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.c om Service Manual c ua ls GenSet Models: DFEB DFEC DFFA DFFB KTA12 tM .i;; KTI11 KTI12 1 I I tri DFGA VTA1 DFGB VTA2 DFGC VTA3 -� lP c • NT4 NT4 NT5 NT6 NTA2 NTA3 ca · · DFBC DFBD DFBE DFBF DFCB DFCC ar DFAA DFAB DFAC an GENERATOR AND CONTROL KTA31 KTA32 KTA33 DFLA DFLB DFLC DFLD DFMA DFMB KTA51 KTA52 KTA53 KTA54 KTI51 KTT52 w .E lec DFJA DFJB DFJC DFJD ww ·c Printed U.S.A. 960-0504 4-93 w ww .E tri lec an tM ar lP ca ua ls .c om 1 PAGE TITLE SAFETY PRECAUTIONS INTRODUCTION •••••••••••••••••••.•••••••••••••••••••••••••••••••••••••••••••••••••••••••.••••••.•••••••••••••••••••••••••••••••••••••••••• About th is Manual ....... ........................... ........................ ......... .. ..... . . ..... ............ .......... .. ..... .... .. Te st ECJ,Iiprnert . . .. . .. ....... .. . . . .. . . . . .. . . .. .. . ........ .. . . . .. . . . . .. ... . ..... .. . . . . .. . . . ... . ........ ...... .... ... . . . . ........... .. . .. ... . . . .. ...... How to C>btain Service . . .. . . ..... .. ............. .. . . . . .. . ......... .. . . . .. . . .. .. . . .. .. . . ........ .. . . . . .. . . .. .. . . . . .. . ..... ... .. .. .. .. . ....... .... Co rtrols and Generators Ove rview ..................................................................................................... . 2 . . . . .. . . CONTROLS . . .. General ..................................................................................................... .............................................. Control Descriptions . .. . . . . .. .. . . ... .. ... . .. . .. . . . .. . . . ... . .. ... . . . . .. . . . . .. . ........ ...... .. . . .. .. . . . .. .. . . .. . . . . .. . .. . .. ... . .. ......... ... . . ... Control Panel Interior ............ .............. . .. . .. .......... . ......... . ....... ..... .. ......... . ...... ....... ... . .... Ge nSet ()peration ...... ........................................................................... ......... ................... ..................... . . . . ... . . . . .. . GENERATOR . . . . . . .. .. . .. Gene rator De scriptions . . .. . . . ....... ...... .. . . . . .. .. .. .. . . . .. . . . . .. . . .. .. .. . . ... . . . .. . . . . .. . . . .. . . . . ... . . . .. . . ........ ...... .. . . . .. . . ...... .... Generator Control Co l11l0 nents .................................... ........ ................ . ........ ... . ...... ............ . ... Generator ()peration ............................................................................................................................. Optional C ira.Jit Breaker .................. ...................................................................................................... an 3 . TROU BLESHOOTING 5 COMPONENT TESTS AND ADJUSTMENTS General . . . . . . tM 4 .. .. . ................................................................................................................................................... ii 1-1 1-1 1 -1 1-2 2-1 2-1 2-3 2-6 3-1 3-2 3-3 3-4 4-1 ar General ....................................................................................... ............................................................ 5-1 Control Components Engine Co rtrol M oritor (ECM) ............................................................................................................. 5-1 Run Rel ay ....................................................................................................... ........................................ 5-3 Interface Relay Mock.des ............... ........... .. ......... . ....... ..... ..... . ..... ....................................... 5-4 lime Delay Sta rVStop M odule . .. ........... ............. ............. ................. ................................................. 5-5 AC Meters and Current Transfo rmers ................................................................................................. 5-5 Generator Components Automatic Vol tage R egulator................... ............................................................................................. 5-6 Generator ()peration Review ... ............ ................ .. ........ ..... ...... . ...... .......... ......... ....................... 5-8 Over/Under Voltage Sensor M odule.................................................................................................. 5-10 Over/Under Frequency Sensor M od.lle. ......................................... .................................... ............... 5-10 Overspeed (FreCJ,�e ncy Detection) M odule .................. ............... ..................................................... 5-10 Rotating Rectifier Asse nt>ly .. ... . . ... . . . . .. . . . . ... . . . .. . . . . .. ... . .. . . . . . . . . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . . .. . . . .. . . . ... . . . . ... . . ... . . . . .. 5-1 1 Pe rma nent M agnet E xdter ............ .. ............. .......................... ..................... ....................................... 5-1 1 E xdter Rotor ...... ....................... ............................. ............ ......... ............ ... .......... ................................ 5-1 2 E xdter Stator . . .. . . . . .. . .. . .. . . . . . ... ... . . . . .. . .. ...... .. . . . . .. . . . .. . . . . .. . . . . ... . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. 5-1 2 Ge nerator Rotor................................................................................................................................... 5-1 2 Ge nerator Stator . .... ......................... .. .. ........... ........... ............. ....... .. ... .. ........ .......... ... .. . . ........ ............. 5-13 Reconnection ... .... ............. ......... ............. ........... ... . .. ............ ... ................... ..... ......................... 5-14 Engine Components Electro nic Governor............................................................................................................................. 5-1 6 Batteries ...... .................. .......... .. ....... ........ ........... ......... .......... ....... .......... ....... .. . ............... ................... 5-1 7 Batte ry Cables . . .. . . . . .. . . . . .. . . . . . . . . . . .. . . . . .. . . . .. . . . . .. . . . . ... . . . .. . . . . .. . . . . . . . . . . .. . . . .. . . . . . . . . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . . . .. . . .. 5-1 7 Alternator ........... .............................................................. ................................................................... 5-18 Starter Solenoid . . . . . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . . . . . . . .. . . . .. . . . . .. . . . . . . . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . . . . . . .. . . . . .. . . . . .. . . . . . . . . . .. . . . . .. 5-18 Fuel Solenoid .... .. ........ ........... ......... .. .. .............. .......... ... ...... ..... .. . ......... .......... ...... ............ .. ............... .. 5-18 Control Switch .. .... .......... .. ... ........ ... ........ ... . . . ............ ..... .. . .. ....... ..... .. . . ........ ......... .... ... .. ...... ... . .. . . . .... .... 5-18 Other Optional Components Testing AC Load Ci ra.Jit Breaker ..... ... ............ .......... ....... .. . . ...... .. ...... .. .. ....... ...... .. .... .. . . . .... .. .. . . . . ... . . . .. 5-1 8 ... . . ..... . .. .. .. . .. . lP . ... . ca ... . . . . tri . lec . . . .. . . .. . . . . .E . . . . GENERATOR 7 Generator Disassembly ............................................................................. ............................................ 6-1 Generator Reasse nt>ly ........ .. .......... .. .......... .. ......... ...... ........... ....... .. . .. .. . . . ... .. . . .. .......... .. .. .. .. ..... .......... .. 6-7 WIRING DIAGRAMS/SCHEMATICS Refer to Section Usti ng w 6 ww .. . ua ls SECTION .c om Co nte nts DISASSEMBLY/REASSEMBLY •.•.••••...•.•••••••...•.•••....•••••....••••.•...••.....•••••...••• .c om Safety Precautions Safe and efficient operation can be achieved only If the equipment Is properly oper ated and m aintained. Many accidents are caused equipment. by failure to follow fundamental rules and precau tions. • Be sure all fuel supplies have a positive shutoff valve. • Do not smoke while servicing lead acid batter ies. Lead acid batteries emit a highly explosive hydrogen gas that can be ignited by electrical arcing or by smoking. EXHAUST GASES ARE DEADLY The following symbols, found throughout this man ual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment. • hazards which will result In severe persona/ In jury or death. tM Do not use exhaust gases to heat a compart ment. • Be sure the unit is well ventilated. MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH lP FUEL AND FUMES ARE FLAMMABLE Provide an adequate exhaust system to prop erly expel discharged gases away from en closed or sheltered areas and areas where in dividuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Ensure that ex haust manifolds are secured and not warped. ar lA CAUTION I This symbol refers to a hazard or un safe practice which can resultIn persona/Injury or product or property damage. ca Fire, explosion, and personal injury or death can re sult from improper practices. • Keep your hands, clothing, and jewelry away from moving parts. • Before starting work on the generator set, dis connect starting batteries, negative (-) cable first. This will prevent accidental starting. DO NOT fill fuel tanks while engine is running, unless tanks are outside the engine compart ment. Fuel contact with hot engine or exhaust is a potential fire hazard. • Make sure that fasteners on the generator set are secure. Tighten supports and clamps, keep guards in position over fans, drive belts, etc. • DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank. • • Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use copper piping on flexible lines as Do not wear loose clothing or jewelry in the vi cinity of moving parts, or while working on elec trical equipment. Loose clothing and jewelry can become caught in moving parts. Jewelry can short out electrical contacts and cause shock or burning. lec tri • .E • copper will become brittle if continuously vi brated or repeatedly bent. If adjustment must be made while the unit is running, use extreme caution around hot mani folds, moving parts, etc. w ww .. an t!'J•t!UM#!;I This symbol warns of Immediate lAWARNINGlTh/s symbol refers to a hazard or un safe practice which can result In severe per sonal injury or death. ua ls Before operating the generator set, read the Op erator's Manual and become familiar with it and the ii r • • • Remove electric power before removing pro tective shields or touching electrical equip ment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. heat exchanger pressure cap while the engine is running. Allow the generator set to cool and bleed the system pressure first. • have been identified by some state and federal Use extreme caution when working on electri toxicity. fumes, or contact gasoline. Follow all applicable state and local electrical codes. Have all electrical installations per formed by a qualified licensed electrician. Tag open switches to avoid accidental closure. • Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive tM DO NOT CONNECT GENERATOR SET DI RECTLY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This cre ates a potential tor electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling de vice. When checking or changing engine oil, take care not to ingest, Provide appropriate fire extinguishers and in ar • stall them in convenient locations. Consult the local fire department tor the correct type of ex lP tinguisher to use. Do not use foam on electri ca High voltage acts differently than low voltage. Special equipment and training is required to work on or around high voltage equipment. cal fires. Use extinguishers rated ABC by NFPA. • Make sure that rags are not left on or near the engine. • Operation and maintenance must be done only by persons trained and qualified to work on such devices. Improper use or procedures will result in severe personal injury or death. Remove all unnecessary grease and oil from tri the unit. Accumulated grease and oil can cause overheating and engine damage which lec present a potential fire hazard. • Do not work on energized equipment. Un authorized personnel must not be permitted near energized equipment. Due to the nature of high voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the time tor maintenance with authorized person nel so that the equipment can be de-energized Keep the generator set and the surrounding area clean and tree from obstructions. Re move any debris from the set and keep the floor clean and dry. .E • toxicity. breathe the fumes, or contact used oil. HIGH VOLTAGE GENERATOR SETS (1.9kV to 15kV) • When checking, draining or adding gasoline, take care not to ingest, breathe the an • Benzene and lead, found in some gasoline, agencies as causing cancer or reproductive cal components. High voltages can cause in jury or death. DO NOT tamper with interlocks. • Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or ua ls • .c om GENERAL SAFETY PRECAUTIONS ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH • Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe. ww w and safely grounded. KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE iii LS-10 w ww .E r tri lec an tM ar lP ca ua ls .c om Introduction ABOUT n-tiS MANUAL r�lar maintenance schedule is important to obtain longer unit life, better performance, and safer operation. This manual provides troubleshooting and repair informa tion regarding the controls and generators used on the following generator sets. ua ls For proper replacement parts identifiCation, refer to ap propriate Parts Manual supptied with urit. Repair of printed circuit board components other than fuses requires well-trained, quatified personnel with the proper equipment; repair of the printed circuit boards is not recorrmencled except by the factory. Applcation of meters or hot soldering irons to printed circuit boards by other than qualified personnel can cause unnecessary and expensive damage. GENERATOR SET MODEL DESIGNATIONS DFAA DFAB DFAC 1 75 200 220 200 230 250 NT4 NT4 NT4 NT5 1 75 1 75 200 220 200 200 230 250 DFBF DFCB DFCC NT6 NTA2 NTA3 250 275 31 0 275 300 350 DFEB DFEC DFFA DFFB KTA1 2 330 400 400 450 DFGA DFGB DFGC VTA1 VTA2 VTA3 DFJD DFLA DFLB DFLC DFLD DFMA DFMB High voltage testing or high potential (or Megger) testing of generator windings can cause damage to solid state components. Isolate these components before testing. For any operation, maintenance, or troubleshoodng Information beyond 1he scope of this manual, refer to oth• manuals received with unit, or contact your distributor. lP 400 450 450 500 ca KTA31 KTA32 KTA33 .E lec DFJC 440 KTA51 KTA52 KTA53 KTA54 KTT51 KTT52 500 600 620 660 800 900 750 800 900 1 000 900 1 000 1 1 00 1 250 1 1 20 1 200 1 1 00 1 280 • • • • • • Battery Hydrometer Tachometer or Frequency Meter Jurf1)9r Leads Wheatstone Bridge or Digital Ohmmeter Variac Load Test Panel Megger or Insulation Resistance Meter HOW TO OBTAIN SERVICE !Wiays give the complete Model and Serial number of the generator set as shown on the nameplate when seeking additional service information or replacement parts. The nameplate is located on the side of the generator output box. 1 250 1 500 I &WARN I NG I w For further operation, service, and troubleshooting infor mation regarding engine components, refer to support manuals specific to your generator set. Incorrect service or replacement of parts can result In severe personal Injury or death, and/or equipment damage. Service personnel must be qualified to perfonn electrical and mechanical service. Read and follow Safety Precautions, on pages II and Ill. Study this manual carefully and observe all warnings and cautions. Be sure to review Safety Precautions. on pages ii and iii. Using the generator set properly and following a ww TEST EQUIPMENT Most of the test procedures in this marual can be per formed with an AC-DC rrultimeter such as a Sifi1)SOn Model 260 VOM or a digital VOM. Some other instruments to h ave available are: • 550 tri DFJA DFJB KTT1 1 KTT1 2 I ACAUTION I ar DFBC DFBD DFBD DFBE an KW RATING 50Hz 60Hz tM • .c om 1. Section 1-1 .c om CONTROLS AND GENERATORS OVERVIEW Control Panel Depending on customer order, the control options and generator type may differ. Read through this manual to identify the control options, and generator type. A more in depth description of the control and generator compo nents follow in the Controls and Generator sections. Read this information well and understand the function of each component. The control panel is mounted inside the front portion of the generator output box with vibration isolators on both top and bottom. The controls are separated into a DC panel for monitoring the engine and an AC panel for monitoring the generator. See Figure 1 -1 and Section 2. Generator ua ls General The generators fitted to this series of generator sets are a Permanent Magnet Generator (PMG) type. Also, periodically review this manual and the unit Operator's Manual when no fault condition is present. You will want to become familiar with the generator set com ponent locations, their proper operation and interaction with other components in order to be effective trou bleshooting a fault condition, if one occurs. tM an The generators are controlled by an Automatic Voltage Regulator (AVR). The AVR is mounted on the inside, back wall of the control panel. See Figure1 -1 and Section 3. ar @) l!J[!J � lP § [3 t=121!...!:::::=�-_____.!