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PI Manufacturing AC generators - page 1
Installation, Service & Maintenance Manual AC generators with the following for prefixes: UCI; UCM; UCD 224 & 274 . ...
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PI Manufacturing AC generators - page 2
SAFETY PRECAUTIONS Before operating the generating set, read the generating set operation manua l and this generator manual and become familiar with it and the equipment. SAFE AND EF FICIENT OPERAT ION CAN ONLY BE ACHIEVED IF THE EQUIPMENT IS CORRECTLY OPERATED AND MA INTAINED. Many accidents occur because of failure to follow fundamental rules and ...
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PI Manufacturing AC generators - page 3
FOREWORD The function of this book is to prov ide the user of the Stamford 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 ...
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PI Manufacturing AC generators - page 4
CONTENTS SAFETY PRECAUTIONS FOREWORD 1 CONTENTS 2&3 SECTION 1 INTRODUCTION 4 1.1 INTRODUCTION 4 1.2 DESIGNATION 4 1.3 SERIAL NUMBER LOCATION AND IDENTITY NUMBER LOCATION 4 1.4 RATING PLATE AND CE MARKING 4 SECTION 2 PRINCIPLE OF OPERATION 5 2.1 SELF-EXCITED AVR CONTROLLED GENERATORS 5 2.2 PERMANENT MAGNET GENERATOR (PMG) EXCITED - AVR CONTROLLE ...
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PI Manufacturing AC generators - page 5
CONTENTS SECTION 6 ACCESSORIES 17 6.1 REMOTE VOLTAGE ADJUST (ALL AVR TYPES) 17 6.2 PARALLEL OPERATION 17 6.2.1 DROOP 17 6.2.1.1 SETTING PROCEDURE 18 6.2.2 ASTATIC CONTROL 18 6.3 MANUAL VOLTAGE REGULATOR (MVR) - MX341 and MX 3 2 1 AV R 18 6.4 OVERVOLTAGE DE-EXCITATION BREAKER SX421 a nd MX321 AVR 18 6.4.1 RESETTING THE BREAKER 19 6.5 CURRENT LI MIT ...
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PI Manufacturing AC generators - page 6
SECTION 1 INTRODUCTION 1.1 INTRODUCTION The UC22/27 range of generators is of brushless rotating field design, available up to 660V/50Hz (1500 rpm) or 60Hz (1800 rpm), and built to meet BS5000 Part 3 and international standards. All the UC22/27 range are self-e xcited with excitation power derived from the main output windings, using either the SX4 ...
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PI Manufacturing AC generators - page 7
SECTION 2 PRINCIPLE OF OPERATI ON 2.1 SELF-EXCITED AVR CONTROLLED The main stator provides power for excitation of the exciter field via the SX460 (SX44 0 or SX421) AVR which is the controlling device governing the leve l of excitation provided to the exciter field. The AVR responds to a voltage sensing signal derived from the main stator winding. ...
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PI Manufacturing AC generators - page 8
SECTION 3 APPLICATION OF THE GENERATOR The generator is supplied as a component part for installation in a generating set. It is not, ther efore, practicable to fit all the necessary warning/hazard labels during ge nerator manufacture. The additional labels required are packaged with this Manual, together with a drawing identifying their locations. ...
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PI Manufacturing AC generators - page 9
In standby applications where the running time is limited and reduced life expectancy is accepted, higher levels than specified in BS5000 can be tolerated, up to a maximum of 18mm/sec. Two bearing generators open coupled require a substantial bedplate with engine/generator mounting pads to ensu re a good base for accurate alignment . Close coupling ...
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PI Manufacturing AC generators - page 10
SECTION 4 INSTALLATION - PART 1 4.1 LIFTING Incorrect lifting or inadequate lifting capacity can result in severe personal injury or equipment damage. MINIMUM LIFTING CA PA CITY REQUIRED IS 750Kg. Generator lifting lugs should NOT be used for lifting the complete generator se t. Two lifting lugs are provided for use with a shackle and pin type lift ...
