Manual Generador Kato [PDF]

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Manual Package Installation • Operation • Maintenance Drawings & Parts List Customer: Maestranza Diesel S.A. Customer P.O.: ENE018.322/12 Project: 1.6MW, 380V, 50Hz, 80C Kato Serial Number: 28469



Kato Engineering Inc. P.O. Box 8447 Mankato, MN USA 56002-8447 Tel: 507-625-4011 Fax: 507-345-2798 Email: [email protected] www.kato-eng.com Page 1



Publication Number: 350-05013-00 Publication Date: July 1994



Bearing Lubrication Instructions For Generator or Motor Serial Number 28469



Model Number



Type Number 28819



AA28819000



Gen Motor



Where grease fittings and grease relief valve are mounted into bearing housing, remove cover from exciter end of unit for access to fittings. Replenish the bearings using the amounts of grease listed below and at intervals shown in running time hours or months, whichever comes first. Do not overfill. Wipe excess grease from internal parts of unit. Use a high quality NLGI electric motor bearing grease (Lithium Base) with extreme pressure additives which will lubricate satisfactorily over a range from the lowest ambient temperature expected to +250F.



GREASE BASE MATERIAL Outboard or Exciter End



Lithium Drive End



Bearing Number



012-92659-15



012-92659-16



Replenish Interval in Running Time



200



200 Replenish Interval in Months



12



12 Replenish Amount in Ounces



0.15



0.15



P.O. Box 8447, Mankato, MN 56002-8447, (507) 625-4011 Fax (507) 345-2798 www.kato-eng.com



Publication # 350-05010-00



Publication Date: April 1994 Revised: January, 2010



INSTRUCTION MANUAL FOR



SPLIT ROLLER BEARINGS



P.O. Box 8447, Mankato, MN 56002-8447, (507) 625-4011 Fax (507) 345-2798 www.kato-eng.com



1



Table of Contents Introduction



3



General



4



Lubrication



5



Bearing Replacement and Disassembly



5



Initial Grease Fill Chart



8



Bearing Replacement, Assembly



9



Periodic Maintenance



12



Field Service of Split Roller Bearings



13



Anti Brinelling Device



14



Torque Chart



16



2



Introduction Foreword This manual contains instructions for installing, operating and maintaining split roller bearings in Kato Engineering generators. This specific bearing maintenance must be performed by an individual fully trained to perform maintenance on this split roller bearing. 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 and all included manuals in its entirety before unpacking, installing, and operating your generator. If your manual came on a CD, read all the files included on the CD.



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 procedure, practice, condition, or statement that, if not strictly followed, 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.



3



INSTRUCTION SUPPLEMENT FOR KATO Generators Fitted With Split Roller Bearings GENERAL This instruction covers the installation and removal of split roller bearings in Kato Generators. Refer to your generator manual for maintenance schedules.



Figure 1 Exploded View of Split Roller Bearing The picture above shows an exploded view of a split roller bearing. Note the names of the parts and be familiar with them. Use this page for reference as needed while performing the maintenance on the bearing.



4



1. LUBRICATION Replenishment - For periodic replenishment of lubrication, refer to the Bearing Lubrication Plate mounted on your unit. If your unit does not have a Lubrication Plate, Contact Kato Engineering Parts Department for a replacement. Very stiff greases which tend to channel or very soft greases which may churn at high speed should not be used. We use and recommend Mobilith SHC 220. NOTE: Do not mix synthetic and non-synthetic greases. Mixing greases may result in rapid failure of the grease by setting up hard or breakdown Figure 2 Loosen Bolts



2. BEARING REPLACEMENT, DISASSEMBLY NOTE: It may be necessary to remove the exciter/ PMG to do maintenance on your bearing, especially if the complete bearing has to be changed. Also, for units without an anti brinelling bracket, some disassembly may be required to remove internal bearing parts. The pictures being used in these procedures are for reference only. They may not match your unit. If they do not match, use them as a guide, adapting them for your needs. Use good shop safety procedures. A. To remove drive end bearing, proceed as follows: 1. Remove exciter and drive end covers.



Figure 3 Remove PMG Rotor



2. Place wood or fiber protective strips between the generator field poles and the bottom of the stator. These strips must be of such thickness and strength as to minimize downward movement of the rotor if it rests on the stator.



CAUTION TAKE SUITABLE PRECAUTIONS TO PREVENT INJURY TO FINGERS CAUSED BY THE STATOR FRAME BEING FORCIBLY ATTRACTED TO PERMANENT MAGNETS ON PILOT ROTOR.



3. Disconnect alternator field leads. Remove the exciter armature and PMG retaining bolts. Thread two 5/8 threaded stock through the PMG rotor into the shaft as shown in figure 3.



4. Remove clips securing exciter field leads to the exciter frame, generator frame and generator endbell. 5. Connect a hoist to the lifting eyes on the exciter stator and remove the exciter stator mounting bolts. Remove the exciter stator from the endbell, being careful not to dam age stator or rotor windings. See figures 4 & 5.



Remove the PMG rotor. The rotor should be removed by grasping the inside magnets and then pulling quickly and sharply straight back, overcoming the magnetic pull off the PMG rotor to the PMG armature. Take care not to cock the PMG when pulling it off. Place the PMG in a clean area, or seal it in plastic to avoid contamination with metal particles. See Figures 2 & 3.



5



Figure 6 Remove Exciter Armature



Figure 4 Remove Bolts



7. Place a sling about the drive end of the shaft and attach the sling to an overhead crane or hoist. Put enough pressure on the sling to hold the shaft level. See figure 7.



6. Remove the exciter armature and rotating rectifier as follows: a. Disconnect alternator field leads from the positive (+) and negative (-) terminals located on the heat sinks of the rotating rectifier assembly.



Figure 7 Sling Placement 8. Remove the bolts holding the two halves of the flanged bearing cap together. Take out the bolts holding the flanged bearing cap to the endbell and remove the two halves. Since the cartridge cannot move axially on the drive end bearing, the flanged cap halves must be tilted out of the recess in the end bell. See figures 8, & 9.



Figure 5 Remove Exciter Stator b. Using a hoist and strap, remove exciter armature and rotating rectifier. See figure 6.



Figure 8



6



Figure 9



Figure 11 Removing Clamping Rings



9. Remove the joint screws from the housing; remove the two halves of the housing. Leave the outer race in the housing. See figure 10.



14. If the sling is to be removed, make sure that the wood or fiber strips are in position between the generator field and stator. B. To remove the exciter end bearing, proceed as follows: Note: Remove exciter per previous steps. 1. Place a strap around the exciter end of the shaft and lift enough to take the pressure off the bearing. 2. Remove the bolts holding the flanged bearing cap to the endbell; slide the bearing assembly out so that the cap is clear of the recess in the endbell



Figure 10 Removing Housing



3. Remove the joint screws from the cap; remove the two halves of the cap.



10. Pull the outer seal off the shaft. Clean it and set it aside.



4. Remove the joint screws from the housing; remove the two halves of the housing. Leave the outer race in the housing.



11. Remove the jointing clips from the roller cage; remove the roller cage.



5. Slide the seals out of the way. Do not remove them unless they are to be replaced.



12. Carefully measure the position of the inner race on the shaft so that the new inner race can be placed in exactly the same position. Measure from a specific surface on the coupling or shaft step.



6. Remove the jointing clips from the roller cage; remove the roller cage. 7. Measure and record the position of the inner race on the shaft. Measurement should be accurate within 0.015". Kato Engineering can be contacted for the measurement re corded during assembly.



13. Remove the screws from the clamping rings. Remove the clamping rings and the inner race. See figure 11.



8. Remove the screws from the clamping rings. Remove the clamping rings and inner race. 9. If the sling is to be removed, make sure that the strips are in position between the generator field and stator.



7



Note: Initial grease fills only. Do not use for periodic regreasing.



Table 1 Split bearing grease initial fill chart (Shaft size measured at end of drive end)



8



Note: The inner race and the clamping rings are matched sets and are not interchangeable. They are stamped with identifying numbers. Make sure the numbers match and are facing the same direction. The clamping ring stamps will face away from the inner race on both sides.



3. BEARING REPLACEMENT, ASSEMBLY To assemble a bearing, proceed as follows: Note: Clean the parts and shaft with solvent to remove any oil. 1. Apply a light coat of O-ring lubricant to the o-rings in the ID of the seal. See figure 12.



Figure 14 Match Numbers and Direction



Figure 12 Lube ID of Inner Seal 2. Install the inner seal onto the shaft. Use a square to get the correct position. See figure 13.



Figure 15 Placing inner race 4. There should be a gap at the joints of the inner race. Some gap in each joint helps insure good seating. The gaps should be even, It may be helpful to place shim stock in the gaps to keep them even, and remove them before final tightening. If the measured gap is outside the range of 0.05" to 0.020, contact Kato Engineering.



Figure 13 Install Inner Seal



5. Verify the shoulders of the clamp collars face each other. Fit the clamping rings with their joints rotated between 30o and 90° from the joints in the inner race. Partially tighten all four clamping screws equally. Strike each clamping ring with a soft mallet about 90O from the parting line to ensure the proper seating of the clamping rings. Tighten bolts and strike with mallet again. Fully tighten bolts to torque value specified on page 15. See figure 16.



3. Place the two halves of the inner race at the correct position on the shaft. A light tap with a rawhide or rubber hammer may be required to spring the races over the shaft. Hold together with plastic ties or a hose clamp temporarily. Consult the measurements taken during disassembly. The drive end race and non drive end race must be placed exactly where the original race had been. See figures 14 & 15.



9



7.Inject sufficient grease to fill the grease passages of the roller bearing cage. Refer to Table 1 for grease amounts. See figure 18.



Figure 18 Grease the bearing rollers



Figure 16 Install Clamping Rings 6. Tap down each half of the inner race and clamping rings all around the shaft, placing a fiber or hardwood block between hammer and bearing parts. Retighten screws. Repeat until the screws are fully tight. Make sure that the rings are hard against the race shoulders all around. The total gap is not critical provided the shaft is within the required tolerance. Make sure the placement of the inner race is the same measurement as recorded earlier. Also, lubricate the bores and the seal area of the outer seal and install. See figure 17.



8. Place the cage around the inner race, matching the race halves. Insert the jointing clips. Note: Some units will have Allen screws. See page 16 for torque specification. Verify the grease is evenly distributed between the rollers and the cage, and the joint clips remain in position by rotating the cage on the race five times. See figures 19 and 20.



