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Power Tech Generators PTS-30 Operator's Manual

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9/2008
MANPT30-40
PTS-30
PTS-35
PTS-40
PTS-50
Operators
Manual
Supplemental
Manual
Stand-By Generators
Power Technology Southeast, Inc.
634 State Road #44
♦ (352) 365-2777 ♦ Fax (352) 787-5545 ♦
&
For
Leesburg, FL 34748-8103

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Summary of Contents for Power Tech Generators PTS-30

  • Page 1 PTS-30 PTS-35 PTS-40 PTS-50 Operators Manual & Supplemental Manual Stand-By Generators Power Technology Southeast, Inc. 634 State Road #44 Leesburg, FL 34748-8103 ♦ (352) 365-2777 ♦ Fax (352) 787-5545 ♦ 9/2008 MANPT30-40...

  • Page 2: To Our Customers

    Thank you for your purchase of a Power Technology Generator. The information contained in this manual applies to PTS-30, PTS-35 and PTS-40 generators and optional equipment available for Stand-By systems. Your generator was custom built to your specific requirements and may or may not be equipped with each of these options listed.
  • Page 3 Limited Warranty on Power Tech Generators Power Technology Southeast, Inc. warrants to you, the original purchaser, that each product of our manufacture is free from defects in materials, and workmanship. That each generator will deliver its rated output as indicated on The Power Technology Nameplate, if properly installed, serviced, and operated under normal conditions in accordance with Power Technology’s instructions.
  • Page 4 POWER TECHNOLOGY SOUTHEAST, INC. Export Warranty on All Power Technology Products The Power Technology standard commercial warranty shall be modified as follows for all sales and delivery of products outside of the United States and Canada. The terms of the warranty shall be for a period of 12 months from the delivery to the first retail user.
  • Page 5 SECTION 1 “SAFETY” SAFE OPERATION Observe Safety Instructions Wear Safety Clothing Check Before Operating the Engine Keep Area Around the Engine Clean Safe Handling of Fuel and Lubricants Exhaust Gases and Fire Prevention Escaping Fluids Cautions Against Burns and Battery Explosion Keep Hands and Body Away From Rotating Parts Anti-Freeze and Disposal of Fluids Conducting Safety Checks and Maintenance...

  • Page 6: Wear Safety Clothing

    SAFE OPERATION Cautious operation is your best insurance against an accident. Read and understand this section carefully before operating the engine. All operators, no matter how knowledgeable they may be, should read this and other related manuals before operating the engine or any equipment attached to it. It is the owner’s responsibility to instruct all operators in safe operation.
  • Page 7 KEEP AREA AROUND THE ENGINE CLEAN • Be sure to stop the engine before cleaning. • Keep the engine clean and free of accumulated dirt, grease and trash. • DO NOT stop the engine without idling; Temperatures around the engine rises suddenly. Keep the engine idling for about 5 minutes before stopping.
  • Page 8 ESCAPING FLUIDS • Relieve all pressure in the air, oil and cooling systems before any lines, fittings or related items are removed or disconnected. • Be alert for possible pressure release when disconnecting any device from a system that is pressurized. DO NOT check for pressure leaks with your hands.
  • Page 9 ANTI-FREEZE AND DISPOSAL OF FLUIDS • Anti-freeze contains toxic chemicals. Wear rubber gloves when handling anti-freeze. In case of contact with skin, wash immediately to avoid personal injury. • DO NOT mix different types of Anti-freeze. The mixture can produce a chemical reaction resulting in the formation of harmful substances.

  • Page 10: Engine Starting Controls

    OPERATING THE ENGINE PT-ECU-64 CONTROLLED ENGINE STARTING CONTROLS 1) Generator Main Switch must be in the ON position. 2) Toggle the Start/Stop Switch to the Start position. 3) Glow Plugs will preheat for 8 seconds. LED flashes slowly. 4) Preheating will cease during engine cranking cycle. LED continues flashing. 5) Engine begins an 8 seconds crank cycle, After 4 seconds of cranking the PT-ECU-64 will check for an AC signal from the generator.
  • Page 11 OPERATING THE ENGINE NON-ECU CONTROLLED ENGINE STARTING CONTROLS 3. Press the Start / Stop switch to the “Start” position. This will engage the 1. Main Switch: Turns power On or Off to starter motor and start the engine. the engine start circuit. 4.
  • Page 12 V3600-E3 · V3600-T-E3 · MODELS V3800-DI-T-E3 · V3300-E3BG · V3600-T-E3BG · V3800-DI-T-E3BG 1J411-8911-4...

  • Page 13: Table Of Contents

    CONTENTS SAFE OPERATION ....................1 SERVICING OF THE ENGINE .................. 1 NAMES OF PARTS ....................2 PRE-OPERATION CHECK..................3 BREAK-IN ......................3 DAILY CHECK ....................... 3 OPERATING THE ENGINE..................4 STARTING THE ENGINE(NORMAL) ..............4 COLD WEATHER STARTING ................5 STOPPING THE ENGINE..................
  • Page 14 CONTENTS AIR CLEANER ..................... 21 Cleaning Primary Air Filter Element.................. 21 Evacuator valve ......................... 21 For the air cleaner with a dust cup (optional)..............21 Dust indicator (optional) ..................... 22 ELECTRIC WIRING ..................... 22 FAN BELT ......................22 Adjusting Fan Belt Tension ....................22 CARRIAGE AND STORAGE ...................