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PI Manufacturing AC generators - page 11
4.2.2 TWO BEARING GENERATORS A flexible coupling should be fitted and aligned in accordance with the coupling manufacturer's instruction. If a close coupling adaptor is used the alignment of machine d faces must be checked by offering the generator up to the eng ine. Shim the generator feet if necessary. Ensure adaptor guards are fitted a fter ...
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PI Manufacturing AC generators - page 12
4.4.2 DIRECTION OF ROTATION The generator is supplied to give a phase sequence of U V W with the generator running clockwise looking a t the drive end (unless otherwise specified at the time of ordering). If th e gener ator ph ase rotati on has to b e reversed after the generator has been despatched apply to factory for appr op riat e wir ing diag ...
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PI Manufacturing AC generators - page 13
4.4.4.4 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 . 4 for locati on of setting links. 1. Frequenc y selectio n terminal s 50Hz o perati on LI NK 2-3 60Hz o perati on LI NK 1-3 2. Stability select ion terminals Frame UC22 ...
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PI Manufacturing AC generators - page 14
4.4.5 TRANSFORMER CONTROLLED EXCITATION SYSTEM (Series 5) This control system is identi fied with the dig it 5 as the last digit of the frame size quo ted on the nameplate. The excitation control is factory set for the specific voltage shown on the nameplate and requires no adjustment. 4.5 GENERATOR SET TESTING Duri ng te sting it may b e ne cessar ...
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PI Manufacturing AC generators - page 15
4.7 LOAD TESTING During testing it may be necessary to remove covers to adjust controls exposing 'live' terminals or components. Only personne l qualified to perf orm electrical service should carry out testing and/or adjustments. Refit all access covers after adjustments are completed. 4.7.1 AVR CONTROLLED GENERATORS – AVR ADJUST MENT ...
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PI Manufacturing AC generators - page 16
4.7.1.2 EXC TRIP (Excitation Trip) AVR T ypes M X341 and MX32 1 An AVR supplied from a permanent magnet generator inherently delivers maximum excitation power on a line to line or line to neutral short circuit or large overload. In order to protect the generator windings th e AVR incorporates an over excitation circuit whic h detect s high excitati ...
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PI Manufacturing AC generators - page 17
4.7.1.5 RAMP AVR Type MX321 The RAMP potentiometer enables adjustment of the time taken for the generator's initial build up to normal rated voltage during each start and run up to speed. The potentiome ter is factory set to gi ve a ramp time of three seconds, which is considered to be suitable for most applications. This time can be reduced t ...
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PI Manufacturing AC generators - page 18
SECTION 5 INSTALLATION - PART 2 5.1 GENERAL The extent of site installation will depend upo n the generating set build, e.g. if the g enerator is installed in a canopied set with integral switchboards and circuit breaker, on s ite installation will be limited to connecting up the site load to the generating set output terminals . In this case refer ...
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PI Manufacturing AC generators - page 19
SECTION 6 ACCESSORIES Generator control accessories may be fitted, as an optio n, in the generator terminal box. 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. The following matrix indicates availab ...
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PI Manufacturing AC generators - page 20
Generally 5% droop at full load curre nt zero p.f. is sufficient to ensur e kVAr shari ng. 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 commissio ning. The following setting procedure wil ...
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PI Manufacturing AC generators - page 21
6.4.1 RESETTING THE BREAKER In the event of operation of the circuit breaker, indicated by loss of generator outp ut voltage, manual resetting is required. When in the "tripped" state the circuit breaker switch lever shows "OFF". To reset move the switch lever to the position showing "ON". When fitted in the generator, ...
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PI Manufacturing AC generators - page 22
Stop the generating set. Remove the link between terminals K1-K2 at the auxili ary termi nal block and connec t a 5A switc h across the terminals K1-K2. Turn the "I/LIMIT" control potentiometer fully anticlockwise. Short circuit the stator windin g with a bolted 3 phase short at the main terminals. An AC current clip-on a mmeter is requ i ...
