Northern Lights Newage / Stamford User Manual

Publication No: BCH-018

12th Edition

01/01

Installation, Service &

Maintenance Manual

For the BC Range of Generators.

SAFETY PRECAUTIONS

Before operating the generating set, read the generating set operation manual and this generator manual and become familiar with it and the equipment.

SAFE AND EFFICIENT OPERATION CAN ONLY BE ACHIEVED IF THE EQUIPMENT IS CORRECTLY OPERATED AND MAINTAINED.

Many accidents occur because of failure to follow fundamental rules and precautions.

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.

•Ensure installation meets all applicable safety and local electrical codes. Have all installations performed by a qualified electrician.

•Do not operate the generator with protective covers, access covers or terminal box covers removed.

•Disable engine starting circuits before carrying out maintenance.

•Disable closing circuits and/or place warning notices on any circuit breakers normally used for connection to the mains or other generators, to avoid accidental closure.

Observe all IMPORTANT, CAUTION, WARNING, and DANGER notices, defined as:

Important ! Important refers to hazard or unsafe method or practice which can result in product damage or related equipment damage.

Caution refers to hazard or unsafe method Caution ! or practice which can result in product

damage or personal injury.

Warning refers to a hazard or unsafe method or practice which CAN result in

severe personal injury or possible death.

Warning !

Danger refers to immediate hazards which

will result in severe personal injury or death.

Danger !

Due to our policy of continuous improvement, details in this manual which were correct at time of printing, may now be due for amendment. Information included must therefore not be regarded as binding.

Front Cover Photograph

This photograph is representative only. Several variations are available within the range of generators covered by this manual.

FOREWORD

The function of this book is to provide the user of the Stamford generator with an understanding of the principles of operation, the criteria for which the generator has been designed, and the installation and maintenance procedures. Specific areas where the lack of care or use of incorrect procedures could lead to

equipment damage and/or personal injury are highlighted, with

WARNING and/or CAUTION notes, and it is IMPORTANT that the contents of this book are read and understood before proceeding to fit or use the generator.

The Service, Sales and technical staff of Newage International are always ready to assist and reference to the company for advice is welcomed.

Incorrect installation, service or replacement of parts can result in severe personal injury or death, and/or equipment damage . Service personnel must be

Warning ! qualified to perform electrical and mechanical service.

EC DECLARATION OF INCORPORATION

All Stamford generators are supplied with a declaration of incorporation for the relevant EC legislation, typically in the form of a label as below.

EC DE CLA RATIO N O F INCO RPO R ATIO N

IN A C C O R D A N C E W IT H TH E SU P P LY O F M A C H IN ER Y (S AF ETY ) R E G U L AT IO N S 19 92 A N D TH E SU P P LY O F M A C H IN ER Y (S AF ET Y) (A M E N D M E N T) R E G U LAT IO N S 199 4

IM PLE M E N TIN G T H E E C M AC H IN ER Y D IR EC T IVE 8 9/39 2/E E C AS A M E N D E D B Y 9 1/368 /EE C .

TH IS STAMFO RD A.C . GENE RATOR W AS

M A N U FAC T U R ED B Y O R O N BE H A LF O F

NE WAGE INTE RNATIONAL LTD

B AR N A C K R O A D S TA M FO R D LIN C O LN SH IR E E N G LA N D .

TH IS C O M P O N E N T M A C H IN E RY M U S T N O T B E PU T IN TO S ER V IC E U N T IL T H E M A C H IN ER Y IN TO W H IC H IT IS TO B E IN C O R P O R AT ED H A S BE E N D EC LA R E D IN C O N FO R M ITY W ITH TH E P R O V ISIO N S O F TH E S U P PLY O F MA C H IN E RY (S A FE TY ) R E GU L ATIO N S 1 995 /MA C H IN E R Y D IR E C TIV E .

FO R AND ON BE HALF OF NEWAG E INT ERN ATIONA L LIMITE D

POS ITION: TECHNICAL DIRE CTOR

SIGNAT URE:

THIS CO MP ONEN T M ACHINE RY CARRIE S T H E C E MA RK FO R CO M PLIANC E W ITH TH E STATUTO R Y REQ UIREM ENTS FO R TH E IMP LEM ENTATION OF TH E F O LLO W IN G DIRECTIV ES

The E M C D irec tiv e 89 /336 /E E C

This C o m pon ent M ac hin ery shall not be us ed in the R eside ntial, C om m ercial a nd WARNING! Light Industrial en viro nme nt unles s it also conform s to the relevant stan dard

(E N 5 0081 - 1) R E FE R TO FAC TO R Y FO R D E TA ILS

ii) T he L ow Voltage D irec tiv e 73 /23/E E C as am en ded by 9 3/68 /E EC

When this manual is supplied to support a specific generator at point of sale, the generator identity is clearly displayed on the front cover of this book.

