Installation, Service and Maintenance Manual For STAMFORD P80 Generators LVSI804, MVSI804, HVSI804, LVSM804 Original Instructions
SAFETY PRECAUTIONS Before operating the generating set, read the generating set operation manual and the AvK ‘Installation Service & Maintenance Manual’ (supplied with the generator) and become familiar with them and the equipment. This guide is in no way a replacement for internationally recognized standards for installations of such equipment and should be reviewed as an addition to such literature.
CONTENTS SAFETY PRECAUTIONS ......................................................................................................................... ii FOREWORD ............................................................................................................................................. 1 Standards. ............................................................................................................................................. 1 European Directives. ..............................
MV generator stators .................................................................................................................... 31 HV generator stators .................................................................................................................... 31 Drying out procedure ................................................................................................................... 32 7.2. Fault finding .......................................................................
FOREWORD The function of this book is to provide the user of the AvK generator with an understanding of the principles of operation, the criteria for which the generator has been designed, and the installation and maintenance procedures. Specific areas where the lack of care or use of incorrect procedures could lead to equipment damage and / or personal injury are highlighted with WARNING and / or CAUTION notes.
The generator is CE marked; CE labels are supplied loose in case the generating set manufacturer needs to paint the generating set before delivery to the end user. Note: Once the generator is build into a generating-set (machinery), it is the responsibility of the generating-set manufacture to ensure that the generating-set complies with the relevant EC Directives.
• • • • Road transport (auxiliary power) Industrial vehicle (earthmoving, cranes etc.) Fixed installation (Industrial – factory / process plant) Fixed installation (residential, commercial and light industrial – home / office / health.) Energy management (combined heat & power and/or peak lopping.) Alternative energy schemes. The standard generators are designed to meet the ‘industrial’ emissions and immunity standards.
1. Introduction P80 – Low Voltage (LV) The LV range of generators is of brushless rotating field design, available up to 1000 V/50 Hz (1500 rpm, 4 pole) and 1000 V/60 Hz (1800 rpm, 4 pole) and built to meet BSEN 60034-1, BS5000 Part 3 and other appropriate international standards P80 – Medium Voltage (MV) The MV range of generators is of brushless rotating field design, available up to 3.
1.2. Serial number designation Each generator has its own unique serial number stamped into the upper section of the frames driveend end plate. Inside the terminal box two adhesive labels have been fixed, each carrying the generators unique identity numbers. One label has been fixed to the inside of the terminal box sheet metal work, and the second label fixed to the saddle, supporting the terminal box. 1.3.
2. Principle of Operation The permanent magnet generator provides power for excitation of the exciter field via the AVR which is the controlling device governing the level of excitation provided to the exciter field. The AVR responds to a voltage sensing signal derived, usually via the isolating transformer, from the main stator winding.
3. Application of the Generator Warning Labels Warning labels are affixed to the generator. These must be visible at all times. As we expect the set builder to paint the generator in his own livery, a second set of labels can be found in a wallet attached to the generator. Use the labels as per the instructions printed on the reverse of the labels.
The ambient conditions in which a generator is operated or stored should be fully understood, to ensure the generator is maintained in a fully serviceable condition. Areas for consideration include temperature, humidity and even vibration levels. Temperatures should be stable, but if combined with high humidity levels, anti-condensation heaters should be connected to a suitable single phase mains supply.
Note: The manufacturer will not be held responsible for equipment failure due to incorrect specification at time of order. The reader should consider, if the above recommendations are not complied with, the effect on bearing / grease life will be a considerable reduction. These effects are illustrated graphically in figure 3-3.
Important! Reduction in cooling air flow or inadequate protection to the generator can result in damage and / or failure of windings. If air filters are fitted, a differential pressure switch or alarm must be fitted to limit changes in air flow or pressure. Dynamic balancing of the generator rotor assembly has been carried out 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.
The standard build terminal box arrangement is for cable entry into the left hand side of the terminal box when viewed from generator D. E. Cable entry from the right hand side is possible if specified at the time of order. The terminal box is constructed with a removable panel for easy adaptation to suit specific glanding requirements. Within the terminal box there are insulated terminals for line and neutral connections and provision for earthing. The neutral is NOT connected to the frame.
