TJ-311-03 EDG Alternator.pdf

T9311-BC-OMI-010

TECHNICAL MANUAL

OPERATION AND MAINTENANCE

INSTRUCTIONS FOR

GENERATOR,EMERGENCY

KATO 150KW

MANUFACTURED BY

KATO ENGINEERING

DIV. OF RELIANCE ELECTRIC

2075 HOWARD DR.

MONKATO, MN 56001

N00024-89-C-2079

HALTER MARINE INC.

T-AGS 51/52 CLASS

DISTRIBUTION: LIMITED TO U.S. GOVERNMENT AGENCIES ONLY: REQUESTS FOR

THIS DOCUMENT MUST BE REFERRED TO COMMANDER, MILITARY SEALIFT COM

MAND, WASHINGTON, DC 20390.

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS

RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC.) OR

EXECUTIVE ORDER 12470. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT

TO SEVERE CRIMINAL PENALTIES.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DIS

CLOSURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT.

PUBLISHED BY DIRECTION OF COMMANDER, MILITARY SEALIFT COMMAND

.11-BC-OMI-Ol0

I FOR OFFICIAL USE ONLY

-0910-LP-440-3300-

T9311-8C-OMI-010

TECHNICAL MANUAL

OPERATION AND MAINTENANCE

INSTRUCTIONS FOR

GENERATOR,EMERGENCY

KATO 150KW

MANUFACTURED BY

KATO ENGINEERING

DIV. OF RELIANCE ELECTRIC

2075 HOWARD DR.

MONKATO, MN 56001

N00024-89-C-2079

HALTER MARINE INC.

T-AGS 51/52 CLASS

DISTRIBUTION: LIMITED TO U.S. GOVERNMENT AGENCIES ONLY: REQUESTS FOR

THIS DOCUMENT MUST BE REFERRED TO COMMANDER, MILITARY SEALIFT COM

MAND, WASHINGTON, DC 20390.

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS

RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC.) OR

EXECUTIVE ORDER 12470. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT

TO SEVERE CRIMINAL PENALTIES.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DIS

CLOSURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT.

PUBLISHED BY DIRECTION OF COMMANDER, MILITARY SEALIFT COMMAND

ell-BC-OMI-OlO

1 MAY 1991

I FOR OFFICIAL USE ONLY

LIST OF EFFECTIVE PAGES INSERT LATEST CHANGED PAGES· DESTROY SUPERSEDED PAGES.

A

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to Illustrations are Indicated by miniature pointing hands.

Changes to wiring diagrams are indicated by shaded areas.

Date(s) Of Original And Change Pages Are:

Original .. . 0 . .. 1 MAY 1991

Total Number Of Pages In This Publication Is 123. Consisting Of The Following:

Page No. . . . . . Chg No.· Page No. .... Chg No: Page No. . . . . . Chg No:

A Record of Change . . 0 APR Page Validation Cert . . 0 Foreword . . 0 Warranty . . . 0 i-xiii 1-1-1-1. ..0 2-1-2-10 .. 0 3-1 - 3-14 .. 0 4-1 - 4-2 . . . 0 5-1-5-10 .. 0 6-1 - 6-31 .. 0 7-1 - 7-7 . . . 0 8-1 - 8-27 . 0 A-1 - A2. . . 0

• ZERO IN THIS COLUMN INDICATES AN ORIGINAL PAGE.

T9311-BC-OMI-OlO

• RECORD OF CHANGES

Change No. Date TItle Or Brief Description Entered By

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: T9311-BC-OMI-010

TITLE OF MANUAL: GENERATOR, EMERGENCY KATO 150KW

APPROVAL AUTHORITY: SUPERVISOR OF SHIPBUILDING, PASCAGOULA, MS 39567

CONTRACT NO. APPLICABILITY aTY BUILDING YARD

N00024-89-C-2079 T-AGS 51/52 2 HALTER MARINE

REMARKS:

CERTIFICATION DATE: 'L-b -eZ

IT IS HEREBY CERTIFIED THAT T9311-BC-OMI-01 0 TO BE PROVIDED UNDER CONTRACT

NUMBER N00024-89-C-2079 HAS BEEN APPROVED BY THE APPROVAL AUTHORITY

SHOWN ABOVE.

HALTER MARINE

• TECHNICAL MANUAL VALIDATION CERTIFICATE

NAVSEA 4160/3 (4-82)

TECHNICAL MANUAL TITLE: GENERATOR, EMERGENCY KATO 150KW

EQUIPMENT NAME:

NAVSEA TECHNICAL MANUAL NUMBER: DATE:

T9311-BC-OMI-010 1 MAY 1991

CONTRACTrrMCR NO.:

N00024-89-C-2079

I· VALIDATION

Except as stated in II, the technical manual identified above has been satisfactorily validated in accordance with all requirements of the ap plicable TMCR and the approved Validation Plan. The technical manual is hereby certified to be accurate and complete, and the information, instructions, text, and illustrations conform in all respects to the applicable general and detailed specifications.

II· EXCEPTIONS

EXCEPTIONS AUTHORIZED BY

~IGNA'liURE OF ~!JJ3L1CA'!10~~ITY ASSURANCE OFFICER:

~ /.9fk: /. r-

T9311-BC-OMI-01O

FOREWORD

This Technical Manual is intended to provide operation, maintenance and repair infor mation for the Generator, Emergency Kato IS0KW. The manual contains descriptive and functional information, operating instructions and maintenance and repair instruc tions for this system. This manual is one volume subdivided into the following chap ters:

CHAPTER 1 - GENERAL INFORMATION AND SAFETY PRECAUTIONS

CHAPTER 2 - OPERATION

CHAPTER 3 - FUNCfIONAL DESCRIPTION

CHAPTER 4 - SCHEDULED MAINTENANCE

CHAPTER S - TROUBLESHOOTING

CHAPTER 6 - CORRECTIVE MAINTENANCE

CHAPTER 7 - ILLUSTRATED PARTS BREAKDOWN

CHAPTER 8 - INSTALLATION

Ships, training activities, supply points, depots, Naval Shipyards, and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of NA VSEA technical manuals. All errors, omissions, discrepancies and suggestions for improvement to NA VSEA technical manuals shall be reported to Commanding Officer, Naval Ship Weapon Systems Engineering Station (Code SHOO), Port Hueneme, CA 93043 on NA VSEA Technical Manual DeficiencylEvaluation Report, Form NA VSEA 9086/10. To facilitate such reporting, three copies of Form 9086/10 are included at the end of this technical manual. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting therefrom.

Extra copies of NA VSEA Form 9086/10 may be requisitioned from the Naval Publi cations and Forms Center, Philadelphia, PA 19120 .

