DSG/DIG DSG/DIG Generators Generators
Installation, Service and Maintenance
English
04-2014 ING-WI-0395/A046V044 (Issue Original Instructions
3)
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 Alternator 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
3. SAFETY DIRECTIVES AND STANDARDS ........................................................................... 11
3.1 Machinery Directive: Declaration of Incorporation of partly completed Machinery ......... 12
3.2 Low Voltage Directive: Declaration of Conformity ........................................................... 13
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
5. TRANSPORTATION, STORAGE AND CORROSION PROTECTION .................................. 19
5.1 Transportation and Packaging ........................................................................................ 19
5.1.1 General ................................................................................................................. 19
5.1.2 General Information for Anti-friction bearings....................................................... 19
5.1.3 General information for sleeve bearings .............................................................. 19
5.1.4 General Information for Air-Water Coolers ........................................................... 19
5.1.5 Packaging ............................................................................................................. 19
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5.1.6 During Transport (All DSG and DIG 120/130) ...................................................... 19
5.1.7 During Transport (DIG 142) .................................................................................. 21
5.1.8 During Transport (DIG 140/150/156/163/167/183) ............................................... 23
5.1.9 Unpacking Checks/Items supplied ....................................................................... 24
5.1.10 Inspection on Arrival ........................................................................................... 24
5.1.11 Inspection on Unpacking .................................................................................... 24
5.2 Storage ............................................................................................................................ 25
5.2.1 Storage in a Suitable Room (Less Than 6 Months) ............................................. 25
5.2.2 Storage in a Suitable Room (Longer than 6 Months) ........................................... 25
5.2.3 Storage in Unsuitable Conditions For Less Than 2 Months ................................. 26
5.2.4 Storage under Unsuitable Conditions longer than 2 Months................................ 26
5.3 Protect Against Corrosion ............................................................................................... 27
5.3.1 Bare Surfaces ....................................................................................................... 27
5.3.2 Sleeve Bearings ................................................................................................... 27
5.3.3 Anti-friction Bearings ............................................................................................ 28
5.3.4 Air-air Cooler ........................................................................................................ 28
5.3.5 Air-water Cooler.................................................................................................... 28
5.3.6 Customer Connection Openings .......................................................................... 28
5.4 Remove Corrosion Protection ......................................................................................... 28
5.4.1 Anti-friction Bearings ............................................................................................ 29
5.4.2 Sleeve Bearings ................................................................................................... 29
5.4.3 Cooler ................................................................................................................... 29
5.4.4 Condensed Water Drain ....................................................................................... 30
5.5 Oil Drain Points ............................................................................................................... 30
6. INSTALLATION AND ALIGNMENT........................................................................................ 33
6.1 General ............................................................................................................................ 33
6.2 Preparation of the Generator........................................................................................... 33
6.2.1 Generators with Anti-friction Bearings .................................................................. 33
6.2.2 Generators with Sleeve Bearings ......................................................................... 34
6.2.3 Recommendations for Coupling Assembly........................................................... 34
6.3 Mounting Design.............................................................................................................. 35
6.3.1 General ................................................................................................................. 35
6.3.2 Mounting Forces ................................................................................................... 35
6.3.3 Mounting on Ships ................................................................................................ 35
6.3.4 Installation on Concrete Foundations ................................................................... 36
6.3.5 Installation on Steel Foundation ........................................................................... 37
6.4 Align the Prime Mover and Generator............................................................................. 38
6.4.1 General ................................................................................................................. 38
6.4.2 Theory of Alignment ............................................................................................. 38
6.4.3 Compensate for Thermal Expansion .................................................................... 39
6.4.4 Assemble the Coupling Halves............................................................................. 40
6.4.5 Coarse Alignment ................................................................................................. 41
6.4.6 Final Alignment ..................................................................................................... 41
6.5 Fit the Dowel Pins ........................................................................................................... 44
6.6 Measures for Delayed Commissioning............................................................................ 44
