The information in this manual covers revolving field type alternator sets

using s t a t i c excitation. This type of excitation will be discussed in detail

in l a t e r paragraphs of this manual. The information contained should be
studied carefully and the instruction book kept a t hand for ready reference.
Read very carefully the paragraphs on proper use and maintenance of the alter-
nator set.
The equipment described i s the result of careful engineering design and manu-
facturing techniques. I t has been thoroughly inspected and tested before
shipment. Carefully inspect on delivery for evidence of shipping damage. If
damage has occurred i t should be noted on the freight bill in order t h a t a
claim can be filed to recover the cost of the damage. If the damage appears
to be of a major nature, the alternator should not be operated until the fault
has been corrected.
If you wish to contact your dealer or the factory, make sure you mention the
model and serial number as listed on the nameplate on the side of the alterna-
tor.
Winpower a1 ternators are designed t o del iver voltage and current identical t o
that of a normal power 1ine. Equipment that can be operated on normal power
can also be operated by the generator s e t , provided .the capacity i s -not
exceeded. I t should be remembered t h a t the power line, for a l l practical pur-
poses, i s backed by an unlimited generator.
Promptly f i l l in and return the guarantee card enclosed in the front of the.
manual.
ENGINE
Information on the engine i s to be found in the engine instruction manual
attached. Engine problems and trouble shooting information will be found to
be included in t h a t part of the instructions. I t i s important that proper
care and maintenance be given t o the engine. I t should be operated in a clean
and well ventilated area.
When i t i s necessary to operate under dusty conditions the a i r cleaner should
be serviced daily. Consult the engine instruction manual for the proper pro-
cedure. Follow instructions for frequency of oi 1 change using recommended
grade and type. Make sure cooling a i r passages are free fr6m d i r t and chaff.
Gasoline fueled engines should not be stored for long periods with gasoline
in the fuel t a n k and carburetor. Gum deposits may form, blocking fuel lines
and carburetor jets. Drain the fuel tank and allow the engine t o r u n until
i t stops from lack of fuel. This i s a good precaution when the length of
storage i s n ' t known.
An a1 t e r n a t o r s e t should be operated a t p e r i o d i c i n t e r v a l s , p r e f e r a b l y n o t t o
-
exceed 30 days. Operation should be more frequent i n s a l t a i r o r c o r r o s i v e
atmosphere. This use should be f o r s u f f i c i e n t d u r a t i o n t o assure t h a t s t a b i -
l i z e d operating temperature has been reached before shutdown. An i n t e r v a l o f
t o o s h o r t d u r a t i o n w i l l r e s u l t i n condensation, formation o f sludge, carbon
and poor i g n i t i o n . T h i r t y minutes i s recommended.

ALTERNATOR

The a l t e r n a t o r i s a r e v o l v i n g f i e l d type, using a s t a t i c system f o r e x c i t a t i o n

I
and c o n t r o l o f the voltage r e g u l a t i o n . The s e c t i o n below describes the s t a t i c
e x c i t a t i o n . The a l t e r n a t o r r o t o r i s attached d i r e c t l y t o a tapered extension
o f the engine crankshaft and supported on t h e outboard end by a p r e - l u b r i c a t e d
b a l l bearing. The speed a t which the r o t o r t u r n s determines t h e frequency o f
the current. A 60 cycle, two p o l e a l t e r n a t o r must be operated a t approximately
3600 RPM and a 50 c y c l e a l t e r n a t o r a t approximately 3000 RPM. Engine speed i s
c o n t r o l l e d by mechanical governor which maintains engine R.P.M. w i t h i n 5% o f
t h e nominal r a t e . As frequency v a r i e s i n d i r e c t r e l a t i o n t o engine speed,
t h e r e w i l l be a v a r i a t i o n i n frequency o f approximately 3 cycles from no l o a d
t o r a t e d load. This s l i g h t v a r i a t i o n i n frequency i s o f l i t t l e consequence
f o r normal equipment which w i l l be powered. It i s important t h a t t h e a l t e r n a -
t o r be kept i n a clean c o n d i t i o n and proper v e n t i l a t i o n provided.

WHAT I S STATIC EXCITATION?

