INSTALLATION,

SERVICE&
MAINTENANCE
MANUAL

power generation
SAFETY PRECAUTIONS
Before operating the generating set,read the generating set
operation manual and this generator manual and become
familiar with it and the equipment.

SAFE AND EFFICIENT OPERATION CAN ONLY BE

ACHIEVED IF THE EQUIPMENT IS CORRECTLY
OPERATED AND MAINTAINED.

Many accidents occur because of failure to follow

fundamental rules and precautions.

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL

INJURY OR DEATH.

Ensure installation meets all applicable safety and local

electrical codes. Have all installations performed by a
qualified electrician.

Do not operate the generator with protective covers,

access covers or terminal box covers removed.

Disable engine start circuits before carrying out

maintenance.

Disable closing circuits and/or place warning notices on

any circuit breakers normally used for connection to the
mains or other generators, to avoid accidental closure.

Observe all IMPORTANT, CAUTION, WARNING, and

DANGER notices, defined as :

lmportant, refers to hazard or unsafe

IMPORTANT! method or practice which can result in
product damage or related equipment
damage.

Caution, refers to hazard or unsafe

CAUTION! method or practice which can result in
product damage or injury to personnel.

Warning refers to a hazard or unsafe

method or practice that can result
severe injury to personnel, possibly
death.
Warning !

Danger, refers to immediate hazards

which will result in severe injury or
death to personnel.

Danger !

Due to our policy of continuous improvement, details in this

manual which were correct at time of printing, may now be
due for amendment. lnformation included must therefore not
be regarded as binding.
Photograph
The Front Cover photograph is representative only.
Publication No. DGSM-001
Version:2nd Edition,2012.06

1
 CONTENTS
SAFETY PRECAUTIONS IFC
CONTENTS 2&3
SECTION 1 INTRODUCTION 4
1.1 INTRODUCTION 4
1.2 SERIAL NUMBER LOCATION 4
1.3 DESIGNATION 4

SECTION 2 PRINCIPLE OF OPERATION 5

2.1 SELF-EXCITED AVR CONTROLLED GENERATORS 5
2.2 AVR CONTROLLED GENERATORS 5
2.3 AVR ACCESSORIES 5
SECTION 3 APPLICATION OF THE GENERATOR 6
3.1 VIBRATION 7
SECTION 4 INSTALLATION - PART 1 9
4.1 LIFTING 9
4.2 ENGINE TO GENERATOR COUPLING ASSEMBLY 9
4.2.1 TWO BEARING GENERATORS 9
4.2.2 SINGLE BEARING GENERATORS 10
4.3 EARTHING 10
4.4 PRE-RUNNING CHECKS 10
4.4.1 INSULATION CHECK 10
4.4.2 DIRECTION OF ROTATION 10
4.4.2.1 PHASE ROTATION 10
4.4.3 VOLTAGE AND FREQUENCY 10
4.4.4 AVR SETTINGS 10
4.4.4.1 TYPE MX341 AVR 11
4.5 GENERATON SET TESTING 12
4.5.1 TEST METERING/CABLING 12
4.6 INITIAL START-UP 12
4.7 LOAD TESTING 12
4.7.1 AVR ADJUSTMENTS 12
4.7.1.1 UFRO (Under Frequency Roll Off) 12&13
4.7.1.2 EXC TRIP (Excitation Trip) AVR TYPES MX341 AND MX321 13
4.7.1.3 OVER/V (Over Voltage) AVR MX321 13
4.7.1.4 TRABSIENT LOAD SWITCHING ADJUSTMENTS AVR TYPES, MA341
AND MX321 13
4.8 ACCESSORIES 14
SECTION 5 INSTALLATION - PART 2 15
5.1 GENERAL 15
5.2 GLANDING 15
5.3 TORQUE SETTINGS FOR TERMINAL CONNECTIONS 15
5.4 EARTHING 15
5.5 PROTECTION 15
5.6 COMMISSIONING 15

2
 CONTENTS
SECTION 6 ACCESSORIES 16
6.1 REMOTE VOLTAGE ADJUST 16
6.2 PARALLEL OPERATION 16
6.2.1 DROOP 16
6.2.1.1 SETTING PROCEDURE 17
SECTION 7 SERVICE AND MAINTENANCE 18
7.1 WINDING CONDITION 18
7.1.1 WINDING CONDITION ASSESSMENT 18
7.1.2 METHODS OF DRYING OUT GENERATORS 18&19
7.2 BEARINGS 20
7.3 AIR FILTERS 21
7.3.1 CLEANING PROCEDURE 21
7.3.2 RECHARGING (CHARGING) AIR FILTERS 21
7.4 FAULT FINSING 21
7.4.1 MA341 AVR,FAULT FINDING 21
7.4.2 FAULT FINDING - MX341 MX321 AVR 21
7.4.3 RESIDUAL VOLTAGE CHECK 22
7.5 SEPARATE EXCITATION TEST PROCEDURE 22
7.5.1 GENERATOR WINDINGS, ROTATING DIODES & PERMANENT 22
MAGNET GENERATOR (PMG)
7.5.1.1 BALANCED MAIN TERMINAL VOLTAGES 22
7.5.1.2 UNBALANCED MAIN TERMINAL VOLTAGES 23
7.5.2 AVR FUNCTION TEST 23
7.5.3 REMOVAL AND REPLACEMENT OF COMPONENT ASSEMBLIES 23
7.5.3.1 ANTI-CONDENSATION HEATERS 24
7.5.3.2 REMOVAL OF BEARINGS 24
7.5.3.3 MAIN ROTOR ASSEMBLY 26
7.6 RETURNING TO SERVICE 27
SECTION 8 SPARES AND AFTER SALES SERVICE
8.1 RECOMMENDED SPARES 28
8.2 AFTER SALES SERVICE 28
8.3 KLUBER ASONIC GHY72 GREASE 28

3
 SECTION 1
INTRODUCTION

1.1 INTRODUCTION
The generator is of brushless rotating field design, available up to 660V at 50 Hz or 60 Hz.

The design, build and test procedures meet a range of British, European and lnternational standards including, BS 5000,
BS EN 60034 and ISO 60034, where applicable.
The generator are self-excited with power from main output,using either the SX460/SX440/AS440 AVR.
A permanent magnet generator (PMG) powers the excitation system is available as option by using either MX341 or MX321 AVR.
1.2 SERIAL NUMBER LOCATION

Each generator has its unique serial number stamped in to the upper section of the drive end frame end-ring.

1.3 DESIGNATION

D G 2 7 4 C 1 4
D G 2 7 4 C 2 4

Generator type

Frame No.

Number of poles

Core lenght

Number of bearing

AVR type

4
 SECTION 2
PRINCIPLE OF OPERATION

2.1 SELF-EXCITED AVR CONTROLLED The MX341 AVR senses average voltage on two phases
ensuring close regulation. ln addition it detects engine speed
GENERATORS
and provodes an adjustable voltage fall off with speed bolow a
AUTOMATIC pre-selected speed (Hz) setting, prreventing over-excitation at
VOLTAGE
REGULATOR low engine speeds and softening the effect of load switching to
relieve the burden on the enging. lt also provides over-excitation
protection which acts following a time delay, to de-excite the
OUTPUT generator in the event of excessive exciter field voltage.
MAIN
EXCITER
STATOR
STATOR The MX321 provides the protection and engine relief features
ROTATING
DIODES
of the MX341 and additional incorporates 3 phase rms sensing
and over-voltage protection.
SHAFT

EXCITER MAIN The detailed function of all the AVR circuits is covered in the
ROTOR
ROTOE load testing section (subsection 4.7).

The main stator provides power for excitation of the exciter fieldvia 2.3 AVR ACCESSORIES
the SX440 SX460 AS440 AVR which are the controlling device
governing the level of excitation provided to the exciter field.
The AVR responds to a voltage sensing signal derived from the The SX440 SX460 AS440,MX341 and MX321 AVRs incorporate
main stator winding. By controling the low power of the exciter circuits which, when used in conjunction with accessories, can
field, control of the high power requirement of the main field is provide for parallel operation either with ’droop’ or ‘astatic’ control,
achieved through the rectified output of the exciter armature VAR/PF control and in the case of the MX321 AVR ,short circuit
current limiting.
The SX440 SX460 AS440 AVR sense average voltage on two
phases ensuring cIose regulation. ln addition it detects engine Function and adjustment of the accessories which can be fitted
speed and provides voltage fall off with speed, below a pre- inside the generator terminal box are covered in the accessories
selected speed (Hz) setting, preventing over-excitation at low section of this book.
engine speeds and softening the effect of load switching to
relieve the burden on the engine. Separate instructions are provided withe other accessories
available for control panel mounting.
2.2 PRRMANENT MAGNET GENERATOR(PMG)
EXCITED - AVR CONTROLLED GENERATORS
AUTOMATIC ISOLATING
VOLTAGE TRANSFORMER
REGULATOR (if fitted)

OUTPUT
PMG
STATOR
EXCITER MAIN
STATOR STATOR
ROTATING
DIODES

SHAFT

PMG EXCITER MAIN

ROYOR ROTOR ROTOR

The permanent magnet generator (PMG) provides power for

excitation of the exciter field via the AVR MX341 (or MX321)
which is the controlling device governing the level of excitation
provided to the exciter field. The AVR responds to a voltage
sensing signal derived ,via an isolating transformer in the case
of MX321 AVR from the main stator winding By controlling the
low power of the exciter field, control of the high power
requirement of the main field is achieved through the rectified
output of the exciter armature.
The PMG system provides a constant source of excitation power
irrespective of main stator loafing and provides high motor
starting capability as well as immunity to waveform distortion on
the main stator output created by non linear loads,e.g. thyristor
controlled dc motor.

