INSTRUCTION MANUAL

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

Flrst coll C\rrrent transfomer

Secoad colI Generator Static exciter

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

-ll {: wire connectlon

reqrrtred
parallel
onIY for
nrnnlng- For

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

SyoboI Deslgnatlon Synbof DcslgnatJ.on

G AC grenerator cr C\rrzent traneforoer
E Fleld syetern of n3 Reastor
generator proper
A\IR AutmatJc voltago regrutator
E:( AC excltor
TIT Rheosta,t for voltagre adjustocnt
ELr2 Exclter fleld eystern
cqf Curren
S1lr2 Slllcon rec-elf1e.r cu:rent co{qpnqat.l.orr
srr2r3 SlC varletor ccR for czoss-current
fl,esl'ator
(51lletor; c@pJaaaLion

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.

ft" In case of the bearirg used is an opened baII bearing, it is

f: necessary to repfenish grse eveq/ 1500 trours operation- If tlte bearirtg
t used is an sealed ball bearing, it is not necessary to add grrease-
fc:

t 5-2 HeasurerDent of insr-rlatioa reelstince

when measuring the insulacion reslst:,:rcee us a 500 V megger.

Flrst, connect toget.her the corurection terz-lrrals (R, S, T, O, J, K, Jc,

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

of less tban I y.fl and repalr.

'wlth
t{hen -eagurlng the lnsulatloa reslstaace a Dgger? Elteays

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

N0. Partnane N0. nane

Part
I I VentiLation port cover L2 Armature coil
2 B all bearing 13 Armatr:re co re

3 Bearilg cover I4 Field coil

4 Bearing shield 15 Cl amper
5 Armature co iL ( n=) L6 Field core
6 Armature core (nt) t7 PoIe copper plate
7 Fie1d coiJ- (n-) I8 Drip-pr.oof cover
B Fiera. cbre ( u.) I9 Ad.aptor ring
9 Silicon rectifier N Fan and coupli-rrg boss
10 Self-erc it er 2L Shaf t
11 Frame

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)

Fan arrd. ooupling

lrA Section

Hclu to attach the rotor loctclng suplrcrters

6-3 Coupllng wlth ttre englne

-
Follos the revera sequence of. the disassenbly procedure Ln 6-2-

Wben coupllngr perfo::a ghg rprk sltb the rotor locklng supporters

flxed ln place betveen ttre cot4rllng bose and the fra:ae (or adapter),

and, rercve then whe:r ttre vork 1a coopleted. Accurate lnstallatlon le

especlally lnport .nt for the elngle-bearlng generator. lf nece66ary,

lngert }lne.rs under ths feet to rercve atry tlltlng caused by unevenneaa

lu the base' surface.

6-4 Rerrcval of the rotor

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

rcve lt Lo the vork locatlon.

-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

Pull out slowly

^b^xillary couplJng

I
trt

Ew to prrll ont tbe rotor

9
 a

6-5 Insertlon of the rotor

When lnsertlng the rotorr tsake the sane precautions as in 6-4. _
Follw the reverse aequence to that in 6-4 for lnsertlon of the
rotor.

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

Detall of the bearlng ptrller

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

Cond.ltlon Cause -" Cotnterueasures

1 . tlo voltage 1. abnor-nal drop l'n 1. Ralse to ttre rated speed.
or too lov rotatlon epeed
voltage 2. Deflclency of 2 . Apply a 24 V battery to the
resl,dual voltage temlnals J, K lnslde ure statlc
of AC exclter excLter for forced excltatlon.
3. Tlghtenlng of 3 . Chects tbe tlghtaess of the
conductor conductor fastenlng parts
fastening parts ( especlally teraLnal bolts ) and
'
.l-s fatrlty. t.ighteu if required.
4. Broken ylre or 4. Check wlnding insulatlon and
short clrcrrit ln resLstance values and lf
wiadr ags Decess&-]r, relni.r or rwlnd.
5. Faulty A\tR 5 . Rsve tbe cable connected to
tb A\nfr a'ld if a voltage hlgher
th-l t.be rated voltage is
obtalaed, ttre aVn 1s faulty.
Replace lt rdth a nery orre.
t*ren no voJ'tage ls obtalned,,
rercve tbe lead rrlres (J, K)
frool tJre generator ln ttre statLc
occiter, operate tbe generator
at tbe Eated rotatloa sgeed, and
meanrbJ.l'e a5p1y a 12 V battery
to tbe lead wlres (J K) to
exclte forclbly. If a proper
voltage le obtalaed under s:trch
condltloalBo there are Do faulte
la.ttrc Areaerator or A\lR. The
statlc exclter le far:lty.
6. Patrlty etatlc
exc1ter
(1) Brokea rdre la (1) t-hc..k and retrnlr or replace
reactor rdtb a Der oae.

