60706-097 Operators Manual 2FSM2PC-1/A
Contents
1. For proper generator output the surface of these slip rings must have a highly polished finish Under sustained use it is advisable to check and occasionally polish the ring surfaces with a crocus cloth to maintain the finish under normal conditions This should not be required more than once each thousand hours of operation Maintenance Continued ELECTRICAL TESTING Testing generator field for opens and grounds 1 Disconnect field lead from rectifier 2 Set multimeter to read resistance and connect the meter leads to the field leads If field is open meter will read infinite resistance very high ohms Repair or replace field if it is open Typical resistance for these fields vary from 12 8 to 14 1 ohms 3 Leaving one meter lead connected to the field con nect the other meter lead to the field shell If meter indicates continuity any reading should be infinite resistance The field is grounded and should be repaired or replaced To determine which of the fields is grounded cut the connector between the two coils and retest to determine which coil has the low resistance path Figure 2 TESTING ARMATURE FOR OPENS AND GROUNDS See Figure 3 1 Remove all brushes 2 Ground fault test set multimeter to read high e sistance meg ohms Holding one meter lead against a clean spot on the armature shaft touch the other lead to each of the slip rings one at a time while observing the meter If meter2. An engine with adequate horsepower and a close regu lating fixed speed governor is required for satisfactory operation of any alternating current generator About 1 4 horsepower is required to produce each 1000 watts of generator output power assuming 100 effi ciency of both the engine and the generator However due to engine and generator efficiencies of 80 to 90 the loss of power due to engine driving accessories such as cooling fans battery charging alternators etc friction losses and slippage in the drive pullies and belts the gen eral conservative rule of thumb allowing approximately two 2 horsepower for every 1000 watts of generator output is much more realistic For example this 2 000 watt generator output will require a 4 or 5 H P engine for full output good speed voltage regulation and satisfactory load performance When determining the prime mover generator pulley ratio to drive the generator at the correct operating speed bear in mind that the power rating of most prime movers usually an engine varies with the speed that is it pro duces more power at higher speeds less when slowed The prime mover must be run fast enough to reach the desired horsepower for good gencrator set operation The drive belt system must be of adequate size and must be tight enough to power the generator without slippage Be careful not to overtighten to the extent that it puts ex cessive strain on the bearings doing so can
3. 2 Armature rubbing pole shoes Generator overheating 3 Poor ventilation 4 Short circuit in fields Short turns in armature 5 1 Generator overloaded 2 Brushes not seated properly 3 Slip rings rough or eccentric 4 5 Sparking at the brushes Brushes sticking in brush holder Brushes worn down shorter than 3 8 inch ao PON Replace armature Replace field coil s Generator must be operated at 3600 RPM 90 RPM for proper output voltage Reduce load to generator nameplate Disconnect the load Check voltage at receptacle Check motors appliances and load leads for short circuits Repair short Remove panel cover and check all wiring and connections Tighten and or repair where necessary Test rectifier Replace if defective Clean and polish Use 00 sandpaper and crocus cloth never emery paper Check brushes for swelling Replace defective brushes Clean brush holders Check output voltage with sensitive meter If very low eg 1 2 volt flash fields with 12 VDC batte Reduce load Check bearing condition Check field shell bearing bracket alignment Clear inlet and outlet air vents of debris If unit is housed ensure at least 2 ft clearance on all sides and that inlet and outlet vents are of adequate size Repair or teplace open or shorted fields should be replaced Grounded fields may be repaired by insulating at the point whe
4. cause bearing failure and other possible damage to the genera tor Alignment of the generator to the prime mover is impor tant Misalignment of the pullies will cause excessive belt and pulley wear and unnecessary stress on the prime mover The following table shows the effect of various operating speeds and electrical loads on a typical generator when matched and mounted to an adequate prime mover The following table shows the effect of various operating speeds and electrical loads on a typical generator when matched and mounted to an adequate prime mover Although individual units and models may vary slightly the normal voltage and frequency of typical 60 cycle engine driven generators described in this manual are ap proximately as follows when powered by a typical prime mover engine run first with no load applied then at half the generator capacity and finally when toaded to its full capacity as rated on the nameplate GENERATOR LOAD SPEED FREQUENCY VOLTAGE None 3690 RPM 61 1 2Hz 129 Volts Half 3600 RPM 60 Hz 120 Volts Full 3510RPM 58 1 2Hz 115 Volts NOTE Required generator speed must be maintained at 3600 90 RPM under all load conditions All engines have a tendency to slow down when a load is applied The governor on the engine is designed to hold the engine speed nearly constant When the electrical load connected to the generator is increased the en gine is more heavily loaded and as a resu
