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1. 7 KIRLOSKAR POWER IDEAS SECTION ALTERNATOR Enriching Lives USER MANUAL ALTERNATOR 4 KIRLOSKAR SECTION E INDEX Alternator Illustrations 3 1 General Information 4 2 Safety Reguirements 5 3 Electrical Checks 6 4 Safety 6 5 Do s amp Don ts 6 6 Voltage Setting 7 7 Maintenance 8 8 Brushless Exploded Illustrations 11 9 Brushtype Exploded Illustrations 13 USER MANUAL ALTERNATOR 264 KIRLOSKAR USER MANUAL ALTERNATOR POWER IDEAS KIRLOSKAR GREEN ALTERNATORS Fig E 1 Fig E 2 KG BRUSHLESS ALTERNATOR KG BRUSH TYPE ALTERNATOR 1 End Cover 1 DE Shield 2 NDE Vent Cover 2 Slotted surround cover 3 Terminal Board and Rectifier Diode Assly 3 Shaft 4 Terminal Box Cover 4 Fan 5 Compound Assembly of Fan and 5 Eye bolt Exciter Rotor Stator 6 Terminal box with LID 7 Excitation CX Unit 8 Magnet Frame Body NOTE Depending on which alternator you have in your KGPI genset please refer our sales office service dealer you must refer the illustrations of the same shown above Only the user serviceable parts are illustrated on the surface of both the alternators above 1 0 1 1 1 2 1 3 1 4 GENERAL INFORMATION The Kirloskar Green Alternators are manufactured using the most accurate methods of design construction and test Their characteristics if properly used ensure a continuous working and a very prolonged trouble free life For the best use of
2. in figs E 5 and E 4 respectively If you still are in need of any of the spare parts mentioned in the list please contact your nearest Kirloskar Service Dealer USER MANUAL ALTERNATOR 9 0 DESIGNATION OF THE SPARE PARTS Please Refer Fig C 4 KIRLOSKAR GREEN POWER DEAS In case of replacements of spare parts use original spare parts only for the best performance of alternator For the replacements of worn parts carefully follow the maintenance instruction these operations must be carried out by skilled and trained technicians or our authorized service personnel FRAME 160 200 250 280 315 PART DESCRIPTION NO FRAME WITH WND PACK ROTOR Wound WOUND EXCITER STATOR 160 Frame 200 Frame 250 280 Frame 315 Frame WOUND EXCITER ROTOR 160 Frame 200 Frame 250 280 Frame 315 Frame D E END SHIELD G1R 160 SAE3 G1R 160 SAE2 G1R 200 SAE3 G1R 250 SAE3 G1R 280 SAE1 G1R 315 SAE1 FAN 160 Frame 200 Frame 250 Frame 280 Frame 315 Frame END COVER 160 Frame 200 Frame T Box ASBY G1R 250 T Box ASBY G1R 280 T Box ASBY G1R 315 PART DESCRIPTION NO NO D E VENT COVER G1R 160 SAE 3 G1R 160 SAE 2 G1R 200 SAE 3 G1R 280 SAE 1 G1R 315 SAE 1 TERMINAL BOX COVER 160 Frame 200 Frame NDE VENT COVER 160 Frame 200 Frame COUPLING HUB SAE 11 5 FOR G1R160 Frame SAE 11 5 FOR G1R200 Frame SAE 14 FOR G1R250 Frame SAE 14 FOR G1R280 Frame SAE 14 FOR G1R315 Frame COUPL
3. D C Voltage replace the rectifier if in doubt Faulty surge suppressor unit Check the connections F1 to positive terminal red and F2 to negative terminal black Defective excitation capacitor Check for short circuit or open circuit of the capacitor if faulty replace it Short circuit or open curcuit Armature rewinding is necessary in armature winding Brushes not bedding properly Check if the brushes are sticking in boxes or if bedding is short proper If the brushes are found tight in the box just polish the faces of the brush with emery cloth Check if brush holder leavers are in locked position and the spring pressure is even USER MANUAL ALTERNATOR TROUBLE SHOOTING CHART BRUSHTYPE ALTERNATORS FAULT CAUSE REPAIR Low or high voltage from Incorrect tappings shunt connected Select tappings to get correct voltage alternator on no load if voltage and regulation are not satisfactorily obtained Incorrect speed of prime mover Check the speed and adjust the speed to 1560 rpm on no load and 1500 rpm on load Unbalanced currents in excitation Reset the excitation unit as per the transformer windings instructions given Faulty rectifier Check the rectifier unit if current in excitation unit windings are balanced and if the input voltage to the rectifier unit is unbalanced replace the rectifier Turns shorted in the field coil Check the faulty coil and replace it Voltage regulation is Incorrect speed of the