T931l-BC-OMI-OlO

• TABLE OF CONTENTS

CHAPTER~ARAGRAPH TITLE PAGE NO.

1 GENERAL INFORMATION AND SAFETY PRECAUTIONS ........ 1-1

1-1 INTRODUCTION .......................... 1-1

1-1.1 GENERAL INFORMATION .................... 1-1

1-1.2 SAFETY PRECAUTIONS ...................... 1-1

1-2 EQUIPMENT DESCRIPTION .................... 1-2

2 OPERATION .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2 GENERATOR OPERATION .................... 2-1

2-2.1 PRE-STARTINSPECTION ..................... 2-1

2-2.2 IDLING ................................ 2-1

2-2.3 FIELD FLASHING . . . . . . . . . . . . . ............. 2-2

2-2.4 VOLTAGE ADJUSTMENTS (VOLTAGE REGULATION) .... 2-2

2-2.4.1 SYSTEM START-UP ........................ 2-2

2-2.4.2 FREQUENCY ROLL-OFF ADJUSTMENT ............. 2-2

2-2.4.3 STABILITY ADJUSTMENT .................... 2-3 • 2-2.4.4 VOLTAGE ADJUSTMENT ..................... 2-3

2-2.4.5 OPERATIONAL TEST ....................... 2-3

2-2.5 CURRENT BOOST SYSTEM . . . . . . . . . . . . . . . . . . . .2-4

2-2.6 ELECTRONIC MANUAL VOLTAGE CONTROL ......... 2-4

2-3 STARTING GENERATOR FOR SINGLE UNIT OPERATION .. 2-5

2-4 PARALLEL OPERATION . . . . . . . . . . . . . . . . . . . . . .2-6

2-4.1 PRIME MOVER GOVERNOR ........ ........... 2-6

2-4.2 VOLTAGE REGULATOR PARALLELING PROVISIONS .... 2-6

2-4.3 SYNCHROSCOPE OR SYNCHRONIZING LIGHTS .......2-6

2-4.4 METERING .............................2-6

2-4.5 AUTOMATIC/MANUAL CONTROL DURING

PARALLEL OPERATION . . . . . . . . . . . . . . . . . . . . . . 2-7

2-4.6 PHASE ROTATION .........................2-7

2-4.7 PRE-PARAIJ FLING ADJUSTMENTS AND CHECKS . . . . . . 2-7

2-4.8 PARALLELING ........................... 2-8

2-4.9 SHUTTING DOWN ONE OR MORE GENERATORS

OPERATING PARAIJ FL ...................... 2-9

• 2-5 OVEREXCITATION SHUTDOWN ................. 2-9

T9311-BC-OMJ-01O

TABLE OF CONTENTS (Cont'd)

CHAPTERIPARAGRAPH TITLE PAGE NO.

3 FUNCTIONAL DESCRIPTION ........................ 3-1

3-1 3-2 3-2.1

3-2.2

3-2.2.1

3-2.2.2

3-2.2.3 3-2.2.4 3-2.2.5 3-2.2.6 3-2.2.7 3-2.2.8 3-3

3-3.1

3-3.2 3-3.3

3-4

3-4.1 3-4.2

3-4.3

3-4.4 3-4.4.1

3-4.4.2

3-4.5

3-5

3-5.1 3-5.2 3-5.3 3-5.4

INTRODUCTION .......................... 3-1

GENERAL ............................... 3-1

PRINCIPLES OF OPERA nON .. , . . . . . . . . . . . . . . . .3-1

MECHANICAL CONSTRUCTION . . . . . . . . . . . . . . . . .3-4

GENERATOR FRAME AND STATOR . . . . . . . . . . ..... 3-4

GENERATOR FRAME COVER .................. 3-4

GENERATOR ROTOR ASSEMBLY. . . . . . . . . . . . . . . . 3-4

EXCITER ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

EXCITER FIELD ASSEMBLY ................... 3-7

END BELL .............................. 3-7

ADAPTER .............................. 3-8

TERMINAL BOX .......................... 3-8

BASLER ELECTRIC MODEL APR 63-5 VOLTAGE

REGULATOR ............................ 3-8

GENERAL .............................. 3-8

SPECIFICATIONS .......................... 3-8

OVEREXCITA TION SHUTDOWN . . . . . . . . . . . . . . . . .3-9

BASLER ELECTRIC MODEL CBS 305 CURRENT

BOOST SYSTEM ..........................3-9

GENERAL DESCRIPTION .....................3-9

CURRENT BOOST MODULE DESCRIPTION ......... 3-10

CURRENT TRANSFORMER DESCRIPTION ., ........ 3-11

SPECIFICATIONS ......................... 3-11

ELECTRICAL SPECIFICATIONS ................ 3-11

PHYSICAL SPECIFICATIONS .................. 3-12

TIME DELAY RELAY (OPTIONAL) . . . . . . . . . . . . . . . 3-12

BASLER ELECTRIC MODEL MVC-300 ELECTRONIC

MANUAL VOLTAGE CONTROL ................ 3-13

GENERAL ............................. 3-13

OVERALL DESCRIPTION ..................... 3-13

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

PRINCIPLES OF OPERATION .................. 3-13

4 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 GENERATOR INSPECTION .................... 4-1

ii

T9311-BC-OMJ-OlO

• TABLE OF CONTENTS (Cont'd)

CHAPTER~ARAGRAPH TITLE PAGE NO.

4-2.1 GENERATOR CLEANING ..................... 4-2

4-3 VOLTAGE REGULATOR ...................... 4-2

4-4 ELECfRONIC MANUAL VOLTAGE CONTROL ......... 4-2

4-5 CURRENT BOOST MODULE ...................4-2

5 TROUBLESHOOTING............................. 5-1

5-1 INTRODUCTION ..........................5-1

5-2 GENERATOR ............................5-1

5-2.1 GENERAL .............................. 5-1

5-2.2 TROUBLESHOOTING PROCEDURE ...............5-1

5-2.2.1 NO VOLTAGE ............................ 5-2

5-2.2.2 LOWVOLTAGE ........................... 5-4

5-2.2.3 HIGH VOLTAGE .......................... 5-6

5-2.2.4 VOLTAGE FLUCTUATING .................... 5-7 • 5-3

5-3.1

VOLTAGE REGULATOR ...................... 5-8

TROUBLESHOOTING .......................5-8

5-4 CURRENT BOOST SYSTEM . . . . . . . . . . . . . . . . . ... 5-9

5-5 MANUAL VOLTAGE CONTROL ................. 5-9

5-5.1 TROUBLESHOOTING FLOW CHART ..............5-9

6 CORRECfIVE MAINTENANCE .............. ......... 6-1

6-1 INTRODUCTION .......................... 6-1

6-2 GENERATOR TESTS ........................ 6-1

6-2.1 MEASURING EXCITER FIELD EXCITATION .......... 6-1

6-2.2 TESTING EXCITER ROTATING RECfIFIER DIODES ..... 6-3

6-2.3 TESTING SURGE SUPPRESSOR . . . . . . . . . . . . . . . . . .6-5

6-2.4 MEASURING WINDING RESISTANCE .............. 6-6

6-2.4.1 MEASURING EXCITER FIELD WINDING RESISTANCE .... 6-6

6-2.4.2 MEASURING GENERATOR FIELD WINDING

RESISTANCE ............................ 6-7

6-2.4.3 MEASURING EXCITER ARMATURE WINDING

RESISTANCE ............................ 6-7

• 6-2.4.4 MEASURING GENERATOR STATOR WINDING

RESISTANCE ............................ 6-8

iii

T9311-BC-OMI-01O

TABLE OF CONTENTS (Cont'd)

CHAPTER~ARAGRAPH TITLE PAGE NO.

