Alternator Manual

Table of Contents
1 Introduction ........................................................................................................................................ 1-1

2 Safety .................................................................................................................................................. 2-2
2.1 Cautions on Safety .......................................................................................................................... 2-2
2.2 Safety label ..................................................................................................................................... 2-2
2.2.1 Safety label to be attached to the exciter ................................................................................ 2-2
2.2.2 Safety label to be attached to the generator ............................................................................ 2-2
2.2.3 Position of Safety Labels ........................................................................................................ 2-2
3 Outline of Product .............................................................................................................................. 3-3
3.1 Purpose of Use ................................................................................................................................ 3-3
3.2 Features of This Machine ............................................................................................................... 3-3
3.3 Outline of Exciting system ............................................................................................................. 3-3
4 QUALIFICATION OF OPERATOR ................................................................................................. 4-4
5 IDENTIFICATION ............................................................................................................................ 5-5
6 UNLOADING, UNPACKING AND STORAGE .............................................................................. 6-5
6.1 Unloading ....................................................................................................................................... 6-5
6.2 Unpacking....................................................................................................................................... 6-5
6.3 Storage ............................................................................................................................................ 6-5
7 Installation .......................................................................................................................................... 7-7
7.1 Name of Parts ................................................................................................................................. 7-7
7.2 Description of Parts ........................................................................................................................ 7-9
7.2.1 Stator Frame ........................................................................................................................... 7-9
7.2.2 Stator Core .............................................................................................................................. 7-9
7.2.3 Stator Coil ............................................................................................................................... 7-9
7.2.4 Rotor Core ............................................................................................................................ 7-10
7.2.5 Rotor Coil ............................................................................................................................. 7-10
7.2.6 Shaft...................................................................................................................................... 7-10
7.2.7 Bearing ................................................................................................................................. 7-11
7.2.8 Fan ........................................................................................................................................ 7-13
7.2.9 Ventilation cover .................................................................................................................. 7-13
7.2.10 AC Exciter ............................................................................................................................ 7-13
7.2.11 Rotating Rectifier ................................................................................................................. 7-14
7.2.12 Connection Diagram ............................................................................................................ 7-14
7.2.13 Exciting System.................................................................................................................... 7-15
7.3 Installation .................................................................................................................................... 7-22
7.3.1 Installation Procedures ......................................................................................................... 7-23
8 OPERATION ................................................................................................................................... 8-26
8.1 Inspection before Operation ......................................................................................................... 8-26
8.1.1 Installation Condition ........................................................................................................... 8-26
8.1.2 Terminal section (including exciter)..................................................................................... 8-26
8.1.3 Insulation Resistance ............................................................................................................ 8-26
8.1.4 Bearing section ..................................................................................................................... 8-27
8.2 Operation Procedures ................................................................................................................... 8-27
8.3 During Operation .......................................................................................................................... 8-27
8.3.1 Monitoring of the Generator ................................................................................................. 8-28
8.3.2 Monitoring of the Panel ........................................................................................................ 8-28
8.4 Parallel Running ........................................................................................................................... 8-29
8.4.1 Requirements for Parallel Running ...................................................................................... 8-29
8.4.2 Synchronizing ....................................................................................................................... 8-29
8.4.3 Load Sharing......................................................................................................................... 8-30
8.4.4 Release from Parallel Running ............................................................................................. 8-30
8.5 Stop Operation .............................................................................................................................. 8-30
9 MAINTENANCE AND INSPECTION ........................................................................................... 9-31
9.1 Periodical Inspection .................................................................................................................... 9-31
9.1.1 Daily inspection .................................................................................................................... 9-32
9.1.2 Daily Inspection (during stop) .............................................................................................. 9-33
9.1.3 Periodical inspection (during stop) ....................................................................................... 9-33
9.1.6 Overhaul Inspection.............................................................................................................. 9-36
9.2 Method of Maintenance and Inspection ....................................................................................... 9-39
9.2.1 Temperature Rise.................................................................................................................. 9-39
9.2.2 Bearing and Lubrication ....................................................................................................... 9-39
9.2.3 Bearing Clearance Limit ....................................................................................................... 9-42
9.2.4 Vibration ............................................................................................................................... 9-42
9.2.5 Maintenance of air filter ....................................................................................................... 9-42
9.2.6 Cleaning and Drying of Coil ................................................................................................ 9-43
9.2.7 Insulation Resistance ............................................................................................................ 9-45
9.2.8 Operation Suspension ........................................................................................................... 9-46
9.2.9 Inspection of Exciter and AVR............................................................................................. 9-46
9.2.10 Inspection of Rotating Rectifier ........................................................................................... 9-47
9.2.11 Maintenance and inspection for normal machine after FWBLAFFS worked. ..................... 9-48
10 Troubleshooting .............................................................................................................................. 10-49
10.1 In case of no voltage build up ................................................................................................. 10-49
10.2 In case of voltage decrease ..................................................................................................... 10-49
10.3 In case of voltage increase ...................................................................................................... 10-49
10.4 In case of voltage instability ................................................................................................... 10-50
10.5 Trouble with Bearing .............................................................................................................. 10-50
11 DISASSEMBLY AND ASSEMBLY ............................................................................................ 11-50
11.1 Precautions on Disassembly and Assembly ........................................................................... 11-50
11.2 Disassembling and assembling procedures ............................................................................ 11-50
11.2.1 Disassembling procedure for model FE ............................................................................. 11-50
11.2.2 Assembling procedure for model FE.................................................................................. 11-52
11.2.3 Disassembling procedure for model FEK .......................................................................... 11-52
11.2.4 Assembling procedure for model FEK ............................................................................... 11-53
11.2.5 How to replace the Rotating Rectifier ................................................................................ 11-53
11.2.6 Installation of Generator..................................................................................................... 11-54
12 Check list ........................................................................................................................................ 12-57
13 PARTS LIST ...................................................................................................................................... 13-58
1 Introduction
TAIYO brushless A.C. generators have been designed so as to fulfil various laws, regulations, and standards
upon the basis of our company's long years of experience in production of marine generators and in careful
consideration of electrical, mechanical and other operational requirements for various marine conditions. Just as
careful considerations and timely medical examinations are necessary to maintain human health, adequate
periodical inspection and maintenance work is indispensable for any generator to display the best performance for
a long time.
Habitual proper handling will keep the generator in optional conditions at all times.
1-1
2 Safety
2.1 Cautions on Safety
2.2 Safety label
2.2.1 Safety label to be attached to the exciter
2.2.2 Safety label to be attached to the generator
2.2.3 Position of Safety Labels
No.1 Warning Static Exciter

Label
Rating name
Plate
No.3 Warning
No.5 Warning
Label
Label
No.4 Warning
Label
Generator
AVR Frame
BOX
No.2 Warning Label
2-2
3 Outline of Product
3.1 Purpose of Use
This product is a generator operated by a prime mover (specified diesel or turbine engine), in which the output
current of a revolving-armature type AC exciter incorporated in the generator excites the field winding of the
generator via a rotating rectifier, and thereby generates 3-phase AC electric power.
This instruction manual relates to the operation only for the specified purpose of use of this product. In the
case to carry out any operation other than - specified in this instruction manual, those operators to do so are
responsible for their results.
Do not carry out any operation or handling that is prohibited in this manual.
3.2 Features of This Machine

• This is a brushless 3-phase AC generator.
• The cooling system of this product is of ’’free circulation type" (IC01).
• The protective system of this product by enclosure is of protected drip-proof type” (IP22), or of a
protective system below it.
• The bearing is of one-end bearing type.
• The bearing is of a sleeve bearing and either self-oil ring type (FE type) or forced lubrication type (FEK
type) is specified.
• The exciter is a compact built-in type arranged within the bearing part of the anti-coupling side.
• The static exciter is normally mounted on generator, and consists of a current transformer, reactor,
Silicone rectifying modules, discharge resistor (surge protective device) and so on. When the static exciter
is not mounted on generator in accordance with specifications, it is integrated into generator panel or
exciting panel.
3.3 Outline of Exciting system

The basic circuit structure of this product is as shown in Figure 3-1.
The output current of a revolving-armature type AC exciter arranged on the rotating shaft of the generator
excites the field winding of the generator via a rotary rectifier.
And the exciting current of AC exciter is taken out as exciting current by static exciter, that is current
transformer (CT) and reactor CRT) so as to obtain compound characteristics from part of generator output, and is
converted into direct current by silicone rectifying modules Si, thereby excites the field winding of AC exciter.
Namely, exciting current to compensate terminal voltage at no load is obtained by RT, while exciting current
for compensation for voltage drops by leakage reactance with the armature reaction caused by load current at load
is obtained by CT. At this time, the output of CT and RT is set to become over compensation in advance as the
control amount to keep constant the terminal voltage of generator, and separation is controlled by automatic voltage
regulator (AVR) to become separation method.
3-3
Rotating Portion Static exciting portion
G AC generator RT Reactor
Si2 Silicone rectifying modules AVR Automatic voltage regulator
F2 Exciter field coil Si1 Rotary rectifier
VR Manual voltage rheostat F1 Generator field coil
EX AC exciter CT Current transformer
RcL2 Discharge resistor CCT Current transformer for cross current
compensation
Figure 3-1: Basic circuit diagram
4 QUALIFICATION OF OPERATOR
• In the case to use this product in vessel, operator should be a qualified marine engineer (engine) or should
be assigned under the responsibility of such engineer.
• In the case to use this product on land, operator should be a qualified electric lead engineer or should be
assigned under the responsibility of such engineer, or should be an expert person.
4-4
5 IDENTIFICATION
Any inquiries should be addressed to:
Quality Control Section, Gifu Factory, Taiyo Electric Co., Ltd.
TEL 058-387-4119
FAX 058-387-1374
Model: FE, FEK
Any inquiry, let us know your model, the number of poles, and serial number.
6 UNLOADING, UNPACKING AND STORAGE

6.1 Unloading
Warning
WHEN TO ENGAGE HOOK TO THE SUSPENDING LUG, MAKE SURE THAT THE HOOK
IS ENGAGED SECURE.
DISCONNECTION OF THE HOOK MAY CAUSE A SERIOUS PERSONAL INJURY OR

DAMAGE.
KEEP A DISTANCE FROM THE MACHINE FOR REAR OF ITS DROPPING DOWN OR
FALLING DOWN.
Warning
WHEN TO LOAD THIS PRODUCT WITH A FORKLIFT, PAY SUFFICIENT ATTENTION TO

THE PRODUCT WEIGHT AND STABILITY OF IT WHILE LIFTED UP.
IF THE ALLOWABLE LOAD OF FORKLIFT IS EXCEEDED, OR THE PRODUCT IS LIFTER

