Onan UR Generator Manual Pub 900 0150
Onan UR Generator Manual Pub 900 0150
Onan UR Generator Manual Pub 900 0150
Please adjust your printer settings according to the size of each page you wish to print.
Service Manual
2 5 t o I 8 0 kW
900-0150
10-78
Printed in U.SA
Safety Precautions
The following symbols in this manual highlight conditions potentially dangerous to service personnel, or equipment. Read this manual carefully. Know when these conditions can exist. Then take necessary steps to protect personnel as well as equipment. moving parts, etc. Do not work on this equipment when mentally or physically fatigued.
This symbol is used throughout the I W A R N I N G 1 manual to warn of possible serious personal injury. This symbol refers t o possible equipment damage.
If you must make adjustments while the unit is running, use extreme caution around hot manifolds,
Follow all state and local codes. To avoid possible personal injury or equipment damage, a qualified electrician or an authorized service representative must perform installation and all service.
If you experience any of these symptoms, get out into fresh air immediately, shut down the unit and do not use until it has been inspected.. Thebest protection agalnst carbon monoxide inhalation Is proper installallon and regular, frequent visual and audible inspections of the complete exhaust system. If you notice a change in the sound or appearanceof exhaust system, shut the unit down immediately and have it inspected and repaired at once by a competent mechanlc.
TABLE OF CONTENTS
'
PAGE ' Introduction .......................................... :................ 2 Generator - Section I ................................................. 5 Question and Answer Troubleshooting Guides. .......................... 8 Adjustments and Procedures ............................................ 16 Generator - Section II ............................................... 26 Question and Answer Troubleshooting Guides. ......................... 27 35 Adjustments and Procedures ........................................... Index of Generator Adjustments and Procedures. ....................... 38 Control Section 111 ................................................. 39 Question and Answer Troubleshooting Guides. ......................... 40 Adjustments and Procedures .......................................... 51 Wiring Diagrams ..................................................... 53
ONAN RECOMMENDS THAT ALL SERVICE, INCLUDING INSTALLATION OF REPLACEMENT PARTS, BE PERFORMED BY QUALIFIED PERSONNEL.
I
Redistribution or publication of this document, by any means, is strictly prohibited.
INTRODUCTION
FOREWORD
This manual provicds troubleshooting and repair information for ONAN series UR generators. It is intended to provide the maintenance technician, serviceman or Onan distributor with a logical procedure to enable him to systematically locate and 'repair malfunctions in the generator and control systems. This information is not applicable to the prime mover; refer to the engine manufacturer's manual. Repair information is not extensive because the plugin solid-state printed circuit modules lend themselves more to replacement than repair. ONAN does not recommend repair of the printed circuit module, except at the factory and has initiated a returdexchange service, obtainable through distributors, whereby faulty modules can be returned and exchanged for good units. For more information, contact your distributororthe ONAN service department.
Application of meters or high heat soldering
tion on later UR generator. Section 11 contains troubleshooting information for the later model UR generator where the exciter diode rectifier assembly has been relocated into the contrd panel. Refer to Table 1 for a description of t / : f . appropriate section for your generator.
2 . CONTROLS - S e c t i o n 111 c o n t a i ! $ s troubleshooting guides and procedures lor testing and repairing the system controls, P description of the components and an analysiz' ti+ the module circuitry is included.
'
TEST EQUIPMENT
Most of the tests outlined in this manual can be performed with an AC-DC multimeter such as a Simpson 260 VOM. Other suggested test instruments are ONAN multitester Part No. 420-0303 Wheatstone or Kelvin bridge
Exercise care when purchasing a foreign made VOM. Some units deliver +9VDC, others, +22VDC to the circuit under test on R x 1 scale. Maximum recommended voltage is +l.SVDC. Damage to solid state devices can result from excessive voltage application.
- Section I contains general specifications on the U R generator, troubleshooting guides and procedures for testing and repairing of the early UR generator with VR22 exciter regulator and general informa-
I
CONTROL FAILS CONTROL SECTION Ill
'
2
Redistribution or publication of this document, by any means, is strictly prohibited.
Section 1 Spec A
kW Model
25.0 EK 30.0 EK Penn EK 25.0 DDA 3 . DDB 00 30.0 DEH 25.0 MDEH 30.0 MDEH Penn DEH 37.5 EM 45.0 EM Penn EM 37.5 DEF 45.0 DEF Penn DEF 37.5 DYJ 45.0 DYJ 40.0 DDB 50.0 DDB 40.0 DEG 50.0 DEG Penn DEG 40.0 MDEG 50.0 MDEG 45.0 KB 55.0 KB Penn KB 50.0 DYA 60.0 DYA Penn DYA 55.0 EN 70.0 EN
Frequency 50 Hz 60 Hz 50 Hz 60 Hz 60 Hz 50 Hz 60 Hz
kW Model
55.0 KB 5 . KB 50 "enn KB 50.0 DYC 7 . DYC 50 30.0 DYC 100.0 DYC 'enn DYC 7 . KR 00 3 . KR 50 Penn KR 7 . DYC 50 30.0 DYC 30.0 DYD 100.0 DYD Penn DYD 3 . WA 50 . 115 0 WA 100.0 DYD 125.0 DYD Penn DYD 115.0 WE 140.0 WE 125.0 WE 150.0 WE 125.0 DYG 150.0 DYG Penn DYG 130.0 DFE 155.0 DFE Penn DFE 140.0 WB 170.0 WB 145.0 DYG 175.0 DYG Penn DYG 150.0 DFE 180.0 DFE Penn DFE
Frequency
1
j
Section 1 Spec A
ThN
R P
'
E D E
D
D C E
50 Hz 60 Hz
E
D E H F G
50 Hz
60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz
G E F F E
50 60 50 60
Hz Hz Hz Hz
R
P Q E
50 Hz 60 Hz
60 Hz 60 Hz
C D
F F F A A G G G G F F F J J J A A A A H H H H H S S S F F F A A
50 Hz 60 Hz 50 Hz 60 Hz 50Hz 60 Hz 50 Hz 60 Hz
50 Hz 60 Hz 50 Hz 60 Hz
'
c
R
P
D B
Q
D B C A B H G C A B B B B B C A B
50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz60'HZ
50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz
S S S E E G G 'E S S S E E . D D D J J D D D
D D D H H H
K J C A B
L L
D D D H H H
50 Hz 60 Hz
3
Redistribution or publication of this document, by any means, is strictly prohibited.
RATING
I_
:ode
60 -
1-PHASE STANDARD
1-PHASE
:ode
kVA 31.25 37.50 46.80 50.0 56.25 62.5 68.75 75.0 78.13 81.25 87.5 93.75
X
15 515 -
kW
25.0 30.0 37.5 40.0 45.0 50.0 55.0
50 X
a 2 gg K -@@
SPE -
L--
156
c c 0 0 -g -g 95 90 E7 104 142 152 135 144 162 180 198 130 139 156 173 191 208 237 226 217 226 266 285 304 253 271 289 243 260 278 295 312 361 343 361 415 330 347 399 312 328 377 230 246 262 205 123 131 148 164 180
- - 82 98 123 131 148 164 180 197 205 213 230 246 262 279 295 312 328 377 298 314 361 220 235 251 196 118 126 141 157 173
3-PHASE
0 0
78
g g g g - --g - - - k y 600
- - - -
E E
45
142
X
136
82
47 90 90 71 76 135 150 165 180 135 150 165 180 119 195 210 226 195 210 226 133 142 152 256 27 1 256 271 180 301 346 301 346 190 218 85 95 104
45
43
41 49 62 36
. 52
68 72 81 90 99 65 69 78 87 95 104 113 108 113 126 135 144 121 130 139 147 156 171 180 207 165 173 200
X X
X X X
66
74 82 90 98 103 107 115 123 131 139 148 156 164 189 150. 173 120 138 128 135 102 108 98 105 113 78 84 90
234
68
75 83 90
54
X
X
60
66 72
X X
60.0
62.5 65.0 70.0 75.0
4
X
X X
355
340 339
365 391
X X
80.0 85.0 90.0 95.0 100.0 115.0 120.0 125.0 130.0 140.0 145.0 150.0 155.0 170.0 175.0 180.0.
100.0
106.25 112,5 118.75 125.0 143.75 150.0 156.25 162.50 175.0 181.25 187.5 193.75 212.5 218.75 225.25
HZ only.
X
X X
X
X
X X
568
380 437
- .
475 494 451 469 505 523 541 434 451 486 503 520 538 590 607 625 410 426 459 476 492 410 426 459 476 492 508 558 574 591 392 408 439 455 471 451 466 51 1 526 542 451 466 51 1 526 542 42 1 421 376 376 237 247 266 275 285 226 235 253 262 271 217 226 243 252 260 269 295 304 313 205 213 230 238 246 254 279 287 296 226 233 256 263 271 180 186 204 210 210 168 188 150
X X X
X X X X
0- o:,
- @ - 50- and 60 Hz
@Not Reconnectible.
217
@ - 60 Hz only.
. . .
