Generator Manual: Installation - Operation - Maintenance
Generator Manual: Installation - Operation - Maintenance
Generator Manual: Installation - Operation - Maintenance
Packaged Generator
Single or double-bearing
Drive-end air discharge
Page 1
Table of Contents
Introduction......................................................... 4
Foreword............................................................................4
Safety instructions..............................................................4
Ratings/description............................................................ 4
Application.......................................................................... 4
Construction and Operating Principles............ 7
Stator................................................................................. 7
Rotor.................................................................................. 7
Bearings............................................................................ 7
Connection boxes.............................................................. 8
Excitation system............................................................... 8
Optional PMG system........................................................ 9
Other options..................................................................... 9
Installation..........................................................10
Receiving inspection........................................................ 10
Unpacking and moving.....................................................10
Location............................................................................10
Base design..................................................................... 10
Assemble to prime mover, alignment............................... 11
Two-bearing alignment...........................................11
Two-bearing close-coupled alignment................... 13
Single-bearing alignment....................................... 19
Foot deflection................................................................. 26
Doweling.......................................................................... 26
Electrical connections...................................................... 26
Note: Because of rapid changes in designs Space heaters................................................................. 26
and processes and the available variability Inspection before startup................................................. 27
of our products, information in this manual
is not contractually binding and is subject to Operation........................................................... 28
change without notice. Initial startup: generators w/auto & manual control.......... 28
Initial startup: generators w/auto control only................... 28
The image on the front cover is representa- Restoring residual magnetism/field flashing..................... 29
tive only and may include optional features.
Several variations are available within the
Continuous operation....................................................... 30
range of generators covered within this Idling................................................................................. 31
manual. Parallel operation..............................................................31
Page 2
Maintenance.......................................................33
Schedules........................................................................ 33
Maintenance procedures................................................. 34
Visual inspection methods of windings.................. 34
Cleaning................................................................ 36
Insulation resistance tests at low voltage.............. 36
Dry out procedures............................................... 38
Bearing lubrication................................................ 39
Rectifier tests........................................................ 39
Disassembly..................................................................... 42
Overall disassembly............................................... 42
Exciter armature removal.......................................43
PMG removal.........................................................45
Bearing removal.................................................... 45
Assembly..........................................................................46
Bearing installation................................................ 46
Overall assembly................................................... 47
Exciter installation................................................. 47
PMG installation.................................................... 48
Storage............................................................................ 49
Troubleshooting Guide.....................................50
Appendices....................................................... 51
1: List of equipment for installation/maintenance............. 51
2: Standard SAE engine flywheel.................................... 54
3: Standard SAE engine flange........................................ 55
4: Six-lead generator marking.......................................... 56
5: 12-lead generator marking........................................... 56
6: Optional component marking........................................57
7: Six lead generator connections.................................... 58
8: 12-lead generator connections..................................... 59
9: Single bearing 40 Frame key parts ............................. 60
10: Single bearing 50/500 Frame key parts......................61
11: Single bearing 60/600 frame key parts....................... 62
12: Single bearing 80/800 frame key parts.......................63
13: Two bearing 60/600 frame key parts.......................... 64
14: Two bearing 80/800 frame key parts.......................... 65
Page 3
Introduction
Foreword
This manual contains instructions for installing, operating and
maintaining AC brushless revolving field generators. These generators
are manufactured in many sizes and ratings and with various options.
Please read this manual in its entirety before unpacking, installing, and
operating your generator.
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.
Ratings/description
Nameplates, which are located on the side of the generator, include serial
and model number as well as rating information.
Application:
The generators have been designed for use in a maximum ambient
temperature of 40° C, and altitude less than 3300 ft (1000 meters)
above sea level in accordance with NEMA MG1. Ambient temperatures
in excess of 40° C, and altitudes above 3300 ft (1000 meters) can be
tolerated with reduced ratings. Refer to the generator nameplate for
rating and ambient temperature and to the factory for appropriate
derating factors. Refer to NEMA MG1 for additional information on
usual/unusual operating conditions.
Page 4
The generators are self ventilated screen protected designs and are Caution: Reduction in cooling air flow or
not suitable for mounting outdoors unless adequately protected by inadequate protection to the generator can
enclosures. The enclosure must provide sufficient cooling air so the result in damage and/or failure.
generator does not overheat. The enclosure air intake must also be
designed to prohibit the ingress of moisture. The air intake/outlet must
be sized for the air flow required. Consult the factory for air flow and
additional pressure drops.
Dynamic balancing of the generator rotor assembly has been carried out
during manufacture to ISO 1940 Class G2.5. The vibration produced by
the generator is caused by residual unbalance at operating speed. The
fundamental vibration frequencies are shown in Table 1.
Fundamental
Pole RPM
vibration frequency
1500 25 Hz
4
1800 30 Hz
1000 16.7 Hz
6
1200 20 Hz
Table 1: Fundamental vibration frequencies
Page 5
Warning: Exceeding ISO 8528-9 vibration It is the responsibility of the generating set designer/manufacturer to
levels will have a detrimental effect on ensure the alignment of the genset, stiffness of the skid and mountings
the generating set and also the life of are such that the vibration limits as defined above are met.
the bearings. This will void the generator
warranty. Refer to the product service group If the vibration levels of the generating set are not within what is
at the factory if you are in doubt. specified in Table 2, then 1) Consult the genset builder. The genset
builder should address the genset design to reduce the vibration levels
Warning: Torsional incompatibility and/or
excessive vibration levels can cause
as much as possible. 2) Consult the factory if the above levels cannot be
damage or failure of the generator and/or met.
genset components.
