NEWAGE PRODUCT TRAINING

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Maintenance - Requirements SAFETY NOTICE !! DANGER!

ELECTRIC SHOCK [Live Terminals]

WHO Me ?

The following tests should only be carried out by qualified and/or experienced engineers who have received SAFETY TRAINING ON LIVE EQUIPMENT. All test instruments and their leads/connectors/ probes must be checked to ensure that they are suitable for the voltage levels being tested, and are in good working order. Never attempt to test a LIVE generator without another competent person present to shut down the engine or switchgear as necessary. Ensure that the work area is SAFE, other personnel in the area are advised of what you are doing, warning notices and tapes are displayed to advise others of the hazards.

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Maintenance - Requirements
Maintenance requirements for A.C Brushless Generators are :-

1. Bearing inspection ( Single or 2 Bearing). 2. Winding Insulation/ Contamination checks. 3. Visual Inspection for Corrosion and Contamination 4. Operational Checks

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Maintenance requirements - Bearings

Newage Generators are supplied with three types of bearing assembly. All bearings are packed with Kluber Asonic GHY72 grease, which is a Synthetic Polyurea /Ester oil based grease, and should not be mixed with dissimilar greases. 1. Manufacturers Sealed for Life Ball bearings Standard on Frames BC and UC ranges. Introduced as standard on Frames HC4, HC5, from July 1999. 2. Newage Sealed Cartridge Assemblies, (Non- regreasable). Standard on Frame HC6 Up to July 1999, standard on Frames HC4,5 Up to March 1999, standard on Frame HC7 3. Newage Regreasable Cartridge Assemblies. Standard on Frame HC7 from March 1999 Optional on Frame HC 5 & 6 from April 2000. Standard on Frame 8,

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BC & UC Bearing Assembly

Frames BC and UC Ball Bearings are manufacturers sealed for life as standard. Bearings are packed with Kluber Asonic GHY 72 grease Typical Bearing housing machined into Non-Drive End- bracket. Typical Sealed for Life 2RS Ball Bearing. Grease pre-packed & sealed with steel reinforced rubbing synthetic seal.

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HC & F8 Bearing Cartridge Assembly

Typical re-greasable bearing Cartridge & Cap for HC7 & Frame 8 (shown with N.D.E PMG Stator Housing ) Bearing Wave Washer Grease Flinger Bearing Typical Bearing Cartridge for HC 6, with sealed bearings.

Cap Cap bolts

Cap Cap bolts

o Frames HC4,5 are manufacturer sealed bearings packed with Kluber Asonic grease type GHY72. They are assembled directly into the Generator end-brackets. o Frame HC6 have cartridge assemblies, with manufacturers sealed for life bearings. o Frames HC7 and Frame 8, have regreaseable cartridge assemblies, packed with Kluber Asonic grease type GHY72. o Regreasable bearings are optional on Frames HC 5 and 6. o Application and Environmental conditions can effect bearing life, excessive moisture, vibration, or airborne dust, can reduced bearing life.

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Maintenance requirements - Bearings

What are the symptoms of a Bearing problem?
Non drive end Bearing INCREASED TEMPERATURE INCREASED VIBRATION INCREASED NOISE. Drive end Bearing

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Maintenance requirements - Bearings

What are the symptoms of a Bearing problem? Temperature rise in the bearing housing
Monitoring temperature is achieved with R.T.Ds or Laser (remote) thermometer. ( Note: Localised Ambient temperature variations should be taken into account).

Vibration
Increased vibration in the Generator, suddenly, or slowly over a period of time. Vibration equipment is expensive, a check by hand near the bearing will give an indication. ( Note: this could also be an engine related problem).

Noise
Bearing making abnormal noises, audible, with or without Stethoscope. ( A Stethoscope is required for elimination of other possible causes of noise ) Experience gained from touch and sound, will establish normal conditions. Periodic Health monitoring is recommended throughout the life of the Generator to establish normal conditions.

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Maintenance requirements - Bearings

Re-lubricated Bearings Frames HC7 & 8 (Optional for HC5 & 6)
Re-lubrication with Kluber Asonic grease type GHY72, is recommended, Full details of grease quantities for both initial fill and re-lubrication are available in the manual supplied with the Generator, or from the factory.

