PX-300K1 SERIES A.C. GENERATORS

For Generator Models:PX-308K1, PX309K1, PX-310K1, PX-312K1, PX-316K1, PX-320K1, PX-325K1, and PX-332K1

OPERATORS & PARTS MANUAL

OPERATORS & PARTS MANUAL

Northern Lights4420 14th Avenue N.W.Seattle, WA 98107Tel: (206) 789-3880Fax: (206) 782-5455

Copyright 2015 Northern Lights, Inc.All rights reserved. Northern Lights, and the Northern Lights logo are trademarks of Northern Lights, Inc.

Printed in U.S.A.PART NO.: OPX300K1 03/15

*Note: 03/2015 revisions: covers. No internal information altered.

Diesel engine exhaust and some of its constitu-ents are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

CALIFORNIA Proposition 65 Warning:

OPERATORS & PARTS MANUALPX-300K1 SERIES A.C. GENERATORS For Generator Models:PX-308K1, PX-309K1, PX-310K1, PX-312K1, PX-316K1, PX-320K1, PX-325K1, and PX-332K1

Read this manual thoroughly before starting your equipment.This manual contains information needed to operate your set correctly and safely.

Introduction. .....................................................................2Safety Rules .....................................................................2Models and Serial Numbers ...........................................3Mechanical Construction .................................................4

INITIAL INSPECTION AND COUPLING Initial Inspection..........................................................4Coupling with Prime Mover........................................4Grounding ...................................................................4

PERFORMANCE AND FUNCTIONExcitation System........................................................5 Automatic Voltage Regulator (AVR) ..........................5 Under Speed Protection...............................................5 Rotary Rectifier and Surge Suppressor .......................5

CHARACTERISTICSVoltage Regulation ......................................................6Response .....................................................................6 Voltage Stability ..........................................................6 Motor Starting .............................................................6 Short Circuit ................................................................6 Phase Rotation .............................................................6

STANDARD VOLTAGE SELECTION TABLE .......6

OPERATION - GENERATOR SET Starting ........................................................................7

Voltage Adjustment .....................................................7Running .......................................................................7Stopping ......................................................................7

OPERATION - VOLTAGE REGULATORSafety Rules ................................................................8Operation .....................................................................8Adjustment ..................................................................8

MAINTENANCEBearing Inspection ......................................................9Insulation Resistance Measurement Method ..............9Rotating Rectifier Assembly ......................................9 Parts Replacement Method .................................9 - 10Automatic Voltage Regulator Maintenance ..............11

SPECIFICATIONSGenerator Specifications .................................. 12 - 13Specifications: DST-51-DFK ................................... 14

TROUBLESHOOTING ............................................ 15

PARTS LIST ..................................................... 16 - 27

WIRING DIAGRAMAVR DST-51-DFK .................................................. 28

Table of Contents

Proprietary InformationThis publication is the property of Northern Lights, Inc.

It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc. Northern Lights, Inc. 2015. All rights reserved. Litho U.S.A. Publication number OPX300K1 03/15

OPX300K1 09/093

OPX300K1 03/154

Introduction

This manual describes procedures for operation,maintenance, inspection and adjustment. It will help theoperator realize peak performance through effective,economical and safe operation.

Read this manual carefully BEFORE operating the generator.

Study this manual until proper operation becomes personal habit.

Operation, inspection, and maintenance should be carried out carefully. Safety must be given the first priority.

Safety Rules

To insure years of trouble-free operation, the specified maintenance is important and should be performed.

Electrical equipment should always be kept clean. Oil, dust, moisture and salt are all harmful to genera tors.

Be careful with electricity. Do not touch rotating parts.

Ambient Environmental Conditions a) Gas: Do not use in an environment of corrosive

or flammable gas (gasoline, hydrogen sulfide, meth ane gas, etc.)

b) Sandy Dust: Do not use equipment in places with excessive sand and dust.

c) Humidity: Do not use in very humid environments for long periods of time. d) Salt/Seawater: Protect your generator from

exposure to salt, water, and water vapor.

Insulation Resistance and Dielectric: When measuring insulation resistance and dielectric, be

sure to disconnect the AVR and rectifier.

Be sure that the regulator is shut off by switching the CPR (circuit breaker) on the AVR to the off position when the unit is run ning at less than rated speed, or when the unit is to be run but no power generation is required.

Before starting your generator, be sure oper ating conditions are safe.

Ventilation: When selecting the installation site, be sure that the area is well ventilated and that ambient temperature does not exceed 40C. If the

temperaure exceeds 40C, de-rate the generator output as per data sheet for operation. Be sure to provide generator with cover and protection when op erating outside.

PX-300K Series AC generators are based on BS 4999 part 20 and IEC34-5, IP21.

OPX300K1 03/155

Model and Serial Numbers

GENERATOR END MODEL NUMBERS Generator Set Model No................. PXK Generator Model M and NL753K ............................................PX-308K1 M and NL773L ..............................................PX-309K1 M and NL843JK ...........................................PX-310K1 M and NL843NK ..........................................PX-312K1 M844K ..........................................................PX-316K1 M844LK .......................................................PX-320K1 M864 ..............................................................PX-325K M984 ............................................................PX-332K1

SERIAL NUMBERS

When referencing Northern Lights equip ment by serial number, it is important to differentiate between the engine, generator end and generator set serial numbers.

The engine serial number is either on a metal tag or stamped directly into the engine block.

The generator END serial number is on a metal tag attached to the generator end.

The generator SET serial number is on a separate metal tag attached to the generator end. It may be a five by one inch tag installed directly below the gen erator end tag. Or, it may look like the illustrations below. Please use the generator SET number in cor respondence or when ordering parts.

Figure 1: Generator Set Serial Number Plate

OPX300K1 03/156

Mechanical Construction

STATORThe stator frame is fabricated from rolled steel. The round construction provides rigidity and strength to resist excessive mechanical shocks. The stator core is made of high quality silicon steel plates coated with insulating film for prevention of eddy currents. The core is positioned along the internal surface of the frame. The exciter field core is made of special steel plates capable of retaining a high degree of residual magnetism.

BEARINGSThe long-life ball bearings are sealed to prevent grease from escaping and to keep dirt out.

ROTORThe rotor shaft is made of high quality carbon steel, and is designed and manufactured to be mechanically durable. The rotor is a salient revolving field type with the main field core made from special steel plates having superior magnetic characteristics. The field core elements, exciter rotor, rotary rectifier and cooling fan are integral parts of the same shaft.

VENTILATIONCooling is provided by the cooling fan of the rotor through suction ports and exhausted through outlet ports. Every machine conforms to the cooling code ICO1 of BS.

Initial Inspection and Coupling

INITIAL INSPECTIONIf the generator is stored for long periods of time, store in a clean, dry, ventilated area. After extensive storage time, check the resistance of the coil insulation in accordance with this manual (see MAINTENANCE, page 9) before operation. Be sure there are no abnormal sounds or any overheating during operation. It is recommended that standby generators utilize a space heater (op tional) in order to keep the coil insulation in optimum working condition.

COUPLING BOLT SPECIFICATIONSThe Coupling Bolt Torque for all PX-300K series models is 32 lbs.ft.

COUPLING WITH PRIME MOVER PX-300K series single bearing generators make centering and direct coupling easy. Shim the generator legs as needed for proper leveling. Coupling bolt size and torque will vary according to the engine manufactur