Northern Lights PX-300K2 Parts Manual

OPERATOR’S

& PARTS

MANUAL

PX-300K2 SERIES A.C. GENERATORS

For Generator Models:

PX-308K2, PX309K2, PX-310K2, PX-312K2, PX-316K2, PX-320K2, PX-325K2, and PX-332K2

— 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.: OPX300K2 08/07

OPERATOR’S & PARTS MANUAL

PX-300K2 SERIES A.C. GENERATORS

For Generator Models:

PX-308K2, PX-309K2, PX-310K2, PX-312K2, PX-316K2, PX-320K2, PX-325K2, and PX-332K2

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

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

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

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

SPECIFICATIONS

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

Voltage Regulator Specications ............................. 16

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

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

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.

OPX300K2 08/07

PARTS LIST .................................................... 18 - 24

WIRING DIAGRAM

AVR DST-100-2FAK ............................................. 25

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-300K2 Series AC generators are based on

BS 4999 part 20 and IEC34-5, IP21.

OPX300K2 08/07

Model and Serial Numbers

GENERATOR END MODEL NUMBERS

Generator Set Model No ................ PXK Generator Model

M and NL753W2 ..........................................PX-308K2

M and NL773LW2 / LW3 ..............................PX-309K2

M and NL843JW ..........................................PX-310K2

M and NL843NW2 / NW3 .............................PX-312K2

M844W2 / W3 ..............................................PX-316K2

M844LW2 / LW3 ..........................................PX-320K2

M864W / W3 ................................................PX-325K2

M944W / W3 ................................................PX-332K2

M984W .........................................................PX-332K2

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

OPX300K2 08/07

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.

OPX300K2 08/07

Performance and Function

EXCITATION SYSTEM

The excitation system of the PX-300K Series generator 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-300K2 Block Diagram

AUTOMATIC VOLTAGE REGULATOR (AVR)

The PX-300K2 Series generators use a DST-100-2FAK AVR. This is a compact voltage regulator for generators with an output up to 50kW. The AVR can be used in 120V single phase applications and is installed inside the generator junction box.

The AVR obtains sensing input from the main stator coils

and compares the rectied value of the sensing voltage 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.

OPX300K2 08/07

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-300K2 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-300K2 Series 1-phase 4-wire and 3-phase 12-wire AC

generators. See Page 23.

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

OPX300K2 08/07

+ 17 hidden pages