Operation & Maintenance Manual

AL - SERIES
A C G E N E R AT O R S

Crompton Greaves Limited

LT Motors Division
A - 6/2, M.I.D.C., Ahmednagar 414111.
AL - SERIES AC GENERATOR

Dear Customer,

Crompton Greaves Limited in Technical

Collaboration with world’s leading
Alternator manufacturers, combining up -
to - the - minute technology in our design
and manufacturing, together with a high
standard of quality control,
we are pleased to introduce our latest
generation of AC GENERATORS :
The 'AL SERIES' & New 'USTAD' Series
Slipring Alternators in Aluminium
Stator Frame

We request you to read this manual

and follow carefully the information on
installation and adjustments so that you
may enjoy many years of dependable,
trouble free operation.

Yours,
“CROMPTON GREAVES LIMITED”
 l INDEX l

1. General Information 1

2. Principle of Operation 2

3. Machine Identification 2

4. Safety Requirements 3

5. Installation 11

6. Starting Up : Preliminary checks 13

7. Electrical Data (At 250C) 14

8. Maintenance 18

9. Designation Of The Spare Parts 27

10. Wiring Diagram for 'Ustad' Series Slipring Alternator 33

11. Exploded View :

'Ustad' Series Slipring Alternator 132/160/200 Frame 35

12. Exploded View :

Brushless Alternator 160/200/250 Frame 36

13. Exploded View :

Brushless Alternator 315/355/400 Frame 37

14. Connection Diagrams 38-41

15. Automatic Voltage Regulator :

AVR SR 7/3, SR 7/6, UVR-7 & SMR 42

16. Dimension Drawing Single Bearing AC Generator 46-47

17. Dimension Drawing Double Bearing AC Generator 48-49

1.0 GENERAL INFORMATION :
The AL SERIES Alternators are manufactured using the most accurate
methods of design, construction and test. Their characteristics, if
properly used, ensure a continuous working and a very prolonged
trouble free life. For the best use of AL SERIES Alternators, please
follow these instructions carefully.

Please note that the instructions provided here-in are meant

only for authorised, technical personnel qualified to install /
Warning ! service Generators.

1.1 SPECIFICATIONS :
AL SERIES Alternators are self excited, self regulated and supplied with
Electronic voltage regulator or Compound Excitation Transformer. They
are manufactured to meet requirement with the following
International/Indian Standards :
l IS : 4722 & 13364 (Part I & II)
l BS : 5000 (Part 99)
l CSA : CSA 22.2 No 100 2004
l IEC 60034-1 : International Electromechanical Commission

1.2 MECHANICAL FEATURES :

l Aluminum Body with integral N.D.E. shield, (upto 250 frame).
l Cast Iron D.E. shield.
l Life Lubricated sealed Ball Bearings, (upto 6317 size).
l Screen protected Self ventilated Machine.
l Degree of Protection : IP23

1.3 NORMAL OPERATING CONDITIONS :

l Altitude : Less than 1000m (3300 ft)
l Ambient temperature : Less than 400 C
l Power Factor : From 0.8 lagging up to UPF

1.4 LIMITS FOR SAFE OPERATION :

l Over speed : 20 % (1800 rpm for 50 Hz)
l Over load : 110 % of rated value for one Hr.

1.5 ELECTRICAL FEATURES :

l Class H Insulation.
1
 l Motor starting capability : The Alternator is capable to start
1.0 H.P. Induction Motor for its each kVA rating with DOL.
Motor starting applicable for only S1 duty, upto 10 kVA rating
with slipring construction & 3 times rated current can be
drawn from alternator for 10 sec. above 10 kVA.
l Steady State Voltage Regulation to the order of
± 5% with compound excitation unit
± 1% with electronic regulator
At rated speed when supplying non - distorting, three- phase,
balanced, linear loads.
l Voltage build - up based on residual magnetism.

1.6 OUTPUT VOLTAGE AND FREQUENCY

The standard alternators are designed for supply voltage of :
- 415 V at 50 Hz in three phase.
- 240 V at 50 Hz in single phase.

2.0 PRINCIPLE OF OPERATION :

When started, the residual magnetism induces a voltage in the exciter
armature. This voltage is rectified by the rotating diodes and fed to the
main field. The induced voltage in the auxiliary winding is then used to
increase the excitation power via the compound excitation (CE) unit /
electronic regulator (AVR) to the exciter field, to ensure a rapid and
smooth build up of output voltage in the main stator winding.
On load / over load or short circuit, the 'L' winding of CE Unit, which is
in series with the load, supplies an additional excitation voltage (the
booster effect), to maintain the terminal voltage constant (within ± 5% of
rated value).
In case of alternator fitted with electronic regulator (AVR SR 7/3,
SR 7/6, UVR-7 & SMR), AVR provides additional excitation
requirements and maintains terminal voltage constant (within ± 1% of
rated value) from no load to rated load condition.

3.0 MACHINE IDENTIFICATION :

Always indicate the Alternator Frame type and M/C Ref. No. with kVA
rating while contacting Factory or our authorized after sales service
centres.
2
4.0 SAFETY REQUIREMENTS :
l Before any cleaning, lubrication
or maintenance operation,

STOP
ensure that the gen - set is
stationary and disconnected from
the power supply.
While stopping the gen-set,
ensure the compliance with the
procedure for stopping the prime
mover.
The alternator, in fact has no
emergency stop, but is controlled
by the device arranged by the
installer to stop the prime mover.
l Before installing the alternator,
arrangements must be made to
earth the machine in compliance
with relevant electrical
regulations. The installer must
make sure that the grounding
system is in good conditions and
in compliance with the
regulations of the country where
the generators will be installed.

CAUTION :
THE FINAL INSTALLER IS
RESPONSIBLE FOR THE
INSTALLATION OF ALL THE
PROTECTIONS (SECTIONING
DEVICES, PROTECTION AGAINST
DIRECT AND INDIRECT
CONTACTS, OVERCURRENT AND
OVER VOLTAGE PROTECTIONS,
EMERGENCY STOP ETC.)
NECESSARY FOR THE MACHINE
TO COMPLY WITH THE
PREVALENT NATIONAL / REGU-
LATORY SAFETY REGULATIONS.

3
l For handling the unpacked alternators, always use the special eyebolts
only. Use ropes having suitable carrying capacity. Do not lift the
alternator too much from the floor (max. 30 cm.)

Only qualified operator personnel should be assigned with the

work of installation, maintenance and operation of Genset.
Warning !

The operator must always wear

work gloves and safety shoes. In
case the alternator or whole DG-
SET must be lifted from the floor,
the operators must wear a safety
helmet.

l Make sure that the gen-set

foundations and base frame are
suitable to bear the combined
weight of the alternator and
prime mover.

The alternator should

be securely connected
and perfectly aligned
with the prime mover,
Warning !
otherwise dangerous
vibrations may occur
resulting in alternator
bearing failure.
1000m
l The machine has been
designed to ensure the rated
output when it is installed in a 400C
room having a max. temperature
of 400 C and at an altitude not
exceeding 1000 meters; in case
of deviations please make
reference to our technical
leaflets.

l No person must wear fluttering

4
cloths (such as scarves etc.) near the machine and any such garment
must be fastened with elastic bands at its ends.
Alternator must never and for no reason run with following guards
removed :
l Terminal box cover
l Rear cover
l Fan ventilation guard
l Alternators produce heat proportional to the output. Therefore do
not touch it if you do not wear antiscorch gloves, and after
switching it off, do not touch it until it has cooled down.
l Even if all machine components are protected, keep away from
the gen-set. Do not lean or sit on the alternator for whatever
reason.

4.1 DANGER OF SHORT CIRCUIT

The degree of protection of the alternator is IP21/23. Short

circuit may occur if liquids (e.g. water etc.) are split onto
Danger ! areas containing electrical parts.

4.2 TRANSPORT AND STORAGE

Alternators will be packed for shipment in a manner suitable to their
mode of transportation and final destination.
Prior to handling goods, please ensure that lifting equipment is of
sufficient capacity. Under lifting conditions machinery should be elevated
to a minimal distance from the ground.
Both packed and unpacked alternators shall be stored in a cool and dry
room, and shall never be exposed to the inclemency of the weather.
Once the generator is coupled with an engine, mounted on a base
frame, or is installed on a complete gen-set, it can not be lifted by its
lifting lugs. The relevant instruction for lifting the complete gen-set
should be followed.
Any packing material should be disposed of via correct waste disposal
methods. Do not discard waste materials into the environment.

4.3 STARTING AND STOPPING OPERATIONS :

All the instrumentation for starting, running and stopping the system
shall be provided by the installer.
5
THE STARTING, RUNNING AND STOPPING OPERATIONS MUST BE
CARRIED OUT BY SKILLED PERSONNEL WHO HAVE READ AND
UNDERSTOOD ALL THE INSTRUCTIONS.
PLEASE NOTE :
When the system is set to work for the first time, which has to be done
at reduced speed, the operator shall check that no anomalous noises is
detected.
If an anomalous noise is detected, stop the set immediately and
improve the mechanical coupling.

4.4 CLEANING :
Prior to approaching or touching the alternator, ensure that it is not live
and it is at room temperature; at this stage it is possible to clean it on
the out side using compressed air.
NEVER USE LIQUIDS OR WATER FOR INSIDE CLEANING.
DO NOT CLEAN INSIDE ELECTRIC COMPONENTS WITH THE
COMPRESSED AIR because this may cause short-circuits or other
anomalies.
N.B.: The alternator frame is provided with many fixing holes so that
vibration - damping may be applied in the proper position to ensure the
best trim of the gen-set.

4.5 MECHANICAL COUPLING :

CAUTION :
ALTERNATOR FOOT FIXING ON THE DE SIDE IS ON
END-SHIELD FOOT. HENCE CARE MUST BE TAKEN
WHILE CLOSING THE VENT COVER AFTER
Danger ! TIGHTENING THE BOLT THAT NO MATERIAL SHOULD
BE LEFT INSIDE, WHICH MAY CAUSE DAMAGE TO THE
FAN OPERATION.

4.5.1 ASSEMBLY OF A.C. GENERATOR TO PRIME MOVER :

FOUNDATION :
The machine should be mounted on a foundation, which may be of
steel structure or concrete platform. The foundation must be well
designed for adequate rigidity and long life, taking into consideration the
6
dynamic loading under abnormal running of the machine, vibration
resulting from running machinery and other relevant factors. Care must
be taken to ensure that the surface to which the machine is bolted
down is aligned and leveled in all directions prior to mounting the
machine.