4. prevent failure during running as this could cause irreversible damage to the generator USER MANUAL ALTERNATOR GREEN POWERS DEAS TROUBLE SHOOTING CHART BRUSHLESS ALTERNATORS FAULT REPAR No voltage build up Low no load voltage Low voltage on load High voltage on load Too high no load voltage Voltage oscillations Unbalance Voltage 1 Insufficient residual voltage 2 Improper connection 3 Low speed 4 Faulty Winding 5 Rotating rectifier failure 6 Faulty AVR 1 Low speed 2 Faulty Rotating rectifier 3 Faulty Winding 1 Low speed at full load 2 AVR faulty 3 Faulty rotor winding 4 Over load on alternator 1 Capacitors on the load side 2 Faulty AVR setting or AVR is faulty 1 Excessive speed 2 Correct the setting Replace AVR 1 Incorrect AVR setting 2 Thyristor load more than specified limits 3 Insufficient engine flywheel 1 Unbalance load 2 Loose connections 3 Stator winding faulty Excite the rotor using a battery Correct the connection Reset the speed to the nominal Check the winding resistance and rewind if required Replace the rotating rectifier Replace the AVR Reset the speed to the nominal Replace the rotating rectifier Check the winding resistance and rewind if required Set the rated speed of the prime mover Change AVR Check the rotor winding resistance and if faulty rewind it Operate on specified load Disconne
5. sets The operator must always wear work gloves and safety shoes In case the alternator or whole DG SET must be lifted from the floor the operators must wear a safety helmet Make sure thatthe gen set foundations and base frame are suitable to bear the combined weight of the alternator and prime mover The alternator should be securely connected and perfectly aligned with the prime mover otherwise dangerous vibrations may occur resulting in alternator bearing failure The machine has been designed to ensure the rated output when it is installed a room having a max temperature of 40 C and at an altitude not exceeding 1000 meters in case of deviations please make reference to our technical leaflets KIRLOSKAR POWER IDEAS No person must wear fluttering cloths such as scarves etc near the machine and any such garment must be fastened with elastic bands at its ends Alternator must never and for no reason be run with following guards removed e Terminal box cover Rear cover e Fan ventilation guard Alternators produce heat proportional to the output Therefore do not touch it if you do not wear antiscorch gloves and after switching it off do not touch it until it has cooled down Even if all machine components are protected keep away from the gen set Do not lean or sit on the alternator for whatever reason 21 DANGER OF SHORT CIRCUIT The degree of protection of the alternator is IP21 Shor
6. 200 250 280 315 Remote regulation of the voltage is obtained by mounting a 100 KQ potentiometer between the terminals 5 and 7 permitting a regulation of 5 of the nominal voltage WARNING FOR THE ALTERNATOR GOOD WORKING IT IS ADVISABLE NOT TO DEVIATE FROM THE NOMINAL VOLTAGE MORE THAN 5 ELECTRICAL FAILURE TROUBLESHOOTING When an electrical failure occurs check for trouble as explained below 1 In order to find out if the failure has happened in the alternator itself or in the regulation system one has to test the alternator at no load at nominal speed exciting the exciter stator directly using an external dc source When applying the voltage to the exciter stator one has to comply with polarities apply the negative polarity of the auxiliary source to the negative terminal and positive terminal to the positive terminal of the exciter fields Verify that A When feeding the winding according to the excitation data at no load listed in the table the voltage supplied by the alternator is almost the rated one After the localization of fault repair properly 8 MAINTENANCE 8 1 GENERAL The machine should be completely isolated from all electrically live wires before any electrical or rotating part of itis touched The freguency of maintenance depends largely on the site conditions Freguent maintenance of approximate once a week should be practiced at first and the period extended as experience is ga
