens i o n .
D. Based u p o n continuous k W ratings.
o These sheave d iameters exceed the maximum
recommended belt speed of 6000 fI/m in .
CD B-'1 0
l o n g or longer.
ENVIRO NMENTAL CO NSI DERATIONS
D i rt, moisture, heat, and v i b ration are enemies of
electrical equipment. Excessive exposure to the
elements will shorten the life of the generator. The
ambient temperature s h o u l d not exceed the value
shown on the generator nameplate. The MagnaPLUS
is b u i lt in a N E MA open type enclosure. Generators
for outdoor application should be p rotected from
the elements by housings with proper openings for
ventilation. T h i s protection should be designed to
prevent the d i rect contact of wind driven rai n , snow,
or dust with the generator. In moist or humid areas,
such as the T ropics a n d marine service, additional
protection is recommended. Although the standard
windings are hum idity a n d moisture resistant, special
INSTALLATION
1 2 LEAD HI WYE
60
HZ
50
HZ
LN
380
219
416
240
440
254
460
266
480
277
380
219
400
231
416
240
CONNECT
T '0 T"
L,
L2
L3
NEUTRAL
T,
T2
T3
T '2
T 4 T7
T5 T 8
T 6 T9
10 LEAD HI WYE
Ten lead generators are dual voltage generators with six coils.
One end of the three inner coils i s connected together. There are
10 or 20 cables coming out of the generator.
VOLTAGE
60
HZ
50
HZ
LL
LN
380
219
416
240
440
254
460
480
266
277
380
219
400
416
231
240
CONNECT
L,
L2
L3
NEUTRAL
T,
T2
T3
TO
T 4 T7
T5 T8
T6 T 9
INSTALLATION
1 2 L EAD LOW WYE
L,
--------'-1
LL
60
HZ
LL
LN
190
110
120
220
2 30
127
133
240
139
T, T7
110
T2T8-
120
T3 T9
200
208
HZ
1 15
L,
L2
T,
T2
L3
NEUTRAL
208
190
50
CONNECT
T4 T5 T6
---- --- -- --
__r.iL __.
L L
,1
60
HZ
190
110
208
120
220
12 7
230
50
HZ
133
240
139
190
110
200
115
208
CONNECT
L,
L2
L3
NEUTRAL
T,
T2
T3
T4 T5 T6 TO
LN
120
T, T7
T2 T8
T3 T9
T4 T5T6 T O
INSTALLATION
12 LEAD HI D ELTA
T,,________________-
II
LL
60
HZ
SO
HZ
CONNECT
LL
LN
240
27 7
'20
'39
T4 T7
200
'00
T6 T9
220
,,0
240
220
TS T 8
L,
L2
L3
T,
T2
T3
L,
L2
L3
T,
T2
T3
T, T'2
T2 T,O
T3 T"
L L
60
HZ
50
HZ
LL
,20
139
,00
'20
CONNECT
T, T7 T6 T'2
T 2 T 8 T 4 T lO
T3 T9 TS T"
INSTALLATION
6 L EAD WYE
Six lead generators have 3 coil groups with 6 or 12 cables or
bus bars coming out of the generator.
VOLTAGE
60
HZ
SO
HZ
LL
LN
190
203
220
230
240
3300
4160
110
120
12 7
133
139
1905
2400
190
110
11S
120
200
208
3300
CONNECT
L1
L2
L3
NEUTRAL
T4 TS T6
T1
T2
T3
T4 TS T6
1905
6 L EAD DELTA
VOLTAGE
LL
L
60
HZ
SO
HZ
L
31r-:o-5
T3
,,,,
____
______
L. L
L2
____
2400
CONNECT
L1
L2
L3
T1
T2
T3
T1 T6
T2 T 4
1905
T3 TS
INSTALLATION
4 LEAD
WYE
Four lead generators have 3 coil groups with one end of each
group connected together. There are 4,
bars coming oul of the generator.
VOLTAGE
LL
380
416
440
460
480
60
HZ
TO
600
380
400
416
50
HZ
LN
L,
L2
L3
NEUTRAL
T,
T2
T3
TO
219
240
254
266
277
346
219
480
231
240
277
3 LEAD DELTA
Three lead generators have 3 coil groups with one end of each
group connected into a Delta internally. There are 3,
cables or 3bus bars coming out of the generator.
