AVK DSG DIG Generators
AVK DSG DIG Generators
AVK DSG DIG Generators
English
Original Instructions 01-2014 A046V044 (Issue 2)
Table of Contents
1. FOREWORD............................................................................................................................. 1
1.1 General.............................................................................................................................. 1
1.2 The Manual........................................................................................................................ 1
1.3 Legal.................................................................................................................................. 2
2. SAFETY PRECAUTIONS......................................................................................................... 3
2.1 Safety Information and Notices used in this manual......................................................... 3
2.2 Skill Requirements of Personnel ....................................................................................... 3
2.3 Risk Assessment ............................................................................................................... 3
2.4 Personal Protective Equipment (PPE) .............................................................................. 3
2.5 Grounding.......................................................................................................................... 4
2.6 Noise ................................................................................................................................. 4
2.7 Electrical Equipment.......................................................................................................... 4
2.7.1 Work on Electrical Equipment ................................................................................ 5
2.8 Lock Out/Tag Out .............................................................................................................. 5
2.9 Lifting ................................................................................................................................. 5
2.10 Generator Operating Areas ............................................................................................. 6
2.11 Safety Information Signs ................................................................................................. 6
2.11.1 Hazard Warning Labels ........................................................................................ 6
2.12 Oils and Grease .............................................................................................................. 7
2.12.1 Solvents and Substances Containing Solvents.................................................... 7
2.13 General Guidance ........................................................................................................... 8
2.13.1 General Safety Instructions .................................................................................. 8
2.13.2 General Guidance for Use.................................................................................. 10
4. INTRODUCTION .................................................................................................................... 15
4.1 Serial Number.................................................................................................................. 15
4.2 Rating Plate ..................................................................................................................... 15
4.3 Important Remarks .......................................................................................................... 15
4.4 Liability, Warranty and Guarantee................................................................................... 16
4.5 Intended Use ................................................................................................................... 17
4.5.1 Operating Conditions............................................................................................ 17
4.6 Documentation ................................................................................................................ 18
4.6.1 Additional Information........................................................................................... 18
4.6.2 Information Not Included in the Documentation ................................................... 18
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9. OPERATION........................................................................................................................... 69
9.1 General............................................................................................................................ 69
9.2 Normal Operating Conditions .......................................................................................... 69
9.3 Number of Starts ............................................................................................................. 69
9.4 Monitoring........................................................................................................................ 69
9.4.1 Bearings................................................................................................................ 70
9.4.2 Vibration................................................................................................................ 70
9.4.3 Stator Temperatures............................................................................................. 70
9.4.4 Heat Exchangers .................................................................................................. 70
9.4.5 Slip Ring Units ...................................................................................................... 70
9.4.6 Documentation of Operation................................................................................. 70
9.5 Shutting Down ................................................................................................................. 70
9.6 Anti-condensation Heaters .............................................................................................. 71
9.7 Flashover Pressure Protection ........................................................................................ 71
9.8 Firefighting and Extinguishing Agents ............................................................................. 72
9.8.1 General ................................................................................................................. 72
9.8.2 Extinguishing Agents ............................................................................................ 73
9.8.3 Cleaning After Fire-fighting................................................................................... 74
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A046V044 (Issue 2) v
Table of Contents 01-2014
vi A046V044 (Issue 2)
1 Foreword
1.1 General
This manual forms part of the items supplied and is an important technical guide to the
intended use of the generator. It represents an essential source of information for the user
and also for managers for the prevention of injuries and damage to the generator.
The generator was manufactured by:
Cummins GeneratorTechnologies GmbH & Co. KG
Bunsenstr. 17
D - 85053 Ingolstadt, Germany
Tel. no.: 0049-(0)841 / 792-0
Fax no.: 0049-(0)841 / 792 250
NOTICE
On the pages that follow the complete name of the company is replaced with the term
"manufacturer".
The generator is the intellectual property of Cummins Generator Technologies. The general
safety regulations, the specific regulations for the place of use and the precautions
described in this document must be followed at all times.
NOTICE
Information in this manual was correct when published. It may be superseded due to our
policy of continuous improvement. Please visit www.cumminsgeneratortechnologies.com for
latest documentation.
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1. Foreword 01-2014
1.3 Legal
All rights to the generator, the principle of the machine, the related drawings etc. lie with the
manufacturer and subject to the "Gesetz über Urheberrecht und verwandte Schutzrechte"
(UG) (German law on copyright and related property rights) dated 09.09.1965 in the
applicable version.
According to copyright law, competition law and the BGB (German civil code) copying is only
allowed with prior written approval.
2 A046V044 (Issue 2)
2 Safety Precautions
2.1 Safety Information and Notices used in this
manual
Danger, Warning and Caution panels are used in this manual to describe the sources of
hazards, their consequences and how to avoid injury. Notice panels emphasize important or
critical instructions.
DANGER
Danger indicates a hazardous situation which, if not avoided, WILL result in death or serious
injury.
WARNING
Warning indicates a hazardous situation which, if not avoided, COULD result in death or
serious injury.
CAUTION
Caution indicates a hazardous situation which, if not avoided, COULD result in minor or
moderate injury.
NOTICE
Notice refers to a method or practice which can result in product damage, or to draw
attention to additional information or explanations.
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2. Safety Precautions 01-2014
2.5 Grounding
WARNING
High Voltage
Will shock, burn or can cause death.
Work on electrical systems must be done by an electrician or instructed persons under the
management and supervision of an electrician wearing suitable PPE.
Parts of the machine and system on which inspections, servicing and repair work are done
must, if so stipulated, be electrically isolated.
1. Test the electrically isolated parts for electrical isolation using a suitable voltage tester,
then ground and short-circuit and also isolate neighboring live parts.
2. In case of work on high-voltage assemblies, after electrically isolating connect the line
cable to ground and short-circuit the components, e.g. capacitors, using a grounding bar.
The generator is permanently grounded.
2.6 Noise
CAUTION
Generators in operation emit noise.
Exposure to noise can cause hearing damage.
Wear appropriate ear protection at all times. Maximun A-weighted noise emissions may reach
110 dB(A). Contact the supplier for application-specific details.
Work that requires access to electrical conductors must comply with all applicable local and
national electrical safety procedures for the voltages involved and any site specific rules.
Always use genuine branded replacement parts.
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DANGER
Hazardous voltage.
Will shock burn or cause death.
Faulty electrical components can be live and as a result life-threatening. Any defects found in
electrical systems, assemblies, equipment must be rectified without delay. If there is an acute
risk until rectified, the system or the assembly must not be used in the defective state.
WARNING
Magnetic field.
Generator has a powerful magnetic field that can interfere with implanted medical devices
such as heart pacemakers.
Do not approach the generator if you have an implanted medical device.
Work on electrical cables is to be done in accordance with local or national electrical safety
regulations applicable for the voltage as well as the safety regulations applicable on the site.
Each generator is built in accordance with the applicable regulations. The electrical control
system is compliant with the VDE regulations, VBG 4 and EN 60204.
• Only use approved protective equipment
• In case of malfunctions in the supply of electrical power, immediately shut down the
unit (exception: if used as an emergency power generator).
2.9 Lifting
WARNING
Improper lifting can cause serious injuries to persons or can cause death.
Do not use the generator lifting points to lift the complete generating set (generator coupled
to motive power source)
The lifting points provided are designed for lifting the generator only.
Do not remove the lifting label attached to one of the lifting points.
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2. Safety Precautions 01-2014
Always wear suitable PPE when working in hatched areas or directly in-line with any air
inlet/outlet.
