943-0016 Onan YHB Alternator Service manual (02
Contents
1. Onon Service Manual YHB Generator YHB Generator x with Torque Match il Regulator 943 0016 2 86 Printed in U S A Redistribution or publication of this document by any means is strictly prohibited Safety Precautions The following symbols in this manual highlight con ditions potentially dangerous to service personnel or equipment Read this manual carefully Know when these conditions can exist Then take necessary steps to protect personnel as well as equipment This symbol warns of immediate DANGER hazards which will result in severe personal Injury or death This symbol refers to a hazard or AWARNING unsafe practice which can result in severe personal injury or cee This symbol raters to a hazard or A CAUTION unsafe practice which can result in personal injury or product or property damage PROTECT AGAINST MOVING PARTS Avoid moving Garte of the unit Avoid use of loose jackets shirts or sleeves due to danger of becoming caught in moving parts _ Make sure all nuts and bolts are secure Keep power shields and guards in position If you must make adjustments while the unit is run ning use extreme caution around hot manifolds moving parts etc Do not work on this equipment when mentally or physically fatigued GUARD AGAINST ELECTRIC SHOCK Disconnect electric power before removing protec tive shields or touching electrical equipment Use rubber insulati2. FIGURE 2 3 THREE PHASE GENERATOR SCHEMATIC Redistribution or publication of this document by any means is strictly prohibited Optional Circuit Breaker Most Onan generator sets are installed for use with exterior circuit breakers and transfer switch equipment But depending on customer requirements an optional generator output circuit breaker might be mounted on side of generator box housing Figure 2 4 Review the installation specifications for information regarding the addition of this circuit breaker If so equipped be sure to add its actuation ON and OFF to your operating and troubleshooting procedures NOTE TIE LO LEAD TO OTHER LEADS TO PREVENT RUBBING ON EDGE OF BACKPLATE TAPE AND INSULATE END FIGURE 2 4 OPTIONAL CIRCUIT BREAKER GENERATOR OPERATION With the generator directly coupled to the engine fly wheel full rated output voltage is accomplished in a matter of seconds The following briefly describes generator operation and voltage regulator interaction in reference to Figure 2 5 Refer to Voltage Regulation for further specifics regard ing regulator operating modes 1 Demand for power starts the engine thereby turning the generator rotor 2 Residual magnetism in the rotor s main field indu ces voltage in the main stator 3 Single phase AC voltage is taken from the main stator winding and fed to the Torque Match ll Voltage Regulator VRAS 2 as a reference voltage 4
3. Section 3 Generator Regulator Troubleshooting CONTROL LOCATIONS Review the following listing of component parts involved in generator troubleshooting Because the following Troubleshooting Flow Charts will only be calling them by name and not location Voltage Regulator VRAS 2 Inside control box Terminal Board TB21 Inside control box Field Breaker CB21 On control box door Current Transformer CT21 22 and 23 Inside housing behind control box Rotating Rectifiers Inside housing beneath control box AWARNING Accidental generator set starting canresultin severe personalinjury or death during service procedures Disconnect battery cable before performing any checks on generator PREPARATION A few simple checks and a proper troubleshooting procedure can locate the probable source of trouble _ and cut down service time 1 Check all modifications repairs and replacements performed since the last satisfactory operation of the set to ensure that all generator leads are cor rectly connected A loose wire connection over looked when installing a replacement part could cause problems as could an incorrect connection an opened circuit breaker or a loose connection ona printed circuit board A thorough visual check can quickly eliminate these potential problems Visually inspect the components of Voltage Reg ulator VRAS 2 Look for dust dirt or moisture and cracks in the printed solder condu
4. death Make sure to disconnect the negative bat tery cable before beginning 2 Removethe generator outputbox cover Figure 5 1 3 Disconnect the stator lead wires from the load wires 4 Disconnectlead wires from control box Check wire markings for legibility to ease assembly Arrange leads so they can be easily withdrawn from the control box SC 1441 FIGURE 5 1 OUTPUT BOX AND CONTROL Disconnect all engine and generator control wire leads from inside control box as follows DC Wiring e A11 TB1 8 10 and terminals 1 through 7 as required e Unplug A11 J1 J2 J3 and J4 AC Wiring e VRAS 2 TB1 1 5 9 and 10 e 1B21 22 to 30 5 Remove overspeed switch assembly Figure 5 2 6 Use a hoist or similar lifting device to support the output box and control assembly To prevent personal injury use AWARNING adequate lifting devices to sup port heavy components Keep hands and feet clear while lifting GENERATOR SHAFT SWITCH CONTACTS D i di L Hib AIR GAP NOT LESS THAN 0 005 IN 0 13 MM END A ADJUST SCREW A ie ES 1488 FIGURE 5 2 OVERSPEED SWITCH Redistribution or publication of this document by any means is strictly prohibited 10 11 12 13 14 15 16 17 Remove the endbell capscrews that secure the out putbox supportbrackets to the endbeil and remove the output box and control box as an assembly Refer to Figure 5 4
5. ADDER MODULES OPTIONS VRel VOLTAGE REGULATOR LEFT SIDE WALL LIWSIOE VIEW 21 CONTACTS CLOSED DEER EE EES ER DEER arz araa aaea CARA EEE OFF 2128 3 36 araea rm Ts ae 332 41 43 44 120 240V 60HZ BOTTOM OF CABINET IHSIOE VIEW YRe1 7 a E pa LEFT SIDE DOOR REAR INSIDE VIEW K M21 CHECK AARM SEE RECONNECTION DIAGRAM ct kb To DC CONTROL Jetas PART OF SEE DC WIRING DIAGRAM ZONE 5 A B C PTCITZTTNDIZ Fee zg werd Ei WEED oa a 2 DASH RUVBERS RENE fae 302443 1 REES EEE AMMETER gt ana Deen ec EE Jo z00 o 4001 250 0 s00 10 375 0 7501 1 WEE LSD EES fe REF DES PART XO Eier DESCRIPTION OF DASH 301 9617 COYER WLONT CONTROL 402 0527 S09 005 406 0332 STUO FASTENER WASHEA STUD ATHR CLIP WIRE 5 87 NUT HEX W ET 110 32 BON STRAP HUT HEX 15716 181 WASHER EIT LX 15 16 ISOLATOR VISAATION GROMMET n RECEPTACLE FASTENER 406 0334 332 0052 870 0131 18 815 0544 SCREW AHW XREC W IT 16 32 X 1 2 19 821 0003 SCREW LKH 174 20 X 37 81 20 821 C004 SCREW LX H 110 32 X 5716 DOOR WLONT CONTAOL LHI SILKSCAEEN PHL FA IAC HORIZ SILKSCAEEN PAL AEAR JACHORIZ TRAY CONTROL LN IMARHESS AC IH09R1Z1 ICIRCUIT SREAKER MAG IFIELOI TRANSFORMER ASSY CUR LAMP ASSY IUPPER LOWEA SCALE GENERATOR VOLTMETER AC 10 3C0 0 6001 AMWETER AC
