Onan UR Generator Manual pub 900 0150

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Service

Manual

25to

I80

kW

Generators

And

Controls

Troubleshooting and

Test Procedures For

Generators

Regulator

Controls

900-0150

10-78

Printed

in

U.SA

Redistribution or publication of this document, 

by any means, is strictly prohibited.

Safety Precautions

The following symbols

in

this manual highlight con-

ditions potentially dangerous

to

service personnel, or

equipment. Read this manual carefully. Know when

these conditions can exist. Then take necessary

steps to protect

I

WARNING1

personal injury.

personnel as well as equipment.

equipment damage.

This symbol is used throughout the

manual

to

warn

of

possible serious

This symbol refers to possible

PROTECT AGAINST MOVING PARTS

Avoid moving parts of the unit. Avoid use of loose

jackets, shirts or sleeves due to danger of becoming

caught

in

moving parts.

Make sure all nuts and bolts are secure. Keep power

shields and guards

in

position.

If

you

must make adjustments while the unit is

running, use extreme caution around hot manifolds,

moving parts, etc.

Do not work on this equipment when mentally or

physically fatigued.

Y

GUARD AGAINST

ELECTRIC

SHOCK

Disconnect electric power before removing protec-

tive shields or touching electrical equipment.

Use

rubber insulative mats placed on dry wood platforms

over floors that are metal or concrete when around

electrical equipment.

Do

not wear damp clothing

(particularly wet shoes) or allow skin surfaces to be

damp when handling electrical equipment.

..

Disconnect batteries to prevent accidental engine

start. Jewelry is a good conductor of electricity and

should be removed before working on electrical

equipment.

Use extreme caution when working on electrical

components. High voltages cause injury or death.

Follow

all state and local codes. To avoid possible

personal injury or equipment damage, a qualified

electrician or an authorized service representative

must perform installation and all service.

EXHAUST GAS

IS

DEADLY!

Exhaust gases contain carbon monoxide,

a

poisonous gas that might cause

unconsciousness and death. It is an odorless and colorless gas formed during

combustion of hydrocarbon fuels. Symptoms of carbon monoxide poisoning

are:

Dizziness Vomiting

Headache Muscular Twitching

Weakness and Sleepiness Throbbing in Temples

If you experience any of these symptoms, get out into fresh air immediately,

shut down the unit and do not use until it has been inspected..

The best protection agalnst carbon monoxide inhalation Is proper installallon

and regular, frequent visual and audible inspections of the complete exhaust

system. If

you

notice

a

change in the sound

or

appearance

of

exhaust system,

shut the unit down immediately and have it inspected and repaired at once by a

competent mechanlc.

Redistribution or publication of this document, 

by any means, is strictly prohibited.

.

GENERATORS

AND

CONTROLS

25

kW

-

180

kW

TABLE

OF

CONTENTS

'

PAGE

'

Introduction

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

:

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

2

.

Generator

-

Section

I

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

5

Question and Answer Troubleshooting Guides.

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

8

Adjustments and Procedures

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

16

Generator

-

Section

II

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

26

Question and Answer Troubleshooting Guides.

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

27

Adjustments and Procedures

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

35

Index

of

Generator Adjustments and Procedures.

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

38

Control

-

Section

111

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

39

Question and Answer Troubleshooting Guides.

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

40

Adjustments and Procedures

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

51

Wiring Diagrams

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

53

.

I

ONAN RECOMMENDS THAT ALL SERVICE, INCLUDING

INSTALLATION

OF

REPLACEMENT PARTS, BE PERFORMED

BY

QUALIFIED PERSONNEL.

I

Redistribution or publication of this document, 

by any means, is strictly prohibited.

I

NTRO

DU

CTIO

N

FOREWORD

This manual provicds troubleshooting and repair

information for ONAN series

UR

generators. It is

intended to provide the maintenance technician,

serviceman or Onan distributor with a logical

procedure to enable him

to

systematically locate and

'

'repair malfunctions

in

the generator and control

systems. This information is not applicable to the

prime mover; refer to the engine manufacturer's

manual.

Repair information is not extensive because the plug-

in solid-state printed circuit modules lend themselves

more to replacement than repair. ONAN does not

recommend repair

of

the printed circuit module,

except at the factory and has initiated a returdex-

change service, obtainable through distributors,

whereby faulty modules can be returned and ex-

changed for good units.

For

more information, con-

tact your distributororthe ONAN service department.

,

Application

of

meters or high heat soldering

irons

to

modules

by

other than qualified

personnel can result in unnecessary and expensive damage.

This

rnanual is arranged

as

follows:

i.

GENERATOR

-

Section

I

contains general

specifications

on

the

UR

generator,

troubleshooting guides and procedures for

testing and repairing of the early

UR

generator

with

VR22

exciter regulator and general informa-

tion on later

UR

generator.

Section

11

contains

troubleshooting information for the later model

UR

generator where the exciter diode rectifier

assembly has been relocated into the contrd

panel.

Refer

to

Table

1

for

a

description of

t/:f.

appropriate section for your generator.

2.

CONTROLS

-

Section

111

contai!$s

troubleshooting guides and procedures

lor

testing and repairing the system controls,

P

description of the components and an analysiz'

ti+

the module circuitry is included.

TEST EQUIPMENT

Most

of

the tests outlined

in

this manual can be

performed with an AC-DC multimeter such as a

Simpson

260

VOM.

Other suggested test instruments are

-

ONAN multitester Part No.

420-0303

Wheatstone or Kelvin bridge

Exercise care when purchasing

a

foreign

made

VOM.

Some units deliver

+9VDC,

others,

+22VDC

to the circuit under test

on

R

x

1

scale. Maximum

recommended voltage is

+l.SVDC.

Damage

to

solid state devices

can result from excessive voltage application.

GENERATING SET

MALFUNCTION

GENERATOR

FAILS

SEE GENERATOR

SECTION

I

OR

II

ENGINE FAILS

SEE

ENGINE

I

SERVICE MANUAL

I

I'

CONTROL FAILS

CONTROL SECTION

Ill

2

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by any means, is strictly prohibited.

TABLE

1.

GENERATOR SPECIFICATION BREAKDOWN

kW

Model

25.0

EK

30.0 EK

Penn EK

25.0 DDA

30.0

DDB

30.0 DEH

25.0

MDEH

30.0 MDEH

Penn DEH

37.5

EM

45.0 EM

Penn EM

37.5 DEF

45.0

DEF

Penn DEF

37.5 DYJ

45.0

DYJ

40.0

DDB

50.0

DDB

40.0

DEG

50.0 DEG

Penn DEG

40.0

MDEG

50.0 MDEG

45.0 KB

55.0 KB

Penn KB

50.0

DYA

60.0 DYA

Penn DYA

55.0

EN

70.0 EN

50

Hz

60 Hz

50

Hz

60

Hz

60

Hz

50

Hz

60 Hz

50

Hz

60 Hz

50

Hz

60

Hz

50

Hz

60

Hz

50

Hz

60

Hz

50

Hz

60

Hz

50

Hz

60 Hz

50

Hz

60 Hz

50

Hz

60 Hz

E

D

E

-

D

C

E

D

E

H

F

G

-

G

E

F

E

R

P

Q

E

C

D

-

Section

1

Spec

A

Frequency

Section

2

Begin

Spec

F

A

G

F

J

A

H

S

F

A

kW

Model

55.0

KB

55.0

KB

"enn KB

50.0

DYC

75.0

DYC

30.0

DYC

100.0

DYC

'enn DYC

70.0

KR

35.0

KR

Penn KR

75.0

DYC

30.0

DYC

30.0

DYD

100.0

DYD

Penn DYD

35.0

WA

11

5.0

WA

100.0 DYD

125.0 DYD

Penn DYD

115.0 WE

140.0 WE

125.0 WE

150.0 WE

125.0 DYG

150.0 DYG

Penn DYG

130.0 DFE

155.0 DFE

Penn DFE

140.0 WB

170.0 WB

145.0 DYG

175.0 DYG

Penn DYG

150.0 DFE

180.0 DFE

Penn DFE

Section

1

Spec

A

Frequency

1

ThN

'

50

Hz

60

Hz

50

Hz

60

Hz

50Hz

'

60

Hz

50

Hz

60 Hz

50

Hz

60

Hz

50

Hz

60 Hz

50

Hz

60 Hz

50

Hz

60

Hz

50

Hz

60

Hz

50

Hz

60

Hz

50

Hz-

60'HZ

50 Hz

60 Hz

50

Hz

60 Hz

50

Hz

60 Hz

50

Hz

60 Hz

R

P

Q

D

B

-

jc

R

P

Q

D

B

C

A

B

H

G

C

A

B

C

A

B

-

K

J

C

A

B

-

Section

2

Begin

Spec

S

E

G

'E

S

E

.D

D

J

D

-

D

H

L

D

H

3

Redistribution or publication of this document, 

by any means, is strictly prohibited.

UR G’ENERATOR VOLTAGE/CURRENT OPTIONS

1-PHASE 3-PHASE

1-PHASE

STANDARD

@@

2K

156

234

I_

:ode

15

60

-

X

-

HE

:ode

50

-

515

-

X

-

SPE

-

0

g

-

142

21 3

227

256

284

31 3

355

398

426

455

540

568

L

0

-

156

234

260

286

313

339

365

391

443

469

521

599

625

RATING

-

c

g

-

90

135

144

162

180

198

226

253

271

289

343

361

415

451

469

505

523

541

-

0

g

-

82

123

131

148

164

180

205

230

246

262

31 2

328

377

41

0

426

459

476

492

-

0

g

-

78

118

126

141

157

173

196

220

235

251

298

314

361

392

408

439

455

471

-

@

g

-

90

135

150

165

180

195

210

226

256

271

301

346

376

421

451

466

51

1

526

542

-

g

-

47

71

76

85

95

104

119

133

142

152

’

180

190

218

237

247

266

275

285

-

c

-

95

142

152

171

190

209

237

266

285

304

361

380

437

475

494

532

551

570

-

0

-

82

98

123

131

148

164

180

197

205

213

230

246

262

279

295

312

328

377

410

426

459

476

492

508

558

574

591

-

c

-

45

68

72

81

90

99

113

126

135

144

171

180

207

226

235

253

262

271

-

E

-

43

.

52

65

69

78

87

95

104

108

113

121

130

139

147

156

165

173

200

217

226

243

252

260

269

295

304

313

-

E

g

-

45

68

75

83

90

98

105

113

128

135

150.

173

188

210

226

233

256

263

271

-

E

-

41

49

62

66

74

82

90

98

103

107

115

123

131

139

148

156

164

189

205

213

230

238

246

254

279

287

296

a

g

-

136

204

21 7

245

272

299

340

380

408

435

516

543

0

-

E7

.

104

130

139

156

173

191

208

217

226

243

260

278

295

312

330

347

399

434

451

486

503

520

538

590

607

625

g

-

90

135

150

165

180

195

210

226

256

27

1

301

346

-.

376

42 1

451

466

51 1

526

542

ky

600

- -

36

54

60

66

72

78

84

90

102

108

120

138

150

168

180

186

204

210

217

-

kW

25.0

30.0

37.5

40.0

45.0

50.0

55.0

60.0

62.5

65.0

70.0

75.0

80.0

85.0

90.0

95.0

100.0

115.0

120.0

125.0

130.0

140.0

145.0

150.0

155.0

170.0

175.0

180.0.

kVA

31.25

37.50

46.80

50.0

56.25

62.5

68.75

75.0

78.13

81.25

87.5

93.75

100.0

106.25

112,5

11 8.75

125.0

143.75

150.0

156.25

162.50

175.0

181.25

187.5

193.75

212.5

218.75

225.25

4

0

-

,:o

HZ

only.

