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MagnaMaxDVR® Installation, Operation, and

1. Figure 6 59 NOTE Mobil and Polyrex are registered trademarks of Exxon Mobil Corporation or one of its subsidiaries marathon Generators 33 Service On large generators a hoist and lifting strap should be used to assist in the drive end bracket or the SAE adapter assembly 4 a For single bearing generators insert a guide stud into the drive hub Position all spacers if any then all drive discs one at a time until all discs are installed figure 6 61 Make sure that all disc mounting holes at the inner and outer diameter are properly aligned Secure the discs with the grade 8 5 8 18 capscrews and hardened washers Torque to 192 ft lb 260 N m see figure 6 62 for torquing sequence Figure 6 63 5 Install the outer bearing cap on the exciter end figure 6 63 Align holes in inner and outer bearing cap and install cap screws Torque to 25 ft lb 34 N m see figure 6 64 Dm Viz Figure 6 64 Figure 6 61 Torque the bolts in the above sequence according to the correct bolt pattern Then check the torque in each bolt in a clock wise direction around the bolt circle to insure that all the bolts are properly torqued Figure 6 62 marathon 34 Generators Service PMG Installation 1 Install inboard snap ring 430 frame generators and loading spring on shaft figure 6 65 2 Slide PMG rotor onto shaft figure 6 66 3 Install snap ring figure 6 67 Use a
2. Service the mounting bolts and remove the screen figure 6 79 Note Do not remove the drip cover from the screen assembly if so equipped Insert two guide pins in the flywheel and two in the flywheel housing Adjust the generator position until the drive discs are piloted in the flywheel Remove the guide pins and secure the discs with Grade 8 place bolts and hardened washers or Grade 8 capscrews and heavy series lockwashers Torque per specifications given in section 12 Do not apply any force to the generator fan for lifting or rotating the generator rotor Disregarding these instructions may cause personal injury or equipment damage Position the generator so that the SAE adapter mates with the flywheel housing Figure 6 78 Figure 6 79 marathon Generators 37 Service Do not force the alignment of the units Shift the generator from side to side or raise or lower with a lifting device as necessary 38 It may be necessary to use shims under the mounting feet of either the generator or the prime mover to obtain proper alignment use the same shims as removed under disassembly or proceedas follows usingtheextremebottom four capscrews mount the SAE adapter to the flywheel housing With a 0015 to 002 inch feeler gauge placed at the extreme top of the adapter between the adapter and flywheel housing raise the generator or lower the prime mover until the gauge is snug Relieve just enough
3. Dry components thoroughly with moisture free low pressure compressed air Cloth and Compressed Air Cleaning with a dry cloth may be satisfactory when components are small the surfaces are accessible and only dry dirt is removed Blowing dirt out with compressed air is usually effective particularly when the dirt has collected in places which cannot be reached with a cloth Use clean dry air at 30 psi 206 KPa Brushing and Vacuum Cleaning Dry dust and dirt may be removed by brushing with bristle brushes followed by vacuum cleaning Do not use wire brushes Vacuum cleaning is an effective and desirable method of removing dry and loose dirt Shell Blasting Air blasting with ground nut shells may be satisfactory for removal of hard dirt deposits from insulation Use mild abrasives such as 12 20 mesh ground walnut shells Steam Cleaning If the generator is completely disassembled including bearings and electronic components steam cleaning of the major parts and windings is very effective However before the generator can be put back into service the machine must be thoroughly dried in an oven to remove all moisture marathon Generators 19 Service Removal from Prime Mover AWARNING Be sure all power is off before servicing Failure to follow all safety instructions can result in serious personal injury or death Note Before disconnecting any electrical wiring be sure it is marked and can be ide
4. PF Power Factor Motor HP Eff Power Factor HP Volts kWe Volts Power Factor marathon Generators Three Phase Ex1x 1 73 x PF 1000 kVA x PF Ex1x1 73 _ Ke 1000 PF Ex 1 x 1 73 xV1 PF 1000 Rad Bat kWe Cooling Chg Efficiency x 746 Fan HP Gen HP HP x 746 Efficiency HP x 746 Efficiency x PF HP x 746 1 73 x E x Efficiency x PF kWe x 1000 E x 1 73 x PF kVA x 1000 Ex 1 73 rpm x Poles 2 x 60 2 x 60 x Hz rpm 2 x 60 x Hz Poles 61 Warnings amp Cautions AAWARNING IMPORTANT INFORMATION AA CAUTION Please Read Carefully This catalog is not intended to provide operational instructions Appropriate Marathon Electric instructions provided with the motor and precautions attached to the motor should be read carefully prior to installation operation and or maintenance of the equipment Injury to personnel or motor failure may be caused by improper installation maintenance or operation The following WARNING and CAUTION information is supplied to you for your protection and to provide you with many years of trouble free and safe operation of your Marathon Electric product dAWARNING e Disconnect power and lock out driven equipment before working on a motor e Always keep hands and clothing away from moving parts e The lifting support on the motor is not to be used to lift the entire machine Only the motor attached directly to the support may be safel
5. marathon 46 Generators Visual Inspection Whenever testing and troubleshooting a generator set it is always a good practice to make a thorough visual inspection Remove covers and look for any obvious problems Burnt windings broken connectors leads mounting brackets etc can usually be identified Look for any loose or frayed insulation loose or dirty connections and broken wires Be sure all wiring is clear of rotating parts Verify that the generator is connected for the voltage required This is especially important on newinstallations Check for any foreign objects loose nuts bolts and electrical connectors Clear paper leaves building materials etc that could be sucked into the gener ator Generator is air cooled air enters the lower portion of the conduit box Check the air gap for clearance or obstructions main generator and exciter If possible rotate the generator rotor by hand to be sure it turns freely If serious problems can be identified before attempting to operate the machine additional damage can be avoided Constant Excitation 12V Battery Test Theory The generator output voltage is dependent on generator speed generator design load and exciter input current Ifthe generator speed and exciter input are known the output voltage at no load can be measured and compared to the design value Problems can be isolated to either the generator or regulator system by using this test
6. Dirt and dust will conduct electricity between points of different electrical potential Moisture will aggravate the problem further Insulation system failure can result if corrective action is not taken The condition of the insulation system can be tested by measuring insulation resistance see section 8 Generator Testing Insulation resistance should be checked when putting the generator into service after it has been in storage and any time contamination by moisture and dirt is sus pected Normally moisture buildup is not a problem when the generator is running since heat produced internally will tend to keep it dry Moisture can collect in the generator when it is shut down The problem will be worse in humid environments or in areas where extreme temperature changes cause condensation dew to form inside the generator Space heaters air filters and premium insulation sys tems such as our VPI process should be considered in difficult environments Accumulations of dust and dirt not only contribute to insulation breakdown but they can also increase temperature by restricting ventilation and by blocking the dissipation of heat Some machines are exposed to accumulations of materials such as talc lint rock dust or cement dust which may obstruct the ventilation The most harmful type of foreign materials include carbon black metallic dust and chips and similar substances which not only impede the ventilation but also form
7. Keep away from other components that can be damaged by strong magnetic fields 1 Clean dust and dirt from the PMG rotor see section 5 Check to be sure all magnets are tightly bonded to the PMG rotor Check for burrs or corrosion in the bore and keyway where the rotor mounts to the shaft Look for score marks on the outside diameter caused by rubbing this could indicate bearing or assembly problems and should be investigated Inspect snap rings and loading spring replace as required Main Rotor Inspection A Bearing 1 Check the bearing for damage or wear Clean the old grease from the bearing cap and fill the bearing cap grease cavity 1 3 to 1 2 full of new Mobil Polyrex EM or equivalent see page 17 If the bearing needs to be removed for any reason always install a new bearing 2 If the bearing is to be replaced remove with a suitable puller figure 6 38 Be sure the inner bearing cap is on the shaft before installing the new bearing Heat the new bearing in an oven to a maximum temperature of 212 F 100 C Apply a thin coat of clean lubricating oil to the press fit area of the rotor shaft Using suitable heat resistant gloves install the bearing over the end of the shaft until it seats against the shaft shoulder figure 6 39 The bearing should slide on the shaft and be seated without excessive force If the bearing binds onthe shaft before being fully seated a piece of tubing
8. etc B Equipment must be kept dry 1 Store in a dry area indoors 2 Temperature swings should be minimal to prevent condensation 3 If stored in an unheated or damp building space heaters will be required to prevent internal condensation 4 Treat unpainted flanges shafts drive discs and fittings with a rust inhibitor 5 Check insulation resistance of all windings before starting the generator If readings are low the windings must be dried see section C Keep bearings lubricated 1 Every six months rotate shaft several turns to distribute grease in bearings 2 If unit has been stored more than one year add grease before start up D Review and follow instructions in sections 3 and 4 before putting the gen set into service marathon Generators 55 Specifications Table 12 1 MAGNAMAX e Fastener amp Torque Specifications 430 570 Frames 740 Frames Size Torque Size Torque Part Description Fastener Spec OG Dia Thread Ft Lb Dia Thread Ft Lb Front Bracket Grade 5 capscrews with flat 3 8 16 25 1 2 13 60 and lock washers Bearing Caps Grade 5 capscrews 3 8 16 25 3 8 16 25 with lock washers Drive Disc Grade 8 capscrews with 5 8 18 192 5 8 18 192 hardened washers Adapter Grade 5 capscrews with flat 3 8 16 25 1 2 13 60 or Rear Bracket and lock washers Conduit Box Grade 5 capscrew with star 3 8 16 1 2 13 60 type lock washer PMG Stator Grade 5 capscrews with 1 4 20 6
9. 23 15 20 27 37 3 8 16 18 24 6 22 4 19 31 42 28 38 25 34 44 60 24 20 27 8 24 6 22 35 47 32 43 28 38 49 66 7 16 14 28 38 25 34 22 30 49 66 44 60 39 53 70 95 20 30 41 27 37 24 33 55 75 50 68 44 60 78 106 1 2 13 39 53 35 47 31 42 75 102 68 92 60 81 105 142 20 41 56 37 50 33 45 85 115 77 104 68 92 120 163 9 16 12 51 69 46 62 41 56 110 149 99 134 88 119 155 210 18 55 75 50 68 44 60 120 163 108 146 96 130 170 230 5 8 11 83 113 75 102 66 89 150 203 135 183 120 163 210 285 18 95 129 86 117 76 103 170 230 153 207 136 184 240 325 3 4 10 105 142 95 130 84 114 270 366 243 329 216 293 375 508 16 115 156 104 141 92 125 295 400 266 361 236 320 420 569 7 8 9 160 217 144 195 128 174 395 535 356 483 316 428 605 820 14 175 237 158 214 140 190 435 590 392 531 348 472 675 915 1 8 235 319 212 287 188 255 590 800 531 720 472 640 910 1234 14 250 339 225 305 200 271 660 895 594 805 528 716 990 1342 NOTES Capscrews threaded into aluminum may require reductions in torque of 30 or more marathon Generators 150 000 PSI Torque Ft Lb N m Oiled 11 15 13 18 22 24 40 54 108 146 140 190 153 207 18
10. 25 in lb Never torque against the diode terminal use a 7 16 inch wrench to support the terminal figure 6 35 4 Check the exciter armature and rectifier assembly for a loose frayed or burnt winding or loose connections Measure winding resistance and insulation resistance see section 8 DO NOT megger diodes or surge suppressor Repair or replace as necessary If field repair of the winding is necessary contact Marathon Electric for special winding procedures and materials 5 Look for score marks on the outside diameter of the armature core caused by rubbing this could indicate bearing or assembly problems and should be investigated REVERSE STANDARD POLARITY POLARITY DIODES DIODES Figure 6 32 Figure 6 34 ZZ Figure 6 35 Figure 6 33 marathon Generators 27 Service PMG Inspection A PMG Stator figure 6 36 1 Clean dust and dirt from the PMG stator winding see section 5 Check PMG stator for a loose frayed or burnt winding Measure winding resistance and insulation resistance see section 8 Repair or replace as necessary Contact Marathon Electric for special winding procedures and materials Look for score marks in the bore caused by rubbing this could indicate bearing or assembly problems and should be investigated B PMG Rotor figure 6 37 QWARNING The PMG rotor uses very strong mag nets Keep away from iron and steel parts that could be drawn to the magnets
