Regal Marathon Electric Pancake User manual

PANCAKE GENERATOR
Installation, Operation
and Maintenance Manual
A Regal Brand
A Regal Brand
100 E. Randolph Street (54401)
PO Box 8003
Wausau, WI 54402-8003 U.S.A.
PH: 715-675-3359
FAX: [phone]
www.marathonelectric.com
©2015 Regal Beloit Corporation MANUAL GPN016 7892J-NP/???/07-15/??? Printed in the U.S.A.

TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Location/Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Initial Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Initial Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Shut Down Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drying Generator Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Restoring Residual Magnetism (Flashing the Exciter Field) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Testing the Rotating Recifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPARE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RETURNED GOODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TROUBLESHOOTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WARNINGS AND CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Back Cover

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
ELECTRONIC VOLTAGE REGULATED BRUSHLESS GENERATOR
INTRODUCTION
Thank you for choosing a MARATHON ELECTRIC PANCAKE Generator. Please read the installation and service
sections of this manual carefully. A clean environment and proper installation are critical to generator performance. If
you have any difficulty in installing or servicing your Marathon Generator, our service and technical staff will be happy
to help you. We are confident that by following these guidelines, you will get many years of reliable service from your
Marathon generator.
General Data
Construction: Brushless, Revolving Field
Number of Poles: 4
Frequency: Frequency is model specific. Consult the generator name plate or the factory for
your generator’s designed frequency.
Synchronous Speeds: 60 Hz – 1800 rpm
Cooling: Fan cooled
Enclosure: IP20
Max. Ambient Temp: 40°C
Insulation Class: (See generator nameplate)
Initial Inspection
Your Marathon Pancake generator has been carefully inspected and tested before leaving the factory. However, it
is wise to examine the generator before installation. Carefully unpack and examine the unit. If there is any shipping
damage, file a damage claim with the shipper or agent immediately. Save all packing materials for inspection by agent.
SAFETY
PLEASE REMEMBER SAFETY FIRST. If you are unsure of
the instructions or procedures contained in this manual,
seek qualified help before continuing. WHEN IN DOUBT,
ASK.
This manual emphasizes the safety precautions necessary
during the installation, operation, and maintenance of
your Pancake generator. Each section has caution and
warning messages. These messages are for your safety
and the safety of the equipment involved. If any of the
cautions or warnings are not readily understood, seek
clarification from qualified personnel before proceeding.
Before any service work is done, disconnect all
external power sources and, where appropriate, lock
out all controls to prevent an unexpected start-up
of the generator set driver. Proper grounding
(earthing) in compliance with local and national
electrical codes and standards must be provided.
These safety precautions are necessary to prevent
potential serious personal injury or even death.
The hazards associated with lifting or moving your
generator are pointed out in the installation and service
sections. Incorrect lifting or moving can result in personal
injury or damage to the unit. Prior to start-up of the unit,
insure that all generator leads are properly connected
and insulated.
Always assume that there will be voltage present at
the generator terminals whenever the generator’s
shaft is rotating, and proceed accordingly. Residual
voltage is present at the generator terminals, and at
the automatic voltage regulator panel connections,
even with the regulator fuse removed. Caution must
be exercised, or serious injury or death can result.
This manual is not intended to be a substitute for properly
trained personnel. Installation and repairs should only be
conducted by qualified, trained people. The cautions
and warnings point out known conditions and situations
that are potentially hazardous. Each installation may well
create its own set of hazards. No manual can cover every
possible situation.
INSTALLATION
Location/Environment
The engine-generator set must be installed in a protected
environment with minimal exposure to fumes, moisture,
dust, and dirt. THE AMBIENT AIR TEMPERATURE MUST
NOT EXCEED 40°C (104°F) FOR CONTINUOUS DUTY
WITHOUT A RECOMMENDED REDUCTION IN RATING.
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a.
DO NOT obstruct the generator intake and outlet
air passages.
b. Provide sufficient air circulation around the set to
remove engine heat and to provide ample generator
cooling.
c. Hot air from the radiator or engine should not pass
through the generator.
d. Check the mounting surface to be sure that it is rigid
enough to keep vibration and noise to a minimum.
Mounting
Mount the generator to the driver securely. Before
tightening hold-down bolts, use shims as necessary under
generator feet for uniform support. If this is not done, the
frame may become distorted resulting in excess vibration
that could damage the generator.
Assembly of a Single Bearing Generator to an Engine
To mount a single bearing generator to an engine (See
Figure 1 for component identification):
a. If the engine is equipped with electric start,
disconnect the positive (+) terminal from battery.
b. Place a jack or other support under the engine
flywheel housing.
c. Remove the pot cover or control box cover from
back of generator and disconnect all incoming
power leads.
d. Detach main rotor leads from the red and black
threaded studs on rectifier assembly (See Figure 2
on page 9.
e. Remove exciter armature (rotor) mounting bolt from
center of shaft, marking position of the rotor to aid
in re-assembly.
f. Remove exciter rotor from the shaft.
Take care not to damage the laminations or coil
end turns.
g. Remove exhaust screen band.
h. Place a strap around generator rotor assembly and
support from hoist.
i. With the exciter armature removed, pull the rotor
assembly from the frame.
Do not scratch or cut the copper stator windings.
k. Insure that the flex discs are flush (flat) against the
register of the flywheel. Bolt drive disk to engine
flywheel, using proper sized flat washers and SAE
grade 8 bolts. Consult engine manufacturer for
proper torque value.
I. Push generator frame assembly carefully back over
rotor.
m. Mount frame assembly to engine flywheel housing
with proper size bolts, lock washers, and nuts.
Figure 1- General Arrangement
POT
COVER
EXCITER
ROTOR
RETAINING
BOLT
EXCITER
STATOR
BEARING
BRACKET MAIN
ROTOR
DRIVE
DISKS
FAN
MAIN
ROTOR
LEADS
SCREEN
BAND
ASSEMBLY
FRAME & MAIN
STAOR ASSEMBLY
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n. Remount exhaust screen band.
o. To reassemble the armature, pull main rotor leads
through the holes in the exciter rotor.
DO NOT PINCH ROTOR LEADS.
p. Replace the mounting bolt, lock washer, and
Belleville washer. Using a 9/16” socket on a torque
wrench, torque the mounting bolt to 30 to 35 ft-lb.
q. Reconnect main rotor leads to proper connections.
r. Reconnect all incoming power leads as shown on
wiring diagram.
s. Replace pot cover or control box cover.
t. Remove jack support from under engine flywheel
housing.
u. See preceding paragraph “a.” If necessary, reconnect
positive (+) lead to the engine cranking battery.
NOTE: INSURE THAT ALL ELECTRICAL CONNECTIONS ARE CORRECT BEFORE STARTING GENERATOR.
REFER TO THE AUTOMATIC VOLTAGE REGULATOR (AVR) MANUAL FOR SPECIFIC INSTRUCTIONS FOR
CONNECTING THE AVR.
SINGLE PHASE CONNECTION - DUAL VOLTAGE SERIES
VOLTAGE
L-L L-N
60 HZ 240 120
SINGLE PHASE CONNECTION - SINGLE VOLTAGE PARALLEL
VOLTAGE
L-L
60 HZ 120
DEDICATED 4 LEAD SINGLE PHASE GENERATOR CONNECTIONS.
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