TRANSFORMER REGULATED
Contents
1. Increase the number of transformer secondary turns by replacing the 4 transformer lead to AC on the Bridge Rectifier with the x transformer lead See SECTION 7 2 8 7 UNCONTROLABLE VOLTAGE a CAUSE Incorrect engine adjustment SOLUTION Check engine operation speed fuel lines and injector b CAUSE Transformer secondary leads shorting SOLUTION Check resistance GENERATOR RESISTANCE VALUES ARMATURE 470 520 Ohms per phase 5 10kW 655 720 Ohms per phase 12 5 50 kW FIELD 10 14 ohms 5 10kW 11 15 ohms 12 5 50 kW STATOR ohms vary with kW rating but less than 1 0 OHM per phase ROTOR kW s 8 10 12 5 15 17 5 20 25 30 50 ohms 1 47 1 58 1 73 1 84 2 00 2 1 2 2 2 5 3 8 9 FLASHING THE FIELD Disconnect all incoming power leads to the generator Disconnect amp C leads from the Exciter Field Connect the F lead to the lead of a 12 volt battery Connect the C lead to the lead of a 12 volt battery Start the engine and operate at 1800 rpm no load Check the NO LOAD VOLTAGE the voltage should be within 10 of rated load If the residual voltage is now normal the transformer is OK and the problem is elsewhere sao Boop 10 CHECKING DIODES IN THEARMATURE All Fidelity Electric armatures have 6 diode rectifiers arranged in a full wave pattern Three forward biased diodes are mounted on a heat sink and three reversed biased diodes are m2. APPLIED 43 PROTECT YOURSELF AGAINST ELECTRICAL SHOCK Never operate the generator or handle any electrical equipment while wet barefoot or while it is raining 44 MAINTAIN ALL ELECTRICAL CORDS IN GOOD CONDITION Worn frayed or bare wires will cause severe electrical shock 45 ALWAYS DISCONNECT ALL ELECTRICAL LOADS BEFORE WORKING ON THE GENERATOR 46 ALWAYS PROVIDE ADEQUATE VENTILATION Engines consume oxygen and give off deadly monoxide gases 5 INSTALLATION 5 1 Location Environment The engine generator set must be installed in a protected environment With minimal exposure to fumes moisture dust and dirt THE AMBIENT AIR TEMPERATURE MUST NOT EXCEED 40 C 104 F CONTINUOUS DUTY a b DO NOT obstruct the generator intake and outlet air passages Provide sufficient air circulation around the set to remove engine heat and to provide ample generator cooling Hot air from the radiator or engine should not pass through the generator Check the mounting surface to be sure that it is rigid enough to keep vibration and noise to a minimum 52 Base Mounting Generator must be mounted securely Use shims as necessary under generator feet to be sure that feet are uniformly supported before tightening hold down bolts If the generator is not uniformly supported the frame could become distorted resulting in noise and vibration that could damage the generator 53 Mechanical Mounting To mount a single bearing generator to
3. Road salts are extremely corrosive to the insulation and terminals All possible precautions should be made to avoid road splash and salts coming into contact with any generator parts KEEP PARTS FREE OF CORROSION Inspection With the pot cover or control box cover removed examine rotor shaft and bearing for excessive wear Replace bearings after 10 000 hours of normal operating time or sooner if wear is evident SPARE PARTS Always include the name or the part the quantities of each part ordered and the serial and model numbers from the generator nameplate when ordering parts
4. in voltage replace suppressor WILL NOT HOLD VOLTAGE a CAUSE Loss of residual magnetism SOLUTION Flash Field see SECTION 9 b CAUSE Exciter Field has been disconnected SOLUTION Flash Field see SECTION 9 c CAUSE Rotor shorting out when unit gets hot SOLUTION Check rotor windings for broken or burned wires d CAUSE Pinched leads SOLUTION Examine all lead wires and connections FULL VOLTAGE AT NO LOAD VOLTAGE DROPS AT FULL LOAD a CAUSE Loose or broken lead wires SOLUTION Check lead wires and connections for broken wires loose connections Compare connections with the wiring diagram supplied with generator b CAUSE Rotor is opened or shorted SOLUTION Measure the resistance between the leads See FIG 8 1 for resistance values c CAUSE Stator ground or shorted SOLUTION Run generator for five minutes Stop immediately if there is smoke or a hot smell is detected If the voltage does not build and the generator is hot there is a short circuit in the stator windings Examine for burred insulation DO NOT REMOVE FROM FRAME Disconnect leads from terminal board and measure the resistance T1 amp T2 T3 amp T4 each should have equal resistance A lower reading indicates a short in that winding Replace stator CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION 8 5 LOW VOLTAGE a CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOL
