User Manual Capacitor Type Generator 1CBC08AL · for tightness and examine the insulation on lead wires for chafing. NOTE: Wet windings should be ... The generator needs sufficient

1CBC08AL User Manual

1

User Manual

Capacitor TypeGenerator

1CBC08AL


2

Please read this manual carefully prior to installing and operating this generator.

General Technical Data of the Generators Brushless capacitor type generator, single phase

Rated 8kW 60Hz or 6.5 kW 50Hz, 4 leads, P.F.=1.0

4-pole, 60Hz, 1800RPM, P.F.=1.0, Continuous Duty

4-pole, 50Hz, 1500RPM, P.F.=1.0, Continuous Duty

Temp rise 125°C / 40°C ambient temperature

Insulation Class H

Single bearing

The use of any spare parts that are not genuine or not expressly authorized shall freeColiseum Electric Corporation from any warranty liability and any responsibilityconcerning conformity to regulations and relevant consequences.

Installation, after-sales modifications and maintenance must be carried out byadequately trained staff.


3

TABLE OF CONTENTS

RULES FOR SAFE OPERATION........................................................................................................................4

RECEIVING THE GENERATOR.........................................................................................................................5

STORING THE GENERATOR ...........................................................................................................................5

INSTALLATION...............................................................................................................................................6

LIFTING THE GENERATOR..........................................................................................................................6

LOCATION/ENVIRONMENT.......................................................................................................................6

MOUNTING GENERATOR TO ENGINE ....................................................................................................... 6

EARTH/GROUND THE GENERATOR........................................................................................................... 6

OPERATION ...................................................................................................................................................7

BEFORE STARTUP ...................................................................................................................................... 7

START-UP ..................................................................................................................................................7

SHUTDOWN ..............................................................................................................................................7

MAINTENANCE..............................................................................................................................................8

GENERAL MAINTENANCE..........................................................................................................................8

INSULATION RESISTANCE TEST .................................................................................................................8

DRYING OUT THE GENERATOR WINDINGS ...............................................................................................8

TROUBLESHOOTING...................................................................................................................................... 9

MECHANICAL ISSUES................................................................................................................................. 9

ELECTRICAL ISSUES.................................................................................................................................... 9

FLASHING THE FIELD ...............................................................................................................................11

CHECKING THE DIODES ...........................................................................................................................11

REPLACING THE DIODES..........................................................................................................................12

CHECKING THE CAPACITOR.....................................................................................................................12

RESISTANCE VALUES FOR WINDINGS .....................................................................................................12

APPENDIX A – EXPLODED VIEW ..................................................................................................................13

APPENDIX B – SPARE PARTS LIST ................................................................................................................14

APPENDIX C – WIRING DIAGRAM – 50Hz or 60Hz ......................................................................................15

....................................................................................................................................................................15


4

RULES FOR SAFE OPERATION

CAUTION!

FAILURE TO FOLLOW INSTRUCTIONSIN THIS MANUAL MAY LEAD TOSERIOUS INJURY OR EVEN DEATH! THEGENERATOR IS TO BE OPERATED BYTRAINED AND QUALIFIED PERSONNELONLY! THE GENERATOR IS FORINDUSTRIAL USE ONLY.

The following safety guidelines shouldalways be used when operating,servicing, or maintaining the generator.

DO NOT operate or service this generatorbefore reading this entire manual. Thisgenerator should not be operated bypersons under 18 years of age.

ALWAYS make sure generator installationis in accordance with electrical codes foryour location.

ALWAYS have a qualified electricianperform the generator wiring installation.

NEVER operate the generator withoutproper protective clothing, shatterproofglasses, steel toed boots and otherprotective devices.

NEVER operate the generator when notfeeling well due to fatigue, illness or takingmedicine.

NEVER operate the generator under theinfluence of drugs or alcohol.

NEVER use accessories or attachments,which are not recommended by your localdistributor or original manufacturer for thegenerator. Manufacture does not assumeresponsibility for any accident due togenerator modifications.

