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CD40T4 Operators Manual

1. Vibration Levels As Measured On The Generator Engine Speed Min Set Output Kva Vibration Vibration Vibration Displacement Velocity Acceleration S rms V rms a rms gt 1300 rpm lt 50 kVA 0 64 mm 40 mm sec 25 m sec lt 2000 The Broad band is taken as 2 Hz 300 Hz Caution Exceeding either of the above specifications will have a detrimental effect on the life of the bearings and other components This will invalidate the generator warranty Vibration Monitoring We recommend that the set builder checks the vibration levels using vibration analysing equipment Ensure that the vibration levels of the generating set are within the levels stated in BS 5000 3 and ISO 8528 9 If the vibration levels are not within tolerance the genset builder should investigate the root cause of the vibrations and eliminate them The best practice is for the genset builder to take initial readings as a base line and the user to periodically monitor the genset and bearings to detect any deteriorating trend It will then be possible to plan ahead for bearing changes and eliminate vibration problems before excessive damage to the generating set occurs Vibration checks should be made every 3 months Excessive Vibration levels If the vibration levels of the generating set are not within the parameters quoted above Consult the genset builder the genset builder should address the genset design to reduce the vibration levels as mu
2. d E a ALS Bis Never try to retension or renew V Belts while the engine is running Replace all guards and panels when Warning completed 11 0 Points of Maintenance 11 7 V belt Drives V Belt Tension Tensioning 1 To tension pull alternator Item 6 outward until correct tension is achieved 2 Tighten bolts 3 4 amp 5 Figure 11 7 3 CD20 CD30 3 Replace v belt guard Item 2 Figure 11 7 1 4 Tighten bolts Item 1 Figure 10 7 1 CD40T4 3 Replace v belt guard Item 2 8 support bracket Item 1 Note When a new belt is installed it needs to be pre tensioned and then retensioned 15 minutes after the engine is run under load 1 Tension to 450N 101Ibf 2 Run engine for 15 minutes under full load 3 Stop engine and tension v belt to 300N 68 Ibf Figure 11 7 3 Never try to retension or renew V Belts while the engine is running Replace all guards and panels when Warning completed O 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 11 Page 38 11 11 0 Points of Maintenance 11 8 Valve Clearance Checking Valve Clearance e Before adjusting any valve clearances Allow the engine to cool down oil temperature be niin i RT low 80 C 176 F Place toggle Power Switch Item 1 Figure 5 1 1 to Off position Remove the cylind
3. 10 The rotor is now free at both ends and can be inched out with the careful use of slings Note bearings can now be changed without moving the rotor Assemble in reverse order torque to 26Nm Removal of the Rotor single bearing generator 1 2 3 4 NOD Remove the EBS unit if fitted Ensure that a full pole face of the rotor is at the bottom dead centre of the stator Remove the coupling disc and the outer section of the fan to prevent damage to them Disconnect stator leads at the terminal block Remove the plastic cover from the NDE bracket Access is now available for the removal of the bolts holding the NDE bracket in place Because of the angle on the rotor it will help with the removal of the NDE bracket if the rotor is pulled Copyright Cummins 2009 33 P0 1 MAN EN 4 STAMFORD out by a few cm Use a rope or web sling to support the rotor from when moving it 8 Lift the NDE bracket clear when free to do so 9 The rotor is now free at both ends and can be inched out with the careful use of slings Note bearings can now be changed without moving the rotor Assemble in reverse order torque to 26Nm Bearing Removal e Use the appropriate method described above to remove the end bracket s or remove the rotor e Use three legged bearing pullers to remove the bearings from the shaft Fitting new bearings Only use genuine STAMFORD replacement parts The bearings are pre packed with grease and sealed for life
4. note do not reuse the old bearing oi rings or wave washers always use the new ones supplied with the bearing kit Caution set up a clean area around the job to eliminate the possibility of contamination Unpack the bearing and clean off the preservative oil using a lint free cloth Heat the bearing to 20 C above ambient do not exceed 100 C fit the oi ring in the bearing housing s using using MP14002 Kluber Altenp Q NB 50 anti fretting grease Position the wave washer fit the bearing s onto the shaft ensure that it is hard up against the shoulder Allow to cool Refit the NDE bracket gently tap the bracket onto the bearing using a hide mallet Use slings work the rotor back into the frame Position and bolt up NDE bracket On two bearing generators align and fit the bracket onto the bearing Align the DE bracket position the bolts and take up the slack Tighten and torque from both ends ensuring that the shaft is free to rotate at all times Replacing anti condensation heaters Warning ensure that the power is removed from the heaters Remove the plastic end cover from the non drive end to gain access to the heater Identify the heater at the bottom of the NDE bracket Cut the leads unbolt the fixin arrangement Replacing Rectifier diodes and Surge Suppessor Remove the plastic end cover from the non drive end to gain access The rectifier plates are positioned on the NDE of the exciter rotor Rotate the roto
5. Measure insulation resistance between sections and each section to earth Unbalanced or incorrect winding resistances and or low insulation resistances to earth indicate rewinding of the stator will be necessary Copyright Cummins 2009 31 P0 1 MAN EN 4 STAMFORD Main stator 4 Pole winding resistances windings 311 P044D 1 908 P044E 1 33 P044F 0 95 P044G 0 625 P044H 0 51 P144D 0 353 P144E 0 3 P144F 0 26 P144G 0 213 P144H 0 171 P144J 0 15 P144K 0 155 Main stator 2 Pole winding resistances Windings 311 P042D 1 149 P042E 0 726 P042F 0 640 P042G 0 494 P142D 0 336 P142E 0 283 P142F 0 231 P142G 0 165 P142H 0 144 P142J 0 118 PO 1 MAN EN 4 32 Copyright Cummins 2009 STAMFORD Removal and Replacement of Component Assemblies Caution The following procedures assume that the generator has been removed from the generating set On single bearing generators before removal from the engine position the rotor such that a full pole face is at bottom dead centre Use engine pulley to turn rotor Metric threads are used throughout Warning When lifting single bearing generators care is needed to ensure the generator frame is kept in the horizontal plane The rotor is free to move in the frame and can slide out if not correctly lifted Incorrect lifting can cause serious personal injury Removal of EBS unit
6. TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 40 4 6 AC Monitor The controller has the ability to monitor AC voltage and current from a generator The following sections are use to configure settings associated with AC monitoring 4 6 1 Generator Voltage The following settings are used to configure how the controller responds to voltage measurements Description Voltage Source Disable The wiring configuration of the generator Selecting Auto 2 Wire Single Selection will use the Voltage Select inputs to determine 3 Wire Single which wiring configuration is implemented and displayed 3 Wire 3 Phase 4 Wire 3 Phase 4 Wire Delta Auto Selection Scaling Factor 0 500 2 500 Scaling factor at which the voltage is read into the controller See below for more information Nominal Volts 50 800Vac Voltage at which the generators runs at when operating under normal running conditions A B Phase this determines which phases the voltage is read from Application Note Scaling Factor The scaling factor setting can be used to calibrate the AC voltage if there is discrepancies between the reading and the actual value It can also be used if transformers are used to step up down the voltage The scaling factor applies to all phases in a system Example The voltage source is a 3 Wire 3 Phase system with a nominal voltage of 208V The controller is reading 206 3V but a calibrated multimeter gives 208 3V Use the formu
7. 50 0 50 0 F Calibrate a sensor by using the offset to correct errors Setpoints gt Bypass Time 0 90 seconds Amount of time to bypass warnings and failures after engine has started Setpoints gt Low Warning 32 200 F Reading at which a warning occurs Setpoints gt High Warning 50 300 F Reading at which a warning occurs Setpoints gt High Failure 50 300 F Reading at which a failure occurs 4 4 2 Oil Pressure The following settings are used to configure how the controller reads and interprets data from the oil pressure sender Name Range Description AAA Signal Source Sensor Port X The source from which the sensor data is attained 41939 Bus Sensor Type Sender Table X Select one of the pre configured sender tables or one of the Close Warning switch functions A custom table can also be created using Open Warning the DYNAGEN Configurator Close Failure Open Failure Close Ground Open Open Circuit Trim Offset 50 0 50 0 PSI Calibrate a sensor by using the offset to correct errors Setpoints gt Bypass Time 0 90 seconds Amount of time to bypass warnings and failures after engine has started Setpoints gt Low Warning 0 1 99 0 PSI Reading at which a warning occurs Setpoints gt Low Failure 0 1 99 0 PSI Reading at which a failure occurs TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 28 44 3 Fuel Level The following settings are used to configure
8. Code 030 02318 This compound must not be applied to diode thread Diodes to be tightened to a torque of 2 03 2 37 Nm PO 1 MAN EN 4 38 Copyright Cummins 2009 STAMFORD A C GENERATOR WARRANTY WARRANTY PERIOD A C Generators In respect of A C generators the Warranty Period is eighteen months from the date when the goods have been notified as ready for despatch or twelve months from the date of first commissioning whichever is the shorter period DEFECTS AFTER DELIVERY We will make good by repair or at our option by the supply of a replacement any fault which under proper use appears in the goods within the period specified on Clause 12 and is found on examination by us to be solely due to defective material and workmanship provided that the defective part is promptly returned carriage paid with all identification numbers and marks intact or our works or if appropriate to the Dealer who supplied the goods Any part repaired or replaced under warranty will be returned free of charge via sea freight if outside the UK We shall not be liable for any expenses which may be incurred in removing or replacing any part sent to us for inspection or in fitting any replacement supplied by us We shall be under no liability for defects in any goods which have not been properly installed in accordance with recommended installation practices as detailed in the publication Installation Service and Maintenance Manual or whic
9. POWER switch is in the OFF position to prevent an arc which could cause the bat tery to explode Disconnect the ground NEGATIVE cable first preferably at a point away from the battery Reconnect the ground cable last again away from the battery if possible Do not check a battery by sparking across the posts Eye injury from the arc or an ex plosion may occur Exhaust System Carbon monoxide is a deadly gas Never operate the en gine in closed areas unless properly ventilated Internal Warning combustion engine exhaust gases have a high content of carbon monoxide which is very danger ous when ventilation is poor Breathing carbon monoxide polluted air causes dis turbances depending upon the exposure time these disturbances may range from a simple headache to fainting fits paral ysis coma death Precautions for Filters and Elements The materials used in the manufacture and treatment of some filters may cause irritation or discomfort if they come into contact with the eyes or mouth and they may give off toxic gasses if they are burned Used liquid filters and elements contain some of the filtered liquid and should be handled and disposed of with care After handling new or used elements the users hands should be thoroughly washed particularly before eating CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 6 2 0 Contacts Registration 2 1 Contacts STADCO
10. S e Elo Q 2 ve O pa 2 es D bana S 4 K Z O gt O CN S OD g oi 0 Ca a lz O pe Re ba AZ EN o HZ Re oy D BO S 2 O TOU BE S 4 S sa N ul pi a Oz A 4 DES S GE gt E SEI R ul 2 a le R S vi z joen E z u do 3 E E 2 01 lu KI a a a slo E D fy 2382 a 5 aa ie ds 5 E Zei alo A E 5922 O 3205 E 3 EEE z ui za uu Duot a ZIzZZRE r 25 ei E S T 2 Ge lt i a D Ol i 5 5 STANDARD 1779 CONTROL PANEL DEEMED RELIABLE BUT NOT GUARANTEED INFORMATION CONTAINED HEREIN EXHAUST omg ii a xd j i y de 3 P E a UE ig CT TT E mre iy w Fame P D LOAD CIRCUIT m n A S Y HOT AIR DISCHARGE O 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 SHEET 1 OF 1 WEIGHT SCALE 1 12 6X 0 563 x 0 750 Page 13 5 0 Control System Description Figure 5 1 1 3 2 1 Figure 5 1 2 7 6 See Section 6 0 Starting amp Operating Instructions for details on Control System Operation 5 1 Digital Control System 1790 Standard Features 1 Power Switch Turns on off 12VDC power to control system Unit cannot be started with this switch in the OFF position This applies to remote stations as well 12 Volt Circuit Breaker Protects D C circuits against shorted overloaded circuits Reset button
11. The Triggers are different from the regular triggers for this function See the Start Stop Momentary Function section for more information Shutsdown the engine when active and displays Emergency Stop Controller ignores under speed voltage and frequency warnings and failures when active If using J1939 the controller will broadcast TSC1 as the Idle Speed parameter found in the Engine Speed section Emergency Stop Idle Mode Voltage Select 1 Used for changing the systems voltage configuration See Voltage Select for more information Voltage Select 2 Used for changing the systems voltage configuration See Voltage Select for more information Global Auto Battery Charger Fault Controller displays Charger Fault warning when active Momentary Start Starts the engine when momentarily active Approximately 2 seconds Momentary Stop Running Stops the engine when momentarily active Approximately 2 seconds Configurable Warning 1 Configurable Controller displays a warning with configurable text when active The DYNAGEN Configurator must be used to change the text Configurable Warning 2 Configurable Controller displays a warning with configurable text when active The DYNAGEN Configurator must be used to change the text Configurable Failure 1 Configurable Controller displays a warning with configurable text and shutsdown engine when active Configurable Failure 2 Configurable Controller displays a
12. e Maintenance counter e Momentary Start Stop inputs e Exerciser Clock e Pre heat and many other configurable timers e 150 Event Log e Accepts common senders VDO Datcon e Conformally coated for protection against moisture e Custom senders configurable with DYNAGEN Configurator Displays e Engine Temperature e Engine Speed e Real Time Clock e J1939 DTCs Custom e Oil Pressure e AC Metering e Engine Hours Text e Fuel Level e Battery Voltage e Time to Maintenance e Custom Senders e Warnings and Failures Feature Included 5V Sensor Output for Electronic Sensors Configurable Switched Outputs e TOUGH Series Manual O 2014 DYNAGEN Technologies Inc Introduction 4 1 1 Specifications The TOUGH Series controllers were rigorously tested to ensure durability reliability and functionality The following specifications are a brief summary of the standards to which the controller has been tested For complete details on the testing performed please contact DYNAGEN Testing Specifications Specification Rating Electrical Transients SAE1113 11 Physical Specifications Specification Rating Operating Temperature 40 to 158 F 40 to 70 C LCD Viewing Temperature 4 to 158 F 20 to 70 C Optional AR available call factory Weight 0 83lb 0 38kg Weight w RelayPak 1 32lb 0 60kg Dimensions 4 17 x 6 50 x 1 38 10 59cm x 16 51cm x 3 51cm Dimensions w RelayPak 4 41 x 6 79 x 3 33 11 20cm x 17 25cm x 8
13. fuel system can cause irregular running of the engine and decrease its performance even leading to stopping of the genset and prevent ing its restarting Fuel suction dip tube and or fuel connection at the fuel tank should be located below fuel level at all times to prevent air cavitation of the fuel system Fuel suction point in fuel supply tank should be located a minimum of 1 to 1 1 2 inches above the floor of the tank to minimize the pick up of fuel sediment and tank conden sate material into the fuel system To prevent fuel drain back install a fuel check valve in the suction line at the fuel tank NOTE Due to the design of the fuel injection pumps the fuel return line should enter the tank above the maximum fuel level and should not be immersed in the fuel Also the fuel return line should be kept gt 12 away from the fuel suction point inside the tank This will help prevent the aerated fuel from being picked up by the suction line If the tank is equipped with a dip tube for the return line drill a 1 8 dia hole in the tube inside the tank but above the fuel full level Note If the fuel for the generator is being supplied by the vehicle tank the supply line must be configured so that it can only utilize 75 of the total tank volume IMPORTANT Air cavitation causes engine starting problems Make sure that all joints and con nections in the fuel system are 100 air tight Do not install fuel shut off valve
14. in center of circuit breaker permits resetting after fault conditions are corrected Alternator Lamp Monitors the battery charging current Digital Controller Controls genset startup and monitors en gine amp generator functions RUN Button Starts the engine manually and will contin ue to run until OFF button is pressed Emergency Stop input is activated or a fail ure occurs 2013 Stadco Products Division Ephrata PA 17522 USA 6 AUTO Button Places the controller in Auto mode which allows it to start or stop based upon certain conditions Must be in Auto mode to start from Remote locations 7 OFF Button Used for turning off engine controller or ex iting out of Auto mode 8 LCD Screen Displays the engine generator parameters that are being monitored Also displays warning and failure notifications 9 Navigation Buttons Used to move throughout the menu sys tem view parameters and change settings 10 LED Indicator Displays the current status of the system Solid Green Engine Running Solid Amber Warning Solid Red Failure CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 14 5 0 Control System Description RK 13 GENERATOR 0 no START 11 ENGINE 12 STARTING RUNNING O ENGINE FAULT RESET AT MAIN PANEL STOP A STADCO GENERATORS o Figure 5 2 1 5 2 Remote Start Stop Station PN 1780 Optional 11 Start Stop Toggle Switch Starts and stops the generato
15. protection against major engine damage in the event of abnormal operating conditions Failure of this system may occur if not properly maintained When working on or around a running engine use extreme caution Be aware of moving or rotating parts which can catch onto loose clothing or jewelry 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 17 7 0 12VDC Wiring 7 1 Wiring General All wiring must meet applicable local electrical codes Have a qualified electrician install and inspect the wiring Mount switches and controls securely to prevent damage from vibration and road shocks All switches must be vibration proof to prevent accidental opening or closing while the vehicle is in motion The conductors to the generator system output must have an ampere rating of not less that 115 of the nameplate current rating of the generator system The factory supplied conductor insulation must be rated at 105 C Wires connected to the generator must meet or exceed this insulation rating See National Electrical Code NFPA 70 State and local codes specify different grounding requirements for mobile vehicles with electric generator systems These specific codes must be followed in order to insure personal protection CAUTION Read topic BATTERY HAZ ARD in the Safety Guide lines section of this manual before servicing or main taining battery sys
16. 2 Figure 11 6 2 The degree of soiling of the air cleaner de pends on the amount of dust contained in the air Consequently the cleaning intervals cannot be fixed generally but have to be determined from case to case Servicing the Air Cleaner The air cleaner is due for servicing when the entire red section Item 1 Figure 11 6 1 is visible in the service indicator with the engine shut off After servicing the air cleaner reset the signal by pressing the re set button of the service indicator The service 2588511 indicator is ready to resume its function Figure 11 6 1 1 Place toggle Power Switch Item 1 Figure 5 1 1 to Off position 2 Remove the service cover of the air clean er Item 2 Figure 11 6 2 by unlatching clips Item 3 3 The primary filter is fitted over the outlet tube creating a critical seal on the inside diameter of the filter end cap Gently re move the primary filter by moving the filter back and forth to break the seal 4 Remove the element from the filter hous ing NOTE lf the air cleaner is equipped with a safety element it only needs to be replaced every three air cleaner services or every two years whichever occurs first 4 The safety filter is fitted inside the outlet tube creating a critical seal on the outside diameter of the filter end cap Gently re move the safety filter by moving the filter back and forth to break the seal 5 Remove the element fro
17. 38 000 17 000 25 000 35 000 Standby Rating 20 000 29 000 38 000 17 000 25 000 35 000 Generator Rating 3 phase 480 240V 60HZ Generator Rating 3 phase 208V 60HZ Generator Rating 1 phase 240V 60HZ Figure 10 5 1 10 Capacity is approx always fill to upper marking on dipstick Refer to Section 11 2 for oil fill procedures 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 29 10 0 Installation Instructions 10 6 Installation Checks Prestart Checks Before starting the generator set perform these steps e Check oil level in oil pan Section 11 2 Check for leaks See Section 9 1 for the recommended oil and quantity Section 10 5 e Check Battery connections for tightness e Check to make sure that the Load circuit breaker is in the OFF position e Check all electrical connections and be sure that all bolts have been securely tightened Refer to Installation Review this section e Follow the Start Up Section in Section 6 Do not attempt to start generator system until all Installation Review questions have been answered satisfactorily Once this has been done proceed to the Operator s Section for the Start Up sequences Installation Review Prior to initial start up of the generator system address each of the following installation review items correct as necessary e Is the generator mounted secure
18. 46cm Electrical Specifications Specification Rating 38mA 24V Switched Outputs Battery 1A Max Low Resistance Sensors 0 750 High Resistance Sensors 0 7 500 Magnetic Pickup 10 10 000Hz at 1 50VAC AC Voltage Line To Line 50 575VAC True RMS Accuracy 1 Full Scale AC Current TG410 only 0 5A Current Transformer Accuracy 1 Full Scale Communications SAE J1939 Tier Il 111 IV Isolated pels Slave Modbus RTU TOUGH Series Manual 2014 DYNAGEN Technologies Inc Installation 5 2 Installation Generator systems contain high voltage circuitry and precautions to protect against it should be taken Failing to power down and lock out equipment can cause damage injury or death A WARNING Wiring of this controller should be performed by qualified electricians only The following general electrical safety precaution should be followed e Do a thorough inspection of the area before performing any maintenance e Keep fluids away from electrical equipment e Unplug connectors by pulling on the plug and not the cord e Use fuses where appropriate e Ensure all equipment is properly grounded Provide support to wires to prevent stress on terminals To ensure proper and safe operation caution must be taken at the installation site to make sure it is free from excessive moisture fluctuating temperature dust and corrosive materials Choose a mounting surface with the least amount of vibration a
19. PRODUCT SUPPORT To expedite your inquiries and fill your needs most efficiently we recommend channeling your Stadco related inquiries to the appropriate department as follows Sales Tony Stauffer mail stadcogen com Parts Sandy Schaeffers schaeffer staufferdiesel com Service amp Electrical Tim Stauffer genservice stadcogen com Application amp Installation Travis Stauffer tjstauffer staufferdiesel com Main Office Phone 717 738 2500 FAX 717 738 2550 Toll free 800 377 2120 E mail mail stadcogen com Website www stadcogen com For emergency service after office hours call the following number 717 738 2500 When requesting service or parts please provide the following information Genset model no Genset serial no Engine serial no This information is located on page 1 of this manual and can also be found on the unit as shown in section 3 4 of this manual Deutz Engine Service Nationwide To find your nearest Deutz engine distributor contact Deutz headquarters in Atlanta as follows a Telefax 770 564 7132 Service Dept b Nationwide toll free 1 800 241 9886 Emergency Only c Deutz Service Desk d Website www deutzusa com 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 7 2 2 Registration 2 0 Contacts Registration Fill in the following information and send fax or It is very important to register your generato
20. Single Bearing Generators conan cnn nro nan n nr nn nn rca 15 4 pole Single Bearing Coupling Alignment ooooononcnicnnncnnocnnonnnonnnonancnrn cnn no no conan orar nnnn no rarnnn rra 15 EARTH ARRANGEMEN Ta dad n 15 EIN EISE 16 WARNING LABELS sat iia ziwa kikawa ika Kwakuwa none ninas ERROR BOOKMARK NOT DEFINED DIRECTION GF ROTATION uereg dd idea 16 EISE CHEN EE 16 VOLTAGE AND FREQUENCY dada 16 AVR ADJUSTMENT eerste deeg A ee 16 AUTOMATIC VOLTAGE REGULATOR AVR cssssscceesssceeesssssseeeeessseeeeeseseeeeseessaaeseeseeeeseeessseaeeneneees 17 PSA SODA EE 17 MAIN STATOR POWERED AV 17 OPTIONAL EXCITATION BOOST SYSTEM ERBRG cnn nn nn nc ran nnnnnnnnnnnncins 17 Vie bg Tee eu 18 TO ADJUST THE GENERATOR OUTPUT VOLTAGE PROCEED AS FOLLOWS cooocccccccnnncnnccnnncnnnnnnnnoncnnnnncnnnnnnnnnns 18 STABILITY ADJUSTMENT WEEN 18 UNDER FREQUENCY ROLL OFF ADJUSTMENT UFRO ccssccccssseceeesseeseeeeessseeeeeseseeeeeessenees 18 eier Gel CIE 18 GENERATOR SET TESTING css idad 18 Test Metering Cabling EE 19 INITIALESTART UP at A See 19 Pre Running Check civic dr cia 19 Insulation resistance teSt oo occccccccnccnnncnnoncnnnananana nana n cnn n rurinta nono nonnnnnono nono nono nn AEAEE EEA cnn cn cnn manana nanma nana 19 SETTING THE VOLTAGE ci ii 19 SETTING THE STABILITY CONTROL cccccccceccccececcccccccceucceeusueuauseuuusuueusueeuececeeceeceeeeeeueueuseuseueueuueuuasenaeseeeess 20 LOAD at GREEN 20 AVR Controlled Genera
21. The engine is filled by Stadco with 15W40 Deutz brand oil DO NOT mix oils of different brands amp types Conversion to F DE yo fe Oil Viscosity F C x 1 8 32 The viscosity of lube oil is dependent on the ambient temperature therefore the choice of the SAE grade should be governed by the am bient temperature prevailing at the engine op erating site Optimum operating performance can be attained by using the oil viscosity dia gram Figure 9 1 1 The temperatures given in the Oil Viscosity table are the ambient temperatures at the time when the engine is started However if the running ambient temperatures are much higher than the starting temperatures a higher viscos ity oil must be used Oil changes dictated by changing temperatures can be avoided by us ing multigrade lube oils Multigrade oils over come the problem provided they have a suita ble specification Should the temperatures tem porarily fall below the limits of the SAE grade selected this will merely affect the starting per formance but will not cause any damage to the engine The temperature limits should not be exceeded over lengthy periods of time in order to conserve engine service life Y E o ul lt SAE 10W 40 SAE 5W 40 Figure 9 1 1 O 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 22 9 0 Operating Media CAUTION Always use clean d
22. and does not shutdown Engine can now only be shutdown by the OFF button or Emergency Stop input NO PODN gt Remote Start Operator Presses Contacts Close RUN Button Engine Starts Controllers leaves Running Mode Cooldown Mode Remote Start Contacts Open Engine Running Cooldown Timer Starts TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 19 4 Settings The following section relates to settings that can be changed to alter the way the controller performs its functions Read and review these sections carefully to ensure your settings are set correctly for your engine 4 1 Operator Setup The following settings are used to change the way the user interacts with the controller They are not password protected and can be changed by anyone from the front panel Name Range Description Lamp Test Performs a lamp test on the LED s when selected Display gt LCD Reverse Reverses the white and black pixels when selected Display gt LCD Contrast 5 95 Changes the contrast of the LCD Display gt Page Scroll 1 10 seconds Amount of time between each auto scroll of the parameter pages Display gt Message Pop Up 1 10 seconds Amount of time each message is displayed on the screen before displaying next message in buffer Display gt DPF DEF Display Time 0 10 seconds See the J1939 Reference Manual for more information Display gt LCD Backlight Timeout 10 600 seconds Amo
23. cont d Optional Fuel Water Separator Before changing the filter refer to the warnings in Precautions For Filters and Elements 1 Place toggle Power Switch Item 1 Figure 5 1 1 to Off position 2 Place a container beneath the fuel filter to collect any fuel which may spill 3 Use a band type gripping tool to remove the fuel filter element Item 6 Figure 11 5 3 from the filter base 4 With a clean rag wipe the filter seating sur face on the filter base clean off any dirt 5 Lightly oil the face of the rubber gasket on the new filter 6 Screw the new filter onto the filter adapter and tight en according to the in structions on the filter 6 gt X y Poa 7 Figure 11 5 3 Draining Water from the Fuel Water Separa tor 1 Place toggle Power Switch Item 1 Figure 5 1 1 to Off position 2 Place a container beneath the fuel filter to collect the fuel amp water 3 Open drain valve Item 7 Figure 11 5 3 and observe the liquid flowing out If water drain until only fuel begins to flow 4 Close valve completely 5 Dispose of fuel water properly 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 11 Page 35 11 0 Points of Maintenance 11 6 Dry type Air Filter Read Precautions for Filters and Elements Section 1 0 before servicing An air filter for the engine combustion air is mounted as shown Item