7. ING DISC SET SAE11 5 Set of 2 Nos for GIR 160 SAE11 5 Set of 3 Nos for GIR 200 SAE14 Set of 4 Nos for GIR 280 31 386 N D E BEARING 160 Frame 6310 2RS 200 Frame 6310 2RS 250 Frame 6310 2RS 280 Frame 6313 2RS 315 Frame 6314 2RS PART DESCRIPTION MAIN TERMINAL BOARD WITH 6 TERMINAL 160 Frame 200 Frame 250 Frame 280 Frame 315 Frame AUXILIARY TERMINAL BOARD 3 TERMINAL G2R G1R 160 Frame G2R G1R 200 Frame DIODE BOARD ASSEMBLY 160 200 250 280 Frames 315 Frame AVR SR 7 3 AVR UVR 6 MOV RDN 440 14 for roating Rectifier USER MANUAL ALTERNATOR CONSTRUCTIONAL FEATURES OF THE KIRLOSKAR GREEN BRUSH TYPE ALTERNATORS Fig E 5 9 1 PARTS DESCRIPTION Please refer Fig C 5 AT ros 0 seen A A INT A EXTENSION KEY 1NO KIRLOSKAR USER MANUAL ALTERNATOR GREEN POWER DEAS PART NO DESCRIPTION 15 CIRCLIP 1 16 DE BEARING CAP 1 17 DE BEARING 1 1 23 NDE SHIELD 1 24 VENTILATION GIRDS 2 25 TERMINAL BOX WITH LID 1 26 EXCITATION CX UNIT 1 USER MANUAL ALTERNATOR
8. Kirloskar Green Alternators Please follow these instructions carefully SPECIFICATIONS Kirloskar Green Alternators are self excited self regulated and supplied with Electronic Voltage regulator They comply with the following International Indian Standards 150 9001 85 5000 15 4722 8 13364 e CSA Canadian Standard Association 1995 MECHANICAL FEATURES Low Weight e Very Compact Steel Body 8 End Shields Life Lubricated Sealed Ball Bearings at both the ends Screen Protected IP 20 S e Optional IP 21 S IP 23 S IP 44 S can be provided Self Ventilated e Rotating Parts are Dynamically Balanced ELECTRICAL FEATURES e Single Three Phase 240 Volts 415 Volts output at 50 Hz e Class Insulation e Steady State Voltage Regulation of 5 e Current Compounded Self Excitation System Lower Harmonic Content of less than 3 at no load e Power Factor 0 8 Lagging Phase Sequence is U V W when rotated Clockwise viewing from DE side NORMAL OPERATING CONDITIONS AS PER IS 13364 amp IS 4722 Altitude Less than 1000 m USER MANUAL ALTERNATOR Less than 40 C 0 8 Lagging 1500 r p m e Ambient temperature Power factor Speed on load Current nameplate of alternator 1 5 LIMITS FOR SAFE OPERATION e Over speed e Over load 110 of rated value for one Hr 2 0 SAFETY REQUIREMENTS Before any clea
9. ct the PF improvement capacitors Correct the setting Replace AVR Adjust the revolving speed Correct the setting Replace AVR Set the AVR stability pot Reduce the Thyristor load Correct the load Tighten the loose connections Check winding resistance amp rewind if required USER MANUAL ALTERNATOR TROUBLE SHOOTING CHART BRUSHLESS ALTERNATORS FAULT CAUSE REPAIR Excessive overheating of one or both bearings temp of bearings over 80 C with or without noise Excessive overheating of alternator frame Excessive vibrations Excessive vibration and humming noise coming from the alternator Smokes spark or flames coming from the alternator Alternator damaged by a significant impact which is followed by humming and vibration 1 Set misalignment 2 Bearing loose in end shield housing 1 Air flow inlet outlet partially clogged or hot air is being circulated either from alternator or prime mover 2 Alternator operating at high Voltage at load 3 Alternator overloaded 4 Load PF less than 0 8 lag Defective mounting or play in the coupling 1 Three phase alternator is single phase loaded in excess of acceptable limits 2 Start up with no load if humming persists faulty alternator stator winding Short circuit in the external circuit including wiring between alternator and control board Object fallen into the machine short circuit or flash in the stator winding Short circuit
10. fles Blocking of inlet ventilation louvers Clean for free air intake Misalignment Check the alignment and readjust it Overloading of machine Check the load and current with nameplate ratings Over heating of bearing Low speed frequency incorrect Correct the speed assemble reassembly of worn out bearings correctly and replace the bearings Misalignment Loose coupling bolts Check and correct the misalignment Tighten the coupling bolts Over heating of armature Over loading Adjust load on the alternator Internal short circuit Rewind the armature Over heating of field coils Over heating of alternators Check the load current and reduce the load of capacitors Load power factor low Improve power factor with connection of capacitor Internal short circuit Replace field coils shorted High vibrations Loose Broken Coupling Loose Tighten or replace the component Foundation Bolts Damaged Bearings Misalignment Correct the alignment USER MANUAL ALTERNATOR N 9 x JE A X lt 72 LLI mal D x carry out defective part replacement you may reguire spares mentioned in the Tables 9 0 and 9 1 as follows As these parts of an alternator can be seen only after dismantling the alternator only let trained technicians Kirloskar Service Dealer handle it we have shown exploded views of the brush type and brushless alternators
