Markon SAWAFUJI BL105A Installation and user guide

Publication No. M2/0/025ED6E
March 2000
Installation, Service
& Maintenance Manual
for models
BL, NL, SL, TL, CL
105A, 105B, 105C, 105D, 105E, 105F, 105G

SAFETY PRECAUTIONS
Before operating the generating set, read the generating set operation manual and
this generator manual and become familiar with it and the equipment.
SAFE AND EFFICIENT OPERATION CAN ONLY BE ACHIEVED IF THE
EQUIPMENT IS CORRECTLY OPERATED AND MAINTAINED.
Many accidents occur because of failure to follow fundamental rules and
precautions.
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.
lEnsure installation meets all applicable safety and local electrical codes. Have
all installations performed by a qualified electrician.
lDo not operate the generator with protective covers, access covers or terminal
box covers removed.
lDisable engine starting circuits before carrying out maintenance.
lDisable closing circuits and/or place warning notices on any circuit breakers
normally used for connection to the mains or other generators, to avoid
accidental closure.
Observe all IMPORTANT, CAUTION, WARNING, and DANGER notices,
defined as:
Important ! Important refers to hazard or unsafe method or practice
which can result in product damage or related equipment
damage.
Caution ! Caution refers to hazard or unsafe method or practice
which can result in product damage or personal injury.
Warning refers to a hazard or unsafe method or practice
which CAN result in severe personal injury or possible
death.
Danger refers to immediate hazards which WILL result in
severe personal injury or death.
Due to our policy of continuous improvement, details in this manual which were correct at time of printing,
may now be due for amendment. Information included must therefore not be regarded as binding.
Warning !
Danger !

FOREWORD
The function of this book is to provide the user of the Markon generator with an
understanding of the principles of operation, the criteria for which the generator
has been designed, and the installation and maintenance procedures.
Each generator has been so designed, constructed, tested and examined as to
ensure that it will be safe and without risk to health when properly used. Machine
outputs etc. are shown on the nameplate attached to the frame.
Specific areas where the lack of care or use of incorrect procedures could lead to
equipment damage and/or personal injury are highlighted, with IMPORTANT,
CAUTION, WARNING and/or DANGER notes, and it is IMPORTANT that the
contents of this book are read and understood before proceeding to fit or use the
generator.
Any persons carrying out operating and maintenance procedures should wear
any appropriate protective clothing and equipment, use the correct tools and
observe any regulations contained in, or made pursuant, to the Health and Safety
at Work Act 1974 or any other relevant statute.
The Service, Sales and technical staff of Markon are always ready to assist and
reference to the company for advice is welcomed.
EC DECLARATION OF INCORPORATION
All Markon generators are supplied
with a declaration of incorporation
for the relevant EC legislation,
typically in the form of a label as below.
Under the EC Machinery Directive
section 1.7.4. It is the responsibility
of the generator set builder to
ensure the generator serial and
identity numbers are clearly
displayed in the space provided
inside the back cover of this book.
1
Markon generators are manufactured to Q.A. procedures
conforming to BS EN ISO 9002.
IN ACCORDANCE WITH THE SUPPLY OF MACHINERY (SAFETY) REGULATIONS 1992
AND THE SUPPLY OF MACHINERY (SAFETY) (AMENDMENT) REGULATIONS 1994
IMPLEMENTING THE EC MACHINERY DIRECTIVE 89/392/EEC AS AMENDED BY 91/368/EEC.
THIS WAS
MANUFACTURED BY
BARNACK ROAD STAMFORD LINCOLNSHIRE ENGLAND
STAMFORD A.C GENERATOR
NEWAGE INTERNATIONAL LTD
THIS COMPONENT MACHINERY MUST NOT BE PUT INTO SERVICE UNTIL THE
MACHINERY INTO WHICH IT IS TO BE INCORPORATED HAS BEEN DECLARED IN
CONFORMITY WITH THE PROVISIONS OF THE SUPPLY OF MACHINERY (SAFETY)
REGULATIONS 1992/MACHINERY DIRECTIVE.
OR AND ON BEHALF OF
NAME:
POSITION:
SIGNATURE:
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ELECTROMAGNETIC COMPATIBILITY
Additional Information
European Union
Council Directive 89/336/EEC
For installations within the European Union, electrical products must meet the
requirements of the above directive, and Markon ac generators are supplied on the
basis that:
lThey are to be used for power-generation or related function.
lThey are to be applied in one of the following environments:
Portable (open construction - temporary site supply)
Portable (enclosed - temporary site supply)
Containerised (temporary or permanent site supply)
Ship-borne below decks (marine auxiliary power)
Commercial vehicle (road transport / refrigeration etc)
Rail transport (auxiliary power)
Industrial vehicle (earthmoving, cranes etc)
Fixed installation (industrial - factory / process plant)
Fixed installation (residential, commercial and light industrial - home / office /
health)
Energy management (Combined heat and power and/or peak lopping)
Alternative energy schemes
lThe standard generators are designed to meet the industrial emissions and
immunity standards. Where the generating set is required to meet the
residential, commercial and light industrial emissions and immunity standards
then reference should be made to the factory.
lThe installation earthing scheme involves connection of the generator frame
to the site protective earth conductor using a minimum practical lead length.
lMaintenance and servicing with anything other than factory supplied or
authorised parts will invalidate any Newage liability for EMC compliance.
2