VOLTAGE
ll
LL
L,
L2
L3
T,
T2
T3
60
HZ
480
---,.j
Ll--
12 LEAD ZIGZAG
ZIG-ZAG
VOLTAGE
LL"
..
l2
I:
120V
TS
T2
T11
T8
120V
l1
T3T9
60
HZ
120/240
L1
CONNECT
T2T8
T, T 6T 7T'2
L2
NEUTRAL
I
T2
T3
...
T4
T4 T'0T 5T n
240V
_______________________
10
INSTALLATION
NOTE: The MagnaPLUS is provided with a dual winding on the exciter field. Three leads are brought out F 1, F2, and
F3. Use F1 and F2 for a field resistance of 18.60hms. Use F1 and F3 for a field resistance of 28.7 ohms. See
manual for installed regulator for specific interconnection diagrams and exciter field requirements.
TYPICAL SYSTEM DIAGRAM WITH STANDARD REGULATOR SYSTEM
,
I
--- -------- -- ,
STATOR
:
&
EXCITER
I
I
I
I
L
MAIN
ROTOR
R9!.ATING
______
I
I
I
_____
.-.I
L3
RECTIFIER
ASSEMBLY
VOLTAGE
REGULATOR
PMG ROTOR
N
a:
o
'"
'"
w
a:
EXCITER ROTOR
MAIN ROTOR
..
..
ii:
w
.----;
LJ
l..-L::=:i:
::':::-: :-....J
ROTATING
RECTIFIER
ASSEMBLY
OOOOOOOOOO
OO
:c'::EOR
STATOR
OUTPUT
F2(-)
POWER
INPUT
SENSING
INPUT
VOLTAGE REGULATOR
PMG
PMG
E1
E.
E3
11
L1
L'
STATOR
Fl(+)
INSTALLATION
PARALL EL I N G OPERATI O N S
Paralleling Basics
The followi n g points are basic c riteria which m u st
be met before two units can be paralleled. T H I S I S
N OT MEANT T O B E S P ECIF IC INST R UCT I ONS
F O R PARALL E L I N G O P ERAT I ON.
Prime Mover
D. Switchgear
2. T he voltage and frequency must be the same
for a l l sets with voltages in phase.
3. The voltage regulation characteristics of the
individual generators should be similar.
Voltage Regulator
Switchgear
--
12
--
INSTALLATION
load to the gene rat or with the lower field current.
This is known as t h e reactive circulat i n g current and
t here are two methods of controlling it in parallel
operation:
13
OPERATION
PRE-START INSPECTION
2.
WARNING
WARNING
3.
4
5.
6.
7.
8.
VOLTAGE ADJUSTMENTS
12I'l -------------------1-4--------------------------------------
MAINTENANCE
MAINTENANCE - GENERAL INFORMATION
FIGURE 5-1'
--------15-- 12I'l
MAINTENANCE
Space Healers
Electric space heaters can be installed i nside of the
generator. When energized (from a power source
other t ha n the generator) t hey wi ll heat and dry the
i nside of the generat or. If an alternate source of
electricity is not avail able, enclose t h e generator
wit h a covering an d i n sert heating units to raise t h e
t emperature 1 5- 1 8 degrees F (8- 1 0 degrees C)
above t he temperature outside of t h e enclosure.
Leave a hole at t h e top of the enclosure to permit t h e
escape o f moisture.
Oven
Place t h e machine in an oven and bake it at a
t emperature noll o exceed 1 94 F (90 C). The voltage
regulator and any electronic component accessories
m u st be rem oved from the generator when using
t his method.
Forced Air
A portable forced air heater can be used by di recti ng
heat i nt o the air i ntake (conduit box) and running
the generator wi th no load and without exci tati o n
(this ca n be accom plished b y removi n g t h e regulator
fuse) . Heat at point of entry s h ou l d not exceed
150F (66 C).
CLEANI NG METHODS
WARNING:
B E SURE THAT ALL OF TH E FOLL O W ING
STEPSARE PERFO R M E D A N D AL L PRECAU
TIONS TAK E N AS PERSONAL I NJ U R Y O R
SERIOUS DAMAGE T O TH E GEN ERATOR
COULD RESULT.
