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Special Instruction
Cleaning and Drying of the Generator{4450}
Media Number -SEHS9124-02 Publication Date -02/02/2009 Date Updated -02/02/2009
i03314784
Cleaning and Drying of the Generator{4450}

SMCS - 4450
Generator Set: All
Introduction
Many electrical failures in generators are a result of a breakdown in the insulation. These
breakdowns normally occur in specific locations. The current leakage through these locations causes
deterioration in the insulation. This deterioration causes a lower resistance to high voltage that
eventually allows a short circuit.
Another problem is the potential risk of failure of the stator for generators that are stored or operated
in contaminated environments and/or humid environments. Problems can develop in the generator
windings if one of the following items are present: dust, water, salt and grease. Also, problems can
occur if the generator windings are ever below the dew point.
The following contaminants should not be allowed to accumulate on the stator windings: dirt, dust,
grease, oil films, salt and water. These conditions increase the risk of moisture that collects in the
windings. Moisture can provide a conductive path between bundles of wire. When this occurs,
current will leak from the bundle of wire with the higher voltage to the bundles of wire with the
lower voltage. The current leak produces heat. Also, the current leak causes a breakdown and the
winding insulation can be burned. If the problem continues to be undetected, the windings may be
severely damaged.
This Special Instruction provides information for testing and maintenance procedures that may be
carried out in the field on an electric generator. The potential problems with the insulation will be
removed or reduced by these procedures. Also, this Special Instruction will provide some preventive
maintenance practices that will reduce the risk of failure of the stator for generators that are stored or
operated in contaminated environments and/or humid environments.
ReferenceRefer to the following documents for more information:
"IEEE STD #43 Recommended Practice for Insulation Testing of Rotating AC Machinery"
Engine News, SEBD0660, "Operating Environment and its Effects on SR4 Generators"
Application and Installation Guide, LEBW4993, "Generator Systems"
https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 15/07/2010
Application and Installation Guide, LEBE5294, "EP Applications, Engine & Generator
Sizing"
Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by
failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing
potentially hazardous situations before an accident occurs. A person must be alert to potential
hazards. This person should also have the necessary training, skills, and tools in order to perform
these functions properly. Safety precautions and warnings are provided in this instruction and on the
product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to
other persons. Caterpillar cannot anticipate every possible circumstance that might involve a
potential hazard. Therefore, the warnings in this publication and the warnings that are on the product
are not all inclusive. If a tool, a procedure, a work method or operating technique that is not
specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other
people to use. You should ensure that the product will not be damaged or the product will not be
made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.
Personal injury or death can result from high voltage.
When power generation equipment must be in operation to make tests

and/or adjustments, high voltage and current are present.
Improper test equipment can fail and present a high voltage shock
hazard to its user.
Make sure the testing equipment is designed for and correctly operated
for high voltage and current tests being made.
When servicing or repairing electric power generation equipment:
Make sure the unit is off-line (disconnected from utility and/or

other generators power service), and either locked out or tagged
DO 2OT OPERATE.
Remove all fuses.
Make sure the generator engine is stopped.
Make sure all batteries are disconnected.
Make sure all capacitors are discharged.
Failure to do so could result in personal injury or death. Make sure

residual voltage in the rotor, stator and the generator is discharged.
Personal injury or death can result from a spark.
An incompletely discharged capacitor can cause a spark.
Do not use the insulation tester in an explosive atmosphere.
Personal injury or death can result from electrocution.
The megohmmeter is applying a high voltage to the circuit.
To avoid electrocution, do not touch the instrument leads without first

discharging them. When finished testing also discharge the generator
windings.
Required Tool
Caterpillar recommends the use of a calibrated insulation tester that is industry standard for checking
the insulation resistance. Insulation testers apply a nominal test voltage to test insulation resistance
for most applications of Caterpillar generator sets. For generator sets with a rated voltage up to 600
VDC, use a test voltage of 500 VDC. For generator sets with a rated voltage over 600 VDC, use a
test voltage of 1000 VDC.
2ew Equipment
Storage
After a new generator arrives to the site, the generator should be protected against moisture until the
generator is ready to be installed.
When a generator is in storage, moisture condenses in the windings. In order to minimize