  • Page 15: Safety First

    FOREWORD FOREWORD You are now the proud owner of a KUBOTA Engine. This engine is a product of KUBOTA quality engineering and manufacturing. It is made of fi ne materials and under a rigid quality control system. It will give you long, satisfactory service.

  • Page 16: Safe Operation

    SAFE OPERATION SAFE OPERATION Careful operation is your best assurance against an accident. Read and understand this section carefully before operating the engine. All operators, no matter how much experience they may have, should read this and other related manuals before operating the engine or any equipment attached to it.

  • Page 17: Safe Handling Of Fuel And Lubricants -Keep Away From Fire

    SAFE OPERATION 3. CHECK BEFORE STARTING & OPERATING THE ENGINE A Be sure to inspect the engine before operation. Do not operate the engine if there is something wrong with it. Repair it immediately. A Ensure all guards and shields are in place before operating the engine.
  • Page 18 SAFE OPERATION 6. EXHAUST GASES & FIRE PREVENTION A Engine exhaust fumes can be very harmful if allowed to accumulate. Be sure to run the engine in a well ventilated location and where there are no people or livestock near the engine. A The exhaust gas from the muffler is very hot.
  • Page 19 SAFE OPERATION 8. CAUTIONS AGAINST BURNS & BATTERY EXPLOSION A To avoid burns, be cautious of hot components, e.g. muffler, muffler cover, radiator, hoses, engine body, coolants, engine oil, etc. during operation and after the engine has been shut off. A DO NOT remove the radiator cap while the engine is running or immediately after stopping.
  • Page 20 SAFE OPERATION 10. ANTI-FREEZE & DISPOSAL OF FLUIDS A Anti-freeze contains poison. Wear rubber gloves to avoid personal injury. In case of contact with skin, wash it off immediately. A DO NOT mix different types of Anti-freeze. The mixture can produce a chemical reaction causing harmful substances.

  • Page 21: Warning And Caution Labels

    SAFE OPERATION A Replace fuel pipes and lubricant pipes with their hose clamps every 2 years or earlier whether they are damaged or not. They are made of rubber and age gradually. A When servicing is performed together by two or more persons, take care to perform all work safely.

  • Page 22: Safe Operation

    SERVICING OF THE ENGINE SERVICING OF THE ENGINE Your dealer is interested in your new engine and has the desire to help you get the most value from it. After reading this manual thoroughly, you will find that you can do some of the regular maintenance yourself. However, when in need of parts or major service, be sure to see your KUBOTA dealer.

  • Page 23: Names Of Parts

    NAMES OF PARTS NAMES OF PARTS (1) Intake manifold (11) Exhaust manifold (2) Speed control lever (12) Alternator (3) Engine stop lever (13) Starter (4) Shut off solenoid (14) Fan belt (5) Fuel feed pump (15) Oil pressure switch (6) Cooling fan (16) Flywheel (7) Engine hook (17) Oil drain plug...

  • Page 24: Pre-Operation Check

    PRE-OPERATION CHECK PRE-OPERATION CHECK BREAK-IN During the engine break-in period, observe the following by all means: 1. Change engine oil and oil filter cartridge after the first 50 hours of operation. (See "ENGINE OIL" in "PERIODIC SERVICE" section.) 2. When ambient temperature is low, operate the machine after the engine has been completely warmed up. DAILY CHECK To prevent trouble from occurring, it is important to know the conditions of the engine well.

  • Page 25: Operating The Engine

    OPERATING THE ENGINE OPERATING THE ENGINE STARTING THE ENGINE(NORMAL) 1. Set the fuel lever to the "ON" position. CAUTION To avoid personal injury: A Do not allow children to approach the machine while the engine is running. A Be sure to install the machine on which the engine is installed, on a flat place.

  • Page 26: Cold Weather Starting

    OPERATING THE ENGINE 4. Insert the key into the key switch and 8. Warm up the engine at medium speed turn it "ON". without load. A If the glow lamp should redden too quickly or too slowly, immediately ask your KUBOTA dealer to check and repair it.

  • Page 27: Stopping The Engine

    OPERATING THE ENGINE STOPPING THE ENGINE CHECKS DURING OPERATION While running, make the following checks to see that all parts are working correctly. 1. Return the speed control lever to low idle, and run the engine under idling BRadiator Cooling water(Coolant) conditions.

  • Page 28: Fuel

    OPERATING THE ENGINE REVERSED ENGINE REVOLUTION AND BFuel REMEDIES CAUTION To avoid personal injury: CAUTION A Fluid escaping from pinholes may To avoid personal injury: be invisible. Do not use hands to A Reversed engine operation can search for suspected leaks; Use a make the machine reverse and run it piece cardboard...

  • Page 29: Maintenance

    MAINTENANCE MAINTENANCE CAUTION To avoid personal injury: A Be sure to conduct daily checks, periodic maintenance, refueling or cleaning on a level surface with the engine shut off and remove the key. A Before allowing other people to use your engine, explain how to operate, and have them read this manual before operation.

