INSTRUCTION MANUAL FOR SOLAR TURBINES, INC. PART NO. 1010946-52291 -1 P/O NO.KM9702639 PROJECT BLUEWATER MARINE 12748 SERIAL NUMBER @ Rockwell Automation 5% Kato EngineeringNote: This unit is BASEEFA CERTIFIED. Fittings, electrical connections, covers, or engineering design should not be modified. Any modifications to the original design of this unit may affect BASEEFFA certification. If there is any question concerning this unit and it's BASEEFA certification, please refer to the BASEEFA speci- ficationSERIAL NUMBER 12748 - CIRCULATING OIL LUBRICATION a LUBRICATE BEARING WITH A CIRCULATING LUBE OIL SYSTEM WHICH MAINTAINS OIL LEVEL AT THE CENTER OF THE SITE GLASS USE A HIGH QUALITY, DOUBLE INHIBITED MINERAL OIL. WITH VISCOSITY, PRESSURE AND FLOW RATES INDICATED BELOW. THE OIL SHOULD CONTAIN OXIDATION AND RUST INHIBITORS AND DEFOAMANTS )PPOSTE DRIVE BEARING NUMBER. 012-63719-26 012-63719-27 SUMP CAPACITY 6.4 GAL. 6.4GAL. OIL VISCOSITY ISO VG32 ISO VG32 OIL FLOW RATE (GPM) 2.4-2.8 GPM 3.0-3.4 GPM 7 OIL PRESSURE 45 PSIG MAX 45 PSIG MAX ODE ORIFICE - 5/32". DE ORIFICE - 11/64" @8 Rockwell Automation Kato Engineering 00 157-00128: :SERIAL NUMBER 12748 - CIRCULATING OIL LUBRICATION ate LUBRICATE BEARING WITH A CIRCULATING LUBE OIL SYSTEM WHICH MAINTAINS OIL LEVEL AT THE CENTER OF THE SITE GLASS USE A HIGH QUALITY, DOUBLE INHIBITED MINERAL OIL WITH VISCOSITY, PRESSURE AND FLOW RATES INDICATED BELOW. THE OIL SHOULD CONTAIN OXIDATION AND RUST INHIBITORS AND DEFOAMANTS. )PPOSTE DRIVE on DRIVE END BEARING NUMBER 012-63719-26 012-63719-27 SUMP CAPACITY 24.2 LITER 24.2 LITER OIL VISCOSITY ISO VG32 ISO VG32 OIL FLOW RATE (GPM) 9.0-10.6 LPM 11.3-12.9 LPM > OIL PRESSURE 3.1 BAR MAX 3.1 BAR MAX : ODE ORIFICE -3.97mm DE ORIFICE -4.37mm @ Rockwell Automation Kato Engineering 00 00128. 157.Publication # 250:05009.00 Publication Date Nov. 1993 Instruction Manual for Renk Bearings (Type "EM" & "EF") In Kato Generators Includes: Installation } & ; Recommended Storage of Kato Generators with Renk Bearings @® Rockwell putomation go) Kato Engineering Trance, S60 847 (607) 625-4011, FAX (607) 345-2708PAGE Table of Contents DESCRIPTION Introduction Pre - Installation Bearing Installation Recommended Torque Values - Table 1 Part Description (Sealents) - Table 2 Parts Drawing "EM" Type Bearing Parts Drawing "EF" Type Bearing Oil throughput Graphs Bearing Temperature/speed Graph Recommended Storage Procedures For Kato Generators with Renk BearingsInstructions for Installation of Renk Sleeve Bearings Type "EM" and "EF" Flange Mounted Bearings Equipped With Loose Oil Ring ‘These instructions contain only specific information relating to the bearing models listed below. Bearing Code Definition: Type E electric machines Housing F finned, flange-mounted M finned, flange-mounted Heat dissipation N natural cooling Z lubrication by oil circulation with external oil cooling ‘Shape of bore and type of lubrication L_ plain cylindrical bore, loose oil ring lubrication Thrust surface B plain white-metal lined shoulders with oil grooves K —_ white-metal ined shoulders with taper land, faces Q no thrust capability Example: E FNL Q 14-160 Slide bearing type E with finned housing, flange- ‘mounted, natural cooling, plain cylindrical bore, loose oil ring lubrication, non-locating bearing, housing size 14, 160 mm shaft diameter. INTRODUCTION Sleeve bearing performance is dependent on proper installation, lubrication and maintenance. Before assembling the bearing carefully read all instructions contained herein to become familiar with the com- plete bearing assembly procedure. ‘Threaded holes for connecting the RTE’s, Tempera- ture Bulbs, oil sight glass, oil inlet, and oil outlet are provided on either side, so that all connections ‘can be made on the right or left side of the bearing Publication 360.05000-00 Publication Date Nov. 1993 housing as required. Refer to the generator dimen- sional drawing and reference drawings for proper location. The oil filler plug for "EM" type bearings ‘can be found on the housing cap. The oil drain plug, is located centrally in the underside of the bearing housing. In the case of circulating oil lubrication, the outlet connection can be screwed into the threaded hole of an oil sight glass. (see figures 1 & 2) Figure 1 Oit inlet and Outlet Figure 2 RTE and Sight Glass ‘The “EN