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1. 61 Engine Control Monitor 12 V Five 4 62 Engine Control Monitor 24 V 63 Cycle 12 M ics ed ege ERES 64 Tap SWC zs d 65 25 90 kW Brushless 158 5158 66 25 180 kW Brushless Full Meter ITE PES 67 25 45 kW 3R Brushless 120 240 V 1 Phase 68 25 45 kW Brushless 120 240 V 1 Phase Full Meter Panel 69 25 90 kW Brushless 347 600 70 25 180 9XR Brushless 347 600V Full Meter Panel mv 71 Generator Set Engine Control 12V Ignition EK EM EN 72 Generator Set Engine Control 12 V Ignition EK EM 73 Generator Set Engine Control 12V Ignition KR WA 74 Generator Set Engine Control 12 V Ignition KR WA 75 Redistribution or publication of this document 53 by any means is strictly prohibited 2 GI2C 4173 WIRING DIAGRAM SCHEMATIC DIAGRAM PARIS LIST REAR VIEW PANEL CONTROL BOX INSIDE DESCRIPTION m Per 065 Tl 1213 320840 1 CIRCUIT BREAKER 2 AMP 8 621 15 0521 21 3xeoP307 1 10 BRKR HANOLE PENN STAT 2 O M22 M O
2. ne ER MMC B NO TABLE J UNBALANCED GENERATOR OUTPUT VOLTAGE ves NO PROCEOURE Remove load from generator terminals Is output still unbalanced 2 Are generator leads properly connected or grounded 5 generator stator winding continuous 4 Is grounding procedure of generator and load correct Check for ground faults on load TABLE J SYNOPSIS UNBALANCED TERMINAL VOLTAGES INCORRECT RECONNECTION INCORRECT GROUNDING AND OR GROUNDING OF OF LOAD OR GROUND 2 GENERATOR LEADS FAULT IN LOAD MOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of the appropriate section 33 Redistribution or publication of this document by any means is strictly prohibited TABLE J SYNOPSIS Continued VOLTAGE 150 OR MORE THAN RATED OPEN WIRE OR CONNECTION AT DEFECTIVE COMPONENT OPEN TRANSFORMER VR21 MODULE ON RECTIFIER T21 WINDING TERMINALS 5 6 9 10 ASSEMBLY 21 DEFECTIVE COMPONENT ON VOLTAGE REGULATOR VR21 11 OH 12 MODULE DIODE CR3 OPEN VOLTAGE BREAKDOWN OF SCR1 OR SCR2 NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of the appropriate section Malfunction occurs after warmup or voitage adjustment 34 Redistribution or publication of this document by any means is strictly prohibi
3. 11 PRINTED SHORTED CIRCUIT i BOARD NN NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of this section With switch in run position check for voltage across R9 27 ohms A voltage of 0 5 to 1 0 will turn on SCR CR6 If voltage is present remove TB11 terminal 29 If voltage is still present check transistors Q7 for short emitter to collector Remove TB11 terminal 30 and 31 If engine still shuts down remove transistor Q8 If this prevents shutdown replace Q8 FIVE LAMP ENGINE MONITOR FAULT LAMP LIGHTS AS CRANK SOON AS RUN SWITCH CLOSES CIRCUIT PATH HIGH ENGINE 18 19 TEMPERATURE OPEN LAMP LIGHTS LOW OIL OVERSPEED PRESSURE LAMP LAMP LIGHTS LIGHTS DIODE SCR CR 18 SCR CR 17 SCR CR 20 CR2 FAILS TO FAILS TO FAILS TO OPEN BLOCK BLOCK BLOCK K1 RELAY CAPACITOR CAPACITOR CAPACITOR CONTACT ON A 11 FAILS TO OPEN OPEN OPEN CLOSE CHECK POTENTIOMETER TRANSISTOR R 15 ON A 11 TRANSISTOR Q10 PRINTED CIRCU Q13 SHORTED BOARD FOR SHORTED CORRECT TIME DELAY CAPACITOR 5 C8 OPEN OPEN NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of this section Capacitor C1 must be discharged when engine starts to prevent an overcrank shutdown Check relay contact that connects to
4. Service Manual 25 to 180 kW UIR Generators And Controls Troubleshooting and Test Procedures For Generators Regulator Controls 900 0150 10 78 Printed 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 dangerousto 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 is used throughout the manual to warn of possible ser ous personal injury This symbol refers to possible equipment damage PROTECT AGAINST MOVING PARTS Avoid moving parts 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 running 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 insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment Do not wear damp clothing particul
5. 238 50017266 lt 3 Tomum L eet uS BT dWVG O31VM LInONIO WEY IV 310434 A gion 236 ee M E 95 KINO TOULNOD WHY 1v 38d NO 035072 va ove 06 WAOOINNS Muy W 3ud el aes Lee ud ei uei 1081N02 018 NO 5 ZIM I 4881 NO 5961 NMOGLNHS DE O 0c 39svH3 1134mv 190206 cin T 92 S310N 29 WH31 01 8 WNuva v 3Udd SLINA Po 480 331vAa 3903 17777777777 92 z ni S a uim 1 L 47 5 Eq IT ttt ti42INIM NMOQQTOH Av 38 9NI4d5 26144096 opere ed ____ GGOIGLOE 24 FX 133 02510 1uviS Avi3u 1 b 0 283 01 950 __ ________4 19 1 601404 5150 23 FE ECEL div 11162261 6150 12 D EL dT 1 D 20 0 0009 HOLIDVdVD 21009946 465 9 6 1554 3 t 6 00 96 ONILVYIN39 8 14 9nd i 9 ___ ES vty 31913 109 N02 1 5 0 3 ne 8D 0145 1081802 1 ciw dW31 MINOS 3N19N3 BOLINON 1 __1 9006 ie CD 5 HOLIMS ST Fas 108 108102 7 a o 310838 ron tio ft PCr a ona 2 AD i ee
6. ITEM NO PROCEDURE Does engine crank as soon as run stop switch is put into run position Check contacts K12 3 9 for failure to close or to make proper contact TABLE D SYNOPSIS ENGINE SOMETIMES HESITATES BEFORE CRANKING RELAY K12 3 9 FAILS TO CLOSE DIRTY CONTACTS BAD CONNECTION 43 Redistribution or publication of this document by any means Is strictly prohibited PROCEDURE ee TABLE STARTER FAILS TO DISENGAGE OR TRIES RE ENGAGE WHILE YES RUNNING Does starter continue to run after engine starts Does charge ammeter show a charging current while running Is charging alternator belt on and driving alternator properly Does start disconnect relay K11 and starter protection relay K14 pick up when engine starts Does voltage from ground to K13 coil terminal drop to zero when K11 relay picks up Does voltage at starter terminal drop to zero when K13 drops out Check for faulty starter Start solenoid contacts may be welded K13 solenoid Check K11 and K14 contacts 1 7 to make sure they open when relay picks up Does voltage across K11 terminals A B build up to battery voltage h A Replace start disconnect relay K11 or starter protection relay K14 Coil may be open Does relay K12 5 8 close to bring battery voltage to alternator regulator
7. R2 _ 303 0170 P 1 RHEOSTAT VOLTAGE ADJ 3 5K 259 1303 00321 1 521 1308 0284 swiTCH VOLT AMMETER _ _ L 1303 0076 1 KNOB __ ______ 721 1 3 5 04311 D 1 TRANSFORMER VOLT REF 182 332 1242 B 1 MARKER STRIP ERE MET UCET 352 1956 D 1 BOARDASSY PC VOLTAGE ROLTR c HERE 75045 29 wi2 1336 1913 LEAD ASSY DER AERE CI PANEL GEN CONTROL ____ 402 0070 4 DAMPENER VIBRATION 337 0049 1 5 __ ________ ____ 508 000 P GROMMET RUBBER 545 0023 A 1 PARTS LIST AC CONT HOW 1 98 2281 1 SILKSCREEN CONTROL PANEL A Kw RANGES REVISED 14 8 13 77 CIN SOKW 9XR I4 100 180 KW 9XR I 1 coNTROL GEN SET BRUSHLESS WIRING DIAGRAM 77 612 5305 NOTE UNLESS OTHERWISE NOTED ALL COMPONENTS ARE SHOWN IN THE DE ENERGIZED POSITION ONILBVL 310N3H Z 01663219 NYUD5YIQ NOI A21 9N3 135 39 1081 7 wun 0350 NIHA 7 v0 20 N338253118 0152886 0 10 318253115 012886 281433 9014 NOH 1 93 1511 51814 ALLT 108102 JN19N1 12108 DEA 6000 1 2 CRUS RN 01815 a 1 10 8012313
8. 21 15 04311 01 TRANSFORMER VOLT REF T821 L MARKER STRIP 32 1956 D _ 8OARD ASSY PC VOLTAGE REGULATOR 89 07661 D 6 1913 1 1 WIRING HARNESS LEAO ASSY Ut ot Win m o os ce PANEL GEN CONTROL CONTROL BOX DAMPENER VIBRATION STRAP BONO GROMMET RUBBER SILKSCREEN CONTROL PANEL PARTS LIST AC CONT HOW 01 3158 02 007 37 004 08 000 8 228 h wD UN ow O 143 7 Jc 4 cor WU CONTROL GEN SET AC WIRING DIAGRAM IZ 612 5305 NOTE 25 35 xw 3 36 70 Kw 2 21180 1 521 CONTACTS CLOSED 21 25 31 32 41 43 44 __ 11 12 21 25 31 33 41 42 44 11 12 21 27 31 34 41 42 43 114 21 27 31 35 41 42 43 44 1 13121 28 31 36 4142 43 44 9 1 16 21 22 31 32 41 43 24 21 22 31 33 41 42 44 OSITION 7 M22 EXCITER EXCITER Ks GENERATOR m ARMATURE T3 a o x 6 ALTERNATOR 8 634 FIELD T3 9 64 To 2 10 WIRING DIAGRAM REAR VIEW PANEL _ 3456789101 wie ALL 2221 KW __ __ 25 55 Or 07 36 55 02 08 56 70 03 09 71 10 04 10 iii i45 05 11 46 180 06 12 LA 1821 mr er t le G2 2
9. 5 TO REMOVE BRUSH SPRING PRESS Y SPRING HOLDER DOWN AND OUT AS 4 SHOWN IN BROKEN LINES 2 FIGURE 6 BRUSH REMOVAL watt resistor in series with diode or a 24 volt automotive generator set battery can be used by increasing the resistor value to 40 ohms 3 After starting the set touch the positive lead to 5 and the negative lead to TB4 hold on terminals just long enough for voltage to build up Y caution Do not keep excitation circuitry connected longer than 5 seconds damage may occur to the exciter regulator Be cautious when working on a generator that _is running High voltages are present 12 AMP VR 22 300 V EXCITER REGULATOR DIODE CHASSIS ASSEMBLY 6 VOLT DRY CELL LANTERN BATTERY FIGURE 7 FLASHING THE FIELD Redistribution or publication of this document by any means is strictly prohibited ee eee m Residual should be checked before the circuit breaker the best place to check it is at the five leads 61 through 65 coming directly out of the stator The combination of leads should be chosen by the wiring configuration of the stator i e 120 240 Delta 120 208 Parallel Wye 277 430 Series Wye Alter checking residual proceed to VR21 PC board and then check the circuit breaker CB21 If residual voltage is present check AC voltage at terminals 1 and 2 on VR21 voltage regulator prin
10. __ 3208430 CIRCUIT BREAKER 2AMP 7 E A ie ee ee eed VR 2I 320P307 LOCK CKT BRKR HANDLE PENN STAT BRKR HANDLE PENN STATE 5 181771 p auc mE 2 5 21 23 3028743 TRANSFORMER ASSY CUR Sa ASSY CUR 25 40KW a imu rer rper Tia ____ 3028744 gu TRANSFORMER ASSY CUR 41 45K Lr i SEE 625 1245 0 lt 13028745 TRANSFORMER ASSY CUR 46 60 HOUSING CONTROL BOX 521 POSITION CONTACTS CLOSED LI4 2 55 1 18 21 25 31 32 41 43 44 2 5 39111 12 21 25 31 35 41 42 44 53 11 34 1 12 21 27 31 34 41 42 43 t 11 10 3 11 14 21 27 31 35 41 42 43 44 __ __ 11 14 21 28 31 36 41 42 43 44 11 12 16 21 22 31 32 41 45 44 LI L2 14111 16 21 22 31 33 41 42 44 ARMATURE T3 EXCITER FIELD ALTERNATOR FIELO 621 T9 UNLESS OTHERWISE NOTED ALL COMPONENTS ARE SHOWN 46 60 03 09 45 18191018417 3028746 H TRANSFORMER ASSY CUR GL IOOKW 123245 121 3028747 TRANSFORMER ASSY CUR IOI I25KW BECA AUS 6 227 901 5471 1 3028748 1 TRANSFORMER ASSY CUR I26 180K AA pp 9 9 RECTIFIER BRIDGE NA LIGHT LOWER SCALE GENERATOR WI2 NOTE SEE VOLTAGE CHART 1 3056524 heat eT LIGHT UPPER SCAL 0522 322410 62 i
11. rotor Is generator stator winding OK Is exciter rotor winding OK Are generator rotor windings OK 17 18 19 b 24 gt N Redistribution or publication of this document by any means is strictly prohibited CB21 CIRCUIT BREAKER IN OFF POSITION RESET NO AC POWER TO REGULATOR LOW RESIDUAL VOLTAGE FLASH FIELD TABLE F SYNOPSIS NO VOLTAGE BUILD UP FAULT IN GENERATOR ROTOR OR FIELD WINDING DEFECTIVE COMPONENT ON REGULATOR PC BOARD VR21 DEFECTIVE COMPONENT ON RECTIFIER BRIDGE 21 FAULTY ROTATING DIODE ON EXCITER ROTOR FAULT IN EXCITER ROTOR OR STATOR WINDING 6c SCR1 OR SCR2 OPEN DEFECTIVE DIODE CR1 CR2 OR CR3 OPEN LEAD OPEN LEAD AT TERMINAL 1 AC2 G1 OR G2 CB 1 REGULATOR PC BOARD TERMINALS 1 OR2 DEFECTIVE NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of the appropriate section TABLE G UNSTABLE OUTPUT ENGINE RUNNING 1800 RPM FLUCTUA YES PROCEDURE TION Are there any loose or broken wires or connections at VR21 terminals Does adjustment of R26 damping control potentiometer on VR21 stabilize generator voltage i Replace VR21 7 TABLE SYNOPSIS UNSTABLE OUTPUT VOLTAGE BROKEN WIRES OR
12. 3028718 1 VOLTMETER AC O 300 0 600 302P466 METER RUNNING TIME 6 2 302 469 1 METER RUNNING TIME 50 Hz ian eerie lees 303P170___ 1 RHEOSTAT VOLTAGE ADJ 35K 25W 303932 71 KNOB RHEOSTAT 350 556 1 RESISTOR 47000 1 2WATT 30842 1 SWITCH VOLTMETER 303 76_ 50781061 2 3150431 33241248 1 BOARD ASSY BC VOLTAGE ELT 2 BOARD ASSY PC VOLTAGE RGLTR ee ed 3380764 33631913 3oic3274 MARKER STRIP WIRING HARNESS LEAD ASSY PANEL GEN CONTROL CONTROL BOX DAMPENER VIBRATION 5 ______ GROMMET RUBBER SILKSCREEN CONTROL PANEL AC 30103158 402 70 337 49 508 98C2169 545A22 PARTS LIST AC CONT PHASE 110 220V 5 2 H6 3158 115 230V 50 Hz H6 I5RI20 240V 60Hz 5 Tle Li A MODEL 2540 SR I eee 9Q 0 CONTROL GEN SET WIRING DIAGRAM 62 5300 ore 50 60 Hz 12 W ECONNECTABLE 13 WIRING SCHEMATIC DIAGRAM DII eee SI 612 5301 2 CONTROL BOX INSIDE _ EXCITER exciren 780 92 mr PART NO dom eie ARMATURE
13. D 1 12 77713028744 TRANSFORMER ASSY CUR A4I ASKW 23028145 TRANSFORMER ASSY CUR 46 GOKW T8 riora 17 3028746 i TRANSFORMER ASSY CUR 51100 x 910 11 12 __ 3028747 1 TRANSFORMER ASSY CUR OLI25IW 8 o iol 4 7 1 3028748 TRANSFORMER ASSY CURU26 I75KW ee eoe L lp Ho cir 2 052 1 LiGHT UPPER SCALE 13949 6969 G363 62 9 M23 DZENE LSCHEM DIAG 62501007 0522 322 30 1 LIGHT LOWER SCA 1 441 164 SEE VOLTAGE G21 GENERATOR i CHART 30781061 1 RELAY VOLTAGE SELECTOR 30183244 BRACKET RELAY io 6900 6269 9 23 Toa i e 3028719 1 0 75 0 150 25 40 1696 OOo cw 3028720 AMMETER AC 0 100 6 200AMP 4I 45KW ET ET 3028721 AMMETER ACO 150 0 300AMP 46 6OKW 3028722 0 200 0 400AMPI6I IOOKW 3028723 1 JAMMETER AC 0 250 0 500AMP IQI 25K 3028724 1 AMMETER ACO 375 0 750AMP I26 175KW 3026718 i VOLTMETER AC O 300 0 600 3028256 METER FREQUENCY ______ 50 2 EX 427 E 8 AU gt 3028466 METER RUNNING TIME M ME 3028469 METER RUNNINGTIME 50Hz nan nines 7 RHEOSTAT VOLTAGE ADJ 35K 25W l i 303 32 KNOB RHEOSTAT __________ i 350 556 R
