Babson Bros. Co. SURGE 20005 User manual

PTO-POWEREDALTERNATORS
OPERATORS MANUAL
AND PARTSCATALOG
25 KW
MODEL NO. 20005
MODEL NO. 20006
BABSONBROS.CO.2100,s.YORKRD.OAKBROOK,ILLINOIS60521
BABSON BROS. CO.(CANADA)LTD. PORTCREDIT, ONTARIO
971-0005
Printed inU.S.A.
9-75
•• Replaces 3-74

INTRODUCTION
THIS OPERATOR'S MANUALCONTAINSINFORMATION
PERTAINING TOTHEOPERATIONANDMAINTENANCEOF
YOUR UNIT.
WE SUGGEST YOU KEEP THEMANUALANDTHEWIRING
DIAGRAMWHICH ACCOMPANIES EVERY UNIT AND REFER
TO ITWHENMAKINGEQUIPMENTADJUSTMENTSOR
ORDERING PARTS. ADDITIONAL COPIES ARE AVAILABLE
FOR A NOMINAL CHARGE FROMYOURDISTRIBUTOR.
WHENORDERING PARTS, REMEMBERTOINCLUDETHE
MODEL, SPECIFICATION LETTER, AND SERIAL NUMBER
LOCATED ONTHE UNIT NAMEPLATE. THISIS ESSENTIAL
TO ENSURE THE CORRECT PART IS SHIPPED TOYOU.
FOR REPAIR SERVICE, CONTACTYOURAUTHORIZED
SERVICE REPRESENTATIVE.
WARNING
TO AVOID POSSIBLE PERSONAL INJURY OR
EQUIPMENT DAMAGE, A QUALIFIED ELECTRI-
CIAN OR AN AUTHORIZED SERVICE
REPRESENTATIVE MUST PERFORM IN-
STALLATION AND ALL SERVICE.

Important SafetyPrecautions
Readandobservethesesafetyprecautionswhenusing
orworkingonelectricgenerators,enginesandrelated
equipment.Alsoreadandfollowtheliteratureprovided
withtheequipment.
Properoperationandmaintenancearecriticaltoperfor-
manceandsafety.Electricity, fuel, exhaust,movingparts
andbatteriespresenthazardsthatcancausesevere
personalinjuryordeath.
FUEL, ENGINE OIL,AND FUMES ARE
FLAMMABLE AND TOXIC
Fire, explosion,andpersonalinjurycanresultfromim-
properpractices.
•Usedengineoil,andbenzeneand lead, foundin
somegasoline,havebeenidentifiedbygovernment
agenciesascausingcancerorreproductivetoxicity.
Whenchecking,drainingoraddingfuelor oil, donot
ingest,breathethefumes,orcontactgasolineor
usedoil.
•Donotfilltankswithenginerunning.Donotsmoke
aroundthearea.Wipeupoilorfuelspills.Donot
leaveragsinenginecompartmentoronequipment.
Keepthisandsurroundingareaclean.
•Inspectfuelsystembeforeeachoperationand peri-
odicallywhilerunning.
•Equipfuelsupplywitha positivefuelshutoff.
•Donotstoreortransportequipmentwithfuelintank.
•KeepanABC-ratedfireextinguisheravailablenear
equipmentandadjacentareasforuseonalltypesof
firesexceptalcohol.
•Unlessprovidedwithequipmentornotedotherwise
ininstallationmanual,fuellinesmustbecopperor
steel, secured,freeofleaksandseparatedor
shieldedfromelectricalwiring.
•Useapproved,non-conductiveflexiblefuelhosefor
fuelconnections.Donotusecopper tubing asa flex-
ibleconnection.Itwillwork-hardenandbreak.
EXHAUST GASIS DEADLY
•Engineexhaustcontainscarbonmonoxide(CO),
anodorless,invisible,poisonousgas.Learnthe
symptomsofCOpoisoning.
•Neversleepina vessel, vehicle,orroomwitha gen-
setorenginerunningunlesstheareaisequipped
withanoperatingCOdetectorwithanaudible
alarm.
•Eachtimetheengineorgensetis started, oratleast
everyday,thoroughlyinspecttheexhaustsystem.
Shutdowntheunitandrepairleaksimmediately.
•Warning:EngineexhaustisknowntotheStateof
Californiatocausecancer,birthdefectsandother
reproductiveharm.
Make sure exhaust is properly ventilated.
•Vesselbilgemusthaveanoperatingpower
exhaust.
•Vehicleexhaustsystemmustextendbeyondve-
hicleperimeterandnotnearwindows,doorsor
vents.
•Donotuseengineorgensetcoolingairtoheatan
area.
•Donotoperateengine/gensetinenclosedarea
withoutamplefreshairventilation.
•Expelexhaustawayfromenclosed,sheltered,or
occupiedareas.
•Makesureexhaustsystemcomponentsarese-
curelyfastenedandnotwarped.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
•Donotremoveanyguardsorcoverswiththeequip-
mentrunning.
•Keephands,clothing,hair,andjewelryawayfrom
movingparts.
•Beforeperforminganymaintenance,disconnect
battery(negative[-]cablefirst)topreventacciden-
talstarting.
•Makesurefastenersandjointsaresecure.Tighten
supportsandclamps,keepguardsinpositionover
fans, drivebelts,etc.
•Ifadjustmentsmustbemadewhileequipmentis
running, useextremecautionaroundhotmanifolds
andmovingparts,etc.Wearsafetyglassesandpro-
tectiveclothing.
BATTERY GASIS EXPLOSIVE
•Wearsafetyglassesanddonotsmokewhileservic-
ingbatteries.
•Alwaysdisconnectbatterynegative(-)leadfirst
andreconnectitlast.Makesureyouconnectbattery
correctly.Adirectshortacrossbatteryterminalscan
causeanexplosion.Donotsmokewhileservicing
batteries.Hydrogengasgivenoffduringchargingis
explosive.
•Donotdisconnectorconnectbatterycablesiffuel
vaporsarepresent.Ventilatetheareathoroughly.
GSP-1
1of2