Figure 19 Insert joint clips or Allen screws



Figure 17 On drive end, Positioning must be exact



10



Figure 21 Fill grease passages



Figure 20 Installing roller cage



Grease hole



9. Inject sufficient grease to fill the grease passages. Fill each half of the cartridge with grease. See Table 1 for grease amounts. See figure 21. 10. After the cartridge has grease in it, tap and slide in the outer race. Repeat for the bottom half. See figure 22. 11. Assemble the cartridge with races installed. Tighten the four split screws to set the outer races in position. Tighten and torque the twelve Allen head race locking screws to secure the outer races. Disassemble the cartridge.



No grease hole



Figure 22 Install outer race



11



12. Assemble the two halves of the cartridge around the bearing cage and seals. (The outer race halves should be in the housing halves). Tighten the four joint screws, making sure the end faces are flush. 13. Tighten in an X pattern to torque spec, refer to page 15 for torque spec.



Figure 24 Assemble bearing housing



4. RECOMMENDED MAINTENANCE



Figure 23 Lubricate Spherical Seating



14. Rotate the cartridge five times to ensure proper seating. Make sure the anti-rotation pin is on top. 15. Lubricate the spherical seating all the way around with MolyKote or similar. 16. Allow the spherical seating to self-align while tightening the flange bolts. Then loosen the flange bolts on the top housing and at the split line. Note: If working on both bearings, loosen flange and split line bolts on both drive end and non drive end. Rotate the shaft at least five revolutions to allow the cartridge to align. Fully tighten the bolts to torque spec, refer to page 15 for torque spec. Caution: Tightening the flange halves without ensuring the cartridge alignment will result in premature bearing failure. Note: the cap screws or bolts holding the bearing assembly to the end bell on the exciter end each have a lock washer and a hardened flat metal washer. These screws must not be allowed to bottom out in their holes. Verify all the bolts are torqued to the proper levels when assembling the generator, refer to page 15.



Replenishment - For periodic replenishment of lubrication, refer to the Bearing Lubrication Plate mounted on your unit. If your unit does not have a Lubrication Plate, Contact Kato Engineering Parts Department for a replacement. Very stiff greases which tend to channel or very soft greases which may churn at high speed should not be used. We use and recommend Mobilith SHC 220. NOTE: Do not mix synthetic and non-synthetic greases. Mixing greases may result in rapid failure of the grease by setting up hard or breakdown. Caution: Kato Engineering strongly advises rotating idle units, especially those subject to vibration, at least 1/2 turn each week to keep a film of grease between the roller and the race. This will help prevent bearing damage and brinelling.



Every 12,000 hours or 3 years of operation Remove the upper flange cap and the upper outer race and remove the old grease. Inspect the bearing, re-pack with grease as indicated in table 1. Re-torque the roller bearing cage if it is equiped with Allen screws. See the generator manual for complete maintenance instructions.



12



5. Prepare and lubricate the roller cage per previous instructions.



5. FIELD SERVICE OF SPLIT ROLLER BEARINGS This section is for bearing maintenance when a full shop disassembly is not possible. Refer to Chapter 3 for full procedures. Torque all bolts and screws per page 15. Be sure to safely support generator parts while working on them.



6. Install the cage first, then roll in the cartridge. Add Molykote to spherical seat only. 7. Roll the cartridge to verify ease of rotation. 8. Ensure the lower cartridge is seated squarely to eliminate a cocked bearing. Place a straight edge across the cartridge and flange to check for even seating.



Drive end bearing Disassemble 1. Set a jack to support the shaft, be sure to center the jack on the shaft. Protect the shaft surface with hardwood or brass, etc.



9. Slowly lower the shaft to allow the bearing to take the rotor weight. Recheck that the lower cartridge is still seated squarely.



2. Check the torque of the lower bearing flange. Insure bearing lower half is secure.



10. Install the upper cartridge. Install, tighten and torque the split line screws.



3. Remove the upper flange.



11. Install the upper cap. Leave loose if working on the opposite end.



4. Remove the upper cartridge.



Non drive end bearing



5. Place the dial indicator on the shaft so as to measure the upward force on the shaft.



1. Loosen the PMG and remove.



6. With a jack or a Kato lifting device, raise the shaft .020”, (insure the jack is sufficient to support the rotor during work).



2. Reinstall the PMG bolts to the shaft for saftey. 3. Move the exciter to the rear, no need to remove it from the shaft.



7. Roll out the lower cartridge to expose the bearing cartridge roller. Inspect. 8. Remove the roller. Inspect in cage.



4. Work within the constraints of the exciter frame, making sure the shaft is supported during bearing disassembly.



9. Inspect and disassemble the inner race. Remove the screws and collar. Take care not to drop the inner race.



5. Tighten and torque the bearing bolts after completion of ODE and DE assembly.



10. Inspect the grease seals. Replace if necessary.



Bearing removal, inspection and maintenance is the same as the drive end.



Use a hose clamp to squeeze and remove pins. Prep and assemble 1. Install the inner race and torque. (Measurements from shaft center line or race line.) 2. Prepare the cartridge. Clean and lubricate. Remove, clean, and reinstall the outer race per instructions. 3. Clean the shaft, seals and rollers, inspect for damage. 4. Reinstall and re-lubricate the rollers or replace with new parts.



13



Optional Anti-Brinelling Device



Lifting Block



Figure 25 Optional anti-brinnelling device, note brass lifting block



Prior to start up, bolts MUST be loosened three or four turns. Verify clearance to brass lifting block, see figure 25 and 26. FAILURE TO DO SO MAY CAUSE DAMAGE TO THE EQUIPMENT To block rotor for transportation, tighten both screws indicated above to 25 ft/lbs. Total rise in shaft is about .005"-.010"



14



Optional Anti-Brinelling Device



Figure 26 Lifting Bolts



15



16



TORQUE SPECIFICATION HEX WRENCH SIZE IN/LBS FT/LBS N/m 1/4 240.0 20.0 27.1 3/16 68.4 5.7 7.7 3/32 40.0 3.3 4.5 1/4 216.0 18.0 24.4 5/16 396.0 33.0 44.7 1/2 1,908.0 159.0 215.6 5/16 396.0 33.0 44.7 NA 5,448.0 454.0 615.6



BOLT SIZE 5/16-24 X 1 S.H.C.S. 1/4-20 X 1/2 LOW HEAD 1/4-20 X 1/2 S.S. 5/16-18 X 1 S.H.C.S. 3/8-16 X 1/2 S.H.C.S. 3/4-10 X 3 S.H.C.S. 1 (GRADE 8) COARSE



TORQUE SPECIFICATIONS HEX WRENCH SIZE IN/LBS FT/LBS N/m 1/4 240.0 20.0 27.1 3/16 68.4 5.7 7.7 1/8 108.0 9.0 12.2 1/4 216.0 18.0 24.4 5/16 396.0 33.0 44.7 5/8 3,384.0 282.0 382.4 NA 8,184.0 682.0 924.8



6" shaft bearings



BOLT SIZE 5/16-24 X1 S.H.C.S. 1/4-20 X 3/8 LOW HEAD #10-24 X 3/4 S.S. 5/16-18 X 1 S.H.C.S. 3/8-16 X 1/2 S.H.C.S. 5/8-11 X 2 1/2 S.H.C.S. 3/8-16 X 1 5/8 S.H.C.S. 7/8 (GRADE 8) COARSE



5.5" shaft bearings



BOLT SIZE 1/4-28 X 1 S.H.C.S. #10-32 X 3/8 LOW HEAD #10-24 X 3/4 S.S. 1/4-20 X 1 S.H.C.S. 3/8-16 X 1/2 S.H.C.S. 5/8-11 X 2 1/2 S.H.C.S. 3/8-16 X 1 5/8 S.H.C.S. 7/8 (GRADE 8) COARSE



NOTE: ALL VALUES REPRESENT DRY OR LIGHTLY OILED, IF THEY ARE HEAVILY OILED REDUCE TORQUE RATING BY 10% *The NYLOK™ patch incorporated into the threads is a thread locking compound. According to the screw manufacturer, any screw with NYLOK embedded into the threads can be re-used up to 5 times. In the event of inspection or change out, re – use the screws if spares are not available We strongly recommend using new screws if available



CLAMP COLLAR ROLLER CAGE* CARTRIDGE PUSHER SCREWS CARTRIDGE ASSEMBLY BOLTS LOCATING PIN (BOLT) FLANGE ASSEMBLY BOLTS FLANGE MOUNTING BOLTS



CLAMP COLLAR ROLLER CAGE* CARTRIDGE PUSHER SCREWS CARTRIDGE ASSEMBLY BOLTS LOCATING PIN (BOLT) FLANGE ASSEMBLY BOLTS VIBRATION BRACKET FLANGE MOUNTING BOLTS



CLAMP COLLAR ROLLER CAGE* CARTRIDGE PUSHER SCREWS CARTRIDGE ASSEMBLY BOLTS LOCATING PIN (BOLT) FLANGE ASSEMBLY BOLTS VIBRATION BRACKET FLANGE MOUNTING BOLTS



TORQUE SPECIFICATION HEX WRENCH SIZE IN/LBS FT/LBS N/m 3/16 120.0 10.0 13.6 3/32 29.3 2.4 3.3 3/32 40.0 3.3 4.5 3/16 108.0 9.0 12.2 5/16 396.0 33.0 44.7 1/2 1,908.0 159.0 215.6 5/16 396.0 33.0 44.7 NA 5,448.0 454.0 615.6



5" shaft bearings



Torque Specifications for Split Roller Bearings



Field Installation Split Roller Bearing Checklist BEFORE DISMANTLING Technician's Name: ___________________ Serial Number: _______________________ Date: _______________________________



Technician's Company: _________________ # Hours ran: _________________________ Site Location: ________________________



Check cleanliness of insulation on Exciter End Vibration recorded by site operation Visual Estimation of Axial Movement of the rotor in operation ENGINE STOPPED, COUPLING GUARD REMOVED



Location of Magnetic center, relative to the seal face WHEN BOTH BEARINGS ARE OPENED ( TOP CASING AND TOP CARTRIDGE REMOVED) Dimension between center of roller and center of lower part of out race, for both bearings



Drive End : Non Drive End :



Slowly rotate the generator and visually check the rollers and cage condition, record



Roller Condition: Cage Condition:



Record grease amount in bearings and grease color ALUMINUM RACE



Type of seal present?



