Publication Number: 350-06002-00 Publication Date: f 1981 4 abe ic! INSTRUCTION MANUAL INCLUDES INSTRUCTIONS FOR ASSEMBLING KATO ENGINEERING COMPANY BRUSHLESS GENERATORS TO ENGINES NOTE: KEEP THIS INSTRUCTION WITH GENERATOR SERIAL NUMBER [2422-0 @8 Rockwell automation Kato Engineering Ianicaro i S60023447 (607) 625-4011 FAX (607) 945-2799CONTENTS SECTION 1 contains safety precautions and dimensions recorded in this instruction. SECTION 2 contains receiving, handling, storage, and generator inspection instruction SECTION 3 contains recommended procedures for drying windings and testing generator insulation SECTION 4 contains exciter, fan, and permanent magnet alternator instructions. SECTION 5 contains recommended measurements to be made to ensure correct coupling and alignment of the engine generator set. SECTION 6 contains coupling and mounting general procedure. SECTION 7 contains recommended torque tables, a flywheel dimensions table, a recommended minimum exciter air gap table, and figures showing dimensions to be measured. ySECTION 1 DIMENSIONS RECORDED IN THIS INSTRUCTION AND SAFETY PRECAUTIONS SAFETY PRECAUTIONS To guard against personal injury and equipment damage, extreme care must be taken while handling the generator and coupling the generator to the prime mover. Various safety precautions are given in these instructions. Be sure to follow the precautions listed and, depending on the application, take any additional precautions that may be necessary in order to avoid personal injury or equipment damage. DIMENSIONS RECORDED IN THIS INSTRUCTION To facilitate coupling of the generator to the prime mover, two of the various inspection measurements taken during manufacture of this generator are recorded below and on Page 2 ‘A. Outboard Exciter Shaft Extension Where generators of the type that has an outboard exciter, the exciter rotor unit mounts on extension of the generator shail that protrudes beyond the bearing and endbell while the exciter field mounts on raised shaft On the outside face of the endbell, The shaft extension measurement (dimension a, Figure 7-1) establishes axial alignment of the exciter armature with the exciter field and ensures bearing endclearance. It is taken from the outboard face on the bearing housing section of the endbell to the end of the shaft extension Aiter the generator is coupled to the prime mover but before installing the exciter rotor unit, measure the extension and compare the measurement with recorded dimension (a) DIMENSION (a) MEASURED AT FACTORY IS__6/e INCHES. BEARING END CLEARANCE MEASURED AT FACTORY IS__Yf__INCHES. NOTE: Where generator includes a permanent magnet alternator (PMG), the PMG rotor unit mounts on the shaft ‘outboard from the exciter rotor unit. In this case the PMG rotor and the exciter rotor must be removed to attain measurement (a B. Drive Plate to Adaptor Face (Dimension Y) Steel drive plates on the drive end of the generator rotor mount into the driving-ring pilot bore in the flywheel, while the face on the generator adaptor mounts to the flywheel housing. The axial distance from the mounting face on the flywheel housing tothe driving-ring pilot bore in the flywheel (dimension ¥ Figure 7-2) is established when the flywheal and flywheel housing is mounted on the engine. The axial distance from the rive plates to the adaptor (dimension Y Figure 7-3) is established during manufacture of the generator. To ensure correct axial alignment of the generator rotor the difference between dimension G and dimension Y must not exceed 1/32 inch DIMENSION Y MEASURED AT FACTORY Is__O__incH.SECTION 2 RECEIVING, HANDLING, STORAGE AND GENERATOR INSPECTION RECEIVING GENERATOR Upon receipt of the generator, itis recommended that t be carefully examined to determine if any shipping damage has occurred before accepting shipment from the transportation company. UNPACKING Unpack the generator with care to avoid damage to the unit. Read all instruction cards carefully. Keep all instructions and separately packaged components with the generator. Single bearing generators are shipped with rotor support blocking across the face on the drive plates and adaptor, land may have wood or fiber strips in the generator air gap to keep the rotor centered within the stator. This blocking must be kept in place while handling the generator. Be sure to support drive end of generator rotor while coupling the generator rotor to the prime mover flywheel. HANDLING When lifting the generator, attach an overhead crane to the lifting eyes located on the top of the generator frame. Apply lifting force in vertical direction, it possible. Be sure to select crane and lifting hardware that has sufficient ‘capacity for safely lifting the unit. Weight of the generator can be found by referring to the shipment bill of lading WARNING Do not apply any force to generator fan for lifting or rotating rotor. Disregarding these instructions may result in personal injury or equipment damagc WARNING Do not lift complete generator set by means of lifting eyes on generator frame. Disregarding these instructions may result in personal injury or equipment damage. STORAGE In the event the generator will not be installed on the prime mover immediately, it is recommended the unit be stored in a clean, dry area not subject to rapid changes in temperature. If thisis not possible, itis recommended the Unit be completely wrapped in plastic film. Placing packages filled with moisture absorbing material such as silica {gel within the plastic covering and sealing any openings in the plastic covering will provide additional protection GENERATOR INSPECTION Before coupling the generator to the prime mover it is recommended the generator interior be carefully inspected. Windings should be inspected to make certain they are not wet and are free of dirt and abrasive material. All bolts, terminals, and other hardware that hold the generator together should be checked to make certain they have not loosened during shipment of handling. Table 7-2 in this manual gives the recommended torque for rotating rectifiers; the recommended torque for SAE ‘cap screws is given in Table 7-3. The recommended torque for the oxciter rotor retaining bolt used on generators with an outboard exciter is 60 foot pounds when the shrank diameter is 1/2-inch, and 200 foot pounds when the shrank diameter is 3/4-inch. Its recommended that the generator bolts and screws except the rectifiers and exciter retaining bolt be tightened to the torque given for SAE cap screws. Where SAE 8 cap screws are used to couple the ‘generator to the prime mover, those bolts should be tightened to the recommended torque for SAE 8 cap screws (see Table 7-3—, In the event the generator was subjected to rapid changes in temperature or freezing or wet climate during shipment or storage, itis recommended the stator winding insulation resistance be tested. f the winding insulation resistance does not exceed the minimum allowable value the generator should be dried out. vSECTION 3 DRYING WINDINGS AND GENERATOR INSULATION TESTING DRYING WINDINGS Ifit is necessary to dry out the generator, it is recommended that the stator winding be throughly tested using the ‘Generator Insulation Testing” procedure. The following are recommended drying methods. Heated Enclosures Remove the cover from the exciter end of the machine, Enclose the generator and insert heating units as space heaters, lamps or coils of steam pipe to raise the temperature. Leave a hole at the top of the enclosure to permit the escape of moisture. Temperature within the enclosure should not exceed 93 degrees C or 200 degrees F. The voltage regulator and any electronic components must be removed from the generator when using this method. Forced Air Aportable forced air heater can be used by directing heat into the exciter end of the generator through openingsin the endbell. Heat at point of entry should not exceed 93 degrees C or 200 degrees F. @ Oven “ Place the machine in a thermostat controlled oven and bake it at a temperature not to exceet 93 degrees C or 200 degrees F. The voltage regulator and any electronic component accessories must be removed from the generator when using this method. GENERATOR INSULATION TESTING The following tests can be used to check minimum insulation resistance. Minimum insulation resistance can be tested using a megohmmeter as a 500 VDC hand-cranked megger. CAUTION. Megohmmeter must never be applied to exciter diodes, the voltage regulator, generator set meters, transformers, or generator set protective devices. Disregarding these instructions can result in equipment damage. Generator Stator (Armature) 1. Calculate minimum insulation resistance using the formula that follows. Minimum insulation = machine voltage +1000 resistance in megohms 1000 2. Disconnect all wires connected to the stator leads, including the ground wire on neutral grounded « generators. 8. Connect all stator leads together. 4, Connect one megohmmeter lead to stator leads and the other megohmeter lead to the generator frame. Make sure the non-insulated terminals on the stator leads are not touching the generator frame or other metal parts. 5, Test insulation resistance. A reading lower than the calculated minimum indicates an unacceptably low generator insulation resistance. Generator Rotor (Field) 1. Remove both generator field leads from the terminals on the exciter rectifier assembly (diodes). 2. Insulate on generator field lead, using electrical tape to prevent its grounding. Connect one megohmmeter lead to the remaining field lead making sure the connection is not touching the generator rotor or other metal parts. Connect the remaining meghohmmeter lead to the generator shaft or other rotating parts such as the drive hub or exciter retaining bolt. 3. Test insulation resistance. A reading lower than one megohm indicates an unacceptably low insul resistance. Exciter Fleld 1. Disconnect the exciter field leads. The positive lead may be identified either (+), F+, or F2. The negative lead may be identified (-), F-, or F12. Connect one megohmmeter lead to one of the exciter field leads and the other megohmmeter lead to the ‘generator frame. Make certain non-insulated connectors on the field leads do not touch the frame or other ‘metal parts. 3, Test insulation resistance. A reading lower than one megohm indicates an unacceptably low insulation resistance. Exelter Rotor (Armature) 1. Disconnect all exciter armature leads from the exciter rotating rectifier assembly diodes. 2. Connect the exciter armature leads together. 3, Connect one megohmmeter lead to the exciter armature leads and the other megohmmeter lead to either the armature core, generator shaft, or exciter retaining bolt. Make certain non-insulated connection on armature loads is not touching the core, shaft, or other metal parts. 4. Test insulation resistance. A reading lower than one megohm indicates an unacceptably low insulation resistance.SECTION 4 EXCITER, PERMANENT MAGNET ALTERNATOR AND FAN INSTRUCTIONS GENERAL The instructions contained in this section are included to facilitate coupling the engine-generator set and help to prevent equipment damage. EXCITER [The exciter air gap is small in comparison to the generator air gap. To prevent equipment damage while coupling the generator to the prime mover extreme care must be taken to maintain exciter air gap or one of the procedures given below should be followed, A. Exciter Rotor Unit (Outboard Exciter Generators) The exciter rotor unit comprised of the exciter armature and rotating rectifier mounts on an extension of the generator shaft that protrudes beyond the endbell. The exciter rotor unit is held in place on the shat by akey in the shatt and a bolt and washer located on the end of the shaft. Generator field lead wires attach to (+) and (-) terminal on the rotating rectifier assembly heat sink. To prevent equipment damage it is recommended the exciter rotor unit be removed while coupling the ‘ generator to the prime mover. General procedure is as follows: ‘1. Where generator includes a permanent magnet alternator (PMG), remove the PMG rotor as described in the Permanent Magnet Alternator Instruction contained in this section, 2. Remove exciter field lead wires trom the terminals on the heat sink and remove bolt and washer from end of shaft 3. Pull exciter rotor off key and shaft. Be careful not to damage exciter armature windings or the rotating rectifier assembly. 4. Keep key, bolt, and washer with exciter rotor unit 5. After coupling process is complete and shatt extentsion measurement (a) is correct, install exciter rotor unit as follows, 6. Install key in the machined keyway on the generator shaft. 7. Align exciter rotor unit with key and push the exciter rotor unit onto the shalt. Be careful not to damage rotating rectifier or armature windings. 