Northern Lights UCD 224 User Manual

Publication No: UCH-027

27th Edition

2/001

Installation, Service &

Maintenance Manual

for AC generators with the following prefixes:

UCI; UCM; UCD 224 & 274 .

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 ! Caution refers to hazard or unsafe method 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.

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, operation, servicing or replacement of parts can result in

severe personal injury or death, and/or

equipment damage.

Warning ! Service personnel must be 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 DECLARATION O F INCORPORATIO N

IN A C C OR 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 LAT ION S 1992 A N D TH E SU P P LY O F M A C H IN ER Y (S AF ET Y) (A ME N D M E N T) R E G U LAT IO N S 1994

IM PLE M E N TIN G T H E E C M AC H IN ER Y D IR EC T IVE 89/392/E E C AS A ME N D E D B Y 91/368/EE C .

TH IS S TA M FO R D A.C. GE NE R ATOR W AS

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

NE WA GE INTER NAT IONA L LTD

B AR N A C K R OA D S TA M FOR D LIN C O LN SH IR E E N GLA 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 OR AT ED H A S BE E N D EC LA R E D IN C O N FOR M ITY W ITH TH E P R OV ISIO N S O F TH E S U P PLY O F MA C H IN E RY (S A FE TY ) RE GU LATIO N S 1995/MA C H IN E R Y DIRE CTIV E .

FO R AN D ON B EH ALF OF NE WAG E IN TER N ATION A L LIM ITED

P OS ITION : TECH NICA L DIRE CTOR

S IGNAT UR E:

T H IS C O M P O N E N T M A C H IN E RY C AR R IE S T H E C E M A R K FO R C O M P LIA N C E W IT H T H E S TAT U TO R Y R E Q U IR E M EN T S FO R T H E IM P L EM E N TAT IO N O F TH E F O L LO W IN G D IR E C TIV E S

The E M C D irective 89/336/E E C

This C om ponent M achinery shall not be use d in the R esidential, C om m ercial and WA RN IN G ! Light Industrial environment unless it als o conform s to th e relevant standa rd

(E N 5008 1 - 1) R E FE R TO FAC TO RY FO R D E TA ILS

ii) T he Lo w Volta ge D irectiv e 73/23/E E C as am ende d b y 93/68/E EC

Under the EC Machinery Directive section 1.7.4. It is the responsibility of the generator set builder to ensure 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
FOREWORD		1
CONTENTS		2&3
SECTION 1	INTRODUCTION	4
1.1	INTRODUCTION	4
1.2	DESIGNATION	4
1.3	SERIAL NUMBER LOCATION
	AND IDENTITY NUMBER LOCATION	4
1.4	RATING PLATE AND CE MARKING	4
SECTION 2	PRINCIPLE OF OPERATION	5
2.1	SELF-EXCITED AVR CONTROLLED GENERATORS	5
2.2	PERMANENT MAGNET GENERATOR (PMG) EXCITED -
	AVR CONTROLLED GENERATORS	5
2.3	AVR ACCESSORIES	5
2.4	TRANSFORMER CONTROLLED GENERATORS	5
SECTION 3	APPLICATION OF THE GENERATOR	6
SECTION 4	INSTALLATION - PART 1	8
4.1	LIFTING	8
4.2	ASSEMBLY	8
4.2.1	NO FOOT OPTION	8
4.2.2	TWO BEARING GENERATORS	9
4.2.3	SINGLE BEARING GENERATORS	9
4.3	EARTHING	9
4.4	PRE-RUNNING CHECKS	9
4.4.1	INSULATION CHECK	9
4.4.2	DIRECTION OF ROTATION	10
4.4.3	VOLTAGE AND FREQUENCY	10
4.4.4	AVR SETTINGS	10
4.4.4.1	TYPE SX460 AVR	10
4.4.4.2	TYPE SX440 AVR	10
4.4.4.3	TYPE SX421 AVR	11
4.4.4.4	TYPE MX341 AVR	11
4.4.4.5	TYPE MX321 AVR	11
4.4.5	TRANSFORMER CONTROLLED
	EXCITATION SYSTEM (Series 5)	12
4.5	GENERATOR SET TESTING	12
4.5.1	TEST METERING/CABLING	12
4.6	INITIAL START-UP	12
4.7	LOAD TESTING	13
4.7.1	AVR CONTROLLED GENERATORS - AVR ADJUSTMENTS	13
4.7.1.1	UFRO (Under Frequency Roll Off)
	(AVR Types SX460, SX440, SX421, MX341 and MX321)	13
4.7.1.2	EXC TRIP (Excitation Trip)	14
4.7.1.3	OVER/V (Over Voltage)	14
4.7.1.4	TRANSIENT LOAD SWITCHING ADJUSTMENTS	14
4.7.1.5	RAMP BUILD UP TIME	15
4.7.2	TRANSFORMER CONTROLLED GENERATORS -
	TRANSFORMER ADJUSTMENT	15
4.8	ACCESSORIES	15
SECTION 5	INSTALLATION - PART 2	16
5.1	GENERAL	16
5.2	GLANDING	16
5.3	EARTHING	16
5.4	PROTECTION	16
5.5	COMMISSIONING	16