4. Installation – Part 1 4.1. Lifting Warning! Incorrect lifting can result in severe personal injury or equipment damage. Lifting capacity required for complete generator is 10 tonnes. See data sheets for weights of individual lifts. Generator lifting lugs should not be used for lifting the complete generating set. Four lifting lugs are provided for use with a shackle and pin type lifting aid in conjunction with a spreader bar. Chains of suitable length and lifting capacity must be used.
4.2. Installation with engine (factory / on site) Before the generator can be installed, suitable mounting conditions must first exist. Failure to comply with the following will result in structural damage to the generator and premature bearing failure. The following guidelines must be observed: • There must be an adequate foundation under genset taking into consideration sub-soil conditions loading thereon.
type of bearing is shorter that a standard ball bearing. Automatic re-greasing equipment can also be purchased from your local distributor. Note: Failure to comply with these recommendations may void warranty claims. Open coupled sets require a suitable guard, to be provided by the set builder. Caution! Incorrect guarding and / or generator alignment can result in personal injury and / or equipment damage. 4.2.2. Single bearing machines 4.2.2.1.
• Tighten coupling disc to flywheel bolts. Refer to engine manual for torque setting of disc to flywheel bolts. • Replace covers. Check for excessive vibration at the time of initial run-up. Note: Failure to comply with these recommendations may void warranty claims. Incorrect guarding and / or generator alignment can result in personal injury and / or equipment damage. Danger! 4.3. Earthing The generator frame should be solidly bonded to the generating set bedplate.
4.4. Pre-running checks Caution! Refer to local regulation to ensure that the correct earthing procedure has been followed. 4.4.1. Insulation checks Before starting the generating set after completing assembly, test the insulation resistance of the main stator windings. It should be noted that as winding temperature increases values of insulation resistance will significantly reduce. Therefore true values of insulation resistance should be established with windings at ambient temperatures.
4.4.1.3. HV generators A 5000V motorised megger or similar instrument should be used. Separate the three neutral leads, ground V an dW leads and megger U to ground. Repeat for V phase with U and W grounded and W phase with U and V grounded. The 1 minute insulation resistance for each phase should not be less than 300 MΩ and the polarisation index should be in the order of 2 or greater at 20 ºC.
The load cable termination should be placed on top of the winding lead termination and clamped between the two nuts provided, as in figure 4-2. Note: For torque setting value, see Maintenance Manual section 1. Figure 4-2 4.6. Accessories If 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.
5. Insulation – Part 2 5.1. General The extent of site installation will depend upon the generating set build, e.g. if the generator is installed in a canopied set with integral switchboards and circuit breaker, on site installation will be limited to connecting up the site load to the generating set output terminals. In this case reference should be made to the generating set manufacturer’s instruction book and any pertinent local regulations.
LV generators: 1000V motorised instrument MV generators: 2500V motorised instrument HV generators: 5000V motorised instrument The measured insulation resistance should be above the value stated in Table 5-1 taken at 1 minute. GENERATOR TYPE LV MV HV 10 Meg Ohms 100 Meg Ohms 300 Meg Ohms Table 5-1 If these values cannot be achieved the windings should be dried out as detailed in the Service and Maintenance section of this manual.
Figure 5-3 5.2.2. Connections on LV generators When making connections directly on to the busbars, the incoming cable termination should be made by directly placing the palm of the lug either on the top or bottom surface of the busbar. The screws used should be M12 grade 8.8 and tightened to a torque of 80 Nm. Note: Figure 5-4 shows a two hole lug termination on top of the busbar, but terminations can be made top / bottom with one or two hole lugs (the torque setting remains the same).
5.3. Earthing The neutral of the generator is not bonded to the generator frame as supplied from the factory. An earth terminal is provided inside the terminal box adjacent to the main terminals. Should it be required to operate with the neutral earthed a substantial earth conductor (normally equivalent to one half of the section of a line conductor) must be connected between the neutral and the earth terminal inside the terminal box.
