Alternator Training
Alternator Training
Course Overview
Lessons:
Fundamentals of AC 1. Overview and Requirements
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The Genset
AC Generator
Lesson 1: Overview and Requirements Control
System
Objectives Turbo
• Describe Low, Medium, and High Voltages
Cooling System
Mounting Skid
Lesson Length : 20 Minutes
LV = up to 690V (1000V)
MV = up to 4,160V
EXCITER
HV = up to 13,800V SLIPRINGS
ROTOR
Fan
THE
THEMAIN
MAINROTOR
ROTORCURRENT
CURRENTIS
ISSUPPLIED
SUPPLIEDVIA
VIASLIPRINGS
AN EXCITER
AND
GENERATOR
BRUSHES
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Rotor
& Stator
Bearing
Main Rotor
Main Rotor Shaft
PMG
PMG
Rotor Rectifier
Rotor & Stator
Fan
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220-240V/50Hz
220-240V/60Hz
100-127V/60Hz
100-127V/50Hz
Lesson Length : 60 Minutes
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AVR Fabricated
Frame DE Bracket
NDE Bracket &
Exciter Stator
assy
Bearing Cap
PMG Rotor
PMG Stator
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IP RATINGS IP RATINGS
FIRST DIGIT - MECHANICAL PROTECTION SECOND DIGIT - WATER INGRESS
IP #1 - Vertically falling water droplets will not cause a problem if they enter the machine
IP 1 – Anything LARGER than 50mm diameter cannot touch anything MOVING OR LIVE
IP #2 - Water drops falling at up to 150 from vertical etc…..
inside the Generator.
AIR INLET & OUTLET IP #3 - Water drops falling at up to 600 from vertical, (protection from RAIN)
IP 2 – Anything LARGER than 12mm etc…. IP #4 – Water sprayed or splashed from any direction - limited ingress permitted.
IP 3 – Anything LARGER than 2.5mm etc...
IP 4 – Anything LARGER than 1mm etc... FOR IP44
IP 5 – No harmful deposits of DUST PARTICLES AIR INLET FILTERS
WITH WATER VANE
IP 6 – TOTALLY ENCLOSED SEPARATORS
AND
AIR OUTLET
SCREENS WITH 1MM
DIAMETER HOLES
FOR IP44
AIR INLET
FILTERS
NOT
& SPECIAL
AVAILABLE
1mm
SCREENS
REQUIRED
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Fan
Main Rotor (4 Pole)
Exciter Rotor DE
NDE Bearing Bearing
Key
Shaft
PMG
Rotor
Rectifier
(Optional)
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Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Main Rotor Shaft
Rectifier
Fan
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4 Pole 6 Pole Generator Frequency (HZ or CYCLES) = Speed (N) X Pairs of poles (P)
2 Pole
60
S
S
N No. Poles
Pairs of Poles 50Hz
50Hz 60Hz
60Hz
SHAFT N SHAFT N SHAFT 22 3000
3000 ?
3600
S 44 1500
1500 1800
N
66 1000
1000 1200
88 750
750 900
900
10
10 600
? 720
720
3000rpm 12
12 500
500 600
?
1500rpm 1000rpm
3600rpm 1800rpm 1200rpm 14
14 429
429 514
514
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Maintenance Maintenance
Insulation Resistance (IR) tests in order of importance: Winding insulation levels should be checked if:
1. Main stator windings. Minimum value of Insulation should be 1 MΩ to The Generator has been STATIONARY for a long period with Anti-
earth for Low voltage machines up to 690 V. Condensation heaters SWITCHED OFF, e.g. Standby applications.
2. The Exciter Stator Winding. This winding is exposed to contamination
from the air intakes. Severe contamination may cause temporary or The Generator has been subjected to high intake of water, snow, or ice.
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 The Generator windings are contaminated with Airborne DUST and DIRT,
insulation should be 1 MΩ to EARTH. and have become DAMP (through humidity and/or condensation).
