FM3V2-DS Operators Manual, Parts List & Wiring Diagram

FM3V2-DS Operators Manual, Parts List & Wiring Diagram
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INTROCUCTION
f ! information
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in t h i s manual covers revolvina f i e l d type a1 ternators using
- t a t i c excitation. This type of e x c i t a t k n wd-:l be discussed in detail in
Il a t e r paragraphs of t h i s manual . The i nformati on contained shoul d be studied
carefully and the instruction book kept a t hand f o r ready reference. Read
very carefully the paragraphs on proper use and maintenance.
The equipment described i s the result of careful :ncjii,ct:ing design and manufacturing techniques. I t has been thoroughly -inspected and tested before
shipment. Carefully inspect on del ittery f o r evicknce of shipping damage. If
damage has occurred i t should be noted on the freight b i l l in order t h a t a
claim can be f i l e d t o recover the cgst of the damage. If the damage appears
t o be of a major nature, the f a u l t should be corrected before using.
If you wish t o contact your dealer or the factory, make sure you mention the
model and s e r i a l number as l i s t e d on the nameplate on the side of the alternator.
Winpower a1 ternators are designed t o del iver voltage and current identical to
t h a t of a normal power l i n e . Equipment that can be operated on normal power
can also be operated by the a l t e r n a t o r , provided the capacity of the alternator
i s not exceeded. I t should be remembered t h a t the power l i n e , f o r a l l practical purposes, i s backed by an unlimited generator.
Promptly f i l l in and return the guarantee card enclosed in the front of the
manual.
ALTERNATOR
The a1 ternator i s a revolving f i e l d type, using a s t a t i c system f o r excitation
and control of the voltage regulation. The section below describes the s t a t i c
excitation. The rotor in a two pole machine must revolve a t 3600 RPM f o r 60
cycle current and a t 3000 RPM f o r 50 cycle. Frequency varies in direct relation t o the speed of rotation. The governor of the driving engine or t r a c t o r
will therefore determine the variation in frequency. An unstable governor or
one t h a t droops in speed excessively under load wi 11 r e s u l t in excessive frequency variation. A droop a t 5% in speed will r e s u l t in a frequency variation
of 3 cycles. This variation i s of l i t t l e consequence f o r most equipment to be
powered. The driving engine should have s u f f i c i e n t power t o maintain speed
under load. The best of governors cannot control an overloaded engine.
WHAT IS STATIC EXCITATION?
The word " s t a t i c " means without motion; thus, the term " s t a t i c excited" means
t h a t the control system which provides the current f o r the electro-magnetic
f i e l d i s provided without thc use of an o~t-moded revolving DC armature.
Commutators and commutator brushes with the inherent problem of sparking and
maintenance are eliminated. The use of a mechanical voltage regulator with
vibrating or multiple moving contacts i s also eliminated.
D i r e c t current i s required f o r the electro-magnetic f i e l d . A s i n g l e c o i l i s
wound i n t h e a l t e r n a t o r s t a t o r ( t h e s t a t i o n a r y w i n d i n g ) t o p r o v i d e t h e c u r r e n t
f o r t h e base f i e l d . T h i s c o i l i s e n t i r e l y separate f r o m t h e main winding and
i s a t r i g h t angles i n mechanical p o s i t i o n . The AC v o l t a g e generated i n t h i s
c o i l i s f e d t o a f u l l wave s i l i c o n diode b r i d g e t o p r o v i d e r e c t i f i e d d i r e c t
c u r r e n t f o r t h e base f i e l d . As t h e f i e l d i s t h e r o t a t i n g component, t h e c u r r e n t
connection i s accomplished by t h e use of s l i p r i n g s and brushes. The base f i e l d
i s connected t o r i n g #1 ( n e a r e s t t o t h e b e a r i n g ) and r i n g #3. The base f i e l d
i s designed t o p r o v i d e magnetic 1 i n e s o f f o r c e r e q u i r e d t o generate r a t e d v o l t age w i t h no l o a d on t h e a1 t e r n a t o r .