5. current amperes to help start them than to run them Certain motors panlculerly inexpensive split phase motors are very ard to start Typically they require 7 to 10 times as much current to start them as to run them Capacitor motors are easier to start but still require 3 to 5 times their running current to start Repulsion induction motors are the easiest to start and usually require only 2 to 4 times their running current to start Refer to the nameplate of the generator for the running current ampere rating and starting code of your motors NOTE The starting code is an alpha character A code motors are the easiest to start R S or T code motors are very hard starting Most fractional horsepower motors take about the same amount of current to run them regardless of their type of construction repulsion induction Rl capacitor CAP or split phase SP type A self excited generator responds differently to severe overloading than a transformer connected to a power line To illustrate suppose that a 115 volt 5 H P capacitor start induction run motor is connected to a small transformer with a maximum rating of 2 000 watts and then to a generator of 2 000 watts capacity The transformer would not be able to supply enough power to bring the motor up to operating speed but would be very severely overloaded and probably would burn out in a short time The motor might also be damaged When this motor
6. is connected to a self excited 2 000 watt generator the generator output voltage drops to its 3 residual voltage level nearly zero typically 3 to 7 volts The exciter voltage is also taken from the generator ouptut voltage Since there is no exciter vol tage the generator magnetic field collapses Now there is virtually no load on the generator or engine so no harm is done to either Under these conditions the motor may revolve a few times when it is first turned on and then stop when the generator field collapses under massive overloads The generator is self or inherently protected and since the generator is producing nearly zero voltage the motor or other load is not damaged in any way CAUTION On the other hand an electric motor that requires slightly more output than the generator can produce will run but will not reach a high enough speed for the centrifugal switch to discon nect the starting winding The generator output vol tage instead of being 115 may drop to 70 or 80 volts Running the generator under these condi tions may result in burning out the motor start wind ing Exercise care the first time each new load is energized to be sure that the load is compatible and within the capacity of the generator Because the heavy surge of current required for starting motors is required for only an instant the generator will not be damaged if it can bring the motor up to speed in a few seconds of
7. shipping base General Safety Information DEFINITION OF CAUTIONS AND WARNINGS CAUTION Possible damage to equipment Notes indicate any condition or practice which if not strictly observed or remedied could result in dam age or destruction of the equipment WARNING PERSONAL DANGER NOTES INDI CATE ANY CONDITION OR PRACTICE WHICH IF NOT STRICTLY OBSERVED COULD RESULT IN PERSONAL INJURY OR POSSIBLE LOSS OF LIFE Despite the safe design of this generator operating it imprudently neglecting its maintenance or being care less with it can cause serious injury or death This generator is powerful enough to deliver a fatal electric shock Allow only a responsible and capable person to operate this generator 1 For permanent wiring or wiring into existing electricat service or system the installation must comply with all national state and local codes 2 Do not allow anyone to operate the generator with out proper instruction 3 Avoid touching live terminals or receptacles General Safety Information Cont d 4 Be extremely careful if operating this generator in rain or snow 5 This generator must be properly grounded 6 Hot prime mover engine parts moving drive parts and generator output all can seriously injure the generator operator The operator must use caution and remain alert when using this generator 7 Keep ail safety guards and drive shields in position and tightly secured while equipment is operati