L
I
The word " s t a t i c " means w i t h o u t motion; thus, the term " s t a t i c e x c i t e d " means
t h a t the c o n t r o l system which provides t h e c u r r e n t f o r t h e electro-magnetic
f i e l d i s provided w i t h o u t the use o f an. out-moded r e v o l v i n g DC armature.
Commutators aqd commutator brushes w i t h t h e inherent problem o f sparking and
maintenance are eliminated. The use o f a mechanical voltage r e g u l a t o r w i t h
v i b r a t i n g o r mu1t i p l e moving contacts i s a l s o eliminated.

D i r e c t c u r r e n t i s r e q u i r e d f o r t h e electro-magnetic f i e l d . A s i n g l e c o i l i s
wound i n t h e a1t e r n a t o r s t a t o r ( t h e s t a t i o n a r y winding) t o provide t h e c u r r e n t
f o r t h e base f i e l d . The c o i 1 i s e n t i r e l y separate from the main winding and
i s a t r i g h t angles i n mechanical p o s i t i o n . The AC voltage generated i n t h i s
c o i l i s f e d t o a f u l l wave s i l i c o n diode b r i d g e t o provide r e c t i f i e d d i r e c t
c u r r e n t f o r t h e base f i e l d . As the f i e l d i s t h e r o t a t i n g component, t h e cur-
r e n t connection i s accomp.lished by t h e use o f s l i p r i n g s and brushes. The
base f i e l d i s connected t o r i n g #1 (nearest t o t h e bearing end) and r i n g #3.
The base f i e l d i s designed t o provide magnetic l i n e s o f f o r c e r e q u i r e d t o
generate r a t e d voltage w i t h no l o a d on t h e a l t e r n a t o r .

I n order t o m a i n t a i n close voltage r e g u l a t i o n as the l o a d i s varied, a c o n t r o l

f i e l d i s used. The c o n t r o l c i r c u i t consists o f an a d d i t i o n a l f u l l wave bridge,
i n s e r i e s w i t h one l o a d l i n e , and a c o n t r o l winding on t h e r o t a t i n g f i e l d
poles. The c o n t r o l f i e l d i s connected t o r i n g #1 and r i n g #2. When a l o a d
i s connected t o t h e a l t e r n a t o r , t h i s c u r r e n t i s r e c t i f i e d and f e d through the
c o n t r o l f i e l d winding. By t h i s means, t h e t o t a l s t r e n g t h o f t h e f i e l d i s
v a r i e d i n r e l a t i o n t b t h e load. Voltage i s maintained w i t h i n 5% o f the r a t e d --
v a l ue.
The d e s c r i p t i o n o f s t a t i c e x c i t a t i o n opened w i t h t h e statement t h a t 'st,? t""
i s d e f i n e d as w i t h o u t motion. I n l a t e r paragraphs t h e r e v o l v i n g f i ~ l ciral;
been discussed. To a v o i d confusion, a word o f e x p l a n a t i o n i s i n o r d e r . '!'i-!erc:
must be some r e l a t i v e motion between t h e c o i l s which generate v o l t a g e anc' :.!x
magnetic f i e l d which causes t h e v o l t a g e t o be produced. I n a r e v o l v i n ? f i e l c
a l t e r n a t o r , t h e w i n d i n g t h a t produces t h e v o l t a g e i s s t a t i o n a r y and t h o f i e l d
p o l e s r e v o l v e . The r e v e r s e i s t r u e i n t h e case o f a r e v o l v i n g armature a l t e r -
n a t o r ; t h e f i e l d i s s t a t i o n a r y and t h e v o l t a g e producing w i n d i n g r o t a t e s .
ALTERNATOR MODELS

There a r e several v a r i a t i o n s o f t h e b a s i c design. The models h a v i n g t h e stif.-

f i x l e t t e r "A" (GR6036AP) a r e termed TOTAL POWER. Any combination o f 125 v o l t
and 250 v o l t l o a d i n g , up t o t o t a l c a p a c i t y , can be used. Up t o 90% o f t o t a l
r a t i n g can be used on one c i r c u i t a t 125 v o l t s . The 125 v o l t l o a d need n o t be
d i v i d e d between two c i r c u i t s .