14. RECTIFIER GATE cour 4 CRS LAMP 2 3457 8 35724 5 RECTIFIER DIODE __ 1 7 39402 11 DIODE 2ENER 7 5 88 204006 355030 1 1 CAMCITOR ___ _ 5 a0 TED 0 5 4 3595 12 CAPACITOR 22NFD ce 511 1 1 _______________ pe zi D Sc Lt 06 4 PRINTED CIRCUIT O O n 30 1 Ole REF DES PART _ BULK DESCRIPTION OR MATERIAL 4 44 4 o fena 5 159 mere EE va Gee 4 Lop 1 1 57 MONITOR ENGINE CONTROL 24 gt t a i a 1 sz m 5 Xx 5 b 44 Cr ox a wa o 12 1 1 ec 2 ows aa gt 67 an tas CN prm cx QJ e 14 om OF wt mer gt v3 om m 14 350 932 11 xe EE BIS Ao AN pum view A A unl p 4 R29 Ri 2 gt 1 5 5 0 Tum z C 5 Y 5 o a 5111 111 4r Jr Beales c eU 5 BYS E o 2 ut ei
15. tS 3 Or 9N3 01 255 2 38055184 110 AAI pora 1 _______ cisq dN31 9ON3 IH po 108 581 ___ 3114 38145 50151538 2 ____ S 62 1 310N e 2150 4 55384 10 0103 105 5 REC s SY9 1 0N3 105 5 981135 110 115 010 1105 gt Qa HOLVIONANNY 1015 11938 3 UOIYNESLYW LA 6 194 Gi 2 5 ROM 25 11 1208 13 Gi 3 ZIS 9 310838 8831 8311 330815 1 9 24551 a WEY TV 80 O 310N Way 14 MJA Avay 1083 v nan asp paa vem oo 3NI981 010 3108 5 9318815 WvHOVIO BS clesddl9 n NOII XI ee 2 1338 161 Suave gt 3 by any means is strictly prohibited Redistribution or publication of this document 15 Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited Onan Corporation 1400 73rd Avenue N E Minneapolis MN 55432 612 574 5000 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
16. QUESTION ANSWER TROUBLESHOOTING GUIDE FOR UNITS WITH ONE FAULT LAMP To correct a particular problem answer the question either yes or no then proceed to the next step given in whichever column question was answered NOS TABLE A ENGINE FAILS TO CRANK WHEN SWITCH TO RUN PROCEDURE Is voltage from ground terminal to center terminal of run stop remote switch equal to battery voltage Switch is defective or in stop position Is voltage from ground terminal to ignition relay K12 terminal B equal to battery voltage Jumper battery positive from center terminal of run stop remote switch to terminal B of ignition relay K12 Does engine now crank Replace engine monitor printed circuit board o Is voltage from ground to terminal 26 on TB11 equal to battery voltage N 1 Does ignition relay K12 4 7 contact close a Check socket connection b Coil may be open c Replace ignition relay K12 13 Clean relay contacts and check wiring Is voltage from ground to start disconnect relay K11 terminal 1 1 h equal to battery voltage 15 Clean relay contact K11 7 1 and check wiring cdi ET E o A NOTE On EM and EN series start solenoid relay is mounted the engine rather than in the control and is designated K6 40 Redistribution or publication of this document by any mea
17. or PIN ZNA AvT3H 9NIMdS 154106 gt 8 NMOGLOHS A1343VS 1 1 2 118 e 41815 f Sx 1091802 ALS 12 15 90g 11 E hus ew i Tene 1 W 6 9 vA 32018 WNIMH3I 1 13185611 181 I moz win isc WEVIV 310 3H 0 10 80193135 8 11855 1 ecidae 25 5 y pn anon 09 061 lt gt ius ee RES ieee 1281 NO 9 9 ING 72214 E 22 5 2222 22 22 22 22 0 0 01 7 ee oe 7 2 HEP s Ut 0 0t 3388 33138 188068 CIN 23 3 Po 8 18103 1 zin 77 TT gu Te 34155384 110 39nv9 28651 tim LO ETHER NENNEN st Od OAT Saw 009 YOLIYAYI 2 00 94 ___ 7 723 12 assy worpvavo 1 6 00955 62 7 navis 1 13018006 _ 13 9 32 zis lt 7 MONTHS 1 9 ely d OLS t zix 310N3uc i93NN0
18. 15 350 517 RESISTOR 210 R2 1 RESISTOR 1 70 A ms j s 350 572 11 810 15 3034168 2 3 5aEm tn c o m 14 350 528 t RESISTOR 1500 ins 3 quoa __ 12 3048 2 TRANSISTOR SILICON 283792 m 3 5 8 it 362295 4 TRANSISTOR FLO EFFECT 245457 01 04 10 3613 __ 2 TRANSISTOR 2881 TO FAULT 13 RECTIFIER EKTE CONT LAMP 082 3 4 5 1 8 3571M 5 RECTIFIER DIODE cn 7 35927 1 1 5 e a 1 CAPACITOR CR3 90 555 s 0 CX cs a asses 2 MACH c2 Ol de ee ee o xo ____ 2 30710039 t RELAY _______ 332m2 1 PRINTED CIRCUIT BOARD NO NK Ot ___ LL IL dL Dell e Division or cowonaton 054 504 T HET sb 11 71 18 ana ngn 8 7 9 15222 4 1 Lo 1 1 MONITOR ENG INL e SERIES Lena Bos ot ha 1p wat be ethers 19 300C680 7 6 9 10 13 14 FUEL SOL OR IGN RELAY 7 CHO T i CR3 Jo ___________ lt lt 27 C REVISED CIRC 83 ITEY 15 WAS 350 552 15 Cl ITEM 3 REMOVED
19. 505D48MREF CHASSIS ASSY V RGLTRI6I SOKW wit 3380524 _ WIRING HARNESS WI 3 6 9 5 SSY ___ 30103168 PANEL GEN CONTROL A 4 am na 30105158 CONTROL BOX 7 17402470 sm DAMPENER VIBRATION _1 337 49 1 STRAP BOND 7 508 dus OROMMET RUBBER _ 5 1 98 69 e SILKSCREEN CONTROL PANEL _ 5 22 ie 17 PARTS LIST AC CONT HOW ee a PHASE 118 230V 50 Hz H6 120 240 60 Hz 5 LI LO SUPERSEDES SAME DWG NO DATED 5 21 70 5 2E 2221 CONTROL GEN SET AC WIRING DIAGRAM 612 3919 25 90KW ISR STATIC 3PH 50 60 H 12 W RECONNECTABLE 96 eg _________ Te IeTle I 62501007 pr o crees Lo 1 0 O EC Y T v 22 ius 1 4 1 ews TBI l2 TBI 2 TBI 9 T7 329 em 2 1 CIRCUIT PART OF VR22 J BOARD ASSY PC 1 33201266 4 1 i V GEN VR22 WINDING 2 305049 R22 CR4 FIELD XFMR V4 W LLL wd TC 4 PART OF VR 22 NOTES 1 MWORM L CONNECTION 15 61 T2 1 SOR VOLTAGE REFE ENCE CIPCUIT SENStTIVE TO FRECUEKCT SHEN 3 CONNECIEO TO 2 YOLTAGE REFERENCE CIRCUIT 15
20. 9 1380 5 8 3 0104320 11 S n dS 01811938 3 HDiYNE31Y Sa ae 4 c a v 8 did MM 9 O3 430 112 YA 22 210 4811 83108 810838 ee MS 18051384 110 330838 Solves 3140 342 v6 21 wWixv3u8 11103813 59 4026 183 L NOI 41825 X3 Wavy NOWWOD QNO 13108 Woy MNYH9VIO 2ilNMW3H2S 4 1281 NO 9 9 015 NOILISOd Q32i5H3N3 3Q NI NMOtS SIN3NOdWO2 03104 3SIMH3HIO SSIINN 11138 0 3 BOLYH3N39 NI OSLNNOW HOLIMS 43345830 SS 55384710 07 8 9N3 IH NO WHY WW 134 5 222 033dSH3AO 8 NNYHOH3AO NO WHY TV 8 NMOGLOHS AL33VS 272 1081102 31916 NN3d 2 2 55384 10 018 dW3il 983 IH Q33dSH3AO X4NYH2H3AO NO WHW1Y 8 NMOGLNHS 134 5 1 2 015 2 SWHY TV 8 NMOGLNHS 2 IVA 092 06 29 WH3101 03198 LINDYID WYY TV 310839 1 15310 IYA 062 061 1281 NO 9 29 431 OL 96 S vC CE ZE T yp eamm S 1 OBL ode 1 06 62 82 22 92 92 98 62 22 1 1 1 1 1 1 Has 1NV 1d s Os OL 8 i 148 QN9 21 ON ly 19 7 ts a OT TNT o Ne 10 NS o 2s HILHA
21. DEFECTIVE COMPONENT LOOSE CONNECTIONS INCORRECT SETTING ON VR21 VOLTAGE AT VR21 VOLTAGE OF R26 POT ON VR21 REGULATOR PRINTED REGULATOR PRINTED PRINTED CIRCUIT CIRCUIT BOARD CIRCUIT BOARD BOARD TERMINALS 06 NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of the appropriate section 30 Redistribution or publication of this document by any means is strictly prohibited TABLE H OUTPUT VOLTAGE HIGH OR LOW PROCEDURE Does adjustment of R21 voltage adjust knob on meter panel correct voltage level Does adjustment of R18 potentiometer VR21 correct voltage level If generator output voltage has been optionally reconnected consider the following Is reference transformer T21 tap correctly connected on TB21 TABLE H SYNOPSIS OUTPUT VOLTAGE TOO HIGH OR TOO LOW INCORRECT REFERENCE TRANSFORMER TAP ON 21 INCORRECT SETTING OF VOLTAGE ADJUST POT R21 ON METER PANEL INCORRECT SETTING OF VOLTAGE ADJUST POT R18 ON VR21 PC BOARD DEFECTIVE COMPONENT ON RECTIFIER ASSEMBLY CR21 OPEN LEAD OR CONNECTION AT TERMINALS G1 OR G2 OPEN CR1 CR2 OR CR3 VOLTAGE BREAKDOWN OF SCR1 OR SCR2 NOTE Whenever a letter appears near the box a separate procedure corresponding DEFECTIVE
22. FIGURE 21 ADJUSTING VOLTAGE ON 21 25 Redistribution or publication of this document by any means is strictly prohibited GENERATOR SECTION II GENERAL Generators discussed in this section are brushless type only The difference between these and the generators in Section l is in the VR22 diode assembly and the commutating reactor These have been removed from the generator end bell and relocated in the control panel The diodes are now encapsulated within a hermetically sealed block therefore if any diode or silicon controlled rectifier fails the entire unit has to be replaced See Figure 27 for details of the rectifier assembly CR21 and Figure 25 for the reactor L21 Principles of operation and method of excitation remain unchanged from the units described in Sec tion 1 Refer to Table 1 for generators to which this section applies VR2 VOLTAGE REGULATOR L21 REACTOR ROTATING EXCITER OVERSPEED SWITCH WITH RECTIFIERS GENERATOR END VIEW GRILLE REMOVED FIGURE 22 ROTATING RECTIFIER ASSEMBLY SCR BRIDGE FIGURE 23 SCR BRIDGE AND REACTOR LOCATION TROUBLESHOOTING Use the following troubleshooting charts and procedures to locate malfunctions in the generating system Section I also references procedures A thru P of Section The question and answer troubleshooting guides which follow give a step by step procedure for check 26 ing the generator To use the guides answ
23. IN THE DE ENERGIZED POSITION SEE VOLTAGE TO VR2I 1 Abu M a MM M di e EXCITER EXCITER 3 ARMATURE 5 5 E FOR VR SYSTEM SCHEMATI SEE VOLTAGE CONNECTIONS PER VOLTAGE CHART BELOW 5 PHASE 127 220V 50 Hz H5 120 208V 50 Hz H4 110 190 50 Hz H3 115 200V 50 H4 120 208V 60 Hz lH 3 127 220 V 60 Hz H4 139 240V 60 Hz lH5 T8 254 440V 50 Hz H5 240 416 V 50 Hz H4 5158 220 380 50 Hz H3 230 400V 50 Hz H4 240 416 V 60 Hz H3 ISR 254 440V 60 Hz H 27 480 V 60 Hz H5 62 Ti T2 T3 1 T9 TioT4 5 TII T7 PARTS 451 DESCRIPTION Ot Pr NO jov 32084531 1 CIRCUIT BREAKER 2 AMP a ay MES 7771 320P307 1 10 BRKR HANDLE 16 crei 3056524 RECTIFIER BRIDGE 9 ee Bo de cm m rien LIGHT UPPER SCALE __ 322A130 LIGHT LOWER SCALE GENERATOR 3 RELAY VOLTAGE SELECTOR 30183244 BRACKET RELAY MTG 307 157 SPRING RELAY HOLDDOWN 121 3158384 REACTOR ASSY COMM eee ee
24. NNij NYHDVIQ ___10 HOLINOW 015 Sy HS NOt 21 9 3 135 39 1081 02 VM d 33NVHO 22 21 58 1242 015 x uzere ocu w 3 eat n 2 12 1 a d 11 8 UM Y _______ BASIC 2000 oxnv 22 HUBS REA EH REL GND o a 3 fs 5 8 11 97 23 21 zi 4 0321583N3 3 5 HE ANNO 0351 53 JHL NI 6 SLN3NOdNO2 x 3 23 Sea ee Soa cupo E 03104 SSIMYSHLO 553700 82 VAKEN e SN 4138 dN3 Eee cu 22 2 90 20 38355115 9 1 182 FIN NI S Le IVA 0928 0561 dWil 0 10 33825 715 ___ gt 1281 80 98 NI IH NO WHY AL33VS 222 5 2 881 Der ier 52 8334583 0 8 ANVHOH3AO NO ee 310N 335 1803 1511 51884 Ji 514585 ___ e is cs t WHY IV 9 NMOGLAHS A133VS 1 2 2 1 i 3 99 5 __ SS3NNFB ___ 55384 10 018 I 2697 75 219022 9 Ass bid 9N3 IH 033dSU3AO INVHOH3AO UE 4 MA cr
25. SCHEMATIC DIAGRAM EXCITER ARMATURE FOR VR SYSTEM SCHEMATIC SEEG EXCITER AC CONTROL PARTS 1157 REF DES PART NO 320 043 320 0431 __ DESCRIPTION CIRCUIT BREAKER 2 LOCK BRKR HANDLE PENN STATE RECTIFIER BRIDGE GENERATOR L2 315 0384 REACTOR ASSY COMM 1245 0 ALTERNATOR FIEL m ul o o nm gt T2 To M2t 1302 0421 VOLTMETER AC 0 300 V 22 1302 0466 P METER RUNNING TIME aa ee 1303 0170 P 1 RHEOSTAT VOLTAGE ADU 3 5K 25W peream Pol KNOB RHEOSTAT ___ o 01 2 135 043110 1 TRANSFORMER VOLT REF 7821 332 le42 B MARKER STRIP ad 4 vR21 1332 1956 D 1 BOARD ASSY PC VOLTAGE RGLTR PRI 1338 0765 0 t WIRING HARNESS wi2 356 1915 t LEAD ASSY __________ eee ie Se Pe ____ 50 3822 PANEL GEN CONTROL ________ _____ 0 3158 D 1 CONTROL ____ 402 0070 A 4 DAMPENER VIBRATION ____ 337 0049 1 STRAP BOND 1508 000 P 4 GROMMET RUBBER sss _____ 545 002 1 PARTS LIST AC CONT Se SILKSCREEN CONTROL PANEL AC pce Ede Vins un quum UNMUNUT UE A TREE J ey ae EE UNES ee MEME as p
26. 25 FIGURE 20 GENERATOR DISASSEMBLY 24 Redistribution or publication of this document by any means is strictly prohibited GENERATOR ASSEMBLY Generator assembly is the reverse of disassembly procedure 1 Always replace bearing with a new one apply a layer of grease on end bell bearing hole before inserting bearing 2 Torque bearing capscrew to 60 70 Ib ft 3 Torque drive disc to rotor capscrews to 200 240 lb ft 4 Torque drive disc to flywheel capscrews to 45 50 Ib ft 5 Torque generator through stud nuts to 30 40 Ib P P 6 Refer to Parts Catalog for replaceable parts and assemblies Refer to Wiring Diagram for VOLTAGE ADJUSTMENT reassembly After replacement voltage regulator VR21 adjust ment is performed as follows see Figure 21 1 Center the voltage adjust knob so pointer is in a vertical position 2 Open meter panel doors Start unit 3 Using a screwdriver turn R18 potentiometer on printed circuit board VR21 counterclockwise to increase the voltage or clockwise to decrease the voltage Observe voltmeter on meter panel while making adjustment Set voltage with no load connected to generator Example For a 120 240 volt connection set at no load voltage or ap proximately 246 volts If voltage is unstable or tends to hunt turn R26 potentiometer on VR21 in the direction shown on printed circuit board to increase voltage sensitivity ADJUST R26 ADJUST R18 HERE HERE
27. COMPONENT ON VOLTAGE REGULATOR PC BOARD VR21 DEFECTIVE ROTATING DIODE OR BAD INSULATOR ON HEAT SINK MOUNTING SCREW to that letter is given at the end of the appropriate section 31 Redistribution or publication of this document by any means is strictly prohibited PROCEDURE TABLE EXCITER CIRCUIT BREAKER TRIPS YES Does AC output build up to 15096 or more of rated voltage before CB21 trips Are there loose or broken terminals or connections at VR21 Is diode connected between and in CR21 rectifier assembly OK Are reference voltage transformer 721 windings connections OK Replace 21 Does AC output build up to rated value before tripping CB21 7 Are rotating diodes CR1 through CR6 on exciter rotor OK Is exciter stator winding OK Is generator field winding OK 10 15 exciter rotor winding OK TABLE SYNOPSIS VOLTAGE BUILDS UP BUT CB21 CIRCUIT BREAKER ON METER PANEL TRIPS DEFECTIVE ROTATING DIODE CR1 CR2 CR3 CR5 OR CR6 FAULT IN FAULT IN EXCITER ROTOR GENERATOR OR STATOR MAIN FIELD ON EXCITER WINDING WINDING ROTOR 27 gt NOTE Whenever letter appears near the box separate procedure corresponding to that letter is given at the end of the appropriate section 32 Redistribution or publication of this document by any means is strictly prohibited
