Onan Protec Series User manual

Installation Manual
YD PTO
PROTEC Series
Printed inU.SA
929-0600
10-94

TableofContents
SECTIONTITLEPAGE
SAFETYPRECAUTIONSii,iii
1INTRODUCTION1-1
General1-1
Generator1-1
VoltageRegulator1-1
Meter/BreakerBox1-1
Operation1-1
2 SPECIFICATIONS 2-1
3PRE-INSTALLATION3-1
General3-1
GeneratorMounting3-1
Meter/BreakerBoxMounting3-1
PTOSystemConfiguration3-2
4GENERATORMOUNTING4-1
GeneratorSupportFramework4-1
ConnectingthePTO4-2
5METER/BREAKERBOX,VOLTAGEREGULATORMOUNTING5-1
General5-1
6SYSTEMWIRING6-1
SystemConnections6-1
7INSTALLATIONAND WIRING DIAGRAMS7-1

SafetyPrecautions
Beforeoperatingthegenerator,readtheOperator's Manual andbecomefamiliar with it and theequipment.
Safe anaefficientoperationcanbeachievedonlyiftheunitisproperlyoperatedandmantained.
Manyaccidentsarecausedbyfailuretofollowfundamentalrulesandprecautions.
Thefollowingsymbols,foundthroughoutthismanual,alertyoutopotentiallydangerousconditionstotheop-
erator,servicepersonnel,ortheequipment.
EliTiVMihl This symbol warns of Immediate hazards which will result in severe personal injury or
death.
IAWARNINGI This symbol refers to a hazard or unsafe practice which can result in severe personal in-
jury or death.
This symbol refers to a hazard or unsafe practice which can result in personal Injury or
product or property damage.
GASOLINE AND LPG FUEL MAY BE ACCIDENTALLY IGNITEDBY ELECTRICAL SPARKS, presenting
thehazardof fire or explosion, whichcanresultin severe personal Injuryordeath.WhenInstallingthe
generatorset:
•Donottieelectricalwiringtofuellines.
•Donotrunelectricallinesandfuellinesthroughthesamecompartmentopenings.
•Keepelectricalandfuellinesasfarapartaspossible.
•Placea physicalbarrierbetweenfuellinesandelectricallineswhereverpossible.
•Ifelectricalandfuellinesmustpassthroughthesamecompartmentopening,makecertainthattheyare
physicallyseparatedbyrunningthemthroughindividualchannels,orbypassingeachlinethrougha sepa-
ratepieceoftubing.
•DONOTSMOKEwhileservicingbatteries.Leadacidbatteriesemita highlyexplosivehydrogengasthat
canbeignitedbyelectricalarcingorbysmoking.

SafetyPrecautions
MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH
•Beforestartingworkonthegenerator,disconnectbatteries,negative(-)cablelast.Thiswillprevent acci-
dentalarcing.
•Keepyourhandsawayfrommovingparts.
•Makesurethatfastenersonthegeneratoraresecure.Tightensupports and clamps,keepguards in position
overfans,drivebelts,etc.
•Donotwearlooseclothingorjewelrywhileworkingongenerators.Looseclothingandjewelrycanbecome
caughtinmovingparts.Jewelrycanshortoutelectricalcontactsandcauseshockorbuming.
•Ifadjustmentmustbemadewhiletheunitisrunning,useextremecautionaroundhotmanifolds,moving
parts, etc.
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH
•Disconnectstartingbatterybeforeremovingprotectiveshieldsortouchingelectricalequipment.Userubber
insulativematsplacedondrywoodplatformsoverfloorsthataremetalorconcretewhenaroundelectrical
equipment.Donotweardampclothing(particularlywetshoes)orallowskinsurfacestobedampwhen han-
dlingelectricalequipment.
•Useextremecautionwhenworkingonelectricalcomponents.Highvoltagescancauseinjuryordeath.
•Followallstateandlocalelectricalcodes.Haveallelectricalinstallationsperformedbya qualifiedlicensed
electrician.Tagopenswitchestoavoidaccidentalclosure.
•DONOTCONNECTGENERATORDIRECTLYTOANYBUILDINGELECTRICALSYSTEM.Hazardous
voltagescanflowfromthegeneratorsetintotheutilityline.Thiscreatesa potentialforelectrocutionorprop-
ertydamage.Connectonlythroughanapproveddeviceandafterbuildingmainswitchisopen.Consultan
electricianinregardtoemergencypoweruse.
GENERAL SAFETY PRECAUTIONS
•Haveafireextinguisher nearby. Maintainextinguisherproperlyandbecomefamiliarwithits use. Extinguish-
ersratedABCbytheNFPAareappropriateforallapplications.Consultthelocalfiredepartmentforthe
correcttypeofextinguisherforvariousapplications.
•Removeallunnecessarygreaseandoilfrom theunit.Accumulatedgreaseandoilcancauseoverheating
andgeneratordamage,whichpresentsa potentialfirehazard.
•DONOTstoreanythinginthegeneratorcompartmentsuchasoilorgascans,oilyrags,chains,wooden
blocks,portablepropanecylinders,etc.A firecouldresultorthegeneratorsetoperation(cooling,noiseand
vibration)maybeadverselyaffected.Keepthecompartmentfloorcleananddry.
•Donotworkonthisequipmentwhenmentallyorphysically fatigued, orafterconsuminganyalcoholordrug
thatmakestheoperationofequipmentunsafe.
GEN-1
iii

