Cummins Onan DFAA NT4, DFAB NT4, DFAC NT4, DFBC NT5, DFBD NT5, DFBE NT6, DFBF NT6, DFCB NTA2, DFCC NTA2, DFEB KTA12, DFEC KTA12, DFFA KTT11, DFFB KTT12, DFGA VTA1, DFGB VTA2, DFGC VTA3, DFJA KTA31, DFJB KTA32, DFJC KTA33, DFJD KTA51, DFLA KTA52, DFLB KTA53, DFLC KTA54, DFLD KTT51 Service manual

c

Service Manual

GenSet

Models:

DFAA

DFAB

DFAC c

· · • .i;;

DFBC NT4

DFBD NT4

DFBE NT5

DFBF NT6

DFCB NTA2

DFCC NTA3

DFEB KTA12

DFEC

DFFA KTI11

DFFB KTI12

GENERATOR AND CONTROL

DFGA VTA1

DFGB VTA2

DFGC VTA3

DFJA KTA31

DFJB KTA32

DFJC KTA33

DFJD

DFLA KTA51

DFLB KTA52

. ElectricalPartManuals

DFMB KTT52

Printed U.S.A.

·c www

960-0504

. com

4-93

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1

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I

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Contents

SECTION TITLE

1

SAFETY PRECAUTIONS

INTRODUCTION

About this Manual .......

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Te st ECJ,Iiprnert . . .. . .. ....... .. . . . .. . . . . .. . . .. .. . ........ .. . . . .. . . . . .. ... . ..... .. . . . . .. . . . ... . ........ ...... .... ... . . . . ........... .. . .. ... . . . .. ...... 1-1

How to C>btain Service . . .. . . ..... .. ............. .. . . . . .. . ......... .. . . . .. . . .. .. . . .. .. . . ........ .. . . . . .. . . .. .. . . . . .. . ..... ... .. .. .. .. . ....... .... 1 -1

Cortrols and Generators Ove rview ..................................................................................................... 1-2

2

3

CONTROLS

General ..................................................................................................... .............................................. 2-1

Control Descriptions

.

. .. . . . . .. .. . . ... .. ... . .. . .. . . . .. . . . ... . .. ... . . . . .. . . . . .. . ........ ...... .. . . .. .. . . . .. .. . . .. . . . . .. . .. . .. ... . .. ......... ... . . ... 2-1

Control Panel Interior ............

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2-3

Ge nSet ()peration ...... ........................................................................... ......... ................... ..................... 2-6

GENERATOR

Gene rator De scriptions . . .. . . . ....... ...... .. . . . . .. .. .. .. . . . .. . . . . .. . . .. .. .. . . ... . . . .. . . . . .. . . . .. . . . . ... . . . .. . . ........ ...... .. . . . .. . . ...... .... 3-1

Generator Control Co l11l0nents ....................................

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3-2

Generator ()peration ............................................................................................................................. 3-3

Optional C ira.Jit Breaker .................. .................. .................. .................. ............................. ................... 3-4

TROUBLESHOOTING 4

5

6

General

...................................................................................................................................................

COMPONENT TESTS AND ADJUSTMENTS

4-1

General ....................................................................................... ............................................................ 5-1

Control Components

Engine Cortrol M oritor (ECM) ............................................................................................................. 5-1

Run Rel ay ....................................................................................................... ........................................ 5-3

Interface Relay Mock.des ...............

lime Delay StarVStop M odule .

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............. ............. ................. ................................................. 5-5

AC Meters and Current Transformers ................................................................................................. 5-5

Generator Components

Automatic Vol tage R egulator................................................................................................................

Generator ()peration Review ...

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5-6

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Over/Under Voltage Sensor M odule.................................................................................................. 5-10

Over/Under Frequency Sensor M od.lle. ......................................... .................................... ............... 5-10

Overspeed (FreCJ,�e ncy Detection) M odule ..................

.

............... ..................................................... 5-10

Rotating Rectifier Asse nt>ly .. ... . . ... . . . . .. . . . . ... . . . .. . . . . .. ... . .. . . . . . . . . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . . .. . . . .. . . . ... . . . . ... . . ... . . . . .. 5-1 1

Pe rma nent M agnet E xdter ............ .. ............. .......................... ..................... ....................................... 5-1 1

E xdter Rotor ...... ....................... ............................. ............ ......... ............ ... .......... ................................ 5-1 2

E xdter Stator . . .. . . . . .. . .. . .. . . . . . ... ... . . . . .. . .. ...... .. . . . . .. . . . .. . . . . .. . . . . ... . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. 5-1 2

Ge nerator Rotor................................................................................................................................... 5-1 2

Ge nerator Stator .

Reconnection

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Engine Components

Electro nic Governor............................................................................................................................. 5-1 6

Batteries

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...... .................. .......... .. ....... ........ ........... ......... .......... ....... .......... ....... .. . ............... ................... 5-1 7

Batte ry Cables . . .. . . . . .. . . . . .. . . . . . . . . . . .. . . . . .. . . . .. . . . . .. . . . . ... . . . .. . . . . .. . . . . . . . . . . .. . . . .. . . . . . . . . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . . . .. . . .. 5-1 7

Alternator ...........

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................................................................... 5-18

Starter Solenoid . . . . . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . . . . . . . .. . . . .. . . . . .. . . . . . . . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . . . . . . .. . . . . .. . . . . .. . . . . . . . . . .. . . . . .. 5-18


GENERATOR DISASSEMBLY/REASSEMBLY

Generator Disassembly ......................................................................................................................... 6-1

Generator Reasse nt>ly ........ .. .......... .. .......... .. ......... ...... ........... ....... .. . .. .. . . . ... .. . . .. .......... .. .. .. .. ..... .......... .. 6-7

WIRING DIAGRAMS/SCHEMATICS

•.•.••••...•.•••••••...•.•••....•••••....••••.•...••.....•••••...•••

Refer to Section Usti ng 7 www

Safety Precautions

Before operating the generator set,

read the Op erator's Manual and become familiar with it and the equipment.

Safe and efficient operation can be achieved only If the equipment Is properly oper ated and maintained.

Many accidents are caused by failure to follow fundamental rules and precau tions.

• valve.

•

Do not smoke while servicing lead acid batter ies. Lead acid batteries emit a highly explosive hydrogen gas that can be ignited by electrical arcing or by smoking.

EXHAUST GASES ARE DEADLY

The following symbols, found throughout this man ual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment. t!'J•t!UM#!;I

This symbol warns of Immediate hazards which will result In severe persona/In jury or death.

•

Provide an adequate exhaust system to prop erly expel discharged gases away from en closed or sheltered areas and areas where in dividuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Ensure that ex haust manifolds are secured and not warped.

Do not use exhaust gases to heat a compart ment. lAWARNINGlTh/s symbol refers to a hazard or un safe practice which can result In severe per sonal injury or death.

•

Be sure the unit is well ventilated. lA CAUTION

I

This symbol refers to a hazard or un safe practice which can result In persona/Injury or product or property damage.

MOVING PARTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH

•

Keep your hands, clothing, and jewelry away from moving parts.

FUEL AND FUMES ARE FLAMMABLE

Fire, explosion, and personal injury or death can re sult from improper practices.

•

•

•

DO NOT fill fuel tanks while engine is running, unless tanks are outside the engine compart ment. Fuel contact with hot engine or exhaust is a potential fire hazard.

•

•

Before starting work on the generator set, dis connect starting batteries, negative (

-

) cable first. This will prevent accidental starting.

Make sure that fasteners on the generator set are secure. Tighten supports and clamps, keep guards in position over fans, drive belts, etc.

•

Do not wear loose clothing or jewelry in the vi

DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank. cinity of moving parts, or while working on elec trical equipment. Loose clothing and jewelry can become caught in moving parts. Jewelry

Fuel lines must be adequately secured and can short out electrical contacts and cause free of leaks. Fuel connection at the engine shock or burning. should be made with an approved flexible line.

Do not use copper piping on flexible lines as

•

If adjustment must be made while the unit is

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•

GENERAL SAFETY PRECAUTIONS

ELECTRICAL SHOCK CAN CAUSE

SEVERE PERSONAL INJURY OR DEATH

•

Remove electric power before removing pro tective shields or touching electrical equip ment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment.

Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment.

•

•

Coolants under pressure have a higher boiling bleed the system pressure first.

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Benzene and lead, found in some gasoline, have been identified by some state and federal

•

Use extreme caution when working on electri agencies as causing cancer or reproductive toxicity. When checking, draining or adding cal components. High voltages can cause in jury or death. DO NOT tamper with interlocks.

•

Follow all applicable state and local electrical codes. Have all electrical installations per formed by a qualified licensed electrician. Tag open switches to avoid accidental closure.

• gasoline, take care not to ingest, breathe the fumes, or contact gasoline.

Used engine oils have been identified by some state or federal agencies as causing cancer or

•

DO NOT CONNECT GENERATOR SET DI

RECTLY TO ANY BUILDING ELECTRICAL

SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This cre ates a potential tor electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling de vice.

• reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or contact used oil.

Provide appropriate fire extinguishers and in stall them in convenient locations. Consult the local fire department tor the correct type of ex tinguisher to use. Do not use foam on electri

•

• cal fires. Use extinguishers rated ABC by

NFPA.

HIGH VOLTAGE GENERATOR SETS

(1.9kV

to

15kV)

•

Make sure that rags are not left on or near the

High voltage acts differently than low voltage.

• engine.

Remove all unnecessary grease and oil from

Special equipment and training is required to work on or around high voltage equipment.

Operation and maintenance must be done only by persons trained and qualified to work on such devices. Improper use or procedures will result in severe personal injury or death. the unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard.

•

Keep the generator set and the surrounding

Do not work on energized equipment. Un area clean and tree from obstructions. Re authorized personnel must not be permitted move any debris from the set and keep the near energized equipment. Due to the nature floor clean and dry. of high voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the

•

Do not work on this equipment when mentally


KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE www iii

LS-10

. com www

. ElectricalPartManuals r

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Section

1.

Introduction

ABOUT n-tiS MANUAL

This manual provides troubleshooting and repair informa tion regarding the controls and generators used on the following generator sets.

GENERATOR SET

MODEL

DESIGNATIONS

DFAA

DFAB

DFAC

KW RATING

50Hz 60Hz

1 75

200

220

200

230

250 propriate Parts Manual supptied with urit.

Repair of printed circuit board components other than fuses requires well-trained, quatified personnel with the proper equipment; repair of the printed circuit boards is not recorrmencled except by the factory. Applcation of meters or hot soldering irons to printed circuit boards by other than qualified personnel can cause unnecessary and expensive damage.

DFBC

DFBD

DFBD

DFBE

DFBF

DFCB

DFCC

NT4

NT4

NT4

NT5

NT6

NTA2

NTA3

1 75

1 75

200

220

250

275

31 0

200

200

230

250

275

300

350

I

A CAUTION

I

High voltage testing or high potential (or Megger) testing of generator windings can cause damage to solid state components. Isolate these components before testing.

For any operation, maintenance, or troubleshoodng Information beyond 1he scope of this manual, refer to oth• manuals received with unit, or contact your distributor.

DFEB

DFEC

DFFA

DFFB

DFGA

DFGB

DFGC

KTA1 2

KTT1 1

KTT1 2

VTA1

VTA2

VTA3

330

400

400

450

440

550

400

450

450

500

500

600

TEST EQUIPMENT

Most of the test procedures in this marual can be per formed with an AC-DC rrultimeter such as a Sifi1)SOn

Model 260 VOM or a digital VOM.

Some other instruments to h ave available are:

•

•

•

•

•

•

•

Battery Hydrometer

Tachometer or Frequency Meter

Jurf1)9r Leads

Wheatstone Bridge or Digital Ohmmeter

Variac

Load Test Panel

Megger or Insulation Resistance Meter

DFJA

DFJB

DFJC

DFJD

KTA31

KTA32

KTA33

620

660

800

900

750

800

900

1 000

DFLA

DFLB

DFLC

DFLD

DFMA

DFMB

KTA51

KTA52

900 1 000

1 1 00

KTA53

KTA54

KTT51

KTT52

1 1 20

1 200

1 1 00

1 280

1 250

1 250

1 500

HOW TO OBTAIN SERVICE

!Wiays give the complete Model and Serial number of the generator set as shown on the nameplate when seeking additional service information or replacement parts. The nameplate is located on the side of the generator output box.

For further operation, service, and troubleshooting infor mation regarding engine components, refer to support manuals specific to your generator set.

Study this manual carefully and observe all warnings and cautions.

Be sure to review Safety Precautions. on pages ii and iii. Using the generator set properly and following a www

1-1

I

&WARNING

I

Incorrect service or replacement of parts can result In severe personal Injury or death, and/or equipment damage. Service personnel must be qualified to perfonn electrical and mechanical service. Read and follow Safety Precautions, on pages II and Ill.

CONTROLS AND GENERATORS

OVERVIEW

General

Depending on customer order, the control options and generator type may differ. Read through this manual to identify the control options, and generator type. A more in depth description of the control and generator compo nents follow in the Controls and Generator sections.

Read this information well and understand the function of each component.

Also, periodically review this manual and the unit

Operator's Manual when no fault condition is present. You will want to become familiar with the generator set com ponent locations, their proper operation and interaction with other components in order to be effective trou bleshooting a fault condition, if one occurs.

Control Panel

The control panel is mounted inside the front portion of the generator output box with vibration isolators on both top and bottom. The controls are separated into a DC panel for monitoring the engine and an AC panel for monitoring the generator. See Figure 1 -1 and Section 2.

Generator

. com

The generators fitted to this series of generator sets are a Permanent Magnet Generator (PMG) type.

The generators are controlled by an Automatic Voltage

Regulator (AVR). The AVR is mounted on the inside, back wall of the control panel. See Figure1 -1 and Section 3.

@) l!J[!J

PMG

VOLTAGE

REGULATORS

C===:J

�

[3

§ t=121!...!:::::=�-_____.!@J:u

OTHER GENERATOR

CONTROL COMPONENTS

(i.e.,

OVER/UNDER

VOLTAGE AND FREQUENCY

MODULE� ARE LOCATED

INSIDE CONDUIT BOX.

REFER TO SECTION

3.

VOLTAGE REGULATOR

(LOCATED INSIDE

CONTROL PANEL).

REFER TO SECTION

3.

CONTROL PANEL

{REFER TO SECTION 2)

AC METERING

REFER TO SECTION 2.


PMG

EXCITER

HOUSING

COVE R

PLATE

(FOR ACCESS TO ROTATING

RECTIFIER ASSEMBLY) www

FIGURE 1-1 . TYPICAL PUG GENERATOR AND CONTROLS

1-2

..

Section

2.

Controls

GENERAL

Depending on rustomer order, the control configuration and options may differ. This section identifies the control config.uations used; Detector-7 and Detector-12 (NFPA)

DC Panel, and AC Panel options.

The control panels are separated into an AC panel for monitoring the generator

(if equipped with meter options), and a DC panel for monitoring the engine. Review F�gure

2-1 to identify the control configuration and options, and refer to Control Descriptions that follow for further infor mation.

AC Ammeter (Optional): Dual range instrument indi cates AC generator fine current. Measurement range in use shown on indcator la"l>5.

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Frequency/RPM Meter (Optional): lndcates generator output frequency in hertz and engine speed in revolu tions-per-minute (RPM).

Wattmeter (Optional): Continuously gives readng of the generator output in kilowatts.

Voltage Adjust (Optional): Rheostat providng approxi mately plus or minus five percent adjustment of the rated output voltage.

CONTROL DESCRIPTIONS

AC Panel

The following describes the function and operation of the optional AC panel for monitoring the generator. Review the following component descriptions and Figure 2-1 .

Upper and Lower

Scale

Indicator Lamps (Optional):

Indicates which scale to use on the AC voltmeter and AC ammeter.

Phase Selector Switch (Optional): Selects phases of generator output to be measured by AC voltmeter and AC ammeter.

AC Voltmeter (Optional): Dual range instrument indicat ing generator AC voltage. Measurement range in use shown on indicator la"l>5.

Field Bteaker: Provides generator exciter and regulator protection from overheating in the event of an overvoltage faul condtion.

01.. PI£SSURE

GAUGE

RUN-STOP-REMOTE

SWITCH

PANEL

LAMP

RESET, J_AY) TEST,

PAtEL J_AY)

SWITCH

AC

VOLTMETER

INDICATOR

LAMPS

\

---��-lr--r--

COOlANT

TEMPERATURE

GAUGE

AC

AMMETER

PHASE

SELECTOR

SWITCH

FREQUENCY/RPM

METER

WATIMETER

OTHER

OPTIONAL

METERS www

METER


RI.JN.IING TM:

TACHOMETER

AC PANEL

DC PANEL

FIGURE 2·1.

CONTR

OLS

(DETECTOR-12 AND

AC

METER

OPl10NS

SHOWN)

2-1

OR.. TEMPERATURE

GAUGE

ES-181111-1

DC Panel

The following describes the function and operation of the

DC panel components. The Detector-? panel is standard, and Detector-1 2 panel includes options to more effec tively monitor the generator set and ancillary equipment during operation. Both controls include pre-alarm moni toring to infonn the operator that a shutdown might occur if attention is not given to an aspect of engine operation soon. Review the following component descriptions and

Figure 2-1 .

Panel Lamp: Illuminates control panel.

The green Run lamp comes on as soon as both primary and secondary starter circuits are opened after unit starts.

The yellow pre-alarm lamps indicate that engine oil pres sure is marginally low, or coolant temperature is margin ally high, and should be attended to when the generator set is shut down. The red fault lamps indicate a shutdown of the generator set for low oil pressure, high engine tem perature, overspeed, or overcrank fault condition.

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Detector-12 Control {Optional): The optional control panel has a 1 2 lamp monitoring system. The following de scribes each lamp function.

'

•

RUN (green) lamp comes on when both starter circuits are opened after unit starts.

Oil Pressure Gauge: Indicates pressure of lubricating oil in engine (wired to a sensor unit located on the engine).

•

PRE LO OIL PRES (yellow) indicates engine oil pres sure is marginally low.

Water Temperature Gauge: Indicates temperature of circulating coolant in engine (wired to a sensor unit located on the engine) .

•

PRE HI ENG TEMP (yellow) indicates engine temper ature is marginally high.

DC Voltmeter: Indicates the battery condition. Proper reading should be approximately 26 to 28 volts when set is running.

•

LO OIL PRES (red) indicates engine has shut down because of critically low oil pressure.

