Kato Generator Manual PDF

31065
Serial Number
BEARING LUBRICATION
MAINTAIN OIL LEVEL AT

THE CENTER OF THE SITE GLASS
USE A HIGH QUALITY, DOUBLE INHIBITED

MINERAL OIL WITH VISCOSITY INDICATED
BELOW. THE OIL SHOULD CONTAIN OXIDATION
AND RUST INHIBITORS AND DEFOAMANTS
OPPOSTE DRIVE DRIVE END

END BEARING NUMBER
012-68369-07 012-68369-06
SUMP CAPACITY
10.0 Liter 10.0 Liter

OIL VISCOSITY
157-00129-00
ISO VG 46 ISO VG 46
Kato Engineering Inc.

Instruction Manual
Publication 350-01015-00, 07/18/2012
Installation • Operation • Maintenance
AC Center Air Generator

P.O. Box 8447
Mankato, MN USA
56002-8447
Tel: 507-625-4011
Fax: 507-345-2798
Email: katoengineering@emerson.com
www.kato-eng.com
Copyright © 2012 Kato Engineering, Inc. All rights reserved
Page 1
Table of Contents
Introduction 4
Foreword 4
Safety instructions 4
Ratings/description 4
Construction and Operating Principles 6

Stator 6
Rotor 7
Bearings 8
Connection boxes 8
Excitation system 9
PMG system 11
Installation 12
Receiving inspection 12
Unpacking and moving 12
Location 12
Base design 12
Note: Because of rapid changes in designs
and processes and the variability of Kato Assemble to prime mover, alignment 13
Engineering’s products, information in this
manual must not be regarded as binding Two-bearing alignment 13
and is subject to change without notice.
Foot deflection 15
The image on the front cover is representa-
tive only. Several variations are available Doweling 15
within the range of generators covered
within this manual. Electrical connections 15
Space heaters 15
Inspection before startup 15

Page 2
Storage of Kato Generators 17
Operation 20
Initial startup: generators w/auto & manual control 20
Initial startup: generators w/auto control only 20
Restoring residual magnetism/field flashing 21
Continuous operation 22
Idling 23
Parallel operation 23
Maintenance 26
Schedules 26
Maintenance procedures 28
Visual inspection methods of windings 28
Cleaning 29
Insulation resistance tests at low voltage 30
Dry out procedures 31

Bearing lubrication 32
Rectifier tests 32
Disassembly 34
Overall disassembly 34
Exciter armature and PMG removal 34
Bearing removal 35
Assembly 37
Bearing installation 38
Exciter armature and PMG installation 40
Troubleshooting Guide 42
Torque Chart 45
List of Required Equipment 47

Page 3
Introduction
Foreword
This manual contains instructions for installing, operating and
maintaining Kato Engineering AC brushless revolving field generators.
These generators are manufactured in many sizes and ratings and with
various options.
Lubrication information, electrical connection drawings, dimensional

drawings and parts listings for your model are contained in the manual
package as supplementary information and are the specific source of
information for making connections and ordering replacement parts.
Information about optional components of your generator may also be
contained as a supplement.
Please read this manual in its entirety before unpacking, installing, and
operating your generator.
Safety instructions
In order to prevent injury or equipment damage, everyone involved in
installation, operating and maintenance of the generator described in this
manual must be qualified and trained in the current safety standards that
govern his or her work.
While “common-sense” prevention of injury or equipment damage

cannot be completely defined by any manual (nor built into any piece
of equipment), the following paragraphs define warnings, cautions, and
notes as they are used in this manual:
Warning: Warnings identify an installation, operating or maintenance

procedure, practice, condition, or statement that, if not strictly followed,
could result in death or serious injury to personnel.
Caution: Cautions identify an installation, operating or maintenance

could result in destruction of or damage to equipment or serious
impairment of system operation.
Note: Notes highlight an installation, operating or maintenance

procedure, condition, or statement and are essential or helpful but are not
of known hazardous nature as indicated by warnings and cautions.
Ratings/description
Nameplates, which are located on the side of the generator, include
serial and model number as well as rating information and bearing and
lubrication information.

Page 4
Figure 1: Typical center air generator

Page 5
Construction and Operating Principles
Enclosures
The standard design is open drip proof. The following options may apply
to your unit:
• Air filtered
• Air-to-air heat exchanger cooled (TEAC/CACA)
• Air-to-water heat exchanger cooled (TEWAC/CACA)
• Weather protected II
• IP 22, 23,25,44,54
• Sealed windings
See your drawings included in the drawing section for details on your
unit.
Stator
The stator consists of the supporting frame, core, and armature windings.
The stator core is made from laminations, thin sheets of electrical steel,
which are stacked and held in place by steel end rings and support
bars. The rings and bars are welded to or are part of the steel frame.
Base mounting plates are welded to the bottom of the frame. The base
mounting plates allow the assembly to be mounted on the genset base.
Some stators are made of rolled steel with foot gussets. See Figure 2.
Figure 2: Generator frame

Page 6
The windings (coils) are constructed of layered and insulated copper
wire. The coils are inserted in the core slots, connected together, and
the entire assembly is vacuum-pressure impregnated with resin. Stator
leads terminate in standard connection lug or strap terminals for ease of
connection to the load.
Rotor
The main rotor assembly is the revolving field. It consists of windings
in a core, which is in turn mounted on a steel shaft. The exciter armature
assembly and permanent magnet generator (PMG) rotor are also mounted
on the shaft as are the fan(s) and other optional accessories. The core
consists of laminations, thin sheets of electrical steel, which are stacked
together. The core makes the salient poles. See Figure 3.
The rotor windings consist of insulated magnet wire wound around

each pole. V-blocks or spreader bars between each pole keep the rotor
windings in place. Damper windings consist of copper or aluminum rods
that are inserted through each pole surface and are brazed to copper or
aluminum damper end plates at each end of the lamination stack.
Figure 3: Generator rotor
The end plates are brazed to adjacent poles to form a continuous damper
winding. The ends of the windings are supported with bars or aluminum
pole shoes. Some designs have neither end shoes or plates. The rotor is
vacuum-pressure impregnated with resin.
The shaft is made from high-strength rolled or forged steel and machined
to accommodate all the rotating generator components. Keyways in the
shaft ensure precise positioning of the rotor, fans, exciter armature, and
PMG rotor as well as drive couplings. On the exciter side, the shaft has
a slot or hole in its centerline for running the revolving field leads to the
rectifier.

Page 7
Bearings
The sleeve bearings may be self lubricated or force fed from a separate
oil system. Temperature detectors monitor the operating conditions of
the bearing and lubrication system. The sleeve bearing is self-aligning.
See bearing manual for details. RTDs are provided to monitor bearing
temperature during operation. A non-conducting liner insulates the
bearing against shaft currents. See your bearing manual under seperate
cover for more information. See Figure 4.
Figure 4: Sleeve bearing
Connection boxes
The main lead connection box houses the load lead terminals, and may
be located either side or on top. In addition, the generator may have
auxiliary connection boxes for connecting temperature detector outputs,
space heater connectors, and sensing outputs. See your drawings for
details. See Figure 5.
Figure 5: Typical terminal box

Page 8
Excitation system
The excitation system consists of the exciter stator assembly and the
exciter armature assembly. See Figure 6.
The exciter stator assembly consists of windings in a core. The core is

made from steel laminations that are stacked and welded together. The
main exciter stator coils are placed in slots in the core and form alternate
north and south poles. The entire assembly is either mounted to the end
bracket or mounted in a frame, which is mounted to the end bracket. The
stator is a stationary field, which is powered by the voltage regulator.
The assembly consists of two subassemblies: the exciter armature and

the rotating rectifier. The exciter armature assembly contains steel
laminations that are stacked and keyed on the shaft or onto a sleeve,
which is keyed to the generator shaft. A three-phase winding is inserted
into slots in the laminations. The coils are held in place by insulating
wedges. The coil extensions are braced with tape. Output leads from the
winding are connected to the rotating rectifier assembly.
Figure 6: Excitation system
The rotating rectifier is a three-phase, full wave bridge rectifier,

converting the AC from the exciter armature to DC, which is transferred
to the revolving field windings. Two aluminum steel plates, each
containing three rotating rectifier diodes, are mounted on each side of
an insulating hub to form the negative and positive terminals. The plates
also act as heat sinks for the diodes.
Excitation system functional overview: Exciter field control is

established by the strength of the exciter field current developed by
the voltage regulator system. The DC voltage and current levels of the
exciter field signal from the voltage regulator varies depending upon the
generator output voltage and the loading of the output lines. See Figure
7.

Page 9
Power input

Voltage
regulator
Output leads
Main stator
(armature)
PMG stator Exciter stator
(armature) (field)
Main rotor (DC) Prime mover

Shaft
Page 10
PMG rotor
(field)
Rectifier
Figure 7: Overview of excitation system

Exciter
armature (AC)
PMG system
The permanent magnet generator (PMG) system consists of the PMG
stator and PMG rotor:
The PMG stator is a stationary armature and is located within the stator
assembly that also contains the exciter stator or is a separate stator
mounted next to the exciter stator. The PMG stator consists of steel
laminations. The laminations are held in place by steel compression rings
and are welded to the frame bars of the exciter-PMG frame. The PMG
windings are placed in slots in the laminations. Insulating wedges are
inserted at the top of each slot to hold the coils in position.
The PMG rotor consists of rectangular permanent magnets and cast pole
tips secured to a steel hub with nonmagnetic stainless steel bolts. The
PMG rotor is keyed to the shaft and secured with a nut and lock washer.
PMG system overview: The PMG system functions as a pilot exciter,

providing power to the automatic voltage regulator power supply. The
PMG is an AC generator that uses permanent magnets in the rotor instead
of electromagnets to provide the magnetic field. See Figure 8.
Figure 8: PMG

Page 11
Warning: Be alert at all times when
installing, operating and maintaining the Installation
generator. Avoid contact with the uninsulated
metal parts of the generator. Most injuries Receiving inspection
occur from faulty ground connections on Before accepting a shipment, examine the packaging for any sign of
portable electrical equipment and failure to
damage that might have occurred during transit. Report any damage to
ground stationary equipment.
the transportation company and Kato Engineering.
Test all portable devices frequently to
prove that a solid electrical circuit exits Unpacking and moving
from the metal frame though the grounding If the generator is received during cold weather, reduce condensation on
conductor, in the electrical cord, to the cold surfaces and failure due to wet windings by allowing the generator
grounding contact in the attachment plug. to reach room temperature before removing the protective packing.
Do not use electrical equipment with frayed,
burned or damaged cords. Always take
Unpack the generator carefully to avoid scratching painted surfaces.
extreme care when moving the generator.
Be careful to not strike objects or personnel.
Do not remove the protecting lubricant from the shaft end. Inspect for
loosely mounted components and the presence of moisture. Inspect
Apply lifting force to structural points to make certain foreign material, such as crating nails, loose bolts
specifically provided for lifting. Do not use or packing material, which may have fallen into the machine during
the enclosure lifting holes to lift the whole unpacking, is removed. If damage is noted, determine the extent of
unit. Use lifting means adequate for the damage and immediately notify the transportation company claims office
weight. Observe lifting notices attached and Kato Engineering. Be sure to give complete and accurate details
to the generator. Failure to observe these when reporting damage.
instructions can result in injury and damage
to the generator.
Move the generator by attaching an overhead hoist to the eyebolts
Caution: Do not attempt to transport a
installed on the generator frame or by lifting the generator from
single-bearing generator without maintaining underneath the skid with a forklift.
proper rotor support and with the exciter
rotor assembly removed. Failure to observe Location
this warning can result in equipment Install the generator in an area so it complies with all local and industrial
damage. regulations. Locate it in a clean, dry, well-vented area or area that is
suitable for the generator enclosure. Make sure it is easily accessible for
Caution: Blocking or restriction of normal air
inspection and maintenance.
flow into or out of the generator may cause
damage to the electrical windings.
Protect generators operating intermittently in very damp locations with
space heaters. Slowly warm generators placed in operation after being
subjected to very low temperatures to prevent excessive condensation.
Check winding resistance before placing the generator in operation (see
page 27).
Base design
The type of base to be used will depend upon the nature of the
installation site. However, the generator base must be rigid, level, and
free from vibration. Mounting holes must be larger than the fasteners to
allow for alignment.

Page 12
Assemble to prime mover, alignment Notes: Mounting of the indicators must
Two-bearing alignment allow complete rotation of the prime mover.
Follow the tolerances specified by the coupling manufacturer when they Use dial indicators that are rigid so indicator
are less than described in this manual. sag won’t be a factor. Using the shortest
offset distance of the indicator bracket will
reduce the effects of indicator droop or sag.
Use shims, if necessary, between the mounting pad and the base to
properly level and align the generator to the prime mover. During alignment, you may also need to
compensate for engine expansion due to
Install the coupling(s) on the generator and engine drive shafts in heating. Generator expansion is generally
accordance with coupling manufacturer installation procedures. Use a not considered a factor.
straight edge and a thickness gauge for rough alignment as shown in
Figure 9. Check for angular and parallel alignment as follows: If the genset is moved to a different
location, check alignment before startup.
Straight edge
Caution: Do not pry on the generator fan.
Caution: Generators equipped with sleeve

oil bearings must have oil added to the
bearing prior to rotation. See the bearing
manual.
Thickness gauge
Figure 9: Rough alignment
Angular alignment: Fasten a dial indicator to one of the coupling halves,

and scribe the position of the dial button on the face of the opposite
coupling half as shown in Figure 10. Rotate both shafts simultaneously,
keeping the finger or button on the indicator at the reference mark on the
coupling hub. Note the reading on the indicator dial at each one quarter
revolution.
A variation of readings at different positions will indicate how the

machine needs to be adjusted to obtain a maximum misalignment of
0.001 inch for each inch of the coupling hub’s radius, total indicator
runout. Place or remove slotted shims from under the front or rear engine
or generator mounting pads and/or shift the front or back half of one
component from side to side until the components are properly aligned.
Tighten the mounting bolts, and recheck alignment.

Page 13
Dial indicator
Figure 10: Angular alignment
Parallel alignment: Fasten a dial indicator to one of the coupling halves,

and scribe the position of the dial button on the top of the opposite
coupling half as shown in Figure 11. Rotate both shafts simultaneously,
keeping the finger or button on the indicator at the reference mark on the
coupling hub. Note the reading on the indicator dial at each one quarter
revolution. A variation of readings at different positions will indicate how
the machine needs to be adjusted to obtain a maximum misalignment of
0.002 inch. Place or remove slotted shims from under all of the engine
or generator mounting pads and/or shift one component from side to side
until the components are properly aligned. Tighten the mounting bolts,
and recheck alignment.
Dial indicator
Figure 11: Parallel alignment

Page 14
Foot deflection
After alignment, check for foot deflection or “soft foot” condition on
each shim location to eliminate distortion of the generator frame. Do
this by loosing one mounting bolt at a time and checking deflection
after retightening. Deflection at the shim location from shims under
compression to a loosened condition must not exceed 0.003 inch.
Doweling
In case the mounting bolts loosen during operation, doweling will
prevent movement of the generator. Dowel as follows:
Check the alignment after the generator has been in operation for at least
48 hours. If alignment is not satisfactory, realign.
Drill holes through the footpads and into the base in two mounting pads
opposite each other. Drill the holes slightly smaller than the dowel pin.
Ream the holes to the proper diameter for the pin. Clean out chips, and
install the pins.
Electrical connections
If the generator was subjected to a rapid change in temperature, freezing
or wet conditions during shipment or storage, measure the insulation
resistance of each winding and dry the generator, if necessary, as
described in the maintenance section.
Make all electrical connections (main load, temperature monitoring

device, space heater, AVR) in accordance with local regulations and
national/international electrical code requirements. Check the electrical
diagrams provided with the generator or manual. The main terminals
need to be properly spaced for the load connections. Refer to Table 3 for
the proper torque values for the connections.
Grounding points are provided for properly grounding the system to

the generator frame. The grounding wire must be sized to national/
international code requirements.
Space heaters
To prevent water condensation during long periods of downtime, connect Warning: The space heaters are designed
the space heaters so they start when the generator is turned off and stop to be energized when the generator is
when the generator is switched on. Refer to the electrical diagrams for shut down. They are hot enough to cause
skin burns. Terminals for power at the
the space heater characteristics.
space heaters are live during operation.
Disconnect power to the space heaters
Inspection before startup before removing the generator covers.
After electrical connections have been made, perform the following
checks:

Page 15
a. Check all the connections to the electrical diagrams provided.
b. Secure all covers and guards.
c. Turn the rotor slowly with the appropriate starting mechanism (bar
the engine or flywheel) through one revolution to see if the rotor
turns freely.
d. Check the bearings to see they are properly lubricated.
e. Determine the direction of the engine rotation, and make sure that it
matches the rotation of the generator.
f. Make sure the power requirements comply with the data on the
generator nameplate.
g. Make sure that the engine-generator set is protected with an adequate

engine governor and against excessive overspeed.
h. Make sure the output of the generator is protected with an overload

protection device, such as circuit breakers or fuses, sized in
accordance with national/international electrical code and local
electrical code standards. Fuses need to be sized using the lowest
possible current rating above the full-load current rating (115% of
rated current is commonly recommended).
i. Remove tools and other items from the vicinity of the generator.

Page 16
Storage of Kato Generators
If the generator is not installed in its operating location as soon as
received, follow the following procedures.
Make sure the storage area temperature is between 10º F (-12o C.) and
120º F (49o C.) and the relative humidity is less than 60%.
(Store the generators in an ambient temperature of approximately normal
room temperature if possible).
Protect the shaft from corrosion by applying an anti-corrosion agent.

Cover the unit with a durable cover.
Prepare units that cannot be stored in a temperature and humidity

controlled area as follows:
a. Install desiccant bags in the exciter cover and inside the

end bells.
b. Vacuum seal the unit in a covering of plastic or other
material designed for that purpose.
c. Adequately tag the generator to ensure that preservative
greases and desiccant bags are removed before the unit is
placed in operation.
d. If space heaters are supplied, energize them to keep
condensation from the windings.
e. Lubricate the sleeve bearings and the shaft as describe in the
following paragraphs.
On applications where the generator has been coupled to the prime

mover the prime mover and the generator may be rotated as a
complete unit.
For storage longer than 2 months, rotate the shaft a minimum of 10

revolutions every 60 days. If the generator has an automatic lubrication
system activate it before turning the shaft. If the generator has an manual
prelube pump; actuate before rotating the shaft. If the generator has no
prelube system, remove the access glass or top vent and pour oil into
bearing before rotating the shaft.

Page 17
On applications where the prime mover is coupled to the generator
and the prime mover manufacturer requires that the prime mover
NOT be rotated at periodic intervals.
WARNING: When removing the oil or 1. Separate the coupling from the prime mover and the generator
external lubrication system from bearings for
and rotate the generator separately a minimum of 10 revolutions
long term storage oil must be added to the
bearing, or the external lubrication system every 60 days. If the generator has an automatic lubrication
must be reconnected prior to operation. system activate it before turning the shaft. If the generator has a
Please refer to the generator lubrication manual prelube pump; actuate it before rotating the shaft. If the
plate and the generator dimensional drawing generator has no prelube system, remove he access glass
for amount of oil required or location for oil or top vent and pour oil into bearing before rotating the shaft.
input and drain port locations.
2. If it is not possible to rotate the generator separately then flush
the bearings with an anti rust preservative using one of the two
following procedures; the first for self contained ring
oil lubrication and the second for bearings with
an external lubrication system.
Bearing preservation for generators equipped with sleeve bearings

with a self contained ring oil lubrication.
1. Remove oil drain port plug and drain oil from the bearing (refer
to the specific generator outline drawing for drain location).
2. Identify the sleeve bearing casing oil inlet port on one side of the
bearing (refer to the specific generator outline drawing oil inlet
Caution: Before using this product, the location).
operator must read carefully the MSDS
sheet to ensure that the process is
carried out safely for the operator and the
3. Attach a manual pump filled with Daubert Nox-Rust VCI-10
preservative. Flush 2 gallons of the preservative through
environment.
the oil inlet port for 1 minute at 2 GPM flow.
Drain the bearing casing after flushing and reinstall the
drain and oil plugs. Repeat this procedure for each bearing.
4. Repeat the flushing procedure every 12 months.
Bearing preservation for generators equipped with sleeve bearings

with an external lubrication system.
Note: It should not be necessary to open
the bearing for cleaning the remaining
preservative before starting the generator, 1. Disconnect external lubrication system following the
however it is recommended to verify the manufactures recommendations.
compatibility of the VCI-10 oil with the
specific oil used to lubricate the bearings.
2. Identify the sleeve bearing casing oil inlet port on one side of
the bearing and the drain port underneath the bearing casing
(refer to the specific generator outline drawing for oil inlet and
drain locations).

Page 18
3. Attach a manual pump filled with Daubert Nox-Rust VCI-10 Caution: Before using this product, the
preservative. Flush 2 gallons of the preservative through the oil operator must read carefully the MSDS
inlet port for 1 minute at 2 GPM flow. sheet to ensure that the process is
Drain the bearing casing after flushing and reinstall the carried out safely for the operator and the
drain and oil plugs. Repeat this procedure for each bearing. environment.
4. Repeat flushing procedure every 12 months
When the unit is taken out of storage, check the insulation resistance on
all windings. See pages 30 and 31.
Note: It should not be necessary to open
Clean the shaft of anti-corrosion agent. the bearing for cleaning the remaining
preservative before starting the generator,
however it is recommended to verify the
compatibility of the VCI-10 oil with the
specific oil used to lubricate the bearings.
WARNING: When removing the oil or

external lubrication system from bearings for
long term storage oil must be added to the
bearing, or the external lubrication system
must be reconnected prior to operation.
Please refer to the generator lubrication
plate and the generator dimensional drawing
for amount of oil required or location for oil
input and drain port locations.

Page 19
Operation
Initial startup: generators with both automatic and
Caution: Do not make connections or other- manual voltage control
wise make contact with the generator leads
1. Disconnect the generator output from the load by opening the main
or other devices connected to them unless
the genset is stopped and the phase leads
circuit breaker.
are grounded.
2. Turn the manual voltage adjust rheostat fully counterclockwise.
3. Put the auto-manual switch in the manual position.