. -
. ..
..
- .
GENERATOR
- SECTION I
COMPONENT LOCATION
To gain access to generator, remove grille section below control box.
1 . Exciter-regulator chassis assembly VR22 mounts on the rear portion of the generator; SCRs (silicon controlled rectifiers) and diodes are easily accessible for testing. See Figures 1-3. 2. On static-excited generators, brushes attach to the brush rig inside of end bell housing; inspect through large access holes in the end bell. See Figure 1. 3. On brushless models, rotating exciter assembly mounts directly behind exciter-regulator chassis assembly with all diodes accessible for servicing. See Figure 2. 4. Voltage-regulator PC Board VR21 (Printed Circuit Board) mounts inside the control box on the rear panel (left side); turn 114 turn fasteners o,n front of control box to gain access. See Figure 4.
GENERAL
There are two generator designs used on the UR series. They are basically the same except for the method of field excitation.
,
The Static Exciter (brush type) design uses a brush rig and collector rings for field excitation. This design was used on some of the earlier models within the range of 25 KW - 90 KW. The Brushlessdesign uses a rotating rectifier exciter assembly in place of the brush rig for field excitation. The brushless design is standard on all models from 25 KW - 175 KW.
Unless otherwise specified, the tests in this section apply to both designs.
AC OUTPUT
\--
208-240 VOLTS AC
&
.
.TOR
R E V O L V I N G FIELD
OVERSPEED S W I T C H
EXCITATION S C H E M A T I C
A LT E R N A T 0 R
FENDBELL
iTATOR
FIELD
BREAKER
EXCITER ARMATURE
VOLTAGE R E(3U L A T O R
~~~
EXCITATION S C H E M A T I C
,
!
t
FIGURE 3.
'FIGURE 4.
6 ,
VISUAL INSPECTION
I
Before proceeding with the troubleshooting on the following pages, a few simple checks can be made which could directly indicate the cause'of trouble.
1. Always be sure that connection of generator leads is correct. Whenever leads are reconnected for a different voltage, check the output with an independent voltmeter. Do not use the control panel meter since it could indicate that the voltage is correct even i f connection is wrong. 2. Visually inspect the voltage regulator printed circuit board assembly (VR21) in the control box for burned components, broken wires, loose connections, dust, dirt or moisture. If dirty, clean with a suitable solvent and compressed air. 3. Visually inspect the exciter-regulator chassis assembly (VR22) for burned components, broken wires, loose connections, carbon tracks caused by arcing between parts or between parts and ground. Also check for shorted paths between terminals caused by dust, dirt and moisture. 4. Large banks of SCR (Silicon Controlled Rectifier) regulated loads can cause the generator voltage to increase as load is applied. If such loads exist, and the voltage increased more than 5 or lo%, consult the factory; an additional filter is available for the regulator circuit to correct the situation.
THE QUESTION AND ANSWER TROUBLESHOOTING GUIDES BEGINNING ON PAGE 8 GIVE A STEP-BY-STEP PROCEDURE FOR CHECKING THE GENERATOR. THE FLOW-CHART TROUBLESHOOTING GUIDES ARE GIVEN AS A GENERAL GUIDE TO RESOLVE VARIOUS GENERATOR PROBLEMS. ALL CHARTS REFER TO PROCEDURESSHOWN AT THE END OF THIS SECTION. . PRIOR TO ANY TROUBLESHOOTING, CHECK ALL MODIFICATIONS, REPAIRS, REPLACEMENTS, ETC.. PERFORMED SINCE LAST SATISFACTORY OPERATION OF SET.
LiM
~~
- ENGINE RUNNING
YES
NO
PROCEDURt
1. 2.
1 I
Switch circuit breaker to the on position. Does AC voltage build up? NOTE: If voltage builds up, but is high, low or unstable, or causes the circuit breaker on the meter panel to trip, refer to Table B, C or D of the troubleshooting guide.
I
3.
Is AC voltage at terminals 1 and 2, on VR21 voltage regulator printed circuit board and at terminals 9 and 10 on VR22 exciterregulator chassis assembly 5 to 10 volts?
~~ ~~
4.
Check continuity of wires and connections between terminal 1 on VR21 printed circuit board and terminal 9 on VR22 chassis assembly; and between terminal 2 on VR21 printed circuit board . and terminal 10 on VR22 chassis assembly. I there continuity s between these connections? Check for broken wires and loose connections on VR22 exciterregulator chassis assembly. Replace or repair any that are defective and clean all dust, dirt and other foreign material from the assembly. Does AC voltage now build up? Is DC voltage at terminals 4 and 5 on VR22 exciterregulator chassis assembly 5 to 10 volts? Are diodes CR1, CR2 and CR3 on VR22 exciter-regulator chassis assembly OK?
10
5.
6.
7.
8.
9.
The trouble is probably caused by a defective component on the voltage regulator printed circuit board. REPLACE VR21 PRINTED CIRCUIT BOARD (see Figure 4).
10.
With the circuit breaker on the meter panel in the off position, is AC voltage at terminals 62 and 63 (on terminal board TB21 on the left side of control box) 5 to 10 volts?
11.
With the circuit breaker on the meter panel in the off position, flash the exciter field. Is AC voltage at terminals 62 and 63 now 5 to 10 volts?
,
8
l3
11
12
13
8
Redistribution or publication of this document, by any means, is strictly prohibited.
YES
NO
PROCEDURE
Turn circuit breaker on the meter panel t o the on position. Does AC output voltage build up? NOTE: If voltage builds up, but is high, low or unstable,
NOTE: If voltage does build up, the circuit breaker CB21 is defective and MUST BE REPLACED.
~
~-
Is 11 commutating reactor mounted on the back side of VR22 exciter-regulator chassis assembly OK?
Check continuity of wires and connections between 1821 terminal
62 on left side of control box and terminal 1 on VR21 printed circuit board. Also check between TB21 terminal 63 on the left side of control box and terminal 2 on VR21 printed
circuit board. Are rotating diodes CR1,CR2, CR3,CR4,CR5 and CR6 on brushless exciter rotor OK? Is generator field winding OK?
18 19 20
J
H
9
Redistribution or publication of this document, by any means, is strictly prohibited.
TABLE A. SYNOPSIS
++
NO AC POWER TO EXCITER LOSS OF RESIDUAL VOLTAGE (FLASH
FIELD)
I
/E\
OPEN LEAD
R l , R2 OR R3
OPEN
PC BOARD NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of this section.
*
TERM"ALS 1 OR 2
P I
TERMINAL 1, 2,4,5
**
__
...
-..
i
L
ITEM NO.
YES
NO
PROCEDURE
t
1 8
I I
2.
Are there any loose or broken wires or connections at VR21 printed circuit board terminals? Does adjustment of R26* (damping control pot) on VR21 printed circuit board result in stable generator voltage?
3.
The trouble is probably caused by a defective component on VR21 voltage regulator printed circuit board. REPLACE VR21 PRINTED CIRCUIT BOARD (see Figure 4).
I
7:
i !
TABLE B. SYNOPSIS
UNSTABLE OUTPUT VOLTAGE
BROKEN WIRES OR LOOSE CONNECTIONS AT (VR21) VOLTAGE REGULATOR PRINTED CIRCUIT BOARD TERMINALS
INCORRECT SETTING OF R26 POT ON (VR21) PRINTED CIRCUIT BOARD (BRUSHLESS ONLY)
I
C6. C7, R14 OR R1S OPEN
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of this section.
F
5.
YES
NO
PROCEDURE
Does adjustment of R21 "Voltage Adjust" knob on the meter panel result in correct voltage? Does adjustment of R l b potentiometer on VR21 printed circuit board result in correct voltage? Is correct voltage reference transformer tap on TB21 being used?
4
5
L L
TABLE C. SYNOPSIS
TOO HIGH O R
I
INCORRECT SETTING OF VOLTAGE ADJUST POT (R21) ON METER PANEL
I
DEFECTIVE COMPONENT ON REGULATOR CHASSIS ASSEMBLY (VR22)
I
DEFECTIVE COMPONENT ON REGULATOR PC BOARD (VR21)
CONNECTION AT TERMINALS 3 , 4 , .
. I
-.
. .
..
NOTE Whenever a letter appears near the box, a separate procedure, corresponding s to that letter, i given at the end of this section.
12
Redistribution or publication of this document, by any means, is strictly prohibited.
NO:
ITEM
TABLE D. GENERATOR VOLTAGE BUILDS UP BUT CAUSES THE CIRCUIT BREAKER ON CONTROL PANEL TO TRIP. ENGINE RUNNING OK.
Does AC output voltage build up to 150% or more of rated voltage before CB21 circuit breaker trips? 2.
1,
. Are
there any loose or broken terminals or connections at VR21 voltage regulator printed circuit board terminals?
Is diode CR3 on center heat sink of VR22 exciter-regulator chassis assembly OK?
3.
4.
~
5.
6.
I
The trouble is probably caused by a defective component on VR21 voltage regulator printed circuit board. REPLACE VR21 PRINTED CIRCUIT BOARD (see Figure 4).
