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Alternator Training

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100% found this document useful (4 votes)
454 views28 pages

Alternator Training

Uploaded by

ibsamengistu29
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 28

2019/11/21

Course Overview

 Lessons:
Fundamentals of AC 1. Overview and Requirements

Generators (Awareness Level) 2.


3.
Generator Build
Main Generator – Rotor and Stator
Version 2.0 4. Excitation Systems
5. AVR Systems
6. Wiring and Reconnections
7. Bearings
8. Accessory Components
9. Operation
10. Maintenance & Trouble Shooting

2 11/21/2019

The Genset
AC Generator
Lesson 1: Overview and Requirements Control
System
Objectives Turbo
• Describe Low, Medium, and High Voltages
Cooling System

• Distinguish between self- and separately excited generators AC Generator


• Distinguish between brushed and brushless generators Filter
• Recognize various requirements for generator applications
Engine

Mounting Skid
Lesson Length : 20 Minutes

3 11/21/2019 Cummins Confidential 4 11/21/2019 Cummins Confidential

Low, Medium, and High Voltage Brushed vs. Brushless


CONTROL
 There is no actual definition as SYSTEM
to what is Low, Medium or High Main Stator
EXCITER
Voltages as this depends CARBON
STATOR
BRUSHES
greatly on the nature of the
industry you work within.
 CGT works on (as does most
Main Rotor
other generator manufacturers) Main Rotor

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

5 11/21/2019 6 11/21/2019

1
2019/11/21

Self vs. Separately Excited Understanding Requirements


PMG
Power X+ (F1) AVR AC Sensing
A.C Sensing&
Supply AVR
ONLY power
From
to AVR XX- (F2) supply from
Main Stator
Main Stator Main
(2 or 3Stator
Phase)
Exciter (2 or 3 Phase sensing)

Rotor
& Stator

Bearing

Main Rotor
Main Rotor Shaft

PMG
PMG
Rotor Rectifier
Rotor & Stator
Fan

7 11/21/2019 8 11/21/2019

Types of Power Requirement Sizing Requirements

 Prime  Power requirements


 Standby – Voltage (V)
– Frequency (Hz)
 Emergency
– Load (prime function
 Marine
– Load & Equipment Characteristics
– Power Sharing (Island mode)
– Grid Connection

9 11/21/2019 10 11/21/2019

Worldwide Standard Supplies


Lesson 2: Generator Build
Objectives
• Recognize rolled frame and frame bar designs
• Outline general generator assembly
• Recall IP ratings and their meanings
• Recall maintenance procedures for generator enclosures and
frames

220-240V/50Hz
220-240V/60Hz

100-127V/60Hz
100-127V/50Hz
Lesson Length : 60 Minutes

11 11/21/2019 12 11/21/2019 Cummins Confidential

2
2019/11/21

Build Types Rolled Frame Design

There are a number of ways to manufacture an AC


Generator this section will look at two differing designs
used within CGT.
 Rolled Frame Design
– Produced by rolling thick steel plate into a cylinder to form an outer
cage and frame for the generator Stator & inner components to be
pressed into.
 Frame Bar & End plate Design
– Structural ‘Frame’ Bars directly welded to the stator core pack,
with further strength and support coming from two very substantial
end brackets.

13 11/21/2019 14 11/21/2019

Rolled Frame Assembly Rolled Frame Example – Stamford P7


Main Rotor

Main Terminals Main Stator

AVR Fabricated
Frame DE Bracket
NDE Bracket &
Exciter Stator
assy
Bearing Cap

PMG Rotor

PMG Stator

15 11/21/2019 16 11/21/2019

Frame Bar Design Frame Bar Assembly

Form Wound Main Stator Winding


Main Frame Bars –
Welded to Core Pack

17 11/21/2019 18 11/21/2019

3
2019/11/21

Frame Bar Example – Stamford P80 Build for Environment

 IP Rating (ingress protection)


– An international classification system which indicates the
degree of protection within an enclosure against the
intrusion of foreign bodies, dust & Moisture
– The system uses the letters ‘IP’ followed by two
numbers/digits

 Note: IP protection does not specify effectiveness


against condensation, mechanical damage,
atmospheric vapours, explosive environments, or
vermin.