Caution: Do not actuate the auto-manual
switch with full load applied to the generator. 4. Start the prime mover, and bring the set to rated speed. Turn the
Whenever possible, stop the generator manual voltage adjust rheostat to reach rated voltage. Close the
before switching. output circuit breaker, and apply load in steps until the rated load is
reached. Adjust the manual adjust rheostat as necessary to obtain the
desired output voltage.
5. Gradually reduce load, and adjust the rheostat accordingly until no

load is reached. Open the circuit breaker, and stop the prime mover.
6. Actuate the auto voltage rheostat. Then start the genset, and bring it
to rated speed. Adjust the voltage to the desired value.
7. Close the output circuit breaker. Then check the generator voltage
Caution: Operating the unit beyond name- and voltage regulation. Apply load in steps until the rated load is
plate values may cause equipment damage reached.
or failure.
8. Check for vibration levels at no load and rated load. A slight increase
is normal. As the load is maintained for 2-3 hours, the vibration
levels will gradually increase and reach a final level.
Initial startup: Generators with automatic voltage control

Caution: Refer to the voltage regulator
manual for complete details and possible only (generator has an automatic voltage regulator (AVR)
additional instructions. Damage to the rotat- with no auto-manual switch)
ing diodes, generator, and voltage regulator 1. Disconnect the generator output from the load by opening the main
can be caused if the regulator is operated circuit breaker.
improperly.
2. Turn the voltage adjust rheostat fully counterclockwise. Start the
prime mover, and bring the set to rated speed. Turn the voltage adjust
rheostat to obtain the desired voltage.
3. Close the output circuit breaker, and apply load in gradual steps
until the rated load is reached. Note the voltage regulation with the
changes in load steps.
4. Check for vibration levels at no load and rated load. A slight increase
is normal. As the load is maintained for 2-3 hours, the vibration
levels will gradually increase and reach a final level.

Page 20
Restoring residual magnetism/field flashing
The direct current necessary to magnetize the revolving field is obtained
from the exciter. Upon starting the generator, current and voltage is
induced into the exciter by the magnetic lines of force set up by residual
magnetism of the exciter field poles. Residual magnetism of the exciter
field poles may be lost or weakened by a momentary reversal of the field
connection, a strong neutralizing magnetic field from any source, or non-
operation for a long time. If the generator fails to generate voltage after
it has come up to rated speed, it may be necessary to restore residual
magnetism.
Note: If the polarity of the exciter is reversed

- 12 or 24 V by flashing the field, it may be corrected by
battery interchanging the battery leads.
+
3 amp or
larger diode F- Voltage
F+ regulator
EF2 EF1
Figure 12: Field flashing setup with the field wires

connected to the regulator
To restore the small amount of residual magnetism necessary to begin the
voltage build up, connect a 12 or 24-volt battery to the exciter field coil
circuit and flash as follows:
1. Open the output circuit breaker, and stop the engine.
2. Disconnect the exciter field coil wires EF1 at the terminal EF1 and
EF2 at the terminal EF2, and connect the battery positive lead to the
field coil lead EF1.
3. Flash the field by touching the battery lead to the field coil circuit
terminal EF2.
4. Disconnect the battery leads.
5. Reconnect the field coil lead EF1 to terminal EF1, and reconnect the
field coil lead EF2 to terminal EF2.
6. Start the generator, and check for voltage build up. Reflash if
the generator output voltage does not build up, or flash with the
generator running, the field coil wires connected to the regulator, and
a 3-amp or larger diode off the positive terminal of the battery per
Figure 12.

Page 21
Continuous operation
Operate the generator within the nameplate values . If the generator is
operated below the rated power factor and voltage, decrease the kVA to
prevent overheating of the field and stator windings. Consult the factory
for de-rating factors if the application requires the unit to be operated
beyond nameplate values.
Rotor overheating may occur when the generator is carrying excessive

unbalanced loads. Negative sequence currents flowing in the field pole
face cause the rotor heating. For a general guide to the allowable phase
unbalance, see Figure 13, Guide to allowable phase unbalance (which is
based on a 10% equivalent negative sequence current).
The guide is used in the following manner: Find the point where the
vertical line (determined by the maximum current in any of the phases
and expressed in percent of rated current) crosses the horizontal line
(determined by the minimum current in any of the phases and expressed
in percent of rated current). Ensure the point where these two lines
intersect is within the permissible allowable unbalance region for safe
operation of the generator.
100
Min. current in any phase (% of rated)
80
Allowable
unbalance
60
Excessive
40 unbalance
20
0 20 40 60 80 100
Max. current in any phase (% of rated)
Figure 13 Guide to allowable phase unbalance
Loss of field excitation can result in the unit operating out of

synchronization with the system when operating in parallel. This has the
effect of producing high currents in the rotor, which will cause damage
very quickly. Protective relays should be considered to open the circuit
breaker.

Page 22
Idling
Unless the voltage regulator has V/Hz protection built in, having the
generator set in operating mode while idling the engine can cause
permanent equipment damage. If engine adjustments require that
the engine be run at idle speed and the regulator does not have V/Hz
protection, make the generator regulating system inoperative during
idling by one of the following methods:
When the generator is provided with a voltage shutdown switch, be sure

the switch is set to the idle position while the engine is running at idle
speed.
Where the generator set is provided with field circuit breakers, set the
circuit breaker to the off position while the generator is running at idle
speed.
Where the generator set is provided with an automatic/manual control

switch that has an off position, switch it to off while the engine is
running at idle speed.
Where the generator set does not have any of the above options, remove
the wires from the voltage regulator input power terminals when the
engine is running at less than rated speed.
Parallel operation
For the generator to operate in parallel with a system in operation, the
phase sequence of the generator must be the same as that of the system.
Use transformers to reduce the voltage to an acceptable level, and then
use a phase rotation meter or incandescent lamp method, described in
electrical machinery handbooks, for a phase sequence check.
The output voltage at the paralleling point must be the same each instant,
which requires that the two voltages be of the same frequency, same
magnitude, same rotation, and in coincidence with each other.
Voltmeters indicate whether the voltage magnitude is the same, and

frequency meters indicate whether the frequencies are the same. Whether
the voltages are in phase and exactly at the same frequency is indicated
by a synchroscope or by synchronizing lamps.
A synchroscope can be used to indicate the difference in phase angle

between the incoming machine and the system. The generator can be
paralleled by using incandescent lamps connected as shown in Figure 14.
The voltage rating of the series lamps must equal the voltage rating of the
transformer-low voltage winding.

Page 23
System bus
Load Synchronizing
switch lamps
Load lines from the incoming generator
Figure 14: Synchronizing paralleled generators with test lamps
Each prime mover in the system must have the same speed regulating
characteristics, and the governors must be adjusted to give the same
speed regulation as determined by applying load that is proportional to
the full load rating of the generator.
The voltage regulator must include paralleling circuitry. In addition, the

voltage, droop settings and the V/Hz regulation characteristics must be
the same for all the voltage regulators. This will allow the generators to
properly share reactive loads.
If cross-current compensation is used, paralleling current transformers

must give the same secondary current.
Current transformer secondary windings provide reactive kVA droop

signal to the voltage regulator. Accidental reversal of this electrical
wiring will cause the voltage to attempt to rise with load rather than
droop. If this occurs during paralleling, stop the unit and reverse the
wires at the voltage regulator terminals.
If the set is provided with a unit/parallel switch, set the switch to the
parallel position on the unit being synchronized.
Synchronize the generator by adjusting the speed (frequency) slightly

higher than the system. Observe the synchroscope or the lamps. The
lamps should fluctuate from bright to dark at the rate of one cycle every
2 to 3 seconds. When the generator is in phase (the lights will be dark),
close the circuit breaker. Immediately after closing the breaker, measure
the line current kVAR of the generator. The readings must be within
the rating of the unit. A high ammeter reading accompanied by a large
kW reading indicates faulty governor control. A high ammeter reading
accompanied by a large kVAR unbalance indicates problems with the
voltage regulator. Adjusting the cross current or voltage droop rheostat
should improve the sharing of kVAR.

Page 24
To shut down the generator operating in parallel, gradually reduce the
kW load by using the governor to reduce speed. When kW load and
line current approach 0, open the generator circuit breaker. Operate
the generator unloaded for several minutes to dissipate the heat in the
windings. Refer to the prime mover manual for shutdown and cool-down
procedures.

Page 25
Warning: Do not service the generator
or other electrical machinery without de- Maintenance
energizing and tagging the circuits as out of
service. Dangerous voltages are present, Schedules
which could cause serious or fatal shock. A regular preventive maintenance schedule will ensure peak
performance, minimize breakdowns and maximize generator life. The
schedule listed below is a guide for operating under standard conditions.
Specific operating conditions may require reduced or increased
maintenance intervals. Also, if there is a different or more specific
schedule for your generator than the schedule provided below, it will be
included as a supplement to the manual package.
Every day
Visually check generator bearing housings for any sign of oil seepage.
Check the operating temperatures of the generator stator windings.
Check the control panel voltmeter for proper stability and voltage output.
Monitor the power factor and generator loading during operation.
With generators that have sleeve oil bearings, check the operating
temperatures and sight glass levels (if applicable).
Every week
Visually inspect the bearing exterior for dirt, and clean if necessary.
Inspect any generator air filters for build up of contaminants, and clean or
replace as required
Every 2000 hours or 6 months of operation

Remove generator outlet box cover. Visually inspect the stator output
leads and insulation for cracking or damage. Check all exposed electrical
connections for tightness. Check transformers, fuses, capacitors, and
lightning arrestors for loose mounting or physical damage. Check all lead
wires and electrical connections for proper clearance and spacing.
Clean the inside of the outlet box, air screens, bearing housings, and air
baffles with compressed air and electrical solvent if needed.
With generators that have ball or roller bearings, check machine

vibrations and bearing condition with a spectrum analyzer or shock
pulse.
Regrease the regreaseable-type bearings. With generators that have

sleeve oil bearings, inspect bearing oil for proper levels and clarity.
Every 8000 hours or 1 year of operation

Check insulation resistance to ground on all generator windings,

Page 26
including the main rotating assembly, the main stator assembly, the
exciter field and armature assemblies, and the optional PMG assembly.
Check the space heaters for proper operation.
Check the rotating rectifier connection tightness.
With generators that have sleeve oil bearings, replace the bearing oil.
Every 20,000 hours or 3 years of operation

With generators that have sleeve oil bearings, perform a sleeve bearing
inspection to include the removal of the upper bearing housing and
bearing liner to inspect the liner, shaft journal, and seal surfaces for wear
or scoring.
Remove the endbrackets, and visually inspect the generator end windings
for oil or dirt contamination. Excessive contamination may necessitate
surface cleaning with compressed air and electrical solvent.
Inspect the fan and fan hub for damage.
Every 30,000 hours or 5 years of operation

(Contact Kato Engineering for assistance)
Disassemble the generator (this includes rotor removal).
Clean the generator windings using either (depending upon the severity
of contamination) 1) compressed air and electrical solvent or 2) de-
greaser and high pressure hot water wash. Dry the windings to acceptable
resistance levels (see the dry out procedure).
Inspect the rotor shaft bearing journals for wear or scoring.
With generators that have ball or roller bearings, replace the bearings.
With generators that have sleeve bearings, replace the bearing liners and
oil seals.

Page 27
Maintenance procedures
Visual inspection methods of windings
Electric machines and their insulation systems are subjected to
mechanical, electrical, thermal and environmental stresses that give rise
to many deteriorating influences. The most significant of these are the
following:
Thermal aging: This is the normal service temperature deteriorating

influence on insulation.
Over temperature: This is the unusually high temperature of operation

caused by conditions such as overload, high ambient temperature,
restricted ventilation, foreign materials deposited on windings, and
winding faults.
Overvoltage: This is an abnormal voltage higher than the normal service

voltage, such as caused by switching or lightning surges or non-linear
loads. Operating above rated nameplate voltage will reduce insulation
life.
Contamination: This deteriorates electrical insulation by 1) conducting

current over insulated surfaces 2) by attacking the material to reduce
electrical insulation quality or physical strength, or by 3) thermally
insulating the material so the generator operates at higher than normal
temperatures. Such contaminants include water or extreme humidity, oil
or grease including unstable anti-wear and extreme pressure lubricants,
conducting and non-conducting dusts and particles, industrial chemicals
such as acids, solvents, and cleaning solutions.
Physical damage: This contributes to electrical insulation failure by

opening leakage paths through the insulation. Physical damages can be
caused by physical shock, vibration, over-speed, short-circuit forces or
line starting, out-of-phase paralleling, erosion by foreign matter, damage
by foreign objects and thermal cycling.
Ionization effects: Ionization (corona), which may occur at higher

operating voltages, is accompanied by several undesirable effects such as
chemical action, heating, and erosion.
To achieve maximum effectiveness, a direct visual inspection program

initially to those areas that are prone to damage or degradation caused
by the influences listed above. The most suspect areas for deterioration
or damage are 1) ground insulation, which is insulation intended to
isolate the current carrying components from the non-current bearing
components, and 2) support insulation, which includes blocks and slot
wedges and are usually made from compressed laminates of fibrous
materials, polyester, or similar felt pads impregnated with various types
of bonding agents. Check for the following:

Page 28
Deterioration or degradation of insulation from thermal aging:
Examination of coils reveal general puffiness, swelling into ventilation
ducts, or a lack of firmness of the insulation, suggesting a loss of bond
with consequent separation of the insulation layers from themselves or
from the winding conductors or turns.
Abrasion: Abrasion or contamination from other sources, such as

chemicals and abrasive or conducting substances, may damage coil and
connection surfaces.
Cracking: Cracking or abrasion of insulation may result from prolonged

or abnormal mechanical stress. In stator windings, looseness of the
bracing structure is a certain sign of such phenomena and can itself cause
further mechanical or electrical damage if allowed to go unchecked.
Erosion: Foreign substances impinging against coil insulation surfaces

may cause erosion.
Cleaning
Exterior: Wipe loose dirt from the exterior with a clean, lint-free cloth. Warning: When using cleaning solvents,
Remove stubborn accumulations of dirt with a detergent or solvent ensure adequate ventilation and user
that won’t damage the paint or metal surfaces. Use a vacuum to clean protection.
ventilating ports.
Windings, assembled machines: Where cleaning is required at the

installation site and complete disassembly of the machine is unnecessary
or not feasible, pick up dry dirt, dust or carbon with a vacuum cleaner to
prevent the redistribution of the contaminant. A small non-conducting
nozzle or tube connected to the vacuum cleaner may be required to reach
dusty surfaces or to enter into narrow openings. After most of the dust
has been removed, a small brush can be affixed to the vacuum nozzle to
loosen and allow removal of dirt that is more firmly attached.
After the initial cleaning with a vacuum, compressed air may be used to
remove the remaining dust and dirt. Compressed air used for cleaning
must be clean and free of moisture or oil. Air pressure or velocity must
be adequately controlled to prevent mechanical damage to the insulation.
Disassembly of the machine and more effective cleaning by a qualified

Kato technician may be required if the above described field service
cleaning procedures do not yield effective results.
Windings, disassembled machines: Take an initial insulation resistance

reading on the machine to check electrical integrity. The high pressure
hot water wash method of cleaning, which sprays a high velocity
jet of hot water and water containing a mild detergent, is normally
effective in cleaning windings, including those subjected to flooding
or salt contamination. Use multiple sprays with clean water to remove
or dilute the detergent following the detergent spray. Dry the machine

Page 29
Caution: The insulation resistance tests are until acceptable insulation resistance values are obtained at room
usually made on all or parts of an armature temperature. See the insulation resistance procedures below for minimum
or field circuit to ground. They primarily recommended values.
indicate the degree of contamination of the
insulating surfaces or solid insulation by Electrical contacts: Clean electrical contacts, switch contacts and
moisture and other conducting influences terminals with an approved contact cleaner. Do not file contacts.
and will not usually reveal complete or
uncontaminated ruptures.
Insulation resistance tests at low voltage
Note: The insulation resistance value Insulation tests are conducted for two reasons: to discern existing
increases with decreasing winding weakness or faults or to give some indication of expected service
temperatures. All readings must be reliability. Insulation resistance tests are based on determining the current
corrected to winding temperatures. Use through the insulation and across the surface when a DC voltage is
Table 4 for converting megger readings to applied. The leakage current is dependent upon the voltage and time of
other temperatures (e.g., 100 megohms at application, the area and thickness of the insulation, and the temperature
50º C is converted to 170 megohms: 1.7 x and humidity conditions during the test.
100).
Refer to the following electrical measurement procedures for testing
Winding detail. Contact Kato Engineering or refer to IEEE Standard. 432-1992
Temp Conversion
when more extensive insulation tests are required
(ºC) factor
10 0.23
When checking insulation resistance with a megger, first verify the
20 0.37
30 0.6 ground path. Connect one test lead to a ground point. Then connect
40 1 the second test lead to another ground location to prove the ground
50 1.7 connection. Once the ground path has been proven, the second test lead
60 2.7 can be connected to the leads of the component to be tested.
70 4.5
80 7.5
90 14 Exciter field (stator) and PMG armature (stator)
100 23
110 38 1. Disconnect the exciter leads from the terminals in the terminal box or
120 61 the voltage regulator.
Table 4: Temperature conversion
factor for resistance readings 2. Connect exciter leads to one clamp of 500-volt megger, and connect
the other clamp to the exciter field frame.
Warning: Never apply the megger to the
rotating rectifier, the voltage regulator, or 3. Apply 500 V from the megger, and measure the resistance reading
generator accessories (e.g., temperature after 1 minute. The reading must be a minimum of 50 megohm. If it
detectors, space heaters). is not, refer to the cleaning or dry out procedures.
4. Ground the exciter field leads to the exciter field frame for several
minutes after the megger has been disconnected. This will allow the
voltage build up to be properly discharged.
Note: New generators should measure
about 100 megohms minimum of insulation 5. Repeat steps 1-4 for the PMG armature (stator).
resistance when meggered. Generators that
read 50 megohms or less should be dried
out according to the dry out procedures Exciter armature
here. Generators with insulation resistance
readings of 10 megohms or less should be 1. Disconnect the exciter armature leads from the rotating rectifiers.
investigated.

Page 30
2. Connect the leads of the exciter armature to one clamp of a 500-volt Winding rated Insulation
megger, and connect the other clamp to a suitable connection on voltage (V)* resistance test
exciter sleeve or shaft. direct voltage
(V)
3. Apply 500 V from the megger, and measure the resistance reading
<1000 500
after 1 minute. The reading must be a minimum of 50 megohms. If it
is not, refer to the cleaning or dry out procedures. 1000-2500 500-1000
2501-5000 1000-2500
4. Ground the exciter leads to the exciter sleeve or shaft after 5001-12000 2500-5000
disconnecting the megger. This will allow the voltage build up to be
>12000 5000-10000
properly discharged.
Table 5
Main rotor Guidelines for DC voltages to be
applied during insulation resistance
1. Disconnect the generator field leads from the positive and negative tests
terminals of the rotating rectifier assembly.
a
Rated line-line voltage for three-phase
2. Connect the positive and negative leads to one clamp of the megger, ac machines, and line-to-ground voltage
and connect the other clamp to the shaft. for single-phase machines, and rated
direct voltage for dc machines or field
3. Apply voltage from the megger, and measure the resistance reading windings.
after 1 minute. The reading must be a minimum of 50 megohms. If it
is not, refer to the cleaning or dry out procedures. (See Table 5).
4. Ground the field leads to the shaft after disconnecting the megger for
a minimum of 1 minute. This will allow the voltage build up to be
properly discharged.
Main stator
1. Disconnect power connections and all control apparatus from the

generator terminals.
2. Measure insulation resistance of each phase separately with the two

other phases shorted to the frame. Caution: Do not apply heat too rapidly. It
could damage the windings.
3. Use a megger connected between the lead(s) of the phase to be
measured and generator frame. The minimum 1-minute insulation
resistance must not be less than 50 megohms. (See Table 5).
4. Ground the leads to the frame after the 1-minute megger test. This
will allow the voltage build up to be properly discharged.
Dry out procedures

If the insulation resistance readings are below the recommended mini-
mum values specified previously, use one of the dry out procedures
described below. Select the procedure based on the size and location
of the unit, available equipment, and experience of personnel. Before
drying, remove the voltage regulator, and cover all inlet and discharge

Page 31
openings. Provide an opening at the top of the machine, preferably at the
fan end, for moisture to evaporate.
Drying with external heat: Place heat lamps, space heaters (in addition
to the ones already supplied) or a steam pipe near the windings. Monitor
winding temperatures. Raise winding temperature gradually at a rate
of 10-20° F (-12° to -6° C) per hour up to 200° F (93° C). Measure
insulation resistance at 1-hour intervals. Typically the insulation
resistance will slowly drop while the temperature is coming up, and then
gradually increase and level out.
Drying with AC current in the armature: Short circuit the generator

terminals. Provide DC excitation to the brushless exciter field winding.
Insert a current transformer and an ammeter to read full load current.
Run the generator at rated speed. Apply excitation to the exciter field
until rated current is developed. Monitor winding temperatures until they
stabilize. Continue running until insulation resistance values level off.
Monitor winding temperatures. Raise winding temperature gradually at a
rate of 10-20° F (-12° to -6° C) per hour up to 200° F (93° C). Measure
insulation resistance at 1-hour intervals. Typically, the insulation
resistance will slowly drop while the temperature is coming up and then
gradually increase and level out.
Bearing lubrication
Sleeve bearings: Lubricate the bearings in accordance with the
lubricating instructions attached to the generator and the bearing
lubrication instructions, which are provided in the manual package as
supplementary material.
Roller bearings: In applications where regreaseable bearings are used,

grease fill fittings and relief valves are incorporated into the bearing
housing. Lubricate the bearings in accordance with the lubricating
instructions attached to the generator.
Rectifier tests
If a failure of a rectifier is suspected, remove the exciter cover. Remove
the nut and washer holding the rectifier in the heat sink, and remove the
diode lead wire. Lift the rectifier from the heat sink (see figure 20 for
an overview). Test the entire rectifier with an ohmmeter or test lamp as
follows:
Negative
Positive
Positive
Figure 20: Rectifier

Page 32
Ohmmeter: Connect the ohmmeter leads across the rectifier in one
direction (see Figure 21). Note the meter reading. Reverse the leads, and
note the meter reading. The meter should indicate a low resistance when
the leads are across the rectifier in one direction and a high resistance
when the leads are across the rectifier in the opposite direction. A low
resistance in both directions indicates a short. A high resistance in both
directions indicates an open rectifier.
Cathode
Ohmmeter
Anode
Reverse Standard Caution: Do not pound on the rectifier or

diode diode armature windings.
Figure 21: Testing the rotating rectifier with an

ohmmeter
Test lamp: Connect the leads of a test lamp, consisting of standard

flashlight batteries and a flashlight and built, as shown in Figure 22,
across the rectifier in one direction. Then reverse the leads. The light
should light in one direction but not the other. If the light lights in both
directions, the rectifier is shorted. If the light does not light in either
direction, the rectifier is open.
Figure 22: Test lamp
Replace defective rectifiers with rectifiers of the same operating

characteristics as rectifiers installed in the generator at the factory.
Order rectifiers by part number, including the model and type of exciter
as well as the generator serial number.
Surge protectors may be included on the rotating rectifier assembly.