IN UNSTABLE STATUS, THE PRODUCT MAY DROP DOWN, CAUSING A SERIOUS PERSONAL
INJURY OR DAMAGE
1) Engage a crane hook with the suspending lug of this product, and unload it from transportation vehicle.
2) In the case of product packed with wooden frame, unload it from transportation vehicle with a forklift.
6.2 Unpacking
1) Unpack the wooden frame. (This is not necessary in the case without wooden frame.)
2) Loosen the bolt to remove the wooden foot beam.
6.3 Storage
(1) Protect the product from moisture, foreign matter, or damage in the storage from unloading to
unpacking and installation, and from installation to operation.
(2) Protect it with a water-proof sheet cover with appropriate amount of moisture absorbent such as silica
gel.
6-5
(3) In the case of generator with space heater, be sure to use space heater when | e temperature of storage
house is low and humidity is high.
Pay sufficient attention in order to prevent the moisture absorption of coil, rust on iron core or other
metallic parts.
(4) Measure and monitor whether the insulation resistance of coil is within the allowable range or not (See
the section 9.2.7)
(5) In a long storage period from installation to operation, in the case of self-oil ring lubrication type
without lubricant oil in bearing, supply lubricant oil up to the red round mark before storage.
In the case of forced lubrication type, carry out priming periodically.
(6) Rotate the shaft periodically, to make smooth the engaging surface with sleeve bearing.
6-6
7 Installation
7.1 Name of Parts
Figure 7-1: Model FE
No. Name of parts No. Name of parts No. Name of parts No. Name of parts
1 Static exciter 7 Exciter field coil 13 Storage core 19 Cover
2 Bearing shield 8 Exciter frame 14 Rotor core 20 Fan boss
3 Sleeve bearing 9 Exciter rotor 15 Stator coil 21 Shaft
4 Bearing case 10 Rotating rectifier 16 Rotor coil 22 Coupling side
ventilation cover
5 Thermometer 11 Discharge resistor 17 Cover 23 Anti-coupling
side ventilation
cover
6 Exciter armature 12 Stator frame 18 Fan 24 Oil Ring
coil
7-7
Figure 7-2: Model FEK
No. Name of parts No. Name of parts No. Name of parts No. Name of parts
1 Static exciter 7 Exciter field coil 13 Storage core 19 Cover
2 Bearing shield 8 Exciter frame 14 Rotor core 20 Fan boss
3 Sleeve bearing 9 Exciter rotor 15 Stator coil 21 Shaft
4 Bearing case 10 Rotating rectifier 16 Rotor coil 22 Coupling side ventilation cover
5 Thermometer 11 Discharge resistor 17 Cover 23 Anti-coupling side ventilation cover
6 Exciter armature coil 12 Stator frame 18 Fan
7-8
7.2 Description of Parts
As shown in the structure figure (Figure 7-1, Figure 7-2), this product comprises a stator frame, stator core,
stator coil, rotor core, rotor coil, shaft, sleeve bearing, AC exciter, rotating rectifier, and other main components.
As for its cooling, cooling air is induced from the anti-coupling side ventilation cover by a fan arranged at
the coupling side rotor, passes through rotor core, surface of coil end, stator core, and the inside of rotor core,
thereby takes heat generated by them, and goes out from the coupling side ventilation cover.
The AC exciter is built in the anti-coupling side of generator, and equipped with rotating rectifier, and
supplies exciting current to the rotor coil of generator.
7.2.1 Stator Frame

Stator frame is of steel plate welded structure, and has sufficient mechanical strength for purposes of use, and
is manufactured so as to withstand electric shock (by short-circuit current and so on).
The appearance of stator frame is shown in Figure 7-3.
Figure 7-3: Stator Frame
7.2.2 Stator Core

Stator core is provided as follows: silicon steel plate which is good magnetic characteristics and coated with
an insulating varnish for prevention of eddy current is punched, the punched plate elements are piled along the
inside circumference from one side of stator frame, and vent ducts are inserted at specified intervals per layer. The
both ends of iron core is clamped by thick steel plate.
7.2.3 Stator Coil

Stator coil, using class F insulation electric wire, is inserted in the slots insulated by class F insulation material
on the inner circumference of stator core, fixed to stator core by wedge, and is subjected to sufficient varnish
impregnation and drying.
7-9
7.2.4 Rotor Core
Rotor core is also piled core by use of silicon steel plate and is engaged into shaft, and the both ends of piled
core is fastened by rotor clamper.
The cross section of core viewed from the shaft direction is as shown in Figure 7-4.
Figure 7-4: (This figure shewing 8 poles)
In order to cope with parallel operation, the damper bars are arranged also to rotor core.
7.2.5 Rotor Coil

Class F insulation electric wire is used at the field coil. After a salient pole is protected by a class F insulation
material, it is varnish impregnated and dried sufficiently. Straight section of the field coil is secured a non-magnetic
metal fitting.
7.2.6 Shaft
Shaft is designed and manufactured by use of forged steel material, in consideration of strength and
dimensions to torsional vibration through the confirmation on technical particulars with the manufacturer of prime
mover. The appearance of rotor is as shown in Figure 7-5.
Figure 7-5: Appearance of Rotor
7-10
7.2.7 Bearing
CAUTION
PREPARE AND USE THE SPECIFIED GRADE OF LUBRICATING OIL FOR BEARING.
(LUBRICATING OIL IS SPECIFIED IN THE SECTION 9. 2. 2 IN PAGE 9-13,)
CAUTION
LUBRICATING OIL MUST BE SUPPLIED UP TO THE RED CIRCLE MARK OF OIL GAUGE
BEFORE OPERATION BECAUSE OF SLEEVE BEARING OF THIS MACHINE.
ISO VG-46 IS RECOMMENDED AS LUBRICATING OIL.
(OIL SUPPLY HOLE IS MARKED BY YELLOW.)
NOTE: The above is for the case of self-oil ring lubrication method (FE model).
CAUTION
KEEP THE BEARING OIL SUPPLY PRESSURE OF THIS MACHINE 1.5kg/cn* 1 2 TO 2.

5kg/cm2. PRESSURE BELOW 1. 5kg/cm2 MAY CAUSE BURNING AT BEARING METAL,
AND PRESSURE OVER 2. 5kg/cn2 MAY INCREASE OIL AMOUNT AND CAUSE OIL
LEAKAGE
NOTE: The above is the case for forced lubrication method (FEK model).
The bearing is sleeve bearing, separated into upper and lower portions, and is supported by bearing shield
and bearing case.
Its sliding surface to shaft is made of white metal.
There are 2 lubrication methods of bearing oil as follows:
(1) Self oil ring lubrication method (FE model)
(2) Forced lubrication method (FEK model)
The structure of bearing is shown in Figure 7-6 to Figure 7-9.
7-11
Figure 7-6: Bearing Construction, Employing Oil Ring Lubrication (541, 547 type)
Figure 7-7: Bearing Construction, Employing Oil Ring Lubrication (553 type)
7-12
Figure 7-8: Bearing Employing Forced Lubrication (Left: Lower portion Right: Upper portion
Figure 7-9: Bearing Employing Oil Ring Lubrication (Left: Lower portion Right: Upper portion)
7.2.8 Fan
Fan is of mild steel welded structure. It is fixed to fan boss engaged into the shaft of the coupling side by
bolt. This fan induces cooling air from the ventilation coyer at the anti-coupling side, and takes heat generated at
the anti-coupling side coil end, rotor core, rotor coil, stator core, stator coil, and the coupling side coil end. And
exhaust cooling air from the coupling side ventilation cover.
7.2.9 Ventilation cover

Ventilation cover is made of punched and embossed mild steel plate, and is attached so that each punched
and embossed dimension does not exceed diameter 12mm against intrusion of solid foreign matter and protection
of human body, and harmful influence by water drops falling in the direction within 15 - degrees from a plumb line
is avoided.
7.2.10 AC Exciter
Exciter is of rotating armature type, and is built in the anti-coupling side of generator, and comprises exciter
frame, field core, field coil, armature core, armature coil and other main components.
7-13
7.2.10.1 Field core
Field core is also piled core by use of silicon steel plate and fixed to the exciter frame by bolts. In field core,
slots for field coil configure slot groups corresponding to the number of poles.
To assure good build-up of voltage, a permanent magnet that has sufficient letentivity is built in. If the field
lead wires (J, K) are disconnected, pay attention to the polarity when re-connecting them.
7.2.10.2 Field Coil
Class F insulation electric wire is used at the field coil.
After it is wound around the bobbin, it is inserted into a slot distributed in inner periphery of the field core
through a class F insulation material, secured to the field core by means of a wedge, and is varnish impregnated and
dried sufficiently.
7.2.10.3 Armature Core
Armature core (at rotor side) is provided as follows. Silicon steel plate of high quality which is coated with
an insulating varnish for prevention of eddy current is punched, and the punched plate elements are piled on the
shaft and fastened by end plate.
7.2.10.4 Armature Coil
Armature coil, using class F insulation electric wire, is inserted in slot insulated by insulation material of the
employed class, fixed to armature core by wedge, and is subjected to sufficient varnish impregnation and drying.
Its coil end is fixed by special tape.
7.2.11 Rotating Rectifier

Rotating rectifier is arranged on the co-axis of generator, and fixed to rotating rectifier boss.
This rotating rectifier boss is equipped with silicon rectifying modules of each phase, thereby, 3 phase full
waves rectifies the AC output of exciter and supplies DC exciting current to generator rotor coil.
7.2.12 Connection Diagram

The basic circuit composition is shown in Figure 7-10.
7-14
Symbol Name of parts Symbol Name of parts
G A. C generator RT Reactor
Ex A. C. exciter CCT Current transformer for cross-
current compensation
F1,2 Field coil AVR Automatic voltage regulator ij
Si1,2 Silicon rectifying modules VR Manual voltage rheostat
RC1,2 Discharge resistor
CT Current transformer
Figure 7-10: Connection diagram
7.2.13 Exciting System

Its exciting system is as mentioned in the section 3.3 “Outline of Exciting system” in Page 3-3.
The structure and functions of static exciter are described as below.
7-15
No. Name of p a r t No. Name of part
24 Current transformer 30 Cable glands
25 Side cover 31 Discharge resistor
26 Main terminal 32 Aux. terminal
27 Drip proof cover 33 Cable supporter
28 Silicon rectifier modules 34 Exciting system frame
29 Reactor
Figure 7-11: Exciting unit mounted on generator top
7-16
7.2.13.1 Automatic Voltage Regulator (AVR)
CAUTION
DO NOT MEGGER AND HIGH POTENTIAL TEST!
SUCH TEST WILL DESTROY THE SEMICONDUCTORS IN BOX.
AVR is integrated into panel.