19 11/21/2019 20 11/21/2019

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

IP Ratings for CGT Generators


Lesson 3: Main Generator – Rotor and
 Both Stamford and AvK current ranges of generators Stator
meet with IP23 as standard Objectives
– First digit (2) – Protection against solid objects up to 12mm • Describe the functions of the main generator rotor and stator
diameter (i.e. a finger) touching anything live or moving • Describe the makeup of the main rotor and stator
inside the generator • Recall the important features of the main rotor and stator
• Summarize the symptoms of failed main rotor and failed main stator
– Second digit (3) – Protection against water spray up to 60°
• Explain troubleshooting and testing procedures for main rotor and stator
from the vertical in any direction. Ingress of water will not
cause problems in the Generator.
 Up to IP44 available for Stamford
 Up to IP55 available for AvK
Lesson Length : 120 Minutes

23 11/21/2019 24 11/21/2019 Cummins Confidential

4
2019/11/21

Main Rotor Assembly – Two Bearing Two Bearing Rotor

Fan
Main Rotor (4 Pole)
Exciter Rotor DE
NDE Bearing Bearing
Key

Shaft
PMG
Rotor
Rectifier
(Optional)

25 11/21/2019 26 11/21/2019

Main Rotor Assembly – Single Bearing Single Bearing Rotor


 Drive end of Generator supported by engine Flywheel Single bearing coupling
assembly
 Flexible coupling discs fit into flywheel Recess

27 11/21/2019 28 11/21/2019

Main Stator Main Stator Core Assembly


Main Stator

Main Stator
Exciter
Rotor
& Stator

Bearing

Main Rotor
Main Rotor Shaft

Rectifier
Fan

29 11/21/2019 30 11/21/2019

5
2019/11/21

Main Stator Windings Main Stator Assembly

Output Leads Laminated Steel core Copper Windings

31 11/21/2019 32 11/21/2019

Poles and Frequency Poles and Frequency

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

33 11/21/2019 34 11/21/2019

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
35 11/21/2019 36 11/21/2019

6
2019/11/21

Maintenance – Drying the Windings Maintenance – Cleaning the Windings

It is necessary to clean the windings if:

 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.

 The windings are contaminated with corrosive deposits (salt or other


chemical deposits) which immediately give low IR reading with condensation
or high humidity.

37 11/21/2019 38 11/21/2019

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.

39 11/21/2019 40 11/21/2019

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

Lesson Length : 120 Minutes

41 11/21/2019 Cummins Confidential

7
2019/11/21

Exciter Generator and Rectifier Assembly Exciter Stator Example

X+ (F1)
AVR
XX- (F2)
Rectifier
Assembly

Exciter
Rotor
SHAFT
SHAFT
Exciter
Stator

43 11/21/2019 44 11/21/2019

Exciter Rotor Exciter Rotor


 3 Phase A.C output, each Phase connected to 2 diodes on Main Rectifier.
 High Frequency output, ( from 10 to 14 Pole Exciter Stator ).
 The Exciter generator is a power amplifier supplying the main rotor current.

W U

V
SHAFT V

U
W

45 11/21/2019 46 11/21/2019

Main Rectifier Split-Hub Type Rectifier


Main 3 Phase A.C Input
Rectifier from Exciter Rotor. Aluminium
(Insulated Terminals) Heat-sinks

Main Stator Split Two-Piece


Exciter Rectifier Hub Varistor
Rotor (Surge Suppressor)
& Stator

Bearing

SHAFT
Main Rotor
Main Rotor Shaft

Rectified output
to Main Rotor
Rectifier
Fan

47 11/21/2019 48 11/21/2019

8
2019/11/21

Rotating Rectifier Example Main Rectifier Circuit


Exciter Rotor and
Main Rectifier
Circuit

Main Stator
Exciter
Rotor
& Stator

Bearing

Main Rotor
Main Rotor Shaft

Rectifier
Fan

49 11/21/2019 50 11/21/2019

Main Rectifier Circuit Main Rectifier Circuit


Exciter Rotor 3 Phase
Main Rectifier Main Rotor
with Internal Star Point

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

51 11/21/2019 52 11/21/2019

Metal Oxide Varistor Metal Oxide Varistor


Direction
of fault
transient

Energy absorbed
by Varistor.

