Maintenance of

A.C Generators
 Maintenance - Requirements WHO
Me ?
SAFETY NOTICE !!

DANGER!
ELECTRIC SHOCK
[Live Terminals]

• 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.
 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
 Maintenance requirements - Bearings

CGT Generators are supplied with three types of bearing assembly :-

1. Manufacturers Sealed-for-Life Ball bearings :-
Standard on Frames P0/P1, BC16/18, and UC22/UC27, ranges.
Introduced as standard on frames HC4, HC5,
from July 1999.
Introduced on P7 (Single bearing Generators only), from April 2005.

2. CGT Non Regreasable Sealed Cartridge Assemblies.

Standard on Frame HC6
Standard on Frame HC7, up to March 1999.

3. CGT Regreasable Cartridge Assemblies.

Standard on frame HC7 from March 1999.
Standard on frames P7, (2 bearing), Frame 8, & P80.
Optional on Frame HC 5 & 6 from April 2000.

HC range, P7, & P80, 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.
 P0-P1, BC & UC Bearing Assembly

Frames P0/1, BC, and UC Ball Bearings are manufacturers sealed for life as standard.

Typical BC/UC Bearing housing Typical Sealed for Life Ball Bearing.
machined into Non-Drive End- Grease pre-packed & sealed with steel
bracket. reinforced synthetic rubber seal (2RS).
 HC, P7, F8, P80 Bearing Cartridge Assemblies

Typical regreasable Cartridge & Cap for HC7, P7,F8, Typical Bearing Cartridge for HC 6,
& P80, (shown with PMG Stator Housing ) with sealed bearings.

Regreasable Bearing Sealed Bearing

Wave Washer
Grease
Flinger

Cap Cap
Cap bolts Cap bolts

• Frames HC4,HC5 have manufacturer sealed bearings packed with Kluber Asonic
grease type GHY72. They are assembled directly into the Generator end-brackets.
• Frame HC6 have cartridge assemblies, with manufacturers sealed for life bearings.
• Frames HC7, P7, Frame 8,and P80, have regreasable cartridge assemblies, packed
with Kluber Asonic grease type GHY72.
• Regreasable bearings are optional on Frames HC5 and HC6.
• Relubrication details are available in the Generator Operation & Maintenance manuals.
 Maintenance requirements - Bearings

What are the symptoms of a Bearing problem?

Non drive INCREASED INCREASED INCREASED Drive end

end Bearing TEMPERATURE VIBRATION NOISE. Bearing
 Maintenance requirements - Bearings
What are the symptoms of a Bearing problem?
• Temperature rise in the bearing housing
Temperature monitoring is achieved with R.T.D’s, (fitted to bearing housing), or
alternatively, Laser Thermometer, (a portable hand held instrument).
Note: Local ambient temperatures around the
bearing should be taken into account.
• Vibration
Increased vibration in the Generator, suddenly, or slowly over a period of time.
Vibration test equipment can be expensive, regular checking by hand near the
bearing housing will establish normal levels over long periods of time.
Note: Increased vibration could also
indicate an engine related problem.
• Noise
Bearings making abnormal noises, audible, with or without Stethoscope.
A Stethoscope is required for elimination of all other possible causes of noise.
• Periodic health checks
Experience gained by touch and hearing in operation, will in time, establish ‘normal’
conditions, and help identify any future changes in temperature, noise, or vibration.
 Maintenance requirements - Bearings

Re-lubricated Bearings Frames HC7, P7, F8, & P80

(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
regreasable specification are available from CGT 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
 Maintenance requirements - Insulation checks

Winding Insulation levels should be checked if :-

• The Generator has been STATIONARY for a long period with Anti-
Condensation heaters SWITCHED OFF, e.g. Standby applications.

• The Generator has been subjected to high intake of water, snow, or ice.

• The Generator windings are contaminated with Airborne DUST and DIRT,
and have become DAMP ( through humidity and/or condensation).

• The Generator windings have become contaminated with airborne

corrosive elements, e.g. salt, (marine atmospheres), or corrosive elements,
(methane gas, petro-chemical sites, gassing from batteries etc).
 Maintenance requirements - Insulation checks
Insulation Resistance (IR) tests in order of importance :-

1. The Main Stator Winding DANGER!

ELECTRIC
Minimum value of Insulation should be 1 M to EARTH. SHOCK
(For Low voltage machines up to 690V).

2. The Exciter Stator Winding

This winding is exposed to 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.
 Maintenance requirements - Testing the Main Stator Insulation
Connections shown in Series Star
EARTH

AVR Sensing W6
& Power supply N U6V6 Neutral
00
100
10 1
MW
0.1
.01
from Main Stator 10
W5
6
W2 W W1

Test
V5
7
V2
V V1
3 Phase MW
1K
Output MW V500V
U5
8
U2
U U1

EARTH MEGGER
FRAME

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 Meg-Ohm
to Earth (Ground).
WINDINGS MUST BE DRIED OUT IF BELOW 1.0 MEG-OHM.
 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.
(Requires a standard 13 amp supply, Mains or portable Generator).

