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STAMFORD BC - Cummins Generator Technologies

1. ease enn 13 BCA SINGLE BEARING COUPLING ALIGNMENT 2 2 44 4 000 02000 2 000 6 65 65 1010011 1000000100001 14 50 17 PAINT HIPINIS E 17 E E E 17 17 DIRECTION OF ROTATION 22252 17 552 17 VOLTAGE ANDIFREQUENGY I E E 18 E 18 AGGESSORIES oh cee eect e 18 AUTOMATIC VOLTAGE 53 19 5525082 Con qa Th Fx a X e SEES sat ERROR BOOKMARK NOT DEFINED AGGESSORIESA ee LS Linea e ue tA e D D M D th LL DA Dip 22 INSTALLATION ON 25 Copyright 2010 4 TD_BC MAN GB_10 06_03_GB STAMFORD SERVICE AND MAI
2. Remote Voltage Adjust All AVR Types A remote voltage adjust can be fitted to the control panel Remove link 1 2 on the AVR and connect adjuster to terminals 1 and 2 Parallel Operation Understanding of the following notes on parallel operation is useful before attempting the fitting or setting of the droop kit accessory When operating in parallel with other generators or the mains it is essential that the phase sequence of the incoming generator matches that of the bulbar and also that all of the following conditions are met before the circuit breaker of the incoming generator is closed on to the bus bar or operational generator Frequency must match within close limits Voltages must match within close limits Phase angle of voltages must match within close limits Copyright 2010 22 TD BC MAN GB 10 06 03 GB STAMFORD A variety of techniques varying from simple synchronising lamps to fully automatic synchronisers can be used to ensure these conditions are met Important Failure to meet conditions 1 2 and 3 when closing the circuit breaker will generate excessive mechanical and electrical stresses resulting in equipment damage Once connected in parallel a minimum instrumentation level per generator of voltmeter ammeter watt meter measuring total power per generator and frequency meter is required in order to adjust the engine and generator controls to share kW in relation to engine ratings and kVAr in relation
3. Residual Voltage Check Field Flashing This procedure applies to all generators fitted with AVR control With the generator set stationary remove AVR access cover and leads F1 and F2 from the AVR Start the set and measure voltage across AVR terminals 7 8 A minimum level of 5 volts is required at these terminals If the voltage is less than 5 volts stop the set because it will be necessary to carry out the following Field Flashing procedure Replace leads F1 and F2 on the AVR terminals Using a 12 volt D C battery as a supply clip leads from battery negative to AVR terminal F2 and from battery positive through a diode to AVR terminal F1 Important A diode must be used as shown below to ensure the AVR is not damaged TD MAN 10 06 03 GB 31 Copyright 2010 STAMFORD Fig 5 Important If the generating set battery is used for field flashing the generator main stator neutral must be disconnected from earth Restart the set and note output voltage from the main stator which should be approximately nominal voltage or voltage at AVR terminals 7 and 8 which should be between 170 and 250 volts Stop the set and unclip battery supply from terminals F1 and F2 Restart the set The generator should now operate normally If no voltage build up is obtained it can be assumed a fault exists in either the generator or the AVR circuits Follow the SEPARATE EXCITATION PROCEDURE to check generator windings rotating diodes and
4. Two bearing generators require a substantial bedplate with engine generator mounting pads to ensure a good base for accurate alignment Close coupling of the engine to the generator can increase the overall rigidity of the set A flexible coupling designed to suit the specific engine generator combination is recommended to minimise the torsional effects Accurate alignment of single bearing generators is essential vibration can occur due to the flexing of the flanges between the engine and generator A substantial bedplate with engine generator mounting pads is required 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 The maximum bending moment of the engine flange must be checked with the engine manufacturer 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 Caution Torsional incompatibility and or excessive vibration levels can cause damage or failure
5. will reduce the effectiveness of the insulation and lead to premature failure of the windings Consider using air filters or an enclosure to protect the generator Air Filters Air filters are available on request Filters present a restriction to the airflow so the rating of the generator must be reduced by 5 If the filters are supplied factory fitted the rating on the nameplate will include the reduced rating The filters can be up fitted after delivery in which case the customer must apply the power reduction Air filters remove airborne particulates above 3 microns The frequency of changing and cleaning the filters depend on the site conditions We recommend that the filters are monitored frequently until a suitable cycle of change is established Air filters do not remove water Additional protection must be employed to prevent the filters from getting wet If the filters are allowed to get wet the airflow will be restricted and the generator will overheat This will reduce the life expectancy of the insulation leading to premature failure of the generator High Humidity environments The humidity of the air will allow condensation to form on the windings if the temperature of the windings falls below the dew point The dew point is a relationship between the ambient temperature and humidity In areas of high humidity additional protection may be required even if the generator is fitted inside an enclosure Anti condensation heaters A
6. 1 16 1 19 1 21 0 91 1 16 0 17 0 12 BC164D 0 83 0 84 0 87 0 74 0 93 0 28 0 22 BC184E 0 59 0 60 0 63 0 48 0 61 0 16 0 12 BC184F 0 41 0 43 0 45 0 35 0 43 0 15 0 08 BC184G 0 33 0 34 0 36 0 26 0 33 0 09 0 07 BC184H BC184J Measure insulation resistance between sections and each section to earth Unbalanced or incorrect winding resistances and or low insulation resistances to earth indicate rewinding of the stator will be necessary TD BC MAN GB 10 06 03 GB 35 Copyright 2010 STAMFORD Excitation Control Test AVR Function Test All types of AVR S can be tested with this procedure 57 Remove exciter field leads X amp XX F1 amp F2 from the AVR terminals X amp XX F1 amp F2 58 Connect a 60W 240V household lamp to AVR terminals X amp XX F1 amp F2 59 Set the AVR VOLTS control potentiometer fully clockwise 60 Connect a 12V 1 0A DC supply to the exciter field leads X amp XX F1 amp F2 with F1 to the positive 61 Start the generating set and run at rated speed 62 Check that the generator output voltage is within 10 of rated voltage Voltages at AVR terminals 7 8 on SX460 AVR or P2 P3 on SX421 AVR should be between 170 and 250 volts If the generator output voltage is correct but the voltage on 7 8 or P2 P3 is low check auxiliary leads and connections to main terminals The lamp connected across X XX should glow
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8. In the case of the SX460 and SA465 AVRs the lamp should glow continuously Failure to turn off indicates faulty protection circuit and the AVR should be replaced Turning the VOLTS control potentiometer fully anti clockwise should turn off the lamp with all AVR types Should the lamp fail to light the AVR is faulty and must be replaced Important After this test turn the VOLTS control potentiometer fully anti clockwise Transformer Control The transformer rectifier unit can only be checked by continuity resistance checks and insulation resistance measurement Rectifier Diodes Separate primary leads T1 T2 T3 T4 and secondary leads 10 11 Examine windings for damage Measure the resistances across T1 T2 and T3 T4 These will be a low value but should be balanced Check that there is resistance in the order of 5 ohms between leads 10 and 11 Check insulation resistance of each winding section to earth and to other winding sections Low insulation resistance unbalanced primary resistance open or short circuited winding sections indicates the transformer unit should be replaced Three phase transformer Separate primary leads T1 T2 T3 and secondary leads 6 7 8 and 10 11 12 Examine windings for damage Measure resistances across T1 T2 T2 T3 T3 T1 These will be low but should be balanced Check that resistances are balanced across 6 10 7 11 and 8 12 and in the order of 8 ohms Check insulation resistance of each winding sectio
9. 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 Fit the disc spacer ring over the two dowel pins and position firmly against the flywheel face Follow steps 6 8 from BCA 4 pole instruction procedure 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 Follow step 10 and 11 from BCA 4 pole instruction procedure Support the weight of the rotor at the coupling end whilst sliding the rotor forward to locate coupling disc holes over support pins H TD BC MAN GB 10 06 03 GB 15 Copyright 2010 STAMFORD Important Ensure coupling disc dowel pinholes 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 Follow steps 12 14 from 4 pole instruction procedure BCL 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 25 Remove louvred end co
10. Megohm is not obtained Air Filters Air filters for the removal of airborne particulate matter dust are offered as an addition to the standard build option The filter elements do not remove and must not be allowed to get wet The frequency of filter maintenance will depend upon the severity of the site conditions Regular inspection of the elements will be required to establish when cleaning is necessary Caution Do not charge filters with oil Warning Removal of filter elements enables access to LIVE parts Only remove elements with the generator out of service Air Filter Cleaning Procedure 49 Remove the filter elements from the filter frames taking care not to damage them 50 Invert the filters dirty side down and agitate to remove particles of dirt To remove stubborn particles low pressure air can be used in the reverse direction of flow to force out stubborn particles If necessary use a soft brush to gently brush off any remaining dirt particles Clean the sealing gaskets and surrounding area Visually check the condition of the filter elements and sealing gaskets replace as necessary Ensure that the filter elements are dry before putting them back into service Carefully replace the filter elements 51 52 53 54 2 He we Copyright 2010 30 TD BC GB 10 06 03 GB STAMFORD Maintenance Fault Finding Important Before commencing any fault finding procedures examine all wiring for broke
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12. of the generator and or engine components Coupling 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 Axial loading of the generator bearings should be avoided Should it be unavoidable contact the factory for advice Warning Incorrect guarding and or generator alignment can result in injury and or equipment damage TD MAN 10 06 03 GB 13 Copyright 2010 STAMFORD Coupling Single Bearing Generators Alignment of single bearing generators is critical 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 Warning Care should be taken not to allow any cleaning agent to come into prolonged contact with skin BCI 4 pole Single Bearing Coupling Alignment 1 the engine check the di
