Section 06 - Generator Table of Contents, ‘System Troubleshooting and Repair List Procedure No. Page No. ‘Automatic Voltage (AVR) - Adjustments. o18 6 ‘Automatic Voltage Regulator (AV) - Information. eT 6 ‘Automatic Voltage Regulator (AVR) - Replace Cocosnsennannennnnees 6-04 6 Generator - Replace 9. Removethe 8 capscrews holding the drive end bracket to the frame. Note: Two of the capscrews are under the generator bo- ‘ween the generator feot t may be nocossary to It tho ‘Generator © got access to these two capscrows. through 7, the dive end brackot while tapping the end bracket from the recess In the 9 or ame, 11. Move the rotor out rom the stator by prying onthe fan ring at fan blade, Caution: Do not pry on the fan ring between the fan blades. The fan blades ean be easily bent or broken. The entire gonerator rotor must be disassembled (novmally atthe factory) to replace a gonerator fan,42, Rotate the rotor while pulling it from the st ‘Sembly. Pull the rotor out unl the maln roto ‘are exposed. 18, Suppor the rotor dive ond with a sing around the ‘main generator rotor polos. Not: This operation wil be easier with a Sipporng and guving the nowve ond othe eh "4. Continu to pul and cat the rotor ase sis mowed Irom the stator. 18 Move th ang oot he cotrbatanon pat of rotor ag itis removed, 16. The best location forthe sling is whore only a sight downward force on the fan is required to balance the ‘ascombly, 17. Set the rotor ina formed support as shown to avoid damage to the main excter rotor windings. ® ® Be ®Main Rotor Assembly - Replace (6-09) Page 68 Fc ® ® 8 S Install 1. Puta sling around the main generator ror at the ‘approximate center balerice pot The best location forthe slings where only a sight downward force on the fan's Yoqured to balance the assombly 2. Postion th rotor into the stator as far asthe sing wil, allow. Use care to avoid bumping the main ext Totor ino the main generator satr, Note: This oporation wil be easier with a second person supporting ana guiding the non-driva end ofthe shat ‘sling can no longer be used, Caution: Donat wrap the sing around the rotor winding fondtums.Asling.ean damage the rotor winding ondtum Insulation. 4. Finish Instaling the rotor in hand Rock the rotor fom sd pushingitintothe stator. Continue unt the main rotor poles are evan with the main stator‘Main Rotor Assembly - Replace sn Rtor Assembly - Replace (0) 5 Install the bearing rame 3) or bearing and cartridge (tame 4 through 7) ithe bearing has bean removed. Fotor to Procedure 6-08. 6 Install ho drive end bracket on the [Rhoist should be used tot tne drive ond bracket on 7. Install the two drive end bracket capscrows at the bottom! the generator. may be necsesarytolftthe ‘onerator to access these capser ‘Noto: Make sure thatthe permanent magnet exciterhar- ‘ess attached to the stators through the end bracket and hhemoss Bela he top ofthe generate.Main Rotor Assombly -Replace (09) Ss © S 10. na ‘capsorews which hold the end bracket to ator frame. Tap the end bracket ightly- ag the Saperewe oe ightned 11. ul ne main exc ons and) and the a nent magnetic excite statorleade (2,2 and Pa) {Trough te ole inthe frame terminal box 12. Connect the leads tothe corresponding terminals.on the ausdiary terminal book 13. Qnganartor tamale dnpscrms trough ‘ulboard bearing cap and ond brecht ana ine the bows bearing 14 On ganormorfamos 4 uh 7 len he bates cane tveaed capac hls wih he hls {he and bracket by tuning te Bearing end cap. The boating cage wil rotate in the nd bracket. 15. Install the bearing caridge capecraws. In 7. check the toraue althebearng cap the bearing cartidge. See Section (1208)17 Install the pormanent magnet excite. Refer to Pro: cedure 6-06. 18. Install the non-ive end access cover, the terminal box edes, lid and suppor Bracke Permanent Magnet Exciter - Check (10) 1. Flemove the four captive screws and the cover from the AVR (Automatic Vatage Regulator) box. 2. Remove the four tveaed pitas holding he AVR AVR from the box and remove all of the cs Permanent Mapnot Exciter - Check (10) Page 6) af S$manent Magnet Exciter - Check 10) Page 6-38 " aoe & & 4, Uso a multimetor and moasure the resistance be- tween oxltorleads (P2 and PS), 8 and Pa) and (P2 land Pa), The resistance for each pair should be 4 to S ohms at 20 to 40°C [68 to 104° FL 5. tho resistance is more than 10 ohms on any prof Toads, check for the following: 4) Disconnected wie at the auxiliary terminal lock 2) Broken or detective wire betweenthe AVR and ‘the auxiliary terminal biock 8) Broken or dtective wire betwoen the auxiliary terminal biock and the permanent magnetic cher stator, 6. Repair or roplace any broken loads 7. Start the engine and bring the: unit up to governed speed (1500 or 1800 APR. Warning: Use a multimeter and set it to measure A.C. voltage (tie meter must be capable of measuring 200 to 250 volts). Measure and rocord the voltage from the following loads. 