@J:u CONTROL PANEL {REFER TO SECTION 2) .E lec tri OTHER GENERATOR CONTROL COMPONENTS (i.e., OVER/UNDER VOLTAGE AND FREQUENCY MODULE� ARE LOCATED INSIDE CONDUIT BOX. REFER TO SECTION 3. C===:J ca PMG VOLTAGE REGULATORS VOLTAGE REGULATOR (LOCATED INSIDE CONTROL PANEL). REFER TO SECTION 3. ww w AC METERING CURRENT TRANSFORMERS (LOCATED INSIDE CONDUIT BOX.) REFER TO SECTION 2. PMG EXCITER HOUSING COVE R PLATE (FOR ACCESS TO ROTATING RECTIFIER ASSEMBLY) FIGURE 1-1 . TYPICAL PUG GENERATOR AND CONTROLS 1-2 G EN ERAL AC Ammeter (Optional): Dual range instrument indi cates AC generator fine current. Measurement range in use shown on indcator la"l>5. Depending on rustomer order, the control configuration and options may differ. This section identifies the control config.uations used; Detector-7 and Detector-12 (NFPA) DC Panel, and AC Panel options. ua ls Frequency/RPM Meter (Optional): lndcates generator output frequency in hertz and engine speed in revolu tions-per-minute (RPM). The control panels are separated into an AC panel for monitoring the generator (if equipped with meter options), and a DC panel for monitoring the engine. Review F�gure 2-1 to identify the control configuration and options, and refer to Control Descriptions that follow for further infor mation . Wattmeter (Optional): Continuously gives readng of the generator output in kilowatts. an Voltage Adjust (Optional): Rheostat providng approxi mately plus or minus five percent adjustment of the rated output voltage. CONTROL DESCRIPTIONS AC Panel Upper and Lower Scale Indicator Lamps (Optional): Indicates which scale to use on the AC voltmeter and AC ammeter. tM The following describes the function and operation of the optional AC panel for monitoring the generator. Review the following component descriptions and Figure 2-1 . Phase Selector Switch (Optional): Selects phases of generator output to be measured by AC voltmeter and AC ammeter. lP ar AC Voltmeter (Optional): Dual range instrument indicat ing generator AC voltage. Measurement range in use shown on indicator la"l>5. Field Bteaker: Provides generator exciter and regulator protection from overheating in the event of an overvoltage faul condtion. RUN-STOP-REMOTE SWITCH RESET, J_AY) TEST, PAtEL J_AY) SWITCH tri AC VOLTMETER PANEL LAMP ca 01.. PI£SSURE GAUGE .E lec INDICATOR LAMPS \ AC AMMETER ---���-lr--r-- PHASE SELECTOR SWITCH COOlANT TEMPERATURE GAUGE RI.JN.IING TM: METER w FREQUENCY/RPM METER TACHOMETER WATIMETER ww .. .c om Section 2. Controls OTHER OPTIONAL METERS DC PANEL AC PANEL FIGURE 2·1. CONTROLS (DETECTOR-12 AND AC METER OPl10NS SHOWN) 2-1 OR.. TEMPERATURE GAUGE ES-181111-1 .c om DC Panel The green Run lamp comes on as soon as both primary and secondary starter circuits are opened after unit starts. The yellow pre-alarm lamps indicate that engine oil pres sure is marginally low, or coolant temperature is margin ally high, and should be attended to when the generator set is shut down. The red fault lamps indicate a shutdown of the generator set for low oil pressure, high engine tem perature, overspeed, or overcrank fault condition. The following describes the function and operation of the DC panel components. The Detector-? panel is standard, and Detector-1 2 panel includes options to more effec tively monitor the generator set and ancillary equipment during operation. Both controls include pre-alarm moni toring to infonn the operator that a shutdown might occur if attention is not given to an aspect of engine operation soon. Review the following component descriptions and Figure 2-1 . Oil Pressure Gauge: Indicates pressure of lubricating oil in engine (wired to a sensor unit located on the engine). • Water Temperature Gauge: Indicates temperature of circulating coolant in engine (wired to a sensor unit located on the engine) . • • PRE LO OIL PRES (yellow) indicates engine oil pres sure is marginally low. PRE HI ENG TEMP (yellow) indicates engine temper ature is marginally high. LO OIL PRES (red) indicates engine has shut down because of critically low oil pressure. tM DC Voltmeter: Indicates the battery condition. Proper reading should be approximately 26 to 28 volts when set is running. RUN (green) lamp comes on when both starter circuits are opened after unit starts. an Panel Lamp: Illuminates control panel. ua ls Detector-12 Control {Optional): The optional control panel has a 1 2 lamp monitoring system. The following de scribes each lamp function. • Tachometer(Optlonal}: Provides constant monitoring of engine r/min. HI ENG TEMP (red) indicates engine has shut down because of critically high temperature. ar • Oil Temperature Gauge (Optional): Indicates tempera ture of lubricating oil in engine (wired to a sensor unit located on the engine) . lP • Run-Stop-Remote Switch: Starts and stops the unit locally, or from a remote location that is wired to the control engine monitor board. ca • tri Reset, Lamp Test, Panel Lamp Switch: Resets the fault circuit only when the Run-Stop-Remote switch is in the Stop (Reset) position. Tests fault lamps and turns on the control panel lamp. Frequency A djust (Optional): Potentiometer providing engine speed adjustment to achieve proper AC fre quency. • • lec • Running Time Meter: Registers the total number of hours the unit has run. Use it to keep a record of periodic servicing. Time is cumulative; meter cannot be reset. .E Emergency Stop Pushbutton (Optional): Stops the generator set immediately when depressed. Must be reset (pulled out) before restarting generator set. • • Indicator Lamps RUN (green) PRE LO OIL PRES (yellow) PRE HI ENG TEMP (yellow) LO OIL PRES (red) HI ENG TEMP (red) OVERCRANK (red) OVERSPEED (red) ww • w Detector-7 Control (Standard): The standard control panel has seven monitor system indicator lamps. • • • • • • 2-2 OVERSPEED (red) indicates engine has shut down be cause of excessive speed. OVERCRANK (red) indicates the starter has been locked out because of excessive cranking time. FAULT 1 (red) an undedicated fault. May be program med as a timed or non-timed shutdown or fault light only (normally factory set for timed shutdown). 2 (red) same features as Fault 1 (nonnally factory set for non-timed shutdown) . FAULT LOW E N G TEMP (yellow) engine temperature is mar ginally low for starting. Indicates possible inoperative coolant heater. Lamp lights when engine water jacket temperature is 70° F (21 o C) o r lower. The lamp may stay on during initial generator set operation, but should go out after the engine warms up. LO FUEL (yellow) indicates fuel supply is marginally low (if equipped). SWITCH OFF (flashing red) indicates generator set is not in automatic start operation mode. ' .c om CONTROL PANEL INTERIOR AUTOMATIC VOLTAGE REGULATOR (AVR) VR21 (SEE SECTION 3) ENGINE CONTRa. MONITOR (ECM) A11 TIM: DELAYED START/STOP MODULE A15 OVERSPEED (FREQUENCY DETECTDI) MODULE w .E lec FIGURE 2·2. CONTROL PANEL INTERIOR ww (] DC PANEL tri ACPANEL ca lP ar tM an TERMINAL BOARDTB21 ua ls Refer to Figure 2-2 for component locations inside control panel. Review the following component descriptions to better understand the operation of the generator set should a fault condition occur. Also refer to Section 5, Component Tests and Adjustments, for more in-depth information about these components. 2-3 Fuses: The ECM has five replaceable fuses to protect it from overloads and ground fautts. They are: This circuit board assembly oontains the basic OOillJO nents for normal engine start-up and shutdown, terninals for remote oontrol interoonnection, plug-in oonnectors for option modules and engine sensor i'l'l)ts. The ECM provides the following functions of unit protection: • Overcrank - Umits engine cranking to 75 seoonds. H engine fails to start, the module lights a fautt lamp and opens the cranking circuit . This cycle cranking circuit al lows three 1 5-seoond cranking cycles with two 1 5-sec ond rest periods. Starter solenoid circuit, 20 amps Fuel solenoid (switched B+) circuits, 20 amps Continuous B+ out to remote circuits, 1 5 amps ECM circuits, 5 amps Engine guage circuits, 5 amps. Overspeed - Shuts down the engine immediately if an overspeed oondition occurs and lights a fautt lamp. The generator sets are equipped with an overspeed (fre quency detection) module, inside the oontrol panel. The module is factory set to shut down the generator set at approximately 21 00 r/rnin (60 Hz units), or 1 850 r/min (50 Hz units). Refer to Component Tests and Adjust ments section for further information. ua ls Function Selection Jumpers: The ECM has six selec tion jumpers that can be repositioned to provide the following timed or non-timed warnings or timed or non timed shutdowns with warnings: W1 Jumper Position ijurrper W8 must be in the B posi tion): Non-timed warning under FLT 2 oonditions. Non-timed shutdown and warning under FLT 2 conditions. C Timed warning under FLT 2 oonditions. D Timed shutdown and warning under FLT 2 oon ditions. A B an • F1 F2 F3 F4 FS Low Oil Pressure - Shuts down the engine immediately tM • .c om Engine Control Monitor if oil pressure drops below 1 4 psi (97 kPa) and fights a W2 fautt lamp. The fautt is inhibited during cranking and time delayed about 1 0 seoonds following starter disoon nect. The delay allows oil pressure to rise to normal before the electronic oontrol module monitors this system. Jumper Position ijumper W9 must be in the B posi tion): Non-timed warning under FLT 1 oonditions. Non-timed shutdown and warning under FLT conditions. C Timed warning under FLT 1 oonditions. D Timed shutdown and warning under FLT 1 oon ditions. ar A B W6 Jumper Positio n: ca High Engine Terrperature - Shuts down the engine immediately if coolant terrperature rises above 21 5° F (1 02° C) and lights a fautt lamp. The fautt is inhibited during cranking and time delayed about 1 0 seconds fol lowing starter disconnect. This delay allows coolant in a hot engine time to circulate and return the water jacket to normal before the electronic control module resumes monitoring this system. tri • lP The pre-low oil pressure sensor and lamp provides an alarm that oil pressure is marginally low, 20 psi (1 38 kPa) or less. The cause should be found and oorrected as soon as possible. Warning under Pre-Low 011 Pressure oonci tions. B Shutdown and warning under Pre-Low Oil Pres sure oonditions. .E lec A W8 Jumper Position: I ACAUTION I T1Je high engine tempetatute shut down system will not operate N the coolant level Is A B too low. The high engine temperatute sensor monitors coolant temperatute. Loss of coolant will prevent sensor operation and allow the engine to ovelheat causing severe damage to the engine. TJJerefote, maintain adequate coolant level to en sure the operation of the high engine tempetatute shutdown system. Warning during standby under FLT 2 oonditions. Allows selection of functions with W1 jumper. W8 Jumper Position: A B w ww Low Coolant Level Shutdown (Optional) - A soHd-state sensor installed into the radiator provides engine shut down if coolant level falls too low. It also lights the high engine temperature fautt lamp. Warning under Pre-High Engine Temperature co nditions. B Shutdown and warring under Pre-High Engine Temperature oonditions. A W7 Jumper Position: The pre-high engine temperature sensor and lamp pro vides an alarm that engine terrperature is marginally high, 205° F (97° C) or higher. The cause should be found and oorrected as soon as possible. • 1 Warning during standby under FLT 1 oonditions. Allows selection of functions with W2 jumper. The ECM also has solder finks and rectifiers that can be repositioned to provide other functions such as: negative signal mode, 1 OS second cycle cranking, 75 seoond non cycle cranking and 60 seoond non-cycle cranking. 2-4 .c om 0 0 I 2 3 4 5 6 P 4 ar tM an ua ls 7 - ";" ]" P 11 11 1 9a..__s_7 _s_:_•�-1_12 ,_1 _2_ _ / ca O lP TBI 1 tri ....... lJIII oc TEST IIESET 115 ... LO 1 _, '""" 6 s .... "' :.:..o.. N r-- 4P2 3 ww w .E lec RGURE 2-3. ENGitE CONTROL MONITOR (DETECTOR 12 ECM SHOWN) 2-5 2 1 .c om GENSET OPERATION Run Relay(s) (K11) This relay (may be up to three) provides wiring connec tions for external functions of the site installation that are to be controlled by the starting and/or stopping of the generator set such as ventilation air louvers, blowers, etc. The sets of contacts in the relay base provide for either closing a circuit or opening a drcuit upon energizing and de-energizing the relay (depending on the desired func tion wires to the base connections). The relay is energized when the generator set run circuitry is energized (ie., fuel solenoid) when connected to the ECM at TB1 -1 0 (switched B+ connection). Because of varying control option combinations, the fol lowing operating descriptions will encorrpass a Detector1 2 controller with full options. Read the information through to Emergency Shutdown to gain a full under standing of the options and how they interact with the engine control monitor (ECM). ua ls Regardless of the controller model you have, the ECM in cludes the shutdown fault commands. Controllers with options provide delineation and pre-alarm of the shut down faults, time delayed starting and stopping, and additional monitoring/control, but all engine operation commands through these options are still controlled through the ECM. Interface Relay Modules (A13, A14) These relay modules are used in conjunction with the Detector ECM's to provide external monitoring of the en gine-generator at customers control panel. As add-on circuit boards, they interface with the remote annunciator signals from the ECM and allow the use of either AC or DC for alarm drives. The relays are configured for low side switching by the control and supply sets of contacts for external alarm connections. an Starting Sequence Manual: The starting sequence is initiated by placing the ar All units equipped with AC meters have current transform ers installed inside the conduit box through which the cus tomer can route the load leads. tM Current Transformers (Not shown) If you are reviewing this operation information for trou bleshooting purposes, make sure you have elininated all other malfunction checks external of the controls prior to troubleshooting the printed drcuit board type compo nents of the controller. Also review the Generator section for generator related control components and Corrpo nent Tests and Adjustments section for more in-depth information. Refer to appropriate DC Schematic - Ladder Diagram in Wiring Diagrams section when reviewing the following information. Automatic Voltage Regulator (VR21) Run/Stop/Remote switch (S1 2) in the Run position. Refer to section 3 for more information. Placing switch S1 2 in the Run position energizes the ECM Run Relay (1<7). By energizing K7, B+ is supplied through the electrical circuits of the ECM to energize the engine run circuits (i.e., fuel solenoid) and front panel gauges and the starter solenoid (through K3). lP Overspeed (Frequency Detection) Module This rnc::KiJie derives a speed (Hz) signal from the PMG, ca but is powered from the generator set battery. A small time delay, typically one second, is incorporated in the over speed function to allow for engine overshoot. The module contains two adjustable potentiometers, Overspeed and Crari<ing (the cranking potentiometer is not used how ever). Refer to Section 5 for more information. tri The engine cranking period is detemined by the Over crank Timer and Cycle Crank Driver (U1 ). and the Cycle Crank Relay (K1 2), whic h co ntrol energizing and de energizing the Power Relays K2 and K3 that supply cur rent to the on-set starter and fuel solenoids. Tlme Delayed Start/Stop Module (A15) This module provides time delays for starting and stop ping the generator set as follows: .E lec Automatic: Wrth the Run/Stop/Remote switch (S1 2) in Remote position, a remote start command (closure of on site, dry contacts) to the generator set controller (B+ to remote) activates the Time Delayed Start/Stop Module (A1 5), which initiates its time delay start period. Delayed Stanlng: The time delay start function is to preclude automatic start-up of the generator set for a de temined amount of time (adjustable from 1 to 1 5 sec onds) for installations that night experience power inter ruptions of short duration, and therefore not want the gen erator set starting. Upon completion of the ti me delay start period, the ECM initiates engine cranking and start-up by energizing Run Relay (1<7) as described in manual start-up. Delayed Stopping: The time delay stop function is ad justable from 1 to 1 5 minutes to provide for automatic cool-down running of the engine for prescribed amount of time (approximately 3 to 5 ninutes is recommended). w When engine successfully crari<s and starter discon nects, input signals from either start disconnect system of the ECM 'Nill activate the Start Disconnect Relay of mod ule A1 5 (K1) which enables the module for Time Delayed Stop mode. Control cabinet Heater ww A control cabinet heater provides a means of hunidity/ temperature control of the control box interior to protect the COJ"ll)Onents and assist their effectiveness when the generator set is subjected to varying ambient conditions during extended periods of non-use. The element is con trolled by an adjustable thermostat. 2-6 .c om After the starter disconnects, the LOP and HET fault shutdowns will remain inhibited for another 1 0 seconds to allow oil pressure and engine temperature to stabilize within the operating range. During generator set operation, all safety systems func tion to protect and monitor set operation. At end of the generator set duty cycle, when generator output is discon nected from load and the remote run signal is discontin ued, the time delayed stop function of module A15 will continue the engine-generator run time for the prescribed engine cool-down period of 3 to 5 rrinutes before deacti vating the run circuits of the ECM. Normal Operating Parameters After a successful engine start-up, with all conditions satisfied, the engine will gain in speed to governor con trolled operation. Should the engine go into an overspeed condition, either an Over/Under Frequency Sensor, an Overspeed Module, or a mecharical overspeed switch (depending on generator type and options ordered) will ground the overspeed input circuit to the ECM to cause a shutdown and fight the Overspeed fault lamp. After the problem is corrected, starting will not occu r until the Reset switch is pressed. ua ls Starter-Disconnect Parameters This type of control uses two means of starter-disconnect in order to protect the starter in the case one means should fail. The first uses a DC relay (K14); a B+ signal taken from the battery charging alternator in most cases energizes the relay to disconnect the starter. The second method uses an AC relay (K10); voltage from the genera tor energizes this relay to provide a back-up to the DC relay. The control uses this method to provide uninter rupted generator set operation even if only one means of start disconnect is operational. However, the local Run lamp does not Hght unless both start disconnect relays operate. H the generator set is equipped with a remote Run lamp, the operator can then deterrrine which means of start disconnect has failed for such an occurrence. H the remote Run lamp lights (and the local Run lamp does not), the DC relay is not functioning. an Continuous operation of the generator set also depends on the proper oil pressure and engine temperature being maintained, and also any customer required fault condi tions connected to the ECM. tM Stopping Sequence Placing the Run/Stop/Remote switch to the Stop position de-energizes Run Relay (K7) which opens the current supply through the ECM (K2) to de-energize the genera tor set mounted fuel solenoid (stops fuel flow which stops the engine). ar High Engine Temperature (HET) and Low Oil Pressure (LOP) faults are time delayed about 1 0 seconds following starter disconnect and inhibited during cranking. This allows the coolant in a hot engine some time to circulate and return the water jacket to normal temperature before the ECM begins to monitor this parameter. It also allows the oil pressure to build to normal before monitoring this system. Following this delay, these faults beoome imme diate shutdowns for engine protection. ca lP Emergency Shutdown lec tri H conditions are correct, the engine will start and the starter will disconnect. H not, an overcrank fault occurs by U1 having cycled/timed out through drive transistor U4 to energize Fault Relay K6, which opens the start drcuit of the ECM. The Reset switch (S1 1) must be pushed to clear the fault before attempting to restart. Start-Disconnect Sequence ww w .E When the generator set starts, output voltage from the DC alternator energizes Start-Disconnect relay K14. Energiz ing K14 then closes its N .O. contacts whic h lights the control panel Run lamp. Also, when the generator set starts, output voltage from the generator stator energizes Starter-Disconnect relay K1 0. Energizing K10 then closes its N.O. contacts and lights a Remote Run lamp (If equipped). 