7. MECHANICAL AND ELECTRICAL CONNECTIONS............................................................. 45
7.1 General ............................................................................................................................ 45
7.2 Mechanical Connections ................................................................................................. 45
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7.2.1 Cooling Air Connections ....................................................................................... 45
7.2.2 Connect Cooling Water ........................................................................................ 46
7.2.3 Oil Supply for the Sleeve Bearings....................................................................... 46
7.3 Connect Vibration Sensors.............................................................................................. 47
7.3.1 Anti-friction Bearings ............................................................................................ 47
7.3.2 Sleeve Bearings ................................................................................................... 47
7.4 Electrical Installation ........................................................................................................ 47
7.4.1 General Information .............................................................................................. 47
7.4.2 Safety.................................................................................................................... 48
7.4.3 Moisture ................................................................................................................ 48
7.4.4 Insulation Resistance ........................................................................................... 48
7.4.5 Main Terminal Box................................................................................................ 49
7.4.6 Auxiliary Terminal Boxes ...................................................................................... 49
7.4.7 Isolation Distances for the Primary Line Connections.......................................... 49
7.4.8 Primary Line Cables ............................................................................................. 50
7.5 Criteria That Affect the Output Power ............................................................................. 53
7.5.1 Design Criteria ...................................................................................................... 53
7.5.2 Effect of Coolant Temperature ............................................................................. 53
7.5.3 Effect of Installation Altitude ................................................................................. 53
7.5.4 Effect of Power Factor Cos Phi ............................................................................ 54
7.6 Electrical Behavior ........................................................................................................... 55
7.6.1 Principle of Operation ........................................................................................... 55
7.6.2 Voltage Regulator ................................................................................................. 55
7.6.3 Self-excitation, De-excitation ................................................................................ 56
7.6.4 Voltage and Frequency ........................................................................................ 56
7.6.5 Currents ................................................................................................................ 58
7.7 Parallel Operation ............................................................................................................ 60
7.7.1 General ................................................................................................................. 60
7.7.2 Parallel Switching Conditions ............................................................................... 60
7.7.3 Island Parallel Operation ...................................................................................... 61
7.7.4 Operation in Parallel with the Line System .......................................................... 61
8. COMMISSIONING AND STARTING ...................................................................................... 63
8.1 General ............................................................................................................................ 63
8.2 Check the Mechanical Installation ................................................................................... 63
8.3 Check the Electrical Installation ...................................................................................... 63
8.4 Controller and Protective Equipment............................................................................... 63
8.4.1 General ................................................................................................................. 63
8.4.2 Stator Winding Temperature ................................................................................ 64
8.4.3 Monitoring the Bearing Temperature .................................................................... 64
8.5 First Run .......................................................................................................................... 65
8.5.1 General ................................................................................................................. 65
8.5.2 Before Starting...................................................................................................... 65
8.5.3 Starting ................................................................................................................. 66
8.5.4 Direction of Rotation of the Generator and External Motors ................................ 66
8.5.5 Ground Fault Monitoring ....................................................................................... 66
8.6 Operate the Generator for the First Time ........................................................................ 66
8.6.1 Monitoring During Operation ................................................................................ 66
8.7 Check the Generator in Operation .................................................................................. 67
8.7.1 Bearings................................................................................................................ 67
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8.7.2 Vibration................................................................................................................ 68
8.7.3 Temperature Level ............................................................................................... 68
8.7.4 Heat Exchanger .................................................................................................... 68
8.8 Shut Down the Generator................................................................................................ 69
