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

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constitu-

ents are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

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 Rectier and Surge Suppressor .......................7

CHARACTERISTICS

Voltage Regulation ......................................................8

Response .....................................................................8

Voltage Stability ..........................................................8

Motor Starting .............................................................8

Short Circuit ................................................................8

Phase Rotation .............................................................8

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 Rectier Assembly ....................................11

Parts Replacement Method ...............................11 - 12

Automatic Voltage Regulator Maintenance ............. 13

SPECIFICATIONS

Generator Specications .................................. 14 - 15

Specications: DST-51-DFK ................................... 16

TROUBLESHOOTING ............................................ 17

PARTS LIST ..................................................... 18 - 29

STANDARD VOLTAGE SELECTION TABLE .........8

OPERATION - GENERATOR SET

Starting ........................................................................9

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.

OPX300K1 06/04

WIRING DIAGRAM

AVR DST-51-DFK .................................................. 30

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 rst .

priority.

Safety Rules

• To insure years of trouble-free operation, the specied maintenance is important and should be

performed.

• Insulation Resistance and Dielectric: When

measuring insulation resistance and dielectric, be

sure to disconnect the AVR and rectier.

• 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.

• 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 ammable gas (gasoline, hydrogen sulde, 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.

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 ve 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 lm for prevention of eddy currents. The

core is positioned along the internal surface of the

frame. The exciter eld 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 eld type with the main eld core made from special steel plates having superior magnetic characteristics. The eld core elements, exciter rotor, rotary rectier and cooling fan

are integral parts of the same shaft.

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 specied.

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.

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

AVR: Automatic Voltage Regulator

EX: Exciter

Si: RotatingRectier

Figure 3: For 50 Hz

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 rectied value of the sensing volt-

age with the reference voltage produced inside the AVR. Input power is obtained from the main stator.

Rectied output power to the exciter eld is controlled by switching a transistor on and off. This AVR will

control terminal voltage even if the input sine wave is distorted.

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 rectier assembly, consisting of six diodes, functions as a 3-phase full wave rectier for

the output of the exciter armature and supplies this

to the main eld. To protect the diodes from large, instantaneous voltage surges, surge absorbers are provided as part of the rotating rectier 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 (High Wye)

3 Phase Parallel Star (Low Wye)

1 Phase

60 Hz 120

1 Phase

50 Hz 110

50 Hz 415/240 400/231 380/219

50 Hz 208/120 200/115 190/110

60 Hz 120/240

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

Figure 5: Standard Voltage Table

60 Hz 480/277 460/266 440/254 416/240

60 Hz 240/139 230/133 220/127 208/120

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.

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.

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. Insufcient 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.

OPX300K1 06/04

+ 21 hidden pages

Northern Lights PX-300K1 Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual