ATUYAC

10 4
OPERATION & MAINTENANCE
MANUAL FOR
BRUSHLESS A.C. GENERATOR

iusr u1
 CONTENTS

Page
1. CONSTRUCTION OF BRUSHLESS A.C. GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3 ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 .4 BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.5 A.C. EXCITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. STATIC EXCITATION EQUIPMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 AUTOMATIC VOLTAGE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2 VOLTAGE ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.1 BEFORE THE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2 PARALLEL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.3 OVERALL CHARACTERISTIC OF GENERATOR

AND AUTOMATIC VOLTAGE REGULARTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1o

4.1 SCHEDULED MAINTENANCE FOR A.C. GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . 10

4.2 METHOD OF MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.3 SCHEDULED MAINTENANCE FOR AUTOMATIC VOLTAGE REGULATOR . . . . . . . . . 14

4.4 CHECKING OF EQUIPMENT RELATING TO AYR . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5. TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.1 CHART OF TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5 .2 CHECKING METHOD FOR DEFECTIVE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6. DISASSEMBLY OF A.C. GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.1 DISMANTLING PROCEDURES BRACKET TYPE-I . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.2 DISMANTLING PROCEDURES BRACKET TYPE-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6.3 CAUTIONS FOR DISASSEMBLING/REASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . 19

7. ADDITIONAL ORDER OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

 I Stator Frame
2. Stator core
3. Stator coil
4. Embedded temperature detector
5. Protective cover
6. Terminal box
7. Space heater
8. Shaft
®CD~ 9. Rotor spider
\\ \
\ .
\ \
\
I 0. Rotor core
11 . Rotor coil
\ \
12. Damper winding
I 3. Rotary rectifier
\ Air Water outlet 14. Cooling fan

® \
.\ 0
I
\
\\
;._flow 15 Bearing
18. Bearing stand
\(J \ 19. Thermometer
\ \ Water intake 20 Olifice
\ 21. Oilsight
23. Exciter field core
24. Exciter field coil
25. Exciter armature core
26. Exciter rotor spider
27. Exciter armature coil
~?;~:;;::'.1- Air flow 28. Exciter stator enclosure
~'Air intake
Oil intake '

®
®

Fig. l. l Construction of generator of totally enclosed with water cooled air cooler
 I. Stator frame
2. Stator core
3. Stator coil
5. Cover
6. Terminal box
7. Space heater
8. Shaft

®\~~~~CD®® ®©© @ 9. Rotor spider

10. Rotor core
\ \ \ \ \
®, \ \ \ II
' ,;=:t:==========:::;i
I 11. Rotor coil
12. Damper winding

@\ \ 0
I Air Filter
13. Rectifier element
14. Fan
15. Bearing metal
16. Insulation sleeve
17. Bearing bracket
19. Thermometer
21. Oil sight
® 23. Exciter field core
24. Field coil
4ir I
..4 / , ;· !Jfet 25. Armature core
27. Armature coil

l:w

(j) @

Fig. 1.2 Construction of drip-proof type brushless generator

PREFACE
Based on our long Years' experience and numerous
practical accomplishments, NISHISHIBA's Marine A.C.
Generators have been so designed and manufactured that
a stable performance can be demonstrated on the ship
where the environmental conditions are severe.
As an aid for the maintenance work for maintaining
the high performance and efficiency of the Marine A.C.
Generators, please utilize this Operations & Maintenance
Manual.

1. CONSTRUCTION OF BRUSHLESS A.C.

GENERATOR
1.1 COMPOSITION
The brushless A.C. generator, as shown in Fig. 1.1 Fig. 1.5 Stator of totally-enclosed with seawater
(totally-enclosed internal-cooling type) and Fig. 1.2 cooled aircooled type
(drip-proof type), is composed of plate. The hull vibrations and the atmospheric
( 1) a synchronous generator condition of the engine room have been fully taken
(2) a A.C. exciter into consideration to let it have sufficient strength,
( 3) a rotary rectifier and at the same time, the well considered air passages
( 4) static excitation devices, for ventilation to make cooling effect sufficient. is
and its special feature is in the rotor. provided, the typical stators with enclosure are
The brushless generator, as shown in Fig. 1.3, the A.C. indicated in both Figs. 1.4 and 1.5.
exciter and the rotary rectifier are mounted on the (2) STATOR CORE
generator's rotor shaft. The armature core is the laminated silicon steel
The three-phase output of A.C. exciter is rectified to plate carefully selected to prove the electrical and
D.C. by means of the rotary rectifier, thus enabling the mechanical characteristics and is securely fixed on
exciting current to be supplied, not through sliding parts, the stator, magnetical frame, with stator spider.
but directly to the field coil of the generator. (3) STATOR COIL
The armature coil shall be constructed and insulated
suitabley for marine in accordance with the ma-
..-i-----;Static Exciter nufacturer's practice
Class "F" insulation system is our standard.
(4) EMBEDDED RESISTANCE TEMPERATURE
DETECTOR
In order to measure the coil temperature inside the
slots, a embedded resistance temperature senser may
be provided inside the coil. This senser is a three-
terminal resistance of Pt 100f2 at 0°C, one for
ordinary use and one spare use, a total of six pieces,
Stator Rotor Exciter Stator are embedded in each phase of U.V.W.
(6) TERMINAL BOX
1.2 STATOR The terminals of the main circuit, excitation circuit
(Note;(n) indicate the part number in Fig. 1~2) and space heater circuit of the generator are assem-
(I) STATOR FRAME bled in a watertight steel plate-made terminal box
The Stator Frame supports the armature core and (es).
coil, etc. The one for the machines of smaller (7) SPACE HEATER
capacity is of cast iron and the one for the machines In order to prevent the accumulation of moisture
of larger capacity is of the welded structure of steel and condensation while the generator is in idle,
space heaters are provided on the both sides within
the stator frame. The space heaters are so equipped
as to be easily removed from outside of enclosure.
The heater clements are stainless-sheathed nichrome
heater, filled with insulators in the sheath and is
W-shaped as shown in Fig. 1.8.

Fig. 1.4 Stator of dripproof type Fig. 1.8 Space heater

3 ~
 D.C. output

Armature of exciter

1
Cooling fan Rotor coil

Fig. 1.9 Rotor assembly

1.3 ROTOR
(8) SHAFT
Concerning the generator shaft, the ship's classifica-
tion certified forged steel shall be applied and
designed with ample strength for coupling of prime
mover.
( 11) ROTOR COIL
There are three types, the round wire multi-layer
winding, the square wire multi-layer winding and
the single-layer winding. The suitable rotor type is
applied from above three in compliance with the Fig. l.11 Rectifier connection
generators output and speed.
Class "F" insulation system is applied as well as it of (14) COOLING FAN
stator winding. To let the required amount of cooling air pass
(12) DAMPER WINDING through, a fan of either cast iron or of welded con-
In order to reduce the transient voltage variation struction of steel plate is provided. Concerning the
due to the sudden load variation during running and site of its installation, in either case, it is to be
to enhance the electric stability of the generator arranged on the prime mover's side of the generator.
during the parallel operation, the damper winding It is of one-way ventilating system which takes into
of copper bars are installed in a cage shape on the the air from the opposite side of the prime mover
surface of the rotor core. Figs. -1. l 0 shows the and exhausts the air to the prime mover's side. We
typical example of a damper winding. have taken into consideration that the engine's oil
vapor should not be sucked into the machine.