24. coupling discs are against flywheel face and the housing spigots are located Caution Do not pull the generator to the engine using bolts through the flexible discs 7 Fit housing and coupling bolts taking care to use heavy gauge washers between coupling bolt head and coupling disc Tighten bolts evenly around assembly sufficiently to ensure correct alignment 8 Tighten housing bolts 9 Tighten coupling disc to flywheel bolts Refer to engine manufacturer s manual for correct tightening torque 10 Remove rotor aligning aids the sling or wooden wedges and replace all covers Caution Incorrect generator alignment can result in damage to the generator Warning Failure to replace protective covers can result in injury Earth arrangement Copyright Cummins 2009 15 P0 1 MAN EN 4 STAMFORD The generator frame should be earth bonded to the generating set bedplate If anti vibration mounts are fitted between the generator frame and its bedplate a suitably rated earth conductor normally one half of the cross sectional area of the main line cables should bridge across the anti vibration mounts Warning Refer to local regulations to ensure that the correct earth requirements are incorporated into the installation Inadequate earth installations put lives at risk Paint Finish Unless previous arrangements have been agreed the generator will be supplied in a water based primer coat It is expected that the generating set assem
25. for broken or loose connections Three excitation control systems can be fitted to the range of generators covered by this manual identified by the last digit of the generator frame size designation Refer to the nameplate and then proceed to the appropriate subsection as indicated below AVR Fault Finding 1 Check speed No voltage build up 2 Check residual voltage 3 Follow separate excitation test procedure to when starting set check generator Unstable voltage either on no load or 1 Check speed stability 2 Check stability setting with load bio or er speed ei with load 2 Check that generator load is not capacitive leading power factor Low voltage 1 Check speed no load 2 Check link 1 2 or external hand trimmer leads for continuity PO 1 MAN EN 4 28 Copyright Cummins 2009 STAMFORD Low voltage 1 Check speed on load 2 Check UFRO setting 3 Follow separate excitation procedure to check generator and AVR Residual Voltage Check Field Flashing This procedure applies to all generators fitted with AVR control With the generator set stationary remove AVR access cover and leads F1 and F2 from the AVR Start the set and measure voltage across AVR terminals 7 8 A minimum level of 5 volts is required at these terminals Replace leads F1 and F2 on the AVR terminals If the voltage is less than 5 volts stop the set and carry out field flashing procedure Field Flashing p
26. for a predetermined amount of time When a properly configured Auxiliary sensor falls below rises above a certain point the engine will start as determined by the Auxilairy Sensors gt Mode Select settings When loss of mains power is detected the engine will start to provide power to the load All the appropriate settings in regards to Auto Mains Failure must be set properly When a certain command is sent to the controller over Modbus the engine will start See the Modbus Reference Manual for more information A WARNING See the Using Cooldown Mode section for more information on how it affects starting and stopping TOUGH Series Manual 2014 DYNAGEN Technologies Inc Using the Controller 18 3 2 Using Cooldown Mode When the controller is configured to have a cooldown period See Engine Logic section for the engine there is some special functionality that must be considered The cooldown period is special in that during this time it will accept a Start Command This means that if the engine is cooling down and a start command is received the controller will be placed back into a running mode and will not shutdown Example The following is an example of how the cooldown functionality works Remote Start contacts close Engine starts and is in the running mode Remote Start contacts open Engine starts cooldown period User presses RUN button on the front panel Engine moves back into running mode
27. given in Section 11 3 Routine Maintenance Schedule are based on average operating conditions and cover the minimum requirements to keep an engine running at peak performance with trouble free operation e Under very dusty conditions air cleaners lubricating oil and fuel filters will require more frequent attention e Before carrying out any maintenance work on engine or generator make sure Power Switch Item 1 Figure 5 1 1 is in the OFF position and the negative battery cable is removed e It is essential to ensure that nuts and bolts are tightened to the torques as specified in the Workshop Manual e Renew nuts and bolts that have been taken from high stress locations e The fuel injector can only be checked and set off the engine using suitable nozzle testing equipment Have fuel injectors test ed by an authorized service agent only 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 11 2 Break in Instructions It is recommended that the following receive regular attention until the engine has run 50 hours e Check the alternator belt tension Section 11 7 Check lube oil level 2x daily adjust if neces sary Section 11 4 Check nuts bolts and connections paying particular attention to the fuel system con nections Check for leaks and tighten if nec essary Observe the exhaust at full load A black exhaust means that the engine is overload ed or the
28. gradual rise to a steady state Point A the steady state must be greater than 1 0 Megohm If the windings are only slightly damp the dotted portion of the curve may not appear For general guidance expect that the typical time to reach point A will be around 3 hours Drying should be continued after point A has been reached for at least one hour It should be noted that as winding temperature increases values of insulation resistance may significantly reduce Therefore the reference values for insulation resistance can only be established with windings at a temperature of approximately 20 C If the IR value remains below 1 0 Megohm even after the above drying methods have been carried out correctly then a Polarisation Index test PI should be carried out If the minimum value of 1 0 Megohm for all components cannot be achieved rewinding or refurbishment of the generator will be necessary Caution The generator must not be put into service until the minimum values are achieved After drying out the insulation resistances should be rechecked to verify the minimum resistances quoted p above are achieved On re testing it is recommended that the main stator insulation resistance is checked as follows Copyright Cummins 2009 27 P0 1 MAN EN 4 STAMFORD Separate the neutral leads Ground V and W phase and megger U phase to ground Ground U and W phase and megger V phase to ground Ground U and V phase a
29. hourly intervals The process is complete when the parameters covered in the section entitled Typical Drying Out Curve are met Remove the heaters replace all covers and re commission as appropriate If the set is not to be run immediately ensure that the anti condensation heaters are energised and retest prior to running Short Circuit Method Warning This process should only be performed by a competent engineer familiar with safe operating practices within and around generator sets of the type in question Ensure the generator is safe to work on initiate all mechanical and electrical safety procedures pertaining to the genset and the site Caution The short circuit must not be applied with the AVR connected in circuit Current in excess of the rated generator current will cause damage to the windings e Bolt a short circuit of adequate current carrying capacity across the main terminals of the generator The shorting link should be capable of taking full load current e Disconnect the cables from terminals F1 and F2 of the AVR PO 1 MAN EN 4 26 Copyright Cummins 2009 STAMFORD e Connect a variable dc supply to the F1 positive and F2 negative field cables The dc supply must be able to provide a current up to 2 0 Amp at 0 24 Volts e Position a suitable ac ammeter to measure the shorting link current e Set the dc supply voltage to zero and start the generating set Slowly increase the dc voltage to pass curre
30. hours of operation It is important to note that bearings in service under good operating conditions can continue to run beyond the recommended replacement period It should also be remembered that the risk of bearing failure increases with time If in doubt about any aspect of the bearing life on STAMFORD generators contact your nearest supplier of STAMFORD generators or contact the Stamford factory direct PO 1 MAN EN 4 12 Copyright Cummins 2009 STAMFORD Installation into the Generating Set The generator is supplied as a component part for installation into a generating set Delivery Upon receipt of the generator check the generator for damage that may have occurred during transport Also check that the rating plate details are correct and as ordered for the application Handling the generator When lifting the generator always use a spreader bar as shown Ensure that the lifting chains are vertical to the lifting position on the generator at all times 193 Kg MAX When generators are fitted with an optional large box bolt on extensions to the lifting lugs are required to extend the lifting position clear of the terminal box When fitted these extensions form an integral part of the terminal box support Do not remove them Warning The generator lifting points are designed to lift the generator only Do not lift the complete generating set by the generator lifting lugs Single bearing generat
31. indefinitely or until 200 F is reached Relevant Settings Switched Outputs Setting 350 300 250 Stop Level Temperature Fahrenheit 150 100 50 04 0 5 10 15 20 25 30 Time Minutes The chart above shows the connection between engine temperature and time At approximately 10 minutes run time the temperature rises above the 325 F start threshold and the fan turns on The fan continues to run as the temperature declines When the temperature falls below the 200 F stop threshold the fan turns off TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 35 4 4 7 Custom Sender Tables Custom Sensor Tables are created using the DYNAGEN Configurator when using a sensor that is not supported by DYNAGEN The configurator has the ability to create these custom tables so that the controller can properly read the sensor data A NOTE Custom sender tables can only be created when using the configurator Parameter Description The label that will be displayed in the controller Engine Temp Oil Pressure etc Choose resistance voltage or current based on the sensor type Use the Terminal Descriptions section to determine if your sender is compatible with a sensor port Input Type Choose temperature pressure voltage current or percentage based on the sensor Unit Type This defines what unit of measurement will be displayed on the front panel F PSI V A Yo The following steps are an ex
32. minutes Amount of time to display a warning before starting the engine Recharge Setup gt Duration Amount of time to run the engine Setpoints gt Low Warning Reading at which a warning occurs Setpoints gt Low Failure Reading at which a failure occurs Setpoints gt High Warning Reading at which a warning occurs Setpoints gt High Failure Reading at which a failure occurs Crank Low Batt 6 0 24 0V Screen displays a Low Voltage During Cranking warning if voltage dips below this level during cranking NOTE When the engine is running the battery voltage will equal the alternator charging voltage The actual open circuit battery voltage may be lower than displayed Battery Recharge Sequence Monitor Voltage H Recharge Required Start Pre Alarm Timer Start Engine for Recharge Time TOUGH Series Manual O 2014 DYNAGEN Technologies Inc Settings 31 4 4 6 Auxiliary The Auxiliary sensors on the controller are used for performing functions based on sensor readings There are 2 different ways in which the auxiliary sensors can be utilized Scenario 1 Custom Sensors Use the auxiliary sensors to create custom sensors Current Voltage etc that are not supported by the controller by default Engine Temperature Oil Pressure Fuel Level Scenario 2 Add On Functionality Double up the auxiliary sensor onto the same Sensor Port that is currently being used by one of the other sensors Engi
33. output is off Event Functions Name Active Mode Description Glowplug Preheat Midheat Active during the Preheat Midheat and Postheat timers Postheat Off Not In Auto Active when the controller is in the OFF mode Idle Mode Warmup Idle Mode Warmup Timer Active when Idle Mode switched input is active Active after Warmup timer has expired to apply load to engine Cooldown Cooldown Timer Active when Cooldown timer is active Engine Running Cranking Running Active when engine is cranking or running Exercising Exercise Timer Active during the engine exercising cycle Battery Recharge Battery Recharge Timer Active during the battery recharge cycle Maintenance Required Global Active when Maintenance timer has expired Low Battery During Cranking Cranking Active when Low Battery During Cranking warning is displayed Auxiliary Sensor 1 Auxiliary Settings Active dependent upon settings in the Auxiliary sensor section Dependent Auxiliary Sensor 2 Auxiliary Settings Active dependent upon settings in the Auxiliary sensor section Dependent Auxiliary Sensor 3 Auxiliary Settings Active dependent upon settings in the Auxiliary sensor section Dependent Auxiliary Sensor 4 Auxiliary Settings Active dependent upon settings in the Auxiliary sensor section Dependent System Ready Active when controller is in Auto mode and no warnings or failures are Delay to Start Battle Mode Force Regeneration Delay to Start T
34. should be enabled See the Preheat Mode section for more J1939 information 0 90 seconds Amount of time the Glowplug output is active before cranking the engine Used on diesel engines to warm the engine before cranking 3 30 seconds Amount of time the Crank output is active before going to crank rest This timer immediately expires upon successful cranking 0 90 seconds Keeps Glowplug output turned on while cranking but not during crank rest Output will turn off upon cranking failure crank success or midheat time expiration 1 90 seconds Amount of time to delay between each attempt to start the engine Crank Attempts 1 20 Number of attempts to start the engine before going to a overcrank failure Fuel Crank Rest Fuel ON Determines if the fuel output stays on during the crank rest Fuel OFF time RPM Disconnect 100 2000 RPM Speed at which controller determines the engine has started successfully and turns off the Crank output Postheat Time 0 90 seconds Amount of time the Glowplug output remains on after crank success and the engine is running Restart on False Start False Restart Detect Time Enable Disable Determines if the controller will monitor for false starts and attempt a restart Controller will only attempt restarting the engine as many times as determined by Crank Attempts 5 30 seconds Amount of time after successful cranking to monitor for a false restart If this time expires and the engines stall
35. systems over communication buses The following sections relate to settings associated with communications 4 7 1 CAN Bus J1939 For detailed information about J1939 settings and functions please use the J1939 Reference Manual The manual can be found at www dynagen com support Name Description ECM Model Generic J1939 Choose the one of the available ECM modules from the list John Deere JDEC Volvo EMS Cummins CM850 Yanmar ECO Detroit Diesel Volvo EMS2B Isuzu 4H GM PSI econtrol ECM Communication Failure Enable Disable If no CAN messages are received for more than 6 seconds the controller shuts down the engine DTC Display Enable Disable Enables or disables active fault messages DM1 monitoring Active DTC Log Enable Disable Enables or disables the storing of active faults DM1 Read Stored DTC Enable Disable Enables or disables the ability to request stored fault codes from the ECM DM2 Auto Power ECM Enable Disable When enabled the fuel relay is enabled in Auto mode so that the ECM is already booted up and initialized before the user decides to start the engine ECM Power Delay 5 30 seconds Used in conjunction with Auto Power ECM When the engine shutdowns the controller waits the ECM Power Delay before turning on the fuel relay again This is to prevent unwanted start ups due to the engine not being completely shut down Cummins PGNs Enable Disable Enables or disables the broadcasting of PGNs required
36. the Genset production line with IR values still at the factory test levels of above 100 Megohm to be guaranteed At Generating Set Assembler s Works The generator should have been transported and stored such that it will be delivered to the assembly area in a clean dry condition If held in appropriate storage conditions the generator IR value should typically be 25 Megohm If the unused new generator s IR values fall below 5 Megohm then a drying out procedure should be implemented by one of the processes outlined below before being despatched to the end customer s site Some investigation should be undertaken into the storage conditions of the generator while on site Generators in Service It is known that a generator will give reliable service with an IR value of just 1 0 Megohm For a relatively new generator to be so low it must have been subjected to inappropriate operating or storage conditions Any temporary reduction in IR values can be restored to expected values by following one of the drying out procedures Winding Condition Assessment Caution The AVR should be disconnected and the Resistance Temperature Detector R T D leads grounded during this test Caution The windings have been H V tested during manufacture and further H V testing may degrade the insulation with consequent reduction in operating life Should it be necessary to demonstrate H V testing for customer acceptance the tests must be carried out at reduced vo
37. to be replaced or repaired in the course of normal maintenance service iv improper installation use fuels lubricants operation maintenance trans portation or packing v misuse alteration negligence and accidents vi chemical or electrical action or vii unauthorized repairs or modifications 11 Components used in warranty repairs will carry the same warranty cover age as the components they replace but the expiration dates will be the same as those of the original Product Any Product or component that is replaced by or for Stadco shall become the property of Stadco 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 43 12 Warranty claims must be submitted on STADCO WARRANTY CLAIM FORM within 30 days after completion of the warranty repair Stadco reserves the right to request return of Warrantable Failure parts for evalu ation prior to making a determination such parts must be shipped trans portation prepaid 13 STADCO IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUEN TIAL LOSS OR DAMAGE THIS WARRANTY IS THE SOLE WARRAN TY MADE BY STADCO IN REGARD TO THE PRODUCT STADCO MAKES NO OTHER WARRANTIES EXPRESSED OR IMPLIED OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE 14 Installer Reseller User Customer agrees to indemnify and hold Stadco harmless from and against any loss liability damages or expenses result ing from injury to persons or
38. will repeat the preheat amp crank cycle If after 2 con secutive tries the engine fails to start the controller will shutdown on overcrank 8 Overcrank failure will be displayed in the LCD display screen Note Engine preheat is optional preheat cycle may be turned off 7 5 Start Inhibit Feature The digital Controller is equipped with a start inhibit feature which when activated will pre vent the genset from being started and also will shutdown the genset if it is already running This feature is designed to work in conjunction with a transfer switch to prevent shore power and Auxiliary genset power simultaneously To utilize this feature remove jumper wire in control panel 1790 between terminals 12 8 15 The start inhibit feature triggers or is ac tive on Open circuit Connect a Closed con tact from the transfer switch to terminal 15 for genset running an Open contact to prevent starting running 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 19 8 0 AC Wiring 8 1 Electrical Connections All wiring must meet applicable local amp national electrical codes Have a qualified electrician install and inspect the wiring Mount switches and controls securely to prevent damage from vibration and shocks All switches must be vibration proof to prevent accidental opening or closing The conductors to the generator system output must hav
39. 2 Provide a suitable container to collect any oil which may spill Use a band type grip ping tool to remove the filter item 1 Figure 11 4 1 from the engine 2 With a clean rag wipe the filter seating sur face on the engine clean off any dirt 3 Lightly oil the face of the rubber gasket on the new filter 4 Screw the new filter onto the filter adapter and tighten to 15 17 Nm 11 12 5 ft lbs Take care when draining hot oil Danger of scalding Catch used oil in appropri ate container for proper disposal to prevent envi ronmental pollution Draining the Oil Since the engine is cooled by the lubricating oil oil must be drained from the oil pan and also from the heat exchanger 1 Place toggle Power Switch Item 1 Figure 5 1 1 to Off position 2 Place a container beneath the oil drain hose item 4 Figure 11 4 2 3 Remove oil fill cap item 2 Figure 11 4 1 4 Drain oil into the container by removing cap item 5 from drain hose 5 Replace and tighten cap item 5 on drain hose when draining is complete 6 Next place a container beneath heat ex changer drain plug item 6 7 Drain oil into container by removing plug 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 8 Replace and tighten plug item 6 when draining is complete 9 Fill the oil sump with new lube oil through the oil fill item 2 to the upper mark on the dipstick item 3 For oil grade vi
40. 3 Diode Stud fwd 073 50032 Diode Stud rev 073 50033 Complete Rectifer Assembly Rectifier assembly 45 0427 Rectifier assembly BC fwd 130 1413 Rectifier assembly BC rev 130 1414 EBS EBS 190 EBS0001 When ordering parts the machine serial number or machine identity number and type should be quoted together with the part description Orders and enquiries for parts should be addressed to STAMFORD PARTS Dept Telephone 44 0 1780 484000 STAMFORD Fax 44 0 1780766074Stamford Lincolnshire PE9 2NB UK Or any of our subsidiary companies listed on the back cover After Sales Service A full technical advice and on site service facility is available from our Service Department at Stamford or through our Subsidiary Companies A repair facility is also available at our Stamford Works Copyright Cummins 2009 35 P0 1 MAN EN 4 STAMFORD Parts Identification Single Bearing 13 air flow battle 14 exciter rotor 15 rotating rectifier assembly 16 main rotor assembly 17 fan removable 18 fan hub fixed 19 shaft 20 shaft spacer 21 coupling disc 22 DE adapter 23 DE screen item Description 1 cover EBS EBS unit EBS rotor rear screen plastic NDE casting with bearing housing AVR cover AS480 AVR NDE bearing o ring terminal block exciter stator frame main stator N D E
41. A Figure 8 1 1 AC wiring should only be carried out by a qualified technician familiar with state a local electrical codes Failure to follow proper grounding tech niques can result in serious personal injury or death CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 20 1 phase Dwg 13066 agram D iring W 8 3 1 AC S 9 AA AA LA ONT TISTIA ATALNVLS ed en an asma w ODTVES kwa sinnini owm SHL O6LL LIN TAN d 08109 NI d s TWNINUSL Y3TIONINOD JNI NI NO 8 ONISN3S daads OL JE ZE 3015 INMI 20 134905 SOYYMAN CNR SNid 40 3015 II D LOINNOOSIA HIMOLSNO A8 20094 38 OL INISIM JLVJIONI SINN HSN Z NINO SNOMOINNO9 TWOldAl SI der YOLVINIIY Grey AUS Qin u us a o SI ene ele T X NOUT DS ADNINDIYA Page 21 O 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 9 0 Operating Media 9 1 Lube Oil Lube oils are distinguished according to their performance and quality class Oil quality has a considerable effect on the life and perfor mance of the engine In common use are the API 8 ACEA Specifications Approved API oil classes CG 4 CH 4 C1 4 CJ 4 Approved ACEA oil classes E7 04 E3 96 E5 02 E4 07 E6 04 For a complete description of the oil qualifica tions see the latest revision of Deutz technical circular 0199 99 3002
42. A See Front Panel Speed Control section for more information Settings on these settings RPM Switch gt Secondary RPM 500 4000 The Rated RPM when the Secondary RPM 50Hz is 50Hz selected See RPM Frequency Select section for more information RPM Switch gt Primary RPM 60Hz 1500 4000 The Rated RPM when the Primary RPM 60Hz is selected See RPM Frequency Select section for more information NOTE When using J1939 or Genset Signal as a signal source connections to the speed sensing terminals are not required TOUGH Series Manual O 2014 DYNAGEN Technologies Inc Settings 29 4 4 4 1 Front Panel Speed Control The controller is able to adjust the speed of the engine through use of the front panel This section will describe the 2 methods in which speed control is implemented the settings the parameters as well as the steps the operator must take in order to control the speed REN peed Control Methods Setting Description J1939 TSC1 Speed Command The controller can instruct the ECM of an electronic engine to adjust its speed by broadcasting the the TSC1 command Switched Outputs The controller can instruct the ECM of an electronic engine to adjust its speed by using switched outputs on the controller set to RPM Increment and RPM Decrement to interface with digital inputs on the ECM When the speed is changed the corresponding switched output will be on for 1 second each time increment or decrement is pres
43. A deed eege E E T 33 Output on Low 7 High Example eu Sege a At 34 4 4 7 Gustom Sender Ta geet EAR EES EEN 35 TIMES gt AAA 36 O 2014 DYNAGEN Technologies Inc TOUGH Series Manual 4 6 4 7 4 5 1 Engine Logic Preheat Mode OFF ButtON FUNCHON tia AA A E EES 37 4 5 2 AN 38 E N 39 AC Monitora 40 456 1 METAS EC E 40 41 4 6 2 Generator Frequency 4 6 3 Generator Current Ri full e EE ATA E EEN 4 7 2 MOD Bus RS485 5 Troubleshooting O 2014 DYNAGEN Technologies Inc Introduction 3 1 Introduction The TOUGH series controllers are designed to provide complete control protection AC metering and engine instrumentation for both standard and electronic engines The module is easily configured using either the front panel buttons or our DYNAGEN Configurator software TOUGH series controllers are ideally suited for severe duty applications where reliability is critical such as mobile and stationary generators T ier 4 Ready se Features and Functions e 5 Year Warranty e Gasket for water ingress protection IP65 e SAE J1939 CAN Bus Protocol e Free DYNAGEN Configurator Software e RPM via J1939 Magnetic Pickup or Generator e Fast and rugged installation clips e Speed control offset for electronic engines e Passcode protected e Autostart on low battery and other sensors e Automatic shutdowns and warnings e Trim feature for AC monitoring and sensors e Manual and Remote start
44. CD20 30 40 Operators Manual 13067 Rev 02 121514 DEUTZ ENGINE GENUINE DEUTZ PART OR GENUINE DEUTZ peutz Kenner ENGINE PART 5 This warranty does not cover any components supplied by DC manufactured by sameone other than DEUTZ AG such as components obtained by DC from its suppliers other than DEUTZ AG and DC makes no warranty whatsoever with respect to such components Such components will be covered only by the warranties if any as may be issued by such suppliers themselves which warranties will be made available to customer upon request This warranty does not cover any components added by DC s customers before reselling it to the end customer and DC makes no warranty whatsoever with respect to such components 6 The warranties obligations liabilities and remedies of the parties as provided herein are exclusive and in lieu of any others available at law or in equity DC s total aggregate liability with respect to any defective Engine or Part shall not exceed the amount paid by the customer for such Engine or Part and customer agrees to release defend indemnify and hold DC harmless from and against any and all further liability in excess thereof arising in any manner from any alleged defective Engine or Part To the fullest extent allowed by law releases from and limitations of liability shall apply notwithstanding breach of contract tort including negligence strict liability or other theory of legal liability of
45. H Series Manual O 2014 DYNAGEN Technologies Inc Settings 36 4 5 4 5 1 Timers The controller has an internal clock which is used not only to keep time but to make sure certain events happen at the correct times The following sections are used to configure settings associated with timing functions NOTE The controller has an on board backup battery to keep time even when main power is not supplied to the unit This battery has an un powered no main power lifetime of approximately five years Engine Logic The following settings determine how the controller starts and stops the engine lt gives the user the functionality to add delays and timers to the sequences Most of the settings have a switched output associated with them that must be set in the Switched Outputs settings NOTE Setting a timers value to O seconds will disable the timer Example If Delay to Start is set to O seconds the controller will not perform a Delay to Start when starting the engine Name Range Description Delay to Start 0 90 seconds Amount of time to delay the starting of the engine after receiving a command to start Delay to Start on Manual Run Enable Disable Determines if the the Delay to Start timer is used when the front panel RUN button is used to start the engine Preheat Mode Preheat Time Crank Time Midheat Time Crank Rest Time Preheat Timer Determines which method controls when the glowplug output Switched Input
46. NEW OR peutz Kenner Warranty coverage is provided for the DEUTZ engine series listed below Warranty Period parating Hours asd S ol 1006 1001 511 909 e 1011F 2010 2011 2008 2009 1012 2012 1013 2013 910 912 913 914 913 and 914 gas engines 413 513 1015 2015 2015 gas engine 1003 1008F Main engine 511 909 1011 1011F 2070 2011 components 8 2009 Crankcase 1012 2012 1013 2013 Crankshaft 910 912 913 914 Camshaft 913 and 914 gas engines Connecting Rods 413 513 1015 2015 2015 gas angine Cylinder Head Casting The Engine warranty will commence at the date of sale to the original retail customer or one year from the date of manufacture whichever occurs first 3 PARTS Warranty coverage is provided for each new genuine DEUTZ Part or DEUTZ Part fora period of 12 months from the date of sale to the original retail customer 4 This warranty does not cover the following i wear and tear or contaminants ii exposure corrasion or pralonged or improper storage ili normal maintenance service or the replacement or repair of parts required to be replaced or repaired in the course of normal maintenance service iv improper installation use fuels lubricants operation maintenance transportation or packing v misuse alteration negligence and accidents vi chemical or electrical action and vii unauthorized repairs 2013 Stadco Products Division Ephrata PA 17522 USA