13. the generator Remove transformer cover box Normally left hand side of the terminal box when viewed from the non drive end Slacken the three transformer mounting bolts along the top of the transformer and the two bolts holding the mounting bracket to the base plate Start the set with a voltmeter connected across the main output terminals Adjust the air gap between the transformer top lamination section and the transformer limbs to obtain required voltage on no load Slightly tighten the three mounting bolts Switch load and off two or three times Application of load will normally raise the voltage setting slightly With the load off recheck the no load voltage Readjust air gap and finally tighten mounting bolts Refit the access cover Warning Failure to refit covers can result in operator personal injury or death Accessories Generator control accessories may be fitted as an option in the generator terminal box If fitted at the time of supply the wiring diagram s in the back of this book shows the connections When the options are supplied separately fitting instructions are provided with the accessory Accessories available are droop transformer for parallel operation applicable to generators with AS440 AVR and remote voltage adjust hand trimmer The latter being available for all AVR types but not fitted on the generator NOTE None of the accessories can be fitted with a transformer controlled generator
14. to generator ratings It is important to recognise that kW are derived from the engine and speed governor characteristics determine the kW sharing between sets kVAr are derived from the generator and excitation control characteristics determine the kVAr sharing Reference should be made to the generating set manufacturer s instructions for setting the governor controls Droop The most commonly used method of kVAr sharing is to create a generator voltage characteristic which falls with decreasing power factor increasing kVAr This is achieved with a current transformer C T which provides a signal dependent on current phase angle i e power factor to the AVR The current transformer has a burden resistor on the AVR board and a percentage of the burden resistor voltage is summed into the AVR circuit Increasing droop is obtained by turning the DROOP control potentiometer clockwise The diagrams below indicate the effect of droop in a simple two generator system kVV No 2 2 No 4 kVAr kVAr kVAr Generally 5 droop at full load current zero p f is sufficient to ensure kVAr sharing If the droop accessory has been supplied with the generator it will have been tested to ensure correct polarity and set to a nominal level of droop The final level of droop will be set during generating set commissioning TD BC MAN GB 10 06 03 GB 23 Copyright 2010 STAMFORD Setting Procedure Depending upon availabl
15. 06_03_GB STAMFORD ROTATING Description Quantity RECTIFIER ASSEMBLY Plate Ref 1 Diode Hub 2 2 Rectifier Fin 2 3 Forward Diode 3 4 Reverse Diode 3 5 Insulating Washer 4 6 Varistor 1 7 M5 Plain Washer 2 8 M5 Plain Washer large 6 9 M5 Lockwasher 6 10 Tamila hex 2 11 No 10 UNF Brass Screw 2 12 No 10 UNF Brass Screw 2 13 2 NOTE Underside of diodes to be smeared with Midlands Silicons Heat sink compound type MS2623 Code 030 02318 This compound must not be applied to diode thread Diodes to be tightened to a torque load of 2 03 2 37 Nm Strip insulation for 10 mm from end cable If conductor is untinned this section should be trimmed before threading through hole in diode tag solder in accordance with DD15500 Fig 10 ROTATING RECTIFIER ASSEMBLY A i Ef FEE 2 9 i1 WW m 819 iio i 7X gt zT pa T Ms TOL e TE lt p wo UTE 79 11 13 Ie D j aed j N 6 L 2 m amp DE 4 A Tu WWE 7 Diode Hub Rectflar Fin Forward Dioda Revarsa Diode Insulating Washer Varistor M5 Plan Washer M5 Pisin Washar Largs M5 Lockwasher hex No 10 UNF Brass 10 UNF Erass M MON MN m m N kU t NUN NOTE Underside of diodes to be smeared wih Midland Silicons Heg Sink compund type 152623 Newage Code No 030 02318 This compound must n
16. 1 Side Panel 22 Main Terminal Panel 23 Terminal Link 24 Main Rectifier Assembly Forward 25 Main Rectifier Assembly Reverse 26 Varistor 27 Diode Reverse Polarity 28 Diode Forward Polarity 29 AVR 30 AVR Mounting Plate 31 AVR Mounting Bracket 32 AVM 33 Fan Hub For Balancing Purpose Only 34 Lifting Lug TD BC MAN GB 10 06 03 GB 45 Copyright 2010 STAMFORD TYPICAL SINGLE BEARING GEMERATOR TAPER SHAFT ARRANGEMENT BCL Fig 7 TYPICAL SINGLE BEARING GENERATOR TAPER SHAFT ARRANGEMENT BCL 18 Copyright 2010 46 TD BC 10 06 03 GB STAMFORD PARTS LIST TYPICAL SINGLE BEARING SERIES 5 TRANSFORMER CONTROLLED GENERATOR Plate Ref Description 1 Stator 2 Rotor 3 Exciter Rotor 4 Exciter Stator 5 N D E End bracket 6 Cover N D E 7 Bearing O Ring N D E 8 Bearing N D E 9 D E Adaptor 10 D E Screen 11 Coupling Disc 12 Pressure Plate 13 Coupling Bolt N D E Non Driven End 14 Foot D E Driven End 15 Frame Cover Bottom 16 Frame Cover Top 17 Terminal Box Lid 18 End panel D E 19 End panel N D E 20 Side Panel 21 Mounting Plate Series 5 22 ud Control Assembly Series 23 Control Rectifier Assembly 24 Main Rectifier Assembly Forward 25 Main Rectifier Assembly Reverse 26 Varistor 27 Diode Reverse Polarity 28 Diode Forward Polarity 29 Fan Hub 30
17. 7 Bearing O Ring N D E 8 Bearing N D E 9 D E Adaptor 10 D E Screen 11 Coupling Hub 12 Pressure Plate 13 Coupling Bolt N D E Non Driven End 14 Foot D E Driven End i Cover Baton 2 16 17 Terminal Box Lid 18 End panel D E 19 End panel N D E 20 Side Panel AVR 21 Side Panel 22 Main Terminal Panel 23 Terminal Link 24 Main Rectifier Assembly Forward 25 Main Rectifier Assembly Reverse 26 Varistor 27 Diode Reverse Polarity 28 Diode Forward Polarity 29 AVR 30 AVR Mounting Plate 31 AVR Mounting Bracket 32 AVM 33 Fan Hub 34 Fan 35 Fan Securing Screw TD BC MAN GB 10 06 03 GB 43 Copyright 2010 STAMFORD TYPICAL SINGLE BEARING GENERATOR Fig 6 TYPICAL SINGLE BEARING GENERATOR Copyright 2010 44 TD_BC MAN GB_10 06_03_GB STAMFORD PARTS LIST TYPICAL SINGLE BEARING GENERATOR TAPER SHAFT ARRANGEMENT BCL Plate Ref Description 1 Stator 2 Rotor 3 Exciter Rotor 4 Exciter Stator 5 N D E End bracket 6 Cover N D E 7 Bearing O Ring N D E 8 Bearing N D E 9 D E Adaptor 10 Air Intake Side Panel 11 Coupling Hub 12 Rotor Shaft Stud 13 Binx Nut N D E Non Driven End 14 Foot D E Driven End 15 Frame Gaver Bottom 16 Frame Cover 17 Terminal Box Lid 18 End panel D E 19 End panel N D E 20 Side Panel AVR 2
18. 8 9 If the vibration levels are not within tolerance the genset builder should investigate the root cause of the vibrations and eliminate them The best practice is for the genset builder to take initial readings as a base line and the user to periodically monitor the genset and bearings to detect any deteriorating trend It will then be possible to plan ahead for bearing changes and eliminate vibration problems before excessive damage to the generating set occurs Vibration checks should be made every 3 months Excessive Vibration levels If the vibration levels of the generating set are not within the parameters quoted above Consult the genset builder the genset builder should address the genset design to reduce the vibration levels as much as possible Discuss with us the impact of not meeting the above levels on both bearing and generator life expectancy When requested or it is deemed necessary we will work with the genset builder in an attempt to find a satisfactory solution Bearings Sealed for life or re greasable bearings are fitted to the P range of generators The bearings are fitted within machined housings these housings form an assembly located and bolted within the end brackets All of the have bearings have pressed steel cages and are type C3 The grease used is a high specification synthetic compound that must not be mixed with grease with a different specification Re greasable Bearings When re greasable bearing
19. AVR Separate Excitation Test Procedure The generator windings diode assembly and AVR can be checked using this procedure With the generating set stationary remove AVR access cover and leads F1 and F2 from the AVR On transformer controlled generators remove the terminal box lid for access and remove leads F1 and F2 from the control rectifier bridge Connect a 60W 240 volt household lamp or two 120V lamps in series to AVR terminals F1 and F2 on AVR controlled generators On transformer controlled generators refer to Transformer Control Connect a 0 12 volt 1 0 Amp supply to leads F1 and F2 The positive of the D C supply is connected to the lead marked F1 and the negative to the lead marked F2 The procedure is simplified by dividing into two sections 55 Generator windings and rotating diodes 56 Excitation control test Copyright 2010 32 TD BC MAN GB 10 06 03 GB STAMFORD Generator Windings And Rotating Diodes Important The resistances quoted apply to a standard winding For generators having windings or voltages other than those specified refer to factory for details Ensure all disconnected leads are isolated and free from earth This procedure is carried out with leads F1 and F2 disconnected at the AVR or transformer control rectifier bridge and using a 12 volt d c supply to leads F1 and F2 Start the set and run at rated speed on no load Measure the voltages at the main output terminals U V and W These s
20. Fan 31 Fan Securing Screw 32 Main Terminal Panel 33 Terminal Link TD BC GB 10 06 03 GB 47 Copyright 2010 STAMFORD TYPICAL SINGLE BEARING SERIES 5 TRANSFORMER CONTROLLED GENERATOR Fig 8 TYPICAL SINGLE BEARING SERIES 5 TRANSFORMER CONTROLLED GENERATOR Copyright 2010 48 TD_BC MAN GB_10 06_03_GB STAMFORD PARTS LIST TYPICAL TWO BEARING GENERATOR Plate Ref Description 1 Stator 2 Rotor 3 Exciter Rotor 4 Exciter Stator 5 N D E End bracket 6 Cover 7 Bearing O Ring N D E 8 Bearing N D E 9 Bearing D E 10 Bearing Wave Washer D E 11 D E Screen 12 D E Adaptor 13 D E End bracket N D E Non Driven End 14 Foot D E Driven End 15 Frame Gaver Bottom 2 16 Frame Cover 17 Terminal Box Lid 18 End panel D E 19 End panel N D E 20 Side Panel AVR 21 Side Panel 22 Main Terminal Panel 23 Terminal Link 24 Main Rectifier Assembly Forward 25 Main Rectifier Assembly Reverse 26 Varistor 27 Diode Reverse Polarity 28 Diode Forward Polarity 29 AVR 30 AVR Mounting Plate 31 AVR Mounting Bracket 32 AVM 33 Fan Hub 34 Fan 35 Fan Securing Screw TD BC MAN GB 10 06 03 GB 49 Copyright 2010 STAMFORD TYPICAL TWO BEARING GENERATOR Fig 9 TYPICAL TWO BEARING GENERATOR Copyright 2010 50 TD_BC MAN GB_10
21. 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 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 Copyright 2010 12 TD BC GB 10 06 03 GB STAMFORD designer to ensure that the alignment and stiffness of the bedplate and mountings are such that the vibration limits of BS5000 part 3 and ISO 8528 part 9 are not exceeded In standby applications where the running time is limited and reduced life expectancy is accepted higher levels than specified in BS5000 part 3 can be tolerated up to a maximum of 18mm sec Side Loads 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 2 4 Pole Side ode Shaft extension mm kgf N BC16 92 900 82 BC18 173 1700 82 Coupling Arrangements Single and two bearing arrangements are available both arrangements can be close coupled Both arrangements also need a firm level foundation
