OPERATION AND

MAINTENANCE MANUAL

Three-Phase Synchronous Generators

translation of original instructions

SAFETY WARNING
The generators which are the subject of these “instructions” are components designed for use in industrial areas (machines/plants) and
therefore cannot be treated as retail goods.
This documentation consequently contains information that is only suitable for use by qualified personnel. It must be used in compliance with
the regulations, laws and technical Standards in force and cannot under any circumstances take the place of plant standards or additional
prescriptions, including any which are not legally enforceable, which have been issued for the purpose of ensuring safety.
Machines built to customer specifications or with constructional differences may differ in detail from the generators described herein. If you
encounter any difficulties please do not hesitate to contact EvoTec Power, specifying:
- The type of machine
- The full code number of the generator
- The serial number of the generator

Electric rotating machines have dangerous parts: when operating, they have live and rotating components. Therefore:
- improper use
- the removal of protective covers and the disconnection of protection devices
- inadequate inspection and maintenance
can result in severe personal injury or property damage.

The person responsible for safety must therefore ensure that the machine is transported, installed, operated, maintained and repaired by
qualified personnel only, that must have:
- specific training and experience
- knowledge of applicable standards and laws
- knowledge of the general safety regulations, national and local codes and plant requirements
- the skill to recognize and avoid possible danger.
All maintenance and inspection operations must be carried out only with the authorization of the person responsible for safety, with the
machine at a standstill, disconnected from the supply (including auxiliary circuits such as the anti-condensation heaters).

As the electric machine is a product to be installed in industrial areas, additional protection measures must be taken and assured by the
person responsible for the installation, if stricter protection conditions are required.

As the electric generator is a component to be coupled to another machine, it is the responsibility of the installing engineer to ensure, during
operation, proper protection against the risk of contact with bare rotating parts and to prevent people or things from approaching the
machine.

If the machine shows deviations from the normal performance (excessive or too low voltage, increase in temperature, noise and vibrations)

promptly advise the personnel responsible for maintenance.

Here enclosed with the “instructions manual” there are self-adhesive leaflets which are reporting symbols for security: the self-adhesive
leaflets are to be applied to the generator surface, at the customer’s charge, according the instruction presented on the sheet of the
self-adhesive.
 CONTENTS

1. INTRODUCTION
1.1 Standard 1.2 Generator Designation
1.3 Products Serial-number Position 1.4 Rating Plate

2. GENERATOR APPLICATION
2.1 Operating Environment 2.2 De-rating Table

3. GENERATOR PRINCIPLES
3.1 Self-excited Generators with AVR Control 3.2 PMG Excited Generators with AVR Control
3.3 Other Description of the AVR

4. THE ESSENTIAL COMPONENTS OF GENERATOR

4.1 Main Stator 4.2 Main Rotor
4.3 Excitation System 4.4 Automatic Voltage Regulator

5. INSTALLATION
5.1 Lifting 5.2 Operating Conditions
5.3 Installation 5.4 Direction of Rotation
5.5 Electrical Connection 5.6 Protection

6. STARTING UP AND TURNING OFF

6.1 Pre-running Checking 6.2 Pre-running Testing
6.3 Starting up 6.4 Turning Off

7. MAINTENANCE
7.1 General Maintenance 7.2 Inspection and Maintenance
7.3 Assembling and Disassembling 7.4 Troubleshooting
7.5 AVR Troubleshooting

8. CHECKING AND STORAGE

9. STRUCTURAL DRAWING AND PARTS LIST

10. SERVICE
1. INTRODUCTION

The instructions refer to three-phase synchronous generators series TCU. Technical data and constructive details are given in the catalogue.
In order to obtain the proper working of the generator it is necessary to read carefully all included instructions.

1.1. Standard
The generators TCU are synchronous generators, brushless type, self excited and self regulated, manufactured according to the standards
and in compliance to IEC34-1; EN60034-1; GB755; VDE 0530; BS5000 and NEMA MG21.
EvoTec is well recognized in Europe, Middle East, Africa and Asian continents as the leading supplier to the industrial, petrochemical, marine,
on-shore and off-shore and any places where dependable electrical power is highly needed.

