Onan 50.0DDB-15R Series Instruction Manual

DQODQ
•it
OPERATORS
D PARTS C
UAL
LOG
FOR
ELECTRIC GENERATING SETS
DDB
SERIES
944-0302
4A74
Printed in U.S.A.

TABLE OF CONTENTS
TITLEPAGE
Introduction 1
Specifications... 2
SafetyPrecautions4
Description 7
Installation11
Operation18
General Maintenance• 23
Parts Catalog—25
WARNING
MANUFACTURER RECOMMENDS THAT ALL SERVICE IN-
CLUDING INSTALLATION OF REPLACEMENT PARTS BE
DONE BY QUA LI FIED ELECTRICA L A ND/OR MECH A N/CA L
SERVICEMEN. FROM THE STANDPOINT OF POSSIBLE IN-
JURY AND/OR EQUIPMENT DAMAGE IT IS IMPERATIVE
THATTHE SERVICEMAN IS QUALIFIED.

INTRODUCTION
FOREWORD
ThismanualisapplicabletotheDDBSerieselectric
generatingset,consistingofanOnanUR50.0KWAC
generator,drivenbya JohnDeere6329Ddiesel
engine.Informationisprovidedoninstallation,
operation, troubleshootingandpartsorderingforthe
set.Themanualshouldbeusedinconjunctionwith
theJohnDeereenginemanual,asyourspecific
enginemayhavevariationsduetooptionalequip-
mentavailable.
WARNING| Onan uses thissymbol
'throughoutthe text towarnof
possible injuryordeath.
This symbolis used towarnof
possible equipmentdamage.
MODEL IDENTIFICATION
IdentifyyourmodelbyreferringtotheMODELand
SPECIFICATIONNO.asshownontheOnan
nameplate.Electricalcharacteristicsareshownon
thelowerportionofthenameplate.
50.0DDB15R/IB
12 3 4 5
1. IndicatesKilowattrating.
2. FactorycodeforSERIESJdentification..
3.Indicatesvoltagecode.
15indicatesreconnectible
Rindicatesremoteelectricstart
4. Factorycodefordesignatingoptionalequipment.
5.Specificationletter.(Advanceswhenfactory
makesproductionmodifications.)
Ifitisnecessarytocontacta dealerorthefactory
regardingtheset,alwaysmentionthecomplete
Model, SpecNo.andSerialNo.asgivenontheOnan
nameplate.Thisnameplateinformationisnecessary
toproperlyidentifyyourunitamongthemanytypes
manufactured.Refertotheenginenameplatewhen
requestinginformationfromitsmanufacturer.The
Onannameplateislocatedontherightsideofthe
generator;theJohnDeerenameplateisontheleft
side, ontheengineblock.
Leftsideandrightsideareconsideredwhenviewedfromthe
ngineorfrontendofthegeneratingset.
IMPORTANT! RETURN WARRANTY CARD ATTACHED TO UNIT.

ENGINE DETAILS
EngineManufacturerJohnDeere
EngineSeries300—6329D
NumberofCylinders6
Displacement329cu.inches
BHP@ 1800RPM85
CompressionRatio16.3:1
Bore4.02-inches
Stroke'.4.33-inches
FuelASTMNo.2Diesel
BatteryVoltage12
BatteryGroup(Two6-Volt,135-A.H.)2H
StartingMethodSolenoidShift
GovernorRegulation5%Noload— Fullload
GENERATOR DETAILS
TypeUR15R60Hz
UR515R50Hz
UR3R60Hz
Rating(Watts)
60HertzContinuousStandby50,000(62.5KVA)
50HertzContinuousStandby40,000(50.0KVA).
ACVoltageRegulation2%
.60HertzRPM1800
50HertzRPM1500
OutputRating0.8PF.
ACFrequencyRegulation3..Hz
BatteryChargingCurrent35Amperes
CAPACITIES AND REQUIREMENTS
CoolingSystem(IncludesRadiator)5 aal.
EngineOilCapacity(Crankcase)12ats.
ExhaustConnection(inchespipethread)ats.
AIR REQUIREMENTS (1800RPM)
.EngineCombustion200CFM
RadiatorCooledEngine4185CFM
TotalforRadiatorCooledModel4385 CFM
AlternatorCoolingAir
(1800RPM)1000CFM
(1500RPM)834CFM
FuelConsumptionatRatedLoad3.9GPH
GENERAL
Height: 52.6-inches
Width! 33.0-inches
Length79.75-inches
Weight(approx.)2180-pounds