1.4 BEARING
Concerning the lubricating system for bearings, there
are both the self-lubricating system and the forced-lubri-
cating system.
In case of the self-lubricating system, oil ring lubricat-
ing is applied, except that the small capacity machine may
use ball bearings and apply the grease lubricating system.
Figs. 1.1 2 ~ 1.14 show the structure of bearing.
(I 5) BEARING
Bearing is the split sleeve type and cast the white
metal into the back metal of cast iron.
To prevent the oil leakage, grooves are provided on
the both ends of the bearing so that oil may not
ooze out to the direction of the shaft.
Figs. 1.1 5 a-d show the typical examples of bear-
ings.
·Fig. 1.10 Damper Winding
(16) INSULATION FOR THE PREVENTION OF
SHAFT CURRENT
(13) ROTARY RECTIFIER To prevent the shaft current caused by the un-
The rotary rectifier is a silicon rectifier which is balance of magnetic resistance of magnetic circuits
connected so as to compose a three-phase half-wave the insulater is provided to non driven end bearing.
rectification circuit as shown in Fig. 1.11 and is In case of a bracket type bearing, the insulater is
mounted on the rotor shaft of generator. provided on the back of the bearing metal and in

4
 case of a stand-type bearing, the insulater is provid-
ed between the common base and bearing stand.
In case of a stand-type bearing of forced lubricating
system, the insulaters are provided on the both oil
inlet and oil outlet, and piping frange. Please refer
to fig. 1.16.
(17) BRACKET
The Bracket is made of cast iron and is provided
with an oil pot where the required amount of oil
for the bearing may be sufficiently contained.
(in case of self-lubrication).
In case of the machines of larger capacity, to facili-
tate its disassembly and re-assembly, the bracket is
so constructed that it may be divided into three
independent parts as the lower half as in one body
and the upper half to be divided into two portions.
In case of the machines of smaller capacity, it may
be divided into two portions and some may be just
one portion.
Refer to Fig. 1.17.
(18) BEARING-ST AND
The Bearing-stand is of cast iron and mainly applied
for the forced lubricating bearing of the machines
of large capacity.
It is constructed so as to facilitate the disassembling
and reassembling.
Fig. J .14 is a typical example of the Bearing-stand.
(19) THERMOMETER
For the checking of the bearing temperature, the
~ fhermometer
Lid
bearing is provided with a alcoholic thermometer.
The thermometer provided on the opposite side of
the prime mover as to the bracket type bearing is.
to prevent the accidental touch, to the bearing
metal that causes the shaft current, covered with an
insulated tube at the feeler part.
(20) ORIFICE
The Orifice is to be used to adjust the oil flow of
forced-lubricating bearing.
The oil flow is adjusted by inner diameter, that is
larger than 3 mm, and length of oil path on orifice.
Its outside view is shown in Fig. 1. 18.
(21} OIL SIGHT
The bearing of forced lubricating system is provided
with an oil sight at the oil outlet in order that the
lubricating oil flow may be checked easily.
The windows are provided on three directions so
that the oil flow may well be observed and the
upper window is protected with a steel plate cover
as shown in Fig. 1.19.
(21 ') OIL GAUGE
The bearing of self lubricating system is provided
with an oil gauge to check the oil level in the oil
pot.
At the time of operation, oil is to be filled up to the
level of the red mark (center) of the oil gauge.

Insulating washer

Bearin0

Note
Inside of Insulating
sleeve shall
machine
be provided
only on the
opposite side of
prime mover

- Oil ring

Oil outlet plug

Fig. l. l 2b Bearing of self-lubricating system

Fig. I .12a Structure of bracket type self-lubricating system bearing

PF Y, screw Thermometer Insulation sleeve

\ (non-driven side only)
I nsu lat or
__...,;:/'(non-driven side only)
..,....,._,,,-t-__
._,J /
/White metal

Orifice

Oil inlet flange

011

11 Oil box
1 I
Oil outlet flange
Arrows indie<ite the direction of oil flow

I
Packing
. Fig. 1.13 Structure of bracket type forced lubricating system bearing

~ 5
 Note
1 The arrow 1nd1c.ates the oil flow.
2. The figure shown in the dotted line
shows the condition oi 15 1ncl1nat1on
3_ I nsu!ating plates are provided only on the
opposite side of prime mover.

Oil 1nlf't

I nsuldtinq platt:

Fig. I .14a Structure of bearing of stand type with forced lubricating system

Fig. 1.14b Bearing of forced lubricating system

Fig. l.15a Self-lubricating bearing (Upper halO Fig. l.15b Self-lubricating bearing (Lower halO

Fig. I. !Sc Forced lubricating bearing (Upper ha!O Fig. l.15d Forced lubricating bearing (Lower halO

6-
 ~ {\

Oil inlet

2?;-~
Oil outlet

Insulation washer Insulated bolt

Insulated dowel pin
Insulation washer Insulation washer

Insulation plate

Insulated bolt

Insulation plate
Insulation plate

Detailof"A" Detail of "B"

Detail of "C"

Fig. l. l 6 Insulation for prevention of shaft current

stand type forced lubricating system

(Assembled figure) (Lower half)

Fig. 1.17 Division of end bracket

Fig. l.l 9 Oil sight

1.5 A.C. EXCITER

The AC exciter is composed for revolving-armature
type three phase synchronous generators. In revolving-
armature type generators, unlike the ordinary ones, the
stator and rotor are in reverse relation.
As shown in Fig. 1.9, the armature is installed at the
shaft end on the non-connection side where AC power is
generated, and the output of static excitation device for
control is connected to the field winding installed on the
fixed side.
j)(

Fig. l.l 8 Orifice

Rotating armature Stationaly field

Fig. 1.20 Rotating armature ac exciter

-7-
 Table 2.1 Components of standard static excitation system
2. STATIC EXCITATION EQUIPMENTS Parts Unit
,----~ --------- --------j;- ----
Static excitation system is composed of semicondac- AYR ~ u tomatic voltage regulator ---+Y~RAB type , __ _
torized automatic voltage regulator. Fig. 2.1 shows the
standard connection diagram of the excitation device and CT Current transformer 1 ~ 1
for cross current compensation ; ___ _
Table 2-1 shows its components.
CT Current transformer 2
for excitation
--- - - i - - - - - ---
~:::~~: ;:~u:~~:tat1on -l ~=--=-- T~1~
YAD 1

RX
SIRF Silicon rectifier for excitation
RS Resistor for excitation

3. OPERATION
Prior to the operation of the generator, thoroughly
check the inside of the generator.
Confirm that no obstructing or impedimenting material
for smooth operation are adulterated or exist and whether
or not screws are loosen.
Also bear in mind that the circumference of the
machine should be always kept clean.

