INSTRUCTION MANUAL FOR BRUSHLESS GENERAIOR A.C.

TilODEL TWY

CONTENTS

lr 2t 3r 4t

rntroduc*'1o' contrrcsltlo' wlrlngMgthod operatlon 4-1 4-2

- - - - -......'........................... - - -.......................... ----..........................o...... . . o.........

Page 1 1 2 4 4

...----.................................. for operatlon ....................

a a a a a a a a a a a a a

Preparatlons Prgcautlons

. . . . . . . . . . . . . . o. . . . - . . o
--....o......--..o.....................

4 4

5.

tttalntgnance

5-1 5-2 6.

Routl.ng naLntgnance t{easurepent 'bf

........

...,..... reslsta.nce

.. ..
o a a a a a a a a

A ''

insulatlon

5 7 7 7 B B 10 10 10

Dlsasseobly 6-l 6-2 6-3 6-'{ 6-5 6 -6

and, Reasserubly ....

..........o....

Gengral prgcau.sloas ............................. urrcoupllng frooo the canpllag englne o....................

wlttr the englne ......................o ........................... ---.--o................... .' ....... o.... . . . . . . ..

Re'oovalof the rotor rasgrtlon of tbe rotor

R e p l a c e rn e n t of

ttre bearl ag

7t

Troubleshootlng 7-l 7-2

................................... table ...... oo.... o..... . .. . . . . .

Trorrbleghootlng Farrlt lnspectloa of the rotatlng

11 13

and replace.,eut rectlfler ........

o - .e o . . . . . . . . . .

I.

Introductlon This brt.ehlees AC Aenerator 1s a neuly developed generator v!.ttrout arose out of .Talyore long yeara of experlence ln ttre fleld. has excellent electrlcal a current ctraracterletlcs transfor:uer, because of vo'l tage reactor and seal-

bnrshee vhlch Tbe generator regrulatJ'ng conductors.

equlpoent

eoploytng

As a restrlt vlbraLlon wlttr

of d.lrect

consultatlon

on such mattere ttre slngle-bearlng

as torslonal geaerator 6et. has

the englne nanufacttrrer, to fo:ru a Mgtrly

beea deelgned

corDpact engtne-generator

2.

Cooposltlon

Flrst Secoad

coll colI Generator

C\rrrent Static

transfomer exciter

Reactor

ortpur fF-c=:rtJ'c reS.Iator voltage (ArrR)

Detectlo

lagrt

I .Porer latrrut

Aa c'n thle

bo Eeen ilr the ftgure elestrlc porer ls

abover sntrptled

rrhlch

sttons a baslc

cJ.rsult

of AC

geaeratorl vla

to the flrst voltage

rlndtng

of thc

exclter and the output

t-be reactor outFrt thc

b1z aeana of tba. regla:al le obtalDcd Aeaerator qrnent hrt ry excltatlon voltage

of ttre geaerator Tbi,s fleld vlndlng

ecclter establlshee

of tbe AC exclter. ttre generator tbe flret

bry exeltlug la a;r;rlledl

v1a ttre rotatlag 1g firrttrer exclted

rectlfler. by tla

t{trea tbe load tranefortrer 1n order

aad the voltage to lncrease

varlatJ'oa

duc to tttc load aectrracy,

ta coqlcrsatedr noltage

ttre voltage to 6ugpl

ttre geaerator

ta detected,

and the AVR o,peratei

tlre eecond vlndlng regrulated.

of tbe AC exclter ls deterrdaed to the

ao tJrat ttre voltage for d.lffereatlal vlnd{ng.

ls autoatJcally operatlon of the

The polarlty

aecondarlz wladlng

ln realrcct

flrst

-l-

3 . Wiring 225v

Methcd

-t
Generator

KCTt

E;

*r."r*.'u

Sr Sir

{: wire connectlon for only requlred For runnlng. parallel runnJ-ng, short olngle terro.inals /t and .I. For runnlng, lnrallel the shortrercve rrlre from clrcr:it teralrrals I and I.

I I
Single running

450v
SWICH

--t-

BOARD

-ll
;9i'h* lit+*

11,r
Siz 5z

l2

I AvR
i.h t<cz t

lb'

{: wire connectlon onIY for reqrrtred For nrnnlngparallel short nrnning, alngle S and .?- For ter:u.inals runn'lng, parallel Ehe shortrenove from wire cl-rcrrit I and !. rerminals

_t
Single nrnrling

.s
I

trloI ACB

t{o 2 ACB

tl

t'S-r
Parallel nrnnJ.ng

SyoboI
G

Deslgnatlon AC grenerator Fleld syetern of generator proper AC excltor

Synbof

DcslgnatJ.on C\rrzent Reastor AutmatJc voltago regrutator traneforoer

cr
n3
A\IR

E E:( ELr2 S1lr2

TIT Exclter Slllcon fleld eystern cqf rec-elf1e.r

Rheosta,t for Curren

cu:rent

voltagre adjustocnt

co{qpnqat.l.orr czoss-current

srr2r3

SlC varletor (51lletor;

ccR

for fl,esl'ator c@pJaaaLion

4.

