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Engi
neer
ing
Stan
dard
Engineering Standard Rolling Stock
ESR 0604
OVERHAUL OF AG 32 EXCITER
Version 1.0
Issued June 2010
Disclaimer This document was prepared for use on the RailCorp
Network only. RailCorp makes no warranties, express or implied,
that compliance with the contents of this document shall be
sufficient to ensure safe systems or work or operation. It is the
document user’s sole responsibility to ensure that the copy of the
document it is viewing is the current version of the document as in
use by RailCorp. RailCorp accepts no liability whatsoever in
relation to the use of this document by any party, and RailCorp
excludes any liability which arises in any manner by the use of
this document. Copyright The information in this document is
protected by Copyright and no part of this document may be
reproduced, altered, stored or transmitted by any person without
the prior consent of RailCorp.
Owner: Chief Engineer Rolling Stock Approved by:
Stephen White, Technical Specialist Rolling Stock Performance
Standards, Rolling Stock Access Integrity
Authorised by:
Michael Uhlig, Manager, Rolling Stock Access Integrity
UNCONTROLLED WHEN PRINTED Page 1 of 23
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RailCorp Engineering Standard — Rolling Stock Overhaul of AG 32
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Document control
Revision Date Summary of change (RSS 0604) 1.0 August 2007 Based
on TRS 1450 (ESR 0604) 1.0 June 2010 Reformatted and renumbered ESR
0604
Summary of changes from previous version
Summary of change Section NOTE – If the final document is small
enough for the ‘Contents’ and ‘Document control’ to fit on one page
remove the page break between the existing pages 2 and 3. HOWEVER
if the ‘Document control’ page carries over to a second page
separate pages must be used for ‘Contents’ and ‘Document
control’
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Contents
1
Scope..................................................................................................................................................5
2 General
...............................................................................................................................................5
3 Torque settings
.................................................................................................................................5
4 Pre service/overhaul inspection
......................................................................................................5
4.1 Pre cleaning activity
..................................................................................................................5
4.2 Post cleaning
activity.................................................................................................................5
5 Service procedures
...........................................................................................................................7
5.1 Armature and commutator
........................................................................................................7
5.2
Brushgear..................................................................................................................................7
5.3 Machine frame
..........................................................................................................................7
5.4 Bearings
....................................................................................................................................8
5.5 Fan
............................................................................................................................................8
5.6 Machine painting
.......................................................................................................................8
6 Post service
test................................................................................................................................8
6.1
General......................................................................................................................................8
6.1.1 Continuous rating
.........................................................................................................8
6.1.2 Rated voltage
...............................................................................................................9
6.1.3 Rated speed
.................................................................................................................9
6.1.4 Maximum speed of the machine
..................................................................................9
6.1.5 Direction of rotation
......................................................................................................9
6.1.6 Runout of
commutator..................................................................................................9
6.1.7 Eccentricity of commutator
...........................................................................................9
6.2 Summary of tests to be performed on the
exciter.....................................................................9
6.2.1 Resistance measurement
............................................................................................9
6.2.2 Insulation resistance test
1...........................................................................................9
6.2.3 Neutral point setting
.....................................................................................................9
6.2.4 Direction of rotation test
.............................................................................................10
6.2.5 Temperature rise and vibration test
...........................................................................10
6.2.6 Overspeed test
...........................................................................................................10
6.2.7 Insulation resistance test
2.........................................................................................10
6.2.8 Commutator
roundness..............................................................................................10
6.2.9 Brush pressure
...........................................................................................................10
6.3 Documentation
........................................................................................................................10
7 Overhaul/rewind
procedure............................................................................................................11
7.1
General....................................................................................................................................11
7.2 Armature
overhaul...................................................................................................................11
7.3
Brushgear................................................................................................................................12
7.4 Machine frame
........................................................................................................................12
7.5 Bearings
..................................................................................................................................13
7.6 Fan
..........................................................................................................................................13
7.7 Machine painting
.....................................................................................................................13
