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GENERATOR

INSTALLATION,
OPERATION, AND
MAINTENANCE
MANUAL

INDEX
Section

Safety
1
General I nformation
. .
2, 3
I nstallation ...... . . . . . .. .. . . . . . . . . . . . .. 4-1 3
Operati on .
, . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance . . . . . .. . . . . . . . . . . .. . . . . . 1 5- 1 7
Service
.
..
1 8-31
Troubleshooti ng
..
32-35
.

. . . . . . . .

. . . . . . .

. . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . .

. . . . . . .

. . . . . . . . . . . . . .

Section

!il

Generator Testi ng .
Parts List & Recommended
Spare Parts
Special Tools . .
P reparation For Shipment
Specifications a n d Data
Generator Formulas
.

36-39

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

40-4 1
42
. . 43
. 44-47
48

. . . . . . . . . . . . . . . . . . . . . . .
. . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . .

SAFETY$
Whenever the generator i s running, always assume
and proceed as if voltage is present. Resi d ual
voltage is present at th e generator leads and at the
reg ulator panel connections, even with the regulator
fuse removed. Caution must be observed, o r s.e r
personal i nj ury or death can result.

A FEW WOR DS ABOUT SAFETY


PLEASE REMEMBER SAFETY FIRST. I f you are not
sure of the instructions or procedures, seek qu alified
help before conti n ui ng.
This service manual emphasizes the safety precau
ti ons necessary d u ri ng the i nstallation, operati o n ,
a n d maintenance of t h e MagnaPLUS generator.

Whenever solvents, cleaners, or flammable liquids


are present, adequate ventilation must be avai lable
to avoid fire, explosi o n , and health hazards. Always
avoid breathing vapors and use suitable personal
protective equipment to p revent personal i nj u ries.
(Such as eyes, face, and hand protection.)

Each section has caution and warning messages.


These messages are for your safety and the safety of
the equi pment i nvolved. I f any of the cauti ons or
warnings are not readily understood, seek clarifica
ti on from q ualified personnel before proceedi ng.

This manual is not i ntended to be a substi tute for


properly trained perso n n e l . Repairs should only be
attempted by qualified trai ned people. The cautions
and warnings point out known conditions that are
potentially d angerous. Each i nstallation will c reate
its own set of circumstances. No man ual can cover
every possible situati on.

Before any service work is done, disconnect a l l


power sources a n d , where appropriate, lock out a l l
controls, t o prevent an u n expected start-up o f the
generator set. Proper g rounding in compliance with
local and national electrical codes must be provided.
These safety precautions are necessary to prevent
potenti al serious personal i njury, or even death.

When i n doubt, ask. Don't be em barrased to ask


" d u m b questions". Remember, d u m b questions are

'
The hazards associated with liftin g or movIng the
MagnaPLUS generator are pOinted out i n the i nstalla
tion and servi ce sections; i n c orrect lifti ng or movi ng
can result in personal i nj u ry o r property damage to
the u n it.

mucheasleTf6handfefhan'durilbrilisliikes:

"GENERAL INFORMATION
I EC, and a l l popular mari n e agencies are avai lable).
All standard prod ucts have 2/3 pitch main wi ndings
to eliminate the third harmonic. This serves to lower
operating temperatures, give lower harmo n i c con
tent and better wave form , and extend the overa l l life
of the generator.

MECHANICAL DESIGN
General
All single and two bearing units are man ufactured
with cast iron end brackets and adapters, and
fabricated steel frames. Flexi ble d rive discs and SAE
adapters are machined to SAE standards. Pre
l u b ri c ated , sealed b a l l b e a rin g s are used o n
MagnaPLUS generators. Standard units are fully
guarded. Dripp roof shields are available as an
opti o n .

Standby Generator
Synchronous generators used on emergency backup
power ca n have tem perature ri ses up to 25" C above
those for conti n uous operation. ( N EMA M G 1 -22.40
and MG 1 -22.84).

Co nduit Box
Premium Insulation System
The large front end mounted conduit box is con
structed of formed sheet steel w h i c h wi l l allow the
addition of top m o u nted control packages. Refer to
Marathon Electric for top mounted controls of more
than 240 Ibs. The cond uit box cover properly d i rects
outside venti lating air through the generator.

A l l Mag naPLUS generators are b uilt with Class H or


better i nsulation materials. All standard generators
are suitable for contin uous duty at Class F tempera
ture ri se and wi ll g ive equivalent or better wi nding
life expectancy to generators supplied wit h Class A
or B insulation systems operated within their tem
perature limits. The varni shes and epoxies used are
synthetic, non-hygroscopic. Multiple dip and bake
cycles of the main windi ng, make the standard
winding f un g u s and mo isture resistant. The
Magna PLUS rotor is wet wound wit h thermo-setti ng
epoxy applied between each layer for moisture and
abrasion resi stance.

MagnaPLUS Uni rotor' Construction


An a l umin u m di e cast rotor core affords high me
chanical integrity and low vibration at operati ng
speeds. Amortisseur w i nding and coil su p ports are
d ie cast as an integral part of the rotor. Laminations
are 4-Pole, one piece lam inations which are sh run k
fit and keyed to the s h aft. No dovetails, cross bolts
or other pole to shaft connecting devices are used.
The cast unidirectional a lu mi n u m alloy ventilating
fan provides even air distributi on to maxi mize cooling
and generator efficiency.

Power Factor
All stan dard generators are designed for operation
at rated kVA at 0.8 power factor but can be operated
at rated kVA over the 0.8 to 1 .0 power factor range.

Adapters and Drive Discs


MagnaPLUS Voltage Regulator
All single beari ng u n its 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 cha nging flexible drive
discs, spacers are used between the discs and cast
i ron hub to maintain SAE standard dimensions.

The standard voltage regulator is a f u l ly encap


s ulated, static type with a solid state bui ld up circuit.
T he MangaPL U S can use several optional regula
tors. A 3 lead exciter field is used allowing external
selecti on of field resi stances to better m atch various
reg ulator requi rements.

ELECTRI CAL DESIGN


Temperature Rise
All rati ng s and frame sizes are based on N EMA and
CSA Class F temperature rises on both the rotor and
stator windings. Ratings for B ritish, German, French,

--------2--

'

GENERAL INFORMATION
FIGURE 2-1

HOW TO READ A MODEL NUMBER


I t i s extremely i mportant to properly identify the
machine when requesti ng parts or service.

Arrangement
A
B

Always have the generator model n u m ber and serial


n u m ber when requesti n g informati on from the fac
tory. We cannot help you wi thout this informati o n .

E
F
H
J
K
L
M
N
0
S

AN EXAMPLE FOR M A G N A PLUS G EN ERATORS


Example:

43 2 S
CD

1 268
CD

3286 A A- F A

@@

CD 43 - 430 Frame
0 -4-Pole
1 - 6-Pole
2 - 4-Pole, extra length
3 - 6-Pole, extra length

S - SE R Generator

M - MAC Generator
R - Synchronous Motor
0- DOD Generator

CD Wi nding Model N u m ber


Mechanical Model N u m be r
@ Electrical modification - minor modifi cati on,
used in sequence A, B, C , etc.
Mechanical modification - minor modifcation
used in sequ ence A, B, C, etc.
@ Mounting arrangement - indicates adapter size
and d rive disc size. (Fi g ure 2-1)
A - Li ma Manufacturing Plant

Adaptor
SAE Size

Drive Disc
SAE Size

3
2
3
1

1 1 -1/2
1 1-11 2
10
1 1 -112
14
Delco
14
10
Delco
14
Small Delco
None
Delco

1
112
2
112
0
2
N one
0

INSTALLATION
If the machine has been exposed t o damp, h urnie]
c o n d i t i o n s the i n s u l atio n resistance s h ould be
checked . Refer to section 8.

RECEIVI NG YOUR MagnaPLUS GENERATOR

Upon receipt of th e generator, it is recomm ended


that it be carefu l l y examined for possible damage
i ncu rred in sh i pment. The generator was given to
the freight company in good condition, and they are
respo nsible for the produCt from our dock to yours.
Any damage s h o u l d be noted on the freight b i l l
before accepting the shipment. C l a i m s f o r d a m ages
must be promptly filed with the freight company.

GENE RATOR MOUNTING - SINGLE BEARING

Read all i n struction cards careful ly. When lifting,


attach a n overhead crane to the lifti n g lugs on the
generator frame. Apply lifti n g forces in a vertical
d i rection.

Single bearing generators are provided with an SAE


flywheel adapter and f lexi ble d ri ve discs. Very close
tolerances are m a i ntained i n the manufacture of the
generator so that the a l i g n ment procedure is ex
tremely si mple. A coupl ing h u b of nodular i ron is
shrunk on the shaft a n d special steel d rive d i scs are
bolted to the hub. Holes are provided in the periphery
of the c o u p l i n g d i sc w h i ch correspond to tapped
holes i n the flywheel. The outside diameter of the
discs fits i n a rabbet in the flywheel so that con
centricity is assu red in all cases.

WARN ING

WARN I N G

T H E L I FT I N G LUGS O N THE G E N ERATOR


ARE DES I G N ED TO S U P PORT THE G EN
ERATOR O N LY. DO NOT L I FT COM PLETE
GE N ERATOR SET B Y MEANS OF L I FT I N G
LUGS ON G E N E RATOR. PERSONAL I N J U R Y
O R E Q U I P M ENT DAMAGE MAY R ES U LT.

DO N OT A P P L Y ANY F O R C E T O G E N ERA
TOR FAN F O R L IF T I N G OR ROTA T I N G
G E N ERATOR R OTOR. DISREG A R D I N G
THESE INSTRUCTIONS MAY CAUSE PER
SONAL INJURY O R E Q U I PM ENT DAMAGE.

UNPACKING AND HANDLING

CAUTION: G R A D E 8 CAPSCREWS A ND HEAVY


SERIES LOCKWASHERS OR GRADE 8 PLACE
BO LTS A ND H A R D E N E D WASHERS ARE REC
O M M EN DED TO M OUNT THE DRIVE D I SCS TO
THE FLYWHEEL.

STORAGE
In the event that the generator is not to be i nstalled
on the prime mover i m mediately, it is recommended
that it be sto red in a clean, dry area which i s not
s u bject to r a p i d c h a n g e s i n t e m p e ra t u re a n d
h umidity.

The SAE adapter and the flywheel housing are de


sig ned to match eac h other with no further align
ment necessary. S h i m s may be necessary u n der the
feet of the generator to i ns u re a solid mounti n g. See
section 6 for more information.

PREPARATION FOR USE


Although the g e nerator is carefully i nspected and
tested in operati o n before it leaves the factory, it is
recommended th e u n it be thoroughly i nspected.
T h e i nsul ation on the wire should be i nspected a n d
a l l bolts s h o u l d be checked for tightness.

GENERATOR MOUNTING - TWO BEARING


Two bearing generators are provided with a shaft
extension and k eyway. F o r d i rect-coupled u n its, the
assem bler furnishes a flexible coupling which is i n
stalled between the driver and the generator shaft.

Remove all s h ipping tapes, bags, block s , and skids


which are used to prevent vibration a nd rotor
movement d u ri n g shipment. Dry, low-pressure com
pressed air of approximately 30 PSI (206 KPA) can
be used to blow o u t the interior of the generator. I n
t he case o f two bearing machines, it i s possible to
turn the rotor by hand to make sure that it rotates
sm oothly without binding.

I'(';"lMAAAI
HDN'
...::: L_=_=:....... _=_._=:

IMPORTANT: A l i g n i n g the two machines as ac


c u rately as possible w i l l reduce the vibration, in
crease beawear. I! may be necessary to s h i m the generator feet
for proper support and a l i g n ment. Consul! the
coupling manufacturer's instructions for al i gn ment
specifications and procedures.