2-7 The K6 fault relay is energized when fault sensors re spond to one of the following fault conditions: overcrank, low oil pressure, high engine temperature, overspeed, and over/under voltage/frequency (if equipped). Energiz ing the K6 fault relay opens its N.C. contacts and closes its N.O. contacts. Opening the N.C. contacts cisconnects B+ from the Power Relays K3 and K2. This stops crali<ing if the engine is being cranked and shuts off the fuel flow. Closing one of the N.O. contacts of K6 activates the K8 relay which breaks power to the fault interface relays so that only the indicator associated with the fault will acti vate. Closing the other N.O. contacts of K6 connects B+ to the remote alann tenninal. w ww .E tri lec an tM ar lP ca ua ls .. .c om .c om Section 3. Generator GENERATOR DESCRIPTIONS An exciter/rotating rectifier assembly is mounted inter nally to the non-drive-end bearing, while the permanent magnet exciter is overhung from the non-drive-end bear ing. ua ls The AC generators are brushless, rotating field type, con trolled by an automatic voltage regulator (AVA). Perma nent magnet exciter (PMG) types are used in these series of generator sets. The AVA of these generator sets is powered by the permanent magnet pilot exciter which provides a source of constant excitation power, independ ent of load changes or load current distortions. lP BLOWER ca END BEARING tri COUPLING EXCITER STATOR ar tM an Removable access covers are provided at each end of the generators and on each side of the conduit box for cleaning and inspection, and easy access to the output terminals and other ancillary equipment. See Rgures 3-1 and 3-2. .E lec ROTATING RECTIFIER ASSEMBLY ROTOR ENDBRACKETIENGINE ADAPTOR ww w ROTOR SHAFT RllG-1115 FIGURE 3-1. TYPICAL PMG GENERATOR 3-1 .c om GEN ERATOR CONTROL COMPON E NTS voHage is over or under the nominal voltage by the preselected amount (typically 1 0 percent). The module in cludes an adjustable time delay relay to prevent nuisance tripping (typically set at 25 percent, or approximately 2.5 seconds). The module and time delay relay are mounted on a bracket in the generator conduit box. The following briefly describes generator related control components that affect the proper operation or shutdown of the generator set. See Figure 3-2 for component locations. Automatic Voltage Regulator (AVR) Over/Under Frequency Sensor Module The AVR is mounted on the inside back wall of the control box. Refer to Generator Operation following for further AVR operation information, and to Component Tests and Adjustments section for further description and adjust ment procedure of the AVA. ua ls This is an adjustable frequency-sensitive relay typically connected to the Engine Control Monitor (ECM) Fault 2 circuit if the Over/Under Voltage module is also installed, or Fault 1 for overfrequency and Fault 2 for underfre quency if installed alone, to shut down the generator set when the output frequency is over or under the nominal frequency by the preselected amount. (Also, Fault 2 must be converted for timed shutdown.) The module is mounted on a bracket in the generator conduit box. Over/Under Voltage Sensor Module an This is an adjustable voHage-sensitive relay typically connected to the Engine Control Monitor (ECM) Fault 1 circuit to shut down the generator set when the output tM @] (�](!] VOlTAGE REGULATOR IS lOCATED INSIDE CONTROL PANEl, AND AUXIliARY TERMINAl BOARD IS lOCATED INSIDE CONDUIT BOX. ar OR ca CONTROL PANEl (REFER TO SECTION 2) lec tri OPTIONAL GENERATOR CONTROL COMPONENTS (i.e., OVER/UNDER VOLTAGE AND FREQUENCY MODUlES) ARE lOCATED INSIDE CONDUIT BOX. lP PMG VOLTAGE REGULATORS .E OPTIONAL CIRCUIT BREAKER (NOT SHOWN) IS MOUNTED ON SIDE OF CONDUIT BOX. w AC METERING CURRENT TRANSFORMERS (lOCATED INSIDE CONDUIT BOX.) REFER TO SECTION 2. ww COVER PLATE (FOR ACCESS TO ROTATING RECTIFIER ASSEMBlY) FIGURE 3-2. GENERATOR CONTROL COMPONENT LOCATIONS 3-2 ' .c om GENERATOR OPERATION regulator (at auxiliary terminal block). The AVA compares the main stator output with a reference value and feeds a controlled excitation current to the main exciter stator. The AC output of the main exciter rotor is converted to DC by the rectifier assembly, comprised of six diodes mounted on two heatsinks to form positive and negative plates. The diodes ar e protected against harmful over voltages (caused for example, by switching circuits or out�f-phase paralleling) by a metal�xide varistor (MOV). The DC output of the rectifier assembly provides the excitation onto the main rotor. tM an ua ls A permanent magnet generator exciter (PMG), mounted to the end of the main rotor shaft, provides power by way of the AVA to the main exciter stator. Excitation power is therefore independent of output voltage, resulting in positive voltage build-up, without reliance on residual magnetism. The main exciter stator mounts in the end bell, the main exciter rotor and its rotating rectifier assem bly mount on the rotor shaft. Within the end bell, leads X (+, positive) and XX (-, negative) from the exciter stator winding, connect to the output terminals of the voltage MAlt STATOR EXCITER STATOR ca PERMANENT MAGNET STATOR lP ar AUTOIMTIC VOLTAGE REGU..ATOR tri �SHAFT--_. --1 ��--=---t- I --�--D� ---tEXCITOR ROTOR ww DIODES RGURE 3-3. GENERATOR OPERA110N DIAGRAM w .E lec PERMANENT MAGNET ROTOR 3-3 MA... ROTOR Depending on site specifications and applicable code requirements, an optional circuit breaker may be mounted in the generator AC output box. Description The thermal trip action of the breaker is accomplished by bimetal strips. A sustained ove �current con� ition will cause a thermal reaction of the b1metal and tnp the breaker. Response of the bimetal is proportional to current; high current-fast response, low current-slow response. This action provides a time delay f �r normal _ such inrush current and temporary overload cond1t1ons as motor starting . The magnetic trip action of the breaker is caus �d by an electromagnet, which partially surrounds t� e mternal bimetal strips. If a short circuit occurs, the h1gh current through the electromagnet will attract the bimetal armatu re and trip the breaker. Some breaker models provide front adjustment of the magnetic trip action. These adjustments are normally set at the factory at the high position, but provide for individual conductor settings to suit customer needs. • ua ls Auxiliary contacts (if equipped) are used for local or remote annunciation of the breaker status. They usually have one normally-open and one normally closed contact (1 form C contacts) to comply with the annunciator requirement. an When an overload or short circuit occurs on any one conductor, a common trip bar will disconnect all three conductors. • The trip actuator (if applicable) is for periodic exercise of the breaker to clean and maintain its proper opera tion. Rotating this actuator mechanically simulates over-current tripping through actuation of linkages not operated by the On/Off handle. See Section 5, C�m _ ponent Tests and Adjustments, for further mformat1on. Operation of the circuit breaker is determined by site established procedures. In emergency standby ���tal lations, the breaker is often placed to the On pos1t1on, and is intended for safety trip actuation in the event of a fault condition. If the breaker trips open, investigate the cause and perform remedial steps per the trou bleshooting procedures. To close the breaker, the handle must be placed to the Reset position and then to On. Refer to Section 4 fortroubleshooting and safety procedures. tri ca lP • • tM • Generator set output is connected to the load through the circuit breaker. ar • The shunt trip mechanism (if equi J?ped) consists o! a solenoid tripping device mounted m the ? rea�er w1th external lead connections for remote s1gnahng. A momentary signal to the solenoid coil will cause the breaker to trip. This feature is available in AC or DC voltages, and is normally installed at the factory to meet customer needs. The shunt trip mechanism is most often con nected to a common fault shutdown circuit of the generator set. This quickly disconnects the set from the load on shutdown and avoids a reverse power condition. All supplied breakers are thermal and magnetic trip type. Depending on customer requirements, the breaker may _ also include shunt trip and remote alarm connections. Review the following functions/requirements and Figure 3-4. • .c om • OPTI ON AL C I RCU IT BREAKER GENERATOR ww w .E lec OUTPUT BOX LD 11DE VIEW - HANDLE POIITIONI SHUNT niP +COMMON ALAAM -GROUND AUXIUAAV A ,t--.,-�r.•--....- COMMON 8 FIGURE 3-4. TYPICAL GENERATOR-MOUNTED CIRCUIT BREAKER 3-4 4. .c om Section Troubleshooting GENERAL analysis before reviewing the tables in this section should be to ask yourself the following questions: This section contains troubleshooting information for engine1Jenerator control systems. Be sure to review the troubleshooting information as outlined in the unit Operato(s Manual before performing the procedures in this section. Refer to Componert Tests and Adjustments �ion for further engine1Jenerator COrJ1X>nent informa tiOn and appropriate engine service manuals for adcti tional information specific to the engine. ua ls 1. Was the engine running when it shut down? If it was, shutdown is not due to overcrank. 2. Did srutclown oca.Jr within one minute after start up? H it did, the shutdown is probably due to low oil pressure. 3. Was engine operation noticeably erratic or faster than usual? If it was, the sh.Jtdown was probably due to overspeed. an Because this section contains information about various control options, read through this section before a fault oca.Jrs to identify what is or is not applicable to your genset. This will save troubleshooting time when the actual need arises. 4. If the engine starts and runs, observe the oil pres sure, engine temperature and fre<J.Iency meter or tachometer until sh.Jtclown oca.Jrs, to determine the cause. tM �etore starting a troubleshooting procedure, make a few s1rrple checks that migt1 expose the problem. Check all rt:JOOifications, r�irs, or parts replacements performed s1nce the last satisfactory operation of the generator set. A �se or ot�rwise incorrect wire connection, an opened _ breaker, or a loose plug-in are all potential switch or curuit problems that can be eliminated by a visual check. This section is divided into engine-related troubleshoot ing tables and generator-related troubleshooting flow charts to aid you. They are: ar Table 4-1. Engine does not crank. Table 4-2. Engine aanks, but does not start. Table 4-3. Engine starts, but stops after running short time. Table 4-4. Engine-generator is in operation, then a fault sRrtdown occurs. lP When troubleshooting a problem, remember to keep your problem soMng a methodical and most of all safe proc ess. Ha&tY decisions can be costly, harmful to your health, dangerous to others, and may not solve the problem. ca Regardless of the cortroller model a generator set has the basics of problem analysis are fundamertally thfi same. Identify the fault condition then get specifiC about the corrective action to take. However, the Detector-7 controller does not have all the lamp indicators that the Detector-12 has; to aid in identifying other customer required fault conditions (i.e., low fuel, fault 1 and 2) that may have caused the sh.Jtdown. Your initial problem .E lec tri speed. Flow Chart 4-2. Unstable outJ:U voltage, engine speed stable at rated speed. Flow Chart 4-3. Ouq:x.rt voltage too high or low. Flow Chart 4-4. Exciter field breaker ti1JS (if equipped). Flow Chart 4-5. Unbalanced generator output voltage. Flow Chart 4-6. No AC output through set-mounted circuit breaker. w ww Flow Chart 4-1. No AC output voltage at rated engine 4-1 .c om I AWARNING I Atiny troubleshooting procedures present hazards which can result In severe personal Injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perfonn service ptOCedures. Review Safety Precautions, on pages II and Ill. TABLE SYMPTOM 4-1 . ENGINE DOES NOT CRANK CORRECTIVE ACTION CAUSE Press to desired, Run or Remote position. 2. Other fault indicator lafll)S iluminated, but no fault exists. Lamp Reset switch not actuated after a previous fault was remedied. Press Lamp Reset switch to de-energize faJit lalll> relays a ECM, after Rui'VStop/Rernote switch is pressed to Stop position. 3. Fuses blown on ECM board A1 1 . Check fuses F1 and F4. Replace if necessary with proper fuse: F1 - 20 Alll>ere F4 - 5 Alll>9fe tM No indication. an SWITCH OFF indictor lamp flashing. ua ls Run/Stop/Remote switch in Stop position. 1. To reset, pull switch out and move the RUN/STOP/REMOTE switch to STOP position. Then push test switch to RESET!La!ll> position. Starter solenoid will not energize. Inspect starter solenoid per proper test procedure. Possible defective ECM board A1 1 . Check A1 1 board TB1-9 for B+ voltage in. tri ca lP ar Emergency stop button pushed in. lec Broken wi� or poor comections between board A1 1 TB1-8 and starter solenoid. .E Fauly ECM board A1 1 . ww at TB1 -8 of board A1 1 . Check and repai" as necessary. If there is no voltage between and ground stud when the panel switch is in the Run position, TB1-8 the ECM is faulty. Replace. Possible defective lime Delayed Start! Stop Module Check A1 5 board TB1-4 for constant B+ voltage in. A15. Check A1 5 board TB1-5 for Run Signal In voltage. Voltage at A15 board TB1 -6 should be at B+ at end of start delay period. w 4. Time delay start is initiated, but starter solenoid does not energize after desired time delay period. With S12 switch in Run position, check for voltage out to starter solenoid 4-2 Check wiring and connections from A1 5 TB1 -6 to A1 1 TB1 -6. .c om �WARNING I Many troubleshooting procedures present hazards which can result In severe personal Injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should pertonn service procedures. Review Safety Precautions, on pages II and Ill. TABLE 4-2. ENGINE CRANKS BUT DOES NOT START SYMPTOM Low Fuel larll> also lit. InsuffiCient fuel in supply tank. Fuel solenoid does not energize. Fuse blown on ECM board A1 1 . ua ls Overcrank lamp lit. Possible defective ECM board A1 1 . tM Broken wiring or poor oonnections between board A1 1 TB1-10 and fuel solenoid. Fuel solenoid energizes, but no fuel flows. lP ar Blockage of fuel supply system. �ngine hard to start due to cold antliert air te�rature. Fault shutdown occurs, but no fault lamp Short cranking period. Delective ECM board A 1 1 . w .E lec Note: The ECM board A1 1 P.C. board oontrols are to provide cycle cranking, but generator set stops before 1 5 ±3 seoonds. ww Check fuse F2. Replace if necessary. F2 - 20 Arll>ere. Check for voltage out at TB1 -1 0 when engine is cranking. Check and rectify as necessary. Check fuel supply system (fuel supply tank, shutoff valves, lines and connections, filters and transfer pump, etc.). Check heater system power supply, oontrols, etc., and oorrect as necessary. Place Rui'VStopiRernote switch to Stop position, then depress larll> Test switch to Test position to check fault lamps. lamp burned out. tri indication. 3. Heater system not keeping engine warm. ca 2. Fill with oorrect fuel. an 1. CORREC11VE ACTION CAUSE 4-3 Replace ECM (A1 1). .c om I AWARNING I Many troubleshooting procedures present hazards which can result In severe personal Injury or death. Only qualified serviCe personnel with knowledge of fuels, electricity, and machinery hazards should pertonn serviCe pmceclures. Review Safety Precautions, on pages II and Ill. TABLE 4-3. ENGINE STARTS, BUT STOPS AFTER RUNNING SHORT TIME CORREcnVE AcnON 1 . Overspeed lafll) lit. ua ls CAUSE SYMPTOM Refer to Tests and Adjustments section. Perform necessary adjustments of O.S. module. Overspeed MoWle initialized shutdown. an Perform start-up and monitor engine speed to overspeed sl'lltdown. If shutdown occurs before desired setpoint, readjust O.S. module. If adjustment does not correct fault condition, replace o.s. module. Engine governor faulty or out of adjustment. 2. Low Oil Pressure lamp lit. ar Low oil level in engine. lP LOP switch faulty. High Engine Temperature lafll) lit. HET SWitch is faulty. Check coolant level, perform restart, and monitor engine tefll)erature gauge. If gauge reading is within normal range, switch S2 is faulty. Replace. Thermostat defective. Replace thermostat. Fan belt slipping. TJQhten fan belt. tri lec No fault oondition. Intermittent control wiring connections. w ww Check oil level, perform restart, and monitor oil pressure gauge. If gauge reading is within normal range, switch 81 is faulty. Replace. Replenish as necessary. .E 4. Replenish as necessary. Low coolant level in engine. ca 3. Refer to Tests and Adjustments section. Perform appropriate tests. tM Unstable engine operation. 4-4 Check condition of all oontrol wiring are correct and seaJre. to make sure connections .c om �ARNING I Many troubleshooting procedures present hazards which can result In severe personal Injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perfonn service procedures. Review Safety Precautions, on pages II and Ill. TABLE 4-4. ENGINE-GENERATOR IS IN OPERATION, THEN A FAULT SHUTDOWN OCCURS SYMPTOM CORRECTIVE ACTION 1. LOP, HET, Overspeed lamp lit. As indicated. 2. Fault 1 or Fault 2 lamp lit. Over/Under Voltage or Frequency, as dedicated by customer. ua ls CAUSE Refer to Table 4-3. Refer to Tests and Adjustments section, and perform necessary adjustments. Restart unit and monitor gauges. No fault lamp lit. Possible defective ECM board A1 1 . ca 3. lP ar tM an H shutdown was we to over/under voltage, the voltage regulator may require adjustment or is faulty. Refer to Tests and Adjustments section for adjustments, replace if faulty. tri .E lec Refer also to generator-related Flow Charts that follow. Check fuses F4 and F2 of ECM board A1 1 . F4 (Main) 5 Ampere F2 (Fuel solenoid or ignition) - 20 Ampere - Perform restart and check for B+ voltage in at TB1 -9 and voltage out at TB1 -1 0 to fuel solenoid. H there is voltage out at TB1-10, check fuel supply solenoid, sn.rtofl valves, etc. H there is no voltage out at TB1 -10, ECM boan:f A1 1 is defective. Replace. Olher aJstomer re<J.Jired studown conmand. w ww H shutdown was we to over/under frequency, the engine governor may require adjustment or is faulty. Refer to Tests and Adjustments section for adjustments, replace if faulty. 4-5 Refer to ilstalalion reference or ooruct your service represerUiiYe tor assistara. malerial, .c om [ AWARNING [ Many troubleshOoting procedures present hazants which can result In severe personal Injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazants should pertonn service procedures. Review Safety Precautions, on pages II and Ill. Is field breaker CB21 position? 4-1 . NO AC OUlPUT VOLTAGE AT RATED SPEED v.. at ON (fuly-in) , Repla:e defective field breaker. No Remove one lead from breaker and check continuity with ohmmeter. Is breaker open? No Place breaker swik:h 10 ON position. Does generator AC OU1pUt voltage buik:t up? ua ls FLOW CHART v.. If voltage is unstable, high or low, or causes breaker 10 trip, refer 10 other Flow Char1s. an v.. No v.. Is resid.Jal voltage across TB21-22 and -23 equal to 5 10 10 VAC or more? tM Rash exciter field. Does generator output voltage buik:t up? No v.. Is exciter field voltage aaoss VR21-X and at approximately 24 10 32 VDC? -XX No ca v.. lP ar v.. No Disconnect slat>!" leads U2 and V2 from TB21-22 and -23. Is residual voltage across lhe leads 150 10 250 VAC ro��? No Check lead continuity between Auxiliary Terminal Board (leads 6, 7, and 8) and TB21-22, -23, and -25. Check exciter field wiring for shorts. tri Replace bad wiring. Check exciter field wiring for opens. Check dodes CR1 lhrough CR6 Replace if bad. lec Replace bad wiring. on rotH". .E Replace voltage regulator VR21. Check exciter field wincing. Replace if bad. Check exci& ro10r wincing. Repla:e if bad. w Check generaa roo field wincing. I A CAUTION I Replace if bad. ww Do not replace Voltage Regulator VR21 until external trouble has been corrected to avoid possible damage to new regulator boant. Check generator slaiOr wincings. Replace if bad. 4-6 .c om I AWARNING I Many troubleshooting procedures present hazards which can result In severe personal Injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perlorm service procedures. Review Safety Precautions, on pages II and IIi. FLOW CHART 4-2. UNSTABLE VOLTAGE, ENGINE SPEED STABLE AT RATED SPEED Are there any broken wires or loose connections on voltage regula1Dr assembly? Does voltage cycle from zero to rated output? No Check wiring harness from regulator assembly to end bell. Check ok? I Yes Ye. Check voltage regulator adjustment setting. Check ok? I Repair wiring or replace as required. Is voltage stable within specifications at no load to full load range of generator set? I No / ACAUTION I tM I No ua ls No an I Repair as required. Check control panel voltage aqust rheostat and replace if defective (open). Ye. Do not replace Voltage Regulator VR21 until external trouble has been COtTeCted to avoid possible canage to new regulator board. ar Replace Voltage Regulator VR21 . l v• ca correct rpm? Is engine running at lP FLOW CHART 4-3. OUTPUT VOLTAGE TOO HIGH OR LOW Are generator output connections correct Md secue? tri (If lec R21 IY• of Voltage Adjust control equipped) result in correct output Does aqustment voltage? l r• Check Voltage Regulau Aqustment. Check ok? .E No J l ooncition of rotalilg dodes . Vi� inspect for loose connections, faulty dodes, Check Check ok? ww w etc. I Y• Replace Voltage Reguaa VR21 . No No No v.. No [ A CAUTION I Refer D Governor Refer to Aqustmenls. appropriaae eleclrical schemalic. Set Voltage Aqust oonbd R21 . Check vol1age aqust rheostat and replace if defective. Is wltage within specificdons at ful No load range of generata ser! Test I rotating <iocles. Replace if no load D defective. Do not replace Voltage Regulldor VR21 until external trouble has been corrected to avold possible damage to new regulator board. 