6-2.5 MEASURING WINDING INSULATION RESISTANCE ..... 6-9

6-2.5.1 MEASURING GENERATOR STATOR WINDING

INSULATION RESISTANCE . . . . . . . . . . . . . . . . . . . 6-10

6-2.5.2 MEASURING GENERATOR FIELD WINDING

INSULATION RESISTANCE . . . . . . . . . . . . . . . . . . . 6-10

6-2.5.3 MEASURING EXCITER FIELD WINDING INSULATION

RESISTANCE ............................ 6-10

6-2.5.4 MEASURING EXCITER ARMATURE WINDING

INSULATION RESISTANCE . . . . . . . . . . . . . . . . . . . 6-11

6-3 VOLTAGE REGULATOR ..................... 6-11

6-3.1 OPERATIONAL TEST ...................... 6-11

6-4 CURRENT BOOST SYSTEM . . . . . . . . ........... 6-13

6-4.1 OPERATIONAL TEST ...................... 6-13

6-4.1.1 PRELIMINARY .......................... 6-13

6-4.1.2 TESTING .............................. 6-13

6-4.2 BENCH TEST ........................... 6-15

6-5 ELECTRONIC MANUAL VOLTAGE CONTROL UNIT .... 6-15

6-5.1 OPERATIONAL TEST ...................... 6-16

6-6 DRYING GENERATOR ...................... 6-18

6-6.1 HEATENCLOSUREMETHOD .................. 6-18

6-6.2 FORCED AIR METHOD ..................... 6-18

6-6.3 OVEN METHOD .......................... 6-19

6-7 REMOVINGGENERATORFROMENGINE .......... 6-19

6-8 REMOVING AND INSTALLING EXCITER

ARMATURE ASSEMBLY .................... 6-21

6-8.1 REMOVAL ............................. 6-21

6-8.2 INSTALLATION .......................... 6-22

6-9 REMOVING AND INSTALLING TERMINAL BOX

AND END BELL . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

6-9.1 REMOVING THE TERMINAL BOX AND END BELL . . . . . 6-24

6-9.2 INSTALLING TERMINAL BOX AND END BELL ....... 6-25

6-10 REMOVING AND INSTALLING BEARING .......... 6-26

6-11 REMOVING AND INSTALLING GENERATOR ROTOR ... 6-28

6-11.1 REMOVING ROTOR ....................... 6-29

6-11.2 INSTALLING ROTOR ....................... 6-31

6-12 INSTALLING REPLACEMENT SURGE SUPPRESSOR .... 6-31

iv

T9311-BC-OMI-OlO

TABLE OF CONTENTS (Cont'd)

CHAPTERIP ARAGRAPH TITLE PAGE NO.

7 ILLUSTRATEDPARTSBREAKDOWN ................... 7-1

7-1 INTRODUCTION .......................... 7-1

7-2 ILLUSTRATIONS AND LEGENDS ................ 7-1

7-3 LISTOFMANUFACI1JRERS ................... 7-7

8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1 8-1.1 8-1.2 8-2

8-2.1 8-2.2 8-2.3 8-2.4 8-2.5 8-3

8-3.1 8-3.1.1

8-3.1.2

8-3.1.3 8-3.1.4 8-3.2

8-3.3 8-3.4 8-4 8-4.1 8-4.2

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

COMPONENTS ........................ ... 8-1

GENERAL .............................. 8-1

RECEIVING INSPECTION, HANDLING INSTRUCTIONS

AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

RECEIVING KAMAG GENERATOR ...............8-2

WINDING INSPECTION ................. ..... 8-2

UNPACKING ............................ 8-2

HANDLING INSTRUCTIONS ...................8-2

STORAGE ........................... ... 8-3

COUPLING AND ALIGNING GENERATOR AND

PRIME MOVER ...........................8-3

PRE-COUPLING MEASUREMENTS . . . . . . . . . . . . . . . . 8-3

ENGINE CRANKSHAFT AND FLYWHEEL

DEFLECTION ............................ 8-3

MEASURING GENERATOR DRIVE PLATE AND

FLYWHEEL DRIVING RING PILOT BORE . . . . . . . . . ... 8-4

CHECKING EXCITER ALIGNMENT ............... 8-5

CHECKING BEARING AND CLEARANCE . . . . . . . . . . . . 8-7

COUPLING AND MOUNTING GENERATOR ONTO

ENGINE AND BASE ........................ 8-7

MEASURING GENERATOR ROTOR ECCENTRICITY .... 8-12

MEASURING ROTOR ANGULAR ALIGNMENT ....... 8-13

MOUNTING GENERA TOR CONTROL MODULES ... ... 8-15

VOLTAGE REGULATOR ..................... 8-15

CURRENTBOOSTMODULE .................. 8-15

v

• TABLE OF CONTENTS (Cont'd)

CHAPTERIPARAGRAPH TITLE PAGE NO.

8-4.3 CURRENT BOOST TRANSFORMER .............. 8-15

8-4.4 ELECTRONIC MANUAL VOLTAGE CONTROL ........ 8-15

8-5 ELECTRICAL CONNECTIONS ................. 8-16

8-5.1 GENERAL ............................. 8-16

8-5.2 EXCITER FIELD LEAD WIRES ................. 8-16

8-5.3 VOLTAGE REGULATOR (APR 63-5) .............. 8-16

8-5.4 CURRENT BOOST SYSTEM ................... 8-16

8-5.4.1 CURRENT BOOST MODULE (CBS 305) ............ 8-16

8-5.4.2 CURENT TRANSFORMER (Cf) '" .............. 8-16

8-5.5 ELECTRONIC MANUAL VOLTAGE CONTROL (MVC 300) .8-18

8-5.6 SPACE HEATER .......................... 8-18

APPENDIX

A MISC. DIMENSIONAL DRAWINGS

• A-I KAMAG-AC SINGLE BEARING OUTBOARD EXCITER

GENERATOR ........................... A-I

A-2 KAMAG-AC SINGLE BEARING OUTBOARD EXCITER

GENERATOR SHAFT ....................... A-2

vi

FIGURE

2-1 2-2 2-3 3-1 3-2

3-3 3-4 3-5 3-6 3-7 3-8 5-1

5-2 5-3 5-4 6-1

6-2 6-3 6-4 6-5 6-6 6-7

6-8 6-9 6-10 6-11 6-12

7-1 7-2 8-1 8-2

8-3

8-4

8-5 8-6 8-7

T9311-BC-OMI-01O

LIST OF ILLUSTRATIONS

TITLE

Frequency Compensation Operational Test (Voltage Regulator) MVC-3oo Single Bearing Kamag Generator . .

