Page 1 Magna One Generator Installation, Operation and

Page 1 Magna One Generator Installation, Operation and
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Generator
Installation,
peration and
Maintenance
Manual
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GENERAL INFORMATION
GENERAL
A generator is a device which transforms mechani-
cal energy into electrical energy. Magna One
Generators are brushless, 4-pole machines pro-
ducing 60 Hz power at 1800 rpm, or 50 Hz power at
1500 rpm (Hz = Hertz = cycles per second). All
standard units are rated at 0.8 power factor.
Single bearing generators are supplied with an SAE
adaptor and flexible drive discs on the drive end as
standard. Alignment of the generator and engine is
assured by the concentricity of the flywheel housing
and the generator adaptor. Flexible drive discs are
piloted in a rabbet in the flywheel itself, again
assuring alignment. It may be necessary toshimthe
generator feet on the base for solid support. Two
bearing units come standard with two brackets and
a shaft extension for a drive coupling.
Ac generators require direct current flowing
through the rotor winding to set up the magnetic
flux which allows the unit to generate. A small ac ex-
citer, which actually is a miniature replica of the
' main generator, provides this direct current. The
exciter is mounted on the same shaft as the genera-
tor rotor. While the main generator field rotates and
the armature is stationary, the exciter field is sta-
tionary and the armature rotates. The output from
this exciter is fed into the rectifying elements
mounted on a heat sink. This rectifier assembly is
located on the end of the main shaft, opposite the
drive end (see figure below).
The ac exciter itself requires direct current for its
excitation. This excitation is supplied by rectifying a
portion of the output of the main generator by
means of a static voltage regulator. The amount of
GENERAL
MECHANICAL CONSTRUCTION
current going into the field of the exciter will deter-
mine the output voltage of the exciter, and this in
turn will control the output voltage of the main
generator. Meters, controls, or other features
needed to satisfy installation requirements are
available as optional extras.
MECHANICAL CONSTRUCTION
Magna One brushless generators are designed and
manufactured with the same engineering precision
and craftsmanship that has, for years, gained
Marathon Electric an outstanding reputation in this
field. Precision machine parts, together with careful
hand assembly, give the Magna One durability and
reliability.
A solid, rolled steel frame, results in rigid support for
the stator core and end brackets. The stator core is
firmly anchored to the frame by the welding of bar
steel core supports to the core and frame.
The end brackets and adaptors are made of cast
iron for the ultimate rigidity required to support the
heavy duty shielded bearings. A front bracket sup-
ports the stationary exciter field structure. For single
bearing units, the frame is fitted with a rugged cast
iron SAE adaptor, precision rabbeted to insure align-
ment with the prime mover. A nodular iron hub is
keyed and heat shrunk to the shaft. This hub carries a
number of flexible steel drive discs which have holes
for fastening to the flywheel (for some adaptor-disc
combinations a spacer is used between the hub and
discs to maintain the proper distance between the
discs and SAE adaptor face). This affords flexibility,
in the axial direction, while in the radial direction it
acts as a rigid coupling providing a uniform air gap.
Dashed lines indicate rotating portico
re 1
TT
“|
Lo ROTATING
RECTIFIER
ASSEMBLY
|
|
EXCITER |
FIELD |
|
|
EXCITER
ARMATURE
L4
|
À Lo
AC
0 Г
FIELD |
| AC
GENERATOR
| STATOR
|
L3
VOLTAGE
REGULATOR
GENERAL INFORMATION
UNIROTOR™ CONSTRUCTION
STATOR
VENTILATION SYSTEM ; ,
ELECTRICAL CONNECTIONS —.-
For two bearing generators, a second bracket and
standard shaft extension is substituted for the
adaptor and flexible drive discs. The 360 and 440
Frames are available with long shaft extensions for
belt drive applications while all frame sizes are suit-
able for coupled drive. When selecting a belt driven
generator, refer to the chart on Page 6 for the drive
details under which these units wil! operate
successfully.
UNIROTOR™ CONSTRUCTION
A unique feature of the Magna One generator is that
the amortisseur winding and coil supports are die
cast as an integral part of the rotor. The 4 poles
which carry the field windings are one piece lami-
nations die cast with aluminum providing high me-
chanical integrity, and iow vibration at operating
speeds. This method has been time proven to be far
superior to separate pole pieces which must be
dovetailed to a spider or fastened by screws to the
shaft.
The rotor pole assembly is heat shrunk and keyed to
the shaft, forming a very rigid rotating element.
A thermo-setting bonding epoxy is applied between
layers of the field winding and is applied to the
finished rotor, The completed rotor is baked under a
controlled cycle to ensure a solid, mechanically
stable rotor. All rotors are dynamically balanced
and then tested at a speed of 125% of the operating
speed.
The ac exciter armature and the heat sink which car-
ries the diodes are mounted on an assembly which
is placed on the generator shaft outboard of the
front generator bearing.
STATOR
The stator laminations are composed of thin, low-
loss steel, notched on precision presses. The cores
are reinforced by rugged steel stack rings and sup-
porting bars which are welded around the core. Up
to 600 volts, random-wound coils are placed in siots
insulated with Class F materials. Once the properly
insulated coils have been inserted in the stator core,
the entire core is then given multiple dips and bakes
in a thermo-setting varnish by a special process
which ensures complete coverage. This premium
insulation system utilizes all synthetic and non-
hygroscopic materials making the standard
windings fungus resistant and suitable for operation
in high humidity and abrasive environments. Sub-
sequently, the wound cores placed into and welded
to the frame.
VENTILATION SYSTEM
Magna One generators employ an advanced fiow-
through ventilation system. The cast aluminum
alloy ventilating fan draws air through louvers in the
conduit box, over the main stator and exciter
windings and exhausts it through ventilation
screens in the adaptor. This exclusive design
provides efficient cooling as airis distributed evenly
throughout the generator, effectively reducing the
recirculation of hot air. Since there is only one air
intake, mounting of air filtration systems is easily
accomplished.
ELECTRICAL CONNECTIONS
The large front end mounted conduit box is
constructed of formed sheet steel with ample room
inside for the voltage regulator, most circuit
breakers and other options. A hole-saw or any
suitable tool can be used to provide a hole for the
conduit entrance. An approved connector must be
used in conjunction with the conduit. The regulator
can be moved from the left to the right side with rela-
tive ease if the entrance of the conduit is needed in
this location.
IMPORTANT: To minimize the transmission of
vibration, it is essential that flexible conduit be used
for all electrical connections to the generator. Refer
to the connection diagrams supplied with the
generator and install all intercomponent and
external wiring in accordance with the regulations
of the national and local regulatory bodies. Be sure
the generator frame is grounded to all the other
components of this system with the ground wire
complying with national and local codes. Terminal
lugs® are provided on all low voltage (below 600
volts) generators except 682 frames where buss
bars are used. Above 600 volts, terminal lugsPare
used exclusively. Clean all contaci surfaces to
assure good electrical bonding with the generator
lugs or buss bars. Use heavy duty terminal lugs or
good quality clamps for making all connections.
Tape ail connections in accordance with national
and local regulations.
D CSA certified terminal lugs are used.
INSTALLATION
RECEIVING YOUR MAGNA ONE GENERATOR
Upon receipt of the generator, it is recommended
_ that it be carefully examined to determine if any
shipping damage has occurred before accepting
the shipment from the transportation company.
UNPACKING AND HANDLING
Read all instruction cards carefully. When lifting,
attach an overhead crane to the lifting lugs on the
generator frame. Apply lifting forces in a vertical di-
rection, if possible.
WARNING
DO NOT LIFT COMPLETE GEN ERATOR SET
BY MEANS OF LIFTING LUGS ON GENERA-
TOR. PERSONAL INJURY OR EQUIPMENT
DAMAGE MAY RESULT.
WARNING
DO NOT APPLY ANY FORCE TO GENERA- |
TOR FAN FOR LIFTING OR ROTATING
GENERATOR ROTOR. DISREGARDING
THESE INSTRUCTIONS MAY CAUSE PER-
SONAL INJURY OR EQUIPMENT DAMAGE.
STORAGE
In the event that the generator is not to be installed
on the prime mover immediately, itisrecommended
that it be stored in aclean, dry area whichis not sub-
ject to rapid changes in temperature and humidity.
RECEIVING YOUR MAGNA ONE GENERATOR
INSPECTION
It is recommended that the insulation resistance of
the generator stator be checked with a megohm-
meter prior to initial operation. In order to do this, all
stator leads must be connected together and the
insulation resistance measured from the lead ter-
minals to the stator frame. Make certain the stator
leads are not touching the frame. A megohm
reading should be obtained that is equal to or
greater than the following formula:
Rated Voltage
Minimum Megohms = + 1
. 1000
An insulation resistance greater than the minimum
indicates the insulation is in good condition.
(NOTE: 1 megohm = 1,000,000 ohms.) A record
should be kept of the resistance readings for com-
parison with future data. A drop in resistance values
indicates wet, dirty or grounded insulation. In this
case, clean and dry the winding using one of the
listed methods on the following pages and check for
grounds following the instructions in the
“GENERATOR INSULATION TESTING” section.
CAUTION: READ THE “GENERATOR INSUL-
ATION TESTING” SECTION THOROUGHLY
BEFORE USING A MEGGER ON THE ROTOR OR
EXCITER FIELD. EXTENSIVE EQUIPMENT
DAMAGE CAN RESULT FROM IMPROPER
TESTING.
MARATHON
E= A. E= CO 6
®
INSTALLATION
MOISTURE REMOVAL
MOISTURE REMOVAL
Machines that have been idle for sometime in un-
heated and damp locations, may have “sweated” as
a result of sudden changes in temperature or may
have become wet by accident. These should be
dried out thoroughly before being put into service.
The following are recommended drying methods.
Oven
Place the machine in an oven and bake it at a
temperature not to exceed 90 degrees C or 194 de-
grees F. The voltage regulator and any electronic
component accessories must be removed from the
generator when using this method.
Space Healers
Enclose the generator with a covering and insert
heating units (space heaters, lamps or coils of steam
pipe) to raise the temperature. Leave a hole at the
top of the enclosure to permit the escape of
moisture.
Forced Air
A portable forced air heater can be used by directing
heat to the end of the generator opposite the
coupling and running the generator with no load
and without excitation (this can be accomplished by
removing the regulator fuses). Heat at point of entry
should not exceed 66 degrees C (150 degrees F) at
the bearing hub.
“Short Circuit” Method
The Generator can be dried out quickly:and thor-
oughly by using this method. NOTE: Be sure that all
of the following steps are performed and all pre-
cautions taken as personal injury or serious damage
to the generator could result.
1. Disconnect exciter leads F1 and F2 from the
terminal block.
2. Connect a dc battery or other dc power
source of approximately 20-35 volts (de-
pending on the kW of your unit) to the exciter
leads F1 and F2. An adjustable voltage source
is desirable, however a voltage adjust
rheostat (rated approximately 2 amps) in
series with the dc power source will ac-
complish the same result.
3. Short circuit the generator lead wires to each
other (L1 to L2 to L3}.
4. Start the generator and measure the current
through the leads with a clip-on ammeter.
5. Adjust the voltage source to produce
approximately 80% of the rated ac nameplate
current, but in no case exceed nameplate
amps. If an adjustable source is not available
and current is excessive, use a smail dec
source or a large resistor in series with the
source.
Running time will be determined by the
amount of moisture present in the machine.
Insulation resistance checks should be taken
every one to four hours until a fairly constant
value is obtained, equal to or greater than the
following formula:
Rated Voltage
Megohms = +1
1000
6. After machine has achieved a constant re-
sistance value, disconnect the dc power
source and reconnect F1 from the exciter to
F(+) on the terminal block, and F2 to F(-).
Make sure that all leads are reconnected
properly.
If it is necessary to dry out the generator, itis recom-
mended that the unit be thoroughly tested using the
“Generator Insulation Testing” procedures found
on the next page.