4-7 .c om I AWARNING I Many troubleshooting procedures present hazards which can result In severe personal Injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perfonn service procedures. Review Safety Precautions, on pages II and Ill. FLOW CHART 4-4. EXCITER FIELD BREAKER TRIPS No Check dodes in bad. rou or Check Voltage Regulat>r aquslments and connections. assembly. Replace if Check generau stator leads for proper, secure COI11ecliou. Rater m approprial9 an Check exciter stab' winding. Replace if and bad. tM eleclricaJ schematic. Check exciler rou wincing. Repla:e if bad. Check generator Sla1Dr windngs. Repla:e if ca bad. High-voltage, 1,900 to 15,000 volts, present special hazards of severe personal lnjuty or death. Even after genset shutdown, an electl1cal shock hazard may still exist, caused by Induced voltage within the generator. Service personnel must be well-trained/qualified to worlc with distribution voltages. ar Replace if bad. A DANGER lP Check generat>r ro1Dr field windng. I ACAUTION I Do not replace Voltage Regulator VR21 until external trouble has been corrected to avoid possible damage to new regulstor board. w .E lec tri Replace Voltage Regulalor VR21 . ww Check for any loose or broken wires connections m VR21 assembly. ua ls Does AC output voltage build up m 150% or 1-----"-----l • more of rated voltage before breaker trips? 4-8 .c om / AWARNING I Many troubleshooting procedures present hazards which can result In severe personal injuty or death. Only qualified service personnel with knowledge of fuels, electricity, and machlnety hazards should perfonn service procedures. Review Safety Precautions, on pages 11 and Ill. FLOW CHART 4-5. UNBALANCED GENERATOR OUTPUT VOLTAGE load at generatx' terminals. Is Check each No not withit load. phase for balanced anent If 10% of each other, reclslriluE ua ls Remove ou1pUt slil unbalanced? Yes Check for correct gromdng of genenmr and load . No gromded property? tM Yes No Is generatx' statx' windng continuous? A DANGER ca tri lec .E w ww as necessary. Replace stator assembly. High-voltage, 1,900 to 15,000 wits, present special hazards ot severe personal lnjuly or death. Even after genset shutdown, an electtlcal shock hazard may still exist, caused by Induced voltage within the generator. Service personnel must be well-trained/qualified to WOlfe with distribution voltages. lP Check load for ground fa�Als and conect as necessary. ar Yes Correct an Ale getl9faD leads connected and 4-9 .c om I AWARNING I Many troubleshooting procedures present hazards which can result In severe persona/ Injury or death. Only qualified setVIce personnel with knowledge of fuels, electricity, and machinery hazards should perfonn setVIce procedures. Review Safety Precautions, on pages II and Ill. FLOW CHART 40. NO AC OUTPUT THROUGH SET MOUNTED CIRCUIT BREAKER Is set-mounted ciraJit breaker at Tripped position? Is set-fTlOIM'ltad ciraJit breaker at OFF position? ua ls No Y• Y• Detarmile cause � breaker tip. H not immeciately known, s� generaa set and investigale cause Cirait owerload (per sil&-eslabishecl procedures). Confirm flat no 111Mltanance is being perb1ned, or other pwpose for breaker at OFF position, and flat set is avalable for . use. taUt AIMaw Teeing AC laad Cirail Blaakar in TasfS tn1 ....... 18dion. operating and available for use, reset cira.it breaker t» ON posiion. ww w .E lec tri ca Conac:t fault COidlioii ... I8Set ciR:UI ballar lEt ON poeilian. If set is tM Shunt tip (check for generaa set stMdcwn, or ofler SVNII sowce). ar • Short cira.it (per sile oslabished proceclu)res . lP • an • 4-1 0 .c om Section 5. Component Tests and Adjustments U1 will energize and de-energize K12 depencing on the number of crari<s programmed, K1 2 N.C. contacts (1 0,7) open and close to energize and de-energize K3, K3 N.O. contacts (S,3) open and ck>se connecting and removing B+ from TB1 -8. GENERAL ua ls This section contains test and adjustment information for the GenSet control, generator, and engine COIT1JOnents. Refer to the figures included with this information and also the Wiring Diagrams section when instructed. H the set fails to start after the pre-set number of cranks, U1 pins 1 0, 1 1 , and 1 2 go high and trigger the drive transistor U4 pins 6 and 1 1 which grounds K6 fault relay, stopping the starting sequence by opening its N.C. con tacts (9,8) de-energizing K3 and K2. U 1 pins 1 0, 1 1 , and 1 2 going high also triggers U4 pins 1 2 and S which energizes overcrank lamp drive relay K9. K9 N.O. con tacts (9, 1 3 and 4,8) ck>se putting a ground on TB2-6 for a remote indication and also the DS1 8 lamp. High-voltage, 1,900 to 15,000 volts, present special hazards of severe personal injury or death. Even after genset shutdown, an electrical shock hazard may still exist, caused by Induced voltage within the generator. Service personnel must be well-trained/qualified to work with distribution voltages. tM I A CAUTION I an A DANGER H the set starts, voltage builds up on the DC (K1 4) and AC (K1 0) start disconnect relays. K1 4 energizes at approxi mately 1 4 VDC. K10 energizes at approximately 1 00 VAC. Regardless of which one energizes first, either relay will break the ground path to starter relay K3, K3 de energizes opening its N.O. contacts (S,3) removing B+ from TB1 -8. Both K1 0 and K14 must be energized to operate the run lamp DS1 2. Bther relay will also inhibit the overcrank timer U1 by making U1 pin 2 go high. This is achieved by removing the ground path from U1 pin 2 through U3 pins 6-1 1 , N.C. K14 contacts (1 6,9) and N.C. K1 0 contacts (3,S). A positive is then alk>wed through the K3 coil, N.C. K6 contacts (3,7), N.C. K 1 2 contacts (10, 7), U3 pins 6-1 1 to pin 2 on U1 or via RS, U3 pins 6-1 1 to U1 pin 2 if K6 fault relay has operated. By making pin 2 high the timer is reset and put into a standby mode. lP ar In-depth intonnatlon Is provided tor some components such as the ECM's. Only qualffled personnel with proper equipment should use this ln fonnatlon to attempt repair of printed circuit board assemblies. Contacting your distributor tor replace ment pans is recommended. ENGINE CONTROL MONITOR (ECM) Sequence of Operation - Detector-7 ECM ca Refer to schematic diagram in Wiring Diagrams section when reviewing this information. • • tri Starting is initiated by applying B+ or ground to P4-7 depending on the position of �nks W3 and W4. Position A - Ground signal to run Position B - B+ signal to run Either K1 0 or K14 will initiate US - LOP/HET time delay timer. This is achieved by removing the ground from U4 pin 3 and allowing a positive there. This triggers U4 pin 1 4 to ground US pi n 2 . After a 1 0 seco nd delay U5 pin 1 4 energizes K1 through U4 pins 1 a nd 1 6. K1 N.O. (1 ,8) contacts (9, 1 4) ck>se, latching in fault circuits. K1 N.C. contacts open to latch US into an inactive state during run, made by removing B+ from pin S and grouncing it through R8 and U2 pins 2 and 1 S. (K1 N.O. contacts (2,8) also ck>se providing timing shutdown path to K6 fault relay.) .E lec This energizes run relay 1<7, which closes its N.O. con tacts (9, 1 4) connecting B+ to starter relay K3, switched B+ relay K2 fault circuits, overcrank/cycle crank timer U1 , and HET/LOP time delay timer U5 through N.C. fault relay K8 (1 6,9). This also opens N.C. K7 (9, 1 6) , disconnecting B+ to the reset circuit (K6). K2 energizes, closing its N.O. contacts (S,3) connecting B+ to tenninal TB1 -10 through fuse F2 and to P4-9 through fuse FS. H a fault should ocrur a ground is placed on the following plug points. • K3 energizes, closing its N.O. contacts (S,3) connecting B+ to tenninal TB1 -8 through fuse F1 . K3 is controlled by timer U1 through cycle crank relay K12. U1 can be programmed to give 3 crank periods by combining diodes across U1 pins 1 0, and 1 2; CR6 to pin 1 2 with CR8 to pin 1 0 3 cranks. ww w • • • • P2-2, for Pre-Low Oil Pressure (PLOP) P2-3, for Pre-High Engine Temperature (PHEl) P2-4, for Low Oil Pressure (LOP) P2-S, for High Ergne Temperature (HET) P2-6 or termnal TB1-1 , for Overspeed (OS) Pre-LOP and pre-HET only activate a warning lamp and do not stop the set. = 5-1 .c om K2 energizes, closing its N.O. contacts (5,3) connecting B+ to terminal TB1 -1 0 through fuse F2 and to P4-9 through fuse F5. LOP, HET, ard OS activate a lamp ard also shut down the set. Fault relay K6 is in series with the K1 3 (HET) , K15 (LOP), K1 1 (OS), K4 (Fault 1 ) ard K5 (Fault 2) fault relays. Therefore, when a grourd is placed on the respective plug input it will cause both the K6 relay ard the associated fault relay to energize. K6 N.C. contacts (9,8) open to de energize K2 relay, stopping the set. K6 N.O. contacts (1 1 , 1 0) close to energize K8 relay. K8 opens its N.C. contacts (1 6,9) to remove B-t from the operational parts of the circuit. The associated fault relay will bring up an indicating lamp ard also connect a grourd to one of the following terminals for a remote indication: TB2-8, for HET TB2-1 1 , for PLOP TB2-7, for Overspeed TB2- 1 0, for PHET TB2-9, for LOP TB2-6, for Overcrank • • • • • ua ls • K3 energizes, closing its N.O. contacts (5,3) connecting B+ to terminal TB1 -8 through fuse F1 . K3 is controlled by timer U1 through cycle crank relay K1 2 through N.C. fault relay K6 contacts (2,3). U1 is set to provide 3 cranking periods through CR6 and era. The timing is set to 15 seconds on, and 1 5 seconds off through oscillator circuit comprising C3, and resistors U3 (3,6), (15,2), and (1 6,1 ). The total crank time is 75 seconds. U1 will energize and de-energize K1 2 through U4 (7, 1 0). K12 N.C. contacts ( 10 ,7) open arxl close to energize and de-energize K3, K3 N.O. contacts (5,3) open ard close connecting and removing B+ from TB1 -8. H the set fails to start after the three cranks, U1 pins 1 0, and 1 2 go high and trigger the drive transistor U4 pins 6 and 1 1 which grounds K6 fault relay, stopping the starting Se<J.Jence by opening its N.C. contacts (9,8) de-energiz ing K3 aoo K2. U1 pins 1 o, 1 1 , aoo 1 2 going high also triggers U4 pins 1 2 and 5 which energizes overcrank lamp drive relay K9. K9 N .O. contacts (9,13 and 4,8) close putting a ground on TB2-6 for a remote indication and a reound on P3-8 to light the DS18 lamp. • • • • tM • • an To reset a fault the run signal must be removed from P47 to de-energize K7, closing its N.C. contacts (9, 1 6) to connect B-t to the fault reset circuit. A grourd is placed on P4-1 1 which grounds all of the latchable fault relays reset coils as follows: K6 - Fault Relay K15 - LOP K9 - Overcrank K17 - PHET K19 - PLOP K1 1 - Overspeed K13 - HET • H the set starts, voltage builds up on the DC (K14) and AC (K1 0) start disconnect relays. K14 energizes at approxi mately 1 4 VDC. K10 energizes at approximately 1 00 VAC. Regardless of which one energizes first, either relay will break the ground path to starter relay K3, K3 de energizes opening its N.O. contacts (5,3) removing B+ from TB1-8. Both K1 0 ard K14 must be energized to operate the run lamp DS1 2. Either relay will also inhibit the overcrank timer U1 by making U1 pin 2 go high. This is achieved by removing the ground path from U1 pin 2 through U3 pins 6-1 1 , N.C. K14 contacts (1 6,9) and N.C. K1 0 contacts (3,5) . A positive is then allowed through the K3 coil, N.C. K6 contacts (3,7), N.C. K1 2 contacts (1 0, 7), U3 pins 6-1 1 to pin 2 on U1 or via R6, U3 pins 6-1 1 to U1 pin 2 if K6 fault relay has operated. By making pin 2 high the timer is reset and put into a standby mode. ar This resets K6 fault relay and any fault relays that are latched in an active state. ca lP To stop the set normally, the run signal is removed from P4-7 which de-energizes K7. K7 N.O. contacts (9,14) open to remove B-t from K2 relay. K2 de-energizes opening its N.O. contacts (5,3) removing B+ from TB1 - 1 0, stopping the set. Sequence of Operation - Detector-12 ECM tri Refer to schematic diagram in Wiring Diagrams section when reviewing this information. • • lec Starting is initiated by applying B-t or grourd to P4-7 deperding on the position of �nks W3 ard W4. Either K 1 0 or K14 will initiate U5 - LOP/HET time delay timer. This is achieved by removing the grourd from U4 pin 3 and allow a positive there. This triggers U4 pin 1 4 to ground U5 pin 2. After a 1 0 second delay U5 pin 14 energizes K1 through U4 pins 1 and 1 6. K1 N.O. contacts (9,1 5) close, connecting B-t to the fault circuits. K1 N.C. (1 ,8) contacts open to latch U5 into an inactive state during run, made by removing B+ from pin 5 and ground ing it through R8 and U2 pins 2 and 1 5. (K1 N.O. contacts (2,8) also close providing tirring shutdown path to K6 fault relay from appropriate fault circuit.) Position A - Grourd signal to run Position B - B+ signal to run ww w .E This energizes run relay K7, which closes its N.O. con tacts (9, 1 4) connecting B+ to starter relay K3, switched B+ relay K2 fault circuits, overcrank/cycle crank timer U1 , and HET/LOP time delay timer U5 through N.C. fault relay K8 (1 6,9). This also opens N.C. K7 (9, 1 6), disconnecting B+ to the reset circuit (K6). 5-2 Checking Relay Coil • Connect B+ across relay coil terminals. Relay should activate if coil is okay. • • Checking Relay Contacts • • Connect B+ to one side of relay contacts. Connect a volt meter to other side of relay contact. If B+ i s present when relay is energized, contact is okay. The B+ reading is present in reverse order when checking normally closed (N.C.) contacts. Typical wiring diagram is shown in Figure 5-1 . • • ua ls • • • Low fuel, pre-LOP, pre-HET, and LET only activate a warning lamp and do not stop the set. • • • • • • lP • • ar tM an LOP, H ET, OS, Fault 1 , Fault 2 and Remote shutdown (TB2-1 6) activate a lamp and also shuts down the set. Fault relay K6 is separately in series with the K 1 3 (HET) , K 1 5 (LOP) , K1 1 (OS). K4 (Fault 2) and K5 ( Fault 1 ) fault relays. Therefore, when a ground is placed on the respec tive plug input it will cause both the K6 relay and the associated fault relay to energize. K6 N.C. contacts (9,8) open to de-energize K2 relay, stopping the set. K6 N.O. contacts ( 1 1 ,1 0) close to energize K8 relay. K8 opens its N.C. contacts ( 1 6,9) to remove B+ from the operational parts of the circuit. The associated fault relay will bring up an indicating lamp and also connect a ground to one of the following terminals for a remote indication: TB2-8, for HET TB2-2, for Fault 2 TB2-9, for LOP TB2-4, for Fault 1 TB2-1 0, for PHET TB2-6, for Overcrank TB2-1 1 , for PLOP TB2-7, for Overspeed .c om RU N RELAY (IF EQUIPPED) If a fault should occur a ground is placed on the following plug points: P2-1 , for Low Engine Temperature (LET) P2-2, for Pre-Low Oil Pressure (PLOP) P2-3, for Pre-High Engine Temperature (PHET) P2-4, for Low Oil Pressure (LOP) P2-5, for High Engine Temperature (HET) P2-6 or terminal TB1 -1 , for Overspeed (OS) TB2-1 4, for Low Fuel TB2-1 , for Fault 2 TB2-3, for Fault 1 TB2-1 6, for shutdown of customers requirements ca To reset a fault the run signal must be removed from P47 to de-energize K7, closing its N.C. contacts (9, 1 6) to connect B+ to the fault reset circuit. A ground is placed on P4-1 1 which grounds all of the latch able fault relays reset coils as follows: K6 - Fault Relay K 1 3 - HET K - Fault 2 K 1 5 - LOP K5 - Fault 1 K 1 7 - PHET K 1 9 - PLOP K9 - Overcrank K 1 1 - Overspeed • A -�1--� tri • OUTPUT • 4 • • • INPUT • lec • • This resets K6 fault relay and any fault relays that are latched in an active state. s --1-----l .E To stop the set normally, the run signal is removed from P4-7 which de-energizes K7. K7 N.O. contacts open to remove from K2 relay. K2 de-energizes opening its N.O. contacts (5,3) removing from stopping B+ B+ FIGURE 5-1. RUN RELAY ww w the set. (9,14) TB1-1 0, 5-3 .c om INTERFACE RELAY MODULES (IF EQUIPPED) 2 3 5 4 7 6 8 I TB2 (INPUT) TB1 (OUTPUT) 2 3 2 an -1 ' ua ls When the customer provides a remote control panel having alarm circuits powered by a separate AC or DC source, Module A1 3 (7 relays) and Module A14 (5 relays) can be provided to interface with the ECM (A1 1 ) circuits. Typical wiring diagrams are shown in Figure 5-2. 4 5 3 K1 K5 K4 K3 K2 . 2 4 3 7 6 5 8 9 12 11 10 tM 1 4 13 14 I ar I 6 7 K7 K6 TB1 8 9 5 10 11 6 12 13 7 14 8 B+ ca lP A13 -I I 1 2 181 ww K3 K2 w I (INPUT) tri .E lec K1 TB2 3 4 5 6 7 K4 2 3 2 4 5 K5 3 6 7 4 8 9 10 TB1 (OUTPUT) I A14 FIGURE 5-2. INTERFACE RELAY MODULES 5-4 8 9 5 10 6 B+ ES-1854 .c om TIME DELAYED START/STOP MODULE (IF EQUIPPED) AC METERS AN D CURRENT TRANSFORMERS If a meter malfunctions, the problem might be a loose wiring connection, the meter itseH, the phase selector switch, or the current transformer for that meter. If more than one meter is malfunctioning, you may have to check for proper and secure generator tap connections. Check appropriate AC wiring diagram/schematic for wire lead and terminal connections. Checking continuity of the wiring and components should identify the problem. Repair or replace any faulty wiring, replace faulty meter, current transformer, switch, etc. Refer to appropriate wiring diagram/schematic in Wiring Diagram section. an tM lWE DELAY STOP POTENTIOMETER ca lP ar TIME DELAY START POTENTIOMETER ua ls This module contains adjustable potentiometers for time delayed start (1 to 1 5 seconds) , and time delayed stop ( 1 to 1 5 minutes). Time delay adjustment i s made by turning the appropriate potentiometer clockwise to increase or counterclockwise to decrease the time delay. Set the time delay start per site requirements, and the time delay stop for approximately 3 to 5 minutes. Typical wiring diagram is shown in Figure 5-3. Refer to Wiring Diagrams section for further information. tri TB1 2 3 4 5 6 .E lec PRIMARY START-DISCONNECT (A1 1 - TB1 -2) SECONDARY START-DISCONNECT (A1 1 - TB1-3) B- (A1 1 - TB1-5) B+ (A1 1 - TB1-7) RUN SIGNAL OUT (A1 1 - TB1-6) RUN SIGNAL. IN (REMOTE START/STOP CONTROL) ww w FIGURE 5-3. TIME DELAYED START/STOP MODULE 5-5 ES-1855 .c om AUTOMATIC VOLTAG E REG ULATOR Quadrature Droop Circuit (Optional): Converts the cur rent input from a CT into a voltage which is phase mixed with sensing voltage. The result is a net increase in the outp� t from the sensing network as the power factor lags, causmg a reduction in excitation. The automatic voltage regulator (AVA) is a three-phase full wave poweroutput type device, which forms part of the excitation system for the generator. I� a�diti�n to regulating the generator voltage, the AVA c1rcu1try Includes a number of protective features which provide safe reliable control of the generator. Excitation power is derived from a permanent magnet generator (PMG), providing low Radio Frequency Interference (RFI) and immunity from thyristor type loads. RMS Convener: Is a square law precision rectifier circuit !hat converts the AC signals from the sensing networks ua ls 1nto a composite DC signal representing the mean squared value of the waveform. The output of the RMS converter includes a variable potential divider which forms the voltage range control for the AVA. Th� AVR is interlinked with the main stator windings, _ exc1ter f1eld and PMG to provide closed loop control of the output voltage with load regulation at approximately ±0.5% RMS. Current Convener: Is a three-phase precision rectifier and amplifier that converts the inputs from current trans formers into a DC signal representing the mean value of the current waveform. an The AVA senses the output voltage from the main stator windings and in response to this controls the power fed to the ex�iter field, a�d the main field, in such a way as to _ mamta1n the machme output voltage within the specified limits, compensating for load, speed , temperature and power factor of the generator. tM Offset Control: Provides an interface between the AVA and accessories and allows the generator's excitation to be controlled by adding or subtracting the accessory DC output voltage to the AVA rectified sensing voltage. Soft start circuitry is included to provide a smooth con trolled build up of generator output voltage. ar Power Supply: Components consist of zener diodes, dropper resistors and smoothing to provide the required voltages for the integrated circuits. Sust�ined overvoltage situations caused by open drcuit sen�mg terminals or short circuit power device are �vo1ded by overvoltage detection circuitry which provides mternal shutdown and circuit breaker trip signals for circuit i �lation if required. lP Precision Voltage Reference: Is a highly stable tem perature compensated zener diode used for DC compari son. tri ca A frequency measuring circuit continually monitors the shaft speed of the generator and provides underspeed protection of the excitation system by reducing the gen erator output voltage proportionally with speed below a P!eset value. A further enhancement of this feature pro VIdes greater voltage roll off in response to rate of falling speed (dHz/dt) , to improve frequency recovery time on turbocharged engines. Current 6miting circuitry (optional) provides control over the amount of short circuit current flowing during three phase and single-phase shorts on the generator output. Main Comparator/Amplifier: Compares the conditioned sens��g voltages with the precision reference voltage and _ amphf1es the dtfference (error) to provide a controlling sig �al fo� the power �evice in such a way as to supply the exc1ter w1th the requ1red amount of power to maintain the generator voltage within the spedfied limits. lec Stability Circuit: Provides adjustable negative AC feed back to prevent voltage hunting and ensure good steady state and transient performance of the control system. Over excitation situations left uncontrolled are limited to a sat� durat�on by i �ternal shutdown of the AVA output . dev1ce. ThiS cond1t1on remains latched until the generator has been stopped. .E Power Control Driver: Provides the means to infinitely control the conduction period of the output device. This is achieved by pedestal and ramp control followed by a level detector and driver stage. Basic Operation Power Control Devices and Rectifier: Are configured as a three phase 4 diode bridge, power mosfet and freewheel diode to vary the amount of exciter field current in response to the error signals produced by the main comparator. w The internal block diagram of the AVA board is shown in Figure 5-4. The main functions of the AVA are as follows. Sensing Resistors: Take a portion of the generator output voltage and attenuate it to a suitable lower level. This input chain of resistors includes the hand trimmer adjustment. ww Soft Stan C!rcuitry: Overrides the precision voltage reference dunng run up to provide a linear rising voltage. 