  • Page 30: Service Intervals

    MAINTENANCE SERVICE INTERVALS Observe the following for service and maintenance. Ref. Interval Item page Check of fuel pipes and clamp bands Every 50 hours Draining water separator See NOTE Change of engine oil 15 to 17 Cleaning of air cleaner element Cleaning of fuel filter Every 250 hours Check of fan belt tightness...
  • Page 31 MAINTENANCE A The jobs indicated by must be done after the first 50 hours of operation. *1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions. *2 After 6 times of cleaning. *3 Consult your local KUBOTA Dealer for this service. *4 Replace only if necessary.
  • Page 32 MAINTENANCE A CJ-4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter) and is Not Recommended for use in Kubota E3 specification engines. A Oil used in the engine should have API classification and Proper SAE Engine Oil according to the ambient temperatures as shown below: Above 25°C (77°F) SAE30, SAE10W-30 or 15W-40...

  • Page 33: Periodic Service

    PERIODIC SERVICE PERIODIC SERVICE FUEL Distillation Viscosity Viscosity Temperatures, Kinematic Fuel is flammable and can be dangerous. You should Saybolt, °C(°F) cSt or handle fuel with care. SUS at mm /s at 37.8°C(100°F) Point 40°C CAUTION To avoid personal injury: A Do not mix gasoline or alcohol with 32.6 40.1...

  • Page 34: Air Bleeding The Fuel System

    PERIODIC SERVICE [GRAVITY FEED SYSTEM] A Be sure to use a strainer when filling the fuel tank, or dirt or sand in the fuel may cause trouble in the fuel injection pump. A For fuel, always use diesel fuel. You are required not to use alternative fuel, because its quality is unknown or it may be inferior in quality.

  • Page 35: Checking The Fuel Pipes

    PERIODIC SERVICE BChecking the fuel pipes BCleaning the fuel filter pot CAUTION Every 100 hours of operation, clean the fuel filter in a clean place to prevent dust intrusion. To avoid personal injury; 1. Close the fuel filter lever. A Check or replace the fuel pipes after stopping the engine.

  • Page 36: Fuel Filter Cartridge Replacement

    PERIODIC SERVICE BFuel filter cartridge replacement 1. Replace the fuel filter cartridge with a new one every A Do not operate a diesel engine when engine oil is overfilled. This oil can drain through the air intake 500 operating hours. system, which cause engine disacceleration and oil 2.

  • Page 37: Changing Engine Oil

    PERIODIC SERVICE BChanging engine oil 4. If the oil level is too low, remove the oil filler plug, and add new oil to the prescribed level. 5. After adding oil, wait more than 5 minutes and check CAUTION the oil level again. It takes some time for the oil to drain down to the oil pan.

  • Page 38: Replacing The Oil Filter Cartridge

    PERIODIC SERVICE RADIATOR BReplacing the oil filter cartridge Coolant will last for one day's work if filled all the way up CAUTION before operation start. Make it a rule to check the coolant level before every operation. To avoid personal injury: A Be sure to stop the engine before WARNING changing the oil filter cartridge.

  • Page 39: Checking Coolant Level, Adding Coolant

    PERIODIC SERVICE BChecking coolant level, adding coolant 3. When the coolant level drops due to evaporation, add water only up to the full level. 1. Remove the radiator cap, after the engine has 4. Check to see that two drain cocks; one is at the completely cooled, and check to see that coolant crankcase side and the other is at the lower part of reaches the supply port.

  • Page 40: Changing Coolant

    PERIODIC SERVICE BChanging coolant BChecking radiator hoses and clamp 1. To drain coolant, always open both drain cocks and simultaneously open the radiator cap as well. With CAUTION the radiator cap kept closed, a complete drain of To avoid personal injury: water is impossible.

  • Page 41: Anti-Freeze

    PERIODIC SERVICE BAnti-freeze Freezing Point Boiling Point * Vol % CAUTION Anti-freeze °C °F °C °F To avoid personal injury: A When using anti-freeze, put on some protection such as rubber gloves (Anti- *At 1.013 × 10 Pa (760 mmHg) pressure freeze contains poison.).

  • Page 42: Air Cleaner

    PERIODIC SERVICE AIR CLEANER BEvacuator valve Open the evacuator valve once a week under ordinary Since the air cleaner employed on this engine is a dry conditions - or daily when used in a dusty place - to get type, never apply oil to it. rid of large particles of dust and dirt.

  • Page 43: Dust Indicator (Optional)

    PERIODIC SERVICE FAN BELT BDust indicator (optional) If the red signal on the dust indicator attached to the air cleaner is visible, the air cleaner has reached the BAdjusting Fan Belt Tension service level. Clean the element immediately, and reset the signal CAUTION with the "RESET"...

  • Page 44: Carriage And Storage

    CARRIAGE AND STORAGE CARRIAGE AND STORAGE CARRIAGE STORAGE CAUTION CAUTION To avoid personal injury: To avoid personal injury: A Fix the engine securely not to fall A Do not clean the machine with during operation. engine running. A Do not stand near or under the A To avoid the danger of exhaust fume engine while carrying it.

  • Page 45: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING If the engine does not function properly, use the following chart to identify and correct the cause. BWhen it is difficult to start the engine BWhen engine suddenly stops Cause Countermeasures Cause Countermeasures Check the fuel tank and refill the fuel, Check the fuel tank and fuel filter.
  • Page 46 TROUBLESHOOTING BWhen engine overheats Cause Countermeasures Engine oil * Check oil level. Replenish oil as insufficient required. Fan belt broken or * Change belt or adjust belt tension. elongated Coolant insufficient * Replenish coolant. Excessive * Add water only or change to coolant concentration of with the specified mixing ratio.