CYMARATHON-
EE CIA
INSTALLATION
GENERATOR INSULATION TESTING
The following tests can be used to check minimum
insulation resistance. Minimum insulation re-
sistance can be tested using a megohmmeter.
CAUTION: MEGOHMMETER MUST NEVER BE
APPLIED TO VOLTAGE REGULATOR ORDIODES
- EQUIPMENT DAMAGE WILL RESULT,
Minimum insulation Machine Voltage
resistance in megohms = + 1
1000
Example: 480 volt line to line generator:
Minimum
Insulation 480
Resistance = + 1 = 1.48 Megohms
1000
MAIN STATOR (ARMATURE)
1. All stator leads must be connected together.
Connect one megohmmeter lead to stator
leads and the other megohmmeter lead to the
generator frame. Make sure the other stator
leads are not touching the frame.
a. A reading lower than the calculated mini-
mum indicates an unacceptably low
generator insulation resistance.
Clean, dry and/or repair stator, replace if
necessary.
MAIN ROTOR (MAIN FIELD)
1. Disconnect the two generator main field
leads which come out through the end of the
rotor shaft. These wires connect to each of
the two diode heat sinks.
NOTE: Make sure neither of the two leads
touch any other part.
GENERATOR INSULATION TESTING
2. Apply one megohmmeter
generator field lead and the other megohm-
meter lead to the aluminum standoff casting
(behind insulation plate on exciter rotor).
a. A reading of less than the calculated mini-
mum indicates an unacceptably low main
field insulation resistance.
Clean, dry and/or repair generator rotor, re-
place if necessary.
EXCITER STATOR (FIELD)
1. Disconnect exciter field leads from F+ and F-
on terminal strip next to opening inside
regulator box.
NOTE: Location and markings on wires.
2. Connect one megohmmeter lead to exciter
field lead and the other to the exciter frame.
a. A reading lower than the calculated mini-
mum indicates an unacceptably low
exciter field insulation resistance.
Clean, dry and/or repair the exciter stator, re-
place if necessary.
EXCITER ROTOR (ARMATURE)
1. Remove diode leads from studs, being certain
to note the proper location for reconnection.
2. Apply one megohmmeter lead to one of the
exciter rotor leads and the other lead to the
aluminum standoff casting (behind insula-
tion plate on exciter rotor).
a. A reading of less than the calculated mini- _
mum indicates an unacceptably low ex-
citer rotor insulation resistance.
Ciean, dry and/or repair the exciter rotor, re-
place if necessary.
[О] МАНАТНОМ
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lead to one
o
INSTALLATION
PREPARATION FOR USE
GENERATOR MOUNTING
PREPARATION FOR USE
Although the generator is carefully inspected and
tested in operation before it leaves the factory, itis
recommended that the unit бе thoroughly in-
spected. The insulation on the wire should be in-
spected and all bolts should be checked for
tightness.
Remove all shipping tapes, bags, blocks and skids
which are used to prevent vibration and rotor move-
ment during shipment. Dry, low-pressure com-
pressed air of approximately 30 PSI (206 KPA) can
be used to blow out the interior of the generator. in
the case of two bearing machines, it is possible to
turn the rotor by hand to make sure that it rotates
smoothly without binding.
If the machine has been in storage for a year or
longer, it is recommended that it be lubricated
according to the tubrication instructions and chart
found in the “Lubrication” section of this manual.
GENERATOR MOUNTING
Single bearing generators are provided withan SAE
flywheel adaptor and flexible drive discs. Very close
tolerances are maintained in the manufacture of the
generator so that the alignment procedure is ex-
tremely simple. A coupling hub of nodular iron is
shrunk on the shaft and special steel drive discs are
bolted to the hub. Holes are provided in the
periphery of the coupling disc which correspond to
tapped holes in the flywheel. The outside diameter
of the discs fits in a rabbet in the flywheel so that
concentricity is assured in all cases.
CAUTION: GRADE 8 CAPSCREWS AND HEAVY
SERIES LOCKWASHERS OR GRADE 8 PLACE-
BOLTS AND HARDENED WASHERS ARE REC-
CMMENDED TO MOUNT THE DRIVE DISCS TO
THE FLYWHEEL.
The SAE adaptor and the flywheel housing are de-
sighed to match each other with no further align-
ment necessary. Shims may be necessary under the
feet of the generator to insure a solid mounting.
TWO BEARING GENERATOR MOUNTING
Two bearing generators are provided with a shaft
extension and keyway. For direct-coupled units, the
assembler furnishes a flexible coupling which is in-
stalled between the driver and the generator shaft.
[CJMARATHON:
IMPORTANT: Aligning the two machines as ac-
curately as possible will reduce vibration and insure
minimum coupling wear. It may be necessary to
shim the generator feet for proper support.
BELT DRIVE
360 and 440 frame, two bearing generators can be
belt driven. Please refer {0 Marathon Electric for
application assistance involving belt driven instalia-
tions. Sheave diameters should be chosen ac-
cording to the table below.
Magna One Sheave Application for
Two Bearing Units@
—
Min. Sheave | Min. Sheave
Dia. in Dia. in
Inches @ Inches @
10,000 Hr. | 20,000 Hr. Max.
B-10 Life® | B-10 Life® |Sheave
Width
Model 60 Hz 50 Hz! 60 Hz 50 Hz inches
360FDR8500 71 | 60 | 95 8.1 5.88
360FDR8504 79 6.7 [10.4 8.7 5.88
362FDR8508 8.7 7.7 1118 [103 5.68
362FDR8512 | 12.2 | 10.0 |16.8®| 13,7 | 5.88
440FDR8016 | 102 | 85 [13.79 113 8.50
440FDR8020 | 127 | 112 [1729 151 8.50
440FDR8024 | 144 | 124
1969@| 1699 8.50
MO Assumptions:
A. Belting factor is 1.3.
B. The drive and the driven sheaves are the
same diameter.
C. The sheave load is located at the center of
the shaft extension.
D. Based upon continuous kW ratings.
© These sheave diameters exceed the maximum
recommended belt speed of 6000 ft/min.
® B-10 Life means 90% of the bearings will last
this long or longer.
EEL ELT SET
mm
7
INSTALLATION
GENERATOR LEAD CONNECTIONS
The electrical connections in the conduit box
should be made in accordance with the appropriate
“connection diagram.” Use the diagram appropriate
for the number of leads and voltage range required.
The final voltage setting is established within the se-
lected range by an adjustment of the voltage
regulator.
12 LEAD HI WYE
ELECTRICAL CONNECTIONS
The use of flexible conduit is required to minimize
the effect of the engine vibrations.
CAUTION: SOME GENERATORS HAVE MULTIPLE,
IDENTICALLY MARKED, CABLES FOR EACH LEAD.
CONNECT ALL IDENTICALLY MARKED CABLES TO-
GETHER WHEN MAKING CONNECTION TO LOAD.
" - A
Ta
T7
L-L
T
7,2 SO
T Mi T
T6 г в Ц
AT hy,
T2
Twelve lead generators are dual voltage generators with six
coils which don't have the connection of the three inner coils.
There are 12 or 24 cables coming out of the generator.
VOLTAGE
CONNECT | Ly | Lo | Ly | NEUTRAL
L-L L-N
380 | 219
во | #16 | 240 T10 T11 T12
но | 440 | 254 Ta Ty
460 | 266 T4 | To | Ta | Tan Tua 7
480 277 1 2 3 10 11112
Ts T8
50 380 | 219
но | 400 | 231 Tg Tg
416 | 240
10 LEAD HI WYE
Ty La
А
Ta
17
L-L
To
T TR
Tg > T5
AT My |
L3 T2
Ten lead generators are dual voltage generators with six coils.
One end of the three inner coils is connected together. There are
10 or 20 cables coming out of the generator.
VOLTAGE
60
HZ
LL
L-N
CONNECT
L1
Lo | La
NEUTRAL
380
416
440
460
480
219
240
254
266
277
Ta Ту
Ts Tg
50
HZ
380
400
416
219
231
240
Ts Tg
To | Ta
To
RIMARATHON
©
INSTALLATION
ELECTRICAL CONNECTIONS
12 LEAD LOW WYE
Tg
L3
T3
L4
L-
T10 Ta
Ho T5
16| 7,4 T2
Twelve lead generators are dual voltage generators with six
coils which don’t have the connection of the three inner coils.
There are 12 or 24 cables coming out of the generator.
VOLTAGE
CONNECT | L4 | Lo | La | NEUTRAL
LL | LN
60 | 190 | 110 || Tho Tia T2
ну] 208 | 120 TA Te T
220 | 127 +56 T10 711 T2
230 | 133
240 | 139 п H | Ta | Ta
— T4 Ts T
50 | 190 | 110 T2 Tg 5
hz | 200 | 115
208 | 120 T3 T9
10 LEAD LOW WYE
Ten lead generators are dual voltage generators with six coils.
One end of the three inner coils is connected together. There are
10 or 20 cables coming out of the generator.
VOLTAGE
CONNECT | L4 | Lo | La | NEUTRAL
L-L | EN
L -
60 190 | 110 T4 T7
HZ 208 | 120
220 | 127 Т2 18 т
1 | To | T3 | Ta T5 16 TO
230 | 133 TT
240 | 139 39
50 190 | 110 Ta Ts Te To
17 | 200 | 115
208 | 120
12 LEAD HI DELTA
T42
Delta connection with 12 lead generators only.
VOLTAGE
CONNECT | Li Lo La
L-L L-N
Tg T4 60
T6 T7 Le HZ 240 120 Ta T7
277 139
T5 Tg T, To T3
50 200 100 Ts Ta
HZ 220 110
240 220 T1 H2
3 mn Тв | 75 Т2 | +2 T3 T41
—#—L-N
KMARATHON
®
еб
INSTALLATION
12 LEAD LOW DELTA
ELECTRICAL CONNECTIONS
Li,
Delta connection with 12 lead generators only.
VOLTAGE
CONNECT L4 La L3
L-L
60 То ТА Т
120 T4 17 16 H2
HZ 139
Ta Tg T4 H0 TH То T3
50 100
HZ 120 Ta Tg Ts T414
6 LEAD WYE
L1
T1 Six lead generators have 3 coil groups with 6 or 12 cables or
A bus bars coming out of the generator.
VOLTAGE
CONNECT | L4 | Lo | Lg | NEUTRAL
L-L L-N
190 | 110
203 | 120
L-L 60 | 220 | 127
HZ | 230 | 133
T TA 240 139
6 3300 | 1905 Т4 15 16 | 4 | T2 | T3 | Ta 1516
Ts 4160 | 2400 | -
190 | 110
T 50 200 | 115
3 Y HZ | 208 | 120
La To 3300 | 1905
— | - № — Lo
6 LEAD DELTA
L4
Te ATH À
Six lead generators have 3 coil groups with 6 or 12 cables coming
out of the generator.
VOLTAGE
CONNECT Li Lo La
E-L
и HT
60 116
HZ 2400
Ta T4 T4 T9 Ta
0 1905
HZ
T3 15
Ta Ta \
L3 T To, 42 ——
5 2
a L-L .
(IMARATHEN
®
10
INSTALLATION
ELECTRICAL CONNECTIONS
4 LEAD WYE
L1
| ;
T3
La To
EK—— —— L - —
N Lo
Four lead generators have 3 coll groups with one end of each
group connected together. There are 4, 8 or 16 cables or 4 bus
bars coming out of the generator.
VOLTAGE
Lq La La NEUTRAL
L-L L-N
380 219
416 240
60 440 254
HZ 460 266
480 | 277 T+ To | T3 To
600 | 346
380 | 219
50 400 231
HZ 416 240
480 277
3 LEAD DELTA
L4
\ |
L3 T3 N
| В
Three lead generators have 3 coil groups with one end of each
group connected into a Delta internally, There are 3, 6, or 12
cables or 3 bus bars coming out of the generator.