4. Permanent Magnet Stator. This windings is totally enclosed and unlikely
to be affected by low IR. The Generator windings have become contaminated with airborne corrosive
elements, e.g. salt, (marine atmospheres), or corrosive elements, (methane
DANGER! gas, petro-chemical sites, gassing from batteries etc).
ELECTRIC
SHOCK
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After drying, the windings are still reading less than 1 MΩ to earth.
Domestic Supply
or portable Generator The windings are heavily contaminated with dust, dirt, and/or diesel exhaust
deposits.
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Troubleshooting Troubleshooting
What are the symptoms of a main rotor failure? What are the symptoms of a main stator failure?
When separately excited with a 12 V battery, output voltage will be low The output voltage will be unbalanced phase-phase or phase-neutral.
– Low voltage can be expected to be proportional to the loss of winding turns – if 50% of the When separately excited with a battery, the engine will appear to be loaded.
windings are shorted, output will be 50% of nominal
This results from short circuit current in the winding fault.
A self-excited machine may be unable to build up voltage on startup
If the generator is run for a short period, the fault area in the windings will
A separately excited machine may trip out repeatedly on AVR protection due become very hot. This can be detected by hand or by the smell of burning
to a high excitation volts condition insulation
A rotor winding fault may not be visible, as the outer turns are cooled by the Failed main rotor windings will require repair or replacement.
airflow and may appear to be undamaged.
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Excitation Generator
Lesson 4: Excitation Systems
Exciter Main Stator
Rotor
Objectives & Stator
• Describe the functions of the exciter generator, main rectifier, and PMG
generator Bearing
• Describe the makeup of the exciter generator, main rectifier, and PMG
generator
Main Rotor
• Recall important features of the exciter generator, main rectifier, and PMG Main Rotor Shaft
generator
• Summarize symptoms of failed excitation system components
• Explain troubleshooting and testing procedures for the exciter generator,
main rectifier, and PMG generator Rectifier
Fan
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X+ (F1)
AVR
XX- (F2)
Rectifier
Assembly
Exciter
Rotor
SHAFT
SHAFT
Exciter
Stator
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W U
V
SHAFT V
U
W
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Bearing
SHAFT
Main Rotor
Main Rotor Shaft
Rectified output
to Main Rotor
Rectifier
Fan
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Main Stator
Exciter
Rotor
& Stator
Bearing
Main Rotor
Main Rotor Shaft
Rectifier
Fan
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SHAFT
SHAFT D.C
Each phase is connected to a positive and negative Diode The Rectifier Output is a smooth D.C Supply across the Aluminium Heat Sinks
This is fed to the Main Rotor windings
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Energy absorbed
by Varistor.
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Stamford Rectifier Assembly AvK Rectifier Assembly P2, P3, P4 Power Supply To A.V.R
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Ceramic
Permanent
Magnets
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Maintenance Maintenance
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The voltage will be low when separately exciting with a 12 V battery Ω.--
mV
A self-excited machine may not build up voltage on run-up mA
V
A separately excited machine may trip repeatedly on high excitation
protection when load is applied (depending on how many diodes have failed) SHAFT µA
V
Two or more diodes short circuited can overheat the exciter rotor OFF
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mA Failure of the varistor usually results in the device going short circuit
V
µA
The varistor will often fail catastrophically (explode)
SHAFT V
OFF
On self-excited machines, a short circuit varistor will prevent voltage build-up
on initial startup.
On a separately excited machine , the PMG can open circuit the varistor after
Diode Positive Plate failure
Cathode Stud
The generator will function normally without the varistor. If the varistor is failed,
Reverse the Multimeter leads, so that the Positive lead is on the Anode side of the all diodes must also be replaced.
diode, the Multimeter should now read OL, (no electron flow).
A faulty diode will give a short circuit reading in both directions, or an open circuit reading
in both directions, (usually because the solder joint has failed).