Varistor clamping level

Full load D.C


output from t = µ sec's
main duration.
Rectifier
Direction of D.C current to Main rotor
53 11/21/2019 54 11/21/2019

9
2019/11/21

AvK Rotating Rectifier Permanent Magnet Generator (PMG)

Stamford Rectifier Assembly AvK Rectifier Assembly P2, P3, P4 Power Supply To A.V.R

Generator Shaft (Non-Drive -End)

 Dowel Pin for PMG Rotor Location


 Ceramic Magnet Rotor, highly magnetic saturated field. 8 Pole Rotor , 100 HZ
(at 1500 RPM ) or 120 HZ (at 1800 RPM )
 Through Bolt fixture to Shaft non drive end
 Permanent Magnet Stator 3 Phase A.C 170 to 220 Volts, separate power supply
for the A.V.R

55 11/21/2019 56 11/21/2019

PMG Assembly PMG Identification


Rare Earth
Permanent
Magnets

Ceramic
Permanent
Magnets

57 11/21/2019 58 11/21/2019

Maintenance Maintenance

 DC Excitation Check Insulation Resistance (IR) tests in order of importance:


– Run the generator without load at nominal speed
– Record the DC voltage across the AVR terminals X+(F1) and X-(F2) 1. Main stator windings. Minimum value of Insulation should be 1 MΩ to
earth for Low voltage machines up to 690 V.
DATE FRAME S/N R.P.M VOLTS LOAD DC EXT. 2. The Exciter Stator Winding. This winding is exposed to contamination
MAY 2010 P734C C098765/1 1530 415 0 12.3 from the air intakes. Severe contamination may cause temporary or
permanent low IR, which could effect the AVR performance.
– Keep this record in the genset maintenance logbook for future reference 3. The Exciter Rotor, & Main Rotor. These are rotating low voltage
– This excitation figure should not change throughout the life of the windings, and are unlikely to be affected by low IR. Minimum value of
generator. insulation should be 1 MΩ to EARTH.
– Higher no-load DC voltage could indicate 4. Permanent Magnet Stator. This windings is totally enclosed and unlikely
• Low engine speed or terminal voltage too high to be affected by low IR.
• Faulty main rectifier diode(s)
• Faulty Exciter generator windings or main rotor windings DANGER!
ELECTRIC
SHOCK
59 11/21/2019 60 11/21/2019

10
2019/11/21

Troubleshooting Diode Testing


FLUKE 87

What are the symptoms of a diode failure? Diodes Negative Plate


Anode Stud

 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

 A short circuited diode can sometimes melt its solder terminal


Diode Positive Plate
Cathode Stud

Diodes usually become short circuited when faulty

 Switch the Multi-meter to the position indicating ‘diode’ test position.


 With the Positive test lead on the Cathode side of the diode, the meter should
give a reading, indicating electron flow

61 11/21/2019 62 11/21/2019

Diode Testing FLUKE 87


Troubleshooting
Diodes Negative
Plate Anode Stud
What are the symptoms of a varistor failure?
mV
Ω.--

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).

63 11/21/2019 64 11/21/2019

Varistor Failure Troubleshooting

What are the symptoms of an exciter stator failure?

 When separately exciting with a 12 V battery, the generator will produce


residual voltage only. This is due to an open circuit in the windings
 Earth faults in the exciter stator can cause AVR instability and can cause
overheating of the PMG stator winding
 A severe earth fault may cause the AVR power diodes to fail due to
excessive leakage current. This can also burn out the PMG stator windings

 A faulty Varistor will be short circuit, or burnt (destroyed) by fault current

65 11/21/2019 66 11/21/2019

11
2019/11/21

Exciter Stator Testing Exciter Stator Testing


FLUKE 87

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.

67 11/21/2019 68 11/21/2019

Troubleshooting Exciter Rotor Testing


W
What are the symptoms of an exciter rotor failure? U
DUCTER Digital Ohmmeter

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.