TABLE 1.UR GENERATORVOLTAGE OPTIONS
VOLTS
FREQr
PHASE "AMPERES DOUBLE
DELTA
SERIES
DELTA
PARALLEL
WYE
SERIES
WYE
REF. VOLTAGE
WIRE (W12)TAP
120/240 60Hz 1 260
X
H5
115/230
50Hz 1 216
X
H6
120/240 60Hz
3
151
X
H5
115/230
50Hz
3
125
X
H6
120/208 60Hz
3
174
X
H3
127/220 60Hz
3
164 'X H4
139/240
60Hz
3
151
X
H5.
110/190 50Hz
3
151
X
H3
115/200 50Hz
3
142
X
H4
240/416
60Hz
3
87
X
H3;
254/440
60Hz 3
82
X H4
277/480 60Hz
3 75
X
H5
220/380
50Hz 3
76
X H3
230/400 50Hz .3 72
X
H4
9X R
347/600
60Hz
3
60 H3— Not
Reconnectible
50.0KW
40,000KW
.62.5KVA
50.0KVA
60Hz
50Hz

SAFETY PRECAUTIONS
Throughoutthismanual you willfindeye-catching
flagscontainingWarningsandCautions,alertingyou
toconditionsthatcouldresult in danger to you or the
equipment, if the notice is ignored.
ONANrecommendsthat you readyourmanual and
becomethoroughlyacquaintedwith itand your
equipmentbefore you startyourunit. Theac-
cumulatedexperience of ONANengineers is
available to you,enabling you to operateyour set in
themostefficientandsafestmannerpossible.These
recommendations andthe followingsafety
precautions are for yourprotection.Studyandknow
them!
If itis necessary to makeadjustmentswhile the
unit is running, use extremecautionwhenclose
to hot exhausts,movingparts, etc.
Do not stand ona wet floorwhileworking on
electricalequipment. Use rubberinsulativemats
placed ondry woodplatforms.
REMEMBER.Mostaccidentsarecaused by failure to
followsimple and fundamentalsafetyrules or
precautions.
Most accidents can be prevented!
KNOW YOUR MANUAL - KNOW YOUR EQUIP-
MENT
Fuel System
• DO NOT fillfueltankswhileengine is running,
unlesstanks are outsideenginecompartment.
DO NOT SMOKE OR USE AN OPENFLAME in
thevicinity ofthe generator setor fueltank.
Internalcombustionenginefuelsarehighlyflam-
mable.
REMEMBER — IF YOU CAN SMELLFUMES —
YOU'RECOURTING A POSSIBLEEXPLOSION
ANDFIRE!
General
•Keepyourgenerating setandthe surrounding
areacleanandfreefromobstructions.Remove all
oildeposits;keep the floorclean and dry.
•Provideappropriatefireextinguishersandinstall
them in convenientlocations.Consultyourlocal
firedepartment forthe correcttype ofex-
tinguisher to use. Donot use foam or carbon
tetrachloride on electricalfires.Useextinguisher
rated ABC by NFPA.
•Makesurethat all fasteners on thegenerating set
aresecure.Tightensupports and clamps,keep
guards in positionoverfans,drivingbelts, etc.
• Donot wearlooseclothing inthe vicinity of
movingparts, or jewelrywhileworking on elec-
tricalequipment.
Makesurethatoilyragsare not lefton or nearthe
engine.
Fuellinesmust beof steelpiping,adequately
secured, andfreefromleaks.Pipingattheengine
should be approvedflexibleline. Donotuse
copperpipingonflexiblelinesascopperwillwork
harden and becomebrittle. Use blackpipe on
naturalgas or gaseousfuels, but notongasoline
ordiesel fuel.
Yourengineinstallationshouldbeequippedwith
ameans of positivefuelshutoff in applications
whenfuel is conductedfrom a remotesource.
Fuelsunderpressure(e.g.naturalgas or liquified
petroleumgas)shouldbecontrolledbya positive
shutoffvalve,preferablyautomatic, in addition to
anyvalveintegralwith the carburetor or gas
regulatorequipment.