Operatlon 4-1 Preparatlong for operatlon la to bc operated after ruJclng after etoppt ng for a long

When ttre generator perlodl belw: (11 Clean the lnslde dltt, operate lC only

tlre chccks ln the seqfuence glven

and outslde &oplets. parts

of the generator

anld, remove all reslstanrce

o11 and sater

Masure .the insulation and ground wlth I UQ (refer

betseea confln If

the con&rcting that lt

a 500 V meggrer and 5-21. and use

le Eoro than ls less

to section

t.be reelstance after

than 1 MOe dry ttre generator reslstance or nuts ls more than I tlfl. ln the varlous

only (2)

the lnnrlatlon

Check that geacrator the rotatbg also loose.

none of the boltg (especlally rectlfler pa:it8

parts

of

the

dlrectly coupled uith the engine and 'are loose or have fallen out and lnrta) te.:rmlnals of the "*ai" exciter tre not

that, tbe corurectlon Tlgbtea lf

necessary.

A:?

Precautlong The srrrroundlng areas of clear ttre grenerator cooling If the inlet obstructed, air inlet and becomes

outlet clogged effests

Eust

be kept

and clean.

or outlet

or tbc florr

of the coot-J-ng a1r ls drop { '' accldeats to avold

the coollng ttre teuq>erature br:rning cl:rn- g o

l.n the grenerator rdll and lt could resrrlt

rnd, as a result,

v111 rlge

guch as coll

So, sgrcclal.

care raust be taken

thlg.

5.

Mal-atenance 5-1 Routlne I rna ntenance at lts best' lt ls necessary lt to

For any type of roactrlrre to perforu understand, carefrilly. Slnce elecrlc equlgncot lt le hon to trandlc'tbe machlne

correcily

and ahrays rnalntaln

adversely cleah.

susceptlble

to nolsture, tbe geuerator,

o11 vapqtr and dust, u.Be a drlz clotb. parts rltJr clotbg

nlrst be kept

t{hen eleanlng

ac especJ'ally rhlcb are rct

careful or olly. tor or

not to wlpe any conductlng

whe9,-:u^slng coqqrresscd alr preaaure sufflc1catly Slnce of about 2 atuoapheres beforehand

cleenlng, lesg. blon

uss acryressed

a1r at a of the p1ps to use. 1s ao need

Clean the laslde a1r through AC generatorl prlor there

and alrays

tb,ls nacblne le a h^ehless tbe bnrsbes.

to check or mrlntaln

-4-

T h e ro u tl n e (I, (2) ( 3) ( 4l

p o l n ts

arc

aa fol l ove: and clernlng ln of the exterior

Normal Inspectlon ttonitsorlng ltonitorlng llonitorlng Parts of

any changea

vlbrationa

teeperature any abnormal

rlsee sounds or overheating 1n the bearJ.ng

Fe

However, perLod or

when the

generator moistrrre

has not been operated conditlons the

for

a long of the

ts

shen adverse

such as the penetrat.ion reslstance. after If

trat.e.r have occurred, resiet.nce reslstance

always belos

aeastrre

insrrlation and use olly

has dropped has again case to of the

I I.{Q, &y I Hfl. is

che insuLat.ion

rlsen bearirg

above used

ft"

f:
t

In necessary used is

an opened 1500 trours is not

baII

bearing, If

it

is tlte bearirtg

repfenish ball

grse bearing,

eveq/ it

operationto

an sealed

necessary

add grrease-

fc:

t
i
lr.