Tachometer(Optlonal}: Provides constant monitoring of engine r/min.

•

HI ENG TEMP (red) indicates engine has shut down because of critically high temperature.

Oil Temperature Gauge (Optional): Indicates tempera ture of lubricating oil in engine (wired to a sensor unit located on the engine) .

•

OVERSPEED (red) indicates engine has shut down be cause of excessive speed.

•

OVERCRANK (red) indicates the starter has been locked out because of excessive cranking time.

Run-Stop-Remote Switch: Starts and stops the unit locally, or from a remote location that is wired to the control engine monitor board.

•

FAULT 1 (red) an undedicated fault. May be program med as a timed or non-timed shutdown or fault light only

(normally factory set for timed shutdown).

Reset, Lamp Test, Panel Lamp Switch: Resets the fault circuit only when the Run-Stop-Remote switch is in the

Stop (Reset) position. Tests fault lamps and turns on the control panel lamp.

•

FAULT

2

(red) same features as Fault 1 (nonnally factory set for non-timed shutdown).

Frequency Adjust (Optional): Potentiometer providing engine speed adjustment to achieve proper AC fre quency.

Running Time Meter: Registers the total number of hours the unit has run. Use it to keep a record of periodic servicing. Time is cumulative; meter cannot be reset.

•

LOW ENG TEMP (yellow) engine temperature is mar ginally low for starting. Indicates possible inoperative coolant heater. Lamp lights when engine water jacket temperature is 70° F (21 o C) or lower. The lamp may stay on during initial generator set operation, but should go out after the engine warms up.

Emergency Stop Pushbutton (Optional): Stops the generator set immediately when depressed. Must be

Indicator Lamps


Detector-7 Control (Standard): The standard control panel has seven monitor system indicator lamps.

•

•

LO FUEL (yellow) indicates fuel supply is marginally low

(if equipped).

SWITCH OFF (flashing red) indicates generator set is not in automatic start operation mode.

•

•

•

•

•

•

•

RUN (green)

PRE LO OIL PRES (yellow)

PRE HI ENG TEMP (yellow) www

2-2

CONTROL PANEL INTERIOR

Refer to Figure 2-2 for component locations inside control panel. Review the following component descriptions to better understand the operation of the generator set should a fault condition occur. Also refer to Section 5,

Component Tests and Adjustments, for more in-depth information about these components.

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TERMINAL

BOARDTB21

AUTOMATIC VOLTAGE

REGULATOR (AVR)

VR21

(SEE SECTION 3)

ENGINE CONTRa.

MONITOR (ECM)

A11

TIM: DELAYED

START/STOP

MODULE

A15

OVERS PEED

(FREQUENCY DETECTDI)

MODULE

ACPANEL

DC PANEL

(]

FIGURE 2·2. CONTROL PANEL INTERIOR www


2-3

•

•

•

•

•

Fuses:

The ECM has five replaceable fuses to protect it from overloads and ground fautts. They are:

Engine Control Monitor

This circuit board assembly oontains the basic OOillJO nents for normal engine start-up and shutdown, terninals for remote oontrol interoonnection, plug-in oonnectors for option modules and engine sensor i'l'l)ts. The ECM provides the following functions of unit protection:

Overcrank - Umits engine cranking to 75 seoonds. H engine fails to start, the module lights a fautt lamp and opens the cranking circuit. This cycle cranking circuit al lows three 1 5-seoond cranking cycles with two 1 5-sec ond rest periods.

Overspeed - Shuts down the engine immediately if an overspeed oondition occurs and lights a fautt lamp. The generator sets are equipped with an overspeed (fre quency detection) module, inside the oontrol panel. The module is factory set to shut down the generator set at approximately 21 00 r/rnin (60 Hz units), or 1 850 r/min

(50 Hz units). Refer to Component Tests and Adjust ments section for further information.

F1

F2

F3

F4

FS

Starter solenoid circuit, 20 amps

Fuel solenoid (switched B+) circuits, 20 amps

ECM circuits, 5 amps

Engine guage circuits, 5 amps.

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Function Selection

Jumpers: The ECM has six selec tion jumpers that can be repositioned to provide the following timed or non-timed warnings or timed or non timed shutdowns with warnings:

W1 Jumper Position ijurrper W8 must be in the B posi tion):

A

B

C

D

W2 Jumper Position ijumper W9 must be in the B posi tion):

A

B

Non-timed warning under FLT 2 oonditions.

Non-timed shutdown and warning under FLT 2 conditions.

Timed warning under FL T 2 oonditions.

Timed shutdown and warning under FL T 2 oon ditions.

Low Oil Pressure - Shuts down the engine immediately if oil pressure drops below 1 4 psi (97 kPa) and fights a fautt lamp. The fautt is inhibited during cranking and time delayed about 1 0 seoonds following starter disoon nect. The delay allows oil pressure to rise to normal before the electronic oontrol module monitors this system.

The pre-low oil pressure sensor and lamp provides an alarm that oil pressure is marginally low, 20 psi (1 38 kPa) or less. The cause should be found and oorrected as soon as possible.

C

D

Non-timed warning under FL T 1 oonditions.

Non-timed shutdown and warning under FLT conditions.

Timed warning under FL T 1 oonditions.

Timed shutdown and warning under FL T 1 oon ditions.

1

W6 Jumper Position:

High Engine Terrperature - Shuts down the engine immediately if coolant terrperature rises above 21 5° F

(1 02° C) and lights a fautt lamp. The fautt is inhibited during cranking and time delayed about 10 seconds fol lowing starter disconnect. This delay allows coolant in a hot engine time to circulate and return the water jacket to normal before the electronic control module resumes monitoring this system.

W7

A

B

Warning under Pre-High Engine Temperature conditions.

Shutdown and warring under Pre-High Engine

Temperature oonditions.

Jumper Position:

A

The pre-high engine temperature sensor and lamp pro

B

Warning under Pre-Low

011

Pressure oonci tions.

Shutdown and warning under Pre-Low Oil Pres vides an alarm that engine terrperature is marginally sure oonditions.

I high, 205° F (97° C) or higher. The cause should be found and oorrected as soon as possible.

A CAUTION

down

system

will

N

the

coolant

level

Is

too low. The high engine

temperatute

sensor monitors

coolant

t

em peratute. Loss

of

coolant

will

prevent sensor

TJJerefote,

I

T1Je not

high engine

tempetatute

operate

operation

and allow

the

engine to ovelheat causing severe

damage

to

the

engine. maintain adequate

coolant

level

to en

W8 Jumper Position:

A


A

B

Warning during standby under FL T 2 oonditions.

Allows selection of functions with W1 jumper.

Warning during standby under FL T 1 oonditions.

Allows selection of functions with W2 jumper. sure

the operation of the high engine

tempetatute

shutdown

system.

The ECM also has solder finks and rectifiers that can be repositioned to provide other functions such as: negative signal mode, 1

OS second cycle cranking, 75 seoond non cycle cranking and 60 seoond non-cycle cranking.

Low Coolant Level Shutdown (Optional) - A soHd-state sensor installed into the radiator provides engine shut engine temperature fautt lamp.

2-4

0

O

TBI

P]"";"

/ lJIII oc 115

... LO

_, '"""

1

6 s 4P2

3

2

1 r--

RGURE 2-3. ENGitE CONTROL MONITOR (DETECTOR 12 ECM SHOWN) www


2-5

0

I -

2

. com

Run

Relay(s) (K11)

This relay (may be up to three) provides wiring connec tions for external functions of the site installation that are to be controlled by the starting and/or stopping of the generator set such as ventilation air louvers, blowers, etc.

The sets of contacts in the relay base provide for either closing a circuit or opening a drcuit upon energizing and de-energizing the relay (depending on the desired func tion wires to the base connections). The relay is energized when the generator set run circuitry is energized (ie., fuel solenoid) when connected to the ECM at TB1 -1 0

(switched B+ connection).

GENSET OPERATION

Because of varying control option combinations, the fol lowing operating descriptions will encorrpass a Detector-

1 2 controller with full options. Read the information through to Emergency Shutdown to gain a full under standing of the options and how they interact with the engine control monitor (ECM).

Regardless of the controller model you have, the ECM in cludes the shutdown fault commands. Controllers with options provide delineation and pre-alarm of the shut down faults, time delayed starting and stopping, and additional monitoring/control, but all engine operation commands through these options are still controlled through the ECM.

Interface Relay Modules (A 13, A 14)

These relay modules are used in conjunction with the

Detector ECM's to provide external monitoring of the en gine-generator at customers control panel. As add-on circuit boards, they interface with the remote annunciator signals from the ECM and allow the use of either AC or DC for alarm drives. The relays are configured for low side switching by the control and supply sets of contacts for external alarm connections.

Current Transformers (Not shown)

All units equipped with AC meters have current transform ers installed inside the conduit box through which the cus tomer can route the load leads.

If you are reviewing this operation information for trou bleshooting purposes, make sure you have elininated all other malfunction checks external of the controls prior to troubleshooting the printed drcuit board type compo nents of the controller. Also review the Generator section for generator related control components and Corrpo nent Tests and Adjustments section for more in-depth information. Refer to appropriate DC Schematic - Ladder

Diagram in Wiring Diagrams section when reviewing the following information.

Automatic Voltage Regulator (VR21)

Refer to section 3 for more information.

Starting Sequence

Manual:

The starting sequence is initiated by placing the

Run/Stop/Remote switch (S1 2) in the Run position.

Overspeed (Frequency Detection) Module

This rnc::KiJie derives a speed

(Hz) signal from the PMG, but is powered from the generator set battery. A small time delay, typically one second, is incorporated in the over speed function to allow for engine overshoot. The module contains two adjustable potentiometers, Overspeed and

Crari<ing (the cranking potentiometer is not used how ever). Refer to Section 5 for more information.

Placing switch S1 2 in the Run position energizes the ECM

Run Relay

(1<7).

By energizing K7, B+ is supplied through the electrical circuits of the ECM to energize the engine run circuits (i.e., fuel solenoid) and front panel gauges and the starter solenoid (through K3).

Tlme Delayed Start/Stop Module (A15)

2-6

The engine cranking period is detemined by the Over crank Timer and Cycle Crank Driver (U1 ). and the Cycle

Crank Relay (K1 2), which control energizing and de energizing the Power Relays K2 and K3 that supply cur rent to the on-set starter and fuel solenoids.

This module provides time delays for starting and stop ping the generator set as follows:

Delayed Stanlng:

The time delay start function is to preclude automatic start-up of the generator set for a de temined amount of time (adjustable from 1 to 1 5 sec onds) for installations that night experience power inter ruptions of short duration, and therefore not want the gen erator set starting.

Delayed Stopping:

Upon completion of the ti me delay start period, the ECM

. ElectricalPartManuals time (approximately 3 to 5 ninutes is

Control cabinet Heater recommended).

Automatic: Wrth the Run/Stop/Remote switch (S1 2) in

Remote position, a remote start command (closure of on site, dry contacts) to the generator set controller

(A1 5), which initiates its time delay start period.

(B+ to remote) activates the Time Delayed Start/Stop Module the ECM 'Nill activate the Start Disconnect Relay of mod ule A1 5 (K1) which enables the module for Time Delayed

Stop mode. as described in manual start-up.

A control cabinet heater provides a means of hunidity/ temperature control of the control box interior to protect the COJ"ll)Onents and assist their effectiveness when the www of non-use. The element is con trolled by an adjustable thermostat.

During generator set operation, all safety systems func tion to protect and monitor set operation.

At end of the generator set duty cycle, when generator output is discon nected from load and the remote run signal is discontin ued, the time delayed stop function of module A15 will continue the engine-generator run time for the prescribed engine cool-down period of 3 to 5 rrinutes before deacti vating the run circuits of the ECM.

After the starter disconnects, the LOP and HET fault shutdowns will remain inhibited for another 1 0 seconds to allow oil pressure and engine temperature to stabilize within the operating range.

Normal Operating Parameters

Starter-Disconnect Parameters

This type of control uses two means of starter-disconnect in order to protect the starter in the case one means should fail. The first uses a DC relay (K14); a

B+ signal taken from the battery charging alternator in most cases energizes the relay to disconnect the starter. The second method uses an AC relay (K10); voltage from the genera tor energizes this relay to provide a back-up to the DC relay. The control uses this method to provide uninter rupted generator set operation even if only one means of start disconnect is operational. However, the local Run lamp does not Hght unless both start disconnect relays operate. H the generator set is equipped with a remote

Run lamp, the operator can then deterrrine which means of start disconnect has failed for such an occurrence. H the remote Run lamp lights (and the local Run lamp does not), the DC relay is not functioning. satisfied, the engine will gain in speed to governor con trolled operation. Should the engine go into an overspeed condition, either an Over/Under Frequency Sensor, an

Overspeed Module, or a mecharical overspeed switch

(depending on generator type and options ordered) will ground the overspeed input circuit to the ECM to cause a shutdown and fight the Overspeed fault lamp. After the problem is corrected, starting will not occur until the Reset switch is pressed.

Continuous operation of the generator set also depends on the proper oil pressure and engine temperature being maintained, and also any customer required fault condi tions connected to the ECM.

Stopping Sequence

Placing the Run/Stop/Remote switch to the Stop position de-energizes Run Relay (K7) which opens the current supply through the ECM (K2) to de-energize the genera tor set mounted fuel solenoid (stops fuel flow which stops the engine).

High Engine Temperature (HET) and Low Oil Pressure

(LOP) faults are time delayed about

10 seconds following starter disconnect and inhibited during cranking. This allows the coolant in a hot engine some time to circulate and return the water jacket to normal temperature before the ECM begins to monitor this parameter. It also allows the oil pressure to build to normal before monitoring this system. Following this delay, these faults beoome imme diate shutdowns for engine protection.

H conditions are correct, the engine will start and the starter will disconnect. H not, an overcrank fault occurs by

U1 having cycled/timed out through drive transistor U4 to energize Fault Relay K6, which opens the start drcuit of the ECM. The Reset switch (S1 1) must be pushed to clear the fault before attempting to restart.

Emergency Shutdown

The K6 fault relay is energized when fault sensors re spond to one of the following fault conditions: overcrank, low oil pressure, high engine temperature, overspeed, and over/under voltage/frequency

(if equipped). Energiz ing the K6 fault relay opens its N.C. contacts and closes its N.O. contacts. Opening the N.C. contacts cisconnects

B+ from the Power Relays K3 and K2. This stops crali<ing if the engine is being cranked and shuts off the fuel flow.

Closing one of the N.O. contacts of K6 activates the K8 relay which breaks power to the fault interface relays so that only the indicator associated with the fault will acti vate. Closing the other N.O. contacts of K6 connects to the remote alann tenninal.

B+

Start-Disconnect Sequence

When the generator set starts, output voltage from the DC alternator energizes Start-Disconnect relay K14. Energiz ing K14 then closes its N.O. contacts which lights the control panel Run lamp. Also, when the generator set starts, output voltage from the generator stator energizes

Starter-Disconnect relay K1 0. Energizing K10 then closes its N.O. contacts equipped).

. ElectricalPartManuals www

2-7

www


. com

..

Section

3.

Generator

GENERATOR DESCRIPTIONS

The AC generators are brush less, rotating field type, con trolled by an automatic voltage regulator (AVA). Perma nent magnet exciter (PMG) types are used in these series of generator sets. The AVA of these generator sets is powered by the permanent magnet pilot exciter which provides a source of constant excitation power, independ ent of load changes or load current distortions. nally to the non-drive-end bearing, while the permanent magnet exciter is overhung from the non-drive-end bear ing.

Removable access covers are provided at each end of the generators and on each side of the conduit box for cleaning and inspection, and easy access to the output terminals and other ancillary equipment. See Rgures

3-1 and 3-2.

EXCITER

STATOR

END BEARING

BLOWER

COUPLING

ROTOR

ROTATING

RECTIFIER

ASSEMBLY

ENDBRACKETIENGINE

ADAPTOR


FIGURE 3-1. TYPICAL PMG GENERATOR www

3-1

RllG-1115

GENERATOR CONTROL COMPONENTS

The following briefly describes generator related control components that affect the proper operation or shutdown of the generator set. See Figure

3-2 for component locations.

Automatic Voltage Regulator (AVR)

The AVR is mounted on the inside back wall of the control box. Refer to Generator Operation following for further

AVR operation information, and to Component Tests and

Adjustments section for further description and adjust ment procedure of the AVA.

Over/Under Voltage Sensor Module

This is an adjustable voHage-sensitive relay typically connected to the Engine Control Monitor (ECM) Fault 1 circuit to shut down the generator set when the output voHage is over or under the nominal voltage by the preselected amount (typically

1 0 percent). The module in cludes an adjustable time delay relay to prevent nuisance tripping (typically set at 25 percent, or approximately 2.5 seconds). The module and time delay relay are mounted on a bracket in the generator conduit box.

Over/Under Frequency Sensor Module

. com connected to the Engine Control Monitor (ECM) Fault 2 circuit if the Over/Under Voltage module is also installed, or Fault 1 for overfrequency and Fault 2 for underfre quency if installed alone, to shut down the generator set

' when the output frequency is over or under the nominal frequency by the preselected amount. (Also, Fault

2 must be converted for timed shutdown.) The module is mounted on a bracket in the generator conduit box.

OR

PMG

VOLTAGE

REGULATORS

@]

(�](!]

VOlTAGE REGULATOR

IS lOCATED INSIDE

CONTROL PANEl, AND

AUXIliARY TERMINAl

BOARD IS lOCATED INSIDE

CONDUIT BOX.

CONTROL PANEl

(REFER TO SECTION 2)

OPTIONAL GENERATOR

CONTROL COMPONENTS

(i.e., OVER/UNDER

VOLTAGE AND FREQUENCY

MODUlES) ARE lOCATED

INSIDE CONDUIT BOX.

OPTIONAL

CIRCUIT BREAKER

(NOT SHOWN)

IS MOUNTED

AC METERING

CURRENT TRANSFORMERS

(lOCATED INSIDE CONDUIT BOX.)

REFER TO SECTION 2.


ON SIDE

OF

CONDUIT BOX.

COVER PLATE

(FOR ACCESS

TO ROTATING

RECTIFIER ASSEMBlY) www

FIGURE 3-2. GENERATOR CONTROL COMPONENT LOCATIONS

3-2

GENERATOR OPERATION

A permanent magnet generator exciter (PMG), mounted to the end of the main rotor shaft, provides power by way of the AVA to the main exciter stator. Excitation power is therefore independent of output voltage, resulting in positive voltage build-up, without reliance on residual magnetism. The main exciter stator mounts in the end bell, the main exciter rotor and its rotating rectifier assem bly mount on the rotor shaft. Within the end bell, leads X

(+, positive) and XX (-, negative) from the exciter stator winding, connect to the output terminals of the voltage regulator (at auxiliary terminal block). The AVA compares the main stator output with a reference value and feeds a controlled excitation current to the main exciter stator.