-------

INSTALLATION
BELT DRIVE
430 frame, two bea ring generators can be belt
dri ven. Please refer to Marathon Electric for appli
cation assistance involving belt d riven installations.
Sheave diameters should be c h osen according to
the table below.

i nsulations and accessories such as space heaters


c a n i n c rease gen erator l i fe s i g n ificantly. I n ex
tremely d i rty and dusty e nvironments, a means of
providing filtered coo l i n g air to the generator is
recommended. Refer to M a rathon Electric for more
i nformation.
ELECTRI CAL CO NNECTIONS

MagnaPLUS Sheave Application


for T wo Bearing Units CD
Min. Sheave
Dia. in
Inches@
10,000 Hr.
B-10 LifeCD
Model
430S1260
430S1261
430S1262
430S1263
430S1 264
430S1 265
432S1266
432S1267
432S1268

60 Hz
6.6
7.3
8.3
9.8
1 1 .7
1 3.80
1 6.90
1 6.70
2 1 .30

50 Hz
5.5
5.6
6.5
7.6
9.2
1 0.8
1 2.4
1 3.2
1 4.6

Min. Sheave
Dia. i n
Inches@
20,000 Hr.
B-10 LifeCD
60 Hz
8.6
9.4
1 0.8
1 2.8
1 5.30
1 8.10
22.40
22.20
28.60

Max.
Sheave
Width
50 Hz Inches
7.3
7.5
8.8
1 0.2
1 2.4
1 4.60
1 7.00
1 8.00
20.1CD

8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5

CD Assumptions:
A. Belting factor is 1 .3.
B. The drive and the driven sheaves are the same
diameter.
C. The sheave load is located a the center of the
shaft extens i o n .
D. Based u p o n continuous k W ratings.
o These sheave d iameters exceed the maximum
recommended belt speed of 6000 fI/m in .
CD B-'1 0
l o n g or longer.
ENVIRO NMENTAL CO NSI DERATIONS
D i rt, moisture, heat, and v i b ration are enemies of
electrical equipment. Excessive exposure to the
elements will shorten the life of the generator. The
ambient temperature s h o u l d not exceed the value
shown on the generator nameplate. The MagnaPLUS
is b u i lt in a N E MA open type enclosure. Generators
for outdoor application should be p rotected from
the elements by housings with proper openings for
ventilation. T h i s protection should be designed to
prevent the d i rect contact of wind driven rai n , snow,
or dust with the generator. In moist or humid areas,
such as the T ropics a n d marine service, additional
protection is recommended. Although the standard
windings are hum idity a n d moisture resistant, special

T he generator conduit box construction allows


conduit to enter the top, bottom, o r either side of the
box. A hole-saw or any s u i table tool can be used to
provide for the conduit entrance. Protect the interior
of the generator from shavings when d ri l l i n g or
sawing. An approved con nector must be used i n
conjunction with the conduit.

T o m i n i m ize the transmission of vib ration, it is


essential that flexible c o n d u i t be used for all electri
cal entrance to the generator.
Refer to the connection d iagram supplied with the
generator and/or the proper diagrams shown in th is
section. I nstall a l l intercomponent and external
wiring in accordance with the regulations of the
national and local electrical codes. Clean a l l contact
surfaces to assure good e lectrical bonding with the
generator l ug s or bus bars. Use heavy duty term i n al
l ug s or good qual ity clamps for making all connec
tions. I nsulate all connections in accordance with
national and local regulations.
Be s u re the generator frame is grounded to a l l the
other components of the system with a ground wire
in accordance with national and local reg ulations.
GENERATOR LEAD CONNECTIONS
The electrical connections in the conduit box should
be made in accordance with the appropriate "con
nection diagram." Use the diagram appropriate for
the n u m ber of leads and voltage range required.
Refer to the d rawings s u p p l ied with the generator
and to d rawings in this section.
The f i n a l voltage setting is established within the
selected range by an adjustment of the voltage
regulator
CAUTION:S O M E G EN ERATORS HAVE M U LT I PLE,
I D E N T I CA L L Y M A R K ED , CAB LES FOR EACH
LEAD. CON NECT ALL I DEN TICALLY MARKED
CABLES TOG ET H E R WHEN MAKING C O N N EC
T I ONS.

---------------------------- ---------------- ---------------------- ""'MARADHDN


1L-=
5

INSTALLATION
1 2 LEAD HI WYE

Twelve lead generators are dual voltage generators with six


coils which don't have the connection of the three inner colis.
There are 12 or 24 cables coming out of the generator.
VOLTAGE
LL

60
HZ

50

HZ

LN

380

219

416

240

440

254

460

266

480

277

380

219

400

231

416

240

CONNECT

T '0 T"

L,

L2

L3

NEUTRAL

T,

T2

T3

T '0 T11 T'2

T '2

T 4 T7
T5 T 8
T 6 T9

10 LEAD HI WYE

Ten lead generators are dual voltage generators with six coils.
One end of the three inner coils i s connected together. There are
10 or 20 cables coming out of the generator.
VOLTAGE

60

HZ

50

HZ

LL

LN

380

219

416

240

440

254

460
480

266
277

380

219

400
416

231
240

CONNECT

L,

L2

L3

NEUTRAL

T,

T2

T3

TO

T 4 T7
T5 T8
T6 T 9

INSTALLATION
1 2 L EAD LOW WYE
L,

--------'-1

LL

Twelve lead generators are dual voltage generators with six


coils which don't have the connec tion of the three inner coils.
There are 12 or 24 cables coming out of the generator.
VOLTAGE

60
HZ

LL

LN

190

110
120

220
2 30

127
133

240

139

T, T7

110

T2T8-

120

T3 T9

200
208

HZ

1 15

L,

L2

T,

T2

L3

NEUTRAL

T'0 T11 T'2

208

190

50

CONNECT

T4 T5 T6

TlO T11 T'2


T3

---- --- -- --

__r.iL __.

1 0 LEAD LOW WYE


Ten lead generators are dual voltage generators with six coils.
One end of the three inner coils is connected together. There are
10 or 20 cables coming out of the generator.
VOLTAGE
LL

L L

,1

60

HZ

190

110

208

120

220

12 7

230

50
HZ

133

240

139

190

110

200

115

208

CONNECT

L,

L2

L3

NEUTRAL

T,

T2

T3

T4 T5 T6 TO

LN

120

T, T7
T2 T8
T3 T9
T4 T5T6 T O

INSTALLATION
12 LEAD HI D ELTA
T,,________________-

II

Delta connection with 12 lead generators only.


VOLTAGE

LL

60

HZ
SO

HZ

CONNECT

LL

LN

240
27 7

'20
'39

T4 T7

200

'00

T6 T9

220

,,0

240

220

TS T 8

L,

L2

L3

T,

T2

T3

L,

L2

L3

T,

T2

T3

T, T'2
T2 T,O
T3 T"

12 LEAD LOW DELTA

Delta connection with 12 lead generators only.


VOLTAGE

L L

60

HZ
50

HZ

LL
,20
139
,00
'20

CONNECT
T, T7 T6 T'2
T 2 T 8 T 4 T lO
T3 T9 TS T"

INSTALLATION
6 L EAD WYE
Six lead generators have 3 coil groups with 6 or 12 cables or
bus bars coming out of the generator.
VOLTAGE

60
HZ

SO
HZ

LL

LN

190
203
220
230
240
3300
4160

110
120
12 7
133
139
1905
2400

190

110
11S
120

200
208
3300

CONNECT

L1

L2

L3

NEUTRAL

T4 TS T6

T1

T2

T3

T4 TS T6

1905

6 L EAD DELTA

Six lead generators have 3 coil groups with 6 or 12 cables coming


out of the generator.

VOLTAGE
LL

L
60

HZ
SO

HZ

L
31r-:o-5

T3

,,,,

____

______

L. L

L2

____

2400

CONNECT

L1

L2

L3

T1

T2

T3

T1 T6
T2 T 4

1905
T3 TS

INSTALLATION
4 LEAD

WYE
Four lead generators have 3 coil groups with one end of each
group connected together. There are 4,
bars coming oul of the generator.
VOLTAGE
LL
380
416
440
460
480

60
HZ

TO

600
380
400
416

50
HZ

LN

L,

L2

L3

NEUTRAL

T,

T2

T3

TO

219
240
254
266
277
346

219

480

231
240
277

3 LEAD DELTA

Three lead generators have 3 coil groups with one end of each
group connected into a Delta internally. There are 3,
cables or 3bus bars coming out of the generator.
VOLTAGE

ll

LL

L,

L2

L3

T,

T2

T3

60
HZ
480

---,.j
Ll--

12 LEAD ZIGZAG

ZIG-ZAG
VOLTAGE
LL"
..

l2

I:

120V

TS

T2

T11

T8

120V

l1

T3T9

60
HZ

120/240

L1

CONNECT

T2T8
T, T 6T 7T'2

L2

NEUTRAL

I
T2

T3

...

T4

T4 T'0T 5T n

240V

I'i'\t MARAi HDN


-== L-== _=: ...... ._=

_______________________

10

INSTALLATION
NOTE: The MagnaPLUS is provided with a dual winding on the exciter field. Three leads are brought out F 1, F2, and
F3. Use F1 and F2 for a field resistance of 18.60hms. Use F1 and F3 for a field resistance of 28.7 ohms. See
manual for installed regulator for specific interconnection diagrams and exciter field requirements.
TYPICAL SYSTEM DIAGRAM WITH STANDARD REGULATOR SYSTEM

Dashed lines Indicate rotating porlion

,
I

--- -------- -- ,

STATOR

:
&

EXCITER

I
I
I
I
L

MAIN

ROTOR

R9!.ATING

______

I
I
I

_____

.-.I

L3

RECTIFIER
ASSEMBLY

VOLTAGE
REGULATOR

TYPICAL SYSTEM DIAGRAM WITH OPTIONAL PMG INSTALLED


- Dashed lines indicate rolallng portion -

PMG ROTOR
N

a:
o
'"
'"
w
a:

EXCITER ROTOR

MAIN ROTOR

..
..

ii:
w

.----;

LJ

l..-L::=:i:
::':::-: :-....J
ROTATING
RECTIFIER
ASSEMBLY

OOOOOOOOOO

OO

:c'::EOR
STATOR

OUTPUT

F2(-)
POWER
INPUT

SENSING
INPUT

VOLTAGE REGULATOR

PMG

PMG

E1

E.

E3

11

L1

L'

STATOR

Fl(+)

INSTALLATION
PARALL EL I N G OPERATI O N S

the generator is delivering power, not accepti ng it.


These power relays control breakers, which are a
means of connecti n g and disconnecting the genera
tor from the load. T he total system can include over
voltage, overcurrent protection, under frequency
protection, power factor correction provision and
various associated control equipment from manual
switchgear to micro-processors. T he amount of
control gear and level of sophi sti cation will be
determi ned by the needs and requirements of the
parti cular applicati on.

MagnaPLUS generators c o m e standard with amor


tisseur wi ndings die cast as an i ntegral part of the
rotor. This exc lusive Uni rotor construction makes
all MagnaPLUS generators suitable for parallel ing
operati o n s when the proper control equipment is
added. Paralleling with other generator sets and/or
with the utility power g rid offers a n umber of
advantages. M u ltiple u n it i nstallations i n c rease
power capacity; they can be added or removed from
the line depending on the load requirements; they
can be better maintained and repai red (since single
source breakdown would mean total loss of power),
and they often provide more reliable, efficient, and
economical operation.

Paralleling Basics
The followi n g points are basic c riteria which m u st
be met before two units can be paralleled. T H I S I S
N OT MEANT T O B E S P ECIF IC INST R UCT I ONS
F O R PARALL E L I N G O P ERAT I ON.

Successful parallel operation means that the gen


erators deliver power to the external system without
deliveri n g power to each other, or accepting power
from the load bus or power grid. Additi onal equip
ment is necessary to i n s u re safe and successful
operati on.

1. Additi onal paralleling circuitry


A. Voltage regulator - paralleling provisi o n s
B. Paralleling c u rrent transformer(s)

Prime Mover

C. Paralleling provi sions on governor controls

T he prime mover provides the speed and torque


which will be necessary to keep the machines i n
synch ronized operati o n . T he governor will directly
control the frequency (speed) of the unit. When i n
parallel, the governor wi l l control the amount of
power ( kW) s upplied to the bus. The governor must
have special paralleling provisions to permit parallel
operation.

D. Switchgear
2. T he voltage and frequency must be the same
for a l l sets with voltages in phase.
3. The voltage regulation characteristics of the
individual generators should be similar.

Voltage Regulator

4. The generators m ust have the same phase


rotati on.

The voltage regulator controls the generator output


voltage and the reactive power supplied by the
generator. When two or more ac generators operate
in parallel, the voltage regulator must have parallel
ing provisions (either i nternally or external to the
regulator) to permit it to control the reactive power
( kVAR) supplied to the bus while in parallel opera
ti on. A separate paralleling current transformer i s
required t o sense the reactive c u rrent and signal the
voltage regulator. This additi onal paralleling circuitry
is absolutely necessary to control the reactive current
flowing between the generator sets.

5. The drivi ng engines should have the same


speed regulation characteristics and the gover
nors should be adjusted to give the same speed
regulati o n .
Before operati ng generator sets i n parallel, each set
should be checked by starti ng, operati ng, and
adjusti n g the sets as i ndivi d ual units before at
tempti n g paralleli ng.
Reactive Load Control

Switchgear

When two identical generators are operati ng to


gether in parallel and an u n balance occurs i n field
excitation, circulating currents begin to flow between
the generators. This current will appear as a lagging
power factor o r i n ductive load to the highly excited
generator, and as a leading power factor or capacitive

There are additi o n a l relays and breaker controls


which are necessary to insure safe, trouble free
operation of paralleled units. Reverse power relays
monitor the directi o n of power flow to i ns u re that

""" MAAAi HaN

E:LE:II:::::: _.__ _==t . 1I::::::

--

12

--

INSTALLATION
load to the gene rat or with the lower field current.
This is known as t h e reactive circulat i n g current and
t here are two methods of controlling it in parallel
operation:

ways of connecti ng paralleled units and an alm ost


u n li mited variety of appl icati ons and associated
equipment.
When parallel operati on is desired, it is im portant
t h at t he control man ufact urer, t he generator manufact u rer, and the systems engineer work toget her to
i nsure the proper selection of all components.
Please refer t o Marat hon Electric for application
assistance.