5. to Bridge Rectifier c The OHMMETER should show a resistance in only one direction d Make the following connections in a clockwise direction meter lead meter lead meter reading Bridge AC Bridge 0 Ohms Bridge Bridge 0 Ohms Bridge AC Bridge 0 Ohms e Reverse the polarity for the readings indicated below meter lead meter lead meter reading AC Bridge Bridge 10 Ohms Bridge Bridge 50 Ohms AC Bridge Bridge 10 Ohms f If a resistance reading other than those indicated is found a short exists in that Junction and the rectifier must be replaced 12 MAINTENANCE AND REPAIR 12 1 Periodic Cleaning and Inspection Clean and inspect the generator after every 200 hours of normal operating time If the generator is housed in a harsh environment clean and inspect more frequently If dirt and grease is allowed to build up the generator will run hotter lose efficiency and reduce the life of the generator 12 2 Cleaning 13 12 3 12 4 Remove all dust dirt and oil and grease build up from all external surfaces Use a low pressure air hose 25 PSI maximum to blow dirt and grease from the internal components through the fan opening NEVER USE STEAM OR WATER PRESSURE TO CLEAN ELECTRICAL EQUIPMENT Clean inside the control box Check for loose or damaged lead wires and loose components mounted in the box DO NOT REMOVE INTERNAL GENERATOR PARTS OR THE WARRANTY IS VOID
6. turning the armature bolt The shaft and rotor assembly is balanced and should turn freely f Start engine g Check vibration If excessive check all mechanical connections The generator voltage is adjusted at factory to a specified speed however it is advisable to verify upon installation To supply 60 HZ the speed should be 1800 to 1860 RPM at no load and should not fall below 1800 RPM by more than one percent at full load To supply 50 HZ the speed should be 1500 to 1550 RPM at no load and 1500 RPM at full load The generator voltage should build to its rated value within 5 seconds after rated speed is attained If voltage does not build the cause may be loss of residual magnetism in the exciter field due to improper installation See TROUBLE SHOOTING SECTION 8 of this manual for more information To be sure that the generator voltage will always build operate the generator at full load before installing in service Observe and record the generator voltage at no load and at full load Immediately after start up cold and after 30 minutes of full load hot the voltage can be adjusted to optimum values at no load and full load Test at actual load if possible If the voltage cannot be adjusted see TROUBLE SHOOTING SECTION 8 of this manual After operating for 30 minutes at full load check temperature rise If excessive examine the generator for obstructed air flow hot air recirculating into the generat
7. TRANSFORMER REGULATED BRUSHLESS GENERATOR INSTALLATION OPERATION AND SERVICE MANUAL GPN015 TABLE OF CONTENTS 1 INTRODUCTION 2 GENERAL DATA 3 INITIAL INSPECTION 4 SAFETY GUIDELINES 5 INSTALLATION 5 1 LOCATION ENVIRONMENT 5 2 BASE MOUNTING 5 3 MECHANICAL MOUNTING 54 ELECTRICAL CONNECTIONS 6 INITIAL START UP 7 ADJUSTING THE VOLTAGE 71 NO LOAD VOLTAGE ADJUSTMENT 7 2 FULL LOAD VOLTAGE ADJUSTMENT 73 ADJUSTING RESISTORS 8 TROUBLE SHOOTING 8 1 VISUAL EXAMINATION 82 NO VOLTAGE PRODUCED 83 WILL NOT HOLD VOLTAGE 84 FULL VOLTAGE AT NO LOAD VOLTAGE DROPS AT FULL LOAD 8 5 LOW VOLTAGE 8 6 VOLTAGE TOO HIGH 87 UNCONTROLABLE VOLTAGE 9 FLASHING THE FIELD 10 CHECKING DIODES IN THEARMATURE 11 BRIDGE RECTIFIER TEST 12 MAINTENANCE AND REPAIR 12 1 PERIODIC CLEANING AND INSPECTION 12 2 CLEANING 13 SPARE PARTS 13 14 15 15 15 15 INSTRUCTIONS TRANSFORMER REGULATED BRUSHLESS GENERATOR INTRODUCTION Thank you for choosing a MARATHON ELECTRIC transformer regulated generator We have been in the business of building quality generators since 1894 Taking advantage of the latest technical advancements to assure you the most reliable efficient trouble free generator available anywhere Please read the installation and service sections of this manual carefully A clean environment and proper installation are as critical to generator performance as is the engineering of the intern