I n o r d e r t o m a i n t a i n c l o s e v o l t a g e r e g u l a t i o n as t h e l o a d i s v a r i e d , a c o n t r o l
f i e l d i s used. The c o n t r o l c i r c u i t c o n s i s t s o f an a d d i t i o n a l f u l l wave b r i d g e ,
i n s e r i e s w i t h . one l o a d 1 i n e , and a c o n t r o l w i n d i n g on t h e f i e 1 d p o l e s . The
c o n t r o l . f i e l d i s ,connected t o I-ing #1 and r i n g #2. When a l o a d i s connected t o
t h e a l t e r n a t o r , t h i s c u r r e n t i s r e c t i f i e d and f e d through t h e c o n t r o l f i e l d
winding. By t h i s means, t h e t o t a l s t r e n g t h o f t h e f i e l d i s v a r i e d i n r e l a t i o n
t o t h e load.
The d e s c r i p t i o n o f s t a t i c e x c i t a t i o n opened w i t h t h e statement t h a t " s t a t i c " i s
d e f i n e d as w i t h o u t motion. I n l a t e r paragraphs t h e r e v o l v i n g f i e l d has been
discussed. To a v o i d confusion, a word of e x p l a n a t i o n i s i n o r d e r . There must
be some r e l a t i v e motion between t h e c o i 1s which generate v o l t a g e and t h e magnetic
f i e l d which causes t h e v o l t a g e t o be produced. I n a r e v o l v i n g f i e l d generator,
t h e w i n d i n g t h a t produces t h e v o l t a g e i s s t a t i o n a r y and t h e f i e l d p o l e s r e v o l v e .
The r e v e r s e i s t r u e i n t h e case o f a r e v o l v i n g armature generator; t h e f i e l d i s
s t a t i o n a r y and t h e v o l t a g e p r o d u c i n g w i n d i n g r o t a t e s .
-
Standard connection f o r 2000 w a t t , s i n g l e v o l t a g e a1 t e r n a t o r s use duplex groundi n g t y p e r e c e p t a c l e s . S p e c i a l a p p l i c a t i o n s , t o be used as p a r t o f o t h e r equipment, may p r o v i d e a p l a t e t o accept c o n d u i t f i t t i n g s . S h o r t leads a r e brought
o u t f o r connection.
L a r g e r c a p a c i t y machines are p r o v i d e d w i t h an o u t l e t box e n c l o s i n g a t e r m i n a l
s t r i p f o r connection. O p t i o n a l panels are a v a i l a b l e f o r c a p a c i t i e s above 2000
w a t t s . These a r e designed t o be i n s t a l l e d i n t h e f i e l d . A v o l t a g e i n d i c a t o r ,
a c i r c u i t breaker, 15 ampere duplex r e c e p t a c l e and a 50 ampere r e c e p t a c l e a r e
incl'uded i n t h e s p e c i a l panels. The v o l t a g e i n d i c a t o r uses a c o l o r band o f r e d
and green i n p l a c e o f a numbered scale. Voltage and frequency are c o r r e c t i n
t h e green p o r t i o n o f t h e c o l o r band.
MA1NTENANCE
L i t t l e maintenance i s r e q u i r e d o t h e r t h a n r o u t i n e i n s p e c t i o n and cleaning. The
bearings a r e p r e - l u b r i c a t e d and w i l l be a l o n g l i f e i t e m unless damaged by a c c i dent o r excessive d r i v i n g b e l t t e n s i o n .
The i n t e r i o r o f t h e a l t e r n a t o r should be c l e a n and unobstructed. S l i p r i n g s and
brushholders be k e p t f r e e from d i r t , o i l , and m o i s t u r e . I f compressed a i r i s
a v a i l a b l e i t can be used e f f e c t i v e l y f o r c l e a n i n g .
-
S E R V I C E DAAGNOS13
LOW OUTPUl VOLl A G t
0
1.
2.
Low Speed
Check f o r o v e r l o a d on t h e engine.
' D e f e c t i v e governor. Check governor s p r i n g
tension, t i g h t o r defective t h r o t t l e levers
and j o i n t s .
3. D e f e c t i v e engine.
Increase s i z e o f l i n e w i r i n a . M i a h t a l s- o- bet h e r e s u l t o f loose connections w6ich w i l l be
i n d i c a t e d by excessive h e a t i n g a t t h e loose
connections.
See i n f o r m a t i o n f o r t e s t i n g f i e l d c i r c u i t s .