BRONZE RACE



WHEN THE INNER RACE IS REMOVED FROM THE SHAFT Measure the shaft diameter where the race was mounted. Measure at 3:00 and 9:00 and 12:00 and 6:00 at (2) locations under the race (Ex.: 4.999 - 3 digits) Visual aspect of the shaft under the race If Inner race removed / replaced



Inner race NOT removed / replaced



Record the gap with a feeler gage between the two halves of the inner race tightened on the shaft



Inner race removed / replaced Gap Measurement: ____________________



All screws are torqued with a torqued wrench WHEN THE BEARINGS ARE PARTIALLY REASSEMBLED, NOT HAVING THE UPPER PART OF THE CASING AND CARTRIDGE ON YET Rotate slowly by hand for 5 turns or with turbine slowly REMAINING REASSEMBLY The rotor can be rotated smoothly and quietly by hand AFTER ALIGNMENT, BUT BEFORE THE GUARD IS INSTALLED



Location of Magnetic center, relative to the seal face DURING OPERATION Check cleanliness of insulation on Exciter End Vibration recorded by site operation ALL PARTS REMOVED AND REPLACED FROM BEARINGS MUST BE RETURNED TO KATO WITH IDENTIFICATION S/N and Site Name: ____________________________________ DE or ODE: ___________________________________________ 17 Number of hours on turbine: ______________________________ Date and Name of Service Tech: __________________________



Instruction Manual Publication 350-01001-00, 09/29/11



Installation • Operation • Maintenance



Standard AC generator Single or two-bearing Drive-end air discharge



Kato Engineering Inc. P.O. Box 8447 Mankato, MN USA 56002-8447 Tel: 507-625-4011 Fax: 507-345-2798 Email: [email protected] www.kato-eng.com Page 1



Table of Contents Introduction......................................................... 4 Foreword............................................................................4 Safety instructions..............................................................4 Ratings/description............................................................ 4



Construction and Operating Principles............ 5 Stator................................................................................. 5 Rotor.................................................................................. 5 Bearings.............................................................................5 Connection boxes.............................................................. 6 Excitation system............................................................... 6 Optional PMG system........................................................ 7 Other options..................................................................... 7



Installation........................................................... 8



Note: Because of rapid changes in designs and processes and the variability of Kato Engineering’s products, information in this manual must not be regarded as binding and is subject to change without notice. The image on the front cover is representative only. Several variations are available within the range of generators covered within this manual.



Receiving inspection.......................................................... 8 Unpacking and moving...................................................... 8 Location............................................................................. 8 Base design....................................................................... 8 Assemble to prime mover, alignment................................ 8 Two-bearing alignment............................................ 9 Two-bearing close-coupled alignment................... 11 Single-bearing alignment....................................... 18 Foot deflection................................................................. 23 Doweling.......................................................................... 23 Electrical connections...................................................... 23 Space heaters................................................................. 23 Inspection before startup................................................. 24



Operation........................................................... 25 Initial startup: generators w/auto & manual control.......... 26 Initial startup: generators w/auto control only................... 25 Restoring residual magnetism/field flashing.....................26 Continuous operation....................................................... 27 Idling................................................................................. 28 Parallel operation..............................................................28



Page 2



Maintenance.......................................................30 Schedules........................................................................30 Maintenance procedures................................................. 32 Visual inspection methods of windings.................. 32 Cleaning................................................................ 33 Insulation resistance tests at low voltage.............. 34 Dry out procedures............................................... 36 Bearing lubrication................................................ 36 Rectifier tests........................................................ 37 Disassembly..................................................................... 39 Overall disassembly............................................... 39 Exciter armature and PMG removal...................... 40 Bearing removal.................................................... 42 Assembly..........................................................................42 Bearing installation................................................ 42 Overall assembly................................................... 43 Exciter armature and PMG installation.................. 43 Storage............................................................................ 44



Troubleshooting Guide.....................................45 Appendices........................................................48 List of equipment required for installation and maintenance............................................................. 48 Main part location............................................................. 49



Torque chart..................................................16-17



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. Note: For specific lubrication instructions, always refer to the bearing lubrication sheet that came with your manual or the lube plate on the generator.



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 and all included manuals in its entirety before unpacking, installing, and operating your generator. If your manual came on a CD, read all the files included on the CD.



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 procedure, practice, condition, or statement that, if not strictly followed, 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



Construction and Operating Principles 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 endrings 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. 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 optional 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 (four, six, eight or 10). With six or more poles, the poles are typically attached to a center hub. The rotor windings consists of insulated magnet wire wound around each pole. V-blocks 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. 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. The rotor either has resin applied during the winding process or 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, exciter armature, and optional 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.



Bearings The generator may contain either one or two bearings. Bearings are typically ball or roller type and are regreaseable bearings, which contain fill and drain ports for easy lubrication. Sleeve bearings are optional on some designs. A supplementary instruction will be included in



Page 5



Note: For specific lubrication instructions, always refer to the bearing lubrication sheet that came with your manual or the lube plate on the generator.



the manual package for sleeve bearings if they are applicable to this generator. Some smaller generators may use heavy duty double shielded bearings, which are typically used on smaller generators and are greased for life.



Connection boxes The main lead connection box houses the load lead terminals. In addition, the generator may have auxiliary connection boxes for connecting temperature detector outputs, space heater connectors, and sensing outputs.



Excitation system The excitation system consists of the exciter stator assembly and the exciter armature assembly: 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 on to 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. 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 1).



Page 6



Power input Voltage regulator Output leads Main stator (armature)



Exciter stator (field)



PMG stator (armature)



Main rotor (DC)



Prime mover Shaft



PMG rotor (field) Exciter armature (AC)



Rectifier



Figure 1: Overview of excitation system (with an optional PMG)



Optional 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 1).



Other options Other options include, but are not limited to, space heaters, filters, and temperature sensing devices.



Page 7



Installation Warning: Be alert at all times when installing, operating and maintaining the generator. Avoid contact with the uninsulated metal parts of the generator. Most injuries occur from faulty ground connections on portable electrical equipment and failure to ground stationary equipment. Test all portable devices frequently to prove that a solid electrical circuit exits from the metal frame though the grounding conductor, in the electrical cord, to the grounding contact in the attachment plug. Do not use electrical equipment with frayed, burned or damaged cords. Always take extreme care when moving the generator. Be careful to not strike objects or personnel. Apply lifting force to structural points specifically provided for lifting. Do not use the enclosure lifting holes to lift the whole unit. Use lifting means adequate for the weight. Observe lifting notices attached to the generator. Failure to observe these instructions can result in injury and damage to the generator. Caution: Do not attempt to transport a single-bearing generator without maintaining proper rotor support and with the exciter rotor assembly removed. Failure to observe this warning can result in equipment damage. Caution: Blocking or restriction of normal air flow into or out of the generator may cause damage to the electrical windings.



Receiving inspection Before accepting a shipment, examine the packaging for any sign of damage that might have occurred during transit. Report any damage to the transportation company and Kato Engineering.



Unpacking and moving If the generator is received during cold weather, reduce condensation on cold surfaces and failure due to wet windings by allowing the generator to reach room temperature before removing the protective packing. Unpack the generator carefully to avoid scratching painted surfaces. Do not remove the protecting lubricant from the shaft end or drive plates. Inspect for loosely mounted components and the presence of moisture. Inspect to make certain foreign material, such as crating nails, loose bolts or packing material, which may have fallen into the machine during unpacking, is removed. If damage is noted, determine the extent of damage and immediately notify the transportation company claims office and Kato Engineering. Be sure to give complete and accurate details when reporting damage. Move the generator by attaching an overhead hoist to the eyebolts installed on the generator frame or by lifting the generator from underneath the skid with a forklift. Single-bearing generators are shipped with the exciter rotor assembly removed from the shaft and a support mounted across the drive discs to support the rotor.



Location Install the generator in an area so it complies with all local and industrial 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 inspection and maintenance. Check winding insulation resistance before placing the generator in operation (see the maintenance section). 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.



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 8



Assemble to prime mover, alignment Follow either the two-bearing alignment (if your generator model has two bearings but no adapter to bolt to an engine flywheel housing), two-bearing close-coupled alignment (if your generator model has two bearings and an adapter for bolting to a flywheel housing), or singlebearing alignment (if your generator has one bearing and drive plates). Consult the factory for belt or gear drive alignment). Two-bearing alignment Follow the tolerances specified by the coupling manufacturer when they are less than described in this manual. Use shims, if necessary, between the mounting pad and the base to properly level and align the generator to the prime mover. Install the coupling(s) on the generator and engine drive shafts in accordance with coupling manufacturer installation procedures. Use a straight edge and a thickness gauge for rough alignment as shown in Figure 2. Check for angular and parallel alignment as follows: Straight edge



Notes: Mounting of the indicators must allow complete rotation of the prime mover. Thickness gauge



Figure 2: 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 3. 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 9



Use dial indicators that are rigid so indicator sag won’t be a factor. Using the shortest offset distance of the indicator bracket will reduce the effects of indicator droop or sag. During alignment, you may also need to compensate for engine expansion due to heating. Generator expansion is generally not considered a factor. If the genset is moved to a different location, check alignment before startup. 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.



Dial indicator



Figure 3: 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 4. 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 4: Parallel alignment



Page 10



Two-bearing close-coupled alignment Check the engine flywheel housing pilot’s radial and face runout by mounting a dial indicator and measuring the flywheel to the flywheel housing as shown in Figure 5. See Table 1 for maximum allowable runout. Flywheel Dial indicator pointer for radial runout



Flywheel housing



Notes: Mounting of the indicators must allow complete rotation of the prime mover. Use dial indicators that are rigid so indicator sag won’t be a factor. Using the shortest offset distance of the indicator bracket will reduce the effects of indicator droop or sag. During alignment, you may also need to compensate for engine expansion due to heating. Generator expansion is generally not considered a factor. If the genset is moved to a different location, check alignment before startup.



Shaft



Caution: Do not pry on the fan. Caution: Generators equipped with sleeve oil bearings must have oil added to the bearing prior to rotation. See the bearing manual.



Dial indicator pointer for face runout



Figure 5: Flywheel housing check



SAE housing number



Housing inside dia.