ELECTROMAGNETIC COMPATIBILITY

Additional Information

European Union

Council Directive 89/336/EEC

For installations within the European Union, electrical products must meet the requirements of the above directive, and Newage ac generators are supplied on the basis that:

●They are to be used for power-generation or related function.

●They are to be applied in one of the following environments:

Portable (open construction - temporary site supply) Portable (enclosed - temporary site supply) Containerised (temporary or permanent site supply) Ship-borne below decks (marine auxiliary power) Commercial vehicle (road transport / refrigeration etc) Rail transport (auxiliary power)

Industrial vehicle (earthmoving, cranes etc)

Fixed installation (industrial - factory / process plant)

Fixed installation (residential, commercial and light industrial home / office / health)

Energy management (Combined heat and power and/or peak lopping)

Alternative energy schemes

●The standard generators are designed to meet the ‘industrial’ emissions and immunity standards. Where the generator is required to meet the residential, commercial and light industrial emissions and immunity standards reference should be made to Newage document reference N4/X/011, as additional equipment may be required.

●The installation earthing scheme involves connection of the generator frame to the site protective earth conductor using a minimum practical lead length.

●Maintenance and servicing with anything other than factory supplied or authorised parts will invalidate any Newage liability for EMC compliance.

●Installation, maintenance and servicing is carried out by adequately trained personnel fully aware of the requirements of the relevant EC directives

1

CONTENTS

SAFETY PRECAUTIONS		IFC
FOREWORD		1
CONTENTS		2&3
SECTION 1	INTRODUCTION	4
1.1	INTRODUCTION	4
1.2	DESIGNATION	4
1.3	PACKAGED LOOSE ADAPTOR HARDWARE	4
1.4	SERIAL NUMBER LOCATION	4
1.5	RATING PLATE AND CE MARK	4
SECTION 2	PRINCIPLE OF OPERATION	5
2.1	SELF-EXCITED AVR CONTROLLED GENERATORS	5
2.1.1	MAIN STATOR POWERED AVR	5
2.1.2	AUXILIARY WINDING POWERED AVR	5
2.2	TRANSFORMER CONTROLLED GENERATORS	5
SECTION 3	APPLICATION OF THE GENERATOR	6
SECTION 4	INSTALLATION - PART 1	8
4.1	LIFTING	8
4.2	ASSEMBLY TO ENGINE	8
4.2.1	TWO BEARING GENERATORS	8
4.2.2	SINGLE BEARING GENERATORS	9
4.2.2.1	SINGLE BEARING 4-POLE & 2-POLE	9
4.2.2.2	SINGLE BEARING 2-POLE GENERATOR TO ENGINE
	ASSEMBLY INSTRUCTIONS (WITH DOWELED FLYWHEELS)	10
4.2.3	TAPER SHAFT ARRANGEMENTS	10
4.3	EARTHING	11
4.4	PRE-RUNNING CHECKS	11
4.4.1	INSULATION CHECK	11
4.4.2	DIRECTION OF ROTATION	11
4.4.3	VOLTAGE AND FREQUENCY	11
4.4.4	AVR INITIAL SETTINGS	11
4.4.4.1	TYPE SX460 AVR	11
4.4.4.2	TYPE SA465 AVR	12
4.4.5	TRANSFORMER CONTROLLED EXCITATION SYSTEM	12
4.5	GENERATOR SET TESTING	12
4.5.1	TEST METERING/CABLING	12
4.6	INITIAL START-UP	13
4.7	LOAD TESTING	13
4.7.1	AVR CONTROLLED GENERATORS - AVR ADJUSTMENTS	13
4.7.1.1	UFRO (Under Frequency Roll Off)	13
4.7.2	TRANSFORMER CONTROLLED GENERATORS -
	TRANSFORMER ADJUSTMENT	14
4.8	ACCESSORIES	14
SECTION 5	INSTALLATION - PART 2	15
5.1	GENERAL	15
5.2	GLANDING	15
5.3	EARTHING	15
5.4	PROTECTION	15
5.5	COMMISSIONING	15
SECTION 6	ACCESSORIES	16
6.1	REMOTE VOLTAGE ADJUST (All AVR Types)	16
6.2	PARALLEL OPERATION	16
6.2.1	DROOP	16
6.2.1.1	SETTING PROCEDURE	17
6.2.2	ASTATIC CONTROL	17