2

CONTENTS

SECTION 6	ACCESSORIES	17
6.1	REMOTE VOLTAGE ADJUST (ALL AVR TYPES)	17
6.2	PARALLEL OPERATION	17
6.2.1	DROOP	17
6.2.1.1	SETTING PROCEDURE	18
6.2.2	ASTATIC CONTROL	18
6.3	MANUAL VOLTAGE REGULATOR (MVR) -
	MX341 and MX321 AVR	18
6.4	OVERVOLTAGE DE-EXCITATION BREAKER
	SX421 and MX321 AVR	18
6.4.1	RESETTING THE BREAKER	19
6.5	CURRENT LIMIT - MX321 AVR	19
6.5.1	SETTING PROCEDURE	19
6.6	POWER FACTOR CONTROLLER (PFC3)	20

SECTION 7	SERVICE AND MAINTENANCE	21
7.1	WINDING CONDITION	21
7.1.1	WINDING CONDITION ASSESSMENT	21
7.1.2	METHODS OF DRYING OUT GENERATORS	21
7.2	BEARINGS	23
7.3	AIR FILTERS	23
7.3.1	CLEANING PROCEDURE	23
7.4	FAULT FINDING	23
7.4.1	SX460 AVR - FAULT FINDING	23
7.4.2	SX440 AVR - FAULT FINDING	24
7.4.3	SX421 AVR - FAULT FINDING	24
7.4.4	TRANSFORMER CONTROL - FAULT FINDING	24
7.4.5	MX341 AVR - FAULT FINDING	25
7.4.6	MX321 AVR - FAULT FINDING	25
7.4.7	RESIDUAL VOLTAGE CHECK	26
7.5	SEPARATE EXCITATION TEST PROCEDURE	26
7.5.1	GENERATOR WINDINGS, ROTATING DIODES and
	PERMANENT MAGNET GENERATOR (PMG)	26
7.5.1.1	BALANCED MAIN TERMINAL VOLTAGES	26
7.5.1.2	UNBALANCED MAIN TERMINAL VOLTAGES	27
7.5.2	EXCITATION CONTROL TEST	27
7.5.2.1	AVR FUNCTION TEST	27
7.5.2.2	TRANSFORMER CONTROL	28
7.5.3	REMOVAL AND REPLACEMENT OF COMPONENT
	ASSEMBLIES	28
7.5.3.1	REMOVAL OF PERMANENT MAGNET GENERATOR (PMG)	28
7.5.3.2	REMOVAL OF BEARINGS	28
7.5.3.3	REMOVAL OF ENDBRACKET AND EXCITER STATOR	28
7.5.3.4	REMOVAL OF THE ROTOR ASSEMBLY	29
7.6	RETURNING TO SERVICE	29