8. TWO BEARING GENERATORS 2FSM2PC SERIES INSTALLATION OPERATION and MAINTENANCE INSTRUCTIONS READ INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO OPERATE OR SERVICE THE DAYTON GENERA TOR FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND OR PROPERTY DAMAGE RETAIN INSTRUCTIONS FOR FUTURE REFERENCE Testing Policy Before any generator is shipped from the factory it is fully checked for performance The generator is loaded to its full capacity and the voltage current and fre quency are carefully checked A test card with this data is filed by unit serial number for permanent record of performance Rated output of generators is based on factory tests of typical units and is subject to and limited by the ambient operating temperature The generator will not provide full power output unless driven by a prime mover of adequate horsepower The prime mover engine or other input power source horsepower is also affected by temperature as well as a number of other factors such as fuel altitude and all other conditions specified by the prime mover manufacturer Description The WINCO generator is a 3600 RPM two bearing belt driven brush type revolving armature design The generator is self excited and inherently regulated to plus or minus 7 no load to full rated load It can be operated under any load within its rating without being damaged The frequency regulator is determined by the sensi
9. ading should be observed 5 Check each terminal to the case An open circuit very high resistance reading should be observed A battery powered test light is used Follow the same procedures described above A good diode element will allow current to pass to the light in the test lamp when the leads are connected in the forward direction 6 Ifthe rectifier fails any of the above tests it should be considered defective and replaced Maintenance Continued CONDENSER TESTING RED TEST LEAD Condensers are built into the generator circuit to minimize radio interference during operation If a con denser shorts out it will also short out the generator output To determine whether a condenser is shorted stop the generator and disconnect the condenser lead wire from the brush holder Using a multimeter on the R x 100 scale check the resistance of the condenser Normal response is a sharp swing of the meter towards low resistance and then a steady rise towards high resistance open circuit If the capacitor is shorted it will show as a constant low resistance Otherwise restart the generator without the capacitor connected to recheck the generator for output If the a then provides power the condenser was at ult and should be replaced If the generator did not provide power after the problem was not caused by that condenser reconnect the lead wire if these tests have not located the trouble remove the armature and have it te
10. ely high speed may also cause damage to the generator armature windings Assembly Continued Plans for installation should be prepared with proper attention to mechanical and electrical engineering detail to assure a Satisfactory system installation The infor mation in this manual is offered as a guide to finalizing your installation plans The installation sequence is summarized below PLAN THE INSTALLATION Generally these two bearing generators are used on portable equipment For best service consider the following 1 All electrical equipment should be protected from excessive moisture Failure to do so will result in deterioration of the insulation and short circuits and grounds 2 The generator should be installed in a sheltered area If the unit must be left in the open it should always be protected with a weather cover such as a tarp or large piece of canvas after each use to keep out water and dust CAUTION Always allow the generator and prime mover to cool before covering with a flammable weather covering MOUNTING CAUTION The generator must be mounted with the engine to a common rigid base to prevent stress on the engine and generator shafts and bearings due to vibration displacement For permanent installa tions the engine generator is usually mounted ona sub frame which can be shock mounted with spe cial neoprene pads on the main frame Operation USE OF ELECTRIC MOTORS Electric motors require much more
11. indicates continuity any reading lower than one meg ohm the armature is grounded Dirt be tween the slip rings and on the insulator surface can cause grounding If grounding was indicated care fully clean all dirt off the slip rings and their insulators and then recheck it Replace the armature if it is grounded and unrepairable 4 3 Testing for opens Set meter to read low resistance R x 1 ohms Holding one meter lead on surface of slip ring No 1 touch other meter lead to surface of slip ring No 2 while observing the meter Meter should indicate continuity low resistance less than one ohm is typical If the meter indicates open circuit infinite resistance part of armature winding is open This may be caused by a repairable defect in the connec tion at the slip ring however generally an open arma ture will have to be replaced Figure 3 TESTING RECTIFIERS See Figure 4 The field excitation is supplied through a half wave bridge rectifier This type of rectifier has three terminats two AC anda DC positive A rectifier may be tested in the following manner 1 Disconnect all leads from rectifier 2 Connect the red ohmmeter lead to the positive DC terminal 3 Connect the black lead to each of the AC terminals in turn Either a high or low resistance reading will be obtained 4 Reverse the meter leads black lead to the DC pos and red to the AC terminals each in turn An opposite re