Torsional vibrations occur in all engine-driven shaft systems and may be
Warning: Ground the neutral in accordance of a magnitude to cause damage at certain critical speeds. It is therefore
to local, national and international codes. necessary to consider the torsional vibration effect on the generator shaft
Incorrect grounding and/or protection can and couplings.
result in personal injury and equipment
damage. It is the responsibility of the generator set manufacturer to ensure
compatibility. Rotor torsional data is available upon request for torsional
Warning: Protection devices must be
coordinated in order to prevent personal
analysis.
injury and equipment damage.
Grounding terminals are provided on the feet of the generator and inside
the main terminal box. The neutral terminal is NOT connected to the
frame.
Damage and decrement curves along with reactance and time constants
are available upon request to assist the system designer with the
coordination of the protection devices. It is the responsibility of the
user, system designer and/or generator set manufacturer to coordinate
protections on breakers installed or supplied with a generator.
Page 6
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 end rings and support bars.
The rings and bars are welded to or are part of the steel frame. Feet are
welded to the bottom of the frame and allow the assembly to be mounted
on the genset base.
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 thin sheets of electrical steel, which are stacked together.
The core makes the salient poles (four or six).
Bearings
The generator will contain either one or two bearings. Bearings are
typically ball or roller type and are either 1) heavy duty double shielded
bearings, greased for life or 2) regreaseable bearings, which contain fill
and drain ports for easy lubrication.
Page 7
Connection boxes
The main lead connection box houses the load lead terminals. In
addition, the generator may have auxiliary terminal strips for temperature
detectors, space heaters, sensing leads, and other accessories.
Excitation system
The excitation system consists of the exciter stator assembly and the
exciter armature assembly:
The exciter armature assembly is keyed onto 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.
Page 8
Power input
Voltage
regulator
Output leads
Main stator
PMG stator Exciter stator (armature)
(armature) (field)
Main rotor (DC) Prime mover
Shaft
PMG rotor
(field)
Rectifier
Exciter
Optional
armature (AC)
The PMG rotor consists of a magnetized disk and cast pole tips or
permanent magnets assembled into a rotor using round insulating plates
and steel magnet separators. The PMG rotor is secured to an aluminum
hub. The PMG rotor hub is keyed to the shaft and secured with a
hardened retaining washer and bolts.
Other options
Other options include, but are not limited to, space heaters, filters, and
temperature sensing devices.
Page 9
Installation
Warning: Be alert at all times when Receiving inspection
installing, operating and maintaining the Before accepting a shipment, examine the packaging for any sign of
generator. Avoid contact with the uninsulated damage that might have occurred during transit. Report any damage to
metal parts of the generator. Most injuries the transportation company and the factory.
occur from faulty ground connections on
portable electrical equipment and failure to Unpacking and moving
ground stationary equipment.
If the generator is received during cold weather, reduce condensation on
Test all portable devices frequently to cold surfaces and failure due to wet windings by allowing the generator
prove that a solid electrical circuit exits to reach room temperature before removing the protective packing.
from the metal frame though the grounding
conductor, in the electrical cord, to the Unpack the generator carefully to avoid scratching painted surfaces. Do
grounding contact in the attachment plug. not remove the protecting lubricant from the shaft end, drive plates, and
Do not use electrical equipment with frayed, flange machined surfaces. Inspect for loosely mounted components and
burned or damaged cords. Always take the presence of moisture. Inspect to make certain foreign material, such
extreme care when moving the generator. as crating nails, loose bolts or packing material, which may have fallen
Be careful to not strike objects or personnel. into the machine during unpacking, is removed. If damage is noted,
determine the extent of damage and immediately notify the transportation
Apply lifting force to structural points
specifically provided for lifting. Do not use company claims office and the factory. Be sure to give complete and
the enclosure lifting holes to lift the whole accurate details when reporting damage.
unit. Use lifting means adequate for the
weight. Observe lifting notices attached Move the generator by attaching an overhead hoist to the lifting
to the generator. Failure to observe these eyes installed on the generator frame or by lifting the generator from
instructions can result in personnel injury underneath the skid with a forklift.
and damage to the generator.
Single-bearing generators are shipped with plastic strips between the
Caution: Do not attempt to transport a main rotor and stator to maintain air gap and a shipping bar across the
single-bearing generator without maintaining
drive discs.
proper rotor support. Failure to observe this
warning can result in equipment damage.
Location
Caution: Blocking or restriction of normal air Install the generator in an area so it complies with all local and industrial
flow into or out of the generator may cause regulations. Locate it in a clean, dry, well-vented area or area that is
damage to the electrical windings. suitable for the generator enclosure. Make sure it is easily accessible for
inspection and maintenance.
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 10
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 single-
bearing alignment (if your generator has one bearing and drive plates).
Two-bearing alignment
Follow the tolerances specified by the coupling manufacturer when they
are tighter 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.
A variation of readings at different positions will indicate how the If the genset is moved to a different
machine needs to be adjusted to obtain a maximum misalignment of location, check alignment before startup.
0.001 inch (0.0254 mm) for each inch (25.4 mm) of the coupling hub’s
Caution: Do not pry on the generator fan.
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 11
Dial indicator
Dial indicator
Page 12
Two-bearing close-coupled alignment Notes: Mounting of the indicators must
Check the engine flywheel housing pilot’s radial and face runout by allow complete rotation of the prime mover.
mounting a dial indicator and measuring the flywheel to the flywheel
housing as shown in Figure 5. See Table 3 for maximum allowable Use dial indicators that are rigid so indicator
runout. sag won’t be a factor. Using the shortest
offset distance of the indicator bracket will
reduce the effects of indicator droop or sag.