type bearing is fumished with an additional air seal to prevent oil from being drawn out of the inboard end of the bearing by a low-pressure zone generated by the rotor movement. Atmospheric equalization is accomplished by dual heat-resistant hoses, Bearing liners size 18 to 28 are provided with M16threads, where lifting eyebolts may be temporarily attached. For the transport of a completely assembled bearing, Lifting eyes are provided in the upper half of the bearing housing. For safety reason special care should be taken that the threads of these eyebolts are Subjected only to tensile stress and not to bending stress. It the bearing is electrically insulated by RENK, the spherical liner seat surfaces in the housing are lined with a nonconducting material. NOTE: Do not remove this lining. The anti-rotation pin is also insulated and the shaft seals are manufactured from a special non-conduct- ing material. ‘Temperature monitoring instruments with contact to the bearing liner should be insulated appropriately (de, insulated protection tubes, synthetic fitings, etc.) ‘The bearing has been shipped assembled, but without lubricant. Accessories, such as oll ring are enclosed but separately packed. PRE - INSTALLATION ‘The “EF” type bearing requires the installation of the machine seal over the shaft before installing the bearing bracket. Install mounting screws and tighten to rated torque after the bearing bracket is installed, Check the contact face and mounting recess of the bracket making sure its clean and properly ma- cchined. Inspect the shaft to ensure itis smooth (R, 0.4, equivalent to 32 micro-inch finish, or better.) After removing the upper part of the housing and the bearing liner the interior of the housing and the running surfaces of the liner are to be cleaned thoroughly and checked for any damage caused in transit. Look for signs of sealant on all plugs and sight glasses. If it does not appear that sealant was used fn the plugs or sight glasses, remove the plugs or sight glasses, clean the threads of the plugs or sight glasses and threaded holes and reseal with teflon pipe sealant. Pubscation # 250-05000-00 Publeation Date Nov. 1903 ‘The oil drain plug located at the bottom of the bearing housing has a copper washer. This copper washer can not be reused. Discard the washer and replace itwith a new one if the plug is removed for any reason. The bearings used for ol circulation systems have a pipe nipple with a lock nut installed. The pipe nipple replaces one of the sight glasses. Clean the threads and the threaded hole witha cleaning solvent and dry. Apply teflon pipe compound othe threads of the nipple before instalation. The pipe nipple has a dam welded into one end of the nipple. This dam must be ‘ext to the housing and rotated tothe bottom during installation. Do not allow the pipe nipple to rotate when drain lines are connected. ‘Welded, hot bent, rusted or contaminated pipes and tubes must be pickled before use. After installation, all pipes must be purged to avoid damage to the bearing due to contamination. Use kerosene, flushing oll or solvent for this purpose. During the cleaning procedure disconnect all measuring instruments and seal the connection. lll cleaning fluid must be removed and all instruments etc. reconnected before star-up. CAUTION: Under no circumstances may the bearings be connected to the piping while the lubrication system is being purged. BEARING INSTALLATION 1. Clean Bearing Parts. a, Remove grease, oil, preservatives or other deposits from all surfaces using a brush moistened with solvent. Remove grease, cil, preservatives or other deposits from all recesses and mounting surfaces on the generator and bearing. b. Threaded fasteners and threaded hole must be clean (use Loctite Cleaning Solvent or equivalent) and dry before using Loctite 242. 2. Assemble the bearing as described in the following steps. CAUTION: Bearing brackets, housings, seals and liners may be interchanged as complete assem- lies only. Individual halves are not interchange- able. a. Install the bottom bearing housing halt to the bearing bracket. Tighten mounting screws alternatingside to side starting with the bottom screw to pull the housing into the bearing bracket. These screws will be torqued after the top is installed. b. Remove the protective covering from the shaft and clean the shaft. Apply oil o the spherical seats in the housing and the shaff.