22. NTENANCE 27 iddsc ERROR BOOKMARK NOT DEFINED Sc 27 PROCEDURE FOR INSULATION 2 001 28 METHODS OF DRYING OUT 11 28 TYPICAL DRYING OUT CURVE mere 29 AIR FILTERS MR RT 30 31 REMOVAL REPLACEMENT OF COMPONENT ASSEMBLIES 444 37 SPARES AND AFTER SALES 41 TD BC MAN 10 06 03 GB 5 Copyright 2010 STAMFORD INTRODUCTION General Description The BC16 18 range of generators is of brushless rotating field design available up to 660V 50Hz 1500 rpm 4 pole and 3000 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 The BC16 18 range are self excited with excitation power derived f
23. STAMFORD Installation Service amp Maintenance Manual for STAMFORD BC Range of Generators STAMFORD SAFETY PRECAUTIONS First Steps to Safe Operation Read this manual obey all Warnings and Cautions and become familiar with the product Warnings amp Notices used in this manual The various warnings are out lined below and appear in the text in this format Warnings and Cautions appear at the appropriate position in the to which they refer Warning Information that draws attention to the risk of injury or death Caution Information that draws attention to the risk of damage to the product process or surroundings Note Used to convey or draw attention to additional information or explanations Notes appear after the text to which they refer Skill requirements of personnel Service and maintenance procedures should only be carried out by experienced and qualified engineers who are familiar with the procedures and the equipment Before any intrusive procedures are carried out ensure that the engine is inhibited and the generator is electrically isolated Electrical Equipment All electrical equipment can be dangerous if not operated correctly Always service and maintain the generator in accordance with this manual Always use genuine STAMFORD replacement parts Warning Electrical shock can cause injury or death Ensure that all personnel operating servi
24. aintenance is carried out vibration levels do not exceed the levels stated in ISO 8528 9 and BS5000 3 and the ambient temperature does not exceed 50 C Plan to replace bearings within 30 000 hours of operation It is important to note that bearings in service under good operating conditions can continue to run beyond the recommended replacement period It should also be remembered that the risk of bearing failure increases with time If in doubt about any aspect of the bearing life on STAMFORD generators contact your nearest supplier of STAMFORD generators or contact the Stamford factory direct TD BC MAN GB 10 06 03 GB 11 Copyright 2010 STAMFORD Installation into the Generating Set The generator is supplied as a component part for installation into a generating set Delivery Upon receipt of the generator check the generator for damage that may have occurred during transport Also check that the rating plate details are correct and as ordered for the application Handling the generator When lifting the generator use a spreader bar to ensure that the angle on the lifting chains are vertical to the lifting position on the generator Warning The generator lifting points are designed to lift the generator only Do not lift the complete generating set by the generator lifting points Single bearing generators have a transit bar fitted at the drive end This bar holds the rotor in position during transit Th
25. aking the readings Resistance values should be within 10 of the values given in the table below Main Exciter Stator Frame Size Rotor Typei Type2 Type 3 Exciter Rotor BC164A 0 44 19 26 110 0 26 BC164B 0 48 19 26 110 0 26 BC164C 0 52 19 26 110 0 26 BC164D 0 56 19 26 110 0 26 BC184E 0 64 20 27 115 0 21 BC184F 0 74 22 30 127 0 23 BC184G 0 83 22 30 127 0 23 BC184H 0 89 24 2 0 24 184 0 96 24 5 0 24 BC162D 0 81 18 0 26 162 0 89 18 0 26 BC162F 0 95 18 0 26 BC162G 1 09 19 0 27 BC182H 1 17 20 0 21 BC182J 1 28 20 0 21 BC182K 1 40 20 0 21 BCA162L 1 55 20 5 0 21 Used with 1 phase transformer controlled 3 phase or 1 phase generators Used with 3 phase transformer controlled 3 phase generators Generators fitted with auxiliary stator windings Frame Size Main Rotor Exciter Exciter Stator Rotor BC184E 0 64 8 0 21 BC184F 0 74 8 0 23 BC184G 0 83 8 0 23 BC184H 0 89 8 0 24 BC184J 0 96 8 0 24 Incorrect resistances indicate faulty windings and component replacement is necessary Refer to removal and replacement of component assemblies in Unbalanced Main Terminal Voltages If voltages are unbalanced this indicates a fault on the main stator winding or main cables to the circuit breaker NOTE Faults on the stator winding or cables may also cause noticeable load i
26. all covers and re commission as appropriate If the set is not to be run immediately ensure that the anti condensation heaters are energised and retest prior to running Short Circuit Method Warning This process should only be performed by a competent engineer familiar with safe operating practices within and around generator sets of the type in question Ensure the generator is safe to work on initiate all mechanical and electrical safety procedures pertaining to the genset and the site Caution The short circuit must not be applied with the AVR connected in circuit Current in excess of the rated generator current will cause damage to the windings 40 Bolt a short circuit of adequate current carrying capacity across the main terminals of the generator The shorting link should be capable of taking full load current Copyright 2010 28 TD BC MAN GB 10 06 03 GB STAMFORD 41 Disconnect the cables from terminals X and XX of the AVR 42 Connect a variable supply to the positive and XX negative field cables The supply must be able to provide a current up to 2 0 Amp at 0 24 Volts 43 Position a suitable ac ammeter to measure the shorting link current 44 Set the supply voltage to zero and start the generating set Slowly increase the dc voltage to pass current through the exciter field winding As the excitation current increases so the stator current in the shorting link will incre
27. ase This stator output current level must be monitored and not allowed to exceed 80 of the generator s rated output current 45 After every 30 minutes of this exercise Stop the generator and switch off the separate excitation supply measure and record the stator winding IR values and plot the results The resulting graph should be compared with the classic shaped graph This drying out procedure is complete when the parameters covered in the section entitled Typical Drying Out Curve are met 46 Once the Insulation Resistance is raised to an acceptable level minimum value 1 0 Megohm the dc supply may be removed and the exciter field leads X and re connected to their terminals on the AVR 47 Rebuild the genset replace all covers and re commission as appropriate 48 If the set is not to be run immediately ensure that the anti condensation heaters are energised and retest the generator prior to running Typical Drying Out Curve Whichever method is used to dry out the generator the resistance should be measured every half hour and a curve plotted as shown 9 1 axis Resistance G 2 X axis Time 3 One Megohm limit 9 The illustration shows a typical curve for a machine that has absorbed a considerable amount of moisture The curve indicates a temporary increase in resistance a fall and then a gradual rise to a steady state Point A the steady state must be greater than 1 0 Megohm I
28. by the generating set builder but will normally be required to be connected to the site earth system Warning Reference to local electricity regulations or safety rules should be made to ensure correct earthing procedures have been followed TD BC MAN GB 10 06 03 GB 25 Copyright 2010 STAMFORD Protection It is the responsibility of the end user and his contractors subcontractors to ensure that the overall system protection meets the needs of any inspectorate local electricity authority or safety rules pertaining to the site location To enable the system designer to achieve the necessary protection and or discrimination fault current curves are available on request from the factory together with generator reactance values to enable fault current calculations to be made Warning Incorrect installation and or protective systems can result in personal injury and or equipment damage Installers must be qualified to perform electrical installation work Commissioning Ensure that all external cabling is correct and that all the generating set manufacturer s pre running checks have been carried out before starting the set The generator AVR controls will have been adjusted during the generating set manufacturer s tests and should normally not require further adjustment Should adjustment on site be necessary and for paralleling adjustments see section on Automatic Voltage Regulators Should malfunction occur during commissioning
29. cing maintaining or working near this equipment are fully aware of the emergency procedures in case of accidents Before removing the protective covers to carry out service maintenance or repair ensure that the engine is inhibited and the generator is electrically isolated The AVR access covers are designed to be removed while the generator is on load Lifting Lift the generator using the points provided with the aid of a spreader and chains The angle on the chains must be vertical during the lift Do not lift single bearing generators without the securely fitted transit bar When removing the transit bar just prior to offering the generator up to the engine be aware that the rotor is not securely held in the generator Keep the generator in the horizontal plane to when the transit bar is not fitted Warning The lifting points provided are designed for lifting the generator only Do not lift the Generating Set by the generator s lifting points Note Due to our policy of continuous improvement details in this manual which were correct at time of going to print and may now be due for amendment Information included must therefore not be regarded as binding Copyright 2010 2 TD_BC MAN GB_10 06_03_GB STAMFORD Foreword The Manual Before operating the generating set read this manual and all additional documentation supplied with it Great care has been taken with the design of this product to ensure that it is safe to operat
30. d have been transported and stored such that it will be delivered to the assembly area in a clean dry condition If held in appropriate storage conditions the generator IR value should typically be 25 Megohm If a unused new generator s IR values fall below 5 Megohm then a drying out procedure should be implemented by one of the processes outlined below before being despatched to the end customer s site Some investigation should be undertaken into the storage conditions of the generator while on site Generators in Service It is known that a generator will give reliable service with an IR value of just 1 0 Megohm For a relatively new generator to be so low it must have been subjected to inappropriate operating or storage conditions Any temporary reduction in IR values can be restored to expected values by following one of the drying out procedures Winding Condition Assessment Caution The AVR should be disconnected and the Resistance Temperature Detector R T D leads grounded during this test Caution 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 The condition of the windings can be assessed by measurement of insulation resistance IR between phase t
