NEWAGE PRODUCT TRAINING

NEWAGE PRODUCT TRAINING

 Maintenance - Requirements WHO
Me ?
SAFETY NOTICE !!

DANGER!
ELECTRIC SHOCK
[Live Terminals]

 The following tests should only be carried out by qualified and/or experienced
engineers who have received SAFETY TRAINING ON LIVE EQUIPMENT.
 All test instruments and their leads/connectors/ probes must be checked to ensure
that they are suitable for the voltage levels being tested, and are in good working
order.
 Never attempt to test a ‘LIVE’ generator without another competent person present
to shut down the engine or switchgear as necessary.
 Ensure that the work area is SAFE, other personnel in the area are advised of what
you are doing, warning notices and tapes are displayed to advise others of the
hazards.

NEWAGE PRODUCT TRAINING

 Maintenance - Requirements

Maintenance requirements for A.C Brushless Generators are :-

 1. Bearing inspection ( Single or 2 Bearing).

 2. Winding Insulation/ Contamination checks.

 3. Visual Inspection for Corrosion and Contamination

 4. Operational Checks

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Bearings
Newage Generators are supplied with three types of bearing assembly :-
1. Manufacturers Sealed for Life Ball bearings :-
Standard on Frames BC16,BC18, and UC22,UC27, ranges.
Introduced as standard on Frames
HC4, HC5, HC6, from July 1999.
Introduced on P7 (Single bearing Generators only), from April 2005.
2. Newage Sealed Cartridge Assemblies, (Non- re-greaseable).

Standard on Frames HC4, HC5, HC6, up to July 1999.

Standard on Frame HC7, up to March 1999.

3. Newage Re-greaseable Cartridge Assemblies.

Standard on Frame HC7 from March 1999.
Optional on Frame HC 5 & 6 from April 2000.
Standard on Frame P7(2 bearing), Frame 8, & P80.

All HC range, P7, & P80, bearings are packed with Kluber Asonic GHY72 grease,
which is a Synthetic Polyurea / Ester oil based grease, and should not be mixed with
dissimilar greases.

NEWAGE PRODUCT TRAINING

 BC & UC Bearing Assembly
 Frames BC and UC Ball Bearings are manufacturers sealed for life as standard.

Typical Bearing housing machined into Typical Sealed for Life 2RS Ball Bearing.
Non-Drive End- bracket. Grease pre-packed & sealed with steel
reinforced synthetic rubber seal (2RS).

NEWAGE PRODUCT TRAINING

 HC, P7, F8, P80 Bearing Cartridge Assemblies
Typical re-greasable bearing Cartridge & Cap for HC7, Typical Bearing Cartridge for HC 6,
P7,F8 & P80, (shown with N.D.E PMG Stator Housing ) with sealed bearings.

Bearing Bearing
Wave Washer
Grease
Flinger

Cap Cap
Cap bolts Cap bolts

o Frames HC4,5 are manufacturer sealed bearings packed with Kluber Asonic grease
type GHY72. They are assembled directly into the Generator end-brackets.
o Frame HC6 have cartridge assemblies, with manufacturers sealed for life bearings.
o Frames HC7, P7, Frame 8,and P80, have regreaseable cartridge assemblies, packed
with Kluber Asonic grease type GHY72.
o Regreasable bearings are optional on Frames HC5 and H6.
o Re-lubrication details are available in the Generator Operation & Maintenance manuals.

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Bearings
What are the symptoms of a Bearing problem?
Non drive INCREASED INCREASED INCREASED Drive end
end Bearing TEMPERATURE VIBRATION NOISE. Bearing

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Bearings
What are the symptoms of a Bearing problem?

 Temperature rise in the bearing housing

Monitoring temperature is achieved with R.T.D’s or Laser (remote) thermometer.
( Note: Localised Ambient temperature variations should be taken into account).

 Vibration
Increased vibration in the Generator, suddenly, or slowly over a period of time.
Vibration equipment is expensive, a check by hand near the bearing will give an
indication. ( Note: this could also be an engine related problem).

 Noise
Bearing making abnormal noises, audible, with or without Stethoscope. (
A Stethoscope is required for elimination of other possible causes of noise )
Experience gained from touch and sound, will establish ‘normal’ conditions.
Periodic Health monitoring is recommended throughout the life of the Generator to
establish normal conditions.

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Bearings
Re-lubricated Bearings Frames HC7, P7, F8, & P80
(Optional for HC5 & 6)

 Re-lubrication with Kluber Asonic grease type GHY72, is recommended,

 Full details of grease quantities for both initial fill and re-lubrication are
available in the manual supplied with the Generator, or from the factory.