Flywheel
During alignment, you may also need to
Dial indicator compensate for engine expansion due to
pointer for radial Flywheel housing
heating. Generator expansion is generally
runout
not considered a factor.
Page 13
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 4 for maximum allowable runout.
Flywheel
Flywheel housing
Dial indicator pointer
for radial runout
Shaft
Dial indicator
pointer for face
runout
Page 14
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 (0.254 mm).
Adapter
Dial indicator pointer
for radial runout
Shaft
Dial indicator
pointer for face
runout
Adapter
Shaft
Dial indicator
pointer for face
runout
Dial indicator
pointer for radial
runout
Page 15
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 (0.102 mm).
Flywheel
Flywheel housing
Dial indicator
pointer for face
runout Shaft
Measure and record the engine crank shaft end play and generator
end play. Set the engine end play to the manufacturer’s recommended
position for alignment. Verify the generator end play 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 (0.254 mm) of the engine. Place two 0.010-inch (0.254 mm)
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 (0.254
mm) 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 16
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 feet.
Flywheel
Shaft
Page 17
Grade 2
in-lbs. ft-lbs N-M
Size
Min. Max. Min. Max. Min. Max.
4-40 3.3 4.7 0.4 0.5
6-32 6.1 8.7 0.7 1.0
Grade 2 Grade 5 Grade 8 8-32 12.5 17.8 1.0 1.5 1.4 2.0
ASTM & SAE grade markings 10-32 20.8 29.7 1.7 2.5 2.3 3.4
1/4-20 50.4 72.0 4.2 6.0 5.7 8.1
5/16-18 92.4 132.0 7.7 11.0 10.4 14.9
3/8-16 159.6 228.0 13.3 19.0 18.0 25.8
7/16-14 252.0 360.0 21.3 30.0 28.5 40.7
1/2-13 378.0 540.0 31.5 45.0 42.7 61.0
9/16-12 46.2 66.0 62.6 89.5
Class 8.8 Class 10.9 5/8-11 65.1 93.0 88.3 126.1
Metric grade markings
3/4-10 105.0 150.0 142.4 203.4
1-NM = 0.737 ft-lbs. = 8.85 in-lbs. 7/8-9 141.4 202.0 191.7 273.9
Grade 5 Grade 8
in-lbs. ft-lbs N-M in-lbs. ft-lbs N-M
Size Size
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
1/4-20 60 84 5 7 6.8 9.5 10-32 36 49 4.1 5.5
5/16-18 120 192 10 16 13.5 21.7 1/4-20 72 144 6 12 8.1 16.3
3/8-16 228 336 19 28 25.8 38 5/16-18 156 276 13 23 17.6 31.2
7/16-14 360 528 30 44 40.7 59.7 3/8-16 324 444 27 37 36.6 50.2
1/2-13 540 804 45 67 61 90.8 7/16-14 480 720 40 60 54.2 81.3
9/16-12 792 1152 66 96 89.5 130.2 1/2-13 780 1020 65 85 88.1 115.2
5/8-11 1104 1608 92 134 124.7 181.7 9/16-12 1140 1500 95 125 128.3 169.5
3/4-10 2052 2724 171 227 231.8 307.8 5/8-11 1560 2040 130 170 176.8 230.5
7/8-9 3372 4368 281 364 381 493.5 3/4-10 2760 3600 230 300 311.8 406.7
1-8 5160 6432 430 536 583 726.7 7/8-9 4320 5760 660 480 488.1 650.8
1-8 6720 8640 560 720 759.3 976.2
Measure the generator drive plate diameter (dimension S of Figure 11) Caution: Never grind the OD of drive
and flywheel bore diameter (dimension B of Figure 12). Drive plate discs or attempt to drill out the holes. If the
dive discs do not fit properly, use different
diameter must not be greater than the flywheel bore diameter. Also check
discs or a different flywheel.
to make sure the hole centers match (dimension W of Figure 11 and
dimension C of Figure 12).
Adaptor
Drive Y
plates
Fan
Shaft
S A
W
Bolt holes
Page 19
Tapped
bolt holes
C B
Flywheel G
Caution: The number and thickness Measure the axial distance from the surface on the generator adapter to
of drive discs are specified for torque the outside surface on the drive disc coupling plates (dimension Y in
requirements. Do not remove drive discs Figure 11). This dimension is specified on the generator’s corresponding
to compensate for spacing. outline drawing. If the dimensions do not match, move the rotor axially
relative to the stator until the dimensions are equal, ensuring the bearing
is not contacting either face. Approximately 0.060 inch (1.52 mm) gap is
needed to avoid axial or thrust loading.
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 12). Make sure the difference between
dimensions Y (of Figure 11) and G are less than 1/32 inch (0.79 mm).
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 (if supplied)
between the drive discs and generator hub. If not spacers were
provided, move the rotor, ensuring the bearing is not contacting either
face. Approximately 0.060 inch (1.52 mm) gap is needed to avoid axial
or thrust loading.
Support the generator shaft to ease the mating process, and 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 criss-cross pattern
to the values in Table 5.
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 a shorter
bolt or spacers inserted in the bolts as shown in Figure 13 to increase
the clearance between the bolt head and the flywheel.
Page 20
Lock washer
Bolt
Spacer
Drive hub
Drive plates
Flywheel
Fan
Dial indicator pointer
Shaft
Drive plates
Drive hub
Page 21
1. Clean the machined surface of any dirt, grease, rust, or paint. Use
Emery cloth, if necessary, to ensure a smooth surface to measure
from.