The AC output of the main exciter rotor is converted to DC by the rectifier assembly, comprised of six diodes mounted on two heatsinks to form positive and negative plates. The diodes ar voltages e protected against harmful over

(caused for example, by switching circuits or out�f-phase paralleling) by a metal�xide varistor the excitation onto the main rotor.

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AUTOIMTIC

VOLTAGE

REGU..ATOR

MAlt

STATOR

PERMANENT

EXCITER

MAGNET

STATOR

STATOR

---t------t-D�I --�------1

PERMANENT

MAGNET

ROTOR

EXCITOR

ROTOR

MA ...

ROTOR

RGURE 3-3. GENERATOR OPERA110N DIAGRAM


3-3

OPTIONAL CIRCUIT BREAKER

Depending on site specifications and applicable code requirements, an optional circuit breaker may be mounted in the generator AC output box.

Description

All supplied breakers are thermal and magnetic trip type.

Depending on customer requirements, the breaker _ may also include shunt trip and remote alarm connections.

Review the following functions/requirements and Figure

3-4.

•

Generator set output is connected to the load through the circuit breaker.

•

When an overload or short circuit occurs on any one conductor, a common trip bar will disconnect all three conductors.

•

The thermal trip action of the breaker is accomplished by bimetal strips. A sustained ove�current con

� ition will cause a thermal reaction of the b1metal and tnp the breaker. Response of the bimetal is proportional to current; high current-fast response, low current-slow response. This action provides a time delay_f�r normal inrush current and temporary overload cond1t1ons such as motor starting.

• electromagnet, which partially surrounds t

� e mternal bimetal strips. If a short circuit occurs, the h1gh current through the electromagnet will attract the bimetal armatu re and trip the breaker. Some breaker models provide front adjustment of the magnetic trip action.

These adjustments are normally set at the factory at the high position, but provide for individual conductor settings to suit customer needs.

•

The shunt trip mechanism (if equiJ?ped) consists o solenoid tripping device mounted m the

?

! a rea�er w1th external lead connections for remote s1gnahng. A momentary signal to the solenoid coil will cause the breaker to trip.

. com generator set. This quickly disconnects the set from the load on shutdown and avoids a reverse power condition.

•

Auxiliary contacts (if equipped) are used for local or remote annunciation of the breaker status. They usually have one normally-open and one normally closed contact (1 form C contacts) to comply with the annunciator requirement.

•

The trip actuator (if applicable) is for periodic exercise of the breaker to clean and maintain its proper opera tion. Rotating this actuator mechanically simulates over-current tripping through actuation of linkages not operated by the On/Off handle. See Secti_on 5, C�m ponent Tests and Adjustments, for further mformat1on.

•

Operation of the circuit breaker is determined by site established procedures. In emergency standby ��tal lations, the breaker is often placed to the On pos1t1on, and is intended for safety trip actuation in the event of a fault condition. If the breaker trips open, investigate the cause and perform remedial steps per the trou bleshooting procedures. To close the breaker, the handle must be placed to the Reset position and then to On. Refer to Section 4 fortroubleshooting and safety procedures.

GENERATOR

OUTPUT

BOX www

LD

A

8

11DE VIEW - HANDLE POIITIONI


FIGURE 3-4. TYPICAL GENERATOR-MOUNTED CIRCUIT BREAKER

3-4

Section

4.

Troubleshooting

GENERAL

This section contains troubleshooting information for engine1Jenerator control systems. Be sure to review the troubleshooting information as outlined in the unit

Operato(s Manual before performing the procedures in this section. Refer to Componert Tests and Adjustments

�ion for further engine1Jenerator COrJ1X>nent informa tiOn and appropriate engine service manuals for adcti tional information specific to the engine.

Because this section contains information about various control options, read through this section before a fault oca.Jrs to identify what is or is not applicable to your genset. This will save troubleshooting time when the actual need arises.

�etore starting a troubleshooting procedure, make a few s1rrple checks that migt1 expose the problem. Check all rt:JOOifications, r�irs, or parts replacements performed s1nce the last satisfactory operation of the generator set.

A

�se or switch or

_ breaker, or a loose plug-in are all potential problems that can be eliminated by a visual check.

When troubleshooting a problem, remember to keep your problem soMng a methodical and most of all safe proc ess. Ha&tY decisions can be costly, harmful to your health, dangerous to others, and may not solve the problem.

Regardless of the cortroller model a generator set has the basics of problem analysis are fundamertally thfi same. Identify the fault condition then get specifiC about the corrective action to take. However, the Detector-7 controller does not have all the lamp indicators that the

Detector-12 has; to aid in identifying other customer required fault conditions (i.e., low fuel, fault 1 and 2) that may have caused the sh.Jtdown. Your initial problem analysis before reviewing the tables in this section should be to ask yourself the following questions:

1. Was the engine running when it shut down? If it was, shutdown is not due to overcrank.

2. Did srutclown oca.Jr within one minute after start up? H it did, the shutdown is probably due to low oil pressure.

3. Was engine operation noticeably erratic or faster than to usual?

If it overspeed. was, the sh.Jtdown was probably due

4. If the engine starts and runs, observe the oil pres sure, engine temperature and fre<J.Iency meter or tachometer until sh.Jtclown oca.Jrs, to determine the cause.

This section is divided into engine-related troubleshoot ing tables and generator-related troubleshooting flow charts to aid you. They are:

Table 4-1. Engine does not crank.

Table 4-2. Engine aanks, but does not start.

Table 4-3. Engine starts, but stops after running short time.

Table

4-4.

Engine-generator is in operation, then a fault sRrtdown occurs.

Flow Chart 4-1. No AC output voltage at rated engine speed.

Flow Chart 4-2. Unstable outJ:U voltage, engine speed stable at rated speed.

Flow Chart 4-3. Ouq:x.rt voltage too high or low.

Flow Chart 4-4. Exciter field breaker ti1JS

Flow Chart 4-5. Unbalanced generator output voltage.

Flow

(if equipped).

Chart 4-6. No AC output through set-mounted circuit breaker. www


4-1

I

A WARNING

I

Atiny troubleshooting procedures present hazards

which

can result In severe personal Injury or death. Only qualified service personnel with knowledge of fuels, electricity, perfonn service ptOCedures. Review Safety Precautions, on pages II and Ill.

and

machinery hazards should

SYMPTOM

1 .

SWITCH OFF indictor lamp flashing.

TABLE 4-1 . ENGINE DOES NOT CRANK

CAUSE

Run/Stop/Remote switch in Stop position.

CORRECTIVE ACTION

Press to desired, Run or Remote position.

. com

2. Other fault indicator lafll)S iluminated, but no fault exists.

Lamp Reset switch not actuated after a previous fault was remedied.

3. No indication. Fuses blown on ECM board A1 1 .

Emergency stop button pushed in.

Press Lamp Reset switch to de-energize faJit lalll> relays a ECM, after

Rui'VStop/Rernote switch is pressed to Stop position.

Check fuses F1 and F4.

Replace if necessary with proper fuse:

F1 - 20 Alll>ere

F4 - 5 Alll>9fe

To reset, pull switch out and move the

RUN/STOP/REMOTE switch to STOP position. Then push test switch to

RESET!La!ll> position.

Starter solenoid will not energize.

Inspect starter solenoid per proper test procedure.

Possible defective

ECM board A1 1 .

Check A1 1 board TB1-9 for B+ voltage in.

With S12 switch in Run position, check for voltage out to starter solenoid at TB1 -8 of board A1 1 .

Check and repai" as necessary.

Broken wi� or poor comections between board A1 1 TB1-8 and starter solenoid.

Fauly ECM board A 1 1 .

4.

Time delay start is initiated, but not energize after desired time delay period.

Delayed Start!

Stop

Module A15.

If there

TB1-8 is no voltage between and ground stud when the panel switch is in the Run position, the ECM is faulty. Replace.


Check A15 board TB1-5 for

Run Signal In voltage.

Voltage at A 15 board

TB1 -6 should be at B+ at end of start delay period. www

4-2

Check wiring and connections from A15 TB1 -6 to A1 1 TB1 -6.

�WARNING

I

Many troubleshooting procedures present hazards which can result In severe personal Injury or death. Only qualified service personnel with knowledge of fuels, electricity, pertonn service procedures. Review Safety Precautions, on pages

II and Ill.

and


TABLE 4-2. ENGINE CRANKS BUT DOES NOT START

CORREC11VE ACTION

. com

CAUSE SYMPTOM

1 . Overcrank lamp lit.

Fill with oorrect fuel.

Low Fuel larll> also lit.

Fuel solenoid does not energize.

Fuel solenoid energizes, but no fuel flows.

�ngine hard to start due to cold antliert air te�rature.

InsuffiCient fuel in supply tank.

Fuse blown on ECM board A1 1 .

Possible defective ECM board A1 1 .

Broken wiring or poor oonnections between board A1 1 TB1-10 and fuel solenoid.

Blockage of fuel supply system.

Heater system not keeping engine warm.

Check fuse F2. Replace if necessary. F2 - 20 Arll>ere.

Check for voltage out at TB1 -1 0 when engine is cranking.

Check and rectify as necessary.

Check fuel supply system

(fuel supply tank, shutoff valves, lines and connections, filters and transfer pump, etc.).

Check heater system power supply, oontrols, etc., and oorrect as necessary.

2. Fault shutdown occurs, but no fault lamp indication. lamp burned out. Place Rui'VStopiRernote switch to Stop position, then depress larll> Test switch to Test position to check fault lamps.

3. Short cranking period.

Delective ECM board A 1 1 . Replace ECM (A1 1).

Note:

The ECM board A 1 1

P.C. board oontrols are to provide cycle cranking, but generator set stops before 1 5 ±3 seoonds.


4-3

I

A WARNING

I

Many troubleshooting procedures present hazards which can result In severe personal Injury or death. Only qualified serviCe personnel with knowledge of fuels, electricity, pertonn serviCe pmceclures. Review Safety Precautions, on pages II and Ill.

and


TABLE 4-3. ENGINE STARTS, BUT STOPS AFTER RUNNING SHORT TIME

. com

SYMPTOM CAUSE

CORREcnVE AcnON

1 . Overspeed lafll) lit. Overspeed MoWle initialized shutdown.

Refer to Tests and module.

Adjustments section.

Perform necessary adjustments of O.S.

Unstable engine operation.

2. Low Oil Pressure lamp lit.

3. High Engine

Temperature lafll) lit.

4. No fault oondition.

Engine governor faulty or out of adjustment.

Low oil level in engine.

LOP switch faulty.

Low coolant level in engine.

HET SWitch is faulty.

Thermostat defective.

Fan belt slipping.

Intermittent control wiring connections.

Perform start-up and monitor engine speed to overspeed sl'lltdown.

If shutdown occurs before desired setpoint, readjust O.S. module.

If adjustment does not correct fault condition, replace o.s. module.

Refer to

Tests and

Adjustments

Perform appropriate tests. section.

Replenish as necessary.

Check oil level, perform restart, and monitor oil pressure gauge.

If gauge reading is within normal range, switch 81 is faulty. Replace.

Replenish as necessary.

Check coolant level, perform restart, and monitor engine tefll)erature gauge.

If gauge reading is within normal range, switch S2 is faulty. Replace.

Replace thermostat.

TJQhten fan belt.

Check condition of all oontrol wiring to make sure connections are correct and seaJre.


4-4

�ARNING

I

Many troubleshooting procedures present hazards which can result In severe personal Injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perfonn service procedures. Review Safety Precautions, on pages II and Ill.

TABLE

4-4.

SYMPTOM

ENGINE-GENERATOR IS IN OPERATION, THEN A FAULT SHUTDOWN

CAUSE CORRECTIVE ACTION

. com

LOP, HET, Overspeed lamp lit.

As indicated.

Refer to Table 4-3. 1 .

2. Fault 1 or Fault 2 lamp lit.

3. No fault lamp lit.

Over/Under Voltage or

Frequency, as dedicated by customer.

Possible defective ECM board A1 1 .

Refer to Tests and Adjustments section, and perform necessary adjustments.

Restart unit and monitor gauges.

H shutdown was we to over/under voltage, the voltage regulator may require adjustment or is faulty. Refer to Tests and Adjustments section for adjustments, replace if faulty.

H shutdown was we to over/under frequency, the engine governor may require adjustment or is faulty. Refer to Tests and Adjustments section for adjustments, replace if faulty.

Refer also to generator-related

Flow Charts that follow.

Check fuses F4 and F2 of ECM board A1 1 .

F4 (Main)

-

5 Ampere

F2 (Fuel solenoid or ignition) - 20 Ampere

Perform restart and check for B+ voltage in at TB1 -9 and voltage out at TB1-1 0 to fuel solenoid.

H there check is voltage out at TB1-10, fuel supply solenoid, sn.rtofl valves, etc.

H there is no voltage

ECM out at TB1 -10, boan:f A1 1 is defective.

Replace.

Refer to ilstalalion reference malerial, or ooruct your www

4-5

[A WARNING

[

Many troubleshOoting procedures present hazants which can result In severe personal Injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazants should pertonn service procedures. Review Safety Precautions, on pages II and Ill.

FLOW CHART 4-1 . NO AC OUlPUT VOLTAGE AT RATED SPEED

Is field breaker CB21 position?

, at

ON

(fuly-in)

No v ..

Repla:e defective field breaker.

. com

Remove continuity one lead from breaker and check v .. with ohmmeter. Is breaker open?

No v ..

Place breaker swik:h

10 ON position.

Does generator AC OU1pUt voltage buik:t up?

If voltage is unstable, high or low, or breaker 10 trip, refer 10 other causes

Flow Char1s.

No v ..

Rash exciter field. Does generator output voltage buik:t up?

No

Is resid.Jal voltage across

TB21-22 equal to 5 10 10 VAC or more? and

-23

No v ..

Is exciter field voltage aaoss VR21-X

-XX at approximately 24 10 32 VDC? and v ..

No v ..

Disconnect

TB21-22 slat>!" leads

U2 and

V2 from and

-23. Is residual voltage across lhe leads

150

10 250

VAC ro��?

No

Check lead continuity between

Auxiliary

Terminal Board (leads 6, 7, and 8) and

TB21-22, -23, and

-25.

Check exciter field wiring for shorts.

Replace bad wiring.

Check exciter field wiring for opens.

Replace bad wiring.

Check dodes

CR1 lhrough

CR6 on rotH".

Replace if bad.

Replace voltage regulator VR21.

Check exciter field


IACAUTION

I

Do not replace Voltage Regulator

VR21 until external trouble has been corrected to avoid possible damage to new regulator boant. www

4-6

Check generaa roo field wincing.

Replace if bad.

Check bad. generator slaiOr wincings. Replace if

I

A WARNING

I

Many troubleshooting procedures present hazards which can result In severe personal Injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perlorm service procedures. Review Safety Precautions, on pages II and IIi.

Are there any broken wires or loose connections on voltage regula1Dr assembly?

Does voltage cycle from zero to rated output?

FLOW CHART 4-2. UNSTABLE VOLTAGE, ENGINE SPEED STABLE AT RATED SPEED

Ye.

. com

I

No

Repair as required.

Check control panel voltage aqust rheostat and replace if defective

(open).

No

Check wiring harness from regulator assembly to end bell. Check ok?

I

Yes

Check

Check voltage regulator adjustment setting. ok?

I

No

I

Replace Voltage Regulator VR21 .

Repair wiring or replace as required.

Ye.

Is voltage stable within specifications at no load to full load range of generator set?

I

No

/ACAUTION

I

Do not replace Voltage Regulator

VR21 until external trouble has been COtTeCted to avoid possible canage to new regulator board.

FLOW CHART 4-3. OUTPUT VOLTAGE TOO HIGH OR LOW

Is engine running at correct rpm?

No

Refer

D Governor

Aqustmenls. lv•

Are generator output connections correct

Md secue?

No

Refer to appropriaae eleclrical schemalic.

IY•

Does aqustment of

Voltage Adjust control

R21

(If equipped) result voltage? in correct output

No

Set

Voltage

Aqust oonbd R21 .

Check vol1age aqust rheostat and replace if defective. lr•

Check Voltage Regulau

Aqustment.

Check ok?

JNo l

Check ooncition of rotalilg dodes

.

Vi� inspect for etc.

Check loose ok? connections, faulty dodes

,

IY•

Replace Voltage Reguaa VR21 .

Is wltage within ful load range specificdons at of generata

I

No ser! no v ..

. ElectricalPartManuals if defective. load D

[ACAUTION

I

VR21 until external trouble has been corrected to

a

vo ld

Do not possible damage to new regulator board. www

4-7

I

A WARNING

I

Many troubleshooting procedures present hazards which can result In severe personal Injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perfonn service procedures. Review Safety Precautions, on pages II and Ill.

FLOW CHART 4-4. EXCITER FIELD BREAKER TRIPS

Does

AC output voltage build up m 150% or more of rated voltage before breaker trips?

1--

---

--

-

-l

Check for any loose or broken wires or connections m VR21 assembly.

. com

No

Check bad. dodes in rou assembly. Replace if

Check Voltage Regulat>r aquslments connections. and

Check bad. exciter stab' winding. Replace if

Check generau stator leads for proper, and secure

COI11ecliou. Rater m approprial9 eleclricaJ schematic.

Check exciler rou wincing. Repla:e if bad.

Check generat>r ro1Dr field windng.

Replace if bad.

Check bad. generator Sla1Dr windngs. Repla:e if

Replace Voltage Regulalor VR21 .

A

DANGER

High-voltage, 1,900 to 15,000 volts, present special hazards of severe personal lnjuty or death. Even after genset shut

down

, an electl1cal shock hazard may still exist, caused by Induced voltage within the generator. Service personnel must be well-trained/qualified to worlc with distribution voltages.

I

A CAUTION

I

Do not replace

Voltage Regulator

VR21 until external trouble has been corrected to avoid possible damage to new regulstor board. www


4-8

/A WARNING

I

Many troubleshooting procedures present hazards which can result In severe personal injuty or death. Only qualified service personnel with knowledge of fuels, electricity, and machlnety hazards should perfonn service procedures. Review Safety Precautions, on pages 11 and Ill.