8. UTION CAUSE SOLUTION CAUSE SOLUTION 8 6 VOLTAGE TOO HIGH a b CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION CAUSE SOLUTION Exciter field opened or shorted Measure resistance values See FIG 8 1 Defective diodes in the armature See section 10 Defective Bridge Rectifier Check polarity See test section 11 Low engine speed Check engine speed and generator ratings 1800 rpm 60 hertz 1500 rpm 50 hertz Transformer air gap too small Increase air gap in top laminations See SECTION 7 Open circuit in transformer secondary winding Check for continuity Resistance in VR1 resistor is too high No load voltages only see SECTION 7 3 Decrease resistance in 1 resistor Too many circuits in transformer secondary winding Decrease the number of transformer secondary turns by replacing the x transformer lead to AC on the Bridge Rectifier with the 4 transformer lead See SECTION 7 2 Defective Diode Check resistance see SECTION 10 Fast engine speed Check engine speed Transformer air gap too large No load voltage Reduce air gap in top laminations See SECTION 7 Short circuit on transformer secondary winding Check resistance value Resistance in Resistor too low No load voltages only see SECTION 7 3 Increase resistance in 1 Resistor Not enough circuits in transformer secondary winding
9. al components If you have any difficulty in installing or servicing your Fidelity generator our service and technical staff will be happy to assist you We are confident that if these guidelines are taken you will get many years of reliable service from your MARATHON ELECTRIC generator GENERAL DATA Construction Brush less Rotating Field Speed 60 hertz 1800 rpm 50 hertz 1500 rpm Fan cooled 40 degrees C Max Ambient Temp Insulation Class H NOTE If the generator is operated at 1500 RPM The voltage and kW rating will be 5 6 of the 1800 RPM rating Consult the manufacturer if a higher voltage or kW rating is required at 50 hertz 1500 RPM INITIAL INSPECTION Your MARATHON generator has been carefully inspected and tested before leaving the factory However it is wise to examine the unit before installation 3 1 Carefully unpack the generator and examine for any damage If there is any file a damage claim with the shipper or agent immediately Save all packing materials for inspection by agent SAFETY GUIDELINES In order to avoid personal injury and to prevent damage to equipment it is imperative that all the safety precautions listed below are followed when operating this equipment 4 1 READ THE OPERATIONS MANUAL CAREFULLY familiarize yourself with the equipment before operating Consider the limitations and potential hazards of electrical equipment before operation 42 NEVER START THE GENERATOR WITH AN ELECTRICAL LOAD
10. an engine See FIG 5 1 ao Tf Disconnect the positive terminal from the battery Place a jack or other support under the engine flywheel Remove the control box cover from the back of the generator Detach the ground lead Q and R lead from the rotor on the exciter armature See FIG 5 2 Remove the armature fastening bolt from the center of the shaft Mark the position of the armature so it can be replaced in the same position Remove armature from shaft CAUTION Do not damage the laminations or windings Remove the fan cover After the armature is removed the rotor shaft and drive disk assembly can be pulled from the frame CAUTION Do not scratch or cut the copper stator windings when removing rotor Use a strap around the generator rotor and shaft assembly and support from hoist DO NOT LOOSE the bearing anchor when the bearing is removed from exciter end bracket See FIG 5 3 FIGURE 5 1 DRIVE DISK LEADS MOUNTING FLANGE Exciter field and end bracket Exciter i Armature Es STATOR FAN COVER ARMATURE MOUNTING BOLT ROTOR amp STATOR Diode Rectifier Six Total AF22 Ky S Z uppressor Exciter Field Mounting Bolt R Lead Bolt the rotor and drive disk to the engine flywheel using the proper size lock washers and SAE grade 8 bolts Push the generator frame assembly carefully back over the rotor Replace the bearing anchor and car
11. e below to increase voltage or follow in reverse to decrease voltage Bridge Rectifier Transformer lead Stator lead to Transformer lead NOTES AC W U1 to 32 Minimal increase AC 4 W U1 to 32 AC x U1 to 24 AC x W U1 to 24 Maximum increase 7 3 ADJUSTING RESISTORS Adjusting the voltage on generators with resistors will be different from what was just explained above ADD SHIM TO REDUCE FULL LOAD VOLTAGE REMOVE SHIM TO INCREASE FULL LOAD VOLTAGE No load voltage is adjusted by changing the resistance in the resistors INCREASE VOLTAGE BY DECREASING RESISTANCE Decrease the distance between the leads on the 1 resistor DECREASE VOLTAGE BY INCREASING RESISTANCE Increase the distance between the leads on the resistor 8 1 8 2 8 3 8 4 TROUBLE SHOOTING This section is intended to help the user isolate the cause of the most common generator failures VISUAL EXAMINATION Inspect the generator visually Many problems are the result of simple oversight Look for obvious evidence burned areas pinched wires cracked insulation all connections should be fastened securely Check the operating speed and see that the unit has been reassembled and reconnected correctly NO VOLTAGE PRODUCED a CAUSE Faulty suppressor SOLUTION Disconnect suppressor from circuit Test generator If there is an obvious improvement