condensation, always put the generator in a dry storage area.
When the generator is placed in storage, it is necessary to perform an insulation resistance check.
Record the results from the insulation tester. The temperature and the level of humidity should also
be recorded. This check will provide a baseline for future reference.
2ote: Ensure that the baseline is established with the unit dry.
In order to protect against collecting contaminants, the generator should be covered with a plastic
cover or a similar type of protective cloth. The protective cover should extend to the ground, but the
cover should remain loose around the generator in order to allow the generator to properly breathe.
Caterpillar recommends maintaining the temperature of the insulated parts and the air that surrounds
the parts at a temperature of at least 5°C (9°F) above the normal room temperature. This will prevent
condensation. The following methods are the normal methods for providing the required heat:
Space heaters.
Warm air blowers. Do not exceed 206.7 kPa (30 psi).
Light bulbs. Install a light bulb (60 Watt minimum) inside the generator in the proximity of the
stator core at the lowest possible location.
Ensure that the shaft is rotated 10 revolutions over a period of every 60 days throughout the storage
period.
Removal from Storage
Operate space heaters for at least 24 hours prior to removing covers.
Remove all protective covers. If the unit does not have a space heater, use an alternate means in
order to raise the temperature to at least 5°C (9°F) higher than the normal room temperature. Refer to
""External Heat " " for more information.
Before start-up of a generator, visually inspect the generator for any foreign material. Use an
insulation tester to check insulation resistance for moisture and/or foreign material. Refer to the
Operation and Maintenance Manual for the generator for the procedure.
Resistance readings with a 50% reduction or more from the previous reading or 30 megohms for a
new unit may indicate that the winding has absorbed too much moisture and needs to be cleaned. If
cleaning or drying is necessary, refer to the methods that are covered in ""Cleaning" " and ""Drying"
" for more information.
Checking the Equipment

Visual Checks
The generator should be checked periodically for any accumulation of dust, water, salt, grease, or oil
films. If cleaning is necessary, refer to the methods that are covered in ""Cleaning" " and ""Drying" "
for more information.
2ote: Windings must be kept clean and dry. Any accumulation of dirt will trap moisture. This
moisture will reduce the dielectric strength of the insulation, which will cause the insulation to fail.
Insulation Resistance Tests
The frequency of the insulation resistance checks will be determined by the environmental
conditions and the operating conditions of the operation of the generator. Before determining a
preventive maintenance schedule, ensure that the readings are not changing more rapidly than the
selected frequency. An insulation resistance check must be performed at least yearly.
For determining a preventive maintenance schedule, use the following guidelines:
Generators that have a seasonal operation should be tested and inspected prior to being put
back in service.
If the generator is installed in an enclosed building with relatively low humidity and minimal
temperature variations, test the insulation yearly.
If the previous two conditions are not met, the insulation tests should be performed over a
period of every three months.
If the generator is in a sea water environment, near a sea water environment, or in an