4.5.2 SINGLE BEARING GENERATORS :

The rotor of the single bearing generator is locked by means of a
locking arrangement on the drive end side to prevent damage during
transportation. It is essential to remove this lock before coupling it to the
(prime mover) engine. The sequence is as follows.
l Position and align the prime mover.
l On the engine measure the distance between the engine bell
housing mounting surface to the drive discs recess in the engine
flywheel. Dimension 'WB' is shown in the figure 4.5.
l Measure the distance from the alternator end shield spigot (adaptor
spigot) face to the outside surface of the flexible disc assembly
(Dimension 'WA' as shown in the figure 4.5. Ensure that the
generator is parallel to its frame while measuring the distance 'WA'.

WA WB
ENGINE BELL
HOUSING

ENGINE
FLYWHEEL

D' C' C D

DISC COUPLING TO SUIT

FLYWHEEL SIZE

GENERATOR ADAPTOR TO SUIT

ENGINE BELLHOUSING

Fig. 4.5

7
l Measure the diameter of the flexi disc and the engine flywheel drive
disc recess dimensions C' and C as shown in the fig. 4.5. If there is
any variation contact the manufacturer.
l Check the rotor position by verifying the dimension 'WA' & it should
be equal to 'WB'.
l Measure the Pitch Circle Diameter of the fixing holes both on the
flexidisc and the engine flywheel drive disc recess (Dimension D and
D' in fig. 4.5) If there is any variation, contact the manufacturer. Do
not attempt to redrill the holes.
l Check the engine flywheel runout and also the runout of the flywheel
housing.
l After the above checks have been made the machine is ready for
coupling.
l The generator is supported using a hoist and the machine is moved
horizontally towards the engine flywheel. Ensure that the flexi discs are
properly seated within the drive disc recess in the engine flywheel.
l Fix the bolts between the flexi disc and the flywheel. The bolts are to be
tightened alternately and evenly. Also, the bolts fixing the adaptor to
the engine housing are to be tightened with specified torque.
l Do not attempt to force plastic fan to rotate the alternator rotor.
l Now run the machine to its full speed and check for the vibration.

1) NUMBER OF COUPLING DISCS & TIGHTENING TORQUE FOR

1-BRG.ALTERNATOR :
When fitting coupling discs ensure that the number and thickness of
discs, and tightening torque of hub or shaft bolts is in accordance
with the table below.

8
A) For coupling disc SAE 10”/11.5”/14”
NO.OF SINGLE DISC TOTAL TIGHTENING
FRAME SCREW SIZE
DISCS THK(mm) THK (mm) TORQUE
M16 X 45 24.9 kg-m
132 2 1.2 2.4
(10.9 CLASS) (244 N-m)
160/ M10 X 40 (12.9 CLASS)
1 3.0 3.0
160S1 FOR 10" DISC & 7.6 Kg-m
M10 X 25 (12.9 CLASS) (75 N-m)
200S1 3 1.5 4.5
FOR 11.5" DISC
200/ M16 X 45 24.9 kg-m
3 1.2 3.6
250 (10.9 CLASS) (244 N-m)
315/ M20 X 45 48 kg-m
4 1.2 4.8
355 (10.9 CLASS) (480 N-m)
M24 X 75 84 Kg-m
400 6 1.2 7.2
(10.9 CLASS) (822 N-m)

B) For coupling disc SAE 6.5”/7.5” :-

FRAME NO.OF SINGLE DISC TOTAL SCREW SIZE TIGHTENING

DISCS THK(mm) THK (mm) TORQUE
132/160 2 2.0 4.0 M10X25 (12.9 CLASS) 7.6 kg-m (75 N-m)

2) “WA” DIMENSION :
After fitting coupling discs ensure that the “WA” is in accordance with
the table below for various coupling disc SAE (Measure “WA” near to
the Rt. Locking plate)

ENDSHIELD SPACER
FRAME SAE DISC SAE THK 'T' WA±0.5
WA±0.5 END-SHIELD
132/160 11.5" - 39.6
2, 3
/200 10" 14.2 53.8
200 1 14” - 25.4 SPACER
(WHEN
132/160 4, 5 6.5" & 7.5" - 30.2
FITTED)
T
14" - 25.4
1 SCREW
11.5" 14.2 39.6 (8.8 CL)
250 COUPLING
10" 14.2 53.8
2, 3
HUB
11.5" - 39.6
1/2, 14" - 25.4
315 SHAFT
1, 2, 3 11.5" 14.2 39.6
355SB/ 11.5" 14.2 39.6
0, 1/2, 1
355S 14" - 25.4
18" - 15.8
355M 0, 1/2, 1
14" 9.5 25.4
18” - 15.8
400 0, 1/2, 1
14” 9.5 25.4

9
4.5.3 DOUBLE BEARING GENERATORS :
l The prime mover is placed on the bed plate and aligned.
l The drive end of the shaft is cleaned well and half coupling is fitted
to it. The key provided on the shaft is only to be used for fixing half
coupling. The half coupling should be heated and fitted on the shaft.
Hammer blow fixing of the half coupling is to be avoided. The
heated half coupling should be cooled by blowing air over it. Attempt
should not be made to cool the coupling by sprinkling water over it.
The tapped hole provided at the shaft end can be used to press in
the half coupling.
l The generator is positioned on the base plate and the centre height,
transverse and the axial positions are adjusted.
l The generator coupling is then engaged with that of the prime
mover.
l Now proceed to check the alignment in accordance with the coupling
manufacturers recommendations.
l When the machines are perfectly aligned, the holding down bolts are
tightened.

10
5.0 INSTALLATION :
Unpack the alternator, check for any damage to the packing case. If
any damage is visible, it is possible the alternator itself has been
damaged.
Such damage should be reported to the transporter and insurance
agents.

5.1.1 LOCATION - COOLING :

The air in which the alternator is installed shall be such that the
ambient temperature never exceeds 400C (at nominal ratings). For
higher ambient a derating factor should be applied.
Fresh air, free from humidity and dust, must circulate easily through the
screen at the non-drive end of the alternator. The recycling of heated
air, from the D.E. or circulating from prime mover, should be avoided as
far as possible.
Ensure adequate ventilation for a good air flow at all times.

5.1.2 OPERATING IN PARTICULAR ENVIRONMENTAL

CONDITIONS :
l If the alternator is going to be operated at altitude higher than 1000
Mt. above sea level it is necessary a derating of 4% each 500 Mt. of
increase.
0
l If the ambient temperature exceeds 40 C it is necessary a derating
0
of 4% each of 5 C of increase.
l If the alternator is going to be used in a sound proof set, make sure
that only fresh air enters it; place the alternator air inlet near and
infront of air opening.
Remember that the air required for alternator is :

50 Hz 60 Hz
132 Frame, 4 pole 5 m3/min 6 m3/min
160 Frame, 4 pole 9 10.8
200 Frame, 4 pole 20.5 24.6
250 Frame, 4 pole 26.5 31.8
315 Frame. 4 pole 50 60
355 Frame, 4 pole 80 96
400 Frame, 4 Pole 96 115

11
5.2 ELECTRICAL CHECKS :
Before putting the machine into service, an Insulation Resistance check
between phase and earth and between phases is recommended. For
this test every single parts to be checked has to be isolated from the
others. This test should be done with a “megger” using 500 V DC. The
insulation resistance when machine is cold should normally be >10
mega ohms.
CAUTION : Machine whether new or used should not be operated if
insulation resistance is less than 1 mega ohm for stator and other
windings.
If megger value is low, the machine must be dried until the minimum
value is obtained.
To get the minimum value, there are several methods :
a) Bake the machine for 24 Hr. in an oven at 1100C ± 0
5 C.
b) Dry out the machine with a stream of hot air.
c) Disconnect the CE Unit (For G2S series) and AVR (in case of G2R
series).
l short circuit the three output (power) terminals through
connections capable of carrying rated current.
l with an appropriate ammeter, monitor the current flowing in
the short circuited connections.
l connect a 48 V storage battery to the field winding terminals
of the exciter (respecting polarities), fitted in series a rheostat
of about 20 ohms (250 watts)
l open completely all the apparatus of the alternator, terminal
box panels, protection screens etc.
l start up the gen - set to its rated speed and adjust its
excitation through the rheostat in order to obtain the rated
current in the short circuited connections & run under this
condition for 1/2 hr. to get 1MW Insulation Resistance.

5.3 DIRECTION OF ROTATION :

The alternator can be driven in either direction of rotation (except 250
double bearing) but standard phase sequence is U-V-W, when rotation
is clock wise looking in the drive end.
For anticlockwise rotation interchange the two phases V and W to get
U-V-W phase sequence.
12
6.0 STARTING UP :
6.1 PRELIMINARY CHECKS :
6.1.1 MECHANICAL CHECKS :
Before starting up, check :
l that all foot and flange bolts are tightened
l that the cooling air circulates freely around and through the
machine
l that all louvers, guards, etc. are correctly fitted
l for single bearing alternators the discs are fastened to the
coupling hub with bolts torqued as specified in table (ref. page
no. 8)
6.1.2 ELECTRICAL CHECKS :
Make sure :
l A suitable electrical protection device is fitted in the output
circuit for safety reasons (in line with the codes of practice in
force within the country where the alternator is installed)
l Ensure before start up that terminal nuts are properly
tightened.
l The control panel protection equipment is correctly set.
l There is no short circuit due to wrong connections either / or
in between the terminals of the alternator and the power
switch or breaker (this part of the circuit is not protected by
the breaker).
l When the alternator is operating at nominal voltage, at no
load, DC voltage at field Wdg (Vf) should approximately match
with the values as mentioned in the Table (7.0)

13
 7.0 ELECTRICAL DATA :

WINDING RESISTANCE (in W) at 250C (MIN/MAX) EXCITATION DATA

TYPE
ALTERNATOR AUXILIARY COMPOUND X-mer (CE - unit) NO LOAD FULL LOAD
G2S/G1S
STATOR (PH) ROTOR WINDING (L-L) L WDG (m-ohms) C WDG (ohms) Vf (DC) If (DC) Vf (DC) If (DC)
132 MR 2.323/2.417 11.55/12.03 2.479/2.581 171.5/178.5 1.21/1.25 25 2.2 65 5.8
132 MA 1.485/1.545 13.68/14.24 1.891/1.969 91.1/94.9 1.04/1.08 30 2.2 70 5.2
132 MC 0.986/1.026 16.27/16.93 1.950/2.03 61/63.4 1.04/1.08 35 2.2 85 5.2
132 MA-1PH 0.823/857 13.68/14.24 1.735/1.805 60.5/62.9 1.21/1.25 30 2.2 65 4.7
132 MC-1PH 0.571/0.591 16.27/16.93 1.519/1.581 35.1/36.5 1.25/1.31 35 2.2 70 4.2
160SE 1.07/1.12 19.6/19.9 1.37/1.42 53/55 1.11/1.16 35 1.8 100 5