47. Non Driven End D E Driven End A V R Automatic Voltage Regulator 24 standard terminal box 25 standard terminal box lid 26 large terminal box 27 large terminal box lid P0 1 MAN EN 4 36 Copyright Cummins 2009 STAMFORD Parts Identification Two Bearing 14 exciter rotor 15 rotating rectifier assembly 16 main rotor 17 fan removable 18 fan hub fixed 19 bearing 20 wave washer 21 DE adapter 22 DE screen 93 DE adapter with bearing housing 24 standard terminal box 25 standard terminal box lid 26 large terminal box 27 large terminal box lid item Description 1 cover EBS 2 EBS unit 3 EBS rotor 4 rear screen plastic 5 NDE casting with bearing housing 6 AVR cover 7 AS480 AVR 8 NDE bearing o ring 9 terminal block 10 exciter stator 11 frame 12 main stator 13 air flow baffle N D E Non Driven End D E Driven End A V R Automatic Voltage Regulator Copyright Cummins 2009 37 PO 1 MAN EN 4 STAMFORD Parts Identification Rectifier Assembly Description Quantity exciter field forward diodes reverse diodes 1 3 varistor 1 3 1 da amp Oo PO exciter hub The rectifier assembly is on the NDE of the exciter rotor NOTE Coat the underside of diodes with Midlands Silicons Heat sink compound type MS2623
48. OPERATION AND MAINTENANCE MANUAL 20 0kW 40 0kW GENERATORS MODELS CD20 CD30 CD40T4 For Service or Repairs to your generator contact Stadco Generator Support at 1 800 377 2120 or 717 738 2500 When seeking information please provide Genset Serial No and Engine Serial No as shown on Rating Plate Products Division O 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Foreword Important This Operators Manual describes the appropriate measures for operation and mainte nance for the models of Stadco generators set forth herein It is presumed that operations described in this manual will be carried out by qualified per sonnel with prior experience in handling this type of machinery and electronics conse quently this manual shall not be considered a teaching manual for the inexperienced If you do not clearly understand the references in this manual please contact Stadco Products Division immediately Contact information is posted in Section 2 0 The accident prevention regulations and all other generally recognized regulations on safety and occupational medicine shall be observed Contents of this manual are copyrighted and are the property of Stauffer Diesel Inc Stadco Unauthorized reproductions of this manual are prohibited 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 2 TABLE OF CONTEN
49. P0 1 MAN EN 4 Generator Technologies Head Office Address Barnack Road Stamford Lincolnshire PE9 2NB United Kingdom Tel 44 0 1780 484000 Fax 44 0 1780 484100 www cumminsgeneratortechnologies com Copyright 2009 Cummins Generator Technologies Ltd All Rights Reserved Stamford and AvK are registered trade marks of Cummins Generator Technologies Ltd Cummins and the Cummins logo are registered trade marks of Cummins Inc Part Number PO 1_MAN_EN_4 STAMFORD AS480 AUTOMATIC VOLTAGE REGULATOR AVR SPECIFICATION INSTALLATION AND ADJUSTMENTS General description The AS480 is a half wave phase controlled AVR which forms part of the excitation system of the brushless generator The design employs Surface Mount Technology SMT custom mouldings and heatsinks to produce a compact AVR assembly The AVR also incorporates an interface to the optional Excitation Boost System EBS for use where short circuit current maintenance is required The AVR is linked with the main stator windings and the exciter field windings to provide closed loop control of the output voltage with load regulation of 1 0 The AVR voltage sensing terminals continuously sample the output windings for voltage control purposes In response to this sample voltage the AVR controls the power fed to the exciter field and hence the main field to maintain the machine output voltage within the specified limits compensating for load speed temp
50. TS SECTION 1 Safety Precautions 2 Contacts Registration 3 General Information 3 1 Introduction 3 2 Factory Settings 3 3 Initial Inspection 3 4 How to Identify Genset 4 Genset Drawings 5 Control System Description 5 1 1779 Digital Control System 5 2 1780 Remote Station 6 Starting Operating Instructions 6 1 Starting Procedure from 1790 Main Control Panel 6 2 Resetting the control system 6 3 Starting Procedure from 1780 Remote Station Optional 6 4 Shutdown Procedure 7 12VDC Electrical System Wiring General 12V Battery Connections Control System Wiring Digital Controller Start Inhibit Feature 8 AC Electrical System 8 1 Electrical Connections 8 2 Generator Grounding 8 3 AC Wiring Diagram 9 Operating Media 9 1 Lube Oil Specification 9 2 Fuel Specification 10 Installation Instructions 10 1 General Mounting Instructions 10 2 Exhaust Gas System 10 3 Fuel System 10 4 Cooling System 10 5 Design Features and Specifications 10 6 Installation Checks NNNNN UN UN PA O 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 TABLE OF CONTENTS SECTION 11 Points of Maintenance 11 1 Maintenance Precautions 11 2 Break in Instructions 11 3 Routine Maintenance Schedule 11 4 Lubrication System 11 5 Fuel System 11 6 Dry Type Air Filter 11 7 V belt Drive 11 8 Valve Clearance 11 9 Cooling System 12 Service Items List 13 Limited Warranty A C Alternat
51. This unit is designed to be be fitted and removed as a single unit 1 2 aa Thi a gt Remove the AVR cover and disconnect the flag connectors from terminals DR EB F2 F1 on the AVR ensure the cable is free to move Remove the terminal box lit and free the cable ties holding the cable in place ensure the cable is free to move Remove the cover from the rear of the EBS unit Look into the unit and identify the bolt holding the rotor to the shaft remove and put aside Remove four bolts holding the unit in position e whole unit together with the connecting cable can be lifted clear as one unit Assemble in reverse order torqued to 10Nm Removal of the Rotor two bearing generator SO NOARWN 9 Remove the EBS unit if fitted Ensure that a full pole face of the rotor is at the bottom dead centre of the stator Remove the eight bolts from the DE bracket and use fox wedges to remove the bracket Remove the outer section of the fan This is necessary on large cores but good practice on all cores Disconnect stator leads at the terminal block Remove the plastic cover from the NDE bracket Access is now available for the removal of the bolts holding the NDE bracket in place Because of the angle on the rotor caused by the removal of the DE bracket it will help with the removal if the rotor is pulled out by a few cm Use a rope or web sling to support the rotor when moving it Lift the NDE bracket clear when free to do so
52. Up to 1125ft 18AWG 4 Up to 1800ft 16AWG 5 Up to 2800ft 14AWG Distance Power and Ground Communications Wiring To Controllers RS485 Connections COMMON o A o B TOUGH Series Manual O 2014 DYNAGEN Technologies Inc Installation 14 2 4 5 Current Transformers When wiring current transformers into the system you must follow these considerations 1 The current transformer of each phase must be facing the same direction See below 2 The CT Common connection must be connected the black wire on each current transformer 3 The wires from the current transformers to the controller should be as short as possible NOTE If readings are unstable with the configuration shown below attempt connecting the CT Commons to the negative terminal of the battery Ensure the connecting wire is as short as possible Load Side Current Transformer CT Common Black Phase X White Line Side Generator TOUGH Series Manual O 2014 DYNAGEN Technologies Inc Installation 15 2 4 6 RelayPak Optional The RelayPak is used to provide built in slave relays in a compact and easy to wire package This allows the low current outputs of the controller to switch high current relays on the RelayPak Electrical Specifications Specification Rating Operating Voltage 12V 24V Output Pilot Duty Rating 5 83A Per Relay 12V Output Resistive Rating 10A Continuous Per Relay 12V 40A Momentary Per Relay 12V R
53. VR includes an optimised stability circuit to provide good steady state and transient performance of the generator Links are provided to change the response of the stability circuit to suit different frame size generators and applications On generators of this size a slow response setting is more appropriate and will prove helpful in reducing lamp flicker The correct setting of the Stability adjustment can be found by running the generator at no load and slowly turning the stability control anti clockwise until the generator voltage starts to become unstable The optimum position for the control is slightly clockwise from this point i e where the machine volts are stable but close to the unstable region UNDER FREQUENCY ROLL OFF ADJUSTMENT UFRO The AVR incorporates an under speed protection circuit which produces a volts Hz characteristic when the generator frequency falls below a preset threshold known as the knee point The red Light Emitting Diode LED gives indication that the UFRO circuit is operating in the low frequency region The UFRO adjustment is preset and sealed and only requires the selection of 50Hz or 60Hz operation using the jumper link Accessories Droop CT P1only RFI suppression thermistors and anti condensation heaters are available Generator Set Testing Warning During testing it may be necessary to remove covers to adjust controls exposing live terminals or components Only personnel qualified to pe
54. When the controller is running and there is other functions occurring the controller will scroll through its display parameters as usual When the speed control page is displayed it will show the Engine Speed as well as the following instructions Hold AUTO Up Down to Adjust RPM MANUAL RUN MANUAL RUN ngine Sp RP 1800 0 RPM Hold AUTO fa to Adjust APA Speed Control Parameter Page Speed Control Adjust Page Set RPM 1800 Pressing and holding the AUTO button will display the screen to the right If a Display Adjust Parameter is set it too will be displayed underneath the Engine Speed While still holding the AUTO key press the up or down arrows to adjust the RPM The Engine Speed display should update as the engine physically changes it speed to accommodate the speed request A NOTE When using switched outputs for speed control the Set RPM will display instead of the set speed TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 30 44 5 Battery Level The following settings are used to configure how the controller reads and interprets the battery voltage level Name ange Description n Battery Recharge Enable Disable Enables or disables the ability to have the engine start on low battery voltage in order to charge it Recharge Setup gt Level 6 0 30 0V Voltage level at which the controller starts the engine to recharge the battery Recharge Setup gt Pre Alarm 1 20
55. Y PRODUCTS DIVISION OF STAUFFER DIESEL INC EPHRATA PA 17522 USA MODEL NO SPEC NO Figure 3 4 1 Engine Identification It is necessary and important to identify the Model No and Serial No of the engine when ordering parts or needing service Figure 3 4 2 The engine Rating Plate Model SN tag is attached to the top of the engine valve cover Item 1 Figure 3 4 2 The engine serial number is also stamped on the engine crankcase Figure 3 4 3 Figure 3 4 3 CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 9 3 0 General Information E AL ys me H o 9 1 Lube Oil Filter 2 Fuel Filter A Vol Regulat 3 Lube Oil Dipstick 9 utomatic oltage Regulator 4 Lube Oil Fill Cap 10 Engine Air Cleaner 5 Load Circuit Breaker iv Exhaueeonnecdon 6 AC Connection Cabinet 7 12VDC Alternator 8 12VDC Starter O 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 10 Figure 4 1 1 Stadco Model CD20 Genset Dwg 12916 t D E v Ss y i a 140 1 HS HOM all zeg ro or APE 3 916Z1 0102 80 11 ert Da ES 7 TON OMG lol TAR NAM VII Hi Te ETH TESLI VOSA Vd VAVUHdT d TS EE S DNI TISTIA AAA VES desta CAaINVYVNS LON ing Ze dawa3a S OOdVIS EST VD OINIVINOD NOUYWXOJNI rs LNOAW LASNAS 02099 awu i 3015 3D AY3S POL 007 ROS OOO t ROS OC ak Gee WA yan Di 431014 10 t
56. all travel expenses required to perform Warrantable Repair on job site List of authorized repair stations available from Stadco upon request User Customer is solely responsible for contingent expenses and repairs and for downtime expenses and all contingent business costs and losses resulting from Warrantable Failures LIMITATIONS 8 CONDITIONS User Customer s option for repair of Warrantable Failures is strictly limited to repair at a Stadco facility or in lieu thereof a qualified Stadco designat ed repair facility which has expressly obtained prior approval to perform such repair Labor allowance for Warrantable Failure repairs is strictly limited to labor required for repair of the Product This warranty does not cover any other labor which may be required to complete Warrantable Failure repairs including but not limited to recovery of the Product cleaning reinstalla tion or any other contingent labor costs Without limiting the generality of the foregoing or other limitations herein warranty for engines is limited to the prevailing terms and policies of man ufacturer of the engines furnished with the Product Engine manufacturers warranty statement is available from Stadco or from the manufacturer of the engine This warranty does not cover the following i wear and tear or contami nants ii exposure corrosion or prolonged or improper storage iii nor mal maintenance service or the replacement or repair of parts required
57. ample of how to create a custom sensor table 1 Navigate to the sensor input that will be using your custom sensor table 2 Select a Name Input Type and Unit Type for the controller Definitions in table above 3 Click the check box next to Build Table Image Step 1 4 From the Gender drop down menu select Custom Image Step 2 5 Click the Ed button next to the drop down menu Image Step 3 6 Enter the sensor values Once entered click Apply then OK TG350 Firmware 1 12 Sender Table Utility Close Save To File More Details JE a SE ohms Fu 4 Switched Inputs Pi i gt ge Caas Inputs 4 Engine Temperature SE E Switched Outputs Signal Source Sensor Port A 306 3401 AAA o F 4 Sensors Sensor Type Datcon DAH e g Datcon 02022 00 7 Se a2 4 Battery L C 263 160 Recharge Setup Trim Offset 0 Ny 175 Setpoints e TA SE 4 Engine Speed 147 1 Speed Settings 96 221 49 275 7 330 Si s oo Jou une w E 5 Wl E m gt Custom e Setpoints s 4 Engine Temperature Input Type Resistance z Unit Type Temperature Setpoints 4 Oil Pressure a o Setpoints 4 Fuel Level DAT DAH e g Datcon 02022 00 Setpoints 325 F to 32 F 4 Aux Sensor 1 Mode Settings Setpoints n Disable 4 Aux Sensor 2 Mode Settings Setpoints i Disable Ge 4 Timers Apply ok Cancel Engine Logic A 4 Exerciser Delays Schedule Maintenance Disable TOUG
58. ance 11 7 V belt Drives V Belt Tension It is important that the tension of the v belts are checked after the first 50 hours after an overhaul after a new belt has been fitted and as specified in Section 11 3 Routine Maintenance Schedule Changing Adjusting V belts CD20 CD30 1 Place toggle Power Switch Item 1 Figure 5 1 1 to Off position 2 Remove bolts Item 1 Figure 11 7 1 3 Remove fan guard Item 2 CD40T4 1 Place toggle Power Switch Item 1 Figure 5 1 1 to Off position 2 Remove cooling system support bracket Item 7 Figure 11 7 2 3 Remove fan guard Item 8 to gain access to alternator Item 6 Figure 11 7 3 V belt Adjustment 4 To check proper adjustment of V belts ob tain a v belt tension gauge 5 Place the tension gauge midway between the pulleys The proper v belt tension should be 300N 68 Ibf If tensioning is required see Tensioning below Changing V belts 1 Loosen bolts Items 3 4 amp 5 Figure 11 7 3 2 Push alternator Item 6 inward 3 Remove belt from pulley grooves and place one side of belt into the notch of the fan shroud hole 4 Rotate the fan by hand and allow the other side of the belt to rotate with the fan until it lines up with notch remove belt 5 Replace new belt in reverse order and align into pulley grooves 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 37 11 Sn
59. and make sure that all personnel who work on the equipment have access to the manual The manual should be considered as part of the product and should remain with the product Make sure that the manual is available to all users throughout the life of the product Scope This manual contains guidance and instructions for the Installation Servicing and Maintenance of the generator It is not possible within the scope of the manual to teach the basic electrical and mechanical skills required to safely carry out the procedures enclosed The manual is written for skilled electrical and mechanical technicians and engineers who have prior knowledge and experience of generating equipment of this type We offer a range of training courses that cover all aspects of STAMFORD generators Generator Designation The Product The product is an AVR controlled self excited synchronous P 14 4 E 1 example ac generator Designed for incorporation into a generating set A generating set is defined as machinery in European P Generator type directives Applications Industrial M Marine Serial Number Location 1 Frame size 0 or 1 Each generator has a unique serial number stamped into the 4 AS480 AVR upper section of the drive end of the frame 4 Number of poles 2 or 4 The serial number is also shown on the nameplate core Size bearings 1 or 2 Two other labels are located inside the terminal b
60. anty statements for this Product 13 3 Deutz Engine Warranty DEUTZ Limited Warranty Statement H DEUTZ 1 DEUTZ Corporation DC warrants to the original retail customer that each new DEUTZ engine or genuine DEUTZ engine Engine or genuipe new DEUTZ spare or replacement part or DEUTZ y part Part supplied by DC or an authorized distributor of DC purchased by the original retail customer and properly installed in an application will be free from defects in material and workmanship under normal use and service f during the warranty period following the delivery of the Engine or Part it is shown there is a defect in material or workmanship caused solely by failure of DC s manufacturer DEUTZ AG to meet such standards and customer has notified DC in writing of such defect within that period DC shall repair or replace at DC s cost and option such defective Engine or Part Such repair or replacement will be made without charge to the customer at customer s premises or at the option of DC at such other location as DC may designate Any Engine or Part that is replaced shall become the property of DC Any repaired or replaced Engine or Part shall be warranted until the expiration of the original warranty period DC s warranty obligation is expressly conditioned upon the customer fulfilling all obligations pursuant to customer s purchase order including without limitation all payment obligations 2 ENGINES
61. ation Read this manual obey all Warnings and Cautions and become familiar with the product Warnings amp Notices used in this manual The various warnings are out lined below and appear in the text in this format Warnings and Cautions appear at the appropriate position in the to which they refer Warning Information that draws attention to the risk of injury or death Caution Information that draws attention to the risk of damage to the product process or surroundings Note Used to convey or draw attention to additional information or explanations Notes appear after the text to which they refer Skill requirements of personnel Service and maintenance procedures should only be carried out by experienced and qualified engineers who are familiar with the procedures and the equipment Before any intrusive procedures are carried out ensure that the engine is inhibited and the generator is electrically isolated Electrical Equipment All electrical equipment can be dangerous if not operated correctly Always service and maintain the generator in accordance with this manual Always use genuine STAMFORD replacement parts Warning Electrical shock can cause injury or death Ensure that all personnel operating servicing maintaining or working near this equipment are fully aware of the emergency procedures in case of accidents Before removing the protective covers to carry out service maintenance or repair ensure that the engin
62. attery Voltage High Battery Voltage Low Coolant Level menssa ES ER ER TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 26 4 3 1 Group Outputs Group functions are designed so that multiple output functions can be bundled together and assigned to a single switched output pin The definition of a group output is as follows When any of the functions in a group is active OR logic the assigned switched output will be active Group Functions Name Active Mode Description Group 1 Group Dependent Must be set from DYNAGEN Configurator software Group 2 Group Dependent Must be set from DYNAGEN Configurator software Group 3 Group Dependent Must be set from DYNAGEN Configurator software Group 4 Group Dependent Must be set from DYNAGEN Configurator software Example Low AC Frequency High AC Frequency are bundled in Group 1 and assigned to Switched Output D This output is connected to an external indicator lamp labeled AC Frequency Warnings This allows one output to indicate there is a warning with the AC frequency The following table shows the output state based on the warnings status Low AC Frequency Warning High AC Frequency Warning Switched Output State 4 3 2 Pull and Hold Coil On some engine systems the fuel pump has two coils The reason for this is that the initial power on of the fuel solenoid requires substantial current Pull Coil but only needs a small amount of current to hold it in pla
63. ay Pak ccoooomoonooccccccnnnnnnonncnncnccncnnnnnnnnnnnnnnnnnnnnnnnnnnnnrnnnnnnnnns 9 Wiring CONSIDEratiONS a an ia iii idad iii 10 2 44 Emergency OP WNG a 10 2 4 2 Universal Sensor ii as 11 243 GAN BUS MO neger a a a aa de a tet deal 12 2 4 4 Modbus WINING DEE 13 LABS Current Transformers ta 14 2 4 6 R layPak Optional narini a A A a aa 15 3 Using the Controller 3 1 3 2 Modes Starting and StOppiND oococonnocccnnnnonnnnnnannnnnnrrnnnncr rr 17 Using Cooldown Mod e cccccecssecceeeeeeeeeeeneeeeeceneeeeeeeeeeeseeeeeseseaeeeeeseeeeeeseeneeseseeneeaseeneeeneeeneeenss 18 4 Settings 4 1 4 2 4 3 4 4 4 5 Operator Sell cosida 19 Switched InputS iii dirias 20 4 2 1 Voltage Select EE 22 4 2 2 REM e Ee 22 4 2 3 Configurable inputs id A di dE 23 4 2 4 Start Stop Momentary FUNCTION ccccoccccnoncncnnnonnnonnnnnnonanoncnnnann conan nana Kuhama kunia n naas uwa nan n aran ana nn anar n nana nnnnnnananannnnna 23 Switched Outputs 4 3 1 Group Outputs iii A A ad A daddies 4 3 2 Pull and Hold Coil To aua WANA Na KISA dd A E tii AAA Engine Tetpetalute eet e TT E A A KUKI KIKE EES degen 27 44 2 CO Ya WA AAA NAA AAA AAA AAA AWA MASAA Ea a USAWA SETI MASON ENEE 27 d Fuel ds 28 44A Engine SPCOO EE iris 28 Eront Panel Speed Control vito AA AAA EE Ee 29 4 4 5 Battery Level ivan ii iaa A 30 4 46 Alan is TO 31 Fault Monitor Example ci acia 32 Start on ow High appes dt A e addi Gases
64. bler will want to paint the generating set with a final coat in their company livery The primer coat will not provide adequate protection for used out doors Note The primer coat is not adequate protection for many applications without additional protection Warning Labels Warning labels are affixed to the generator These must be A visible at all times As we expect the set builder to paint the generator in his own DA lt gt livery a second set of labels can be found in a wallet attached to the generator Use the labels as per the instructions printed E ap 7 E on the reverse of the labels NOTE If removed or painted over it is the genset manufacturer s responsibility to reaffix warning symbols onto the generator Direction of Rotation The direction of rotation of the generator is designed to be clockwise as viewed from the drive end of the generator It will run in the reverse direction with some loss of performance Refer to the factory for guidance Phase Rotation The output from the generator will have a phase sequence of U V W with the generator running clockwise as viewed from the drive end If the phase rotation of the generator has to be reversed the customer must rearrange the output cables to a UVW configuration Ask for a circuit diagram of reverse phase connections Voltage and Frequency Check the generator nameplate to ensure that the generator parameters are as required for the generating set appli
65. but not fitted on the generator PO 1 MAN EN 4 20 Copyright Cummins 2009 STAMFORD Remote Voltage Adjust A remote voltage adjust can be fitted to the control panel Remove link 1 2 on the AVR and connect adjuster to terminals 1 and 2 Parallel Operation Understanding of the following notes on parallel operation is useful before attempting the fitting or setting of the droop kit accessory When operating in parallel with other generators or the mains it is essential that the phase sequence of the incoming generator matches that of the bulbar and also that all of the following conditions are met before the circuit breaker of the incoming generator is closed on to the bus bar or operational generator Frequency must match within close limits Voltages must match within close limits Phase angle of voltages must match within close limits A variety of techniques varying from simple synchronising lamps to fully automatic synchronisers can be used to ensure these conditions are met Failure to meet conditions 1 2 and 3 when closing the circuit breaker will Caution generate excessive mechanical and electrical stresses resulting in equipment damage Once connected in parallel a minimum instrumentation level per generator of voltmeter ammeter watt meter measuring total power per generator and frequency meter is required in order to adjust the engine and generator controls to share kW in relation to engine ratings and kVAr in
66. by Cummins engines SPN Conversion Version 1 Select the SPN conversion method Version 2 Version 3 EMS2B Frequency Select Primary For Volvo EMS2B Engine Control Modules only Secondary EMS2B Accelerator Pedal 40 0 60 0 For Volvo EMS2B Engine Control Modules only TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 43 4 7 2 MOD Bus RS485 The Modbus functionality on the controller provides the ability to interface to PLCs SCADA and building management systems For detailed information about the Modbus registers and their interpretations please use the Modbus Reference Manual The manual can be found at www dynagen com support Name Description Range Values Device Address The device address of the controller 1 247 The speed at which the controller slave Baud Rate BPS communicates with the master 9600 19200 38400 57400 SN The controller always communicates in e Communication Protocol Modbus RTU Modbus RTU Fixed The controller is always the slave and Slave Master Configuration must be queried by the master Slave Fixed TOUGH Series Manual 2014 DYNAGEN Technologies Inc Troubleshooting 44 5 Troubleshooting If you are having issues with your controller please refer to the table below for a solution before contacting technical support Issue Solution Engine starts but the crank output The controller is not receiving a speed signal does not turn off 1 Veri
67. cation AVR adjustment To make AVR selections and adjustments remove the AVR cover Use the tool provided to make adjustments to the AVR settings The AVR is factory set and will give satisfactory performance during initial running tests Subsequent voltage adjustment both on and off load may be required Guidance can be found in the AVR section PO 1 MAN EN 4 16 Copyright Cummins 2009 STAMFORD Automatic Voltage Regulator AVR AS480 AVR This AVR is specifically designed to fit into and work with the PO 8 P1 generator it is the only AVR that fits into the terminal box and is capable of working with the optional Excitation Boost System EBS The following jumper connections on the AVR should be checked to ensure they are correctly set for the generating set application connections for the EBS Hand Trimmer optional A a U U 1 H 1 lt 100kW 1 lt 100kW 1 gt 100kW i Slow Fast Ir RAY 2 emm 1 STABILITY Pa 25 UFRO Gm optional Remove link before fitting PA A EE Control Function Direction VOLTS Generator output voltage setting Clockwise raises voltage STABILITY Output voltage stability Clockwise increases stabilisation effect DROOP Voltage droop for paralleling Clockwise increases drooping effect UFRO Under frequency Knee point Clockwise decreases Knee point Refer to the Generator Wiring Diag
68. ce Hold Coil 1 Hold Coil Fuel is energized 2 Pull Coil is energized for 2 seconds before cranking 3 Repeat if engine cranking failed Configuring a switched output to Pull Coil automatically configures the engine logic necessary for a Pull Coil system Pull Coil Wiring Example ij Fuel Solenoid Pull Coil Output gt E Fuel Output TOUGH Series Manual O 2014 DYNAGEN Technologies Inc Settings 27 4 4 Sensors The controller has sensor ports which can be connected to a variety of different sensor types Temperature Pressure Level etc See the Terminal Descriptions section for more information on which terminals your sensor is compatible with Low High 0 5V or 4 20mA Most sensors are used to monitor for warnings and failures but the Auxiliary sensors can be used to perform special functions Example Starting engine on low temperature 4 4 1 Engine Temperature The following settings are used to configure how the controller reads and interprets data from the engine temperature sender Name Range Description Signal Source Sensor Port X The source from which the sensor data is attained J1939 Bus Sensor Type Sender Table X Select one of the pre configured sender tables or one of the Close Warning switch functions A custom table can also be created using Open Warning the DYNAGEN Configurator Close Failure Open Failure Close Ground Open Open Circuit Trim Offset
69. cedure a First the engine will preheat for a preset preheat time b Next the engine controller will crank the engine until it begins to start The LCD Screen Item 8 will display Running and LED Indicator Item 10 will light Sol id Green The engine should continue to run normally unless a fault condition ex ists If the engine fails to start after cranking for the preset crank cycle the unit will stop and Overcrank failure will appear in the LCD Screen and LED Indi cator will light Solid Red If a fault oc curs the control system will need to be reset See Section 6 2 6 2 Resetting the Control System The control system needs to be reset after the generator has shutdown from any fault condition Check the fault indication on the LCD Screen Item 8 Figure 5 1 2 to determine what caused the generator to shutdown Cor rect this fault before restarting To reset push the Off Function button Item 7 Figure 5 1 2 Return back to Auto mode by pushing the Auto function button Item 6 2013 Stadco Products Division Ephrata PA 17522 USA Do not use starting fluid while the electrical manifold heater is in use otherwise a dangerous Warning explosion will occur in the intake system which may seriously injure operator CAUTION Never move the START switch to START position while engine is running or in motion in any way 6 3 Starting Procedure for optional Remote Station PN 1780 1 Power sw