Generator output terminals can be offered in an arrangement to suit the fitting of specific DIFFERENTIAL PROTECTION current transformers supplied by your local distributor. This requirement should be specified at time of order. 5.5. Commissioning Ensure that all external cabling is correct, permits adequate movement and that all the generating set manufacturer’s pre-running checks have been carried out before starting the set.
T1 = ∆T + (40 – T ambient max.) + 5 (ºC) T1 = Alarm setting (ºC) ∆T = Stator temperature rise (ºC) (Actual RTD value – ambient temperature) T ambient max. = Maximum site ambient temperature (ºC) Note: The maximum site ambient temperature is not necessarily the temperature at the time of setting.
6. Accessories 6.1. General Generator control accessories may be fitted, as an option. If fitted at the time of supply, the wiring diagram(s) in the back of this book shows the connections. When the options are supplied separately, fitting instructions are provided with the accessory. Available accessories for generator mounting are as follows: • Quadrature droop current transformer; • VAr/PF controller and associate current transformers; • Fault level limiting current transformers.
Reference should be made to the generating set manufacturer’s instructions for setting the governor controls. 6.2. Droop The most commonly used method of kVAr sharing is to create a generator voltage characteristic which falls with decreasing power factor (increasing kVAr). This is achieved with a current transformer (CT) which provides a signal dependent on current phase angle (i.e. power factor) to the AVR.
If the droop accessory has been supplied with the generator it will have been tested to ensure correct polarity and set to a nominal level of droop. The final level of droop will be set during generating set commissioning. Setting procedure Depending upon available load, the following settings should be used – all are based on rated current level. Power factor Load 0.
The unit monitors the power factor of the generator current and adjusts excitation to maintain the power factor constant. This mode can also be used to control the power factor of the mains if the point of current monitoring is moved to the mains cables. Refer to the factory for appropriate details. It is also possible to operate the unit to control kVAr of the generator if required. Refer to the factory for appropriate details. 6.4.
7. Service and Maintenance Warning! Service and fault finding procedures present hazards which can result in severe personal injury or death. Only competent personnel qualified to perform electrical and mechanical service, and who are familiar with the systems to be worked on, should carry out these procedures. Ensure all prime mover starting circuits are disabled and that any source of potential energy is isolated and locked out before commencing service or maintenance procedures.
Caution! The AVR plus any voltage transformers should be disconnected. Any temperature detector devices (RTDs / Thermistors) should be disconnected and grounded during the test. Refer to the generator winding diagram for details. Important! The windings have been HV tested during manufacture and further HV testing may degrade the insulation with consequent reduction in operating life.
LV generator stators A 1000V megger or similar instrument should be used. Disconnect any earthing conductor connected between neutral and earth and megger an output lead terminal U, V or W to earth. Minimum acceptable limits after 1 minute for the total winding are: New machine In-service machine 10 MΩ 5 MΩ Should the insulation resistance be less than specified, the winding must be dried out as below. MV generator stators A 2500V motorised megger or similar instrument should be used.
Short stator terminals to earth with an earthing rod after IR and HV testing, for at least 5 minutes to discharge windings. Danger! Drying out procedure This should only be undertaken by qualified experience personnel. Danger! Drying out may be carried out by directing warm air from a fan heater or similar apparatus into the generator air inlets and / or outlets. Caution – take care not to scorch or over heat the windings by applying a high localised heat source.
Example: A main stator winding at an initial temperature of 20 ºC will take a minimum of 12 hours to rise to 90 ºC and then could take a further 24 to 48 hours to complete the drying process satisfactorily. During drying, the resistance should be measured at regular intervals, typically every 15 minutes and a graph plotted of insulation resistance against time. The shape of the resulting curve will be similar to figure 1-1 below.
To check the main terminal voltages, suitable equipment must be used by trained, competent personnel who are familiar with the generator construction and design. Danger! Important! Before commencing any fault finding procedures, shut the generating plant down, ensure full isolation, lock off and system earthing has been completed, then inspect all termination points an cables for broken, loose or disturbed connections.
7.3. Fault finding procedure Important! Before commencing physical inspection procedures, shut the generating plant down, ensure full isolation, lock off and system earthing has been completed. Inspect all termination points and cables for broken, loose or disturbed connections. If the cause of the generator problem cannot be easily identified, a basic check of the generators major components should be undertaken.