Allowable runout (TIR)



6 5 4 3 2 1 0.5 0 00



10.500 12.375 14.250 16.125 17.625 20.125 23.000 25.500 31.000



0.002 0.003 0.003 0.004 0.004 0.005 0.005 0.006 0.007



Table 1: Maximum allowable flywheel housing runout (inches)



Page 11



Check the engine flywheel’s radial and face runout by mounting a dial indicator and measuring the flywheel housing to the flywheel as shown in Figure 6. See Table 2 for maximum allowable runout.



Flywheel



Flywheel housing Dial indicator pointer for radial runout



Shaft



Dial indicator pointer for face runout



Figure 6: Flywheel check



Pilot diameter



Allowable runout (TIR)



6.5 7.5 8 10 11.5 14 16 18 21 24



0.002 0.002 0.002 0.003 0.003 0.004 0.005 0.005 0.006 0.007



Table 2: Maximum allowable flywheel runout (inches)



Page 12



Check the generator adapter’s radial and face runout by mounting a dial indicator on the generator shaft or coupling as shown in Figure 7. The maximum radial and face runout on the generator adaptor must not exceed 0.010 inch. Adapter Dial indicator pointer for radial runout Shaft



Dial indicator pointer for face runout



Figure 7: Generator adapter check



Check the generator coupling’s radial and face runout by mounting a dial indicator to the generator adapter as shown in Figure 8. The maximum radial and face runout on the coupling must not exceed 0.003 inch. Adapter



Shaft Dial indicator pointer for face runout



Dial indicator pointer for radial runout



Figure 8: Generator coupling check



Page 13



Install the portion of the coupling that fits into the engine flywheel following the manufacturer’s recommended procedures and in accordance with engine manufacturer’s specifications. Check the coupling’s radial and face runout by mounting a dial indicator to the engine flywheel housing as shown in Figure 9. The maximum radial and face runout on the coupling must not exceed 0.004 inch. Flywheel



Flywheel housing



Dial indicator pointer for face runout



Shaft



Dial indicator pointer for radial runout



Figure 9: Engine coupling check



Measure and record the engine crank shaft endplay and generator endplay. Set the engine endplay to the manufacturer’s recommended position for alignment. Verify the generator end-float is set at a position of one half of the measured distance or at a position that will allow full thermal growth of the generator shaft when operated at rated temperatures. Mount the generator on the skid, and move the generator to within 0.010 inch of the engine. Place two 0.010-inch shims in the horizontal (9 o’clock and 3 o’clock) positions between the generator adapter and the engine flywheel housing. Raising the rear, exciter end of the generator as necessary, place two 0.010-inch shims in the vertical (6 o’clock and 12 o’clock) positions between the generator adapter and the engine flywheel housing. This will give a good starting point for alignment. Remove the vertical shims at this time. (If necessary, mark holes to be drilled on the base, and remove the generator at this time.)



Page 14



Mount a dial indicator on the generator shaft or half coupling to the flywheel radial surface for parallel alignment as shown in Figure 10. Mount a dial indicator on the flywheel coupling to the face of the generator half coupling for angular alignment as shown in Figure 10. Align the engine by rotating the prime mover in 90-degree increments and measuring total indicator runout. Tighten the generator to the base before taking each set of readings. Raise or lower the generator by adding or removing shims under the machined feet. Flywheel Dial indicator pointer for parallel alignment



Flywheel housing



Shaft



Dial indicator pointer for angular alignment



Figure 10: Alignment check



Following the final generator adjustment and runout check, remove the horizontal shims from the adaptor flywheel housing, and move the generator all the way to the adaptor. Then tighten the fasteners. Recheck alignment. Make sure angularity (face) total indicated runout does not exceed 0.001 inch per inch of generator shaft diameter and parallel (radial) total indicated runout does not exceed 0.003 inch. Torque the fasteners to the value shown in Table 3.



Page 15



Note: Clearances between the adaptor pilot and the flywheel housing recess are designed to meet the tolerance of 0.001 to 0.015 inches.



ASTM and SAE Torque Values Specific Drawings, OMS, BOMS supercede this generic table.



SCREW SIZE



Grade 2 Foot-Pounds



Ft-Lbs



#4-40 #6-32 #8-32 #10-24 #10-32 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 1.0-8 1 1/8-7 1 1/4-7 1 3/8-6 1 1/2-6



4* 8* 14 * 20 * 23 * 4 8 15 24 36 55 75 130 145 190 265 375 490 625



Grade 5 GASKETED COVERS



Grade 5



Newton-Meter



Foot-Pound



Newton-Meter



Foot-Pound



Newton-Meter



Grade 8 Foot-Pound



Newton-Meter



Tol



N-M



Tol



Ft-Lbs



Tol



N-M



Tol



Ft-Lbs



Tol



N-M



Tol



Ft-Lbs



Tol



N-M



Tol



1 2 3 5 7 10 12 25 20 22 27 40 50 60



0.4 0.9 1.6 2.3 2.6 6 11 20 32 50 75 100 175 195 250 350 500 650 850



1 2 4 6 10 14 17 24 28 30 35 55 70 90



8 17 31 50 75 ** 110 150 260 425 650 790 1100 1450 1750



2 3 6 10 15 20 25 50 60 75 80 120 150 180



11 24 42 65 100 150 200 350 575 875 1075 1500 1950 2350



3 4 8 13 20 25 20 70 80 100 100 150 200 250



5 10 12



1 2 2



7 14 16



2 3 3



24



5



32



6



10 25 40 70 100 150 200 370 600 900 1200 1750 2300 3000



2 5 10 15 20 30 40 50 60 90 120 180 230 300



14 34 54 95 135 200 275 500 800 1200 1650 2400 3100 4000



3 7 14 20 27 40 55 70 80 120 160 250 300 400



* Inch-pounds SCREW SIZE



Set Screws Foot-Pounds



Ft-Lbs



#4-40 #6-32 #8-32 #10-24 #10-32 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 1.0-8 1 1/8-7 1 1/4-7 1 3/8-6 1 1/2-6



Tol



20 *



Brass Screws



Newton-Meter



N-M



Tol



2.3



34 * 6 13 23 36 50



1 2 2 5.14 10



3.8 9 18 31 50 70



2 3 6 10 14



110 180 430 580



18 35 60 70



145 240 580 790



24 46 82 90



Foot-Pound



Ft-Lbs



4* 8* 16 * 18 * 33 * 5 9 16 26 35 55 85 120



Stainless Screws



Newton-Meter



Tol



N-M



1 2 3 5 7 10 14 23



0.4 0.9 1.8 2 2.9 7 12 22 35 45 70 115 160



Tol



2 2 4 7 9 13 19 31



Foot-Pound



Ft-Lbs



5* 10 * 21 * 24 * 33 * 6 11 21 33 45 60 100 130 205 300 430 550 700 930



Grade B Top Lock Nuts



Newton-Meter



Foot-Pound



Newton-Meter



Tol



N-M



Tol



Ft-Lbs



Tol



N-M



Tol



1 2 4 7 9 11 17 25 30 35 45 60 70 100



0.6 1.1 2.4 2.7 3.7 8 15 28 45 60 80 140 180 280 400 590 750 950 1250



2 3 5 9 12 15 23 35 40 45 60 80 100 130



6 11 18 28 44 **



1 2 2 4 6



8 15 24 38 60



1 3 3 5 12



* Inch-pounds ** For Electrical Lugs use 44 Ft-lbs (60 N-M) See Fig 4 and Fig 5



Table 3: Recommended lubricated torque values. (If no lubricant is used, increase values by 25%.)



Page 16



Metric Torque Values



SCREW SIZE



Grade 4.8 to 6.8 Foot-Pounds



Ft-Lbs



M4 x .70 M5 x .80 M6 x 1.00 M7 X 1.00 M8 x 1.25 M10 x 1.50 M12 x 1.75 M14 x 2.00 M16 x 2.00 M18 x 2.50 M20 x 2.50 M22 x 2.50 M24 x 3.00 M27 x 3.00 M30 x 3.50



1.1 2.3 4 6.5 10 20 34 54 80 114 162 202 245 360 500



Grade 8.8 GASKETED COVERS



Grade 6.9 to 8.8



Newton-Meter



Foot-Pound



Newton-Meter



Tol



N-M



Tol Ft-Lbs Tol



N-M



1 1 2 4 7 10 13 22 23 23 25 40 50



1.5 3.1 5.2 8.7 13 27 45 72 108 152 216 269 327 480 667



2 4 7 11 18 32 58 94 144 190 260 368 470 707 967



2.7 5.3 9.3 15 24 43 77 125 192 253 347 491 627 943 1289



1 2 3 5 9 13 18 29 30 31 33 52 70



Grade 2



1 1 2 4 7 10 13 22 23 23 25 40 50



Tol



2 3 5 9 15 23 32 50 50 55 65 100 130



Foot-Pound



Ft-Lbs



Tol



N-M



Tol



4



1



5



1



11 13 19



2 3 4



15 18 26



4 4 5



Grade 5



Grade 8



ASTM & SAE grade markings



Class 10.9 Class 8.8 Metric grade markings 1-NM = 0.737 ft-lbs. = 8.85 in-lbs.



Page 17



Newton-Meter



Grade 10.9 Foot-Pound



Newton-Meter



Ft-Lbs



Tol



N-M



Tol



2.9 6 10 16 25 47 83 132 196 269 366 520 664 996 1357



2 5 10 15 20 30 40 50 60 90 120 180 230



14 34 54 95 135 200 275 500 800 1200 1650 2400 3100



3 7 14 20 27 40 55 70 80 120 160 250 300



Notes: Mounting of the indicators must allow complete rotation of the prime mover. Use dial indicators that are rigid so indicator sag won’t be a factor. Using the shortest offset distance of the indicator bracket will reduce the effects of indicator droop or sag. During alignment, you may also need to compensate for engine expansion due to heating. Generator expansion is generally not considered a factor. If the genset is moved to a different location, check alignment before startup.



Single-bearing alignment Before assembling the generator to the prime mover, remove the exciter cover and adapter cover. Remove the blocking holding the drive discs to the adapter. Also make sure the generator bearing end clearance is not less than the total engine crankshaft axial movement plus 1/16 inch. The generator is shipped from the factory with 1/8-inch minimum bearing end clearance. (This dimension is recorded on the Factory Recorded Dimensions sheet, packaged with the generator.) Measure the distance from the end of the exciter shaft extension to the bearing housing on the endbracket (dimension A in Figure 11). This dimension is recorded on the Factory Recorded Dimensions sheet, packaged with the generator. If the dimensions do not match, move the rotor axially relative to the stator until the dimensions are equal.



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.