@

-

60

Hz

only.

@

-

50-

and

60

Hz

@

-

Not

Reconnectible.

.

-

.

..

-.

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by any means, is strictly prohibited.

GENERATOR

v

GENERAL

There are two generator designs used

on

the

UR

series. They are basically the same except for the

method of field excitation.

,

The

Static Exciter

(brush type) design uses a brush

rig and collector rings for field excitation. This design

was

used on some of the earlier models within the

range of 25

KW

-

90

KW.

The Brushlessdesign uses a rotating rectifier exciter

assembly

in

place of the brush rig for field excitation.

The brushless design is standard on all models from

25

KW

-

175

KW.

.

Unless otherwise specified, the tests in this section apply to both

designs.

V R

-22

EXCITER REGULATOR

CHASSIS ASSEMBLY END

B

ELL

.TOR

-

SECTION

I

COMPONENT LOCATION

To

gain access to generator, remove grille section

below control box.

1.

2.

3.

4.

Exciter-regulator chassis assembly VR22 mounts

on the rear portion of the generator; SCR’s

(silicon controlled rectifiers) and diodes are easi-

ly accessible for testing. See Figures

1-3.

On static-excited generators, brush”es attach to

the brush rig inside of end bell housing; inspect

through large access holes in the end bell. See

Figure

1.

On brushless models, rotating exciter assembly

mounts directly behind exciter-regulator chassis

assembly with all diodes accessible for servicing.

See Figure

2.

Voltage-regulator PC Board VR21 (Printed Cir-

cuit Board) mounts inside the control box on the

rear panel (left side); turn

114

turn fasteners o,n

front of control box to gain access. See Figure

4.

AC

STATOR

L

OUTPUT

-

208-240

VOLTS

‘\--

RESIDUAL MAGNETISM AC

IN ROTOR STARTS

PROCESS

,

&

~

SOLID STATE

4ND VOLTAGE

REGULATOR

REVOLVING FIELD OVERSPEED SWITCH

QENERATOR END

VIEW

(QRILLE REMOVED) EXCITATION SCHEMATIC

FIGURE

1.

STATIC EXCITER

DESIGN

5

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by any means, is strictly prohibited.

EXCl TE

R-

REGU LATO

R

CHASSIS ASSEMBLY FENDBELL

QENERATOR END VIEW (QRILLE REMOVED)

I

A

LT

ERN AT0 R

iTATOR

w

FIELD

I

.

208-240

VOLTS

AC

EXCITER

CIRCUIT

BREAKER

EXCITER

ARMATURE

VOLTAGE

R E(3U LATOR

~~~

EXCITATION SCHEMATIC

t

CHECK THESE SINGLE LEAD RECTIFIERS

ACCORDING TO PROCEDURE "E"

FIGURE

3.

TOP VIEW OF EXCITER-REGULATOR CHASSIS ASSEMBLY

V R21

VOLTAGE REGULATOR

PRINTED CIRCUIT

BOARD

,

!

i

'FIGURE

4.

VOLTAGE REGULATOR PRINTED CIRCUIT BOARD LOCATION

6,

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by any means, is strictly prohibited.

I

VISUAL

INSPECTION

Before proceeding with the troubleshooting on the

following pages, a few simple checks can be made

which could directly indicate the cause'of trouble.

1.

Always be sure that connection of generator

leads is correct. Whenever leads are reconnected

for a different voltage, check the output with an

independent voltmeter.

Do

not use the control

panel meter since it could indicate that the

voltage is correct even

if

connection is wrong.

2.

Visually inspect the voltage regulator printed

circuit board assembly (VR21)

in

the control box

for

burned components, broken wires, loose

connections, dust, dirt

or

moisture.

If

dirty, clean

with a suitable solvent and compressed air.

3.

Visually inspect the exciter-regulator chassis

assembly

(VR22)

for burned components, broken

wires, loose connections, carbon tracks caused

by arcing between parts

or

between parts and

ground.

Also

check for shorted paths between

terminals caused by dust, dirt and moisture.

4.

Large banks of SCR (Silicon Controlled Rectifier)

regulated loads can cause the generator voltage

to increase as load is applied.

If

such loads exist,

and the voltage increased more than

5

or

lo%,

consult the factory; an additional filter is available

for the regulator circuit to correct the situation.

THE QUESTION AND ANSWER TROUBLESHOOTING GUIDES BEGINNING

ON PAGE

8

GIVE A STEP-BY-STEP PROCEDURE FOR CHECKING THE

GENERATOR. THE FLOW-CHART TROUBLESHOOTING GUIDES ARE

GIVEN AS

A

GENERAL GUIDE TO RESOLVE VARIOUS GENERATOR

PROBLEMS. ALL CHARTS REFER TO PROCEDURESSHOWN AT THE END

OF

THIS SECTION.

.

PRIOR TO ANY TROUBLESHOOTING, CHECK ALL MODIFICATIONS,

REPAIRS, REPLACEMENTS, ETC.. PERFORMED

SINCE

LAST SATISFAC-

TORY OPERATION OF SET.

7

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by any means, is strictly prohibited.

QUESTION AND ANSWER TROUBLESHOOTING GUIDE

To

correct a particular problem, answer the question either “yes”

or

“no,” then proceed to the next step given in

‘LiM

I

TABLE

A.

NO OUTPUT VOLTAGE

-

ENGINE RUNNING

.-

whichever column question was answered. Procedures A thru P follow the troubleshooting guide.

~~

YES NO PROCEDURt

Are diodes CR1, CR2 and CR3 on VR22 exciter-regulator chassis

assembly

OK?

Are SCR’s

Q4

and

Q5

on VR22 exciter-regulator chassis

-

assembly

OK?

1.

2.

3.

4.

5.

8

9

6.

7.

8.

9.

10.

11.

13

Is circuit breaker on the meter panel in the

“on”

position?

‘

I

Switch circuit breaker to the “on” position.

Does AC voltage build up?

NOTE:

If voltage builds up, but is high, low

or

unstable,

or

causes

the circuit breaker on the meter panel to

trip,

refer to

Table

“B,”

“C’

or

“D” of the troubleshooting guide.

I

Is AC voltage at terminals

1

and 2, on VR21 voltage regulator

printed circuit board and at terminals

9

and

10

on VR22 exciter-

regulator chassis assembly

5

to 10 volts?

5

~~ ~~

Check continuity of wires and connections between terminal

1

on

VR21 printed circuit board and terminal

9

on VR22 chassis

assembly; and between terminal 2 on VR21 printed circuit board

.

and terminal 10 on VR22 chassis assembly.

Is

there continuity

between these connections?

Check for broken wires and loose connections on VR22 exciter-

regulator chassis assembly. Replace

or

repair any that are

defective and clean all dust, dirt and other foreign material

from the assembly. Does AC voltage now

build

up?

Is DC voltage at terminals

4

and

5

on VR22 exciter-

regulator chassis assembly

5

to

10

volts?

I

l3

The trouble is probably caused by a defective component on

the voltage regulator printed circuit board.

REPLACE VR21 PRINTED CIRCUIT BOARD (see Figure

4).

With the circuit breaker on the meter panel

in

the “off” position,

is

AC voltage at terminals 62 and 63 (on

,

terminal board

TB21

on

the left side of control box)

5

to 10 volts?

With the circuit breaker on the meter panel

in

the “off” position,

flash the exciter field.

Is

AC voltage at terminals 62 and 63

now

5

to 10 volts? 12

10

6

11

13

C

F

B

8

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by any means, is strictly prohibited.

TABLE

A.

NO

OUTPUT

VOLTAGE

-

ENGINE

RUNNING

(continued)

YES

NO

PROCEDURE

Turn circuit breaker on the meter panel to the “on” position.

Does

AC

output voltage build up?

NOTE:

If

voltage builds up, but

is

high, low

or

unstable,

or

causes circuit breakerto trip. refer

to

table

“B.”

“C”

or

“D”

of

this troubleshooting guide.

Is

brushless exciter stator winding

OK?

With a jumper wire connected across the terminals

of

the circuit

breaker on the meter panel, does voltage build up?

NOTE:

If

voltage does build up, the circuit breaker

CB21

is defective and

MUST

BE

REPLACED.

~

~-

Is

11

commutating reactor mounted on the back side

of

VR22

exciter-regulator chassis assembly

OK?

Check continuity of wires and connections between

1821

terminal

62

on left side of control box and terminal

1

on

VR21

printed

circuit board.

Also

check between

TB21

terminal

63

on the left

side of control box and terminal

2

on

VR21

printed

circuit board.

Are rotating diodes

CR1,

CR2,

CR3,

CR4,

CR5

and

CR6

on

brushless exciter rotor

OK?

Is

generator field winding

OK?

Is

brushless exciter rotor winding

OK?

Are generator stator windings

OK?

17

18

19

20

D

E

G

J

H

9

Redistribution or publication of this document, 

by any means, is strictly prohibited.

TABLE

A.

SYNOPSIS

NO AC

POWER

TO

EXCITER

LOSS OF

RESIDUAL

VOLTAGE

(FLASH

FIELD)

BRUSHES

OR

LOOSE

BRUSH

-I-

CB2l

CIRCUIT

BREAKER

ON METER

PANEL IN

"OFF"

POSITION

(RESET)

++

DEFECTIVE

CIRCUIT

BREAKER

ON METER

PANEL

1

NOTE: Whenever a letter appears near the box, a separate procedure,

corresponding to that letter, is given at the end

of

this section.

*

-

Check

SCR's,

Q4

and

Q5

on

VR22

voltage regulator chassis assembly

and replace

(if

defective) before repairing or replacing

VR21

voltage

regulator printed circuit board.

**

-

Static excited generators

only.

FAULT IN

GENERATOR

FIELD

WINDING

n

DEFECTIVE

COMPONENT

ON

REGULATOR

PC

BOARD

(VR21)

I

COMPONENT

VOLTAGE

REGULATOR

CHASSIS

ASSEMBLY

BUILD-UP

RELAY, K1

CR8

OR

CR9

OPEN

Rl,

R2

OR R3

OPEN

PC BOARD

P

TERM"ALS

1

OR

2

I

Q4

OR

Q5

-I

FAULTY

ROTATl NG

DIODE

ON

BRUSHLESS

EXCITER

A

DEFECTIVE

DIODE CR1

/E\

OPEN LEAD

TERMINAL

1,

2,4,5

FAULT IN

BRUSHLESS

EXCITER

ROTOR

OR

STATOR

WINDING

.

-..

__

...

Redistribution or publication of this document, 

by any means, is strictly prohibited.

L

t

18

:

i

ITEM TABLE

B.

OUTPUT VOLTAGE BUILDS UP BUT IS UNSTABLE

-

YES NO PROCEDURE

NO. ENGINE RUNNING

OK

I

Are there any loose

or

broken wires

or

connections at

VR21

printed circuit board terminals?

I

2.

Does adjustment of

R26*

(damping control pot) on

VR21

printed

circuit board result in stable generator voltage?

I

3.

The trouble is probably caused by a defective component on

VR21

voltage regulator printed circuit board.

REPLACE

VR21

PRINTED CIRCUIT

BOARD

(see Figure 4).

I

-

R26

is

used on brushless generators

only.

TABLE

B.

SYNOPSIS

UNSTABLE OUTPUT

VOLTAGE

7:

i

!

DEFECTIVE COMPONENT

ON (VR21) VOLTAGE

REGULATOR PRINTED

CIRCUIT BOARD

I

C6. C7, R14

OR

R1S

OPEN

C11, C12, R27

OR

R28

OPEN

BROKEN WIRES

OR

LOOSE CONNECTIONS

AT (VR21) VOLTAGE

REGULATOR PRINTED

CIRCUIT BOARD

TERMINALS

INCORRECT SETTING

OF R26 POT ON (VR21)

PRINTED CIRCUIT

BOARD (BRUSHLESS ONLY)

NOTE: Whenever a letter appears near the

box,

a separate procedure, corresponding

to that letter,

is

given at the end

of

this section.

Redistribution or publication of this document, 

by any means, is strictly prohibited.

F

5.

-

TABLE C. OUTPUT BUILDS UP BUT

IS

HIGH

OR

LOW

-

ENGINE RUNNING

OK

YES

I

Does adjustment of R21 "Voltage Adjust" knob on the meter

panel result in correct voltage?

Does adjustment

of

Rlb

potentiometer on VR21 printed circuit

-

board result in correct voltage?

-

Is

correct voltage reference transformer tap on TB21

being used?

4

Are generator output leads properly connected?

5

NO PROCEDURE

2

3

P

L

-

TABLE

C.

SYNOPSIS

TOO

HIGH

OR

I

INCORRECT

REFERENCE

TRANSFORMER TAP

ON

T21

INCORRECT

SETTING OF

VOLTAGE ADJUST

POT (R21) ON

METER PANEL

INCORRECT

SETTING

OF

VOLTAGE ADJUST

POT

(R18)

ON

VR21 PC BOARD

I

DEFECTIVE DEFECTIVE

COMPONENT ON COMPONENT ON

REGULATOR CHASSIS REGULATOR PC

ASSEMBLY (VR22) BOARD (VR21)

CONNECTION AT

TERMINALS

3,4,.

.

I

.I

--

.

..

I

..

!

NOTE

Whenever a letter appears near the

box,

a separate procedure, corresponding

to that letter,

is

given at the end

of

this section.

12

Redistribution or publication of this document, 

by any means, is strictly prohibited.

NO:

TABLE D. GENERATOR VOLTAGE BUILDS

UP

BUT CAUSES THE CIRCUIT BREAKER

ON

CONTROL PANEL

TO

TRIP.

ENGINE RUNNING

OK.

ITEM

I

3.

4.

Does AC output voltage build up to 150% or more of rated

voltage before CB21 circuit breaker trips?

Is

diode CR3 on center heat sink of VR22 exciter-regulator

chassis assembly

OK?

Are voltage regulator transformer (T21) windings and

connections

OK?

2.

.

Are

there any loose or broken terminals or connections at VR21

1,

voltage regulator printed circuit board terminals?

~

5.

~

Are stator leads connected properly?

6.

The

trouble is probably caused by a defective component

on

VR21 voltage regulator printed circuit board. REPLACE VR21

PRINTED CIRCUIT BOARD (see Figure 4).

I

8.

Does

AC

output voltage build up to rated voltage or less

before tripping CB21 circuit breaker

on

meter panel?

Are rotating diodes CR1, CR2, CR3, CR4, CR5 and CR6 on

brushless exciter rotor

OK?

9.

.

10..

Is

brushless exciter stator winding

OK?

Is

generator field winding

OK?

11.

DEFECTIVE

ROTATING DIODE

CR1, CR2, CR3,

CR4, CR5

OR

CR6

ON

EXCITER

ROTOR

Is

brushless exciter rotor winding

OK?

l-l

FAULT IN

EXCITER ROTOR

OR

STATOR

WINDING

FAULT IN

GENERATOR

MAIN FIELD

WINDING

A

NOTE:

Whenever a letter appears near the box, a separate procedure, corresponding

to that letter, is given at the end

of

this section.

13

Redistribution or publication of this document, 

by any means, is strictly prohibited.

ITEM

NO.

1..

-.

-

TABLE

E.

UNBALANCED GENERATOR TERMINAL VOLTAGE

YES

2.

3.

NO PROCEDURE

4.

5.

_________

~~ ~

Are generator leads properly connected and/or grounded?

Is

continuity of generator stator windings

OK?

-

3

H

- -

Remove load from 'generator terminals. Are genefator'terminal

voltages still unbalanced?

UNBALANCED

TERMINAL VOLTAGES

*

I

*141

INCORRECT GROUNDING

OF LOAD

OR

GROUND

FAULT IN LOAD

'

FAULTY GENERATOR

STATOR WINDING

t

I

51--1

I

Is grounding procedure of generator and load correct?