Twelve Wire Generator Stator Lead Wire

PAGE NO.

· .2-3

· .2-4

· .2-5

· .3-2

Connection Diagram . .3-3 Exciter Rotor ....... . .3-6 Exciter and Generator Field . .3-6 Rotating Rectifier . . . . . . . .3-7 Frequency Compensation . . . ......... 3-10 Typical Inverse Time Delay Characteristic Curves . .3-11 Electronic Manual Voltage Control ... .3-14 Field Excitation Measurement Meter Connection Diagram Rotating Rectifier Exciter and Generator Field Interconnection MVC-3oo Troubleshooting Flow-Chart Field Excitation Measurement Meter Connection Diagram Testing Rotating Rectifiers with an Ohmmeter . . .

Rotating Rectifier Exciter and Generator Field Interconnection Testing Surge Suppressor with a Test Lamp Exciter Rotor Twelve Wire Generator Stator Lead Wire

· .5-2

· .5-3

· .5-4

.5-10

.6-2 . . . . 6-4

· .6-4

· .6-4

· .6-5

· .6-8

Connection Diagram .......... . .6-9 Operational Test (APR 63-5) ..... . .6-12 Bench Test Interconnection (CBS 305) . . . . . . . . . . .6-17 Operational Test (MVC 300) ............... .6-18 Exciter Armature Assembly . . . . . . . . .6-21 Removing Exciter Armature and Rotation Rectifier Assembly with Puller Kamag Generator Exciter Rotor and Rotating Rectifier ..

SAE Flywheel Single Bearing Generator Adapter and Drive Plates Extension of Generator Rotor Shaft for Mounting of Exciter Rotor Assembly . .

Recommended Torque Sequence for Circular Bolt Pattern Checking Rotor Eccentricity Checking Angular Alignment Voltage Regulator vii

.6-23 .... 7-2

· .7-5

· .8-6

· .8-6

· .8-8

· .8-10

· .8-13

· .8-14

· .8-19

T9311-BC-OMI-01O

LIST OF ILLUSTRATIONS (Cont'd)

FIGURE TITLE PAGE NO.

8-8 Current Boost Module . . . . . . . . . . . . . . . . . ... 8-20 8-9 Current Boost Transformer ................ .8-21 8-10 MVC 300 Drilling Template ............... .8-22 8-11 MVC 300 Outline Drawing ................. 8-23 8-12 3 Phase Series WYE .................... 8-24 8-13 Wiring Diagram Generator Controls ............8-25 8-14 Wiring Diagram 115V 250W Space Heater ......... 8-26

LIST OF TABLES

NUMBER TITLE PAGE NO.

1-1 3-1

3-2 3-3 5-1 6-1 6-2

8-1 8-2

8-3

Principal Characteristics . . . . . . . . . . . . . . . . . . .1-1 Generator Voltage - Standard Kamag Generators . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Specifications (APR 63-5) ................ .3-8 Specifications (MVC-300) ................ .3-13 Troubleshooting (APR 63-5) ............... .5-8 Minimum Air Gap for Kato Brushless Exciter ...... .6-23 Recommended Torque SAE 5 Steel and SAE 8 Steel Cap Screws ................... ... 6-27 Dimensions of Flywheels - Inches ............. 8-5 Recommended Torque SAE 5 Steel and SAE 8 Steel Cap Screws ...................... 8-10 Minimum Air Gap for Kato Brushless Exciter ...... .8-12 viii

T9311-BC-OMI-OlO

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement specific warnings and cautions appear ing elsewhere in this manual. General and specific precautions must be understood and applied during operation and maintenance. The Commanding Officer or other authority will issue orders as deemed necessary for any situation not covered in the general and specific safety precautions.

KEEP AWAY FROM LIVE CIRCUITS

Operating personnel must observe all safety regulations at all times. Do not replace components, make adjustments, or perform internal equipment maintenance without first securing electrical power. Dangerous potential may exist when the electrical power is in the OFF position because of charges retained by capacitors. Before touching, al ways secure electrical power and discharge the circuit by shorting through a load to ground with a shorting probe.

DO NOT REPAIR OR ADJUST ALONE

Under no circumstances should any person reach into or enter equipment enclosures for the purpose of servicing or adjusting equipment except in the presence of personnel capable of rendering aid.

FIRST AID

An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.

ENERGIZED EQUIPMENT

Before working on energized equipment, ensure against grounding. If possible, make repairs/adjustments with one hand, leaving the other hand clear of the eqUipment.

Never work alone.

MOVING EQUIPMENT

If eqUipment must be repaired/adjusted while in motion, a safety watch shall be posted.

The safety watch must have a full view of the repair/adjustment operation and immedi ate access to controls that can stop the equipment in motion.

SPECIFIC SAFETY NOTICES

The specific safety warnings and cautions summarized below appear in appropriate chapters of this manual.

A WARNING is an operating or maintenance procedure, practice, condition or state me[1t which, if not strictly observed, could result in injury or death to personnel.

A CAUTION is an operating or maintenance procedure, practice, condition or statement which, if not strictly observed, could result in damage to, or destruction of, equipment or loss of mission effectiveness.

ix

T9311-BC-OMI-OlO iWARNINGl1 This equipment contains high speed (1800 rpm) rotating parts and develops lethal voltage (480 Vac or higher). Stop generator set before removing protective covers for the purpose of making electrical connections, Installation, ad justments, Inspection, troubleshooting, test Ing, repair, or parts replacement. Install protective covers before starting the generator set. Failure to observe this precaution can result In serious Injury or electrocution.

!WARNINGI!

Where meters or test Instruments are used for purpose of troubleshooting and testing, It Is recommended the test equipment be placed external to the generator and the generator set be stopped while making or removing meter and Instrument connections. Be sure protec tive covers are Installed before running unit.

Failure to observe this precaution can result In serious Injury or electrocution.

!WARNINGI!