5-2

HeasurerDent of when measuring

insr-rlatioa the

reelstince reslst:,:rcee terz-lrrals ln us a 500 V megger. (R, S, T, excl,ter, the than O, J, viEh K, a Jc,

insulacion the

Flrst, Kc) ttr-ln for

connect

toget.her

corurection generator the

lea<i vires wire,

frorn the

ttre stat.ic betveen ls tlre lees

bare

aod Eeasure If

reslsta,nce

connected I HQ, 4lscomect and divide ProPr grouP using to

terrntna,Is atl t}le lead

and grorrndwlres froro parts Connect the

the

r:eeist!.nce inslde

geaerator tro

st^a,tic of ttre

exclter generator of each

conducting

Jlto

gfoups, the

those

and ot$ers.

togcttrer

conductlng

parts

tc

a ttr-tn

rra,ked vlre, vhlch the tban

and neasrrre of area parts of

tJre insulatJ.on 1s causlng

reslstantce

t,o ground &op.

determlne Ascertaln of less

group faulty

tJre lnsuLatlon wlth

t}re

parts

group

lastrlati.on

resista.nce

I y.fl and repalr. the lnsulatloa of reslstaace 'wlth a Dgger? (Sl) Elteays respectlvely

t{hen -eagurlng corurect vlth together bare the

terralnals for

the L\IR and rectlfler devlce oot done, for

a ttr1n

con&rctor

each unltatT If thls ls

short-ctrcrrltlng

-919. tben nJ.ght

perforu

'reasurenent's.

t'tre se.ro,lconductors

bc d.--ged-

N0.
I

nane port VentiLation Part B all bearing

cover

N0. cover

L2

nane Armature coil Part Armatr:re Field coil Cl amper

Field core

13 I4 15
( n=) (nt)

co re

3
4

Bearilg

Bearing Armature Armature

shield co iL core (n-)

5
6

L6

t7
I8 I9 N 2L

PoIe copper plate Drip-pr.oof cover

7
B 9
10 11

Fie1d coiJ-

Fiera. cbre
Silicon Self-erc
Frame

( u.)

Ad.aptor ring Fan and coupli-rrg boss

Shaf t

rectifier it er

6.

Dlsassenbly 6-1 (1) General Before to

and Reassembly precautlong d.lsagsenbly and aseembly, froo. etudy ttre the greneral 6l rnq ln of respecl the

dlsassenbly

and assembly

gectlonal

&awlng

gienerator. (2, t{hen d'lsassembly efflclency and asseubly 1s perforrned Ls a posslbllty by one EEn, the of serlous rrrnags

1g lorr and ttrere Thereforel

to ttre nachlnery. vorkers. (3)

Lt ls best to have trro or nore

Place the d'lsassenbled cover it ge carefirl coee into rslth a sheet that contact the the

rotor of vlnyl

oa ir base, etc. resla, rqd fleld obJect-s. a clotb

and be aqre to uat, etc. do not

aruature ottrer

vl.naLngrsl tc.

wlth rotor,

(4)

ntren rercrrlng rotor

uake sure'that so tbat

the axes of both the do not colrrc lnto a:.e eads, contact be

a'rd stator

are aligFed surfaces sort

both

contact.

SLnce the

of botb ends of the rotor for clanplng portlons the coil, lnto

bound wl'th a special carefirl rrith 6-2 to avold

of tape

brlngrlng

tbe tape-borrnd

the stator. frou ttre engiine geaerator of the rotc h-no bearlng on the drlven vhea ttre

Uncoqrltng Becausg th.

slngle-bearlag

alde'

there

ls tbe poss{blllty fro ttre eagtae .tbe corprrlg t-te

fallrng

dmanards

tmc'ot4lltng gtator, forer'' (lt -

and, of danagc belng boea,

carured to ttre rotor,

th.e fan,

and the fra:ne (or adapter).

There-

-for. . dlsaeseoblyr Reowe the venlllatloa

.the,fouorlhg:groce&rre: port cover e on tbe sl.de. surface on ttre

(2'

Fit

the rotor

locking

supporters

securely

between the fan

and.

@ (nef er to the d.rawilg

coupli.ng boss

(3t
(4)

Renove the bolts Renorre the bolts Eoist-up

(s)

(o" dapter ring @ @. for attaphong the r.otor locking supporto"s. ) connectitra: the flyrdreel e'i. the fan and. coupling b holdi.g the foot part of the generator propro

and the frane

so that it is suspend.ed. slightly above the mountin errrfa,ce ( so as to arlow the rlnere to be d.rann out) r and remove the complete generator rotor from the f lyn1eel using the jack screw of the coupring boes. The rots loct<lng aqEqrters arc guplrrted as accessorrles.

the generator

Note:

Support"r ( z)

Supporter (f)

Fan arrd. ooupling

lrA

Section

Hclu to

attach

the

rotor

loctclng

suplrcrters

6-3

Coupllng Follos

wlth the

ttre

englne sequence of. the sltb disassenbly the rotor procedure locklng (or Ln 6-2supporters adapter), le

revera

Wben coupllngr flxed ln place then lnport

perfo::a ttre

ghg rprk cot4rllng

betveen

bose and the

fra:ae

and, rercve especlally lngert lu 6-4 the

whe:r ttre .nt for ths

vork the feet

1a coopleted. elngle-bearlng to rercve

Accurate generator.

lnstallatlon lf

nece66ary, by unevenneaa

}lne.rs

under

atry tlltlng

caused

base' surface. of vhea the rotor tble touch .rrcrk, lbe be Errre thlt etttor as vaa t'he rotor meatloned o:r the ln 6-1-

Rerrcval Flrat,

perfonalng do Dot

taie-bound Perfom 1. Rovo rcve lt tho

trrcrtlon^s vprk the

1n tJte follovlag generator vork fro the

sequencs: eaglne by the urethod glven ln bZ and

Lo the

locatlon.

-B-

2.

port cover O on the non-driven end, the bearlng cover (outer 'aLdet ana tne bearlng shJ.elC f" thar e @
order. =Slnce therc ls a lnselblllty of the rotor falllng dotrnwar& yhen and causlng the bearlng tben gently shleld darnage to the rotor sbleld lorer or et^ator of the eC exclter lt by hotstlng helght lt

Rercve thc ventllatlon

la removed, rerbve lt.

utrnard and

(The aplgot, Jolnt tdatd

of the bearlng

lg 3 m. ) slonly the driven slde using the remo'raI

3.

PulI

out ttre rotor shaft

aurlllary dlagran. )

so aa to keep balance.

(Refer to the rotor

Tape-bound portion

Pull

out slowly

^b^xillary

couplJng

I
trt

Ew to prrll

ont

tbe rotor

6-5

Insertlon

of

the

rotor rotorr aequence tsake the to

When lnsertlng Follw rotor. Before rotor 6-6 rrlth insertlonr a clean of the

the

sane precautions in 6-4 for

reverse

as in 6-4. _ of the

that

lnsertlon

ulpe

off

any dustr

ol1,

etc.

on any part

of

the

cloth. the bearing

Replacement

( Refer After 1n 6-4' 1. 2. 3. 4. 5.

to the detalr renoval

drarring

of the bearlng generator

pulrer. frane

) by the method sequence:

of the rotor

from the

replace

the bearlng @. ptrlrer nut

in accordance nith

the folroulng

Rerove the lock F1t the bearing

on the non-drlven end bearing O O. of the bearing puller wlth the center of shafa . rf the handle is turned srwry, the bearing c.u) O * reuroved. tt'hen attachlng a nery bearbg, place an iron plpe on. the side surface of the bearlng irurer rlng a-nd tap in Lightly wlth a hanoer. contact the handle

Detall 7. Troubleehootlag The bnr-strless transforner, a'nd eince deslgned fw fanltg grenerator

of the bearlng

ptrller

coaslste

br a rotatlng

rectlfler,

reactore there

c,urre't part6, etc. r

aGslatorge

capocltors, electrlcal all

eealcoadrrctor pa'ts

are no s't1d{ng lt

so that arlse'

caa wlttrstand Hwever, lf

condltjons

a farrlt

polnts:

has been whlch ntght, arlsee vert ehorrrd occrrrl check the follonlng -

arrd eacb part

i0

7-l

Troubleshootlng

table

Cond.ltlon

Cause -" 1. abnor-nal rotatlon 2. Deflclency resl,dual drop l'n epeed of voltage 2 . Apply

Cotnterueasures 1. Ralse to ttre rated a 24 V battery J, for K lnslde forced speed.

1 . tlo voltage
or too lov

voltage

to

the

temlnals excLter

ure statlc

of AC exclter 3. Tlghtenlng conductor fastening ' .l-s fatrlty. or ln

4.

excltatlon. of the parts bolts ) and

of

3 . Chects tbe tlghtaess conductor fastenlng teraLnal required. ( especlally t.ighteu if

parts

4. Broken ylre short clrcrrit

Check wlnding resLstance Decess&-]r,

insulatlon and lf or rwlnd. connected a voltage voltage is

and

values relni.r

wiadr ags 5. Faulty A\tR

5 . Rsve

tbe cable

to hlgher

tb A\nfr a'ld if th-l t.be rated

obtalaed, Replace lt

ttre aVn 1s faulty. rdth a nery orre. ls obtalned,, (J, K)

t*ren no voJ'tage rercve

tbe lead rrlres ln

frool tJre generator occiter, operate

ttre statLc

tbe generator

at tbe Eated rotatloa sgeed, and meanrbJ.l'e a5p1y a 12 V battery to tbe lead wlres exclte voltage forclbly. le obtalaed there (J K) to If a proper under s:trch

condltloalBo la.ttrc statlc 6. Patrlty exc1ter (1) Brokea rdre reactor la etatlc

are Do faulte or A\lR. The

Areaerator exclter

le far:lty.