DONOT OPERATE IN FLAMMABLE AND
EXPLOSIVE ENVIRONMENTS
Flammablevapor can beignitedbyequipmentoperation
or cause a diesel enginetooverspeedandbecome diffi-
cult to stop, resultingin possible fire, explosion, severe
personal injuryanddeath.Donotoperate diesel equip-
mentwherea flammablevaporenvironmentcanbe
created byfuel spill, leak,etc., unless equipped with
anautomaticsafetydevicetoblocktheairintakeand
stop theengine.
HOT COOLANT CAN CAUSE SEVERE
PERSONAL INJURY
•Hotcoolantisunderpressure.Donotloosenthe
coolantpressurecapwhiletheengineishot.Letthe
enginecoolbeforeopeningthepressurecap.
ELECTRICAL SHOCK CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
•Donotservicecontrolpanelorenginewithunit run-
ning. Highvoltagesarepresent.Workthatmustbe
donewhileunitisrunningshouldbedoneonlyby
qualifiedservicepersonnel.
•Donotconnectthegeneratorsettothepublicutility
ortoanyotherelectricalpowersystem.Electrocu-
tioncanoccurata remotesitewherelineorequip-
mentrepairsarebeingmade.Anapprovedtransfer
switchmustbeusedifmorethanonepowersource
isconnected.
•Disconnectstartingbattery(negative[-]cablefirst)
beforeremovingprotectiveshieldsortouchingelec-
tricalequipment.Useinsulativematsplacedondry
woodplatforms.Donotwearjewelry,dampclothing
orallowskinsurfacetobedampwhenhandling
electricalequipment.
•Useinsulatedtools.Donottamperwithinterlocks.
•Followallapplicablestateandlocalelectrical
codes.Haveallelectricalinstallationsperformedby
aqualifiedlicensedelectrician.Tagopenswitches
toavoidaccidentalclosure.
•Withtransferswitches,keepcabinetclosedand
locked. Onlyauthorizedpersonnelshouldhave
cabinetoroperationalkeys.Duetoseriousshock
hazardfromhighvoltageswithincabinet,allservice
andadjustmentsmustbeperformedbyanelectri-
cianorauthorizedservicerepresentative.
Ifthecabinetmustbeopenedforanyreason:
1. MovegensetoperationswitchorStop/Auto/
Handcrankswitch(whicheverapplies)toStop.
2. Disconnectgensetbatteries(negative[-]'ead
first).
3.RemoveACpowertoautomatictransfer
switch. Ifinstructionsrequireothenvise,use
extremecautionduetoshockhazard.
MEDIUM VOLTAGE GENERATOR SETS
(601VTO15kV)
•Mediumvoltageactsdifferentlythanlowvoltage.
Specialequipmentandtrainingarerequiredtowork
onoraroundmediumvoltageequipment.Operation
andmaintenancemustbedoneonlybypersons
trainedandqualifiedtoworkonsuchdevices.Im-
properuseorprocedureswillresultinsevereper-
sonalinjuryordeath.
•Donotworkonenergizedequipment.Unauthorized
personnelmustnotbepermittednearenergized
equipment.Inducedvoltageremainsevenafter
equipmentisdisconnectedfromthepowersource.
Planmaintenancewithauthorizedpersonnelso
equipmentcanbede-energizedandsafely
grounded.
GENERAL SAFETY PRECAUTIONS
•Donotworkonequipmentwhenmentallyorphysi-
callyfatiguedorafterconsumingalcoholordrugs.
•Carefullyfollowallapplicablelocal,stateandfeder-
alcodes.
•Neversteponequipment(aswhenenteringorleav-
ingtheenginecompartment).Itcanstressand
breakunitcomponents,possiblyresultingin dan-
gerousoperatingconditionsfromleaking fuel, leak-
ingexhaustfumes,etc.
•Keepequipmentandareaclean.Oil,grease,dirt,or
stowedgearcancausefireordamageequipment
byrestrictingairflow.
•Equipmentownersandoperatorsaresolelyre-
sponsibleforoperatingequipmentsafely.Contact
yourauthorizedOnan/Cumminsdealerordistribu-
torformoreinformation.
KEEPTHISDOCUMENTNEAREQUIPMENTFOR
EASYREFERENCE.
GSP-1
2of2

GENERAL INFORMATION
INTRODUCTION
Thisinstructionbookcontainsinformationforthe
properinstallation,operationandmaintenanceof
youralternator.Wesuggestyoukeepthisbookhandy
soitcanbereferredtowhennecessary.
ALTERNATOR DESCRIPTION
These25kWmodelsarerevolving field, twobearing
(UTSeries)alternators.ACoutputvoltageis
generatedinthestatorandcontrolledbya static
exciterattachedtotheend bell. Thestaticexciter
producesDCforfieldexcitationandregulatestheAC
output.
Therotorconsistsoffourinter-connectedcoils
spacedsymmetricallyona steelshaft.Slipringson
theshafttransmitexcitationvoltagetothefieldcoils.
Theshaftissupportedatbothendsbyprelubricated
ballbearings.A centrifugalbloweronthedriveendof
thealternatordrawsairthroughthealternatorfor
cooling.
Thecompletealternatorincludesa built-inexciter
andvoltageregulator,mountingfeet,liftingeye,
mountedgearboxandsplineddriveshaftandcontrol
box.
Gear Box
Thegearboxissecuredtothealternator's-rearend
bellandhastwogears.A piniongearispressedon
andkeyedtothealternatorrotorshaft.Itmesheswith
alargerspurgearwhichispressedonandkeyedto
thegearreductionshaft.Thisshaftissupportedby
tworollerbearings.Thegearboxcapacityis1/2pint
(.24lit)ofSAE90multi-purposegearlubricant.
Control Box
Thecontrolboxincludesa voltmeter,a manualreset
circuitbreaker(alternatorprotection),one120volt,
15ampduplexreceptacle,one50amp,240voltrange
receptacleandmainoutputterminalposts.The
circuitbreakerisintheexciterinputcircuit.Itcanbe"
usedasa linedisconnectswitchwitha light load.
However,a loadtransferswitchisrequiredfor
disconnectingloadsexceeding5000wattsandisalso
recommendedforlighterloads.
TABLE OF CONTENTS
General Information 1
SafetyPrecautions2
Specifications
3
Installation4
Operation10
Service andMaintenance12
Wiring Diagrams18
Parts Catalog21
OPTIONAL ACCESSORIES
PowerTake-OffShaft:Telescoping,shielded,heavy
dutypowertake-offshafts(tumblingrods),
recommendedforusewithPTOpowered,geardrive
alternatorsprovidemaximumsafetyfortheoperator.
Thesplineduniversaljointwithsnapringtypeshield
andquickdisconnectfeature,fitsa 1-3/8-inch
(35mm)tractorPTOdrive.Telescopingpowertake-
offshaftoperatinglengthsare:minimum45inch
(1143mm),maximum60inch(1524mm);weight35
pounds.Sixsplineuniversalfor540rpmPTO.