~~~

Check

for ground faults in load.

1-14

I'

,

ji

*

NOTE:

Unbalanced voltages of up to

5

percent will occur if unbalanced loads

are applied to the generator terminals.

TABLE

E.

SYNOPSIS

INCORRECT RECONNECTION

OR

GROUNDING OF

GENERATOR LEADS

I

\

,

NOTE:

Whenever

a

letter appears near the

box,

a separate procedure,

corresponding to that letter, is given at the end of this section.

14

Redistribution or publication of this document, 

by any means, is strictly prohibited.

TABLE

E.

SYNOPSIS

1

I

OPEN

IN

R21 DEFECTIVE COMPONENT

OPEN LEAD AT

(VR21)

PRINTED CIRCUIT

BOARD TERMINALS

1,

2,

5,

7

OR

8

ON VR21 PRINTED

VOLTAGE ADJUST POT

ON METER PANEL CIRCUIT BOARD

<

L

OPEN TRANSFORMER

(T21) WINDING

I

VOLTAGE

150%

I

[;I

MORE

THAN

RATED

I I

1

I

OPEN WIRE

OR

CONNECTION AT

VOLTAGE REGULATOR

CHASSIS ASSEMBLY

(VR22)

TERMINALS

4,5

OR

6

DEFECTIVE COMPONENT

ON VOLTAGE

REGULATOR CHASSIS

r-

ASSEMBLY (VR22)

I

DEFECTIVE COMPONENT

ON VOLTAGE

REGULATOfi PRINTED

CIRCUIT

BOARD

(VR21)

OPEN

WIRE

OR

CONNECTION AT

PRINTED CIRCUIT

BOARD (VR21)

TERMINALS

5,6,

9,10,

11

OR

12

CYCLING

BUILD-UP

*

OPEN IN R18

VOLTAGE ADJUST POT

ON VR21 PRINTED

CIRCUIT BOARD

NOTE Whenever a letter appears near the box, a separate procedure,

corresponding to that letter,

is

given at the end

of

this section.

*

-

Generator voltage builds up. then collapses. builds up. etc.

Redistribution or publication of this document, 

by any means, is strictly prohibited.

ADJUSTMENTS

AND

PROCEDURES

BRUSHES

ment.

Do

not use a substitute brush that may look

1

I

When brushes wear to approximately

5/8

inch or

when wear extends into the stamped Onan part

number, replace brushes.

Do

not attempt to remove

the brush without first removing its spring and

brackets. Never bend a spring back over its bracket

-

doing

so

will put a kink in it and require its replace-

identical but may have entirely different electrical

characteristics. Be sure to install the brush

SO

that the

short side of its taper is toward the spring and its

bracket. See Figures

5

and

6.

i

REPLACE

BEFORE

BRUSH

WEARS

TO

THIS

POINT

INSTALL BRUSHES

WITH

BEVELED

TOP

SLANTING

DOWN

TOWARD

SPRING HOLDER-,

TO

REMOVE

BRUSH

SPRING,PRESS

SPRl

NG

HOLDER

DOWN

AND OUT AS

SHOWN

IN

BROKEN

tJ

LINES.

FIGURE

6.

BRUSH REMOVAL

..

.watt resistor in series with diode; or a 24 volt

.

'

automotive (generatorset) battery can be used by

increasing the resistor value

to

40-ohms.

FIGURE 5. BRUSH REPLACEMENT

FLASHING THE FIELD (No

Voltage)

If

output voltage will not build up, it may be necessary

'.

to flash the field to restore residual masnetism.

1.

2.

-

Remove end grille to obtain access to'exciter-

regulator chassis assembly:.

Use a six volt

dry

cell (lantern) battery with a 12

amp

300

volt diode as shown

in'

Figure

7.

This

prevents current flow from exciter circuit to

battery when voltage builds up. If a lantern battery

is not available, a 12 volt automotive (generator

set) battery can be used by installing a 20-ohm 2

3.

After starting the set, touch the positive

(+)

lead to

TB5 and the negative

(-)

lead to TB4; hold on

terminals just long enough forvoltage to build up.

Do not keep excitation circuitry connected

longer than 5-seconds or damage

may

occur

to the exciter regulator.

Be cautious when working on agenerator that

is running. High voltages aye present.

CHASSIS

ASS

TO

BUILD

UP.

FIGURE

7.

FLASHING THE FIELD

16

Redistribution or publication of this document, 

by any means, is strictly prohibited.

CCI

NO

AC

POWER

TO

EXCITER

Residual should be checked before the circuit breaker; the best

place

to

check

it

is

at the five leads

61

through

65

coming directly

out

of the stator. The combination of leadsshould bechosen by the

wiring configuration of the stator, Le.,

120/240

Delta,

120/208

Parallel Wye.

277/430

Series Wye. After checking residual, proceed

to

VR21

PC

board arid then check the circuit breaker

CB21.

If

residual voltage is present, check AC voltage at

terminals

1

and 2 on VR21 voltage regulator printed

circuit board. Voltage should be

5-10

volts. The AC

voltage at terminals

9

and

10

on VR22 exciter-

regulator chassis assembly should be the same

(5

to

10 volts). If not, check continuity between these

points.

If

voltage is low, check L1 reactor.

TESTING

L1

REACTOR

The

L1

reactor mounts

on

the rear

of

VR22 exciter-

regulator chassis assembly. Terminals are marked

1,

2, 3

and 4.

3h4

Coils 1-2 and 3-4 are wound on the same iron core.

Resistance between 1-2 and

3-4

should be .0544 and

.0614-ohms

f

1O0/o respectively (brush type

generators)

.

LEAD

Resistance between coils (e.g., 1-4)

or

from any

terminai

to

reactor frame should be infinity.

If

any of the above conditions are not met, install a

new reactor.

TESTING

DIODES

On both brushless and brush type generators. three

diodes mount on the center heat sink of the exciter-

regulator chassis assembly. They are labeled CR1,

CR2 and CR3 as shown

in

Figure

3.

On brushless

generators, six diodes mount on the rotating exciter

assembly as shown in Figure 2. These six diodes are

labeled CR1. CR2, CR3, CR4, CR5 and CR6. Test

diodes as follows:

1.

Disconnect one diode at a time. Test that diode

and reconnect lead before proceeding to the next

one.

2. Use an accurate ohmmeter to check the

resistance

of

the diode. Connect one lead to the

top of the diode and the other lead to the heat

sink. Observe reading.

3. Now reverse leads and again observe reading.

A

good diode should have a higher reading

in

one

direction than the other.

If

both readingsare high,

or if both readings are low, diode is defective and

must be replaced with a new, identical part.

Excessive dust or dirt on diodes and other

m

components

will

causeoverheating and even-

tual failure. Keep these assemblies clean!

CAUTION

LEAD

GOOD DIODE WILL HAVE HIGH RESISTANCE READING IN ONE DIRECTION

AND LOW READING WHEN OHMMETER LEADS ARE REVERSED.

FIGURE

8.

TESTING

DIODES

17

Redistribution or publication of this document, 

by any means, is strictly prohibited.

0

H

MM ETER

FIGURE

9.

TESTING

SCR’s

[FI

1.

2.

3.

4.

5.

-

ANODE

SHORT BETWEEN

SATE AND ANODE

CATHODE

FIGURE

10.

TESTING

SCR’s

FIGURE

11.

TESTING

SCR’s

TESTING

SCR’s

SCR’s mount on the outer heat sinks of the exciter-

regulator chassis assembly. They are labeled

Q4

and

Q5

as shown in Figure

3.

