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OwnerslOperators Manual EMERGENCY RESCUE

1. Sk IIIT 140 ACEP Tac als 1 i TALL i LO 240 7 3 PHASE CSA amp STD DEC 140 YOUAGE CONNECTIONS 140 3 8 i apy j aee 1207 18 igy t i lf Lo LE XTRA BREAKERS ON CSA MOOELS ONLY GENERAL SUP Fae MERTI CANOES ALL WOON mp o b i TECHNICAL DATA UNIT MODEL SERIES 27PSB4G 53 A 35PSB4G 3 A COMPLETE UNIT ASSY 64535 004 64535 001 AC RESIDUAL VOLTS 7 0 VAC L L 7 0 VAC L L FIELD RESISTANCE 3 51 OHMS 3 51 OHMS SCHEMATIC DIAGRAM B 91322 B 64521 WINDING SPEC SS 1388 1298 ARM CONNECTION 315 315 UNIT MODEL SERIES 4OPSB4G 4 A 45PS84G 17 A COMPLETE UNIT 55 64535 003 64535 002 AC RESIDUAL VOLTS 7 0 VAC L L 7 0 VAC L L FIELD RESISTANCE 3 51 OHMS 5 51 5 SCHEMATIC DIAGRAM B 91323 B 64521 WINDING SPEC SS 1307 1299 ARM CONNECTION AC 317 316 UNIT MODEL SERIES 75PSB4G 4 A 75PSB amp 4G 17 A COMPLETE UNIT ASSY 64544 003 64544 002 RESIDUAL VOLTS 7 0 VAC L L 7 0 VAC L L FIELD RESISTANCE 5 36 OHMS 5 36 5 SCHEMATIC DIAGRAM B 91323 B 64521 WINDING SPEC SS 1347 1314 ARM CONNECTION AC 317 316 10
2. Owners Operators Manual EMERGENCY RESCUE GENERATORS PINCO INCORPORATED 60706 108 ER2165 1 TABLE CONTENTS Operation 6 Maintenance 6 Troubleshooting 8 Wiring Diagrams 10 Technical Data 11 Warranty 12 Introduction and Description Specifications Unpacking Instructions Safety Information installation Final system check VWI CA M 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 frequency are carefully checked Rated output of generators 1 based on factory tests of typical units and is subject to and limited by the temperature altitude fuel and other conditions specified by the manufacturer of the applicable engines and governors in each installation INTRODUCTION AND DESCRIPTION This two bearing rotating field generator is a direct drive two bearing generator specifically designed for auxiliary PTO drive and vehicle mounting It provides primary power for lighting motors and equipment loads for the emergency rescue ER market The height and length are minimized to permit fitting between the rails of rescue vehicles with a minimum of box and chassis modification and cost The generator uses simple proven excitation and boost circuits for exceptional motor starting ability The unit is complete tested and ready for installation All items necessary for installation
3. and local codes Do not allow anyone to operate the generator without proper instruction Avoid touching live terminals or receptacles Be extremely careful if operating this generator in rain or snow This generator must be properly grounded Hot parts moving parts and generator output all can seriously injure the generator operator The operator must use caution and remain alert when using this generator Provide permanent safety guards and shields for the input power drive system Keep all safety guards and power shields in position and tightly secured while equipment is operating When working around this generator and drive system do not wear neckties loose articles of clothing or anything else that can be caught in the generator or drive system parts 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 repair parts be used in it Do not work on this generator or other potentially hazardous equipment when fatigued Use extreme caution when working on electrical components High generator output voltage can cause serious injury or death Keep the generator and the area around it clean Remove all material that can create dangerous conditions such as grease water ice and snow Also remove all flammable material from the area Keep fire extinguishers on the vehicle at all times Extinguisher
4. Initial system start up G Generator electrical power connections H Final system check A Space required and location 1 The space required should allow for ample working room around and in back of generator A general rule to follow is 6 inches minimum clearance all around the unit This allows service men to repair and remove engine or generator parts in the event service is needed In general all service can be performed from the rear of the generator junction box 2 The generator must be mounted in direct line with the drive line Allow space for cooling air to sweep across the shell Locate as close to electrical service as possible This will reduce the cost of electrical wiring and minimize the losses in the power conductors Position the unit to keep clear of the drive line and exhaust runs Protection from adverse weather conditions and road spray must be provided without restricting adequate ventilation for cooling Careful planning will eliminate costly rework 3 Mounting support frame loading frame type and strength should be taken into consideration when installing an emergency rescue generator 4 Moisture and dirt all electrical equipment should be protected from excessive moisture Failure to do so will result in deterioration of the insulation and will result in short circuits and grounds Foreign materials such as dust sand lint and abrasive materials have a tendency to cause excessive wear not only to the engi
