here - Cojo Technologies, Inc.
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1. on INN COJO Technology CERAMAG 403 275 6047 HAZARDOUS LOCATION POWER SYSTEMS www cojo ca Calgary Alberta w ef A 60 Alternator Class 1 Division 2 Owners manual rev1 0 models A 6024 A 6012 A 6024S A 6012S Hazardous Location Generator and Power Products Specialists Generators Alternators Power supplies Controls COJO Technology Inc 1003 P 55th Ave NE Calgary AB T2E 6W1 p 403 275 6047 f 403 275 6175 info cojo ca www cojo ca TABLE OF CONTENTS 1 OVERVIEW 2 CONSTRUCTION 3 OPERATION 3 1 Self Exciting and Charging 3 2 Regulating the Output Voltage 3 3 Re magnetizing or Flashing 3 4 Installing the pulley 4 PRECAUTIONS 5 TROUBLESHOOTING 6 Alternator dimensions AIK Universal mount dimensions Speed power curve 1 OVERVIEW This alternator has been developed specifically for industrial equipment which demand a high level of durability In order to decrease maintenance the brushes and slip rings which wear in time have been eliminated from the brushless alternator To generate electricity this alternator adopts a system in which the alternator s internal residual magnetism is used for initial activation Once the alternator starts operating the electrical power that the alternator itself generates is supplied to the exciting coil which is used for self excitation This alternator is equipped with an internal voltage regulator The voltage regulator monitors t2. self excited starting and the alternator rpm at this time is called turn on speed 3 Simultaneously with self excited starting the charging current flows from the alternator s B terminal to the battery and starts the charging of the battery 3 2 REGULATING THE OUTPUT VOLTAGE 1 As the charging of the battery advances and the battery terminal voltage reaches the regulator s regulating voltage the regulator shuts off the current that flows to the exciting coil 2 When the current that flows to the exciting coil is shut off the magnetic field that is generated in the exciting coil weakens causing the voltage that is generated in the stator coil to decrease which reduces the alternator s output voltage 3 When the voltage that is generated in the stator coil becomes lower than the regulator s regulated voltage the regulator allows the current to flow to the exciting coil As a result the magnetic field that is generated in the exciting coil strengthens causing the voltage in the stator coil to increase 3 3 Loss of magnetization In the event that the A 60 Alternator loses magnetism it will be unable to self start To re magnetize the alternator you must flash the alternator 1 Magnetizing Flashing disconnect the battery s from the alternator terminal posts using a Y2 socket remove the nuts holding the wires to the alternators terminal posts L Terminal lift the alternator wires from the terminal po
3. wound over a donut shaped insulated core An electric current flows through the coil to produce a magnetic field 3 Rotor The rotor is two claw shaped cores which face each other The rotor rotates in the space between the exciting coil and the stator in order to transfer the magnetic field that is generated in the exciting coil to the stator in the form of magnetic flux 4 Junction Box The junction box comes in two sizes LJB 2 3 4 depth with 1 1 4 trade size KO for applications of up to 60 amps SJB S models 1 3 4 depth with 3 4 trade size KO for applications up to 30 amps The junction box contains 2 battery connection posts Polarity is indicated by colour red and black Stator Exciting Coil JUNCTION BOX Fw Rectifier d Pulley Lock Nut Battery Stator Coil po H4 L d Exciting Coil 3 1 SELF EXCITING AND CHARGING 1 When the engine is started the alternator s rotor rotates and the residual magnetic field generates voltage in the stator coil 2 As generated voltage increases with the increase in the engine rpm the electric current flows from the auxiliary diode to the exciting coil Thus a strong magnetic field is created by the exciting coil causing the voltage that is generated in the stator coil to increase suddenly to the battery voltage NOTE The excitation by residual magnetism changes over to that of self generated excitation This is called