Remove the leads from both

SCR’s.

Determine polarity of ohmmeter leads. Connect

the ohmmeter leads to the anode and cathode as

shpwn in Figure

9.

Use the high scale on the

ohmmeter. The resistance should be

1

megohm

or greater.

The cathode

is

the longer lead, the gate

is

the shorter lead. The

anode

is

the threaded stud.

Reverse the leads as shown in Figure

10.

The

resistance again should be

1

megohm or greater.

With the leads connected as

in

Step

3,

and using

the low scale on the ohmmeter, short the gate to

the anode as shown in Figure

11.

The resistance

should drop to a

low

value.

Remove the short between the anode and the

gate. The resistance should remain at the same

low

value.

REPLACING RECTIFIERS (SCR’s

and

Diodes)

1.

Unsolder leadwires from terminals.

2.

Use proper size wrenches to hold the body while

removing the nut.

3.

Push the rectifier free of its mounting hole

in

the

heat sink.

4.

Insert new rectifier into its mounting hole in the

heat sink. Using nut and washer provided, secure

rectifier to heat ,sink.

5.

.Torque the two large diodes on the center heat

sink of exciter-regulator chassis assembly to

20-

25

in. Ib.

6.

Torque the small diode on center heat sink

of

exciter-regulator chassis

assemb.ly to

12-15

in.

Ib.

7.

Torque SCR’s on outer heat sinks- to

20-25

in. Ib.

8.

On brushless generators, torque diodes

on

9.

Solder leadwires to new rectifiers.

rotating exciter assembly to

15

in: Ib.

Use a

40

watt soldering iron. Hold

a

needlenose pliers between rectifier and

soldering point to prevent destructive heating. Excessive heat on

these components

will

destroy them.

18

Redistribution or publication of this document, 

by any means, is strictly prohibited.

TESTING GENERATOR

ROTOR

Testing

for

Grounds:

Use an ohmmeter

(R

x

100

scale'); measure as follows:

Brush Type

-

from each slip ring to the rotor shaft.

Brushless Type

-

disconnect F1 and F2 rotor leads

from the rotating diodes; measure between either

lead and the rotor shaft.

A

reading of less than infinity

indicates a ground. See Figure 12.

0

H

M M ETER

BRUSH

DESIGN

CONTACT ONE PROD TO EACH OF THE SLIP

RINGS AND THE OTHER PROD TO THE ROTOR

SHAFT.

IF ROTOR

IS

GOOD THERE SHOULD BE NO

READING ON OHMMETER.

OHMMETER

CONTACT ONE PROD TO EACH OF THE FIELD

LEADS AND THE OTHER PROD TO THE ROTOR

SHAFT.

IF

ROTOR

IS

GOOD'THERE SHOULD BE NO

READING ON OHMMETER

FIGURE

12.

TESTING

ROTOR

FOR GROUNDS

Testing

for

an Open Circuit:

On brush type

generators, check for an open circuit by measuring

resistance in the windings. Check between the two

slip rings as shown in Figure 13.

On brushless generators, disconnect and test

between F1 and F2 leads as shown in Figure 13.

Resistance values given in Table

3

apply to both brushless and

brush type generator rotors.

Replace the rotor if

it

is grounded or has an open or

short.

CONTACT ONE PROD TO ONE

SLIP

RING AND

THE OTHER PROD TO THE SECOND SLIP RING.

CONTACT ONE PROD TO ONE FIELD LEAD AND

THE SECOND PROD TO THE OTHER FIELD LEAD

FIGURE

13.

TESTING ROTOR FOR AN OPEN CIRCUIT

TABLE

3.

RESISTANCE VALUES

FOR

ROTORS

KW

RATING

I

RESISTANCE

IN

OHMS

50HERTZ

I

60HERTZ

1

FROM TO

25.0

37.0

40.0

45.0

50.0

55.0

60.0

70.0

75.0

80.0

95.0

1

10.0

11

5.0

125.0

140.0

145.0

30.0

40.0

45.0

50.0

55.0

60.0

65.0

75.0

85.0

90.0

100.0

115.0

125.0

140.0

150.0

170.0

175.0

3.32 4.06

2.49 3.05

2.76 3.38

3.02 3.70

3.16 3.86

2.76 3.38

3.19 3.90

3.26 3.99

3.96 4.40

3.09 3.78

3.42

,

4.18

3.42 4.18

All

resistances should be within the values specified at

20°C

(68"

F).

This includes readings between slip rings on static excited

rotors and between field leads (with rectifiers disconnected) on

brushless rotors. Use Wheatstone Bridge for testing.

19

Redistribution or publication of this document, 

by any means, is strictly prohibited.

TESTING GENERATOR STATOR

Testing

for

Grounds:

Connect all stator output leads

(Tl-T12) together. Use an ohmmeter set on the

R

x

100

scale and measure the insulation resistance

between these windings and the stator frame.

A

reading of less than infinity indicates a ground. Field

circuit breaker can be either

“ON”

or

“OFF”.

Testing

for

Shorts:

To check for shorts between

individual windings first refer to Figure 18 to deter-

mine individual coil lead wires (Tl-T4, T7-Tl0, etc.)

Connect one lead of an ohmmeter (RX100 scale) to

one of the stator windings and the other ohmmeter

lead

to

all other stator leads connected together.

A

reading of less than infinity indicates a short. Repeat

until all stator coils have been tested in this manner.

Coil Resistances:

Measure resistance of windings

using a Wheatstone or Kelvin bridge meter. SeeTable

4 and Figure 14. If any windings are shorted, open

or

grounded, replace the stator assembly. Before

replacing the assembly, check the leads for broken

wires

or

damaged insulation.

FROM

KELVIN

BRIDGE

FIGURE 14. TESTING STATOR WINDINGS

Stator output leads T4, T7, T8, T9 and T10 are interconnected

(within the stator) to five stranded (#lo aircraft) control wires.

These wires are labeled 4,7,8,9 and 10 respectively and terminate

at

TB2.1

(terminals 61-65).

TABLE

4.

.RESISTANCE VALUES

FOR

STATORS*

KW

R

50

HERTZ

25.0

37.0

’

40.0

,450

55.0

60.0

70.0

75.0

80.0

95.0

110.0

11 5.0

125.0

140.0

145.0

’

50.0

TlNG

6O.HERTZ

30.0

40.0

45.0

50.0

55.0

60.0

65.0

75.0

85;O

90.0

100.0

115.0

125.0

140.0

150.0

170.0

175.0

VOLTAGE CODE (Resistance in

Ohms)

I

15

I

9x

I

3

0.116

-

0.141

0.047

-

0.058

0.047

-

.

0.058

0.047

-

0.058

0.028

-

0.035

0.038

-

0.047

0.028

-

0.035

0.028

-

0.035

0.022

-

0.027

0.019

-

0.024

0.019

-

0.024

0.015

-

0.018

0.012

-

0.015

0.009

-

0.011

0.009

-

0:Oll

0.0075

-

0.0092

0.0059

-

0.0072

0.0059

-

0.0072

0.425

-

0.520

0.193

-

0.236

0.193

-

0.236.

0.156

-

0.191

0.113

-

0.138

0.113

-

0.138

-6.089

-

0.108

0.072

-

0.089

0.072

-

0.089

0.054

-

0.067

0.045

-

0.055

0.039

-

0.048

0.039

-

0.048’

0.027

-

0.033

0.018

-

0.023

0.018

-

0.023

0.052

-

0.063

0.047

-

0.058

.

0.047

-

0.058

!

i.

AI:

r’(?sislances should be within the values shown at

20°C (68’

F).

Use an accurate instrument such

as

a Kelvin Bridge for this test.

Test

between the following coil leads:

T1 -T4 17-T 10 T3-T6

T9-Tl2 T2-T5 T8-Tl1

20

Redistribution or publication of this document, 

by any means, is strictly prohibited.

!

Testing Winding Resistance:

Measure coil resistance

between leads F1 and F2 with an ohmmeter (scale Rx

1).

Resistance should be17.82 to 21.78ohmsat 20°C

(68°F). See Figure 16A.

IJI

TESTING EXCITER ROTOR (Armature)

Testing for Grounds:

Remove diodes

CR1,

CR2, CR3,

CR4,

CR5,

and CR6 from diode heat sink assemblies.

Using an ohmmeter

(R

x 100 scale) measure insula-

tion resistance between any of the leads and the

laminations (exclude the diodes from the test circuit).

A reading of less than infinity indicates a ground.

Testing Winding Resistance:

Using a Wheatstone or

Kelvin bridge meter, measure resistance between

leads pairs T1-T2, T2-T3 and Ti-13. Resistance

should be 0.464 to 0.567 ohms at 20°C (68°F). See

Figure

15.

FIGURE 16A. TESTING EXCITER FIELD

FIGURE 15. TESTING EXCITER ARMATURE

TESTING EXCITER STATOR

Testing for Grounds:

Using an ohmmeter

(R

x

100

scale), measure the insulation resistance between

either lead F1 or

F2

and the laminations.

A

reading of

less than infinity indicates a ground. See Figure 16.

RECONNECTION

Figure 18 shows reconnection possibilities forthe

UR

series generators. When reconnecting for

a

different

voltage, be sure to also reconnect lead from terminal

63 (inside control box) to either H3, H4, H50rH6.See

Figures

17

and 18.

(W12

WIRE)

CONNECT LOOSE WIRE

FROM TERMINAL

#63

TO EITHER

H3.H4.H5

OR

H6

DEPENDING'ON

VOLTAGE SELECTED.

FIGURE 16. TESTING EXCITER FIELD

21

FIGURE 17. CONNECTING LEAD

FROM

TERMINAL

63

Redistribution or publication of this document, 

by any means, is strictly prohibited.

NAMEPLATE VOLTAGE CODE

9X

NAMEPLATE VOLTAGE CODE

3

T1

CONNECT LEAD

FROM

TERMINAL

63

10

H5

E,

+

CONNECT LEAD FROM

TERMINAL

63

TO

H5

IS

120/240

1

60

H5

115/230

1

50

H6

115

116220

1

50

H6

15

120/140

3

60

H5

115/230

3

50

H6

i1S

THIS

DIAGRAM APPLIES

TO

12 LEAD GENERATORS

ONLY

GENERATOR CONNECTION WIRING DIAGRAM

SCHEMATIC

(WITH

CURRENT

TRANSFORMERS

WHEN

USED)

DIAGRAM

THIS

DIAGRAM APPLIES

TO

12 LEAD GENERATORS

ONLY

GENERATOR CONNECTION WIRING DIAGRAM

SCHEMATIC

(WITH

CURRENT

TRANSFORMERS

WHEN

USED)

DIAGRAM

8'l

LO

TI0

77

75

L2

13

I

W

5

'7:

111

LO

71

0

711

79

L3

/

LO

11

12

T1

12

16

111

18112

14

19

1s

17

T3

110

LO L1

12

L3

11

T10

16

17

12

111

14

T8

'73

T12 T5

19

LO

L1 L2

13

4

16

111

12

T8

13

19

I5

110

112"

l7

LO

L1

12

13

T3T9

1

1101lt

T12 TI T7 T4

12

T8

15

98C2193

i

I

1

,.

t

i.

FIGURE

18.

RECONNECTION

DIAGRAM

22

Redistribution or publication of this document, 

by any means, is strictly prohibited.

1

I

il

:!

..

SENSITIVITY REFERENCE CIRCUIT

UR

series voltage regulators

(VR21)

can be set to

either frequency sensitive or non-frequency sensitive

reference. With a frequency sensitive reference, the

output voltage of the generator will decrease in

proportion to the frequency (Le., prime moverspeed).

