Onan UR 25 to 180 kW Generator Service Manual
Below you will find brief information for Generator UR 25 to 180 kW. The UR 25 to 180 kW generators offer a wide range of power output options for various applications. These generators are designed for reliability and durability, making them suitable for use in a variety of environments. They are equipped with advanced control systems that ensure stable operation and efficient performance.
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Service
Manual
2 5 t o I 8 0
kW
Generators
And Controls
Troubleshooting and
Test Procedures For
Generators
Regulator
Controls
900-0150
10-78
Printed in U.SA
Redistribution or publication of this document, by any means, is strictly prohibited.
Safety Precautions
The following symbols in this manual highlight con- ditions potentially dangerous to service personnel, or equipment. Read this manual carefully. Know when these conditions can exist. Then take necessary steps to protect personnel as well as equipment.
I
W A R N I N G 1
This symbol is used throughout the manual to warn of possible serious personal injury.
This symbol refers t o possible equipment damage.
PROTECT AGAINST MOVING PARTS
Avoid moving parts of the unit. Avoid use of loose jackets, shirts or sleeves due to danger of becoming caught in moving parts.
Make sure all nuts and bolts are secure. Keep power shields and guards in position.
If you must make adjustments while the unit is running, use extreme caution around hot manifolds, moving parts, etc.
Do not work on this equipment when mentally or physically fatigued.
GUARD AGAINST ELECTRIC SHOCK
Disconnect electric power before removing protec- tive shields or touching electrical equipment.
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 surfaces to be damp when handling electrical equipment.
Disconnect batteries to prevent accidental engine start. Jewelry is a good conductor of electricity and should be removed before working on electrical equipment.
Use extreme caution when working on electrical components. High voltages cause injury or death.
Follow all state and local codes. To avoid possible personal injury or equipment damage, a qualified electrician or an authorized service representative must perform installation and all service.
..
Y
EXHAUST GAS IS DEADLY!
Exhaust gases contain carbon monoxide, a poisonous gas that might cause unconsciousness and death. It is an odorless and colorless gas formed during combustion of hydrocarbon fuels. Symptoms of carbon monoxide poisoning are:
Dizziness
Headache
Weakness and Sleepiness
Vomiting
Muscular Twitching
Throbbing in Temples
If you experience any of these symptoms, get out into fresh air immediately, shut down the unit and do not use until it has been inspected..
The best protection agalnst carbon monoxide inhalation Is proper installallon and regular, frequent visual and audible inspections of the complete exhaust system. If you notice a change in the sound or appearance of exhaust system, shut the unit down immediately and have it inspected and repaired at once by a competent mechanlc.
Redistribution or publication of this document, by any means, is strictly prohibited.
I
I
.
GENERATORS AND
CONTROLS
25
kW
-
180
kW
TABLE OF CONTENTS
'
PAGE
' Introduction
.......................................... ................
2
Generator
I
.................................................
8 Question and Answer Troubleshooting Guides.
Adjustments and Procedures
............................................
16
Generator
II
...............................................
26
Question and Answer Troubleshooting Guides.
Adjustments and Procedures
27
...........................................
35
Index of Generator Adjustments and Procedures.
Control
38
.................................................
39
Question and Answer Troubleshooting Guides.
Adjustments and Procedures
..........................................
Wiring Diagrams
.....................................................
.
ONAN RECOMMENDS THAT ALL SERVICE, INCLUDING
INSTALLATION
OF
REPLACEMENT PARTS, BE PERFORMED
BY QUALIFIED PERSONNEL.
.
I
Redistribution or publication of this document, by any means, is strictly prohibited.
I DU CTIO N
'
FOREWORD
This manual provicds troubleshooting and repair information for ONAN series UR generators. It is intended to provide the maintenance technician, serviceman or Onan distributor with a logical procedure to enable him to systematically locate and
'repair malfunctions in the generator and control systems. This information is not applicable to the prime mover; refer to the engine manufacturer's manual.
,
Repair information is not extensive because the plug- in solid-state printed circuit modules lend themselves more to replacement than repair. ONAN does not recommend repair of the printed circuit module, except at the factory and has initiated a returdex- change service, obtainable through distributors, whereby faulty modules can be returned and ex- changed for good units.
For
more information, con- tact your distributororthe ONAN service department.
Application of meters or high heat soldering irons to modules by other than qualified personnel can result in unnecessary and expensive damage.
This rnanual is arranged as
follows:
i .
GENERATOR
specifications
-
Section I contains general
on
the U R generator, troubleshooting guides and procedures for testing and repairing of the early UR generator with
VR22 exciter regulator and general informa- tion on later UR generator. Section 11 contains troubleshooting information for the later model
UR generator where the exciter diode rectifier assembly has been relocated into the c o n t r d panel.
Refer
to
t / : f . appropriate section for your generator.
2 .
C O N T R O L S
-
S e c t i o n 111
c o n t a i ! $ s troubleshooting guides and procedures lor testing and repairing the system controls, P description of the components and an analysiz'
ti+
the module circuitry is included.
TEST EQUIPMENT
Most of the tests outlined in this manual can be performed with an AC-DC multimeter such as a
Simpson 260 VOM.
Other suggested test instruments are
-
ONAN multitester Part No. 420-0303
Wheatstone or Kelvin bridge
Exercise care when purchasing a foreign made VOM. Some units deliver
+9VDC,
others,
+22VDC
to the circuit under test on R
x 1
scale. Maximum recommended voltage is
+l.SVDC.
Damage to solid state devices can result from excessive voltage application.
I
GENERATING SET
MALFUNCTION
GENERATOR FAILS
SEE GENERATOR
SECTION I OR II
CONTROL FAILS
CONTROL SECTION
Ill
2
I
ENGINE FAILS
SEE
ENGINE
SERVICE MANUAL
Redistribution or publication of this document, by any means, is strictly prohibited.
I '
TABLE 1. GENERATOR SPECIFICATION BREAKDOWN
kW Model
25.0 EK
30.0 EK
Penn EK
25.0 DDA
30.0
DDB
30.0 DEH
25.0 MDEH
30.0 MDEH
Penn DEH
37.5 EM
45.0 EM
Penn EM
37.5 DEF
45.0 DEF
Penn DEF
37.5 DYJ
45.0 DYJ
40.0 DDB
50.0 DDB
40.0
DEG
50.0 DEG
Penn DEG
40.0 MDEG
50.0 MDEG
45.0 KB
55.0 KB
Penn KB
50.0 DYA
60.0 DYA
Penn DYA
55.0 EN
70.0 EN
50
Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50
Hz
60 Hz
60 Hz
60 Hz
Frequency
50 Hz
60 Hz
50 Hz
60 Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
Section 1
Spec A
Section 2
Begin
Spec
A
A
A
F
F
J
J
J
G
G
G
F
A
A
G
F
F
F
F
F
F
H
S
S
S
A
A
A
H
H
H
H
E
H
F
G
-
-
-
-
D
D
C
E
E
D
E
D
E
-
-
G
E
F
F
E
R
P
Q
E
C
D
-
-
kW Model
55.0 KB
55.0
KB
"enn KB
50.0
DYC
75.0
DYC
30.0 DYC
100.0 DYC
'enn DYC
35.0
KR
Penn KR
75.0
DYC
30.0 DYC
30.0 DYD
100.0 DYD
Penn DYD
35.0
WA
5.0
WA
100.0 DYD
125.0 DYD
Penn DYD
115.0 WE
140.0 WE
125.0 WE
150.0 WE
125.0 DYG
150.0 DYG
Penn DYG
130.0 DFE
155.0 DFE
Penn DFE
140.0 WB
170.0 WB
145.0 DYG
175.0 DYG
Penn DYG
150.0 DFE
180.0 DFE
Penn DFE
Frequency
50 Hz
60 Hz
50 Hz
60 Hz
50Hz
'
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50
Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz-
60'HZ
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
50 Hz
60 Hz
1
Section 1
Spec A
ThN
'
R
P
Q
D
B
-
- j c
R
P
C
A
B
B
B
B
B
A
B
H
G
Q
D
B
C
C
A
B
-
-
-
K
J
C
A
B
-
-
-
Section
2
Begin
Spec
S
S
S
E
E
. D
D
D
J
J
D
D
S
S
S
E
E
G
G
' E
D
-
-
-
-
D
D
D
H
H
H
L
L
D
D
D
H
H
H
3
Redistribution or publication of this document, by any means, is strictly prohibited.
UR G’ENERATOR VOLTAGE/CURRENT OPTIONS
kW
RATING
25.0
30.0
37.5
40.0
45.0
50.0
55.0
60.0 kVA
31.25
37.50
46.80
50.0
56.25
62.5
68.75
HE
:ode
515
:ode
X
X
X
X
X
X
X
X
X
X
1-PHASE
STANDARD
@ @
2K
156
142
1-PHASE
0
a
L
0
c
g
c g
0 0
3-PHASE
-
-
0
0
@
g g
c
136
204
156
95
142
90
135
E7
104
.
130
82
123
82
98
123
78
118
90 90
.
E
E
-
E
k y
g
600
-
227
152 144 139 131 131 126
76
85
81
78
234 256
284
62.5
65.0
70.0
75.0
78.13
81.25
87.5
X
X
X
X
X
355
398
426
75.0
80.0
85.0
90.0
95.0
93.75
100.0
106.25
112,5
X
X
X
X
X
X
455
100.0
115.0
120.0
125.0
130.0
540
568
125.0
143.75
150.0
156.25
162.50
175.0
X
X
X
X
X
X
X
X
X
140.0
145.0
150.0
155.0
170.0
175.0
181.25
187.5
193.75
212.5
218.75
X
X X
X
X
X
180.0. 225.25
0
HZ only.
Hz
only.
-
X
-
Hz
@
-
Not Reconnectible.
245
272
299
340
380
408
435
516
543
234
260
286
313
339
365
391
443
469
521
599
625
171
190
209
237
266
285
304
361
380
437
475
494
532
551
570
162
180
198
226
253
271
289
343
361
415
451
469
505
523
541
156
173
191
399
434
451
486
503
520
538
590
278
295
312
330
347
208
217
226
243
260
607
625
148
164
180
205
230
246
262
328
377
0
426
459
476
492
148
164
180
197
205
213
230
246
262
279
295
312
328
377
410
426
459
476
492
508
558
574
591
141
157
173
196
220
235
251
298
314
361
392
408
439
455
471
135
150
165
180
195
210
226
256
301 301
346
- .
346
376
451
466
526
542
135
150
165
180
195
210
226
256
271
376
421
451
466
526
542
95
104
119
133
142
152
’
180
190
218
237
247
266
275
285
90
99
113
126
135
144
171
180
207
226
235
253
262
271
87
95
139
147
156
165
173
200
104
108
113
121
130
217
226
243
252
260
269
295
304
313
74
82
90
238
246
254
279
287
296
98
103
107
115
123
131
139
148
156
164
189
205
213
230
75
83
90
98
105
113
128
135
150.
173
188
210
226
233
256
263
271
78
84
90
102
108
120
138
150
168
180
186
204
210
217
-
-
. . ..
..
- .
Redistribution or publication of this document, by any means, is strictly prohibited.
GENERATOR
-
.
v
GENERAL
There are two generator designs used on the UR series. They are basically the same except for the method of field excitation.
,
The Static Exciter (brush type) design uses a brush rig and collector rings for field excitation. This design
was
used on some of the earlier models within the range of 25 KW
-
90
KW.
The Brushlessdesign uses a rotating rectifier exciter assembly in place of the brush rig for field excitation.
The brushless design is standard on all models from
25
KW
-
175 KW.
Unless otherwise specified, the tests in this section apply to both designs.
COMPONENT LOCATION
To gain access to generator, remove grille section below control box.
1 .
Exciter-regulator chassis assembly VR22 mounts on the rear portion of the generator; SCR’s
(silicon controlled rectifiers) and diodes are easi- ly accessible for testing. See Figures 1-3.
2. On static-excited generators, brush”es attach to the brush rig inside of end bell housing; inspect through large access holes in the end bell. See
3.
On brushless models, rotating exciter assembly mounts directly behind exciter-regulator chassis assembly with all diodes accessible for servicing.
See Figure 2.
4.
Voltage-regulator PC Board VR21 (Printed Cir- cuit Board) mounts inside the control box on the rear panel (left side); turn
114 turn fasteners o,n
front of control box to gain access. See Figure
4.