11. Test Procedure 1 Shut the generator set down 2 Connect a voltmeter to the generator output 3 Disconnect the F1 and F2 leads at the regulator 4 Connect a 12 volt battery capable of supplying 1 amp to the F1 and F2 leads F1 is plus F2 is minus Generator Testing AXCAUTION Beware of arcing when connecting leads Stay clear of battery vents Escaping hydro gen gas can explode If hazardous conditions exist use a suitable switch to connect or disconnect the battery 5 With no load applied to on the generator main breakers open run generator at rated speed 1800 rom 60 Hz or 1500 rpm 50 Hz 6 Measure the generator output voltage 7 Shut generator down 8 Disconnect battery see preceding CAUTION statement 9 Compare voltage reading with value shown in section 12 Conclusion If voltage readings are normal the main generator and exciter are operating properly Troubleshooting should continue with the regulator If readings are not normal the problem is in the generator Continue testing diodes surge suppressor and windings Measuring Voltages When testing the generator and regulator the most frequent and usually easiest measurement will be a voltage The generator will need to be running at rated speed and may have some of the protective guards and covers removed Be Careful Keep your self and your test leads out of the way It is best to shut the unit down when connecting meters
12. The main rotor resistance can be measured with a very accurate meter that is able to measure low 1 ohm resistance but it is difficult to determine if there are turn to turn shorts in the field pole wind ings One shorted turn would only change a resis tance reading on the order of one half of one percent The AC impedance test measures the impedance inductance and resistance of the field pole coils Shorted turns in the field pole windings change the coil inductance to a much greater degree than the resistance Procedure Step 1 The rotor must be supported on a non magnetic surface such as a wooden skid Do not use a steel table that would create a magnetic short circuit between the poles Step 2 Apply 120 volts AC to disconnected main rotor leads F1 and F2 Step 3 Measure and record voltages across each pole Between points A and BI BI and ao a GE and D and 4 D La and g figure 8 1 Step 4 The voltage readings should balance within one volt Results If the AC voltages are not balanced 30V 1V AC with 120V AC input across each pole the winding has shorted turns and should be rewound Refer to Marathon Electric for further information Ft F2 Figure 8 1 marathon 50 Generators Parts MAGNAMAX Exploded View marathon Generators 51 Parts Table 9 1 Parts List Item Part Description 1 Screen Assembly Screen Screen Mounting Bolt Screen M
13. Voltage or residual Voltage Important Note Verify all Test equipment against Known good Also verify all fuses wiring and generator connections are correct as per SEC 3 amp 8 of this Manual prior to Trouble Shooting Constant Excitation test 12 Volt Battery Test Refer to Sec 8 Refer to your Regulator Manual in order to continue Trouble Shooting The Generator is Functionally operating Bad Contact Marathon Electric for parts or new generator pu rchase Email generator help marathonelectric com Web site http www marathonelectric com assembly and Test Diodes Refer to Sec 8 Replace Diodes Rectifier assembly Test exciter Windings Refer to Sec 8 Bad Exciter Stator Rotor Repair replace and retest as needed Exciter Stator Rotor Test Generator main stator rotor Windings Refer to Sec 8 Bad Main Stator Rotor Contact an Authorized Service Station or Marathon Electric Email generator help marathonelectric com Main Stator Rotor Verify all results and if problem persist contact Marathon Electric Email generator help marathonelectric com marathon Generators Troubleshooting Symptom Voltage Regulator Functionally Inoperative equipment against known good Also verify all fuses wiring and generator connections are correct as per SEC 3 amp 8 of this Manual prior to Trouble Shooting Contact M
14. always given per phase Amperage should never exceed the nameplate rating when running the intended load amperage may go above nameplate momentarily when starting large motors When measuring exciter field amps F1 and F2 leads a DC meter is required The maximum field current under full regulator forcing is 6 5 amps DC Normal full load reading is approximately 3 amps DC E1 E2 and E3 terminals PMG leads at the regulator or capacitor F2 is minus Usually the same as the system voltage generator output volts however in some cases sensing is taken from winding center taps or instrument potential transformers Maximum 600 volts AC Example Center tap of 480 volt system would give 240 volts at E1 E2 or E3 Example A 4160 volt system must use a transformer to step voltage down below 600 volts See the connection diagram supplied with generator set 200 240 VAC 180 220 VAC 300 Hz 1800 rpm 250 Hz 1500 rpm Measuring Resistance The generator windings can be measured and com pared to the values shown in the service specification section 12 Main Stator The main stator winding resistance is very low A meter capable of readings in the milliohm range would be required however a standard VOM volt ohm meter can be used to check for continuity shorts or grounds Example With leads disconnected a measurement from T1 to T4 should be very low continuity on most VOMs Measured from T1 or T4
15. and the governors should be adjusted to give the same speed regulation Before operating generator sets in parallel each set should be checked by starting operating and adjusting the sets as individual units before attempting paralleling Reactive Load Control When two identical generators are operating to gether in parallel and an unbalance occurs in field excitation circulating currents begin to flow between marathon 12 Generators the generators This current will appear as a lagging power factor or inductive load to the highly excited generator and as a leading power factor or capacitive load to the generator with the lower field current This is known as the reactive circulating current and there are two methods of controlling it in parallel operation 1 Reactive droop compensation formerly known as parallel droop compensation the bus voltage droops or decreases as the reactive lagging power factor load is increased 2 Reactive differential compensation formerly known as cross current compensation the reactive differential compensation circuit allows parallel generators to share reactive loads with no decrease or droop in generator voltage The circuit must meet the following criteria A All paralleling current transformers for all the generators being paralleled must be included in the secondary interconnection loop B When different size generators are paralleled all paralleling current tr
16. be noted on the freight bill before accepting the shipment Claims for damage must be promptly filed with the freight company Unpacking and Handling Read all instruction cards carefully When lifting attach an overhead crane to the lifting lugs on the gen erator frame Apply lifting forces in a vertical direction The lifting lugs on the generator are designed to support the generator only Do not lift complete generator set by means of lifting lugs on generator Personal injury or equipment damage may result Storage In the event that the generator is not to be installed on the prime mover immediately it is recommended that it be stored in a clean dry area which is not sub ject to rapid changes in temperature and humidity See Section 11 for more information Preparation for Use Although the generator is carefully inspected and tested in operation before it leaves the factory it is recommended that the unit be thoroughly inspected The insulation on the wire should be inspected and all bolts should be checked for tightness Remove all shipping tapes bags blocks and skids which are used to prevent vibration and rotor move ment during shipment Dry low pressure compressed air of approximately 30 psi 206 KPa can be used to blow out the interior of the generator In the case of two bearing machines it is possible to turn the rotor by hand to make sure that it rotates smoothly without binding lf the machine has bee
17. bearing generators if generator is to be shipped see Shipping Instructions section 11 for proper rotor support Figure 6 3 marathon 20 Generators Service Conduit Box Removal 1 Note the location and markings remark as required and remove connections from voltage regulator capacitor and any other conduit box mounted control figures 6 4 and 6 5 2 On generators equipped with bus bars mark all connections and disassemble main stator power leads from the generator side of the bus bars 3 Remove bolts holding conduit boxin place figure 6 6 4 Remove conduit box figure 6 7 Figure 6 6 Figure 6 4 Figure 6 7 Figure 6 5 marathon Generators 21 Service Exciter Stator Field Removal 1 Disconnect F1 and F2 leads from the corres ponding F1 and F2 terminals on the regulator 2 Remove all cable ties so the F1 and F2 leads can be removed withthe exciter stator Remove the four capscrews and belleville washers holding the exciter stator in place figure 6 8 Remove the exciter stator using alifting strap or fixture figure 6 9 Exciter Armature Rotor Removal 1 Note markings and disconnect the main rotor leads coming out of the aluminum standoff plate lead hole from the rectifier aluminum angle figure 6 10 Figure 6 10 2 Remove the capscrew and belleville washer which holds the exciter rotor armature to the generator shaft figure 6 11 3 Use a six inch
18. belleville washers Exciter Stator Grade 5 capscrews with 1 2 13 60 belleville washers Exciter Armature Grade 8 capscrew with 1 2 13 84 Rotor belleville washer 3 4 10 300 Cooling Fan Grade 5 capscrews with 1 2 13 1 2 13 60 belleville washers Main Rotor Coil Grade 8 capscrews with 5 16 18 3 8 16 35 Supports belleville washers Rectifier Assembly Grade 5 capscrews 1 4 20 4 Mounting Drive Hub Socket head set screw 1 2 13 50 1 2 13 50 Set Screw 1 4 in hex key NOTES All fasteners are SAE American standard All torque values are for plated hardware which is standard on the MAGNAMAX If hardware is replaced with non plated refer to Table 12 2 Always use quality hardware of the grade specified 570 and 740 frame only Not used on 430 frames marathon 56 Generators Specifications Table 12 2 Capscrew Torque Values Capscrew Dia and Ultimate To 1 2 69 000 PSI To 3 4 120 000 PSI To 3 4 64 000 PSI Tensile Strength To 1 55 000 PSI To 1 115 000 PSI PSI SAE Grade Capscrew Head Markings Capscrew Body Size Inches Thread Torque Ft Lb N m Torque Ft Lb N m Dry Oiled Plated Dry Oiled Plated Dry 1 4 20 5 7 4 5 6 4 5 8 11 7 9 6 8 12 16 28 6 8 5 4 7 4 8 6 10 14 9 12 8 11 14 19 5 16 18 11 15 0 14 9 12 17 23 15 20 14 19 24 33 24 13 18 2 16 10 14 19 26 17
19. cables together when making connections marathon Generators Installation 12 Lead High Wye Twelve lead generators are dual voltage gener ators with six coils which don t have the connection of the three inner coils There are 12 or 24 cables coming out of the generator as 10 Lead High Wye Ten lead generators are dual voltage generators with six coils One end of the three inner coils is con nected together There are 10 or 20 cables coming out of the generator 10 Lead marathon 6 Generators Installation 12 Lead Low Wye Twelve lead generators are dual voltage gener ators with six coils which don t have the connection of the three inner coils There are 12 or 24 cables coming out of the generator 12 Lead Connect L LO 10 Lead Low Wye Ten lead generators are dual voltage generators with six coils One end of the three inner coils is con nected together There are 10 or 20 cables coming out of the generator 10 Lead marathon Generators 7 Installation 12 Lead High Delta Delta connection with 12 lead generators only 12 Lead Low Delta 12 Lead Delta connection with 12 lead generators only UP Connect I RESEST L L b T L T L T marathon 8 Generators Installation 6 Lead Wye Six lead generators have 3 coil groups with 6 or 12 cables or bus bars coming out of the generator 6 Lead Delta Six lead g
20. exceeded Does the load exceed the name plate rating Yes The load exceeds the available T R Ra Contact Marathon Electric for parts or new Trouble Reeg agieg to verify Email Pet eeh purchase mail generator help marathonelectric com that the generator is functionally Web site http www marathonelectric com operational If problem goes away PS with no load resolution can be found with reduction of the applied load or new generator purchase ls the generator set up for paralleling Some voltage droop is normal as load is increased Refer to your Regulator Manual in order to continue Trouble Shooting Verify all results and if problem persist Refer to Low Voltage No Load Trouble shooting Symptom marathon Generators 41 Troubleshooting Symptom Generator Produces Low Voltage No Load Important Note Verify all Test equipment against known good Also verify all fuses wiring and generator connections are correct as per SEC 3 amp 8 of this Manual prior to Trouble Shooting Use Tachometer and or Frequency Meter Verify shaft speed matches Name Plate Do they match No Correct shaft speed and retest Contact Marathon Electric for parts or new generator purchase Email generator help marathonelectric com When Generator is at rest Web site http www marathonelectric com disconnect F1 amp F2 leads at regulator then restart Does the voltag