Make sure this consideration is captured in your risk assessment.
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• Pay attention to fire alarm and firefighting procedures; pay attention to location and
operation of fire extinguishing systems (see Section 9.8 on page 72).
• Only allow trainees, apprentices or personnel under instruction or personnel
undergoing general training to work on the generator under the constant supervision of
an experienced person.
• Only task trained, experienced persons with the attachment of loads and signaling to
crane drivers. The person providing the signals must be visible for the operator.
• During installation work above head height, climbing aids and working platforms
intended for this purpose with appropriate safety features must be used. Do not use
generator components and attachments as climbing aids! During servicing work at
heights, wear fall arresting equipment.
• Keep all grips, steps, railing, pedestals, platforms, ladders free of debris and dirt.
• The generator electrical equipment is to be checked regularly; loose connections or
burnt, damaged cables must be rectified immediately.
• If work is necessary on electrically live parts, involve a second person who can provide
immediate assistance in case of an emergency. Cordon off working area with a red-
white safety chain and a warning sign. Only use electrically insulated tools. Follow the
local safety regulations, e.g. VDE 0105
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2. Safety Precautions 01-2014
• Make sure individual parts, as well as larger assemblies, are fastened to lifting
equipment and secured on replacement so that they can cause no harm. Only use
suitable lifting equipment in correct working order with adequate load bearing capacity.
Do not stand or work under suspended loads.
• At the start of servicing / repair, clean generator of dirt and residue of anti-corrosion
agents. Do not use aggressive cleaning agents. Use fluff-free cloths for cleaning.
• After cleaning, check all oil, compressed air lines for leaks, loose connections, chafing
and damage. Correct any defects found immediately.
• If it is necessary to remove safety features during set-up, servicing and repair, the
safety features must be re-fitted and checked immediately on completion of the
servicing and repair work.
• Ensure any materials used are disposed of safely with due consideration for the
environment.
Generators have dangerous, live and rotating parts and hot surfaces. All work in relation to
transport, storage, installation, connection, commissioning, operation and servicing must be
done by authorized, trained specialist staff. National standards, e.g. EN 50 110-1 / DIN VDE
0105 / IEC 60364 are to be followed in the specific case.
It is forbidden to place the unit in operation until the end product is compliant with local
regulations (follow in particular local safety and installation regulations, e.g. EN 60204).
These machines comply with the IEC EN 60034 series of standards. It is forbidden to use
them in potentially explosive atmospheres.
Under no circumstances use a degree of protection ≤ IP23 outdoors or in dusty
environments. Standard Air-cooled models are suitable for ambient temperatures from -
15 °C to +40 °C and altitudes of ≤ 1000 m above sea level. The ambient temperature for
air/water-cooled models must not be less than +5 °C without additional precautions. For
generators with sleeve bearings, the ambient temperature must not be lower than 0° C. The
oil temperature must be at least 15 °C for the start. (For generators with sleeve bearings
also see the documentation from the bearing manufacturer). Pay attention to any differing
information on the rating plate. The conditions in the place of operation must match all
agreed information on the rating plate and in the specification.
In cases where there is a contradiction between the content of this manual and the machine
supplied, contact the manufacturer.
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3 Safety Directives and Standards
AVK generators comply with European safety regulations as well as national and
international regulations on generators issued in the EC. The generator must be used in
accordance with the standards and intended use within the limits stated on the rating plate.
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14 A046V044 (Issue 2)
4 Introduction
4.1 Serial Number
Each generator is marked with a unique serial number. It is marked on the rating plate on
the generator. (See Section 4.2 on page 15)
The serial number is to be stated in any future correspondence related to the generator, as it
is the only information that is used to identify the specific generator.
A rating plate is permanently attached to the generator and must not be removed. The rating
plate provides information on manufacture, identification, electrical and mechanical aspects.
In cases where there is a contradiction between the content of this manual and the
generator supplied, contact the manufacturer.
• The safety measures that are listed in the safety instructions in the manual must be
observed at all times.
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4. Introduction 01-2014
Safety in the workplace is dependent on the alertness, care and common sense of all
persons who operate and service the machines. Along with the safety precautions
recommended here, caution is always required in the vicinity of machines: Pay attention to
your safety!
NOTICE
The installation must comply with the instructions and regulations for health and safety. This
statement applies for general safety regulations in the related country, specific agreements
made for the related works, safety instructions included in this manual, and separate safety
instructions supplied with the generator.
NOTICE
Claims cannot be made under the warranty if the operating conditions of the generator have
been changed, changes have been made to the design of the generator or repair work has
been done on the generator without prior written agreement from the manufacturer.
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4.5.1.2 Purpose
WARNING
Improper use.
Can cause hazards that could result in death or serious injury.
Always a operate in an accordance with the operation instructions.
NOTICE
Consult the manufacturer if you want to use the generator in a different manner to that
described in the order documents.
The generator is designed for onshore or maritime applications as per the order
documentation.
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4. Introduction 01-2014
NOTICE
Damage caused by operation otherwise than as intended or by incorrect operation is not
covered by the manufacturer's warranty and guarantee obligations. The risk is borne solely
by the user.
We recommend that operating hours, malfunctions, inspections, servicing and repairs are
documented in a log.
If malfunctions or damage cannot be rectified by the operating organization's specialist
personnel, please contact our customer service department.
Address:
Cummins Generator Technologies Germany GmbH
Bunsenstr. 17
85053 Ingolstadt, Germany
Telephone: +49 841 / 792-0
Fax: +49 841 / 792-195
4.6 Documentation
4.6.1 Additional Information
NOTICE
Some customer-specific elements may not be included in this user manual. Additional
documentation can be found in the Appendix. If the information in this manual does not
match the information in the Appendix, the data in the supplementary documentation in the
Appendix applies.
In addition to this manual, each set of documentation is supplied with a dimension drawing
and rotor drawing, an electrical circuit diagram as well as data sheets that state, among
others, the following order-specific information:
1. External dimensions of the generator
2. Generator weight
3. Moment of inertia of the rotor
4. Position of the lifting eyes on the generator
5. Instrumentation and position of additional equipment
6. Requirements on bearing oil and lubricants
7. Main and ancillary connections.
18 A046V044 (Issue 2)
5 Transportation, Storage and
Corrosion Protection
5.1 Transportation and Packaging
5.1.1 General
The generator is supplied on a transport frame with a transport lock.
The following protective measures are taken in the factory before the delivery of the
generator. If the generator is moved subsequently, the same protective measures are to be
taken:
1. Protect machined surfaces
e.g. the seat for the drive coupling, are protected against corrosion using an anti-
corrosion coating.
5.1.5 Packaging
Packaging depends on the mode of transport (truck, ship, air freight).
The generator is packed using environmentally-friendly materials (blocks of wood, wooden
crates, plastic sheet) that comply with the IPPC regulations.
• For transport by ship, the generator must be packed for a maritime environment to
protect against splashes of salt water, moisture and vibration damage during loading,
transport and unloading
• For long transport routes, on customer request the generator will be sealed with air-
and dust-tight plastic sheet with desiccant.
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5. Transportation, Storage and Corrosion Protection 01-2014
The generator must be transported and unloaded by persons who are familiar with the lifting
equipment and related ancillary equipment. All lifting equipment and tackle must be suitable
for the weight of the generator and must comply with local safety regulations. Secure
transport routes. Lifting fixtures (for example, lifting eyes) must only be used to lift the item to
which they are attached. Always use the lifting features on the base frame to lift the
complete generating set.