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X+ F1) MΩ
X+ (F1)
XX- (F2)
XX- (F2)
Ω. --
mV
Test
mA
V M Ω 1KV
MΩ 500V
µA
V
OFF
MEGGER
EARTH
Check the Exciter Stator resistance across X+ & XX- with a multi-meter set on the Ω Also check the Exciter Stator insulation with a 500V or 1000V Insulation tester,
range. The MINIMUM insulation value should be 1.0 Megohm to Earth (Ground).
The correct resistance figures are given in the Operation and Maintenance Manual If lower than 1 MegOhm, The windings should be cleaned, dried, and re- coated with
supplied with the Generator. anti-track varnish, or replaced if permanently low.
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MILLIOHMS OHMS
When separately exciting with a 12 V battery, the generator output voltage
will be low V
SHAFT
SHAFT V
With a self-excited machine the generator may not be able to build up voltage
on startup (residual voltage is too low)
With a separately excited machine a short in the exciter rotor may cause
repeated tripping of the AVR excitation protection circuit on load. This is U
caused by high excitation voltage
W
Visual inspection is recommended, any winding or insulation damage is usually visible
The exciter rotor windings can be damaged by short circuited diodes on the on the exciter rotor end windings, (burnt or blackened coils).
main rectifier A Low Resistance Bridge is required to accurately measure values below 0.5 Ω.
The correct resistance figures are given in the Operation and Maintenance Manual
supplied with the Generator.
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3 Phase Ω
6 W1
When separately exciting with a 12 V battery, the generator output voltage W Output mV
Loss of residual magnetism will prevent voltage build-up when the AVR is
7 V V1 V
µA
V
working normally
Decay of residual magnetism can be caused by long storage periods
8 U U1 OFF
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Failure of the power diodes in the AVR, causing a short circuit across one of
the phases of the PMG Stator.
Wear of the non drive end bearing housing, causing contact between the
BLOCKING PMG stator and Rotor cores.
DIODE
RUN
+ -
ENGINE
12v BATTERY
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PMG Testing
FLUKE 87
P2, P3, P4 Power Supply To A.V.R P2 P3 P4 Lesson 5: AVR Systems
Objectives
Ω • Distinguish between digital and analogue AVR systems
mV
• Identify the inputs and outputs of an AVR
mA
V • Describe the DC output from an AVR
µA
V
• Summarize the operating logic of an AVR
OFF • Explain troubleshooting and testing procedures for AVR systems
Run the Generator at nominal speed, and set the Multi-meter to read A.C Volts.
Check the Permanent Magnet Stator output Voltage across the 3 input terminals
to the AVR. The Voltage across P2,P3,P4, should be 170 VAC to 220 VAC, and
Lesson Length : 90 Minutes
balanced across phases.
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wn J1000
M275V
Sensing supply 121K
C1334
Into
Exciter Stator (feedback)
R6- µ33
from Main Stator
48300
Exciter ( 170 - 240V)
Rotor 2 or 3 phase
& Stator
Bearing WARNING !
E00-14065A
33732/2833
ELECTRIC SHOCK RISK
[LIVE TERMINALS
AND HEATSINK ]
AS440 [E000-24403]
Main Rotor
Main Rotor Shaft
EXT
Rectifier
Fan
STABILITY UFRO 60 C 50
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PMG
Power X+ (F1) A.V.R A.C Sensing
Supply 6-7-8 Supply From
To A.V.R XX- (F2) Main Stator
Main Stator (2 or 3 Phase)
Exciter
Rotor
& Stator
Bearing
Main Rotor
Main Rotor Shaft
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S2 S1 A2 A1
TRIM
Input Var/ PFC3
63V47µF
MX341-2 E000-23412
[Live Terminals]
ELECTRIC SHOCK
WARNING! DROOP Input Droop C/T High voltage – This can be caused by loss of signal (sensing supply) from the
main stator
V2115
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
No voltage – This can also be caused by loss of power supply to the AVR
47nk
VOLTS Linking for
580µ0k
Low Voltage – This could be caused by a high voltage sensing signal,
W23 6%
3 Phase
Sensing Unit
possibly caused by shorted turns on the sensing transformer or a
47nk
1µ0k
misconnection of the sensing supply to high voltage connections.