Degree of protection – characteristics

The protection degree of the generators and the rated data are shown on the name-plate.

Frequency
The generators are suitable for operation at 50Hz and 60Hz, according to the data reported on the name-plate: for correct operation for 50Hz
and 60Hz, it is necessary to verify that the settings of the voltage regulator are proper for the required operation and that the use of the
generator is in accordance with the value of the name-plate.

Accessories
According to the customer’s order the generators can be equipped with accessories, such as anti-condensation heaters, thermistors, etc.

1.2. Generator Designation

Example: TC U288AP
TC- series generator U - common standard machines S- special standard machines
288- core height A- power section mark (A, B, C, D, E, F etc.)
P- PMG generator
NOTE: S TYPES ARE USED FOR MARINE APPLICATION OR SPECIAL WORKING SURROUNDINGS

1.3. Products Serial-number Position

Each generator has an only serial-number on the end ring of non-drive end.

1.4. Rating Plate

Rating-plates are of special sticker type and shall be stick onto the right-hand side of the generator drive end position.

2. GENERATOR APPLICATION

2.1. Operating Environment

TCU series generator rated output shall be operated according to the following altitude and temperature.
- Altitude height shall not over 1000m.a.s.l;
- Environment temperature shall be between -15°C and 40°C respectively
- Cool air relative humility： ≤90%（25°C）
- Generator shall be operated in a protected area and shall not be used outdoor.
- It is strongly recommended that use anti-condensation heater to protect generator winding insulation.
NOTE: INSUFFICIENT OF COOLING AIR FLOW OR PROTECTION WILL RESULT IN FAILURE, DAMAGE OR DECREASING THE LIFE

1
EXPANTANCY OF THE MACHINES
2.2. De-rating table

Following de-rating table must be considered if generator needs to be operated under conditions below ：
Altitude（m.a.s.l） Revise coefficient Temperature（ºC） Revise coefficient
1500 0.97 45 0.97
2000 0.94 50 0.94
2500 0.91 55 0.91

3000 0.88 60 0.88

3500 0.85

Operating attitude and temperature above the standard, revise coefficient should be calculated together.

All the generator ratings are specified in the rating-plate. The manufacturer holds no responsibility if
any damage occurred to the machine caused by misuse.

3. GENERATOR PRINCIPLES

3.1. Self-excited Generators with AVR Control

Power for the excitation system is provided from the main stator output to the AVR to the exciter field. The AVR is the controlling device
governing the level of excitation provided to the exciter field. The AVR responds to a voltage-sensing signal derived from main stator winding.
By controlling the low power of the excited field, control the high power requirement of the main field is achieved through the rectified output
of exciter armature.

The ETC-1（ETC-2）AVR senses average voltage on two phases ensuring close regulation. In addition, it detects engine speed and provides
voltage fall off with speed, below a pre-selected speed (Hz) setting, preventing over-excitation at low engine speeds and soften the effect of
load switching to relieve the burden on the engine. The detailed function of the AVR circuits and their adjustment are covered in the load
testing section.

Figure 1 - Operation Principle

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3.2. PMG Excited Generators with AVR Control

The Permanent Magnet Generator (PMG) provides power for the excitation of the exciter field via the AVR which is the controlling device
governing the level of excitation provided to the exciter field. The AVR responds to a voltage-sensing signal derived, via an isolating
transformer, from the main stator winding. By controlling the low power of the exciter field, control of the high power requirement of the main
field is achieved through the rectified output of the exciter armature.

Figure 2 - PMG Operation Principle

3.3. Other Description of the AVR

ETC-2 and ETC-3 AVR provides the function of paralleling. ETC-1, ETC-2 and ETC-3 AVR provides the function of short-circuit current limit
control. ETC-3 AVR is used for PMG excitation system.

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4. THE ESSENTIAL COMPONENTS OF GENERATOR

Figure 3 - Generator profile drawing

4.1. Main Stator

The main stator frames are most ruggedly constructed with high strength and solid support. The frame is welded with heavy rings and steel
bars and reinforced with welding places between bars. The main stator windings are the configuration of triple-layer winding insulation type
to ensure maximum insulation properties. All laminations of the stator core are externally welded under pressure.