70. ch as possible Discuss with us the impact of not meeting the above levels on both bearing and generator life expectancy When requested or it is deemed necessary we will work with the genset builder in an attempt to find a satisfactory solution Bearings This product is fitted with sealed for life fitted within machined housings in the end brackets All of the bearings have pressed steel cages and have type C3 fit The grease used is a high specification synthetic compound that must not be mixed with grease with a different specification Factors that effect bearing life The life of a bearing in service is subject to the working conditions and the environment Copyright Cummins 2009 11 P0 1 MAN EN 4 STAMFORD High levels of vibration from the engine or misalignment of the set will stress the bearing and reduce its service life If the vibration limits set out in BS 5000 3 and ISO 8528 9 are exceeded bearing life will be reduced Long stationary periods in an environment where the generator is subject to vibration can cause false brinnelling Long stationary periods in an environment where the rotor is stationary will leave flats on the balls and grooves on the races leading to premature failure when run Very humid atmospheric or wet conditions can emulsify the grease causing corrosion and deterioration of the grease leading to premature failure of the bearings Health Monitoring of the Bearings We recommend that the u
71. citation boost generator EBG The EBG responds to the level of excitation provided by the AVR and supplies additional power as it is needed to support the overload TD_AS480 AVR_04 08_02_GB AS480 AVR Links and Adjustments refer to the generator wiring diagram for all connection details Operation at 110Vac optional remove link before fitting connect the 15k 1W sensing link the hand trimmer cannot be used in this mode Overload performance is limited in this mode connections for excitation boost Hand Trimmer optional Raise kim O optional Remove link before fitting Frios Der Refer to the Generator Wiring Diagrams for all Connection detail Cummins 2008 3 TD_AS480 AVR_04 08_02 GB ADJUSTMENT OF AVR CONTROLS VOLTAGE ADJUSTMENT The generator output voltage is set at the factory but can be altered by adjustment of the VOLTS control on the AVR board or by the external hand trimmer if fitted Before adjusting the generator output voltage note the following warnings WARNING Do not increase the voltage above the rated generator voltage shown on the rating plate mounted on the generator case WARNING Do not ground any of the external hand trimmer terminals Failure to observe this could cause equipment damage To adjust the generator output voltage proceed as follows 1 Before running the generator set turn the VOLTS control fully anti clockwise Turn t
72. combustion engine driven alternating current generating sets Part 3 Alternating current generators for generating sets BS 5000 3 2006 Rotating electrical machines of particular types or for particular applications Part 3 Generators to be driven by reciprocating internal combustion engines Requirements for resistance to vibration The manufacturer s authorised representative in the Community and person empowered to draw up this declaration and to compile the relevant technical documentation on behalf of the manufacturer is Mr Jeffrey Matthews Director Engineering Cummins Generator Technologies Bamack Road Stamford Lincolnshire PEO 2NB England A Signed N ohh gt Date 21 December 2009 af Description Serial Number f 5 D z Registorex in England under Registration No 441273 Cummins Generator Tachnologes Lid Registered Office Bamack Road Stamford Lincoinshire PES 2NB England All STAMFORD generators meet the following Standards and Directives Directives 2004 108 EC EMC Directive 2006 95 EC Low Volts Directive 2006 42 EC Machinery Directive Standards EN 61000 6 1 EN 61000 6 2 EN 61000 6 4 EN ISO 12100 1 EN ISO 12100 1 EN ISO 14121 1 EN 60034 1 BS ISO 8528 3 BS5000 3 Note Once the generator is built into a generating set it is the responsibility of the generating set manufacture to ensure that the generating set complies with the relevant EC Directives P0 1 MAN EN 4 8 Copyrig
73. condary RPM for an engine or Secondary RPM 50Hz 50Hz 60Hz for a generator See RPM Frequency Select for more Select information Switched Input It uses this input to determine to control the preheat time Active Modes Name Description A NOTE More than one Active Mode can be selected Triggers Name Description Close BAT Input is active when Battery is present at the terminal Close GND Input is active when Ground is present at the terminal Close BAT GND Input is active when either Battery or Ground is present at the terminal Input is active when neither Battery or Ground is present at the terminal NOTE When running wires over long distances 100 it is recommended to use BATTERY as the trigger method TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 22 4 2 1 Voltage Select The controller has the ability to automatically change its AC voltage display mode and it s associated warnings and failures through use of switched inputs The AC Metering gt Generator Voltage gt Voltage Configuration setting must be set to Auto Selection When using voltage select the controller will continue to monitor the inputs for 10 seconds after crank success once that time expires the controller will then display the selected voltage configuration Use the table below to see how the switched inputs status correspond to the voltage configuration Volt Select 1 Input Volt Select 2 Input Voltage Con
74. d the generator Ensure that the generator air supply is clean free from moisture and contaminates and at or below the ambient temperature stated on the rating plate The PO and the P1 generators have round end brackets that will create an air flow pattern that is different to previous generators of this size The air flow should be modelled to identify and prevent hot air from recirculating within the enclosure PO 1 MAN EN 4 10 Copyright Cummins 2009 STAMFORD Vibration STAMFORD generators are designed to withstand the vibration levels encountered on generating sets built to meet the requirements of ISO 8528 9 and BS 5000 3 Where ISO 8528 is taken to be broad band measurements and BS5000 refers to the predominant frequency of any vibrations on the generating set Definition of BS5000 3 Generators shall be capable of continuously withstanding linear vibration levels with amplitudes of 0 25mm between 5Hz and 8Hz and velocities of 9 0mm s rms between 8 Hz and 200 Hz when measured at any point directly on the carcass or mainframe of the machine These limits refer only to the predominant frequency of vibration of any complex waveform Definition of ISO 8528 9 ISO 8528 9 refers to a broad band of frequencies the broad band is taken to be between 2 Hertz and 300 Hertz The table below is an example from ISO 8528 9 value 1 This simplified table lists the vibration limits by kVA and speed for acceptable genset operation
75. dividing into two sections Generator Windings and Rotating Diodes and Excitation Control Test 1 Generator Windings and Rotating Diodes Caution The resistances quoted apply to a standard winding For generators having windings or voltages other than those specified refer to factory for details Ensure all disconnected leads are isolated and free from earth This procedure is carried out with leads F1 and F2 disconnected at the AVR and with a 12 volt d c supply to leads F1 and F2 Copyright Cummins 2009 29 P0 1 MAN EN 4 STAMFORD e Start the set and run at rated speed on no load e Measure the voltages at the main output terminals U V and W These should be balanced and within 10 of the generator nominal voltage Balanced Main Terminal Voltages If all voltages are balanced within 1 at the main terminals it can be assumed that all exciter windings main windings and main rotating diodes are in good order and the fault is in the AVR Refer to AVR section for test procedure If voltages are balanced but low there is a fault in the main excitation windings or rotating diode assembly Proceed as follows to identify Rectifier Diodes The diodes on the main rectifier assembly can be checked with a multimeter The flexible leads connected to each diode should be disconnected at the terminal end and the forward and reverse resistance checked A healthy diode will indicate a very high resistance infinity in the reverse di
76. e 3 Carry out the insulation test in accordance with the operating instructions for the test equipment 4 he measured value of insulation resistance for all windings to earth and phase to phase should be compared with the guidance given above for the various life stages of a generator The minimum acceptable value is 1 0 Megohm on a 500V megger If low winding insulation is confirmed one or more of the methods given below for drying the winding should be carried out Methods of Drying Out Generators Cold Run In the case of a generator in otherwise good condition that has not been run for some time and has been standing in damp humid conditions a simple procedure may suffice It is possible that simply running the generator set unexcited AVR terminals K1 K2 open circuit for a period of say 10 minutes will sufficiently dry the surface of the windings and raise the IR to greater than 1 0 Megohm and so allow the unit to be put into service Blown Air Drying Remove the covers from all apertures to allow the escape of the water laden air During drying air must be able to flow freely through the generator in order to carry off the moisture Direct hot air from two electrical fan heaters of around 1 3 kW into the generator air inlet apertures Ensure the heat source is at least 300mm away from the windings to avoid over heating and damage to the insulation Apply the heat and plot the insulation value at half
77. e engine and the alternator are connected Single and two bearing arrangements are available both arrangements can be close coupled Both arrangements also need a firm level foundation Two bearing generators require a substantial bedplate with engine generator mounting pads to ensure a good base for accurate alignment Close coupling of the engine to the generator can increase the overall rigidity of the set A flexible coupling designed to suit the specific engine generator combination is recommended to minimise the torsional effects Accurate alignment of single bearing generators is essential vibration can occur due to the flexing of the flanges between the engine and generator A substantial bedplate with engine generator mounting pads is required For the purposes of establishing set design the bending moment at the engine flywheel housing to generator adaptor interface should not exceed 125ft Ib 17 kgm The maximum bending moment of the engine flange must be checked with the engine manufacturer Torsional vibrations occur in all engine driven shaft systems and may be of a magnitude to cause damage at certain critical speeds It is therefore necessary to consider the torsional vibration effect on the generator shaft and couplings It is the responsibility of the generator set manufacturer to ensure compatibility and for this purpose drawings showing the shaft dimensions and rotor inertias are available for customers to forward to t
78. e is inhibited and the generator is electrically isolated The AVR access covers are designed to be removed while the generator is on load Lifting Lift the generator using the points provided with the aid of a spreader and chains The angle on the chains must be vertical during the lift Do not lift single bearing generators without the transit bar securely fitted When removing the transit bar just prior to offering the generator up to the engine be aware that the rotor is not securely held in the generator Keep the generator in the horizontal plane to when the transit bar is not fitted If large terminal boxes are fitted extensions to the lifting points may be necessary Warning The lifting points provided are designed for lifting the generator only Do not lift the Generating Set by the generator s lifting points Note Due to our policy of continuous improvement details in this manual which were correct at time of going to print and may now be due for amendment Information included must therefore not be regarded as binding PO 1 MAN EN 4 2 Copyright Cummins 2009 STAMFORD Foreword The Manual Before operating the generating set read this manual and all additional documentation supplied with it Great care has been taken with the design of this product to ensure that it is safe to operate Misuse and the failure to follow the safety precautions contained in the manual are potential causes of accidents Read the manual
79. e an ampere rating of not less that 115 of the nameplate current rating of the generator system The factory supplied conductor insulation must be rated at a minimum of 105 C Wires connected to the generator must meet or exceed this insulation rating Connections for load cables are to be made directly to the load circuit breaker Item 1 Fig ure 8 1 1 The neutral conductor should be connected to the neutral post on the generator main terminal strip Item 2 Due to the many different AC connection op tions voltage phase etc not all AC connec tion diagrams are included in this manual Con tact Stadco if you have any questions regard ing connection diagrams See Section 8 3 for AC wiring diagrams Note Some items shown may be optional Make sure all electrical cables are adequately protected against chafing or any other failure of insulating material Protect all loose wiring with appropriate wire protection material NOTE The Automatic Logic Controller in the Remote Control Panel also requires a high voltage connection for speed monitoring This connec tion is pre wired and is part of the standard connection cord from genset to remote panel See AC 8 DC Wiring Diagrams 8 2 Generator Grounding State and local codes specify various grounding requirements for electric generator systems These specific codes must be followed in order to insure personal safety O 2013 Stadco Products Division Ephrata PA 17522 US
80. e the air space for preventing mois ture condensing Keep the fuel tank free from water and contaminant by draining periodically 2013 Stadco Products Division Ephrata PA 17522 USA Keep open flames away when working on the fuel system Do not smoke Summer diesel fuel Il Winter diesel fuel A Outdoor temperature B Paraffin mixing proportion Figure 9 2 1 Note Mix kerosene with fuel in tank only First add appropriate amount of kerosene then fill with diesel fuel CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 23 10 0 Installation Instructions 10 10 1 General Mounting Instructions The framework must be constructed in accordance with good mechanical design so that the weight of the generator system will not stress the compartment construction Plan the location to be large enough to permit set re moval Allow additional clearance for easy ac cess to the oil fill oil filter oil drain fuel filter air filter as well as the voltage regulator and main load circuit breaker Allow enough clear ance so that the exhaust system may be dis connected for future service work Design the compartment large enough for the generator system Install the generator system in its own compartment Separate the compartment area from the storage areas fuel supply areas and personnel See Section 4 0 for genset drawing Construct the compartment floor in a manne
81. e to the exhaust gas flow exhaust backpressure consisting of the total re sistance of the system including the pipes pipe bends muffler tailpipe and or exhaust accessories The exhaust system design must ensure that the total system flow resistance does not exceed the maximum permissible backpressure Refer to Section 10 5 for Speci fications The engine exhaust manifold I D constitutes the reference value for designing the exhaust piping It is not permissible to reduce the I D beyond this size Mufflers CD20 CD30 Generators are supplied with an engine mounted exhaust muffler An optional exhaust kit with muffler is available from Stad co See Figure 10 2 2 CD40T4 Generators are supplied with an ex haust muffler kit loose Figure 10 2 2 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 If you are going to supply your own muffler for the genset the following are factors that gov ern the selection of the muffler 1 Exhaust volume flow at rated output and speed 2 maximum permissible engine exhaust back pressure 3 degree of noise reduction required in dB A 4 configuration required Whenever the muffler is not mounted on the engine suitable engine muffler connections must be provided These connections must be kept as short as possible Elbows Provide sweeping bends to minimize exhaust backpressure 90 elbows should have a radius not
82. ectives designed for incorporation into an electricity generating set and is CE marked This synchronous ac generator is designed for incorporation into an electricity generating set and fulfils all the relevant provisions of the following EC Directive s when installed in accordance with the installation instructions contained in the product documentation 2006 95 EC Low Voltage Directive ja d fat E a E ZE Our authorized representative in the Community is 2006 42 EC The Machinery Directive 5 E A mi hwa rr sir xi acc rc Jun to Mr Jeffrey Matthews Director Engineering EN 61000 6 1 2007 Electromagnetic compatibility EMC Generic standards Part 6 1 Immunity S D for residential commercial and ighi industrial anvironman Cummins Generator Technologies Ltd EN 61000 6 2 2005 Electromagnetic compatibility EMC Generic standards Part 6 2 Immunity ior industrial environments EN 61000 6 4 2007 Electromagnetic compatibility EMC Generic standards Part 6 4 Emission standard for industrial environments EN ISO 12100 1 2003 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN ISO 12100 1 2003 Safety of machinery Basic concepts general principles for design Pan 2 Technical principles EN ISO 14121 1 2007 Safety of machinery Risk assessment Part 1 Principles EN 60034 1 2004 Rotating electrical machines Part 1 Rating and performance BS ISO 2528 2 2005 Reciprocating internal
83. ed every 12 000 operating hours 3 Check hardware amp connections for tight ness 4 Check for cracked or broken wires 5 Check for proper operation 6 Replace every 2 years 7 If engine does not reach hour limit replace maximum 5 years 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 7 0 8 0 N 00 6 1 7 14 Scheduled maintenance inter vals apply only for normal en gine utilization and at normal environmental conditions When utilization or environ mental conditions become particularly severe scheduled maintenance intervals must be reduced accordingly Stop engine before attempting any kind of service Be sure the Power Switch Item 2 Fig ure 5 1 1 is in the OFF posi tion This will prevent the gen set from being started Page 32 11 0 Points of Maintenance 11 4 Lubrication System Before changing oil and filters read Precautions for Filters and Elements in Sec tion 1 0 Changing the Oil Filter The oil filter is a spin on cartridge type located on the side of the engine Item 1 Fig 11 4 1 Only OEM filters should be used as these have high temperature joints adequate filter paper characteristics and a rigid case Other filters may have the same external dimensions and thread as the genuine one but may fail in service 1 Place toggle Power Switch Item 1 Figure 5 1 1 to Off position
84. eeeeeusaueueueaaeass 10 EE 10 HIGH HUMIDITY ENVIDRONMENTS nano n nn nono naaa 10 Anti condensati0N heaiers nana nana nana aran arc nnnnnanoncnonononnononnnnnananos 10 Bi AA ka Secccecchueesetesace 10 AIR 11 Definition 0f BS5000 Buu tiesa 11 Definition em ISO 8528 D ps 11 Visite Be Tel e WEE 11 Excessive Vibration evels nana nc nano na nono nonnnnnnonnono non nn nnn nn nan anna anar cnn ncnnnnannnns 11 BEARINO Si a a tdt 11 Factors that effect bearing life ooo oconcninononnconnonnnonocnorennrnnorncrnrnnnrncnrncrnncrnrn rn nan Basi n g reus nenes 11 Health Monitoring of the Bearings conan o nanc ron nn nano nan nnn ona n nn na nena nana nana 12 Bearing Service Life Expectancy ccccccececceeenceeeeeeeeeeneeceneeceeeeeeceneeesaeeeseaeeeseaeeseaeeseeaeeteeaeeeees 12 INSTALLATION INTO THE GENERATING SET cccccccsseesesccecccscsssscsssssssessseeseeeeeeeeneeeeeseeeuseeeeeeneaeees 13 DELIVERY me Seas a ue Eege 13 HANDLING THE GENERATOR 13 enee 13 AFTER STORAGE Et A a A e 13 ROTORIBALANCING maai madii wai NA SA AA ami E WA AN BA EA le cil 13 GENERATOR VIBRATION FREQUENGY ccccccccceeceeeeessnsnecececececesssssceeeeceeeceesececesseeseseeececeeeseeeseeessnees 13 A AWA AA AAA WAWA 14 COUPLING ARRANGEMENTS naa manana maana nana nana manana manana manana nana nawananu manana nanananaaaananaa manana wa 14 Coupling Two Bearing Generator 14 PO 1 MAN EN 4 4 Copyright Cummins 2009 STAMFORD Coupling
85. eeuseuuuseuaeseueeseueeeeeeeeeees 2 WARNINGS amp NOTICES USED IN THIS MANUALE 2 SKILL REQUIREMENTS OF PDERSONNEL narran nnnannn nana anazaa 2 ELECTRICAL Ge EE 2 EIN 2 FOREWORD iii iii 3 THE ANI Ai eebe 3 SCOPE ee ee Eed ege 3 GENERATOR DESIGNATION ere A A Ee 3 THE PRODUC Ta Ee dd e 3 SERIAL NUMBER LLOCA TON Latidos ia dida E ieran en iaiia 3 BATING PLATE as 3 CONTENT OT 4 INTRODUCTION ion di 7 GENERAL DESCRIPTION ti a ida ib 7 SELF EXCITED AVR CONTROLLED GENERATORS nn nanaac anno 7 Main Stator Powered AND 7 SEPARATELY EXCITED AVR CONTROLLED GENERATORS cccccceeceseeeecececcceceeceeeusueuueuuuesuaeseaeeseeeeeeeeeeeeeeeess 7 Optional Excitation Boost Gvstem EB 7 FOR PARALI E OPERAT ON eege eege coca dooce ENNEN 7 Function and Adjustment of the Fitted Accessories ooonccinncnncnonccnonononnnonncnnnonanonon cnn nn ama namana 7 e Re 8 EUROPEAN DIRECTIVES iisi ia aia i 8 Applications the Generator is designed for 8 UNSUITABEE APPLICATIONS dad 9 ADDITIONAL INFORMATION FOR EMC COMPLIANCE oococccconcccnncccnncnnnnocononnnnnononononcnnnnnnnnnnnnnncnnnnnnnnccnannnnoninnnn 9 APPLICATION OF THE GENERATOR o occnccccccccocccocococnocononcnnnncononanananananananancn raro rora ro nor rr nnronnarnnnn naaa aa anananas 10 ENVIRONMENTAL BROTECTION cnn cnnnnnnnnnnnnnnnnnnnnnn ono nono 10 7 oT led Wa ee a eS a 10 AIRBORNE CONTAMINATES ccccccsseceeceeeseceeecceecceceececceceucceceucusseueuaeuuuusuuuseeuseeusseeseseeeeeeeeue
86. efore proper mainte nance is critical in extending the life of the en gine 1 Place toggle Power Switch Item 1 Figure 5 1 1 to Off position 2 Cleaning the heat exchanger Item 1 Fig ure 11 9 1 can be accomplished by blow ing compressed air through the core in the direction of the arrows as shown Take care not to damage the fins of the heat ex changer core 3 When finished clean up loose dirt and de bris Do not spray water through radiator core due to sensitive electronic equipment in the generator compartment Figure 11 9 1 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 11 Page 40 12 0 Routine Service Parts List Routine Maintenance Parts List Genset Engine Pre filter V belt M l M l i ode ode Final Optional Primary Safety CD20 D2011L030 1174416 1174696 56795 C14200 CF200 1174612 CD30 D2011L040 1174416 1174696 56795 C14200 CF200 1174612 CD40T4 TD2011L040 1174416 1174482 56795 P827653 P829332 1180195 Engines are filled from the factory with Deutz lube oil PN 305656 SAE 15W40 13067 filter list xls 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 12 Page 41 13 0 Warranty 13 13 1 GENERAL WARRANTY NOTICES Installation inconsistent with the instructions contained in this document and accep
87. elay Style Automotive Cube WARNING You must use relays in the RelayPak that are suitable for the system voltage Example 12V relays in a 12V system and 24V relays in a 24V system Relay Pak RP100 37 Relay D Contact TOUGH Series Manual 2014 DYNAGEN Technologies Inc Using the Controller 16 3 Using the Controller The LCD display is the primary source of information of the controller The LCD allows you to view change settings and monitor the status of sensors and other engine peripherals LCD Display RUNNING Using the Menu System Task Description Entering Menu When in the OFF mode press the enter button to bring up the menu Navigating Menu Once in the menu use the up and down arrows to navigate Pressing enter will move you into that menu Change a Setting Scroll to the desired value and press enter to select A check mark should now be beside that item Press enter again to save the setting and return to the previous screen Scroll Parameters When in Auto or Running mode pressing the up and down arrows will scroll through the parameters pages Lock Screen When in Auto or Running mode you can lock the screen onto a certain parameter page by pressing enter You can unlock the screen by pressing enter again Events History Once in the menu select Events History to view the most recent controller event Use the up and down arrows to navigate to other events The controller can store up to 150
88. elow the warning threshold and the warning disappears TOUGH Series Manual O 2014 DYNAGEN Technologies Inc Settings 33 4 4 6 2 Start on Low High Example In this example a sensor is monitoring the voltage of an external battery bank If the voltage falls below 10 5V the engine will start and run for 40 minutes to charge the battery Relevant Settings Setting Value 1 Stop Level is disabled because when the engine is running the battery voltage will equal the alternator charging voltage Having this disabled will force the engine to run for the entire duration of the active time 20 5 15 Battery Level k z Voltage Start Level Engine Run i 54 KE t o 20 40 60 80 100 120 140 Time Minutes The chart above shows the connection between a battery bank and time At approximately 80 minutes time the voltage falls below the 10 5V start threshold causing the engine to start The engine runs for the 40 minutes active time regardless of the voltage reading and the shuts down TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 34 4 4 6 3 Output on Low High Example In this example a sensor is monitoring the temperature of an engine If the temperature rises above 325 F a fan will turn on to cool the engine Once the temperature drops to below 200 F the fan will turn off Relevant Settings Auxiliary Sensor Setting 1 Active time is disabled because the fan needs to stay on
89. er head cover Position the crank shaft to Position 1 5 as per the setting schematic Figure 4 11 8 1 Check the valve clearance between pad of rocker arm 2 and valve 3 with feeler blade 6 e Clearance is correct if the feeler blade can PA just be inserted in the gap with a slight drag cronkshalt Posion T Figure 11 8 1 ok Turn the crankshaft until both valves at cylinder Permissible valve clearances 1 overlap exhaust valve about to close inlet Intake 0 3mm Exhaust 0 5mm valve about to open Adjust clearances of the Adjust valve clearance if necessary valves marked all black in Position 1 Figure 11 8 1 Mark the respective rocker arm with chalk to show that the adjustment has been made Adjusting Valves Release locknut 4 Use allen key 7 to turn setscrew 5 until the correct clearance is obtained after tightening Crankshaft Position 2 locknut 4 Check and adjust valve clearance on all remaining cylinders Replace cylinder head cover with new gasket if nec essary Turn the crankshaft further by one revolution 360 The clearances of the other valves marked all black in Position 2 Figure 11 8 1 can now be adjusted 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 39 11 0 Points of Maintenance 11 9 Cooling System Cleaning the Heat Exchanger The cooling system is a very essential part of the generator set ther
90. erature and power factor of the generator Positive voltage build up from residual levels is ensured by the use of efficient semiconductors in the power circuitry of the AVR A frequency measuring circuit continually monitors the generator output frequency and provides under speed protection of the excitation system This is done by reducing the output voltage proportionally with speed below a pre settable threshold A manual adjustment is provided for factory setting of the under frequency roll off point UFRO This can be changed to 60Hz or 50Hz in the field by push on link selection A wide range of stability settings are available to compensate for machine sizes and applications A slow setting is available for applications involving single twin cylinder engines and where lamp flicker could be a problem Provision is made for the connection of a remote voltage trimmer allowing the user fine control of the generator s output voltage Operation with 110Vac sensing is possible replace the hand trimmer link with fixed resistor The hand trimmer option cannot be used in this configuration The generator overload capability is reduced in 110V operation The AVR has the facility for droop CT connection to allow parallel running with other similarly equipped generators Over excitation conditions are limited to a safe period by a protection circuit within the AVR Once activated by a sustained over excitation condition the genera
91. events If more than 150 events occur the oldest event is deleted to make room for the next event Front Panel Items Description Off Button Used for turning off the engine or exiting out of Auto mode This is not intended to function as an Emergency Stop as there are conditions in which it will not shutdown the engine See the OFF Button Function section for more information Auto Button Used for placing the controller into Auto mode Once in Auto the controller A waits for a start command to be received Run Button Used to start the engine manually Must use the Off button to shutdown the engine if started from front panel Up Button Used for moving around in the menu changing a settings value or changing the currently displayed parameter page Enter Button Used for entering the menu system accepting settings or locking the ENTER LCD screen when viewing parameters Down Button Used for moving around in the menu changing a settings value or changing the currently displayed parameter page Generator LED Green Engine running with no issues Amber Engine running with warnings Red Engine shutdown on failure TOUGH Series Manual 2014 DYNAGEN Technologies Inc Using the Controller 17 3 1 Modes Starting and Stopping The following table describes the different operating modes of the controller Modes Mode State OFF Auto Running Failure Menu Description When in the OFF mode the engine can
92. figuration 3 Phase C 3 Phase 2 Phase G NOTE Both Voltage Select 1 and Voltage Select 2 must be assigned to switched inputs for the feature to function properly The following settings are affected by the Voltage Select Inputs 1 AC Monitor gt Generator Voltage gt Auto Nominal 2 AC Monitor gt Generator Voltage gt Auto Scaling Factor 3 AC Monitor gt Generator Current gt Auto Rated Amps 4 AC Monitor gt Generator Current gt Auto Scaling Factor 4 2 2 RPM Frequency Select The controller has the ability to change between Primary RPM 60Hz and Secondary RPM 50Hz through use of a switched input The AC Metering gt Generator Frequency gt Frequency Source setting must be set to RPM Switch for this feature to work This setting can only be changed when the controller is not in running mode The following settings must be set in order for this feature to function e Switched Input X gt Primary RPM 60Hz Secondary RPM 50Hz Select e AC Metering gt Generator Frequency gt Frequency Source gt RPM Switch e Sensors gt Engine Speed gt Auto RPM Nominal gt Primary RPM 60Hz e Sensors gt Engine Speed gt Auto RPM Nominal gt Secondary RPM 50Hz Use the table below to see how the switched input status corresponds to the RPM Frequency Switched Input Frequency NOTE If enabled the TSC1 PGN will be broadcasted according to the selected speed Otherwise only the warning a