5
 SECTION 3
APPLICATION OF THE GENERATOR
The generator is supplied as a component part for for standby duty to ensure winding insulation is maintained
installation in a generating set. lt is not, therefore, in good condition.
practicable to fit all the necessary warning/hazard labels
during generator manufacture. The additional labels When installed in a closed canopy it must be ensured that
required are packaged with this Manual, together with a the ambient temperature of the cooling air to the generator
drawing identifying their locations.(see below). does not exceedthat for which the generator has been rated.
The canopy should be designed such that the engine air
lt is the responsibility of the generating set manufacturer to intake to the canopy is separated from the generator intake,
ensure that the correct labels are fitted, and are clearly particularly where the radiator cooling fan is required to draw
visible. air into the canopy. ln addition the generator air intake to the
LABEL’A’ canopy should be designed such that the ingress of
TERMINAL BOX LID OR
ALTERNATIVELY APPROPRIATE
moistureis prohibited, preferably by use of a two stage filter.
LABEL’B’ VISIBLE TERMINAL BOX ACCESS
ALL ACCESS COVERS
The air intake/outlet must be suitable for the air flow given in
the following table with additional pressure drops less than
or equal to those given in table 1 below:

Airflow
Additional
50Hz 60Hz intake/outlet
Frame
1500 RMP 1800 RPM pressure Drop
LABEL’C’
3
P.M.G COVER LABEL’C’
ADJACENT TO ALL COVERS
m / sec cfm m3/ sec cfm
POSITIONS FOR WARNING LABELS HC/MV DG164/184 0.15 318 0.19 403 3mm water gauge
LABEL’A’
DG162/182 0.25 538 0.3 644 0.1”
DG22 0.22 458 0.28 595
REFER TO SERVICE MANUAL
BEFORE REMOVING COVERS DG27 0.58 1230 0.69 1463 6mm water
ABNEHMEN DER ABDECKUNGEN NUR
GEMAESS HANDBU CH ANWEISUNG DG4 0.8 1700 0.99 2100 gauge
LEGGERE IL MANUALE DI ASSISTENZA
PREMA DI RIMUOVERE I COPERCHI DG5 1.16 2457 1.4 2965 0.25”
CONSULTAR MANUAL ANTES
DE RETIRAR TAPAS DG6 2.18 4619 2.63 5573
VOIR MANUEL DE SERVICE AVANT
D’ENLEVER LES COUVERCLES
DG7 2.69 5700 3.45 7300
Table 1

LABEL’B’ LABEL’C’
The generators may be fitted with air filters. These are oil
charged wire gauze filters and require charging during
installation
Reduction in cooling airflow or
inadequate protection to the
IMPORTANT !
generator can result in damage
and/or failure of wingings.

Dynamic balancing of the generator rotor assembly has

been carried our during manufacture in accordance with BS
6861 Part 1 Grade 2.5 to ensure vibration limits of the
generator are in accordance with BS 4999 Part 142.
Fig 1
The generators have been designed for use in a maximum The main vibration frequencies produced by the component
ambient temperatue of 40, and altitude less than 1000 generator are as follows:
metres above sea level in accordance with BS5000.
Ambients in excess of 40, and altitudes above 1000 1500 rpm 1800 rpm
metres can be tolerated with reduced ratings-refer to the 4 pole 25 Hz 30 Hz
factory. Table 2

The generators are of air-ventilated screen protected drip- The standard terminal box is arranged for cable entry on the
proof design and are not suitable for mounting outdoors right hand side looking from the end of the generator. lf
unless adequately protected by the use of canopies. Anti- specified at the time of order cable entry may be arranged
condensation heaters are recommended during storage and on the opposite side.

6
The terminal box is constructed with removable panels for lt is the responsibility of the generating set designer to
easy adaotation to suit specific glanding requirements. ensure the alignment of the genset, stiffness of the bed-
Within the terminal box there are insulated terminals for line frame and mountings are such that the vibration limits as
and neutral connections and provision for earthing. defined above are met.
Additional earthing points are provided on the generator feet.

The neutral, as supplied from the factory, is NOT connected

to the frame.
lf the vibration levels of the generating set are not within the
No earth connections are made on parameters quoted above: -
the generator and reference to site
regulations for earthing must be
made. lncorrect earthing or 1. Consult the genset builder. The genset builder should
protection arrangements can result address the genset design to reduce the vibration levels
Warning! in personal injury or death. as much as possible.
Fault current curves (decrement curves), together with
generator reactance data, are available on request to assist 2. Contact with Dingol to understand the impact of not
the system designer to select circuit breakers,calculate fault meeting the above levels on both bearing and generator
currents and ensure discrimination within the load network. life expectancy.

3.1 VIBRATION lmportant, refers to hazard or unsafe

method or practice which can result
Vibrations generated by the engine are complex and contain IMPORTANT ! in product damage or related
harmonics of 1.5, 3, 5 or more times the fundamental equipment damage.
frequency of vibration. The generator will be subjected to
this vibration, which will result in the generator being Exceeding either of the above
subjected to vibration levels higher than those derived from specifications will have a
the generator itself. detrimental effect on the generating
The generators are designed to withstand the vibration set and in particular on the life of the
IMPORTANT ! bearings. (See section on bearings).
levels encountered on generating sets built to meet the
requirements of ISO 8528-9 and BS5000-3. (Where ISO This will invalidate the generator
8528 is taken to be broad band measurements and BS5000 warranty. lf you are in any doubt,
refers to the predominant frequency of any vibrations on the contact DINGOL.
generating set.)
ln standby applications where the running time is limited and
Definition of BS5000 - 3 reduced life expectancy is accepted, higher levels than
specified in BS5000 can be tolerated, up to a maximum of
Generators shall be capable of continuously withstanding
18mm/sec.
linear vibration levels with amplitudes of 0.25mm between
5Hz and 8Hz and velocities of 9.0 mm/s rms between 8 Hz
Two bearing generators require a substantial bedplate with
and 200 Hz when measured at any point directly on the
engine/generator mounting pads to ensure a good base for
carcass or main frame of the machine, These limits refer
accurate alignment. Close coupling of engine to generator
only to the predominant frequency of vibration of any
can increase the overall rigidity of the set. A flexible coupling,
complex waveform.
designed to suit the specific engine/generator combination,
is recommended to minimise torsional effects.
Definition of ISO 8528 - 9
ISO 8528-9 refers to a broad band of frequencies, the broad
band is taken to be between 2 Hertz and 300 Hertz, The Alignment of single bearing generators is critical and
table below is an example from ISO 8528 - 9 (value1). This vibration can occur due to the flexing of the flanges between
simplified table lists the vibration limits by kVA range and the enging and generator. A substantial bedplate with
speed for acceptable genset operation. engine/generator mounting pads is required.

VIBRATION LEVELS AS MEASURED ON THE GENERATOR

Engine Set Vibration
Vibration Vibration
Speed Output Accelera-
1 Displacement Velocity The maximum bending moment of the engine flange must
Min - kVA tion
≥10 kVA - - -
be checked with the engine manufacturer.
10 but
4 POLE 0.64 40 25
≤50 kVA
1500 rpm
50 but
50Hz 0.4 25 16
1800 rpm ≤125 kVA Torsional vibrations occur in all engine-driven shaft systems
60 Hz 125 but and may be of a magnitude to cause damage at certain
0.4 25 16
≤250 kVA critical speeds. lt is therefore necessary to consider the
250 kVA 0.32 20 13 torsional vibration effect on the generator shaft and
The ‘Broad band’ is taken as 2 Hz - 300 Hz
couplings.
Table 3

7
lt is the responsibility of the generator set manufacturer to
ensure compatibility, and for this purpose drawings showing
the shaft dimensions and rotor inertia are available for
customers to forward to the engine supplier. ln the case of
single bearing generators coupling details are included.

Torsional incompatibility and/or

excessive vibration levels can cause
IMPORTANT ! damage or failure of generator
and/or engine components.

8
 SECTION 4
INSTALLATION - PART 1
4.1 LIFTING 4.2 ENGINE TO GENERATOR COUPLING
ASSEMBLY
lncorrect lifting or inadequate lifting
capacity can result in severe During the assembly of the Generator to the Engine it will be
personal injury or equipment necessary to firstly carefully align, then rotate, the combined
damage. MINIMUM LIFTING Generator rotor - Engine crankshaft assembly, as part of the
CAPACITY REQuIRED IS AS construction process, to allow location, insertion and
INDICATED ON THE LIFTING LABEL. tightening of the coupling bolts. This requirement to rotate
Warning! Generator lifting lugs should not be the combined assemblies exists for both single and two
used for lifting the complete bearing units.

Two lifting lugs are provided for use with a shackle and pin During the construction of single bearing units it is
type lifting aid.A spreader with chains, to ensure that the lift necessary to align the generator’s coupling holes with the
is vertical, of suitable length and lifting capacity must be engine flywheel holes. lt is suggested that two diametrically
used. Lifting points are designed to position the craneage opposite location dowel pins are fitted to the engine flywheel.
point as close to the centre of gravity of the generator as The coupling can then slide into final location on the engine
possible, but due to design restrictions it is not possible to flywheel recess. The dowels must be removed and replaces
guarantee that the generator frame will remain horizontal by coupling bolts before the final bolt tightening sequence.
while lifting. Care is therefore needed to avoid personal
injury or equipment damage. The correct lifting arrangement While fitting and tightening the coupling bolts it will be
is shown on the label attached to the lifting lug. (See samole necessary to rotate the Engine crankshaft - Generator rotor
below) assembly. Care should be taken to ensure that rotation is
carried out in an approved manner that ensures safe
working practice when reaching inside the machine to insert
IMPORTANT
or tighten coupling bolts, and that no componenr of the
REFER TO SERVICE MANUAL assembly is damaged by non-approved methods of
BEFORE REMOVING COVERS assembly rotation.
IT IS THE GENERATOR SET
MANUFACTURER’S Engine Manufacturers have available a proprietary tool
RESPONSIBILITY TO FIT
THE SELF ADHESIVE WARNING
designed to enable manual rotation of the crankshaft
LABELS SUPPLIED WITH THE assembly. This tool must always be used, having been
GENERATOR. THE LABEL SHEET engineered as an approved method of assembly rotation, by
CAN BE FOUND WITH THE engaging the manually driven pinion with the engine
INSTRUCTION BOOK. flywheel starter ring-gear
Before working inside the generator,
during the aligning and fitting of
coupling bolts, care should be taken
to lock the assembly to ensure there
is no possibility of assembly
Danger ! rotational movement.
3870Kgs MAX

4.2.1 TWO BEARING GENERATORS

A flexible coupling should be fitted and aligned in

accordance with the coupling manufacturer’s instruction.
HC7/MV7
FRANE

lf a close coupling adaptor is used the alignment of

SIZE

machined faces must be checked by offering the generator

up to the engine. Shim the generator feet if necessary.
Fig. 2 Ensure adaptor guards are fitted after generator/engine
assembly is complete.
Single bearing generators are supplied fitted with ties to
prevent rotor to slip out during transportation. Open coupled sets require a suitable guard, to be provided
by the set builder.
Once the ties are removed to couple the rotor to engine, the
rotor is free to move in the frame, and care is needed during Axial loading of the generator bearings should be avoided.
coupling and alignment to ensure the frame is kept in the Should it be unavoidable contact the factory for advice.
hprizontal plane.