14
160S1B(120) 0.637/0.663 21.85/22.75 1.127/1.173 24.9/25.9 1.12/1.16 40 1.8 100 4.5
160 SC 0.317/0.329 27.29/28.41 0.921/0.959 14.4/15.0 0.88/0.92 50 1.8 115 4.2
160MC 0.316/0.329 29.4/30.6 0.56/0.58 8.8/9.2 0.88/0.92 50 1.8 125 4.2
160MR 0.22/0.23 34.3/35.5 0.41/0.42 5.5/5.7 0.88/0.92 50 1.8 150 4.2
160SE(SLC)-1 ph 0.542/0.564 19.6/19.9 1.68/1.75 32.8/34.2 0.98/1.02 35 1.8 100 5
160S1B(120)-1PH 0.399/0.415 21.85/22.75 1.058/1.102 12.3/12.8 0.94/0.98 30 1.5 105 4.7
160 SC-1PH 0.272/0.284 27.29/28.41 0.882/0.918 9.3/9.7 0.98/1.02 40 1.5 130 4.7
160 MC-1PH 0.214/0.222 32.09/33.29 0.823/0.857 5.7/5.9 0.98/1.02 45 1.4 115 3.5
200SE 0.188/0.196 25.87/26.93 0.343/0.357 7.4/7.7 0.89/0.93 50 2 185 7
200 SB 0.108/0.112 33.08/34.44 0.206/0.214 4.4/4.6 0.79/0.83 55 1.7 180 5.4
 WINDING RESISTANCE (in W) at 250C (MIN/MAX) EXCITATION DATA
TYPE
ALTERNATOR AUXILIARY COMPOUND X-mer (CE - unit) NO LOAD FULL LOAD
G2S/G1S
STATOR (PH) ROTOR WINDING (L-L) L WDG (m-ohms) C WDG (ohms) Vf (DC) If (DC) Vf (DC) If (DC)
200 SD 0.069/0.071 37.34/38.86 0.137/0.143 3.8/4.0 0.79/0.83 95 2.5 240 6.3
200 MD 0.049/0.051 39.29/40.89 0.098/0.102 2.5/2.6 0.68/0.70 105 2.6 250 6.2
200SE-1 PH 0.134/0.140 25.87/26.93 0.892/0.928 7.2/7.4 1.00/1.04 50 1.9 130 5
0
WINDING RESISTANCE (in W) at 25 C (MIN/MAX) EXCITATION DATA
TYPE
ALTERNATOR AUXILIARY EXCITER NO LOAD FULL LOAD
G2R/G1R
STATOR (PH) ROTOR WINDING (L-L) STAT. (ohms) ROT. (ohms) Vf (DC) If (DC) Vf (DC) If (DC)
132MR 4.11/4.27 2.73/2.85 2.9/3.1 12.8/13.3 0.75/0.79

15
132 MA 2.07/2.15 3.23/3.37 2.4/2.5 12.8/13.3 0.75/0.79 6 0.5 25 1.7
132 MC 1.62/1.68 3.87/4.03 2.3/2.4 12.8/13.3 0.75/0.79 6 0.5 25 1.7
132 MA-1PH 1.19/1.24 2.73/2.85 NA 12.8/13.3 0.75/0.79 6 0.5 25 1.5
132 MC-1PH 0.83/0.90 3.87/4.03 NA 12.8/13.3 0.75/0.79 6 0.5 25 1.5
160SE 1.1/1.14 4.2/4.4 3.7/3.9 13.34/13.88 1.63/1.69 5 0.5 28 1.9
160S1A 0.883/0.919 4.47/4.65 2.45/2.55 13.34/13.88 1.63/1.69 10 0.7 30 2.2
160S1B(120) 0.660/0.686 5.89/5.09 2.23/2.32 13.34/13.88 1.63/1.69 10 0.7 30 2.2
160SB 0.506/0.526 5.05/5.25 1.97/2.05 14.02/14.6 1.04/1.08 10 0.7 30 2.2
160 SC 0.370/0.386 5.9/6.14 1.93/2.01 14.02/14.6 1.04/1.08 10 0.7 30 2.2
 WINDING RESISTANCE (in W) at 250C (MIN/MAX) EXCITATION DATA
TYPE
ALTERNATOR AUXILIARY EXCITER NO LOAD FULL LOAD
G2R/G1R
STATOR (PH) ROTOR WINDING (L-L) STAT. (ohms) ROT. (ohms) Vf (DC) If (DC) Vf (DC) If (DC)
160 MA 0.285/0.297 6.7/6.98 1.60/1.66 14.02/14.6 1.04/1.08 10 0.7 30 2.2
160 MR 0.237/0.247 6.96/7.24 1.67/1.73 14.02/14.6 1.04/1.08 10 0.7 30 2.2
160SE(SLC)-1PH 0.55/0.57 4.2/4.4 N.A. 13.34/13.88 1.63/1.69 5 0.5 28 1.9
160S1B(120SLC)-1PH 0.599/0.623 4.89/5.09 N.A. 13.34/13.88 1.63/1.69 8 0.6 32 2.3
160 SB-1PH 0.514/0.534 5.05/5.25 N.A. 14.02/14.6 1.04/1.08 8 0.6 34 2.3
160 SC(SLC)-1PH 0.250/0.260 5.9/6.14 N.A. 13.34/13.88 1.63/1.69 8 0.6 34 2.3
160MC(SLC)-1PH 0.131/0.137 6.3/6.6 N.A. 13.34/13.88 1.63/1.69 8 0.6 24 1.7

16
160 MR-1PH 0.188/0.196 6.96/7.24 N.A. 14.02/14.6 1.04/1.08 8 0.6 34 2.3
200SE 0.238/0.248 8.37/8.71 1.91/1.99 14.02/14.6 1.04/1.08 8 0.6 35 2.4
200 SA 0.165/0.171 2.31/2.41 1.79/1.87 17.85/18.57 0.28/0.29 7 0.5 25 1.7
200 SB 0.138/0.144 2.66/2.76 1.68/1.75 17.85/18.57 0.28/0.29 7 0.5 25 1.7
200SC 0.110/0.114 2.84/2.96 1.71/1.78 17.85/18.57 0.28/0.29 7 0.5 25 1.7
200 SD 0.100/0.104 3.09/3.21 1.49/1.55 17.85/18.57 0.28/0.29 7 0.5 25 1.7
200 MD 0.054/0.056 3.83/3.99 1.41/1.47 17.85/18.57 0.28/0.29 7 0.5 25 1.7
200 MDX 0.053/0.055 0.94/0.98 1.42/1.48 17.85/18.57 0.28/0.29 7 0.5 36 2.5
200SF(SLC)-1PH 0.145/0.155 9.24/9.62 N.A. 17.85/18.57 0.28/0.29 7 0.5 30 2.2
200SB-1PH 0.101/0.105 2.66/2.76 N.A. 17.85/18.57 0.28/0.29 7 0.5 25 1.7
200SC-1 PH 0.084/0.087 2.8/2.9 N.A. 17.85/18.57 0.28/0.29 7 0.5 25 1.7
 WINDING RESISTANCE (in W) at 250C (MIN/MAX) EXCITATION DATA
TYPE
ALTERNATOR AUXILIARY EXCITER NO LOAD FULL LOAD
G2R/G1R
STATOR (PH) ROTOR WINDING (L-L) STAT. (ohms) ROT. (ohms) Vf (DC) If (DC) Vf (DC) If (DC)
200SD-1ph 0.074/0.077 0.76/0.78 N.A. 17.85/18.57 0.28/0.29 7 0.8 30 2.2
250 SB(New) 0.0596/0.062 1.43/1.49 0.811/0.844 17.85/18.57 0.28/0.29 7 0.5 38 2.6
250 SD (New) 0.0426/0.0444 1.68/1.74 0.669/0.697 17.85/18.57 0.28/0.29 7 0.5 38 2.6
250 MA (New) 0.0365/.0380 1.78/1.86 0.573/0.597 17.85/18.57 0.28/0.29 7 0.5 38 2.6
250 MB 0.02548/0.02652 1.97/2.05 0.620/0.646 17.85/18.57 0.28/0.29 7 0.5 38 2.6
250 LB 0.02058/0.02142 2.16/2.24 0.533/0.555 17.85/18.57 0.28/0.29 7 0.5 38 2.6
250 LD 0.01862/0.01938 2.30/2.40 0.527/0.549 17.85/18.57 0.28/0.29 7 0.5 38 2.6

17
315 SE 0.01568/0.01632 1.67/1.73 0.578/0.602 17.50/18.21 0.17/0.18 9 0.5 40 2.25
315 SA 0.01176/0.01224 1.84/1.92 0.549/0.571 17.50/18.21 0.17/0.18 9 0.5 40 2.25
315 SB 0.0081/0.0085 2.04/2.12 0.402/0.418 17.50/18.21 0.17/0.18 9 0.5 40 2.25
315 MB 0.0076/0.0079 2.38/2.48 0.473/0.493 17.50/18.21 0.17/0.18 9 0.5 40 2.25
355 SB 0.0076/0.008 2.21/2.3 0.278/0.290 19.72/20.52 0.092/0.096 10 0.5 50 2.5
355 SE 0.0050/0.0052 2.69/2.79 0.241/0.251 19.72/20.52 0.092/0.096 10 0.5 50 2.5
355 ME 0.00412/0.00428 2.69/2.79 0.219/0.227 19.72/20.52 0.092/0.096 10 0.5 50 2.5
355 MA 0.00323/0.00337 3.10/3.22 0.149/0.155 19.72/20.52 0.092/0.096 10 0.5 50 2.5
400SB 0.044/0.0442 1.65/1.71 0.615/0.641 18.28/19.02 0.28/0.30 14 0.7 60 2.6
400SC 0.0034/0.0356 1.77/1.85 0.458/0.476 18.28/19.02 0.28/0.30 14 0.7 60 2.6
400MA 0.0019/0.0020 2.29/2.39 0.384/0.400 18.2/19.0 0.176/0.184 14 0.7 60 2.6
8.0 MAINTENANCE :
8.1 COOLING CIRCUIT :
It is recommended to check that the cooling air circulation is not restricted.
8.2 BEARINGS :
The bearings of the alternators are self lubricated and do not require
maintenance for a period of working of approximately 15,000 Hours.
8.3 VOLTAGE SETTING AND REVOLVING SPEED :
The output voltage of the alternator should be checked at the nominal
revolving speed 1500 R.P.M.
8.3.1 'USTAD' SERIES SLIPRING ALTERNATORS
Usually the alternators are preset at the factory to supply voltage
slightly higher ( from 3 to 5 % ) than the nominal one at the nominal
revolving speed. In Frame G2S 132 / 160 / 200 if one want to regulate
the no load voltage of the alternator at determined revolving speed it is
necessary to operate on the air gap of the compound transformer as
follows, referring to fig. 8.3.
1) Loosen the two screws N.
N
2) Regulate the air - gap
considering that.
a) if one increases it, the
voltage will increase.
b) if one decrease it, the N
voltage will decease.
If the voltage variation required is
Air Gap
higher than 5% it is necessary to T
replace the insulating paper (T) of
Fig. 8.3
the air gap.
3) After setting the voltage tighten up the two screws N.
In addition to air gap adjustment, voltage can also be adjusted by
changing the taps on capacitor. By changing taps from 1 towards 9 will
decrease the voltage & vice-versa. (For details refer instructions
provided on capacitor). For Single Phase Slipring type Alternator, CE
Unit is provided with a tapping for convenience of Voltage setting.
Connections to 'LHS' terminal of the 'C' wdg. will boost up the terminal
voltage.