Disconnect one lead of the surge protector, and connect the leads of
an ohm meter or makeshift test lamp, consisting of standard flashlight
batteries and a flashlight and built as shown in Figure 21, across the surge
protector in either direction.. If the light comes on, the surge protector
is defective. Order surge protectors by part number, including the model
and type of exciter as well as the generator serial number. Following
replacement, make sure that the revolving field, exciter armature, and
rotating diode leads are properly secured.

Page 33
Note: The following procedures are meant Assembly and disassembly of generator
to be a general guide. Procedures for your
unit may vary. Disassembly
Warning: Ensure the generator has stopped
Remove the outlet box covers and disconnect the generator load leads.
and is de-energized before disassembly.
Tag the leads and terminals to make certain the leads are correctly
Warning: Use a hoist and slings or chains connected when the unit is reassembled. Disconnect the other electrical
to support the components during removal. connections (current transformers, potential transformers, RTDs, AVR
Use lifting devices that are selected for and governor power supply inputs and outputs, and space heaters).
generator component weights. Be extremely
careful not to damage components. Shut down the oil supply system, and disconnect it from the generator. (if
applicable).
Loosen or remove the bolts (as needed) from the coupling to separate the
coupling halves.
Remove the PMG.
1. Remove the exciter cover.

Caution: Ensure the generator field wires
are flat in the wireway so they don’t tear 2. Disconnect the alternator field leads, and remove the exciter
during pulling. Do not pull on the edges of armature and PMG retaining bolts.
the heat sinks or on the exciter armature
windings. 3. Install a wire or metal strap around the OD pf the PMG to
ground the magnets. Grasp the inside magnets and pull quickly
and sharply straight back, overcoming the magnetic pull of the
PMG rotor toward the PMG armature.
Warning: Pull the exciter-PMG frame-stator
straight out. The assembly may pull toward 4. Wrap the PMG rotor in plastic to avoid contamination with metal
the PMG. filings.
Remove the exciter armature and rectifier as a unit.
1. Remove the clips securing the exciter field leads to the exciter
frame, the generator frame and generator endbell.
Caution: Do not pull on the edges of the
rectifier or on the exciter armature windings. 2. Disconnect the generator field (rotor) leads from the positive
(+) and negative (-) exciter armature lead terminals located on
the rotating rectifier assembly.
3. Using a hoist and strap, slide out and remove the exciter
armature and rectifier tube assembly, which is keyed onto the
shaft.

Page 34
Remove the exciter-PMG frame-stator.
1. Connect a hoist to the lifting eyes.
2. Remove the exciter-PMG frame-stator mounting bolts, and

remove the exciter-PMG frame-stator. Caution: Make sure that the work place is
clean. Contamination and damage to the
Remove the opposite-drive end bracket. bearing, especially of the running surfaces,
reduce operating quality and could lead to
premature damage or failure.
Dismantle the bearings.
1. Twist the knob on the spring-loaded holders, and pull the

RTDs out of the bearing hanger
2. Dismantle all air tubes and oil supply lines.
3. Dismantle the outboard seal carrier and inboard seal carrier.
4. Loosen the bolts that connect the carriers to the housing, and Note: If necessary, tap the bearing housing
remove them. lightly with a rubber or fiber mallet to loosen
it.
5. Loosen and remove the split line bolts.
6. Remove simultaneously, in the axial direction, both the top

Note: The outside seal carrier on the drive
and bottom halves of the seal carriers. end bearing does not have split line bolts.
7. Remove the garter springs and the gap seal and labyrinth seal.
8. Remove the gasket.
Dismantle the top half of the bearing housings.
1. Remove the split-line bolts.
2. On the opposite-drive-end side, lift the top part of the bearing

housing until it can be moved in an axial line over the bearing
liner without touching it, and then move it out.
3. On the DE side lift the housing out and over the top of the
generator.
4. On the opposite-drive-end side, unscrew the split line screws in

the bearing liners. Screw in two lifting eyes in the top, and lift
the top half off the bearing liners.
5. Lift the shaft up slightly (about 0.015 to 0.25 inch) on both ends
of the rotor to the point where the shaft and bottom half of the
bearing liner do not touch each other.

Page 35
Caution: Be careful to not damage running 6. Place shims between the rotor and the stator the thickness of the
surfaces. air gap. Lower the shaft.
Warning: Before transport or lifting bearing 7. On the opposite-drive-end side, remove the bottom halves of the
components, check if the eye bolts are tight. bearing liners.
Insecure eyebolts could result in the part
coming loose and falling Make sure the
eyebolts are not exposed to bending stress, 8. Rotate the bottom half of the liner 180º so it is facing upward
otherwise they could break. Make sure the
(where the top half of the liner was). Move the shaft
lifting equipment does not contact the seal
and running surfaces of the shaft. as necessary. Slide the liner forward so it rests on the bottom
bearing housing’s top surface.
Note: On the DE side, you can remove
the bearing liners after the rotor has been 9. Use lifting eyes and hoist to remove the liner.
removed.
10. Remove the bottom half of the bearing housings from the frame.
Caution: Make sure the RTD is removed
before rotating the bearing liner. 11. Remove the opposite-drive end bearing bracket and air baffle.
Caution: Make sure the pipe is strong Float out the rotor.
enough to support the weight of the rotor
and that it does not have rough edges on 1. Fit a pipe over the shaft. Depending upon the space available,
the inside, which could damage the shaft. you may have to use a pipe that can be assembled, adding an
To prevent tension on the shaft, put slings additional piece during each stage of movement outward.
around the largest shaft step possible. Make
sure the rotor does not hit the stator. 2. Attach slings around the pipe on one end and around the shaft
on the opposite end.
Note: If the generator is mounted on
the engine base, the drive end bearing 3. Lift up the rotor, and move it out, gently resting the rotor on
bracket and air baffle may not be able to be the stator as the slings are moved down the pipe for the next
removed until the rotor passes through the lifting stage. (See figure 23).
generator.
4. Remove the drive-end side bearing liners from the shaft.

Page 36
Assembling the generator: Caution: Make sure all components are
clean before assembly. Make sure all
Use standard torque specifications per Chart 1 unless otherwise specified. gaskets have not deteriorated and are
positioned correctly.
Install the bearing liners on the drive-end side of the shaft.
1. Make sure the surfaces are clean. Apply STP Oil Treatment
over the running surface on the shaft where the liner will sit.
2. Make sure the engraved numbers on the top and bottom halves
correspond and are on the same side. Mate the top liner over the
bottom liner on the shaft.
3. Put Loctite 242 on the split line screws, insert the screws, and
tighten.
Caution: Make sure the pipe is strong
enough to support the weight of the rotor
Float in the rotor. and that it does not have rough edges on
the inside, which could damage the shaft.
1. Move the rotor up and in line with the stator. Fit a pipe over To prevent tension on the shaft, put slings
the drive end of the rotor. Depending upon the space around the largest shaft step possible. Make
available, you may have to use a pipe that can be disassembled, sure the rotor does not hit the stator.
taking off an additional piece during each stage of movement
inward.
2. Attach slings around the pipe on one end and around the shaft
on the opposite end.
3. Lift up the rotor, and move it in, gently resting the rotor on the
stator as the slings are moved down the pipe
Put a bead of premium siliconized acrylic latex caulk (or equivalent)

over the opposite-drive-end baffle mating surface, and install the baffle.
Figure 23: Floating the rotor

Page 37
Caution: Make sure all components are Assemble the bearings as follows:
clean before assembly.
Install the liner insulators on the inside diameter of the top and bottom
Note: Torque fasteners to the values speci- bearing housing of both bearings. Each housing gets two insulators.
fied in Chart 1 unless otherwise specified.
1. Fit up the insulators in the liner seat, and crease the outside
Caution: Carry out these operations very edge over the lip.
carefully as to not damage the shaft or
bearing components. 2. Trim the top of the insulators flush with the mating surface (of
the top and bottom halves of the housing).
3. Make sure the insulator surface is clean. Mix Metallon two-

Caution: Remove all impurities or other part epoxy in equal parts, and brush it over the track.
objects such as screws, nuts, etc., from
the bearing components. If left inside,
they could lead to bearing damage. To 4. Peel the backing off, and put the insulators in place. Press
prevent contamination, cover the bearing them tightly on the track, and place the liners (or fixtures) in the
components when they are not being housings to maintain good compression. Let the epoxy set for 12
worked on. hours. Make sure it has no voids or air bubbles.
Install the bottom bearing housings. Before installing, brush Nox rust on
frame mating surfaces that will fit into bearing housing.
1. On the opposite-drive-end side, lift up the ends of the shaft

Note: If no fixture is available to compress slightly, so the bearing housing clears the shaft, and
the insulators, use the top liner for both bolt it in place on the frame.
halves of the bearing. Make sure all tubes
and fasteners are in the liner to ensure a 2. On the drive end side, lift the housing up and bolt it into place
smooth surface.
on the frame.
Install the bottom half of the bearing liners on the opposite-drive-end

side.
1. Lift the shaft up slightly (about 0.005 inch) on both ends of the
rotor to the point where shaft and bottom half of the liner do not
touch each other.
2. Make sure the surfaces are clean. Apply STP Oil Treatment
over the running surface on shaft where the liner will sit.
3. Set the liner on the shaft so it rests on the housing. Use

eyebolts for lifting. The ID numbers on the lining face outward.
4. Remove the lifting eyes from the liner. Move the rotor gently
from side to side and up and down as necessary, and slide the
liner down into the housing. If the liner doesn’t turn easily, check
the position of the shaft and the alignment of the housing.
5. Lower the shaft onto the liner.

Page 38
Install the top half of the bearing liner on the drive end side.
1. Apply STP Oil Treatment on the running surface of the shaft

where the top half of the liner will sit.
2. After making sure the engraved numbers on the top and

bottom halves correspond and are on the same side, place the top
liner over the bottom liner.
3. Put Loctite 242 on the split line screws, insert the screws, and
tighten.
Install the top bearing housings.
1. Apply STP Oil Treatment on the top of the bearing liner.
2. Spread Loctite 587 Blue on the bottom housing where it will

mate with the top housing.
3. Put the top housing in place, making sure the dowel pin in
the inside diameter of the top housing lines up with the pin hole
in the bearing liner. Put Loctite 242 on the split lines screws,
and fasten the housings together, leaving the screws snug but not
tight.
Torque the split line screws to 1100 ft-lbs.
Install the seal carrier assemblies.
1. Cut the gasket, if necessary to fit it over the shaft. Coat it with
Loctite Hi-Tack gasket sealant or equivalent, and fit it over the
shaft.
2. Attach the gap seal and labyrinth seal with the labyrinth
seal nearest the bearings. Put the two halves of the seals
together, and slip the garter springs around the seals to fasten
them. (The outside seal carrier on the drive end side only
gets a labyrinth seal.)
3. Put Curil-T on the inside diameter of the seal carriers where

they will contact the seals, (one bead in the narrow (inside)
groove and one bead in each of the three wider (outside)
grooves. Also put Curil-T on the surface of the labyrinth seal on
both sides of the spring.
4. Use Loctite 587 Blue to caulk the mating surface of the

bottom seal carrier (where it mates with the top half). Put gasket
sealant on the flange surface of the seal carrier where it will mate
with the bearing hanger. Also, put gasket sealant on the mating
surface of the bearing hanger.

Page 39
5. Set the top half of the seal carrier over the seals. Make sure the
Exciter armature Minimum air
notch in the top of the seal lines up with the opening in the seal
diameter (in.) gap (in.)
carrier. Attach the bottom half of the seal. Put Loctite 242 on the
5 3/4 0.014 threads of the two split line screws. Add a flat washer, insert, and
9 7/8 0.014 tighten.
12 1/2 0.018
16 1/4 0.035
6. Slide the seal carrier assembly up against the gasket and
bearing hanger. Bolt (with flat and lock washer) the seal carriers
Table 6: Exciter air gap
to the bearing hanger, and tighten.
Install the air tube and oil supply lines.

Note: To measure air gap, measure com-
pletely around the gap between the exciter Install the RTDs in the spring-loaded holders.
armature and exciter field with a feeler
gauge. Keep the gauge at the tightest point, Before operating the generator, start the oil flow to the bearings, and
and turn the generator over to measure the
follow the startup procedure to ensure the bearing is functioning properly
air gap as the rotor turns.
and so that damage to the bearing doesn’t occur.
Caution: Do not pry on the fan.
Brush Nox rust on frame mating surface that will fit into the opposite-
drive end bracket (which fits over the top of the top bearing housing),
and attach the opposite-drive end bracket and tighten.
Attach the exciter-PMG frame-stator.
1. Apply Nox rust to the machined surface on the bearing bracket

where the exciter-PMG frame-stator will mount.
2. Attach the exciter-PMG frame-stator to the bearing bracket

mounting surface.
3. Torque the bolts per Chart 1.
Attach the exciter armature and rectifier tube assembly.
1. Brush Nox rust on the exposed PMG shaft journal.
2. Position the exciter armature-rotating rectifier assembly in line

with the shaft, and turn the assembly to the position where the
keyway in the exciter sleeve is in line with the key in the
generator shaft.
3. With hand force, push the armature assembly and rotating

rectifier tube over the shaft, so the end of the sleeve is against
the shoulder on the shaft. It may be necessary to tap lightly on
the exciter sleeve in order to move the assembly over the key.
Use a fiber or rubber mallet. If installation is still a problem, use
a heat gun to expand the exciter sleeve.
4. Connect the field leads to the rotating rectifier.

Page 40
Attach the PMG.
1. Brush Nox rust on the exposed PMG shaft journal.
2. Put the armature key in the slot on the shaft.
3. Align the PMG rotor with the key on the shaft and holding by
the inside magnets, slide the PMG into position.
4. Install the PMG/Exciter armature retaining bolts. Torque the

bolts per Chart 1.
Check the air gap between the PMG rotor and PMG stator.
1. Measure completely around the gap between the PMG rotor

and PMG stator with a feeler gauge.
2. Keep the gage at the tightest point, and turn the generator over
to measure the air gap as the rotor turns. Minimum air gap is
0.035 inch.
Check the air gap between the exciter armature and exciter stator.
1. Measure completely around the gap between the exciter

armature and exciter stator with a feeler gauge.
2. Keep the gage at the tightest point, and turn the generator over Caution: Do not pound on the rectifier.
to measure the air gap as the rotor turns. Minimum air gap is
0.035 inch.
Attach the exciter cover.
Connect the air temperature RTDs.
Mount the generator to the prime mover, and make the electrical
connections as described earlier.

Page 41
Troubleshooting Guide Warning: Problems left uncorrected can
result in injury or serious damage, which can
(corrective maintenance) result in costly repairs and downtime.
Between regular preventive maintenance inspections, be alert for any

signs of trouble. Correct any trouble immediately.
Symptom Cause Remedy

No Voltage Open voltage regulator, circuit breaker or Check. Reset the circuit breaker or replace
fuses fuses if open.
Overvoltage, undervoltage, or overload Check for the cause of the abnormal condition.
devices tripped (when protective devices Correct any deficiencies. Reset devices.
are incorporated into the circuit) Check the generator nameplate for nominal
operating values.
Open circuit in exciter field Check continuity of shunt field and leads
to voltage control. (Use ohmmeter or
Wheatstone bridge) If open in field coils,
remove exciter field assembly and return
assembly to factory for repair.
Loss of residual magnetism in exciter Restore residual magnetism or flash field. When
field poles the voltage regulator is a model that requires
flashing, install an automatic field flashing
system.
Open circuit in stator windings Check for continuity in the windings. Return the
generator to the factory for repair if open.
Malfunction of automatic voltage See troubleshooting of voltage regulator.
regulator Correct deficiencies.
Short-circuited generator output leads Clear lead to restore voltage buildup.
Open in rotating rectifiers Check rotating rectifiers, and replace if
open.
Open in generator field Check for continuity and return rotor to
factory for repair if field coils are open.
Shorted or grounded surge protector Check for shorts or grounds. Replace .
Shorted or grounded rotating rectifier Check for shorts grounds. Replace or repair.
Shorted or grounded exciter armature Check for shorts or grounds. Replace or repair.
Low voltage Shorted leads between the exciter armature Test and repair.
and generator field
Incorrect stator connections Check the connections, and reconnect
Table 6: Troubleshooting

Page 42
Low voltage Improper adjustment of voltage adjust Adjust rheostat.
(cont.) rheostat
Excessive load Reduce load. With three-wire, single-phase and
four-wire, three-phase generators, the load on
each leg must be as evenly balanced as possible
and must not exceed the rated current on any leg.
Line loss Increase the size of the line wire.
High resistance connections (hot) Make better connections.
Shorted main or exciter field Test the field coils for possible short by
checking resistance with an ohmmeter or
resistance bridge. Return the rotor assembly
to the factory for repair if field coils are shorted.
Low power factor Reduce inductive (motor) load. Some AC
motors draw approximately the same
current regardless of load. Do not use
motors of larger horsepower rating than
is necessary to carry the mechanical
load.
Weak field due to operating in a warm Improve the ventilation of the generator.
temperature Field current can be increased providing
the generator temperature rating
stamped on the nameplate is not
exceeded.
Defective rectifiers in rectifier assembly Check rectifier assembly. Replace
(stationary) defective fuses or rectifiers.
Excessive load Reduce load to rated value.
Bearing overheating Inspect the bearing.
Improper speed of engine driven Check and correct deficiencies.
generator set due to defective governor,
ignition system, or carburetor
Voltage regulator not operating properly Check the regulator. Adjust, repair or replace.
Fluctuating Prime mover speed fluctuating Check frequency and voltage of incoming
voltage power when the generator set is motor
driven. Check engine governor on
engine-driven generator sets.
Loose internal or load connections Tighten all connections.
Generator overloaded Reduce load to rated value.
DC excitation voltage fluctuating Trace DC excitation circuit. Correct any
defects.
Overspeed Correct speed of prime mover.
High voltage Improper adjustment of voltage adjust Adjust rheostat and/or voltage regulator.
rheostat or voltage regulator

Page 43
Overheating Clogged ventilating screens and air Clean all screens and air passages.
passages
Dry or defective bearings Inspect bearings.
Coupling misaligned Align the generator set.
Generator field coils shorted or Test field coils for shorts. Replace
grounded shorted rotor or return it to the factory for
repair.
Unbalanced load or overload, low PF Adjust load to nameplate rating.
Vibrations Defective or dry bearings Inspect bearings.
Misalignment of generator and prime Align the generator set.
mover
Generator not properly mounted Check mounting. Correct defective
mounting.
Transfer of vibration from another Isolate the generator set from the source of
source vibration.

Page 44
ASTM and SAE Torque Values
Grade 5
Grade 2 Grade 5 GASKETED COVERS Grade 8
SCREW
SIZE Foot-Pounds Newton-Meter Foot-Pound Newton-Meter Foot-Pound Newton-Meter Foot-Pound Newton-Meter
Ft-Lbs Tol N-M Tol Ft-Lbs Tol N-M Tol Ft-Lbs Tol N-M Tol Ft-Lbs Tol N-M Tol
#4-40 4* 0.4
#6-32 8* 0.9
#8-32 14 * 1.6
#10-24 20 * 2.3
#10-32 23 * 2.6
1/4-20 4 1 6 1 8 2 11 3 5 1 7 2 10 2 14 3
5/16-18 8 2 11 2 17 3 24 4 10 2 14 3 25 5 34 7
3/8-16 15 3 20 4 31 6 42 8 12 2 16 3 40 10 54 14
7/16-14 24 5 32 6 50 10 65 13 70 15 95 20
1/2-13 36 7 50 10 75 ** 15 100 20 24 5 32 6 100 20 135 27
9/16-12 55 10 75 14 110 20 150 25 150 30 200 40
5/8-11 75 12 100 17 150 25 200 20 200 40 275 55
3/4-10 130 25 175 24 260 50 350 70 370 50 500 70
7/8-9 145 20 195 28 425 60 575 80 600 60 800 80
1.0-8 190 22 250 30 650 75 875 100 900 90 1200 120
1 1/8-7 265 27 350 35 790 80 1075 100 1200 120 1650 160
1 1/4-7 375 40 500 55 1100 120 1500 150 1750 180 2400 250
1 3/8-6 490 50 650 70 1450 150 1950 200 2300 230 3100 300
1 1/2-6 625 60 850 90 1750 180 2350 250 3000 300 4000 400
* Inch-pounds
SCREW Set Screws Brass Screws Stainless Screws Grade B Top Lock Nuts
#4-40 4* 0.4 5* 0.6
#6-32 8* 0.9 10 * 1.1
#8-32 20 * 2.3 16 * 1.8 21 * 2.4
#10-24 18 * 2 24 * 2.7
#10-32 34 * 3.8 33 * 2.9 33 * 3.7
1/4-20 6 1 9 2 5 1 7 2 6 1 8 2 6 1 8 1
5/16-18 13 2 18 3 9 2 12 2 11 2 15 3 11 2 15 3
3/8-16 23 2 31 6 16 3 22 4 21 4 28 5 18 2 24 3
7/16-14 36 5.14 50 10 26 5 35 7 33 7 45 9 28 4 38 5
1/2-13 50 10 70 14 35 7 45 9 45 9 60 12 44 ** 6 60 12
9/16-12 55 10 70 13 60 11 80 15
5/8-11 110 18 145 24 85 14 115 19 100 17 140 23
3/4-10 180 35 240 46 120 23 160 31 130 25 180 35
7/8-9 430 60 580 82 205 30 280 40
1.0-8 580 70 790 90 300 35 400 45
1 1/8-7 430 45 590 60
1 1/4-7 550 60 750 80
1 3/8-6 700 70 950 100
1 1/2-6 930 100 1250 130
* Inch-pounds
** For Electrical Lugs use 44 Ft-lbs (60 N-M)
Chart 1: Torque Values

Page 45
Metric Torque Values
Grade 8.8
SCREW Grade 4.8 to 6.8 Grade 6.9 to 8.8 GASKETED COVERS Grade 10.9
M4 x .70 1.1 1.5 2 2.7 2.9
M5 x .80 2.3 3.1 4 5.3 6
M6 x 1.00 4 1 5.2 1 7 1 9.3 2 4 1 5 1 10 2 14 3
M7 X 1.00 6.5 1 8.7 2 11 1 15 3 16 5 34 7
M8 x 1.25 10 2 13 3 18 2 24 5 11 2 15 4 25 10 54 14
M10 x 1.50 20 4 27 5 32 4 43 9 13 3 18 4 47 15 95 20
M12 x 1.75 34 7 45 9 58 7 77 15 19 4 26 5 83 20 135 27
M14 x 2.00 54 10 72 13 94 10 125 23 132 30 200 40
M16 x 2.00 80 13 108 18 144 13 192 32 196 40 275 55
M18 x 2.50 114 22 152 29 190 22 253 50 269 50 500 70
M20 x 2.50 162 23 216 30 260 23 347 50 366 60 800 80
M22 x 2.50 202 23 269 31 368 23 491 55 520 90 1200 120
M24 x 3.00 245 25 327 33 470 25 627 65 664 120 1650 160
M27 x 3.00 360 40 480 52 707 40 943 100 996 180 2400 250
M30 x 3.50 500 50 667 70 967 50 1289 130 1357 230 3100 300
Grade 2 Grade 5 Grade 8

ASTM & SAE grade markings
Class 8.8 Class 10.9

Metric grade markings
1-NM = 0.737 ft-lbs. = 8.85 in-lbs.