9
 lncorrect guarding and/or generator 4.3 EARTHING
CAUTION! alignment can result in personal
injury and/or equipment damage. The generator frame should be solidly bonded to the
generating set bed-plate. lf anti-vibration mounts are fitted
4.2.2 SINGLE BEARING GENERATORS between the generator frame and its bed-plate a suitably
rated earth conductor (normally one half of the cross
For transit and storage purposes the generator frame spigot sectional area of the main line cables) should bridge across
and rotor coupling plated have been coated with a rust the anti-vibration mount.
preventative. This MUST BE removed before assembly to
engine.
A practical method for removal of this coating is to clean the Refer to local regulations to.
mating surface areas with a de-greasing agent based on a ensuer that the correntearthing
petroleum solvent. procedure has been followed.
Warning!

Care should be taken not to allow

CAUTION! any cleaning agent to come into 4.4 PRE-RUNNING CHECKS
prolonged contact with skin.
4.4.1 INSULATION CHECK
Alignment of single bearing generators is critical. lf lnsulation tests should be carried out before running the
necessary shim the generator feet to ensure alignment of generating set, both after assembly and after installation on
the machined surfaces. site. (see Section 7.1).

The sequence of assembly to the engine should generally The windings have been H.V. tested
be as follows : during manufacture and further H.V.
testing may degrade the insulation
1. On the engine check the distance from the coupling with consequent reduction in
mating face. on the flywheel to the flywheel housing IMPORTANT! operating life. Should it be necessary
mating face. This should be within 0.5mm of nominal to demonstrate H.V. testing, for
dimension. This is necessary to ensure that a thrust is customer acceptance, the tests must
not applied to the ac generator bearing or engine be carried out at reduced voltage
bearing. levels i.e. Test Voltage= 0.8 (2 X Rated
Voltage + 1000)
2. Check that the bolts securing the flexible plates to the
coupling hub are tight and locked into position. Refer to 4.4.2 DIRECTION OF ROTATION
Section 7, subsection 7.5.3.4 for tightening torques.
The standard direction of rotation is clockwise, as viewed
3. Remove covers from the drive end of the generator to from the drive end. This matches the predominant direction
gain access to coupling and adaptor bolts, Check of rotation used by diesel engine manufacturers. The
coupling joint interfaces are clean and lubricant free. generator can be driven in the opposite direction with a
small reduction in efficiency and an increased noise level.
4. Check that coupling discs are concentric with adaptor The phase rotation will also be effected.
spigot. This can be adjusted by the use of tapered 4.4.2.1 PHASE ROTATION
wooden wedges between the fan and adaptor.
Alternatively the rotor can be suspended by means of a Phase rotation is fixed for the standard direction of rotation,
rope sling through the adaptor opening. Offer the clockwise as viewed from the drive end. lf the generator is
generator to engine and engage both coupling disce to be rotated in the counter-clockwise direction it will
and housing spigots at same time, pushing generator be necessary to connect the customer output cables
towards engine until coupling discs are against flywheel accordingly. Refer to the factory for ‘reverse rotation wiring
face, and housing spigots located. diagram’.
4.4.3 VOLTAGE AND FREQUENCY
5. Fit housing and coupling bolts taking care to use heavy
gauge washers between coupling bolt head and Check that the voltage and frequency that are required for
coupling disc. Tighten bolts evenly around assembly the generating set application is as indicated on the
sufficiently to ensure correct alignment. generator nameplate. lf it is necessary to reconnect the
stator for the voltage required, refer to diagrams in the back
6. Tighten housing bolts. of this manual.
7. Tighten coupling disc to flywheel bolts. Refer to engine 4.4.4 AVR SETTINGS
manufacturers manual for correct tightening torque. To make AVR selections and agjusytments remove the
AVR cover and refer to depending upon type of AVR fitted.
8. Remove rotor-aligning aids, either wodden wedges, or Reference to the generator nameplate will indicate AVR type.
the two M10 set screws and sheet metal wear plates.
Most of the AVR adjustments are factory set in positions that
lncorrect guarding and/or
will give satisfactory performance during initial running tests.
generator alignment can Subsequent adjustment may be required to achieve
CAUTION! result in personal injury and/or
equipment damage.

10
optimum performance of the set under site operating
conditions. Refer to ‘Load Testing’ section for details.

4.4.4.1 TYPE MX341 AVR

The following ‘jumper’ connections on the AVR should

be checked to ensure they are correctly set for the
generating set application.

Refer to Fig. 3 for location of selection links.

1.Freguency selection terminals
4 pole 50Hz operation LINK 2-3
4 pole 60Hz operation LINK 1-3

2. Stability selection terminals LINK A-B

3. Sensing selection terminals LINK 2-3

LINK 4-5
LINK 6-7
4. Excitation lnterruption Link LINK K1-K2

k1-k2 linked for

nomnal operation

SX440

Fig 3

11
 4.5 GENERATOR SET TESTING

During testing it may be necessary Do not increase the voltage above the
to remove covers to adjust controls IMPORTANT ! rated generator voltage shown on the
exposing ‘live’ terminals or generator nameplate.
components. Only personnel
qualified to perform electrical
Warning! service should carry out testing. The STABILITY control potentiometer will have been pre-set
and should normally not require adjustment, but should this
be required, usually identified by oscillation of the voltmeter,
4.5.1 TEST METERING/CABLING refer to Fig.3 for control potentiometer location and proceed
as follows:
Connect any instrument wiring and cabling required for initial
test purposes with permanent or spring-clip type connectors.
Minimum instrumentation for testing should be line to line or
line to neutral voltmeter, Hz meter, load current metering 1. Run the generating set on no-load and check that
and kW meter. lf reactive load is used a power factor meter speed is correct and stable.
is desirable.
2. Turn the STABILITY control potentiometer clockwise,
When fitting power cables foe load then turn slowly anti- clockwise until the generator
testing purposes, ensure cable voltage voltage starts to become unstable.
rating is at least equal to the generator
IMPORTANT ! rated voltage. The load cable terminal
should be placed on top of the winding The correct setting is slightly colockwise from this position (i.e.
lead terminal and clamped between where the machine volts are stable but close to the unstable
the two nuts provided. No nut is allowed region).
between two terminals.
Check that all wiring terminations for 4.7 LOAD TESTING
internal or external wiring are secure,
CAUTION! and fit all terminal box covers and
During testing it may be necessary
guards. Failure to secure wiring
and/or covers may result in peraonal to remove covers to adjust
injury and/or equipment failure. controls exposing ‘live’ terminals
or components. Only personnel
4.6 INITIAL START-UP qualified to perform electrical
service should carry out testing
During testing it may be necessary to and/or adjustments. Refit all
remove covers to adjust controls Warning!
access covers after adjustments
exposing ‘live’ terminals or
are completed.
components. Only personnel qualified
to perform electrical service should
carry out testing and/or adjustments.
Warning! Replace all access covers after 4.7.1 AVR ADJUSTMENTS
adjustments are completed.
Refer to Fig.3 for control potentiometer locations. Having
On completion of generating set assembly and before adjusted VOLTS and STABILITY during the initial start-up
starting the generating set ensure that all engine procedure, other AVR control functions should not normally
manufacturer’s pre-running procedures have been need adjustment. lf instability on load is experienced,
completed, and that adjustment of the engine governor is recheck stability setting. Refer to subsection 4.6.
such that the generator will not be subjected to speeds in
excess of 125% of the rated speed.

Over-speeding of the generator is lf however, poor voltage regulation on-load or voltage

never advisable as this can result in collapse is experienced, refer to the following paragraphs on
damage to the generator rotating each function to
IMPORTANT ! components. Special care is a) Check that the symptoms observed do indicate
necessary during initial setting of the adjustment is necessary.
speed governor. b) Make the adjustment correctly.

ln addition remove the AVR access cover and turn VOLTS

control fully anti-clockwise. Start the generating set and run 4.7.1 1 UFRO (UNDER FREQUENCY ROLL OFF)
on no-load at nominal frequency. Slowly turn VOLTS control
potentiometer clockwise until rated voltage is reached. Refer The AVR incorporates an underspeed protection circuit
to Fig. 3 for control potentiometer location. that gives a voltage/speed (Hz) characteristic as shown:

12
 Clockwise Anticlockwise 4.7.1.4 TRANSIENT LOAD SWITCHING ADJUSTMENTS
Adjustment
Knee AVR Types, MX341 and MX321
Point
The additional function controls of DIP and DWELL are
% Volts

provided to enable the load acceptance capability of the

generating set to be optimised. The overall generating set
100 performance depends upon the engine capability and governor
response, in conjunction with the generator characterstics.

