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MagnaMaxDVR Installation, Operation, andMaintenance Manual

Table of ContentsSectionPage1Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-134Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-155Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-196Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-387Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-468Generator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-509Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-5210Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-5411Preparation for Shipment or Extended Storage . . . . . . . . . . . . . . . . . . . . . . 5512Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56-60Generator Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Warnings & Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 62-Back Inside Cover

SafetyA Few Words About SafetyPLEASE REMEMBER SAFETY FIRST. If you are notsure of the instructions or procedures, seek qualifiedhelp before continuing.This service manual emphasizes the safety precautions necessary during the installation, operation andmaintenance of the MAGNAMAXDVR generator.Whenever the generator is running, always assumeand proceed as if voltage is present. Residualvoltage is present at the generator leads and at theregulator panel connections, even with the regulatorfuse removed. Caution must be observed. Otherwise,serious personal injury or death can result.Each section has caution and warning messages.These messages are for your safety and the safetyof the equipment involved. If any of the cautions orwarnings are not readily understood, seek clarification from qualified personnel before proceeding.Whenever solvents, cleaners, or flammable liquidsare present, adequate ventilation must be availableto avoid fire, explosion, and health hazards. Alwaysavoid breathing vapors and use suitable personal protective equipment to prevent personal injuries (suchas eyes, face, and hand protection).Before any service work is done, disconnect all powersources and, where appropriate, lock out all controlsto prevent an unexpected start-up of the generatorset. Proper grounding in compliance with local andnational electrical codes must be provided. Thesesafety precautions are necessary to prevent potentialserious personal injury, or even death.This manual is not intended to be a substitute forproperly trained personnel. Repairs should only beattempted by qualified, trained people. The cautionsand warnings point out known conditions that arepotentially dangerous. Each installation will create itsown set of circumstances. No manual can cover everypossible situation.The hazards associated with lifting or movingthe MAGNAMAXDVR generator are pointed out inthe installation and service sections; incorrect liftingor moving can result in personal injury or propertydamage.When in doubt, ask. Don’t be embarrassed to ask“dumb questions.” Remember, dumb questions aremuch easier to handle than dumb mistakes.11

General InformationMechanical Design2GeneralTemperature RiseAll single and two bearing units are manufactured withcast iron end brackets and adapters and fabricatedsteel frames. Flexible drive discs and SAE adaptersare machined to SAE standards. Prelubricated,regreasable, shielded ball bearings are used onMAGNAMAXDVR generators. Standard units are fullyguarded. Dripproof shields are available as an option.All ratings and frame sizes are based on NEMA andCSA Class F and Class H temperature rises on boththe rotor and stator windings. Ratings for international and marine applications are available.Conduit BoxThe large, front end-mounted conduit box is constructed of formed sheet steel, which will allow theaddition of top-mounted control packages. Refer toMarathon Electric for top mounted controls of morethan 240 lbs. There is ample room inside the conduitbox for a circuit breaker (through 800 amp ratings)and other options. The conduit box cover properlydirects outside ven-tilating air through the generator.MAGNAMAXDVR Uni-rotor ConstructionAn aluminum die cast rotor core affords high mechanical integrity and low vibration at operating speeds.Amortisseur winding and coil supports are die cast asan integral part of the rotor. Laminations are 4-pole, onepiece laminations which are shrunk fit and keyed to theshaft. No dovetails, cross bolts or other pole to shaftconnecting devices are used. The cast unidirectionalaluminum alloy ventilating fan provides even air distribution to maximize cooling and generator efficiency.Adapters and Drive DiscsStandby GeneratorSynchronous generators used on emergency backuppower can have temperature rises up to 25 C abovethose for continuous operation (NEMA MG1-22.40and MG 1-22.84).Premium Insulation SystemAll MAGNAMAXDVR generators are built with Class Hor better insulation materials. All standard generatorsare suitable for continuous duty at Class F temperaturerise and will give equivalent or better winding life expectancy to generators supplied with Class A or B insulationsystems operated within their temperature limits.The varnishes and epoxies used are synthetic, nonhygroscopic. Multiple dip and bake cycles of the mainwinding, plus a final coat of epoxy, make the standard winding moisture and fungus resistant. TheMAGNAMAXDVR rotor is wet wound with thermosetting epoxy applied between each layer, plus a finalcoating of epoxy for moisture and abrasion resistance.MAGNAMAXDVR generators can be ordered with anepoxy vacuum pressure impregnated (VPI) insulationsystem as an option (MAGNAMAXDVR generatorswith form wound coils include VPI as standard).All single bearing units are available with severaladapter and drive disc arrangements. These can beshipped to order or can be changed in the field withstandard shop tools. When changing flexible drivediscs, spacers are used between the discs and thecast iron hub to maintain SAE standard dimensions.Power FactorElectrical DesignThe standard voltage regulator is a fully encapsulated,static type with a solid state build up circuit. Standardfeatures include 3 phase RMS sensing, paralleling,adjustable underfrequency protection, and overexcitation protection. Refer to the regulator manual formore information.GeneralAll standard products have 2/3 pitch main windingsto eliminate the third harmonic. This serves to loweroperating temperatures, give lower harmonic contentand better wave form, and extend the overall lifeof the generator. The phase sequence is ABC whenrotated counterclockwise viewing exciter end.2All standard generators are designed for operationat rated kVA at 0.8 lagging power factor but can beoperated at rated kVA over the 0.8 to 1.0 powerfactor range.MAGNAMAXDVR Voltage Regulator