VOLTAGE
L L L
Li 1 2 3
60
HZ
480 Tq To T3
12 LEAD ZIG-ZAG
ZIG-ZAG connection with 12 lead machine only.
VOLTAGE
EL CONNECT Eq Lo NEUTRAL
60 T3 19
HZ 120/240 To Tg
To T3 T4
T1 Tg T7 Th2
T4 40 Ts 11 |
(IMARATHON-
11
INSTALLATION
ELECTRICAL CONNECTIONS
VOLTAGE REGULATOR CONNECTION DIAGRAM - KR4 SERIES (208-240 VOLT TAP)
ст! MAIN
GENERATOR
Note: Connect Voltage Regulator Sensing ——
Transformer to 208-240 Volt Tap. cr: See Connection
. Le Platé for
Ef Proper Connection
— T9 TA T
Ll] 4
ES
]
F1
T7
Fuses
Voltage T9
Adjust Rheostat F2
= F +
СНВ
ca Field Circuit Breaker Coil
Breakar | |
6 | 7 3 | 4 El | ES F+ | F— Terminal F1
Voltage input Sensing Field Strip
Adjust Power Voltage Power Exciter
Field
KRA Series Voltage Regulator F2
VOLTAGE REGULATOR CONNECTION DIAGRAM - KR7 SERIES (208-240 VOLT TAP)
MAIN
CT1
GENERATOR
Note: Connect Voliage Regulator Sensing mm ——
Transformer to 208-240 Voit Tap. ст? Sea Connection
| Plate tor
El Ргорег Connection
— 778% TAO
E3 | 1
F1 —
17
Fusas |
Voltage WA TO
Adjust Aheostat F2
weiter
Fini Field Circuit Breaker Coil On & Bus Bar (208 - 240V)
Вговког F— Generators T1 and T3 are
| j used instead cf T7 and T9.
6 | 7 | 3 | 4 | 6 | € | F+|F- Terminal FI
Voltage Input Sensing Field Strip
Adjust Power Voltage Power Exciter
Field
KRT Serles Voitage Regulator Fa °
RIMARATTION
LO
12
INSTALLATION
ELECTRICAL CONNECTIONS
VOLTAGE REGULATOR CONNECTION DIAGRAM - KR7 SERIES(416-480 VOLT TAP)
cri MAIN
DA
Note: Connect Voltage Regulator Sensing — GENERAT
Transformer to 416-480 Vol! Tap. ст? Ses Cannectlon
[ _ Plate for
ET Proper Cannectlon
— T1 TA TQ
«
E3 ' 1
Т
F1
va 17 -
Fuses
Voltage 79
Adjust Rheostat Fz
Field Circuit Breaker Coil
—
| 6 | 7 3 | 4 E1 | E3 F + = Terminal F1
Voltage Inpui Sansing Field Strip
Adiust Power voltage Power Exciter
ibld
KR7 Series Voltage Regulatar Е?
To External Potential Transiormsr
Provided by Customer © © !
Note: Isolation transformer connection shown for 4160 voit A ~~ a ENCAAT oR \
generator. For 2400 volts, change line 3 from H3 ta H2. CT1 | L4| La (51) >
— L Ses Connection
Note: Connect intemal transformer to match extemal £.T. cr 3 Plate tor
or 208 - 24) volt sensing for altemate connection. í E + Propar Connnetian
HI HZ Ha
ET 41502400. PAL
Ld ISOLATION
| TRANSFORMER
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AF / 4 XA x X3 XI
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eu ; ue connect the voltage regulator sensing terminals to a
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Covent TOM! Е Fiald separate potential transformer which is not supplied with
| | Е? the generator. These are normally a pant of the cus-
6 | 7 3 | а | £i | et | F- | F— — tomers metering and switchgear control panel. If the
a regulator power isolation transformer is also used for
Voltage put Sensing Field regulator sensing input, voltage regulation will be ap
Adsl Power Vallage Power - proximately + 3%.
| KR Aygulalar
CIMARATHON’
ELECT Rc
13
INSTALLATION
PARALLELING OPERATIONS
Magna One generators come standard with
amortisseur windings die cast as an integral part of
the rotor. This exclusive Unirotor construction
makes all Magna One generators suitable for
paralleling operations when the proper control
equipment is added.Paralleling with other genera-
tor sets and/or with the utility power grid offers a
number of advantages. Multiple unit installations
increase power capacity; they can be added or re-
moved from the load depending on the load re-
quired; they can be better maintained and repaired
(since single source breakdown would mean total
loss of power) and they often provide more reliable,
efficient and economical operation.
Successful parallel operation means that the
generators deliver power to the external system
without delivering power to each other, or accepting
power from the load buss or power grid. Additional
equipment is necessary to insure safe and success-
ful operation.
PRIME MOVER
The prime mover provides the speed and torque
which will be necessary to keep the machines in
synchronized operation. The speed will directly
control the watt or kW load and frequency of the
unit. The prime mover speed is controlled by a
governor. The governor must have special parallel-
ing and droop provisions to permit paralle! opera-
tion with other machines.
VOLTAGE REGULATOR
The voltage regulator controls the generator output
voltage and the reactive power supplied by the
generator. When two or more ac generators operate
in parallel, the voltage regulator must have parallel-
ing provisions (either internally or external to the
regulator) to permit it to control the reactive or VAR
load while it is in parallel operation. A separate
paralleling current transformer is required to sense
the reactive current and signal the voltage regulator.
This additional paralleling circuitry is absolutely
necessary to control the reactive current flowing be-
tween the generator sets.
PARALLELING OPERATIONS
SWITCHGEAR
There are additional relays and breaker controls
which are necessary to insure safe, trouble free
operation of paralleled units. Reverse power relays
monitor the direction of power flow to insure that
the generator is delivering power, not accepting it.
These power relays control breakers, which are a
means of connecting and disconnecting the
generator from the load. The total system can
include over-voltage, over-current protection,
under frequency protection, power factor cor-
rection provision and various associated control
equipment from manual switchgear to micro-pro-
cessors. The amount of control gear and level of
sophistication will be determined by the needs and
requirements of the particular application.
PARALLELING BASICS
The following points are basic criteria which must
be met before two units can be paralleled. THIS IS
NOT MEANT TO BE SPECIFIC INSTRUCTIONS
FOR PARALLELING OPERATION.
1. Additional paralleling circuitry
A. Voltage regulator - paralieling provisions
B. Paralleling current transformers(s)
C. Paralleling provisions on governor con-
trois
D.Switchgear
2. The voitage and frequency must be the same
for all sets with voltages in phase.
3. The voltage regulation characteristics of the
individual generators should be similar.
4. The generators must have the same phase
rotation.
5. The driving engines should have the same
speed regulation characteristics and the
governors should be adjusted to give the
same speed regulation.
Before operating generator sets in parallel, each set
should be checked by starting, operating and
adjusting the sets as individual units before at-
tempting paralleling.
RIMARATHON
a
14
INSTALLATION
PARALLELING OPERATIONS
THYRISTOR OR SILICON CONTROLLED RECTIFIER LOADING
REACTIVE LOAD CONTROL
When two identical generators are operating to-
gether in parallel and an unbalance occurs in field
excitation, circulating currents begin to flow be-
tween the generators. This current will appear as a
lagging power factor or inductive load to the highly
excited generator, and as a leading power factor or
capacitive load to the generator with the lower field
current. This is known as the reactive circulating
current and there are two methods of controlling it
in parallel operation:
1. Reactive droop compensation. (Formerly
known as parallel droop compensation.)
The bus voltage droops, or decreases, as the
reactive lagging power factor load is
increased.
2. Reactive differential compensation. (For-
merly known as cross current compen-
sation.)
The reactive differential compensation
circuit allows parallel generators to share re-
active loads with no decrease or droop in
generator voltage. The RDC circuit must
meet the following criteria:
A. All paralleling current transformers for all
the generators being paraileled must be in-
cluded in the secondary interconnection
loop.
B. When different size generators are
paralleled, all paralleling current trans-
formers must have the same or propor-
tional ratios that give approximately the
same secondary current.
C.Voltage regulator
must be the same.
paralleling circuitry
D.Current transformer secondaries and the
generator lines must be isolated
electrically.
Because of the above criteria, reactive
differential compensation cannot be used
when paralleling with the utility power grid.
There is no limit, however, inthe number of
generators that can be included in this type
of circuit.
®
E. It is also desirable to have an auxiliary con-
tact on the main generator breaker to short
the parallel CT secondary when that
breaker is open (not connected to the load
buss).
PARALLELING CIRCUITRY
Because of the number of variables involved in
paralleling generator sets, every installation will
have its own circuitry and methods or procedures of
bringing paralleled units on line. There are
numerous ways of connecting paralleled units and
an almost unlimited variety of applications and
associated equipment.
When parallel operation is desired, it is important
that the control manufacturer, the generator manu-
facturer and the systems engineer work together to
insure the proper selection of all components.
Please refer to Marathon Electric for application
assistance.
THYRISTOR OR SILICON CONTROLLED
RECTIFIER LOADING
Solid state electronic control devices which utitize
thyristors or SCR firing circuits (such as variable
frequency induction motor controls, precision
motor speed controls, no-break powered battery
chargers, etc.) can introduce high frequency
harmonics which adversely affect or distort the
normal waveform of the generator. This creates
additional heat in the generator stator and rotor, and
can cause overheating. These devices can and do
present problems to non-utility power generating
equipment or any limited power buss system. The
problems which can occur are not limited to the
generator itself, but can effect the solid state control
devices, the equipment it controls, other associated
loads, monitoring devices or a number of combina-
tions over the entire system.
Magna One generators can supply some thyristor
and SCR loads when properly applied. For a single
thyristor (SCR) load, the maximum KVA load on the
generator should be limited to about 60% of the
generator rating. Where thyristor (SCR) loading is
less than 30% of the total loading, derating of the
generator is not normally required. It is important that
the control manufacturer, the generator manufac-
turer and the systems engineer work together to in-
sure the proper selection of all components. Please
refer to Marathon Electric for application assistance.
[MARATHON
a a
Fa >
15
OPERATION
PRE-START INSPECTION
Before operating the generator for the first time, the
following checks are recommended.
1. Check all wiring against the proper con-
nection diagrams and make sure all con-
nections are properly insulated.
2. Inspect for any remaining packing materials
and remove loose clothes and all tools.
3. Check that all covers and guards are installed
and tight.
IDLING
Permanent equipment damage can be caused by
idling the engine between 650 and 1400 generator
rpm. If engine adjustments require idling at these
speeds, the REGULATOR FUSES MUST BE RE-
MOVED before engine start-up and adjustment.
WARNING
RESIDUALVOLTAGE ISPRESENTATTHE GEN-
ERATOR LEADS AND AT THE REGULATOR
PANEL CONNECTIONS, EVEN WITH THE REG-
ULATOR FUSES REMOVED. CAUTION MUST BE
OBSERVED OR SERIOUS PERSONAL INJURY
OR DEATH CAN RESULT. CONSULT QUALIFIED
PERSONNEL WITH ANY QUESTIONS.
If generator is supplied with the optional regulator
power “off-on” switch, simply turn the switch to the
“off” position; or if supplied with the optional under-
frequency module, the regulatoris protected. WHEN
IN DOUBT, REMOVE THE FUSES. After engine ad-
justment, the regulator fuses should be replaced.
The engine should be brought through the 650-1400
rom range in less than 45 seconds.
VOLTAGE ADJUSTMENTS
A means for adjusting the voltage is incorporated in
the regulator. For details refer to the Voltage
Regulator Manual applicable to this unit.
PRE-START INSPECTION
STARTING-UP THE GENERATOR
FIELD FLASHING
STARTING-UP THE GENERATOR
The following procedure should be followed for
starting-up the generator set:
1. The generator output must be disconnected
from the load. Be certain that the main circuit
breaker is open.