E x p o r t models do n o t use t h e TOTAL POWER connection. These a r e i d e n t i f i e d by

t h e s u f f i x "X". The o u t p u t v o l t a g e i s a l s o i d e n t i f i e d by a s u f f i x l e t t e r .
The l e t t e r "B" i n d i c a t e s 115 v o l t s , "F" i n d i c a t e s 230 v o l t s and "C" i n d i c a t e s
1151230 v o l t s .
The l a s t two numbers i n t h e model number d e s i g n a t e t h e r o t a t i o n a ' l speed and
frequency. (GR6036AP - 3600 RPM, 60 c y c l e ; GR5030FP - 3000 RPM, 50 c y c l e . )

ENGINE STARTING
Consult t h e engine i n s t r u c t i o n manual f o r d e t a i l e d s t a r t i ng procedure.

Manual s t a r t g e n e r a t o r s e t s a r e cranked by e i t h e r a rewind t y p e cord o r by a

rope wrapped on t h e s t a r t i n g p u l l e y .

E l e c t r i c s t a r t s e t s use a combination s t a r t e r and b a t t e r y c h a r g i n g g e n e r a t o r

f o r cranking. An automatic v o l tage r e g u l a t o r c o n t r o l s b a t t e r y charging.
The manual choke i s used f o r s e t s t h a t a r e s t r i c t l y e l e c t r i c s t a r t ( S u f f i x
l e t t e r "EM).

The b a t t e r y charge ammeter, s t o p s w i t c h , and s t a r t b u t t o n a r e mounted on t o p

o f t h e engine. P u l l o u t t h e s t o p s w i t c h , c l o s e choke and depress s t a r t b u t t o n .
Do n o t over choke. I f f l o o d i n g o f t h e c a r b u r e t o r occurs, open choke f u l l y and
c o n t i n u e cranking.

Remote s t a r t s e t s ( S u f f i x l e t t e r "R") use an automatic choke. The automatic

choke i s a d j u s t e d a t t h e f a c t o r y . I t i s a c t i v a t e d when engine c r a n k i n g i s
i n i t i a t e d and r e l e a s e d when c r a n k i n g stops. Do n o t a l t e r the adjustment.

ENGINE SHUTDOWN

Generator s e t s u s i n g B r i g g s - S t r a t t o n engines (Model GR2036BP, GR1630FPX, e t c . )

are shutdown by means o f a s t o p s w i t c h on t h e engine c y l i n d e r head which
grounds t h e spark p l u g .

Manual and E l e c t r i c s t a r t s e t s u s i n g t h e Wisconsin S-8D (GR4036AP, GR3330FPX,

etc.) a r e shutdown u s i n g a ground s w i t c h on t h e b r e a k e r p o i n t box on the s i d e
o f the engine. (Continued n e x t page)
Manual and E l e c t r i c s t a r t sets using the Wisconsin S-12D engine (GR6036AP,
GR5030FPX, e t c . ) use a stop s w i t c h mounted on a p r o t e c t i v e governor s h i e l d on L

the s i d e o f t h e engine. The s w i t c h i s depressed and h e l d u n t i l t h e engine i s

a t r e s t . The s h i e l d p r o t e c t s the engine from a c c i d e n t a l overspeed by contact-
i n g t h e governor l i n k a g e i n stopping t h e engine. Overspeed, a c c i d e n t a l o r
i n t e n t i o n a l , w i l l destroy t h e components o f the diode b r i d g e r e s u l t i n g i n f a i l -
ure o f -the a l t e r n a t o r .

Remote s t a r t s e t s (GR4036APR, GR3330FPRX, GR6036APR, GR5030FPRX, e t c . ) are

shutdown by means o f remote c o n t r o l .

LOAD CONNECTION

TYPICAL PANEL - TOTAL POWER

Rated 250 V o l t

Load connection i s provided by means o f receptacles.

S i n g l e v o l t a g e models, 2000 w a t t s and under, use grounding type convenience

r e c e p t a c l e s mounted i n t h e b e a r i n g end be11.

Larger models use two o r more r e c e p t a c l e types. T w i s t l o c k receptacles, i n

a d d i t i o n t o t h e grounding convenience type, are provided. The t w i s t l o c k type
prevents a c c i d e n t a l disconnection when u s i n g a power cable extension.