5. are included except mounting drive and wiring hardware The generator is equipped with a wide spaced four foot mounting 1 5 8 keyed drive input shaft and junction box for wiring electrical output The junction box is designed to provide complete access to all the electrical circuits from the electrical output end with the removal of a single end cover The unit is fully tested to insure proper operation of all components system performance and reliability The generator design is 1800 rpm 4 pole 60 Hz series of five units ranging from 35 kw 35 000 Watt 120 240 v single phase through 75 kw 75 000 Watt 120 240 volt three phase Comparable special order 50 Hz models are available 50 Hz models operate at 1500 rpm and must be derated approximately 20 Base 50 Hz model is rated at 27 Kw 27 000 Watt The generator has a current boost transformer compensated brush type exciter revolving field design The generator is self excited with magnetic inserts to insure reliable buildup It is inherently regulated to plus or minus 7 no load to full rated load at unity power factor 1 0 pf It can be operated continuously under any load within its rating The frequency regulation is dependent on the drive engine and governor Typical emergency rescue vehicles are usually equipped with large engines and precision electronic governors that are able to maintain the output frequency to within less than a 1 cycle variation The generator is designed
6. current carrying wires 1 must be sized to handle the maximum load current without excessive voltage drop By NEC code conductors must be heavy enough to handle the full current rating of the main line circuit breaker fuse in the load distribution panel protecting the conductors All wires should be installed in rigid or flexible conduit Knockouts are provided the control box Because of the many different types of wiring service feeder and distribution panels used on rescue equipment no specific wiring instructions can be provided Please note If auxiliary Shore Conmercial power may also be connected to the load for demonstration training or alternate source power THERE MUST BE AN ISOLATION SWITCH TO PREVENT BACK FEED OF COMMERCIAL POWER INTO THE GENERATOR OR GENERATOR POWER INTO THE COMMERCIAL LINE When the load is connected to the generator there must be absolutely no feedback from the generator to the power line or from the power line to the generator during any operating condition When correctly connected the design of the wiring control system prevents an possibility of feedback Improper installation can create a serious hazard that could result in equipment damage serious personal injury or death H Final System Check Recheck voltages at mainline circuit breaker Voltages should match readings taken at the pre wire check out If problems are noted consult troubleshooting section or factory OPERATIO
7. rectifier test Procedure follows Connect one ohmmeter lead to the positive DC terminal and the other lead to each of the AC terminals in turn A high or low resistance reading will be obtained Reverse the meter leads and an opposite reading should be observed Now check from the negative terminal to each of the AC terminals using the same procedures Check each terminal both ways to the case No resistance reading should be observed Check between the two AC terminals There should never be any reading either direction between the AC terminals A rectifier that does not pass any of these tests is defective and must be replaced If a battery powered test light is used follow the procedures described above If the rectifier is good the light will come on in one direction only between a DC and AC terminal but never between the terminals and the case or between the two AC terminals If the rectifier fails any of the above tests it should be considered defective and replaced 4 Transformer testing The transformer is mounted on the end of the generator above the brush rack and slip rings There are four secondary wires that provide alternative connection patterns for increased or decreased voltage boost depending upon the application and connected load Consult factory if changes appear necessary The boost transformer provides extra current boost for the field to start large electric motors and to compensate for normal voltage droop under lo
