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