This decrease

in

output voltage will reduce the load

on the prime mover, permitting

it

to return to rated

voltage and frequency when overload is removed.

A

temporary overload with a non-frequency sensitive

reference could cause a prime mover to reduce

speed, then would require a further

50%

to

60%

load

reduction

to

allow it to return to rated speed.

This reference change is accomplished by soldering

wire

W1

to terminal

El

for frequency sensitivity or to

terminal

E2

for non-frequency sensitive reference.

See Figure

19.

Unless requested otherwise by purchaser, Onan sets are con-

nected at the factory to a frequency sensitive reference.

TOP SIDE

OF.

VOLTAGE

REGULATOR

WHENMOUNTED

UNSOLDER THIS WIRE

FROM E

I

AND CONNECT

TO E2

FOR

A NON-

FREQUENCY SENSITIVE

VOLTAGE REFERENCE

CIRCUIT.

-

FIGURE

19.

VR21

PRINTED CIRCUIT BOARD

23

Redistribution or publication of this document, 

by any means, is strictly prohibited.

GENERATOR

DISASSEMBLY

,

If generator testing determines that generator needs

repair, remove and disassemble according to Figure

'20

and the following instructions:

7.

Using an overhead hoist and sling, slide the stator

Use care not to damage the brush rig (or

Ez3

exciter on brushless models) while

removing the stator. Do not allow the stator to rest on rotor

assembly off the rotor assembly.

CAUT,ON

Disconnect and remove load wires.

Disconnect leadwires from the control box.

Check wire markings for legibility to ease

assembly. Arrange leads

so

they can be

withdrawn easily from the control box.

Remove front grille (14) and sheet metal work.

Remove the four capscrews securing voltage

regulator chassis

(23)

to end bell

(9)

and remove

chassis assembly.

Remove the centrifugal switch

(8)

from end bell

and rotor shaft. On static excited models, slip the

brushes (7) and brush springs

(6)

from brush rig

(5)

-

it is not necessary to disconnect the brush

leads unless brush replacement is required.

Block the rear of the engine

in

place by suppor-

ting the flywheel housing. Remove the narrow

generator band

(10).

Remove the large capscrews

securing generator mounting pad

(11)

to the skid

base. Remove the capscrews securing the stator

assembly

(4)

to the engine flywheel housing.

during removal.

8.

Remove end bell from stator assembly; dis-

connect and remove brush rig from end bell on

static excited generators. On brushless models,

remove exciter field (24) from end bell assembly

if

required.

9.

Attach the hoist and sling to the rotor assembly

(1) and apply a slight lift to support the rotor.

Remove the capscrews securing the flexibledrive

coupling (13) to the engine flywheel and remove

'

rotor from the engine.

10.

Remove bearing capscrew (18) and washer (17)

and remove bearing from shaft.

If

required,

remove blower

(2)

from the rotor.

11. Disconnect rotor field leads from heat sinks

F1

and

F2

on the exciter armature. Remove exciter

armature

(25).

9

23

LA

/

BRUSHLESS

GENERATOR

FIGURE

20.

GENERATOR DISASSEMBLY

24

Redistribution or publication of this document, 

by any means, is strictly prohibited.

GENERATOR

ASSEMBLY

Generator assembly is the reverse of disassembly

procedure:

1.

Always replace bearing with a new one; apply a

layer of grease on end bell bearing hole before

inserting bearing.

2.

Torque bearing capscrew to

60-70

Ib. ft.

3.

Torque drive disc-to-rotor capscrews to 200-240

Ib. ft.

4. Torque drive disc-to-flywheel capscrews to 45-50

Ib. ft.

5.

Torque generator through-stud nuts to

30-40

Ib.

ft.

6. Refer to

Purrs

Curu/o,y

for replaceable parts and

assemblies. Refer to

Wiring

Diuputii

for

reassembly.

[PI

VOLTAGE ADJUSTMENT

After replacement, voltage regulator (VR21) adjust-

ment is performed as follows (see Figure 21):

1. Center the voltage adjust knob

so

pointer is in a

2. Open meter panel doors. Start unit.

3.

Using a screwdriver, turn R18 potentiometer on

printed circuit board VR21 counterclockwise to

increase the voltage

or

clockwise to decrease the

voltage. Observe voltmeter on meter panel while

making adjustment. Set voltage with no load

connected to generator. (Example: For a 120/240

volt connection, set at no-load voltage

or

ap-

proximately 246 volts.)

vertical position.

If

voltage is unstable

or

tends to hunt, turn R26

potentiometer on VR21

in

the direction shown on

printed circuit board to increase voltage sensitivity.

I

\

ADJUST R26 ADJUST R

18

HERE HERE

FIGURE

21.

ADJUSTING VOLTAGE

ON

VR21

25

Redistribution or publication of this document, 

by any means, is strictly prohibited.

GENERATOR

-

SECTION

II

GENERAL

Generators discussed in this section are brushless

type only. The difference between these and the

generators in Section

I

is

in

the VR22 diode assembly

and the commutating reactor. These have been

,

removed from the generator end bell and relocated in

the control panel. The diodes are now encapsulated

within a hermetically sealed block, therefore if any

diode or silicon controlled rectifier fails, the entire

unit has to be replaced. See Figure27fordetailsof the

,

rectifier assembly (CR21) and Figure 25 for the

reactor

(L21).

Principles of operation and method of excitation

remain unchanged from the units described in Sec-

tion

I.

Refer to Table

1

for generators to which this section

.

applies.

VR2‘ VOLTAGE

RE

GU

LATO R

121 REACTOR

/

ov

ROTATING EXCITER

‘ERSPEED SWITCH WITH RECTIFIERS

QENERATOR END VIEW (QRILLE REMOVED)

FIGURE 22. ROTATING RECTIFIER ASSEMBLY

\

CR2

I

SCR BRIDGE

FIGURE

23.

SCR BRIDGE AND REACTOR LOCATION

:TROUBLESHOOTING

ing the generator. To use the guides, answer the

Use the following troubleshooting charts and questions either “yes” or

“no”

then proceed to the

procedures to locate malfunctions

in

the generating next step given in whichever column

is

indicated.

system.

Section

11

also references procedures

A

thru

P

of

Section

1.

When using block diagrams, a letter with a triangle

indicates a procedure

in

Generator

-

Section

1.

A

letter

The question and answer troubleshooting guides

within a diamond indicates a procedure in

Generator-

which follow give a step-by-step procedure for check-

Section

II.

26

Redistribution or publication of this document, 

by any means, is strictly prohibited.

!

;

QUESTION

AND

ANSWER

TROUBLESHOOTING

GUIDE$

To

correct a particular problem, answer the question either “yes” or “no,” then proceed

to

the next step given in

whichever column question was answered. Procedures

R

thru

P

follow the troubleshooting guide.

ITEM

NO.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

12.

TABLE

F.

NO

AC OUTPUT VOLTAGE

-

ENGINE RUNNING

AT

RATED

RPM YES NO PROCEDURE

Is

Exciter Circuit Breaker (CB21) on the meter panel

in

the

“ON”

position?

3

2

Switch CB21 to

“ON”

position. Does AC voltage build up?

3

-

NOTE

If

voltage builds up but is high,

low

or

unstable,

or causes CB21 to trip, refer to table

G.

H

or

I

of

troubleshooting guide.

Is

AC

voltage measured at terminals

1

and 2 on voltage

regulator (VR21) printed circuit board 5 to 10 volts? 6

4

Is

AC voltage measured at terminals 11 and 12 on

VR21

5

to 10 volts?

5

7

Replace reactor assembly (L21).

-

Rectifier Bridge (CR21)

5

to 10 volts? 15 11

Is

DC voltage measured at terminals

+

and

-

on

Shut down generator set. Check continuity through L21

coils between terminal 2 on VR21 and T8 on generator,

between terminal 1 on VR21 and

T7

on generator.

Is

there continuity between these connections?

VR21-2 to T8 14

10

VR21-1 to T7 14

8

If

there is no continuity between VR21-1 and T7

((2621

-ON)

apply

a

shorting jumper across CB21.

Is

continuity obtained?

9

10

Replace CB21.

-

Check for loose or broken wires on VR21, CR21, L21,

reference voltage transformer (T21), generator

bus-bars and terminal board (TB21) in control

box. Secure or repair where necessary.

If

repairs have been made, restart engine. 14

Does AC voltage now build up?

Are diodes CR1, CR2 and CR3 on CR21 assembly good?

-

T

-

12

(See method T in procedure section for checking

diodes.) If faulty diode located, replace CR21.

Are

SCRs

1 and 2 in CR21 good?

(See method T in procedure section for checking

diodes.)

If

faulty SCR’s located, replace CR21.

T

-

13

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by any means, is strictly prohibited.

.

ITEM

NO.

13.

14.

15.

16.

17.

18.

19.

Fault probably lies with a defective component on VR21.

Replace VR21.

TABLE

F.

NO AC OUTPUT VOLTAGE- ENGINE RUNNING AT RATED RPM

(continued)

~~ ~

Start engine. Place CB21

in

“OFF” position. Using method

prescribed under

“R”

in

procedure section flash the exciter

field

to

restore residual magnetism. Place CB21

ON.

Does the AC output voltage build up?

I

No

lPROCEDURE

YES

Shut off engine.

is

exciter field winding (F1: F2)

OK?

16

Are rotating diodes CRI, through CR6 on exciter

rotor

OK?

17

Is

generator stator winding

OK?

Is

exciter rotor winding

OK?

18

19

-

Are generator rotor windings

OK?

13

I

...

I.

...

i

28

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by any means, is strictly prohibited.

TABLE

F.

SYNOPSIS

1

NO

VOLTAGE

BUILD-UP

N

eo

-

SCRl

OR

SCRP

OPEN

,

DEFECTIVE

-

DlODECR1

CR2

OR

CR3

.

OPEN LEAD

AT

-

TERMINAL

OPEN LEAD

REGULATOR

PC BOARD

TERMINALS

1

OR

2

NOTE: Whenever

a

letter appears near the

box,

a separate procedure, corresponding

to that letter,

is

given at the end

of

the, appropriate section.

....

._

.-

_.

-

.

....

Redistribution or publication of this document, 

by any means, is strictly prohibited.

TABLE G. UNSTABLE OUTPUT

-

ENGINE RUNNING AT

1800

RPM

-

NO FLUCTUA-

I

YES

1

NO IPROCEDURE

TION

I

Are there any loose or broken wires or connections at

VR21

terminals?

Does adjustment

of

R26

(damping control potentiometer)

I

on

VR21

stabilize generator voltage?

Replace

VR21.

2

-

3

P

-

TABLE

G.

SYNOPSIS

UNSTABLE OUTPUT

VOLTAGE

i

.

, ,

..

.

.-

-

BROKEN

WIRES

OR

AT (VR21) VOLTAGE

CIRCUIT BOARD

TERMINALS

DEFECTIVE COMPONENT LOOSE CONNECTIONS

REGULATOR PRINTED REGULATOR PRINTED

ON (VR21) VOLTAGE

CIRCUIT BOARD

NOTE:

Whenever a letter appears near the

box,

a

separate procedure, corresponding

to

that letter,

is

given at the end

of

the appropriate section.

INCORRECT SETTING

OF R26 POT ON (VR21)

PRINTED CIRCUIT

BOARD

,

._ .

..

".

1

. ..

.I

I

30

Redistribution or publication of this document, 

by any means, is strictly prohibited.

i

&M

1.

2.

3.

.-

TABLE

H.

OUTPUT VOLTAGE TO

HIGH

OR

LOW YES NO PROCEDURE

__

--

Does adjustment of

R21

“voltage adjust knob” on meter

2

panel correct voltage level?

-

voltage level?