2. Start the prime mover and adjust it for the
proper speed. If unit is not frequency pro-
tected, remove the fuses.
3. If fuses have been removed, replace the fuses
and adjust the voltage to the required value
by means of the voltage adjust rheostat.
4. Close the main circuit breaker and apply the
load.
5. Adjust engine speed at full load to 1800 rpm
for 60 hertz, 1500 rem for 50 hertz.
6. Before stopping the engine, remove the load
by tripping the main circuit breaker.
FIELD FLASHING
The generator relies on residual voltage to start the
generator action which in turn produces the rated
voltage. If the generator fails to produce a voltage
after it has come up to rated speed, it may be neces-
sary to flash the field. This procedure must be done
while the generator is at a standstill. See the Field
Flashing Procedure for further information.
FIELD FLASHING PROCEDURE
With the generator set shut down, apply a 12 volt de
flashing source (battery) across terminals F+ and F-
on the voltage regulator. The positive terminal of the
battery must be connected to F+ and the negative
terminal to. F-. CAUTION: If these leads are re-
versed, the voltage regulator will be destroyed. A
diode in the voltage regulator allows the flashing
source to be removed from the field without the
danger of inductive arcing. This action re-
magnetizes the exciter field and allows build-up
when the system is restarted.
[CIMARATHON
æ
16
OPERATION
PREVENTATIVE MAINTENANCE
CLEANING METHODS
PREVENTATIVE MAINTENANCE
Dirt and heat are common enemies of a generator.
Keeping the generator clean, preventing overloads,
and proper alignment of the generator and its prime
mover will result in efficient operation.
Accumulations of dust and dirt not only contribute
to insulation breakdown, but they can also increase
temperature by restricting ventilation and by
blocking the dissipation of heat from the winding
and frame surfaces. Some machines are exposed to
accumulations of materials such as tale, lint, or
cement dust, which may obstruct the ventilation.
The most harmful types of foreign materials include
carbon black, metallic dust and chips, and similar
substances which not only impede the ventilation,
but also form a conductive film over the insulation,
increasing the possibility of insulation failure.
Machines operating in dirty places should be disas-
sembled and cleaned periodically.
Dirt and dust will conduct electricity between points
of different electrical potential. The regulator must
be kept free of excessive amounts of dust and dirt.
Low pressure, moisture-free compressed air may be
used to blow out any dust and dirt.
CLEANING METHODS
When electrical components get dirty, the insula-
tion must be cleaned. There are a number of ac-
ceptable methods for cleaning the generator, each
of which will necessitate disassembly of the unit.
The method of cleaning will be determined by the
Kind of dirt, and when the unit must be returned to
service. Drying after cleaning is necessary.
Whenever the generator is disassembled, the
windings should be given a thorough inspection
and the insulation cleaned, if necessary. The in-
spection should cover the condition of the windings
and insulation, and the effectiveness of the sup-
porting ties as evidenced by the rigidity of the coil
end turns.
SOLVENTS
It is recommended that only petrecieum distillates be
used for cleaning electrical components.
A solvent is usually required to remove accumulated
soil containing oil or grease. A wet rag with solvent
is suitable for wiping.
Dry components thoroughly with moisture-free, low
pressure compressed air.
CAUTION: CARE MUST BE TAKEN NOT TO GET
SOLVENT ÓN INSULATING VARNISHES OR DE-
TERIORATION OF VARNISH WILL OCCUR.
Petroleum solvents of the safety type should be
used. The flash point of these solvents should be
greater than 100° F (38°C).
WARNING
ADEQUATE VENTILATION MUST BE AVAIL-
ABLE TO AVOID FIRE, EXPLOSION AND
HEALTH HAZARDS WHERE SOLVENTS ARE
USED. AVOID BREATHING SOLVENT
VAPORS. RUBBER GLOVES OR OTHER
SUITABLE PROTECTION FOR THE HANDS
SHOULD BE USED.
CLOTH AND COMPRESSED AIR
Cleaning with a dry cloth may be satisfactory when
components are small, the surfaces are accessible
and only dry dirt is to be removed.
Blowing dirt out with compressed air is usually ef-
fective particularly when the dirt has collected in
places which cannot be reached with a cloth. Use
clean dry air at 30 PSI {206 KPA).
BRUSHING AND VACUUM CLEANING
Dry dust and dirt may be removed by brushing with
bristle brushes followed by vacuum cleaning. Do
not use wire brushes. Vacuum cleaning is an ef-
fective and desirable method of removing dry and
loose dirt.
‘SHELL BLASTING
Air blasting with ground nut shells may be satis-
factory for removal of hand dirt deposits from
insulation. Use mild abrasives such as 12-20 mesh
ground walnut shells.
DRYING ELECTRICAL INSULATION
Electrical components, after cleaning, storing or
shipping must be dried before placing in operation if
tests indicate that the insulation resistance is below
a safe value. See approved drying procedures inthe
“Installation Section” of the manual.
DRYING ELECTRICAL INSULATION
Eiectrical components, after cleaning, storing or
shipping must be dried before placing in operation if
tests indicate that the insulation resistance is below
a safe value. See approved drying procedures inthe
“Installation Section” of the manual.
AIR INTAKE AND EXHAUST
Check the area around the air intake and exhaust
openings to be sure they are clean and un-
obstructed. Remove all foreign material and clean
all screens.
ELECTRICAL CONNECTIONS AND WINDINGS
Inspect for loose or contaminated connections.
Check wires for cracked or frayed insulation.
Tighten connections and replace defective or oil
soaked insulation.
If inspection shows that varnish coatings on the
windings have deteriorated, they should be re-
coated with insulating varnish. Please refer to
Marathon Electric for insulation system require-
ments.
LUBRICATION
All generators are lubricated before leaving the
factory and are ready for operation. As a general
rule, bearings should be relubricated annually or
at the indicated intervals in table 1, whichever
occurs first. Unusually severe operating condi-
tions, such as high ambient or dusty environments,
require more frequent lubrication (every six months
or one half the table intervals, whichever occurs
first). 360 Frame generators are premanently lubri-
cated, and therefore regreasing is not necessary.
Use Cheveron SRI #2 or equivalent anti-friction
type, high quality, grease with a lubrication
temperature range of lowest ambient temperature
expected to + 260°F.
During an overhaul, the grease reservoir should be
thoroughly cleaned and new grease added. The re-
servoir should be 1/3 to 1/2 filled with new grease.
To add or renew grease, proceed as follows:
1. Stop unit.
17
OPERATION
PREVENTATIVE MAINTENANCE
LUBRICATION
2. Wipe clean the grease plugs and surrounding
paris.
3. Remove filler and drain plugs (see figure
to right).
4. Insert 1/8” N.P.T. grease fitting or appro-
priate fitting in filler pipe.
5. Free drain hole of any hard grease, using a
piece of wire if necessary.
6. Using a low pressure grease gun, add grease
according to the amounts in table 1.
7. Start unit with drain plug removed - filler pipe
may be open or closed. Allow unit to run 15
minutes to allow excess grease to drain.
8. Stop unit, wipe off any drained grease, and
replace filler and drain plugs.
CAUTION: USE ONLY CLEAN GREASE FROM
CLEAN, CLOSED CONTAINERS AND KEEP IT
FROM BEING CONTAMINATED WHILE RE-
GREASING.
The amount of grease added is very important! Only
enough grease should be added to replace the
grease used by the bearing.
CAUTION: TOO MUCH GREASE CAN BE AS
"HARMFUL AS INSUFFICIENT GREASE - USE THE
PROPER AMOUNT.
DRAIN
GREASE
| PLUG IS
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GREASE FILLER
PIPE ACCESS
RIMARATHON
18
OPERATION
LUBRICATION
TABLE 1: RELUBRICATION AMOUNTS AND INTERVALS
FRAME BEARING AMOUNT OF GREASE INTERVALSO
SIZE SIZE OUNCES | CUBIC INCHES | TEASPOONS | 60 HZ | 50 HZ
440 312 1.0 1.8 5.8 7600 | 8800
SINGLE |
BEARING 500, 502 314 12 2.1 7.0 6500 | 8400
UNITS
680, 682, 683 320 2 1 3.7 12.2 3800 | 5300
DOUBLE 440 318 1.7 3.0 9.9 46 200
BEARING 00 | 620
UNITS 500, 502 318 1.7 3.0 9 4 0
SHAFT END 9 600 | 620
BEARING | 680, 682, 683 322 24 4.2 14.0 3000 | 4500
ONLY)
OHOURS OF RUNNING TIME
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MARATHON -
ELECT IRI
REMOVAL FROM PRIME MOVER
WARNING
DISCONNECT ALL POWER BEFORE SER-
VICING. FAILURE TO FOLLOW ALL SAFETY
INSTRUCTIONS CAN RESULT IN SERIOUS
PERSONAL INJURY OR DEATH.
1. Remove louvered conduit box cover. {See
Figure 1).
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2. Disconnect all electrical load leads from the
generator leads (or buss bars) inside the
conduit box.
3. Remove all conduit or ducting from the
conduit box.
4. Attach a suitable hoist to the generator lifting
lugs.
5. a. For two-bearing generators, disconnect
the coupling or sheave and belts between
the generator and prime mover. (Follow
the coupling manufacturer's instructions
for disconnection.)
b. For single bearing generators, remove the
bolts mounting the screen assembly to the
SAE adaptor and remove the screen. (See
Figure 2.) (NOTE: Do not remove the drip-
cover from the screen assembly if so
equipped.) Remove the capscrews
attaching the drive discs to the flywheel
and remove the capscrews attaching the
SAE adaptor to the flywheel housing.
19
SERVICE.
DISASSEMBLY
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Gas bn wh
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* DRIP COVER
5% (OPTIONAL) EE
crie Hoi
SCREEN
ASSEMBLY
WARNING
DO NOT APPLY ANY FORCE TO THE |
GENERATOR FAN FOR LIFTING OR ROTAT-
ING THE GENERATOR ROTOR. DIS-
REGARDING THESE INSTRUCTIONS MAY
CAUSE PERSONAL INJURY OR EQUIPMENT
DAMAGE.
6. Remove the mounting bolts which secure the
generator to the base.
7. Raise the generator slightly and move the
generator away from the prime mover.
8. On single bearing generators, if generator is
to be shipped, see Shipping Instructions
Section for proper rotor support.
EXCITER REMOVAL
1. Remove regulator enclosure and discon-
nect F1 and F2 leads from the corresponding
F+ and F— terminals on the terminal block
on the regulator panel. (See Figure 3).
Li
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20
SERVICE
DISASSEMBLY
2. Remove all lead fasteners connecting F1 and
F2 leads to the front end bracket or conduit
box. Remove the four capscrews and belle-
ville washers holding the exciter stator and
lead shield in place. (See Figure 4.) Remove
4. Remove the capscrew and belleville washer
which holds the exciter (rotor) armature to
the generator shaft. Use a six inch, 3/4- 16NF
capscrew threaded into the aluminum
standoff plate to push against the end of the
the lead shield. Mark the exciter stator “top shaft. (See Figure 7.) Carefully feed the leads
front” for reference. (See Figure 5.) Remove through the lead hole in the aluminum stand-
the exciter stator. off plate as the armature is removed.
AFMATUREN Е ; I CAUTION: DO NOT TIGHTEN THE ARMATURE
а у REMOVAL CAPSCREW BEYOND THE END OF
THE THREADS. IF THE THREAD LENGTH IS NOT
—— SUFFIFICIENT TO REMOVE THE EXCITER ARMA-
STATOR À A, ON TURE, USE A PIECE OF THREADED ROD WITH A
MOUNTING
CAPSCREWS (4) | que NUT WELDED ON THE END.