8 Post overhaul/rewind
test...............................................................................................................13
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8.1
General....................................................................................................................................13
8.1.1 Continuous rating
.......................................................................................................14
8.1.2 Rated voltage
.............................................................................................................14
8.1.3 Rated speed
...............................................................................................................14
8.1.4 Maximum speed of the exciter
...................................................................................14
8.1.5 Direction of rotation
....................................................................................................14
8.1.6 Radial runout of
commutator......................................................................................14
8.1.7 Eccentricity of commutator
.........................................................................................14
8.2 Summary of tests to be performed on the
exciter...................................................................14
8.2.1 Resistance measurement
..........................................................................................14
8.2.2 Insulation resistance test
1.........................................................................................15
8.2.3 Neutral point setting
...................................................................................................15
8.2.4 Direction of rotation test
.............................................................................................15
8.2.5 Temperature rise and vibration test
...........................................................................15
8.2.6 Overspeed test
...........................................................................................................15
8.2.7 Commutator
roundness..............................................................................................15
8.2.8 Brush pressure
...........................................................................................................15
9 Documentation
................................................................................................................................15
10 Technical specifications AEI AG32
exciter................................................................................16
10.1 For pre service/overhaul inspection specification
...................................................................16
10.1.1
Armature.....................................................................................................................16
10.1.2 Fields and interpoles
..................................................................................................16
10.2 Service specification
...............................................................................................................16
10.2.1 Armature and commutator
.........................................................................................16
10.2.2
Brushgear...................................................................................................................16
10.2.3 Bearings
(approved)...................................................................................................16
10.3 Post service testing specification
............................................................................................17
10.3.1 Resistance measurement @ 25oC -
average............................................................17
10.3.2 Insulation
resistance...................................................................................................17
10.3.3 Temperature and vibration test
..................................................................................17
11 Reference
standards.......................................................................................................................18
11.1 RailCorp standards
.................................................................................................................18
11.2 Drawings
.................................................................................................................................18
11.3 AEI Maintenance instructions
.................................................................................................18
11.4 Australian standards
...............................................................................................................18
11.5 Other standards
......................................................................................................................18
Appendix A - Torque
Charts................................................................................................................19
Appendix B - Drawing
004-653............................................................................................................21
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1 Scope This standard sets out the minimum requirements,
procedures and tests for the overhaul of AG 32 exciters used on
some 48 class locomotives.
2 General This standard is to be used in conjunction with the
Manufacturer's Maintenance Instructions, drawings and technical
information, listed herein, for the respective exciters and SRA
Drawing 004-653, Auxiliary electrical machines service flow chart.
(See Appendix B)
3 Torque settings The following applications in machine
assemblies are critical in relation to the tightness of the
fastening:
• Mounting of brush holders in frame
• Inter-field connections (where not brazed)
• Connection of field circuit leads onto brush holders
• Mounting of main fields in frame
• Mounting of interpoles in frame
The checking of the fastening tightness or their installation
during assembly must be effected by torque wrench, the torque
values being appropriate for the size and grade of the fastenings.
(See Appendix A - Torque charts)
4 Pre service/overhaul inspection If it is not visually obvious
that a rewind is required the following checks shall be carried out
and the results recorded. Any non-conformance with the
specification and noted defects shall be reported to the Purchaser
to determine further action.
4.1 Pre cleaning activity The following inspection has to be
carried out on a dismantled exciter clean of all dirt and
grease.
Measure the position of the brush holders relative to the
commutator riser bars and face.
4.2 Post cleaning activity The following inspections are to be
carried out after the exciter has been dismantled, cleaned of all
dirt and grease, immersion rinsed (only if required to achieve two
voltage and PI test standards) and oven dried.
• Visually check commutator for any bar pattern, grooving, high
bars, high mica or physical damage.
• Examine the armature insulation for charring, cracking and
physical damage.
• Examine glass banding for physical damage, burning or
tracking. If fitted with wire bands check for looseness or thrown
solder.
• Measure diameter of commutator to ensure it is above
condemning size.
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RailCorp Engineering Standard — Rolling Stock Overhaul of AG 32
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• Measure commutator for eccentricity.