FLOW CHART 4-5. UNBALANCED GENERATOR OUTPUT VOLTAGE

Remove load at generatx' terminals. ou1pUt slil unbalanced?

I s

No

Check each not withit load. phase

10% of each other,

. com

Yes and load

.

Correct as necessary

.

Ale get l9faD leads connected and gromded property?

Yes

Is generatx' statx' windng continuous?

Yes

Check load for ground fa�Als and conect as necessary.

No

No

Replace stator assembly.

A DANGER present special

High-voltage, 1,900

hazards ot

death. Even after genset severe to shutdown,

15,000 wits, personal lnjuly or an electtlcal shock hazard may still exist, caused voltage within the generator. Service personnel must be well-trained/qualified to WOlfe voltages. with by

Induced distribution www


4-9

I

A WARNING

I

Many troubleshooting procedures present hazards which can result In severe persona/ Injury or death. Only qualified setVIce personnel with knowledge of fuels, elect ricity, perfonn setVIce procedures. Review Safety Precautions, on pages II and Ill. and machinery hazards should

FLOW CHART 40. NO AC OUTPUT THROUGH SET MOUNTED CIRCUIT BREAKER

Is set-mounted ciraJit position? breaker at

Tripped

No

Is set-fTlOIM'ltad ciraJit position? breaker at OFF

. com

Y•

Y•

Detarmile cause

� breaker tip.

H not immeciately known

, s� generaa set and investigale

•

Cirait cause

. owerload (per sil&-eslabishecl procedures) .

•

Short cira.it (per sile oslabished proceclures).

•

Shunt tip (check for generaa set taUt stMdcwn

, or ofler SVNII sowce).

Confirm flat no

111Mltanance is being perb1ned, or other pwpose for breaker at

OFF use. position, and flat set is avalable for

If set is operating and available for use, reset cira.it breaker t» ON posiion.

AIMaw

TasfS

Teeing

AC laad

Cirail Blaakar in tn1 .......

18dion.

Conac:t fault ballar lEt

COidlioii ... I8Set ciR:UI

ON poeilian. www


4-1 0

Section

5.

Component Tests and Adjustments

GENERAL

This section contains test and adjustment information for the GenSet control, generator, and engine COIT1JOnents.

Refer to the figures included with this information and also the Wiring Diagrams section when instructed. number of crari<s programmed, K1 2 N.C. contacts (1 0,7) open and close to energize and de-energize K3, K3 N.O. contacts (S,3) open and ck>se connecting and removing

B+ from TB1 -8.

A DANGER

High-voltage, 1,900 to 15,000 volts, present special hazards of severe personal injury or death. Even after genset shutdown, an electrical shock hazard may still exist, caused by Induced voltage within the generator. Service personnel must be well-trained/qualified to work with distribution voltages.

I

A CAUTION

some

I

In-depth intonnatlon Is provided tor components such as the ECM's. Only qualffled personnel with proper equipment should use this ln fonnatlon to attempt repair of printed circuit board assemblies. Contacting your distributor tor replace ment pans is recommended.

ENGINE CONTROL MONITOR (ECM)

Sequence

of

Operation - Detector-7 ECM

Refer to schematic diagram in Wiring Diagrams section when reviewing this information.

Starting is initiated by applying

B+ or ground to P4-7 depending on the position of �nks W3 and W4.

H the set fails to start after the pre-set number of cranks,

U1 pins 1 0, 1 1 , and 1 2 go high and trigger the drive transistor U4 pins 6 and 1 1 which grounds K6 fault relay, stopping the starting sequence by opening its N.C. con tacts (9,8) de-energizing K3 and K2. U1 pins 1 0, 1 1 , and

1 2 going high also triggers U4 pins 1 2 and S which energizes overcrank lamp drive relay K9. K9 N.O. con tacts (9, 1 3 and 4,8) ck>se putting a ground on TB2-6 for a remote indication and also the DS1 8 lamp.

H the set starts, voltage builds up on the DC (K1 4) and AC

(K1 0) start disconnect relays. K1 4 energizes at approxi mately 1 4 VDC. K10 energizes at approximately 1 00

VAC. Regardless of which one energizes first, either relay will break the ground path to starter relay K3, K3 de energizes opening its N.O. contacts (S,3) removing B+ from TB1 -8. Both K1 0 and K14 must be energized to operate the run lamp DS1 2. Bther relay will also inhibit the overcrank timer U1 by making U1 pin 2 go high. This is achieved by removing the ground path from U1 pin 2 through U3 pins 6-1 1 , N.C. K14 contacts (1 6,9) and N.C.

K1 0 contacts (3,S). A positive is then alk>wed through the

K3 coil, N.C. K6 contacts (3,7), N.C. K12 contacts (10, 7),

U3 pins 6-1 1 to pin 2 on U1 or via RS, U3 pins 6-1 1 to U1 pin 2 if

K6 fault relay has operated. By making pin 2 high the timer is reset and put into a standby mode.

•

•

Position A - Ground signal to run

Position B - B+ signal to run

Either K1 0 or K14 will initiate US - LOP/HET time delay timer. This is achieved by removing the ground from U4 pin 3 and allowing a positive there. This triggers U4 pin 1 4

This energizes run relay

1<7, which closes its

N.O. con tacts (9, 1 4) connecting B+ to starter relay K3, switched B+ relay K2 fault circuits, overcrank/cycle crank timer U1 , to ground US pi n 2 . After a 1 0 seco nd delay

U5 pin 1 4 energizes K1 through

U4 pins 1 a nd 1 6. K1 N.O. (1 ,8) contacts (9, 1 4) ck>se, latching in fault circuits. K1 N.C. and HET/LOP time delay timer U5 through N.C. fault relay

K8 (1 6,9). This also opens N.C. K7 (9, 1 6) , disconnecting

B+ to the reset circuit (K6).

B+ to tenninal through fuse FS. contacts open to latch US into an inactive state during run, made

R8 by removing

B+ from pin S and grouncing it through and U2 pins 2 and 1 S. (K1 N.O. contacts (2,8) also ck>se providing timing shutdown path to K6 fault relay.)


K3 energizes, closing its N.O. contacts (S,3) connecting

B+ to tenninal TB1 -8 through fuse F1 .

K3 is controlled by timer U1 through cycle crank relay K12. U1 can be

H a fault should ocrur a ground is placed on the following plug points.

•

P2-2, for Pre-Low Oil Pressure (PLOP)

•

•

P2-3, for Pre-High Engine Temperature (PHEl)

P2-4, for Low Oil Pressure (LOP)

•

P2-S, for High Ergne Temperature (HET) programmed to give 3 crank periods by combining diodes across U1 pins 1 0, and 1 2; CR6 to pin 1 2 with CR8 to pin

1 0

=

3 cranks. www

5-1

•

P2-6 or termnal

TB1-1 , for Overspeed (OS)

Pre-LOP and pre-HET only activate a warning lamp and do not stop the set.

LOP, HET, ard OS activate a lamp ard also shut down the set.

Fault relay

K6 is in series with the K1 3 (HET), K15 (LOP),

K1 1 (OS), K4 (Fault 1 ) ard K5 (Fault 2) fault relays.

Therefore, when a grourd is placed on the respective plug input it will cause both the K6 relay ard the associated fault relay to energize. K6 N.C. contacts (9,8) open to de energize K2 relay, stopping the set. K6 N.O. contacts

(1 1 ,1 0) close to energize K8 relay. K8 opens its N.C. contacts (1 6,9) to remove B-t from the operational parts of the circuit. The associated fault relay will bring up an indicating lamp ard also connect a grourd to one of the following terminals for a remote indication:

•

•

•

TB2-1 1 , for PLOP

TB2- 1 0, for PHET

TB2-9, for LOP

•

•

•

TB2-8, for HET

TB2-7, for Overspeed

TB2-6, for Overcrank

To reset a fault the run signal must be removed from P4-

7 to de-energize K7, closing its N.C. contacts (9, 1 6) to connect B-t to the fault reset circuit. A grourd is placed on

P4-1 1 which grounds all of the latchable fault relays reset coils as follows:

•

K6 - Fault Relay

•

K9 - Overcrank

•

•

K1 1 - Overspeed

K13 - HET

•

•

•

K15 - LOP

K17 - PHET

K19 - PLOP

K2 energizes, closing its N.O. contacts (5,3) connecting

B+ to terminal TB1 -1 0 through fuse F2 and to P4-9 through fuse F5.

K3 energizes, closing its N.O. contacts (5,3) connecting periods through CR6 and era.

. com seconds on, and 1 5 seconds off through oscillator circuit comprising C3, and resistors U3 (3,6), (15,2), and (1 6,1 ).

The total crank time is 75 seconds.

U1 will energize and de-energize K1 2 through U4 (7,10).

K12 N.C. contacts (10,7) open arxl close to energize and de-energize K3, K3 N.O. contacts (5,3) open ard close connecting and removing B+ from TB1 -8.

H the set fails to start after the three cranks, U1 pins 1 0, and 1 2 go high and trigger the drive transistor U4 pins 6 and 1 1 which grounds K6 fault relay, stopping the starting

Se<J.Jence by opening its N.C. contacts (9,8) de-energiz ing K3 aoo

K2.

U1 pins 1 o,

1 1 , aoo 1 2 going high also triggers U4 pins 1 2 and 5 which energizes overcrank lamp drive relay K9. K9 N .O. contacts (9,13 and 4,8) close putting a ground on TB2-6 for a remote indication and a reound on P3-8 to light the DS18 lamp.

This resets K6 fault relay and any fault relays that are latched in an active state.

To stop the set normally, the run signal is removed from

P4-7 which de-energizes K7. K7 N.O. contacts (9,14) open to remove

B-t from K2 relay. K2 de-energizes opening its N.O. contacts (5,3) removing B+ from TB1 - 1 0, stopping the set.

Sequence of Operation - Detector-12 ECM

Refer to schematic diagram in

Wiring Diagrams section when reviewing this information.

H the set starts, voltage builds up on the DC (K14) and AC

(K1 0) start disconnect relays. K14 energizes at approxi mately 1 4 VDC. K10 energizes at approximately 1 00

VAC. Regardless of which one energizes first, either relay will break the ground path to starter relay K3, K3 de energizes opening its N.O. contacts (5,3) removing B+ from TB1-8. Both K1 0 ard K14 must be energized to operate the run lamp DS1 2. Either relay will also inhibit the overcrank timer U1 by making U1 pin 2 go high. This is achieved by removing the ground path from U1 pin 2 through U3 pins 6-1 1 , N.C. K14 contacts (1 6,9) and N.C.

K1 0 contacts (3,5) .

A positive is then allowed through the

K3 coil, N.C. K6 contacts (3,7), N.C. K1 2 contacts (1 0, 7),

U3 pins 6-1 1 to pin 2 on U1 or via R6, U3 pins 6-1 1 to U1 pin 2 if

K6 fault relay has operated. By making pin 2 high the timer is reset and put into a standby mode.

Starting is initiated by applying

B-t or grourd to P4-7 deperding on the position of �nks W3 ard W4.

•

•

Position A - Grourd signal to run

Position B - B+ signal to run

Either K10 or K14 will initiate U5 - LOP/HET time delay timer. This is achieved by removing the grourd from U4 pin 3 and allow a positive there. This triggers U4 pin 14 to ground U5 pin 2. After a 1 0 second delay U5 pin 14

This energizes run relay K7, which closes its N.O. con tacts (9, 1 4) connecting B+ to starter relay K3, switched B+ relay

K2 fault circuits, overcrank/cycle crank timer U1 , energizes K1 through U4 pins 1 and

1 6. K1 N.O. contacts

(9,1 5) close, connecting B-t to the fault circuits. K1 N.C.

. ElectricalPartManuals relay from appropriate fault circuit.) www

5-2

If a fault should occur a ground is placed on the following plug points:

•

•

•

•

•

P2-1 , for Low Engine Temperature (LET)

P2-2, for Pre-Low Oil Pressure (PLOP)

P2-3, for Pre-High Engine Temperature (PHET)

P2-4, for Low Oil Pressure (LOP)

P2-5, for High Engine Temperature (HET)

•

•

•

•

P2-6 or terminal TB1 -1 , for Overspeed (OS)

TB2-1 4, for Low Fuel

TB2-1 , for Fault 2

TB2-3, for Fault 1

•

TB2-1 6, for shutdown of customers requirements

RUN RELAY (IF EQUIPPED)

Checking Relay Coil

Connect B+ across relay coil terminals. Relay should activate if coil is okay.

Checking Relay Contacts

. com relay is energized, contact is okay. The B+ reading is present in reverse order when checking normally closed

(N.C.) contacts. Typical wiring diagram is shown in Figure

5-1 .

Low fuel, pre-LOP, pre-HET, and LET only activate a warning lamp and do not stop the set.

LOP, HET, OS, Fault 1 , Fault 2 and Remote shutdown

(TB2-1 6) activate a lamp and also shuts down the set.

Fault relay K6 is separately in series with the K 1 3 (HET) ,

K 1 5 (LOP), K1 1 (OS). K4 (Fault 2) and K5 (Fault 1 ) fault relays. Therefore, when a ground is placed on the respec tive plug input it will cause both the K6 relay and the associated fault relay to energize. K6 N.C. contacts (9,8) open to de-energize K2 relay, stopping the set. K6 N.O. contacts ( 1 1 ,1 0) close to energize K8 relay. K8 opens its

N.C. contacts ( 1 6,9) to remove B+ from the operational parts of the circuit. The associated fault relay will bring up an indicating lamp and also connect a ground to one of the following terminals for a remote indication:

•

TB2-2, for Fault 2

•

TB2-8, for HET

•

•

•

TB2-4, for Fault 1

TB2-6, for Overcrank

•

•

TB2-9, for LOP

TB2-1 0, for PHET

TB2-7, for Overspeed

•

TB2-1 1 , for PLOP

To reset a fault the run signal must be removed from P4-

7 to de-energize K7, closing its N.C. contacts (9, 1 6) to connect B+ to the fault reset circuit. A ground is placed on

P4-1 1 which grounds all of the latch able fault relays reset coils as follows:

•

K6 Fault Relay

•

•

K

4

Fault 2

K5 Fault 1

K9 Overcrank

•

K 1 1 - Overspeed

•

•

•

•

K 1 3 - HET

•

K 1 5 - LOP

K 1 7 - PHET

K 1 9 - PLOP

A -�1--�

INPUT

This resets K6 fault relay and any fault relays that are latched in an active state. s --1-----l

To stop the set normally, the run signal is removed from

P4-7 which de-energizes K7. K7 N.O. contacts open to remove opening its N.O. contacts (5,3) removing stopping

the set.


FIGURE 5-1.

RUN RELAY

OUTPUT www

5-3

INTERFACE RELAY MODULES

(IF EQUIPPED)

When the customer provides a remote control panel having alarm circuits powered by a separate AC or DC source, Module A1 3 (7 relays) and Module A14 (5 relays) can be provided to interface with the ECM (A 1 1 ) circuits.

Typical wiring diagrams are shown in Figure 5-2.

. com

-1 '

2 3 4 5 6 7 8

I

K3 K4 K5 K6 K1

.

K2 K7

I

1 2

3

4 5 6 7

8 9 1 0 1 1

TB1

1 2 1 3

1 4

I

A13

TB2

(INPUT)

2

3

4

5

6

7

8

B+

-I

I

2

K1 K2 K3 K4 K5

3

4

I

1

181

2 3

5

B+


A14

1 0

8

9

6

7

4

5

2

3

ES-1854 www

FIGURE 5-2. INTERFACE RELAY MODULES

5-4

8

9

1 0

1 1

2

3

4

5

6

7

1 2

1 3

1 4

TIME DELAYED START/STOP MODULE

(IF EQUIPPED)

This module contains adjustable potentiometers for time delayed start (1 to 1 5 seconds) , and time delayed stop ( 1 to 1 5 minutes). Time delay adjustment i s made by turning the appropriate potentiometer clockwise to increase or counterclockwise to decrease the time delay. Set the time delay start per site requirements, and the time delay stop for approximately 3 to 5 minutes. Typical wiring diagram is shown in Figure 5-3. Refer to Wiring Diagrams section for further information.

AC METERS AND

CURRENT TRANSFORMERS

If a meter malfunctions, the problem might be a loose wiring connection, the meter itseH, the phase selector

. com and terminal connections. Checking continuity of the wiring and components should identify the problem.

Repair or replace any faulty wiring, replace faulty meter, current transformer, switch, etc. Refer to appropriate wiring diagram/schematic in Wiring Diagram section.

TIME DELAY START POTENTIOMETER lWE DELAY STOP POTENTIOMETER www

TB1

2

3

4

5

6

PRIMARY START-DISCONNECT (A1 1 - TB1 -2)

SECONDARY START-DISCONNECT (A1 1 - TB1-3)

B- (A1 1 - TB1-5)

B+ (A1 1 - TB1-7)

RUN SIGNAL. IN (REMOTE START/STOP CONTROL)

RUN SIGNAL OUT (A 1 1 - TB1-6)

ES-1855

5-5

AUTOMATIC VOLTAGE REGULATOR

The automatic voltage regulator (AVA) is a three-phase full wave poweroutput type device, which forms part of the excitation system for the generator.

I� a

� diti�n to regulating the generator voltage, the AVA c1rcu1try Includes a number of protective features which provide safe reliable control of the generator. Excitation power is derived from a permanent magnet generator

(PMG), providing low Radio Frequency Interference (RFI) and immunity from thyristor type loads.

Quadrature Droop Circuit (Optional): Converts the cur rent input from a CT into a voltage which is phase mixed with sensing voltage. The result is a net increase in the outp�t from the sensing network as the power factor lags, causmg a reduction in excitation.

!

RMS Convener: Is a square law precision rectifier circuit hat converts the AC signals from the sensing networks

1nto a composite DC signal representing the mean squared value of the waveform.

. com

The output of the RMS converter includes a variable potential divider which forms the voltage range control for the AVA.

Th� AV_R is interlinked with the main stator windings, exc1ter f1eld and PMG to provide closed loop control of the output voltage with load regulation at approximately

±0.5% RMS.

Current Convener: Is a three-phase precision rectifier and amplifier that converts the inputs from current trans formers into a DC signal representing the mean value of the current waveform.

The AVA senses the output voltage from the main stator windings and in response to this controls the power fed to the_ ex�iter field, a�d the main field, in such a way as to mamta1n the machme output voltage within the specified limits, compensating for load, speed, temperature and power factor of the generator.