The transport eyes on the generator are only to be used to transport the individual
generator, (not for lifting a complete generating set).
NOTICE
Do not transport using a trolley over uneven surfaces (e.g. rails).
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5. Transportation, Storage and Corrosion Protection 01-2014
The generator must be transported and unloaded by persons who are familiar with the lifting
equipment and related ancillary equipment. All lifting equipment and tackle must be suitable
for the weight of the generator and must comply with local safety regulations. Secure
transport routes. Lifting fixtures (for example, lifting eyes) must only be used to lift the item to
which they are attached. Always use the lifting features on the base frame to lift the
complete generating set.
The transport eyes on the generator are only to be used to transport the individual
generator, (not for lifting a complete generating set).
NOTICE
Do not transport using a trolley over uneven surfaces (e.g. rails).
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01-2014 5. Transportation, Storage and Corrosion Protection
NOTICE
Do not transport using a trolley over uneven surfaces (e.g. rails).)
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01-2014 5. Transportation, Storage and Corrosion Protection
5.2 Storage
5.2.1 Storage in a Suitable Room (Less Than 6 Months)
CAUTION
Fire Hazzard
Will burn, cause personal injury or could cause death
Make sure no highly flammable or flammable objects are stored in the vicinity of the anti-
condensation heateror generator packaging.
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01-2014 5. Transportation, Storage and Corrosion Protection
3. All bare surfaces on the generator are protected with Tectyl or protective lacquer on
delivery. Regularly check the protection and proceed as follows in case of damage:
a. In case of damage, clean any rust film and other dirt from bare surfaces (ends of
shaft, flange, screws etc.).
b. Cover cleaned, damaged surfaces using protective lacquer or protective wax
(Tectyl 511M or 846K).
Refer to an Appendix for documentation from the sleeve bearing manufacturer. If the
instructions in the Appendix vary from those in this manual, the instructions in the Appendix
apply.
To protect the sleeve bearings against corrosion take the following measures:
• Fittings on the sleeve bearings are sealed in the factory and sealing lacquer applied.
1. If the sleeve bearing has already been filled with oil (e.g. after test run on the unit),
drain this oil.
2. Spray Tectyl 511 or equivalent with a compressed air tool through the filler
opening into the bearing. Repeat this corrosion protection treatment every six
months for two years. For this purpose it is recommended to open the packaging
at the bearings.
3. Check the compatibility of synthetic oil with bearing materials, corrosion protection
materials and oil filling.
4. Remove the sight glass for the oil ring, remove the oil and open the oil drain (see
Figures 2&3).
5. Spray corrosion protection agent into the openings using compressed air.
6. The parts of the bearing must be fully covered with lubricant to prevent corrosion
during the storage period.
7. Seal the sight glasses and the oil drain.
8. Repeat the procedure on the second bearing.
9. After protection against corrosion, carefully re-seal the packaging to prevent
corrosion due to external effects.
Generators with sleeve bearings are fitted with a transport lock to protect the bearing against
damage during transport and storage.
Check the transport lock for bolt tightness regularly.
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5. Transportation, Storage and Corrosion Protection 01-2014
2. Remove the transport lock and Turn the rotor monthly so that the position of the rolling
elements changes. The rotor must rotate at least 420°.
3. Fill the entire bearing chamber with grease.
Before operating a corrosion-protected generator, remove the measures taken and logged
for storage and establish the state required to commission the generator.
• Remove the anti-corrosion coatings using white spirit or a similar oil-based solvent.
NOTICE
An excessive amount of grease or old grease in the bearings during operation will result in
serious bearing damage! Pay regard to the storage time and the grease amount.
Check the amount of grease in the attachments. If necessary contact the manufacturer for
information on the first filling.
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01-2014 5. Transportation, Storage and Corrosion Protection
5.4.3 Cooler
Follow the operation and maintenance instructions supplied by the cooler manufacturer.
Check whether condensed water has formed in the generator. If there is condensed water
present, open the drain plug at the lowest point on the generator and close again after
draining the condensed water.
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5. Transportation, Storage and Corrosion Protection 01-2014
No Description
1 Oil Ring Sight Glass
2 Oil Sight Glass
3 Oil Drain
No Description
1 Oil Ring Sight Glass
2 Oil Sight Glass
3 Oil Drain
30 A046V044 (Issue 2)
6 Installation and Alignment
6.1 General
DANGER
Hazardous voltage and rotating parts.
Will shock, burn, or cause loss of limbs or death.
Prevent unintentional operation of the generator and accidental damage caused when work is
done nearby.
Follow general and local health and safety instructions during installation.
Good planning and comprehensive preparations before installation are necessary for
malfunction-free, reliable and safe operation of the generator
Follow the standards for connections and use of electrical equipment, in particular national
standards, for the installation of the equipment (e.g. see standard IEC 60079-14 or EN
60204).
When welding, do not use generator as (earth) ground.
NOTICE
An excessive amount of grease or old grease in the bearings during operation will
result in serious bearing damage. Pay regard to the storage time and the grease
amount.
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6. Installation and Alignment 01-2014
6.2.3.2 Assembly
WARNING
Rotating Parts.
Will cause severe injury. The coupling is to be protected with a guard. There is a hazard in
operation due to rotating parts.
In operation, be careful of rotating parts.
WARNING
Hot parts.
Cause serious burns.
Prevent skin contact with hot parts using PPE.
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01-2014 6. Installation and Alignment
6.3.3.2 Calculations
Check and calculate during the project phase
1. The natural frequency of vibration in the overall system in 6 degrees of freedom.
2. Calculate the static displacements in x, y and z directions on all elastic components.
Take into account all loads effective at nominal power output due to the inherent weight
of the motor, the motor nominal torque (or output torque for flange-mounted
gearboxes), and ship pitch and roll motion.
3. Compare the displacement values calculated with the values allowed for the electrical
components.
4. Calculate the forced damped vibration.
The result must conform to the specifications for the ship classification and be agreed with
the manufacturer of the component
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6. Installation and Alignment 01-2014
The contact surfaces for screw heads and nuts must be flat and machined parallel.
Do not tack weld generator mounting screws and nuts.
The screw joint must be designed for the maximum possible load that can occur.
The required pre-load on the mounting screws is to be defined in agreement with the
manufacturer of the prime mover or the manufacturer of the related system component.
The preferred fastener type is a cap screw, installed so that the screw pre-load can be
checked at any time.
6.3.3.4 Requirements
Follow the manufacturer's installation regulations during the mechanical mounting of the
individual components on the foundation.
Design of the mounting must be agreed with the certification authority.
Make sure the assembly and inspection openings on the drive systems provided for
maintenance measures remain accessible.
Final fastening must be done after alignment done. Consider the operation-related thermal
expansion and the dynamic behavior of the system components (coupling, gearbox etc.)
during alignment.
Make sure that the alignment of the individual system components to each other does not
change during mechanical work on the mounting.
All welding work in the area of the mounting must be completed before mounting the
generator.
During the design of an elastic mounting, consider the aging and natural wear of the
mounting elements. Check and log the settling rates at intervals specified by the
manufacturer. Replace the elastic mounting when the maximum allowed amount of settling
occurs.
6.3.4.2 Calculations
Check and calculate during the design phase
1. The natural frequency of vibration for the overall system in 6 degrees of freedom.
2. Calculate the forced damped vibration.
3. Calculate the mounting forces and screw joints
The results must conform to the specifications and be agreed with the manufacturer of the
related system component.