2

CONTENTS

SECTION 7	SERVICE AND MAINTENANCE	18
7.1	WINDING CONDITION	18
7.1.1	WINDING CONDITION ASSESSMENT	18
7.1.2	METHODS OF DRYING OUT GENERATORS	18
7.2	BEARINGS	20
7.3	AIR FILTERS	20
7.3.1	CLEANING PROCEDURE	20
7.3.2	RECHARGING (Charging)	20
7.4	FAULT FINDING	20
7.4.1	ALL AVR TYPES - FAULT FINDING	20
7.4.2	TRANSFORMER CONTROL - FAULT FINDING	20
7.4.3	RESIDUAL VOLTAGE CHECK	20
7.5	SEPARATE EXCITATION TEST PROCEDURE	21
7.5.1	GENERATOR WINDINGS AND ROTATING DIODES	21
7.5.1.1	BALANCED MAIN TERMINAL VOLTAGES	21
7.5.1.2	UNBALANCED MAIN TERMINAL VOLTAGES	21
7.5.2	EXCITATION CONTROL TEST	23
7.5.2.1	AVR FUNCTION TEST	23
7.5.2.2	TRANSFORMER CONTROL	23
7.5.3	REMOVAL AND REPLACEMENT OF COMPONENT
	ASSEMBLIES	23
7.5.3.1	REMOVAL OF BEARINGS	24
7.5.3.2	MAIN ROTOR ASSEMBLY	24
7.5.3.3	RE-ASSEMBLY OF GENERATOR ENGINE	25
7.6	RETURNING TO SERVICE	25
SECTION 8	SPARES AND AFTER SALES SERVICE	26
8.1	RECOMMENDED SPARES	26
8.1.1	AVR CONTROLLED GENERATORS	26
8.1.2	TRANSFORMER CONTROLLED GENERATORS	26
8.1.3	ASSEMBLY TOOLS	26
8.2	AFTER SALES SERVICE	26
	PARTS IDENTIFICATION
Fig. 6	TYPICAL SINGLE BEARING GENERATOR	28
Fig. 7	TYPICAL SINGLE BEARING - TAPER SHAFT ARRANGEMENT	30
Fig. 8	TYPICAL SINGLE BEARING - SERIES 5 TRANSFORMER
	CONTROLLED GENERATOR	32
Fig. 9	TYPICAL TWO BEARING GENERATOR	34
Fig. 10	ROTATING RECTIFIER ASSEMBLY	35
WARRANTY DETAILS		IBC

3

SECTION 1

INTRODUCTION

1.1 INTRODUCTION

1.4 SERIAL NUMBER LOCATION

The BC16/18 range of generators is of brushless rotating field

Each generator has its unique serial number stamped into the

design, available up to 660V/50Hz (1500 rpm, 4 pole and 3000

upper section of the non-drive end frame.

rpm, 2 pole) or 60Hz (1800 rpm, 4 pole and 3600 rpm, 2 pole),

and built to meet B.S. 5000 Part 3 and international standards.

Inside the terminal box two adhesive rectangular labels have

been fixed, each carrying the generator's unique identity number.

The BC16/18 range are self-excited with excitation power derived

One to the inside of the terminal box sheet metal work, and the

from the main output windings, using either the SX460/SA465

second label fixed to the main frame of the generator.

AVR or transformer controlled excitation system.

The BC184 may be supplied fitted with an auxiliary winding in

1.5 RATING PLATE AND CE MARK

the main stator, using the SA465 AVR.

The generator has been supplied with a self adhesive rating

Detailed specification sheets are available on request.

plate label to enable fitting after final assembly and painting. It

is intended that this label will be stuck to the outside of the

1.2 DESIGNATION

terminal box on the left hand side when viewed from the drive-

end. To assist with squarely positioning the label, location

To provide standardisation of systems with minimal change to

protrusions have been made in the sheet metalwork.

customers.