SAFETY PRECAUTIONS
Thefollowingsymbolsinthismanualsignalpoten-
tiallydangerousconditionstotheoperatororequip-
ment.Readthismanualcarefully.Knowwhenthese
conditionscanexist.Then,takenecessarystepsto
protectpersonnelaswellasequipment.
[WARNING^Onan uses thissymbol
l——throughoutthismanualto
warnof possible serious personalinjury.
This symbolrefersto possible
TTTrr^T^rrr? This symooirefers i<
££yi!S!llequipmentdamage.
Studythefollowingsafetyprecautionscarefullyand
insistthattheybefollowedbythoseworkingwithyou
andforyou.
GUARD AGAINST ELECTRIC SHOCK
•Useextremecautionwhenworkingonelectrical
components.Highvoltagecurrentscauseinjury
ordeath.
•Followallstateandlocalelectricalcodes.Haveall
electricalinstallationsperformedbya qualified
licensedelectrician.
•Whenworkingaroundelectricalequipment,
moveslowly.
•Donotlungeafterfallingtools.
•Stopallpower,andgroundallhighvoltagepoints
beforetouchingwires.
•Makecertainthatpowercannotbeaccidentally
restored.
•Besurepowerisoffifyoumustworkon
undergroundelectricalequipment.
•Donotexamineliveequipmentwhenmentallyor
physicallyfatigued.
•Donottouchliveelectricalequipmentwhile
standingonmetalfloors,dampconcreteorother
wellgroundedsurfaces.
i
•Donothandleliveelectricalequipmentwhile
wearingdampclothing(particularlywetshoes)or
whileskinsurfacesaredamp.
•Beextracautiouswhenworkingwithalternator
duringa rain.
•Donottakeunnecessaryrisks.
•Donotworkalone.
EXHAUST GASES ARETOXIC
•Provideanadequateexhaustsystemtoproperly
expeldischargedgases.Checkexhaustsystem
regularlyforleaks.
•Besuretheunitiswellventilated.
PROTECT AGAINST MOVING PARTS
•Avoidmovingpartsoftheunit.Loosejackets,
shirtsorsleevesshouldnotbepermittedbecause
ofthedangerofbecomingcaughtinmoving
parts.
•Clothingwornbytheoperatorshouldbefairly
tightandbelted.Loosejackets,shirts,orsleeves
shouldnotbepermittedbecauseofthedangerof
gettingintomovingparts.
•Donotallowanyonetooperatethealternator
withoutproperinstructions.
•Makesureallnutsand'boltsaresecure.Keep
powershieldsandguardsinposition.
•Ifadjustmentsmustbemadewhiletheunitis
running, useextremecautionaroundmoving
parts, etc.
•Donotworkonthisequipmentwhenmentallyor
physicallyfatigued.
•Beforelubricatingalternatoralways:
1. Disengageallpower
2. Shutoffengine,andthen
3.Waituntilrotorstops.
•Itisa goodpracticetohavea fireextinguisher
nearby.Besurethattheextinguisherisproperly
maintainedandbefamiliarwithitsproperuse.
•ExtinguishersratedABCbytheNFPAareap-
propriateforallapplications.Consultthelocal
firedepartmentforthecorrecttypeofex-
tinguisherforvariousapplications.
KEEP THE UNIT ANDSURROUNDING
AREA CLEAN
•Removeoil,grease,ice,snowormaterialsthat
createslipperyconditionsaroundunit.
•Removeoilyragsandothermaterialsthatcreate
potentialfirehazards. c

SPECIFICATIONS
Phase.
Wire
RecommendedGear
MODEL MODEL
20005 20006
25,000 25,000
120/240
240*
1 3
60 60
104 60
1.0 1.0
4 4
Yes Yes
1800 1800
540 540
50 50
.. 3.32:1 3.32:1
1/2(.24lit) 1/2(.24lit)
SAE90 SAE90
460(209kg)460(209kg)
Deltawound,onephasecentertappedtodeliver120/240,singlephasepower
incapacitiesto20kW(84amperes).
240VOLT.SOAMP
ISAMPFUSE
CIRCUITBREAKER
120VOLT
CONTROLBOX
VOLTMETER
LIFTINGEYE
PTOSHAFTGUARD
ALTERNATOR
FIGURE 1. PTO-POWERED ALTERNATOR