V R -22
EXCITER R E G U L A T O R
C H A S S I S A S S E M B L Y
END B
S T A T O R
AC
O U T P U T
L
-
‘\--
IN R O T O R S T A R T S
P R O C E S S
,
&
208-240
V O L T S
AC
~
S O L I D S T A T E
4 N D V O L T A G E
REGULATOR
. T O R
O V E R S P E E D S W I T C H R E V O L V I N G FIELD
QENERATOR E N D VIEW (QRILLE REMOVED) E X C I T A T I O N S C H E M A T I C
FIGURE
1. STATIC EXCITER DESIGN
5
Redistribution or publication of this document, by any means, is strictly prohibited.
EXCl T E R- REGU LATO
R
CHASSIS ASSEMBLY FENDBELL
A
LT
E R N i T A T O R
.
208-240
V O L T S
AC
I
EXCITER
CIRCUIT
BREAKER
FIELD
E X C I T E R
A R M A T U R E
w
V O L T A G E
R E(3U L A T O R
~~~
E X C I T A T I O N S C H E M A T I C
I
QENERATOR E N D V I E W (QRILLE REMOVED)
t
CHECK T H E S E S I N G L E L E A D R E C T I F I E R S
ACCORDING T O P R O C E D U R E "E"
FIGURE 3.
TOP VIEW OF EXCITER-REGULATOR CHASSIS ASSEMBLY
V R 2 1
V O L T A G E R E G U L A T O R
P R I N T E D C I R C U I T
B O A R D
'FIGURE 4. VOLTAGE REGULATOR PRINTED CIRCUIT BOARD LOCATION
6 ,
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i
,
!
!
I
I
VISUAL INSPECTION
Before proceeding with the troubleshooting on the following pages, a few simple checks can be made which could directly indicate the cause'of trouble.
1.
Always be sure that connection of generator leads is correct. Whenever leads are reconnected for a different voltage, check the output with an independent voltmeter.
Do not use the control panel meter since it could indicate that the voltage is correct even i f connection is wrong.
2. Visually inspect the voltage regulator printed circuit board assembly (VR21) in the control box
for
burned components, broken wires, loose connections, dust, dirt
or
moisture. If dirty, clean with a suitable solvent and compressed air.
3. Visually inspect the exciter-regulator chassis assembly
(VR22) for burned components, broken
wires, loose connections, carbon tracks caused by arcing between parts
or
between parts and ground. Also check for shorted paths between terminals caused by dust, dirt and moisture.
4. Large banks of SCR (Silicon Controlled Rectifier) regulated loads can cause the generator voltage to increase as load is applied. If such loads exist, and the voltage increased more than
5
or
lo%,
consult the factory; an additional filter is available for the regulator circuit to correct the situation.
THE QUESTION AND ANSWER TROUBLESHOOTING GUIDES BEGINNING
ON PAGE 8 GIVE A STEP-BY-STEP PROCEDURE FOR CHECKING THE
GENERATOR. THE FLOW-CHART TROUBLESHOOTING GUIDES ARE
GIVEN AS A GENERAL GUIDE TO RESOLVE VARIOUS GENERATOR
PROBLEMS. ALL CHARTS REFER TO PROCEDURESSHOWN AT THE END
OF THIS SECTION.
.
PRIOR TO ANY TROUBLESHOOTING, CHECK ALL MODIFICATIONS,
REPAIRS, REPLACEMENTS, ETC.. PERFORMED SINCE LAST SATISFAC-
TORY OPERATION OF SET.
7
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QUESTION AND ANSWER TROUBLESHOOTING GUIDE
To correct a particular problem, answer the question either “yes” or “no,” then proceed to the next step given in whichever column question was answered. Procedures A thru P follow the troubleshooting guide.
‘LiM
I
TABLE A. NO OUTPUT VOLTAGE
-
ENGINE RUNNING
1. Is circuit breaker on the meter panel in the “on” position? ‘
YES
1 3
I
~~
NO PROCEDURt
2.
Switch circuit breaker to the “on” position.
Does AC voltage build up?
NOTE: If voltage builds up, but is high, low
or unstable, or causes the circuit breaker on the meter panel to trip, refer to
Table “B,” “C’ or “D” of the troubleshooting guide.
I
I
3.
4.
~~
Is AC voltage at terminals 1 and 2, on VR21 voltage regulator printed circuit board and at terminals 9 and 10 on VR22 exciter- regulator chassis assembly 5 to 10 volts?
~~
Check continuity of wires and connections between terminal 1 on
VR21 printed circuit board and terminal 9 on VR22 chassis assembly; and between terminal 2 on VR21 printed circuit board
. and terminal 10 on VR22 chassis assembly.
Is
there continuity between these connections?
5
10
C
5. Check for broken wires and loose connections on VR22 exciter- regulator chassis assembly. Replace or repair any that are defective and clean all dust, dirt and other foreign material from the assembly. Does AC voltage now build up? 6
6.
7.
8.
10.
11.
9.
Is DC voltage at terminals 4 and 5 on VR22 exciter- regulator chassis assembly 5 to 10 volts? assembly OK?
- assembly
OK?
Are diodes CR1, CR2 and CR3 on VR22 exciter-regulator chassis
Are SCR’s Q4 and
Q5 on VR22 exciter-regulator chassis
The trouble is probably caused by a defective component on the voltage regulator printed circuit board.
REPLACE VR21 PRINTED CIRCUIT BOARD (see Figure 4).
I l3
8
9
,
With the circuit breaker on the meter panel in the “off” position, is AC voltage at terminals 62 and 63 (on terminal board
TB21 on the left side of control box) 5 to 10 volts?
With the circuit breaker on the meter panel in the “off” position, flash the exciter field.
Is AC voltage at terminals 62 and 63
11
F
12 13 B now 5 to 10 volts?
8
Redistribution or publication of this document, by any means, is strictly prohibited.
TABLE A. NO OUTPUT VOLTAGE
-
(continued)
Turn circuit breaker on the meter panel t o the “on” position.
Does AC output voltage build up?
NOTE: If voltage builds up, but is high, low or unstable, or causes circuit breakerto trip. refer to table
“B.”
“C” or “D” of this troubleshooting guide.
Is brushless exciter stator winding OK?
Y E S
17
With a jumper wire connected across the terminals of the circuit breaker on the meter panel, does voltage build up?
NOTE: If voltage does build up, the circuit breaker
CB21
is defective and MUST BE REPLACED.
~
Is
11
commutating reactor mounted on the back side of
VR22
exciter-regulator chassis assembly
OK?
~-
Check continuity of wires and connections between
1821 terminal
1
on
VR21
printed circuit board. Also check between TB21 terminal
63
on the left side of control box and terminal circuit board.
VR21
printed
Are rotating diodes brushless exciter rotor OK?
Is generator field winding OK?
Is
brushless exciter rotor winding
OK?
Are generator stator windings OK?
18
19
20
N O
PROCEDURE
D
E
G
J
H
9
Redistribution or publication of this document, by any means, is strictly prohibited.
TABLE A. SYNOPSIS
BRUSHES
OR
LOOSE
BRUSH
CB2l
CIRCUIT
BREAKER
ON METER
PANEL I N
"OFF"
POSITION
(RESET)
++
NO AC
LOSS OF
RESIDUAL
FAULT I N
POWER GENERATOR
VOLTAGE
TO FIELD
(FLASH
EXCITER WINDING
FIELD)
DEFECTIVE
COMPONENT
ON
REGULATOR
PC
BOARD
COMPONENT
VOLTAGE
REGULATOR
CHASSIS
FAULTY
ROTATl NG
DIODE
ON
BRUSHLESS
(VR21)
EXCITER
ASSEMBLY n
-I-
A
DEFECTIVE
CIRCUIT
BREAKER
ON METER
PANEL
1
BUILD-UP
RELAY, K1
Q4 OR Q5
-I
CR8 OR CR9
OPEN
DEFECTIVE
DIODE CR1
FAULT IN
BRUSHLESS
EXCITER
ROTOR
OR
STATOR
WINDING
R l ,
R2
OR R3
OPEN
/E\
PC BOARD
P
I
OPEN LEAD
TERMINAL
1, 2,4,5
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of this section.
*
-
Check
SCR's, Q4
and Q5 on VR22 voltage regulator chassis assembly and replace (if defective) before repairing or replacing VR21 voltage regulator printed circuit board.
* *
-
Static excited generators only.
_ _
. . .
.
-..
Redistribution or publication of this document, by any means, is strictly prohibited.
: t
L
i
1 8
ITEM TABLE
B.
OUTPUT VOLTAGE BUILDS UP BUT IS UNSTABLE
NO. ENGINE RUNNING
OK
-
I
I
I
Are there any loose
or
broken wires
or
connections at VR21
I I printed circuit board terminals?
2. Does adjustment of R26* (damping control pot) on VR21 printed circuit board result in stable generator voltage?
I
I
3.
The trouble is probably caused by a defective component on
VR21 voltage regulator printed circuit board.
REPLACE VR21 PRINTED CIRCUIT BOARD (see Figure 4).
I
-
R26
is
used on brushless generators only.
YES NO PROCEDURE
7: i
TABLE B. SYNOPSIS
UNSTABLE OUTPUT
VOLTAGE
!
DEFECTIVE COMPONENT
ON (VR21) VOLTAGE
REGULATOR PRINTED
CIRCUIT BOARD
I
C6. C7, R14 OR
R1S OPEN
BROKEN WIRES OR
LOOSE CONNECTIONS
AT (VR21) VOLTAGE
REGULATOR PRINTED
CIRCUIT BOARD
TERMINALS
INCORRECT SETTING
OF R26 POT ON (VR21)
PRINTED CIRCUIT
BOARD (BRUSHLESS ONLY)
C11, C12, R27 OR
R28 OPEN
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end
of
this section.
Redistribution or publication of this document, by any means, is strictly prohibited.
5.
I
IS
HIGH OR LOW
-
F
ENGINE RUNNING OK
-
Does adjustment of R21 "Voltage Adjust" knob on the meter panel result in correct voltage?
Does adjustment of R l b potentiometer on VR21 printed circuit board result in correct voltage?
-
Is correct voltage reference transformer tap on TB21
being used?
Are generator output leads properly connected?
YES
NO PROCEDURE
-
2
4
5
-
3
-
-
P
L
L
I
I
INCORRECT
REFERENCE
TRANSFORMER TAP
ON T21
TABLE C. SYNOPSIS
TOO HIGH
O R
I
INCORRECT
SETTING OF
VOLTAGE ADJUST
POT (R21) ON
METER PANEL
I
I
DEFECTIVE
COMPONENT ON
REGULATOR CHASSIS
ASSEMBLY (VR22)
INCORRECT
SETTING
OF
VOLTAGE ADJUST
POT (R18) ON
VR21 PC BOARD
I
CONNECTION AT
TERMINALS
3 , 4 , .
I
DEFECTIVE
COMPONENT ON
REGULATOR PC
BOARD (VR21)
I
.I
- -
.
.
. .
..
I
!
NOTE Whenever a letter appears near the box, a separate procedure, corresponding to that letter,
is
given at the end of this section.
12
Redistribution or publication of this document, by any means, is strictly prohibited.
NO:
TABLE D. GENERATOR VOLTAGE BUILDS
UP BUT CAUSES THE CIRCUIT BREAKER
ITEM
I
ON CONTROL PANEL TO TRIP. ENGINE RUNNING
OK.
Does AC output voltage build up to 150% or more of rated voltage before CB21 circuit breaker trips?
2.
1,
.
Are there any loose or broken terminals or connections at VR21 voltage regulator printed circuit board terminals?
3.
Is diode CR3 on center heat sink of VR22 exciter-regulator chassis assembly OK?
~
4.
5.
Are voltage regulator transformer (T21) windings and connections OK?
~
Are stator leads connected properly?
6.
The trouble is probably caused by a defective component
on
VR21 voltage regulator printed circuit board. REPLACE VR21
PRINTED CIRCUIT BOARD (see Figure 4).
I
Does
AC output voltage build up to rated voltage or less before tripping CB21 circuit breaker on meter panel?
8.
Are rotating diodes CR1, CR2, CR3, CR4, CR5 and CR6 on brushless exciter rotor OK?
9.
.
Is brushless exciter stator winding OK?
10..
Is generator field winding OK?
11.
Is brushless exciter rotor winding OK?
DEFECTIVE
ROTATING DIODE
CR1, CR2, CR3,
CR4, CR5 OR CR6
ON
EXCITER
ROTOR
l - l
FAULT I N
EXCITER ROTOR
OR STATOR
WINDING
FAULT I N
GENERATOR
MAIN FIELD
WINDING
A
NOTE:
Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of this section.
13
Redistribution or publication of this document, by any means, is strictly prohibited.
-.
ITEM
NO.
-
TABLE E. UNBALANCED GENERATOR TERMINAL VOLTAGE
1 . .
2.
Remove load from 'generator terminals. Are genefator'terminal voltages still unbalanced?