Sectioni. Introduction
GENERAL
Thismanualprovidesinstructionsformounting:
•OnanACPTOgenerator
•Voltageregulatorbox
•Meter/breakerpanel
Onandoesnotprovidetheassociatedcomponents
thatcomprisea completePTOsystem(power take-
offs, in-cabcontroldevices,interlock switches, PTO
transmissions, etc.). Consultthemanufacturer's
instructionsfordetailsonnon-Onanequipment.
TheOperator'sManual(929-0100)thataccompa-
nieseachACPTOgeneratordescribesoperation
andmaintenance.
IAWARNINGI Incorrect Installation, service, or re-
placement ofparts can result In severe personal
injury, death and/or equipment damage. Ser-
vice personnel must be qualified to perform
electrical and mechanical component installa-
tion.
GENERATOR
TheOnanYDseriesACgeneratorsaretwo-bear-
ing, 1800rpm,60hertzunitsdesignedfordirect
drivefroma powertakeoffunitconnectedtoa ve-
hicleengine.
Acentrifugalbloweronthefrontendoftherotor
shaftdrawscoolingairthroughtheendbellcover,
overthegeneratorrotor,anddischargesitthrough
anoutletattheblowerend.
Aballbearingateachendofthegeneratorsupports
therotor shaft. Theendbellandstatorhousingare
attachedbyfourthrough-studswhichpassthrough
thestatorassembly.Thebrushlessexciterstator
mountsintheend bell. Theexciterrotoranditsro-
tatingrectifierassembliesmountontherotorshaft.
VOLTAGE REGULATOR
Thevoltageregulatorassemblyincludesthefollow-
ingcomponents:
•Printedcircuitboard
•Voltagereferencetransformer
•Commutatingreactorassembly
•Fieldcircuitbreaker
Thevoltageregulatorboxismountednearthe gen-
erator.
METER/BREAKER BOX
Themeter/breakerboxcontainsthefollowingcom-
ponents:
•Voltmeter
•Ammeters
•Hourmeter
•Frequencymeter
•Linecircuitbreakers
•Markedoutputterminals
ThegeneratorACoutputisroutedtotheOnanme-
ter/switchboxwhereamperage,voltageandfre-
quencyaredisplayedona meterpanel.Circuit
breakersprotectthegeneratorfromovercurrent
conditions.Themeter/breakerboxismounted
withina 15footradiusofthegenerator:theACload
isattachedhere.
OPERATION
Thegeneratorandvoltageregulatoroperateas fol-
lows:
•Residualmagnetismintherotoranda perma-
nentmagnetembeddedinoneexciterfield
polebeginthevoltagebuildupprocessasthe
generatorstartsrunning.
•Single-phaseAC voltage, takenfromoneofthe
statorwindings,isfedtothevoltageregulator
asa referencevoltageformaintainingthe gen-
eratoroutputvoltage.
•TheACreferencevoltageisconvertedtoDC
bya siliconcontrolledrectifierbridgeonthe
voltageregulatorprintedcircuitboardandfed
intotheexciterfieldwindings.
•Theexciterarmatureproducesthree-phase
ACvoltagethatisconvertedtoDCbytherotat-
ingrectifierassembly.
•TheresultingDCvoltageexcitesthegenerator
rotorwindingtoproducethestatoroutputvolt-
agefortheAC load.
1-1

GENERATOR
DRIVESHAFT
WITHKEY
JUNCTIONBOX
VOLTAGEOUTPUTLEADS
EXTENDOUTOFJUNCTIONBOX
TOVOLTAGEREGULATORBOX,
METER/BREAKERBOX
COOUNGAIRINUET
(ENDOFGENERATOR)
MOUNTINGFOOT
FIGURE 1-1.YDPTO GENERATOR
1-2

