hyd350-6

hyd350-6
Setting the Standard in Mobile Power
Instruction Manual for Model
HYDRO 350-6
Hydraulic Generator
Manufacturing of: Vehicle Mounted Generators • Hydraulic Generators
P.O. Box 582 • Chester, NY 10918 • 845-469-9151 • Fax: 845-469-7871 • Web Site/E-mail: www.fabcopower.com
Fabco Power
Instruction Manual
GENERAL INFORMATION
MODEL: HYDRO 350-6
GENERATOR ............ BRUSHLESS
GENERATOR ............ 3600 (60 Hz)
GENERATOR VOLTAGE ............ 120 or 120/240
MOTOR STARTING............ 300% SURGE
VOLTAGE REGULATOR ............ INHERENT
OUTPUT ............ 3500 WATTS CONTINUOUS
4000 WATTS PEAK AT
100° F OIL TEMPERATURE
HYDRAULIC MOTOR............ GEAR TYPE
MAXIMUM SPEED............ 4200RPM
(3600 RPM IDEAL)
MOTOR SHAFT ............ ½ inch
PORT SIZE
INLET ............ 3/4 - 8 S.A.E.
RETURN............ 7/8 - 10 S.A.E.
CASE DRAIN PORT............ 7/16 - 4 S.A.E.
• Page 2 •
Fabco Power
Instruction Manual
RECOMMENDATIONS
MODEL: HYDRO 300-6
HIGH PRESSURE LINE ........................ ½ inch
LOW PRESSURE LINE .......................... ¾ inch
FLOW RATE .......................................... 6 to 25 GPM
(6 GPM IDEAL)
FOR BEST RESULTS KEEP HYDRAULIC OIL
TEMPERATURE BETWEEN 80°F AND 120°F.
DO NOT EXCEED 175°F.
AN OIL COOLER IS RECOMMENDED.
MAXIMUM BACK PRESSURE ............. 150 PSI
WILL OPERATE ON ANY 2500 PSI OPEN CIRCUIT
OR CLOSED LOOP SYSTEMS.
RECOMMEND FILTER ........................ 10m
RECOMMEND HYDRAULIC OIL ....... DEXTRON III A.T.F.
INSTALLATION TIPS
Excessive pressure in your return line will damage the hydraulic motor seal. High back pressure can be caused by
“spikes” sent back through the return from other equipment on a common return line. Another potential problem
can develop if several pieces of equipment are connected to one “common” return line causing a high back
pressure (150 PSI is the maximum). We recommend you run the return line from the generator back to the
cooling tank with a separate line.
You can either run the 3/4 inch return line back to the tank or leave the 3/4 inch line connected to a common
return and run a separate 3/8 inch line from the case drain (located at the bottom of the hydraulic motor) directly
back to the tank. Either way you completely eliminate any problem of excessive return line pressure damaging
your hydraulic motor.
• Page 3 •
Fabco Power
Instruction Manual
Initial Installation and Start-Up
Be sure you set the hydraulic flow (GPM) to the generator at
Approximately 62.5 HZ or 3750 RPM with NO electrical load
on the generator.
By using this setting you will have approximately 60HZ
(cycles) or 3600 RPM when you are running at full rated load.
One way this can be accomplished is by using a Photo
Tachometer on our generator coupling or generator
cooling fan.
A Photo Tachometer is an inexpensive tool that can be
purchased at McMasters, Grainger, Sears or any other electrical
supplier.
• Page 4 •
Fabco Power
Instruction Manual
TECHNICAL INFORMATION
These self-excited and self-regulating generators, although overall dimensions have been reduced to a minimum,
are designed for high-level electrical performance and the maximum in operating reliability.
PRELIMINARY CHECKS:
Before touching the machines, perform a thorough and in depth visual
inspection, checking that components are correctly connected up and
that no cables or terminals are broken or loose.
STARTING UP:
Make sure, when starting up, that cooling air intake and discharge openings
are free and unblocked. We also recommend (when the machine operates
in a dusty environment) do periodic checks to make sure it is properly
ventilated
THE IMPORTANCE OF SPEED:
Frequency and voltage depend directly on rotation speed. This must be
kept as constantly as possible on its nominal value no matter what the
load. Drive motor speed control systems generally have a small drop in
speed between no load and loaded conditions. We therefore
recommend setting no load speed 3÷4% above nominal speed.
CHECKING VOLTAGE:
All the machines are regulated during factory testing. If voltage
readings differ from the value indicated on the name plate, this maybe
caused by a mistaken reading or by a different rotation speed and we
recommend regulating motor speed in order to have nominal RPM
under loaded conditions.
CHECKING THE DIODES:
For the ohmmeter test it is best to disconnect the diode from its circuit.
Measure continuity in one direction only. The test can also be made
without disconnecting the diode form the circuit, using a 12V battery
and a 45 watt light bulb (automobile light) as shown in the illustration.
The light should turn totally on only in one direction, as shown below.