4.2. Main Rotor

The main rotor is also the configuration of triple-layer winding protection type and the copper wires are of special made rectangular type. The
magnetic core of the main field is directly mounted on the shaft. The laminated rotor core reduces the effect of superficial losses on the rotor.
The rotor core at both end additional copper laminations and are used as “end rings” for the copper squirrel cage.

4.3. Excitation System

Excitation system is composed of A.C exciter, rotating diodes and AVR. A.C exciter contains exciter stator and exciter rotor.

4.4. Automatic Voltage Regulator

AVR Description Drawing
The wiring diagram of AVR ETC-N0/N1 (ETC-1/0A) in 400Vac system(Figure 4)

4
Figure 4 The wiring diagram of AVR ETC-N0/N1 (ETC-1/0A) in 400Vac system

5
The wiring diagram of AVR ETC-N2(ETC-2) in 400Vac system (Figure 5)

6
 Figure 5 The wiring diagram of AVR ETC-N2(ETC-2) in 400Vac system

The wiring diagram of AVR ETC-N3(ETC-3) with PMG in 400Vac system (Figure 6)

7
8
 Figure 6 The wiring diagram of AVR ETC-N3(ETC-3) with PMG in 400Vac system

Parallel Requirements

When it is required to operate the regulator in parallel with an isolated or utility bus, in addition to the regulator provisions, a 5 VA current
transformer (CT) is required (see Figure 5 & 6). This CT is connected in a generator W line and should deliver from S1 to S2 amperes
secondary current at rated load. The phase relationship of CT signal to the regulator sensing voltage must be correct or the system will not
parallel properly. The CT device need to be supplied by customer self. Figure 5 & 6 show the correct CT polarity for A-B-C phase rotation
sequence. If the phase rotation sequence is A-C-B, the CT’s secondary leads must be interchanged.

Voltage Adjustment
The voltage adjustment possibility depends on the characteristics of the generator. Normally the internal potentiometer VOLT allows
possibility of adjusting the voltage from the control panel, or in order to limit the voltage range, an external potentiometer can connect a finer
possibility of voltage to the terminal “R1” and “R2” (minimum 1 Watt, resistance 1KΩ).

Stability
The STABILITY control potentiometer is pre-set and should not normally require adjustment. If adjustment is necessary proceed as follow:
 Run the generating set on no-load and check that speed is correct and stable.
 Turn the STABILITY control potentiometer anti-clockwise to the end, and then turn slowly clockwise until the generator voltage
starts to become unstable. The correct setting is slightly anti-clockwise from this position (i.e. where the machine volts are stable
but close to the unstable region).

Under Frequency Roll-Off (UFRO)

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 Figure 7

The AVR incorporates an under-speed protection circuit which gives a voltage/speed (Hz) characteristic as shown (Figure 7): The UFRO
control potentiometer sets the “knee point”.

[1] Symptoms of incorrect setting are :-

a) The LED indicator permanently lit when the generator is on load
b) Poor voltage regulation on load, example: operation on the top of sloping part of the characteristic

[2] Adjustment Method ：Clockwise adjustment lowers the frequency setting of the “knee point” and extinguishes the LED. For Optimum
setting the LED should illuminate as the frequency falls just below nominal frequency, i.e.47Hz on a 50Hz generator or 57HZ on a 60HZ
generator.

Droop
The device is included in the voltage, to allow parallel operation between similar generators: the device permits to share correctly the total
reactive required by the load among all generators operating in parallel. The device is composed by an external CT (which is sensing the
current in phase U) and by a “droop” circuit internal in the regulator. The voltage regulator is provided with input terminals（terminals S1 and
S2）for easy connection to CT. Such terminals are normally short circuit by a connection, when the generator is used in single operation. If the
voltage is increase as load increases, It is necessary to reverse the leads of current transformer at terminals S1-S2.

