Northern Lights PX-300K1 Parts Manual

OPERATOR’S

& PARTS

MANUAL

PX-300K1 SERIES A.C. GENERATORS

For Generator Models:

PX-308K1, PX309K1, PX-310K1, PX-312K1, PX-316K1,

PX-320K1, PX-325K1, and PX-332K1

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Northern Lights

4420 14th Avenue N.W.

Seattle, WA 98107

Tel: (206) 789-3880

Fax: (206) 782-5455

Printed in U.S.A.

PART NO.: OPX300K1 06/04

OPERATOR’S &

PARTS MANUAL

PX-300K1 SERIES A.C. GENERATORS

For Generator Models:

PX-308K1, PX-309K1, PX-310K1, PX-312K1,

PX-316K1, PX-320K1, PX-325K1, and PX-332K1

Read this manual thoroughly before starting your equipment.

This manual contains information needed to operate your set correctly and safely.

Table of Contents

Introduction.......................................................................	4
Safety Rules......................................................................	4
Models and Serial Numbers ............................................	5
Mechanical Construction..................................................	6
Initial Inspection and Coupling
Initial Inspection..........................................................	6
Coupling with Prime Mover........................................	6
Grounding....................................................................	6
Performance and Function
Excitation System........................................................	7
Automatic Voltage Regulator (AVR)...........................	7
Under Speed Protection...............................................	7
Rotary Rectifier and Surge Suppressor........................	7
Characteristics
Voltage Regulation.......................................................	8
Response......................................................................	8
Voltage Stability...........................................................	8
Motor Starting..............................................................	8
Short Circuit.................................................................	8
Phase Rotation..............................................................	8
Standard voltage selection table..........	8
Operation - Generator SET
Starting.........................................................................	9

Voltage Adjustment......................................................	9
Running........................................................................	9
Stopping.......................................................................	9
Operation - Voltage Regulator
Safety Rules..............................................................	10
Operation...................................................................	10
Adjustment................................................................	10
Maintenance
Bearing Inspection.....................................................	11
Insulation Resistance Measurement Method.............	11
Rotating Rectifier Assembly .....................................	11
Parts Replacement Method................................	11 - 12
Automatic Voltage Regulator Maintenance..............	13
Specifications
Generator Specifications...................................	14 - 15
Specifications: DST-51-DFK....................................	16
TroubleshootinG .............................................	17
Parts list ......................................................	18 - 29
Wiring diagram
AVR DST-51-DFK ...................................................	30

Proprietary Information

This publication is the property of Alaska Diesel Electric, Inc.

It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric, Inc. © Alaska Diesel Electric, Inc. 2004. All rights reserved. Litho U.S.A. Publication number OPX300K1 06/04

OPX300K1 06/04

Introduction

This manual describes procedures for operation, maintenance, inspection and adjustment. It will help the operator realize peak performance through effective, economical and safe operation.

•Read this manual carefully BEFORE operating the generator.

•Study this manual until proper operation becomes personal habit.

•Operation, inspection, and maintenance should be carried out carefully. Safety must be given the first .. priority.

Safety Rules

•To insure years of trouble-free operation, the specified maintenance is important and should be performed.

•Electrical equipment should always be kept clean. Oil, dust, moisture and salt are all harmful to generators.

•Be careful with electricity. Do not touch rotating parts.

•Ambient Environmental Conditions

a)Gas: Do not use in an environment of corrosive or flammable gas (gasoline, hydrogen sulfide, methane gas, etc.)

b)Sandy Dust: Do not use equipment in places with excessive sand and dust.

c)Humidity: Do not use in very humid environments for long periods of time.

d)Salt/Seawater: Protect your generator from exposure to salt, water, and water vapor.

•Insulation Resistance and Dielectric: When measuring insulation resistance and dielectric, be sure to disconnect the AVR and rectifier.

•Be sure that the regulator is shut off by switching the

CPR (circuit breaker) on the AVR to the off position when the unit is running at less than rated speed, or when the unit is to be run but no power generation is required.

•Before starting your generator, be sure operating conditions are safe.

•Ventilation: When selecting the installation site, be sure that the area is well ventilated and that ambient temperature does not exceed 40°C. If the temperaure exceeds 40°C, de-rate the generator output as per “data sheet” for operation.