~~ ~
_________
Are generator leads properly connected and/or grounded?
3.
Is
continuity of generator stator windings OK?
4.
5.
Is grounding procedure of generator and load correct?
~~~
Check for ground faults in load.
*
NOTE: Unbalanced voltages of up to 5 percent will occur if unbalanced loads are applied to the generator terminals.
\
YES
NO PROCEDURE
I * 1 4 1
-
3
- -
H
I 5 1 - - 1 I
1-14
ji
I'
,
TABLE
E.
SYNOPSIS
*
UNBALANCED
TERMINAL VOLTAGES
I
INCORRECT RECONNECTION
OR GROUNDING OF
GENERATOR LEADS
INCORRECT GROUNDING
OF LOAD OR GROUND
FAULT I N LOAD t
'
FAULTY GENERATOR
STATOR WINDING
,
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of this section.
14
Redistribution or publication of this document, by any means, is strictly prohibited.
OPEN TRANSFORMER
(T21) WINDING
TABLE E. SYNOPSIS
I
VOLTAGE 150%
I
[ ; I
MORE THAN RATED
I I
1
I
OPEN WIRE OR
CONNECTION AT r-
ASSEMBLY (VR22)
I
ON VOLTAGE
REGULATOR CHASSIS
DEFECTIVE COMPONENT
ON VOLTAGE
REGULATOfi PRINTED
CIRCUIT BOARD (VR21)
VOLTAGE REGULATOR
CHASSIS ASSEMBLY
(VR22)
TERMINALS
4,5
OR 6
OPEN WIRE OR
CONNECTION AT
PRINTED CIRCUIT
BOARD (VR21)
TERMINALS 5,6, 9,10,
11 OR 12
<
OPEN LEAD AT
(VR21)
PRINTED CIRCUIT
BOARD TERMINALS
1, 2, 5, 7 OR
8
CYCLING
BUILD-UP *
OPEN
IN R21
VOLTAGE ADJUST POT
ON METER PANEL
1
L
OPEN I N R18
VOLTAGE ADJUST POT
ON VR21 PRINTED
CIRCUIT BOARD
DEFECTIVE COMPONENT
ON VR21 PRINTED
CIRCUIT BOARD
I
N O T E Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end
of
this section.
*
-
Generator voltage builds up. then collapses. builds up. etc.
Redistribution or publication of this document, by any means, is strictly prohibited.
ADJUSTMENTS
AND PROCEDURES
BRUSHES
When brushes wear to approximately 5/8 inch or when wear extends into the stamped Onan part number, replace brushes.
Do not attempt to remove the brush without first removing its spring and brackets. Never bend a spring back over its bracket
- doing so will put a kink in it and require its replace- ment.
Do not use a substitute brush that may look
1 identical but may have entirely different electrical characteristics. Be sure to install the brush
SO that the short side of its taper is toward the spring and its
and 6. i
REPLACE
BEFORE
BRUSH
WEARS
TO THIS POINT
I N S T A L L B R U S H E S W I T H BEVELED
TOP S L A N T I N G D O W N TOWARD
S P R I N G HOLDER-,
TO
REMOVE
BRUSH
SPRING,PRESS
SPRl NG HOLDER
DOWN A N D OUT A S
SHOWN
I N
BROKEN
LINES.
tJ
FIGURE 5. BRUSH REPLACEMENT
FIGURE 6. BRUSH REMOVAL
FLASHING THE FIELD (No Voltage)
If output voltage will not build up, it may be necessary
.
.
'.
.
' '
.watt resistor in series with diode; or a 24 volt automotive (generatorset) battery can be used by increasing the resistor value to 40-ohms.
1.
Remove end grille to obtain access to'exciter- regulator chassis assembly:.
3. After starting the set, touch the positive
(+) lead to
TB5 and the negative
(-) lead to TB4; hold on terminals just long enough forvoltage to build up.
2. Use a six volt dry cell (lantern) battery with a 12 amp
300 volt diode as shown
prevents current flow from exciter circuit to battery when voltage builds up. If a lantern battery is not available, a 12 volt automotive (generator set) battery can be used by installing a 20-ohm 2
Do not keep excitation circuitry connected longer than 5-seconds or damage may occur to the exciter regulator.
Be cautious when working on agenerator that is running. High voltages aye present.
I
C H A S S I S A S S
T O BUILD UP.
FIGURE 7. FLASHING THE FIELD
16
Redistribution or publication of this document, by any means, is strictly prohibited.
CCI
NO
AC POWER TO
EXCITER
Residual should be checked before the circuit breaker; the best place to check it is at the five leads 61 through 65
out
of the stator. The combination of leadsshould bechosen by the wiring configuration of the stator, Le., 120/240 120/208 to
VR21
PC board arid then check the circuit breaker CB21.
If residual voltage is present, check AC voltage at terminals
1 and 2 on VR21 voltage regulator printed circuit board. Voltage should be 5-10 volts. The AC voltage at terminals 9 and 10 on VR22 exciter- regulator chassis assembly should be the same (5 to
10 volts). If not, check continuity between these points. I f voltage is low, check L1 reactor.
TESTING
L1
REACTOR
The L1 reactor mounts on the rear of VR22 exciter- regulator chassis assembly. Terminals are marked
1,
2, 3 and 4.
3 h 4
Coils 1-2 and 3-4 are wound on the same iron core.
Resistance between 1-2 and 3-4 should be .0544 and
.0614-ohms
f
1O0/o respectively (brush type generators)
.
Resistance between coils (e.g., 1-4) or from any terminai to reactor frame should be infinity.
If any of the above conditions are not met, install a new reactor.
TESTING
DIODES
On both brushless and brush type generators. three diodes mount on the center heat sink of the exciter- regulator chassis assembly. They are labeled CR1,
CR2 and CR3 as shown in
On brushless generators, six diodes mount on the rotating exciter assembly as shown in Figure 2. These six diodes are labeled CR1. CR2, CR3, CR4, CR5 and CR6. Test diodes as follows:
1. Disconnect one diode at a time. Test that diode and reconnect lead before proceeding to the next one.
2. Use an accurate ohmmeter to check the resistance of the diode. Connect one lead to the top of the diode and the other lead to the heat sink. Observe reading.
3. Now reverse leads and again observe reading. A good diode should have a higher reading in one direction than the other. I f both readingsare high, or if both readings are low, diode is defective and must be replaced with a new, identical part. m
components will causeoverheating and even- tual failure. Keep these assemblies clean!
LEAD
LEAD
GOOD DIODE W I L L H A V E HIGH RESISTANCE READING I N ONE DIRECTION
AND LOW READING WHEN OHMMETER LEADS ARE REVERSED.
FIGURE 8. TESTING DIODES
17
Redistribution or publication of this document, by any means, is strictly prohibited.
0 H
MM ETER
SHORT BETWEEN
SATE AND ANODE
CATHODE
FIGURE 9. TESTING SCR’s
ANODE
-
FIGURE 10. TESTING SCR’s
FIGURE 11. TESTING SCR’s
[FI
TESTING SCR’s
SCR’s mount on the outer heat sinks of the exciter- regulator chassis assembly. They are labeled
Q4
and
Q5
1. Remove the leads from both SCR’s.
2. Determine polarity of ohmmeter leads. Connect the ohmmeter leads to the anode and cathode as shpwn in Figure 9. Use the high scale on the ohmmeter. The resistance should be 1 megohm or greater.
The cathode i s the longer lead, the gate is the shorter lead. The anode is the threaded stud.
3.
Reverse the leads as shown in Figure 10.
The resistance again should be 1 megohm or greater.
4.
With the leads connected as in Step
3, and using the low scale on the ohmmeter, short the gate to
the anode as shown in Figure 11.
The resistance should drop to a low value.
5.
Remove the short between the anode and the gate. The resistance should remain at the same
low value.
REPLACING RECTIFIERS (SCR’s and
Diodes)
1. Unsolder leadwires from terminals.
2.
Use proper size wrenches to hold the body while removing the nut.
3. Push the rectifier free of its mounting hole in the heat sink.
4.
Insert new rectifier into its mounting hole in the heat sink. Using nut and washer provided, secure rectifier to heat ,sink.
5. .Torque the two large diodes on the center heat sink of exciter-regulator chassis assembly to 20-
25 in. Ib.
6.
Torque the small diode on center heat sink of exciter-regulator chassis assemb.ly to 12-15 in. Ib.
7. Torque SCR’s o n outer heat sinks- to
20-25 in. Ib.
8. On brushless generators, torque diodes on rotating exciter assembly to 15 in: Ib.
9. Solder leadwires to new rectifiers.
Use a 40 watt soldering iron. Hold a needlenose pliers between rectifier and soldering point to prevent destructive heating. Excessive heat on these components will destroy them.
18
Redistribution or publication of this document, by any means, is strictly prohibited.
TESTING GENERATOR ROTOR
Testing
for Grounds: Use an ohmmeter (R
scale'); measure as follows:
x
100
Brush Type
-
Brushless Type
- from the rotating diodes; measure between either lead and the rotor shaft. A reading of less than infinity
indicates a ground. See Figure 12.
BRUSH DESIGN
C O N T A C T ONE P R O D TO ONE
SLIP
RING AND
T H E OTHER P R O D T O T H E SECOND SLIP RING.
C O N T A C T ONE P R O D TO EACH O F T H E SLIP
R I N G S AND T H E OTHER PROD T O T H E R O T O R
S H A F T .
IF ROTOR IS G O O D THERE S H O U L D B E NO
READING O N OHMMETER.
OHMMETER
C O N T A C T O N E P R O D TO ONE FIELD LEAD AND
T H E SECOND P R O D T O T H E OTHER FIELD LEAD
FIGURE
13.
TESTING ROTOR FOR AN OPEN CIRCUIT
C O N T A C T ONE P R O D TO EACH O F T H E FIELD
L E A D S AND T H E OTHER PROD T O THE ROTOR
S H A F T .
IF
ROTOR IS G O O D ' T H E R E S H O U L D B E N O
READING ON O H M M E T E R
FIGURE 12. TESTING ROTOR FOR GROUNDS
Testing
for an Open Circuit: On brush type
generators, check for an open circuit by measuring resistance in the windings. Check between the two slip rings as shown in Figure 13.
On brushless generators, disconnect and test between F1 and F2 leads as shown in Figure 13.
Resistance values given in Table 3
apply to both brushless and brush type generator rotors.
Replace the rotor i f it is grounded or has an open o r short.
TABLE
3.
RESISTANCE VALUES FOR ROTORS
KW RATING
50HERTZ
I
RESISTANCE IN OHMS
I
60HERTZ
1
FROM TO
25.0
37.0
40.0
45.0
50.0
55.0
60.0
70.0
75.0
80.0
95.0
1 10.0
125.0
140.0
145.0
30.0
40.0
45.0
50.0
55.0
55.0
60.0
65.0
75.0
85.0
90.0
100.0
115.0
125.0
140.0
150.0
170.0
175.0
3.32
2.49
2.49
2.49
2.76
2.76
3.02
3.02
3.16
2.76
2.76
3.19
3.26
3.96
3.96
3.09
3.42
,
3.42
4.06
3.05
3.05
3.05
3.38
3.38
3.70
3.70
3.86
3.38
3.38
3.90
3.99
4.40
4.40
3.78
4.18
4.18
All resistances should be within the values specified at
20°C
F).
This includes readings between slip rings on static excited rotors and between field leads (with rectifiers disconnected) on brushless rotors. Use Wheatstone Bridge for testing.
19
Redistribution or publication of this document, by any means, is strictly prohibited.
TESTING GENERATOR STATOR
Testing
for
Grounds:
Connect all stator output leads
(Tl-T12) together. Use an ohmmeter set on the R
x
100 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 “ON” or “OFF”.
Testing for Shorts:
To check for shorts between
individual windings first refer to Figure 18 to deter-
mine individual coil lead wires (Tl-T4, T 7 - T l 0 , etc.)
Connect one lead of an ohmmeter (RX100 scale) to one of the stator windings and the other ohmmeter lead to all other stator leads connected together.
A
reading of less than infinity indicates a short. Repeat until all stator coils have been tested in this manner.
Coil Resistances:
Measure resistance of windings using a Wheatstone or Kelvin bridge meter. SeeTable
4 and Figure 14. If any windings are shorted, open
or grounded, replace the stator assembly. Before replacing the assembly, check the leads for broken wires or damaged insulation.
Stator output leads T4, T7, T8, T9 and T10 are interconnected
(within the stator) to five stranded ( # l o aircraft) control wires.
These wires are labeled 4,7,8,9 and 10 respectively and terminate at TB2.1 (terminals 61-65).