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6.3.4.7 Cementing
NOTICE
Cracks in the concrete or poor fastening to the concrete foundation can loosen the generator.
Fill the holes in the foundation completely and avoid cavities.
Cementing the generator in the foundation is a very important part of the installation. Follow
the instructions of the concrete manufacturer.
Use high-quality concrete that is not subject to shrinkage to prevent problems during
cementing.
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6. Installation and Alignment 01-2014
WARNING
Rotating parts.
Can cause loss of limbs or death.
The coupling must be protected with a guard. In operation, be careful of rotating parts.
Keep the alignment and installation equipment together with the transport lock for future use
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01-2014 6. Installation and Alignment
General figure for the angular offset: ≤ 0.05 mm / 100 mm coupling diameter
General figure for the coupling distance: ≥ 3 mm
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01-2014 6. Installation and Alignment
The alignment process starts with the measurement of the run-out on the coupling halves.
This measurement provides an indication of any inaccuracy on the shaft and/or the coupling
halves.
The run-out on the coupling halves is measured in relation to the generator bearing housing.
Fit the dial gauges as shown in Figure 8 on page 39. Rotate the rotor shaft with a simple
lever. Check the run-out of the coupling half on the prime mover in relation to the bearing
housing.
Fill sleeve bearings with oil before rotating. The permissible run-out error is less than 0.02
mm (0.8 mil).
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6. Installation and Alignment 01-2014
NOTICE
Do not turn generator rotor using the fan. The fan will not withstand such forces and will be
damaged.
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01-2014 6. Installation and Alignment
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6. Installation and Alignment 01-2014
• Check the radial alignment accuracy by measuring the distance between the shaft and
the machined inside diameter of the bearing plate.
42 A046V044 (Issue 2)
7 Mechanical and Electrical
Connections
7.1 General
Do not drill additional holes and threads. The generator will be damaged.
Mechanical and electrical connections are made after installation and alignment. Mechanical
connections can include the connection of air ducts, water pipes and/or an oil supply system.
Electrical connections include the connection of line cables and additional cables, ground
cables and optionally external fan motors.
NOTICE
Check the direction of rotation of the external fan motor (fan) visually before you start the
generator. If the fan motor runs in the wrong direction, its phase sequence must be changed.
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NOTICE
The bearings are supplied without lubricant. If the generator is operated without lubricant,
immediate bearing damage will result.
Do not drill additional holes and threads. The generator will be damaged.
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01-2014 7. Mechanical and Electrical Connections
Sleeve bearings with hydrostatic lifting are used in critical cases To prevent damage due to
metal contact on the bearing surfaces, hydrostatic systems ensure low bearing wear where
the generator starts at low speeds, or with frequent starts/stops, high starting load or very
long coast-down times. For these application conditions, the use of hydrostatic systems is
strongly recommended by the manufacturer.
The maximum load bearing capacity of the system is defined by the maximum pump
pressure. The hydrostatic pump pressure is normally limited to 200 bar. Due to small
lubrication gap at the shaft surface in case of metal-on-metal contact, the pump pressure is
highest at the start of lifting. Lifting is associated with a noticeable pressure surge. As the
lubrication gap increases in size after lifting the shaft, the pressure drops as a function of the
bearing geometry and the volume of lubricant. The static pump pressure for supporting the
shaft should be around 100 bar.
Refer to the order-specific documentation for the minimum speed for operating a generator
without a hydrostatic system.
7.4.2 Safety
Electrical work must be done by appropriately qualified specialist personnel. The following
safety instructions must be followed:
1. Switch off all units including ancillary equipment
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7.4.3 Moisture
The ability of air to absorb water is temperature-dependent. If the air temperature drops
below the saturation point, condensation may form on the winding insulation, as a result the
electrical resistance will drop. Further protective measures are necessary in a humid
operating environment!
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01-2014 7. Mechanical and Electrical Connections
NOTICE
On all secondary connections and measuring connections, the maximum test voltage is 500
V DC. The insulation resistance must not be less than 5 MΩ
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DANGER
Hazardous voltage.
Will shock, burn or cause death.
Before installation of the generator, make sure that the power cables are disconnected from
the supply system and that the cables are connected to the protective ground.
The dimensions of the power cables must be designed for the rated current and comply with
local standards. The cable terminating fittings must be of a suitable type and be of the
correct size. Check the connections on all equipment.
Standard stator terminals are marked in accordance with IEC 60034-8 using the letters U, V
and W. The neutral terminal is marked with N. Insulation stripping, connecting and insulating
high-voltage cables must be done in accordance with the instructions from the cable
manufacturer.
Fasten the cables so that the bus bar in the terminal box is not placed under mechanical
load.
Compare the phase sequence with the circuit diagram and rating plate.
• Seal unused cable glands in the terminal box and generator against the ingress of dust
and moisture so they cannot loosen.
• Re-tighten all contact screws and nuts to the specified torque.
• If sudden loads or generator vibration are to be expected, fasten cables using cable
clips or cable racks.
• Make sure there is enough play at elastically mounted equipment.
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FIGURE 10. VIBRATION DAMPERS ON BASE FRAME. ENSURE FREE CABLE LENGTH.
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7. Mechanical and Electrical Connections 01-2014
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G1 Primary machine
G2 Excitation machine
G3 Auxiliary windings
T6 Static transforme
T24 Measuring transformer
T32 Isolating transformer
R1 Set point adjuster
The auxiliary windings G3 supply the excitation winding of the brushless three-phase AC
exciter G2 with power via the control element of the voltage regulator.
The voltage generated in the three-phase winding in the excitation rotor is rectified in a B6
bridge circuit and fed to the rotor in the generator G1.
The voltage of the primary generator is controlled with changing loads by the voltage
regulator changing the excitation current in winding G2.
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7.6.3.2 De-excitation
DANGER
Hazardous voltage.
Will shock, burn or cause death.
When working on electrical systems be cautious because of the voltages. The value of the
residual voltage is above the permitted physical contact voltage. Ensure that you adhere to
the circuit diagram and use appropriate PPE.
The interruption must always be made on the regulator supply side (see order-specific
documentation). For de-excitation the current in winding J1K1 on the excitation machine G2
must be reduced to zero.
• Disconnect power supply to the regulator by removing the jumpers or using a switch as
per the circuit diagram.
• The switch contacts must be designed for 10 A and 230 V AC.
Follow the information in the related circuit diagram. After de-excitation the generator
continues to generate a residual voltage of approx. 15% of UN at the rated speed.
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FIGURE 16. GENERATOR DIG 150I/8; 3300 KVA; 11 KV; 50 HZ; 750 MIN-1 SWITCHING IN 1000
KVA; COS ⱷ = 0.1
FIGURE 17. GENERATOR DIG 150I/8; 3300 KVA; 11 KV; 50 HZ; 750 MIN-1 SHUTTING DOWN
1000 KVA; COS ⱷ = 0.1
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7.6.5 Currents
7.6.5.1 Asymmetrical Loading
The electrical design of the generator also permits asymmetrical loading.
For an asymmetrical load without loading on the other phases, the following are allowed as
per IEC 60034-1.
1. I2/IN ≤ 8% continuous, where no stator current exceeds the rated current.
2. (I2/IN)²*t ≤ 20 s for transient processes.
7.6.5.2 Overload
• The generator is sized for 1.5 times rated current for 30 s duration.
• In line with the specifications for combustion engines, an overload of 1.1 times rated
current for 1 hour is permitted once within 6 hours.
• The excitation system permits a brief overload up to 1.8 times rated current for approx.
10 s.