Do not 11ft complete generator set by means of lifting eye on generator. Disregarding these In structions may result In serious Injury or equipment damage.

!WARNINGII

Do not 11ft or pry on generator fan. Failure to observe this precaution can result In serious Injury and eqUipment damage.

IWARNINGII

Make certain that suffiCient clearance exists between fan and stationary parts and make certain fan and fan hub bolts are torqued.

Failure to observe this precaution can result In serious injury and equipment damage .

x

T9311-BC-OMI-OIO

\WARNINGI\

When circuit breakers are not Included with the generator, the terminals on the ends of the stator lead wires are not Insulated. These ter minals must be Insulated before generator set is operated. Failure to observe this precaution can result In serious Injury and equipment damage.

\WARNINGI!

With the VOLTAGE CONTROL MODE switch In either MANUAL or OFF position, some ter minals of the regulator are connected to the generator and present a potential shock hazard. No attempt should be made to remove or troubleshoot the regulator while the gener ator Is running.

iWARNINGli

No attempt should be made to open, Inspect, or clean the generator or generator controls while the generator Is running. Failure to ob serve this precaution may result In Injury or electrocution.

!WARNINGI!

To prevent personnel Injury or equipment damage, only qualified technicians/operators should Install, operate, or service this equip ment.

!WARNINGI!

Make certain generator Is stopped, wear gloves to protect fingers when removing or In stalling parts.

!WARNINGI!

Do not apply any lifting force to generator fan for lifting or turning generator rotor. Failure to observe this precaution may result In serious Injury or equipment damage.

xi

T9311-BC-OMI-OlO

\CAUTIOij Do not attempt to 11ft or transport any single bearing generator without proper rotor sup port. Failure to observe this precaution can result In extensive equipment damage. Make certain exciter rotor is removed while handling generator.

ICAUTION!

Do not push on rotating rectifier or exciter winding. Failure to observe this precaution can result In equipment damage.

!CAUTiON!

Be sure to maintain polarity (+) to (F+) and (-) to (F-).

ICAUTION!

Do not flash field with generator In motion.

Voltage buildup cannot occur and the regulator may be damaged .

ICAUTIOij This drawing does not show Interconnection for voltage regulator and other controls that could be provided with the generator set. Be sure to follow the wiring diagram provided with the generator set when making electrical connections.

ICAUTIOij Meggers and high potential test equipment must not be used. Incorrect use of such equip ment could damage components contained In the device.

lCAUTIOij The voltage regulator and any electronic com ponents must be removed from the generator when using this method.

!CAUTiON!

Excessive axial misalignment of the rotor can result In eqUipment damage.

xii

T9311-BC-OMJ-OlO

ICAUTIOij Under no circumstances should pressure be applied to the outer race of the bearing, as per manent bearing damage could result.

!CAUTIOij The exciter air gap Is small compared to the air gap within the main generator. Remove ex citer rotor before transporting and coupling the generator to the prime mover. Failure to observe this precaution can result In eqUip ment failure.

ICAUTION!

This circuit must not be either grounded or opened while generator Is running.

!CAUTIOij Incorrect electrical connection of the voltage regulator will result in immediate eqUipment damage.

!CAUTIOij The generator leads must be provided with adequate Insulation for generator operating voltage. Proper support for the cables must be provided.

xiii

T9311-BC-OMI-010

CHAPTERl

GENERAL INFORMATION AND SAFETY

PRECAUTIONS

1·1 INTRODUCTION

1-1.1 General Infonnation. This manual provides the necessary infonnation to install, maintain, operate, and repair the Kamag-AC Generator.

1-1.2 Safety Precautions. Personnel involved with the installation, maintenance, and operation of the generator shall comply with the U.S. Navy Safety Precautions for Forces Afloat, OPNAVINST 5100 Series. Specific safety precautions are included in the appropriate chapters of this manual. General and specific warnings and cautions are contained in the Safety Summary which is located in the front matter of this manual.

1-2 EQUIPMENT DESCRIPTION

The generator consists of Kamag AC, four pole, horizontal, brushless, drip proof, revolving field alternating current generator. Integral to the unit is a space heater, voltage regulator, current boost system and manual voltage control. Its rated output is 150 kW, 440 V, 3 phase, 60 Hz at 1800 rpm. Table 1-1 lists the principal characteristics of the generator.

Table 1-1. Principal Characteristics

Item Data

Generator Manufacturer ........................................ Kato Engineering Type ..................................................... revolving field, 4-pole, brushless

Rating Voltage ................................................. 440Vac Frequency ............................................. 60Hz Rating ................................................... 150kW

AC Voltage Regulation Electronic Regulation ........................... ±O.25%

1-1

T9311-BC-OMI-OI0

CHAPTER 2

OPERATION

2-1 INTRODUCTION

This chapter provides the necessary information to operate the Kamag AC Generator.

Indicator readings outside the normal operating ranges may require corrective maintenance to prevent equipment damage. Operating the generator above or below the rated. values may damage the generator or control equipment

2-2 GENERATOR OPERATION

2-2.1 Pre-Start Inspection

Before operating the generator for the fIrst time, the following checks are recommended.

n WARNING II When circuit breakers are not included with the generator, the terminals on the ends of the stator lead wires are not insulated. These terminals must be insulated before generator set is operated. Failure to observe this precaution can result in serious injury and equipment damage.

a. Check to make sure bolts that mount and couple the generator onto the engine and engine base are tight

b. Check to make sure fan bolts are tight and space exists between the fan and stator windings. Check to make sure exciter retaining bolt is tight.

c. Check all wiring against the proper connection diagrams and make sure all connections are properly insulated.

d. Inspect to make sure all packing materials and shipping support blocking has been removed. Remove loose cloths and tools.

e. Install covers and guards.

2-2.2 Idling

Permanent equipment damage can be caused by having the generator set in operating mode while idling the engine. If engine adjustments require that the engine be run at idle speed, the generator set regulating system should be made inoperative by the method that follows.

a. Where generator set includes an automatic/manual control with switch that has OFF position, be sure switch is set to OFF while engine is running at idle speed.

2-1

T9311-BC-OMI-OlO

2·2.3 Field Flashing

The genemtor relies on residual voltage to start the generator action which in turn genemtes the mted voltage. If the generator fails to genemte voltage after it has come up to rated speed, it may be necessary to flash the exciter field. Field flashing must be done while the generator is at a standstill as described in the procedure that follows.

a. Stop the engine and open the output circuit breaker.

CAUTION

Be sure to maintain polarity (+) to (F +) and (-) to (F.).

CAUTION

Do not flash field with generator in motion.