93. flected on the generator nameplate If the operating environment for the generator has changed after purchase the rating of the generator needs to be revised refer to the factory for details Air Flow The airflow requirements for the generator can be found in the Data section at the back of this manual Ensure that the air inlets and outlets are not obstructed when the generator is running Airborne Contaminates Contaminates such as salt oil exhaust fumes chemicals dust sand etc will reduce the effectiveness of the insulation and lead to premature failure of the windings Consider using air filters or an enclosure with greater protection to protect the generator Air Filters Air filters are available on request Filters present a restriction to the airflow so the rating of the generator must be reduced by 5 If the filters are supplied factory fitted the rating on the nameplate will include the reduced rating The filters can be up fitted after delivery in which case the customer must apply the power reduction Air filters remove airborne particulates above 3 microns The frequency of changing and cleaning the filters depend on the site conditions We recommend that the filters are monitored frequently until a suitable cycle of change is established Air filters do not remove water Additional protection must be employed to prevent the filters from getting wet If the filters are allowed to get wet the airflow will be rest
94. found to be helpful Setting Procedure Depending upon available load the following settings should be used all are based on rated current level 0 8 P F LOAD at full load current SET DROOP TO 3 O P F LOAD at full load current SET DROOP TO 5 Setting the droop with low power factor load is the most accurate Run each generator as a single unit at rated frequency or rated frequency 4 depending upon type of governor and nominal voltage Apply available load to rated current of the generator Adjust DROOP control potentiometer to give droop in line with above table Clockwise rotation increases amount of droop Refer to AVR section for potentiometer location After adjustment check NO LOAD voltage level and adjust if necessary Note 1 Reverse polarity of the C T will raise the generator voltage with load The polarities S1 S2 shown on the wiring diagrams are correct for clockwise rotation of the generator looking at the drive end Reversed rotation requires S1 S2 to be reversed Note 2 The most important aspect is to set all generators equal The precise level of droop is less critical Note 3 A generator operated as a single unit with a droop circuit set at rated load 0 8 power factor is unable to maintain the usual level of regulation A shorting switch can be connected across S1 S2 to restore regulation for single running Caution LOSS OF FUEL to an engine can cause its generator to motor with consequent damage to
95. fy the Sensors gt Engine Speed gt Signal Source setting is set correctly 2 Verify the Timers gt Engine Logic gt RPM Disconnect setting is set correctly 3 Ensure the correct wiring to the controller For magnetic pickup Speed Sensing A and B terminals are used For generator voltage the AC voltage connections are used Sender always displayed its lowest The sender could either be open not connected or shorted to ground Verify your or highest value connections and ensure the correct sender table is loaded Reserved for future troubleshooting Reserved for future troubleshooting Reserved for future troubleshooting Contacting DYNAGEN can be done by any of the methods below Technical support is offered Monday Friday 8 00am 4 00pm EST If you are unable to get a hold of one of our engineers please leave a message and they will return your call as soon as possible Type Information Address 3 Spectacle Lake Drive Unit B105 Dartmouth NS B3B1W8 Canada TOUGH Series Manual 2014 DYNAGEN Technologies Inc
96. ge to Read Vout SE x Vin R1 Common Resistor Value gt 10k R2 Calculated Resistor Value Select closest common resistor value The following diagram shows the typical wiring of a voltage divider The resistors values have been selected to allow the controller to read up to 36V from an external battery bank 0 36V Wiring Example To Universal Sensor Input Battery 0 36V TOUGH Series Manual 2014 DYNAGEN Technologies Inc Installation 12 2 4 3 CAN Bus Wiring The following table outlines some items that must be taken into consideration when connecting to a CAN bus engine Consideration Description Each end of the bus must be terminated from H to L with 120 resistors If the controller is a Bus Termination device that is not at the end of the bus it does not require a terminating resistor A J1939 twisted pair 120 cable is required for communications Possible options are Cable Selection 1 Belden 9841 One twisted pair 24AWG 2 Belden 7895A Two twisted pair 20AWG second pair can be used for power Shieldin When using a Belden style cable the shield must be grounded on one end of the bus This 9 prevents loss of data from electromagnetic interference Communications Wiring To Controllers 31939 Connections SHIELD H For the ECM to function it must first receive power for a short time before cranking to allow it to boot up It is common practice to use the fuel relay outpu
97. ght radius at the point of entry into the terminal box panel and allow movement of the generator set on its anti vibration mountings without excessive stress on the cable Before making final connections test the insulation resistance of the windings The AVR should be disconnected during this test A 500V Megger or similar instrument should be used Should the insulation resistance be less than 5MW the windings must be dried out as detailed in the Service and Maintenance section of this manual When making connections to the terminals the incoming cable termination should be placed on top of the winding lead termination s and clamped with the nut provided eg current carrying component next to current carrying component Caution To avoid the possibility of swarf entering any electrical components in the terminal box panels must be removed for drilling The AVR can be fitted on either side of the NDE bracket in its own compartment There is sufficient length of wiring to allow the customer to swap sides without rewiring Earthing The neutral of the generator is not bonded to the generator frame as supplied from the factory An earth terminal is provided inside the terminal box adjacent to the main terminals Should it be required to operate with the neutral earthed a substantial earth conductor normally equivalent to one half of the section of the line conductors must be connected between the neutral and the earth terminal inside the te
98. ghtly oil the face of the rubber gasket on the new filter 6 Screw the new filter onto the filter adapter and tighten to 10 12 Nm 7 4 8 9 ft lbs 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Figure 11 5 2 Cleaning the Fuel Pump Screen 1 Place a container beneath the fuel pump to collect any fuel which may spill 2 Close supply line shutoff valve 3 Disconnect fuel hose Item 4 to fuel filter 4 Remove the fuel screen cover Item 2 Fig ure 11 5 2 by removing the screw Item 3 5 Clean the fuel screen amp o ring seal with diesel fuel Replace if damage is found Replace fuel screen cover Item 2 making sure o ring is in the proper position Tighten mounting screw Item 3 Reconnect fuel hose Item 4 Open fuel shutoff valve O After restarting check for leaks D AON Venting the Fuel System Make sure the supply hose fuel valve is open 1 Operate the hand pump ltem 5 Figure 11 5 2 until a strong resistance is felt 2 Start the engine and run without load to allow the air to return to the fuel tank via the return line CAUTION After restarting engine check to make certain there are no leaks All waste fuel which has been collected must be dis posed of in a manner which will prevent environ Warning mental pollution 11 Page 34 11 0 Points of Maintenance 11 5 Fuel System
99. got and rotor coupling plates have been coated with a rust preventative This MUST BE removed before assembly to engine A practical method for removal of this coating is to clean the mating surface areas with a de greasing agent based on a petroleum solvent Warning Care should be taken not to allow any cleaning agent to come into prolonged contact with skin 4 pole Single Bearing Coupling Alignment 1 On the engine check the distance from the coupling mating face on the flywheel to the flywheel housing mating face This should be within 0 5mm of nominal dimension This is necessary to ensure that a thrust is not applied to the ac generator bearing or engine bearing 2 Check that the bolts securing the flexible plates to the coupling hub are tight and locked into position torque 75Nm 55 lb ft 3 Remove air outlet cover from the drive end of the generator to gain access to coupling and adaptor bolts Check that coupling joint interfaces are clean and lubricant free 4 Check that coupling discs are concentric with adaptor spigot This can be adjusted by the use of tapered wooden wedges between the fan and adaptor Alternatively the rotor can be suspended by means of a rope sling through the adaptor opening 5 Consider using alignment studs to ensure that the disc and the flywheel are in alignment 6 Offer the generator to engine and engage both coupling discs and housing spigots at the same time pushing generator towards engine until
100. h have been improperly stored or which have been repaired adjusted or altered by any person except ourselves or our authorised agents or in any second hand goods proprietary articles or goods not of our own manufacture although supplied by us such articles and goods being covered by the warranty if any given by the separate manufacturers Any claim under this clause must contain fully particulars of the alleged defect the description of the goods the date of purchase and the name and address of the Vendor the Serial Number as shown on the manufacturers identification plate or for Spares the order reference under which the goods were supplied Our judgement in all cases of claims shall be final and conclusive and the claimant shall accept our decision on all questions as to defects and the exchange of a part or parts Our liability shall be fully discharged by either repair or replacement as above and in any event shall not exceed the current list price of the defective goods Our liability under this clause shall be in lieu of any warranty or condition implied by law as to the quality or fitness for any particular purpose of the goods and save as expressly provided in this clause we shall not be under any liability whether in contract tort or otherwise in respect of defects in goods delivered or for any injury damages or loss resulting from such defects or from any work undone in connection therewith Copyright Cummins 2009 39
101. he STABILITY control to its midway position and the external hand trimmer if fitted to its midway position 2 Connect a suitable voltmeter 0 300Vac across Line and Neutral of the generator 3 Start the generator set and run on no load at nominal frequency e g 50Hz or 60Hz 4 If the red Light Emitting Diode LED is illuminated refer to the section on Under Frequency Roll Off adjustment 5 Carefully turn the VOLTS control clockwise until the required voltage is reached 6 If instability is present at rated voltage refer to the section on Stability adjustment 7 Voltage adjustment is now completed STABILITY ADJUSTMENT The AVR includes an optimised stability circuit to provide good steady state and transient performance of the generator Links are provided to change the response of the stability circuit to suit different frame size generators and applications A slow response setting is more appropriate on small generator sets and will prove helpful in reducing lamp flicker The correct setting of the Stability adjustment can be found by running the generator at no load and slowly turning the stability control anti clockwise until the generator voltage starts to become unstable The optimum position for the control is slightly clockwise from this point i e where the machine volts are stable but close to the unstable region Cummins 2008 4 UNDER FREQUENCY ROLL OFF ADJUSTMENT UFRO The AVR incorporates an
102. he engine supplier In the case of single bearing generators coupling details are included Caution Torsional incompatibility and or excessive vibration levels can cause damage or failure of the generator and or engine components Coupling Two Bearing Generators PO 1 MAN EN 4 14 Copyright Cummins 2009 STAMFORD Warning Do not use the fan to rotate the shaft this is particularly important when the engine and the alternator are connected A flexible coupling should be fitted and aligned in accordance with the coupling manufacturer s instruction If a close coupling adaptor is used the alignment of machined faces must be checked by offering the generator up to the engine Shim the generator feet if necessary Ensure adaptor guards are fitted after generator engine assembly is complete Open coupled sets require a suitable guard to be provided by the set builder Axial loading of the generator bearings should be avoided Should it be unavoidable contact the factory for advice Warning Incorrect guarding and or generator alignment can result in injury and or equipment damage Coupling Single Bearing Generators Warning Do not use the fan to rotate the shaft this is particularly important when the engine and the alternator are connected Alignment of single bearing generators is critical If necessary shim the generator feet to ensure alignment of the machined surfaces For transit and storage purposes the generator frame spi
103. hen working on the generator set Disconnect the cable end that is away from the battery Do not wear jewelry watches or rings These items can short out and cause severe burns to the wearer O 2013 Stadco Products Division Ephrata PA 17522 USA High Voltage AC Current Never attempt any kind of service or repair while the engine is running When servicing or repairing a generator set with the engine running the possibility of serious or even fatal injury from electrical shock exits Lethal voltage potentials may exist e Treat all wires and connections as high voltage until meter and wiring diagram show otherwise e Do not attempt to work on high voltage equipment Have a qualified electrician perform these tasks IMMEDIATE action must be initiated after a person has received an electric shock Quickly obtain expert medical assistance The source of shock must be immediately removed by either turning the generator off or turning the circuit breaker off Guard Against Electric Shock Do not operate the generator with protective covers access covers or safety shields removed Never operate the generator or handle any electrical equipment while standing on wet surfaces or while in touch with wet surfaces Maintain all electrical cords in good condition Worn frayed or bare wires will cause severe electrical shock Use extreme caution when working on electrical components High voltages cause inju
104. how the controller reads and interprets data from the fuel level sender Name II Description Signal Source Sensor Port X The source from which the sensor data is attained Sensor Type Sender Table X Select one of the pre configured sender tables or one of the Close Warning switch functions A custom table can also be created using Open Warning the DYNAGEN Configurator Close Failure Open Failure Close Ground Open Open Circuit Trim Offset 50 0 50 0 Calibrate a sensor by using the offset to correct errors Setpoints gt Bypass Time 0 90 seconds Amount of time to bypass warnings and failures after engine has started Setpoints gt Low Warning 1 90 Reading at which a warning occurs Setpoints gt Low Failure 1 90 Reading at which a failure occurs Setpoints gt High Warning 1 125 Reading at which a warning occurs 444 Engine Speed The following settings are used to configure how the controller reads and interprets speed sensing data Name Description Signal Source J1939 Bus The source from which the sensor data is attained Mag Pickup Genset Voltage Speed Settings gt Rated RPM 500 4000 Speed at which the engine runs under normal operating conditions Warning and failure setpoints are calculated from this setting Setpoints gt High Warning 101 150 Reading at which a warning occurs Setpoints gt High Failure 101 150 Reading at which a failure occurs Front Panel Speed Control N
105. hrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 42 13 2 Stadco Warranty 13 STADCO LIMITED WARRANTY POLICY D25 2 FOR CELLPAC TOP DOG MOBILE GENERATOR SYSTEMS COVERAGE 8 TERM This Warranty statement applies exclusively to Stadco Mobile Generator Sets hereinafter referred to as the Products sold by STADCO PROD UCTS DIVISION of Stauffer Diesel Inc Stadco subject to conditions stated herein Stadco warranty coverage area limited to continental USA and Canada Stadco guarantees such Products against defects which occur under normal non marine use and service in mobile compartment and enclosed applications for Cellpac type Products and Non Enclosed applications for Top Dog type Products which can be proved to the rea sonable satisfaction of Stadco to be a result of defect in workmanship or materials Warrantable Failure Stadco does not guarantee defects arising out of installation of the Product unless the recommended installa tion procedures are followed pursuant to the provisions in this Policy and defects can be proved to the reasonable satisfaction of Stadco to be a result of defect in workmanship or materials Term of this Stadco warranty is limited to the earlier of a period of 24 consecutive months of service or 2000 hours of operation to the first User User but not to exceed 30 months from the date of invoice by Stadco to its origina
106. ht Cummins 2009 STAMFORD Applications the Generator is designed for STAMFORD ac generators are supplied on the basis that They are used for power generation or related functions They are to be applied in one of the following environments Portable open construction temporary site supply Portable enclosed temporary site supply Containerised temporary or permanent site supply Ship borne below decks marine auxiliary power Commercial vehicle road transport refrigeration etc Road transport auxiliary power Industrial vehicle earthmoving cranes etc Fixed installation Industrial factory process plant Fixed installation residential commercial and light industrial home office health Energy management combined heat 8 power and or peak lopping Alternative energy schemes The standard generators are designed to meet the industrial emissions and immunity standards Where the generator is required to meet the residential commercial and light industrial emissions and immunity standards reference must be made to document reference N4 X 011 This publication outlines the additional equipment that may be required The installation earth ground arrangements require the connection of the generator frame to the site protective earth conductor using a minimum lead length Maintenance and servicing with unauthorised parts not of STAMFORD brand will invalidate us from any liabilit
107. hy yayaya Disk 39y vHOSIG i i WO NANT aly EAT yen av LOH deL TINO 1SMWHX3 Weds ire 4 Sum CIOAINVW JANVd TOYINOD 6221 QUVGNVIS ceee SMi 7210270279 ai TaNVd TOJINOD MAN a esze Ha Z102 90 21 Hm CIOJINVWW ay Y Noa uni ava NOlIdISDS3O Ma Ea PR SNOISIARY H D v s H H Page 11 O 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Figure 4 1 2 Stadco Model CD30 Genset Dwg 12917 t 2 140 EHS HK EM ZL SWOs 167l 1102 2 1 sf o Om ava A NM VANI TWHNEGEINOD ONV Kev aaen CSN Vd VLVAHAT ONT TASHIA YAAAAVIS CA ODAVLS IMOAWA L3SN39 0 09 31111 O3JIANVAVNO LON ina 3181138 314330 Hau OINIWINODO NOILLWW4O4NI NONDANNOD 3915 3DIAYIS dd Tans aan ru AAA WO 4 Y 1388 Tie ated Set Td WO SYNYT aly ica hes TANVd TOYINOO 6221 OYVONVLS gece stl 7210270279 6 11 TINVd TOYINOD MIN 8 esze Hx8 2102 90 21 ANANN GIOJINVW GOV naz wee No3 e 210 NOILdIYDS30 KE 8 KK SNOISIAZS 1 H E y Page 12 O 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 REVISIONS Figure 4 1 3 Stadco Model CD40T4 Genset Dwg 13012 a o a lt KAS O18 R DE x
108. iesel fuel The use of contaminat ed fuel may result in en gine damage 9 2 Fuel Always use commercial brands of diesel fuel having a sulfur content of less than 0 5 In the case of a higher sulfur content the periods between oil changes must be shorter Never use substitute fuel kerosene or heavy oil Use ASTM 2 D diesel fuel for best performance during normal weather The following are approved diesel fuel specifi cations ASTM D 975 1 D and 2 D DIN EN 590 JIS K 2204 Grade 1 and Grade 2 NATO Code F 54 The certification measurements to satisfy the legal emission limits are performed with the test fuels defined by law These correspond to the diesel fuels according to EN 590 and ASTM D 975 described in this operating manu al No emission values are guaranteed with the other fuels described in this operating manual Winter Grade Fuel Waxing may occur at low temperatures clog ging the fuel system and reducing engine effi ciency If the ambient temperature is less than 0 C winter grade fuel suitable down to 20 C should be used This fuel is usually availa ble from suppliers well in advance of the cold months At temperatures below 20 C kerosene should be added to the diesel fuel The rele vant percentages are given in Figure 9 2 1 If summer grade diesel fuel must be used at temperatures below 0 C up to 60 kerosene can be added In winter fill the fuel tank as often as possible to eliminat
109. imer Battle Mode User Controlled Active when the Delay to Start timer is active Active when Battle Mode switched input is active When user triggers a Force Regeneration output is active for 20 seconds then switches off Regeneration Inhibit User Controlled When user triggers a Regeneration Inhibit output is active for 20 seconds then switches off Common Failure Any Failure Active when any failure occurs RPM Increment Running Output is used to to trigger inputs on an ECM to control speed See Front Panel Speed Control section for more information RPM Decrement Running Output is used to to trigger inputs on an ECM to control speed See Front Panel Speed Control section for more information o po oO n 4 5 ad TOUGH Series Manual O 2014 DYNAGEN Technologies Inc Settings 25 DEF Fluid Level Running Active when DEF Fluid Level falls below the DEF Low Level and stays active until the level rises above the DEF High Level See CAN Bus 41939 section for more information Generator Coil Global Active when transfer switch is to be switched to the generator position TG350AMF only Mains Coil Global Active when transfer switch is to be switched to the mains position TG350AMF only Warning Functions Functions DEER DEER TA Failure Functions Functions Engine Failed to Stop DM1 Stop Lamp High Engine Temperature Low Oil Pressure Low Fuel Level Under Speed Over Speed Low B
110. injection system is out of order Do not allow the engine to run with a dirty ex haust without determining the cause as this may result in an expensive breakdown 10 Page 31 Service Item Walk around inspection Valve clearance 11 0 Points of Maintenance Check e Adjust O Clean A Replace 8 ROUTINE MAINTENANCE 8 SERVICE INTERVALS Every 10 Hrs or Daily Running Hours Every 500 Hrs Every 1000 Hrs Notes Section Every Every Every Year 3000 Hrs 6000 Hrs Minimum 11 Oil level Lube oil Oil filter Fuel level Fuel filter s Fuel pump screen Fuel tank Fuel Injector Nozzles Lube Oil Cooling System Heat exchanger V belt tension Restriction indicator Hose clamps 8 connectors Filter element Dust Discharge Valve Heater Plugs Wiring amp AC load cables Air Cleaner AC amp DC Replace as indicated by restriction indicator or Maximum 1 000 Hrs Clean when performing Air Filter maintenance Electrical System Battery amp cable connectors Engine protection amp monitoring devices Timing Belt Mounting hardware amp engine mounts Engine Overhaul Figure 11 3 1 Notes 1 Have this service performed by an author ized Deutz service de 2 If engine runs fewer hours during the year than what is stated in this table perform this maintenance at least once a year aler Recommend
111. isance tripping and to support normal transients and short term overloads The generator voltage falls to low levels when the trip is activated The generator must be stopped to reset an over excitation shutdown condition EXCITATION BOOST SYSTEM There are no user adjustments on the EBS module just connect the unit and it is ready for use TD_AS480 AVR_04 08_02 GB Cummins 2008 EBC Excitation Boost Controller gt Block Diagram Output Excitation Boost Controller Connections EB Micro controller F2 EBS Circuit description The EBS comprises an add on permanent magnet generator EBG with embedded control electronics the EBC module The main functions of the EBC are as follows The Input Rectifier and Power Supply provides supplies to the internal control parts of the EBC The Micro controller measures the drive signal DR generated by the AVR and determines the e Seeger Level Shifter Level Shifter Mid Output d Power Control Low Output Power Control ole Exciter Field Windings na 1 U Ar ig need for excitation power support As this support is required it is delivered at low medium or high levels to the exciter field The AVR control function maintains generator voltage within broad limits until both AVR and EBS are fully conducting The micro processor contains three timer functions to prevent ac
112. itch Item 1 Figure 5 1 1 in the main control panel must be in the ON position and Digital Controller Item 4 Figure 5 1 1 must be in Auto Mode be fore starting from remote station 2 Push Start Stop Toggle switch Item 11 Figure 5 2 1 to GENERATOR START po sition When the Engine Starting Running lamp Item 73 lights up release the switch The engine controller will begin the following start up procedure a First the engine will preheat for a preset preheat time b Next the engine controller will crank the engine until it begins to start The en gine Starting Running LED will remain lit The engine should continue to run normally unless a fault condition exists If the engine fails to start after the de fault cranking procedure the unit will stop and the Engine Fault lamp Item 12 will become lit If a fault occurs the control system will need to be reset at the main control panel before being restarted See Section 6 2 Note See Section 7 5 for Digital controller default setup The main generator will automatically activate and build up current immediately upon engine CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 16 6 0 Starting and Operating 6 4 Shutdown Procedure Prior to shutdown of the engine 1 Switch the main circuit breaker to OFF position to disengage load Check the AC electrical load systems and driven machinery to make sure all unsafe conditions are corrected prior t
113. ivity 0 07 A for 5 droop OPF Max input 0 33 A OVER EXCITATION PROTECTION Set point 67 Vdc 3 fixed Time delay 10 15 seconds fixed ENVIRONMENTAL Vibration 20 100 Hz 50mm sec 100Hz 2kHz 3 39 Operating temperature 40 to 70C note 6 Relative Humidity 0 70C 95 note 7 Storage temperature 55 to 80C NOTES De rate by 20 if mounted external to generator Inclusive of 4 engine governing After 2 minutes warm up Generator de rate may apply Check with factory Factory set semi sealed jumper selectable De rate output current by 5 per deg C above 60C Non condensing DMA TD AS480 AVR 04 08 02 GB a AS480 AVR kui Block Diagram K The AVR Circuit Description The main functions of the AVR are Sensing Voltage Divider Adjust takes a proportion of the generator output voltage and attenuates it The potential divider is adjustable by the AVR Volts potentiometer and external hand trimmer when fitted The output from the droop CT is also added to this signal A Precision Rectifier converts the a c input signal into d c for further processing The Amplifier compares the sensed voltage to the Reference Voltage and amplifies the difference error to provide a controlling signal for the power devices The and Level Detector and Level Shifter infinitely contro the conduction period of the AVR Output Power Control devices This provides the exciter field windings with the variable power necessa
114. l Customer Customer STADCO RESPONSIBILITIES In case of Warrantable Failure Stadco s responsibility is limited solely to at its option repairing or replacing the defective Product or parts of the Product or refunding Stadco s reasonable estimate of the costs of repairs Stadco may at its option replace faulty components with new or factory rebuilt components of their choice Stadco at its option may elect to have units returned to Stadco for repair of Warrantable Failure in which case Stadco will provide return freight to customer via Stadco choice of carrier BUYER INSTALLER RESELLER OWNER RESPONSIBILITIES Reseller is responsible for proper Product model selection from Stadco Product Information publications Installer is responsible for proper appli cation and installation of the Product Installation operation and mainte nance procedures are specified in regular publications and operators manual available from Stadco and are made a part of this warranty by reference Resellers users and maintenance personnel are expected to have Stadco publications available and be familiar with contents before proceeding with sales installation and operation of the Product Before the expiration of the warranty first User or original Customer must immediately notify Stadco of any Warrantable Failures and deliver the defective Product at his own expense to a facility designated by Stadco for repair User Customer is solely responsible for
115. la below to determine the scaling factor 1 Scaling Factor Multimeter Reading Controller Reading 2 Scaling Factor 208 4V 206 3V 3 Scaling Factor 1 010 TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 41 4 6 2 Generator Frequency The following settings are used to configure how the controller responds to frequency measurements Description Frequency Source Nominal 50Hz The wiring configuration of the generator Selecting Auto Nominal 60Hz Selection will use the Frequency Select input to determine Auto Selection which frequency is used 4 6 3 Generator Current The following settings are used to configure how the controller responds to current measurements Name Range Description Enable Disable Enables or disables current metering 5 5000A 5A The turns ratio of the current transformers See below for more information Scaling Factor when using the Voltage Select inputs Setpoints gt Rated Amps 5 5000A Maximum current draw the generator can provide when operating under normal running conditions Setpoints gt High Warning 1 125 Reading at which a warning occurs Percentages based off the Rated Amps value Setpoints gt High Failure 1 125 Reading at which a failure occurs Percentages based off the Rated Amps value TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 42 4 7 Communications The controller has the ability to communicate with other
116. lates The respective leads must be disconnected before taking the readings Resistance values should be within 10 of the values given in the table below 4 Pole Main Rotor Exciter stator Exciter Rotor EBS P044D 0 437 17 5 0 211 12 9 P044E 0 415 17 7 0 211 12 9 P044F 0 465 18 5 0 228 12 9 P044G 0 551 18 5 0 228 12 9 P044H 0 545 18 5 0 228 12 9 P144D 0 657 18 5 0 228 12 9 P144E 0 67 19 36 0 215 12 9 P144F 0 708 20 25 0 201 12 9 P144G 0 857 22 25 0 201 12 9 P144H 0 89 22 9 0 21 12 9 P144J 0 983 22 9 0 21 12 9 P144K 0 99 22 9 0 21 12 9 2 Pole Main Rotor Exciter stator Exciter Rotor EBS P042D 0 798 13 5 0 0479 12 9 P042E 0 895 13 5 0 0479 12 9 P042F 0 931 13 5 0 0479 12 9 P042G 0 993 13 5 0 0479 12 9 P142D 1 125 18 0 128 12 9 P142E 1 214 19 0 134 12 9 P142F 1 28 20 0 105 12 9 P142G 1 479 20 0 105 12 9 P142H 1 59 20 0 105 12 9 P142J 1 709 20 0 105 12 9 Incorrect resistances indicate faulty windings and component replacement is necessary Main Stator Resistance If voltages are unbalanced this indicates a fault on the main stator winding or main cables to the circuit breaker NOTE Faults on the stator winding or cables may also cause noticeable load increase on the engine when excitation is applied Disconnect the main cables and separate the winding leads U1 U2 U5 U6 V1 V2 V5 V6 W1 W2 W5 W6 to isolate each winding section