1µ0k
47nk
47nk
100nk
100nk
1µ0k
UFRO 3 2 1 STAB C B A
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µA
V 8 U U1
OFF
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U 8 Objectives
• Distinguish between 6 wire and 12 wire stator outputs
U1
Isolation • Explain how stator winding ends are connected to produce configurable
Transformer Ω outputs
U2 mV
• Recognize various 12 wire connection configurations
8 mA
N V • Interpret generator wiring diagrams
W2 V2
µA
V
7
OFF
W1 V1 7
w v
6 6
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N V6 Neutral
6 W1
W
3 Phase Output
AVR Sensing 7 V V1
& Power supply
from Main Stator
8 U U1
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W1 V1 7
7
W V
6 6
The AVR Sensing supply is connected to the main stator via a sensing
isolation transformer, which is fitted in the main terminal box.
Other windings producing higher voltage requirements will require a
different transformer ratio, to supply the AVR with the correct voltage
adjustment range
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Connection Diagram
12 Wire Connections
Bearing Types
Lesson 7: Bearings
There are many differing bearing types. Because of the
Objectives
methods and scale of engineering in manufacturing
• Differentiate between ball, roller, and sleeve bearings Generators, CGT uses three principle types of bearings
• Identify the type of bearing available for various generator applications – Ball Bearings
• Explain the value of proper re-greasing and the effects of re-greasing
• Sealed
• Explain troubleshooting methods for bearings
• Re-greasable
– Roller Bearings
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Regreasable Combo
Regreasable Ball
Flanged Sleeved
Flanged Sleeved
Pedestal Sleeve
Anti-frictional
Anti-frictional
Anti-frictional
Sealed Ball
Pumped
Variant
Brand
Model
stated:
Re-lubricating interval in hours of operation
Quantity of grease
Stamford P 0 l
Stamford P 1 l
Type of anti-friction bearing grease
Stamford UC 22 l
Stamford UC 27 l
Stamford HC 4 l
Stamford HC 5 l l
Stamford HC 6 l
Stamford P 7 l
Stamford MV 7 l
Stamford P 80 l
Stamford MV 80 l
Stamford HV 80 l
AvK DSG 62-74 l
AvK DSG 86-99 l l l l
AvK DSG 114-125 l l l l
AvK DIG 110-130 l l l l
AvK DIG 140-156 l l l l
AvK DIG 161-171 l l
AvK DIG 181-191 l
Regreasing Regreasing
Location
of the
grease
points
Periodic health checks: Experience gained by touch and hearing in operation, will in time,
During the lubrication process the temperature of the bearings
establish ‘normal’ conditions, and help identify any future changes in temperature, noise, or
may rise, but should decrease to normal values after a few hours
vibration.
of operation.
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Troubleshooting
INCREASED INCREASED INCREASED
Lesson 8: Accessory Components
TEMPERATURE VIBRATION NOISE.