CONTENTS
SECTION 1 INTRODUCTION 5
1.1 BL105 Generator 5
1.2 NL105 Generator 6
1.3 SL105 Generator 7
1.4 TL105 Generator 8
1.5 CL105 Generator 9
SECTION 2 APPLICATION 10
2.1 Standards 10
2.2 Airflow 10
2.3 Direction Of Rotation 10
2.4 Drive Arrangement 10
2.4.1 Road Vehicle Generators 10
2.5 Bearings 11
2.5.1 Road Vehicle Generators 11
2.6 Earthing 11
2.7 Loading 11
SECTION 3 INSTALLATION 12
3.1 Safety Warnings 12
3.2 Inspection 12
3.3 Coupling to Engine 12
3.4 Electrical Connections 12
3.5 Voltage Selection 14
3.6 Voltage Adjustment For The SL105 - AVR MD1C 15
SECTION 4 SERVICE & MAINTENANCE 17
4.1 General 17
4.2 Insulation Resistance Check 18
4.3 Fault Finding 18
4.4 Residual Voltage/Field Flashing 24
4.4.1 Linear Reactor Check 25
4.4.2 Current Transformer Check 25
4.5 Resistance Charts 26
SECTION 5 ASSEMBLY/DISMANTLING PROCEDURE 28
5.1 Assembling Generator To Engine 28
5.2 Dismantling Stator Frame Assembly 29
5.3 Withdrawing Rotor From Engine 29
5.4 Removal/Replacement Of Capacitor - BL Models 29
3

CONTENTS
5.5 Removal/Replacement Of Diode
Varistor Assembly - BL Models 29
5.6 Removal/Replacement Of AVR - SL Models 30
5.7 Removal/Replacement Of AVR
- TL Models 30
5.8 Removal/Replacement Of Diode Bridge
- SL and NL Models 30
5.9 Removal/Replacement Of Choke
- SL and NL Models 31
5.10 Removal/Replacement Of Radio Interference
Suppressor (RIS) -SL and TL Models 31
5.11 Removal/Replacement Of Bearing 31
5.12 Removal/Replacement Of Brushes/Brush Calliper
Assembly - CL Models 32
5.13 Removal/Replacement Of Brushes/Brushbox
Assembly - SL, TL, & NL Models 32
5.14 Torque Settings 32
SECTION 6 SPARES AND AFTER SALES SERVICE 33
6.1 Recommended Spares 33
6.2 After Sales Service 34
BL105 Parts Identification - Single Bearing 35
Typical BL105 Generator - Single Bearing 36
NL105 Parts Identification 37
Typical NL105 Generator 38
SL105 Parts Identification 39
Typical SL105 Generator 40
BL105 Parts Identification - Two Bearing 41
Typical BL105 Generator - Two Bearing 42
TL105 Parts Identification 43
Typical TL105 Generator 44
CL105 Parts Identification 45
Typical CL105 Generator 46
Warranty Details Inside Backcover
4

SECTION 1
INTRODUCTION
Models covered by this manual are designated as follows:-
BL105A NL105E SL105A TL105E CL105G
BL105B NL105F SL105B TL105F
BL105C NL105G SL105C TL105G
BL105D SL105D
BL105E SL105E
BL105F SL105F
BL105G SL105G
1.1 BL105 GENERATOR
The BL105 is a self exciting brushless generator, designed to operate with single
phase loads at or near a power factor of 1.0. The principle of operation is
schematically represented in the diagram below. The auxiliary winding, in
conjunction with the excitation capacitor, provides excitation by inducing current in
the rotor (field) windings which is rectified to produce a direct current field. The
main stator winding is designed for series/parallel connection to give a dual voltage
output and no voltage adjustment is possible.
5
Rotor Windings
Main Stator Windin
g
s
Auxiliary Windings
Excitation
Capacitor