ARMATURE
REMOVAL
CAPSCREW
MAIN ROTOR REMOVAL
1. a. For two bearing generators, remove the
two capscrews and lockwashers holding
3. Disconnect both main rotor leads coming out the bearing lock to the drive end bracket.
of the aluminum standoff plate lead hole from On 680, 682 Frame generators, remove the
the rectifier aluminum angle. (See Figure 6.) two capscrews holding the bearing cap to
the front end bracket. (See Figure 8.)
ARMATURE
MOUNTING
CAPSCREW
BEARING
CAP
CAPSCREWS (2)
b, For single bearing 680, 682 Frame
generators, remove the lwo capscrews
holding the bearing cap to the front end
bracket (See Figure 8.)
2. If the screen assembly is stil mounted,
remove the bolts securing the screen assem-
bly to the drive end bracket or the SAE
adaptor and remove the screen assembly.
(See Figure 9.) (NOTE: Do not remove the
drip cover from the screen assembly if 50
equipped.)
RAISED
DRIP COVER
5 (OPTIONAL)
i
3. a For two bearing generators, remove the
drive coupling half or sheave from the shaft
extension
b. For single bearing generators, remove the
capscrews and hardened washers holding
the drive discs to the drive hub. (See Figure
10.) (NOTE: Capscrew removal can most
zasily be accomplished by starting at the
pottom and removing the capscrews in a
clockwise sequence.) Remove all drive
discs (and spacers if any).
т ADAFTOR ME
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J CAPSCREWS [iS
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Figure 10
21
SERVICE
DISASSEMBLY
4. a For two bearing generators, remove the
capscrews holding the drive end bracket to
the generator and remove the bracket.
b. For single bearing generators, remove the
capscrews holding the SAE adaptor to the
generator and remove the adaptor. (See
Figure 11.)
CAUTION: ON LARGE GENERATORS, A HOIST
AND LIFTING STRAP SHOULD BE USED TO
ASSIST IN DRIVE END BRACKET OR SAE
ADAPTOR REMOVAL.
Figure 11
5. Using a rotor lifting fixture and a suitable
hoist, carefdlly remove the rotor assembly
from the main stator and frame assembly
through the drive end. (See Figure 12.)
CAUTION: SPECIAL CARE SHOULD BE USED IN
THE ROTOR ASSEMBLY REMOVAL, OR
WINDING DAMAGE COULD RESULT
WARNING
DO NOT APPLY ANY FORCE TO THE GEN-
ERATOR FAN FOR LIFTING OR ROTATING
THE GENERATOR ROTOR. DISREGARDING
THESE INSTRUCTIONS MAY CAUSE PER-
SONAL INJURY OR EQUIPMENT DAMAGE.
ON’
CIMARATHON
22
SERVICE
DISASSEMBLY
FIXTURE
MAIN ROTOR
ASSEMBLY
Figure 12
CONDUIT BOX AND FRONT END
BRACKET REMOVAL
1. Disconnect the following leads from the cor-
responding points on the terminal strip onthe
regulator panel: (See Figure 13.)
Frame Size Leads to be Disconnected
360, 440, 500 TO, T7, E3, [CT-1, CT-2 if used]
502, 680 T7, T9, [CT-1, CT-2 it used]
682 TO, T7 £1, E3, [CT-1, CT-2 if used]
NOTE: The above lead combinations are
used on the standard generators, other leads
may have to be removed depending on the
particular application.
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Li
VOLTAGE ==
REGULATOR
REGULATOR
ENCLOSURE
REMOVED
TERMINAL
BLOCK
Figure 13 |
2. On generators with buss bars, disconnect all
main stator leads bolted to the buss bar
assembly, making sure all leads are marked
for identification before removal. (See Figure
14.)
3. a On generators with four buss bars (T1, TZ,
T3, TO), remove the capscrew, flat washer
and lockwasher mounting the red insulat-
ing channel to the front end bracket. He-
move the buss bar support mounting cap-
screws and lockwashers. Remove the buss
bar assembly. Remove the capscrews and
fockwashers mounting the neutral buss
bar to the support.
b. On generators with six buss bars (T1,T2, T3,
T4, T5, 16), remove the capscrews and lock-
washers mounting the buss bar support to
the front end brackel. Remove tne buss bar
assembly (T1, T2 and T3} The neutral buss
bar assembly (T4, T5 and T6) can remain in
the bottom of the conduit box,
LES
| CHANNEL MOUNTING
CAPSCREW
BUSS BAR Mat TRE
ASSEMBLY :
i
MAIN STATOR
LEADS
BUSS BAR SUPPORT LA
MOUNTING CAPSCREWS
=
NEUTRAL BUSS
BAR MOUNTING
CAPSCREWS
NEUTRAL BUSS |
BAR
1
4 Remove the capscrews and starwashers
holding the conduit box and front end
bracket to the main stator assembly. (See
Figure 15) Lift off the conduit box.
5. On 680, 682 Frame generators, remove the
one additional mounting capscrew at the
bottom of the front end bracket. {See Figure
16.)
CONDUIT
BOX
М, CONDUIT BOX AND
BRACKET MOUNTING
CAPSCREWS
Figure 15 *
FRONT END
BRACKET
BRACKET MOUNTING
Figure 16 CAPSCREW
SERVICE
DISASSEMBLY
6. Remove the front end bracket from the main
stator assembly. (See Figure 17.)
CAUTION: ON LARGE GENERATORS, A HOIST
AND LIFTING STRAP SHOULD BE USED TO
ASSIST IN THE FRONT END BRACKET
REMOVAL.
FRONT END MAIN STATOR
BRACKET
AND FRAME ASSEMBLY
Figure 17
RIMARATHON
24
SERVICE
INSPECTION
EXCITER INSPECTION
A. Exciter Stator
1. Clean dust and dirt from the stator winding
with a soft cloth or brush. (See Figure 18.)
(See cleaning methods under Preventative
Maintenance.)
2. Check the exciter stator winding for a loose,
frayed, or burnt winding. Repair or replace as
necessary. If field repair of the winding is
necessary, contact Marathon Electric for
special winding procedures and materials.
3. Look for score marks in the bore of the exciter
core caused by rubbing.
STATOR CORE
WINDING
Fi, F2 LEADS
E
Figure 18
B. Exciter (Rotor) Armature
1. Clean all metal parts with an approved clean-
ing solvent.
2. Clean dust and dirt from the exciter armature
and rectifier assembly with a soft cloth or
brush. (See Figure 19.) (See cleaning
methods.)
3, Check the exciter armature for burrs on the
mating surfaces.
4. Check the rectifiers and surge protector for
proper operation. (See Troubleshooting
Section.) Replace defective parts.
5. Check the exciter armature and rectifier
assembly for aloose, frayed, or burnt winding
or loose connections, Repair or replace as
necessary. If field repair of the winding is
necessary, contact Marathon Electric for spe-
cial winding procedures and materials.
6, Look for score marks on the outside diameter
of the armature core caused by rubbing,
| RECTIFIER ASSEMBLY | |. RECTIFIER ASSEMBLY!
| MOUNTING CAPSCREWS (4) dha
RECTIFIERS |
WINDING
ARMATURE
CORE
RECTIFIERS #
Figure 19 SURGE PROTECTOR!
MAIN ROTOR INSPECTION
A. Bearing
1. Check the bearing for damage or wear, On
680-684 Frame generators, clean the old
grease from the bearing cap, and fill the
bearing cap grease cavity 1/3 to 1/2 full of
new multipurpose lithium based grease.
NOTE: Ifthe bearing needs to be removed, lor
any reason, always install a new bearing.
2. Ifthe bearing is to be replaced, remove with a
suitable puller. {See Figure 20) On 680-684
Frame generators and two bearing genera-
lors, be sure the bearing cap is on the shaft
before installing the new bearing.
SEARING CAP |
(680-684 FRAMES ONLY)
BALL BEARING
Figure 20 BEARING PULLER
25
SERVICE
Heat the new bearing in an oven to a maxi-
mum temperature of 212" F (100° C). Apply a
thin coat of clean lubricating cil to the press-
fit area of the rotor shaft. Using asbestos
gloves, install the bearing over the end of the
shaft until it seats against the shaft shoulder.
(See Figure 21.) The bearing should slide on
the shaft and be seated without excessive
force. If the bearing binds on the shaft before
being fully seated, a piece of tubing, slightly
larger than the press-fit area, can be used to
drive the bearing into place. Using light taps
with a soft mallet, apply pressure to thé inner
race only.
CAUTION: UNDER NO CIRCUMSTANCES
SHOULD PRESSURE BE APPLIED TO THE
OUTER RACE OF THE BEARING, AS
PERMANENT BEARING DAMAGE COULD
RESULT,
Allow the bearing to cool for one hour before
attempting to assemble the generator.
* NEW
BEARING
—
IN
e | |
BEARING САР
| ASBESTOS GLOVES ™ (690.684 FRAMES ONLY)
Figure 21
B. Drive Hub (Single Bearing Generators Only)
1. Check the drive hub for cracks or stripped
drive disc mounting holes. Replace the hub if
defective.
2. If the hub is to be replaced, mark the fan and
hub for alignment to ensure proper balance
after reassembly. Remove the fan mounting
capscrews and belleville washers and move
the fan back away from hub. (See Figure 22.)
Install a suitable puller to the hub. Hemove
the setscrew in the hub over the key. Using à
torch, rapidly heat the hub at the outer dia-
meter while tightening the puller. {This must
INSPECTION
be done rapidly before the heat can expand
the shaft.) Remove the hub. {Check the fan
for defects according to Section C.)
EAN . TORCH
N LOCATION
MARKS
A | \
г PULLER I)
DRIVE HUB ©
Mark the new hub in the same place as the old
hub relative to the keyway. Heat the new hub
in an oven to 500°-600° F (260°-316° C). Be
sure that the fan is still on the shaft, Using
asbestos gloves, slide the hub over the key in
the shaft until it seats against the shaft
shoulder. (See Figure 23.)
HUB KEY
Allow the hub to cool for one hour. After the
hub has cooled, tighten the setscrew in the
hub to 50 ft-Ibs (68 N.m) torque. Malch the
alignment marks on the fan and hub and
mount the fan with the capscrews and belle-
ville washers. (See Figure 24) Torque the
capscrews per Figure 49. (See Figure 25)
AMARA
26
SERVICE
INSPECTION
BELLEVILLE WASHERS
MUST BE MOUNTED IN THIS DIRECTION.
нЕ
Figure 24
FAN MOUNTING
CAPSCREWS (4)
Rebalancing of the rotor assembly is not
necessary if only the hub is replaced and the
fan is mounted in the same location relative to
the hub.
C. Fan
1. Check the fan for cracks or broken blades.
Replace the fan if defective.
2. a For two-bearing generators, remove the
drive end bearing cap. (See bearing
removal instructions above.) Remove the
lan setscrews. Using a torch, rapidly heat
the backside of the fan.
CAUTION: DO NOT HEAT THE FAN ABOVE 400-
500° F (204-2609 C) AS THIS WILL REMOVE THE
TEMPER FROM THE FAN.
Using asbestos gloves, slide the fan off the
shaft. Heat the new fan in an oven to 400° -
500° F (204°-260°C). Using asbestos
gloves, slide the fan over the key in the
shaft until it seats against the shaft
shoulder. Allow the fan to cool for one-half
hour. After the fan has cooled, tighten the
setscrews in the fan to 17 ft-lbs (23 N.m)
torque. Install the bearing cap and a new
bearing according to the bearing assembly
instructions above.
b. For single bearing generators, remove the
hub according to the above drive hub
removal instructions. Slide the fan off the
shaft. Slide the new fan on the shaft making
sure the fan mounting surface is toward the
drive hub. Mount the hub according to the
drive hub assembly instructions above.
Mount the fan to the drive hub with the cap-
screws and belleville washers (see Figure
24). Torque the capscrews per Figure 49.