69 11/21/2019 70 11/21/2019

Troubleshooting Testing for Residual Magnetism


FLUKE 87
What are the symptoms of a loss of residual
magnetism? N V6 Neutral

3 Phase Ω
6 W1
 When separately exciting with a 12 V battery, the generator output voltage W Output mV

will appear to be normal (balanced and within 10% of nominal) mA

 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

Loss of residual magnetism affects self-excited machines only – PMG systems


do not require residual magnetism for voltage build-up CHECK AT AVR.
Power supply
Leads 7 & 8 , (or P2 – P3 ) from Stator

71 11/21/2019 72 11/21/2019

12
2019/11/21

Restoring Residual Magnetism Troubleshooting


X+
What are the symptoms of a PMG failure?
XX-

 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

73 11/21/2019 74 11/21/2019

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

Generator Drive Shaft (Non-Drive -End)

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.

75 11/21/2019 76 11/21/2019 Cummins Confidential

Excitation Control Analogue AVR

 Excitation control can be provided in a number of  Automatically – Via an Analogue system


ways – Similar to what the Stamford product utilises as standard. A
– Manually simplistic Thyristor/SCR switching or PWM system.
– Automatically – Features dependant upon model used.
• Via an Analogue system – Settings readily adjustable via potentiometers
• Via an Digital system MA 330 AvK Cosimat+
SX460 3 phase sensing Modular additions
 Manually – MVR 2 phase sensing PWM (QPF, TF & more)
– Hand Controlled Excitation system

77 11/21/2019 78 11/21/2019

13
2019/11/21

Digital AVR Self-Excited Analogue AVR

 Automatically – Via a Digital system


– Purchased to order
– Many features available dependant upon model used.
– Settings on Basler adjustable via RS232 connection &
Bestcom Windows based software program.(software shelf)
DECS 100 & DM110 DECS 200 ABB UNITROL

79 11/21/2019 80 11/21/2019

AVR Control and Operation AVR Example – Stamford AS440


F2 F1 7 8 8 Z2
X+ (F1) AC Power Input
AVR from Main Stator

VOLTS 1 2 3 L L DROOP S1 S2 A1 A2 TRIM TRIP


D.C Output ( 170 - 240V)
From AVR XX- (F2)

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
81 11/21/2019 82 11/21/2019

Separately Excited Analogue AVR AVR Control and Operation


P2 -P3 -P4

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

THE PMG PROVIDES A Rectifier


SEPARATE POWER Fan
SUPPLY FOR AVR

83 11/21/2019 84 11/21/2019

14
2019/11/21

AVR Example – Stamford MX341 Troubleshooting


K2 K1 P2 P3 XX X P4 3 2 2 1

What are the symptoms of an AVR failure?


30114/00166

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

DIP EXC TRIP


 Unstable voltage – This can also be caused by loose wiring or corroded
47nk

47nk

terminals from the AVR to the generator


47nk

47nk
100nk

100nk

1µ0k

UFRO 3 2 1 STAB C B A

85 11/21/2019 86 11/21/2019

Checking AVR Environmental Conditions Testing AVR Supply Circuits

 Check that the AVR is not being affected by adverse


environmental conditions AVR Sensing Neutral
FLUKE 87
– Excessive temperature (local to AVR) – Limits -40°C to & Power supply
+70°C (-40°F to 158°F) from Main Stator N V6

– Excessive vibration – Limits 50 mm/s velocity at 20-100 Hz 6


W W1
Ω 3 Phase
– Excessive humidity – Limits 0-60°C (32-140°F), 95% mV
Output
mA
7 V V1
V

µA
V 8 U U1
OFF

87 11/21/2019 88 11/21/2019

Testing AVR Supply Circuits


Lesson 6: Wiring and Reconnections
Wound Main Stator 6 Ends Out FLUKE 87

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

Lesson Length : 30 Minutes

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15
2019/11/21

6 vs. 12 Wire Reconnectable 12 Wire Main Stator – UC Type


 6 or 12 wire alternators relate to the connect-ability of the internal
coils within the main stator coils.
– A 12 wire re-connectable simply means that it can be connected in differing
configurations, Series-Star/Wye, Parallel- Zig-Zag etc. Which in turn produces a
different output voltage from the Alternator.
 CGT offer a number of 12 wire re-connectable alternators within it’s
smaller Stamford ranges (up to 1000kVA). Making them Ideal for the
rental market.
 This is not offered on larger equipment because of cable sizes
involved, cost and feasibility. Larger machines being generally prime
power and require dedicated connection, so normally will be 6 wire.