Voltage buildup cannot occur and the regulator may be damaged.

b. Connect the negative lead (-) from a common 12 volt storage battery onto exciter field lead F-.

c. Connect the positive lead (+) from the battery onto exciter field lead F+. Only a few seconds flashing should be necessary.

d. Remove battery and connect exciter field leads onto voltage regulator terminals F+ and F-. Be sure to maintain correct polarity.

e. Start generator and check for satisfactory voltage build up.

2·2.4 Voltage Adjustments (Voltage Regulator)

2-2.4.1 System Start Up

a. Start prime mover and bring up to rated speed.

b. Slowly adjust the screwdriver volt adjustment on the external voltage adjustment until the voltage reaches nominal.

c. Apply and remove load to check stability.

d. Check regulation under normal operations and loading conditions.

e. Reduce genemtor frequency to approximately 55 Hz. Genemtor output should decrease from this point.

2-2.4.2 Frequency Roll-Off Adjustment

a. Adjust the prime mover RPM to the desired frequency compensation point (comer frequency roll-off). Refer to Figure 2-1.

b. Adjust the FREQ control until the output voltage starts to drop off.

2-2

J

'00

• 00 o z

• o c

! 00 o '0

• o c w ~ 20 o o

T9311-BC-OMI-OlO

I ·CO"HER FREQUENCY" I ,

I L L I I V I I I L 1 I I I

I 50"_._~ L II

I I I V I 1/ Ij'-eo H, .--V ,../

::;.-- I

V o '0 20 I. •• 50 I.

Figure 2-1. Frequency Compensation

c. Bring the prime mover up to rated speed. The output voltage should return to nominal.

2-2.4.3 Stability Adjustment

NOTE

If stability setting is desired that provides the fastest possible voltage response with good generator stability, an oscilloscope or other voltage recording device should be used.

a. Rotation of the STAB control clockwise (CW) will slow response time.

b. Rotation of the STAB control counterclockwise (CCW) will speed response time. If rotated too far CCW, the generator voltage may oscillate (hunt).

2-2.4.4 Voltage Adjustment

Intalling a jumper across terminals 6 and 7 of the voltage regulator provides for the internal "VOLT" adjustment to vary the generator nominal voltage over the range shown in Table 3-2.

The 1000 ohm external potentiometer (supplied with the regulator) may be connected in place of the jumper and will allow for a ±10% adjustment of the voltage range. The nominal value of this range is set by the internal "VOLT" adjustment. If a range less than or greater than the range provided by the 1000 ohm potentiometer is desired, a 2 watt potentiometer of any value from 50 ohms to 5000 ohms may be substituted.

2-2.4.5 Operational Test

a. Connect the voltage regulator as shown in Figure 2~2.

b. Adjust the VOLT control fully counterclockwise.

RESULT: Observe that the lamp is not lit.

c. Adjust the VOLT control fully clockwise.

2-3

• @ I?..

APR 63-5 @

I?..

" r:

~ " r:

FREO. ,,-;:.,.

'GI

z

STAB. ,,-

I?..

VOLT. "<::.1

f?

'<::I

@ 0

•• J JI

c"'" ca-

C'I IJ3

, J J2

"0 I 0'"

T9311-BC-OMI-OlO

10.J\. lOW

I ( 240 V8C

( §) 100W

BULB

240V, SA, FAST B

HIGH CAPACITY F

LOW,

USE.

Figure 2-2. Operational Test (Voltage Regulator)

d. Adjust VOLT control until lamp just extinguishes.

• 2·2.5 Current Boost System

The operation of the current boost system is completely automatic and controlled by the voltage regulator.

2.2.6 Electronic Manual Voltage Control

a. With the VOLTAGE CONTROL MODE switch placed in MANUAL (Figure 2-3), the automatic voltage regulator is removed from the line and generator output voltage is controlled manually by the MANUAL VOLTAGE ADJUST control. When placed in the AUTOMATIC position, the generator output voltage is controlled by the automatic voltage regulator. Complete excitation shutdown occurs when the VOLTAGE CONTROL MODE switch is placed in the OFF position.

II WARNING II

With the VOLTAGE CONTROL MODE switch in either MANUAL or OFF position, some terminals of the regulator are connected to the generator and present a potential shock hazard.

No attempt should be made to remove or troubleshoot the regulator while the generator is running.

b. Start the prime mover following the procedures outlined in Engine Technical Manual, set the MANUAL VOLTAGE CONTROL to minimum (counterclockwise), and place the VOLTAGE CONTROL MODE switch in MANUAL position. Note that

2-4

2·3

'tOl T AGE ..: eN T RDL MODE

MANUAL VOLTAGE CONTROL

a aasler EloctrlC ='>.HkI""'na, lilinoi.

",oal ... 0 •• e .,Ool

Figure 2-3. MVC-300 i I i I

.~I

I:;IJ I

11J311-BC-OMI-OIO

the voltage may be unstable (hunting) if the MANUAL VOLTAGE ADJUST control is set below 30 Vac.

c. Allow the generator to build up and slowly increase the generator output voltage with the MANUAL VOLTAGE ADJUST control until the generator output voltage reaches the desired level.

STARTING GENERATOR FOR SINGLE UNIT OPERATION

The following procedures should be followed for starting the generator set.

a. The generator output must be disconnected from the load. Be sure the main circuit breaker is open.

b. If fuses have been removed, install the fuses.

c. Set electronic voltage control switch to the AUTO position.

d. Turn off the generator space heater.

e. Start prime mover and bring to rated speed. Adjust voltage to required value by means of the voltage adjust rheostat on the voltage control box.

f. Close main circuit breaker and apply load.

g. Adjust engine speed to 1800 rpm.

h. Before stopping the engine, remove the load by tripping the main circuit breaker.

2-5

T9311-BC-OMI-OlO

2-4 PARALLEL OPERATION

This generator is used to provide electrical service in an emergency situation. This system works independently from the other generator systems and is not designed to be paralleled with other generators. Paralleling should never be attempted.

2-5 OVEREXCITATION SHUTDOWN

a. Overexcitation shutdown is included to remove the output power if the exciter field voltage exceeds 100 ±5 Vdc. Refer to paragraph 3-3.3 and Figure 3-7 for details.

b. After output power is removed, the regulator can be reset by decreasing the input voltage to less than 6 Vac for a minimum of 2 seconds; this may be accomplished by stopping the prime mover or by interrupting the regulator input with the shutdown switch.

2-6

T931l-BC-OMJ-OI0

CHAPTER 3

FUNCTIONAL DESCRIPTION

3·1 INTRODUCTION

This chapter provides a detailed functional description of the Kamag-AC Generator and its control equipment.