High l i n e l o s s . I n d i c a t e d by l o w e r v o l t a g e a t
l o a d than a t generator t e r m i n a l s
Shorted o r grounded f i e l d c o i l . I n some cases
one c o i 1 o n l y , t h a t i s s h o r t e d o r grounded,
w i l l reduce v o l t a g e t o approximately one h a l f
s f rating.
I
I See i n f o r m a t i o n f o r t e s t i n q- f i e l d c i r c u i t s .
D e f e c t i v e compound f i e i d c i r c u i t . F i e l d
connected t o Rings #1 and #2
Defective c o n t r o l f i e l d brjdge.
.See i n f o r m a..t.i.o n on t e s.t i n g b r i d g e assemblies.
H I G H OUTPUT VOLTAGE
'Check governor l i n k a g e , s p r i n g tension, e t c .
Excessive speed
Governor l i n k a g e must b e . f r e e from d i r t & gum.
EXCESSIVE HEATING
-
Clogged v e n t i l a t i n g i n l e t and/or outlet..
Excessive h e a t f r o m o t h e r equipment
Over1oad
-
- --
- -- -
I
Clean,maKe
I
Construct b a f f l e o r some means t o d i r e c t h e a t
i n another d i r e c t i o n .
-
I
s u r e i n t e r i o r i s unobstructed.
Reduce Load
NO OUTPUT VOLTAGE
-Clean Brush Holder. Brush should move f r e e l y
p o o r Brush Contact: Brushes t i g h t i n h o l d e r
i n holder.
Brush s p r i n g t e n s i o n should snap brush i n t o
Weak Brush S p r i n g Tension
c o n t a c t w i t h r i n g when l i f t e d and released. .. .
Clean r i n g s w i t h f i n e sandpaper
during rotaFilm on C o l l e c t o r Rings caused by c o r r o s i v e
. .
o r d i rt.y
I tion.Caution : Tape sandpaper
- atmosphere.
. .
I t o s t i f f cardboard f o r s a f e t y .
.- - ---.
f i e f e c t i v e R e c t i f i e r B r i d a"e (See
i1l u s t r a t i o n
I R e ~ace
l d e f e c t i v e b r i d a e assemblv. F i n d
assembly number under ~ I O D E A S S E ~ B L Y i n p a r k
f o r method o f checking b r i d g e )
list.
.,...,
Replace Rotor Assembly.
Open f i e l d c i r c u i t (see i l l u s t r a t i o n f o r
method f o r checking)
-Replace Rotor Assembly.
Grounded o r s h o r t e d f i e l d c o i l ( s ) (See i l l u s , t r a t i on f o r method)
See n o t e under f i e l d assembly f o r procedure
Loss o f r e s i d u a l maqnetism. T h i s i s a condit o r e s t o r e magnetism.
t i o n brought about gy some unusual c o n d i t i o n .
I t w i l l always occur a f t e r disassembly.
.
A
-L.
--
defective Stator:
$"hcrrea FiiidTn<. - TFi F F a i i Fe-i i r e i i t T fT e a 6yYtiiee
use o f a " g r o w l e r " a t a competent r e - w i n d i n g
shop.
......................
Srounded winding. Check by t e s t lamp f r o m
s t a t o r w i n d i n g t o frcmg. - - - - - - - - - fipfihaiycircuit.
Check a l l c i r c u i t s f o r
c o n t i n u i t y . I E : S2 t o S1, S4 t o L
1
See i l l u s t r a t i o n f c
Replace t h e S t a t o r .
t e s t i n g method. ( I n c l u d e generator model
and s e r i a l number on t h e o r d e r . )
-
BRUSH HOLDER ASSEMBLY
Models r a t e d a t 2000 watts and under use one bracket assembly@as shown
i n s o l i d l i n e s . Models above t h a t r a t i n g have two brushes n r i n g s #I
and #2 (numbering from end o f s h a f t ) and use added b r a c k e t b a s shown i n
dotted lines.
Note:
2.
3.
fie
5.
A-745
A-746
8-701
B-791-A
0-701 -B
When r e p l a c i n g brushes, t h e most simple method i s t o
disconnect t h e e n t i r e bracket assembly by removing
t h e screw a t each end. The bracket can then be t i l t e d
forward f o r easy access t o t h e brush h o l d e r caps.
