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Marathon Electric MAGNAMAX, Installation, Operation And Maintenance Manual

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62

TABLE 9-1 PARTS LIST
NOTE: The parts in this list are subject to change, model number and serial number must
accompany any parts order or inquiry.

430 Frame Series

570 Frame Series

740 Frame Series

Item

Part Description

Part Number

Qty.

Part Number

Qty.

Part Number

Qty.

1

Screen Assembly
 Screen
Screen Mounting Bolt Screen
Mounting Nut

B-525565-1
A-9646-200
A-7551-18

1
2
2

B-525565-2 A-
9646-200 A-
7551-18

1
2
2

B-525565-3
A-9646-200
A-7551-18

1
2
2

2

Drip Cover assembly

B-525566-1

1

B-525566-2

2

B-525566-3

1

3

Adapter
#3Adapter
#2Adapter
#1 Adapter
#1/2 Adapter
#0Adapter
#00 Adapter (#18 Disc)
#00 Adapter (#21 Disc)

B-525512A
B-525512B
B-525513A
B-525514B
B-525514A

1
1
1
1
1

B-525618A
B-525616A
B-525603A
B-525617A
B-526228A

1
1
1
1
1

B-525720A
B-525721A
B-52572 1A

1
1
1

4

Disc Mounting Fasteners
Cap screw for #11-1/2
Cap screw for #14
Cap screw for #18
Cap screw for #21
Cap screw for Delco
Hardened Washer

A-9674-200
A-9674-150
A-9674-150

A-9674-150
A-9667-1

6
6
6

6
6

A-9674-150
A-9674-150

A-9674-150
A-9667-1

9
9

9
9

A-9674-200
A-9674-150
A-9674-200
A-9667-1

18
18
18
18

5

Drive  Discs
  #11-1/2 Disc
  #14 Disc
  #18 Disc
  #21 Disc
   Delco Disc (17.75” 0.0.)

A-525506
A-525508
B-525975
 —
A-525507

5
5
4
—
5

 —
A-525508
A-525579

A-525507

—
5
5

5

—
 —
A-525579
A-525580
A-525507

—
—
10
10
10

6

Spacers
 For #11-1/2 Disc
  For #14 Disc
  For#18 Disc
 For #21 Disc
  For Delco Disc

A-525567
A-525567
 —
 —
 —

14
5
—
—
—

 —
A-525503
 —
 —
A-525503

—
6
—
—
1

—
 —
A-525503
 —
A-525503

—
—
10
—
12

7

Fan Mounting Fasteners
  Cap screw
  Cap screw (2 Brg. Only)
  Belleville Washer

A-9626-150
A-9626-150
A-9682-1

4
4
4

A-9626-150
A-9626-200
A-9682-1

8
8
8

A-9626-1 50
A-9626-200
A-9682-1

8
8
8

8

Fan

B-525510A

1

B-525604A

1

B-525719A

1

9

Hub
 Drive Hub [Sgl Brg. Only)
 Fan Hub (2 Brg. Only)

B-525509A
A-525568A

1
1

B-525606A
B-525694A

1
1

B-525726A
B-525750A

1
1

10

Drive Hub Set Screws

—

A-9675-50

2

A-9675-50

2

Summary of Contents for MAGNAMAX

Page 1: ...1 MAGNAMAX GENERATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL ...

Page 2: ... 10 RECEIVING YOUR MAGNAMAX GENERATOR 10 UNPACKING AND HANDLING 10 STORAGE 10 PREPARATION FOR USE 10 GENERATOR MOUNTING SINGLE BEARING 10 GENERATOR MOUNTING TWO BEARING 11 BELT DRIVE 11 ENVIRONMENTAL CONCERNS 11 ELECTRICAL CONNECTIONS 12 GENERATOR LEAD CONNECTIONS 12 12 LEAD HIGH WYE CONNECTION 13 12 LEAD LOW WYE CONNECTION 13 12 LEAD HIGH DELTA CONNECTION 14 12 LEAD LOW DELTA CONNECTION 14 10 LEA...

Page 3: ...THE GENERATOR 22 FIELD FLASHING 22 VOLTAGE ADJUSTMENTS 22 OTHER ADJUSTMENTS 23 MAINTENANCE 23 GENERAL INFORMATION 23 AIR INTAKE AND EXHAUST 23 ELECTRICAL CONNECTIONS WINDINGS 24 LUBRICATION 24 DRYING ELECTRICAL INSULATION 26 Space Heaters 26 Oven 26 Forced Air 26 Short Circuit Method 26 CLEANING METHODS 27 Solvents 27 Cloth and Compressed Air 27 Brushing and Vacuum Cleaning 27 Shell Blasting 27 St...