8. Install washer and retaining bolt. Torque bolt with 1/2-inch shank diameter 60 tV/Ibs, 3/4-inch shank diameter bolt 200 ft/Ibs. 8. Connect field leads onto the (+) and (-) terminals located on rotating rectifier assembly sink. 8. Exciter Field (Inboard Exciter Generators) Where machine has inboard exciter, several bolts mount the exciter field to raised bosses located on the inside face of the endbell. Access is attained through openings in the endbell To prevent damage it is recommended the exciter field be removed from the endbell while coupling the generator to the prime mover. While removed, the exciter field may rest on the exciter armature. Be sure to Install the exciter field before rotating the rotor. Torque bolts as given in the recommended torque for SAES. cap screws (see Table 7-3) GENERATOR FAN WARNING Do not lift or pry on fan. Disregarding this warning can result in personal injury and damage. WARNING Make certain fan Is clear of stationary pi id check torque of all fan bolts before starting generator set. Fallure to observe this precaution can result in serious Injury and ‘equipment damage.The generator fan mounts between the generator field and the drive coupling. Where its necessary to loosen the rae ne oe eva inetaling he bolts that mount the generator drive latos to the lywhet, follow) the applicable procedure that follows. {A Press Fit Fan Hub with Sheet Metal Fan Fp attain additional space during the coupling proceess, remove the bolts that mount the fan to the fan hub Before rotating the rotor, be sure to install the fan and torque the fan bolts in accordance with recommended torque for SAE § cap screws (see Table 7-3 and Figure 7-4). B. Cast Fan with Split Hub Batt on the side of the hub hold the fan in place on the generator shaft. Before loosening the volts and roving the fan make a small mark on the shatt as close as possible to the fan hub. Alignment ofthe fan hub ith thus mark when fan is again tightened to the shaft will ensure correct axial alignment of the fan. Before votating the rotor, align fan and then torque bolts in accordance with recommended torque for SAE cap ‘screws (see Table 7-3 and Figure 7-4). C.Sheet Motal with Fan Hub Located on Drive Hub Assembly ‘Whore this is the case, a sheet metal fan mounts on the fan hub which in turn is mounted on the drive hub. ‘The drive hub is press fit on the shaft, while the fan hub is held in palce on the drive hub by a key and bolts or screws Where itis necessary to move the fan during the coupling process, the general procedure is as follows + Make a small mark on the drive hub as close as possible tothe drive fan hub. Alignmentof the fan hub with this mark when fan is moved back into place will ensure correct axial alignment of the fan. Loosen or remove bolts that mount fan onto the fan hub, Loosen bolts (or set screws) that hold fan hub in place on the drive hub. Insert bar in slot located in fan hub to spread fan hub slightly. Then move fan hub. ‘After coupling the generator to the prime mover, resposition hub and install bolts as follows. e Move fan hub into alignment with mark made on the drive hub. Tighten and torque fan hub bolts or set screws in accordance with torque given for SAES cap screws (see Table 7-3) 8, install bolts that mount the fan to the fan hub, Torque bolts in accordance with recommended torque for SAE 5 cap screws (see Table 7-3 and Figure 7-4). PERMANENT MAGNET ALTERNATOR Where provided, the permanent magnet alternator stator mounts to the generator endbell while the permanent magnet rotor mounts on the end of the generator shaft. The PMG rotor Is secured in place by a bolt and washer through the center of the PMG rotor hub. The hub also may include a key and two setscrews to keep the rotor aligned on the shaft. The recommended torque of the bolt that passes through thenole in the center ofthe hub will be entigal to the recommended torque for an exciter retaining bolt as shown in Table 7-1, while setscrows should be torqued in accordancewith the recommended torque for SAE 6 cap screws as shown in Table7-3. Remove and install PMG rotor as described in the procedure that follows. WARNING Permanent magnet rotor is highly magnetized and will move with force toward any iron or steel part. Wear protective gloves and be careful while removing or installing the PMG rotor. Fallure to observe this precaution can result In injury and equipment damage. A. Removing PMG Rotor 1. Visually check to determine mounting hardware such as bolts and setscrews that hold the PMG rotor on. generator shaft, 2. Remove hardware that mounts PMG rotor on generator shaft. 3. Wrap a thin sheet of insulating material or cardboard around the air gap between the PMG rotor and stator. 4, Pull PMG rotor from shaft following the safety precaution described above. Yom ~ B. Installing PMG Rotor 1. Reverse removal procedure when installing PMG rotor. Then torque bolts, 2. After generator is completely coupled to the prime mover, measure PMG air gap. Air gap should not be less than 0.020 inch.SECTION 5 Y MEASUREMENTS ¢ GENERAL This section describes measurements to be made in order to ensure correct coupling and alignment of the engine generator set. This section is separated into pre-coupling measurement instructions, measurements to be made while coupling the units, and measurements made after the generator has been coupled to the prime mover PRE-COUPLING MEASUREMENTS Itis recommended the measurements that follow be made before coupling the generator to the prime mover. GENERATOR DRIVE PLATE AND FLYWHEEL DRIVING-RING PILOT BORE MEASUREMENTS The generator drive plates fit into the flywheel driving-ring pilot bore. Before coupling the generator to the prime mover itis recommended the following measurements be made. ‘A. Measure flywheel driving-ring bore diameter (dimension B, Figure 7-2). Compare measured diameter with dimension and tolerance given by flywheel manufacturer. B. Measure generator drive-plate diameter (dimension S, Figure 7-8). Drive-plate diameter must not be greater than tho flywheel driving-ring pilot bore diameter. C.Measure flywheel driving-ring bore face runout. Compare measured runout with maximum tolerance specitied by flywheel manufacturer. D.Measure flywheel driving-ring pilot bore eccentricity. Compare measured eccentricity with maximum allowable eccentricity specified by flywheel manufacturer. E, Measure eccentricity between the driving-ring pilot bore B and pilot bearing bore L (see Figure 7-2) Compare eccentricity measured with maximum eccentricity specified by flywheel manufacturer. F. Measure depth from flywheel housing face to the flywhee! driving-ring pilot bore face (dimension G, Figure 7-2. Compare measured depth G with dimension specified by flywheel manufacturer. G.Compare measured depth from flywheel housing face to flywheel driving-ring pilot bore face (dimension G. Figure 7-2) with the depth trom the generator drive plates to the generator adaptor dimension ¥ recorded in Section 1 in this manual). Contact factory if difference exceeds 1/32 inch ENGINE CRANKSHAFT AND FLYWHEEL DEFLECTION Two methods often specified to determine angular loading of coupled engine driven generator sets are measurement of crankshaft deflection and flywhee! deflection. Where specified by the engine manufacturer, deflection may be specified either as a maximum allowable deflection, or the difference between a measurement taken before the prime mover and generator are coupled with measurement taken after the units are completely Coupled. Where the latter is specified, be sure to make initial measurement before starting to couple the generator to the prime mover, Measure according to engine manutacturer’s instructions. MEASUREMENTS MADE DURING COUPLING PROCEDURE The following measurements made while generator is being coupled to the prime mover will facilitate accurate coupling and alignment. A. Parallel Alignment of Adaptor Face with Flywheel Housing Face This measurement facilitates accurate alignment of the adaptor with the flywheel housing. Measurement is made after the drive plates have been coupled to the prime mover. Measure using thickness gauge between the two faces while thr bolts that mount the adaptor to the flywheel housing are tightened. Faces are paralle! when space between faces is equal at all points around the circumference. Use jack screws or overhead hoist as necessary to align generator while tightening the bolts. B. Exciter Rotor Unit Shaft Extension on Generators with Outboard Exciter This measurement (dimension a) is made from the outer face on the bearing housing on the endbell to the end of the generator shatt as shown in Figure 7-1. The exciter rotor unit is removed while making the measurement. Where generator includes permanent magnet alternator (PMG), the PMG rotor also must be removed. Refer to procedures contained in Section 4 in this manual. Make measurements atter generator drive plates have been coupledte the flywheel andthe adaptorhas been) coupled to the flywheel housing.Compare measured length of shat extension with the dimension (a) recorded in Section 1 in this manual Measured distance should not be more than 1/32 inch longer or 1/32 Inch shorter than the shatt extension length (dimension a) recorded in Section 1 ALIGNMENT MEASUREMENT OF COUPLED ENGINE-GENERATOR SET Following coupling and mounting of the generator to the prime mover its recommended the measurements that follow be made to ensure that correct alignment has been attained A. Engine Crankshatt Detlection Where specified by the engine manufacturer, measure crankshatt deflection in accordance with engine manufacturers instructions B. Flywheel Deflection Where specified by the engine manufacturer, measure flywheel deflection in accordance with engine manufacturer's instructions C.Generator Rotor Eccentricity Alter the generator has been coupled to the prime mover, a measurement of generator rotor eccentricity should be made to ensure generator rotor shaft has been aligned with the engine. Do nat pry on generator fan, Measure eccentricity and, where necessary, correct alignment as follows 1. Mount dial indicator base on the generator adaptor and position the dial indicator finger on the generator drive hub or generator shatt. « 2. Set dial indicator needle to zero 7 3. Bar engine or flywheel through one revolution. Do not pry on generator fan. 4. Eccentricity should not exceed 0.006 inch total indicator reading where rated RPM is 120 RPM or lower, or (003 inch, total indiactor reading on 1500 RPM to 1800 RPM generator sets 5. In the event eccentricity exceeds the maximum tolerance given above, align coupling as given in procedure 6 6. Attach hoist and cable about drive coupling to support driven end of generator rotor, or use jack under rive hub with jack base on adaptor rib or base cross member. Loosen bolts that mount the drive plates to the flywheel. Then move drive plates in the direction within the flywheel driving-ring recess bore that will decrease eccentricity. Remove cable hoist, torque bolts, and again measure eccentricity. If eccentricity Still exceeds maximum tolerance, proceed to step 7. 7. Rotate the drive plates with respect to the flywheel driving-ring-pilot bore. Support the drive end on the generator rotor with a cable and hoist or jack, Remove coupling bolts and turn the flywheel. Bo sure to Keep the generator drive plates stationary. Rotate the flywheel to position where eccentricity will be minimum 8nd bolt holes are aligned, Then install and torque bolts, remove cable and holst, and again moasure eccentricity. D. Generator Rotor Angular Alignment Alter the generator has been coupled to the prime mover, a measurement of angular alignment of the generator rotor with the engine flywheel should be made. Measure angular alignment and where necessary, Correct as follows, 1. Measure approximate distance between shaft center and any convenient point on the flywheel slightly © larger than the driving-ring pilot Bore. This dimension is used in the procedure described nsteps 2 and 6 that follow 2. Mount dial indicator base on the generator fan and positin the dial indicator finger on the flywheel According to dimension measured in step 1 Set dial indicator to zero. Do not pry on generator fan Bar engine or flywheel through one revolution while measuring angular runout. ‘Angular runout must not exceed .010 inch per foot of radius measured trom shaft center to indicator finger. Where radius used during measurement is other than one foot, calculate according to dimension from preceeding step 1 7. Inthe event excessive angular runout occurs, inspect ang verity previous measurements as necessary to insure tho items that follow were installed correctly and tolerenaces are within the specified limits. 8. Make certain drive plates are seated in the flywheel driving-ring pilot bore and coupling bolts are torqued (see Table 7-3 and Figure 7-4), ». Verity that adaptor face and flywheel housing face are aligned and bolts torqued (see Table 7-3 and Figure 7-4) 6. Be sure that while mounting the generator to the base an angular load which could cause flywheel housing deflection was not applied. Inspect by loosening mounting bolts and moving generator stator Slightly with hoist or jack Screws while measuring angular alignment. 4. Verity that flywheel deflection and crankshatt detlection are not excessive@ Compare measured length of shaft extension with the dimension (a) recorded in Section 1 in this manual, Measured distance should not be more than 1/32 inch longer or 1/32 inch shorter than the shaft extension length (dimension a) recorded in Section 1 ALIGNMENT MEASUREMENT OF COUPLED ENGINE-GENERATOR SET Following coupling and mounting of the generator to the prime mover it is recommended the measurements that follow be made to ensure that correct alignment has been attained. A. Engine Crankshaft Deflection Where specified by the engine manutacturer, measure crankshaft deflection in accordance with engine manufacturer's Instructions. B. Flywheel Deflection Where specified by the engine manufacturer, measure flywheel deflection in accordance with engine manufacturer's instructions. C. Generator Rotor Eccentricity Aiter the generator has been coupled to the prime mover, a measurement of generator rotor eccentricity should be made to ensure generator rotor shaft has been aligned with the engine. Do not pry on generator fan, Measure eccentricity and, where necessary, correct alignment as follows. 1. Mount dial indicator base on the generator adaptor and position the dial indicator finger on the generator drive hub or generator shatt 2. Set dial indicator needle to zero 3. Bar engine or flywheel through one revolution. Do not pry on generator fan, 4. Eccentricity should not exceed 0.006 inch total indicator reading where rated RPM is 120 RPM or lower, or (003 inch, total indiactor reading on 1500 RPM to 1800 APM generator sets 5. In the event eccentricity exceeds the maximum tolerance given above, align coupling as given in procedure 6 6, Attach hoist and cable about drive coupling to support driven end of generator rotor, or use jack under drive hub with jack base on adaptor rib or base cross member. Loosen bolts that mount the drive plates to the flywheel. Then move drive plates in the direction within the flywheel Griving-ring recess bore that will decrease eccentricity. Remove cable hoist, torque bolts, and again measure eccentricity. If eccentricity slill exceeds maximum tolerance, proceed to step 7. 7. Rotate the drive plates with respect to the flywheel driving-ring-pilot bore. Support the drive end on the generator rotor with a cable and hoist or jack. Remove coupling bolts and turn the flywheel. Be sure to keep the generator drive plates stationary. Rotate the flywheel to position where eccentricity will be minimum and bolt holes are aligned. Then install and torque bolts, remove cable and hoist, and again measure eccentricity, D. Generator Rotor Angular Alignment Alter the generaior has been coupled to the prime mover, a measurement of angular alignment of the ‘generator rotor with the engine flywheel should be made, Measure angular alignment and where necessary, Correct as follows. 