environment with high humidity (above 75% relative humidity), test the insulation after every
month.
If the most recent test results were less than three megohms, increase the frequency of the
insulation test.
The use of a space heater is recommended whenever the unit is not running. Even generators that
cycle on and off within a 24 hour period should use space heaters during the off hours.
Consider the following items during the test:
Good results from the insulation resistance checks do not guarantee that the unit will not fail.
Certain conditions will give acceptable insulation resistance values or even high insulation
resistance values but the unit may still fail. However, these tests are an indication about when
the cleaning and/or the repairing is becoming more critical.
The insulation resistance will vary greatly with temperature. The test should be performed as
near as possible to the same temperature and humidity.
A permanent record of the temperature for the unit and the values of the temperature readings
for the insulation should be kept.
Test Setup for Insulation Resistance
Personal injury or death can result from a spark.
An incompletely discharged capacitor can cause a spark.
Do not use the insulation tester in an explosive atmosphere.
Carefully follow the instructions from the manufacturer for connecting any insulation tester to
the electrical system.
The circuit that will be the subject of the test must be switched off before connecting the test
leads.
Before performing an insulation resistance check, disconnect any of the following items:
grounds, loads, meters and controls.
Connect all the sections of the stator windings together in the normal high voltage or low
voltage connections.
Connect one lead of the insulation tester to each of the stator windings one at a time with the
other lead of the insulation tester on the generator frame.
2ote: If the voltage regulator is connected and a problem with the resistance is found, disconnect the
voltage regulator in order to verify that the voltage regulator is not affecting the readings.
Personal injury or death can result from electrocution.
The megohmmeter is applying a high voltage to the circuit.
To avoid electrocution, do not touch the instrument leads without first

discharging them. When finished testing also discharge the generator
windings.
Perform the following procedure before checking the exciter field winding insulation:
1. Disconnect the leads for the exciter field, that typically have the "F1" and "F2" labels, from the
regulator.
2. Connect one lead of the insulation tester to either the "F1" field lead or the "F2" field lead and
ensure that the other lead is touching nothing.
3. Connect the other lead for the insulation tester to the generator frame.
Test Procedure for Insulation Resistance
Perform the following procedure in order to check the resistance in the exciter field winding
insulation:
1. Take the generator out of service.
2. Visually inspect the generator for moisture. If moisture exists, do not check the insulation. Dry
the unit first. In order to completely dry the insulation, refer to the procedure in ""Drying" "
for more information.
3. Inspect the installation in order to determine the equipment that will need to be tested by the
insulation tester.
4. Discharge the capacitance of the windings.
5. Disconnect "T0" from ground.
6. Disconnect the regulator sensing lead wires. These wires typically have the following labels:
"20", "22" and "24".
7. Connect the red lead of the insulation tester to ground ("+").
8. Connect the black lead of the insulation tester to "T0" ("-").
9. Set the voltage for 500 volts for units that are 600 volts or less. Set the voltage for 1000 volts
for units that are 600 volts or more.
10. Test the resistance in the winding by performing the following procedure:
a. Apply voltage.
b. Observe the readings at 30 seconds and at 60 seconds again.
c. Record the 60 second reading. This reading must be corrected for temperature.
d. Record temperature.
e. Record humidity.
f. Remove voltage.
11. Evaluate readings. Refer to ""Evaluating the Test Results" " for more information.
12. Discharge the leads and the windings before disconnecting the insulation tester leads by
switching the insulation tester to OFF.
2ote: Results from the checks of the resistance for the insulation give a good indication of the time
that cleaning and/or repairing is becoming more critical.
The insulation resistance will vary greatly with temperature. The test should be performed as near as
possible to the same temperature and humidity.
Evaluating the Test Results
The actual value of the resistance may vary greatly between generators. For this reason, the
evaluation of the condition of the insulation must be based on the resistance readings in comparison
to the resistance readings that were taken on previous dates under similar conditions. A 60 second
reading of the resistance with a 50% reduction from the previous reading indicates that the insulation
may have absorbed too much moisture.
The cause should be determined if the measurements show a wide variation from previous readings
under similar test conditions. The abnormal conditions should be corrected before an insulation
failure occurs.
Illustration 1 g01696934
Curve of insulation resistance for windings in good condition
(1) Resistance after 30 seconds
Illustration 1 indicates the curve of the resistance of a normal high resistance in the windings over a
period of 60 seconds. The resistance after 60 seconds (2) will be greater than the resistance or equal
to the resistance after 30 seconds (1).
Curve of insulation resistance for windings that are wet or dirty
Illustration 2 indicates the curve of the resistance that is decaying over a period of 60 seconds. If the
insulation resistance after 60 seconds (2) is not higher than the resistance after 30 seconds (1), then
clean the windings and thoroughly dry the windings. Refer to the methods that are covered in
""Cleaning" " and ""Drying" " for more information.
If the levels of the resistance can be brought up to acceptable levels, then the windings can be
resealed. In order to reseal the windings, dip the windings in a tank of varnish for insulation.
2ote: Caterpillar recommends a minimum acceptable insulation resistance of one megohm for
generators that are operating with less than 1000 volts of operating voltage or rated voltage.
Generators that are operating at 1000 volts of operating voltage or rated voltage should have a
minimum insulation resistance that can be determined by using the following equation:
R = (V/1000) + M
"R" is the minimum insulation resistance.
"V" is the rated voltage.
"M" is one megohm.
These values are approximate. A generator may possibly be operated with less resistance.
2ote: For new units that are being placed into service, the reading of the resistance should be greater
than 30 megohms.
Periodic readings of the insulation resistance should establish a trend in deterioration of the
insulation. Resistance readings with a 50% reduction or more from the previous reading may indicate
an abnormal condition.
If the minimum acceptable readings of the resistance in the insulation that is recommended by
Caterpillar cannot be obtained after cleaning and drying the generator windings, the insulation has
probably deteriorated and the insulation should be reconditioned by a qualified electrical shop.
Cleaning
The following contaminants should not be allowed to accumulate on the windings:
Dirt
Dust
Grease
Salt
Oil films
Before cleaning, check if the insulation is in good condition. Refer to ""Insulation Resistance Tests"
" for more information.
Generators may be routinely cleaned by the following methods:
""Wiping" "
""Vacuuming" "
""Washing" "
""Steam Cleaning" "
""Pressure Air" "
Generators that have been submerged, flooded, or completely filled with dirt may need extreme
cleaning. Refer to ""Extreme Cleaning" " for more information.
Personal injury or death can result from the engine starting.
Regardless of the cleaning method used; to avoid serious injury or