6
1.2 NL105 GENERATOR
The NL 105 generator is of self-exciting rotating field design.
The principle of operation is schematically represented in the diagram below. The
auxiliary winding provides excitation power through a choke and rectifier into the
rotating field via sliprings.
The main stator winding is designed for series/parallel connection to give a dual
voltage output primarily designed for unity power factor loads.
Some NL 105 generators are supplied with a d.c. auxiliary output winding and are
schematically represented in the diagram below.
Auxilary
Winding
Rectifier
+ ve
- ve
dc
Rotor
Main Stator Windings
Windings
Rectifier
Auxiliary
Windings
Choke

1.3 SL105 GENERATOR
The SL105 generator is of self-exciting, automatic voltage regulator (AVR)
controlled, rotating field design. It is designed to operate with close regulation when
supplying single phase loads. Primarily designed for loads at or near unity power
factor, it has a capability of operation at 0.8 power factor.
The principle of operation is schematically represented in the diagram below. The
auxiliary winding provides excitation power through a choke and rectifier into the
rotating field via sliprings.
The AVR diverts excess excitation at low loads to maintain the main stator winding
output voltage within close limits.
The main stator winding is designed for series/parallel connection to give a dual
voltage output with voltage adjustment.
The SL105 generator may be supplied without a divertor AVR for specific
applications. For these generators the instructions given in this manual for the
SL105 generator apply, but references to the AVR or its control should be ignored.
7
Rotor
Main Stator Windings
AVR
Windings
Rectifier
Auxiliary
Windings
Choke

1.4 TL105 GENERATOR
The TL105 is a self-exciting, automatic voltage regulator (AVR) controlled rotating
field three phase generator. It is designed to operate with close voltage regulation
when supplying balanced and unbalanced loads at power factors between 0.8
and 1.0.
The principle of operation is schematically represented in the block diagram
below.
The aux stator winding provides excitation power through the AVR which controls
the level of excitation passed via the sliprings into the field winding (rotor).
The AVR senses the voltage output of the main stator winding and controls the
excitation at varying loads to maintain the main stator winding output voltage
within close limits.
Note: AVR tapping point varies depending upon generator output voltage, the AVR
input voltage must be in the range of 100 - 120v.
8
Stator Windings
AVR
Rotor Windings
Brushes/Sliprings
N
W
V
U
AUX

1.5 CL105 GENERATOR
The CL105 is a self-exciting three phase generator having current compounded
excitation control. It is specifically designed for use in vehicle refrigeration
equipment and is capable of operation over a wide speed range, i.e. 1800 to 3600
r.p.m., delivering an output voltage of 250 to 500 volts at frequencies of 30 to 60 Hz
respectively.
The excitation control, which may be generator mounted or remote, consists of a
linear reactor (LR) providing the no-load excitation component, and a current
transformer (CT) providing the increased excitation required when the generator is
loaded.
It is the frequency sensitive nature of the LR and CT that enables virtually
proportional control of output voltage with respect to speed (or Hz).
The principle of operation is schematically represented below.
The elements of excitation power derived from the LR and CT are vectorially
summed, rectified and fed via sliprings into the main field (rotor) winding, such that
the generator output voltage is maintained within limits with varying load.
9

SECTION 2
APPLICATION
2.1 STANDARDS
The generator has been designed to comply with the requirements of most
International Standards and is suitable for operation in an ambient temperature of
40°C maximum.
2.2 AIRFLOW
The generator should be positioned so that the cooling air may enter and leave the
machine without restriction. Inadequate ventilation to the generator will lead to
serious overheating and subsequent damage to windings.
2.3 DIRECTION OF ROTATION
The generator is suitable for either direction of rotation.
2.4 DRIVE ARRANGEMENT
All models are designed to suit engines having a drive shaft/crankcase mounting
arrangement to SAE J609a Flange A Extension 5 (3/4" Taper) or Flange B
Extension 6 (7/8" Taper) depending upon output kW.
Two bearing drive arrangements are available with a 22mm diameter 45.5mm long
shaft extension.
The minimum pulley pitch diameter to be used for belt driven application is 118mm
with a maximum side loading of 700N, to achieve full output and a reasonable
bearing life. If smaller pulleys are required refer to factory for maximum side load
and bearing life. Where single bearing to two bearing conversion parts have been
supplied fitting instructions are provided with the kit.
2.4.1 ROAD VEHICLE GENERATORS
A special two bearing arrangement is used for this application to accomodate high
bearing loadings and vibration. The standard 22mm diameter, 45.5mm long shaft
extension is used.
The minimum pulley pitch diameter to be used is 118mm with a maximum side
loading of 1000N.
10