1)P2t0P9 2) Po 10 Pa 3) Pato 2 8, The vottage of each pair should be above 160 volts a1 1500 RPH or above 180 volts at 1800 RPM, magnotized and must be replaced, Note: If the voltage is lass than 150 or 180 volts, check to make sure the engine RPM is correct (1500 or 1600 RPM). 10. tthe diference betwen the highest and lowest vt Aageis 10voltsormore, the permanent magnet excher Slaor is detective and must be replaced.Rotating Diodes - Chock (6-1) sos 8 Rotating Diodes - Check (6-11) 1. Remove the non deve end access cover and the two ‘Side covers from the terminal Box fro chock 3.Alead from a diode and a lead from the main excter Totor are both attachedioan adjacent connector stud. Femove the diode lead from the connection stud. Note: On generator frames 4 through 7, during assembly tha code lead is put atthe bottom ofthe connection stud To make lator service easier, put the diode lead on tho ‘connector stud last (under the na)Frame 4-7 Insert Molded Base Diode 4. Use the multimeter, Part No. 3376898, and fad ohms. Connect one lead of the mater to the ‘ode leadandthe other meterleadtothe diode pate, cord tho reading. Reverse the meter leads and again record the reading, 5 Agoodclede wil ge ahighesetance eacinginone ‘ection and a lower resistance reading In the op- posite dvection. The high resistance reading should Be atleast 10 times the low roading 6. A faully diode wal give a high resistance reading {op0n) In both directions ora low resistance reading (Shorea) In botn directions. 7. Betoreinsaling a new diode, check the appearance ofthe varistor urge suppressor).On generatorframe the varator fs located between the wo plates, and isheldin place by the capscrows that atach the main {generator otorleads. On generator rames 4 through ‘ine varistor is located on the opposis side ot the shaft from the main generator rotor leads 8. fauity generator fame 3 varistor wal be burned or missing. Taulty goneratortrame 4 through 7 varstor wi be burned oF have the lead wie burned af 8. The diodes are held in place by captive inserts within the maided base. Remove the diode by turning ‘counter-dockwise12. To replace the varistor on trames 4 through 7: 1) Disconnect the main generator rotor leads 2) Remove all 6 diodes. 3) Move the ends ofthe two plates away from the ‘main excite roe 4) Remove the nut from the varistor stud. '5) Remove the varstor wir lead from 6) Replace the varistor assombly Note: When replacing a diode, the replacement must be from the same. manutacurer and have the same Model umber, odes with ack leads are reverse polarty and have tho letter" A In the model doignaton. The arrow on the diode wil pont towards the terminal. Aways check tho lode with 2 meter to be aure of te poly Example: | R&S 49 40HFR100 identifies a lode made by Intemational Rlectiir Co. The 8549 ls the date code, Th 40 Indicates a 40 ampere continugus rating, The HF is & designation forthe size and shape. The A indicates reverse aanty, The 100 indleates thatthe code Is rated to wit and 1000 volts nthe reverse ection Rotating Diodes - Check (11) Page 6 Frames 2 and 8 Replacement Diods International Rectiier Red Lead 25F80 = M25-800 Black Lead 25FRB0 M2500 Frames rough 7 Replacement Diodes International Rectifier Marcon! Red Lead 40HF100 41-1000 Black Lead _AOHFRI00__Ma1R1000,Insulation Resistance - Measurement (6-12) rage 6-42 All Diodes ‘Same Polarity Ce Ae Months © 18. diode obtained from an electrical supply company ‘willpot have a Yead soldered tothe terminal ata, Mustbe solderedto the terminal, use 60-40 rosin cors ‘alder. Hold the diode terminal with long nose pliers ‘during soldering to provent excossive Roat transl through the terminal to the diode junction 14. The area ofthe diode that wil be in contact with the plate should be coated wih Migland Siicone Heat ‘Sink Compound Type MS 2623 or equivalent. Caution: This compound must not be applied 1o the diode stud threads, since It wil act as a lubricant and allow the diode to loosen. 