28. Co Check for faulty alternator regulator or shorted alternator output Check K12 ignition relay for dirty contact or broken wire e NOTE On EK EM and EN series start solenoid is mounted on the engine rather than the control and is designated K6 ani anh 44 Redistribution or publication of this document by any means is strictly prohibited TABLE E SYNOPSIS STARTER FAILS TO DISENGAGE START SOLENOID CONTACT FAILS TO OPEN ALTERNATOR FAILS TO ENERGIZE START DISCON NECT RELAY K11 AND K14 START DISCONNECT RELAY K11 e FAILS K14 STARTER PROTECTION RELAY FAILS 5 K11 START K14 COIL OPEN DISCONNECT COIL OPEN CONTACTS 1 7 ON K14 FAIL TO OPEN CONTACTS 1 7 ON K11 FAIL TO OPEN Ja DRIVE BELT OFF OR SLIPPING IGNITION RELAY 12 5 8 FAILS CLOSE ALTERNATOR OUTPUT SHORT CIRCUITED DEFECTIVE REGULATOR NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of this section K14 starter protection relay was added to units beginning with the Specs shown below This relay prevents starter engagement when unit is running SERIES SPEC SERIES SPEC SERIES EK EM D DEH D DYC EN A DEF F DYD KB KR DEG D DYG DDA MDDA A DFE H 150 175 kW DDB A DYA C DYJ 45 SPEC SERIES SPEC B WA F A WE B WB H A A Redistributi
29. EN series start solenoid relay is mounted on the engine rather than in the control and is designated 5 Go ond Redistribution or publication of this document by any means Is strictly prohibited TABLE F ENGINE FAILS TO CRANK continued YES No PROCEDURE Is voltage from ground to K11 terminal 1 equal to battery voltage anh Clean relay contact K11 1 7 and check wiring Replace relay K11 if necessary f Does voltage from ground to coil terminal of K13 sta solenoid equal battery voltage Does voltage from ground to TB11 22 equal battery Jumper from K13 coil terminal to K11 terminal 1 Does relay K13 start solenoid pick up Replace cycle cranker and check printed circuit connection Replace 13 start solenoid 22 Does voltage from ground to starter coil terminal equal battery voltage Replace starter N NO C Check wiring between TB11 terminal 22 and starter Some units have an automatic resetting circuit breaker in this circuit NO Remove lead from TB11 31 Reset switching to stop then back to run Does engine crank OK Inspect for bare wires and shorts to ground Replace engine temperature sensor 27 Are relay contacts K11 B 5 open eplace relay and reset switching to stop then back to run Does engine crank OK Replac
30. H5 NOTE UNLESS OTHERWISE NOTED ALL COMPONENTS ARE SHOWN IN THE DE ENERGIZED POSITION 32082 1 CIRCUIT BREAKER ISAMP 25 40 320BIB t CIRCUIT BREAKER 2 4i 9OK 320 307 _ LOCK CKT BRKR HANDLE PENN STATE iin Ra r ef 2332 le ee 052 322 71 LIGHT UPPER SCALE 0522 322 130 LIGHT LOWER 5 1 GENERATOR 30751061 1 RELAY VOLTAGE SELECTOR 30183244 BRACKET RELAY MTG sape me t 1 anan m A Pe MM 4 aX ra 0 an ert pe ony eee arasam ee e a eet a j m 4 e m ee i ERREUR 3028718 VOLTMETER C 0 300 0 600 _ TEE 4 4 o P PARE a mama a 098 1 3O3PITO 171 RHEOSTAT VOLTAGE ADJ 35K 25W 303832 KNOB RHEOSTAT R22 _ 1350 5 1 RESISTOR 47000 17 LU 2WATT 5 3OBAIQ SWITCH VOLTMETER _______ 4303 76 KNOB UI 77450342 7 TRANSFORMER VOLT REF TB2i 33241248 MARKER STRIP P Edi VRAI 3320264 1 BOARD ASSY PC VOLTAGE RGLTR CHASSIS ASSY V RGLTR 25 60KW mma m L 7
31. T8 on generator between terminal 1 21 and T7 on generator 15 there continuity between these connections VR21 2 to T8 VR21 1 to T7 If there is no continuity between VR21 1 and T7 CB21 ON apply a shorting jumper across 21 15 continuity obtained gt Replace CB21 Check for loose or broken wires on VR21 CR21 L21 reference voltage transformer T21 generator bus bars and terminal board TB21 in control box Secure or repair where necessary If repairs have been made restart engine Does AC voltage now build up Are diodes CR1 CR2 and CR3 on CR21 assembly good See method T in procedure section for checking diodes If faulty diode located replace CR21 2 Are SCRs 1 and 2 in CR21 good See method T in procedure section for checking diodes If faulty SCR s located replace 21 Redistribution or publication of this document JJ by any means is strictly prohibited ITEM TABLE F NO OUTPUT VOLTAGE ENGINE RUNNING AT RATED RPM continued YES PROCEDURE Fault probably lies with a defective component on VR21 Replace VH21 4 Start engine Place CB21 in OFF position Using method prescribed under R in procedure section flash the exciter field to restore residual magnetism Place CB21 ON Does the AC output voltage build up 15 Shut off engine 15 exciter field winding F1 F2 OK Are rotating diodes through CR6 on exciter
32. TB21 terminals 61 65 FROM KELVIN BRIDGE E WEE xt FIGURE 14 TESTING STATOR WINDINGS TABLE 4 RESISTANCE VALUES FOR 5 KW RATING VOLTAGE CODE Resistance in Ohms 2 s __ o 0 116 0 141 0 047 0 058 0 047 0 058 0 047 0 058 0 028 0 035 0 038 0 047 0 028 0 035 0 028 0 035 0 022 0 027 0 019 0 024 0 019 0 024 0 015 0 018 0 012 0 015 0 009 0 011 0 009 0 011 0 0075 0 0092 0 0059 0 0072 0 0059 0 0072 0 052 0 063 0 047 0 058 0 047 0 058 resistances should be within the values shown at 20 C 68 F Use an accurate instrument such as a Kelvin Bridge for this test Test between the following coil leads 1 4 17 10 T3 T6 T9 T12 T2 T5 T8 T11 20 Redistribution or publication of this document by any means is strictly prohibited J TESTING EXCITER ROTOR Armature Testing for Grounds Remove diodes CR1 CR2 CR3 CR4 CR5 and CR6 from diode heat sink assemblies Using an ohmmeter R x 100 scale measure insula tion resistance between any of the leads and the laminations exclude the diodes from the test circuit A reading of less than infinity indicates a ground Testing Winding Resistance Using a Wheatstone or Kelvin bridge meter measure resistance between leads pairs 1 2 T2 T3 and T1 T3 Resistance should be 0 464 to 0 567 ohms at 20 68 F See Figure 15 CRI CRE CRS FIGURE 1
33. _ 1081802 04536 NI NMOHS 34Y SLN3NOGNOD W OF iene AzI 9N3 135 N3971081N03 yez2e Iel Ic Ogu VA y33Nvu2 U33NVEO 11v 0310N 3S1MH3H10 65318079 009 1 23 3 44 41 16 31242 015 1138 ONS HOLYH3N39 eal I 66803219 __ WvHOVIQ m 1 NT G3LNNOW HOLIMS 033dSH3AO 65 5 EM JN AM TED 12226 8 8 203p W3L re jl 0 O 92157 29 50 _ M ______ unum KINO waww Alas P ys 17 ET Wye lu vs TETE dz A equo i 9 EX 5 8 983 IH 033d5U3AO 4NVH283A0 NO 28 2H 117 92 23 9 553762 219 SWHV1V NMOGLNHS A133VS 27 T L4 55388 710 01 8 dW31 55 NO SWHY V 3J4d 13495 2 23 1081 WHVV 3Hd b t e s po ad IH NO SWYYIY AL33VS 2279 9 2 D 50 50 120 110 118254115 gt A JVA Ob 06 0234583 0 8 ANY YJYJAO NO 1 s J uva pi 13831081 n VelNO c9 9 SWBVIV 8 NMOGLNHS AL3JVS 27 16 2 Sie 10H1NOO 31V1S NN3d 2 sz eae TOWING INI 115888 77 ES gh 24 6 p a 2 5 7983 MOH 1 03 1513 518844 oO 3431 22 pssi eI 9N3 03 NO ANNO WHVANV A133VS 2770 is TAINO INOJ
34. cp s 9222 _________ ee te __ 2 4 031 22 22 ecco O STO 02 STATE EN EE DI NES ule c 022 ______ nen DiviSiOn CF StyOLBIA 8 AT nen Mera a M ravi 1 13 77 ye 7722 CONTROL GEN SET AC WIRING DIAGRAM 62 5302 f NOTE UNLESS OTHERWISE NOTED ALL COMPONENTS ARE SHOWN BRUSHLESS 25 45 38 1 IN THE DE ENERGIZED POSITION I20 246V IPH 3W GOHz 69 12 5303 WIRING DIAGRAM REAR VIEW PANEL CONTROL BOX INSIDE On 354567893101 12 5 J LJ AE Z 21 ot l I TO VR2 wie 4 1 J c2 2 m HOUSING CONTROL BOX 70 68 ww TI 1 Le ww Te CT22 Lo TO GENERATOR ARMATURE 9 T3 1 o x ul 62 VOLTAGE CONNECTION 120 240 ALTERNATOR SIRE To T T2 2 esiu roe 7 20 B 1 CIRCUIT BREAKER ea 1 SURE fsos oszal 1 RECTIFIER BRIDGE E BRIDGE nnr l pou c Fez 1 GENERATOR 22 20 12 3 5 0384 REACTOR ASSY COMM uicem w
35. fAgd 1 4 800 vi y vad 4 BLAME ________________ 88815 9 DIS 338 4 41815 1 Waimea fi 80 50 1 80133139 3 85 1 1069808 0 O Z0 10 7 80133135 821185 1 88 215 430 1 3 4 1 7 16913 11 4 1 51112 PIN 215115 345 2 0 00 398 2 831388 1 cin 483 39 5 1 951861 38055384 110 390v9 1 _ oss 7 2 ERN sr e 19018106 CU 2 067 11394095 10 18Y18 1Y 3H 1 113 11013 4 13 821220 1158 poe non i Pout ru Tu 8382 327212 7981809 _ 12200 7 015 1 7 1715 11051907 3 19 3 3011 08 66130081 015 0 02 380983 1 f 5 836 ny 1317 Yra 108 70118402 ee 10 015 1350 N3HM ae EN Rian REESE Ben 2224 ame SECS ELE ETAL Vs 1 1 5 dmu a gir ra Tas as od 10 301 8211851 111 15 as re T 62 cs ____ zx 7 23
36. frequency meter ammeter or ammeters plus volts amps selector switch to the left hand door The right hand door attached to a removable bracket holds the instrument lamp fault lights switches and A12 CRANKING LIMITER MAY ALSO USE AN OPTIONAL CYCLE CRANKER 1 11 START DISCONNECTS RELAY ST gt AM K12 IGNITION RELAY K13 START SOLENOID gauges An optional door has holes for electric tachometer and or oil temperature gauge The bracket supports the terminal blocks cycle cranker and relays in the DC engine control circuit Plug mounted relays in both the AC section and DC section plus printed circuit modules in the DC section facilitate troubleshooting and servicing Snap in lamps with Faston connectors make lamp replace ment very easy See Figure 28 FAULT LAMPS N TIME DELAY ADJUSTMENTS OF E lb ENGINE MONITOR PC BOARD K1 RELAY K2 RELAY FIGURE 28 LOCATION OF DC CONTROL COMPONENTS THE QUESTION AND ANSWER TROUBLESHOOTING GUIDES BEGINNING ON PAGE 39 GIVE A STEP BY STEP PROCEDURE FOR CHECKING CONTROL SYSTEM PROBLEMS THE FLOW CHART TROUBLESHOO TING GUIDES ARE GIVEN AS A GENERAL GUIDE TO RESOLVE VARIOUS CONTROL SYSTEM PROBLEMS ALL CHARTS REFER TO PROCEDURES AND NOTES WHICH ARE GIVEN AT THE END OF THIS SECTION 39 Redistribution or publication of this document by any means is strictly prohibited
37. jumper read voltmeter See Figure 27 Apply temporary jumper from 2 to G2 to test SCR2 Remove jumper read voltmeter See Figure 27 107 02 JJ Redistribution or publication of this document by any means is strictly prohibited INDEX OF GENERATOR ADJUSTMENTS AND PROCEDURES SECTION I PROCEDURE TITLE PAGE A 565 2222555 55 16 B Flashing 16 C No AC Power to 17 D Testing L1 Reactor 17 E Testing Diodes 17 F Testing 18 Testing Generator Rotor 44 19 H Testing Generator Stator 20 J Testing Exciter Rotor 21 K Testing Exciter Stator 21 L Reconnection 21 M Sensitivity Reference Circuit xs 23 N Generator Disassembly 24 P Voltage Adjustment PT 25 SECTION PROCEDURE TITLE PAGE R Flashing Field m 35 S Testing L21 Reactor 35 T Testing Bridge Rectifier CR21 36 38 Redistribution or publication of this document by any means is strictly prohibited CONTROLS SECTION 111 GENERAL The shock mounted control box has two doors that open from the center The left hand door holds the field circuit breaker voltmeter and voltage adjusting rheostat The optional meter package adds running time meter
38. meter panel result in correct voltage Does adjustment of R18 potentiometer on VR21 printed circuit board result in correct voltage Is correct voltage reference transformer tap on TB21 being used The trouble is probably caused by a defective component on VR21 voltage regulator printed circuit board REPLACE VR21 PRINTED CIRCUIT BOARD TABLE C SYNOPSIS OUTPUT VOLTAGE TOO HIGH OR TOO LOW INCORRECT INCORRECT DEFECTIVE REFERENCE SETTING OF COMPONENT ON TRANSFORMER TAP VOLTAGE ADJUST VOLTAGE ON T21 POT R21 REGULATOR CHASSIS METER PANEL A ASSEMBLY VR22 INCORRECT SETTING OF VOLTAGE ADJUST OPEN LEAD OR CONNECTION AT TERMINALS 3 4 POT R18 ON E OH VR21 PC BOARD NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of this section 12 4 Are generator output leads properly connected YES E PROCEDURE DEFECTIVE COMPONENT ON VOLTAGE REGULATOR BOARD VR21 Redistribution or publication of this document by any means is strictly prohibited ITEM PROCEDURE NO TABLE D GENERATOR VOLTAGE BUILDS UP BUT CAUSES THE CIRCUIT BREAKER YES ON CONTROL PANEL TO TRIP ENGINE RUNNING OK Does AC output voltage build up to 150 or more of rated voltage before CB21 circuit breaker trips NO Are there any loose or broken terminals or connections at VR21 voltage regulato
39. on static excited rotors and between field leads with rectifiers disconnected on brushless rotors Use Wheatstone Bridge for testing Redistribution or publication of this document by any means is strictly prohibited H TESTING GENERATOR STATOR Testing for Grounds Connect all stator output leads 71 712 together Use an ohmmeter set on the R x 100 scale and measure the insulation resistance between these windings and the stator frame A reading of less than infinity indicates a ground Field circuit breaker can be either ON or OFF Testing for Shorts To check for shorts between individual windings first refer to Figure 18 to deter mine individual coil lead wires T1 T4 T7 T10 etc Connect one lead of an ohmmeter RX100 scale to one of the stator windings and the other ohmmeter lead to all other stator leads connected together A reading of less than infinity indicates a short Repeat until all stator coils have been tested in this manner Coil Resistances Measure resistance of windings using a Wheatstone or Kelvin bridge meter See Table 4 and Figure 14 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 interconnected within the stator to five stranded 10 aircraft control wires These wires are labeled 4 7 8 9 and 10 respectively and terminate at