This short-term overload capability is available, e.g. for starting currents for
asynchronous motors.
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NOTICE
A double ground fault behaves in all circumstances like a short circuit.
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0% at cos phi = 1
1.3% at cos phi = 0.9
1.8% at cos phi = 0.8
3% at cos phi = 0.1
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8 Commissioning and Starting
8.1 General
The commissioning report is an important document for future servicing and maintenance of
the generator as well as any troubleshooting. Commissioning can only be considered
complete once an adequate commissioning report has been prepared and archived.
It is imperative that the commissioning report is submitted on making claims under the
warranty. For contact information see Section 12.2 on page 120.
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The temperature alarm level for resistive temperature sensors must be set as low as
possible. The level can be determined based on test results or the operating temperature
measured. The temperature alarm can be set 5 - 10 K (11 - 20 °F) higher than the operating
temperature of the generator with maximum load at the highest possible ambient
temperature.
If a temperature monitoring system with two functions is used, the lower level is normally
used as the alarm level and the higher level as the shutdown level.
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• These warning values and shutdown values can only be achieved by using the
synthetic oils stated on the outline drawing.
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8.5.3 Starting
First check the direction of rotation of the generator on starting for the first time. If external
fan motors are installed, check the direction of rotation. Check that the rotating parts do not
touch any fixed components.
If the generator does not have a fixed bearing and the generator is started with a flexible
coupling, it is normal for the shaft to move axially before it stabilizes. If installed, check the
adjustment indicator and correct the alignment in case of errors (see Section 6.4 on page
36).
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8.7.1 Bearings
8.7.1.1 Generators with Anti-friction Bearings
• Do not re-grease the generator during commissioning.
• If the generator has been protected against corrosion, remove the corrosion protection
before starting for the first time.
The type of grease used originally is stated on the rating plate on the generator. Refer to the
allowed grease types in Section 10.6.2.4 on page 92, types of greases.
The temperature of the bearings increases at the start due to excess grease. After a few
hours the excess grease is driven out and the temperature of the bearing drops to the
normal operating level. See Section 10.6.2.4 on page 92
Adhere strictly to the re-lubrication interval. The interval between two lubrication intervals
must not exceed 12 months under any circumstances. After the generator has been
operated for several hours, measure the vibration and record the values for subsequent
reference.
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8.7.2 Vibration
You will find a detailed description of the vibration in Section 10.5 on page 86.
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9 Operation
9.1 General
CAUTION
Hot Surfaces.
Will burn.
Use PPE and measure the temperature of the surfaces before touching them.
NOTICE
Generator overload can result in serious damage.
NOTICE
Always observe the safety precautions.
To ensure trouble-free operation, the generator must be carefully serviced and monitored.
Before starting the generator, ensure the following:
1. Check the sleeve bearings for the correct oil and oil level according to the technical
data and the outline drawing
2. All cooling systems are operating
3. Check the generator and all attachments for leaks, soiling or damage
4. Check that there is no servicing work in progress
5. The operators and the system are ready for the machine start.
In case of deviations from the normal operating state, e.g. raised temperatures, noise or
vibration, shut down the generator and find the cause. If in doubt, contact the manufacturer.
9.4 Monitoring
Check the generator at regular intervals. Abnormal operating conditions must be
investigated.
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The objective of monitoring inspection is to make operating personnel familiar with the
system. This aspect is very important for the timely identification and rectification of
deviations and malfunctions. Normal operational monitoring includes logging the operating
data such as load, temperatures and vibration.This data form a useful basis for servicing and
maintenance.
During the initial operating period (up to 200 hours) monitor the generator particularly
intensively. Check the temperature of the bearings and windings, the load, the current, the
cooling, the lubrication and vibration several times a day.
In the subsequent weeks and months (200-1000 hours) a daily check is sufficient. Record
the results of the check in the inspection report and archive it at the operating organization.
Subsequently, the interval between the inspections can be further extended if operation is
continuous and stable.
9.4.1 Bearings
Monitor bearing temperatures (see Section 8.4.3 on page 62) and lubrication (see Section
10.6 on page 89).
9.4.2 Vibration
Monitor the vibration level in the generator. See Section 10.5 on page 86.
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It is not sufficient to simply renew the flashover protection. A protective system for pressure
relief is installed in Cummins generators; this system limits the extent of damage due to an
event in the terminal box. A pressure event can occur if a fault causes flashover in the
terminal box. During this process air and other materials suddenly expand to several times
their initial volume due to the extremely high temperature.
Flashover protection attempts to reduce the pressure caused by this reaction in a defined
manner using predetermined breaking points so that the effects of the event can be
minimized. The objective is to exclude a hazard for personnel.
For this purpose a predefined breaking point for pressure relief is integrated into the sleeve
on the terminal box. This feature consists of four individual plates that are arranged to form a
square plate, or a metal film. The flashover protection is mounted pointing towards the
generator to prevent harm to any person nearby and to minimize any debris thrown out.
The flashover protection must be sealed so that the required degree of protection is
achieved, but the pressure relief function is not affected.
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Pay attention to the generally applicable and national safety distances to electrical systems,
e.g. DIN VDE 0132 (Fire-fighting in the area of electrical systems). Make sure regular
inpection and tests are done.
Pay attention to the generally applicable and national health and safety regulations.
During extinguishing tasks in electrical systems and in their vicinity, take precautions to
prevent an electric shock hazard for the fire fighters or operators.
This requirement also involves:
• The use of suitable tools and equipment, e.g.
• Insulated tools
• Grounding rods
• Short circuiting devices
• Insulating covers
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Carbon dioxide is not electrically conducting and does not leave any residue. It can be used
on live systems without restriction.
NOTICE
Extinguishing agent residue can have a highly corrosive effect on parts of the generator.
Contact the manufacturer of the extinguishing agent for information on suitable measures to
counteract this effect and regularly check their effectiveness.
After all necessary measures for firefighting, immediately start to remove extinguishing agent
residue.
Also check if parts of a system not directly affected by a fire may have been damaged or
soiled by extinguishing agent.
The manufacturer does not provide any warranty on generators and their attachments if
these are soiled by extinguishing agent.
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10 Service and Maintenance
10.1 Preventive Servicing
A generator is often an important element of a larger installation.
If the generator is correctly monitored and serviced, the generator will function correctly and
reliably for a long time.
The purpose of the servicing is therefore:
• To ensure that the generator operates reliably and without anomalies or interruptions
• To be able to plan the necessary maintenance work in advance to minimize the
downtimes.
The normal monitoring during operation includes the recording of operating data, e.g. load,
temperature and vibration, as well as checking for correct lubrication and measuring the
insulation resistances.
During the first days and weeks after commissioning or undertaking maintenance measures,
the generator must be monitored intensively. The temperature of the bearings and windings,
the load, the current, the cooling, the lubrication and vibration are to be checked regularly.
This section contains recommendations in relation to a servicing schedule as well as
instructions for normal servicing tasks. These instructions and recommendations are to be
read carefully and used as the basis during the planning of the servicing schedule. Please
note that the servicing recommendations stated in this section represent a minimum. More
intensive maintenance and monitoring will increase the reliability and service life of the
generator. The servicing should be intensified if there are local conditions with high
requirements or extreme reliability is required. Cummins Service will be pleased to assist
you in case of questions on the specific requirements categorization or servicing
recommendations.
The data recorded during the monitoring and servicing will make it easier to foresee and
plan further measures. If you detect anomalies, the instructions in troubleshooting will assist
you in the location of the causes.