INSTALLATION
LOCATION
Figure2 showsalternatordimensionsandbolt-hole
centersforinstallation.Selecta siteforthealternator
withthefollowingpointsinmind.
Servicing Convenience
Allowatleast24inches(610mm)ofspaceonallsides
ofthealternator.
Ventilation
Thealternatorcreatesconsiderableheatwhen
operatingunderloadconditions.Itisimportantthat
thisheatberemovedbyproperventilation.Ifthe
alternatorisinstalledinsidea smallroomorcompart-
ment,providea ventforexhaustingtheairheatedby
thealternator.Locatetheheatedairexhaustvent
abovetheinletvent.Heatedairisdischargedfromthe
drive-shaftendofthealternator.
WARNING
aredeadly!
Provideanoutletfortractorexhaustif
operatinginsidea building.Exhaustfumes
Convenience toDrivingPower
Locatethealternatorforeasyconnectiontothe
tractor.Alignthepowertakeofftothealternator.Stay
withinthelimitsofthetumblingrod.
Dusty orDampConditions
Avoiddustyordampconditionsasmuchaspossible.
Alternatorshouldbemountedundercoverorinsidea
buildingtoprotectitagainsttheweather.
Wiring Convenience
Donotlocatethealternatorina locationdifficultto
serviceorwhichwouldhavepoorventilation,tosave
afewfeetofwiring.Installthealternatorascloseto
theloadtransferswitchaspossible.
MOUNTING THE ALTERNATOR
Providea substantialmountingbaseofconcrete,
woodorsteel.Figure3 showsdimensionsof
recommendedmountingbase.Thesurfaceofthe
baseshouldbelevelsothealternatormounting
bracketswillnotbesprungwhentighteneddown.
Thetorquewillflipthealternatoroverunlesssecured
toa strongsubstructure.A narrow(30 inch, 762mm)
trailerisnotsuitableforoperation.Fortyinchhub-to-
hubminimummeasurementisrequired.
Besurethatthealternatorisproperlyalignedwiththe
drivingmechanismandthatitwillstayinalignment.
1.37(35mm)OIA-6SPLINE
PERSAEJ7I8
—7.48-H
(189mm)
_15.81
(402mm) :
35.75
(908mm) CONTROLBOX
t^
-12.94
(330mm) 12(305mm)
(3'8mm) 14
(356mm)
•ALTERNATEPOSITION
GEARBOX .65(17mm)DIA.
4MTG.HOLES
FIGURE2.INSTALLATIONOUTLINE

i
11/A*"
PTO ENDFACING
TRACTOR
III //M/z/MlW// ///A\).V\1u/////Avi l(„V
FIGURE 3.RECOMMENDED MOUNTING BASE
FIGURE 4. PORTABLE INSTALLATION

WIRINGCONNECTIONS
Forwiringconnectionswithalternatormountedona
permanentbase,connectloadwiresfromterminal
boxonalternatortoloadtransferswitch.Use
weather-protectivefittings,couplingsandwires
throughout.
Forportableuse(alternatormountedona trailer),
connectloadwiresfromterminalblockinalternator
controlboxtoanapproveddisconnectplugthatcan
beconnectedtoloadtransferswitch.Usea flexible
powercordsocablecanbeeasilywrappedupwhen
notinuse(Figure4).
Receptaclesonalternatorcontrolboxallowconnec-
tionswhenalternatorhastobemovedtothefieldora
remotelocationwherenoppwerisavailable.
SINGLE PHASE ALTERNATORS
Themostpopularsinglephaseconnectionisthe
120/240combination.Withthisconnectioneither120
or240voltscanbeusedaloneoratthesametime.
ConnectionsareshowninFigure5.Besurejumper
stripisconnectedbetweenT2andT3onterminal
block.
Tl T3
T! T3 T2
JUMPER-
r -
®
-N fe
m
UNGROUNDED
LOADWIRE-|GROUNDED
WIRE.
120V.
240V.
TERMINAL
BLOCK.
INSIDE
CONTROL
BOX
UNGROUNDED
LOADWIRE
FIGURE5. 120/240VOLT,SINGLEPHASECONNECTION
Seriousoverloadingcandamagethealter-
natorwindings.Whenusingtwoormore
singlephasecircuits,don'toverloadanyonecircuit;dividetheload
equallybetweenthem.,
Figure6 showsconnectionsforuseof120voltsonly.
BesurejumpersareconnectedbetweenT1andT3,
andT2andT4.
JUMPER—
Cj-
(D
UNGROUNDED
LOADWIRE-
(
—GROUNDED
LOADWIRE
'20V.
FIGURE6.120VOLTONLY,SINGLEPHASECONNECTION
THREE PHASE ALTERNATORS
Threephasealternatorsareconnectedasshownin
Figure?ThethreeloadwiresareconnectedtoT1,T2
andT3.Singlephase(240volts)canbeobtained
betweenanytwothree-phaseterminals.Singlephase
(120volts),canbeobtainedbetweenTlandTOorT2
andTO.TOisthegroundedterminalfor120volts.
r^TTSTZZTl.»nothree Phase
0UtvuXlsused'usab,esin9,e
^5j33^>>^ Phasepoweris2/3ofthreephasekVA.Any
overloadingabove2/3maydamagethealternatorwindings.
TERMINAL
BLOCK
INSIDE
CONTROL
BOX
A=I20VOLT
SINGLEPHASE
B^ 240VOLT
SINGLEPHASE
,THREEPHASE
240V.
FIGURE7.THREEPHASECONNECTIONS

USETHISDIA-
GRAMIFNEUTRAL
ISNOTSWITCHED
METER-l
SWITCH
ORSAFETY
BREAKER
LOAD
TRANSFER
SWITCH-
ALTERNATOR
UJ
Z
NEUTRAL•
uso:
o.
SERVICE
HEAD
DRIP
LOOPS
USETHISDIA-
GRAMIFNEUTRAL
ISSWITCHED
SWITCH
ORSAFETY
BREAKER.
CAUTION
GROUNDUNIT
PROTECTALTERNATOR
FROMWEATHER
LOAD
TRANSFER
SWITCH-"
TOMAINSWITCHOR
BREAKERATMETER
TOELECTRICALLOAD
MOT
•FUSE
"$"7" POWERRETURNSIGNAL
HOTi
LIGHTANDSWITCH
TOCIRCUITBREAKERBOX
LOAD TRANSFER SWITCHCONNECTIONS
FIGURE8.TYPICALFARMSTANDBY,SINGLEPHASE

