“C” type Generator End User`s Manual Addendum For 15,17.5, 20
Contents
1. type Generator User s Manual Addendum For 15 17 5 20 and 25kW gensets with in third position in Serial Number Please read this manual carefully prior to installing and operating this generator If you have any questions please feel free to contact us at 800 760 0027 or via our website at www powertech gen com General Technical Data of the Generators Synchronous brushless generator single phase Rated 22kW and 25kW 120 240V 250 125Amps 4 pole 60Hz 1800RPM PF 1 0 Continuous Duty Temp rise 105 C 50 C ambient temperature Suitable for operation with VR3 1 Insulation Class H SAE 4 SAE 7 Single bearing The use of any spare parts that are not genuine or not expressly authorized shall free Power Technology Southeast Inc from any warranty liability and any responsibility concerning conformity to regulations and relevant consequences Installation after sales modifications and maintenance must be carried out by adequately trained staff 5 RULES FOR SAFE OPERATION sini na Bean I Ana nan 4 RECEIVING THE GENERATOR une ee em ema ea ana nana 5 STORING THE GENERAT OR 5101ns200 nenen ee an aa Sada 5 INSTALLATION erinnere 6 LIFTING THE GENERAT OR sn naa asa naa he REIHE 6 LOCATION ENVIRONMENT ccecceccesccscescessceeaecsesseceaecaeseecaesaecaeeeaeseeceaesaeseeseeseseseaecaeseeeseeseaeeaesseserseaeeas 6 MOUNTING GENERATO2. the housing A WARNING MAKE SURE THAT EARTHING GROUNDING IS DONE PROPERLY NOT DOING SO CAN CAUSE SHOCK AND EVEN DEATH GENERATOR OPERATION BEFORE STARTUP The following steps are recommended prior to starting the generator for the first time 1 Make sure generator and engine are level and bolted securely on a base 2 Check visually for any foreign materials 3 Make sure all nuts and bolts are tightened properly 4 Check all connections against the wiring diagram especially the generator lead wires Make sure connections are tight and properly insulated Vibration can cause connections to loosen disconnect or rotate causing short circuits 5 Make sure generator is grounded correctly using generator grounding bolt located on the housing 6 Make sure fan screen is assembled on the bell housing START UP 1 Make sure generator is in no load condition disconnect generator output from load This can be done switching the circuit breaker in the OFF position or not connecting a load to the gen set terminals 2 Remove field excitation wires F and F from AVR See the Automatic Voltage Regulator User Manual 3 Check that that all engine start up procedures have been followed 4 Start engine and adjust engine speed initially between 60Hz to 62Hz for 60Hz rated generator Reference engine manual for how to adjust speed 5 Using properly rated voltmeter check line to line and line
3. ALIFIED PERSONNEL ONLY THIS EQUIPMENT IS FOR INDUSTRIAL USE ONLY The following safety guidelines should always be used when operating servicing or maintain the generator end DO NOT operate or service this equipment before reading this entire manual This equipment should not be operated by persons under 18 years of age ALWAYS make sure generator installation is in accordance with electrical codes for your location ALWAYS have a qualified electrician perform the generator wiring installation NEVER operate this equipment without proper protective clothing shatterproof glasses steel toed boots and other protective devices NEVER operate this equipment when not feeling well due to fatigue illness or taking medicine NEVER operate this equipment under the influence of drugs or alcohol NEVER use accessories or attachments which are not recommended by your local distributor or original manufacturer for this equipment Manufacture does not assume responsibility for any accident due to equipment modifications ALWAYS check the machine for loosened threads bolts or other parts before starting NEVER operate the generator in an explosive atmosphere or where fire could result ALWAYS allow the generator to cool before performing service and maintenance functions Contact witn HOT components can cause serious burns NEVER operate the generator in any enclosed or narrow area where free flow of the air is res