Excitation Tripping

An AVR supplied from a permanent magnet generator inherently delivers maximum excitation power on a line to line or line to neutral short

circuit. In order to protect the generator windings, the AVR incorporates an over excitation circuit. When it detects high excitation after a

pre-determined time (8-10 seconds), the excitation will be cut-off. Symptoms of incorrect setting are the generator output collapses on load

or small overload, and the LED is permanently illuminated.

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5. INSTALLATION

Before installing the generator,

 make sure that name-plate data corresponds to the power supply and operating conditions and that the installation complies with
the manufacturer’s recommendation
 clean any protecting varnish from all connecting surfaces (such as surface of couplings and flanges and shaft extension for
two-bearing generators).

5.1. Lifting
When moving the generator, always keep it in the horizontal position. The generator lifting points are designed to lift the generator only. Do
not lift the complete generating set by the generator lifting points.

5.2. Operating Conditions

The operating conditions of the generator shall be identified before installation. The generator shall be operated and installed in a clean
environment, with good air flow and with ample space for inspection, maintenance and routine checking. The surrounding of the generator
shall be free of atmospheric contamination such as gasses and various chemicals, salt water spray, dust and rainfall.

It is also important to have a good airflow position, away from any hot or exhaust system. It is also recommended that if the generator were
to install in an area with high condensation, a space heater shall be added as an extra protection. If installed in an area of heavy laden of fine
dust or sand, an inlet air filter shall be added on but due to these, a certain output deration is required.

5.3. Installation
During assembling of the generator and the engine, it is important to have a solid and rigid base-frame to ensure no frame deformation or
frame twisting arises. We recommended to use Grade 8.8 bolts and nuts to assemble the generator set and to also make sure the base-frame
is sitting firmly to the ground surface.

During installation, it is also important not to harm the bearing and shall always keep the rotor assembly in alignment. During the lifting of the
generator, it is important to ensure the lifting slings or wires rope are in good condition and also ensure the lifting block are able to sustain the
generator weight. We recommended the lifting method shown above.

Single bearing generator installation

Assembling procedure as follow:
 initial checking of the engine housing and flywheel measurement is correct as per generator flange and coupling SAE dimension

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 supplied.
 dismantle the flange cover, position the generator in-line with the engine and then aligned the generator flange to the engine
housing. After that, align the generator coupling to the engine flywheel. This is to make sure all the surface is vertically in-line with
each other. Should it is not aligned, it can be adjusted by adding several shim to the base-frame.
 bolt the coupling disc to the flywheel housing using recommended number of bolts and size. We recommended to use Grade 8.8 or
above bolt type.
 it is recommended to turn the rotor to check there is no touching between the rotor and the stator assembly.
 after assembling the generator footing to the base-frame, install back the flange cover.

Double bearing generator installation

Assembling procedure as follow:
- standard generators supplied are without special housing for connection between the generator to the engine housing and can be
available upon request.
- before installation, it is required to have a pre-balancing coupling/adaptor fit to the generator shaft end.
- position the generator in-line with the engine and then aligned the generator to the engine side. After that, align the generator
pre-balanced coupling to the engine flywheel. This is to make sure all surface is vertically in-line with each other.
- should it is not aligned, it can be adjusted by adding several shim to the base-frame.
- it is recommended to turn the rotor to check there is no touching between the rotor and the stator assembly.
- after that, assemble the generator footing to the base-frame.

5.4. Direction of Rotation

Please ensure the generator rotating direction shall be the same as the label indicated direction. Generators are normally supplied to operate
correctly when rotating clockwise.

5.5. Electrical Connection

Before the cable connection, please ensure to have the right connection. This can be referred to the Connection Diagram base on the specific

voltage requested. The output cables have to be fixed to the terminal board as indicated in Figure 9.