240V
30LINE
TRANSFORMER240V.
240V.
GROUND
GROUNDING
ELECTRODE
ATPOLE
TWO-POLEFUSEOR
CIRCUITBREAKER
120/240V
\0LINETRANSFORMER
GROUNDING
ELECTRODE
ATPOLE
30MOTOR
LOADS
GROUNDING
ELECTRODE
TOMOTORFRAME
TYPICALCIRCUITSBEFOREINSTALLING
ONANPTOALTERNATOR
240V
ie LINE
TRANSFORMER
3-POLE
DOUBLETHROW
240V.
240V.
^i) FUSE
GROUND
(!) i
i_- ± —J
^•SWITCH
POWERRETURN
SIGNAL(240V.)
GROUNDINGELECTRODE
MUSTBEONUTILITYSIDE
OFFUSE.
CAUTION: CHECKALL
LOADSFORGROUNDS
WITHOHMMETERBEFORE
CONNECTINGALTERNA-
TORTOLOAO.
REMOVEALLGROUNDLINE
JUMPERS.BUTGROUND
THEFRAMEOFALL
MOTORSTOEARTH
DELTA
ALTERNATOR
2-POLE
DOUBLETHROW 120/240V
\0LINETRANSFORMER
GROUNDING
ELECTRODE
ATPOLE
SWITCH
POWERRETURN
SIGNAL(120V.)
-NEUTRAL
120/240V
LOADS
GROUNDING
ELECTRODE
TOMOTORFRAME
TYPICALCIRCUITAFTERINSTALLING
ONAN30PTOALTERNATOR
FIGURE 9.COMBINATION SINGLE AND THREEPHASE LOAD TRANSFER

INSTALLING THE LOAD TRANSFER
SWITCH
Beforeusingthealternatorforstandbypurposes,
installa DOUBLETHROWLOADTRANSFER
SWITCH. Theswitchmusthaveanampererating
largeenoughtocarrythetotalloadwhenthemain
sourceofpowerisinuse.Followthelocalelectrical
code. Theloadtransferswitchshouldalwaysbe
installedclosetothemainlineswitch,andbetween
themainlineswitchandthe load. Whenproperly
installed, theloadtransferswitchinonepositionwill
connecttheelectricalloadtothehighline.Whenthe
loadtransferswitchisthrowntotheotherposition,
theloadisfirstdisconnectedfromthemainsourceof
power,andthenconnectedtothetractoralternator.
Usingtheloadtransferswitchmakesitimpossibleto
connectthealternatortothemainsourceofpower.
Theloadlinesmustconnecttothecenterterminalsof
thetransferswitch.Thealternatorleadsandthemain
powersourceleadsmustbeconnectedatOP-endsof
theswitch.
POWER RETURN SIGNAL
Whenthegeneratorisused
applications,install isusedforemergency
apilotlightoralarmsignalto'
indicatewhenthepowerisrestoredandwhenthe
alternatorcanbedisconnected.Connecta signal
lightacrosstheregularpowerline,justaheadofthe
loadtransferswitch,Figure8.Installanon-offswitch
anda fuseforthesignallight.Whena powerfailure
occurs,snapthesignalswitchtotheONposition
beforeputtingthealternatorintooperation.Whenthe
normalpowerreturns,thesignaloperatesandthe
alternatorcanthenbedisconnected.
COMBINATION SINGLE AND THREE
PHASE LOAD TRANSFER CONNECTIONS
Twoloadtransferswitchesandadditionalwiringare
requiredtoconnectonestandbydeltaalternatorin
locationswhereseparate 1 -phaseand3-phasepower
linesnormallysupplythepower.A 3-poiedouble
throwswitchalternatelyconnectsthe240volt3-
phaselinetransformerpowerorthe240volt3-phase
alternatormotorloads.A 2-poledoublethrowswitch
alternatelyconnectsthe120/240volt 1-phase line
transformerpowerorthe 1 -phasealternatorpowerto
the120voltand240voltloads.Thealternatorand
loadtransferswitchesshouldbelocatedclosetothe
powerlinetransformerwhichcarriestheheavier load.
Separatepowerlinesmustbeinstalledtocarrypower
fromthealternatortothelighterloads,Figure9.

