new age generator

NEWAGE PRODUCT TRAINING


SAFETY NOTICE !!

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.

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.

Never attempt to test a ‘LIVE’ generator without another competent person present to shut down the engine or switchgear as necessary.

Maintenance - Requirements WHOMe ?

DANGER!ELECTRIC SHOCK[Live Terminals]


Maintenance - Requirements

1. Bearing inspection ( Single or 2 Bearing).

2. Winding Insulation/ Contamination checks.

3. Visual Inspection for Corrosion and Contamination

4. Operational Checks

Maintenance requirements for A.C Brushless Generators are :-


Maintenance requirements - Bearings

1. Manufacturers Sealed for Life Ball bearings Standard on Frames BC and UC ranges. Introduced as standard on Frames HC4, HC5, from July 1999.

Newage Generators are supplied with three types of bearing assembly.

2. Newage Sealed Cartridge Assemblies, (Non- regreasable). Standard on Frame HC6 Up to July 1999, standard on Frames HC4,5Up to March 1999, standard on Frame HC7

3. Newage Regreasable Cartridge Assemblies. Standard on Frame HC7 from March 1999 Optional on Frame HC 5 & 6 from April 2000.Standard on Frame 8,

All 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.


BC & UC Bearing Assembly

Frames BC and UC Ball Bearings are manufacturers sealed for life as standard. Bearings are packed with Kluber Asonic GHY 72 grease

Typical Bearing housing machined into Non-Drive End- bracket.

Typical Sealed for Life 2RS Ball Bearing.Grease pre-packed & sealed with steel reinforced rubbing synthetic seal.


HC & F8 Bearing Cartridge Assembly

Bearing

Typical Bearing Cartridge for HC 6, with sealed bearings.

Cap bolts

Typical re-greasable bearing Cartridge & Cap for HC7 & Frame 8 (shown with N.D.E PMG Stator Housing )

Bearing

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.

Wave Washer

Cap Cap

GreaseFlinger

o Frame HC6 have cartridge assemblies, with manufacturers sealed for life bearings.

o Frames HC7 and Frame 8, have regreaseable cartridge assemblies, packed with Kluber Asonic grease type GHY72. o Regreasable bearings are optional on Frames HC 5 and 6. o Application and Environmental conditions can effect bearing life, excessive moisture, vibration, or airborne dust, can reduced bearing life.


Maintenance requirements - BearingsWhat are the symptoms of a Bearing problem?

INCREASEDNOISE.

INCREASEDVIBRATION

INCREASED TEMPERATURE

Non drive end Bearing

Drive end Bearing


Maintenance requirements - BearingsWhat 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).

VibrationIncreased 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).

NoiseBearing 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.


Maintenance requirements - Bearings

Re-lubricated Bearings Frames HC7 & 8(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 KITSHC6, 45 - 0880, HC7 45 - 0872.

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


Maintenance requirements - Insulation checks

1. The Generator has been STATIONARY for a long period without Anti-Condensation heaters SWITCHED ON.

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).

Winding Insulation levels should be checked if :-


Maintenance requirements - Insulation checks

1. The Main Stator WindingMinimum value of Insulation should be 1 MΩ to EARTH. Low IR on the Main Stator is A SAFETY ISSUE.

DANGER!ELECTRICSHOCK

2. The Exciter Stator WindingThis 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 MΩ to EARTH.

4. Permanent Magnet StatorThis windings is totally enclosed and unlikely to be affected by low IR.

Insulation Resistance (IR) tests in order of importance :-


Maintenance requirements - Testing the Main Stator Insulation

AVR Sensing & Power supplyfrom Main Stator

U

VW

N V6

W2W5

V2

W6U6

W1

V1

U1

V5

U2U5

6

7

8

FRAMEEARTH

EARTH

3 PhaseOutput

Neutral

Connections shown in Series Star

4. For low voltage machines (up to 690V), the MINIMUM insulation value is 1.0 Meg-Ohm to Earth (Ground).

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).

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

Test

Ω 1KVM

MΩ 500V

MEGGER

ΩM

1000100 10 1 0.1 .01

2. Disconnect any connections from Neutral to Earth.

WINDINGS MUST BE DRIED OUT IF BELOW 1.0 MEG-OHM.


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

Maintenance requirements - Drying the Main Stator Windings

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


Maintenance requirements - Drying the Main Stator WindingsMETHOD 1. STATIONARY DRYING

Remove Air Intake Access CoversDirect 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 MΩ )

Domestic Supply


Maintenance requirements - Drying the Main Stator WindingsMETHOD 2. SHORT CIRCUIT MAIN STATOR WINDINGS

A.V.R

1. Stop the Generator Set and disable the Engine.2. Disconnect the AVR wiring.

12v BATTERY+-

4. Connect the battery to the Exciter Stator,(polarity must be correct).

Output FromBattery intoExciter Stator

X+ XX-

3. Replace the AVR with a 12V or 24V battery

Bearing

Shaft

Rectifier

ExciterRotor& Stator

Main Stator

Fan

Main RotorMain Rotor



U

VW

N V6

W2W5

V2

W6U6

W1

V1

U1

V5

U2U5

6

7

8

FRAMEEARTH

EARTH

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).

TRUE

RM

S

Clampmeter

Short Circuit Link

METHOD 2. SHORT CIRCUIT MAIN STATOR WINDINGS

CHECK ALL WIRING IS SECURE BEFORE RUNNING GENSETWARNING!

!

MAKE SURE THAT THE AVR IS DISCONNECTED


METHOD 2. SHORT CIRCUIT MAIN STATOR WINDINGS


The Current MUST NOT BE HIGHER THAN FULL LOAD AMPERESFor 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 MΩ , the windings require cleaning /refurbish.

T

- +12-24v

BATTERY

12 - 24 voltBatteries intoExciter Stator

X+

XX-

ClampmeterShort Circuit Link

RUN ENGINE


Slowly increase the Current until FULL LOAD AMPERES are indicated.

The M.V.R must be switched to MANUAL control, MINIMUM setting, before running the engine.

P.M.G Power Supply

Clampmeter Short Circuit LinkAcross 3 Phases

RUN ENGINE

T

X+ (F1)

XX- (F2)

PT4

X XX P2 P3 P4 X XX P2 P3 P4

MANUAL VOLTAGE REGULATOR

MVR-1

MODULE 450-11400

NEWAGE INTERNATIONAL

X XX P2 P3 P4 X XX P2 P3 P4AVR GENERATOR

º º º

ToExciterStator

If the IR is still less than 1 MΩ , the windings require cleaning /refurbish.For effective drying, run for at least 1 hour at FULL LOAD CURRENT. .


METHOD 2. SHORT CIRCUIT METHOD USING THE M.V.R


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 MΩ 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.


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.



. 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 MΩ.

A final coating of Anti-track paint can be added for further protection, I.e :SterlingVA63 or VA39, or Ultimeg 2000, 372, air drying varnish ranges.


Maintenance requirements - Healthchecks

Final Inspection before running Gen-set :-

1. AVRCONNECTIONS

2. MAIN TERMINAL CONNECTIONS

3. MAIN RECTIFIER COMPONENTS



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.

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).

A.C Generators may be subjected to environmental conditions which are detrimental to the Generator :-

Final Inspection before running Gen-set :-

Periodic checks should be made to :-



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 :-

Running checks on the the GeneratorRun the Generator up to nominal speed, and check :-

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 HEALTHFAULTS WITHIN THE GENERATOR WILL CAUSE AN INCREASE IN THE D.C. VOLTS.

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


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