4. R TO ceeeeseeceeeesnececeseeeeeeseaeeecesaeeeeeeaaeeeeessaeeeeeseeaeeeseeseeeeeeeeeaeeeeeeeeers 6 EARTH GROUND THE GENERATOR ooocoocoroo WoWoWo Kanan 6 OPERATION dee na na O An Pen nan Senat 7 BEFORE STARTUP orisom a aman has mai nya aa aa na akad ih 7 STARTUP ee nana nama naa ea 7 SHUTDOWN 35 bae one ma hama ha sa mmm maka Eh lei Ranah ha bae ama na 7 MAINTENANCE iiep iee banana tenant ama asam amanah uan amis 8 GENERAL MAINTENANCE sva ina nm Abas ma aa nan han 8 INSULATION RESISTANCE seien 8 DRYING OUT THE GENERATOR 5 8 TROUBLESHOOTIN Gras 2 eta Sate emak sen ae andre ng maan aa sad 9 MECHANICAL ISSUES 2 200 aaa aan ba 9 ELECTRICAL ISSUES irinna hee inna en eb bein 9 FLASHING THE FIELD ee ae ee 11 REPLACING THE RECTIFIED 11 ANR ADJUSTMENTS aman Kn ea us ma este eS 11 RESISTANCE VALUES FOR WINDINGS Heat emak ma nga 11 APPENDIX A EXPLODED mandorna niee masalan ringen 12 APPENDIX B SPFPARE PARTS han nga aa 13 APPENDIX Wiring diagram for Single Phase Generator 4 5 Wo WoWoW oo 14 RULES FOR SAFE OPERATION FAILURE TO FOLLOW INSTRUCTIONS IN THIS MANUAL MAY LEAD TO SERIOUS INJURY OR EVEN DEATH THIS EQUIPMENT IS TO BE OPERATED BY TRAINED AND QU
5. TION Check the generator thoroughly before starting installation Make sure there is no damage during shipment or during storage Perform the Insulation Resistance Test and dry out the generator windings if necessary Check Maintenance Section of this Manual for additional instructions LIFTING THE GENERATOR A WARNING THE GENERATOR LIFTING EYE IS DESIGNED FOR LIFTING THE GENERATOR ONLY IT IS NOT DESIGNED TO USE TO LIFT THE GENERATOR AND ENGINE GENERATOR SET USING EQUIPMENT WITHOUT PROPER LOAD BEARING CAPACITY CAN CAUSE SEVERE INJURY AND DAMAGE Do not lift single bearing generators without the rotor anchor bar securely fixed Remove the rotor anchor bar only when attaching the generator to the engine Lift the generator horizontally in order to prevent the rotor from slipping out LOCATION ENVIRONMENT Installation of the generator to the engine must be done in a location that is protected from moisture dust dirt and harmful fumes Generator intake and outlet air passages need to be unobstructed during generator operation Please do not mount any obstructions that would restrict the airflow The generator needs sufficient air circulation in order to provide proper cooling Make sure that hot air from radiator or engine does not pass through the generator Make sure the mounting surface generator set base has sufficient strength rigidity and uses the proper anti vibration mounts in order to keep
6. ances If found please remove rotor and clean Make sure the generator windings are dry before assembling O Check generator intake and exhaust venting openings bearing cover and bell housing screen to ensure airflow is not obstructed Clean as needed O Periodically check bearings for unusual operation Unusual operation is defined by excessive vibrations unusual noise grease leaking etc Replace bearings if unusual operation determined Before operation check the resistance of the stator winding by performing the Insulation Resistance Test The reading should be greater than 2 MQ otherwise drying out the windings will be necessary INSULATION RESISTANCE TEST 1 Disconnect all electronic components AVR etc 2 Short out the diodes on the rotating diode assembly 3 Use a MegOhmMeter or Insulation Multimeter rated at least 500V and connect between output lead terminal and ground and later disconnect the lead wires from the terminal board and measure the resistance between lead wires and ground 4 Measured value of insulation resistance for all windings to ground and between phases Measured values should be greater than 2 If not then dry out the generator windings DRYING OUT THE GENERATOR WINDINGS One or more of the following methods can be used to dry out the windings Push hot air through the generator using heaters and blowers Make sure the air can flow freely throu