  • Page 47: Specifications

    SPECIFICATIONS SPECIFICATIONS Model V3600-E3 V3600-T-E3 Type Vertical, water-cooled, 4-cycle diesel Number of cylinders Bore and stroke mm (in.) 98 × 120 (3.86 × 4.72) Total displacement L(cu.in.) 3.620 (220.9) Combustion type Spherical type (E-TVCS) SAE NET Intermittent kW / min (rpm) 45.8 / 2600 58.8 / 2600...
  • Page 48 SPECIFICATIONS Model V3800-DI-T-E3 Type Vertical, water-cooled, 4-cycle diesel Number of cylinders Bore and stroke mm (in.) 100 × 120 (3.94 × 4.72) Total displacement L(cu.in.) 3.769 (230) Combustion type Direct injection type (E-CDIS) SAE NET Intermittent kW / min (rpm) 71.4 / 2600 H.P.
  • Page 49 SPECIFICATIONS Model V3300-E3BG Type Vertical, water-cooled, 4-cycle diesel Number of cylinders Bore and stroke mm (in.) 98 × 110 (3.86 × 4.33) Total displacement L(cu.in.) 3.318 (202.49) Combustion type Spherical type (E-TVCS) 30.6 / 1800 (41.0 / 1800) SAE NET Continuous kW / min (rpm) H.P.
  • Page 50 SPECIFICATIONS Model V3600-T-E3BG Type Vertical, water-cooled, 4-cycle diesel Number of cylinders Bore and stroke mm (in.) 98 × 120 (3.86 × 4.72) Total displacement L(cu.in.) 3.620 (220.9) Combustion type Spherical type (E-TVCS) 39.2/1800 (52.5/1800) SAE NET Continuous kW / min (rpm) H.P.
  • Page 51 SPECIFICATIONS Model V3800-DI-T-E3BG Type Vertical, water-cooled, 4-cycle diesel Number of cylinders Bore and stroke mm (in.) 100 × 120 (3.94 × 4.72) Total displacement L(cu.in.) 3.769 (230) Combustion type Direct injection type (E-CDIS) SAE NET Intermittent kW / min (rpm) —...

  • Page 52: Wiring Diagrams

    WIRING DIAGRAMS WIRING DIAGRAMS BV3600-E3, V3600-T-E3, V3300-E3BG, V3600-T-E3BG...
  • Page 53 WIRING DIAGRAMS BV3800-DI-T-E3...
  • Page 54 WIRING DIAGRAMS BV3800-DI-T-E3BG...
  • Page 56 ENGINE POWER FACTORS ALTITUDE POWER LOSS FACTORS High altitudes can cause sizeable losses or reductions in available power. The exact amount of loss can be difficult to estimate, because these losses vary with the type of engine. Generally, two stroke engines lose more power than four stroke engines, and turbocharged or supercharged engines lose less power than naturally aspirated engines.

  • Page 57: Relative Humidity

    ATMOSPHERIC TEMPERATURE & HUMIDITY POWER LOSSES These losses are generally considered to be nominal with values seldom exceeding 5%. Natural atmospheric variations, however, can combine causing nearly 20% de-rating. For example, air of 120°F (50°C) at 100% humidity. Even 100°F (40°C) temperature at 90% to 100% humidity will cause a 10% de-rating.
  • Page 58 Engine Maintenance Service Schedule Min. Every Maintenance *See Daily Every Every 100 Every 250 Every 500 1000 Remarks Service Item Note 25 Hours Hours Hours Hours Hours Engine Oil Level Deterioration & Leakage Engine Oil Or Once Change a Year Oil Filter Or Once Change...

  • Page 59: Engine Oil Maintenance

    ENGINE OIL MAINTENANCE CHECKING ENGINE OIL LEVEL V-3300 & V-3300-T ENGINE REFILL CAPACITIES Crankcase Oil Sump 14 Qts. (13.2L) and Filter LUBRICATING OIL VISCOSITY RECOMMENDATIONS ( Y ) “ADD” mark. ( X ) “FULL” mark. The minimum ambient temperature during cold 1.

  • Page 60: Engine Coolant Maintenance

    ENGINE COOLANT MAINTENANCE COOLANT RECOMMENDATIONS COOLANT SERVICE LIFE For optimum performance, Power Technology Coolant Type Service Life recommends a 1:1 mixture of water / glycol. Commercial Heavy-Duty NOTE: Use a mixture that will provide Coolant/Antifreeze that 3000 Service Hours protection against the lowest ambient Meets “ASTM D5345”...

  • Page 61: Operating Hours And Service Log

    OPERATING HOURS and SERVICE LOG THIS SERVICE LOG IS PROVIDED TO HELP YOU KEEP AN ACCUMULATIVE RECORD OF OPERATION HOURS ON YOUR GENERATOR SET AND THE DATES REQUIRED SERVICES WERE PERFORMED. ENTER TIME TO THE NEAREST HOUR. OPERATING HOURS SERVICE RECORD DATE HRs.

  • Page 62: Engine Starts But Won't Run

    ENGINE STARTS BUT WON’T RUN Engine Runs OK Unplug Remote Start-Stop from Control Box Problem with Remote Connection. Contact Jump across Equipment Manufacturer Oil Pressure Switch with Jumper Wire (2 pole) Oil Pressure Switch Check Power Single Pole to Hold Circuit Check of Run Solenoid Disconnect Wire to Test...