18
8.3.2 BRUSHLESS ALTERNATORS
In case of alternators equipped with electronic voltage regulator, one
can regulate the no load voltage of the alternator by operating on the
potentiometer ‘VOLT’ of the AVR.

8.4 REMOTE REGULATION OF THE VOLTAGE :

(for Brushless)
Remote voltage adjustment 0f ± 5% is possible with 100 KW
potentiometer. For details refer AVR connection diagrams.
WARNING : FOR ALTERNATOR GOOD WORKING IT IS ADVISABLE
NOT TO DEVIATE FROM THE NOMINAL VOLTAGE BY MORE
THAN 5%

8.5 VOLTAGE BUILD UP - BY FIELD FLASHING AT NO LOAD :

The alternator is self exciting from the residual magnetism of the
magnetic circuit of the exciter. When first tested (at the factory) this
magnetic circuit is magnetized. After a breakdown it may be necessary
to remagnetise.
Proceed as follows for field flashing :
Connect a 12 - 24 V battery to the terminals of the exciter field (main
field winding for Slipring types) for two to three seconds.
CAUTION : ENSURE THAT THE SET IS NOT RUNNING BEFORE
PROCEEDING FOR FIELD FLASHING & EXCITER FIELD
CONNECTIONS TO THE AVR ARE REMOVED IN G2R/G1R FRAME.

8.6 INSTRUCTION FOR THE DISASSEMBLY

OF THE ALTERNATORS
The following section explains step by step procedure for the
disassembly of the alternators and the truobleshooting of the faults :
BEFORE PERFORMING THIS OPERATION, KINDLY READ ALL THE
SAFETY REQUIREMENTS OF THIS MANUAL CAREFULLY.
1) Remove the terminal box cover.
2) a) IN Slipring Alternator :
Disconnect the two terminals of the field winding from
the rectifier bridge
b) IN Brushless Alternator :
Disconnect the connections between the winding and the AVR.

19
3) Remove the end cover
4) Disconnect from the rotating rectifier the two wires going to the
main field.
5) Remove the rotating rectifier after screwing out the fastening
screws.
6) Take away the diode holding support by removing three Allen
screw. (See fig. 8.6.a)

7) Unscrew the three screws

which fasten the exciter stator.
8) Remove the exciter stator.
9) Make use of three M-6 tapped
holes on exciter rotor for its
Fig. 8.6.a
removal with suitable puller.
(See fig. 8.6.b)

Fig. 8.6.a

10) Unscrew the DE end shield fixing screws and remove DE end
shields.
11) Remove the rotor from the stator paying attention not to damage
the windings by holding the rotor properly using a hoisting
mechanism with soft rope of sufficient strength. Place the rotor in

20
 the work area which has been
previously prepared. (In case
of Slipring Alternator : Before
withdrawing the rotor from the
stator it is necessary to
remove the brush holder
assembly).
12) Remove the bearings, using
suitable puller & use pressing
technique with suitable
mandrel for refitting the
Fig. 8.6.c
bearings on the shaft. (See fig.
8.6.c)

8.6.1 MOULDED RECTIFIER BRIDGE

(Slipring Type Alternator) :
The moulded bridge rectifier used is of rating 25A, 800V
Three phase alternators are equipped with three - phase bridges while
the single phase alternators are supplied with single - phase bridges.

8.6.2 RECTIFIER BRIDGES CHECKOUT :

To check each diode of the rectifier bridge one can use either an
ohmmeter or a battery with a bulb, as follows :
A diode is working :
l when, with an ohmmeter, one can verify that the resistance is
very low in one direction and very high in other direction.
l when a battery and a bulb, the bulb will light up with one of the
two possible connections, as illustrated in the diagram 8.6.2.

Lamp Off Lamp turned On

Fig. 8.6.2

21
8.7 HELPFUL HINTS IN TROUBLE SHOOTING
When an electrical failure occurs, check for trouble as explained below :
1) In order to find out if the failure has happened in the alternator
itself or in the regulation system one has to test the alternator at
no load (at nominal speed) exciting the exciter stator directly,
using an external dc source.
When applying the voltage to the exciter stator one has to comply
with polarities : apply the negative polarity of the auxiliary source
to the negative terminal and positive terminal to the positive
terminal of the exciter fields.
Verify that :
A) When feeding the winding according to the excitation data at
no load (listed in the table) the voltage supplied by the
alternator is almost the rated one
B) After locating the fault, repair as per troubleshooting.

8.8 Possible Faults :

While running, if the alternator is not functioning properly, first check :
That the connections as per specified diagram for the machine
That the connections are properly tightened
That the running speed of the prime mover is as per requirement
from Frequency meter.
That the protection equipment is properly set.

22
 l VOLTAGE FAULTS :

FAULT CAUSE REPAIR

No voltage build - up 1) Insufficient residual voltage 1) Excite the rotor using a battery
2) Improper connection 2) Correct the connection
3) Faulty moulded rectifier bridge 3) Replace the rectifier bridge
4) Low speed 4) Reset the speed to the nominal
5) Faulty Winding 5) Check the winding resistance
and rewind if required
6) Rotating rectifier failure 6) Replace the rotating rectifier
7) Faulty AVR 7) Replace the AVR
Low no - load voltage 1) Low speed 1) Reset the speed to the nominal
2) Air - gap of compound too small 2) Regulate the compound air gap

23
3) Faulty Rotating rectifier
4) Faulty Winding
5) Faulty moulded bridge rectifier
Low voltage on load 1) Low speed at full load
2) Compound defective
3) Faulty rotor winding
4) Over load on alternator
3) Replace the rotating rectifier
4) Check the winding resistance
and rewind if required
5) Replace the rectifier bridge
1) Set the rated speed of the
prime mover
2) Check and, if necessary change
the compound unit
3) Check the rotor winding
resistance and if faulty, rewind it
4) Operate on specified load
 FAULT CAUSE
High voltage on load 1) Capacitors on the load side
2) Incorrect compound assembly
Too high 1) Excessive speed
no - load voltage 2) Air - gap compound too high
Voltage oscillations 1) Incorrect AVR setting
2) Thyristor load more than
specified limits
3) Insufficient engine flywheel
24
inertia.
Unbalance voltage 1) Unbalance load
2) Loose connections
3) Stator winding faulty
Light Flickering 1) Insufficient engine flywheel
inertia.
2) Faulty engine governer setting.
3) No endfloat after assembly of
closed coupled set.
REPAIR
1) Disconnect the PF
improvement capacitors
2) Check the compound winding
resistance & if necessary replace it.
1) Adjust the revolving speed
2) Reduce the compound air gap
1) Set the AVR stability pot
2) Reduce the Thyristor load
1) Correct the load
2) Tighten the loose connections
3) Check winding resistance &
rewind if required
1) Ensure proper weight.
2) Tune the governer properly.
3) Ensure proper alignment of
coupling disc & end play.
 l Evident Physical Defects (overheating, noise, vibration....)

FAULT CAUSE REPAIR

Excessive overheating 1) Set misalignment 1) Align the set properly
of one or both bearings 2) Bearing loose in end shield 2) Replace the faulty End shield
(temp. of bearings over housing
800C) (with or without
noise)
Excessive overheating 1) Air flow (inlet - outlet) partially 1) Check air inlet - outlets of the
of alternator frame clogged or hot air is being alternator
circulated either from alternator or
prime mover
2) Alternator operating at high 2) Set the voltage to rated value

25
voltage at load
3) Alternator overloaded 3) Operate at specified load
4) Load PF less than 0.8 lag 4) Correct the load power factor
Excessive vibrations Defective mounting or play in the Replace the coupling & check the
coupling alignment Reset the speed to the
nominal
Excessive vibration and 1) Three phase alternator is single 1) Check and correct the load
humming noise coming phase loaded in excess of
from the alternator acceptable limits

Continued . . . .
 Evident Physical Defects (overheating, noise, vibration....)
FAULT
Excessive vibration and
humming noise coming
from the alternator
Smokes, spark or flames
coming from the alternator
26
Alternator damaged by a
significant impact which
is followed by humming
and vibration
CAUSE REPAIR
2) Start up with no-load : if humming 2) Rewind stator
persists - faulty alternator stator
winding
1) Short circuit in the external circuit Stop the set immediately
(including wiring between
alternator and control board)
2) Object fallen into the machine
3) Short circuit or flash in the stator
winding
1) Short circuit in external circuit Stop the gen-set immediately
2) Faulty parallel connection (out of
phase)
3) Break or deterioration in the
coupling
4) Break or twist in shaft extension
5) Shifting or short circuit of main
field winding
6) Bursting or unlocking of the fan
9.0 DESIGNATION OF THE SPARE PARTS :
In case of replacements of spare parts use original spare parts only for
the best performance of alternator.
For the replacements of worn parts, carefully follow the maintenance
instruction, these operations must be carried out by skilled and trained
technicians or our authorized service personnel.