95 Slope lt is not possible to adjust the level of voltage dip or recovery

shown is independently from the engine performance, and there will
typical always be a “trade off” between frequency dip and voltage dip.
90
setting
DIP-AVR Types MX341 and MX321
85 The dip function control potentiometer adjusts the slope of the
voltage/speed (Hz) characteristic below the knee point as
shown below:
80 Knee
75 80 85 90 95 100 Point

% Volts
% Speed (Hz)

Fig 4 100

The UFRO control potentiometer sets the “knee point” Anticlockwise

Adjustable
95 Adjustment
Symptoms of incorrect setting are a) the light emitting diode Slope
(LED) indicator, just above the UFRO Control potentiometer,
90
being permanently lit when the generator is on load, and b) Clockwise
poor voltage regulation on load, i.e. operation on the sloping Adjustment
part of the characteristic. 85

Clockwise adjustment lowers the frequency (speed) setting 80

75 80 85 90 95 100
of the “knee point” and extinguishes the LED. For Optimum % Speed (Hz)
setting the LED should illuminate as the frequency falls just Fig.5
below nominal frequency, i.e. 47Hz on a 50Hz generator or
57Hz on a 60Hz generator. DWELL-AVR Type MX321
The dwell function introduces a time delay between the
recovery of voltage and recovery of speed.
with AVR Types MX341 and MX321.lf The purpose of the time delay is to reduce the generator kW
the LED is illuminated and no output below the available engune kW during the recovery perion,
IMPORTANT ! voltage is present,refer to EXC TRIP thus allowing an improved speed recovery.
and/or OVER/V sections beloe. Again this control is only functional below the “knee point”,i.e.
if thespeed stays above the knee point during load switching
there in no effect from the dwell function setting.
4.7.1.2.EXC TRIP (Excitation Trip) AVR Types MX341 and
Clockwise adjustment gives increased recovery time.
MX321
An AVRA supplied from a permanent magnet generator Adjustable
inherentiy delivers maximum excitation power on a line to line Slope
% Volts

or line to neutral short circuit. ln order to protect the generator Anticlockwise

windings the AVR incorporates an over excitation circuit which Adjustment
detects high excitation and removes it after a pre-determined 100
time,i.e. 8-10 seconds.
95
Symptoms of incorrect setting are the generator output collpses
on load or small overload,and the LED is permanently illuminated. 90
Clockwise
Adjustment

The correct setting is 70volts +/-5% between terminals X and XX. 85

4.7.1.3 OVER/V (Over Voltage) AVR MX321
Over voltage protection circuitry is included in the AVR to re 80
-move generator excitation in the event of loss of AVR Instant of Load Time
sensing input. Application
Fig.6

The MX321 has both internal eleotronic de-excitation and

provision of a signal to operate an external circuit breaker. The graphs shown above are representations only, since it is
impossible to show the combined effects of voltage regulator
The correct setting is 300 volts +/-5% across terminals E1,E0. and engine governor performance.

Clockwise adjustment of the OVER/V control potentiometer

will increase the voltage at which the circuit operates.
13
 Failure to refit covers can result
in personal injury or death.
Warning!

4.8 ACCESSORIES
Refer to the “ACCESSORIES” Section of this Manual for
setting up procedures related to generator mounted.
accessories.
lf there are accessories for control panel mounting supplied
with the generator refer to the specific accessory fitting
procedures inserted inside the back cover of this book.
Replace AVR access cover after all adjustments are
completed.

14
 SECTION 5
INSTALLATION - PART 2

5.1 GENERAL
Carry out periodic checks to ensure that the torque
The extent of site installation will depend upon the settings are correct.
generating set bulid, e.g. if the generator is installed in a
canopied set with integral switchboards and circuit breaker, 5.4 EARTHING
on site installation will be limited to connecting up the site
load to the generating set output terminals. ln this case The neutral of the generator is not bonded to the generator
reference should be made to the generating set frame as supplied from the factory. An earth terminal is
manufacturer’s instruction book and any pertinent local provided inside the terminal box adjacent to the main
regulations. terminals. Should it be required to operate with the neutral
lf the generator has been installed on a set without earthed a substantial earth conductor (normally equivalent
switchboard or circuit breaker the following points relating to to one half of the section of the line conductors) must be
connecting up the generator should be noted. connected between the neutral and the earth terminal inside
the terminal box. lt is the responaiblity of the generating set
5.2 GLANDING builder to ensure the generating set bedplate and generator
frame are all bonded to the main earth terminal in the
terminal box.
To avoid the possibility of swarf
IMPORTANT ! entering any electrical components
in the terminal box, panels must be Reference to local electricity
removed for drilling. regulations or safety rules should be
CAUTION! made to ensure correct earthing
The terminal box is arranged for glanding on the right hand procedures have been followed.
side (or if specifically ordered on the left -hand side) viewed
from the end. Both panels are removable for drilling / 5.5 PROTECTION
punching to suit glands/or glanding boxes. lf single core
cables are taken through the terminal box side panel an lt is the responsibility of the end user and his
insulated or non-magnetic gland plate should be fitted. contractors/subcontractors to ensure that the overall system
protection meets the needs of any inspectorate, local
At entry to the terminal box incoming cables should be electricity authority or safety rules, pentaining to the site
supported by a recognised glanding method such that location. To enable the system designer to achieve the
minimum unsupported weight, and no axial force, is necessary protection and/or discrimination, fault current
transferred to the terminal assembly. curves are available on request from the factory, together
with generator reactance values to enable fault current
lncoming cables external to the terminal box, should be calculations to be made.
supported. The supports should allow for an adequate
radius at each bend, and allow for the vibration of the lncorrect installation and/or
generating set without putting excessive stress on the protective systems can result in
cables. personal injury and/or equipment
Before making final connections, test the insulation damage. lnstallers must be
resistance of the windings. The AVR should be qualified to perform electrical
disconnected during this test and RTD leads grounded. Warning!
installation work.
A 500V Megger or similar instrument should be used.
Should the insulation resistance be less than 5M the 5.6 COMMISSIONING
windings must be dried out ad detailed in the Service and
Maintenance section of this manual. Ensure that all external cabling is correct and that all of the
generating set manufacturer’s pre-running checks have
been carried out before starting the set.
5.3 TORQUE SETTINGS FOR TERMINAL
CONNECTIONS Generators fitted with air filters should have the filters
charged with oil prior to commissioning. Refer to Service
Pre treatment: Clean plated surfaces with a degreasing Section for charging procedure (subsection 7.3.2).
agent, then lightly abrade them to remove any tarnish. Don’t
score the surface. The generator AVR controls will have been adjusted during
the generating set manufacturer’s tests and should normally
The generator torque settings for all generator connections, not require further adjustment.
links, CT’s, accessories, cables, etc. is 45 Nm.
Should malfunction occur during commissioning refer to
The customer output cables should be connected to the Service and Maintenance section ‘Fault Finding’ procedure
terminals using 8.8 grade steel bolts and associated abti- (subsection 7.4).
vibration hardware. The following table is for your guidance
when connecting the customer output cables.

15
 SECTION 6
ACCESSORIES
Generator control accessories may be fitted, as an option, Reference should be made to the generating set
in the generator terminal box. lf fitted at the time of supply, manufacturer’s instructions for setting the governor controls.
the wiring diagram(s) in the back of this book shows the
connections. When the options are supplied separately, 6.2.1 DROOP
fitting instructions are provided with the accessory.
The most commonly used method of kVAr sharing is to
create a generator voltage characteristic that falls with a
6.1 REMOTE VOLTAGE ADJUST decreasing power factor (increasing kVAr). This is achieved
with a current transformer (C.T.) that provides a signal
A remote voltage adjust (hand trimmer) can be fitted. dependent on current phase angle (i.e. power factor) to the
AVR.
The remote voltage adjustment potentiometer is connected The current transformer has a burden resistor on the AVR
across AVR terminals 1&2. board, and a percentage of the burden resistor voltage is
summed into the AVR circuit. lncreasing droop is obtained
These terminals are normally linked.
by turning the DROOP control potentiometer clockwise.
When the remote voltage adjust potentionmeter is used the
The diagrams below indicate the effect of droop in a simple
link across terminals 1&2 must be removed.
two generator system :-
On MX321 the link 1&2 is on an adjacent terminal block.

6.2 PARALLEL OPERATION

Failure to meet conditions 1, 2, and

3 when closing the circuit breaker,
IMPORTANT ! will generate excessive mechanical
and electrical stresses, resulting in
equipment damage.

Understanding of the following notes on parallel operation is

useful before attempting the fitting or setting of the droop kit
accessory. When operating in parallel with other generators
or the mains, it is essential that the phase sequence of the
incoming generator matches that of the busbar and also that
all of the following conditions are met befoer the circuit
breaker of the incoming generator is closed on to the busbar
(or operational generator).
1. Frequency must match within close limits.

2. Voltages must match within close limits.

3. Phase angle of voltages must match within close limits.

A variety of techniques, varying from simple synchronising

lamps to fully automatic synchronisers, can be used to
ensure these conditions are met.
Once connected in parallel a minimum instrumentation level
per generator of voltmeter, ammeter, wattmeter (measuring
total power per generator), and frequency meter is required
in order to adjust the engine and generator controls to share
kW in relation to engine ratings and kVAr in relation to Fig 7
generator ratings.
lt is important to recognise that :-

1. kW are derived from the engine, and speed governor

characteristics determine the kW sharing between sets
and
2. kVAr are derived from the generator, and excitation
control characteristics determine the kVAr sharing.

16
Generally 5% droop at full load current zero power factor is When using this connection
sufficient to ensure kVAr sharing. arrangement a shorting switch is
required across each C.T. burden
lf the droop accessory has been supplied with the generator IMPORTANT ! (terminals S1 and S2.) The switch
it will have been tested to ensure correct polarity and set to must be closed a) when a generating
a nominal level of droop. The final level of droop will be set set is not running and b) when a
auring generating set commissioning. generating set is selected for single
running.
Although nominal droop setting may be factory set it is
advisable to go through the setting procedure below. Should ‘Asiatic’ control of the generator be required, request
the diagrams from the factory.
6.2.1.1 SETTING PROCEDURE
The setting procedure is exactly the same as for DROOP.
Depending upon available load the following settings should (Subsection 6.2.1.1)
be used, all are based on rated current level.