1, Measure approximate distance between shatt center and any convenient point on the flywhee! slightly larger than the driving-ring pilot bore. This dimension is used in the procedure described in steps 2 and6 that follow. 2. Mount dial indicator base on the generator fan and positin the dial indicator finger on the flywheel according to dimension measured in step 1 Set dial indicator to zero. Do not pry on generator fan. Bar engine or flywheel through one revolution while measuring angular runout. Angular runout must not exceed .010 inch per foot of radius measured from shaft center to indicator finger. Where radius used during measurement is other than one foot, calculate according to dimension from preceeding step 1 7. Inthe event excessive angular runout ocours, inspect and verity previous measurements as necessary to ensure the items that follow were installed correctly and tolerenaces are within the specitied limits a, Make certain drive plates are seated in the flywheel driving-ring pilot bore and coupling bolts are torqued (see Table 7-3 and Figure 7-4) b. Verify that adaptor face and flywheel housing face are aligned and bolts torqued (see Table 7-3 and Figure 7-4) ¢. Be sure that while mounting the generator to the base an angular load which could cause flywhee! housing deflection was not applied. Inspect by loosening mounting bolts and moving generator stator slightly with hoist or jack screws while measuring angular alignment 4. Verify that flywheel deflection and crankshatt deflection are not excessive.SECTION 6 COUPLING GENERATOR TO THE PRIME MOVER GENERAL Couple the generator to the prime mover and mount the generator in accordance with the instructions provided by the engine generator set assembler. The instructions that follow and those contained in preceding sections in this manual are included to facilitate correct coupling of the generator set and help to prevent equipment damage. COUPLING PROCEDURE 1 .Review preceding instructions. Itis recommended the “pre-coupling” measurements described in Section S in this manual be made before lifting the generator onto the generator set base. 2 .Lift generator onto base with overhead crane. Leave rotor support in place while lifting the generator. 3 .Larger generators may include jack screws located in the generator base plate. Where provided, these bolts facilitate alignment of the generator adaptor with the flywheel housing during the coupling process. WARNING ‘The exclter air gap and, where provided, the permanent magnet alternator alr gap are ‘small compared with the alr gap within the main generator. While coupling the generator to the prime mover, either the alr gap must be carefully maintained or PMG rotor and exelter rotor or the exciter fleld must be removed. Failure to observe this precaution can result in serious Injury and equipment fallure. 4 Drive end of generator rotor must be supported while coupling the drive plates to the flywheel. Support drive end of generator shaft by wrapping a cable around the drive hub and attaching the cable ends to an overhead hoist, or use jack under drive hub with jack base on adaptor rib or base cross member. NOTE: Where generator has removable screen and cover around the adaptor, those Items may be removed to attain access for cable. 5 Remove wooden support block from face of drive plates and adaptor and, where provided, remove support blocking from generator air gap. 6 .Refer to the exciter instructions contained in Section 4 in this manual. Where generator includes a PMG refer to permanent magnet alternator instructions contained in Section 4. 7 .Reter to the fan instructions contained in Section 4 in this manual. 8 Attach drive plates to the flywheel. SAE8 bolts are recommended. Make certain plates it completely into the driving-disk recess bore in the flywheel. Move generator stator as necessary to maintain axial alignment of the generator rotor within the stator. 9 Remove sling and hoist from drive hub, Then, torque coupling bolts (see Table 7-3 and Figure 7-4). 10.Use overhead hoist or jack screws to align adaptor face with the flywheel housing. Install and Torque bolts (see Table 7-3 and Figure 7-4) ‘1.Level generator base with the generator set base. Use shims, when necessary. 12 Remove hoist from generator lifting eyes. 13.Remove jack screws. 4.Install and torque bolts that mount the generator to the base (see Table 7-3). WARNING Make certain sufficient clearance exists between fan and stationary parts and make certain fan and fan hub bolts are torqued. Fallure to observe this precaution can reault In serlous Injury and equipment damage©. Verify that drive plate bore is concentric with driving plate pilot on the generator drive hub. f. Verify that flywheel housing face runout does not exceed specified tolerance, 9. Verify that flywheel driving-ring pilot bore face runout does not exceed specified tolerance h. Verify that eccentricity between the flywheel pilot bore (L) and driving-ring pilot bore (B) does not exceed specified tolerance. D. Flywheel Deflection Measurement Where specified by the engine manufacturer or, in the event angular alignment of the generator rotor with respect to the prime mover exceeds specified tolerance, measure flywheel deflection in accordance with engine manufacturer's instructions. E. Crankshaft Deflection Measurement Where recommended by the engine manufacturer or, in the event angular alignment is not within specitied tolerance, measure crankshaft deflection in accordance with engine manufacturer's instructions. F. Exciter Measurement After the generator has been completely coupled to the prime mover and mounted to the base, measure exciter air gap and check axial alignment. Axial misalignment should not exceed 1/8-inch. The air gap will be less on the lower part of the air gap due to bearing tolerance. Minimum air gap is shown in Table 7-6. p!SECTION 7 TABLES AND FIGURES GENERAL The tables and figures that follow are included to facilitate correct coupling and alignment of the generator set. TABLE 7-1 RECOMMENDED TORQUE TABLE 7-2 RECOMMENDED TORQUE FOR FOR EXCITER RETAINING BOLT AVALANCE SILICON POWER RECTIFIERS Shank Diameter] Recommended Torque| | Shank Dia. and Recommended Mounting {in inches) (in foot pounds) Thread Torque (in inch Ibs) See note V2 60 No. 10-32 30, max. Vs 75, max. 34 200 3/8 125, max. Wi 225, max. 3/4"-16 325, max. 278, min, NOTE: Torque for UNF-2A; for UNF-2 or NF2A decrease torque approximately 50%. TABLE 7-3, RECOMMENDED TORQUE SAE 5 STEEL AND SAE 8 STEEL CAP SCREWS. Mipte => 3,354 Recommended Torque (in foot pounds) Shank Diameter AS.T.M, A449 (in inches) S.A.E. 5 Steel SAE. 8 Steel W4 9 13 5/16 18 28 3/8 31 46 7/16 50 75 2 7 hs 9/16 110 165 5/8 150, 225 3/4 250 370 mi 3 oar 1 583 893 11/8 782 1410 14 1097 1964 13/8 1461 2633 11/2 1748 31501S.install generator fan and torque tan bolts as described in the fan instructions contained in Section 4 in this manual, yEWhere generator has inboard exciter, install the exciter field and torque bolts using recommended torque for SAE 5 cap screws (see Table 7-3) y7Where generator has outboard exciter. measure the shaft extension and compare with dimension (a) recorded in Section 1 in this manual, Maximum allowable difference between recorded dimension (a) and measurement made after generator is coupled to the prime mover is 1/32 inch. 18Where generator has an outboard exciter, install the exciter rotor as described in Section 4 in this manual where generator has permanent magnet alternator, install the PMG rotor as described in Section 4 in this manual, 18Measure exciter axial alignment and air gap. Axial misalignment should not exceed 1/8 inch. Because of bearing clearance tolerances, less air gap may exist in lower part of exciter while generator rotor is stopped. Minimum exciter air gap is shown in Table 7-8. PMG air gap should not be less than 0.020 inch. To measure air gap, the following procedure is recommended. Using thickness gauge, measure completely around air gap to detemrine tightest point. Then, keeping gauge at this point, bar engine or flywheel through one revolution measuring air gap as rotor turns. DO NOT PRY ON GENERATOR FAN. 21.Test engine-generator set alignment in accordance with engine manufacturer's recommendations and instructions, See Crankshaft Deflection Measurement and Flywheel Deflection Measurement, Section 5, Dandé, ‘22Measure generator rotor eccentricity as described in Section § in this manual. a ea generator rotor angular alignment as described in Section $ in this manual 24.Atter koupling and mounting is complete and measurements are satisfactory, inspect to make certain all bolts are tight and torqued (see Table 7-3). 2Be sure to remove all tools, shop cloths, and test equipment. 2 Bar engine generator set through one revolution. DO NOT PRY ON GENERATOR FAN. Stop immediately if any unusual noise or rubbing sound occurs. Z1.Install covers and guards before starting generator set. 2BWith cranking circuit operative but starting circuit disabled, turn engine-generator set through several revolutions, Stop immediately if any unusual noise or rubbing sound occurs, 22.Vibration test is recommended. This test is made with a portable vibration analyzer while generator set is running. Refer to maximum vibration specified by engine manufacturer.TABLE 7-4 DIMENSIONS OF FLYWHEELS-INCHES ey (SAE Standard for Flywheels for industrial Engines used for Drive-Ring Type Overcenter " Clutches and Engine Mounted Marine Gears- SAE-J620c) Nominal B c G a Tapped Holes Clutch see notes see notes (see note d) Diameter ab be No. Size 612 8.500 7.875 1.19 2.0472 6 | 56-18 72 9.500 8750 119 2.0872 a | sn6-18 8 10.375 9.625 2.44 2.4409 6 | 3-16 10 12.375 11.625 2.12 2.8346 a | set W120 13.875 13.125 1.56 2.8946 a | s16 4 18.375 17.250 1.00 3.1496 a | ve43 16 20.375 19.250 0.62 3.9370 a | vats 18 22.500 21.375 0.62 3.9370 6 | set 21 26.500 25.250 0 5.1181 12 | Set 24 28.875 27.250 0 5.1181 12 | 3/410 Note: 4 Diameter tolerance of driving-ring pilot bore B is plus 0.005, minus 0.000; maximum eccentricity is 0.005 total indicator reading (see footnote b); face runoutis 0.0005 maximum (;)) total indicator reading per inch of diameter. b. Eccentricity between driving-ring pilot bore B and pilot bearing bore L is not to exceed 0.008 total indicator reading. ©. Kis length of bore for pilot bearing; L is nominal diameter of bearing. Diameter and fit are to suit installation. Maximum eccentricity is 0.005 total indicator reading (see footnote b). d. Tapped holes should be threaded in accordance with UNC Class 2B tolerances of the SAE Standard, Screw Threads-SAE J475. TABLE 7-5 MINIMUM AIR GAP FOR KATO BRUSHLESS EXCITER Exciter Rotor (Armature) Minimum Air Gap Diameter (in inches) {in inches) 53/4 0.014 97/8 0.014 4121/2 0.018 16 1/4 0.035ENDBELL EXCITER Procedure FIELD Remove exciter rotor unit. Measure length EXCITER (dimension a) from bearing housing on FIELD —_endbell to end of shaft. BOLTS BEARING Note: Dimension (a) measured at factory is recorded in section 1 in this manual. BEARING HOUSING a GENERATOR HAE SHAFT EXTENSION (torexclter armature-rotating rectifier assembly) Figure 7-1 Extension of Generator Rotor Shaft for Mounting of Exciter Rotor Assembly (Outboard Exciter Generators) —————,__ Tapped Holes Equally Spaced Where: B= Driving Ring Pilot Bore Diameter C= Hole Centers G= Depth from flywheel Ave c housing face ee L= Pilot Bearing Bore k= Length of bore for pilot bearing ‘Note: G measured rom taceon flywheel housing with tapped holes See table 7-4 Flywheel Pilot Bearing Housing Flywheel Figure 7-2. SAE FlywheelDrive Y Adaptor Plates 2 \ : Generator Shaft s | w Where: S = Drive plate diameter W- Hole Center CA, | Y -Depth from drive plate to face on adaptor Note: Y measured to face on adaptdt with tapped holes Uw Drive plate diameter B’ equals flywheel driving-ring pilot bore Holes Equally Spaced diameter B so Figure 7-3 Single Bearing Generator Drive Plate and Adaptor RECOMMENDED PROCEDURE Torque bolts in sequence according to bolt _-$ Te _y ales direction around the bolt circle to ensure all bolts are properly torqued « 5 i 4 Figure 7-4 Recommended Torque Sequence For Circular Bolt Pattern.SECTION 1 INTRODUCTION AND DESCRIPTION 1 INTRODUCTION This manual contains instructions for installing, operating and maintaining Kato Brushless Revolving Field Genera- tors. Electrical connection drawings, dimensional drawings and Part listings for the specific model, type and serial number ‘of generator are usually contained as supplementary information in a separate excerpt of the generator manu- al. These drawings are the official source of information for making electrical connections or ordering replacement parts. 4.2. GENERAL DESCRIPTION 1.24 The Synchronous Alternating Current Genera- tors desoribed in this manual are of the brushless revoly- ing field type of single and two bearing construction. Single bearing generators are designed for direct coupling to a stationary prime mover and two bearing generators are desighed for gear, bell ‘or flexible coupling to a stationary prime mover. The generators are mariutactured in many sizes and ratings with various optional features such as enclosures, terminal boxes, bearing types, and Controls. Generator excitation current is supplied from a direct connected brushless rotating DC exciter. 1.2.2 The generators may be supplied with various controls designed to provide the user's exact power needs. Controls may be contained in separate wall mounted cubicles, in tree standing control cubicles, or in ‘a control box mounted to the generator frame depending upon the number and size of the controls required or the customers specitications. 1.23 Generators may be supplied with permanent magnet generators (PMG) to provide power to the regulator under short circuit conditions, or field flashing (in case generator or brushless exciter loses residual magne- tism) and to reduce electromagnetic interference. 1.2.4 Generators are supplied with a side mounted terminal box which is designed to accommodate the connections to the load. Specially buill oversized box can also accommodate various controls and protection devices such as the voltage regulator, surge suppressors, and current transformers. Auxiliary boxes are provided to ‘accommodate accessory connections to ATD's, space | \ Cols ra heaters, bearing vibration sensors, exciter and PMG leads. 4.3. CONSTRUCTION ‘The basic generator includes frame and stator, rotor, enclosures and brushless exciters with optional perma- ent magnet generator mounted on the shaft to provide Power to the voltage regulator. 