1) Compensation of AVR
The A V R is consisted of detection transformer, voltage detection circuit, microprocessor(MPU),
power circuit, display circuit, pulse amplification circuit, magnetic-field current control circuit, A/D for
voltage setting circuit, photo-couplers and the like.
Figure 7-12 is a block diagram showing circuit composition and signal flow.
Figure 7-12: Block Diagram
2) Magnetic field current control circuit

Figure 7-13 shows magnetic field current control circuit. (Thyristor half-wave shunt circuit)
AVR terminals A and B are connected to ac side of the rectifier provided in the exciter.
AC current supplied by reactor and current transformer provided in the exciter is rectified to
become magnetic field current.
This current is shunted in part by means of phase control of the Thyristor provided in the AVR
while magnetic field current is regulated.
7-17
Figure 7-13: Thyristor half-wave shunt circuit
3) Control circuit
(1) Voltage detection circuit
Generator voltage is reduced by the detection transformer, passed through the voltage detection
circuit and RMS detected by MPU. At the same time, a synchronized signal is supplied from this
transformer to MPU and the power is supplied to the power circuit.
(2) DROOP
The current supplied by current transformer CCT provided in the power distribution board is
supplied to terminals K and L, insulated by current transformer DCT provided in the voltage
detection circuit, converted into 1/1000 and then converted to a voltage signal.
This signal is proportional to the load current from vector viewpoint.
This signal and generator detection voltage are vector composed in the detection circuit in
order to provide appropriate droop characteristics to the generator voltage characteristics.
(3) Micro-processor (MPU)
MPD executes RMS calculation of the generator voltage, PID calculation of the reference value
and deviation signal, calculation of timing of signal transmitted to thyristor, alteration and storage of
PID constants, control of display circuit and the like.
Alteration of PID constants are possible even during operation.
(4) Pulse amplification circuit
In the pulse amplification circuit, a fine pulse signal from MPU is passed through the photo-
coupler and is insulated, and a pulse is given to the thyristor through the amplification circuit.
(5) Power circuit
The power circuit supplies 5 V power to MPU, pulse amplification circuit and Display circuit.
(6) Voltage setting circuit
Two circuits are available for voltage setting. One is to use external variable resistor and the
other is to use increase/decrease contact signals. An analogue voltage setting signal from the variable
resistor is converted into a digital signal by A/D converter and is input to MPU.
Further, a signal from the contact signal is capable of transmitting an increase/a decrease signal
to MPU via photo-coupler. Thus voltage setting can be changed freely.
These signals are set referring to the voltmeter while the generator is being operated.
(7) Display circuit
The display circuit consists of four switches (Enter, Shift, Up and Down push buttons) and
numeric display. It is possible to input various constants using these four switches.
7-18
Figure 7-14
7.2.13.2 Manual Voltage Rheostat (VR)

Manual voltage rheostat is integrated into panel.
Manual voltage rheostat is variable resistor to adjust terminal voltage manually to rated voltage from outside.
7.2.13.3 Reactor (RT)
Reactor is integrated into static exciter.
The appearance of reactor is as shown in Figure 7-15, and a set of coil is wound around the iron core. The
iron core has clearance where magnetic insulating material is inserted.
The role of the reactor in the exciting system is to supply the exciting current necessary to keep the rated
voltage at no load of generator from the output of generator via reactor and silicon rectifying modules to the rotor
coil of generator.
7-19
Figure 7-15: Reactor
7.2.13.4 Current Transformer (CT)

Current transformer is integrated into static exciter.
The appearance of current transformer is as shown in Figure 7-16, and secondary coil is wound around the
iron core.
The role of the current transformer in the exciting system is to supply the exciting current necessary to
compensate for leakage reactance generated by load current and voltage down by armature reaction from secondary
coil via silicon rectifying modules to the rotor coil of generator.
Figure 7-16: Current Transformer
7.2.13.5 Silicon rectifying modules (Si)

Silicon rectifying modules is integrated into static exciter.
The appearance of silicon rectifying modules (Si) is as shown in Figure 7-17(a), and its rectifying device
conducts current in one direction, and does not conduct current in the opposite direction.
Silicon rectifying modules will be damaged by the application of an over-voltage which exceeds the peak
reverse voltage, therefore, it is necessary to arrange a protective device against over-voltage (surge voltage) in the
case to use silicon rectifying modules.
7-20
Figure 7-17: Silicon Rectifying modules
7.2.13.6 Discharge resistor (protective device)

Discharge resistor is integrated into static exciter.
The appearance of Discharge resistor (Rc) is as shown in Figure 7-18(a),
Figure 7-18: Discharge resistor (protective device)
When an overload is applied to the silicon rectifying modules, the discharge Resistor reduces overload by
applying current proportional to the voltage to protect the silicon rectifying modules.
7.2.13.7 Current Transformer for Cross-Current Compensation (CCT)
The current transformer for cross-current compensation is integrated into panel.
The current transformer for cross-current compensation is double molding type metering current transformer.
It is used detecting load current at parallel running.
7-21
7.3 Installation
Warning
WHEN TO THIS PRODUCT, ENGAGE THE CRANE HOOK (OR WIRE ROPE) TO THE
SUSPENDING LUG SECURE.
DISCONNECTION OF THE HOOK MAY CAUSE A SERIOUS PERSONAL INJURY OR

DAMAGE.
KEEP A DISTANCE FROM THE MACHINE FOR REAR OF ITS DROPPING DOWN OR
FALLING DOWN.
Warning
DO NOT USE THE MACHINE IN EXPLOSIVE ATMOSPHERE. OTHERWISE, PERSONAL

INJURY OR FIRE MAY RESULT.
CAUTION
AVOID THE USE OF THIS PRODUCT UNDER THE AMBIENT ENVIRONMENTAL

CONDITIONS OTHER THAN SPECIFIED. OTHERWISE, ELECTRIC CHOCK. PERSONAL
INJURY OR DAMAGE MAY RESULT.
THE AMBIENT ENVIRONMENTAL CONDITIONS ARE SPECIFIED BY RESPECTIVE SHIP

CLASSIFICATION SOCIETIES AND THEIR SPECIFICATIONS.
CAUTION
DO NOT RIDE ON OR HUNG FROM THE PRODUCT. OTHERWISE, PERSONAL INJURY

MAY RESULT.
CAUTION
DO NOT PLACE ANYTHING THAT MAY PRIVENT VENTILATION AROUND THE

PRODUCT. OTHERWISE, PERSONAL INJURY, FIRE, OR DAMAGE MAY RESULT.
CAUTION
AS FOR WORK (ADJUSTMENT) OF DRIVING APPARATUS RELATING TO

INSTALLATION AND DIRECT COUPLING REFER TO THE OPERATION MANUAL FOR PRIME
MOVER.
7-22
7.3.1 Installation Procedures
(1) Before installation, check parts for defect.
In the event of any defect, contact us or our agent.
(2) Check parts for lacking.
In the event of any lacking, contact us or our agent.
(3) Rust prevent coating is painted on the direct coupling side shaft end portion (shaft flange
portion) at delivery from factory, so wipe it away carefully with thinner before installation.
CAUTION
IN MEASURING INSULATION RESISTANCE, DO NOT CONTACT THE TERMINAL.

OTHERWISE, ELECTRIC SHOCK MAY RESULT.
4) Measure and confirm whether insulation resistance is over requirement. (Refer to the section 9.2.7)
5) Dimensions necessary for installation are specified in the drawing of outline submitted and discussed
previously, so confirm them.
CAUTION
KEEP A SAFE MAINTENANCE SPACE. OTHERWISE, ELECTRIC SHOCK OR PERSONAL

INJURY MAY RESULT. 6 7
(6) Use the specified suspending lug to move the machine to the installation place with care.
(7) Fasten the mounting bolt of the foot to install the machine temporarily.
(8) Adjust the generator by liner etc. so that flange side of the generator and the flywheel side of the engine
may became the horizontal.
(Do size A of Figure 7-19 as paving at the places, up, down, left and right.)
Figure 7-19
7-23
(9) Insert the flange into faucet of the flywheel and fasten the coupling bolt (reamer bolt) lightly.
(10) Adjust the shaft center height by liner or the like in reference with the driving apparatus.
(11) Remove the transport instruments and engage the rotor and the magnetic center in the shaft direction of
the stator by use of the magnetic center gauge (accessory). (Refer to Figure 7-20.)
Figure 7-20
(12) Confirm whether the gaps even between cover 19 and Fan boss 20 by Clearance gauge if not even, adjusts
from clause (8) again.
(13) Fasten the foot fastening bolt and the coupling bolt of this machine.
(14) Hit the knock pin into foot.
(15) In the case of bearing of self-oil ring method (FE model), supply the specified lubricant oil up to the red
round mark of the oil gauge (.Figure 9-1).
(16) In the case of forced lubrication method (FEK model), arrange pipe for supply and drain of oil via
packing. Arrange the pipe lower than the position of bearing oil drain hole.
(17) Keep the transportation instruments because it is necessary for disassembly.
WARNING
IN T H E CASE OF A MACHINE FOE USE ON LAND, AND EARTH TERMINAL

EQUIPPED T Y P E F O R USE ON VESSEL, CARRY OUT EARTH TERMINAL ARRANGEMENT
SECURE. OTHERWISE, ELECTRIC SHOCK MAY RESULT.
CAUTION
CHECK THE PHASE ROTATION FOR CORRECT/ ROTATION. SOME KINDS OF LOADS
M A Y CAUSE PERSONAL INJURY AND DAMAGE ON DEVICE.
CAUTION
CHECK THE CONNECTION AND ACTION OF THE PROTECTIVE DEVICE. OTHERWISE,

PERSONAL INJURY OR FIRE M AY RESULT.
7-24
CAUTION
CHECK THE WIRING FOR MISWIRING WITH REFERENCE TO THE CONNECTION

DIAGRAM. OTHERWISE ELECTRIC SHOCK OR FIRE MAY RESULT.
(18) Carry out electric wiring in accordance with the connection diagram submitted and discussed
previously.
(19) Fix the main cable U and V phases with cable supporter. ( Refer to Figure 7-11)
(20) Insert the cable into the cable ground and fasten it.
(21) Seal up clearance between the cable and cable gland with compound.
(22) Arrange the cable outside of exciter with slackness.
By the way, fasten the fastening bolts and nuts with the torque specified in Table 7-1. Unless
otherwise specified.
Table 7-1: Fastening torque of bolt and nut
2-side width Fastening torque Screw 2-side width Fastening torque

Screw size
(mm) (kg-m) size (mm) (kg-m)
M5 - 0.28 ~ 0.30 M 20 30 19.0 ~ 23.0
M6 - 0.48 ~ 0.50 M 24 36 33.0 ~ 39.0
M8 13 1.1 ~ 1.3 M 30 46 60.0 ~ 72.0
M 10 17 2.2 ~ 2.6 M 36 55 95.0 ~ 115
M 12 19 3.8 ~ 4.6
M 16 24 9.5 ~ 11.5
8 OPERATION
8.1 Inspection before Operation
WARNING
KEEP THE PRODUCT AWAY FROM OPEN FIRE. OTHERWISE, PERSONAL INJURY OR
FIRE MAY RESULT.
BY THE WAY, MAKE'SURE THE INSTALLATION PLACE OF A FIRE EXTINGUIHER

BEFORE OPERATION.
8-25
8.1.1 Installation Condition
(1) Make sure that the coupling is made at the proper position.
(2) Make sure that fastening bolts are sufficiently tightened
8.1.2 Terminal section (including exciter)

(1) Check lead wire cover for scratch or crack. In the event of any, contact us or our agent.
(2) Make sure that termination is arranged properly.
(3) Make sure there is no mistake in terminal mark, phase, and wiring.
(4) Check for the loose bolts and nuts at terminal.
8.1.3 Insulation Resistance

CAUTION
MAKE SURE THAT THE NECESSARY INSULATION RESISTANCE IS OBTAINED.