11. hould be connected between any one AC output terminal and the magnet frame In case the test reveals the insulation resistance to be less than 2 0 mega ohms IR value at room temperature identify the winding or the component by step by step isolation CAUTION IF THE INSULATION RESISTANCE IS LESS THAN 2 MEGA OHMS THEN THE ALTERNATOR SHOULD NOT BE OPERATED 4 2 ELECTRICAL CHECKS Make sure e A suitable electrical protection device is fitted in the output circuit for safety reasons in line with the codes of practice in force within the country where the alternator is installed Ensure before start up that terminal nuts properly tightened e The control panel protection equipment is correctly set e There is no short circuit due to wrong connections either or in between the terminals of the USER MANUAL ALTERNATOR alternator and the power switch or breaker this part of the circuit is not protected by the breaker A 5 SAFETY Basic safety precautions should always be followed to eliminate fire electric shocks or personal injuries Always remember safety first Read and understand all the instructions Follow alt warnings safety precautions necessary during the installation operation amp maintenance of the alternator Cleaning should be done only when the DG set is not running Do not use damp cloths for cleaning Do not use any liquid or aerosol cleansers Use only the eyebolt
12. in external circuit Faulty parallel connection out of phase Break or deterioration in the coupling Break or twist in shaft extension Shifting or short circuit of main field winding Bursting or unlocking of the fan Diode burnt rectifier bridge damaged 1 Align the set properly 2 Replace the faulty End shield 1 Check air inlet outlets of the alternator 2 Set the voltage to rated value 3 Operate at specified load 4 correct the load power factor Replace the coupling amp check the alignment Reset the speed to the nominal 1 Check and correct the load 2 Rewind stator Stop the set immediately Stop the gen set immediately KIRLOSKAR USER MANUAL ALTERNATOR GREEN POWERS DEAS TROUBLE SHOOTING CHART BRUSHTYPE ALTERNATORS FAULT CAUSE REPAIR No voltage from alternator Open circuit in excitation unit Check the continuity of excitation transformer windings Check rectifier Connections Wrong field connections Check the positive terminal of the rectifier red wire connected to F1 and the negative terminal black wire to F2 Open circuit in field winding Check the continuity of the field winding if open connected the joint that have been broken Loss of residual magnetism Check the residuaal voltage at the alternator terminals This should be about 10 volts and balanced between all the three lines Fault rectifier After charging check voltage at the terminals F1 amp F2 If there is no
13. ined 8 2 CLEANING The generator and excitation unit should be cleaned internally by blowing out with a jet of dry air and by wiping away any deposits of grease and carbon dust with a clean dry cloth All fasteners especially the connectors should be inspected for tightness at less freguent intervals 8 3 BRUSHES For Brushtype only The brushes should be closely examined after every 500 hours of operation to establish that they are bedded properly and are not sticking in their holders and that the correct brush pressure is being maintained Brushes should be replaced with genuine spares before they wear down to 10mm in length New brushes must be bedded by placing a piece of fine carborundum cloth between the brushes and the slipring with the abrasive side towards the brushes and high application of spring pressure The cloth should be drawn forward and backward under tension so that it follows the curvature of the slipring This operation should be finished by several strokes in the direction of rotation lifting the brushes during the return stroke It is essential that all carbon and abrasive particles be removed by a jet of dry air and by wiping with clean and dry cloth During bedding the adjacent winding should be masked to prevent entry of carbon dust The pressure on each brush should be checked and adjusted to 200 250gms per square cm USER MANUAL ALTERNATOR Note Emery paper or any other abrasive should never be used