(Figure 3 & Figure 4). Figure 3 Figure 4 Applying Oil to Shaft Journal Surface. CAUTION: Care must be taken to avoid damage to the axial surfaces of the locating bearing. cc. Lower the liner bottom haif onto the top of the shaft. (Remove the lifting eyebolts, f used). Rotate the liner bottom haf into position by raising the shaft to allow clearance for the liner. Pubiaton # 350-05000-00 Publication Date Nov. 1993, Figure 5 Installing Liner Bottom Halt CAUTION: Do not strike the liner with any object. 4d. Align the spit faces of the housing and liner. Lower the shaft into place. Strike the housing bottom half with a slight hammer blow to seat the liner. CAUTION: The oil ring must be handled with care as safe operation of the bearing is dependent on proper functioning of the oll ring. . Disassemble the oil ring and clean. Clean threaded holes and screws with cleaning solvent. Reassemble the oil ring in the bearing, carefully ‘engaging the dowels holding the oll ring halves together. Place (1) drop of Loctite 242 on each screw. Install and tighten the screws at the split ine Of the oil ring. Installing Oil Ring CAUTION: The outside of the two liner halves is stamped with identification numbers or marks near the split ine. Make sure that these marks align when placing the top liner half into position. Incorrect fitting may result in damage to the shaft, ‘housing and finer.1. Check the position of the alignment pins. They should extend at least 5/16" out of the liner half split face. Lower the top liner half into position. (Remove the liting eyebolts if used). Check to ensure that the loose oll ring can stil rotate freely on the shaft. CAUTION: The two halves of the floating labyrinth seal are held together by a garter spring. They ‘must be inserted into the groove of the carrier ring in such a way that the stop pin is always in the corresponding recess in the upper half of the housing or carrier ring. Incorrect installation destroys the seal. g. Verity that the contact faces of the seal to the housing are clean and free of grease, rust, etc. Disassemble the seal. Reassemble the seal in the bearing housing as follows. Apply a thin (1/32" or Jess) coating of non-hardening sealant (CurilT) to the seal faces that contact the housing groove. (The oil drain holes of the seal bottom half must be free of sealant). Tum the seal bottom halt (thas the oil dt holes) into the housing. Feed the garter spring through the seal bottom half. Set the seal top half Into place. Twist the ends of the garter spring to- ‘gether to close making sure that the anti-rotation pin isin the correct position. The seal must move freely inthe housing. (Figures 7-10) Applying Sealent Pbieaton # 350-05000.00 Publication Date Nov. 193, Figure 8 Note Position of Anti-rotation Pin Figure 9 Feeding Garter Through Seal Bottom Half ‘Twist the Ends Of the Garter Spring Togetherh. Clean the housing halt split faces of all grease and, oll with a cleaning solvent. Apply a thin (1/32" or less) coating of Loctite Uttrablue sealant on the dry lower housing half spit face. CAUTION: Verity that the anti-rotation pin is installed and seated in the top housing halt before and atter installation. CAUTION: Verity that the seal anti-rotation pin is in the correct position. Make sure that the seal fits properly into the groove. i. Cheek the position ofthe alignment pins in the housing half. The alignment pins must extend at least 5/16" out ofthe housing half spi face. Lower the top housing half into place. Verity that the anttrotation pin inthe top bearing housing halts stil in place and has not been pushed up. Ifthe pin has moved up, remove the top housing half and reinstall. Figure 11 Installing Top Bearing Housing. Note Fixture. (CAUTION: The socket head screws and the flange Screws must be tightened in a diagonal pattern to rated torque to prevent loss of oll through the splitline. |. Clean the threaded holes and screws of grease and oll with cleaning solvent. Dry the threaded holes and screws. Place (4) drops of Loctite 242 on each screw. Install the four screws holding the housing halves together tightening to rated torque in a diago- nal pattem. Tighten to rated torque the screws holding the bottom housing half to the bearing