8. to maintain proper output voltage even if operated at up to a 3 cycle variation 61 5 Hz 58 5 Hz no load to full rated load The vehicles power input PTO drive shaft operates at 1800 rpm 1500 rpm for 50 Hz and must provide approximately 2 Hp per required kw See specifications for the drive power requirements of each model The PTO drive power is generally taken from an auxiliary drive output on the vehicle transmission or through a special gear reduction box driven by a modified split drive line The power is coupled to the generator through a rotating drive shaft generally with universal or constant velocity joints SPECIFICATIONS Generator Model Watts Volts Amps HZ PH PF Motor Insulation Start 35PSB4G 3 A 35 000 120 240 145 8A 60 1 1 0 20Hp Class F 4OPSB4G 4 A 40 000 120 208 111 0A 60 3 1 0 25Hp Class F 45PSB4G 17 A 45 000 120 240 108 2A 60 3 1 0 30Hp Class F 55PSB4G 3 A 55 000 120 240 229 1 60 1 1 0 30Hp Class F 5 5 46 4 75 000 120 208 208 1 60 5 1 0 40Hp Class F 75 5 46 17 75 000 120 240 180 4 60 3 1 0 40Hp Class F 27 5 46 53 27 000 110 220 122 7A 50 1 1 0 15 Class Mechanical Drive Model Input Input Shaft Key Net Shipping RPM Horsepower Diam Weight Weight 35PSB4G 3 A 1800 58 6 1 5 8 3 8 416 4364 4OPSB4G 4 A 1800 63 0 1 5 8 3 8 420 440 45PSB4G 17 A 1800 70 9 1 5 8 3 8 420 440 55PSB4G 3 A 1800 92 1 1 5 8 3 8 600 625 75PSB4G 4 A 1800 118 4 1 5 8 3 8 605 650 75PSB4G 17 A 1800 118
9. 4 61 T1 to N 120 125 vac 62 T2 to N 120 125 vac G3 T3 to 120 125 vac 17 G1 T1 to N 120 125 vac 62 T2 to 120 125 vac G3 T3 to N 208 217 vac 53 61 T1 to 110 115 vac G3 T3 to N 110 115 vac G3 is the high wild Leg This voltage combination is normal for the 3 phase delta winding Notice for reason during the check out procedure the voltage and frequency not correct stop the engine and refer to the trouble shooting procedures After verifying the voltage and frequency are correct prepare for final wiring of the generator by disabling the drive system and or engine generator can be connected to the load circuits G Generator Electrical Power Connections All wiring should be done by an experienced electrician and should conform to the national electrical code and with state and local regulations The generator terminals marked The hot leads marked G1 G2 and G3 are wired to the main line circuit breaker in the distribution panel The neutral wire is run to the neutral terminal in the distribution panel Note Most codes require that the neutral conductor be bonded grounded directly to the frame of the generator Check local codes to insure compliance Refer to the national electrical code NEC for portable mobile equipment No further electrical connections are required load
10. 4 1 5 8 3 8 605 630 27PSB4G 53 A 1500 45 2 1 5 8 3 8 416 436 The rated power of each generator 5 subject to and is limited the engine input power provided Both the generator and the engine are affected temperature In addition the engine 15 derated by altitude and all other ambient conditions specified by the engine manufacturer Drive engine power will typically decrease about 3 1 2 for each 1000 ft above sea level and will decrease an additional 1 for each 10 degrees fahrenheit above 60 degrees fahrenheit UNPACKING INSTRUCTIONS Notice 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 consignee s memo of the loss or damage Contact the carrier for claim procedures When loss or damage is noted after delivery segregate the damaged material and contact the carrier for claim procedures NCONCEALED DAMAGE is understood to mean damage to the contents of a package which is not in evidence at the 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 to goods rests with the consignee when generators are shipped FOB factory and only the consignee can legally file claims 1 Carefully examine