Page 4: ...R INSPECTION 42 FRONT END BRACKET INSTALLATION 42 MAIN ROTOR INSTALLATION 42 PMG INSTALLATION 45 EXCITER INSTALLATION 46 CONDUIT BOX INSTALLATION 47 ASSEMBLY TO PRIME MOVER 48 TROUBLESHOOTING 50 INTRODUCTION 50 SYMPTOM 51 NO VOLTAGE OR RESIDUAL VOLTAGE 51 LOW VOLTAGE 52 NO LOAD 52 LOW VOLTAGE WHEN LOAD IS APPLIED 53 HIGH VOLTAGE 53 VOLTAGE IS FLUCTUATING 54 OPERATES SATISFACTORILY WHEN COLD BUT SH...

Page 5: ...LATION RESISTANCE MAIN ROTOR 59 INSULATION RESISTANCE EXCITER STATOR 60 INSULATION RESISTANCE EXCITER ROTOR 60 MAIN ROTOR FIELD AC IMPEDANCE TEST 60 MAGNAMAX EXPLODED VIEW 61 STANDARD TOOLS 64 SPECIAL TOOLS 65 MISCELLANEOUS 66 PREPARATION FOR SHIPMENT OR EXTENDED STORAGE 66 SHIPPING INSTRUCTIONS 66 STORAGE INSTRUCTIONS 66 TABLE 12 1 MAGNA MAX FASTENER AND TORQUE SPECIFICATIONS 68 TABLE 12 2 CAPSCR...

Page 6: ...he installation and service sections incorrect lifting or moving can result in personal injury or property damage Whenever the generator is running always assume and proceed as if voltage is present Residual voltage is present at the generator leads and at the regulator panel connections even with the regulator fuse removed Caution must be observed or serious personal injury or death can result Wh...

Page 7: ...nduit box cover properly directs outside ventilating air through the generator MagnaMAX UnirotorTM Construction An aluminum die cast rotor core affords high mechanical integrity and low vibration at operating speeds Amortisseur winding and coil supports are die cast as an integral part of the rotor Laminations are 4 pole one piece laminations which are shrunk fit and keyed to the shaft No dovetail...

Page 8: ...ms operated within their temperature limits The varnishes and epoxies used are synthetic non hygroscopic Multiple dip and bake cycles of the main winding plus a final coat of epoxy make the standard winding moisture and fungus resistant The MagnaMAX rotor is wet wound with thermo setting epoxy applied between each layer plus a final coating of epoxy for moisture and abrasion resistance MagnaMAX ge...

Page 9: ... character Bearing arrangement S 1 Bearing D 2 Bearings 6th character Voltage range L Up to 480 volts M 1000 6600 volts S 600 volts 7th Character Product style 4 Magna 8th Character Type 9th 10th Character Wk2 Code 11th Character Modification A Z assigned sequentially 12th Character Mounting Arrangement A Y see chart figurer 2 1 13th 14th 15th characters Modification numbers For internal use only ...

Page 10: ...on PREPARATION FOR USE Although the generator is carefully inspected and tested in operation before it leaves the factory it is recommended the unit be thoroughly inspected The insulation on the wire should be inspected and all bolts should be checked for tightness Remove all shipping tapes bags blocks and skids which are used to prevent vibration and rotor movement during shipment Dry low pressur...

Page 11: ...ator shaft IMPORTANT Aligning the two machines as accurately as possible will reduce vibration increase bearing life and insures minimum coupling wear It may be necessary to shim the generator feet for proper support and alignment Consult the coupling manufacturer s instructions for alignment specifications and procedures BELT DRIVE Please refer to Marathon Electric for applications involving belt...

Page 12: ... surfaces to assure good electrical bonding with the generator lugs or bus bars Use heavy duty terminal lugs or good quality clamps for making all connections Insulate all connections in accordance with national and local regulations Be sure the generator frame is grounded to all the other components of the system with a ground wire in accordance with national and local regulations GENERATOR LEAD ...