A CE Mark label is also supplied loose for fitment after final

B

C

L

I

1

6

4

A

1

assembly and painting. This should be attached to an external

B

C .

I

1

6

2

D

1

surface of the Generator at a suitable location where it will not

be obscured by the customer's wiring or other fittings. Before

B

C

A

I

1

6

2

D

1

fitting the CE Mark label the genset builder must address the

B

C .

M

1

8

4

F

2

requirements of the relevant EC legislation to ensure the

compliance of the genset as a whole. CE compliance will also

need to be addressed when installed on site.

The surface on the area where a label is to be stuck must be

flat, clean and any paint finish must be fully dry before attempting

to attach label. Recommended method for attaching label is

peel and fold back sufficient of the backing paper to expose

GENERATOR TYPE

BC

some 20mm of label adhesive along the edge which is to be

located against the sheet metal protrusions. Once this first

SPECIFIC TYPE L = TS OR TR ENGINE

section of label has been carefully located and stuck into

A = ALPHA ENGINE

position the backing paper can be progressively removed, as

the label is pressed down into position. The adhesive will

INDUSTRIAL = (I) OR MARINE = (M)

achieve a permanent bond in 24 hours.

SHAFT HEIGHT IN CM ON BC/UC

NUMBER OF POLES 2 or 4

CORE LENGTH

NUMBER OF BEARINGS 1 OR 2

1.3 PACKAGED LOOSE ADAPTOR HARDWARE

Several adaptors are only partially fitted to generators to simplify removal prior to engine-generator assembly. The remaining hardware is contained within a plastic bag located in the terminal box.

Adaptor Types

SAE2

SAE3

SAE5 Spacer Rings

SAE6

Coupling Plate Dowel Pins

4

SECTION 2

PRINCIPLE OF OPERATION

2.1 SELF-EXCITED AVR CONTROLLED GENERATORS

2.1.1 MAIN STATOR POWERED AVR

The main stator provides power for excitation of the exciter field via the SX460 (SA465) AVR which is the controlling device governing the level of excitation provided to the exciter field. The AVR responds to a voltage sensing signal derived from the main stator winding. By controlling the low power of the exciter field, control of the high power requirement of the main field is achieved through the rectified output of the exciter armature.

The AVR senses average voltage on two phases ensuring close regulation. In addition it detects engine speed and provides voltage fall off with speed, below a pre-selected speed (Hz) setting, preventing over-excitation at low engine speeds and softening the effect of load switching to relieve the burden on the engine.

The detailed function of the AVR circuits and their adjustment are covered in the load testing section.

In addition the SA465 AVR incorporates circuits which, when used in conjunction with accessories, can provide for parallel operation either with 'droop' or 'astatic' control and VAR/PF control.

Function and adjustment of the accessories which can be fitted inside the generator terminal box are covered in the accessories section of this book.

Separate instructions are provided with other accessories available for control panel mounting.

The auxiliary winding provides power for excitation of the exciter field via the SA465 AVR which is the controlling device governing the level of excitation provided to the exciter field. The AVR responds to a voltage sensing signal derived from the main stator winding. By controlling the low power of the exciter field, control of the high power requirement of the main field is achieved through the rectified output of the exciter armature. The AVR senses average voltage on two phases ensuring close regulation. In addition, it detects engine speed and provides voltage fall off with speed, below a pre-selected speed (Hz) setting, preventing over-excitation at low engine speeds and softening the effect of load switching to relieve the burden on the engine.

Under fault conditions on the main stator output the auxiliary winding continues to generate voltage from the harmonic content of the magnetic field in the main stator core providing the necessary power via the SA465 AVR, to maintain short circuit fault currents.

The detailed function of the AVR circuits and their adjustment are covered in the load testing section.

Function and adjustment of the accessories which can be fitted inside the generator terminal box are covered in the accessories section of this book.

Separate instructions are provided with other accessories available for control panel mounting.

2.2 TRANSFORMER CONTROLLED GENERATORS

2.1.2 AUXILIARY WINDING POWERED AVR

The main stator provides power for excitation of the exciter field via a transformer rectifier unit. The transformer combines voltage and current elements derived from the main stator output to form the basis of an open-loop control system, which is self regulating in nature. The system inherently compensates for load current magnitude and power factor and provides short circuit maintenance in addition to a good motor starting performance.