1.3.1 The generator frame is fabricated of heavy stee! members welded to the endbell or bearing brackel pilot rings. The feet are welded to the frame to simplty installation and alignment with the primer mover. Eye bolts are fastened to the frame to enable illing of the generator with an overhead hoist. Steel wrapper cover ‘encloses the frame assembly 1.32 The generator stator core is built of laminated electrical grade steel. Laminations are secured under pressure and clamped to steel endrings. Windings are inserted into the stator slots and the entire assembly is vacuum pressure impregnated with 100 percent epoxy resin (see Figure 1-1), Stator leads terminate in standard connection lug or sirap copper terminals for ease of connection to the load (see Figure 1-2) Figure 1-1 Stator of Kato Revolving Field Synchronous Alternating Current Generator 1.3.3. The generator rotor consists of the shalt, spider, fans, field poles and windings (see Figure 1-3). 1.8.3.1 The shalt is machined from high strength sleel stock or forging. Mechanical center line is scribed on the drive end for units with floating bearings for proper alignment. On single bearings with forged flange holes are drilled to mate with the© SECTION 1 INTRODUCTION AND DESCRIPTION 4.1 INTRODUCTION This manual contains instructions for installing, operating and maintaining Kato Brushless Revolving Field Genera- tors. Electrical connection drawings, dimensional drawings and Par listings for the specitic model, type and serial number of generator are usually contained as supplementary information in a separate excerpt of the generator manu- al, These drawings are the official source of information for making electrical connections or ordering replacement parts. 1.2. GENERAL DESCRIPTION 1.2.1. The Synchronous Alternating Current Genera- tors desoribed in this manual are o! the brushless revolv- ing field type of single and two bearing construction Single bearing generators are designed for direct coupling to a stationary prime mover and two bearing generators are designed for gear, belt or flexible coupling to a stationary prime mover. The generators are manufactured in many sizes and ratings with various optional features such as enclosures, terminal boxes, bearing types, and controls. Generator excitation current is supplied from a direct connected brushless rotating OC exciter, 1.22 The generators may be supplied with various controls designed to provide the user's exact power needs. Controls may be contained in separate wall mounted cubicles, in free standing control cubicles, or in a control box mounted to the generator frame depending upon the number and size of the controls required or the customer's specifications. 1.2.3. Generators may be supplied with permanent Magnet generators (PMG) to provide power to the regulator under short circuit conditions, or field flashing (in case generator or brushless exciter loses residual magne- tism) and to reduce electromagnetic interference. 1.2.4 Generators are supplied with a side mounted terminal box which is designed to accommodate the connections to the load. Specially built oversized box can also accommodate various controls and protection devices such as the voltage regulator, surge suppressors, and current transtormers. Auxillary boxes are provided to ‘accommodate accessory connections to RTD's, space heaters, bearing vibration sensors, exciter and PMS leads, 1.3 CONSTRUCTION ‘The basic generator includes frame and stator, rotor, enclosures and brushless excilers with optional perma- ent magnet generator mounted on the shatt to provide power fo the voltage regulator. 1.3.1. The generator frame is fabricated of heavy steel members welded to the endbell or bearing bracket pilot Tings, The feet ate welded 10 the frame to simply installation and alignment with the primer mover. Eye bolts are fastened to the frame to enable Iilling of the generator with an ovethead hoist. Steel wrapper cover encloses the frame assembly. 1.3.2 The generator stator core is built of laminated electrical grade steel. Laminations are secured under pressure and clamped to steel endrings. Windings are, inserted into the stator slots and the entire assembly is vacuum pressure impregnated with 100 percent epoxy resin (see Figure 1-1). Stator leads terminate in standarc. connection lug or strap copper terminals for ease of connection to the load (see Figure 1-2). Figure 1-1 Stator of Kato Revolving Field Synchronous Alternating Current Generator 1.3.3 The generator rotor consists of the shall, spider, tans, field poles and windings (see Figure 1-3) 1.3.3.1 The shalt is machined from high strength steel slock or forging. Mechanical center tine is sorbed on the drive end for units with floating bearings for proper alignment. On single bearinge with forged flange holes are drilled to mate with the© Figure 1-5 Exelter Stator and Windings 1.3.43 The exciter stator is built of laminations stacked under pressure and welded. Field windings are inserted and the entire assembly is vacuum pressure impregnated with 100 percent epoxy resin, The stator is mounted on the bearing bracket (endb_ all) 1.3.5 Permanent Magnet Generator (Optional) ‘The permanent magnet generator (PMG) provides ower to the voltage regulator under all operating condi- tions regardless of the main generator output conditions. The PMG is a single phase AC generator with rotating Permanent magnets providing excitation. For detailed description and operating instructions refer to Publication 950-01003-00 “Kato Pilot Exciters." The block diagram, Figure 1-8, illustrates the operation of the brushless excitation system. 1.3.6 — Enclosures ‘Steel wrappers enclose the generator ramo. A removable sheet metal covers the entire exciter assembly. Ambient air is drawn into the machine through openings at the exoiter end and exhausted through screened openings enclosing the blower assembly. Enclosures can be open dripproof, splash proof, and filered construction. 13.7 Bearings Heavy duty "greased for life" double shiold bearings are Used on small generators less than 75 Kw. On large machines bearings are of “regreasable” design. The bearing housings are provided with grease fill and drain Ports for easy lubrication (see Figures 1-6 and 1-7), Roller bearings and sleeve bearings are also incorporated on special designs and applications. A supplementary instruction manual is included for these bearings HeaVY DUTY DOUALE sHIELOCO BALL Beanias fale kenp gtoose in — dit and moisture ‘eare durng life of beating ‘Typical "Shielded" Bearing and Bearing Housing Construction GREASE FITTING installed at factory DEARING SHIELD Korps grease i GREASE RESERVOIR holds large reser of grease GREASE RELIEF slong the shaft automatically RELIEF VALVE ditional telit of oxcesive grease: protety beating Seo! from high renee gun, pressure Figure 1-7 Typical "Regreasable” Bearing and Bearing Housing ConstructionROTATING ON COMMON SHAFT (STATIONARY)} | ROTOR | |ISTATIONARYI} | ARMATURE] FIELD ISTATIONARY) PMG PERMANENT) | EXCITER ROTATING] [ALTERNATOR] | ALTERNATOR STATOR, MAGNET FIELD EXCITER fe] REVOLVING STATOR, "REGULATOR POWER [yoy Tage VOLTAGE SENSING REGULATOR Figure 1-8 Block Diagram, Typical Brushless Generator - Voltage Regulator System€) SECTION 2 INSTALLATION 24 RECEIVING INSPECTION ‘Two-bearing generators are shipped completely assem- bled. Single bearing units are shipped with brushless exciter armature and rectifier assembly removed from the shaft. NOTE: Prior to accepting shipment from the transporta- tion company, examine crating for any damage which might have occurred during transit, Report any evidence of crating damage to transportation company claims ottice and Kato Engineering. lithe generator is received during cold weather, allow the rated unit to reach room temperature before removing the protective packing material. This will reduce the condensation of moisture on cold surtaces and prevent early fallures due to wet windings and insulating materi- als, 2.2 UNPACKING AND STORAGE 2.2.1 Moving Generator Unpack the equipment with care to avoid scratching painted surfaces. Move the unit to the mounting location either by attaching an overhead hoist 1o the eye bolls installed on the generator frame or by liting the generator form undemeath the skid with a forklift. Hoist and hoist cables should have a rating of not less than 1-1/2 times the weight of the generator. When moving unit with a forklift, make certain it is completely onto and balanced on the forklift tines. WARNING Apply lifting force to structural points specitically provided for that purpose. DO NOT USE enclosure lifting holes to lift the whole unit. Use lifting means adequate for the weight. Failure to observe these Instructions can result in injuries to personnel and damage to the generator. 2.2.2 Rotor Support All single bearing generators are shipped from factory with rotor shipping support blocking bolted across the drive discs and adaptor. Before transporting any genera- tor, the main rotor must be supported by the adaptor using an appropriate fixture. CAUTION Do not attempt to transport any single bearing generator without proper rotor support. Failure to ob- serve this precaution can result In exterisive equi ment damage. Make certain exciter rotor is removed while handling generator. 223 © Storage 2.2.3.1, Short Term Storage I the generator is not to be installed in its operating location immediately, it is recommended that it be stored in a clean dry area not affected by rapid changes in temperature and humidity. I space heaters are supplied, they should be energized to keep condensation trom the windings, All accessory equipment supplied with the unit should be stored with the generator, and the combined unit covered with durable cover for protection against dust, dir, moisture and other airborne contaminants. 2.2.3.2. Long Tem Storage Units which are to be in storage for a period longer than six months should be prepared for storage as follows: a. Inslall desiccant bags in the exciter cover and inside the fan screen. b. Vacuum seal the unit in a covering of plastic or other material designed for that purpose. c. Adequately tag the generator to insure thal preservative greases and desiccant bags are removed before the unit is placed in operation, 224 — Bearing Inspection Grease used in ball bearing generators is subject to time deterioration. If the generator is stored for one year or longer, it is recommended that new ball bearings be installed and greased to the proper level betore puting into operation. f inspection indicates that bearings are free of rust or corrosion,, and no noise or excessive vibration appear on start-up, replacement is not neces: sary. 23 LOCATION ‘The location of the generator must comply with all local and special industrial regulations. Attempt to locate the generator in clean, dry, well ventilaled area, easily accessible for inspection and maintenance. Air inlet and discharge openings must not be obstructed to the flow ofaccessible for inspection and maintenance. Air inlet and discharge openings must not be obstructed to the tlow of coolant air. If the location is subject to harsh environmen- tal conditions, the generator can be field modified to incorporate dust filters and space heaters. In addition itis recommended that a more rigid periodic maintenance be established. 2.4 ASSEMBLY TO PRIME MOVER 2.4.1. Assembling Single Bearing Generator to Prime Mover ‘See Figure 2-1 for typical method of coupling single bearing generator to prime mover. The generator and prime mover should be mounted on a rigid level base ‘The following steps describe the assembly work: 2.4.1.2 Before assembling generator to the prime + mover, check to make certain generator bearing and clearance is sullicient. GENERATOR BEARING END CLEARANCE SHOULD NOT BE LESS THAN TOTAL ENGINE CRANKSHAFT AXIAL MOVEMENT PLUS 1/16 INCH. NOTE: Generator shipped from lactory with approximately 1/8 inch minimum bearing end clearance. Figure 2-1 ‘Typical Single Bearing Generator-Engine Coupling 2.4.1.1 Belore assembling generator to prime mover, remove exciter cover and adaptor cover or screen. Remove blocking holding the drive discs to the adaptor. NOTE: If exciler armature and rotating rectitier assembly was not installed (shipped as loose equip- ment), do not install it until the generator has been assembled to the prime mover. ree t Figure 2-2 Extension of Generator Rotor Shaft for Mounting of Exciter Rotor Assembly (Outboard Exciter Genera- tors) Before allempting to mount the generator to the engine, measure the distance trom the end of the exciter shafl extension to the bearing housing on the endbell as shown on Figure 2-2. This dimension is recorded on Section P-1 of the Assembly Manual. It the dimensions do not match, move the rotor axially relative to the stator until dimensions are identical 2.4.1.3 Check the run-out of the prime mover fly- wheel and flywheel housing (bell housing) with a dial indicator as shown in Figures 2-3 and 2-4. TOTAL INDICATOR READING SHOULD NOT EXCEED (003 INCH PER EACH FOOT OF DIAMETER OF FLYWHEEL AND BELL HOUSING, SEE TABLE 2-1 It reading exceeds the allowable limit, excessive vibration couki result. Contact the prime mover. manufacturer for recommendations.a) wy TABLE 2-1 Allowable Flywheel & Drive Disc Recess Run-out FLYWHEEL DRIVE DISC RECESS Pot Hominal Allowable Runout ha Gluten Dia, | (otal indicator Reading) en 500 002 ™ 9.500 02 @ 375 002 10 12375, 003 ne 19.75 003 14 18.375 cou 16 20375 005, 8 22.800 ‘00s a 26.500 ‘08 26 26.075 ‘oo? FLYWHEEL HOUSING SAE Housing | Housing Allowable Runout Number | inside ofa. | (rota indleator Aes 6 10500 ong 5 12975 03 4 v4.20 003 2 16.128 004 2 17625 04 1 20.125 005 ” 23.000 008 ° 25.500 08 00 31.000 (00? FLYWHEEL HOUSING iat eee Imoicaron. POINTER CHECK OF RADIAL RUNOUT iat INDICATOR, POINTER CHECK OF Face ‘RUNOUT Figure 2-3 Checking Flywheel Run-out Figure 2-4 Checking Engine Flywheel! Housing Run-out 2.4.1.4 Measure the axial distance from the surface fon the generator adapior that bolts 10 the prime ‘mover flywheel housing to the outside surface on the drive disc coupling plates (Dimension "Y" Figure 2- 5), ‘Also measure the axial distance from the machined surface on the prime mover flywheel housing to the bottom of the drive dise recess in the flywheel (Dimension "G* Figure 2-6). Contact factory it difer ence in dimensions "G" in Figure 2-6 and *Y" in Figure 2-5 exceed 1/32 inch. I"G" is more than "Y" install additional spacers between drive dises and generator drive hub. W "Y" is more than “G’, remove spacers located between the drive discs and genera tor drive hub (see Figure 2-7). 