death, make sure there is no voltage applied to the windings.
Make sure the engine can not be started.
Wiping
If the unit is small enough and the dirt on the exposed parts is dry, wiping with a dry lint free cloth is
acceptable.
2ote: The cloth must be free of lint or the lint will adhere to the insulation which will collect dust,
moisture and oil. This is particularly unacceptable on high voltage insulation.
In order to completely dry the insulation, refer to the procedure in ""Drying" " for more information.
Vacuuming
Dry contaminants may be removed by vacuuming. A soft bristle brush may be used in order to
loosen the dirt before vacuuming or during vacuuming.
In order to completely dry the insulation, refer to the procedures in ""Drying" " for more
information.
Washing
If the equipment for drying is available, washing may be performed in a dealer shop or in the field
while a shop environment is more preferable. Refer to the procedures in ""Drying" " in order to
determine the equipment that may be needed.
Personal injury can result from working with cleaning solvent.
Because of the volatile nature of many cleaning solvents, extreme

caution must be exercised when using them. If unsure about a
particular cleaning fluid, refer to the manufacturer's instructions and
directions.
Always wear protective clothing and eye protection when working with
cleaning solvents.
2OTICE
Read and understand the information on the container label before
using. A cleaner that is nonflammable and safe for all ferrous and
nonferrous parts should be used. The cleaner should be readily
removable with water. Failure to do so may cause equipment damage.
Caterpillar recommends the use of Hydrosolv liquid cleaner in order to clean the generators. The
concentration level of the solvent may be varied from five percent to 100 percent as the solvent is
needed in order to remove all foreign material. Consult your Caterpillar technical communicator for
part numbers and sizes of containers.
Other solvents such as Stoddard Solvents may also be used. Refer to "NBS Standard P-D-680, Dry
Cleaning and Degreasing Solvent" for more information which is published by the National Institute
of Standards and Technology.
Refer to the following procedure in order to clean the generators:
1. Create the cleaning solution.
2. Clean the insulation and rinse the insulation with fresh warm water.
2ote: Cleaning should be done as rapidly as possible in order to avoid long periods of
exposure of the insulation to the solvent.
3. Wipe off excess moisture with a clean dry cloth.
4. Bake dry in an oven before placing back into service. Refer to the ""Ovens" " procedure in
""Drying" " for more information.
Steam Cleaning
Steam cleaning should only be performed if there is a great amount of grease or dirt that is present.
2OTICE
After steam cleaning, a complete drying and reapplying varnish are
required before the unit is placed back into service otherwise damage
to the equipment may occur. Use a qualified electrical rebuild shop.
Perform the following procedure in order to steam clean the generators:
1. Clean the generator with a unit for steam cleaning that is operating at a pressure of 0.1 MPa
(15 psi) to 0.2 MPa (30 psi) and a temperature of 121° C (250° F) to 149° C (300° F).
2. Bake the unit in an oven in order to remove moisture before applying varnish to the unit. Refer
to the ""Ovens" " procedure in ""Drying" " for more information.
3. Once the unit is dry, apply varnish to the windings.
2ote: The windings must have a new coat of varnish in order to protect the windings.
4. Bake dry in an oven before placing back into service. Refer to the ""Ovens" " procedure in
""Drying" " for more information.
Pressure Air
The generators may be cleaned with filtered pressure air.
2ote: This is the least desired method of cleaning. In some instances, the air can relocate the dirt
instead of removing the dirt.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When