Offset Control: Provides an interface between the AVA and accessories and allows the generator's excitation to be controlled by adding or subtracting the accessory DC output voltage to the AVA rectified sensing voltage.

Soft start circuitry is included to provide a smooth con trolled build up of generator output voltage.

Power Supply: Components consist of zener diodes, dropper resistors and smoothing to provide the required voltages for the integrated circuits.

Sust�ined overvoltage situations caused by open drcuit sen�mg terminals or short circuit power device are

�vo1ded by overvoltage detection circuitry which provides mternal shutdown and circuit breaker trip signals for circuit i�lation if required.

Precision Voltage Reference: Is a highly stable tem perature compensated zener diode used for DC compari son.

Soft Stan C

!

rcuitry: Overrides the precision voltage reference dunng run up to provide a linear rising voltage.

A frequency measuring circuit continually monitors the shaft speed of the generator and provides underspeed protection of the excitation system by reducing the gen erator output voltage proportionally with speed below a

P!eset value.

A further enhancement of this feature pro

VIdes greater voltage roll off in response to rate of falling speed (dHz/dt), to improve frequency recovery time on turbocharged engines.

Main Comparator/ Amplifier: Compares the conditioned sens

�

�g voltage_s with the precision reference voltage and amphf1es the dtfference (error) to provide a controlling sig�al fo� the power

� evice in such a way as to supply the exc1ter w1th the requ1red amount of power to maintain the generator voltage within the spedfied limits.

Current 6miting circuitry (optional) provides control over the amount of short circuit current flowing during three phase and single-phase shorts on the generator output.

Stability Circuit: Provides adjustable negative AC feed back to prevent voltage hunting and ensure good steady state and transient performance of the control system.

Power Control Driver: Provides the means to infinitely

Over excitation situations left uncontrolled are limited to a sat� durat

� on by . i�ternal shutdown of the AVA output dev1ce.

ThiS cond1t1on remains latched until the generator has been stopped.

Basic Operation

The internal

Figure

5-4.

The


Sensing Resistors: Take a portion of the generator control the conduction period of the output device. This is achieved by pedestal and ramp control followed by a level detector and driver stage.

Power Control Devices and Rectifier: Are configured as a three phase 4 diode bridge, power mosfet and freewheel diode to vary the amount of exciter field current in response to the error signals produced by the main comparator. output voltage and attenuate it to a suitable lower level.

This input chain of resistors includes the hand trimmer adjustment. www

5-6

S ync

:

Circuit provides a short pulse near the zero point of one of the phases on the

PMG and is used to synchronize the Under Frequency Roll-Off (UFRO) and power control circuits to the generator cycle period.

Under Frequency Roll-Off: Circuit measures the period of each electrical cycle and causes the reference voltage to be reduced approximately linear with speed below a presettable threshold. A light emitting diode (LED) gives indication of underspeed running.

Block Relief: Circuit measures the rate of falling speed of the generator (dHz/dt) and causes greater voltage roll off

(makes the V/Hz slope steeper) to aid engine speed recovery after application of a "block" load.

Over Voltage Monitor: Continuously monitors the volt age at the generator terminals and provides signals to shut down the output device and trip an optional circuit breaker, to i solate power from the exciter and AVR in event of sustained overvoltages. A one second timer is

. com excitation and provides signals to shut down the output device in event of sustained overloads lasting greater than ten seconds. Both the overload and overvoltage conditions are latched faults requiring the generator to be stopped for reset.

OVER

VOLTAGE

DETECTOR

,..

ACCESSORY

INPUT

GENERATOR

VOLTAGE

SENSING

::.

....

REMOTE

VOLTAGE

TRIMMER

.....

CURRENT

INPUT

"'-

,..

,..

SENSING

RESISTORS

QUAD

D R

OO

P

OVER

VOLTAGE

MONITOR

OFFSET

CONTROL -

RMS

CONVERTER

SOFT

START

CIRCUIT

I

PRECISION

-

VOLTAGE

,...__

REFERENCE �

R

.....__ _ v

'--

STABIUTY

CIRCUIT

-

UF

RO

+ BlOCK

REUEF r-o-

100 HZ PMG

"""

.... �

SYNC

BREAKER

DRIVE

+ INHIBIT

POWER

RECTIFIER

_..

EXC ITATION

Cl RCUIT

BR EAKER

(OPT IONAL)

POWER

CONTROL

DRIVER

POWER

SUPPUES r---4

OVERLOAD

DETECTOR

+ INHIBIT

POWER

CONTROL

DEVICES

,--

�

I>-

EXCIT

LD

1 www

FIGURE

5-4.

PMG VOLTAGE REGULATOR BLOCK DIAGRAM

5-7

GENERATOR OPERATION REVIEW

The PMG provides power via the AVA to the main exciter stator, see Figure 5-5. Excitation power is therefore inde pe�dent of _output voltage, resulting in positive voltage build-up, w1thout reliance on residual magnetism. The

A VA compares the main stator output with a reference value and feeds a controlled excitation current to the main exciter stator. The AC output of the main exciter rotor is c?n�erted to DC by the rectifier assembly, comprised of s1x d1�des mounted on two heatsinks to form positive and negat1ve plates. The diodes are protected against harmful overvoltges (caused for example, by switching circuits or out-of-phase paralleling) by a metal-oxide varistor

(MOV)._Th_e DC output of the rectifier assembly provides the exc1tat1on onto the main rotor.

AVR Sensing and Power Supply

3-Phase Sensing: With rated output voltage on the main terminals, the reference supply to this unit should be between 1 70 and 250 volts AC across 6-7, 7-8 and 8-6.

This supply can be by way of a quadrature droop burden resistor and/or dropper transformer. These should be checked for continuity.

Power Supply (PMG): Power supply is derived from the permanent magnet exciter. Its output leads are connected at AVA terminals P2, P3 and P4. These must first be dis connected. With the machine at rated speed the output voltage between leads P2-P3, P3-P4, and P4-P2 should be balanced at approximately 1 65 volts for 50 Hz (1 500 rpm) units or 200 volts for 60 Hz ( 1 800 rpm) units.

Voltage Regulator Adjustment

Generator voltage is controlled by the optional voltage control rheostat (A21 ) located on the control front panel and the solid-state voltage regulator located inside control panel (see Figure

5-6) .

Two, similar PMG voltage regulators have been used In per manent magnet exciter generator sets. One Is a four position mount, and the newer of the two has six mounting holes (of which only four are used). Adjustment proce dures are the same for both, even though the potentlone ters are located differently. Refer to Figure which

PMG

AVR the unit is equipped.

5-6

. com of the rated nameplate voltage via the optional control pa�el mounted voltage control rheostat (A21 ). If the adjustment cannot be made with A21 , or if A21 is not in stalled, adjust the voltage regulator as follows:

1 . Adjust voltage control rheostat A21 (if available) to the mid position.

•

Loosen the locking nut. With a screwdriver, turn rheostat A21 fully counterclockwise, then fully clockwise, then to mid position.

2. Open the control panel doors to gain access to the voltage regulator.

3. With the generator set operating, and the voltage being monitored (either by meters on the set or with remote metering) , adjust voltage regulator board

Volts potentiometer to the desired generator voltage.

4. :e�orm fine voltage adjustment (±3 percent) by ad

JUSting rheostat A21 , retighten locking nut.

5. Stor:> and restart generator set to confirm proper op eratiOn.

6. If adjusting the Volts potentiometer of the voltage regulator ��rd do�s not allow the generator voltage

�o come Wl!htn d�s1red range, refer to wiring diagram

Included w1th untt and check for proper connections.

Repe�t t�e adjustm_ent procedure. If proper adjust ment 1s still not possible, review the following regard-

AUTOMATIC

VOLTAGE

REGULATOR

MAIN

PERMANENT

MAGNET

STATOR

STATOR

STATOR

IJm

MAGNET

---+-

EXCITOR

ROTOR

Jn

DIODES

---I---

MAIN sHAFT www

ROTOR

ROTOR

FIGURE

5-5.

PERMANENT MAGNET GENERATOR (PMG) EXCITATION SYSTEM (BLOCK DIAGRAMS)

5-8

OUTPUT

ES-1852

ing other potentiometers on the AVR (note that a non

PMG regulator does not have all the same potenti ometers as a PMG regulator). Replace voltage regu lator board, or contact your service representative for

I assistance.

A CAUTION

)

Sealed voltage regulator poten tiometers are factory-calibrated for operation with this generator set

.

Any adjustment of other components could cause generator

set

voltage instability or overheating. Further adjustments should only be made by a qualified service repre sentative.

Stability: If the voltage is unstable after a block load reduction, tum the Stability control clockwise. Opti mum setting should be found around mdpoint. Any stability adjustment affects the generator output volt age. Reset the output voltage after any stability ad justment.

Under Frequency Roll Off (UFRO) Knee Point:

This control is set at 58 to 59 Hz (60 to 49 Hz (50

Hz

Hz units) or 48 units). The LED (light emtting diode) adjacent the UFRO potentiometer will be lit when the voltage regulator is in the under frequency mode, off is the standard operating mode. To check, reduce generator frequency from rated to where the LED just begins to illuminate. Note set point frequency. Turn ing the UFRO potentiometer clockwise reduces the knee point fre<JJency, and the LED will extinguish.

Return set to rated frequency.

DIP (Voltage Dip Limit): This control is preset at ap proximately 30 percent of the operating voltage.

Turning the control clockwise increases the voltage dip on large load pickup. This will make it easier for the

. com wise.

Droop: To set generator droop to 5% at full load, 0

PF. Turning this control clockwise increases the droop (the VUmt may also need to be adjusted if there is too much d roo p

.

)

Trim: To match AVR input to accessory output.

Turning this control clockwise allows accessories, like a V ARIPF controller, more control over the AVR.

OverN: To set the overvoltage protection cutoff level.

Turning this control clockwise increases the overvolt age cutoff level.

ULimit: To set the maximum short drcuit current.

Turning this control clockwise increases the short drcuit current.

Stab/1, EXC, and RMS: Are set at factory, and should not require any adjustment. Replace AVR.

PERMANENT

MAGNET GENERATOR (PMG) AVR

(PRIOR

10

JAN

. 1, 1990)

DIP

STABILITY

PERMANENT MAGNET GENERATOR (PMG) AVR

(AFTER

JAN.

1, 1990)

1

-

SELECnON LINKING:

2,

60Hz,

2 3,

50Hz,

1

3,

6-pole

4-pole www

§

§ �

I I

STABLITY

[!]

VITRN

0

DROCP (!]

�

CPTMJM

RESPONSE

SELECTION

EXC (!]

[Q]

CNEPJII

[!]

[QJ

§

RMS

(FACTORY

SET)

TRIM

ES-1856-1

OPTIMUM

RESPONSE SELECTION UNKING:

RGURE

5-6.

PMG VOLTAGE REGULATORS

5-9

A - B, FRAMES 6 & 7

B - C, FRAMES 3, 4 & 5

A - C, FRAMES

1

& 2 c

A

B

OVE�UNDER VOLTAGE SENSOR

MODULE (IF EQUIPPED)

Rotate the appropriate arrow i ndicator to adjust the module , the recommended approximate settings are:

Under % Volts Set

% Volts Reset

Over % Volts Set

% Volts Reset

90

5

1 1 0

5

The module includes an adjustable time delay relay to prevent nuisance tripping (typically set at 25 percent, or approximately 2.5 seconds). See typicalwiring diagram in

Figure 5-7.

A1 1 - TB2-1

0

14 1 1

1 2

2 1 24

A18

. com

1 8 1 5 1 6 L N 26 25 28

0 0 0 0 0 0

TB21-26

ES-1858

FIGURE

5-8.

OVER/UNDER FREQUENCY SENSOR MODULE

GND

0

14 1 1 12

22 21 24

A17

1 8 1 5 16 L N 26

25 28

0 0 0 0 0 0

TB21-26

K17

1

9

GND

A1 1 - TB2-3

T.D.

9

3

�:

B

A

A1 1 - TBH O

ES-1857

FIGURE

5-7.

OVER/UNDER VOLTAGE SENSOR MODULE

OVERSPEED (FREQUENCY DETECTION)

MODULE

This module derives a speed (Hz) signal from the PMG but is powered from the generator set battery. A small time delay, typically one second, is incorporated in the over speed function to allow for engine overshoot. The module contains two adjustable potentiometers, Overspeed and

Cranking (the cranking potentiometer is not used how ever).

The Overspeed potentiometer is adjustable from 1 500 to

2500 RPM. Adjust the Overspeed potentiometer to achieve overspeed at approximately 1 800 to 1 900 RPM for 50 Hz units and 2100 to 2200 RPM for 60 Hz units. See typical wiring diagram in Figure 5-9.

CRANKING

POTENTIOMETER

OVERS PEED

POTENTIOMETE R

OVE�UNDER FREQUENCY SENSOR

MODULE (IF EQUIPPED)

Nominal Hz 50

Under Hz Set 45

Over Hz Set 55

Reset

53

60

55

10 (P3)

1---lr+- B-

Rotate the appropriate arrow indicator to adjust the module , the recommended settings are:

Reset 47


65

63

1--+-+-

9

(P2)

}-

AUXILIARY

TERMINAL

BLOCK

0

DO

@]oD D

1--+-+r- B+ (A1 1 - TBHO)

1--i<-+- SIGNAL OUT (A1 1 - TB1-5)

1--+-+- NOT USED

�1-+-- B+ OR B- (A1 1 - TB1 -1)

1--1-+- NOT USED

ES-1858

See typical wiring diagram in Figure 5-8. www

5-1 0

FIGURE

5·9.

OVERSPEED (FREQUENCY DETECTION) MODULE

ROTATING RECTIFIER ASSEMBLY

The rectifier assembly, Rgure 5-1 0, is split into two plates, the positive and negative, and the main rotor is connected acros� these plates. Each plate carries 3 diodes, the negat1ve plate carrying negative based diodes, and the positive plate carries positive based diodes. The correct polarity diodes must be fitted to their respective plate.

6.

4. Reverse ohmmeter leads from Steps 2 and 3 and record resistance value of each rectifier; positive stud (X) to CR1 , CR2, and CR3; and negative stud

(XX) to CR4, CR5, and CR6.

. com

� eplace defective rectifier assembly with new, iden tical part.

I

A CAUTION

I

Excessive dust or din on di odes and other components will cause over heating and eventual failure. Keep these assem blies clean!

Use 24 Jn.lbs.

(2.

7

N•m) torque when replacing nuts of positive (X) and negative (XX) studs, and

CR1 to CR6.

FIGURE 5-10. TES11NG ROTA11NG RECllAER ASSEMBLY

Replacing Rectifiers

To replace rectifiers use the following procedure:

1 . Disconnect diode lead wire from stud terminal.

2. Use proper size wrench to u nscrew dode from rectifier assembly base.

3. AWIY heatsink COI1lJOUnd to underside of new threads. ci ode.

DO

NOT apply this COI1lJOUnd to clode stud

Surge Suppressor

4. Insert new diode into mounting hole. Torque cfJOdes on rotating rectifier assembly to 36-42 in-1:>5. (4-4.8

N•m).

The surge suppressor (varistor) connected across the two rectifier plates prevents high transient reverse voltages in i� no� polari_zed and will show an infinite reading in both d1�ect1ons with an ohmmeter. H defective, signs of burning w111 probably be apparent and it will give a full deflection

(short-circuit) reading. Replace if defective.

5. Reconnect diode lead wire to stud teminal. Use 24 in-lbs. (2.7 N•m) torque when repladng nuts.

PERMANENT MAGNET EXCITER

The permanent magnet exciter is the main power supply

Rectifier Diodes

':J sing an accurate ohmmeter, test each CR using nega tive and positive polarities. Test rectifiers (diodes) as follows: for a PMG A VR and is isolated from all other windings.

For this reason the output from the exciter must be tested independently across its terminals, which are connected to auxiliary terminal board (exciter leads P2, P3, and P4).

1 . Disconnect all leads from assembly to be tested.

2. Connect one lead to the positive (X) stud and connect other lead to CR1 , CR2, and CR3 in tum;

With the machine run up to full speed, the output voltage across the leads P2, P3, and P4 should be balanced at

. ElectricalPartManuals independent from the rest of the machine, and has no effect on the separate excitation tests that follow. Refer

3. Connect one lead to the negative (XX) stud and

' record resistance value of each rectifier. to appropriate wiring diagram/schematic in Section 7.

The permanent magnet excHer stator resistance Is

4.4 ohms line www to-line.

5-1 1

EXCITER ROTOR

Testing for Grounds

Connect leads of ohmmeter between each CR lead and exciter rotor laminations. Use an ohmmeter set at the highest resistance range. An ohmmeter reading less than one megohm (1 ,000,000 ohms) indicates defective ground insulation. See Figure 5-1 1 .

Testing for Open or Shorted Windings

Use a Wheatstone Bridge for this test. Disconnect main rotor field leads which oonnect to rotating rectifier assem blies at the positive and negative studs. Disconnect lead wires from diodes CR1 , CR2, CR3, CR4, CR5, and CR6.

Test between exciter lead pairs U6-V6, V6-W6 and U6-

W6. Refer to Table 5-1 for resistance values.

Be sure to Identify the gensel model, kW rating and generator frame size from the generator set nameplate before reviewing

Table

5-1.

EXCITER STATOR

Testing for Grounds

Using an ohmmeter, R x 1 00 scale, measure the insula tion resistance between either lead X or

XX and the lam nations, Rgure 5-1 2. A reading of less than infinity indi cates a ground.

. com

FIGURE 5-12. TESllNG EXaTER STATOR FOR GROUNDS

Testing Winding Resistance

Measure ooil resistance between leads X and

XX with an ohmmeter, scale R x 1 . See Rgure 5-1 3. Refer to Table

5-1 for resistance values.

Be sure to frame

Table 5-1.

Identify the genaet model, kW rating and generator size from the generator set nameplate before reviewing

OHMMETER

CR5

G-1183-2

SCHEMATIC

OF EXCITER

WIRING


FIGURE 5-11. TESTING EXaTER ROTOR

G-1183-1

FIGURE 5-13. TES11NG EXaTER STATOR FOR OPEN aRCUIT

GENERATOR ROTOR

Testing for Grounds

Use an ohmmeter, (R x 1 00 scale) and measure as follows: www

1 . Disconnect rotor leads from the rotating diodes.

2. Measure between either lead and the rotor shaft,

FigUre 5-14.