• Measure armature winding resistance.
• Measure the resistance of the machine fields.
• Measure resistance of the interpole coils.
• Measure insulation resistance as per SRA Drawing 004-653
Auxiliary electrical machines service flow chart,. (See Appendix
B)
• Apply surge test and bar-to-bar comparison test to commutator
to check for open or short circuited coils.
• Check armature shaft for straightness, size (including 4
points on the bearing seat for ovality and taper, length of shaft
overall, and critical sections) and surface integrity.
• Examine the armature for any physical damage or loose slot
wedges.
Figure 1 AEI AG32 Exciter (pulley driven)
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5 Service procedures Service work shall generally be in
accordance with Manufacturer's Maintenance Manual and SRA drawing
004-653 (see Appendix B) with particular attention being given to
the following:
5.1 Armature and commutator • Inspect for indication of high or
loose bars and take corrective action as necessary.
• Inspect V-ring band and riser bars for any flashover damage
and correct.
• Resurface the commutator (where needed) with the minimum cut
to ensure surface integrity and roundness.
• Undercut the mica (width 0.79 mm, depth 0.76 to 1.27 mm).
• Chamfer the commutator bar edges (45°, 0.2-0.4mm across
face).
• Clean debris from commutator/armature after undercutting and
chamfering.
• Dip armature in varnish or VPI (compatible with existing
insulation) where machines have been recovered by rinsing or there
has been visible damage to the insulation.
• Dynamically balance armature. Balance quality grade 2.5 (AS
3709; ISO 1940/1).
• Apply red air drying insulating varnish to armature (shaft,
bands and commutator to be suitably masked before applying
varnish).
5.2 Brushgear • Remove brush holders and check insulators for
any visible damage, and replace if
damaged.
• Inspect for any flashover deposits on brush holders and
correct.
• Ensure brush holders are not deformed.
• Sand blast brush holders. Brushways and insulators to be
suitably masked.
• Set brush spring pressure. (1.1 kg ± 0.1 kg)
• Ensure mounting screws and clamps are sound and correctly
torqued (see clause 6.3).
• Ensure brushgear alignment is parallel to commutator centre
line.
• Ensure spacing of brush holders is correct.
• Fit new brushes. Ensure brushes move freely in brush
holder.
• Inspect braiding of brushes and tightness of brush terminal
connections. (Braiding must be positioned to allow free movement of
hammers).
5.3 Machine frame • Inspect for any flashover damage and
correct.
• Ensure connections are sound and correctly torqued (see clause
3).
• Ensure all mounting bolts and nuts are correctly torqued (see
clause 3).
• Ensure main field and interpole insulation are in good
condition. Apply red air drying insulation varnish to inside
assembly.
• Inspect cables, crimp lugs and markers for any signs of
mechanical or electrical damage and replace any defective
parts.
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• Internal field leads must be securely bound to the bracing
staples. Replace any loose or defective binding. (Cable ties are
not permitted for this purpose.)
• Inspect bearing housing and seals for excess wear as indicated
in maintenance manual and restore where necessary.
• Inspect condition of cable terminal block. Replace if
damaged.
• Ensure inspection cover components including locating lugs,
latching mechanisms, springs, bolts and sealing strips will provide
correct securing of covers and sealing for cooling air.
5.4 Bearings New bearings shall be provided and fitted by the
Contractor as described in the Maintenance Manual AEI 139011.
Acceptable bearings are listed in the individual exciter
specifications.
5.5 Fan • Inspect fan for evidence of physical damage.
Report/repair as required
• Ensure mounting holes are not deformed or damaged.
• Inspect fan blades for physical damage and/or wear.
Report/repair as required
• Dynamically balance fan. Balance quality grade 2.5 (AS 3709;
ISO 1940/1)
5.6 Machine painting After stripping off old paint work all
exciters shall be painted with 1 coat of suitable primer and 1 coat
of enamel paint - which shall be approved under GPC-E-24. The
colour will be nominated by the Purchaser and shall comply with AS
2700.