using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi)
for cleaning purposes.
2OTICE
2ever aim the pressured air directly against the insulation without first
removing all of the moisture and contaminates from the insulation.
Contaminates that are blown into the insulation and some areas of the
generator may cause damage.
Carefully blow the dirt out of the windings by using 135 kPa (20 psi) to 205 kPa (30 psi) of filtered
dry air.
Once the dirt is out of the windings, refer to the procedures in ""Drying" " for more information in
order to completely dry the unit.
Extreme Cleaning
This method is for electrical equipment that has been completely submerged, flooded or filled with
dirt.
2ote: Even with the best treatment and careful testing, a generator that has been submerged
sometimes fails when the unit is put back into service.
2OTICE
When water pressure is used for cleaning purposes, the pressure of the
water must not exceed 172 kPa (25 psi) otherwise damage to the
equipment may occur.
Flush the unit with fresh warm water in order to remove all traces of salt and silt. Washing should
continue until tests of the fresh water show the insulation to be free of salt.
2ote: It may be necessary to disassemble the generator completely in order to accomplish proper
cleaning.
Bake and dry the unit completely with externally applied heat before placing back into service. If
necessary, apply varnish in order to seal the windings. Refer to the procedure in ""Drying" " for
more information.
2ote: If the generator is used in environments or near environments that have salty air and/or high
humidity, special electric component cleaners and protectors may be needed in order to prevent
corrosion. Contact your Caterpillar technical communicator for recommendations.
Drying
Drying may be accomplished by external heat, internal heat, a combination of internal heat and
external heat, or circulating current.
2OTICE
When using external heat to dry the generator, do not exceed 75° C
(167° F) otherwise damage to the equipment may occur.
External heat is the most preferable method. Insulation drying time can vary from a few hours to
several days. This depends on the moisture content and the process for drying that is used.
2ote: Drying sometimes does not produce the required results. It may be necessary to use a qualified
rebuild shop for dipping and drying of the generator.
Typical curves of the resistance in the insulation that is drying
(3) Curve of the temperature in the windings
(4) Heat turned off.
(5) Drying time in hours
(6) Temperature in degrees celsius
(7) Curve of insulation resistance during drying process
(8) Insulation resistance in megohms
2ote: When new insulation or very damp insulation is being dried, the resistance will probably fall
rapidly as the temperature is raised to a value for drying. After reaching a minimum for a given
temperature, the resistance will again rise as moisture is driven out of the insulation. The actual
values will vary with each situation. Refer to Illustration 3.
If the windings or insulation are wet during the resistance measurement, use a five megohm resistor
for protection in series with red positive lead in order to limit the voltage across the circuit under the
test. Use this method until drying is well in progress and the resistance has reached an acceptable
level.
During the period of drying, check the windings after every four hours or after every hour for the
method of circulating current with the insulation tests. Refer to ""Insulation Resistance Tests" " for
more information.
Drying is complete when the tests show no increase in resistance and the resistance is above the
minimum. Record these readings and compare these readings. Keep these records for future
reference.
Curve of insulation resistance for windings in good condition
Illustration 4 indicates the curve of the resistance of a normal high resistance in the windings over a
period of 60 seconds. The resistance after 60 seconds (2) will be greater than the resistance or equal
to the resistance after 30 seconds (1) .
2ote: If the insulation resistance after 60 seconds (2) is not higher than the resistance after 30
seconds (1), the insulation may be weak.
Curve of insulation resistance for windings that are wet or dirty
Illustration 5 indicates the curve of the resistance that is decaying over a period of 60 seconds. If the
insulation resistance after 60 seconds (2) is not higher than the resistance after 30 seconds (1), then
clean the windings and thoroughly dry the windings. Refer to the methods that are covered in
""Cleaning" " and ""Drying" " for more information.
2ote: Caterpillar recommends a minimum acceptable insulation resistance of one megohm for