117. llation are as critical to generator performance as is the engineering of the internal components If you have any diffi culty in installing or servicing your STADCO genset our service and technical staff will be happy to assist you We are confident that if these guidelines are observed you will get many years of reliable service from your STADCO generator set 3 2 Factory Settings The generator set consists of a Deutz diesel engine which is directly coupled to a revolving field brushless alternator The STADCO AC and DC electronic control systems are com pletely pre wired at the factory The generator A C alternator is totally brush less with a revolving field and is electronically regulated Configuration is single bearing at one end having the opposite end supported and driven by a disc coupling 3 3 Initial Inspection Your STADCO generator has been carefully inspected and tested before leaving the facto ry However it is wise to examine the genera tor before installation Upon delivery carefully unpack the generator and examine for any shipment damage If there is any damage file a damage claim with the carrier Save all packing materials for in spection by the carriers agent 2013 Stadco Products Division Ephrata PA 17522 USA 3 4 How to Identify Genset For genset identification locate tag similar to Figure 3 4 1 This tag is located on the gener ator connection cabinet A MANUFACTURED B
118. ltage levels i e Test Voltage 0 8 2 X Rated Voltage 1000 The condition of the windings can be assessed by measurement of insulation resistance IR between phase to phase and phase to earth Measurement of winding insulation should be carried out e As part of a periodic maintenance plan e After prolonged periods of shutdown e When low insulation is suspected e g damp or wet windings Copyright Cummins 2009 25 P0 1 MAN EN 4 STAMFORD Care should be taken when dealing with windings that are suspected of being excessively damp or dirty The initial measurement of the IR Insulation Resistance should be established using a low voltage 500V megger type instrument If manually powered the handle should initially be turned slowly so that the full test voltage will not be applied If low values are suspected or immediately indicated the test should only continue for long enough to very quickly assess the situation Full megger tests or any other form of high voltage test should not be applied until the windings have been dried out and if necessary cleaned Procedure for Insulation Testing 1 Disconnect all electronic components AVR electronic protection equipment etc Ground the RTD s Resistance Temperature Detection devices if fitted 2 Short out the diodes on the rotating diode assembly Be aware of all components connected to the system under test that could cause false readings or be damaged by the test voltag
119. ly to the floor of compartment Section 10 1 e Is there adequate airflow openings both for inlet airflow and discharge airflow e Are all the generator power output cables routed in such a way as to prevent chaffing e Are the power output cables of the generator connected properly amp tightened See Wiring Diagrams Section 8 3 e Are the battery cables connected properly amp tightened Section 7 2 e Are the 12VDC control system plugs wired amp connected properly Section 7 3 amp 7 4 Can the following routine maintenance be performed e Change oil filter fuel filter and air filter e Check the valve clearance e Check oil level in engine e Operate main load circuit breaker NOTE Are electrical junction boxes adequately sealed and of adequate size for the power circuit 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 10 Page 30 11 0 Points of Maintenance 11 1 Maintenance Precautions The recommendations and instructions in this section may be of a general nature if more detailed information is required The Workshop Manual should be consulted e The engine should receive regular attention during the first 500 hours of its life from new and after a major overhaul e Long periods of light or no load running early in the engines life may lead to cylin der bore glazing and high oil consumption e The instructions
120. m the filter hous ing 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 6 Wipe the sealing surfaces of the outlet tube with a clean cloth Be careful not to leave any dirt which could prevent a good seal or be ingested into the engine Inspect the old filters for any signs of dam age A streak of dust on the inside surface of the filter is a indication of damage Re move any cause of leaks before installing new filters Inspect the new filters before installing and make sure they are not damaged Carefully insert the safety filter into the filter housing making certain it is completely seated into the housing Carefully insert the primary filter into the filter housing over the safety filter Seat the filter by hand making certain it is complete ly seated into the housing before latching the cover in place If the cover hits the pri mary filter before it is fully in place remove the cover and push the filter further into the housing The cover should go on with no extra force 11 Secure lid with snap clips Item 3 11 Figure 11 6 2 Cleaning the Dust Discharge Valve e Empty the dust dis yg Vian charge valve by pressing together the discharge slot applying pressure as indicated by the arrows Figure 11 6 3 Clean the discharge slot Figure 11 6 3 Page 36 11 0 Points of Mainten
121. mp F2 Set the AVR VOLTS control potentiometer fully clockwise Connect a 12V 1 0A DC supply to the exciter field leads F1 amp F2 with F1 to the positive Start the generating set and run at rated speed Check that the generator output voltage is within 10 of rated voltage Voltages at AVR terminals 7 8 should be between 170 and 250 volts If the generator output voltage is correct but the voltage on 7 8 is low check auxiliary leads and connections to main terminals 8 The lamp connected across F1 amp F2 should glow Turning the VOLTS control potentiometer fully anti clockwise should turn off the lamp Failure to turn off indicates faulty protection circuit and the AVR should be replaced 9 Should the lamp fail to light the AVR is faulty and must be replaced SEET Caution After this test turn the VOLTS control potentiometer fully anti clockwise PO 1 MAN EN 4 30 Copyright Cummins 2009 STAMFORD Main Excitation Windings If after establishing and correcting any fault on the rectifier assembly the output is still low when separately excited then the main rotor exciter stator and exciter rotor winding resistances should be checked see Resistance Charts as the fault must be in one of these windings The exciter stator resistance is measured across leads F1 and F2 The exciter rotor is connected to six studs which also carry the diode lead terminals The main rotor winding is connected across the two rectifier p
122. n can remove the fault or enable the generator to pick up a motor and drive the voltage recovery Copyright Cummins 2009 17 P0 1 MAN EN 4 STAMFORD Voltage Adgustment The generator output voltage is set at the factory but can be altered by adjustment of the VOLTS control on the AVR board or by the external hand trimmer if fitted Before adjusting the generator output voltage note the following warnings WARNING Do not increase the voltage above the rated generator voltage shown on the rating plate mounted on the generator case WARNING Do not ground any of the external hand trimmer terminals Failure to observe this could cause equipment damage To adjust the generator output voltage proceed as follows Before running the generator set turn the VOLTS control fully anti clockwise Turn the STABILITY control to its midway position and the external hand trimmer if fitted to its midway position 1 Connect a suitable voltmeter 0 300Vac across Line and Neutral of the generator 2 Start the generator set on no load at nominal frequency e g 50Hz or 60Hz 3 If the red Light Emitting Diode LED is illuminated refer to the section on Under Frequency Roll Off adjustment 4 Carefully turn the VOLTS control clockwise until the required voltage is reached 5 If instability is present at rated voltage refer to the section on Stability adjustment 6 Voltage adjustment is now completed STABILITY ADJUSTMENT The A
123. nd failure set points are affected by this function TOUGH Series Manual O 2014 DYNAGEN Technologies Inc Settings 23 4 2 3 4 2 4 Configurable Inputs These inputs are used to create custom warnings and failures Using the DYNAGEN Configurator you can change the text that is displayed when the warning or failure occurs If you select one of these inputs without changing the text it will default to Config Warn X and Config Fail X There are also timers associated with which can be found in the menu under Timers gt Trigger Delays These timers change the amount of time the input has to be active before the controller registers the warning or failure NOTE If the switched input becomes inactive before the trigger delay time expires the warning or failure will not occur Example The user wants a pump to turn on 30 seconds after a high water level switch is tripped and remain on until the level switch turns off The level switch is connected to Switched Input C and closes to ground when the water level is too high The words Water Pumping are also required to be displayed on the controllers LCD screen The pump is connected to a slave relay which is controlled by Switched Output D on the controller Relevant Settings Setting Value Switched Input C gt Function Configurable Warning 1 Switched Input C gt Active Mode Global Switched Input C gt Trigger Close GND Configurable Warning 1 Custom Text Water Pum
124. nd megger W phase to ground Caution The generator must not be run if the minimum insulation value of 1 0 Megohm is not obtained Air Filters Air filters for the removal of airborne particulate matter dust are offered as an addition to the standard build option The filter elements do not remove WATER and must not be allowed to get wet The frequency of filter maintenance will depend upon the severity of the site conditions Regular inspection of the elements will be required to establish when cleaning is necessary Caution Do not charge filters with oil Warning Removal of filter elements enables access to LIVE parts Only remove elements with the generator out of service Air Filter Cleaning Procedure 1 Remove the filter elements from the filter frames taking care not to damage them Invert the filters dirty side down and agitate to remove particles of dirt To remove stubborn particles low pressure air can be used in the reverse direction of flow to force out stubborn particles If necessary use a soft brush to gently brush off any remaining dirt particles Clean the sealing gaskets and surrounding area Visually check the condition of the filter elements and sealing gaskets replace as necessary Ensure that the filter elements are dry before putting them back into service Carefully replace the filter elements DAR Maintenance Fault Finding Caution Before commencing any fault finding procedures examine all wiring
125. nd not more than 0 125 thick 1 Choose a suitable mounting location based on the criteria above 2 Create a rectangular cutout in the panel that is minimum 3 9 high and 6 2 wide 3 Place the controller into the panel cutout so that the LCD screen and buttons are facing out 4 Place the mounting clips into the designated slots on the top and bottom of the controller 5 Tighten the screws on the clips until controller is snug against the panel Do not over tighten the bottom of the screws should angle very slightly away from the controller 6 If applicable snap the RelayPak RP100 to the back of the controller Place one side of the RP100s tabs into the slot on the back of the controller and without pushing on the relays snap the other tab into place 6 200 3 900 Dimensions are in inches Not to scale TOUGH Series Manual 2014 DYNAGEN Technologies Inc Installation 6 2 1 Terminal Descriptions Main Connector J4 Terminal Name Description J4 14 Sensor Input C Universal sensor input 0 750 0 7 500 0 5VDC 4 20mA See Universal Sensor section for more information Expansion Connector J3 Terminal Name Description Switched Output F Outputs Battery voltage when active Max Current 1A Provides 5V for electronics sensors Provides ground return for 2 wire sensors J3 8 Sensor Input D Universal sensor input 0 750 0 7 500 0 5VDC 4 20mA See Universal Sensor section for more informati
126. ne temperature Oil pressure Fuel level This allows you to use the special functions Start on Low Output on High etc in conjunction with those sensors A NOTE You must set the auxiliary sensor port and sender table to the same values as the other sensor Name II Description Signal Source Sensor Port X The source from which the sensor data is attained Display Enable Disable Determines if the sensors value is displayed on the screen when the engine is running Active Modes Disable Determines under which operating conditions the Auxiliary Global Sensor is monitored Multiple selections are allowed Refer to Not In Auto the Switched Inputs section for more information on the Auto State Active Modes Running Cranking After Cranking Cooldown Mode Select Fault Monitor Determines how the controller responds to the readings of the Output on Low auxiliary sensor Refer to the examples in the following Output on High pages for more information on how each mode functions Start on Low Start on High Trim Offset 50 0 50 0 units Calibrate a sensor by using the offset to correct errors Mode Settings gt Bypass Time 0 90 seconds Amount of time to bypass warnings and failures after engine has started Mode Settings gt Active Time 1 600 minutes The amount of time to turn on the auxiliary switched output or engine before turning off Mode Settings gt Start Level Sender Table The level at which the auxiliary switched output o
127. ng the Start Date and Hour you must select a time in the future in which to run the initial exerciser sequence After the initial sequence the exerciser runs at an interval determined by Repeat Days Exerciser Sequence Start Date Delay for Repeat Days Time Start Pre Alarm Timer Start Engine for Exercise Time TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 39 4 5 3 Maintenance The controller has the ability to count down the time between scheduled maintenance by a technician Once maintenance is required the controller will alert the operator via the LCD screen and a switched output if enabled wired to a lamp horn buzzer The following settings are used to configure the maintenance timer Name Range Description Reset Counter Enable Disable Once the maintenance count interval expires use this setting to reset the time and turn off the switched output if enabled Enable Counter Enable Disable Determines the number of hours between required maintenance A switched output can be configured to turn on once the count interval expires Counter Interval 10 9990 hours Enables or disables the maintenance function To find out the amount of time until next maintenance follow these menu steps Main Menu gt Device Info gt Maintenance Maintenance counter is disabled if is displayed A negative number indicates the amount of time since maintenance timer expired
128. not be remotely started When in the Auto mode the engine waits to receive a start command When engine is Running the controller monitors engine parameters and waits to receive a stop command When a failure occurs the controller shuts down the engine and displays reason for failure The unit must be reset using the front panel OFF button with the exception of Modbus When in the menu you can change settings and view the events history The following table describes the different methods in which a controller can start The controller must be in the AUTO mode in order to start for all methods with the exception of Manual Run Starting Methods Methods Manual Run Start Stop Switched Input Momentary Switched Inputs Battery Recharge Exerciser Auxiliary Sensors Loss of Mains TG350AMF only Modbus Start TG410 only Description Pressing the Run button will start the engine You must press the OFF button to shutdown the engine When this input is active the engine will start When the input becomes inactive the engine will shutdown Switched inputs Momentary Start and Momentary Stop can be used for starting and stopping of the engine Unlike other inputs they only have to be activated for a short period of time When the battery voltage drops below a certain level the engine will start and run for a predetermined amount of time When the scheduled exerciser interval occurs the engine will start and run
129. nt through the exciter field winding As the excitation current increases so the stator current in the shorting link will increase This stator output current level must be monitored and not allowed to exceed 80 of the generator s rated output current e After every 30 minutes of this exercise Stop the generator and switch off the separate excitation supply measure and record the stator winding IR values and plot the results The resulting graph should be compared with the classic shaped graph This drying out procedure is complete when the parameters covered in the section entitled Typical Drying Out Curve are met e Once the Insulation Resistance is raised to an acceptable level minimum value 1 0 Megohm the dc supply may be removed and the exciter field leads F1 and F2 re connected to their terminals on the AVR e Rebuild the genset replace all covers and re commission as appropriate e If the set is not to be run immediately ensure that the anti condensation heaters are energised and retest the generator prior to running Typical Drying Out Curve Whichever method is used to dry out the generator the resistance should be measured every half hour and acurve plotted as shown Q 1 Y axis Resistance G 2 X axis Time 3 One Megohm limit The illustration shows a typical curve for a machine that has absorbed a considerable amount of moisture The curve indicates a temporary increase in resistance a fall and then a
130. o 2 Permit engine to run without load or with tivati FG t tand light load for 3 5 minutes cool down cycle SCNYSNSH ge SE ar GIE eh SS Shutdown can be accomplished several Engagemenr or Man eee ways Also check all electrical connections and a By pressing the OFF button Item 7 Figure conductors to make certain that no 5 1 2 shorted circuits open conductors or open ground circuits exist In the event b By moving the toggle Power Switch Item 1 i Figure 51 1 to he OFF position portable equipment hand tool portable c By pushing the Start Stop Toggle Switch heaters or portable lighting are operated Item 11 Figure 5 2 1 to the GENERATOR STOP position from this unit use Ground Fault Inter rupting GFI type secondary circuit breaker s in the output circuits for the personal safety of the operators OBSERVE ALL THESE PRECAUTIONS BEFORE ATTEMPTING TO ENGAGE AC LOAD Manual shutdown should be exercised whenever any abnormal events occur precluding the possibility of engine damage which may occur if the automatic engine protection devices fail to function properly NOTE To reduce the chances of catastrophic engine failure we recommend to inspect and test the function of the automatic safety engine protection system at regular intervals Check the system at each oil change interval or once per year whichever occurs first Automatic safety engine protection system does not provide absolute
131. ollowing paragraph to a check that the symptoms observed do indicate adjustment is necessary and b to make the adjustment correctly volts T Q de UFRO Under Frequency Roll Off 100 The AVR incorporates an under speed protection circuit which gives a voltage speed Hz characteristic as shown The UFRO control 95 potentiometer sets the knee point Symptoms of incorrect setting are a the light emitting diode LED indicator adjacent to the UFRO Control potentiometer being permanently lit when the generator is on load and b poor voltage 80 regulation on load i e operation on the sloping part of the 75 80 85 90 95 100 characteristic Hz Clockwise adjustment lowers the frequency speed setting of the knee point and extinguishes the LED For Optimum setting the LED should illuminate as the frequency falls just below romina sasana i e 47Hz on a 50Hz generator or 57Hz on a 60Hz generator 1 Knee point 2 Typical slope Accessories Generator control accessories may be fitted as an option in the generator terminal box If fitted at the time of supply the wiring diagram s in the back of this book shows the connections When the options are supplied separately fitting instructions are provided with the accessory Accessories available are droop transformer for parallel operation applicable to P1 generators and remote voltage adjust hand trimmer The latter being available for all AVR types
132. om the fuel tank to the fuel filter system and subsequently to the fuel injection pumps Connect the fuel supply line to engine fuel pump Item 1 Figure 10 3 1 The pump con nection is 5 16 dia and is the minimum pipe LD for the fuel suction line up to 6 ft long Connect the fuel return line to Item 2 Figure 10 3 1 The fuel return connection is 1 4 dia Place a hose clamp on all fuel line connec tions Be sure that all connections are air tight Figure 10 3 1 2 1 Pipe Length Pipe I D minimum lt 6 ft 5 16 lt 19 ft 3 8 lt 32 ft 1 2 The fuel piping system may consist of both rig id and flexible material Rigid lines can be made of seamless copper or stainless steel Metal lines must be thoroughly cleaned prior to installation When using rigid lines use an approved flexible line to make the connection from rigid lines to fuel connections on engine The flexible hoses should be able to withstand the environment they will be operating in and be compatible with the diesel fuel being used 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 All fuel pipes must be located in protected areas away from intensive heat sources engine exhaust system and securely fas tened The fuel piping routing must also be carefully designed Avoid sharp bends and keep the number of connections to a minimum Any air which has found its way into the
133. on TOUGH Series Manual 2014 DYNAGEN Technologies Inc Installation 7 Communications Connector J6 Terminal Name Description CAN Shield Connect the shield of the twisted pair cable to this terminal J6 7 Speed Sensing A Connect to a magnetic pickup tachometer or a flywheel alternator Not polarity sensitive and not required if using AC voltage terminals for speed sensing J6 8 Speed Sensing B Connect to a magnetic pickup tachometer or a flywheel alternator Not polarity sensitive and not required if using AC voltage terminals for speed sensing J6 10 RS485 Common Common line for Modbus RS485 Generator AC Voltage J7 Terminal Name Description Generator AC Current J5 Terminal Name Description Connect to current transformer for Phase A of the generator Connect to current transformer for Phase B of the generator Connect to current transformer for Phase C of the generator Connect to the commons of the current transformers TOUGH Series Manual 2014 DYNAGEN Technologies Inc Installation 8 2 2 Typical Wiring Diagram SILON ON WWWO mn pryn w cds rare IINA rem Commune pntg eene 3 ES a D 2 8 3 E 2 a 3 o ES E 2 5 2 a E 2 ES E E 8 3 E 2 E bi S P 5 a 3 3 2 o 2 o gt E RS a lt S g 3 S 2 2 D Q bi gt g BD S A LD aa Eu ca pr rc a A SU vg A AY pal j sede Spy reg auf maer a We at Mitt Eur pu Be Arm am ya
134. onocnconncnnnononnnnnncno conc cono nn nro n nr non n rn nn nn arras 29 GENERATOR WINDINGS AND ROTATING DIODES AND EXCITATION CONTROL TEST 29 1 GENERATOR WINDINGS AND ROTATING Dons 29 Copyright Cummins 2009 5 P0 1 MAN EN 4 STAMFORD Balanced Main Terminal Voltages conan cnn nro n non cnn crono nana n nen nn 30 Rectifier Elle 30 Replacement of Faulty Diodes ooooocccinncncconocononononncnoncnon ccoo conocio nano non cnn cnn cren cnn nro rra 30 SUIGE SUPPFESSOM a an ae 30 2 EXCITATION CONTROL EST WEE 30 AURA FUNGUO TOS tato eebe 30 MAIN EXCITATION WINDINGS cccccccccccccccecccccecceceeueseeeesueueeueseeesscceeeceeceeeseuceseuceeuusueuueuuuausaaessceeeeeeeeeseeeeess 31 Incorrect resistances indicate faulty windings and component replacement is necessary 31 MAIN STATOR RESISTANCE EE 31 REMOVAL AND REPLACEMENT OF COMPONENT ASSEMBLIES ssseeeeeiiessieesrrrertriirrirrirrrenrreenesennrenerre riren 33 Removal Bi EE 33 REMOVAL OF THE ROTOR TWO BEARING GENERATOR 33 REMOVAL OF THE ROTOR SINGLE BEARING GENERATOR 33 BEARING le EE 34 FITTING NEW BEARINGS wsicess cccesesaiessosecsadeedsecinsceccccedeocsnctcasdescedusessesveces lesdeieedectecessacddecpscccsvensesusauvevsnaites 34 REPLACING ANTI CONDENSATION HEATERS ooccooccconcccnnccnnnnnnnnnnnnnononnnnonnnnononnnnnnnnnnananccnnnnnncnnnnnnononononennnninns 34 REPLACING RECTIFIER DIODES AND SURGE SUPPESSOR cocccccccccccnnccnoncnononononnnannanananacnnnccanancnnnccn
135. ononcnnononns 34 REMOVING THE TERMINAL BON 34 Lifting the generator with a large Don 34 SPARES AND AFTER SALES SERVICE cccssscccsssccsssssssssssssssesssseseeeeeeeseeeeeeeeseeeeeeeeaeeegaesnesseusseseeseeess 35 ReECOMMENEM Ee EC 35 Alter Sales Senice EE 35 PARTS IDENTIFICATION SINGLE BEARING ccccccccccccececceseeeesceeeccececcseeececeesesceseueeseeuausuuausuaeusesseeesecseeeeeess 36 PARTS IDENTIFICATION TWO BEARING cccccccccccccecccceceeeeseeeeesueeseceeeeceeeeceeceeeeeeceeeuseeuaeseuausuueeaeeseeeeeseeeeeess 37 PARTS IDENTIFICATION RECTIFIER ASSEMBLY ccccccescceesseeeseceeeeceeecceceeceeceseusesuuseeuuuausuaeeseseeeeseeeeeees 38 A C GENERATOR WARRANTY nccccccccccnnncnnncnnnnnnnnanacancncnanonnnnnnnnnnnnnnnononononnnnnonnnnnnnnann nana nan nn na nacannnnnnns 39 PO 1 MAN EN 4 6 Copyright Cummins 2009 STAMFORD INTRODUCTION General Description The PO8 P1 generators are brushless with rotating field available up to 660V 50Hz 1500 rpm 4 pole and 3000 rpm 2 pole or 60Hz 1800 rpm 4 pole and 3600 rpm 2 pole and built to meet B S 5000 Part 3 and other international standards The PO amp P1 are self excited generators with excitation power derived from the main output windings using the AS480 Self Excited AVR Controlled Generators 5 Main Stator Powered AVR 7 The main stator provides power for excitation of the exciter field via the SX480 AVR which is the controlling device governing
136. or Operation amp Maintenance Stamford Electronic Regulated Generator PO 1 MAN AS480 Automatic Voltage Regulator AS480 TG410 Digital Engine Controller 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 1 0 Safety Precautions Safety Precautions General Before operating the generator set read the operation manual s and become familiar with it and the equipment In order to avoid personal injury and to prevent damage to equipment it is imperative that all the safety precautions listed are followed when operating this equipment Observe all IMPORTANT CAUTION WARNING and DANGER notices defined as Important Important refers to hazard or unsafe method or practice which can result in product damage or related equipment damage Warning refers to a hazard or unsafe method or prac tice which CAN result in se vere personal injury or pos Warning sible death This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage Danger refers to immediate hazards which WILL result in severe personal injury or Low Voltage Control circuits utilized by the generator set are low voltage 12 volts D C This voltage is not considered dangerous but the large amount of current available over 300 amps can cause severe burns if shorted to ground e Disconnect the negative terminal of the battery if possible w
137. ors have a transit bar fitted at the drive end This bar holds the rotor in position during transit The transit bar should be left in position until it is necessary to remove it to allow the generator to be coupled to the engine Warning If the generator is moved without the transit bar be aware that the rotor could fall out of the frame When moving the generator always keep it in the horizontal plane this will reduce the risk of the rotor falling out Storage If the generator is not to be used immediately H must be stored in a clean dry vibration free environment H anti condensation heaters are fitted switch them on If heaters are not fitted use other means to ensure that condensation cannot form on the windings Spin the shaft by hand every month to prevent flat spots in the bearings and to free up the grease After Storage After a period of storage carry out pre running checks to determine the condition of the windings If the winding are damp or the insulation is low follow one of the drying out procedures in the Service section of this manual Replace the bearing after 12 months in storage Rotor balancing Dynamic balancing of the generator rotor assembly has been carried out during manufacture in accordance with BS 6861 Part 1 Grade 2 5 to ensure vibration limits of the generator are in accordance with BS 4999 Part 142 Generator Vibration Frequency The main vibration frequencies produced by the component gene
138. ox one on the sheet metal work and the other on the main frame of the generator Neither of these two labels is considered to be permanently fixed Excitation Boost System EBS is optional Rating Plate The generator has been supplied with a self adhesive rating plate label to enable fitting after final assembly and painting Stick the plate on the side of the barrel either side we suggest the opposite side to the output cables The surface in the area where a label is to be stuck must be clean dry and any paint finish must be cured before attempting to attach label Recommended method for attaching label is peel and fold back sufficient of the backing paper to expose some 20 mm of label adhesive along the edge which is to be located against the sheet metal protrusions Once this first section of label has been carefully located and stuck into position progressively peel off the backing paper and smooth down with a clean cloth The adhesive will achieve a permanent bond in 24 hours A factory fitted metal nameplate is available for some applications Caution Do not exceed the parameters as marked on the rating plate Copyright Cummins 2009 3 P0 1 MAN EN 4 STAMFORD Contents SAFETY PRECAUTIONS www wananunua aa awana aana kaaa na wanawaua aaa aa aana LLANA LARA AR RR NARRAR RAR RR nn rra r cnn nn nan nn nana anaanana 2 FIRST STEPS TO SAFE OPERATION cccccccccccccccccecceccccucceeeeuesueeucueuseuseceeeeeecececeuceseuece
139. ping Switched Output D gt Warnings Configurable Warning 1 Start Stop Momentary Function When a switched input is configured to Start Stop the trigger modes have different meanings than other inputs The following table describes the trigger mode functionality Trigger Description Close to Battery Input active when Battery is applied Close to Ground Input active when ground is applied Close to Battery Ground Input active when Battery or ground is applied for approximately 2 seconds then deactivated Open Input active when neither Battery or ground is applied for approximately 2 seconds then H deactivated The reason for changing these trigger mode is to allow the user to wire a single push button to be used for both starting and stopping the engine Holding the button for too long will cause the engine to shutdown immediately after starting and vice versa TOUGH Series Manual O 2014 DYNAGEN Technologies Inc Settings 24 4 3 Switched Outputs The controller has switched outputs that are turned on under certain conditions to perform a function The outputs turn on to Battery voltage to drive the load when active The following items are the available functions for switched outputs logic it will be necessary to put a pull down resistor 1k from the output to ground to ensure a low logic level WARNING Switched outputs have a floating voltage of approximately 8V when off If using the outputs for digital when