Fig. 2.1 AYR "YZRAB·l"

3.1 BEFORE THE OPERATION
3.1 .1 Cautions prior to the operation
Prior to the operation, check the following items and
2.1 AUTOMATIC VOLTAGE REGULATOR (AYR) confirm the safety of the machine and operation.
This equipment regulates the exciter field current auto- Items to be
matically, compares the generator terminal voltage with checked Standard
& & Remarks
the standard voltage and thus maintaining the generator Procedure
terminal voltage to the constant value regardless of the confirmed
amount of load. The voltage adjusting rheostat enables the ]. Inside and
outside of Remove chip and dust or
generator terminal voltage to be adjusted in the range of machine. dirt.
about ±5'}!; of the rated value.
2. Connectingj
parts of
cable and Check for looseness.
1

wire
R S T Fill the lubricating oil
3. Lubricat- to the level mark. (red
ing oil. In case of the forced
ID 1D l »(CB) Circuit breaker
lubrication, ascertain
whether sufficient oil is
Current transformer for cro flown at oil sight.
I (CT) current compensation
L 4. Measure- Check both the stator To be performed
K
k I ment of winding and rotor winding. only in case the
insulation More than 1 megohm is machine has long
TO been at rest
ANOTHER resistance desireble.
(Over a month).
IA AVR
Reactor (RX) TERMINAL
r 3.1. 2 Preparations prior to operation
I
(CT) (CT) Set the voltage adjuster (V AD) for approximately the
L
i center 5 (scale position).
K C>< i!:I
1_:_
k 3.1.3 Cautions at the time of the start of operation
Current ( 1) Check up of each part.
transformer
for e,;citation When starting operation, the following items should
Silicon rectifier
(SIRF)
be inspected and if any abnormality is found, stop
rl . . t w
the machine immediately and the cause should be
investigated and removed.
u It is dangerous to touch the revolving part with
(SIRF2) o:: hands during operation.
*
(RS) Resistor (PBS )6MIH601RS2) * F 6
J ~piui Items to be
~NJ checked
u v w K N1 • F ;;;: &
Checking Remarks
-- --- -~--

- - ·- ·-1 N
confirmed
I *Mar k shipyard service u

~-
I a..
,,..._____, I There should be no
I
I. The sound : abnormal sound caused by
when start I the touch of the fan and/or 1Refer to clause 4.
'
AC generator AC exciter the adulteration of foreign
substances.
J
Fig. 2.2 Connection diagram of exciting system
To confirm that the oil ring
2. The condi- smoothly revolves.
2.2 VOLTAGE ADJUSTER (VAD) tion of Also the oil circulation is
lubrication to be checked (in the case
This is a rheostat to set the generator voltage and usual- of forced lubricating
ly located on the main switchboard. I system, the oil flow).

-8-
 (2) Voltage establishment c. In case that the load variations on the side of the
Since the self-establishment is normally made by the bus bar are violent, it may be difficult to
residual voltage, the flashing won't be necessary. manipulate the governor which might keep rest-
If and when the voltage is not established. refer to ing the >ynchroscope at the synchronous point,
the item 5 "TROUBLESHOOTING". however. 11 the angle of the pointer of the
3.1.4 Normal operation synchroscope deviates from right above the
( 1) Inspection and confirmation of various parts cer:ter by more than ±]0°, case should be taken
When the normal operation has been initiated, the not to throw in the breaker.
following items shall be checked. 3.2.2 Adjustment of sharing of Effective power.
If and when the synchronously throwing in is complet-
Items to be ed, as you pay attention to the frequency, manipn!ate the
checked governor of the generator prime mover on the side of the
Checking Remarks
and
confirmed bus bar toward the "down" direction and manipulate the
1. Vibration & governor of the generator prime mover put in towards the
abnormal Attention should be paid to "up" direction and as you gradually shift the load, let
the vibrations of the covers, IR f t 0 l· . 4
sound dur- etc., them share the allotment of load.
improperly tightened. e er cause ·
ing no-load
conditions. 3.2.3 Adjustment of reactive power
--------- ---·----t-·--------i
If and when the sharing of the load is completed. as
2. Bearing Tak f f .d
tern erature ' e no ice o. a rap1 you observe the ammeter and power factor meter, adjust

3. ;~~~ction Ii;:::::::::~s:~ter th-;-·-+---------.4

of oil stop of the operation of
leakage. the machine.
(2) Voltage adjusting
It has been set up by a shop test so that the rated
voltage may be generated in the vicinity of the
center position (in the vicinity of the scale position
5) of the voltage adjuster (V AD).
The range of adjusting shall be more than ±5% of
the rated voltage.
3.2 PARALLEL OPERATION
When a generator is to be paralleled with the generator
already being operated under loaded condition, operation
be the follow-
ing procedures.
If operated incorrectly, the generator might he caused
to break down.
3.2.1 Putting into parallel operation.
(1) By manipulating the governor of the prime mover,
adjust it to the vicinity of the frequency of the
generator to which you desire to put in parallel to
the bus bar.
If the difference between the two is adjusted to
approximately 0.2 Hz (the pointer of the synchro-
scope revolves once in 5 seconds), the operation
may be easily performed.
This is the recommended value with which it can
be put in parallel without seriously shocking the
generator.
the voltage adjuster (VAD) so that the current ratio of
each generator may be equal kW allotment ratio.
In other words, by bringing the V AD of the lagging
power factored generator toward the "down" direction
and the V AD on the leading power factored generator
toward the "up" direction, adjustment should he made
in order that the power factor may become equal.
3.2.4 Separation from bus
In case that the generator under parallel running is to
be separated from the bus, manipulate as follows:
(I) Manipulate the governor of the prime mover for the
generator desired separating from the bus bar
toward the "down" direction and manipulate the
governor of the prime mover for the generator of
the bus bar side toward the "up" direction and
then shift the load of the generator desired separat-
ing to the vicinity of zero.
(2) When kW has become almost zero, the breaker of
·the machine to separated shall be thrown off.
3.3 OVERALL CHARACTERISTIC OF GENERATOR
AND AUTOMATIC VOLTAGE REGULATOR
3.3. l Characteristic of automatic voltage regulator
Typical characteristic of A VR applied in the brushless
generator is as shown in Fig. 3 .1.
~

(2) As you finely manipulate the voltage adjuster :J

&
(VAD), adjust the voltage of the generator which :J
0
you desire to put in parallel to it of the bus bar. 0::
Where the voltage difference is large, either breaker >
might trip because of the reactive cross current or <
an abnormal voltage might arise in the field circuit
which might be the cause for the break down of the
field circuit.
(3) As you observe the synchronizing lamp or the
synchroscope, throw the breaker on at the synchro-
nized point by further finely adjusting the governor.
0 450V Input voltage