3·2 GENERAL

Kamag AC generators are brushless 4-pole machines producing 60 Hz power at 1800 rpm or 50 Hz power at 1500 rpm. The generators are of the revolving field type, having rotating field poles called the rotor and a stationary armature called the stator. All standard units are broad voltage range machines that have twelve lead wires brought out from the stator coil groups. This feature permits connection of the stator winding in either three- phase wye, three-phase delta, or single-phase configuration. Table 3-1 lists the voltages that can be obtained from the output of Kamag generators.

Single bearing generators are supplied with an SAE adapter and flexible drive disks on the drive end of the unit. Alignment of the generator frame and engine is ensured by the concentricity of the flywheel housing and the generator adapter, while alignment of the generator rotor and engine crankshaft is ensured by the concentricity of the drive disks and engine flywheel.

The major parts comprising the Kamag generator are shown in Figure 3-1. Figure 3-4 is an electrical schematic of the generator field and exciter. The twelve stator lead wires and respective stator coil groups are shown in Figure 3-2.

Table 3-1. Generator Voltage - Standard Kamag Generators

Connection Voltage Range (SeeNote) (By Adjusting of voltage control rheostat) bUHertz

3 Phase series wye 408 to 490 (Phase-to-Phase) 3 Phase parallel wye 204 to 245 (Phase-to-Phase) 3Phase series delta 236 to 283 (Phase-to-Phase)

NOTE: Phase-to-neutral voltage for 3-phase wye connections are 58% of line-to-line voltages listed. Line-to-neutral voltage for 3 wire single phase is one-half the line-to-line voltage listed.

3-2.1 Principles of Operation

AC generators require direct c~nt flowing ~~)Ugh the fiel.d win~g ~o set up the ma~etic flux which generates ac power m the stator wmding. An eXCIter, which IS a small altematmg

3-1

Frame and -- Stator

Fan

Cover, Drive End

T9311-BC-OMI-OlO

Drive Hub l

- Drive Plates

Dripproof (:~ ..

Shield r, .". -

\ , r. ~ .\.:;'" /'1 '. '·\®'T~) /// I

\. Spacer ,/ - J

Endbell

/GrOUnd

StUd t.

y . ~/>:' r-~ ,...> E:iterField

~earing

~ .(. Exciter

- Armature

Rotating Rectifier

Terminal Box

Figure 3-1. Single Bearing Kamag-AC Generator

3-2

'J1J311-BC-OMI-OlO

__ :_LtleA) . , .

UlfB)

~ .. ~r---7---?o~ N

~"7- ~ \.)..___0 L2fl., '-I --------0 L3fGC, '------ L3fIC,

a. 3·PhaS8 aenes wye b. 3-Phase parallel wye of

"" '~~: LIIOA,

l '0 , L2fl., /CI---;;'"';\ ~

I U LllIC,

c. 3-Pnase senes aelta

Figure 3-2. Twelve Wire Generator Stator Lead Wire Connection Diagram

NOTE

This drawing does not show interconnection for voltage regulator and other controls that could be provided with the generator set. Be sure to follow the wiring diagram provided with the generator set when making electrical connections.

current generator with rectified output, provides this direct current. While the generator armature is stationary and the field rotates, the exciter field is stationary and the armature and rectifier rotate.

The exciter itself requires direct current for excitation. This excitation may be provided by any dc power supply that provides the proper excitation. However, in order to keep the generator output voltage relatively constant, the dc excitation must be automatically regulated by means of a voltage regulator.

The voltage regulator provides regulated de excitation. This device measures the generator voltage and compares the measured voltage with a pre-set voltage established by adjustment of a voltage adjust potentiometer or rheostat. It then uses the result of the comparative process to automatically control the excitation supplied to the exciter field winding. This action in turn regulates the excitation applied to the generator field winding, which controls .the magnetic flux and thereby the ac power generated by the generator stator winding.

The voltage regulator requires electrical power for operation of its circuitry. Usually a portion of the power generated bY,the generator is used to power the voltage regulator.

3-3

T931 I-BC-OMI-OIO

3-2.2 Mechanical Construction

• The major parts comprising the Kamag generator are shown in Figure 3-1 and described in the paragraphs that follow.

3-2.2.1 Generator Frame and Stator

Rectangular steel bars welded to endrings provide rigid support for the stator, the generator endbell, and the adapter. Weldments rigidly secure the stator to the frame bars.

The stator core is comprised of a stack of thin, notched electrical steel laminations assembled under pressure and welded to the frame bars. The semi-closed notched slots are Class F insulated; random wound coils are fIrmly wedged in the insulated slots. The stator coils in Kamag generators are connected in three-phase groups with twelve lead wires that terminate within the terminal box. Stator wire connections are insulated and the entire stator is then impregnated with thermo-setting 100 percent solid bonding epoxy and baked under a controlled cycle. This process minimizes voids and ensures high dielectric strength and excellent moisture resistance.

3-2.2.2 Generator Frame Cover

A removable sheet metal cover encloses the generator frame.

3-2.2.3 Generator Rotor Assembly

A precision machined steel shaft, the four-pole rotating fIeld, the exciter armature and the rotating rectifIer comprise the rotor assembly. Also mounted on the shaft and provided with a replacement rotor are the drive hub and the generator bearing. A two-section fan mounts on

• the rotor at the adapter end of the generator.

a. Shaft. The rotor shaft includes a keyway and key at the drive end for mounting the drive hub. a keyway and key for mounting the rotor fIeld core, and a keyway and key for mounting the exciter armature and rotating rectifIer.

b. Generator Field Poles. The four poles which carry the fIeld windings are comprised of a stack of one-piece electrical steel laminations press-fItted together using a hydraulic press. Copper rods of the amortisseur winding are pressed into circular holes through the pole head portion of the core structure and welded to copper end plates that form the front and back section of the assembled fIeld core structure. The fIeld core structure is pressed on the shaft using a high pressure hydraulic press and keyed, forming a rigid rotating element. Round steel studs are pressed into each pole head for attachment of rotor balance rings at the front and back section of the field assembly.

Heavily insulated series-connected fIeld coils are wound about the four poles. A support block made of insulating material provides coil support at the bottom and top of the field coil. Two lead wires are brought out to the rotating rectifIer.

A thermo-setting epoxy is applied to the completed generator field assembly and the field assembly is baked under a controlled cycle to ensure high dielectric strength and mechanical strength.

c. Driving Hub and Drive Disks. The Kamag single bearing generator is fItted with a precision machined interference fIt drive hub that is keyed to the shaft. This hub carries a number of flexible steel drive disks which have holes for fastening to the

3-4

T9311-BC-OMI-OIO

flywheel. The outside and inside diameter are precision machined and bolt holes are precision located and drilled, ensuring concentric alignment with the drive hub and the engine flywheel. Ring shaped steel spacers used between the hub and disks provide a small amount of field adjustment to maintain proper alignment.

d. Air Circulating Fan. The fan consists of two half-sections that clamp together and are held securely in place on the shaft by two steel bolts. The fan mounts at the drive end of the generator between the drive hub and the generator field poles.