Figure 9 - Correct connection

Connections of different voltage on 50Hz

12
 L1 T1
L1 T1 T7
SERIESS STAR T4 PARALLEL STAR
T7
T4 T10
LEA D V T10 LEA D V T12 T5
T12 T11
L1-L2 -L3 400 T9 T8 L1-L2 -L3 20 0 T9 T2
T6 T5
L1 L2 400 L3 T3 T2 L1 L2 20 0 T6 T11
L3 T3 T8
L1 L3 400 N L2 L1 L3 20 0 L2
N
L2 L3 400 4 7 5 8 6 9 L2 L3 20 0 8 4 6
7 9 5
L1 N 230 L1 N 11 5
L2 N 230 10 12
L2 N 11 5
10 11
L3 N 230 1 2 3 11 L3 N 11 5 1 2 3 12

400VOLT.3PHAES L1 L2 L3 200VOLT.3PHASE L1 L2 L3
230VOLT.1 PHASE U V W N 115VOLT.1 PHASE U V W N

L1
PARALLEL DELTA
DOUBLE DELTA T11 T9
T5
T3

T6 T1 T8 T12 T6
T12 T2
T3 T7 T4
T9 T10 T7 T4 T1
LEA D V T10
T11 T8
L1-L2 -L3 115 L3 L2 LEA D V N
L1 L2 23 0 L2 L1
L1 L2 115 T5 T2

L1 L3 115 6 7 4 8 5 9 L1 N 11 5 6 5 9 11 4 7

L2 L3 115 L2 N 11 5

1 3 8 10 2 12
1 12 2 10 3 11

115VOLT.3PHASE L1 L2 L3 L1 L2
115VOLT.1 PHASE U V W 115/230VOLT.1 PHASE U W N

L1
T1
STAR L1
SERIES DELTA T12
T1
T9
T4 LEAD V T4
LEAD V N
T6 T7
L1-L2-L3 400 T6 T5
T3 T2
L1-L2-L3 230 L1 L2 400 L3
T10
L1 L2 230 L3
T3
L1 L3 L2
L2 400 N
L1 L3 230 T11 T8 T5 T2 L2 L3 400
L2 L3 230 L1 N 230 4 5 6
L1 N 115 4 7 5 8 6 9 L2 N 230
L2 N 115 L3 N 230
1 2 3
1 12 2 10 3 11

230VOLT.3PHASE L1 L2 L3 400VOLT.3PHASE
L1 L2 L3
115/230VOLT.1 PHASE U V W N 230VOLT.1 PHASE U V W N

1 PHASE ZIG- L1
DELTA
ZAG T5
T11
T9
T6 T1
T2 T3 T12 LEAD V T4
T4 T1 T3
T8 T6 L1-L2-L3 230 L3 L2
LEAD V N T10 T7 L1 L2 230 T5 T2

L1 L2 230 L2 L1 L1 L3 230
L1 N 115 L2 L3 230 6 4 5
7 8 5 9 4 6
L2 N 115
1 2 3
1 2 3 11 10 12

230VOLT.3PHASE L1 L2 L1 L2 L3
230VOLT.3PHASE
115/230VOLT.1 PHASE N U V W

Figure 10

Connections of different voltage on 60Hz

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 SERIESS STAR L1 T1 PARALLEL STAR L1 T1 T7
T4
LEAD V T7 LEAD V T4 T10
T10
L1-L2-L3 380 T12 T11 L1-L2-L3 190 T12 T5
T9 T8 T9 T2
L1 L2 380 T6 T5 L1 L2 190
T3 T2 T6 T11
L1 L3 380 L3 L1 L3 190 L3 T3
N T8
L2 L3 380 L2 L2 L3 190 N L2
L1 N 220 4 7 5 8 6 9 L1 N 110 4 6
7 8 9 5
L2 N 220 L2 N 110
L3 N 220 10 12 L3 N 110 10 11
1 2 3 11 1 2 3 12
380VOLT.3PHASE
220VOLT.1 PHASE L1 L2 L3 190VOLT.3PHASE L1 L2 L3
U V W N 110VOLT.1 PHASE U V W N

L1
PARALLEL DELTA
DOUBLE DELTA T11 T9
T5
T3
T6 T1 T8 T12 T6
T12 T2
T7 T4
T3
T9 T10 T7 T4 T1
LEAD V T10
L3 T11 T8
L1-L2-L3 110 L2 LEAD V N
L2 L1
L1 L2 110 T5 T2 L1 L2 220
L1 L3 110 6 7 4 8 5 9 L1 N 110 6 5 9 11 4 7