(See Figure 25)
3. The rotor assembly must be rebalanced if a
new fan has been installed.
D. Main Rotor Core and Windings
1. Clean all metal parts with an approved
cleaning solvent. Remove dust and dirt from
the rotor windings with a soft cloth or brush.
(See Figure 26.) (See cleaning methods.)
MAIN ROTOR
CORE
Figura 28
FHemove any accumulated dust or dirt in the
winding air channels with a piece of wire or
with low-pressure, moisture-free air,
CAUTION: IF A PIECE OF WIRE 1S USED FOR
CLEANING THE AIR CHANNELS; CARE MUST BE
TAKEN NOT TO SCRATCH THE WINDING AS
THIS COULD CAUSE AN INSULATION FAILURE.
2. Check the rotor for loose, frayed, or burnt
windings. A defective rotor winding must be
rewound by Marathon Electric. The rotor
assembly must be rebalanced after any
rework or repair has been completed.
OMARATIEN-
1
how y
LE
27
SERVICE
FLYWHEEL MOUNTING
Figura 27
ALIGNMENT
HOLES
HOLES
DRIVE HUB MOUNTING
HOLES
F. Drive Discs {Single Bearing Generators Only)
de
Inspect the drive discs for distorted or bent
edges. (See Figure 27.) Inspect for worn
mounting holes. Replace all defective discs
as necessary,
Inspect the drive disc mounting capscrews
for damaged threads. Replace capscrews if
damaged.
FRONT END BRACKET INSPECTION
1.
Remove the filler and drain grease pipes and
the grease plugs from the bracket. (See
Figure 28.)
Clean the end bracket, grease pipes, and cap-
screws in an approved solvent to remove all
dust, dirt, and orease. Dry the parts thor-
oughly with compressed air.
Inspect the canscrews for stripped threads
and replace if defective.
Inspect the end bracket for cracks and burred
or rough mating surfaces. Inspect the bearing
bore for burrs or wear. If the brackel shows
excessive bearing bore wear, it should be
replaced.
nes E
¡DRÁIN GREASE
PIPE
|
INSPECTION
FILLER
GREASE
PIPE
DRIVE END BRACKET OR
SAE ADAPTOR INSPECTION
1.
Figure 29
For two-bearing generators, remove the
grease plugs from the bracket.
Clean the bracket or adaptor, capscrews and
screen assembly in an approved solvent to
remove all dust, dirt, and grease. (See Figure
29.) Dry the parts thoroughly with com-
pressed air.
Inspect the capscrews for stripped threads
and replace if defective.
Inspect the bracket or adaptor for cracks and
burred or rough mating surfaces,
For two-bearing generators, inspect the bear-
ing bore for burrs or wear. If the drive end
bracket shows excessive bearing bore wear,
it should be replaced,
28
SERVICE
INSPECTION
MAIN STATOR INSPECTION
1.
Clean dust and dirt from the stator frame and
winding with a clean cloth, brush, or low-
pressure, moisture-free air, (See Figure 30.)
(See cleaning methods.)
Inspect the frame for cracks, burred mating
surfaces, or other damage.
Inspect the stator for a loose, frayed, or burnt
winding. Repair or replace as necessary, If
field repair of the winding is necessary, con-
lact Marathon Electric for special winding
procedures and materials,
CONDUIT BOX AND VOLTAGE
REGULATOR INSPECTION
Te
Clean dust from the conduit box and the
louvered cover with a clean cloth, brush, or
low-pressure, moisture-free air. (See ctean-
ing methods)
Clean dust and dirt from the voltage regulator
with a clean cloth, brush, or low-pressure,
moisture-free air. (See cleaning methods.)
Check all electrical connections for loose or
broken wires.
STATOR
CORE
| FRAME
RIMABATHON- -
CONDUIT BOX AND FRONT END
BRACKET INSTALLATION
1. Fill the grease cavity of the front end bracket
1/3 to 1/2 full of new multipurpose lithium
based grease. See "Lubrication Instructions”
In this manual. Assemble all grease pipes and
plugs In the bracket,
2. Install two guide pins in the main stator as-
sembly trame. Align the bracket mounting
holes to the guide pins and slide the bracket
over the pins, (See Figure 31,) On 680, 682
Frame generators, install the bottom cap-
screw, (See Figure 32.)
CAUTION: ON LARGE GENERATORS, A HOIST
AND LIFTING STRAP SHOULD BE USED TO
ASSIST IN THE FRONT END BRACKET
INSTALLATION,
FRONT END
BRACKET
PIN
Figure 31
Figure 32 CAPSCREW
3. Insert Iwo capscrews and starwashers
through the conduit box and mount the
conduit box to the bracket and main stator
and frame assembly. (See Figure 33)
y;
29
SERVICE
ASSEMBLY
Remove the two guide pins and insert the re-
maining capscrews and slarwashers.
CONDUIT
CONDUIT BOX AND BRACKET п =
BOX
MOUNTING CAPSCREWS
Figura 33 |
—
4. a. On generators with four buss bars (T1, T2,
T3, T0), mount thé néutral buss bar to the
Support with the capscrews and lock-
washers, (See Figure 34.) Mount the buss
bar assembly to the front end bracket with
the capscrews and lockwashers. Assemble
the capscrew, flat washer, and lockwasher
through the red insulating channel into the
fron! end bracket
= он
=
E
b. On generators with six buss bars (T1, T2,
T3, T4, T5, T6), mount the buss bar assem-
bly support to the front end bracket with
the capscrews and lockwashers
BUSS BAR SUPPORT
MOUNTING CAPSCREWS
NEUTRAL BUSS II =
BAR MOUNTING SKY
CAPSCAEWS 8
NEUTRAL |
BUSS SAR MI
Figura M
30
SERVICE.
ASSEMBLY
On generators with buss bars, connect the
main stator leads to the appropnate buss bar
according to the lead markings. Insert a flat
washer on the bolt, then assemble one termi-
nal to the buss bar with the boll and flat
washer. (See Figure 35.) Insert a second lead
on the bolt on the other side of the buss bar,
then a flat washer, lockwasher, and locknut.
5 =
BUSS BAR I
ASSEMBLY
ri
o
- WASHERS
а =~ al : |
¡BOLT E am LOCKWASHER
6. Connect the lollowing leads to the corre-
sponding points on the terminal strip on
the regulator panel: (See Figure 36).
Frame Size Leads to be Connected
360, 440, 500 TO, T7, E3, [CT-1, CT=2 if used]
202, 680 T7, T9, [(CT-1, CT-2 if used]
582
7
TO, Ty, El, E3, [CT-1, CT-2 if used]
Install regulator enclosure.
TERMINAL
BLOCK
Figure 46 |
NOTE: These lead combinations are used on
the standard generator; other leads may have
to be reconnected depending on the
particular application.
MAIN ROTOR INSTALLATION
1. Using a rotor lifting fixture and a suitable
hoist, carefully install the rotor assembly into
the main stator assembly through the drive
end. (Sea Figure 37.) Carefully feed the rotor
leads through the front end bracket shaft hole
as the rotor is installed.
CAUTION: SPECIAL CARE SHOULD BE USED IN
THE ROTOR ASSEMBLY INSTALLATION, OR
WINDING DAMAGE COULD RESULT.
WARNING
DO NOT APPLY ANY FORCE TO THE
GENERATOR FAN FOR LIFTING OR ROTAT-
ING THE GENERATOR ROTOR, DiIS-
REGARDING THESE INSTRUCTIONS MAY
CAUSE PERSONAL INJURY OR EQUIPMENT
DAMAGE.
“ROTOR LIFTING
| FIXTURE
| Figure 37
31
SERVICE
2.
a. For two bearing generators, insert guide
pins in the rear bearing lock holes. Fill the
grease cavity of the driveend bracket 1/310
1/2 full of new miltipurpose lithium based
grease. Assemble all grease plugs in the
bracket. Mount the bracket on the bearing
and guide the bearing lock pins through
the bracket holes. Align the drive end
bracketand mount with the capscrews, Re-
move one bearing lock quide pinand insert
a capscrew and lockwasher into the
bearing lock and tighten. Hemove the re-
maining quide pin and replace with the re-
maining capscrew and lockwasher.
. Far single bearing generators, pilot the
SAE adaptor to the fan and secure to the
main stator and frame assembly with cap-
screws torqued per Figure 49. (See Figure
38) It may be necessary to raise the rotor
assembly slightly to allow the mounting
of the SAE adaptor.
CAUTION: ON LARGE GENERATORS, A HOIST
AND LIFTING STRAP SHOULD BE USED TO
ASSIST IN THE DRIVE END BRACKET OR THE
SAE ADAPTOR ASSEMBLY.
MAIN |
STATOR
AND
FRAME EN
ASSEMBLY [I
Ty! =
Figure 38 SAE ADAPTOR
3. a. For two-bearing generators, install the
drive coupling half or sheave on the shaft
extension.
. For single bearing generators, insert a
guide stud into the drive hub. Position all
spacers (if any), then all drive discs, one at
a time until all discs are installed. (See
Figure 39.) Make sure that all disc
mounting holes at the inner and outer dia-
meter are properly aligned. Secure the
ASSEMBLY
discs with the capscrews and hardenad
washers torqued per Figure 49, (See Figure
40 for torquing sequence.)
Torque the bolts in the above sequence ac-
cording to the correct bolt pattern.
Then check the torque in each bolt In a clock-
wise direction around the bolt circle to insure
that all the bolts are properly torqued.
Figure 40
Je
SERVICE
ASSEMBLY
4. Mount the screen assembly on the drive end Insert the capscrew and belleville washer
bracket or the SAE adaptor and tighten the (see Figure 44) through the mounting hole in
bolts. (See Figure 41.) the aluminum standoff plate and secure to the
shaft (see Figure 45). Tighten the capscrew
5. On 680, 682 Frame genarators, insert the two until the armature seats on the shaft. Torque
capscrews and lockwashers into the front the capscrew per Figure 49,
end brackel and secure the bearing cap. (See
Figure 42.)
EXCITER
| ARMATURE
SAE ADAPTOR
iL
EN SCREEN
ASSEMBLY
a ALLE >.
уч E MAIN ROTOR
в. LEADS
y >
i
"we :
Le rl Г Г
x E 3 Г
й M -
of i ыы
. A
BN MOUNTING
BELLEVILLE WASHERS MUST BE
BEARING MOUNTED IN THIS DIRECTION
mn CAP A
CAPSCREWS —
| _ МОИМ =
| A MOTTA |
dr
Figura 42
EXCITER INSTALLATION
1. Install the exciter key In the armature bore
keyway. Attach a wire to the main rotor leads
and feed the wire through the armature bore
and out the lead hole in the aluminum stand-
off plate. Mount the armature on the end of
the shaft and align the key In the armature
bore to the keyway In the shaft. Slide the TORQUE
armature on the shaft while feeding the main WRENCH
rotor leads through the lead hole in the alumi- =
num standoff plate, (See Figure 43.) Figure 45 § :
CIMARATHON: ——
33
SERVICE
ASSEMBLY
2. Connect both main rotor leads coming out of
the aluminum standoff plate to the rectifier
aluminum angle; one to each angle. (See
Figure 46.)
3. Mount the exciter stator on the front end
bracket mounting pads and align the
mounting holes, noting the position of “top
iront” previously marked for reference (field
leads al inside bottom). (See Figure 47.) Align
the lead shield on the exciter stator and
mount with the capscrews and belleville
washers (see Figure 44). Torgue the cap-
screws per Figure 49 Install new lead fasteners
lo secure F1 and F2 to the front end bracket
and conduit box
i VOLTAGE
; REGULATOR
AY
TERMINAL? у
BLOCK
Figure 48 §
ASSEMBLY TO PRIME MOVER
i. Attach a suitable hoist to the generator lifting
lugs, and move the generator until the
generator foot mounting holes are aligned
ROTOR T= with the base and slightly above.