1 . Reactive d ro o p compen sati o n . ( F o rm e r l y


known as paral lel droop compensation.)
The bus voltage droops, or decreases, as t h e
reactive lagging power factor load i s increased.
2.

Reactive different i a l compensatio n . ( Formerly


known as cross cu rrent compensati on.)

THYRISTOR OR SCR LOADING

Solid state electronic control devices which uti lize


t h yristors or SCR firi ng circuits (such as vari able
frequency i nd uction motor controls, preci si o n motor
s peed controls, no-break powered battery chargers,
etc.) can i ntroduce high frequency harmonics which
adversely affect or destroy the normal waveform of
t h e generator. This creates additi o nal heat i n t he
generator stator and rotor, and ca n cause over
heating. These devices can and do present problems
to non-utility power generati ng equipment or any
limited power bus system . The problems w hich can
occur are not limited to t h e generator itself, but can
effect t he solid state contr o l device, t h e equipment it
controls, ot her associated loads, m o nitori n g devices
or a number of com binati o n s over t h e entire system .

The reactive differenti al compensati on circuit


allows parallel generators to share reactive
loads with no decrease or droop i n generator
volt age. The circuit m u st meet t h e followi n g
criteria:
A. A l l paralleli n g cu rrent t ransformers for all
t h e generators being paralleled m u st be
i ncluded i n t h e secondary interconnection
loop.
B. When different size generat ors are paralleled,
all paralleli ng cu rrent t ransformers m ust
have t h e same or proporti onal ratios t h at
give approxim ately t h e same secondary
current.

MagnaPLUS generators can supply powerto t hyristor


or SCR loads when properly applied. When SCR
loads are more t han 25% of the total load, select t he
generator based on t h e 80C RIR rating. The optional
PMG and P M 1 00 regulator is recommended. The
PM 1 00 senses 3 phase RMS voltages for m aximum
stability against severelydist orted wave form s . SCR
type applications such as cranes, shovels, et c.,
require special considerati on of the generator i n
su lation system due t o greater dielectric stress and
severe environmental conditions. It i s important t hat
t h e control m a n ufact urer, t he generator m a nufac
t u rer, and t he systems engineer work together t o
i n sure t h e proper selection of all com ponents.
Please refer t o Marat h o n Electric for application
assistance.

C. Voltage regulator paralleling circuitry m ust


be the same.
D. Cu rrent t ransformer secondaries and the
generator lines m ust be isolated electrically.
Because of t h e above criteria, reactive dif
ferenti al compensation cannot be used when
paralleli n g wit h the utility power grid. There
i s no limit , however, in t h e number of genera
tors t h at ca n be included in this type of
circuit.
E. It is also desirable to have an auxiliary
cont act on t h e main generator breaker t o
short t h e parallel C T secondary when that
breaker is open ( n ot connected to the load
bus).
Paralleling Circuitry

Because of t h e number of variables i nvolved i n


paralleli ng generator sets, every i n stallation will
have its own circuitry and methods or procedure of
bringing paralleled u nits on line. There are n umerous

13

OPERATION
PRE-START INSPECTION

Before operating the generato rforthe first time, the


following checks are recommended.
1 . A visual inspection should be made to check

for any loose parts, connections, or foreign


materials. Refer to section 8.

STARTING-UP THE GENERATOR

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.

2. Check for clearance in the generator and

WARNING

exciter air gap. Be sure the g enerator set turns


over freely. Bar the generator over by hand at
least 2 revolutions to be sure there is no inter
ference.

DO NOT OVERSPE E D THE GENERATOR. EX


CESSIVE CE NTRIFUGAL FORCES COULD
DAMAGE THE ROTATI NG F I EL DS . B E PRE
PARED FOR AN E MERGEN CY SHUTDOW N.

WARNING

DO NOT APPL Y ANY FO RC E TO GEN ERATO R


FAN WH EN ROTAT I N G GEN ERATO R ROTO R.
D I S R E GA R D I N G TH ESE I N STRU CTIO NS
MAY CAU S E P E RSO NAL I NJ URYOR EQ U IP
M E N T DAMAGE.

3.
4

3. Check all wiring against the proper connection

diagrams and make sure all connections are


properly insulated.

Be sure the equipment is properly g rounded.

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

RESI DUAL VO LTAGE I S PRESENT AT THE


G E N E RATO R LEADS AND AT TH E R EG U
LATO R PAN E L CO N N ECTIONS, EVEN WITH
TH E REGULATO R FUSE REMOVED. CAUTIO N
MUST B E O B SERVED O R SERIOUS PER
SO NAL I NJ U R Y O R DEATH CAN R ESULT.
CO NSULT Q UA L I F I E D PERSO N N E L W I TH
ANY QUESTIONS.

Replace the regulator fuse and adjust the voltage to


the required value by means of the voltage adjust
rheostat. Check all line to line and line to neutral
voltages to be sure they are correct and balanced.
If the voltages are not correct, shut down immedi
ately and recheck all connections. See Section 3.

5.

Close the main circuit breaker and apply the load.

6.

Monitor the generator output current to verify it is at


or below nameplate amps.

7.

Adjust engine speed at full load to 1800 rpm for 6 0


hertz, 1500 rpm for 5 0 hertz. (Refer to prime mover!
governor instruction manuals.)

8.

Before stopping the engine, remove the load by


tripping the main circuit breaker.

5. Inspect for any remaining packing materials

and remove any loose debris, building materials,


rags, etc., that could be d rawn into the gen
erator.

Follow the manufacturers instructions and start the


prime mover. Check the speed and adjust to the
RPM shown on the generator nameplate.

VOLTAGE ADJUSTMENTS

The generator output voltage is adjusted by the voltage


adjust rheostat located under the panel on the side ofthe
generator conduit box. Refer to the rE!gulator manual for
detailed information. In cases where special or remote
mounted regulators are used, refer to instructions sup
plied by the generator set assembler and to the voltage
regulator manual.
OTHER ADJUSTMENTS

Depending upon application, adjustments to other pro


tective and control gear may be required. Refer to
instructions supplied by the generator set manufacturer.

12I'l -------------------1-4--------------------------------------

MAINTENANCE
MAINTENANCE - GENERAL INFORMATION

Dirt, heat, m o isture, and vibrat ion are c om m on


enemies of a generator. Keeping the generat o r
clean a n d dry, m a i nt a i n i n g proper a l i g n ment o f the
generator and its prime mover, and preventing
overloads will result i n efficient operation and long
life.
Generators t h at are outdoors s h o u ld be protected
from t he elements by suitable houses or enclosures.
Dirt and dust will conduct electricity between points
of d ifferent electrical pot e nt ial. Moisure will aggre
vate t h e problem f u rther. I nsulation system fail ure
can result if corrective action i s not taken. The
con d it i o n of the i nsulation syst em can be tested by
measuring insulation resistance. (See section 8
Generator Test i n g . )
-

Insulation resistance should be checked when put


ting the generator into service after it has been i n
storage a n d anyt i me contam i nation by moisture
and d i rt is suspected. Normally, moisture buildup is
not a problem when t h e generator is r u n n in g since
heat produced internally w ill tend t o keep it dry.
Moisture can col lect in t h e generator when it i s s h u t
d o w n . T h e problem w i l l be worse i n humid environ
ments o r i n areas where ext reme t e m p e rat ure
changes cause condensation (dew) t o form inside
the generator. Space heaters, air filters, and p rem i um
insulat io n systems should be considered i n difficult
envi ronments.
Accum u lat ions of d ust and d i rt not only contribute
to insulat i o n breakdown, but they can also i n crease
t em pe rat u re by rest rictin g ven t i l at i o n a n d by
blocking t he dissipation of heat. Some machines are
ex posed to accumulations of materials such at talc,
lint, rock dust, or cement d ust, which may obstruct
t h e vent ilation. The most harmful types of foreign
materials include carbon black, metallic dust and
chi ps, and similar s u bstances which not only impede
the vent i l at io n , but also form a cond uctive f il m over
the insu lation, increasing t h e possibilit y of insulat ion
fai l u re. Mac h ines operating i n d i rt y places should
be disassembled and cleaned periodically.
AIR INTAKE AND EXHAUST

Check t h e area around the air intake and ex haust


openings t o be sure they are clean and unobstructed.
Remove all foreign material and clean all screens
(F i g u re 5-1 ) .

FIGURE 5-1'

ELECTRICAL CONNECTIONS AND WINDINGS

Inspect for loose or contam i n ated connect ions.


Check wi res for cracked o r frayed insulation. Tighten
connections and replace defective o r oil soaked
insulat i o n .
If inspect i o n shows t hat varn i s h coat i ngs on the
windings have deteriorated, they should be recoated
with insulating varnish. Please refer to Marathon
Electric for insulation system req u i rements.
LUBRICATION

All MagnaPLUS generators use a sealed ball beari n g.


It is l u bricated at t h e factory and requires no furt her
attention fo r t he life o f the bearin g.
If t he bearing is changed, a sealed type should be
used for replacement.
DRYING ELECTRICAL INSULATION

Electrical component s m u st be dried before placing


i n operat ion if tests indicate t h at the insulation
resistance is below a safe value. (See sect i on 8
Generator Testing for test procedure.)

Machines t hat have been id le for somet i m e in


u n heated and damp locations, may have absorbed
moisture. S udden changes in temperature can cause
condensat i o n or t h e g enerator may have become
wet by accident. Windings should be dried out
t ho r o u g h l y before b e i n g put i nt o service. Th e
follow i n g are recommended drying methods.

--------15-- 12I'l

MAINTENANCE
Space Healers
Electric space heaters can be installed i nside of the
generator. When energized (from a power source
other t ha n the generator) t hey wi ll heat and dry the
i nside of the generat or. If an alternate source of
electricity is not avail able, enclose t h e generator
wit h a covering an d i n sert heating units to raise t h e
t emperature 1 5- 1 8 degrees F (8- 1 0 degrees C)
above t he temperature outside of t h e enclosure.
Leave a hole at t h e top of the enclosure to permit t h e
escape o f moisture.
Oven
Place t h e machine in an oven and bake it at a
t emperature noll o exceed 1 94 F (90 C). The voltage
regulator and any electronic component accessories
m u st be rem oved from the generator when using
t his method.
Forced Air
A portable forced air heater can be used by di recti ng
heat i nt o the air i ntake (conduit box) and running
the generator wi th no load and without exci tati o n
(this ca n be accom plished b y removi n g t h e regulator
fuse) . Heat at point of entry s h ou l d not exceed
150F (66 C).

3. Sh ort circ uit t h e ge nerator output lead wires t o


each other ( L 1 t o L 2 t o L3). If usi ng jumpers, be
sure t h ey are large enough to carry f u l l load
am ps.
4 . St a rt t h e generat or and measure t h e c u rrent
through t h e output leads with a clip-on am
meter.
5. Adj ust the voltage source t o produce approx
i m ately 80% of the rated ac nameplate cu rrent ,
but in no case exceed nameplate amps. If an
adj ustable source i s not avai lable an d c u rrent
is excessive, use a lowerdc source voltage or a
larger resistor i n series with the source.
Running t illie will be determined by t h e amount
of moist u re present in the machine. I nsulation
resi st ance checks should be taken every one t o
four hours unt i l a fairly constant val u e i s
obtained. (See section 8 - Generator Testi ng
for i nstruct i o n s on measuring insulati o n re
sistance.)
6. After the generator is dry and the i ns u l ation
resistance i s brought up to specificati ons,
rem ove t h e sh ort circuit from the line leads,
disconnect the d c source and reconnect the F1
and F2 leads at t h e regulator. B e s u re a l l
connecti o n s are tight a n d correct before at
tem pti ng to run t h e generator.

"SharI Circuit" Method

CLEANI NG METHODS

The generator can be dried out quickly and thor


oughly by using t hi s method.

When electrical components get d irty, t h e i nsula


ti o n m ust be cleaned. There are a n um ber o f accept
able methods for cleaning t h e generator, each of
which will necessitate disassembly of the unit. The
method of cleaning wi ll be determined by t h e kind of
dirt , and when t h e unit m u st be ret urned to service.
Dryi ng after cleanin g is necessary.

WARNING:
B E SURE THAT ALL OF TH E FOLL O W ING
STEPSARE PERFO R M E D A N D AL L PRECAU
TIONS TAK E N AS PERSONAL I NJ U R Y O R
SERIOUS DAMAGE T O TH E GEN ERATOR
COULD RESULT.
1 . Disconnect exciter leads F 1 and F 2 f rom t h e
regulator.
2. Connect a battery or other dc power source of
approximately 20-35 volts to t he exciter leads
F1 and F2. An adjustable voltage source is
desi rable, however, a rheostat (rated approx
imately 2 amps) in series with t h e dc power
source wi ll work.