Frames HC6 and HC7 Re-lubrication Bearing Kits

Conversion kits with full instructions to upgrade HC6 and HC7 Generators to re-greasable specification are available from Newage Parts dept. Special tool kits, and greasing equipment are available on request. 2 BEARING KITS HC6, 45 - 0880, HC7 45 - 0872. 1 BEARING KITS HC6, 45 - 0879, HC7 45 - 0877

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Maintenance requirements - Insulation checks

Winding Insulation levels should be checked if :-

1. The Generator has been STATIONARY for a long period without AntiCondensation heaters SWITCHED ON. 2. The Generator has been subjected to intake of high volumes of water 3. The Generator windings are contaminated with Airborne DUST and DIRT, and have become DAMP ( through high humidity). The Generator windings have become contaminated with airborne corrosive elements ( Salt or corrosive chemicals in the atmosphere).

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Maintenance requirements - Insulation checks

Insulation Resistance (IR) tests in order of importance :1. The Main Stator Winding Minimum value of Insulation should be 1 M to EARTH. Low IR on the Main Stator is A SAFETY ISSUE.
DANGER! ELECTRIC SHOCK

2. The Exciter Stator Winding This winding is subject to all contamination from the air intakes. Severe contamination may cause temporary or permanent low IR, which could effect the AVR performance. 3. The Exciter Rotor, & Main Rotor These are rotating low voltage windings, and are unlikely to be affected by low IR. Minimum value of insulation should be 1 M to EARTH. 4. Permanent Magnet Stator This windings is totally enclosed and unlikely to be affected by low IR.

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Maintenance requirements - Testing the Main Stator Insulation

EARTH
AVR Sensing & Power supply from Main Stator
Connections shown in Series Star

N
W5 W2

W6 U6V6

Neutral
00 10

100

10

M
0.1
.01

6 7 8

W V U
FRAME

W1 Test V1 3 Phase Output U1

M 1KV M 500V

V5 V2
U5

U2

EARTH

MEGGER

1. Disconnect the AVR completely before carrying out this test. 2. Disconnect any connections from Neutral to Earth. 3. The Stator insulation should be checked with an Insulation tester.The test instrument should be 500 or 1000 volts for low voltage Generators (up to 690V). 4. For low voltage machines (up to 690V), the MINIMUM insulation value is 1.0 MegOhm to Earth (Ground).

WINDINGS MUST BE DRIED OUT IF BELOW 1.0 MEG-OHM.

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Maintenance requirements - Drying the Main Stator Windings

Recommended methods of drying out DAMP, WET, or CONTAMINATED Stator Windings are :- .

1. DRYING WHILE STATIONARY Hot air is blown into the Generator AIR INTAKE. 2. DRYING WHILE RUNNING ON SHORT CIRCUIT The Main Stator is Short Circuited while separately exciting the Generator with a BATTERY, or the MANUAL VOLTAGE REGULATOR.

Both Methods can be carried out ON SITE, without dismantling the Generator. (NOTE: Example 1 requires a standard 13 Amp Mains supply socket).

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Maintenance requirements - Drying the Main Stator Windings

METHOD 1. STATIONARY DRYING

Domestic Supply

Remove Air Intake Access Covers Direct a Domestic FAN HEATER ( 2 - 2.5 kW) into the AIR INTAKE. Leave Overnight (or 8 Hours min.) to blow out all Moisture. RE-CHECK INSULATION RESISTANCE AFTER DRYING ( Minimum value 1 M )

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Maintenance requirements - Drying the Main Stator Windings

Output From Battery into Exciter Stator Exciter XX- Rotor & Stator

+
Main Stator

METHOD 2. SHORT CIRCUIT MAIN STATOR WINDINGS

A.V.R 12v BATTERY

X+

Bearing
Main Rotor

Main Rotor

Shaft

Rectifier Fan 1. Stop the Generator Set and disable the Engine. 2. Disconnect the AVR wiring. 3. Replace the AVR with a 12V or 24V battery 4. Connect the battery to the Exciter Stator,(polarity must be correct).

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Maintenance requirements - Drying the Main Stator Windings

EARTH METHOD 2. SHORT CIRCUIT MAIN STATOR WINDINGS Short Circuit Link
W1

N
6 7 8
W5 W2

W6 U6V6

W V U
FRAME

V5 V2
U5

Clampmeter
V1
RM S

U2

EARTH MAKE SURE THAT THE AVR IS DISCONNECTED

Attach SHORT CIRCUIT link to all 3 phases (NOTE: Shorting Links must carry full load current).. Attach Clampmeter to Link, capable of measuring FULL LOAD AMPERES, (or use the Generator set panel meters). CHECK ALL WIRING IS SECURE BEFORE RUNNING GENSET

TR UE

U1

!
WARNING!