4. he voltage that is generated during operation of the alternator and regulates the current that is supplied to the exciting coil thus maintaining the constant output voltage For Hazardous locations Listed as CLASS 1 DIV 2 GROUP C D for use in hazardous locations Cast Aluminum Housing Corrosion resistant housing and rotor in a compact and lightweight design SAE J180 mounting standard Upgrades existing alternators which utilize this standard Heavy Duty bearings Aligned in precision castings for optimum alignments and protection from debris Specifications A 6024 A 6012 A 60 S rated voltage 24 Vdc 12 Vdc 12 24 rated output 60A 60A 30A starting RPM 1200 1200 1200 Max RPM 8000 8000 8000 regulated voltage 27 29 Vdc 13 14 5 Vdc weight 23 lbs 23 lbs 23 lbs Length 11 1 8 11 1 8 10 3 8 operating temperature 40 90C 40 90C 40 90C Area classification Class1 Div2 Classi Div2 Classi Div2 mounting kit AIK CIK AIK CIK AIK CIK 2 CONSTRUCTION The interior of the alternator is self cooled by a rotating fan The alternator consists of the following parts a stator rotor exciting coil regulator rectifier frames etc 1 Stator The stator consists of a laminated steel core The core contains a coil providing a three phase stator connection The stator coil receives magnetism from the rotor which generates an alternating current 2 Exciting Coil The exciting coil consists of a coil that is
5. ion 10 89 ADJUST ANCHOR 1 2 NC JUNCTION BOX us SS Ii 7 8 shaft 1 1 4 lona i i 11 4 TRADE SIZE K D 0 55 SS EEN CLEARANCE F R 1 2 T o O AUS A 6860 UNIVER Abe MEN O 1 10 00 5 00 cen 1 1 y 9 50 gt 80 E Z D UI SU x E gt O Z0 E 2 V 25 degC 2 al 20 O 1 2 3 4 5 6 7 RPM x1000
6. s Another cause of undercharged batteries is cable length and wire size It is recommended to use no less than 2 AWG and keep wire runs between the alternator and the batteries no more than 30 feet of one way wire length No charging can also be caused by the rotor having no residual magnetism refer to flash magnetizing method in this document Symptom Location of Malfunction Possible Cause Action Mo charging Alternator Faulty regulator Replace regulator Faulty stator coil Replace stator open or short circuit Faulty exciting coil Replace exciting coil open or short circuit Faulty rectifier Replace rectifier diode open or short circuit Poor contact at connections Repair or replace wining Open circuit in wiring Repair or replace Blown fuse or fusible link Constantly Alternator Faulty stator coil Replace stator undercharging 1 phase open or short circuit paid bos Faulty rectifier Replace rectifier cla aa diode open or short circuit Repair or replace Excessive curent demand Increase alt output EC ADAN A large electric load is used Reduce the electric load Belt Insufficient tension Altennator Faulty regulator Replace regulator Poor contact at voltage detection Repair or replace portion Faulty battery Replace battery Alternator Faulty stator coil Replace stator Constantly overcharging battery electrolyte is depleted in a short time Abnormal noise short Faulty bearing s Improper beit tens
7. sts using a 8mm socket remove the 3 screws that fasten the junction box to the alternator housing remove the junction box from the rear of the alternator Momentarily connect an appropriate battery 12V or 24V to the L terminal plus and F Wi terminal minus A ze F Terminal of the regulator as shown in the figure A 12V type alternator 12V battery 24V type alternator 24V battery Magnetizing 3 4 Tightening the pulley Insert the collar and fan onto the rotor shaft Insert the pulley shim onto the rotor shaft between the pulley and fan Secure the pulley with belt using a vise as shown in the figure tighten the pulley lock nut with specified torque Tightening torque 117 6 137 2N m 1200 1400kgf cm Torque Wrench 4 PRECAUTIONS 1 Precautions during operation Do not disconnect the battery while the alternator is rotating Do not operate the alternator with the alternator s terminal output terminal disconnected 2 Other precautions Make sure to disconnect the battery terminal before inspecting the alternator Do not interchange the polarity of the battery cables when replacing the battery Make sure to disconnect the cables and charge the battery separately when using a charger Never use a Mega Ohm tester on the alternator Make sure to disconnect the wiring to the alternator when performing a Mega ohm test on other wiring 5 TROUBLESHOOTING Additional trouble shooting note
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