POWR-PAK 3000B, 3000BE, 3000BP, 3000BEP Operators Manual

Generating Quality

Since

7925

POWR-PAK"

WINPOWER CORPORATION

NEWTON, IOWA 50208 U.S.A.

PHONE: (515) 792-1301

/

~

-

Printed in U.S.A.

OPEFATION

ENGINE STARTING

The engine manual should be followed in regards to operation. The engine crankcase must be filled with an oil recommended by the engine manufacturer.

The fuel should be regular grade automotive gasoline. When filling the tank, allow for fuel expansion. Never fill tank when engine is running.

The carburetor choke should be adjusted as required by temperature conditions.

When starting the generator, the operator should assume a stable stance to prevent injury in the event of engine kickback. Pull the start rope with a quick, smooth pull to crank the engine. Be sure to pull the rope completely through until it clears the starting pulley.. After the engine starts, return choke to its normal position. In cold temperatures it may be necessary to keep the choke in the choke position longer;

HIGH MOISTURE CONDITIONS

The use of electrical epuipnent

under

extremely wet conditions should be avoided.

L

Generator units must be operated

in a

well ventilated area to provide adequate cooling air for the engine

and

proper discharge of exhaust fumes.

STABILITY

Generator units should be placed on a solid level surface for proper engine operation. If there is any indication that the unit may shift during opera- tion,

the

use of tie darns is recaaanended.

EXTENSION CORDS

The proper selection of

an

extension cord is necessary for optimum tool opera- tion. Consult

the

following chart for proper wire size to carry the required load current. Voltage drops due to the extension cord should not exceed five volts.

VOLTAGE DROP @ MAXIMUM AMPS FOR

WIRE SIZE

-

W . AMPS 25

'

GIVEN W I R E LENGTHS

-

50

'

75 100'

INTRODUCTION

T h i s manual c o v e r s t h e s a f e t y , o p e r a t i n g and m a i n t e n a n c e i n s t r u c t i o n s f o r t h e

WINPOWER l i n e o f a i r - c o o l e d g e n e r a t o r sets. I n c l u d e d a s a p a r t o f t h e package is a p a r t s l i s t a n d w i r i n g d i a g r a m c o v e r i n g t h e p a r t i c u l a r model you have pur- c h a s e d . The e n g i n e m a n u f a c t u r e r ' s manual i s a l s o f u r n i s h e d w i t h t h e s e t and g i v e s t h e n e c e s s a r y o p e r a t i n g a n d m a i n t e n a n c e i n f o r m a t i o n f o r t h e e n g i n e .

GENERAL

The e n g i n e g e n e r a t o r s e t s c o v e r e d by t h i s manual a r e o f t h e s i n g l e b e a r i n g t y p e . The r o t a t i n g member o f t h e g e n e r a t o r is mounted o n a t a p e r e d e x t e n s i o n o f t h e e n g i n e c r a n k s h a f t .

A l l sets h a v e been t h o r o u g h l y t e s t e d a t t h e f a c t o r y . The normal c a r b u r e t o r and e n g i n e s p e e d , a d j u s t m e n t s have been made.

The s e t s h o u l d be c a r e f u l l y i n s p e c t e d on d e l i v e r y f o r e v i d e n c e o f p o s s i b l e s h i p p i n g damage. I f damage h a s o c c u r r e d , a n o t a t i o n s h o u l d be made on t h e f r e i g h t b i l l and you s h o u l d f i l e a c l a i m , i f n e c e s s a r y . I f t h e damage a p p e a r s t o b e o f a major n a t u r e , t h e s e t s h o u l d n o t be o p e r a t e d u n t i l t h e f a u l t h a s been c o r r e c t e d .

The model number and t h e s e r i a l number o f t h e s e t must be g i v e n when c o n t a c t i n g t h e d e a l e r or t h e f a c t o r y .

ELECTRICAL DESCRIPTION

The g e n e r a t o r s used i n t h e WINPOWER l i n e o f a i r - c o o l e d e n g i n e g e n e r a t o r are r e v o l v i n g a r m a t u r e t y p e . sets

The s t a t i c , or e l e c t r o n i c e x c i t a t i o n s y s t e m , u s e s r e c t i f i e r s t o change p a r t o f t h e o u t p u t o f t h e AC g e n e r a t o r t o DC f o r e x c i t a t i o n o f t h e f i e l d . On most models u s i n g s t a t i c e x c i t a t i o n , t h i s s y s t e m i s e x t e n d e d s t i l l f u r t h e r by u s i n g c u r r e n t f e e d b a c k t h r o u g h r e c t i f i e r s i n o r d e r t o o b t a i n i n c r e a s i n g f i e l d s t r e n g t h w i t h l o a d i n c r e a s e t o g i v e b e t t e r v o l t a g e r e g u l a t i o n .