31. ds delivered or for any injury damages or loss resulting from such defects or from any work undone in connection therewith MACHINE SERIAL NUMBER Copyright 2010 52 TD BC MAN GB 10 06 03 GB STAMFORD Fd Generator Technologies lg Head Office Address Barnack Road Stamford Lincolnshire PE9 2NB United Kingdom Tel 44 0 1780 484000 Fax 44 0 1780 484100 www cumminsgeneratortechnologies com Copyright 2009 Cummins Generator Technologies Ltd All Rights Reserved Stamford and AvK are registered trade marks of Cummins Generator Technologies Ltd Cummins and the Cummins logo are registered trade marks of Cummins Inc Part Number TD_BC MAN GB_01_10_Rev 4_GB
32. e Misuse and the failure to follow the safety precautions contained in the manual are potential causes of accidents Read the manual and make sure that all personnel who work on the equipment have access to the manual The manual should be considered as part of the product and should remain with the product Make sure that the manual is available to all users throughout the life of the product Scope This manual contains guidance and instructions for the Installation Servicing and Maintenance of the generator It is not possible within the scope of the manual to teach the basic electrical and mechanical skills required to safely carry out the procedures enclosed The manual is written for skilled electrical and mechanical technicians and engineers who have prior knowledge and experience of generating equipment of this type We offer a range of training courses that cover all aspects of STAMFORD generators Generator Designation The Product The product is an AVR controlled self excited synchronous ac 1 8 4 D 1 example generator Designed for incorporation into a generating set A generating set is defined as machinery in European directives Generator type Applications Industrial Marine Serial Number Location Each generator has a unique serial number stamped into the upper section of the drive end of the frame 1 Frame size The serial number is al
33. e for all windings to earth and phase to phase should be compared with the guidance given above for the various life stages of a generator The minimum acceptable value is 1 0 Megohm on a 500V megger If low winding insulation is confirmed one or more of the methods given below for drying the winding should be carried out Methods of Drying Out Generators Cold Run In the case of a generator in otherwise good condition that has not been run for some time and has been standing in damp humid conditions a simple procedure may suffice It is possible that simply running the generator set unexcited AVR terminals K1 K2 open circuit for a period of say 10 minutes will sufficiently dry the surface of the windings and raise the IR to greater than 1 0 Megohm and so allow the unit to be put into service Blown Air Drying Remove the covers from all apertures to allow the escape of the water laden air During drying air must be able to flow freely through the generator in order to carry off the moisture Direct hot air from two electrical fan heaters of around 1 3 kW into the generator air inlet apertures Ensure the heat source is at least 300mm away from the windings to avoid over heating and damage to the insulation Apply the heat and plot the insulation value at half hourly intervals The process is complete when the parameters covered in the section entitled Typical Drying Out Curve are met Remove the heaters replace
34. e load the following settings should be used all are based on rated current level 0 8 P F LOAD at full load current SET DROOP TO 3 0 P F LOAD at full load current SET DROOP TO 5 Setting the droop with low power factor load is the most accurate Run each generator as a single unit at rated frequency or rated frequency 4 depending upon type of governor and nominal voltage Apply available load to rated current of the generator Adjust DROOP control potentiometer to give droop in line with above table Clockwise rotation increases amount of droop Refer to AVR drawing for potentiometer location After adjustment check NO LOAD voltage level and adjust if necessary Note 1 Reverse polarity of the C T will raise the generator voltage with load The polarities S1 S2 shown on the wiring diagrams are correct for clockwise rotation of the generator looking at the drive end Reversed rotation requires S1 S2 to be reversed Note 2 The most important aspect is to set all generators equal The precise level of droop is less critical Note 3 A generator operated as a single unit with a droop circuit set at rated load 0 8 power factor is unable to maintain the usual regulation A shorting switch can be connected across 51 52 to restore regulation for single running Important LOSS OF FUEL to an engine can cause its generator to motor with consequent damage to the generator windings Reverse power relays should be fitted to trip main c
35. e plate carrying positive biased diodes Care must be taken to ensure that the correct polarity diodes are fitted to each respective plate When fitting the diodes to the plates they must be tight enough to ensure a good mechanical and electrical contact but should not be over tightened The recommended torque tightening is 4 06 4 74Nm 36 42lb in Surge Suppressor The surge suppressor is a metal oxide varistor connected across the two rectifier plates to prevent high transient reverse voltages in the field winding from damaging the diodes This device is not polarised and will show a virtually infinite reading in both directions with an ordinary resistance meter If defective this will be visible by inspection since it will normally fail to short circuit and show signs of disintegration Replace if faulty TD MAN 10 06 03 GB 33 Copyright 2010 STAMFORD Main Excitation Windings If after establishing and correcting any fault on the rectifier assembly the output is still low when separately excited then the main rotor exciter stator and exciter rotor winding resistances should be checked see Resistance Charts as the fault must be in one of these windings The exciter stator resistance is measured across leads F1 and F2 The exciter rotor is connected to six studs which also carry the diode lead terminals The main rotor winding is connected across the two rectifier plates The respective leads must be disconnected before t
36. e transit bar should be left in position until it is necessary to remove it to allow the generator to be coupled to the engine Warning If the generator is moved without the transit bar be aware that the rotor could fall out of the frame When moving the generator always keep it in the horizontal plane this will reduce the risk of the rotor falling out Storage If the generator is not to be used immediately it must be stored in a clean dry vibration free environment If anti condensation heaters are fitted switch them on If heaters are not fitted use other means to ensure that condensation cannot form on the windings Spin the shaft by hand every month to prevent flat spots in the bearings and to free up the grease After Storage After a period of storage carry out pre running checks to determine the condition of the windings If the winding are damp or the insulation is low follow one of the drying out procedures in the Service section of this manual Replace the bearing after 12 months in storage See the Maintenance section Rotor balancing 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 Generator Vibration Frequency 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
37. e you with a satisfactory technical solution to meet your requirement Additional information for EMC compliance 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 must be made to document reference N4 X 011 This publication outlines the additional equipment that may be required Copyright 2010 8 TD_BC MAN GB_10 06_03_GB STAMFORD Application of the generator Environmental Protection STAMFORD generators are protected to IP23 IP23 is not adequate protection for use outdoors without additional measures Ambient Temperature lt 40 C This table represents the normal operating conditions that the Humidity lt 60 generator is designed for Operation outside of these parameters is Altitude lt 1000m possible after due consideration and will be reflected on the generator nameplate If the operating environment for the generator has changed after purchase the rating of the generator needs to be revised refer to the factory for details Air Flow The airflow requirements for the generator can be found in the Data section at the back of this manual Ensure that the air inlets and outlets are not obstructed when the generator is running Airborne Contaminates Contaminates such as salt oil exhaust fumes chemicals dust sand etc
38. edplate a suitably rated earth conductor normally one half of the cross sectional area of the main line cables should bridge across the anti vibration mounts Warning Refer to local regulations to ensure that the correct earth requirements are incorporated in the installation Inadequate earth installations put lives at risk Paint Finish Unless previous arrangements have been agreed the generator will be supplied in a water based primer coat It is expected that the generating set assembler will want to paint the generating set with a final coat in their company livery Note The primer coat is not adequate DEUX protection for many applications without additional protection Warning labels Anl tS 16 anl As we expect the set builder to paint the generator in his own m mm livery we supply the warning labels loose The labels can be E found in a wallet attached to the generator together with this manual lt gt lt Use the labels as per the instructions printed on the reverse of the labels Pre Running Checks Before starting the generating set Test the insulation resistance of windings Check all connections are in the correct location and tight Check the generator air path is clear of obstructions Replace all covers Insulation resistance test The AVR should be disconnected during this test A 500V Megger or similar instrument should be used Disconnect any earth conductor connected between neu
39. eet the requirements of all the major marine classification societies European Directives AC generators sold for use in the European Union must meet the relevant European directives An ac generator has no intrinsic function it must be have a mechanic input in order to provide an electrical output The generator is supplied as a component part of a Generating Set To reflect this each generator is supplied with an EC Declaration of Incorporation in accordance the Machinery Directive EC Declaration of Incorporation In accordance with the EC s Machinery Directive 98 37 EEC os amended This STAMFORD a c synchronous generator is manufactured in accordance with the above directive the generator is defined as component machinery When the generator is incorporated into Generating set the resultant machinery musi not be put into service until the machinery into which it is being incorporated hos been declared m confarmity with the provisions of the directive The manufacturer s authorised responsible person or as the manufacturer s representative in the Community is Sv Ja wh Ati Mr W Marsh Engineering Director ornack Rood Stomford Lincolnshire PES 2NB United Kingdom This component machinery carries ihe Maik for compliance wilh fi lalutory requirements for the implementation of thefolioning odditioncl The ac generator meets the relevant directives applicable to an ac generator co