15 Install the dlodes on the plates. Note: Alot the dodes install on one pate must have the Same polarity, end al ofthe dlodes fetalled on the other Date must have the opposite poarty. Do not mixthe platy tthe diodes on a pate, Note: On generators with pormanent magnet excite, i ‘makesnodiflrence which patehasthe”R° polarty Sodes. Insulation Resistance - Measurement (612) Note Ifa gonarator has boon in storage or oer 8 meni ‘r'has ser exposed to high humaly or tmpereture ‘hanges that could cause condensation, check te aus tion estan bore puting te unt sorvica.‘Note:The insulation resistance f the main stator winding ‘Sthe most important valve. The insulation resistance othe train siator and the permanent magnet stator are easy 10 measure, ‘The insulation resistance ofthe main excte rotor and main toto are more dificult to measure and are less significant [tis recommended that these resistances bo checked ony tehon elagnosing a problem. AVE trom the AVR box and disconnect ral leads trom the AVR Refer to Pro: rate the leads so that the terminals do not touch ‘one another orthe AVR box. Remove both sides ofthe terminal box. Remove the EO and E2 leads from the overvotage ‘module. Separate the leads so they do not touch anything, '5, Remove the two leads from the voltage adjust cheo- sat Separatothe leads sothey donotiouch anything, 7. Open the generator main tine circu breaker (there ‘sone). 8. Disconnect any instrumentation and controls (ot: m (load sensing governor, synchro- Mize, ete) as well as any capactors that may be onnacted to the main leads (U or Ub, Vor V6, W oF We ana\N. Insulation Resistance - Measurement (6-12) Page 6-43 Main Stator WindingInsulation Resistance - Measuremant (6-12) Page 6-4 & Dally 8. Use the megger, PartNo. 9376204, Connect oneload, cf the megger tothe ground connection point inthe {erminal box. Connect the other load tothe terminal box 10. Crankor operate the meggér2 or3 turns. The megge should indicate zerochms. Azero reading showsthat {he ground is ok the mogger does not read 26, ‘move theciipstomakebetter contact and keep check Ing unt 2er0 reaaing is obtained. Remove the lead from the terminal box and connect Ito generatorteadv or terminal U. Crank the megger _atapproximately 120 RPM @ turns per second} for 10 seconds and record the reading. 12, Areadingof 1.5 megohms or above satisfactory for (generators that operate Upto 480 vols. 18, A roading of § met (Generators thal operate up to #160 vol A reading of 0.5 to 1.5 (or 5.0 magohms for 4160 volt (generators) indicates thatthe mat ‘is mar: Binal Dry the generator insulation and test again. Rotor to Procedure 6-13, {A reading of loss than 0.5 megohms indicates an accidental grounding ora severe insulation prob Fecheck to make sure none of the terminals are touching the frame. CCheck the main stator leads for worn insulation. Re- pair or replace as necessary Recheck to make sure that no contol equipment or Instrumentation is connected to terminals U,V, W oF19, To measure the insulation resistance of the main ‘exit stator, remove the megger lead trom terminal and reconnect to terminal X atthe AVR box: 20. rankthe meager at approximately 120 RPM @ turns ‘par second) for 10 seconds and record the reading. ‘A reading of 1.2 megohms or above indicates th insulation resistance of the main excter stator satsfacory au 22.A reading of 0.5 to 1.2 megohms indicates the insu lation resistance is marginal. Dry the generator and {ost again, Rotor to Procedure 6-3, ‘A reading of les than 0.5 mogohms indicates an {ident groundingor a severe inaulaton problem, 2 frame. Dry the generator and test again. Refer 10 Procedure 6-13, 24, To measure the insulation resistance ofthe perme nent magnet excter windings: 1) Remove the permanent magnet exciter end 2) Disconnect the thee wire permanent magnet ‘exctor herness atthe plug '3) Connect one megger lead to any ofthe three pronge extending from the pug, 4) Connect the other megger lead toa convenient part ofthe frame, Insulation Resistance - Measurement (12) Page oa &Senerte Wining - Dying 12) B © eS 25. Crank the megger at approximately 120 RPM (2 turns er second) for 10 seconds and record the readi 26. A reading of 1.2 mogohms or above indie insulation resistance of the permanent magnet ex- ‘er windings is satistactoy 27. Ateadingofless than 1.2 megohms indicates that the ;Bermanent magnet excter Insulation Is marginal jecidental grounding. that 28, Remove the permanent magnet excite stator, Check ‘andthe leads going tothe plug for worn ‘oF damaged insulation. 