FROM
KELVIN
BRIDGE
FIGURE 14. TESTING STATOR WINDINGS
,450
’
50.0
55.0
60.0
70.0
75.0
80.0
95.0
110.0
11 5.0
125.0
140.0
145.0
KW R TlNG
50 HERTZ 6O.HERTZ
25.0
37.0
’
40.0
65.0
75.0
85;O
90.0
100.0
115.0
125.0
140.0
150.0
170.0
175.0
30.0
40.0
45.0
50.0
55.0
55.0
60.0
TABLE
4.
.RESISTANCE VALUES F O R STATORS*
15
0.116 - 0.141
0.047
-
0.058
0.047
0.047
0.028
0.038
0.028
0.028
0.022
0.019
0.019
0.015
-
.
0.058
-
0.058
-
0.035
-
0.047
-
0.035
-
0.035
-
0.027
-
0.024
-
0.024
-
0.018
0.012 - 0.015
0.009
-
0.011
0.009
0.0075
-
0:Oll
-
0.0092
0.0059
- 0.0072
0.0059
-
0.0072
VOLTAGE CODE (Resistance in Ohms)
I
I
9x
I
I
0.425
- 0.520
0.193
0.193
-
0.236
-
0.236.
.
3
0.052
0.047
0.047
-
0.063
-
0.058
-
0.058
0.156
0.113
0.113
-6.089
0.072
-
0.191
-
0.138
-
0.138
-
0.108
-
0.089
0.072
- 0.089
0.054
-
0.067
0.045
0.039
0.039
0.027
0.018
0.018
-
0.055
-
0.048
-
0.048’
-
0.033
-
0.023
-
0.023
AI: r’(?sislances
20°C (68’
F).
Use an accurate instrument such as a Kelvin Bridge for this test.
Test between the following coil leads:
T1 -T4 17-T 10
T9-Tl2 T2-T5
T3-T6
T8-Tl1
20
Redistribution or publication of this document, by any means, is strictly prohibited.
! i .
!
IJI
TESTING EXCITER ROTOR (Armature)
Testing for Grounds:
Remove diodes CR1, CR2, CR3,
CR4, CR5, and CR6 from diode heat sink assemblies.
Using an ohmmeter (R x 100 scale) measure insula- tion resistance between any of the leads and the laminations (exclude the diodes from the test circuit).
A reading of less than infinity indicates a ground.
Testing Winding Resistance:
Using a Wheatstone or
Kelvin bridge meter, measure resistance between leads pairs T1-T2, T2-T3 and Ti-13. Resistance should be 0.464 to 0.567 ohms at 20°C (68°F). See
Figure 15.
Testing Winding Resistance:
Measure coil resistance between leads F1 and F2 with an ohmmeter (scale R x
1). Resistance should be17.82 to 21.78ohmsat 20°C
(68°F). See Figure 16A.
FIGURE 16A. TESTING EXCITER FIELD
FIGURE 15. TESTING EXCITER ARMATURE
RECONNECTION
Figure 18 shows reconnection possibilities forthe
UR
series generators. When reconnecting for a different voltage, be sure to also reconnect lead from terminal
63 (inside control box) to either H3, H4, H50rH6.See
Figures 17 and 18.
TESTING EXCITER STATOR
Testing for Grounds:
Using an ohmmeter
(R x 100
scale), measure the insulation resistance between either lead F1 or F2 and the laminations. A reading of
less than infinity indicates a ground. See Figure 16.
(W12
WIRE)
C O N N E C T L O O S E W I R E
F R O M T E R M I N A L #63
T O E I T H E R
H3.H4.H5
O R
H6 D E P E N D I N G ' O N
V O L T A G E S E L E C T E D .
FIGURE 16. TESTING EXCITER FIELD
21
FIGURE 17. CONNECTING LEAD FROM TERMINAL
63
Redistribution or publication of this document, by any means, is strictly prohibited.
N A M E P L A T E VOLTAGE CODE 3
E,
CONNECT L E A D FROM
TERMINAL
63
H5
+
NAMEPLATE VOLTAGE CODE
9 X
T 1
CONNECT LEAD FROM
TERMINAL
IS
120/240 1 60 H5
115
115/230 1 50
H6
116220 1 5 0 H6
8'l
LO
/
LO
(WITH CURRENT TRANSFORMERS WHEN USED)
11 12
T I 0
7 7
75
T 1 1 2 16 111 18112 14 19
1s
17
T 3 110
L 2
LO L 1 12
L3
15 120/140
3
60 H5 i1S
115/230 3 50 H6
11 T 1 0
16
17 12 111 14 T 8 '73 T12 T5 19
LO
L1 L 2 13
W
5
71 0
711
I
'7:
13
111
LO
4
16
111
I5
110 112"
LO
L 1 l7
79
1101lt T12 T I T 7 T 4
L 3
1 2 T 8
12
1 2 T 8
15
T 3 T 9
9 8 C 2 1 9 3
1
13
19
13
FIGURE 18. RECONNECTION DIAGRAM
22
Redistribution or publication of this document, by any means, is strictly prohibited.
I
1
t
, . i . i
I
1
il
. .
SENSITIVITY REFERENCE CIRCUIT
UR series voltage regulators (VR21) can be set to
either frequency sensitive or non-frequency sensitive reference. With a frequency sensitive reference, the output voltage of the generator will decrease in proportion to the frequency (Le., prime moverspeed).
This decrease in output voltage will reduce the load on the prime mover, permitting it to return to rated voltage and frequency when overload is removed. A temporary overload with a non-frequency sensitive reference could cause a prime mover to reduce speed, then would require a further 50% to 60% load reduction to allow it to return to rated speed.
This reference change is accomplished by soldering wire W1 to terminal E l for frequency sensitivity or to terminal E2 for non-frequency sensitive reference.
Unless requested otherwise by purchaser, Onan sets are con- nected at the factory to a frequency sensitive reference.
TOP SIDE O F .
VOLTAGE
REGULATOR
WHENMOUNTED
UNSOLDER THIS WIRE
FROM E I AND CONNECT
TO E2
FOR
A NON-
FREQUENCY SENSITIVE
VOLTAGE REFERENCE
CIRCUIT.
-
FIGURE 19. VR21 PRINTED CIRCUIT BOARD
23
Redistribution or publication of this document, by any means, is strictly prohibited.
GENERATOR DISASSEMBLY
,
If generator testing determines that generator needs repair, remove and disassemble according to Figure
'20 and the following instructions:
Disconnect and remove load wires.
Disconnect leadwires from the control box.
Check wire markings for legibility to ease assembly. Arrange leads so they can be withdrawn easily from the control box.
Remove front grille (14) and sheet metal work.
Remove the four capscrews securing voltage regulator chassis (23) to end bell
(9) and remove chassis assembly.
Remove the centrifugal switch (8) from end bell and rotor shaft. On static excited models, slip the brushes (7) and brush springs (6) from brush rig
(5)
- leads unless brush replacement is required.
Block the rear of the engine in place by suppor- ting the flywheel housing. Remove the narrow generator band (10). Remove the large capscrews securing generator mounting pad (11) to the skid base. Remove the capscrews securing the stator assembly (4) to the engine flywheel housing.
7. Using an overhead hoist and sling, slide the stator assembly off the rotor assembly.
E z 3
removing the stator. Do not allow the stator to rest on rotor during removal.
8. Remove end bell from stator assembly; dis- connect and remove brush rig from end bell on static excited generators. On brushless models, remove exciter field (24) from end bell assembly if required.
'
9.
Attach the hoist and sling to the rotor assembly
(1) and apply a slight lift to support the rotor.
Remove the capscrews securing the flexibledrive coupling (13) to the engine flywheel and remove rotor from the engine.
10. Remove bearing capscrew (18) and washer (17) and remove bearing from shaft. If required, remove blower
(2) from the rotor.
11. Disconnect rotor field leads from heat sinks F1 and
F2
on the exciter armature. Remove exciter armature (25).
9
2 3
L A
/
B R U S H L E S S G E N E R A T O R
FIGURE 20. GENERATOR DISASSEMBLY
24
Redistribution or publication of this document, by any means, is strictly prohibited.
Generator assembly is the reverse of disassembly procedure:
1. Always replace bearing with a new one; apply a layer of grease on end bell bearing hole before inserting bearing.
2. Torque bearing capscrew to 60-70 Ib. ft.
3. Torque drive disc-to-rotor capscrews to 200-240
Ib. ft.
4. Torque drive disc-to-flywheel capscrews to 45-50
Ib. ft.
5.
Torque generator through-stud nuts to 30-40 Ib. ft.
6. Refer to Purrs
Curu/o,y
for replaceable parts and assemblies. Refer to
Wiring
Diuputii
for reassembly.
[ P I
VOLTAGE ADJUSTMENT
After replacement, voltage regulator (VR21) adjust-
ment is performed as follows (see Figure 21):
1. Center the voltage adjust knob so pointer is in a vertical position.
2. Open meter panel doors. Start unit.
3. Using a screwdriver, turn R18 potentiometer on printed circuit board VR21 counterclockwise to increase the voltage or clockwise to decrease the voltage. Observe voltmeter on meter panel while making adjustment. Set voltage with no load connected to generator. (Example: For a 120/240 volt connection, set at no-load voltage or ap- proximately 246 volts.)
If voltage is unstable or tends to hunt, turn R26 potentiometer on VR21 in the direction shown on printed circuit board to increase voltage sensitivity.
25
HERE
I
ADJUST R26
\
ADJUST R 18
HERE
FIGURE
21. ADJUSTING VOLTAGE ON VR21
Redistribution or publication of this document, by any means, is strictly prohibited.
GENERATOR
GENERAL
,
,
Generators discussed in this section are brushless type only. The difference between these and the generators in Section
I
is in the VR22 diode assembly and the commutating reactor. These have been removed from the generator end bell and relocated in the control panel. The diodes are now encapsulated within a hermetically sealed block, therefore if any diode or silicon controlled rectifier fails, the entire unit has to be replaced. See Figure27fordetailsof the
rectifier assembly (CR21) and Figure 25 for the
reactor (L21).
Principles of operation and method of excitation remain unchanged from the units described in Sec- tion I.
for generators to which this section
.
applies.
ROTATING EXCITER
WITH RECTIFIERS
QENERATOR E N D V I E W (QRILLE R E M O V E D )
FIGURE 22. ROTATING RECTIFIER ASSEMBLY
VR2‘ VOLTAGE
RE GU LATO R
121 REACTOR
/
\
CR2 I
SCR BRIDGE
FIGURE 23. SCR BRIDGE AND REACTOR LOCATION
:TROUBLESHOOTING
Use the following troubleshooting charts and procedures to locate malfunctions in the generating system.
Section 11 also references procedures A thru
P
of
Section 1.
The question and answer troubleshooting guides which follow give a step-by-step procedure for check- ing the generator. To use the guides, answer the questions either “yes” or
“no” then proceed to the next step given in whichever column is indicated.
When using block diagrams, a letter with a triangle indicates a procedure
in
Generator
-
Section 1. A letter
within a diamond indicates a procedure in
Generator-
Section II.
26
Redistribution or publication of this document, by any means, is strictly prohibited.
QUESTION
AND ANSWER TROUBLESHOOTING GUIDE$
To
correct a particular problem, answer the question either “yes” or “no,” then proceed to the next step given in whichever column question was answered. Procedures R thru P follow the troubleshooting guide.
!
;
ITEM
NO.
TABLE
-
RATED RPM
1.
Is
Exciter Circuit Breaker (CB21) on the meter panel in the “ON” position?
2.
Switch CB21 to “ON” position. Does AC voltage build up?
NOTE
If
voltage builds up but is high,
low
or
unstable, or causes CB21 to trip, refer to table G. H or
I
of
troubleshooting guide.
3.
Is
A C voltage measured at terminals 1 and 2 on voltage
regulator (VR21) printed circuit board 5 to 10 volts?
4.
Is AC voltage measured at terminals 11 and 12 on
VR21 5 to 10 volts?
5.
Replace reactor assembly (L21).
6.
Is DC voltage measured at terminals + and
- on
Rectifier Bridge (CR21) 5 to 10 volts?
7.
Shut down generator set. Check continuity through L21 coils between terminal 2 on VR21 and T8 on generator, between terminal 1 on VR21 and
T7
Is
there continuity between these connections?
VR21-2 to T8
VR21-1 to T7
8.
If there is no continuity between VR21-1 and T7
((2621 -ON) apply a shorting jumper across CB21.
Is continuity obtained?
9.
Replace CB21.
10.
Check for loose or broken wires on VR21, CR21, L21, reference voltage transformer (T21), generator bus-bars and terminal board (TB21) in control box. Secure or repair where necessary. If repairs have been made, restart engine.