Whenever t h e generator is disassem bled, t h e wi nd


in g s should be given a t horough i nspect ion and t h e
i n s u lati o n cleaned, if necessary. T h e i nspect ion
should i n c l ude t he con necti on of the windi ngs,
i nsulation, and varnish coverage. Check the wi nding
ties and coil s u p ports. Look for any si g n s of coi l
movement , o r looseness and repair as required.
An electric motor repair shop in your area can
normally assist wit h t h e proper cleaning of the
generator wi ndings. They may also be experienced
in speci al problems (such as seacost, marine, oil rig,
mini ng , etc.) t h at may be peculiar t o a certain area.

MAINTENANCE
SOLVENTS

SHELL BLASTING

A solvent is usually required to remove acc u m ulated


soi l cont a i n i ng oi l or grease.

Ai r blasti ng with g ro u n d nut shells may be satis


factory for removal of hard di rt deposits from
i nsulati on. Use mild abrasives such as 1 2-20 mesh
g round wal n ut shells.

O n ly petroleum dist i l l ates should be used for clean


i n g electrical components.

STEAM CLEANING

Petroleu m solvents of t h e safety type with a flash


point greater t ha n 1 00F (38C) are recommended.

If the generator is completely disassembled, including


bearings and electronic components, steam cleaning of

the major parts and windings is very effective. However,


the windings must be thoroughly dried in an oven to
remove all moisture before the generator can be put
back into service.

CAUTION:WI N D I N G VARNISHES ARE EPOXY O R


POLYESTER BASED. A SO LVENT THAT DOES
NOT ATTACK TH ESE MATERIALS S H O U L D B E
USED.
WARNING

ADEQ UATE VENTILATION MUST B E AVAIL


ABLE TO AVO I D F I R E, EXPLOSION AN D
H EALTH HAZARDS WHERE SOLVENTS ARE
U S E D . AV O I D B R EATH I N G S O L V E N T
V A P O R S . R U B B E R G LOVES O R O T H E R
SU ITABLE PROTECT I O N F O R T H E HANDS
SHOULD BE USED. WEAR EYE PROTECTION.
Apply t h e solvent wit h a soft brush or rag. B e careful
not to damage t h e magnet wire or i nsulation on t h e
w in d i ngs.
Dry components t horoughly with moistu re-free, low
pressure compressed air.
CLOTH AND COMPRESSED AIR

Cleaning wit h a dry cloth may be satisfact ory when


componets are s m a l l , the surfaces are accessible
and only dry dirt is removed.
B lowi ng dirt out with compressed air is usually
effective parti cularly when t he dirt has collected in
places which cannot be reached with a clot h . Use
clean dry air at 30 PSI (206 K PA).
BRUSHING AND VACUUM CLEANING

Dry dust and di rt may be removed by brushing wit h


bristle brushes followed by vacuum cleaning. D o
not use wire brushes. Vacuum cleaning i s a n ef
fective and desi rable met hod of removing dry and
loose dirt .

17

SERVICE
REMOVAL FROM PRIME MOVER
WARNING
B E SURE AL L POWER IS OFF B EFORE SER
V I C I N G . F A I L U R E TO FOLLOW ALL SAFETY
I NSTRU CT I O N S CAN RESULT I N SE RIOU S
PERSONAL I NJURY OR DEATH.
NOTE: Before discon necting any electrical w i ri n g ,
b e s u re it i s m arked a n d c a n b e identified for
reinstallation. Remark as required.
1.

4. Attac h a suitable hoist to the generator lifting


lugs.
5. a. For single bearing generators, rem ove the
bolts m o u nt i ng the screen assem b ly to the
SAE adapter and remove the screen. (Figure
6-3.) ( N OT E: Do not rem ove the drip cover
from the screen assem bly if so equi pped.)
Remove the capscrews attaching the drive
d iscs to the flywheel and remove the cap
screws attac hing the SAE adapter to the
flywheel housing.

Remove conduit box covers ( Fig ure 6-1 and


6-2).

FIGURE

6-3

b. For two-bearing generators, disconnect the


coupling o r s heave and belts between the
generator and prime mover. ( Follow the
coupling manufacturer's instructions for dis
connection.)
WARNING
DO NOT APPLY A N Y FORCE TO TH E GEN
ERATOR FAN F O R L I FTI N G O R ROTATI N G
T H E G EN ERATOR ROTOR. DISR EGAR D I N G
TH ES E INSTRUCTIONS MAY CAUSE PER
SONALI NJ U RY OR EQU IPMENT DAMAGE.
6. Remove the m o u nting bolts which secure the
generator to the base. To make reinstallation
eaSier, note the position of and save any s h im s
that were used under the feet for alignment.
7.
FIGURE 6-2

2.

3.

Disconnect all external wiring f rom the gen


erator leads (or bus bars) inside the conduit
box .
Remove all conduit or d u cting from the cond uit
box .

8
.

Raise the g e nerator slig htly and move the


generator away f rom the prime mover. Raise or
low e r the g e nerator to take pressure off of the
drive discs so they slide easily out of the
flywheel.
On s i n g le bea ring generators, if generator is to
be s h ipped, see Shipping I nstructions Section
1 1 for proper rotor support.

-- . --------------------------------------------------------------r;r;'IMARAa"HDN
1 8

---

SERVICE
CONDUIT BOX REMOVAL
1.

Note the location and markings (re-mark as


required) and remove connections from voltage
regulator terminal str ip and any other conduit
box mounted control. (Figure 6-4 .)

4.

Remove conduit box. ( Figure 6-7 . )

N OTE: The MagnaPLUS generator c a n b e equippe d


with a permanent magnet generator (PMG) as a factory
modification. If yo ur unit is not equipped with a PMG,
disregard instructions pertaining to it.
2.

Remove the regulat or panel assembly and


conduit box extension ring (if used). (Fig ure
6-5 and 6-6.)

PMG STATOR REM OVAL


1.

3. Remove bolts holding conduit box in place.


(Figure 6-7 .)

Remove the PMG leads (Figure 6-8) and loosen


all cable ties so t he leads can be re moved with
the P MG stator.

2. Note the position of the PMG stator leads


which ex it at the left outboard side or mark the
stator so it can be r ei nstalled in the same
position.
3. Remove the four m ounting capscrews. (See
Figure 6-9 . )

19

SERVICE

FIGURE 6-10

FIGURE 6-8

4.

Using 2 screwdrivers, gently pry t h e PMG


stator from t he mounting pad and slide over
t h e P M G rotor. The magnets used i n the P M G
are very strong. They will resist removal o f t h e
PMG stat or. (Fi g u re 6-9.)

FIGURE 6-11

2. To remove the PMG rotor from the st ub shaft,


use a snap ring plier, remove the snap ring and
slide t h e P M G rot o r off t he shaft. A loading
spring behind t he PMG rotor keeps tension on
the snap ring t o prevent movement. (See F igure
6-12 and 6- 13.)

FIGURE 6-9

PMG ROTOR RE M OVAL


1. The PMG rotor is mounted to the generator
shaft us i ng a st ub shaft ex tension. Remove the
center cap screw and pull the assembly off of
its locating pin. (See F ig u re 6-10 and 6- 1 1.)

FIGURE 6-12

a N-E:LIEE -=-'-.-=

--

--------------------------------

20

SERVICE

OUTER
SNAPR

LOADING SPRING

PMG ROTOR

----il,-------'j

SHAFT

FIGURE 6-13

MAIN ROTO R RE MOVAL


1.
2.

Remove the P M G . (Follow instructions found


earlier i n this secti on.)

b. For two-bearing generators, remove t he drive


coupl i n g half or sheave from the shaft ex
tension.

If the sc ree'n assem bly i s sti l l m o u nted, rem ove


the bolts securing t h e screen assem bly to the
drive end bracket or the SAE adapter and
rem ove the screen assem b ly. (Figure 6-14.)
(NOTE: Do not remove the drip cover from the
screen assem bly if so equipped.)

4. a. For sing le bear i n g generat ors, rem ove the


capscrews hol d i n g the SAE adapter to the
generator and remove the adapter. (Fig ure
6-16 and 6-17.)

,,' FIGURE 6-14


3.

FIGURE 6-15

a. For single bearing generators, remove t h e


capscrews and hardened washers holding
the drive discs to the drive hU b. ( Fi g u re 615.) Remove a l l drive discs (and spacers if
any).

21

II

SERVICE

:. FIGURE 6-18

FIGURE 6-17

II

b. For two-beari ng generators, rem ove the cap


screws h o l d i n g the drive e n d bracket to the
generator and remove the bracket.
CAUTION: ON LAR G E G E N ERATORS, A H O I ST
AN D LI F TI N G STRAP S H O U L D B E USED TO
A SS I S T I N D R I V E E N D B R A CK ET O R S A E
ADAPTOR REMOVAL.

6.

U s i n g a rotor lift i n g fixture and a suitable hoist,


carefully remove the rotor assembly from the
mai n stator and frame assembly through the
drive end. (F ig ure 6-19.)

WARNING
DO NOT APPLY ANY FORCE TO T H E GEN
ERATOR FAN FOR L I F T I N G O R ROTATING
T H E G E N E RATOR ROTOR. D I S R E G A R D I N G
TH ESE I NSTRUCTI O N S M A Y CAUSE PER
SONAL I N JU R Y OR EQ U I PMENT DAMAGE.

5. If the g e nerator fan requ i res service it can be


removed atthis ti m e. See m a i n rotor i nspection
later in this section for details. ( F ig u re 6-18.)
NOTE: The fan does not need to be removed in
order to remove the rotor assembly from the
generator.

CAUTI O N: SPECIAL CARE SHOUL D B E TAK E N


W H E N R EMOVI N G T H E MA I N ROTOR, W I N D I N G
DAMAG E COULD RESULT I F T H E ROTOR I S
ALLOWED T O H I T THE MAI N STATOR.
FRONT END BRACKET REMOVAL
1. Remove front bracket mounting screws.
2. Remove the front end bracket from the m a i n
stator assem bly. (Fig ure 6-20.)

12J------------------- 2

SERVICE
EX CITER INSPECTION
A. Exciter Stator
1. Clean d ust and d i rt from the stator w i n d i n g .
(See section 5 . )
2 . Check t h e exciter stator f o r a loose, frayed, or
b ur n t wind i n g . Measure wind ing resistance
and insulation resistance. (See section B.)
Repai r or replace as necessary. If field repa i r of
the winding is necessary, contact Marathon
Electric for special wind ing procedu res and
materia ls.
3.

CAU T I O N: ON LARGE GENERATORS, A H O I ST


AND L I FT I N G STRAP S H O U L D BE U S E D TO
ASSIST I N T H E FRONT E N D BRACKET REM OVAL.
EX CIT ER STATOR (FI ELD) REMOVAL
1. Remove the exciter stator retaining screw. (Figure

6-21.)

2. Note the position of the exciter stator in the housing,


remove stator.

ENDBELL

Look for score marks in the bore of the exciter


core ca used by ru b b i n g . (This could i nd icate
bearing or assembly problems and shou l d be
invest igated.)

B. Exciter (Rotor) Armature


1. Clean d ust a n d d i rt from t he exciter armature
and rectifier assem bly. (See section 5.)
2. Check the rectifiers and s u rge protector for
proper operati o n . (See section B.) Replace
defective parts.
CAUTI ON: T H R EE FORWARD POLARITY AND
THREE REVERSE POLARITY D I ODES ARE US ED.
B E SURE YOU HA VE THE CORRECT PART I N
STALLED I N T H E C O R RECT LOCAT I O N . T H E
SURG E SU P R ESSOR IS POLARIZED. O BSERVE
POLARITY MARK I N G S WHEN CHAN G I N G T H E
SU RGE SU P R ESSOR. (Fig ure 6-22.)
FORWARD
POLARITY
0100

RETAINING SCREW
AND LOCKWASHER
EXCITER STATOR

REVERSE
POLARITY
DIODE

ASSEMBLY
POLARITY
DIODE

REVERSE
POLARITY
DIODE

FIGURE 6-21

EX CITER ROTOR (ARMATURE) REMOVAL


1 . The exciter a rmat ure i s a shrink fit to the shaft .
It is not easily removed.
2.

If the winding is intact, do not remove.

3. If the wi ndi ng is damaged, use a bearing p u l ler


to remove the assembly from the shaft .

FIGURE

6-22

Torque diode mount i n g n. u t to 25 inch-pounds. Use


a heat s i n k when soldering diode leads.

----------------------------------------
23 --------------------

r;t;"IMAJU[I1ot DN
ILor.

SERVICE
3. Check the exciter armature and rectifi er assem
bly for a loose, frayed, or burnt wi nding o r
loose con nections. Measure winding resist
ance and i nsu lation resistance. (See section
8.) D O NOT megger diodes or surge sup
pressor. Re pai r or replace as necessary. If field
repair of the winding i s necessary, contact
Marathon Electric for special winding proce
dures and materials.
4.