Does AC output voltage build up to rated voltage or less before tripping CB21 circuit breaker on meter panel?
8.
Are rotating diodes CR1, CR2, CR3, CR4, CR5 and CR6 on brushless exciter rotor OK?
.
9.
10..
11.
DEFECTIVE ROTATING DIODE CR1, CR2, CR3, CR4, CR5 OR CR6 ON EXCITER ROTOR
l-l
A
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of this section.
13
ITEM
- NO. .
YES
NO
PROCEDURE
1..
Remove load from 'generator terminals. Are genefator'terminal voltages still unbalanced?
_________
~~ ~
I*141
3
2.
I'
3.
4.
~~~
ji
5 .
*
I 51--1 1-14
\
TABLE
E SYNOPSIS .
'
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of this section.
14
TABLE E. SYNOPSIS
[ ; I
I
OPEN TRANSFORMER (T21) WINDING OPEN WIRE OR CONNECTION AT VOLTAGE REGULATOR CHASSIS ASSEMBLY (VR22) TERMINALS 4,5 OR 6
VOLTAGE 150%
rI
DEFECTIVE COMPONENT ON VOLTAGE REGULATOR CHASSIS ASSEMBLY (VR22)
1
1
I
OPEN WIRE OR CONNECTION AT PRINTED CIRCUIT BOARD (VR21) TERMINALS 5,6, 9,10, 1 OR 12 1
CYCLING
BUILD-UP *
NOTE Whenever a letter appears near the box, a separate procedure, f corresponding to that letter, is given at the end o this section.
*
i
I N S T A L L B R U S H E S W I T H BEVELED TOP S L A N T I N G D O W N TOWARD S P R I N G HOLDER-, TO REMOVE BRUSH SPRING,PRESS SPRl NG HOLDER DOWN A N D OUT A S SHOWN IN BROKEN LINES.
tJ
FIGURE 5.
BRUSH REPLACEMENT
FIGURE 6.
BRUSH REMOVAL
. .
If output voltage will not build up, it may be necessary '. to flash the field to restore residual masnetism. 1. Remove end grille to obtain access to'exciterregulator chassis assembly:. 2. Use a six volt dry cell (lantern) battery with a 12 amp 300 volt diode as shown in' Figure 7. This prevents current flow from exciter circuit to battery when voltage builds up. If a lantern battery is not available, a 12 volt automotive (generator set) battery can be used by installing a 20-ohm 2
.watt resistor in series with diode; or a 24 volt automotive (generatorset) battery can be used by increasing the resistor value to 40-ohms. 3. After starting the set, touch the positive (+) lead to TB5 and the negative (-) lead to TB4; hold on terminals just long enough forvoltage to build up.
' '
Do not keep excitation circuitry connected longer than 5-seconds or damage may occur to the exciter regulator. Be cautiouswhen working on agenerator that is running. High voltages aye present.
CHASSIS ASS
T O BUILD UP.
16
CI C
NO AC POWER TO EXCITER
Residual should be checked before the circuit breaker; the best place to check it is at the five leads 61 through 65 coming directly out of the stator. The combinationof leadsshouldbechosen by the wiring configuration of the stator, Le., 120/240 Delta, 120/208 ParallelWye. 277/430Series Wye. After checking residual,proceed to VR21 PC board arid then check the circuit breaker CB21.
Resistance between coils (e.g., 1-4) or from any terminai to reactor frame should be infinity.
If any of the above conditions are not met, install a new reactor.
If residual voltage is present, check AC voltage at terminals 1 and 2 on VR21 voltage regulator printed circuit board. Voltage should be 5-10 volts. The AC voltage at terminals 9 and 10 on VR22 exciterregulator chassis assembly should be the same (5 to 10 volts). If not, check continuity between these points. If voltage is low, check L1 reactor.
TESTING DIODES
On both brushless and brush type generators. three diodes mount on the center heat sink of the exciterregulator chassis assembly. They are labeled CR1, CR2 and CR3 as shown in Figure 3. On brushless generators, six diodes mount on the rotating exciter assembly as shown in Figure 2. These six diodes are labeled CR1. CR2, CR3, CR4, CR5 and CR6. Test diodes as follows:
1. Disconnect one diode at a time. Test that diode and reconnect lead before proceeding to the next one. 2. Use an accurate ohmmeter to check the resistance of the diode. Connect one lead to the top of the diode and the other lead to the heat sink. Observe reading. 3. Now reverse leads and again observe reading. A good diode should have a higher reading in one direction than the other. I f both readingsare high, or if both readings are low, diode is defective and must be replaced with a new, identical part.
Excessive dust or dirt on diodes and other componentswill causeoverheatingand eventual failure. Keep these assemblies clean!
TESTING L1 REACTOR
The L1 reactor mounts on the rear of VR22 exciterregulator chassis assembly. Terminals are marked 1, 2, 3 and 4.
Coils 1-2 and 3-4 are wound on the same iron core. Resistance between 1-2 and 3-4 should be .0544 and .0614-ohms f 1O0/o respectively (brush type generators) .
m
CAUTION
LEAD
LEAD
GOOD DIODE WILL HAVE HIGH RESISTANCE READING I N ONE DIRECTION AND LOW READING WHEN OHMMETER LEADS ARE REVERSED.
FIGURE 8.
TESTING DIODES
17
0 H MMETER
ANODE
[FI
TESTING SCRs
SCRs mount on the outer heat sinks of the exciterregulator chassis assembly. They are labeled Q4 and Q5 as shown in Figure 3.
1. Remove the leads from both SCRs. 2. Determine polarity of ohmmeter leads. Connect the ohmmeter leads to the anode and cathode as shpwn in Figure 9. Use the high scale on the ohmmeter. The resistance should be 1 megohm or greater.
The cathode is the longer lead, the gate is the shorter lead. The anode is the threaded stud.
REPLACING Diodes)
RECTIFIERS
(SCRs
and
3. Reverse the leads as shown in Figure 10. The resistance again should be 1 megohm or greater. 4. With the leads connected as in Step 3, and using the low scale on the ohmmeter, short the gate to the anode as shown in Figure 11. The resistance should drop to a low value. 5. Remove the short between the anode and the gate. The resistance should remain at the same low value.
1. Unsolder leadwires from terminals. 2. Use proper size wrenches to hold the body while removing the nut. 3. Push the rectifier free of its mounting hole in the heat sink. 4. Insert new rectifier into its mounting hole in the heat sink. Using nut and washer provided, secure rectifier to heat ,sink. 5. .Torque the two large diodes on the center heat sink of exciter-regulator chassis assembly to 2025 in. Ib. 6. Torque the small diode on center heat sink of exciter-regulator chassis assemb.ly to 12-15 in. Ib. 7. Torque SCRs o n outer heat sinks-to 20-25 in. Ib. 8. On brushless generators, torque diodes on rotating exciter assembly to 15 in: Ib. 9. Solder leadwires to new rectifiers.
Use a 40 watt soldering iron. Hold a needlenose pliers between rectifier and soldering point to prevent destructive heating. Excessive heat on these components will destroy them.
18
Redistribution or publication of this document, by any means, is strictly prohibited.
C O N T A C T ONE P R O D TO EACH O F THE SLIP RINGS AND T H E OTHER PROD T O THE R O T O R SHAFT. IF ROTOR I G O O D THERE S H O U L D BE NO S READING O N OHMMETER. OHMMETER
I
1
60HERTZ
C O N T A C T ONE P R O D TO EACH O F THE FIELD L E A D S AND T H E OTHER PROD T O THE ROTOR SHAFT. IF ROTOR I G O O D ' T H E R E S H O U L D BE N O S READING ON OHMMETER
25.0 37.0 40.0 45.0 50.0 55.0 60.0 70.0 75.0 80.0 95.0 1 10.0 1 1 5.0 125.0 140.0 145.0
FIGURE 12.
Testing for an Open Circuit: On brush type generators, check for an open circuit by measuring resistance in the windings. Check between the two slip rings as shown in Figure 13.
On brushless generators, disconnect and test between F1 and F2 leads as shown in Figure 13.
Resistance values given in Table 3 apply to both brushless and brush type generator rotors.
30.0 40.0 45.0 50.0 55.0 55.0 60.0 65.0 75.0 85.0 90.0 100.0 115.0 125.0 140.0 150.0 170.0 175.0
3.32 2.49 2.49 2.49 2.76 2.76 3.02 3.02 3.16 2.76 2.76 3.19 3.26 39 .6 3.96 3.09 3.42 3.42
40 .6 3.05 30 .5 3.05 3.38 3.38 3.70 3.70 38 .6 3.38 3.38 3.90 3.99 4.40 4.40 3.78 4.18 4.18
All resistances should be within the values specified at 20C (68" This includes readings between slip rings on static excited F). rotors and between field leads (with rectifiers disconnected) on brushless rotors. Use Wheatstone Bridge for testing.
19
Redistribution or publication of this document, by any means, is strictly prohibited.
!
i .