2.5 BEARINGS
The bearing is preloaded and sealed for life and should require no further attention.
Care must be taken to ensure that the anti-creep circlip is correctly located in the
groove before mating with the end bell bearing housing, i.e. the bump on the circlip
is in the deepest part of the groove.
On two bearing machines the drive end bearing is a standard ball bearing sealed
for life.
2.5.1 ROAD VEHICLE GENERATORS
These generators are fitted with larger bearings than standard. The drive end
bearing is clamped in the drive end bracket and the non drive end bearing is fitted
in a steel housing with an 'O' ring to prevent turning.
2.6 EARTHING
The generator is manufactured and delivered with the stator windings completely
isolated from the frame; a suitable earth terminal is provided on the bearing support
for bonding to the generating set frame.
Access to the earth terminal is gained by removal of the end cover.
2.7 LOADING
The generators are suitable for supplying, continuously, most types of load with a
total load current not exceeding the current quoted on the nameplate. Two points
should be noted however:
1. Engine Power.
The generator set output may be limited by the horsepower rating of the
engine. As a guide the engine has to supply approximately two horsepower
for each 1000 watts (1kW) of electrical load. Refer to factory for specific
generator efficiency.
2. Electric Motor Loads.
The current taken by a motor on full load is shown on its nameplate, but it
will be several times this value at the instant of starting even when there is
no load on the motor. The actual value depends on the type of motor and
the starting current should be checked before attempting to decide the size
of generator required.
When starting a motor the total current including any other load should not exceed
twice the full-load current of the generator on BL105 models. The total current
should not exceed 1.5 times the full-load current on SL105 and TL105 models.
The total current during motor starting on CL models should not exceed 3 times the
generator full load current. In this case the total kW during the starting period may
exceed the generator rated kW and it is essential to ensure that the selected
engine is capable of providing the kW required. As a guide the engine rating
should be approximately 3 HP for each 1000 watts (1kW) of the starting kW. Refer
to the factory for specific applications. 11

3.1 SAFETY WARNINGS
The generator is supplied as a component part for
installation on a generating set and it is the
responsibility of the generating set builder to fit the
safety warning label, illustrated right, which is
supplied packaged with this manual. The label
should be attached to the generator in a position
where it is clearly visible on the generating set.
3.2 INSPECTION
When the equipment is received all details,
especially the Serial Number of the generator,
should be checked against the Advice Note.
Carefully remove all dust and packing materials.
In the event of any part being damaged or
missing, this should be reported at once to the
manufacturer and the transport company.
Always quote the Serial Number
on correspondence with the manufacturer.
When nameplates are supplied packaged with the machine, but not fitted, it is the
responsibility of the installer to fit the nameplate to the generator.
3.3 COUPLING TO ENGINE
Refer to Assembly/Dismantling Procedure. SECTION 5.
3.4 ELECTRICAL CONNECTIONS
The generators are supplied from the factory with flying leads from the main stator
windings. The BL105, NL105 & SL105 may be permanently connected or switched
in the generator set outlet box to obtain the required output voltage(s). The
installer must provide necessary overload protection. The windings are not bonded
to the machine frame and it is the responsibility of the installer to provide suitable
bonding to earth. Reference should be made to relevant site or safety regulations.
Note that the point of earthing the stator winding is at the discretion of the installer.
Normally a 230 volt 2 wire output will be earthed at one end giving a maximum of
230 volts to earth (0r 115 volts in parallel mode).
SECTION 3
INSTALLATION
12

A 110 volt 2 wire output will normally be earthed at the centre tap (series
connection point) giving a maximum of 55 volts to earth.
The standard TL105 arrangement provides six line output leads for connection in
Star or Delta configuration.
The CL105 generator may be supplied with flying leads from the main stator
windings terminated in a socket and separate excitation control components, or as
a complete generator package with control components located in a generator
mounted box with output terminals. The neutral of the windings on the CL
generator is connected to the frame earth terminal.
When separate excitation components are supplied, interconnection between them
is made with multipin sockets and plugs. The installer must provide mounting for
the components and ensure adequate ventilation. Refer to the factory if in doubt.
Reference should be made to relevant site or safety regulations.
13