PART DESCRIPTION RECOMMENDED ORDERING

NO. SPARES QTY. CODE
3 FRAME WITH WOUND PACK - Ref to Divn.
4 ROTOR (Wound) - Ref to Divn.
7 WOUND EXCITER STATOR
132 Frame 60312416
160S1 / 160S2 / 160M1 Frame 60482416
160/200S1 Frame - 60492416
200/250 Frame - 60992416
315 / 315SB Frame - 60092416
355 Frame - 60162416
400 Frame - 60542416
8 WOUND EXCITER ROTOR
132 Frame 60312425
160S1 / 160S2 / 160M1 Frame 60482425
160/200S1 Frame - 60492425
200/250 Frame - 60992425
315 / 315SB Frame - 60072425
355 Frame - 60162425
400 Frame - 60542425
10b DE END SHIELD (G2R/S)
132 Frame - 60322430
160 Frame - 60422430
200 Frame - 60622430
250 Frame - 60772430
315 Frame - 60092430
355 Frame - 60192430
400 Frame - 60592430
10a DE END SHIELD (G1R/S)
G1R132 SAE2 6036143023
G1R132 SAE3 - 6036143034
G1R132 SAE4 - 6036143046
G1R132 SAE5 6035133057
G1R160 SAE2 - 6048243023
G1R160 SAE3 - 6047243033
G1R160 SAE4 - 6048243042
G1R160 SAE5 - 6048243056
G1R200 SAE1 - 6069243011
G1R200 SAE2 - 6069243024

27
PART DESCRIPTION RECOMMENDED ORDERING
NO. SPARES QTY. CODE
G1R200 SAE3 - 6069243012
G1R200 SAE4 - 6069243044
G1R 250 SAE1 - 6084243012
G1R 250 SAE2 - 6084243023
G1R 250 SAE3 - 6084243032
G1R 315 SAE1 - 6008243012
G1R 315 SAE2 - 6008243023
G1R 315 SAE3 - 6009243033
G1R 315 SAE1/2 - 6009243092
G1R 355 SAE1 - 6019243012
G1R 355 SAE1/2 - 6016243092
G1R 355 SAE 0 - 6016243001
G1R 400 SAE0 - 6056243001
G1R 400 SAE1 - 6056243012
11 NDE END SHIELD
315 Frame - 60072432
355 Frame - 60132432
400 Frame - 60532432
12 BRG COVER DE O/S -
315 Frame - 63613261
355 Frame - 60152161
400 Frame - 361036018
13 BRG COVER DE I/S -
250 Frame - 67423163
315 Frame - 61625164
355 Frame 60152163
400 Frame - 361036017
14 BALANCING RING -
250 Frame - 361036101
315/355 Frame 361036002
400 Frame - 361036012
46 MOULDED SLIPRING
G2S/G1S 132 Frame 1 365241001
G2S/G1S 160/200 Frame 1 361241004
47 FAN
132 Frame (Nylon) - 361087060
160 Frame (Nylon) - 361087070
200 Frame (Nylon) - 361087074
250 Frame - 60782423
250 (1.Brg.) Frame - 60772423
315 Frame - 60092423
355 Frame - 60192423
400 Frame - 60592423
50 T.BOX ASSLY:
T.Box ASBY G1R 315 - 361055011
T.Box ASBY G1R 355 - 361055004
400 Frame - 361055016

28
PART DESCRIPTION RECOMMENDED ORDERING
NO. SPARES QTY. CODE
51 END COVER
132 Frame (Plastic) - 361034041
132 Frame (Sheet Metal) 362087014
160 Frame - 361031007
200 Frame - 369031002
250 Frame - 361031055
315 Frame - 361055013
355 Frame 361055014
400 Frame - 361055017
53a DE VENT COVER
G2R/S 132 Frame - 361034093
G2R/S 160 Frame - 361034092
G2R/S 200 Frame - 361034091
G2R 250 Frame - 361034048
G2R 315 Frame - 361034031
G2R 355 Frame - 361034035
G2R 400 Frame - 361034089
G1S 132 SAE 2 361034069
G1S 132 SAE 3 - 361034081
G1S 132 SAE 4,5 - 361034013
G1R 160 SAE 3 - 361034081
G1R 160 SAE 2 - 361034069
G1R 160 SAE 4,5 - 361034085
G1R 200 SAE 3,4,2 361034021
G1R 250 SAE1 - 361034083
G1R 250 SAE 2,3 - 361034086
G1R 315 SAE 1,2 - 361034079
G1R 315 SAE 1/2, 3 - 361034030
G1R 355 SAE 1 , 1/2 - 361034042
G1R 355 SAE 0 - 361034064
G1R 400 SAE 0,1 - 361034088
54 TERMINAL BOX COVER
132, 160S1 Frame - 361034019
160 Frame (Brushless) - 365031006
160 Frame (Slipring) - 361031039
200 Frame - 363031001
250 Frame - 361031054
55 NDE VENT COVER
160 Frame - 361087067
200 frame - 361087068
250 frame - 361034047
63 WOUND BOBBINS
G2S 132MR - 3ph (K6) 3 60311441
G2S 132MA - 3ph (K8) 3 60321441
G2S 132MC - 3ph (K10) 3 60341441
G2S 132MD - 3ph (K12) 3 60351441
G2S 160S1B - 3ph (K15) 3 60421441

29
PART DESCRIPTION RECOMMENDED ORDERING
NO. SPARES QTY. CODE
G2S 132MA - 1ph (S5) 1 60321241
G2S 132MC - 1ph (S6) 1 60341241
G2S 132MD - 1ph (S8) 1 60351241
G2S 160S1B - 1ph (S10) 1 60421241
G2S 160SC - 1ph (S12) 1 60451241
G2S 160MC - 1ph (S15) 1 60471241
G2S 200SE - 1ph (S20) 1 60601241
G2S 160SC - 3ph (K20) 3 60451441
G2S 160MC - 3ph (K25) 3 60471441
G2S 160MR - 3ph (K30) 3 60491441
G2S 200SF - 3ph (K37) 3 60601441
G2S 200SB - 3ph (K50) 3 60631441
G2S 200SD - 3ph (K63) 3 60651441
G2S 200MD - 3ph (K82) 3 60691441
65 COUPLING HUB
SAE 6.5/7.5 for 132 Frame - 6031243223
SAE 11.5 for 132 Frame - 6031243223
SAE 11.5 for 200 Frame - 6061243233
SAE 14 for 250 Frame - 6090243212
SAE 14 for 315 Frame - 6009243212
SAE 14 for 355 Frame - 6015243212
SAE 14 for 400 Frame - 6055243212
66 COUPLING DISC SET
SAE 6.5 (Set of 1 No) for 132/160 - 361031073
SAE 7.5 (Set of 1 No) for 132/160 - 361031074
SAE 10 (Set of 1 No) for 160 - 361031064
SAE 10 (Set of 2 Nos) for 132/160 - 361031035
SAE 10 (Set of 3 Nos) for 200/250 - 361031043
SAE 10 (Set of 3 Nos)(small bore)
for 200 - 361031068
SAE 11.5 (Set of 1 Nos) for 160 - 361031063
SAE 11.5 (Set of 2 Nos) for 132/160 - 361031033
SAE 11.5 (Set of 3 Nos)
for G1R 200/250 - 361031034
SAE 11.5 (Set of 4 Nos) for G1R 315 - 361031052
SAE 14 (Set of 3 Nos)
for G1R 200/250 - 361031018
SAE 14 (Set of 4 Nos)
for G1R 315/355 - 361031042
SAE 18 (Set of 4 Nos) for G1R /355 - 361031058
SAE 14 (Set of 6 Nos)
for 400 Frame - 361031075
SAE 18 (Set of 6 Nos)
for 400 Frame - 361031076
67 COUPLING PRESSURE DISC
(SAE 6.5/7.5) 361031032
(SAE 10” & 11.5”) 361034070

30
PART DESCRIPTION RECOMMENDED ORDERING
NO. SPARES QTY. CODE
68 COUPULING DISC SPACER
132 / 200 Frame:- 10" - 361049001
160 / 200S1 Frame:- 10" - 361049014
250 Frame :- 10" & 11.5" - 361049004
315 Frame :- 11.5" - 361049008
355S Frame :- 11.5" 361049012
355M Frame-:- 14" - 361049013
400 Frame-:- 14" - 361049017
71 COMPOUND PLATE -
132 Frame - 365031011
160 Frame - 364031009
200 frame - 362031004
301 DE BEARING
132 Frame - 6308.2RS.C3 1 361123006
160 Frame - 6310.2RS.C3 1 369123002
200 Frame - 6313.2RS.C3 1 363123001
250 Frame - 6315.C3 1 316121107
315 Frame - 6318.C3 1 312121108
355 Frame - 6220.C3 1 361121003
400 Frame - 6224.C3 1 361121004
302 NDE BEARING
132 Frame - 6207.2Z 1 369123005
160 Frame - 6209.2RS 1 366123003
200 Frame - 6310.2RS 1 369123002
250 Frame - 6313.2RS 1 363123001
315/355 Frame - 6314.2RS 1 361123007
400 Frame - 6317.2RS 1 361123008
325 MAIN TERMINAL BOARD
WITH 6 TERMINALS
132 Frame - 369086027
160 Frame (FOR S/R ALT) - 369086025
200 Frame (FOR S/R ALT) - 369086023
315 Frame - 361086061
MAIN TERMINAL BOARD -
WITH 8 TERMINALS -
160 Frame (FOR BRUSHLESS ALT) - 361086065
200 Frame (FOR BRUSHLESS ALT) - 361086066
250 Frame - 361086084
315 Frame - 361086062
355/400 Frame - 379086902
330 B/H ASSLY.
G2S/G1S 132 Frame 1 361241002
G2S/G1S 160/200 Frame 1 361241009
347 CABLE ENTRY GROMMET
132 Frame - 369086015
160 Frame - 364086011
200 Frame - 364086006

31
PART DESCRIPTION RECOMMENDED ORDERING
NO. SPARES QTY. CODE
250 Frame - 360086013
353 MOULDED RECTIFIER BRIDGE
G2S/G1S-132/160/200 - 3 Ph. 1 361260001
G2S/G1S-132/160/200 - 1 Ph. 1 362260008
359 AUXILIARY TERMINAL
BOARD ( 3 TERMINAL )
G2R/G1R 160 Frame 1 369086026
G2R/G1R 200 Frame 1 369086024
371 DIODE BOARD ASSEMBLY
132 Frame PCB type 1 36126016
160/200/250 Frames 1 60692495
315/355 Frames 1 60092495
400 Frame 1 60592495
386 AUTOMATIC VOLTAGE
REGULATOR
AVR SR 7/3- 1 Ph (132/160 Fr.) 1 361260030
AVR SR 7/3- 3 Ph (132/160 Fr.) 1 361260011
AVR SR 7/6- 3 Ph
(200/250S/250M Fr.) 1 361126018
AVR SR 7/6 –1 Ph (200 Fr.) 1 361260053
AVR UVR - 7 (250L/315 /355 Fr.) 1 361260055
AVR SR 7/5 - (132 Fr.) 1 361260017
AVR SMR - (400 Fr.) 1 361260058
387 QUADRATURE DROOP
TRANSFORMER
(250L/315/355/400 Fr) 1 361260054
388 RECTIFIRE PROTECTION
UNIT (RPU)
(G2S 132/160/200) 1 361260002