-

Are rotating diode heat sink mounting screw insulators

OK?

Does adjustment of

R18

potentiometer on

VR21

correct

3

P

-

If

generator output voltage has been optionally reconnected,

consider the following

-

5.

6.

Is

reference transformer

(T21)

tap correctly connected

on

TB21?

4-

I

Are the reconnections correct and secure?

6

Replace

VR21.

-

15

%

DEFECTIVE DEFECTIVE

COMPONENT ON

VOLTAGE

REGULATOR PC

BOARD (VR21)

COMPONENT ON

CR21

RECTIFIER ASSEMBLY

TABLE

H.

SYNOPSIS

TOO

HIGH

OR

TOO

LOW

r

INCORRECT

SETTING OF

VOLTAGE ADJUST

POT (R18) ON

VR21 PC BOARD

I

-

I

1

H

OPEN LEAD

OR

CONNECTION AT

TERMINALS

G1

OR

G2

INCORRECT

SETTING OF

VOLTAGE ADJUST

POT (R21) ON

METER PANEL

INCORRECT

REFERENCE

TRANSFORMER TAP

ON T21

DEFECTIVE ROTATING

DIODE

OR

BAD INSULATOR

ON HEAT SINK MOUNTING

SCREW

1

OPEN

IN

CR1,

CR2

OR

CR3

/L\

1

VOLTAGE

BREAKDOWN OF

I

SCRl ORSCR2

NOTE: Whenever a letter appears near the

box,

a

separate procedure, corresponding

to that letter,

is

given at the end

of

the appropriate section.

31

Redistribution or publication of this document, 

by any means, is strictly prohibited.

IiLM

1.

2.

Is

diode

CR3

(connected between

+

and

-

in

CR21

rectifier assembly)

OK?

TABLE

1.

EXCITER CIRCUIT BREAKER TRIPS

Does

AC

output build up to

150%

or more

of

rated voltage

before

CB21

trips?

Are there loose or broken terminals or connections at

VRZl?

Are reference voltage transformer

(T21)

windings and

connections

OK?

5.

6.

Replace

VR21.

Does

AC output build up

to

rated value before tripping

CB21?

7.

Are rotating diodes

CR1

through CR6 on exciter

rotor

OK?

8.

9.

YES

NO PROCEDURE

Is

exciter stator winding

OK?

Is

generator field winding

OK?

DEFECTIVE

ROTATING DIODE

CR1,

CR2, CR3,

ON, EXCITER

ROTOR

10.

FAULT

IN

EXCITER ROTOR

OR

STATOR

WINDING

Is

exciter rotor winding

OK?

NOTE

Whenever a letter appears near the

box,

a separate procedure, corresponding

to

that letter, is given at the end

of

the appropriate section.

32

Redistribution or publication of this document, 

by any means, is strictly prohibited.

TABLE

J.

UNBALANCED GENERATOR OUTPUT VOLTAGE

-

YES

[

NO lPROCEDUREl

Remove load from generator terminals.

Is

output

still unbalanced?

Are generator leads properly connected or grounded?

I-

Check for ground faults

on

load.

2

3

TABLE

J.

SYNOPSIS

TERMINAL

VOLTAGES

Is

generator stator winding continuous?

Is grounding procedure of generator and load correct?

4

5

INCORRECT RECONNECTION

AND/OR GROUNDING OF

GENERATOR LEADS

I

!

1

INCORRECT GROUNDING

OF LOAD

OR

GROUND

FAULT IN LOAD

I

FAULTY GENERATOR

STATOR WINDING

I

1

NOTE:

Whenever a letter appears near the

box,

a

separate procedure, corresponding

to that letter is given at the end

of

the appropriate section.

33

Redistribution or publication of this document, 

by any means, is strictly prohibited.

TABLE

J.

SY

NOPSlS

(Continued)

VOLTAGE

150%

MORE

THAN

RATED

I

OPEN WIRE

OR

DEFECTIVE COMPONENl

ON RECTIFIER

ASSEMBLY CR21

CONNECTION AT

VR21 MODULE

TERMINALS 5,

6,

9,10,

OPEN TRANSFORMER

(T21) WINDING

11

OR

12

*

DlODECR3

-

1.

OPEN

I

BREAKDOWN

OF

SCRl

OR

SCRP

NOTE:

Whenever a letter appears near the

box,

a separate procedure, corresponding

to that letter,

is

given at the end of the appropriate section.

Malfunction occurs after warmup or voitage adjustment.

DEFECTIVE COMPONENl

ON VOLTAGE

REGULATOR (VR21)

MODULE

34

Redistribution or publication of this document, 

by any means, is strictly prohibited.

ADJUSTMENTS

AND

PROCEDURES

(Applies

to

Section

II

Only)

FLASHING

THE

FIELD

If output voltage does not build up

it

may be

necessary to restore the residual magnetism of the

poles by flashing the field. Assembleasixvolt battery,

and diode

as

shown

in

Figure 24. If a

six

volt lantern

battery is not available a 12-volt (generator set

battery) or a 24-volt battery can be used, however a

20-ohm or a 40-ohm 2 watt resistor must be used in

conjunction with the 12 amp 300

V

diode. Start the

generator set, touch positive lead to

+

on

rectifier

bridge, and negative lead to the

-

terminal. Hold leads

on terminals just long enough for voltage to build up.

Do

not keep excitation circuitry connected

longer than 5-seconds, or damage may occur

to the exciter regulator.

I

I2

AMP.

I

300

v.

RECTIFIER

BRIDGE

FIGURE

24.

FIELD

FLASHING

CIRCUIT

I

TESTING

L21

REACTOR

The L21 commutating reactor mounts inside the

control box, below the

VR21

Voltage Regulator.

The coils 1-2 and 3-4 are wound on the same core.

Resistance between 1-2 and 3-4 should be .034 ohm

f

.0034 and .042 ohms

*

.0042 respectively (brushless

units). Resistance between coils (e.g.,

1/4)

or from

any terminal to frame

of

the reactor should

be

icfinity

(Figure

25).

I

1

FIGURE

25.

L21

REACTOR

35

Redistribution or publication of this document, 

by any means, is strictly prohibited.

TESTING RECTIFIER BRIDGE ASSEMBLY

(CR21)

The rectifier bridge located within the control cabinet,

below the voltage regulator, contains

3

diode?

CRl.

CR2.

and CR3, and two silicon

COIIII~I~III~~~~

r'cxttlittt

SCR1

and

SCR2.

These diodes and

SCR's

arc cncali-

:;dated

within a hermetically sealed block, therefore

lailurc!

of

any diode

or

SCR means the entire unit has

to

bc

replaced. See Figure 26.

I

7i-

-1

h

I

CR2

'

CR

I

CR3

-

I

-

AC TERMINALS ARE

GIVEN NUMERIC

DESIGNATIONS

FOR

TEXT REFERENCE

ONLY.

DOES

NOT

APPEAR

ON

UNIT.

FIGURE

26.

RECTIFIER ASSEMBLY

Disconnect wires from rectifier unit prior to testing.

Test unit in order shown in Table

5.

Refer to Figure 27

for SCR1 and SCR2test circuit. When test is complete

and satisfactory, reconnect unit observing correct

wiring hoo k-up.

r---

6

VOLT

DRY CELL

BATTERY

'I

FIGURE

27.

TESTING

SCR

36

Redistribution or publication of this document, 

by any means, is strictly prohibited.

NG

SCR

REMARKS

METER

SCALE

CR3

CR1

CR2

Infinity

RXlOK

6-

to

50-Ohms

RXl

Infinity

RXlOK

SCRl

lnfinitv

RXlOK

RX1

2CR2

Infinity

RXlOK

I

nf

ini ty

RXl OK

6-

to

50-Ohms

RX1

DC

Voltmeter

DC

Voltmeter

lead Reading

I+

3

Volts

I

1+1

3CR2.I

AC2

I

+

I

3

Volts

-

Apply

temporary jumper from AC1 to

G1

to test

SCR1.

Remove jumper,

**.Apply temporary jumper from AC2 to G2 to test

SCR2.

Remove jumper,

read voltmeter. See Figure 27.

37

Redistribution or publication of this document, 

by any means, is strictly prohibited.

INDEX

OF

GENERATOR

!

ADJUSTMENTS

AND

PROCEDURES

PROCEDURE

A

B

C

D

E

F

G

H

J

K

L

M

N

.

P

SECTION

I

TITLE

Brushes

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

No

AC Power to Exciter

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

Flashing Field

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

Testing L1 Reactor

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

Testing Diodes

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

Testing

SCR’s

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

Testing Generator Rotor

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

Testing Generator Stator

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

Testing Exciter Rotor

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

Testing Exciter Stator

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

Reconnection

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

Sensitivity Reference Circuit

..........

Generator Disassembly

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

Voltage Adjustment

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

:

....

PAGE

16

17

18

19

20

21

23

24

25

SECTION

II

R

Flashing Field

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

35

S

Testing L21 Reactor

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

35

PROCEDURE

TITLE

PAGE

T Testing Bridge Rectifier (CR21)

.......

36

38

Redistribution or publication of this document, 

by any means, is strictly prohibited.

CONTROLS

-

SECTION

111

GENERAL

The shock mounted control box has two doors that

open from the center. The left hand door holds the

field circuit breaker, voltmeter and voltage adjusting

rheostat. The optional meter package adds running

time meter, frequency meter, ammeter or ammeters

plus volts-amps selector switch to the left hand door.

The right hand door, attached to a removable bracket,

holds the instrument lamp, fault lights, switches and

gauges.

An

optional door has holes for electric

tachometer and/or oil temperature gauge. The

bracket supports the terminal blocks, cycle cranker

and relays

in

the

DC

engine control circuit.

Plug mounted relays in both the AC section and DC

section plus printed circuit modules

in

the DCsection

facilitate troubleshooting and servicing. Snap-in

lamps with Faston connectors make lamp replace-

ment very easy. See Figure

28.

A12 CRANKING LIMITER

(MAY ALSO USE AN

OPTIONAL CYCLE

CRANKER)

I

K11 START DISCONNEC

RELAY

K12 IGNITION RELA

K13 START SOLENOI

FIGURE

28.

LOCATION OF

DC

CONTROL COMPONENTS

-FAULT LAMPS

TIME DELAY

-ENGINE MONITOR

PC BOARD

\KI RELAY

lK2 RELAY

THE QUESTION AND ANSWER TROUBLESHOOTING GUIDES BEGINNING

ON

PAGE

39

GIVE A STEP-BY-STEP PROCEDURE FOR CHECKING

GUIDES ARE GIVEN AS A GENERAL GUIDE TO RESOLVE VARIOUS

CONTROL SYSTEM PROBLEMS. ALL CHARTS REFER TO PROCEDURES

AND NOTES WHICH ARE GIVEN AT THE END OF THIS SECTION.

CONTROL SYSTEM PROBLEMS. THEFLOW-CHART TROUBLESHOOTING

39

Redistribution or publication of this document, 

by any means, is strictly prohibited.

QUESTION

AND

ANSWER TROUBLESHOOTING GUIDE

l3

~

Is

battery connected correctly and is voltage normal?

FOR

UNITS

WITH

ONE FAULT LAMP

I

lo

~

Does ignition relay

K12

pick up?

To

correct

a

particular problem, answer the question either “yes“ or “no” then proceed to the next step given in

whichever column question was answered.

TABLE A. ENGINE FAILS

TO

CRANK WHEN SWITCH

TO

“RUN”

Does fault lamp light?

YES

1

Is

voltage from ground terminal to center terminal of

run-stop-remote switch equal to battery voltage?

Switch is defective or in “stop” position.

7

-

Replace engine monitor printed circuit board.