Note: Areas to be masked shall include:
• Manufacturer's data plate
• Leads
• Commutator inspection hatches.
• Armature shaft.
6 Post service test
6.1 General This procedure covers the performance testing of
exciter used on rail vehicles.
The definitions applicable to this standard are:
6.1.1 Continuous rating The rating that corresponds to a load
that the exciter can withstand on the test for an unlimited period,
without exceeding the limits of temperature rise as given in BS
173, clause 31. The test being started with the machine cold (see
BS 173, clause 34).
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6.1.2 Rated voltage The specified value of the voltage at the
terminals of the machine.
6.1.3 Rated speed The speed corresponding to the manufacturer's
guarantee.
6.1.4 Maximum speed of the machine The maximum rotational speed
of the exciter corresponding to the maximum speed.
6.1.5 Direction of rotation The direction of rotation of the
armature when facing the commutator end of the machine.
6.1.6 Runout of commutator Maximum out of round measured over
six (6) segments.
6.1.7 Eccentricity of commutator Out of round measured over the
full circumference of the commutator.
6.2 Summary of tests to be performed on the exciter The test
program shall, in principle, be carried out in accordance with the
requirements of BS 173.1980.
6.2.1 Resistance measurement Measure the resistance value of all
windings in the main field, the interpoles and the armature
windings. If the ammeter and voltmeter method is used for the
measurement of resistance, the current used shall be of a value
such as to obtain a suitable accuracy of measurement, whilst being
low enough to neither cause the armature to start through the
effect of residual flux nor influence the temperature rise.
6.2.2 Insulation resistance test 1 Prior to the rotational test,
the machine shall be subjected to a high potential test as detailed
below:
60 sec high potential testing
New windings Used windings
Test voltages 1,750 AC & DC 650 DC
Pass vriteria less than 2.5 µA DC and no disruptive discharges
AC
less than 2.5 µA DC and no disruptive discharges
6.2.3 Neutral point setting Ensure neutral point setting is
correct.
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6.2.4 Direction of rotation test Connect leads to a suitably
rated power supply. Increase the voltage until the armature
rotates. Rotation should be counter-clockwise as viewed from the
commutator end of the machine when the positive lead of the machine
is connected to the positive terminal of the power supply.
6.2.5 Temperature rise and vibration test Run the exciter for
sixty minutes at the speed referred to in the individual machine
specifications in the counter-clockwise direction.
Record temperature of the bearing every ten (10) minutes. Listen
for any abnormal bearing noise during rotation.
Measure and record vibration of the machine running. This shall
not exceed range classification 1.12, Table 1 AS 2625.
Measure and record the temperature of the commutator at the end
of the test. This temperature shall not exceed 60°C.
6.2.6 Overspeed test An overspeed test as per clause 36 BS173
shall be carried out.
6.2.7 Insulation resistance test 2 After the overspeed test, the
machine shall be subjected to a high potential test as below:
60 Sec high potential testing
New windings Used windings
Test voltages 1,750 AC & DC 650 DC
Pass criteria less than 2.5 µA DC and nodisruptive discharges
AC
less than 2.5 µA DC and nodisruptive discharges
Compare results with insulation resistance test 1 (6.2.2).
6.2.8 Commutator roundness Position dial gauge to touch the
commutator surface. Rotate armature slowly by hand and measure the
commutator eccentricity and run out. Record values on test
sheet.
6.2.9 Brush pressure Use a suitable instrument to test the brush
spring pressure of all brush springs to read as 1.1 ± 0.1kg. Reset
brush spring pressure if necessary.
6.3 Documentation The recorded measurements shall be entered in
dated test report sheets and returned with the machine.
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7 Overhaul/rewind procedure
7.1 General This part of the Specification covers the
rewind/overhaul of the exciter. The work shall incorporate
rewinding the armature, correcting machine frame and fields and
installation of the following new components:
• Commutator (new or rebuilt)
• Armature bearings
• Brushes
The following shall be inspected for suitability for further
duty and restored to service specifications. If beyond repair they
shall be replaced with new components:
• Armature shaft
• Brush holders
• Commutator inspection covers
• Machine leads
• Fan
The commutators, fields and bearings removed from machines and
replaced shall be returned to the Purchaser.