1 . Disconnect exciter leads F 1 and F 2 f rom t h e
regulator.
2. Connect a battery or other dc power source of
approximately 20-35 volts to t he exciter leads
F1 and F2. An adjustable voltage source is
desi rable, however, a rheostat (rated approx
imately 2 amps) in series with t h e dc power
source wi ll work.
MAINTENANCE
SOLVENTS
SHELL BLASTING
STEAM CLEANING
17
SERVICE
REMOVAL FROM PRIME MOVER
WARNING
B E SURE AL L POWER IS OFF B EFORE SER
V I C I N G . F A I L U R E TO FOLLOW ALL SAFETY
I NSTRU CT I O N S CAN RESULT I N SE RIOU S
PERSONAL I NJURY OR DEATH.
NOTE: Before discon necting any electrical w i ri n g ,
b e s u re it i s m arked a n d c a n b e identified for
reinstallation. Remark as required.
1.
FIGURE
6-3
2.
3.
8
.
-- . --------------------------------------------------------------r;r;'IMARAa"HDN
1 8
---
SERVICE
CONDUIT BOX REMOVAL
1.
4.
19
SERVICE
FIGURE 6-10
FIGURE 6-8
4.
FIGURE 6-11
FIGURE 6-9
FIGURE 6-12
a N-E:LIEE -=-'-.-=
--
--------------------------------
20
SERVICE
OUTER
SNAPR
LOADING SPRING
PMG ROTOR
----il,-------'j
SHAFT
FIGURE 6-13
FIGURE 6-15
21
II
SERVICE
:. FIGURE 6-18
FIGURE 6-17
II
6.
WARNING
DO NOT APPLY ANY FORCE TO T H E GEN
ERATOR FAN FOR L I F T I N G O R ROTATING
T H E G E N E RATOR ROTOR. D I S R E G A R D I N G
TH ESE I NSTRUCTI O N S M A Y CAUSE PER
SONAL I N JU R Y OR EQ U I PMENT DAMAGE.
12J------------------- 2
SERVICE
EX CITER INSPECTION
A. Exciter Stator
1. Clean d ust and d i rt from the stator w i n d i n g .
(See section 5 . )
2 . Check t h e exciter stator f o r a loose, frayed, or
b ur n t wind i n g . Measure wind ing resistance
and insulation resistance. (See section B.)
Repai r or replace as necessary. If field repa i r of
the winding is necessary, contact Marathon
Electric for special wind ing procedu res and
materia ls.
3.
6-21.)
ENDBELL
RETAINING SCREW
AND LOCKWASHER
EXCITER STATOR
REVERSE
POLARITY
DIODE
ASSEMBLY
POLARITY
DIODE
REVERSE
POLARITY
DIODE
FIGURE 6-21
FIGURE
6-22
----------------------------------------
23 --------------------
r;t;"IMAJU[I1ot DN
ILor.
SERVICE
3. Check the exciter armature and rectifi er assem
bly for a loose, frayed, or burnt wi nding o r
loose con nections. Measure winding resist
ance and i nsu lation resistance. (See section
8.) D O NOT megger diodes or surge sup
pressor. Re pai r or replace as necessary. If field
repair of the winding i s necessary, contact
Marathon Electric for special winding proce
dures and materials.
4.
PMG INSPECTION
A. PMG Stator
1 . Clean dust and d irt f rom the PMG stator
winding. (See section 5.)
II
FIGURE 6-23
B. PMG Rotor
WARNING
TH E P M G RO T O R U SE S V E RY STRONG
MAGNETS. K EEP AWAY FROM I R O N AND
STEEL PARTS THAT COULD BE DRAWN TO
THE MAGN ETS. KEEP AWAY FROM OTH E R
COMPON ENTS THAT CAN B E DAMAGED
B Y STRONG MAGNETIC F I ELDS.
1 . Clean dust and dirt from the PMG rotor. (See
section 5.)
2. Check to be sure all magnets are tightly bonded
to the PMG rotor.
3. Check for burrs or corrosion i n the bore and
keyway where the rotor mounts to the shaft.
