Retrofitting
Procedure
PD500
Series ECO38
Operating Instructions
The world’s largest
independent producer of
alternators 1 – 5,000kVA
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 1
INDEX
INTRODUCTION page 4
ECO38 AVR PANELS page 4
PD500 RETROFIT KIT FOR ECO38 page 5
INSTALLATION page 7
TECHNICAL REFERENCE GUIDES page 16
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 2
The information contained in this manual may be modified without advance notice.
This revision supersedes and replaces all previous editions.
Even partial reproduction of this manual is prohibited, with any means whatsoever, without prior written au-
thorisation by Mecc Alte S.p.A.
INTRODUCTION
This manual contains information about PD500 retrofitting operations on ECO38 series.
WARNING: These informations are applicable only for ECO38 equipped with below AVR panels, alter-
nators ordered after about june 2016.
In order to avoid damage to persons and/or property, only qualified personnel, having full
knowledge and understanding of the information contained in this manual, should perform the
procedures described herein; when power to the unit is on, the voltage present may be lethal for
the operator.
Before to perform the operations explained, read the PD500 manual reported on technical
reference guide section.
All connections must be made with the power off.
The jumpers J1 and J2 must always be present both.
ECO 38 AVR PANELS
1. PD-I main fixing holes
2. DSR fixing holes
3. PD-I alternative fixing
holes
1 2 3
Fig.1 AVR hold panel, A9115/02
Fig.2 high front panel, A9144/03 Fig.3 low front panel, A9340/01
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 3
PD500 RETROFIT KIT FOR ECO38
The kit for the PD500 retrofit on ECO38 alternator includes the following components:
1. PD500 and fixing accessories
1.1 self-drilling screw M5: 4pcs.
2. PD-I and fixing accessories:
2.1 screw M4x25:2pcs.
2.2 toothed iron washer: 4pcs.
2.3 metal nut: 2pcs.
3. PD-I and AVR connection wire marked P1.
4. Isolator and fixing accessories:
4.1 flat iron washer: 2pcs.
4.2 toothed iron washer: 2pcs.
4.3 screw M10x16: 1pcs.
4.4 screw M10x20: 1pcs.
5. Power cable (1m x 70mmq) with mounted accessories:
5.1 terminal M10: 1pcs.
5.2 terminal M16: 1pcs.
5.3 markers n.2: 2pcs.
6. Plastic cable ties:
6.1 size 2.5x100: 2pcs.
6.2 size 7.5x360: 2pcs.
1.1 2.1
2
2.2
1
2.2
2.3
Fig.4 kit components: 1 and1.1 Fig.5 kit components: 2, 2.1, 2.2 and 2.3
Fig.6 kit components: 3
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 4
4.3 4.2 4.1 4 4.4
Fig.7 kit components: 4, 4.1, 4.2, 4.3 and 4.4
5.1
5.3
5.2
Fig.8 kit components: 5, 5.1,5.2 and 5.3
6.2
6.1
Fig.9 kit components: 6.1 and 6.2
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 5
INSTALLATION
1. Remove the terminal box cover and lateral panels
Fig.10 ECO38 Cover detail Fig.11 ECO38 with only frontal panel
2. Fix the PD-I on the AVR holding panel
Fig.12 PD-I mounting procedure Fig.13 Mounted PD-I and DSR detail
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 6
3. Fix the isolator on the terminal board support
Fig.14 Isolator mounting procedure
Fig.15 Mounted Isolator detail
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 7
4. Disconnect the n.2 power cable from the terminal board and fit it on the isolator
Fig.16 n.2 power cable disconnected Fig.17 n.2 power cable on the isolator
5. Fix the M16 n.2 power cable terminal and M10 kit power cable terminal on the isolator
M10
Kit power cable Fig.18 M16 n.2 power cable and M10 kit power cable terminals on the isolator
terminal
M16
n.2 power cable
terminal
Fig.19 M10 and M16 terminals fixing detail Fig.20 M16 and M10 terminals fixing detail
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 8
6. Fix the PD500 under the terminal board support and make ready the kit power cable coil
Care must be taken in the direction of the turn of the power cable through the PD500.