NOTE: AMMETERRATINGS
VARYDEPENDINGONMODEL
FREQUENCY
METER-
(45-65HZ)
TWO-POLE
CIRCUIT-
BREAKER
AMMETER AMMETER
so 100 ISO
200
VOLTMETER HOURMETER
so 100150H
/« AMPERES
® 100 150200
250
A* VOLTS 300
J0=
HOURS
loWolololol
e
o
FIGURE 1-2.YDPTO GENERATOR METER/BREAKER BOX(20kW UNIT SHOWN)
1-3

CONDUITCONNECTOR
INCH)
FIELDCIRCUIT
BREAKERCB21
TERMINAL
STRIPTB"
VOLTAGE.
ADJUST
O o
VOLTAGE
REGULATOR
ASSEMBLY
CONDUITCONNECTOR
(1/2INCH)
VIEWWITH
COVERREMOVED
TERMINALSTRIPTB21
(CONNECTIONTO
GENERATOR)
.FIELDCIRCUIT
BREAKERCB21
FIE
FIGURE 1-3.YDPTO GENERATORVOLTAGEREGULATOR BOX
1-4

Section 2. Specifications
Design: Revolving field: 4 pole.Drip-proof
construction.Skewedstatorminimizesfieldheat-
ingandvoltageharmonics.Statorlaminations
weldedinheavysteel frame. Dynamicallybalanced
rotor.Windingsepoxyimpregnatedandover-
coatedforenvironmentalprotectionandimproved
cooling.
Bearings:2,doublesealed,prelubricatedball
Cooling: Direct-drivecentrifugalblower.Single-
openingairoutlet,250f^/m(7.08m3/min),easily
ducted
OutputBox:Topmounted.Housesoutputtermi-
nalsandconduitconnectors.
ExciterSystem:Brushless,with 8-pole stator
mountedinend bell. Rectifierassembliesencapsu-
latedforenvironmentalprotection.Permanent
magnetinstatorfieldprovidesreliablevoltage
buildup.
VoltageRegulator:Componentsincludeprinted
circuitboard,voltagereferencetransformer,com-
mutatingreactor,fieldcircuitbreaker,voltageadjust
rheostat.
InsulationSystem:ClassF,perNEMA MG1 -1.65
definition. Insulatingvarnishconformswith
MIL-l-24092,GradeCB,Class155°C.
Electromagnetic InterferenceAttenuation:
Meetsrequirementsofmostindustrialandcommer-
cialapplications.
Configuration:Platform-mountedorside-
mounted.
2-1

15KW GENERATOR
Voltage/Frequency:120/240VAC <S> 60Hz
Phase:One
Wires: Four
Watts: 15Kw
kVAatPF:15.0@ 1.0powerfactor
Circuitbreakerrating:70amps
Amperemeterrating:0-100amperes
Height:19.55inches
Width: 15.0inches
Length: 21.9inches
Weight:306pounds
Meter/breakerboxdimensions:
10-15/16"x 16-7/16"x 4-1 /2"
20KW GENERATOR
Voltage/Frequency:120/240VAC@ 60Hz
Phase:One
Wires: Four
Watts: 20Kw
kVAatPF:20.0@ 1.0powerfactor
Circuitbreakerrating(amps):85
Amperemeterrating:0-100amperes
Height:19.55inches
Width: 15.0inches
Length: 23.34inches
Weight:356pounds
Meter/breakerboxdimensions:
15" x 16-1/2"x 10"
24KW GENERATOR
Voltage/Frequency:120/240VAC@ 60Hz
Phase:One
Wires: Four
Watts: 24Kw
kVAatPF:24.0 <3> 1.0powerfactor
Circuitbreakerrating(amps):100
Amperemeterrating:0 -150amperes
Height:19.55inches
Width: 15.0inches
Length: 24.59inches
Weight:398pounds
Meter/breakerboxdimensions:
15" x 16-1/2"x 10"
30KW GENERATOR
Voltage/Frequency:120/240VAC@ 60Hz
Phase:One
Wires: Four
Watts: 30Kw
kVAatPF:30.0@ 1.0powerfactor
Circuitbreakerrating:150amps
Amperemeterrating:0 - 200amperes
Height:19.55inches
Width: 15.0inches
Length: 26.21inches
Weight:453pounds
Meter/breakerboxdimensions:
15" x 16-1/2"x 10"
35KW GENERATOR
Voltage/Frequency:120/240VAC@ 60Hz
Phase:One
Wires: Four
Watts: 35Kw
kVAatPF:35.0@ 1.0powerfactor
Circuitbreakerrating:175amps
Amperemeterrating:0 - 200amperes
Height:19.55inches
Width: 15.0inches
Length: 27.97inches
Weight:512pounds
Meter/breakerboxdimensions:
15" x 16-1/2"x 10"
Voltage RegulatorBoxDimensions(allgenerators)
8"x 7.75"x 2.75"
2-2