SECTION 8	SPARES AND AFTER SALES SERVICE	30
8.1	RECOMMENDED SPARES	30
8.2	AFTER SALES SERVICE	30
SECTION 9	PARTS IDENTIFICATION	32
	TYPICAL SINGLE BEARING GENERATOR (Fig. 11)	33
	TYPICAL TWO BEARING GENERATOR (Fig. 12)	35
	TYPICAL TWO BEARING (SERIES 5) GENERATOR (Fig. 13)	37
	ROTATING RECTIFIER ASSEMBLY (Fig. 14)	38

3

SECTION 1

INTRODUCTION

1.1 INTRODUCTION

The UC22/27 range of generators is of brushless rotating field design, available up to 660V/50Hz (1500 rpm) or 60Hz (1800 rpm), and built to meet BS5000 Part 3 and international standards.

All the UC22/27 range are self-excited with excitation power derived from the main output windings, using either the SX460/ SX440/SX421 AVR. The UC22 is also available with specific windings and a transformer controlled excitation system.

A permanent magnet generator (PMG) powered excitation system is available as an option using either the MX341 or MX321 AVR.

Detailed specification sheets are available on request.

1.2 DESIGNATION

U		C		.	I	2		2		4	C	2
U		C		.	M	2		7		4	C	2

GENERATOR TYPE

UC

SPECIFIC TYPE

INDUSTRIAL = (I) OR MARINE = (M)

SHAFT HEIGHT IN CM ON BC/UC

NUMBER OF POLES 2, 4, OR 6

CORE LENGTH

NUMBER OF BEARINGS 1 OR 2

1.3 SERIAL NUMBER LOCATION AND IDENTITY NUMBER LOCATION

Each generator is metal stamped with it’s own unique serial number, the location of this number is described below.

UCI and UCM generators have their serial number stamped into the upper section of the drive end frame to end bracket adaptor ring, shown as item 31 in the parts lists at the back of this book.

UCD generators have their serial number stamped into the top of the drive end adaptor /fan shroud casting. If for any reason this casting is removed, it is imperative that care is taken to refit it to the correct generator to ensure correct identification is retained.

Inside the terminal box two adhesive rectangular labels have been fixed, each carrying the generators unique identity number. One label has been fixed to the inside of the terminal box sheet metal work, and the second label fixed to the main frame of the generator.

1.4 RATING PLATE

The generator has been supplied with a self adhesive rating plate label to enable fitting after final assembly and painting.

It is intended that this label will be stuck to the outside of the terminal box on the left hand side when viewed from the N.D.E. To assist with squarely positioning the label, location protrusions have been made in the sheet metalwork.

A CE Mark label is also supplied loose for fitment after final assembly and painting. This should be attached to an external surface of the Generator at a suitable location where it will not be obscured by the customer's wiring or other fittings.

The surface in the area where a label is to be stuck must be flat, clean, and any paint finish 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 some 20 mm of label adhesive along the edge which is to be located against the sheet metal protrusions. Once this first section of label has been carefully located and stuck into position the backing paper can be progressively removed, as the label is pressed down into position. The adhesive will achieve a permanent bond in 24 hours.

4

SECTION 2

PRINCIPLE OF OPERATION

2.1 SELF-EXCITED AVR CONTROLLED GENERATORS

The main stator provides power for excitation of the exciter field via the SX460 (SX440 or SX421) 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 SX460 or SX440 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 SX421 AVR in addition to the SX440 features has three phase rms sensing and also provides for over voltage protection when used in conjunction with an external circuit breaker (switchboard mounted).