bracket. k. Clean the seal carrier mounting bolts and threaded holes of grease and oil with cleaning solvent. Dry the threaded holes and bolts. Apply alight coating of Pbsicaton # 360-05008-00 Publication Date Nov. 1952 ‘sealing compound (Permatex No. 3) on both sides of ‘anew seal gasket. Place the gasket in a clean location for 15 minutes to let the sealing compound become tacky. Install the seal gasket around the shaft inside the generator using the sealing com- pound to hold the gasket to the bearing housing. CAUTION: The two halves of the floating labyrinth seal are held together by a garter spring. They ‘must be inserted into the groove of the carrier ring in such a way that the stop pin is always in the corresponding recess in the upper haif of the housing or carrier ring. Incorrect installation destroys the seal. |. Verity that the contact faces of the seal to the seal carrier are clean and free of grease, rust, etc. Disas- semble the seal. Reassemble the seal around the shatt near the bearing housing. Place the seal bottom haif (it has the oil drain holes) under the shaft {and the seal top half on to the shaft. Feed the garter spring around the seal bottom and top halves. Twist the ends of the garter spring together to close making sure that the anti-rotation pin is in the correct position. im. Apply a thin (1/82* or less) coating of non-harden- ing sealant (Curil) to the seal faces that contact the cartier groove. (The oil drain holes ofthe seal bottom half must be free of sealant) 1. Apply a thin (1/82" or less) coating of Loctite Untrabiue sealant to the seal carrier top haf split face. Place the seal carrier bottom half (including labyrinth ‘seal) onto the shaft near the bearing housing. Place the seal carrier top half into position on the seal bottom halt. ‘The labyrinth seal must move freely in the housing. Install the assembly into the bearing housing against the gasket. ©. Verify that the threaded holes and bolts are clean and dry. Place (2) drops of Loctite 242 on each ‘screw. Install mounting screws in place and tighten finger tight. P. Apply a slight upward pressure on the seal bottom half while tightening the seal mounting screws. Tighten the screws in a diagonal pattern to rated torque. 4. Install temperature monitoring devices located on either side of the bearing housing bottom half as. follows, Refer to generator dimensional and instruc- tion drawing for location.Publication # 350-05000-00 Publication Date Nov. 1993 3. INSTALL BEARING RTE (if required). ‘The RTE is assembled by following the procedure given below. ‘a. Apply teflon pipe sealant to the holder mounting threads and install in the bearing housing . Pull the knurled knob on the holder out, rotate clockwise and push in to allow insertion of the probe. cc. Push the probe through until it contacts the bearing liner. Pull the knob out, rotate counterclock- wise and release. The probe is now properly spring loaded. Figure 12 Installing R.T.E For disassembly, reverse assembly procedure.TORQUE VALUES IN [FOOT-POUNDS] FOR RENK "E" BEARING HOUSING BOLTS Publication 360-05009-00 Pubicaion Date Nov. 1063 Bearing Size 9 9 4 14 18 [22 | 28 EM | EF Flange Mounting Bolts |66 |6s |66 | 159 |311 |537 | 1073 M12 Bearing Housing Split Line Botts |38 |66 | 66 159 | 311 | 837 | 1073 M10 Seal Mounting | 84" | sar [ear jaar | 2ter | ate" | 216" Bolts Me__|[Me_|M6_ (Me |Ma_ |Ms_ | MB Bolt Size wiz |mi2 |mi2 |Mie |m20 | M24 | M30 M10 Tnch-pounds Table 1 Recommended Torque Values Description Part Number Kato Part Number Elring, Curil T 246.948 991-50725-12 Permatex, Ultra Blue 77C, 81725 991-50738-13 Permatex, Aviation Form- | 3D, 80017 991-50215-03 A-Gasket, 1 pt Loctite, Threadlocker 24231 991-50195-08 242, 50 ml Loctite, Cleaning Solvent, | 755, 75559 991-50231-02 1202 Table 2 Parts Description and NomenclaturePublication # at : PSs Fi Wi 4 J FN Pe Cassin Ss. Oe Say ZY AWN \ te. “EM” TYPE BEARINGPublication # 350-06000.00 Publication Date Nov. 1893 mae \ REX ees PLESPublication # 360:05008.00 Publication Date Now. 1993, Oil throughput graphs ll throughput for cyl. journal bearing, tlat shoulders of the shell with oll grooves Veotai = Va vane) “ io 2s os 0 » 2 . asia = 1. 