28, Repair any damaged lead insulation with vinyl tape. 30. Dry the permanent magnet excite stator and test ‘again. Roter to Procedure 6-13, Generator Windings - Drying (6-13) ‘Note: Check the gonerator insulation before atemsting to Gry tho neuation. Salt, carton dust, ol and general in ean ‘cause low insulation resistancs, Contact a commercial it shop to core these problems.For gonerators connected to @ unable engine: 1, Remove the terminal box sides. Connect the threo phase short eicuit connection ‘Note: Wires connecting he generator output leads together ‘must be capable of carrying 3a the rated generator output lamps. The wire conecting the junction ofthe three output feade tte Warne must bo #0 or lager 2. Remove the AVR from the AVR box. Remove fand XX leads from the AVE, 0x Note: Use a d.c. power source or storage battery, capable of producing 0.6 amps at 12 vols but not excoading 13:2 ‘als to provide power to tho generator X and XX loads 3. Connect the postive (+) lead of power supey to je. Alter five minutes a low ida, bring the engine up to rated speed, Generator Winns - Drying 6.13) a Oneoeea JyGonorator Windings - Drying (6-19) Page 648 1 He Me z EY @ timetersnmt ons 1.5 or Above for Volts empha 5.0 or Above tor 4160 Volts Below 1.5 for 480 Volt leiow 5.0 tor 4160 Vo {Stop the engine. Rs 1 Donn he vase om he 0. oxo. * Disconnectthe shorted generator outputlads from the generator frame ‘mogger. Refer to Procedure 612, 7. Put the generator into service I a reading 1s 1.50 above for 400 vl gen- @ “SSrkovere ne 2) The reading le 6.0 oF above for 4160 volt ‘onerators 8. the raadings are below 1.5 magohms for 480 volt generators oF below 6.0 for 4160 volt generator, ontinue drying ‘9. Reconnect all three output termin previous drying and repeat al Note: For gonerators not connected to a runable engine, se forced warm air orf equipped, the internal Heats 10 {ry tho gonerater windings. 10.1 tor has intemal heaters, connect the 8 10 8 sutable power source.11, Diract the warm the openings: com one of two fan heaters into ner end of the generator. Mal ‘over the windings through the Note: Do not exceed 80°C [176"F] a temperature when {ying the generator. 12, After two hours, fesiatance Rater to Procedura 6-13, Nota: If internal heaters are being used, disconnect the eaters balore measuring the insulation resistance. ie the main stator insulation 12. the insulation resistances satisfactory, put the unit Into service. 14. fthe insulation resistance i tiltoolow, repeat allthe previous drying stops. Note:The pomanat pagnetexcersatorcan notte cios bythe previous procedures, (onerator Refer to Procedure €-08, 5 © & Gonerator Windings - Drying (6-13) 98 -yna‘No Load 0.0. Excitation - Test (-14) Page 6.80, 16. Inspect the stator. Check the leads going tothe plug Tortwom or damaged insulation. Ropal 8s roquired 17. Recheck the insulation resistance. Reter to Proce. SS ture 6-13, 18. tlhe insulation resistances stillbelow 1.2 magohms, place the stator ian oven at 110°C [200"F] ford Fours 12. Reme te sor fom he oven, Alow testa Ee eis ‘tine reneg is t.2megonm or above, re. sae ee gta ‘aie rng p12 megs, eee Besant Ses vot: dation oun pos der ay 25 oe Seance tes ait Stee cone No Load D.C. Excitation - Test (6-14) Note:The nolead ©. Exctaton tes wl inicate whathar CRs Mata im ihe AV ere gre 1. Remove the AVR. Refer to Procedure 6-01 2, Temporarily insulate (ape all ofthe lead terminals pt X and XX that wore removed from the AVR,and set t to measure ohms, Mas- the resistance between terminals X and XX at ‘stator, possible. during eval oF instalation. '5, Remove the non.drive end bracket, Refer to Proce- (ure 6-07. Repair or replace the excler stator. Table 6-1 D.C. Exciter (K to XX) Resistance Frame ‘hme cou 34210396 cosas 29.7 10275 cosas 23.7 10275 cosse 26610308 cores 26610208 4, Remove all loads which may be connected tothe (generator. This includes fans, coolant pumps, het rs and any other equipment powered trom the ‘generator. 