Is

voltage from ground to terminal

26

on

TBll

equal to

battery voltage?

Does ignition relay

K12 (4-7)

contact close?

-

14

13

1.

2.

~~~

relay

K13’

(start solenoid) pick up?

I

l7

3.

4.

5.

6.

,

7.

Is

voltage from ground terminal to ignition relay

K12

terminal

“B”

equal to battery voltage?

I

lo

0.

Jumper battery positive from center terminal of run-stop-remote

switch to terminal

“6”

of

ignition relay

K12.

Does engine

now crank? 9

9.

10.

11.

12.

a. Check socket connection.

b. Coil may be open.

c. Replace ignition relay

K12.

I-

Clean relay contacts and check wiring.

13.

14.

I

Is

voltage from ground to start disconnect relay

K11

terminal

1

equal to battery voltage?

I

l6

15.

I-

Clean relay contact

K11

(7-1)

and check wiring.

t

NOTE:

On

EK.

EM,

and

EN

series, start solenoid relay is mounted

on

the engine,

rather than in the control, and

is

designated

K6.

40

Redistribution or publication of this document, 

by any means, is strictly prohibited.

ITEM

NO.

A. ENGINE FAILS TO CRANK WHEN SWITCHED

TO

“RUN”

YES NO PROCEDURE

(Continued)

Is

voltage from ground to coil terminal of

K13’

start solenoid

I

equal to battery voltage?

17

18

21 20

Does voltage from ground to

TBll-22

equal battery voltage?

Does relay

K13’

pick up?

Replace cycle cranker printed circuit board

A12.

-

Replace start solenoid

K13’.

-

Is

voltage from ground to starter coil terminal equal to

battery voltage?

22 23

Jumper from

K13’

coil terminal to

K11

terminal

1.

-

19

Replace starter.

-

Check thermal breaker

CB1

and wiring

to

starter.

- -

16.

17.

18.

19.

20.

21.

22.

23.

‘NOTE:

On

EK.

EM,

and

EN

series.

start

solenoid

is

mounted on engine,

rather than in

the

control, and

is

designated

K6.

TABLE

A.

SYNOPSIS

ENGINE

FAILS

TO

CRANK

A12 CYCLE

CRANKER

FAILS

IGNITION

RELAY K12

FAILS

LOOSE

OR

REVERSED

BATTERY

CON N ECTlO

N

I

~

K12 COIL

(4-7)

FAILS

TO CLOSE

START

SOLENOID

FAILS

SOLENOID

COIL OPEN

SOLENOID

CONTACT FAILS

TO CLOSE

MO N

IT0

R

PRINTED

CIRCUIT BOARD

CONTACT FAILS

TO

CLOSE

CIRCUIT PATH

41

Redistribution or publication of this document, 

by any means, is strictly prohibited.

ITEM

NO. TABLE B. ENGINE SHUTS DOWN IMMEDIATELY AFTER START

1.

1

Is

overspeed switch S3 closed? 12

YES NO PROCEDURE

Open overspeed switch, then reset fault lamp by switching

to “stop”, then back to “run”. Does engine crank and run OK?

5.

6.

I

Check overspeed switch and wiring for grounds.

Jumper from ignition relay K12 terminal “B” to center terminal

of run-stop-remote switch. See Method M in Procedure section.

Does engine crank?

Remove wire from TB11-29. Reset fault lamp by switching

to “stop”, then back to “run”. Does engine crank?

~

7.

4

Replace engine monitor printed circuit board and remove jumper.

-

Place wire back onto TB11-29 while engine is running.

Does fault lamp light and engine stop?

1.

2.

Does fault lamp light and does plant stop after running about

12 seconds?

Does fault lamp light and does plant stop after running about

1

minute?

5

-

~

3.

4.

. 5.

7

Remove wire from terminal TB11-30. Does engine run

OK

after

restarting?

Engine is either not pumping oil properly or oil pressure

sensor is defective.

Replace wire on TB11-30 and remove wire from TB11-31.

Does engine run OK after restarting?

6.

7.

ITEM

I

TABLE C. ENGINE SHUTS DOWN AFTER RUNNING

A

SHORT

TIME

NO.

I

Engine is either operating over temperature, temperature

sensor is defective or wire between sensor and terminal block

is grounded.

Jumper K11 terminals

6-9.

Does engine run OK?

~~ ~

8r-1

Replace relayG1 or clean contacts

6-9.

9.

I

Replace engine monitor.

YES

I

NO IPROCEDUREI

6

-

a

42

Redistribution or publication of this document, 

by any means, is strictly prohibited.

ITEM

NO.

1.

2.

TABLE

D.

SYNOPSIS

TABLE

D.

ENGINE HESITATES WHEN ATTEMPTING TO CRANK

Does engine crank as soon as run-stop switch is put into

“run” position?

Check contacts K12

(3-9)

for

failure to close

or

to make

proper contact.

ENGINE

SOMETIMES

HESITATES

BEFORE

CRANKING

5

YES NO PROCEDURE

.

I

DIRTY CONTACTS,

BAD CONNECTION

I

43

Redistribution or publication of this document, 

by any means, is strictly prohibited.

ITEM

NO.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Does starter continue to run after engine starts?

Does charge ammeter show

a

charging current while running?

TABLE E. STARTER FAILS

TO

DISENGAGE

OR

TRIES

TO

RE-ENGAGE WHILE

YES

RUNNING

I

2

4

Does voltage at starter terminal drop to zero when K13* drops out?

Check for faulty starter.

l4

Is

charging alternator belt on and driving alternator properly?

7

-

Does start disconnect relay K11 and starter protection relay

K14 pick up when engine starts?

Does voltage across K11 terminals

(A-B)

build up’to battery

voltage?

Does voltage from ground to K13’ coil terminal drop to zero

when K11 relay picks up?

11

l6

Check for faulty alternator, regulator or shorted

alternator output.

Check K12 ignition relay for dirty contact or broken wire.

-

I-

Start solenoid contacts may be welded

-

..I

replace K13’ solenoid.

~ ~

Check K11 and K14 contacts (1-7) to make sure they open when

relay picks up.

l-

Replace start disconnect relay K11 or starter protection

relay K14. Coil may be open.

l-

Does relay K12

(5-8)

close to bring battery voltage to

alternator regulator?

I

l3

,

NOTE

On

EK.

EM

and

EN

series,

start solenoid

is

mounted on the engine,

rather than the control, and

is

designated

K6.

44

Redistribution or publication of this document, 

by any means, is strictly prohibited.

TABLE

E.

SYNOPSIS

ENERGIZE

NECT RELAY

K11 AND K14

D.RlVE BELT

OFF

OR

START DISCON-

7

SLIPPING

J

K14 STARTER

PROTECTION

RELAY FAILS

STARTER

FAILS

TO

DISENGAGE

START

SOLENOID

COWTACT

FAILS

TO

OQEN

START

DISCONNECT

RELAY K11

FAILS

-

AND-c

I

-

K14 COIL,

7

.',

1

CONTACTS

FAIL TO OPEN

1-7 ON K14

I

K11 START

I

DISCONNECT

COIL OPEN

w

CONTACTS 1-7

ON K11 FAIL

TO OPEN

/G\

NOTE: Whenever a letter appears near the box, a separate procedure, corresponding

to

that letter, is given at the end

of

this section.

-

K14

starter protection relay was added to units beginning with the Specs shown below.

This relay prevents starter engagement when unit is running.

IGNITION RELAY

TO CLOSE

K12

(5-8)

FAILS

I

ALTERNATOR

OUTPUT SHORT

CIRCUITED

I

DEFECTIVE

REGULATOR

SERIES SPEC SERIES SPEC SERIES SPEC SERIES SPEC

EK-EM D DEH D DYC

B

WA F

EN

A

DEF F DYD

A

WE B

KB-KR

P

DEG D DYG WB H

DDA-MDDA

A

DFE H

(1

50-1

75

kW) A

DDB

.

A DYA C DYJ A

45

Redistribution or publication of this document, 

by any means, is strictly prohibited.

QUESTION

AND

ANSWER TROUBLESHOOTING GUIDE

-

I

‘LkM

I

TABLE

F.

ENGINE

FAILS

TO

CRANK

When switch is put into “run” position, does. engine csank?

.

:

’

Is

battery connected correctly and is voltage normal?

..

’

FOR

UNITS

WITH

5

FAULT

LAMPS

--

YES

NO PROCEDURE

2

-

3

Does ‘relay K13* (sfarfsolenoid) pick up?

Does ignition relay K12 pick up?

Is

voltage from ground terminal to center terminal of run-stop-

remote switch equal to battery voltage?

Switch is in “stop” position

or

defective.

I

I’

I

22

5

11

6

8

7

-

Does

one of the following fault lamps light?

(Choose one

of

the following:)

.

Overspeed?

..

High Engine Temperature?

Low Oil Pressure?

Overcrank?

..

~~ ~~

Remove jumper and replace engine monitor printed circuit board.

Is

voltage from ground to terminal 26 on TB11 equal to battery

voltage?

Does contact ignition relay K12 (4-7) close?

Clean socket connection. Coil may be open. Replace ignition

relay K12.

Clean relay contacts

or

replace relay and check wiring.

-

30

25

27

29

-

15 12

14 13

-

I

Is

voltage from ground terminal to ignition relay K12

terminal

“B”

equal to battery voltage?

1131g1

I

1

Jumper battery positive from center terminal of run-stop-remote

switch to terminal “B” of relay K12. Does engine crank? I10

1-1

.M

NOTE:

On

EK.

EM

and

EN

series, start solenoid relay is mounted on the engine,

rather than in the control, and is designated

K5.

46

Redistribution or publication of this document, 

by any means, is strictly prohibited.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

Does voltage from ground to starter coil terminal equal battery voltage?

Replace starter.

28.

29.

30.

31.

32.

33.

34.

23 24

-

Is

voltage from ground to K11 iterminal 1 equal to

battery voltage?

Remove lead from TB11-31. Reset by switching to “stop”,

then back to “run”. Does engine crank OK?

Inspect for bare wires and shorts to ground. Replace engine

temperature sensor.

Are relay contacts K11 (8-5) open?

I

l6

I

17

26 29

-

29 28

Clean relay contact K11 (1-7) and check wiring. Replace

relay K11 if necessary.

Replace relay and reset by switching to “stop”, then back to

“run”. Does engine crank OK?

Replace engine monitor printed circuit board.

Does voltage from ground to coil terminal

of

K13’ start

solenoid equal battery voltage?

29

-

I

l9

I

18

Stop and start engine several times. Works

OK?

Does voltage from ground to TB11-22 equal battery voltage?

I

34

-

Jumper from K13* coil terminal to K11 terminal

1.

Does relay K13* start solenoid pick up?

Replace engine monitor printed circuit board.

22

20

- -

I

Replace cycle cranker and check printed circuit connection.

Replace K13* start solenoid.

1-1-1

Check wiring between TB11 terminal 22 and starter. Some units

have an automatic resetting circuit breaker

in

this circuit.

1-1-1

Remove lead from TB11-29. Reset by switching to “stop”, then.

back to “run”. Does engine crank when switched to run?

I

31

I

29

I

Replace the lead to TB11-29 when engine is running. Does

overspeed lamp light and engine stop?

’

I

32

I

33

I

I I I

I

Check for defective overspeed switch

or

bare wires grounding

terminal TB11-29.

I-1-1

NOTE:

On

EK,

EM

and

EN

series,

start solenoid

is

mounted on the’engine,

rather than the control, and

is

designated

K6.

Redistribution or publication of this document, 

by any means, is strictly prohibited.