2.2 PERMANENT MAGNET GENERATOR (PMG) EXCITED - AVR CONTROLLED GENERATORS

The permanent magnet generator (PMG) provides power for excitation of the exciter field via the AVR (MX341 or MX321) which is the controlling device governing the level of excitation provided to the exciter field. The AVR responds to a voltage sensing signal derived, via an isolating transformer in the case of MX321 AVR, 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 PMG system provides a constant source of excitation power irrespective of main stator loading and provides high motor starting capability as well as immunity to waveform distortion on the main stator output created by non linear loads, e.g. thyristor controlled dc motor.

The MX341 AVR senses average voltage on two phases ensuring close regulation. In addition it detects engine speed and provides an adjustable 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. It also provides over-excitation protection which acts following a time delay, to de-excite the generator in the event of excessive exciter field voltage.

The MX321 provides the protection and engine relief features of the MX341 and additionally incorporates 3 phase rms sensing and over-voltage protection.

The detailed function of all the AVR circuits is covered in the load testing (subsection 4.7).

2.3 AVR ACCESSORIES

The SX440, SX421, MX341 and MX321 AVRs incorporate circuits which, when used in conjunction with accessories, can provide for parallel operation either with 'droop' or 'astatic' control, VAR/ PF control and in the case of the MX321 AVR, short circuit current limiting.

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.

2.4 TRANSFORMER CONTROLLED GENERATORS

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. (See below).

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 1000m above sea level in accordance with BS5000.

Ambients in excess of 40°C and altitudes above 1000m 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 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
		0.216m³/sec	0.281m³/sec	6mm water gauge
	UC22
		458cfm	595cfm	0.25''
		0.25m³/sec	0.31m³/sec	6mm water gauge
	UCD22
		530cfm	657cfm	0.25''
		0.514m³/sec	0.617m³/sec	6mm water gauge
	UC27
		1090cfm	1308cfm	0.25''
		0.58m³/sec	0.69m³/sec	6mm water gauge
	UCD27
		1230cfm	1463cfm	0.25''

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 generator are as follows:-

4 pole	1500 rpm	25 Hz
4 pole	1800 rpm	30 Hz

However, vibrations induced by the engine are complex and contain frequencies of 1.5, 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 BS5000 Part 3 are not exceeded.

6

In standby applications where the running time is limited and reduced life expectancy is accepted, higher levels than specified in BS5000 can be tolerated, up to a maximum of 18mm/sec.

Two bearing generators open coupled 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 1000ft.lb. (140 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:-

	Side Load			Shaft
Frame				extension mm
	kgf		N
UC22	408		4000	110
UC27	510		5000	140

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 1000ft.lb. (140 kgm). A substanial bedplate with engine/generator mounting pads is required.

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.

Generators can be supplied without a foot, providing the option for customers own arrangement. See SECTION 4.2.1 for assembly procedure.

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.	7

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. Additional earthing points are provided on the generator feet.

The neutral is NOT connected to the frame.

The main stator winding has 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

Warning ! arrangements can 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, service or

replacement of parts can result in severe

personal injury or death, and/or equipment damage. Service personnel

Warning ! must be qualified to perform electrical and mechanical service.

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 750Kg.

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

Two lifting lugs are provided for use with a shackle and pin type lifting aid. Chains of suitable length and lifting capacity must be used. Lifting points are designed to be as close to the centre of gravity of the generator as possible, but due to design restrictions it is not possible to guarantee that the generator frame will remain horizontal while lifting. Care is therefore needed to avoid personal injury or equipment damage. The correct lifting arrangement is shown on the label attached to the lifting lug. (See sample below).

Single bearing generators are supplied fitted with a rotor retaining bar at the non-drive end of the shaft.

To remove retaining bar:

1.Remove the four screws holding the sheet metal cover at the non drive end and remove cover

2.Remove central bolt holding the retaining bar to the shaft

Once the bar is removed, to couple the rotor to engine, 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.