11
 Condltlon Cauee Countermeaaures

(2, Broken ulre or (2, Check and repalr or replaee

ehort clrc.trlt ulth a n4 one.

rect'lfler oll o

(4) Broken vlre or (4) Check and repalr.

ehort clrcrrlt ln
wlrlng l-n statJc
exclter
7. Faulty rotating 7. Renove the rectifler elements
rec*.lfler a'rd Eeasure the reslstance with
a tester. If the resistance ln
the fo::nard directl.on ls De.ur O
and tlut in the reverse dlrectlon
1s infinlte, the rectifier is
no::ual. If othe.rwlse, the
rectlfler is faulty. Replace 1t
wlth a Derr one.

2. Voltage ls 1 . Abnorually htgh I. T,ovet to the rated rotatlon

too hlgh. rotatlng qrced apeed.
(Voltage 2 . PeuJ.ty eeeood
'
does not vlndlng cl.rorlt
drop even ln AC erclter
rbea AVR Faulty statlc
voltagre ercl.ter
regrulatlng (1) Brokea rlre or (1) Clreck repal-r or replace wlth
lcnob ls short clrctrlt a Dgr
trnned to 1n aul!.J'ary
decrceaslng cl'rqrtt (R, S, T,
glde.l O, Jc, Kc) 1.tr
etatlc exclter

12
 Cond:lt1on Cauea Countemeaaurell

(21 Broken vlre or (21 Check and repalr or replace

short clrcrrlt ln ulth a nsr one.
second rlnd.lng
of AC excl.ter or
Its lead wlres
(Jc, Jl c)
3. Generated I. A\IR faulty 1. Replace slth a new orr o
voltage ls (1) Loose connectlo (1) TJ.ghten.
unstable. screffs 1n parts
(2t Faulty At/R (21 Replace AtfR with a nefl oDe.
C--plng cirqrlt
4. ebnonal (1) Greaee deterio- (1) Check anrd replace the grease or
sound or rated bearing *ith a new onr
I

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

7'2 elle fusgecr|{dr adt-replac@t of t}re rotatlng rectlfler

Ia lnspectlo of the ek rectlfler eleoeot-r of ttre rotatlng
rectlfler, flrst reloovc tbo veotllatlon port cover ou ttre slde of the
traD-c{pllng eud. thco dlaconnect ttre ac sldg lead rlres ( 3 rlree )
and DC gldo lead vlreg (2 vlrce) fro tbc occlgar vhlcb ar conDest,ed to
the rectlfler eletaeate, anrd,toaasur ttre reglstaace betreen tbe terulrr.ts
of eacb rectlfylag cleoeat vlth a testet ar ehorg ln ttra flg1rc belov.
There 1s no probleo 1t the reglgtaace ln tbe forrard dlrectloa Le near

13
 v

zero and.Chat. ln the reverse dlrectlon but values

ls lnfinlty, lf the
are otlrenrlse, there ls a fault and the must b replaced
recilfler
slth a neu ort o
l{hen lnstalllng the rectlfler ele.srentse not to
it ls lmportants
tlghten thea excesslvely. when the ele,,,ents are coo tlght,1 the
ereoents n111 be dartaged,. A tj.ghtenrng torque of aboqt 40 kg-cm 1s
sultable.

Condqct|ng rlng
i

C\rrrqrt dlrectloa

n
;*{

Note: Thle dravlng shor.s rneasureo,ent of the reslsta-Dce ln the

forard d.lrectlon. t{tren tbe reslstanee ln the reverge
dltectlon le meagurede srltch over bettreen tester tera.lnals
A rqd B.

14
TAIYO ELECTRIC MFG. CO.,LTD.
2 ' 4 , K a n d a n i s h i k i - c h oC h r v o c a - k uT, o k y o ,J a c a n rEL03-293-3001-g FAxo3-2gz-7wz
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T-02