Page 46
List of equipment required for installation and maintenance
Test equipment Notes
Ammeter Clamp-on, 0 to 500 amp range for measuring of electrical current.
Multimeter Digital, for measuring voltage, current, frequency and resistance.
Thermometer For measuring temperature in Celsius
Megger To measure insulation resistance.
Resistive Bridge To measure resistance of windings.
Special tools
Bearing puller For changing bearing.
Exciter puller For pulling exciter armature
Standard tools
Cable tool Crimping
Flashlight As required
Grease gun For lubricating bearings
Hammer Soft-faced
Lamp (incandescent) Safety light
Screwdrivers Standard, sized as required
Screwdrivers Phillips, sized as required
Wrench Adjustable, 12-inch
Wrench Torque 0 to 100 ft-lb
Wrench set Allen, 1/8 to 1/2 inch
Wrench set Socket, 1/4 to 1 inch with 3/8 and 1/2 inch drive
Wrench set Standard, open-end/box-end combination sized 1/4 to 1 inch
Vacuum Electric with nonmetallic nozzle
Materials
Air Compressed, dry.
Corrosion inhibitor Nox-Rust VC #10 Oil or equivalent
Covering material Waterproof desiccant bags for protection from
moisture during long-term equipment storage
Detergent As required for cleaning
Gloves Chemical-protective
Gloves Electrical-protective
Heaters Space Heater, for eliminating excess moisture in damp areas and dry
out of motor or generator windings
Plastic Protection for long-term storage
Rags As required for cleaning
Water Warm and clean, for cleaning
Tags Warning and cautions

Page 47
Page 48
Instruction Manual
Publication 351-01002-00A, 09/23/05
Installation • Operation • Maintenance
KCR 760 Voltage Regulator

P.O. Box 8447
Mankato, MN USA
56002-8447
Tel: 507-625-4011
Fax: 507-345-2798
Email: katoengineering@lsusa.com
www.kato-eng.com
Page 1
Table of Contents
Note: Because of rapid changes in designs Introduction...................................................................... 4
and processes and the variability of Kato Foreword............................................................................................... 4
Engineering’s products, information in this Safety instructions................................................................................. 4
manual must not be regarded as binding Ratings/description............................................................................... 4
and is subject to change without notice. Features, options and specifications...........................4
Overview................................................................................................4
Standard features and options.............................................................. 5
Specifications........................................................................................ 7
Operating principles.......................................................10
Installation...................................................................... 16
Mounting..............................................................................................16
Interconnection....................................................................................16
Single phase 100 to 600 Vac sensing................................................. 16
Three-phase 100 to 600 Vac sensing..................................................16
Input power..........................................................................................20
Output power....................................................................................... 20
Grounding........................................................................................... 20
External voltage adjust rheostat.......................................................... 20
Connection to reactive voltage droop................................................. 21
UFL circuit 50/60 and 400 Hz selector J1........................................... 25
Voltage regulator fuse......................................................................... 25
Accessory items................................................................................. 25
Operation........................................................................ 30
Adjustments........................................................................................ 30
Field flashing....................................................................................... 30
Single unit initial operation.................................................................. 32
Parallel operation................................................................................ 34
Maintenance....................................................................37
Preventive maintenance......................................................................37
Corrective maintenance...................................................................... 37
Operational test...................................................................... 38
Troubleshooting...................................................................................38
Page 2
Figures and Tables
Figure 1: Standard UFL operational threshold for 50/60 Hz system.............9
Figure 2: Effect of timed gating signal on SCR phase angle...................... 13
Figure 3: Outline drawing............................................................................17
Figure 4: Single phase sensing schematic................................................. 18
Figure 5: Three-phase sensing schematic..................................................19
Figure 6: Interconnection............................................................................22
Figure 7: Parallel operation, reactive voltage droop mode......................... 23
Figure 8: Parallel operation, cross-current compensation mode................ 24
Figure 9: Circuit board schematic (with UFL or volts-per-Hz).................... 26
Figure 10: Circuit board schematic (with flat regulation option)................. 27
Figure 11: UFL electrical schematic........................................................... 28
Figure 12: Operational test........................................................................ 39
Table 1: Voltage across under frequency limit terminals TP1-TP2, 60 Hz..31

Table 2: Voltage across under frequency limit terminals TP1-TP2, 50 Hz..31
Table 3: Replacement parts list.................................................................. 37
Table 4: Troubleshooting............................................................................ 40
Page 3
Introduction
Foreword
This manual contains instructions for installing, operating and
maintaining Kato Engineering KCR 760 voltage regulators.
Please read this manual in its entirety before installing, operating, and
servicing your regulator.
Safety instructions
In order to prevent injury or equipment damage, everyone involved
in installation, operating and maintenance of the equipment described
in this manual must be qualified and informed of the current safety
standards that govern his or her work.
While “common-sense” prevention of injury or equipment damage

cannot be completely defined by any manual (nor built into any piece
of equipment), the following paragraphs define warnings, cautions, and
notes as they are used in this manual:
Warning: Warnings identify an installation, operating or maintenance

could result in death or serious injury to personnel.
Caution: Cautions identify an installation, operating or maintenance

could result in destruction of or damage to equipment or serious
impairment of system operation.
Note: Notes highlight an installation, operating or maintenance

procedure, condition, or statement and are essential or helpful but are not
of known hazardous nature as indicated by warnings and cautions.
Features options and specifications

Overview
The KCR 760 voltage regulator is designed for operation with brushless
synchronous generators. The voltage regulator controls generator voltage
by regulating the amount of current it supplies the exciter field.
The KCR 760 voltage regulator consists of transformers, transistors,

silicon diodes, silicon controlled rectifiers (SCRs), integrated circuits,
resistors, and capacitors. The regulators is relatively unaffected by
humidity, temperature, vibration, or shock and is not subject to wear from
moving parts. Solid-state field flashing components rather than relays
are used in the field flashing and underfrequency circuits, eliminating the
possibility of contact arcing or contact failure.
Page 4
Standard features and options
Features provided in standard KCR 760 voltage regulators, options
available in this series, and various accessories that can be supplied
with the generator set voltage regulating system are described in the
paragraphs that follow. Where options are specified in the purchase order,
the required circuitry changes are made within the regulator at the factory
while accessories are parts that mount external to the regulator.
Standard sensing: The basic KCR 760 regulator uses single phase 50/60
Hz sensing. The sensing transformer has a multi-tap primary permitting
operation at sensing voltages of 100 to 600 Vac. The standard regulator
includes an underfrequency limit circuit that decreases voltage in
proportion to the decrease in frequency when speed drops below the UFL
operational threshold. The UFL in standard 50/60 Hz sensing regulators
is adjusted with an operational threshold of 48 Hz for a 50 Hz application
and 58 Hz for a 60 Hz application.
Optional sensing: When specified in the purchase order the regulator

can be supplied with the following variations in sensing circuitry:
- Three phase 50/60 Hz, 100 to 600 Vac sensing.
- UFL set 49.5/59.5 Hz for use with turbocharged engines.
- Volts-per-hertz circuitry in place of UFL for applications where

voltage must be proportional to frequency over a speed range from
rated rpm down to approximately 1/2 rated speed.
- 400 Hz, single or three-phase, 100 to 600 Vac with 385 Hz UFL
operational threshold.
- 400 Hz with UFL threshold higher or lower than 385 Hz.
- 50/60 Hz or 400 Hz, single or three-phase 100 to 600 Vac with flat
regulation for a motor-generator set or variable frequency/constant
voltage applications. Regulators with flat regulation will not include
UFL or V/Hz circuitry.
Standard input power and dc output: Standard KCR 760 regulator

uses single-phase, 120 Vac ±10% input power and has rated maximum
continuous output of 65 Vdc, 10 A; 90 Vdc, 15 A one-minute field
forcing.
Optional input power and dc output: When specified in the purchase

order, the KCR 760 regulator may be modified to operate from single
phase, 240 Vac ±10% input power and thereby have rated maximum
continuous output of 125 Vdc, 10 A; 180 Vdc, 15 A one-minute field
forcing.
Page 5
Field flashing: KCR 760 voltage regulators include solid-state field
flashing circuitry.
Standard fuse: Standard KCR 760 regulators are supplied with a 15 A

normal blow fuse in the input power circuitry within the regulator. This
fuse provides voltage regulator overload protection.
Optional fuse: In applications where the system does not include a field
circuit breaker and generator field protection is required, a smaller fuse
may be used. For generator field protection, fuse amperage should be one
and a half to two times the exciter field current with rated load connected
to the generator. Fuse amperage must not exceed 15 A or two thirds open
circuit forcing. The fuse must be normal blow type. Do not install a time-
delay type fuse.
Standard voltage adjust: KCR 760 voltage regulators are provided with
an internal voltage range adjust potentiometer and an auto voltage adjust
rheostat for remote mounting. The auto voltage adjust rheostat permits
adjustment of generator voltage approximately ±10% from the nominal
sensing voltage.
Wide-range voltage adjust: For applications where voltage must be

adjusted more than ± 10% from nominal, wide range voltage adjust
circuitry can be provided with the generator set. This accessory is
designed for remote mounting and is electrically connected between the
generator sensing lines and the regulator sensing terminals.
Parallel operation components: KCR 760 voltage regulators include a

parallel operation reactive voltage droop transformer (T2) and a parallel
voltage droop potentiometer (R4). For parallel operation each generator
must be equipped with a current transformer for sensing reactive current.
The transformer may have either a 1 A or 5 A secondary. When a 1 A
current transformer is used, the secondary leads connect to regulator
terminals CT• and CT1. When a 5 A current transformer is used, the
secondary connects to regulator terminals CT• and CT5.
Electromagnetic interference filters: When specified in the purchase

order the KCR 760 regulator can be supplied with EMI filters as an
external accessory.
Input power load isolation or voltage matching transformers: Load

isolation and voltage matching transformers are accessory items that
mount external to the voltage regulator. Load isolation transformers are
available with 120 V primary/120 V secondary (for use with standard
120 Vac input power voltage regulators), or 240 Vac primary/240 Vac
secondary (for use with 240 Vac input power regulators). Load isolation
transformers are recommended for any application where frequency of
the input power to the regulator is different from the sensing frequency,
Page 6
such as 400 Hz motor-generator applications where regulator input power
is taken from 50/60 Hz motor-generator set input power lines. Voltage
matching transformers are available for applications where available
voltage is different from the voltage regulator rated input voltage.
Field circuit breaker: When specified in the purchase order, the

generating system can be provided with a field circuit breaker for
generator field protection.
Voltage shutdown switch: When specified in the purchase order, the

generating system can be supplied with a switch that electrically connects
in the line that supplies input power to the regulator. This protective
device is recommended for engine driven generator applications not
provided with field circuit breaker or underfrequency protection.
Automatic/manual voltage control: When specified in the purchase

order, the generating system can be supplied with an automatic/manual
voltage control module. This accessory includes a full wave rectifier and
a variable transformer (variac) for manual voltage control and a three-
position switch. The switch allows the generator to be controlled either
automatically by the voltage regulator or manually. The OFF position
provides voltage shut-down by de-energizing both the voltage regulator
and the manual voltage control rectifier.
Specifications
Power output:
- 65 Vdc, 10 A; maximum continuous output; 90 Vdc, 15 A one-minute

field forcing where the regulator is constructed for 120 Vac input.
- 125 Vdc, 10 A; maximum continuous output; 180 Vdc, 15 A one-minute

field forcing where the regulator is constructed for 240 Vac input.
Power input: Single phase, 50/60 Hz, 120 Vac ±10%; or single phase,
50/60 Hz, 240 Vac ±10%.
Sensing: Standard regulators are constructed for single phase 100 Vac to
600 Vac sensing. Three phase 100 Vac to 600 Vac available as optional
feature. Special voltage or frequency is available as an optional feature.
V/Hz sensing available as optional feature.
Voltage adjustment range: ±10% is standard. Wide-range voltage

adjust is available as an optional accessory.
Page 7
Field resistance:
- 6.5 Ω minimum, 100 Ω maximum for a standard 65 Vdc regulator.
- 12.5 Ω minimum, 200 Ω maximum for an optional 125 Vdc

regulator.
Burden resistance: Sensing: 6 VA maximum. Input power: 2400 VA

maximum for 240 Vac input; 1200 VA maximum for 120 Vac input.
Paralleling: 10 VA maximum.
Paralleling: 1 A for 6% droop or 5 A for 6% droop on current

transformer. For 1 A, connect to terminals CT• common and CT1; for 5 A
connect to terminal CT• common and CT5. Factory adjusted 4% droop.
Fuse: 15 A maximum, ABC type fuse for voltage regulator protection.
Underfrequency protection: Except where flat regulation, V/Hz

sensing or UFL with special operational threshold is specified in the
purchase order, the underfrequency limit (UFL) circuit will provide
underfrequency protection by reducing voltage in proportion to
frequency. The UFL operational threshold where limiting starts is as
follows (see also Figure 1):
- Standard:
58 Hz for 60 Hz system
- Optional for use with generator driven by turbocharged engine:

59.5 Hz for 60 Hz system
49.5 Hz for 50 Hz system
Regulator accuracy: Voltage regulation is maintained within ±0.5%

over full range of generator loading and for generator speed variations of
up to 5%.
Regulator response: Less than 17 milliseconds.
Thermal stability: Less than ±0.5 percent for 40° change in ambient
temperature.
Operating temperature: -40° C to 60° C.
Storage temperature: -60° C to +85° C.
Power dissipation: Less than 35 W at maximum continuous rating

during single generator operation; less than 45 W at maximum
continuous rating during parallel generator operation.
Page 8
Figure 1: Standard UFL operational threshold for 50/60 Hz system
Shock: Tested to withstand up to 20 gs in each axis.
Vibration: Tested to withstand 1.2 gs from 6 to 26 Hz; 0.32 in. double

amplitude from 26 to 52 Hz; 5 gs from 53 to 150 Hz.
Construction: Steel chassis with welded seams; zinc plated according

to specification QQ-2-325, Type 11, Class 2; circuit board is silicon resin
conformal coated.
Dimensions: 11.5 in. (292 millimeters) x 8.5 in. (216 millimeters) x 4.75
in. (121 millimeters).
Weight: 13 pounds (5.9 kilograms).
Mounting: The voltage regulator may be mounted in any position

providing that sufficient space is retained about the unit for satisfactory
cooling, and shock and vibration do not exceed regulator specifications.
Page 9
Operating Principles
General: Parts comprising the KCR 760 voltage regulator are shown on
the electrical schematics.
A standard single-phase sensing KCR 760 voltage regulator with

underfrequency limit or V/Hz sensing circuitry is described in the
paragraphs that follow. When the regulator has either three-phase sensing
or is designed for flat regulation the following difference will apply:
- When the three-phase sensing option is included the regulator will

have two sensing transformers (T1 and T3) with interconnected
primary windings and interconnected secondary winding.
- When the regulator is designed for flat regulation the regulator will
not have the UFL or V/Hz circuitry and the voltage applied to the
reference side of the first stage differential amplifier in the error
detector will be the voltage across Zener diode Z1.
Voltage regulator circuits: The voltage regulator senses the generator

voltage, compares a rectified sample of that voltage with a reference
voltage, and supplies the field current required to maintain the
predetermined ratio between the generator voltage and the reference
voltage. Transformer T1 is the sensing transformer in a standard
single-phase sensing KCR 760 voltage regulator while a KCR 760
voltage regulator designed for three-phase sensing includes two
sensing transformers (T1 and T3). The sensing circuitry also includes a
transformer (T2) and potentiometer (R4). Transformer T2, potentiometer
R4, and an external current transformer provide means of attaining
reactive kVA load sharing during parallel generator operation. The
parallel operation components do not affect voltage regulator operation
when the generator is operated singly.
On regulators equipped with underfrequency limit (UFL) or V/Hz option,

this circuitry interacts with the regulator sensing and error detector in a
manner that decreases voltage during underspeed operation. A solid-state
flashing circuit operates each time the generator is started. The flashing
circuit de-energizes when generator voltage has built up to about 70%
of rated voltage output. Most of the circuits are contained on a printed
circuit board. Parts that are individually mounted on the regulator
case are the sensing transformer(s), parallel operation transformer T2,
choke L1, nominal voltage range set adjust R2, stability adjustment R6,
capacitors C32, C33, & C34, parallel voltage droop potentiometer R4,
the power stage, and a fuse. External voltage adjust rheostat VAR is
provided for installation on a control panel.
Sensing circuit during single generator operation: The voltage sensing

transformer(s) provides a voltage proportional to the generator voltage
output. This voltage is fed across the primary of T2 to a full-wave
rectifier comprised of silicon diodes D3, D4, D17, D18, D23, and D24.
Page 10
The rectified voltage is filtered by resistor R3, choke L1, and capacitor
Cl. The dc signal from the filter is applied to the error detector and the
underfrequency limit.
Shorting the secondary parallel operation transformer T2, either by

using the jumper bar across CT• and CT1, or turning R4 to its full
counterclockwise position or setting the UNIT/PARALLEL switch to
UNIT, eliminates the effect of T2 during single generator operation.
Sensing circuit during parallel generator operation in reactive

voltage droop compensation mode: Generators interconnected for
reactive voltage droop compensation will proportionally share inductive
reactive loads during parallel operation by a decrease in generator
system voltage. This method of kVAR load sharing is described in the
paragraphs that follow.
The sensing transformer(s) provides a voltage proportional to the

sensing voltage. A current transformer (CT) installed in line two of
the generator develops a signal that is proportional in amplitude and
phase to the line current. This signal develops a voltage across the
slide-wire parallel voltage droop adjust potentiometer R4. The setting
R4 determines how much of this voltage is applied to the primary
transformer T2.
The voltage developed in the secondary of the sensing transformer(s)

and the voltage developed in the secondary of T2 add vectorially. This
action provides a voltage to the sensing diodes that is the vector sum of
the stepped down sensing voltage and the parallel current transformer
signal through T2. The sensing rectifier dc output is filtered and applied
to the error detector and underfrequency limit.
When a resistive (unity power factor) load is connected to the generator,

the voltage that appears across the droop potentiometer leads the sensing
voltage by 90 degrees, and the vector sum of the two voltages is nearly
the same as the original sensing voltage; consequently, almost no change
occurs in generator output voltage.
When lagging power factor (inductive) load is connected to the

generator, the voltage across the droop potentiometer becomes more
in phase with the sensing voltage, and the combined vectors of the two
voltages result in a larger voltage being applied to the sensing rectifiers.
Since the action of the regulator is to maintain a constant voltage at the
sensing rectifiers, the regulator reacts by decreasing the generator output
voltage.
When a leading power factor (capacitive) load is connected to the

generator, the voltage across the droop potentiometer becomes out of
phase with the sensing voltage, and the combined vectors of the two
voltages result in a smaller voltage being applied to the sensing rectifiers.
Then the regulator reacts by increasing the generator voltage.
Page 11
During parallel operation of two or more generators interconnected
for reactive voltage droop, if field excitation on one of the generators
becomes excessive and causes a circulating current to flow between the
generators, the circulating current will appear as an inductive load to the
generator with excessive excitation and a capacitive load to the other
generator(s). The parallel components R4 and T2 will cause the voltage
regulator of the generator with excessive field excitation to decrease the
generator voltage while the voltage regulators of the other generator(s)
will increase the generator voltage.
Sensing circuit during parallel generator operation in parallel cross-

current compensation mode: Parallel cross-current compensation
allows two or more paralleled generators to share inductive reactive loads
with no droop or decrease in the generator system output voltage when
the line currents are proportional and in phase. This is accomplished by
the action and circuitry described previously for parallel reactive voltage
droop compensation and the interconnection of the current transformer
secondaries in a closed series loop. Circulating currents cause the system
to react as described previously for parallel voltage droop compensation.
A unit/parallel switch connected in each generator system eliminates the

series resistance of the CTs in the generator sets that are shut down from
the CTs of the generator sets that are operating.
Error detector: The error detector circuitry consists of a voltage adjust

circuit, a voltage divider, a two-stage differential amplifier, and an
internal minor feedback filter. The voltage adjust circuit consists of an
external voltage adjust rheostat VAR, a voltage range adjustment R2, and
fixed resistor R1. Full travel of the external voltage adjust provides ±10%
adjustment of the generator output voltage from nominal. The voltage
range adjustment R2 establishes the maximum and/or minimum voltage
adjust limit of VAR. The voltage adjust circuit and a voltage divider
consisting of resistors R5 and R71 determine the input signal to the first
differential amplifier.
The first differential stage is comprised of transistors Q1, Q2, & Q12,
resistors R9 through R18, R21, R22, R23, R83, & R93, capacitors
C3, C23, C30, & C31, ferrite beads L2 & L3, Zener diode Z1, and the
circuitry within the underfrequency limit. Underfrequency limit (UFL)
provides a reference voltage to the base of transistor Q2 as described
in the UFL circuit description. During generator operation at rated
frequency the reference signal is constant and identical to the Zener
voltage. Voltage from the sensing circuit, which is proportional to the
generator voltage, is applied to the base of transistor Q1. When Q1 base
voltage is different from the reference voltage applied to the base of
Q2, there will be a difference in Q1 collector current with respect to Q2
collector current.
The current from the collector of transistor Q1 is divided by resistors

R9 and R16 and injected into the base of the second stage differential
amplifier transistor Q3. Similarly, the current from the collector of
Page 12
transistor Q2 is divided by resistors R14 and R15 and injected into the
second stage differential amplifier transistor Q4. Resistors R10 and
C3 help to prevent oscillations at high frequencies. The second stage
differential amplifier amplifies the output of the first stage differential
amplifier. Components included in the second stage differential
amplifier are transistors Q3 and Q4, and resistors R24 through R27. The
collector voltage of transistor Q3 controls the phase control circuit. The
minor feedback filter consists of resistor R8 and capacitor C2. The filter
removes any remaining ac from the dc signal.
Phase control circuit: One of T1’s secondary windings, diodes D1, D2,
D21 & D22, resistors R87 & R88, capacitors C20, C21, & C22, supply
power to the first and second differential stage and the underfrequency
limit stage. The phase control circuit consists of diodes D5 and D6,
resistors R28 through R32, & R80, capacitors C20, C21, & C22, Zener
diode Z2, and programmable unijunction transistor (PUT) Q5.
The phase control circuit is a “ramp-and-pedestal” control that regulates

the phase angle of the power controller circuit SCRs by controlling the
“turn on” signal it supplies to the gate of the SCRs. An exponential ramp
voltage that starts from a voltage pedestal provides the “turn on” gating
signal. Because the ramp voltage starts from the voltage pedestal, a
small change in the amplitude of the pedestal voltage results in a large
change in SCR phase angle as shown in Figure 2.
ac input power to
the regulator
SCR phase angle
voltage required to
fire SCR
ramp voltage
pedestal voltage Note: This drawing is for illustration

only. Do not use it to make voltage
measurements.
Figure 2: Effect of timed gating signal on SCR phase angle
Page 13
The amplitude of the pedestal voltage is determined by the collector
current of second stage differential amplifier transistor Q3. Zener
diode Z2 serves as a voltage clamp and resistors R31 and R32 are a
voltage divider, which determines the threshold of the programmable
unijunction transistor Q5. The output of PUT Q5 is applied to the gate
of the power controller SCRs through resistors R43 & R44 and didoes
D15 & D16 and an amplifying stage that is comprised of transistor Q11,
diode D10, resistors R46 & R81, and capacitor C24.
Power stage (power controller): The power stage supplies the generator
exciter field current. The power stage consists of an SCR/diode bridge
rectifier. The power stage input is either single phase 120 Vac or single
phase 240 Vac depending on regulator design. The output of the power
stage is regulated by the “turn on” gating signal that its SCRs receive
from the phase control circuit. The circuit includes a free wheeling diode
for field discharge of the inductive exciter field load and a fuse (Fl) in its
input power line.
Field flashing circuit: The field flashing circuit includes SCR1, field
effect transistor (FET) Q6, transistors Q7 through Q10, resistors R34
through R42, R82, and R85, Diodes D7, D11, & D29, and capacitors
C25 & C27. Transistors Q8 and Q9, diode D7, and resistors R36, R37,
R38, R40, & R41 comprise a Schmidt trigger circuit. The Schmidt
trigger turns on when an increasing voltage is present with magnitude
approximately 70% of the nominal 24 Vdc output of the sensing
rectifiers, and turns off when a decreasing voltage is present with
magnitude of approximately 30% of the nominal output of the sensing
rectifier.
When the Schmidt trigger is off, FET Q6 is on. This action turns
on transistors Q10 and Q7, which supply current to fire slave SCR1
located on the circuit board. Slave SCR1 fires the silicon controlled
rectifiers SCR1 and SCR2 in the regulator power controller circuit
which, when on, supply current to the exciter field. When the Schmidt
trigger turns on, FET Q6 turns off. This action turns off transistors Q10
and Q7, which removes the gating signal to slave SCR1 and in turn the
gating signal of the flashing circuit from the power controller SCRs.
Resistor R70 and capacitor C19 provide assistance in the firing of the
power stage SCRs. Capacitor C8 and resistor R45 assist in limiting
conducted EMI. Diodes D8, D9 and those in the power stage supply
power to the flashing and phase control circuits.
Stability control: The stability circuit is a rate feedback RC network.