Three phase generators normally have a three phase transformer control for improved performance with unbalanced loads but a single phase transformer option is available.

No accessories can be provided with this control system.

5

SECTION 3

APPLICATION OF THE GENERATOR

The generator is supplied as a component part for installation in a generating set. It is not, therefore, practicable to fit all the necessary warning/hazard labels during generator manufacture. The additional labels required are packaged with this Manual, together with a drawing identifying their locations.

It is the responsibility of the generating set manufacturer to ensure that the correct labels are fitted, and are clearly visible.

The generators have been designed for use in a maximum ambient temperature of 40°C and altitude less than 1000 metres above sea level in accordance with BS 5000.

Ambients in excess of 40°C and altitudes above 1000 metres can be tolerated with reduced ratings - refer to the generator nameplate for rating and ambient. In the event that the generator is required to operate in an ambient in excess of the nameplate value or at altitudes in excess of 1000 metres above sea level, refer to the factory.

The generators are of air-ventilated screen protected drip-proof design and are not suitable for mounting outdoors unless adequately protected by the use of canopies. Anti-condensation heaters are recommended during storage and for standby duty to ensure winding insulation is maintained in good condition.

When installed in a closed canopy it must be ensured that the ambient temperature of the cooling air to the generator does not exceed that for which the generator has been rated.

The canopy should be designed such that the engine air intake to the canopy is separated from the generator intake, particularly where the radiator cooling fan is required to draw air into the canopy. In addition the generator air intake to the canopy should be designed such that the ingress of moisture is prohibited, preferably by use of a 2 stage filter.

The generator air intake is through the non drive end cover and the generating set and canopy design must be such that the intake is not restricted. It is recommended that a minimum clearance of 50mm is allowed between the generator air intake and any vertical flat surface.

The air intake/outlet must be suitable for the air flow given in the following table with additional pressure drops less than or equal to those given below:

		Air Flow		Additional
	Frame			(intake/outlet)
		50Hz	60Hz	Pressure Drop
		0.071 m³/sec	0.09 m³/sec
	BC164
		150 cfm	190 cfm
	BC184	0.095 m³/sec	0.119 m³/sec
	EFG	200 cfm	250 cfm
				3mm water
	BC184	0.15 m³/sec	0.19 m³/sec
				gauge (0.1")
	HJ	318 cfm	403 cfm
		0.19 m³/sec	0.23 m³/sec
	BC162
		403 cfm	487 cfm
		0.254 m³/sec	0.304 m³/sec
	BC182
		538 cfm	644 cfm

If specified at the time of ordering, the generator itself may be fitted with air filters.

The BCL construction has no fan fitted to the generator. The engine flywheel fan draws air through the generator and additional restrictions on air flow such as filters on the generator or canopies are not permissible.

6

Important ! Reduction in cooling air flow or inadequate protection to the generator can result in damage and/or failure of windings.

Dynamic balancing of the generator rotor assembly has been carried out during manufacture in accordance with BS 6861 Part 1 Grade 2.5 to ensure vibration limits of the generator are in accordance with BS 4999 Part 142.

The main vibration frequencies produced by the component generator are as follows:-

4 pole	1500 r.p.m.	25 Hz
4 pole	1800 r.p.m.	30 Hz
2 pole	3000 r.p.m.	50 Hz
2 pole	3600 r.p.m.	60 Hz

However, vibrations induced by the engine are complex and contain frequencies of 1, 3, 5 or more times the fundamental frequency of vibration. These induced vibrations can result in generator vibration levels higher than those derived from the generator itself. It is the responsibility of the generating set designer to ensure that the alignment and stiffness of the bedplate and mountings are such that the vibration limits of BS 5000 Part 3 are not exceeded.

In standby applications where the running time is limited and reduced life expectancy is accepted, higher levels than specified in BS 5000 can be tolerated, up to a maximum of 18mm/sec.

Two bearing generators require a substantial bedplate with engine/generator mounting pads to ensure a good base for accurate alignment. Close coupling of engine to generator can increase the overall rigidity of the set. For the purposes of establishing set design the bending moment at the engine flywheel housing to generator adaptor interface should not exceed 125ft.lb. (17 kgm). A flexible coupling, designed to suit the specific engine/generator combination, is recommended to minimise torsional effects.