Brush h o l d e r b r a c k e t ( r i g h t )
Brush h o l d e r bracket ( l e f t )
Brush h o l d e r
Cap
Cli p
6.
7.
8.
9.
10.
Y-114
S-6096
if2005
#1110
Brush
Clamp
Screws
Lock Washer
#2652 Screw - S e l f tapping
B R I DGE ASSEMBLIES
1.
2.
3.
Base F i e l d R e c t i f i e r Bridge Assembly
Negative C o n t r o l F i e l d R e c t i f i e r B r i d g e Assembly
P o s i t i v e C o n t r o l F i e l d R e c t i f i e r B r i d g e Assembly
Note: Both diodes i n each h a l f o f t h e c o n t r o l f i e l d b r i d g e a r e pressed i n t o t h e aluminum
h e a t s i n k on Models BR2036B and BR4036B5. Models BR4036B, BR4036C and BR6036C have one
diode i n each h a l f t h a t i s s t u d mounted. Pressed i n diodes r e q u i r e s p e c i a l t o o l i n g f o r
replacement and cannot be changed i n t h e f i e l d . Repair i s made by replacement o f assemblies.
Check f o r D e f e c t i v e Diode
1.
2.
3.
Disconnect a1 1 e x t e r n a l w i r i n g from both AC and DC c i r c u i t s . ( C a r e f u l l y mark t h e
p o i n t o f connection o f each w i r e t o assure p r o p e r re-connection).
A diode t h a t i s i n good o r d e r w i l l conduct c u r r e n t i n one d i r e c t i o n and b l o c k i n
t h e o p p o s i t e . The conducting d i r e c t i o n i s marked on t h e case by an arrow(-*)on
t h e l a r g e r and by a c o l o r band on t h e smaller(&).
Use an ohmmeter ( o r a 1.5 v o l t f l a s h l i g h t b a t t e r y and b u l b as i l l u s t r a t e d ) t o
check t h e c u r r e n t d i r e c t i o n . Connect p o s i t i v e a t t h e base o f t h e arrow and negat i v e a t t h e end t o which t h e arrow p o i n t s . (See i l l u s t r a t i o n ) A diode t h a t conducts i n both d i r e c t i o n s o r n e i t h e r d i r e c t i o n i s d e f e c t i v e .
A l t e r n a t e means f o r t e s t i n g a diode i f an ohmmeter i s n o t a v a i l a b l e .
F I E L D ASSEMBLY
Resistance o f F i e l d C i r c u i t s a t 25OC (77OF)
Model
BR4036B5
BR2036B
BR4036B
BR4036C
BR6036C
Base F i e l d (Ring #I t o 3)
43 t o 53 ohms
32 t o 42 ohms
43 t o 53 ohms
43 t o 53 ohms
47 t o 57 ohms
Control F i e l d (Ring #1 t o 2)
Less than 1 ohm
Less than 1 ohm
Less than 1 ohm
Less than 1 ohm
Less than 1 ohm
Note : When o r d e r i n g rep1acement f i e l d assemblies, be
sure t o i n c l u d e model and s e r i a l number from
nameplate on a1 t e r n a t o r frame.
TESTING A FIELD CIRCUIT
Ilake sure t h a t a l l brushes are n o t i n contact w i t h -the s l i p r i n g s . I f t h e
a l t e r n a t o r has n o t been disassembled, paper i n s e r t e d between t h e brush and
s l i p r i n g w i l l serve as i n s u l a t i o n . The complete brushholder bracket can be
~cmovedi f t h i s procedure i s p r e f e r r e d , by removing the screws and nuts a t
each end o f the bracket. The brush gear may use one b r a c k e t o r two brackets,
depending on t h e capacity o f t h e a l t e r n a t o r . When two are used, both must be
i n q u l ated o r disconnected.
o fi70esure the r e s i s t a n c e o f the base f i e l d , touch t h e ahmmeter leads t o r i n g
' 1 n ~ X3
d as shown i n t h e i l l u s t r a t i o n .
Measure f w m r i n g s #1 and #2 f o r t h e
; o ~ t r a l f i e l d.
