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.comService ;KTI11KTI121IItriDFGA VTA1DFGB VTA2DFGC VTA3- lPc NT4NT4NT5NT6NTA2NTA3ca· R AND ·cPrinted U.S.A.960-05044-93

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1PAGETITLESAFETY PRECAUTIONSINTRODUCTION . . . About th is Manual . . . . . . . . . . . . . . .Te st ECJ,Iiprnert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .How to C btain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Co rtrols and Generators Ove rview .2.CONTROLS.General . .Control Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Panel Interior . . . . . . . . . . . . . . . . . . . .Ge nSet ()peration . . . . . . . . .GENERATOR. . .Gene rator De scriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Generator Control Co l11l0 nents . . . . . . . . . . .Generator ()peration .Optional C ira.Jit Breaker . .an3.TROU BLESHOOTING5COMPONENT TESTS AND ADJUSTMENTSGeneral. .tM4. .ii1-11-11 -11-22-12-12-32-63-13-23-33-44-1arGeneral . . 5-1Control ComponentsEngine Co rtrol M oritor (ECM) . 5-1Run Rel ay . . 5-3Interface Relay Mock.des . . . . . . . . . . . 5-4lime Delay Sta rVStop M odule . . . . . . . 5-5AC Meters and Current Transfo rmers . 5-5Generator ComponentsAutomatic Vol tage R egulator. . 5-6Generator ()peration Review . . . . . . . . . . . . 5-8Over/Under Voltage Sensor M odule. 5-10Over/Under Frequency Sensor M od.lle. . . . 5-10Overspeed (FreCJ, e ncy Detection) M odule . . . 5-10Rotating Rectifier Asse nt ly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1Pe rma nent M agnet E xdter . . . . . . 5-1 1E xdter Rotor . . . . . . . . . 5-1 2E xdter Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 2Ge nerator Rotor. 5-1 2Ge nerator Stator . . . . . . . . . . . . . . . . . . . . 5-13Reconnection . . . . . . . . . . . . . . 5-14Engine ComponentsElectro nic Governor. 5-1 6Batteries . . . . . . . . . . . . . . . . 5-1 7Batte ry Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 7Alternator . . . 5-18Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . 5-18Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18Other Optional ComponentsTesting AC Load Ci ra.Jit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 8. . .lP.ca.tri.lec.E.GENERATOR7Generator Disassembly . . 6-1Generator Reasse nt ly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7WIRING DIAGRAMS/SCHEMATICSRefer to Section Usti ngw6ww.ualsSECTION.comCo nte ntsDISASSEMBLY/REASSEMBLY . . . . . . . . . . . .

.comSafety PrecautionsSafe and efficient operation can beachieved only If the equipment Is properly oper ated and m aintained. Many accidents are causedequipment.by failure to follow fundamental rules and precau tions. Be sure all fuel supplies have a positive shutoffvalve. Do not smoke while servicing lead acid batter ies. Lead acid batteries emit a highly explosivehydrogen gas that can be ignited by electricalarcing or by smoking.EXHAUST GASES ARE DEADLYThe following symbols, found throughout this man ual, alert you to potentially dangerous conditions tothe operator, service personnel, or the equipment. hazards which will result In severe persona/ In jury or death.tMDo not use exhaust gases to heat a compart ment. Be sure the unit is well ventilated.MOVING PARTS CAN CAUSE SEVEREPERSONAL INJURY OR DEATHlPFUEL AND FUMES ARE FLAMMABLEProvide an adequate exhaust system to prop erly expel discharged gases away from en closed or sheltered areas and areas where in dividuals are likely to congregate. Visually andaudibly inspect the exhaust daily for leaks perthe maintenance schedule. Ensure that ex haust manifolds are secured and not warped.arlA CAUTION I This symbol refers to a hazard or un safe practice which can resultIn persona/Injuryor product or property damage.caFire, explosion, and personal injury or death can re sult from improper practices. Keep your hands, clothing, and jewelry awayfrom moving parts. Before starting work on the generator set, dis connect starting batteries, negative (-) cablefirst. This will prevent accidental starting.DO NOT fill fuel tanks while engine is running,unless tanks are outside the engine compart ment. Fuel contact with hot engine or exhaustis a potential fire hazard. Make sure that fasteners on the generator setare secure. Tighten supports and clamps,keep guards in position over fans, drive belts,etc. DO NOT permit any flame, cigarette, pilot light,spark, arcing equipment, or other ignitionsource near the generator set or fuel tank. Fuel lines must be adequately secured andfree of leaks. Fuel connection at the engineshould be made with an approved flexible line.Do not use copper piping on flexible lines asDo not wear loose clothing or jewelry in the vi cinity of moving parts, or while working on elec trical equipment. Loose clothing and jewelrycan become caught in moving parts. Jewelrycan short out electrical contacts and causeshock or burning.lectri .E copper will become brittle if continuously vi brated or repeatedly bent.If adjustment must be made while the unit isrunning, use extreme caution around hot mani folds, moving parts, etc.www.ant!'J t!UM#!;I This symbol warns of ImmediatelAWARNINGlTh/s symbol refers to a hazard or un safe practice which can result In severe per sonal injury or death.ualsBefore operating the generator set, read the Op erator's Manual and become familiar with it and theiir