Residual balanced sensing terminal voltages If all voltages are balanced within 1% at leads 6-7-8 it can be assumed that all exciter windings, main windings, main rotating diodes and the isolation sensing transformer are in good order. A separate excitation test may now prove useful to confirm condition of main component assemblies.
Never allow the generator output terminal voltage to exceed the rated (nameplate) voltage. Do not exceed the rated excitation voltage. Do not exceed the rated excitation voltage or current. To check the main terminal voltages, suitable equipment must be used by trained, competent personnel who are familiar with the generator construction and design. Danger! On MV and HV machines a matched set of high voltage potential dividers and associated instruments must be used.
The transformer winding resistances should be measured. These should be balanced and be in line with the values stated in the MPT. If there is any doubt about condition of transformer a replacement should be fitted and the separate excitation test repeated to establish balanced – correct voltage levels on leads 6-7-8. Refer to factory for further advice.
Surge suppressor The surge suppressor consists of a matched pair of metal-oxide varistors connect across the two rotating rectifier plates. They are designed to prevent high transient reverse voltages, generated in the main rotor winding, from damaging the rotating diodes. These devices are not polarised and will show virtually infinite readings in both directions if checked with an ordinary resistance meter. If defective it will be visible by inspection. Inspect both devices for signs of disintegration.
Disconnect the main cables and separate the three neutral winding leads or open the delta connection. Measure each phase, resistance-values should be balanced and within ± 10% of the value given in the MPT. Stator winding resistances may vary if the generator windings have been designed for a specific application. The factory can be consulted for confirmed winding resistances. Measure insulation resistance of all phases as previously described under Winding condition – section 1.1.
correct voltage is present. Leads P2, P3 and P4 are connected to AVR and previous tests have established the correct voltage is present. Note: Do not run the machine without the terminal box lid fully bolted in place. During this test RATED VOLTAGE will exist at the generator main terminals. Ensure terminal box cover is fully bolted in place. Warning! Connect a voltmeter to measure output terminal voltage L-L. Turn the AVR “volts” potentiometer fully clockwise.
Danger! Important! When lifting single bearing generators, care is needed to ensure the generator frame is kept in the horizontal plane. The rotor is free to move in the frame and can slide out if not correctly lifted. Incorrect lifting can cause serious personal injury. The following procedures assume that the generator has been removed from the generating set. On single bearing generators before removal from the engine, refit the transport plate under the fan hub.
assembled with the correct amount of grease. Provision has been made for the bearings to be regreased with a grease gun. It is important that the bearing assembly is never overfilled with grease. An information label has been fitted to the generator adjacent to each bearing with information regarding grease quantities and re-lubrication time periods.
This grease can be recognised by its whitish-beige colour and its stiff consistency. It has been chosen for its superior lubricating properties under arduous conditions, and to provide the bearing with these lubricating characteristics this grease must not be mixed with any other type. It is important that the correct quantity of grease is used for the initial fill for new bearings, and for periodic re-lubrication with a grease gun during planned maintenance.
Two bearing designs Important! The end bracket removal MUST be undertaken in the following order: 1. The drive end (DE) bracket must not be removed unless the non drive end NDE bracket has first been removed. 2. Before disassembly commences, all tooling that comes into contact with greased parts must be thoroughly cleaned. Figure 1-2 shows the NDE arrangement.
Note: If the bearing(s) are seized and the shaft will not rotate, fit two packer tools that will support the bottom two poles. Since the rear feet are attached to the NDE bracket, the machine must be supported using either Stamford tooling or a suitable support must be placed under the stator core with a bridge plate over both landing bars (avoid the landing bar overhangs). Next, bolt the Stamford shaft extension tooling to the end of the rotor.
Equipment: A steel stub shaft which is located off the NDE of the shaft / bearing cartridge. A thick walled steel tube that will support the rotor and reach through the complete length of the machine A ‘Vee’ shaped roller assembly, mounted within a cradle securely fitted to the top of a jack. A hoist / crane and sling cable of taking the full weight of the rotor. Note: Rotor loadings are available from the factory. Procedure: 1.