21. figure 6 51 and section 5 2 Inspect the frame for stripped threads cracks burred mating surfaces or other damage 3 Inspect the stator for a loose frayed or burnt winding Measure winding resistance and insulation resistance see section 8 Repair or replace as necessary If field repair of the winding is necessary contact Marathon Electric for winding data Figure 6 51 Front End Bracket Installation 1 Install two guide pins threaded rod can be used into the generator side of the end bracket mounting holes Align the guide pins with the holes in the generator frame and slide the bracket onto the frame figure 6 52 Install bracket mounting capscrews figure 6 53 On large generators a hoist and lifting strap should be used to assist in the front end bracket installation Figure 6 52 2 Remove the two guide pins and insert the remaining capscrews and torque to specifications given in section 12 Main Rotor Installation 1 Grease bearing cavity and bearing with Mobil Polyrex EM grease or equivalent see page 17 Figure 6 53 2 Using a rotor lifting fixture and a suitable hoist carefully install the rotor assembly into the main stator assembly through the drive end figure 6 54 Carefully feed the rotor leads through the front end bracket shaft hole as the rotor is installed ACAUTION Special care should be taken when installing the rotor assembly Winding damage could result if the
22. longer 431RDL4005 Environmental Considerations Dirt moisture heat and vibration are enemies of electrical equipment Excessive exposure to the elements will shorten the life of the generator The ambient temperature should not exceed the value shown on the generator nameplate The MAGNAMAX is built in a NEMA open type enclosure Generators for outdoor application should be protected from the elements by housings with proper openings for ventilation This protection should be designed to prevent the direct contact of wind driven rain snow or dust with the generator In moist or humid areas such as the tropics and marine service additional protection is recommended Although the standard windings are humidity and moisture resistant special insulations and accessories such as space heaters can increase generator life significantly In extremely dirty and dusty environments a means of providing filtered cooling air to the generator is Installation recommended When generators are marked 11 3 G T3 X they must be installed in a clean environment If not possible a means to providing filtered cooling air to the generator is mandatory for safe use Refer to Marathon Electric for more information Electrical Connections The generator conduit box construction allows conduit to enter the top bottom or either side of the box A hole saw or any suitable tool can be used to provide for the conduit entrance Protect t
23. m for 3 4 bolt 2 Observe the polarity markings and connect the main rotor leads to the rectifier assembly figure 6 74 Torque the nuts to 4 ft lb 5 4 N m 3 Position the exciter field leads at the left 9 o clock inboard position Using a suitable lifting device mount the exciter stator on the front end bracket mounting pads and align the mounting holes Ka figure 6 75 Mount with the capscrews and Figure 6 73 belleville washers figure 6 72 Torque the cap screws to 60 ft lb 81 N m Route and secure the exciter stator leads away from any moving parts Kar 20 _ L Figure 6 74 Figure 6 70 Figure 6 75 marathon 36 Generators Conduit Box Installation 1 Install the conduit box over the main stator leads be sure leads are in upper compartment Secure with bolts and lock washers figures 6 76 and 6 77 On generators with bus bar assemblies reassemble main stator leads and insulating blocks to bus bars figure 6 78 Reconnect exciter leads PMG leads and other accessories according to the connection diagrams and markings installed before disassembly Assembly to Prime Mover 1 Attach a suitable hoist to the generator lifting lugs and move the generator until the generator foot mounting holes are aligned with the base and slightly above a For single bearing generators if the screen assembly is mounted on the adapter remove Figure 6 76 Figure 6 77
24. rises up to 25 C above those for continuous operation NEMA MG1 22 40 and MG 1 22 84 Premium Insulation System All MAGNAMAX generators are built with Class H or better insulation materials All standard generators are suitable for continuous duty at Class F temperature rise and will give equivalent or better winding life expect ancy to generators supplied with Class A or B insulation systems operated within their temperature limits The varnishes and epoxies used are synthetic non hygroscopic Multiple dip and bake cycles of the main winding plus a final coat of epoxy make the stan dard winding moisture and fungus resistant The MAGNAMAXP rotor is wet wound with thermo setting epoxy applied between each layer plus a final coating of epoxy for moisture and abrasion resistance MAGNAMAX generators can be ordered with an epoxy vacuum pressure impregnated VPI insulation system as an option MAGNAMAX generators with form wound coils include VPI as standard Power Factor All standard generators are designed for operation at rated kVA at 0 8 lagging power factor but can be operated at rated kVA over the 0 8 to 1 0 power factor range MAGNAMAX Voltage Regulator The standard voltage regulator is a fully encapsulated static type with a solid state build up circuit Standard features include 3 phase RMS sensing paralleling adjustable underfrequency protection and overex citation protection Refer
25. rotor is allowed to hit the main stator Figure 6 54 NOTE Mobil and Polyrex are registered trademarks of Exxon Mobil Corporation or one of its subsidiaries marathon 32 Generators Service Do not apply any force to the generator fan for lifting or rotating the generator rotor Disregarding these instructions may cause personal injury or equipment damage 3 a For single bearing generators slide the SAE adapter over the fan and secure to the main stator and frame assembly with capscrews torqued per section 12 figures 6 55 and 6 56 It may be necessary to raise the rotor assembly slightly to allow the mounting of the SAE adapter Figure 6 56 b For two bearing generators insert two guide pins in the rear bearing lock holes figure 6 57 Fill the grease cavity of the drive end bracket 1 3 to 1 2 full of Mobil Polyrex EM grease or equivalent see page 17 Assemble all grease plugs in the bracket Mount the bracket on the bearing and guide the bearing lock pins through the bracket holes figure 6 58 Align the drive end bracket and mount with the capscrews figure 6 59 Insert two capscrews with lockwashers into the bearing lock and tighten Remove the guide pins and replace with the remaining two cap screws with lock washers Torque bearing cap screws to 25 ft lb 34 N m Torque bracket mounting capscrews per specifications given in section 12 Figure 6 57 Figure 6 58 Figure 6 55
26. slightly larger than the press fit area can be used to drive the bearing into place Using light taps with a soft mallet apply pressure to the inner race only Figure 6 36 Figure 6 37 Figure 6 38 NOTE Mobil and Polyrex are registered trademarks of Exxon Mobil Corporation or one of its subsidiaries 28 marathon Generators Service AXCAUTION Under no circumstances should pres sure be applied to the outer race of the bearing as permanent bearing damage could result Allow the bearing to cool for one hour before attempting to assemble the generator B Fan 1 Check the fan for cracks or broken blades Replace the fan if defective Figure 6 39 2 Mark the hub and fan for alignment This is necessary to be sure the balance weights will be in the same position when the fan is reinstalled 3 a For single bearing generators remove the fan mounting capscrews figure 6 40 and slide the fan off the shaft figure 6 41 b For two bearing generators remove the drive end bearing and bearing cap see bearing removal instructions Remove the fan mounting capscrews and slide fan off the shaft figure 6 40 amp 6 41 Figure 6 40 4 To install slide the fan on the shaft making sure the fan mounting surface is toward the drive hub Align reference marks this is important for assembly balance and mount the fan to the drive hub with the capscrews and belleville washers figure 6 42 Torque the capscr
27. the rotor assembly is not neces sary if only the hub is replaced and the fan is mounted in the same location relative to the hub and shaft D Main Rotor Core and Windings 1 Clean all parts Remove dust and dirt from the rotor windings see section 5 Remove any accumulated dust or dirt in the winding air passages with a piece of wire or with low pressure moisture free air figure 6 45 ACAUTION If a piece of wire is used for cleaning the air passages care must be taken not to scratch the winding as this could cause an insulation failure 30 2 Check the rotor for loose frayed or burnt windings Measure winding resistance and insulation resistance see section 8 Test for shorted turns using an AC impedance test see section 8 A defective rotor winding must be rewound by Marathon Electric The rotor assembly must be rebalanced after any rework or repair has been completed marathon E Drive Discs Single Bearing Generators Only 1 Generators Inspect the drive discs for distorted or bent edges figure 6 46 Inspect for worn mounting holes Replace all defective discs as necessary Inspect the drive disc mounting capscrews for damaged threads Replace capscrews if damaged Figure 6 43 Figure 6 44 Figure 6 46 Service Front Exciter End Bracket Inspection 1 Remove the filler and drain grease pipes and the grease plugs from outer bearing cap figure 6 47 2 Clean the
28. voltage varies but the most common is 500 Vdc A megger voltage over 500 is not recom mended except for measuring medium voltage 2400 4160 stators only AA CAUTION First disconnect any electronic compo nents Regulators diodes surge protectors protec tive relays etc will be destroyed if subjected to the high megger voltages To measure insulation resistance connect the red or positive megger lead to the leads for the winding to be tested connect the back or negative megger lead to the generator frame Be sure the leads of the part being tested are not touching any metal parts of the generator if the neutral is grounded it must be disconnected Take megger reading refer to the manual for the megger Insulation Resistance Main Stator Be sure the regulator and any other electric components metering protective relays etc are disconnected before meggering High megger voltages will destroy these parts All stator leads must be isolated from ground and connected together on most systems with grounded neutrals the neutral can be isolated from ground and used as atest point Connect the positive megger lead to the main stator leads Connect the negative megger leadtothe generator groundingstud Takethe megohm reading refer to instructions for the megger marathon Generators 49 Generator Testing The minimum acceptable value for random wound coils is 5 megohms For form wound coil
29. 30 2 Remove the front end bracket from the main stator assembly figure 6 31 On large generators a hoist and lifting strap should be used to assist in the front end bracket removal Figure 6 30 Figure 6 31 marathon 26 Generators Exciter Inspection A Exciter Stator 1 Clean dust and dirt from the stator winding see figure 6 32 and section 5 Check the exciter stator for a loose frayed or burnt winding Measure winding resistance and insulation resistance see section 8 Repair or replace as necessary If field repair of the winding is necessary contact Marathon Electric for special winding procedures and materials Look for score marks in the bore of the exciter core caused by rubbing this could indicate bearing or assembly problems and should be investigated B Exciter Rotor Armature T Clean dust and dirt from the exciter armature and rectifier assembly see figure 6 32 and section 5 Check the exciter armature for burrs on the mating surfaces Check the rectifiers and surge protector for proper operation see section 8 Replace defective parts Service Three forward polarity and three reverse polarity diodes are used Be sure you have the correct part installed in the correct location The surge suppressor is polarized Observe polarity markings when changing the surge suppressor figure 6 34 Torque mounting nuts to 80 in lb Torque lead terminal nuts to