7.2 Armature overhaul • Remove bearings and commutator.
• Strip the armature of coils and insulation.
• Shafts suitable for resizing may be repaired by Gas Metal Arc
Welding - GMAW and machined to specified dimensions. The welding
procedure shall be strictly in accordance with AS 1554.1, the
electrodes shall be type ESD2 to AS 2717.1 and the gas shall be
Argoshield 51. This procedure may be utilised for restoration
requiring weld deposits to 6 mm. Repairs exceeding 6 mm deposit
shall be referred to the Purchaser. All welding shall comply with
Australian Standards.
• Fit new shaft, where required, in accordance with the relevant
drawing.
• Flux test the core to ensure no shorts or damage exist in the
laminations. Defective cores are to be referred to the
Purchaser.
• Fit new or rebuilt fully seasoned commutator.
• Rewind armature with new main coils insulated to
Classification 180 of AS 2768.
• TIG weld/resistance braze coil ends to riser bars.
• VPI the armature with Isonel 772 varnish.
• Oven dry.
• Check torque of commutator bolts. Correct as required or refer
to commutator supplier.
• Resurface the commutator with minimum cut to ensure surface
integrity and roundness.
• Undercut commutator mica (width 0.79 mm, depth 0.76 to 1.27
mm)
• Chamfer commutator bar edges (45°, 0.2 to 0.4 mm across
face).
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• Clean debris from commutator/armature after undercutting and
chamfering.
• Dynamically balance the armature. Balance quality grade 2.5
(AS 3709; ISO 1940/1)
• Apply red air drying insulation varnish to armature (shaft and
commutator to be suitably masked before applying varnish).
• Cleaning, drying, rewinding, testing and banding throughout
the process shall be in accordance with the Manufacturer's
Maintenance Manuals for original equipment or previously approved
replacement, (e.g. glass band).
• Fit new armature shaft bearing, as approved in the Machine
specification . (refer Clause 10)
• Fit a qualified fan as described below:
• Inspect fan and blades for evidence of physical damage or
excessive wear and distortion.
• Restore to serviceable condition.
• Ensure mounting holes are not deformed or damaged.
• Dynamically balance fan to balance Quality Grade 2.5 AS 3709;
ISO 1940/1).
7.3 Brushgear • Check clearance between a new brush and the
holder, if found in excess of 0.38 mm,
scrap the holder.
• Check brush holder insulators for any visible damage, replace
if damaged.
• Inspect for any flashover deposits on brush holders and
correct.
• Sand blast brush holders. (Brushways and insulators to be
suitably masked.) Paint the whole of the brush arm with Insulderm
500 Grey Enamel or equivalent paint.
• Inspect arc horns and replace if damaged.
• Replace any deformed brush holders.
• Ensure mounting screws and clamps are sound and correctly
torqued (see Clause 3).
• Ensure brushgear alignment is parallel to commutator centre
line.
• Ensure spacing of brush holders is correct.
• Fit new brushes. Ensure brushes move freely in brush
holder
• Ensure correct clearance between commutator and brush holder
(1.8-3.3 mm)
• Check braiding of brushes and tightness of brush terminal
connections. (Braiding must be positioned to allow free movement of
hammers.)
• Set brush pressure. (1.1 kg ± 0.1 kg)
7.4 Machine frame • Thoroughly clean the machine inside and
outside, preferably by an ultrasonic process
that does not utilise a detergent. Alternatively a spray wash
may be used in conjunction with a detergent incorporating a
non-ionic surfactant wetting agent and such detergent shall have
the Purchaser's written approval. Machines so cleaned shall have
all traces of detergent removed by a clean water/steam rinse.
• Remove main and interpole coils and pole pieces.