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Terminal Block Terminal Block

Connections shown in Series Star

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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Main Stator Winding Voltage Ranges Star (Wye) Connections


VOLTAGE LEVEL MUST BE WITHIN THE RANGE SPECIFIED FOR THE GENERATOR WINDINGS.
Series Star Parallel Star
TYPICAL WINDING TYPES WITH VOLTAGE RANGES ( SERIES STAR)
U U
Winding Number Stator 50HZ 60HZ 8
Number Phases Ends Min Mid Max Min Mid Max U1
U1 U5
311 3 12 380 415 440 416 460 480 U2
312 3 6 380 415 440 416 460 480 U5 8
U2 U6
25 3 12 660 675 690 - - -
U6
26 3 6 660 675 690 - - - W2 N V6
W6 N V5
13 3 6 - - - 380 400 416 W5 7 W1
14 3 12 - - - 380 400 416 W2 V6
W1 7
V5
17 3 12 - - 500 - - 600 V2 W6
6 V1 w V2 v
7 3 6 - - 500 - - 600 w v W5 V1
6
5 1 4 220 230 240 - - -
Voltage Range (for winding 311) Voltage Range (for winding 311)
6 1 4 - - - 220 230 240
BELOW MINIMUM LEVEL - POOR VOLTAGE RESPONSE TO LOAD CHANGES
380 to 440 V @ 50 HZ 190 to 220 V @ 50 HZ
ABOVE MAXIMUM LEVEL - EXCITATION CURRENT WILL BE TOO HIGH ON LOAD 416 to 480 V @ 60 HZ 208 to 240 V @ 60 HZ

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Delta Connections 6 Wire Star Connection


Series Delta Double Delta Star connection
U
8 6 Voltage Range (winding 312) 8
Centre 380 to 440 V @ 50 HZ
Tap U1
416 to 480 V @ 60 HZ
Single Phase (N) = L–L / √3
6 7 8
Dropper transformer required U2
7
for AVR sensing
N
W2 V2
N
W1 V1 7

Voltage Range (winding 311) w v


Voltage Range (Winding 311)
220 to 250 V @ 50 HZ, 240 to
220 to 250 V @ 50 HZ, 240 to 277 V @ 60 HZ 6
277 V @ 60 HZ
Single Phase Only, output across U & W
No Neutral connection.
Centre Tap (N) for low volts  Each phase group is producing the full LINE to NEUTRAL
Centre Tap for low volts (low
110 to 125 @ 50 HZ, 120 to 138 @ 60 HZ voltage (Coil groups in each phase are in four parallel circuits).
current only)
 The AVR cannot be connected directly to 6,7,and 8, for
sensing signal or power

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6 Wire Sensing Supply Wiring Diagram – Stamford SX440


SENSING SUPPLY FOR A.V.R IN STAR CONNECTION
Examples - 6 ends Stators U 8
Winding 312
380 to 440 V @ 50 HZ U1
416 to 480 V @ 60 HZ
Isolation transformer
Single Phase (N) = L-L / √3
U2 8
Winding 26 N
660 - 690 Volts @ 50 HZ W2 V2

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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Wiring Diagram – Stamford MX341 Wiring Diagram – Stamford MX321

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Connection Diagram

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12 Wire Connections

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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

Lesson Length : 30 Minutes – Sleeve Bearings

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Bearing Selection Bearing Grease


Machines with re-lubricating devices

Regreasable Combo
Regreasable Ball

Flanged Sleeved

Flanged Sleeved

Pedestal Sleeve
Anti-frictional

Anti-frictional

Anti-frictional

Ball & Roller


Are fitted with a plate on which the following information is

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

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Regreasing Regreasing

Location
of the
grease
points

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Bearing Grease Characteristics Troubleshooting


Temperature Curve of re-greased bearing What are the symptoms of a bearing problem?