Taken as reference the external PD500 output wire side, the M16 kit power cable terminal must enter in the
PD500 from the opposite one.
WARNING: If the turn direction is inverted, the voltage will rise intead of decreasing.
M16
Kit power cable
terminal
(U2 terminal
M10 board)
Kit power cable
terminal
(isolator)
PD500
output wires
M16 kit power
terminl enter
side
Fig.21 kit power cable coil instructions
Fig.22 kit power cable coil detail Fig.23 Mounted PD500 detail
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 9
7. Fix the M16 n.2 kit power cable terminal and the n.3 power cable terminal on the U2
threaded power terminal stud
M16 power
cable n.3
M16 kit power
cable n.2
U2 power
terminal stud
Fig.24 n.2 and n.3 power cable terminals and U2 power terminals stud detail
Fig.25 n.2 and n.3 power cable terminals fixed on U2 power terminal stud
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 10
8. Insert the PD500 output wires in the AVR plastic spiral
PD500 5 pole Alternator Plastic spiral PD500 output
connector sensing wire wires
Fig.26 PD500 output wires detail Fig.27 PD500 and DSR wires detail
9. PD-I wiring
For AVR wiring scheme refer to manuals reported in technical reference guide section.
9.1. Connect PD-I and PD500 output wires through the 5 pole connector.
9.2. Connect the kit green wire P1 to the PD-I terminal 11.
9.3 Disconnect the AVR sensing green wire(marked n.3) and connect the kit green wire P1 to the same
AVR terminal.
9.4. Connect the AVR sensing green wire (marked n.3) to the PD-I terminal 12.
9.5 Set J1 and J2 jumpers as indicated by the table(A9865/00) on point 10.
Fig.28 DSR wiring detail Fig.29 DSR wiring detail
Kit green wire
P1
Fig.30 PD-I and AVR connection kit wire marked P1
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 11
10. J1 and J2 PD-I jumpers setting table(A9865/00)
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 12
11. Fix the power cables and AVR /PD-I wires with the plastic ties
WARNING: Be careful that all the wires don’t touch the lamination panels.
Fig.31 wires and cables detail
12. PD-I test
12.1. With the machine switched off, check again the PD and PD-I settings according to the alternator mo-
del, as said in the previous points.
12.1.1 The PD and PD-I must be connected through the 5 pin connector.
12.1.2 The alternator and regulator sensing wires must be connected respectively to fastons 12 and
11 of the PD-I.
12.1.3 Place the jumpers J1 and J2, as indicated in point 10, with J3 inserted (PD disabled).
12.1.4 Turn PD-I trimmer DROOP in the middle position.
12.2. Remove the J3 to enable the PD.
12.2.1 Switch on the machine in no-load condition.
12.2.2 The measured alternator voltage will be about 10V greater than the rated value.
12.2.3 Turn the AVR trimmer VOLT anticlockwise to reduce the alternator voltage to the rated value
13. Close the terminal box with the lateral panels
Fig.32 ECO38 lateral panels mounting detail
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 13
14. Close the terminal box with the cover
Fig.33 ECO38 with mounted lateral panels Fig.34 ECO38 with mounted cover
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 14
TECHNICAL REFERENCE GUIDES
Title Link
Parallel operation http://www.meccalte.com/send_file.php?fileid=parallel%
20manual_PD500.pdf
http://www.meccalte.com/send_file.php?
DSR technical guide
fileid=manual_dsr_en.pdf
http://www.meccalte.com/send_file.php?
DER1 technical guide
fileid=Manuale_DER1_EN_rev06.pdf
http://www.meccalte.com/send_file.php?
DER2 technical guide
REVISION HISTORY
Revision Date Description
rev.00 11/16 Initial Release
rev.01 11/16 Back Cover typo corrected
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 15
Retrofitting Procedure PD500 on ECO38 - rev. 01 - pag. 16
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