If the runnout exceeds this amount, roll the highest point to the
top. Loosen the coupling bolts at this point to allow the shaft and
coupling to drop in the flywheel counterbore. Once all the bolts are
loose, re-torque the bolts.
Angular alignment
To measure angular alignment, mount a dial indicator on the shaft of
one machine to read against the shaft face of the other machine (see
Figure 15. The dial indicator can be clamped to the generator fan and
measured from the flexplate-to-flywheel mounting bolt.
Flywheel
Generator fan
Drive plates
Page 22
Before taking readings, roll the shaft in reverse 45º and then back 45º,
and zero the dial indicator. This sets the axial position of the crankshaft
and the generator shaft.
Take readings at the 12:00, 9:00, 6:00 and 3:00 o’clock positions.
Readings in the 12:00 and 6:00 o’clock positions determine the
vertical alignment, and readings in the 9:00 and 3:00 o’clock positions
determine horizontal alignment.
-0.009 +0.004
-0.005
Figure 16: Example of runnout readings
R
S
S = 1/2 (TIR)
L R
S = L x (1/2 TIR)/R
Page 23
This relationship is used with the outboard mount or any inboard
mount (closer to the flywheel) as long as the distance to the required
mount is used for “L”.
Engine
Generator
Page 24
Figure 18: Setup for horizontal adjustment
Page 25
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 (0.076
mm).
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.
Page 26
Inspection before startup
After electrical connections have been made, perform the following
checks:
• Turn the rotor slowly with the appropriate starting mechanism (bar Caution: Do not pry on the fan.
the engine or flywheel) through one revolution to see if the rotor
turns freely.
• 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.
• Remove tools and other items from the vicinity of the generator.
Page 27
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.
3. 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.
6. Put the auto-manual switch in auto. Then start the genset, and bring it
to rated speed. Adjust the voltage to the desired value.
Caution: Do not actuate the auto-manual 7. Close the output circuit breaker. Then check the generator voltage
switch with the full load applied to the and voltage regulation. Apply load in steps until the rated load is
generator. Whenever possible, stop the reached.
generator before switching.
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. See Table 2 for
acceptable vibration levels .
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.
Page 28
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. See Table 2 for
acceptable vibration levels .
2. Disconnect the exciter field coil wires F1 and F2, and connect the
battery positive lead to the field coil lead F1.
3. Flash the field by touching the battery lead to the field coil circuit Note: If the polarity of the exciter is reversed
terminal F2. by flashing the field, it may be corrected by
interchanging the battery leads.
4. Disconnect the battery leads, and reconnect the field coil lead F1, and
reconnect the field coil lead F2.
5. 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 10-amp or larger diode off the positive terminal of a maximum 12
V battery per Figure 19.
-12 V battery
+
10 amp or
larger diode F- Voltage
F+ regulator
F2 (-) F1(+)
Figure 19: Field flashing setup with the field wires con-
nected to the regulator
Page 29
Caution: Operating the unit beyond name- Continuous operation
plate values may cause equipment damage Operate the generator within the nameplate values. If the generator is
or failure. 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 run beyond
nameplate values.
100
Excessive
40 unbalance
20
0 20 40 60 80 100
The guide is used in the following manner: Find the point where the
vertical line (determined by the minimum current in any of the phases
and expressed in percent of rated current) crosses the horizontal line
(determined by the maximum 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.
Page 30
Idling Caution: Refer to the voltage regulator
Unless the voltage regulator has V/Hz protection built in, having the manual for complete details and possible
generator set in operating mode while idling the engine can cause additional instructions. Damage to the rotat-
permanent equipment damage. If engine adjustments require that ing diodes, generator, and voltage regulator
the engine be run at idle speed and the regulator does not have V/Hz can be caused if the regulator is operated
improperly.
protection, make the generator regulating system inoperative during
idling by one of the following methods:
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 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 Caution: Do not make connections or other-
phase sequences of the generator must be the same as that of the system. wise make contact with the generator leads
Use transformers to reduce the voltage to an acceptable level, and then or other devices connected to them unless
use a phase rotation meter or incandescent lamp method, described in the genset is stopped and the phase leads
electrical machinery handbooks, for a phase sequence check. are grounded.
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.
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 31
System bus
Load Synchronizing
switch lamps
If the set is provided with a unit/parallel switch, set the switch to the
parallel position on the unit being synchronized.
Every day
Visually check generator bearing housings for any sign of grease/oil
seepage.
Check the control panel voltmeter for proper stability and voltage output.
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
Clean the inside of the outlet box, air screens, and air baffles with
compressed air or electrical solvent if needed.
Clean the generator windings using either (depending upon the severity
of contamination) 1) compressed air and electrical solvent or 2) de-
greaser and high pressure hot water wash. Dry the windings to acceptable
resistance levels (see the dry out procedure).
Inspect the rotor shaft bearing journals and bracket bearing cavity for
wear or scoring.
Maintenance procedures
Visual inspection 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:
Page 34
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.
Page 35
Warning: When using cleaning solvents, Cleaning
ensure adequate ventilation and user Remove dust, preferably using a vacuum cleaner to prevent the
protection. redistribution of the contaminant. A small non-conducting nozzle or tube
connected to the vacuum cleaner may be required to reach dusty surfaces
Warning: Exercise safety precautions when or to enter into narrow openings. After most of the dust has been
using compressed air. removed, a small brush can be affixed to the vacuum nozzle to loosen
and allow removal of dirt that is more firmly attached.
Caution: Use only manufacturer-approved
cleaning fluids.
If compressed air must be used, exercise care in the application of
pressure to prevent damage to the insulation. If available, (30 PSI (2
Bars) or less) instrument air should be used. In any case, the air must be
clean, oil-free and dry.