Endbracket Exciter field



Bearing



A



Shaft extension



Figure 11: Generator coupling check



Page 18



Check the engine flywheel housing pilots’s radial and face runout by mounting a dial indicator and measuring the flywheel to the flywheel housing as shown in Figure 5. See Table 1 for maximum allowable runout. Check the engine flywheel’s radial and face runout by mounting a dial indicator and measuring the flywheel housing to the flywheel as shown in Figure 6. See Table 2 for maximum allowable runout. Measure the generator drive plate diameter (dimension S of Figure 12) and flywheel bore diameter (dimension B of Figure 13). Drive plate diameter must not be greater than the flywheel bore diameter. Also check to make sure the hole centers match (dimension W of Figure 12 and dimension C of Figure 13). Measure the axial distance from the surface on the generator adapter to the outside surface on the drive disc coupling plates (dimension Y in Figure 12). This dimension is recorded on the Factory Recorded Dimensions sheet, which was packaged with the generator. If the dimensions do not match, move the rotor axially relative to the stator until the dimensions are equal.



Y



Drive plates



Adaptor



Fan



Shaft



S



W



A



Bolt holes



Figure 12: Single bearing generator drive plate and adaptor



Page 19



Caution: Never grind the OD of drive discs or attempt to drill out the holes. If the dive discs do not fit properly, use different discs or a different flywheel.



Caution: The number and thickness of drive discs are specified for torque requirements. Do not remove drive discs to compensate for spacing.



Measure the axial distance from the machined surface on the engine flywheel housing the bottom of the flywheel drive disc recess (dimension G in Figure 13). Make sure the difference between dimensions Y (of Figure 12) and G are less than 1/32 inch. If G is more than Y, install additional spacers between the drive discs and the generator hub. If Y is more than G, remove spacers between the drive discs and generator hub. Tapped bolt holes



C



B



G



Flywheel



Figure 13: SAE flywheel and adapter



Install the generator to the engine. Make sure the drive discs seat in the recess of the flywheel housing. Secure the generator to the engine (drive discs to flywheel, adapter to flywheel housing), and the base. Use lock washers on all bolts. Torque the adapter and drive discs in a crisscross pattern to the values in Table 3. Ensure that the bolts in the flywheel do not bottom out. If they are too long or cannot be tightened with a socket or box wrench, use 1/4 to 3/8inch long spacers inserted in the bolts as shown in Figure 14 to increase the clearance between the bolt head and the flywheel. Lock washer Bolt Spacer



Drive hub Drive plates Flywheel



Figure 14: Disc-to-flywheel installation Page 20



Occasionally, there is insufficient clearance to install the bolts that fasten the drive discs to the engine flywheel, and the fan will have to be temporarily moved to accommodate this. This situation will typically occur with several types of generators: • With the three-frame units that have an aluminum fan, loosen the fan hub bolts to move the fan. After installing the drive disc-to-flywheel bolts, move the fan back so the rotor-side edge is flush with the air opening and the minimum distance between the windings and the fan is 3/8 inch. Torque the fan hub bolts to 75 ft-lbs. • With sheet metal fans with cast hubs that are in turn mounted on the drive hub, mark the drive hub as closes as possible to the fan hub. Loosen the two set screws, the fan clamping bolt, and the fan bolts. Wedge the fan open, and move it out of the way (See Figure 15). After attaching the drive discs-to-fly wheel bolts, align the fan hub to the mark to move the fan back to its original position. Ensure the key is fully in place under the fan hub and positioned so the set screw will press on the key. Tighten the fan hub clamping bolt and the set screws. Install the fan bolts and torque them according to Table 3.



Fan Drive discs



Fan bolts



Keyway



Set screw Key



Bolt holes Alignment mark on drive hub Fan hub bolt Fan hub



Figure 15: Moving sheet metal fans



Page 21



Note: The generator with sheet metal fans and cast fan hubs is shipped from the factory with the fan 1/2 to 3/4 inch from the fan baffle and clear of the inside adaptor for optimum air flow through the exhaust screen.



After installing the drive disc-to-flywheel bolts, check the runout of the generator shaft by placing the base of a dial indicator on the generator frame and positioning of the probe on the shaft as shown in Figure 16. If the total indicated runout exceeds 0.003 inch, remove the drive discs bolts, and rotate the generator relative to the engine flywheel. Reinstall the bolts, and check the runout again. Recheck the shaft-end-to-bearing-housing distance (dimension A in Figure 11). Mount the brushless exciter armature assembly to the generator shaft (as described in the assembly procedures below). Adapter



Fan Dial indicator pointer



Shaft



Drive plates



Drive hub



Figure 16 Runout check



Page 22



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 below. 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. On larger generators 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 When the generator has optional space heaters to prevent water condensation during long periods of downtime, connect the space heaters so they start when the generator is turned off and stop when the generator is switched on. Some generators with space heaters have thermostats. The thermostat should be set above the dewpoint. Refer to the electrical diagrams for the space heater characteristics.



Page 23



Warning: The space heaters are designed to be energized when the generator is shut down. They are hot enough to cause skin burns. Terminals for power at the space heaters are live during operation. Disconnect power to the space heaters before removing the generator covers.



Caution: Do not pry on the fan.



Inspection before startup After electrical connections have been made, perform the following checks:



Note: For specific lubrication instructions, always refer to the bearing lubrication sheet that came with your manual or the lube plate on the generator.



•



Check all the connections to the electrical diagrams provided.



•



Secure all covers and guards.



•



Turn the rotor slowly with the appropriate starting mechanism (bar the engine or flywheel) through one revolution to see if the rotor turns freely.



•



Check the bearings to see they are properly lubricated.



•



Determine the direction of the engine rotation, and make sure that it matches the rotation of the generator.



•



Make sure the power requirements comply with the data on the generator nameplate.



•



Make sure that the engine-generator set is protected with an adequate engine governor and against excessive overspeed.



•



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).



•



Remove tools and other items from the vicinity of the generator.



Page 24



Operation Initial startup: generators with both automatic and manual voltage control 1. Disconnect the generator output from the load by opening the main circuit breaker. 2. Turn the manual voltage adjust rheostat fully counterclockwise. 3. Put the auto-manual switch in the manual position. 4. Start the prime mover, and bring the set to rated speed. Turn the manual voltage adjust rheostat to reach rated voltage. Close the 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 and voltage regulation. Apply load in steps until the rated load is reached. 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 only (generator has an automatic voltage regulator (AVR) with no auto-manual switch) 1. Disconnect the generator output from the load by opening the main circuit breaker. 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 reach. 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 25



Caution: Do not actuate the auto-manual switch with the full load applied to the generator. Whenever possible, stop the generator before switching.



Restoring residual magnetism/field flashing



Note: If the polarity of the exciter is reversed by flashing the field, it may be corrected by interchanging the battery leads.



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 nonoperation 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. 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 17.



- 12 or 24 V battery



+ 3 amp or larger diode



FF+



Voltage regulator



EF1



EF2



Figure 17: Field flashing setup with the field wires connected to the regulator Page 26



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 derating 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 18, Guide to allowable phase unbalance (which is based on a 10% equivalent negative sequence current). Min. current in any phase (% of rated)



100



80



Allowable unbalance



60



Excessive unbalance



40



20



0



20



40



60



80



100



Max. current in any phase (% of rated)



Figure 18: Guide to allowable phase unbalance



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. Loss of field excitation can result in the unit operating out of synchronization with the system when operating is 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 27



Caution: Operating the unit beyond nameplate values may cause equipment damage or failure.



Caution: Refer to the voltage regulator manual for complete details and possible additional instructions. Damage to the rotating diodes, generator, and voltage regulator can be caused if the regulator is operated improperly.



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.



Caution: Do not make connections or otherwise make contact with the generator leads or other devices connected to them unless the genset is stopped and the phase leads are grounded.



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 as 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 19. The voltage rating of the series lamps must equal the voltage rating of the transformer-low voltage winding. 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. Page 28



System bus



Load switch



Synchronizing lamps



Load lines from the incoming generator



Figure 19: Synchronizing paralleled generators with test lamps



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. 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 29



Maintenance Warning: Do not service the generator or other electrical machinery without deenergizing and tagging the circuits as out of service. Dangerous voltages are present, which could cause serious or fatal shock.



Schedules 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.



Note: For specific lubrication instructions, always refer to the bearing lubrication sheet that came with your manual or the lube plate on the generator.



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.



Page 30



Every 8000 hours or 1 year of operation Check insulation resistance to ground on all generator windings, 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) degreaser 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 31



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 32



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. Remove stubborn accumulations of dirt with a detergent or solvent that won’t damage the paint or metal surfaces. Use a vacuum to clean 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 until acceptable insulation resistance values are obtained at room temperature. See the insulation resistance procedures below for minimum recommended values. Page 33



Warning: When using cleaning solvents, ensure adequate ventilation and user protection.



Caution: The insulation resistance tests are usually made on all or parts of an armature or field circuit to ground. They primarily indicate the degree of contamination of the insulating surfaces or solid insulation by moisture and other conducting influences and will not usually reveal complete or uncontaminated ruptures. Note: The insulation resistance value increases with decreasing winding temperatures. All readings must be corrected to winding temperatures. Use Table 4 for converting megger readings to other temperatures (e.g., 100 megohms at 50º C is converted to 170 megohms: 1.7 x 100). Winding Temp (ºC)



Conversion factor



10 20 30 40 50 60 70 80 90 100 110 120



0.23 0.37 0.6 1 1.7 2.7 4.5 7.5 14 23 38 61



Electrical contacts: Clean electrical contacts, switch contacts and terminals with an approved contact cleaner. Do not file contacts. Insulation resistance tests at low voltage Insulation tests are conducted for two reasons: to discern existing weakness or faults or to give some indication of expected service reliability. Insulation resistance tests are based on determining the current through the insulation and across the surface when a DC voltage is applied. The leakage current is dependent upon the voltage and time of application, the area and thickness of the insulation, and the temperature and humidity conditions during the test. Refer to the following electrical measurement procedures for testing detail. Contact Kato Engineering or refer to IEEE Standard. 432-1992 when more extensive insulation tests are required When checking insulation resistance with a megger, first verify the ground path. Connect one test lead to a ground point. Then connect the second test lead to another ground location to prove the ground connection. Once the ground path has been proven, the second test lead can be connected to the leads of the component to be tested. Exciter field (stator) and PMG armature (stator) 1. Disconnect the exciter leads from the terminals in the terminal box or the voltage regulator. 2. Connect exciter leads to one clamp of 500-volt megger, and connect the other clamp to the exciter field frame.



factor for resistance readings



3. Apply 500 V from the megger, and measure the resistance reading after 1 minute. The reading must be a minimum of 50 megohm. If it is not, refer to the cleaning or dry out procedures.