40. terminal 16 of engine monitor See typical wiring diagram OVERCRANK LAMP LIGHTS SCR CR 10 FAILS TO BLOCK CAPACITOR OPEN CHECK POTENTIOMETER R2 ON A 11 PRINTED CIRCUIT BOARD FOR CORRECT TIME DELAY ENGINE SHUTS DOWN LOW OIL PRESSURE LAMP LIGHTS AFTER APPROX 12 SECONDS TRANSISTOR Q6 FAILS TO TURN OFF OVERCRANK LAMP LIGHTS RELAY FAILS TO DISCHARGE CAPACITOR 1 ADJUSTMENTS AND PROCEDURES A CAUTION If starter fails to disengage the engine may drive Starter 0 unsafe speeds that could cause starter rotor windings to separate B REMOVE K11 OR K12 FROM CONTROL BOX PULL STRAIGHT UP CONNECT AN OHMMETER TO TERMINALS MARKED AND B ON BASE OF RELAY RESISTANCE OF 12 VOLT RELAY IS 120 OHMS RESISTANCE OF 24 VOLT RELAY 15 470 OHMS FIGURE 29 TESTING K11 AND K12 RELAYS C When connecting battery cables terminal will spark if connection is reversed 5 ai Unit wil not crank with reversed cables loose connections DC alternator will overheat and will probably burn up A reverse battery connection will show a maximum positive charge on the DC ammeter On dry charged batteries no voltage is present until electrolyte is A D See operators manual for alternator belt tension adjustment Check for voltage from starter terminals to ground Voltage should be present at both terminals when solenoid
41. the gate The resistance should remain at the same low value FIGURE 10 TESTING SCR s 18 SHORT BETWEEN GATE AND ANODE FIGURE 11 TESTING SCR s REPLACING Bee ene Diodes 1 Unsolder leadwires from terminals 2 Use proper size wrenches to hold the body while removing the nut 3 Push the rectifier free of its mounting hole in the heat sink 4 Insert new rectifier into its mounting hole in the heat sink Using nut and washer provided secure rectifier to heat sink 5 Torque the two large diodes on the center heat sink of exciter regulator chassis assembly to 20 25 in Ib 6 Torque the small diode on center heat sink of exciter regulator chassis assembly to 12 15in Ib 7 Torque SCR s on outer heat sinks to 20 25 in Ib 8 On brushless generators torque diodes on rotating exciter assembly to 15 in Ib 9 Solder leadwires to new rectifiers Use a 40 watt soldering iron Hold needlenose pliers between rectifier and soldering point to prevent destructive heating Excessive heat on these components will destroy them SCR s and Redistribution or publication of this document by any means is strictly prohibited 12 ee 27415 LG TESTING GENERATOR ROTOR Testing for Grounds Use an ohmmeter R x 100 scale measure as foilows Brush Type from each slip ring to the rotor shaft Brushless disconnect F1 and F2 roto
42. 0 220 50 Hz H6 5158 115 230V 50 Hz H6 15 120 240 60 Hz H5 TH 5 2 CONNECT LEAD WI2 FROM TERMINAL 7821 63 TO 21 _ VOLTAGE CONNECTIONS PER VOLTAGE CHART BELOW 3 PHASE 127 22 0V 50 Hz H5 120 208 50 Hz H4 5158 110 190V 50 Hz H3 115 200V 50 Hz H4 120 208V 60 Hz H3 127 220 60 Hz H4 158 139 240V 60 Hz H5 254 4 40V 50 Hz H5 240 416 V 50 Hz H4 220 380V 50 Hz H3 230 400V 50 Hz H4 240 416 V 60 Hz H3 254 440V 60 Hz H4 277 480 V 60 Hz H5 10 220 50Hz H6 5158 115 230V 50 Hz H6 I5R 120 240V 60 Hz H5 DIVISION CF STUDERAXIR CORPORATION MODEL NO 25 90KW I5R I 25 90KW 515 i00 180K W I5R 1 NAME CONTROL GEN SET AC 3PH i Lj 612 5301 IN THE DE ENERGIZED 0 __ 16 ___ POSITION 101 125 05 I 1 89 612 5302 EXCITER FIELD WIRING DIAGRAM REAR VIEW PANEL 125456 1111 w12 HOUSING CONTROL BOX 2 ee ES EXCITER EXCITER GENERATOR ARMATURE F T3 Ti 62 VOLTAGE CONNECTION 2 120 240 ALTERNATOR FIELO i 29 T TA T2 T eee n CONTROL BOX INSIDE NX VR21 E mm 2 E io 7 8 9101 lz a J U 4 M by TO VR2I 3 E
43. 1 MARK 5 amp LO OIL PRESS 311 3380524 1 WIRING UNITS 4 1 2 SAFETY ALARM ONLY ON LO ENG 8 oe 112 33641918 1 LEAG ASSY STO EDIT ONLY i G O O FH atia m us SEE NOTE 5 29 4 2 PENN STATE CONTROL T TA BI 2 30103257 1 PANEL ENG CONTROL 9 CBI DYC ONLY 4 2 1 SAFETY SHUTDOWN ALARMS i 63 ON 21 K 3882179 1 SILKSCREEN 1 01 02 03 04 D gt 4 2 2 SAFETY ALARMS ON HI ENG 1 i xL 308 321 on SWITCH SELECTOR 05 08 el 22 eT 27 LT TEMPLO OIL PRESS LO ENG TEMP O sores s JSPRING RELAY HOLDDOWNIKILKTZ d 4 3 PRE ALARM CONTROL n TE ooo 2135 327 3 1 322973 2 928 1 4 3 1 SAFETY PRE ALARMS HI Si 0511 922 F ADDED 7 m zr LE TEMP LO PRESS m A DOn ROSTER a APT i SPECC DEF G 4 3 2 SAFETY SHUTDOWN amp ALARMS 25 6 50 9222 G2 E ALS Ke 8115 DDB 50 9222A No 9882510 01 52 ES aL Fes BTI TEMP 8 LO OIL PRESS 24 F R 9222F T gt U nm 5 KII DE FATADDED GEM CIRCUIT 717128281 4 3 3 SAFETY ALARM ONLY ON LO A DEH ADEG R 92220 Hir DEE 97228 Qn n Dij OF COUR AT O P c UNLESS OTHERWISE ae gt 886 150 82221 LU C 6 UNLESS OTHERWISE NOTED ALL RANKER Vend CONTROLGEN SET ENGI
44. 11 29 Reset fault lamp by switching to stop then back to run Does engine crank Place wire back onto TB11 29 while engine is running Does fault lamp light and engine stop Check overspeed switch and wiring for grounds Jumper from ignition relay K12 terminal B to center terminal of run stop remote switch See Method M in Procedure section Does engine crank Replace engine monitor printed circuit board and remove jumper ITEM TABLE C ENGINE SHUTS DOWN AFTER RUNNING A SHORT TIME ves NO PROCEDURE Does fault lamp light and does plant stop after running about 12 seconds a Does fault lamp light and does plant stop after running about 1 minute Remove wire from terminal TB11 30 Does engine run OK after restarting Engine is either not pumping oil properly or oil pressure sensor is defective Replace wire on TB11 30 and remove wire from TB11 31 Does engine run OK after restarting Engine is either operating over temperature temperature sensor is defective or wire between sensor and terminal block is grounded Jumper K11 terminals 6 9 Does engine run OK E Replace relay K11 or clean contacts 6 9 9 Replace engine monitor Redistribution or publication of this document by any means is strictly prohibited ee B an mm LA Gag o 7 v gt ete
45. 2 45 TOYLNOD 31915 NN3d 22 55384 10 018 4831 9N3 IH 033dSH3AO NO 8 NAOQLnHS 13395 112 71081NO2 015 SNYV IY 8 NAOQLRHS 2 97 O Ops 9 JAYS 02 12 310W3MH 1 5310 VA Ov2 061 281 NO 69 9 29 WH31 01 l 9 SF wt 26 If Ot 62 92 22 92 62 92 62 22 12 HOLIMS 31 IIT oNIA3 90194 9NIA34 T WYVHSVIQ 9NIHIM Nvu9viQ 21v SHOE 01 2150 NAY 4015 310N3H c y Fo 40 1 C 310N NY ayay M3 A 18083 01682209 72 Redistribution or publication of this document by any means is strictly prohibited 11682219 ONILHVIS 90 50 31715 NN3d ee 7 hm 310W38 2 0 20 WUY V 3bd NOILISOd 0321943N3 30 O Ee 86 42226 0 3 1 dz226 8 N3L 0 0 1041802 OLS NINMOHS SIN3NOdWO2 a AWS NO AZIONI 135 N391081NO9 X3 l UNNVEO T1W G3LON ISIMYIHLO 6531819 un vex ym PIO ere OL 1 41 1 3 31220 015 1138 ON3 HO1VH3N39 c3 zs MT PR Q3LNNOW HOLIMS 03345 3 0 576 5 2 D y pu mm zo Eil A Ont EIN 1684 PETIT MR 9N3 07 NO ANO WV T
46. 2S 10 1uv1S 13 18 t 860 8 08 s 3372A3 1081802 2 015 10814023 6642006 ziy CF 99 21415 NH3d 10851503 1 06 200 iY STA 4 015 10815023 3NIOW3 UVOLIINOW 1 6299008 0 2150 9 onud 4 310838 7T 713n4 01093105 1 L AN 5 0 SSvdAg t O 22 62 _______________ 1 TT 22 t D 51 1 55 4 l assy 80181 1011 11 35 013488350 821145 UL ______ tS PAL 5 l 01 49 5384 110 1 is 5 8 110 41528 11 9014 845 80151534 8 UU gt 831 8 01083103 11 9 0 1304 0 100 01083105 1 X 7272222 nrus 1 __ Nisi 01083105 1 2154 HOLVINDIR 1 801 83118 1 Un Notssis 1 1 H31V3H 21912313 3902 1 dois 59014 4 45 8 310W3u 8831 71 734055384 110 3043 1 2 2357 1 83 81113813 11 NOWWOD 597918 80 12 43 5 ONS 1 3106 eee TAZA AWA LIYE Yo 8 MBIA UYI MIIA 3NISN3 010N3105 18318115 S A _ 2 EEJ JilvW3HoS NVHOVIO 9NIBIM 21 902 9 90 50 31415 1 2 fpo rag Pa ee MEME NOILISOd Q3Zi943N3 30 gog E 459 65 40 10
47. 2i 2e 302 0412 P 2 AMMETER AC O 280AMP 23 _ 302 042 gt VOLTMETER AC 0 300V 24 302 022 B 1 METER FREQUENCY M25 302 0466 P METER RUNNING TME __ 303 0170 P 1 RHEOSTAT VOLTAGE ADJ 3 5 288 ____ 0 2 1 000007 eee Tai __ 55 048 1 TRANSFORMER VOLT REF TB2 332 242 8 1 MARKER STRIP cae E CODE vRet 1332 1956 D BOARD ASSY PC VOLTAGE HERREN DRESSER S 2241 REFER UMEN _____ 538 0735 0 WIRING HARNESS wi2 336 1913 1 ASSY _ O c a FERRE ____ 30 3 69 PANEL GEN CONTROL _____ 1130 3158 10 1 CONTROL 1402 0070 A 4 DAMPENER VIBRATION 22 _____ 537 0049 1 5 1508 0001 P 4 GROMMET RUBBER ss _____ 545 002 Al 1 PARTS 451 CONT ______ 98 2169 C SILKSCREEN CONTROL PANEL 2 2 2 45 1 5 111 22 23222958 EIE 20325011 SCHEMATIC DIAGRAM EXCITER x ARMATURE m EXCITER FIELD AUTERNATOR FIELD FOR VR SYSTEM 5 SEE 625 1245 D STATE act cR FENN Onan ae ae t 25 45KW SR IA 77 CONTROL GEN SET ALL COMPONENTS ARE SHOWN BRUSHLESS WIRING DIAGRAM IN THE DE ENERGIZE
48. 302B720 0 100 0 200A 41 A5KW 3028721 1 AMMETER ACO 50 0 300A 46 6O0KW 3028722 1 61410 d x l 3028724 ACO S eee 22 5028718 VOLTMETER AC O 300 0 600 1 62 J AC M23 3028221 METER FREQUENCY 60 Hz 67 t2l 3028256 METER FREQUENCY 5OHz 2 M24 3028466 METER RUNNING TIME ____ 60 3028469 METER RUNNING TIME ___ 50 2 T R2l 3O3PI7O 1 RHEOSTAT VOLTAGE ADJ 35K 254 303P32 1 KNOB RHEOSTAT R22 350 556 REF n NE T S 2l 3088284 1 SWITCH VOLT amp AMMETER 67 i 303 76 l 65 6569 3 696362 G7 c deri 065 219 YOOQOOGOO 21 3150431 TRANSFORMER VOLT REF MARKER STRIP 5457 SPRING RELAY HOLDDOWN K2I i 78 R22 0521 3158384 REACTOR ASSY COMM m wm 91550522 vRel 332019561 1 BOARD 55 VOLTAGE RGLTR ee ae Gees 3380730 WIRING 33641913 _ 30103170 1 30103158 CONTROL BOA _______ 402470 4 DAMPENER VIBRREIQN 337 49 STRAP 8OND 508P 4 GROMMET RUBBER rp BEGEIES SILKSCREEN CONTROL PANET AC L pee _ PARTS LIST AC CONT HOW I x PHASE 11
49. 5 211 5 0 0 338 1H2 N31 3KRY 1930 095 10 iuviS AY 34 45004 _ 10104 PANSY BOM Ua 1 VINNY 015 1091503 1 629002 V 141983 4011 08 1 0612006 015 1041402 3 1981 4011 0 1 693006 uv 1 0011118 4106 1091502 811031 WANSYA HOLIMS 1 ______ G amp S ASSY 80108181510 1 1 1 1 35 011488340 523 1 5 1 6 4831 25 18055384 110 801 2 145 1 _______ 145 8014 5 538 M 110 830N3S py pido 4 0 55 4 0212 9 2 NOI14I32530 1181 4151 Slave 381383 HESSE SURUIPONON vo 20 BOLINOW NN3d _ 0 10 HOLINOW 415 1e OCH W3 9 8 3 782 178 833 31242 015 p D T 22 LX 5 8 19 LSA jez 2 NOILISOd Q32i943N3 30 3H1 NI NMOHS 3HY SIN3NOdHO2 mos 031004 3SIMH3HLIO 5537 v 1138 0 3 YOLVESNZ9 lig oy NI Q3LNnON HOLIMS 033dSH3 O CS lt i8 e 2 _ C s E IVA Ov2 06 65344110 O1 8 4131 4 4 95 1281 NO 598 9N3 IH NO WHY AL343VS 222 9 2 033dSH3A0 8 NO ee E 228 8 NMOOLNHS AL33VS 1 2
50. 5 TESTING EXCITER ARMATURE TESTING STATOR Testing for Grounds Using an ohmmeter x 100 scale measure the insulation resistance between either lead F1 or F2 and the laminations A reading of less than infinity indicates a ground See Figure 16 OHMMETER FIGURE 16 TESTING EXCITER FIELD Testing Winding Resistance Measure coil resistance between leads F1 and F2 with an ohmmeter scale R x 1 Resistance should be 17 82 to 21 780hms at 20 C 68 F See Figure 16A FIGURE 16A TESTING EXCITER FIELD L RECONNECTION Figure 18 shows reconnection possibilities for the UR series generators When reconnecting for a different voltage be sure to also reconnect lead from terminal 63 inside control box to either H3 H4 H5 or H6 See Figures 17 and 18 j L 4 9 s Ki h L i m M v LOCSE WIRE FROM TERMINAL 63 H6 DEPENDING ON VOLTAGE SELECTED FIGURE 17 CONNECTING LEAD FROM TERMINAL 63 Redistribution or publication of this document by any means is strictly prohibited a __ 4 8 aje 347 600 VOLT 5 60 HERTZ NAMEPLATE VOLTAGE CODE 9X 120 240 VOLT 1 PHASE 60 HERTZ NAMEPLATE VOLTAGE CODE 3 T 72 CONNECT LEAD FROM TERMINAL 63
51. 642087 1 LEAD ASSEMBLY TAP SW 25 405882160 11 PANEL REAR HSG ACCESS O2 INJADSED DY DDB Lu 13 75 74 IM ADDED 405552160 4 13 15 74 LI SILKSCREEENED IN SHIPPING AUDEL 10 4 11 K ADDED No 336A2087 5 6 7 H WAS No 307Bl06 5 6 71 J ADDED N2323A81I9 1223 16 77 ADDED 9 307 106 3 16 71 G WAS SOBAION 2441 5 71 Hun ror Sue NOTE D MOVED SW FROM L3 TO 12 T TIH 12 7 22 70 BIWAS 766722 JY 7 22 70 72678 2 12 7 22 70 MODEL NO t 02 DY J amp DDB nan oP MODEL NO ___ __ 3 3 70 me v c wig DEH DEF DDA ww wp UR SERIES HSD SWITCH i20 208V 3 PH 4 W 120 240V 3 W PARTS LIST 625 036 99 F2 FI EXCITER REAR VIEW PANEL WIRING DIAGRA j 3 o HOUSING CONTROL RR dE ee Oe EXCITER ARMATURE TY T CONTROL BOX INSIDE SCHEMATIC DIAGRAM WI2 NOTE CHART BOX TI T2 T3 T4 T6 T7 T8 TIO TH Ti2 NOTE CONNECT LEAD WI2 FROM TERMINAL 21 63 TO TB2l H_ 110 220V 50 Hz H6 5I5R 115 230V 50 Hz H6 ISR 120 240V 60 Hz H5 Li T6 LO T4 T3 L2 TB TS L5 NOTE UNLESS OTHERWISE NOTED ALL COMPONENTS ARE SHOWN