L2 L3 110 L2 N 110

1 3 2 12
1 12 2 10 3 11 8 10

110VOLT.3PHASE L1 L2 L3 L1 L2
110VOLT.1 PHASE U V W 110/220VOLT.1 PHASE U W N

L1 STAR L1
SERIES DELTA T12 T1
T1
T9 T4 LEAD V T4
LEAD V N
T6 T7
L1-L2-L3 380 T6 T5
T3 T2
L1-L2-L3 220 L1 L2 380 L3
T10
L1 L2 220 L3
T3 L2
L2 L1 L3 380 N
L1 L3 220 T11 T8 T5 T2 L2 L3 380
L2 L3 220 L1 N 220 4 5 6
L1 N 110 4 7 5 8 6 9 L2 N 220
L2 N 110 L3 N 220 1 2 3
1 12 2 10 3 11

220VOLT.3PHASE L1 L2 L3 380VOLT.3PHASE L1 L2 L3
110/220VOLT.1 PHASE 220VOLT.1 PHASE U V W N
U V W N

1 PHASE ZIG- DELTA L1

ZAG T5
T11 T3
T9
T6 T1
T2 T12 V
LEAD T3 T4
T4 T1
T8 T6
L1-L2-L3 220 L3 L2
T10 T7 L1 L2 220 T5 T2
LEAD V N
L2 L1 L1 L3 220
L1 L2 220
L1 N 110 7 8 5 9
L2 L3 220 6 4 5
4 6
L2 N 110
1 2 3
1 2 3 11 10 12

220VOLT.3PHASE L1 L2 220VOLT.3PHASE L1 L2 L3
110VOLT.1 PHASE N 220VOLT.1 PHASE U V W

Figure 11

5.6. Protection
The generator supplied neutral cable is not connected to the frame. Should it is required, it can be connected. Inside the terminal box, there
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is an earth terminal provided. There is a possibility during the complete generator set in operation, over-speed, over-voltage, short-circuit and
other possibilities can be occurred. Reliable protections are required. If running on parallel operation, reverse power protection is also
required.

During operation, it is required to followed strictly to the local regulations, laws and technical standard in force

6. STARTING UP AND TURNING OFF

6.1. Pre-running checking

After transportation, storage, installation and assembling of the complete machine, it is necessary to do a final check on all the mechanical
and electrical components before operation to ensure it is totally safe and properly protected.

 Check the rotating rectifier set

It is required to test the diodes of the rotating rectifier set with a multi-meter. Prior to the testing, it is required to disconnect all the connection
cable of the diodes. A good condition diode enables the current to flow only on direction, from the anode to the cathode.
Surge suppressor is a metal oxidation voltage-dependent resistance type and connected between both incoming and outgoing cable of the
main rotor. This surge suppressor is to protect the rotating diodes from damage caused by high load changes or misuse.

 Check the insulation

The generator has a very good insulation protection construction, unless it is being store for a long time or used in severe climatic or
atmospheric conditions, otherwise no other protection, for example heating is required. It is a good practice to test stator windings for ground
insulation before starting the machine. If the ground resistance is below 2mohm, then it is necessary to dry the generator.

 Check the earth connection

All the earth bolts in the generator support should be connected. Grounding has to be carried out using a copper wire of suitable size, in
compliance with applicable standards.

 Check the connection

Standard generators are supplied with either 12 leads or 6 leads. The entry terminals cables in the terminal box are on the right-hand side.
Terminals arrangement permits star series and star parallel connection. It is necessary when changing the connection from tar series and star
parallel, to check and modify the connection to the AVR, according to the diagram provided.

 Checking the final assembly

 check the engine and generator are properly alignment.
 check the inlet and outlet air passage is smooth and not being block by any big or large object or machinery. Also make sure there
is no back pressure or hot air back circulation.
 check all the bolts are securely fastened and tighten and all protection are in proper.
 check if there is any dirty particles or waste inside the generator and check by turning the rotor to ensure again that there is no
touching in between.