We recommend the use of checklists (in the Appendix) for the preparation of servicing
schedules. The actual servicing as well as any troubleshooting must be done by specialist
personnel. Cummins Service will be pleased to provide assistance with this task. You will
find the related contact information at the start of the documentation.
A key element of the preventive servicing is the availability of a selection of suitable service
parts. To be able to have quick access to crucial service parts in case of need, you should
keep a basic range in stock.
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WARNING
Hazardous voltages, rotating parts and hot surfaces will shock, burn or cause loss of limbs
or death.
Before starting work on the unit, it is to be shut down and locked. During the work make sure
that a potentially explosive atmosphere is not produced and is not present.
Qualified, specialist personnel trained in the necessary servicing procedures and tests are to
be tasked with the servicing of the electrical system and the installation.
For general safety information, see safety instructions at the start of the manual. See on
page 3. Before starting any work on electrical systems, take general electrical safety
precautions and follow local regulations to prevent injuries. This action should be taken in
accordance with the instructions from the operating organization's safety personnel.
Safety rules before starting work:
1. Switch off
2. Lock out
3. Check all lines and equipment are dead
4. Ground and short-circuit phases
5. Cover, partition and screen off adjacent line sections.
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The servicing is to be done after an interval of 25,000 equivalent operating hours or three
years after commissioning or servicing at the latest.
Servicing interval 50000 operating hours
This servicing interval can require the removal of generator components. The purpose of this
servicing is to check inaccessible components to safeguard long-term operation.
The servicing is dependent on the type and the installation of the generator as well as the
feasibility of undertaking the inspection. The tools for this servicing include special servicing
tools.
The servicing is to be done after an interval of 50000 equivalent operating hours or 6 years
after commissioning at the latest.
Servicing interval 100000 operating hours
This servicing interval requires a complete generator overhaul.
The purpose of this servicing is to equip the generator for continued long-term operation.
The servicing is dependent on the type and the installation of the generator. The servicing
can only be done by appropriately qualified personnel.
The servicing is to be done after an interval of 100000 equivalent operating hours after
commissioning.
10.3.1 Generator
SERVICING WORK TYPE Servicing Intervals
Repair or Replace
Test and Measure
Visual inspection
100,000 hours
X = required
Clean
* = if necessary
O= see rating
plate/documentation
Machine operation - Starting,
shutting down, vibration * X X * X X
measurement
General overhaul * X
Coupling and foundation - * X X X X
Specially cracks, rust, alignment
General
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Repair or replace
100,000 hours
X = required
Clean
* = if necessary
O= see rating
plate/documentation
Main electrical cables - Wear, X X X X
fastening
Main electrical cables -
Oxidation, fastening, cracks, X X X X
Main electrical connections
screw joints
Main electrical connections - X X X X
Insulation, resistance
Main electrical cables - Strain X X X
relief X
Regulator - Function X X X X
Current transformers, voltage
transformers, isolators - General X X X X
condition, fastening,
connections
Cable routes - Condition of the
cables to the generator and in X X X X
the generator
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Repair or replace
100,000 hours
X = required
Clean
* = if necessary
O= see rating
plate/documentation
Stator - Fastening, cracks, weld X X X
seams
Insulation of the stator winding -
Wear, cleanliness, insulation X X * X X
resistance,
Stator winding assembly - X * X X
Damage to insulation
Exciter stator - rotor Resistance X X X
Rectifier carrier - Fastening, X X * X X
cable, diodes, varistors
Auxiliary windings - Resistance X X X
measurement
Stator and rotor
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10.3.4 Accessories
SERVICING WORK TYPE Servicing Intervals
Repair or Replace
Test and Measure
Visual inspection
100,000 hours
X = required
Clean
* = if necessary
O= see rating
plate/documentation
Accessories
Repair or Replace
Test and Measure
Visual inspection
100,000 hours
X = required
Clean
* = if necessary
O= see rating
plate/documentation
Assembly - Fastening, * X * * X X
insulation, connections
Slip Ring Units
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Repair or Replace
Test and Measure
Visual inspection
100,000 hours
X = required
Clean
* = if necessary
O= see rating
plate/documentation
Lubrication system and anti-friction bearings
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Repair or Replace
Test and Measure
Visual inspection
100,000 hours
X = required
Clean
* = if necessary
O = see rating
plate/documentation
Bearing assembly -Fastening, X X * X X
general condition, soiling
Oil - oil level X * O
Bearing shells -General X * X
condition, wear
Loose lubrication ring - X * X
Lubrication system and sleeve bearings
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Repair or Replace
Test and Measure
Visual inspection
100,000 hours
X = required
Clean
* = if necessary
O = see rating
plate/documentation
Generator cooling
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10.3.9 Safety
SERVICING WORK TYPE Servicing Intervals
Repair or Replace
Test and Measure
Visual inspection
100,000 hours
X = required
Clean
* = if necessary
O= see rating
plate/documentation
Alarm system - Function and X X X
correctness
Safety
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NOTICE
The values in the table General tightening torques are of a general nature and do not apply to
components such as diodes, auxiliary isolators, bearings, cable terminals or pole fastenings,
bus bar terminals, overvoltage arrestors, current transformer fastenings, rectifiers or
varistors or other electrical connections, or if another value is stated in this manual or in the
manufacturer's documentation.
10.5 Vibration
High or increasing vibration levels are indicative of changes in the condition of the generator.
Normal levels vary widely as a function of the use, the type and the generator foundation.
Typical causes of high vibration levels are:
• The alignment has changed
• Bearing wear or bearing damage
• Vibration is occurring on machines connected or the vibration has changed
• Fastening or foundation screws have loosened
• Rotor imbalance has changed
• Couplings are worn
The following instructions are part of the following two ISO standards:
ISO 10816-3 Mechanical vibration - Evaluation of machine vibration by measurements on
non-rotating parts: Part 3: Industrial machines with nominal power above 15 kW and nominal
speeds between 120 r/min and 15 000 r/min when measured in situ
ISO 8528-9 Reciprocating internal combustion engine driven alternating current generating
sets: Part 9: Measurement and evaluation of mechanical vibrations.
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Declared engine Rated power output of the generating set Vibration velocity V rms
speed Value 1 mm/s
revs/min (cos phi = 0.8) kVA KW
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NOTICE
On starting the generator pay attention to the ambient temperature. The temperature of the oil
must not be below a minimum limit. State the minimum temperatures during order
clarification. See standard IEC 60034. Consult Cummins Service department if your
installation is below the minimum temperature. Starting at excessively low temperatures can
result in serious bearing damage.
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NOTICE
Check for the correct oil quality using the bearing identification plate and the outline drawing.
Incorrect or soiled oil will result in serious bearing damage.
10.6.1.12 Oil Change Schedule for Mineral Oils and Synthetic Oil
CAUTION
Oils can cause skin irritation and eye infections.
Avoid physical contact by wearing disposable gloves and protective equipment.
Pay attention to all the safety measures stated by the oil manufacturer.
Perform the oil change interval for self-lubricating bearings after 8,000 operating hours, for
externally lubricated bearings after 20,000 h.
For frequent starts, slow turning, high oil temperatures or excessively high contamination
due to external effects, shorter intervals are required.
NOTICE
For slow turning and for frequent starts and stops, it is highly recommended to use a hydro
static device.
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All generators are supplied with rating plates that are attached to the stator. The rating
plates provide information on bearings, for instance:
• Type of grease used
• Re-lubrication interval
• Amount used for re-lubrication
10.6.2.4 Re-lubrication
CAUTION
Grease can cause skin irritation and eye infections.