FOR STATORS*
I
I
0.141 0.058 0.058 0.058 0.035 0.047 0.035 0.035 0.027 0.024 0.024 0.018 0.015 0.011 0:Oll 0.0092 0.0072 0.0072
9x
I
0.236 0.236.
55.0
60.0 65.0 75.0 85;O 90.0 100.0 115.0 125.0 140.0 150.0 170.0 175.0
55.0
60.0 70.0
75.0
80.0 95.0 110.0 115.0 125.0 140.0 145.0
0.116 0.047 0.047 0.047 0.028 0.038 0.028 0.028 0.022 0.019 0.019 0.015 0.012 0.009 0.009 0.0075 0.0059 0.0059 -
0.156 - 0.191 0.113 - 0.138 0.113 - 0.138 -6.089 - 0.108 0.072 - 0.089 0.072 - 0.089 0.054 - 0.067 0.045 - 0.055 0.039 - 0.048 0.039 - 0.048 0.027 - 0.033 0.018 - 0.023 0.018 - 0.023
AI: r(?sislances should be within the values shown at 20C (68 F). Use an accurate instrument such as a Kelvin Bridge for this test. Test between the following coil leads: T1-T4 17-T 10 T3-T6 T9-Tl2 T2-T5 T8-Tl1
20
Redistribution or publication of this document, by any means, is strictly prohibited.
IJI
TESTING EXCITER ROTOR (Armature)
!
Testing Winding Resistance: Measure coil resistance between leads F1 and F2 with an ohmmeter (scale Rx 1). Resistance should be17.82 to 21.78ohmsat 20C (68F). See Figure 16A.
Testing for Grounds: Remove diodes CR1, CR2, CR3, CR4, CR5, and CR6 from diode heat sink assemblies. Using an ohmmeter (R x 100 scale) measure insulation resistance between any of the leads and the laminations (exclude the diodes from the test circuit). A reading of less than infinity indicates a ground. Testing Winding Resistance: Using a Wheatstone or Kelvin bridge meter, measure resistance between leads pairs T1-T2, T2-T3 and Ti-13. Resistance should be 0.464 to 0.567 ohms at 20C (68F). See Figure 15.
RECONNECTION
Figure 18 shows reconnection possibilities forthe UR series generators. When reconnecting for a different voltage, be sure to also reconnect lead from terminal 63 (inside control box) to either H3, H4, H50rH6.See Figures 17 and 18.
FIGURE 15. TESTING EXCITER ARMATURE
(W12 WIRE)
21
Redistribution or publication of this document, by any means, is strictly prohibited.
N A M E P L A T E VOLTAGE CODE 3
E,
IS 120/240
1 60 1 50
H5
15 1
115/230
H6
H6
8'l
SCHEMATIC DIAGRAM
GENERATOR CONNECTION W I R I N G D I A G R A M
(WITH
/
LO
1 1
12
LO
116220 1 5 0
TI0 77
75
L2
T 1 12 16 111 18112 14 LO L1
19
1s 17 T 3
12
110
L3
15 120/140 3 60
H5
H6
115/230
i1S
3 50
11
LO
T10
16 17
L1
12
111 14 T 8 L2
'73
T12 T5 19 13
I
W
'7:
13
111
, .
I5
16
110 112"
111
l7
12 T 8
13 19
13
LO
L1
12
i.
710
711 79
LO
L3
1101lt T12
T I T 7 T4
12 T 8 15
T3T9 1 98C2193
22
il
:!
. .
UNSOLDER THIS WIRE FROM E I AND CONNECT TO E2 FOR A NONFREQUENCY SENSITIVE VOLTAGE REFERENCE CIRCUIT.
23
GENERATOR DISASSEMBLY
If generator testing determines that generator needs repair, remove and disassemble according to Figure '20 and the following instructions: Disconnect and remove load wires. Disconnect leadwires from the control box. Check wire markings for legibility to ease assembly. Arrange leads so they can be withdrawn easily from the control box. Remove front grille (14) and sheet metal work. Remove the four capscrews securing voltage regulator chassis (23) to end bell (9) and remove chassis assembly. Remove the centrifugal switch (8) from end bell and rotor shaft. On static excited models, slip the brushes (7) and brush springs (6) from brush rig (5) - it is not necessary to disconnect the brush leads unless brush replacement is required. Block the rear of the engine in place by supporting the flywheel housing. Remove the narrow generator band (10). Remove the large capscrews securing generator mounting pad (11) to the skid base. Remove the capscrews securing the stator assembly (4) to the engine flywheel housing.
7. Using an overhead hoist and sling, slide the stator assembly off the rotor assembly.
Use care not to damage the brush rig (or exciter on brushless models) while removing the stator. Do not allow the stator to rest on rotor during removal.
E z 3
CAUT,ON
8. Remove end bell from stator assembly; disconnect and remove brush rig from end bell on static excited generators. On brushless models, remove exciter field (24) from end bell assembly if required. 9. Attach the hoist and sling to the rotor assembly (1) and apply a slight lift to support the rotor. Remove the capscrews securing the flexibledrive coupling (13) to the engine flywheel and remove rotor from the engine. 10. Remove bearing capscrew (18) and washer (17) and remove bearing from shaft. If required, remove blower (2) from the rotor. 11. Disconnect rotor field leads from heat sinks F1 and F2 on the exciter armature. Remove exciter armature (25).
'
23
BRUSHLESS G E N E R A T O R
FIGURE 20. GENERATOR DISASSEMBLY
24
Redistribution or publication of this document, by any means, is strictly prohibited.
GENERATOR ASSEMBLY
Generator assembly is the reverse of disassembly procedure:
1. Always replace bearing with a new one; apply a layer of grease on end bell bearing hole before inserting bearing. 2. Torque bearing capscrew to 60-70 Ib. ft. 3. Torque drive disc-to-rotor capscrews to 200-240 Ib. ft. 4. Torque drive disc-to-flywheel capscrews to 45-50 Ib. ft. 5. Torque generator through-stud nuts to 30-40 Ib. ft. 6. Refer to Purrs Curu/o,y for replaceable parts and assemblies. Refer to Wiring Diuputii for reassembly.
[PI
VOLTAGE ADJUSTMENT
After replacement, voltage regulator (VR21) adjustment is performed as follows (see Figure 21): 1. Center the voltage adjust knob so pointer is in a vertical position. 2. Open meter panel doors. Start unit. 3. Using a screwdriver, turn R18 potentiometer on printed circuit board VR21 counterclockwise to increase the voltage or clockwise to decrease the voltage. Observe voltmeter on meter panel while making adjustment. Set voltage with no load connected to generator. (Example: For a 120/240 volt connection, set at no-load voltage or approximately 246 volts.)
If voltage is unstable or tends to hunt, turn R26 potentiometer on VR21 in the direction shown on printed circuit board to increase voltage sensitivity.
I
ADJUST R26 HERE
\
ADJUST R 18 HERE
25
GENERATOR
- SECTION II
GENERAL
Generators discussed in this section are brushless type only. The difference between these and the generators in Section I is in the VR22 diode assembly and the commutating reactor. These have been removed from the generator end bell and relocated in the control panel. The diodes are now encapsulated within a hermetically sealed block, therefore if any diode or silicon controlled rectifier fails, the entire unit has to be replaced. See Figure27fordetailsof the rectifier assembly (CR21) and Figure 25 for the reactor (L21). Principles of operation and method of excitation remain unchanged from the units described in Section I. Refer to Table 1 for generators to which this section . applies.
ovERSPEED SWITCH
FIGURE 22.
121 REACTOR
\
CR2 I SCR BRIDGE
FIGURE 23.
:TROUBLESHOOTING
Use the following troubleshooting charts and procedures to locate malfunctions in the generating system. Section 11 also references procedures A thru P of Section 1. The question and answer troubleshooting guides which follow give a step-by-step procedure for check-
ing the generator. To use the guides, answer the questions either yes or no then proceed to the next step given in whichever column is indicated.
When using block diagrams, a letter with a triangle indicates a procedure in Generator - Section 1. A letter within a diamond indicates a procedure in GeneratorSection II.
26
Redistribution or publication of this document, by any means, is strictly prohibited.
ITEM NO.
TABLE
YES
NO
PROCEDURE
1.
2.
NOTE If voltage builds up but is high, low or unstable, or causes CB21 to trip, refer to table G. H or I of troubleshooting guide.
3. Is A C voltage measured at terminals 1 and 2 on voltage regulator (VR21) printed circuit board 5 to 10 volts?
4.
7
11
5.
15
6.
7.
14 14
10 8
8.
10
9.
10.
12
14
12.
Are SCRs 1 and 2 in CR21 good? (See method T in procedure section for checking diodes.) If faulty SCRs located, replace CR21.
13
ITEM NO.
YES
No
lPROCEDURE
13.
14.
Start engine. Place CB21 in OFF position. Using method prescribed under R in procedure section flash the exciter field to restore residual magnetism. Place CB21 ON. Does the AC output voltage build up? Shut off engine. is exciter field winding (F1: F2) OK? Are rotating diodes CRI, through CR6 on exciter rotor OK? 16
15. 16.