Look for score m arks on the outside diameter


of the armature core caused by rubbi n g . (This
could i ndicate beari ng or assembly problems
and should be i n vestigated.)

MAIN ROTOR I N S PECTION


A. Bearing
1 . Check the beari ng for damage or wear. Clean
t h e old grease from the bearing cap, and fill the
bearing cap grease cavity 1/3 to 1/2 fu l l of new
Cheveron SRI (or equivalent) grease.
CAUT ION: If the bearing needs to be removed,
for any reason, always install a new beari ng.
2. If the beari n g i s to be replaced, remove with a
suitable puller. ( Fi g ure 6-23.)

PMG INSPECTION
A. PMG Stator
1 . Clean dust and d irt f rom the PMG stator
winding. (See section 5.)

II

2. Check PMG stator for a loose, frayed, or burnt


windi ng. Measure winding resistance and i n
sulation resistance. (See section 8.) Repair or
r e p l a ce a s nec essary. Contact M aratho n
Electric fo r special winding procedures and
materials.
3. Look for score marks in the bore caused by
rubbing. (This could i ndicate beari ng or assem
bly problems and should be i n vesti gated.)

FIGURE 6-23

3. Heat the new bearing in an oven to a maximum

B. PMG Rotor
WARNING
TH E P M G RO T O R U SE S V E RY STRONG
MAGNETS. K EEP AWAY FROM I R O N AND
STEEL PARTS THAT COULD BE DRAWN TO
THE MAGN ETS. KEEP AWAY FROM OTH E R
COMPON ENTS THAT CAN B E DAMAGED
B Y STRONG MAGNETIC F I ELDS.
1 . Clean dust and dirt from the PMG rotor. (See
section 5.)
2. Check to be sure all magnets are tightly bonded
to the PMG rotor.
3. Check for burrs or corrosion i n the bore and
keyway where the rotor mounts to the shaft.
4. Look for score marks on the outside diameter
caused by rubbing. (This could i ndicate beari ng
or assem b l y problems and should be investi
gated.)

temperature of 21 2F (1OOC). 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 6-24.) The
bearing should slide on the shaft and be seated
without excessive force. If the bearing binds on the
shaft before being fully seated, a piece of tubing,
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.

CAUT I O N : U N D E R N O CI R C U M ST A N C E S
SHOULD PRESSURE B E APPLIED TOTHE OUTER
R A C E O F TH E B EA R I N G , AS P E R M A N E N T
B EA R I N G DAMAGE COULD RESULT.

5. I nspect snap ri ngs and loading spri ng, replace


as required.

12I1l-----------24--

SERVIC E
Allow the beari n g to cool for one hour before
attempting to assemble the generator.

r
"J
,,;.;Jo

4. To rei nstall, slide t h e fan on the shalt m a ki n g


sure the fan m o unti ng surface is toward t h e
d rive hUb. Ali g n reference marks (this is important for assem b ly balance) a n d mount the
fan to the d rive h u b with the capscrews and
bellevi lle washers. (Figure 6- 27.) Torque the
capscrews to 60 It-lb. (81 N-m).

B . Fan
1. Check the f a n for cracks o r broken blades.
Replace the fan i f defective.
2. Mark the h u b and fan for a li g nment. this i s
necessary t o be s u re the balance weights wi l l
b e i n t h e same position when t h e fan i s re
i nstalled.

II

BELLEVILLE WASHERS
MUST BE M OUNTED I N THIS DIRECTION.

3. a. For si n g le beari ng generators. Remove the


fan m o u nti n g capscrews (Fig ure 6-25.) and
slide the fan off the shafl. (Figure 6-26.)
b. For two-bearing generators, remove the drive
end beari ng a n d bearing cap. (See beari n g
removal i n structions.) Remove the fan mou nt
i ng capscrews and slide fan off the shafl.
(Figure 6-25 and 6-26.)

FIGURE 6-27

5. NOTE: Balance weights on the fan are for


balance of the complete rotor assem bly. The
rotor assem bly should be rebalanced if a new
fan has been i nstalled.
6. On two-bearing generators, i nstall beari n g cap
and new bearing according to the bearing
assem bly instructi ons. (Item A.)
C. Drive H u b (Single B ea ri n g Generators O n ly)
1 . Check the drive h u b for cracks or stripped
drive eisc m ounting holes. Replace the h u b i f
defective.
2. If the

hub is to be replaced, remove the fan (See


Item 8) and install a suitable puller to the hub.
Remove the setscrew (if used) in the hub over the
key. Using a torch, rapidly heatthe hub althe outer
diameter while tightening the puller. (This must be
done rapidly before the heat can expand the shaft.)
Remove the hub. (Figure 6-28.)

25

r?;"IMARAI HaN'"

E:: L.IE:::: -=-.--==:1 1 -=

SE R VICE
D. Main Rotor Core and Windi ngs
1 . Clea n all parts. Remove d ust and d i rt from the
rotor w i n d i ngs. (See section 5.)
Remove any accumulated dust o r di rt in the
winding air passages w i th a piece of w i re or
with low-pressure, moisture-free air. (Figure
6-30.)

3. 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 hubin an
oven to 500-600F (260-31 6C). Using suitable
heat resistant gloves, slide the hub over the key in
the shaft until it seats against the shaft shoulder.
(Figure 6-29.)

CAUT ION: I F A P I ECE O F WIRE IS USED F O R


CLEA N I N G TH E A I R PASSAG ES: C A R E M UST B E
TAKEN NOT TO SCRATCH TH E W I N D I N G AS
TH IS C OUL D CAUSE AN I N S U LATION FAI LU R E.
2. Check the rotor for loose, frayed, or burnt
w i n d i ngs. Measure w i n d i n g resistance and
insulation resistance. (See section 8.) Test for
shorted turns using an A-C impedance test.
(See section 8.) A defective rotorw i nding m ust
be rew o u n d by Marathon Electric. The rotor
assembly m ust be rebalanced after any rew o rk
or repair has been completed.
E. Drive Discs (Single Beari ng Generators O n ly)

1. Inspect the drive discs for distorted or bent

edges. (Figure 6-31) Ins pect for worn m o u nt


ing holes. Replace any defective discs .

4. A l low the h u b to cool for one hour. After the


hub has cooled, tighten the setscrews in the
hub to 50 ft-Ibs (68 N.m) torque. Match the
alignment marks on the fan and h u b and m o unt
the fan . (See item B . )
5. Reba lancing the rotor assembly is not neces
sary if only the h u b is replaced and the fan is
m o u nted in the same location relative to the
hub and shaft.

12J1!

o
2

--------------------------------

SERVICE
2. I n spect t he d rive disc mount i n g capscrews for
d a m a g e d t h re a ds . R e p l ace c a p screws i f
damaged.

MAIN STATOR INS PECTION


1 . Clean dust and d i rt from the stator frame and
winding. (Figure 6-33.) (See section 5.)

FRONT ( EXCITER) END BRACKET I NSPECTION


1. Clean the end bracket, bearing bore, and
capscrews t o remove all dust, d i rt, and grease.
2. I nspect the capscrews for stripped threads and
replace if defective.
3. I nspect t h e end bracket for stri pped th reads,
cracks, a n d b urred or rough mati n g s u rfaces.
I nspect t h e bearing bore for b urrs or wear. If
t h e bracket shows excessive bearing bore
wear, it should be repaired or replaced. (Fig ure
6-32 . )
FIGURE

6-33

2. Inspect t h e frame for stripped t h reads, cracks,


burred mating surfaces, or other damage.

3. Inspect the stator for a loose, frayed, or burnt


winding. Measure winding resistance and insula
tion resistance. (See section 8.) Repair or
replace as necessary. I f field repair of the
winding is necessary, contact Marathon Electric
for winding data.
FIGURE

6-32

FRONT END BRACKET I NSTALLATION

4. Inspect t he mounting area for the P M G stator


and exciter stat or. Be s u re they are smoot h ,
clea n, a n d free o f any burrs or rust. That could
i nterfere with proper align ment.

1. Install two guide pins (threaded rod can be


used) into the generator side ofthe end bracket
mounti ng holes. A lig n the g u ide p ins with the
holes in the generator frame and slide the
bracket onto t h e frame. (Figure 6-34.) I nstall
bracket m o u nt i n g capscrews.

DRIVE END BR ACKET O R


SAE ADAPTER INSPECTION
1. Clean t h e bracket or adapter, capscrews and
screen assembly t o remove all dust, dirt, and
grease.
2. Inspect t h e capscrews for stripped t h reads and
replace if defective.
3. I n spect the bracket or adapter for stripped
threads, cracks, and bu rred or rough mating
surfaces.
4. For two-bearing generators, i nspect the bearing
bore for burrs or wear. If the drive end bracket
shows excessive bearing bore wear, it should
be repaired or replaced.

27

SERVICE
3. a. For si ngle bearing generators, sl ide the SAE
adapter over the fan, be sure the locating
mark I S at the bottom (See F i g u re 6-36 and
6-37), and secure to the main stator assembly
with capscrews. Torque per section 1 2 .
( F i g u re 6-38.) I t may be necessary t o raise
the rotor assembly slightly to allow the
mounting of the SAE adapter.

CAUTI ON: ON LARGE G EN ERATORS, A H O I ST


AND L I FT I N G STRAP S H O U L D B E USED TO
A SS I ST I N T H E F R O N T E N D B R A C K ET
I N STALLATI ON.
2. Remove t he two g uide pins a n d in sert the
remaining capscrews and torque to specifica
tions given in section 1 2 .
MAIN ROTOR INSTALLATION
1. G rease bearing cavity with Cheveron S R I or
equivalent. The cavity should be about 1 /3 full.
2. Using a rotor lifti n g fixtu re a n d a suitable hoist,
careful ly install the rotor assembly into the
main stator asse m b l y through the drive end.
(Figure 6-35.)

CAUTION: SPEC I A L CARE SH O U L D BE TAKEN


W H E N I NSTA L L I N G THE ROTOR A S S E M B LY.
W I N D I N G DA MA G E C O U L D R ESULT IF T H E
ROTOR I S ALLOWED TO H I T T H E M A I N STATOR.

FIGURE

6-36

FIGURE

6-37

CATING MARK
(BOTTOM)

WARNING
D O N O T A P P L Y A N Y F O R C E TO T H E
G E N ERATOR FAN FOR L I FT I N G O R R OTAT
I N G THE GEN ERATOR ROTOR. DISREGARD
I N G THESE I N STR UCTI O N S MAY CAUSE
PERSONAL I N J U RY OR E Q U I PMENT
DAMAGE.

DN
.E::: L .IE:::: -=-"- . -=

------

----------

28

----

----

SERVICE
b. For two-bea ri n g generators, in sert guide
pins i n the rear bearing lock holes. Fill the
grease cavity of the drive end bracket 1 /3 f u l l
o f new grease. A l i g n the drive end bracket
and m ount with the capscrews. P in and
i nsert a capscrew and lockwasher into the
bearing lock and ti g hten. Remove the re
m a i n i n g gu id e pin and replace with the
remaining capscrew and lockwasher. Torque
bearing cap capscrews to 25 Ib-It (34 N-m).
Torque bracket mounting capscrews per
specifications given i n section 1 2.
CAUT ION: ON LAR G E G E N ERATORS, A H O I ST
AND LI FT I NG STRAP S H O U L D B E USED TO
ASSIST I N T H E D R I V E E N D BRACKET O R THE
SAE ADAPTER ASS E M B LY.

B I
I

94

--- +-_.-

4. a. Forsingle bearing generators, in sert a g uide


stud into the drive hub. Position a l l spacers
(if a n y ) , then a l l drive discs, one at a time
until a l l discs are installed. (Figure 6-39.)
Make sure that a l l disc mounting holes at the
i n n e r a n d o u ter d i a meter are properly
a l igned. Secure the d i scs with the grade 8
5/8-1 8 capscrews and hardened washers.
Torque to 1 92 It-Ib (260 N-m). (See Fig ure
6-40 for torq u i n g sequence.)

5.

Torque the bolts i n the above sequence ac


cording to the correct bolt pattern.
Then check the torq u e in each bolt in a clock
wise d i rection around the bolt circle to insure
that all the bolts are properly torqued.
FIGURE 6-40

PMG I NSTALLATION ( OPTI ONAL)

. . .....
. .

1 . If u nit is equipped with the optional PMG,


the stub shall (Fig ure 6-4 1 . ) Torque
bolt to 84 It-lb.

0:
;

..
.

.. .

.
.
.

., ....'.......
-

'-

- -- ,

FIGURE 6-41

29

SERVICE
2. Temporarily hang mounting ring for the PMG
stator over the shaft.
3. I nstall load i n g spring and P M G rotor on the
stu b_s_b_llJLaD_d_s_e_C_m!Lwith the s n a p r i n g . The
loading spring w i l l push out on the P M G rotor.
A piece of pipe s li g htly larger than the shalt
can be used to push the snap ring back unti l it
engages in its slot. (Fig ure 6-42.)