5-1 2

3. A reading of less than infinity indicates a ground.

CONTACT ONE PROD TO

EACH OF 1HE FIELD LEADS

AND OTHER POOD TO ROTOR SHAFT.

F ROTOR IS GOOD, lHERE WU BE

ONE MEGOI-N OR GREATER RESISTANCE.

G-1187

FIGURE 5-14. TESllNG GENERATOR ROTOR

FOR

GROUNDS

Testing for an Open Circuit

1 . Disconnect and test between rotor leads, F�gure 5-

1 5.

2. Replace the rotor if it is grounded or has an open or short. Refer to Table 5-1 for resistance values.

Be .ure to frame size

Table 5-1.

Identify the gensel model, kW rating and generator from the generator aet nameplate before reviewing

OHMMETER

Connect all (U, V, and W) stator output leads together.

Use an ohmmeter set on the R x 1 00 scale and measure the insulation resistance between these windings and the stator frame. A reading of less than infinity indicates a ground. Field circuit breaker can be either open or closed for this test.

Testing for Shorts

. com wires (U5-U6, U1 -U2, etc.).

Be sure to disconnect the in strumentation leads and stator leads U1 , U2, US, V2, and

W2. Connect an ohmmeter, R x 1 00 scale to one lead of a stator winding (leaving the other end of coil winding being tested open), and the other ohmmeter lead to all other stator leads connected together.

Example:

•

•

•

Ohmmeter lead to: U6 coil winding lead.

Ohmmeter lead to: U1 , 2, V1 , 2, 5, 6, W1 , 2, 5, and 6 connected together.

Coil winding lead US, open.

A reading of less than infinity indicates a short. Repeat test for all six coils.

Measure resistance of windings using a Kelvin Bridge meter. Refer to

Figure 5-1 6.

H any windings are shorted, open, or grounded, first check the leads for broken wires or damaged insulation.

H winding leads show no damage, and it is determined that windings are damaged internally, replace the stator assembly. Refer to Table 5-1 for resis tance values.

Be a�re to

Identify the gensel model, kW rating and genwator rr.ne size from the generator aet nameplate before reviewing

Table

5-1. ca.ITACT ON: PROO TO EACH

FELD LEAD

G-1187-1

FIGURE

5-15. TES11NG GENERATOR ROTOR FOR

OPEN aRCtJT

TEST

BEJW:EN WIRE PAIRS

UIH.O, V6-LO, W&-LO

GENERATOR STATOR

A DANGER

High-voltage,

1,900

to

15,000 volts,

present special hazards of severe personal Injury or shock hazard may still exist, caused by Induced voltage within the generator.

Setvlce

personnel must

be

well-trained/qualified to worlc with distribution voltages.

Testing for Grounds

Before testing stator, disconnect all external load and www

5-1 3

THREE PHASE t.l)[)ELS,

TEST BETWEEN WIRE PAIRS

U1 -U2, V1 -V2, W1·W2, lJ5.U6, V5-V6, W5-W6

FIGURE 5-16. TES11NG GENERATOR STATOR WINDINGS

TABLE 5-1 . WINDING RESISTANCE VALUES*

GENSET

MODEL

DESIGNATIONS

OFCC

OFEB

OFFA

OFEC

OFFB

OFGA

OFGB

OFGC

OFJA

OFJB

OFJC

OFJO

OFLA

OFLB

OFLC

OFLO

OFMA

OFMB

OFAA

OFBC

OFBO

OFAB

OFBO

OFBE

OFAC

OFBE

OFBF

OFCB

OFCB

NT4

NT4

VTA1

VTA2

VTA3

KTA31

KTA32

KTA33

KTA51

KTA52

KTA53

KTA54

KTT51

KTT52

NT4

NTS

NTS

NT6

NTA2

NTA2

NTA3

KTA1 2

KTT1 1

KTT1 2

GEN. EXCITER

KW RATING FRAME STATOR ROTOR

50Hz 60Hz SIZE

1 75 200

1 75 200

1 75 200

4C

4C

4C

25

25

25

0 . 1 4

0 . 1 4

0.1 4

200 230

200 230

220 250

220 250

220

250 275

300

275

40

40

40

40

4E

4E

4E

4F

25

25

25

25

25

25

25

25

31 0

330

400

400 450

450

500

440

550

350

400

450

500

600 sc sc

50

50

SE

SE

S F

6A

25

25

25

25

25

25

25

1 7""

0 . 1 4

0 . 1 4

0 . 1 4

0. 1 4

0 . 1 4

0. 1 4

0 . 1 4

0 . 1 4

0.1 7

0. 1 7

0. 1 7

0. 1 7

0. 1 7

0. 1 7

0. 1 7

0. 1 6

620 750

660 800

800 900

900 1 000

900

1 1 20

1 000

1 1 00

1 250

1 200

1 1 00

1 250

1 280 1 500

6B

6B

6C

6C

60

60

7B

7G

7G

7G

1 7""

1 7""

1 7""

1 7""

1 7""

1 7""

1 7""

1 7"*

1 7""

1 7**

0. 1 6

0.1 6

0 . 1 6

0. 1 6

0. 1 6

0.1 6

0.20

0.20

0.20

0.20

STATOR

(Per Phase: Wye or Series Wye)

0.01 7-0.023

. com

0.01 7-0.023

0.01 7-0.023

0 .91

0.91

0.014-0.020

0.01 4-0.020

0.01 4-0.020

0.01 4-0.020

0.01 0-0.01 5

0.01 0-0.015

0.01 0-0.015

0.0097-0.01 0

1 .04

1 .04

1 .04

1 .04

1 . 1 7

1 . 1 7

1 .1 7

1 .35

0.068-0.0090

0. 0068-0.0090

0.0058-0.0080

0. 0058-0.0080

0.0043-0.0069

0.0043-0.0069

0.0031 -0.0042

0 .0037-0.0053

0.0030-0.0033

0.0030-0.0033

0.0023-0.0028

0.0023-0.0028

0.001 8-0.0023

0.001 8-0.0023

0 .001 2-0.001 8

0.001 2-0.001 8

0.001 2-0.00 1 8

0.001 2-0.00 1 8

1 .55

1 .55

1 .77

1 .77

1 .96

1 .96

2 . 1 6

1 .37

1 .47

1 .47

1 .66

1 .66

1 .89

1 .89

2 .29

2.29

2.29

2.29

* Resistance figures are approximates, at 68°F (20°C) ±1 0%.

** Units built prior to November, 1989, were 28 ohms.

Rgure 5-1 7 shows the general reconnection possibilities for the generators. When reconnecting for a different voltage, refer to AC Reconnect Wiring Diagram in Section 7 and AC diagrams that came with unit. www

5-1 4

C') c

L

1 20/240 1

60

�

�-+--------4---�-4

1 1 0/220 1 50

� c w ffi

:::> g

V6

W I v

W5

GENERATOR

CONNECTION

SCHEMATIC

DIAGRAM

GENERATOR CONNECTION

WIRING DIAGRAM

ROTATING CLOCKWISE VIEWED

AT THE DRIVE END

I

FRAME 4 FRAME S, 6, 7

Vi

I

.

L Ll

(U) t

�.

...,

�6)1---- LO(N)

U2

5

V2 -

W5 -

V

6----'1

I._ __.

-

W

I

4

-

' w

w

6

•

5

V2-:.

W5-

7 l �r-

V f--W2

4

•

-

W2

U l

. P"'"i

L2(WJ r;:::;::;===::::Lji'*TJ-u cu J

C') c

�

L

1 20/240 3 60

� z

1 1 0/220 3 50 a:

1 1 5/230 3 50

·�

W5

Ul CT22

L2(V)

W6

V5

V2

CT2

�===:=!J.c:J.L3

(WJ

L-------

LO(NJ

W2 -

W5

N w

•

V2 -r,.. V

V5 -V""

5

- W6 7

4

- V6 6

- U I

�

--

-

��+-----HH-----

5

W2 W5-

V2---...

V5-./"' u2-'>a

U5-C

V

�� u r--u6

�r--w 1

6

8

4

L

1 20/208 3 60

1 27/220 3 60

C')

1 39/240 3 60 c �-+--------;---r-�

�

U2 r;========:J..JI-+T_J__

L I ( U )

U6 v

V2

V6"

CT22

L2 ( V )

...J

...J

V5

W5 � I

--- LO ( N ) z

1 1 0/1 90

1 1 5/200

1 20/208

1 27/220

3

3

3

3

50

50

50

50

4

-=�\_�-N�-

U I

6

7

W5

W2

-

----..�

V2

W f-

---t=w:===-+-

W I

W6

V6

8 l:ui22-=�-===u=-+-

U6

,---

-

W5-

V5-l/

�r-u l

U5iri- V

I

•

.__

--'W-'-'1---t-41

1-t---

V2----�7

U2-

-i;:r--U6

�

8

�

C\1 c

�

L z

220/380 3 60

240/41 6 3 60

60

50

� w

W2

W5

W6

'----��6bl-�-

LJ ( W)

5-----+-=:=::IIEt- V

I

6--�

7 V2 -

_IJI'

6

W5-

7

V2-

::a

-

W

•- w& v

V6

V5-

4 8 U2

-

-

254/440

277/480

220/380

230/400

240/41 6

3

3

3

3

3

60


50 CT23

4

8

U5 u

•- u6

U5__j-

254/440 3 50

'--

ES1866c

I

H 347/600 3 60 www

FIGURE 5-17. RECONNECTION DIAGRAM

5-1 5

ELECTRONIC GOVERNOR

Generator frequency is in direct ratio to engine speed which is controlled by the governor. The governor control has four potentiometers for making adjustments. See

Figure 5-18. Use a frequency meter or tachometer to monitor the unit during adjustment procedure.

Q.

::l

8 8

"""

C\1

5 5

....

+

0

¢ n

...J e z a:

�.ffl�

:::E t>

1�1�11@1�1�11�11�1�1�1�1@1

2 3 4 5 6 7

8 9 1 0 1 1

IDLE S PEED

RUN SPEED

D

GAIN

DROOP

1f2

�

2. Idle Speed potentiometer.

A. Tum the screw counterclockwise 20 turns.

B. Tum the screw clockwise 1 0 turns.

C. This will set the idle speed potentiometer to its mid position.

3. Run Speed potentiometer.

B. Tum the screw clockwise 1 0 turns.

C. This will set the run speed potentiometer to its mid position.

. com

4. Gain potentiometer.

A. Set the Gain adjustment at the third division from zero.

5. Droop potentiometer.

A. For i sochronous operation, the droop potenti ometer must be turned fully counterclockwise and will not require any further adjustment.

B. Tum the screw to approximately 40 for 3 percent droop.

C. Tum the screw to approximately 80 for 5 percent droop.

Calibration Checks:

1 . Start the generator set.

FIGURE 5·18. ELECTRONIC GOVERNOR

Gain: The Gain control is a one-turn potentiometer. It is used to adjust the sensitivity of the governor. A clockwise rotation of the potentiometer will shorten the response t:me to load changes.

2. For proper full-load generator set operation the engine no-load speed must first be adjusted to the desired allowable speed droop. (For example : iso chronous operation set to 60.0 Hz/1 800 r/min (50.0

Hz/1 500 r/min), for 3% speed droop set to 61 .8 Hz/

1 854 r/min (51 .5 Hz/1 545 r/min) , for 5% speed droop set to 63.0 Hz/1890 r/min (52.5 Hz/1 575 r/ min.)

Droop: The Droop control is a one-turn potentiometer. It is adjustable for zero % (isochronous) to more than 5% speed droop. Fully counterclockwise rotation is 0% speed droop.

Idle Speed: The Idle Speed control is a 20-turn po tentiometer for adjusting the idle speed. A clockwise rotation will increase the idle speed.

Run Speed: The Run Speed control is a 20-turn po tentiometer for setting the desired no-load governed

With the generator set warmed up to proper operat ing temperature, adjust the Run Speed potentiome ter until the engine is operating at the desired frequency or r/min.

3. With no load connected to the generator set, turn the

GAIN adjustment clockwise slowly until the actuator lever oscillates. Reduce the GAIN adjustment slowly counterclockwise until the lever is stable.

Upset the lever by hand. If the lever oscillates up to

3 deminishing oscillations and stops, the setting is correct. speed. A clockwise rotation will increase the run speed.

Adjustments


Preliminary A djustments:

1 . Frequency Adjust (engine speed) potentiometer on

4. Apply and remove loads to check generator set re sponse. If generator set operation is satisfactory, the governor is now calibrated. If generator set response is not satisfactory, review Step 3. If electric governor cannot be properly calibrated, contact your service representative for assistance.

Fine Speed Adjustment: After the GAIN adjustment is made, the full load governed Run Speed may require a control panel (if equipped) .

A. Loosen the locking nut. minor adjustment to equal the desired speed (i.e . , 60 Hz,

B. With a screwdriver, turn th e potentiometer fully counterclockwise , then fully clockwise , then to

1 800 r/min or 50 Hz, 1 500 r/min) . Use the SPEED AD

JUST potentiometer (when supplied) on the engine in strument panel for fine speed adjustments of less than mid position.

C. Hold mid position setting with screwdriver, and

±1 00 r/min.

5-1 6

Electric Fuel Control {EFC) Governor

System Description

The EFC governor system contains a magnetic pickup, electronic control, and the fuel pump actuator. See Rgure

5-1 9.

FUEL PUMP

ACTUATOR

MAGNETIC

PICKUP

SENSOR

ACTUATOR

STUDS

FUEL

SHUTOFF

VALVE

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FUEL

FLOW

FIGURE 5-20. FUEL PUMP ASSEMBLY

GOVERNOR

CONTROL

ENGINE

FLYWHEEL

RING GEAR

3. H further tests and repair is required, oontact your

Cummins/Onan distributor for further information, or request a oopy of

Electric Fuel Control Governor brochure (bulletin no. 3379231 -03).

AGURE 5-19.

EFC

GOVERNOR SYSTEM

The magnetic pickup senses engine speed at the flywheel ring gear and sends an alternating current (AC) electrical signal to the governor oontrol.

BATTERIES

Check that oonnections are clean and tight. A light coating of non-conductive grease will help retard oorrosion at terminals.

The governor oontrol oompares the electrical signal from the magnetic pickup with a preset reference point.

H there is a difference in the two signals, the oontrol will change the current to the actuator (located on the ergne side of

Check the charge oondition of the starting batteries with a hydrometer. Keep the electrolyte at the proper level above the plates by adding distilled water. Check specific gravity and re-charge if below 1 .260. the fuel pump).

H 1he generator set Is operated In an area where the ambient temperature

Is consistently above gsa

F (35° C), a specific gravity of 1.225 is recommended to reduce electrolyte loss.

The change in current in the actuator ooil will make the actuator shaft rotate. The fuel flow, and engine speed or power will change when the actuator shaft rotates.

I

A WARNING

I

Perlonnance Checks

If the generator set operation is rough or surges, review servicing batteries. Wear protective apron and goggles when checking specfflc gravity and adding distilled water. the following:

1

.

Start the generator set and check voltage readings at governor oontrol terminals for; magnetic pickup

(1 .5 VAC minimum at cranking, to 30 VAC maximum at genset operating speed), battery

B+

(24 VDC), fuel pump actuator (1 9-20 VDC).

H the battery loses excess water, the alternator charge may be too high. Ukewise, if battery state of charge is not maintained, the charge rate may be too low. Refer to

. ElectricalPartManuals click in the actuator should be heard when B+ is applied and removed. This check only shows that

BATIERY CABLES

With the starter motor operating, check the voltage drops

(1) from the battery negative post (not the cable clamp) to the actuator is operating (rotating to open and the grounding stud, (2) from the battery positive post to the closed position), but not if its binding, futher disas sembly of fuel pump may be required to inspecV repair 0-rings, pump, etc. www

5-17 battery terminal stud on the solenoid. Normally, each of these should be less than 0.3 volt. H extra long battery cables are used, slightly higher voltage drops may result.

Thoroughly clean all connections in any part of the circuit showing exces::-Jve voltage drop.

ALTERNATOR

With the engine running, check the battery condition DC voltmeter. If the alternator is operating properly, the voltmeter reading should be between 26 and 28 volts. If the voltmeter reading is constantly more or less than this, stop the generator set and check for a loose or slipping drive belt, poor terminal connections, or broken lead wires. Repair or replace as required. Also check the condition of the batteries and battery cables.

If everything checks out okay, use a separate voltmeter to determine the alternator output voltage, and to verify accuracy of panel mounted DC voltmeter. Connect the positive (+) lead to the output terminal, and connect the negative (-) lead to ground. Start the generator set and run for a few minutes to allow the voltage to stabilize. A proper operating system will have nominal output voltage of 26 to

28 volts.

If the output voltage is high (over 28 volts), the regulator is probably shorted and should be replaced.

If the output voltage is low (equals battery voltage), the problem could be wom or broken brushes, an open regu lator, or an open field diode.

If further tests and repair is required, contact your Cummins/Onan distributor, or replace alternator.

STARTER SOLENOID

Apply B+ to the terminal marked "S". Jui"Jl)er a ground wire to the solenoid mounting bracket. Solenoid should activate.

TESTING AC LOAD CIRCUIT BREAKER

General

The AC circuit breaker does not require any special maintenance other than periodic exercise and a check of conductor mounting. customer requirements.

. com to the breaker. A typical breaker diagram is shown in

Figure 5-21 for reference. When performing tests and adjustments, avoid accidental start-up by placing the

Run/Stop/Remote switch in Stop position and discon necting the battery negative (-) cable.

�WARNING

J

Accidental staning of the generator set during service procedures can result In severe persona/ Injury or death. Place the Run/Stop/Remote switch In Stop position, and disconnect the battery negative (

-

) cable.

. SHUNT TRIP

+COMMON ALARM

-GROUND

AUXJUARY

A

COMMON

B

If the contacts are good, B+ should be present between terminal marked

"I" and ground. The voltage drop meas ured across the contacts should never exceed one volt in circuit application.

FUEL SOLENOID

If there is fuel to the injection pump, but no fuel at injection nozzle, the fuel solenoid might be defective.

OFF;:::::::..

RESET

To check fuel solenoid operation, remove the B+ lead connection from the solenoid, and jumper a separate

B+ connection to this teminal. The injection pump should

SIDE VIEW

-

HANDLE

POSITIONS click. If no click is heard, the fuel solenoid must be replaced.