It consists of capacitors C4 and C5, resistors R7, R19, and R20, and
stability adjust potentiometer R6. This RC network injects a stabilizing
signal from the regulator output which helps to prevent generator voltage
oscillation.
Underfrequency limit (UFL): The UFL provides a reference voltage to

the error detector which is constant when the generator output frequency
Page 14
is higher than a predetermined limiting frequency. When the generator Note: The underfrequency limit circuitry is
is operating slower than the predetermined UFL operational threshold, not included when the regulator includes
the UFL will provide the error detector with a reference voltage that is the flat regulation option. Where regulator
proportionally lower. is supplied with the V/Hz sensing option,
operation and construction of the V/Hz
circuitry is similar to the underfrequency
The reference voltage to the UFL is supplied by Zener diode Z1. The limit.
UFL operational threshold for standard 50 Hz, 60 Hz, and 400 Hz KCR
760 regulators are given above. The operation of the various components
comprising the UFL assembly is described in the paragraphs that follow.
The voltage from the sensing transformer is rectified by diodes D19 and
D21, and the rectified signal is applied to a Schmidt trigger consisting
of operational amplifier IC2A, resistors R47 through R51, and capacitor
C29. A 24 Vdc peak-to-peak square wave is generated at the output of
IC2A at double the frequency of the sensing voltage.
The 24 Vdc square wave from the Schmidt trigger is fed to the first
stage of a two-stage monostable multivibrator IC1 and associated
parts, where it is decreased to a 5 Vdc peak-to-peak square wave at
double the frequency of the sensing voltage. The 5 Vdc square wave
is applied to the second stage of the monostable multivibrator. The
monostable multivibrator output pulse is uniform in amplitude and
duration for each input pulse. Thus, the average voltage level of the
collective pulses at the output of the monostable multivibrator is
directly proportional to the frequency of the pulses. The monostable
multivibrator output is fed into a four-pole Butterworth low pass filter
comprised of operational amplifier IC2B and IC2C, resistors R60
through R66, and capacitors C13 through C18. This filtering circuit
does the actual averaging of the collective pulses from the monostable
multivibrator. Amplifier gain is set at level where its output equals the
Zener reference at rated 60 Hz or 400 Hz operation by resistors R65,
R66, and capacitor C16. When operated at rated frequency of 50 Hz,
the circuit is set for 50 Hz operation by removing jumper J1. This
action adds R57 to the circuit.
Diode D12 and integrated circuit IC2D form a voltage clamping circuit.
If the voltage from the Butterworth filter is equal to that of the Zener
reference, the UFL output to the error detector will be the same as the
Zener reference and the UFL will have no effect on regulator operation.
However, when the voltage from the filter decreases as occurs during
underspeed operation of the generator, the reference voltage applied
to the error detector is less than the Zener reference. This action will
cause the error detector differential signal to proportionally increase
in a manner that results in a proportionally later turn-on signal to the
regulator output SCRs. The regulator then decreases excitation and a
lowering of generator output voltage occurs.
Resistors R54 & R56, potentiometer R55, and capacitor C12 determine
the underfrequency limit operational threshold. Zener diode Z3 and
capacitors C9 and C10 protect the integrated circuits from damage
should excessive voltage spikes occur.
Page 15
Installation
Mounting: The voltage regulator can be mounted in any position without
affecting its operating characteristics. The voltage regulator is convection
cooled. Retain sufficient space around the regulator for heat dissipation
and for making electrical connections and controls adjustments. Mount
the voltage regulator in any location where shock and vibration are not
excessive and the ambient temperature does not exceed its ambient
operational limits.
Warning: De-energize the generator set Interconnection: Connect the regulator to the generator system as
starting circuit before making repairs, instructed in this section and as shown in the connection diagram
connecting test instruments or removing or provided with the generator set. See Figure 3 for an overall outline
making connections to or within the voltage
drawing that shows the location of regulator mounting provision
regulator. Dangerous voltages are present
at the voltage regulator terminal boards and parts of the voltage regulator. See Figures 4 to 11 for a typical
and within the voltage regulator when the interconnection diagrams and electrical schematics of the voltage
generator set Is running. These include regulator. Use 14 gauge or larger wire for connections to the voltage
the sensing voltage, power to the voltage regulator.
regulator, and the voltage regulator output.
Accidental contact with live conductors Single-phase 100 to 600 Vac sensing (terminals El and E3): The
could result in serious electrical shock or standard KCR 760 voltage regulator designed for single phase sensing
electrocution. has an internal sensing transformer (T1) as shown in Figure 4. This
transformer is provided with taps on the primary winding for sensing
Caution: Do not use a megger or high
voltages of 100 to 139, 200 to 228, 216 to 265, 375 to 458, 432 to 528,
potential test equipment when testing
the voltage regulator. Disconnect
and 540 to 600 Vac. The transformer primary winding taps are identified
interconnecting conductors between the with the corresponding nominal voltages, which are 120, 208, 240, 416,
generator and voltage regulator when 480, and 600. Vac. To obtain proper operation the internal wire from
testing the generator or exciter with a voltage regulator terminal E3 must be connected onto the correct primary
megger or high potential test equipment. tap on transformer T1. Electrical wires within the regulator connect to
The high voltage developed by megger or the sensing transformer secondary winding as shown in Figure 4.
high potential test equipment will destroy the
solid state components within the voltage Three-phase 100 to 600 Vac sensing (terminals El, E2, and E3): When
regulator. the regulator is designed for three-phase sensing, it includes two sensing
transformers (T1 and T3) as shown in Figure 5.
Caution: Never open the regulator sensing
circuit while power is applied to the regulator
Except when otherwise specified in the purchase order, the regulator
input power terminals. Loss of sensing
voltage will result in maximum regulator
sensing transformers will both include multi-tap primary winding for
output. use with the sensing voltages described in the single phase 100 to 600
Vac sensing procedure.
To properly operate, connect the internal wire from voltage regulator

terminal E3 to the correct primary winding tap on transformer T1,
and connect the internal wire from voltage regulator terminal E2 to
the corresponding primary winding tap on transformer T3. Connect
electrical wires within the regulator to the sensing transformer’s
secondary winding as shown in Figure 5.
Page 16
Figure 3: KCR 760 outline drawing
Page 17
Notes:
Sensing: Using sensing
terminals E1 and E3, the
internal wire form E3 must
connect to the tap on T1
that matches the genera-
tor voltage.
Parallel operation: An
external current trans-
former is required for
parallel operation. Where
the current transformer
has a 1 A secondary, con-
nect to terminals CT• and
CT1. Where the current
transformer has a 5 A
secondary, connect to ter-
minals CT• and CT5. For
single generator opera-
tion, remove the droop
signal by adjusting R4 to
0 resistance measured
across terminals CT• and
CT1.
Fuse F1: Has normal

blow: 15 A maximum for
voltage regulator protec-
tion.
Input power: For 120 Vac

input with 65 Vdc output:
install circuit board jumper
J3. For 240 Vac input with
125 Vdc output, remove
the circuit board jumper
J3.
Figure 4: KCR 760 single-phase sensing schematic
Page 18
Notes:
Sensing: Uses terminals
E1, E2, E3 and sensing
transformers T1 and T3.
The wire from E2 must
connect to the tap on T3
that matches the generator
voltage. The wire from E3
must connect to the tap
on T1 that matches the
generator voltage.
Parallel operation: An
external current trans-
former is required for
parallel operation. Where
the current transformer
has a 1 A secondary, con-
nect to terminals CT• and
CT1. Where the current
transformer has a 5 A
secondary, connect to ter-
minals CT• and CT5. For
single generator operation,
remove the droop signal by
adjusting R4 to 0 resis-
tance measured across
terminals CT• and CT1.
Fuse F1: Has normal blow:

15 A maximum for voltage
regulator protection.
Input power: For 120 Vac

input with 65 Vdc output:
install circuit board jumper
J3. For 240 Vac input with
125 Vdc output, remove
the circuit board jumper J3.
Figure 5: KCR 760 three-phase sensing
Page 19
Note: Jumper wire J3 on the regulator Input power (terminal P1 and P2): Before making electrical
circuit board is installed when regulator input connections, refer to the wiring diagram provided with the generator.
power is 120 Vac ±10% and removed when Connect input power as follows.
input power is 240 Vac ±10%.
- When the regulator is designed for 120 Vac ±10% input power and
65 Vdc maximum continuous output, connect single-phase 120 Vac
power to terminals P1 and P2. Refer above for recommended use of
load isolation and voltage matching transformers.
- When the regulator is designed for 240 V ac ±10% input power and
125 Vdc maximum continuous output, connect single-phase 240 Vac
power to terminals P1 and P2. Refer above for recommended use of
load isolation and voltage matching transformers.
- When the regulating system is supplied with electromagnetic

interference filters, connect as shown on the wiring diagram
provided with the generator set.
Output power (terminals F+ and F-): Be sure regulator output matches

the generator exciter rating. The KCR 760 voltage regulator designed for
120 Vac input is designed for 65 Vdc maximum continuous output. The
KCR 760 voltage regulator designed for 240 Vac input is designed for
125 Vdc maximum continuous output.
Maintain correct polarity between the regulator output and exciter field.
Make sure field resistance for the 65 Vdc regulator is not less than 6.5 Ω
and field resistance for the 125 Vdc regulator is not less than 12.5 Ω.
Make sure the field circuit is not grounded and/or opened or shorted
during operation of the generator set.
Because the regulator output leads are not connected to any part of
the system except the exciter field, they are not filtered. To minimize
conducted EMI the keep the leads as short as possible and shielded.
Effective shielding can be attained by routing both leads through 0.5
inch conduit. In general, do not leave unshielded more than 1 to 2 feet
of field leads. If the voltage regulator is installed within the generator
outlet box, it is possible to achieve satisfactory results with short
unshielded leads.
Grounding: A good electrical power ground is not necessarily a good

electromagnetic interference ground. Make the ground leads as short
as possible, preferably of copper strap with a width of 1/5 the length.
Grounding the chassis to earth ground makes all grounds common.
External voltage adjust rheostat (terminals R1 and R2): Terminals

R1 and R2 are provided for connection of the voltage adjust rheostat. The
rheostat provides adjustment of the regulated generator voltage ±10% of
Page 20
nominal. It is provided as a separate item for panel mounting. Connecting
wires from the rheostat attach to terminals R1 and R2. A jumper wire
must be connected between rheostat terminal 2 and rheostat terminal 1 as
shown in Figure 6.
Connection to reactive voltage droop terminals CT•, CT1, and CT5
Parallel operation: When generators will be operating in parallel, install

the current transformer in Phase B from each generator and connect as
follows:
- Current transformer (1 A secondary): Connect secondary leads to

CT• common and CT1. Be sure to maintain correct polarity. Make
certain the jumper, when supplied, is removed from across CT• and
CT1.
- Current Transformer (5 A secondary): Connect secondary leads to

CT• common and CT5. Be sure to maintain correct polarity. Make
certain the jumper, when supplied, is removed from across CT• and
CT1.
Reactive voltage droop or cross-current compensation: The regulating

system may be connected for parallel operation in either the reactive
voltage droop or cross-current compensation mode. Connect according to
either reactive voltage droop or cross-current compensation.
- Reactive voltage droop: Connect the current transformer to the

respective regulator (see Figure 7).
- Cross-current compensation: For cross-current, connect each CT

to its respective regulator. Then connect the finish of the first CT to
the start of the third CT, etc. Continue until all CTs are connected in
series and connect the finish of the last CT to the start of the first CT
(see Figure 8).
- On parallel cross-current compensation applications consisting

of two or more generators, use a unit/parallel switch if all the
generators are not always on the bus. If the switch is not used,
a voltage droop will be introduced into the system, which will
cause the voltage of the incoming generator to fluctuate prior to
paralleling. This is due to the unloaded generator parallel CT not
supplying its compensating signal, but allowing a voltage drop to
occur across it. Ideally, the switch is an auxiliary on the generator
output circuit breaker that opens when the breaker is closed.
Page 21
Notes:
1) For single-phase sensing, terminals are E1 and E3. See Figures 2 and 3.
2) The field must not be opened, shorted or grounded while the generator is operat-
ing.
3) The external voltage adjust must have a jumper across its terminals 1 and 2.
4) Input power standard KCR 760 voltage is 120 Vac; optional 240 Vac. Maximum
continuous output is 65 Vdc for a 120 Vac input and 125 Vdc for a 240 Vac input. See
Figures 4 and 5.
5) A current transformer is required for generators operating in parallel. The connec-

tion is shown on this drawing: 1 A current transformer and reactive voltage droop
compensation. See Figures 2 and 3.
6) Ground the neutral in accordance with applicable electrical codes.
Figure 6: KCR-760 interconnection
Page 22
Regulator 1
Note: Single-phase sensing terminals E1

and E3. Three-phase sensing terminals E1,
E2, and E3.
Generator 1
Note: Remove the jumper bar across termi-

Regulator 2 nals CT• and CT1 before parallel operation
is attempted. Where the CT has a 1 A sec-
ondary, connect to terminals CT• and CT1
as shown. When the CT has a 5 A second-
ary, connect to terminals CT• and CT5.
Generator 2
Regulator 3
Note: When more than three generators will

be operated in parallel, continue connec-
tions as shown.
Generator 3
Figure 7: Parallel operation, reactive voltage droop mode
Page 23
Regulator 1
Note: Single-phase sensing terminals E1

and E3. Three-phase sensing terminals E1,
E2, and E3.
Generator 1
Note: Remove the jumper bar across termi-

Regulator 2 nals CT and CT1 before parallel operation is
attempted. Where the CT has a 1 A second-
ary, connect to terminals CT• and CT1 as
shown. Where the CT has a 5 A secondary,
connect to terminals CT• and CT5.
Generator 2
Regulator 3
Note: When more than three generators will

be operated in parallel, continue connec-
tions as shown.
Generator 3
Figure 8: Parallel operation, cross-current compensation mode
Page 24
Generator operating singly: When generators are not operating parallel
and reactive voltage droop is not required, use one of the following
methods to eliminate the effect of the parallel operation transformer
within the voltage regulator.
- Install a unit/parallel switch across the current transformer

secondary, and close switch during single generator operation.
- Set the voltage droop resistor R4 to its minimum droop position.
- Where the generator will be operating singly, install a jumper across

terminals CT• and CT1.
UFL circuit 50/60 and 400 Hz selector J1: The underfrequency limit
components or V/Hz components are located on the voltage regulator
circuit board (see Figure 9). Parts comprising the UFL or V/Hz
components are shown in Figure 11. A jumper wire J1 eliminates the
effect of resistor R57. Removing the jumper J1 places R57 in the circuit.
60 or 400 Hz operation: Make certain the jumper wire is installed across

area marked J1. Wire is mounted on component side of circuit board and
ends of jumper wire are soldered on foil side of the circuit board.
50 Hz operation: Make certain the jumper wire is removed from across

area marked J1. Remove J1 by cutting each end of the jumper wire.
Voltage regulator fuse: The voltage regulator contains a 15 A normal Warning: A fire hazard can exist if the
blow fuse in the voltage regulator input power circuit (see Fig. 1, 2 voltage regulator fuse is larger than 15 A or
and 3). In applications where voltage regulator power requirements are if a delay-type fuse is used.
reduced, as when used with small generators where excitation is less than
Note: On generator systems that include
given, a smaller fuse may be used. Never install a fuse larger than 15 A
the auto/manual voltage control option, the
and never install a delay-type fuse.
OFF position on the AUTO/OFF/MANUAL
selector switch provides voltage shutdown.
Accessory items: Accessory items provided with the generator system On generator systems that include a field
must be connected as shown on the wiring diagram provided with the circuit breaker, manually tripping the circuit
generator set and the accessory item drawing or instruction. Observe breaker OFF provides voltage shutdown.
the precautions and general procedures that follow when connecting
accessory items. Caution: Never install the voltage shutdown
switch in the exciter field circuit as the
Voltage shutdown (engine idle switch): The system can be equipped with voltage regulator dc output (terminals
a switch to allow removal of excitation in an emergency or when the F+ and F-) must not be opened during
operation. To do so would produce inductive
prime mover must be operated at reduced speeds. This switch must be
arcing that could destroy the exciter or
placed in the input power line to the regulator (terminal P1 or P2). voltage regulator output power bridge.
Field circuit breaker: The field circuit breaker must be of the type that Caution: Never open the dc output
has separate terminals for the thermal element and the contacts. (terminals F+ and F-) during operation.
The circuit breaker thermal element receives heat from either the field To do so would produce inductive arcing
current or generator line current. Where it is heated by field current, the that could destroy the exciter or voltage
thermal element connects between the voltage regulator output and the regulator. Therefore, never place circuit
breaker contacts in the exciter field circuit.
Page 25
240 Vac.
circuitry, see Figure 11.

