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ATHLON
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Capacitor Generator
User's Manual\\
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ATHLON CAPACITOR GENERATOR
Model AG164S16 – 6 kW
Model AG164T16 – 8 kW
TABLE OF CONTENTS
SUBJECT PAGE
Installation 2
Operation 3
Maintenance 4
Service 4
Appendix A – Electrical Connections 6
Appendix B – Troubleshooting Guide 7
INSTALLATION
Mounting to base/frame
The alternator must be securely mounted to the base, using shims where required to insure that
the alternator is not subjected to distortion. Otherwise, dangerous vibrations may occur, causing
damage to the alternator.
Mechanical Mounting
CAUTION: Insure that engine starting battery is disconnected before installing the alternator.
2
Place a support under the engine flywheel housing.
Remove the cover from the back of the generator. Disconnect all incoming power leads.
Remove the exhaust screen band.
Support the generator rotor assembly with a mounting strap and hoist.
Remove the rotor assembly from the frame, being especially careful not scratch or cut the
copper stator winding when removing the rotor.
Bolt the rotor assembly’s drive disc to the engine flywheel, Torque the drive disc
mounting bolts per the engine supplier’s specifications.
Reinstall the generator frame assembly over the rotor. Mount the frame assembly to the
engine flywheel housing.
Remount the exhaust screen band.
Reconnect all incoming power leads (refer to wiring diagrams).
Reinstall the cover.
Remove supports from under the engine flywheel housing.
Electrical Connections
For electrical connections, see connection diagrams in Appendix A. Ground the generator frame
and neutral lead in accordance with all National and Local Electrical Codes..
OPERATION
Frequency and voltage are directly dependent on rotational speed. Speed control systems may
have a small drop in speed between no-load (NL) and full-load (FL) conditions. Therefore, adjust the
speed at no load conditions approximately 3% higher than the full load speed.
Alternator Type Capacitor (Condenser) Excitation
Speed 60 Hz. - 1850 RPM, NL to 1800 RPM, FL
50 Hz. - 1540 RPM, NL to 1500 RPM, FL
Ambient Temperature Limit 40oC
Insulation Class H
Voltage Response <0.1 second
Initial Start-up
Check all electrical connections, and insure that all bolts are secure.
Rotate the shaft to insure that the rotor assembly turns freely.
Start engine and check for excessive vibration.
Check the generator voltage at no load and at full load. Voltage is adjusted by changing
the engine speed.
If voltage cannot be adjusted, see Appendix B, “TROUBLE SHOOTING”,
Check temperature rise after 30 minutes of full load operation. If excessive, examine the
generator for obstructed air flow.
The alternator has been designed to insure rated output when installed in locations with
maximum ambient temperature of 40°C (104oF), and at an altitude not exceeding 3300 feet. For
operation at higher ambient temperatures, reduce the generator kW rating 1% for each degree
above 40°C. For operation at high altitudes, reduce the generator kW rating 2% for each 1000 ft
above sea level.
3
MAINTENANCE
Periodic Inspection
Clean and inspect the alternator after every 200 hours of normal operation, and more frequently if
the unit is in a harsh environment. Dirt and grease build-up buildup will cause the alternator to run
hotter, lose efficiency, and reduce the expected life of the unit
Cleaning
Clean all dirt and oil from external surfaces using clean cloths. Use low-pressure air (25 psi
maximum) through a fan opening, to blow contaminants from the internal components. Clean
inside the saddle box, and check for loose or damaged lead wires and loose components
mounted in the box. Do not use liquid cleaning solutions to clean any parts.
SERVICE
Flashing the Rotor (see figures below)
Disconnect all incoming power leads to the generator.
Connect the (+) lead of a 12 volt battery to the "R" connection.
Connect the (-) lead of the battery to the rotor shaft.
Disconnect battery leads.
Check the generator no load terminal voltage. It should be within ±10% of rated value.
4
Checking the Capacitor Charge
Check the capacitor "charge and discharge" readings using an ohmmeter on the RX-
1000 scale.
Place the ohmmeter leads on the capacitor terminals, one terminal a time. A meter
deflection should be seen (charging), followed by a slow return to infinity (discharging).
Reverse the ohmmeter leads and repeat the procedure. The results should be the same.
No meter deflection or continuity indicates a defective capacitor that should be replaced.
NOTE: A single capacitor is used to regulate the voltage to within 5% of the rated load. It is
CRITICAL that caution when handling capacitors since units will still maintain high voltage even
after the engine-generator has stopped. Before handling, always discharge the capacitor by
using an insulated jumper wire to short the capacitor terminals. Do not handle capacitor or touch
any leads on alternator until capacitor is safely discharged. Failure to do so may result in shock
and/or injury.
Checking Diodes
Check each diode by removing the positive (+) rotor lead stud connection. Use a multimeter with
a diode check function. With the meter set to diode check, connect each lead to each side of the
diode, note the reading, then reverse the leads and note the reading. One reading should be a
voltage while the other should indicate either an open circuit or infinite resistance. If both
readings are voltages or if both readings are open circuits, the diode needs to be replaced.
Repeat this test for second diode if present.
When replacing diodes, torque the diode base between 20 to 30 in-lbs.
5
APPENDIX A – ELECTRICAL CONNECTIONS
120VAC WIRING DIAGRAM
Rectifier Assembly, Single Diode Excitation Coils
R (+) E1 E4
L1
Rotor T1
O (-)
T2 Terminal Wiring
T1 T3 T2 T4
Rectifier Assembly, Dual Diode 120VAC
R (+)
T3
Rotor
L1 L2
T4
O (-) L2 Ground MUST BE connected to frame and frame
MUST BE connected to EARTH GROUND and
comply with local and national electrical codes
.
240/120VAC WIRING DIAGRAM
Rectifier Assembly, Single Diode Excitation Coils
R (+) E1 E4
L1
T1
Rotor
120VAC
T2
O (-)
Terminal Wiring
L0
220VAC
T1 T2 T3 T4
Rectifier Assembly, Dual Diode
T3
R (+)
120VAC
Rotor T4
L2 L1 L0 L2
O (-)
Ground MUST BE connected to frame and frame
MUST BE connected to EARTH GROUND and
comply with local and national electrical codes
.
6
APPENDIX B – TROUBLESHOOTING GUIDE
Problem Possible Causes Corrective Actions
Unit is shorted → Flash rotor
Check windings for broken/burned
Faulty windings →
Generator wires; check resistance
excitation failure
Pinched leads → Examine and correct
(does not maintain
voltage) Faulty capacitor → Replace capacitor
Faulty diodes → Replace diodes
Faulty surge suppressor → Replace surge suppressor
Check leads for broken wires or
Full voltage at no Loose or broken lead wires → loose connections; check wiring
load, voltage diagram
drops at full load
Rotor opened or shorted → Measure resistance between leads
High No-Load Fast engine speed → Adjust engine speed
Voltage High capacity capacitor → Replace capacitor
Loss of residual magnetism → Flash rotor
Low Voltage
Low engine speed → Adjust engine speed
under load
Faulty diode → Replace diode
High voltage
under loaded Incorrect engine adjustment → Check engine speed & operation
conditions
Disconnect suppressor. If voltage
No voltage Faulty suppressor → rises, replace suppressor and
reconnect.
Incorrect voltage adjustment and/or
→ Check engine speed and fuel system
operation
Unstable voltage Loose connection → Inspect connections
Faulty ground connection → Inspect connections
Load induced → Filter load
Noisy alternator Worn bearings → Replace bearings
7
Athlon Generator, LLC
Montross, Virginia
U.S.A.