7. gh the generator Also be careful not to overheat the windings which could cause permanent damage Run the generator set unexcited by disconnecting the AVR terminals open circuit for 15 minutes Oven dry the generator for up to 3 hours at 60 C 80 C temperature Make sure to remove AVR during oven drying Once the Insulation Resistance is raised to a level of greater than 2 then the generator can be put into service TROUBLESHOOTING MECHANICAL ISSUES SYMPTOM Generator Overheating Excessive Vibration Noise CAUSE Air vents obstructed preventing normal air flow required for cooling Load exceeds generator rated load High ambient temperature High altitude Misalignment of coupling between generator and engine Faulty or damaged bearing ELECTRICAL ISSUES SYMPTOM Generator will not excite no voltage No load voltage too low CAUSE Exciter stator output voltage too low to start AVR Loss of residual magnetism Faulty AVR Faulty diodes or rectifier assembly Disconnected or shorted exciter rotor or main rotor lead wires Damaged or burnt exciter rotor stator stator or rotor windings Check engine speed RPM Incorrect or faulty wiring AVR not adjusted correctly SOLUTION Check vents at rear bearing cover and fan intake air vent and make sure obstructions are removed Reduce the load on the generator to equal or below rated load listed on generator name plate I
8. ires 7 Mount the bearing on the shaft AWN 8 Put back on the rear bearing cover AVR ADJUSTMENTS Adjustments on the AVR include screws potentiometers that can adjust voltage and stability 1 Voltage Adjustment Change the output voltage by adjusting the Voltage potentiometer screw on the AVR Make sure generator is rotating at rated RPM Turn clockwise to increase voltage and counter clockwise to reduce voltage See AVR manual for additional instructions Stability Adjustment Change the stability of the generator by adjusting the Stability potentiometer screw on the AVR Turn clockwise to increase stability and counter clockwise to reduce stability See AVR manual for additional instructions RESISTANCE VALUES FOR WINDINGS Stator Exciter Exciter Rating U1 U2 Rotor Stator Rotor kw 0 0 20 60 1 03 18 126 22 60 0 9 18 130 25 47 1 0 18 130 1CB Series User Manual APPENDIX A EXPLODED VIEW Reference Part Name Reference Part Name Number Number 1 Bearing cover 11 Exciter rotor 2 Exciter stator 12 Main rotor 3 Exciter stator lead wires 13 Fan 4 Bolts for exciter stator 14 Coupling disc 5 Generator housing 15 Bolts for coupling disc 6 Generator mounting feet 16 Automatic Voltage Regulator AVR 7 Stator 17 Terminal board 8 Terminal lead wires 4 leads 18 Base for AVR and Terminal board 9 Bearing 19 Control box cover 10 Rectifier assembly 20 Control b
9. is required There exists the possibility of electrocution electrical shock or burn which can cause severe bodily harm or even death Back feed to a utility system can cause electrocution and or property damage DO NOT connect to any building s electrical system except through an approved device or after building main switch is opened ALWAYS have licensed electrician perform the installation RECEIVING THE GENERATOR Once the generator is received you should first examine it carefully for any damages during shipping and for missing parts If there is shipping damage then please make note of the damage with the carrier and contact Power Technology Southeast Inc immediately NOTE Please note any damage with the carrier and be sure to note this damage on the Bill of Lading document Take digital photos when available and be sure to properly document the damage STORING THE GENERATOR If the generator is not immediately used it should be stored indoors in a clean and dry environment If the generator is stored for an extended period of time it should be cleaned and tested before operation Also check all bolts for tightness and examine the insulation on lead wires for chafing NOTE Wet windings should be thoroughly dried out before operation otherwise serious damage to the generator can result Please see the Maintenance section of the User Manual on how to how to dry out the generator windings INSTALLA