6. 4 7 8 9 and 10 from TB21 Isolate from ground and each other Connect all stator output leads T1 T12 together Use an ohmmeter set on the R x 100 scale and mea sure the insulation resistance between these wind ings and the stator frame A reading of less than infinity indicates a ground Field circuit breaker can be either open or closed for this test Testing for Shorts To check for shorts between individual windings first refer to electrical schematic to determine individual coil lead wires 11 14 T7 T 10 etc Be sure to disconnect the instrumentation leads and stator leads T4 T7 T8 T9 and T10 Connect an ohmmeter R x 100 scale to one lead of a stator winding leaving the other end of coil winding being tested open and the other ohmmeter lead to all other stator leads connected together Example e Ohmmeter lead to T1 coil winding lead e Ohmmeter lead to T9 12 7 10 2 5 3 6 8 and 11 connected together e Coil windings lead T4 Open A reading of less than infinity indicates a short Repeat test for all six coils Measure resistance of windings using a Kelvin Bridge meter Refer to Figure 4 6 and Table 4 1 If any windings are shorted open or grounded replace the stator assembly Before replacing the assembly check the leads for broken wires or damaged insulation Stator output leads T4 T7 T8 T9 and T10 are inter connected within the stator to five stranded 10 aircraft control wires These w
7. DIAGRAM SCHEMATIC WITH CURRENT TRANSFORMERS WHEN USED DIAGRAM LO LT Ke A TI F2 T6 TN T8 7FI2 T4 TO TF 73 TIO 12 gt ja d TI0 T6 17 TH T4 T8 4 mpm yoe aerd aratam oe ke eme PARALLEL WYE JL series DERTA DOUBLE DELTA T 112 T5 Ta L3 C124 CT23 3 T2 T4 T6 on T2 T8 T3 19 T5 TIO T12 LO LI L2 L3 cra CT21 CT22 eraf r T10 Tli T12 TI T7 T T2 T8 rs T3 T9 T6 UE ma E SE SUNE EE SC i N NOTE This figure is for reference only Refer to electrical schematic specific to your generator for further connection information FIGURE 2 2 GENERATOR VOLTAGE CONNECTIONS 2 2 Redistribution or publication of this document bv anv means is strictly orohibited TABLE 2 1 YHB VOLTAGE CURRENT OPTIONS Maximum Current Amperes Parallel Series Series sow osiw ew w w We Dota Code 515 110 190 115 200 120 208 127 220 410 220 115 230 220 380 230 400 240 416 254 440 Code 15 120 208 127 220 139 240 120 240 240 416 254 440 227 480 Code 7R 220 380 Code 9XR 347 600 Single phase power can be taken in capacities up to full rated 3 phase kW at 1 0 PF Broad range alternators have 12 leads brought out for user reconnect CONTROL AND METER LEADS TAPS OF CORRESPONDING AC OUTPUT LEADS F2 10 TO VOLTAGE EXCITER REGULATOR FIELD CIRCUIT S 7 AND 9X THREE PHASE
8. Down 1 2 3 Touch the positive battery lead to TB1 9 and the negative lead to TB1 10 of VRAS 2 Hold the leads in place for no longer than 5 seconds Start generator and run at no load Unit must build up voltage without field flashing If it does not shut down generator set and perform continuity check of all related wiring x Incorrect field flashing proce A CAUTION dures can damage regulator Do not maintain field flash connection to exciter cir cuit longer than 5 seconds PLACE RESISTOR HERE FOR 12V OR 24V BATTERY DC TO SOURCE VRAS 2 TB1 TERMINALS 6 VOLT DRY CELL BATTERY FIGURE 4 1 FIELD FLASHING CIRCUIT Redistribution or publication of this document pv anv means is strictly prohibited C VOLTAGE REGULATOR VRAS 2 REPLACEMENT Use the following procedure for replacing the voltage regulator assembly 1 Stop the engine and disconnect starter batteries 2 Disconnect and if necessary label the wires from VRAS 2 TB1 Refer to AC control wiring diagram 3 Remove the mounting screws replace old VRAS 2 with new and secure in place with mounting screws 4 Reconnect wires removed in step 2 to proper terminals 5 Perform voltage regulator adjustment switch set tings for specific voltage and method of regulation desired per procedure K D TESTING ROTATING RECTIFIERS DIODES Two different rectifier assemblies make up the rotating rectifier bridge assembly Figure
9. FlashingiheFiel g u EE 4 1 C Voltage Regulator VRAS 2 Replacement 4 2 D Testing Rotating Rectifiers Diodes S ses zam Sua eege 4 2 E Testing Exciter Salor y u sas ayau us cake ones eee eee e cee eh se E E 4 3 F Testing EXCier ROO uuu ce uyu su yuyu os suis spiqsuyhuyapipssuupayuspapaas 4 3 G Testing Generator Stator s a s 4 4 H Testing Generator Rotor Tu aasma eae 4 5 J Wiring Harness Check oii uu yu s lege AER ERENNERT SEN 4 5 K Voltage Regulator VRAS 2 Adjustment 4 5 L Generator Voltage Adjust R21 4 6 5 GENERATOR DISASSEMBLY ASSEMBLY 5 1 Generator Disassembly ccc ccc ccc ccc reece cece nee ce cece cess encase ssnecccens 5 1 Generator Assembly as s ss 5 4 6 WIRING DIAGRAMS Geer 6 1 ill Redistribution or publication of this document pv anv means is strictly prohibited Redistribution or publication of this document bv anv means is strictlv prohibited Section 1 Introduction ABOUT THIS MANUAL This manual provides troubleshooting and repair infor mation regarding the Onan series YHB
10. The voltage regulator compares the input with preset requirements rectifies ACto DC andsendsa DC voltage to the exciter field 5 The exciter stator field induces voltage in the exciter armature 6 Three phase AC voltage is tapped from the exci ter and fed tothe rotating full wave bridge rectifiers 7 DC voltage from the rotating rectifiers is fed to the main field of the generator rotor 8 The main field continues to build until rated or preset voltage is reached GENERATOR BRUSHLESS ROTATING EXCITER DIODE ROTOR ARMATURE ASSEMBLIES EXCITER FIELD MAGNETISM STATOR ASSY BRUSHLESS EXCITER 4 s MAIN FIELD RESIDUAL MAGNETISM IN ROTOR STARTS ey E PROCESS POR GENERATOR STATOR FIELD VOLTAGE LOAD REGULATOR VRAS 2 ES 1322 1 FIGURE 2 5 EXCITATION BLOCK DIAGRAM 2 4 Redistribution or publication of this document by any means is strictly prohibited na Bint iw ele ts dh Mat BY eat ee en VOLTAGE REGULATOR DESCRIPTION The design of the Torque Match il Voltage Regulator VRAS 2 provides switch selections that alter its sens ing and command signals in order to achieve maximum operating performance in a variety of generator sizes and applications Review the following then refer to Voltage Regulator Adjustments for switch locations and settings specific to your generator set model Operating Modes Torqu