5-6 .c om Sync: Circuit provides a short pulse near the zero point of one of the phases on the PMG and is used to synchronize the Under Frequency Roll-Off (U FRO) and power control circuits to the generator cycle period. Over Voltage Monitor: Continuously monitors the volt age at the generator terminals and provides signals to shut down the output device and trip an optional circuit breaker, to i solate power from the exciter and AVR in event of sustained overvoltages. A one second timer is included i n the circuitto prevent operation during transient overvoltages, which are normal after load removal. Under Frequency Roll-Off: Circuit measures the period of each electrical cycle and causes the reference voltage to be reduced approximately linear with speed below a presettable threshold. A light emitting diode (LED) gives indication of underspeed running. ua ls Overload Detector: Continuously monitors the level of excitation and provides signals to shut down the output device in event of sustained overloads lasting greater than ten seconds. Both the overload and overvoltage conditions are latched faults requiring the generator to be stopped for reset. tM an Block Relief: Circuit measures the rate of falling speed of the generator (dHz/dt) and causes greater voltage roll off (makes the V/Hz slope steeper) to aid engine speed recovery after application of a "block" load. UFRO + BlOCK REUEF OVER ,.. VOLTAGE ..... DETECTOR - ar OVER VOLTAGE MONITOR ::. CONTROL tri ,.. SENSING RESISTORS �� '<� RMS CONVERTER lec GENERATOR VOLTAGE .... SENSING OFFSET REMOTE ..... .E VOLTAGE TRIMMER "'- POWER SOFT ,...__ - BREAKER DRIVE + INHIBIT I PRECISION '-- POWER VOLTAGE SUPPUES REFERENCE � ww _.. EXCITATION ClRCUIT BREAKER (OPTIONAL) r---4 R .....__ _ rr- .... � SYNC v STABIUTY CIRCUIT POWER CONTROL DRIVER - POWER CONTROL DEVICES OVERLOAD DETECTOR + INHIBIT ,-- � I>I>- CURRENT CONVERTER 1 w CURRENT ,.. INPUT ,.. QUAD DROOP - """ RECTIFIER START CIRCUIT lP ca ACCESSORY ,.. INPUT r-o- 100 HZ PMG FIGURE 5-4. PMG VOLTAGE REGULATOR BLOCK DIAGRAM 5-7 EXCITER FIELD .c om G EN ERATO R O PERATI ON REVI EW Two, similar PMG voltage regulators have been used In per manent magnet exciter generator sets. One Is a four position mount, and the newer of the two has six mounting holes (of which only four are used). Adjustment proce dures are the same for both, even though the potentlone ters are located differently. Refer to Figure 5-6 to Identify which PMG AVR the unit is equipped. The PMG provides power via the AVA to the main exciter stator, see Figure 5-5. Excitation power is therefore inde pe �dent of output voltage , resulting in positive voltage _ build-up, w1thout reliance on residual magnetism. The AVA compares the main stator output with a reference value and feeds a controlled excitation current to the main exciter stator. The AC output of the main exciter rotor is c? n �erted to DC by the rectifier assembly, comprised of s1x d1 �des mounted on two heatsinks to form positive and negat1ve plates. The diodes are protected against harmful overvoltges (caused for example, by switching circuits or out-of-phase paralleling) by a metal-oxide varistor (MOV). Th e DC output of the rectifier assembly provides _ _ onto the main rotor. the exc1tat1on ua ls The generator voltage may be adjusted within ±3 percent of the rated nameplate voltage via the optional control pa�el mounted voltage control rheostat ( A21 ). If the adjustment cannot be made with A21 , or if A21 is not in stalled, adjust the voltage regulator as follows: 1 . Adjust voltage control rheostat A21 (if available) to the mid position. Loosen the locking nut. With a screwdriver, turn rheostat A21 fully counterclockwise, then fully clockwise, then to mid position. • an AVR Sensing and Power Supply 3-Phase Sensing: With rated output voltage on the main terminals, the reference supply to this unit should be between 1 70 and 250 volts AC across 6-7, 7-8 and 8-6. This supply can be by way of a quadrature droop burden resistor and/or dropper transformer. These should be checked for continuity. tM 2. Open the control panel doors to gain access to the voltage regulator. 3. With the generator set operati ng, and the voltage being monitored (either by meters on the set or with remote metering) , adjust voltage regulator board Volts potentiometer to the desired generator voltage. ar Power Supply (PMG): Power supply is derived from the permanent magnet exciter. Its output leads are connected at AVA terminals P2, P3 and P4. These must first be dis connected. With the machine at rated speed the output voltage between leads P2-P3, P3-P4, and P4-P2 should be balanced at approximately 1 65 volts for 50 Hz (1 500 rpm) units or 200 volts for 60 Hz ( 1 800 rpm) units. lP 5. Stor:> and restart generator set to confirm proper op eratiOn. ca Voltage Regulator Adjustment 4. :e �orm fine voltage adjustment (±3 percent) by ad JUSting rheostat A21 , retighten locking nut. .E lec tri Generator voltage is controlled by the optional voltage control rheostat (A21 ) located on the control front panel and the solid-state voltage regulator located inside control panel (see Figure 5-6) . PERMANENT MAGNET STATOR AUTOMATIC VOLTAGE REGULATOR OUTPUT MAIN STATOR EXCITER STATOR IJm ----t---r- w ww 6. If adjusting the Volts potentiometer of the voltage regulator ��rd do� s not allow the generator voltage �o come Wl! htn d�s1red range, refer to wiring diagram Included w1th untt and check for proper connections. Repe�t t�e adjustment procedure. If proper adjust _ ment 1s still not possible, review the following regard- MAGNET ROTOR ---t-1 Jn 1 -t--- ---+EXCITOR ROTOR sHAFT ----...1 ----IL� TING DIODES MAIN ROTOR FIGURE 5-5. PERMANENT MAGNET GENERATOR (PMG) EXCITATION SYSTEM (BLOCK DIAGRAMS) 5-8 ES-1852 .c om DIP (Voltage Dip Limit): This control is preset at ap proximately 30 percent of the operating voltage. Turning the control clockwise increases the voltage dip on large load pickup. This will make it easier for the engine to pick up load. Turning the control counter clockwise reduces the voltage dip (makes the AVR "stiffer"). The engine may not be able to pick up the load if the Voltage Dip Limit is set too far counterclock wise. ing other potentiometers on the AVR (note that a non PMG regulator does not have all the same potenti ometers as a PMG regulator). Replace voltage regu lator board, or contact your service representative for assistance. I A CAUTION ) ua ls Sealed voltage regulator poten tiometers are factory-calibrated for operation with this generator set. Any adjustment of other components could cause generator set voltage instability or overheating. Further adjustments should only be made by a qualified service repre sentative. Droop: To set generator droop to 5% at full load, 0 PF. Turning this control clockwise increases the droop (the VUmt may also need to be adjusted if there is too much droop ) . Stability: If the voltage is unstable after a block load reduction, tum the Stability control clockwise. Opti mum setting should be found around mdpoint. Any stability adjustment affects the generator output volt age. Reset the output voltage after any stability ad justment. an Trim: To match AVR input to accessory output. Turning this control clockwise allows accessories, like a VARIPF controller, more control over the AVR. OverN: To set the overvoltage protection cutoff level. Turning this control clockwise increases the overvolt age cutoff level. tM Under Frequency Roll Off (UFRO) Knee Point: This control is set at 58 to 59 Hz (60 Hz units) or 48 to 49 Hz (50 Hz units). The LED (light emtting diode) adjacent the UFRO potentiometer will be lit when the voltage regulator is in the under frequency mode, off is the standard operating mode. To check, reduce generator frequency from rated to where the LED just begins to illuminate. Note set point frequency. Turn ing the UFRO potentiometer clockwise reduces the knee point fre<JJency, and the LED will extinguish. Return set to rated frequency. ar ULimit: To set the maximum short drcuit current. Turning this control clockwise increases the short drcuit current. lP FREQUENCY SELECnON LINKING: 1 2, 60Hz, 6-pole 2 - 3, 50Hz, 4-pole 1 - 3, 60Hz, 4-pole No lilk, 50Hz, 6-pole - [Q] 0 DROCP (!] VITRN TRIM .E lec § § STABLITY [!] §� w ww PERMANENT MAGNET GENERATOR (PMG) AVR (AFTER JAN. 1, 1990) STABILITY tri DIP ca PERMANENT MAGNET GENERATOR (PMG) AVR (PRIOR 10 JAN. 1, 1990) Stab/1, EXC, and RMS: Are set at factory, and should not require any adjustment. Replace AVR. I I CPTMJM RESPONSE SELECTION EXC (!] [Q] CNEPJII RMS (FACTORY SET) � § [!] [QJ OPTIMUM RESPONSE SELECTION UNKING: ES-1856-1 RGURE 5-6. PMG VOLTAGE REGULATORS 5-9 A - B, FRAMES 6 & 7 B - C, FRAMES 3, 4 & 5 A - C, FRAMES 1 & 2 A B c .c om OVE�U N DER VOLTAG E SENSOR MODULE (IF EQUIPPED) A1 1 - TB2-1 Rotate the appropriate arrow i ndicator to adjust the module , the recommended approximate settings are: 90 5 Over % Volts Set % Volts Reset 1 10 5 0 14 18 0 The module includes an adjustable time delay relay to prevent nuisance tripping (typically set at 25 percent, or approximately 2.5 seconds). See typicalwiring diagram in Figure 5-7. 0 16 0 L N 21 26 25 0 0 0 A1 1 - TB2-3 A1 1 - TBH O A T.D. �: B FIGURE 5-7. OVER/UNDER VOLTAGE SENSOR MODULE lec CRANKING POTENTIOMETER @] 0 0 OVE�UN DER FREQUENCY SENSOR MODULE (IF EQUIPPED) .E Rotate the appropriate arrow indicator to adjust the module , the recommended settings are: w Under Hz Set Reset ww Over Hz Set Reset 50 45 47 55 53 28 0 ES-1858 The Overspeed potentiometer is adjustable from 1 500 to 2500 RPM. Adjust the Overspeed potentiometer to achieve overspeed at approximately 1 800 to 1 900 RPM for 50 Hz units and 2100 to 2200 RPM for 60 Hz units. See typical wiring diagram in Figure 5-9. tri ES-1857 Nominal Hz 25 0 This module derives a speed (Hz) signal from the PMG but is powered from the generator set battery. A small time delay, typically one second, is incorporated in the over speed function to allow for engine overshoot. The module contains two adjustable potentiometers, Overspeed and Cranking (the cranking potentiometer is not used how ever). ca 93 GND 26 0 lP 9 1 N OVERSPEED (FREQUENCY DETECTION) MODULE A1 7 TB21-26 K17 L FIGURE 5-8. OVER/UNDER FREQUENCY SENSOR MODULE 24 28 16 0 an 22 A18 tM 0 15 12 24 ar 18 11 21 12 TB21-26 GND 0 14 15 0 11 ua ls Unde r % Volts Set % Volts Reset DO 60 10 (P3) 0 @]oD D 55 57 65 63 See typical wiring diagram in Figure 5-8. OVERS PEED POTENTIOMETE R 1--+-+- 9 (P2) 1---lr+- B- }- TERMINAL AUXILIARY BLOCK 1--+-+r- B+ (A1 1 - TBHO) 1--i<-+- SIGNAL OUT (A1 1 - TB1-5) 1--+-+- NOT USED �1-+-- B+ OR B- (A1 1 - TB1 -1) 1--1-+- NOT USED ES-1858 FIGURE 5·9. OVERSPEED (FREQUENCY DETECTION) MODULE 5-1 0 The rectifier assembly, Rgure 5-1 0, is split into two plates, the positive and negative, and the main rotor is connected acros� these plates. Each plate carries 3 diodes, the negat1ve plate carrying negative based diodes, and the positive plate carries positive based diodes. The correct polarity diodes must be fitted to their respective plate. .c om ROTATING RECTIFIER ASSEMBLY 4. Reverse ohmmeter leads from Steps 2 and 3 and record resistance value of each rectifier; positive stud (X) to CR1 , CR2, and CR3; and negative stud (XX) to CR4, CR5, and CR6. 5. All the resistance readings should be high in one test and low in the other test. If any reading is high or low in both tests, rectifier assembly is defective. �eplace defective rectifier assembly with new, iden tical part. ua ls 6. I A CAUTION I s e dust or din on di Excesiv odes and other components will cause over heating and eventual failure. Keep these assem blies clean! an Use 24 Jn.lbs. (2.7 N•m) torque when replacing nuts of positive (X) and negative (XX) studs, and CR1 to CR6. tM Replacing Rectifiers To replace rectifiers use the following procedure: 1 . Disconnect diode lead wire from stud terminal. ar 2. Use proper size wrench to unscrew dode from rectifier assembly base. lP 3. AWIY heatsink COI1lJOUnd to underside of new ci ode. DO NOT apply this COI1lJOUnd to clode stud threads. FIGURE 5-10. TES11NG ROTA11NG RECllAER ASSEMBLY ca Surge Suppressor lec tri The surge suppressor (varistor) connected across the two rectifier plates prevents high transient reverse voltages in the field winding from damaging the diodes. This device i � no� polarized and will show an infinite reading in both _ an ohmmeter. H defective, signs of burning d1�ect1ons with w111 probably be apparent and it will give a full deflection (short-circuit) reading. Replace if defective. Rectifier Diodes ':Jsing .E an accurate ohmmeter, test each CR using nega tive and positive polarities. Test rectifiers (diodes) as follows: 1. Disconnect all leads from assembly to be tested. Connect one lead to the positive (X) stud and connect other lead to CR1 , CR2, and CR3 in tum; record resistance value of each rectifier. w 2. Connect one lead to the negative (XX) stud and connect other lead to CR4, CR5, and CR6 in tum·' record resistance value of each rectifier. ww 3. 4. Insert new diode into mounting hole. Torque cfJOdes on rotating rectifier assembly to 36-42 in-1:>5. (4-4.8 N•m). 5. Reconnect diode lead wire to stud teminal. Use 24 in-lbs. (2.7 N•m) torque when repladng nuts. PERMANENT MAGNET EXCITER The permanent magnet exciter is the main power supply for a PMG A VR and is isolated from all other windings. For this reason the output from the exciter must be tested independently across its terminals, which are connected to auxiliary terminal board (exciter leads P2, P3, and P4). With the machine run up to full speed, the output voltage across the leads P2, P3, and P4 should be balanced at approximately 1 65 volts for 1 500 rpm (50 Hz) or 200 volts for 1 800 rpm (60 Hz) between terminals. The permanent magnet exciter will produce an output voltage completely independent from the rest of the machine, and has no effect on the separate excitation tests that follow. Refer to appropriate wiring diagram/schematic in Section 7. The permanent magnet excHer stator resistance Is 4.4 ohms line to-line. 5-1 1 .c om EXCITER ROTOR Testing for Grounds EXCITER STATOR Testing for Grounds Connect leads of ohmmeter between each CR lead and exciter rotor laminations. Use an ohmmeter set at the highest resistance range. An ohmmeter reading less than one megohm ( 1 ,000,000 ohms) indicates defective ground insulation. See Figure 5-1 1 . Using an ohmmeter, R x 1 00 scale, measure the insula tion resistance between either lead X or XX and the lam nations, Rgure 5-1 2. A reading of less than infinity indi cates a ground. ua ls Testing for Open or Shorted Windings Use a Wheatstone Bridge for this test. Disconnect main rotor field leads which oonnect to rotating rectifier assem blies at the positive and negative studs. Disconnect lead wires from diodes CR1 , CR2, CR3, CR4, CR5, and CR6. Test between exciter lead pairs U6-V6, V6-W6 and U6W6. Refer to Table 5-1 for resistance values. an Be sure to Identify the gensel model, kW rating and generator frame size from the generator set nameplate before reviewing Table 5-1. tM FIGURE 5-12. TESllNG EXaTER STATOR FOR GROUNDS Testing Winding Resistance ar Measure ooil resistance between leads X and XX with an ohmmeter, scale R x 1 . See Rgure 5-1 3. Refer to Table 5-1 for resistance values. lec CR5 .E SCHEMATIC OF EXCITER WIRING CAL' G-1183-2 FIGURE 5-13. TES11NG EXaTER STATOR FOR OPEN aRCUIT CR5 G-1183-1 GENERATOR ROTOR Testing for Grounds FIGURE 5-11. TESTING EXaTER ROTOR Use an ohmmeter, (R x 1 00 scale) and measure as follows: w ww OHMMETER tri ca lP Be sure to Identify the genaet model, kW rating and generator frame size from the generator set nameplate before reviewing Table 5-1. 1 . Disconnect rotor leads from the rotating diodes. 2. Measure between either lead and the rotor shaft, FigUre 5-14. 3. A reading of less than infinity indicates a ground. 