CERAMAG™ G-25 Permanent Magnet Generator

Class 1 Division 2 Group C, D

CERAMAG is the worlds finest hazardous area power generator. Ceramag generators are used to provide DC power for controls and back up battery charging in remote or off grid industrial stationary engines, such as natural gas compressors and pumps.

Unlike a common engine alternator the G-25 PM generator produces a 3 phase AC output that is converted to DC voltage by an external regulator that is mounted near a back up battery pack. PM generators are typically used in applications where the battery back up and DC distribution system is located off skid or more than 9 Meters (30 feet) from where the generator is mounted. Use of common alternators in these applications typically results in loss of power in the connecting cables.

Ceramag generators are designed to fit any natural gas compressor package. Installation kits are available for both engine side and cooler plenum mounting. The Ceramag is belt driven from any rotating shaft . Installation assemblies are individually pre-configured at our factory to fit your specific equipment. The generator will provide full rated output over a wide speed range, ideal for use on engines where wide speed fluctuations are common.

The power regulator included with the generator gives accurate voltage and current control from 12-30 volts DC, up to 25 amps.

Features:

• Class 1 Division 2 Group C, D
• 2 year warranty on generator, 1 year controller
• Integrated junction box for easy connection
• Sealed maintenance free design incorporating heavy duty bearing assemblies
• Adjustable voltage and current set points
• OEM installation or field retrofit
• Operates across a wide and variable speed range
• All weather operation corrosion resistant housing and winding

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Specifications:

Generator	Ceramag G-25
AC Volts	40-70 Vac, 3 Phase
AC Current	3 A
Phase	3
Frequency (Hz)	125-185
Drive speed (rpm)	1500-2200
Classification	Class 1 Division 2 Group C, D
Certification	QPS
Controller	PM-750
Input	30-70 Vac 15A, 1 or 3 Phase
Output Volts DC	12 - 30 (user-settable via front panel control)
Output Current	25A Max
Maximum controller power	750W

Figure 1: Ceramag G-25 Dimensions

Cooler installation:

1. Locate “T” bracket against forward pillow block support, flush with the forward edge of the support and parallel with the fan shaft. Clamp in place.
2. Weld bracket in 6 places as indicated in FIG 1.
3. Mount pre-assembled generator stand to “T” bracket by sliding tabs over mounting bar. Hold up right and install the 3/4" threaded rod provided into the generator stand and “t” bar tensioning holes.
4. Mount the split shieve on the fan shaft in line with the centre shieve on the generator stand.
5. Shorten the 3/4" tensioning rod to its shortest position and install the link belt around the split shieve and the generator stand centre shieve.
6. Tension the link belt with the threaded rod (remove links if you can’t place enough tension on the belt)
7. Adjust the pivot frame to its most upright position and tighten in place.
8. Mount the CERAMAG generator and tighten the nuts and washers provided down on the prepared studs
9. Install the 3VX belt between the jog shaft secondary shieve and the CERAMAG shieve, loosen the pivot frame bolts and tension the generator belt with the pivot frame, tighten the pivot frame bolts

NOTE:

1. Link belts stretch. After the first few hours of operation the units should be shut down and the belts re-tensioned. Especially if you are noticing a drop-off in produced generator voltage.
2. DO NOT OVER TENSION GENERATOR DRIVE BELTS. The only wear items in a CERAMAG generator are the bearings, if they are overloaded they may prematurely wear. “B” size belts are the largest recommended belt to use for a CERAMAG generator installation.

Figure 2: Ceramag G-25 Connection Diagram

Figure 3: Ceramag G-25 Connection Diagram

Engine Bay Installation

1. Weld the pivot frame mount parallel to the shaft that is to drive the generator.
2. Adjust the pivot frame to its most upright position and tighten in place.
3. Mount the CERAMAG generator and tighten the nuts and washers provided down on the prepared studs.
4. Install the belt between the drive shaft shieve and the CERAMAG shieve, loosen the pivot frame bolts and tension the generator belt with the pivot frame, tighten the pivot frame bolts.

Figure 4: Ceramag G-25 Engine Bay Installation Diagram

Electrical Installation

1. Installation must be carried out by qualified personnel.
2. The CERAMAG generator and controller along with any optional equipment must be located, installed and wired according to all local codes and area classifications

Wiring

1. A main disconnect is required between the CERAMAG generator and the controller. Use 250 volt, 3 pole fused disconnect with three (3) 15A slow blow fuses.
2. Use minimum #12 AWG when connecting the CERAMAG generator.
3. DC output conductors to the batteries or load distribution should be a minimum of #10 AWG. All loads powered by the controller or the batteries require their own fusing.

Figure 5: Ceramag G-25 Electrical Installation Diagram

Operation

Start Up

1. Double check battery polarity before connecting to controller. Reverse polarity at controller will damage the unit and void warranty.
2. Before connecting DC loads energize controller with the CERAMAG generator and check controller output setting.
3. De-energize the controller and disconnect batteries before making final DC load connections.

Front Panel Operation

1. The front panel interface (SAM) acts as operational display and user interface.
2. SET / MONITOR button will toggle the display between the actual output (monitor) and the set points (SET).
3. VOLTS / AMPS button toggles between displaying the output voltage or current in both SET and MONITOR modes.
4. In set mode The UP and DOWN button s are used to adjust the upper limits of both the voltage and the current set points.
5. The display is normally turned off. To turn on press any but ton four (4) times rap idly. After use the display times out and shuts off again.

Figure 6: Ceramag G-25 Front Plate Diagram

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