Wipe all exposed surfaces with clean cloths to remove any remaining
oil or dirt. It may be necessary to use a cleaning solution made of mild
soap and water in order to effectively remove the dirt. Use clean water to
remove any soap residues.
Dry the machine according to the procedure in this manual until normal
insulation resistance values are obtained at room temperature.
Page 36
Exciter field (stator) and PMG armature (stator) Caution: The insulation resistance tests are
usually made on all or parts of an armature
1. Disconnect the exciter leads from the terminals in the terminal box or or field circuit to ground. They primarily
from the voltage regulator. indicate the degree of contamination of the
insulating surfaces or solid insulation by
2. Connect exciter leads to one clamp of 500-volt megger, and connect moisture and other conducting influences
and will not usually reveal complete or
the other clamp to the generator frame.
uncontaminated ruptures.
3. Apply 500 V from the megger, and measure the resistance reading Note: The insulation resistance value
after 1 minute. The reading must be a minimum of 1 megohm. If it is increases with decreasing winding
not, refer to the cleaning or dry out procedures. temperatures. All readings must be
corrected to winding temperatures. Use
4. Ground the exciter field leads to the generator frame for several Table 6 for converting megger readings to
minutes after the megger has been disconnected. This will allow the other temperatures (e.g., 100 megohms at
voltage build up to be properly discharged. 50º C is converted to 170 megohms at 40°
C: 1.7 x 100).
Exciter armature
Winding
1. Disconnect the exciter armature leads from the rotating rectifiers. Temp Conversion
(º C) factor
2. Connect the leads of the exciter armature to one clamp of a 500-volt 10 0.23
megger, and connect the other clamp to a suitable connection on the 20 0.37
shaft. 30 0.6
40 1
50 1.7
3. Apply 500 V from the megger, and measure the resistance reading 60 2.7
after 1 minute. The reading must be a minimum of 1 megohm. If it is 70 4.5
not, refer to the cleaning or dry out procedures. 80 7.5
90 14
100 23
4. Ground the exciter leads to the shaft after disconnecting the megger.
110 38
This will allow the voltage build up to be properly discharged. 120 61
Main rotor
Table 6: Temperature conversion
factor for resistance readings
1. Disconnect the generator field leads from the positive and negative
terminals of the rotating rectifier assembly.
Warning: Never apply the megger to the
2. Connect the positive and negative leads to one clamp of the 500-volt rotating rectifier, the voltage regulator or
generator accessories (eg., temperature
megger, and connect the other clamp to the shaft.
detection devices, space heaters).
3. Apply 500 V from the megger, and measure the resistance reading
after 1 minute. The reading must be a minimum of 1 megohm. If it is
not, refer to the cleaning or dry out procedures.
4. Ground the field leads to the shaft after disconnecting the megger.
This will allow the voltage build up to be properly discharged.
Page 37
Main stator
Resistance
in megohms = Rated generator voltage + 1000
1000
4. Ground the leads to the frame after the 1-minute megger test. This
will allow the voltage build up to be properly discharged.
Drying with external heat: Place heat lamps or space heaters (in addition
to the ones already supplied). Monitor winding temperatures. Raise
winding temperature gradually at a rate of 50° F (28° 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.
Page 38
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.
Rectifier tests
If a failure of a rotating rectifier is suspected, remove the exciter cover.
Test the entire rectifier assembly with an ohmmeter or test lamp as
follows.
Six discrete diodes: 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 Figures 25 and 26 for an overview.
!# !#
!#
!#
!#
!#
Page 39
!# !#
!#
!#
!#
!#
!# !#
!#
!#
!#
!# !#
!# !#
!#
!#
!#
!#
!# !#
!# !#
!#
!#
!#
!#
!#
!#
!#
!#
!#
!#
!#
!#
Page 40
Negative
Positive
Positive
Ohmmeter method:
Discrete components: Connect the ohmmeter leads across the rectifier in Caution: Failure to properly secure the
one direction (see Figure 26). Note the meter reading. Reverse the leads, leads can cause equipment damage or
and note the meter reading. The meter should indicate a low resistance failure.
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. Replace the rectifier / heat sink
assembly if defective.
Cathode
Ohmmeter
Anode
Reverse Standard
diode diode
Figure 26: Testing the rotating rectifier with an
ohmmeter
Page 41
Test lamp:
Connect the leads of a test lamp built as shown in Figure 27, consisting
of standard flashlight batteries and a flashlight. Test the rotating rectifiers
as described above but using the two test probes of this makeshift tester
instead of the ohmmeter probes. The light should light in one direction
but not in 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.
Replace the rectifier/heat sink assembly if defective.
Disassembly
Overall disassembly
Note: The following procedures are meant 1. Remove the terminal box cover, and disconnect the load leads and
to be a general guide. Procedures for your all other generator leads. Tag the leads to ensure they are correctly
unit may vary. connected when the generator is reassembled.
Warning: Ensure the generator has stopped 2. Remove the bolts securing the generator to the base and the engine,
and is de-energized before disassembly.
and move the generator to an area that allows sufficient room for
Warning: Use a hoist and slings or chains disassembly.
to support components during removal. Use
lifting devices that are selected for generator 3. Remove the coupling or drive plates.
component weights, which can be found on
the mechanical data sheet. Be extremely 4. Remove the exciter cover, rotating diode assembly, optional PMG if
careful not to damage components. necessary, and the exciter assembly as explained later.
5. Support the shaft. Remove the exciter-end bracket bolts, and remove
the bracket. Tap lightly with a rubber or fiber mallet to loosen
the bracket if necessary. Repeat with the drive-end bracket (if
applicable).