  • Page 63: Engine Runs Rough Or Slow

    ENGINE RUNS ROUGH or SLOW NO Visible Exhaust Smoke Excessive Exhaust Smoke BLUE Insufficient Fuel to Engine GRAY/WHITE Excessive Oil Level BLACK Check Replace Fuel Level Fuel Filter Dirty Air Filter Engine Overheated Air IN Check Engine Over Loaded Fuel Fuel System PUMP...

  • Page 64: Engine Will Not Start

    ENGINE WILL NOT START Engine Does NOT Engine Engine Cranks Crank Cranks SLOW Main Switch Battery Dead Smoke Turn Exhaust From Oil Viscosity Switch Smoke Exhaust Start TOO HEAVY “ON” Switch Check Check Glow Terminal Battery Check Plugs Ends Voltage Starter Fuel Check Fuel...
  • Page 65 SECTION 3 “GENERATOR END” SAFETY PRECAUTIONS _________________________________________________ INSTALLATION REQUIREMENTS_________________________________________ GENERATOR ASSEMBLY INFORMATION__________________________________ ENGINE and GENERATOR DIAGRAM_____________________________________ SECTION A: GENERATOR __________________________ 1-19 MARATHON MAGNAPLUS GENERATOR MANUAL Installation Operation Maintenance SECTION B: VOLTAGE REGULATORS and ENGINE CONTROLLERS MARATHON SE350 VOLTAGE REGULATOR INSTRUCTION MANUAL _______________ BASLER AVC64-4 ANALOG VOLTAGE CONTROLLER ______________________________ PT-ECU-64 ENGINE CONTROL MODULE __________________________________________ APEC 3100 ELECTRONIC ENGINE SPEED GOVERNING SYSTEM _____________________...

  • Page 66: Safety Precautions

    SAFTEY PRECAUTIONS A generator set can be potentially dangerous if not properly maintained and operated. The best Safe Guard against a dangerous situation is education, good judgment and common sense. For safe trouble free operation of your generator set some general precautions are listed below. Be sure to read, understand and follow these precautions.
  • Page 67 7) EXPLOSION: Never connect the negative (-) battery cable to the positive (+) connection terminal of the starter solenoid, or test the battery by shorting terminals together. This could ignite fuel vapors or cause the battery to explode. To disconnect the battery remove the negative battery cable first and reconnect it last.

  • Page 68: Installation Requirements

    INSTALLATION REQUIREMENTS & RECCOMENDATIONS Installation requirements may vary with each application depending on generator specification and optional equipment. Listed below are general recommendations for installing a Power Technology Stand-By Generator. Only qualified and licensed personnel should be employed to perform the installation. Follow all Safety Procedures outlined in this manual as well as those in the optional equipment manuals.

  • Page 69: Generator Assembly Information

    GENERATOR ASSEMBLY INFORMATION EXCITER TYPE GENERATOR The exciter pole pieces contain residual magnetism, which sets up lines of force across the air gap to the exciter armature. When the exciter begins to rotate a voltage is induced and current flow is initiated in the exciter armature AC windings.
  • Page 70 ROTATING FIELD ASSEMBLY (ROTOR) The rotating field assembly consists basically of four members: 1) the shaft assembly, 2) the core assembly, 3) the field coil damper windings, and 4) balance lugs to provide a high degree of static and dynamic balance. CORE ASSEMBLY The core assembly consists of a quantity of thin steel plates compressed and fastened together to form a single laminated assembly.
  • Page 71 KUBOTA V-3300 & V-3300T ENGINE with MARATHON GENERATOR END...

  • Page 72: Section A: Generator

    SECTION A: GENERATOR...
  • Page 92 SECTION B: VOLTAGE REGULATORS ENGINE CONTROLLERS...

  • Page 97: Basler Avc64-4 Analog Voltage Controller

    BASLER AVC63-4 ANALOG VOLTAGE CONTROLLER The AVC63-4 voltage regulator is designed for use on 50/60 Hz brushless generators. Features include frequency compensation, over excitation shutdown, a solid-state build-up circuit and EMI filtering. The AVC63-4 attaches to the generator with spade type wire terminals for a secure connection. The AVC63-4 has three adjustable potentiometers for fine-tuning the output voltage, stability and under frequency.
  • Page 98 BASLER MODEL AVC63-4 VOLTAGE REGULATOR Control is different on previous versions of the AVC63-4. When adjusting the Underfrequency Control on previous versions, clockwise rotation decreased the corner frequency while counterclockwise increased the corner frequency. NOTE: Further reference to corner frequency adjustments of the AVC63-4 are for the Current Version and should be reversed for the Previous Version.

  • Page 99: Frequency Compensation

    BASLER MODEL AVC63-4 VOLTAGE REGULATOR IMPORTANT: The exciter field DC resistance must be 15 Ohms or higher and less than 100 Ohms. If the exciter field DC resistance is less than 15 Ohms and the full load field current does not exceed the maximum continuous current rating of the controller, a resistor of ample wattage must be added in series with the field to increase the total resistance to 15 Ohms.

  • Page 100: Pt-Ecu-64 Engine Control Module

    PT-ECU-64 ENGINE CONTROL MODULE 1) Generator Main Switch must be in the ON position. 2) Toggle the Start/Stop Switch to the Start position. 3) Glow Plugs will preheat for 8 seconds. LED flashes slowly. 4) Preheating will cease during engine cranking cycle. LED continues flashing. 5) Engine begins an 8 seconds crank cycle, After 4 seconds of cranking the PT-ECU-64 will check for an AC signal from the generator.