52. 823544 uDISISNYE 1 11261 9 bud ELGENZ 83804 40115 1 8 0 0001 8313401183104 z 6 03 13 90151539 r or 2410 UOL 85482 03113 50151538 z 11 GN EN ote waa Reno 85 0 21 5 1815 01 UXPZ _ 03 13 80151538 oze ose 81 98 UN s 1 _ T _ 8 88482 03114 40151538 1 008428 08 098 Aas 03113 0151538 91 C X 9 12802 2 182814 ___________________ PCOS 110 08 12 E LLL 15 1 4808 Z2 ____ 001 034 2200 93Hl9313id MolDYdv2 4646 2 22 O AN7134 300C714 3811 5080915 2 6 804 vH 104 SnfOY AU01 Y 3N1L 1538 5080935 2 01 801 19 104 ISRIOY 1 76 Quyo8 30 JOVIBAS 0438 91 2 INOW 1937084 LOM 11 5 1 143 04803 ORY SIMID 830105 Z 712 WALI 830105 SNISN 2109 5 71 5532084 981830105 834 830105 71 453108 342 5 6 9 2 2 200 Qzs ASH 2 9 6 014856 Ee wani Lm mere 711 2005 64 69 LI LO L3 120 208V 3d 73 79 009 9 T4 TIO T6 TI2 EQU
53. AD AT TERMINAL 1 2 4 5 9 FAULTY ROTATING DIODE ON BRUSHLESS EXCITER FAULT IN BRUSHLESS EXCITER ROTOR OR STATOR WINDING ITEM TABLE B OUTPUT VOLTAGE BUILDS UP BUT IS UNSTABLE NO ENGINE RUNNING OK Are there any loose or broken wires or connections at VR21 printed circuit board terminals wee wee PA cama Does adjustment of R26 damping control pot on VR21 printed circuit board result in stable generator voltage The trouble is probably caused by a defective component on VR21 voltage regulator printed circuit board REPLACE VR21 PRINTED CIRCUIT BOARD see Figure 4 Y R26 is used brushless generators only TABLE B SYNOPSIS UNSTABLE OUTPUT VOLTAGE BROKEN WIRES OR DEFECTIVE COMPONENT LOOSE CONNECTIONS INCORRECT SETTING VR21 VOLTAGE AT VR21 VOLTAGE OF R26 POT ON VR21 REGULATOR PRINTED REGULATOR PRINTED PRINTED CIRCUIT CIRCUIT BOARD CIRCUIT BOARD BOARD BRUSHLESS ONLY TERMINALS C6 C7 R14 OR R15 OPEN C11 C12 R27 OR R28 OPEN NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of this section Redistribution or publication of this document by any means is strictly prohibited TABLE OUTPUT BUILDS UP IS HIGH LOW ENGINE RUNNING OK i Does adjustment of R21 Voltage Adjust knob on the
54. C EXCITER CIRCUIT BREAKER EXCITER IN BOGOR ODHODE EXCITER FIELD ROTATING EXCITER OVERSPEED SWITCH WITH RECTIFIERS GENERATOR END VIEW GRILLE REMOVED VOLTAGE REGULATOR R21 EXCITATION SCHEMATIC FIGURE 2 ROTATING BRUSHLESS EXCITER DESIGN CHECK THESE DOUBLE LEAD SCR S ACCORDING TO PROCEDURE F mm THESE SINGLE LEAD RECTIFIERS ACCORDING TO PROCEDURE E FIGURE 3 TOP VIEW OF EXCITER REGULATOR CHASSIS ASSEMBLY VR21 VOLTAGE REGULATOR PRINTED CIRCUIT BOARD v eee ee m v e ee mar FIGURE 4 VOLTAGE REGULATOR PRINTED CIRCUIT BOARD LOCATION 6 Redistribution or publication of this document by any means is strictly prohibited VISUAL INSPECTION Before proceeding with the troubleshooting on the following pages a few simple checks can be made which could directly indicate the cause of trouble 1 Always be sure that connection of generator leads is correct Whenever leads are reconnected for a different voltage check the output with an independent voltmeter Do not use the control panel meter since it could indicate that the voltage is correct even if connection is wrong 2 Visually inspect the voltage regulator printed A circuit board assembly VR21 in the control box for burned components broken wires loose connections dust dirt or moisture If dirty clean with a suitable solvent and compressed air 3 Visually inspect th
55. CONTROL BOX INSIDE VR2I EXCITER FIELD frrr TO VR2I L21 VOLTAGE CONNECTION 3PHASE 347 600V GO Hz L3 SCHEMATIC DIAGRAM o G21 DES part wo fwolary EXCITER 111213 CB2i 320 043 B 1 CIRCUIT BREAKER 2AMP CR2 305 0524 c 1 RECTIFIER BRIDGE g CT21 23 302 0775 t TRANSFORMER ASSY CUR 25 35 KW 302 0776 8 TRANSFORMER ASSY CUR 35 55 KW z 302 0777 1 TRANSFORMER ASSY CUR 58 70 _____ 502 0743 1 TRANSFORMER ASSY CUR 71 110 2 ____ 502 0744 1 TRANSFORMER ASSY CUR IM 145KW j302 0778 B 1 TRANSFORMER ASSY CURI 146 180 KW LOCK CHT BRKR HANDLE STATE GENERATOR 320 0307 G2 fe Le 5 5 0584 REACTOR ASSY COMM o SE Met 02 0405 0 50AMP 25 35 KW 302 0406 1 0 75 AMP 36 55 KW 1302 0408 P 0 10 56 70 KW 302 0410 P 0 150 71 0 KW 1302 04 1 AMMETER AC 200 145 302 0412 P 1 250 146 180 KW 13 22 ESI Heg ozone 1 0 750 300V MOVEMENT M23 302 022 1 METER FREQUENCY 240 Me4 1302 0466 P 1 METER RUNNING TIME 2407
56. D 612 5303 POSITION EX IM IPH 0 WIRING DIAGRAM 612 5304 REAR VIEW PANEL sa L2 K 2 24021 FRONT 63 HOUSING CONTROL BOX EXCITER EXCITER GENERATOR ARMATURE T 1 ALTERNATOR 63 FIELD 8 T3 62 9 TO 65 Te 5 1 1 EXCITER FIELD 2111 al VR2 Gi ac 1 t E G2 J 2 ul EN SCHEMATIC DIAGRAM EXCITER 621 ARMATURE 111213 2 2 8 2 3 E fa FOR VR SYSTEM SCHEMATIC 5 11 5 625 1245 0 lt 8 U b 52 1 21 l VOLTAGE CONNECTION 3 PHASE 347 600V L2 LO L3 NOTE UNLESS OTHERWISE NOTED ALL COMPONENTS ARE SHOWN IN THE DE ENERGIZED POSITION 25 90KW 9XR I BRUSHLESS 47 600V 8PH 612 5304 AC CONTROL PARTS UST wo O O ntscmeON 320 04 8 CIRCUIT BREAKER 2AMP _______ cR2i 505 0524 cf 1 RECTIFIER BRIDGE BRIDGE _____ 820 0307 1 LOCK CKY BRKR HANDLE PENN STAT 621 1 GENERATOR Le 35 03884 a 1 REACTOR 557 comm M21 202 0779 8 1 0 750 0 300 INPUT Mee 302 0466 22 303 070 P 1 RHEOSTAT VOLTAGE ADJ 3 5K 25W P KNOB RHEOSTAT T P 08 0012 03 0076 1 SWITCH VOLTMETER SELECTOR NOB
57. ED CIRCUIT BOARD see Figure 4 10 With the circuit breaker on the meter panel in the off position is AC voltage at terminals 62 and 63 on terminal board 21 on the left side of control box 5 to 10 volts mol 11 With the circuit breaker on the meter panel in the off position flash the exciter field 15 AC voltage at terminals 62 and 63 now 5 to 10 volts 16 Redistribution or publication of this document by any means is strictly prohibited 0 fae wma m o PROCEDUHE TABLE A NO OUTPUT VOLTAGE ENGINE RUNNING continued ES Turn circuit breaker on the meter panel to the on position Does AC output voltage build up NOTE If voltage builds up but is high low or unstable or causes circuit breaker to trip refer to table B C or D of this troubleshooting guide Is brushiess exciter stator winding OK Is generator field winding OK With a jumper wire connected across the terminals of the circuit breaker on the meter panel does voltage build up NOTE If voltage does build up the circuit breaker CB21 is defective and MUST BE REPLACED Is L1 commutating reactor mounted on the back side of VR22 exciter regulator chassis assembly OK Check continuity of wires and connections between TB21 terminal 62 on left side of control box and terminal 1 on VR21 printed circuit bo
58. EF RESISTOR 47000 172 WATT 3088284 1 SWITCH VOLT 8 AMMETER 67 30576 KNOB 2 5 64 65696 636505 6 15 9 99 60000 ma S2 7821 33241242 MARKER STRIP Te R22 E TS 33201268 55 VOLTASE RGLTR 41 42 43 TIO ZN VR22 S05D491 REFY 1 CHASSIS ASSY VOLTAGE RGLTR 741 42 43 44 _OFF 4 121 281 31 36 41 42 43 44 25 90 KW I5R 9484 12 16 70 NOTE Bo gt 3 5n 4 1 20 3 15 ALL COMPONENTS ARE SHOWN 46 60 03 09 5 BRUSHLESS WIRING DIAGRAM iN THE DE ENERGIZED 61 100 04 D 1 14 21 28 3t 336AI913 1 ASSY prada C 1 16 21 22 31 35 4 42 44 p oi 30103170 1 PANEL GEN CONTROL 30103158 1 CONTROL BOX CONNECT LEAD WI2 FROM i 1402470 4 DAMPENER VIBRATION TERMINAL 7821 63 TO TB2I H_ 1 337 49 STRAP BOND 5 PER VOLTAGE CHART BELOW LLL sosP 4 GROMMET RUBBER VOLTAGE CONNECTIONS 98Cce169 1 SILKSCREEN CONTROL PANEL AC GENERATOR 3 PHASE 7 A 110 190 50 Hz H3 220 380V 50 Hz 1 545 23 j PARTS LIST AC CONT 115 200V 50 Hz
59. GIS 1553 0131 1 cin i S4INN SSB 1 99Oinstt ___ o 55384 10 018 Le 2197 5 NN3d 41815 85 biy dW3L 9N3 033458 NVH2H3AO 8 5 41018 1 nere bes 221 HT _ NO SWHV1Y 8 NAOQInHS A133VS 171 118 A GEL IEEE ____ 70H1NO2 015 1 19 oT pue usa t eem s a i 3139018 i 435 0026 1181 D S 28 18 58 ela 20 ADE 9 0 14 0009 0112 4 2 024007956 AINO 1081 093 WHV 1V 3Hd NO 03512 vA 052 061 NAOOInHS _ WHV V 3Hd 3554 2 6200799 AINO 1081NO2 OLS NO 8360 2141 1281 NO 9 NMOGLNHS Of 189yH1 93 11 Fi T aser na 1 8 S310N 29 WYJ OL Wuviv 3Hd SLINN mM 5 21 E 223984 it I OF 62 82 48 92 GZ v2 lt 2 22 12 12338803510 1815 880 T 11 TINT avi 3r 7 1104 usui wen D p st sis Ae A 033428180 135 80 92 YNYU2H140 amv coit i0 UW 1 66 eA 9NIA34 9n4 9221 266 65 9 6 N3NNVH2 313 9 1081509 1 2006 SNI1VU3N39 V34NYV9 015 1081102 LS erem TORS O aT od OO 1 HILIAS dmn 31 310W 34 9N 3 1H 2831 1 5s 9 lt 155 TO gla
60. H4 234 400V 50 Hz H4 O 15 230 50 Hz H6 120 208 60 Hz K3 240 416 60 Hz H3 T3 120 240 60 Hz H5 127 220 V 60 Hz H4 254 440V 60 Hz H4 PHASE 74 8 39 240V 60 Hz H5 277 480V 60 Hz H5 115 230V 50 Hz H6 i 4 120 240 60Hz H5 T5 T6 T7 D FIELD gt 7 T8 T9 27 i p A ADDED UI 3 Sz VRE i 55 SUPERSEDES SAME DWG NO DATED 4 1 10 CUORE TT mm rr I GN 12 i 1 101 125 1 05 3PH 50 60 Hz pee TE 1 98 6120417 5 66 HOUSING CONTROL BOX a WIRING DIAGRAM SCHEMATIC DIAGRAM CONTROL BOX INSIDE Tl 7 22 VR 22 2 1 T9 99999 4135205658 0 8 io 4 7 242200644 11 11 SCHEM DIAG 6250987 E W12 NOTE m VOLTAGE ART uu LJ NOTE 2 CONNECT LEAD Wi2 FROM TERMINAL 7821 63 TO 21 1 PER VOLTAGE CHART BELOW m VOLTAGE CONNECTIONS 3 PHASE 220 380V 50 Hz H3 234 400V 50 Hz H4 240 416 V 60 Hz H3 254 440 60 Hz H4 277 480 V 60 Hz 85 110 190v 50 Hz H3 115 200V 50 Hz H4 120 208 60 Hz H3 127 200 V 60 Hz H4 139 240 60 Hz H5 15 230 50 Hz H6 20 240 60 Hz
61. I2V DIESEL STO CONTROL ol DYC R50 9222C WIRING DIAGRAM PRE ALARM amp PENN STATE SPEC 8 6 0 PENN STATE SPEC C D E G 2 WIRE REMOTE DDA DDB DYJ 127 2264 D 2 STARTING 6120 4353 09 3oncers Piper ee ie 2 8 2 7 8 2 11 701 0 303 69 WAS QTY I 7 2 141 2 2 1 70 ADDED RESISTOR N0 350 971 le B Iy we 2 11 70 PADDED NOTE 3_______ _ _ 2 MP 2 01 76 NO 252P5 WAS QTY Ho 342p WAS TY 2 704 WAS 350 483 WE 3 4 70 Hn weg tg o LER 1 21 418 2135 0258 7 89 jo it 12 13 14 3 REMOVED WAS 35GA38 ___ 2 1 70 NER NO CIN Il DAT A ADU am A WAS 350 576 12 8 25111 6 32 NOTES 1 SOLDER PER SOLDERING PROCESS 11 5 8872 USING SOLDER ITEM 23 2 SOLDER JOINTS AND OR COMPONENT LEADS SHALL NNT PROJECT WORE THAN 3 16 BEYOND SURFACE OF BOARD 3 FACTORY ADJUST POTENTIOWETER RID FOR 12 5 2 5 SECONDS DELAY D FACTORY ADJUST POTENTIOMETER R4 FOR 75 10 SECONDS QVERCRAMK DELAY 12229095 C ____ 25 30128 111 nesisron 201 110241 9842160 1 SILKSCREEN PC 80 ENG FUEL SOL OR _________ 23 880 12 102 50 8 980 IGN RELAY 7 RiS RI6 22 350 540 2 Resistor 2 2K ha GES 2434 21 350 529 RESISTOR 2700 posf fa RESISTOR 10 REN Poros
62. IVALENT CIRCUIT T5 TH L2 LI LM TS LO L3 20 240 1 2 21 1 5 REMOVE JUMPER 12 BETWEEN TB21 C3 amp 821 3 MOUNT VOLTAGE SELECTOR RELAY 5 5 IN CONTROL BOX AND WIRE AS SHOWN RELAY WILL ENERGIZE OW 120 298v 38 CIRCUIT COMPLETING CONNECTION BETWEEN TB21 63 amp TB21 H3 RELAY WILL REMAIN DE ENERGIZED ON 120 240 18 CIRCUIT COMPLETING CONNECTION BETWEEN 21 03 amp TB21 H5 625 1036 09 33641920 1 LEAD ASSEMBLY TAP Swi Cd 4 33683821 1 LEAD ASSEMBLY TAP SW __5 1 3013283 1 CONTROL BOX TAP SWITCH B 812 153 4 SCREW RHSM 1 4 20 1 LG 1 850 40 4 WASHER LK 8 526 52 4 WASHER FLAT 8 526 54 4 VWASMER CLAT 10 30183284 1 COVER TAP SW CONT BOX 1 11 40581840 1 PANEL REAR HSS ACCESS OI 12 508 9 1 GROMMET RUBBER 13 813 97 B SCREW RHSM 10 32 5 16 LGC 14 850 30 8 WASHER LK 5 O 19 50881115 2 GROMMET RUBBER 17 526 22 110 WASRER FLAT 18 1 850 45 5 WASHERK __ 18 862 15 __ 5 ________________ DI 20 3882247 1 SILKSCREEN TAP SW SILKSCREENED IN SAPW 21 898 867 68 SLEEVING INSULATION 22 323188 1 SOCKET ASSY Ss CC 23 30781143 1 RELAY VOLTAGE SELECTOR _ 9 24 33
63. MEE LN INNER KE QNNM CCCAMEN C UC MIN GCNN s circuit breaker on the meter panel in the position 2 Switch circuit breaker to the on position Does AC voltage build up NOTE voltage builds up but is high low or unstable or causes the circuit breaker on the meter panel to trip refer to Table B C or D of the troubleshooting guide Is AC voltage at terminals 1 and 2 on VR21 voltage regulator printed circuit board and at terminals 9 and 10 on VR22 exciter regulator chassis assembly 5 to 10 volts Check continuity of wires and connections between terminal 1 on VR21 printed circuit board and terminal 9 on VR22 chassis assembly and between terminal 2 on VR21 printed circuit board and terminal 10 on VR22 chassis assembly 15 there continuity between these connections 24 Check for broken wires and loose connections on VR22 exciter regulator chassis assembly Replace or repair any that are defective and clean all dust dirt and other foreign material from the assembly Does AC voltage now build up Is DC voltage at terminals 4 and 5 on 22 exciter regulator chassis assembly 5 to 10 volts Are diodes CH1 CR2 and CR3 on VR22 exciter regulator chassis assembly OK Are SCR s Q4 and Q5 on VR22 exciter regulator chassis assembly OK The trouble is probably caused by a defective component on the voltage regulator printed circuit board REPLACE VR21 PRINT
64. MP _________ 1 1 mec LIUM TCH DVERSPEED 2 055 5 u EE SWITCH LOW WATER TEMP sENERATING 3 14 c LL dur 011 PRESS 15 3 WITCH HIGH WATER TEMP PA 6 1A SNC LL REMOTE a SWITCH fo 0 5 3000714 CONTROL CYCLE CRANKER _________ CYCLE CRANKER 5 or ESEVvICI9 0514 3224108 1 LAMP LOY OIL PRESS 0515 32241098 1 ENG oste 2224110 LANP LD ENG TEMP RELAY START DISCONNECT 30781058 RELAY IGNITION A 21 22 23 24 25 26 27 28 29 30 3 32 33 34 35 36 K13 30781031 1 RECAY START SOLENOID 1 222222 114 23 Ki4 30781061 RELAY STARTER PROTECTION Mii 1938107 1 GAUCE OTL PRESSURE rg 1938106 11 T 0075 NITICRRERCARMOR oo 5 MEP NOTES 1 19 AMNETER CHARGE 30 0 30 SHUTDOWN __ 865 ON TB2I 1 WI2 USED ON STO CONTROL ONLY 511 382 11 SWITCH PANEL LIGHT PREAL ARN 190 240 VAC 2 USED PRE ALARM CONTROL ONLY aj THE NM IE 4L Vd 3 REMOTE ALARM CIRCUIT RATED SAMP 12 11 TERMINAL BLOCK 33281241 1 MARKER STRIP s 4 SHUTDOWN amp ALARMS TBi2 3324531 RtF 1 TERMINAL 41 STD CONTROL 33211238 MARKER STRIP 4 1 1 SAFETY SHUTDOWN 8 ALARMS O 1813 3324699REF 1 TERMINAL BLOCK _ STANDARD 8 OVERCRANK OVERSPEED HI ENG TEMP 332A1240