Does AC voltage now build up?
Are diodes CR1, CR2 and CR3 on CR21 assembly good?
(See method T in procedure section for checking diodes.) If faulty diode located, replace CR21.
12.
Are SCRs 1 and 2 in CR21 good?
(See method T in procedure section for checking diodes.) If faulty SCR’s located, replace CR21.
YES NO PROCEDURE
3
-
2
3
6
4
5
7
-
-
15 11
14
14
10
8
9
10
- -
-
12
14
-
13
-
T
T
Redistribution or publication of this document, by any means, is strictly prohibited.
ITEM
NO.
TABLE F. NO AC OUTPUT VOLTAGE- ENGINE RUNNING AT RATED RPM
(continued)
13.
14.
Fault probably lies with a defective component on VR21.
Replace VR21.
~~ ~
Start engine. Place CB21 in “OFF” position. Using method prescribed under “R” in procedure section flash the exciter field to restore residual magnetism. Place CB21
ON.
Does the AC output voltage build up?
15.
Shut off engine.
is exciter field winding (F1: F2)
OK?
16. Are rotating diodes CRI, through CR6 on exciter rotor OK?
17.
18.
Is
generator stator winding OK?
Is exciter rotor winding
OK?
.
.
19. Are generator rotor windings
OK?
YES
16
I
No
lPROCEDURE
17
18
-
19
13
I
.
.
.
. . .
I .
i
28
Redistribution or publication of this document, by any means, is strictly prohibited.
TABLE F. SYNOPSIS
NO VOLTAGE
BUILD-UP
1
N eo
NOTE: Whenever a letter appears near the
box,
a separate procedure, corresponding to that letter, is given at the end of the, appropriate section.
-
SCRl
OR SCRP
OPEN
,
-
DEFECTIVE
DlODECR1
CR2
OR
CR3
.
OPEN LEAD
REGULATOR
PC BOARD
TERMINALS
1 OR 2
-
OPEN LEAD
AT
TERMINAL
. .
....
-
....
Redistribution or publication of this document, by any means, is strictly prohibited.
I
TABLE G. UNSTABLE OUTPUT
-
1800 RPM
-
TION
I
I
I
YES
1
NO IPROCEDURE
I
I
I
I
Are there any loose or broken wires or connections at
VR21
terminals?
I
-
2
Does adjustment of R26 (damping control potentiometer) on VR21 stabilize generator voltage?
-
3
-
-
P
Replace VR21.
DEFECTIVE COMPONENT
ON (VR21) VOLTAGE
REGULATOR PRINTED
CIRCUIT BOARD
TABLE G.
SYNOPSIS
UNSTABLE OUTPUT
VOLTAGE
i
-
BROKEN
WIRES OR
LOOSE CONNECTIONS
AT (VR21) VOLTAGE
REGULATOR PRINTED
CIRCUIT BOARD
TERMINALS
INCORRECT SETTING
OF R26 POT ON (VR21)
PRINTED CIRCUIT
BOARD
.
, ,
. .
.
.-
I
, ,
.
..
._
. ..
".
.
I
1
NOTE:
Whenever a letter appears near the box, a separate procedure, corresponding
to
that letter, is given at t h e end
of
the appropriate section.
30
Redistribution or publication of this document, by any means, is strictly prohibited.
i
&M
1.
TABLE H. OUTPUT VOLTAGE TO HIGH
OR LOW
Does adjustment of R21 “voltage adjust knob” on meter panel correct voltage level?
2.
Does adjustment of R18 potentiometer on VR21 correct voltage level?
3.
Are rotating diode heat sink mounting screw insulators
OK?
YES
-
.-
NO PROCEDURE
--
__
2
-
3
- -
P
If generator output voltage has been optionally reconnected,
consider the following
-
4-
5.
I
Is reference transformer (T21) tap correctly connected on TB21?
Are the reconnections correct and secure?
6.
Replace VR21.
TABLE H. SYNOPSIS
INCORRECT
REFERENCE
TRANSFORMER TAP
ON T21
/L\
1 5
6
-
I
INCORRECT
SETTING OF
VOLTAGE ADJUST
POT (R21) ON
METER PANEL
TOO HIGH OR
TOO
LOW
I
-
%
I
DEFECTIVE
COMPONENT ON
RECTIFIER ASSEMBLY
CR21
r
INCORRECT
SETTING OF
VOLTAGE ADJUST
POT (R18) ON
VR21 PC BOARD
1
DEFECTIVE
COMPONENT ON
VOLTAGE
REGULATOR PC
BOARD (VR21)
I
I
OPEN LEAD OR
CONNECTION AT
TERMINALS
G1
OR G2
H
DEFECTIVE ROTATING
DIODE OR BAD INSULATOR
ON HEAT SINK MOUNTING
SCREW
1
OPEN IN CR1,
CR2
OR CR3
1
VOLTAGE
BREAKDOWN OF I
SCRl ORSCR2
I
NOTE: Whenever a letter appears near the
box,
a separate procedure, corresponding to that letter, is given at the end
of
the appropriate section.
31
Redistribution or publication of this document, by any means, is strictly prohibited.
IiLM
TABLE 1. EXCITER CIRCUIT BREAKER TRIPS
1. Does AC output build up to 150% or more of rated voltage before CB21 trips?
2.
Are there loose or broken terminals or connections at V R Z l ?
Is diode CR3 (connected between + and
- in CR21 rectifier assembly)
OK?
Are reference voltage transformer (T21) windings and connections
O K ?
5. Replace VR21.
6.
Does AC output build up to rated value before tripping CB21?
7.
Are rotating diodes CR1 through CR6 on exciter rotor
OK?
8.
Is exciter stator winding
OK?
9.
Is
generator field winding
OK?
10.
Is exciter rotor winding
OK?
YES NO PROCEDURE
DEFECTIVE
ROTATING DIODE
CR1,
CR2, CR3,
ON, EXCITER
ROTOR
FAULT IN
EXCITER ROTOR
OR
STATOR
WINDING
N O T E
Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of the appropriate section.
32
Redistribution or publication of this document, by any means, is strictly prohibited.
-
UNBALANCED GENERATOR OUTPUT VOLTAGE
Remove load from generator terminals. Is output still unbalanced?
Are generator leads properly connected or grounded?
Is generator stator winding continuous?
Is grounding procedure of generator and load correct?
Check for ground faults on load.
TABLE
J.
SYNOPSIS
TERMINAL VOLTAGES
I
INCORRECT RECONNECTION
AND/OR GROUNDING OF
GENERATOR LEADS
INCORRECT GROUNDING
OF LOAD OR GROUND
FAULT IN LOAD
YES
[
NO lPROCEDUREl
2
3
4
5
I -
I
I
1
FAULTY GENERATOR
STATOR WINDING
1
I
!
NOTE:
Whenever a letter appears near the
box,
a separate procedure, corresponding to that letter is given at the end
of
the appropriate section.
33
Redistribution or publication of this document, by any means, is strictly prohibited.
TABLE
J.
SY NOPSlS (Continued)
VOLTAGE 150%
MORE THAN RATED
OPEN TRANSFORMER
(T21) WINDING
I
OPEN WIRE OR
CONNECTION AT
VR21 MODULE
TERMINALS 5, 6, 9,10,
11
OR
12
DEFECTIVE COMPONENl
ON RECTIFIER
ASSEMBLY CR21
DEFECTIVE COMPONENl
ON VOLTAGE
REGULATOR (VR21)
MODULE
*
1.
DlODECR3
OPEN
I
-
BREAKDOWN OF
S C R l
OR
SCRP
I
NOTE:
Whenever a letter appears near the
box,
to that letter,
is
given at the end of the appropriate section.
Malfunction occurs after warmup or voitage adjustment.
34
Redistribution or publication of this document, by any means, is strictly prohibited.
ADJUSTMENTS AND
PROCEDURES
(Applies to Section II Only)
FLASHING THE FIELD
If output voltage does not build up it may be necessary to restore the residual magnetism of the poles by flashing the field. Assembleasixvolt battery, and diode as shown
in Figure 24. If a six volt lantern
battery is not available a 12-volt (generator set battery) or a 24-volt battery can be used, however a
20-ohm or a 40-ohm 2 watt resistor must be used in conjunction with the 12 amp 300 V diode. Start the generator set, touch positive lead to
+ on rectifier bridge, and negative lead to the
- terminal. Hold leads on terminals just long enough for voltage to build up.
Do not keep excitation circuitry connected longer than 5-seconds, or damage may occur to the exciter regulator.
TESTING L21
REACTOR
The L21 commutating reactor mounts inside the control box, below the VR21 Voltage Regulator.
The coils 1-2 and 3-4 are wound on the same core.
Resistance between 1-2 and 3-4 should be .034 ohm
f
.0034 and .042 ohms
*
.0042 respectively (brushless units). Resistance between coils (e.g.,
1/4) or from any terminal to frame of the reactor should be icfinity
(Figure 25).
1
I
I
I2 AMP.
300 v.
I
I
RECTIFIER BRIDGE
FIGURE 24. FIELD FLASHING CIRCUIT
FIGURE 25. L21 REACTOR
35
Redistribution or publication of this document, by any means, is strictly prohibited.
6
VOLT
DRY CELL
BATTERY
TESTING RECTIFIER BRIDGE ASSEMBLY
(CR21)
The rectifier bridge located within the control cabinet, below the voltage regulator, contains
3
diode?
CRl.
CR2. and CR3, and two silicon
C O I I I I ~ I ~ I I I ~ ~ ~ ~
SCR1 and SCR2. These diodes and SCR's arc cncali-
:;dated within a hermetically sealed block, therefore lailurc! of any diode or
SCR means the entire unit has t o
bc
I
7i-
CR3
-
h
CR
I
-1
I
-
CR2
I
'
A C TERMINALS ARE
GIVEN NUMERIC
DESIGNATIONS
FOR
T E X T REFERENCE
ONLY. DOES NOT
APPEAR
ON
UNIT.
FIGURE
26. RECTIFIER ASSEMBLY
Disconnect wires from rectifier unit prior to testing.
Test unit in order shown in Table 5. Refer to Figure 27
for SCR1 and SCR2test circuit. When test is complete and satisfactory, reconnect unit observing correct wiring hoo k-up.
r - - -
' I
FIGURE 27. TESTING SCR
36
Redistribution or publication of this document, by any means, is strictly prohibited.
CR3
N G
SCR
CR3
SCRl
CR1
REMARKS
Infinity
6-
to 50-Ohms
Infinity lnfinitv
METER SCALE
RXlOK
R X l
RXlOK
RXlOK
RX1
RXlOK 2CR2 Infinity
CR2
CR2
R X l OK
R X 1
6-
to 50-Ohms
DC Voltmeter DC Voltmeter
3CR2.I
AC2
Reading lead
I +
I
1 + 1
3 Volts
I
+
I
3 Volts
-
Apply
temporary jumper from AC1 to G1 to test SCR1. Remove jumper,
read voltmeter. See Figure 27.
**.Apply temporary jumper from AC2 to G2 to test
SCR2. Remove jumper,
read voltmeter. See Figure 27.
37
Redistribution or publication of this document, by any means, is strictly prohibited.
!
INDEX OF GENERATOR
ADJUSTMENTS AND PROCEDURES
L
M
P
B
PROCEDURE
.
TITLE
..............................
SCR’s
PAGE
PROCEDURE
R
TITLE
PAGE
Testing Bridge Rectifier (CR21)
38
Redistribution or publication of this document, by any means, is strictly prohibited.
CONTROLS
-
GENERAL
The shock mounted control box has two doors that open from the center. The left hand door holds the field circuit breaker, voltmeter and voltage adjusting rheostat. The optional meter package adds running time meter, frequency meter, ammeter or ammeters plus volts-amps selector switch to the left hand door.
The right hand door, attached to a removable bracket, holds the instrument lamp, fault lights, switches and gauges. An optional door has holes for electric tachometer and/or oil temperature gauge. The bracket supports the terminal blocks, cycle cranker and relays in the DC engine control circuit.
Plug mounted relays in both the AC section and DC section plus printed circuit modules in the DCsection facilitate troubleshooting and servicing. Snap-in lamps with Faston connectors make lamp replace-
ment very easy. See Figure 28.