0.8 P.F. load (at full load current) set droop to 3%

zero P.F. load (at full load current) set droop to 5%

Setting the droop with low power factor load is the most
accurate.

Run each generator as a single unit at rated frequency or

rated frequency + 4% depending upon type of governor and
nominal voltage. Apply available load to rated current of the
generator. Adjust ‘DROOP’ control potentiometer to give
droop in line with above table. Clockwise rotation increases
amount of droop. Refer to Fig.3 for potentiometer
locations.

Note 1)
Reverse polarity of the C.T. will raise the generator voltage
with load. The polarities S1 & S2 shown on the wiring
diagrams are correct for clockwise rotation of the generator
looking at the drive end. Reversed rotation requires S1 &S2
to be reversed.

Note 2)
The most important aspect is to set all generators equal.
The precise level of droop is less critical.

Note 3)
A generator operated as a single unit with a droop circuit set
at rated load 0.8 power factor is unable to maintain the usual
0.5% regulation. A shorting switch can be connected across
S1 & S2 to restore regulation for single running.

LOSS OF FUEL to an engine can

cause its generator to motor with
consequent damage to the generator
IMPORTANT ! windings. Reverse power relays
should be fitted to trip main circuit
breaker.
LOSS OF EXCITATION to the
generator can result in large current
oscillations with consequent
IMPORTANT ! demage to generator windings.
Excitation loss detection equipment
should be fitted to trip main circuit
breaker.

17
 SECTION 7
SERVICE AND MAINTENANCE

As part of routine maintenance procedures, periodic atten Any temporary reduction in IR values can be restored to
-tion to winding condition(particularly when generators have expected values by following one of the drying out
been idle for a long period) and bearings is recommended. procedures.
(Refer to subsections 7.1 and 7.2 respectively ).
7.1.1 WINDING CONDITION ASSESSMENT
When generators are fitted with air filters regular inspection The AVR should be disconnected
and fliter maintenance is required. (Refer to subsection 7.3) and the Resistance Temperature
CAUTION!
Detector (R.T.D.) leads grounded
7.1 WINDING CONDITION during this test.

Service and fault finding procedures The condition of the windings can be assessed by
prosent hazards that can result in measurement of insulation resistance [IR] between phase
severe personal injury or death. Only to phase, and phase to earth. Measurement of winding
personnel qualified to perform insulation should be carried out:-
electrical and mechanical service
should carry out these procedures. 1. As part of a periodic maintenance plan.
Danger ! Ensure engine start circuits are 2. After prolonged periods of shutdown.
disabled before commencing service 3. When low insulation is suspected, e.g. damp or wet
or maintenance procedures. lsolate windings.
any anti-condensation heater supply.
Care should be taken when dealing with windings that are
Guidance of Typical lnsulation Resistance [IR] Values suspected of being excessively damp or dirty. The initial
The following is offered as general infornation about IR measurement of the [IR] lnsulation Resistance should be
values.The aim is to provide guidance about the typical IR established using a low voltage (500V) megger type
values for generators from new through to the point of instrument. lf manually powered the handle should initially
refurbishment. be turned slowly so that the full test voltage will not be
applied, and only applied for long enough to very quickly
New Machines assess the situation if low values are suspected or
The generators lnsulation Resistance, along with many immediately indicated.
other critical factors, will have been measursd during the
alternator manufacturing process. The generator will have Full megger tests or any other form of high voltage test
been transported with a appropriate packaging suitable should not be applied until the windings have been dried
for the method of delivery to the Generating Set out and if necessary cleaned.
assemblers works, where we expect it to be stored in a
suitable location protected from adverse conditions. Procedure for lnsulation Testing
Disconnect all electronic components, AVR, electronic
However, absolute assurance that the generator will arrive protection equipment etc. Ground the [RTD’s] Resistance
at the Gen-set production line with IR values still at the Temperature Detection devices if fitted. Short out the
factory test levels of above 100 M cannot be guaranteed. diodes on the rotating diode assembly. Be aware of all
components connected to the system under test that could
At Generating Set Manufacturers Works cause false readings or be damaged by the test voltage.
The generator should have been transported and stored
such that it will be delivered to the assembly area in a Carry out the insulation test in accordance with the
‘operating instructions’ for the test equipment.
clean dry condition. lf held in appropriate storage
conditions the generator IR value should typically be 25
The measured value of insulation resistance for all
M .
windings to earth and phase to phase should be compared
with the guidance given above for the various ‘life stages’
lf the unused/new generator’s IR values fall below 10
of a generator. The minimum acceptable value is 1.0 M .
M then a drying out procedure should be implemented by
one of the processes outlined below before being lf low winding insulation is confirmed, one or more of
despatched to the end customer’s site.Some investigation the methods, given below, for drying the windings
should be undertaken into the storage conditions of the should be carried out.
generator while on site.
7.1.2 METHODS OF DRYING OUT GENERATORS
Generators in Service
Whilst lt is known that a generator will give reliable service Cold Run
with an IR value of just 1.0 M . For a relatively new Providing a generator in good condition but has not been
generator to be so low it must have been subjected to run for some time. lt is possible that simply running the
inappropriate operating or storage conditions. genset, without excitation, will raise the IR sufficiently
(greater than 1.0 M ) to allow the unit to be put into
service. Run the generator for approximately 10 minutes

18
with AVR terminals K1 and K2 open. Visually check that Once the lnsulation Resistance is raised to an acceptable
the windings appear dry and carry out an insulation level - minimum value 1.0 M - the dc supply may be
resietance test to prove that the minimum (1.0 M ) removed and the exciter field leads F+ and F- re-
insulation value has been achieved. lf this method fails, connected to their terminals on the AVR.
use one of the traditional methods outlined below.
Rebuild the genset, replace all covers and re-commission
Blown Air Drying as appropriate.
Remove the covers from all apertures to allow the escape
of the water-laden air. During drying, air must be able to lf the set is not to be run immediately ensure that the anti-
flow freely through the generator in order to carry off the condensation heaters are energised, and retest the
moisture. generator prior to running.

Direct hot air from two electrical fan heaters of around 1 - 3 Typical Drying Out Curve
kW into the generator air inlet apertures. Ensure the heat Whichever method is used to dry out the generator the
source is at least 300mm away from the windings to avoid resistance should be measured every half-hour and a
over heating and damage to the insulation. curve plotted as shown.

Apply the heat and plot the insulation value at half hourly A
intervals. The process is complete when the parameters
covered in the section entitled, ‘Typical Drying Out Curve’,
Minimum reading 1.0 M
are met.

Resistance
Remove the heaters, replace all covers and re-commission
as appropriate.

lf the set is not to be run immediately ensure that the anti-

condensation heaters are energised, and retest prior to Time
running.
Fig 8
Short Circuit Method
NOTE: This process should only be performed by a The illustration shows a typical curve for a machine that
competent engineer familiar with safe operating practices has absorbed a considerable amount of moisture. The
within and around generator sets of the type in question. curve indicates a temporary increase in resistance, a fall
Ensure the generator is safe to work on, initiate all and then a gradual rise to a steady state. Point ‘A’, the
mechanical and electrical safety procedures pertaining to steady state, must be greater than 1.0 M . (lf the windings
the genset and the site. are only slightly damp the dotted portion of the curve may
not appear).
Bolt a short circuit of adequate current carrying capacity,
across the main terminals of the generator. The shorting For general guidance expect that the typical time to reach
link should be capable of taking full load current. point ‘A’ will be approximately 3 hours for a LV6 generator.

Disconnect the cables F+,F- from terminals “X” and Drying should be continued after point “A” has been
“XX” of the AVR. reached for at least one hour.

Connect a variable dc suooly to the F+ (pos itive) and F- lt should be noted that as winding temperature increases,
(negative) field cables. The dc supply must be able to values of insulation resistance may significantly reduce.
provide a current up to 2.0 Amp at 0 - 24 Volts. Therefore, the reference values for insulation resistance
can only be established with windings at a temperature of
Position a suitable ac ammeter to measure the shorting link approximately 20℃.
current.
After drying out, the insulayion resistances should be
Set the dc supply voltage to zero and start the generating rechecked to verify minimum resistances quoted above are
set. Slowly increase the dc voltage to pass current through achieved. Oh re-testing it is recommended that the main
the exciter field winding. As the excitation current incresses, stator insulation resistance is checked as follows:-
so the stator current in the shorting link will increase. This Separate the neutral leads
stator output current level must be monitored, and not
allowed to exceed 80% of the generatore rated output Ground V and W phase and megger Uphase to ground
current. Ground Uand W phase and megger Vphase to ground
Ground Uand W phase and megger Wphase to ground
After every 30 minutes of this exercise: Stop the generator lf the minimum value of 1.0M is not obtained, drying out
and switch off the separate excitation supply, and measure must be continued and the test repeated.
and record the stator winding IR values, and plot the
results. The resulting graph should be compared with the lf the minimum value of 1.0 M for all components cannot
classic shaped graph. This drying out procedure is be achieved rewinding or refurbishment of the generator
complete when the parameters covered in the section will be necessary.
entitled ‘Typical Drying Out Curve’ are met.