OTHERWISE CURRENT LEAKAGE OR PERSONAL INJURY MAY RESULT.
CAUTION
IN MEASURING INSULATION RESISTSNCE DO NOT CONTACT THE TERMINAL.

OTHERWISE ELECTRIC SHOCK MAY RESET.
CAUTION
IN THE CASE OF INSEATION RESISTANCE MEASUREMENT, REMOVE TERMINAL OR

SHORT-CIRCUIT IT BEFORE MEASUREMENT, SO AS TO AVOID MEGGER VOLTAGE ON
AVR.
(1) Measure the insulation resistance between each coil of generator and ground by use of a 500V megger,
and make sure that it is over 1MΩ as standard.
8.1.4 Bearing section

(1) In the case of self-oil ring lubrication method, make sure that lubricant oil is supplied up to the red round
mark of oil gauge (Figure 9-1).
8.2 Operation Procedures

As for operation procedures, refer to the operation manuals for driving apparatus and panel.
As for a new generator, carry out no-load operation or slow-speed operation.
8-26
8.3 During Operation
WARNING
KEEP THE PRODUCT AWAY FROM OPEN FIRE. OTHERWISE, PERSONAL INJURY OR
FIRE MAY RESULT.
BY THE WAY, MAKE'SURE THE INSTALLATION PLACE OF A FIRE EXTINGUIHER

BEFORE OPERATION.
WARNING
DURING THE ROTATION OF THE PRODUCT, NEVER TOUCH THE ROTATING

PORTION. THERE IS A FEAR OF PERSONAL INJURY, THEREFORE ARRANGE A SAFETY
GUARD OVER EXPOSED ROTATING PORTION.
CAUTION
• WHEN TO COME NEAR THE PRODUCT OR INSPECT IT, AVOID WEARING CLOTH
THAT MAY TOUCH OR BE CAUGHT IN ITS ROTATING PORTION OR HOT
LINE PORTION. OTHERWISE ELECTRIC SHOCK OR PERSONAL INJURY MAY RESULT.
• BE SURE TO WEAR PROTECTIVE CLOTH SUCH AS A HELMET, SAFETY SHOES,
GLOVES IN NECESSARY WORK
CAUTION
AVOID THE USE OF THIS PRODUCT UNDER LOAD OTHER THAN RATED.
OTHERWISE, PERSONAL INJURY, FIRE, OR DAMAGE MAY RESULT.
(LOADS REQUIRING ATTENTION: THYRISTER LOAD, SINGLE PHASE LOAD,
OVERLOAD, SPECIAL PROPERTY LOAD, ETC,)
CAUTION
BECAUSE THE STATOR FRAME GETS VERY HOT DURING OPERATION, DO NOT
TOUCH IT. OTHERWISE, A BURN MAY RESULT.
As for trial operation or operation after a long suspension, check the following:
8.3.1 Monitoring of the Generator

(1) In the case of self-oil ring lubrication method, make sure that oil ring moves smoothly.
(2) In the case of forced lubrication method, make sure that bearing oil pressure is kept at the
specified value (normally, 1.5kg / cm2 to 2.5 kg / cm2
(3) Check the rotor, stator, bearing for abnormal noise.
8-27
(4) Check each component for abnormal vibration. (Refer to the section 9.2.4) In the event of
abnormal vibration, check the installation condition once again. (Refer to the section 7.3.1)
(5) Make sure that there is not rapid temperature rise in each component
(6) Make sure that the temperature of each component does not exceed the allowable value.
(Refer to the section 9.2.1 and the test record.)
(7) Check the bearing for oil leakage.
8.3.2 Monitoring of the Panel

CAUTION
EACH INDICATOR ON TOE PANEL SHOULD NOT SHOW VALUE SPECIFIED ON THE
RATING PLATE (ESPECIALLY, OUTPUT, VOLTAGE CURRENT VALUE)
(I) A new generator has been adjusted in consideration of power-factor change, rotation speed change,
load fluctuation and so on at factory test, but in actual operation, adjust the manual voltage rheostat
(VR) to rated voltage under no load condition.
8.4 Parallel Running

CAUTION
IN THE CASE OF PARALLEL RUNNING OF GENERATOR, PAY THE FOLLOWING

ATTENTION. ERRONEOUS HANDLING MAY CAUSE A GENERATOR FAILURE
8.4.1 Requirements for Parallel Running

(1) There are the following requirements for the parallel running of a generator with another already in
operation:
a. To be identical in frequency.
b. To be equal in voltage magnitude.
c. To be matched in phase.
(2) Requirements for prime movers
a. Uniform angular velocities
b. Appropriate speed regulation
(3) Phenomena when requirements are not met
a. In case there is no matching in phase, much cross current will flow, and closing for parallel
running will be impossible.
b. Any difference in voltage magnitude will cause a flow of cross current between the generators,
so that the generators with higher and lower voltages will have lagging and leading currents
respectively, and thus reactive power sharing will be impossible.
c. If the load characteristic of generator does not include a drooping characteristic with respect to
reactive power, stable sharing of reactive power is impossible, and this may give rise to hunting
or step-out.
d. In case the angular speed is not uniform, load sharing cannot be performed. The prime mover is
provided with an adequately sized flywheel for angular velocity uniformity.
e. Without governor characteristics, load sharing is not stable.
f. If the governor speed characteristics, do not include stability or quick response, just as in the case
of (5) load sharing is unstable, or hunting or step-out may result.
8-28
8.4.2 Synchronizing
(1) Carry out governor adjustment on the prime mover side until the frequency of the generator (follow-
up generator) to be connected in parallel with the forerunning generator is approached.
(2) While watching the synchronizing lamps or synchroscope, finely adjust the governor, and close the
circuit breaker at the point of synchronism.
Remarks:
a. As to the synchronizing lamps, the time when one of the three lumps has gone off and the two
others have become brightest is the phase coincidence point.
b. As to the synchroscope, the time when the needle has come to the top center is the phase
coincidence point.
c. It is a proper method to start the closing operation with the closing time of the circuit breaker taken
into account, and to close the circuit breaker just at the point of synchronism (when the needle of
the synchroscope has come to the top center).
8.4.3 Load Sharing

(1) It is desirable to carry out the governor adjustment of the follow-up generator and that of the
forerunning generator at same time.
(2) After synchronizing, pay attention to frequency, and operate the governor of the forerunning
generator in the speed lowering direction.
(3) Operate the governor of the follow-up generator in the speed raising direction, shift load gradually to
carry out load sharing.
8.4.4 Release from Parallel Running

When to stop one generator (hereinafter referred to as the generator to be released) of generators in parallel
operation, proceed the following:
(1) Make sure that the electric power use is few with a wattmeter, and power supply can be made by the
remaining generator, and there is not rapid power increase.
(2) Operate the governor of the generator to be released in the speed lowering direction.
(3) When the load of the generator to be released becomes 0 to 5% of the rated power, make the breaker
of the generator to be released trip.
8.5 Stop Operation

As to how to stop operation, refer to the operation manual for the driving apparatus and panel and the like.
8-29
9 MAINTENANCE AND INSPECTION
WARNING
DURING THE ROTATION OF THE PRODUCT, NEVER TOUCH THE ROTATING

PORTION. THERE IS A FEAR OF PERSONAL INJURY, THEREFORE ARRANGE A SAFETY
GUARD OVER EXPOSED ROTATING PORTION.
WARNING
When TO COME NEAR THE PRODUCT OR INSPECT IT. AVOID WEARING CLOTH
THAT MAY TOUCH OR BE CAUGHT IN ITS ROTATING OR HOT LINE PORTION. OTHERWISE,
ELECTRIC SHOCK OR PERSONAL INJURY MAY RESULT.
BE SURE TO WEAR PROTECTIVE CLOTH SUCH AS A HELMET, SAFETY SHOES,

GLOVES IN NECESSARY WORK
WARNING
DO NOT WORK IN HOT LINE CONDITION. BE SURE TO TURN THE MACHINE OFF
BEFORE WORKING. OTHERWISE ELECTRIC SHOCK MAY RESULT.
WARNING
IN INSPECTION, BE SURE TO CHECK EACH PHASE TERMINAL FOR LOOSENESS OR

DISCONNECTION. OTHERWISE PERSONAL INJURY OR FIRE MAY RESULT.
CAUTION
DO NOT MODIFY THE MACHINE AT YOUR OWN CIRCUMSTANCE.
In the event of inspection or repair other than specified in this operation manual contact us at the address
listed in the section 5 “IDENTIFICATION".
9.1 Periodical Inspection

For complete performance and safety maintenance, it is important to inspect the machine with proper
knowledge about it.
Section 9.1.1 to 9.1.6 describe daily inspection, periodical inspection, overhaul inspection, and as for the
details of inspections, refer to the section 9.2.
As for disassembly and assembly, refer to the section 11.
9-30
9.1.1 Daily inspection
Inspection
Inspection item Inspection method Judgment criteria Improvement measures
cycle
Voltage current Within the rated values Adjust values within the rated values
Output Panel instrument
power specified in name plate specified in name plate.
Adjust the value to the normal one.
Stator (coil. Below average value (Refer
Thermometer If with error, stop the machine, and remove
Iron core) to the section 9.2.1)
Temperature
the possible cause.