140. property without limitation due to acts or omissions of the Installer Reseller User Customer its agents and employ ees in the sale installation use and operation of Products purchased from Stadco and shall assert no claim against Stadco for consequential damag es 15 The warranties obligations liabilities and remedies of the parties as provided herein are exclusive and in lieu of any other available at law or in equity Stadco s total aggregate liability with respect to any defective Products shall not exceed the amount paid by the Customer for such Products To the fullest extent allowed by law Customer releases Stadco from all contingent liabilities and limitations of liability shall apply notwith standing breach of contract tort including negligence strict liability or other theory of legal liability asserted LIMITED MONEY BACK WARRANTY 16 Stadco CELLPAC or TOP DOG Product may be returned by original Buyer for money back if Product fails to perform reliably or fails to perform to specifications as advertised by Stadco Buyer reimbursement is limited to refund of purchase price of such Product less cost of restoration for resale Money back guarantee is limited to either ninety 90 days from original shipment date or 300 hours of operation whichever occurs first In no case will return for reimbursement be allowed for any Product that is not physically received at Stadco plant within one hundred and twenty 120 days from o
141. r 12 Engine Fault Lamp When this lamp is illuminated it indicates the system has shutdown due to a fault Check the main control panel LCD Screen Item 8 Figure 5 1 2 to see which fault has occurred Correct the problem before re starting NOTE After a fault has occurred the control system must be reset at the main control panel Reset by pushing the Off Function button Item 7 Figure 5 1 2 Return back to Auto mode by pushing the Auto function button Item 6 13 Engine Starting Running Lamp When this lamp is illuminated it indicates that the controller is performing the normal startup procedure or the engine is running 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 15 6 0 Starting and Operating 6 0 Starting And Operating Instructions Prestart Checks 1 Check lube oil level at dipstick Add oil if required Section 11 2 2 Check fuel level in fuel tank 3 Set main load circuit breaker to OFF position before starting generator 4 Make sure all personnel are clear of moving parts and all enclosure panels and guards are in place 6 1 Starting Procedure for Digital Control System PN 1790 1 Move toggle Power switch Item 1 Figure 5 1 1 to ON position this activates the con trol system 2 Push RUN function button Item 5 Figure 5 1 2 to start engine The engine controller will activate and perform the following start up pro
142. r so as to prevent oil fuel or water accumula tion Secure the modular generator system to the compartment frame using 1 2 13 UNC grade 5 bolts Exhaust gases are poison ous and should be di rected away from any oc cupied area Be certain that exhaust gases cannot be drawn into any enclosed spaces where gases could accumulate O 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 24 10 0 Installation Instructions Exhaust gases are poison ous and should be di rected away from any oc cupied area Be certain that exhaust gases cannot be drawn into any enclosed spaces where gases could accumulate 10 2 Exhaust Gas System Typically the exhaust gas system consists of exhaust gas manifold muffler and tailpipe All of this will necessarily restrict the flow of the exhaust gas such restriction must not exceed the limits specified for the particular engine Additionally e The exhaust system must prevent the entrance of rain road sprays or other water sources into the engine e To prevent recirculation of exhaust gases into the engine combustion or cooling air system locate the exhaust outlet as far as possible from these systems e Use flexible tubing to connect the engine exhaust to any rigid pipe extensions This is used to prevent transmission of vibration Exhaust Backpressure The exhaust system will produce a certain resistanc
143. r email to so that we may keep you informed of product updates and improvements Also registration Stauffer Diesel Inc will help to verify in service date for warranty PO Box 586 purposes 34 Stauffer Lane Ephrata PA 17522 Fax 717 738 2550 Email mail stadcogen com Generator Registration Info Generator Model Generator Serial No Generator Model 4 Serial No can be found on first page of this manual amp on Stadco tag riveted to generator Date Purchased Name Company Address 1 Address 2 City State Prov Country Zip Postal Code Phone Fax Email Comments 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 8 3 0 General Information 3 1 Introduction Thank you for choosing a STADCO Generator STADCO is the full service supplier for the STADCO generator products line We design it We build it We support it Most parts includ ing major repair parts are usually available same day from our own stock Deutz diesel engines are additionally supported by inde pendent engine distributors located throughout the U S and Canada We are constantly im proving on our products taking advantage of the latest technical advancements to assure you the most reliable efficient generator avail able anywhere Please read the installation and service sec tions of this manual carefully A clean environ ment and proper insta
144. r engine Dependent turns on Mode Settings gt Stop Level Sender Table The level at which the auxiliary switched output or engine Dependent turns off Setpoints gt Low Warning Sender Table Reading at which a warning occurs Dependent Setpoints gt Low Failure Sender Table Reading at which a failure occurs Dependent Setpoints gt High Warning Sender Table Reading at which a warning occurs Dependent Setpoints gt High Failure Sender Table Reading at which a failure occurs Dependent 1 Refer to the sections below for more information on how these settings affect the auxiliary sensors TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 32 4 4 6 1 Fault Monitor Example In this example a sensor is monitoring the temperature of an engine block If the temperature rises above 275 F a warning message is displayed If the temperature rises above 350 F the engine shuts down and a failure message is displayed Relevant Settings Setting Value Failure Level 300 Warning Level 250 Temperature Fahrenheit 150 100 50 0 T T T T 0 5 10 15 20 25 30 Time Minutes The chart above shows the connection between engine temperature and time At approximately 13 minutes run time the temperature rises above the 275 F warning threshold so a warning is displayed The engine continues to run because it does not reach the 350 F failure threshold At 20 minutes run time the temperatures falls b
145. r until each diode in turn is accessible from the bottom quadrant Remove and replace each diode and the suppressor in turn Smear Midlands Silicons Heat sink compound type MS2623 on the underside of each diode when assembling the diodes Caution This compound must not be applied to the thread of the diodes Diodes to be tightened to a torque of 2 03 2 37 Nm Removing the Terminal box The terminal box has knockouts for customer cables there should be no need to remove the box To remove the box take off the lid and remove 4 bolt securing the box The box is in two parts the lid and a four sided frame There are optional larger boxes for customers that require additional room Lifting the generator with a large box The standard fitted lifting eyes will be obstructed if the large box is fitted A set of extension pieces can be bolted onto the standard lifting eyes to facilitate the lift PO 1 MAN EN 4 34 Copyright Cummins 2009 STAMFORD Spares and After Sales Service Recommended Spares Service parts are conveniently packaged for easy identification Genuine parts may be recognised by the STAMFORD name We recommend the following for Service and Maintenance In critical applications a set of these service spares should be held with the generator AVR PO P1 AVR control E000 14800 Bearings Bearing 6306 C3 051 01058 O Ring 051 21792 Diodes Rectifier service kit RSK 1101 Comprises Metal Oxide Varistor BC 073 0806
146. rams for all Connection detail Main Stator Powered AVR The main stator provides power for excitation of the exciter field via the SX480 AVR which is the controlling device governing the level of excitation provided to the exciter field The AVR responds to a voltage sensing signal derived from the main stator winding By controlling the low power of the exciter field control of the high power requirement of the main field is achieved through the rectified output of the exciter armature The AVR senses average voltage on two phases ensuring close regulation In addition it detects engine speed and provides voltage fall off with speed below a pre selected speed Hz setting preventing over excitation at low engine speeds and softening the effect of load switching to relieve the burden on the engine The detailed function of the AVR circuits and their adjustment are covered in the load testing section Optional excitation Boost system EBS The EBS is a single self contained unit attached to the non drive end of the generator The EBS unit consists of the Excitation Boost Controller EBC and an Excitation Boost Generator EBG Under fault conditions or when the generator is subjected to a large impact load such as a motor starting the generator voltage will drop The EBC senses the drop in voltage and engages the output power of the EBG This additional power feeds the generator s excitation system supporting the load until breaker discriminatio
147. rator are as follows 4 pole 1500 r p m 25 Hz 4 pole 1800 r p m 30 Hz 2 pole 3000 r p m 50 Hz 2 pole 3600 r p m 60 Hz However vibrations induced by the engine are complex and contain frequencies of 1 5 3 5 or more times the fundamental frequency of vibration These induced vibrations can result in generator vibration levels higher than those derived from the generator itself It is the responsibility of the generating set Copyright Cummins 2009 13 P0 1 MAN EN 4 STAMFORD designer to ensure that the alignment and stiffness of the bedplate and mountings are such that the vibration limits of BS5000 part 3 and ISO 8528 part 9 are not exceeded In standby applications where the running time is limited and reduced life expectancy is accepted higher levels than specified in BS5000 part 3 can be tolerated up to a maximum of 18mm sec Side Loads In the case of belt driven generators ensure alignment of drive end and driven pulleys to avoid axial load on the bearings Screw type tensioning devices are recommended to allow accurate adjustment of belt tension whilst maintaining pulley alignment Belt and pulley guards are not provided by the company Note Incorrect belt tensioning will result in excessive bearing wear Side Load Shaft extension 2 4 Pole kgf N iiri PO 92 900 82 P1 173 1700 82 Coupling arrangements Warning Do not use the fan to rotate the shaft this is particularly important when th
148. re reliable and immediate shutdown upon activation Shown below is an example wiring diagram of a double pull single throw switch being use to activate the e stop input and cut power to the fuel solenoid In this configuration the e stop is activated when there is an open circuit to the switched input and inactive when the input detects Battery voltage Emergency Stop Input Emergency Stop Fuel Solenoid Fuel Relay Output TOUGH Series Manual 2014 DYNAGEN Technologies Inc Installation 11 2 4 2 Universal Sensor Universal Sensors have the ability to be configured to detect different sender types 0 750 0 7 500 0 5VDC 4 20mA The examples shown below are advanced applications of the universal sensor NOTE Custom Sender tables are required for the universal sender to work with these examples See the Custom Sender Table section for more information Example 1 The following example shows the correct way for wiring a 4 20mA sensor The 240 resistor is required to change the 4 20mA current into a 0 5V voltage level that the controller can understand 4 20mA Wiring Example To Universal Sensor Input Battery 4 20mA Sensor Example 2 Sometimes it is required to measure voltages outside the 0 5V range allowed by the controller To do this you must use a voltage divider with appropriate scaling resistors The equation to calculate the resistor values is as follows Vout 5V R1 _ Vin Maximum Volta
149. rection and a low resistance in the forward direction A faulty diode will give a full deflection reading in both directions with the test meter on the 10 000 ohms scale or an infinity reading in both directions Replacement of Faulty Diodes The rectifier assembly is split into two plates the positive and negative and the main rotor is connected across these plates Each plate carries 3 diodes the negative plate carrying negative biased diodes and the positive plate carrying positive biased diodes Care must be taken to ensure that the correct polarity diodes are fitted to each respective plate When fitting the diodes to the plates they must be tight enough to ensure a good mechanical and electrical contact but should not be over tightened The recommended torque tightening is 4 06 4 74Nm 36 42lb in Surge Suppressor The surge suppressor is a metal oxide varistor connected across the two rectifier plates to prevent high transient reverse voltages in the field winding from damaging the diodes This device is not polarised and will show a virtually infinite reading in both directions with an ordinary resistance meter If defective this will be visible by inspection since it will normally fail to short circuit and show signs of disintegration Replace if faulty 2 Excitation Control Test AVR Function Test Remove exciter field leads F1 amp F2 from the AVR terminals F1 amp F2 Connect a 60W 240V household lamp to AVR terminals F1 a
150. relation to generator ratings It is important to recognise that kW derived from the engine and speed governor characteristics determine the kW sharing between sets kVAr derived from the generator and excitation control characteristics determine the kVAr sharing Reference should be made to the generating set manufacturer s instructions for setting the governor controls Droop The most commonly used method of kVAr sharing is to create a generator voltage characteristic which falls with decreasing power factor increasing kVAr This is achieved with a current transformer C T which provides a signal dependent on current phase angle i e power factor to the AVR The current transformer has a burden resistor on the AVR board and a percentage of the burden resistor voltage is summed into the AVR circuit Increasing droop is obtained by turning the DROOP control potentiometer clockwise The diagrams below indicate the effect of droop in a simple two generator system Copyright Cummins 2009 21 P0 1 MAN EN 4 STAMFORD No 1 No 2 kw kW oz No 2 Date o No 1 kVAr E kVAr Generally 5 droop at full load current zero p f is sufficient to ensure kVAr sharing If the droop accessory has been supplied with the generator it will have been tested to ensure correct polarity and set to a nominal level of droop The final level of droop will be set during generating set commissioning The following setting procedure will be
151. rform electrical service should carry out testing and or adjustments PO 1 MAN EN 4 18 Copyright Cummins 2009 STAMFORD Test Metering Cabling Connect any instrument wiring and cabling required for initial test purposes with permanent or spring clip type connectors Minimum instrumentation for testing should be line line or line to neutral voltmeter Hz meter load current metering and kW meter If reactive load is used a power factor meter is desirable When fitting power cables for load testing purposes ensure cable voltage Caution rating is at least equal to the generator rated voltage The load cable termination should be placed on top of the winding lead termination and clamped with the nut provided Check that all wiring terminations for internal or external wiring are secure and fit all terminal box covers and guards Failure to secure wiring and or covers may result in personal injury and or equipment failure INITIAL START UP Pre Running Checks Before starting the generating set Test the insulation resistance of windings Check all connections are in the correct location and tight Check the generator air path is clear of obstructions Replace all covers Insulation resistance test 1 Disconnected all leads connected to the AVR 2 Use a 500V Megger or similar instrument 3 Disconnect any conductor connected between neutral and earth 4 Megger an output lead terminal U V or W to earth The insulation resi
152. ricted and the generator will overheat This will reduce the life expectancy of the insulation leading to premature failure of the generator High Humidity environments The humidity of the air will allow condensation to form on the windings if the temperature of the windings falls below the dew point The dew point is a relationship between the ambient temperature and humidity In areas of high humidity additional protection may be required even if the generator is fitted inside an enclosure Anti condensation heaters Anti condensation heaters are designed to raise the temperature of the windings above the temperature of the surrounding material so that the condensation will not form on the windings We recommend that anti condensation heaters are fitted to all generators that are left switched off for any period of time The best practice is to wire the heaters such that the heaters come on when the generator is switched off This is particularly important in applications where high humidity is a significant problem Always check the condition of the generators windings before switching the generator on If moisture is observed carry out one or more of the drying out methods outlined in the Service section of this manual Enclosures An enclosure should be employed to protect the generator from adverse environmental conditions If the generator is to be fitted inside an enclosure ensure that there is adequate airflow to support both the engine an
153. riginal shipment date Evidence of tampering with the Product will completely void this provision of warranty Offer limited to first model unit purchased by each Customer SAFETY NOTICE 17 To prevent possible accidents that may result from the use of any genera tor set system it is important that correct installation maintenance and operation procedures are followed Installation maintenance and opera tion procedures specified by Stadco and the engine manufacturer must be followed in conjunction with engineering and safety information speci fied Grounding equipment guards and other suitable safety equipment or procedures that may either be desirable or specified in safety codes must be provided to assure safe operation in the prevailing conditions THESE DEVICES MAY NOT BE INCLUDED WITH THE PRODUCT AND ARE NOT THE RESPONSIBILITY OF STADCO INSTALLER IS RESPONSI BLE FOR PROVIDING SAFETY ITEMS TO SATISFY PREVAILING SAFETY CODES SUMMARY 18 Provisions of this warranty are limited to these terms no other claims will be valid unless authorized in writing by an Executive officer of Stadco 19 This warranty shall be construed in accordance with the laws of the Com monwealth of Pennsylvania Exclusive venue and jurisdiction for resolu tion of any disputes arising out of or related to this Agreement shall be in the Court of Common Pleas of Lancaster County Pennsylvania USA Effective date October 1 2009 Supersedes all previous warr
154. rminal box A hole is provided on the generator foot which may be tapped to give an additional earthing point The feet should be already bonded to the generating set bedplate by the generating set builder but will normally be required to be connected to the site earth system Warning Reference to local electricity regulations or safety rules should be made to ensure correct earthing procedures have been followed Copyright Cummins 2009 23 P0 1 MAN EN 4 STAMFORD Protection It is the responsibility of the end user and his contractors subcontractors to ensure that the overall system protection meets the needs of any inspectorate local electricity authority or safety rules pertaining to the site location To enable the system designer to achieve the necessary protection and or discrimination fault current curves are available on request from the factory together with generator reactance values to enable fault current calculations to be made Warning Incorrect installation and or protective systems can result in personal injury and or equipment damage Installers must be qualified to perform electrical installation work Commissioning Ensure that all external cabling is correct and that all the generating set manufacturer s pre running checks have been carried out before starting the set The generator AVR controls will have been adjusted during the generating set manufacturer s tests and should normally not require further adjus
155. rocedure Using a 12 volt D C battery as a supply clip leads from battery negative to AVR terminal F2 and from battery positive through a diode to AVR terminal F1 Caution A diode must be used as shown below to ensure the AVR is not damaged Caution If the generating set battery is 1000V used for field flashing the generator 1 AMP Diode f 7 main stator neutral must be disconnected F2 FA from earth Restart the set and note output voltage from the ss S AVR main stator which should be approximately nominal voltage or voltage at AVR terminals 7 12V BATTERY and 8 which should be between 170 and 250 volts Stop the set and unclip battery supply from terminals F1 and F2 Restart the set The generator should now operate normally If no voltage build up is obtained it can be assumed a fault exists in either the generator or the AVR circuits Follow the SEPARATE EXCITATION PROCEDURE to check generator windings rotating diodes and AVR Separate Excitation Test Procedure The generator windings diode assembly and AVR can be checked using this procedure With the generating set stationary remove AVR access cover and leads F1 and F2 from the AVR Connect a 60W 240 volt household lamp or two 120V lamps in series to AVR terminals F1 and F2 Connect a 0 12 volt 1 0 Amp supply to leads F1 and F2 The positive of the D C supply is connected to the lead marked F1 and the negative to the lead marked F2 The procedure is simplified by
156. roller A wiring diagram should be provid ed along with the generator If not available a copy can be requested from Stadco Remote Start Stop Station PN 1780 Optional Installers are responsible to supply the wiring from the main control panel terminals 10 14 on Terminal Strip 1 to the terminals on re mote station Use a minimum of 16 gauge wir ing 105 C rated to make these connections NOTE Make sure all electrical cables are ade quately protected against chafing or any other failure of insulating material Protect all loose wiring with appropriate wire pro tection material SR Battery Positive Figure 7 2 1 CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 18 7 0 12VDC Wiring 7 4 Digital Controller Default Settings The Digital Engine Controller is programmed by Stadco with the following default settings These settings are programmed according to the engine manufacturers specifications and should not be changed without consulting with Stadco Crank cycles 2 attempts 15 sec crank Crank rest 15 seconds Preheat timer 0 seconds Crank Disconnect 450 RPM 15 HZ Overspeed 2 100 RPM 70 HZ Start up Routine 1 First the controller will preheat the engine for a preset period of time 2 Next the controller will crank the engine for 15 seconds or until engine starts If engine fails to start after 15 seconds the controller will rest for 15 seconds then it
157. ry or death Follow all state and local safety codes Do not wear jewelry while working on electrical equipment Keep the Unit Area Clean Keep engine and equipment clean and in good working condition Remove all oil deposits Remove all unnecessary grease and oil from the unit Accumulated grease and oil can cause overheating and subsequent generator damage and may present a potential fire hazard DO NOT store anything in or around the generator such as oil or gas cans oily rags chains wooden blocks portable propane cylinders etc A fire could result or the generator system operation cooling noise and vibration may be adversely affected CD20 30 40 Operators Manual 13067 Rev 02 121514 Page 5 1 0 Safety Precautions Protect Against Moving Parts Avoid moving parts on the unit Loose clothing or jewelry should not be permitted because of the danger of becoming caught in moving parts Keep safety shields and guards in position Be sure to stop the engine whenever checking and correcting the engine fluids If adjustments must be made while the unit is running use extreme caution around rotating hot or electrical components General Precautions Have all installations performed by qualified licensed personnel Always stop engine and disable engine starting circuit before attempting to perform any type of service Make sure that all fasteners are secure and are the correct length Keep the genset and surro
158. ry to maintain the generator voltage within specified limits The il ircuit provides adjustable feedback to ensure good steady state and transient performance of the control system The Low Hz Detector measures the period of each electrical cycle and causes the reference voltage to be reduced approximately linearly with speed below a pre settable threshold A Light Emitting Diode gives indication that the circuit is activated by the low speed running condition Cummins 2008 2 The Synchronising circuit is used to keep the Ramp Generator and Low Hz Detector locked to the generator waveform period The Low Pass Filter prevents distorted waveforms affecting the operation of the AVR control circuit AVR Output Power Control devices vary the amount of exciter field current in response to the error signal produced by the Amplifier Input Power Suppression components are included to prevent load generated voltage transients from damaging the AVR components and also to reduce the amount of conducted radio frequency noise on the generator terminals The Over Excitation Detector continuously monitors the exciter field voltage and provides the signal required to collapse the output voltage This protection circuit triggers only if an over excitation condition persists for a specific amount of time The Power Supply provides the required voltages for the AVR circuitry The EBS Interface provides the signals necessary to control the ex
159. s in the return line of the engine fuel system 10 Page 27 10 0 Installation Instructions 10 4 Cooling System The CD Series gensets are powered by oil cooled diesel engines so no other coolant is required It is critical however to supply ade quately sized openings for cooling air flow to both the engine and the AC generator See Figure 10 4 1 for diagram of air intake and dis charge locations It must be assured that these areas are not covered or blocked Engine Combustion Engine Cooling Air Air Inlet Hot Air Discharge A ne Seen w se u SC es i A T J Generator e Hot Air Figure 10 4 1 Discharge 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 10 Generator Cooling Air Inlet Page 28 10 0 Installation Instructions 10 5 Design Features and Specifications Pp tem Unit CD20 CD30 CD40T4 Engine Speed RPM 1800 1 80 1800 Engine Model D2011L030 D2011L04o TD2011L040 Engine Lube oil Capacity including Quarts 95 14 3 15 9 Cooler amp Filter Combustion Air Flow Maximum Intake Restriction In H20 Exhaust Gas Flow cM 15 2 3 Max Exhaust Backpressure In H20 26 Engine cooling Air Flow 1260 En Se AC Alternator cooling Air Flow Standby Rating 20 000 30 000 38 000 17 000 27 000 35 000 Standby Rating 20 000 29 000
160. s out the controller will not attempt a restart Auto Idle Enable Disable Determines if the controller will automatically enter Idle Mode during the Warmup and Cooldown delays Warmup Time 0 600 seconds After successful cranking engine delays this amount of time before turning on the Warmup output This allows the engine to warmup before applying any load to it The output will turn off when the controller enters the Cooldown Delay TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 37 OFF Button Function Cooldown The function the OFF button on the front panel performs while Shutdown engine is running See the OFF Button Function section for Force Cooldown more information Cooldown Delay 0 600 seconds Amount of time to cooldown the engine after a stop command has been received During this time the Warmup output turns off and the Cooldown output turns on If another start command is received during cooldown the controller will return to running mode Energize to Stop Duration 0 30 seconds Amount of time the Energize to Stop output is on after the engine has shutdown If controller still detects speed RPM after this time expires it goes to a Failed to Stop failure Time must be greater than 0 seconds for the Energize to Stop function to work 4 5 1 1 Preheat Mode The controller has the ability to control the length of the preheat time through 3 different methods The table below de
161. scosity See Section 9 1 10 Start the engine and run it for a few minutes to circulate the oil 11 Stop the engine and allow two minutes for the oil to drain down and check the level on the dipstick as described below Add more oil if necessary Checking the Oil Level 1 Remove oil dipstick Item 3 Figure 11 4 1 and wipe clean 2 Insert oil dipstick fully and then remove 3 Oil should be maintained between high and low marks Add oil if necessary 5 4 Figure 11 4 2 11 Page 33 11 0 Points of Maintenance Keep open flames away when working on the fuel system Do not smoke 11 5 Fuel System The fuel filter is an essential part of the engine and it must never be run without a filter The element should be renewed every 1000 hours or more frequently if for any reason the fuel is known to be dirty Sediment and or water accu mulation in the fuel filter will cause trouble with the operation of the engine Changing the Fuel Filter Element Before changing the filter refer to the warnings in Precautions For Filters and Elements 1 Place toggle Power Switch Item 1 Figure 5 1 1 to Off position 2 Place a container beneath the fuel filter to collect any fuel which may spill 3 Use a band type gripping tool to remove the fuel filter Jtem 1 Figure 11 5 1 from the engine 4 With a clean rag wipe the filter seating sur face on the engine clean off any dirt 5 Li