Frames HC6 and HC7 Re-lubrication Bearing Kits

 Conversion kits with full instructions to upgrade HC6 and HC7 Generators to
re-greasable specification are available from Newage Parts dept.

 Special tool kits, and greasing equipment are available on request.

 2 BEARING KITS
HC6, 45 - 0880, HC7 45 - 0872.

 1 BEARING KITS
HC6, 45 - 0879, HC7 45 - 0877

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Insulation checks

Winding Insulation levels should be checked if :-

1. The Generator has been STATIONARY for a long period with Anti-
Condensation heaters SWITCHED OFF.

 2. The Generator has been subjected to intake of high volumes of water

 3. The Generator windings are contaminated with Airborne DUST and

DIRT, and have become DAMP ( through high humidity).

 The Generator windings have become contaminated with airborne

corrosive elements ( Salt or corrosive chemicals in the atmosphere).

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Insulation checks
Insulation Resistance (IR) tests in order of importance :-
1. The Main Stator Winding
DANGER!
Minimum value of Insulation should be 1 M to EARTH. ELECTRIC
(For Low voltage machines up to 690V). SHOCK

 2. The Exciter Stator Winding

This winding is subject to all contamination from the air intakes. Severe
contamination may cause temporary or permanent low IR, which could
effect the AVR performance.

 3. The Exciter Rotor, & Main Rotor

These are rotating low voltage windings, and are unlikely to be affected
by low IR. Minimum value of insulation should be 1 M to EARTH.

 4. Permanent Magnet Stator

This windings is totally enclosed and unlikely to be affected by low IR.

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Testing the Main Stator Insulation
Connections shown in Series Star
EARTH

W6
AVR Sensing
& Power supply N U6V6 Neutral
00
100
10 1
M
0.1
.01
from Main Stator 10
W5
6
W2 W W1

Test
V5
7
V2 V V1
3 Phase M  1KV

Output M  500V
U5
8
U2
U U1

EARTH MEGGER
FRAME

 1. Disconnect the AVR completely before carrying out this test.

 2. Disconnect any connections from Neutral to Earth.
 3. The Stator insulation should be checked with an Insulation tester.The test
instrument should be 500 or 1000 volts for low voltage Generators (up to 690V).
 4. For low voltage machines (up to 690V), the MINIMUM insulation value is 1.0 Meg-
Ohm to Earth (Ground).
WINDINGS MUST BE DRIED OUT IF BELOW 1.0 MEG-OHM.
NEWAGE PRODUCT TRAINING
 Maintenance requirements - Drying the Main Stator Windings

Recommended methods of drying out DAMP, WET, or CONTAMINATED Stator

Windings are :- .

 1. DRYING WHILE STATIONARY

Hot air is blown into the Generator AIR INTAKE.

 2. DRYING WHILE RUNNING ON SHORT CIRCUIT

The Main Stator is Short Circuited while separately exciting the
Generator with a BATTERY, or the MANUAL VOLTAGE
REGULATOR.

Both Methods can be carried out ON SITE, without dismantling the Generator.
(NOTE: Example 1 requires a standard 13 Amp Mains supply socket).

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Drying the Main Stator Windings
METHOD 1. STATIONARY DRYING

Domestic Supply

 Remove Air Intake Access Covers

 Direct a Domestic FAN HEATER ( 2 - 2.5 kW) into the AIR INTAKE.
 Leave Overnight (or 8 Hours min.) to blow out all Moisture.
 RE-CHECK INSULATION RESISTANCE AFTER DRYING ( Minimum value 1 M )

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Drying the Main Stator Windings
Output From METHOD 2. SHORT CIRCUIT MAIN
Battery into - + STATOR WINDINGS
Exciter Stator 12vA.V.R
BATTERY

Main Stator
Exciter
X+ XX- Rotor
& Stator
Bearing

Main Rotor
Main Rotor Shaft

Rectifier
Fan
 1. Stop the Generator Set and disable the Engine.
 2. Disconnect the AVR wiring.
 3. Replace the AVR with a 12V or 24V battery
 4. Connect the battery to the Exciter Stator,(polarity must be correct).

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Drying the Main Stator Windings
EARTH METHOD 2. SHORT CIRCUIT MAIN
STATOR WINDINGS
W6
N U6V6
Short Circuit Link
W5
6
W2 W W1

Clampmeter
V5
7
V2 V V1

MS
U5
U

R
8 U1

UE
U2

TR
EARTH
FRAME
MAKE SURE THAT THE AVR IS DISCONNECTED
 Attach SHORT CIRCUIT link to all 3 phases (NOTE: Shorting Links must carry full
load current)..
Attach Clampmeter to Link, capable of measuring FULL LOAD AMPERES, (or use
the Generator set panel meters).
 CHECK ALL WIRING IS SECURE BEFORE RUNNING GENSET !
WARNING!