19
The generator must not be put in to service until the only to the predominant frequency of vibration of any
minimum value, of 1.0 M Ω for all components, can be complex waveform.
achieved.
Definltion of ISO 8528 - 9
ISO 8528-9 refers to a broad band of frequencies, the
7.2 BEARINGS broad band is taken to be between 2 Hertz and 300
Hertz. The table below is an example from ISO 8528 -
All bearings are supplied from the factory pre-packed 9 (value 1).This simplified table lists the vibration limits
with Kluber Asonic GHY 72grease. by kVA range and speed for acceptable genset operation.
Do not mix Kluber Asonic GHY 72 with any grease of
different specifications. Mixing grease of differing VIBRATION LEVELS AS MEASURED ON THE GENERATOR
specifications will reduce bearing life. Engine Set Vibration
Vibration Vibration
Speed Output Accelera-
Displacement Velocity
The specification for Kluber Asonic GHY72 is available Min -
1
kVA tion
on request from the factory. ≥10 kVA - - -
10 but
4 POLE 0.64 40 25
Sealed for life bearings are fitted with integral seals and ≤50 kVA
1500 rpm
are not re-greasable. 50 but
50Hz 0.4 25 16
1800 rpm ≤125 kVA
BEARING LIFE. 60 Hz 125 but
0.4 25 16
≤250 kVA
250 kVA 0.32 20 13
The life of a bearing in service is The ‘Broad band’ is taken as 2 Hz - 300 Hz
IMPORTANT ! subject to the working conditions and
the environment. Table 4
High levels of vibration from the engine
or misalignment of the set will stress Exceeding either of the above
the bearing and reduce its service life. specifications will have a
IMPORTANT ! lf the vibration limits set out in BS IMPORTANT ! detrimental effect on the life of the
5000-3 and ISO 8528 -9 are exceeded bearing. This will invalidate the
bearing life will be reduced. Refer to generator warranty. lf you are in any
‘Vibration’ below. doube, contact DINGOL
Long stationary periods in an
environment where the generator is
IMPORTANT ! subject to vibration can cause false lf the vibration levels of the generating set are not within
brinnelling, which puts flats on the ball the parameters quoted above: -
and grooves on the races, leading to
premature failure. 1. Consult the genset bulider. The genset builder
Very humid atmospheric or wet should address the genset design to reduce
conditions can emulsify the grease the vibration levels as much as possible.
IMPORTANT ! causing corrosion and deterioration of
the grease, leasing to premature failure 2. Discuss the impact of not meeting the above levels
of the bearings. on both bearing and generator life expectancy.
HEALTH MONITORING OF THE BEARINGS Where requested, or deemed necessary, DINGOL will
work with the genset builder in an attempt to find a
lt recommends that the user check the bearing condition, satisfactory solution.
using monitoring equipment,to de termine the state of the
bearings. The ‘best practice ’ is to take initial readings as BEARING ‘SERVICE LIFE’ EXPECTANCY
a base line and periodically monitor the bearings to detect Bearing manufacturers recognise that the “service life”of
a deteriorating trend. lt will then be possible to pian a their bearings is dependent upon many factors that are
bearing change at an appropriate generating set or not in their control, they cannot therefore quote a
engine service interval. “service life”.

VIBRATION Although “service life” cannot be guaranteed, it can be

maximised by attention to the generating set design. An
The generators are designed to withstand the vibration understanding of the genset application will also help the
levels encountered on generating sets built to meet user to maximise the service life expectancy of the bear
the requirements of ISO 8528-9 and BS5000-3. (Where -ings.Particular attention should be paid to the alignment,
ISO 8528 is taken to be broad band measurements reduction of vibration levels, environmental protection,
and BS5000 refers to the predominant frequency of maintenance andmonitoring procedures.
any vibrations on the generating set.)
We does not quote life expectancy figures for bearings,
Definition of BS5000 - 3 but suggests practicable replacement in tervals based
Generators shall be capable of continuously withstanding on the lifetime of the bearring, the grease and the
linear vibration levels with amplitudes of 0.25mm recommendations of the bearing and grease manu
between 5Hz and 8Hz and velocities of 9.0mm/s -facturers.
rms. between 8 Hz and 200 Hz when measured
at any point directly on the carcass or Foe general-purpose applications, providing the vibration
main frame of the machine. These limits refer levels do not exceed the levels stated in ISO 8528-9* and
20
BS5000-3* and the ambient temperature does not exceed 7.4.1 FAULT FINDING -SX440,SX460 AS440 AVR
50℃ the following approximations can be applied when
planning bearing replacements. 1. Check link K1-K2.
*(See section on vibration) 2. Check speed.
No voltage 3. Check residual voltage. Refer to
Sealed for Life Bearings. - Approximately 30,000 hours. build-up when subsection 7.4.3 Follow separate
starling set excitation test procedure to check
Re-greaseable bearings. - Approximately 40,000 hours. generator andAVR.Refer to
subsection 7.5.
This is provided the correct maintenance is carried out, and
Unstable voltage 1. Check sepaed stability
only Kluber Asonic GHY 72 grease (or equlvalent) is used either on no-load
in all bearings.
2. Check stability setting. Refer to
or with load subsection 4.6.
lt is important to note that bearings in service, under good 1. Check sepaed
High voltage
operating conditions, can continue to run beyond the either on no-load 2. Check that generator load is not
recommended replacement period. lt should also be or with load supacitive( leading power factor ).
remembered that the risk of bearing failure increases with
time. Low voltage 1. Check speed.
on-load 2. Check link 1-2 or external hand
trimmer leads for continuity.
7.3 AIR FILTERS 1. Check speed.
2. CheckUFRO setting. Refer to subsection
Air filters for the removal of airborne particulate matter Low voltage 4.7.1.1.
(dust) are offered as an addition to the standard build on-load 3. Follow separator excitation procedure
option. Filters on it’s need to be ordered with the generator. to check generator and AVR. Refer to
subsection 7.5.
The frequency of filter maintenance will depend upon the Table 5
severity of the site conditions. Regular inspection of the
elements will be required to establish when cleaning is 7.4.2 FAULT FINDING -MX341,MX321 AVR
necessary.
1. Check link K1-K2 on auxiliary terminals.
No voltage Follow Separate Excitation Test Procedure
Removal of filter elements enables build-up when
access to LIVE parts. Only remove to check machine and Avr. Refer to
starling set subsection 7.5.
elements with the generator out of
service.
1. First stop and re-stan set.lf no voltage
Danger ! or voltage collapses after short time,
Loss of voltage
when set running follow Separate Excitation Test
7.3.1 CLEANING PROCEDURE Procedure. Refer to subsection 7.5.

Remove the filter elements from the filter frames. lmmerse Generator voltage 1. Check sensing leads to AVRA
or flush the element with a suitable degreasing agent until high followed by 2. Refer to Separate Excitation Test
the element is clean. collapse Procedure. Refer to subsection 7.5.
As an alternative procedure a high-pressure water hose Voltage unstable 1. Check speed stability
with a flat nozzle can be used. Sweep the water spray back either on no-load 2. Check “STAB” setting. Refer to Load
and forth across the element from the clean side (fine or with load Testing section for procedure. Refer
mesh side of element) holding the nozzle firmly against the to subsection 4.6.
element surface. Cold water may be adequate depending
upon type of contamination although hot water is preferable.
1. Check speed.
Low voltage 2. lf correct check “UFRO” setting.
The element can be inspected for cleanliness by looking on-load
Refer to subsection 4.7.1.1.
through the filter towards the light.

When thoroughly clean, no cloudy areas will be seen. Excessive 1. Check governor response. Refer to
voltage/speed dip generating set manual. check “DIP”
Ensure the filter elements to completely drain before on load switching setting Refer to subsection 4.7.1.4.
refitting the elements into the frames and putting into service.
7.4 FAULT FINDING 1. Check governor response. Refer to
Sluggish
Before commencing any recovery on load generating set manual.
faultfinding procedures, examine switching 2. For MX321AVR, check“DWELL” setting.
IMPORTANT !
all wiring for broken or loose Refer to load Testing section 4.7.1.4.
connections.

Refer to the generator nameplate for type of AVR fitted Table 6

21
7.4.3 RESIDUAL VOLTAGE CHECK
Never connect a battery to the AVR terminals
This procedure is applicable to generators wit either ,without a blocking diode.in most cases this
CAUTION!
SX460 or SX440 or AS440 AVR. will destroy the AVR power devices. Battery
With the generator set stationary remove AVR access polarity MUST be correct!
cover and leads F+ and F- from the AVR.

Start the set and messure voltage acros AVR terminals

7-8 on SX460 or AS440 AVR or P2-P3 on SX440 AVR.
7.5 SEPARATE EXCITATION TEST PROCEDURE
Stop the set, snd replace leads F+ and F- on the AVR
terminals. lf the measured voltage was above 5V follow The generator windings, diode assembly and AVR can be
the generator should operate normally. checked using the appropriate following sections.

lf the measured voltage was under 5V follow the 7.5.1 GENERATOR WINDINGS, ROTATING DIODES and
procedure below. PERMANENT MAGNET GENERATOR (PMG)
7.5.2 EXCITATION CONTROL TEST.
Using a 12 volt dc battery as a supply clip leads from
battery negative to AVR terminal XX, and from battery 7.5.1 GENERATOR WINDINGS, ROTATING
positive through a diode to VAR terminal x.See Fig. 9. DIODES & PERMANENT MAGNET GENERATOR
(PMG)
A diode must be used used as shown
IMPORTANT !
below to ensure the AVR is not damaged.

The resistances quoted apply to a

standard winding. For generators
having windings or voltages other
IMPORTANT! than those specified refer to factory
for details. Ensure all disconnected
AVR leads are isolated and free from
F+
XX (F2) earth.
X (F1)
1000V
1A DIODE
F-
IMPORTANT! lncorrect speed setting will give
proportional error in voltage output.