Generators fitted with a PMG excitation system are not fitted with retaining bar. Refer to frame designation to verify generator type (subsection 1.2)

4.2 ASSEMBLY

During the assembly of the generator to the engine it will be necessary firstly to carefully align, then rotate, the combined generator rotor - engine crankshaft assembly, as part of the construction process, to allow location, insertion and tightening 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 or facility designed to enable manual rotation of the crankshaft assembly. This must always be used, having been engineered as an approved method of assembly rotation, engaging the manually driven pinion with the engine flywheel starter ring-gear.

Caution ! 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 rotational movement.

4.2.1 NO FOOT OPTION

Generators can be supplied without a foot providing the option for customers own arrangement.

For details of mounting this arrangement, see the general arrangement drawing supplied with the generator. Alternatively refer to Newage International for a copy of the latest general arrangement drawing showing the 'NO FOOT OPTION' appropriate to your generator.

3.Refit sheet metal cover.

8

4.2.2 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 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 pully alignment. Side loads should not exceed values given in SECTION 3.

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

Important !	Incorrect belt tensioning will result in
	excessive bearing wear.
Caution !	Incorrect guarding and/or generator
	alignment can result in personal injury
	and/or equipment damage.

4.2.3 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.

Care should be taken not to allow any cleaning agent to come into prolonged contact with skin.

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 flexible plates to the coupling hub are tight and locked into position. Torque tightening is 24.9kgfm (244Nm; 180 lb ft).

2a. UCD224 Only

Torque tightening is 15.29 kgfm (150Nm; 110 lb ft).

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

4.Check that coupling discs are concentric with adaptor spigot. This can be adjusted by the use of tapered wooden wedges between the fan and adaptor. Alternatively the rotor can be suspended by means of a rope sling through the adaptor opening.

5.Offer the a.c. generator to engine and engage both coupling discs 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.

7.Remove wooden wedges.

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

4.3 EARTHING

The generator frame should be solidly bonded to the generating set bedplate. If antivibration mounts are fitted between the generator frame and its bedplate a suitably rated earth conductor (normally one half of the cross sectional area of the main line cables) should bridge across the antivibration mount.

Refer to local regulations to ensure that the correct earthing procedure has been

followed.

Warning !

4.4 PRE-RUNNING CHECKS 4.4.1 INSULATION CHECK

Before starting the generating set, both after completing assembly and after installation of the set, test the insulation resistance of windings.

The AVR should be disconnected during this test.

A 500V Megger or similar instrument should be used. Disconnect any earthing conductor connected between neutral and earth and megger an output lead terminal U, V or W to earth. The insulation resistance reading should be in excess of 5MΩ to earth. Should the insulation resistance be less than 5MΩ the winding must be dried out as detailed in the Service and Maintenance section of this Manual.

Important ! The windings have been H.V. tested during manufacture and further H.V. testing may degrade the insulation with consequent reduction in operating life. Should it be necessary to demonstrate H.V. testing, for customer acceptance, the tests must be carried out at reduced voltage levels i.e. Test Voltage= 0.8 (2 X Rated Voltage + 1000)

9

4.4.2 DIRECTION OF ROTATION

The generator is supplied to give a phase sequence of U V W with the generator running clockwise looking at the drive end (unless otherwise specified at the time of ordering). If the generator phase rotation has to be reversed after the generator has been despatched apply to factory for appropriate wiring diagrams.

UCI224, UCI274, UCM224, UCM274

Machines are fitted with bi-directional fans and are suitable for running in either direction of rotation.

UCD224, UCD274

Machines are fitted with uni-directional fans and are suitable for running in one direction only.

4.4.3 VOLTAGE AND FREQUENCY

Check that the voltage and frequency levels required for the generating set application are as indicated on the generator nameplate.

Three phase generators normally have a 12 ends out reconnectable winding. If it is necessary to reconnect the stator for the voltage required, refer to diagrams in the back of this manual.