17 18
17. 18.
.
.
19
19.
13
. . .
28
Redistribution or publication of this document, by any means, is strictly prohibited.
TABLE F. SYNOPSIS
1
NO VOLTAGE
BUILD-UP
eo
N
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of the, appropriate section.
.. _ . -_
. . ....
....
I
I
YES
1
I
NO IPROCEDURE
I
2
3
P
Does adjustment of R26 (damping control potentiometer) on VR21 stabilize generator voltage? Replace VR21.
TABLE G. SYNOPSIS
UNSTABLE OUTPUT VOLTAGE
BROKEN WIRES OR LOOSE CONNECTIONS AT (VR21) VOLTAGE REGULATOR PRINTED CIRCUIT BOARD TERMINALS
..
.-
._
. ..
. I
".
1
. ..
I
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of the appropriate section.
30
. -
& M
YES
NO
PROCEDURE
__
1.
Does adjustment of R21 voltage adjust knob on meter panel correct voltage level? Does adjustment of R18 potentiometer on VR21 correct voltage level? Are rotating diode heat sink mounting screw insulators OK?
2.
3.
If generator output voltage has been optionally reconnected, consider the following -
4-
5
6
5.
6.
TABLE H. SYNOPSIS
TOO HIGH OR TOO LOW
I
INCORRECT REFERENCE TRANSFORMER TAP ON T21 INCORRECT SETTING OF VOLTAGE ADJUST POT (R21) ON METER PANEL
DEFECTIVE
%
/L\
r
H
1
1
I
31
I
Redistribution or publication of this document, by any means, is strictly prohibited.
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding f to that letter, is given at the end o the appropriate section.
IiLM
YES
NO
PROCEDURE
1.
Does AC output build up to 150% or more of rated voltage before CB21 trips? Are there loose or broken terminals or connections at VRZl?
2.
7.
8.
9.
10.
ROTOR
N O T E Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of the appropriate section.
32
YES
NO lPROCEDUREl
Remove load from generator terminals. Is output still unbalanced? Are generator leads properly connected or grounded?
Is generator stator winding continuous?
2
3
4
Is grounding procedure of generator and load correct? Check for ground faults on load.
I TABLE J. SYNOPSIS
TERMINAL VOLTAGES
!
I
INCORRECT RECONNECTION AND/OR GROUNDING OF GENERATOR LEADS INCORRECT GROUNDING OF LOAD OR GROUND FAULT IN LOAD
I
I
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter is given at the end of the appropriate section.
33
1.
DlODECR3 OPEN
I-
BREAKDOWN OF S C R l OR SCRP
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding s to that letter, i given at the end of the appropriate section.
34
Do not keep excitation circuitry connected longer than 5-seconds, or damage may occur to the exciter regulator.
The coils 1-2 and 3-4 are wound on the same core. Resistance between 1-2 and 3-4 should be .034 ohm f .0034 and .042 ohms .0042 respectively (brushless units). Resistance between coils (e.g., 1/4) or from any terminal to frame of the reactor should be icfinity (Figure 25).
I AMP. 2 300 v.
RECTIFIER BRIDGE
FIGURE 24.
FIGURE 25.
L21 REACTOR
35
CR I
7iCR3
-1 h
CR2
'
A C TERMINALS ARE GIVEN NUMERIC DESIGNATIONS FOR T E X T REFERENCE ONLY. DOES NOT APPEAR ON UNIT.
FIGURE 26.
RECTIFIER ASSEMBLY
Disconnect wires from rectifier unit prior to testing. Test unit in order shown in Table 5. Refer to Figure 27 for SCR1 and SCR2test circuit. When test is complete and satisfactory, reconnect unit observing correct wiring hook-up.
r---
'
FIGURE 27.
TESTING SCR
36
Redistribution or publication of this document, by any means, is strictly prohibited.
NG
SCR REMARKS
METER SCALE
RXlOK
CR3
Infinity
CR3
6- to 50-Ohms
R X l
SCRl
Infinity
RXlOK
lnfinitv
RXlOK
CR1
RX1
2CR2
Infinity
RXlOK
Infinity CR2
CR2
6- to 50-Ohms
R X l OK
RX1
I
3CR2.I
DC Voltmeter lead
DC Voltmeter Reading
1
AC2
+
+
3 Volts
3 Volts
read voltmeter. See Figure 27. **.Apply temporary jumper from AC2 to G2 to test SCR2. Remove jumper, read voltmeter. See Figure 27.
37
Redistribution or publication of this document, by any means, is strictly prohibited.
TITLE
Brushes .............................. Flashing Field ........................ No AC Power t o Exciter Testing L1 Reactor Testing Diodes Testing SCRs Testing Generator Rotor Testing Generator Stator Testing Exciter Rotor Testing Exciter Stator ................. Reconnection Sensitivity Reference Circuit .......... Generator Disassembly Voltage Adjustment .............. :
PAGE
B
C D
E
F G H J
K
L M N P
............... ....
16 16 17 17 17 18 19 20 21 21 21 23 24 25
SECTION I I
PROCEDURE
TITLE
Flashing Field ........................ Testing L21 Reactor .................. Testing Bridge Rectifier (CR21)
PAGE
R S T
.......
35 35 36
38
Redistribution or publication of this document, by any means, is strictly prohibited.
CONTROLS
GENERAL
The shock mounted control box has two doors that open from the center. The left hand door holds the field circuit breaker, voltmeter and voltage adjusting rheostat. The optional meter package adds running time meter, frequency meter, ammeter or ammeters plus volts-amps selector switch to the left hand door. The right hand door, attached to a removable bracket, holds the instrument lamp, fault lights, switches and
- SECTION 111
gauges. An optional door has holes for electric tachometer and/or oil temperature gauge. The bracket supports the terminal blocks, cycle cranker and relays in the DC engine control circuit. Plug mounted relays in both the AC section and DC section plus printed circuit modules in the DCsection facilitate troubleshooting and servicing. Snap-in lamps with Faston connectors make lamp replacement very easy. See Figure 28.
LAMPS TIME D E L A Y
K13 S T A R T S O L E N O I
FIGURE 28.
LOCATION OF
DC CONTROL COMPONENTS
THE QUESTION AND ANSWER TROUBLESHOOTING GUIDES BEGINNING ON PAGE 39 GIVE A STEP-BY-STEP PROCEDURE FOR CHECKING CONTROL SYSTEM PROBLEMS. THEFLOW-CHART TROUBLESHOOTING GUIDES ARE GIVEN AS A GENERAL GUIDE TO RESOLVE VARIOUS CONTROL SYSTEM PROBLEMS. ALL CHARTS REFER TO PROCEDURES AND NOTES WHICH ARE GIVEN AT THE END OF THIS SECTION.
39
YES
1. 2 . 3 . 4.
5 .
~ ~
l 3
I I
l7 lo
7
relay K13 (start solenoid) pick up? Does ignition relay K12 pick up?
Is voltage from ground terminal to center terminal of run-stop-remote switch equal to battery voltage?
Switch is defective or in stop position.
6.
7.
Is voltage from ground terminal to ignition relay K12 terminal B equal to battery voltage?
Jumper battery positive from center terminal of run-stop-remote switch to terminal 6of ignition relay K12. Does engine now crank? Replace engine monitor printed circuit board.
lo
0.
9.
10.
TBll equal to
14 13
11.
Does ignition relay K12 (4-7) contact close? a. Check socket connection. b. Coil may be open. c. Replace ignition relay K12. Clean relay contacts and check wiring.
12.
13. 14.
I I
K11 terminal 1
l6
t
15.
I -
NOTE: On EK. EM, and EN series, start solenoid relay is mounted on the engine, rather than in the control, and is designated K6.
40
ITEM NO.
A. ENGINE FAILS TO CRANK WHEN SWITCHED TO RUN (Continued) Is voltage from ground to coil terminal of K13 start solenoid I equal to battery voltage?
YES
NO
PROCEDURE
16.
17 2 1
18
Does voltage from ground to TBll-22equal battery voltage? Jumper from K13 coil terminal to Does relay K13 pick up?
20
K11 terminal 1.
19
Replace cycle cranker printed circuit board A12. Replace start solenoid K13. Is voltage from ground to starter coil terminal equal to battery voltage? Replace starter. Check thermal breaker CB1 and wiring to starter.
23
22
22. 23.
NOTE: On EK. EM, and EN series. start solenoid is mounted on engine, rather than in the control, and is designated K6.
TABLE A. SYNOPSIS
ENGINE FAILS TO CRANK
K12 COIL
CIRCUIT PATH
41
ITEM NO.
YES
NO
PROCEDURE
1.
Remove wire from TB11-29. Reset fault lamp by switching to stop, then back to run. Does engine crank? Place wire back onto TB11-29 while engine is running. Does fault lamp light and engine stop? 5. 6. Check overspeed switch and wiring for grounds. Jumper from ignition relay K12 terminal B to center terminal of run-stop-remote switch. See Method M in Procedure section. Does engine crank? Replace engine monitor printed circuit board and remove jumper.