11. during generator disassembly to identify and locate components Disconnect the exciter stator lead wires F1 and F2 from the terminal block on the endbell Loosen the four screws that secure the exciter stator to the endbell and remove the exciter stator Remove the rotor shaft capscrew lock washer overspeed switch flat washers and spacer from the end of the rotor shaft Disconnect the generator lead wires from terminals F1 and F2 on the exciter rotor and remove the exciter rotor from the rotor shaft Remove the bearing retainer capscrews and bear ing retainer from the endbell Remove the remaining capscrews that secure the endbell to the stator housing and remove endbell from stator It might be necessary to tap around the joint to separate the endbell assembly Remove the center capscrew lock washer and flat washer from the two generator vibration isolators Using an adequate lifting device lift the generator until the mounting brackets clear the vibration isolators Block the rear of the engine in place by supporting the flywheel housing A length of steel channel and wooden blocking is required to support the rear of the engine Place the channel and blocking under the flywheel housing Lower the generator until most of the set weight is supported by the blocking Remove the protective screening from the genera tor air discharge openings and disconnect the grounding strap from the flywheel housing Ve
12. generator in connection with a Torque Match ll VRAS 2 voltage regulator For further operation service and trouble shooting information regarding engine or controller componenis refer to support manuals specific to your generator set Study all manuals carefully and observe all warnings and cautions Knowing your generator set using it properly and following a regular maintenance sche dule will result in longer unit life better performance and safer operation Repair information in this manual for printed circuit board components other than fuses is not extensive as solid state printed circuit boards lend themselves more to replacement than repair Application of meters or hot soldering irons to printed circuit boards by other than qualified personnel can cause unne cessary and expensive damage Repair of the printed circuit boards is not recommended except by the factory High voltage testing or high poten 4 CAUTION tial or Megger testing of generator windings can cause damage to solid state compo nents isolate these components before testing TEST EQUIPMENT Most of the test procedures in this manual can be performed with an AC DC multimeter such as a Simpson Model 260 VOM or a digital VOM Some other instruments to have available are Onan Multitester Jumper Leads AC Voltmeter DC Voltmeter Wheatstone or Kelvin Bridge See Onan Tool Catalog 900 0019 HOW TO OBTAIN SERVICE In the event the generato
13. 3 Replace the rotor if it is grounded or has an open or short CONTACT ONE PROD TO EACH FIELD LEAD G 1167 FIGURE 4 8 TESTING ROTOR FOR AN OPEN CIRCUIT J WIRING HARNESS CHECK Carefully check wiring harnesses as follows 1 Inspect all wires for breaks loose connections and reversed connections Refer to applicable wiring diagram 2 Remove wires from terminals at each end and using an ohmmeter check wire end to end for continuity or opens 3 Using an ohmmeter check each wire against each of the other wires for possible shorts or insulation breaks under areas covered by wrap ping material 4 Reconnect or replace wires according to appli cable wiring diagram K VOLTAGE REGULATOR VRAS 2 ADJUSTMENT After replacement voltage regulator VRAS 2 adjust ment is performed as follows l 1 Loosen locking nut of Voltage Adjust potentiometer R21 Locate adjustment screw to mid position and retighten locking nut 2 Open controller panel doors High voltages in the control AWARNING present an electrical shock hazard which can cause severe personal injury or death Proceed with care 3 Refer to Figure 2 6 Voltage Regulator for proper Stability Range S1 and Mode Selection S2 and S3 switch settings 4 Ensure that all connections are proper and secure Redistribution or publication of this document by any means Is strictly prohibited 5 Controller with Detector AC meter option Ref
14. 4 2 Using an accurate ohmmeter test each CR using negative and positive polarities Test rectifiers as follows 1 Disconnect all leads from assembly to be tested 2 Connect one lead to F1 stud and connect other lead to CR1 CR2 and CR3 in turn record resistance value of each rectifier 3 Connect one lead to F2 stud and connect other lead to CHA CR5 and CR6 in turn record resistance value of each rectifier 4 Reverse ohmmeter leads from steps 2 and 3 and record resistance value of each rectifier F1 to CR1 CR2 and CR3 and F2 to CR4 CR5 and CR6 5 All the resistance readings should be high in one test and low in the other test If any reading is high or low in both tests rectifier assembly is defective 6 Replace defective rectifier assembly with new iden tical part Excessive dust or dirt on diodes ACAUTION and other components will cause overheating and eventually failure Keep these assemblies clean Use 24 in Ibs 2 7 Nem torque when replacing nuts of F1 and F2 CR1 CR2 CR3 CR4 CR5 and CR6 e OHMMETER St ws Tester SY d SAY SS S OTS CR3 m Z keerad aa G 1162 1 DISCONNECT LEADS FROM ASSEMBLY TO BE TESTED FIGURE 4 2 TESTING ROTATING RECTIFIERS Redistribution or publication of this document by any means is strictly prohibited E TESTING EXCITER STATOR Testing for Grounds Using an ohmmeter R x 100 scale measure the insula tion re