11. N Since the generator is self excited and regulated no operational controls for the generator are needed The vehicle manufacturer will provide operation manual for the control s MAINTENANCE A General information The main components of the generator are Stator bar and ring boost transformer rotating field rotor mounted cooling fan brushes brush holder assembly end brackets and junction box Before performing any maintenance on the generator isolate and or disable the drive system so the unit can not be accidentally started while being repaired Service maintenance items include periodic external physical inspection for missing hardware or damage to mounting or drive system It is recommended that the generator be operated at least monthly under normal loads to familiarize operators with the procedures and controls as well as to dry out any accumulated condensation or other moisture in the generator electrical windings The maintenance and service attention invested will insure getting the peak performance that was designed into the unit B Generator maintenance 1 Brushes Under ordinary circumstances brushes will operate for extremely long periods without requiring replacement They should be inspected after the first 5000 hours of operation and after every 1000 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 wo
12. ach model The PTO drive line power should be maintained in as straight a line as possible Install the generator so the drive line is aligned to within 5 degrees 10 degrees max Be sure that the auxiliary drive power output on the vehicle transmission and the gear reduction box 15 capable of the expected mechanical load It is generally recommended that the drive shaft be balanced to minimize drive Line vibration and stress The generator uses permanently lubricated bearings No further lubrication is necessary or possible Bearings should be checked annually to minimize potential catastrophic failures E Pre Wire system check Before wiring the generator to the distribution load circuits the installation and operation of the drive system and generator should be checked to insure proper drive line engine and generator operation Use the following check list to verify correct installation before starting the engine Item Check 1 Drive engine Lube oil coolant and filters 2 Unit mounting base and hardware Solid and bolts torqued 3 Ventilation clear and protected 4 Clearance on all sides and service access on end After completing the above checklist the generator is ready for the initial start up test Initial start and test procedure 1 See vehicle manufacturers instructions for operating procedures The generator should be turning at specified rpm and producing correct voltage and frequency If the generator fails to o
13. ad To determine whether a transformer is defective stop and disable the engine disconnect all the power lead wires from the transformer and the secondary leads from the rectifier Measure the windings for continuity and grounds as described for the stator and rotor above Grounded transformers or transformers with internal primary to secondary shorts must be replaced Safety control circuits generator protection In addition to a main line circuit breaker to protect the generator stator and load wiring an over speed relay or circuit should be supplied by the vehicle manufacturer that is factory pre set to operate at 67 hertz Capproximately 2000 rpm on the generator shaft DO NOT EXCEED 2000 RPM ON THE GENERATOR SHAFT FOR ANY REASON CENTRIFUGAL FAILURE OF THE ROTOR IS PROBABLE AND NOT WARRANTABLE D Operating Speed If operating speed is out of tolerance consult the vehicle manufacturer for instructions Under a full load condition of 80 to 100 capacity the drive system should maintain a 59 to 60 hz reading Under full load do not adjust the Hz above 60 If a higher hz reading is used as the load is decreased and the governor is not maintaining proper regulation the Hz may go beyond the upper design limits 61 5 to 62 hz SYMPTOM TROUBLESHOOTING TABLE CAUSE S No output or low output voltage Open or shorted stator Output voltage too high Generator overheating on all sides Sparking at the brushes Open or