ALWAYS check the machine for loosenedthreads, bolts, or other parts before starting.

NEVER operate the generator in anexplosive atmosphere or where fire couldresult.

ALWAYS allow the generator to cool beforeperforming service and maintenancefunctions. Contact with HOT componentscan cause serious burns.

NEVER operate the generator in anyenclosed or narrow area where free flow ofthe air is restricted. If the air flow isrestricted it will cause serious damage tothe generator or engine and may causeinjury to people. The generator engine givesoff DEADLY carbon monoxide gas.

ALWAYS make sure generator is properlygrounded.

DO NOT place hands or fingers inside thegenerator when engine is running(generator is rotating).

NEVER allow power cables or cords to layin water or any other liquid.

The electrical voltage required to operatethe generator can cause severe injury oreven death through physical contact withlive circuits. Turn all circuit breakers OFFbefore performing maintenance on thegenerator.

ALWAYS make sure that electrical circuitsare properly grounded per the NationalElectrical Code (NEC) and local codesbefore operating generator. Severe injury ordeath by electrocution can result fromoperating an ungrounded generator. If theunit is sold internationally (outside USA),please make sure that grounding is doneaccording to the local electrical code.

ALWAYS store the generator properly whennot being used. The generator should bestored in a clean and dry location.

!


5

DANGER!

DANGER!

HAZARDOUS VOLTAGE. Voltage orcurrent hazard sufficient to cause shock,burn, or death. Disconnect and lockoutthe load before servicing.

NEVER touch output terminals duringoperation. This is extremely dangerous.ALWAYS stop the machine and place thecircuit breaker in the “OFF” position whencontact with the output terminals is required.There exists the possibility of electrocution,electrical shock or burn, which can causesevere bodily harm or even death!

Back feed to a utility system can causeelectrocution and or property damage. DONOT connect to any building's electricalsystem except through an approved deviceor after building main switch is opened.ALWAYS have a licensed electricianperform the installation.

When handling capacitor please useextreme caution as there is possibilityfor shock, explosion, or burning, evenafter the engine and generator set havestopped rotating.

Disconnect capacitor from the circuit beforedoing any work. Make sure that there is anopen circuit so that the capacitor isdisconnected. Wait for at least 10 minutesafter the capacitor is disconnected for self-discharge and then short-circuit (using ashorting stick or screw driver with aninsulated handle across the capacitorterminals) and ground the capacitor beforehandling.

RECEIVING THE GENERATOR

Once the generator is received you shouldfirst examine it carefully for any damagesduring shipping and for missing parts. Ifthere is shipping damage, then please makenote of the damage with the carrier, andcontact Coliseum Electric immediately.

NOTE: Please note any damage with thecarrier and be sure to note this damageon the Bill of Lading document. Takedigital photos when available and besure to properly document the damage.

STORING THE GENERATOR

If the generator is not immediately used, itshould be stored indoors in a clean and dryenvironment.

If the generator is stored for an extendedperiod of time, it should be cleaned andtested before operation. Also, check all boltsfor tightness and examine the insulation onlead wires for chafing.

NOTE: Wet windings should bethoroughly dried out before operationotherwise serious damage to thegenerator can result. Please see theMaintenance section of the User Manualon how to how to dry out the generatorwindings.

!

!


6

INSTALLATION

Check the generator thoroughly beforestarting installation. Make sure there is nodamage during shipment or during storage.

Perform the Insulation Resistance Test anddry out the generator windings if necessary.Check Maintenance Section of this Manualfor additional instructions.

LIFTING THE GENERATOR

WARNING!

THE GENERATOR LIFTING EYE ISDESIGNED FOR LIFTING THEGENERATOR ONLY. IT IS NOTDESIGNED TO USE TO LIFT THEGENERATOR AND ENGINE(GENERATOR SET).USING GENERATOR WITHOUT PROPERLOAD BEARING CAPACITY CAN CAUSESEVERE INJURY AND DAMAGE.