5-1 2 .c om Connect all (U, V, and W) stator output leads together. Use an ohmmeter set on the R x 1 00 scale and measure the insulation resistance between these windings and the stator frame. A reading of less than infinity indicates a ground. Field circuit breaker can be either open or closed for this test. Testing for Shorts G-1187 FIGURE 5-14. TESllNG GENERATOR ROTOR FOR GROUNDS ua ls CONTACT ONE PROD TO EACH OF 1HE FIELD LEADS AND OTHER POOD TO ROTOR SHAFT. F ROTOR IS GOOD, lHERE WU BE ONE MEGOI-N OR GREATER RESISTANCE. To check for shorts between individual windings, first refer to electrical schematic to determine individual coil lead wires (U5-U6, U1 -U2, etc.). Be sure to disconnect the in strumentation leads and stator leads U1 , U2, US, V2, and W2. Connect an ohmmeter, R x 1 00 scale to one lead of a stator winding (leaving the other end of coil winding being tested open), and the other ohmmeter lead to all other stator leads connected together. Example: Ohmmeter lead to: U6 coil winding lead. Ohmmeter lead to: U1 , 2, V1 , 2, 5, 6, W1 , 2, 5, and 6 connected together. Coil winding lead US, open. Testing for an Open Circuit an • 1 . Disconnect and test between rotor leads, F�gure 51 5. • • 2. Replace the rotor if it is grounded or has an open or short. Refer to Table 5-1 for resistance values. tM A reading of less than infinity indicates a short. Repeat test for all six coils. Measure resistance of windings using a Kelvin Bridge meter. Refer to Figure 5-1 6. H any windings are shorted, open, or grounded, first check the leads for broken wires or damaged insulation. H winding leads show no damage, and it is determined that windings are damaged internally, replace the stator assembly. Refer to Table 5-1 for resis tance values. ar Be .ure to Identify the gensel model, kW rating and generator frame size from the generator aet nameplate before reviewing Table 5-1. ca lP OHMMETER G-1187-1 TEST BEJW:EN WIRE PAIRS UIH.O, V6-LO, W&-LO tri ca.ITACT ON: PROO TO EACH FELD LEAD Be a�re to Identify the gensel model, kW rating and genwator rr.ne size from the generator aet nameplate before reviewing Table 5-1. FIGURE 5-15. TES11NG lec GENERATOR ROTOR FOR OPEN aRCtJT .E GENERATOR STATOR A DANGER ww w High-voltage, 1,900 to 15,000 volts, present special hazards of severe personal Injury or death. Even after genset shutdown, an electrical shock hazard may still exist, caused by Induced voltage within the generator. Setvlce personnel must be well-trained/qualified to worlc with distribution voltages. THREE PHASE t.l)[)ELS, TEST BETWEEN WIRE PAIRS U1 -U2, V1 -V2, W1·W2, lJ5.U6, V5-V6, W5-W6 Testing for Grounds Before testing stator, disconnect all external load and control wires. Isolate from ground and each other. FIGURE 5-16. TES11NG GENERATOR STATOR WINDINGS 5-1 3 .c om TABLE 5-1 . WINDING RESISTANCE VALUES* NTS NT6 NTA2 NTA2 OFCC OFEB OFFA OFEC OFFB NTA3 KTA1 2 KTT1 1 OFGA OFGB OFGC 1 75 1 75 1 75 200 200 200 4C 4C 4C 25 25 25 0.14 0.14 0. 1 4 0.01 7-0.023 0.01 7-0.023 0.01 7-0.023 0.91 0 .91 0.91 200 200 220 220 220 250 230 230 250 250 40 40 40 40 4E 4E 4E 4F 25 25 25 25 25 25 25 25 0.14 0.14 0.14 0. 1 4 0.14 0. 1 4 0.14 0.14 0.014-0.020 0.01 4-0.020 0.01 4-0.020 0.01 4-0.020 0.01 0-0.01 5 0.01 0-0.0 1 5 0.01 0-0.0 1 5 0.0097-0.01 0 1 .04 1 .04 1 .04 1 .04 1 .17 1 .1 7 1 .1 7 1 .35 sc sc 25 25 25 25 25 0.1 7 0. 1 7 0. 1 7 0. 1 7 0. 1 7 0.068-0.0090 0. 0068-0.0090 0.0058-0.0080 0. 0058-0.0080 0.0043-0.0069 1 .55 1 .55 1 .77 1 .77 1 .96 275 300 275 350 400 450 450 500 VTA1 VTA2 VTA3 440 500 600 OFJA OFJB OFJC OFJO OFLA OFLB KTA31 KTA32 KTA33 620 660 800 900 900 OFLC OFLO OFMA OFMB KTA53 KTA54 KTT51 KTT52 SE SF 6A 25 25 1 7"" 0. 1 7 0. 1 7 0. 1 6 0.0043-0.0069 0.0031 -0.0042 0 .0037-0.0053 1 .96 2.16 1 .37 6B 6B 6C 6C 60 60 1 7"" 1 7"" 1 7"" 1 7"" 1 7"" 1 7"" 0. 1 6 0.1 6 0.16 0. 1 6 0. 1 6 0. 1 6 0.0030-0.0033 0.0030-0.0033 0.0023-0.0028 0.0023-0.0028 0.001 8-0.0023 0.001 8-0.0023 1 .47 1 .47 1 .66 1 .66 1 .89 1 .89 7B 7G 7G 7G 1 7"" 1 7"* 1 7"" 1 7** 0.20 0.20 0.20 0.20 0 .001 2-0.001 8 0.001 2-0.001 8 0.001 2-0.00 1 8 0.001 2-0.00 1 8 2 .29 2.29 2.29 2.29 ca 750 800 900 1 000 1 000 1 1 00 tri KTA51 KTA52 550 50 50 SE lP 31 0 330 400 400 450 KTT1 2 ROTOR lec 1 1 20 1 200 1 1 00 1 280 1 250 1 250 1 500 ua ls NT4 NTS STATOR (Per Phase: Wye or Series Wye) an OFAB OFBO OFBE OFAC OFBE OFBF OFCB OFCB NT4 NT4 EXCITER STATOR ROTOR ar OFAA OFBC OFBO GEN. FRAME SIZE KW RATING 50Hz 60Hz tM GENSET MODEL DESIGNATIONS .E * Resistance figures are approximates, at 68°F (20°C) ±1 0%. ** Units built prior to November, 1989, were 28 ohms. RECONN ECTION ww w Rgure 5-1 7 shows the general reconnection possibilities for the generators. When reconnecting for a different voltage, refer to AC Reconnect Wiring Diagram in Section 7 and AC diagrams that came with unit. 5-1 4 .c om GENERATOR CONNECTION WIRING DIAGRAM GENERATOR CONNECTION SCH EMATIC DIAGRAM 1 60 � �-+--z 1 1 5/230 1 50 ---4---�-4 1 1 0/220 1 50 � ...J w c w ffi U2 V6 :::> WI g W2 Ul �. P"'" I i L2 (WJ .� • WI C') 1 20/240 3 60 c z �-+------�--�� en w < L 3 50 1 1 5/230 3 50 1 20/208 1 27/220 1 39/240 3 3 3 60 60 60 C\1 c z ww H 6----'1 W2 W5 L2 (V) 50 50 50 N • V2 -r,.. V5 -V"" U2 -r,.. U5 -V"" T (WJ �===:=!J.c:J.L3 w V U �-- LO( N J 5 V2-:. 4 W5- 5 - W6 7 - VI - V6 6 • - 60 220/380 3 50 230/400 3 50 240/41 6 3 50 254/440 3 50 347/600 3 60 f-- W2 V r- W I 4 t-- V6 U I=-V I L..3;r-U6 8 6 4 - UI - U6 - WI 8 5 W2 ��+--w r- w6 --HH--- 7 W5V2---... V5-./"' u2- '>a U5-C •'-"-' � U2 U6 V2 v V6" 4 L2 ( V ) V5 Ul W5 ...J CT22 - LO ( N ) � W,_ I -- � � -=�\_�-N�- UV II 5" 5= u::;: 5== V5 W5 W f6 W2 7 ----..� v V2 ---t=w:===-+- V 4 ��� 6 r--- U I u r-- u6 �r-- w 1 8 8 WI W6 V6 l:ui22-=�-===u=-+- U6 W5- ,-- N iri- V I V5-l/ �r- u l U5• � en w a: w en W2 W5 CT23 4 '----��6bl-�- LJ ( W) - W26 v � 6 V2----�7 u U2- -i;:r-- U6 8 �r-- w 1 5 -+==+-El'-�I W ::a W57 V2- ::a V5 - 4 8 U2 - w W2-��W6 � .__ -WI 5-----+-=:=::IIEt- V I -UI W2 6--� W •- w6 W5 -f't v 7 V2 •- V6 V5 _IJI' u U2 •- u6 8 U5 - - ..-t'----'W-'-'1� --t-411-t-- 60 60 60 7 �r-- U I l1 -;r--- CT2 1 r;========:J..JI-+T_J__ L I ( U ) tri 3 3 3 3 V -W I V2 - V6 W5 U:_,t- V I ... 8 -----t.�� I._ __. U6 5 CT23 f • lec 220/380 240/41 6 254/440 277/480 w � 3 3 3 .E L 1 1 5/200 1 20/208 1 27/220 VI V5 V2 L----- C') c �-+------;---r-� ...J z w < 1 1 0/1 90 3 50 ...J z W6 a: w en Ul CT22 lP 1 1 0/220 ·� W5 ca z U5 U2 � 'w --,__- w6 �5 --1;-.+==::J:ii U2- ar � � L FT21 r;:::;::;= T u cu J 6 ==::::Lji'*J- ...J - •CT21 �6)1---- LO (N) ua ls 1 20/240 t �...., FRAME S, 6, 7 FRAME 4 an L v W5 I . L L l (U) I tM C') c Vi PHASE SEQUENCE U.V.W. WHEN ROTATING CLOCKWISE VIEWED AT THE DRIVE END U5 __j- •- w& v ..I- V 6 U •r-- u& '-- W6 ES1866c FIGURE 5-17. RECONNECTION DIAGRAM 5-1 5 I a: 0 1<( 8 8 > > """ C\1 """ C\1 C\1 .... + C\1 .... 5 5 0 -:.1::. t> a: t> i= w z ¢ t> <( n w ...J e z ::l a: �. ffl� z 0 :::E :::E 0 t> 1�1�11@1�1�11�11�1�1�1�1@1 4 5 6 7 8 9 10 3. Run Speed potentiometer. A. Tum the screw counterclockwise 20 turns. B. Tum the screw clockwise 1 0 turns. C. This will set the run speed potentiometer to its mid position. 4. Gain potentiometer. A. Set the Gain adjustment at the third division from zero. 5. Droop potentiometer. A. For i sochronous operation, the droop potenti ometer must be turned fully counterclockwise and will not require any further adjustment. B. Tum the screw to approximately 40 for 3 percent droop. C. Tum the screw to approximately 80 for 5 percent droop. 11 IDLE S PEED RUN SPEED GAIN DROOP an 3 Idle Speed potentiometer. A. Tum the screw counterclockwise 20 turns. B. Tum the screw clockwise 1 0 tu rns. C. This will set the idle speed potentiometer to its mid position. D D 1f2 � tM 2 @ � Calibration Checks: 1 . Start the generator set. lP ca Gain: The Gain control is a one-turn potentiometer. It is used to adjust the sensitivity of the governor. A clockwise rotation of the potentiometer will shorten the response t:me to load changes. With the generator set warmed up to proper operat ing temperature, adjust the Run Speed potentiome ter until the engine is operating at the desired frequency or r/min. tri Droop: The Droop control is a one-turn potentiometer. It is adjustable for zero % (isochronous) to more than 5% speed droop. Fully counterclockwise rotation is 0% speed droop. 3. With no load connected to the generator set, turn the GAIN adjustment clockwise slowly until the actuator lever oscillates. Reduce the GAIN adjustment slowly counterclockwise until the lever is stable. Upset the lever by hand. If the lever oscillates up to 3 deminishing oscillations and stops, the setting is correct. lec Idle Speed: The Idle Speed control is a 20-turn po tentiometer for adjusting the idle speed. A clockwise rotation will increase the idle speed. .E Run Speed: The Run Speed control is a 20-turn po tentiometer for setting t h e desired no-load governed speed. A clockwise rotation will increase the run speed. 4. Refer to the following adjustment procedures. Adjustments w Preliminary A djustments: 1 . Frequency Adjust (engine speed) potentiometer on control panel (if equipped) . A. Loosen the locking nut. B. With a screwdriver, turn th e potentiometer fully counterclockwise , then fully clockwise , then to mid position. C. Hold mid position setting with screwdriver, and tighten locking nut. ww For proper full-load generator set operation the engine no-load speed must first be adjusted to the desired allowable speed droop. ( For example : iso chronous operation set to 60.0 Hz/1 800 r/min (50.0 Hz/1 500 r/min), for 3% speed droop set to 61 .8 Hz/ 1 854 r/min (5 1 .5 Hz/1 545 r/min) , for 5% speed droop set to 63.0 Hz/1890 r/min (52.5 Hz/1 575 r/ min.) ar 2. FIGURE 5·18. ELECTRONIC GOVERNOR .c om Q. ::l 2. ua ls ELECTRON IC G OVER NOR Generator frequency is in direct ratio to engine speed which is controlled by the governor. The governor control has four potentiometers for making adjustments. See Figure 5-18. Use a frequency meter or tachometer to monitor the unit during adjustment procedure. Apply and remove loads to check generator set re sponse. If generator set operation is satisfactory, the governor is now calibrated. If generator set response is not satisfactory, review Step 3. If electric governor cannot be properly calibrated, contact your service representative for assistance. Fine Speed Adjustment: After the GAIN adjustment is made, the full load governed Run Speed may require a minor adjustment to equal the desired speed (i. e . , 60 Hz, 1 800 r/min or 50 Hz, 1 500 r/min) . Use the SPEED AD JUST potentiometer (when supplied) on th e engine in strument panel for fine speed adjustments of less than ±1 00 r/min. 5-1 6 .c om Electric Fuel Control {EFC) Governor System Description FUEL SHUTOFF VALVE ACTUATOR STUDS The EFC governor system contains a magnetic pickup, electronic control, and the fuel pump actuator. See Rgure 5- 1 9. MAGNETIC PICKUP SENSOR ua ls FUEL PUMP ACTUATOR an FUEL FLOW FIGURE 5-20. FUEL PUMP ASSEM BLY ENGINE FLYWHEEL RING GEAR AGURE 5-19. EFC GOVERNOR SYSTEM Check that oonnections are clean and tight. A light coating of non-conductive grease will help retard oorrosion at terminals. lP The magnetic pickup senses engine speed at the flywheel ring gear and sends an alternating current (AC) electrical signal to the governor oontrol. ca The governor oontrol oompares the electrical signal from the magnetic pickup with a preset reference point. H there is a difference in the two signals, the oontrol will change the current to the actuator (located on the ergne side of the fuel pump). tri I AWARNING I Ignition of explosive battery gases can cause severe persona/ Injury. Do not smoke while servicing batteries. Wear protective apron and goggles when checking specfflc gravity and adding distilled water. lec Perlonnance Checks If the generator set operation is rough or surges, review the following: 1 Start the generator set and check voltage readings at governor oontrol terminals for; magnetic pickup (1 .5 VAC minimum at cranking, to 30 VAC maximum at genset operating speed), battery B+ (24 VDC), fuel pump actuator (1 9-20 VDC). .E H the battery loses excess water, the alternator charge may be too high. Ukewise, if battery state of charge is not maintained, the charge rate may be too low. Refer to Alternator, this section. Also, if the battery will not re charge, replace it. Stop generator set, disconnect the leads to the actuator (see Rgure 5-20), and oonnect battery B+ voltage directly to the actuator studs. An audible click in the actuator should be heard when B+ is applied and removed. This check only shows that the actuator is operating (rotating to open and closed position), but not if its binding, futher disas sembly of fuel pump may be required to inspecV repair 0-rings, pump, etc. BATIERY CABLES With the starter motor operating, check the voltage drops ( 1) from the battery negative post (not the cable clamp) to the grounding stud, (2) from the battery positive post to the battery terminal stud on the solenoid. Normally, each of these should be less than 0.3 volt. H extra long battery cables are used, slightly higher voltage drops may result. Thoroughly clean all connections in any part of the circuit showing exces::-Jve voltage drop. ww w 2. Check the charge oondition of the starting batteries with a hydrometer. Keep the electrolyte at the proper level above the plates by adding distilled water. Check specific gravity and re-charge if below 1 .260. H 1he generator set Is operated In an area where the ambient temperature Is consistently above gsa F (35° C), a specific gravity of 1 .225 is recommended to reduce electrolyte loss. The change in current in the actuator ooil will make the actuator shaft rotate. The fuel flow, and engine speed or power will change when the actuator shaft rotates. . BATTERIES ar GOVERNOR CONTROL H further tests and repair is required, oontact your Cummins/Onan distributor for further information, or request a oopy of Electric Fuel Control Governor brochure (bulletin no. 3379231 -03). tM 3. 5-17 General With the engine running, check the battery condition DC voltmeter. If the alternator is operating properly, the voltmeter reading should be between 26 and 28 volts. If the voltmeter reading is constantly more or less than this, stop the generator set and check for a loose or slipping drive belt, poor terminal connections, or broken lead wires. Repair or replace as required. Also check the condition of the batteries and battery cables. ua ls The AC circuit breaker does not require any special maintenance other than periodic exercise and a check of conductor mounting. Circuit breaker options vary by Review the Optional Circuit customer requirements. Breaker Description in Section 6. GeneratorNoltage Regulator and perform checks and adjustment applicable to the breaker. A typical breaker diagram is shown in Figure 5-21 for reference. When performing tests and adjustments, avoid accidental start-up by placing the Run/Stop/Remote switch in Stop position and discon necting the battery negative (-) cable. If everything checks out okay, use a separate voltmeter to determine the alternator output voltage, and to verify accuracy of panel mounted DC voltmeter. Connect the positive (+) lead to the output terminal, and connect the negative (-) lead to ground. Start the generator set and run for a few minutes to allow the voltage to stabilize. A proper operating system will have nominal output voltage of 26 to 28 volts. �WARNING J Accidental staning of the generator an set during service procedures can result In severe persona/ Injury or death. Place the Run/Stop/Remote switch In Stop position, and disconnect the battery negative ( ) cable. If the output voltage is high (over 28 volts), the regulator is probably shorted and should be replaced. - tM If the output voltage is low (equals battery voltage), the problem could be wom or broken brushes, an open regu lator, or an open field diode. If further tests and repair is required, contact your Cummins/Onan distributor, or replace alternator. . SHUNT TRIP +COMMON ALARM -GROUND AUXJUARY A COMMON ar STARTER SOLENOID .c om TESTING AC LOAD CIRCUIT BREAKER ALTER NATOR B lP Apply B+ to the terminal marked "S". Jui"Jl)er a ground wire to the solenoid mounting bracket. Solenoid should activate. ca If the contacts are good , B+ should be present between terminal marked "I" and ground. The voltage drop meas ured across the contacts should never exceed one volt in circuit application. tri FUEL SOLENOID If there is fuel to the injection pump, but no fuel at injection nozzle, the fuel solenoid might be defective. OFF;:::::::. . RESET .E lec To check fuel solenoid operation, remove the B+ lead connection from the solenoid, and jumper a separate B+ connection to this teminal. The injection pump should click. If no click is heard, the fuel solenoid must be replaced. SIDE VIEW HANDLE POSITIONS ES-1564-5 CONTROL SWITCH Remove battery B+ cable. Place ohmmeter leads across switch. Open and close switch while observing the ohm meter. A normally open switch should indicate infinite resistance when open and continuity when closed. A normally closed switch should indcate continuity when closed and infinite resistance when open. Replace switch if defective. FIGURE 5-21. OPllONAL CIRCUIT BREAKER DIAGRAM Exerr;/slng Breaker: Actuate the breaker handle to the On and Off positions several times. If the breaker is equipped with a Trip Test button, the breaker should be tripped, reset and actuated to On several times. This will remove any dust from the mechanism and latch surfaces. w ww - 5-1 8 .c om Checking Insulation Resistance: Disconnect the load and line conductors from the breaker, and place the breaker in the On position. Use an insulation resistance ' meter that will apply at least 500 volts to the test leads. Measure the insulation resistance between each pole, and to ground. Also test between the line and load terminals with the breaker in the Off position. A resistance reading less than 1 00,000 ohms indicates a ground. Investig ate for possible c ontam i n atio n on the breaker case surfaces, clean if necessary and retest. 3. There should only be slight variation in the voltage dropped across each pole of the breaker. Unequal or excessive millivolt drops across the complete breaker, or one pole, indicates contaminated con tacts or loose connections. Checking Contact Resistance: Extensive operation of the breaker under load may eventually cause contacts to deteriorate. Test by a Resistance Check, or by a Voltage Drop Check across the breaker poles. Except when generator set operation is required for testing, avoid accidental start-up by placing the Run/Stop/Remote switch in Stop position and disconnecting the battery negative (-) cable. Accidental starting of the gen erator set during service procedures can result In severe personal Injury or death. Place the Run/Stop/Remote switch In Stop position, and disconnect the battery negative (-) cable. Stop the generator set by placing the Run/Stop/ Remote switch in Stop position and disconnecting the battery negative (-) cable. ua ls 4. I AWARNING] an Checking Shunt-Trip Operation: The shunt-trip feature is available in varying AC or DC voltages. The circuit breaker model is selected and installed at the factory to meet customer requirements. Check the shunt-trip func tion as follows: �WARNING I Accidental starting of the generator tM set during service procedures can result in severe personal Injury or death. Place the Run/Stop/Remote switch In Stop position, and disconnect the battery negative (-) cable. Refer to the original equipment order, installation wiring diagrams, and unit wire routing to identify and confirm proper AC or DC signal source connections. ar 1. Resistance Check: 1 . Disconnect the line and load wires from the circuit breaker. lP Move the breaker handle to the On position and check the resistance across each pole (line to load). 3. Resistance should be very low (near zero) and relatively equal across all poles. ca 2. lec tri Voltage Drop Check: This test is done with the conduc tors connected, generator set operating, and load ap plied. As a precaution against electrical shock, place an insulating mat or a dry wood platform on the floor to stand on when taking measurements. [AWARNING I .E Contact with high voltage can cause severe personal Injury or death. Do not touch any exposed wiring or components with any body part, clothing, tool or jewelry. Stand on an insulating mat or dry wood platfonn when taking measurements. 1 . 3. Apply the appropriate signal voltage (12 VDC; 240, 480-VAC) . The shunt-trip solenoid should energize and trip the breaker open. Operate the generator set with the breaker in the On position and load applied. 4. Checking Auxiliary Contacts: H equipped, the breaker will have three leads for wiring to an internal single-pole, double-throw switch. The switch allows connection of a remote annunciator (see installation wiring diagrams). Perform continuity checks of the switch with the breaker in On and Off positions to confirm operation. Adjusting Magnetic Trip Operation: If equipped with front-adjustable magnetic trip controls, the short circuit protection feature for each pole of the breaker can be adjusted equally or i ndividually as required. Surge cur rent above the trip settings will actuate the trip mecha nism. These adjustors are set equally to the high position at the factory. Consult on-site requirements and adjust to proper position. w 2. Take voltage readings at the line connections, then the load connections. ww H the breaker did not trip open, remove the signal source. Perform continuity check of interconnect wiring and shunt-trip solenoid lead wires. Replace interconnect wiring if defective. 