Avoid physical contact with the hands by wearing disposable gloves.
Pay attention to all the safety measures stated by the grease manufacturer.
All anti-friction bearings on rotating electrical machines must be regularly re-lubricated, see
rating plate. The lubrication can be either manual or with the aid of an automatic system. In
both cases make sure that an adequate amount of the correct lubricant reaches the bearing
at the stipulated intervals.
Manual re-lubrication of the bearings
Generators that are designed for manual lubrication are fitted with grease nipples. To ensure
that no dirt enters the bearings, clean the grease nipples and their surrounding area
thoroughly before lubrication.
Only re-lubricate with the generator running!
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Do not stand behind the generator for the first 10 hours after lubrication.Re-lubrication can
be done in various ways. The grease can be applied to the bearing in one pass or in several
stages. The important aspects are the duration of the re-lubrication process and the order.
The re-lubrication of a bearing should not be completed in less than 5 minutes, and should
also not take more than 30 minutes. The total amount of grease for the re-lubrication must
not be exceeded or dropped below in any circumstances. The manufacturer recommends
the use of suitable instruments to measure the amount of grease.
For the order in which the bearings are to be lubricated the combination of fixed, loose, fixed
bearing is to be followed.
1. Clean the grease nipple and its surrounding area
2. Make sure that you use grease as per the rating plate
3. Measure (weight or volume) the amount of grease that is pressed in during one stroke
4. Make sure the lubrication pipes are intact
5. Press the stated amount of the type of grease stated into the bearing in the order stated
above while following the requirements on the time taken
6. Leave the generator to run for 1-2 hours to make sure the old excess grease is pressed
out of the bearing. The bearing temperature may increase temporarily during this time.
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An elevated temperature in the bearings can exist for up to 96 hours. During this period
significant temperature increases can be seen (see Section 10.6.2.6 on page 93). An
increase in the temperature is helpful for the lubricant change, as the old grease becomes
softer and can escape better from the bearing. Finally, the increase in the temperature is a
good indicator that the lubricant has actually reached the bearing.
When the temperature increases due to re-lubrication it is important that the warning and
shutdown temperatures stipulated by the manufacturer are met.
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WARNING
Hazardous voltage will shock, burn or can cause death.
Tests at high voltage (HV) must only be done by authorized specialist personnel following the
related safety regulations.
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CAUTION
Danger of chemical burn and poisonous vapors will chemically burn or burn or cause
suffocation.
Flammable and hazardous substances like solvents, resins and lacquers must be handled
and used by authorized specialist personnel only while following the related safety
regulations and instructions. These substances must not be inhaled or swallowed or come
into contact with the skin or other organs. Seek medical attention immediately in case of an
accident.
Take the necessary precautions if you are working in pits or poorly accessible / poorly
ventilated areas. Do not smoke or eat in the workplace. Wear PPE.
For spray lacquering, ensure that the lacquering equipment, the generator frame and the
windings are earthed.
Solvents, lacquers and resins are required to clean and re-lacquer the windings.
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Measure the insulation resistance measurement in the terminal box. The test is normally
done on the entire winding as an assembly; connect the tester between the stator housing
and the winding. Ground the stator and leave the three phases of the stator winding
connected to the star point. If the insulation resistance measured in the entire winding is
lower than stated and the phase windings can be easily disconnected from each other,
measure each phase separately. This action is not possible on all generators. To measure
separately, connect the tester between the stator and one of the windings. Ground the stator
and the two phases not measured.
If phases are measured separately, remove all star points in the winding system.
Measure the insulation resistance on the rotor winding using an insulation resistance tester.
The test voltage for the rotor windings should be 1000 VDC.
1. Make sure that all power supply cables are disconnected from the main power supply
and secured against unintentional switching back on.
2. Check the tester for correct function.
3. Make sure the generator and the stator windings as well as the temperature monitoring,
auxiliary winding, auxiliary exciter stator, exciter stator are grounded.
4. Make sure the shaft is grounded.
5. During the insulation resistance measurement in the exciter rotor the rotor windings not
tested must be grounded. The rotor winding can be connected internally in series or 2
groups connected in parallel.
6. Measure the rotor winding temperatures. If this is not possible, use the stator winding
temperatures as a reference.
7. Connect the insulation resistance tester between the entire rotor winding and the shaft.
After the measurement, the rotor winding must be grounded for at least as long as the
duration of the measurement to discharge the winding.
Optimal servicing and care of the brushes and slip rings is a prerequisite for low wear. The
brushes must be cleaned from time to time by blowing with air or vacuum cleaning.
• The servicing must be done at specific intervals. The frequency of this servicing
depends on the size of the generator as well as on the load conditions and ambient
conditions.
It is recommended to initially check the brushes every three months to be able to estimate
the replacement intervals under the actual operating conditions. Replace only with approved
brushes.
• Check all brushes and holders for freedom of movement. Sticking brushes can result in
damage.
• Renew worn brushes in good time so that damage to the brush contact surfaces is
avoided.
2 Brush pin
• The minimum distances between the cooling air inlet and neighboring components are
not maintained.
• The outlet air is drawn in with the inlet air.
• Defective temperature measuring instruments.
NOTICE
To avoid any material damage ensure that the distance between the air inlet (AI) or air outlet
(AO) on the generator and a wall or another plant component is at least a minimum of 500
mm. Unhindered AI and AO must be ensured.
Regular servicing and cleaning of the dust protection filter system is essential for the reliable
operation of the generator.
Do not wet filter mats using oil! Pay attention to environmental obligations!
Soiling such as salt, oil, fumes, chemicals, dust, sand etc. will reduce the efficiency of the
insulation and result in premature failure of the windings.
Therefore it is necessary to clean the filters regularly. If the temperature sensors in the
winding indicate an abnormal temperature close to the alarm level, the filters must be
cleaned.
If a monitoring system for the filter differential pressure is used, replace the filters in case of
a pressure alarm. The alarm is triggered if 50% of the air filter surface is clogged. Check the
filter manually on a frequent basis.
For cleaning the filter with cleaning agent the following applies:
• Commercially available cleaning agents can be used for mechanized cleaning or
cleaning using a high-pressure cleaner. The cleaning agent must be compatible with
the materials.
• If only manual cleaning is possible, use Repoint / RG 1083 or equivalent.
All work related to repair, dismantling and re-assembly must be done by specially trained
personnel.
Before starting any fault finding procedure, examine all wiring for broken or loose
connections. If in doubt, refer to the wiring diagram supplied with the generator. Compare
measurements with the test report supplied with the generator.
The following list is to aid in troubleshooting and is not exhaustive. If in doubt, consult the
Cummins service department.
2. Tighten the bearing house halves and the labyrinth seal cover to the related torque.
(See sleeve bearing documentation from the manufacturer). This aspect is particularly
important after extended generator standstill.
3. Measure the vibration at the leaking bearing in three directions at full load. If the
vibration level is too high, the bearing housing may be open wide enough to allow the
oil to flow away between the halves of the housing.
4. Eliminate any causes of low pressure in the vicinity of the bearing. For example a shaft
or coupling cover may be designed so that it causes a low air pressure in the vicinity of
the bearing
5. Make sure there is no overpressure inside the bearing. Overpressure can enter the
bearing via the oil outlet line from the lubrication unit. Provide vents on the bearing
housing to relieve the overpressure from the bearing. Also check the vent at the oil
supply unit.
6. In case of an external lubrication system, check whether the fall on the oil outlet pipes
is adequate.