OPERATION
STANDBY OPERATION
Whena poweroutageoccurs,thealternatorshould
bereadytorunandtotakeovertheelectrical load.
Figure10.
1. SetuptractorandinstallPTOshaft.Depress
springloadedpinonPTOshaftatalternatorend
ofdriveshaft!SlideyokeontoalternatorPTO
shaftmakingsurespringloadedpinfallsonto
grooveonalternatorsplinedshaft.
Besureallpowershieldsandguardsare
inplaceandsecuredbeforestarting
WARNING
unit.
2. PositionalternatorcircuitbreakertoOFF.
3.Ifalternatorismountedona trailerforportable
use, connectpowerleadsbetweenreceptaclesor
alternatorand load, Figure4.
4. Throwtransferswitchtodisconnectcommercial
powerandconnectloadtoalternator,Figures8
and9.
5.TurnpowerreturnsignalON,ifonehasbeen
installed.
Toavoidinjurytotheoperator,besure
tractorrangeshiftleverisinthePARK
POWERTAKE-OFFSHOULD
BEASSTRAIGHTAS
POSSIBLE
PERMANENTBASE
WARNING FIGURE10.TRACTORCONNECTION
positionbeforedismountingtractororoperatingalternator.|nsomecasesjtmaybenecessarytochangethe
enginethrottlesettingtomaintain542rpmwhenlarge
changesintheelectricalloadaremade.
6.Starttractor,engagepowertake-off,andbring
PTOshaftspeedupto542rpm;alternatorspeed
to1800rpm.
7.Withalternatorrunning,positionalternatorcir-
cuitbreakertoONposition.At1800rpmthe
voltmeteronthealternatorcontrolboxreads
about250volts(inthegreenrangeonvoltmeter).
8.Variouselectricalloadscannowbeconnected.
Whentwoormoresinglephasecircuitsareavailable,
donotoverloadanyonecircuit—dividetheload
equallybetweenthem.
Keepthealternatorloadwithinitsnameplaterating.If
thealternatorisseriouslyoverloaded,thecircuit
breakerwillautomaticallytrip,disconnectingthe
entireelectrical load. Reducetheloadbeforethrow-
ingthecircuitbreakertotheONposition.
Ifthetractorenginehasverylittlereservepower,use
carewhenoperatingalternator.
CAUTION 2
CAUTION|
Seriousoverloadingcandamagethealter-
natorwindings!
APPLYING LOAD TO ALTERNATOR
Whenconnectingmotorloads,connectonemotorat
atimeallowingeachmotortoreachrunningspeed
beforeconnectingthenextone.Motorsrequiremuch
morecurrentforstartingthanforrunningatnormal
speed. Ifseveralmotorsarestartedatthesametime,
thetotalelectricalloadmayoverloadthealternator,
trippingthecircuitbreaker.Removetheloadbefore
throwingthecircuitbreakerbacktotheONposition.
Thisalternatorrequiresatleasta 50to55hp.
(atthePTO)engine.Ifthetractorhaslittle
reservepowerthegovernorcannotactquicklyenoughwhenthe
electricalloadis removed. Thiswillcauseasurgeofspeedandhigh
voltagewhichmaydamageanyelectricalequipmentleft con-
nected.
Whendisconnectinglargeportionsofthe load,
disconnectonepieceofequipmentata time,orfirst
disconnectthatpartoftheloadwhichwillbelefton.
Thenremovetherestofthe load. Waituntilvoltage
hasstabilized,thenreconnecttheportionoftheload
whichwillbelefton.Thealternatorvoltagewill
remainstabilizedandthetractorenginespeedwillnot
changeorsurgeenoughtocauseanydamageifthis
procedureisfollowed.
r
10

LOAD REQUIREMENTS
Addupallofthewattagerequirementsofallelectrical
equipmentthatcouldbeoperatingsimultaneously
duringa poweroutage.Taketheinformationeither
fromtypicalwattagerequirements(Table1)orfrom
thenameplateontheequipmentitself.Comparethe
totalloadrequirementswiththeoutputratingofthe
alternatortodeterminehowmotorstartingandtotal
loadwillaffectthealternator.
Checkthemotornameplatesforthehorsepower
ratingofessentialequipment:oilburnerpump,
furnaceblowermotor,circulatingheater,electric
milkingmachine,milkpump,barncleaner,feed
conveyor,silageunloader,chickbrooder,sump
pump, wellpump,poultryhouseventilatingfan,
freezer,refrigerator,washingmachine,etc.
Startmotorsoneata time,beginningwiththelargest
one. Then,afterallmotorsarerunning,therewillbe
extrapowerforotherlesscriticalequipmentsuchasa
television, airconditioner,etc.
OUTPUT VOLTAGE
Outputvoltagecanbeadjustedovera rangeof5
percentbychangingthelocationoftheslideclipon
thecontrolresistorintheexciter.Besurespeedand
frequencyarecorrectbeforemakinganadjustment.
TABLE 1.
TYPICAL WATTAGE REQUIREMENTS
MOTORS*(CAPACITORTYPE) WATTSREQUIRED MOTORS*(CAPACITORTYPE) START RUN
1/2horsepower 2800 550
3/4horsepower 4300 775
1horsepower 5500 1000
2horsepower 7130 1960
3horsepower 10350 2970
5horsepower 16660 3500
7-1/2horsepower 23000 5250
Repulsion-inductionmotorsrequirelessstartingwattage.
Splitphasemotorsrequireslightlymorestartingwattage.
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ii

SERVICE ANDMAINTENANCE
PERIODIC SERVICE AND INSPECTION
Followa definitescheduleofinspectionandser-
vicing. Makea goodvisualcheckbefore,while,and
afteralternatorisoperating;lookforlooseorbroken
leadsandbadconnections.
GEAR BOX LUBRICATION
UseonlySAE90multi-purposegearlubricant.Drain
thegearboxafterthefirst100hoursofoperationand
refillwithfreshlubricantoftherecommendedgrade.
Repeatthisprocedureeverysixmonthsthereafter,or
every100hours.Maintaintheproperoillevelbetween
changes.
Overlillingwillcausefoaming,whichcanlead
toanoilleakduetooverheating.
Removeoilfillplugattopofthecaseandoillevelplug
fromthefaceofthegearcase,Figure 11. Fillcaseuntil
oiljustbeginstoflowfromtheoillevelplughole.Gear
boxholds1/2pint(0.24lit)U.S.measure.Replace
bothplugs.
OILFILLPLUG
OILLEVEL
PLUGHOLE
DRAINPLUG
FIGURE11.GEARBOXLUBRICATION
TUMBLINGROD LUBRICATION
GreasetheuniversaljointsonthePTOshaftatleast
every25operatinghours.Underadverseconditions,
greasethejointsasrequired,possiblyevery4 to8
hours. Neveroperatethealternatorwiththeshield
removedfromthetumblingrod.
SLIP RINGS
Slipringsmustbecleanandfreeofscratchesand
burrs(donotremovethedarkbrownfilm).If
necessarytouseanabrasiveonthesliprings,useNo.
240sandpaper,neveremeryclothorotherconduc-
tingabrasives.
Ifringsaregrooved,outofround,pitted,orroughso
brushesseatpoorly,removerotorandrefinishrings
ina lathe.Removeorshieldthebearingduring
refinishing.
BEARINGS
Theballbearingsaredoublesealedandlubricatedfor
life. Iftheballbearingsbecomenoisy,worn,or
otherwisedefective,replacethem.Removetheold
ballbearingswitha gearpulleranddriveorpressnew
onesintoplace.
BRUSHES
Toexaminethebrushes,brushspringsandsliprings
removetheexcitercoverfromthealternator.Remove
thescrewsfromtherightsideoftheexciterplateand
swingtheexciterassemblyoutward.Toremovethe
brushholders,unscrewthefourmachinescrewsfrom
theend bell, Figure12.Dothisevery500hours.
Replacethebrusheswhentheyweartoabout5/16
inch(7.94mm)inlength.Orderreplacementbrushes
bypartnumber,neverbydescription;similarbrushes
mayhavedifferentelectricalcharacteristics.
WARNING ^Becarefulwhenworkingonanalternatorthat
isrunning.Electricshockhazardispresent.
Onansuggeststhatonlya qualifiedmechanicorelectrician
performthesetests.
ENDBELL
FIGURE12.BRUSHREMOVAL
12