LEADS
[3
2. a For two-bearing generators, align the
coupling halves or sheaves between the
generator and the prime mover by adding
shims under the feet.
LY ARMATURE
KE MOUNTING
CAPSCREW
b. For single bearing generators, if the screen
assembly is mounted on the adaptor, re-
move the mounting bolts and remove the
screen (see Figure 50). (NOTE: Do not
remove the drip cover from the screen
assembly if so equipped.) Insert two guide
pins in the flywheel and two in the flywheel
housing. Adjust the generator position
until the drive discs are piloted in the fly-
wheel. 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
Figure 49.)
“TOP FRONT" E ds,
LOCATION pa 8
STATOR
4 MOUNTING La E
CAPSCREWS ES )
WARNING
STATOR
Figure 47
DO NOT APPLY ANY FORCE TO THE
GENERATOR FAN FOR LIFTING OR ROTAT-
4. Connect the F1 and F2 leads to the corre- ING THE GENERATOR ROTOR. DIS-
sponding F+ and F- terminals on the ter-
minal block on the regulator panel and In-
stall the regulator enclosure. (See Figure 48).
REGARDING THESE INSTRUCTIONS MAY
CAUSE PERSONAL INJURY OR EQUIPMENT
DAMAGE.
34
SERVICE
ASSEMBLY
FIGURE 49: CAPSCREW TORQUE VALUES
Capscrew Dia-
meter and Ultimate To 1/2 - 69,000 PSI
Tensile Strength To 3/4 - 64,000 PS! To 3/4 - 120,000 PSI
(PSI) 4 To 1 - 55,000 PSI To 1 - 115,000 PSI 150,000 PSI
SAE Grade
Number 1or2 5 8
Capscrew Head (> (> CI
Markings : <
Capscrew Body
Size Torque Torque Torque
(inches) - (Thread) Ft-Lb (N-m) Ft-Lb (N-m) Ft-Lb (N-m)
Dry! Oiled? Plated® | Dry: Oiled? Plated®| Dry' Oiled? Plated®
1/4 - 20 5 (7) 45 (6) 4 5) 8 (11) 7 (9) 6 (8); 12 (16) 11 (15) 10 (14)
- 28 6 (8) 54 (7) 48 (6)| 10 (14) 9 (12) 8 (11)} 14 (19) 13 (18) 11 (15)
5/16 - 18 11 (153 10 (14) 9 (12) 17 (23) 15 (20) 14 (19) 24 (33) 22 (30) 19 (26)
- 24 13 (18) 12 (16) 10 (14) 19 (26) 17 (23) 15 (20) 27 (37) 24 (33) 22 (30)
3/8 - 16 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)
7/16 - 14 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 (106) 70 (95) 62 (84)|
1/2 - 13 39 (53) 35 (47) 31 (42)! 75(102) 68 (92) 60 (81)|105 (142) 95 (129) 84 (114)
- 20 41 (56) 37 (50) 33 T(45)| 85(115) 77(104) 68 (92)|120 (163) 108 (146) 96 (130)
9/16 - 12 51 (69) 46 (62) 41 (56)|110(149) 99(134) 88(119)|155 (210) 140 (190) 124 (168)
- 18 55 (75) 50 (68) 44 (60)|120(163) 108 (146) 96(130)|170 (230) 153 (207) 136 (184)
5/8 - 11 83(113) 75 (102) 66 (89)|150(203) 135(183) 120(163)|210 (285) 189 (256) 168 (228)
- 18 95(129) 86 (117) 76 (103)|170(230) 153 (207) 136 (184) |240 (325) 216 (293) 192 (260)
3/4 - 10 105 (142) 95 (130) 84 (114)|270(366} 243 (329) 216 (293) |375 (508) 338 (458) 300 (407)
- 16 115 (156) 104 (141) .92 (125)|295 (400) 266 (361) 236 (320) 1420 (569) 378 (513) 336 (456)
7/8 - 9 160 (217) 144 (195) 128 (174) 395(535) 356 (483) 316 (428)|605 (820) 545 (739) 484 (656)
- 14 175(237) 158 (214) 140 (190)|435 (590) 392 (531) 348 (472)|675 (915) 608 (824) 540 (732)
1-8 235 (319) 212 (287) 188 (255)|590(800) 531 (720) 472 (640) 1910 (1234) 819 (1110) 728 (987)
= 14 250 (339) 225 (305) 200 (271)| 660 (895) 594 (805) 528 (716) | 990 (1342) 891 (1208) 792 (1074)
NOTES:
1. Based on use of clean, dry threads.
2. Torque reduced by 10% when engine oil is used as a lubricant.
3. Torque reduced by 20% if new plated capscrews are used.
4. Capscrews threaded into aluminum may require reductions in torque
of 30% or more.
| © ju LETT Ria
®
35
SERVICE
Position the generator so that the SAE
adaptor mates with the flywheel housing.
CAUTION: DO NOT FORCE THE ALIGNMENT OF
THE UNITS. SHIFT THE GENERATOR FROM SIDE
TC SIDE OR RAISE OR LOWER WITH A LIFTING
: DEVICE AS NECESSARY.
3.
It may be necessary to use shims under thé
mounting feet ofeitherthe generator or the
prime mover to obtain proper alignment;
use the same shims as removed under
disassembly or proceed as follows: Using
the extreme bottom four capscrews, mount
the SAE adaptor to the flywheel housing.
With a .0015 to .O02 inch feeler gauge at the
extreme top adaptor to flywheel housing to
fit, raise the generator or lower the prime
mover until the gauge 15 snug. Relieve just
enough to release the feeler gauge and
torque the remaining SAE adaptor cap-
screws to the flywheel housing.
Mount the screen assembly and tighten the
mounting bolts.
Shim under the generator feet for proper sup-
port, ensuring that the generator mounting
surfaces are level.
Install the mounting bolts which secure the
generator to the mounting base.
For two bearing generators, assemble the
coupling halves or sheave balts between the
generator and the prime mover. (Follow the
coupling manufacturer's instructions for
assembly.)
ASSEMBLY
Connect all existing conduit or ducting to the
conduit box,
Connect all electrical load leads to the
generator leads (or buss bars) Inside the
conduit box.
Check the exciter air gap (gap between the
exciter armature and slalor) by inserting a
010 inch feeler gauge in the gap and rotating
it around the armature diameter to ensure
that a minimum air gap is available. (See
Figure 51.) If the feeler gauge cannot be ro-
tated one full revolution, then check for a
“cocked’ exciter stator orloose stator mount-
Ing capscraws.
NOTE: On single bearing units, the exciter air
gap cannot be checked properly until the
generator 1s mounted to the prime mover,
9. Mount the louvered conduit box cover.
10. Relubricate the bearing according to the
lubrication instructions. (See Figure 52.)
GREASE FILLEFI
EN PIPE ACCESS
BOX
36
TROUBLE SHOOTING
GENERATOR PRODUCES NO VOLTAGE
THIS SECTION IS DIVIDED BY SYMPTOMS:
GENERATOR PRODUCES NO VOLTAGE
GENERATOR PRODUCES LOW VOLTAGE
GENERATOR PRODUCES HIGH VOLTAGE
GENERATOR VOLTAGE IS FLUCTUATING
WARNING
RESIDUAL VOLTAGE IS PRESENTATTHEGEN-
ERATOR LEADS AND AT THE REGULATOR
PANEL CONNECTIONS, EVEN WITH THE REG-
ULATOR FUSES REMOVED. CAUTION MUST BE
OBSERVED OR SERIOUS PERSONAL INJURY
OR DEATH CAN RESULT. CONSULT QUALIFIED
PERSONNEL WITH ANY QUESTIONS.
NOTE: Always include the Model Number and Ser-
lal Number of your generator when corresponding
with Marathon Electric
GENERATOR DOES NOT PRODUCE VOLTAGE
STEP 1
STEP 2
STEP 3
STEP 4
SHUT DOWN THE GENERATOR SET
and remove conduit box cover. Check
main generator leads for loose or
broken connections.
Check regulator fuses with onmmeter.
If defective, replace.
Start up generator. Measure voltage at
voltage regulator terminals 3 and 4. The
voltmeter reading should exceed 5V ac.
Ifitdoes, proceed to Step 4. Ifitdoes not,
check continuity of wiring from connec-
tions 3 and 4 to the voltage source. If
wiring is okay, — flashing is required.
See the section on Field Flashing, page 15.
SHUT DOWN THE GENERATOR SET.
Disconnect voltage regulator by re-
moving the connections to terminals
F+ and F- on the regulator. Connect a
common 12 volt storage battery to the
disconnected wires keeping polarity
the same. Start up the generator set.
With the generator at rated speed,read
the voltage output of the unit on a volt-
meter. Following these steps, if the
reading is one-half or greater of the
STEPS
STEP 6
STEP 7
STEP 8
rated output when there is no load on
the generator, the problem is in the
voltage regulator. Consult your
voltage regulator owner's manual for
further information. If the reading re-
mains near zero, the voltage regulator
is okay, and the problem is further on.
SHUT DOWN THE GENERATOR.
Reconnect the voltage regulator. Pro-
ceed to Step 5.
Examine the rotating exciter for loose
or broken lead wires. Be sure to check
that all six rectifier connections are
secure as well as all other wires on the
exciter. Repair, replace or tighten as
necessary. Proceed to Step 6.
Test each rectifier with an ohmmeter.
Remove the bolted leadwire from one
rectifier at the terminal stud. Test the
resistance between the disconnected
leadwire and the rectifier base. Make
sure you have a good connection. Note
the reading and reverse the ohmmeter
probes. One reading should be high
and the other low if the rectifier is good.
If this is the case, reconnect that recti-
fier and proceed to the next, repeating
the procedure until all sixrectifiers have
been checked. If the high and low
readings are not achieved, the rectifier
is defective and must be replaced.
Torque the new rectifier to 20-30 in-1bs.
Please note that two different types of
rectifiers (with different polarities) are
used on your unit. If all rectifiers are
good, proceed to Step 7.
Locate the surge protector and dis-
connect one of the two bolted surge
protector leads. With an ohmmeter,
measure the resistance between the
disconnected lead and the other surge
protector terminal. Reverse the ohm-
meter probes and repeat the test. If a
high resistance is measured in both
directions, proceed to Step 8. If re-
sistance is low in one or both direc-
tions, replace the surge protector.
Check windings for continuity. |
opens or shorts are found in the exciter
armature or stator, replace the neces-
sary component. |f the condition is
found in the main generator stator or
rotor, major repair or generator re-
placement is probably required.
37
TROUBLE SHOOTING
NOTE: Always include the Model Number and
Serial Number of your generator when correspond-
ing with Marathon Electric
GENERATOR PRODUCES LOW VOLTAGE
STEP 1
STEP?
STEP 3
STEF 4
STEP 5
STEPS
SIEP 7
STEP B
Low voltage condition should be veri-
fied at the generator load leads with an
auxiliary voltmeter.
SHUT DOWN THE GENERATOR SET
and remove conduit box cover, Check
main generator leads for correct
connection.
Start up the generator set. Verify
correct speed (1800 rpm at 60 Hertz
and 1500 rpm at 50 Hertz) with a
tachometer.
Make sure generator load does not ex-
ceed nameplate capacity. Verify this
with à “clamp-on” ammeter on the
main load leads. Current in any line
must not excead nameplate amps.
Adjust the range pot on the voltage
regulator in the extreme clockwise
direction to increase generator voltage
as necessary.
Be sure the voltage adjust rheostat is
adjusted, as necessary, to increase
generator voltage.
SHUT DOWN THE GENERATOR SET,
Check the sensing tap on the voltage
regulator to be sure it is correct. On
some applications, full line voltage is
not used for regulatory sensing. Refer
to the generator connection diagram.