14. ning lubrication or maintenance operation ensure that the genset is stationary and disconnected from the power supply While stopping the gen set ensure the compliance with the procedure for stopping prime mover The alternator in fact has no emergency stop but is controlled by the device arranged by the installer to stop the prime mover Before installing the alternator arrangements must be made to earth the machine in compliance with any relevant electrical regulations This is the reason why installer must make sure that the grounding system is in good conditions and in compliance with the regulations of the country where the generators will be installed CAUTION THE FINAL INSTALLER IS RESPONSIBLE FOR THE INSTALLATION OF ALL THE PROTECTIONS SECTIONING DEVICES PROTECTION AGAINST DIRECT AND INDIRECT CONTACTS OVER CURRENT AND OVER VOLTAGE PROTECTIONS EMERGENCY STOP ETC NECESSARY FOR THE Rated current value as mentioned in the 20 1800 rpm for 50 Hz USER MANUAL ALTERNATOR MACHINE TO COMPLY WITH THE EXISTING INTER NATIONAL SAFETY REGULATIONS For handing the unpacked alternators always usethe special eyebolts only use ropes having a suitable carrying capacity and do not lift the alternator too much from the floor max 30 cm The operators in charge of the installations operation and maintenance ofthe gen sets must be skilled technicians who know the characteristics of the gen
15. prime mover Adjust the speed of the prime mover unsatisfactory to correct value on no load and full load The speed should be 1560 rpm on no load On load the speed should be uniform at 1500 rpm Full load Load current are not balanced and Adjust and reduce the load within the rated current Open or short circuit in capacitor Check the capacitor and replace if necessary Series winding of excitation unit are If voltage falls excessively low when reserved load is applied a possible reason is that the series winding are reversed Check the voltage at the terminals and slipring unit if there is a large difference reconnect properly Air gap of excitation unit transformer If the regulation is marginally outside not correct the limits 5 then adjustments in air gap to be made Machine over loaded Check the load current with the rated current mentioned on the nameplate Reduce load if necessary KIRLOSKAR USER MANUAL ALTERNATOR GREEN POWER DEAS TROUBLE SHOOTING CHART BRUSHTYPE ALTERNATORS FAULT CAUSE REPAIR Low power factor of the connected load Check power of the load Power factor equipment is necessary if the power factor is lower than rated p f Over heating of alternator Over heating may be generally due to Reduce load so that allowable excessive ambient temperature or altitude temperature are not exceeded Re circulation of hot air in the Avoid re circulation by erecting vicinity of the alternator external baf
16. provided for lifting the alternator Incorrect lifting or moving may result in equipment damage or personal injuries Do not overload the cables as it may lead to fires or electric shocks Never insert any objects inside the alternator as it may lead to fires or electric shocks Do not spill any liquid on the alternator Removing the cover of the alternator while it is running will expose you to the dangers of high voltages Incorrect reassembly can cause electric shocks when the alternator is subsequently used Ensure that the field pole fasteners are not loose The earthing for body of alternator and for neutral should always be as specified 6 DO S and DON T S DO S Tighten the foot mounting bolts Ensure that the alternator is properly grounded Ensure the tightness of the terminal bolts Ensure the crimping of lead wires Check the fuse if provided The body and neutral earthing should be perfect protection gears should be used as reguired The rating of generator should match the load 0100 OMR Ensure thatthe brushes are fully bedded centrally on the slipring 10 Check the free movement of the generator shaft by lifting the brushes 11 Check the spring pressure 12 Check the voltage during commissioning 13 Check the phase sequence during installation 14 All covers and guards should be fitted before starting the generator USER MANUAL ALTERNATOR 15 Af