15. ET tXSIDE VIEW POSITION d ILLUSTRATION NUMSERS REFER TO CAAWING 539 9749 3i cw SEE DC WIRING DIAGRAM ZONE 5 A B C RECONNECTION OJAGRAMS 3 FHASE I PHASE i E Ee REESEN ee p IIQ 220V 50H2 l0 190V SOHZ 120 208v GOHZ 220 380V 5042 240 416V GOHZ 110 22G SOHZ 115 230V 50HZ 115 220 SOH2 1277220 GOHZ 230 400 50HZ 254 440 GOH2 115 230 60HZ 120 240 GOHZ 120 208V 50HZ 1397 2404 80H2 240 416 SOHZ 277 480V GOHZ 120 240V GOHZ 1227 2209 SOHZ cT2i 254 440 SDHZ cT2i LEFT SIDE 000R IREAR INSIDE VIEW ONAN CCAPCRATICN MINNEAPOLIS NU OTA M GEN SET 3 6 5 4 IO 8925 219 3 612 6267 D G2 GENERATOR EXCITER FIELD i D M23 4 FREQUENCY VETER E SC LINE I T oc CONTROL IZONE G C SCHEMATIC DIAGRAM lt l T ALTERHATOR FIELD tUPPER LOWER RECONNECTION DIAGRAMS 11072207 SOHZ N5 230 50H2 120 240 GOHZ 1107 190 SOHZ 115 220V SOHZ 120 208 SOHZ 127 220 SOUZ 1 SEN W FULL WAYE Tt T2 T3 T EXCITER ARMATURE BRIDGE RECTIFIER 3 PHASE 120 208V 6OHZ 12772204 GOHZ 139 240 GOHZ Crt SSES 2122 aaa 41 42 44 I PHASE 220 380V SOHZ 240 416 GOHZ 110 220 SOHZ 250 400V SOHZ 254 440V GOHZ 115 230 60HZ 240 4IGV SOHZ 277 480V GOHZ 254 440V 50HZ CYZI WIRING DIAGRAM G21 GENERATOR EXCITER FIELD ALTERNATOR FIELO FULL WAVE EXCITER ARMATURE erer RECTIFIER B2I 28 P T821 30
16. ROL BOX 332 0552 P CLIP wiaz 13789 2 D m pee 970 93 M t WET 1 G 321 3 D CG og S t5 a Tl Z a 1337 00491 A BOND ST3AP 8 z 76 12 4 i i E lt 8 ei SI A DI lasz ocre f Inyt Ex 187 6 181 1 oss aju 4 7 es occa WaShEA EIT e SE lt H Tuy a TE wv d D GEoi ISCREW IreM INES eat ea t 3 uw 6 ang e a lt Tg 5 H lear ceng 2 SCRE Mocks 4 2G r 3 81 4 Ts CAR aaa cane Fe L r r 19 z M2 s tz lt 5 SCHWANZ C 32 2 5 lt lt T10 aA 8 s 4 z E DRECHEN EECH e sassa Toy 22 199 537 E SILKSCREEN BN_ PA Ap o EXCITER ARVATURE PULL DE eem UE Geess 3 ck 23 98 550 C SHLRSCREEN ONL ALAS Ate lt ARNIONE RECI Ti EH TI 24 I 34 D TAAY SONTAJU Rh ADDER MODULES OPTIONS sj 338 1655 9 MARNESS ac lt 3R ZaS 5 7c et alea 20609 a CIRCUIT BSE acea uas EE 3 r AEF GENEQATGR Ki 1257820 AEF PART QF AC RAANESS 1S 028 G 14 1332 2725 a MARKER STATE Wi 42 212 6663 2 SCRER rN 6 52 xz EG 2 hee Laglva2r REF WGL ASE ATSC ANIA I Go pute E 8 PART OF KUU SH P I ANPER ZERW 6 Bee F il LR i VOLTAGE REGULATOR g f 120 VAC TO H DAIJI 2 r OC CONTROL OAH THE c c All di 2 CcB2t VOLTAGE REGULATOR 2 gt LINE I CB l LINEI NCTES i ALL COMPONENTS SHOWN Th THE DE ENEAGIZES LEFT SIDE WALL IINSIOE VIEW BOTTOM OF CABIN
17. SEE CHAATI METER FREQUENCY 145 65 HZ RHEOSTAT VOLTS ADJUST A KN B RHEOSTAT Ace SWITCH ROTARY VOLT A AUWETEQ Aa PART OF AC HARNESS ITLLUS 253 MARKER STRIP SCAEW RHM 6 32 X 5 81 ALL VOLTAGE REGULATGR 99 5300 93 5301 I 6 z 5 I F I 3 I mmn oooh jac 302 1720 A2i 303 026 303 0032 52 506 0284 m gt mio o NOTES I ALL COMPONENTS SHOWN IN THE OE ENEAGIZED POSITION 2 ILLUSTRATION KUNBERS REFER TO DRAWING 539 0740 ID 302 1769 302 1147 302 302 ete E schei CADD SYSTEM DWG Fem ir SE E sare Onan ONAN CORPORATION WIMA APOLIK Epad KOTA WD GEN SET AC CONT HORIZ MTA 150 amp 60 HZ 612 6267 ret h i 1 Redistribution or publication of this document bv anv means is strictlv prohibited Redistribution or publication of this document bv anv means is strictlv prohibited Onon Onan Corporation 1400 73rd Avenue N E Minneapolis MN 55432 1 800 888 ONAN 612 574 5000 International Use Telex 275477 Fax 612 574 8087 Onan is a registered trademark of Onan Corporation Redistribution or publication of this document by any means is strictly prohibited
18. and Test Procedures can be found on the electrical schematic in Figure 3 1 and on assembly and wiring diagrams G21 tGENERATOR SEE RECONBECTION BELOW FULL WAVE EXCITER ARMATURE GRIDGE RECTIFICA kb EXCITER FIELD ALTERNATOR FIELO ei PJ only Use electrical schematic specific to your application when troubleshooting VIS EI VOLTAGE REGULATOR CODDA 000 i Ted 1 AlLSE 2 Y sania oe COWIROL M230 gt L 0828 gy een Fntoueac Sea ps22 om DCH RS L EE L z Cat CINE i FIGURE 3 1 ELECTRICAL SCHEMATIC Includes Detector AC Meter Option Redistribution or publication of this document pv anv means is strictly prohibited FLOW CHART A NO AC OUTPUT VOLTAGE AT RATED ENGINE SPEED Replace defective field breaker Yes Yes Is control panel field breaker CB21 on fully in position Remove one lead from breaker and check continuity with ohmmeter Is breaker open No H voltage is unstable high or low or Yes causes breaker to trip see Flow Charts B C D or E Push to reset breaker Does generator AC output voitage build up No Flash exciter field per TEST B Does generator output voltage build up Is residual voltage across TB21 22 and 23 equal to 5 to 10 VAC or more per No TEST A Disconnect stator leads 7 and 8 from TB21 22 and 23 Is residual voltage across the leads 5 t
19. ctors Burned resistors and arcing tracks are readily identifiable Do not mark on PC boards with a pencil graphite lines conduct and can cause leakage or short circuits between components Visually inspect the exciter rotor assembly for burned components broken wires loose connec tions and carbon tracks caused by arcing between parts or between parts and ground Also check for shorted paths between terminals caused by dust dirt and moisture Unless absolutely sure that panel instruments are accurate use portable test meters for troubleshooting _ This figure is for reference 3 1 Ohmmeter checks must be ACAUTION made with the unit stopped to prevent meter damage TROUBLESHOOTING PROCEDURES The information in this section is divided into Trouble shooting Flow Charts as follows A B No AC Output Voltage at Rated Engine Speed Unstable Output Voltage Engine Speed Stable at Rated Speed Output Voltage Too High or Low Exciter Field Breaker Trips Unbalanced Generator Output Voltage m DC To troubleshoot a problem determine the problem and then refer to the appropriate troubleshooting flow chart Start at the upper left hand corner of chart and answer all the questions with either a YES or NO Follow the chart until the problem is found performing the referenced Adjustment and Test Procedures fol lowing the flow charts The referenced components in the flow charts and in the Adjustment