Page 13: ... 8 0 4 6 0 4 4 0 4 1 6 3 8 0 2 7 7 2 6 6 2 5 4 2 4 0 2 1 9 5 0 H Z 4 1 6 4 0 0 3 8 0 2 4 0 2 3 1 2 1 9 12 LEAD LOW WYE CONNECTION L2 T7 T10 T1 T4 L1 L3 T5 T2 T11 T8 T6 T3 T12 T9 L L L N V O L T A G E L L L N 6 0 H Z 2 4 0 2 3 0 2 2 0 2 0 8 1 9 0 1 3 9 1 3 3 1 2 7 1 2 0 1 1 0 5 0 H Z 2 0 8 2 0 0 1 9 0 1 2 0 1 1 5 1 1 0 ...

Page 14: ...2 T9 T6 T3 L L L N V O L T A G E L L L N 6 0 H Z 2 4 0 2 7 7 1 2 0 1 3 9 5 0 H Z 2 0 0 2 2 0 2 4 0 1 0 0 1 1 0 2 2 0 12 LEAD LOW DELTA CONNECTION L1 L2 L3 T1 T4 T7 T10 T2 T5 T8 T11 T3 T6 T12 T9 L L L L V O L T A G E L L L N 6 0 H Z 1 2 0 1 3 9 N A 5 0 H Z 1 0 0 1 2 0 N A ...

Page 15: ... 8 0 4 6 0 4 4 0 4 1 6 3 8 0 2 7 7 2 6 6 2 5 4 2 4 0 2 1 9 5 0 H Z 4 1 6 4 0 0 3 8 0 2 4 0 2 3 1 2 1 9 10 LEAD LOW WYE CONNECTION L2 T7 T0 T1 T4 L1 L3 T5 T2 T8 T6 T3 T9 L L L N V O L T A G E L L L N 6 0 H Z 2 4 0 2 3 0 2 2 0 2 0 8 1 9 0 1 3 9 1 3 3 1 2 7 1 2 0 1 1 0 5 0 H Z 2 0 8 2 0 0 1 9 0 1 2 0 1 1 5 1 1 0 ...

Page 16: ...0 66 00 41 60 33 00 24 0 23 0 22 0 20 3 19 0 79 67 38 11 24 00 19 05 13 9 13 63 12 7 12 0 11 0 50 H Z 11 00 0 66 00 33 00 20 8 20 0 19 0 63 51 38 11 19 05 12 0 11 5 11 0 6 LEAD DELTA CONNECTION L1 L2 L3 T1 T4 T2 T5 T6 T3 L L V O L T A G E L L L N 6 0 H Z 7 9 6 7 2 4 0 0 N A 5 0 H Z 6 3 5 1 1 9 0 5 N A ...

Page 17: ...L L N 60 HZ 7967 2402 NA NA 50 HZ 6351 1905 NA NA 4 LEAD WYE CONNECTION T 3 L3 T2 T1 L 1 L2 L L L N T 0 VOLTAGE L L L N 60 HZ 13800 6600 4160 3300 2400 600 480 380 7967 3811 2400 1905 1386 346 277 219 50 HZ 11000 6600 3300 416 400 380 6351 3811 1905 240 231 219 ...

Page 18: ... 0 1 1 0 1 0 0 LOW ZIG ZAG SINGLE PHASE CONNECTION L2 T3 T6 L1 T7 T10 T1 T4 T2 T5 T8 T11 T12 T9 L N L N L L V O L T A G E L L L N 6 0 H Z 2 4 0 2 2 0 2 0 0 1 2 0 1 1 0 1 0 0 5 0 H Z 2 2 0 2 0 0 1 1 0 1 0 0 HIGH ZIG ZAG SINGLE PHASE CONNECTION L1 L2 T1 T4 T7 T10 T2 T5 T8 T11 T12 T9 T6 T3 L N L N L L V O L T A G E H Z L L L N 6 0 4 8 0 4 4 0 2 4 0 2 2 0 5 0 4 4 0 4 0 0 2 2 0 2 0 0 ...

Page 19: ...When two or more ac generators operate in parallel the voltage regulator must have paralleling provisions either internally or external to the regulator to control the reactive or VAR load while it is in parallel operation A separate paralleling current transformer is required to sense the reactive current and signal the voltage regulator This additional paralleling circuitry is absolutely necessa...

Page 20: ...se or droop in generator voltage The circuit must meet the following criteria A All paralleling current transformers for all the generators being paralleled must be included in the secondary interconnection loop B When different size generators are paralleled all paralleling current transformers must have the same proportional ratios that give approximately the same secondary current C Voltage reg...

Page 21: ...r to insure the proper selection of all components Please refer to Marathon Electric for application assistance OPERATION PRE START INSPECTION Before operating the generator for the first time the following checks are recommended 1 A visual inspection should be made to check for any loose parts connections or foreign materials 2 Check for clearance in the generator and exciter air gap Be sure the ...