CONTROL SWITCH

Remove battery

B+ cable. Place ohmmeter leads across switch. Open and close switch while observing the ohm meter. A normally open switch should indicate infinite

ES-1564-5

. ElectricalPartManuals resistance when open and continuity when closed. A

FIGURE

5-21. OPllONAL

CIRCUIT BREAKER DIAGRAM

Exerr;/slng Breaker: Actuate the breaker handle to the normally closed switch should indcate continuity when closed and infinite resistance when open. Replace switch if defective.

On and Off positions several times. If the breaker is equipped with a Trip Test button, the breaker should be tripped, reset and actuated to On several times. This will remove any dust from the mechanism and latch surfaces. www

5-1 8

Checking Insulation Resistance: Disconnect the load and line conductors from the breaker, and place the

' meter that will apply at least 500 volts to the test leads.

Measure the insulation resistance between each pole, and to ground. Also test between the line and load terminals with the breaker in the Off position. A resistance reading less than 1 00,000 ohms indicates a ground.

Investigate for possible c o nta m i n a t i o n on the breaker case surfaces, clean if necessary and retest.

Checking Contact Resistance: Extensive operation of the breaker under load may eventually cause contacts to deteriorate. Test by a Resistance Check, or by a Voltage

Drop Check across the breaker poles. Except when generator set operation is required for testing, avoid accidental start-up by placing the Run/Stop/Remote switch in Stop position and disconnecting the battery negative (-) cable.

�WARNING

I

Accidental starting of the generator set during service procedures can result in severe personal Injury or death. Place the Run/Stop/Remote switch In Stop position, and disconnect the battery negative (-) cable.

3. There should only be slight variation in the voltage dropped across each pole of the breaker. Unequal or excessive millivolt drops across the complete breaker, or one pole, indicates contaminated con tacts or loose connections.

. com the battery negative (-) cable.

I

A WARNING]

erator

Accidental starting of the gen

set

during service procedures can result

In severe personal Injury or death. Place the

Run/Stop/Remote switch In Stop position, and disconnect the battery negative (-) cable.

Checking Shunt-Trip Operation: The shunt-trip feature is available in varying AC or DC voltages. The circuit breaker model is selected and installed at the factory to meet customer requirements. Check the shunt-trip func tion as follows:

Resistance Check:

1 . Disconnect the line and load wires from the circuit breaker.

1 . Refer to the original equipment order, installation wiring diagrams, and unit wire routing to identify and confirm proper AC or

DC signal source connections.

3. Apply the appropriate signal voltage (12 VDC; 240,

480-VAC). The shunt-trip solenoid should energize and trip the breaker open.

2. Move the breaker handle to the On position and check the resistance across each pole (line to load).

4. H the breaker did not trip open, remove the signal source. Perform continuity check of interconnect wiring and shunt-trip solenoid lead wires. Replace interconnect wiring if defective.

3. Resistance should be very low (near zero) and relatively equal across all poles.

Voltage Drop Check: This test is done with the conduc tors connected, generator set operating, and load ap plied. As a precaution against electrical shock, place an insulating mat or a dry wood platform on the floor to stand on when taking measurements.

Checking Auxiliary Contacts: H equipped, the breaker will have three leads for wiring to an internal single-pole, double-throw switch. The switch allows connection of a remote annunciator (see installation wiring diagrams).

Perform continuity checks of the switch with the breaker in On and

Off positions to confirm operation.

[A WARNING I

Contact with high voltage can cause severe personal Injury or death. Do not touch any exposed wiring or components with any body part, clothing, tool or jewelry. Stand on an insulating mat

Adjusting Magnetic Trip Operation: If equipped with front-adjustable magnetic trip controls, the short circuit protection feature for each pole of the breaker can be

1

. adjusted equally or i ndividually as required. Surge cur rent above the trip settings will actuate the trip mecha nism. These adjustors are set equally to the high position or dry wood platfonn when taking measurements.

. ElectricalPartManuals the load connections. at the factory. Consult on-site requirements and adjust to proper position. www

5-1 9

www


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Section

6.

Generator

Disassembly/Reassembly

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2. Remove the generator air inlet panel and access

GENERATOR DISASSEMBLY

covers from control housing (see Figure 6-1 ).

The following procedures provide information for removal and reassermly of the generator PMG exciter, control housing, and stator/rotor assemblies.

Be sure to read through this section first, before performing procedures listed, to determine the steps most appropriate for the service attention required.

3. Remove the three M5x1 2mm capscrews and bck washers from the PMG exciter assembly cover, and remove cover.

4. Disconnect the PMG wiring harness connector.

A DANGER

High-voltage, 1,900 to 15,000 volts, present special hazards of severe personal Injury or death. Even after genset shutdown, an electrical shock hazard may still exist, caused by Induced voltage within the generator. Setvlce personnel must be well-trained/qualified to work with distribution voltages.

6. Tap the stator housing out of its spigot, and care fully remove from generator endbracket.

The highly magnetic rotor wiU attract the stator core, care must be taken to avoid any contact which may damage the windings.

Permanent Magnet Exciter Removal

5. Remove the four bolts and clamps retaining the exciter stator housing to the endbracket.

1 . Disconnect the negative (-) battery cable to pre

I vent accidental starting of the generator set while servicing.

A

WARNING

I

Accidental starting of the gen erator set during this procedure presents the hazard of severe personal Injury or death.

Make sure to disconnect the negative tery cable before beginning.

(-) bat

7. Remove the hex head through-bolt from the rotor shaft and firmly pull the complete rotor �embly from its location. Keep the rotor clean by avoiding contact with metal dust or particles.

J

A

CAUTION

I

The rotor assembly should under no circumstances be dismantled, or the magnetic properties will be destroyed.

CONTROL

HOUSING ACCESS

COVERS

CONTROL HOUSm

-----------

GENERATOR

AIR DISCHARGE

COVERS


PMG

EXCITER

ASSEMBLY www

GENERATOR

AIR INLET AND

ACCESS

COVERS

FIGURE �1. GENERATOR AND CONTROL HOUSING ASSEMBLY

6-1

Main

1

.

Stator and Rotor Removal

Remove the air inlet and discharge panels and ac cess covers from control housing and generator

(see Figure 6-1 ).

2. Crank or bar the engine/generator to position the rotor such that a full pole face is at the bottom of the main stator core. Proper positioning can be viewed through the generator access openings. Refer to engine service manual for proper cranking or bar ring procedure.

3. Disconnect the negative (-) battery cable to pre vent accidental starting of the generator set while servicing.

I

A WARNING

I erator set during this procedure presents the hazard of severe personal Injury or death.

Make sure to disconnect the negative (-) bat tery cable before beginning.

4. Disconnect all load wires from the reconnection terminal block assembly (see Rgure 6-2). If equipped with the circuit breaker option, discon nect load wires from circuit breaker. Check that all leads are labeled to ease reassembly.

PLACE SLING STRAPS

THROUGH HOUSING

AUXILIARY

TERMINAL

BLOCK r--r

I

I

I

--·-'---+------1

I

I

I

I

._ __ _

I

I I

IJ

•

6. Refer to the proper wiring diagram/schematic in

Wiring Diagrams section and on-site specifics for remote control/monitoring. Open control box doors, and check wire markings for legibility to trol box and conduit box such as:

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DC

•

Wiring

A1 1!TB1 -8,-1 0, and terminals -1 through -7 and

TB2 as re<JJired.

Unplug A1 1/J1 and J2.

AC

•

Wiring

VR21-X and -XX.

•

TB21-22 to -30.

Arrange leads so they can be easily withdrawn from the control box.

7. Use a hoist or similar lifting device to support the control housing assembly (see Fi�re 6-2).

I

A WARNING

I

To prevent personal Injury, use adequate lifting devices to suppon heavy components. Keep hands and feet clear while lifting.

B. Loosen the fasteners that secure the control hous ing side and bottom panels to generator. Make sure that hoisting device is controlling weight of control housing assembly.

9. Remove control housing fasteners, and remove the control housing assembly from the generator.

Replace panel fasteners to their respectibe posi tions for safe keeping, and tighten finger-tight.

1 0. Remove control housing mounting brackets from both sides of generator, and assemble lifting eyes to generator.

1 1 . Remove as necessary, air intake components to engine that may interfere with disassembly and reassembly of generator.

To remove the stator and rotor at the same time, refer to

Generator Assembly Removal, later this section. To re move the stator and rotor Individually, continue with step

1 2.

RECONNECTION

TERMINALS

LIFTING EYES

1 2. Remove the four botts retaining the bearing car tridge housing in the endbracket (outer four botts).

FIGURE 6-2.

REMOVING CONTROL HOUSING

1 3. Remove the eight botts holding the endbracket to the generator housing.

5.

Disconnect all wire leads from the auxiliary termi nal block, inside conduit box (see Rgure 6-2), that would interfere with control housing removal. www

6-2

14. Insert two botts (M1 0) in the two holes provided for

"jacking" purposes, on the endbracket center line.

Screw botts in until endbracket spigot is clear of locating recess.

1 5. Carefully tap the whole assembly off the bearing

cartridge housing, ensuring the endbracket is supported to prevent the exciter stator from dam aging the windings on the exciter rotor.

I

I

INGl

To prevent personal injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting.

1 6. The exciter stator is now accessible for inspection and removal from endbrackeVengine adaptor.

1 7 .

The end bearing can now be removed if required.

Refer to Bearing Removal.

1 8.

Remove the fasteners from the two generator mounting feet brackets.

1 9.

Using an adequate lifting device, lift the generator

(at lifting eyes provided, and main stator housing) until the mounting feet brackets are clear of the frame member (see Figures 6-3 and 6-4).

GENE RATOR

LIFTING POSITIONS is not resting on inside of stator assembly. See

Rgure 6-4.

23. Verify that the stator is adequately supported and then carefully remove the capscrews from the stator attachment ring.

I

A WARNING

I

. com use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting.

I

A CAUTION

I

Improper stator assembly rig ging and handling can resun In damage to stator and rotor assemblies. Lfftlng eyes may not be at center-of-gravity position of stator assembly. Therefore, lffting and moving the stator assembly alone, by hoisting at lifting eyes only, presents the hazard of load Imbal ance; allowing one end to drop and other end to rise. Make sure the stator is adequately hookedlstraped to maintain level control of stator assembly while lfftlng and moving.

24. Being careful not to drag the windings on the rotor, move the stator assembly suffidently away from engine to sling and support the rotor assermly.

Do not allow rotor assembly to hang on engine fly wheel.

[ACAUTION

I

Drive disc damage can bP. caused by allowing the rotor assembly to hang on fl)wheel. Use adequate hoist and sling to suppott the rotor assembly.

25. Reposition or add hoist and sling support for the main rotor, and remove the forklift. See Rgure 6-5,

Rotor Uft detail.

MCA.JNTING FEET

BRACKETS

BLOCKING UNDER

ENGINE FLYWHEEL

HOUSING

FIGURE

6-3.

GENERATOR UFTlNG

POSillONS

jAWARNING

I

To prevent personal Injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting.

20.

2 1 .

If generator set does not have chassis mounts at generator end (N855 and

K19), block the rear of the engine in place by supporting the flywheel housing.

. ElectricalPartManuals of the set weight is supported by the blocking (see

Figure 6-3). drag the windings on the rotor. Place stator as sembly away from the chassis in the horizontal position.

27. Using the hoist and sling to support the rotor, care fully remove the capscrews and flat washers that secure the drive discs to the engine flywheel.

I

A

WARNING

I

Disconnect the grounding strap from the flywheel housing.

26. Remove the stator assembly, being careful not to

22.

Using a forklift, position a lifting bar of the forklift www

6-3 components. Keep hands and feet clear while lifting.

STATOR

ASSEMBLY

LIFT l

ROTOR

ASSEMBLY

LIFT l

USE FORKLFT OR OTHER

ADEQUATE

UFTING DEVICE

TO SUGHTL Y

UFT ROTOR

SHAFT

UNTIL ROTOR CAN BE

SUPPORTED BY HOISTJSL.m.

---- r::::·==

• -

STATOR

ASSEMBLY

FIGURE 6-4. REIIOVWG

STATOR

ASSEMBLY

ROTOR

ASSEMBLY

28. Remove the rotor asseni>ly and place it on wood blocks in the horizontal position. To avoid possible distortion, do not allow the drive discs and fan to rest on anything. www


6-4

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BLOWER

COUPLING

RECONNECTION

TERMINALS

ROTOR SHAFT

AIR DISCHARGE

COVERS

EXCITER

STATOR

PMG

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STATOR

PMG

EXCITER

ROTOR

END BEARING

EXCITER

ROTOR

ROTATING

RECTIFIER

ASSEMBLY

All G-1185

STATOR UFT

(EXAMPLE) www

FIGURE 6-5. TYPICAL GENERATOR ASSEMBLY

6-5

Generator Assembly Removal

29. Remove the fasteners from the two generator mounting feet brackets.

30. Using an adequate lifting device, lift the generator

(at lifting eyes provided, and main stator housing) until the mounting feet brackets are clear of the frame member (see Rgures 6-5 and 6-6).

GENERATOR

LIFTING POSrTIONS

J

A CAUTION

J

Improper generator assembly rigging and handling can result In damage to stator and rotor assemblies. Lifting eyes may not be at center-of-gravity position of stator as

. com sure the generator Is adequately hooked/ straped to maintain level control of assembly while lifting and moving.

35.

Remove the generator assembly away from en gine. Place generator assembly on floor with a piece of wood beneath the stator housing (toward

PMG end) to allow for endbracket removal, if de sired.

MOUNTING FEET

BRACKETS

BLOCKING UNDER

ENGINE FLYWHEEL

HOUSING

FIGURE

6-6.

GENERATOR UFTING POS

I110NS

31 . If generator set does not have chassis mounts at generator end (N855 and K1 9), block the rear of the engine in place by supporting the flywheel housing. A length of steel channel and wooden blocking is required to support the rear of the engine. Place the channel and blocking under the flywheel housing. Lower the generator until most of the set weight is supported by the blocking (see

Figure 6-3).

32.

Disconnect the grounding strap from the flywheel housing.

33. that secure the drive discs to the engine flywheel.

34. Verify that the generator assembly is adequately supported. Carefully remove the capscrews se curingthe engine adaptor endbracket to the engine flywheel housing.

A Y!ARNING

;

To prevent persona/ Injury, use adequate lifting devices to suppon heavy compo www

6-6

Bearing Removal

The end bearing is enclosed in a pre-packed cartridge housing and must only be dismantled as n�essary for r� lubrication, replacement, or when a majOr overhaul

IS carried out on the generator set.

Removal of the bearing can only be accomplished after removal of the endbracket, as follows:

1 . Remove the four screws holding bearing cap.

2. Remove cap.

3. Remove circlip.

4. Remove bearing cartridge housing complete with bearing.

When replacing bearing onto rotor shaft, be sure to apply pressing force to the

Inner face of the bearing only.

Bearing Lubrication: When re-lubricating or replacing the bearing, review the following.

•

•

•

Recommended Lubricant: Lithium based grease,

Mobilux No. 2 or Shell Alvania R3.

Temperature Range: -22°F to +248°F (-30°C to

+1 20°C}.

Quantity: 2.74 oz. (81 ml). About a third of the grease should be inserted in the bearing, the bearing cap cavity, and the bearing cartridge cav ity.

GENERATOR REASSEMBLY

Generator reasserrbly is the reverse of dsasserrbly procedure.

To with step

1 .

To assemble the stator and rotor I n d ividua l ly skip to step

16.

' procedures. Position the end bearing cartridge as serrbly close to proper position for hole alignment

9. with endbracket. torque.

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1 0. Install endbracket to the stator frame using the proper capscrews and lock washers, but do not tighten securely as yet.

1 . Using an adequate lifting device, locate the gen erator asserrbly into position near the engine fly wheel housing. Align the holes of the rotor drive discs with the holes of the engine flywheel. Install the capscrews and flat washers that secure the drive discs to the engine flywheel, hand tighten.

I

A WARNING

I

To prevent personal Injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting.

1 1 . Insert and start the threads of the bearing cartridge fasteners, and remove threaded alignment studs, through the endbracket into the cartridge housing.

1 2.

Uft slightly on endbracket and remove wooden whims holding rotor on center with stator.

1 3. Securely tighten the endbracket fasteners.

[ACAUTION

I

Improper generator assembly rigging and handling can result In damage to stator and rotor assemblies. Lifting eyes may not be at center-of-gravity position of stator as sembly. Therefore, lifting and moving the generator by hoisting at lifting eyes only, pres ents the

hazard

of load Imbalance; allowing one end to drop and other end to rise. Make sure the generator Is adequately hooked/ straped to maintain level control of assembly while lifting and moving.

1 4. Tighten the bearing cartridge fasteners to 4.5 ft lbs. (6 N•m) torque.

1 5 .

Install the PMG exciter assembly, if removed.

Refer to Permanent Magnet Exciter Installation, later this section.

Perform the

'Aligning Generator with

Engine' procedures, later

In thla section, then return to the following steps.

To assemble the control housing, skip to step

34.

2. Align the holes of the engine adaptor endbracket with the holes in the flywheel housing and install the capscrews and lock washers. Tighten to 45-55

1 6. If removed, replace exciter rotor and rotating rec tifier assembly to main rotor shaft. Reconnect main rotor wire leads to positive and negative terminals of rectifier assembly. ft-lbs. (61 -74 N•m) torque.

1 7. If removed, install the drive disc spacer, drive disc, and pressure plate on the rotor shaft. Install the

3. Secure the rotor assembly to the flywheel. Tighten eight capscrews and flat washers and tighten to capscrews to 1 90-200 ft-lbs. (257-271 N•m)

352 ft-lbs. (476 N•m) on frame sizes 4 to 6, 607 ft torque. lbs. (822 N•m) on frame 7. Note: 1500 kW, frame

7 uses 1 2 capscrews.

4.

Uft the generator slightly and remove any blocking from under the flywheel housing. Lower the gen shims to hold rotor on center with stator.

8. Press bearing onto rotor shaft, applying force to www into end bearing cartridge to aid subsequent

6-7

1 8. Using a hoist and sling to support the rotor, align erator (see Rgure 6-3).

5.

6.

� onn

� the grounding strap to the flywheel hous tighten securely.

I the holes in the drive disc with the corresponding holes in the flvwheel.

A WARNING

use adequate lifting devices to suppott heavy components. Keep hands and feet clear while lifting.

I


If endbracket has been removed, continue with step 7, otherwise skip to step

15.

1 9 . Secure the rotor assembly to the flywheel using appropriate capscrews and flat washers. Tighten to 190-200 ft-lbs. (257-271 N•m) torque. Do not allow rotor asserrbly to hang on engine flywheel.