Note: When re-tightening fasteners the following torque settings must be used: Figure 1-3 Fastener Tightening Torque Values Reference (Figure 1-3)) Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 NDE bracket (to landing bar) – M24 DE bracket (to landing bar) – M24 Bearing carrier / adapter ring – M24 Feet fixing – M24 Coupling disc to hub – M30 Fan fixing – M10 Balance weight - M10 NDE bearing cartridge – M10 NDE bearing cap – M10 DE bearing cartridge – M10 DE bearing cap – M10 Side panels / base pl
Single bearing coupling plates Before assembly of a single bearing rotor into stator housing, check that the drive discs are not damaged, cracked or showing any other signs of fatigue, and that the holes in the discs are not elongated. Damaged components must be replaced. The number of coupling discs required and the tightening torque for discs to coupling hub are detailed in Table 1-3. Number of discs Thickness of each disc (mm) Total thickness of combined plates (mm) Bolt size 10 1.
LV804 Parameters Frame Size L-L AC Volts Freq.
MV804 Parameters Frame Size L-L AC Volts Freq. Hz Typical Residual AC Voltages Term’ls Main L-L 6,7,8 Term’ls Transformer Primary Winding Ohms 20 C Transformer Secondary Winding Ohms 20 C Exciter Stator Winding Ohms 20 C Exciter Rotor Winding L-L Ohms 20 C Main Rotor Winding Ohms 20 C Main Stator L-N Ohms 20 C PMG Stator Winding Ohms 20 C Refer to Factory Refer to Factory 17.5 0.075 1.32 0.0338 2.7 MV804R kV 3.3 50 35 500 Normal AC Voltage on Terminals 6,7,8 190-250 MV804S 4.16 3.
HV804 Parameters Frame Size HV804R HV804S HV804T HV804W HV804X L-L AC Volts Freq. Hz kV 6.0 6.6 10 11 7.2 13.8 6.0 6.6 10 11 7.2 13.8 6.0 6.6 10 11 7.2 13.8 6.0 6.6 10 11 7.2 13.8 6.0 6.6 10 11 7.2 13.
3. Spares and after sales service 7.7. Recommended spares Service parts are conveniently packaged for easy identification. We recommend the following for service and maintenance. In critical applications a set of these service spares should be held with the generator. 1. Diode set (6 diodes with surge suppressors). FRAME 8 RSK6001 MA330 AVR E000 – 13300 or third part AVR manufacturer Bearings R.S.T. CORES W.X.
PARTS LIST TYPICAL P80 SINGLE BEARING GENERATOR Plate Ref.
TYPICAL P80 SINGLE BEARING GENERATOR Figure 2-1 55 P80_MAN_EN_04
PARTS LIST TYPICAL LV8 TWO BEARING GENERATOR 22 Plate Ref.
TYPICAL P80 TWO BEARING GENERATOR Figure 2-2 57 P80_MAN_EN_04
TYPICAL P80 GENERATOR LV TERMINAL BOX Figure 2-3 58 P80_MAN_EN_04
PARTS LIST TYPICAL LV80 TERMINAL BOX Plate Ref.
TYPICAL P80 GENERATOR MV / HV TERMINAL BOX Figure 2-4 60 P80_MAN_EN_04
PARTS LIST TYPICAL MV / HV80 TERMINAL BOX 27 Plate Ref.
LV8 ROTATING RECTIFIER ASSEMBLY Figure 2-5 62 P80_MAN_EN_04
PARTS LIST TYPICAL MV / HV80 TERMINAL BOX Plate Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 Description Rectifier Hub Rectifier Fin Diode Lead Assembly (Forward) Diode Lead Assembly (Reverse) Varistor Assembly Hexagonal Head Screw S.C. Lock washer Plain Washer Hex Nut S.C. Lock washer Plain Washer CH.HD. Screw Through Stud Assembly Qty 1 2 3 2 2 4 4 4 17 15 21 1 1 1. A rectifier assembly must comprise diodes from one manufacturer only. 2.