General InformationHow to Read a Model NumberIt is extremely important to properly identify themachine when requesting parts or service.Always have available the generator model number andserial number when requesting information from thefactory. We cannot help you without this information.It is also beneficial to know the mounting arrangement code (see figure 2-1).An Example for MAGNAMAXDVR GeneratorsExample:431jRSLkl m4000noAAqjFrame NumberkR – Random WoundF – Form WoundlS – 1 BearingD – 2 BearingsmL – Up to 480 voltsS – 600 voltsM – 1000-6900 voltsnStyle4-Magna (slant type conduit box)8-Magna (square conduit box)oModel in SeriesqElectrical/mechanical modification–minormodification, used in sequence A, B, C, etc.(must specify when requesting WK2)ArrangementAdapterSAE SizeDrive DiscSAE ll DelcoNone18Delco186-1/221102Figure 2-13

InstallationReceiving Your MAGNAMAXDVR Generator3Upon receipt of the generator, it is recommended thatit be carefully examined for possible damage incurredin shipment. The generator was given to the freightcompany in good condition, and they are responsiblefor the product from our dock to yours. Any damageshould be noted on the freight bill before acceptingthe shipment. Claims for damage must be promptlyfiled with the freight company.Unpacking and HandlingRead all instruction cards carefully. When lifting,attach an overhead crane to the lifting lugs on the generator frame. Apply lifting forces in a vertical direction.The lifting lugs on the generator aredesigned to support the generator only. Do not liftcomplete generator set by means of lifting lugs ongenerator. Personal injury or equipment damagemay result.If the machine has been exposed to damp, humidconditions, the insulation resistance should bechecked. Refer to Section 8.Generator Mounting – Single BearingSingle bearing generators are provided with an SAEflywheel adapter and flexible drive discs. Very closetolerances are maintained in the manufacture ofthe generator so that the alignment procedureis extremely simple. A coupling hub of nodulariron is shrunk onto the shaft and special steeldrive discs are bolted to the hub. Holes are provided in the periphery of the coupling disc whichcorrespond to tapped holes in the flywheel.The outside diameter of the discs fits in a rabbet in theflywheel so that concentricity is assured in all cases.StorageDo not apply any force to generator fan for lifting or rotating generator rotor.Rotate engine flywheel or use slots on fan hubfor rotation. Disregarding these instructions maycause personal injury or equipment damage.In the event that the generator is not to be installedon the prime mover immediately, it is recommendedthat it be stored in a clean, dry area which is not subject to rapid changes in temperature and humidity.See Section 11 for more rsorgrade8placeboltsandhardened washers are recommended to mount thedrive discs to the flywheel.Preparation for UseAlthough the generator is carefully inspected andtested in operation before it leaves the factory, it isrecommended that the unit be thoroughly inspected.The insulation on the wire should be inspected and allbolts should be checked for tightness.Remove all shipping tapes, bags, blocks, and skidswhich are used to prevent vibration and rotor movement during shipment. Dry, low-pressure compressedair of approximately 30 psi (206 KPa) can be usedto blow out the interior of the generator. In the caseof two bearing machines, it is possible to turn therotor by hand to make sure that it rotates smoothlywithout binding.If the machine has been in storage for a year or longer, itis recommended that it be lubricated according to thelubrication instructions and chart found in Section 5.4.

InstallationBelt Drive430 frame, two bearing generators can be belt driven.Please refer to Marathon Electric for applicationassistance involving belt driven installations. Sheavediameters should be chosen according to the tablebelow.MAGNAMAX DVR Sheave Application forTwo Bearing Units jModel431RDL4005431RDL4007432RDL4009Min. SheaveDia. InInches @10,000 Hr.B-10 Life l60 Hz 50 Hz13.0 k 10.915.2 k 13.317.0 k 14.8Min. SheaveDia. InInches @Max.20,000 Hr. SheaveB-10 Life lWidth60 Hz 50 Hz Inches16.9 k 14.28.519.8 k 17.3 k8.522.5 k 19.5 k8.5j Assumptions:A. Belting factor is 1.3.B. The drive and the driven sheaves are thesame diameter.C. The sheave load is located at the center ofthe shaft extension.D. Based upon continuous kW ratings.k These sheave diameters exceed the maximumrecommended belt speed of 6000 ft/min.l B-10 Life means 90% of the bearings will last thislong or longer.Environmental ConsiderationsDirt, moisture, heat, and vibration are enemies ofelectrical equipment. Excessive exposure to theelements will shorten the life of the generator.The ambient temperature should not exceed thevalue shown on the generator nameplate. TheMAGNAMAXDVR is built in a NEMA open typeenclosure. Generators for outdoor application shouldbe protected from the elements by housings with properopenings for ventilation. This protection should bedesigned to prevent the direct contact of wind drivenrain, snow, or dust with the generator. In moist orhumid areas, such as the tropics and marine service,additional protection is recommended. Althoughthe standard windings are humidity and moistureresistant, special insulations and accessories such asspace heaters can increase generator life significantly.In extremely dirty and dusty environments, a meansof providing filtered cooling air to the generator isrecommended. When generators are markedthey must be installed in a clean environment.If not possible, a means to providing filtered coolingair to the generator is mandato