5.

6 KW BTY CHARGING SET

PURPOSE AND FACILITIES
THE GREAVES 5.6KW SPECIAL PURPOSE GENERATOR SET HAS
BEEN DEVELOPED TO SUPPLY POWER FOR OPERATION OF BTY
CHARGING SET. SWITCH BOARDS, I.E. (CONTROL CUBICLE AND
CHARGING CUBICLE) ARE PROVIDED ON THE SET, TO ENABLE
DEFERENT CONTROL AND SWITCHING OPERATIONS TO BE CARRIED
OUT.
GENERAL DESCRIPTION :
GENERATOR AC, 12.5KVA, 240V, SINGLE PHASE, 50HZ, 2B IS
SPECIALLY DESIGNED FOR GIVING AN OUT PUT ON 7.5KVA, 0.8P.F AND
6KVA AT UNITY PF FOR GETTING A DC OUT PUT OF 5.6KW AT 112V DC
FROM THE CHARGING CUBICLE. AN AC OUTPUT OF 7.5KVA (30AMPS)
CAN ALSO BE OBTAINED FROM THE AC SOCKETS.
 6.5KW GENR, CONTROL, CUBICLE AND CHARGING CUBICLE TECH DATA
GENERATOR AC
1. MAKE : CROMPTON GREAVES EUROGEN
2. TYPE : G2R 160 SB/4
3. VOLTAGE : 240V, AC
4. PHASE : SINGLE
5. SPEED : 1500RPM
6. FREQUENCY : 50HZ
7. POWER FACTOR : 0.8 LAG
8. OUTPUT CMR : 12.5KVA
9. MAX CURRENT : 52 AMP
10. CLASS OF INSULATION
STATOR & ROTOR : ‘H’
11. EXCITATION SYSTEM : SELF EXCITED, SELF REGULATED
12. EXCITATION CONTROL : THROUGH AVR
13. BAND OF REGULATED VOLTAGE : ± 1% OF RATED VOLTAGE
14. RANGE OF MANUAL VOLTAGE ADJUSTMENT : ± 5% OF RATED VOLTAGE
15. ENCLOSURE : SCREEN PROTECTED, VERTICALLY DRIP ROOF
16. METHOD OF COOLING : AIR COOLED
17. COMPLIANCE WITH STANDARD : DESIGNED TO MEET THE REQUIREMENTS OF
ROTATING ELECTRICAL MACHINERY LAY
DOWN IN IS : 4722
 PRINCIPLE OF OPERATION
WHEN STANDARD, THE RESIDUAL MAGNETISM INDUCES A
VOLTAGE IN THE EXCITER ARMATURE. THIS VOLTAGE IS RECTIFIED
BY ROTATING DIODES AND FEEDS THE MAIN FIELD. THIS INDUCES
VOLTAGE IN THE AUXILIARY WINDING IS THEN USED TO INCREASES
THE EXCITATION POWER VIA THE COMPOUND EXCITATION (CE)
UNIT/ELECTRONIC REGULATOR (AVR) TO THE EXCITER FIELD TO
ENSURE A RAPID AND SMOOTH BUILD UP OF OUT PUT VOLTAGE IN
THE MAIN STARTER WINDING.
ON LOAD, OVER LOAD OF SHORT CIRCUIT THE PRIMARY
WINDING OF CE UNIT WHICH IS IN SERIES WITH THE LOAD SUPPLY
AND ADDITIONAL EXCITATION VOLTAGE (THE BOOSTER EFFECT), TO
MAINTAIN THE TERMINAL VOLTAGE CONSTANT (WITHIN ± 5% OF
RATED VALUE).
IN CASE OF ALTERNATOR FITTED WITH ELECTRONIC
REGULATOR (AVR SR 7/3), AVR PROVIDES ADDITIONAL EXCITATION
REQUIREMENTS AND MAINTAINS TERMINAL VOLTAGE CONSTANT
(WITHIN ± % OF RATED VALUE) FROM NO LOAD TO RATED LOAD
CONDITION.
 POWER CIRCUIT DIAGRAM OF 5.6KW BTY CHARGING SET
CROMPTON ALT 12.5KVA,220V, 1Φ, 50 HZ, 0.8PF
0-50A SC4
S2
X A1
U1 MCB
FIELD