Page 42
6. Remove the fan from the hub where applicable. If necessary, make Warning: Make sure the pipe is strong
sure to mark the location of the fan for reinstallation. enough to support the weight of the rotor
and that it does not have rough edges on
7. Float out the rotor (see Figure 28). First attach a thick-wall pipe over the inside, which could damage the shaft.
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 Caution: To prevent tension on the shaft,
put the slings around the largest shaft step
it out, resting the rotor as the slings are moved down the pipe for the
possible.
next lifting stage. Finally attach slings to each side of the core for
moving the rotor to the final work space. Caution: Make sure the rotor does not
rest on the stator during the stages of
Drive end Exciter end movement. Make sure the rotor does not hit
the stator.
3. Locate and remove the four bolts in the end of the shaft that hold the
retaining washer. Remove the retaining washer.
4. Remove the aluminum sleeve, and slide the exciter rotor off the shaft. Caution: Ensure the generator field wires
are flat in the wireway so they don’t tear
5. Remove the four bolts that hold the exciter stator to the bearing during pulling. Do not pull on the edges of
bracket. the heat sinks or on the exciter armature
windings.
6. Mark the location of the exciter for reassembly, and remove the
exciter stator. Warning: Pull the PMG and exciter rotor
straightly off. The assembly may pull toward
other steel components. Be careful that your
fingers or hands do not get pinched.
Page 43
Rotating diode Exciter stator
assembly
PMG stator
Exciter
armature
PMG rotor
Shaft
Bearing
Exciter
armature Shaft
PMG rotor
PMG rotor
spacer
Retaining
washer
Rotating diode
assembly
Retaining
bolts
Page 44
Optional PMG removal
1. Remove the exciter cover.
4. Remove the four bolts that hold the PMG stator to the bearing
bracket. Mark the location for reassembly, and remove the PMG
stator.
4. Remove the PMG rotor spacer if supplied, and slide the PMG rotor
assembly off the shaft.
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 (see
Figure 31). Replace it with a new bearing.
Page 45
Caution: Make sure all components are .Assembly
clean before assembly.
Bearing installation (done prior to installing the rotor)
Note: Torque fasteners to the values speci- 1. Heat the bearing to 220º to 250º F (104º to 121º C) in a clean oven or
fied in Table 5 unless otherwise specified. 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.
4. Grease the generator bearing and/or bearing bracket cavity after the
bearing has cooled according to bearing type as follows:
Warning: Grease migrates between the Shielded bearings are factory packed with grease. Fill the bearing
shields and into the bearing. The same bracket cavity to 40% with high quality ball bearing grease of NLGI
type of grease must be used. Grease #2 grade, which must be capable of lubricating satisfactorily over a
incompatibly can cause bearing and temperature range of the lowest ambient temperature to 250° F (121°
generator failure. C). Standard grease is Chevron SRI or Polyrex EM with mineral oil
base.
Page 46
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 anti-
corrosion agent on the bare mating surfaces.
5. Lay the generator field wires flat in the wire slot with the wire ends
protruding past the end of the shaft if applicable.
6. Position the exciter armature assembly in line with the shaft, and Caution: Ensure the generator field wires
turn the assembly to the position where the keyway in the exciter are flat in the wire slot so they don’t tear
laminations is in line with the key in the generator shaft. during assembly. Do not pull on the edges
of the heat sinks or on the exciter armature
7. With hand force, push the exciter armature assembly over the shaft, windings.
so the edge of the armature is against the shoulder on the shaft or
Caution: Do not pound on the rectifier or
sleeve. armature windings.
9. Secure the exciter rotor assembly using the retaining washer and four
retaining bolts at the end of the shaft.
10. Connect the exciter armature and evolving field wires to the rectifier Note: To measure air gap, measure com-
terminals. pletely around the gap between the exciter
armature and exciter field with a feeler
11. Measure the air gap between the exciter armature and exciter field. gauge. Keep the gauge at the tightest point,
Nominal values are shown in Table 8. If the air gap is less than 0.02 and turn the generator over to measure the
inch (0.058 mm), 1) check generator-engine alignment, 2) check for air gap as the rotor turns.
bearing wear, 3) check for misalignment of the exciter armature or
Caution: Do not pry on the fan.
stator.
Page 47
Optional PMG installation (See Figures 25 and 26)
1. Attach the PMG stator to the bearing bracket.
Caution: Ensure the generator field wires 3. Carefully slide the PMG onto the shaft. Avoid contact between the
are flat in the wire slot so they don’t tear rotor and stator that could damage the windings or the permanent
during assembly. Do not pull on the edges magnets.
of the heat sinks or on the exciter armature
windings. 4. Connect the PMG stator leads.
5. Measure the air gap between the PMG rotor and PMG stator.
Nominal values are shown in Table 8. If the air gap of the PMG
is less than 0.020 inch (0.508 mm), 1) check generator-engine
alignment, 2) check for bearing wear, 3) check for misalignment of
the armature, PMG or stator.
Page 48
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.
Install desiccant bags in the exciter cover and inside the end bells.
For storage longer than 2 months, rotate the shaft a minimum of 10 Warning: If necessary, remove the covers
revolutions every 60 days. around the space heaters to reduce the risk
of fire.
Page 49
Troubleshooting Guide
(corrective maintenance)
Warning: Problems left uncorrected can Between regular preventive maintenance inspections, be alert for any
result in injury or serious damage, which can signs of trouble. Correct any trouble immediately. See Table 9 for
result in costly repairs and downtime. symptoms, causes and remedies.
Page 50
Troubleshooting Guide (cont.)