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PI Manufacturing AC generators - page 23
SECTION 7 SERVICE AND MAINTENANCE As part of routine maintenance procedures, periodic attention to winding condition (particularly when generators have been idle for a long period) and bearings is recommended. (Refer to subsections 7.1 and 7.2 respectively). When generators are fitted with air filters regular inspection and filter maintenance is re ...
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PI Manufacturing AC generators - page 24
It is possible that simply running the gen set unexcited – AVR terminals K1 K2 open circuit - for a period of say 10 minutes will sufficiently dr y the surface of the winding s and raise the IR sufficiently, to greater than 1.0 M Ω , and so allow the unit to be put into ser v ice. ...
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PI Manufacturing AC generators - page 25
Blow n Air D rying Remove the covers from all apertures to allow the escape of the water-laden air. During drying, air must be able to flow freely through the generator in order to carry off the moisture. Direct hot air from two electrical fan heaters of around 1 – 3 kW into the generator air inlet apertures. Ensure the heat source is at least 30 ...
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PI Manufacturing AC generators - page 26
Ground V and W phase and megger U phase to ground Ground U and W phase and megger V phase to ground Ground U and V phase and megger W phase to ground If the minimum value of 1.0M Ω is not obtained, drying out must be continued and the test rep eated. 7.2 BEARINGS All bearings are supplied sealed for life and are, therefore, not regreasable. Import ...
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PI Manufacturing AC generators - page 27
7.4.2 SX440 AVR - FAULT FINDING No voltage build-up when starting set 1. Check link K1-K2 on auxiliary terminals. 2. Check speed 3. Check residual voltage. Refer to subsection 7.4.7. 4. Foll ow Sepa rate Exci tation Tes t Procedure to check generator and AVR. Refer to su bsection 7.5. Unstable voltage either on no-load or with load 1. Check spee d ...
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PI Manufacturing AC generators - page 28
7.4.5 MX341 AVR - FAUL T FINDING No voltage build-up when starting set 1. Check link K1-K2 on auxiliary terminals 2. Foll ow Sepa rate Exci tation Tes t Procedure to check machine and AVR. Refer to su bsection 7.5. Loss of voltage when set runninig 1. First sto p and resta rt set. If no voltage or voltage collapses after short time, follow Separate ...
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PI Manufacturing AC generators - page 29
7.4.7 RESIDUAL VOLTAGE CHECK This procedure is applicable to generators with either SX46 0 or SX440 or SX421 AVR. With the generator set stationary remove AVR access cover and leads X and XX from the AVR. Start the set and measure voltage across AVR terminals 7-8 on SX460 AVR or P2-P3 on SX440 or SX421 AVR. Stop the set, and replace leads X and XX ...
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PI Manufacturing AC generators - page 30
Rectifier Diodes The diodes on the main rectifier assembly can be checked with a multimeter. The flexible leads connected to each diode should be disconnected at the terminal end, and the forward and reverse resistance checked. A healthy dio de will indicate a very high resistance (infinity) in the reverse direction, and a low resistance in the for ...
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PI Manufacturing AC generators - page 31
3. Set the AVR VOLT S control potentiometer full y clockwise. 4. Connect a 12V, 1.0A DC supply to the exciter field leads X & XX (F1 & F2) with X (F1) to the positive. 5. Start th e generating set and run at rated speed. 6. Check that the generator output voltage is within +/-1 0% of rated voltage. Voltages at AVR terminals 7-8 on SX460 AVR ...
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PI Manufacturing AC generators - page 32
The bearing(s) are a press fit a nd can be removed from the shaft with 3 leg or 2 leg manual or hydraulic bea ring pullers. SINGLE BEARING ONLY : Before trying to pull off the bearing remov e the small circ lip ret aining it. When fitting new bearings use a bearing heater to expand the bearing before fitting to the shaft. Tap the bearing into place ...
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PI Manufacturing AC generators - page 33
Damaged or worn components must be replaced. When major components have been replaced, ensure that all cov ers and guar ds ar e secur ely f itte d, be fore th e generator is put into service. 7.6 RETURNING TO SERVICE After rectif ication of a ny faults f ound, rem ove all test connections and reconnect all control system lea ds. Restart the set an ...