Page 22: ...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 60 hertz 1500 rpm for 50 hertz Refer to prime mover governor instruction manuals 8 Before stopping the engine remove the load by tripping the main circuit breaker FIELD FLASHING The standard MagnaMAX generator is supplied with a PMG permanent magnet ge...

Page 23: ...hecked when putting the generator into service after it has been in storage and anytime contamination by moisture and dirt is suspected Normally moisture buildup is not a problem while the generator is running since heat produced internally will tend to keep it dry but can collect in the generator when it is shut down The problem will be worse in humid environ ments or in areas where extreme tempe...

Page 24: ...t or dusty environments require more frequent lubrication every six months or one half the table intervals whichever occurs first Use Chevron SRI or equivalent anti friction type high quality grease with a lubrication temperature range of 22 to 350 F 30 to 175 C To add or renew grease proceed as follows 1 Stop unit 2 Wipe the grease plugs and surrounding parts to insure they are clean 3 Remove bot...

Page 25: ...ally Ounces Cubic Inches Teaspoons 60 Hz 50 Hz Single 431 432 433 314 1 2 2 1 7 0 6500 8400 Bearing 571 572 Units 573 574 316 1 5 2 6 8 3 5600 7200 741 742 743 744 322 2 4 4 2 14 0 3000 4500 431 432 318 1 7 3 0 9 9 4600 6200 Double 571 572 Bearing 573 574 318 1 7 3 0 9 9 4600 6200 Units 741 742 743 744 322 2 4 4 2 14 0 3000 4500 TABLE 5 3 During an overhaul the grease reservoir should b thoroughly...

Page 26: ...r intake conduit box and running the generator with no load and without excitation this can be accomplished by removing the regulator fuse Heat at point of entry should not exceed 150 F 66 C Short Circuit Method Using this method can dry out the generator quickly and thoroughly WARNING BE SURE THAT ALL OF THE FOLLOWING STEPS ARE PERFORMED AND ALL PRECAU TIONS TAKEN AS PERSONAL INJURY OR SERIOUS DA...

Page 27: ...or grease Only petroleum distillates should be used for cleaning electrical components Petroleum solvents of the safety type with a flash point greater than 100 F 38 C are recommended CAUTION A SOLVENT THAT DOES NOT ATTACK EPOXY OR POLYESTER BASED MATERIALS SHOULD BE USED Apply the solvent with a soft brush or rag Be careful not to damage the magnet wire or insulation on the windings Dry component...

Page 28: ...conduit box 4 Attach a suitable hoist to the generator lifting 5 For single bearing generators remove the bolts mounting the screen assembly to the SAE adapter and remove the screen Figure 6 3 Figure 6 3 NOTE Do not remove the drip cover from the screen assembly if so equipped Remove the cap screws attaching the drive discs to the flywheel and remove the cap screws attaching the SAE adapter to the...

Page 29: ...capacitor Figure 6 5 and any other conduit box mounted controls Figure 6 4 Figure 6 5 2 On generators equipped with bus bars mark all connections and disassemble main stator power leads from the generator side of the bus bars 3 Remove bolts holding conduit box in place Figure 6 6 Figure 6 6 4 Remove conduit box Figure 6 7 Figure 6 7 ...

Page 30: ...ixture Figure 6 9 Figure 6 9 EXCITER ARMATURE ROTOR REMOVAL 1 Note markings and disconnect the main rotor leads coming out of the lead hole of the aluminum standoff plate from the rectifier aluminum angle Figure 6 10 Figure 6 10 2 Remove the cap screw and Belleville washer that holds the exciter rotor armature to t generator shaft Figure 6 11 Figure 6 11 3 Use a six inch 3 4 16NF cap screw for a p...

Page 31: ... WITH A NUT WELDED ON THE END PMG STATOR REMOVAL 1 Remove exciter armature Follow instructions found earlier in this section 2 Remove the PMG output leads from the capacitor Figure 6 14 and loosen all cable ties so the leads can be removed with the PMG stator Figure 6 14 3 Note the position of the PMG stator leads that exit at the left inboard side or mark the stator so it can be reinstalled in th...

Page 32: ... instructions found earlier in this section 2 Remove the snap ring that holds the PMG rotor in place on the shaft Figure 6 17 and 6 18 Figure 6 17 Figure 6 18 3 Slide the PMG rotor off of the shaft Figure 6 19 Figure 6 19 4 Remove the loading spring if the loading spring is not on the shaft check to see if it is stuck on the back of the PMG rotor 5 On 430 frame generators a second snap ring is use...