10. k that air gap is even on all sides Re mount rotor and generator housing on engine Calibrate AVR by adjusting the Stability control screw potentiometer on AVR See AVR Manual SERVICE FLASHING THE FIELD Residual magnetism of the exciter stator may be lost or weakened if the generator is not operated for long periods of time during long periods of transport or due to other situations While flashing the field the generator MUST BE out of operation Steps to flashing the field 1 Make sure the generator is not in operation not rotating and all terminals disconnected 2 Disconnect exciter stator leads F and F from the AVR 3 Connect 12V DC battery to terminals F and F making sure that the pole of the 12V DC battery is connected to F and pole connected to F 4 Connect battery leads for approximately 3 to 5 seconds and then disconnect from F and F 5 Reconnect the F and F to AVR 6 Start the engine and run at rated RPM with no load and check voltages 7 Re flash the field if generator voltage does not build up to rated values REPLACING THE RECTIFIED ASSEMBLY 1 Disconnect the exciter stator leads F and F from AVR Remove the rear bearing cover Remove the bearing from the shaft Disconnect all the wires to the rectifier assembly 5 Remove rectifier assembly 6 Replace with new or repaired rectifier assembly Lock the screws with thread adhesive and reconnect all the w
11. mprove airflow to generator Make sure that hot air is not recycled from generator or engine Altitude reduces the rating and affects the cooling of generator Reduce load of generator until overheating stops Realign and tighten connection between coupling disc and engine flywheel and generator housing and engine housing Make sure correct grade bolts are used and are tightened to appropriate torque level using calibrated torque wrench Replace bearing SOLUTION First try increasing the engine speed to 110 of rated RPM for a few seconds to see if excitation is achieved If this does not work then Flash the Field to restore residual magnetism Flash the Field to restore the residual magnetism Adjust or replace AVR See AVR Manual Check diodes first Then replace the faulty rectifier assembly Check lead wires for short or disconnection and repair Check windings visual check smell check measure resistances and compare with the rated values Replace faulty parts Increase speed on engine slowly to increase voltage Do not increase speed over 110 of rated RPM Check wiring against the Generator Wiring Diagrams in the Appendix Check wires for short and open connections Calibrate AVR by adjusting the Voltage screw potentiometer See AVR Manual Damaged or burnt rotor stator stator or rotor windings Check windings visual check smell check measure resistances and compare with the rated val
12. ox 1CB Series User Manual APPENDIX SPARE PARTS LIST Reference Part Name Part Number Number _ 1 Bearing cover 1CB xx 001 00 2 Exciter stator 1CB xx 002 00 3 Exciter stator lead wires N A 4 Bolts for exciter stator N A 5 Generator housing N A 6 Generator mounting feet N A 7 Stator N A 8 Terminal lead wires 4 12 leads N A 9 Bearing 1CB xx 009 00 10 Rectifier assembly 1CB xx 010 00 11 Exciter rotor 1CB xx 011 00 12 Main rotor 1CB xx 012 00 13 Fan 1CB xx 013 00 14 Coupling disc N A 15 Bolts for coupling disc N A 16 Automatic Voltage Regulator VR3 1 00UL 17 Terminal board 1CB TB OOUL 18 Base for AVR and Terminal board N A 19 Control box 1CB xx 019 00 20 Control box cover N A xx Insert KW rating for generator to complete Part Number For example Exciter Stator for 25kW generator is 1CB 25 002 00 1CB Series User Manual APPENDIX Wiring diagram for Single Phase Generator 240V OUTPUT STATOR 240V INPUT RECTIFIER ASSEMBLY EXCITER ROTOR EXCITER STATOR 1CB Series User Manual
13. to neutral residual voltages on generator terminal connections Residual voltages will be much smaller than rated generator voltages If voltages are unbalanced or not according to expected ratios shut down the engine and re check the wiring 6 If voltages are correct balanced shut down the engine and connect exciter field wires F and F to AVR See the Automatic Voltage Regulator User Manual 7 Start the engine again Have voltmeter hooked up to generator terminal board and adjust voltage to the rated value 120V 240V by rotating the AVR voltage adjust screw See the Automatic Voltage Regulator User Manual 8 Once AVR is adjusted check again all line to line and line to neutral voltages on generator terminal connections for proper voltage levels 9 If voltage levels in Step 8 are correct then shut down the engine and close the main circuit breaker to the load Start up engine with load applied 10 Check generator speed frequency under load Adjust as necessary 11 is recommended to apply different load levels for a few minutes 25 load 50 load 75 load full load and 110 load to the generator and test voltage levels for proper adjustment and function SHUTDOWN Shutdown varies based on the engine used Please reference the engine User Manual for proper shut down procedures MAINTENANCE GENERAL MAINTENANCE Check generator windings for buildup of dirt oil or any other subst