2.4.1.5 Make certain drive discs “seat” in the drive disc recess of flywheel CAUTION Never grind OD of drive discs or attempt to “atill out” holes in drive discs. If drive discs do not fit properly, order new discs or flywheel after carefully checking the dimensions of both parts. 2.4.1.6 Use lock-washers on all bolls used to secure the generator to engine and base. Use recommend- ed torque values for each type of cap screws given in Table 2-2. 1f the bolts that secure the drive discs to the flywheel cannot be installed due to insutficient clearance between fan and drive disks, it may be necessary to loosen and move fanAdaptor = Gonerator Shalt Y= Depth From Drive Plate 10 Face on Adapter NOTE: YY measured to face on adaptor with tapped he U Drive plate diamotar S equals Hlywheet drivinging pllot bore diameter 8 + .000, ~ .008 Holes Equally Spaced Figure 2. j Single Bearing Generator Drive Plate and Adaptor _— Tapped Holos Equally Spa Driving Ring Pilot Bore Diam: = Hole Centers 8 Depth From Flywheel Housing Face lot Beating Bore Length 0! Bore For Pilot Bearing Note: {G measurad from face on tlywheo! housing with tapped holes Figure 2-6 SAE Flywheel 8LOCK WASHER SPACER Table 2-2 Recommended Torque SAE 5 Steel and SAE 8 Steel Cap Screws Recommended Torque (in foot pounds) ‘Shank Diameter AS.T.M, A449 (in Inches) S.A.E. 5 Steel S.A.E. 8 Steel 14 9 13 5/16 18 28 318 3 46 716 50 75 2 75 115 96 110 165 518 150 228 314 250 370 78 378 591 1 583 893 1118 7e2 1410 114 1097 1964 1318 1461 2633 1412 1748 3150 NOTE: Mako certain bolts {40 not bottom out in flywheel HEX HEAD BOLT NOTE: Use spacers only should Insullicient clearance nat permit tightening nex head bolts, v GENERATOR Drive HUB J DRIVE PLATE FLYWHEEL © Lbsijod Nim IAL INDICATOR CLAMPED TO J KoabrER WITH TIP ON HUB ‘on shart ADAPTER Fania Figure 2-7 Typical Drive Disk to Flywheel installation Figure 2-8 Checking Generator Shaft Run-outCAUTION It tan is moved, make certain that before generator set is placed In operation, fan is positioned with about 1/2 inch clearance between fan and battle and all fan bolts are installed and tightened. NOTE: Check to make ceratin bolts do not bottom out in flywheel. I bolts are too long or cannot be tightened with socket or box wrench, use 1/4 to 3/8 inch long spacers inserted on the bolts as shown in Figure 2-7 to increase the clearance between the bolt head and the flywheel 2.4.1.7 Belore installing the tan screen, check run- out of the generator shaft. Check run-out by placing the base of the dial indicator on the generator frame rip end positioning the indicator finger on the shaft as shown in Figure 2-8. Total shaft run-out should. not exceed .003 inch. If this figure is exceeded, remove drive disc bolls and rotate generator relative to the engine flywheel. Reinstall bolts and check run- out again. 2.4.1.8 Make sure generator mounting pads contact, the base evenly and with equal pressure. Use shims it necessary. Recheck shatl end to endbell distance (Dimension “a” in Figure 2-2). 2.4.1.9 Mount the brushless exciter armature and rotating rectifier assembly to the generator shalt. The exciter rotor unit is held in place on the shalt by a key in the shaft and a bolt and washer at the end of the shalt. Install key in the machined keyway on the generator shait. Align exciter rotor unit with key and push the exciter rotor unit onto the shaft. install washer and retaining bolt. Torque bolt with 1/2 inch shank diameter 60 ft-lbs, 3/4 inch shank diameter bolt 200 ft-lbs. See Figure 2-9 and 2-10. DO NOT APPLY FORCE TO THE ROTATING ASSEMBLY OR EXCITER ARMATURE WINDING. Inspect the clearance between stationary and rotat- ing parts. Connect positive (+) and negative (-) leads from generator field onto positive (+) and negative (-) terminals located on the aluminum heat sinks of rotating rectifier assembly. 2.4.1.10 Tur engine several revolutions. Use a crank of barring device but do not pry on the fan 10 Visually inspect clearance between generator sta- tionary and rotating parts. Listen for unusual noises such as produced by parts rubbing together.FIGURE 29 PROCEDURES FOR REMOVING AND INSTALLING AN OUTBOARD WARNING Make certain generator is stopped. Wear gloves to protect fingers socx a t, Bg AEH cenenaron niet Se REMOVAL 1. Remove exciter cover. 2. Remove telsining bolt and washer 3 Disconnact (+) and (—) generator Fela wires al (+) and {-—) terminals on rotating rec: tifier assembly heat sinks. 4 Slowly pull exciter armature rotating rectitier assembly, as a unit, olf ef he generator Shall. Make certain generator lield wites are flat in wireway In generator shalt and ase fal accidently torn when exciter Is pulled CAUTION: Do not pull on edges of hoat sinks oF on exeiter armature windings, NOTE: If exciter armature will not pull trom ganerator shalt by hand force, 1 Generator instruction manual for proper Installation of mechanical pullers 5, Remove key from keyway in generator shaft INSTALLATION 1. Clean inside of dxciter sieeve and outside of generator shalt 2. Place key in the keyway in generator shall 3. Lay generator field wires Nat in wireway in generator shaft with wire ends protruding ‘981 the end of the generator shalt 4, Position the exciter armature rotating recilier asgembiy in ine with generator shalt and urn assembly to position where Keyway in the axciter sleeve fs in fine with the key in genorator shatt 8. Using hand tora, push the exciter a generator shatt NOTE: Final position Is with end of excitor sleeve against shoulder on gonerator shalt. It ‘may be necessary to tap lightly on end of exciter slaeve in order ta move the assembly over the key, Use a liber or rubber mallet, 6 Connect { +) and (~) generator fiold wires onto (+) and (—) terminals on heal sinks, 7 Install retaining washer and bolt. Make certain generator lead wiles are through si01 in washer 8. Torque the retaining bolt. Recommended torque is 60 foatIpounds for V2 inch diameter boltand 200 foot/pounds for % Inch diameter bolt 9. Use a feeler gauge to measure air gap between exciter armature and exciter fold 10.1 alr gap Is loss than recommended minimum check the following (1) check generator {0 engine alignment; (2)! unit has been in operation, check for exeassiva bearing wear, (9) if generator nas boon taken apart and reassembled, check endball and excite field for loose mounting bolts and misalignment. ‘install excitar cover when alr gap is salistactory ature rotating rectifier assembly over the \ | ney snr moe AUXILIARY VIEW A.A ENO VIEW OF EXCITER ARMATURE SLEEVE ? OR ronmetanne eoct a AUXILIARY VIEW 8-8 CUTAWAY OF GENERATOR SHAFT — EXCITER END OF UNIT 1 1 1 1 I, 47 ~snowoen ron i 1 1 1 1 1 (Minimum) Minimum Ale Gap jouinenca (in inches) sa cou | a8 or 1202 cow | 16 14 0.035, "oO 2.8.2 Assembling Two Bearing Generator to Primer Mover 2.4.2.1 Install shims if necessary to properly level and align the generator to the primer mover. 2.4.2.2 Install coupling hubs on generator and drive shafts in accordance with the installation procedures, specified by the coupling manufacturer. Check for angular and parallel alignment as shown in Figure 2- 11 using dial indicator. 2.4.2.3 To check for parallel shaft (run-out) mis- alignment, bolt the indicator to one of the coupling halves and scribe the position of the dial button on the opposite coupling half. Rotate both shafls simul- taneously, keeping the finger or button of the indica- tor at the reterence mark on the coupling hub. Note the reading on the indicator dial at each one quarter revolution. A variation of readings at different posi- tions will indicate how the machine should be adjust- ed to obtain maximum misalign- ment of 002 inch. Place or remove slotted shims trom under engine or generator mounting pads until properly aligned. 2.4.2.4 To check to angular misalignment, fasten the dial indicator to one half of the coupling hub and a reference surface fastened to the otter coupling hail. Scribe the location of the dial button on the reler: ence surface and take all readings with the indica {ors al this position. Rotate both shalis simultaneous: ly, note the reading at each quarter revolution, ANGULAR MISALIGNMENT OF THE SHAFTS MUST NOT EXCEED .001 INCH FOR EACH INCH OF RADIUS OF THE COUPLING HUB, TOTAL INDICATOR READ- ING. 2.4.2.5 Tighten the mounting bolts and recheck alignment. It alignment is within the above tolerance, check coupling manufacturer's recommendation for lubrication and bolting information, THICKNESS GAUGE ROUGH ALIGNMENT ANGULAR ALIGNMENT DIAL INDICATOR DIALINDICATOR Figure 2-11 Testing Coupling Alignment 132.5 BELT DRIVES - GENERAL INFORMATION Proper alignment and tightness of belt drives is essential. Improper alignment and belt tightness will increase belt wear as well as increase bearing loads and vibration. Select belt drive in accordance with belt manutacturer’s, specifications. Make certain generator and prirhe mover are rigidly mounted. In general, belt drives aro not recommended when belt speed exceeds 5000 feet per minute. 26 V-BELT 2.6.1 Use only matched belt sets and avoid minimum pitch sheaves and belts. Follow the manulacturer’s specifications or NEMA limits for sheave pitch. 2.6.2 — Make certain the shaft axis of the prime mover and generator are paralleled. Belts must enter and leave sheaves with no side bending, Tighten just enough to prevent slippage at full load. Never grease or use bell dressing on belts. 27 FLAT BELT Selection of belts and pulleys of ample width will reduce amount of tension required to prevent slippage at full load. Lower belt tension reduces bearing loads and belt wear. 2.8 GEAR BELTS (TIMING BELTS) in general, installation of gear-belts will be the same as, {or flat belts. The following, precautions should be taken when installing a gear-belt drive. 281 — Gear-belis should be installed with snug fit, neither too tight not too loose. High initial tension is not necessary but when torque is unusually high a loose belt may “jump grooves." If the belt “jumps the grooves," the tension should be increased gradually until satistactory operation is attained. 2.8.2 Be sure that shafts are parallel and pulleys are in alignment. On a long canter drive, because of the tendency of the belt to run against one flange, it is sometimes advisable to offset the driven pulley to com- pensate. 2.8.3 Ona long center drive it is imperative that belt ‘sag is not enough to permit teeth on the slack side to ‘engage the teeth at the tight side. 4 2.8.4 Il is important that both prime mover .anc generator are mounted rigidly to prevent variation in bel tension, 2.8.5 Although belt tension requires litle attentior alter initial installation, provision should be made for some center disiance adjustment to ease in installing anc removing belt. Do not force belt over flange of pulley. 2.9 GEAR AND FLEXIBLE COUPLINGS + GENERAL INFORMATION When drives of these types are used instead of bel drives the prime mover and generator shalts must be carefully aligned and following alignment, the set must be firmly mounted to a rigid base to prevent misalignment o the unit shafts during operation, Excessive misalignmen may be the cause of vibration, noisy operation, ev >ssive coupling of gear wear or premature bearing failu. 240. GEAR DRIVE 2.101 Accurate alignment and rigid mounting are essential for salistactory operation with gear drives. Pit diameter and width should not be outside recommeridec NEMA limits and AGME Standards. Avoid coupling whic will impose excessive thrust on bearings 2.10.2 Check tor backlash through al least one revolu tion of shaft. Backlash at tightest point should be ii accordance with AGME Standards. Avoid engagement o teeth so deep that they will bind or deflect, 241 INSTALLATION AND ALIGNMENT OF FLEXIBLE COUPLED DRIVES 2.11.1 The procedures outlined are for alignin abl coupled drives. Follow the tolerances specified by th coupling manulacturer when less than described in thi manual. 2.41.2 Install coupling hubs on generator and div shafts in accordance with the installation procedure supplied by the manulacturer of the coupling. Then chec for angular misalignment by scribing a reference mark o the coupling hub at the bution or finger of the indicator t mark its position on the hub, Rotale both shatts simulta neously, keeping the finger or button of the indicator z the reference marks on the coupling hub. Note th reading on the indicator dial at each one-quarter revolu tion. Refer to Figure 2-11 for test setup.oO ANGULAR MISALIGNMENT OF THE SHAFTS MUST NOT EXCEED .001 INCH FOR EACH INCH OF RADIUS OF THE COUPLING HUB, TOTAL INDICATOR READ- ING. 2.11.3 If angular misalignment is excessive, loosen set mounting bolts and place slotted shims under mounting pads, as necessary, to correct alignment. Re-check alignment. Install or remove shims from under the mount- ing pads until aligned. 2.11.4 Check for parallel shaft (run-out) alignment by soribing a reference mark on the ground or machine diameter of the coupling hub al the finger or button of the indicator. Rotate both shafts simultaneously, keeping the button or finger of the indicator at the reference mark on the hub. Note the reading on the indicator dial at each one-quarter revolution. Refer to Figure 2-11 for test setup. TOTAL RUN-OUT BETWEEN HUBS SHOULD NOT EXCEED .002 OF AN INCH. 2.11.5 When run-out between hubs is excessive, instal or remove shims from under each of the prime mover or ‘generator mounting pads; then re-check alignment. Add ‘or remove shims until shatts are parallel. Tighten the set mounting bolts following angular and run-out alignment Check base mounting bolts for tightness. Re-check alignment betore installing coupling 2.42 FLYWHEEL AND TWIN DISC CLUTCH OR OTHER FLEXIBLE COUPLING A flywheel and twin disc clutch coupling provides a satisfactory coupling for motor-generator sets operating with shaft speeds not in excess of 3760 RPM. The coupling should be parallel between the spider and the tings. Align within .03 inch total indicator reading between spider and ring by installing or removing shims, as necessary, from under motor or generator mounting pads (see Figure 2-12) 243 VIBRATION After alignment of prime mover to generator has been ‘completed, run unit at no load and check for excessive vibration. If vibration is excessive loosen one mounting bolt slightly and i vibration decreases, add shims until lightening of bolt reduces or eliminates vibration. Repeat in turn for all mounting bolts. 