4.4.4 AVR SETTINGS

To make AVR selections and adjustments remove the AVR cover and refer to 4.4.4.1, 4.4.4.2, 4.4.4.3, 4.4.4.4 or 4.4.4.5 depending upon type of AVR fitted. Reference to the generator nameplate will indicate AVR type (SX460, SX440, SX421, MX341 or MX321).

Most of the AVR adjustments are factory set in positions which will give satisfactory performance during initial running tests. Subsequent adjustment may be required to achieve optimum performance of the set under operating conditions. Refer to 'Load Testing' section for details.

4.4.4.1 TYPE SX460 AVR

The following 'jumper' connections on the AVR should be checked to ensure they are correctly set for the generating set application.

Refer to Fig. 1 for location of selection links.

1. Frequency selection

50Hz operation LINK C-50 60Hz operation LINK C-60

2. External hand trimmer selection

No external hand trimmer LINK 1-2
External hand trimmer required -	REMOVE LINK 1-2 and
	connect trimmer across
	terminals 1 and 2.

3. AVR Input Selection

High voltage	(220/240V) Input	NO LINK
Low voltage	(110/120V) Input	LINK 3-4

Refer to diagram in the back of this manual to determine wiring.

Fig. 1

4.4.4.2 TYPE SX440 AVR

The following 'jumper' connections on the AVR should be checked to ensure they are correctly set for the generating set application.

Refer to Fig. 2 for location of selection links.

1. Frequency selection terminals

50Hz operation LINK C-50 60Hz operation LINK C-60

2. Stability selection terminals

Frame UC22	LINK A-C
Frame UC27	LINK B-C

3. Sensing selection terminals

LINK 2-3

LINK 4-5

LINK 6-7

4. Excitation Interruption Link

LINK K1-K2

K1-K2 Linked for normal operation.

K2 K1 P2 P3	P4 XX X	3	2	2 1
		TR IM		A1
				A2
S X44 0	DR OO P			S1
				S2
				1	S
	VO LTS			2	EN
				3	IN S
				4	G
					E S
				5
					LEC
				6
					TION
				8
				7
	FR EQU ENCY
IN DICATOR	SELEC TION
LED
UFRO	STABILITY	SELEC TION
50 C 60		C	B	A
50Hz				90kW - 550kW
60Hz				O VE R 550kW

Fig. 2

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4.4.4.3 TYPE SX421 AVR

The following 'jumper' connections on the AVR should be checked to ensure they are correctly set for the generating set application.

Refer to Fig. 3 for location of selection links.

1. Frequency selection terminals

50Hz operation LINK C-50 60Hz operation LINK C-60

2. Stability selection terminals

Depending upon kW output LINK B-D or LINK A-C

or LINK B-C

3. Terminals K1 - K2

Excitation circuit breaker closed

Fig. 3

4.4.4.4 TYPE MX341 AVR

The following 'jumper' connections on the AVR should be checked to ensure they are correctly set for the generating set application.

Refer to Fig. 4 for location of setting links.

1. Frequency selection terminals

50Hz operation LINK 2-3 60Hz operation LINK 1-3

2. Stability selection terminals

Frame UC22	LINK A-C
Frame UC27	LINK B-C

3. Sensing selection terminals *

LINK 2-3

LINK 4-5

LINK 6-7

4. Excitation Interruption Link

LINK K1-K2

K1-K 2 Linke d for norm al operation .

	K2 K1 P2 P3	P4 XX X	3	2 2 1
		TRIM			A1
					A2
	M X 3 41	D RO O P			S1
					S2	E S
					1
						S N
		VO LTS			2
						IN
					3
						S G
					4
					5	E
						LE
					6
	D IP	EX C TRIP				T C
					7
						N IO
					8
		FREQ UE NC Y
	IND IC ATO R	SELE CTIO N
	LED
	U FR O	STABILITY	SELE CTIO N
	3 2 1	C	B		A
		4P/60H z			90kW - 55 0kW
		4P/50H z			O VE R 550kW
		6P/60H z
	N O LIN K	6P/50H z

Fig. 4

4.4.4.5 TYPE MX321 AVR

The following 'jumper' connections on the AVR should be checked to ensure they are correctly set for the generating set application.