I
A12 C R A N K I N G L I M I T E R
( M A Y A L S O U S E A N
O P T I O N A L C Y C L E
C R A N K E R )
K11 S T A R T D I S C O N N E C
R E L A Y
K12 I G N I T I O N R E L A
K13 S T A R T S O L E N O I
-FAULT L A M P S
TIME D E L A Y
-ENGINE M O N I T O R
P C B O A R D l
\ K I
K 2
R E L A Y
R E L A Y
FIGURE 28. LOCATION OF
DC
CONTROL COMPONENTS
THE QUESTION AND ANSWER TROUBLESHOOTING GUIDES BEGINNING
ON
PAGE 39 GIVE A STEP-BY-STEP PROCEDURE FOR CHECKING
CONTROL SYSTEM PROBLEMS. THEFLOW-CHART TROUBLESHOOTING
GUIDES ARE GIVEN AS A GENERAL GUIDE TO RESOLVE VARIOUS
CONTROL SYSTEM PROBLEMS. ALL CHARTS REFER TO PROCEDURES
AND NOTES WHICH ARE GIVEN AT THE END OF THIS SECTION.
39
Redistribution or publication of this document, by any means, is strictly prohibited.
QUESTION
AND
ANSWER TROUBLESHOOTING GUIDE
FOR UNITS WITH ONE FAULT LAMP
To correct a particular problem, answer the question either “yes“ or “no” then proceed to the next step given in whichever column question was answered.
TO CRANK WHEN SWITCH TO “RUN”
1.
Does fault lamp light?
2.
~
Is
battery connected correctly and is voltage normal?
3.
~~~ relay
K13’
(start solenoid) pick up?
4.
~
I
Does ignition relay
K12
pick up?
5.
Is voltage from ground terminal to center terminal of run-stop-remote switch equal to battery voltage?
6.
Switch is defective or in “stop” position.
7.
Is voltage from ground terminal to ignition relay
K12
terminal
“B” equal to battery voltage?
0.
Jumper battery positive from center terminal of run-stop-remote switch to terminal
“6”
now crank?
9.
Replace engine monitor printed circuit board.
10.
Is voltage from ground to terminal
26
on
TBll
equal to battery voltage?
11.
Does ignition relay
12.
a. Check socket connection. b. Coil may be open. c. Replace ignition relay
K12.
13.
Clean relay contacts and check wiring.
14.
Is voltage from ground to start disconnect relay
K11
terminal
1
equal to battery voltage?
15.
Clean relay contact
K11 (7-1)
I
YES
1 l 3
I
l7
I
l o
7
I
lo
-
9
-
14
13
I -
I
l6
I -
NOTE:
On
EK. EM,
and
EN
series, start solenoid relay is mounted rather than in the control, and is designated
K6.
on
the engine,
40
Redistribution or publication of this document, by any means, is strictly prohibited.
,
t
ITEM
NO.
A. ENGINE FAILS T O CRANK WHEN SWITCHED TO “RUN”
(Continued)
16.
Is voltage from ground to coil terminal of
K13’
start solenoid
I equal to battery voltage?
17.
Does voltage from ground to
TBll-22
18.
Jumper from
K13’
coil terminal to
Does relay
K13’
pick up?
K11
terminal
1.
19.
Replace cycle cranker printed circuit board
A12.
20.
Replace start solenoid
K13’.
21.
Is voltage from ground to starter coil terminal equal to
battery voltage?
22.
Replace starter.
23.
Check thermal breaker CB1 and wiring to starter.
‘NOTE: On EK.
EM, and
EN
series. start solenoid is mounted on engine, rather than in the control, and is designated
K6.
TABLE A. SYNOPSIS
ENGINE
FAILS TO
CRANK
YES NO PROCEDURE
17
18
21 20
19
-
-
-
-
-
22 23
-
-
- -
A12 CYCLE
CRANKER
FAILS
LOOSE OR
REVERSED
BATTERY
CON N ECTlO N
IGNITION
RELAY K12
FAILS
I
~
K12 COIL
(4-7) FAILS
TO CLOSE
START
SOLENOID
FAILS
MO N IT0 R
PRINTED
CIRCUIT BOARD
SOLENOID
COIL OPEN
SOLENOID
CONTACT FAILS
TO CLOSE
CONTACT FAILS
TO CLOSE
CIRCUIT PATH
41
Redistribution or publication of this document, by any means, is strictly prohibited.
ITEM
NO.
1.
TABLE B. ENGINE SHUTS DOWN IMMEDIATELY AFTER START
1
Is overspeed switch S3 closed?
I
Open overspeed switch, then reset fault lamp by switching to “stop”, then back to “run”. Does engine crank and run OK?
Remove wire from TB11-29. Reset fault lamp by switching to “stop”, then back to “run”. Does engine crank?
Place wire back onto TB11-29 while engine is running.
Does fault lamp light and engine stop?
5. Check overspeed switch and wiring for grounds.
6.
Jumper from ignition relay K12 terminal “B” to center terminal of run-stop-remote switch. See Method M in Procedure section.
Does engine crank?
~
7.
Replace engine monitor printed circuit board and remove jumper.
YES
1 2
NO PROCEDURE
4
5
-
7
-
1.
I
I
TABLE C. ENGINE SHUTS DOWN AFTER RUNNING
A SHORT TIME
Does fault lamp light and does plant stop after running about
12 seconds?
2.
~
3.
Does fault lamp light and does plant stop after running about
1 minute?
Remove wire from terminal TB11-30. Does engine run
OK
after restarting?
4.
Engine is either not pumping oil properly or oil pressure sensor is defective.
.
5. Replace wire on TB11-30 and remove wire from TB11-31.
Does engine run OK after restarting?
6.
Engine is either operating over temperature, temperature sensor is defective or wire between sensor and terminal block is grounded.
7.
Jumper K11 terminals 6-9. Does engine run OK?
~~ ~
8r-1 Replace r e l a y G 1 or clean contacts 6-9.
9.
I
Replace engine monitor.
42
YES
I
NO IPROCEDUREI
6
- a
Redistribution or publication of this document, by any means, is strictly prohibited.
ITEM
NO.
TABLE
D.
ENGINE HESITATES WHEN ATTEMPTING TO CRANK
1.
Does engine crank as soon as run-stop switch is put into
“run” position?
2.
Check contacts K12
(3-9)
failure to close or to make proper contact.
YES NO PROCEDURE
.
TABLE D. SYNOPSIS
ENGINE
SOMETIMES
HESITATES
BEFORE
CRANKING
5
I
DIRTY CONTACTS,
BAD CONNECTION
I
43
Redistribution or publication of this document, by any means, is strictly prohibited.
ITEM
NO.
TABLE E. STARTER FAILS
TO DISENGAGE OR TRIES
RUNNING
TO
RE-ENGAGE WHILE
I
1.
YES
Does starter continue to run after engine starts? 2
2.
3.
Does charge ammeter show a charging current while running?
Is charging alternator belt on and driving alternator properly?
4.
Does start disconnect relay K11 and starter protection relay
K14 pick up when engine starts?
5.
Does voltage from ground to K13’ coil terminal drop to zero when K11 relay picks up?
4 l 4
6.
Does voltage at starter terminal drop to zero when K13* drops out?
7.
Check for faulty starter.
8.
9.
Start solenoid contacts may be welded
-
.
.
I replace K13’ solenoid.
~ ~
Check K11 and K14 contacts (1-7) to make sure they open when relay picks up.
10. Does voltage across K11 terminals (A-B) build up’to battery voltage?
11. Replace start disconnect relay K11 or starter protection relay K14. Coil may be open.
12. Does relay K12 (5-8) close to bring battery voltage to alternator regulator?
13. Check for faulty alternator, regulator or shorted alternator output.
14.
Check K12 ignition relay for dirty contact or broken wire.
,
NOTE On EK. EM and EN series, start solenoid is mounted o n the engine, rather than the control, and is designated K6.
l 6
7
-
I - l -
11 l -
I l3
-
-
44
Redistribution or publication of this document, by any means, is strictly prohibited.
E. SYNOPSIS
J
STARTER
FAILS TO
DISENGAGE
START
SOLENOID
COWTACT FAILS
TO OQEN
K14 STARTER
PROTECTION
RELAY FAILS
I
-
AND-c
7
ENERGIZE
START DISCON-
NECT RELAY
K11 AND K14
START
DISCONNECT
RELAY K11
FAILS
OFF
-
SLIPPING
IGNITION RELAY
K12 (5-8) FAILS
TO CLOSE
K14 COIL,
7
.
' ,
CONTACTS
1
I
K11 START
DISCONNECT
COIL OPEN
CONTACTS 1-7
I w
1-7 ON K14
FAIL TO OPEN
ON K11 FAIL
TO OPEN
/G\
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of this section.
-
K14 starter protection relay was added to units beginning with the Specs shown below.
This relay prevents starter engagement when unit is running.
ALTERNATOR
I
OUTPUT SHORT
CIRCUITED
I
DEFECTIVE
REGULATOR
SERIES
EK-EM
EN
KB-KR
DDA-MDDA
DDB .
SPEC
D
A
P
A
A
SERIES
DEH
DEF
DEG
DFE
DYA
SPEC
D
F
D
H
C
45
SERIES
DYC
DYD
DYG
DYJ
SPEC
B
A
A
A
SERIES
WA
WE
WB
SPEC
F
B
H
Redistribution or publication of this document, by any means, is strictly prohibited.
QUESTION AND ANSWER TROUBLESHOOTING GUIDE
FOR UNITS WITH 5 FAULT LAMPS
-
I
‘LkM
I
TABLE
F. ENGINE FAILS TO CRANK
When switch is put into “run” position, does. engine csank?
.
:
’
Is battery connected correctly and is voltage normal?
’
.
I ’
Does one of the following fault lamps light?
(Choose one of the following:)
Overspeed?
High Engine Temperature?
Low Oil Pressure?
Overcrank?
. .
. .
-
YES NO PROCEDURE
.
.
-
2
-
3
I
I
-
I
30
25
27
29
22
11
5
6
Does ‘relay K13* (sfarfsolenoid) pick up?
Does ignition relay K12 pick up?
Is voltage from ground terminal to center terminal of run-stop- remote switch equal to battery voltage?
Switch is in “stop” position or defective.
Is voltage from ground terminal to ignition relay K12 terminal
“B” equal to battery voltage?
Jumper battery positive from center terminal of run-stop-remote switch to terminal “B” of relay K12. Does engine crank?
~~ ~~
Remove jumper and replace engine monitor printed circuit board.
Is voltage from ground to terminal 26 on TB11 equal to battery voltage?
Does contact ignition relay K12 (4-7) close?
Clean socket connection. Coil may be open. Replace ignition relay K12.
Clean relay contacts or replace relay and check wiring.
NOTE:
On
EK.
EM and EN series, start solenoid relay is mounted on the engine, rather than in the control, and is designated
K5.
8
-
7
-
I
1 1 3 1 g 1
I
1
I 1 0
1 - 1
. M
-
-
15
14
12
13
- -
- -
46
Redistribution or publication of this document, by any means, is strictly prohibited.
15.
17.
18.
19.
20.
21.
22.
23.
24.
25.
16.
Is voltage from ground to K11 iterminal 1 equal to battery voltage? 17
I l6
I
Clean relay contact K11 (1-7) and check wiring. Replace relay K11 if necessary.
Does voltage from ground to coil terminal of K13’ start solenoid equal battery voltage?
Does voltage from ground to TB11-22 equal battery voltage?
18
I
22
I l9
I
Jumper from K13* coil terminal to K11 terminal 1.
Does relay K13* start solenoid pick up?
20
Replace cycle cranker and check printed circuit connection.
Replace K13* start solenoid.
Does voltage from ground to starter coil terminal equal battery voltage?
I
1 - 1 - 1
23 24
Replace starter.
Check wiring between TB11 terminal 22 and starter. Some units have an automatic resetting circuit breaker in this circuit.
-
-
1 - 1 - 1
Remove lead from TB11-31. Reset by switching to “stop”, then back to “run”. Does engine crank OK?
26 29
26. Inspect for bare wires and shorts to ground. Replace engine temperature sensor.
27. Are relay contacts K11 (8-5) open?
28.
Replace relay and reset by switching to “stop”, then back to
“run”. Does engine crank OK?
29. Replace engine monitor printed circuit board.
30.
Remove lead from TB11-29. Reset by switching to “stop”, then. back to “run”. Does engine crank when switched to run?
’
31. Replace the lead to TB11-29 when engine is running. Does overspeed lamp light and engine stop?
32. Check for defective overspeed switch or bare wires grounding terminal TB11-29.
33. Stop and start engine several times. Works OK?
34. Replace engine monitor printed circuit board.
- -
29
-
28
29
- -
I
31
I
29
I
I
32
I
33
I
I I
I
I - 1 - 1
-
34
I
I
- -
NOTE: On EK,
EM
and
EN
series, start solenoid is mounted o n the’engine, rather than the control, and is designated K6.
Redistribution or publication of this document, by any means, is strictly prohibited.
ITEM
NO.
1.