Note: For a schematic of UFL
Note: Install jumper J3 when input is
120 Vac, and remove it when input is
From sensing
transformers. See
Figures 2 and 3.
{
To voltage range
adjust and voltage {
adjust. See Figures
2 and 3.
From stability con-
Page 26
trol. See Figures 2 {
and 3. { To field F +. See
Figures 2 and 3.
From sensing
choke. See Figures { { To field F +. See
2 and 3. Figures 2 and 3.
Figure 9: KCR 760 (with UFL or volts-per Hz) circuit board schematic
{ To field F +. See
Figures 2 and 3.
To field F +. See
{
Figures 2 and 3.
From sensing
transformers. See
Figures 2 and 3.
{
To voltage range
adjust and voltage {
adjust. See Figures
2 and 3.
From stability con-

trol. See Figures 2 {
and 3. { To field F +. See
Figures 2 and 3.
From sensing
Page 27
choke. See Figures { { To field F +. See
2 and 3. Figures 2 and 3.
{ To field F +. See
Figures 2 and 3.
To field F +. See
{
Figures 2 and 3.
Figure 10: KCR 760 (with flat regulation option) circuit board schematic
input is 240 Vac.
Note: With jumper J3, install when
input is 120 Vac, and remove when
Figure 11: UFL electrical schematic
Page 28
exciter field. Where it is heated by generator line current, the thermal
element connects to a current transformer located in one of the generator
load lines.
Auto/manual voltage control: The auto/manual voltage control option

includes the components described below. Connect the auto/manual
voltage control module as shown on the wiring diagram provided with
the generator.
- Three-position selector switch: When this switch is set to the AUTO,

power is fed across the switch contacts to the regulator input power
terminal P1 and P2. When the switch is set to MAN, power is fed
across the switch contacts to the manual voltage control circuit
rectifiers. OFF position opens input power to both the voltage
regulator and the manual voltage control rectifiers.
- Manual voltage control circuit: The manual voltage control circuit

consists of a full wave rectifier assembly and a manual voltage
control variac. The manual voltage control variac controls generator
output whenever the generator set is operated in the manual voltage
control mode of operation.
Page 29
Operation
Caution: Before initial operation, verify Adjustments: The adjustments pertaining to the voltage regulator and
that the regulator is connected for the system operation are described in the paragraphs that follow and, except
application. See wiring diagram provided where noted, adjustment is made during initial operation and normally
with the generator set and review the does not have to be repeated during the life of the voltage regulator.
procedures given above.
Generator voltage adjust rheostat (VAR): This adjustment is
provided to control the generator voltage. When set to its maximum
counterclockwise position, minimum generator voltage is obtained.
Maximum generator voltage is obtained when the rheostat is set to its
maximum clockwise position.
Nominal voltage range set adjust (R2): This adjustment is provided

to extend the limits of the generator voltage adjust rheostat (VAR).
Normally R2 is set to provide the generator voltage adjust rheostat with
an adjustment range of ±10% of rated voltage. R2 is located on the
regulator. Loosen the 1/2 inch locknut before attempting to adjust R2
(with a small screwdriver). Retighten the locknut after adjustment is
complete.
Stability adjustment (R6): Stability control R6 provides for stable

regulating operation by controlling the amount of feedback that is
applied to the error detector stage. Turning the control counterclockwise
decreases the amount of the stability feedback, making the regulator
respond faster.
This control is located on top of the cover, mounted below the heat
sink and above the RANGE adjust. Loosen the 9/16 inch hex-head
locknut that keeps the control shaft from turning due to vibration before
attempting to adjust R6 (with a screwdriver). Retighten the locknut after
adjustment is complete.
Operate the generator at rated frequency, no load, the point at which the
stability adjustment is most critical. Adjust STABILITY by first rotating
the control fully clockwise with screwdriver. One end of the screwdriver
slot will point to 2 o’clock; this end is the pointer. Set the STABILITY
by rotating pointer counterclockwise to 10 o’clock. This setting normally
ensures good stability, but may not provide optimum response time for
the generator.
If the generator voltage oscillates (hunts), turn the control clockwise past
the point where oscillation stops. If faster response is required, rotate
the control counterclockwise until the voltage becomes unstable, and
then rotate clockwise until the voltage is stable. Optimum adjustment
is attained when generator voltage is stable and response is satisfactory
at no-load and also during operation under any load up to the full load
rating of the generator.
Page 30
Parallel voltage droop potentiometer (R4): This adjustment is provided Note: Where the generator will be
to control the voltage droop signal of generators operating parallel. It operating singly and use of reactive voltage
is located on the regulator chassis. Maximum voltage droop is attained droop circuitry is not desired, either set R4
when the potentiometer is set to its maximum clockwise position. Adjust to the minimum droop position or install
each generator that will be operated parallel for identical voltage droop a jumper or unit/parallel switch across
as described in the parallel operation procedure that follows. Make the terminals CT• and CT1.
adjustment by loosening the locknut with a 1/2 inch wrench, adjusting
the droop with a screwdriver and then tightening the locknut after the
adjustment has been made.
Underfrequency Adjustment (R55): This adjustment is included in

voltage regulators provided with the underfrequency limit option. R55 Operational dc voltage
threshold TP1-TP2
is adjusted at the factory as listed above or as requested in the generator
purchase order. 60 Hz 0.000
59 Hz -0.087
58 Hz -0.169
- Adjusting the underfrequency limit when the generator 57 Hz -0.265
frequency can be set to the desired breakpoint: 56 Hz -0.350
1. Connect a voltmeter between the circuit board 55 Hz -0.438
terminals TP1 and TP2.
2. Run generator at the desired underfrequency limit set Table 1: Voltage across under-
frequency limit terminals TP1-
point (for example 58 Hz).
TP2 with a 60 Hz generator
3. Adjust R55 for 0 volts as indicated on the meter. and rated sensing voltage
- Adjusting the underfrequency limit when generator Note: The jumper wire must be across
frequency can not be adjusted. J1 on a 60 Hz system. Measured voltage
1. Connect a voltmeter between the circuit board must be negative. Slight variation in
operating threshold may exist due to
terminals TP1 (negative) and TP2 (positive).
circuit and meter tolerances.
2. Run the generator at rated speed and voltage.
3. Determine the desired underfrequency limit setting voltage
from Table 1 for 60 Hz generators or Table 2 for 50 Hz
generators. Operational dc voltage
4. Adjust R55 until the voltage between TP1-TP2 equals the test threshold TP1-TP2
voltage given in the appropriate table. EXAMPLE: With unit 50 Hz 0.000
running at 60 Hz and where limiting is desired at about 55 Hz, 49 Hz -0.107
the voltage across TP1-TP2 should be -0.438 Vdc. 48 Hz -0.210
47 Hz -0.315
46 Hz -0.425
Manual voltage control variac: This control is included in generators 45 Hz -0.553
equipped with the automatic/manual voltage control option. During
generator operation using the manual voltage control mode, the mode Table 2: Voltage across under-
selector is set to MAN and generator voltage output is controlled by the frequency limit terminals TP1-
manual voltage control variac. In order to maintain generator output TP2 with a 50 Hz generator
voltage at a constant level during operation in the manual voltage control and rated sensing voltage
mode, adjust the manual voltage control variac each time a change in Note: The jumper wire J1 must be
load occurs (either added or shed). removed during 50 Hz operation.
Measured voltage must be negative.
Slight variation in operating threshold
may exist due to circuit and meter
tolerances.
Page 31
Field flashing: The voltage regulator contains an internal solid state field
Caution: Do not attempt to flash the exciter flashing circuit. A minimum of about 6 Vac at the regulator input power
field while the generator set is running. Be terminals is required for operation of the flashing circuit. Usually the
careful to observe polarity when connecting exciter field poles retain sufficient magnetism to allow circuit operation
flashing source. Accidental polarity reversal and generator voltage buildup However, if flashing is required, stop the
will destroy the voltage regulator power generator, and then flash the field as given in the procedure that follows:
stage.
1. Connect the negative lead of a 12 or 24 Vdc flashing source onto
regulator terminal F-. Do not remove any other wires from terminal
F-.
2. Slide the positive lead of the flashing source onto the regulator
terminal F+. Only a few seconds flashing should be necessary.
3. Slide the flashing source positive lead off terminal F+. Then remove
the flashing source negative lead from terminal F-, and tighten the
terminal.
4. Start the generator, and check for satisfactory voltage buildup.
Caution: Before operating the generator for Single unit initial operation: When the generator set is equipped with
the first time, double check to make certain the automatic/manual voltage control option, normal operation of the
all wiring connections are made correctly. generator set is the automatic voltage control mode. During generator
Review the wiring diagrams provided set operation in the automatic voltage control mode, generator output
with the generator set, the installation voltage is pre-established during no-load operation by adjustment of
instructions above and the preceding the external voltage adjust rheostat and automatically maintained at the
adjustment procedures.
amplitude under all load conditions from no-load to full rated load by the
voltage regulator.
Note: Deviation in generator output voltage Automatic mode operation: Review the preceding adjustment and
approximately ±10% of rated can be single unit operation procedures. The general procedure for single unit
corrected by adjusting the voltage adjust automatic mode operation is as given in the procedure that follows:
rheostat and if necessary, the voltage range 1. If the generator set is equipped with the auto/manual control option,
set adjust. set the selector switch to AUTO.
2. Turn the voltage adjust rheostat to about one-half of the way
between the maximum counterclockwise and maximum clockwise
positions.
3. Open the output circuit breaker. Do not apply load until satisfactory
no-load operation is attained.
4. If a voltage shutdown switch or field circuit breaker is used, close
the switch to connect input power to the voltage regulator.
5. On generators that will be operated parallel and if the sets are
equipped with unit/parallel switches, close the switch on all
generators.
6. Start the prime mover and bring up to rated speed.
7. Verify generator voltage. Any of the following conditions can occur.
- No voltage buildup: If this condition exists, the exciter may not
have sufficient residual magnetism. Residual magnetism may be
restored by flashing the field as described in the “Field Flashing”
instructions.
- Overvoltage (+15% or more): If this condition occurs, open
the shutdown switch immediately and/or stop the prime mover.
Determine the cause of overvoltage.
Page 32
- Undervoltage (-15% or more): If this condition occurs, open
the shutdown switch immediately and/or shut down the prime
mover. Determine the cause of undervoltage.
- Undervoltage by operation of the underfrequency limit circuit
(UFL): Undervoltage by operation of the underfrequency
circuit can occur if the prime mover governor is not adjusted to
maintain rated speed or when the underfrequency limit circuit is
adjusted to operate at a frequency that is very close to the rated
frequency of the generator.
- Voltage begins to build up and then collapses: If this condition
exists, stop the prime mover and determine the cause of collapse.
If necessary refer to troubleshooting procedure.
- Oscillating voltage (hunting): If this condition occurs, be sure
prime mover speed is not fluctuating. Then, if this condition
persists, adjust the stability adjust (R6) as given in the stability
adjustment section above.
8. Operate the generator set for about 1/2 hour.
9. After about 1/2 hour of satisfactory operation, close the output circuit
breaker and connect the load.
10. Be sure the generator output voltage is correct and stable. Verify that
steady voltage regulation is satisfactory.
11. Remove the load.
12. If the generator will be operating parallel, adjust the parallel
operation potentiometer R4 as given in the steps that follow. To stop
the unit see step 19.
13. If the generator set is equipped with a unit/parallel switch, open the
switch.
14. Monitor no-load voltage.
15. Apply inductive load, and note the droop in generator voltage.
A droop of about 6% is attained when R4 is turned to complete
clockwise position for maximum resistance and the current
transformer secondary current is one ampere connected to terminals
CT• and CT1 or 5 amperes connected to terminals CT• and CT5.
16. If droop is more than is required, turn R4 counterclockwise. If droop
is less than is required, turn R4 clockwise.
17. Repeat steps 14 through 16 as necessary to obtain required droop
signal.
18. To stop the unit, remove the load, open the output circuit breaker,
and then stop the prime mover.
Manual mode operation: This test applies only to generator sets

equipped with the auto/manual voltage control option. Normal
operation of the generator set is in the automatic voltage control mode.
The manual voltage control mode provides a means of operating the
set should the voltage regulator fail. Test the manual control for proper
operation during the initial operation of the set and determine whether
cause of system malfunctions is due to a faulty generator or a faulty
voltage regulator as follows:
Page 33
1. Perform the preceding automatic mode operating procedure.
2. Open the output circuit breaker and, if it is running, stop the prime
mover.
3. If it is included, close the unit/parallel switch.
4. Set the auto/off/manual selector switch to MAN.
5. Set manual voltage adjust variac to the complete counterclockwise
position.
6. Start the prime mover, and bring it up to rated speed.
7. Turn the manual voltage adjust variac to the position where the
correct generator voltage is measured by the generator voltmeter.
8. Turn the manual voltage adjust variac to the position where
voltmeter indicates generator voltage is about 5% higher than rated.
9. Close the output circuit breaker, and apply load.
10. Measure the output voltage. If it is not correct, adjust the manual
voltage adjust variac.
11. Repeat steps 8 and 10 each time the load is increased.
12. Before shedding load, decrease generator voltage about 5% below
rated.
13. Adjust manual voltage adjust variac to position where the voltmeter
indicates generator is producing required voltage.
14. Repeat steps 12 and 13 each time any part of the load is shed.
15. Remove the load and open generator circuit breaker.
16. Set voltage adjust rheostat for rated generator output voltage.
17. Stop the prime mover.
18. Set the auto/off/manual switch to AUTO.
Caution: In generating systems equipped Parallel operation: The paragraphs that follow describe the procedures
with the automatic/manual voltage control to operate two or more generators in parallel.
option, always make parallel operation in
the automatic voltage control mode. Never Metering: In order to attain satisfactory paralleling and to check for
attempt to parallel generators when the proper parallel operation all generators should be equipped with the
mode switch is set to MAN. following monitoring equipment:
1. ac voltmeter to measure generator output voltage (one per set)
2. ac voltmeter to measure bus voltage (one per system)
3. ac ammeter (one per set)
4. Power factor or kVAR meter (one per set)
5. kW meter (one per set)
6. Exciter field current dc ammeters (one per set)
7. Synchroscope or a set of lights to indicate when units are in phase
Checks before initial parallel operation: Before initial parallel operation,

review the procedures and checks that follow:
1. Verify that each generator is connected to the bus with the same
phase rotation as that of the bus. Use a phase rotation test instrument
or an induction motor of known rotation during the initial single unit
operation procedure.
2. Verify that the voltage regulating system of each generator is
equipped with the parallel signal sensing transformer.
3. Make certain the paralleling signal at regulator terminals CT• and
CT1 or CT5 have the proper phase rotation with that of the sensing
Page 34
voltage at terminals El and E3. In applications where units are
connected for reactive voltage droop, verify that the connection is
made as shown in Figure 7. Cross-current compensation application
requires interconnection of the system as shown in Figure 8.
4. Prior to operation, set the parallel voltage droop potentiometer R4
on all regulators for identical droop. This can be accomplished by
individually testing each generator set, one at a time, as given in the
single unit initial operation procedure.
Preliminary parallel operation: Before attempting to parallel two or

more generator sets, test individual sets to ensure that paralleling features
function properly. The test that follows may be used.
1. On generating systems equipped with the auto/manual control
option, verify that the switch is set to AUTO.
2. Verify that the jumper bar has been removed from across the
regulator terminals CT• and CT1.
3. On generating systems equipped with unit/parallel switches, verify
that the switch on the generator set being tested is set to PAR (open),
and be sure that the switch for each remaining generator is set to
UNIT (closed).
4. Place the generator in operation as described in the section single
unit initial operation.
5. Apply 25% to 100% unity power factor load to the set under
test. The generator voltage should change less than 1%, and the
frequency should decrease if the governor is set for droop operation.
6. Apply a 25% to 100% 0.8 P.F. inductive load. Voltage should droop.
If the voltage rises instead of drooping, reverse the CT leads. If
droop is not correct adjust parallel droop resistor R4 as described
in the parallel voltage droop resistor adjustment procedure at the
beginning of this section.
Paralleling generators: Review and understand these instructions and

those contained in preceding paragraphs before attempting to parallel.
1. Set auto/off/manual switch on all generators to AUTO (generator set
equipped with automatic/ manual voltage control option).
2. On generating systems equipped with unit/parallel switches, set the
switch on unit being started (generator set No. 1) to PARALLEL
(open). Set the switch on the remaining generator sets to UNIT
(closed).
3. Start generator set No. 1.
4. Adjust the generator voltage and frequency to nominal.
5. Apply the load.
6. Verify satisfactory voltage regulation, and make certain frequency is
not fluctuating.
7. Repeat steps 1 and 2 on generator set No. 2.
8. Start generator set No. 2.
9. Adjust generator set No. 2 frequency and voltage to nominal.
10. Adjust the speed of generator set No. 2 slightly higher than that of
generator set No. 1.
Page 35
11. Observing the synchroscope (or lights), when generator No. 2 is in
phase with generator No. 1, close the circuit breaker for generator
No. 2.
12. Immediately after closing the circuit breaker, measure the line
current of generator No. 2. It should be well within the rating of
the generator. Also, immediately after closing the circuit breaker,
observe the kW or power factor meters. The following conditions
could occur:
- A high ammeter reading accompanied by a large kW unbalance:
When this condition exists, the speed governor is either not
adjusted correctly or is faulty.
- A high ammeter reading accompanied by a large kVAR
unbalance: When this condition exists, the voltage regulating
system is either not adjusted correctly or is faulty.
13. Adjust the speed of generator set No. 2 to the point where each
generator is carrying the desired share of kW load.
Note: If kVAR or power factor meters 14. Adjust the voltage of generator No. 2 until the ammeter readings of
are available, adjust the voltage adjust both generators are near minimum.
rheostats for equal or proportional kVAR 15. With full load applied, readjust the speed and voltage of generator
or power factor readings. If the generators No. 2 until the desired load division is obtained.
are equipped with power factor meters, 16. In applications where three or more generators are to be operated
alternately adjust the speed and voltage parallel, repeat preceding steps 7 through 15 for generator set No. 3,
on No. 2 until the ammeter readings are then No. 4, etc.
proportional and the power factor readings
are equal.
Shutting down one or more generators operating in parallel: Before
Note: To obtain best results, make final
dropping one or more generators operating parallel from the line bus,
adjustments with full load on the bus. reduce the total load on the bus to equal to or less than the combined
capacity of the generators remaining on the bus. Shut down one or more
Note: The best adjustment is obtained of generator sets operating parallel as follows:
when each generator supplies the same 1. Reduce load to combined capacity of generators remaining on the
percent of its rated current, the power bus.
factor readings are equal, or the sum of the 2. On systems where the prime mover governor is equipped with a
ammeter currents is minimum. manual speed adjust, shift the load to generators remaining on the
bus by reducing the speed of the generator set being dropped from
the bus.
3. Close its unit/parallel switch (on generator sets equipped with a unit/
parallel switch).
4. Shutdown the prime mover.
5. In applications where three or more generators are operated parallel,
repeat preceding steps 1 through 4 for each generator set being taken
off the bus.
Page 36
Maintenance
Preventive maintenance: Inspect the regulator periodically to ensure
that air flow is not restricted. Dirt, dust, and other foreign material may
be removed using low pressure (25 to 50 PSI) compressed air. Check the
connections between the regulator and system periodically to ensure they
are tight and free of corrosion.
Corrective maintenance: Make repairs to the regulator by following

the figures in this manual. Due to a protective conformal coating, do not
attempt repairs on the printed circuit board.
Refer to Table 3 for a list of replacement parts.
On generator sets equipped with the auto/manual voltage control option,

operation of the generator set in the automatic voltage control mode can
be compared to how well it operates in the manual voltage control mode.
Faulty operation in the automatic mode and satisfactory operation in the
manual mode indicates a problem in the voltage regulator while, if faulty
operation in both the automatic and manual voltage control mode occurs,
the problem is probably within the exciter or generator.
Key No. Description Part number Qty

Circuit board (It is better to replace the entire AVR) Contact the factory 1
Terminal strip 531-30311-13 1
Fuse holder 516-10035-00 1
Fuse, ABC 15 A 515-01215-31 1
R2 Potentiometer 500 Ω, 25 W, wire wound 867-35075-09 1
R4 Potentiometer 5 Ω, 25 W, wire wound 867-15075-29 1
R6 Potentiometer, 5000 Ω, 25 W, wire wound 867-45075-79 1
T1, T3 Transformer (sensing) 855-63619-02 1
L1 Filter choke 859-61010-00 1
T2 Cross-current transformer 855-11610-02 1
Power block 600 V, 25 A 851-33620-70 1
VAR External voltage adjust potentiometer, 250 Ω 867-32522-80 1
Table 3: Replacement parts list
Page 37
Voltage regulator operational test: Use the following test procedure to
determine if the regulator is basically operational:
1. Connect regulator as shown in Figure 12.
2. Connect internal wire from terminal E3 to the tap on the sensing
transformer T1 that matches the input power described in step 6.
3. Connect jumper across terminals CT• and CT1.
4. Adjust the external voltage adjust for maximum resistance (complete
counterclockwise position). If the light is on when voltage adjust
is turned to its complete counterclockwise position, the problem is
likely in the regulator.
5. Connect light bulb across terminals F+ and F- and wires to terminals
E1, E3, P1, and P2 as shown in Figure 12.
6. Connect to 120 Vac power source when regulator full load output
rating is 65 Vdc. Connect to 240 Vac power source when regulator
full load output rating is 125 Vdc.
7. Turn the external voltage adjust clockwise. Before reaching the
maximum clockwise position, the bulb should come on to near full
brilliance.
8. At the regulating point a small change in adjustment of the external
voltage adjust rheostat should turn the light on or off. If the light does
not come on, the problem is likely in the regulator.
9. Before installing back in the generating system, connect the regulator
as it was before steps 2 through 7.
Note: Incorrect electrical connections Troubleshooting: Between regular preventive maintenance inspections,
between the generator system and the be alert for any signs of trouble. Correct any trouble immediately. See
regulator and poor electrical connections Table 4 for typical symptoms, causes, and remedies.
are often the cause of system malfunction.
Before assuming a failure of the generator
or regulator has occurred, check wiring
against the wiring diagrams provided with
the generator set and the instructions given
above. Also make certain all connections
are tight and free of corrosion.
Page 38
Note: The internal wire from E3 must
connect to the 120 Vac tap on transformer
T1.
Note: 120 Vac may be used to test

voltage regulators designed for 120 Vac or
240 Vac input power.
Jumper
Light bulb
External voltage
adjust
120 Vac power

source
Figure 12: KCR 760 operational test
Page 39
Voltage does Shutdown switch is open Close the switch.
not built Fuse is blown Replace the fuse. If the fuse blows repeatedly,
up to rated determine the cause of the overload.
value
Auto/off/manual switch is on OFF Set to the switch to AUTO.
Field circuit breaker is open Close the circuit breaker.
No input power to terminals P1 and P2 Verify wiring.
Inaccurate generator voltmeter Verify using a test voltmeter. Calibrate or replace
a faulty meter.
Voltage too low at terminals P1 and P2 Verify wiring.
Low residual voltage (or reverse residual) Flash the field per the procedure.
Internal wire from the sensing terminals on Verify wiring.
the regulator is not connected to the correct
tap on the sensing transformer(s)
No connection or poor connection between Correct the wiring, and check the connections.
the exciter field and the regulator terminals
F+ and F-
Prime mover not up to rated speed Bring the prime mover up to rated speed.
Open or incorrectly connected external Verify wiring.
voltage adjust rheostat
Voltage range adjust R2 is set too low Refer to the setting procedure.
Potentiometer R89 out of adjustment The adjustment is factory set. If it is accidently
adjusted during operation, contact Kato
Engineering.
Faulty regulator power stage Test. If it is faulty, replace the voltage regulator or
power module.
Faulty printed circuit board Replace the voltage regulator.
Defective rectifiers in the exciter, defective Verify operation of the exciter and/or the
exciter windings, or defective generator generator. Refer to the generator instruction
manual for additional information.
Generator output heavily loaded Remove excessive load.
Voltage Faulty printed circuit board Replace voltage regulator.
builds up
until flash-
ing circuitry
operates
and then
oscillates
between
approxi-
mately 1/3
to 2/3 rated
voltage
Voltage is No voltage to sensing terminals on the Verify wiring.
high and not regulator
controllable
with the volt-
age adjust
rheostat
Page 40
Voltage is Open sensing transformer Verify wiring, and check for open windings.
high and not Automatic/off/manual switch set to MAN Set to Auto for automatic voltage regulation.
controllable
External voltage adjust rheostat shorted Verify wiring. Use an ohmmeter to test resistance
with the volt-
across the rheostat. Replace shorted rheostat.
age adjust
rheostat Internal wire from sensing terminals on the Verify the nominal sensing voltage from the
(cont.) regulator is not connected to the correct tap generator and wiring to the sensing transformers.
on the sensing transformer(s)
Faulty regulator circuit board Replace the voltage regulator.
Faulty regulator power stage SCRs or diodes Replace the power module or the voltage
regulator.
Voltage high, Internal wire from terminals) E2 and E3 to Verify the nominal generator voltage. Correct the
controllable the wrong tap on the sensing transformer(s) wiring.
with volt- T1 and T3
age adjust Improper connection of the sensing to the Verify wiring to the voltage regulator.
rheostat regulator sensing terminals
Single-phase sensing applied to a regulator Connect three-phase sensing.
designed for three-phase sensing
Voltage range adjust R2 set too high Adjust R2 per the procedure.
R89 adjustment is off Factory set. If accidently turned, contact Kato
Engineering.
Generator voltmeter is inaccurate Connect a test voltmeter to check operation of
the generator output. Calibrate or replace the
meter.
Faulty regulator power stage Replace the voltage regulator or power module.
Faulty regulator circuit board Replace the voltage regulator.
Poor regula- Voltage at regulator terminals P1 and P2 are Input voltage for standard KCR 760 voltage
tion too low at the nominal generator voltage regulators is 100 to 139 Vac for a unit with 65
Vdc output and 200 to 240 Vac for a unit with 125
Vdc output.
Jumper not installed across terminals CT• Install a jumper.
and CT1 while the generator is operating
singly
Unit/parallel switch in PARALLEL during Switch to UNIT.
single generator operation
Unit/parallel switch of the generator not on Set the switch of the generators not on the bus to
the bus set to PAR position UNIT.
The prime mover is not up to rated speed, or Bring the prime mover up to rated speed and/or
the prime mover speed is fluctuating adjust the governor.
Unbalanced load Balance the load.
Exciter field resistance is too low and /or the Add a series resistor. Resistance must not be
exciter field volts are too low less than 6.5 Ω for a 65 Vdc continuous full-load
rated regulator or 12.5 Ω for a 125 Vdc regulator.
The voltage applied to the exciter field at no load
must not be less than 10 Vdc. Best operation
occurs when the voltage is about 20 Vdc during
no-load operation. The resistor must not limit
regulator output during full load operation.
Page 41
Poor regula- Faulty regulator circuit board Replace the circuit board.
tion (cont.)
Faulty regulator power stage diodes or SCRs Replace the voltage regulator or power module.
Poor voltage Stability adjust R6 not adjusted to provide Adjust R6 per the procedure.
stability sufficient stabilizing signal.
Frequency unstable. Adjust the prime mover or the governor.
No-load field voltage and/or resistance is too Add a series resistor. Resistance must not be
low less than 6.5 Ω for a 65 Vdc continuous full-load
rated regulator or 12.5 Ω for a 125 Vdc regulator.
The voltage applied to the exciter field at no load
must not be less than 10 Vdc. Best operation
occurs when the voltage is about 20 Vdc during
no-load operation. The resistor must not limit
regulator output during full-load operation.
Voltage at regulator input power terminals P1 Input voltage for standard KCR 760 voltage
and P2 is too low regulators is 100 to 139 Vac for a unit with 65
Vdc output and 200 to 240 Vac for a unit with 125
Vdc output.
Voltage fluctuated to a point where flashing Replace the circuit board or the voltage regulator.
circuit energizes or de-energizes
Fault in the exciter or generator Verify the exciter and generator operation.
Voltage Stability adjust R6 maladjusted Adjust R6 per procedure.