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Maintenance requirements - Drying the Main Stator Windings

Clampmeter 12 - 24 volt Batteries into Exciter Stator
T

Short Circuit Link

XXX+

METHOD 2. SHORT CIRCUIT MAIN STATOR WINDINGS

RUN ENGINE

12-24v BATTERY

The Current MUST NOT BE HIGHER THAN FULL LOAD AMPERES For effective drying, at least 70% of FULL LOAD CURRENT is required. Add more Batteries to increase the short circuit current if necessary (24VDC) Run until the windings are HOT and DRY, (at least 1 HOUR). If the IR is still less than 1 M , the windings require cleaning /refurbish.

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Maintenance requirements - Drying the Main Stator Windings

Clampmeter
T

Short Circuit Link Across 3 Phases

NEWAGE INTERNATIONAL MANUAL VOLTAGE REGULATOR MVR-1 MODULE 450-11400 P T 4

AVR GENERATOR X XX P2 P3 P4 X XX P2 P3 P4

XX- (F2) X+ (F1) To Exciter Stator

METHOD 2. SHORT CIRCUIT METHOD USING THE M.V.R

X XX P2 P3 P4 X XX P2 P3 P4

P.M.G Power Supply

RUN ENGINE

The M.V.R must be switched to MANUAL control, MINIMUM setting, before running the engine. Slowly increase the Current until FULL LOAD AMPERES are indicated. For effective drying, run for at least 1 hour at FULL LOAD CURRENT. . If the IR is still less than 1 M , the windings require cleaning /refurbish.

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Maintenance requirements - Cleaning the Windings When is it necessary to clean the windings?

1. When (after drying), the windings are still reading less than 1 M to earth. 2. When the windings are heavily contaminated with dust,dirt, and/or diesel exhaust deposits. 3. When the windings are contaminated with corrosive chemicals ( salt deposits or other deposits), which immediately give a temporary low IR reading when damp.

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Maintenance requirements - Cleaning the Windings

For removal of embedded dirt, grease, salts, hydrocarbons, and other chemicals from the winding surfaces, HOT WATER CLEANING at maximum 25 psi pressure is recommended. For very heavy contamination, a non- corrosive detergent additive, (i.e : Karcher RM81 or equivalent), can also be used. NOTE: Detergents containing CAUSTIC chemicals must never be used on copper windings.

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Maintenance requirements - Cleaning the Windings

. The windings should then be thoroughly WASHED with clean water to remove all traces of detergents. . The windings must be dried in an oven at approximately 100 to 110C for at least 12 hours until the IR is higher than 1 M. A final coating of Anti-track paint can be added for further protection, I.e :Sterling VA63 or VA39, or Ultimeg 2000, 372, air drying varnish ranges.

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Maintenance requirements - Healthchecks

Final Inspection before running Gen-set :1. AVR CONNECTIONS 2. MAIN TERMINAL CONNECTIONS

3. MAIN RECTIFIER COMPONENTS

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Maintenance requirements - Healthchecks

Final Inspection before running Gen-set :A.C Generators may be subjected to environmental conditions which are detrimental to the Generator :High humidity, or exposure to the elements, rainwater, and/or offshore sea mists. Dust, dirt, and/or corrosive chemicals in the atmosphere. Excessive vibration from the Engine, or worn coupling rubbers/ vibration mounts.

Periodic checks should be made to :1. AVR and accessory terminal connections, for corrosion or loose joints. 2. Main Rectifier diodes, should be cleaned or changed if badly corroded. 3. Main output terminal, look for loose or high resistance joints, (Joints can be scanned with a laser thermometer for hot-spots while running on load).

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Maintenance requirements - Healthchecks Running checks on the the Generator

Run the Generator up to nominal speed, and check :1. The NO LOAD D.C voltage across the AVR terminals X+ (F1) and X-. Keep this reading in the Gen-set maintenance record book for future reference. Example :-

DATE ########

FRAME SIZE SERIAL NUMBER R.P.M HCI734E C098976/2 1560

VOLTS 415

LOAD 0

D.C EXT 11.5

This figure should NOT CHANGE throughout the life of the generator. If the D.C reading becomes HIGHER, it is an indication of :1. Possible SHORTS in the EXCITATION WINDINGS, OR, 2. Possible faults with the MAIN RECTIFIER DIODES. THE NO-LOAD D.C VOLTAGE GIVES AN INDICATION OF GENERATOR HEALTH FAULTS WITHIN THE GENERATOR WILL CAUSE AN INCREASE IN THE D.C. VOLTS.

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