17. t circuit may occur if liquids e g water etc are split onto areas containing electrical parts 2 2 STARTING AND STOPPING OPERATIONS All the instrumentation for starting running and stopping the system shall be provided by the installer THE STARTING RUNNING AND STOPPING OPERATIONS MUST BE CARRIED OUT BY SKILLED PERSONNEL WHO HAVE READ AND UNDERSTOOD THE SAFETY INSTRUCTIONS AT THE BEGINNING OF THIS MANUAL 2 3 CLEANING Prior to approaching or touching the alternator ensure that it is not live and it is at room temperature at this stage it is possible to clean it on the out side using compressed air NEVER USE LIQUIDS OR WATER FOR INSIDE CLEANING N B The alternator frame is provided with many fixing holes so that vibration damping may be applied in the proper position to ensure the best trim of the gen set 3 0 MECHANICAL COUPLING IS ON END SHIELD FOOT HENCE CARE MUST BE TAKEN WHILE CLOSING THE VENT COVER AFTER TIGHTENING THE BOLT THAT NO MATERIAL SHOULD BE LEFT OUT INSIDE WHICH MAY CAUSE DAMAGE OF FAN UNDER OPERATION A ALTERNATOR FOOT FIXING ON THE DE SIDE 4 0 ELECTRICAL CHECKS 4 1 CHECKING THE INSULATION RESISTANCE If the alternator has been stored under damp conditions or has taken a lengthy time in shipment the insulation resistance should be checked For this purpose all external connections and neutral to earth link if any should be removed A Megger of not more than 500 Volts D C s
18. ter servicing the generator make sure the connections are as per connection diagrams 16 If the lifting of the alternator is necessary then lift using eye bolts only as shown in the figure 17 Maintain and operate the generator correctly 18 Run the DG set daily for at least 5 10 minutes on no load DON T S 1 Don t operate the machine with higher current than the nameplate current 2 Don t operate the machine at less than 0 8 power factor within deration 3 Don t start the machine with load 4 Don t operate the generator without the covers 5 Don t block the air inlet and outlet of the machine 6 Don t have excessive wiring lengths at the application end 7 expose the generator to moist condition Don t use low grade cables Don t operate the alternator if the IR value is found to be less than 2 mega ohms 10 Don t apply capacitive loads 12 Don trunthe machine with the field pole fasteners loose 7 0 7 1 7 2 KIRLOSKAR POWER 5 VOLTAGE SETTING AND ROTATING SPEED The output voltage of the alternator should be checked at rated speed 1500 R PM Usually the alternators are preset at the factory to supply voltage slightly higher from 3 to 5 than the nominal one at rated speed In Frame G2R 160 200 250 280 if one want to regulate the no load voltage of the alternator at determined rated speed it is necessary to operate REMOTE REGULATION OF THE VOLTAGE In Frame G2R 160
19. to clean bedded brushes 8 4 SLIPRINGS For Brushtype only Satisfactory electrical operation of the generator depends principally upon maintenance of good working condition of the sliprings During normal running the rings should have a dark burnished appearance without grooving or uneven wear During periodic maintenance the sliprings and the grooves between them should be cleaned If any signs of wear or blackening are observed the spring pressure should be checked and readjusted if required If blackened badly the rings should be polished by running the machine and using a fine carborundum or emery paper This operation is to be carried out with the brushes lifted If pronounced flats have developed the rings must be skimmed brushes bedded and the machine cleaned out by blowing compressed air before it is put back in to service The brush holders should be positioned on the spindle so as to let the brushes ride on the centre of the width of the sliprings WARNING The field connections FI amp F2 should be removed before working on the sliprings 8 5 BEARINGS The bearings used in the machine are from reputed manufacturers and are of sealed type thus requiring no greasing The bearings are designed for approximately 40 000 hours of use and should be replaced after that However in case high bearing noise is observed or leakage of grease noticed it is strongly recommended that the bearing be checked and replaced immediately to

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