7.
YES
NO
IPROCEDUREI
1.
Does fault lamp light and does plant stop after running about 12 seconds? Does fault lamp light and does plant stop after running about 1 minute? Remove wire from terminal TB11-30. Does engine run restarting?
2.
~
3.
OK after
4.
Engine is either not pumping oil properly or oil pressure sensor is defective. Replace wire on TB11-30 and remove wire from TB11-31. Does engine run OK after restarting? Engine is either operating over temperature, temperature sensor is defective or wire between sensor and terminal block is grounded. Jumper K11 terminals 6-9. Does engine run OK?
~~ ~
. 5.
6.
7.
42
ITEMTABLE NO.
YES
NO
PROCEDURE
1.
Does engine crank as soon as run-stop switch is put into run position?
for Check contacts K12 (3-9) failure to close or to make proper contact.
2 .
TABLE D. SYNOPSIS
ENGINE SOMETIMES HESITATES BEFORE CRANKING
5
43
ITEM NO.
YES
1. 2.
3.
Does starter continue to run after engine starts? Does charge ammeter show a charging current while running?
2 4
l 4
4.
5.
6.
l6
7
7.
8.
I -
9.
Check K11 and K14 contacts (1-7) to make sure they open when relay picks up. Does voltage across K11 terminals (A-B) build upto battery voltage? Replace start disconnect relay K11 or starter protection relay K14. Coil may be open. Does relay K12 (5-8) close to bring battery voltage to alternator regulator? Check for faulty alternator, regulator or shorted alternator output. Check K12 ignition relay for dirty contact or broken wire.
l11
10.
11.
l-
12.
l3
13.
14.
,
NOTE On EK. EM and EN series, start solenoid is mounted on the engine, rather than the control, and is designated K6.
44
TABLE E SYNOPSIS .
J
I
K14 STARTER PROTECTION RELAY FAILS
AND-c
D.RlVE BELT OFF OR SLIPPING IGNITION RELAY K12 (5-8) FAILS TO CLOSE
7w 1
K14 COIL,
'
DEFECTIVE REGULATOR
/G\
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of this section.
K14 starter protection relay was added to units beginning with the Specs shown below. This relay prevents starter engagement when unit is running.
SPEC D A P A A
SPEC D F D H C
SPEC
SERIES WA WE WB
SPEC F B H
B A
A A
45
I LkM I
YES
NO PROCEDURE
3
I
Does one of the following fault lamps light? (Choose one of the following:)
Overspeed? High Engine Temperature? Low Oil Pressure? Overcrank? Does relay K13* (sfarfsolenoid) pick up? Does ignition relay K12 pick up?
30 25 27 29
..
. .
I
22
11
Is voltage from ground terminal to center terminal of run-stopremote switch equal to battery voltage?
Switch is in stop position or defective.
Is voltage from ground terminal to ignition relay K12 terminal B equal to battery voltage?
Jumper battery positive from center terminal of run-stop-remote switch to terminal B of relay K12. Does engine crank?
~~ ~~
1131g1
I
I
I 1 0
1-1
12 13
. M
15 14
46
15.
17
I I
l6
16.
17.
18
18. 19.
I I
l9
22
20
1 - 1 - 1
23 24
1-1-1
26 29
25.
26.
29
28
27. 28.
29
29. 30.
31.
I I I I I I
31
29
32
33
32.
I-1-1
34
33. 34.
NOTE: On EK, EM and EN series, start solenoid is mounted o n theengine, rather than the control, and is designated K6.
Redistribution or publication of this document, by any means, is strictly prohibited.
ITEM NO.
~
YES
NO
PROCEDURE
1.
Does low oil pressure lamp light and plant stop after running about 12 seconds? Does overcrank lamp light and plant stop after running about 1 minute? Remove wire from terminal TB11-30. Reset alarm by switching to stop, then back to run. Does engine run OK? (Replace wire after test.) Engine is either not pumping oil properly o r oil pressure sensor is defective. Does relay K11 pick up after engine starts? Jumper relay K11 contacts (6-9) after engine starts. Does engine continue to run OK? (Remove jumper after test.) Replace relay K l l . Replace engine monitor printed circuit board. Does charge ammeter show a charging current while running? Does battery voltage appear across K11 co,iI terminal (A-B) when engine runs? Check for an open circuit in wiring or a loose connection from alternator AUX terminal to K11 coil circuit. Check .alternator and regulator output; replace if necessary.
2.
5
4
3 .
4.
l6
5.
6.
7.
8. 9.
10
10.
11.
lI
12.
TABLE G. SYNOPSIS
SHUTS DOWN
TEMPERATURE
PRESSURE
1
48
SENSOR CLOSED
F % w
SWITCH ,CLOSED . oE : E v RE D
I
NO ALTERNATOR OUTPUT DEFECTIVE REGULATOR
r
EXTERNAL ALARM FAILS ON ALARM SHUTDOWN CONTACT FAILS TO
LOW OIL PRESSURE OR HIGH ENG. TEMP. CIRCUIT FAILS AFTER APPROX. 12 SECONDS *'*
CLOSE ON
SHUTDOWN
CAPACITOR c2 SHORTED
NOTE: Whenever a letter appears near the box, a separate procedure, corresponding to that letter, is given at the end of this section
**
I . .
With swiich in run position, check for voltage across R9 (27-ohms). A voltage of 0.5 to 1.0 will turn on SCR CR6. If voltage is present, remove TB11 terminal 29. If voltage is still present, check transistors 0 7 for short-emitter to collector. Remove TB11 terminal 30 and 31. If engine still shuts down, remove transistor Q8. If this prevents shutdown - replace Q8.
ENGINE MONITOR **
I
ENGINE FAILS TO CRANK LIGHTS AS SOON AS RUN
I
I
CIRCUIT PATH 18-19 OPEN HIGH ENGINE TEMPERATURE LAMP LIGHTS
I
LOW OIL PRESSURE LAMP LIGHTS
I
OVERSPEED LAMP LIGHTS
I
OVERCRA'NK LAMP LIGHTS
_ I -
OVERCRANK
CAPACITOR C6 OPEN
F l
CAPACITOR POTENTIOMETER R-15 ON A-11 PRINTED ClRCUl BOARD FOR CORRECT TIME
CAPACITOR OPEN
CAPACITOR OPEN
I
TRANSISTOR Q13 SHORTED
..
.-
NOTE: Whenever a letter appears near the box, a separate procedure, correspondjng to that letter, is given at the end of this section.
T I
CAPACITOR
T I
CAPACITOR
.
'
I -
'
**
Capacitor C1 must be discharged when engine starts to prevent an overcrank shuidown. Check relay contact that connects to terminal 16 of engine monitor. See typical wiring diagram.
Inspect contacts for dirt particles, obstructions or insulating film. Clean, using low pressure compressed air and bond paper. Check relay socket.
Contacts are normally closed when engine is not running. Contacts must open when engine is running normal.
O F 12 V O L T RE.LAY IS 120 O H M S . R E S I S T A N C E O F 2 4 V O L T R E L A Y IS 4 7 0 O H M S .
IH1
Contacts are normally open; contacts close for alarm condition only. (Overspeed switch may have to be reset manually.)
'
IJI
Contacts may have welded closed or plunger may be stuck. Remove solenoid from circuit to test for proper operation.
FIGURE 2 . TESTING K11 AND K12 RELAYS 9
[KI
When connecting battery cables, terminal will spark i f connection is reversed. Unit will not crank with reversed cables or loose connections. Inspect printed circuit board paths that supply voltage to relay K12. (Between terminals 18-19of 3000681; between terminals 7-9 of 300-0679.)
DC alternator will overheat and will probably burn up. A reverse battery connection will show a maximum positive charge on the DC ammeter.
On dry charged batteries, no woltage is present until electrolyte is
added.
[LI
Remove cycle cranker printed circuit board and jumper terminal 2-3 to by-pass cycle cranker circuit.
Check for voltage from starter terminals to ground. Voltage should be present at both terminals when solenoid is energized for cranking.
In an extreme emergency, engine may be operated without any safeties by removing engine monitor printed circuit board and jumping terminals 7-9. (It may be easier to jump from center contact of RunStop switch to terminal "B" on Kl-2 relay; see Figure 30.)
51
Units With Five Fault Lamps: Potentiometer H2 on All printed circuit board is factory adjusted for 75 seconds ( ' 5 seconds). To lengthen delay, use a screwdriver and turn R2 clockwise; to shorten delay, turn counterclockwise. See Figure 32.
SWITCH
. . '.
ADJUSTING LOW OIL PRESSURE TIME DELAY ON ENGINE MONITOR PRINTED CIRCUIT BOARD
Units With Single Fault Lamp: Potentiometer R l O on A-11 printed circuit board is factory adjusted for 12112 seconds ( ? 2-1/2 seconds). To lengthen delay, use a screwdriver and turn potentiometer clockwise. To shorten delay, turn ' potentiometer counterclockwise. Refer to Figure 31. Units With Five Fault Lamps: Potentiometer R15 on All printed circuit board is factory adjusted for 12-1/2 seconds ( 2 2-1/2 seconds). To lengthen delay, use a screwdriver and turn clockwise; to shorten delay, turn counterclockwise. See Figure 32.