Adjust the value to the specified one.
Ambient Below specified value
Thermometer If the allowable value is exceeded, stop the
temperature (Refer to the section 9.2.1)
machine, and remove the possible cause.
Bearing and Thermometer Within the rated values
Operation Adjust the value to the normal one
stator frame measured by touching specified in name plate
Vibration meter, Without abnormal vibration Adjust in periodical inspection.
Vibration measurement by or increase of vibration (Refer If the allowable value is exceeded, stop the
touching to the section 9.2.4) machine, and remove the possible cause.
Inspect in overhaul. If too excessive for
Abnormal noise, Hearing, stethoscope, Without abnormal noise,
operation, stop the machine, and remove
abnormal smell smelling abnormal smell
the possible cause.
Appearance, Every day
Stator Visual inspection Without abnormality Clean if dirty too mach.
contamination
Within allowable values of
Bearing Oil Level Oil gauge gauge (Refer to the Remove the possible cause and recover.
section 9.2.2)
Within the specified oil
Oil amount, oil Oil sight (visual
pressure (Refer to the Adjust within specified oil pressure and
pressure (FEK inspection) Pressure
section 9.2.2) make it flow normally.
type) gauge
Normal flow
Clean, remove the possible cause and
Oil leakage Visual inspection Without oil leakage
recover to normal condition.
Oil ring (FE type) Visual inspection Normal rotation Adjust it so as for it to rotate normally.
Hearing, stethoscope, Without abnormal noise or
Bearing noise Remove the possible cause and recover.
smelling increase of noise level
Ventilation Ventilation hole Visual inspection Without obstacle Remove obstacle.
Exhaust should not go into
Exhaust path Visual inspection Change exhaust path.
suction path
9-31
9.1.2 Daily Inspection (during stop)
Inspection
cycle
Appearance,
Appearance
Visual Inspection Without abnormality Clean if dirty too mach.
contamination
Stator
Fasten Knocking sound Without looseness Fasten again.
Every
Clean, remove the possible cause and
Oil leakage Visual inspection Week Without oil leakage
recover to normal condition.
Bearing Within allowable values of gauge
Refill up to the normal level of oil
Lubrication Oil Pressure gauge (Refer to the section 9.2.2) Normal
gauge.
flow
Air filter Dirt Visual inspection Clogging Clean.
9.1.3 Periodical inspection (during stop)

Inspection
cycle
Lead wire Visual Inspection Without abnormality Clean if dirty too mach.
Over 1 MΩ (Refer to the

Coil
Stator Clean and dry the stator 1 coil. If

Insulation 500V Insulation section 9.2.7)
Every recovery is impossible, carry out
resistance resistance meter Within 2 digits from the measured
months overhaul.
value in the previous time
Without oil leakage leading to oil
Bearing Oil leakage Visual inspection Correct manually.
dropping and oil pool
Terminal
Fasten Visual inspection Without looseness Fasten again.
Portion
9-32
Inspection
cycle
Without foreign matter,
Oil quality (FE discoloration, or deterioration (Refer
Bearing Visual inspection Exchange with specified type.
TYPE) to
the section 9.2.2
Electric Visual inspection, Every 6
Insulation Without damage, discoloration, crack Correct manually.
wiring touching months
Terminal fastening
Visual inspection Without looseness Fastening again.
portion
Exciter
Silicon rectifying Within resistance of Specified range
Tester Exchange silicon rectifying modules.
modules (Refer to the section 9.2.9)

Inspection Inspection
Inspection item Judgment criteria Improvement measures
method cycle
Rotary Without deformation or Exchange silicon rectifying
Rotary rectifying element Visual inspection
rectifier Abnormality. modules.
Without damage, discoloration,
Lead wire Visual inspection Correct manually.
crack
Every year
Visual inspection, Appropriate to grounding j with
Grounding with panel Correct manually.
touching panel
AVR
Without discoloration by
Internal parts Visual inspection Exchange AVR.
overheat
Fan Appearance Visual inspection Without crack, damage Correct manually.
Fastening bolt Visual inspection Without looseness Fasten again.
500V insulation
Space heater Over 0.5 MΩ Correct manually.
resistance meter
500V insulation
Temperature measuring Over 0.5 MΩ
resistance meter Correct manually. Exchange.
Others element
Tester Without discoloration
Appearance Visual inspection Without crack, damage
Taco-
Without damage, discoloration, Correct manually. Exchange.
generator Lead wire Visual inspection
crack
9-33
9-34
9.1.6 Overhaul Inspection
Inspection
cycle
Visual inspection,
Coil Without discoloration, dirt, scratch Clean, varnish, correct manually.
touching
Visual inspection, Without dropping, displacement,
Wedge Repair, exchange.
knocking sound slackness
Visual inspection,
Thread combing Without slackness or displacement Combine again.
touching
Coil Visual inspection,
Coil supporter Without slackness or displacement Repair.
touching
Visual inspection,
Lead wire Without scratch, discoloration, or crack Repair.
touching
Stator
Over 1 MΩ (Refer to the section 9.2.7) Clean and dry the stator] coil.
Insulation 500V insulation
Within 2 digits from the measured If recovery is impossible, apply
resistance resistance meter
Every 4 years or 2400 hours

value in the previous time varnish or exchange coil.
Iron core Visual inspection Without rust or discoloration Repair.
Duct interval Visual inspection, Without slackness, rust or
Repair.
piece knocking sound displacement
Iron
Fastening Visual inspection,
core Without slackness Fasten again.
portion knocking sound
Duct clogging,
Visual inspection Without clogging or dirt Cleaning.
dirt
Visual inspection,
Coil Without discoloration, dirt, scratch Clean, varnish, correct manually.
touching
Visual inspection,
Coil supporter Without slackness or displacement Repair.
touching
Coil Visual inspection,
Lead wire Without scratch, discoloration, or crack Repair.
touching
Rotor
Over 1MΩ (Refer to the section 9.2.7) Clean and dry the stator] coil.
Within 2 digits from the measured If recovery is impossible, apply
value in the previous time varnish or exchange coil.
Iron core Visual inspection Without rust or discoloration Repair.
Iron
Duct interval Visual inspection, Without slackness, rust or
core Repair.
piece knocking sound displacement
9-35
method cycle
Fastening Visual inspection,
Without slackness Fasten again.
portion knocking sound
Duct
clogging, Visual inspection Without clogging or dirt Cleaning.
Rotor Iron core dirt
Brake coil
bar
Visual inspection Without crack Fasten again.
connection
portion
Within standard value (Refer to
Micrometer
Bearing clearance the section Exchange metal.
clearance gauge
9.2.3)
Without uneven attachment,
Visual inspection, engagement, separation on
Bearing metal Repair. Exchange metal.
color check upper half portion and thrust
portion
Visual inspection, Every 4 years
Oil ring dimensional or 2400 hours Without deformation Repair, exchange.
measurement
Bearing
Without foreign matter,
discoloration, contamination, or
Oil quality Visual inspection Exchange with specified type.
deterioration (Refer to
section 9.2.2)
Without oil leakage leading to oil
Oil leakage Visual inspection Repair or Exchange.
dropping and oil pool
Visual inspection Within 0.2 to 0.4mm of
Oil cutting Repair or Exchange.
clearance gauge clearance in diameter to shaft
Pipe of lubrication and
Visual inspection Without abnormality Repair.
drain
Silicon
Normal direction: bellow 10Ω
rectifying Analog tester Exchange silicon rectifying modules
Exciting Exciting Reverse direction: Over 100KΩ
modules
circuit system
Without scratch, discoloration,
Reactor Visual inspection Repair, exchange.
disconnection
9-36
method cycle
Current Without scratch, discoloration,
Visual inspection Repair, exchange.
transformer disconnection
Exciting Other Without scratch, discoloration,
system component disconnection
Electric Without scratch, discoloration,
wiring disconnection
Exciting
Silicon
circuit Every 4 years Normal direction: bellow 10Ω
rectifying Analog tester Exchange silicon rectifying modules
Rotary or 2400 hours Reverse direction: Over 100KΩ
modules
rectifier
Over 0.5MΩ Clean, repair.
In accordance
Exciter In accordance with generator In accordance with generator
with generator
Direct Direct coupling with Confirm whether the air gaps is
Clearance gauge Adjust, direct coupling again.
coupling driving apparatus even. (Refer to the section 7.3.1)
9-37
9.2 Method of Maintenance and Inspection
Carry out the maintenance and inspection of each part in proper procedures.
9.2.1 Temperature Rise

To monitor the temperature of the device is an effective manner to judge the presence of
nonconforming portion in it. In reference to the Table 9-1, inspect temperature rise of each portion.
Table 9-1Allowable temperature rise in each portion (ambient temperature 50⁰C)
Allowable temperature rise

Portion of device Measurement method
class B class F
Armature coil (generator stator By thermometer 60 75
coil) By resistance 70 90
Field coil of Salient pole rotor By resistance 70 90
Portion adjacent to insulated coil
in iron core and other By thermometer 70 90
components
When measured by temperature detector element embedded in
Bearing
metal 35
Remarks:
1. The standard ambient temperature of air is 45*C or 4(TC, the difference 1 between the standard
temperature and these temperatures is added to each temperature rise limit.
2. In the case of NY in ship classification, when the standard ambient temperature is 45 *C, the
temperature rise limit of the above table is applied.
9.2.2 Bearing and Lubrication

Bearing is especially important in the mechanical functions of generator, carry out careful
maintenance and inspection.
9.2.2.1 Sleeve Bearing
(1) Self-oil ring lubrication method (FE
type)
a. Main causes of bearing burning
• Shortage of oil amount
• Incomplete rotation of oil ring
• Failure in direct coupling
• Excessive vibration
• Defective oil including dust or
dirt
b. Lubricating oil amount
Figure 9-1
CAUTION
FILL OIL UP TO THE RED ROUND MARK OF THE OIL LEVEL SO THAT OIL RING
BRINGS SUFFICIENT AMOUNT OF LUBRICATING OIL ONTO THE SHAFT.
9-38
The upper and lower limits of the oil level are 5mm upper or lower from the red round mark
respectively. (Figure 9-1) Keep the bearing clean, and inspect the lubrication condition (oil level)
periodically every day.
c. In the case of excessive lubricating oil. It may leak out along the shaft, While, in the case of
shortage of lubricating oil, the bearing may burn.
d. In the inspection on the bearing, check the oil ring for deformation or abrasion.
e. Inspect the bearing periodically every day, and pay attention to rapid increase in temperature.
The maximum temperature of the bearing is 80 to 85CC by thermometer in normal operation.
f. Overheat of bearing.
CAUTION
IN CASE OF BEARING OVERHEAT. WAIT FOR IT TO COOL DOWN BEFORE

INSPECTION OR EXCHANGE WORK. OTHERWISE A BURN MAY RESULT.
CAUTION
IN CASE OF BEARING OVERHEAT, DO NOT STOP THE ROTATION ABRUPTLY.

OTHERWISE, THE SHAFT IS SEIZED WITH THE BEARING.
• In case of bearing overheat, continue the rotation.

• Supply oil between the bearing and the shaft.
• Decrease the rotation gradually.
• Wait for it to cool down before stopping the rotation.
g. In the case of bearing burning or wear, exchange it with new one.
(2) Forced Lubrication Method (FEK type)
a. Main causes of bearing burning:
• Pressure below specification
• Failure in direct coupling
• Excessive vibration
• Defective oil including dust or dirt
• Clogging of lubrication pipe
b. Lubricating oil pressure
CAUTION
SET THE LUBRICATING OIL PRESSURE IN THE RANGE 1. 5 k g /cm TO 2.5kg/cm

DURING OPERATION.
Continuing operation with decreased lubricating oil pressure may cause overheat or burning of
the bearing.
Look into the oil sight to confirm the flow of lubricating oil.
Keep the bearing clean, and inspect the lubrication condition, (oil level) periodically every day.
c. Inspect the bearing periodically every day, and pay attention to rapid increase in temperature.
The maximum temperature of the bearing is 80 to 85t: in normal operation.
9-39
d. Overheat of bearing
CAUTION
IN CASE OF BEARING OVERHEAT, WAIT FOR IT TO COOL DOWN BEFORE

[INSPECTION OR EXCHANGE WORK. OTHERWISE A BURN MAY RESET.
CAUTION
IN CASE OF BEARING OVERHEAT, DONOT STOP THE ROTATION ABRUPTLY.

OTHERWISE THE SHAFT IS SEIZED WITH THE BEARING.
• In case of bearing overheat, continue the rotation.