Exhaust System
•Exhaustproductsofanyinternalcombustion
enginearetoxicandcancauseinjury,ordeathif
inhaled. Allengineinstallations,especiallythose
withina confine,shouldbeequippedwithan
exhaustsystemtodischargegasestotheat-
mosphere.Donotuseexhaustgasestoheata
compartment.
•Makesurethatyourexhaustsystemisfreeof
leaks. Ensurethatexhaustmanifoldsaresecure
andhavenotwarpedbyboltsunevenlytorqued.
Coolant System
•Coolantsunderpressurehavea higherboiling
pointthanthatofwater.DONOTopena radiator
orheatexchangerpressurecaporbreaka system
whiletheengineisrunning,andinnocaseuntil
thesystemhasbeenbledoff.
•Radiatorfanbeltsareguardedforyourprotec-
tion. DONOTremovecoversorguards.
• Keep your hands away from movingparts.
Ventilation System
•Checkremoteradiatorsfrequently.Removeany
dirt,debris,birdnests,etc.
•Checkventilationlouvresfrequently.Makesure
thatfree-falllouvresandmotoroperatedlouvres
openandcloseproperlyandthatthereisno
restrictioninthefreeairflow.
Electrical System
Theelectricalinstallationexteriortoyourgenerator
shouldhavebeenperformedbyqualifiedlicensed
electricians.Alllocalandstatecodesshouldhave
beenconsultedandcomplied with. Itisessentialthat
allloadcircuitbreakersadequatelyprotectelectrical
functions,allcircuitsareproperlygroundedand
wiringiscorrectcapacity.
•Tagopenswitches.
•DON'Ttamperwithinterlocks.
•Beforestartingworkonthegeneratingset,dis-
connectbatteries.Thiswillpreventinadvertent
startingoftheset.
•Useextremecautionwhenmakingadjustments
ontheelectricalcomponentsinthecontrolpanel
whiletheengineisrunning.Highvoltagesare
presentandcouldcauseseriousinjuryordeath.
•DONOTSMOKEwhileservicingbatteries.Verify
correctpolarityofbatterycablesbeforeconnec-
ting. Leadacidbatteriesgiveoffa highlyex-
plosivehydrogengaswhichcanbeignitedby
electricalarcingorbysmoking.Whenconnecting
batteries,connectthegroundleadlast.

DUALRANGE
ACVOLTMETER
VOLTAGEADJUSTING
RHEOSTAT
EXCITER
CIRCUITBREAKER
INDICATORLAMPS-INDICATEUPPER
ORLOWERSCALEONVOLTMETER
PANELLIGHTANDSWITCH
OILPRESSUREGAUGE
WATERTEMPERATURE
GAUGE
FAULTLAMP
DCAMMETER
1/4 TURNFASTENERS.TURNBOTH TO
OPENHINGEDCONTROLPANELDOORS.
PHASESELECTORSWITCH
•—RUN- STOP-REMOTESWITCH
FIGURE 1. TYPICALCONTROLPANEL (ONE FAULT LAMP)
DUALRANGE AC AMMETER
INDICATORLAMPS
INDICATEUPPER AND LOWERSCALE
ONVOLTMETER AND AMMETER—.
DUALRANGE
ACVOLTMETER
VOLTAGE
ADJUSTING
RHEOSTAT
FREQUENCY
METER
RUNNINGTIME
METER
%TURNFASTENERS-TURNBOTH
SCREWS TO OPENHINGEDCONTROL-
PANELDOORS
PANELLIGHT AND SWITCH
EXCITERCIRCUITBREAKER
PHASESELECTORSWITCH
OILPRESSURE
GAUGE
WATERTEMPERATURE
GAUGE
DCAMMETER
«UN-STOP-REMOTESWITCH
(ALSO A. RESETSWITCH FOR
ENGINEMONITOR)
FAULTLAMPS
TESTLAMPBUTTON AND
ENGINEMONITORRESETSWITCH
USEDONLY ON CONTROLPANELS
WITHFIVEFAULTLAMPS
FIGURE 2.OPTIONAL CONTROLPANEL(FIVEFAULTLAMPS)