 Temperature rise in the bearing housing. Temperature monitoring is achieved with


R.T.D’s, (fitted to bearing housing), or alternatively, Laser Thermometer, (a portable
hand held instrument). Note: Local ambient temperatures around the bearing should be
taken into account.
 Vibration. Increased vibration in the Generator, suddenly, or slowly over a period of
time. Vibration test equipment can be expensive, regular checking by hand near the
bearing housing will establish normal levels over long periods of time. Note: Increased
vibration could also indicate an engine related problem.
 Noise. Bearings making abnormal noises, audible, with or without Stethoscope.
A Stethoscope is required for elimination of all other possible causes of noise.

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

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Electronic Accessories Anti-Condensation Heaters

EXCITATION FREQUENCY DIODE


LOSS DETECTION FAILURE WRAP- AROUND TYPE TAPE HEATER
MOULE MODULE DETECTOR

EMC / RFI / EMP MANUAL


DIFFERENTIAL
SUPPRESSION VOLTAGE
PROTECTION
MODULES REGULATOR

CARTRIDGE TYPE HEATING ELEMENT


ANTI THERMISTOR
CONDENSATION & R.T.D 120-185 W
220/260V
HEATERS

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Cartridge Heaters Tape Heaters

WRAP AROUND TYPE TAPE


HEATERS
CARTRIDGE TYPE HEATING
ELEMENT

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

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RTDs RTDs
RESISTANCE TEMPERATURE DETECTORS
RTD RESISTANCE/TEMPERATURE
PT100 RTD FOR STATOR PT100 RTD FOR CHARACTERISTIC
WINDING SLOT INSERTION GENERATOR BEARINGS 250

PT100 PLATINUM PT100 PLATINUM 200


TEMPERATURE TEMPERATURE ºC
TEMPERATURE SENSOR 150
SENSOR 100 OHMS @ 0 °C
100 OHMS @ 0 °C 100

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

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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

CARTRIDGE Lesson Length : 60 Minutes

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Operation Basics Operation Basics


 ACTIVE MATERIAL
Movement
Magnetic – Conductive Steel & Copper
Flux
(laminations & windings)

Active
Material  MAGNETIC FLUX
– Strength of Generated Field

Electrical Energy  MOVEMENT


– Mechanical drive or energy

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Self-Excited Generator Operation Energy Transfer


X+ (F1) U
V GENERATOR
D.C Output AVR A.C Power &
AVR W OUTPUT
XX- (F2) Feedback Signal
From A.V.R N
Into Exciter (Sensing) From
Stator Main Stator
Main Stator MAIN ROTOR / STATOR
Exciter F1+ F2-
Rotor MAIN STATOR AIR GAP
& Stator EXCITER AIR GAP D.C RECTIFIER AC

Bearing AC
3PH MAIN ROTOR Shaft
A.C DC
+
_
Main Rotor DC
Main Rotor Shaft

MAGNETIC FLUX MAGNETIC FLUX

Rectifier
Fan

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Separately Excited Generator Operation


PMG
Power P2 -P3 -P4
AC Sensing
Lesson 10: Maintenance & Troubleshooting
X+ (F1) AVR
Supply 6-7-8 Supply From
to AVR XX- (F2) Main Stator
Objectives
(2 or 3 Phase)
• Maintained Requirements
• Final Inspection Before Running Genset
• Troubleshooting Procedures

Main Rotor

Lesson Length : 60 Minutes

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Generator Maintenance Generator Maintenance

WHO
Me ?

DANGER!
ELECTRIC SHOCK
[Live Terminals]

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Maintenance Requirements Maintenance Tasks and Scheduling SERVICE ACTIVITY TYPE SERVICE LEVEL

30,000 hrs / 5 years


10,000 hrs / 2 year
Post Commission

250 hrs / 0.5 year

1000 hrs / 1 year


Commission
Generator running

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

Insulation resistance of all windings (PI test for MV/HV) X X * * X X


Insulation resistance of rotor, exciter and PMG X X X

 Vibration Temperature sensors


Customer settings for temperature sensors
Condition of bearings
X
X
X
X X
X
X
X X X X

X
Grease exhaust & trap X X X X X
Bearings

Bearing grease X X X X X

 Winding insulation/contamination checks Bearing(s)


Temperature sensors
Customer settings for temperature sensors
X
X
X
X
X
X
X X X
* X
X
Terminal Box

All generator/customer connections and cabling in terminal box

 Visual inspection for corrosion and contamination


X X X X X X

Initial AVR & PFC set up X X X


Controls & Auxiliaries

AVR & PFC settings X 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

Air inlet temperature


Cooling System

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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Visual Inspection Further Recommended Routine Checks


 Examination of cable entry and cable lugs to main terminal box

Check Load Cables connected to Main Terminals


Check Cable Entry & Cable Lugs
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Further Recommended Routine Checks Further Recommended Routine Checks


 Examination of cable entry and cable connections to auxiliary terminal
box  Visual inspection of rotating rectifier assembly

 Even if the generator operates perfectly, the Varistor


could have failed.