15 NOTE Vibration of direct coupled engine driven generators may be due to Improper Installation of generator to engine. it excessive vibration of engine driven gener- ator Is nole, review the Installation procedure. 2.14 — DOWELING : Doweling generator sets will prevent movement of the units during operation should the mounting bolts loosen slightly. Install dowels as follows. RUBBER BLOCK Figure 2-12 Checking Alignment of Twin Disc Coupling 2.14.1. Check the alignment alter the generator set has been in operation about 40 hours. Correct alignment if not salistactory (refer 1o preceding paragraphs) 2.14.2 Through opposite generator pads dill holes through and into the base. Holes should have a diameter slightly smaller than the dowel pin. 2.14.3 Ream the holes to the proper diameter for the pints, clean out chips and then install pins 214.4 Repeat procedure for doweling of prime mover according to instructions supplied by the primer mover manufacturer.2.15 ELECTRICAL MEASUREMENTS AND CONNECTIONS In the event the generator was subjected to rapid chang- es in temperature or freezing or wet climate during shipment or storage, itis recommended thal the insulation resistance of each winding be measure. CAUTION ‘These tests should be conducted before any power and control connections are made. 2.15.4 Exciter Field 2.1.1.1 Disconnect the exciter leads from the terminals in the terminal box. 2.1.1.2 Conneet exciter leads to one clamp of 500 volt megger and connect the other clamp to the generator frame. 2.15.1.3 Apply 500 volts from the megger and mea- sure the resistance reading alter one minute. The minimum reading should be 1.0 megohm. If not, refer to dry out procedures. 2.15.1.4 Short the exciter field leads to the generator frame for several minutes after the megger has been disconnected. This will allow the voltage build up to be properly discharged. 2.15.2 Exciter Armature 2.45.2.1 Disconnect the exciter armature leads from the rotating rectifiers. Disconnect the generator field leads from the positive and negative rectifier heat sinks. 2.15.2.2 Never apply megger to rotating reciifiers. Connect the leads of exciter armature to one clamp of a 500 volt megger and connect the other clamp to suitable connection on the shaft. 2.15.2.3 Record the megohm reading alter one minute of applying 500 volts. 2.15.2.4 One minute reading must be a minimum of 1 megohim. If not, refer to dry out procedures. 2.15.2.5 Ground the exciter leads to the shall alter disconnecting the’ megger. 16 2.15.3 Generator Rolor Winding 2.15.3.4 Connect the positive and negative leads to one clamp of the 500 volt mogger and connect the other clamp to the shat 2.15.3.2 Record the megohm reading after one minute of applying 500 volts. 2.15.3.3 One minute reading must be a minimum of 1 megohrm. If not, reter to dry out procedures. 2.15.3.4 Ground the field leads to the shalt after disconnecting the megger. 245.4 Generator Stator 2.15.4.1 Disconnect power connections, it any, ar all control apparatus from the generator terminals. 2.15.4.2 Measure insulation resistance of each phase separately with the wo phases shorted to the frame. 2.18.4.3 Use a 500 voll megger connected between the lead of the phase to be measured and generator frame. The minimum one minute insulation resis- tance (corrected to 40 degrees centigrade) should not be less than that given by the following formula: Resistance in megohms = __ Rated generator voltage 1000 +t ess than above, refer to dry oul procedure. 2.15.4.4 Ground the leads to the frame alter the 0, minute megger test. NOTE: The insulation resistance value increases with decreasing winding temperatures. All readings must be relerenced to winding temperatures. Use Figure 2-13 for converting megger readings to other temperatures. 2.15.5 Drying Methods Ii the insulation resistance readings are below the recom- mended minimum values speciied previously, use one of dry out methods described below. The method selected should be based on the size and location of the unit, and available equipment with experi- enced personnelFigure 2-13, Chart for Converting Megger Readings to 40 Degrees Centigrade Remove voltage regulator and cover all inlet and dis- charge openings. Provide an opening at the top of the machine, preferably at the fan end, for moisture to evaporate. Monitor winding temperatures. DO NOT APPLY HEAT TOO RAPIDLY. Winding temperature should be raised gradually at a rate of 10 degrees centigrade per hour up to 93 degrees centigrade (200, degrees fahrenheit). Measure insulation resistance at one hour intervals. Typically the insulation resistance will slowly drop while the temperature is coming up, and then gradually increase and level otf 2.16.6 All electrical connections to the generator must be made in accordance with local regulations and Nation- al Electrical code requirements. Check wiring the connec- tion diagram provided with the generator. The main terminals should be properly spaced for the load connec: tions. Refer to Table 2-2 for proper torque values for the connections. Grounding lug has been provided tor 7 properly grounding the system to the generator frame. Grounding wire should be the same size as the main leads. 2.15.7 Alter all wiring is complete, perform the follow: ing checks. 2.15.7.1 Double check all interconnections against the connection diagrams furnished. 2.15,7.2 Remove all tools and shop cloths trom the vicinity of the operating equipment 2.15.7.3 Secure all covers and guards in place. 2.15.7.4 Tum rotor slowly with appropriate starting mechanism (bar engine or flywheel) through one revolution to see that the rotor tums freely. DO NOT PRY ON GENERATOR FAN 2.15.7.5 Check bearings for the proper lubrication 2.15.7.6 Determine the direction of the engine rotation and verily with the rotation arrows provided ‘on the generator. 2.15.7.7 Voltage, frequency and phase sequence of power line must agree with the data on generator and control nameplates or connection diagrams. 246 PROTECTIVE DEVICES 2.16.1 Engine driven sets must be protected with adequate engine governors and protection against excessive overspeed. Refer to National Electrical Code and local electrical codes for minimum electrical require ments for the gonorator set. 2.16.2 The output to the load of the generator should always be protecled with an overload protection device such as a circult breaker or fuses. Fuses should be sized using the lowest possible current rating above the full load current rating. 115 percent of raled current is commonly recommended. Size tuses or circuit breaker in accordance with National Electrical Code and Local Electrical Codes.SECTION 3 OPERATION 34 IDLING Permanent equipment damage can be caused by having the generator set in operating mode while idling the engine. If engine adjustments require that the engine be run at idle speed, the generator set regulating system should be made inoperative by one of the methods that follow. 3.1.1 Where generator set is provided with voltage shutdown switch, be sure switch is set to IDLE position while engine is running at idle speed. 9.1.2 Where generator set is equipped with field circuit breakers, be sute the circuit breaker is set to OFF while engine is running at idle speed. 3.4.9 Where generator set includes an automat: ic/manual control with switch that has OFF position, be sure switch is set to OFF while engine is running at idle speed. 3.1.4 Where generator set does not include switches described above, remove wites trom voltage regulator input terminals during under speed operation of the generator set. 3.1.8 Check for vibration. If excessive, loosen one foot mounting bolt slightly and it vibration decreases, add shims until tightening of the bolt reduces the vibration level. Repeat in turn for all mounting bolts. if vibration levels remain above the allowable limits, recheck the alignment steps outlined in Section 2. 3.2 INITIAL START-UP WITH BOTH AUTO MAN- UAL AND AUTOMATIC VOLTAGE CONTROL 3.1.1 Generator output must be disconnected from load. Main circuit breaker is open. 3.1.2 Tum voltage adjust rheostat to full counter- clockwise. 3.1.3 Actuate aulo-manual switch to MANUAL posi- tion 3.1.4 Start the primer mover and bring the set 0 raled speed. Turn manual voltage adjust rheostat to reach raled voltage. Close output circuit breaker and 18 apply load in steps until rated load is reached. Adjust” | manual adjust rheostat as necessary to obtain desired oulput voltage. 3.2.5 Stop unit. This is accomplished by opening the circuit breaker to remove the load. Then stopping the prime mover in accordance with prime mover manufactur er’s specilications. 3.2.6 Actuate aulo voltage rheostal. Then start engine-generator set and bring to rated speed. Adjust voltage to desired value. 32.7 Close output circuit breaker. generator vollage and voltage regulation Then check 3.2.8 Check for vibration levels at no load and rated oad. A slight increase in vibration level from no load full oad Is normal. As the load is maintained for 2-3 hours the vibration levels will gradually increase and reach a final level. CAUTION Do not actuate auto manual switch with full load. applied to generator. Whenever possible, stop the generator prior to switching. 3.3. INITIAL START-UP PROCEDURES: FOR GENERATORS WITH AUTOMATIC VOLTAGE CONTROL NOTE: Unit will have automatic voltage regulator but will not have auto-manual switch, 3.3.1 Generator output must be disconnected {rom load. Main circuit breaker is open 3.3.2 Turnauto-vollage adjust rheostatto full counter clockwise position. 3.3.3 _Slart the prime mover and bring the set to rated speed. Turn voltage adjust rheostat to obtain desired voltage 3.3.4 Close output circuit breaker and apply load in ‘gradual steps unl he rated load is reached. Note voltage regulation with changes in load steps. 3.3.5 Check for vibration levels at no load and rated load. A slight increase in vibration level from no load to {ull oad is normal. As the load is maintained for 2-3 hours the vibration levels will gradually increase and reach a final level© 34 FIELD FLASHING ‘The voltage regulator relies on residual voltage to start the generator action which in turn generates the rated voltage. It the generator fails to generate voltage alter it has come up to rated speed, it may be necessary to flash the exciter field. Field flashing must be done while the generator is at a standstill as described in the procedure that follows. 3.4.1 Open the output circuit breaker and stop the engine. CAUTION Be sure to maintain polarity (+) to (F+) and (-) to (F-). 3.4.2 Connect the negative lead (-) from a common 12 volt storage battery onto exciter field lead F- 3.4.3 Connect the positive lead (+) from the battery ‘onto exciter field lead F+. Only a few seconds flashing should be necessary. 3.4.4 Remove battery and connect exciter field leads ‘onto voltage regulator terminals F+ and F-. Be sure to maintain correct polarity. 3.45 "Start generator and check for satistactory voltage build up. 35 PARALLEL OPERATION 3.5.1 For the generator to operate in parallel with a system in operation the phase sequence of the generator must be the same as the system. Phase sequence check can be made by a phase rotation meter or incandescent lamp methods described in electrical machinery hand- books. 3.5.2 The output voltage at the paralleling point must be the same at each instant which requires that two voltages be of the same frequency, same magnitude and same rotation, and must be in coincidence with each other. ‘Voltmeters indicate whether the voltage magnitude is the same and frequency meters indicate whether the frequen cies are the same. Whether the voltages are in phase ‘and exactly at the same frequency is indicated by a synchroscope or by synchronizing lamps. A.synchroscope can be ulllized to indicate the difference in phase angle between incoming machine and the system. If not provided with the set, generator can be 19 paralleled by using incandescent lamps connected as shown in Figure 3-1. The voltage rating of series lamps ‘must equal the voltage rating of the generator. | ssystom Bus Lone | tarp Load Lines From incoming Generator | Figure 3-1 Synchronizing Paralloled Generators with Test Lamps 3.5.3 Each prime mover in the system must have the same speed regulating characteristics, and the governors must be adjusted to give the same speed regulation by applying load thal is proportional to full oad rating of the generator. 35.4 Voltage regulator must include paralleling circuitry 3.5.5 Paralleling current transformers must give the same secondary current. 3.5.6 Current transformer secondary winding provides Teactive KVA droop signal to the voltage regulator. ‘Accidental reversal of this electrical wiring will cause the voltage to rise rather than droop. If this occurs during paralleling, stop the unit and reverse the wires at the voltage regulator terminals. 3.5.7 Il sel is provided with unitiparaltel switch, set switch 10 PARALLEL position on the unit being syn: chronized, 3.5.8 Synchronize the generator by adjusting speed (frequency) slightly higher than the system. Observe the synchroscope or the lamps. The lamps should fluctuatefrom bright to dark at the rate of one cycle every 2 to 3 ‘seconds. When the generator is in phase the lights will be dark, close the circuit breaker. Immediately atter closing the breaker measure the line current, Kw and kVAR of the generator. The readings should be within the rating of the unit. 3.5.8.1 A high ammeter reading accompanied by a large Kw reading indicates faully governor control. 3.5.82 A high ammeter reading accompanied by 2 large KVAR unbalance indicates problems with voltage regulator. Adjustments of the cross current or voltage droop rheostat should improve the phas- ing of kVAR, 359 To shut down the generator operating in parallel, gradually reduce the KW load by turning the governor switch to reduced speed. When kW load and line current approach zero, open the generator circuit breaker. Close unitiparallel switch (it generator is so equipped). Operate the generator unloaded for several minutes 10 dissipate the heat in the winding. Refer,to prime mover manual for shut down and cool down procedures. 3.6 CONTINUOUS OPERATION 3.6.1 The generator should be operated within the nameplate values of kW, power factor and voliage. If generator is operate below the rated power factor and voltage, the kVA rating should be decreased to prevent ‘overheating of the field and stator windings. 