recovery
slow on load Slow prime mover response Check the speed governor operation, and adjust
change as necessary.
Exciter field resistance too high Refer to the specifications given. Resistance
must not limit regulator output.
Voltage regulator capacity is less than Refer to the regulator specifications.
exciter requirements
Generator and/or prime mover are Reduce load to rated.
overloaded
Underfre- Prime mover needs adjustment. Verify governor operation, and adjust as required.
quency
limit (UFL) Incorrect use of 50/60 or 400 Hz selector J1 Correct the use of jumper J1 per procedure.
operates at
too high or
Wrong voltage regulator Contact Kato Engineering.
too low of a
frequency
UFL threshold adjust (R55) not adjusted Adjust R55 per procedure.
correctly
No droop Jumper across terminals CT• and CT1 Remove the jumper.
compensa-
tion can be
obtained
for parallel
generators
Page 42
No droop Unit/parallel switch closed (set to UNIT) Set the switch on the generator sets to PAR.
compensa- Leave the switch on UNIT on any generators that
tion can be will remain shutdown.
obtained Parallel droop adjust R4 set to minimum Turn R4 clockwise to increase droop.
for parallel droop
generators
Parallel CT does not supply the correct When a 1 A CT is used, connect to the regulator
(cont.)
secondary current terminals CT• and CT1. Terminals CT• and CT5
are for use with a 5 A CT. Determine rated line
current and voltage, and consult the factory.
Verify the number of turns on the generator line
through transformer are correct.
Voltage rises Wrong polarity between the parallel CT Interchange leads at terminals CT• and CT1.
instead of secondary leads and the regulator terminals Where a 5 A CT is used, terminals will be CT•
droops on and CT5.
application
of inductive
load
Parallel Terminals CT• and CT1 or CT5 shorted by Remove the jumper. Set the unit/parallel switch
generators jumper or unit/parallel switch to PAR.
do not divide
reactive
kVAR load
equally
resulting in
circulating
reactive
current
between
generators
Unequal adjustment of voltage droop Adjust for equal droop
potentiometers
Droop potentiometers on generators Adjust R4 on all generators for identical droop
operating parallel are set at different droop per the procedure.
positions
Wrong parallel CT or wrong ampere turns Consult Kato Engineering.
through the CT primary
Parallel CT is not in the correct generator Verify the wiring.
line
Parallel CT polarity is reversed Interchange the CT secondary leads at the
regulators terminals. CT• and CT1 are for use
with a 1 A CT. CT• and CT5 are for use with a 5
A CT.
Parallel Improper setting of the governor power Adjust the governor.
generators sensing
do not evenly
divide kW
load
Table 3: Troubleshooting
Page 43
Manual #: 351-07001-00
Date: July 2010
Instructions for generators with air filters

and differential pressure switch
General
If your generator is equipped with air filters, it may have an optional differential pressure
switch. This switch senses the pressure differential between the two sides of the filter,
and as dust and dirt accumulate in the filter, the pressure differential increases. When
the pressure differential reaches the set point, the switch actuates. The switch may be
connected to an alarm, indicator lights, or shutdown circuitry. See your wiring diagram
for details.
Application
This instruction applies to all generators with inlet filter and cooling fan on the exhaust
side of the filter.
Cleaning the Filters
Generator air filters are stainless steel and can be removed from the generator and
cleaned. Filters may be cleaned with steam, soapy water or cleaning solution. Following
cleaning the filter, it should be thoroughly rinsed with either water or steam and dried.
Air pressure switch
The air pressure switch contacts are mechanically operated when air pressure expands
a sealed diaphragm assembly. The pressure switch includes an actuating pressure set
point adjusting screw, normally open contact and normally closed contact. The set point
adjusting screw and the contact terminals are located under the switch terminal box
cover. Normally open contact terminals are marked N.O. and common while normally
closed contact terminals are marked N.C. and common.
Customer electrical connections

The switch may be connected to either a warning circuit such as an alarm or indicating
light or the switch may be connected into the generator set shutdown circuit. Wire the
switch accordingly to a resistive load no more than 15 amps A.C.
NOTE: If desired, the N.C. contact may be connected in series with the power source to
the voltage regulator. This will remove the excitation from the generator until the
generator is stopped or the filter is unclogged.
Air pressure switch adjustments
Turn the slotted screw clockwise to raise the differential pressure to where the switch will
actuate and counterclockwise to lower the set point pressure difference. Allowable static
pressure drop in air filters above clean condition is given on Table A.
The switch high-pressure port is at the atmospheric pressure outside of the generator
while the low-pressure port connects to the lower pressure ·that exists within the sheet
metal housing located between the generator and the air filter.
Calibration should be made by using a manometer to measure the static pressure drop.
Connect its low-pressure port to the air outlet side of the filter and high-pressure port to
atmospheric pressure.
Calibrate and adjust the pressure switch as detailed in the paragraph that follows.
Make certain the air filter is clean. Then operate generator at no-load, rated rpm and
measure the pressure drop. Slowly cover inlet side of the air filter using metal, plywood
or cardboard strips.
Observe when manometer indicates that pressure drop is equal to the sum of the clean
filter pressure drop plus the allowable static pressure drop. (See Table A). Keeping this
area of the filter blocked, adjust set point adjusting screw. The switch may be adjusted to
actuate when less static pressure drop exists. However, too low a pressure difference
may result in actuation of the warning or shutdown circuit before the filter is clogged to
extent where cleaning is necessary.
NOTE:
1. Use U tube manometer to measure pressure drop. Partially cover the filter face to
simulate a dirty filter.
2. The shutdown pressure drop will result in about a 10% reduction in air flow.
3. Frame number is 3rd and 4th digits in generator code number given on generator
nameplate.
Generator Frame Size For Warning Circuit For Shutdown Circuit

(See note 3) (Pressure in inches of water) (Pressure in inches of water)
01 Frame 0.1 0.15
02 Frame 0.15 0.25
03 Frame 0.2 0.3
04 & 05 Frame 0.2 0.3
06 Frame 0.3 0.5
07 Frame 0.3 0.6
10,11, & 12 Frame 0.2 0.4
Table A
Allowable Static Pressure Drop in Air Filters - Above Clean Condition

g
Protective Capacitors
for AC Rotating Machines
l Surge Protection for AC

Generators, Synchronous
Condensors and Large Mo-
tors
l Time proven GE HAZY® Film
Foil Dielectric System
l DIELEKTROL® Non-PCB
insulating fluid
l Provides Turn-to-Turn insula-
tion protection by reducing
steepness of wave fronts
applied to or reflected within
the machine.
l Used in combination with
TRANQUELL Station Arrest-
ers for Optimum Protection
GE Pr otective Capacitors & TTranquell

Protective ranquell Surge Ar
Surge Arrresters Provide
Provide
Inexpensive Insurance For Motors & Generators
GE Capacitors
DIELEKTROL Non-PCB Dielectric Protective Capacitors
With Internal Discharge Resistors - Indoor or Outdoor Mounting
Vo lta g e M a xi m um A pprox
P o le s Ne t
Ra ti ng Vo lta g e Mi crofarads F i g ur e
Cat #'s per W e i g ht
rms rms p e r P o le #
Uni t
Vo lts L -L Vo lts L -L Lb Kg
9L18BBB301 0-650 715 3 1 4 1.8
18L0015WH 2400 2640 3 0.5 36 16.4 4
18L0015WH 4160 4576 3 0.5 36 16.4 4
18L0019WH 6900 7590 1 0.5 29 13.1 1
18L0065WH 7200 7960 3 0.5 35 15.8 5
18L0009WH 13800 15180 1 0.25 33 14.9 2
18L0012WH 13800 15180 3 0.25 66 29.7 6
18L0010WH 24000 26400 1 0.125 57 22.7 3
Note 1 For other mounting requirements contact factory or GE Sales Office.

Note 2 CSA labeling is available by request.
Note 3 Current Catalog Numbers are available on the internet at www.ge.com/capacitor or a GE
Sales Office
Protective Capacitor
Figure 1: Single-pole, 6900 volts Figure 2: Single-pole, 13,800 Figure 3: Single-pole, 24,000 volts
volts
Figure 4: Three-poles, 2400 & Figure 5: Three-poles, 7200 volts Figure 6: Three-poles, 13,800 volts
4160 volts
g GE Capacitors
GE Transmission, Distribution & Industrial Systems
DEA-224 381 Broadway, Ft. Edward, NY, 12828
(6/99) www.ge.com/capacitor
© 1999 General Electric Corporation
Type POLIM-S Surge Arresters
Maximum System Voltage 2.52 to 245 kV
POLIM-S Metal Oxide Gapless Surge Arresters
POLIM-S Surge Arresters are used for the protection of switchgear,

transformers and other equipment in high voltage systems against
atmospheric and switching overvoltages. For use when requirements
of lightning intensity, energy capability and pollution are moderate.
Superior design where low weight, reduced clearances, flexible

mounting, and shatter-proof housing is required.
Application
The POLIM-S Surge Arrester has been verified to meet Station Class
requirements of IEEE C62.11 (IEEE Standard for Metal-Oxide
Surge Arresters for AC Power Circuits) and Line Discharge Class 3
requirements of IEC 60099-4 (IEC Standard for Metal-Oxide Surge
Arresters without gaps for AC Systems). The POLIM-S Surge Arrester is
designed to meet the following performance data:
Performance data
Maximum system voltages (Vm) 2.52 - 245 kVrms
Duty cycle rated voltages (Vr) 3 - 198 kVrms
Classifying current (IEEE) 10 kApeak
Discharge current withstand strength:

High current 4 / 10 µs 100 kApeak
Low current 2000 µs 900 Apeak
Energy capability:
2 impulses, (IEC CI. 7.5.5) 9.8 kJ / kV of MCOV
Fullfills requirements of IEEE
transmission-line discharge
test for 24 kV systems
Short-circuit / pressure relief capability 63 kArms sym

80 kA 1
rms sym
Maximum cantilever strength2 20000 in - lbs / 2260 Nm

Service conditions:
Ambient temperature -50 °C to + 60 °C
Design altitude3 6000 ft / 1830 m
Frequency 15 - 62 Hz
Type tested to the following standards:

IEEE standard C62.11a (2008)
IEC standard 60099-4 Ed 2.1 (2006)
Notes:
1 The POLIM-S has demonstrated values of 80 kArms sym short circuit to IEEE C62-11 (1993)
Standard.
2 Higher strength designs available on request
3 Higher altitude designs available on request
2 POLIM-S Metal Oxide Gapless Surge Arresters

Benefits Reduced electrical clearance
Polymer construction has resulted in much smaller housing
Direct-molded construction dimensions in comparison with porcelain units of the same
ABB’s POLIM-S Surge Arrester consists of high performance metal voltage rating. This size reduction enables efficient use of
oxide disks molded in a shatter-proof polymer housing. The space for switchgear enclosures, mobile substations and other
POLIM-S Surge Arrester now has a new construction to enhance applications where space restrictions are present.
overall lifetime performance.
Lightweight
The metal oxide disks are enclosed in a support assembly The POLIM-S Surge Arrester is less than 50 percent the weight
consisting of reinforced epoxy/fiberglass loops connecting the of its porcelain counterpart, which results in easier handling and
upper and lower aluminum end pieces. The silicone polymer installation.
material is then molded directly to the metal oxide loop assembly
eliminating any air pockets which could cause moisture ingress Damage resistant
over time. Polymer construction reduces possible shipping and handling
damage, as well as, damage due to vandalism.
Each arrester is furnished with a mounting base for an 8.75 in
/ 222 mm to 10.0 in / 254 mm diameter bolt circle along with Safety
4-hole NEMA pad, and line and ground terminals for electrical Shatter-resistant construction provides greater protection for
connections. personnel, as well as, nearby equipment.
100% silicone based housing

The silicone rubber housing features high tracking and arc
resistance, excellent hydrophobic properties, and resistance to
weathering, UV radiation and pollution.
Nameplates Drilling plan
Standard (Mylar)
STYLE NO. SERIAL NO.
RATING kV RMS MCOV kV RMS
WT. DATE
GRADING RING PRESS RELIEF kA RMS

CLASS
BEFORE INSTALLING READ INSTRUCTIONS IEEE / IEC CLASS
4F4002H02
MADE IN USA
Stainless steel nameplates available. To select, add ‘SN’ to the

end of the style number.
(Example: Q015SA012ASN)
POLIM-S Metal Oxide Gapless Surge Arresters 3

Quick selection guide
System Voltage Surge Arrester

Nominal ANSI/IEEE Ratings
Four-Wire
Four-Wire
Grounded High
Maximum Three-Wire Four-Wire Three-Wire Grounded
Impedance
Vm Vn Vn Vr / VMCOV Vr / VMCOV
Vr / VMCOV
(kVrms) (kVrms) (kVrms) (kVrms) (kVrms)
(kVrms)
Medium Voltage 2.52 2.4 3 / 2.55
4.37Y / 2.52 4.16Y / 2.4 3 / 2.55 5 / 4.25
4.37 4.16 5 / 4.25
5.04 4.8 6 / 5.1
7.24 6.9 9 / 7.65
8.73Y / 5.04 8.32Y / 4.8 6 / 5.1 12 / 10.2
12.6Y / 7.27 12.0Y / 6.93 9 / 7.65 15 / 12.7
13.09Y / 7.56 12.47Y / 7.2 9 / 7.65 18 / 15.3
13.86Y / 8.0 13.2Y / 7.62 10 / 8.4 18 / 15.3
14.49Y / 8.37 13.8Y / 7.97 10 / 8.4 18 / 15.3
14.49 13.8 18 / 15.3
21.82Y / 12.6 20.78Y / 12.0 15 / 12.7 27/ 22
24.0Y / 13.86 22.86Y / 13.2 18 / 15.3 30 / 24.4
24.15 23.0 30 / 24.4
26.19Y / 15.12 24.94Y / 14.4 21 / 17 33 / 27
36.23Y / 20.92 34.5Y / 19.92 27 / 22 42 / 34
36.23 34.5
High Voltage 48.30 46 36 / 29
72.50 69 60 / 48
123 115 96 / 76
145 138 120 / 98
170 161 144 / 115
245 230 192 / 152
Key
Vn Nominal System Voltage per NEMA C84.1
Vm Maximum System Voltage per NEMA C84.1
Vr Duty Cycle Rated Voltage per IEEE C62.11
MCOV Maximum Continuous Operating Voltage per IEEE C62.11
TOV Temporary Overvoltage
SPL Switching Protective Level
500 A 3-132 Vr (kVrms)
1000 A 144-198 Vr (kVrms)
LPL Lightning Protective Level
FOW Front of Wave

Guaranteed performance data
Electrical characteristics
Ratings (kVrms) TOV (kVrms) Maximum residual voltage with current wave, (kVpeak)
with prior energy SPL (SIPL) LPL (LIPL) FOW
Voltage MCOV single impulse of 4.5 kJ/kVr 30/60 µS 8/20 µs 0.5 µs
Vr VMCOV 1 sec 10 sec 500 A 1.5 kA 3 kA 5 kA 10 kA 20 kA 40 kA 10 kA
3.0 2.55 5.15 4.93 9.77 10.5 10.9 11.2 11.3 12.9 14.4 12.8
4.0 3.40 5.15 4.93 10.0 10.8 11.2 11.5 11.6 13.3 14.8 13.1
5.0 4.25 6.87 6.57 12.3 13.2 13.7 14.2 14.4 16.3 18.2 16.1
6.0 5.10 6.87 6.57 12.8 13.8 14.3 14.8 15.0 17.0 19.0 16.8
7.0 5.95 10.3 9.86 17.7 19.1 19.8 20.5 21.0 23.6 26.3 23.3
8.0 6.80 10.3 9.86 18.5 20.0 20.7 21.4 22.0 24.7 27.6 24.4
9.0 7.65 10.3 9.86 19.0 20.5 21.3 22.0 22.6 25.4 28.3 25.0
10 8.40 11.5 11.0 21.0 22.6 23.5 24.3 25.0 28.0 31.3 27.6
12 10.2 13.7 13.1 25.1 27.1 28.1 29.0 30.0 33.5 37.4 33.1
15 12.7 17.2 16.4 31.3 33.7 35.0 36.1 37.5 41.8 46.6 41.2
18 15.3 20.6 19.7 37.4 40.3 41.9 43.3 45.0 50.0 55.9 49.3
21 17.0 24.0 23.0 41.8 45.1 46.9 48.4 50.4 55.9 62.5 55.2
24 19.5 27.5 26.3 47.7 51.5 53.5 55.2 57.6 63.9 71.3 63.0
27 22.0 30.9 29.6 53.6 57.8 60.1 62.1 64.8 71.8 80.2 70.8
30 24.4 34.4 32.9 59.5 64.2 66.7 68.9 72.0 79.7 89.1 78.6
33 27.0 37.8 36.1 65.4 70.6 73.4 75.7 79.2 87.6 97.9 86.4
36 29.0 41.2 39.4 71.3 77.0 80.0 82.6 86.4 95.5 107 94.2
39 31.5 44.7 42.7 77.3 83.3 86.6 89.4 93.6 103 116 102
42 34.0 48.1 46.0 83.3 89.9 93.4 96.5 101 112 125 110
45 36.5 51.5 49.3 89.1 96.1 99.9 103 108 119 133 118
48 39 55.0 52.6 95.6 103 107 111 116 128 143 126
51 41 58.4 55.8 101 109 114 117 123 136 152 134
54 42 61.8 59.1 107 116 120 124 130 144 160 142
55 44 63.0 60.2 109 117 122 126 132 146 163 144
60 48 68.7 65.7 119 128 133 137 144 159 178 157
66 53 75.6 72.3 131 141 147 152 159 175 196 173
72 57 82.4 78.8 142 153 159 165 173 191 213 188
75 60 85.9 82.1 148 160 166 172 180 199 222 196
78 63 89.3 85.4 155 167 173 179 188 207 232 204
81 65 92.7 88.7 160 173 180 186 195 215 240 212
84 68 96.2 92.0 166 179 186 192 202 223 249 220
90 70 103 98.6 178 192 199 206 216 238 266 235
94 73 108 103 186 201 208 215 226 249 278 246
96 76 110 105 190 205 213 220 231 255 285 251
102 82 117 112 201 217 226 233 245 270 302 266
108 84 124 118 214 231 240 248 260 287 320 283
108 88 124 118 214 231 240 248 260 287 320 283
114 92 131 125 225 243 253 261 274 302 338 298
120 98 137 131 237 255 265 274 288 317 355 313
129 104 148 141 255 275 286 295 310 342 382 337
132 106 151 145 260 281 292 302 317 349 390 344
138 111 158 151 273 294 306 316 332 366 409 361
144 115 165 158 284 307 319 329 346 381 426 376
150 121 172 164 296 319 332 343 360 397 443 391
168 131 192 184 332 358 372 384 404 445 497 439
172 140 197 188 339 366 380 393 413 455 508 448
180 144 206 197 355 383 398 411 432 476 532 469
192 152 220 210 379 408 425 438 461 508 568 501
198 160 227 217 391 422 438 453 476 524 586 517

Style numbers and technical data for housings
Vertical mounting styles with standard creepage distance