• Inspect insulation quality. Where required re-insulate in
accordance with Manufacturer's Maintenance Manual, to ensure
suitability for nominated duty
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requirements. Re-insulation shall be with an approved
asbestos-free system incorporating B stage epoxy rich materials to
classification 180 of AS 2768.
• Pot the coils onto the pole pieces.
• Fit all coils into the frame and connect. Ensure all mounting
and connect bolts and nuts are correctly torqued (see clause
3).
• Inspect cables, crimp lugs and markers, correct any signs of
mechanical or electrical damage and replace any defective
parts.
• Internal field leads must be securely bound to the bracing
staples. Replace any loose or defective binding. (Cable ties are
not permitted for this purpose.)
• Ensure that flash rings or arcing horns are clean and free of
paint. Replace if damaged.
• Inspect bearing housing and seals for excess wear as indicated
in relevant exciter data and restore where necessary.
• Inspect condition of cable terminal block. Replace if
damaged.
• Spray the interior of the machine ensuring certain areas are
masked with red air drying insulating varnish.
7.5 Bearings New bearings shall be provided and fitted by the
Contractor. Acceptable bearings are listed in the machine
specifications. (Refer clause 10)
7.6 Fan • Inspect fan and blades for evidence of physical damage
or excessive wear. Restore to
serviceable condition.
• Ensure mounting holes are not deformed or damaged.
• Dynamically balance fan. Balance Quality Grade 2.5 AS 3709;
ISO 1940/1.
7.7 Machine painting After stripping of old paintwork all
machines shall be painted with 1 coat of suitable primer and 1 coat
of enamel paint - which shall be approved under GPC-E-24. The
colour will be nominated by the Purchaser and shall comply with AS
2700.
Note: Areas to be masked shall include:
• Manufacturer's data plate
• Leads
• Commutator inspection hatches
• Armature shaft
8 Post overhaul/rewind test
8.1 General This procedure covers the performance testing of
direct current exciter used on rail vehicles.
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The definitions applicable to this standard are:
8.1.1 Continuous rating The rating that corresponds to a load
that the exciter can withstand on the test for an unlimited period,
without exceeding the limits of temperature rise is given in BS
173, clause 31. The test being started with the machine cold (see
BS 173, clause 34).
8.1.2 Rated voltage The specified value of the voltage at the
terminals of the machine.
8.1.3 Rated speed The speed corresponding to the manufacturer's
guarantee.
8.1.4 Maximum speed of the exciter The maximum rotational speed
of the exciter is 2400 rev/Min.
8.1.5 Direction of rotation The direction of rotation of the
armature when facing the commutator end of the machine.
8.1.6 Radial runout of commutator Maximum out of round measured
over six (6) segments will be 0.03 mm.
8.1.7 Eccentricity of commutator Out of round measured over the
full circumference of the commutator will be less than 0.03 mm.
8.2 Summary of tests to be performed on the exciter The test
program shall, in principle, be carried out in accordance with the
requirements of BS 173.1980.
8.2.1 Resistance measurement Measure the resistance value of the
main field, the interpoles and the armature windings. If the
ammeter and voltmeter method is used for the measurement of
resistance, the current used shall be of a value such as to obtain
a suitable accuracy of measurement, whilst being low enough to
neither cause the armature to start through the effect of residual
flux nor influence the temperature rise.
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8.2.2 Insulation resistance test 1 Prior to the rotational
tests, the machine shall be subjected to a high potential test as
detailed below:
60 sec high potential testing New windings
Test voltages 1,750 AC & DC
Pass criteria less than 2.5 µA DC and no disruptive discharges
AC
8.2.3 Neutral point setting Ensure neutral point is set
correctly.
8.2.4 Direction of rotation test Connect leads to a suitably
rated power supply. Increase the voltage until the armature
rotates. Rotation should be counter-clockwise as viewed from the
commutator end of the machine when the positive lead of the machine
is connected to the positive terminal of the power supply.
8.2.5 Temperature rise and vibration test A temperature rise
test, generally in accordance with clause 29.1 of BS 173, but of
two (2) hours duration and test conditions specified herein. During
this test the main, interpole and bearing temperatures shall be
logged and the armature winding temperature and commutator
temperatures shall be measured immediately upon shutdown.