Remove electric power before removing pro tective shields or touching electrical equip ment. Use rubber insulative mats placed ondry wood platforms over floors that are metal orconcrete when around electrical equipment.Do not wear damp clothing (particularly wetshoes) or allow skin surface to be damp whenhandling electrical equipment.heat exchanger pressure cap while the engineis running. Allow the generator set to cool andbleed the system pressure first. have been identified by some state and federalUse extreme caution when working on electri toxicity.fumes, or contact gasoline.Follow all applicable state and local electricalcodes. Have all electrical installations per formed by a qualified licensed electrician. Tagopen switches to avoid accidental closure. Used engine oils have been identified by somestate or federal agencies as causing cancer orreproductivetMDO NOT CONNECT GENERATOR SET DI RECTLY TO ANY BUILDING ELECTRICALSYSTEM. Hazardous voltages can flow fromthe generator set into the utility line. This cre ates a potential tor electrocution or propertydamage. Connect only through an approvedisolation switch or an approved paralleling de vice.When checkingorchanging engine oil, take care not to ingest,Provide appropriate fire extinguishers and in ar stall them in convenient locations. Consult thelocal fire department tor the correct type of ex lPtinguisher to use. Do not use foam on electri caHigh voltage acts differently than low voltage.Special equipment and training is required towork on or around high voltage equipment.cal fires.Use extinguishers rated ABC byNFPA. Make sure that rags are not left on or near theengine. Operation and maintenance must be doneonly by persons trained and qualified to workon such devices. Improper use or procedureswill result in severe personal injury or death.Remove all unnecessary grease and oil fromtrithe unit.Accumulated grease and oil cancause overheating and engine damage whichlecpresent a potential fire hazard. Do not work on energized equipment. Un authorized personnel must not be permittednear energized equipment. Due to the natureof high voltage electrical equipment, inducedvoltage remains even after the equipment isdisconnected from the power source. Plan thetime tor maintenance with authorized person nel so that the equipment can be de-energizedKeep the generator set and the surroundingarea clean and tree from obstructions.Re move any debris from the set and keep thefloor clean and dry.E toxicity.breathe the fumes, or contact used oil.HIGH VOLTAGE GENERATOR SETS(1.9kV to 15kV) When checking, draining or addinggasoline, take care not to ingest, breathe thean Benzene and lead, found in some gasoline,agencies as causing cancer or reproductivecal components. High voltages can cause in jury or death. DO NOT tamper with interlocks. Coolants under pressure have a higher boilingpoint than water. DO NOT open a radiator oruals .comGENERAL SAFETY PRECAUTIONSELECTRICAL SHOCK CAN CAUSESEVERE PERSONAL INJURY OR DEATH Do not work on this equipment when mentallyor physically fatigued, or after consuming anyalcohol or drug that makes the operation ofequipment unsafe.wwwand safely grounded.KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCEiiiLS-10

