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:
OR ON
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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