Warning: Never apply the megger to the rotating rectifier, the voltage regulator, or generator accessories (e.g., temperature detectors, space heaters).



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.



Table 4: Temperature conversion



Note: New generators should measure about 100 megohms minimum of insulation resistance when meggered. Generators that read 50 megohms or less should be dried out according to the dry out procedures here. Generators with insulation resistance readings of 10 megohms or less should be investigated.



5. Repeat steps 1-4 for the PMG armature (stator). Exciter armature 1. Disconnect the exciter armature leads from the rotating rectifiers. 2. Connect the leads of the exciter armature to one clamp of a 500-volt megger, and connect the other clamp to a suitable connection on exciter sleeve or shaft.



Page 34



3. Apply 500 V from the megger, and measure the resistance reading after 1 minute. The reading must be a minimum of 50 megohms. If it is not, refer to the cleaning or dry out procedures.



Winding rated voltage (V)*



4. Ground the exciter leads to the exciter sleeve or shaft after disconnecting the megger. This will allow the voltage build up to be properly discharged. Main rotor 1. Disconnect the generator field leads from the positive and negative terminals of the rotating rectifier assembly. 2. Connect the positive and negative leads to one clamp of the megger, and connect the other clamp to the shaft. 3. Apply voltage from the megger, and measure the resistance reading 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.



12000



2500-5000 5000-10000 Table 5



Guidelines for DC voltages to be applied during insulation resistance tests



Rated line-line voltage for three-phase ac machines, and line-to-ground voltage for single-phase machines, and rated direct voltage for dc machines or field windings.



a



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. 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.



Page 35



Caution: Do not apply heat too rapidly. It could damage the windings.



Caution: Do not apply heat too rapidly. It could damage the windings.



Dry out procedures If the insulation resistance readings are below the recommended minimum 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 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.



Note: For specific lubrication instructions, always refer to the bearing lubrication sheet that came with your manual or the lube plate on the generator.



Bearing lubrication Shielded or sealed ball bearings: Shielded or sealed ball bearings are factory packed with lubricants and generally can be operated several years without requiring replenishment or change of the grease. If repacking the grease is necessary, disassemble the machine, clean the bearings, and repack the bearings about 1/2 full using a high quality ball bearing grease, which must be capable of lubricating satisfactorily over a temperature range of the lowest ambient temperature to 250º F (121o C). Regreaseable ball or 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. 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.



Page 36



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



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 diode



Standard diode



Figure 21: Testing the rotating rectifier with an ohmmeter



Page 37



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 ohmeter or makeshift test lamp, consisting of standard flashlight batteries and a flashlight and built as shown in Figure 22, 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 38



Disassembly Overall disassembly 1. Remove the terminal box cover, and disconnect the load leads and all other leads. Tag the leads to ensure they are correctly connected when the generator is reassembled. 2. Remove the bolts securing the generator to the base and prime mover, and move the generator to an area that allows sufficient room for disassembly.



Note: The following procedures are meant to be a general guide. Procedures for your unit may vary. Warning: Ensure the generator has stopped and is de-energized before disassembly. Warning: Use a hoist and slings or chains to support components during removal. Use lifting devices that are selected for generator component weights. Be extremely careful not to damage components.



3. Remove the coupling or drive plates.



4. Remove the exciter cover. 5. Remove the clips securing the exciter field leads to the exciter frame and endbracket. Disconnect the leads and remove the exciter frame/ stator and/or exciter-PMG frame/stator. 6. Remove the (optional) PMG and exciter armature as described below. 7. Support the shaft. Remove the exciter-end endbracket bolts, and remove the endbracket. Tap lightly with a rubber or fiber mallet to loosen the endbracket if necessary. Repeat with the drive-end endbracket (if applicable). 8. Remove the fan from the hub where applicable. If necessary, make sure to mark the location of the fan for reinstallation. 9. Float out the rotor (see Figure 23). First attach a pipe over the shaft on the drive end. Attach slings around the pipe on one end and around the shaft on the opposite end. Lift up the rotor, and move it out, resting the rotor as the slings are moved down the pipe for the next lifting stage.



Warning: Make sure the pipe is strong enough to support the weight of the rotor and that it does not have rough edges on the inside, which could damage the shaft. Caution: To prevent tension on the shaft, put the slings around the largest shaft step possible. Caution: Make sure the rotor does not rest on the stator during the stages of movement. Make sure the rotor does not hit the stator.



Page 39



Figure 23: Floating the rotor



Exciter armature and PMG removal (see Figure 24) 1. Remove the exciter cover. 2. Remove the retaining bolt and washer. 3. Disconnect the field wires on the rotating rectifier assembly. Warning: Pull the PMG off straightly. The assembly may pull toward other steel components. Be careful that your fingers or hands do not get pinched.



Caution: Ensure the generator field wires are flat in the wireway so they don’t tear during pulling. Do not pull on the edges of the heat sinks or on the exciter armature windings.



4. If the generator has a PMG rotor, pull it off separately using hand force. Wrap the PMG rotor in plastic to avoid contamination with metal filings. Note: Some inboard PMG assemblies use a locknut to secure the PMG rotor. See figure 26. To remove the PMG rotor with a lock nut: a) On the lockwasher, pry up the tab that is bent down in a notch of the locknut. Then unscrew the locknut with a spanner wrench, and remove the lockwasher. b) Pull the PMG rotor straight back. Take care not to cock the PMA when pulling it off. c) Wrap the PMG rotor in plastic to avoid contamination with metal filings. 5. Slowly pull the armature assembly off of the generator shaft. If the exciter can not be pulled off by hand, use a hydraulic jack as shown in Figure 25. 6. Remove the key from the keyway in the generator shaft.



Page 40



PMG aligning Hole in sleeve for field pin wires (some models PMG may have a slot) Retaining Rectifier washer Retaining bolts



PMG rotor aligning



Retaining



A



B



A



B



Field leads Wire slot



Keyway Key



Exciter armature



Exciter armature sleeve



Shoulder



A-A end view of exciter



B-B cutaway view of shaft Wire slot



Figure 24: Exciter armature assembly



Bolt holes Shoulder Key



Keyway



Plate



Figure 25: Pulling the armature assembly



Hydraulic jack Exciter sleeve



Threaded rod



Locknut



Figure 26: PMG rotor with locking nut



Lock washer and tab



Page 41



Bearing removal 1. Remove the endbracket(s) to expose the bearing(s). 2. Use a puller to remove the bearing from the shaft end with a cap. If the bearing is going to be used again, make sure the puller supplies pressure only against the bearing inner ring (see Figure 26). Cap to protect shaft end



Puller against bearing



Caution: Make sure all components are clean before assembly. Note: Torque fasteners to the values specified in Table 3 unless otherwise specified.



Outer ring



Inner ring



Figure 27: Pulling the bearing



Assembly Bearing installation (done prior to installing the rotor) 1. Heat the bearing to 220º F (104o C) - 250º F (121o C) in a clean oven or with an induction heater. 2. Start the heated bearing on the shaft. Then use a fiber or soft metal tube to tap the bearing into place. 3. Ensuring that pressure is applied only to the bearing inner ring, press the bearing onto the shaft until the inner ring seats against the bearing shoulder on the shaft. Assemble the rest of the generator after the bearing has cooled.



Page 42



Overall assembly 1. Float in the rotor until the rotor and stator laminations line up. Position the rotor such that a full pole face is at the bottom. 2. Install the endbrackets. Support the rotor during installation. Put an corrosion inhibitor on the bare mating surfaces to prevent rust. 3. Install the exciter armature and optional PMG as described below. 4. Install the covers. 5. Install the coupling or drive plates. 6. Reconnect the load leads and exciter leads. Exciter armature and PMG installation (see Figure 24) 1. Clean the shaft and inside of the exciter sleeve. 2. Place the key in the slot in the shaft. 3. Lay the generator field wires flat in the wireway with the wire ends protruding past the end of the shaft. 4. Position the exciter armature 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. 5. With hand force, push the exciter armature assembly over the shaft, so the end of the sleeve is against the shoulder on the shaft. When it is part of the way onto the shaft, start the field lead wires through the wire hole or slot in the exciter sleeve. 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. 6. Connect the exciter armature wires to the rectifier terminals. 7. If the generator has a PMG, place it onto the end of the exciter sleeve. Make sure it is aligned with the pin slot in the end of the exciter sleeve. 8. Install the retaining washer and bolt, and torque (60 ft-lbs for a 1/2inch diameter bolt; 200 ft-lbs for a 3/4-inch diameter bolt). 9. Install the exciter frame/stator and/or exciter-PMG frame/stator. Install the clips securing the exciter field leads to the exciter frame and endbracket and connect the leads.



Page 43



Caution: Do not pound on the rectifier or armature windings.



Note: To measure air gap, measure completely around the gap between the exciter armature and exciter field with a feeler gauge. Keep the gauge at the tightest point, and turn the generator over to measure the air gap as the rotor turns.



10. Measure the air gap between the exciter armature and exciter field and between the PMG rotor and PMG stator. If the air gap of the armature is less than specified in Table 5 or if the air gap of the PMG is less than 0.020 inch, check 1) generator-engine alignment, 2) check for bearing wear, 3) check for misalignment of the armature, PMG or stator.



Caution: Do not pry on the fan. Exciter armature Minimum air gap diameter (in.) (in.) 5 3/4 9 7/8 12 1/2 16 1/4



0.014 0.014 0.018 0.035



Table 5: Exciter air gap



11. Install the exciter cover. Warning: If necessary, remove the covers around the space heaters to reduce the risk of fire. Caution: Grease used in ball and roller bearing generators is subject to time deterioration. Before placing the unit into service after long-term storage, check the bearings for corrosion, and replace the grease.



Storage If the generator is not installed in its operating location as soon as received, store it in a clean, dry area, not subject to vibrations or sudden temperature or humidity changes. 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%. If possible, storage should be in an ambient temperature of approximately normal room temperature. 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: Install desiccant bags in the exciter cover and inside the end bells. Vacuum seal the unit in a covering of plastic or other material designed for that purpose. Adequately tag the generator to ensure that preservative greases and desiccant bags are removed before the unit is placed in operation. If space heaters are supplied, energize them to keep condensation from the windings. For storage longer than 2 months, rotate the shaft a minimum of 10 revolutions every 60 days. When the unit is taken out of storage, check the insulation resistance on all windings. (See the maintenance section).