Do not lift single bearing generators withoutthe rotor anchor bar securely fixed. Removethe rotor anchor bar only when attaching thegenerator to the engine. Lift the generatorhorizontally in order to prevent the rotorfrom slipping out.

LOCATION/ENVIRONMENT

Installation of the generator to the enginemust be done in a location that is protectedfrom moisture, dust, dirt, and harmful fumes.

Generator intake and outlet air passagesneed to be unobstructed during generatoroperation. Please do not mount anyobstructions that would restrict the airflow.The generator needs sufficient aircirculation in order to provide propercooling. Make sure that hot air from radiatoror engine does not pass through thegenerator.

Make sure the mounting surface (generatorset base) has sufficient strength, rigidity,and uses the proper anti-vibration mounts inorder to keep vibration and noise to aminimum.

MOUNTING GENERATOR TO ENGINE

Generator is mounted to the engine by theuse of the generator coupling disc which fitsperfectly into the recess on the engineflywheel.

Holes on the coupling disc correspond tothreaded holes on the engine’s flywheel.The coupling disc will mate with the primemover’s flywheel so that concentricity isobtained.

Coupling to Engine:1. Make sure that the generator and

engine are level.2. Carefully pull out the main rotor

assembly from the generator housing.Be careful not to damage the copperstator, rotor, or capacitor windings.

3. Make sure the generator coupling disc isflat against the engine flywheel and fitsperfectly into the recess on the engineflywheel. Use appropriate bolts andhardened washers to mount thecoupling disc to the engine flywheel.Tighten with calibrated torque wrench.Split type lock washers should NOT beused due to possible damage tocoupling disc.

4. Mount generator housing over rotor andmount to engine housing.

5. Mount the generator SAE housing to theengine housing. If bolted properly thereshould be no further alignmentnecessary.

EARTH/GROUND THE GENERATOR

The generator housing has to be connectedto ground. If flexible anti-vibration mountsare used, then an earth conductor should beconnected in parallel to the base for propergrounding. Generator has an “earthing” bolt

!


7

on the generator housing or generatormounting feet.

WARNING!

MAKE SURE THAT GENERATOREARTHING/GROUNDING IS DONEPROPERLY. NOT DOING SO CANCAUSE SHOCK AND EVEN DEATH.

HI-POT TEST

The generator end and capacitor are eachalready hi-pot tested by the manufacturer.If you must perform hi-pot testing of thefinal system or light tower, please consultmanufacturer for proper instructions forproper hi-pot procedures including de-rated hi-pot testing. Not doing so cancause premature failure of the gen end orthe capacitor.

During hi-pot testing the generator endcapacitor MUST be disconnected. Notdoing so will cause failure of the capacitorin the field.

OPERATION

BEFORE STARTUP

The following steps are recommended priorto starting the generator for the first time:1. Make sure generator and engine are

level and bolted securely on a base.2. Check visually for any foreign materials.3. Make sure all nuts and bolts are

tightened properly.4. Check all connections against the wiring

diagram in Appendix C – especially thegenerator lead wires. Make sureconnections are tight and properlyinsulated. Vibration can cause

connections to loosen, disconnect orrotate causing short circuits.

5. Make sure generator is groundedcorrectly using generator grounding bolt.

START-UP

1. Make sure generator is in no-loadcondition - disconnect generator outputfrom load. This can be done byswitching the circuit breaker in the OFFposition or not connecting a load to thegen set terminals.

2. Check that all engine start-upprocedures have been followed.

3. Start engine and adjust engine speed toget desired setting for 1500RPM, 50Hzor 1800RPM, 60Hz operation. (Forexample, adjust engine speed for no-load operation between 60Hz-62Hz for60Hz application). Reference enginemanual for how to adjust engine speed.