Refer to Fig. 5 for location of setting links.

Fig. 5

1. Frequency selection terminals

50Hz operation LINK 2-3 60Hz operation LINK 1-3

2. Stability selection terminals

Frame UC22	LINK A-C
Frame UC27	LINK B-C

3. Terminals K1 - K2

Excitation circuit breaker closed.

If this option not fitted, K1 - K2 linked at auxiliary terminal block.

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4.4.5 TRANSFORMER CONTROLLED EXCITATION

SYSTEM (Series 5)

This control system is identified with the digit 5 as the last digit of the frame size quoted on the nameplate.

The excitation control is factory set for the specific voltage shown on the nameplate and requires no adjustment.

4.5 GENERATOR SET TESTING

During testing it may be necessary to remove covers to adjust controls

exposing 'live' terminals or components.

Only personnel qualified to perform Warning ! electrical service should carry out testing

and/or adjustments.

4.5.1 TEST METERING/CABLING

Connect any instrument wiring and cabling required for initial test purposes with permanent or spring-clip type connectors.

Minimum instrumentation for testing should be line - line or line to neutral voltmeter, Hz meter, load current metering and kW meter. If reactive load is used a power factor meter is desirable.

Important ! When fitting power cables for load testing purposes, ensure cable voltage rating is at least equal to the genrator rated voltage.

The load cable termination should be placed on top of the winding lead termination and clamped with the nut provided.

Caution ! Check that all wiring terminations for internal or external wiring are secure, and fit all terminal box covers and guards. Failure to secure wiring and/or covers may result in personal injury and/or equipment failure.

4.6 INITIAL START-UP

During testing it may be necessary to remove covers to adjust controls

exposing 'live' terminals or components. Only personnel qualified to perform

Warning ! electrical service should carry out testing and/or adjustments. Refit all access covers after adjustments are completed.

On completion of generating set assembly and before starting the generating set ensure that all engine manufacturer's prerunning procedures have been completed, and that adjustment of the engine governor is such that the generator will not be subjected to speeds in excess of 125% of the rated speed.

Important ! Overspeeding of the generator during initial setting of the speed governor can result in damage to the generator rotating components.

In addition remove the AVR access cover (on AVR controlled generators) and turn VOLTS control fully anti-clockwise. Start the generating set and run on no-load at nominal frequency. Slowly turn VOLTS control potentiometer clockwise until rated voltage is reached. Refer to Fig. 6a, 6b, 6c, 6d or 6e for control potentiometer location.

Important ! Do not increase the voltage above the rated generator voltage shown on the generator nameplate.

The STABILITY control potentiometer will have been pre-set and should normally not require adjustment, but should this be required, usually identified by oscillation of the voltmeter, refer to Fig. 6a, 6b, 6c, 6d or 6e for control potentiometer location and proceed as follows:-

1.Run the generating set on no-load and check that speed is correct and stable

2.Turn the STABILITY control potentiometer clockwise, then turn slowly anti-clockwise until the generator voltage starts to become unstable.

The correct setting is slightly clockwise from this position (i.e. where the machine volts are stable but close to the unstable region).

Fig. 6a

K1-K2 Linked for normal operation.

K2 K1 P2 P3	P4 XX X	3	2	2 1
		TR IM		A1
				A2
S X44 0	DR OO P			S1
				S2
				1	S
	VO LTS			2	EN
				3	IN S
				4	G
					E S
				5
					LEC
				6
				8	TION
				7
	FR EQU ENCY
IN DICATOR	SELEC TION
LED
UFRO	STABILITY	SELEC TION
50 C 60		C	B	A
50Hz				90kW - 550kW
60Hz				O VE R 550kW

Fig. 6b

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