Marathon Electric Magna Plus 280-430 Frame, Installation, Operation & Maintenance Manual

Page 1: ...OR 280 430 Frame Installation Operation and Maintenance Manual Marathon Electric Mfg Corp A Subsidiary of Regal Beloit Corp P O Box 8003 Wausau WI 54402 8003 Phone 715 675 3359 Fax 715 675 8026 www marathonelectric com ...

Page 2: ... 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 attempted 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 When in doubt ask Questions are much ea...

Page 3: ...ge Regulator Exciter Field stator N S PMG Field rotor PMG Armature stator PMG optional L1 L2 L3 Input Power Single Phase shunt powered regulator Sensing Input Single Phase 3 phase optional Exciter Field Power DC out PMG Input Power optional 1 phase 300 250 hertz Main Armature stator 3 Phase AC out FIGURE 1 MagnaPLUS Circuit Diagram FIGURE 2 Typical MagnaPLUS Layout Diagram ...

Page 4: ...er field required to maintain constant generator terminal voltage The generator s terminal voltage is changed by adjusting the regulator s reference set point Consult the regulator manual for specific adjustment and operating instructions MOTOR STARTING When a motor is started a large surge of current is drawn by the motor This starting current is equivalent to the motors locked rotor or stall cur...

Page 5: ...er foot GENERATOR MOUNTING Two Bearing Generators Direct Drive Two bearing generators are provided with a keyed shaft extension For direct drive generators the assembler furnishes a flexible coupling which is installed between the driver and the generator s shaft Aligning the generator and its driver as accurately as possible will reduce vibration increase bearing life and ensure minimum coupling ...

Page 6: ... or sawing An approved connector must be used in conjunction with the conduit To minimize the transmission of vibration it is essential that flexible conduit be used for all electrical entrance to the generator conduit box All MagnaPLUS generators are equipped with link boards terminal strips for both internal and external connections All connections made to the studs of the link board should be m...

Page 7: ...20 190 110 50 208 120 200 115 190 110 HIGH SERIES DELTA CONNECTION L1 L2 L3 T1 T4 T7 T10 T2 T5 T8 T11 T12 T9 T6 T3 L L L N VOLTAGE HIGH DELTA Hz L L L N 60 277 139 240 120 50 240 120 220 110 200 100 LOW PARALLEL DELTA CONNECTION L1 L2 L3 T1 T4 T7 T10 T2 T5 T8 T11 T3 T6 T12 T9 L L L L VOLTAGE LOW DELTA Hz L L L N 60 120 NA 110 NA 50 110 NA 100 NA ...

Page 8: ...ION L2 T3 T6 L1 T7 T10 T1 T4 T2 T5 T8 T11 T12 T9 L N L N L L VOLTAGE LOW ZIGZAG Hz L L L N 60 240 120 220 110 50 220 110 200 100 Note Single phase KW KVA ratings are approximately equal to 50 of the generator s three phase ratings HIGH ZIG ZAG SINGLE PHASE SERIES CONNECTION L1 L2 T1 T4 T7 T10 T2 T5 T8 T11 T12 T9 T6 T3 L N L N L L VOLTAGE HIGH ZIGZAG Hz L L L N 60 480 240 460 220 50 415 208 380 190...

Page 9: ...rt up instructions and ensure that all recommended steps and procedures have been followed 9 Remove any masking materials affixed during painting Inspect the generator prime mover and any accessory equipment to ensure that nameplates and all safety warning caution signs and decals provided with the equipment are in place and clearly visible Note It is strongly recommended that the authority having...

Page 10: ...ons during generator coast down 2 Isolate all conditions that could apply voltage to the generator terminals while the generator is at rest Failure to comply could result in personnel injury or equipment damage 3 If the unit is equipped with space heaters verify that the heater circuit is energized MAINTENANCE The following maintenance procedures should be followed to ensure long equipment life an...

Page 11: ...jects which may have been drawn into the generator Verify that the generator s air gaps main rotor and exciter are free from obstructions If possible rotate the generator manually to ensure free rotation Never bar over the engine generator set using the generator fan WARNING THE FOLLOWING TEST MUST BE CONDUCTED BY QUALIFIED ELECTRICAL PERSONNEL LETHAL VOLTAGE MAY BE PRESENT AT BOTH THE GENERATOR A...