(Cautions): Fig. 3.1 Characteristics of AVR

a. When the center lamp of the synchronizing lamp
dies out and the two others have become bright-
est, this is the point where the phases have
coincided.
b. Concerning the synchroscope, when its pointer
has come to immediately above the center (the
twelve hour point of the clock), this is the point
where the phases have coincided.
3.3.2 Overall characteristic of generator and automatic
voltage regulator.
No-load and full-load saturation characteristics of the
generator are as shown in 1 and 2 of Fig. 3.2. If A VR
controlled exciting current is over-lapped with them, the
result as shown in Fig. 3.2 will be obtained. Suppose the
generator is operating with no-load rated revolution, the

- 9
generator terminal voltage is stabilized as the voltage Vo No-load saturation curve
at the intersecting point B' of AYR output curve and ·---~-- ·--~ -

no-load saturation curve. If the load is increased, the

saturation curves in the direction toward l '. _../~~l .,.......-<
Suppose the exciting current stays to unincreased at /' ' 2 Load
/'/ / saturation curve
I's. the generator voltage would drop down to V L.
However. since A YR controlled current has characteristics ;..---IJ' ' .\ :)AVRControlled
0 :....--- exciting current
>
shown in A-B of Fig. 3.2, it detects very small amounts
of change in generator voltage caused by load increase, "'c
and augments the exciting current up to I"B to make the E
Q; '
difference with the standard voltage (formed within A YR)
become zero, maintaining the generator terminal voltage
I-
I
at the value of B".
Likewise. against increase or decrease of load, the
generator voltage is always maintained at a certain point Field current
on the curves A-B.
If the curve A- B is perpendicular to the axis of Fig. 3.2 Overall characteristic of A.C. generator
voltage, IN = 0 is attained and voltage regulation becomes
zero. On the other hand, the smaller the angle with the 4. MAINTENANCE
axis of voltage, the greater the amount of voltage regula- Maintenance is the key to maintaining long life and
tion. reducing repair works and running cost of generator.
Our generators, in consideration of stability during The scheduled maintenance chart is shown in clause
operation, are adjusted to have regulation at approx. ± l %. 4.1 and complece details are described in clause 4.2.
However. for parallel operation, in order to improve the Study them carefully and maintain each part before
stability of reactive current sharing. the generator is excessive ware or damage. For the generator equipped
adjusted so that the voltage may drop 3% under rated load with air filter or air cooler, please refer to another main-
and at rated power-factor, having the cross current tenance manual ENE-1815 for air filter and ENE-1816
compensating circuit in it. for air cooler.

4.1 SCHEDULED MAINTENANCE OF A.C. GENERATOR

Interval Maintenance Refer to

Daily 1. Check bearing
L.0. condition
oil ring
noise
-· vibration
temperature
Check electric circuit
Earth fault by earth lamp
Check loading condition
Voltage, output kW, current
~-··---------·-·--·-------·

1. Check insulation resistance

Caution: Before checking insulation resistance, disconnect and earthed
the leads from A.V.R.
and nuts
all bolts and nu ts.
3. Check ventilation openings Refer to separated
Check air intake opening and its air filter, clean or replace the filter, air-filter manual
if necessary.
Every 6 1. Change lubrication oil and clean bearing(s).
monthly At the same time. check fitting or seating of bearing·-·-·-------·-·-···---~~---+-------~~-----l
2. Clean generator
Inspect generator winding and air filters for dirt. dust and oil and salt vapor
accumulation.
Blow out contamination by dry and oil free compressed air.
Wipe off accumulated vapor by a lint free cloth and adequate solvent.
f----··············

Check electrical connection

Inspect for loose electrical connection
Inspect cracked, frayed, or oil soaked insulation.
Tighten or replace as neccessary.
4. Check static exciter
- Check all wire and cables for frayed or damaged insulation.
Check all connections to be sure they are tight.
-· Remove cover and remove dirt and dust by low-pressure moisture-free
compressed air or wiping with a clean cloth.

10 -
4.2 METHOD OF MAINTENANCE AND INSPECTION / Hectifier rnountintJ shell
4.2. 1 Temperature
Monitoring the temperature rise of a machine is one of
the most effective means of judging the presence of defec-
tive parts. F rorn phase U of ac exciter
Inspect each part as you refer to the following Table,
Permissible Limit of Temperature Rise of Each Part
(Ambient Temperature S0°C).

Method of Allowable limit

Part of machine of temperature
measurement
CI~~I~~~'
\'
---------- ---"-""""-"
f rorn phase V of ac exciter
1. Armature winding T
To field winding
(Generator stator winding)

2. Multi-layer field winding

-·
R or E
---------"---
T
70
60
90
J
R or E 70
3. Single-layer field winding CT. 70 90
with exposed bar surface
--~~-""-

4. Winding and adjacent

R or E
-:-+JOO
parts insulated with core T 70 90
and other mechanical parts

T: Thermometer method
R or E: Resistance or Embedded thermometer method
fig. 4.1 Connection of rotating rectifier
(Reference)
l. 80° to 8S° C will be the limit for temperature reading
of the bearing thermometer.
2. The exhaust air temperature will be increased by I S°C
to 20° C from the room temperature (In case of Class
F, 20°C to 2S°C).
3. The generator frame surface temperature will be in-
creased by l 0°C to l S°C from the room temperature.
4. In case of the totally enclosed with water cooled air
cooler, the temperature rise and the above Table "S0°C
minus temperature of cooled sea water" will be the
permissible limit of temperature rise. This means that
since the temperature of the cooled sea water is general-
ly 30°C, 20°C may be added to the above table.
4.2.2 Check up of the rectifier
Check the silicon rectifier using the resistance range of Fig. 4.2 Rotating rectifier
circuit tester according to the following procedures:
( 1) Disconnect two lead wires to the field winding
connected to the rectifier stack, disconnect either
one of protective resistance on DC side, and discon-
nect at least two of three output lead wires of AC Spots to
exciter. rnr:asured
Otherwise, the measurement is impossible because
it is affected by the resistance of field winding and
exciter winding.
( 2) As seen in Fig. 4. 1, the rectifier has rectifying ele-
ments which meet the requried current at each
phase, connected in parallel. Fig. 4.3 Spots to be measured for gap

4.2.3 Measurement of air gap the top, left and right. shall be measured (If possible.
The unbalance of the air gap (the gap between the gaps should be measured at 4 places).
stator core and rotor core) may cause abnormal vibration (4) Confirm if the difference of the maximum values of
and deterioration of the electrical characteristic of the the gaps is within 15% of an average value. Whatever
generator and result in shorting the life of a machine. exceeds is required to be readjusted.
Also the unbalance will be caused by the "looseness" (S) When inserting a gap gauge, as shown in Fig. 4.4, it
of the mounting bolts, the "distortion" of the base and should be inserted at an angle of approximately I 5°
the "sinking" due to the wear of bearings. When an air with the center of a shaft. Since the rotor surface
gap unbalance over indicated (4) has occurred, the gap
should be adjusted as well as adjusting the centering. The
methods for measuring the air gap shall be shown as
follows:
15
(I) Prepare a gap gauge (The one, 300 mm to SOO mm
in length, is desirable).
(2) Remove the generator cover easily to access to the
air gap.
(3) As shown in Fig. 4.3. the gaps at such 4 places as
the top. bottom, left and right or such 3 places as Fig. 4.4 Inserting angle of gap gauge