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
 Maintenance requirements - Drying the Main Stator Windings
METHOD 1. DRYING A STATIONARY GENERATOR

Domestic Supply
Or portable
Generator

• 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,(Min 1 Megohm).
 Maintenance requirements - Drying the Main Stator Windings
METHOD 2. SHORT CIRCUITING THE MAIN STATOR WINDINGS
Output From
Battery into - +
Exciter Stator 12vA.V.R
BATTERY

Exciter
X+ XX- Rotor Main Stator
& Stator

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).
 Maintenance requirements - Drying the Main Stator Windings
METHOD 2. SHORT CIRCUITING THE MAIN STATOR WINDINGS
EARTH

W6
N U6V6
Short Circuit Link
W5
6
W2 W W1

Clamp meter
V5
7
V2
V V1

S
U5

RM
8 U U1

UE
U2

TR
EARTH
FRAME

CHECK THAT THE AVR IS DISCONNECTED !

• Attach a SHORT CIRCUIT CABLE LINK to all 3 phases

NOTE: LINK MUST CARRY THE FULL LOAD RATED CURRENT.
• Attach a Clamp Meter to Short Circuit Link, capable of measuring FULL LOAD
AMPERES, (Alternatively use the Gen-Set instrument panel ammeters).
!
CAUTION!
CHECK ALL WIRING IS SECURE BEFORE RUNNING GENSET
 Maintenance requirements - Drying the Main Stator Windings
METHOD 2. SHORT CIRCUITING THE MAIN STATOR WINDINGS

Clamp meter Short Circuit Link

T
12 - 24 VOLT
BATTERY TO
EXCITER XX-
STATOR LEADS

X+

RUN ENGINE
- +
12-24v
BATTERY

• For effective drying, MINIMUM 70% FULL LOAD CURRENT is required.

• Add more Batteries to increase the short circuit current if necessary (12 -
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.
 Maintenance requirements - Drying the Main Stator Windings
SHORT CIRCUITING THE MAIN STATOR USING THE M.V.R
Clamp meter Short Circuit Link

NEWAGE INTERNATIONAL
XX- (F2)
MANUAL VOLTAGE REGULATOR
MVR-1 X+ (F1)
MODULE 450-11400
P To
T
4 Exciter
X XX P2 P3 P4 X
AVR GENERATOR
Stator
X XX P2 P3 P4 X XX P2 P3 P4
XX P2 P3 P4

º º º

PMG Power Supply

RUN ENGINE

• Switch the Manual Voltage Regulator to MANUAL control (Minimum setting).

• Slowly increase the Excitation current to achieve full load current
• Run for a minimum of 1 HOUR at full load current
• Check the insulation resistance - MINIMUM VALUE 1M to earth.
CAUTION: CURRENT MUST NOT BE HIGHER THAN RATED FULL LOAD !
 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 deposits, (salt

deposits or other chemical deposits), which immediately give a low IR
reading with condensation or high humidity.
 Maintenance requirements - Cleaning the Windings

• For removal of embedded dirt, grease, salts, hydrocarbons, and other chemicals from
the winding surfaces, WARM 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 NOT be used on or near

copper conductors.
 Maintenance requirements - Cleaning the Windings

• The windings should then be thoroughly WASHED with CLEAN WATER to remove all
traces of detergents.
• The windings must then be dried in an oven at approximately 100 to 110ºC for at
least 12 hours until the INSULATION RESISTANCE 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.
 Maintenance requirements - Health checks
Final Inspection before running Gen-set :-

2. MAIN
TERMINAL
1. AVR CONNECTIONS
CONNECTIONS

3. MAIN
RECTIFIER
COMPONENTS
 Maintenance requirements - Health checks

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, worn flexible couplings, or anti-vibration mounts.

• Periodic checks should be made to :-

1. AVR and accessory terminal connections, for corroded or loose joints.

2. Main Rectifier Diodes, should be cleaned or changed if badly corroded.
3. Main output terminals, look for loose or high resistance joints, (joints can be scanned
for ‘hot spots’ with a laser thermometer, (on load).
 Maintenance requirements - Health checks
D.C Excitation check on the Generator
RUN THE GENERATOR WITHOUT LOAD AT NOMINAL SPEED

RECORD THE D.C VOLTAGE ACROSS THE AVR TERMINALS X+ (F1) and X- (F2)

EXAMPLE :-

DATE FRAME S/N R.P.M VOLTS LOAD DC EXT.

MAY 2010 P734C C098765/1 1530 415 0 12.3

Keep this record in the Gen-set maintenance log book for future reference.
This Excitation figure should NOT CHANGE throughout the life of the Generator.
If the NO LOAD D.C Voltage becomes HIGHER, this is a possible indication of :-

1. LOW ENGINE SPEED, OR TERMINAL VOLTAGE TOO HIGH.

2. FAULTY MAIN RECTIFIER DIODE(S).
3. FAULTY EXCITER GENERATOR WINDINGS OR MAIN ROTOR WINDINGS.

THE NO-LOAD D.C VOLTAGE GIVES AN INDICATION OF GENERATOR HEALTH

THROUGHOUT THE LIFE OF THE GENERATOR.
RETURN TO MAIN MENU