Ambient air is drawn into the outboard end of the generator, and passes over the exciter, across the outside of the generator stator windings and stator laminations, and through the air gap between the generator stator and field poles. This circulation of air removes heat from the windings and laminations. The cooling fan exhausts the heated air from the generator.

e. Bearing. Single bearing Kamag generators have a duty- selected shielded ball bearing located at the outboard end of the generator. The bearing outer race is supported within a machined bearing housing located in the center of the endbell, while the inner race fits onto a machined section on the generator shaft. The bearing is factory packed with lubricating grease.

3-2.2.4 Exciter Rotor

The exciter rotor consists of the exciter armature wound with a three-phase winding and a full-wave rotating rectifier. Three lead wires, one from each phase of the exciter armature winding, connect to the rectifier diodes as shown in Figure 3-4. The direct current from the rotating rectifier is conducted to the generator field through lead wires.

Two bolts mount the rectifier assembly to the exciter armature core structure. The entire exciter rotor unit slides over the generator shaft and is held in place by a rectangular key located in the shaft keyway and a retaining bolt and washer at the outboard end of the shaft as shown in Figure 3-1.

a. Exciter Armature. The exciter armature core structure is comprised of a stack of thin, notched, one-piece laminations held assembled under pressure and kept compressed and aligned by steel rivets through the stack of laminations. The semi-closed slots are insulated with Class F insulation, and the coils of the three-phase exciter armature winding are then securely wedged in the slots. The entire exciter armature is completely impregnated with thermo-setting epoxy and baked under a controlled cycle. Three lead wires, one from each phase of the exciter armature winding, connect to the rotating rectifier as shown in Figure 3- 4.

b. Rectifier. The exciter armature three-phase ac output is applied to a full-wave rectifier, Figure 3-5, comprised of a positive heat sink, a negative heat sink, a molded insulating plate, a metal plate, three forward polarity diodes, three reverse polarity diodes, and a surge suppressor. The heat sinks are molded onto the insulating plate.

The three forward polarity diodes mount on the positive heat sink, while the three reverse polarity diodes mount on the negative heat sink. A surge suppressor is mounted across the heat sinks. A generator field lead wire attaches to the positive heat sink while the second generator field lead attaches to the negative heat sink.

This rectifier output circuit provides excitation to the series- connected generator field winding. Three wires, one from each phase of the exciter armature winding, 3-5

~~washer

~311-BC-OMI-OlO

~'" ,"00"" ,,,.,, '" ,",ft

Part of Generator Shaft

Fiber Wire Retaining Ring

'---- Generator Field Leads

L Retaining Bo~ Exciter Rotor (Includes exciter armature and rotating rectifier assembly)

Figure 3-3. Exciter Rotor

NOTE: Exciter and Generator Field Interwiring is shown in Figure 3-4 •

Dc from Voltage Regulator ElIclter Field

F-

NOTE

Three forward polarity diodes are mounted on the positive heat sink, and three reverse polarity diodes are mounted on the negative heat sink. A surge suppressor Is mounted across the heat sinks.

Figure 3-4. Exciter and Generator Field

3-6

Rotating Rectifier

Positive Heat Sink

Generator Field

Neg8tlve He.t Sink

T9311-BC-OMI-OI0

attach to the diodes as shown in Figure 3-4. The complete rectifier assembly is held in place on the exciter armature by two bolts.

3-2.2.5 Exciter Field Assembly

Surge suppressor ~,ate

'U

Diode, forward polarity (3 required)

Figure 3-5. Rotating Rectifier

The exciter field core structure is comprised of a stack of thin, notched electrical steel laminations that are held axially and tangentially aligned by a weldment across the stack of laminations. The steel laminations are of the type that retain residual magnetism. This residual magnetism produces a magnetic field which, when the generator is started, induces current in the exciter armature, providing the generator field with sufficient dc excitation for generator voltage build-up.

The slots in the exciter field core structure are insulated with Class F insulation and the coils are then firmly wedged in the slots. The coils are series connected; lead wires are brought out for connection to the voltage regulator dc output. The entire exciter field assembly is completely impregnated with thermo-setting epoxy and baked under a controlled cycle. Bolts that pass through holes in the exciter field core structure and thread into tapped holes in the bosses located on the generator endbell provide rigid mounting and ensure concentric alignment.

3-2.2.6 Endbell

A cast iron endbell encloses the outboard end of the generator. Precision machined matching pilot and recess on the endbell and generator frame endring ensure concentric alignment with the generator frame. The endbell is rigidly secured to the frame by bolts that pass through holes in the terminal box and in the endbell and thread into tapped holes in the frame endring.

A machined bearing housing at the center of the endbell supports the outer race of the generator bearing while raised bosses with tapped holes provide mounting for the exciter field assembly.

3-7

T9311-BC-OMI-OlO

3-2.2.7 Adapter

A cast iron adapter at the drive end of the generator mounts to the engine flywheel housing while the inboard side of the adapter mounts to the generator frame endring. The face on both the inboard and outboard surfaces are precision machined with pilot or recess to ensure concentric alignment with generator frame and the engine flywheel housing. Bolts that pass through the holes in the adapter and thread into tapped holes in the frame endring rigidly secure the adapter to the frame, while bolts that pass through the adapter and thread into tapped holes in the flywheel housing rigidly mount the generator frame and stator to the engine.

3-2.2.8 Terminal Box

Kamag generators include a large terminal box with ample room inside for the voltage regulator, most circuit breakers, and other options. The twelve generator stator lead wires and the exciter field leads terminate within the terminal box. The terminal box mounts on the outboard end of the engine.

3·3 BASLER ELECTRIC MODEL APR 63-5 VOLTAGE REGULATOR

3-3.1 General

The APR 63-5 voltage regulator controls the dc exciter field power of conventional 60 Hz brushless generators to maintain a constant output voltage.

3-3.2 Specifications

a. Output power (with a 240 Vac Input):

b. Exciter field dc resistance:

c. AC input power:

d. Input burden:

e. AC sensing voltage:

f. Sensing burden:

g. Voltage adjust range:

h. -External voltage adjust rheostat:

Table 3-2. Specifications APR 63-5

5.0 Adc@ 63 Vdc (315W) Maximum Continuous

8.5 Adc@ 105 Vdc (893W) Forcing, 1 Minute

12.6 ohms minimum 100 ohms maximum

190 to 277 Vac, single phase, 50/60 Hz ±1O%

650 VA

190 to 240 (240 volt tap), 380-480 Vac (480 volt tap), single phase, 50/60 Hz ±1O%

5 VA maximum

170 to 264 Vac, 340 to 528 Vac…