- 1I
 may not be of coaxial in its structure, as in case of
having slots or in the salient pole type, if the gap
gauge is inserted paralled to the shafL the minimum
gap may not be always measured.
(6) At operating condition, the rotor would be lifted
more or less.
Therefore, the air gap on the top side should be
adjusted at approximately 0.1 mm wider than that
on the bottom side.
4.2.4 Bearing and lubrication oil
Since bearings arc particularly important in the
mechanical function of a generator, the maintenance
inspection should be carefully enforced as follows:
( I ) Periodically check the level and the degree of con-
tamination of oil.
(2) When starting, it must be confirmed by all means
that the oil ring is revolving smoothly.
(3) In case of forced lubricating system, check through
the oil sight window on the oil outlet side of the
bearing stand to confirm that the flow and color
of oil are not abnormal.
( 4) Check the bearing temperature with the thermo-
meter. Daily check the temperature and pay atten-
tion to any change due to the rapid temperature
rise. The maximum bearing temperature during the
normal operation should not exceed 80°C to 85°C
by thermometer reading;
Causes for the overheat of bearings are:
a. Shortage of lubricating oil.
b. Contamination and deterioration of lubricating
oil
c. Excessive thrusting load is being placed due to
improper installation.
d. The shaft journal is strongly pressed to the upper
half of the bearing due to the improper centering
and/or alignment.
e. The roughness of the shaft journal due to ele-
ctrolytic corrosion by the shaft current.
f. Abnormal contact and/or gap between shaft
journal and bearing surface due to the excessive
wear of bearing.
(5) The bearing gaps are to be measured to compare the
outside and inside diameters of the shaft at mroe
than several places with a micrometer.
The most simple and reliable method of measure-
ment is as follows.
a. Remove bearing cover and upper half of bearing
metal.
b. Place thin lead wire on the shaft.
c. Place bearing metal at normal position.
d. Place bearing cover at normal position and tighten
bolts.
e. After loosen bolts and remove cover and metal,
take out pressed lead wire.
f. Thickness of pressed lead wire is equal to gap.
(Fig. 4.5) The gap of a bearing shall be maintain-
ed within the value to be given the following
formula and if this is exceeded, the hearing
should be replaced.
C = The gap on the top part
of the bearing (mm)
C=Dx-L5 +OJ
1000 . sure to be taken.
D Shaft diameter (mm)
The pressed lead
Bearing
Shaft
Fig. 4,5 Measurement of gap of bearing
-12
(6) Check oil leakage from the jointing flange of the
bearing box.
If severe, it will be necessary to take a counter-
measure for oil leakage.
( 7) Inspect that the flank surfaces of the oil ring is not
abnormally worn out.
Also check that the screws of the joints which
divides into 2 pieces, are not loose.
(8) When cleaning the bearings, use a soft and clean
lintfree cloth to wipe off oil.
Also take care of removing oil dregs, dust or dirt
and metal flakes remaining in the bottom of the oil
pot.
(9) The simple maintenance and repair of the bearing
are shown as follows, take care according to the
case.
a. Partial touching or abnormal ware of white
metal.
Check and observe the luster of white metal care-
fully. When it's touching partially, check align-
ment and correct as necessary.
However no doubt is existing in alignment and
considering defect of bearing itself, scrape off the
improper touchding surface(s) so as to let it
contact equally.
Check finishing surface applying red lead.
Scraping should be minimum as far as possible
to avoid the gap is increasing abnormally.
b. Eccentricity and lateral deflection of oil ring.
Machining to an accuracy of approximately
5/IOOmm.
c. Looseness of jointing screws of oil ring.
Check join ting screw.
Re-tapping the hole one class larger, if necessary.
d. Streaks and scars on bearing surface.
Scrape off as descnbed in (a).
e. Electrolytic corrosion.
Check insulation of shaft current protection,
correct them as necessary.
Bearing metal is maintained with scraper as case
(a).
f. Rust on the shaft journal, soak a hemp rope with
oil and polish it by applying oxidizing chrome.
g. Burning out or breaking off of white metal.
Replace with a spare bearing.
(I 0) Lubricating oil.
The following or the equivalent is recommended
(Mixing two diffrent kinds of oil must be absolutely
avoided).
* High speed machine (2 pole:4 pole machine)
.. ...... turbine oil #I (90) (JIS K2213)
* Low speed machine (Above 6 pole machine)
.. ...... turbine oil #2-- 4 (140-200) (JIS K2213)
( 11) Oil quanitty of forced lubricating system, Refer
to outline drawing for each vessel.
4.2.5 Vibration
At the time of shop test, the balancing has been fully
completed. However, just in case the vibration value
should greatly change for some reason or other, since this
might be connected with the breakdown of the machine;
the cause should be investigated and an appropriate mea-
(I) Cause and countermeasure
Cause for abnormal vibration Countermeasure
Foreign material is attached Rc'move the foreign
to the rotor material
2. Unbalance of electrical load Remove the unbalance of
to each phase load
3. Inequality of air gap Adjust the gap
 Check the deflection of the The degree of deterioration will depend upon the con-
4. Miss-alignment couplings and correct it ditions and situations to which the equipment is exposed.
within the value 5/100 mm.
for instance, the environments. operating manner. load
Retigh ten the bolts and condition and the degree of handling care.
nu ts of each part
5. Loosen bolts and nuts (including the stator and Even though extreme care is used. the oxidation and
bearing stand, etc.) erosion may be the cause for deterioration.
6. Inproper bearing touch or Adjust the fitting or In particular. it is not desirable to leave the generator
wide bearing gap. replace with spare bearing. unused.
The rotor coil needs to be Were the other factors to be constant, the insulation
7. Layer short of rotor coil either reparied or replaced. resistance would decrease because of the deterioration of
the insulator itself.
Because of these reasons. measuring the insulation
4.2.6 Cleaning of winding resistance periodically is useful to ascertain the condition
When the coil surface is contaminated with oil vapor, of insulation and as to wheather or not the particular
etc. it should be cleaned in the method described as machine will be suitable for the operation, in measuring
follows. the insulation resistance, the following matters should be
However, when splashed with sea water and the like, taken into consideration.
since this subclause won't be applicable, please contact a. Measure periodically and record with tempera-
our company. ture and humidity.
( 1) Solvent can be used. b. The measurement shall be conducted immediate-
Such non-inflammable solvent as Parchrolethlene or ly after the machine shut down while it's still in
Trichlene shall be recommended. a hot state.
Due to the presence of hazard of fire on board, the c. If the machine is exposed either to over load or
inflammable solvent must be absolutely avoided. to the moisture, sea water, vapor and dust or
(2) Cleaning dirt, etc, or if the machine always shows a low
Disassemble the generator to facilitating of cleaning resistance value, measure frequently.
the generator and as spray the solvent on the coil d. In addition to the measurement while hot,
surface with a spary-gun, lightly rub the coil surface measurement should also be made while shut-
with a brush, etc. down at the room temperature.
a. Stator coil The record of the effect of the moisture and
The whole surface of the coil ends, series connec- temperature for the insulation resistance of the
tions and phase connections should be carefully machine may be obtained by the measurement
cleaned. while cold.
Also check whether or not the slot wedge is e. The parts where such semi-conductors as a tran-
loose. sistor, silicon rectifier and thyristor are used,
coil shall be separated or short-c!fcu1ted lest
The entire surface of the coil should be cleaned. abnormal voltage should be placed and then shall
The insulated collar and the pole connection near be measured.
the earth should also be cleaned.
c. Cautions during cleaning ( 1) Methods of measurement
Don't damage to the insulation. DC500V Megger shall be prepared.
Clean until the solvent which dropped off a. Separate electrical connections as practicably as
become~ clear. possible.
To avoid being poisoned, take care of ventilation. Normally the connections and attached equip-
(3) Drying method ments can be separated by opening the power
Cover the whole generator (the stator and rotor) switch, braker and contactor.
with a canvas sheet and blow the hot air with a hot However, in case the data for measurement are
air dryer. judged to be too low to the safe value, measure
Care should be taken so as not to locally overheat after all the cables have been disconnected at
due to the direct blowing of the hot air with the coil terminals.
surface and the shaft, etc. The insulation resistance of equipments (machine)
The drying temperature shall be approx. 90°C. may be often higher as compared with the cables
When covering it with the sheet, provide spaces in and often insignificant as a measuring value.
order that the hot air may sufficiently circulate the Also if the measuring value of the equipment
whole. itself is too low, as you separate the internal
(4) Judgement of drying condition connections, proceed with measuring each part
The insulation resistance during drying may be one after another until the place of low resis-
varied as indicated Fig. 4.5. tance is found out.
The drying is finished when the insulation resistance b. Short-circuit each terminal by the each blocks
is saturated. such as the main circuit and excitation circuit,
(5) Varnish treatment etc.
In selecting the varnish to treat with, it will differ The terminals group not to be measured shall be
according to the drying conditions, etc. contact our grounded.
company. c. Connect the insulation resistance tester between
the terminal block to be desired and the ground
4.2.7 Insulation resistance and measure the insulation resistance.
Insulation resistance is one of the important factor Due to the distributed capacity of the machine,
with which to decide the quality of an electrical machine. even though the pointer of the insulation resis-
The insulation materails will vary together with the tance tester indicates near zero, since the resis-
time due to the single of combined effects of the heat, tance value will gradually rise as it's charged,
moisture, vibration, dust or dirt, oxidation and the continue measuring it until it's settled at a
chemical transformation by an acid or alkali, salty, air and certain value.
oil, etc. d. After the measurement is over, remove the short-