Symptom Cause Remedy
Low voltage Improper adjustment of voltage adjust Adjust rheostat.
(cont.) 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 Improve the ventilation of the generator.
temperature Field current can be increased providing
the generator temperature rating
stamped on the nameplate is not
exceeded.
Defective rectifiers in rectifier assembly Check rectifier assembly. Replace
(stationary) defective fuses or rectifiers.
Excessive load Reduce load to rated value.
Defective bearing Replace the bearing.
Improper speed of engine driven Check and correct deficiencies.
generator set due to defective governor,
ignition system, or carburetor
Voltage regulator not operating properly Check the regulator. Adjust, repair or replace.
Fluctuating Prime mover speed fluctuating Check frequency and voltage of incoming
voltage 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.
High voltage Improper adjustment of voltage adjust Adjust rheostat and/or voltage regulator.
rheostat or voltage regulator
Voltage regulator not operating properly Check the regulator. Adjust, repair or replace.
Page 51
Troubleshooting Guide (cont.)
Symptom Cause Remedy
Overheating Clogged ventilating screens and air Clean all screens and air passages.
passages
Dry or defective bearings Replace defective bearings.
Coupling misaligned Align the generator set.
Generator field coils shorted or Test field coils for shorts. Replace
grounded shorted rotor or return it to the factory for
repair.
Unbalanced load or overload, low PF Adjust load to nameplate rating.
Vibrations Defective or dry bearings Replace defective bearings.
Misalignment of generator and prime Align the generator set.
mover
Generator not properly mounted Check mounting. Correct defective
mounting.
Transfer of vibration from another Isolate the generator set from the source of
source vibration by installing vibration dampeners
between generator set base and foundation.
Table 9: Troubleshooting
Page 52
Appendices
Appendix 1: List of equipment required for installation and maintenance:
Special tools
Bearing puller For changing bearing.
Exciter puller For pulling exciter armature
Standard tools
Cable tool Crimping
Flashlight As required
Grease gun For lubricating bearings
Hammer Soft-faced
Lamp (incandescent) Safety light
Screwdrivers Standard, sized as required
Screwdrivers Phillips, sized as required
Wrench Adjustable, 12-inch
Wrench Torque 0 to 800 ft-lb (1085 N-M)
Wrench set Allen, 1/8 to 1/2 inch
Wrench set Socket, 1/4 to 1 Inch (6-25 mm) with 3/8 and 1/2 inch drive
Wrench set Standard, open-end/box-end combination sized 1/4 to 1 inch (6-25 mm)
Vacuum Electric with nonmetallic nozzle
Materials
Air Compressed, dry.
Anti-corrosion agent Nox-Rust VC #10 Oil or equivalent
Covering material Waterproof desiccant bags for protection from
moisture during long-term equipment storage
Detergent As required for cleaning
Gloves Chemical-protective
Gloves Electrical-protective
Heaters Space Heater, for eliminating excess moisture in damp areas and dry
out of motor or generator windings
Plastic Protection for long-term storage
Rags As required for cleaning
Water Warm and clean, for cleaning
Tags Warning and cautions
Page 53
Appendix 2: Standard SAE engine flywheel per SAE J 620
Page 55
Appendix 4: Six-lead generator marking
STAR CONNECTION
U(L1)
U1(T1)
U2(T4)
N(L0)
W2(T6)
V2(T5)
W1(T3) V1(T2)
W(L3) V(L2)
621518-01
U (LI) 5,)
U1(T1)
54 54
U2(T4)
54 54
U5(T7)
U6(T10)
N(L0) .,
W6(T12)
V6(T11)
W5(T9) 74 64
V5(T8)
W2(T6) V2(T5) 7 6
74 64
4
V1(T2)
W1(T3)
74 64
W (L3) V (L2)
7, 6,
621517-01
Page 56
STATOR BEARING
RTD'S
STATOR BEARING
Appendix 6: Optional component marking
THERMOCOUPLES
Page 57
SPACE HEATERS
SERIES PARALLEL
T6 T3
+ L3 - L3 REVOLVING FIELD
L4 STATOR
CR8
R5 SUPPRESSION RESISTOR
CR7 RFA REVOLVING FIELD ASSEMBLY
POLARTY MARK
CR1 CR4
L4
RFA CR2 CR5
OPTIONAL
SENSING TRANSFORMERS
CR3 CR6
Page 58
E1 E2
R5 L2
20
22
OPTIONAL 24
PMG FUSE 26
28
FUSE 30
+ F1
L1
F2
-
T8
SYMBOLS
5 CR1-CR6 ROTATING RECTIFIERS
T9
CR7-CR8 SURGE SUPPRESSION DIODES
T12 T10
6 E1 POSITIVE HEATSINK
T6 T1 T11
T7 OPTIONAL PARALLELING CURRENT TRANSFORMER E2 NEGATIVE HEATSINK
T3
T4 L1 EXCITER STATOR
T5
T2
L2 EXCITER ARMATURE
+ L3 - L3 REVOLVING FIELD
L4 STATOR
CR8
R5 SUPPRESSION RESISTOR
CR7 RFA REVOLVING FIELD ASSEMBLY
L4
POLARTY MARK
CR1 CR4
E1 E2
R5 L2
Page 59
20
22
OPTIONAL 24
PMG FUSE 26
28
FUSE 30
+ F1
L1
F2
-
Appendix 9: Single bearing 40 frame key parts (Shunt and PMG models)
15
17 16 9
11 13
8
3
6 12 3
8
14 5
14
2
1
7
Optional PMG Shunt
Item Description
1 Air outlet screen
18
2 Bearing (Exciter end)
3 Bracket (Exciter end)
19 4 Drip proof cover
5 Drive discs
6 Exciter armature
7 Exciter cover
8 Exciter stator
4 9 Fan
11 PMG rotor
12 PMG stator
2/4!4)/.