3 7 B 1orn10 speed in RPM Additional oil throughput, shoulders with integral taper lands Vote Va + Va Vall mn 38 20005 250/290 0080 sat ia mm perry ee ee ee ee) soeedin RPM,Pubiication # 250-05000-00 Pubication Date Nov. 1893 Bearing temperature/speed graph ‘These graphs are valid for the following operating conditions: For mean surface pressures be- tween 0.5 and 2.5 Nimm?, bearing temperatures can be interpolated — oll viscosity to ISO VG 32 or extrapolated. — ambient temperature 40° = still air — no thrust load weet Ee ee 838 wm & fe B88 3 8 wre fs & 2 > z a seer Si Pr * el 3 Src a Beare pe ay wey ory oy my my mes coy oy ESE SE ptt ta ° Tritt ome ee 9 7 7 Te soaed nM 4RECOMMENDED STORAGE PRO- CEDURES FOR KATO GENERA- TORS WITH SPLIT SLEEVE RENK RING OIL BEARINGS 1. Generators should be stored in a clean, dry, protected warehouse where control over temperature, dust, dew points, shocks and vibration are reasonably maintained. AA. Storage areas should be free from shock (or vibration of 2 mils maximum. B. Warehouse temperatures should not be below 10° F or over 120° F and relative humicity should be a maximum of 60%. All generators are to have the heaters energized during storage. CAUTION: REMOVE ANY FLAMMABLE PROTEC- ‘TIVE COVERING MATERIAL FROM THE GENERA- ‘TOR WHEN HEATERS ARE ENERGIZED. C. Generators with Renk split sleeve ring oil bearings will require periodic service while in storage. 1. Bearing pump should be filed to sight glass level with Mobil DTE Medium ISO VG-46 oil or equivalent. NOTE: SYNTHETIC OIL IS NOT ACCEPTABLE AS ASTORAGE LUBRICANT. 2. Shafts on two bearing generators should be rotated a minimum of 10 revolutions every 60 days. a. Before rotating generator shaft, manually pour 4 to 6 ounces of ISO VG-46 oil over the bearing liner to prevent possible oll starvation during manual rotation. Manual oiling can be accomplished by removing the sight glass at the top of the bearing housing and funneling, pumping or pouring the oil into the opening b. On applications where the generator has been coupled to the prime mover, the prime mover/ generator may be rotated as a complete unit. c. When the Manufacturer requires that prime ‘mover not be rotated at periodic intervals, the cou- pling grid must be removed and the generator rotated separately. Publication # 350-05000-00, Publication Date Nov. 198 3. For generators to be stored over 24 months, the following procedures are recommended. a. Drain oil from bearing pump. b. Apply Volvoline Tectyl 846 or an equivalent product to all metal surfaces without paint or primer, ‘such as split ines, spherical seats, complete liner and shaft journals. . Preservation with Tecty! 846 should be fective up to 12 months after initial application. After 12 months all bearing component parts should be thoroughly inspected and thepreservation process repeated, NOTE: BEARINGS WILL REQUIRE DISASSEMBLY ‘TO PERFORM RECOMMENDED PRESERVATION PROCEDURE. 4d. All extemal parts and surfaces subject to corrosion such as shafts, machined fits and threaded holes should be protected by a corrosive resistant rust inhibitor coating. @. Generators should be protected from dust, dirt and other foreign material with a non-flammable, non-sealed protective cover. I, When generators are removed from storage and, before placing into service. ‘A. Resistance readings should be taken on all windings. 1. Any drop in resistance value greater than '50% of the original factory reading may necessitate electrical or mechanical drying. 2. Insulation resistance readings of less than 100 megohms will necessitate electrical or mechani- cal drying. 3. Oil used during storage should be replaced with new oil as specified in the Instruction Manual or lubrication plates mounted on the generator. 4, All preservatives should be thoroughly cleaned from bearing surfaces and the bearing teassembled in accordance with recommended procedures. B. Manually pour 4-6 ounces of ISO VG-46 oil over bearing liners through top sight glass opening before generator shaft is rotated during final alignment or before starting prime mover.Publication # 350-05000-00 Publication Date Nov. 1993 1. Any excess oil accumulated during manual lubrication should be drained from bearing before starting prime mover. For detailed information and procedures on insulation resistance testing, drying windings, bearing inspec- tion and replacement and safety instructions, refer to the Manuals and Instructions furnished with individual units, 13@ Rockwell svomaton Kato Engineering Haven. un so002-0447 (507) 625-4011 FAX (607) 345-2798 Printedin USAPUBLICATION NUMBER 352-23009-00 PUBLICATION DATE: June 97 MAINTENANCE SCHEDULES KATO MOTOR, GENERATOR, OR MOTOR- GENERATORS (SYCHRONOUS OR INDUCTION) 8 Rockawelll Automation 6%) Kato Engineering Tiana, wi 56002847 (07) 625-4011 FAX (607) 345-2798(This page intentionally left blank)Contents THE SIGNIFICANCE OF MAINTENANCE..........c::ecsessesseeer 3 SERVICE CONDITIONS REDUCING INSULATION LIFE .. 