•Be sure to provide generator with cover and protection when operating outside.

PX-300K Series AC generators are based on BS 4999 part 20 and IEC34-5, IP21.

OPX300K1 06/04

Model and Serial Numbers

GENERATOR END MODEL NUMBERS

Generator Set Model No.................	PXK Generator Model
M and NL753K .............................................	PX-308K1
M and NL773L..............................................	PX-309K1
M and NL843JK............................................	PX-310K1
M and NL843NK ..........................................	PX-312K1
M844K...........................................................	PX-316K1
M844LK ........................................................	PX-320K1
M864...............................................................	PX-325K
M984.............................................................	PX-332K1

SERIAL NUMBERS

•When referencing Alaska Diesel Electric equipment by serial number, it is important to differentiate between the engine, generator end and generator set serial numbers.

•The engine serial number is either on a metal tag or stamped directly into the engine block.

•The generator END serial number is on a metal tag attached to the generator end.

•The generator SET serial number is on a separate metal tag attached to the generator end. It may be a five by one inch tag installed directly below the generator end tag. Or, it may look like the illustrations below. Please use the generator SET number in correspondence or when ordering parts.

Figure 1: Generator Set Serial Number Plate

OPX300K1 06/04

Mechanical Construction

STATOR

The stator frame is fabricated from rolled steel. The round construction provides rigidity and strength to resist excessive mechanical shocks. The stator core is made of high quality silicon steel plates coated with insulating film for prevention of eddy currents. The core is positioned along the internal surface of the frame. The exciter field core is made of special steel plates capable of retaining a high degree of residual magnetism.

BEARINGS

The long-life ball bearings are sealed to prevent grease from escaping and to keep dirt out.

ROTOR

The rotor shaft is made of high quality carbon steel, and is designed and manufactured to be mechanically durable. The rotor is a salient revolving field type with the main field core made from special steel plates having superior magnetic characteristics. The field core elements, exciter rotor, rotary rectifier and cooling fan are integral parts of the same shaft.

VENTILATION

Cooling is provided by the cooling fan of the rotor through suction ports and exhausted through outlet ports. Every machine conforms to the cooling code

ICO1 of BS.

COUPLING BOLT SPECIFICATIONS

The Coupling Bolt Torque for all PX-300K series models is 32 lbs.ft.

COUPLING WITH PRIME MOVER

PX-300K series single bearing generators make centering and direct coupling easy. Shim the generator legs as needed for proper leveling. Coupling bolt size and torque will vary according to the engine manufacturer. The bolt torque for attaching the coupling plates to the generator rotor are shown in COUPLING BOLT SPECIFICaTIONS, above.

GROUNDING

The generator frame should be electrically grounded to the base of the generator set. The neutral is not grounded to the frame unless specified.

Initial Inspection and Coupling

INITIAL INSPECTION

If the generator is stored for long periods of time, store in a clean, dry, ventilated area. After extensive storage time, check the resistance of the coil insulation in accordance with this manual (see MAINTENANCE, page 9) before operation. Be sure there are no abnormal sounds or any overheating during operation. It is recommended that standby generators utilize a space heater (optional) in order to keep the coil insulation in optimum working condition.

OPX300K1 06/04

Performance and Function

EXCITATION SYSTEM

The excitation system of the PX-300K Series genera tor uses an Automatic Voltage Regulator (AVR) which uses a portion of the output power to supply controlled

DC power to the exciter field (EX) as show in Figure 2. When DC power is supplied to the exciter field, output from the exciter armature is rectified by a 3-phase bridge rotary rectifier (Si) and supplied to the main field coils. See Figure 2.

AVR: Automatic Voltage

Regulator

EX: Exciter

Si: Rotating Rectifier

Figure 2: PX-300K Block Diagram

AUTOMATIC VOLTAGE REGULATOR (AVR)

The PX-300K Series generators use a DST-51 AVR. This is a compact voltage regulator for generators with an output up to 50kW. The DST-51 can be used in 120V single phase applications and is installed inside the generator junction box.

The DST-51 obtains sensing input from the main stator coils and compares the rectified value of the sensing voltage with the reference voltage produced inside the AVR. Input power is obtained from the main stator.