2. Open the main line cccut breaker, ifthe generator hes one, 2, Stan the engine and bring up to rated speed. No Load 0.0. Excitation - Test (6-14) Page 651 Remove all Loads Fans + Coolant Pumps * Heaters: ®¥ - sariorgon_| raiie 0s ane RPM I 50 HZ [_] 6onz vwnaven | Soe BIE Line to Neutral and ine to Line Voltage @ © ‘Note: Use a D.C. power source or storage battory, capable of producing 0.8 amps at 12 volts but not exceeding 13.2 ‘als to prowde power to tho gonerator X and XX lands 4, Connect the powar source posive (+) lead tothe x terminal atthe AV box. Connect the negative (lead {othe XX tormnal. Temporary insulate ape) the {5nd X terminals to prvert ecevdetal shoring, 5, Check the engine speed. Engine speed should be 1407 to 1808 RPM (40.90 $0.1 He} or 50 Hz frators or 1797 to 1803 RPM (59.910 60.1 Hz) treo Hz. generators. Adjust the engine’ speed. se 6. Measure the D.C. voltage at terminals X and XX, This voltage must be 12.00 12.2 vate If Rls nt ‘* Adjust the D.C. power supply voltage ‘* Check the battery lead connections. '* Connect a charger tothe battory or replace the Battery with a trash one1, The line to neutral ine to line for delta connected 0. ators) volages must all Se win 1 peresnt Beay he Lnbatance,eheck for any lead on the genertor A load can eause a voltage unbalance condition. I there i a votage unbalance at no load! # Disconnect the power supply from X and XX. © Stop the engine A voltage unt ture in the ‘ail destroy Stator laminations, lance at no load indicates short ‘© Example: High Wye or Serie Star connection. 60 Be In this example the main generator windings are ok No Load D.C. Excitation - Test 6-14) Page ess [Votage Unbalanced @ © OwNo Load D.C. Excitation - Test (6-14) Page 6-54 ‘© Example: High Wye or Series Star connection, 0 Ke In this example, W6 to neutral winding has a de- Fact Have the Generator repaired or replacad. ‘ne-hat the Tine to line votage. It the vottage is not one-half of line 10 tne voltage, check the auxiliary terminal lock and éroppar trans: ‘wiring dlagrams, 3052054 2. Is not the same, check the auxtiary k connections. See wiring. diagrams 3082054 and 2052058 for wiring.se sensingAVA {hevoltage at the auxiliary terminal block, terminals Zand 9 should be 10 t9 19 vals D.C. Ccheck the dropper transtormer (wo transformers for the ‘Sensing) connections. Chock the aux ay lock connections. Chack the three ‘phase sensing module connections. 2 shows the normal, 19 range that should be obtained with 19.0 volts D.C. connected to excitr leads X and XX. Table 6-2 Line to line voltage range with 13.0 volts at X and XX Generator 50 Hz. 6OHE 6D Ha 60 HE Model Hiviye HiWye Lo Wye Delta ccs 05-455 495.845 247.272 206.075 cca “440-490 690690 265290 905.095. cos 300-440 475525 237262 274-308, cs 400-450 490540 245.270 289512 cor 60-410 440-490 220-245 254.283 ‘working order, The correct voltage terminal blocs, terminals 2 and 9 indicate thet [AVR ig receiving the correct no load voltage. Omitthe ‘eps on checking the rotating diodes and checking therotor windings. Any remaining electrical problems are in the voltage control system, Seo wiring Cla frame 3052054, 6, and 6, examine the wiring Tor Foose, broken oF corroded connections 16.lfthe generator output vltage isnot withinthe rangos shown in Table 6-2, check the rotating diodes. Refer to Procedure 6-1. Replace any detective diode oF ‘Surge suppressor. ‘No Load D.C. Excitation - Test (6-14) Page 6-5 & © Balanced Line to Line VoltagesNo Load D.C. Excitation - Tost (614) Page 68 17. Repeat the 19 volt no load D.C excitation test. Mea. Sure the line voltage and compare k with Table 62 18. the gonerator voltage i sil NOT within the range shown in Tablo 62, thoro 8 probaly a dotectin's rotor winding. Table 6:3 Rotor Winding Resistances exater Tain Generator Rotor Rotor Moda (ohms) (ohms) ‘casa 018 134 coss45 ox. 155 cess4c ox. wm cossa0 016 18h coasac oar 099 ccasaD ox7 1.06 Coase oa7 120 coaseF oar 135 cossec axe. 155 coss40 036 17 cossie 016 198 ccssaF os. 218 cossaas 0.10 126 casa 010 197 C8948 010 147 cc8s40 010 168 ces40 0x0 231 co7a4a 0x3 205 cc7s48 ons 229 orate ona an Note: All resistances are approximate and at 20°C Berl