32
 'Ustad' Series G2S / G1S 132,160, 200 Frames,
3 Phase Alternator Wiring Diagram

B
ROTOR WDG

Y
R W1 U1 V1
'ARM' WDG 'L'WDG

U2 V2 W2
B
Y

'AUX'WDG R 'C' WDG

ROTOR STATOR CONNECTORS CE UNIT
Red
Blue Cable MAIN TERMINAL
Cable + BOARD
DC AC

MOV -
BRIDGE
RECTIFIRE R : Red Cable
CAPACITOR Y : White Cable
B : Blue Cable
RPU

'Ustad' Series G2S / G1S 132, 160, 200 Frames,

1 Phase Alternator Wiring Diagram
ROTOR WDG

'ARM' WDG 'L'WDG PH N

'AUX'WDG 'C' WDG

MAIN TERMINAL
ROTOR STATOR CONNECTOR CE UNIT BOARD

Red
Blue Cable
Cable +
DC AC

MOV -
BRIDGE
RECTIFIRE
CAPACITOR
RPU

33
 12 WIRES CONNECTIONS
G1R/G2R (FRAMES 160-200-250-315)
SERIES STAR U
Frequency Terminals Different Voltage Levels
U4
U3
U2
50Hz U-V 380* 400* 415*
U1 N
W1 V1 50Hz U-N 220 230 240
W2 V2
W3 V3 60Hz U-V 460 480 500
V4
W4
V
W 60Hz U-N 265 277 290
U
SERIES DELTA 50Hz U-V 220 230 240
W1 U4
c
W2 U3
50Hz U-c 110 115 120
W3 U2

W4 U1
60Hz U-V 265 277 290
W
V1 V2 V3 V4 V 60Hz U-c 133 138 145
PARALLEL ZIG-ZAG 50Hz U-W 220 230 240
W3 V4
W1 c 50Hz U-c 110 115 120
V3
W4 V2
U3 U4
W2 V1
U 60Hz U-W 265 277 290
W U1 U2
60Hz U-c 133 138 145

12 LEAD TERMINAL CONNECTIONS (160/200/250/315 Frame)

SERIES STAR SERIES DELTA PARALLEL ZIG-ZAG

U W1 W1 V4
U4 U4
W3 V2
W2 U3 W4 V3
U3 W3 U2 U3 U4
U2 W2 V1
W4 U1
W U1 U2 U
U1
Danger ! W1 V1
V1 V2 V3 V4

Any intervention W2
W3
V2
V3
on the alternator W4 VOLTAGE V4 VOLTAGE VOLTAGE
W V U
380/220V (3Ph.) 220V (3Ph.) 220V (1Ph.)
terminals during W V
reconnection or
U2 U3 V2 V3 W2 W3 U1V1W1 U2 U3 V2 V3 W2 W3 U1 V1W1 U1 U3 V1 V3 V2 V4 W1W3
check should be
performed with
the machine
stopped.

U4 V4 W4 W1 U4 U1 V4 V1 W4 U2 U4 W4 W2

U V W N C U V W C U (PH) W (N)

NOTE:-ADJUST ' VOLT' POTENTIOMETER OF AVR (IF REQD) TO GET REQUIRED VOLTAGE

Note : AVR ADJUSTMENT FOR 1 PHASE / 3 PHASE LOW VOLTAGE

CONNECTIONS :
(Not required for RED 1 PH AVR.)
When terminal connections are changed at site, Voltage Setting of AVR should be
reseted accordingly as per following steps :
1. In case of single phase connection, isolate the Auxiliary Winding and connect the
sensing wires to phase and Neutral.
2. Provide Link between terminal no. 3 & 4 for Model SR 7/3 and SR 7/6.
3. Rotate 'Volt' POT in anticlockwise direction by 15 turns.
4. Start the D.G. Set and adjust to required voltage using 'Volt' POT.

34
 EXPLODED VIEW FOR 'USTAD' SERIES SLIP RING ALTERNATOR, 132 /160 / 200 FRAME

53a

10a
54
FO
RD
OU
BL
EB
EA
RIN
GA 63
LTR
NA 353
TO 388
301 R
71
47
46 3
10b 4a

35
51
330
66
302
68 325
65 347

53b
47
FO 46
RS
ING
LE 4b
BE
AR
ING
AL
TR
NA 330
TO
R 302
 EXPLODED VIEW FOR BRUSHLESS ALTERNATOR, 160 / 200 / 250 FRAME

302

54 67
65
47 66
386 4
325
10a
347 71

36
8

53a
10b

7 55
395
371 3
51

53b
301
47
4
302
 EXPLODED VIEW FOR BRUSHLESS ALTERNATOR, 315 / 355 / 400 FRAME

325 387

50

386

371
R
NATO
IN G ALTR
BEAR
BLE
DOU
FOR

37
13 51

7
11

302
8
3
14
4
47
301
8
12 10b 53b 302
4a 14 R
NATO
47 I N G ALTR
65 EAR
LE B
68 SING
66 FOR
10a 53a
 CONNECTION DIAGRAM OF G2R/G1R FRAMES 132 / 160
1 PH. BRUSHLESS ALTERNATOR
EXCITER

STATOR
STATOR ROTOR

RECTIFIER ARMATURE
EXCITER WINDING
ARMATURE BRIDGE
EXCITER FIELD

U1(PH) U2 (N)

MAIN FIELD
SUPPRESOR
SURGE
RED COLOR BASE
AVR-SR 7/3, 1 Ph.

200K Optional
4 Amp. Fuse 7
P2
6
INDICATOR P1
5 5
LEAD UFRO N
OL 4 4
SR7/3 PH
AMP 3 3 Cable Marker
(1 PH) F1(+VE)
Hz 2
STAB
1 1
VOLT.
F2(-VE)

Blue Cable

Red Cable

CONNECTION DIAGRAM OF G2R/G1R FRAMES 132 / 160

3-PH. BRUSHLESS ALTERNATOR WITH AUXILIARY WINDING
EXCITER

STATOR
ROTOR
STATOR
EXCITER RECTIFER
ARMATURE BRIDGE ARMATURE
N WINDING
EXCITER FIELD

U
SUPPRESOR

MAIN FIELD
SURGE

AUX.WINDING

AVR-SR 7/3
Red Cable
Blue Cable

200K
4 Amp. Fuse 7
INDICATOR P2
LEAD 6 Cable Marker
SLI P1
5
UFRO 5
OL 4 5
4
(O.L) AMP SR 7/3 3 3
(UFRO) Hz F1(+VE) 3
2
STAB
1 1
VOLT.
F2(-VE)

Blue Cable
Red Cable

38
 CONNECTION DIAGRAM OF G2R/G1R FRAME 200,
1 PH, BRUSHLESS ALTERNATOR
EXCITER

ROTOR STATOR
STATOR
RECTIFIER ARMATURE
EXCITER
BRIDGE WINDING
ARMATURE
EXCITER FIELD

MAIN FIELD
U1(PH) U2 (N)

SUPPRESOR
SURGE RED COLOR BASE
AVR-SR 7/6, 1 Ph.

4 Amp. Fuse 200K Optional

INDICATOR 7
P2
LEAD 6
P1
5 5
UFRO N
OL 4 4
PH Cable Marker
AMP 3 3
UFRO 2 F1(+VE)
STAB
1 1
VOLT.
F2(-VE)

Blue Cable
Red Cable

CONNECTION DIAGRAM OF G2R/G1R FRAMES 200 / 250S / 250M

3 PH, BRUSHLESS ALTERNATOR WITH AUXILIARY WINDINGS
EXCITER

ROTOR STATOR
STATOR
EXCITER RECTIFER
BRIDGE ARMATURE
ARMATURE WINDING
EXCITER FIELD

N
U
MAIN FIELD
SUPPRESOR
SURGE

AUX.WINDING
Blue Cable

Red Cable

AVR-SR 7/6
INDICATOR 9 Q2
LEAD 4 Amp. Fuse 8 Q1 200K
7 P2
TRIM
SLI 6
P1
UFRO 5 5
OL 5
DRP 4
4
AMP 3 3
UFRO F1(+VE) 3 ANALOGUE
2
STAB DC INPUT (+/- 5V)
1 1 (Optional)
VOLT.
F2(-VE)
Cable Marker
Blue Cable
Red Cable

39
CONNECTION DIAGRAM OF G2R/G1R FRAMES 250L / 315 / 355
3 PH, BRUSHLESS ALTERNATOR WITH AUXILIARY WINDINGS
(PARALLEL OPERATION WITH UVR 7)
EXCITER

STATOR ROTOR
Neutral RECTIFER
ARMATURE + VE BRIDGE EXCITER
WINDING ARMATURE

EXCITER FIELD
U

MAIN FIELD
V
W
- VE
AUX.WINDING
Blue Cable

Red Cable

Red Cable

Blue Cable

200K
1 VOLT.
2 STAB
- 3 Hz (UFRO)
F2 + 4 AMP (OL)
F1 5 OL
6 6 UF
7 7 SL
8 8 OV
8
Q1 9 TRIM
Q2 10 DROOP
ANALOGUE A1 11
Cable Marker DC INPUT (+/- 5V) A2 12 FUSE 4 AMP

Optional

OL - OVER LOAD INDICATION UF - UNDER FREQUENCY INDICATION

SL - SENSE LOSS INDICATION OV - OVER VOLTAGE INDICATION

CONNECTION DIAGRAM OF MARINE DUTY & 400 Frame 3-PH. BRUSHLESS ALTERNATOR
EXCITER
STATOR ROTOR
Neutral RECTIFER
ARMATURE + VE EXCITER
BRIDGE
WINDING ARMATURE
U
EXCITER FIELD

V
MAIN FIELD

- VE
AUX.WINDING

Blue Cable
Blue Cable

Red Cable

Red Cable
AVR (SMR)

F1 VOLT.
+

F1
F2 STAB
F2
-

3 AUX.1 Hz (UFRO)
AMP (OL)
4 AUX.2
OL

UF

7 R

8 Y FUSE 6 AMP

TRIM

DROOP
P1 P2 A1 A2 Q1 Q2

Cable Marker
Optional
P1

P2
200K

A1
A2

OL - OVER LOAD INDICATION

ANALOGUE
DC INPUT

UF - UNDER FREQUENCY INDICATION

(+/-5 V)