12. ng 8 When operating this generator do not wear neck ties loose articles of clothing or anything else that can be caught in moving parts 9 Provide adequate ventilation for prime mover ex haust and fuel vapors that may leak through fittings or damaged pipes Be sure generator itself is well ventilated for maximum performance and life 10 The generator manufacturer recommends that only qualified electrical technicians be allowed to service install maintain repair or replace parts this generator and that only factory approved re pair parts be used in it 11 Do not work on this generator or other potentially hazardous equipment when fatigued 12 Use extreme caution when working on electrical components High generator output voltage can cause serious injury or death 13 Keep the generator and the area around it clean Remove all material that can create slippery condi tions such as grease water ice and snow Also remove oily rags and other flammable material from the area 14 Keep a fire extinguisher near the generator Extin uishers rated ABC by the NFPA are appropriate or this use Consult the local fire department if you have questions regarding fire extinguisher ratings Keep the extinguisher properly maintained and be familiar with its proper use Installation CAUTION Before proceeding with the installation be sure that you have completely read and understood the assembly and installation instructions
13. re the ground occurs Replace arm Reduce load Contour brushes see maintenance Redress slip rings see maintenance Remove brushes and inspect and cor rect problem Replace brush NOTE Always replace brushes a full set at a time l l i a7 WINCO INC 12 Month Limited Warranty WINCO Incorporated warrants to the original purchaser for 12 months that goods manufactured or supplied by it will be free from defects in workmanship and material provided such goods are installed operated and maintained in accordance with Winco written instructions WINCO s sole liability and Purchaser s sole remedy for a failure under this warranty shall be limited to the repair of the product At WINCO s option material found to be defective in material or workmanship under normal use and service will be repaired or replaced For warranty service return the product within 12 months from the date of purchase transportation charges prepaid to youen nearest WINCO Authorized Service Center or to WINCO Inc at Le Center Minnesota THERE IS NO OTHER EXPRESS WARRANTY To the extent permitted by law any and all warranties including those of merchantability and fitness for a particular purpose are limited to 12 months from date of purchase In no event is WINCO liable for incidental or consequential damages Note Some states do not allow limitation on the duration of implied warranty and some states do no allow the excl
14. sted for opens shorts and Figure 4 grounds on a growler RECEPTACLE SCHEMATIC DIAGRAM FIELD RECTIFIER a Ro ARMATURE WIRING DIAGRAM Figure 5 Wiring Diagram 5 ILLUSTRATE PARTS LIST MODEL 2FSM2PC 1 A PART NUMBER 61685 000 REF PARTNBR_ QTY DESCRIPTION REF PARTNBR_ QTY DESCRIPTION 1 6372 000 4 10 32 Nut 12 61687 000 1 Field Shell amp Coil Assy 2 484 000 4 10LockWasher 13 60925 000 1 Upper Field Coil 3 20556 002 4 10 32 Thru Bolt 14 60925 001 1 Lower Field Coil 4 7924 000 1 Baffle 15 61689 000 1 Field Shell 5 20557 000 2 Anchor Strap 16 23607 000 3 AC Brush 6 40746 000 6 8 32 X 5 16 Screw 17 59690 000 3 Brush Holder 7 61427 000 1 OutputEnd Bracket 18 41221 000 2 Capacitor 8 8929 000 1 InputEndBracket 19 91452 000 1 Rectifier 9 60928 000 1 Cover 20 59688 000 3 Barrier Spacer 10 61426 000 1 Armaturew Bearings21 60960 000 2 Receptacle 11 55223 000 2 Bearing 22 60931 000 1 Receptacle Plate z l Troubleshooting Chart SYMPTOM POSSIBLE CAUSE S CORRECTIVE ACTION Open or shorted armature Open or shorted field coil s A Generator operating below correct RPM speed No output or low output voltage wN Generator overloaded Short circuit in the load Loose or broken wires or connections in the control box Defective rectifier Dirty slip rings Brushes binding in holders Loss of residual magnetism 1 Generator overloaded