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PI Manufacturing AC generators - page 34
SECTION 8 SPARES AND AFTER SALES SERVICE 8.1 RECOMMENDED SPARES Service parts are conveniently pa ckaged for easy identification. Genuine parts may be recognised by the Nupart name. We recommend the following for Service and Maintenance. In critical applications a set of these service spares should be held with the generator. AVR Controlled Generat ...
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PI Manufacturing AC generators - page 35
PARTS LIST TYPICAL SIN GLE BEARIN G GENERATOR Plate Ref. Descr i ption 1 Stator 2 Rotor 3 Exc iter Rotor 4 Exciter Stat or 5 N.D.E. Bracket 6 Cover N.D.E. 7 Bearing ‘O’ Ring N.D. E. 8 Bearing N.D.E. 9 Bearing Circlip N.D. E. 10 D.E. Bracket/Engine Adaptor 11 D.E. Screen 12 Coupling Disc 13 Couplimg Bolt 14 Foot 15 F rame Cover Bottom 16 F rame ...
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PI Manufacturing AC generators - page 36
Fig. 11. TYPICAL SIN GLE BEARIN G GENERATOR ...
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PI Manufacturing AC generators - page 37
PARTS LIST TYPICAL TWO BEARI NG GENERATOR Plate Ref. Descrip tion 1 Stator 2 Rotor 3 Exciter Rotor 4 Exciter Stator 5 N.D.E. Bracket 6 Cover N.D.E . 7 Bearing ‘O’ Ring N.D.E. 8 Bearing N.D.E. 9 Bearing Wave Washer.D.E. 10 D.E. Bracket 11 D.E. Screen 12 Bearing D.E. 13 14 Foot 15 Frame Cover Bottom 16 Frame Cover Top 17 Air Inlet Co ver 18 Termi ...
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PI Manufacturing AC generators - page 38
Fig. 12. TYPICAL TWO BEARI NG GENERATOR ...
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PI Manufacturing AC generators - page 39
PARTS LIST TYPICAL TWO BEARING (SERIES 5) GENERATOR Plate Ref. Descri ption 1 Stat or 2 Rotor 3 Exciter Rotor 4 Exciter S tator 5 N.D.E. Bracket 6 Cover N.D.E. 7 Bearing ‘O’ Ring N.D.E. 8 Bearing N.D.E. 9 Bearing Wav e Washer N.D.E. 10 D.E. Bracket 11 D.E. Screen 12 Bearing D.E. 13 14 Foot 15 Frame Cover Bottom 16 Frame Cover Top 17 Air Inle t ...
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PI Manufacturing AC generators - page 40
Fig. 13. TYPICAL TWO BEARING (SERIES 5) GENERATOR ...
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PI Manufacturing AC generators - page 41
Fig. 14. ROTATING RECTIFIER ASSEMBLY ...
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PI Manufacturing AC generators - page 42
A.C. GENERAT OR WARRANTY WA RRA NTY P ER IO D A. C. G e ne r at o rs I n respect of a.c. g enerators the Warran ty Period is eighteen mon ths from the date when the goods have been notified as ready for despatch by N.I. or twelve months from th e date of first commission in g (whichever is the shorte r period). DEFECTS AFTER DELIVERY We will make g ...
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PI Manufacturing AC generators - page 43
REGISTERED OFF ICE AND ADDRESS: BARNACK ROAD STAMFORD LINCOLNSHIRE PE9 2NB ENGLAND Telephone: 44 (0) 1780 484000 Fax: 44 (0) 1780 484100 SUBSIDIARY COMPANIES 1. AUSTR ALI A : N EW AG E EN GINE ERS P TY. LI MITE D PO Box 6027, Baulkham Hills Business Centre, Baulkham Hills NSW 2153. Telephone: Sydney (61) 2 9680 2299 Fax: (61) 2 9680 1545 2. CHINA: ...
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