Belt driven applications of two bearing generators require the pulley diameter and design to be such that the side load or force applied to the shaft is central to the extension and does not exceed the values given in the table below:-

Frame	Side Load			Shaft
2/4 Pole				extension mm
	kgf		N
BC16	92		900	82
BC18	173		1700	82

In instances where shaft extensions greater than specified in the table have been supplied, reference must be made to the factory for appropriate loadings.

Alignment of single bearing generators is critical and vibration can occur due to the flexing of the flanges between the engine and generator. As far as the generator is concerned the maximum bending moment at this point must not exceed 125ft.lb. (17 kgm).

Single bearing generators require a substantial bedplate with engine/generator mounting pads to ensure a good base for accurate alignment.

It is expected that the generator will be incorporated into a generating set operating in an environment, where the maximum shock load experienced by the generator will not exceed 3g. in any plane. If shock loads in excess of 3g are to be encountered, anti-vibration mountings must be incorporated into the generating set to ensure they absorb the excess.

The maximum bending moment of the engine flange must be checked with the engine manufacturer.

Important ! Single bearing drive end brackets are designed to be bolted to the engine flywheel housing using cap head screws.

Torsional vibrations occur in all engine-driven shaft systems and may be of a magnitude to cause damage at certain critical speeds. It is therefore necessary to consider the torsional vibration effect on the generator shaft and couplings.

It is the responsibility of the generator set manufacturer to ensure compatibility, and for this purpose drawings showing the shaft dimensions and rotor inertias are available for customers to forward to the engine supplier. In the case of single bearing generators coupling details are included.

Important ! Torsional incompatibility and/or excessive vibration levels can cause damage or failure of generator and/or engine components.

The terminal box is constructed with removable panels for easy adaptation to suit specific glanding requirements. Within the terminal box there are insulated terminals for line and neutral connections and provision for earthing. A hole is provided on the generator foot which may be tapped to give an additional earthing point.

The neutral is NOT connected to the frame.

The main stator winding has 12 leads brought out to the terminals in the terminal box.

No earth connections are made on the generator and reference to site regulations for earthing must be made. Incorrect earthing or protection arrangements can

Warning ! result in personal injury or death.

Fault current curves (decrement curves), together with generator reactance data, are available on request to assist the system designer to select circuit breakers, calculate fault currents and ensure discrimination within the load network.

Incorrect installation and/or protective systems can result in personal injury and/or equipment damage. Installers must be

qualified to perform electrical installation

Warning ! work.

7

SECTION 4

INSTALLATION - PART 1

4.1 LIFTING

Incorrect lifting or inadequate lifting capacity can result in severe personal injury or equipment damage. MINIMUM LIFTING CAPACITY REQUIRED IS 250kg.

Warning ! Generator lifting lugs should not be used for lifting the complete generator set.

Lifting lugs are provided at each end of the generator for use with a shackle and pin type lifting aid or lifting hooks. Chains of suitable length and lifting capacity, with spreader bar to avoid damage to the terminal box, must be used.

The correct lifting arrangement is shown on a label attached to the generator. A typical example is shown below.

BCL generators have no fan to support the drive end and are supplied fitted with a transit strap clamping the coupling hub to the drive end adaptor ring.

Once the transit strap is removed the rotor is free to move in the frame, and care is needed during coupling and alignment to ensure the frame is kept in the horizontal plane.

4.2 ASSEMBLY TO ENGINE

ENGINE TO GENERATOR COUPLING ASSEMBLY

During the assembly of the Generator to the Engine it will be necessary to firstly carefully align, then rotate, the combined Generator rotor - Engine crankshaft assembly, as part of the construction process, to allow location, insertion and tighten-

ing of the coupling bolts. This requirement to rotate the combined assemblies exists for both single and two bearing units. During the assembly of single bearing units it is necessary to align the generator's coupling holes with the engine flywheel holes: it is suggested that two diametrically opposite location dowel pins are fitted to the engine flywheel, over which the generator coupling can slide into final location into the engine flywheel spigot recess. The dowels must be removed and replaced by coupling bolts before the final bolt tightening sequence.

While fitting and tightening the coupling bolts it will be necessary to rotate the Engine crankshaft - Generator rotor assembly. Care should be taken to ensure that rotation is carried out in an approved manner that ensures safe working practice when reaching inside the machine to insert or tighten coupling bolts, and that no component of the assembly is damaged by nonapproved methods of assembly rotation.