Check the machine based on above recommendation before start to operate.

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6.2. Pre-running Testing
All generators are fully tested at the factory prior to delivery. All generators are factory set at star series connection, 400V at 1500rpm.

 No load adjustment
When the prime mover reaches the rated speed, the generator should have also reaches the rated voltage. If there is a difference in the
voltage level, it can be corrected by adjusting the AVR. All three-phase voltage should also be stable and balance.

 Load adjustment
To ensure the generator is in good condition, applied the load by increasing and decreasing the load to check the voltage stability level, check
all the control panel metering is functioning in proper condition and also check on the generator of any abnormal condition. After the above
steps, the generator is safe to operate.

Please note that it is required to unplug the AVR when the prime mover is running at low speed for a long time, otherwise, it will damage the
AVR and the excitation windings.

6.3. Starting Up
- Make sure the switch, which is on the Generator set control panel, is off.
- Start up the engine, gradually increase to the rated speed. The acceleration process should not be too long.

NOTE: After the diesel generator set is installed, it cannot immediately add load for first use. Make sure it runs on NO LOAD for several hours.
Observe the situation and dehumidify and others. It can add load from 30%~50%~70% if it has been in a stable and reliable conditions. Each
load should run about 1 hour.

If no abnormal behaviour is discovered, test run can be conducted. It can be in a long-term operation if the temperature rise, vibration and etc.
are in good conditions during test run.
- Switch on, add load, run as normal.

6.4. Turning Off

- Reduce load
- Switch off
- Stop the engine

7. MAINTENANCE

Improper setting of speed governor will result in rotating parts damage by over speed.

The generator will function in good condition if there is a routine maintenance and checking program. It is important to ensure safe and
trouble-free conditions throughout the operation period. It is recommended to follow every maintenance measures highlighted in this manual.

7.1. General Maintenance

 Generator should always be kept dry. In order to keep out of the humidity, please cover with cloth if not used.
 Generator must be free from metal leftovers, drops, dust, acid-base steam or other harmful gases.
 During operation, the ventilation must be sufficient. Please ensure all openings are free and not be block by any machinery or panel.
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 Do not put anything on top of the alternator for it is bad for ventilation and heat elimination. Please don't remove the top terminal
box cover.
 Please check the generator load from time to time. The load current should not over the rated current of generator. When the load
power factor is low, the excitation current should not over the rated value mentioned on the nameplate. When the three-phase load
is not balance, the biggest phase current of that phase should not over the rated current.
 Please note the temperature of the alternator bearing. The bearing temperature rise should not over 55K in general.
 During operation, the generator shall not over the rated speed, voltage and ampere. Once abnormal smells, strange sound audible
and excessive vibration detected, please stop the machine immediately and a thorough check-up is required before restart the
machine.

7.2. Inspection and Maintenance

- If the generator is not in use for some time, check the windings insulation. If it is lower than 5Mohm, then it is necessary to dry the
generator and then repeat the test. If the grounding insulation still remains the same, then the insulation has already aged and
you should change the wire and insulation.
- Check the bearing and housing position to ensure there is no loose or wear and tear.
- check the airflow and internal condition. If inside the terminal box is too dusty, its required to be cleaned.
- Check the alignment of the generator to the engine to make sure it is not out of alignment and also check the fan assembly to
ensure it is not deform.
- Check all cable connections especially the AVR side to make sure it is not loose.

Bearing checking
There are two types of bearing in generator:
a) Pre-lubricated sealed for life bearing which do not need to lubricate again.
b) Lubricable bearing which need to lubricate periodically during the operation procedure.

Generator Range Bearing position Lubrication weight (g) Lubrication cycle (hour)

TCU468 Drive end 93 4500

Drive end 70 4500

TCU528
Non-drive end 93 4500

Drive end 115 4500

TCU568
Non-drive end 104 4500

The lubrication cycle above is in the condition of operation temperature below 70°C. Each 15°C temperature rise will decrease half lubrication

cycle.