40. f the windings are only slightly damp the dotted portion of the curve may not appear For general guidance expect that the typical time to reach point A will be around 3 hours Drying should be continued after point A has been reached for at least one hour It should be noted that as winding temperature increases values of insulation resistance may significantly reduce Therefore the reference values for insulation resistance can only be established with windings at a temperature of approximately 20 C If the IR value remains below 1 0 Megohm even after the above drying methods have been carried out correctly then a Polarisation Index test PI should be carried out If the minimum value of 1 0 Megohm for all components cannot be achieved rewinding or refurbishment of the generator will be necessary Caution The generator must not be put into service until the minimum values are achieved After drying out the insulation resistances should be rechecked to verify the minimum resistances quoted above are achieved On re testing it is recommended that the main stator insulation resistance is checked as follows TD BC MAN GB 10 06 03 GB 29 Copyright 2010 STAMFORD Separate the neutral leads Ground V and W phase and megger U phase to ground Ground U and W phase and megger V phase to ground Ground U and V phase and megger W phase to ground Caution The generator must not be run if the minimum insulation value of 1 0
41. from the centre line of the generating set so as to avoid a tight radius at the point of entry into the terminal box panel and allow movement of the generator set on its anti vibration mountings without excessive stress on the cable Before making final connections test the insulation resistance of the windings The AVR should be disconnected during this test A 500V Megger or similar instrument should be used Should the insulation resistance be less than 5MW the windings must be dried out as detailed in the Service and Maintenance section of this manual When making connections to the terminals the incoming cable termination should be placed on top of the winding lead termination s and clamped with the nut provided Important To avoid the possibility of swarf entering any electrical components in the terminal box panels must be removed for drilling Earthing The neutral of the generator is not bonded to the generator frame as supplied from the factory An earth terminal is provided inside the terminal box adjacent to the main terminals Should it be required to operate with the neutral earthed a substantial earth conductor normally equivalent to one half of the section of the line conductors must be connected between the neutral and the earth terminal inside the terminal box A hole is provided on the generator foot which may be tapped to give an additional earthing point The feet should be already bonded to the generating set bedplate
42. generating set Definition of BS5000 3 Generators shall be capable of continuously withstanding linear vibration levels with amplitudes of 0 25mm between 5Hz and 8Hz and velocities of 9 0mm s rms between 8 Hz and 200 Hz when measured at any point directly on the carcass or mainframe of the machine These limits refer only to the predominant frequency of vibration of any complex waveform Definition of ISO 8528 9 ISO 8528 9 refers to a broad band of frequencies the broad band is taken to be between 2 Hertz and 300 Hertz The table below is an example from ISO 8528 9 value 1 This simplified table lists the vibration limits by and speed for acceptable genset operation Vibration Levels As Measured On The Generator Engine Speed Min Set Output Kva Vibration Vibration Vibration Displacement Velocity Acceleration S rms V rms a rms 1500 1800 rpm lt 50 kVA 0 64 mm 40 mm sec 25 m sec gt 50 but lt 125 0 4mm 25 mm sec 16 m sec The Broad band is taken as 2 Hz 300 Hz Caution Exceeding either of the above specifications will have a detrimental effect on the life of the bearings and other components This will invalidate the generator warranty Vibration Monitoring We recommend that the set builder checks the vibration levels using vibration analysing equipment Ensure that the vibration levels of the generating set are within the levels stated in BS 5000 3 and ISO 852
43. hould be balanced and within 10 of the generator nominal voltage On generators fitted with an auxiliary winding in the main stator applicable only with the SA665 AVR the voltage at AVR terminals 8 and Z2 should be approximately 150 volts a c Balanced Main Terminal Voltages If all voltages are balanced within 1 at the main terminals it can be assumed that all exciter windings main windings and main rotating diodes are in good order and the fault is in the AVR or transformer control Refer to Maintenance section for test procedure If voltages are balanced but low there is a fault in the main excitation windings or rotating diode assembly Proceed as follows to identify Rectifier Diodes The diodes on the main rectifier assembly can be checked with a multimeter The flexible leads connected to each diode should be disconnected at the terminal end and the forward and reverse resistance checked A healthy diode will indicate a very high resistance infinity in the reverse direction and a low resistance in the forward direction A faulty diode will give a full deflection reading in both directions with the test meter on the 10 000 ohms scale or an infinity reading in both directions Replacement of Faulty Diodes The rectifier assembly is split into two plates the positive and negative and the main rotor is connected across these plates Each plate carries 3 diodes the negative plate carrying negative biased diodes and the positiv
44. housing bolts 9 Tighten coupling disc to flywheel bolts Refer to engine manufacturer s manual for correct tightening torque 10 Remove rotor aligning aids the sling or wooden wedges and replace all covers Caution Incorrect generator alignment can result in damage to the generator Warning Failure to replace protective covers can result in injury BCA Single Bearing Coupling Alignment 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 11 Remove louvered cover A from non drive endbracket B 12 Assemble locating bar E No AF1609 by screwing into shaft 13 Remove transit bar K 14 Remove side screens G 15 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 16 Thread two locating pins H into two top flywheel holes 17 Fit two locating pins J into two top holes of the engine flywheel housing adaptor location holes 18 Pick up generator by the cast lifting lugs on both ends with 1 2 ton shackles TO BS3032 or lifting hooks using suitable lifting equipment Copyright 2010 14 TD BC MAN 10 06 03 GB STAMFORD 19 Rotate generator rotor s
45. ing the close coupling adaptor to the drive end bracket 72 Tap off adaptor after supporting weight with sling 73 Remove the screens and louvres if fitted on either side of drive end adaptor Turn rotor until a full pole face is at bottom dead centre 74 Remove eight cap head screws securing the drive end bracket to the drive end adaptor 75 Tap off drive end bracket from drive end adaptor 76 Support rotor at drive end with a sling 77 Remove four screws securing louvred cover at non drive end and remove cover 78 Tap the rotor from non drive end bearing housing to push the bearing clear of the end bracket and its retaining O ring 79 Continue to push rotor through stator bore gradually moving sling along rotor as it is withdrawn to ensure full support at all times Copyright 2010 38 TD BC MAN GB 10 06 03 GB STAMFORD Tapered Shaft Generator BCL ENGINE FLYWHEEL ENGINE FLYWHEEL 1 Remove louvered end cover G from non drive end bracket H 2 Remove M10 BINX self locking nut DD 3 The shaft securing stud AA has been treated with a thread locking agent before being screwed into the stub shaft B This may make removal of shaft securing stud AA difficult If the shaft securing stud AA can be removed follow steps 4 to 11 to remove generator from engine If the shaft securing stud AA cannot be removed follow steps 12 to 16 to remove complete generator from engine 4 Loca
46. ircuit breaker LOSS OF EXCITATION to the generator can result in large current oscillations with consequent damage to generator windings Excitation loss detection equipment should be fitted to trip main circuit breaker Copyright 2010 24 TD BC GB 10 06 03 GB STAMFORD Installation on site General The extent of site installation will depend upon the generating set build e g if the generator is installed in a canopied set with integral switchboards and circuit breaker on site installation will be limited to connecting up the site load to the generating set output terminals In this case reference should be made to the generating set manufacturer s instruction book and any pertinent local regulations If the generator has been installed a set without switchboard or circuit breaker the following points relating to connecting up the generator should be noted Glanding The terminal box will normally be supplied with the right hand side panel viewed from the non drive end available for cable exit side panel is removable for drilling punching to suit glands or glanding boxes Should the cable exit be required from the left hand side of the generator when viewed from the non drive end the left and right hand panels may be interchanged Sufficient length of wiring to the AVR has been provided for this purpose Incoming cables should be supported from either below or above the box level and at a sufficient distance
47. move for auxiliary winding Output Voltage adjustment Hand trimmer link when not used 1 2 3 4 Low voltage selection 110v 3 O 5 Droop adjustment a 6 To optimise analogue input sensitivity ojo 7 Excitement trip cut off adjustment 7 3 8 Stability control a 9 UFRO adjustment 10 Stability section 11 Frequency selection AS440 Q Stability selection Table AS440 52 ABCD No Power range Response z eouz B D lt 100kW Slow Q OO 501z 100kW Fast Oam anmo B C 100 550kW Fast A B gt 550kW Fast TD_BC MAN GB_10 06_03_GB 19 Copyright 2010 STAMFORD Transformer Controlled Excitation System This control system is identified by the word TRANSF against AVR type on the nameplate The excitation control is factory set for the specific voltage shown on the nameplate and requires no adjustment Generator Set Testing Warning During testing it may be necessary to remove covers to adjust controls exposing live terminals or components Only personnel qualified to perform electrical service should carry out testing and or adjustments 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 sh