TS1
ARM

IL2

0- 230V
TR

45-50-
1 2 3 4 5 6 7

55HZ
230V
B

AVRSR-7/3
XX U2 SC1 SC2
Y HR V1 F

IL1
X FS
U1
100K S2
U2 X PTO
X

1 MFD R1 4A FS 5
SUPPRESOR

S2 MCB
HR HOUR COUNTER SC4

POWER TERMINAL
IL1- GEN RUN LAMP 10Ω/
IL2 – SUP ON LAMP 25 W

TS1- TOGGLE SW
ENGINE CONTROL CIRCUIT DIAGRAM OF 5.6KW BTY CHARGING SET

FROM FLOAT BTY CHG UNIT

10 IL5
9
STPE
HCT SW

8 STP TS2
7
FOS

HOOTER
6 STP SHUNT
SOLENOID

STPE
BTY STARTER

STRE
5
STPE A
35A STR SO
4
+ SC3
FST
- 3
HCTS TS3
2
LOP SW

BY PASS IL4 IL3

ENGINE

IL4 – LOP LAMP BY PASS - BY PASS PB

IL5 – HCT LAMP FOS - FOEL OFF SOLENOID
STP – STOP PB SC3 - CONTROL TERMINAL
STRE – STOP RELAY ON ENGINE SO - ENGINE CONTROL SW
 CIRCUIT DIAGRAM OF CHARGING CIRCUIT 5.6KW SET
+ 9-110V DC, 20A
OUTPUT FOR - + 9-110V DC, 10A
OUTPUT FOR
- + OUTPUT FOR -
9-110V DC, 20A

0-15A FS 4
BTY CHG BTY CHG
0-25A FS 3

BTY CHG

0-25A FS 5
0-150V A 0-150V
A A 0-150V
V2 V2
V2

RES-2
RES-1

RES-3
C4
R1 R2 C3 R3 R4
C1 C2 C5 R5 C6 R6
OFF OFF OFF OFF OFF
OFF
132V
150V

110V
90V
72V
54V

18V
36V
115

36V
54V

132V
9V

110V

150V
72V
18V
9V

90V
115
0V

A2 A2
A1 A1
A3
A3 OFF OFF OFF
OFF OFF OFF
S3 S4 S4 S5 S5
S3
220V AC INPUT
FLANG PLUG
 SWITCH BOARDS
GENEREAL :
1. ENSURE THAT THE INSTRUMENTS, METERS,
FUSES, TERMINALS, SWITCHES & PLUGS ETC. HAVE NOT
SUFFERED BY DAMAGE. TIGHTEN THEN IF NECESSARY.
2. ENSURE THAT MECHANICAL OPEN OF
SWITCHES KNOBS, PUSH BUTTONS ETC. IS SATISFACTORY.
3. ENSURE THAT ALL ELECTRICAL
CONNECTIONS ARE TIGHT.
4. ENSURE THAT ALL INSTRUMENTS ARE
FUNCTIONING AS PER SPECIFICATION.
5. ENSURE THAT THE SWITCH BOARDS WITH
STAND WITHOUT ANY BREAK DOWN OR DAMAGE TO THE
RECOMMENDED SPECIFICATIONS.
LIMITS FOR SAFE OPERATION :
OVER SPEED : 20% FOR 50HZ (1800 RPM)
OVER LOAD : 110% OF RATED VALUE FOR ONE HR. AT THE INTERVAL
OF EVERY SIX HOUR.

ELECTRICAL FEATURES :
CLASS ‘H’ INSULATION AS STANDARD.
MOTOR STARTING CAPABILITY : THE ALTERNATOR IS CAPABLE TO
START 1.0 HP INDUCTION MOTOR FOR ATS EACH KVA RATING WITH DOL.
MOTOR STARTING APPLICABLE FOR ONLY FOR S1 DUTY.