7.3. Assembling and Disassembling

Disassembling steps: (assembling steps reverse)

- disassemble generator lead wires, air outlet screen protection, coupler, coupling flange.
- disassemble end protection cover, terminal box, connection wire between exciter stator and main generator, disassemble the bolts
of the back shield, then take off the back shield with the exciter stator.
- for single bearing generator, disassemble the coupling disc, lifting out the rotor from the stator with professional lifting device.

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 - for double bearing generator, take off the outer bearing cover of the front bearing, take out the bolt of the front shied, then lifting
out the rotor from the stator with professional lifting device.
- for the large capacity generator with very heavy rotor, using professional lifting device as Figure 12.

Figure 12 - professional lifting device

7.4. Troubleshooting
Trouble Possible cause Measures
- Wrong connection - Refer to the connection manual
- Rotating diodes damage - Check in case of short circuit and repair or
No power supply - AVR connection loose change diodes
- Short circuit on main cables - Disconnect and reconnect all wire again
- Insufficient of residual voltage - Apply 12V battery to recharge

- Fuse blown - Replace the fuse.

No load voltage above rated voltage - Wrong connections of exciter - If fuse blown again, check if the exciter stator is
short circuit. otherwise, change the AVR
- Check connection again
No load voltage below rated voltage - AVR setting problem - Adjust the AVR potentiometer.
No load or load voltage unstable - Check the speed stability - Readjust the stability selection
Excitation current too high - Excitation current too high - Check, repair, or replace diode assembly

- Generator to engine not in-line - Check the alignment and rectify the problem
Vibration - Rotor balancing problem after repair - Rebalancing required
- Bearing damage - Check and change bearing immediately
- Engine problem - Check and service the engine
- Operation exceed bearing recommended - Change bearing
Bearing heating running hours - Change bearing or lubricate grease
- Insufficient of grease - Check the alignment and rectify the problem
- Generator to engine not in-line
- Overload - Adjust to the nominal rate
Generator heating - Power factor too low - Adjust the load and the ampere to nominal level
- Airflow problem - Ensure the fan assembly not obstruct
Voltage unstable - AVR problem - Check, adjust or change a new AVR

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7.5. AVR Troubleshooting
Trouble Possible cause Measures
- Insufficient of residual voltage - Apply 12V battery to recharge
- Sensing cable not connected - Reconnect again
No power supply
- Generator set under-speed - Adjust to rated speed
- AVR damage - Change new AVR

- Generator set under-speed - Adjust to rated speed

Voltage too low
- Wrong FREQ setting - Adjust the setting

- AVR setting too high - Adjust AVR setting

Voltage too high
- AVR damage - Checking and replace new AVR

Voltage unstable - Wrong AVR setting - Adjust AVR setting

Voltage fluctuation between - generator set speed too low - Adjust generator set speed
300V~400V - Wrong FREQ setting - Adjust the setting

8. CHECKING AND STORAGE

After the generator set is arrival, customer should check if it is accordance with the order by the rating-plate. Meanwhile, check if there is any

damage or loss of the files and documents about the goods.

Documents with the goods include Maintenance Manual, Certificate of Quality, Structural Drawing, Products List, Contract and etc.

For lifting and handling the purpose made eyebolts must be used. The lifting eyes are designed to support only the

weight of the generator and they are not to be used for lifting the complete gen-set that incorporates the generator. Check that the lifting

means available are suitable for the movement of all parts which have to be handled. Check also that the working conditions are suitable to

operate without danger for safety of personnel.

If the generator is not used immediately, customer should pack it again. And put it in a dry and clean surrounding free of contaminations such

as gases and various chemicals, salt water spray, dust and rainfall. Keep the generator alignment in delivery and upright in storage. It is not

in the warranty range for damage of improper storage.

9. STRUCTURAL DRAWING AND PARTS LIST

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10. SERVICE
Service engineers of the company are available to give technical support and advice.

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Anhui EvoTec Power Generation Co., Ltd
No.9, Su He Road, Lujiang Economic Development Zone,

Hefei City, Anhui Province, China

Tel：+86 511 87655888 +86 400-880-5328

Fax：+86 511 87868333

Email: info@evotecpower.com
Web site: www.evotecpower.com