13
 circuited lead wire (not to be forgotten! I). composed of all the static instruments, no particular
maintenance is required.
( 2) Judgement of measuring value
However, in case the equipment is installed at where
Measuring with SOOY magger, the minimum value
vibration might be severe or dust or dirt may easily
should be higher than the value given by following
stick, periodically (approximately every 6 months
formula.
and when the environments are particularly bad,
every 1 to 3 months) check for the loosened bolts
R= Rated voltage of _ma_(;l1ine _)<_]__ (Megohm) and nuts or screws at terminal and connecting part
Rated output (kV A)+ 1000 of electric wire and also check if any parts might
be broken as well as checking for the accumulation
For the judgement of the quality of insulation, the of dust or dirt. etc.
best method is to compare with the value previously
measured.
The variation from the measurement value taken at 4.3 Scheduled maintenance for automatic voltage
the previous time, will be more significant than the regulator
present measurement value itself.
Therefore, it is required that the insulation resistance Interval
value should be continuously measured and record- Monthly 1. Equipment installation Check
ed always with the same procedure. 2. Wire connection Check
(3) Remedy in case of lower insulation. Half-yearly I. Spare parts Check
a. In case that the cause for low insulation resis- 2. Spare AYR Check
tance is judged to be due to the presence of
excessive moisture and the external conditions of
the moisture and foreign substance accumulated Note-!) Checking of Insulation resistance
on the surface of the insulator, it will be ·necessary Usually the checking of insulation resistance to A VR is
not necessary, but if required, take special care as;
to clean and dry.
i) Jump and short circuit all terminals on A VR and
b. In case that the variation from the previous data
related current transformers and power trans-
as shown in Item (2) rapidly decrease even con-
formers, for getting all equipments into equal
sidering the temperature effect, as shown in
potential when apply the high voltage of megohm-
Item ( 1) a, after separating it in small sections
meter.
one after another, the cause for low insulation
The voltage of megohm-meter should be limited
resistance must be investigated.
up to SOOY DC.
4.2.8 Inspection of excitation equipment The lower limit of insulation resistance to exciting
Concerning the excitation equipment, since it's
equipments are O.S megohm, if the measured
value is less than 0.5 megohm dry them with
heated air as follows.
ii) Keep temperature of heated air lower than 70° C.
,r-------- 90C Remove plastic cover off the A VR.
/ Dry until the insulation resistance is satulated
/ and get constant value, usually about 4 hours are
/
/ necessary.
/ iii) When check the insulation resistance of generator
/ stator winding, exciter field winding, current
/
/ transformers and power transformers directly
connected to A VR, remove all wirings to A VR
At an earier time of drying on terminal boards.

t
the ins. resistance trend to
decrease minir«um value. t
- Time \Hr•

Fig. 4.6 Variation of ins. resistance during drying.

4.4 Checking of equipment relating to A YR.

_ _ _ _ _ _ _J _ _ _ _ _ Remedy if necessary
Fitting I. Check AYR and its parts to be sure they are tight securely Fit them properly.
2. Check inside of cover for substance, dust and dirt. Remove and clean
>--·-------;-----------~~----

Wiring 1. Check all wires for frayed or damaged insulation. Repair the wire or replace with
spare AVR
2. Check all connections to be sure they are tight. Re-tighten
3. Check terminals for contamination of dirt and dust. Clean and remove
--!---- ......... C--·-----------------j---··-----------------------l
Parts 1. Check build up relay for abnormal sound. Dismantle and clean both moving
and fixed iron cores.
2. Check all parts for rust on their surface Clean
3. Check all parts for damaged
4. Check printed module for spotlly and evidently over heated Replace with spare AVR
5. Check resistances for over heated
6. Check transformers for overheated
7. Check voltage adjusting rheostat for smooth rotation, poor contact Replace with spares

14
 Also the chart for troubleshooting shown below should
be utilized as follows;
5. TROUBLE SHOOTING Trouble ............... The concrete phenomenon of a
Each instrument has been designed by based on the trouble.
long experience and actual accomplishment in the marine Check (I) .............. Try as shown
field of our company and delivered after having been Result (I).............. Indicates the result of the trying
strictly tested. performed as shown in Check 1.
It is no exaggeration to say that the breakdown of Check (2) .............. In accordance with the item applica-
instrument itself may be none. ble to the phenomenon appeared in
Therefore, most of the breakdowns are caused by the Result 1, again try as shown in Check
improper contact and tightening of terminals between 2.
equipments. Result (2) .............. The result of the trying performed as
The investigation for the cause of trouble should be shown in Check 2.
first initiated from the contacting parts and tightening Probable ............... The probable cause from the above
parts. cause checks and results.