A Pyrometer shall be used to measure the commutator surface
temperature.
Measure and record vibration of the machine running. This shall
not exceed range classification 1.12, Table 1 AS 2625.
8.2.6 Overspeed test An overspeed test as per clause 36 BS 173
shall be carried out.
8.2.7 Commutator roundness Position dial gauge to touch the
commutator surface. Rotate armature slowly by hand and measure the
commutator eccentricity and run out. Record value on test
sheet.
8.2.8 Brush pressure Use a suitable instrument to test the brush
spring pressure of all brush springs. Adjust as required.
9 Documentation The recorded measurements shall be entered in
dated test report sheets and returned with the machine.
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10 Technical specifications AEI AG32 exciter
10.1 For pre service/overhaul inspection specification
10.1.1 Armature - Insulation resistance 20 M Ohms @ 25oC
(Min)
- Armature resistance AX - 0.109 Ohms ± 2% @ 25oC, AZ - 0.119
Ohms ± 2% @ 25oC
- Commutator diameter 175 mm (Min)
10.1.2 Fields and interpoles - Insulation resistance 20 M Ohms @
25oC (Min)
- Shunt field resistance 0.95 Ohms ± 2% @ 25oC
- Commutating field resistance 0.05 Ohms ± 2% @ 25oC
- Differential field resistance 0.05 Ohms ± 2% @ 25oC
- Control field resistance 18.8 Ohms ± 2% @ 25oC
10.2 Service specification
10.2.1 Armature and commutator - Shaft dimensions Refer AEI
Instruction 133078
- Commutator runout 0.03 mm (max.)
- Commutator eccentricity 0.03 mm (max.)
10.2.2 Brushgear - Spring tension 1.1 kg ± 0.1kg
- Replacement brushes Refer Drawing 407-526
10.2.3 Bearings (approved) - Commutator end NSK 6308Z or
equivalent
- Drive end SKF NU 309 ECMC4
NSK NU 309 ECM4
FAG NU 309 ECM4
STEYR NU 309 ECM4 or equivalent.
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10.3 Post service testing specification
10.3.1 Resistance measurement @ 25oC - average - Armature 0.109
Ohms ± 2% @ 25oC
- Shunt field resistance 0.95 Ohms ± 2% @ 25oC
- Commutating field resistance 0.05 Ohms ± 2% @ 25oC
- Differential field resistance 0.05 Ohms ± 2% @ 25oC
- Control field resistance 18.8 Ohms ± 2% @ 25oC
10.3.2 Insulation resistance 20 M Ohms @ 25oC (Min.)
10.3.3 Temperature and vibration test - Test speed 2400 rpm
- Vibration 0.1 mm/sec (max.)
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11 Reference standards
11.1 RailCorp standards ESR 0550 Overhaul of 48 class Locomotive
engine assembly
11.2 Drawings 004-653 Auxiliary electrical machines service flow
chart
407-526 Diesel electric Locomotives AG32 exciter & AG51 aux.
gen. brush.
AEI 133078 AEI machine data.
11.3 AEI Maintenance instructions MI 139011
11.4 Australian standards AS 1554.1 SAA structural steel welding
code - welding of steel structures
AS 2625 Rotating & reciprocating machinery – mechanical
vibration
AS 2700 Colour standards for general purpose
AS 3709/ISO 1940 Vibration & shock – balance quality of
rotating rigid bodies
AS 2717.1 Welding electrodes - gas metal arc ferritic steel
electrodes
AS 2768 Electrical Insulating materials, evaluation and
classification based on thermal endurance
BS 173 Methods of specifying performance of rotating electrical
machines for rail and road Vehicles
11.5 Other standards GPC-E-24 Full gloss oil and petrol
resistant enamel
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Appendix A - Torque Charts
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Appendix A (cont.)
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Appendix B - Drawing 004-653 Auxiliary Electrical machines Flow
Chart
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Appendix B (Continued)
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Appendix B (Continued)
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