4 VISUAL INSPECTION METHODS ............ccccssssesssseseseeneneees 5 INSULATION MAINTENANCE TESTS INSULATION RESISTANCE TESTS AT LOW VOLTAGE... CLEANING INSTRUCTIONS FIELD SERVICE CLEANING - ASSEMBLED MACHINES.. FIELD SERVICE CLEANING - DISASSEMBLED MACHINES MAINTENANCE SCHEDULES DAILY CHECKS ..... 9 EVERY 2000 HOUR’ EVERY 8000 HOURS OR YEARLY EVERY 20,000 HOURS OR 3 YEARS.. EVERY 40,000 HOURS OR 5 YEARS..Notes and service recordsTHE SIGNIFICANCE OF MAINTENANCE Rotating electric machines are complex structures that are subjected to mechanical, electrical, thermal and environmental stresses of varying magnitude. Of the various components, the insulation systems are the most susceptible to aging or damage due to these stresses. The service life of an electric machine will therefore, largely depend on the serviceability of the insulations systems, Adequate inspection and testing programs are advocated to assure that the ‘equipment is maintained in satisfactory condition to minimize the possibilty of in-service failure. A regular maintenance and inspection program can Provide an evaluation of the present condition of the ‘equipment and indicate potential long term prob- lems. The extent to which a maintenance program is pursued will depend on application, environmental conditions, and the operator's own experience and philosophy. A regular maintenance program involv ing periodic disassembly and knowledgeable visual ‘examination of the equipment, together with the application of electrical tests is strongly recom- ‘mended. it should be recognized that over potential tests can damage insulation that is contaminated or in marginal condition. Where there is uncertainty, refer to LE.E.E, Standard 432-1992 or consult with Kato Engineering Co.SERVICE CONDITIONS REDUCING INSULATION LIFE Electric machines and their insulation systems are subjected to mechanical, electrical, thermal and environmental stresses that give rise to many deteriorating influences. The most significant of these are the following: ‘THERMAL AGING: This is the normal service temperature deteriorating influence on insulation. OVER-TEMPERATURE: This is the unusually high temperature of operation caused by conditions such as overioad, high ambient temperature, restricted ventilation, foreign materials deposited on windings ‘or winding faults. OVERVOLTAGE: This is an abnormal voltage higher than the normal service voltage such as caused by switching or lightning surges. Operating above rated nameplate voltage will reduce insulation life. CONTAMINATION: This deteriorates electrical insulation by conducting current over insulated ‘surfaces or by attacking the material reducing electrical insulation quality or physical strength or by thermally insulating the material that causes the material to operate at higher than normal tempera- tures. Such contaminants include the following: (A) Water or extreme humidity (B) Oil or grease including unstable anti-wear and extreme pressure lubricants (C) Conducting and nonconducting dusts and par- ticles. {D) Industrial Chemicals such as acids; solvents and leaning solutions. PHYSICAL DAMAGE: This contributes to electrical insulation failure by opening leakage paths through the insulation, Physical damages includes the following (A) Physical shock (8) Vibration (c) Over-speed (0) Short-circuit forces or fine starting {E} Erosion by foreign matter {F) Damage by foreign objects (G) Thermal cycting IONIZATION EFFECTS: Ionization (corona), which ‘may occur at higher operating voltages is accompa- nied by several undesirable effects such as chemical action, heating and erosion.VISUAL INSPECTION METHODS ‘To achieve maximum effectiveness, a visual inspec- tion program should be directed initially to those areas that have been shown by previous experience to be most prone