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IntroductionABOUT n-tiS MANUALr lar maintenance schedule is important to obtainlonger unit life, better performance, and safer operation.This manual provides troubleshooting and repair informa tion regarding the controls and generators used on thefollowing generator sets.ualsFor proper replacement parts identifiCation, refer to ap propriate Parts Manual supptied with urit.Repair of printed circuit board components other thanfuses requires well-trained, quatified personnel with theproper equipment; repair of the printed circuit boards isnot recorrmencled except by the factory. Applcation ofmeters or hot soldering irons to printed circuit boards byother than qualified personnel can cause unnecessaryand expensive damage.GENERATOR SETMODELDESIGNATIONSDFAADFABDFAC1 75200220200230250NT4NT4NT4NT51 751 1 0275300350DFEBDFECDFFADFFBKTA1 FLCDFLDDFMADFMBHigh voltage testing or highpotential (or Megger) testing of generator windingscan cause damage to solid state components. Isolatethese components before testing.For any operation, maintenance, or troubleshoodng Informationbeyond 1he scope of this manual, refer to oth manuals receivedwith unit, or contact your 9007508009001 0009001 0001 1 001 2501 1 201 2001 1 001 280 Battery HydrometerTachometer or Frequency MeterJurf1)9r LeadsWheatstone Bridge or Digital OhmmeterVariacLoad Test PanelMegger or Insulation Resistance MeterHOW TO OBTAIN SERVICE!Wiays give the complete Model and Serial number of thegenerator set as shown on the nameplate when seekingadditional service information or replacement parts. Thenameplate is located on the side of the generator outputbox.1 2501 500I &WARN I NG IwFor further operation, service, and troubleshooting infor mation regarding engine components, refer to supportmanuals specific to your generator set.Incorrect service or replacement ofparts can result In severe personal Injury or death,and/or equipment damage. Service personnel mustbe qualified to perfonn electrical and mechanicalservice. Read and follow Safety Precautions, onpages II and Ill.Study this manual carefully and observe all warnings andcautions. Be sure to review Safety Precautions. on pagesii and iii. Using the generator set properly and following awwTEST EQUIPMENTMost of the test procedures in this marual can be per formed with an AC-DC rrultimeter such as a Sifi1)SOnModel 260 VOM or a digital VOM. Some other instrumentsto h ave available are: 550triDFJADFJBKTT1 1KTT1 2I ACAUTION IarDFBCDFBDDFBDDFBEanKW RATING50Hz60HztM .com1.Section1-1

.comCONTROLS AND GENERATORSOVERVIEWControl PanelDepending on customer order, the control options andgenerator type may differ. Read through this manual toidentify the control options, and generator type. A more in depth description of the control and generator compo nents follow in the Controls and Generator sections.Read this information well and understand the function ofeach component.The control panel is mounted inside the front portion of thegenerator output box with vibration isolators on both topand bottom. The controls are separated into a DC panelfor monitoring the engine and an AC panel for monitoringthe generator. See Figure 1 -1 and Section 2.GeneratorualsGeneralThe generators fitted to this series of generator sets area Permanent Magnet Generator (PMG) type.Also, periodically review this manual and the unitOperator's Manual when no fault condition is present. Youwill want to become familiar with the generator set com ponent locations, their proper operation and interactionwith other components in order to be effective trou bleshooting a fault condition, if one occurs.tManThe generators are controlled by an Automatic VoltageRegulator (AVR). The AVR is mounted on the inside, backwall of the control panel. See Figure1 -1 and Section [email protected])l!J[!J lP§[3t 121!.!::::: - [email protected]:uCONTROL PANEL{REFER TO SECTION 2).ElectriOTHER GENERATORCONTROL COMPONENTS(i.e., OVER/UNDERVOLTAGE AND FREQUENCYMODULE ARE LOCATEDINSIDE CONDUIT BOX.REFER TO SECTION 3.C :JcaPMGVOLTAGEREGULATORSVOLTAGE REGULATOR(LOCATED INSIDECONTROL PANEL).REFER TO SECTION 3.wwwAC METERINGCURRENT TRANSFORMERS(LOCATED INSIDE CONDUIT BOX.)REFER TO SECTION 2.PMGEXCITERHOUSINGCOVE R PLATE(FOR ACCESS TO ROTATINGRECTIFIER ASSEMBLY)FIGURE 1-1 . TYPICAL PUG GENERATOR AND CONTROLS1-2

G EN ERALAC Ammeter (Optional):Dual range instrument indi cates AC generator fine current. Measurement range inuse shown on indcator la"l 5.Depending on rustomer order, the control configurationand options may differ. This section identifies the controlconfig.uations used; Detector-7 and Detector-12 (NFPA)DC Panel, and AC Panel options.ualsFrequency/RPM Meter (Optional): lndcates generatoroutput frequency in hertz and engine speed in revolu tions-per-minute (RPM).The control panels are separated into an AC panel formonitoring the generator (if equipped with meter options),and a DC panel for monitoring the engine. Review F gure2-1 to identify the control configuration and options, andrefer to Control Descriptions that follow for further infor mation .Wattmeter (Optional): Continuously gives readng of thegenerator output in kilowatts.anVoltage Adjust (Optional): Rheostat providng approxi mately plus or minus five percent adjustment of the ratedoutput voltage.CONTROL DESCRIPTIONSAC PanelUpper and Lower Scale Indicator Lamps (Optional):Indicates which scale to use on the AC voltmeter and ACammeter.tMThe following describes the function and operation of theoptional AC panel for monitoring the generator. Reviewthe following component descriptions and Figure 2-1 .Phase Selector Switch (Optional): Selects phases ofgenerator output to be measured by AC voltmete