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FOR
BRUSHLESSA.C. GENERAIOR
TilODELTWY
CONTENTS
Page
lr rntroduc*'1o' - - - - -......'...........................
1
2t contrrcsltlo' - - -.......................... o......... 1
3r wlrlngMgthod ----..........................o...... 2
4t operatlon ...----.................................. .
4
4-1 Preparatlons for operatlon .................... . 4
4-2 Prgcautlons . . . . . . . . . . . . . . o. . . . - . . o a a a a a a a a a a a a a
4
5. tttalntgnance --....o......--..o.....................
4
5-1 Routl.ng naLntgnance ........ ...,..... .. ''A
5-2 t{easurepent 'bf
insulatlon reslsta.nce .. o a a a a a a a a
5
6. Dlsasseobly and, Reasserubly .... ..........o.... 7
6-l Gengral prgcau.sloas .............................
7
6-2 urrcoupllng frooo the englne o.................... 7
6-3 canpllag wlttr the englne ......................o
B
6-'{ Re'oovalof the rotor ........................... B
6-5 rasgrtlon of tbe rotor ---.--o................... 10
6 -6 R e p l a c e rn e n t of ttre bearl ag .' ....... o.... . . . . . . .. 10
7t Troubleshootlng ................................... 10
7-l Trorrbleghootlng table ...... oo.... o..... . .. . . . . . 11
7-2 Farrlt lnspectloa and replace.,eut
of the rotatlng rectlfler ........ o - .e o . . . . . . . . . . 13
I. Introductlon
This brt.ehlees AC Aenerator 1s a neuly developed generator v!.ttrout
bnrshee vhlch arose out of .Talyore long yeara of experlence ln ttre fleld.
Tbe generator has excellent electrlcal ctraracterletlcs because of vo'l tage
regrulatJ'ng equlpoent eoploytng a current transfor:uer, reactor and seal-
conductors.
As a restrlt of d.lrect consultatlon on such mattere as torslonal
vlbraLlon wlttr the englne nanufacttrrer, ttre slngle-bearlng geaerator has
beea deelgned to fo:ru a Mgtrly corDpact engtne-generator 6et.
2. Cooposltlon
Reactor
Detectlo lagrt
ortpur f-
F-c=:rtJ'c voltage I .Porer latrrut
reS.Iator (ArrR)
Aa c'n bo Eeen ilr the ftgure abover rrhlch sttons a baslc cJ.rsult of
thle geaeratorl elestrlc porer ls sntrptled to the flrst rlndtng of thc AC
exclter vla t-be reactor b1z aeana of tba. regla:al voltage of ttre geaerator
and the ecclter outFrt le obtalDcd ry excltatlon of tbe AC exclter. Tbi,s
output establlshee thc Aeaerator voltage bry exeltlug ttre generator fleld
v1a ttre rotatlag rectlfler. t{trea tbe load la a;r;rlledl tbe flret vlndlng
1g firrttrer exclted by tla qrnent tranefortrer aad the voltage varlatJ'oa
duc to tttc load ta coqlcrsatedr hrt 1n order to lncrease ttre voltage
aectrracy, ttre geaerator noltage ta detected, and the AVR o,peratei to 6ugpl
tlre eecond vlndlng of tbe AC exclter ao tJrat ttre voltage ls autoatJcally
regrulated. The polarlty ls deterrdaed for d.lffereatlal operatlon of the
aecondarlz wladlng ln realrcct to the flrst vlnd{ng.
-l-
g
3 . Wiring Methcd
225v -t
Generator [ *r."r*.'u
KCTt E;
{: wire connectlon
requlred only for
parallel runnlng. For
Sr olngle runnJ-ng, short
terro.inals /t and .I. For
Sir runnlng,
lnrallel
rercve the short-
clrcr:it rrlre from
teralrrals I and I.
II
Single running
450v --t-
F
SWICH BOARD
11,r
;9i'h*
I AvR
l2
i.h t<cz t
alngle
ter:u.inals
parallel
nrnning, short
S and .?- For
runn'lng,
renove Ehe short-
lit+* Siz cl-rcrrit wire from
rerminals I and !.
lb'
5z
_t
Single nrnrling
2
R
.s
I
trloI ACB t{o 2 ACB
tl 6
t'S-r
Parallel nrnnJ.ng
3
q
4. Operatlon
4-1 Preparatlong for operatlon
When ttre generator la to bc operated after etoppt ng for a long
perlodl operate lC only after ruJclng tlre chccks ln the seqfuence glven
belw:
(11 Clean the lnslde and outslde of the generator anld, remove all
dltt, o11 and sater &oplets. Masure .the insulation reslstanrce
betseea the con&rcting parts and ground wlth a 500 V meggrer and
confln that lt le Eoro than I UQ (refer to section 5-21.
If t.be reelstance ls less than 1 MOe dry ttre generator and use
only after the lnnrlatlon reslstance ls more than I tlfl.