(1) t-hc..k and retrnlr rdtb a Der oae.

or replace

11

Condltlon

Cauee

Countermeaaures or (2, Check and repalr ulth a n4 one. or replaee

(2, Broken ulre ehort clrc.trlt

rect'lfler (4) Broken vlre ehort wlrlng exclter 7. Faulty rec*.lfler rotating
7.

oll

or ln

(4) Check and repalr.

clrcrrlt

l-n statJc

Renove the a'rd Eeasure a tester. the fo::nard in

rectifler the If

elements with ln

reslstance resistance ls

the

directl.on the the reverse

De.ur O dlrectlon is

and tlut 1s infinlte, no::ual. rectlfler wlth

rectifier the

If is

othe.rwlse, faulty.

Replace

1t

a Derr one.

2. Voltage too hlgh. (Voltage does not drop rbea

ls

1 . Abnorually rotatlng

htgh qrced

I.

T,ovet apeed.

to

the

rated

rotatlon

2 . PeuJ.ty eeeood ' vlndlng ln cl.rorlt

even AVR

AC erclter statlc

Faulty ercl.ter (1)

voltagre regrulatlng lcnob ls trnned glde.l to

Brokea rlre short clrctrlt

or

(1) Clreck a Dgr

repal-r

or replace

wlth

1n aul!.J'ary cl'rqrtt (R, S, T,

decrceaslng

O, Jc, Kc) 1.tr etatlc exclter

12

Cond:lt1on

Cauea (21 Broken short second of Its (Jc, vlre clrcrrlt rlnd.lng or or ln

Countemeaaurell

(21 Check and repalr ulth a nsr one.

or replace

AC excl.ter lead Jl c) wlres

3.

Generated voltage unstable. ls

I. (1)

A\IR faulty Loose screffs connectlo 1n parts At/R

1. (1)

Replace TJ.ghten.

slth

a new orr o

(2t

Faulty

(21 Replace

AtfR with

a nefl oDe.

C--plng 4. ebnonal sound or

I

cirqrlt
(1) Check anrd replace bearing *ith the grease or

(1) Greaee deteriorated (2) .aearlng or inner outer balls or

a new onr the bearlng

teoperaturq rlse ln

(21 Check a^nd replace rdttr a Dew oDe.

bearlng.'

rlng

danaged 5. Abnorrnal vlbrat'lon occlxra la ( 1) coupllng faultfz (2) Generator lnstall^atioa faulty (3) Statjc exclter (3) Cbeck anrd,re1n1r. (21 Cbeck rnd repalr.
(f) Check and

retrn1'r.

generator or itatlc erclter.

tnstall^atloa taulty

7'2

elle

fusgecr|{dr

adt-replac@t ek rectlfler

of t}re rotatlng eleoeot-r port

rectlfler

Ia lnspectlo rectlfler, traD-c{pllng flrst eud.

of the

of ttre rotatlng ou ttre slde of ( 3 rlree the )

reloovc tbo veotllatlon thco dlaconnect (2 vlrce)

cover

ttre ac sldg fro tbc

lead rlres vhlcb

and DC gldo lead vlreg the rectlfler of eletaeate,

occlgar

ar conDest,ed to tbe terulrr.ts belov. Le near

anrd,toaasur ttre reglstaace vlth a testet

betreen

eacb rectlfylag

cleoeat

ar ehorg ln ttra flg1rc dlrectloa

There 1s no probleo

1t the reglgtaace

ln tbe forrard

13

zero and.Chat. ln the reverse are otlrenrlse, slth there

ls

dlrectlon and the

ls

lnfinlty,

but

lf

the

values

a fault

recilfler

must b replaced

a neu ort o
l{hen lnstalllng the rectlfler when the ele.srentse ele,,,ents torque it are of ls lmportants tlght,1 not the to

tlghten ereoents sultable.

thea

excesslvely.

coo

n111 be dartaged,.

A tj.ghtenrng

aboqt

40 kg-cm

1s

Condqct|ng

rlng

C\rrrqrt

dlrectloa

n
;*{
of the reslsta-Dce ln the tester ln the reslstanee over reverge tera.lnals srltch bettreen

Note:

Thle forard

dravlng

shor.s

rneasureo,ent t{tren tbe

d.lrectlon. le

dltectlon A rqd B.

meagurede

14

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