Page 33: ... the bearing caps to the front end bracket Figure 6 21 Remove the outer cap Figure 6 22 For two bearing generators remove the drive coupling or sheave and key from the shaft extension Remove the four cap screws holding the bearing lock to the drive end bracket Figure 6 23 Remove the four cap screws holding the bearing caps to the front end bracket Figure 6 21 Remove the outer cap Figure 6 22 Figur...

Page 34: ...the drive discs to the drive hub Figure 6 25 Remove all drive discs and spacers if any Figure 6 25 5 For single bearing generators remove the cap screws holding the SAE adapter to the generator and remove the adapter Figure 6 26 and 6 27 Figure 6 26 Figure 6 27 CAUTION ON LARGE GENERATORS A HOIST AND LIFTING STRAP SHOULD BE USED TO ASSIST IN DRIVE END BRACKET OR SAE ADAPTOR REMOVAL For two bearing...

Page 35: ... THE GENERATOR FAN FOR LIFTING OR ROTATING THE GENERATOR ROTOR DISREGARDING THESE INSTRUCTIONS MAY CAUSE PER SONAL INJURY OR EQUIPMENT DAMAGE FRONT END BRACKET REMOVAL 1 Remove front bracket mounting screws Figure 6 30 2 Remove the front end bracket from the main stator assembly Figure 6 31 CAUTION ON LARGE GENERATORS A HOIST AND LIFTING STRAP SHOULD BE USED TO ASSIST IN THE FRONT END BRACKET REMO...

Page 36: ...ifiers and surge protector for proper operation Replace defective parts CAUTION THREE FORWARD AND THREE REVERSE POLARITY DIODES ARE USED BE SURE THE CORRECT PART IS INSTALLED IN THE CORRECT LOCATION THE SURGE SUPRESSOR IS POLARIZED OBSERVE POLARITY MARKINGS WHEN CHANGING THE SURGE SUPRESSOR Figure 6 34 Torque mounting nuts to 80 in lb Torque lead terminal nuts to 25 in lb Never torque against the ...

Page 37: ...OULD BE DRAWN TO THE MAGNETS AS WELL AS OTHER COMPONENTS THAT CAN BE DAMAGED BY MAGNETIC FIELDS Figure 6 37 1 Clean dust and dirt from the PMG rotor 2 Check to be sure all magnets are tightly bonded to the PMG rotor 3 Check the bore and keyway of the PMG rotor for burrs or corrosion 4 Look for score marks on the outside diameter caused by rubbing This could indicate bearing or assembly problems an...

Page 38: ...th a soft mallet apply pressure to the inner race only CAUTION UNDER NO CIRCUMSTANCES SHOULD PRESSURE BE APPLI ED TO THE OUTER RACE OF THE BEARING AS PERMANENT BEARING DAMAGE COULD RESULT Figure 6 39 Allow the bearing to cool for one hour before attempting to assemble the generator FAN 1 Check the fan for cracks or broken blades Replace the fan if defective 2 Mark the hub and fan for alignment thi...

Page 39: ...uctions Item A Drive Hub Single Bearing Generators 1 Check the drive hub for cracks or stripped drive disc mounting holes Replace the hub if defective 2 If the hub is to be replaced remove the fan See Item B and install a suitable puller to the hub Remove the two set screws in the hub over the key Using a torch rapidly heat the hub at the outer diameter while tightening the puller This must be don...

Page 40: ... Check the rotor for loose frayed or burned windings Measure winding resistance an insulation resistance Test for shorted turns using an A C impedance test A defective rotor winding must be rewound The rotor assembly must be rebalanced after any rework or repair has been completed DRIVE DISCS SINGLE BEARING GENERATORS ONLY 1 Inspect the drive discs for distorted or bent edges Figure 6 46 Inspect f...

Page 41: ...y burrs or rust That could interfere with proper alignment Figure 6 47 and 6 48 6 Re assemble the grease pipes and fittings to the bearing cap DRIVE END BRACKET OR SAE ADAPTER INSPECTION 1 For two bearing generators remove the grease plugs from the bracket 2 Clean the bracket or adapter cap screws and screen assembly to remove all dust dirt and grease 3 Inspect the cap screws for stripped threads ...