4
0
R 4 C R A N K TIME FACTORY SET A T 15 SECONDS., T O INCREASE T U R N CLOCKWISE R1 R E S T TIMEFACTORY SET A T 10 SECONDS. TO INCREASE TURN CLOCKWISE
52
WIRING DIAGRAMS
612-4173 612-3919 625-1007 625-0987 612-4350 612-4353 300-0679 300-0680 300-0681 300-0682 300-0714 625-1036 612-5300 612-5301 612-5302 612-5303 612-5304 612-5305 612-5310 612-5311 612-5312 612-5313
PAGE 100-175 kW Brushless Exciter ...................................... -54 30-90 kW Static Exciter ............................................ -55 VR21 Brushless Exciter ............................................. 56 VR21 Static Exciter ................................................. 57 30-50 kW Controls .Single Light .................................... 58 30-90 kW Controls .Five Light ...................................... 59 Engine Control Monitor .12 V ....................................... 60 Engine Control Monitor . V ....................................... 24 61 Engine Control Monitor 12 V Five Light ............................ 62 Engine Control Monitor . V . Five Light ............................ 63 24 Cycle Cranker .12 V ............................................... 64 Tap Switch ......................................................... 65 25-90 kW Brushless 15R; 515R ..................................... 166 25-180 kW Brushless, Full Meter Panel ............................... 67 25-45 kW-3R Brushless 120/240 V . 1 Phase .......................... 68 25-45 kW .3R Brushless 120/240 V . 1 Phase, Full Meter Panel . . . . . . . .69 25-90 kW 9XR Brushless 347/600V ................................... 70 25-180 kW .9XR Brushless 347/600V. Full Meter Panel ...............71 Generator Set Engine Control, 12V Ignition; EK, EM, EN .............. 72 Generator Set Engine Control, 12 V Ignition; EK, EM, EN ............. 73 Generator Set Engine Control, 12V ignition; KR, WA .................74 Generator Set Engine Control, 12 V Ignition; KR, WA .................75
53
612C4173
WIRING MAGRAM
REAR VIEW_-P/\NEL
__ -
I
111.
cfs
PA111
FIELO
HOUSING-CONTROL BOX
M23 M?4
s
I I
-.. -.
7
rT6 .TI2
$7
C821
3208431 320P307
ow I
... ..
IC ,a .--._< ,
rnY.!"O*
CIRCUIT BREAKER. 2hMP LOCKXKTBRKR HANDLE [PENNSTATE TRANSFORMER ASSY-CUR t 2 5 - 4 0 K W TRWSFORMER ASSY-CUR(41-45KWl FIANSFORMER AS=- CUR ( 4 6 6 o ( w I TRANSFORMER ASST- CUR (61-lWl(W TRANSFORMER *SSY~CUR(IOI~IUI:Wl TRANSFORMER A3SY-CURU26-175KWI
I
I
I
I
CT21-23
I I
I
T2
n.
T3 7
ELlt3219
I 1
I I I
ROARDASSY-PC V0LTA:E RGLTR CHASSIS ASSY-VOLTAGE RGLTR WIRING HARNESS LEAO ASSY
I---
NOTE: CONNECT LEAO W12 FROM TERMINAL TB21-63 TO 7821-IH-I PER VOLTAGE CHART BELOW
,
VOLTAGE CONNECTIONS
.. .
,-234/40OV, 50 Hz. (H41 240/416V, 60 Hz,(H3) 254/440V, 60 Hz.( H4) 277/480V. . 60 Hz..(H51
3PH. 5 0 / 6 0 H z 12 W RECONNECTABLE
. ........- -.--,.-- ,
612C4173
m 1 ,S 1 1 'I
nr.KS.
I'
CBZI
- T.- : -6
aiv
I
KxmnM
-TI1 *TI2
--a
'
11
'
I
7 GENEFA! I TRELAY-VOLTAGE
---q
_.
I --
_ -HOUSING-CONTROL BOX TI T2 T3 74 TS T6 77
\
*
\ \
\ \
TO
T9
I - --I
Si!
3
\
VOLTAGE CONNECTIONS
5CJHr, (H3)
NOTE. CONNECT LEAD W12 FROM TERMINAL TB21-63 TO'TEZI.IH,) PER CHART GENEfi IATOR
3 PHASE 1I 115/23OV. 50H1, (H6) 120/240V, 60Hr, (H51 110/190V. 115/2WV, 120/208V, 127/220V, 139/240V,
220/3EOV, SO HI. (til) 234/400V, 50 HI, (H4) 2 4 0 / 4 1 6 V 60 HZ (H3) 254/440$60 Hr:(H4) 277/480V, 60 HZ. (ti51
F2
T7
LI
FIELD LO LO
(MOUNTED IN E N )
6 7 8 910
O O Q Q ?
TI I
I -
L3
4 1
NOTE. UNLESS OTHERWISENOTED, ALL COMPONENTS ARE SHOWN IN THE 0E.ENERGIZED POSITION
625D1007]
. I. ..
. ,\..,. r. . . . . . . . 1 I ... .
pi i
; I
!
VRZl
i
---T8
Lr
4 l - ..
c121.47 T
CII I
R27 10 K 0
*--
I N N
5
B
I-
.;
57
I I ?
1.:
12
I
I
7
I
. ..
D
. I
---i
_N
58
Redistribution or publication of this document, by any means, is strictly prohibited.
.
612C4353 1
(FRONT VIEW1 WIRING - - DIAGRAM
-7
-(REAR V I F Y I
SCHEMATIC DIAGRAM
hNNUNCIATOR IUEBCRANK
c ;EMOTE
Z V 8OMA
.ow oh PRES!
I1 EN6 TEMP
.C CNG TEMP
, 1
' I I I TO TERM 62 I 8 63 ON TB21 I 190-24OVAC
I6
1)
90 1
id
.
I
CBI
El
12
I I I I
I
C I R C U I I B R E I K t R . I 7 5 AIP(0VC OHLVJ ,
_. -
StNOER -011 PRESSURE SEWOER-WATER TEMP < O V A . O K ) SINOER-WATER TEMP. (OEF. OEH. FUEL PUMP
OEC)
SI
I
I
s2
IVERSPEED iENERATlNG
II
53
s5 S6 57
I
I
1 f SIITCH-OYIRSPfEO
I
S?ITCH-LOI l I T f R TEMP
-4 ;
I
NOTES: I W12 USED ON STD CONTROL ONLY . 2.USED ON PRE-ALARM CONTROL ONLY 3.REMOTE ALARM CIRCUIT RATED 5AMP MAX 4.SHUTDOWN 8 A L A R M S 41 STD CONTROL . 411 SAFETY SHUTDOWN 8 ALARMS Oh .. OVERCRANK,OVERSPEED,HI ENG TEMP 8 L O OIL PRESS 4.1.2 SAFETY A L A R M ONLY ON LO ENG TEMP 4.2 PENN STATE CONTROL " " I 6 3 ON TBZl 4.2.1 SAFETY SHUTDOWN a ALARMS 30-24OVAC ON OVERCRANK 8 OVERSPEED vi 4.2.2 SAFETY A L A R M S ON HI ENG TEM~LO OIL PRESS a LO ENG TEMP 4.3 PRE-ALARM CONTROL 4.3.1 SAFETY'PRE-ALARMS ON HI EN( TEMP 8 LO OIL PRESS 4.3.2 SAFETY SHUTDOWN a ALARMS ON OVERCRANK,OVERSPEED,HI ENG TEMP e LO OIL PRESS KI I 4.3.3 SAFETY ALARM ONLY ON La EN( 13 TEMP B U A WHEN U S E D 5.S3 OVERSPEEO SWITCH MOUNTED IN GENERATOR END B E L L ISTP &UNLESS OTHERWISE NOTED,ALL CRANKER CR*NKI COMPONENTS ARE SHOWN I N T H E ST^ C ~ N T R O L -01 -03 -01 ,-04 DE-ENERGIZED POSITION .ICRE+iLARMBPENH $TATELSWE&QF)
...... "..
ICYCLE
IHlADDCD DDA.DDB,DYJ
F?'ps 4
P E N N STATE (SPEC:C,D,E.ECI
-0s
-06
300C679
U S I N S SOLDER.
3. F A C l O R l AOJUST POTEHTIOYETER R13 FOR 12.5 f 2 . 5 SECONDS LOP 01111. FACTORY AOJUST POTENTIDPETER R4 FBR 7 5 2 IO SECONDS O V E R C R d K 01111.