162. scribes each method Mode Description A NOTE During preheat the Glowplug switched output is on 4 5 1 2 OFF Button Function The OFF button on the front panel of the controller can be configured to function in 3 different ways while the engine is running The table below describes each of these functions Function Description ss ssis ssSCCCS Cooldown This function causes the controller to go into cooldown Pressing the OFF button again will cause the engine to shutdown Shutdown This function bypasses Cooldown and causes the engine to shutdown Force Cooldown This function causes the controller to go into cooldown Pressing the OFF button will have no affect as the controller is forcing the engine to perform a full cooldown WARNING If the controller receives a command to start while in Cooldown it will leave the Cooldown mode and go back to Running mode TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 38 4 5 2 Exerciser The Exerciser function is used start and run the engine periodically This is commonly used to make sure problems with the engine do not arise from sitting idle for too long The following settings configure the Exerciser function Name Range Description Enable Enable Disable Determines if the engine is automatically exercised periodically Delays gt Pre Alarm 1 20 minutes Amount of time to display a warning before starting the engine When configuri
163. sed WARNING Switched outputs have a floating voltage of approximately 8V when off If using the outputs for digital A logic it will be necessary to put a pull down resistor 1k from the output to ground to ensure a low logic level when output is off Speed Control Settings Name Range Description Speed Control Enable Enable Disable Enables or disables front panel speed control RPM Display Nothing Blank Parameter to display when adjusting speed from front panel AC Frequency This is used to provide operator feedback in the case that the Auxiliary Sensor 1 engine RPM affects another parameter such as AC Auxiliary Sensor 2 iere or an Auxiliary Sensor Example Flow rate of pump RPM Control gt Limit Method Speed Bias The method in which the minimum and maximum speeds the Min RPM Max RPM operator is allowed to adjust is determined RPM Control gt Speed Bias The minimum or maximum RPM that the engine speed can be adjusted around the Rated RPM Example Rated RPM is 1800 and Speed Bias is 150 The minimum RPM will be 1650 and maximum RPM will be 1950 Only valid when the correct limit method is chosen RPM Control gt Minimum RPM 500 4000 The minimum RPM that can be set using speed control Only valid when the correct Limit Method is chosen RPM Control gt Maximum RPM 500 4000 The maximum RPM that can be set using speed control Only valid when the correct Limit Method is chosen Speed Control Instructions
164. ser check the bearing condition using monitoring equipment to determine the state of the bearings The best practice is to take initial readings as a base line and periodically monitor the bearings to detect a deteriorating trend lt will then be possible to plan a bearing change at an appropriate generating set or engine service interval Bearing Service Life Expectancy Bearing manufacturers recognise that the service life of their bearings is dependent upon many factors that are not in their control they cannot therefore quote a service life Although service life cannot be guaranteed it can be maximised by attention to the generating set design An understanding of the generating set s application will also help the user to maximise the service life expectancy of the bearings Particular attention should be paid to the alignment reduction of vibration levels environmental protection maintenance and monitoring procedures We do not quote life expectancy figures for bearings but suggests practicable replacement intervals based on the L10 life of the bearing the type of grease and the recommendations of the bearing and grease manufacturers For general purpose applications providing the advice above is considered the correct maintenance is carried out vibration levels do not exceed the levels stated in ISO 8528 9 and BS5000 3 and the ambient temperature does not exceed 50 C Plan to replace bearings within 30 000
165. ses the drop in voltage and engages the output power of the EBG This 1 Main rotor 2 EBG stator additional power feeds the generator s excitation system 2 Rotating diodes 6 Exciter stator supporting the load until breaker discrimination can 3_ Exciter rotor 7_ AVR remove the fault or enable the generator to pick up a 4 EBG rotor 8 Main stator motor and drive the voltage recovery 9 Output 10 Shaft For Parallel operation The AS480 AVR also incorporates circuits which when used in conjunction with accessories can provide for parallel operation with the addition of a CT Voltage droop control Function and Adjustment of the Fitted Accessories Inside the generator terminal box are covered in the accessories section of this book Separate instructions are provided with other accessories available for control panel mounting Copyright Cummins 2009 7 P0 1 MAN EN 4 STAMFORD Standards STAMFORD ac generators meet the relevant parts of national and international standards pertaining to generators The generator must be operated within the limits laid down in the relevant standards and within the parameters on the generator rating plate Marine generators meet the requirements of all the major marine classification societies European Directives Each generator is supplied with an EC Declaration EC Declaration of Conformity lr of Conformity in accordance with the relevant EU dir
166. smaller than the pipe I D NOTE Use of short radius water pipe elbows and or miter cut elbows is strictly forbidden and may void engine warranty Exhaust Connections CD Connect the exhaust piping to the connector provided on the exhaust manifold Item 1 Fig ure 10 2 1 The exhaust outlet should be in stalled so the exhaust is directed away from any operator station and shall be properly guarded to protect the operator Inhalation of exhaust gas es can result in severe personal injury or death Be sure that exhaust sys tem does not leak 10 Page 25 10 10 0 Installation Instructions 10 2 2 Figure N D D ID D 1 3 s 2 140 1 133H5 HOA SL aTWwOS NolldlaSs3d ON lad ALO WLI zent LLOZ EL OL WIH a SSOOFOW LFILNO LFINI 91 2 ATIINA 1SMWHX3 1999 L l ron oma al Sad aa ECO z E kazi KG lt dT aan ZO rage L e e ZSL FS A Vd VIVE OAT TISHIGA AHH VIS Tomm 009 W8tr 134038 43143044 90 eege z 03141D34S Y IOVIS ESA 5135N39 0 99 0299 26214 LIA LSNWHXS oan O 2013 Stadco Products Division Ephrata PA 17522 USA CD20 30 40 Operators Manual 13067 Rev 02 121514 10 0 Installation Instructions 10 3 Fuel System The fuel system on Deutz 2011 series engines require a fuel suction amp return line The engine is equipped with a mechanical fuel transfer pump which feeds the fuel supply fr
167. stance reading should be in excess of 5 Megohm to earth Should the insulation resistance be less than 5 Megohm the winding must be dried out For drying out procedures see the Service section of this Manual The windings have been High Voltage H V tested during manufacture and further H V testing may degrade the insulation with consequent reduction Caution in operating life Should it be necessary to demonstrate H V testing for customer acceptance the tests must be carried out at reduced voltage levels i e Test Voltage 0 8 2 X Rated Voltage 1000 During testing it may be necessary to remove covers to adjust controls Warning exposing live terminals or components Only personnel qualified to perform electrical service should carry out testing and or adjustments Refit all access covers after adjustments are completed On completion of generating set assembly and before starting the Caution generating set ensure that all engine manufacturer s pre running procedures have been completed and that adjustment of the engine governor is such that the generator will not be subjected to speeds in excess of 125 of the rated speed Warning Over speeding of the generator during initial setting of the speed governor can result in damage to the generator rotating components Setting the Voltage Copyright Cummins 2009 19 P0 1 MAN EN 4 STAMFORD In addition remove the AVR access cover and turn VOLTS control fully anti clock
168. t connected to a relay to trigger the key input of the ECM There are two ways to configure this e The fuel relay is on during Preheat therefore increasing the Preheat time in the Engine Logic menu will allow longer time for the ECM to boot up before cranking e Turning on the Auto Power ECM setting in the Communications gt CAN Bus J1939 menu enables the fuel relay to be on when controller is in Auto mode This way the ECM will be always be on except when in OFF mode ECM Wiring Slave Relay Fuel Output Key Input Engine Control Module TOUGH Series Manual O 2014 DYNAGEN Technologies Inc Installation 13 2 44 Modbus Wiring The following table outlines some items that must be taken into consideration when connecting up a Modbus system Consideration Description Each end of the bus must be terminated from A to B with 120 resistors If the controller is a device that is not at the end of the bus it does not require a terminating resistor Bus Termination RS485 twisted pair 120 cables are required for communications Cable Selection 1 Belden 9841 One twisted pair 24AWG the shield of this cable must be used for Modbus common 2 Belden 7895A Two twisted pair 20AWG second pair can be used for power If running power and ground from the battery of your system to another device use the following guidelines for the gauge of the power and ground wires 1 Up to 450ft 22AWG 2 Up to 700ft 20AWG 3
169. ted industry practices will render null and void all Stadco Warranty coverage for the affected equipment and consequential equipment damage including but not limited to the following acts Installation not performed in strict accordance with these instructions Mounting genset in any manner inconsistent with instructions in Section 10 1 Mounting and elsewhere in this document Installation of equipment not strictly approved by Stadco in writing Installation of equipment not approved by Stadco may destroy the integrity performance or service life of critical internal systems and or equipment of the generator unit Unapproved modifications to unit any and all modifications must have prior written approval from Stadco to preserve the intent of Stadco warranty Overloading of the generator Max ratings available from Stadco Installation of equipment which constitutes or creates an operational or environmental hazard Tampering with Stadco factory settings including but not limited to fuel delivery rate voltage regulator adjustments overcurrent system adjustments and logic controller adjustments Damage resulting from improper operation of this unit ie running with contaminated fuel improper maintenance overheating overloading overspeeding low oil or low coolant NOTICE The use of threaded iron pipe elbows in the exhaust system will void Stadco manufacturers warranty coverage O 2013 Stadco Products Division Ep
170. tem CAUTION Do not reverse the battery polarity Reversed battery polarity will damage or de stroy the generator electri cal components 7 2 12 Volt Battery Connections A 12VDC battery is not supplied with the gen set but must be provided Connect the positive cable to the starter post as shown in Figure 7 2 1 The negative cable should be attached to a convenient location on the engine block Be sure to remove the paint before attaching the cable to ensure a good electrical connection When making the con nection from the battery to the engine use mini mum 1 gauge wire this is calculated on a 25 foot system total loop When systems exceed the 25 feet in length consult STADCO for rec ommendation on the size of wire to use 2013 Stadco Products Division Ephrata PA 17522 USA Use all copper stranded cables only Make sure the battery is properly connected Unit control system is a negative ground system For recommended battery size see Design Features and Specification Table Section 10 5 Before connecting the battery cables make sure power switch Item 1 Fig ure 5 1 1 is in the OFF position 7 3 Control System Wiring A 10ft control cord is provided for interconnection between Terminal Strip 1 located inside main control panel and plug in connectors on engine wiring harness Also a plug in connection is required for speed monitoring from the AC generator to the Digital Cont
171. the generator windings Reverse power relays should be fitted to trip main circuit breaker LOSS OF EXCITATION to the generator can result in large current oscillations with consequent damage to generator windings Excitation loss detection equipment should be fitted to trip main circuit breaker PO 1 MAN EN 4 22 Copyright Cummins 2009 STAMFORD Installation on site General The extent of site installation will depend upon the generating set build e g if the generator is installed in a canopied set with integral switchboards and circuit breaker on site installation will be limited to connecting up the site load to the generating set output terminals In this case reference should be made to the generating set manufacturer s instruction book and any pertinent local regulations If the generator has been installed on a set without switchboard or circuit breaker the following points relating to connecting up the generator should be noted Glanding This generator can be fitted with one of several terminal box arrangements Each box comes in two parts a four sided body and a lid The body of the terminal box has knock out punch holes for customer to fit their gland arrangement If these are not adequate the box can be removed and additional holes can be punched through Incoming cables should be supported from either below or above the box level and at a sufficient distance from the centre line of the generating set so as to avoid a ti
172. the level of excitation provided to the exciter field The AVR responds to a voltage sensing signal derived from the main stator winding By 3 8 controlling the low power of the exciter field control of the high power requirement of the main field is achieved through the rectified output of the exciter armature The AVR senses average voltage on two phases ensuring Te Main Totor gt AYA close regulation In addition it detects engine speed and 2 Rotating diodes 6 Main stator provides voltage fall off with speed below a pre selected 3_ Exciter rotor 7 Output speed Hz setting preventing over excitation at low 4 Exciter stator 8 Shatt engine speeds and softening the effect of load switching to relieve the burden on the engine The detailed function of the AVR circuits and their adjustment are covered in the load testing section Separately Excited AVR Controlled Generators 2 Optional Excitation Boost System EBS 7 H y WS o A 5116 The EBS is a single self contained unit attached to the non drive end of the generator The EBS unit consists of the Excitation Boost Controller zZ zZ EBC and an Excitation Boost Generator EBG Under LI a0 fault conditions or when the generator is subjected to a 4 3 2 1 large impact load such as a motor starting the generator voltage will drop The EBC sen
173. the party released or whose liability Is limited The laws of the State of Georgia shall govern this warranty 7 UNDER NO CIRCUMSTANCES WILL THE CUSTOMER BE ENTITLED TO RECISSION OR TO A REDUCTION IN THE PURCHASE PRICE CUSTOMER WAIVES ANY AND ALL CLAIM FOR LOSS OF TIME REPLACEMENT POWER INCREASED COST INCONVENIENCE LOSS OF USE OR PROFIT LOSS OF GOODWILL COST OF CAPITAL COST OF RENTALS OR ANY OTHER DIRECT INDIRECT PUNITIVE SPECIAL EXEMPLARY INCIDENTAL OR CONSEQUENTIAL DAMAGES WHATSOEVER 8 THIS WARRANTY AND THE DEUTZ EMISSION WARRANTIES FOR EPA APPROVED DEUTZ ENGINES AND GENUINE DEUTZ PARTS INSTALLED IN SUCH ENGINES ARE IN LIEU OF ALL OTHER EXPRESS OR IMPLIED WARRANTIES OF DC AND DEUTZ AG WITH RESPECT TO DEUTZ ENGINES AND GENUINE DEUTZ PARTS INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE NEITHER DC NOR DEUTZ AG ASSUME NOR AUTHORIZE ANY DISTRIBUTOR OR OTHER PERSON TO ASSUME ON THEIR BEHALF ANY OTHER OBLIGATION OR LIABILITY 9 For details of the DEUTZ warranty contact DEUTZ Corporation Warranty Department 3883 Steve Reynolds Blvd Norcross GA 30093 USA Phone 770 564 7100 www deutzamericas com Revised April 1 2009 13 Page 44 STAMFORD Installation Service and Maintenance Manual For STAMFORD PO P1 Generators Original Instructions STAMFORD SAFETY PRECAUTIONS First Steps to Safe Oper
174. tinnnvation on generator run up operation below 30Hz and to disconnect the booster power after a period of boost operation e preventing the generator from overheating This function is designed to follow the approximate thermal state temperature of the machine windings TD_AS480 AVR 04 08 02 GB The output characteristic of the EBS is as shown below The high speed interaction between the EBS POWER INPUT output and AVR demand is effectively smoothed by Voltage 90 130 Vac 3 phase the connected generators excitation component Frequency 100 120 Hz nominal time constants OUTPUT Voltage 120 Vd c 100 Va c power input Current continuous 6A Resistance 15 ohms min TYPICAL SYSTEM RESPONSE EBC response 20ms INTERNAL TIMERS Start up timer 5sec nominal Overload protection timer 5sec nominal UNIT POWER DISSIPATION 12 watts maximum E Technologies Barnack Road Stamford Lincolnshire PE9 2NB Tel 00 44 0 1780 484000 Fax 00 44 0 1780 484100 Cummins 2008 6 TD_AS480 AVR_04 08_02_GB you can trust TG410 User Manual RUNNING power controls you can trust OFF AUTO RUN Manual Revision 1 4 0 Min FW Revision 1 42 01 Date Released 09 01 2014 C US 2014 DYNAGEN Technologies Inc TOUGH Series Manual Table of Contents 1 Introduction 1 1 lU Le TEE 4 2 Installation 2 1 2 2 2 3 2 4 Terminal ENT dE 6 Typical Wiring DIAM a Ze Ce 8 Typical Wiring Diagram with Rel
175. tment Should adjustment on site be necessary and for paralleling adjustments see section on Automatic Voltage Regulators Should malfunction occur during commissioning refer to Service and Maintenance section Fault Finding procedure PO 1 MAN EN 4 24 Copyright Cummins 2009 STAMFORD Service and Maintenance Service Warning Service and fault finding procedures present hazards which can result in severe personal injury or death Only personnel qualified to perform electrical and mechanical service should carry out these procedures Ensure engine starting circuits are disabled before commencing service or maintenance procedures Isolate any anti condensation heater supply Winding Condition Guidance of Typical Insulation Resistance IR Values The following is offered as general information about IR values and is aimed at providing guidance about the typical IR values for generators from new through to the point of refurbishment New Machines The generator s Insulation Resistance along with many other critical factors will have been measured during the generator manufacturing process The generator will have been transported with an appropriate packaging suitable for the method of delivery to the Generating Set assembler s works The assembler is expected to store the generator in a suitable location protected from adverse environmental and other conditions However absolute assurance that the generator will arrive at
176. tor voltage is reduced to a low level until reset Stopping the generator or removing power from the AVR will perform the necessary reset Connections are provided to interface to the optional Excitation Boost System This incorporates a small externally mounted rotary power supply which provides excitation power in the event of heavy overloads or short circuits The EBS is short term rated and responds to signals from the AVR to deliver excitation power when required A separate overload protection system within the EBS electronic module protects the generator against sustained overloads Cummins 2008 1 Technical specification SENSING and POWER INPUT Voltage 100 264 V ac 1 phase Frequency 50 60 Hz nominal OUTPUT Voltage 82 V d c 200 Va c power input Voltage 45 V d c 110 Va c power input Current continuous 5A see note 1 transient 7 5A for 10 secs Resistance 15 ohms min REGULATION 1 0 see note 2 THERMAL DRIFT 0 03 per deg C change in AVR ambient see note 3 TYPICAL SYSTEM RESPONSE AVR response 20ms Field current to 90 80 ms Machine Volts to 97 300ms EXTERNAL VOLTAGE ADJUSTMENT 10 with 1 k ohm 1 watt trimmer see note 4 Increasing resistance lowers voltage Fixed 15kOhm resistor enables 110V sensing UNDER FREQUENCY PROTECTION Set point 94 98 Hz see note 5 UNIT POWER DISSIPATION 12 watts maximum BUILD UP VOLTAGE 4 Volts AVR terminals QUADRATURE DROOP INPUT 10 ohms burden Max sensit
177. tors AVR Adlustmemt cono nonno non nn cono nan cnn narco 20 UFRO Under Frequency Roll Om 20 ACCESSORIES EE 20 Remote Voltage Adjust cirio ai 21 Parallel Operativos eliana iaa 21 ire EE 21 Setting IPFOCCOUIE iuris lali ios 22 INSTALLATION ON SIM AAA O 23 EES LEE Pr Rn RN 23 Elte ale EE 23 A A ee Se SeR 23 Protec acta lec 24 COMMISSIONING DEE 24 SERVICE AND MAINTENANCE tiisscsscccscccisccsiccacticaccacsiatiacsivaasvansacevaannicacsececwtesteassassssanscaavsansnasesvaavuaacsannees 25 ee Ce GEN 25 WINDING CONDITION ci aii 25 EE lee 25 At Generating Set Assemblers Work 25 Generators in Eben a tios 25 Winding Condition Assessment eee eee eeeeeeeeeeeeceeeeeeeeeeeeecaeeeeeeeeseeeaeeeeeeseaeeeaeseaeesaeeseaeseaeeeneeeegs 25 PROCEDURE FOR INSULATION TESTING ccccccccsseecseecececeecececccceuscseueeeeuseuuuesuuueseeeeeeeeeeeeeeseeeeeeeeeseseeseeues 26 METHODS OF DRYING OUT GENERATORS c cccccccccnncnnnnnnnnnanananonanccnnnnnnononononononononnn suseseceeeeeeeeeseeeeeeeeeeeeeeeeeees 26 C70 6 RUN ii da 26 Blown Air Ell EG 26 Short Circuit nee WEE 26 TYPICAL DRYING OUT CURVE ai aria 27 AIR BIEBER ES AT E A A ENSE ea ee aa 28 Air Filter Cleaning Procedure ccesccceeccceeeceeeeeeeeeeeeecaneeceaeeceaaeecaeeeseseeeeaeeesaneeseaeeeseaeeeseeeeeess 28 WAIN TENANCE eege 28 Fault RINGING iii A ee teeta Ate A tn eines 28 AN R FAUT FINDING dictada de 28 Field Flashing A 29 Separate Excitation Test Procedure oooococcccnoc
178. ts Sale D 8 Wisen TOUGH Series Manual O 2014 DYNAGEN Technologies Inc Installation Typical Wiring Diagram with Relay Pak 2 3 Relay Pak RP100 Schematic Representation ajo ch 13 Les aer et PODI Dae es E NO Conta Pre masa hamessre wn wett Cette Dreier In mm torreon Des Eat Connector E _ DRAWNGNOTES KA EE Glass et carmen roy cos Glatz eons comas ESCH Switch pi A menm aa Swen oma 76 Sven Oust 4 13 Somer oom vara EZET LS Eimear Conor aa Jama Own aa sent Owe ESETETI EES aa sensor zeg SUCIA ei FOSS e 1200 mear Sata IE Kanama twa o D CAN fu Uni Evan Baan Han EECH la EX a Fal 7 Co aa mo eo We SCHEME arm mme e CT AMEN Er as Si terra Gi Iha Faiten Anaa the catre at AA rt mm peana Cana Lal Your application and winng may vary Refer to full user manual for detailed information on using your controller www dynagen ca support 2014 DYNAGEN Technologies Inc TOUGH Series Manual Installation 10 2 4 Wiring Considerations The following sections are meant to describe certain wiring configurations for illustrative purposes Not all applications are the same and make sure to modify these examples to better fit your system 2 4 1 Emergency Stop Wiring If Emergency Stop functionality is required it is mandatory to install an external mushroom style switched wired in series with the fuel or ignition supply to ensu
179. under speed protection circuit which produces a volts Hz characteristic when the generator frequency falls below a preset threshold known as the knee point The red Light Emitting Diode LED gives indication that the UFRO circuit is operating in the low frequency region The UFRO adjustment is preset and sealed and only requires the selection of 50Hz or 60Hz operation using the jumper link For normal operation the LED should illuminate as the frequency falls just below 95 of nominal Le 47Hz on 50Hz systems or 57Hz on 60Hz systems DROOP ADJUSTMENT Generators intended for parallel operation should be fitted with a quadrature droop C T The C T is connected to S1 S2 on the AVR and provides a power factor dependent signal for the AVR voltage sensing circuit This allows the control of generator reactive current when two or more generators are operated in parallel The DROOP adjustment is normally preset in the works to give 5 voltage droop at full load zero power factor Clockwise increases the amount of C T signal injected into the AVR and increases the amount of voltage droop With the control fully anti clockwise there is no droop OVER EXCITATION TRIP The over excitation trip level is set at the works at 65Vdc and cannot be altered An over excitation condition is indicated on the LED which also indicates under speed running The over excitation is allowed to exist for approximately eight seconds to prevent nu
180. unding area clean Always provide adequate ventilation Engines consume oxygen and give off deadly monoxide gases Use extreme caution if holes are drilled into the generator set Holes drilled into an electrical wire can cause fire explosion or shock hazard Use correct tools Use tools with insulated handles Check that the fuel water and lubricating oil levels are correct Never start the generator with an electrical load applied Do not start any operation until you have taken all the necessary steps to ensure that you are in complete safety Battery Hazzards The electrolyte in a lead acid battery is dilute sulfuric acid H2S0 During charge or discharge functions of a battery a chemical change takes place within the cells that causes the formation of hydrogen and oxygen gases and it is EXPLOSIVE If during this gassing action a means of ignition is present an explosion could occur A battery explosion could hurl corrosive sulfuric acid into your face and eyes and could cause blindness 2013 Stadco Products Division Ephrata PA 17522 USA Precautions Always wear eye protection when servicing batteries If electrolyte is splashed on the skin or in the eyes flush immediately under running water or use a neutralizing fluid Obtain medical help as soon as possible When charging batteries do not remove the vent caps When disconnecting or reconnecting the generator set battery make sure the
181. unt of time the LCD Backlight stays on after button activity stops Date Time gt Date Change 1 31 days Sets the date 1 12 months 2000 2099 years Date Time gt Time Change 0 23 hours Sets the time 0 59 minutes 0 59 seconds Date Time gt Daylight Savings Enable Disable Turns Daylight Savings Time on or off Units gt Temperature Unit Selects the units in which temperature is displayed Units gt Pressure Unit PSI or kPa Selects the units in which oil pressure is displayed Run from OFF Enable Disable When enabled allows user to start engine using the run button while in the OFF mode When disabled the controller must be placed in AUTO mode before the run button can start the engine TOUGH Series Manual 2014 DYNAGEN Technologies Inc Settings 20 4 2 Switched Inputs The controller has switched inputs which when activated cause the controller to perform a function Settings Name Range Description List See Below The function that the switched input performs when active Active Modes List See Below Determines under which operating conditions the switched input can be active Multiple selections are allowed List See Below The state of the input that determines if it is active or inactive Functions Name Active Mode Description Disabled N A Input is disabled and has no function Start Stop Auto Running Starts the engine when active stops the engine when deactivated WARNING
182. warning with configurable text and shutsdown engine when active Configurable Failure 3 Configurable Controller displays a warning with configurable text and shutsdown engine when active Air Pressure Failure Cranking Controller displays Air Pressure Failure and shutsdown engine when active gt gt El amp Oo o Hydraulic Pressure Cranking Controller displays Hydraulic Pressure Failure and shutsdown engine Failure when active Low Oil Pressure Running Controller displays Oil Pressure Warning when active Warning Low Coolant Level Global Controller displays Coolant Level Failure and shutsdown engine when Failure active High Fuel Warning Global Controller displays High Fuel Level warning when active Lamp Test Global Controller performs lamp test when active Fuel In Basin Global Controller displays Fuel In Basin warning when active Battle Mode Running Controller ignores all warnings and failures when active If a failure occurs during Battle Mode it is latched and the engine will shutdown on failure TOUGH Series Manual O 2014 DYNAGEN Technologies Inc Settings 21 A when the controller leaves Battle Mode Start Inhibit Controller ignores all start commands and engine cannot start when active Once Start Inhibit becomes inactive starting is enabled again If the engine is running activating this input will shutdown the engine Primary RPM 60Hz Used for changing between Primary and Se
183. wise Start the generating set and run on no load at nominal frequency Slowly turn VOLTS control potentiometer clockwise until rated voltage is reached Caution Do not increase the voltage above the rated generator voltage shown on the generator nameplate Setting the Stability Control The STABILITY control potentiometer should be set to the midway position and with the stability selection correctly set should not normally require adjustment Should adjustment be required usually identified by oscillation of the voltmeter proceed as follows Run the generating set on no load and check that speed is correct and stable Turn the STABILITY control potentiometer clockwise and then turn slowly anti clockwise until the generator voltage starts to become unstable The correct setting is slightly clockwise from this position i e where the machine volts are stable but close to the unstable region Load Testing During testing it may be necessary to remove covers to adjust controls Warning exposing live terminals or components Only personnel qualified to perform electrical service should carry out testing and or adjustments Refit all access covers after adjustments are completed AVR Controlled Generators AVR Adjustment Having adjusted VOLTS and STABILITY during the initial start up procedure the AVR control function UFRO should not normally need adjustment If however poor voltage regulation on load is experienced refer to the f
184. y for EMC compliance Installation maintenance and servicing are carried out by adequately trained personnel fully aware of the requirements of the relevant EC directives Unsuitable Applications Synchronous generators require a constant speed for power generation Applications where the generator is not run at a constant speed are not suitable for the standard generator Such applications may be possible within certain parameters Contact the factory for advice there is every possibility that we can provide you with a satisfactory technical solution to meet your requirement Additional information for EMC compliance Standard generators are designed to meet the industrial emissions and immunity standards Where the generator is required to meet the residential commercial and light industrial emissions and immunity standards reference must be made to document reference N4 X 011 This publication outlines the additional equipment that may be required Copyright Cummins 2009 9 P0 1 MAN EN 4 STAMFORD Application of the Generator Environmental Protection STAMFORD generators are protected to IP23 IP23 is not adequate protection for use outdoors without additional measures Ambient Temperature lt 40 C This table represents the normal operating conditions that the Humidity lt 60 generator is designed for Operation outside of these parameters is Altitude lt 1000m possible after due consideration and will be re

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