2. If u n i t is e q ui pped with the P M G . i n sta ll the


conduit box exte nsion ring. ( F i g ure 6-45.)

4. I nstall the PMG stator on the m ou nting pad


and secure with 4 capscrews. Torque to 4 It-lb.
(Figure 6-43.)

FIGURE 6-45

3. Install regulator panel assembly. ( Fi g u re 6-46.)

CO N DUIT BOX IN STALLATION


1 . Install the conduit box over the main stator
leads. Secure with bolts and lock washers.
(Fig ure 6-44.)

4. Reconnect exciter leads. P M G leads an d other


accessories accordi ng to the connection prints
and markings i n stalled before disassembly.
(See Fig u re 6-47 and con nection d i a g r a m . )

SERVICE
WARN I NG
DO NOT APPLY ANY FORCE TO THE G EN
ERATOR FAN FOR L I FT ING O R ROTAT I N G
T H E GEN ERATOR ROTOR. DISREGAR D I N G
THESE I N STRUCT IONS MAY CAUSE PER
SONAL I NJ UY O R EQ U I PMENT DAMAGE.
Position the generator so that the SAE
adapter mates with the flywheel housing.
CAUTION: DO NOT FORCE THE A L IG NM ENT OF
THE UN ITS. S H I FT THE G E N ERATOR FROM S I D E
T O S I D E O R RAISE O R LOWER WITH A L I FTI NG
DEVIC E A S NECESSARY.
I t may be necessary to use shims u nder the
mounting feet of either the generator or the
prime mover to obtain proper alignment;
use the same s h i m s as removed u n der diSassembly or proceed as follows: Using the
extreme bottom four capscrews, mount the
SAE adapter to the flywheel housing. With a
.001 5 to .002 inch feeler gauge at the extreme
top adapter to flywheel housing to fit, raise
the ge nerator or lower the pri me mover unti I
the gauge is s n u g . Relieve just enough to
release the feeler gauge and torque the
rema i n i n g SAE adapter capscrews to the
flywheel ho using . (Torque specifications
given in section 1 2 . )

ASSEMBLY TO P R I M E MOVER
1. Attach a suitable hoist to the generator lifting
lugs, and move the generator until the generator
foot mounti n g holes are aligned with the base
and slightly above.
2. a. For single bearing generators, if the screen
assembly is mou nted on the adapter, remove
the moun t in g bolts and remove the screen.
(Figure 6-48.) ( N OTE: Do not remove the
drip cover from the screen assembly if so
equipped.) I nsert two guide p i n s in the
flywheel and two i n 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.

Mount t h e screen assembly and tighten the


mounting bolts.
b. For two-beari ng g enerators, align the coup
ling halves or sheaves between the generator
and the prime mover by add i n g shims under
the feet.
3. S h i m under the ge nerator feet for proper sup
port, e n suring that the generator mounting
surfaces are level.
4. I n stall the mounti n g bolts which secure the
generator to the base.
5. Fortwo bearing generators, assemble the coup
l i n g halves or sheave belts between the gen
erator and the prime mover. (Follow the coup
l i n g man ufacturer's instruction for assembly
and alig nment.)
6. Connect all existi n g conduit or ducting to the
conduit box.
7. Connect a l l external wiring to the generator
inside the conduit box.

FIGURE 6-48

31

I
I

TRO U BLE SHOOTIN G


INTRODUCTION

WARNING

This section is intended to suggest a systematic


approach to locating and correcting generator o r
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
mac h i ne.
The fi rst ard perhaps most im portant step of trouble
shooting s hould be to gather as m uch i nformation
as possi ble from personnel who may have been
present d u r i n g the fai lure. Information on how long
the generator had been running, what loads were on
the l i ne, weather conditions, what protective equip
ment 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.

H I GH VO LTAGES CAN BE PR ESENT AT THE


G E N E RATOR A N D R E G U LATOR T E R
M I NALS. H I GH RESI DUAL VOLTAG ES CAN
BE PRESENT EVEN WITH THE R E G U LATOR
DISCO N N ECTED O R ITS FUSES R E MOVED.
S O M E E Q U I P M E N T ( S U C H AS S P A C E
HEATERS) MAY BE E N E R G I Z E D WHEN THE
G EN ERATOR IS O F F . TOOLS, EQUI PMENT,
CLOTH I N G , AND YO U R BODY MUST BE
KEPT CLEAR OF ROTATI N G PARTS A N D
ELECTRICAL C O N N ECTIONS.
SPEC I A L CAUTION MUST BE TAKEN DUR
I N G T R O U B LESHOOT I N G SINCE PROTEC
. TIVE COVERS A N D SAFETY DEVICES MAY
BE D I SA BL ED TO G A I N ACCESS A N D MAKE
TESTS.
BE C A REFU L. S E R I O U S PERSONAL INJURY
O R D EATH CAN R ES U LT F R O M THESE
HAZAR DS. C ONSU LT QUALIFIED PERSON
NEL WITH ANY Q U ESTIONS.

SYMPT O M: G E NERATOR PRODUCES NO VOLTAGE OR RESIDUAL VOLTAGE


Regulator Fuse Blown

Check fuse with an ohm meter. Replace bad fuse, refer to


regulator manual.

Voltmeter Off

Check to be sure meter phase selector switch is not i n the off


position.

I ncorrect Connections

Verify generator connections. Refer to drawi ng s supplied with


generator set and section 3.

Defective Connections/Wiring

I nspect a l l wiri ng for g ro u nds, open circuits, short c i rcuits. Refer


to section 8.

Defective Voltmeter

Verify proper operat i o n of panel meter with another meter that is


known to be accurate. Refer to section 8.

No Reg u l ator I nput

Measure voltage at regulator input refer to section 8.

Defective Diodes, Surge Suppressor,


or Generator Windings

Test generator with constant excitation


to section 8 and 1 2 .

Voltage Regulator Protective


Shutdown Circuits are Operating

Correct problem a n d adjust reg ulator. Referto regulator manual.

Voltage Regulator I noperative

Adjust or replace regulator. Refer to regulator man ual.

( 1 2 volt battery test) refer

r,l)'lMAFUa'HDN

E: __ E: . --------------------3-2------------------------------------

---

TROUBLE S H OOTING
SYMPTOM: GEN ERATOR PRODUCES LOW VOLTAGE - N O LOAD
Underspeed Operation

Check speed using tachometers and/or frequency meters.

Defective Voltmeter

Verify operation o/panel meter with another meter that is known


to be accu rate. Refer to section 8.

Residual Voltage

Disconnect F1 and. F2 leads at the voltage regulator. If voltage


goes down continue on to next step, if voltage does not change
refer to troubleshooting for symptoms of "No Voltage - Resi d u al
Voltage".

I ncorrect Generator Connections

Verify generator connections refer to drawings supplied with


generator set and section 3.

Defective Connections/Wiring

I nspect a l l wiri ng. for grou nds, open ci rcuits, short c i rcuits, loose
connections, d irty connections.

Regulator Adjustments

Adjust regulator. Refer to regulator manual. Check exciter field


volts. Refer to section 8 and 1 2 .

Defective Diodes, Surge Suppressor,


or Generator W i ndi n gs

Test generator with constant excitatio n ( 1 2 volt battery test).


Refer to section 8 and 1 2 .

Voltage Regulator not Operating


Properly

Adjust or replace regulator. Refer to regulator manual.

SYMPTOM: GENERAT OR PRODUCES LOW VOLTAGE WHEN LOAD I S APPLIED


Overload

Measure a m ps and verify that the l oad does not exceed the
nameplate rating of the generator. Refer to section 8.

Overload - Defective Ammeter

Verify opetfltio n of ammeter by u sing a separate meter that is


known to be accurate.

Droop Circuit

If the generator set is equipped for paral leling, some voltage


droop is normal as load i n c reases. Refer to the regulator
in struction manual.

Continue troubleshooting for symptoms "Generator Produces Low Voltage - No Load".

33

TROUBLESHOOTIN G
SYMPTOM: G E NERATOR PRODUCES HIGH VOLTAG E
Defective Voltmeter

Verify operation of panel meter with another meter that is known


to be accu rate. Refer to section 8.

I ncorrect Operating Speed

Verify speed with tachometer or frequency meter.

Incorrect Connections

Verify generator connections. Refer to drawings su ppl ied with


generator set and section 3.

Defective Connections/Wiring

Inspect all wiring for grounds, open circuits, short circuits.

Regu lator Adjustments

Adjust regulator. Refer to reg u lator manual.

Diode Polarity I ncorrect

Check diodes, verify proper diodes are installed and polarity is


correct. Refer to section

6.

Voltage Regulator not Operating


Properly

Adjust or replace reg ulator. Refe r to reg ulator instruction manual.

SYMPT OM: GEN ERATOR VOLTAGE IS FLUCTUATING


Incorrect Speed

Verify speed with tachometer o r frequency meter.

Unstable Speed

Verify governor stability.

Voltage Regulator Stability

Adjust reg ulator stability. Refer to regulator manual.

Defective/Loose Connections

I nspect all wiring for loose or d i rty connections.

Defective Diodes, Surge Suppressor,


or Generator Windings

Test generator with constant excitation ( 1 2 volt battery test).


Refer to section 8 and 1 2.

Remote Voltage Adjust R h eostat


( I f used)

Check operation of rheostat. Refer to regulator manual.

Defective Regulator

Replace regulator. Refer to reg ulator manual.

----------------------------------------------------------34

---

TROUBLE SHOOTIN G
SYMPTOM: GENERATOR BU I LDS VOLTAGE FROM STARTUP,
THEN GOES TO LOW ( RESI DUAL) VOLTAG E
Regulator Protecti v e Circuit is
Operating

Check i n d i cators on regulator. Correct problems and adjust reg


ulator as required. Refer to regulator manual.

SYMPTOM: EQUIPMENT R U N S NO RMALLY ON UTILITY POWER,


BUT WILL N OT RUN O N GENERATOR SET
Voltage Waveform is Distorted

Analyze load. Excessive SCR (Thyristor) load ing will cause


distortion. Some equipment may be sensitve to distorted wave
forms. Refer to Marathon Electric.

35

GENERATOR TESTIN G
VISUAL INSPECTI ON
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 connec
tors, leads, mounting brackets, etc., can usually be
identified. Look for any loose or frayed insulation ,
loose or di rty connections, broken wires. Be sure a l l
w i r i n g i s clear o f rotating parts.
Verify that the generator is con nected for the voltage
req ui red, this is especially important on new installa
tions.
Check for any foreig n objects, loose nuts, bolts, and
electrical con nectors. Clear paper, leaves, building
materials, etc., that could be sucked into the genera
tor. (Generator is air cooled. A ir enters through 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.
I f s e r i o u s p ro b l e m s c a n be i d e n t i f ied before
att e m pt i n g to operate the m a c h i n e , ad d itio nal
damage can b e avoided.
CONSTANT EXCITAT I O N ( 1 2V BATT ERY) TEST
THEORY: The generator output voltage is dependent
on generator speed, generator desi g n , load, and
exc iter input cu rrent. If the generator speed and
exciter i n put are known, the output voltage at no
load can be measured and compared to the design
val ue. Problems can be isolated to either the gen
erator or reg ulator system by using this test.

5.

With no load on the generator, (main breakers


open) run generator at rated speed (1 800 rpm
-60 Hz or 1 500 rpm - 50 Hz).

6.

Measure the generator output voltage.

7. Shut generator down.


8.

Disconnect battery (see Caution - Step 3).

9. Compare VOltage reading with value shown i n


section 1 2.
Conclusion: I f voltage readings are normal, the
main g e nerator and exciter are operating properly.
Troubleshooting should conti nue with the regulator.
If readings are not normal the problem is in the
generator. Cont i n u e testing diodes, s u rge sup
pressor, windings.
MEASU RING VOLTAGES
When testing the generator and regulator, the most
frequent (and usually easiest) measurement will be
a voltage. The generator w i l l need to be running at
rated speed and may have some of the protective
g uards and covers removed. BE CAR EFUL. Keep
yourself and your test leads out of the way. It is best
to shut the u n it down when co n necting meters.
When using a l l igator c l ips or push on terminals, be
sure the leads are supported so vi b ration does not
shake them loose when running the generator set.
See figu re 8-1 for measurement points and expected
meter rnge settin gs. When in doubt, start with a
higher range and work down.
Consult meter instruction manual to verify its opera
tion and limitations.

TEST PROCEDURE:
1 . Shut the generator set down.
2.

Connect a voltmeter to the generator output.

3.

Disconnect the Fl and F2 1eads at the reg ulator.

4.

Connect a 1 2 volt battery capable of supplying


1 a mp to the Fl and F2 leads.
CAUTI ON: Beware of arcing when connecting
leads. Stay clear of battery vents. Escaping
hydrogen gas can explode. If hazardous condi
tions exist - use a suitable switch to connect or
disconnect the battery.