DESCRIPTION
GENERAL
AnONANDDBserieselectricgeneratingsetisa
completeunitconsistingof'an-enginedrivenAC
generator,withcontrolsandaccessoriesasordered.
ENGINE
TheengineontheDDBisa JohnDeere6329Das
describedinenginemanual.Basicmeasurements
andrequirementswillbefoundunderSpecifications.
However,theengineusedforyourunitmayhave
variationsduetooptionalequipmentavailable,
thereforetheJohnDeeremanualshouldbe con-
sulted.
AC GENERATOR
ThegeneratorisanONANTypeUR,12 lead, 4 pole
revolving field, reconnectiblebrushlessunit.The
alternatingcurrentisgeneratedinthestatorwinding.
Thealternatorrotor,attacheddirectlytotheengine
flywheelturnsatenginespeed.Therefore,thespeed
atwhichtherotorturns,determinesgeneratoroutput
frequency.The60hertzsetoperatesat1800rpmand
the50hertzat1500rpm.Excitationisachievedby
feedingACoutputtoa voltageregulator,whereitis
comparedwitha referencevoltageintheregulator,
rectifiedandreturnedtothefieldoftheexciter,then
totheexciterarmature,rectifiedandfedtothe
generator field. TheURgeneratorisavailablein3-
phaseandsinglephase.Excitationandregulationare
thesameforeitherunit.
CONTROL PANEL
Thefollowingisa briefdescriptionofeachofthe
standardcontrolsandinstrumentslocatedonthe
faceofthepanel.SeeFigure1.
DC PANEL
PanelLightandSwitch:Illuminatescontrolpanel.
OilPressureGauge:Indicatespressureoflubricating
oilinengine(wiredtoa sensorunitlocatedonthe
engine).
WaterTemperatureGauge:Indicatestemperatureof
circulatingcoolantinengine.(Wiredtoa sensorunit
locatedontheengine.)
BatteryChargeRateDCAmmeter:Indicatesthe
batterychargingcurrent.
Run-Stop/Reset-RemoteSwitch:Startsandstopsthe
unitlocallyorfroma remotelocation.
AC PANEL
ACVoltmeter:IndicatesACgeneratoroutputvoltage.
Dualrangeinstrument:measurementrangeinuse
shownonindicatorlight.
ACAmmeter:IndicatesACgeneratoroutputcurrent.
Dualrangeinstrument:measurementrangein.use
shownonindicatorlights.
Voltmeter-AmmeterPhaseSelectorSwitch:Selects
thephasesofthegeneratoroutputtobemeasuredby
theACvoltmeterandACammeter.
VoltageRegulator:Rheostat,providesapproximately
plusorminus5%adjustmentoftheratedoutput
voltage.
ExciterCircuitBreaker:Providesgeneratorexciter
andregulatorprotectionfromoverheatinginthe
eventofcertainfailuremodesofthegenerator,
exciterandvoltageregulator.
RunningTimeMeter:Registersthetotalnumberof
hours, to 1/10th thattheunithasrun.Useittokeepa
recordforperiodicservicing.Timeisaccumulative,
metercannotbereset.
FrequencyMeter:Indicatesthefrequencyofthe
generatoroutputinhertz.Itcanbeusedtocheck
enginespeed.(Eachhertzequals30rpm.)
OPTIONAL EQUIPMENT
DC PANEL
WarningLights:Eliminatestheone"Fault"lightand
substitutesfiveindicatorlightstogivewarningof—
a.Overcrank(failedtostart)
b.Overspeed
c.Lowoilpressure
d. Highengine^t.emperature
e.Lowenginetemperature
Operationoftheselightswillbediscussedin con-
junctionwithenginemonitorpanel.
WarningLights:Indicates"Fault"inengineoperation.
ResetSwitch:Manualresetforenginemonitorafter
shut-down.
Lamp'Test:Presstotestwarninglampbulbs(when
engineisrunningonly).

CONTROL PANEL INTERIOR
Theonlyequipmentsdiscussedinthissectionwillbe
thosewhichtheoperatormayhavereasontoadjustor
inspectforservice.
TerminalBoard(TB)21:ConnectionofwireW12to
terminalsH3,H4,H5,andH6ismadeatthispoint,to
changereferencevoltagewhenreconnecting
generatorfordifferentvoltages.RefertoFigure14.
VoltageRegulator:Solidstateunit,consistingof
VR21, CR21andL21.ControlsACoutputfrom
generatoratpredeterminedlevelregardlessof load..
Regulationplusorminus 2% fromnoloadtofull load,
0.8P.F.
c.Lowoilpressure(14psi).
d. Highenginetemperature(215°F).
Onstandardcontrolpanels,allfouralarmsarewiredintoone
commonfaultlamp;onunitswithfivefaultlamps,fourhave
shutdownalarms,thefifth(lowenginetemperature)lightsa fault
lamponly.RefertoTable2.
StandardCrankingModule:Limitsenginecranking
timeto75seconds.Ifenginefailstostartafter75
secondstheenginemonitorlightsa faultlampand
opensthecrankingcircuit.
EngineMonitor:Printedcircuitplug-inmodules
providethefollowingfunctions:
1. A 75secondcrankingperiod.
2. Approximatelya 12-1/2secondtimedelayforoil
pressurebuildup.
3.Anexternalalarmcontacttolightafaultlampand
shutdownthesetforalarmconditionssuchas:
a.Overcrank(failedtostartaftercranking75
seconds).
b.Overspeed(enginespeedreaches2100rpm).
OPTIONAL MODULES
CycleCranker:Plug-inmodulereplacesstandard
crankingcircuit.Automaticallyprovidesa 15-second
cranktimeanda 10-secondresttimeforthreeONand
twoOFFcyclesin65seconds.Ifenginefailstostart,
after75-secondstheenginemonitorlightsa fault
lampandopensthecrankingcircuit.
Pre-Alarm: Givesadvancewarningforlowoil
pressureorhighenginetemperature.Requirestwo
sensorseachforenginetemperatureandoilpressure.