20. e Matching In most applications in order for the generator set to accept the application of a large momentary overload such as motor starting matching the torque characteristics of the engine and generator is required Because of the differences in engine characteristics different torque matching may be used for various engine generator combinations The switch selectable design of the VRAS 2 provides Onan the flexibility to test and set the torque matching function to best suit each engine generator configuration When set to the proper torque matching switch set tings the VRAS 2 voltage regulator is able to maintain output voltage within reasonable limits by reducing the voltage just enough to take full advantage of the engine s full available power under transient conditions and prevent an unstable response Non Torque Matching Even though the voltage regula tor can also be switch selected to a non torque matching constant voltage mode independent of engine speed this mode will not prevent the generator set from stalling during momentary overload conditions and is not recommended for use Consult an Onan ser vice representative before selecting this voltage regula tion mode to ensure that load demands specific to your installation would not cause an unstable operation of the generator set f Operating Stability Because ofthe differences in exciter and main field time constants different gain compensation is required f
21. eel hous ing using a capscrew and EIT locking washer and tighten securely Install the capscrew locking washer and flat washer in each vibration isolator and tighten securely Apply a thin film of Molyokote grease or equivalent to the mating surfaces of the end bearing and the endbell bearing hole 13 14 15 Install endbell on the stator placing the opening for the stator leads in the 3 o clock position Fasten endbell using the four capscrews and lock washers but do not tighten Install the bearing retainer on the endbell and secure using four capscrews and lock washers Tighten to 4 5 ft lbs 6 N m torque install the exciter rotor on the rotor shaft Connect the generator lead wires to terminals F1 and F2 on 16 17 18 19 20 21 22 23 the exciter rotor Instail the exciter stator on the endbell and secure using four socket head capscrews and lock washers Tighten to 4 5 ft lbs 6 Nem torque Connect the exciter stator lead wires to terminals F1 and F2 on the endbell terminal block Refer to Figure 5 2 Mount and adjust Mechanical Overspeed Switch When installing the overspeed switch assembly capscrew lock washer switch small flat washers large flat washer and spacer on the rotor shaft tighten to 53 ft lbs 72 Nem torque Install the overspeed switch assembly bracket and secure using two capscrews and lock washers Tighten to 4 5 ft Ibs 6 Nem torque R
22. efer to Figure 5 2 and set to proper gap Connect overspeed switch lead wire to terminal on overspeed switch bracket Remove the four capscrews and lock washers from the endbell Use an adequate lifting device to hold the output box in position for mounting to the end bell Replace the capscrews and lock washers and tighten to 20 ft lbs 27 Nem torque Connect the wires using the proper generator set wiring diagram and voltage connections Figure 2 2 Verify that all connections are proper and secure and then install the output box cover Connect the negative battery cable and test the generator set for operation Redistribution or publication of this document by any means Is strictly prohibited Section 6 Wiring Diagrams GenSet AC Control 612 6268 GenSet AC Control 612 6267 6 1 Redistribution or publication of this document by any means Is strictly prohibited 6 5 4 3 2 I 1 Ll ris Liu 612 6268 JD SCHEMATIC DIAGRAM WIRING DIAGRAM SEELEN Seene emer SEE RECONNECT rtdimt i r 22 6617 C ZOVES WLOMT CONTADL 5 K n 7 S D I GENERATOR DIAGRAM SE S TaN 2 402 0527 8 4 ISOLA oA VISAATION 3 FULL WAVE TI T2 73 T5 Ei isC8 005 A SROMMET 2 EI EXCITER ARMATURE BRIDGE RECTIFIER a 2250332 RECEPTACLE TASTENER SS d G21 GENERATOR T mmm 405 0233 A SYude AS EMEA lt e IG a s 40 C394 a WASHES STAD RTN lt S z T4 acrid ROUSINS CONT
23. em Redistribution or publication of this document by any means Is strictly prohibited Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS 6 uu see utc irinin asua deans T ee ii 1 INTRODUCTION iii Siderits vent ee EE 1 1 ADOUL TMS ITT EE 1 1 JTESCEGUIPMEN ee Ee eer Beer enge 1 1 How to Obtain Service ee ete SUNEM 1 1 2 GENERATOR AND VOLTAGE REGULATOR 2 1 Generator DESCrIDNON WEEN 2 1 Generator e e TE EE Voltage Regulator Description eu 2 5 Voltage Regulator Adjustments 2 5 3 GENERATOR REGULATOR TROUBLESHOOTING 3 1 CONUGlLOCAIIONS EE 3 1 PICPAVAUON EE ae ce 3 1 Troubleshooting PYOCOGUICS uu uu 2 u t abe uuu 7 s aa a ae aweetes tame ees 3 1 Flow Chart A No AC Output Voltage at Rated Engine Speed 3 2 Flow Chart B Unstable Voltage Engine Speed Stable at Rated Speed 3 3 Flow Chart C Output Voltage Too High or Too Low 3 3 Fiow Chart D Exciter Field Breaker Trips 3 4 Flow Chart E Unbalanced Generator Output Voltage 3 5 4 GENERATOR REGULATOR TESTS ADJUSTMENTS 4 1 A Testing AC Residual Voltage 4 1 B
24. enerator set 2 Prepare installation equipment for Test Without Load 3 Operate Phase Selector switch to read generator output current and voltage while performing the following steps A Inserta screwdriver into the Voltage Adjust con trol on the front of the generator set control and carefully loosen the locking nut B Slowly turn the screwdriver clockwise to increase voltage or counterclockwise to decrease voltage C When set at correct voltage tighten the lock ing nut Be careful not to change adjustment If correct voltage cannot be attained by R21 adjustment refer to VRAS 2 adjustment proce dure K Observe that ammeter does not register any output current If output current is observed on the ammeter contact an Onan representative 4 Move the Phase Selector switch to the Off position 5 Stop generator set and prepare all installation and generator set controls for operation readiness Redistribution or publication of this document by any means Is strictly prohibited Cte el eel ume a h Section 5 Generator Disassembly Assembly GENERATOR DISASSEMBLY If generator testing determines thatthe generator needs repair remove and disassemble as follows 1 Disconnect the negative battery cable to prevent accidenta starting of the generator set while servicing Accidental starting of the gen AWARNING erator set during this procedure presents the hazard of severe personal injury or