Page 42: ...e holes in the generator frame and slide the bracket onto the frame Figure 6 52 Install bracket mounting cap screws Figure 6 53 Figure 6 52 CAUTION ON LARGE GENERATORS A HOIST AND LIFTING STRAP SHOULD BE USED TO ASSIST IN THE FRONT END BRACKET INSTALLATION Figure 6 53 2 Remove the two guide pins and insert the remaining cap screws and torque to specifications given in section 12 MAIN ROTOR INSTALL...

Page 43: ...over the fan and secure to the main stator and frame assembly with cap screws torqued per section 12 Figure 6 55 and 6 56 It may be necessary to raise the rotor assembly slightly to allow the mounting of the SAE adapter Figure 6 55 Figure 6 56 Figure 6 57 For two bearing generators insert two guide pins in the rear bearing lock holes Figure 6 57 Fill the grease cavity of the drive end bracket 1 3 ...

Page 44: ...RIVE END BRACKET OR THE SAE ADAPTER ASSEMBLY 4 For single bearing generators insert a guide stud into the drive hub Position all spacers if any then all drive discs one at a time until all discs are installed Figure 6 61 Figure 6 61 Make sure that all disc mounting holes at the inner and outer diameter are properly aligned Secure the discs with the grade eight 5 8 18 cap screws and hardened washer...

Page 45: ...igure 6 66 Figure 6 66 3 Install snap ring Figure 6 67 Use a piece of pipe slightly larger than the shaft 2 3 4 inches to push the rotor back against the loading spring until the snap ring seats in the slot Figure 6 68 Figure 6 67 Figure 6 68 4 Install the PMG stator on its mounting pads with the leads in the left 9 00 o clock inboard position and secure with the four ...

Page 46: ...ile fishing the rotor leads through Figure 6 70 Figure 6 70 Align the key in the armature bore to the keyway in the shaft Slide the armature on the shaft while feeding the main rotor leads through the lead hole in the aluminum standoff plate Figure 6 71 Figure 6 71 Insert the cap screw and Belleville washer Figure 6 72 through the mounting hole in the aluminum standoff plate and secure to the shaf...

Page 47: ...screws with Belleville washers Figure 6 72 Torque t cap screws to 60 ft lb 81 N M Route and secure the exciter stator leads away from any moving parts Figure 6 75 CONDUIT BOX INSTALLATION 1 Install the conduit box over the main stator leads be sure the leads are in the upper compartment and secure with bolts and lock washers Fig 6 76 and 6 77 Figure 6 76 Figure 6 77 2 On generators with bus bar as...

Page 48: ...G DO NOT APPLY ANY FORCE TO THE GENERATOR FAN FOR LIFTING OR ROTATING THE GENERATOR ROTOR DISREGARDING THESE INSTRUCTIONS MAY CAUSE PER SONAL INJUY OR EQUIPMENT DAMAGE CAUTION DO NOT FORCE THE ALIGNMENT OFTHE UNITS SHIFT THE GENERATOR FROM SIDE TO SIDE OR RAISE OR LOWER WITH A LIFTING DEVICE AS NECESSARY It may be necessary to use shims under the mounting feet of either the generator or the prime ...

Page 49: ...he generator inside the conduit box 8 Check the exciter air gap the gap between exciter armature and stator by inserting a 010 inch feeler gauge in the gap and rotating around the armature diameter to ensure the minimum air gap is available See Figure 80 If the feeler gauge cannot be rotated full revolution then check for a cocked exciter stator or loose stator mounting screws Figure 6 80 NOTE On ...

Page 50: ...he line 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 WARNING HIGH VOLTAGES CAN BE PRESENT AT THE GENERATOR AND REGULATOR TERMINALS HIGH RESIDUAL VOLTAGES CAN BE PRESENT EVEN WITH THE REGULATORDISCONNECTED OR ITS FUSES REMOVED SOME EQUIPMENT SU...

Page 51: ... Replace bad fuse Check to be sure meter phase selector switch is not in the off position Verify proper operation of panel meter with another meter that is known to be accurate Verify generator connections Inspect all wiring for grounds open circuits short circuits Measure voltage at regulator input PMG output Test generator with constant excitation 12 volt battery test refer or Generator Windings...

Page 52: ...accurate Disconnect Fl 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 No Residual Voltage Verify generator connections refer to drawings supplied V generator set and section 3 Inspect all wiring for grounds open circuits short circuits and loose and dirty connections Adjust regulator...