If it is not possible to correct the leak problem by means of one of the above points, contact
the manufacturer.
11.8.2 Oil
For the bearings to function correctly, the oil must meet certain criteria, including viscosity
and cleanliness. Only use the oil stipulated by the manufacturer with the correct viscosity.
See Section 10.6.1.11 on page 91. Incorrect viscosity will result in bearing failures and can
seriously damage the bearings and the shaft.
11.8.2.1 Sealant
To prevent oil escaping from the bearing through the joints, apply a sealant along the joint.
Use Loctite 2926 for this purpose. On the use of biodegradable oils, request information on
the compatibility of the oil with the sealant from the sealant manufacturer. Only Curil T can
be used for floating labyrinth seals. Refer to the documentation from the sleeve bearing
manufacturer.
Never try to correct low pressure in the bearing by installing a vent, as this would further
amplify the leak. Check the air pressure in the vicinity of the shaft outlet on the bearing. This
aspect is particularly important if the bearing is mounted on the prime mover using a flange
of a coupling, or if the shaft is mounted inside a cover or another construction that together
with the shaft can cause a centrifugal air flow.
If a very low pressure is found or suspected, the air pressure is to be measured in the
vicinity of point where the shaft leaves the bearing housing.
To be certain that the low pressure outside the bearing may be the cause of the leak, the
pressure must also be measured outside the bearing (Pos. 1 and 3 on the DE and Pos. 5, 7
and 9 on the NDE, in the bearing (Pos. 2 on the DE and Pos. 6 on the NDE) and in the area
between the bearing plate and the generator seal (Pos. 4 DE and Pos. 8 NDE). During the
measurement (Pos. 4 DE and Pos. 8 NDE) the pipe is to be inserted as deep as possible
and the ducts must be temporarily sealed, see Figure: Checking the air pressure inside and
outside the sleeve bearing.
To analyze the situation, compare the positions 1-4 on the DE with each other and the
positions 5-9 NDE with each other. The measurements outside the bearing must be
measured free of malfunctions or turbulence in the vicinity of the generator. The following
situations can occur:
If all pressures are equal, the leak is not caused by pressure differences.
If the pressure in the bearing is higher than the exterior pressure, there is an overpressure in
the bearing.
If the pressure outside the bearing is lower than the pressure at other points, there is low
pressure near the bearing.
If all pressures are different, there may be both overpressure in the bearing and low
pressure outside the bearing.
FIGURE 24. CHECKING THE AIR PRESSURE INSIDE AND OUTSIDE THE SLEEVE BEARING (1 -
SLEEVE BEARING COVER)
TECHNICAL SUPPORT
PRODUCT REGION Service / Warranty / AFTERMARKET PARTS
Maintenance / Repair
Quotes
MARKON NORTH AMERICA Louie Shar Judy Smith
STAMFORD SOUTH AMERICA Americas Service Team Americas Parts Team
AvK MEXICO & CENTRAL Toll Free Toll Free Tel
AMERICA Tel (0) 800 367 2764 (USA and Central America)
CANADA Toll Free 1-800 367 2764 Ext. 5
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email: Toll Free Fax
[email protected] (USA and Central America)
1-800 8963 9243
1 763 574 5082
email:
[email protected]
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Mobile +61 (0) 412 886645 Mobile +61 (0) 412 886645
email: email:
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om om
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NEPAL Fax +912066025331 Fax +912066025331
SRI LANKA Mobile +91822395641 Mobile +91822395641
email: email:
[email protected] [email protected]
MARKON SINGAPORE Richard Lee Cynthia Chua (STAMFORD
STAMFORD MALAYSIA Tel +65 6305 3158 Ext 158 / MARKON)
AvK PHILIPINES Fax +65 63053151/2 Tel +65 6305 3169 Ext 169
INDONESIA Mobile +65 97595606 Fax +65 6305 3151/2
THAILAND email: email:
VIETNAM [email protected] [email protected]
m
JAPAN Chek Tay
Cyril Ee (AvK)
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Tel +65 6305 3156 Ext 156
Fax +65 6305 3151/2
Fax +65 6305 3151/2
Mobile +65 91137511
email:
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[email protected]
Ryan Xie
Mike Tami (Japan)
Tel +65 6305 3172 Ext 172
Tel +81(0) 3 5735 0852
Fax +65 6305 3151/2
Fax +81(0) 3 5735 0788
Mobile +65 9712 2009
Mobile +81 (0 )80 5075
2979 email:
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email:
[email protected] Mike Tami (Japan)
Tel +81 (0) 3 5735 0852
Fax +81(0) 5735 0788
Mobile +81 (0) 80 5075
2979
email:
[email protected]
TECHNICAL SUPPORT
PRODUCT REGION Service / Warranty / AFTERMARKET PARTS
Maintenance / Repair
Quotes
MARKON CHINA Jason Xu (Wuxi / Jiangsu) Jason Xu (Wuxi / Jiangsu)
STAMFORD +86 510 8110 3027 Tel +86 510 8110 3027
AvK or +86 510 8110 Ext 3027 Fax +86 510 8521-
Fax +86 510 8521 7673 7673/7603
+86 510 8521 7603 Mobile +86 139 5157 0763
Mobile +86 139 5157 0763 email:
[email protected]
email:
[email protected] Jianguo Xu
Jianguo Xu Tel +86 510 81103088
Tel +86 510 81103088 Mobile +86 150 5221 9180
Mobile +86 150 5221 9180 email:
[email protected]
email:
[email protected]
AvK ALL OTHER Uwe Plep Anita Albrich
COUNTRIES Tel +49 841 792 276 Tel +49 841 791 192
WORLDWIDE
Fax +49 841 791 195 Fax +49 841 791 103
Mobile +49 171 683 7062 email:
email: [email protected]
[email protected]
MARKON ALL OTHER Richard Hardy Fiona Barkhouse
STAMFORD COUNTRIES Tel +44 (0) 1780 484771 Tel +44 (0) 1780 484742
WORLDWIDE
Fax +44 (0) 1780 484104 Fax +44 (0) 1780 766074
Mobile +44 (0)7801 096641 Mobile +44 (0)7718339215
email: service- email:
engineers@cumminsgenera [email protected]
tortechnologies.com m
24 HOUR HELP DESK:
+44 (0)1780 484732
13.1 Disposal
The large portion of iron, steel and copper in the generator can be recovered by specialist
recycling organizations. You can obtain further information from Cummins customer service.
13.2 Introduction
The following instructions are only recommendations for the environment-friendly disposal of
the generators. It is the responsibility of the operating organization to follow local regulations.
Some customer-specific elements may not be included in this user manual. This section
makes no claim to completeness.
• Tributyl Tins
• Triphenyl Tins
• Tributyl Tin Oxide (TBTO)
• Cadmium and Cadmium Compounds
• Hexavalent Chromium and Hexavalent Chromium Compounds
• Mercury and Mercury Compounds
• Polybrominated Biphenyl (PBBs)
• Polybrominated Dephenyl ethers (PDBEs)
• Polychloronsphthalanes (C1= <3)
• Radioactive Substances
• Certain Shortchain Chlorinated Paraffins
The generator must be transported and unloaded by persons who are familiar with the lifting
equipment and related ancillary equipment. All lifting equipment and tackle must be suitable
for the weight of the generator and must comply with local regulations.
The safety regulations on handling the generator are to be followed at all times. The
generator is assembled with screws and can be dismantled. The high weight of the
generator requires the presence of specialist personnel trained in handling heavy
components to avoid hazardous situations.