(2) Check that none of the boltg or nuts ln the varlous parts of the
geacrator (especlally pa:it8 dlrectly coupled uith the engine and
the rotatbg rectlfler 'are loose or have fallen out and
lnrta)
also that, tbe corurectlon te.:rmlnals of the exciter tre not
"*ai"
loose. Tlgbtea lf necessary.
A:? Precautlong
The srrrroundlng areas of ttre grenerator cooling air inlet and
outlet Eust be kept clear and clean. If the inlet or outlet becomes
clogged or tbc florr of the coot-J-ng a1r ls obstructed, the coollng
effests l.n the grenerator rdll drop rnd, as a result, ttre teuq>erature
v111 rlge and lt could resrrlt { '' accldeats guch as coll br:rning cl:rn- g o
So, sgrcclal. care raust be taken to avold thlg.
5. Mal-atenance
5-1 Routlne rnaI ntenance
For any type of roactrlrre to perforu at lts best' lt ls necessary to
understand, hon to trandlc'tbe machlne correcily and ahrays rnalntaln lt
carefrilly.
Slnce elecrlc equlgncot le adversely susceptlble to nolsture,
o11 vapqtr and dust, lt nlrst be kept cleah. t{hen eleanlng tbe geuerator,
u.Be a drlz clotb. ac especJ'ally careful not to wlpe any conductlng
parts rltJr clotbg rhlcb are rct or olly.
whe9,-:u^slng coqqrresscd alr tor cleenlng, uss acryressed a1r at a
preaaure of about 2 atuoapheres or lesg. Clean the laslde of the p1ps
sufflc1catly beforehand and alrays blon a1r through prlor to use.
Slnce tb,ls nacblne le a h^ehless AC generatorl there 1s ao need
to check or mrlntaln tbe bnrsbes.
-4-
T h e ro u tl n e p o l n ts arc aa fol l ove:
(I, Normal Inspectlon and clernlng of the exterior
(2) ttonitsorlng of any changea ln vlbrationa
( 3) ltonitorlng teeperature rlsee
( 4l llonitorlng any abnormal sounds or overheating 1n the bearJ.ng
Parts
Fe However, when the generator has not been operated for a long
ts perLod or shen adverse moistrrre conditlons such as the penetrat.ion of
trat.e.r have occurred, always aeastrre the insrrlation reslstance. If the
resiet.nce has dropped belos I I.{Q, &y and use olly after che insuLat.ion
reslstance has again rlsen above I Hfl.
i Kc) for lea<i vires frorn the generator ln ttre stat.ic excl,ter, viEh a
I ttr-ln bare wire, aod Eeasure the reslsta,nce betveen the connected
lr.
terrntna,Is and grorrnd- If the r:eeist!.nce ls lees than I HQ, 4lscomect
atl lead wlres froro the geaerator inslde tlre st^a,tic exclter and divide
t}le conducting parts Jlto tro gfoups, those of ttre generator ProPr
and ot$ers. Connect togcttrer the conductlng parts of each grouP using
a ttr-tn rra,ked vlre, and neasrrre tJre insulatJ.on reslstantce t,o ground to
tc
determlne vhlch group of parts 1s causlng tJre lnsuLatlon &op.
Ascertaln the faulty area of t}re parts group wlth lastrlati.on resista.nce
corurect together the terralnals of the L\IR and rectlfler (Sl) respectlvely
vlth a ttr1n bare con&rctor for each unltatT devlce for short-ctrcrrltlng
-919. tben perforu 'reasurenent's. If thls ls oot done, t'tre se.ro,lconductors
nJ.ght bc d.--ged-
5
I
6
6. Dlsassenbly and Reassembly
6-1 General precautlong
(1) Before d.lsagsenbly and aseembly, etudy the greneral 6l rnq ln respecl
to dlsassenbly and assembly froo. ttre gectlonal &awlng of the
gienerator.
(2, t{hen d'lsassembly and asseubly 1s perforrned by one EEn, the
efflclency 1g lorr and ttrere Ls a posslbllty of serlous rrrnags
to ttre nachlnery. Thereforel Lt ls best to have trro or nore
vorkers.
(3) Place the d'lsassenbled rotor oa ir base, etc. and be aqre to
cover it rslth a sheet of vlnyl resla, a clotb uat, etc.
ge carefirl that the aruature rqd fleld vl.naLngrsl tc. do not
coee into contact wlth ottrer obJect-s.
(4) ntren rercrrlng the rotor, uake sure'that the axes of both the
rotor a'rd stator are aligFed so tbat both do not colrrc lnto
contact. SLnce the surfaces of botb ends of the rotor a:.e
bound wl'th a special sort of tape for clanplng the coil, eads, be
carefirl to avold brlngrlng tbe tape-borrnd portlons lnto contact
rrith the stator.