Page 44



Troubleshooting Guide (corrective maintenance) Between regular preventive maintenance inspections, be alert for any signs of trouble. Correct any trouble immediately. See Table 6 for symptoms, causes and remedies.



Warning: Problems left uncorrected can result in injury or serious damage, which can result in costly repairs and downtime.



Symptom



Cause



Remedy



No Voltage



Open voltage regulator, circuit breaker or fuses



Check. Reset the circuit breaker or replace fuses if open.



Overvoltage, undervoltage, or overload devices tripped (when protective devices are incorporated into the circuit)



Check for the cause of the abnormal condition. Correct any deficiencies. Reset devices. 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 field poles



Restore residual magnetism or flash field. When 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 regulator



See troubleshooting of voltage 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.



Shorted leads between the exciter armature and generator field



Test and repair.



Incorrect stator connections



Check the connections, and reconect



Low voltage



Page 45



Symptom



Cause



Remedy



Low voltage (cont.)



Improper adjustment of voltage adjust rheostat



Adjust 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 temperature



Improve the ventilation of the generator. Field current can be increased providing the generator temperature rating stamped on the nameplate is not exceeded.



Defective rectifiers in rectifier assembly (stationary)



Check rectifier assembly. Replace defective fuses or rectifiers.



Excessive load



Reduce load to rated value.



Defective bearing



Replace the bearing.



Improper speed of engine driven generator set due to defective governor, ignition system, or carburetor



Check and correct deficiencies.



Voltage regulator not operating properly



Check the regulator. Adjust, repair or replace.



Prime mover speed fluctuating



Check frequency and voltage of incoming 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.



Voltage regulator not operating properly



Check the regulator. Adjust, repair or replace.



Improper adjustment of voltage adjust rheostat or voltage regulator



Adjust rheostat and/or voltage regulator.



Voltage regulator not operating properly



Check the regulator. Adjust, repair or replace.



Fluctuating voltage



High voltage



Page 46



Symptom



Cause



Remedy



Overheating



Clogged ventilating screens and air passages



Clean all screens and air passages.



Dry or defective bearings



Replace defective bearings.



Coupling misaligned



Align the generator set.



Generator field coils shorted or grounded



Test field coils for shorts. Replace shorted rotor or return it to the factory for repair.



Unbalanced load or overload, low PF



Adjust load to nameplate rating.



Defective or dry bearings



Replace defective bearings.



Misalignment of generator and prime mover



Align the generator set.



Generator not properly mounted



Check mounting. Correct defective mounting.



Transfer of vibration from another source



Isolate the generator set from the source of vibration by installing vibration dampeners between generator set base and foundation.



Vibrations



Table 6: Troubleshooting



Page 47



Appendices List of equipment required for installation and maintenance:



Test equipment Ammeter Multimeter Thermometer Megger Resistive Bridge



Notes Clamp-on, 0 to 500 amp range for measuring of electrical current. Digital, for measuring voltage, current, frequency and resistance. For measuring temperature in Celsius To measure insulation resistance. To measure resistance of windings.



Special tools Bearing puller Exciter puller



For changing bearing. For pulling exciter armature



Standard tools Cable tool Flashlight Grease gun Hammer Lamp (incandescent) Screwdrivers Screwdrivers Wrench Wrench Wrench set Wrench set Wrench set Vacuum



Crimping As required For lubricating bearings Soft-faced Safety light Standard, sized as required Phillips, sized as required Adjustable, 12-inch Torque 0 to 100 ft-lb Allen, 1/8 to 1/2 inch Socket, 1/4 to 1 Inch with 3/8 and 1/2 inch drive Standard, open-end/box-end combination sized 1/4 to 1 inch Electric with nonmetallic nozzle



Materials Air Corrosion inhibitor Covering material



Detergent Gloves Gloves Heaters



Plastic Rags Water Tags



Compressed, dry. Nox-Rust VC #10 Oil or equivalent Waterproof desiccant bags for protection from moisture during long-term equipment storage As required for cleaning Chemical-protective Electrical-protective Space Heater, for eliminating excess moisture in damp areas and dry out of motor or generator windings Protection for long-term storage As required for cleaning Warm and clean, for cleaning Warning and cautions



Page 48



Main part location



Exciter cover Exciter stator Lead connection box



Fan



Drip proof cover



Rectifier



Adapter



Exciter armature



Endbracket Rotor



Coupling hub



Stator windings Feet Bearing



Page 49



FOR



INRUSH CURRENT REDUCTION MODULE ICRM-7, ICRM-15



INTRODUCTION The Inrush Current Reduction Module (ICRM) prevents damage to a protected voltage regulator during power-up by limiting inrush current to a safe level. Without inrush protection, the inrush current is limited only by the level of the power source impedance. The lower the impedance, the greater the risk of damaging the regulator from excessive inrush current. Devices with a pulse-width modulated (PWM) power stage are especially vulnerable to high inrush current due to a large amount of capacitance inherent to the design. However, voltage regulators that use SCR-type power stages do not require the protection of an ICRM since these regulators do not have a large amount of capacitance in the power stage. When a voltage regulator with a PWM power stage is energized, the ICRM limits the inrush current by adding a high level of resistance in series with the voltage regulator power input. Once the inrush current subsides, the series resistance diminishes quickly to allow nominal, steady-state current flow.



APPLICATION Applications where a voltage regulator is powered by a permanent magnet generator (PMG), auxiliary winding, or generator output (shunt fed) usually do not require the protection of an ICRM. These sources usually have a higher source impedance which inherently minimizes inrush current. Also, these sources are typically connected directly to the voltage regulator with no interposing relays, contactors, or switches. If this is the case, then no inrush occurs since the source voltage ramps up to its rated value. However, if rated or near rated voltage is applied to the voltage regulator, then some amount of inrush current is expected and an ICRM should be considered. Typically, voltage regulators in these applications receive power from a station service bus that is switched by a relay or contactor. Applications where a PWM type voltage regulator is powered by a low-impedance source need an ICRM to minimize the amount of inrush current. To summarize, if the voltage that powers the voltage regulator ramps up to nominal as the generator comes up to rated speed, then an ICRM is not needed. If this is not the case, an ICRM should be used. If you are unsure whether your application requires an ICRM, contact Basler Electric Technical Sales Support for assistance. ICRM Versions Two versions of the ICRM are available. Each version is uniquely suited to protect a specific family of Basler Electric products. Table 1 lists each ICRM model, its part number, and the compatible products.



Model Number



Table 1. ICRM Cross-Reference Part Number Compatible Products



ICRM-7



9387900103



DECS-100



ICRM-15



9387900104



AVC63-12, AVC125-10, DECS-200



CAUTION If operating power is removed from an energized ICRM, a minimum interval of five minutes should elapse before operating power is restored. This cool-down interval allows the ICRM to regain its ability to limit inrush current.



SPECIFICATIONS The following electrical and physical specifications, type tests, and certifications apply to the ICRM.



Publication



Revision



9387900990



A



First Printing: 02/05 Revised: 08/05



Copyright 2005



Electrical Specifications Input Voltage: 90 to 277 Vac, 90 to 300 Vdc Input Frequency: dc, 50 to 420 Hz Input Current ICRM-7: 9 Aac ICRM-15: 18 Aac Power Dissipation: 25 W Physical Specifications Temperature Operating: –25 to 70°C (–13 to 158°F) Storage: –40 to 70°C (–40 to 158°F) Dimensions: Refer to Figure 1 Weight: 227 g (8 oz) Type Tests Dielectric:



Withstands 2,000 Vac for one minute in accordance with IEC 60255-5.



Shock:



Withstands 15 G in three perpendicular planes in accordance with IEC 60255-21-1.



Vibration:



Tested in accordance with IEC 60255-21-2. Withstands 2 G in each of three mutually perpendicular axes, swept over the range of 10 to 500 Hz for a total of six sweeps, 15 minutes each sweep.



Humidity:



Qualified to IEC 68-1, IEC 68-2-28.



Certifications UL Recognition:



cURus recognition per UL Standard 508 and CSA Standard C22.2 No. 14.



CE Qualification:



This product meets or exceeds the standards required for distribution in the European community.



INSTALLATION The ICRM may be installed in any environment where the conditions do not exceed the capabilities listed in the Specifications section. Mounting For maximum cooling, the ICRM should be mounted on a vertical surface and oriented so that the ventilation holes are located at the top and bottom of the unit. CAUTION Case may become hot during operation. Figure 1 shows the ICRM mounting dimensions. Mounting dimensions are identical for both ICRM models. Dimensions are shown in inches with millimeters in parenthesis. Connections Figure 2 illustrates typical connections for an application using single-phase operating power. The ICRM is not phase sensitive. Figure 3 illustrates typical connections for an application using three-phase operating power. Table 2 lists the terminal connections for each voltage regulator that is compatible with the ICRM.



Table 2. ICRM Terminals Cross-Reference ICRM Output Terminals Voltage Regulator A-OUT B-OUT C-OUT AVC63-12, AVC125-10 DECS-100 DECS-200 Page 2



First Printing: 02/05 Revised: 08/05



26 3 C2



28 4 C3



30 5 C4 Revision



Publication



A



9387900990



Wiring requirements are subject to the specifications of the voltage regulator. Refer to the appropriate device instruction manual for wire sizing, fuse recommendations, and terminal designations.



TROUBLESHOOTING The ICRM contains no serviceable components. Replacement of the ICRM is recommended in the event of a failure. If the protected device is not receiving operating power, check the following: • •



Verify that the ICRM connections between the power source and voltage regulator are correct. Confirm that the voltage supplied by the power source is sufficient to energize the voltage regulator.



If operating power is applied to the input terminals of the ICRM but voltage is not present at the output terminals, remove operating power, disconnect all ICRM wiring, and perform the following procedure. 1. Connect a suitable ohmmeter across the A-IN and A-OUT terminals. The resistance measured across the IN and OUT terminals should be approximately 2.0 ohms for the ICRM-7 and 0.5 ohms for the ICRM-15. If an open circuit or short circuit is detected, the ICRM should be replaced. 2. Repeat Step 1 for the B-IN and B-OUT pair of terminals and the C-IN and C-OUT pair of terminals.