+ Checking Generator Windings and Rotating Diodes

- This procedure is carried out with lesds F+ and F-

disconnected at the AVR and using a 12 volt d.c.
supply to leads F+ and F-
12V Battery Fig.9 Start the set and run at rated speed.
Measure the voltages at the main outout terminals U, V
and W. lf voltages are balanced and within +/-10% of the
generator nominal voltage, butare balanced within 1% phase
to phase. refer to 7.5.1.1
lf the generating set battery is used for
IMPORTANT ! field fiashing, the generator main stator Check voltages at AVR terminals 6, 7 and 8. These should
be balanced and between 170-250 volts.
neutral must be disconnected from earth.
lf voltages at main terminals are balanced but voltage at 6,
7 and 8 are unbalanced, check continuity of leads 6, 7 and
8.
Restart the set and note output voltage from main staor,
which should be approximately nominal voltage, or lf voltages are unbalanced,refer to 7.5.1.2.
voltage at AVR terminals 7 and 8 on SX460 or AS440,
P2-P3 on SX440 which should be between 170 and 250 7.5.1.1 BALANCED MAIN TERMINAL VOLTAGES
volts.
lf all voltages are balanced within 1% at the main terminals,
Stop the set and unclip battery supply fromterminals X it can be assumed that all exciter windings, main windings
and XX. Restart the set. The generator should now and main rotating diodes are in good order, and the fault is
operate normally. lf no voltage build-up is obt ained it in the AVR or transformer control. Refer to subsection 7.3.2
can be assumed a fault exists in either the generator or for test procedure.
the AVR circuits. Follow the SEPARATE EXCITAION lf voltages are balanced but low, there is a fault in the main
TEST PROCEDURE tocheck generator windings, excitation windings or rotating diode assembly. Proceed as
rotating diodes and AVR.Refer to subsection 7.5. follows to identify: -

22
Rectifier Diodes lf voltages are unbalanced, this indicates a fault on the
main stator winding or main cables to the circuit breaker.
The diodes on the main rectifier assembly can be checked NOTE: Faults on the stator winding or cables may alsc
with a multimeter. The flexible leads connected to each cause noticeable load increase on the engine when
diode should be disconnected at the terminal end, and the excitation is applied.
forward and reverse resistance checked. A healthy diode Disconnect the main cables and srparate the winding
will indicate a very high resistance (infinity) in the reverse leads U1-U2, (U5-U6), V1-V2, (V5-V6), W1-W2, (W5-W6)
direction, and a low resistance in the forward direction. A to isolate each winding section.
faulty diode will give a full deflection reading in both Note: - leads suffixed 5 and 6 apply to 12 wire windings
directions with the test meter on the 10,000 ohms scale, or only.
an infinity reading in both directions. On an electronic
digital meter a healthy diode will give a low reading in one Measure each section resistance - values should be
direction, and a high reading in the other. balanced and within +/-10% of the value.

Measure insulation resistance between sections and each

section to earth.
Replacement of Faulty Diodes
Unbalanced or incorrect winding resistances and/or low
The rectifier assembly is split into two plates, the positive insulation resistances to earth indicate rewinding of the
and negative,and the main rotor is connected across these stator will be necessary. Refer to removal and replacement
plates. Each plate carries 3 diodes, the negative plate of component assemblies’ subsection 7.5.3.
carrying negative biased diodes and the positive plate
carrying positive biased diodes. Care must be taken to
ensure that the correct polarity diodes are fitted to each 7.5.2 AVR FUNCTION TEST
respective plate.When fitting the diodes to the plates they
All types of AVR’s can be tested with this procedure:
must be tight enough to ensure a good mechanical and
electrical contact, but should not be over-tightened. The
1. Remove exciter field leads F+,F-from the AVR treminals
recommended torque tightening is 4.06 - 4.74Nm.
X & XX (F1 & F2).
(36-42lb in).
2. Connect a 60W 240V household lamp to AVR
terminals X & XX (F1 & F2).
Surge Suppressor
3. Set the AVR VOLTS control potentiometer fully
The surge suppressor is a metal-oxide varistor connected clockwise.
across the two rectifier plates to prevent high transient
reverse voltages in the field winding from damaging the 4. Connect a 12V, 1.0A DC supply to the exciter field
diodes. This device in not polarised and will show a virtually leads F+,F- with F+ to the positive.
infinite reading in both directions with an ordinary
resistance meter. lf defective this will be visible by 5. Start the generating set and run at rated speed.
inspection, since it will normally fail to short circuit and
show signs of disintegration. Replace if faulty. 6. Check that the generator output voltage is within +/-
10% of reted voltage.

lf after establishing and correcting any fault on the rectifier

assembly the output is still low when separately excited, The lamp should glow for approximately 8 seconds and
then the main rotor, exciter stator and exciter rotor winding then turn off. Failure to tuen off indicates faulty protection
resistances should be checked, as the fault must be in one circuit and the AVR should be replaced. Turning the
of these windings. The exciter stator resistance is measured “VOLTS” control potentiometer fully anti-clockwise should
across leads F+ and F-. turn off the lamp with all AVR types.

Should the lamp fail to liaht the AVR is faulty and should be
replaced.
The exciter rotor is connected to six studs which also carry After this test turn VOLTS control
the diode lead terminals. The main rotor winding is IMPORTANT! potentiometer fully anti-clockwise.
connected across the two rectifier plates. The respective
leads must be disconnected before taking the readings.
7.5.3 REMOVAL AND REPLACEMENT OF
COMPONENT ASSEMBLIES

7.5.1.2 UNBALANCED MAIN TERMINAL METRIC THREADS ARE USED THROUGHOUT

VOLTAGES
 When lifting single bearing generators, Ensure that the bearing contact surface shows no
care is needed to ensure the generator sign of wear or corrosion prior to fitting the bearing.
frame is kept in the horizontal plane. The
CAUTION! rotor is free to move in the frame and can Never refit used bearings, wave washers or ‘O’rings.
slide out if not correctly lifted. incorrect
lifting can cause serious injury to Never refit used bearings, grease flingers, wave
personnel. washer or ‘O’ rings.

Only the outer race should be used to transmit load

7.5.3.1 ANTI-CONDENSATION HEATERS during assembly (NEVER use the inner race).

The external mains electricity supply REMOVAL OF REGREASABLE BEARINGS

used to power the anti-condensation
heater must be switched off and safely The bearings are a press fit on the shaft and can be
isolated before attempting any work removed with standard tooling, i.e. 2 or 3 legged manual
adjacent to the heater, or removal of or hydraulic bearing pullers.
the non drive end endbracket on
Danger ! which the anti-con heater is mounted. To remove bearings proceed as follows:
Ensure that the engine is inhibited
prior to work in generator. 1. Remove 4 screws holding bearing cap.

2. Remove cap.
7.5.3.2 REMOVAL OF BEARINGS
3. Non drive end - remove wave washer and circlip
(single bearing only).
Position the main rotor so that a
full pole face of the main rotor core
IMPORTANT! is at the bottom Remove PMG of
the stator bore if fitted.
4. Remove bearing cartridge housing complete with
bearing (and grease flinger if fitted).
The generators in this manual will be fitted with one of
two different bearing arrangements. There may be two 5. Remove bearing from cartridge.
different arrangements on a two-bearing generator.
6. Discard the old bearing ‘O’ rings and wave washer
where fitted.
Removal of the bearing may be effected either after
the rotor assembly has been removed or more simply The beasing cap(s) and cartridge(s) must be thoroughly
by removal of endbracket(s). flushed out with clean solvent and checked for wear or
damage, before re-assembly. Damaged components
Be sure to note the location of all components during should be replaced before refitting the bearing.
removal to assist during the assembly process.
ASSEMBLY OF REGREASABLE BEARINGS
BEARING REPLACEMENT
NOTE: Gloves must be worn at all times when handling
Environment the bearings, grease and solvent.

Every effort must be made to establish a clean area around 1. Wipe clean the assembly surface, using cleaning
the generator when removing and replacing bearings. solvent on lint free cloth.
Contamination is a major cause of bearing failures.
2. Wipe clean: Bearing Cartridge, Wave Washer,
Equipment Bearing Cap, grease flinger, all re-lubrication pipes
andfittings (internal and external). Visually inspect
Suitable cleaning solvent all components after cleaning, for contamination.
Bearing puller, two or three leg
Thin protective gloves 3. Place all components on the clean assembly surface.
Lint free cleaning cloth Do not use an air line to blow off excess fluid.
lnduction heater.
4. Thoroughly clean the external surface of the grease
Preparation
gun nozzle using lint free cloth.
Remove the lubrication pipework if fitted
Position the rotor so that the full pole face of the main rotor Bearing preparation
is at the bottom of the stator bore.
Remove the end bracket, see 7.5.3.4 for procedure. 1. Remove the bearing from its packaging.

NOTES: 2. Wipe off the preservative oil from the surface of the
lt is not necessary to remove the totor. inner and outer rings - using lint free cloth only.
3. Place the bearing on the clean assembly surface, 2. Apply a small amount of grease to the grooved sealing
with the bearing designation marking facing down. surface in the cap.

Bearing Assembly (Lubrication, see TABLE 17) 3. Fit circlip.

(single bearing only).
Cartridge:
4. Heat flinger to 120℃ and place on shaft up to the
1. Apply the specified cartridge grease fill quanity to the bearing inner race. Hold firmly until positively located.
back face of the bearing housing.
5. Place wave washer in cap, fit cap to bearing cartrudge.
2. Apply a small amount of grease to the grooved sealing
surface in the cartridge.
REMOVAL OF SEALED FOR LIFE BEARINGS
3. Apply anti-fretting lubricant (MP14002 - Kluber)Altemp With Bearing Cartridge
Q NB 50) to the bearing housing circumference. Apply
paste in a thin coherent layer by use of a lint free cloth The bearings are a press fit on the shaft and can be
(DO NOT rub in) (use clean protective gloves). removed with standard tooling, i.e. 2 or 3 legged manual or
hydraulic bearing pullers.
4. Non-drive end - fit new ‘O’ Rings into the ‘O’ Ring
grooves in the bearing housing circumference. To remove bearings proceed as follows:
Bearing: 1. Remove 4 screws holding bearing cap.
1. Apply half the specified bearing grease fill quantity 2. Remove cap.
(see table 16) to the upper face of the bearing
(opposite side to the bearing designation markings).
2. Thumb the applied grease into the bearing, ensuring 3. At the end, remove wave washer and circlip (single
good penetration into the receways/balls (use clean bearing only).
protective gloves).

4. Remove bearing cartridge housing complete with

Assemble Bearing into Cartridge bearing.
1. Heat the bearing cartridge to 25 ℃ above ambient
with an induction heater (Do not exceed 100℃). 5. Remove bearing from cartridge.
2. With greased face of the bearing facing the cartridge
bore, assemble the bearing into the bearing housing. 6. Discard the old bearing, ‘o’ rings and wave washer
Ensure the bearing outer race contacts the location where fitted.
shoulder.