5.1 CHART OF TROUBLE SHOOTING

Item Trouble Check (1) Result (1) Check (2) Result (2) Probable cause Remedy
1. Overheat of Over current ---------+-------_,_.. Over current Decrease load
stator winding
Less than rated-+--------+------~-+--Ambient ---Ventilate and
current temp. high 1
decrease temp.
'
I
Generator--+ Clean generator
contaminated I and winding
Air filter --+clean air filter
contaminated
and accumulated
vapor

Cooling waterlf, Check air cooler

shortage ;
i
Cooling tube ---'
contaminated
I
I
2. Overheat Check L.O. Normal l l C h e c k oil High - - - - + - - - - - - - - C h e c k L.O. system
bearing flow temperature on
forced lub.
system Normal -~--+--L.0. ~Replace new L.O.

Check oil ring

' on self lub.
system
Normal Thrust
touched
ti'
contaminated

Check mounting

Poor fitting of __._Correct

metal caused alignment
misalignment
Metal surface -+.Check shaft
roughed by ' current priventing
shaft current insulation
Abnormal--+- Oil ring ---+-Replace oil ring
' defective
Oil amount a n d - + - - - - - - - - + - - - - - - - - + - - - - - - - -.... Make to have
pressure normal condition
shortage

3. No voltage
establish
Disconnect
leads from·
terminals
U2 and V2 on
AYR
voltage establish I
No voltage
establish
I

Check all
connections in
exciting circuit
Check.being of
l
More than rated-t--------+--------+- AVR defective --Replace AVR
I

less than 3% ~+----------Flashing

remanmg
voltage of Silicon ----+Replace
generator rectifier fault rectifier
Check rotary --+-------+--Silicon -----Replace
rectifier for rectifier rectifier
defect panctured

15
 4. Excessive 11.
high voltage
Re-adjust
voltage by
[90R]
Return to rated
value

2. Re-adjust No change Check [90R] Poor contact-+--------+- Replace [90R l

voltage by for defect or defect.
[RHl] on At normal, have I
I printed 100-150ohm
resistance
I
\ circuit board
I of AVR

I
Check AVR
input voltage
and wiring
Open circuited
°' pom oootod f Make to return
~ noraml condition
Normal AVR Replace AVR
I I
defective

5. The voltage l. Re-adjust iITReturn to rated II

don't reach to voltage by I value
rated value [90R] .
I1 I
2. Re-adjust-' ~ I
voltage by I
[ RHl ] on No change ____J_ Check [ 90 R j Poor contact -+-------+-Replace [90R]
printed 1 for defect or defect
circuit board
of AVR Normal, have _i A VR - - Replace AVR
100-150 ohm I defective
resistance I
I i
I
I
6. Voltage - - - - 1 - Turn [RH2] Become t o - - + - - - - - - - - + - - - - - - - - + - - - - - - - _ , . . . Set on the
fluctuation to right and , stable optimum point
left slowly on I '
----.-Replace AVR
board of AVR I for poor I I defective
contact I
I ' Poor contact-+-------~Replace [90R]

I
1
'
1
7 1. -- load
01..
1
barancing unbalanced defective
effective load
(kW)

2. Check~· Cross current -+--------+---------Miss-adjust- Correct voltage

'· cross-current unbalanced ment of by [90R]
1
• voltage
I

Cross current Check AVR

compensating
circuit defective I

5. 2 Checking method for defective point

I) Silicon rectifier

D~~~ction ~3~~~~ort_<-:_~cuited I Disconnected

1

Nd.orm~ I 10-50 ohm I less than 10 ohm I infinity

uect10n : I ,
---------------~ --r----------t---~----------i----------

R.everse
d uect10n
i infinity I less than 10 ohm I infinity

NOR. REV.

2) SCR
a) Anode-cathode

Direction Normal Short Circuited Disconnected

--- ·---------
Normal infinity infinity
direction
--···
Reverse infinity infinity
direction 0
I

*) It is hard to distingmsh the state of disconnected SCR from

normal
NOR. REV.

- 16
 b) Cathode-Gate

6. DISASSEMBLY OF A.C. GENERATOR

Normally, resistance value in reverse direction is higher
than normal of it by 20 - 900 ohm. 6.1 Dismantling Procedures ... Bracket type-!
Refering to Dismantling drawing E3-6 7709 I. carry out
the works as follows:
I. Disconnect the lead (J and Kl of the exciter field
coil, oil supplying and discharging pipes and oil sight
boxes.
2. Remove the thermometer
3. Remove the covers @ . . Q)
NOR REV 4. Remove the exciter fan
5. Insert the protective board to the exciter air gap qi).
c) Operating check of SCR proper (Insert it up to the thickness as close to the measure-
ment of gap as possible.)
,______
Checking procedure
---~~
Indication of tester
--~·~·~---f---- ·~---1 6. Remove the bolts jointing bearing cover . bracket
1. SWl ON 0 @ and the exciter frame (iOJ And take it (ft!)
2. SW2 ON about 200 mA off to the non-driven side.
3. SW2 , OFF about 200 mA 7. Remove the bolts jointing bearing covers
and Cf6l (f,P . And take (i) , @ off.
The SCR is good when above indications of tester are 8. Take out the upper half bearing @ . (8)
obtained. 9. Remove the fan ® off from the fan boss.
I 0. Insert the protective board into the generator
gap.
(Insert it up to the thickness as close to the measure-
ment of gap as possible.)
11. Hang the rotor with ropes at "A" and "B" parts of
the shaft and take off the lower halves of bearing, and
the bearing brackets @ Q~ , then transfer the
rotor to the non-driven end and separate facet from
the driving shaft, and place the rotor on the stator
":"BATTERY core.
: 1.5Vx4 12. Apply rust preventing oil on the shaft journal and
I
provided it with protective wrapper.
13. Draw the fan out of the shaft.
14. Draw the upper side of the fan guide (§) out of the
frame.
15. Hang the rotor with ropes at "A" and "B" parts of
the shaft and move the shaft to the non driven end
then the center of gravity "G" of the rotor will be
out of the stator frame.
16. Tie the rope at the center of gravity "G" hang it and
draw the rotor out of the stator.
Note: Take care not to damage any parts and insulators.