65. NOT SENSITIVE TO FREQUENCY 2 ALL PART NUMBERS AND VALUES AAE REFERENCE ONLY D ALL RESISTOPS 1 2 BATT EXCEPT WHERE NOTED 4 ALL CIPACILICR RATING Ix MICROFARADS lee eS ES E T 3 FOR AND RATING OF SEMI CORDUCTOPS SEE Ix2IvIOBAL ASSEMBLY MATERIAL 11515 6 RESISTANCE 2000 OMES CR3 jT 8053 TBI 3 000 MR 1 81111 101511 8 TMEMALBK 111 30 031190 MIG 143213 LIVE 1 1 58013137 190 TINTA TEPORE 1314 1111 13319344 OL 241108238 LON 31 11 12 23 01 0312300002 i 11 891 34111703 117812 33383339 33 110A 903 13 01 18 31 MOLINO SILON N39 9 10466 ASSY SNIONI A 211 um 91 by any means is strictly prohibited Redistribution or publication of this document ONILYWLS 310839 Z MYU5YIO 21 058 2441 go K353HTA21 9N3 135 N3971081NOO pevu MOS USO US3XANVUS H3XNYUS KIM 3UOSN H30 31242 91 08 H 33Q 78 8 24Q 21 01 5 9308 HJG 44 430 08 0 AJ 00 V aC 21 4 1 9 13 0 5 5345 0140 12 04 840 03207 0 048 00 a 161184206 _ 03007 3 VI 8
66. S e o 9 4 JLONAY 2181 22 i eu Ol 9nd or E 8 217 MIA 108 E E e Y 6 of tol 1 1 1 199 59 MT 96 29116 21 9 e 8 HY3u MIIA LNOHNJ 9 M WvVH9VIO Oset 2219 98 by any means is strictly prohibited Redistribution or publication of this document 64 2 9 CONTROL BOX LO ENG 3000881 ROHI TOR ENGINE CONTROL 6 o n ENGINE PARTS UST REF O 5 O 612C 4353 MIRME DIAGRAM SCHEMATIC DIAGRAM meee ore STARTER 5 SOLENOID ENGINE FRONT VIEW REAR VIEW oo 5 BTl 11 12 ALM NOTE 3 SND REEL 7 mI 8 ALARM PR 2 1 81 SENDER WATER DYA 17 KE A SENDER WATER TERP DEF DEH DEC i PUMP 1 5 6 08 8 08 FUEL PUMP 8 60 MA d 0639 ALTERNATOR amp REGULATOR o REMOTE 2 6 510856 ANNUNCIATOR 3 AOD CIE 35 SOLENOID TBI3 m 53 051213 552 3 ae 3i 275 kn OW Oh PRESS Qs ES O SEE nx d E 41 ENG TEMP 9 SEE 5 SWITCH LOW OIL PRESSURE lt 5 NOTE 2 icd G ENG TEMP 4 10 A sji 0514 52 HSUIGENIGEYATER TE
67. S 86 _ 24 GN Vn WOU AMIS 15 0169 446 E TW YW 38d 55384 FIO NOT FOIS 1 E UE BL ag sme 71 87 yo 69 1 dz il aie PCS HINGIS eig PISO on ie 0332Su3A0 1 4 9 1 a 25 _ 25 4 2 310N bisa 4 1 91301 0 wos Pet 39 5 dN31 IH 8 CP Let 9 mones 11 19 67 3108 335 re o tW 85384 10 01083105 wm ce o 2150 9 431A 108 Jp 2 M3IA 108 XNVU2H3AO COBRE um NO MOONS OS Ee 7 5 5025 5 i i SWHSWOHOS OS 1 E O Osga pd 8616 11018 Y WOIYMH W 2 19 2 d MW CB nel 1303 010 3108 1 YI 8 3815 9 Dair Oa pT AS G t3 lt HA 2154 310039 dN31 831 9 810835 1 9 21 STS Ou 415 ssvdAg wollovdvo 1 23 3h18 1 ONSN 310N Ww 4 wa 9 iy Do 6 MBIA 2534 530 43 50 1191 158 51 14 SivWsuos 1 11649219 13 14 ONILYVLS eee ee ee 4 31038 vo 20
68. TO H5 CONNECT LEAD FROM TERMINAL 63 TO H5 THIS DIAGRAM APPLIES TO 12 LEAD GENERATORS ONLY GENERATOR CONNECTION GENERATOR CONNECTION WIRING DIAGRAM SCHEMATIC WiTH CURRENT TRANSFORMERS WHEN USED DIAGRAM 10 1 T1 T2 16 11 18112714 19 5 7 110 DOUBLE DELTA s T TIO T6 177 12 TM TA T8 13 112 T5 79 10 1 T6 Tl m 17 T2 T8 T3 T9 T5 TIO 2 12 PARALLEL WYE _ SERIES DELTA LO L1 TIO TH TI2 T7 14 T2 T8 TS SERIES WYE 98C2193 FIGURE 18 RECONNECTION DIAGRAM 22 Redistribution or publication of this document by any means is strictly prohibited om nsa ee sm es 194 44 9 M SENSITIVITY REFERENCE CIRCUIT UR series voltage regulators VR21 can be set to either frequency sensitive or non frequency sensitive reference With a frequency sensitive reference the output voltage of the generator will decrease in proportion to the frequency i e prime mover speed This decrease in output voltage will reduce the load on the prime mover permitting it to return to rated voltage and frequency when overload is removed A temporary overload with a non frequency sensitive reference could cause a prime mover to reduce speed then would require a further 5096 to 6096 load reduction to allow it to return to rated speed This reference change is acc
69. V AL33VS y 7 9 m Tp 2 o3ddv LUN ands vz o pg 33344 10 LE s und E 8 9N3 H 033dSU3AO XNYU2H3AO NO OF 9 11 92 27 LEAR 8 RMOGINHS 134 5 257 a oe 55344 110 018 dW31 5 p EL NARA a ONI NO SWHYTV 3ud 113495 iu 23 Bn JONLNOD WHVV 3Hd Led pe E 0 v 440131 983018 55344 710 018131 T Hl lto 42 80 a BEEN Sa ETE 2 o ig 9 gi NO SWBV1V ALl33VS 27279 1 lz Sot 5 s 1 18 I 80 80 28 ux I noe 88 190000991 SWUWIV NMOGINHS 313345 270 308180 881 13888 1 18253108 A au 29 W831 OL Les V Pet OYLNOD 31915 NN3d 27 9 6z SALON 1081 02 981 128 1 eczeme 6 Pg 5L moe 1 i NUS 91 NO AINO A134VS 27 OTE NN C v opum a 2 LLLLLLLSSIMBYH i 190108 1 O JO 3115 NW3d LLL snis WWW Om 21 dW31 ONS IH O334SH3AO XNVH2H3AO 8 08 0 15 2 0 8 1 338 59 2 181 NO SWYV1Y 8 00 0 5 A133VS 11 mm Po HAS HVA ____ m 10841802 015 5 IE Lu iNimii 1 Kd3u LEGYZLE 2181 9 SWYV1 8 NMOOLNHS p 45 ____________ 44914 660 266 3 e ps oa erro 32018
70. WAS SSGASS _ 2 70 ov 916 c5 6 05 70 DIITEM WAS 307410 2 CP 1 10 70 WAS amp NOTES ITEN 23 gt 5 1 70 SOLDER PER SOLDERING PROCESS 11 5 6872 USING SOLDER SOLOER JOINTS ANU OR COMPONENT LEADS SHALL HOT PROJECT MORE THAN 3 16 3tYOND SURFACE OF BOARD t SET R4 FOR OVERCRANK TIME DELAY OF 7555 SECONDS LOW PRESS TIME DELAY SHOULD BE 12 5 2 5 SECONDS mo 29 i POTENTIOMETER LONEG OUM 28 amp YRAMSISYOR FLD EFFECT A ee MH HERE dE wa 089200t 9007 ___ 350 90 1 RESISTOR SIM 2 w L 25 350 380 1 RESISTOR SIM Bw 24 482245 1 SILKSCREER PC BO ENG 85 12 102 sorer 77 22 350 544 2 503 14 21 350 5298 2 20 oo 18 21 stats __ 1 25 ____ 350 572 resistan 3 5 HM IQ 14 350 534 11 f RESISTOR sen 9 Nar __ 13 350 536 _ 2 77 quat 12 382497 2 TRANSISTOR SILICON PWP 285566 E 11 3605 2 TRANSISTOR FLO EFFECT Qo 10 3613 2 TRANSISTOR 3j TO FAULT ers asaz
71. YO 100 0 DYD Penn DYD 95 0 WA 115 0 WA 100 0 DYD 125 0 DYD Penn DYD 115 0 WE 140 0 WE 125 0 WE 150 0 WE 125 0 DYG 150 0 DYG Penn DYG 130 0 DFE 155 0 DFE Penn DFE 140 0 WB 170 0 WB 145 0 DYG 175 0 DYG Penn DYG 150 0 DFE 180 0 DFE Penn DFE Section 1 Section 2 Spec A Begin Thru Spec coovom Ccoocccoocgommaooodomtaocommododo C R P Q D B C A B H G C A B B B B B C A B DraczA 2 Tt OOO FR 2 2 roo Redistribution or publication of this document by any means Is strictly prohibited UR GENERATOR VOLTAGE CURRENT OPTIONS 1 PHASE STANDARD 1 PHASE SPECIAL B125 TEHASE 9 4 HERTZ Code 515 xw wa 50 RATING b P 24 46 1286 156 234 O 50 Hz only 50 and 60 Hz 2 60 Hz only 4 Not Reconnectible GENERATOR SECTION I GENERAL There are two generator designs used on the UR series They are basically the same except for the method of field excitation The Static Exciter brush type design uses a brush rig and collector rings for field excitation This design was used on some of the earlier models within the range of 25 KW 90 KW The Brushless design uses a rotating rectifier exciter assembly in place of the brush rig for field excitation The brushless design is standard on all models from 25 KW 175 KW Unless otherwise specified the
72. ard Also check between TB21 terminal 63 on the left side of control box and terminal 2 on VR21 printed circuit board Are rotating diodes CR1 CR2 CR3 CR4 CR5 and CR6 on brushless exciter rotor OK Is brushless exciter rotor winding OK Are generator stator windings OK Redistribution or publication of this document by any means is strictly prohibited 01 21 CIRCUIT BREAKER ON METER PANEL IN WORN BRUSHES OR LOOSE BRUSH RIG 5 x wk POSITION RESET DEFECTIVE CIRCUIT BREAKER ON METER PANEL TABLE A SYNOPSIS NO VOLTAGE LOSS OF RESIDUAL VOLTAGE FLASH NO AC FIELD NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of this section Check SCR s 04 and 05 on VR22 voltage regulator chassis assembly and replace if defective before repairing or replacing VR21 voltage regulator printed circuit board Static excited generators only BUILD UP FAULT IN GENERATOR FIELD WINDING DEFECTIVE COMPONENT ON REGULATOR PC BOARD VR21 BUILD UP RELAY K1 OPEN CR8 OR 9 OPEN R1 R2 OR R3 OPEN OPEN LEAD AT REGULATOR PC BOARD TERMINALS 1 2 DEFECTIVE ON VOLTAGE REGULATOR CHASSIS ASSEMBLY VR22 Q4 OR Q5 OPEN DEFECTIVE DIODE CR1 CR2 OR CR3 OPEN LE
73. arly 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 EXHAUST GAS IS DEADLY Exhaust gases contain carbon monoxide a poisonous gas that might cause unconsciousness and death It is an odorless and colorless gas formed during combustion of hydrocarbon fuels Symptoms of carbon monoxide poisoning are e Dizziness e Headache e Weakness and Sleepiness e Vomiting e Muscular Twitching e Throbbing in Temples If you experience of these symptoms get out into fresh air immediately shut down the unit and do not use until it has been inspected The best protection against carbon monoxide inhalation is proper installation and regular frequent visual and audible inspections of the complete exhaust system If you notice a change in the sound orappearance of exhaust system shut the unit down immediately and have it inspected and repaired at once by a competent mechanic Redistribution or publication of this document by any means is strictly prohib
74. e engine monitor printed circuit board Remove lead from TB11 29 Reset by switching to stop then back to run Does engine crank when switched to run EH 29 CJ NO Replace the lead to 11 29 when engine is running Does overspeed lamp light and engine stop C2 NO Check for defective overspeed switch or bare wires grounding terminal TB11 29 Stop and start engine several times Works OK 34 Replace engine monitor printed circuit board 34 C2 NOTE On EK EM and EN series start solenoid is mounted on the engine rather than the control and is designated K6 41 Redistribution or publication of this document by any means is strictly prohibited ae TABLE G ENGINE SHUTS DOWN AFTER RUNNING A SHORT TIME m 9 PROCEDURE Does low oil pressure lamp light and plant stop after running about 12 seconds 2 Does overcrank lamp light and plant stop after running about 1 minute a am ar Remove wire from terminal 11 30 Reset alarm by switching to stop then back to run Does engine run OK Replace wire after test Engine is either not pumping oil properly or oil pressure sensor is defective Does relay K11 pick up after engine starts Jumper relay K11 contacts 6 9 after engine starts Remove jumper after test Does engine continue to run OK Replace relay K11 Replace engine monitor pr
75. e exciter regulator chassis assembly VR22 for burned components broken wires loose connections 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 4 Large banks of SCR Silicon Controlled Rectifier regulated loads can cause the generator voltage to increase as load is applied If such loads exist and the voltage increased more than 5 or 10 consult the factory an additional filter is available for the regulator circuit to correct the situation THE QUESTION AND ANSWER TROUBLESHOOTING GUIDES BEGINNING ON PAGE 8 GIVE A STEP BY STEP PROCEDURE FOR CHECKING THE GENERATOR THE FLOW CHART TROUBLESHOOTING GUIDES ARE GIVEN AS A GENERAL GUIDE TO RESOLVE VARIOUS GENERATOR PROBLEMS ALL CHARTS REFER TO PROCEDURES SHOWN AT THE END OF THIS SECTION PRIOR TO ANY TROUBLESHOOTING CHECK ALL MODIFICATIONS REPAIRS REPLACEMENTS ETC PERFORMED SINCE LAST SATISFAC TORY OPERATION OF SET Redistribution or publication of this document by any means is strictly prohibited QUESTION ANSWER TROUBLESHOOTING GUIDE To correct a particular problem answer the question either yes or then proceed to the next step given in whichever column question was answered Procedures A thru P follow the troubleshooting guide ITEM TABLE A NO OUTPUT VOLTAGE ENGINE RUNNING ves wo PROCEDURE le a a EMEN
76. er the questions either yes or no then proceed to the next step given in whichever column is indicated When using block diagrams a letter with a triangle indicates a procedure in Generator Section 1 Aletter within a diamond indicates a procedure in Generator Section 11 Redistribution or publication of this document by any means is strictly prohibited QUESTION AND ANSWER TROUBLESHOOTING GUIDES To correct a particular problem answer the question either yes or no then proceed to the next step given in whichever column question was answered Procedures R thru P follow the troubleshooting guide TABLE F NO AC OUTPUT VOLTAGE ENGINE RUNNING AT RATED RPM PROCEDURE 210 11 12 Replace reactor assembly 1 21 Is Exciter Circuit Breaker CB21 on the meter panel in the ON position owitch CB21 to position Does AC voltage build NOTE If voltage builds up but is high low or unstable or causes 21 to trip refer to table G H or of troubleshooting guide Is AC voltage measured at terminals 1 and 2 on voltage regulator VR21 printed circuit board 5 to 10 volts Is AC voltage measured at terminals 11 and 12 on VR21 5 to 10 volts Y A Is DC voltage measured at terminals and on Rectifier Bridge CR21 5 to 10 volts Shut down generator set Check continuity through 121 coils between terminal 2 on VR21 and