TOTAL POWER s e t s have an a d d i t i o n a l 3 w i r e "range" receptacle. P r i n t i n g on t h e

f r o n t i d e n t i f i e s the 125 v o l t connection t h a t can be used f o r 90% o f t o t a l
r a t i n g on one c i r c u i t .

The convenience receptacles t h a t are used f o r s i n g l e v o l t a g e s e t s a t 230 v o l t s

have a d i f f e r e n t c o n f i g u r a t i o n t o prevent a c c i d e n t a l connection o f equipment
designed f o r 125 v o l t s . See i l l u s t r a t i o n .
 S E R V I C E DIAGNOSIS
-
- Speed POSSIBLE CAUSE
LOW OUTPUT m A G t
REMEDY
Check f o r overload on the engine.
LOW 1.
2. Defective governor. Check governor spring
tension, t i g h t o r defective t h r o t t l e levers
and j o i n t s .
3. ~ e f e c t i v eengine. (See engine check l i s t . )
High l i n e loss. Indicated by lower voltage a t Increase s i z e o f l i n e wiring. Might also be
load than a t generator terminals the r e s u l t o f loose connections which w i 11 be
i n d i c a t e d by excessive heating a t the loose
connecti ons .
Shorted o r grounded f i e l d c o i l . I n some cases See information f o r t e s t i n g f i e l d c i r c u i t s .
one c o i l only, t h a t i s shorted o r grounded,
w i l l reduce voltage t o approximately one h a l f
o f rating.
Defective compound f i e l d c i r c u i t . F i e l d See information f o r t e s t i n q- f i e l d c i r c u i t s .
connected t o Rings #1 and #2
Defective c o n t r o l f i e l d bridge. - See information on t e s t i n g bridge assemblies.
HIGH OUTPUT VOLTAGE
Excessfve speed Check governor linkage, spring tension, etc.
Governor 1inkage must be f r e e from d i r t & gum,
EXCESSIVE HEATING
Clogged v e n t i l a t i n g i n l e t and/or o u t l e t . Clean screens, make sure i n t e r i o r o f generator
-
i s unobstructed.
iL rheated engine due t o blocked v e n t i l a t i n g Clean i n t a k e and o u t l e t a i r passages on a i r
passages. cooled engines. Check o i l 1eve1 , check coolant
.
l e v e l r a d i a t o r core and fan be1t tension on
1iqui d cooled engines.
High room temperature Improve engine room v e n t i l a t i o n .

Poor Brush Contact: Brushes t i g h t i n holder Clean Brush Holder. Brush should move f r e e l y
.in holder.
Weak Brush Spring Tension ' Brush s p r i n g tension should snap brush i n t o
contact w i t h r i n g when l i f t e d and released.
F i l m on Col l e c t o r Rings caused by corrosive Clean r i n g s w i t h f i n e sandpaper during rota-
o r d i r t y atmosphere. t i o n o f armature. Caution: Tape sandpaper
t o s t i f f cardboard f o r safety.
Defective R e c t i f i e r Bridge (See i l l u s t r a t i o n Replace defective bridge assembly. Find
f o r method o f checking bridge) assembly number under DIODE ASSEMBLY i n p a r t s
list.
Open f i e l d c i r c u i t (see i l l u s t r a t i o n f o r Replace Rotor Assembly.
method f o r checking)
Grounded o r shorted f i e l d c o i l ( s ) (See i l l u s - Replace Rotor Assembly.
t r a t i o n f o r method)
Loss o f residual magnetism. This i s a condi- See note under f i e l d assembly f o r procedure
t i o n brought about by some unusual condition. t o r e s t o r e magnetism.
It w i l l always occur a f t e r disassembly o f the
Generator.
'ective
- - - - - - Stator:
--
. s
Lmort ed w indin g TEi F a n 6e-4aent-i-fiea KyYtFee
use o f a "growler" a t a competen't re-winding
_shop.
_______------------- - - Replace the Stator. See i l l u s t r a t i o n f o r
Grounded winding. Check by t e s t lamp from- t e s t i n g method. (Include generator model
-s t-a t-o r-winding
- - - -t o- - -- --- --- --- -
frame. and s e r i a l number on the order.)
Open winding c i r c u i t . Check a1 1 c i r c u T t s f o r
c o n t i n u i t y . I E : S2 t o S1, S4 t o ~ 1 .
-
 BRUSH HOLDER ASSEMBLY