Page 53: ... symptoms Generator Produces Low Voltage No Load HIGH VOLTAGE Defective Voltmeter Incorrect Operating Speed Incorrect Connections Defective Connections Wiring Regulator Adjustments Diode Polarity Incorrect Voltage Regulator not Operating Verify operation of panel meter with another meter that is known to be accurate Verify speed with tachometer or frequency meter Verify generator connections Refer...

Page 54: ...er to regulator manual Replace regulator Refer to regulator manual OPERATES SATISFACTORILY WHEN COLD BUT SHUTS DOWN WHEN WARM Regulator Shutdown on Over Temperature Correct cooling problems Refer to regulator manual BUILDS VOLTAGE FROM STARTUP THEN GOES TO LOW RESIDUAL VOLTAGE Regulator Protective Circuit is Operating Check indicators on regulator Correct problems and adjust as required Refer to r...

Page 55: ...ORY The generator output voltage is dependent on generator speed generator design load and exciter input current If the generator speed and exciter input are known the output voltage at no load can be measured and compared to the design value Problems can be isolated to either the gen erator or regulator system by using this test TEST PROCEDURE 1 Shut the generator set down 2 Connect a voltmeter t...

Page 56: ...ep yourself and your test leads out of the way It is best to shut the unit down when connecting meters When using alligator clips or push on terminals be sure the leads re supported so vibration does not shake them loose when running the generator set See figure 8 1 for measurement points and expected meter range settings When in doubt start with a higher range and work down Consult meter instruct...

Page 57: ...ystem would give 240 volts El E2 or E3 Example A 4160 volt system must use a transformer to step voltage down below 600 volts See the connection diagram supplied with generator set Regulator Input Volts PMG Output Volts PMG leads at the regulator or capacitor 200 240 VAC 300 Hz 1800 rpm 180 220 VAC 250 Hz 1500 rpm CURRENT AMP MEASUREMENTS Current measurement AC can be easily taken with a clamp on ...

Page 58: ...sconnect the main rotor leads Fl leads and F2 leads from the rectifier assembly Measure the resistance of the main rotor winding Compare reading to value shown in service specification section 12 Measure from the leads to the exciter mounting bolt to check for grounds Exciter Rotor Disconnect the exciter rotor leads at the diodes leave leads disconnected if proceeding to check diodes Measure resis...

Page 59: ...he red or positive megger lead to the leads for the winding to be tested connect the back or negative megger lead to the generator frame Be sure the leads of the part being tested are not touching any metal parts of the generator If the neutral is grounded it must be disconnected Take megger reading refer to the manual for the megger INSULATION RESISTANCE MAIN STATOR CAUTION Be sure the regulator ...

Page 60: ...r repaired 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 on the order of one half of one percent The ac impedance test measures the impedance...

Page 61: ...61 MAGNAMAX EXPLODED VIEW ...

Page 62: ...crew for 11 1 2 Cap screw for 14 Cap screw for 18 Cap screw for 21 Cap screw for Delco Hardened Washer A 9674 200 A 9674 150 A 9674 150 A 9674 150 A 9667 1 6 6 6 6 6 A 9674 150 A 9674 150 A 9674 150 A 9667 1 9 9 9 9 A 9674 200 A 9674 150 A 9674 200 A 9667 1 18 18 18 18 5 Drive Discs 11 1 2 Disc 14 Disc 18 Disc 21 Disc Delco Disc 17 75 0 0 A 525506 A 525508 B 525975 A 525507 5 5 4 5 A 525508 A 5255...

Page 63: ...p B 525520A 1 B 525612A 1 B 525742A 1 20 Bearing Cap Fasteners Cap screw Lock Washer A 9680 350 A 7653 3 4 4 A 9680 400 A 7653 3 4 4 A 9680 450 A 7653 3 4 4 21 Conduit Box D 525673 1 D 525680 1 D 525771 1 22 Conduit Box Mtg Fasteners Cap screw Lock Washer A 9680 75 A 7675 2 8 8 A 9680 75 A 7675 2 8 8 A 9626 75 A 7675 4 8 8 23 Snap Ring Inner A 7610 275 1 24 Loading Spring A 7661 45 1 A 7661 45 1 A...

Page 64: ...C 525647 1 C 525670 1 42 Exciter Rectifier Assy Includes 43 44 45 B 525528A 1 B 525528A 1 B 525528B 1 43 Diode Standard Polarity B 525570 1 3 B 525570 1 3 B 525570 2 3 44 Diode Reverse Polarity B 525571 1 3 B 525571 1 3 B525571 2 3 45 Surge Suppressor B 526482 1 1 B 526482 1 1 B 526482 2 1 46 Cover Mtg Screws A 9646 75 33 A 9646 75 33 A 9646 75 33 TABLE 9 2 EXCITER ASSEMBLIES Frame Type Insulation...