(
I
I

Bracket type brushless generator (L3-6 7709 l)

17 -
 10. Hang the bearing bracket @, turn it upward along
the shaft and remove it.
1 1. Apply rust preventing oil on the shaft journal and
cover it with protective wrapper.
12. Insert the protective board (21J into the exciter rotor.
13. Insert the protective board @ into the generator
gap. (Insert it up to the thickness as close to the
measurement of gap as possible.)
14. Disconnect the leads (J and K) of the exciter field
coil.
15. Remove the fixing bolt of the exciter stator frame @
and place the exciter stator on the exciter rotor.
Fig. 6 The state of the rotor at one line hanging 16. Slacken the rope at "C" part, place the rotor on the
6. 2 Dismantling Procedures ... Bracket type-2
generator stator core, and withdraw the exciter
stator frame @ .
Refering to Dismantling Drawing 3-6 73064, carry out 17. Hang with ropes at "B" part of the shaft, turn
the work as follows: upward the lower half of the bearing @ and take it
1. If the tacho-genc or the speed detector is con- out.
nected to the end of generator, dismantle and remove 18. Hang at "B" and "C" parts of the shaft, transfer
it. the rotor to the non-driven end, and separate faucet
2. Remove the oil drain plugs @J and , and dis- from the driving shaft.
charge the oil. (In case of the forced-lubricating 19. Remove the rope at part "C", rebind it at the bearing
system bearing, also remove oil supplying and oil bracket @ , remove the bracket @ , turn it
discharging pipes and the oil sight box.) upward along the shaft and withdraw it. (Slacken
3. Remove the thermometers and at the point where inlow of the bracket at part "B"
4. Remove the covers , , @ and and place the rotor on the stator core.)
5. Remove the bolt joining the upper and lower parts 20. Apply rust preventing oil on the shaft journal and
of the bearing bracket, and remove the caps @ and provide it with protective wrapper.
'.!:j; the upper half of insulating washer @ . and the 21. Hang at parts "B" and "C" of the shaft, move it to
upper parts of bearings and @) . the non driven end remove the rope at part "B" and
6. Remove oil rings @ and '22 . (In case of forced- withdraw the fan "B".
lubrication, this work is not required because it has 22. Attach the joint shaft CD to the flange, change the
no oil ring.) rope hanging gravity to part "A" and with further
7. Take the fan off from the fan boss. moving, the center of position "G" of the rotor
8. Remove the bolts connecting the prime mover goes out stator.
coupling and generator coupling. 23. Bind the rope at the center of gravity "G" and,
9. Lift ·c' part of the shaft with ropes, turn upward with unifilar lifting, pull the rotor out of the stator.
the lower half of the bearing , and draw it off.

Bracket type brushless generator "A", "B", "C" ....... lifting position
( 3 673064)

-18-
6.3 Cautions for disassembling/reassembling c) The end play between the bearings and the shaft
1) To use a 0.5 ~ 1.6 mm press-board for protective thrust surface.
cushions is recommended. Diesel driven Gen.
2) In suspending the entire generator, use the eye Driven end bearing: 2.5 mm (Both sides)
hooks on the stator frame by all means. Non driven end bearing: 3.5 mm (Both sides)
3) The adjusting shims, insulating plate and bolts and 11) When inserting bearing thermometer, pour oil into
the like should be kept at their respective positions the hole of the bearing (the oil is the same or equiva-
to prevent miss-reassembling. lent to the one used for the bearing).
4) Confirm that the space heater circuit is OFF at the 12) Confirm that the insulators for preventing the shaft
time of the disassembling. current are installed in the proper places.
5) When taking bearings out of the bearing bracket,
confirm the match-mark lest the fitting direction
should be mistaken. 7. ADDITIONAL ORDER OF SPARE PARTS
6) Clean the whole rotor and inside of stator with When making on additional order of spare parts, please
dried compressed air. give us information as follows.
In particular, the inspection and maintenance of the It is required that the order should be made either to
shaft journal should be conducted with extreme the service sect section of our company's head office or to
care. the marine section of our nearest business office.
7) When the installation of the revolving parts have 1) Drawing number of the spare parts list
been removed, inspect to ascertain if the rocking As indicated in Fig. 7 .1, the drawing number is
of screws and nuts is applied, particularly. indicated on the corner of the right below.
8) Bearings and bearing bracket or the inside of the oil 2) Ittm number and name of required spare parts.
bath of the bearing bracket should be cleaned with 3) No. of sets required.
solvent of parchrolethylene or Toyoclean, etc.
Take sufficient care in ordar that no foreign Sub-
stance may be mixed.
9) When fitting bearings into, drop a small amount of
lubricating oil onto the journal surface of the bear-
ing.
10) At the assembly, check the following dimensions.
a) Allowable limit of avarage difference of the air
gaps between the generator stator core and the
rotor core is less than ±5%.
b) Allowable limit of avarage difference of the air
gaps between the exciter field core and the arma-
ture core is less than ±0.5%.
Refer the value to the test record.
Fig. 7. I Spare parts list

19 -
 • PRODUCTION ITEMS

1. Power generation equipment 4. Industrial equipment

• Continuous/emergency power genera-
tion system.
(Engine generator, turbine generator.
mini hydro generator, etc.)
• Co-generation system.
• Automatic control system for power
generation.
2. Electric dynamometers
• Electric dynamometer and control
system.
• Engine and power line test system.
• Computerised automatic operation and
measuring system for engines.
3. For marine and offshore
• Power electronics system.
•Shaft generating system and crane
drive system.
• Computerised power generating and
drive system.
• Submerged motors.
• Various generators, motors and
controllers.
• Various fans and blowers.
•Compressors.
• Ultra sonic cleaning system.
• Mechatronics.
5. Power distribution and
control equipment
• Power electronics application system.
• Automatic control system.
6. Micro-software
•Automated system.
•FA/LA system.
•QA/business software.
7. Precise processing products
• Press and plastic die.
•Tools.Jigs.

~ NISHISHIBA ELECTRIC CO., LTD.

Head Office: 1000, Hamada, Aboshi-ku, Himeji, 671-12 Japan.
& Factory Telephone(0792)74-2382 Fax(0792)74-1094
Tokyo Branch: Mita Plaza Building, 4-3. Mita 5-chome,
Minato-ku, Tokyo, 108 Japan.
Telephone(03)3454-6411 Fax(03)3454-6340
Osaka Branch: Shin-Osaka Sanaru Building, 9-2, Nishinakajima
5-chome, Yodogawa-ku, Osaka, 532 Japan.
Telephone(06)390-0353 Fax(06)390-0360
Nagoya Office: Nagoya Chamber of Commerce & Industry Building,
10-19, Sakae 2-chome, Naka-ku, Nagoya, 460 Japan.
Telephone(052)201-1160 Fax(052)201-1161
Hiroshima Office: Uemura Building, 8-11, Otemachi 3-chome,
Naka-ku, Hiroshima, 730 Japan.
Telephone(082)244-1830 Fax(082)247-4098
Kyushu Office: ltoh-pia Tenjin Building, 10-11, Tenjin 5-chome,
Chuo-ku, Fukuoka, 810 Japan.
Telephone(092)722-2448 Fax(092)722-2300
Tohoku Office: Atami Daiichi Building, 8-1, Futuka-machi,
Aoba-ku, Sendai, 980 Japan.
Telephone(022)262-4820 Fax(022)215-3263

This data in this document are subject to change without notice.