7. Uft slightly on end of rotor shaft and install wooden

I

(Refer to Figure 6-4.)

A

CAUTION

l

Drive disc damage can be caused by allowing the rotor assembly to hang on flywheel. Use adequate holst and sling to support the rotor assembly.

20. Reassemble engine adaptor endbracket to stator frame if removed. Using an adequate lifting de vice, carefully move the stator into position over the rotor assembly, being careful not to drag the windings on the rotor.

I A

WARNING

I

use adequate lifting devices

to

suppon heavy components.

Keep

hands and

feet

clear while lifting.

procedures. Position the end bearing cartridge as sembly close to proper position for hole alignment with endbracket.

28. Assemble exciter stator, if removed, to inside of endbracket. lighten fasteners to 4.5 ft-lbs. (6 N•m) torque. tighten securely as yet.

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29. Install endbracket to the stator frame using the proper capscrews and lock washers, but do not

/A CAUTION

J

Improper

stator assembly rig ging and handling can

result

In damage to stator and rotor assemblies. Lifting eyes may

not

be at center-of-gravity position of stator assembly. Therefore, lifting

and

moving the stator assembly alone, by hoisting at lifting eyes only, presents the

hazard of lOad Imbal

ance; allowing one

end to

drop and other end to rise. Make sure the

stator Is

adequately hoolcedlstraped

to

maintain level

control of

stator assembly while lifting and moving.

30. Insert and start the threads of the bearing cartridge fasteners, and remove threaded afignrnent studs, through the endbracket into the cartridge housing.

31 . Lift sfightly on endbracket and remove wooden shims hok:fing rotor on center with stator.

32.

Securely tighten the endbracket fasteners.

33. lighten the bearing cartridge fasteners to 4.5 ft lbs. (6 N•m) torque.

34. Remove generator lifting eyes. Reasserrble con trol housing mounting brackets to sides of genera tor and fasten securely.

21 . Using a forkfift, position a lifting bar of the forkrlft

(inside and inAne with the generator) under the rotor shaft.

Uft the rotor shaft sHghtly so that rotor is not resting on inside of stator assembly. See

Rgure

6-4.

35. Use an adequate lifting device to fift the control housing in position for mounting to the stator frame. Replace the capscrews and lock washers and tighten to 20 ft-lbs. (27 N•m) torque. 22.

Remove the hoisVsling support of the rotor assem bly. Align the holes of the engine adaptor end bracket with the holes in the flywheel housing and install the capscrews and lock washers. lighten to

45-55 ft-lbs. (61 -74 N•m) torque.

\A

WARNING

I

To prevent personal Injury, use adequate lifting devices

to

suppon heavy components.

Keep

handS and

feet

clear while lifting.

23. Using an adequate lifting device, sfightly raise the generator so that the wooden blocking and steel channel can be removed from under the flywheel housing; then lower the generator so the full weight is resting on the generator mounting feet brackets.

36. Reassemble any engne air intake components removed during generator disassembly.

Perform the

'Aligning

Generator with

Engine' procedures, later

In this section, then return to Step 24.

37. Connect all control wires and generator leads using the proper generator set AC and DC wiring diagram/schematic.

24.

38. Refer to Permanent Magnet Exciter Installation.

Reassemble the covers over the generator air dis charge openings and fasten securely.

25. Connect the grounding strap to the flywheel hous

26. ing using a capscrew and EIT locking washer; and tighten securely. tighten securely.

39. H equipped with the cirruit breaker option, recon nect load wires to cirruit breaker. Reconnect all lead wires to the terminal block assembly using proper reconnection diagram in Section 7.

40. Verify that all connections are proper and secure and then install the air inlet panel and access covers to control housing (see Rgure 6-1 ).

27. Press bearing onto rotor shaft, applying force to the inner face of the bearing. Install two threaded studs into end bearing cartridge to aid subsequent

41 . Connect the negative (

-

) battery cable and test the generator set for operation. www

6-8

Permanent Magnet Exciter Installation

1

.

Install the CO!ll>lete exciter rotor assembly to the end of the main rotor shaft using the hex head through-bolt. Keep the rotor clean by avoiding con tact with metal dust or particles.

2. Carefully locate the exciter stator housing to posi tion on the generator endbracket. Fasten in place using the 4 bolts and cla!Tl>s, and tighten securely.

The highly magnetic rotor will attract the stator core, windings. care must be taken to avoid any contact which may damage the

3.

Connect the PMG wiring harness connector.

4.

Install the PMG exdter assembly cover using the three M5x1 2mm capscrews and lockwashers, and tighten securely.

Aligning Generator with Engine

Proper alignment of the generator and engine assemblies is necessary to avoid premature wear and i!Tl>roper operation of the genset. Review the following alignment conditions and procedures for aligning the generator assembly to engine flywheel housing.

Angular Alignment: Is the result of the generator bear ing center axis not aligning with axis of the engine crank shaft. This condition creates an angle between the generator shaft axis and the crankshaft axis. The cause of this type of misalignment is usually shimning error.

Axial Misalignment: Is the result of the generator shaft axis not aligning with engine crankshaft axis. The toler ances in the bolted flywheel and drive disc connection may add up to displace the generator axially relative to the crankshaft axis.

Misalignment Symptoms: If the assembly is allowed to run under these conditions, the discs must flex in alternate directions twice for each engine revolution. to

It minimize the amount of disc flexing since, if is irr()Ortant it is exces sive, the drive disc will crack. Although perfect bearing deflection to the mini!Tl.lm possible.

. com practical runout. Under these conditions, perfect Angular alignment will be attained when no deflection of the disks is measured.

Excessive Axial nisalignment will cause more generator vibration than Angular nisalignment.

Axial misalignment should be checked only when an objecdon able vibration

Is present

Either type off misalignment may be present in a genera tor set assembly, with angular nisalignment being the most common problem. Angular alignment may also be effected by set installation conditions and/or nishandling during shipping of the genset.

Angular Alignment Procedure (V28 and larger engine gensets):

I A

WARNiNG]

Accidental starting of the generator set during this procedure presents the

hazard

of sev ere personal Injury or death. Make sure to discon nect the negative (-) battery cable(s) before begin ning.

Fasten a dial indicator to either the generator shaft or the cooHng fan with the sensing point resting on the capscrew head or the flat surface of the drive disc at the bolt circle diameter, see Figure 6-7. Bar the engine over in a www

SHIMS


FIGURE 6-7. ANGULAR AUGNMENT MEASUREMENT

6-9

DETAIL A

clockwise rotation as viewed from engine flywheel. Do not allow it to roll back on COfll>ression at the end of the travel of each reading. It is unnecessary to zero the indicator since the total indicator reading (T.I.R.) of the deflection measurement to the bolt heads is what is required. T.I.R. will be the sum of the maximum positive and negative dial indicator readings as the engine COfll>letes one revolu tion.

Sample Generator

Runout Readings:

When taking the deflection readings described, make a diagram sirrilar to the example shown in Rgure

6-8, where a total indicator reading of .025". (The highest positive value of +.010 and the largest negative value of -.01 5".) The indicator is closer to the top and further a»�ay at the bottom. This exafll>le indicates that the generator bearing is high.

Since the side readings are equal, the generator is cen tered side to side. To lower the generator, remove equal shims from under both generator mounting feet. To ap proximate the amount of shims to remove or add:

1 . Measure the dstaoce between generator shaft to the poirt the center

the incicator

is of the measuring at. (For exafll>le; a SAE 18 Disc coupling distance is 10.7").

2. Measure the distance from the generator side of

Frame's distance is 28.4".)

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3. Cofll>are the distance measured in steps 1 and 2.

(28.4" vs

10.7'' or a 2.65 to 1 ratio.) Multiply this ratio times one haH the T.I.R. (In our example,

.025" divided by 2 is .01 25". This, times 2.65 equals .033". Therefore, remove .033" of shims from under both mounting feet.)

In general, the T.I.R. should not be more than .001 " for each inch of radius (center of shaft to indicator axis). H we use our example of 1 0.7", then the maximum T.I.R. would be .01 1 ". This would only require from the T.I.R. of .025". (A re

-.009 at the bottom would range.) a di ng faD a correction of .014" of +.002 at the top and within the satisfactory

M:ASUREO AT

801.. T CIRCLE

DIAMETER

10.7

IN.


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0

1 www

RGURE

6-8.

ANGULAR ALIGNMENT MEASUREMENT READINGS (Example)

6-1 0

Axial Alignment Procedure (all gensets):

Axial misalignment should be checked only when an objection able vibration Is present

If excessive vibration remains after the angular alignment, check for concentric alignment of the generator shaft/ engine crankshaft axes.

Fasten dial indicator holding device to skid base, engine block, or generator shell with a magnetic base or damp and position so the sensor point of indicator rests on the generator shaft hub, see Figure 6-9. Bar the engine over in a clockwise rotation as viewed from engine flywheel, through a couple of rotations. Record indicator readings in eight equally spaced points around the shaft diameter.

This will provide a T.I.R. for Axial shaft misalignment.

The maximum allowable T.I.R. runout is subjective, the optimal T.I.R. for runout would be .000", however that may not be attainable. The recommendation of this procedure will be to redJce the measured T.I.R. runout by one half.

Specific out-of-tolerance runout levels are difficult to establish due to the varying surface quality of the genera tor shaft's drive disc mounting hub.

The goal of the Axial realignment is to reduce the vibration level of the genset while it is operating. A small improve ment in the T.I.R. runout may have dramatic effects in the levels.

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To correct for an out of tolerance T.I.R. indication, remove the capscrews connecting drive discs and flywheel. Mark the drive discs and flywheel with respect to each other.

Rotate either the engine or generator so that drive discs holes are repositioned 1 80 degrees from their original location. Put the drive discs capscrews back in and re torque. Recheck shaft alignment as before. If shaft T.I.R. runout remains unchanged then the discs should be ro tated to either 30, 60, or

90 degrees from original location to correct the out of tolerance condition.

If the T.I.R. does not irrprove after repositioning, a doser inspection of the flywheel pilot and drive disc runouts is required. This will help determine the cause of the Axial misalignment.

�

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GENERATOR

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FIGURE 6-9. AXIAL ALIGNMENT MEASUREMENT

6-11

www


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Section

7.

Wiring Diagrams

Control/Generator

This section contains the following AC and

DC

Wiring Diagrams/Schematics:

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TITLE

PAGE(S)

DC Wiring Diagram/Schematic (7-Light) .......... ................. .......................................................................... ..... 7-2/3

DC Schematic - Ladder Diagram (7-Light) ............................. ......................................................................... 7-4/5

Detector-7 ECM - PCB Assembly . .......................................................... ........................................ ................. 7-6/7

DC Wiring Diagram/Schematic (12-Light) .......... .............................................................................................. 7-8/9

DC Schematic - Ladder Diagram (1 2-Light) ...................................... ......................................................... 7-1 0/1 1

Detector-1 2 ECM -PCB Assembly .................................. ............................................................................. 7-1 2/1 3

Detector-1 2 ECM - Functional Diagram . . ....................... ............................................................ ...... ................ 7-1 4

AC Reconnect Wiring Diagram . ............................... .. .................................................................... ............... 7-1 5/1 6

AC Wiring Diagram'Schematic (W/0 Meters) ................................................................................................... 7-1 7

AC Wiring Diagram'Schematic (With Meters) ................................................................................................... 7-1 8

PMG Voltage Regulator Installation Wiring Diagram . ...................................................................................... 7-1 9

PMG Voltage Regulator Technical Data ........................................................................................................... 7-20

Time

Delay Start/Stop Module

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-21/22

Engine Sensor Locations (L 10 Series) . ............................... ..................... ......................................................... 7-23

Engine Sensor Locations (NT855 Series) ......................................................................................................... 7-24

Engine Sensor Locations (KT19 Series) ....................... ................ ............................................. ....................... 7-25

Engine Sensor Locations (VT28 Series) ........................................................................................................... 7-26

Engine Sensor Locations (KT38 Series) ........................................................................................................... 7-27

Engine Sensor Locations (KT50 Series) ..................... . . . . ........................................................... ....................... 7-28 www

( ACAUTION

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TB2 1 - 2 1

ENGINE HARNESS DIAGRAM

ENGINE SENSOR lOCATIONS (llO SERIES)

7-23

A 1 1

(CNTRL)

. com

HIGH ENGINE

TEMP ERATURE

SWITCH

COOLANT

TEMPE RATURE

GAUGE

S E N D E R

PRE-HIGH ENGINE

TEMPERATURE

SWITCH

PRE-LOW OIL

PRESSURE

SWITCH

LOW ENGINE

TEMP ERAT U R E

SWITCH

. com

D

0 www

OIL

LOW OIL

PRESSURE

P R ESSUR E

GAUGE

SWITCH

S E N D E R

(FAR SIDE)

(FAR SIDE)

O I L

TEMP ERATURE

S E N D E R


REFERENCE DRAWINGS:

GENSET OUTLINE

-

500-2781

ENGINE ACC.

-

1Q0-3075

GND (ENG)

S 1 -2

T26

K1

E2

S6

S2

S4

G 1 -D+

LEGEND

81- STARTER



G 1 - ALTERNATOR

K1-

FUEL SOLENOID

K2-

STARTER SOLENOID



S4-- LOW ENGINE TEMP. SWITCH

S5- PRE-LOW OIL PRESSURE SWITCH

S6- PRE-HIGH ENGINE TEMP. SWITCH

T26- SW. B+

(20

AMP)

G1 -GND

8 1 -SW

S5

E 1

K2

TB 1 -8

R 1

DETAIL A

CONNECTOR

SLEEVE

GND (ENG

SPLIC E Z E N E R

DIODE

C R 1

GND (CNTRL)


TB2 1 -2 1


ENGINE SENSOR LOCATIONS (KT19 SERIES)

7-25

COOLANT

TEMP ERATURE

GAU G E

S E N D E R

PRE-HIGH ENGINE

TEMPERATURE

SWITCH

LOW ENGINE

TEMPERATURE

SWITCH

HIGH ENGINE

TEMPERATU R E

SWITCH

. com

D www

PRE-LOW OIL

PRESSURE

SWITCH

(FAR SIDE)

LOW OIL

PRESSURE

SWITCH

(FAR SIDE)

OIL

PRESSURE

GAU G E

S E N D E R

(FAR SIDE)


REFERENCE DRAWINGS:

GENSET OU1UNE

-

ENGINE ACC.

-

500-2619 & 500-2649

100.281!6

S6

E2

S2

K 1

S2

S4

LEGEND

B1- STARTER



G 1 - ALTERNATOR

K1- FUEL SOLENOID

K2-

STARTER SOLENOID



S4- LOW ENGINE TEMP. SWITCH

S5- PRE-LOW OIL PRESSURE SWITCH

S6- PRE-HIGH ENGINE TEMP. SWITCH

T26- SW. B+

(20

AMP)

B1 -SW

DETAIL A

K2

K2-BAT

K2-(+)

R1

S 1 -2

GND

�

T B 1 -8

SEE DETAIL A

-

T B 1 -2

CONN ECTOR

S PUCE

SLEEVE

ZENER

C R 1

DIODE

GND (CNTRL)

J1

GND (CNTRL)


TB1 -8 TB1 -8

A1 1

TB2 1 -21



ENGINE SENSOR LOCATIONS (KT38 SERIES)

7-27

LOW ENGINE

TEMPERATURE

SWITCH

. com

PRE-HIGH ENGINE

TEMPERATURE

SWITCH

(FAR SIDE)

D

OIL

P R ESSU RE

GAUGE

S E N D E R www

PRE-LOW OIL COOLANT

LOW OIL

P R ESSU RE PRESSURE TEMPERATURE

SWITCH

GAUGE

SWITCH

(FAR SIDE)

(FAR SIDE)

SENDER


REFERENCE DRAWINGS:

GENSET OUTLINE - �2714

ENGINE ACC.

-

1CJ0-2925

c c

, c www


. com

. com

Onan Corporation

1 400 73rd Avenue N. E.

Minneapolis, MN 55432


Onan is a registered trademark of Onan Corporation

\

Cummins Onan DFAA NT4, DFAB NT4, DFAC NT4, DFBC NT5, DFBD NT5, DFBE NT6, DFBF NT6, DFCB NTA2, DFCC NTA2, DFEB KTA12, DFEC KTA12, DFFA KTT11, DFFB KTT12, DFGA VTA1, DFGB VTA2, DFGC VTA3, DFJA KTA31, DFJB KTA32, DFJC KTA33, DFJD KTA51, DFLA KTA52, DFLB KTA53, DFLC KTA54, DFLD KTT51 Service manual

Assistant Bot

Contents

SECTION TITLE

Before operating the generator set,

Safe and efficient operation can be achieved only If the equipment Is properly oper­ ated and maintained.

EXHAUST GASES ARE DEADLY

MOVING PARTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH

FUEL AND FUMES ARE FLAMMABLE

GENERAL SAFETY PRECAUTIONS

ELECTRICAL SHOCK CAN CAUSE

SEVERE PERSONAL INJURY OR DEATH

HIGH VOLTAGE GENERATOR SETS

(1.9kV

15kV)

Section

Introduction

ABOUT n-tiS MANUAL

TEST EQUIPMENT

HOW TO OBTAIN SERVICE

&WARNING

CONTROLS AND GENERATORS

OVERVIEW

General

Control Panel

Generator

Section

Controls

GENERAL

CONTROL DESCRIPTIONS

AC Panel

Scale

DC Panel

Indicator Lamps

CONTROL PANEL INTERIOR

Fuses:

Engine Control Monitor

Function Selection

1

down

will

the

level

too low. The high engine

sensor monitors

t

of

will

high engine

operate

and allow

engine to ovelheat causing severe

to

engine. maintain adequate

level

the operation of the high engine

shutdown

Relay(s) (K11)

GENSET OPERATION

Interface Relay Modules (A 13, A 14)

Current Transformers (Not shown)

Automatic Voltage Regulator (VR21)

Starting Sequence

Manual:

Overspeed (Frequency Detection) Module

Tlme Delayed Start/Stop Module (A15)

Delayed Stanlng:

Delayed Stopping:

Control cabinet Heater recommended).

Normal Operating Parameters

Starter-Disconnect Parameters

Stopping Sequence

Emergency Shutdown

Start-Disconnect Sequence

Section

Generator

GENERATOR DESCRIPTIONS

GENERATOR CONTROL COMPONENTS

Automatic Voltage Regulator (AVR)

Safe and efficient operation can be achieved only If the equipment Is properly oper ated and maintained.