VOLTMETER
SWITCH
'6 VOLT
AsasDRYCELLBATTERY
FIGURE13.FLASHINGTHEFIELD
FLASHING THE FIELD
Ifthereisnovoltagebuildup,removetheexciter
cover,andwiththealternatorrunning,pressthe
residualresetbutton.Iftherestillisnovoltage
buildup,flashthealternatorfield.Proceedasfollows:
1. Usinga 6 voltdrycellbattery,connectleadsas
showninFigure13(positivetoFlandnegativeto
F2).
2. ConnectvoltmeterleadstoElandE2.
3.Withthealternatorrunning,closetheswitch
momentarilytoenergizethebuildupcircuit.
Watchingthevoltmeter:
a.Ifvoltagenowbuildsupnormally,thetrouble
wasduetoa residualvoltagelossinthe field.
b.Ifvoltmeterindicateslowvoltage,theexciteris
atfault.RefertoExciterTroubleshooting,
Table2.
c.Ifthereistoomuchvoltage,andthealternator
isrunningatcorrect speed, thetroubleisinthe
exciter.
d. Ifthereisnovoltagebuildup,thealternatoris
probablyatfault.RefertoAlternator
Troubleshooting,Table3.
STATIC EXCITER TESTING
Troublesarelistedinadvancingorder,fromnooutput
voltagetoratedbutfluctuatingoutputvoltage.See
Table2.Therelationshipbetweentroubleandcause
isnotalwaysconsistentfrommodeltomodel,sothe
followinginformationmustbeusedasaguide,notan
absoluterule.The"PROCEDURE"columninTable2
indicatestheprocedureforcheckinga standard
component.Whentheword"None"appearsinthat
column, alltheinformationneededtocompletethe
checkisgiveninthecolumnheaded"CORRECTIVE
ACTION." Usea multimetertocheckcontinuity,
voltageandresistanceasindicatedinthetests.
Excitercheckingproceduresare:
1. checkingrectifiers.
2. checkingreactorsA andB.
3.checkingreactorcontrol.
4. checkingresistors.
Itisimperativethatthetestingproceduresarecompletelyun-
derstoodbytheservicemanbeforeattemptingtoperformcorrec-
tivemaintenance.
r"
13

TABLE 2. EXCITER TROUBLESHOOTING
NATURE OF TROUBLE
PROBABLE CAUSE
CORRECTIVE ACTION
PROCEDURE
Alternator will not build up
voltage.
Circuit breakerin "off" or
"tripped" position.
Reset andclose breaker. None
Openin circuit breaker.
Stopalternatorandcheckbreaker
continuity.
None
No ACpowertoStaticExciter. CheckACvoltageatt^-Ei
with thealternatoroperating.
Voltage shouldbe five percentof
theratedvoltage.Ifnot.check
continuity from Ei -ET backto
alternator.
None
Partial loss ofresidualinrotor.
With alternatoroperating,jumper
from E2to heat sinkof field
rectifier Z until voltagebegins
to build-up.Thenremove.
None
Pairof field rectifiersopen
(either W & Z orX& Y). Testrectifiersandreplaceif
defective.
(1)
Both field rectifiersX andY
shorted. Testrectifiersandreplaceif
defective.
(1)
Output voltageslowto build
up. Circuit breaker opens in
about five seconds.
Either field rectifierX orY
shorted. Testrectifiersandreplaceif
defective.
(1)
Output voltageslowto build
upand five percentbelowrated
voltageafter build up.Voltage
regulation poor.
Either field rectifier W orZ
shorted. Testrectifiersandreplaceif
defective.
(1)
Output voltageslowto build
upandhigherthanratedvoltage
after build up.
Open circuit inoneormore
control rectifier. Testrectifiersandreplaceif
defective. Checksolderedcon-
nectionstorectifier's.
(1)
Output voltageslowto build up
andtentotwentypercent above
ratedvoltageafter build up.
Openinone field rectifier.
Open circuit in gate winding
.G1-G2ofreactorA orB.
Testrectifiersandreplaceif
defective.
If field rectifiers Y andZ check
okay, checkcontinuitiesof gate
windings Gi-G2.
(1)
(2)
Output voltagebuildsupnor-,
mally but less thanrated
voltageafter build up.
Shorted winding incontrolreactor. Testcontrolreactorandreplace
if defective.
(3)
Output voltagebuildsupnor-
mally with slightly less than
ratedvoltageatnoloadand
low voltageat full load.
Compound winding Si-S2installed
backward orhasopen circuit.
Check wiring diagramforpolarity
of compoundwindingsthrough
reactors A andB and test for
continuity.
None
Output voltagebuildsupnor-
mally but20percent above
ratedvoltageafter build up.
Voltage regulationpoor.
Compound winding Si-S2installeo
backward throughonereactor(A
or B).
Check wiring diagramforpolarity
of compound winding through
reactorA orB.
None
Output voltagebuildsupnor-
mally butistwenty five percent
above ratedvoltageafter
build up.
Open circuit incontrol rectifier
bridge. , Checkcontinuity
from thejunc-
tion ofcontrolrectifiersZ and
Y tothe junction ofcontrol
rectifiers X andW.
None
Output voltagebuildsupnor-
mally but125to150percent
above ratedvoltageafter
build up.
Shorted turn in gate winding
G1-G2ofreactorA orB. Test
reactors A andB forshorted
turnsandreplaceifdefective.
(2)
r
(
14