4. Look for score marks on the outside diameter
caused by rubbing. (This could i ndicate beari ng
or assem b l y problems and should be investi
gated.)
CAUT I O N : U N D E R N O CI R C U M ST A N C E S
SHOULD PRESSURE B E APPLIED TOTHE OUTER
R A C E O F TH E B EA R I N G , AS P E R M A N E N T
B EA R I N G DAMAGE COULD RESULT.
12I1l-----------24--
SERVIC E
Allow the beari n g to cool for one hour before
attempting to assemble the generator.
r
"J
,,;.;Jo
B . Fan
1. Check the f a n for cracks o r broken blades.
Replace the fan i f defective.
2. Mark the h u b and fan for a li g nment. this i s
necessary t o be s u re the balance weights wi l l
b e i n t h e same position when t h e fan i s re
i nstalled.
II
BELLEVILLE WASHERS
MUST BE M OUNTED I N THIS DIRECTION.
FIGURE 6-27
25
r?;"IMARAI HaN'"
SE R VICE
D. Main Rotor Core and Windi ngs
1 . Clea n all parts. Remove d ust and d i rt from the
rotor w i n d i ngs. (See section 5.)
Remove any accumulated dust o r di rt in the
winding air passages w i th a piece of w i re or
with low-pressure, moisture-free air. (Figure
6-30.)
12J1!
o
2
--------------------------------
SERVICE
2. I n spect t he d rive disc mount i n g capscrews for
d a m a g e d t h re a ds . R e p l ace c a p screws i f
damaged.
6-33
6-32
27
SERVICE
3. a. For si ngle bearing generators, sl ide the SAE
adapter over the fan, be sure the locating
mark I S at the bottom (See F i g u re 6-36 and
6-37), and secure to the main stator assembly
with capscrews. Torque per section 1 2 .
( F i g u re 6-38.) I t may be necessary t o raise
the rotor assembly slightly to allow the
mounting of the SAE adapter.
FIGURE
6-36
FIGURE
6-37
CATING MARK
(BOTTOM)
WARNING
D O N O T A P P L Y A N Y F O R C E TO T H E
G E N ERATOR FAN FOR L I FT I N G O R R OTAT
I N G THE GEN ERATOR ROTOR. DISREGARD
I N G THESE I N STR UCTI O N S MAY CAUSE
PERSONAL I N J U RY OR E Q U I PMENT
DAMAGE.
DN
.E::: L .IE:::: -=-"- . -=
------
----------
28
----
----
SERVICE
b. For two-bea ri n g generators, in sert guide
pins i n the rear bearing lock holes. Fill the
grease cavity of the drive end bracket 1 /3 f u l l
o f new grease. A l i g n the drive end bracket
and m ount with the capscrews. P in and
i nsert a capscrew and lockwasher into the
bearing lock and ti g hten. Remove the re
m a i n i n g gu id e pin and replace with the
remaining capscrew and lockwasher. Torque
bearing cap capscrews to 25 Ib-It (34 N-m).
Torque bracket mounting capscrews per
specifications given i n section 1 2.
CAUT ION: ON LAR G E G E N ERATORS, A H O I ST
AND LI FT I NG STRAP S H O U L D B E USED TO
ASSIST I N T H E D R I V E E N D BRACKET O R THE
SAE ADAPTER ASS E M B LY.
B I
I
94
--- +-_.-
5.
. . .....
. .
0:
;
..
.
.. .
.
.
.
., ....'.......
-
'-
- -- ,
FIGURE 6-41
29
SERVICE
2. Temporarily hang mounting ring for the PMG
stator over the shaft.
3. I nstall load i n g spring and P M G rotor on the
stu b_s_b_llJLaD_d_s_e_C_m!Lwith the s n a p r i n g . The
loading spring w i l l push out on the P M G rotor.
A piece of pipe s li g htly larger than the shalt
can be used to push the snap ring back unti l it
engages in its slot. (Fig ure 6-42.)
FIGURE 6-45
SERVICE
WARN I NG
DO NOT APPLY ANY FORCE TO THE G EN
ERATOR FAN FOR L I FT ING O R ROTAT I N G
T H E GEN ERATOR ROTOR. DISREGAR D I N G
THESE I N STRUCT IONS MAY CAUSE PER
SONAL I NJ UY O R EQ U I PMENT DAMAGE.