30. 4160 Volts 12V DC 24V DC 573FSM4352 23 0 3100 4200 573FSM4354 23 0 20 3 3300 4400 574FSM4356 23 0 3200 4300 574FSM4358 23 0 17 3 3500 4600 741FSM4360 22 0 3600 4600 742FSM4364 22 0 3700 4700 742FSM4366 22 0 16 3 3600 4600 743FSM4368 22 1 17 7 3200 4600 743FSM4370 22 1 17 0 3500 4600 744FSM4374 22 1 17 5 3600 4650 744FSM4376 22 1 17 5 3600 4650 NOTES For rated load exciter field volts see generator nameplate For low wye connection divide value shown in table by 2 For high delta connec tion divide value shown in table by 1 732 For delta connection divide value shown in table by 1 732 marathon 58 Generators Specifications Table 12 4 Excitation Data 50 Hz 1500 RPM Exciter Field Exciter Field Volts No Load Output Voltage W Fixed Model Number Resistance F1 amp F2 at Regulator Excitation High Wye Connection Low Volts Ohms 25 C No Load 415 Volts 12V DC 24V DC 431RSL4007 22 5 17 1 370 450 432RSL4009 360 445 432RSL4011 380 455 432RSL4013 400 480 432RSL4015 360 440 432RSL4017 370 450 433RSL4021 22 5 16 7 360 450 572RSL4024 23 0 19 8 360 430 572RSL4027 23 0 20 0 355 430 572RSL4028 23 0 21 2 370 430 360 440 973RSL4034 23 0 20 7 350 430 574RSL4038 23 0 17 7 365 450 972RSL4030 23 0 18 4 575RSL4044 340 420 740RSL4046 340 420 741RSL4045 360 450 742RSL4046 22 0 18 7 350 445 742RSL4048 22 0 20 0 340 440 742RSL4050 22 0 16 1 370 470 743RSL4052 330 420 744
31. 570080 423 572RSL4030 5 0074 426 573RSL4032 570075 0074 472 Exciter Exciter 573RSL4034 507 Medium Stator Rotor PMG 574RSL4036 584 Voltage Field Armature Stator 574RSL4038 570069 0048 601 _ 570 Frames 575RSL4044 570111 0030 704 744 Frames 740RSL4046 704 740 Frames 2 1 741RSL4045 692 741 Frames 2 1 742RSL4046 740042 0036 748 742RSL4048 740043 0030 776 742 Frames 2 1 742RSL4050 740051 0023 889 743 Frames 743RSL4052 979 744RSL4054 1 100 744RSL4056 1 250 744RSL4058 1 250 744FSL4060 892 744FSL4062 1 044 Base Model Winding Main Main Medium Voltage H SG Stator Rotor 573FSM4352 383 573FSM4354 570214 854 411 574FSM4356 508 741FSM4360 667 742FSM4364 768 742FSM4366 740206 151 888 743FSM4368 954 743FSM4370 740208 101 1 053 744FSM4374 1 196 744FSM4376 740260 072 1 196 NOTES Main stator values shown are line to line on the high wye connection For low wye connection divide value shown in table by 4 marathon 60 Generators Generator Formulas O To Find kWe kVA RkVA HP Engine Output Generator Formulas Known Values Volts Current Power Factor Volts Current Volts Current Power Factor Generator kWe Generator Efficiency Radiator Cooling Fan HP Battery Charging Generator HP kWe Required for Motor Motor HP Eff kVA Required for Motor Amps Amps Amps Frequency Hz Poles rpm E Volts Current Amps
32. 7 8 14NF capscrew for a puller see section 9 The hole that the mounting bolt goes through is threaded Screwthe puller bolt into the hole and it will push against the end of the shaft figure 6 12 Carefully feed the main rotor leads through the hole as the exciter armature is removed figure 6 13 Figure 6 11 Figure 6 12 Figure 6 8 Figure 6 13 Figure 6 9 marathon 22 Generators Service Do not tighten the puller bolt beyond the end of the threads If a bolt with sufficient thread length cannot be found use a piece of threaded rod with a nut welded on the end PMG Stator Removal 1 Remove exciter armature follow instructions found earlier in this section 2 Remove the PMG output leads from the capacitor figure 6 14 and loosen all cable ties so the leads can be removed with the PMG stator Figure 6 14 3 Notethe position of the PMG stator leads which exit at the left inboard side or mark the stator so it can be reinstalled in the same position 4 Remove the four mounting capscrews see figure 6 15 5 Carefully remove the PMG stator from its mounting pads and slide over the PMG rotor The magnets used in the PMG are very strong They will resist removal of the PMG stator figure 6 16 KR Figure 6 15 PMG Rotor Removal 1 Remove the exciter armature and PMG stator follow instructions found earlier in this section 2 Remove the snap ring which holds the PMG rotor in place o
33. 9 256 216 293 338 458 378 513 545 739 608 824 819 1110 891 1208 Plated 10 14 11 15 9 26 22 30 35 47 39 53 56 76 62 84 84 114 96 130 124 168 136 184 168 228 192 260 300 407 336 456 484 656 540 732 728 987 792 1074 57 Specifications Table 12 3 Excitation Data 60 Hz 1800 RPM Exciter Field Exciter Field Volts No Load Output Voltage W Fixed Model Number Resistance F1 amp F2 at Regulator Excitation High Wye Connection Low Volts Ohms 25 C No Load 240 480 Volts 12V DC 24V DC 431RSL4007 22 5 14 2 450 545 432RSL4009 445 535 432RSL4011 460 550 432RSL4013 490 580 432RSL4015 440 530 432RSL4017 450 545 433RSL4021 22 5 13 7 450 550 572RSL4024 23 0 16 1 440 520 572RSL4027 23 0 16 1 440 520 572RSL4028 23 0 17 5 425 510 572RSL4030 23 0 15 2 440 530 573RSL4032 15 0 445 530 573RSL4034 23 0 17 0 430 520 574RSL4038 23 0 15 0 440 540 575RSL4044 410 510 740RSL4046 410 510 741RSL4045 440 540 742RSL4046 22 0 15 6 430 540 742RSL4048 22 0 17 4 410 525 742RSL4050 22 0 13 7 460 565 743RSL4052 400 510 744RSL4054 22 1 18 6 400 510 744RSL4056 22 1 19 4 400 515 744RSL4058 22 1 20 3 400 515 744FSL4060 22 1 420 570 744FSL4062 22 1 410 535 Exciter Field Exciter Field Volts No Load Output Voltage W Fixed Model Number Resistance F1 amp F2 at Regulator Excitation Wye Connection Medium Volts Ohms 25 C No Load
34. RSL4054 22 1 22 6 320 420 744RSL4056 22 1 23 3 330 415 744RSL4058 22 1 24 3 330 415 744FSL4060 22 1 17 0 350 470 744FSL4062 22 1 19 5 330 440 Exciter Field Exciter Field Volts No Load Output Voltage W Fixed Model Number Resistance F1 amp F2 at Regulator Excitation High Wye Connection Medium Volts Ohms 25 C No Load 3300 Volts 12V DC 24V DC 573FSM4354 23 0 18 2 2700 3600 574FSM4358 23 0 15 7 2800 3800 741FSM4360 3000 3800 742FSM4366 22 0 15 6 2800 3800 743FSM4370 22 1 15 5 2900 3800 744FSM4374 22 1 16 8 2700 3800 744FSM4376 22 1 16 8 2700 3800 NOTES For rated load exciter field volts see generator nameplate For low wye connection divide value shown in table by 2 For high delta connec tion divide value shown in table by 1 732 For delta connection divide value shown in table by 1 732 marathon Generators 59 Specifications Table 12 5 Resistance Values Table 12 6 Resistance Values Main Windings Exciter Windings Nominal Cold 25 C Nominal Cold 25 C Resistance in Ohms Resistance in Ohms Base Model Winding Main Main Exciter Exciter Low Voltage H SG Stator Rotor Low Stator Rotor PMG 431RSL4005 153 Voltage Field Armature Stator 432RSL4009 190 432RSL4011 186 970 Frames 2 1 432RSL4013 189 740 Frames 2 1 432RSL4015 225 432RSL4017 296 Zemane 2 1 433RSL4019 286 742 Frames 2 1 433RSL4021 430039 0137 297 572RSL4024 570078 EC e 572RSL4027 570072 398 572RSL4028
35. When using alligator clips or push on terminals be sure the leads are supported so vibration does not shake them loose when running the generator set See figure 8 1 for measurement points and expected meter range settings When in doubt start with a higher range and work down Consult meter instruction manual to verify its opera tion and limitations marathon Generators 47 Generator Testing Figure 8 1 Typical Voltage Measurements Test Point Output T leads or bus bars also main circuit breaker line side Voltage Measurement Meter Range Selection Requirement System voltage volts AC see generator nameplate and connection diagram Generator Output Voltage Regulator Output F1 and F2 terminals 200 volts DC range F1 is plus and Excitor Stator Input at the regulator Regulator Sensing Voltage at the regulator Regulator Input Volts PMG Output Volts Current Amp Measurements Current measurements AC can be easily taken with a clamp on type meter Note Most clamp on ammeters will not measure DC When measuring generator output current be sure the clamp is around all cables for each phase If the physical size of the conductors or the capacity of the meters will not permit all cables to be measured at once each one can be measured individually Add the individual readings together to get the total Compare readings to the generator nameplate nameplate ratings are
36. a conductive film over the insula tion increasing the possibility of insulation failure Machines operating in dirty places should be disas sembled and cleaned periodically Air Intake and Exhaust Check the area around the air intake and exhaust openings to be sure they are clean and unobstructed Remove all foreign material and clean all screens figure 5 1 Figure 5 1 Electrical Connections and Windings Inspect for loose or contaminated connections Check wires for cracked or frayed insulation Tighten connec tions and replace defective or oil soaked insulation If inspection shows that varnish coatings on the windings have deteriorated they should be recoated with insulating varnish Please refer to Marathon Electric for insulation system requirements Lubrication All generators are lubricated before leaving the factory and are ready for operation As a general rule bearings should be relubricated annually or at the indicated intervals in table 5 3 whichever occurs first Unusually severe operating conditions such as high ambient or dusty environments require more frequent lubrication every six months or one half the table intervals whichever occurs first Use Mobile Polyrex EM or equivalent anti friction type high quality grease with a lubrication tempera ture range of 22 to 350 F 30 to 175 C During an overhaul the grease reservoir should be thoroughly cleaned and new grease added The res
37. ansformers must have the same or proportional ratios that give approximately the same secondary current C Voltage regulator paralleling circuitry must be the same D Current transformer secondaries and the generator lines must be isolated electrically Because of the preceding criteria reactive differential compensation cannot be used when paralleling withthe utility power grid Thereisno limit however inthe number of generators that can be included in this type of circuit E It is also desirable to have an auxiliary contact on the main generator breaker to short the parallel CT secondary when that breaker is open not connected to the load bus Paralleling Circuitry Because of the number of variables involved in paralleling generator sets every installation will have its own circuitry and methods or procedure of Installation bringing paralleled units on line There are numerous ways of connecting paralleled units and an almost unlimited variety of applications and associated equipment When parallel operation is desired it is important that the control manufacturer the generator manu facturer and the systems engineer work together to insure the proper selection of all components Please refer to Marathon Electric for application assistance Thyristor or SCR Loading Solid state electronic control devices which utilize thyristors or SCR firing circuits such as variable frequency induction motor controls preci
38. arathon Electric for parts or new generator purchase Email generator help marathonelectric com Web site http www marathonelectric com Verify that the voltage at the regulator input from the PMG is within tolerance Refer to SEC 8 No Remove the capacitor and re test If the problem persists replace PMG and re test Yes Symptom Voltage Regulator Protective Circuit Is Operating Symptom Voltage Regulator Shutdown on Over Temperature Check indicators on the regulator Correct problems and adjust regulator as required Refer to regulator manual Correct cooling Problems Refer to the regulator manual Verify all results and if problem persist contact Marathon Electric Email generator help marathonelectric com marathon Generators 45 Troubleshooting Symptom Equipment Runs Normally On Utility Power But Will Not Run On Generator Set Voltage Wave Form Distorted Important Note Verify all Test _ equipment against known good Also verify all fuses wiring and generator connections are correct as per SEC 3 amp 8 of this Manual prior to Trouble Shooting Analyze load Excessive SCR Thyristor loading will cause distortion Some equipment may be sensitive to distorted waveforms Verify all results and if problem persist contact Marathon Electric Email generator help marathonelectric com
39. e change No Refer to No Voltage Residual Voltage Trouble shooting Symptom Check exciter field Voltage Bad Refer to Sec 8 amp 12 ADJ Regulator as per the appropriate regulator manual Verify all results and if problem persist Refer to No Voltage Residual Voltage Trouble shooting Symptom marathon 42 Generators Troubleshooting Symptom Generator Voltage Is Fluctuating Important Note Verify all Test equipment against known goodR Also verify all fuses wiring and generator connections are correct as per SEC 3 amp 8 of this Manual prior to Trouble Shooting Use Tachometer and or Frequency Meter Verify shaft speed matches Name Plate Correct shaft speed and retest Contact Marathon Electric for parts or new generator purchase Email generator help marathonelectric com Web site htto www marathonelectric com ls the Governor Stable No Repair replace and retest as needed Use the Voltage Regulator to adjust stability Does Voltage become stable If remote voltage adjust is used verify operation No Refer to your Regulator Manual in order to continue Trouble Shooting The Generator appears to be Functionally operating Verify all results and if problem persist Refer to No Voltage Residual Voltage Trouble shooting Symptom marathon Generators 43 Troubleshooting 44 Symptom Generator no