9. OPERATION........................................................................................................................... 71
9.1 General ............................................................................................................................ 71
9.2 Normal Operating Conditions .......................................................................................... 71
9.3 Number of Starts ............................................................................................................. 71
9.4 Monitoring ........................................................................................................................ 71
9.4.1 Bearings................................................................................................................ 72
9.4.2 Vibration................................................................................................................ 72
9.4.3 Stator Temperatures............................................................................................. 72
9.4.4 Heat Exchangers .................................................................................................. 72
9.4.5 Slip Ring Units ...................................................................................................... 72
9.4.6 Documentation of Operation................................................................................. 72
9.5 Shutting Down ................................................................................................................. 72
9.6 Anti-condensation Heaters .............................................................................................. 73
9.7 Flashover Pressure Protection ........................................................................................ 73
9.8 Firefighting and Extinguishing Agents ............................................................................. 74
9.8.1 General ................................................................................................................. 74
9.8.2 Extinguishing Agents ............................................................................................ 75
9.8.3 Cleaning After Fire-fighting ................................................................................... 76
10. SERVICE AND MAINTENANCE........................................................................................... 77
10.1 Preventive Servicing ...................................................................................................... 77
10.2 Safety Precautions ........................................................................................................ 77
10.3 Recommended Servicing Schedule .............................................................................. 78
10.3.1 Generator............................................................................................................ 79
10.3.2 Main Electrical Connections ............................................................................... 80
10.3.3 Stator and Rotor ................................................................................................. 81
10.3.4 Accessories ........................................................................................................ 82
10.3.5 Slip Ring Units .................................................................................................... 82
10.3.6 Lubrication System and Anti-friction Bearings.................................................... 83
10.3.7 Lubrication System and Sleeve Bearings........................................................... 84
10.3.8 Cooling System .................................................................................................. 85
10.3.9 Safety.................................................................................................................. 86
10.4 Servicing - General Structure ........................................................................................ 86
10.4.1 Strength of Screw Fasteners .............................................................................. 86
10.5 Vibration ........................................................................................................................ 88
10.5.1 Measuring Methods and Operating Conditions .................................................. 89
10.5.2 Definition in Accordance with ISO 10816-3 ........................................................ 90
10.5.3 Definition in Accordance with ISO 8528-9 .......................................................... 90
10.5.4 Warning Values and Shutdown Values .............................................................. 90
10.6 Servicing the Bearings and the Lubrication System...................................................... 91
10.6.1 Sleeve Bearings ................................................................................................. 91
10.6.2 Anti-friction Bearings .......................................................................................... 94
10.7 Generators with Bearing Insulation ............................................................................... 99
10.7.1 Bearing Insulation on Sleeve Bearings .............................................................. 99
10.7.2 Bearing Insulation on Anti-friction Bearings ....................................................... 99
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10.8 Service Windings ........................................................................................................... 99
10.8.1 Safety Instructions for Servicing Windings ......................................................... 99
10.8.2 Scheduling the Servicing .................................................................................. 100
10.8.3 Correct Operating Temperature of Windings ................................................... 100
10.8.4 Insulation Resistance Test ............................................................................... 100
10.8.5 Insulation Resistance Measurement for Ancillary Equipment .......................... 102
10.8.6 The Polarization Index ...................................................................................... 103
10.8.7 Servicing the Grounding Brushes ..................................................................... 103
10.9 Servicing the Generator Cooling ................................................................................. 104
10.9.1 Servicing Instructions for Generators with Open-circuit Ventilation ................. 104
10.9.2 Service Instructions for Generators with Air Filters .......................................... 105
10.9.3 Servicing Instructions for Generators with Heat Exchangers ........................... 106
10.10 Repairs, Dismantling and Re-assembly .................................................................... 106