Models r a t e d a t 2000 w a t t s and under use on bracket assernbly@as shown

i n s o l i d l i n e s (GR2036, GR1630, etc.). Models above t h a t r a t i n g have
two brushes on r i n g s #1 and #2 (numbering from bearing end) and use the
added b r a c k e t a a s shown by d o t t e d l i n e s .
Note: When r e p l a c i n g brushes, the most simple method i s t o
disconnect t h e e n t i r e bracket assembly by removing
t h e screw a t each end. The bracket can then be t i l t e d
forward f o r easy access t o t h e brush h o l d e r caps.

1. A-745 Brush"ho1der bracket ( r i g h t ) 6. Y-114 Brush

2. A-746 Brush h o l d e r bracket ( l e f t ) 7. S-6096 Clamp -
3. 8-701 Brush h o l d e r 8. #2005 Screws
4. B-791-A Cap . . 9. #I110 Lock Washer
5. B-701-B Clip 10. #2652 Screw -
S e l f tappi,ng
 BRIDGE ASSEMBLIES

1. Base F i e l d R e c t i f i e r Brldge Assembly

2. Negative Control F i e l d R e c t i f i e r Bridge Assembly
3. P o s i t i v e Control F i e l d R e c t i f i e r Bridge Assembly
Note: The diodes i n both sections o f the c o n t r o l f i e l d bridge are pressed
i n t o the aluminum heat sink, on models r a t e d a t 2000 watts and under.
Pressed i n diodes r e q u i r e special t o o l i n g f o r replacement and cannot
be changed i n t h e f i e l d . Repairs are made by replacement o f complete
assembl ies.
Check f o r Defective Diode
1. Disconnect a l l external w i r i n g from both AC and DC c i r c u i t s . ( C a r e f u l l y mark the
2.
p o i n t o f connect1 on o f each w i r e t o assure proper. re-connection) .
A diode t h a t i s i n good order w i l l conduct current i n one d i r e c t i o n and block i n
the opposite. The conducting d i r e c t i o n i s marked on the case by an arrow(*)on
the l a r g e r and by a c o l o r band on the smaller(&).
3. Use an ohmmeter ( o r a 1.5 v o l t f l a s h l i g h t b a t t e r y and bulb as i l l u s t r a t e d ) t o
check the current d i r e c t i o n . Connect p o s i t i v e a t the base o f the arrow and nega-
t i v e a t the end t o which the arrow points. (See i l l u s t r a t i o n ) A diode t h a t con-
ducts i n b o t h dir;ections o r n e i t h e r d i r e c t i o n i s defective.

Alterriatc !nearis f o r t e s t i n g a diode if an ohmmeter i s not available.

 F I E L D ASSEMBLY

Resistance o f F i e l d C i r c u i t s a t 25OC (77OF)

Rating Base F i e l d ( ~ i n g#1 t o 3) Control F i e l d (Ring # I t o 2)
2000 Watts & under 32 t o 42 ohms Less than 1 ohm
3000 t o 4000 Watts 43 t o 53 ohms Less than 1 ohm
Above 4000 Watts 47 t o 57 ohms Less than 1 ohm

Note: When o r d e r i n g replacement f i e l d assemblies, be

sure t o i n c l u d e model and s e r i a l number from
nameplate on generator frame.

TESTING A FIELD CIRCUIT

Make sure t h a t a l l brushes are n o t i n c o n t a c t w i t h t h e s l i p r i n g s . I f t h e

a1 t e r n a t o r has n o t been disassembled, paper i n s e r t e d between t h e brush and
s l i p r i n g w i l l serve as i n s u l a t i o n . The complete brushholder b r a c k e t can be
removed i f t h i s procedure i s p r e f e r r e d , by removing t h e screws and n u t s a t
each end o f t h e bracket. The brush gear may use one b r a c k e t o r two brackets,
depending on t h e c a p a c i t y o f t h e a l t e r n a t o r . When two a r e used, both must be
i n s u l a t e d o r disconnected.

