C6.6 Generator Sets Caterpillar


Generator Winding Insulation - Test

Usage:

C6.6 N6D

------ WARNING! ------

The high voltage that is produced by an operating generator set can cause severe injury or death. Before performing any maintenance or repairs, ensure that the generator will not start.

Place the engine control switch in the "OFF" position. Attach "DO NOT OPERATE" tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator.

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Table 1
TOOLS NEEDED    
Part Number     Tool     Quantity    
142-5055     Insulation Tester
Megohmmeter    
1    

------ WARNING! ------

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.

----------------------

The following materials will cause the winding insulation to deteriorate:

  • moisture (water)

  • dust

  • grease

  • other foreign matter within the generator

This deterioration reduces the resistance of the insulation. This test will measure the resistance of the winding insulation.

The insulation tester (megohmmeter) produces a high potential voltage between the test leads. During the test, a small current flows. The tester converts this current to a resistance reading.

The insulation test is performed as part of periodic maintenance in order to detect the deterioration of the winding insulation. When there is a rapid decrease in the insulation resistance in a short amount of time, the generator needs to be cleaned.

Note: For information on generator cleaning, refer to Special Instruction, SEHS9124.

When generators have not been used for a time, moisture can accumulate. Therefore, the insulation test should be performed on generators that have been idle. If moisture is known to exist, the windings must be dried prior to testing. Refer to Testing And Adjusting, "Generator - Dry".

The insulation test should be performed on generators that are being used for the first time. The insulation test should be performed more frequently in the following cases:

  • The generator set is operating in a humid environment.

  • The generator set is not protected from the elements in an enclosed area.

  • The generator set has not been run under load for 3 months.

Note: Use of space heaters may be necessary around the generator set in the following cases:

  • The generator set has not been run under load for 3months.

  • The generator set is exposed to a sea water environment.

  • The humidity is above 75 percent.

  • A test result was below 3 megohms.

Recondition or replace the winding in the following cases:

  • The measured insulation resistance falls below the specified amount. The cleanup procedure does not correct the discrepancy.

  • The measured insulation resistance falls below the specified amount. The drying procedure does not correct the discrepancy.

The specified insulation resistance is an approximate value. It can be possible to operate the generator with less than the specified value. However, a generator that has a low winding insulation resistance will be more likely to have a failure.

------ WARNING! ------

Personal injury or death can result from improper troubleshooting and repair procedures.

The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.

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The insulation test gives accurate results only when the generator windings are free of moisture and the generator windings are at room temperature.

Each winding must have a minimum insulation resistance of 1 megohm.

Main Armature (Stator L4)

  1. Remove the load from the generator by either of the following:

    • Open the line circuit breaker.

    • Open the following load connections: T1, T2, T3 and T0.

    Prevent these wires from coming into contact with each other and prevent these wires from contacting ground.

  1. Isolate the main armature (L4) from the voltage regulator by disconnecting the wires for voltage sensing. If generator lead (T0) is connected to the generator frame or ground, open the connection.

  1. Connect one test lead of the insulation tester (megohmmeter) to the generator enclosure (ground).

  1. Connect the other test lead of the insulation tester (megohmmeter) to generator lead (T0) .

  1. The insulation resistance must be 1 megohm or more.

Exciter Field (Stator L1)

  1. Isolate exciter field (L1) from the voltage regulator by disconnecting wires 5+ and 6-. Prevent these wires from coming into contact with each other and prevent these wires from contacting ground.

  1. Connect one test lead of the insulation tester (megohmmeter) to the generator enclosure (ground).

  1. Connect one test lead of the insulation tester (megohmmeter) to exciter field lead (5+ or 6-).

  1. Measure the resistance of the exciter field winding insulation to ground. The insulation resistance must be a minimum of 0.25 megohm (250000 ohms).

Exciter Armature (Rotor L2)

  1. Isolate exciter armature (L2) from the rectifier circuit. Disconnect the three wires of the exciter armature from the rectifier blocks.

  1. Connect one test lead of the insulation tester (megohmmeter) to the rotor shaft.

  1. Connect one test lead of the insulation tester (megohmmeter) to any one exciter field lead.

  1. The insulation resistance must be a minimum of 0.25 megohm (250000 ohms).

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