Disconnect the voltage regulator by
removing the connections to terminals
F+ and F- on the regulator. Connect a
common 12 volt storage battery to the
disconnected wires keeping the
polarity the same, Start up the genera-
tor set. With the generator at rated
speed, read the voltage output of the
unit on a voltmeter. Following these
steps, if the reading Is one-half or
greater of the rated output when there
is no load on the generator, the
problem is in the voltage regulator.
Consult your voltage regulator owners’
GENERATOR PRODUCES LOW VOLTAGE
ЭТЕР ®
STEP 10
STEP 11
manual for further Information. If the
reading remains near zero, the voltage
regulator is okay and the problem is
further on. SHUT DOWN THE
GENERATOR SET. Reconnect the
voltage regulator.
Test each rectifier with an ohmmeter.
Remove the bolted leadwire from one
rectifier at the terminal stud. Test the
resistance between the disconnected
leadwire and the rectifier base. Make
sure you have a good connection. Note
the reading and reverse the ohmmeter
probes. One reading should be high
and the other low if the rectifier is good.
If this is the case, reconnect that recli-
fier and proceed to the next, repeating
the procedure until all six rectifiers have
been checked. If the high and low
reading is not achieved, the rectifier is
defective and must be replaced.
Torque the new rectifier to 20-30 in-Ibs.
Please note that two different types of
rectifiers (with different polarities) are
used on your unit. If the rectifiers are
good, proceed to Step 10.
Locate the surge protector and discon-
nect one of the two bolted surge
protector leads, With an ohmmeter,
measure the resistance between the
disconnected lead and the other surge
protector terminal. Reverse the ohm-
meter probes and repeat the test. If a
high resistance is measured in both
directions proceed to Step 11. If re-
sistance is low in one or both direc-
tions, replace the surge protector.
Check the windings for continuity. If
opens or shorts are found in the exciter
armature or stator, replace the neces-
sary component. If the condition is
found in the main generator stator or
rotor, major repair or generator re-
placement is probably required.
O a
E
38
TROUBLE SHOOTING
GENERATOR PRODUCES HIGH VOLTAGE
GENERATOR VOLTAGE IS FLUCTUATING
NOTE: Always include the Model Number and
Serial Number of your generator when correspond-
ing with Marathon Electric
GENERATOR PRODUCES HIGH VOLTAIRE
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP &
STEP 7
STEP B
RIMARATHON:
High voltage condition should be veri-
fied at the generator load leads with an
auxiliary voltmeter,
SHUT DOWN THE GENERATOR SET
and remove conduit box cover. Check
main generator leads for correct
connection.
Start up the generator set. Verify cor-
rect speed (1800 rpm at 60 Hertz and
1500 rpm at 50 Hertz) with a tach-
ometer.
Adjust the range pot on the voltage
regulator in the counterclockwise
direction to decrease generator
voltage as necessary.
Be sure the voltage adjust rheostat is
adjusted as necessary, to reduce
generator voltage.
SHUT DOWN THE GENERATOR SET.
Check the sensing tap on the voltage
regulator to be sure it is correct. On
some applications, full line voltage is
not used for regulator sensing. Refer to
the generator connection diagram.
Check the polarity of the rectifiers on
the rotating rectifier. Allthree rectifiers
on each aluminum standoff should
have the identical part number. Note,
however, that two different types of
rectifiers (with different polarities and
different part numbers) are used on
each aluminum angle.
Disconnect the voltage regulator by re-
moving the connections to terminals
F+ and F- on the regulator. Connect a
common 12 volt storage battery to the
disconnected wires keeping the
polarity the same. Start up the genera-
tor set. With the generator at rated
speed, read the voltage output of the
unit on a voltmeter. If the reading is
one-half or greater of the rated output
when there is no load on the generator,
the problem is in the voltage regulator,
Consult the voltage regulator owners’
manual for further information. Shut
down the generator. Reconnect the
voltage regulator,
GENERATOR VOLTAGE IS FLUCTUATING
STEP 1
STEP 2
STEP 3
STEP 4
STEPS
Adjust voltage regulator stability
clockwise for increased stability.
Verify engine governor performance
with a tachometer to insure stable en-
gine speed.
SHUT DOWN THE GENERATOR SET
and remove conduit box cover. Check
all wiring for loose connections. Be
sure that voltage adjust rheostat is
properly connected and working.
Disconnect voltage regulator by
removing the connections to terminals
F+ and F- on the regulator. Connect a
common 12 volt storage battery to the
disconnected wires keeping polarity
the same. Start up the generator set.
With the generator at rated speed, read
the voltage output of the unit on a volt-
meter. Following these steps, if the
reading is one-half or greater of the
rated output and does not fluctuate
when there is no load on the generator,
the problem is in the voltage regulator.
Consult your regulator owners’
manual for further information. If the
reading continues to fluctuate, the
problem is further on. Shut down the
generator. Reconnect the voltage
regulator. Proceed to Step 5.
Check windings for continuity. If
opens or shorts are found in the exciter
armature or stator, replace the neces-
sary component. If the condition is
found in the main generator stator or
rotor, major repair or generator re-
placement is probably required.
=k —
39
PARIS LIST
SINGLE BEARING GENERATOR PARTS LIST
NOTE: Always include the Model Number and NOTE: Complete Main Rotor Assembly consists of
Serial Number of your generator when correspond- items 7, 8, 9, 10 and 11.
ing with Marathon Electric A
Place Bolt and Hardened Washer
Drive Discs
Spacer Plates (When Used) ©
Screen, Drive End т
Drip Cover {Optional
SAE Adaptor
Drive Hub
Fan
Main Rotor Core with Winding
Bearing Cap (When Used)
Cartridge Ball Bearing
A OD OMAN —
an
O
Exciter (Rotor) Armature and Rectifier
Assembly with Winding
19. Louvered Conduit Box Cover
ВО 20. Regulator Enclosure
12. Main Stator and Frame Assembly with Winding 21. Voltage Regulator
13. Front End Bracket 22. Terminal Block
14, Conduit Box 23. Exciter Field Circuit Breaker
15. Buss Bar Assembly (When Used) 24. Regulator Panel
16. Exciter Stator Assembly with Winding 25. Fuses and Fuse Holders
17. Lead Shield 26. Voltage Adjust Rheoslat
a0
PARTS LIST
EXCITER (ROTOR) ARMATURE, STATOR AND RECTIFIER ASSEMBLY
Rectifier Mounting Torque 20-30 inch-pounds. NOTE: Diodes have distinct polarity and can not be
interchanged.
NOTE: Always include the Model Number and
Serial Number of your generator when correspond-
ing with Marathon Electric
1. Exciter Stator Assembly
with Winding
2. Exciter (Rotor) Armature &
Rectifier Assembly with Winding
Rectifier Assembly
Surge Protector
Rectifiers (Standard Polarity)
Rectifiers (Reverse Polarity)
с ль о
AA
Marathon Electric recommends the following spare
parts to minimize inconvenience. Always include
the Model Number and Serial Number of your
generator when corresponding with Marathon
Electric,
ITEM QTY. PART NUMBER _
Ё
Voltage Regulator 1
KR-4F A-505156
KR-4 FM A-510632
KR-4FFX A-511682
KR-4FFMX A-511683
KR-7F A-505308
KR-7FM A-510633
KR-7FFX A-511684
KR-7FFMX A-51 1685
Hearing 1 Refer to factory
Surge Protector 1 A-A509431-1
Rectifier (Stand- 3 A-A9589-6
ard Polarity)
Rectifier (Reverse 3 A-A96B1-2
Polarity)
Fuse 6 A-505369
Fuse Holder 2 A-505310
Voltage Adjust 1 A-508445
Rheosta!
Exciter Field
Circuit Breaker
For KR-4 Regulators 1 A-511162-1
For KR-7 Regulalors 1 A-511162-3
Exciter Assembly 1 Reter to factory
(In remote areas)
41
PARTS LIST
RECOMMENDED SPARE PARTS
Refer to factory for other voltage regulators.
Parts may be ordered direct from:
Marathon Electric Mfg. Corp.
Р.О. Вох 1407
Wausau, Wis. 54401
Phone (715) 675-3311
a
EL ELT <<
42
SHIPPING INSTRUCTIONS
SHIPPING INSTRUCTIONS
When installed, single bearing generator rotors are
supported on the drive end by the drive discs bolted
to the engine flywheel. When the engine is removed,
the rotor must be supported by an appropriate
fixture to prevent main rotor, main stator or exciter
damage (see photo). Before shipping any genera-
tor, the main rotor must be supported by the adaptor
using an appropriate fixture.
WARNING
DO NOT ATTEMPT TO TRANSPORT ANY
GENERATOR WITHOUT PROPER ROTOR
SUPPORT, OR EXTENSIVE EQUIPMENT
DAMAGE CAN OCCUR,
AMABAN
43
NOTES
1 E
®
KIMARATHON
45
NOTES
*
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CIMARATHON:
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Sales and Service Assistance
7 Y
NA
California New York Tennessee
ANAHEIM SYRACUSE NASHVILLE
625 South Euclid Suite 15 Room 173 Pickard Building 1040 Murfreesboro Road
Anaheim, CA 92802 5858 East Molloy Road Suite 207
Phone: (714) 956-7111
CASTRO VALLEY
Syracuse, NY 13211
Phone: (315) 454-0994
454-3130
Nashville, TN 37217
Phone: (615) 366-4262
20835 Chester Street, Suite B Texas
Castro Valley, CA 94546 Ohio DALLAS
Phone: (415) 889-1393 CINCINNATI 1366 Exchange Drive
1313 E. Kemper Rd., Suite 104
Richardson, TX 75081
Florida Cincinnati, OH 45246 Phone: (214) 689-0251
MIAMI Phone (513) 671-1677
Alvan C. Chaney & Assoc. HOUSTON
117 N.E. 54th St. CLEVELAND 13201 Northwest Freeway
Miami, FL 33137 20800 Center Ridge Rd-Suite 400 Suite 202, #1
Phone: (305) 754-8857
Cleveland, OH 44116
Phone: (216) 331-2910
Houston, TX 77040
Phone: (713) 462-4445
Illinois
CHICAGO Oklahoma Utah
655 Central Ave., Unit E TULSA SANDY
Wood Dale, IL 60191
Phone: (312) 350-1800
Indiana Phone: (918) 438-3391 Phone: (801) 571-4484
INDIANAPOLIS
6520 E. 82nd Street Pennsylvania Washington
Indianapolis, IN 46250 BRIDGEVILLE SPOKANE
Phone: (317) 842-4652
Louisiana
NEW ORLEANS
5622 Perrier Street
New Orleans, LA 70115
Phone: (504) 889-5426
2227 S. Garnett Road, Suite 106
Р.О. Вох 690115
Tulsa, OK 74169
Foster-McGlinton, Inc.
2867 Washington Road
Bridgeville, PA 15017
Phone: (412) 941-4800
FOGELSVILLE
55 Snowdrift Road
Fogelsville, PA 18051
E.L.. Pack & Associates
1830 East 9800 South
Sandy, UT 84092
- Electro-Power Corp.
N. 104 Madelia
P.O. Box 2983
Spokane, WA 99202
Phone: (509) 535-2931
Australia
E.A. Marr & Sons
Minnesota Phone: (215) 395-6880 32 Regent Crescent
MINNEAPOLIS Moorebank, NSW 2170
8700 West 36th Street South Carolina Australia
Minneapolis, MN 55426 GREENVILLE
Phone: (612) 935-8424 100 Executive Center Drive England
Greenville, SC 29615
Phone: (803) 288-8990
Cranfold Electrical Drives
28 Nightingales
Cranleigh, Surrey GUS 8DE
England
[CI MARATHON-
100 E. Randolph Street ™
Wausau, WI 54401 A J
Phone: (715) 675-3311 Saa
TWX: (910) 281-1521
TLX: 26-0175 ME WAS
Litho In U.S.A. SB 187 1/85
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