40. e kind of dirt and when the unit must be returned to service Drying after cleaning is necessary Whenever the generator is disassembled the windings should be given a thorough inspection and the insula tion cleaned if necessary The inspection should include the connection of the windings insulation and varnish coverage Check the winding ties and coil supports Look for any signs of coil movement or looseness and repair as required An electric motor repair shop in your area can normally assist with the proper cleaning of the generator windings They may also be experienced in special problems such as seacost marine oil rig mining etc that may be peculiar to a certain area Solvents A solvent is usually required to remove accumulated soil containing oil or grease Only petroleum distillates should be used for cleaning electrical components Petroleum solvents of the safety type with a flash point greater than 100 F 38 C are recommended Winding varnishes are epoxy or poly ester based A solvent that does not attack these materials should be used Adequate ventilation must be available to avoid fire explosion and health hazards where solvents are used Avoid breathing solvent vapors Rubber gloves or other suitable protection for the hands should be used Wear eye protection Maintenance Apply the solvent with a soft brush or rag Be careful not to damage the magnet wire or insulation on the windings
41. end bracket outer bearing cap grease pipes and capscrews to remove all dust dirt and grease 3 Inspect the capscrews for stripped threads and Figure 6 47 replace if defective 4 Inspecttheend bracket for stripped threads cracks and burred or rough mating surfaces Inspect the bearing bore for burrs or wear If the bracket shows excessive bearing bore wear it should be repaired or replaced figure 6 48 5 Inspect the mounting pads for the PMG stator and exciter stator Be sure they are smooth clean and free of any burrs or rust that could interfere with proper alignment figures 6 47 and 6 48 Figure 6 48 6 Reassemble the grease pipes and fittings to the bearing cap Drive End Bracket or SAE Adapter Inspection 1 For two bearing generators remove the grease plugs from the bracket 2 Clean the bracket or adapter capscrews and screen assembly to remove all dust dirt and grease 3 Inspect the capscrews for stripped threads and replace if defective Figure 6 49 4 Inspect the bracket or adapter for stripped threads cracks and burred or rough mating surfaces figures 6 49 and 6 50 5 For two bearing generators inspect the bearing bore for burrs or wear If the drive end bracket shows excessive bearing bore wear it should be repaired or replaced Figure 6 50 marathon Generators 31 Service Main Stator Inspection 1 Clean dust and dirt from the stator frame and winding see
42. enerators have 3 coil groups with 6 or 12 cables coming out of the generator marathon Generators 9 Installation 4 Lead Wye Four lead generators have 3 coil groups with one end of each group connected together There are 4 8 or 16 cables or 4 bus bars coming out of the generator Cit PLO 3 Lead Delta Three lead generators have 3 coil groups with one end of each group connected into a Delta internally There are 3 6 or 12 cables or 3 bus bars coming out of the generator marathon 10 Generators Installation 12 Lead Zigzag Zigzag connection with 12 lead machine only Connect L L L LO 60 HZ 12 Lead 120 240 T To Ts Tay Ly ACAUTION The generator kW kVA rating is approximately 50 of it s 3 phase rating when connected for single phase Typical System Diagram Exciter Rotor PMG Rotor Main Rotor U0 OO Exciter PMG Stator Stator Voltage Regulator marathon Generators 11 Installation Paralleling Operations MAGNAMAX e generators come standard with amortisseur windings die cast as an integral part of the rotor This exclusive uni rotor construction makes all MAGNAMAX generators suitable for paralleling operations when the proper control equipment is added Paralleling with other generator sets and or with the utility power grid offers a number of advantages Multiple unit installations increase power capacity they can be added o
43. erator The following procedure should be followed for starting up the generator for the first time 1 The generator output must be disconnected from the load Be certain that the main circuit breaker is open 2 Disable the voltage regulator by removing the fuse AWARNING Do not overspeed the generator Excessive centrifugal forces could damage the rotating fields Be prepared for an emergency shut down 3 Followthe manufacturer s instructions and start the prime mover Check the speed and adjust the rom shown on the generator nameplate 4 Replace the regulator fuse and adjust the voltage to the required value figure 4 2 Check all line to line and line to LO voltages to be sure they are correct and balanced If the voltages are not correct shut down immediately and recheck all connections See section 3 5 Close the main circuit breaker and apply the load 6 Monitorthe generator output current to verify itis at or below nameplate amps 7 Adjust engine speed at full load to 1800 rpm for 60 Hz 1500 rom for 50 Hz refer to prime mover governor instruction manuals 8 Before stopping the engine remove the load by tripping the main circuit breaker marathon 14 Generators Voltage Adjustments The generator output voltage is controlled by the voltage regulator There is a cover to access the control panel on the side of the generator conduit box figures 4 1 and 4 2 Refer to the regulator manual f
44. ervoir should be 1 3 to 1 2 filled with new grease NOTE Mobil and Polyrex are registered trademarks of Exxon Mobil Corporation or one of its subsidiaries marathon 16 Generators Lubrication CAUTION Follow the generator nameplate recommendations for grease interval and amount Table 5 3 intervals and amounts are general guide lines A CAUTION Generators are pre greased_ with Mobil Polyrex EM NGLI 2 grease unless stated otherwise on the generator nameplate Non compatible lubricants can break down polyurea thick ened grease and cause bearing failure Compatible greases include but are not limited to Chevron SRI Shell Gadus S5 T100 Rykon Premium EP NLGI 2 Texaco Polystar RB NLGI 2 and Shell Oil Dolium R Use only non contaminated grease and prevent contamination while regreasing dA CAUTION Overgreasing bearings can cause pre mature bearing and or generator failure The quan tity of grease added must be carefully controlled Generators are properly lubricated at the time of manufacture It is not necessary to lubricate at the time of installation unless the generator has been in storage for a period of 12 months or longer Table 5 3 Frame Bearing Type Size Size Ounces 431 432 433 571 572 573 574 Single Bearing Units 741 742 743 744 Double Bearing Units Hours of running time or annually whichever occurs first Amount of Grease Cubic Inche
45. ews to 60 ft lb 81 N m 5 Note Balance weights on the fan are for balance of the complete rotor assembly The rotor assembly should be rebalanced if a new fan has been installed Figure 6 41 Belleville washers must be 6 Ontwo bearing generators install bearing cap ET E director and new bearing according to the bearing assembly instructions Item A C Drive Hub Single Bearing Generators Only Figure 6 42 1 Check the drive hub for cracks or stripped drive disc mounting holes Replace the hub if defective marathon Generators 29 Service If the hub is to be replaced remove the fan see Item B and install a suitable puller to the hub Remove the two setscrews in the hub over the key Using a torch rapidly heat the hub at the outer diameter while tightening the puller this must be done rapidly before the heat can expand the shaft Remove the hub figure 6 43 To insure proper fan location mark the new hub in the same place as the old hub relative to the keyway Install key in shaft Heat the new hub in an oven to 500 600 F 260 316 C Using suitable heat resistant gloves slide the hub over the key in the shaft until it seats against the shaft shoulder figure 6 44 Allow the hub to cool for one hour After the hub has cooled tighten the setscrews in the hub to 50 ft lb 68 N m torque Match the alignment marks on the fan and hub and mount the fan see Item B Rebalancing
46. g Two bearing generators are provided with a shaft extension and keyway For direct coupled units the assembler furnishes a flexible coupling which is installed between the driver and the generator shaft Important Aligning the two machines as accurately as possible will reduce the vibration increase bearing life and insure minimum coupling wear It may be necessary to shim the generator feet for proper sup port and alignment Consult the coupling manufac turer s instructions for alignment specifications and procedures marathon Generators Belt Drive 430 frame two bearing generators can be belt driven Please refer to Marathon Electric for application assistance involving belt driven installations Sheave diameters should be chosen according to the table below MAGNAMAX Sheave Application for Two Bearing Units Min Sheave Dia In Inches 20 000 Hr B 10 Life Width 60 Hz 50 Hz 16 9 14 2 19 8 17 3 22 5 19 5 Min Sheave Dia In Inches 10 000 Hr B 10 Life 60 Hz 50 Hz 13 0 10 9 431RDL4007 15 2 13 3 432RDL4009 17 0 14 8 O Assumptions A Belting factor is 1 3 B The drive and the driven sheaves are the same diameter C The sheave load is located at the center of the shaft extension D Based upon continuous kW ratings These sheave diameters exceed the maximum recommended belt speed of 6000 ft min B 10 Life means 90 of the bearings will last this long or
47. he interior of the generator from shavings when drilling or sawing An approved connector must be used in conjunction with the conduit To minimize the transmission of vibration it is essen tial that flexible conduit be used for all electrical entrance to the generator Refer to the connection diagram supplied with the generator and or the proper diagrams shown in this section Install all intercomponent and external wiring in accordance with the regulations of the national and local electrical codes Clean all contact surfaces to assure good electrical bonding with the generator lugs or bus bars Use heavy duty terminal lugs or good quality clamps for making all connections Insulate all connections in accordance with national and local regulations Be sure the generator frame is grounded to all the other components of the system with a ground wire in accordance with national and local regulations Generator Lead Connections The electrical connections in the conduit box should be made in accordance with the appropriate connection diagram Use the diagram appropriate for the num ber of leads and voltage range required Refer to the drawings supplied with the generator and to drawings in this section The final voltage setting is established within the selected range by an adjustment of the voltage regulator AXCAUTION Some generators have multiple iden tically marked cables for each lead Connect all identically marked
48. he reactive current flowing between the generator sets Switchgear There are additional relays and breaker controls which are necessary to insure safe trouble free operation of paralleled units Reverse power relays monitor the direction of power flow to insure that the generator is delivering the power not accepting it These power relays control breakers which are a means of connecting and disconnecting the generator from the load The total system can include over voltage over current protection under frequency protection power factor correction provision and various associated control equipment from manual switchgear to microprocessors The amount of control gear and level of sophistication will be determined by the needs and requirements of the particular application Paralleling Basics The following points are basic criteria which must be met before two units can be paralleled THIS IS NOT MEANT TO BE SPECIFIC INSTRUCTIONS FOR PARALLELING OPERATION 1 Additional paralleling circuitry A Voltage regulator paralleling provisions B Paralleling current transformer s C Paralleling provisions on governor controls D Switchgear 2 The voltage and frequency must be the same for all sets with voltages in phase 3 Thevoltageregulationcharacteristics ofthe individual generators should be similar 4 The generators must have the same phase rotation The driving engines should have the same speed regulation characteristics
49. in series with the DC power source will work 3 Short circuit the generator output lead wires to each other L1 to L2 to L3 If using jumpers be sure they are large enough to carry full load amperage 4 Start the generator and measure the current through the output leads with a clip on ammeter 5 Adjust the voltage source to produce approximately 80 of the rated AC nameplate amps but in no case exceed nameplate amps If an adjustable source is not available and current is excessive use a lower DC source voltage or a larger resistor in series with the source Running time will be determined by the amount of moisture present in the machine Insulation resistance checks should be taken every one to four hours until a fairly constant value is obtained see section 8 Generator Testing for instructions on measuring insulation resistance 6 After the generator is dry and the insulation resistance is brought up to specifications remove the short circuit from the line leads disconnect the DC source and reconnect the F1 and F2 leads at the regulator Be sure all connections are tight and correct before attempting to run the generator marathon 18 Generators Cleaning Methods When electrical components get dirty the insulation must be cleaned There are a number of acceptable methods for cleaning the generator each of which will necessitate disassembly of the unit The method of cleaning will be determined by th