Check Cable Entry & Cable Connections

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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.

Periodic checks should be made to:

 AVR and accessory terminal connections, for corroded or loose joints.


 Main Rectifier Diodes, should be cleaned or changed if badly corroded.
 Main output terminals, look for loose or high resistance joints, (joints can be scanned for
‘hot spots’ with a laser thermometer, (on load).
3. MAIN  Auxiliary & AVR Connections
RECTIFIER
COMPONENTS

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Troubleshooting Procedures Checking Windings and Rectifier Assembly

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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Separate Excitation Separate Excitation


Output From Output From
Battery into Battery into
Exciter Stator
- +
Exciter Stator - +
12v A.V.R
BATTERY 12v A.V.R
BATTERY
X+ XX- X+ XX-
Exciter Main Stator Exciter Main Stator
Rotor Rotor
& Stator & Stator

Bearing Bearing

Main Rotor Main Rotor


Main Rotor Shaft Main Rotor Shaft
RUN ENGINE

Rectifier Rectifier
Fan Fan

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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

Connections shown in Series Star Connections shown in Series Star

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Checking Output Voltage – Balanced and


Checking Output Voltage – Unbalanced
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

Connections shown in Series Star Connections shown in Series Star

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Checking Output Voltage – Unbalanced Checking Output Voltage – Unbalanced

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

Connections shown in Series Star Connections shown in Series Star

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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

Connections shown in Series Star Connections shown in Series Star

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Checking Output Voltage – Balanced and


Check Main Rectifier
Below Limits
Output From
FLUKE 87
Battery into - +
AVR Sensing Exciter Stator 12vA.V.R
BATTERY
& Power supply X+ XX-
from Main Stator N V6 Neutral
Exciter Main Stator
Rotor
3 Phase Ω & Stator
6 W1
W Output mV

mA Bearing
7 V V1 V

µA
V
Main Rotor
Main Rotor
8 U U1 OFF

Shaft

Rectifier Fan

Connections shown in Series Star

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Check Main Rectifier Troubleshooting Procedures


Output From  AT this point, any faults found with the MAIN STATOR, DIODES, or VARISTOR should
Battery into - + have been identified, and corrected.
Exciter Stator 12vA.V.R
BATTERY
X+ XX-  The Output voltage from the main Main Stator should be balanced across phases, and
Main Stator within 10 % of the nominal Voltage.
Exciter
Rotor
& Stator

Bearing IF ABOVE IS CORRECT, THE WINDINGS AND DIODES ARE O.K

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.

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Check the Exciter Generator Check the Main Rotor


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

Main Rotor Main Rotor


Main Rotor Main Rotor

Shaft Shaft

Rectifier Fan Rectifier Fan

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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

Main Rotor Main Rotor


Main Rotor Main Rotor

Shaft Shaft

Rectifier Fan Rectifier Fan

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Troubleshooting Procedures Check AVR Sensing and Supply


6-7-8
AVR
P2 -P3 -P4
Exciter Main Stator
- +
12v BATTERY AC sensing
Rotor PMG Power and Power
& Stator Supply to AVR Exciter Supply
Main Stator
(when fitted) Rotor (2 or 3 Phase)
Bearing
& Stator

Main Rotor
Main Rotor Shaft Bearing

Main Rotor
Main Rotor Shaft
Rectifier
Fan

Rectifier
Fan

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Check PMG Output Check AVR Conditions

AVR
AVR
Exciter Main Stator Exciter Main Stator
Rotor Rotor
& Stator & Stator

Bearing Bearing

Main Rotor Main Rotor


Main Rotor Shaft Main Rotor Shaft

Rectifier Rectifier
Fan Fan

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End, Thanks!

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