25. ent bv anv means is strictlv prohibited FLOW CHART E UNBALANCED GENERATOR OUTPUT VOLTAGE Check each phase for balanced current Remove load at generator terminals ls output j No If not within 10 of each other still unbalanced redistribute load Yes Check for correct grounding of generator and load Are generator leads connected and Cone ae asas grounded properly No Yes Is generator stator winding continuous Perera Replace stator assembly per TEST G Yes Check load for ground faults and correct as necessary Redistribution or publication of this document by any means Is strictly prohibited Redistribution or publication of this document bv anv means is strictlv prohibited Section 4 Generator Regulator Tests Adjustments All of the following adjustments and tests can be per formed without disassembly of the generator They should be used for testing generator and regulator components in conjunction with the troubleshooting flow charts All ohmmeter tests must be made with the unit stopped to prevent meter damage A TESTING AC RESIDUAL VOLTAGE Generator residual AC voltage should be checked first if there is no AC power output A good place to check is at terminal block TB21 across terminals 22 and 23 Resid ual voltage should be 5 to 10 VAC at normal operating r min If none flash the field following the instructions in Test B If residual voltage is p
26. er also to adjustment L Controller without Detector AC meter option Con nect an accurate voltmeter to VRAS TB1 2 and 3 terminals 6 Start generator set 7 Using a screwdriver turn R32 potentiometer on printed circuit board VRAS 2 to increase or decrease the voltage as required to achieve proper setting Observe voltmeter while making adjust ment Set voltage with no load connected to genera tor Example For a 120 240 volt connection set at no load voltage for approximately 246 volts If volt age is unstable or tends to hunt refer to trouble shooting section 8 Stop generator set and prepare all installation and generator set controls for operation readiness Regulator Specifications Input Power Input voltage across terminals 2 and 4 208 to 240 volts RMS 10 depending on wiring configu ration Input frequency 45 to 65 Hz Maximum burden 800 VA Output Power Continuous Rating 3 0A One minute rating 6 5A in current limit Current limit 6 5A 0 75A Minimum Field Resistance 0 6 ohms 25 C copper winding exciter Regulator Sensing Single phase average voltage directly proportional to generator frequency to breakpoint Independent of fre quency after breakpoint Nominally set to 59 Hz 49 Hz for 50 Hz sets Operating Temperature 40 C to 80 C L GENERATOR VOLTAGE ADJUST R21 The following procedure pertains to generator sets equipped with Detector AC option only 1 Start g
27. ires are labeled 4 7 8 9 and 10 respectively and terminate at TB21 terminals 22 26 TEST BETWEEN WIRE PAIRS T1 L0 T2 L0 T3 LO KELVIN BRIDGE THREE PHASE MODELS TEST BETWEEN WIRE PAIRS T1 T4 T7 T10 T3 T6 T9 T42 T2 T5 T8 711 G 1165 FIGURE 4 6 TESTING STATOR WINDINGS TABLE 4 1 RESISTANCE VALUES FOR STATORS All resistances should be within the values shown at 25 C 77 F Use an accurate instrument such as a Kelvin Bridge for this test Test between the following coil leads T1 T4 T7 T10 T3 T6 T9 T12 T2 T5 T8 T11 kW RATING RESISTANCE Ohms 25 C 77 F BCE 55 0 036 5 eee 0 030 5 Redistribution or publication of this document by any means Is strictly prohibited H TESTING GENERATOR ROTOR Testing for Grounds Use an ohmmeter R x 100 scale and measure as follows 1 Disconnect F1 and F2 rotor leads from the rotat Ing diodes 2 Measure between either lead and the rotor shaft Figure 4 7 3 A reading of less than infinity indicates a ground CONTACT ONE PROD TO EACH OF THE FIELD LEADS AND OTHER PROD TO ROTOR SHAFT G 1166 IF ROTOR IS GOOD THERE WILL BE ONE MEGOHM OR GREATER RESISTANCE FIGURE 4 7 TESTING ROTOR FOR GROUNDS Testing for an Open Circuit 1 Disconnect and test between F1 and F2 leads Fig ure 4 8 2 Refer to resistance values given in the following table TABLE 4 2 ROTOR RESISTANCES _ _ kWRATING RESISTANCE
28. layer of Molykote grease Onan part 524 0118 to the inside diameter of the end bearing Press bear ing on to rotor shaft applying force to the inner face of the bearing Place the rotor fan and spacer in position on the rotor shaft Install the drive disc on the rotor shaft placing the chamfered edge on the flywheel side Install the eight capscrews and flat washers and tighten to 68 ft Ibs 92 Nem torque Using a hoistand slingto supportthe rotor align the holes in the drive disc fan spacer and fan with the corresponding holes in the flywheel Secure the rotor assembly to the flywheel using eight capscrews and flat washers Tighten to 35 ft lbs 48 Nem torque Using an adequate lifting device carefully move the stator into position over the rotor assembly The statorleads should be in the 3 o clock position when viewed from the endbell Align the holes in the stator attachment ring with the holes in the flywheel housing and install the thirteen capscrews and lock washers Tighten to 35 ft lbs 48 N m torque Using an adequate lifting device slightly raise the generator so that the wooden blocking and steel channel can be removed from under the flywheel housing then lower the generator so the full weight is resting on the rear vibration isolators Place the protective screening over the generator air discharge openings and fasten securely Connect the grounding strap to the flywh
29. o 10 VAC or more now Yes Yes No Check lead continuity between VRAS 2 TB1 2 and T7 on the generator and between VRAS 2 TB1 3 and generator lead T8 as per TEST J is exciter field voltage across VRAS 2 TB1 9 and 10 equal to 5 to 10 VAC or more 4 feet mete imapapas ann s a a Check exciter field wiring for shorts per TEST J Replace bad wiring Check exciter field wiring for opens per TEST J Replace bad wiring l Check diodes CR1 through CR6 on rotor per TEST D Replace if bad an ale nent et Mts tnt cba we dn on hn AA ed da rade ee waya o aa Replace voltage regulator VRAS 2 per procedure C Check exciter field winding per TEST Check exciter rotor winding per TEST E Replace if bad F Replace if bad Check generator rotor field winding per TEST H Replace if bad replace Voltage Regulator i Do not CAUTION VRAS 2 until external trouble has Check generator stator windings per been corrected to avoid possible damage to new TEST G Replace if bad regulator board Redistribution or publication of this document by any means is strictly prohibited FLOW CHART B UNSTABLE VOLTAGE ENGINE SPEED STABLE AT RATED SPEED Are there any broken wires or loose connections on voltage regulator assembly Does voltage cycle from zero to rated output Repair as required Check control panel voltage adjust rheostat and