4. Start the engine again (follow EngineManufacturer’s recommended startupprocedures). Have voltmeter hooked upto generator terminal board and checkthe voltage to the rated values.

5. If the there is no voltage or incorrectvoltage level, please reference theTROUBLESHOOTING section of thisUser Manual.

6. Check generator speed (frequency)under load. Adjust as necessary.

7. It is recommended to apply differentload levels for 2 to 3 minutes (25% load,50% load, 75% load, full load, and 110%load) to the generator and test voltagelevels for proper adjustment andfunction.

SHUTDOWN

Shutdown varies based on the engine used.Please reference the engine User Manualfor proper shut down procedures.

!


8

MAINTENANCE

GENERAL MAINTENANCE

Check generator windings for buildup ofdirt, oil, or any other substances. Iffound, please remove rotor and removedebris. Make sure the generatorwindings are dry before assembling.

Check generator intake and exhaustventing openings (bearing cover andopenings on the housing for air outlet) toensure airflow is not obstructed.Remove debris.

Periodically check bearings for unusualoperation. Unusual operation is definedby excessive vibrations, unusual noise,grease leaking, etc. Replace bearings ifunusual operation determined.

Before operation check the resistance ofthe stator winding by performing theInsulation Resistance Test. The readingshould be greater than 2 MΩ otherwisedrying out the windings will benecessary.

Check capacitor for any damage to thecapacitor housing and the top terminal.Any visible damage or bent terminalswarrants replacement of the capacitor.

INSULATION RESISTANCE TEST

1. Disconnect all electronic components,capacitor, etc.

2. Short out the diodes on the rotatingdiode assembly.

3. Use a MegOhmMeter or InsulationMultimeter and connect between anoutput lead terminal and ground, andlater disconnect the lead wires from theterminal board and measure theresistance between lead wires andground.

4. Measured value of insulation resistancefor all windings to ground. Measured

values should be greater than 2 MΩ. Ifnot, then dry out the generator windings.

DRYING OUT THE GENERATORWINDINGS

One or more of the following methods canbe used to dry out the windings.

Push hot air through the generator usingheaters and blowers. Make sure the aircan flow freely through the generator.Also, be careful not to overheat thewindings which could cause permanentdamage.

Run the generator set unexcited bydisconnecting the capacitor terminals for15 minutes.

Oven dry the generator for up to 3 hoursat 60°C-80°C temperature. Make sure toremove the capacitor during ovendrying.

Once the Insulation Resistance is raised toa level of greater than 2 MΩ then thegenerator can be put into service.


9

TROUBLESHOOTING

MECHANICAL ISSUESSYMPTOM CAUSE SOLUTION

GeneratorOverheating

Air vents obstructed, preventingnormal air flow required forcooling

Check vents at rear bearing cover and fan intakeair vent and make sure obstructions are removed.

Load exceeds generator ratedload

Reduce the load on the generator to equal orbelow rated load listed on generator name plate.

High ambient temperatureImprove airflow to generator. Make sure that hotair is not recycled from generator or engine orreduce the ratings / load on the generator.

High altitudeAltitude reduces the rating and affects the coolingof generator. Reduce load of generator untiloverheating stops.

ExcessiveVibration / Noise

Misalignment of coupling betweengenerator and engine.

Realign and tighten connection between couplingdisc and engine flywheel, and generator housingand engine housing. Make sure correct gradebolts are used and are tightened to appropriatetorque level using calibrated torque wrench.

Faulty or damaged bearing Replace bearing.

ELECTRICAL ISSUESSYMPTOM CAUSE SOLUTION

Generator willnot excite, novoltage

Loss of residual magnetism Flash the Field to restore the residual magnetism.Faulty Capacitor Replace the capacitor.

Faulty diodes. Check each diode first. Then replace the faultydiode(s).

Disconnected or shorted mainstator lead wires

Check lead wires for short or disconnection andrepair.