50. inals for AWG 14 wire Figure SS marathon 54 Generators Preparation For Shipment Shipping Instructions Shipping and handling will be much easier if the generator is fastened to a suitable shipping skid that will allow handling by a forklift The skid should extend beyond the generator in all directions If the original skid is available it should be used Marathon Electric will supply shipping skid drawings upon request Overseas shipping may require special export crating Check with your freight carrier When installed single bearing generator rotors are supported on the drive end by the drive discs bolted to the engine flywheel When the engine is removed the rotor must be supported by an appropriate fixture to prevent main rotor main stator or exciter damage figure 11 1 Before shipping any single bearing generator the main rotor must be supported by the adapter using an appropriate fixture ACAUTION Do not attempt to transport any generator without proper rotor support Extensive equipment damage can occur Figure 11 1 Or Extended Storage Storage Instructions If the generator or gen set is placed into storage the following precautions should be taken to protect it A Equipment must be kept clean 1 Store indoors 2 Keep covered to eliminate airborne dust and dirt 3 Cover openings for ventilation conduit connec tions etc to prevent entry of rodents snakes birds insects
51. ing the generator for the first time the following checks are recommended 1 Avisual inspection should be made to check for any loose parts connections or foreign materials Refer to section 8 2 Check for clearance in the generator and exciter air gap Be sure the generator set turns over freely Bar the generator over by hand at least 2 revolutions to be sure there is no interference Do not apply any force to generator fan when rotating generator rotor Disregarding these instructions may cause personal injury or equipment damage 3 Check all wiring against the proper connection diagrams and make sure all connections are properly insulated Support and tie leads to keep them from being damaged by rotating parts or by chafing on sharp corners 4 Be sure the equipment is properly grounded 5 Inspect for any remaining packing materials and remove any loose debris building materials rags etc that could be drawn into the generator 6 Check fasteners for tightness 7 Check to be sure no tools or other hardware have been left inside or near the machine 8 Install and check to be sure all covers and guards are in place and secure WARNING Residual voltage is present at the generator leads and at the regulator panel con nections even with the regulator fuse removed Caution must be observed or serious personal injury or death can result Consult qualified personnel with any questions Starting Up the Gen
52. iter Stator Lifting Fixture figure 10 1 In cases where the exciter stator is to be serviced without removing the generator conduit box this fixture can be used with overhead rigging to remove and rein stall the exciter stator Exciter Rotor Puller Bolt figure 10 2 The exciter rotor has a built in pulling system With the use of this bolt the rotor can be easily removed from the shaft without damage to the winding Figure 10 3 Snap Ring Pliers figure 10 3 The PMG rotor is installed to the generator shaft with a snap ring The nominal shaft diameter is 2 3 4 inches and the ring must be spread approximately 3 4 inches for removal To install the snap ring use a piece of pipe with a 2 3 4 inch ID figure 10 4 Push the PMG rotor and snap ring onto the shaft until the ring snaps into the groove Figure 10 4 marathon Generators 53 Special Tools Rotor Lifting Fixture figure 10 5 The main generator rotor is heavy approx 1 2 the weight of the generator and difficult to handle The proper fixture should be used whenever removing or in stalling the main rotor into the main stator Without proper care and equipment the windings can be easily damaged Miscellaneous A selection of wiring devices such as electric connectors tape cable ties crimping and stripping tools etc should also be a part of the generator service tool kit The standard regulator uses flat 1 4 inch female insulated term
53. marathon Generators MagnaMax Installation Operation and Maintenance Manual d el i i eise coca ty LEE SE M M E x RRE CRW Do E ee 0 RW WWW LU gie oe e D D D H H a d wi ww D D L 6 CR a KL KC a ae ee ee Li kd a e Beef eo A Regal Brand D D D LU kd ee a a ee ee ele k S l e D REGAL u E D LSW vk 6 e eeeeeeeg eee e ee d WWW os 6 d Z WW marathon Generators Table of Contents Section Page Se 1 2 General Information 2 3 It dE E d EE 4 13 D e EE EE EE EE 14 15 5 Maintenance aama vt meee t24828 36232 hee 422220630 0924 16 19 D SOVI c 244 8 E 2 A RARA PARIER RA EE 20 38 Troubleshooting ccc 39 46 D Generator e e WEEN 47 50 D Ee E EE EE 51 52 53 54 Preparation for Shipment or Extended Storage suussusuuesssnss 55 PECINA ON eere ranere ESEESE EPET 56 60 Generator FormulaS cc 61 Warnings amp Cautions cc eee eee eee 62 Back Inside Cover marathon Generators A Few Words About Safety PLEASE REMEMBER SAFETY FIRST If you are not sure of the instructions or procedures seek qualified help before continuing This service manual emphasizes the safety precau tio
54. minum die cast rotor core affords high mechani cal integrity and low vibration at operating speeds Amortisseur winding and coil supports are die cast as an integral part of the rotor Laminations are 4 pole one piece laminations which are shrunk fit and keyed to the shaft No dovetails cross bolts or other pole to shaft connecting devices are used The cast unidirectional aluminum alloy ventilating fan provides even air distri bution to maximize cooling and generator efficiency Adapters and Drive Discs All single bearing units are available with several adapter and drive disc arrangements These can be shipped to order or can be changed in the field with standard shop tools When changing flexible drive discs spacers are used between the discs and the cast iron hub to maintain SAE standard dimensions Electrical Design General All standard products have 2 3 pitch main windings to eliminate the third harmonic This serves to lower operating temperatures give lower harmonic content and better wave form and extend the overall life of the generator The phase sequence is ABC when rotated counterclockwise viewing exciter end Temperature Rise All ratings and frame sizes are based on NEMA and CSA Class F and Class H temperature rises on both the rotor and stator windings Ratings for interna tional and marine applications are available Standby Generator Synchronous generators used on emergency backup power can have temperature
55. n be installed inside of the generator When energized from a power source other than the generator they will heat and dry the inside of the generator If an alternate source of electricity is not available enclose the generator with a covering and insert heating units to raise the tem perature 15 18 F 8 10 C above the temperature outside of the enclosure Leave a hole at the top of the enclosure to permit the escape of moisture Oven Place the machine in an oven and bake it at a temperature not to exceed 194 F 90 C The voltage regulator and any electronic component accessories must be removed from the generator when using this method Forced Air A portable forced air heater can be used by direct ing heat into the air intake conduit box and running the generator with no load and without excitation this can be accomplished by removing the regulator fuse Heat at point of entry should not exceed 150 F 66 C Short Circuit Method The generator can be dried out quickly and thor oughly by using this method Be sure that all of the following steps are performed and all precautions taken as personal injury or serious damage to the generator could result 1 Disconnect exciter leads EI and F2 from the regulator 2 Connect a battery or other DC power source of approximately 20 35 volts to the exciter leads F1 and F2 An adjustable voltage source is desirable however a rheostat rated approximately 2 amps
56. n in storage for a year or longer it is recommended that it be lubricated according to the lubrication instructions and chart found in Section 5 If the machine has been exposed to damp humid conditions the insulation resistance should be checked Refer to Section 8 Generator Mounting Single Bearing Single bearing generators are provided with an SAE flywheel adapter and flexible drive discs Very close tolerances are maintained in the manufacture of the generator so that the alignment procedure is extremely simple A coupling hub of nodular iron is shrunk onto the shaft and special steel drive discs are bolted to the hub Holes are pro vided in the periphery of the coupling disc which correspond to tapped holes in the flywheel The outside diameter of the discs fits in a rabbet in the flywheel so that concentricity is assured in all cases AWARNING Do not apply any force to gen erator fan for lifting or rotating generator rotor Disregarding these instructions may cause personal injury or equipment damage AXCAUTION Grade 8 capscrews and heavy series lockwashers or grade 8 placebolts and hardened washers are recommended to mount the drive discs to the flywheel The SAE adapter and the flywheel housing are designed to match each other with no further alignment necessary Shims may be necessary under the feet of the generator to insure a solid mounting See Section 6 for more information Generator Mounting Two Bearin
57. n the shaft figures 6 17 and 6 18 430 Frame LOADING SPRING OUTER PMG ROTOR INNER SNAP RING SNAP RING p Figure 6 16 OUTER SNAP RING Figure 6 17 Figure 6 18 marathon Generators 23 Service 3 Slide the PMG rotor off of the shaft figure 6 19 4 Remove the loading spring if the loading spring is not on the shaft check to see if it is stuck on the back of the PMG rotor 5 On 430 frame generators a second snap ring is used inboard of the PMG rotor larger generators have a step on the shaft This snap ring must be removed before the generator s main rotor can be removed figure 6 20 Figure 6 20 Main Rotor Removal 1 Remove the exciter armature and PMG follow instructions found earlier in this section 2 a Forsingle bearing generators remove the four capscrews holding the bearing caps to the front end bracket figure 6 21 Remove the outer cap figure 6 22 b For two bearing generators remove the drive coupling or sheave and key from the shaft extension Remove the four capscrews holding the bearing lock to the drive end bracket figure 6 23 Remove the four capscrews holding the bearing caps to the front end bracket figure 6 21 Remove the outer cap figure 6 22 Figure 6 22 Figure 6 19 Figure 6 23 marathon 24 Generators Service 3 If the screen assembly is still mounted remove the bolts securing the screen assembly to the d
58. ns necessary during the installation operation and maintenance of the MAGNAMAX generator Each section has caution and warning messages These messages are for your safety and the safety of the equipment involved If any of the cautions or warnings are not readily understood seek clarifica tion from qualified personnel before proceeding Before any service work is done disconnect all power sources and where appropriate lock out all controls to prevent an unexpected start up of the generator set Proper grounding in compliance with local and national electrical codes must be provided These safety precautions are necessary to prevent potential serious personal injury or even death The hazards associated with lifting or moving the MAGNAMAX generator are pointed out in the installation and service sections incorrect lifting or moving can result in personal injury or property damage Safety Whenever the generator is running always assume and proceed as if voltage is present Residual voltage is present at the generator leads and at the regulator panel connections even with the regulator fuse removed Caution must be observed Otherwise serious personal injury or death can result Whenever solvents cleaners or flammable liquids are present adequate ventilation must be available to avoid fire explosion and health hazards Always avoid breathing vapors and use suitable personal pro tective equipment to prevent per
59. ntified for reinstal lation Remark as required 1 Remove conduit box covers figures 6 1 and 6 2 2 Disconnect all external wiring from the generator leads or bus bars inside the conduit box Remove all conduit or ducting from the conduit box Figure 6 1 Attach a suitable hoist to the generator lifting lugs GA D a Forsinglebearing generators removethe bolts mounting the screen assembly to the SAE adapter and remove the screen figure 6 3 Note Do not remove the dripcover from the screen assembly if so equipped Remove the capscrews attaching the drive discs to the flywheel and remove the capscrews attaching the SAE adapter to the flywheel housing Mi 8 b For two bearing generators disconnect the coupling or sheave and belts between the generator and prime mover followthe coupling manufacturer s instructions for disconnection Do not apply any force to the generator fan for lifting or rotating the generator rotor Disregarding these instructions may cause personal injury or equipment damage Figure 6 2 6 Remove the mounting bolts which secure the generator tothe base To make reinstallation easier note the position of and save any shims that were used under the feet for alignment 7 Raise the generator slightly and move the gen erator away from the prime mover Raise or lower the generator to take pressure off of the drive discs so they slide easily out of the flywheel 8 On single
