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Starlight TFW Generator Inspection And Operation

Jan. 03, 2020

In previous article, we have learned TFW generator installation and adjustment. In this article, let's continue to learn Starlight TFW Series generator inspection and operation. Starlight alternator is divided into two Series. One is TFW, another is GTF ( 800KW - 1500KW 10.5KV high voltage synchronous AC generator).

synchronous ac generator

V. Inspection and operation.

1. Inspection

a. Though the generator, AVR and auxiliary devices are solid and well insulated, if the generator was stored for longtime it might be moistened, and should be inspected carefully before operation.
b. Measure the insulating resistance, of winding against the ground by ohmmeter, if the value is less than 2 in cold condition, the generator should be dried. Caution: At measuring, the electronic elements and capacitor should be shorted, and the AVR. should be disconnected to avoid damaged.
c. Make sure all connecting joints are tight and contact good.
d. Be sure the frame is properly grounded, and ground wire should be same as the size of lead-wires

e. Make familiar with the rated data of nameplate before operation.

2. Voltage adjustment

In general, the generator was carefully inspected and tested in operation before it left the factory, and the normal voltage has been corrected, so it is not necessary to adjust. If necessary, the setting potentiometer of voltage may be adjusted again. If the external potentiometer is used for remote control , it also can be adjusted to set the voltage.

3. AVR. Wiring

The wiring diagram of Sx440 and APR125-5 are shown as Fig .1 Fig .2. The end 3 and 4 of AVR are also connected to the 190V-240V, but there is a plug wire that should be put in the "50Hz" or "60Hz" position.

After inspection and adjustment have been made, and no trouble is found , the generator can run normally and generate the electricity. In order to keep generator run well, please remember following notices;
a. The generator output must be disconnected from the load , then start the prime mover.
b. Check the speed and adjust to the rated RPM, the voltage of generator w… get to normal value, then close the main circuit breaker to the load. The genset speed may be changed under load , and frequency may be tower than the normal frequency , check and adjust the speed as necessary.
c. Before shut down the genset, remove load and turn off the main circuit breaker. This is especially important, or the loss of residue magnetism can result.
d. If starting up the generator for first time or the generator stored for longtime, generator may be loss of the residue magnetism, and voltage can not built up,should charge to F+ and F- with DC 12V voltage , the "+" touch to F, and the" -" touch to F- for 15-20 seconds. Caution: the generator must be stud still during charging the magnetism, or AVR may be damaged.
Three phase AC generator should be operated at balanced load. Should pay more
attention to the load and the balance of current to prevent the generator loaded on the single phase or serious unbalancing condition, or the AVR. and generator can be damaged.

VI. Troubleshooting

Symptom: Generator produces no voltage or abnormal voltage.

Regulator fuse blown

Check all wiring, if there is no problem; replace bad fuse, and start the unit again.

Voltmeter damaged

Verify the panel meter with multi-meter or other meter that is know to be accurate.

Defective voltmeter

Check the meter in time, replace bad meter.

Loose the connecting Plug of AVR

Check the connecting plug, make sure all joints tight and contact good. 

Surge suppressor short circuit

Check the surg suppressor and eliminate the short circuit or replace bad one.

Defective diodes

Take down the diodes and test them by multi-meter, Replace the bad diode.

Lost residue magnetism

Connect a 12V battery   to the exciter field , the "+". of battery to the F+(red lead),and   the"-" to the F.(black lead) for abort 15 to 20 second. Caution: The generator should be stained still during flashing,

Incorrect connect

Check carefully, and correct the wiring refer to the wiring diagram.

Exciter field break

Clean, twist and weld the broken wire. Wrap this place with insulating material.

Loose joints or poor Contact

Clean and tight the joints again.

Armature winding of generator break

Find the failure place, clean, weld and wrap it.

Armature winding of generator short circuit

Short circuit will cause the serious heating, should replace the winding.

Armature winding of exciter break or short circuit

Locate the failure and replace the winding.

Incorrect speed

Verify speed with tachometer or frequency meter.

AVR. Protective shutdown circuits are operating

Correct the problem and adjust AVR. Refer to AVR. Manual.

AVR. Inoperative

Adjust or replace the AVR. Refer to AVR manual.


Symptom: Voltage is fluctuating

Incorrect speed

Verify speed with tachometer or frequency meter.

Unstable speed

Verify governor stability.

AVR stability

Adjust AVR. stability. Refer to AVR. manual.

Defective/loose connecting

Inspect all wiring for loose or dirty connections.

Defective diodes, surge suppressor, or generator winding

Test generator with constant excitation(12V battery test)

Remote voltage adjust rheostat (if used)

Check operation of rheostat. Refer to AVR. manual.

Defective AVR.

Replace the AVR. Refer to AVR. manual.

Defective bearing of worn bearing carrier causing an uneven air gap

Replace worn bearing. Check bearing carrier for wear. Replace as necessary

Symptom: Generator Overheat


Measure amperes and verify that the load does not exceed the nameplate rating of the generator.

Armature winding of generator short circuit

Find the failure place, clean, weld and wrap it.

Ventilation obstruction

Clean dust and dirt in the generator.

Armature winding of exciter short circuit

Replace the bad winding.

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