Damaged stator, rotor, orcapacitor windings

Check windings (visual check, smell check),measure resistances and compare with the ratedvalues. Replace faulty parts.

Check engine speed (RPM)Increase speed on engine slowly to increasevoltage. Do not increase speed over 110% ofrated RPM.

No load voltagetoo low

Incorrect or faulty wiring.Check wiring against the Generator WiringDiagrams in Appendix C. Check wires forincorrect wiring

Damaged stator, rotor, orcapacitor windings

Check windings (inspect visually for wire damageor check for a burnt or unusual smell), measureresistances and compare with the rated values.Replace faulty parts or consult with the supplier.



10

ELECTRICAL ISSUES (continued)SYMPTOM CAUSE SOLUTION

No load voltagetoo high

Incorrect capacitor or faultycapacitor.

Check capacitance value and function ofcapacitor.

Check engine speed (RPM)Decrease speed until rated voltage is achieved(within acceptable RPM range). Rated voltageis listed on generator name plate.

Incorrect or faulty wiring

Check wiring against the Generator WiringDiagrams in Appendix C. Check wires forincorrect wiring, specifically connections 33, 44,55, and 66 (50Hz vs. 60Hz operation).


Voltage belownominal, under load

Current too high (excessive load)or speed below nominal

Reduce load and make sure current does notexceed rated current.






Voltage abovenominal, under load






Unstable voltage

Non-uniform rotation of engine

Check for uniform rotation of engine. Enginecould be at fault. Check with engine UserManual or manufacturer for furthertroubleshooting.

Misalignment of generator andengine.

Check for mounting of rotor and stator onengine. Check that air gap is even on all sides.Re-mount rotor and generator housing onengine.

Faulty capacitor. Check capacitance value and function ofcapacitor.


CBC Series User Manual

11

SERVICE

FLASHING THE FIELD

Residual magnetism of the generator maybe lost or weakened if the generator is notoperated for long periods of time, duringlong periods of transport, or due to othersituations.

While flashing the field, the generatorMUST BE out of operation.

Steps to flashing the field1. Disconnect the load to the generator.

Make sure engine is turned off andgenerator is not rotating.

2. Remove the rear bearing cover of thegenerator.

3. Do not disconnect the rotor lead wiresfrom the diode terminals.

4. Take 12V - 36V DC battery and placethe negative terminal (-) of the batteryon the negative terminal (-) of the diodeand the positive terminal (+) of thebattery on the positive terminal (+) of thediode. Hold for at least 3 seconds butnot more than 5 seconds.

5. Disconnect the battery leads from thediode terminals.

6. Repeat steps 2 and 3 on the otherdiode.

7. Re-install the bearing cover.8. Start rotating the generator. Check the

generator no –load voltage duringoperation. It should be normal andwithin ±10% of rated value.

NOTE: If above still does not excite thegenerator, then please repeat the abovesteps with the same battery but with alonger charge time of 7-8 seconds (a littlelonger than before).

CHECKING THE DIODES

1. Disconnect the load to the generator.Make sure engine is turned off andgenerator is not rotating.

2. Remove the rear bearing cover.3. Check on the side of the diode casing /

housing where is printed which diodeterminal is (+) and which is (-).

4. Disconnect the lead wire from the rotorfrom the (+) end of the diode terminal.You will need to use solder gun to heatthe terminal and disconnect the wire.

5. Set the ohm meter to the lowest setting.Connect the ohm meter (+) probe(usually red color) of the ohm meter tothe (+) terminal of the diode and the (–)probe (usually black color) of the ohmmeter to the (–) terminal of the diode.You should get infinite resistance ornon-continuity.

6. Reverse the ohm meter probes fromabove and you should get measurementof 0Ω or continuity.

7. If you get the above readings – infinity inone direction and 0Ω in the other, thenthe diode is good.

8. If you get 0Ω both ways, the diode isshorted. If you get infinity both ways,then diode is open. In both of thesecases the diode needs to be replaced.