30. or the various generator sizes and applications The VRAS 2 voltage regulator is switch selectable to a kW range of operation that best suits the generator set application VOLTAGE REGULATOR ADJUSTMENTS The VRAS 2 Voltage Regulator is shown in Figure 2 6 There are three switches that require actuation and two potentiometers on the voltage regulator as follows e Switch Si Selects the overall range of operation for the regulator Refer to Table 2 2 e Switches 2 and 3 Determine the mode of regula tion Torque Matched or Non Torque Matched Refer to Table 2 2 e Potentiometer R32 Provides adjustability to in crease or decrease generator voltage to achieve proper setting e Potentiometer R34 Is adjusted at the factory to set the frequency breakpoint and does not require further adjustment Redistribution or publication of this document pv anv means is strictly prohibited TABLE 2 2 VRAS 2 SWITCH SETTINGS REGULATION MODE STABILITY 60 HZ 50 Hz i NON TORQUE MATCHING TORQUE MATCHING TORQUE MATCHING s2_ saa soz s2 ss OFF POS 2 POS 2 POS 2 POS 2 IC kn a ah ath Bs bie anne al teehee hate Mote TT Tet eT TB1 2 3 ACINPUT VOLTS TB1 3 4 CROSS CURRENT COMPENSATION TB1 7 8 VOLTAGE ADJUSTING RHEOSTAT TB1 9 10 EXCITER FIELD F1 TB1 9 F2 TB1 10 SC 1516 2 FIGURE 2 6 VOLTAGE REGULATOR Redistribution or publication of this document by any means Is strictly prohibited
31. r mounted outboard of the generator The generator rotor is directly coupled to the engine flywheel with a flexible drive disc Engine speed determines generator output voltage and frequency A centrifugal blower on the drive disc circulates discharged air through an outlet in the blower end See Figure 2 1 As specified in Voltage Current Options Table 2 1 Volt age Code 15 and 515 generators are reconnectible to provide the listed voltage options Output rating is 0 8 PF See Figure 2 2 and Table 2 1 FAN K E s FAN SPACER E d E Te y i N _ NY Hal ROTOR Five of the AC output leads extending from the stator housing are tapped with control wires leads 4 7 8 9 and 10 These control wires are routed into the control box and used for control input and metering Figure 2 3 The brushless exciter stator mounts in the end bell while the exciter rotor and its rotating rectifier assemblies mount on the generator rotor shaft Within the endbell leads F1 and F2 from the exciter stator winding are connected to the output terminals of the voltage regula tor Figure 2 3 END BELL OVERSPEED SWITCH EXCITER i ROTOR I EXCITER STATOR STATOR G 1159 FIGURE 2 1 YHB GENERATOR 2 1 Redistribution or publication of this document pv anv means is strictly prohibited GENERATOR CONNECTION SCHEMATIC DIAGRAM GENERATOR CONNECTION GENERATOR CONNECTION WIRING
32. r requires servicing beyond the scope of information contained in this manual contact an Onan Distributor for assistance Onan fac tory trained Parts and Service representatives are ready to handle all your service needs When contacting an Onan Distributor always supply the complete Model number and Serial number as shown on the Onan nameplate The Onan nameplate is located on the side of the generator control box Model No Important Give above noe when ordering parts Service Rating Single Phase V W U KVA an Three Phase Volts 110 190 110 220 115 200 115 230 120 208 120 240 127 220 139 240 220 380 230 400 240 416 240 480 254 440 277 480 347 600 115 230 10 120 240 10 For El e a Insul NEMA Class i amb 40 C Onan Corp Minneapolis Mn 55432 USA Made m USA ze up M 1641 FIGURE 1 1 ONAN NAMEPLATE INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN SEVERE PERSONAL INJURY AND OR EQUIPMENT DAMAGE SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND OR MECHANICAL SERVICE 1 1 Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document bv anv means is strictlv prohibited Section 2 Generator and Voltage Regulator GENERATOR DESCRIPTION The YHB generator is atwo pole revolving field genera tor designed for 3000 50 Hz or 3600 60 Hz r min operation Excitation is provided with a brushless exci te
33. replace if defective open Yes No Check wiring harness from regulator assembly to end bell per Test J Check ok No Repair wiring or replace as required Yes Check voltage regulator adjustment switch settings per adjustment K Check ok ls voltage stable within specifications at no load to full load range of generator set No No per procedure C Do not replace Voltage Regulator ACAUTION VRAS 2 until external trouble has been corrected to avoid possible damage to new regulator board Yes FLOW CHART C OUTPUT VOLTAGE TOO HIGH OR LOW is engine running at correct r min No Set r min per instructions in S appropriate engine manual Yes Refer to Generator Description Optional Voltage Connections and appropriate electrical schematic Are generator output connections correct and secure Yes Does adjustment of Voltage Adjust control R21 if equipped result in correct output voltage Set control per Voltage Adjustment K Check voltage adjust rheostat and replace if defective is voltage within specifications at 1 no load to full load range of generator set No RA No Test rotating diodes per TEST D Replace if defective Do not replace Voltage Regulator ACAUTION VRAS 2 until external trouble has been corrected to avoid possible damage to new reg ulator board Yes Check voltage regulator adjustment switch