6-2 Uncoqrltng frou ttre engiine
Becausg th. slngle-bearlag geaerator h-- no bearlng on the drlven
alde' there ls tbe poss{blllty of the rotc fallrng dmanards vhea
tmc'ot4lltng fro ttre eagtae and, of danagc belng carured to ttre rotor, ttre
gtator, th.e fan, .tbe corprrlg boea, and the fra:ne (or adapter). There-
forer'' -for. . dlsaeseoblyr t-te .the,fouorlhg:groce&rre:
-
(lt Reowe the venlllatloa port cover on tbe sl.de. surface on ttre
e
(2' Fit the rotor locking supporters securely between the fan and.
coupli.ng boss and the frane (o" dapter
@ @ ring
@.
(nef er to the d.rawilg for attaphong the r.otor locking supporto"s.
)
(3t Renove the bolts connectitra: the flyrdreel e'i. the fan and. coupling b
(4) Renorre the bolts holdi.g the foot part of the generator propro
(s) Eoist-up the generator
so that it is suspend.ed. slightly above
the mountin errrfa,ce ( so as to arlow the rlnere to be
d.rann
out) r and remove the complete generator rotor from
the f lyn1eel
using the jack screw of the coupring boes.
Note: The rots loct<lng aqEqrters arc guplrrted as accessorrles.
7
Support"r ( z)
Supporter (f)
lrA Section
Wben coupllngr perfo::a ghg rprk sltb the rotor locklng supporters
flxed ln place betveen ttre cot4rllng bose and the fra:ae (or adapter),
lngert }lne.rs under ths feet to rercve atry tlltlng caused by unevenneaa
Flrat, vhea perfonalng tble be Errre thlt t'he rotor o:r the
.rrcrk,
taie-bound do Dot touch lbe etttor as vaa meatloned ln 6-1-
trrcrtlon^s
Perfom tho vprk 1n tJte follovlag sequencs:
1. Rovo the generator fro the eaglne by the urethod glven ln bZ and
-B-
2. Rercve thc ventllatlon port cover
O on the non-driven end, the
bearlng cover (outer 'aLdet ana tne bearlng shJ.elC f" thar
e @
order. =Slnce therc ls a lnselblllty of the rotor falllng dotrnwar&
and causlng darnage to the rotor or et^ator of the eC exclter yhen
the bearlng sbleld la removed, rerbve lt by hotstlng lt utrnard and
tben gently lorer lt. (The aplgot, Jolnt helght of the bearlng
shleld lg 3 m. )
3. PulI out ttre rotor slonly tdatd the driven slde using the
aurlllary shaft so aa to keep balance. (Refer to the rotor remo'raI
dlagran. )
Tape-bound portion
^b^xillary couplJng
I
trt
9
a
Before insertlonr ulpe off any dustr ol1, etc. on any part of the
rotor rrlth a clean cloth.
6-6 Replacement of the bearing
( Refer to the detalr drarring of the bearlng pulrer. )
After renoval of the rotor from the generator frane by the method
1n 6-4' replace the bearlng in accordance nith the folroulng sequence:
1. Rerove the lock nut
@.
2. F1t the bearing ptrlrer
on the non-drlven end bearing
O
3. contact the handle O.
of the bearing puller wlth the center of shafa .
4. .
rf the handle is turned srwry,
the bearing c.u)
5. tt'hen attachlng O * reuroved.
a nery bearbg, place an iron plpe on. the
side
surface of the bearlng irurer
rlng a-nd tap in Lightly wlth a hanoer.
I
7. Troubleehootlag
The bnr-strless grenerator coaslste br a rotatlng rectlfler, c,urre't
transforner, reactore aGslatorge capocltors, eealcoadrrctor part6, etc. r
a'nd eince there are no s't1d{ng electrlcal pa'ts arrd eacb part
deslgned has been
so that lt caa wlttrstand all condltjons whlch ntght, arlsee vert
fw fanltg arlse' Hwever, lf a farrlt ehorrrd occrrrl check the
- follonlng i
polnts:
i0
7-l Troubleshootlng table
11
Condltlon Cauee Countermeaaures
rect'lfler oll o
12
Cond:lt1on Cauea Countemeaaurell
I
teoperaturq (2) balls (21 Check a^nd replace the bearlng
.aearlng
rlse ln or inner or rdttr a Dew oDe.
bearlng.' outer rlng
danaged
5. Abnorrnal ( 1) coupllng (f) Check and retrn1'r.
vlbrat'lon faultfz
occlxra la (2) Generator (21 Cbeck rnd repalr.
generator lnstall^atioa
or itatlc faulty
erclter. (3) Statjc exclter (3) Cbeck anrd,re1n1r.
tnstall^atloa
taulty
13
v
Condqct|ng rlng
i
C\rrrqrt dlrectloa
n
;*{
14
TAIYO ELECTRIC MFG. CO.,LTD.
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