STEADY STATE VOLTAGE REGULATION TO THE ORDER OF ±5% WITH

COMPOUND EXCITATION UNIT ± % WITH ELECTRONIC REGULATOR.
AT RATED SPEED WHEN SUPPLYING NON DISTORTING, THREE PHASE,
BALANCED, LINEAR LOADS, VOLTAGE BUILDUP IS BASED ON RESIDUAL
MAGNETISM.
 TEST PROCEDURE OF GENERATOR
ELECTRICAL CHECKS :
1. ENSURE THAT THE INSULATION RESISTANCE, BETWEEN
THE OUT PUT TERMINALS OF THE GENERATOR AND EARTH, IS NOT
LESS THEN ONE MEGA OHM WHEN CORRECTED TO 40ºC, AS
MEASURED BY A 500V, DC MEGGER.
2. ENSURE THAT THE GENERATOR WITH STANDS WITH OUT
ANY BREAKDOWN OR INJURY FOR ONE MINUTES ON AC RMS
VOLTAGE OF 1700V (85% OF 2000V AS THE GENERATOR HAS ALREADY
BEEN SUBJECTED TO HIGH VOLTAGE TEST AT WORKS).
3. ENSURE THAT THE GENERATOR BUILDS UP THE RATED
VOLTAGE AND FREQUENCY WHEN AT 1500RPM ON NO LOAD. ENSURE
THAT THE VOLTAGE REGN IS MAINTAINED WITHIN ±1% OF THE
RATED VOLTAGE BOTH AT UNITY AND 0.8PF.
 FAULT DIAGNOSIS- GENERATOR
GENERAL :
IF THE SET MAINTAINED AS PER INSTRUCTION GIVEN
EARLIER, THERE WILL BE NORMALLY NOT TROUBLE. HOWEVER, IF A
LAPSE OCCURS THE FOLLOWING FAULT DIAGNOSIS WILL HELP
OPERATOR IN REMOVING DEFECTS OF ELEMENTARY NATURE.
GENERATOR :
FAULT CAUSE RECTIFICATION
NO a. INSUFFICIENT VOLTAGE. a. EXCITE THE ROTOR USING A
VOLTAGE BATTERY.
b. IMPROPER CONNECTION. b. CORRECT CONNECTION.
c. FAULTY MOLDED c. REPLACE THE RECTIFIER
RECTIFIER BRIDGE. BRIDGE.
d. LOW SPEED. d. RESET THE SPEED NOMINAL.
e. FAULT WINDING. e. CHECK THE WINDING
RESISTANCE AND
REWINDING REQUIRED.
f. REPLACE ROTATING
f. ROTATING RECTIFIER RECTIFIER.
FAILURE.
g. REPLACE THE AVR.
g. FAULTY AVR.
 FAULT CAUSE RECTIFICATION

NO LOAD a. LOW SPEED. a. RESET THE TO THE

LOW NOMINAL.
VOLTAGE b. AIR GAP OF COMPOUND b. REGULATE THE
TOO SMALL. COMPOUND AIR GAP.
c. FAULTY ROTATING c. REPLACE THE ROTATING
RECTIFIER. RECTIFIER.
d. FAULTY WINDING . d. CHECK THE WINDING
RESISTANCE AND
REWIND IF REQUIRED.
e. FAULT MOLDED BRIDGE
RECTIFIER. e. REPLACE THE RECTIFIER
BRIDGE.
LOW a. LOW SPEED AT FULL a. SET THE RATED SPEED
VOLTAGE LOAD. OF THE PRIME MOVER.
ON LOAD. b. COMPOUND DEFECTIVE. b. CHECK AND IF
NECESSARY CHANGE
THE COMPOUND UNIT.
c. FAULT ROTOR WINDING. c. CHECK THE ROTOR
WINDING RESISTANCE IF
FAULTY REWIND IT.
d. OVER LOAD ON d. OPERATE ON SPECIFIED
ALTERNATOR. LOAD.
 FAULT CAUSE RECTIFICATION

HIGH ON a. CAPACITOR ON THE a. DISCONNECT THE PF

LOAD. LOAD SIDE. IMPROVEMENT
b. INCORRECT COMPOUND CAPACITORS.
ASSEMBLY. b. CHECK THE COMPOUND
WINDING RESISTANCE
AND IF NECESSARY
REPLACE IT.
TOO HIGH a. EXCESSIVE SPEED. a. ADJUST THE REVOLVING
NO LOAD b. REDUCE THE COMPOUND SPEED.
VOLTAGE. TOO HIGH. b. REDUCE THE AIR GAP.

VOLTAGE a. INCORRECT AVR a. SET THE AVR STABILITY

OSCILLATI SETTING. POT.
ONS b. THYRISTOR LOAD MORE b. REDUCE THE THYRISTOR
THAN SPECIFIED LIMITS. LOAD.
c. INSUFFICIENT ENGINE c. CHECK AND ADJUST.
FLY WHEEL.
UNABLE a. UNABLE UNBALANCE a. CORRECT THE LOAD.
VOLTAGE. LOAD. b. TIGHTEN THE LOOSE
b. LOOSE CONNECTION. CONNECTION.