to the forms of damage or degrada- tion caused by the influences listed. The most suspect areas for deterioration or damage to which inspection should be directed are: GROUND INSULATION: Ground insulation is generally defined as that Insulation intended to isolate the current canying ‘components from the noncurrent bearing compo- nents, ‘SUPPORT INSULATION: ‘Support insulation, such as block, sit wedges, etc are usually made from compressed laminates of fibrous materials, polyester or similar felt pads impregnated with various types of bonding agents. DETERIORATION OR DEGRADATION OF INSU- LATION FROM THERMAL AGING: Examination of coils reveal general puffiness, ‘swelling into ventilation ducts or a lack of firmness of the insulation, suggesting a loss of bond with conse- {quent separation of the insulation layers from them- selves or from the winding conductors or turns. ‘ABRASION: Coil and connection surfaces may be damaged by ‘abrasion or contamination from other sources, such ‘as chemicals or abrasive or conducting substances. ‘CRACKING: Cracking or abrasion of insulation may result from prolonged or abnormal mechanical stress. In stator windings, looseness of the bracing structure is a certain guide to such phenomena and can itself ‘cause further mechanical or electrical damage if allowed to go unchecked. EROSION: Erosion may be caused by foreign substances impinging against coil insulation surfaces.INSULATION MAINTENANCE TESTS Insulation tests are conducted for two reasons: (1) To discem existing weakness or faults (2) To give some indication of expected service reliability INSULATION RESISTANCE TESTS AT LOW VOLTAGE ‘These tests are usually made on all or parts of an armature or field circuit to ground. They primarily indicate the degree of contamination of the insulating surfaces or solid insulation by moisture and other ‘conducting influences and will not usually reveal complete or uncontaminated ruptures. Insulation resistance tests are based on determining the current through the insulation and across the surface when a direct voltage is applied. The current is dependent on the voltage and time of application, the area and thickness of the insulation and on temperature and humidity conditions during the test. ‘The insulation resistance testis used to determine the insulation condition prior to application of more extensive testing measures. Refer to the following electrical measurement procedures for testing detail Contact Kato Engineering or refer to IEEE Std 432-1992 when more extensive insulation tests are required. Exciter Field (Stator) 4. Disconnect the exciter leads from the terminals in the terminal box. 2. Connect exciter leads to one clamp of 500 volt megger and connect the other clamp to the machine ‘frame, '3. Apply 500 volts from the megger and measure the resistance reading after one minute. The minimum, reading should be 1.0 megohm. if not, refer to dry out procedures. 4, Short the exciter field leads to the machine frame for several minutes after the megger has been disconnected. This will allow the voltage b be properly discharged, up to Exciter Armature 41.Disconnect the exciter armature leads from the rotating rectifiers. Disconnect the machine field leads {rom the positive and negative rectifier heat sinks. 2. Never apply megger to rotating rectifiers. Connect the leads of exciter armature to one clamp of a 500 vot megger and connect the other clamp to suitable connection on the shaft 3. Record the megohm reading after one minute of applying 500 volts 4. One minute reading must be a minimum of 1 ‘megohm. If not, refer to dry out procedures. 5. Ground the exciter leads to the shaft after discon- necting the megger. Machine Rotor Winding 4. Connect the positive and negative leads to one ‘clamp of the 500 volt megger and connect the other ‘clamp to the shaft 2. Record the megohm reading after one minute of applying 500 vols. 3. One minute reading must be a minimum of 1 ‘megohm. If not, refer to dry out procedures. 4. Ground the field leads to the shaft after discon- necting the megger. Machine Stator 4. Disconnect power connections and all contro! ‘apparatus from the machine terminals. 2. Measure insulation resistance of each phase ‘separately with the two other phases shorted to the frame. 