34. resent at TB21 then check the continuity of circuit breaker CB21 If CB21 is okay pro ceed to voltage regulator VRAS 2 and check for resid ual voltage between terminal numbers 2 and 3 If none check continuity between these points with the genera tor set shut down B FLASHING THE FIELD If output voltage does not build up it may be necessary to restore residual magnetism by flashing the field This requires a 6 volt battery and a 12 ampere 300 volt diode wired as shown i in Figure 4 1 A 3 volt source will also work as will a 12 or 24 volt source However if a 12 or 24 volt source is used a 2 watt 20 or 40 ohm resistor respectively must be in series with the diode to drop the voltage to 6 volts Flashing the field can be accomplished with generator set operating or not Either of the following procedures should be sufficient to restore residual bi dice With Generator Setin Operation 1 Start the generator setand operaie al normal r min 2 Touch the positive battery lead to TB1 9 of VRAS 2 and the negative lead to TB1 10 Hold the leads in place just long enough for the voltage to build up to the normal operating level then remove the leads 3 Check generator voltage and shut down generator set Restart generator set and run at no load Unit must build up voltage without field flashing If not shut down generator set and perform continuity check of all related wiring With Generator Set Shut
35. rify that the stator is adequately supported and then carefully remove the capscrews from the stator attachment ring 18 19 20 21 22 Remove the stator assembly being careful not to drag the windings on the rotor Place stator on its side in the horizontal position Using a hoistand sling to supportthe rotor carefully remove the capscrews that secure the drive disc to the flywheel Remove the rotor assembly and place it on wood blocks in the horizontal position To avoid possible distortion do not allow the drive disc and fan to rest on anything Remove the capscrews that hold the drive disc to the rotor shait and remove the drive disc spacer and rotor fan Use a gear puiler to remove the end bearing from the rotor shaft Figure 5 3 G 1161 FIGURE 5 3 END BEARING REMOVAL Redistribution or publication of this document by any means Is strictly prohibited EXCITER ROTOR Wi ROTATING N gt N J GEES a BRUSHLESS _ OG EXCITER _ STATOR ie SPACER Pex OVERSPEED BRACKET AND SWITCH N B 31 gt CAPSCREW END BELL DN ROTOR LIFT G 1160 FIGURE 5 4 GENERATOR ASSEMBLY 5 3 Redistribution or publication of this document pv anv means is strictly prohibited GENERATOR ASSEMBLY Generator assembly is the reverse of disassembly procedure refer to Figure 5 4 1 10 11 12 Always replace bearing with a new one Apply a
36. settings per adjustment K Check ok Yes Check condition of rotating diodes Visually inspect for loose connections faulty diodes etc Check ok Yes Replace voltage regulator VRAS 2 per procedure C Redistribution or publication of this document by any means is strictly prohibited oo Ka N del Pe EP Abt eh et BNC He tee Ura ap Lp Ua Rie tal ae a erg a aaa a a ene a j FLOW CHART D EXCITER FIELD BREAKER TRIPS Does AG output voltage build up Check for any loose or broken wires Vereen Berta ei Ge or connections on VRAS 2 assembly before breaker trips Yes y Check Voltage Regulator adjustments Check diodes in rotor assembly per Test D Replace if bad and connections per Test K Check exciter stator winding per Test E Replace if bad Check generator stator leads tor proper and secure connection Refer jio Generator Description Optional Voltage Connections and appropriate electrical schematic Check exciter rotor winding per Test F Replace if bad Check generator stator windings per Test G Replace if bad Check generator rotor field winding per Text H Replace if bad Replace voltage regulator VRAS 2 per procedure C CALUT Do not replace Voltage Regulator ACCAUTION VRAS 2 until extamal trouble has dbeen corrected io avoid possible damage fo new sreg ulatoriboard Redistribution or publication of this docum
37. sistance between either lead F1 or F2 and the laminations Figure 4 3 A reading of less than infinity indicates a ground OHMMETER ES 1574 FIGURE 4 3 TESTING EXCITER FIELD Testing Winding Resistance Measure coil resistance between leads F1 and F2 with an ohmmeter scale R x 1 See Figure 4 4 Resistance should be 13 05 to 15 95 ohms at 25 C 77 F ES 1575 FIGURE 4 4 TESTING EXCITER FIELD F TESTING EXCITER ROTOR Testing for Grounds Connect leads of ohmmeter between each CR lead and exciter rotor laminations Use an ohmmeter set at the highest resistance range An ohmmeter reading less than one megohm 1 000 000 ohms indicates defective ground insulation Testing for Open or Shorted Windings Use a Wheatstone Bridge for this test Disconnect main rotor field leads which connect to rotating rectifier assemblies at F1 and F2 Disconnect lead wires from diodes CR1 CR2 CR3 CR4 CR5 and CR6 Test between exciter lead pairs T1 T2 T2 T3 and T1 T3 Resistance should be 0 6 to 0 7 ohms at 68 F 20 C See Figure 4 5 wWatrtston LEI MAKE D WHEATSTONE BRIDGE CAE A Hi k VLC Y SSES SCHEMATIC OF EXCITER WIRING CR2 CR5 G 1163 1 FIGURE 4 5 TESTING EXCITER ROTOR Redistribution or publication of this document pv anv means is strictly prohibited G TESTING GENERATOR STATOR Testing for Grounds Before testing stator disconnect control wire
38. ve mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment Do not wear damp clothing particularly wet shoes or allow skin surfaces to be damp when handling electrical equipment Disconnect batteries to prevent accidental engine start Jewelry is a good conductor of electricity and should be removed before working on electrical equipment Use extreme caution when working on electrical components High voltages cause injury or death Follow all state and local codes To avoid possible personal injury or equipment damage a qualified electrician or an authorized service representative must perform installation and all service AWARNING EXHAUST GAS IS DEADLY Exhaust gases contain carbon monoxide an odorless and colorless gas Carbon monoxide is poisonous and can cause unconsciousness and death Symptoms of carbon monoxide poisoning can include e Dizziness e Nausea e Headache Weakness and Sleepiness e Throbbing in Temples e Muscular Twitching Vomiting e Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical atten tion Shut down the unit and do not operate until it has been inspected and repaired Protection against carbon monoxide inhalation includes proper installation and regular frequent visual and audible inspections of the complete exhaust syst
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