ITEM

NO.

1.

2.

3.

’

4.

5.

6.

7.

8.

9.

10.

11.

12.

Does relay K11 pick up after engine starts?

Jumper relay K11 contacts

(6-9)

after engine starts.

(Remove jumper after test.)

Does engine continue to

run

OK?

Replace relay Kll.

TABLE G. ENGINE SHUTS DOWN AFTER RUNNING A SHORT TIME

6

7

-

~ ~ ~~~ ~

Does low oil pressure lamp light and plant stop after running

about

12

seconds?

Does overcrank lamp light and plant stop after running about

1

minute?

Remove wire from terminal TB11-30. Reset alarm by switching

to “stop”, then back to “run”. Does engine run OK?

(Replace wire after test.)

Replace engine monitor printed circuit board.

Does charge ammeter show a charging current while running?

when engine runs?

Does battery voltage appear across K11 co,iI terminal

(A-B)

-

10

7

YES

3

5

Check .alternator and regulator output; replace if necessary.

4

-

Engine is either not pumping oil properly or oil pressure

sensor

is

defective.

l-

Check for an open circuit

in

wiring or a loose connection

from alternator

“AUX”

terminal to K11 coil circuit.

l-

TABLE

G.

SYNOPSIS

SHUTS

DOWN

NO PROCEDURE

,

I

TEMPERATURE PRESSURE

START DISCON-

NECT RELAY

K11

(6-9)

1

AEE:YF:E

1

F’%w

I I

SWITCH

.

ovER:EED,

CLOSED

I

SENSOR CLOSED SENSOR CLOSED

I

NO ALTERNATOR DEFECTIVE

OUTPUT REGULATOR

A-11 ENGINE

MONITOR

PRINTED CIRCUIT

48

Redistribution or publication of this document, 

by any means, is strictly prohibited.

I

SINGLE LAMP

ENGINE MONITOR

ENGINE

FAILS TO

CRANK

TRANSISTOR

07

FAILED,

SHORT

EMITTER TO

COLLECTOR

**

.

PATH

9-7

ON A-11

PRINTED

CIRCUIT

BOARD

K1 RELAY

CONTACT

FAILS TO

CLOSE

DIODE

CR3

OPEN

FAULT

LIGHTS AND

ENGINE

SHUTS DOWN

LOW OIL

PRESSURE

OR

HIGH

ENG. TEMP.

CIRCUIT

FAILS AFTER

APPROX. 12

SECONDS

*'*

NOTE: Whenever a letter appears near the

box,

a separate procedure, corresponding to that

letter, is given at the end

of

this section

FAULT

LIGHTS AS

SOON AS

RUN SWITCH

CLOSED

CAPACITOR

c2

SHORTED

SCR

CR6

SHORTED

EXTERNAL

ALARM

FAILS ON

ALARM

SHUTDOWN

r

CONTACT

FAILS TO

CLOSE

ON

SHUTDOWN

CIRCUIT

PATH

9-8

OPEN

**

-

With swiich in run position, check for voltage across

R9

(27-ohms).

A

voltage

of

0.5

to

1.0

will turn on

SCR

CR6.

If

voltage

is

present, remove

TB11

terminal

29.

If

voltage

is

still

present, check transistors

07

for short-emitter to collector.

Remove

TB11

terminal

30

and

31.

If

engine still shuts down, remove transistor

Q8.

If

this

prevents shutdown

-

replace

Q8.

I..

-

Redistribution or publication of this document, 

by any means, is strictly prohibited.

ENGINE

MONITOR

**

ENGINE

FAILS TO

CRANK

LIGHTS AS

SOON AS RUN

I

CIRCUIT PATH HIGH ENGINE LOW OIL OVERSPEED OVERCRA'NK

18-19 TEMPERATURE PRESSURE LAMP LAMP

OPEN LAMP LIGHTS LAMP LIGHTS LIGHTS LIGHTS

_I-

-

K1 RELAY CAPACITOR

CONTACT ON C6

A-11 FAILS TO OPEN

TRANSISTOR

Q10

SHORTED

CAPACITOR

Fl

POTENTIOMETER

PRINTED ClRCUl

BOARD FOR

CORRECT TIME

R-15 ON A-11

CAPACITOR CAPACITOR

OPEN OPEN

I

TRANSISTOR

Q13

SHORTED

..

.-

I

POTENTIOMETER

R2

ON A-11

PRINTED CIRCUIT

BOARD FOR

CORRECT TIME

CAPACITOR

TI

CAPACITOR

TI

NOTE: Whenever a letter appears near the

box,

a separate procedure, correspondjng to that

.

letter,

is

given at the end

of

this section.

'

Capacitor C1 must be discharged when engine starts to prevent an overcrank shuidown.

'

Check relay contact that connects to terminal

16

of

engine monitor.

**

-

See typical wiring diagram.

I

ENGINE

SHUTS DOWN

I

OVERCRANK

LAMP LIGHTS

AFTER APPROX.

12 SECONDS

TRANSISTOR RELAY FAILS

Q6 FAILS TO TO DISCHARGE

TURN OFF CAPACITOR C1

I-

.

Redistribution or publication of this document, 

by any means, is strictly prohibited.

ADJUSTMENTS

AND

P.ROCEDURES

If

starter fails to disengage, the engine may

drive starter to unsafe speeds that could

cause starter rotor windings to separate.

REMOVE K11

OR

K12 FROM

CONTROL

BOX

(PULL

STRAIGHT

TO

TERMINALS MARKED "A"

AND

"6"

ON BASE

OF

RELAY.

up).

cT)NNECT AN OHMMETER

OF

12

VOLT RE.LAY

IS

120

OHMS. RESISTANCE

OF

24

VOLT RELAY

IS

470

OHMS.

FIGURE

29.

TESTING

K11

AND

K12

RELAYS

When connecting battery cables, terminal will spark

if

connection

is

reversed.

Unit will not crank with reversed cables

or

loose

connections.

DC

alternator will overheat and will probably burn up.

A

reverse battery connection will show a maximum

positive charge on the DC ammeter.

On

dry charged batteries, no woltage

is

present until electrolyte

is

added.

See ooerator's manual for alternator belt tension

edjustment.

Check for voltage from starter terminals to ground.

Voltage should be present at both terminals when

solenoid is energized for cranking.

Inspect contacts for dirt particles, obstructions

or

insulating film. Clean, using low pressure com-

pressed air and bond paper. Check relay socket.

Contacts are normally closed when engine is not

running. Contacts must open when engine is running

normal.

IH1

Contacts are normally open; contacts close

for

alarm

condition only. (Overspeed switch may have to be

reset manually.)

'

IJI

Contacts may have welded closed

or

plunger may be

stuck. Remove solenoid from circuit to test for proper

operation.

[KI

Inspect printed circuit board paths that supply

voltage to relay

K12.

(Between terminals 18-19of

300-

0681;

between terminals 7-9 of

300-0679.)

[LI

Remove cycle cranker printed circuit board and

jumper terminal

2-3

to by-pass cycle cranker circuit.

In an extreme emergency, engine may be operated

without any safeties by removing engine monitor

printed circuit board and jumping terminals 7-9. (It

may be easier to jump from center contact

of

Run-

Stop switch to terminal

"B"

on

Kl-2

relay;

see

Figure

30.)

51

Redistribution or publication of this document, 

by any means, is strictly prohibited.

SWITCH

..

'.

FIGURE

30.

EMERGENCY

STARTING

ADJUSTING LOW OIL PRESSURE TIME

DELAY ON ENGINE MONITOR PRINTED

CIRCUIT BOARD

Units With Single Fault Lamp:

Potentiometer

RlO

on

A-11 printed circuit board is factory adjusted for 12-

112 seconds

(

?

2-1/2 seconds). To lengthen delay,

use a screwdriver and turn potentiometer clockwise.

To

shorten delay, turn

'

potentiometer coun-

terclockwise. Refer to Figure 31.

Units With Five Fault Lamps:

Potentiometer R15 on

A-

ll

printed circuit board is factory adjusted for 12-1/2

seconds

(2

2-1/2 seconds).

To

lengthen delay, use a

screwdriver and turn clockwise; to shorten delay, turn

counterclockwise. See Figure 32.

ADJUSTING OVERCRANK TIME DELAY

ON ENGINE MONITOR PRINTED CIRCUIT

BOARD

Units With SingleFault Lamp:

Potentiometer R4on

A-

ll

printed circuit board is factory adjusted for

75

seconds

(

r5

seconds).

To

increase delay, use a

screwdriver and turn R4 clockwise; to shorten delay,

turn counterclockwise. See Figure

31.

R4 OVERCRANK DELAY

(FACTORY SET

AT

OIL PRESSURE DELAY

(FACTORY SET AT

\

12%

SECONDS)

Units With Five Fault Lamps:

Potentiometer

H2

on A-

ll

printed circuit board is factory adjusted for

75

seconds

(

'5

seconds).

To

lengthen delay, use a

screwdriver and turn R2 clockwise; to shorten delay,

turn counterclockwise. See Figure 32.

R15

OIL

PRESSURE

AT

12%

SECONDS

DELAY- FACTORY SET

\

R2 OVERCRANK DELAY'

-FACTORY SET AT

75

SECONDS

FIGURE

31.

ADJUSTING TIME DELAYS ON SINGLE

LAYP

ENGINE

MONITOR

FIGURE

32.

ADJUSTING TIME DELAYS ON'FIVE

LAMP ENGINE MONITOR

ADJUSTING OPTIONAL CYCLE CRANKER

The optional cycle cranker

is

factory set:for 15

seconds crank time and, 10 seconds rest time. To

lengthen crank time, .turn potentiometer R4

clockwise; to shorten crank time, turn coun-

terclockwise.

To

lengthen rest time, turn poten-

tiometer R1 clockwise; to' shorten, turn coun-

terclockwise. See Figure 33.

A12 CYCLE CRANKEF

3OOC714-12V.

'

3OOC715-24V.

'

R4 CRANK TIME

FACTORY

SET

AT

15

SECONDS.,

TO INCREASE

TURN CLOCKWISE

R1 REST TIME-

FACTORY SET AT

10

SECONDS.

TO

INCREASE

TURN

CLOCKWISE

1

4

0

FIGURE

33.

OPTIONAL CYCLE CRANKER

ADWSTMENTS

52

Redistribution or publication of this document, 

by any means, is strictly prohibited.

WIRING

DIAGRAMS

61

2-41 73

612-3919

625-1007

625-0987

612-4350

612-4353

300-0679

300-0680

300-0681

300-0682

300-071

4

625-1036

61 2-5300

61 2-5301

612-5302

61 2-5303

612-5304

61 2-5305

61 2-5310

61 2-531

1

612-5312

612-5313

PAGE

100-175

kW

Brushless Exciter

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

-54

30-90

kW Static Exciter

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

-55

VR21 Brushless Exciter

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

56

VR21 Static Exciter

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

57

30-50

kW Controls

.

Single Light

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

58

30-90 kW Controls

.

Five Light

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

59

Engine Control Monitor

.

12

V

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

60

Engine Control Monitor

.

24

V

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

61

Engine Control Monitor

.

12

V

.

Five Light

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

62

Engine Control Monitor

.

24

V

.

Five Light

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

63

Cycle Cranker

.

12

V

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

64

Tap Switch

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

65

25-90 kW Brushless 15R;

515R

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

166

25-180 kW Brushless, Full Meter Panel

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

67

25-45 kW-3R Brushless 120/240

V

.

1

Phase

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

68

25-45 kW

.

3R Brushless 120/240

V

.

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Onan UR Generator Manual Pub 900 0150

900-0150 Onan UR (25 to 180KW) Generator & Controls Service Manual (10-1978) 900-0150 Onan UR (25 to 180KW) Generator & Controls Service Manual (10-1978)

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