3. Use a 500 volt megger connected between the lead ofthe phase tobe measured and machine frame. ‘The minimum one minute insulation resistance (corrected to 40° C) should not be less than that given by the following formula Resistance inmegohms = Rated machine voltage +1000. 1000 If less than above, refer to dry out procedure. 4. Ground the leads to the frame after the one minutemeggertest NOTE: The insulation resistance value inoreases with decreasing winding temperatures. readings must ee, be referenced to winding temperatures. Use Figure 1 Seamer for converting megger readings to oer temperatures. ed bos Drying Methods. I the insulation resistance readings are below the recommended minimum values specified previously, use one of the dry out methods described below. The ‘method selected should be based on the size and location of the unit, and available equipment with ‘experienced personnel. Remove voltage regulator and cover ail inlet and discharge 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° C per hour upto 93°C (200°F). Measure insulation resistance at ‘one hour intervals, Typically the insulation resistance will slowty drop while the temperature is coming up, and then gradually increase and level out Figure 4CLEANING INSTRUCTIONS Proper maintenance of electrical equipment requires. periodic visual examination of the machine and windings and appropriate electrical and thermal ‘checks. Insulation surfaces should be examined for ‘cracks and accumulations of dirt and dust to deter- mine required action. Lower than normal insulation resistance can be and indication that conductive contaminant is present. The contaminant may be carbon, salts, metal dusts or virtually any dirt satu- rated with moisture. These contaminants develop a conductive path to produce shorts or grounds with, subsequent failure. Cleaning is also advisable if heavy accumulation of dirt and dust can be seen or are suspected to be restricting ventilation as mani- fested by excessive heating. Caution: Without visual, electrical or thermal evidence that dirt is present, cleaning should not be initiated since unnecessary winding deteriorat- ion may occur. If harmful dirt accumulations are present, a variety of leaning techniques are available. The one selected will depend on; (1) The extent of the cleaning operation to be undertaken (2) The type of enclosure and the voltage rating of the machine involved (8) The type of dir to be removed FIELD SERVICE CLEANING — ASSEMBLED MACHINES ‘Where cleaning is required at the installation and complete disassembly of the machine is unnecessary or not feasible, dry dirt, dust or carbon should first be picked up by a vacuum cleaner to prevent the redistri- bution of the contaminant. A small nonconducting nozzle or tube connected to the vacuum cleaner may be required to reach dusty surfaces or to enter into ‘narrow openings. After most of the dust has been removed, a small brush can be affixed to the vacuum ‘nozzle to loosen and allow removal of dirt more firmly attached. ‘After the initial cleaning with vacuum, compressed air ‘may be used to remove the remaining dust and dirt Compressed air used for cleaning should be clean and free of moisture or oil. Air pressure or velocity should be adequately controlled to prevent mechanical damage to the insulation. Disassembly of the machine and more effective cleaning by a qualified Kato Technician may be required if the above described field service cleaning procedure dont yield effective results. DISASSEMBLED MACHINES ‘An initial insulation-resistance reading should be taken on the machine to check electrical integrity. A ‘minimum reading of one to five megohms would be ‘expected with severely contaminated machines. A zero reading may indicate an insulation breakdown requiring repair, not just cleaning. ‘The high pressure hot water wash method of clean- ing, which sprays a high velocity jet of hot water and water containing a mild detergent is normally effec- tive in cleaning windings including those subjected to flooding or salt contamination. The detergent spray is followed by mutiple sprays with clean water to remove or dilute the detergent. The machine should then be dried until normal insulation resistance values are obtained at room temperature. Solvents are effective for removing oil or grease and may be required if water or detergent is not adequat