Position the generator so that the SAE
adapter mates with the flywheel housing.
CAUTION: DO NOT FORCE THE A L IG NM ENT OF
THE UN ITS. S H I FT THE G E N ERATOR FROM S I D E
T O S I D E O R RAISE O R LOWER WITH A L I FTI NG
DEVIC E A S NECESSARY.
I t may be necessary to use shims u nder the
mounting feet of either the generator or the
prime mover to obtain proper alignment;
use the same s h i m s as removed u n der diSassembly or proceed as follows: Using the
extreme bottom four capscrews, mount the
SAE adapter to the flywheel housing. With a
.001 5 to .002 inch feeler gauge at the extreme
top adapter to flywheel housing to fit, raise
the ge nerator or lower the pri me mover unti I
the gauge is s n u g . Relieve just enough to
release the feeler gauge and torque the
rema i n i n g SAE adapter capscrews to the
flywheel ho using . (Torque specifications
given in section 1 2 . )
ASSEMBLY TO P R I M E MOVER
1. Attach a suitable hoist to the generator lifting
lugs, and move the generator until the generator
foot mounti n g holes are aligned with the base
and slightly above.
2. a. For single bearing generators, if the screen
assembly is mou nted on the adapter, remove
the moun t in g bolts and remove the screen.
(Figure 6-48.) ( N OTE: Do not remove the
drip cover from the screen assembly if so
equipped.) I nsert two guide p i n s in the
flywheel and two i n the flywheel housing.
Adjust the generator position until the drive
discs are piloted in the flywheel. Remove the
guide pins and secure the discs with Grade 8
. place bolts and hardened washers or Grade
8 capscrews and heavy series lockwashers.
Torque per specifications given in section
12.
FIGURE 6-48
31
I
I
WARNING
Voltmeter Off
I ncorrect Connections
Defective Connections/Wiring
Defective Voltmeter
r,l)'lMAFUa'HDN
E: __ E: . --------------------3-2------------------------------------
---
TROUBLE S H OOTING
SYMPTOM: GEN ERATOR PRODUCES LOW VOLTAGE - N O LOAD
Underspeed Operation
Defective Voltmeter
Residual Voltage
Defective Connections/Wiring
I nspect a l l wiri ng. for grou nds, open ci rcuits, short c i rcuits, loose
connections, d irty connections.
Regulator Adjustments
Measure a m ps and verify that the l oad does not exceed the
nameplate rating of the generator. Refer to section 8.
Droop Circuit
33
TROUBLESHOOTIN G
SYMPTOM: G E NERATOR PRODUCES HIGH VOLTAG E
Defective Voltmeter
Incorrect Connections
Defective Connections/Wiring
6.
Unstable Speed
Defective/Loose Connections
Defective Regulator
----------------------------------------------------------34
---
TROUBLE SHOOTIN G
SYMPTOM: GENERATOR BU I LDS VOLTAGE FROM STARTUP,
THEN GOES TO LOW ( RESI DUAL) VOLTAG E
Regulator Protecti v e Circuit is
Operating
35
GENERATOR TESTIN G
VISUAL INSPECTI ON
Whenever testing and troubleshooting a generator
set, it is always a good practice to make a thorough
visual inspection. Remove covers and look for any
obvious problems. Burnt windings, broken connec
tors, leads, mounting brackets, etc., can usually be
identified. Look for any loose or frayed insulation ,
loose or di rty connections, broken wires. Be sure a l l
w i r i n g i s clear o f rotating parts.
Verify that the generator is con nected for the voltage
req ui red, this is especially important on new installa
tions.
Check for any foreig n objects, loose nuts, bolts, and
electrical con nectors. Clear paper, leaves, building
materials, etc., that could be sucked into the genera
tor. (Generator is air cooled. A ir enters through the
conduit box.) Check the air gap for clearance or
obstructions (main generator and exciter).
If possible, rotate the generator rotor by hand to be
sure it turns freely.
I f s e r i o u s p ro b l e m s c a n be i d e n t i f ied before
att e m pt i n g to operate the m a c h i n e , ad d itio nal
damage can b e avoided.