  • Page 101: Apec 3100 Electronic Engine Speed Governing System

    APECS 3100 ELECTRONIC ENGINE SPEED GOVERNING SYSTEM APECS Advanced Proportional Engine Control System is an engine speed governing system that maintains the engine speed / RPMs by adjusting the Fuel Control Actuator controlling the fuel injection unit. The APECS microprocessor-based Controller processes the signal received from a speed sensor, in this application a Magnetic Pick-up and compares it to the programmed settings.
  • Page 102 GAC ESD2100 SERIES SPEED CONTROL UNIT The ESD2100 Speed Control Unit is part of an engine governing system designed to control engine speed and stability throughout the load range. Operating in combination with a magnetic pick-up and electric actuator the ESD2100 will maintain the proper engine speed by adjusting the fueling system according to the applied load.

  • Page 103: Section C: Wiring Schematics

    SECTION C: WIRING SCHEMATICS...

  • Page 118: 12-Volt Dc Engine Control Circuit Pt-Ecu-64

    POWER TECHNOLOGY SOUTHEAST, INC. 634 STATE ROAD 44 LEESBURG, FL 34748-8103 (352) 365-2777 FAX (352) 787-5545 12-VOLT DC ENGINE CONTROL CIRCUIT PT-ECU-64...
  • Page 119 POWER TECHNOLOGY SOUTHEAST, INC. 634 STATE ROAD 44 LEESBURG, FL 34748-8103 (352) 365-2777 FAX (352) 787-5545 12V DC ENGINE CONTROL CIRCUIT GAC ESD 2110...

  • Page 120: 12-Volt Dc Engine Control Circuit Series 200 Box

    POWER TECHNOLOGY SOUTHEAST, INC. 634 STATE ROAD 44 LEESBURG, FL 34748-8103 (352) 365-2777 FAX (352) 787-5545 12 VOLT DC ENGINE CONTROL CIRCUIT SERIES 200 BOX...

  • Page 121: Volt, Single Phase, 4 Wire Connection "M" Series Exciter Type

    120 VOLT, SINGLE PHASE, 4 WIRE CONNECTION “M” SERIES EXCITER TYPE...

  • Page 122: 120/240 Volt, Single Phase, 4 Wire Connection "M" Series Exciter Type

    120 / 240 VOLT, SINGLE PHASE, 4 WIRE CONNECTION “M” SERIES EXCITER TYPE...

  • Page 123: Volt, Single Phase, 4 Wire European Connection "M" Series Exciter Type

    220 VOLT, SINGLE PHASE, 4 WIRE EUROPEAN CONNECTION “M” SERIES EXCITER TYPE...

  • Page 124: Resistance Chart

    RESISTANCE CHART “M” SERIES EXCITER TYPE Main Stator Less Than 1.0 Ohm / Less Than 1.0 Ohm / Less Than 1.0 Ohm / Phase Phase Phase Main Rotor 0.75 0.875 0.75 Exciter Stator 23.0 – 28.0 23.0 – 28.0 23.0 – 28.0 Exciter Rotor 0.12 0.12...
  • Page 125 SECTION D: GENERATOR END TROUBLESHOOTING GUIDE...

  • Page 126: Zero Or Low Voltage

    ZERO VOLTAGE Check Main Check Gen Fuse Breaker is “ON” Main Coil Output to Replace Turn “ON” Breaker Fuse Breaker Wiring To Defective Panel Breaker Check Ohm’s on Exciter Leads 12 V Battery Test Replace Exciter Replace Voltage Regulator...

  • Page 127: Voltage Test / 12 Volt Battery Test

    VOLTAGE TEST Output Overload Zero High Voltage OK Voltage Low Voltage Check AMP Check Draw Replace Main Breaker From equipment On GenSet Check Load Distribution One Voltage Line Check may be Gen End Higher than the other 12 VOLT BATTERY TEST One Coil Both Coils Sensing Voltage...