'l--------------------3-6-----------------------------------------

GENERATOR TESTIN G
FIGU RE 8-1: TYPICAL VOLTAGE MEASUREMENTS
Voltage Measurement

Test Point

Meter/Range Selection Requirement

Generator Output
Voltage

Output "T" leads or


bus bars, also main
c i rcuit breaker " l i ne"
side.

System voltage - volts A.C. See generator nameplate


and connection diagram.

Regulator Output
( Exciter Stator I nput)

F1 and F2 terminals
at the regulator.

200 volts D.C. range. F1 is plus (+), F2 is m i n u s ().

Reg u l ator Sensing


Voltage

E1 , E2, E3 terminals at
the regulator.

Usually the same as the system voltage (generator


output volts). However, in some cases, sensing is
taken from w i nd ing center taps or instrument potential transformers. Maximum 600 volts A.C.
Example:
Center tap of 480 volt system would g i ve 240 volts at
E1, E2, or E3.
Example:
A 4 1 60 volt system m ust use a transformer to step
voltage down below 600 volts.
See the connection diagram supplied with generator
set.

Regulator I n put Volts


on U n its Equipped
with PMG

"PMG" leads at the


regulator or capacitor.

200-240 VAC
1 80-220 VAC

300 Hz@ 1 800 rpm


250 Hz@ 1 500 rpm

Normal full load read i n g is approximately 3 amps


D.C.

CU RRENT (AMP) MEASUREMENTS


Current measurements (A.C.) can be easily taken
with a clamp on type meter.

MEASURING RESISTANCE

NOTE: Most clamp on a mmeters W il l not measure


D.C.

The generator w i n d i n g s ca n be measured and


compared to the values shown in the service speci
fication section 1 2.

When measuring generator output current, be sure


the clamp is around all cables for each phase. If the
physical size of the co,\d u ctors or the capacity of
the meters wi.1I not permit all cables to be measured
at once, each one can be measured i n d ividually.
Add the i ndividual readings together to get the total.
Compare readings to the generator nameplate (name
plate ratings are always given per phase).

Main Stator
The main stator w i n d i n g resistance is very low. A
meter capable of readings i n the m i l l i o h m range
would be required. However, a standard V.O . M. can
be use.d to check for continuity, shorts, or grounds.
Example: With leads d isconnected, a measurement
from T1 to T4 sho uld be very low (contin uity on
most V.O. M's). Measured from T1 or T4 to any other
lead should be infi nite. Measure from the 'T' lead to
the generator frame to check for grounds (reading
should be infin ite).

Amperage should never exceed the namep late rating


when r u n n i n g the i ntended load. (Amperage may go
above nameplate momentarily when starting large
motors.)
When measuring exciter field amps ( F 1 and F2
leads) a D.C. meter i s required. The maxi m u m field
c u rrent under f u l l regulator forcing is 6.5 amps D.C.

37

GENERATOR TE STIN G
Exciter Stator

NOTE: Polarities supplied by the meters internal


battery may or may not correspond to the (+) ( )
markings on the meter.
-

The exciter stator resistance is measured by discon


necting t he F 1 and F2 1eads at the reg ulator. Measure
the resistance between the leads. Measure from the
leads to the frame to check for grounds.
Main Rotor
Note markings and discon nect the main rotor leads
from the rectifier assembly. Measure the resistance
across the main rotor winding. Compare rea d i n g to
value shown in service specification section 1 2.
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 proceed ing to check
diodes). Measure resistance between all th ree leads.
Compare value to service specifications section 1 2.
Measure from the leads to the exciter mounting bolt
to check for grounds.

TEST I NG DIODES ( RECT I F I E RS)


Diodes perform the f u nction of a n "electrical check
valve". They conduct in one d irection only and are
used to "rectify" ac c u rrent into dc current. To test,
measure the resistance first in one d i rection and
then reverse the leads and test i n the other direction.
The read ing should be h i g h in the reverse d i rection
and low in the forward d i recti on. A shorted d i ode
will read low i n both d i rections. An open diode will
read high i n both d i rections.
NOTE:
1 . Two different polarities of d iodes are used. The
o n ly di fference is in the way the device is
mechanically placed in the case. When cha ng
i n g diode, be sure the correct polarity is used.
Refer to section 6 fig u re 6-22.
2.

Some meters do not have enough voltage


output from their internal batteries to turn the
diode on (about 0.6 volts is req u i red), and the
voltage can change with different range settings.
Consult the instruction manual for your meter.

I NSULAT I ON RESISTANCE - GENERAL


I nsulation resistance is a measurement of the integ
rity of the i nsulating materials that separate the
electrical wi n d i ngs from the generators steel core.
This resistance can degrade over time or due to
contaminants (dust, d i rt, o i l , grease, and especially
moisure). Most winding fai l u res are due to a break
down in the i nsulation system. In many cases, low
insulation resistance is caused by moisture collected
when the generator is s h ut down. The problem can
be corrected simply by d rying out the windings.
Section 5.
Normally the resistance of the insulation system i s
o n the order o f mil lions o f o hms. It is measu red with
a device called a "megger" which is a megohm
meter (meg is for million) and a power supply. The
power su pply voltage varies, but the most common
is 500 volts. A megger voltage over 500 is not
recommended, except for measuring medi u m volt
age (2400(4160) stators only.
CAUTION: Fi rst disconnect any electronic compon
ents, regulators, diodes, surge p rotectors, protective
relays, etc., will be destroyed if subjected to the h i g h
megger voltages.
To measure insulation resistance, connect one
megger lead to the leads for the winding to be
tested, connect the other megger lead to the gen
erator frame. Be sure the leads of the part being
tested are not tou c h i n g any metal parts of the
generator. (If the neutral is g rounded, it must be
d isconnected.) Take megger read ing ( refer to the
manual for the megger).
INSULATION RESISTANCE - MAIN STATOR
CAUTION: Be sure the regulator, a n d any other
electronic components, metering, protective relays,
etc., are disconnected before meggering. H i g h meg
ger voltages will destroy these parts.
All stator leads must be isolated from ground and
con nected together (on most systems with grounded
neutrals - the neutral can be isolated from ground
and used as a test point). Con nect one megger lead
to the main stator leads. Connect the other megger
lead to the generator g ro u n d i ng stud. Take the
megoh m rea d i n g (refer to instructions for the
megger).

GENERATOR TESTIN G
The m i n i m u m acceptable valu e can be calculated
using the following formula.
M i n i m u m I nsulation Resistance
(Megohms)

MAIN ROTOR FIELD AC IMPEDANCE TEST


THEORY: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
windings. One shorted turn would only change a
resistance reading o n the order of one half of one
percent.

G e n . Voltage +
1
1000

Example: For a 480 volt generator


480
1 000

1 .48 Megohms

The ac impedance test measu res the impedance


(inductance and resistance) of the field pole coils.
Shorted turns i n the field pole windi ngs change the
coil inductance to a much greater degree than the
resistance.

If the read i ng is below the recommended value, the


winding must be dried out or repaired.
I NSULATI ON RESISTANCE - MAIN ROT O R

PROCEDURE:

Disconnect the m a i n rotor leads from the diode


bridge on the exciter rotor. Connect the leads
together with one megger lead. Connect the other
megger lead to a good ground on the rotor assembly
such as the exciter mounting bolt. Tak e th e megohm
read i ng (refer to instructions for the megger).

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 c reate a
magnetic "short c i rcuit" between the poles.

The m i n i m u m acceptable value is 1 .5 megohms.

Step 2: Apply 1 20 volts ac to discon nected main


rotor le.ads F1 and F2.

I f the rea d i ng i s low, the winding m ust be dried out


or repaired.

Step 3: Measure and record voltages across each


pole. Setween points "A" and "S", "S" and
"C", "G" and "0", "D" and "E" (Figu re- 8-1 ) .

I NS ULATI ON RESISTANCE - EXCITER STAT O R


Disconnect t h e exciter leads F 1 a n d F 2 from the
regulator. Never s u bject the regulator to a megger.
Connect F1 and F2 together with one megger lead.
Connect the other megger lead to the grounding
stud. Take the megohm reading (refer to instructions
for the megger).
The m i ni mum value is 1 .5 megohms.
If the read i n g is low, the winding must be d ried out
or repaired.
I N S ULATI O N RESI STANCE - EXCITER ROTOR
Disconnect the exciter rotor windngs (3 leads from
the diodes). Connect all 3 leads together with one
meg ger lead. Connect the other megger lead to a
good gound on the rotor assembly such as the
mounting bolt. Take the megohm reading (refer to
the instructions for the megger).

(F1)

(F2)

Step 4: The voltage readings should balance within


one volt.
RESULTS : If the ac voltages are not balanced (30v
1 v ac with 1 20v ac i n put) across each pole, the
winding has shorted turns and should be rewound.

The m i n i m u m acceptable value is 1 .5 megohms.


I f the read i n g is low, the w i n d i n g must be dried out
or repaired.

Refer to Marathon Electric for further information.

39

PARTS
Note: This parts list is for reference only. Always give complete generator model
and serial numbers when ordering parts.

TABLE 9-1: PARTS LIST


lIem

R.T.F.
R.T.F.

Main Rotor with Shaft and Winding

Adapter Fasteners
3/8-16 x 1 . 25
3/8 Split Lock Washer
3/8 Flat Washer

Dri p Cover (O pti onal)


Screen

Part Number

Description

Main 80dy with Stat or Wi nding

Adapter
SAE #3
or SAE #2
or S A E # 1
or SAE #1/2
or SAE #0

Cooling Fan

801 004-06
801 065-07
801063-04

-= L-== -==-'- -==- . -=

1
12

8-525565-1

8c5255 10A
707717-01

4lIl"i rll3"@------

8-525566-1

8-5255 12A
8-5255 1 2 8
8-525p13A
8-5255 148
8-525514A

8
Drive Hub
R.T.F. - Refer To Factory

Quantity

1
1

__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__
__

40

PARTS
Item
9

10

11

Description

Part Number

Drive Disc Spacers


for SAE 1 1 -1/2 Disc
for SAE 1 4 Disc

A-525567

Drive Discs
SAE 1 1 -1/2
or SAE 1 4
or SAE 1 8

Quantity
14
5

A-525506
A-525508
A-525575

Drive Disc Fasteners


for 1 1 -1/2 Disc
5/8 x 2.00 Grade 8
for 1 4 or 1 8 Disc
5/8-1 8 x 1 .50 Grade 8
5/8 Hardened Washers

6
A-9674-2oo
A-9674-150
A-9667-1

12

Key 3/4 x 3/4 x 4

A-25658-30

13

Rectifier Mounting Hub

707807-01

14

Fan Fasteners
1/2-13 x 1 .50
1/2 Belleville Washers

801 008-05
A96821

15

Conduit Box - Standard


Conduit Box - Special

7236400A
R.T.F.

16

Screws for Conduit Box Covers


1/4-20 x .75 Self Locking

A9646-75

1
1
4

1
32

17

Conduit Box Side Panel - Blank

723640-03

18

Key 3/8 x 3/8 x 3

A-7605-3oo

19

Rectifier Assembly Fasteners


1/4-20 x .62
1/4 Flat Washer

801 000-02
801 063-22

Bearing - Size 31 2 Double Sealed

831 823-01

21

End Cap

A526062

22

End Cap Fasteners


1/4-20 x .62
1/4 Split Lock Washer

801 000-02
801 065-05

23

Rectifier Assembly

777062-0A

24

Exciter Rotor

791 1 48-0A

25

Exciter Stator

789342-0A

26

End Bell

B-526005B

27

Louvered Conduit Box Cover

C-525562

28

Conduit Box Side Panel - Regulator Mounting

723640-04

30

Exciter Stator Retaining Screw


3/8 - 1 6 x 1 .00
3/8 Split Lock Washer

801 004-05
801 065-07

1
1

Grounding Screw
3/8-1 6 x 3.00
3/8-1 6 Nut NonMagnetic
3/8 Flat Washer Non-Magnetic

A-26937-300
A-9786-1
A-9787-1

1
2
2

20

31

32

33

Gasket
End Bell Fasteners
3/8-1 6 x 1 . 25
3/8 Split Lock Washer
3/8 Flat Washer

R.T.F.

1
4

1
1
4

Conduit Box Mounting Fasteners


3/8-1 6 x .75
3/8 Tooth Washer

34

801 004-03
A-7675-2
A-504934-46

1
8

801 004-06
801 065-07
801 063-04

Refer To Factory

41

SP ECIA L TOO LS
STANDARD TOOLS

The M a g n a P L U S g e n erator is asse m b led


American standard SAE hardware. Wrench
from 5/1 6 inch to 7/8 inch are used. A socket
set screw is used in the drive h u b . A 1 /4 inch
type wrench is req u i red to remove it.

with
sizes
head
allen

All fasteners should be properly torqued (See section


1 2 ) . Torque wrenches ranging from 25 in - Ib through
200 ft-Ib should be available.
Electrical test eq u i pment should include a voltmeter
or m u ltimeter (VOM). clamp on ammeter, accu rate
frequency meter or tachometer, and a megohm meter.
See section 8, Generator Testing for more informa
tion.
SPECIAL TOOLS

I n 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

Rotor lifting fixture ( F i g u re 10-3). The main gen


erator rotor i s heavy (approximately 1 /2 the
weight of the generator) and difficult to handle.
The proper fixture should be used whenever
removing or installing the main rotor into the
mai n stator. Without proper care and equi pment,
the windings can be easily damaged.