Assemble Bearing onto Shaft The bearing cap(s) and cartridge(s) must be thoroughly
flushed out with clean solvent and checked for wear or
Bearing Cartridge damage, before re-assembly. Damaged components
should be replaced before refitting the bearing.
1. Heat the Bearing and Cartridge assembly to 80℃
above ambient with an induction heater. (use induction Assembly of Sealed for Life Bearings with Cartridge
heater, no other heat source is suitable)
Pre-assembly, cleaning.
2. Slide the Bearing and Cartridge assembly over the
shaft, pushing it firmly against the bearing seating NOTE:Gloves must be worn at all times when handling the
shoulder. bearings, grease and solvent.

3. Rotate the assembly (including inner race) 45 in 1. Wipe clean the assembly surface, using cleaning
either direction, to provide correct alignment. The solvent on lint free cloth.
bearing must be held firmly in place until it is cool
enough to positively locate. 2. Wipe clean: Bearing Cartridge and Bearing Cap
(internal and external).Visually inspect all components
NOTE: Ensure cartridge is at ambient temperature before sfter cleaning, for contamination.
assembling bracket.

Cap/Flinger: 3. Place all components on a clean assembly surface.

Do not use an air line to blow off excess fluid.
Apply the specified cap grease fill quantity to the inside
face of the cap (see table 16).
4. Thoroughly clean the external surface of the grease
1. Fill the grease exhaust slot with grease. gun nozzle using lint free cloth.
Bearing preparation: Note : Ensure cartridge is at ambient temperature before
assembling bracket.
1. Remove the bearing from its packaging.
7. Refit the end bracket and PMG where fitted.
2. Wipe off the preservative oil from the surface of the
inner and outer rings - using lint free cloth only.
7.5.3. 3 MAIN TOTOR ASSEMBLY
3. Place the bearing on the clean assembly surface,with
the bearing designation marking facing down. Single Bearing Machine

Bearing Assembly NOTE: On single bearing machines, before removal from,

or re-assembly to the prime mover, position the rotor, if
Cartridge : possible, such that a full pole face is at bottom dead centre.

1. Apply anti-fretting lubricant (MP14002 - Kluber 1. Remove all access covers and terminal box lid.
Altemp Q NB 50) to the bearing housing
circumference. Apply paste in a thin coherent 2. Ensure that these leads are free to come away with
layer by use of a lint free cloth (DO NOT rub in) the non-drive endbracket when removed.
(use clean protective gloves).
3. Remove the 8 bolts holding the drive end adaptor to
2. Fit ‘O’ Rings into the ‘O’ Ring grooves in the bearing the frame.
housing circumference.
4. With a rope sling around drive end adaptor, tap
adaptor out of its spigot location; guide over fan and
Assemble Beaeing into Cartridge remove.

1. Heat the bearing cartridge to 25 ℃ above the am 5. lf the generator is fitted with a cartriage. Remove the 4
bient temperature ( with an induction heater , do not bolts retaining the end bearing cartridge in the non
exceed 100℃) and assemble the new bearing drive end endbracket (outer 4 bolts).
into the cartridge. Ensure that the bearing (This includes all regreasable options).
designation is visible after assembly.
6. Remove the 8 bolts securing the non drive end bracket
2. With greased face of the bearing facing the cartridge to the frame.
bore, assemble the bearing into the bearing housing.
Ensure the bearing outer race contacts the location 7. Supporting the non-drive end bracket with a hoist,
shoulder. insert two M10 bolts in the two holes provided for
‘jacking’ purposes (on the end bracket horizontal
centre line). Screw in the bolts until the end bracket
NOTE: Only the outer race should be used to transmit spigot is clear of the locating recess, lower the whole
load during assembly (NEVER use the inner race). assembly until the main rotor is resting in the stator
bore.
Assemble Beaeing and Cartridge onto the Shaft Still supporting the non drive end bracket, tap the
bracket off the non drive end bearing cartridge (taking
1. Heat the Bearing and Cartridge assembly to 80℃ care that the exciter stator does not foul exciter rotor
above ambient. (use induction heater, no other heat windings) and remove.
source is suitable)
8. To withdraw the rotor from the stator the rotor must be
2. Slide the Bearing and Cartridge assembly over the supported by a rope at the drive end and eased out of
shaft, pushing it firmly against the bearing srating the stator core until half the main rotor is protruding out
shoulder. of the stator. At this point it is safe to release the
weight from the rope sling.
3. Rotate the assembly (including inner race) 45℃ in 9. Tightly bind a rope sling around the rotor core, and
either direction, to provide correct alignment. The supporting the non-drive end of the rotor, guide it clear
bearing must be held firmly in place until it is cool of the stator.
enough to positively self locate.
The rope sling may not be at the
centre of gravity of the rotor and
4. Non drive end only-fit circlip (single bearing only)and guidance at the ends of the rotor is
wave washer. essential. THE FULL WEIGHT OF
THE ROTOR GIVEN IN THE TABLE
BELOW MUST BE SUPPORTED BY
5. Fit the bearing cap. THE CRANE AND SLING. lf the
rotor core is allowed to drop more
Warning!
than a few millimetres at this pount,
6. Rotate the bearing assembly on the shaft to check for it will make contact with the stator
free mobement. windings and may damage them.
RE-ASSEMBLY IS A REVERSAL OF THE ABOVE
PROCEDURE.
Before assembly of a single bearing rotor into stator
housing check that the drive discs are not damaged or
cracked or showing any other signs of fatigue. Also check
that holes in the discs for drive fixing screws are not
elongated.

Damaged components must be replaced.

TWO BEARING MACHINES

NOTE:
Position rotor, if possible, such that a full pole face is at
bottom dead centre.

The procedure for removal of a two bearing rotor is similar

to that outlined for single bearing machines with the
exception of Steps 4 and 5 relating to the drive end adaptor.

For removal of this item proceed as follows :-

1. Remove the 8 bolts holding drive end adaptor to frame

and 4 bolts retaining bearing cartridge in drive end
bracket (outer 4 bolts), if fitted.

2. With rope sling around the shaft extension,supporting

the rotor weight tap the drive end bracket spigot out of
its locating recess and lower rotor assembly ro rest in
the stator bore.

3. Take the weight of the drive end bracket on the sling

and tap the bracket off the drive end bearing cartridge,
guide over the fan and remove.

Re-assembly is a reversal of the above procedure.

7.6 RETURNING TO SERVICE

After rectification of any faults found, remove all test
connections and reconnect all control system leads.
Restart the set and adjust VOLTS control potentiometer on
AVR by slowly turning clockwise until rated voltage is
obtained. Refit all terminal box covers/access covers and
reconnect heater supply.

Failure to refit all guards,

access covers and terminal
box covers can result in
personal injury or death.
 SECTION 8
SPARES AND AFTER SALES SERVICE

8.1 RECOMMENDED SPARES

Service parts are conveniently packaged for easy
identification. Genuine parts may be recognised by the
product brand on the packaging.

We recommend the following for Service and Maintenance,

ln critical applications a set of these service spares should
be held with the generator.

1. Diode Set (6 diodes with Surge Suppressors)

2. SX460, SX440, AS440, MX341, MX321 AVR
3. Kluber grease

When ordering parts the machine serial number or machine

identity number and type should be quoted, together with
the part description.

8.2 AFTER SALES SERVICE

A full technical advice and on-site service facility is available

from our Service Department at us or through our subsidiary
companies.

8.3 KLUBER ASONIC GHY72 GERASE

We recommends the use of this Ester Oil/Polyurea
grease. All bearing trials and calculated life expectancy
are based on the use GHY 72.
Kluber has a world-wide distribution network,contact the
manufacturers for your nearest stockist. Alternatively
supplies can be purchased from our parts department in
handy packages at advantageous rates.We also offer a
suitable grease dispenser.
29
 A.C. GENERATOR WARRANTY

WARRANTY PERIOD

In respect of a.c. generators the Wsrranty Period is eighteen months from the date when the goods
have been notified as ready for despatch by us or twelve months from the date of first commissioning
(whichever is the shorter period).
DEFECTS AFTER DEIVERY

We will make good by repair, or at our option by replacement, any fault that under proper use
appears in the goods within the warranty period. Provided. on exanination by us, the defrct is solely
due to defective material or workmanship. The defective part is to be promptly retumed, carriage paid,
to us at the factory, our Subsidiary of or, if appropriate to the Dealer who supplied the goods. All
identification marks and numbers must be intact to aid identification.

Any part repaired or replaced, under warranty, will be returned to the customer by us free of charge.
We shall not be liable for any expenses that may be incurred in removing or replacing any part sent to us for
inspection or in fitting any replacement part supplied by us.
We shall be under no liability for defects in any goods which have not been properly installed in accordance
with our recommended installation practices as detailed in the ‘lnstallation, Service and Maintenance
Manual’ . We shall be under no liability for defects on products that have been improperly used or stored or
which have been repaired, adjusted or altered by any person except our authorised agents or ourselves.
We shall not be liable for any second-hand goods, proprietary articles or goods not of our own manufacture
although supplied by us, such articles and goods being covered by the warranty (if any) given by the
manufacturers.

All claims must contain full particulars of the alleged defect, The description of the goods, the Serial Number,
the date of purchase, and the name and address of the Vendor, (as shown on the manufacturers
identification plate). For Spare Parts, claims must contain the order reference under which the goods were
supplied.

Our judgement, in all cases of claims, shall be final and conclusive and the claimant shall accept our decision
on all questions as to defecls and the exchange of a part or parts.

Our liability shall be fully discharged by either repair or replacement as above, and in any ebernt shall not
exceed the current list price of the defective goods.

Our liability under this clause shall be in lieu of any warrnty or condition implied by law as to the quality or
fitness for any particular purpose of the goods, and save as expressly provided in this clause we shall not be
under any liability, whether in contract, tort or otherwise, in respect of defects in goods delivered or for any
injury, damages or loss resulting from such defects or from any work undone in connection therewith.

Extensions to the warranty period can be purchased, subject to additional terms and conditions pertaining to
the specific application. Apply to our Warranty Department

MACHINE SERIAL NUMBER

30