48. mponent part before it is incorporated into machinery DRAWING REF 0450 15519 The directives identified as pertaining to ac generators are The Machinery Safety Directive 98 37 EEC The Low Voltage Directive 73 23 EEC The EMC Directive 89 336 EEC The generator is CE marked CE labels are supplied loose in case the generating set manufacturer needs to paint the generating set before delivery to the end user Note Once the generator is build into a generating set machinery it is the responsibility of the generating set manufacture to ensure that the generating set complies with the relevant EC Directives is contrary to the EC Directives to misrepresent compliance of the EC directives by displaying the CE mark supplied with a component part of the product The directive requires compliance to be assessed as a component part as the complete product and during installation on site Applications for use within the EU STAMFORD ac generators are supplied on the basis that They are used for power generation or related functions 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 Road transport auxiliary power Industrial vehicle ear
49. n 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 Auxiliary Winding An auxiliary winding can also provide the power for excitation of the exciter field via the AS440 AVR to provide short circuit maintenance when required 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 Standards STAMFORD ac generators meet the relevant parts of national and international standards pertaining to generators The generator must be operated within the limits laid down in the relevant standards and within the parameters on the generator rating plate Copyright 2010 6 TD BC 10 06 03 GB STAMFORD Marine generators m
50. n drive end Bearing BC16 amp BC18 Drive end Bearing RSK 1101 E000 22403 E000 24602 051 01058 051 01032 RSK 1101 E000 22006 051 01058 051 01032 When ordering parts the machine serial number or machine identity number and type should be quoted together with the part description Orders and enquiries for parts should be addressed to STAMFORD PARTS Dept STAMFORD Lincolnshire 9 2NB ENGLAND Telephone 44 0 1780 484000 Fax 44 0 1780 766074 Or any of our subsidiary companies Assembly Tools Locating Bar Single Bearing 8mm Rachet Box Wrench for M10 socket screws After Sales Service AF1609 AF1599 A full technical advice and on site service facility is available from our Service Department at Stamford or through our Subsidiary Companies A repair facility is also available at our Stamford Works TD MAN 10 06 03 GB 41 Copyright 2010 STAMFORD Drawing changes to BC generators 1 New terminal arrangement 2 AVR access cover 3 AVR mounting assembly direct onto the generators body 4 securing mount reantivibration silient mount Copyright 2010 42 TD BC MAN GB 10 06 03 GB STAMFORD PARTS LIST TYPICAL SINGLE BEARING GENERATOR Plate Ref Description 1 Stator 2 Rotor 3 Exciter Rotor 4 Exciter Stator 5 N D E End bracket 6 Cover N D E
51. n or loose connections Three excitation control systems can be fitted to the range of generators covered by this manual identified by the last digit of the generator frame size designation Refer to the nameplate and then proceed to the appropriate subsection as indicated below All AVR Types Fault Finding 1 Check speed No voltage build up 2 Check residual voltage 3 Follow separate excitation test procedure to when starting set check generator Unstable voltage either on no load 1 Check speed stability 2 Check stability setting with load oe or 1 Check speed with load 2 Check that generator load is not capacitive leading power factor Low voltage 1 Check speed no load 2 Check link 1 2 or external hand trimmer leads for continuity Low voltage 1 Check speed on load 2 Check UFRO setting 3 Follow separate excitation procedure to check generator and AVR Transformer Control Fault Finding 1 Check transformers rectifiers un 2 Check transformer secondary winding for open circuit starting set Low voltage Check speed l l Check transformer air gap setting Check speed High voltage Check transformer air gap setting Check transformer secondary winding for short circuited turns Excessive voltage drop on load Check speed drop on load Check transformer rectifiers Check transformer air gap setting
52. n to earth and to other winding sections Copyright 2010 36 TD BC MAN GB 10 06 03 GB STAMFORD Low insulation resistance unbalanced primary or secondary winding resistances open or short circuited winding sections indicates the transformer unit should be replaced Rectifier units Three phase and single phase With the leads 10 11 12 F1 and F2 removed from the rectifier unit lead 12 is not fitted on single phase transformer rectifier units check forward and reverse resistances between terminals 10 F1 11 F1 12 F1 10 F2 11 F2 and 12 F2 with a multimeter A low forward resistance and high reverse resistance should be read between each pair of terminals If this is not the case the unit is faulty and should be replaced Removal and Replacement of Component Assemblies Important The following procedures assume that the generator has been removed from the generating set On single bearing generators before removal from the engine position the rotor such that a full pole face is at bottom dead centre Use engine pulley to turn rotor Metric threads are used throughout Warning When lifting single bearing generators care is needed to ensure the generator frame is kept in the horizontal plane The rotor is free to move in the frame and can slide out if not correctly lifted Incorrect lifting can cause serious personal injury Removal of Bearings Important Position the main rotor so that a full pole face of the main rotor co
53. ncrease on the engine when excitation is applied Disconnect the main cables and separate the winding leads U1 U2 U5 U6 V1 V2 V5 V6 W1 W2 W5 W6 to isolate each winding section Copyright 2010 34 TD BC MAN GB 10 06 03 GB STAMFORD Measure each section resistance values should be balanced and within 10 of the value given below AVR CONTOLLED GENERATORS Size SECTION RESISTANCE Winding 311 Winding 05 Winding 06 BC164A 0 81 0 41 0 31 BC164B 0 51 0 30 0 19 BC164C 0 36 0 21 0 13 BC164D 0 30 0 32 0 21 BC184E 0 20 0 20 0 13 BC184F 0 13 0 14 0 09 BC184G 0 11 0 11 0 07 BC184H 0 085 0 041 0 029 BC184J 0 074 0 034 0 024 BC162D 0 68 0 30 0 25 BC162E 0 42 0 21 0 15 BC162F 0 31 0 17 0 11 BC162G 0 21 0 10 0 095 BC182H 0 16 0 075 0 055 BC182J 0 13 0 06 0 042 BC182K 0 10 0 047 0 030 BCA162L 0 65 0 03 0 02 Generators fitted with auxiliary stator windings AVR CONTOLLED GENERATORS AVR CONTROLLED GENERATORS Frame Size Main Stator Winding 71 Auxiliary BC184E 0 19 1 88 BC184F 0 13 1 44 BC184G 0 10 1 32 BC184H 0 08 BC184J 0 066 TRANSFORMER CONTOLLED GENERATORS SECTION RESISTANCES 3 Phase Windings 1 380V 400 415 416 460 240 240V 164 2 4 2 56 2 62 1 98 2 36 0 37 0 25 BC164B 1 68 1 75 1 81 1 36 1 7 0 26 0 17 BC164C
54. nti condensation heaters are designed to raise the temperature of the windings above the temperature of the surrounding material so that the condensation will not form on the windings We recommend that anti condensation heaters are fitted to all generators that are left switched off for any period of time The best practice is to wire the heaters such that the heaters come on when the generator is switched off This is particularly important in applications where high humidity is a significant problem Always check the condition of the generators windings before switching the generator on If moisture is observed carry out one or more of the drying out methods outlined in the Service section of this manual Enclosures An enclosure should be employed to protect the generator from adverse environmental conditions If the generator is to be fitted inside an enclosure ensure that there is adequate airflow to support both the engine and the generator Ensure that the generator air supply is clean free from moisture and contaminates and at or below the ambient temperature stated on the rating plate TD MAN 10 06 03 GB 9 Copyright 2010 STAMFORD Vibration STAMFORD generators are designed to withstand the vibration levels encountered on generating sets built to meet the requirements of ISO 8528 9 and BS 5000 3 Where ISO 8528 is taken to be broad band measurements and BS5000 refers to the predominant frequency of any vibrations on the
55. o phase and phase to earth Measurement of winding insulation should be carried out 33 As part of a periodic maintenance plan 34 After prolonged periods of shutdown 35 When low insulation is suspected e g damp or wet windings TD BC MAN 10 06 03 GB 27 Copyright 2010 STAMFORD Care should be taken when dealing with windings that are suspected of being excessively damp or dirty The initial measurement of the IR Insulation Resistance should be established using a low voltage 500V megger type instrument If manually powered the handle should initially be turned slowly so that the full test voltage will not be applied If low values are suspected or immediately indicated the test should only continue for long enough to very quickly assess the situation Full megger tests or any other form of high voltage test should not be applied until the windings have been dried out and if necessary cleaned Procedure for Insulation Testing 36 Disconnect all electronic components AVR electronic protection equipment etc Ground the RTD s Resistance Temperature Detection devices if fitted 37 Short out the diodes on the rotating diode assembly Be aware of all components connected to the system under test that could cause false readings or be damaged by the test voltage 38 Carry out the insulation test in accordance with the operating instructions for the test equipment 39 The measured value of insulation resistanc
56. ot be applied to diode thread Diodes to be tightened to a torque bad of 2 0302 37 Strip insulation for 10mm trom end of cable If conductor undinned this section shouk be tinned before threading through hole In diode tag sokler In accordance with 0015500 TD MAN _10 06_03 GB 51 Copyright 2010 STAMFORD A C GENERATOR WARRANTY WARRANTY PERIOD A C Generators In respect of A C generators the Warranty Period is eighteen months from the date when the goods have been notified as ready for despatch or twelve months from the date of first commissioning whichever is the shorter period DEFECTS AFTER DELIVERY We will make good by repair or at our option by the supply of a replacement any fault which under proper use appears in the goods within the period specified on Clause 12 and is found on examination by us to be solely due to defective material and workmanship provided that the defective part is promptly returned carriage paid with all identification numbers and marks intact or our works or if appropriate to the Dealer who supplied the goods Any part repaired or replaced under warranty will be returned free of charge via sea freight if outside the UK We shall not be liable for any expenses which may be incurred in removing or replacing any part sent to us for inspection or in fitting any replacement supplied by us We shall be under no liability for defects in any goods which have not been prope
57. ould 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 generator 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 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 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 pre running 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 12596 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 cont