CONSTANT EXCITAT I O N ( 1 2V BATT ERY) TEST
THEORY: The generator output voltage is dependent
on generator speed, generator desi g n , load, and
exc iter input cu rrent. If the generator speed and
exciter i n put are known, the output voltage at no
load can be measured and compared to the design
val ue. Problems can be isolated to either the gen
erator or reg ulator system by using this test.
5.
6.
TEST PROCEDURE:
1 . Shut the generator set down.
2.
3.
4.
'l--------------------3-6-----------------------------------------
GENERATOR TESTIN G
FIGU RE 8-1: TYPICAL VOLTAGE MEASUREMENTS
Voltage Measurement
Test Point
Generator Output
Voltage
Regulator Output
( Exciter Stator I nput)
F1 and F2 terminals
at the regulator.
E1 , E2, E3 terminals at
the regulator.
200-240 VAC
1 80-220 VAC
MEASURING RESISTANCE
Main Stator
The main stator w i n d i n g resistance is very low. A
meter capable of readings i n the m i l l i o h m range
would be required. However, a standard V.O . M. can
be use.d to check for continuity, shorts, or grounds.
Example: With leads d isconnected, a measurement
from T1 to T4 sho uld be very low (contin uity on
most V.O. M's). Measured from T1 or T4 to any other
lead should be infi nite. Measure from the 'T' lead to
the generator frame to check for grounds (reading
should be infin ite).
37
GENERATOR TE STIN G
Exciter Stator
GENERATOR TESTIN G
The m i n i m u m acceptable valu e can be calculated
using the following formula.
M i n i m u m I nsulation Resistance
(Megohms)
G e n . Voltage +
1
1000
1 .48 Megohms
PROCEDURE:
(F1)
(F2)
39
PARTS
Note: This parts list is for reference only. Always give complete generator model
and serial numbers when ordering parts.
R.T.F.
R.T.F.
Adapter Fasteners
3/8-16 x 1 . 25
3/8 Split Lock Washer
3/8 Flat Washer
Part Number
Description
Adapter
SAE #3
or SAE #2
or S A E # 1
or SAE #1/2
or SAE #0
Cooling Fan
801 004-06
801 065-07
801063-04
1
12
8-525565-1
8c5255 10A
707717-01
4lIl"i rll3"@------
8-525566-1
8-5255 12A
8-5255 1 2 8
8-525p13A
8-5255 148
8-525514A
8
Drive Hub
R.T.F. - Refer To Factory
Quantity
1
1
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
40
PARTS
Item
9
10
11
Description
Part Number
A-525567
Drive Discs
SAE 1 1 -1/2
or SAE 1 4
or SAE 1 8
Quantity
14
5
A-525506
A-525508
A-525575
6
A-9674-2oo
A-9674-150
A-9667-1
12
A-25658-30
13
707807-01
14
Fan Fasteners
1/2-13 x 1 .50
1/2 Belleville Washers
801 008-05
A96821
15
7236400A
R.T.F.
16
A9646-75
1
1
4
1
32
17
723640-03
18
A-7605-3oo
19
801 000-02
801 063-22
831 823-01
21
End Cap
A526062
22
801 000-02
801 065-05
23
Rectifier Assembly
777062-0A
24
Exciter Rotor
791 1 48-0A
25
Exciter Stator
789342-0A
26
End Bell
B-526005B
27
C-525562
28
723640-04
30
801 004-05
801 065-07
1
1
Grounding Screw
3/8-1 6 x 3.00
3/8-1 6 Nut NonMagnetic
3/8 Flat Washer Non-Magnetic
A-26937-300
A-9786-1
A-9787-1
1
2
2
20
31
32
33
Gasket
End Bell Fasteners
3/8-1 6 x 1 . 25
3/8 Split Lock Washer
3/8 Flat Washer
R.T.F.