Appendix 1 In the event of a bearing failure for the cause to be correctly determined, the following information must be provided (fill in the boxes). Ref Information required for bearing failure assessment: Yes / No Comment / Values Items that may / can be determined off site: 1 What is the machine serial number? 2 What is the generator application e.g. marine, industrial, dock-side crane, etc.
15 What is the coupling stiffness / rubber hardness at the time of failure? (Shore hardness). 16 For sets including gear box / gas turbine / steam turbine was a hot / cold alignment procedure followed? If so, what? 17 Remove bolts at the FW housing interface and measure and record the gap at the top and bottom and side to side at the interface. This will allow the machine to move within the clearance of the spigot if there is misalignment. For this disengagement of spigot is necessary.
28 Condition of the (NDE) wave washer? Can be obtained without major machine disassembly. 29 Condition of the bearing cartridge NDE ‘O’ ring. Need to pull bearing to inspect for fretting corrosion. 30 Has the correct specification grease been used for re-lubrication? (Check colour and consistency. Have they got any on site? 31 Is there any evidence of contamination in the most recently applied lubricant (colour, dark particles, etc.
measuring points (limit = 18 mm/s rms)? Horizontal and vertical at bearing location. 42 What are the NDE vibration levels at the ISO measuring points (limit = 18 mm/s rms)? Horizontal and vertical at bearing location.
56 For marine installations, please provide details of the ships mounting structure (stiffness). 57 On spark ignition engines is the spark plug earthing path independent of the alternator? 58 Is there any evidence of bending on skid members for indication of excessive force during transportation or installation? (Especially cross members or beams which have most bending moment). Note: This is not an exhaustive list of factors so please add other relevant information.
Appendix 2 Bearing assembly specification Pre-assembly preparation: Environment: Assembly of all bearings must occur in a clean area free from static / airborne dirt. All tooling should be stored and used in the ‘clean area’. Equipment: • • • • • • • • Pre-assembly cleaning: Note: Gloves must be worn at all times when handling the bearings, grease and solvent. 1. Wipe clean the anti-static assembly surface, using solvent on lint free cloth. 2.
Assemble bearing into cartridge: Assemble bearing onto shaft: Bearing cartridge: 1. With greased face of the bearing facing the cartridge bore, assemble the bearing into the bearing housing. Ensure the bearing outer race contacts the location shoulder. Note: Only the outer race should be used to transmit load during assembly (NEVER use the inner race). 2. Apply half the specified bearing grease fill quantity (see Table A-4) to the free volume of the bearing. 3.
Initial fill for P80 bearings – Kluber Asonic GHY72 Grease Fill Quantity Bearing Designation Cage type Cartridge cm 3 Bearing gram cm 3 Cap gram cm 3 Total gram cm 3 gram 6324 C3 Pressed Steel 170 151 340 302 170 151 680 604 6232 C3 Pressed Steel 136 121 272 242 136 121 544 484 6236 C3 Pressed Steel 195 173 391 348 195 391 781 694 Table A-4 Cummins Copyright 2009 8 P80-MAN-E-2
Appendix 3 Tooling for spares: Description Tool No.
8. End of Life Disposal Companies, specialising in reclaiming material from scrap products can reclaim most of the iron, steel and copper from the generator. Recyclable material Mechanically separate the base materials, iron, copper and steel, removing paint, polyester resin, and insulation tape and/or plastics residues from all components. Dispose of this ‘waste material’ The iron, steel and copper can now be recycled. Items requiring specialist treatment.
AC GENERATOR WARRANTY AC Generators In respect of AC generators, the Warranty period is eighteen months from the date when the first goods have been notified as ready for despatch by the Company or twelve months from the date of first commissioning (whichever is the shorter period).
Head Office Address: Barnack Road Stamford Lincolnshire, PE9 2NB United Kingdom Tel: +44 (0) 1780 484000 Fax: +44 (0) 1780 484100 www.cumminsgeneratortechnologies.com Copyright 2009, Cummins Generator Technologies Ltd, All Rights Reserved Stamford and AvK are registered trade marks of Cummins Generator Technologies Ltd Cummins and the Cummins logo are registered trade marks of Cummins Inc.