DE Objectives
Bearing • Identify various electronic generator accessories
• Describe the operation of anti-condensation heaters and temperature
detectors
• Differentiate between thermistors and RTDs
NDE
Bearing Lesson Length : 20 Minutes
TO SEPARATE HEATER
TERMINAL BOX
210-325W 220/260V
BC16 / 18
MOUNTED ON FRAME
MAIN STATOR
210-325W 220/260V
TYPICAL WRAP-AROUND
CARTRIDGE TYPICAL MOUNTING HEATER MOUNTED ON
HEATERS BRACKET (HC RANGE). BOLTED TO EXCITER STATOR WINDINGS
STATOR CORE PACK
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Thermistors Thermistors
DOPED BARIUM TITANATE DISC THERMISTOR TYPES FOR ALARM OR TRIPPING
IN A CERAMIC PELLET
TR LEAD COLOUR CLASS H CLASS F
ºC HC UC HC UC
INSULATED
80 WHITE/WHITE
SHRINK SLEEVE 90 GREEN/GREEN
100 RED/RED
110 BROWN/BROWN A = ALARM
COLOUR CODED 120 GREY/GREY T = TRIPPING
130 BLUE/BLUE
LEADS
140 BLUE/WHITE
THERMISTOR - 150 BLACK/BLACK
POSITIVE 155 BLUE/BLACK A
160 RED/BLUE
TEMPERATURE A
170 WHITE/GREEN A T
COEFFICIENT 180 WHITE/RED T A T
RESISTOR 190 GREY/BROWN T
RTDs RTDs
RESISTANCE TEMPERATURE DETECTORS
RTD RESISTANCE/TEMPERATURE
PT100 RTD FOR STATOR PT100 RTD FOR CHARACTERISTIC
WINDING SLOT INSERTION GENERATOR BEARINGS 250
50
GLASS FIBRE 0
INSULATOR
-50
-100
-150
COLOUR CODED
40 60 80 100 120 140 160 180 200
LEADS
OUTPUT LEADS & COPPER BRAIDED RTD RESISTANCE Ω
CALIBRATION LEAD SLEEVING
PT100 = 100 OHMS RESISTANCE AT 0oC
RTDs
PT100 RTD FOR PT100 RTD FOR STATOR WINDING Lesson 9: Operation
GENERATOR BEARINGS SLOT INSERTION
Objectives
• Recall basic electrical and generator operating theory
RTD FITTED TO • Describe self-excited generator excitation and operation
MAIN STATOR
BEARING HOUSING • Describe separately excited generator excitation and operation
SLOT (SECTION)
• Explain general generator maintenance procedures
• Explain general generator troubleshooting processes
CAP BOLTS
RTD INSERTED
BEARING CAP INTO SLOT
1 TO 3 PER PHASE
IRON
BEARING CORE
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Active
Material MAGNETIC FLUX
– Strength of Generated Field
Bearing AC
3PH MAIN ROTOR Shaft
A.C DC
+
_
Main Rotor DC
Main Rotor Shaft
Rectifier
Fan
Main Rotor
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WHO
Me ?
DANGER!
ELECTRIC SHOCK
[Live Terminals]
Maintenance Requirements Maintenance Tasks and Scheduling SERVICE ACTIVITY TYPE SERVICE LEVEL
Replace
Inspect
Level 1
Level 2
Level 3
Clean
Test
Maintenance requirements for brushless AC X = required
* = if necessary
generators are:
Generator rating X X
Bedplate arrangement X X
Coupling arrangement X X * X
Environmental conditions and cleanliness X X X X X X
Generator
Ambient temperature (inside & outside) X X X X X X
Complete machine - damage, loose parts & earth bonds X X X X X X
Guards, screens, warning and safety labels X X X X X X
Maintenance access X X
Electrical nominal operating conditions & excitation
Bearing inspection
X X X X X X X
Vibration X X X X X X X
Condition of windings X X X X X X
Windings
X
Grease exhaust & trap X X X X X
Bearings
Bearing grease X X X X X
Operational checks
Customer connection of auxiliaries X X X X X
Function of auxiliaries X X X X X X
Synchronisation settings X X
Synchronisation X X X X X X X
Anti condensation heater X * X
Diodes and surge suppressors
Rectifier
X X X X X
Diodes and surge suppressors X X
X X X X X X X
Air flow (rate & direction) X X X
Condition of fan X X X X X X
Condition of air filter (where fitted) X X X X X X
Air filters (where fitted) X X * * *
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Final Inspection Before Running Genset Final Inspection Before Running Genset
AC Generators may be subjected to environmental conditions which are detrimental to the
2. MAIN Generator:
TERMINAL
1. AVR CONNECTIONS High humidity, or exposure to the elements, rainwater, and/or offshore sea mists.
CONNECTIONS Dust, dirt, and/or corrosive chemicals in the atmosphere.