14. finite resistance Repair slip ring connection or field jumper connection if possible If not replace entire rotor Connect one meter lead to the stator shell and the other lead still connected to one of the field slip rings tf meter indicates continuity resistance reading the field 15 grounded and should be replaced 2 Testing Stator for opens and grounds a Disconnect stator leads Hot and Neutral b Ground test Set multi meter to read resistance holding one meter lead against a clean spot on the stator shell touch the other lead to any of the power conductors G1 G2 or G3 If meter indicates continuity any resistance reading the stator winding is grounded Faults causing the grounded condition even if visually detected are generally not repairable Replace the stator if it is grounded c Testing for opens meter still set to read resistance Rx1 Holding one meter lead on 61 lead touch other meter lead to G3 and G2 if applicable Record the readings The meter should indicate continuity very low resistance If not i e if meter indicates infinite resistance part of stator winding is open and the entire stator must be replaced Check for open between all stator leads in same manner Again record your results for reference 3 Testing rectifiers The field excitation rectifier is a full wave bridge rectifier This type of rectifier has four terminals two AC a DC positive and a DC negative The
15. ne parts but also to the generator parts particularly the brushes It is important that the unit be installed in a reasonably clean location for best service 5 Heat and cold all generators and engines give off considerable heat when they are running In addition these units are generally mounted in a somewhat restricted location which precludes natural convective cooling It is important that the temperature of the ambient air around the unit not exceed 105 degrees fahrenheit while operating Additional cooling louvers or fans may be necessary if adequate cooling flow is not provided by engine cooling air discharge Mounting The generator should be bolted solid to heavy steel cross channel plate It is recommended that the generator be mounted on a steel sub frame which facilitates easy removal of the generator for better service access to the chassis or for generator repair Shock mounting the generator or mounting frame is generally not recommended do to possible harmonic vibration drive misalignment and mounting stress C Ventilation of generator This is an air cooled generator This unit is equipped with a suction fan to cool the rotor and stator Therefore it will be necessary to insure that the hot air discharge plume gets out of the mounting area D Drive Line and lubrication Install input PTO drive shaft 60 Hz units operate at 1800 rpm 50 Hz at 1500 rpm See specifications for the drive power requirements of e
16. ng condition Check bearing bracket alignment Clear inlet and outlet air vents of debris Insure at least 6 inches clearance and inlet and outlet vents are unobstructed Repair or replace shorted or grounded field must be replaced Replace stator Reduce load Contour brushes see maintenance Redress slip rings see maintenance Remove brushes and inspect and correct problem Replace brush Note Always replace brushes full sets don t partial WIRING DIAGRAMS 1244 2 POLE Li CIRCUIT i 3 l e amp hs ec SENERATOR 91 soal i STATOR Lo TN Bu res Gl PHASE 2407 Er ft TOUS MLCEPTA LE TRANSFORMER CEN ERATOR TIF Lo 2227 VOLTAGE CONNECTIONS 140 LE A C 240v 16 A M 120V 19 9 POLE Ling Pease PES 35 gan E A mes 1 ECE i 1 i S sa lirorson MNT CURCUNT CMCUIT Arr Lire 3 FMASE TO TO8 SECEPTACLE 4 3PHASE 35 8 65 CSA amp STD ECRCRATON a a Ae e 16 2067 IS a n 0 16 I IGOA 3
17. perate as specified stop the engine and refer to the trouble shooting section of this manual 2 With the engine running smoothly check the no load voltage and frequency at terminals G1 T1 G2 T2 and G3 T3 61 T1 and either G2 T2 G3 3 are located at the boost transformer On single phase units models ending in 3 or 53 no G2 T2 lead is present The following voltages are present on the generator output terminals measured from line to line and line to neutral Note the correct voltage group by locating the voltage connection suffix in the generator model number 1 45PSB4G 17 A the 17 specifies the 120 240 volt 4 wire 3 phase delta 60 Hz connection Voltage connections are 3 120 240 volt 60Hz 1ph 53 110 220 volt 50Hz 1 4 120 208 volt 60Hz 3ph 17 120 240 volt 60Hz 3ph 517 110 220 volt 50Hz 3ph VOLTAGE FREQUENCY Hz CODE line to line 3 61 T1 to 63 T3 240 250 vac freq 60 To 61 Hz 4 61 T1 to G3 T3 208 230 vac freq 60 To 61 Hz G2 T2 to 61 T1 208 230 vac freq 60 To 61 Hz G3 T3 to G2 T2 208 230 vac freq 60 To 61 Hz 17 61 to 63 T3 240 250 vac freq 60 To 61 Hz 62 T2 to 61 T1 240 250 vac freq 60 61 Hz 63 T3 to 62 T2 240 250 vac freq 60 To 61 Hz 53 G1 T1 to G3 T3 220 230 vac 50 51 Hz CONNECTION VOLTAGE FREQUENCY Hz CODE line to neut 3 G1 1 to N 120 125 vac 63 T3 to N 120 125 vac