Rectified output power to the exciter field is controlled by switching a transistor on and off. This AVR will control terminal voltage even if the input sine wave is distorted.

Figure 3: For 50 Hz

Figure 4: For 60 Hz

Under speed PROTECTION

A frequency sensing circuit is built into the AVR. When the generator speed drops to 90% of rated speed this circuit protects the AVR by reducing the voltage in proportion to the decrease in engine speed. In addition, when the generator is hit with a

rapid overload, this circuit will lower the voltage to protect the engine. See Figures 3 & 4.

ROTARY RECTIFIER AND SURGE SUPPRESSOR

The rotary rectifier assembly, consisting of six diodes, functions as a 3-phase full wave rectifier for the output of the exciter armature and supplies this to the main field. To protect the diodes from large, instantaneous voltage surges, surge absorbers are provided as part of the rotating rectifier assembly.

OPX300K1 06/04

Characteristics

VOLTAGE REGULATION

Generator terminal voltage regulation is within ±1% of the rated voltage in lagging power factor. 1.0 to 0.8, when the load is varied gradually from no load to full load. This value includes the temperature drift and rotating variation.

RESPONSE

After supplying a load instantaneously, the generator voltage should be restored to the steady condition in accordance with

BS4999 Part 40, grade VR2.11 to VR2.23.

VOLTAGE STABILITY

In constant load and engine speed, voltage stability remains 0.25% of the rated voltage.

MOTOR STARTING

The generator is capable of enduring up to 300% of the rated current for 10 seconds at power factor of 0.

SHORT CIRCUIT

PX-300K Series AC generators can provide over 300% of the rated current for a short period of time, with an excitation support system (optional).

PHASE ROTATION

Phase sequence is T1-T2-T3 (U-V-W, A-B-C) with a counterclockwise rotation of generator viewed from the anti-coupling side.

Standard Voltage Tables and Connection Diagrams

Standard voltage selection table and connection diagram for PX-300K Series 1-phase 4-wire and 3-phase 12-wire AC generators. See Page 24.

Winding Connection	Frequency			Voltages

3 Phase Series Star	60 Hz	480/277	460/266		440/254	416/240
(High Wye)	50 Hz	415/240	400/231		380/219

3 Phase Parallel Star	60 Hz	240/139	230/133		220/127	208/120
(Low Wye)	50 Hz	208/120	200/115		190/110

1 Phase	60 Hz	120/240
1 Phase	60 Hz	120
	60 Hz	120

1 Phase	50 Hz	100/200	110/220		115/230	120/240
1 Phase	50 Hz	110
	50 Hz	110

Figure 5: Standard Voltage Table

OPX300K1 06/04

Operation – Generator Set

STARTING

Before starting generator, check the following:

1.Make sure that the wiring is correct.

2.Be sure that nothing is blocking the air inlet/ outlet.

3.Make sure that the inside of the generator is clean.

4.Be sure the main line circuit breaker is switched OFF.

After checking each of the above, start the genertor in the following procedure:

1.Start engine in accordance with instructions in the

Operator’s Manual. Be sure there is no abnormal sound or vibration.

2.The voltage will rise due to the increase in generator speed. After making sure that each interphase voltage is balanced, set the voltage and frequency to the rated level. Be sure the CPR switch is “ON”. The voltage will not rise with CPR “OFF”.

3.After running the generator without load, switch the circuit breaker ON to start the load operation.

VOLTAGE ADJUSTMENT

The generator has been adjusted to obtain optimum voltage at the factory. If the voltage is different, adjust the voltage with the Voltage Adjust provided on the AVR.

RUNNING

Check the following while operating the generator:

1.Abnormal vibration and/or sound

2.Load

3.Environment:

Keep the air inlet/outlet clean and clear for optimum cooling. Insufficient cooling causes overheating of the generator.

Note: When a 3-phase generator is used at single phase load, each phase current should be balanced and should not exceed 50% of the rated current. In addition, allowable unbalanced load is listed on the Data Sheet.

STOPPING

After putting the running generator in a no-load condition by removing the generator load, stop the engine in accordance with the Engine Manual.

OPX300K1 06/04

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