3.62 When generator is carrying unbalanced loads (phase currents varying more than 10 percent of rated value) rotor overheating may result. The rotor heating is caused by negative sequence currents flowing in the field pole face. For a generator guide to the allowable phase unbalance see Figure 3-2, Guide to Allowable Unbalance (which is based on a 10 percent equivalent negative sequence current). ‘The guide is used in the following manner. Find the point where the vertical line (determined by the maximum Current in any of the phases, expressed in percent of rated current) crosses the horizontal line (determined by the minimum current in any of the phases, expresse: percent of rated current). The point where these two lines intersect should be within the permissible “allowable unbalance” region for safe operation of the generator. 3.6.3 Loss of field excitation can result in unit operat- ing out of synchronism with the system when operating is, 20 parallel. This will cause damage to rolaling rectifiers and « Severe mechanical stresses on the shaft and other patts. Protective devices should open the generator circuit breaker. I Figure 3-2 Guide to Allowable Phase Unbalance(@ SECTION 4 MAINTENANCE 44 PREVENTIVE MAINTENANCE 4.1.1 Preventive maintenance is the practice of inspecting the generator set, cleaning the generator set, and eliminating minor disorders before they become serious. A rouline regular preventive maintenance pro- gram practiced conscientiously will ensure peak perfor- mance, lengthen the life of the generator, and eliminate or at least greally reduce breakdown time. 4.4.2 ‘The preventive maintenance schedule described in Table 4-1 is enclosed as a guide for establishing a preventive maintenance program for generators operating under standard conditions. The specific operating condi- tions should be analyzed by the user of the equipment ‘and a preventive maintenance program established ‘accordingly. When preventive maintenance inspection determines cleaning is necessary, clean the generator and controls as described in paragraph 4.2.1. 42 CLEANING When inspection determines cleaning is necessary, clean the generator and controls as follows. 4.2.1 Wipe loose dirt from exterior painted surfaces of generator, and when incorporated, the generator control panel assembly (controller) with a clean lint {ree cloth. Remove stubborn accumulations of dirt with an approved detergent or solvent. Clean all ventilating ports with a vacuum cleaner or filtered compressed air at a pressure of from 25 to 40 psi. WARNING OBSERVE PRECAUTIONS SPECIFIED BY THE MANU- FACTURER OF THE SOLVENT BEING USED. 422 — Cleaninside of generator with a vacuum cleaner or use dry filtered compressed air at a pressure of from 25 to 40 psi. Remove stubborn accumulations of dirt and grease from windings with naphiha. WARNING Exercise extreme care when using naphtha. Use only in well ventilated areas, away {rom flame and sparks. 423 — Cleanelectrical contacts such as relay contacts, switch contacts, and terminals with an approved contact cleaner. DO NOT FILE CONTACTS. a 43 WINDINGS - PROTECTION Generators operating intermittently in very damp locations should be protected with space heaters. Generators being placed in operation atter boing subjected to very low temperatures should be slowly warmed to prevent excessive condensation. Winding resistance should be checked before placing the generator in operation ifthe Unit was subjected to an extremely damp environment. 4.4 INSULATION RESISTANCE TEST ‘A hand cranked megger of not over 500 volts is a ‘convenient and safe method of testing insulation resis: tance. The following formula is an accepted standard for measuring the insulalion resistance of stator windings. Winding insulation resistance measured at §00 VDC alter ‘one minute should not be less than: Resistance Rated Voltage of Machine +1000 in megohms 1000 The above formula is salistactory for most checks. For more information see "Recommended Practice for Insulation Resistance Testing AC Rotating Machinery," AIEE Standard No. 43, Disconnect load lines and all controls from generator stator leads before testing generator windings. See Section 2.15.5 for drying methods. PREVENTIVE MAINTENANCE CHART 1, Lubrication: Lubrcato prime mover gear speed Increasers and coupings in accordance with the Jngtuetions supplied by the manufacturer of these products, Lubricale Kalo generators which have ball ‘or spherical toll bearings as doseribed in paragraph 45.1 tough 452. 2. Inspect load wires and control device witing for | cracked insulation and loose terminals 3. Clean outside of the generator assombly and vena tion screens. When dust or moisue is excessive, clean andlor dy the inside ofthe generator assem by, 4, WIE unit running, observe any unusual noise oF vibration, Reter to troubleshooting chart for possible ‘causes of noise and vibration,45 BEARING LUBRICATION 45.1 Shielded or Sealed Ball Bearings Generators under 75 kW have fully shielded or sealed all bearings. Shielded or sealed ball bearings are factory packed with lubricants and generally can be run several years without requiring replenishment of grease. Should the user decide repacking of the grease is necessary, disassemble machine, clean bearings and repack approxi- mately 1/2 full using a high quality ball bearing grease. Repacking is recommended whenever major repair or ‘overhaul of the generator or its prime mover is done. Grease should be capable of lubricating satisfactorily over fa temporature range of: lowest ambient temperature in which generator is operating to plus 250 degrees fawen- eit 45.2 — Regreasable Ball or Roller Bearings Generators larger than 75 kW have regreasable ball bearings and occasionally when design deems it neces- sary, roller bearings. In applications where regreasable bearings are used, grease fill fitings and grease reliet valve will be incorporated in the bearing housing, Lubri- cate bearings in accordance with the lubricating instruc tions altached to the generator and the bearing lubrication sheel supplied as supplementary information with this instruction manual. 45.3 Oil Lubricated Sleeve Bearing “These bearings should be lubricated in accordance with instructions supplied as supplementary information with this manual. 4,6 TESTING BRUSHLESS EXCITER ROTATING RECTIFIERS WITH AN OHMMETER It a failure of a rectifier is suspected remove the exciter ‘cover and test rectifiers with an ohmmeter as follows. 4.6.1 Remove nut and washer holding rectifier in heat sink and remove diode lead wire, then litt rectifier trom heat sink. Refer to Figure 4-3 (4-4 when unit incorporates dual exciter).. 4.6.2 Refer to Figure 4-1, then connect ohmmeter leads across rectifier in one direction. Note meter reading. Reverse leads and note meter reading. The meter should indicate a low resistance when leads are across rectifier in one direction and a high resistance when leads are across rectifier in the other direction. lonmMereR © caTHODE * ca REVERSE DIODE STANDARD BIODE Figure 4-1 Testing Rotating Rectifiers with an Ohmmeter BATTERIES. Figure 4-2 Test Lamp 4.6.3 It the meter indicates a low resistance In both directions the rectifier is shorted. A high resistance in both directions indicates an open rectilier. 4.6.4 — Replace detective recliliers with rectifiers of « same operating characleristics as reciitiers installed in the generator at the factory. Order rectifiers by part number including the model and type of the exciter as well as the generator serial number. 47 TESTING BRUSHLESS EXCITER ROTATING RECTIFIERS WITH A TEST LAMP Wan ohmmeter is not available, field rectiliors may be tested with a test lamp consisting of standard flashlight balteries and a flashlight bulb as shown in Figure 4-2 Test as follows, 47.4 Remove recilier as described in paragraph 4645 v 4.7.2 Connect leads of tester across rectifier in one 48 TESTING SURGE PROTECTOR direction; then reverse leads. The light should light when WITH TEST LAMP. the leads are across the reciifier in one direction and should not light when placed across rectifier in the other Refer to Figure 4-2 for test selup. Disconnect one lead direction. and check with lamp tester. The lamp should not light when the test leads are placed across the surge protector 4.7.3. Ifthe light lights in both directions the rectitier is in either direction. If the lamp lights, it indicates a shorted shorted. If the light does not light in either direction, the surge protector. Replace defective surge protector with rectifier is open. ‘one of the same operating characteris EXCITER ARMATURE ROTATING RECTIFIERS. 10 GENERATOR Fieto Positive FRONT VIEW sive view PHYSICAL ILLUSTRATION SCHEMATIC ROTATING RECTIFIERS Figure 4-3 Full Wave Rotating Rectifier and Exciter Armature Assembly NEGATIVE excien ExcITER ARMATURE ARMATURE To Fieto 1 a "2 poet ROTATING RECTIFIER FRONT View PHYSICAL ILLUSTRATION SIDE VIEW eee: ro FRU #2 ROTATING RECTIFIERS Figure 4-4 Dual Exciter Rotating Rectifier and Exciter Armature Assembly 23 .tics as the surge protector installed in the generator at the factory. Order by part number and include the serial number of the generator. Following replacement of the surge protector, make certain field lead tie-down lacing is securely wound on shaft and tied 43 RESTORING RESIDUAL MAGNETISM The direct current necessary to magnelize the alternator field is obtained from the exciter. Initially, upon starting the generator, current flow and voltage is induced into the exciter armature by the magnetic lines of force set up by the residual magnetism of the exciter field poles. Residual magnetism of the exciter field poles may be lost or weakened by a momentary reversal of the field connection, a strong neutralizing magnetic field from any source, or if the generator is not operated for a long period of time, To restore the small amount of residual magnetism necessary to begin, the voltage build up, ‘connect a battery of from 6 to 32 volts to the exciter field colt circuit, Normally a battery of 6 to 12 voltage is large enough. When the field windings have a high resistance (75-100 ohms) a larger battery voltage may be required. Connect the battery and flash field as follows: 4.9.1 Disconnect exciter field coil wire F2 at terminal Fe, 492 — Connect ballery positive lead to field coll lead Fa, 49.3 Flash field by touching battery negative lead to field coil circuit terminal F1. 49.4 Disconnect battery leads. 495 — Reconnect field coil lead F2 to terminal F2 and F1 to terminal F1. 49.6 Start unit and observe generator build up. Reflash field (paragraphs 4.9.1 through 4.9.8 above) if generator output voltage does not build up. NOTE It the polarity of the exciter is reversed by flashing the field, it may be corrected by interchanging the battery leads.© SECTION 5 5.2 Bolween regular preventive maintenance inspeo- tions, be alert for any signs of generator set trouble. TROUBLESHOOTING ‘Common symptoms as well as the probable cause and posable remedy are ised in Table Se. Covtect any for tole mimodiatey. Minor dooct et uneorect 5.1 Troubleshooting the process of recognizing «4, eausa Serious damage which can result in malfunctions of the system, intelligently analyzing the ly repairs ime. maltunction, and making tho necessary corrections to place the unit back into proper operation. TABLE 5-1 TROUBLESHOOTING CHART SYMPTOM. POSSIBLE CAUSES REMEDY No Voltage pen circuit breaker or fuses (it voltage is sampled on load side of fuses or cir- cuit breaker). Overvoltage, undervoltage, or overload devices tripped (when protective devices incorporated in circuit). © Open circuit in exciter field. Loss of residual magnetism in exciter field poles or a model voltage regulator is used which requires field flashing to bring generator voltage to level where regulator will operate. Open circuit in stator windings. Open circuited manual field rectifiers. Open circuit in manual voltage adjust circuit. Maltunction of automatic voltage regu- lator. © Shon circuited generator output leads. Check. Reset circuit breaker or replace tuses it open. Check for cause of abnormal condition. Correct any deficiencies. Reset devices. Check Generator | Nameplate for nominal operating values. Check out continuity of shunt field and leads to voltage control, (Use olimmeter or wheatstone brridge-) if open in field coils, remove exciter field assembly and return assembly to factory tor | repair. Adjust manual adjust potentiometer to full resi tance. Flash field by making a flash connection of DC across terminals F1 to F2, See "Restoring Residual Magnetism.” When voltage regulator is such that flashing is required install automatic, field flashing system, Check for continuily in windings, Retuin to factory for repair if open. | Check rectifiers, replace faulty diodes or rectilier assembly. Check potentiometer for continuity. Replace it open circuit See troubleshooting of voltage regulator. Correct deficiencies, Clear lead to restore voltage build up. 25TABLE 5-1 (CONTINUED) SYMPTOM POSSIBLE CAUSES. REMEDY No Voltage Open in rotating rectitiers. Check rotating rectifiers and replace if open. ae Open in alternator field. Check for continuity and return rotor to factory for repair if field coils are open. Shorted surge protector. Check for shorts and replace. Shorted rotating rectitiers. Check for shoris, Replace il shorted or open Shorted exciter armature. Check for short. Repiace i shorted. Shorted leads between exciter armature | Test and repair and generator field. Low Voltage Detective vonage regulator (when used). | Check reguiator, adjust or repair or replace it ‘Automatic field flashing system required. Detective rectifiers in stationary rectifier assembly (when used). Improper adjustment of voltage adjust thoostat. Excessive load. Line loss. High resistance connections. Connec- tions will be warm or hot. ‘Shorted field, Low power factor. detective. Contact Kato Engineering. Describe system and model of voltage regulator used. Check ‘rectifier assembly. Replace defective rectitier, Adjust rheostat. Reduce load. With 3 wire, single phase and 4 wire, three phase generators, the load on each eg should be as evenly balanced as possible and should not exceed the rated current on any eg. Increase size of line wire Make better connections. Test field colls for possible short by checking resistance with an olmmeter or resistance bridge. Return rotor assembly 10 factory for repair if alternator field coils are shorted Reduce inductive (motor) load. Some AC motors draw approximately the same current regardless of load. Do not use motors of larger