Q1 & Q2 - USE ONLY CGL MAKE QDCT's

IN CASE OF PARALLEL OPERATION
Q1
Q2

40
 CONNECTION DIAGRAM OF MARINE DUTY 1- PH. BRUSHLESS ALTERNATOR
EXCITER

STATOR ROTOR
RECTIFER
+ VE BRIDGE EXCITER
ARMATURE ARMATURE

EXCITER FIELD
WINDING

MAIN FIELD
U1(PH) U2 (N)

- VE
AUX.WINDING

Blue Cable
Blue Cable

Red Cable

Red Cable
AVR (SMR)

F1 VOLT.
+

F1
F2 STAB
F2
-

3 AUX.1 Hz (UFRO)
AMP (OL)
4 AUX.2
OL

UF

7 Ph.

8 N FUSE 6 AMP

TRIM

DROOP
P1 P2 A1 A2 Q1 Q2

Cable Marker
Optional
P1

P2

OL - OVER LOAD INDICATION

200K

A1
A2

Q2
Q1 UF - UNDER FREQUENCY INDICATION
ANALOGUE
DC INPUT
(+/-5 V)

41
AUTOMATIC VOLTAGE REGULATOR :
AVR SR 7/3, SR 7/6, UVR 7 & SMR
GENERAL :
The PC Board with electronic components is located inside a box and
embedded in elastomer resin. Terminal consist in 1/4" “Fasten” lugs.
CONNECTIONS :
Connection to the AVR should be made as per schematic diagram
shown in the Fig.
POTENTIOMETER DESCRIPTION :
‘VOLT’ Voltage Adjustment Pot
‘STAB’ Stability Adjustment Pot
‘Hz’ Under Speed Protection Adjustment Pot
‘AMP’ Over Excitation Adjustment Pot
‘DRP’ Droop Adjustment Pot
‘TRIM’ Pot to adjust sensitivity of Analogue Input
FUNCTIONS OF THE AVR POTENTIOMETER :
VOLT : This potentiometer allows to adjust the terminal voltage of the
alternator. Its adjustment range is very simple. Therefore we suggest
adjust it with care. Rotating the Pot. clockwise the voltage increases,
counterclockwise the voltage decreases.
STAB : It allows optimizing the alternator’s response time. Rotating
counterclockwise the stability is decreased, the response times become
short but the voltage is less stable. Rotating it clockwise, the response
time is longer but the voltage is more stable.
Adjust the STAB potentiometer in such a way that oscillations do not
occur and the damping is as desired.
HZ : Hz potentiometer is used to adjust the level of intervention of the
low frequency protection. Usually this adjustment is performed by the
manufacturer during testing and then sealed.
AMP : This potentiometer allows adjusting the level of intervention of
the overexcitation protection. This protection system has a delay, which
permits temporary overloading of the machine during start-up of electric
motor or for other purposes.
DRP : Clockwise increases the amount of CT Signal injected in to the

42
AVR and increases Voltage Droop with lagging Power Factor
(Cos f). With the control fully anticlockwise there is no Voltage Droop.
TRIM : Trim Control allows the user to adjust the sensitivity of analogue
input. The Trim fully clockwise it has maximum effect.
ADJUSTMENT PROCEDURE :
CAUTION : IT IS HAZARDOUS TO PROCEED FOR HIGH
VOLTAGE TEST ON THE ALTERNATOR WITHOUT
HAVING PREVIOUSLY DISCONNECTED ALL
CONNECTIONS TO AUTOMATIC VOLTAGE REGULATOR
Warning ! (AVR). DAMAGES OCCURING TO AVR IN SUCH
CONDITIONS WILL NOT BE CONSIDERED IN
WARRANTY CLAIM.
Alternators equipped with particular AVR is thoroughly tested and
calibrated in test rig at our works. If required following Adjustment
procedures to be followed for normal operation during
commissioning or in subsequent operation.
ADJUSTMENT OF ‘HZ’ POTENTIOMETER :
Operating on the ‘Hz’ Pot. we have the possibility to correct the
frequency corner of the low speed protection. To modify this calibration
one must operate in the following way :
a) Rotate the Hz pot. fully clockwise with generator at its nominal
speed at no load;
b) Decrease the rotating speed until the desired operating point of the
protection (47 Hz for 50 Hz operation) and then rotate the Hz pot.
In counterclockwise direction till voltage decreases of 1.5%
approximately;
c) Seal the Hz pot.
d) Raise the gen-set speed to its nominal value.

415 V
Terminal Voltage

Frequency 47 50 Hz

Threshold for
under speed protection
43
ADJUSTMENT OF ‘AMP’ POTENTIOMETER :
This potentiometer, that is normally calibrated and sealed in our factory,
serves to calibrate the intervention threshold of the overexcitation
protection.
The factory adjustments corresponds to the excitation current for a
sustained three-phase short circuit of about three times the rated
current, unless otherwise specified. (In many countries the short- circuit
current equal to three times the rated one is obligatory in order to allow
selective tripping of circuit breakers.)
For its calibration you must operate in following way :
a) With alternator at no load and at nominal speed rotate the ‘AMP’
pot. Fully clockwise.
b) With full load operate on the ‘VOLT’ pot till to obtain an excitation
voltage (in D.C. measured between 1 (-) & 3(+) terminals of the
regulator) equal to the 110% of nominal one at full load.
At this point check and note the output voltage of the alternator.
c) Turn the ‘AMP’ pot. fully counterclockwise.
d) After about 20 seconds the voltage decreases considerably
e) Operate immediately on the ‘AMP’ pot. in clockwise sense till when
the output voltage of the alternator arrives at a value 2% lower than
the one read and noted at point (b)
f) Discharge the alternator to no load and operate on the ‘VOLT’ pot.
So as to reestablish the output voltage of the alternator to its rated
value.
P) Seal the ‘AMP’ pot.

REMOTE REGULATION OF THE VOLTAGE :

Obtained by application of a 200 KW potentiometer between the
terminal 6 & 7 permitting a regulation of ±5% of the nominal voltage in
case of SR7/3 & SR7/6 and terminal 1 & 2 in case of UVR-7.

DROOP ADJUSTMENT :
Generators intended for parallel operation are fitted with Quadrature
Droop CT which provides a power factor dependent signal for the AVR.
The CT is connected to Q1, Q2 on the AVR (See generator wiring
diagram for details). Clockwise increases the amount of CT Signal
44
injected in to the AVR and increases the Droop with lagging Power
Factor (cos f). With the control fully anticlockwise there is no Droop.

ANALOGUE INPUT :
An Analogue input (A1, A2) is provided to connect to the DC current
source devices. It is designed to accept DC Signal upto ± 5 Volts.

WARNING :
Any device connected to this input must be fully floating and
galvanically isolate from ground with an insulation capability of 500
V AC. Failure to observe this could result in equipment damage.
The DC Signal applied to this input adds to the AVR sensing Circuit. A1
is connected to the AVR 0 Volts. Positive on A2 increases excitation.
Negative on A2 decreases excitation.

TRIM ADJUSTMENT :
The TRIM Control allows the user to adjust the sensitivity of the input.
The TRIM fully clockwise it has maximum effect.

45
 DIMENSION DRAWING FOR SINGLE BEARING AC GENERATOR (132 - 250 FRAME)
AC WA±0.5 X-CG OF M/C L1±1
R HOLES fS
ON M PCD ±0.5
SP (SPIGOT) AIR OUTLET

T
HD±5

fPA
fTA
=

fN
fQ
fP
=
H

AIR INLET

AA ±0.5 R1 HOLES fS1 BS±0.5

HA ON M1 PCD N HOLES fK±0.5
A±0.5
C±0.5 BM±0.5
AB
COUPLING DISC BOLT TO BB
BE TIGHTENED TO TORQUE,
L±5
FOR M10 BOLT 75 N-m
FOR M16 BOLT 244 N-m

G1R:-BRUSHLESS TYPE SINGLE BRG. ALTERNATOR

DIMENSIONS in Milimeters G1S:-SLIPRING TYPE SINGLE BRG. ALTERNATOR
FOOT FIXING COUPLING DETAILS OVERALL
M/C WT.(Kg)
FRAME HD L
A AA AB H BB BS BM C N fK SP T TA HA AC L1 X
G1R G1S G1R G1S G1R G1S
132 MR 70 70 284
132 MA 77 77 299
131.5
132.0

206 56 256 122 - 56 380 4 12 5 12 165 12 345 365 272 550 520 296
132 MC 86 86 322
132 MD 94 94 339
160 S1E 85 85 170
160 S1A 94 -- 254 335 430 462 262 175
159.5
160.0

60 340 40 70 145 6 15 5 17 62 16 385 297

160 S1B 103 103 279 190
160 S2C 122 -- 350 -- 507 200
160 SB 118 -- 190
196 30 95 263 548
160 SC 128 128 200
160.0
159.0

160 MC 152 143 270 70 340 225 50 213 6 15 5 17 62 16 418 350 567 300 225
145
160 M2A 154 145 270
277 110 160 263 617
160 M2R 164 155 280
200 SE 162 152 200
220 238 17 62 590
200 SF 172 -- 205
200 SA 213 -- 120 280
4
200 SB 232 219 125 SAE 2,3=363 SAE 2,3=716 300
225 --
199.5
200.0

200 SC 246 -- 340 75 410 SAE 1=377 19 5 12 165 20 510 424 SAE 1=730 350 315
200 SD 247 247 330
200 MB 296 -- 345
230 SAE 2,3=353 SAE 2,3=816
200 MD 335 335 325 110 6 370
235 SAE 1=367 SAE 1=830
200 MDX 342 -- 400
250 SB 341 SAE 2,3=308 SAE 2,3=749 315
250 SD 385 SAE 1=322.2 SAE 1=763 330
250 MA 427 SAE 2,3=378 SAE 2,3=819 370
249.5
250.0

420 90 510 305 116 216 6 19 6 18 165 20 615 530 376

250 MB 458 -- SAE 1=392.2 SAE 1=833 400
250 LB 504 SAE 2,3=458 SAE 2,3=899 415
250 LD 526 SAE 1=472.2 SAE 1=913 435

FLANGE COUPLING DISC

SAE COUPLING SAE
Q f PA M1 R1 f S1 1 WA
No fN fP M R fS DISC SAE No
250 FR
5 314.3 356 333.4 - 8 11 45° 6.5"-7.5" 6.5" 215.9 200.0 6 9 60° 30.2
4 362 405 381.0 - 12 11 30° 6.5"-7.5"-10" 7.5" 241.3 222.3 8 9 45° 30.2
3 409.6 450 428.6 540 12 11 30° 10"-11.5" 10" 314.32 295.3 8 11 45° 53.8
2 447.7 490 466.7 540 12 11 30° 10-11.5" 11.5" 352.42 333.4 8 11 45° 39.6
1 511.18 553 530.2 553 12 12.5 30° 14" 14" 466.72 438.2 8 13.5 45° 25.4