77. ges of up to 5 percent will occur if unbalanced loads are applied to the generator terminals TABLE E SYNOPSIS UNBALANCED TERMINAL VOLTAGES INCORRECT RECONNECTION INCORRECT GROUNDING OR GROUNDING OF OF LOAD OR GROUND GENERATOR LEADS FAULT IN LOAD FAULTY GENERATOR STATOR WINDING NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of this section 14 Redistribution or publication of this document by any means is strictly prohibited TABLE E SYNOPSIS VOLTAGE 150 OR MORE THAN RATED OPEN WIRE OR CONNECTION AT VOLTAGE REGULATOR CHASSIS ASSEMBLY VR22 TERMINALS 4 5 OR 6 DEFECTIVE COMPONENT DEFECTIVE COMPONENT ON VOLTAGE ON VOLTAGE REGULATOR CHASSIS REGULATOR PRINTED ASSEMBLY VR22 CIRCUIT BOARD VR21 OPEN TRANSFORMER T21 WINDING OPEN WIRE OR CONNECTION AT PRINTED CIRCUIT BOARD VR21 TERMINALS 5 6 9 10 11 OR 12 CYCLING BUILD UP OPEN LEAD AT VR21 PRINTED CIRCUIT BOARD TERMINALS 1 2 5 7 OR8 OPEN IN R21 DEFECTIVE COMPONENT VOLTAGE ADJUST POT ON VR21 PRINTED ON METER PANEL CIRCUIT BOARD OPEN IN R18 VOLTAGE ADJUST POT ON VR21 PRINTED CIRCUIT BOARD NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of this section Generator voitage builds up then collapses builds up etc Redi
78. inted circuit board Hu Does charge ammeter show a charging current while running Does battery voltage appear across K11 coil terminal A B when engine runs Check for an open circuit in wiring or a loose connection from alternator AUX terminal to K11 coil circuit pews Check alternator and regulator output replace if necessary TABLE SYNOPSIS ENGINE SHUTS DOWN OVERSPEED LOW OIL PRESSURE LOW OIL PRESSURE SENSOR CLOSED HIGH ENGINE OVERCRANK TEMPERATURE START DISCON NECT RELAY K11 6 9 FAILS TO CLOSE HIGH ENGINE TEMPERATURE SENSOR CLOSED OVERSPEED SWITCH CLOSED A 11 ENGINE MONITOR PRINTED CIRCUIT BOARD FAILS DEFECTIVE NO ALTERNATOR OUTPUT REGULATOR 48 Redistribution or publication of this document by any means is strictly prohibited 67 SINGLE LAMP ENGINE MONITOR FAULT FAULT LAMP LAMP LIGHTS AS LIGHTS AND SOON AS ENGINE EXTERNAL ALARM FAILS ON ENGINE FAILS TO CRANK ALARM RUN SWITCH SHUTDOWN SHUTS DOWN CLOSED CIRCUIT PATH 9 7 ON A 11 PRINTED CIRCUIT BOARD IS OPEN LOW OIL PRESSURE TRANSISTOR OR HIGH Q7 FAILED ENG TEMP SHORT CIRCUIT EMITTER TO FAILS AFTER COLLECTOR APPROX 12 SECONDS K1 RELAY CONTACT FAILS TO CLOSE ON SHUTDOWN CHECK R10 DIODE POTENTIO CAPACITOR SCR cns CIRCUIT C2 PATH 9 8 SHORTED Aa
79. is energized for cranking 91 F inspect contacts for dirt particles obstructions or insulating film Clean using low pressure com pressed air and bond paper Check relay socket G Contacts are normally closed when engine is not running Contacts must open when engine is running Contacts normally open contacts close for alarm condition only Overspeed switch may have to be reset manually 141 Contacts welded closed or plunger be stuck Remove solenoid from circuit to test for proper K inspect printed circuit board paths that supply voltage to relay K12 Between terminals 18 19 of 300 0681 between terminals 7 9 of 300 0679 L Remove cycle cranker printed circuit board and jumper terminal 2 3 to by pass cycle cranker circuit M In an extreme emergency engine may be operated without any safeties by removing engine monitor printed circuit board and jumping terminals 7 9 It may be easier to jump from center contact of Run Stop switch to terminal B on K12 relay see Figure 30 Redistribution or publication of this document by any means is strictly prohibited RUN STOP REMOTE SWITCH FIGURE 30 EMERGENCY STARTING ADJUSTING LOW OIL PRESSURE TIME DELAY ON ENGINE MONITOR PRINTED CIRCUIT BOARD Units With Single Fault Lamp Potentiometer R10 on A 11 printed circuit board is factory adjusted for 12 1 2 seconds 2 1 2 seconds T
80. ited GENERATORS AND CONTROLS 25 kW 180 kW TABLE OF CONTENTS PAGE Introduction REED TUE 2 Generator Section L 42 tent PENES EY e qur is 5 Question and Answer Troubleshooting Guides 8 Adjustments and Procedures TM aded us 16 Generator Section 1l 26 Question and Answer Troubleshooting Guides 27 Adjustments and Procedures EE 35 Index of Generator Adjustments and 5 38 Control Section 39 Question and Answer Troubleshooting Guides due ioe Nam Ce 40 Adjustments and 51 Wiring DIagrams uve CARNE RS 53 ONAN RECOMMENDS THAT ALL SERVICE INCLUDING INSTALLATION OF REPLACEMENT PARTS BE PERFORMED BY QUALIFIED PERSONNEL Redistribution or publication of this document by any means is strictly prohibited INTRODUCTION FOREWORD This manual provides troubleshooting and repair information for ONAN series UR generators It is intended to provide the maintenance technician serviceman or Onan distributor with a logical procedure to enable him to systematically locate and repair malfunctions in the generator and control systems This information is not applicable to the pri
81. le Eccc 5 2 my E H EOS cine ill Tb T Spr a 58 ES Heo ped o TE 5 2 z 2 2 Ce C lt 0 2 211 e M 25 62 Redistribution or publication of this document by any means is strictly prohibited wavv aua T 401 T TT as T at imk Lon om rae NUVI GAZI MS NOI Ter 00908448 01 P T 1 ANIU J 1303 AJIA 5080335 62 amp 1 36 010085 1 130 3811 55384 310 v 50402355764 10 4Y130 3811 3HYU2U3AO HY 503 28 135 m 04104 10 37930015 080138 9 3408 1231044 LOM 31185 50133 11504803 40 ONY 30105 SE 311 30105 98150 1134 5 113 55320 4 5991030105 34 830105 5310 2890 006 by any means is strictly prohibited Redistribution or publication of this document 63 12006 110 saias an DIXI ITE 31242 1081N0 s ez pe ER ana scene Upan wy 23 wo war gay 10003 ar TWO 311410819113 401121442 i v i 0 c n2 E win t mus v 15 8015158 1 2 5 2 10 60
82. me mover refer to the engine manufacturer s manual Repair information is not extensive because the plug in solid state printed circuit modules lend themselves more to replacement than repair ONAN does not tecommend repair of the printed circuit module except at the factory and has initiated a return ex change service obtainable through distributors whereby faulty modules can be returned and ex changed for good units For more information con tact your distributor or the ONAN service department CAUTION Application of meters or high heat soldering irons to modules by other ihan qualified personnel can result in unnecessary and expensive damage This rnanual is arranged as follows i GENERATOR Section contains general specifications on the UR generator troubleshooting guides and procedures for testing and repairing of the early UR generator with VR22 exciter regulator and general informa GENERATOR FAILS SEE GENERATOR SECTION I OR II GENERATING SET MALFUNCTION Y M tion on later UR generator Section contains troubleshooting information for the later model UR generator where the exciter diode rectifier assembly has been relocated into the panel Refer to Table 1 for a description of th appropriate section for your generator 2 CONTROLS Section 111 contains troubleshooting guides and procedures jor testing and repairing the system controls 2 descripti
83. n crank time turn potentiometer R4 clockwise to shorten crank time turn coun terclockwise To lengthen rest time turn poten tiometer R1 clockwise to shorten turn coun terclockwise See Figure 33 A12 CYCLE CRANKER 300C714 12V 300C715 24V 222200 8 2 gt 0 XD lt gt 40 4 3 ALL AL R4 CRANK TIME 12222562 FACTORY SET 15 SECONDS TO INCREASE TURN CLOCKWISE r R1 REST TIME FACTORY SET AT 10 SECONDS TO INCREASE TURN CLOCKWISE 1 FIGURE 33 OPTIONAL CYCLE CRANKER ADJUSTMENTS Redistribution or publication of this document by any means is strictly prohibited 612 4173 612 3919 625 1007 625 0987 612 4350 612 4353 300 0679 300 0680 300 0681 300 0682 300 0714 625 1036 612 5300 612 5301 612 5302 612 5303 612 5304 612 5305 612 5310 612 5311 612 5312 612 5313 WIRING DIAGRAMS PAGE 100 175 kW Brushless 54 30 90 kW Static Exciter 55 VR21 Brushless Exciter 56 VR21 Static Exciter tle eset 57 30 50 kW Controls Single Light 58 30 90 kW Controls Five 59 Engine Control Monitor 12 60 Engine Control Monitor 24
84. ns is strictly prohibited FAILS TO Continued ANK WHEN SWITCHED TO RUN YES PROCEDURE Is voltage from ground to coil terminal of K13 start solenoid equal to battery voltage NO 6 Jumper from K13 coil terminal to K11 terminal 1 Does relay K13 pick up Replace cycle cranker printed circuit board A12 Replace start solenoid 13 Is voltage from ground to starter coi terminal equal to battery voltage Replace starter Check thermal breaker CB1 and wiring to starter NOTE On EM and EN series start solenoid is mounted on engine rather than in the control and is designated K6 TABLE A SYNOPSIS ENGINE FAILS TO CRANK A 11 ENGINE A12 CYCLE LOOSE OR IGNITION START MONITOR CRANKER REVERSED RELAY K12 SOLENOID PRINTED FAILS BATTERY FAILS FAILS CIRCUIT BOARD CONNECTION FAILS K1 RELAY CONTACT FAILS TO CLOSE K12 COIL SOLENOID OPEN COIL OPEN K12 CONTACT SOLENOID PRINTED CIRCUIT PATH OPEN 4 7 FAILS CONTACT FAILS TO CLOSE TO CLOSE 41 Redistribution or publication of this document by any means is strictly prohibited ITEM TABLE B ENGINE SHUTS DOWN IMMEDIATELY AFTER START Is overspeed switch S3 closed Open overspeed switch then reset fault lamp by switching to stop then back to run Does engine crank and run OK PROCEDURE z m iz 9 JE l Remove wire from TB
85. o lengthen delay use a screwdriver and turn potentiometer clockwise To shorten delay turn potentiometer coun terclockwise Refer to Figure 31 Units With Five Fault Lamps Potentiometer 15 A 11 printed circuit board is factory adjusted for 12 1 2 seconds 2 1 2 seconds To lengthen delay use screwdriver and turn clockwise to shorten delay turn counterclockwise See Figure 32 ADJUSTING OVERCRANK TIME DELAY ON ENGINE MONITOR PRINTED CIRCUIT BOARD Units With Single Fault Lamp Potentiometer R4 11 printed circuit board is factory adjusted for 75 seconds 5 seconds To increase delay use a screwdriver and turn R4 clockwise to shorten delay turn counterclockwise See Figure 31 R4 OVERCRANK DELAY FACTORY SET AT 75 SECOND OIL PRESSURE DELAY FACTORY SET AT 12 SECONDS FIGURE 31 ADJUSTING TIME DELAYS ON SINGLE LAMP ENGINE MONITOR Units With Five Fault Lamps Potentiometer R2 on A 11 printed circuit board is factory adjusted for 75 seconds 5 seconds To lengthen delay use screwdriver and turn R2 clockwise to shorten delay turn counterclockwise See Figure 32 R15 OIL PRESSURE DELAY FACTORY SET AT 12 SECONDS R2 OVERCRANK DELAY FACTORY SET AT 75 SECONDS FIGURE 32 ADJUSTING TIME DELAYS ON FIVE LAMP ENGINE MONITOR ADJUSTING OPTIONAL CYCLE CRANKER The optional cycle is factory 15 seconds crank time and 10 seconds rest time To lengthe
86. omplished by soldering wire W1 to terminal E1 for frequency sensitivity or to terminal E2 for non frequency sensitive reference 5 Figure 19 Unless requested otherwise by purchaser Onan sets are con nected at the factory to a frequency sensitive reference TOP SIDE OF Ed P V 3 5 I 5 a 2 4 5 1 REGULATOR WHEN MOUNTED UNSOLDER THIS WIRE FROM E AND CONNECT TO E2 FOR A NON FREQUENCY SENSITIVE MEI f co NEP VOLTAGE REFERENCE th CIRCUIT My CY x 1 1 Ge f 1 P a 3 i Cyr E aS 7 de 265 E B 3 7 rj FIGURE 19 VR21 PRINTED CIRCUIT BOARD 23 Redistribution or publication of this document by any means is strictly prohibited N GENERATOR DISASSEMBLY If generator testing determines that gener tor needs repair remove and disassemble according to Figure 20 and the following instructions 1 Disconnect and remove load wires 4 Disconnect leadwires from the control box Check wire markings for legibility to ease assembly Arrange leads so they can be withdrawn easily from the control box 3 Remove front grille 14 and sheet metal work 4 Remove the four capscrews securing voltage regulator chassis 23 to end bell 9 and remove chassis assembly 5 Remove the centrifugal switch 8 from end bell and
87. on of the components and an the module circuitry is included TEST EQUIPMENT Most of the tests outlined in this manual can be performed with an AC DC multimeter such as a Simpson 260 Other suggested test instruments are e ONAN multitester Part No 420 0303 e Wheatstone or Kelvin bridge Exercise care when purchasing a foreign made VOM Some units deliver 9VDC others 22VDC to the circuit under test on R x 1 scale Maximum recommended voltage is 1 5VDC Damage to solid state devices can result from excessive voltage application ENGINE FAILS SEE ENGINE SERVICE MANUAL CONTROL FAILS SEE CONTROL SECTION III Redistribution or publication of this document by any means Is strictly prohibited 25 0 EK 30 0 EK Penn EK 25 0 DDA 30 0 DDB 30 0 DEH 25 0 MDEH 30 0 MDEH Penn DEH 37 5 EM 45 0 EM Penn EM 37 5 DEF 45 0 DEF Penn DEF 37 5 DYJ 45 0 DYJ 40 0 DDB 50 0 DDB 40 0 DEG 50 0 DEG Penn DEG 40 0 MDEG 50 0 MDEG 45 0 KB 55 0 KB Penn KB 50 0 DYA 60 0 DYA Penn DYA 55 0 EN 70 0 EN TABLE 1 GENERATOR SPECIFICATION BREAKDOWN Section 1 Spec A Thru omrzmommoocno imom Section 2 Begin Spec F F F A A G G G G F F F J J J A A A A H H H H S S F F F A A 55 0 KB 65 0 KB Penn KB 60 0 DYC 75 0 DYC 80 0 100 0 DYC Penn DYC 70 0 KR 85 0 KH Penn KR 75 0 DYC 90 0 DYC 80 0 D