generators that are operating with less than 1000 volts of operating voltage or rated voltage.
Generators that are operating at 1000 volts of operating voltage or rated voltage should have a
minimum insulation resistance that can be determined by using the following equation:
R = (V/1000) + M
"R" is the minimum insulation resistance.
"V" is the rated voltage.
"M" is one megohm.
These values are approximate and it may be possible to operate a generator with less resistance.
External Heat
Ovens
The best oven is a forced air drying oven for drying electrical equipment. Radiant ovens sometimes
cause localized overheating.
2OTICE
Do not heat the generator too quickly. Try to limit the rise in
temperature of the insulation and windings to 11.11° C (20° F) per
hour. Failure to do so may cause equipment damage.
2ote: Many electrical shops are equipped with baking ovens.
Heat the generator to approximately 75° C (167° F). Never exceed 75° C (167° F) until the insulation
tester tests correctly for insulation resistance (at least four hours).
Alternate Method
A tent formed by a tarp or a canvas in conjunction with heated lamps or a portable space heater may
be used as an alternate method.
A hole should be left in the top of the tarp for ensuring proper circulation through the generator and
for permitting the moisture to exhaust. Heat the generator to approximately 75° C (167° F). Never
exceed 75° C (167° F) until the insulation tester tests correctly for insulation resistance (at least four
hours).
Internal Heating
If generators operate under one of the following conditions, the electric space heaters should be
installed as part of the generator:
Generators are in damp environments and go for long periods of time without operation.
Generators operate regularly in an environment with moisture laden air.
Circulating Current
Drying can be accomplished by circulating low voltage current through the windings. Since the
voltage is low, the breakdown of the insulation will not occur as the breakdown might have occurred
with normal operation and wet insulation.
Schematic for the external power source
(9) Battery (12 VDC)
(10) Switch
(11) "F1"
(12) L (exciter field that is being dried)
(13) "F2"
(14) Rheostat
Refer to the following procedure in order to dry the windings with circulating current:
1. Follow all safety procedures before continuing.
2. Disconnect the generator load and open the breaker.
3. Disconnect the leads of the exciter field from the voltage regulator with the engine stopped.
These leads typically have the following labels:"F1" (11) and "F2" (12) .
4. Connect the output leads for the generator together. These leads typically have the following
labels:"T1", "T2" and "T3".
5. Install a AC current probe (clamp-on probe) to generator output lead "T1".
6. Adjust rheostat (14) in order to give maximum resistance.
7. Connect the external power source to wires "F1" (11) and "F2" (13). Switch (10) remains
open.
2OTICE
Do not exceed the rated phase current that is listed on the generator
nameplate. Exceeding the rated phase current will easily damage the
generator windings.
8. Run the generator set at idle speed. Residual voltage will cause current to circulate within the
generator windings.
9. While the line current is being monitored, slowly increase the rpm until the rated line current is
obtained or until the full generator set speed is obtained.
2ote: When the line current is being measured on multiple lead units, measure the current in
each conductor per phase and add the currents together.
10. If the generator reaches full speed and more line current is still necessary, repeat the following
procedure until the rated phase current is obtained:
a. Run the generator at idle speed.
b. Close switch (10) .
c. Slowly turn rheostat (14) to the rated phase current.
11. Continue running the current at these settings for one hour. Then stop the drying procedure.
Test the insulation resistance with the insulation tester. Observe each resistance reading of the
insulation for at least 60 seconds. Refer to ""Insulation Resistance Tests" " for more
information.
If the resistance decays with time, the winding needs to be cleaned and winding needs to be
thoroughly dried in order to determine the trend from drying. Record these readings and
compare these readings. Keep these records for future reference.
12. Repeat Step 5 through Step 10 until the test on the insulation resistance is correct.
Copyright 1993 - 2010 Caterpillar Inc. Thu Jul 15 09:43:29 UTC-0300 2010
All Rights Reserved.
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Media Search - SEHS9124 - Cleaning and Drying of the Generator{4450} Página 1 de 19