60. on 32 33 34 35 36 37 38 40 41 42 43 44 45 46 Exciter Rotor Fastener Capscrew Belleville Washer Grounding Stud Assembly Stud Washer Nut Bus Bar Assembly Voltage Regulator Capacitor Side Panels Blank Machined For Regulator Fuse Solid Cover Louvered Cover Exciter Rect Assembly incl 43 44 45 Diode Standard Polarity Diode Reverse Polarity Surge Suppressor Cover Mounting Screws Note This parts list is for reference only Always give complete generator model and serial numbers when ordering parts 52 marathon Generators Special Tools Standard Tools The MAGNAMAX generator is assembled with American standard SAE hardware Wrench sizes from 5 16 inch to 7 8 inch are used A socket head set screw is used in the drive hub A 1 4 inch allen type wrench is required to remove it All fasteners should be properly torqued see section 12 Torque wrenches ranging from 25 in lb through 200 ft lb should be available Electrical test equipment should include a voltmeter or multimeter VOM clamp on ammeter accurate frequency meter or tachometer and a megohmmeter See section 8 Generator Testing for more information j Figure 10 1 Special Tools In addition to the standard tools mentioned above the following special tools will facilitate removal and installation of large and or special parts These tools can be obtained from the Marathon Electric parts department Figure 10 2 Exc
61. or detailed information In cases where special or remote mounted regulators are used refer to instructions supplied by the generator set assembler and to the voltage regulator manual Other Adjustments Depending upon application adjustments to other protective and control gear may be required Refer to instructions supplied by the generator set manu facturer The standard MAGNAMAX voltage regulator also has many protective and control circuits built in Refer to the regulator manual for further details Field Flashing The standard MAGNAMAX generator is supplied with a PMG permanent magnet generator It will never require field flashing In rare cases where a special generator may be furnished without a PMG refer to the factory for more detailed information Include the complete gen erator model and serial number see page 3 Regulator Access Operation See Figure 4 2 for enhanced view of this area Figure 4 1 Standard Marathon Electric Regulator marathon Generators Figure 4 2 15 Maintenance Maintenance General Information Dirt heat moisture and vibration are common enemies of a generator Keeping the generator clean and dry maintaining proper alignment of the generator and its prime mover and preventing overloads will result in efficient operation and long life Generators that are outdoors should be protected from the elements by suitable houses or enclosures
62. oth directions An open diode will read high in both directions Notes 1 Two different polarities of diodes are used The only difference is in the way the device is mechanically placed in the case When changing diodes be sure the correct polarity is used refer to section 6 figure 6 34 2 Some meters do not have enough voltage output from their internal batteries to turn the diode on about 0 6 volts is required and the voltage can change with different range settings Consult the instruction manual for your meter 3 Polarities supplied by the meter s internal battery may or may not correspond to the markings on the meter Insulation Resistance General Insulation resistance is a measurement of the integrity of the insulating materials that separate the electrical windings from the generator s steel core This resist Generator Testing ance can degrade over time or due to contaminants dust dirt oil grease and especially moisture Most winding failures are due to a breakdown in the insula tion system In many cases low insulation resistance is caused by moisture collected when the generator is shut down The problem can be corrected simply by drying out the windings see section 5 Normally the resistance of the insulation system is on the order of millions of ohms It is measured with a device called a megger which is a megaohm meter meg is for million and a power supply The power supply
63. ounting Nut 2 Drip Cover Assy Option 3 SAE Adapter 3 Adapter 2 Adapter 1 Adapter 1 2 Adapter 0 Adapter 00 Adapter 18 Disc 00 Adapter 21 Disc 4 Disc Mounting Fasteners Capscrew for 11 1 2 Capscrew for 14 Capscrew for 18 Capscrew for 21 Capscrew for Delco Hardened Washer 5 Drive Discs 11 1 2 Disc 14 Disc 18 Disc 21 Disc Delco Disc 17 75 OD 6 Spacers For 11 1 2 Disc For 14 Disc For 18 Disc For 21 Disc For Delco Disc 7 Fan Mounting Fasteners Capscrew Capscrew 2 brg only Belleville Washer 8 Fan 9 Hub Drive Hub single brg only Fan Hub 2 brg only 10 Drive Hub Set Screws Item Part Description 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 Drive Hub Key Main Rotor Assembly With Windings Front Bearing Cap Front Ball Bearing Main Body Assembly Adapter Mtg Fasteners Capscrew Lock Washer Flat Washer Bracket Mtg Fasteners Capscrew Lock Washer Flat Washer Front Bracket PMG Bearing Cap Bearing Cap Fasteners Capscrew Lock Washer Conduit Box Conduit Box Mounting Fasteners Capscrew Lock Washer Snap Ring Inner Loading Spring PMG Rotor Snap Ring Outer PMG Stator PMG Stator Mtg Fasteners Capscrew Belleville Washer Exciter Stator Exciter Stator Fasteners Capscrew Belleville Washer Exciter Rotor Assembly incl 42 430 Frame All 570 Frame Low Voltage 570 Frame Medium Voltage Item Part Descripti
64. piece of pipe slightly larger than the shaft 2 3 4 inches to push the rotor back against the loading spring until the snap ring seats in the slot figure 6 68 4 Install the PMG stator on it s mounting pads with the leads in the left 9 o clock inboard position and secure with the four mounting capscrews and belleville washers figures 6 69 and 6 72 Torque to 6 ft lb 8 N m 5 Route and secure PMG stator leads away from moving parts Figure 6 68 ech Figure 6 65 PP Figure 6 69 Figure 6 66 marathon Generators 35 Service Exciter Installation 1 Attach a wire to the main rotor leads and feed the wire through the armature bore and out the lead hole in the aluminum standoff plate On larger exciters it will be helpful to install a guide pin in the end of the shaft to support the armature while fishing the rotor leads through figure 6 70 Align the key in the armature bore to the keyway in the shaft Slide the armature on the shaft while feeding the main rotor leads through the lead hole in the aluminum standoff plate figure 6 71 Figure 6 71 Belleville washers must be Insert the capscrew and belleville washer mounted in this direction figure 6 72 through the mounting hole in the aluminum standoff plate and secure to the shaft figure 6 73 Tighten the capscrew until the arma ture seats on the shaft Torque to 84 ft lb 114 N m Figure 6 72 for 1 2 bolt or 300 ft lb 407 N
65. protective device leads marked P1 P2 etc per instructions supplied with the motor e Operation of a motor at other than its nameplate rating may result in fire damage to equipment or serious injury to personnel e For safety Buyer or User should provide protective guards over all shaft extensions and any moving apparatus mounted thereon The User is responsible for checking all applicable safety codes in his area and providing suitable guards Failure to do so may result in bodily injury and or damage to equipment AXCAUTION e Consult qualified personnel with questions and all electrical repairs must be performed by trained and qualified personnel only e For motors nameplated as belted duty only do not operate the motor without belts properly installed e Motors and or driven equipment should not be operated faster than their rated speed e For inverter applications follow the inverter manufacturer s installation guidelines e Make sure the motor is properly secured and aligned before operation marathon 62 Generators Resale Of Goods Important Information Resale of Goods In the event of the resale of any of the goods in whatever form Resellers Buyers will include the following language in a conspicuous place and in a conspicuous manner in a written agreement covering such sale The manufacturer makes no warranty or representations express or implied by operation of law or otherwise as to the merchantabilit
66. r removed from the line depending on the load requirements they can be better maintained and repaired since single source breakdown would mean total loss of power and they often provide more reliable efficient and economical operation Successful parallel operation means that the generators deliver power to the external system without delivering power to each other or accepting power from the load bus or power grid Additional equipment is necessary to insure safe and successful operation Prime Mover The prime mover provides the speed and torque which will be necessary to keep the machines in synchro nized operation The governor will directly control the watt or kW load and frequency of the unit The prime mover speed is controlled by a governor The governor must have special paralleling provisions to permit parallel operation with the other machines Voltage Regulator The voltage regulator controls the generator output voltage and the reactive power supplied by the generator When two or more AC generators oper ate in parallel the voltage regulator must have paralleling provisions either internally or external to the regulator to allow the voltage regulator to control the reactive or VAR load while it is in parallel operation A separate paralleling current transformer is required to sense the reactive cur rent and signal the voltage regulator This addi tional paralleling circuitry is absolutely necessary to control t
67. rive end bracket or the SAE adapter and remove the screen assembly figure 6 24 Note Do not remove the drip cover from the screen assembly if so equipped 4 For single bearing generators remove the cap screws and hardened washers holding the drive discs to the drive hub figure 6 25 Remove all drive discs and spacers if any Figure 6 26 5 a For single bearing generators remove the capscrews holding the SAE adapter to the generator andremove the adapter figures 6 26 and 6 27 b For two bearing generators remove the capscrews holding the drive end bracket to the generator and remove the bracket figures 6 26 and 6 28 Figure 6 27 Figure 6 24 d Figure 6 28 Figure 6 25 marathon Generators Service On large generators a hoist and lifting strap should be used to assist in drive end bracket or SAE adaptor removal 6 Using a rotor lifting fixture and a suitable hoist carefully remove the rotor assembly from the main stator and frame assembly through the drive end figure 6 29 A CAUTION Special care should be taken when removing the main rotor winding damage could result if the rotor is allowed to hit the main stator Do not apply any force to the generator fan for lifting or rotating the generator rotor Disregarding these instructions may cause personal injury or equipment damage Figure 6 29 Front End Bracket Removal 1 Remove front bracket mounting screws figure 6
68. s Maintenance Lubrication Procedure 1 Read CAUTION statements at left 2 Stop generator and lock out of service 3 Remove contaminants from fill and drain plugs and surrounding area 4 Remove fill and drain plugs Figure 5 2 5 Check fill and drain holes for blockage and clean as necessary to allow unobstructed grease flow 6 Insert 1 8 N P T grease fitting in fill pipe 7 Add proper type and amount of grease per gener ator nameplate or see Table 5 3 8 Start unit with drain plug removed Allow unit to run 15 minutes to allow excess grease to drain 9 Wipe off excess grease and replace fill and drain plugs Generator is ready for operation GREASE FILL P ic GREASE RELIEF PIPE Figure 5 2 Intervals Teaspoons 60 Hz 50 Hz 6500 8400 5600 7200 3000 4500 marathon Generators 17 Maintenance Drying Electrical Insulation Electrical components must be dried before placing in operation if tests indicate that the insulation resis tance is below a safe value see section 8 generator testing for test procedure Machines that have been idle for sometime in unheated and damp locations may have absorbed moisture Sudden changes in temperature can cause condensation or the generator may have become wet by accident Windings should be dried out thoroughly before being put into service The fol lowing are recommended drying methods Space Heaters Electric space heaters ca