5-1 9 w ww .E tri lec an tM ar ca lP ua ls .c om Disassem bly/ Reassem bly The following procedures provide information for removal and reassermly of the generator PMG exciter, control housing, and stator/rotor assemblies. Be sure to read through this section first, before performing procedures listed, to determine the steps most appropriate for the service attention required. A DANGER 3. Remove the three M5x1 2mm capscrews and bck washers from the PMG exciter assembly cover, and remove cover. 4. Disconnect the PMG wiring harness connector. 5. 6. Tap the stator housing out of its spigot, and care fully remove from generator endbracket. The highly magnetic rotor wiU attract the stator core, care must be taken to avoid any contact which may damage the windings. ar Disconnect the negative (-) battery cable to pre vent accidental starting of the generator set while servicing. 7. lP I AWARNING I Accidental starting of the gen Remove the hex head through-bolt from the rotor shaft and firmly pull the complete rotor �embly from its location. Keep the rotor clean by avoiding contact with metal dust or particles. J ACAUTION I The rotor assembly should under no circumstances be dismantled, or the magnetic properties will be destroyed. CONTROL HOUSm ----------PMG EXCITER ASSEMBLY .E lec tri ca erator set during this procedure presents the hazard of severe personal Injury or death. Make sure to disconnect the negative (-) bat tery cable before beginning. CONTROL HOUSING ACCESS COVERS Remove the four bolts and clamps retaining the exciter stator housing to the endbracket. tM Permanent Magnet Exciter Removal 1. Remove the generator air inlet panel and access covers from control housing (see Figure 6-1 ). an High-voltage, 1,900 to 15,000 volts, present special hazards of severe personal Injury or death. Even after genset shutdown, an electrical shock hazard may still exist, caused by Induced voltage within the generator. Setvlce personnel must be well-trained/qualified to work with distribution voltages. 2. ua ls GENERATOR DISASSEMBLY .c om Section 6. Generator ww w GENERATOR AIR DISCHARGE COVERS GENERATOR AIR INLET AND ACCESS COVERS FIGURE �1. GENERATOR AND CONTROL HOUSING ASSEMBLY 6-1 Crank or bar the engine/generator to position the rotor such that a full pole face is at the bottom of the main stator core. Proper positioning can be viewed through the generator access openings. Refer to engine service manual for proper cranking or bar ring procedure. Refer to the proper wiring diagram/schematic in Wiring Diagrams section and on-site specifics for remote control/monitoring. Open control box doors, and check wire markings for legibility to ease reassembly. Disconnect all engine, genera tor, and on-site control wire leads from inside con trol box and conduit box such as: DC Wiring • • Disconnect the negative (-) battery cable to pre vent accidental starting of the generator set while servicing. • I AWARNING I Accidental stanlng of the gen • Arrange leads so they can be easily withdrawn from the control box. erator set during this procedure presents the hazard of severe personal Injury or death. Make sure to disconnect the negative (-) bat tery cable before beginning. I AWARN ING I Disconnect all load wires from the reconnection terminal block assembly (see Rgure 6-2). If equipped with the circuit breaker option, discon nect load wires from circuit breaker. Check that all leads are labeled to ease reassembly. PLACE SLING STRAPS THROUGH HOUSING To prevent personal Injury, use adequate lifting devices to suppon heavy components. Keep hands and feet clear while lifting. ca lP AUXILIARY TERMINAL BLOCK r--- I I I 1 I I I I .E ._ __ _ lec r --·-'---+----1 tri I II IJ Loosen the fasteners that secure the control hous ing side and bottom panels to generator. Make sure that hoisting device is controlling weight of control housing assembly. 9. Remove control housing fasteners, and remove the control housing assembly from the generator. Replace panel fasteners to their respectibe posi tions for safe keeping, and tighten finger-tight. 1 0. Remove control housing mounting brackets from both sides of generator, and assemble lifting eyes to generator. 11. Remove as necessary, air intake components to engine that may interfere with disassembly and reassembly of generator. Generator Assembly Removal, later this section. To re move the stator and rotor Individually, continue with step 1 2. GENERATOR LIFTING EYES FIGURE 6-2. REMOVING CONTROL HOUSING Disconnect all wire leads from the auxiliary termi nal block, inside conduit box (see Rgure 6-2), that would interfere with control housing removal. ( Example: exciter stator leads X and XX.) Before disconnecting, check wire markings for legibility to ease reassembly. ww 5. B. To remove the stator and rotor at the same time, refer to w RECONNECTION TERMINALS Use a hoist or similar lifting device to support the control housing assembly (see Fi�re 6-2). tM 7. ar 4. Wiring VR21-X and -XX. TB21-22 to -30. AC an 3. A1 1!TB1 -8,-1 0, and terminals -1 through -7 and TB2 as re<JJired. Unplug A1 1/J1 and J2. ua ls 2. 6. .c om Main Stator and Rotor Removal 1 . Remove the air inlet and discharge panels and ac cess covers from control housing and generator (see Figure 6-1 ). 6-2 1 2. Remove the four botts retaining the bearing car tridge housing in the endbracket (outer four botts). 1 3. Remove the eight botts holding the endbracket to the generator housing. 14. Insert two botts (M 1 0) in the two holes provided for "jacking" purposes, on the endbracket center line. Screw botts in until endbracket spigot is clear of locating recess. 1 5. Carefully tap the whole assembly off the bearing I .c om is not resting on i nside of stator assembly. See Rgure 6-4. cartridge housing, ensuring the endbracket is supported to prevent the exciter stator from dam aging the windings on the exciter rotor. 23. INGl I AWARN � To prevent personal injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting. Verify that the stator is adequately supported and then carefully remove the capscrews from the stator attachment ring. I AWARNING I The exciter stator is now accessible for inspection and removal from endbrackeVengine adaptor. 1 7. The end bearing can now be removed if required. Refer to Bearing Removal. I A CAUTION 1 9. Using an adequate lifting device, lift the generator (at lifting eyes provided, and main stator housing) until the mounting feet brackets are clear of the frame member (see Figures 6-3 and 6-4) . an Remove the fasteners from the two generator mounting feet brackets. GENE RATOR LIFTING POSITIONS ca lP ar 24. Drive disc damage can bP. caused by allowing the rotor assembly to hang on fl)wheel. Use adequate hoist and sling to suppott the rotor assembly. tri BLOCKING UNDER ENGINE FLYWHEEL HOUSING To prevent personal Injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting. w If generator set does not have chassis mounts at generator end (N855 and K19), block the rear of the engine in place by supporting the flywheel housing. A length of steel channel and wooden blocki ng is required to support the rear of the engine. Place the channel and blocking under the flywheel housing. Lower the generator until most of the set weight is supported by the blocking (see Figure 6-3). 22. 26. Remove the stator assembly, being careful not to drag the windings on the rotor. Place stator as sembly away from the chassis in the horizontal position. 27. Using the hoist and sling to support the rotor, care fully remove the capscrews and flat washers that secure the drive discs to the engine flywheel. I AWARN ING I Disconnect the grounding strap from the flywheel housing. ww 21 . Reposition or add hoist and sling support for the main rotor, and remove the forklift. See Rgure 6-5, Rotor Uft detail. j AWARNING I FIGURE 6-3. GENERATOR UFTlNG POSillONS 20. Being careful not to drag the windings on the rotor, move the stator assembly suffidently away from engine to sling and support the rotor assermly. Do not allow rotor assembly to hang on engine fly wheel. [ACAUTION I 25. .E lec MCA.JNTING FEET BRACKETS I Improper stator assembly rig ging and handling can resun In damage to stator and rotor assemblies. Lfftlng eyes may not be at center-of-gravity position of stator assembly. Therefore, lffting and moving the stator assembly alone, by hoisting at lifting eyes only, presents the hazard of load Imbal ance; allowing one end to drop and other end to rise. Make sure the stator is adequately hookedlstraped to maintain level control of stator assembly while lfftlng and moving. tM 1 8. ua ls 1 6. To prevent personal injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting. To prevent personal Injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting. Using a forklift, position a lifting bar of the forklift (inside and inline with the generator) under the rotor shaft. Lift the rotor shaft slightly so that rotor 6-3 l ua ls l tM an USE FORKLFT OR OTHER ADEQUATE UFTING DEVICE TO SUGHTLY UFT ROTOR SHAFT UNTIL ROTOR CAN BE SUPPORTED BY HOISTJSL.m. lP STATOR ASSEMBLY STATOR ca FIGURE 6-4. REIIOVWG w .E lec tri Remove the rotor asseni>ly and place it on wood blocks in the horizontal position. To avoid possible distortion, do not allow the drive discs and fan to rest on anything. ww - ar - - - - r::::·== • 28. .c om ROTOR ASSEMBLY LIFT STATOR ASSEMBLY LIFT 6-4 ASSEMBLY ROTOR ASSEMBLY .c om EXCITER STATOR RECONNECTION TERMINALS ua ls PMG EXCITER STATOR BLOWER END BEARING EXCITER ROTOR ROTATING RECTIFIER ASSEMBLY lP ar tM an COUPLING PMG EXCITER ROTOR AIR DISCHARGE COVERS ca ROTOR SHAFT lec tri All G-1185 .E STATOR UFT (EXAMPLE) ww w ROTOR UFT FIGURE 6-5. TYPICAL GENERATOR ASSEMBLY 6-5 Remove the fasteners from the two generator mounting feet brackets. 30. Using an adequate lifting device, lift the generator (at lifting eyes provided, and main stator housing) until the mounting feet brackets are clear of the frame member (see Rgures 6-5 and 6-6). Improper generator assembly rigging and handling can result In damage to stator and rotor assemblies. Lifting eyes may not be at center-of-gravity position of stator as sembly. Therefore, lining and moving the generator by hoisting at lining eyes only, pres ents the hazard of load Imbalance,· allowing one end to drop and other end to rise. Make sure the generator Is adequately hooked/ straped to maintain level control of assembly while lifting and moving. GENERATOR LIFTING POSrTIONS Remove the generator assembly away from en gine. Place generator assembly on floor with a piece of wood beneath the stator housing (toward PMG end) to allow for endbracket removal, if de sired. an 35. ua ls 29. .c om J A CAUTION J Generator Assembly Removal Bearing Removal tM The end bearing is enclosed in a pre-packed cartridge housing and must only be dismantled as n�essary for r� lubrication, replacement, or when a majOr overhaul IS carried out on the generator set. MOUNTING FEET BRACKETS lP BLOCKING UNDER ENGINE FLYWHEEL HOUSING ar Removal of the bearing can only be accomplished after removal of the endbracket, as follows: If generator set does not have chassis mounts at generator end (N855 and K1 9), block the rear of the engine in place by supporting the flywheel housing. A length of steel channel and wooden blocking is required to support the rear of the engine. Place the channel and blocking under the flywheel housing. Lower the generator until most of the set weight is supported by the blocking (see Figure 6-3). tri 31 . ca FIGURE 6-6. GENERATOR UFTING POSI110NS lec Disconnect the grounding strap from the flywheel housing. 33. Carefully remove the capscrews and flat washers that secure the drive discs to the engine flywheel. 34. Verify that the generator assembly is adequately supported. Carefully remove the capscrews se curingthe engine adaptor endbracket to the engine flywheel housing. 2. Remove cap. 3. Remove circlip. 4. Remove bearing cartridge housing complete with bearing. When replacing bearing onto rotor shaft, be sure to apply pressing force to the Inner face of the bearing only. • • • w AY!ARNING ; ww Remove the four screws holding bearing cap. Bearing Lubrication: When re-lubricating or replacing the bearing, review the following. .E 32. 1. To prevent persona/ Injury, use adequate lifting devices to suppon heavy compo nents. Keep hands and feet clear while lifting. 6-6 Recommended Lubricant: Lithium based grease, Mobilux No. 2 or Shell Alvania R3. Temperature Range: -22°F to +248°F (-30°C to +1 20°C} . Quantity: 2.74 oz. (81 ml). About a third of the grease should be inserted in the bearing, the bearing cap cavity, and the bearing cartridge cav ity. procedures. Position the end bearing cartridge as serrbly close to proper position for hole alignment with endbracket. d Using an adequate lifting device, locate the gen erator asserrbly into position near the engine fly wheel housing. Align the holes of the rotor drive discs with the holes of the engine flywheel. Install the capscrews and flat washers that secure the drive discs to the engine flywheel, hand tighten. I AWARNING I 1 0. Install endbracket to the stator frame using the proper capscrews and lock washers, but do not tighten securely as yet. 11. Insert and start the threads of the bearing cartridge fasteners, and remove threaded alignment studs, through the endbracket into the cartridge housing. 1 2. Uft slightly on endbracket and remove wooden whims holding rotor on center with stator. 1 3. Securely tighten the endbracket fasteners. 1 4. Tighten the bearing cartridge fasteners to 4.5 ft lbs. (6 N•m) torque. tM [ ACAUTION I Asserrble exciter stator, if removed, to inside of endbracket. Tighten fasteners to 4.5 ft-lbs. (6 N•m) torque. an To prevent personal Injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting. 9. ua ls To assemble the stator and rotor at the same time continue with step 1 . To assemble the stator and rotor In ividual ly' skip to step 1 6. 1. .c om G EN ERATOR REASSEMBLY Generator reasserrbly is the reverse of dsasserrbly procedure. Improper generator assembly rigging and handling can result In damage to stator and rotor assemblies. Lifting eyes may not be at center-of-gravity position of stator as sembly. Therefore, lifting and moving the generator by hoisting at lifting eyes only, pres ents the hazard of load Imbalance; allowing one end to drop and other end to rise. Make sure the generator Is adequately hooked/ straped to maintain level control of assembly while lifting and moving. Install the PMG exciter assembly, if removed. Refer to Permanent Magnet Exciter Installation, later this section. ar 15. lP ca Align the holes of the engine adaptor endbracket with the holes in the flywheel housing and install the capscrews and lock washers. Tighten to 45-55 ft-lbs. (61 -74 N•m) torque. Secure the rotor assembly to the flywheel. Tighten capscrews to 1 90-200 ft-lbs. (257-271 N•m) torque. 4. Uft the generator slightly and remove any blocking from under the flywheel housing. Lower the gen erator (see Rgure 6-3). lec 3. 5. To assemble the control housing, skip to step 34. 1 6. If removed, replace exciter rotor and rotating rec tifier assembly to main rotor shaft. Reconnect main rotor wire leads to positive and negative terminals of rectifier assembly. 1 7. If removed, install the drive disc spacer, drive disc, and pressure plate on the rotor shaft. Install the eight capscrews and flat washers and tighten to 352 ft-lbs. (476 N•m) on frame sizes 4 to 6, 607 ft lbs. (822 N•m) on frame 7. Note: 1 500 kW, frame 7 uses 1 2 capscrews. 1 8. Using a hoist and sling to support the rotor, align the holes in the drive disc with the corresponding holes in the flvwheel. tri 2. Perform the 'Aligning Generator with Engine' procedures, later In thla section, then return to the following steps. �onn� the grounding strap to the flywheel hous I AWARNING I .E Ing us1ng a capscrew and EIT locking washer·' and tighten securely. 6. To prevent personal Injury, use adequate lifting devices to suppott heavy components. Keep hands and feet clear while lifting. Install the mounting feet bracket fasteners·' and tighten securely. 19. If endbracket has been removed, continue with step 7, otherwise w skip to step 15. ww 7. 8. Uft slightly on end of rotor shaft and install wooden shims to hold rotor on center with stator. Secure the rotor assembly t o the flywheel using appropriate capscrews and flat washers. Tighten to 1 90-200 ft-lbs. (257-271 N•m) torque. Do not allow rotor asserrbly to hang on engine flywheel. (Refer to Figure 6-4.) I ACAUTION l Press bearing onto rotor shaft, applying force to the inner face of the bearing. Install two threaded studs into end bearing cartridge to aid subsequent 6-7 Drive disc damage can be caused by allowing the rotor assembly to hang on flywheel. Use adequate holst and sling to support the rotor assembly. 28. I AWARN ING I 29. Install endbracket to the stator frame using the proper capscrews and lock washers, but do not tighten securely as yet. 30. Insert and start the threads of the bearing cartridge fasteners, and remove threaded afignrnent studs, through the endbracket into the cartridge housing. 31 . Lift sfightly on endbracket and remove wooden shims hok:fing rotor on center with stator. To prevent personal Injury, use adequate lifting devices to suppon heavy components. Keep hands and feet clear while lifting. ging and handling can result In damage to stator and rotor assemblies. Lifting eyes may not be at center-of-gravity position of stator assembly. Therefore, lifting and moving the stator assembly alone, by hoisting at lifting eyes only, presents the hazard of lOad Imbal ance; allowing one end to drop and other end to rise. Make sure the stator Is adequately hoolcedlstraped to maintain level control of stator assembly while lifting and moving. an Improper stator assembly rig 32. Securely tighten the endbracket fasteners. 33. lighten the bearing cartridge fasteners to 4.5 ft lbs. (6 N•m) torque. 34. Remove generator lifting eyes. Reasserrble con trol housing mounting brackets to sides of genera tor and fasten securely. ar Using a forkfift, position a lifting bar of the forkrlft (inside and inAne with the generator) under the rotor shaft. Uft the rotor shaft sHghtly so that rotor is not resting on inside of stator assembly. See Rgure 6-4. Assemble exciter stator, if removed, to inside of endbracket. lighten fasteners to 4.5 ft-lbs. (6 N•m) torque. tM / A CAUTION J 21 . .c om procedures. Position the end bearing cartridge as sembly close to proper position for hole alignment with endbracket. Reassemble engine adaptor endbracket to stator frame if removed. Using an adequate lifting de vice, carefully move the stator into position over the rotor assembly, being careful not to drag the windings on the rotor. ua ls 20. 23. lP Remove the hoisVsling support of the rotor assem bly. Align the holes of the engine adaptor end bracket with the holes in the flywheel housing and install the capscrews and lock washers. lighten to 45-55 ft-lbs. (61 -74 N•m) torque. ca 22. 35. Using an adequate lifting device, sfightly raise the generator so that the wooden blocking and steel channel can be removed from under the flywheel housing; then lower the generator so the full weight is resting on the generator mounting feet brackets. Use an adequate lifting device to fift the control housing in position for mounting to the stator frame. Replace the capscrews and lock washers and tighten to 20 ft-lbs. (27 N•m) torque. \ AWARNING I To prevent personal Injury, use adequate lifting devices to suppon heavy components. Keep handS and feet clear while lifting. Reassemble any engne air intake components removed during generator disassembly. Perform the 'Aligning Generator with Engine' procedures, later In this section, then return to Step 24. 37. Connect all control wires and generator leads using the proper generator set AC and DC wiring diagram/schematic. 24. Reassemble the covers over the generator air dis charge openings and fasten securely. 38. Refer to Permanent Magnet Exciter Installation. 25. Connect the grounding strap to the flywheel hous ing using a capscrew and EIT locking washer; and tighten securely. 