58. r frame assembly should be supported by a crane and carefully pulled back over the rotor assembly taking care not to damage any winding outhangs 15 With the rotor now exposed it will be possible to apply a sharp blow to the rotor pole face with a hide mallet to shock the rotor free of the taper stub shaft It may be necessary to apply the sharp blow to more than just one rotor pole To ensure the rotor when released cannot fall and do damage the M10 binx nut should be re fitted finger tight to the shaft securing stud leaving at least some 2 mm clearance between nut and rotor shaft end face 16 With the Taper Lock now broken the rotor can be removed from the stub shaft once the binx nut has been removed Care should be taken to ensure that the rotor weight can be supported during removal in a manner which ensures no damage will occur to the rotor assembly Replacement of rotor assemblies is a reversal of the procedures above Re Assembly of Generator Engine Before commencing re assembly components should be checked for damage and bearing s should be examined checked for loss of grease Fitting of new bearing s is recommended during major overhaul Before re assembling to the engine drive shafts and couplings or drive disc should be checked for damage or wear Where fitted the drive disc should be examined for cracks signs of fatigue or elongation of fixing holes Ensure that the disc to shaft end fixing bolts are fitted wi
59. re is at the bottom of the stator bore Removal of bearings may be effected either after the rotor assembly has been removed or simply by removal of end bracket s Refer to main rotor assembly The bearings are pre packed with grease and sealed for life 63 The bearing s are a press fit on the shaft and can be removed with standard tooling i e 2 or 3 legged manual or hydraulic bearing pullers 64 Remove circlip from shaft at non drive end only fitted on single bearing machines When fitting new bearings use a bearing heater to expand the bearing before fitting to the shaft Tap the bearing into place ensuring that it contacts the shoulder on the shaft Refit the retaining circlip on single bearing generators TD MAN 10 06 03 GB 37 Copyright 2010 STAMFORD Main Rotor Assembly 65 Single Bearing Generator 66 Remove four screws securing louvered cover at non drive end and remove cover 67 Remove the screws and covers on each side of adaptor 68 Ensure that rotor is supported at D E on a sling 69 Tap the rotor from non drive end bearing housing to push the bearing clear of the end bracket and its retaining O ring 70 Continue to push rotor through stator bore gradually moving sling along rotor as it is withdrawn to ensure full support at all times Important When re assembling position the rotor such that full pole face is at bottom dead centre Two Bearing Generator 71 Remove eight bolts secur
60. refer to Service and Maintenance section Fault Finding procedure Copyright 2010 26 TD_BC MAN GB_10 06_03_GB STAMFORD Service and Maintenance Warning Service and fault finding procedures present hazards which can result in severe personal injury or death Only personnel qualified to perform electrical and mechanical service should carry out these procedures Ensure engine starting circuits are disabled before commencing service or maintenance procedures Isolate any anti condensation heater supply Winding Condition Guidance of Typical Insulation Resistance IR Values The following is offered as general information about IR values and is aimed at providing guidance about the typical IR values for generators from new through to the point of refurbishment New Machines The generator s Insulation Resistance along with many other critical factors will have been measured during the generator manufacturing process The generator will have been transported with an appropriate packaging suitable for the method of delivery to the Generating Set assembler s works The assembler is expected to store the generator in a suitable location protected from adverse environmental and other conditions However absolute assurance that the generator will arrive at the Genset production line with IR values still at the factory test levels of above 100 Megohm to be guaranteed At Generating Set Assembler s Works The generator shoul
61. rly installed in accordance with recommended installation practices as detailed in the publication Installation Service and Maintenance Manual or which have been improperly stored or which have been repaired adjusted or altered by any person except ourselves or our authorised agents or in any second hand goods proprietary articles or goods not of our own manufacture although supplied by us such articles and goods being covered by the warranty if any given by the separate manufacturers Any claim under this clause must contain fully particulars of the alleged defect the description of the goods the date of purchase and the name and address of the Vendor the Serial Number as shown on the manufacturers identification plate or for Spares the order reference under which the goods were supplied Our judgement in all cases of claims shall be final and conclusive and the claimant shall accept our decision on all questions as to defects and the exchange of a part or parts Our liability shall be fully discharged by either repair or replacement as above and in any event shall not exceed the current list price of the defective goods Our liability under this clause shall be in lieu of any warranty or condition implied by law as to the quality or fitness for any particular purpose of the goods and save as expressly provided in this clause we shall not be under any liability whether in contract tort or otherwise in respect of defects in goo
62. rol 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 1 2 or 3 for control potentiometer location Important Do not increase the voltage above the rated generator voltage shown on the generator nameplate Copyright 2010 20 TD BC MAN GB 10 06 03 GB STAMFORD The STABILITY control potentiometer should be set to the midway position refer to fig 1 2 or 3 for its location and with the stability selection correctly set should not normally require adjustment Should adjustment be required usually identified by oscillation of the voltmeter proceed as follows Run the generating set on no load and check that speed is correct and stable Turn the STABILITY control potentiometer clockwise and 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 Load Testing Warning During testing it may be necessary to remove covers to adjust controls exposing live terminals or components Only personnel qualified to perform electrical service should carry out testing and or adjustments Refit all access covers after adjustments are completed AVR Controlled Generators AVR Adjustments Having adjusted VOLTS and STABILITY during the initial sta
63. rom the main output windings using either the AS440 AVR or transformer controlled excitation system Self Excited AVR Controlled Generators 5 6 Main Stator Powered AVR 7 8 The main stator provides power for excitation of the exciter field via the SX460 AVR which is the 4 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 2 2 1 winding By controlling the low power of the exciter field control of the high power requirement of the 3 2 main field is achieved through the rectified output of the exciter armature The AVR senses average voltage on two phases ensuring close regulation In 1 Main rotor 6 Isolating transformer addition it detects engine speed and provides voltage 2 Rotating diodes if fitted fall off with speed below a pre selected speed Hz 3 Exciter rotor 7 stator setting preventing over excitation at low engine 4 Exciter stator 8 Output speeds and softening the effect of load switching to 5 AVR 9 Shaft relieve the burden on the engine The detailed function of the AVR circuits and their adjustment are covered in the load testing section For Parallel operation The AS440 AVR also incorporates circuits which when used in conjunction with accessories can provide for parallel operation with droop control Functio
64. rt up procedure the AVR control function UFRO should not normally need adjustment If however poor voltage regulation on load is experienced refer to the following paragraph to a check that the symptoms observed do indicate adjustment is necessary and b to make the adjustment correctly UFRO Under Frequency Roll Off The AVR incorporates an under speed protection circuit which gives a voltage speed Hz characteristic as shown The UFRO control potentiometer sets the knee point Symptoms of incorrect setting are a the light emitting diode LED indicator adjacent to the UFRO Control potentiometer being permanently lit when the generator is on load and b poor voltage regulation on load i e operation on the sloping part of the characteristic Clockwise adjustment lowers the frequency speed setting of the knee point and extinguishes the LED For Optimum Ci setting the LED should illuminate as the frequency falls just below vois nominal frequency i e 47Hz on a 50Hz generator or 57Hz on a 1 60Hz generator 100 95 2 90 1 Knee point 85 2 Typical 1 80 75 80 85 90 95 100 Hz TD MAN 10 06 03 GB 21 Copyright 2010 STAMFORD Transformer Controlled Generators Transformer Adjustment Normally no adjustment is required but should the no load voltage and or on load voltage be unacceptable adjustment of the transformer air gap can be made as follows Stop
65. ry humid atmospheric or wet conditions can emulsify the grease causing corrosion and deterioration of the grease leading to premature failure of the bearings Health Monitoring of the Bearings We recommend that the user check the bearing condition using monitoring equipment to determine the state of the bearings The best practice is to take initial readings as a base line and periodically monitor the bearings to detect a deteriorating trend It will then be possible to plan a bearing change at an appropriate generating set or engine service interval Bearing Service Life Expectancy Bearing manufacturers recognise that the service life of their bearings is dependent upon many factors that are not in their control they cannot therefore quote a service life Although service life cannot be guaranteed it can be maximised by attention to the generating set design An understanding of the generating set s application will also help the user to maximise the service life expectancy of the bearings Particular attention should be paid to the alignment reduction of vibration levels environmental protection maintenance and monitoring procedures We do not quote life expectancy figures for bearings but suggests practicable replacement intervals based on the L10 life of the bearing the type of grease and the recommendations of the bearing and grease manufacturers For general purpose applications providing the correct m