• Supply oil between the bearing and the shaft.
• Decrease the rotation gradually.
• Wait for it to cool down before stopping the rotation.
e. In the case of bearing burning or wear, exchange it with new one
9.2.2.2 Lubrication Oil
CAUTION
USE THE LUBRICATING OIL RECOMMENDED BY US.
1) Self-oil ring lubrication method (FE type)
CAUTION
WAIT FOR OIL TO COOL DOWN BEFORE EXCHANGING LUBRICATING O I L

OTHERWISE, BURNING MAY RESULT.
a. Recommended lubricating oil type : ISO VG-46 (equivalent to JIS K 2239)

b. Use a good-quality lubricating oil for the bearing, and filter oil to remove impurities
completely.
c. Exchange lubricating oil once every 6 months.
Nevertheless, this does not apply at the early stage of using the generator or when there is any
abnormality. In such a case, replace the lubricating oil with clean oil according to the conditions.
2) Forced Lubrication Method (FEK type)
a. Recommended lubricating oil type in the case of direct coupling with diesel engine :
(Over 6 poles) SAE No. 30 (equivalent to No. 2 of IIS K 2215 class 3)
b. Recommended lubricating oil type in the case of direct coupling with turbine engine:
(4 poles, 6 poles) VG-68 Turbine Oil No. 180 (equivalent to JIS K 2213
class 3)
c. Use a good-quality lubricating oil for the bearing, and filter oil to remove impurities
completely.
9-40
9.2.3 Bearing Clearance Limit
As for the bearing clearance, measure the shaft external diameter and the bearing inner diameter at
several positions with a micro meter.
Calculate the bearing clearance by use of the following equation, and if this is exceeded, exchange
the bearing.
1.5
𝐶𝐶 = 𝐷𝐷 × + 0.1
1000
C = Upper clearance of bearing (mm)
D = Shaft diameter (mm)
9.2.4 Vibration
By use of a vibration meter, measure the axial, horizontal, and vertical amplitudes, and vibration
velocity (effective value).
At rated load, the both amplitudes (peak value) is below 0.3mm at vibration frequency 30Hz, below
0.6mm at 15Hz, and the vibration velocity (effective value) is below 20mm/s as standard.
9.2.5 Maintenance of air filter

In the case with air filter, inspect it periodically, and if dirty too much, clean it in the following
procedures.
9.2.5.1 Material
Use air filter made of nylon with heat resistance.
9.2.5.2 Cleaning period
CAUTION
(1) CLEAN OR WASH FILTER AFTER REMOVED IT FROM FRAME EVERY THREE
MONTHS INTERVAL.
PERFORM MORE FREQUENTLY IF REQUIRED.
(2) FILTER CAN BE ENDURED UP TO ABOUT TEN TIMES WASHING.
IT IS ADVISABLE TO REPLACE TO SPARE AFTER THEN.
9.2.5.3 Cleaning, recovery

CAUTION
(1) WASH AWAY BY COLD OR WARM WATER.

(2) TO REMOVE CARBON - PARTICLES OR GREASY DIRT, SOAK FILTER IN
SYNTHETIC- CLEANNER FO R SEVERAL HOURS, THEN WASH IT BY PUSHING.
(3) BLOW DRY DIRT OFF FROM OUT FLOW FACE BY COMPRESSED AIR.
9.2.5.4 Notes on Cleaning

CAUTION
(1) DONOT USE HIGH PRESSURE WATER JET.

(2) DONOT CRUMPLE OR WRING IT. NOR USE ELECTRIC WASHING MACHINE.
9-41
Washing several filters in cleaning fluid is effective.
9.2.6 Cleaning and Drying of Coil

9.2.6.1 Cleaning of Coil
It is important to keep all the coils always clean. Dust, dirt, or foreign matter may clog the vent hole,
prevent normal ventilation, and make it difficult for heat to dissipate, thereby, causing partial or entire
overheat of the machine. Collected conductive dust or dusts absorbing water or oil m ay cause short-circuit
of coils or grounding accident. And abrasive dusts may damage insulated materials, therefore, pay attention
to the attachment of various dusts.
1) Wiping with cloth
a. Wiping with cloth is effective but only when to clean dust or foreign matter at reach of hand.
b. Wipe surface with a dry, clean cloth without thread waste.
2) Cleaning by spraying compressed air
CAUTION
WHEN TO SPRAY COMPRESSED AIR TO COIL, BALAST FIRST WATER IN AIR PIPE OR
HOSE. AND MAKE SURE THAT THERE IS NO ABSASIVE POWDERS IN COMPRESSED AIR
a. This method is especially effective to remove dust or foreign matter at places out of reach of
hand.
CAUTION
WHEN TO SPRAY COMPRESSED AIR TO COIL, BE SURE TO OPEN BOTH ENDS OF

DEVICE FOR AIR OR DUST TO GO OUT.
b. Use clean and dry compressed air, and set its pressure at 3 to 4kg/cm.
c. If there is abrasive powder in compressed air, it intrudes into the inside of insulation, and causes
damage, or goes into under the insulation tape.
d. Be sure to let dust go out of the device.
3) Cleaning by sucking
a. This is effective to remove dry dust or soft dirt, and this is effective without pushing dusts
into depth or making adjacent devices dirty as compress air does.
b. This method is recommended for removal of sand or iron powder.
4) Cleaning with solvent
CAUTION
IN CLEANING WITH SOLVENT, PAY ATTENTION TO FIRE. AND CARRY OUT

VENTILATION OF THE ROOM.
USE ONLY KEROSENE No. 2 (EQUIVALENT TO JIS K 2203) AND USE NO OTHER
SOLVENT.
9-42
a. This is effective to remove solid materials such as grease, oil, dust attached to the surface of
insulation materials.
5) Other
a. In case of dirt hard to be removed and with fear of bad influence upon the Quality of product,
contact us or our agent.
9.2.6.2 Drying
CAUTION
WHEN INSULATION MATERIALS HAVE A B S ORBED MOISTURE AND HAVE LOW

INSULATION RESISTANCE, BE SURE TO C L EAN THEM BEFORE DRYING.
DONOT USE COKE, COAL GAS. OR PETROLEUM STOVE AS HEAT SOURCE.
1) Drying instructions
a. Cover the entire of generator (stator and rotor), and blow hot wind with a hot wind fan.
b. Avoid local heating owing b l o w i n g hot wind directly onto coil surface, shaft and so on.
c. Limit the drying temperature 90 to 100⁰C.
d. Use a thermometer for temperature control.
e. When to use a cover, arrange appropriate space so that hot wind ventilate well over the entire
of the machine.
f. During drying, measure insulation resistance at constant intervals.
g. Carry out drying over 24 hours after insulation resistance becomes constant for complete
drying.
h. If the measurement of insulation resistance by drying is recorded, as shown in Figure 9-2,
insulation resistance changes, and w h e n this value becomes saturated, drying is completed.
Description of Figure 9-2
A- When drying starts, insulation resistance increases at a time, and then decreases, and next
increases gradually up to saturated condition.
B- Make sure it is saturated.
Figure 9-2: Change of insulation resistance
9-43
9.2.7 Insulation Resistance
CAUTION
IN MEASURING INSULATION RESISTANCE. DO NOT CONTACT THE TERMINAL.

OTHERWISE ELECTRIC SHOCK MAY RESULT.
CAUTION
IN THE MEASUREMENT OF INSULATION RESISTANCE BE SURE TO REMOVE
TERMINAL OR SHORT-CIRCUIT IT SO THAT MEGGER VOLTAGE SHOULD NOT BE
IMPRESSED ON AVR.
Insulation resistance is one of the important indexes to judge the performance of electric appliance.
Insulating materials change with a single or combination of heat, moisture, vibration, mechanical
damage, dust, chemical changes by acid or alkali, salt, air, oil and so on.
(1) Insulation resistance is the data effective to judge insulation condition, therefore, measure
it periodically during stop, and record ambient temperature and relative humidity too.
(2) Use a 500V DC megger for the measurement of insulation resistance.
(3) Judgment at measurement of insulation resistance
The value measured by use of a 500V megger should be over the following.
3 × 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 (𝑉𝑉) 𝑜𝑜𝑜𝑜 𝑚𝑚𝑚𝑚𝑚𝑚ℎ𝑖𝑖𝑖𝑖𝑖𝑖
𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 = (𝑀𝑀Ω)
𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 (𝑘𝑘𝑘𝑘 𝑜𝑜𝑜𝑜 𝑘𝑘𝑘𝑘𝑘𝑘) + 1000
The best method to judge insulation-condition is to prepare it with the value
previously measured, and the change from the previously measured value is important,
therefore, it is necessary to measure and record continuously the measured values of
insulation resistance.
(4) The minimum value of insulation resistance varies with types and sizes of device, so it is
difficult to show general one, but as a standard for daily maintenance, the safe minimum
value is over 1MΩ.
9.2.8 Operation Suspension

(1) It is desirable to keep coils and insulation materials of generator always 1 clean and dry.
When to suspend operation, avoid humidity.
(2) When to suspend operation for a long period, place a sheet or a vinyl cover 1 to prevent
external atmosphere, dust and dirt.
(3) As for the type with space heater, turn on the space heater at the same time when
operation is suspended, thereby keep the generator dry always.
(The temperature of the generator is 3 to 5⁰C higher than ambient temperature.)
9.2.9 Inspection of Exciter and AVR

CAUTION
BE SURE TO RE-TIGHTEN ALL BOLTS AND SCREWS SECURELY AND PERFORM

SCREWLOCKING (PAINTING ETC.) EFFECTIVELY WHEN THEY ARE LOOSENED.
9-44
CAUTION
MAKE SURE THAT THERE IS NO VOLTAGE ON THE MACHINE BEFORE

MAINTENANCE OR INSPECTION WORK.
CAUTION
REMOVE OF SHORT-CIRCUIT THE TERMINALS OF SILICON RECTIFYING MODULES

AND AVR BEFORE INSULATION RESISTANCE TEST OR INSULATION RESISTANCE
MEASUREMENT OF THE MACHINE.
9.2.9.1 Inspection of Exciter

(1) Inspect the grounding and conductor connection portion at least once every 6 months.
(2) Checking method of silicon rectifying modules
a. Silicon rectifying modules may become defective when over-voltage is impressed or over-
current runs. At the failure of silicon rectifying, modules voltage of generator is hardly
generated. Silicon rectifying modules is connected as shown in Figure 9-3.
Figure 9-3
b. In order to simply judge the performance of silicon rectifying modules, use a tester to
measure the resistance value in accordance with the instructions in Figure 9-4.
• Disconnect all the connecting wires from the rectifier stack.
• Use the resistance measurement range of tester to measure the resistance of each rectifying
element in forward and reverse direction. The forward resistance is acceptable if it is below
10Ω while the reverse resistance is acceptable if above 100Ω. (Restrict analog tester).
Element with conductivity, in both forward and reverse directions, or very low resistance
value is measured, is defective.
After the above checking, if defective element found, exchange it with good one.
9-45
Figure 9-4
9.2.9.2 9.2.9.2 Inspection of AVR