-

TESTING RECTIFIERS AND DIODES

DEFINITIONS

A d i o d e is a s i n g l e r e c t i f y i n g element r e p r e s e n t e d g r a p h i c a l l y a s shown below:

When a d i o d e is used a l o n e such a s i n h a l f wave r e c t i f i c a t i o n it c a n a l s o be c a l l e d a r e c t i f i e r . Two d i o d e s a r e used i n f u l l wave r e c t i f i c a t i o n a s shown:

Four d i o d e s a r e used i n a s i n g l e phase r e c t i f i e r b r i d g e a s shown:

TESTING

An ohmmeter is r e q u i r e d f o r t e s t i n g a d i o d e o r r e c t i f i e r assembly. I t is neces- s a r y t o remove t h e l e a d s g o i n g t o t h e r e c t i f i e r f o r t e s t i n g it. A s i n g l e d i a d e w i l l show a v e r y h i g h r e s i t a n c e i n one d i r e c t i o n and low r e s i s t a n c e i n t h e o t h e r d i r e c t i o n ,

Low Reading Very High Reading

A s h o r t e d d i o d e w i l l have a low r e a d i n g i n both d i r e c t i o n s . An open d i o d e w i l l have a h i g h r e a d i n g i n both d i r e c t i o n s . Each d i o d e i n a n assembly can be t e s t e d as shown below:

A C A C

+=

Low Reading

T h i s r e a d i n g h a s te be r e p e a t e d o n e v e r y diode.

Very High ~ e a d i n g

MAINTENANCE

ENGINE

R e f e r t o e n g i n e manual.

GENERATOR

Check b r u s h l e n g t h s a f t e r 500 h o u r s o f r u n n i n g a n d e v e r y 100 h o u r s t h e r e a f t e r .

I f b r u s h l e n g t h i s l e s s t h a n 1/2", t h e b r u s h s h o u l d b e r e p l a c e d w i t h a new o n e .

SANDING BRUSHES

I t is i m p o r t a n t t h a t t h e b r u s h e s make good c o n t a c t w i t h t h e collector r i n g s . When i n s t a l l i n g a new s e t o f b r u s h e s , t h e y s h o u l d b e s a n d e d i n by u s i n g 00 s a n d p a p e r .

G r i t s i d e o f s a n d p a p e r

'collector r i n g

The s a n d p a p e r s h o u l d b e p u l l e d i n t h e d i r e c t i o n o f r o t a t i o n . When p u l l e d i n t h e o p p o s i t e d i r e c t i o n t o s t a r t a new s t r o k e , t h e b r u s h s h o u l d b e r a i s e d .

C o n t i n u e t h e s a n d i n g u n t i l t h e b r u s h e s a r e f u l l y s e a t e d . D o n o t u s e emery c l o t h .

The collector r i n g s s h o u l d b e c l e a n e d i f d i r t y .

D i r t a n d t h e m o i s t u r e it w i l l h o l d a r e d e t r i m e n t a l t o g e n e r a t o r s . I f d u s t a n d d i r t a c c u m u l a t e , t h e g e n e r a t o r s h o u l d b e c l e a n e d p e r i o d i c a l l y .

THE FOLLOWING SERVICE PROCEDURES SHOULD BE PERFORMED BY AUTORIZED WINPOWER.

SERVICE CENTERS OR OTHER QUALIFIED PERSONNEL.

TESTING FOR OPEN CIRCUITS

TESTING

The most l i k e l y p l a c e f o r a n o p e n c i r c u i t t o o c c u r is t h e s h u n t f i e l d c i r c u i t .

The s h u n t f i e l d is c o n n e c t e d t o t h e r e c t i f i e r o u t p u t . One end o f t h e s h u n t f i e l d s h o u l d b e d i s c o n n e c t e d . An ohmmeter r e a d i n g s h o u l d be t a k e n between t h e d i s c o n n e c t e d e n d t h e o t h e r e n d o b t a i n e d t h e r e t o d e t e r m i n e c o n t i n u i t y . I f n o r e a d i n g i s is a n o p e n c i r c u i t . Its e x a c t l o c a t i o n s h o u l d t h e n b e d e t e r m i n e d a n d t h e o p e n c i r c u i t s h o u l d b e r e p a i r e d . The o u t p u t l e a d s s h o u l d be c h e c k e d f o r c o n t i n u i t y .