12. efully align the groove in the bearing with the bearing anchor before the bearing enters the bracket Mount the frame assembly to the engine flywheel housing with the proper size bolts lock washers and nut Remount the fan cover and hood To reassemble the exciter armature pull the rotor leads through the opening in the armature spider Turn the armature until it slips over the pins in the shaft CAUTION Do not pinch rotor leads Reassemble the armature to the shaft with the bolt and lock washer using Lock tight Use a 9 16 socket on the torque wrench and torque to 25 ft Ib Reconnect the and leads to the proper connections See FIG 5 2 Reconnect all incoming power leads to their proper connections as shown on wiring diagram Return control box cover Remove the jack support from under engine flywheel housing Reconnect the positive battery terminal lead 5 4 Electrical Connections The proper electrical connections required for your 1 PH or 3 PH generator can be found on the Schematic Wiring Diagram attached to the back of this manual NOTE BE SURE THAT ALL ELECTRICAL CONNECTIONS ARE CORRECT BEFORE STARTING THE GENERATOR 6 INITIAL START UP 6 1 6 2 6 3 6 4 6 5 6 6 6 7 Carefully inspect the unit before start up Be sure that all electrical connections are correct Look for pinched leads Tighten all connections securely All bolts should be securely mounted Rotate the shaft by
13. or or bypassed air air not pulled through generator Examine ratings and actual load applied to determine if the generator rating may be too low for the load applied CONTINUOUS DUTY FOR OPERATION AT AMBIENT TEMPERATURES ABOVE 40 DERATE kW RATING 2 PERCENT FOR EACH DEGREE C ABOVE 40 C For operations at high altitudes ratings must be derated 2 percent for each 1000 ft above sea level Frame temperatures above 60 C 140 F are too high ADJUSTING THE VOLTAGE A transformer regulated generator is designed to have superior motor starting compared to other types The regulation is within 5 of rated loads 7 1 NO LOAD VOLTAGE ADJUSTMENT The no load voltage can be adjusted by adding or removing SHIM located between the top laminations ADD SHIM TO INCREASE THE NO LOAD VOLTAGE REMOVE SHIM TO REDUCE THE NO LOAD VOLTAGE The SHIM should be made of a thin non conducting material such as Mylar or Polyester paper 003 015 in thick Pounding on the top laminations with a soft mallet to reduce the air gap can do reducing the voltage by 1 or 2 volts DO NOT increase the no load voltage by separating the laminations without filling in the gap with SHIM material Magnetic forces in the transformer will close the gap and reduce the no load voltage 7 2 FULL LOAD VOLTAGE ADJUSTMENT The full load voltage can be adjusted by changing the number of transformer secondary turns This will also effect the no load voltage See tabl
14. ounted on the armature hub a Use a Basic Analog OHMMeter and set to R 1 scale OHM meter leads red black b Check the diodes as a group with the following connections OHM meter lead to R terminal on armature hub OHM meter lead to ground Diodes are good if the resistance reading is approx 50 Ohms c Check for leakage in the diodes by reversing their polarity Diodes are good if the resistance reading is infinite d Resistance values other than those indicated suggest 1 or more faulty diodes Check each diode separately to isolate the defective diode e Disconnect terminals to each diode Check the Forward Biased Diode FWD group first 3 diodes on heat sink OHM meter lead to R terminal on armature hub OHM meter lead to the on diode indicated by red dot f Check for leakage in each diode by reversing polarity Resistance infinite g Check Reversed Biased Diode RVS group OHM meter lead to Q ground on armature hub OHM meter lead to the on each diode Resistance infinite h Check for leakage in each diode by reversing polarity Resistance 10 Ohms NOTE Resistance values other than those provided indicates that the diode is defective Replace Reconnect terminals to each other 11 BRIDGE RECTIFIER TEST a Use an Ohms METER set at DC scale OHM METER leads red black b Disconnect leads
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