TABLE2.EXCITERTROUBLESHOOTING(Continued)
NATURE OF TROUBLE
PROBABLE CAUSE
CORRECTIVE ACTION
PROCEDURE
Output voltage builds up nor-
Control windingCi-C2of reactor
Check circuit connections of
None
mallybut150to200 percent A orB polarized incorrectly. both reactors A andB.
above rated voltage after build
up.No regulation possible.
Shorted turn in control winding Test reactors A andB for (2)
up.No regulation possible.
Ci -C2or reactor A orB. shorted turn and replace if Ci -C2or reactor A orB.
defective.
Open in control circuit.
Check continuity fromEitoE2
None
Open in control circuit.
through control circuit.
(
V
PROCEDURE 1 — CHECKING RECTIFIERS
Disconnectoneleadfrom,orremove,eachrectifier
foritsindividualtest.
Observecarefullythemountingdirectionofanyrectifierremoved.
Itmustberemountedinitsoriginaldirection.
a.Connectanohmmeteracrossrectifier con-
tactsandobservemeterreading.
b.Reverseconnectionsandcomparenew
readingwithfirstreading.
c.Ifonereadingisconsiderablyhigherthan
otherreading,rectifiercanbeconsidered
satisfactory.However,ifbothreadingsarelow,
orifbotharehighwhichindicatesan"OPEN"
circuit,replacerectifierwitha newidentical
part.
PROCEDURE 2 — CHECKING REACTORS
A andB
Useanaccurateohmmeterwhencheckingresistancevalues.
ResistancereadingsbetweenG1andG2cannotbereadwith
accuracyona multimeter.
a.Setresistancerangeselectoronohmmeterto
properrange.
b.Isolateonegatewindingbydisconnecting
eitherendofgatewindingG1-G2fromitspoint
ofconnection.Measureresistanceingate
windingacrossG1-G2.Readingshouldbe0.66
ohms.
c.Isolateonecontrolwindingbydisconnecting
eitherleadC1orC2fromitspointofconnec-
tion. Measureresistanceincontrolwinding
acrossC1-C2.Readingshouldbe5.5ohms.
d. Connectonemeterleadtodisconnectedgate
windingleadandothermeterleadtodis-
connectedcontrolwindingleadandcheckfor
continuity.
Results:
1. REACTORISSERVICEABLEifresistanceis
within20percenteitherwayfromvaluelistedand
thereisnocontinuitybetweencontrolandgate
windings.
2. REACTORISDEFECTIVEifthereisanopen
circuitineithergateorcontrolwindings. Con-
tinuitybetweengateandcontrolwindingsisalso
anindicationofadefectivereactor.Ineithercase,
reactorshouldbereplaced.
PROCEDURE 3 — CHECKING CONTROL
REACTOR
a.Isolatecontrolreactorbydisconnectingcom-
monleadC fromitspointofconnection.
b.Carefullymeasureresistancefromthisleadto
numberedleadoncontrolreactor.Reading
shouldbe12.5ohms.
Results:
1. CONTROLREACTORISSERVICEABLEif
resistanceiswithin10percentofvaluespecified.
2. CONTROLREACTORISDEFECTIVEifno con-
tinuityisindicatedbetweencommonleadC and
thenumbered lead, indicatinganopencircuit.
PROCEDURE 4 — CHECKING RESISTORS
Theresistorsmustbecheckedwitha multimeter
adjustedtoappropriaterangeofresistances.See
StaticExciterWiringDiagramforcorrectvalues,
a.Isolateresistorbydisconnectingoneendfrom
itspointofconnectionandcarefullymeasure
resistance.
Results:
1. RESISTORISSERVICEABLEifmeasured
resistancefallswithin20percentofvalue
specifiedonwiringdiagram.
2. RESISTORISDEFECTIVEifthereisnocontinui-
tythroughtheresistor.Ifmeasuredresistance
exceedsthepercentlimitseither way, thestabiliz-
ingresistorcanbeadjustedtobringresistance
withinrequiredlimits.
15

TABLE 3. ALTERNATORTROUBLESHOOTING
NATURE OF TROUBLE
PROBABLE CAUSE
CORRECTIVE ACTION
Alternator voltage will not build
up.
Residualmagnetismgone.
Deadshortinload.
Exciter defective.
Open circuit, groundorshortin
revolving field.
Open circuit, groundorshortin
stator.
SeeparagraphonFlashingthe Field.
Inspectloadandcorrect.
SeeExciterTroubleshooting
RefertoAlternatorTesting.
RefertoAlternatorTesting.
Current unsteady butengine
speed notfluctuating. Looseconnection.
Poorbrushcontact.
Cleanandtightenconnections.
Reseat orreplace brushes. Clean
slip rings.
Frequencydropsunderheavy
load.
Low enginepower. Use adequate source ofengine
power." ~ "
Voltage dropsunderheavy
load, little frequency change.
Defective exciter. SeeExciterTroubleshooting
Alternator won'tdeliverrated
current. Unbalancedloadonlines.
Defective exciter.
Defective field windings.
Adjust load.
SeeExciterTroubleshooting
Testandreplaceifdefective.
Alternator overheats.
Overloaded.
Partial shortinload.
Poorventilation.
Reduce load.
Correctshort.
Increase ventilation.
Incorrect outputvoltage.
Voltage outputcontrolresistor
adjustedincorrectly.
Enginegovernorsetwrong speed.
Defective exciter
Adjust slidetapforproperoutput.
Checkengine speed, adjustgovernor.
SeeExciterTroubleshooting
Noiseinalternator
Defective bearing.
Collector ringsoutofround.
Replace.
Tum downinlathe.
16