11. FAULT FINDING ................................................................................................................. 107
11.1 Generator, General...................................................................................................... 108
11.2 Lubrication System and Anti-friction Bearings............................................................. 109
11.3 Lubrication System and Sleeve Bearings.................................................................... 110
11.4 Open Cooling System ................................................................................................. 111
11.5 Air-air Cooling System................................................................................................. 112
11.6 Air-water Cooling System ............................................................................................ 113
11.7 Faults on the Brushes ................................................................................................ 114
11.8 Fault Finding Sleeve Bearings .................................................................................... 114
11.8.1 Oil Leaks on Sleeve Bearings .......................................................................... 114
11.8.2 Oil ..................................................................................................................... 115
11.8.3 Checking the Bearings ..................................................................................... 115
11.8.4 Check on the Oil Tank and the Oil Lines.......................................................... 116
11.8.5 Vibration and Oil ............................................................................................... 116
11.8.6 Check on Vibration ........................................................................................... 116
11.8.7 Hydrostatic System........................................................................................... 116
11.8.8 Air Pressure in the Bearing .............................................................................. 116
11.8.9 Air Pressure Outside the Bearing ..................................................................... 117
11.9 Electrical Power, Excitation, Control and Protection ................................................... 118
11.9.1 Triggering the Protective System ..................................................................... 118
11.9.2 PT-100 Resistive Temperature Sensors .......................................................... 118
11.10 Thermal Performance and Cooling System .............................................................. 119
12. SERVICE PARTS AND AFTER SALES SERVICE ............................................................ 121
12.1 Service Parts for Generators ....................................................................................... 121
12.1.1 General Information on the Service Parts ........................................................ 121
12.2 Customer Service ........................................................................................................ 122
12.2.1 Customer Service and Warranty ...................................................................... 122
13. END OF LIFE DISPOSAL ................................................................................................... 123
13.1 Disposal ....................................................................................................................... 123
13.2 Introduction .................................................................................................................. 123
13.3 Average Material Content ............................................................................................ 123
13.4 Recycling Packaging Material ..................................................................................... 124
13.5 Dismantling the Generator .......................................................................................... 124
13.6 Separation of the Different Materials ........................................................................... 125
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13.6.1 Stator, Bearing Housing, Covers and Fans ...................................................... 125
13.6.2 Components with Electrical Insulation .............................................................. 125
13.6.3 Hazardous Waste ............................................................................................. 125
13.6.4 Residual Waste ................................................................................................ 125
vi ING-WI-0395/A046V044 (Issue 3)
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.
1.2 The Manual
This manual contains guidance and instructions for the installation, servicing and
maintenance of the alternator.
Before operating the alternator, read this manual and make sure that all personnel who work
on the equipment have access to the manual and all additional documentation supplied with
it. Misuse and failure to follow the instructions, and the use of non-approved parts, may
invalidate the product warranty and lead to potential accidents.
This manual is an essential part of the alternator. Make sure that the manual is available to
all users throughout the life of the alternator.
The manual is written for skilled electrical and mechanical technicians and engineers, who
have prior knowledge and experience of generating equipment of this type. If in doubt,
please seek expert advice or contact your local Cummins Generator Technologies
subsidiary.
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.
ING-WI-0395/A046V044 (Issue 3) 1
1. Foreword 04-2014
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 ING-WI-0395/A046V044 (Issue 3)
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CUMMINS AVK DSG DIG Generator Workshop Service Repair Manual
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This workshop service repair manual is designed for the maintenance and repair of the CUMMINS AVK DIG GENERATOR and CUMMINS AVK DSG GENERATOR models.
- Foreword
- Safety Precautions
- Safety Directives and Standards
- Introduction
- Transportation, Storage
- Corrosion Protection
- Installation and Alignment
- Mechanical and Electrical Connections
- Commissioning and Starting
- Operation
- Monitoring
- Shutting Down
- Electrical Installation
- Parallel Operation
- Mounting Design
- Anti-Condensation Heaters
- Flashover Pressure Protection
- Service and Maintenance
- Generators with Bearing Insulation
- Repairs, Dismantling and Re-assembly
- Servicing the Generator Cooling
- Fault Finding
- Service Parts and After Sales Service
- End of Life Disposal
This comprehensive manual features detailed exploded views, step-by-step procedures with illustrations, and is fully printable. It is an essential resource for professional mechanics and DIY enthusiasts for repairs, maintenance, and servicing of the CUMMINS AVK DSG DIG GENERATOR.