39. H equipped with the cirruit breaker option, recon nect load wires to cirruit breaker. Reconnect all lead wires to the terminal block assembly using proper reconnection diagram in Section 7. 26. Install the mounting feet bracket fasteners; and tighten securely. .E lec tri 36. w 40. Verify that all connections are proper and secure and then install the air inlet panel and access covers to control housing (see Rgure 6-1 ). Press bearing onto rotor shaft, applying force to the inner face of the bearing. Install two threaded studs into end bearing cartridge to aid subsequent ww 27. 41 . 6-8 Connect the negative ( ) battery cable and test the generator set for operation. - .c om Permanent Magnet Exciter Installation . 2. Install the CO!ll>lete exciter rotor assembly to the end of the main rotor shaft using the hex head through-bolt. Keep the rotor clean by avoiding con tact with metal dust or particles. Carefully locate the exciter stator housing to posi tion on the generator endbracket. Fasten in place using the 4 bolts and cla!Tl>s, and tighten securely. ua ls 1 Misalignment Symptoms: If the assembly is allowed to run under these conditions, the discs must flex in alternate directions twice for each engine revolution. It is irr()Ortant to minimize the amount of disc flexing since, if it is exces sive, the drive disc will crack. Although perfect bearing alignment is desirable, it is more illl>Ortant to keep disc deflection to the mini!Tl.lm possible. This procedure assumes that the pilot bore of the drive discs are in the exact center and the flywheel counterbore (pilot) has no practical runout. Under these conditions, perfect Angular alignment will be attained when no deflection of the disks is measured. The highly magnetic rotor will attract the stator core, care must be taken to avoid any contact which may damage the windings. Excessive Axial nisalignment will cause more generator vibration than Angular nisalignment. Connect the PMG wiring harness connector. 4. Install the PMG exdter assembly cover using the three M5x1 2mm capscrews and lockwashers, and tighten securely. Axial misalignment should be checked only when an objecdon able vibration Is present an 3. Either type off misalignment may be present in a genera tor set assembly, with angular nisalignment being the most common problem. Angular alignment may also be effected by set installation conditions and/or nishandling during shipping of the genset. Aligning Generator with Engine tM Proper alignment of the generator and engine assemblies is necessary to avoid premature wear and i!Tl>roper operation of the genset. Review the following alignment conditions and procedures for aligning the generator assembly to engine flywheel housing. Angular Alignment Procedure (V28 and larger engine gensets): I AWARNiNG] lP ar Angular Alignment: Is the result of the generator bear ing center axis not aligning with axis of the engine crank shaft. This condition creates an angle between the generator shaft axis and the crankshaft axis. The cause of this type of misalignment is usually shimning error. Fasten a dial indicator to either the generator shaft or the cooH ng fan with the sensing point resting on the capscrew head or the flat surface of the drive disc at the bolt circle diameter, see Figure 6-7. Bar the engine over in a ww w .E lec tri ca Axial Misalignment: Is the result of the generator shaft axis not aligning with engine crankshaft axis. The toler ances in the bolted flywheel and drive disc connection may add up to displace the generator axially relative to the crankshaft axis. Accidental starting of the generator set during this procedure presents the hazard of severe personal Injury or death. Make sure to discon nect the negative (-) battery cable(s) before begin ning. DETAIL A SHIMS FIGURE 6-7. ANGULAR AUGNMENT MEASUREMENT 6-9 uring at. (For exafll>l e; a SAE 18 Disc coupling distance is 1 0.7"). 2. Measure the distance from the generator side of the flex discs to the center of the generator mount ing bolt, refer to Rgure 6-7. (For exafll>le; a HC6 Frame's distance is 28.4".) 3. Cofll>are the distance measured in steps 1 and 2. (28.4" vs 1 0.7'' or a 2.65 to 1 ratio.) Multiply this ratio times one haH the T.I.R. (In our example, .025" divided by 2 is .01 25". This, times 2.65 equals .033". Therefore, remove .033" of shims from under both mounting feet.) ua ls Sample Generator Runout Readings: When taking the deflection readings described, make a diagram sirrilar to the example shown in Rgure 6-8, where a total indicator reading of .025". (The highest positive value of +.010 and the largest negative value of -.01 5".) The indicator is closer to the top and further a»�ay at the bottom. This exafll>le indicates that the generator bearing is high. Since the side readings are equal, the generator is cen tered side to side. To lower the generator, remove equal shims from under both generator mounting feet. To ap proximate the amount of shims to remove or add: an In general, the T.I.R. should not be more than .001 " for each inch of radius (center of shaft to indicator axis). H we use our example of 1 0.7", then the maximum T.I.R. would be .01 1 ". This would only require a correction of .014" from the T.I.R. of .025". (A readi ng of +.002 at the top and -.009 at the bottom would faD within the satisfactory range.) Measure the dstaoce between the center of the generator shaft to the poirt is meas- tM the incicator lP ar 1. .c om clockwise rotation as viewed from engine flywheel. Do not allow it to roll back on COfll>ression at the end of the travel of each reading. It is unnecessary to zero the indicator since the total indicator reading (T.I.R.) of the deflection measurement to the bolt heads is what is required. T.I.R. will be the sum of the maximum positive and negative dial indicator readings as the engine COfll>letes one revolu tion. tri ca M:ASUREO AT 801..T CIRCLE DIAMETER ww w .E lec 10.7 IN. 0 0 -.015 01 5 -. RGURE 6-8. ANGULAR ALIGNMENT MEASUREMENT READINGS (Example) 6-1 0 .c om Specific out-of-tolerance runout levels are difficult to establish due to the varying surface quality of the genera tor shaft's drive disc mounting hub. Axial Alignment Procedure (all gensets): Axial misalignment should be checked only when an objection able vibration Is present The goal of the Axial realignment is to reduce the vibration level of the genset while it is operating. A small improve ment in the T.I.R. runout may have dramatic effects in the mechanically measured or physically observed vibration levels. If excessive vibration remains after the angular alignment, check for concentric alignment of the generator shaft/ engine crankshaft axes. ua ls Fasten dial indicator holding device to skid base, engine block, or generator shell with a magnetic base or damp and position so the sensor point of indicator rests on the generator shaft hub, see Figure 6-9. Bar the engine over in a clockwise rotation as viewed from engine flywheel, through a couple of rotations. Record indicator readings in eight equally spaced points around the shaft diameter. This will provide a T.I.R. for Axial shaft misalignment. To correct for an out of tolerance T.I.R. indication, remove the capscrews connecting drive discs and flywheel. Mark the drive discs and flywheel with respect to each other. Rotate either the engine or generator so that drive discs holes are repositioned 1 80 degrees from their original location. Put the drive discs capscrews back in and re torque. Recheck shaft alignment as before. If shaft T.I.R. runout remains unchanged then the discs should be ro tated to either 30, 60, or 90 degrees from original location to correct the out of tolerance condition. If the T.I.R. does not irrprove after repositioning, a doser inspection of the flywheel pilot and drive disc runouts is required. This will help determine the cause of the Axial misalignment. lP ! ca � GENERATOR SHAFT HUB ww w .E lec tri � ar tM an The maximum allowable T.I.R. runout is subjective, the optimal T.I.R. for runout would be .000", however that may not be attainable. The recommendation of this procedure will be to redJce the measured T.I.R. runout by one half. DETAIL A FIGURE 6-9. AXIAL ALIGNMENT MEASUREMENT 6- 11 w ww .E lec an tM ar lP ca tri ua ls .c om .c om Section 7. Wiring Diagrams Control/G enerator This section contains the following AC and DC Wiring Diagrams/Schematics: ua ls TITLE PAGE(S) tM an DC Wiring Diagram/Schematic (7-Light) .......... ................. ........... ................ ...... ...... .... .............................. . . .... 7-2/3 DC Schematic - Ladder Diagram (7-Light) ............................. . ....................................................... . . . . ............. 7-4/5 Detector-7 ECM - PCB Assembly . ........................................................ . . ...................... . . . . . . . . . . . . . . . . . . ................. 7-6/7 DC Wiring Diagram/Schematic (12-Light) . . . . . . . . .. ........................................................................ . . . . . . . . ... . . . ........ 7-8/9 DC Schematic - Ladder Diagram (1 2-Light) ...................................... ......................................................... 7-1 0/1 1 Detector-1 2 ECM -PCB Assembly .................... .............. ................................................................ ............. 7-1 2/1 3 Detector-1 2 ECM - Functional Diagram . . .. . . . . ................. ............................................................ ...... ................ 7-1 4 AC Reconnect Wiring Diagram . ............................... .. . ................................................................... ............... 7-1 5/1 6 AC Wiring Diagram'Schematic (W/0 Meters) ....................................................... ......... . . . . . . . . . . . . . . . ................ .... 7-1 7 AC Wiring Diagram'Schematic (With Meters) ............................................................................... .................... 7-1 8 PMG Voltage Regulator Installation Wiring Diagram . . ................................................................. ................. ... 7-1 9 PMG Voltage Regulator Technical Data .................................................. ............ ... .......................................... 7-20 Time Delay Start/Stop Module 7-21/22 Engine Sensor Locations (L 10 Series) . ............................... ........... .......... ................ . . . . . . . . . . . . . . . . ......................... 7-23 Engine Sensor Locations (NT855 Series) .................................. ....................................................................... 7-24 Engine Sensor Locations (KT19 Series) ....................... ................ ........................................ . . . .. ............ . . . . . . . . . .. 7-25 Engine Sensor Locations (VT28 Series) ................................. ........ .......................... . . . . . . . . . . .............................. 7-26 Engine Sensor Locations (KT38 Series) ......................................................... ........... . . . . . . . . . . . . . . . . . . .......... ........... 7-27 Engine Sensor Locations (KT50 Series) ..................... . . . . ............................. .............. . . . . . . . . . .. . . . .. ....................... 7-28 tri ca lP ar ............................................................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .............. ( ACAUTION I ww w .E lec Repair of printed circuit board components other than fuses requires well trained, qualified personnel with the proper equipment; repair of the printed circuit boards Is not recommended except by the factory. Application of meters or hot soldering Irons to printed circuit boards by other than qualified personnel can cause unnecessary and expensive damage. 7- 1 w ww .E tri lec an tM ar lP ca ua ls .c om 0 3 4 5 D SCHEMAT I C D I AGRAM IGN I T ION Al l RUN D STOP 2 REMOTE 5 SW OFF B+ 1 2 S 11 � J4 4 J: J4 I Jr---- I I u 'L------< S I 5 ._ JI _ _ _ _ _ CUST GND CONN I p1 4 _,.. ( I OA ) P ---j S I T"',..._.=L� D::._ _.,. 4 ' __:�- P2 TB I � 1 P2 _.,. I P2-+ 2 c P2 TO AC WO . 1 20VAC ZONE 6 - C CR I AL T J3 { D---J;< <>----:Ji" CR I -2 START I I 2 I P3 KI0 n pI F4 5A K l 4 TB I TB2 RUN ( . 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PE .c om 2 I DATE � Il-l l.f./1. ,__ 0 ua ls 3 - tM an STAR TER CONF I GURA T I ONS c l JNS ca lP ar SOLENO I D S � F � 1 2 V D C /2 4 V D C -l BT3 ---E3]_ ":' 6 I I ! lec i O LT tri ---�-- - - JNS 4 VOLT ww w �AI I-TBI-10 .E --------r---�� CAOAM SYSTEM OWG TILEII...CES I.H.ESS DO NO T SCALE PRINT � I ITEM \P'-RT I 0� � r-. CJI 1 CASALENDA . J � C/J PRO..EC TICN 'W "--.1 ::z Cttlfl M . REED - P . ERI CKSON ""' - "' 1 � � ="r-' OnE:RWISf SP£ClfiED SilO TO ���. - :x: ��: === :'�;0€' ""-"", .'.:: "_, \ � oo> ' "' "'Q.ES• - ���� li � A 1 · �ED " ...._. �" I ...0 Mm m -�- J � I � OTY \DESCRIPTION \i 06-25-87 07 02 87 lU \07:0,:87 WD-GEN SET DC CONT ( 7LT l 0 :;.!JI!?c IJ.:' �·f r"' '" 6 1 2 - 6 4 8 7 �D j •IIU.JC C».fE tR MAnoRIAL B 01 FROt.t SHEET 01 WIRE W 0 fT1 .,.., 0 FROt.t SHEET 01 WIRE Y FROt.t SHEET 01 WIRE X K17 l-----...,.j RESETI1s j l K15 ----_j �------_JRESE T/1! 1 ,----- --2 I � '-.J ...... 0 I 0 U'l � I RUN LIGHT 0512 0518 8 TB1 Jj TB2 N 0 I " " ' ' ," -�------::::-�K� j � tri 0 0517 L,J " 3 1 .E lec I '"'"�' H.E.T. 0 P3 0516 (( 10 LO .P. P3 0515 11 PRE H.E.T. P3 -{SO a 11 2 � Ci .... "' REt.tOTE LAt.tP .... 01 K9 -� 4 6 � K9 c.o m � P3 FROt.t SHEET 01 WIRE Z )> K10 ca O'<£R CRANK a KH c t: C) ::r: .::f _.. 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REI FOI A) Bi - 02 & .E lec -0 1 -04 - tri B -03 tM -04 ar c - 02 lP -03 & -0 1 OTY I TEI I W I T H PNL W / O U T P N L VOLTAGE VOLTAGE A D J US T ADJUST I I I I I - 't�3' ' I � 1':" ;�� ) I� I� I § � - - / ww w EXCITER FIELD TO DC CONT ,J I - 1 6 5 PMG VOLTAGE REGULATOR INSTALLATION WIRING DIAGRAM 7-1 9 J l -2 16 4 a 90 2 I 72 337 1 3 ER NO I L TR NO 32 A 8 B 34 1 64 C I I 6 1 508 62 1 71 H 62569 I G 63249 ITEM 8 RE�JVEO "TAB" ADD OTY I ADDEO ITEM I 7 TO PARTS LIST I TEM 16 liAS 8 1 5-0218 (6-32 X I ) DELETED 34566 1 R E V I S ION PROOLX:TION RELEASE ITEM 10. JC ITEM 18 B PE JC B PE JC GP PE 2A JC GP PE 2A JC GP PE JC OS B PE JC c PE 28 REVISED PER ER REVISED PER ER REVISED PER ER JC REVISED PER ER JC 1 0 - 1 1 -88 0 1 - 1 &- 89 0 1 - 16-89 0 1 ·29-89 01 -29-89 01 -29-89 05-08-89 06- 1 7 - 9 1 1 2 -09-9 1 0 1 - 29-92 OG JC 28 2A 226-3939-02 I T E M 6 WAS 226-3939-09 ADDED H ON[ D R CKHR APPROVED D A T E 2A .c om 3 JAD PE -\'5- T A B U _ A T I O� I I - - I I I OR ' lE D ARE IS TO - I ND = C A TE l L L ,J S T R A T I O I� EXTRA WIPE I N TO - - I 'w H E �j I I I - DRAwiNG 5 3 Ci - 0 7 4 FROM , VR2 1 TO 8 OTY . I TEM OTY . I TEM OTY . 4 4 4 23 24 4 .E w I T EM 26 OTY . I T EM I I - - - - - - - - - D T >" . I T E �-1 28 0'Y . I - - - - - - - - - - I - I ---=- - - - - - - A TAB LEAD ( T 3 0 - 0U T - 6 : TAB LEAD I T 3 0 -0UT - 7 , 29 226-4458-04 A TAB LEAD I T 3 0 - 0U T - 8 , LEAD LEAD I T30- I N - 7 , I T30- I N -8 , 28 226-4458-03 A TAB 27 226-4458-02 TAB 226-4458-0 I A 26 A TAB 24 526-0008 - p 23 8 1 3 - 0 1 08 22 332- 1 57 1 21 350 - 1 224 20 305-0868 c 226-3942-07 B p B 19 18 17 16 3 3 2 - I 043 8 1 2 - 0084 c T AB I T 30- IN-6 , LE A D LOCK'WASHER # I 0 TAB SCREW-RHSM TAB T E R M I NAL T AB WASHER-FLAT VR2 TB2 1 - 2 2 I TB2 I I 0 - 32 X 1 - LEAD I VR2 i - I ; LEAD 14 226-3942-04 B 226-3942-03 B TAB I I 226-3942-02 B TAB LEAD 226-3942 - 0 1 B T A B LEAD 9 51 7-0131 A 8 350- 1 222 A 226-3939-08 B TAB LEAD 226-3942-06 B TAB LEAD 5 226-3939 - 0 1 B TAB LEAD 4 8 1 5-0544 3 3 1 9 - 0 652 2 305- 0823 LEAD LEAD B /2 1 VR2 1 - 2 1 JUMPER SCREW-RHM -25 I ADAPTOR TAB TAB I I I #10 R E S I S TOR ASSY 4 -7 I VR2 1 - 8 1 TB2 1 - 23 1 TRANSFORMER PC B - I SL N B I c VR2 1 - 6 1 TAB 226-3942-05 12 - - TAB 15 i 3 3 1 I A 850-0030 I T EM I I : - - 226-4458-C6 OTY . 30 226-4458-05 25 VR 2 1 - 6 . OTY . I TEM r -E" 29 30 31 @ ® @ I I - - 27 - - I 8 - 32X I I I VR 2 1 - E O , T B 2 1 - 2 3 1 I VR2 1 - E I , T B 2 1 -22 I I VR2 1 - ( , TB2 I - 2 3 I I VR 2 1 - 8 , T B 2 1 - 2 2 1 I VR 2 1 - 6 , T B 2 1 - 2 5 1 1 0 7 6 18 43 ww OTY 4 - VR2 1 - 6 . TO I TE M 25 4 - PANEL . USED HARNESS LEA� - - - & I I W I TH RECONNECT 2 P H A S E S E NS I N G . I 1 EM 22 - - - I OTY . - I - 2 I I I 2 I OTY . I TEM 2 1 20 lec JUMPER I I 2 PHASE GENERATOR OPERA T I ON D I SC O N N E C T L E A D F R O M T 6 2 1 - 2 5 C O �N E C T 2 - I I OTY I T EM - I I I T EM 1 8 - I - IJTY . - - QUIET SITE I C O N NE C T E D F O R L E AD S OTY . I TEM 1 3 - - I - 04 - - I I EP - - ITEM 1 2 an I - OTY . I I tM - :JTY . I T EM ar - OT Y . I TEM 7 lP I TE M 6 ca OTY . 5 tri OTY . 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DATE C L AS S 8 S E T S l CB ASSY - TO S T AR T /ST O P 1 2 4V Till£ OWG 1110 . \17z\\r 100 - 7899 rf:�G.�:;:�·.��,. 1 J .c om LEGEND A1 1 - ENGINE CONTROL MONITOR PCB B1- STARTER E1 - OIL PRESSURE SENDER E2- WATER TEMPERATURE SENDER E4 - OIL TEMPERATURE SENDER S4 ua ls G1- ALTERNATOR K 1 - FUEL SOLENOID K2- STARTER SOLENOID S1- LOW OIL PRESSURE SWITCH S2- HIGH ENGINE TEMP. SWITCH S4-- LOW ENGINE TEMP. SWITCH S!>- PRE-LOW OIL PRESSURE SWITCH S6- PRE-HIGH ENGINE TEMP. SWITCH (20 AMP) tM an T26- SW. B+ ar E1 MAG lP PICKUP tri A 1 6-3 ca A 1 6- 1 \) S6 Q E2 S2 DETAIL A E4 R1 CON NECTOR SLEEVE T B 1 -2 T B 1 -8 A 1 6-4 .E lec K2-BAT K2-(+) CR1 K2 K2-S J2 (CNTRL) ww w GND (CNTRL) REF. DRWG. NO. 338-2726 TB1 -8 TB2 1 - 2 1 ENGINE HARNESS DIAGRAM ENGINE SENSOR lOCATIONS (llO SERIES) 7-23 A11 .c om ENGINE T E M P E RATURE SWITCH ua ls PRE-HIGH PRE-LOW OIL PRESS U R E SWITCH COOLANT LOW ENGINE TEMPE RATURE GAUGE TEMP ERAT U R E SWITCH SENDER an HIGH ENGINE TEMP ERAT U R E ca tri 0 lec D lP ar tM SWITCH ww w .E OIL LOW OIL PRESS U R E GAUGE P R ESSUR E SENDER (FAR SIDE) (FAR SIDE) SWITCH OIL TEMP ERATURE SENDER REFERENCE DRAWINGS: GENSET OUTLINE - 500-2781 ENGINE ACC. - 1Q0-3075 S6 E2 .c om LEGEND A 1 1 - ENGINE CONTROL MONITOR PCB 81- STARTER S4 S2 E1 - OIL PRESSURE SENDER E2- WATER TEMPERATURE SENDER K1 ua ls G 1 - ALTERNATOR K1- FUEL SOLENOID K2- STARTER SOLENOID S1- LOW OIL PRESSURE SWITCH S2- HIGH ENGINE TEMP. SWITCH S4-- LOW ENGINE TEMP. SWITCH S5- PRE-LOW OIL PRESSURE SWITCH T26 S6- PRE-HIGH ENGINE TEMP. SWITCH T26- SW. B+ (20 AMP) an G 1 -D+ GND (ENG) tM G 1 -GND ar S 1 -2 8 1 -SW lP S5 .E DETAIL A R1 w ww SLEEVE CR1 SPLIC E GND (ENG J1 GND (CNTRL) REF. DRWG. NO. 338-2622 CONNECTOR TB 1 -8 lec K2 tri ca E1 T B2 1 -2 1 ENGINE HARNESS DIAGRAM ENGINE SENSOR LOCATIONS (KT19 SERIES) 7-25 ZENER DIODE .c om PRE-HIGH ENGINE TEMPERATURE HIGH ua ls LOW ENGINE T E M P E RATURE SWITCH ENGINE T E M P E RATU R E SWITCH SWITCH an COOLANT TEMP ERATURE GAU G E ca lP ar tM SENDER tri D LOW OIL PRESSURE lec PRE-LOW OIL PRESSURE SWITCH (FAR SIDE) SENDER (FAR SIDE) ww w .E SWITCH (FAR SIDE) OIL PRESSURE GAU G E REFERENCE DRAWINGS: 500-2649 GENSET OU1UNE - 500-2619 & ENGINE ACC. - 100.281!6 .c om LEGEND A1 1 - ENGINE CONTROL MONITOR PCB S2 B 1 - STARTER E1 - OIL PRESSURE SENDER ua ls E2- WATER TEMPERATURE SENDER G 1 - ALTERNATOR S6 K1- FUEL SOLENOID K2- STARTER SOLENOID E2 S1- LOW OIL PRESSURE SWITCH S2- HIGH ENGINE TEMP. SWITCH S4- LOW ENGINE TEMP. SWITCH S2 S5- PRE-LOW OIL PRESSURE SWITCH an S4 S6- PRE-HIGH ENGINE TEMP. SWITCH T26- SW. B+ (20 AMP) ca lP ar tM K1 DETAIL A lec tri B 1 -SW K2-BAT � GND .E K2-(+) S P UC E SEE DETAIL A - TB1 -8 T B 1 -2 TB1 -8 A1 1 TB2 1 - 2 1 ENGINE HARNESS DIAGRAM ENGINE SENSOR LOCATIONS (KT38 SERIES) 7-27 ZENER DIODE J1 w ww ENG GND (CNTRL) GND (CNTRL) SLEEVE T B 1 -8 K2 REF. DRWG. NO. 338-2624 CONN ECTOR R1 S 1 -2 CR1 .c om ua ls LOW ENGINE T E M P E RATURE an SWITCH PRE-HIGH ENGINE TEMPERATURE SWITCH lP ar tM (FAR SIDE) lec tri ca D OIL SWITCH PRE-LOW OIL PRESSURE SWITCH (FAR SIDE) (FAR SIDE) LOW OIL P R ESSU R E P R ESSU R E ww w .E GAUGE SENDER COOLANT T E M P E RATURE GAUGE SENDER REFERENCE DRAWINGS: GENSET OUTLINE - �2714 ENGINE ACC. - 1CJ0-2925 ww c w tri lec , .E an tM ar c lP ca ua ls .c om c .c om ua ls an tM ar lP ca tri lec .E w Onan Corporation 1 400 73rd Avenue N. E. ww Minneapolis, MN 55432 61 2-574-5000 Telex: 275477 Fax: 61 2-574-8087 Onan is a registered trademark of Onan Corporation \