69. s the value is 100 megohms If the reading is below the recommended value the winding must be dried out or repaired Insulation Resistance Main Rotor Disconnect the main rotor leads from the diode bridge on the exciter rotor Connect the leads together with the positive megger lead Connect the negative megger lead to a good ground on the rotor assembly such as the exciter mounting bolt Take the megohm reading refer to instructions for the megger The minimum value is 5 megohms If the reading is low the winding must be dried out or repaired Insulation Resistance Exciter Stator Disconnect the exciter leads F1 and F2 from the regulator Never subject the regulator to a megger Connect F1 and F2 together with the positive megger lead Connect the negative megger lead to the ground stud Take the megohm reading refer to instructions for the megger The minimum value is 5 megohms If the reading is low the winding must be dried out or repaired Insulation Resistance Exciter Rotor Disconnect the exciter rotor windings 6 leads from the diodes Connect all leads together with the positive megger lead Connect the negative megger lead to a good ground on the rotor assembly such as the mounting bolt Take the megohm reading refer to the instructions for the megger The minimum value is 5 megohms If the reading is low the winding must be dried out or repaired Main Rotor Field AC Impedance Test Theory
70. section is intended to suggest a systematic approach to locating and correcting generator or regulator malfunctions The sections are arranged according to the symptoms of the problem The steps in each section have been arranged in an attempt to 1 Do the easy checks first 2 Prevent further damage when troubleshooting a disabled machine The first and perhaps most important step of trouble shooting should be to gather as much information as possible from personnel who may have been present during the failure Information on how long the generator had been running what loads were on the line weather conditions what protective equipment operated etc can help isolate the problem Always make a thorough visual inspection to check for any obvious problems before attempting to run the generator Troubleshooting High voltages can be present at the generator and regulator terminals High residual voltages can be present even with the regulator disconnected or its fuses removed Some equip ment such as space heaters may be energized when the generator is off Tools equipment clothing and your body must be kept clear of rotating parts and electrical connections Special caution must be taken curing troubleshooting since protective covers and safety devices may be disabled to gain access and make tests AWARNING Be careful Serious personal injury or death can result from these hazards Consult qualified personnel
71. sion motor speed controls no break powered battery chargers etc can introduce high frequency harmonics which adversely affect or destroy the normal waveform of the generator This creates additional heat in the generator stator and rotor and can cause over heating These devices can and do present problems to non utility power generating equipment or any limited power bus system The problems which can occur are not limited to the generator itself but can effect the solid state control device the equipment it controls other associated loads monitoring devices or a number of combinations over the entire system MAGNAMAX generators can supply power to thyristor or SCR loads when properly applied When SCR loads are more than 25 of the total load select the generator based on the 80 C R R rating The standard voltage regulator is PMG powered and senses 3 phase RMS voltages for maximum stability against severely distorted wave forms SCR type applications such as cranes shovels etc require special consideration of the generator insulation sys tem due to greater dielectric stress and severe envi ronmental conditions It is important that the control manufacturer the generator manufacturer and the systems engineer work together to insure the proper selection of all components Please refer to Marathon Electric for application assistance marathon Generators 13 Operation Pre Start Inspection Before operat
72. sonal injuries such as eyes face and hand protection This manual is not intended to be a substitute for properly trained personnel Repairs should only be attempted by qualified trained people The cautions and warnings point out known conditions that are potentially dangerous Each installation will create its own set of circumstances No manual can cover every possible situation When in doubt ask Don t be embarrassed to ask dumb questions Remember dumb questions are much easier to handle than dumb mistakes marathon Generators 1 General Information Mechanical Design General All single and two bearing units are manufactured with cast iron end brackets and adapters and fabricated steel frames Flexible drive discs and SAE adapters are machined to SAE standards Prelubricated regreasable shielded ball bearings are used on MAGNAMAX generators Standard units are fully guarded Dripproof shields are available as an option Conduit Box The large front end mounted conduit box is con structed of formed sheet steel which will allow the addition of top mounted control packages Refer to Marathon Electric for top mounted controls of more than 240 Ibs There is ample room inside the conduit box for a circuit breaker through 800 amp ratings and other options The conduit box cover properly directs outside ven tilating air through the generator MAGNAMAX Uni rotor Construction An alu
73. to any other lead should be infinite Measure from the T lead to the generator frame to check for grounds reading should be infinite Exciter Stator The exciter stator resistance is measured by discon necting the F1 and F2 leads at the regulator Measure the resistance between the leads this value is 22 24 ohms on standard generators Measure from the leads to the frame to check for grounds marathon 48 Generators Main Rotor Note markings and disconnect the main rotor leads F1 leads and F2 leads from the rectifier assembly Measure the resistance of the main rotor winding Compare reading to value shown in service specifi cation section 12 Measure from the leads to the exciter mounting bolt to check for grounds Exciter Rotor Disconnect the exciter rotor leads at the diodes leave leads disconnected if proceeding to check diodes Measure resistance between phases Compare value to service specifications section 12 Measure from the leads to the exciter mounting bolt to check for grounds Testing Diodes Rectifiers Diodes perform the function of an electrical check valve They conduct in one direction only and are used to rectify AC current into DC current To test measure the resistance first in one direction and then reverse the leads and test in the other direction The reading should be high in the reverse direction and low in the forward direction A shorted diode will read low in b
74. to release the feeler gauge and torque the remaining SAE adapter cap screws to the flywheel housing torque specifications given in section 12 Mount the screen assembly and tighten the mounting bolts b For two bearing generators align the coupling halves or sheaves between the generator and the prime mover by adding shims under the feet Shim under the generator feet for proper support ensuring that the generator mounting surfaces are level Install the mounting bolts which secure the generator to the base For two bearing generators assemble the coupling halves or sheave belts between the generator and the prime mover followthe coupling manufacturer s instructions for assembly and alignment Connect all existing conduit or ducting to the conduit box Connect all external wiring to the generator inside the conduit box Check the exciter air gap gap between the exciter armature and stator by inserting a 010 inch feeler gauge in the gap and rotating it around the armature diameter to ensure that a minimum air gap is available see figure 6 80 If the feeler gauge cannot be rotated on full revolution then check for a cocked exciter stator or loose stator mounting capscrews Note On single bearing units the exciter air gap cannot be checked properly until the generator is mounted to the prime mover Install the conduit box covers Figure 6 80 marathon Generators Introduction This
75. to the regulator manual for more information marathon Generators How to Read a Model Number It is extremely important to properly identify the machine when requesting parts or service General Information Adapter Drive Disc Arrangement SAE Size SAE Size A 3 11 1 2 Always have available the generator model number and 2 11 1 2 serial number when requesting information from the 4 8 factory We cannot help you without this information 3 10 It is also beneficial to know the mounting arrange 1 11 1 2 ment code see figure 2 1 1 14 4 7 1 2 1 Delco An Example for MAGNAMAX Generators 1 2 14 2 10 Example 431 RSL 4000 AA 1 2 Delco 00 00 0 14 2 Small Delco Frame Number None None A 18 R Random Wound 0 Delco F Form Wound 18 6 1 2 S 1 Bearing 21 D 2 Bearings 10 Figure 2 1 L Up to 480 volts S 600 volts M 1000 6900 volts Style 4 Magna slant type conduit box 8 Magna square conduit box Model in Series Electrical mechanical modification minor modification used in sequence A B C etc must specify when requesting WK marathon Generators Installation Receiving Your MAGNAMAX Generator Upon receipt of the generator it is recommended that it be carefully examined for possible damage incurred in shipment The generator was given to the freight company in good condition and they are responsible for the product from our dock to yours Any damage should
76. with any questions marathon Generators 39 Troubleshooting Symptom Generator Produces High Voltage Important Note Verify all Test equipment against Known good Also verify all fuses wiring and generator connections are correct as per SEC 3 amp amp of this Manual prior to Trouble Shooting Use Tachometer and or Frequency Meter Verify shaft speed No matches Name Plate Correct shaft speed and retest Use the Voltage Regulator to adjust valtage Does the voltage change Contact Marathon Electric for parts or new generator purchase Email generator help marathonelectric com No Web site http www marathonelectric com Refer to your Regulator Manual in order to continue Trouble Shooting The Generator appears to be Functionally operating Are the proper diodes installed and is their olarity correct No p ty Refer to Sec 6 Repair replace and retest as needed Yes Verify all results and if problem persist contact Marathon Electric Email generator help marathonelectric com marathon 40 Generators Troubleshooting Symptom Generator Produces Low Voltage When Load is Applied Important Note Verify all Test equipment against known good Also verify all fuses wiring and generator connections are correct as per SEC 3 amp 8 of this Manual prior to Trouble Shooting Measure amps to verify Name Plate rating not
77. y lifted by the support Install and ground per local and national codes e Discharge all capacitors before servicing a single phase motor e Misapplication of a motor in a hazardous environment can cause fire or an explosion and result in serious injury Only the end user local authority having jurisdiction and or insurance underwriter are qualified to identify the appropriate class es group s division and temperature code Marathon Electric personnel cannot evaluate or recommend what motors may be suitable for use in hazardous environments If a motor is nameplated for hazardous locations do not operate the motor without all of the grease and drain plugs installed e Never attempt to measure the temperature rise of a motor by touch Temperature rise must be measured by thermometer resistance imbedded detector or thermocouple e Motors with automaticreset thermal protectors will automatically restart when the protector temperature drops sufficiently Do not use motors with automatic reset thermal protectors in applications where automatic restart will be hazardous to personnel or equipment e Motors with manual reset thermal protectors may start unexpectedly after the protector trips when the surrounding air is at 20 Fahrenheit or lower If the manual reset protector trips disconnect motor from its power supply After the protector cools five minutes or more it can be reset and power may be applied to the motor e Connect all
78. y or fitness for a particular purpose of the goods sold hereunder Buyer acknowledges that it alone has deter mined that the goods purchased hereunder will suitably meet the requirements of their intended use In no event will the manufacturer be liable for consequential incidental or other damages Even if the repair or replacement remedy shall be deemed to have failed of its essential purpose under Section 2 719 of the Uniform Commercial Code the manufacturer shall have no liability to Buyer for consequential damages Resellers Buyers agree to also include this entire document including the warnings and cautions above in a conspicuous place and in a conspicuous manner in writing to instruct users on the safe usage of the product This information should be read together with all other printed information supplied by Marathon Electric For more information contact Regal Beloit America Inc a subsidiary of Regal Beloit Corporation 100 E Randolph St Wausau WI 54401 Phone 715 675 3311 or Fax 715 675 8030 marathon Generators marathon Generators 100 E Randolph Street PO Box 8003 Wausau WI 54402 8003 U S A PH 715 675 3359 FAX 715 675 8026 www marathonelectric com 2013 Regal Beloit Corporation MANUAL GPN008 7598J 5K 8 13 BH FS Printed in the U S A A Regal Brand REGAL www regalbeloit com

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