Engine Manufacturers have available a proprietary tool designed to enable manual rotation of the crankshat assembly. This tool must always be used, having been engineered as an approved method of assembly rotation, by engaging the manually driven pinion with the engine flywheel starter ring-gear.

UNDER NO CIRCUMSTANCES SHOULD A LEVER BE USED AGAINST THE FAN BLADES OR BAFFLE TO ROTATE THE GENERATOR ROTOR / ENGINE CRANKSHAFT ASSEMBLY.

Before working inside the generator, during the aligning and fitting of coupling bolts, care should be taken to lock the assembly to ensure there is no possibility of assembly

Danger ! rotational movement.

4.2.1 TWO BEARING GENERATORS

A flexible coupling should be fitted and aligned in accordance with the coupling manufacturer's instruction.

If a close coupling adaptor is used the alignment of machined faces must be checked by offering the generator up to the engine. Shim the generator feet if necessary. Ensure adaptor guards are fitted after generator/engine assembly is complete. Open coupled sets require a suitable guard, to be provided by the set builder.

In the case of belt driven generators, ensure alignment of drive end and driven pulleys to avoid axial load on the bearings. Screw type tensioning devices are recommended to allow accurate adjustment of belt tension whilst maintaining pulley alignment.

Belt and pulley guards must be provided by the set builder.

Important ! Incorrect belt tensioning will result in excessive bearing wear.

Incorrect guarding and/or generator Caution ! alignment can result in personal injury and/

or equipment damage.

8

4.2.2 SINGLE BEARING GENERATORS

Alignment of single bearing generators is critical. If necessary shim the generator feet to ensure alignment of the machined surfaces.

For transit and storage purposes the generator frame spigot and rotor coupling plates have been coated with a rust preventative. This MUST BE removed before assembly to engine.

A practical method for removal of this coating is to clean the mating surface areas with a de-greasing agent based on a petroleum solvent.

For coupling to the various engine flywheel housings, the

Care should be taken not to allow any Caution ! cleaning agent to come into prolonged

contact with skin.

generators can be supplied with an endbracket-adaptor arrangement as outlined below.

EndBracket/Adaptor

SAE5

SAE4

SAE3

SAE2

SAE5 Plus SAE6 Adaptor Ring

Important ! Drive end adaptors are designed for use with cap head screws.

BC18 generators fitted with an SAE 5 drive end adaptor must also be fitted with a reduced diameter fan and must be operated at reduced output.

Fan securing screws should be tightened to 0.59kgm (6Nm 4.4lb. ft.)

The sequence of assembly to the engine should generally be as follows:

1.On the engine check the distance from the coupling mating face on the flywheel to the flywheel housing mating face. This should be within 0.5mm of nominal dimension. This is necessary to ensure that a thrust is not applied to the a.c. generator bearing or engine bearing.

2.Check that the bolts securing the coupling disc to the coupling hub are tight and locked into position. Torque tightening is 7.6kgm (75Nm; 55 lb ft).

3.Remove covers from the drive end of the generator to gain access to coupling disc and adaptor bolts.

4.Check that coupling disc is concentric with adaptor spigot. This can be adjusted by suspending the rotor by means of a rope sling through the adaptor opening.

5.Offer the a.c. generator to engine and engage both coupling disc and housing spigots at the same time, finally pulling home by using the housing and coupling bolts.Use heavy gauge washers between bolt head and discs on disc to flywheel bolts.

6.Tighten coupling disc to flywheel. Refer to engine manual for torque setting of disc to flywheel bolts.

Important ! When fitting drive disc ensure that flywheel fixing bolt holes fall between fan blades to allow access for flywheel bolts. Use engine pulley to turn rotor.

4.2.2.1 SINGLE BEARING 4-POLE & 2-POLE GENERATORS

Generators offered in the BCA range can be specified to suit different engine build configurations of specific flywheel and flywheel housing combinations.

Important ! It is most important that the appropriate generator build is ordered with prior knowledge of the intended engine flywheel/ housing arrangement.

Important ! During assembly, loss of residual voltage may occur. Refer to subsection 7.4.3 for field flashing.

GENERATOR TO ENGINE ASSEMBLY INSTRUCTIONS

1.Remove louvered cover "A" from non-drive endbracket "B".

2.Assemble locating bar "E" (Newage No AF1609) by screwing into shaft.

3.Remove transit bar "K".

4.Remove side screens "G".