RESTORING RESIDUAL MAGNETISM

I t c a n b e d o n e by a p p l y i n g DC v o l t a g e (6-24 v o l t s ) a c r o s s t h e t e r m i n a l s o f t h e s h u n t f i e l d . C a r e must b e t a k e n t h a t t h e p o l a r i t y is c o r r e c t . I n c o r r e c t p o l a r i t y w i l l d e s t r o y t h e d i o d e s i n t h e r e c t i f i e r b r i d g e i f a l i m i t i n g r e s i s t o r is n o t used.

I f the r e c t i f i e r assembly is a molded assembly, t e s t as follows:

Using a volt-amp-ohm meter i n the following sequence:

( m u l t i meter), check the r e c t i f i e r assembly

For purposes of order i n checking, consider one AC terminal as #1, the other as # 2 .

Check Between

+

Meter lead on + terminal

- meter lead on AC #1

+

Meter lead on

+ terminal

- meter lead on AC # 2

+

Meter lead on

- terminal

- meter lead on AC #1

+

Meter lead on

- terminal

- meter lead on AC # 2

+

Meter lead on AC #1

+

Meter lead on AC #1

+

Meter lead on AC # 2

+

Meter lead on AC # 2

- meter lead on

+ terminal

- meter lead on

- terminal

- meter lead on + terminal

- meter lead on

- terminal

I f any readings do not comply w i t h the above chart, the r e c t i f i e r assembly is defective and should be replaced.

Expected

Resistance

Reading

H i g h

High

Low

L o w

Low

High

Low

High

TROUBLE SHOOTING CHART structions f o r t e s t i n g r e c t i f i e r bridges).

Poor brush contact Free brush i f stuck. Re-

(brush can be stuck in hol der place with new brush i f

, worn or spring

worn.

Replace brush spring

Complete c i r c u i t i f in external wiring

.

Low output voltage a t no Low engine speed.

1 oad.

--.

Shorted diode (see instructions f o r t e s t - ing r e c t i f i e r bridge).

-

Voltage O.K. a t no load Shorted diode in s e r i e s b u t drops off rapidly f i e l d bridge (see in- on 1 oad appl ication. structions f o r testing r e c t i f i e r bridge).

High output voltage

Engine speed drops off rapidly.

Excessive engine speed

Adjust engine speed t o correct val ue.

Adjust engine speed t o correct val ue.

Rep1 ace diode or r e c t i f i e r assembly.

Replace diode or r e c t i f i e r assembly.

See engine manual.

Excessive generator heating.

Arcing a t brushes

Open c i r c u i t (see in- structions f o r t e s t i n g of open c i r c u i t s ) .

Shorted armature coi 1 s in revolving armature unit.

Engine speed too low.

Over1 oad on generator.

Clogged ventilating i n l e t s and/or outlets.

Brushes not seated properly.

Rep1 ace armature

Adjust engine speed t o correct val ue.

Reduce load.

Clean i n l e t s and outlets.

See instructions f o r sanding brushes.

ECON-0-MIZER MAGNET ADJUSTMENT INSTRUCTIONS

1. P l a c e E c o n o m i z e r s w i t c h i n o f f p o s i t i o n , s t a r t e n g i n e .

2. M a n u a l l y p u s h E c o n o m i z e r a r m on c a r b u r e t o r up o r down t o r e a c h a n i d l e speed, a d j u s t e n g i n e i d l e s e t s c r e w cw t o r e a c h 5 0 - 6 0 v o l t s AC a t 1 2 0 v o l t r e c e p t i c a l .

3. S t o p e n g i n e ; a d j u s t m a g n e t up o r down s o t h a t i t j u s t t o u c h e s t h e E c o n o m i z e r arm. W h i l e h o l d i n g t h e arm i n i d l e p o s i t i o n , t i g h t e n magnet i n t o t h i s p o s i t i o n .

4. T u r n i d l e s e t s c r e w o n e - h a l f t u r n ccw s o t h a t s c r e w d o e s n o t t o u c h s t o p on c a r b u r e t o r when arm i s a g a i n s t magnet. A d j u s t m e n t i s c o m p l e t e .

5. I f E c o n o m i z e r w i l l n o t h o l d a t i d l e , o f f l o a d and s w i t c h t u r n e d on, a d j u s t t h e m a g n e t f a r t h e r f r o m t h e c a r b u r e t o r arm.

O W N E R ' S S E R V I C E R E C O R D

CONSULT E N G I N E MANUAL FOR SUGGESTED

MAINTENANCE AND S E R V I C E I N T E R V A L S

CONSULT GENERATOR SET OWNER'S MANUAL

FOR GENERATOR S E R V I C E AND MAINTENANCE

DATE

GENERATOR SET:

M o d e l No.

S e r i a l No.

P u r c h a s e d From

P l a c e d i n S e r v i c e

T y p e

ENGINE:

M o d e l

S e r i a l No.