~
TABLE G. ENGINE SHUTS DOWN AFTER RUNNING A SHORT TIME
~ ~~~ ~
Does low oil pressure lamp light and plant stop after running about 12 seconds?
2. Does overcrank lamp light and plant stop after running about
1 minute?
3.
Remove wire from terminal TB11-30. Reset alarm by switching to “stop”, then back to “run”. Does engine run OK?
(Replace wire after test.)
’
4.
Engine is either not pumping oil properly o r oil pressure sensor
is defective.
5. Does relay K11 pick up after engine starts?
6.
Jumper relay K11 contacts (6-9) after engine starts.
Does engine continue to run OK?
(Remove jumper after test.)
7.
Replace relay K l l .
8 .
Replace engine monitor printed circuit board.
9.
Does charge ammeter show a charging current while running?
10. Does battery voltage appear across K11 co,iI terminal
(A-B) when engine runs?
11. Check for an open circuit in wiring or a loose connection from alternator “AUX” terminal to K11 coil circuit.
12.
Check .alternator and regulator output; replace if necessary.
TABLE G. SYNOPSIS
SHUTS DOWN
I
START DISCON-
NECT RELAY
K11 (6-9)
I
NO ALTERNATOR
OUTPUT
I
TEMPERATURE
1
AEE:YF:E
1
SENSOR CLOSED
DEFECTIVE
REGULATOR
YES NO PROCEDURE
3
5
4
7
-
-
10
7
l -
- l -
6
,
I
I
PRESSURE
SENSOR CLOSED
F ’ % w
I I
SWITCH
A-11 ENGINE
MONITOR
PRINTED CIRCUIT
I
48
Redistribution or publication of this document, by any means, is strictly prohibited.
I
SINGLE LAMP
ENGINE MONITOR
ENGINE
FAILS TO
CRANK
FAULT
LIGHTS AND
ENGINE
SHUTS DOWN
FAULT
LIGHTS AS
SOON AS
RUN SWITCH
CLOSED
PATH
9-7
ON A-11
PRINTED
CIRCUIT
BOARD
LOW OIL
PRESSURE
OR HIGH
ENG. TEMP.
CIRCUIT
FAILS AFTER
APPROX. 12
SECONDS
*'*
TRANSISTOR
0 7 FAILED,
SHORT
EMITTER TO
.
COLLECTOR
**
K1 RELAY
CONTACT
FAILS TO
CLOSE
DIODE
CR3
OPEN
CAPACITOR c 2
SHORTED
SCR CR6
SHORTED
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of this section
* *
-
With swiich in run position, check for voltage across
R9 (27-ohms). A voltage
of
0.5 to 1.0 will turn on SCR CR6. If voltage is present, remove TB11 terminal 29. If voltage is still
I..
- present, check transistors
Remove
TB11 terminal
30 and 31. If engine still shuts down, remove transistor Q8. If this prevents shutdown
-
Q8.
ALARM
SHUTDOWN
CONTACT
FAILS TO
CLOSE
ON
SHUTDOWN
CIRCUIT
PATH 9-8
OPEN
Redistribution or publication of this document, by any means, is strictly prohibited.
ENGINE
FAILS TO
CRANK
CIRCUIT PATH
18-19
OPEN
K1 RELAY
CONTACT ON
A-11 FAILS TO
I
HIGH ENGINE
TEMPERATURE
LAMP LIGHTS
CAPACITOR
C6
OPEN
TRANSISTOR
Q10
SHORTED
ENGINE
MONITOR
**
LIGHTS AS
SOON AS RUN
I
LOW OIL
PRESSURE
LAMP LIGHTS
I
I
OVERSPEED
LAMP
LIGHTS
-
OVERCRA'NK
LAMP
LIGHTS
_ I -
I
ENGINE
SHUTS DOWN
I
OVERCRANK
LAMP LIGHTS
AFTER APPROX.
12 SECONDS
TRANSISTOR
Q6 FAILS TO
TURN OFF
RELAY FAILS
TO DISCHARGE
CAPACITOR C1
CAPACITOR l
POTENTIOMETER
R-15 ON A-11
PRINTED ClRCUl
BOARD FOR
CORRECT TIME
CAPACITOR
OPEN
I
TRANSISTOR
Q13
SHORTED
CAPACITOR
OPEN
I
..
.-
POTENTIOMETER
R2 ON A-11
PRINTED CIRCUIT
BOARD FOR
CORRECT TIME
I-
.
CAPACITOR
T
CAPACITOR
T
NOTE: Whenever a letter appears near the box, a separate procedure, correspondjng to that
I
. letter, is given at the end of this section.
'
Capacitor C1 must be discharged when engine starts to prevent an overcrank shuidown.
'
* *
Check relay contact that connects to terminal
16
of engine monitor.
-
See typical wiring diagram.
Redistribution or publication of this document, by any means, is strictly prohibited.
ADJUSTMENTS AND P.ROCEDURES
If starter fails to disengage, the engine may drive starter to unsafe speeds that could cause starter rotor windings to separate.
Inspect contacts for dirt particles, obstructions or insulating film. Clean, using low pressure com- pressed air and bond paper. Check relay socket.
R E M O V E K11
OR
K 1 2 F R O M
C O N T R O L B O X (PULL S T R A I G H T up). c T ) N N E C T A N O H M M E T E R
T O
T E R M I N A L S M A R K E D " A "
A N D
"6"
O F
R E L A Y .
O F
12 V O L T RE.LAY
IS 120 O H M S . R E S I S T A N C E O F
2 4 V O L T R E L A Y
I S 4 7 0 O H M S .
Contacts are normally closed when engine is not running. Contacts must open when engine is running normal.
IH1
Contacts are normally open; contacts close for alarm condition only. (Overspeed switch may have to be reset manually.)
'
I J I
Contacts may have welded closed or plunger may be stuck. Remove solenoid from circuit to test for proper operation.
FIGURE 29.
TESTING
K11
AND
K12
RELAYS
When connecting battery cables, terminal will spark i f connection is reversed.
Unit will not crank with reversed cables or loose connections.
DC alternator will overheat and will probably burn up.
A reverse battery connection will show a maximum
positive charge on the DC ammeter.
On dry charged batteries, no woltage is present until electrolyte is added.
[KI
Inspect printed circuit board paths that supply voltage to relay K12. (Between terminals 18-19of
300-
0681;
between terminals 7-9 of 300-0679.)
[LI
Remove cycle cranker printed circuit board and jumper terminal 2-3 to by-pass cycle cranker circuit.
See ooerator's manual for alternator belt tension edjustment.
Check for voltage from starter terminals to ground.
Voltage should be present at both terminals when solenoid is energized for cranking.
51
In an extreme emergency, engine may be operated without any safeties by removing engine monitor printed circuit board and jumping terminals 7-9. (It may be easier to jump from center contact of Run-
Stop switch to terminal
"B"
Kl-2 relay; see Figure
30.)
Redistribution or publication of this document, by any means, is strictly prohibited.
Units With Five Fault Lamps:
Potentiometer H2 on A- printed circuit board is factory adjusted for
75 seconds (
' 5
seconds). To lengthen delay, use a screwdriver and turn R2 clockwise; to shorten delay,
turn counterclockwise. See Figure 32.
R15
OIL
PRESSURE
D E L A Y - FACTORY SET
A T
12%
SECONDS
\
S W I T C H
. .
'.
FIGURE 30. EMERGENCY STARTING
ADJUSTING LOW OIL PRESSURE TIME
DELAY ON ENGINE MONITOR PRINTED
CIRCUIT BOARD
Units With Single Fault Lamp:
Potentiometer R l O on
A-11 printed circuit board is factory adjusted for 12-
112 seconds
(
?
2-1/2 seconds). To lengthen delay, use a screwdriver and turn potentiometer clockwise.
To shorten delay, turn
' potentiometer coun-
terclockwise. Refer to Figure 31.
Units With Five Fault Lamps:
Potentiometer R15 on
A-
seconds
( 2
2-1/2 seconds).
To lengthen delay, use a screwdriver and turn clockwise; to shorten delay, turn
counterclockwise. See Figure 32.
ADJUSTING OVERCRANK TIME DELAY
ON ENGINE MONITOR PRINTED CIRCUIT
BOARD
Units With SingleFault Lamp:
Potentiometer R4on A- printed circuit board is factory adjusted for 75 seconds
( r 5 seconds). To increase delay, use a screwdriver and turn R4 clockwise; to shorten delay,
turn counterclockwise. See Figure
R 4 OVERCRANK D E L A Y
(FACTORY SET
A T
R 2 OVERCRANK DELAY'
-FACTORY SET A T
75
SECONDS
FIGURE 32. ADJUSTING TIME DELAYS ON'FIVE
LAMP ENGINE MONITOR
ADJUSTING OPTIONAL CYCLE CRANKER
The optional cycle cranker is factory set:for 15 seconds crank time and, 10 seconds rest time. To lengthen crank time, .turn potentiometer R4 clockwise; to shorten crank time, turn coun- terclockwise. To lengthen rest time, turn poten- tiometer R1 clockwise; to' shorten, turn coun-
A12 C Y C L E CRANKEF
3OOC714-12V.
'
3OOC715-24V.
'
4
1
O I L PRESSURE D E L A Y
(FACTORY SET A T
12%
SECONDS)
\
FIGURE 31. ADJUSTING TIME DELAYS O N SINGLE
LAYP ENGINE MONITOR
52
R 4 C R A N K T I M E
F A C T O R Y
S E T
A T
15
SECONDS.,
T O I N C R E A S E
T U R N CLOCKWISE
R1 R E S T TIME-
F A C T O R Y SET A T
10
SECONDS.
TO
TURN
INCREASE
CLOCKWISE
0
FIGURE 33. OPTIONAL CYCLE CRANKER
ADWSTMENTS
Redistribution or publication of this document, by any means, is strictly prohibited.
WIRING
DIAGRAMS
61 2-5300
61 2-531 1
612-5312
612-5313
PAGE
............................................
.............................................
.................................................
.
.
......................................
....................................
......................................
.......................................
.......................................
.
...............................................
.........................................................
25-90 kW Brushless 15R; 515R
.....................................
166
25-180 kW Brushless, Full Meter Panel
...............................
25-45 kW-3R Brushless 120/240 V
25-90 kW 9XR Brushless 347/600V
...................................
Generator Set Engine Control, 12V Ignition; EK, EM, EN
Generator Set Engine Control, 12 V Ignition; EK, EM, EN
Generator Set Engine Control, 12V ignition; KR, WA
.............
73
.................
74
Generator Set Engine Control, 12 V Ignition; KR, WA
53
Redistribution or publication of this document, by any means, is strictly prohibited.
I---
-
-
I
1
612C4173
I
REAR VIEW_-P/\NEL
WIRING MAGRAM
_ _
-
HOUSING-CONTROL BOX
1 n.
CONTROL BOX (INSIDE)
W 12- NOTE
SEE VOLTAGE
CHART
T2
-
T 3
7
M?4 v
FIELO
I
M 2 3 v
SCHEMATIC DIAGRAM
a
d
I s
I
TI T 2
7
r T 6
I
...
..
111.
cfs
C821
PA111
M
3208431
ow
rnY.!"O*
I
CIRCUIT BREAKER. 2hMP
320P307
I
LOCKXKTBRKR HANDLE [PENNSTATE
1
.TI2
$7
CT21-23 3 0 2 8 7 4 3
, 3 0 2 8 7 4 4
'3088745
3028746
3028747
3028748
I TRANSFORMER ASSY-CUR t 2 5 - 4 0 K W
I
TRWSFORMER ASSY-CUR(41-45KWl
I
FIANSFORMER AS=- CUR ( 4 6 6 o ( w I -
I
TRANSFORMER ASST- CUR (61-lWl(W
I
TRANSFORMER *SSY~CUR(IOI~IUI:Wl
I
TRANSFORMER A3SY-CURU26-175KWI
ELlt3219
3150322
VR21 33201268
I 1
1
I
ROARDASSY-PC V0LTA:E RGLTR
VR22 305D49NREa
W I I
3380525
I
CHASSIS ASSY-VOLTAGE RGLTR
1
I
WIRING HARNESS
W12 336A1913
I
I
LEAO ASSY
.
NOTE:
CONNECT LEAO W12 FROM
TERMINAL
TB21-63
TO 7821-IH-I
PER VOLTAGE CHART BELOW
115/23OV, 50Hz,(H61
120/240V, 60H2, (H51
,
VOLTAGE CONNECTIONS
, -
.
..
.
-
.
I15/2WV, 50 Hz. (H41
IZOl2JEV. 60Hz,(H31
127/220V, 60 Hz,(H41
, - -
234/40OV, 50
-.. -.
Hz.