.. r e s i s t a n c e appreciably lower than shown on the t a b l e i n d i c a t e s shorted t u r n s
in one o r both f i e l d c o i l s . The r e s i s t a n c e o f l e s s than one ohm on the c o n t r o l
7 e l d i s too low t o measure a c c u r a t e l y w i t h the average ohmmeter. A complete
- : i r c u i t between r i n g s should be i n d i c a t e d . A h i g h r e s i s t a n c e would i n d i c a t e a
5 ~ 9 4 e nconnection.
F. grounded f i e l d c i r c u i t can be i d e n t i f i e d by connecting the meter from t h e
s l i p r i n g s t o the r o t o r s h a f t .
WTE: Occasionally an a l t e r n a t o r w i 11 l o s e r e s i d u a l magnetism. I t i s v e r y
?qnusaral unless the a l t e r n a t o r has been dis-assembled, i n which case i t w i l l be
qecessary t o " f l a s h the f i e l d " on t h e f i r s t s t a r t .
( c o n t inued)
FIELD ASSEMBLY (Continued)
A step down transformer with a nominal 125 volt primary winding and from 15 t o
30 volt secondary can be used f o r this purpose. The primary should have a cord
w i t h a plug f o r a wall receptacle. The secondary should have extension leads
with insulated probes. With the alternator operating, plug into the wall outl e t and i n s e r t the probes momentarily into the 125 volt convenience outlet.
For equipment not furnished with the o u t l e t , touch the probes t o the connection
of L1 and L2. A momentary contact i s a l l that i s required. The transformer
assembly can be purchased from the factory a t a nominal cost i f not available
locally.
STATOR P,SSEMBLY
Note: When o r d e r i n g replacement s t a t o r assemblies be sure t o
i n c l u d e the model and s e r i a l number from t h e nameplate on the
s i d e o f the generator.
The s t a t o r assembly has a winding t o develop v o l t a g e f o r the base f i e l d .
The l e a d extensions from t h i s winding are colored brown. Connection from
t h i s winding i s t o the base bridge.
A s i n g l e , two p o l e winding i s used f o r two w i r e , s i n g l e voltage models.
This winding connects t o the c o n t r o l (Series) f i e l d bridge. The c o n t r o l
b r i d g e i s d i v i d e d i n t o a p o s i t i v e and a negative s i d e and i s i n s e r i e s
w i t h the 1oad. (See b r i d g e assembly i1l u s t r a t i on)
Three w i r e , dual voltage models use two i d e n t i c a l , two pole windings. Each
winding generates 125 v o l t s . The voltage from e i t h e r l i n e t o n e u t r a l is.,
therefore, 125. From L1 t o L2 t h e winding i s i n s e r i e s f o r 250 v o l t output.
When a f a u l t i n t h e s t a t o r i s suspected each i n d i v i d u a l winding should be
checked. The r e s i s t a n c e o f the separate windings w i l l be low, l e s s than
one ohm, b u t a complete c i r c u i t should be i n d i c a t e d . I E : #S1 t o #S2, #Sq
t o #L1.
The various windings should a l s o be checked f o r ground. For t h i s purpose
connect an ohmmeter from a bare spot on the frame t o one l e a d o f each c o i l .
A meter d e f l e c t i o n i n d i c a t e s a grounded winding.
When a l l s t a t o r leads are disconnected, t h e r e should be no c i r c u i t from one
winding t o any other. I f a c i r c u i t i s i n d i c a t e d the winding i s shorted.
I f any o f t h e above c o n d i t i o n s a r e i n d i c a t e d , the s t a t o r assembly must be
rep1aced.
--RYU
EXC 1T E y
STAm q
Rlu%
n
w\R\M4 DIAGRAM
A
CHANGE
CqEU 4EV15\0L.14- - I -70
r--,G&c;
WAS ORIGINALLY
TOLERANCE ON
DIMENSIONS N O T
OTHERWISE SPECIFIED
DATE
) DECIMAL
,
T-C.6.
*
-
I
-
2-2- 7 0
NO.
REMOVE ALL BURRS, REO'D.
BREAK ALL SHARP
MACHINED EDGES
FRACTIONAL k
SCALE
CHG. REQUEST
CHK'D
( MATERIAL
M I C R O F I L M DATA
' DWM
I
TC*'
I
/
YODEL NO.
No.
- 2 177
CHK'D
WINPOWER MFG. CO.
NEWTON. IOWA
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