horsepower rating than is necessary to carry the mechanical load. 26TABLE 5-1 (CONTINUED) ‘SYMPTOM POSSIBLE CAUSES REMEDY Low Voltage Weak field due to operating in warm | Improve the ventilation of generator. Field current (cont) temperature. can be increased providing the generator temper. alure rating stamped on the nameplate is not exceeded. Improper voltage andior frequency to | Check input voltage. Correct deficiencies. Check drive motor causing low speed, ‘motor data plate for nominal operating values Excessive load. Reduce load to rated value. Detective bearing, Replace bearing Low speed due to improper bell adjust- | Align and adjust belt. Replace it worn exces- Ment on belt drive motor-generator sets. | sively. Check for proper sheave size Improper speed of engine driven gener- | Check and correct deliciencies, ator set due to defective governor, igni- tion system, or carburetor. Fluctuating Voltage regulator not operating properly | Check regulator. Repair or replace it detective. Voltage (it used). when generator set is motor driven. Engine governor on engine driven generator sets Loose internal or load connections. Make better connections. Generator overloaded, Reduce load to rated value. DC excitation voltage fluctuating. Trace DC excitation circuit. Correct any detects, High Voltage Overspeed, Correct speed of prime mover Improper adjustment of voltage adjust | Adjust rheostat andior voltage regulator. theostat or voltage regulator. Overheating Clogged ventilating screens and air pas- | Clean all screens and air passages sages. Dry or defective bearings. Replace detective bearings Coupling misaligned or on belt driven | Align generator set or adjust belt. generators, belt too tight. a7‘TABLE 5-1 (CONTINUED) SYMPTOM POSSIBLE CAUSES REMEDY Overheating (cont) Vibration, Generator field coils shorted or ground- ed. Detective or dry bearings. Misalignment of generator and prime mover. Generator not properly mounted. Transter of vibration to generator from another source. Test field coils for shorts. Replace shorted rotor oF return to factory for repair. Replace detective bearings. Align generator set. Check mounting. Correct detective mounting. Isolate generator set from source of vibration by installing vibration dampeners between the generator set base and foundation, 28}) SECTION 6 ASSEMBLY AND DISASSEMBLY 64 BEARING REMOVAL Remove the endbell to expose bearings. Use a puller to remove the bearing from the shaft end with a cap. If the bearing is going to be used again, make certain puller applies pressure only against the bearing inner ring (see Figure 6-1). 62 BEARING INSTALLATION ‘eat the bearing to a temperature of from 220 degrees fahrenheit to 250 degrees fahrenheit in a clean thermostatically controlled oven. Start the heated bearing into the shalt. Then use a fiber or soft metal tube to tap bearing into place. See Figure 6-2. Make certain that pressure is applied only to the bearing inner ring. Press bearing onto shaft until inner ring is against bearing shoulder on the shaft. Assemble the generator atter the > Dearing has cooled. Figure 6-1 Removing Bearing from Generator Shaft 63 EXCITER ARMATURE AND ROTATING RECTIFIER ASSEMBLY REMOVAL Remove exciter armature and rotating rectifier bridge assembly as a unit as described in the following general by nsiuetions. 29 Figure 6-2 Installing Bearing on Generator Shaft 63.1 Remove exciler cover. Disconnect alternator field leads from positive (+) and negative (-) terminals located on the heat sinks of the rotating rectifier assom- bly. Remove exciter armature retaining bolt and washer. 63.2 The exciter armature is a “slip fit” on the generator shal. If the armature cannot be removed by hand, remove with a puller installed as. described in paragraph 6.3.3, CAUTION DO NOT PULL ON ROTATING RECTIFIER ASSEMBLY OF THE EXCITER ARMATURE WINDINGS. 63.3 _ Install acap or plug to protect the shatt center. Ulilzing the tapped holes in the end of sleeve, bolt to the end of the sleeve spacers and a metal plate. Reler to Figure 6-3 for fire setup. 63.4 Hook a bearing puller to the metal plate and pull exciter armature and rolating rectifier assembly from the shatt 64 EXCITER ARMATURE AND ROTATING RECTIFIER ASSEMBLY INSTALLATION Install exciter armature and rotating rectifier assembly as unit as described in the following general instructions. 64.1 I the “slip fi” exciter armature and rotating assembly will not easily slide onto the shaft by hand, install with a ficiure as shown in Figure 6-4 and described in paragraph 6.4.2NOTE Usually the exciter armature will slide onto the shaft most of the way by hand. The exciter armature can usually be "seated" by tapping lightly on the sleeve with a soft rubber or fiber mallet. MAKE CERTAIN MALLET HITS ONLY THE SLEEVE, NOT RECTIFIER ASSEMBLY OR ARMATURE WINDINGS. CAUTION if exciter armature Is aligned and locked in place by a removable key, make certain the key Is In place in the generator shaft and the keyway In the exciter armature sleeve Is aligned with key before starting the exciter armature onto generator shaft. if unit uses an aligning lug on the exciter armature sleeve and a slot in the generator shaft rather than a removable key to align and lock the exciter armature ‘on the shaft, make certain lug and slot are aligned and engaged. 642 Refer to Figure 6-4 for fixture setup. Start exciter armature and rectitior bridge on shait. Thread stud in rotor shaft. Install large diameter washers on stud and start stud nut. Pull exciter arma(yre and rotating rectifier onto shaft by turning stud nut. 6.4.3 Install exciter armature retaining bolt and washer, Connect alternator tield leads to positive (+) and negative (-) terminals located on the heat sinks of the rolating rectilier assembly. Install exciter cover. 65 REMOVING AND REPLACING EXCITER STATOR ASSEMBLY Should it be necessary to remove the exciter slator assembly, reler to “Generator Disassembly" procedures and then remove stator as described in the following general instructions. 65.1 Remove exciter cover and exciter armature. Refer to paragraphs under 6.4. 65.2 Disconnect exciter field leads F1 and F2. Remove any clips securing excitor field leads to the exciler frame, generator frame or the endbell 65.3 Remove generator exciter and generator endbell. Refer to "Generator Disassembly” procedures. Check for shims in endbell bearing well. Make certain the shims, if incorporated, are reinstalled when generator is reassembled. key Plug to protec shat cont EXCITER ARMATURE mei PLATE Wi purer 7 ‘ es Spacer SHAFT exciTER ARMATURE out Figure 6-3 Removing Exciter Armature and Rotating Rectiller Assembly LARGE WASHER, UNDER STUD NUT / / | / | snare / |! \ \ tuanicare Luanicare THREADS, Figure 6-4 Installing Exciter Armature and Rotating Rectifier Assembly 65.4 Remove bolts securing exciter frame and stator to the endbell 655 Assembly oxciler stator by reversing disas- sembly procedures. NOTE Install exciter stator with its field leads toward generator endbell. 30HOLVUSNIS sszTHSNuA ee SIU H3LIOX3 ONY H3LIOX3 GHVOBINO HLIM m1 Ald DNINTOASY ONIHYAG-OML OLVA TVOIdAL ¥9-9 ANNO! a-8 b orig eng vee ones | 02 Aqwassy 101g ¥ owEly JOTeIeUED | 11 Suueog pu3 enua'va-9 ainéis | 6b weqpus so1org | ot ann ena 'vs-9 aindis | 61 jog Gununoy weqpua iara | 5 tiog Sununoyy yoqpug enna 'va-8 eun6is | eh (Gs9e oie: 6oe01 v0 pw aa few) oyomIo1g e6ing |B yea sid onug ‘ys-9 einéy | BL og Gununoyy woreig Bowers ioyory |Z wieqpua omg | Lt pug aioxy Suvesa | 9 peg Sununoyy ioweouen | 9b Aquossy sores 9 eweis r19%y | anuues | st oimjowsy sayy | > weg | or Aquessy soynoey Bureiog |G oqo Sune) | eb soysenn 8 you Cuuimjay oinyoury sayoxy | 2 Aquiossy (prety) 1104 ojes0uq | Bb senog sayoK3 |} Wondiiasea Wea “ON AH, wordiesea wea “on Foy ¥9-9 pus 5-9 S3UNDId HOd NOLLdIHOSAG LUVd SWVi4 H3LI9X3 ONY H3LIOXA HVOELNO HLIM MOLVHSINSD SS3THSNUA A73I4 ONIATONSY ONIUVAE FIONIS OLVA TVOIGAL VS-9 3UNDIS ‘ ‘yun ax Jo wontonnisuo® yenioe en wou} ANYBIIE JO} IP ABU pe AIUO UojsendeIp Jo eesodind 10) popuowul o1 66 Ee Ls ! meth, ; tS T _ Cee a eluasoo| 0} JaIjeu s9qy 40 saqgni yum AUB det -(oL) lleqpue arcway (6) siioq yaqpus eroweH — £79 Hoqpue Joy2s0u06 pue auses) so}es@U96 ‘ewes JovOKa 91 spear pray sey0xKe Buunoas sdo ancwoy — 9°z°9 (e9 s9pun sudes6esed aas) yun v se Aquiosse 013981 Bujelos pue aunjeue JoHOxe BAoWaY ‘(z) JoUSEM ue yoq BulUeIes ounjeue 1axOx9 enowes ‘spee| pro1} J0FeUIANE JoaULI09SIC (4) 19409 19}9x9 DROWY—-G'Z-9 ‘suayneoeid Buypuey 40} suoloruisul UOHENEISUL, Z UOHOBS Bag so}e10UAH eAow! 1 (E41) Siog 242 Suny 0} Sus YORNY “AIquassesip 40) woos ua}OH INS BuIpIO|"e uoNeD9} | Jo}eI8UaB BACW HZ" ‘uoHepUNo} 10 aseq 0} (94) sped aseq 1oye1aue6 Guunoas syjoq onoway eso SUOHON|SUI S.Jesnjoe;MUBLE YAR aourpiocoe ul sanvays 40 Buydnos arowoy — 229 ‘pajquiassear st jun uoYA po oauuoo Ajoau109 are sped} WEL99 OYEW! 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Buynoes syjoq @ACWOY “uasi9s Ue} anoWeY ——z'9'9 palquiesseas 51 Wun Lay pa -Joauu0d f1}991409 xe Spee} VIEL OMe O1 SIEUIUIO] PUE pea} B21. “Spee ploy} 4019x9 ue speal peo} so1es0U06 JeuUODSIP PUB Jon0d xO JeUIUIA, eNOWeY —_—L'9°9 “suoponyjsur esous6 Surmojio} oy ul paquosap se sowseua6 ojquossesip ual ‘uoNeoyIUEP! Hed 19) 45-9 pue es-g SiNb14 0} JaJOu) HOLVH3N39 N3AIHG SNIDNA ONINV3E q STONIS JO ATEWASSVSIC GNY ATEW3SS¥ gr \‘These drawings \ hue 2 intended for purposes of discussion only end may differ stighiy from the actual construction of the unit. * 3G ” “ 20 6 18 19 16 FIGURE6-5B TYPICAL KATO SINGLE BEARING REVOLVING FIELD BRUSHLESS GENERATOR WITH OUTBOARD EXCITER FIELD MOUNTED ON ENDBELL. PART DESCRIPTION FOR FIGURES 6-5B and 6-68 Key No. Part Description Part Deseription 1 | Exciter Cover 12 | Generator Rotor (Field) Assembly 2 | Exciter Armature Retaining Bol & Washer 13 | Liting Eyebon 3 | Rotating Rectitior Assombly 14 | Fan 4 | Exciter Armature 16 | FanHub 5 | Exciter Field 16 | Generator Mounting Pad 6 | Bearing, Exciter End 17 | Diive Endbel 7 | Exciter Field Bolt 18 | Figure 6-5B, Drive Disk Bolt 8 | Surge Protector (may ba mid. on ott ecler assy) 18 | Figure 6-6B, Drive Endbell Mounting Bolt 9 | Exciter Endbell Mounting Bolt 19 | Figure 6-58, Drive Hub 10 | Exciter Endbolt 19 | Figure 6-68, Drive End Bearing 11__|_ Generator Frame & Stator Assembly 20 _| Figure 8-5B, Drive Disks ° we a 0 == 16 FIGURE 6-68 TYPICAL KATO TWO-BEARING REVOLVING FIELD GENERATOR WITH OUTBOARD EXCITER FIELD MOUNTED ON ENDBELL 33endbell. Check for shims in the endbell bearing housing (well). Make certain shims, when incorporated, are reinstalled when unit is assembled. 6.7.8 If the exciter stator (field) (5) requires repair or replacement, remove bolts (7) and remove exciter frame and stator assembly (6) from endbell (10) 6.7.9 Remove endbell bolts (18) and endbell (17). Check for shims in bearing well (see paragraph 6.7.7). 6.7.10 Remove fan (14) from hub (15) NOTE Before loosening fan, measure distance from fan to fan baffle and maintain this distance when fan Is reln- stalled. 6.7.11 Install pipes over generator shalt on the drive and exciter end of rotor. Attach slings and hoist 10 pipes and remove rotor assembly (12) trom stator and trame (11). Make certain air gap is maintained between the rotor and stator during removal of the rotor. CAUTION Make certain pipes are of sufficient strength to support weight of rotor and that pipes do not have rough edges which would damage shatt surface. 6.7.12 Assemble generator by reversing order of disassembly procedures listed above (paragraphs 6.7.11 through 6.7.1). NOTE Install bearings as described In paragraph 6.2 and exclter as described In paragraphs under 6.4 and 6. Make certain generator field (rotor) Is aligned with generator armature (stator). 68 ASSEMBLY AND DISASSEMBLY OF SYNCHRONOUS BRUSHLESS DUAL GEN- ERATORS FAN MOUNTED AT DRIVE END Reler to Figure 6-7 for part identification and then disas- semble generator as described in paragraphs under 6.7. ‘Assemble generator by reversing disassembly procedures listed in paragraphs under 6.7. 34 63 ASSEMBLY AND DISASSEMBLY OF SYNCHRONOUS BRUSHLESS DUAL GENER- ATORS WITH CENTER MOUNTED FAN Refer to Figure 6-8 for part identification, then disas: semble generalor as listed in the following general instructions, 69.1 Disconnect generator and proceed with disas sembly and described in 6.7 paragraphs 6.7.1 through 676. 69.2 Remove fan screen. Remove fan blades trom fan hub. Mark each blade and the fan hub for direction of rotation. Number the fan blades and the tan hub as each blade segment is removed to ensure proper reinstallation. NOTE Fan blades must be reinstalled in the correct direc tion of rotation. The rotor assembly was factory balanced with fan blades installed. Each blade seg- ment must be reinstalled to the Identical position on the hub as when removed. Blades and hub must be clearly marked during disassembly to ensure correct reassembly. 69.3 When removal of fan blades and identification marking of blades and hub is complete and satistactory, proceed with disassembly of the generator as described in 6.7 paragraphs 6.7.7 through 6.7.12. 69.4 Reassemble generator by reversing order of steps followed to disassemble the uni. Make certain fan blades are correctly installed. NOTE Install bearing as described in paragraph 6.2 anc Install exciter as described in paragraphs under 6. and 6.5. Make certain generator field (rotor) is aligne with generator armature (stator) and the exciter armature Is aligned with exciter field.‘Those drawings are Intended for purposes of discussion only and may ditfer slighty from the setual construction of the unl 10 13 7 ® Me m © 8 v fe a v v rie | sth Hil a 9 2 & ET a = ait 2 = = t-}- 67 Bo 8b \ / i Io 125 6 FIGURE 6-7 KATO SYNCHRONOUS BRUSHLESS REVOLVING FIELD DUAL GENERATOR OR MOTOR-GENERATOR WITH FAN MOUNTED AT DRIVE END PART DESCRIPTION FOR FIGURES 6-7 and 6-8 Key No. Part Description KeyNo.[ Part Description -[ 1 [Exeter Cover 110.8 115] Generator Frame & Stator Assembly 2 | Exciter Armature Retaining Bott & Washer 12a & 125] Generator Rotor Assembly 3. | Rotating Rectitir Assembly 13 | Liting Eyebot 40840 | Exciter Armature Assombly 14 | Fan 5a 5b | Excitor Frame & Stator Assembly 15 | Fan tub =| "6 | Bearing, Exciter End 18 | Generator Mounting Pads 7 _ | Exciter Field Mounting Bot 17 | Drive Endbet! 8288b | Surge Protectors 18 | Drive Ensbell Mounting Bok 8 | Endbell Mounting Bott 19 | Bearing, Drive End 10 _|_Exeiter Endbeil 10 ea 9 \ g i | es: i 50 5b f do a CHA —| is | imi 2 H = eI as | 1 ia

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