Q)
X5
I
--1
A9
19
RE
.RtO
A6 A2
P I I1
I8 I7
16 15 14 I3
RESISTOR
RESISTOR
I
I 2 1
I
2
loom
7 8 9 I I I I2 I O 3
1 1 1 1
I 4
1 1 1 ' 1 1 1 1
NOTES'
I . SOLOEk ?ER SOLOLklNf PROCESS MIL-S-6172 USINC SOLOER. ITEN 23
2 SOLOER JOINIS ANU'OR'COYPONEkT LEAOS SWLLL HOT PHOJECI MORE IHAN 3 16 3tlWO SURfACL OF EOARO.
3. SET R4
4.
Of 1525 SEMNOS
I-~-n n
71
62
i
I
"
c
63
Redistribution or publication of this document, by any means, is strictly prohibited.
CB M I N I I
...
BY
AVl3U N9I
'.\
-_
- - - .
- - h
EQUIVALENT CIRCUIT
-1
I
NOlcS: I. REMOX JiiMFER W12 B i X E E N TB21-i3 & Ta21-H3. MOUNT VOLTllGC SELECTOR RELAY X!!j I N UOKTROL BOX AND l l R E A; SHOWN. RELAY WILL ENEOGIZ: Oi4 120 '29BV 30 CIRCUIT COMPLETING CONNECTION BETWEEN TB21-63 I TB21-H3. RELAY WILL RElAAlN DE-ENERGIZED ON 1 2 0 / 2 4 0 , 1 1 CIRCUIT COMPLETING CONNECTION BETWEEN TB21-63 & TB21-H5.
\-
I
L3 L3
I
I
120/208V, 3 @
120/240 V, I #
WRING DIAGRAM
--
SCHEMATIC DIAGRAM
'
11115 L'51
/0
/?
G21
;if.
DES
T5
CB21
1 1
m r NO 3208431
law
MXfiIIItON
I IClRCUlT BREAKER.2AMP
GENERATgR RELAY-VOLTAGE
SELEZR-
---
I_ _ _ _ -HOUSING-CONTROL BOX
~ 2 1
R22
i 3 ~ 3 ~ 1 s zii - I i RHEOSTAT-VOLTAGE
I
I I I
33201956
I
I
1
I
1 BOARDASSY-PC
,
VOLTAGE RGLTR
NOTE CONNECT LEAD W12 FROM TERMINAL T821.63 TO TL12I.IH-I PER VOLTAGE CHART BELOW
. -3
VOLTAGE CONNECTIONS PHASE __ 50 Hz. 1H51 50 Hz.1H41 50Hz.IH31 5 0 HI. IH41 60HZ.IH31 60 H z . ~ H 4 ~ 60 HZ.IH51
. ._
230/400V. -240/416V; 2 5 4 /440V, 27?/480V. 545A22
1.
--
LO
T5
NnTF.
'
L3 L3
UNLESS OTHERWISE NOTED, ALL COMPONENTS ARE SHOWN IN THE DE.ENERGIZED , POSITION
'
60 Hz
PfNN 6& Ik
-01
ps
t
1 I'li
I
HOUSING-CONTROL BOX
TOVRZl
'
EXCITER
GENERATOR
I 545A23
I ,
!WRTS
SCHEMATIC DIAGRAM
C O N T R O L BOX IINS-IEE
0
\
2 T
pk/3D1II1LIM.$GiE7K-.S.O-.OOYI
302-0466 P
METER-RUNNING TIME 1332-19SS( D I I BOARD 4SSY-PC VOLTAGE RGLTR I I 1 I 1330-076S D I WIRING HARNESS (336-1913 A I I I L E A 0 ASSY
VR21
WIZ
I 1 I
I 1
--USING-CONTROL BOX
-I
L2
! I
ZOEG-Z19
LO L
GENERATOR
i I
I
CR4 CRS CR6 VOLTAGE CONNECTION
1201240 V
ALTERNATOR.
FIELD
T2
F::
T2
L2
NOTE: UNLESS OTHERWISE NOTED, ALL COMPONENTSARE SHOWN IN THE DE-ENERGIZED POSITION.
(WIRING DIAGRAM)
l20/24CV. IPH.
612-5302
.-
12-5303
REAR
WIRING DIAGRAM
VILE
PANEL
---
SCHEMATIC DIAGRAM
C O N T R O L BOX I I N S I D E I
,
FI
1wF/
2
=
FOR VR SYSTEM SCHEMATIC SE -24S(Dl
EXCITER ARMATURE
: an. , '
0
P C B
I I I I
CfYRlPllON
I
1315-0384
I 1
I B1
WI2
Ii
I
I I
I
USING.CONIROL BOX
TI
I M3 z ] I
T2
-Jg 27
CT22
1
CT22
I EOES-119 :
I I I I
TO
GENERATOR
ALTERNATOR FIELD
u
I l l
. U
CT22 L
512-5304
621
O
,,
f
303-00761 I
'
CR21
I I
SWITCH-VOLTMETER
SELECTOR
I
KNOB
M22
I
HOUSING-CONTROL BOX
I
I
I
I
I I
I
I
I
I .
I
I
I
:
I I
ItOES 2 1 9
I
GENERATOR
I
I
I I
ALTERNATOR
FIELD
T3
6. 7 1 9 TO 65
'I
I
612-5305
REAR_VI_EW PANEL
8
r-
fI
n
M23
T21
K
A
I
I I
L21
1115-03841 8 1 I I 1
I REACTOR ASSYCOMM
I
w12
TO VR21
M22 -
3020779 P
I
I I
. ~~LTMETER+C.O-75OV I 3 0 0 V MOVEMENT)
METER-FkEOUENCVf240) METER-RUNHINO TIME ( 2 4 0 V l
M23
M24
302-0221 B
3024466 P
M
BOX
lG
---
--USING-CONTROL
L3
I I II
nrr
EXCITER ......-..
EXClIER
F+
GENERATOR
^-
I
I
I I
I I
I t
i
ALTERNATOR FIELO
65
5
60H
PLNNW
L3
. .
NOTE:
-01
(WIRING DIAGRAM)
146-180
-06
-12
612-5305
1
I
I
!
j
I
0
2 2
.
N
72
03511 N ~ I M
S S 3 Y d 110 01 9 d W 3 1 N 3 I H N O S W Y V l V - 3 Y d A 1 3 3 V S I'E'b l O Y l N 0 3 W Y V l V - 3 Y d E'b d W 3 2 O N 3 0 1 6 S S 3 Y d 110 O l W 3 1 O N 3 I H N O S W M V l V ,413315 2.Z.b 0 3 3 d S Y 3 A 0 6 X N V t ( 3 Y 3 A 0 NO 5 W Y l l V 9 N M O a l n H S A 1 3 3 V S 1'2'b l O Y l N 0 3 3 1 V l S N N 3 d Z'b dW31 9 N 3 01 NO A l N O W Y V l V A l 3 j V S Z7.b SS3Yd 110 0 1 9 dW31 O N 3 I H ' a 3 3 d S Y 3 A O 1 Y N 1 Y 3 Y 3 A O 0 S W Y V l V 9 N M O O l n H S ,41331s 1'1% 1 0 Y l N 0 3 01s I'b S W Y V l V 6 NM001nHS'b XVW dWVS 0 3 1 V Y lln3Y13 W Y V l V 310W3Y'E A l N O l O Y l N 0 3 W Y V l V - 3 Y d NO a 3 S l l ' Z A i N o ~ O Y I N O ~ ais NO a 3 s n Z I M ' I
S310h
I -
- -_
ONllVYPNB
d N 3 1 9N3 0'
d A 3 1 I N 3 I1
S53Md 1 0 MO 1
XNVM3M3A(
-7NOW.03
ON9
WYVlV
8
WlV
k-
IIW
E 310N
NOI+ISOd 03ZIDM3N3-30 3 H l NI NMOHS 3MV SlN3NOdW63 1 1 ' 0 3 1 0 N 3SIMU3HlO S S 3 l N f l 'C 1 1 1 3 0 dN3 U01VM3N3B N1 03LNflOW HJllMS 033dSM3AO S 'E S S 3 t l d l l O 01 B dW32 3 ~ IH NO wnviv AIPJVS z z z 3 033dSM3AO 9)INVt13L13hO NO W W l V B NMOOlflHS A 1 3 d V S 1'2'2 l O M l N 0 3 31VlS NN3d 2'1 SS3Ud 1 0 0 1 B 1 d W 3 1 BN3 IH'a33dSM~AO1HNVM3n3AO 0 WLlVlV 9 NMOOLnHS A 1 3 N S 1.1'7. 1 0 ~ ~ ais 1.1 0 3 S H M V l V B NMOOlflHS '1
xvw
dKJS 031V8 Llfl3M13 W W l V 310W3M 'I :S310N
3VA OCZ-061 1201 NO E9 W 29 wn3i 01
4-I
--
.... .
. ..
. -
.~
..
L
w
>
.
t
75
Redistribution or publication of this document, by any means, is strictly prohibited.
Onan Corporation 1400 73rd Avenue N. E. Minneapolis, MN 55432 612-574-5000 Telex: 275477 Fax: 612-574-8087
Onan is a registered trademark Of Onan Corporation
Redistribution or publication of this document, by any means, is strictly prohibited.