15. t the speed drops slightly This slight decrease in speed together with the natural voltage drop within the generator itself due to load current and heating of the windings results in a slightly lower voltage than when the generator is running idle The normal slight variations in speed also directly affect the frequency of the output current This frequency vari ation has no appreciable effect in the operation of most loads such as motors lights and most small ap pliances However timing devices and clocks will not keep perfect time unless the engine can keep the oe running at exactly 3600 RPM at all times ince this is not usually possible minor time errors in clocks occur The speed of the engine is usually adjusted so that the generator produces proper voltage If the adjustment is made cold set the voltage a little higher than normal since it will drop a few volts as the generator warms up NOTE When operating continuously at full load the enerator shell becomes very warm It will be uncom ortable to the touch this is normal for any high performance inherently regulated generator Output voltage should be checked periodically to en sure proper operation of the generating plant and appliances CAUTION Low voltage may damage any motors or appliances connected to it Running the generator at excessively high speeds results in too high vol tage which will also damage electrical devices con nected to it Excessiv
16. time If diffi culty is experienced in starting motors turn off all other electrical loads and if possible reduce the load on the electric motor Maintenance GENERAL The main components of the generator are field frame field coils armature brushes brush holder assembly brackets armature and generator cooling fan BRUSHES Under ordinary circumstances brushes will operate for thousands of hours without requiring replacement They should be inspected after the first 1000 hours of opera tion and after every 500 hours of operation thereafter Remove brushes one at a time and check for length Be sure that each moves freely in the brush holder Brushes should be replaced when worn down to 3 8 Always replace brushes in complete sets never singly When replacing brushes be careful to reconnect the lead wire properly Poor contact or skipping between brush and slip ring can be caused by oil and grit flint or other hard contaminant substances on the brushes or by the brush not being properly shaped to fit the slip rings i Remedy these defects by cleaning the rings and brushes and then fitting the brushes to the slip ring curvature Place 00 sandpaper under the brushes with the abrasive side to the brushes and work it back and forth until the brushes are the same shape as the slip rings SLIP RINGS The continuous copper rings located at the end of the armature are the power collector rings or slip rings
17. tivity of the customer supplied prime mov ers governor It is desirable to maintain this speed to within 3 cycles variation 61 5 Hz 58 5 Hz no load to full rated load 3690 RPM 3510 RPM Specifications INSULA WATTS VOLTS TION 2 000 120 16 7 60 1 13600 Class B Unpacking When unpacking the generator be sure to inspect it carefully for freight loss or damage If loss or damage is noted at the time of delivery require that the person making the delivery make note of the loss or damage on the freight bill or affix his signature under the con signer s memo of the loss or damage Contact the car rier for claim procedures When loss or damage is noted after delivery segregate the damaged material and contact the carrier for claim procedures Concealed damage is understood to mean damage to the contents of a package which is not in evidence atthe time of delivery by the carrier but which is discovered later The carrier or carriers are responsible for merchandise lost or damaged in transit The title of goods rests with the consignee when generators are shipped FOB factory And only the consignee can legal ly file claims 1 Carefully open carton 2 After inspecting the generator for external physical damage check for the owner s manual operating instructions wiring diagram parts list and warranty inside the carton 3 Remove generator hold down bolts 4 Unit can now be lifted from
18. usion or limitation of incidental or consequential damages so the above limitations may not apply in every instance This warranty gives you specific legal rights which may vary from state to state WINCO reserves the right to change or improve its products without incurring any obligations to make such changes or improvement on products purchased previously EXCLUSIONS WINCO does not warrant engines batteries or other component parts that are warranted by thier respective manufacturers WINCO does not warrant modifications or alterations which were not made by the WINCO Inc WINCO does not warrant products which have been subjected to misuse and or negligence or have been involved in an accident This warranty does not include travel time mileage or labor for removal or reinstallation of WINCO product from its application INGO 225 South Cordova St LE CENTER MINNESOTA 56057 Phone 612 357 6821 60706 097 00151
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