88. on or publication of this document by any means is strictly prohibited QUESTION AND ANSWER TROUBLESHOOTING GUIDE FOR UNITS WITH 5 FAULT LAMPS To correct a particular problem answer the question yes or no then proceed to the next step given in whichever column question was answered lt o ITEM ABLE F ENGINE FAILS TO CRANK PROCEDURE H i Does one of following fault lamps light Choose one of the following LL Overspeed 30 High Engine Temperature 25 Low Pressure 127 27 I g 29 Does relay K13 sfart solenoid pick up h Does ignition relay K12 pick up Is voltage from ground terminal to center terminal of run stop remote switch equal to battery voltage Switch is in stop position or defective Is voltage from ground terminal to ignition relay K12 terminal B equal to battery voltage ei I Jumper battery positive from center terminal of run stop remote switch to terminal B of relay K12 Does engine crank 0 Remove jumper and replace engine monitor printed circuit board Is voltage from ground to terminal 26 on TB11 equal to battery voltage 2 Does contact ignition relay K12 4 7 close Clean socket connection Coil may be open Replace ignition relay K12 14 Clean relay contacts or replace relay and check wiring NOTE On EK EM and
89. r leads from the rotating diodes measure between either lead and the rotor shaft A reading of less than infinity indicates a ground See Figure 12 OHMMETER BRUSH DESIGN CONTACT ONE PROD TO EACH OF THE SLIP RINGS AND THE OTHER PROD TO THE ROTOR SHAFT IF ROTOR IS GOOD THERE SHOULD BE READING ON OHMMETER OHMMETER CONTACT ONE PROD TO EACH OF THE FIELD ec AND TtE OTHER PROD TO THE ROTOR SHAFT IF ROTOR IS GOOD THERE SHOULD BE READING ON OHMMETER FIGURE 12 TESTING ROTOR FOR GROUNDS Testing for an Open Circuit On brush type generators check for an open circuit by measuring resistance in the windings Check between the two slip rings as shown in Figure 13 On brushless generators disconnect and test between F1 and F2 leads as shown in Figure 13 Resistance values given in Table 3 apply to both brushless and brush type generator rotors Replace the rotor if it is grounded or has an open or short 19 OHMMETER com BRUSH DESIGN CONTACT ONE PROD TO ONE SLIP RING AND THE OTHER PROD TO THE SECOND SLIP RING OHMMETER BRUSHLESS DESION CONTACT ONE PROD TO ONE FIELD LEAD AND THE SECOND PROD TO THE OTHER FIELD LEAD FIGURE 13 TESTING ROTOR FOR AN OPEN CIRCUIT TABLE 3 RESISTANCE VALUES FOR ROTORS KW RATING 50 HERTZ 60 HERTZ RESISTANCE IN OHMS FROM TO AM resistances should be within the values specified at 20 C 68 F This includes readings between slip rings
90. r printed circuit board terminals m Is diode CR3 on center heat sink of VR22 exciter regulator chassis assembly OK Are voltage regulator transformer T21 windings and connections OK 5 Are stator leads connected properly The trouble is probably caused by a defective component VR21 voltage regulator printed circuit board REPLACE VR21 PRINTED CIRCUIT BOARD see Figure 4 Does AC output voltage build up to rated voltage or less before tripping CB21 circuit breaker on meter panel Are rotating diodes CR1 CR2 CR5 and CR6 on brushless exciter rotor OK Is brushless exciter stator winding OK Is generator field winding OK Is brushless exciter rotor winding OK TABLE D SYNOPSIS e VOLTAGE BUILDS UP BUT CB21 CIRCUIT BREAKER ON METER PANEL TRIPS DEFECTIVE ROTATING DIODE CR1 CR2 CR3 FAULT IN EXCITER ROTOR OR STATOR WINDING FAULT IN GENERATOR CR5 OR CR6 MAIN FIELD ON EXCITER ROTOR A WINDING NOTE Whenever a letter appears near the box a separate procedure corresponding to that letter is given at the end of this section 13 Redistribution or publication of this document by any means is strictly prohibited TABLE E UNBALANCED GENERATOR TERMINAL VOLTAGE YES PROCEDURE Remove load from generator terminals Are generator terminal voltages still unbalanced NOTE Unbalanced volta
91. rotor shaft On static excited models slip the brushes 7 and brush springs 6 from brush rig 5 itis not necessary to disconnect the brush leads unless brush replacement is required 6 Block the rear of the engine in place by suppor ting the flywheel housing Remove the narrow generator band 10 Remove the large capscrews securing generator mounting pad 11 to the skid base Remove the capscrews securing the stator assembly 4 to the engine flywheel housing 3 2 x BRUSHLESS GENERATOR 10 11 Using an overhead hoist and sling slide the stator assembly off the rotor assembly Use care not to damage the brush rig or exciter on brushless models while removing the stator Do not allow the stator to rest on rotor during removal Remove end bell from stator assembly dis connect and remove brush rig from end bell on static excited generators On brushless models remove exciter field 24 from end bell assembly if required Attach the hoist and sling to the rotor assembly 1 and apply a slight lift to support the rotor Remove the capscrews securing the flexible drive coupling 13 to the engine flywheel and remove rotor from the engine Remove bearing capscrew 18 and washer 17 and remove bearing from shaft If required remove blower 2 from the rotor Disconnect rotor field leads from heat sinks F1 and F2 on the exciter armature Remove exciter armature
92. s and again observe reading A good diode should have a higher reading in one direction than the other If both readings are high or if both readings are low diode is defective and must be replaced with a new identical part Excessive dust or dirt on diodes and other components wili cause overheating and even tual failure Keep these assemblies clean OHMMETER GOOD DIODE WILL HAVE HIGH RESISTANCE READING IN ONE DIRECTION AND LOW READING WHEN OHMMETER LEADS ARE REVERSED FIGURE 8 TESTING DIODES Redistribution or publication of this document by any means Is strictly prohibited FIGURE 9 TESTING SCR s TESTING SCR s SCR s mount on the outer heat sinks of the exciter regulator chassis assembly are labeled Q4 and Q5 as shown in Figure 3 1 Remove the leads from both SCR s 2 Determine polarity of ohmmeter leads Connect the ohmmeter leads to the anode and cathode as shown in Figure 9 Use the high scale on the ohmmeter The resistance should be 1 megohm or greater The cathode is the longer lead the gate is the shorter lead The anode is the threaded stud 3 Reverse the leads as shown in Figure 10 The resistance again should be 1 megohm or greater 4 With the leads connected as in Step 3 and using the low scale on the ohmmeter short the gate to the anode as shown in Figure 11 The resistance should drop to a low value 5 Remove the short between the anode and
93. stribution or publication of this document TS by any means Is strictly prohibited ADJUSTMENTS AND PROCEDURES A BRUSHES When brushes wear to approximately 5 8 inch or when wear extends into the stamped Onan part number replace brushes Do not attempt to remove the brush without first removing its spring and brackets Never bend a spring back over its bracket doing so will put a kink in it and require its replace Iu REPLACE BEFORE 5 BRUSH WEARS 8 TO THIS POINT FIGURE 5 BRUSH REPLACEMENT FLASHING THE FIELD No Voltage to flash the field to restore residual magnetism 1 Remove end grille to obtain access to exciter regulator chassis assembly 2 Use a six volt dry cell lantern battery with a 12 amp 300 volt diode as shown in Figure 7 This prevents current flow from exciter circuit to battery when voltage builds up if alantern battery is not available a 12 volt automotive generator set battery can be used by installing 20 2 HOLD ON TERMINALS UNTIL VOLTAGE STARTS TO BUILD UP B if output voltage will not build up it may be necessary ment Do not use a substitute brush that may look identical but may have entirely different electrical characteristics Be sure to install the brush so thatthe short side of its taper is toward the spring and its bracket See Figures 5 and 6 INSTALL BRUSHES WITH BEVELED TOP SLANTING DOWN TOWARD SPRING HOLDER
94. ted ADJUSTMENTS AND PROCEDURES Applies to Section II Only 8 FLASHING THE FIELD If output voltage does not build up it may be necessary to restore the residual magnetism of the poles by flashing the field Assemble a six volt battery and diode as shown in Figure 24 If a six volt lantern battery is not available a 12 volt generator set battery or a 24 volt battery can be used however a 20 ohm or a 40 ohm 2 watt resistor must be used in conjunction with the 12 amp 300 V diode Start the generator set touch positive lead to on rectifier bridge and negative lead to the terminal Hold leads on terminals just long enough for voltage to build up Do not keep excitation circuitry connected longer than 5 seconds or damage may occur to the exciter regulator 6 VOLT BATTERY RECTIFIER BRIDGE FIGURE 24 FIELD FLASHING CIRCUIT 39 S TESTING L21 REACTOR The L21 commutating reactor mounts inside the control box below the VR21 Voltage Regulator The coils 1 2 and 3 4 are wound on the same core Resistance between 1 2 and 3 4 should be 034 ohm 0034 and 042 ohms 0042 respectively brushless units Resistance between coils e g 1 4 or from any terminal to frame of the reactor should be infinity Figure 25 FIGURE 25 L21 REACTOR Redistribution or publication of this document by any means is strictly prohibited T TESTING RECTIFIER BRIDGE ASSEMBLY CR21 The rectifier bridge loca
95. ted circuit board Voltage should be 5 10 volts The AC voltage at terminals 9 and 10 on VR22 exciter regulator chassis assembly should be the same 5 to 10 volts If not check continuity between these points If voltage is low check 11 reactor 0 TESTING L1 REACTOR The L1 reactor mounts on the rear of VR22 exciter regulator chassis assembly Terminals are marked 1 2 3 and 4 3 4 Coils 1 2 and 3 4 are wound on the same iron core Resistance between 1 2 and 3 4 should be 0544 and 0614 ohms 10 respectively brush type generators Resistance between coils 0 1 4 from terminal to reactor frame should be infinity lf any of the above conditions are not met install a new reactor E TESTING DIODES On both brushless and brush type generators three diodes mount on the center heat sink of the exciter regulator chassis assembly They are labeled CR1 CR2 and CR3 as shown in Figure 3 On brushless generators six diodes mount on the rotating exciter assembly as shown in Figure 2 These six diodes are labeled CR1 CR2 CR5 diodes as follows 1 Disconnect one diode at a time Test that diode reconnect lead before proceeding to the next one 2 Use an accurate ohmmeter to check the resistance of the diode Connect one lead to the top of the diode and the other lead to the heat sink Observe reading 3 Now reverse lead
96. ted within the control cabinet below the voltage regulator contains 3 diodes CR1 i CR2 and and two silicon rectifiet i SCR1 and SCR2 These diodes and SCR 5 are sulated within a hermetically sealed block therefore failure of any diode or SCR means the entire unit has to be replaced See Figure 26 AC TERMINALS ARE GIVEN NUMERIC DESIGNATIONS FOR TEXT REFERENCE ONLY DOES NOT APPEAR ON UNIT FIGURE 26 RECTIFIER ASSEMBLY Disconnect wires from rectifier unit prior to testing Test unit in order shown Table 5 Refer to Figure 27 for SCR1 and SCR2 test circuit When test is complete and satisfactory reconnect unit observing correct wiring hook up DC VOLTMETER 6 VOL T DRY CELL BATTERY FIGURE 27 TESTING SCR 36 Redistribution or publication of this document by any means is strictly prohibited TABLE 5 TESTING SCR ASSEMBLY 21 TEST OHMMETER LEAD RECTIFIER TESTING TERMINALS METER SCALE 1 X CR3 Infinity RX10K X BI RX10K RX10K X 1 RX1 H X 1 43 Infinity Infinity x x gt 0 1 6 to 50 Ohms Infinity RX10K Infinity RX10K 6 to 50 Ohms 1 2 CR2 DC Voltmeter 2441 DC Voitmeter lead b Reading T _ 6 V Battery with Resistor less than AC1 3 Volts Apply temporary jumper from AC1 to G1 to test SCR1 Remove
97. tests in this section apply to both designs VR 22 EXCITER REGULATOR CHASSIS ASSEMBLY ENDBELL BRUSH RIG STATOR REVOLVING FIELD OVERSPEED SWITCH GENERATOR END VIEW GRILLE REMOVED COMPONENT LOCATION To gain access to generator remove grille section below control box 1 Exciter regulator chassis assembly VR22 mounts on the rear portion of the generator SCR s silicon controlled rectifiers and diodes are easi ly accessible for testing See Figures 1 3 2 On static excited generators brushes attach to the brush rig inside of end bell housing inspect through large access holes in the end bell See Figure 1 3 On brushless models rotating exciter assembly mounts directly behind exciter regulator chassis assembly with all diodes accessible for servicing See Figure 2 4 Voltage regulator PC Board VR21 Printed Cir cuit Board mounts inside the control box on the rear panel left side turn 1 4 turn fasteners on front of control box to gain access See Figure 4 AC STATOR OUTPUT k 208 240 VOLTS N RESIDUAL MAGNETISM AC IN ROTOR STARTS PROCESS SOLID STATE REGULATOR ROTATING A784 FIELD BRUSHES Rev EXCITATION SCHEMATIC FIGURE 1 STATIC EXCITER DESIGN Redistribution or publication of this document by any means is strictly prohibited EXCITER REGULATOR auc CHASSIS ASSEMBLY e FULL WAVE LOAD BRIDGE RECTIFIER ALTERNATOR 208 240 FIELD VOLTS A

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