3.5 VOLTAGE SELECTION
1. Dual Voltage Output
The main stator windings are in two sections which may be connected in series
or parallel to give a choice of output voltage. For example, series connection
gives 230V, parallel connection gives 115V.
This is illustrated below. Each winding section is capable of carrying the same
current I. When the windings are connected in series the maximum load current is
I, but when the windings are connected in parallel the maximum current is 2 X I.
Example:
A 2.5kVA generator when connected in series for 230V operation has a capacity of
10.9A; when connected in parallel for 115V it has a capacity of 21.7A.
14
Red
White
Brown
Blue
4Wire
ParallelConnection
115V
Output
SeriesConnection
Red
White
Brown
Blue
230V
Output
U2
U1
U5
U6
U2
U1
U5
U6
Red
White
Brown
Blue
U2
U1
U5
U6
2. 110V CTE Output (BL105 range only).
The main stator windings are in two sections which should be connected in
series to give 110V output, with the centre tap taken from the series connection
point.

3.6 VOLTAGE ADJUSTMENT FOR THE SL105 -AVR MD1C
The voltage is set during manufacture to give the mid-voltage of the range of
voltages shown on the nameplate, ie: a generator whose nameplate is marked
220-240/110-120V will be set to give 230 volts with the output windings connected
in series and 115 volts when connected in parallel.
The voltage may be reset to any value within the nameplate range.
To RAISE the voltage turn the volts adjust potentiometer VR1
CLOCKWISE and to LOWER the voltage turn the potentiometer
ANTI-CLOCKWISE.
The volts adjust potentiometer is the one at the bottom of the board.
STABILITY
This control should not normally require adjustment having been set during
manufacture, but should the output voltage fluctuate with a steady load connected,
this may be improved by turning the potentiometer anti-clockwise which will
increase the damping effect.
Note
1. Do not use undue force when turning the potentiometers - they can be
damaged by attempting to adjust beyond the internal stops.
2. When making either adjustment the speed must be correct.
TL Models
TL generators have a voltage range of approximately 5%, e.g. 380 - 415 volts.
Voltage adjustment is effected by adjustment of the SET VOLTS control
potentiometer located on the AVR. Access to the AVR is gained by removal of the
cover of the black, side mounted box.
Removal of the air intake cover allows access to LIVE parts.
Only persons qualified to carry out electrical servicing should
carry out adjustments.
Danger !
15

CL Models
CL generators are factory set and require no adjustment.
Should the voltage be incorrect at no-load, switch load (at least 50%) on and off
and recheck voltage. (Voltage will normally rise after application of load.) If voltage
is still incorrect adjustment can be made as follows:-
First check that the speed is correct (normally 3150 rpm no-load and 3000 rpm on
load for 50Hz generators or 3790 rpm and 3600 rpm respectively for 60Hz
generators).
The linear reactor controls the no-load voltage by adjustment of its airgap.
Increasing gap increases voltage; decreasing gap decreases voltage. To adjust
the airgap length, slacken the clamping bolts across the top of the reactor and
adjust the thickness of packing in the airgap. Packing must be non magnetic
material.
After each adjustment, switch load (at least 50%) on and off and recheck no-load
voltage.
Air gap adjustment should be made in small increments, and
should only be carried out by personnel qualified to perform
electrical service.
Danger !
16
The installer must provide suitable terminations or switching arrangements to
provide a safe reconnection means.
TL generators may be supplied with a 12 lead winding suitable for series/parallel
connection.

SECTION 4
SERVICE & MAINTENANCE
Warning !
The following procedures present hazards which can result
in personal injury or death. Only persons qualified to
carry out electrical and mechanical servicing should
undertake this work.
4.1 GENERAL
The BL model generator is fitted with sealed for life bearings and requires no
regular maintenance.
The NL, SL, TL and CL models similarly require no regular mechanical
maintenance. They are, however, fitted with sliprings and brushgear which require
regular attention.
Inspect brushes and sliprings at 500 hours intervals. Replace brushes when they
are worn to a depth of 8mm. The new brush should be bedded using a medium
grade abrasive cloth. If the sliprings are pitted or badly marked the rotor should be
removed and the sliprings lightly skimmed.
The generator must periodically be inspected and any accumulation of dirt or oil
must be removed. Air inlet and outlet openings must be kept unobstructed.
For BL, NL, SL, TL, and CL models it is recommended that:-
1) after storage or long periods of standing idle the condition of windings should
be checked. Refer to 'Insulation Resistance Check' subsection 4.2,
and
2) during generating set overhaul, the bearing is replaced. Refer to
Assembly/Dismantling Procedure, Section 5.
17