(H41
240/416V, 60 Hz,(H3)
254/440V, 60 Hz.( H4)
-
I'PHASE
115/23OV, 5 0 H z .
120/240V, 60Hz.
(H61
(H5)
NOTE.
UNLESS OTHERWISE NOTED,
-
. . . .
. . .
-
-
.--,
.--
,
612C4173
Redistribution or publication of this document, by any means, is strictly prohibited.
'
CONTROL BOX
(INSIDE)
,
$
WI2-NOTE
SEEVOLTAGE
CHART
%
I
I i T 2
SCHEMATIC DIAGRAM
% .
CBZI
I'
-
.-
-TI1
:
*TI2
m111
,'SI aiv KxmnM m.
3 2 0 8 2 I CIRCIJI_T BREAKER.IIAW
IZS-WKN
320818
I
I y O P m 7
-
I
I CIRCUIT BREAKER. 2 0 W P ( 4 - 9 0 K W l
I
J O B C K T ERKR HANDLE
(PEW
STATE
I I
--a
DS22 '
.
G2A131
30lK.224
'
'
LIGHT-UPPER SCALE
I
LIGHT-LOWER
7
!
I
TRELAY-VOLTAGE SELECTOR
11
.BRACKET- RELAY MTG
_.
---q
I -
_ - -
HOUSING-CONTROL
BOX
- -
I
T I
\
T2
T 3
74
TS
\ *
\
\
I
T 6
\
77
TO
T 9
Si!
I --
\
\
3
GENEfi IATOR
NOTE.
CONNECT LEAD W12 FROM
TERMINAL TB21-63 TO'TEZI.IH,)
PER
CHART
I
VOLTAGE CONNECTIONS
3
110/190V. 5CJHr, (H3)
115/2WV,
PHASE
-1
50
Ht. (H4)
220/3EOV,
234/400V,
115/23OV. 50H1, (H6)
120/240V,
60Hr,
(H51
120/208V,
127/220V,
139/240V,
60
HZ.lH3)
60 Hr,(H41
60 Hr.(H51
277/480V,
0
SO
HI. (til)
50
HI, (H4)
60
HZ (H3)
60
HZ.
(ti51
I
T 7
F 2
I
FIELD
L O
LI
.
LO
6 7 8 910
O O Q Q ?
5 4 1
(MOUNTED
IN E N )
TI
I
I
L3
NOTE.
UNLESS OTHERWISENOTED,
ALL COMPONENTS ARE SHOWN
IN THE 0E.ENERGIZED
POSITION
Redistribution or publication of this document, by any means, is strictly prohibited.
625D1007]
!
; I i pi i
I r
V R Z l
W A R D A5SI- PC
332DIL68
-
.
,\..,.
..
r
1 .
I
-
4 l -
.. c 1 2 1 -
.47
T
R27
K
*--
Redistribution or publication of this document, by any means, is strictly prohibited.
i
.;
5
B
57
Redistribution or publication of this document, by any means, is strictly prohibited.
-
I
I ?
1.:
1 2
7
I
I . I
I
I .
..
D
_-
N
* i i
---i
58
Redistribution or publication of this document, by any means, is strictly prohibited.
.
IVERSPEED iENERATlNG
612C4353
1
Z V 8OMA
c
;EMOTE hNNUNCIATOR
I1
EN6 TEMP
(FRONT VIEW1
I6
I
,1
1)
i
- 7
I
IUEBCRANK
.ow
o h
PRES!
.C C N G
TEMP
I
--
( R E A R V I F Y I
II id
SCHEMATIC DIAGRAM
CBI 1201%3-
E l
12
1931108
1931109
_.
193A104
-
I
I C I R C U I I B R E I K t R . I 7 5 AIP(0VC OHLVJ
,
I StNOER -011 PRESSURE
I SEWOER-WATER TEMP < O V A . O K )
I SINOER-WATER TEMP. (OEF.
I
FUEL PUMP
OEH. OEC)
S I s2
53
.
s5
S6
57
I
I
I
I
-
I 1
I
I
I
SWIICH-LOW Dl1 PRESSURE
1
I
1
SIlTCH-HIGH WATER
TEMP
I
I
1 f
SIITCH-OYIRSPfEO
I
I
S?ITCH-LOI l I T f R TEMP
SWITCH-LOU
011 PRESS
(PRE.lJARI)
-
4;
SIITCH-HIGH WATER TEMP (PM-ALARM)
'
I
I
' I
I
I TO TERM
62
I
8
63
I
190-24OVAC
NOTES:
I.
W12 USED ON STD CONTROL ONLY
2.USED ON PRE-ALARM CONTROL ONLY
3.REMOTE ALARM CIRCUIT RATED 5AMP
MAX
4.SHUTDOWN 8 A L A R M S
4.1 STD CONTROL
4.1.1 SAFETY SHUTDOWN
8
ALARMS Oh
OVERCRANK,OVERSPEED,HI ENG TEMP
8
L O OIL PRESS
4.1.2 SAFETY A L A R M ONLY ON LO ENG
TEMP
4.2 PENN STATE CONTROL
4.2.1 SAFETY SHUTDOWN
ON OVERCRANK a
ALARMS
8 OVERSPEED
4.2.2 SAFETY A L A R M S ON HI ENG
T E M ~ L O
PRESS a
LO
ENG TEMP
4.3 PRE-ALARM CONTROL
4.3.1
SAFETY'PRE-ALARMS ON
HI
EN(
TEMP
8
LO OIL PRESS
4.3.2 SAFETY SHUTDOWN a
ALARMS
ON OVERCRANK,OVERSPEED,HI ENG
TEMP e
LO OIL PRESS
4.3.3
TEMP
SAFETY ALARM ONLY ON
La EN(
5.S3 OVERSPEEO SWITCH MOUNTED IN
GENERATOR END B E L L
&UNLESS OTHERWISE NOTED,ALL
COMPONENTS ARE SHOWN I N T H E
DE-ENERGIZED POSITION
IHlADDCD DDA.DDB,DYJ
F?'p s 4
"
......
"
I 6 3 ON
"..
TBZl
30-24OVAC
,
P E N N STATE (SPEC:C,D,E.ECI
WHEN U S E D
$ T A T E L S W E & Q F ) vi
13
KI
n
B U A
CRANKER CR*NKI
- 0 3
, - 0 4
-0s
-06
Redistribution or publication of this document, by any means, is strictly prohibited.
I
.
300C679
I
Q)
0
1 7 -
9
FUELSOL >R
IGN RLLl
7
X 5
t
I
--1
H O W :
1. SOLDER fER SOLDERIH6 PROCESS MIL-S-1872 U S I N S SOLDER.
ITEM 23.
2 .
SOLDER J O l H l S
AN0
OR C W O N E N T
LEAOS
SHALL
NO1 PWOJECT
MORE
THAN 3 4 6 BLYOND SURFACE OF BOARD.
@
3. F A C l O R l AOJUST POTEHTIOYETER R13 FOR 12.5 f 2 . 5 SECONDS LOP
01111.
FACTORY AOJUST POTENTIDPETER R4 FBR 7 5 2 IO SECONDS O V E R C R d K 01111.
A9
RE
. R t O
A6
A2
P I I1
19 350-517
I 8 550-505
I7 350-572
16
3031169
15 350-552
14 350-526
I 3 350-536
I
2
1
I
2
I
I
RESISTOR
RESISTOR
RESISTOR
POTENTIOIETER
RESISTOR
RESlSlOR
RESIPIOP.
27n
2.711
I i i m
3.5
YEm
22m
15On
loom
Redistribution or publication of this document, by any means, is strictly prohibited.
FUEL
SQL
OR
IGN
RELAY 7
8
I - ~ - n
7
1
8
9
1
IO I I
I2 I3
1 1
I4
1 1 1 ' 1 1 1 1
D
NOTES'
I . SOLOEk ? E R SOLOLklNf PROCESS MIL-S-6172 USINC SOLOER.
ITEN 23
2 SOLOER JOINIS
ANU'OR'COYPONEkT LEAOS
SWLLL
HOT
PHOJECI
M O R E IHAN 3 16 3tlWO SURfACL OF EOARO.
3.
SET
R4
FOR
AN OVERCRANK TIME OELAV Of
1525
SEMNOS
4. ton
OIL PRESS TIME OELAY SHOULD BE i z . 5 i z . 5 SECOHDS
Redistribution or publication of this document, by any means, is strictly prohibited.
I
7 1
P
62
Redistribution or publication of this document, by any means, is strictly prohibited.
i
I
I
-
Redistribution or publication of this document, by any means, is strictly prohibited.
C B
d
M I
N I I
...
BY
AVl3U N9I
:
I
' . \
I
Redistribution or publication of this document, by any means, is strictly prohibited.
@
NOlcS:
e
- - - -
.
- - -
EQUIVALENT CIRCUIT
- 1
h
I
I.
R E M O X JiiMFER W12 B i X E E N TB21-i3
&
Ta21-H3.
MOUNT VOLTllGC SELECTOR RELAY
X!!j
I N UOKTROL
BOX AND l l R E A; SHOWN.
RELAY WILL ENEOGIZ:
Oi4 120 '29BV 30
C I R C U I T COMPLETING CONNECTION
BETWEEN TB21-63
I
TB21-H3. RELAY
WILL RElAAlN
DE-ENERGIZED ON 1 2 0 / 2 4 0 , 1 1 C I R C U I T COMPLETING
CONNECTION BETWEEN TB21-63
&
TB21-H5.
L 3
120/208V, 3 @
A
L 3
120/240
V, I
#
\-
I
I
I
I
I
Redistribution or publication of this document, by any means, is strictly prohibited.
---
/ 0
/?
WRING
DIAGRAM
--
I
CEkTROL BOX (INSIDE)
.
I
SCHEMATIC DIAGRAM
'
G21
T 5
7
;if.
DES
1 m r
CB21
,
NO
1
3208431
law
11115
L'51
I
MXfiIIItON
I
I IClRCUlT BREAKER.2AMP
I
GENERATgR
RELAY-VOLTAGE
SELEZR-
HOUSING-CONTROL BOX
_ _ t
~ 2 1 i i
I
i
RHEOSTAT-VOLTAGE ADJ
3 5 ~ 3 5 ~
I
3 0 3 P 3 2
I
I
IKNOB-RHEOSTAT
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BOARDASSY-PC VOLTAGE RGLTR
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NOTE
CONNECT LEAD W12 FROM
TERMINAL T821.63 TO TL12I.IH-I
PER VOLTAGE CHART BELOW
110/220V S O H z IH6l
=115/230< 50Hz:IH6l
1% 120/240V,
6 0 H z . !H5l
VOLTAGE CONNECTIONS
-
_ _ -
127/220V, 50
Hz. 1H51
120R08V. 50 Hz.1H41
110/190V. 50Hz.IH31
115/2OOV. 5 0
HI.
IH41
1201208V. 60HZ.IH31
127/220V, 60 H z . ~ H 4 ~
139/240V.
230/400V.
5 0 HI. 1H41
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1H51
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545A22
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Redistribution or publication of this document, by any means, is strictly prohibited.
CONTROL BOX (INSIDE)
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CHART
T O V R Z l
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EXCITER GENERATOR
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C O N T R O L B O X IINS-IEE
SCHEMATIC DIAGRAM
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302-0466 P METER-RUNNING TIME
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VOLTAGE CONNECTION
F::
L 2
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UNLESS OTHERWISE NOTED,
ALL COMPONENTSARE SHOWN
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IN THE DE-ENERGIZED
POSITION. l20/24CV. IPH.
(WIRING DIAGRAM)
612-5302
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Redistribution or publication of this document, by any means, is strictly prohibited.
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12-5303
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R E A R
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P A N E L
WIRING DIAGRAM
---
C O N T R O L B O X I I N S I D E I
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512-5304
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REAR VIEW-YNEL
WIRING DIAGRAM
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UNLESS OTHERWISE NOTED,
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Redistribution or publication of this document, by any means, is strictly prohibited.
612-5305
WIRING DIAGRAM
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REAR_VI_EW PANEL
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T21 T21
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(WIRING DIAGRAM)
612-5305
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Redistribution or publication of this document, by any means, is strictly prohibited.
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Redistribution or publication of this document, by any means, is strictly prohibited.
Onan Corporation
1400 73rd Avenue N. E.
Minneapolis, MN 55432
61 2-574-5000
Telex: 275477
Fax: 612-574-8087
Onan is
a registered trademark
Of
Onan Corporation
Redistribution or publication of this document, by any means, is strictly prohibited.
i
advertisement
Key Features
- 25 to 180 kW power output
- Reliable and durable construction
- Advanced control systems
- Stable operation
- Efficient performance
