Stamford AC generators, UCI 224, UCI 274, UCM 224, UCM 274 Installation & Maintenance Manual
...
Installation, Service & Maintenance
Manual
AC generators with the following for 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.
Observe all WARNING/CAUTION notices.
• 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 or pr actice w hic h can r esult
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.
Danger refers to immediate hazards
which WILL result in severe personal
injury or death.
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.
Warnin
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Danger !
Caution !
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.
STAMFORD Service, Sales and Technical staff of 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.
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.
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 STAMFORD 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 document reference N4/X/011, as additional
equipment may be required.
• The installation earthing scheme involves co nnection
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 genuine STAMFORD parts will
invalidate warranty and our 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
Warnin
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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
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 RANSFORMER 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
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
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 f inal
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.
.
SECTION 2
PRINCIPLE OF OPERATION
2.1 SELF-EXCITED AVR CONTROLLED
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 preselected 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 overexcitation protection which acts following a time delay, to deexcite 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 transfor mer com bines
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.
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 dripproof design and are not suitable for mounting outdoors
unless adequately protected by the use of canopies. Anticondensation heaters are recommended during storage and
for standby duty to ensure winding insulation is maintained in
good condition.
When installed in a clos ed cano py it must be ens ured t hat 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
Frame
50Hz 60Hz
Additional
(intake/outlet)
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 component
generator are as follows:- :
4 pole 1500 rpm 25 Hz
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.
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 t wo bearing gener ators require t he
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
Frame
kgf N
Shaft
Extension
mm
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. (140kgm). 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.
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
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
must be qualified to perform electrical
and mechanical service.
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Warnin
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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.
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
3. Refit sheet metal cover.
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
acility 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.
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 the STAMFORD
factory for a copy of the latest general arrangement drawing
showing the 'NO FOOT OPTION' appropriate to your
generator.
Warnin
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Caution !
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.
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 n e cessary to ensure that a thrust is not
applied to the a.c. generator bearing or engine bearing.
1. 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).
1. Remove covers from the drive end of the generator to
gain access to coupling and adaptor bolts.
1. 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.
1. 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.
1. Tighten coupling disc to flywheel. Refer to engine manual
for torque setting of disc to flywheel bolts.
1. Remove wooden wedges.
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.
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)
Caution !
Caution !
Caution !
Warnin
g
!
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 w iring diagram s.
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.
4.4.4.2 TYPE AS440 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
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
Fig. 4
4.4.4.5 TYPE MX321 AV R
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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