To measure t h e r e s i s t a n c e o f t h e base f i e l d , touch t h e ohmmeter leads t o r i n g

#1 and #3 as shown i n t h e i l l u s t r a t i o n . Measure from r i n g s #1 and #2 f o r t h e
control f i e l d .

A r e s i s t a n c e appreciably lower than shown on t h e t a b l e i n d i c a t e s shorted t u r n s

i n one o r both f i e l d c o i l s . The r e s i s t a n c e o f l e s s than one ohm on t h e c o n t r o l
f i e l d i s too low t o measure a c c u r a t e l y w i t h t h e average ohmmeter. A complete
c i r c u i t between r i n g s should be i n d i c a t e d . A h i g h r e s i s t a n c e would i n d i c a t e a
broken connection.

A grounded f i e l d c i r c u i t can be i d e n t i f i e d by connecting the meter from t h e

s l i p rings t o the r o t o r shaft.

NOTE: Occasionally an a l t e r n a t o r w i l l l o s e r e s i d u a l magnetism. It i s v e r y

unusual unless the a l t e r n a t o r has been cils-assembled, i n which case i t w i l l be -
necessary t o " f l a s h the f i e l d " on t h e f i r s t s t a r t .
(continued)
 FIELD ASSEMBLY (Continued)

A step down transformer w i t h a nominal 125 v o l t primary winding and from 15 t o

30 v o l t secondary can be used f o r t h i s purpose. The primary should have a cord
w i t h a p l u g f o r a w a l l receptacle. The secondary should have extension leads
w i t h i n s u l a t e d probes. With the a l t e r n a t o r operating, p l u g i n t o the w a l l out-
l e t and i n s e r t the probes momentarily i n t o t h e 125 v o l t convenience o u t l e t .
For equipment n o t f u r n i s h e d w i t h the o u t l e t , touch t h e probes t o the connection
o f L1 and L2. A momentary c o n t a c t i s a l l t h a t i s required. The transformer
assembly can be purchased from the f a c t o r y a t a nominal c o s t i f n o t a v a i l a b l e
1ocal ly.
 STATOR ASSEMBLY

Notc: When o r d e r i n g replacement s t a t o r assemblies be sure t o

i n c l u d e the model and s e r i a l number from t h e nameplate on the
s i d e o f the generator.
The s t a t o r assembly has one s i n g l e c o i l winding t o provide voltage f o r the
base f i e l d . This c o i l has brown l e a d extensions and i s a t 90° i n mechani-
c a l p o s i t i o n from the l o a d winding.

S i n g l e voltage models have a two p o l e s i n g l e winding f o r t h e load.

Dual voltage models have a double winding. Each winding develops voltage
a t the lower r a t i n g . For the h i g h e r voltage the connection r e s u l t s i n a
s e r i e s connection o f each winding. It i s much the same as connecting two
6 v o l t b a t t e r i e s i n s e r i e s f o r 12 v o l t s .

The 125 v o l t winding used f o r a s i n g l e c i r c u i t , 90% capacity, on TOTAL POWER

Models i s wound w i t h l a r g e r w i r e t o provide f o r t h e increase i n c u r r e n t .

A s i n g l e voltage r a t i n g a t the higher r a t i n g (220 t o 250) merely omits t h e

connection f o r t h e lower r a t i n g .

When a f a u l t i n t h e s t a t o r i s suspected each i n d i v i d u a l winding should be

checked. The r e s i s t a n c e o f t h e separate windings w i l l be low, l e s s than
one ohm, b u t a complete c i r c u i t should be i n d i c a t e d . I E : #S1 t o #S2, #Sq
t o #L),

The various windings should a l s o be checked f o r ground. For t h i s purpose

connect an ohmmeter from a bare spot on the frame t o one l e a d o f each c o i l .
A meter d e f l e c t i o n i n d i c a t e s a grounded winding.
When all s t a t o r leads are disconnected, t h e r e should be no c i r c u i t from one
winding t o any other. I f a c i r c u i t i s i n d i c a t e d the winding i s shorted.

I f any o f t h e above conditions a r e indicated, the s t a t o r assembly must be

rep1aced.