12

REPLACING THE DIODES

1. Disconnect the load to the generator.Make sure engine is turned off andgenerator is not rotating.

2. Remove the rear bearing cover.3. Disconnect the wires to the diodes.

Make sure to mark which wire isconnected to (+) terminal and (-)terminal of the diodes for re-connectingto new diode.

4. Remove the diodes by unbolting thediode from the shaft.

5. Replace with new diode. Lock the boltswith thread adhesive (ex. Loctite). Settoque wrench to 25 in-lb and tightenbolt. Please make sure not to overtighten the bolt.

6. Re-connect the diode wires to the newdiode as was previously connected(according to Step 3).

7. Re-install the rear bearing cover.8. Start rotating the generator. Check the

generator no-load voltage duringoperation. It should be normal andwithin ±10% of rated value.

CHECKING THE CAPACITOR

1. Properly discharge the capacitor andmake sure to follow all safetyprocedures and precautions.

2. Set ohm meter terminals (set to a highohms scale 10K–1M) and connectacross the capacitor terminals.

3. For a non-faulty capacitor the resistancewill at first drop (near zero) and thenslowly increase towards infinity.

4. If you experience any of the belowsituations then the capacitor is faultyand should be replaced.

If the capacitor is shorted, then it willdrop to zero and never increase.

If the capacitor is open, the resistancewill be infinite immediately or there willbe no ohm meter indication.

If the resistance never approachesinfinity and comes to rest at some value,then the capacitor is leaky.

RESISTANCE VALUES FOR WINDINGS

Rating(kW)

RotorWinding

(Ω)

CapacitorWinding

(Ω)

StatorWinding

11-22(mΩ)

8 4.19 1.71 220

Rating(kW)

StatorWinding

33-44(mΩ)

StatorWinding

11-55(mΩ)

StatorWinding

33-66(mΩ)

8 220 255 255

Above values are measured in coolcondition at 20°C. Winding measurementscan vary depending on ambient temperatureand temperature of the windings whentaken – please use above values as a guidefor troubleshooting purposes.


13

APPENDIX A – EXPLODED VIEW

ReferenceNumber

Part Name ReferenceNumber

Part Name

1 Bolt - GB/T 5789 M5x12 13 Fan2 Bearing cover plate 14 Main rotor3 “O” ring 15 Bolt - GB5783 M5*204 Rear bearing cover 16 Diodes5 Bolt - GB/T 70.1 M6*16 17 Bearing6 Main stator 18 Grounding bolt7 Housing 19 Control box top / cover8 Bolt - GB/T78 M8*16 20 Terminal board9 Lifting eye - GB/T825 M10 21 Control box sides10 Bolt - GB/T 70.1 M10*20 -12.9 22 Capacitor11 Shaft ring / washer 23 Control box front / access plate12 Coupling Discs (SAE 6 ½) 24 Control box base


14

APPENDIX B – SPARE PARTS LIST

ITEM Part Name 1CBC08ALPart Number

12 Coupling disc C250BC41-56-08-AL-1000113 Fan C250BC41-56-08-AL-10003

10, 1112, 1314, 15

16Main rotor C250BC41-56-08-AL-10000

16 Diodes ZY30-1617 Bearing 6206RZ

GND Grounding bolt CBC-GNDBLT6, 7, 8 9 Housing with stator

and lead wires C250BC41-56-08-AL-200009 Terminal board CBC-TBD-AL-08

3, 4 Rear bearing coverwith “O” ring C250BC41-56-08-AL-20003

22 Capacitor CBB65-R6563019, 21,23, 24 Complete control box CBC-CBX-AL-08


15

APPENDIX C – WIRING DIAGRAM for 60Hz


16

APPENDIX D – WIRING DIAGRAM for 50Hz


17

Documents

User Manual Capacitor Type Generator 1CBC08AL · for tightness and examine the insulation on lead wires for chafing. NOTE: Wet windings should be ... The generator needs sufficient