Snap ring p l iers (Figure 1 0- 1 ) . The PMG rotor is


installed to the generator shaft with a snap ring.
The nominal shaft diameter is 2-3/4 i n c hes and
the ring must be spread approximately 3/4 i n c hes
for removal. To install the snap ring, use a piece of
pipe with a 2-3/4 inch I . D. (Figure 1 0-2). Push the
PM G rotor and snap ring onto the shaft until the
ring snaps into the groove.

FIGURE 10-3

MISCELLANEOUS

A selection of wiri n g devices such as electric con


nectors, tape, cable ties, crimping and stripping
tools, etc., should also be a part of the generator
service tool kit. The PM 1 00 regulator uses flat 1 /4
inch female insu lated terminals for AWG #14 wire.

FIGURE 10-1

1IlJ:jI
E:::' E:::' -= -'- . E:: ---------------------------------rr;"IMAJUtl'HDN
L
42

PREPARATION FOR SHI P MENT


SHIPPING I N STRUCTI O N S
S h i p p i n g a n d h a n d l i n g w i l l b e m uch easier i f the
g e nerator is fastened to a suitable shipping skid that
will allow handl i n g by a fork li ft. The skid should
extend beyond the ge nerator i n all directions. I f the
original skid i s available i t s h ould be used. Marathon
Electric will supply shipping skid d rawings upon
request.
Overseas shi pping may require special export crat
i n g . Check with your freight carrier.
When i nstalled, single bearing generator rotors are
s u p ported on the drive end by the drive discs bolted
to the engi ne flywheel. When the engine is removed,
th e rotor must be s u p p o rted by an appropriate
fixture to prevent main rotor, main stator or exciter
d amage (Figure 1 1 - 1 ) . Before s h ipping any single
bearing generator, the main rotor must be supported
by the adapter using an appropriate fixture.

CAUTI ON
DO NOT ATT EMPT TO TRANSPORT ANY
G E N ERATOR WITH O UT PROPER ROTOR
S U P P O R T , E XT E N S I V E E Q U I P M E N T
DAMAGE CAN OCCUR.

43

SPECIFICATIONS
TABLE 12-1: MAGNA PLU S - FASTENER AND TORQUE SPECIFI CAT IO NS
Part Description

Torque@
Ft-Lb

Grade 5 capscrews with flat and lock washers

3/8 - 16

25

G rade 8 capscrews with hardened washers

5/8 - 18

1 92

Adapter (or rear bracket)

Grade 5 capscrews with flat and lock washers

3/8 - 16

25

Conduit Box

Grade 5 capscrew with star type lock washer

3/8 - 16

25

PMG Stator

Grade 5 capscrews with belleville washers

1/4 - 20

Exciter Stator

Socket head set screws

1/4 - 20

Cooling Fan

Grade 5 capscrews with belleville washers

1/2 - 13

60

Rectifier Assembly Mounting

Grade 5 capscrews with flat washers

1/4 - 20

Drive Hub Set Screw

Socket head set screw

1 /2 - 1 3

50

NOTES:
CD All fasteners are SAE (American) standard.

CD

SizeC!)
Dia.-Thread

Drive Disc

Front Bracket (End Bell)

CD

Fastener Spec. CD

All torque values are for plated hardware which is standard o n


the MagnaPLUS. If hardware i s replaced with non-plated,
refer to Table 1 2-2.
Always use quality hardware 01 the grade specified.

SPECIFICATIONS
TABLE

1 2-2:

CAPSCREW TORQU E VALU ES

Capscrew Diameter and Ulti mate


Tensile Strength
(PSI)

T o 1 / 2 - 69,000 PSI
To 3/4 - 64,000 PSI
To 1 - 55,000 PSI

To 3/4 - 1 20,000 PSI


To 1 - 1 1 5,000 PSI

1 50,000 PSI

SAE Grade
Number

1 or 2

()

Torque CD
Ft-Lb (N-m)

Torque CD
Ft-Lb (N-m)

Capscrew Head
Markings

Capscrew Body
Size
(Inches) - (Thread)

Torque CD
Ft-Lb (N-m)
Oiled

Dry

Dry

Plated

/ \

Plated

Oiled

Oiled

Dry

Plated

1/4 - 20

(7)

4.5

(6)

(5)

(1 1 )

(9)

(8)

12

(16)

11

(15)

10

(14

- 28

(8)

5.4

(7)

4.8

(6)

10

(14)

(12)

(11)

14

(19)

13

(18)

11

(15)

5/16 - 1 8

11

(15)

10

(14)

(12)

17

(23)

15

(20)

14

(19)

24

(33)

22

(30)

19

(26)

- 24

13

( 1 8)

12

(16)

10

(14)

19

(26)

17

(23)

15

(20)

27

(37)

24

(33)

22

(30)

3/8 - 1 6

18

(24)

16

(22)

14

(19)

31

(42)

28

(38)

25

(34)

44

(60)

40

(54)

35

(47)

- 24

20

(27)

18

(24)

16

(22)

35

(47)

32

(43)

28

(38)

49

(66)

44

(60)

39

(53)

7/1 6 - 1 4

28

(38)

25

(34)

22

(30)

49

(66)

44

(60)

39

(53)

70

(95)

63

(85)

56

(76)

-20

30

(41 )

27

(37)

24

(33)

55

(75)

50

(68)

44

(60)

78 (1 06)

70

(95)

62

(84)

1/2 - 1 3

39

(53)

35

(47)

31

(42)

15 (102)

68

(92)

60

(81 ) 105 ( 1 42)

95 ( 1 29)

84 (1 1 4)

- 20

41

(56)

37

(50)

33

(45)

85 ( 1 1 5)

77 (104)

68

(92) 120 ( 1 63)

108 (146)

96 ( 1 30)

41

(56)

1 1 0 (1 49)

99 (134)

88 ( 1 1 9) 1 55 (210)

140 (190)

124 (1 68)

96 (130) 1 70 (230)

153 (207)

136 (184)

189 (256)

168 (228)
192 (260)

9/16 - 1 2

51

(69)

46

(62)

- 18

55

(75)

50

(68)

44

(60)

1 20 (163) 108 (146)

5/8 - 1 1

83 (1 1 3)

75

(102)

66

(89)

1 50 (203) 135 (183) 1 2 0 ( 1 63) 2 1 0 (285)

- 18

95 (129)

86 ( 1 1 7)

76 (103)

1 70 (230) 153 (207) 136 (1 84) 240 (325)

2 1 6 (293)

84 ( 1 1 4)

270 (366) 243 (329) 2 1 6 (293) 375 (508)

338 (458)

300 (407)

92 ( 1 25)

295 (400) 266 (361) 236 (320) 420 (569)

378 (513)

336 (456)

3/4 - 1 0
- 16

105 (1 42)

95 (130)

1 1 5 ( 1 56) 104

(141 )

7/8 - 9

160 (217) 144 (195)

1 28 (174) 395 (535) 356 (483) 3 1 6 (428) 605 (820)

545 (739)

484 (656)

- 14

1 75 (237) 1 58 (214)

1 40 ( 1 90)

435 (590) 392 (531) 348 (472) 675 (915)

608 (824)

540 (732)

1 -8

235 (319) 2 1 2

(287)

188 (255)

590 (800) 531 (720) 472 (640) 9 1 0 (1 234) 8 1 9 ( 1 1 10) 728 (987)

- 14

250 (339) 225 (305)

200 (271 )

660 (895) 594 (805) 528 (716) 990 (1 342) 891 (1208) 792 ( 1 074)

NOTES:
CD Capscrews threaded i n t o a l u m i n u m m a y require reductions i n torque
of 30% or more.

45

SPECIFICATIONS
NOTE: All excitation data based on measurement using F1 and F2 exciter field winding. For F1 to F3 data refer
to factory.
TABLE 12-3: EXCITATION DATA - 60 HZ - 1 800 RPM
No Load Output Voltage
With Fixed Excitation
High Wye Connection

Exciter Field
Resistance Ohms

Exciter Field Volts


F1 and F2 at Regulator
No LoadeD

Model Number

@ 25 C

240/480 Volts

1 2 V DC

24V DC

430S1260
430S1 261
430S1262
430S1263
43051264
430S1265
430S1266
432S1267
432S1268

18.6
18.6
1 8.6
18.6
18.6
18.6
18.6
18.6
1 8.6

8.9
10.4
10.0
10.2
9.7
1 1 .0
1 2. 1
1 1 .7
14.9

530
510
51 0
510
520
500
480
490
440

530
600
600
600
610
590
570
580
550

CD For rated load exciter field volts - see generator nameplate.


CD For low wye connection: divide value shown i n table by 2.

For high delta connection: divide value shown in table by 1 .732.

TABLE 1 2-4: EXCITATION DATA - 50 HZ - 1500 RPM


No Load Output Voltage
With Fixed Excitation
High Wye Connection

Exciter Field
Resistance - Ohms

Exciter Field Volts


F1 and F2 at Regulator
No LoadeD

@ 25 C

4 1 5 Volts

12V DC

24V DC

1 1 .0
1 2.5
12.1
12.1
1 1 .9
13.8
14.9
13.8
1 7.5

430
410
410
410
420
400
380
400
360

510
490
490
490
500
480
470
480
450

Model Number

430S1260
430S 1 261
430S1262
430S1263
430S1264
430S1 265
430S1 266
432S1267
432S1268

1 8.6
18.6
18.6
18.6
18.6
18.6
18.6
18.6
18.6

CD For rated load exciter field volts - see generator nameplate.


CD For low wye connection: divide value shown i n table by 2.

For high delta connection: divide value shown in table by 1 .732.

CD For delta connection: divide value shown in table by 1 .732.

I'i'\"lMARAJ HDN

-== L-== _._II=I. II::::::

--

--

46

SPECIFICATIONS
TABLE 1 2-5:
RESISTANCE VALUES - MAIN WINDINGS
NOMINAL COLD (25"C) RESISTANCE I N O H M S
Model Number

H-SG-

Main
Stator(i)

430S1260
430S1261
430S1 262
430S1263
438S1264
430S1265
432S1266
432S1267
432S1268

430601
430602
430603
430604
430605
430606
430607
430608
430609

.204
.181
123
.0935
.0721
.0541
.0415
.0373
.0264

Winding

Main
Rotor

.482
.504
.520
.558
.594
.636
.704
.711
.825

TABLE 1 2-6:
RESISTANCE VALUES - EXCITER WINDI N G S
NOMINAL COLD (25" C) RESISTANCE I N OHM S
(Field)

ExCiter Rotar
(Armature)

PMG
Stator

18.6

.105

2.00

ExCiter Stator

CD Main stator values shown are l i n e to line on the high wye

connection. For low wye connection divide value shown i n


table b y 4.

II
47

GENERATOR FOR MULASQ

To Find

Three Phase

Known Values

KW

Volts, Current, Power Factor

E x I x 1 ,73 x PF
1 000

KVA

Volts, Current

E x I x 1 ,73
1 000

R KVA

Volts, Current, Power Factor

E x I x 1 .73 x1 - (PF)2
1 000

Hp-Engine Output

G e nerator kW, Generator Eff.


Radiator Fan Horsepower
Battery Charging Generator h p

kVA x PF

kW
PF

KW
Efficiency x .746

Rad
Cooling
+ Fan
hp

KW-Req u i red for Motor

Mo to r hp, Eff.

HI:> x .746
Efficiency

KVA-Req u i red for Motor

Motor hp, Eff., Power Factor

HI:> x .746
Efficiency x PF

Amps

Hp, Volts

H p x 746
1 .73 x E x Efficiency x PF

Amps

K W , Volts, Power Factor

KW x 1 000
E x 1 . 73 x PF

Amps

KVA, Volts

KVA x 1 000
E x 1 .73

Frequency

R p m , Poles

Rl:>m x Poles
2 x 60

Poles

Frequency, rpm

2 x 60 x Freguency
rpm

Rpm

Frequency, Poles

2 x 60 x Freguency
Poles

CD E

Bat. C h g .
Gen. hp

Volts
Current (Amps)
PF Power Factor
I

'l -------------------------------------------------------------48

NOTES

M o d e l N u m be r

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Serial N u m ber

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_

I n sta I I ed Date

__
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_
__
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_
_
_
_

I n stal l ed By

__
_
__
__
__
_
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_
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_

49

Marathon Electric Mfg. Corp.


1 00 East Randolph Street
P.O. Box 8003
VVausau, VVI 54402-8003
Phone: (71 5) 675-331 1
TVVX: 91 0-281 -1521
Telex: 260175 M E VVAS
Fax: ( 7 1 5) 675-6361
Litho in U.S.A.

GPNOO5 3/95