Page 60
Appendix 10: Single bearing 50/500 Frame key parts (Shunt and PMG models)
15
17
3 16
12 13 9
8 11
8 3
14
14
6 2
7
7
1
Item Description
1 Air outlet screen
2 Bearing (Exciter end)
18
3 Bracket (Exciter end)
4 Drip proof cover
5 Drive discs
6 Exciter armature
7 Exciter cover
8 Exciter stator
9 Fan
11 PMG rotor
12 PMG stator
13 Revolving field and shaft
14 Rotating rectifier assembly
15 Stand-off / Buss bar assembly
16 Stator assembly (wound)
17 Terminal box assembly
18 Terminal box top cover
Page 61
Appendix 11: Single bearing 60/600 Frame key parts (Shunt and PMG models)
17
T0
N
T1
U
T2
V
T3
W
15
Optional PMG 16 9
12 13
3
8
5
6
11 2
14
Shunt
7 1
18 Item Description
1 Air outlet screen
2 Bearing (Exciter end)
19
3 Bracket (Exciter end)
4 Drip proof cover
TC4+
TC1+
TC1+
TC4+
20
20
22
22
TC1-
TC4-
TC1-
TC4-
24
24
TC2+
TC5+
TC5+
TC2+
T1
T1
TC5-
TC2-
TC2-
TC5-
T2
T2
TC3+
TC6+
TC6+
TC3+
5 Drive discs
F1
F1
TC3-
TC6-
F2
F2
TC6-
TC3-
C3
C3
C6
C6
SH1
SH1
6 Exciter armature
BGW
BGW
SH2
SH2
BGY
BGY
SH3
SH3
BGP
BGP
SH4
SH4
7 Exciter cover
4 8 Exciter stator
9 Fan
ROTATION
11 PMG rotor
12 PMG stator
13 Revolving field and shaft
14 Rotating rectifier assembly
15 Stand-off / Buss bar assembly
16 Stator assembly (wound)
17 Terminal box assembly
18 Terminal box top cover
19 Voltage regulator
Page 62
Appendix 12: Single bearing 80/800 Frame key parts (Shunt and PMG models)
17 15
16
3 13 9
10 8
12 5
Optional PMG
11 2
14
Shunt
6
1
7
18 Item Description
1 Air outlet screen
2 Bearing (Exciter end)
3 Bracket (Exciter end)
+4CT
+1CT
+1CT
+4CT
-1CT
-1CT
-4CT
+2CT
+5CT
+5CT
+2CT
19
- 5CT
-2CT
-2CT
-5CT
+3CT
+6CT
+6CT
+3CT
-3CT
-6CT
-6CT
-3CT
5 Drive discs
6C
3C
6C
3C
1HS
1HS
WGB
WGB
2HS
2HS
4
YGB
YGB
3HS
3HS
PGB
PGB
6 Exciter armature
4HS
4HS
7 Exciter cover
8 Exciter stator
ROTATION
9 Fan
10 PMG mounting ring
11 PMG rotor
12 PMG stator
13 Revolving field and shaft
14 Rotating rectifier assembly
15 Stand-off / Buss bar assembly
16 Stator assembly (wound)
17 Terminal box assembly
18 Terminal box top cover
19 Voltage regulator
Page 63
Appendix 13: Double bearing 60/600 Frame key parts (Shunt and PMG models)
T0 T1 T2 T3
N U V W
15
17
9
16
8 13 21
12 3
Optional PMG
6
20
2
11
14
Shunt
7
1
Item Description
1 Air outlet screen
18
2 Bearing (Exciter end)
3 Bracket (Exciter end)
4 Drip proof cover
5 Drive discs
19 6 Exciter armature
7 Exciter cover
4 8 Exciter stator
9 Fan
11 PMG rotor
12 PMG stator
13 Revolving field and shaft
14 Rotating rectifier assembly
15 Stand-off / Buss bar assembly
16 Stator assembly (wound)
17 Terminal box assembly
18 Terminal box top cover
19 Voltage regulator
20 Bearing (drive end)
21 Bracket (drive end)
Page 64
Appendix 14: Double bearing 80/800 Frame key parts (Shunt and PMG models)
6 17 15
8 9
10 16 13
3 21
12
14
Optional PMG 2 20
11 MODEL
EMI
kVA
KW
SERIAL NO
DATE
AMB
ALT
P.F. EXC VOLTS
VOLTS EXC AMPS
AMPS TEMP RISE
OVERSPEED ENCLOSURE
ROTATION WEIGHT
Hz INSULATION
RPM STATOR CONN
PHASE ARRANGEMENT
RATING
Shunt
1
7
Item Description
1 Air outlet screen
18 2 Bearing (Exciter end)
3 Bracket (Exciter end)
4 Drip proof cover
5 Drive discs
6 Exciter armature
19
4 7 Exciter cover
8 Exciter stator
9 Fan
10 PMG mounting ring
11 PMG rotor
12 PMG stator
13 Revolving field and shaft
14 Rotating rectifier assembly
15 Stand-off / Buss bar assembly
16 Stator assembly (wound)
17 Terminal box assembly
18 Terminal box top cover
19 Voltage regulator
20 Bearing (drive end)
21 Bracket (drive end)
Page 65
Kato Engineering Inc.
P.O. Box 8447
Mankato, MN USA
56002-8447
Tel: 507-625-4011
Fax: 507-345-2798
Email: katoengineering@emerson.com
www.kato-eng.com
Page 66