Surge Arrester Creepage Strike BIL 1.2/50 µs Weight A
IEEE Ratings Distance Distance dry (Mass) max
Vr / VMCOV (kV) Style Number inches (mm) inches (mm) kVpeak lbs (kg) inches (mm) Fig
3.0 / 2.55 Q003SA002A 11.2 (284) 7.7 (197) 120 18 (8.2) 14.42 (367) 1
4.0 / 3.40 Q004SA003A 11.2 (284) 7.7 (197) 120 18 (8.2) 14.42 (367) 1
5.0 / 4.25 Q005SA004A 11.2 (284) 7.7 (197) 120 18 (8.2) 14.42 (367) 1
6.0 / 5.10 Q006SA005A 11.2 (284) 7.7 (197) 120 18 (8.2) 14.42 (367) 1
7.0 / 5.95 Q007SA006A 11.2 (284) 7.7 (197) 120 18 (8.2) 14.42 (367) 1
8.0 / 6.80 Q008SA007A 11.2 (284) 7.7 (197) 120 18 (8.2) 14.42 (367) 1
9.0 / 7.65 Q009SA008B 11.2 (284) 7.7 (197) 120 18 (8.2) 14.42 (367) 1
10 / 8.40 Q010SA008B 11.2 (284) 7.7 (197) 120 18 (8.2) 14.42 (367) 1
12 / 10.2. Q012SA010A 23.6 (599) 11.6 (297) 175 22 (10) 18.36 (466) 1
15 / 12.7 Q015SA012A 23.6 (599) 11.6 (297) 175 22 (10) 18.36 (466) 1
18 / 15.3 Q018SA015A 23.6 (599) 11.6 (297) 175 22 (10) 18.36 (466) 1
21 / 17.0 Q021SA017B 23.6 (599) 11.6 (297) 175 22 (10) 18.36 (466) 1
24 / 19.5 Q024SA019A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
27 / 22.0 Q027SA022A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
30 / 24.4 Q030SA024A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
33 / 27.0 Q033SA027A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
36 / 29.0 Q036SA029A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
39 / 31.5 Q039SA031B 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
42 / 34.0 Q042SA034B 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
45 / 36.5 Q045SA037A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
48 / 39.0 Q048SA039A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
51 / 41.0 Q051SA041A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
54 / 42.0 Q054SA042A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
55 / 44.0 Q055SA044A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
60 / 48.0 Q060SA048A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
66 / 53.0 Q066SA053A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
72 / 57.0 Q072SA057A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
75 / 60.0 Q075SA060A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
78 / 63.0 Q078SA063A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
81 / 65.0 Q081SA065A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
84 / 68.0 Q084SA068A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
90 / 70.0 Q090SA070A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
94 / 73.0 Q094SA073A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
96 / 76.0 Q096SA076B 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
102 / 82.0 Q102SA082B 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
108 / 84.0 Q108SA084D 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
108 / 88.0 Q108SA088B 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
114 / 92.0 Q114SA092B 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
120 / 98.0 Q120SA098D 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
129 / 104 Q129SA104B 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
132 / 106 Q132SA106D1 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
132 / 106 Q132SA106E 133.4 (3388) 39.7 (1009) 700 94 (43) 58.62 (1489) 3
138 / 111 Q138SA111B 150.7 (3828) 50.0 (1269) 850 109 (50) 68.86 (1749) 4
144 / 115 Q144SA115C 150.7 (3828) 50.0 (1269) 850 109 (50) 68.86 (1749) 4
150 / 121 Q150SA121B 150.7 (3828) 50.0 (1269) 850 109 (50) 68.86 (1749) 4
168 / 131 Q168SA131C 175.4 (4455) 57.8 (1469) 950 123 (56) 76.73 (1949) 4
172 / 140 Q172SA140C 175.4 (4455) 57.8 (1469) 950 123 (56) 76.73 (1949) 4
180 / 144 Q180SA144B 200.1 (5082) 65.7 (1669) 1050 137 (63) 84.61 (2149) 4
192 / 152 Q192SA152C 200.1 (5082) 65.7 (1669) 1050 137 (63) 84.61 (2149) 4
198 / 160 Q198SA160B 200.1 (5082) 65.7 (1669) 1050 137 (63) 84.61 (2149) 4
1 For 145 kV maximum systems only

Vertical mounting styles with extra creepage distance
3.0 / 2.55 Q003SB002A 23.6 (599) 11.6 (297) 175 22 (10) 18.36 (466) 1
4.0 / 3.40 Q004SB003A 23.6 (599) 11.6 (297) 175 22 (10) 18.36 (466) 1
5.0 / 4.25 Q005SB004A 23.6 (599) 11.6 (297) 175 22 (10) 18.36 (466) 1
6.0 / 5.10 Q006SB005A 23.6 (599) 11.6 (297) 175 22 (10) 18.36 (466) 1
7.0 / 5.95 Q007SB006A 23.6 (599) 11.6 (297) 175 22 (10) 18.36 (466) 1
8.0 / 6.80 Q008SB007A 23.6 (599) 11.6 (297) 175 22 (10) 18.36 (466) 1
9.0 / 7.65 Q009SB008B 23.6 (599) 11.6 (297) 175 22 (10) 18.36 (466) 1
10 / 8.40 Q010SB008B 23.6 (599) 11.6 (297) 175 22 (10) 18.36 (466) 1
12 / 10.2. Q012SB010A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
15 / 12.7 Q015SB012A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
18 / 15.3 Q018SB015A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
21 / 17.0 Q021SB017B 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
24 / 19.5 Q024SB019A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
27 / 22.0 Q027SB022A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
30 / 24.4 Q030SB024A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
33 / 27.0 Q033SB027A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
36 / 29.0 Q036SB029A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
39 / 31.5 Q039SB031B 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
42 / 34.0 Q042SB034B 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
45 / 36.5 Q045SB037A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
48 / 39.0 Q048SB039A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
51 / 41.0 Q051SB041A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
54 / 42.0 Q054SB042A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
55 / 44.0 Q055SB044A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
60 / 48.0 Q060SB048A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
66 / 53.0 Q066SB053A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
72 / 57.0 Q072SB057A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
75 / 60.0 Q075SB060A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
78 / 63.0 Q078SB063A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
81 / 65.0 Q081SB065A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
84 / 68.0 Q084SB068A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
90 / 70.0 Q090SB070A 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
94 / 73.0 Q094SB073A 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
96 / 76.0 Q096SB076B 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
102 / 82.0 Q102SB082B 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
108 / 84.0 Q108SB084D 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
108 / 88.0 Q108SB088B 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
114 / 92.0 Q114SB092B 150.7 (3828) 50.0 (1269) 850 109 (50) 68.86 (1749) 4
120 / 98.0 Q120SB098D 150.7 (3828) 50.0 (1269) 850 109 (50) 68.86 (1749) 4
129 / 104 Q129SB104B 150.7 (3828) 50.0 (1269) 850 109 (50) 68.86 (1749) 4
132 / 106 Q132SB106D 150.7 (3828) 50.0 (1269) 850 109 (50) 68.86 (1749) 4
138 / 111 Q138SB111B 175.4 (4455) 57.8 (1469) 950 123 (56) 76.73 (1949) 4
144 / 115 Q144SB115C 175.4 (4455) 57.8 (1469) 950 123 (56) 76.73 (1949) 4
150 / 121 Q150SB121B 175.4 (4455) 57.8 (1469) 950 123 (56) 76.73 (1949) 4
168 / 131 Q168SB131C 200.1 (5082) 65.7 (1669) 1050 137 (63) 84.61 (2149) 4
172 / 140 Q172SB140C 200.1 (5082) 65.7 (1669) 1050 137 (63) 84.61 (2149) 4

Vertical mounting styles with extra extra creepage distance
3.0 / 2.55 Q003SC002A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
4.0 / 3.40 Q004SC003A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
5.0 / 4.25 Q005SC004A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
6.0 / 5.10 Q006SC005A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
7.0 / 5.95 Q007SC006A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
8.0 / 6.80 Q008SC007A 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
9.0 / 7.65 Q009SC008B 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
10 / 8.40 Q010SC008B 42 (1067) 17.6 (447) 250 33 (15) 24.27 (616) 1
12 / 10.2. Q012SC010A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
15 / 12.7 Q015SC012A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
18 / 15.3 Q018SC015A 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
21 / 17.0 Q021SC017B 66.7 (1694) 25.5 (647) 350 47 (22) 32.14 (816) 1
24 / 19.5 Q024SC019A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
27 / 22.0 Q027SC022A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
30 / 24.4 Q030SC024A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
33 / 27.0 Q033SC027A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
36 / 29.0 Q036SC029A 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
39 / 31.5 Q039SC031B 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
42 / 34.0 Q042SC034B 84 (2134) 35.7 (907) 500 62 (29) 42.38 (1076) 2
45 / 36.5 Q045SC037A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
48 / 39.0 Q048SC039A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
51 / 41.0 Q051SC041A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
54 / 42.0 Q054SC042A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
55 / 44.0 Q055SC044A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
60 / 48.0 Q060SC048A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
66 / 53.0 Q066SC053A 108.7 (2761) 43.6 (1107) 600 76 (35) 50.25 (1276) 2
72 / 57.0 Q072SC057A 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
75 / 60.0 Q075SC060A 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
78 / 63.0 Q078SC063A 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
81 / 65.0 Q081SC065A 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
84 / 68.0 Q084SC068A 133.4 (3388) 51.5 (1307) 700 90 (41) 58.12 (1476) 2
90 / 70.0 Q090SC070A 150.7 (3828) 50.0 (1269) 850 109 (50) 68.86 (1749) 4
94 / 73.0 Q094SC073A 150.7 (3828) 50.0 (1269) 850 109 (50) 68.86 (1749) 4
96 / 76.0 Q096SC076B 150.7 (3828) 50.0 (1269) 850 109 (50) 68.86 (1749) 4
102 / 82.0 Q102SC082B 150.7 (3828) 50.0 (1269) 850 109 (50) 68.86 (1749) 4
108 / 84.0 Q108SC084D 150.7 (3828) 50.0 (1269) 850 109 (50) 68.86 (1749) 4
108 / 88.0 Q108SC088B 150.7 (3828) 50.0 (1269) 850 109 (50) 68.86 (1749) 4
114 / 92.0 Q114SC092B 175.4 (4455) 57.8 (1469) 950 123 (56) 76.73 (1949) 4
120 / 98.0 Q120SC098D 175.4 (4455) 57.8 (1469) 950 123 (56) 76.73 (1949) 4
129 / 104 Q129SC104B 175.4 (4455) 57.8 (1469) 950 123 (56) 76.73 (1949) 4
132 / 106 Q132SC106D 175.4 (4455) 57.8 (1469) 950 123 (56) 76.73 (1949) 4
138 / 111 Q138SC111B 200.1 (5082) 65.7 (1669) 1050 137 (63) 86.41 (2149) 4
144 / 115 Q144SC115C 200.1 (5082) 65.7 (1669) 1050 137 (63) 86.41 (2149) 4
150 / 121 Q150SC121B 200.1 (5082) 65.7 (1669) 1050 137 (63) 86.41 (2149) 4

Figures
1 Single housing 2 Double housing
4 Triple housing with ring
3 Double housing with ring

Optional mountings
Under-hung mounted styles Single housing under-hung

Available for all ratings. To select, add ‘UH’ to the end of the style
number.
(Example: 5 kV Q015SA012AUH)
Cubical mounted styles Single housing cubical

Available for rating 3 to 66 kV. To select, add ‘SAA6’ to the end
of the style number.
(Example: 15 kV Q015SA012ASAA6)
DATE U.S.A.
STYLE NO. SERIAL NO.
WEIGHT MCOV kV RATING kV
Nameplate for cubical mounted styles only.

Standard hardware
Line terminal Ground terminal

Aluminum / galvanized steel Galvanized steel
Galvanized steel
Aluminum
Note: Line and ground terminals can accommodate copper or aluminum cable size Number 2 to 1000 MCM / 0.25 to 1.15 in. diameter. Ground terminal can be located on any lug.

Phase-to-ground clearance
The phase-to-ground clearance in substations is usually based The Adjusted Protective Level to be used in Figure 1, is defined
on the selected standard rated lightning and switching impulse as:
withstand voltages. International standards, e.g. IEC 60071-2, - For lightning impulse:
recommend minimum clearances. Lpl x 1.15 x eH/8150
- For switching impulse:
In general, the clearance between a grounded object and a surge Spl x 1.10 x eH/8150
arrester should be the same as the phase-to-ground clearance
selected for other high voltage equipment in a substation. If it H is the altitude in meters above sea level.
is not possible to use the normal phase-to-ground clearance
in special applications of POLIM-S Surge Arresters, a smaller Lpl and Spl are the lightning and switching impulse protective
clearance may be chosen, considering the protective levels for the selected POLIM-S Surge Arresters at the respective
characteristics of the arrester. At system voltages 24 kV and coordinating currents.
below, the margin between the rated withstand voltage of the
substation and the protective level of the surge arrester is large. The minimum clearance is determined either by lightning or
Furthermore, distance effects by fast transients do not exist in the switching impulse withstand, whichever renders a larger value.
immediate vicinity of the surge arrester.
Thus, the recommended minimum phase-to-ground clearance

for POLIM-S Surge Arresters, with regard to lightning and switching
overvoltages are presented in Figure 1. These clearances
are based on IEC 60071-2, Table VI, and on the protective
characteristics of the surge arrester. They include safety margins
and altitude correction.
Figure 1: Recommended minimum phase-to-ground clearance
(cm) 200
Switching impulse
150
Lightning impulse
100
50
0
0 100 200 300 400 500 600 700 800 900 1000
Adjusted Protective Level (kV)

Phase-to-phase clearance
The phase-to-phase clearance for high voltage equipment in The Adjusted Protective Level shown in Figure 2 is based on the
a substation is normally based on the selected standard rated lightning protective characteristics of the selected POLIM-S Surge
lightning and switching impulse phase-to-phase withstand voltages. Arresters. It includes safety margin and altitude correction factors and
International standards, e.g. IEC 60071-3 recommend minimum is defined as:
phase-to-phase clearances. Note that the normal election of surge Lpl x 1.15 x eH/8150 + Vm x √2 / √3
arrester protective levels does not directly protect the phase-to-phase
insulation. - Vm is the highest voltage for equipment according to IEC 60071-1,
which is usually equal to the highest system voltage.
In general, the clearance between surge arresters in adjacent phases - Lpl is the lightning impulse protective level for the selected POLIM-S
should be the same as the phase-to-phase clearance selected for Surge Arrester.
other high voltage equipment in the substation. If it is not possible
to use the normal phse-to-phase clearance in a special application The minimum phase-to-phase clearance for arresters with respect
of POLIM-S Surge Arresters, the minimum clearance with regard to to switching overvoltages should always be based on the selected
lightning overvoltages can be derived from Figure 2. standard rated switching impulse phase-to-phase withstand voltage
for the substation. Consequently, the clearances specified in IEC
The clearances shown in Figure 2 are based on the assumption that 60071-3, Table VI, are valid for most applications of arresters. If a
one phase is subjected to a lightning overvoltage, while the voltage on special application requires a minimized phase spacing, the favorable
the adjacent phase is at the peak of the maximum power frequency electrode configuration established by the grading rings on POLIM-S
operating voltage (opposite polarity). Obviously, these clearances Surge Arresters may permit a further reduction of the phase-to-phase
will also cover the case of lightning overvoltages of the same polarity clearance.
appearing simultaneously on two or three phases.
Figure 2: Recommended minimum phase-to-phase clearance for

lightning overvoltages
(cm) 250
200
150
100
50
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
Adjusted Protective Level (kV)

Contact us
ABB Inc.
Document Number 2GNM110077 /July 2011

High Voltage Products - Surge Arresters
100 Distribution Circle
Mount Pleasant, Pennsylvania 15666, USA
Phone: +1 (724) 696-1568
Fax: +1 (724) 696-1502
www.abb.us
3/13/2013 CERTIFIED FOR: CATERPILLAR INC; PO #: ; PROJECT NAME: VMSC; KATO SN: 31065;
.500 X .250 KST 2.000 X .375 KST 2.000 X .750 KST
Step Diameter Length WK² Weight Added WK² Added Weight DESCRIPTION
(Inches) (Inches) (lb in²) (lbs) (lb in²) (lbs)
1 5.75 6.00 182.23 44.1
2 5.75 6.00 182.23 44.1 9879.80 502.1 EXCITER, PMG
3 7.87 5.19 553.16 71.4
4 7.08 3.56 248.38 39.7
3.00 6.50 6.50 9.00
5 7.08 3.56 248.38 39.7 BRG CENTERLINE
6 7.87 2.94 313.35 40.5
7 8.49 2.50 361.56 40.1 1 2 3 4 5 6 7 8 9 10 11 12 131415 16 17 18 19 20 21
8 10.50 2.38 803.75 58.3
9 11.25 13.62 6061.41 383.1
10 11.51 21.88 10654.45 643.8
11 11.51 21.00 10225.94 617.9 1860713.00 10666.0 ROTOR
12 12.00 8.12 4678.08 259.9
13 11.25 1.62 720.96 45.6
14 10.50 2.38 803.75 58.3
15 8.49 2.50 361.56 40.1
16 7.87 3.34 355.99 46.0
17 7.08 3.16 220.48 35.2
18 7.08 3.16 220.48 35.2 BRG CENTERLINE
19 7.87 3.84 409.28 52.9
20 7.75 7.50 751.72 100.1
21 7.75 3.00 300.69 40.0 14749.00 328.0 COUPLING HUB
Unbalanced Magnetic Pull Per .001 Inch Displacement Equals Lbs
SHAFT TOTAL 127.25 38657.79 2736.0 1885341.80 11496.1 ADDED TOTAL

KATO ENGINEERING IS NOT RESPONSIBLE FOR DAMAGES RESULTING FROM
IMPROPER TORSIONAL, CRANKSHAFT BENDING/DEFLECTION, BASE DESIGN,
TOTAL WK² (lb in²) 1923999.59 ENGINE BEARING AXIAL THRUST CAPACITY, OR PARALLELING CONDITIONS.
TOTAL WEIGHT(lbs) 14232.1
Kato Engineering
TOTAL WK² (lb ft²) 13361.11 TITLE
TORSIONAL DATA
ORIGINAL TDH TDH TDH 1/10/13 DRAWING NUMBER SH 1 OF 1

8P10.5-4200
REF. 062-90303-52 REV ECO ENG'R OP CK DATE 070-00310-65
Step Diameter Length WK² Weight Added WK² Added Weight DESCRIPTION
(cm) (cm) (kg m²) (kg) (kg m²) (kg)
1 14.61 15.24 5.33E-02 20.0
2 14.61 15.24 5.33E-02 20.0 2.89E+00 227.7 EXCITER, PMG
3 19.99 13.18 1.62E-01 32.4
4 17.98 9.04 7.27E-02 18.0
5 17.98 9.04 7.27E-02 18.0 BRG CENTERLINE
6 19.99 7.47 9.17E-02 18.4
7 21.57 6.35 1.06E-01 18.2
8 26.67 6.05 2.35E-01 26.5
9 28.58 34.59 1.77E+00 173.8
10 29.23 55.58 3.12E+00 292.0
11 29.23 53.34 2.99E+00 280.3 5.45E+02 4838.0 ROTOR
12 30.48 20.62 1.37E+00 117.9
13 28.58 4.11 2.11E-01 20.7
14 26.67 6.05 2.35E-01 26.5
15 21.57 6.35 1.06E-01 18.2
16 19.99 8.48 1.04E-01 20.9
17 17.98 8.03 6.45E-02 16.0
18 17.98 8.03 6.45E-02 16.0 BRG CENTERLINE
19 19.99 9.75 1.20E-01 24.0
20 19.69 19.05 2.20E-01 45.4
21 19.69 7.62 8.80E-02 18.2 4.32E+00 148.8 COUPLING HUB
Unbalanced Magnetic Pull Per 0.01 mm Displacement Equals N
SHAFT TOTAL 323.22 1.13E+01 1241.0 5.52E+02 5214.5 ADDED TOTAL

KATO ENGINEERING IS NOT RESPONSIBLE FOR DAMAGES RESULTING FROM
IMPROPER TORSIONAL, CRANKSHAFT BENDING/DEFLECTION, BASE DESIGN,
TOTAL WK² (kg m²) 5.63E+02 ENGINE BEARING AXIAL THRUST CAPACITY, OR PARALLELING CONDITIONS.
TOTAL WEIGHT (kg) 6455.6
Kato Engineering
TITLE
TORSIONAL DATA
ORIGINAL TDH TDH TDH 1/10/13 DRAWING NUMBER SH 1 OF 1

8P10.5-4200
REF. 062-90303-52 REV ECO ENG'R OP CK DATE 070-00310-65

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31065

MAINTAIN OIL LEVEL AT

USE A HIGH QUALITY, DOUBLE INHIBITED

OPPOSTE DRIVE DRIVE END

10.0 Liter 10.0 Liter

Kato Engineering Inc.

Installation • Operation • Maintenance

AC Center Air Generator

Kato Engineering Inc.

Construction and Operating Principles 6

Unpacking and moving 12

Inspection before startup 15

Copyright © 2012 Kato Engineering, Inc. All rights reserved

Initial startup: generators w/auto control only 20

Restoring residual magnetism/field flashing 21

Visual inspection methods of windings 28

Insulation resistance tests at low voltage 30

Dry out procedures 31

Copyright © 2012 Kato Engineering, Inc. All rights reserved

Lubrication information, electrical connection drawings, dimensional

While “common-sense” prevention of injury or equipment damage

Warning: Warnings identify an installation, operating or maintenance

Caution: Cautions identify an installation, operating or maintenance

Note: Notes highlight an installation, operating or maintenance

Copyright © 2012 Kato Engineering, Inc. All rights reserved

Copyright © 2012 Kato Engineering, Inc. All rights reserved

Figure 2: Generator frame

Copyright © 2012 Kato Engineering, Inc. All rights reserved

The rotor windings consist of insulated magnet wire wound around

Figure 3: Generator rotor

Copyright © 2012 Kato Engineering, Inc. All rights reserved

Figure 4: Sleeve bearing

Figure 5: Typical terminal box

Copyright © 2012 Kato Engineering, Inc. All rights reserved

The exciter stator assembly consists of windings in a core. The core is

The assembly consists of two subassemblies: the exciter armature and

Figure 6: Excitation system

The rotating rectifier is a three-phase, full wave bridge rectifier,

Excitation system functional overview: Exciter field control is

Copyright © 2012 Kato Engineering, Inc. All rights reserved

Copyright © 2012 Kato Engineering, Inc. All rights reserved

Main rotor (DC) Prime mover

Figure 7: Overview of excitation system

PMG system overview: The PMG system functions as a pilot exciter,

Copyright © 2012 Kato Engineering, Inc. All rights reserved

Copyright © 2012 Kato Engineering, Inc. All rights reserved

Caution: Generators equipped with sleeve

Angular alignment: Fasten a dial indicator to one of the coupling halves,

A variation of readings at different positions will indicate how the

Copyright © 2012 Kato Engineering, Inc. All rights reserved

Figure 10: Angular alignment

Parallel alignment: Fasten a dial indicator to one of the coupling halves,

Figure 11: Parallel alignment

Copyright © 2012 Kato Engineering, Inc. All rights reserved

Make all electrical connections (main load, temperature monitoring

Grounding points are provided for properly grounding the system to

Copyright © 2012 Kato Engineering, Inc. All rights reserved

b. Secure all covers and guards.

d. Check the bearings to see they are properly lubricated.

g. Make sure that the engine-generator set is protected with an adequate

h. Make sure the output of the generator is protected with an overload

Copyright © 2012 Kato Engineering, Inc. All rights reserved

Protect the shaft from corrosion by applying an anti-corrosion agent.