Figure 1. ICRM Dimensions



Publication 9387900990



Revision A



First Printing: 02/05 Revised: 08/05



Page 3



Figure 2. Typical ICRM Connections, 1-Phase Operating Power



Figure 3. Typical ICRM Connections, 3-Phase Operating Power



Page 4



First Printing: 02/05 Revised: 08/05



Revision



Publication



A



9387900990



INSTRUCTION MANUAL for



DECS-100 Digital Excitation Control System



Publication: 9 2875 00 991 Revision: E 03/04



INTRODUCTION This instruction manual provides information about the operation and installation of the DECS-100 Digital Excitation Control System. To accomplish this, the following information is provided.



C C C C C C



General Information and Specifications Human-Machine Interface Functional Description Installation BESTCOMS Communication Software Troubleshooting



WARNING! To avoid personal injury or equipment damage, only qualified personnel should perform the procedures in this manual. Lethal voltage is present at the rear panel when the unit is energized. Rear panel connections should be made only when the unit is de-energized.



CAUTION The Manual mode excitation level must be evaluated prior to enabling this feature. If the level of excitation current is inappropriate for the generator, severe damage to the generator may occur. Improper PID numbers will result in poor system performance or system damage. When applying operating power to the DECS-100 for programming purposes, observe the precautions called out in Section 4, Installation, Preliminary Setup. When programming the DECS-100 without the generator spinning, the connections to DECS-100 terminals F+ and F– should be removed. Before uploading a settings file, remove operating power from the DECS-100, disconnect the field wiring from terminals F+ and F–, and re-apply operating power to the DECS-100.



NOTE Be sure that the DECS-100 is hard-wired to earth ground with no smaller than 12 AWG copper wire attached to the ground terminal on the rear of the unit case. When the unit is configured in a system with other devices, it is recommended to use a separate lead to the ground bus from each unit.



DECS-100 Introduction



i



First Printing: March 2001 Printed in USA Copyright © 2004 Basler Electric, Highland, IL 62249 USA March 2004



CONFIDENTIAL INFORMATION of Basler Electric, Highland, IL. It is loaned for confidential use, subject to return on request, and with the mutual understanding that it will not be used in any manner detrimental to the interest of Basler Electric.



It is not the intention of this manual to cover all details and variations in equipment, nor does this manual provide data for every possible contingency regarding installation or operation. The availability and design of all features and options are subject to modification without notice. Should further information be required, contact Basler Electric.



BASLER ELECTRIC ROUTE 143, BOX 269 HIGHLAND, IL, 62249 USA http://www.basler.com, [email protected] PHONE 618-654-2341 FAX 618-654-2351 ii



DECS-100 Introduction



PRODUCT REVISION HISTORY The following information provides a historical summary of the changes made to the DECS-100 embedded firmware, hardware, and BESTCOMS software. The corresponding revisions made to this instruction manual (9 2875 00 991) are also summarized. Revisions are listed in chronological order.



Firmware Version and Date



Change



1.09.XX, 01/01



•



Initial release



1.11.XX, 07/01



•



Enabled the protection function during the first five seconds of operation. Modified the OEL setpoint scale factor to be compatible with BESTCOMS version 1.03.00. Added the scale factor for per unit gain. Established minimum voltage regulation at 30 percent of nominal sensing voltage.



• • •



1.12.XX, 03/02



•



Added register to detect CT type.



BESTCOMS for Windows® OS Version and Date



Change



1.02.XX, 02/01



•



Initial release



1.03.XX, 08/01



•



Changed OEL scale from 100 to 1,000 to match the change in firmware version 1.11.01. Changed OEL default setting from 1 to 15. Changed the default for all protection functions to enabled. Added support for French regional settings.



• • • 1.04.XX, 04/02



• • • • • •



Made BESTCOMS compatible with all older firmware versions. Added support for all regional settings. Enabled reading of secondary CT Value for units with firmware version 1.12.01 and higher. Simplified the Analysis screen. Added feature to calculate and send voltage matching reference for different generator and bus PT ratios. Changed minimum Ki setpoint from 0 to 0.01.



BESTCOMS for Palm OS® Version and Date



Change



1.01.XX, 01/01



•



Initial release



1.02.XX, 08/01



• • •



Added a Check for New Version button to the Contact Basler screen Added a date/time stamp to the “Save to File” names Added version checking



1.03.XX, 04/02



• •



Added password protection Improved version checking function



DECS-100 Introduction



iii



Hardware Version and Date



Change



E, 01/01



•



Initial release



F, 05/01



•



Deepened potting shell



G, 10/01



•



Began supplying mounting screws



H, 02/02



• •



SIL-PADS were added between some power components and the heat sinks. Added manufacturing origin to the rear label.



J, 07/02



•



Revised EEPROM



K, 02/03



•



Replaced transistor Q8B1 with an improved part



L, 03/03



•



Incremental improvements to firmware and BESTCOMS



M, 01/04



•



Improved flash memory retention



Manual Revision and Date



Change



None, 03/01



•



Initial release



A, 03/01



•



In Section 5, BESTCOMS Software for the Windows® Operating System and Section 6, BESTCOMS Software for the Palm OS® Platform, Step 2 of Installing BESTCOMS was revised to reflect the addition of an auto-start utility for the DECS-100 CD-ROM.



B, 08/01



•



Added Embedded Software subsection to Section 5, BESTCOMS Software for the Windows Operating System. Corrected various minor errors throughout the manual.



• C, 05/02



• •



D, 01/03



• •



E, 03/04



• •



•



iv



Revised the torque specification for the mounting screws supplied with the unit. In Section 5, BESTCOMS Software for the Windows® Operating System and Section 6, BESTCOMS Software for the Palm OS® Platform, text and illustrations were revised to accommodate software enhancements. Revised Voltage Matching Time Adjustment Range from 0 to 300 seconds to 1 to 300 seconds through manual. Corrected figure number references in Sections 5 and 6. Added Operating Power Considerations During DECS-100 Programming to Section 4, Installation, Preliminary Setup. Added caution box regarding application of operating power during DECS-100 programming to Section 5, BESTCOMS for Windows® OS and Section 6, BESTCOMS for Palm OS®. Corrected CT ratio setting range stated in Section 5.



DECS-100 Introduction



CONTENTS A detailed table of contents is provided at the start of each manual section. The manual sections are ordered as follows.



Section 1



General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1



Section 2



Human-Machine Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1



Section 3



Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1



Section 4



Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1



Section 5



BESTCOMS Software for the Windows® Operating System . . . . . . . . . . . . . . 5-1



Section 6



BESTCOMS Software for the Palm OS® Platform . . . . . . . . . . . . . . . . . . . . . . 6-1



Section 7



Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1



DECS-100 Introduction



v



SECTION 1 • GENERAL INFORMATION TABLE OF CONTENTS SECTION 1 • GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL AND STYLE NUMBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Style Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Voltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bus Voltage Sensing (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessory Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communication Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Alarm Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AVR Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FCR (Manual) Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Var Operating Mode (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PF Operating Mode (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field Overvoltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field Overcurrent Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Overvoltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Soft-Start Function (AVR Mode Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metering (BESTCOMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UL Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CSA Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Patent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



1-1 1-1 1-1 1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-3 1-4 1-4 1-4 1-4 1-4 1-4 1-4



Figures Figure 1-1. DECS-100 Style Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Figure 1-2. Typical V/Hz Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3



DECS-100 General Information



i



SECTION 1 • GENERAL INFORMATION GENERAL The Basler Digital Excitation Control System (DECS-100) is an electronic, solid-state, microprocessor based control device. The DECS-100 regulates the output voltage of a brushless, ac generator by controlling the current into the generator exciter field. Input power to the DECS-100 can be from a multi-pole, high-frequency, permanent magnet generator (PMG) or from the generator output when used as a conventional, shunt-excited, excitation system. The DECS-100 is supplied in an encapsulated package designed for behind-the-panel mounting. The DECS-100 is held in place by thread-forming screws that thread into its plastic shell. Front panel indicators (LEDs) annunciate DECS-100 status and system conditions. DECS-100 connections are made through quarter-inch, quick-connect terminals on the rear panel. A 9-pin DB-9 type connector on the rear panel provides communication between the DECS-100 and an IBM compatible PC.



FEATURES DECS-100 units have the following features and capabilities.



C C C C C C C C C C C C C C C



Four control modes: automatic voltage regulation (AVR), manual or field current regulation (FCR), power factor (PF) regulation, and reactive power (var) regulation. Programmable stability settings. Soft start and voltage buildup control with an adjustable ramp in AVR control mode. Overexcitation (OEL) limiting in AVR, var, and PF control modes. Underfrequency (volts/hertz) regulation. Three-phase or single-phase generator voltage (rms) sensing/regulation in AVR mode. Single-phase bus voltage (rms) sensing. Single-phase generator current sensing for metering and regulation purposes. Field current and field voltage sensing. One analog input for proportional remote control of the setpoint. Five contact sensing inputs for system interface. One common output relay for alarm indication and trip functions. Four protection functions (field overvoltage, field overcurrent, generator overvoltage, and loss of sensing). Generator paralleling with reactive droop compensation and reactive differential compensation. Rear RS-232 communication port for personal computer communication using BESTCOMS Windows® based software for fast, user-friendly, setup and control.



MODEL AND STYLE NUMBER DESCRIPTION General DECS-100 electrical characteristics and operational features are defined by a combination of letters and numbers that make up the style number. The model number, together with the style number, describe the options included in a specific device, and appear on a label affixed to the rear panel. Upon receipt of a DECS-100, be sure to check the style number against the requisition and the packing list to ensure that they agree. Style Number Style number identification chart Figure 1-1 defines the electrical characteristics and operational features available in the DECS-100.



DECS-100 General Information



1-1



Figure 1-1. DECS-100 Style Chart For example, if the style number was A15, the device would have the following characteristics and operating features. A . . . . No var or power factor control 1 . . . . Voltage matching 5 . . . . 5 ampere CT secondary



SPECIFICATIONS DECS-100 electrical and physical specifications are listed in the following paragraphs. Bus Voltage Sensing (Optional)–continued



Operating Power Voltage: Frequency Range: Burden: Terminals: Voltage Buildup:



88 to 250 Vac, single-phase or three-phase (L-L) 50 to 400 Hz 650 VA 3, 4, 5 from a minimum of 6 Vac



Generator Voltage Sensing Type: Burden: Terminals:



1-phase/3-phase, 4 ranges