Page 65: ...moving the generator conduit box this fixture can be used with overhead rigging to remove and reinstall the exciter stator Exciter rotor puller bolt Figure 10 2 The exciter rotor has a built in pulling system With the use of this bolt the rotor can be easily removed from the shaft without damage to the winding Figure 10 2 The PMG rotor is installed to the generator shaft with a snap ring The nomin...

Page 66: ...upply shipping skid drawings upon request Overseas shipping may require special export crating Check with your freight carrier When installed single bearing generator rotors are supported on the drive end by the drive discs bolted to the engine flywheel When the engine is removed the rotor must be supported by an appropriate fixture to prevent main rotor main stator or exciter damage Figure 11 1 B...

Page 67: ...nce of all windings before starting the generator If readings are low the windings must be dried C Keep bearings lubricated 1 Every six months rotate shaft several turns to distribute grease in bearings 2 If unit has been stored more than one year add grease before start up D Review and follow instructions in Sections 3 and 4 before putting the gen set into service CAUTION DO NOT ATTEMPT TO TRANSP...

Page 68: ... washers 1 2 13 4 1 2 13 4 Exciter Stator Grade 5 cap screws with Belleville washers 1 2 13 60 1 2 13 60 Exciter Armature rotor Grade 8 cap screw with Belleville washer 1 2 13 84 1 2 13 84 Cooling Fan Grade 5 cap screws with Belleville washers 1 2 13 60 1 2 13 60 Main Rotor Coil Supports Grade 8 cap screws with Belleville washers 5 16 18 19 3 8 16 35 Rectifier Assembly Mounting Grade 5 cap screws ...

Page 69: ...0 49 66 44 60 39 53 70 95 63 85 56 76 7 16 20 30 41 27 37 24 33 55 75 50 68 44 60 78 106 70 95 62 84 1 2 13 39 53 35 47 31 42 75 102 68 92 60 81 105 142 95 129 84 114 1 2 20 41 56 37 50 33 45 85 115 77 104 68 92 120 163 108 146 96 130 9 16 12 51 69 46 62 41 56 110 149 99 134 88 119 155 210 140 190 124 168 9 16 18 55 75 50 68 44 60 120 163 108 146 96 130 170 230 153 207 136 184 5 8 11 83 113 75 102...

Page 70: ...ed No Load Output Voltage With Fixed Excitation Wye Connection Excitation Wye Connection Excitation Wye Connection Excitation Wye Connection Model Number Model Number Model Number Model Number Medium Volts Medium Volts Medium Volts Medium Volts Exciter Field Exciter Field Exciter Field Exciter Field Resistance Ohms Resistance Ohms Resistance Ohms Resistance Ohms 25 C 25 C 25 C 25 C Exciter Field V...

Page 71: ...xed No Load Output Voltage With Fixed Excitation Wye Connection Excitation Wye Connection Excitation Wye Connection Excitation Wye Connection Model Number Model Number Model Number Model Number Medium Volts Medium Volts Medium Volts Medium Volts Exciter Field Exciter Field Exciter Field Exciter Field Resistance Ohms Resistance Ohms Resistance Ohms Resistance Ohms 25 C 25 C 25 C 25 C Exciter Field ...

Page 72: ... 573RSL2048 573RSL2052 573RSL2056 570027 570028 570029 0082 0068 0054 457 490 542 741RSL2060 741RSL2064 741RSL2068 741RSL2072 740021 740022 740023 740024 0061 0046 0042 0037 609 647 679 718 742RSL2076 740025 0032 750 744RSL2284 744RSL2288 740026 740027 0026 0018 892 1 044 Base Model Medium Voltage Winding H SG Main Stator Main Rotor 573FSM2328 573FSM2336 570201 570202 1 249 837 383 424 574FSM2340 ...

Page 73: ...Rotor Armature PMG Stator 430 Frames 22 5 0 023 2 0 570 Frames 23 0 0 045 2 0 741 Frames 22 5 0 043 2 0 742 Frames 22 7 0 048 2 0 744 Frames 22 0 0 066 2 0 Medium Voltage Exciter Stator Field Exciter Rotor Armature PMG Stator 570 Frames 23 0 0 070 2 0 741 Frames 22 7 0 048 2 0 742 Frames 22 7 0 048 2 0 743 Frames 22 0 0 065 2 0 ...

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