66. s are fitted the bearing housings incorporate fittings for pipe work to an external grease nipple Generators with re greasable bearings are supplied with information labels advising the user of grease type re lubrication frequency and the quality of grease to be used These Copyright 2010 10 TD BC GB_10 06_03_GB STAMFORD instructions must be followed The information is repeated in the Data section of this manual The bearing housing has a grease escapement slot at the bottom of the outer area At the drive end the grease expelled from the escapement slot will discharge into the coupling area At the non drive end the grease from escapement slot is deflected by a metal plate to ensure that it cannot foul the Permanent Magnet Generator PMG The sheet metal cover over the PMG has a slot at the bottom to enable the excess grease to escape Bearing Life Factors that effect bearing life The life of a bearing in service is subject to the working conditions and the environment High levels of vibration from the engine or misalignment of the set will stress the bearing and reduce its service life If the vibration limits set out in BS 5000 3 and ISO 8528 9 are exceeded bearing life will be reduced Refer to Vibration below Long stationary periods in an environment where the generator is subject to vibration can cause false brinnelling which puts flats on the balls and grooves on the races leading to premature failure Ve
67. s to the AVR settings The AVR is factory set and will give satisfactory performance during initial running tests Subsequent voltage adjustment both on and off load may be required Guidance can be found in the section for the relevant AVR Accessories If there are accessories for control panel mounting supplied with the generator refer to the specific accessory fitting procedures inserted inside the back cover of this book Copyright 2010 18 TD BC GB_10 06_03_GB STAMFORD Automatic Voltage Regulators SX460 AVR The following jumper connections on the AVR should be checked to ensure they are correctly set for the generating set application 1 Field and sensing connections 2 Voltage adjustment 3 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 4 AVR Input Selection High Voltage 220 240V INPUT No Link Low Voltage 110 120V INPUT LINK 3 4 UFRO adjustment UFRO indication LED Frequency selection 50Hz operation LINK C 50 60Hz operation LINK C 60 8 Stability control DEO o AS440 AVR F2 F167 8 EO TEO Jo SX460 o do The following jumper connections on the AVR should be checked to ensure they are correctly set for the generating set application 8 amp Z2 linked for normal re
68. so shown on the nameplate 8 18 centre height in cm 4 Number of poles 2 or 4 Two other labels are located inside the terminal box both fixed inside C Core Size of the terminal box one on the sheet metal work and the other on the 1 Number of bearings 1 or 2 main frame of the generator Neither of these two labels is considered to be permanently fixed Rating Plate The generator has been supplied with a self adhesive rating plate label to enable fitting after final assembly and painting Stick the nameplate to the outside of the non drive end of the terminal box The surface in 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 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 progressively peel off the backing paper and smooth down with a clean cloth The adhesive will achieve a permanent bond in 24 hours A factory fitted metal nameplate is available for some applications Caution Do not exceed the parameters marked on the rating plate TD BC MAN GB 10 06 03 GB 3 Copyright 2010 STAMFORD Contents SAFETY PRECAUTIONS 2i a kein cn Fue dag aa aao ena coco eec een n Uvada ecu aug ua crga caia eda En a La
69. stance 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 ac generator bearing or engine bearing 2 Check that the bolts securing the flexible plates to the coupling hub are tight and locked into position Refer to the Data section of the manual for tightening torques 75Nm 55 Ib ft 3 Remove air outlet covers from the drive end of the generator to gain access to coupling and adaptor bolts Check that coupling joint interfaces are clean and lubricant free 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 Consider using alignment studs to ensure that the disc and the flywheel are in alignment 6 Offer the generator to engine and engage both coupling discs and housing spigots at the same time pushing generator towards engine until coupling discs are against flywheel face and the housing spigots are located Caution Do not pull the generator to the engine using bolts through the flexible discs 7 Fit housing and coupling bolts taking care to use heavy gauge washers between coupling bolt head and coupling disc Tighten bolts evenly around assembly sufficiently to ensure correct alignment 8 Tighten
70. te a steel rectangular bar or similar with a central 15mm hole flush with rear vertical face of non drive end bracket H Ensure that hole is aligned with tapped hole in shaft end 5 Insert M14 X 25 hex bolt through bar hole and screw into shaft end The rotor will be drawn towards non drive end thus releasing contact with engine taper stub shaft 6 Remove M14 X 25 hed hd bolt 7 Remove 10 bolts securing adaptor to engine 8 Withdraw generator from engine 9 Ensure rotor is supported at D E on a sling 10 Tap the rotor from non drive end bearing housing to push the bearing clear of the end bracket and a retaining O ring 11 Continue to push rotor through stator bore gradually moving sling along rotor as it is withdrawn to ensure full support at all times If it has not been possible to remove the shaft securing stud the following procedure is necessary 12 Remove the 10 bolts securing adaptor to engine 13 Using a hide mallet tap the sides of the non drive end bracket in order to release the generator adaptor from engine fly wheel housing spigot Sometimes it is possible that the action of taping the sides of the non drive end bracket with the hide mallet will in fact free the taper lock of the rotor shaft to stub shaft TD BC MAN 10 06 03 GB 39 Copyright 2010 STAMFORD 14 If stator frame assembly is freed from the engine flywheel housing yet the rotor is still firmly fixed to the stub shaft the stato
71. th the pressure plate and are torque tightened to 7 6Kgm 75Nm 5516 1 Taper shaft drive end arrangements should be checked for damage to the taper on both shaft and coupling hub Ensure both tapers are free from oil before refitting NOTE The M10 BINX nut should always be renewed Tightening torque 4 6Kgm 45Nm 33lbs ft Damaged or worn components must be replaced Returning To Service After rectification of any faults found remove all test connections and reconnect all control system leads Restart the set and adjust VOLTS control potentiometer on AVR by slowly turning clockwise until rated voltage is obtained Refit all terminal box covers access covers and reconnect heater supply Warning Failure to refit all guards access covers and terminal box covers can result in personal injury or death Copyright 2010 40 TD BC MAN GB 10 06 03 GB STAMFORD Spares and After Sales Service Recommended Spares Service parts are conveniently packaged for easy identification Genuine parts may be recognised by the STAMFORD name We recommend the following for Service and Maintenance In critical applications a set of these service spares should be held with the generator AVR Controlled Generators Diode Set 6 diodes with surge suppressor AS440 AVR SX460 AVR Non drive end Bearing BC16 amp BC18 Drive end Bearing Transformer Controlled Generators Diode Set 6 diodes with surge suppressor Diode Assembly No
72. thmoving cranes etc Fixed installation Industrial factory process plant Fixed installation residential commercial and light industrial home office health Energy management combined heat amp 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 must be made to document reference N4 X 011 This publication outlines the additional equipment that may be required The installation earth ground arrangements require the connection of the generator frame to the site protective earth conductor using a minimum lead length Maintenance and servicing with unauthorised parts not of STAMFORD brand will invalidate us from any liability for EMC compliance Installation maintenance and servicing are carried out by adequately trained personnel fully aware of the requirements of the relevant EC directives TD BC MAN 10 06 03 GB 7 Copyright 2010 STAMFORD Unsuitable Applications Synchronous generators require a constant speed for power generation Applications where the generator is not run at a constant speed are not suitable for the standard generator Such applications may be possible within certain parameters Contact the factory for advice there is every possibility that we can provid
73. tral and earth and megger an output lead terminal U V or W to earth The insulation resistance reading should be in excess of 5 Megohm to earth Should the insulation resistance be less than 5 Megohm the winding must be dried out See the Service section of this Manual Caution 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 Direction of Rotation The direction of rotation of the generator is designed to be clockwise as viewed from the drive end of the generator but it will run in either direction Phase Rotation The output from the generator will have a phase sequence of U V W with the generator running clockwise as viewed from the drive end If the phase rotation of the generator has to be reversed the customer must rearrange the output cables to a UVW configuration Ask for a circuit diagram of reverse phase connections TD BC MAN GB 10 06 03 GB 17 Copyright 2010 STAMFORD Voltage and Frequency Check that the voltage and frequency levels required for the generating set application are as indicated on the generator nameplate AVR adjustment To make AVR selections and adjustments remove the AVR cover Use the tool provided to make adjustment
74. uch that two top holes of coupling disc are in close axial alignment 20 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 21 Support the weight of the rotor at the coupling end whilst sliding the rotor forward to locate coupling disc holes oversupport 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 22 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 23 Remove locating bar E Replace M10 screw C for barring purposes 24 Remove lifting tackle and replace side screens G and louvered cover A ENGINE FLYWHEEL ENGINE FLYWHEEL HOUSING BCA Single Bearing 2 Pole Generator To Engine Assembly Instructions With Doweled Flywheels Follow steps 1 5 from BCA 4 pole instruction procedure
75. ver G from non drive end bracket 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 26 Ensure alternator engine flywheel and flywheel housing locating spigots faces and recesses are free from paint or preservatives 27 Locate stub shaft shaft securing stud assembly on engine flywheel spigot and secure with studs J M12 hex nut L or bolts Refer to engine manual for torque settings 28 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 29 Secure alternator adaptor F to engine flywheel housing Tap adaptor into place before tightening Refer to engine manufacturer for torque setting 30 Fit M10 Binx nut DD to protruding shaft securing stud AA M10 Binx nut tightening torque 45 0Nm 33 0 Ibs ft 31 Fit louvred endcover G to non drive endbracket H 32 Check for excessive vibration at time of initial run up Caution Incorrect guarding and or generator alignment can result in personal injury and or equipment damage Copyright 2010 16 TD BC MAN GB 10 06 03 GB STAMFORD Earth arrangement The generator frame should be solidly bonded to the generating set bedplate If anti vibration mounts are fitted between the generator frame and its b

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