5.If the adaptor ring is an individual item, as indicated "F", bolted to the generator D.E. bracket, remove from generator and fit to engine flywheel housing.

6.Thread two locating pins "H" into two top flywheel holes.

7.Fit two locating pins "J" into two top holes of the engine flywheel housing/adaptor location holes.

8.Pick up generator by the cast lifting lugs on both ends with 1/2 ton shackles (TO BS3032) or lifting hooks (Newage No.LE130) using suitable lifting equipment.

9.Rotate generator rotor such that two top holes of coupling disc are in close axial alignment.

10.Push the generator rotor forward only half (50mm) the available movement provided by locating bar "E". It may be necessary to tap bar "E" with a hide mallet to ease the bearing out of housing.

Important ! Do not push the rotor forward too far.

There is a risk that the rotor will rest on the stator winding outhang resulting in winding damage especially if any

rotational movement occurs during alignment with pins "H".

11.Support the weight of the rotor at the coupling end whilst sliding the rotor forward to locate coupling disc holes over support pins "H". Locating bar "E" will allow the rotor to move forward a further 50mm, the total movement bar "E" allows being 100mm. With coupling discs positioned against flywheel location fit securing screws and washers. Remove pins "H" and fit two final securing screws and washers.

12.Push generator onto engine guiding adaptor over locating pins "J" and onto engine flywheel housing location, or ring "F", secure with screws and washers. Remove pins and replace with two screws and washers.

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13.Remove locating bar "E". Replace M10 screw "C" for barring purposes.

14.Remove lifting tackle and replace side screens "G" and louvered cover "A".

4.2.2.2 SINGLE BEARING 2-POLE GENERATOR TO ENGINE ASSEMBLY INSTRUCTIONS

(WITH DOWELED FLYWHEELS)

1-5. Follow steps 1-5 from 4 pole instruction procedure.

6.Fit the two location dowels pins into appropriate diametrically opposite holes in engine flywheel, leaving sufficient parallel diameter exposed to allow for positive location of the disc-spacer-ring and coupling discs.

7.Fit the disc-spacer-ring over the two dowel pins and position firmly against the flywheel face.

8.Follow steps 6-8 from 4 pole instruction procedure.

9.Rotate generator rotor such that the two coupling disc dowel holes align with flywheel dowel pins, and two top holes of coupling discs are in close axial alignment with the two flywheel location pins "H".

10.Follow step 10 from 4 pole instruction procedure.

11.Support the weight of the rotor at the coupling end whilst sliding the rotor forward to locate coupling disc holes over support pins "H".

Important ! Ensure coupling disc dowel pin holes are in correct alignment.

With the coupling disc positioned against flywheel location fit securing screws and washers.

Remove pins "H" and fit two final securing screws and washers.

12.Follow steps 12-14 from 4 pole instruction procedure.

4.2.3 TAPER SHAFT ARRANGEMENTS

This arrangement is used on the BCL style generators.

As with single bearing generators alignment is critical. If necessary shim the generator feet to ensure alignment of the machined surfaces.

The following procedure should be adopted to assemble the generator to the engine:-

1.Remove louvred endcover "G" from non drive endbracket "H" and M10 Hex Nut "D" from shaft securing stud "AA".“ Remove transit bar "E" and withdraw stub shaft/shaft securing stud "A/B" from rotor.

2.Ensure alternator, engine flywheel and flywheel housing locating spigots, faces and recesses are free from paint or preservatives.

3.Locate stub shaft/shaft securing stud assembly "A"/"B" on engine flywheel spigot and secure with studs "J", M12 hex. nut "L" or bolts. Refer to engine manual for torque settings.

4.Ensure both tapers are clean and free of burrs, oil or grease. Slide alternator complete with rotor towards engine, ensuring that shaft securing stud "A" enters central hole in rotor shaft. Refer to engine manual for torque settings.

5.Secure alternator adaptor "F" to engine flywheel housing. Tap adaptor into place before tightening. Refer to engine manufacturer for torque setting.

6.Fit M10 Binx nut "DD" to protruding shaft securing stud "AA". M10 Binx nut tightening torque 45.0Nm (33.0 lbs.ft).

7.Fit louvred endcover "G" to non drive endbracket "H".

8.Check for excessive vibration at time of initial run-up.

Incorrect guarding and/or generator Caution! alignment can result in personal injury and

/or equipment damage

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