(1) In inspection, check AVR mounting bolt and lead wire terminal bolt for looseness or
disconnection.
(2) Do not open AVR cover for inspection.
(3) As for AVR failure, consult us or our agent.
9.2.10 Inspection of Rotating Rectifier

(1) Wiring
The wiring around the rotating rectifier is a 3-phase full-wave rectifying circuit as shown in
Figure 9-5, and a discharge resistor is connected to the wiring as a protective device for silicon
rectifying modules.
Ex: A.C. exciter

Si: Silicon rectifying modules
Rc: Discharge resistor
F: Generator field
Figure 9-5
(2) Structure
The structure of rotating rectifier and Discharge resistor is as shown in Figure 9-6.
(3) Inspection
It is important to keep clean the peripheral around rotating rectifier as well as the stator and
rotor coil of the main generator and exciter. Clean it periodically in the same manner as for coil.
Besides cleaning, check the bolts and nuts around rotating rectifier for looseness and also
check the terminal and lead wire for complete earthing. Check silicon rectifying modules in
accordance with the section 9.2.9.1 (2)
9-46
No. Name No. Name
36 Lead wire (A. C. side U, V, W ) 39 Lead wire (D. C. side J, K)
37 Silicon rectifying modules (PD) 40 Lock washer
38 Heat sink
Figure 9-6
9.2.11 Maintenance and inspection for normal machine after FWBLAFFS worked.
(1) Removal of the drop of water
a) Remove the drop of water outside surface of the generator.
b) Remove the drop of water with a clean dry cloth after all covers of the generator are
detached
(2) Exchange or clean the air filter.
Refer to 9.2.5 Maintenance of air filter.
(3) Winding coil is cleaned and dried
Refer to 9.2.6 Cleaning and Drying of Coil.
(4) Measure the insulation resistance.
(Measure the insulation resistance regularly according to [9.1.3 Periodical Inspection], and
leave the record.
It depends on [9.2.7 Insulation Resistance] about the measurement.)
a. The measurement values are compared with the record last time.
b. Dry according to [9.2.6.2 (1) Drying instructions] when the insulation resistance differ from
the standard values.
c. The measurement values are compared with the record last time again.
d. 1- When insulation values recovers to the extent of last record operation is acceptable while
paying attention.
d. 2- Execute [9.1.6 Overhaul Inspection] when differ from the standard values.
10 Troubleshooting
In the event of trouble with this product, adjust, exchange, coordinate, and repair it in accordance
with the following instructions, thereby make it into normal condition if recovery is impossible, contact us
or our agent.
10-47
10.1 In case of no voltage build up
No. Trouble Cause Countermeasures
Carry out initial excitation (24V
1. Residual voltage of AC exciter
DC to terminal J, K of exciter,
is lost.
within 3 seconds)
Voltage rise to only a 2. Rotating rectifier rectifying Exchange silicon rectifying
1
few volts element short-circuit modules.
Repair disconnection or
3. Disconnection or incomplete
incomplete contact, and inspect
contact in rotating rectifier
element.
1. Short-circuit of silicon
Exchange silicon rectifying
rectifying modules Si2 of static
modules.
exciting portion
2. Disconnection of circuit of AC Repair disconnection and inspect
Voltage rise 5 to 10% exciter to field coil element.
2
of the rated voltage 3. Disconnection of reactor Repair or replace it.
4. Short-circuit of rotating silicon Exchange silicon rectifying
rectifying modules. modules.
5. Short-circuit of current
Repair or replace it.
transformer secondary
10.2 In case of voltage decrease

1. Short-circuit of silicon
Exchange silicon rectifying
rectifying modules Si2 of static
modules.
exciting portion
2. Disconnection of reactor Repair or replace it.
3. Short-circuit of current
Abnormal voltage Repair or replace it.
1 transformer secondary side
decrease
4. Short-circuit of thyristor in AVR Exchange AYR.
5. Out of control owing to printed
Exchange AVR.
board failure
6. Abnormal temperature rise in Decrease the load on the
the field of the main generator. generator
10.3 In case of voltage increase

1. Failure of printed circuit board
or disconnection of thyristor gate Exchange AVR.
Abnormal voltage circuit
1
rise 2. Disconnection of detecting
Repair or replace it.
transformer
3. Disconnection of AVR circuit Repair or replace it.
10-48
4. Disconnection or incomplete
contact of manual voltage Replace rheostat.
rheostat
5. Rotation speed abnormally Adjust the rotation of prime
high mover.
10.4 In case of voltage instability

1. Imperfect contact of manual
Incessant voltage Adjust or replace rheostat.
1 voltage rheostat
change or hunting
2. Failure of AVR damping circuit Exchange AVR.
10.5 Trouble with Bearing

As for trouble with bearing, refer to the sections 9.2.2 and 9.2.3.
11 DISASSEMBLY AND ASSEMBLY

11.1 Precautions on Disassembly and Assembly
CAUTION
CARRY OUT DISASSEMBLY OR ASSEMBLY WORK BY 2 WORKERS AND MORE.
CAUTION
PLACE A VINYL OR CLOTH COVER OVER IMPORTANT PARTS SUCH AS BEARING.

BEARING PORTION OF SHAFT TO PREVENT DUST OR DAMAGE.
CAUTION
WHEN TO PULL OUT THE ROTOR FROM STATOR PAY SUFFICIENT ATTENTION NOT
TO TOUCH ARMATURE COIL AND FIELD COIL.
When to pull out the rotor from stator, match the axes of the rotor and stator so as to prevent the rotor
from coming into contact with the stator.
11.2 Disassembling and assembling procedures

Before disassembly and assembly, secure space and prepare necessary tools and crane.
There are 2 disassembly methods, namely the method to pull out the rotor toward the coupling side,
and the one to pull out it toward the counter coupling side. As for FE model, the former is described, while
the latter is explained as for FEK model.
11.2.1 Disassembling procedure for model FE

See Figure 7-1: Model FE.
(1) If a taco-generator, a speed detector or the like is connected to an end of shaft of the generator,
first disassemble and remove it.
11-49
(2) Disconnect the cable connected to the generator.
(3) Remove the oil drain plug and drain oil into waste oil can.
(4) Remove the bearing thermometer and its element.
(5) Remove the coupling to prime mover by use of jack bolt.
In this case, in the case of first coupling construction of generator and prime mover,
coupling construction maker makes engagement mark for coupling at the flange portion of
generator shaft and the flange of prime mover, therefore, in the case to remove the coupling of
generator and prime mover, make sure this engagement mark, and if the engagement mark is
difficult to be seen or missing, be sure to make engagement mark.
After disassembly, in the case to couple generator and prime mover be sure to meet this
engagement mark.
(6) Remove the foot mounting bolt and knock pin of the stator.
(7) Lift up the stator and move it to the disassembly place.
CAUTION
LIFT UP THE STATOR WITHOUT SHOCK, AND MOVE IT TO THE DISASSEMBLY PLACE
HORIZONTALLY.
(8) Remove the bolts at the join portion of cover 19 and exciter frame B and bearing case 4, and
bearing shield 2 and take off the bearing case and cover 19.
(9) Remove the bolts joining the upper and lower portions of the sleeve bearing 3 and detach only the
upper portion of the sleeve bearing.
(10) Suspend the rotor by crane. When lifting the rotor, special care is required since the air gap
between the rotor and the stator is narrow.
(11) Remove the lower portion of sleeve bearing 3.
(12) Remove the bearing shield 2 from the cover 17 and exciter frame 8.
(13) Remove the cover 17 of the coupling side.
(14) Insert press board liners (1.6mm x 2) into the air gaps between the stator and the rotor at three
places as shown in Figure 11-1.
Figure 11-1
(15) Lower the rotor suspended in (10).

(16) Disconnect the lead wires J and K of exciter stator 9 from the terminal in the static exciter 1
11-50
(17) Remove the exciter frame 8 (field core and field coil) from the generator stator frame 12. In this
case, pay attention so that the mark band of lead wires should not be apart.
(18) As shown in Figure 11-2, attach auxiliary pipe (separately available) to the counter coupling side
of the rot.
(19) Lift and displace the rotor as shown in Figure 11-2. In this case, use 2 cranes.
(20) Place temporary stands at both ends of the rotor, and lower the rotor on to them
(21) Lift and pull out the rotor as shown in Figure 11-3.
11.2.2 Assembling procedure for model FE

As for assembly, follow the reverse order of disassembly.
1) Prior to assembling, wipe off dust, dirt, oil and the like from the disassembled parts with clean
cloth.
2) Fasten the bolt and nut of each part by the fastening torque shown in Table 7-1, unless otherwise
specified.
3) When to directly connect to the prime mover, do so with the engagement mark of the flange of
generator shaft lining up with that of the flywheel of the prime mover.
4) Make sure that the air GAP between the shaft and the bearing surface is uniform
5) Supply filtered lubricant oil (section 9.2.2.2) up to the red circle of the oil gauge, and make sure
that the rotor and oil rings rotate smoothly. Thereafter fasten the upper metal.
6) Remove protective devices used for parts, and install parts. Make finally electric circuit
connections, and then assembly is completed.
11.2.3 Disassembling procedure for model FEK

Refer to Figure 7-2: Model FEK.
(1) If a taco-generator, a speed detector or the like is connected to an end of shaft of the generator,
first disassemble and remove it.
(2) Disconnect the cable connected to the generator.
(3) Remove oil supply and drain pipes, and drain oil into waste oil can.
(4) Remove the bearing thermometer and its element.
(5) Remove the coupling to prime mover by use of jack bolt.
In this case, in the case of first coupling construction of generator a n d prime mover,
coupling construction maker makes engagement mark for coupling at the flange portion of
generator shaft and the flange of prime mover, therefore, in the case to remove the coupling of
generator and prime mover, make sure this engagement mark, and if the engagement mark is
difficult to be seen or missing, be sure to make engagement mark.
After disassembly, in the case to couple generator and prime mover, be sure to meet this
engagement mark.
(6) Remove the foot mounting bolt and knock pin of the stator.
(7) Lift up the stator and move it to the disassembly place.
CAUTION
LIFT UP THE STATOR WITHOUT SHOCK, AND MOVE IT TO THE DISASSEMBLY PLACE
HORIZONTALLY.
If transportation to the disassembly place is not possible, pull out the rotor toward in the counter
coupling side in accordance with the method to pull out the rotor specified in and after (9).
11-51
(8) Remove the bolts at the join portion of cover 19 and exciter frame 8 and bearing case 4 and
bearing shield 2 and take off the bearing case and cover 19.
(9) Remove the bolts joining the upper and lower portions of the sleeve bearing 3 and detach only the
upper portion of the sleeve bearing.
(10) Suspend the rotor by crane. When lifting the rotor, special care is required since the air gap
between the rotor and the stator is narrow.
(11) Remove the lower portion of sleeve bearing 3.
(12) (Remove the bearing shield 2 from the cover 17 and exciter frame 8.
(13) Remove the cover 17 of the coupling side.
(14) Loosen the fastening bolt and remove the fan 18 from the fan boss 20.
When to remove the fan from the fan boss, do so after engagement mark for balance.
(15) Insert press board liners (1.6mm X 2) into the air gaps between the stator and the rotor at three
places as shown in Figure 11-1.
(16) Lower the rotor suspended in (10).
(17) Disconnect the lead wires J and K of exciter stator 9 from the terminal in the static exciter 1.
(18) Remove the exciter frame 8 (field core and field coil) from the generator stator frame 12. In this
case, pay attention so that the mark band of lead wires should not be apart.
(19) As shown in Figure 11-4 , attach auxiliary shaft (separately available) to the counter coupling
side of the rotor.
(20) Lift and displace the rotor as shown in Figure 11-4. In this case, use 2 cranes.
(21) Place temporary stands at both ends of the rotor, and lower the rotor on to them.
(22) Lift and pull out the rotor as shown in Figure 11-5.
11.2.4 Assembling procedure for model FEK