Excessive vibration from the engine, worn flexible couplings, or anti-vibration mounts.
AVR
AVR
Main Stator
Exciter Main Stator Exciter
Rotor Rotor
& Stator & Stator
Bearing Bearing
Main Rotor
Main Rotor Shaft Main Rotor
Main Rotor Shaft
Rectifier
Fan
Rectifier Fan
FIRST CHECK THAT THE GENERATOR IS SAFE TO RUN, WITH AN INSULATION CHECK
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Bearing Bearing
Rectifier Rectifier
Fan Fan
Checking Output Voltage – Balanced and Checking Output Voltage – Balanced and
in Limits in Limits
FLUKE 87 FLUKE 87
AVR Sensing AVR Sensing
& Power supply & Power supply
from Main Stator N V6 Neutral from Main Stator N V6 Neutral
3 Phase Ω
3 Phase Ω
6 W1 6 W1
W Output mV W Output mV
mA mA
7 V V1 V
µA
7 V V1 V
µA
V V
8 U U1 OFF
8 U U1 OFF
3 Phase Ω
3 Phase Ω
6 W1 6 W1
W Output mV W Output mV
mA mA
7 V V1 V
µA
7 V V1 V
µA
V V
8 U U1 OFF
8 U U1 OFF
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FLUKE 87 FLUKE 87
AVR Sensing AVR Sensing
& Power supply & Power supply
from Main Stator N V6 Neutral from Main Stator N V6 Neutral
6 3 Phase Ω
3 Phase Ω
W1 6
W Output mV W W1
Output mV
mA mA
7 V V1 V 7 V V1 V
µA µA
V V
8 U U1 OFF
8 U U1 OFF
Checking Output Voltage – Balanced and Checking Output Voltage – Balanced and
Below Limits Below Limits
FLUKE 87 FLUKE 87
AVR Sensing AVR Sensing
& Power supply & Power supply
from Main Stator N V6 Neutral from Main Stator N V6 Neutral
3 Phase Ω
3 Phase Ω
6 W1 6 W1
W Output mV W Output mV
mA mA
7 V V1 V
µA
7 V V1 V
µA
V V
8 U U1 OFF
8 U U1 OFF
mA Bearing
7 V V1 V
µA
V
Main Rotor
Main Rotor
8 U U1 OFF
Shaft
Rectifier Fan
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Main Rotor
Main Rotor
If the Output Voltage Is still reading LOW, (MORE THAN 10% BELOW THE
Shaft NOMINAL), this indicates a fault in one of the excitation windings.
The EXCITER STATOR, ROTOR, AND MAIN ROTOR WINDINGS must now be
Rectifier checked for faults.
Fan
The winding RESISTANCE VALUES can be checked against correct values given in
the Generator O & M manuals.
Bearing Bearing
Shaft Shaft
Check Exciter and Main Rotor Windings Check and Restore Residual Magnetism
Output From Output From
Battery into - + Battery into - +
Exciter Stator 12vA.V.R
BATTERY Exciter Stator 12vA.V.R
BATTERY
X+ XX- X+ XX-
Exciter Main Stator Exciter Main Stator
Rotor Rotor
& Stator & Stator
Bearing Bearing
Shaft Shaft
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Main Rotor
Main Rotor Shaft Bearing
Main Rotor
Main Rotor Shaft
Rectifier
Fan
Rectifier
Fan
AVR
AVR
Exciter Main Stator Exciter Main Stator
Rotor Rotor
& Stator & Stator
Bearing Bearing
Rectifier Rectifier
Fan Fan
End, Thanks!
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