  • Page 128: Overload Condition

    OVERLOAD CONDITION Check AMP Draw Check Load Distribution Disconnect Conduct 12-Volt Battery Test Engine Problem Check Stator Coil Resistance See Engine Troubleshooting Replace Stator Replace AVR And Test...
  • Page 141 Safety precautions are absolutely necessary during installation and maintenance of your Athlon ™™ generator. Warning messages are contained throughout this document, often marked with a cautionary symbol, such as . These messages are for your protection. Before any work is done: Be sure installation conforms to all applicable safety and local electrical codes.
  • Page 144 Athlon generators are brushless, self excited or permanent magnet generator (PMG) excited, synchronous AC generators. All units utilize sophisticated Automatic Voltage Regulators (AVR) to control the output voltages and frequencies. The self excited generator is made up of six major components: main stator (armature), main rotor (field), exciter stator (field), exciter rotor (armature), rectifier assembly, and voltage regulator (AVR).
  • Page 145 supplies this in-rush of starting current, the generator voltage dips temporarily. If the motor is too large for the generator, the generator’’s voltage dips greater than 30 percent. This may result in the motor starter de-energizing or the motor stalling. Outdoor Operations ––...
  • Page 146 Different generating set configurations will require different levels of site installation. For example, most enclosed sets that include switchboards and circuit breakers will require little or no connectors, pass- throughs or wiring for grounding whereas open configurations will likely require both. Please read and follow each section as it applies to the specific generating set being installed.
  • Page 147 components. Be sure to follow approved working practices, particularly when reaching inside the assembly to install and fastened coupling hardware. Following the coupling manufacturer’’s guidelines for proper fit and alignment, a flexible coupling should be used to join the engine to the generator. For belt-driven generators, avoid axial load on the bearings by verifying the alignment of the pulleys and belts.
  • Page 148 Verify that the voltage and frequency outputs listed on the generator nameplate match those required for the generat set application. The automatic voltage regulator (AVR) settings are pre-adjusted by the factory to give acceptable performance for initial testing. However, if adjustments need to be made, the AVR can be accessed by removing the saddle box cover.
  • Page 149 2.4.4.1 AGR460...
  • Page 150 2.4.4.2 AGR440...
  • Page 151 2.4.4.3 AGR341...
  • Page 152 2.4.4.4 AGR321...
  • Page 153 While testing, covers may need to be removed to make adjustments, which will expose live circuits and components. Only qualified personnel should esting and adjustments. Use a voltmeter, frequency meter and a current and/or power meter to perform basic checkout of the generating set.
  • Page 154 After adjusting the voltage and stability, the AVR will not typically require further adjustment. However, if voltage collapse or poor voltage regulation result when a load is applied, additional adjustments may need to be made. Please see the subsections below on the other possible adjustments to determine if one or more of these will fix the problem being experienced.
  • Page 155 voltage across terminals X and XX should be within 5% of 70 volts. This is the correct setting of the excitation trip. Stop the generator to reset. Only for the AGR321 AVR The over voltage function removes generator excitation (AVR output) if the AVR sensing input is lost. In addition, this AVR includes an output to trip an optional external circuit breaker.
  • Page 156 wire to connect the neutral terminal to the earth terminal, both located inside the saddle box. If unsure, check the continuity between the neutral terminal inside the saddle box and any inner, unpainted panel in the saddle box. The gen-set builder is responsible for verifying the generator frame generating set bedplate and the main ground output terminal are electrically bonded.

  • Page 157: Air Filter(S)

    4. SERVICE Performing routine service will help keep your generator running smoothly. The condition of the winding and bearings should be examined periodically, especially if the generator has been idle for a long time. Also, regular inspection and maintenance is required for generators fitted with air filters. 4.1 AIR FILTERS Removal of filters exposes live parts.

  • Page 158: Winding Condition Assessment

    4.2.1 WINDING CONDITION ASSESSMENT Be sure to disconnect the AVR and ground the leads of the Resistance Temperature Detector (RTD) before conducting this test. To determine the condition of the windings, the insulation resistance is measured from each phase-to-phase and from each phase to neutral. This measurement should be conducted as part of regular maintenance after extended shutdown periods, or if the insulation resistance value is suspected to be low, e.g., wet or dirty windings.
  • Page 159 Short Circuit Method The short circuit method is a process that should only be performed by a technician qualified in the safe operating practices required around generator sets. Contact the factory for detailed instructions, should this method be chosen. 4.3 BEARINGS All bearings are supplied from the factory pre-packed with Athlon Generator grease, conforming to the specifications of Kluber Asonic GHY 72 grease.
  • Page 160 Athlon generators are provided with excitation control systems. Four automatic voltage regulator (AVR) systems are available across the range of generator models and sizes. The following will assist the user in determining any faults. Follow the guide for the proper AVR in question. SYMPTOMS SOLUTIONS Generator produces no voltage...
  • Page 161 SYMPTOMS SOLUTIONS Generator produces no voltage Check speed with tachometer Check residual voltage and flash the field as necessary Verify generator connections Check diodes Test and adjust or replace AVR Generator produces unstable voltage Check speed with tachometer. Verify generator connections Replace defective or worn rheostat Test and adjust or replace AVR Generator produces high voltage...
  • Page 162 This procedure is appropriate for use to with either AGR460 or AGR440 regulators.) With the generator set stationary, remove the regulator access cover and leads X and XX from the AVR. Start the unit and measure voltage across the regulator terminals 7-8 on AGR460 AVR or P2-P3 on AGR440 AVR.
  • Page 163 SYMPTOMS SOLUTIONS Generator produces no voltage Check link K1-K2 on auxiliary terminals of Verify generator connections Check diodes Test and adjust or replace AVR Generator produces low voltage with load Check speed with tachometer applied Check diodes Test and adjust or replace AVR Generator produces high voltage Check speed with tachometer Verify generator connections...
  • Page 164 SYMPTOMS SOLUTIONS Generator produces no voltage Check link K1-K2 on auxiliary terminals of Verify generator connections Check diodes Test and adjust or replace AVR Generator produces low voltage with load Check speed with tachometer applied Check diodes Test and adjust or replace AVR Generator produces high voltage Check speed with tachometer Verify generator connections...
  • Page 165 With the unit operating, measure voltages at the regulator terminals P2, P3 and P4. These should be balanced and within the following ranges: 50 Hz generators - 170-180 volts 60 Hz generators - 200-216 volts Should the voltages be unbalanced, stop the set, remove the PMG sheet metal cover from the non-drive end bracket and disconnect the multi-pin plug in the PMG output leads.
  • Page 166 plate carrying positive-biased diodes. Insure that correct polarity diodes are fitted to each respective plate. The recommended torque for tightening diodes is 4.06 - 4.74 Nm (36-42 in lb). The surge suppressor is a metal-oxide varistor (““variable resistor”” used to protect circuits against excessive voltage by acting as a spark gap) connected across the two rectifier plates to prevent transient reverse voltages in the field winding from damaging the diodes.
  • Page 167 Frame Main Exciter Exciter Size Rotor Stator Rotor PM Stator AG164A 0.44 0.26 AG164B 0.48 0.26 AG164C 0.52 0.26 AG164D 0.56 0.26 AG184E 0.64 0.21 AG184F 0.74 0.23 AG184G 0.83 0.23 AG184H 0.89 0.24 AG184J 0.96 0.24 AG224C 0.59 0.142 AG224D 0.64 0.142...
  • Page 168 Unbalanced voltages indicate a fault on the main stator winding or main cables to the circuit breaker. These faults may also cause noticeable load increase on the engine. Disconnect the main cables and separate the winding leads U1-U2, (U5-U6), V1-V2, (V5-V6), W1-W2, (W5-W6) to isolate each winding section.
  • Page 169 NOTE: This warranty is extended only to Athlon industrial or commercial clients. It does not extend to customers of Athlon clients. Athlon warrants Standby Duty Generators to be free from defects in materials and workmanship for a period of 24 months from date of commissioning, 30 months from date of shipment, or 1200 hours of run time, whichever occurs first.
  • Page 170 Athlon Generators use a model number system conforming to that used by many manufacturers of similar types and models of generators. For example, Athlon Generator Model AG224D can be interpreted as shown below: Manufacturer Frame Number Number of Poles Core Designation ––...