46
 DIMENSION DRAWING FOR SINGLE BEARING AC GENERATOR (315 - 400 FRAME)
AC±1 WA±0.5 X - CG LI±1
AIR
R HOLES fS ±0.5
SP (SPIGOT) OUTLET
ON M PCD

T
HD±5

1
=

fPA
fTA
fN
fP
Q
=
H

AA HA±0.5 BS±0.5 AIR INLET

A±0.5 R1 HOLES fS1
C±1 BM±0.5 N HOLES fK±0.5
AB ON M1 PCD
BB
COUPLING DISC BOLT TO L±5
BE TIGHTENED TO TORQUE,
FOR M20 BOLT 480 N-m
DIMENSIONS in Milimeters FOR M24 BOLT 822 N-m
FOOT FIXING COUPLING DETAILS OVERALL
M/C WT.
FRAME (Kg) A AA AB H BB BS BM C N fK SP T TA HA HD AC L L1 X

315 SE 732 980 380

315 SA 812 460
315.00
314.50

508 75 570 520 228.5 457 242 6 28 6 21 237 17 850 640 1085 415
315 SB 899 480
315 MB 1029 1155 520
355 SB 1114 1140 445
355 SC 1285 570
1245
354.5
355.0

355 SE 1341 610 80 670 570 250 500 297 6 28 6 21 237 17 940 685 560 590
355 ME 1384 580
1345
355 MA 1494 620
400 SB 1680 1225 545
399.5
400.0

400 SC 1790 686 100 786 660 350 560 350 6 35 6 21 275 29 1100 795 1275 600 590
400 MA 2290 1460 680

FLANGE COUPLING DISC

SAE COUPLING SAE
Q
No fN fP M R fS DISC SAE No f PA M1 R1 f S1 1 WA
315 355 400
3 409.6 450 428.6 620 - - 12 11 30° 11.5" 11.5" 352.42 333.4 8 11 45° 39.6
2 447.7 490 466.7 620 - - 12 11 30° 11.5" 14" 466.72 438.2 8 13.5 45° 25.4
1 511.18 553 530.4 620 708 775 12 12.5 30° 11.5"-14" 18" 571.4 543.0 6 16.7 60° 15.87
1/2 584.1 648 619.0 680 715 775 12 14 30° 14"-18"
0 647.7 712 679.5 - 715 775 16 14 22.5° 14"-18"

47
DIMENSION DRAWING FOR DOUBLE BEARING AC GENERATOR (132 - 250 FRAME)
L±5
AC L1
X - CG OF M/C
AIR OUTLET
CABLE ENTRY
HD±5
HC

AA AIR INLET
BB

HA
A±0.5 2 HOLES fK
±0.5 ±0.5
AB N HOLES fK
E C BS±0.5
GD BM±0.5
G BL±0.5
F
fD

fM TAPPED HOLE

G2R:-BRUSHLESS TYPE DOUBLE BRG. ALTERNATOR

DIMENSIONS in Milimeters G2S:-'USTAD' SERIES SLIPRING TYPE DOUBLE BRG. ALTERNATOR
M/C WT. FOOT FIXING SHAFT & KEY OVERALL
FRAME (Kg) HD L
A AA AB H BB BS BM BL C N fK fD E F G GD fM HA HC AC L1 X
G2R G2S G2R G2S G2R G2S
132 MR 70 70 284
f38.018
f38.002

132 MA 77 77 33.0 41.0 299

131.5
132.0

206 56 256 122 316 372 -- 45 4 12 80 10 M12 12 260 345 365 272 611 581 296
132 MC 86 86 32.8 40.8 322
132 MD 94 94 339
160 S1E 85 85 330
254 42.5 51.5 --
f48.018
f48.002
159.5
160.0

160 S1A 94 -- 60 340 335 79 119 149 66 6 15 110 14 M16 16 323 385 297 570 262 335
279 42.3 51.3
160 S1B 103 103 430 350
160 SB 118 -- 350
196 197 227 292 658
160 SC 128 128 - 360
f48.018
f48.002

42.5 51.5
159.5
160.0

292
160 MC 152 143 270 70 340 225 147 197 307 66 6 15 110 14 M16 16 323 418 350 677 300 380
42.3 51.3
160 M2A 154 145 342 380
277 197 307 727
160 M2R 164 155 357 390
200 SE 162 152 275 335
220 155 - 705
200 SF 172 -- 280 340
200 SA 213 -- 4 400
200 SB 232 219 400 420
-
f60.011
f60.030

225 280 53.0 64.0 830

199.5
200.0

200 SC 246 -- 340 75 410 405 57 19 140 18 M20 20 403 510 424 350 435
52.8 63.8
200 SD 247 247 450
200 MB 296 -- 495
500
200 MD 335 322 325 270 380 6 930 520
505
200 MDX 342 -- 550
250 SB 341 425
225 341 441 885
250 SD 385 450
f70.011
f70.030

250 MA 427 62.5 74.5 465

249.5
250.0

-- 420 90 510 305 295 411 511 66 6 19 140 20 M20 20 510 625 530 955 376
250 MB 458 62.3 74.3 520
250 LB 504 535
375 491 591 1035
250 LD 526 555

48
DIMENSION DRAWING FOR DOUBLE BEARING AC GENERATOR (315 - 400 FRAME)
AC±0.5 L1±1
X-CG
AIR OUT-LET
HD±5

HC
H
AA HA±0.5 BB AIR IN-LET
±0.5
A±0.5 E C±1 BS±0.5 N HOLES
GD AB f K±0.5
BM±0.5
G
L±5
F
fD

fM TAPPED HOLE

DIMENSIONS in Milimeters

FOOT FIXING SHAFT & KEY OVERALL

M/C WT.
FRAME (Kg)
A AA AB H BB BS BM C N fK fD E F G GD fM HA HC HD AC L L1 X

315 SE 732 1150 380

315 SA 812 71.0 85.0 460
80.011
315.00
314.50

80.030

508 75 570 520 228.5 457 216 6 28 170 22 M20 17 620 850 640 1220 415
315 SB 899 70.8 84.7 480
315 MB 1029 1320 520
355 SB 1114 1255 555
355 SC 1285 660
86.0 100 1360
95.035
355.00
354.50

95.013

355 SE 1341 610 80 670 570 250 500 254 6 28 170 25 M24 17 706 940 685 560 690
85.8 99.8
355 ME 1384 710
1460
355 MA 1494 750
400 SB 1680 1365 700
110.025
110.013

100 116
400.00
399.50

400 SC 1790 686 100 786 660 350 560 280 6 35 210 28 M24 29 775 1100 795 1415 600 730
99.8 115.8
400 MA 2290 1600 820

49
FOR FURTHER INFORMATION PLEASE CONTACT :
-SALES SE
AF
TER RV
Crompton Greaves Limited
LT Motors Division
IC
CG

A - 6/2, M.I.D.C., Ahmednagar 414111. DQS GmbH

Tel : 0241 - 2776 150 - 157, 2776 208.
UKAS
EN ISO 14001 : 2004 QUALITY
5
HE

MANAGEMENT
PL NOV. 2004 Edition ISO 9001
-0 Fax : 0241 - 2777800.
50

IN E
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008
: 18 00 - 4 19

Regd. Office : CG House, 6th Floor, Dr. Annie Besant Road, Worli, Mumbai 400 025.
Tel. : 022 - 24237777. Fax : 022 - 24237788. Website : www.cgglobal.com

REGIONAL SALES OFFICES

NORTH WEST
3rd Floor, Express Building, Kanjur Marg (E), Mumbai 400 042.
9-10, Bahadur Shah Zafar Marg, Near ITO Crossing, Phone : 022 - 67558000.
New Delhi 110 002. Phone : (011) 23460700. SOUTH
EAST 3-A, MGR Salai, (K. H. Road),
50, Chowringhee Road, Nungambakkam, Chennai 600 034.
Kolkata 700 071. Phone : 044 - 42247500 / 525.
Phone : 033 - 22829681-85

REGIONAL SERVICE CENTRES

NORTH WEST
Vandana, 11, Tolstoy Marg, Kanjur Marg (E),
New Delhi 110 001. Mumbai 400 042.
Phone : 011 - 23460700. Phone : 022 - 67558590.
EAST SOUTH
21, R.N. Mukherjee Road, Kolkata 700 001. 3 A, MGR Salai, (K. H. Road) Nungambakkam,
Phone : 033 - 22489160. Chennai 600 034. Phone : 044 - 23651369.

BRANCHES
NORTHERN REGION : Indore :
Jaipur : 103-B, Apollo Trade Centre, 2B, Rajgarh Kothi,
Church Road, P.O. Box No. 173, Jaipur 302 001. Mumbai-Agra Road, Indore 452 001.
Phone : 0141 - 3018801. Phone : 0731 - 2498269.
Jalandhar : Nagpur :
416-417, 3rd Floor, Prestige Chambers, 3, West High Court Road, Lal Bahadur Shastri
GT Road, Jalandhar 144 001. Chowk, Dharampeth, Nagpur 440 010.
Phone : 0181 - 3051300. Phone : 0712 - 2531271.
Lucknow : Pune :
Saran Chambers II, 3rd Floor, Premium Point, 4th Floor, Opp. Modern High
5 Park Road, Lucknow 226 001. School, Jangali Maharaj Road, Pune 411 005.
Phone : 0522 - 4152150. Phone : 020 - 25534675.
EASTERN REGION : SOUTHERN REGION :
Bhubaneshwar : Bangalore :
Janpath Tower, 3rd Floor, Ashok Nagar, 1st Floor, Janardhana Towers, 562/640,
Unit II, Bhubaneshwar 751 009, Orissa. Bannerghetta Road, Bilekahalli, Bangalore 76.
Phone : 0674 - 2531128. Phone : 080 - 41391908.
WESTERN REGION : Cochin :
Cat No. : ALA/M3/Dec. 11/2000

Ahmedabad : Cherupushpam Building, 5th Floor,

909-916, Sakar II, Near Ellis Bridge Police 330-6, Shanmugam Road, Ernakulam,
Station, Cochin 682 031.
Ahmedabad 380 006. Phone : 0484 - 2360240.
Phone : 079 - 40012000. Secunderabad :
Minerva House, 4th Floor, 94,
Sarojini Devi Road, Secunderabad 500 003.
Phone : 040 - 40002300.