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Drying the Main Stator Windings
Clampmeter
Short Circuit Link METHOD 2. SHORT CIRCUIT MAIN

T
12 - 24 volt XX-
Batteries into STATOR WINDINGS
Exciter Stator
X+

RUN ENGINE

- +
12-24v
BATTERY

The Current MUST NOT BE HIGHER THAN FULL LOAD AMPERES

 For effective drying, at least 70% of FULL LOAD CURRENT is required.
Add more Batteries to increase the short circuit current if necessary (24VDC)
 Run until the windings are HOT and DRY, (at least 1 HOUR).
 If the IR is still less than 1 M , the windings require cleaning /refurbish.

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Drying the Main Stator Windings
Clampmeter
Short Circuit Link
Across 3 Phases METHOD 2. SHORT

T
CIRCUIT METHOD
XX- (F2)
NEWAGE INTERNATIONAL
USING THE M.V.R
MANUAL VOLTAGE REGULATOR
MVR-1
X+ (F1)
MODULE 450-11400
P To
T Exciter
4
Stator
X XX P2 P3 P4 X
AVR GENERATOR
X XX P2 P3 P4 X XX P2 P3 P4
XX P2 P3 P4

ººº

P.M.G
Power Supply 
RUN ENGINE

 The M.V.R must be switched to MANUAL control, MINIMUM setting, before

running the engine.
 Slowly increase the Current until FULL LOAD AMPERES are indicated.
 For effective drying, run for at least 1 hour at FULL LOAD CURRENT. .
 If the IR is still less than 1 M , the windings require cleaning /refurbish.

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Cleaning the Windings

When is it necessary to clean the windings?

 1. When (after drying), the windings are still reading less than 1 M to
earth.

 2. When the windings are heavily contaminated with dust,dirt, and/or

diesel exhaust deposits.

 3. When the windings are contaminated with corrosive chemicals ( salt

deposits or other deposits), which immediately give a temporary low IR
reading when damp.

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Cleaning the Windings

 For removal of embedded dirt, grease, salts, hydrocarbons, and other chemicals from
the winding surfaces, HOT WATER CLEANING at maximum 25 psi pressure is
recommended.
 For very heavy contamination, a non- corrosive detergent additive, (i.e : Karcher RM81
or equivalent), can also be used.

 NOTE: Detergents containing CAUSTIC chemicals must never be used on copper

windings.

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Cleaning the Windings

. The windings should then be thoroughly WASHED with clean water to remove all
traces of detergents.
. The windings must be dried in an oven at approximately 100 to 110ºC for at least 12
hours until the IR is higher than 1 M.
 A final coating of Anti-track paint can be added for further protection, I.e :Sterling
VA63 or VA39, or Ultimeg 2000, 372, air drying varnish ranges.

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Healthchecks

Final Inspection before running Gen-set :-

2. MAIN
1. AVR
TERMINAL
CONNECTIONS
CONNECTIONS

3. MAIN
RECTIFIER
COMPONENTS

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Healthchecks

Final Inspection before running Gen-set :-

A.C Generators may be subjected to environmental conditions which are detrimental

to the Generator :-

High humidity, or exposure to the elements, rainwater, and/or offshore sea mists.
Dust, dirt, and/or corrosive chemicals in the atmosphere.
Excessive vibration from the Engine, or worn coupling rubbers/ vibration mounts.

Periodic checks should be made to :-

1. AVR and accessory terminal connections, for corrosion or loose joints.

2. Main Rectifier diodes, should be cleaned or changed if badly corroded.
3. Main output terminal, look for loose or high resistance joints,
(Joints can be scanned with a laser thermometer for ‘hot-spots’ while running on load).

NEWAGE PRODUCT TRAINING

 Maintenance requirements - Healthchecks

Running checks on the the Generator

Run the Generator up to nominal speed, and check :-

 1. The NO LOAD D.C voltage across the AVR terminals X+ (F1) and X-.
Keep this reading in the Gen-set maintenance record book for future reference.
Example :-

DATE FRAME SIZE SERIAL NUMBER R.P.M VOLTS LOAD D.C EXT
######## HCI734E C098976/2 1560 415 0 11.5

 This figure should NOT CHANGE throughout the life of the generator.
 If the D.C reading becomes HIGHER, it is an indication of :-
1. Possible SHORTS in the EXCITATION WINDINGS, OR,
2. Possible faults with the MAIN RECTIFIER DIODES.
THE NO-LOAD D.C VOLTAGE GIVES AN INDICATION OF GENERATOR HEALTH
FAULTS WITHIN THE GENERATOR WILL CAUSE AN INCREASE IN THE D.C. VOLTS.

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 RETURN TO MAIN MENU

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