1
4
1
1
4
34
801 004-03
A-7675-2
A-504934-46
1
8
801 004-06
801 065-07
801 063-04
Refer To Factory
41
SP ECIA L TOO LS
STANDARD TOOLS
with
sizes
head
allen
FIGURE 10-2
FIGURE 10-3
MISCELLANEOUS
FIGURE 10-1
1IlJ:jI
E:::' E:::' -= -'- . E:: ---------------------------------rr;"IMAJUtl'HDN
L
42
CAUTI ON
DO NOT ATT EMPT TO TRANSPORT ANY
G E N ERATOR WITH O UT PROPER ROTOR
S U P P O R T , E XT E N S I V E E Q U I P M E N T
DAMAGE CAN OCCUR.
43
SPECIFICATIONS
TABLE 12-1: MAGNA PLU S - FASTENER AND TORQUE SPECIFI CAT IO NS
Part Description
Torque@
Ft-Lb
3/8 - 16
25
5/8 - 18
1 92
3/8 - 16
25
Conduit Box
3/8 - 16
25
PMG Stator
1/4 - 20
Exciter Stator
1/4 - 20
Cooling Fan
1/2 - 13
60
1/4 - 20
1 /2 - 1 3
50
NOTES:
CD All fasteners are SAE (American) standard.
CD
SizeC!)
Dia.-Thread
Drive Disc
CD
Fastener Spec. CD
SPECIFICATIONS
TABLE
1 2-2:
T o 1 / 2 - 69,000 PSI
To 3/4 - 64,000 PSI
To 1 - 55,000 PSI
1 50,000 PSI
SAE Grade
Number
1 or 2
()
Torque CD
Ft-Lb (N-m)
Torque CD
Ft-Lb (N-m)
Capscrew Head
Markings
Capscrew Body
Size
(Inches) - (Thread)
Torque CD
Ft-Lb (N-m)
Oiled
Dry
Dry
Plated
/ \
Plated
Oiled
Oiled
Dry
Plated
1/4 - 20
(7)
4.5
(6)
(5)
(1 1 )
(9)
(8)
12
(16)
11
(15)
10
(14
- 28
(8)
5.4
(7)
4.8
(6)
10
(14)
(12)
(11)
14
(19)
13
(18)
11
(15)
5/16 - 1 8
11
(15)
10
(14)
(12)
17
(23)
15
(20)
14
(19)
24
(33)
22
(30)
19
(26)
- 24
13
( 1 8)
12
(16)
10
(14)
19
(26)
17
(23)
15
(20)
27
(37)
24
(33)
22
(30)
3/8 - 1 6
18
(24)
16
(22)
14
(19)
31
(42)
28
(38)
25
(34)
44
(60)
40
(54)
35
(47)
- 24
20
(27)
18
(24)
16
(22)
35
(47)
32
(43)
28
(38)
49
(66)
44
(60)
39
(53)
7/1 6 - 1 4
28
(38)
25
(34)
22
(30)
49
(66)
44
(60)
39
(53)
70
(95)
63
(85)
56
(76)
-20
30
(41 )
27
(37)
24
(33)
55
(75)
50
(68)
44
(60)
78 (1 06)
70
(95)
62
(84)
1/2 - 1 3
39
(53)
35
(47)
31
(42)
15 (102)
68
(92)
60
95 ( 1 29)
84 (1 1 4)
- 20
41
(56)
37
(50)
33
(45)
85 ( 1 1 5)
77 (104)
68
108 (146)
96 ( 1 30)
41
(56)
1 1 0 (1 49)
99 (134)
88 ( 1 1 9) 1 55 (210)
140 (190)
124 (1 68)
96 (130) 1 70 (230)
153 (207)
136 (184)
189 (256)
168 (228)
192 (260)
9/16 - 1 2
51
(69)
46
(62)
- 18
55
(75)
50
(68)
44
(60)
5/8 - 1 1
83 (1 1 3)
75
(102)
66
(89)
- 18
95 (129)
86 ( 1 1 7)
76 (103)
2 1 6 (293)
84 ( 1 1 4)
338 (458)
300 (407)
92 ( 1 25)
378 (513)
336 (456)
3/4 - 1 0
- 16
105 (1 42)
95 (130)
1 1 5 ( 1 56) 104
(141 )
7/8 - 9
545 (739)
484 (656)
- 14
1 75 (237) 1 58 (214)
1 40 ( 1 90)
608 (824)
540 (732)
1 -8
235 (319) 2 1 2
(287)
188 (255)
590 (800) 531 (720) 472 (640) 9 1 0 (1 234) 8 1 9 ( 1 1 10) 728 (987)
- 14
200 (271 )
660 (895) 594 (805) 528 (716) 990 (1 342) 891 (1208) 792 ( 1 074)
NOTES:
CD Capscrews threaded i n t o a l u m i n u m m a y require reductions i n torque
of 30% or more.