14. tricted If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people The generator engine gives off DEADLY carbon monoxide gas ALWAYS make sure generator is properly grounded DO NOT place hands or fingers inside the generator when engine is running generator is rotating NEVER allow power cables or cords to lay in water or any other liquid The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits Turn all circuit breakers OFF before performing maintenance on the generator ALWAYS make sure that electrical circuits are properly grounded per the National Electrical Code NEC and local codes before operating generator Severe injury or death by electrocution can result from operating an ungrounded generator If the unit is sold internationally outside USA please make sure that grounding is done according to the local electrical code ALWAYS store equipment properly when not being used Equipment should be stored in a clean and dry location DANGER HAZARDOUS VOLTAGE Voltage or current hazard sufficient to cause shock burn or death Disconnect and loackout power before servicing NEVER touch output terminals during operation This is extremely dangerous ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals
15. ues Replace faulty parts ELECTRICAL ISSUES continued SYMPTOM No load voltage too high Voltage below nominal under load Voltage above nominal under load Unstable voltage CAUSE AVR not adjusted correctly Check engine speed RPM Incorrect or faulty wiring Faulty AVR AVR not adjusted correctly Current too high excessive load or speed below nominal Faulty AVR Faulty diodes AVR not adjusted correctly Faulty AVR Non uniform rotation of engine Misalignment of generator and engine AVR is unstable SOLUTION Calibrate AVR by adjusting the Voltage screw potentiometer See AVR Manual Decrease speed until rated voltage is achieved Rated voltage is listed on generator name plate Check wiring against the Generator Wiring Diagrams in the Appendix Check wires for short and open connections Adjust or replace AVR See AVR Manual Calibrate AVR by adjusting the Voltage screw potentiometer See AVR Manual Reduce load and make sure current does not exceed rated current Adjust or replace AVR See AVR Manual Check the diodes Replace the rectifier assembly Calibrate AVR by adjusting the Voltage screw potentiometer See AVR Manual Adjust or replace AVR See AVR Manual Check for uniform rotation of engine Engine could be at fault Check with engine User Manual or manufacturer for further troubleshooting Check for mounting of rotor and stator on engine Chec
16. vibration and noise to a minimum MOUNTING GENERATOR TO ENGINE Generator is mounted to the engine by the use of the generator coupling disc which fits perfectly into the recess on the engine flywheel Holes on the coupling disc correspond to threaded holes on the engine s flywheel The coupling disc will mate with the prime mover s flywheel so that concentricity is obtained to Engine Make sure that the generator and engine are level 2 Carefully pull out the main rotor assembly from the generator housing Be careful not to damage the copper stator windings 3 Make sure the generator coupling disc is flat against the engine flywheel and fits perfectly into the recess on the engine flywheel Use appropriate bolts and hardened washers to mount the coupling disc to the engine flywheel Tighten with calibrated torque wrench Split type lock washers should NOT be used due to possible damage to coupling disc 4 Mount generator housing over rotor and mount to engine housing Check that the exciter rotor and exciter stator are aligned 5 Mount the generator SAE housing to the engine housing If bolted properly there should be further alignment necessary EARTH GROUND THE GENERATOR The generator housing has to be connected to ground If flexible anti vibration mounts are used then an earth conductor should be connected in parallel to the base for proper grounding Generator has an earthing bolt on
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