18. rn down to 3 8 Replace brushes in complete sets never singly When replacing brushes be careful to reconnect the lead wires properly Poor contact or skipping between brush and slip ring is caused by oil and grit flint or other hard substance on the brush or by the brush not being properly shaped to fit the slip rings Remedy these defects by 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 2 Slip rings The two continuous copper rings located at the end of the rotating field are the excitation slip rings For proper generator output the surface of the slip rings must have a smooth shiny highly polished finish Normal brush seating will transfer a shiny black finish that will seal the copper surface This finish should not be removed unless it becomes dull or begins to build up Under sustained use it is advisable to check and if necessary polish the ring surfaces with a crocus cloth to maintain the smooth finish Electrical testing 1 Testing generator rotating field for opens and grounds a Disconnect field slip rings from rectifier b Set multi meter to read resistance ohms and connect the meter leads to the slip rings See technical data on the repair parts list for correct resistance for the unit If field is defective in an open condition the meter will read in
19. s rated ABC by the NFPA are appropriate for 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 ARR Warning Before proceeding with the installation be sure the drive line and engine are disabled and cannot accidentally operate while the generator is being installed Also before beginning the installation process recheck the voltage power rating and physical size and drive line rating and speed horsepower etc Be certain they can handle the intended load and are compatible with the required vehicle equipment voltage phase and current ratings Plans for installation should be prepared with proper attention to mechanical and electrical engineering detail to assure a satisfactory system installation The information in this manual is offered as a guide to finalizing your installation plans The installation sequence 1 summarized below A Plan the installation 1 Space required for installation and service access 2 Protected location close to electrical connections 3 Mounting frame 4 Clear of moisture and dirt 5 Shielded from excess heat and cold B Mounting generator system Clear protected source of ventilation of generator D Drive line aligned within 5 degrees 10 degrees max E Pre wire system check Engine exhaust system plumbed clear of generator and wiring F
20. shorted field winding Generator operating too slow 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 Drive input speed too high Transformer incorrectly tapped Generator overloaded Field rubbing on stator Poor ventilation Short circuit in field Shorted turns in stator Generator overloaded Brushes not seated properly Slip rings rough or eccentric Brushes sticking in brush rack Brushes worn down shorter than 3 8 inch CORRECTIVE ACTION Replace stator Replace rotating field Generator must be operated at 1800 rpm 45 rpm for proper output voltage 1500 rpm for 50 Hz Reduce load to generator nameplate Disconnect the load Check voltage at output receptacles Check motors lights 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 or separately excite field with 12 vdc battery See rescue equipment manual governor adj Consult generator manufacturer Reduce load Check beari
21. the carton and pallet for visible freight damage before opening Immediately report any suspected damage to the freight carrier Don t sign the freight bill until the external examination is complete 2 Carefully dismantle carton and examine the generator for damage 3 After inspecting the generator for external physical damage check for the following items packed inside the carton a Owner s manual and b Repair Parts List c Any additional accessories ordered if any 4 Remove hold down bolts 4 5 Unit now be lifted from shipping SAFETY INFORMATION week Caution Indicates any condition or practice which if not strictly observed remedied could result in damage or destruction of the equipment wekek Warning Indicates any condition 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 careless 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 2 Se 4 10 Bis 12 125 14 Installing and wiring a generator is not do it yourself project Consult a qualified licensed electrician or contractor The installation must comply with all national state

OwnerslOperators Manual EMERGENCY RESCUE

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