  • Page 171: Connection Diagrams

    CONNECTION DIAGRAMS Terminal Ends NEMA Double Delta 1PH 3W DOUBLE DELTA 1 PH 3 W L-L0 L – L0 L – L0 L – L...
  • Page 172 Parallel Low Zig Zag 1PH 3W L – L0 L – L0 L – L PARALLEL LOW ZIG ZAG 1 PH 3 W L-L0 Series High Delta 3PH 4W SERIES HIGH DELTA 3 PH 4 W L – L0 L-L0 L –...
  • Page 173 Parallel Low Wye (Star) 3PH 4W PARALLEL LOW WYE (STAR) 3 PH 4 W L-L0 L – L L – L0 Series High Wye (Star) 3PH 4W SERIES HIGH WYE (STAR) 3 PH 4 W L-L0 L – L L – L0...
  • Page 174 The following points are basic criteria, which must be met before two units can be paralleled. Additional paralleling circuitry Voltage regulator-paralleling provisions (Note: AVR Model AG460 is not suitable for parallel operation). Paralleling current transformer(s) Paralleling provisions on governor controls Before operating generator sets in parallel, each set should be checked by starting, operating, and adjusting the sets as individual units before attempting paralleling.
  • Page 175 Generators use the droop method. The method of kVAr sharing is to create a generator voltage characteristic, which falls with decreasing power factor (increasing kVAr). This is achieved with a current transformer (C.T.), which provides a signal dependent on current phase angle (i.e. power factor) to the AVR.
  • Page 176 APPENDIX D SAE DATA SAE ADAPTOR / COUPLING COMBINATIONS Adaptor Coupling AG16 AG18 AG22 AG27 ALPHA 11.5 11.5 11.5 11.5 17.75D 17.75D 17.75D A - Available O - Most Common X - Special Order AG184 H & J - Only Coupling & Adaptor Combinations Available...
  • Page 177 Standard Industrial Flywheel Housings SAE No. # Holes Size 34-3/4 33-1/2 3-15/16 1/2-13 25-1/2 26-3/4 3-15/16 1/2-13 25-1/2 24-3/8 3-15/16 1/2-13 20-1/8 21-3/4 20-7/8 3-15/16 7/16-14 17-5/8 19-1/4 18-3/8 3-15/16 3/8-16 16-1/8 17/3/4 16-3/8 3-15/16 3/8-16 14-1/4 15-7/8 3-15/16 3/8-16 12-3/8 13-1/8 2-13/16...
  • Page 178 Standard Industrial Flywheels Nom. Clutch AN(G) # Holes Bolt Size Diameter 6-1/2 7-1/4 8-1/2 7-7/8 2-13/16 1-3/16 5/16-18 7-1/2 8-18 9-1/2 8-3/4 2-13/16 1-3/16 5/16-18 8-7/8 10-3/8 9-5/8 3-15/16 2-7/16 3/8-16 10-7/8 12-3/8 11-5/8 3-15/16 2-1/8 3/8-16 11-1/2 12-3/8 16-1/8 13-1/8 3-15/16 1-9/16...
  • Page 179 SAE PLATE BOLT TORQUE VALUES Model Torque Torque Bolt Size Number (Nm) (Ft-lb) AG16 M10 X 30 mm AG18 M10 X 50 mm AG22 M16 X 35 mm AG27 M16 X 55 mm M20 X 55 mm M16 X 65 mm M 24 X 65 mm 1072...
  • Page 200 Athlon™™ Generators are designed and manufactured for safe and reliable operation, in factories certified to ISO 9001:2000. Athlon™™ Generators are rated for standby or continuous duty. Athlon™™ AC synchronous generators are brushless 4 pole, self-ventilated alternators, which create 60 Hz power at 1800 RPM or 50 Hz power at 1500 RPM.
  • Page 203 ATHLON GENERATOR LLC Montross, Virginia...

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