Product: NO EQUIPMENT SELECTED

Cleaning and Drying of the Generator{4450}

Generator Set: All

ReferenceRefer to the following documents for more information:

Application and Installation Guide, LEBW4993, "Generator Systems"

Important Safety Information

Personal injury or death can result from high voltage.

When power generation equipment must be in operation to make tests

When servicing or repairing electric power generation equipment:

Make sure the unit is off-line (disconnected from utility and/or

Remove all fuses.

Make sure the generator engine is stopped.

Make sure all batteries are disconnected.

Make sure all capacitors are discharged.

Failure to do so could result in personal injury or death. Make sure

Personal injury or death can result from a spark.

An incompletely discharged capacitor can cause a spark.

Do not use the insulation tester in an explosive atmosphere.

Personal injury or death can result from electrocution.

The megohmmeter is applying a high voltage to the circuit.

To avoid electrocution, do not touch the instrument leads without first

When a generator is in storage, moisture condenses in the windings. In order to minimize

Warm air blowers. Do not exceed 206.7 kPa (30 psi).

Removal from Storage

Operate space heaters for at least 24 hours prior to removing covers.

Checking the Equipment

Insulation Resistance Tests

For determining a preventive maintenance schedule, use the following guidelines:

If the generator is in a sea water environment, near a sea water environment, or in an

Consider the following items during the test:

Test Setup for Insulation Resistance

Personal injury or death can result from a spark.

An incompletely discharged capacitor can cause a spark.

Do not use the insulation tester in an explosive atmosphere.

Personal injury or death can result from electrocution.

The megohmmeter is applying a high voltage to the circuit.

To avoid electrocution, do not touch the instrument leads without first

Test Procedure for Insulation Resistance

1. Take the generator out of service.

4. Discharge the capacitance of the windings.

5. Disconnect "T0" from ground.

7. Connect the red lead of the insulation tester to ground ("+").

8. Connect the black lead of the insulation tester to "T0" ("-").

b. Observe the readings at 30 seconds and at 60 seconds again.

Evaluating the Test Results

(1) Resistance after 30 seconds

(2) Resistance after 60 seconds

(1) Resistance after 30 seconds

(2) Resistance after 60 seconds

"R" is the minimum insulation resistance.

"V" is the rated voltage.

"M" is one megohm.

Generators may be routinely cleaned by the following methods:

""Steam Cleaning" "

""Pressure Air" "

Personal injury or death can result from the engine starting.

Regardless of the cleaning method used; to avoid serious injury or

Make sure the engine can not be started.

Personal injury can result from working with cleaning solvent.

Because of the volatile nature of many cleaning solvents, extreme

Refer to the following procedure in order to clean the generators:

1. Create the cleaning solution.

3. Wipe off excess moisture with a clean dry cloth.