WINDING RESISTANCE AT 20° C
ROOM TEMPERATURE
Size
Stator Ω
Rotor Ω
Exciter Ω
3.5
0.506
4.38
2.10
4.0
0.506
4.38
2.10
5.0
0.506
4.38
2.10
6.0
0.506
4.38
2.10
8.0
0.300
5.75
1.25
12.0
0.196
7.54
0.44
• Page 5 •
Fabco Power
Instruction Manual
ELECTRICAL CONNECTIONS
CONNECT NEUTRAL
TO GROUND IF USING
GFCI OUTLETS
NEUTRAL
(WHITE)
U2
V2
120/240 VOLT
OPERATION
120
120
V1
W1
RED OR
BLACK WIRE
25 AMP
OVERLOAD
SELF RE-SETTING
240
GROUND SCREW ON
GENERATOR FRAME.
USE GREEN WIRE
FOR GROUND IF
USING GFCI OUTLETS
RED OR
BLACK WIRE
TERMINAL BLOCK
JUMPER
(BLACK)
NEUTRAL
(WHITE)
V2
U2
30 AMP
OVERLOAD
SELF RE-SETTING
HOT LEAD
(BLACK)
W1
V1
120 VOLT
FULL POWER
OPERATION
120
GROUND SCREW ON
GENERATOR FRAME.
USE GREEN WIRE
FOR GROUND IF
USING GFCI OUTLETS
TERMINAL BLOCK
• Page 6 •
Fabco Power
Instruction Manual
PARTS BREAKDOWN
HYDRO 350-6
No.
1
2
3
3a
4
5
6
8
13
15
17
19
20
21
22
23
24
25
26
28
29
30
PART #
572262
572264
572182
572265
572235
572184
572266
572064
572186
572260
572288
572189
572615
572066
572067
572068
572162
572128
572154
572261
572263
572272
572072
572274
572159
572158
DESCRIPTION
Louvered Panel
Frame For Stator
Drive End Bell
Screen
Front Bearing
Fan
Rotor
Rear Bearing
User Terminal Board
Cover
Capacitor 31.5mfd/w Tie Wraps
Diodes
Pump Mount
Coupling 24mm
Spider
Coupling ½
Hydraulic Motor 6gpm
Rails
Mounts
Stud Cover
Rubber Cup
Fan Ring
Seal For Hydraulic Motor
Generator Complete
Voltage Indicating Light
Overload Protection Device
• Page 7 •
PART #
572227
572228
572052
572054
572100
572226
OPTIONAL CONTROL PANEL
Complete Control Panel
Control Box (Shell)
Volt Meter
Receptacle 120 Volt
Waterproof Recpt. Cover
GFI Outlet 120 Volt
Fabco Power
Instruction Manual
TROUBLE SHOOTING
PROBLEMS
ALTERNATOR EXCITATION
FAILURE
CAUSES
1.
Low Speed
2.
3.
Faulty capacitor
Faulty winding
REMEDIES
1. Check RPM and set at nominal
value.
2. Check and replace.
3. Check that winding resistance is
as shown in the tables.
HIGH NO-LOAD VOLTAGE
1. Speed too high.
2. Capacitor with high capacity.
1. Check and adjust RPM’s
2. Check and replace
LOW NO-LOAD VOLTAGE
1. Speed too low.
2. Faulty rotary diodes.
3. Breakdown in windings.
1. Check and adjust RPM’s
2. Check and replace.
3. Check winding resistance, as
per tables.
4. Check and replace.
4.
PROPER NO-LOAD BUT LOW
LOADED VOLTAGE
Capacitor with high capacity.
1. Low loaded speed.
2. Load too large.
3.
Rotary diodes short-circuited
1. Check and regulate RPM.
2. Check and change.
3. Check and replace.
UNSTABLE VOLTAGE
1. Loose contacts.
2. Uneven rotation.
1. Check connections.
2. Check for uniform rotation
speed.
NOISY GENERATOR
1. Broken bearings.
2. Poor couplings.
1. Replace.
2. Check and repair.
• Page 8 •
Fabco Power
Instruction Manual
FIXED DISPLACEMENT
TYPE GEAR PUMP
5
6
4
7
3
2
1
TYPICAL HYDRAULIC SCHEMATIC
8
9
1.
2.
3.
4.
5.
6.
7.
8.
9.
HYDRAULIC PUMP
PRESSURE RELIEF VALVE
CONTROL VALVE
PRIORITY FLOW CONTROL*
GENERATOR HYRAULIC MOTOR
CASE DRAIN LINE**
RETURN LINE FILTER
OIL COOLER
HYDRAULIC FLUID RESERVOIR
*
Some units may be equipped with integral priority flow control, refer
to specific model number.
**
External case drain line may be required on some units refer to
specific model number.
When external case drain is required it should be unobstructed direct
return to reservoir with a minimum I.D. no less than that of case
drain port on generator motor.
FOR SPECIFIC INSTALLATION RECOMMENDATIONS CONSULT FACTORY
• Page 9 •
Fabco Power
Instruction Manual
BRUSHLESS GENERATOR
WIRING
• Page 10 •
Fabco Power
Instruction Manual
• Page 11 •
Fabco Power
Instruction Manual
• Page 12 •
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