As for assembly, follow the reverse order of disassembly.
(1) Prior to assembling, wipe off dust, dirt, oil and the like from the disassembled parts with clean
cloth.
(2) Fasten the bolt and nut of each part by the fastening torque shown in Table 7-1 unless otherwise
specified.
(3) When to directly connect to the prime mover, do so with the engagement mark of the flange of
generator shaft lining up with that of the flywheel of the prime mover.
(4) Make sure that the air GAP between the shaft and the bearing surface is uniform
(5) Remove protective devices used for parts, attach parts, and connect the electric circuit finally, and
then assembly is completed.
11.2.5 How to replace the Rotating Rectifier

Refer to Figure 9-6.
11.2.5.1 Removing procedure

(1) Remove the bolts of the lead wire 36.
(2) Remove silicon rectifying modules 37.
11.2.5.2 Installing procedure
As for install of silicon rectifying modules, follow the reverse order of the removing procedure.
CAUTION
AT INSTALLING SILICON RECTIFYING MODULES BE SURE TO CHECK ITS NUMBER
11-52
(1) Use a torque wrench to fasten silicon rectifying module.
(2) Fasten the bolt of each part by the fastening torque shown in Table 7-1.
11.2.6 Installation of Generator

Refer to Installation Procedures in clause 7.3.1 for installation of the generator.
Figure 11-2
Figure 11-3
11-53
Figure 11-4
Figure 11-5
11-54
12 Check list
Carry out the normal inspection in accordance with the following check list.
Division Inspection Item Point Record Time

7:00 11:00 15:00 19:00 23:00
Output Voltage V Within the rated value
Current (R ) A on the name plate by
Current (S) A use of panel instrument
Current(T)
Power KVA
Power-factor
Frequency HZ
Stator Appearance of stator Without extreme dirt,
abnormality
Fastening Without looseness of
each part
Armature coil Within specified value
temperature ⁰C
Armature iron core Within specified value
temperature ⁰C
Stator frame within normal range
temperature ⁰C (below 90⁰C as
standard)
Vibration Without abnormal
vibration, increase of
vibration
Noise Without abnormal
noise
Smell without bad smell
Bearing Oil Level Within allowable range
oil gauge
Oil amount oil pressure Normal oil pressure,
flow
Oil leakage Without oil leakage
Oil ring Normal rotation
Temperature Within specified value
Vibration Without abnormal
vibration, increase of
vibration
Noise Without abnormal
noise
Ventilation Ventilation hole Without obstacle
Exhaust path Without exhaust going
into suction side
Air filter Without clogging
12-55
Record Time
Division Inspection Item Point
7:00 11:00 15:00 19:00 23:00
Ambient temperature Within specified value
⁰C range
Within specified value
Humidity
Others range
Without abnormal
Atmosphere
dust, dirt, water drop
Fire without lire
As for periodical inspection, carry out inspection in accordance with the sections 9.1.3 through 9.1.6.
13 PARTS LIST
This operation manual is for many frames, and the number of parts varies with frames, so only
main parts are described below. By the way, as for details of parts, refer to the section 7.1 and 7.2 the
numbers in the parts list below correspond with those in Figs 7-1, 7-2, 7-6, 7-7, 7-11 and 9-6. As for the
following parts, consult us or our agent.
(O mark -------- available)
No. Name of parts Type Quantity Remarks Supply

1 Static exciter 1 Set Panel side in case of
separate installation
2 Bearing shield 1 O
3 Sleeve bearing 1 O
4 Bearing case 1 O
5 Thermometer 1 O
6 Exciter armature coil 1 Set
7 Exciter field coil 1 Set
8 Exciter frame 1
9 Exciter stator 1 Set
10 Rotating rectifier 1 Set
11 Discharge resistor 1 O
12 Stator frame 1
13 Stator core 1 Set
14 Rotor core 1 Set
15 Stator coil 1 Set
16 Rotor coil 1 Set
17 Cover 1 O
18 Fan 1
19 Cover 1 O
20 Fan boss 1
21 Shaft 1
22 Coupling side ventilation cover 1 Set O
23 Anti-coupling side ventilation cover 1 Set O
24 Current transformer 1 Set Static exciter part O
25 Side cover 1 Set Static exciter part
13-56
26 Main terminal 1 Set Static exciter part O
27 Air filter 1 Set O
28 Drip proof cover 1 Set Static exciter part
29 Silicon rectifying modules 1 Set Static exciter part O
30 Reactor 1 Static exciter part O
31 Cable glands 1 Set Static exciter part O
32 Discharge resistor 1 Static exciter part O
33 Aux. terminal 1 Set Static exciter part
34 Cable supporter 1 Set Static exciter part
35 Exciting system frame 1 Static exciter part
36 Lead wire (A.C. side U, V, W)
37 Silicon rectifying modules 1 Set Rotating rectifier part O
38 Heat sink 1 Rotating rectifier part O
39 Lead wire (D.C. side J, K)
40 Lock washer 1 Set O
41 Oil ring 1 Onley for FE type O
Automatic voltage regulator EXU 1 Integrated into panel O

Manual voltage rheostat FA 1 FA 50W, 500Ω (Standard) O
Bearing cover (bearing) 1 Set Unnecessary for some types O

End cover (bearing) 1 Set Unnecessary for some types O
Option Parts

Current transformer for cross current CCT 1 O
compensation.
Stator coil thermometer element PTR-F * PT or JPT-100Ω
Bearing thermometer element PTR 1 PT or JPT-100Ω O
Temperature indicator MKH 1 O
Temperature indicator changeover switch TSD 1 O
Digital thermometer * O
Space heater 1 Set O
Thermistor 2 Set
Taco generator 1 O
Air filter 1 Set O
(*) --------- In accordance with specifications
13-57

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Table of Contents

1 Introduction ........................................................................................................................................ 1-1

No.1 Warning Static Exciter

No.2 Warning Label

3.2 Features of This Machine

3.3 Outline of Exciting system

Figure 3-1: Basic circuit diagram

6 UNLOADING, UNPACKING AND STORAGE

DISCONNECTION OF THE HOOK MAY CAUSE A SERIOUS PERSONAL INJURY OR

WHEN TO LOAD THIS PRODUCT WITH A FORKLIFT, PAY SUFFICIENT ATTENTION TO

IF THE ALLOWABLE LOAD OF FORKLIFT IS EXCEEDED, OR THE PRODUCT IS LIFTER

Figure 7-1: Model FE

7.2.1 Stator Frame

Figure 7-3: Stator Frame

7.2.2 Stator Core

7.2.3 Stator Coil

Figure 7-4: (This figure shewing 8 poles)

7.2.5 Rotor Coil

Figure 7-5: Appearance of Rotor

ISO VG-46 IS RECOMMENDED AS LUBRICATING OIL.

(OIL SUPPLY HOLE IS MARKED BY YELLOW.)

KEEP THE BEARING OIL SUPPLY PRESSURE OF THIS MACHINE 1.5kg/cn* 1 2 TO 2.

7.2.9 Ventilation cover

7.2.11 Rotating Rectifier

7.2.12 Connection Diagram

Figure 7-10: Connection diagram

7.2.13 Exciting System

Figure 7-11: Exciting unit mounted on generator top

DO NOT MEGGER AND HIGH POTENTIAL TEST!

SUCH TEST WILL DESTROY THE SEMICONDUCTORS IN BOX.

AVR is integrated into panel.

Figure 7-12: Block Diagram

2) Magnetic field current control circuit

7.2.13.2 Manual Voltage Rheostat (VR)

7.2.13.4 Current Transformer (CT)

Figure 7-16: Current Transformer

7.2.13.5 Silicon rectifying modules (Si)

7.2.13.6 Discharge resistor (protective device)

Figure 7-18: Discharge resistor (protective device)

DISCONNECTION OF THE HOOK MAY CAUSE A SERIOUS PERSONAL INJURY OR

DO NOT USE THE MACHINE IN EXPLOSIVE ATMOSPHERE. OTHERWISE, PERSONAL

AVOID THE USE OF THIS PRODUCT UNDER THE AMBIENT ENVIRONMENTAL

INJURY OR DAMAGE MAY RESULT.

THE AMBIENT ENVIRONMENTAL CONDITIONS ARE SPECIFIED BY RESPECTIVE SHIP

DO NOT RIDE ON OR HUNG FROM THE PRODUCT. OTHERWISE, PERSONAL INJURY

DO NOT PLACE ANYTHING THAT MAY PRIVENT VENTILATION AROUND THE

AS FOR WORK (ADJUSTMENT) OF DRIVING APPARATUS RELATING TO

IN MEASURING INSULATION RESISTANCE, DO NOT CONTACT THE TERMINAL.

KEEP A SAFE MAINTENANCE SPACE. OTHERWISE, ELECTRIC SHOCK OR PERSONAL

IN T H E CASE OF A MACHINE FOE USE ON LAND, AND EARTH TERMINAL

CHECK THE CONNECTION AND ACTION OF THE PROTECTIVE DEVICE. OTHERWISE,

CHECK THE WIRING FOR MISWIRING WITH REFERENCE TO THE CONNECTION

2-side width Fastening torque Screw 2-side width Fastening torque

BY THE WAY, MAKE'SURE THE INSTALLATION PLACE OF A FIRE EXTINGUIHER

8.1.2 Terminal section (including exciter)

8.1.3 Insulation Resistance

MAKE SURE THAT THE NECESSARY INSULATION RESISTANCE IS OBTAINED.

IN MEASURING INSULATION RESISTSNCE DO NOT CONTACT THE TERMINAL.

IN THE CASE OF INSEATION RESISTANCE MEASUREMENT, REMOVE TERMINAL OR

8.1.4 Bearing section

8.2 Operation Procedures

BY THE WAY, MAKE'SURE THE INSTALLATION PLACE OF A FIRE EXTINGUIHER

DURING THE ROTATION OF THE PRODUCT, NEVER TOUCH THE ROTATING

(LOADS REQUIRING ATTENTION: THYRISTER LOAD, SINGLE PHASE LOAD,