45
SPECIFICATIONS
NOTE: All excitation data based on measurement using F1 and F2 exciter field winding. For F1 to F3 data refer
to factory.
TABLE 12-3: EXCITATION DATA - 60 HZ - 1 800 RPM
No Load Output Voltage
With Fixed Excitation
High Wye Connection
Exciter Field
Resistance Ohms
Model Number
@ 25 C
240/480 Volts
1 2 V DC
24V DC
430S1260
430S1 261
430S1262
430S1263
43051264
430S1265
430S1266
432S1267
432S1268
18.6
18.6
1 8.6
18.6
18.6
18.6
18.6
18.6
1 8.6
8.9
10.4
10.0
10.2
9.7
1 1 .0
1 2. 1
1 1 .7
14.9
530
510
51 0
510
520
500
480
490
440
530
600
600
600
610
590
570
580
550
Exciter Field
Resistance - Ohms
@ 25 C
4 1 5 Volts
12V DC
24V DC
1 1 .0
1 2.5
12.1
12.1
1 1 .9
13.8
14.9
13.8
1 7.5
430
410
410
410
420
400
380
400
360
510
490
490
490
500
480
470
480
450
Model Number
430S1260
430S 1 261
430S1262
430S1263
430S1264
430S1 265
430S1 266
432S1267
432S1268
1 8.6
18.6
18.6
18.6
18.6
18.6
18.6
18.6
18.6
I'i'\"lMARAJ HDN
--
--
46
SPECIFICATIONS
TABLE 1 2-5:
RESISTANCE VALUES - MAIN WINDINGS
NOMINAL COLD (25"C) RESISTANCE I N O H M S
Model Number
H-SG-
Main
Stator(i)
430S1260
430S1261
430S1 262
430S1263
438S1264
430S1265
432S1266
432S1267
432S1268
430601
430602
430603
430604
430605
430606
430607
430608
430609
.204
.181
123
.0935
.0721
.0541
.0415
.0373
.0264
Winding
Main
Rotor
.482
.504
.520
.558
.594
.636
.704
.711
.825
TABLE 1 2-6:
RESISTANCE VALUES - EXCITER WINDI N G S
NOMINAL COLD (25" C) RESISTANCE I N OHM S
(Field)
ExCiter Rotar
(Armature)
PMG
Stator
18.6
.105
2.00
ExCiter Stator
II
47
To Find
Three Phase
Known Values
KW
E x I x 1 ,73 x PF
1 000
KVA
Volts, Current
E x I x 1 ,73
1 000
R KVA
E x I x 1 .73 x1 - (PF)2
1 000
Hp-Engine Output
kVA x PF
kW
PF
KW
Efficiency x .746
Rad
Cooling
+ Fan
hp
Mo to r hp, Eff.
HI:> x .746
Efficiency
HI:> x .746
Efficiency x PF
Amps
Hp, Volts
H p x 746
1 .73 x E x Efficiency x PF
Amps
KW x 1 000
E x 1 . 73 x PF
Amps
KVA, Volts
KVA x 1 000
E x 1 .73
Frequency
R p m , Poles
Rl:>m x Poles
2 x 60
Poles
Frequency, rpm
2 x 60 x Freguency
rpm
Rpm
Frequency, Poles
2 x 60 x Freguency
Poles
CD E
Bat. C h g .
Gen. hp
Volts
Current (Amps)
PF Power Factor
I
'l -------------------------------------------------------------48
NOTES
M o d e l N u m be r
__
__
__
__
__
__
__
__
__
__
_
Serial N u m ber
__
__
__
__
__
_
__
__
__
__
_
I n sta I I ed Date
__
__
_
__
_
__
__
__
_
_
_
_
I n stal l ed By
__
_
__
__
__
_
__
_
__
__
_
49
GPNOO5 3/95