Page 12: ...de terminal post FIGURE 3 DIODE POLARITY When the positive test probe is connected to the diode s anode and the negative test probe is connected to the diode s cathode forward biased the diode will switch on and conduct electricity figure 3 This is observed by a low resistance reading when using an ohm meter or the lighting of the bulb when using a battery light continuity tester Reversing the tes...

Page 13: ...ed Remove the bearing bracket retaining cap screws Using a flat bladed screw driver or chisel pry the bracket back from the frame After approximately 1 8 inch the bracket will clear the locating register on the frame Lower the shaft extension until the rotor is resting on the main stator core Continue to pull the bracket free from the bearing Visually inspect the bearing bore for damage or wear If...

Page 14: ...The first step of troubleshooting is to gather as much information as is possible from operating personnel and individuals present during the failure Typical information includes how long the unit had been operating what loads were on line weather conditions protective equipment that did or did not function In addition information as to the operating condition of the generator s prime mover is vit...

Page 15: ...tor using the 12 volt battery test as specified in the testing section If the results indicate generator problems perform insulation continuity and diode tests as specified in the testing section Regulator protection operating Adjust regulator Consult regulator manual Regulator inoperative Adjust or replace regulator Consult regulator manual GENERATOR PRODUCES LOW VOLTAGE NO LOAD CAUSE CHECK AND R...

Page 16: ...ntinuity and diode tests as specified in the testing section GENERATOR PRODUCES FLUCTUATING VOLTAGE CAUSE CHECK AND REMEDY Fluctuating engine speed Check engine and governor systems for malfunctions Check load for fluctuation Regulator stability Adjust Regulator stability Refer to Regulator manual Regulator external rheostat Replace defective or worn rheostat Use shielded cable to minimize electri...

Page 17: ...one leg GENERATOR PRODUCES MECHANICAL NOISE CAUSE CHECK AND REMEDY Defective bearing Replace bearing Loose or misaligned coupling Tighten realign or replace coupling Belt slap or loose guards Check belt tensioning Check belt guard fasteners EQUIPMENT RUNS NORMALLY ON UTILITY POWER BUT WILL NOT RUN ON GENERATOR SET CAUSE CHECK AND REMEDY Distorted voltage waveform Analyze load Excessive SCR thyrist...

Page 18: ... 431PSL6208 0133 715 12 20 475 390 432PSL6210 0214 8114 15 1 440 360 432PSL6212 0226 8656 14 1 445 385 433PSL6216 01215 1 0672 16 2 425 345 433PSL6220 01214 9743 15 6 430 350 Stator resistance measured line to line in a high wye connection DEDICATED GENERATOR RESISTANCE EXCITER FIELD SINGLE PHASE STATOR ROTOR NO LOAD VOLTS 60 HZ 281PSL1511 1 420 381 8 3 281PSL1512 1 106 395 8 1 281PSL1513 632 430 ...

Page 19: ...4 Rectifier Assembly 14 Fan 5 Air Intake Screen 280 frame only 15 Mounting Adapter SAE 6 Exciter Rotor 16 Shaft 7 Exciter Stator 17 Drive Hub 8 Link Board terminal block 18 Drive Disk SAE 9 Conduit Box 19 Exhaust Screen drip cover not shown 10 Generator Frame 20 Mounting Base Note Illustration above is a 280 frame MagnaPlus Other Frame sizes are typical Optional PMG not shown The generator model a...

Page 20: ...gral Keyway 4 Rectifier Assembly 14 Fan 5 Air Intake Screen 280 frame only 15 End Bracket drive end 6 Exciter Rotor 16 Bearing drive end 7 Exciter Stator 17 Shaft 8 Link Board terminal block 18 Key 9 Conduit Box 19 Exhaust Screen drip cover not shown 10 Generator Frame 20 Mounting Base Note Illustration above is a 280 frame MagnaPlus Other Frame sizes are typical Optional PMG not shown The generat...