Three-phase synchronous generators

KAD 30240/E
Issue 08/01

Read before use!

Mounting and
operating instructions
for series SE and SEH
brushless three-phase synchronous generators

AEM
Anhaltische
Elektromotorenwerk
Dessau GmbH After-sales service
Thomas-Müntzer-Straße 32 Tel.: +49 (0) 340 203304/305
06842 Dessau Fax.: +49 (0) 340 8501482
 General safety instructions

Notes for use

The notes used in the operating instructions have the following significance:

Danger !
Is used for activities that may cause considerable personal or material damage.
Please read and observe these notes carefully and act particularly cautiously in these
cases. Make other users aware of these notes concerning work safety.

ATTENTION! Concerns the observation of regulations, notes or the correct sequence of working
steps to avoid damaging or destroying the machine, its parts and/or parts of the
equipment.

NOTE General type of notes

Choke [6] Designation of part [number in circuit diagram]

Terminal R5 Terminal connector in regulator

Terminal X100 Terminal connector in terminal box

General safety instructions

Electrical machines for which these operating instructions were written are designed for use in commer-
cial installations. During operation, these machines have dangerous rotating and non-insulated voltage-
carrying parts. Serious personal and material damage may be caused by impropter use, impermissible re-
moval of covers and protective installations, wrong handling and insufficient maintenance.

All work to be carried out on electrical machines such as assembly, connection or maintenance must only
be carried out while the system carries no voltage and is out of operation. Protect the system against
unintended reactivation.

These machines must only be transported, put up, connected, put into operation, maintenanced and oper-
ated by specialized staff being trained to observe the relevant safety and installation regulations. All proc-
esses must be checked by responsible specialized staff. These specialized staff must have been authorized
for their activities by the security system officer (for specialized staff regulations see
DIN VDE 015 or VDE 364).

Operation by non-qualified staff is prohibited!

The person responsible for the installation must make sure

• to have safety and operating instructions available and observing them;
• to have all safety installations and personal safety equipment available;
• that safety installations and personal safety equipment are used;
• regulatory maintenance work is carried out;
• the maintenance staff are immediately informed or the machine stopped if abnormal volt-
ages, increased temperatures, oscillations, noises etc. occur so that causes can be deter-
mined and damages avoided.

The manufacturer's liability is only maintained if the operating instructions are being observed at
any time!

3
Table of contents
1 Description............................................................................................................................................ 7
1.1 Regulations and Classifications...................................................................................................... 7
1.2 Design ........................................................................................................................................... 7
1.3 Bearings......................................................................................................................................... 7
1.4 Cooling system .............................................................................................................................. 7
1.5 Exciter unit..................................................................................................................................... 7
1.6 Voltage regulator............................................................................................................................ 8
2 Behaviour during operation and notes on use........................................................................................ 9
2.1 Excitation, de-energizing................................................................................................................ 9
2.2 Setting range for voltages, set-point adjuster................................................................................ 10
2.3 Voltage response ......................................................................................................................... 10
2.4 Radio noise suppression .............................................................................................................. 10
2.5 Operation..................................................................................................................................... 10
2.5.1 Overload resistance .............................................................................................................. 10
2.5.2 Operation with different temperatures of the cooling agent .................................................... 11
2.5.3 Operation at power factors cos ϕ < 0.8 .................................................................................. 11
2.5.4 Maintenance at the drive and underspeed ............................................................................. 11
2.6 Short-circuit response .................................................................................................................. 11
2.7 Single operation ........................................................................................................................... 11
2.8 Parallel operation ......................................................................................................................... 11
2.8.1 Practical applications ............................................................................................................ 11
2.8.2 Neutral earthing current......................................................................................................... 12
2.8.3 Synchronization .................................................................................................................... 12
2.8.4 Parallel operation with statics ................................................................................................ 13
2.8.5 Parallel operation with compensating line.............................................................................. 13
2.8.6 Parallel network operation with statics................................................................................... 14
2.9 Emergency operation without regulator ........................................................................................ 14
3 Transport ............................................................................................................................................ 15
3.1 Check after delivery ..................................................................................................................... 15
3.2 Transport security device ............................................................................................................. 15
3.2.1 Cylindrical rolling bearings .................................................................................................... 15
3.2.2 Single bearing - and vertical generators ................................................................................ 15
4 Mounting............................................................................................................................................. 16
4.1 Installation and connection........................................................................................................... 16
4.2 Electrical connection .................................................................................................................... 17
4.3 Terminal box and connectors ....................................................................................................... 18
4.4 Direction of rotation...................................................................................................................... 18
5 First startup......................................................................................................................................... 18
5.1 Electrical check............................................................................................................................ 18
5.2 Measuring of the insulation value ................................................................................................. 19
5.3 Mechanical check ........................................................................................................................ 20
6 Maintenance ....................................................................................................................................... 20
6.1 General information ..................................................................................................................... 20
6.2 Lubrication and maintenance instructions..................................................................................... 21
6.2.1 Lubricant informations........................................................................................................... 21
6.2.2 Bearings with relubrication device ......................................................................................... 21
6.2.3 Removing used grease ......................................................................................................... 22
6.2.4 Bearings without relubrication device .................................................................................... 22
6.2.5 Maintenance ......................................................................................................................... 22
6.3 Slide Bearings.............................................................................................................................. 22
6.3.1 Oil renewal............................................................................................................................ 22
6.3.2 Inspection of bearings ........................................................................................................... 22
6.4 Cleaning ...................................................................................................................................... 23
6.5 Drying the winding........................................................................................................................ 23
6.6 Assembly of bearings................................................................................................................... 24
7 Supplementary installations ................................................................................................................ 24
7.1 Temperature monitoring............................................................................................................... 24
7.2 Standstill heater ........................................................................................................................... 25
7.3 Air filter ........................................................................................................................................ 25
7.4 Additional protection and measuring transformers........................................................................ 25
8 Storage instructions ............................................................................................................................ 25

9 Troubleshooting .................................................................................................................................. 26
4
 9.1 Thermal and mechanical problems .............................................................................................. 26
9.2 Voltage problems ......................................................................................................................... 26
9.3 Checking and replacing the rectifier diode.................................................................................... 27
9.4 Testing varistors........................................................................................................................... 27
9.5 Replacing the regulator ................................................................................................................ 27
9.6 Problems overview ...................................................................................................................... 28
10 Spare parts...................................................................................................................................... 30
11 Appendix ......................................................................................................................................... 30

5
 View of generator N side

Description of view

5 Rotating rectifier 9.2 Regulator potentiometer

6 Choke coil 10 Antinoise capacitor
6.1 Choke coil terminal strip 11 Static current transformer
7 Current transformers K Terminal connectors K1, K2, ...
7.1 Current transformers terminal strip R Terminal connectors R1, R2, ...
8 Stationary rectifier r31 Settling resistor
9 Voltage regulator s1 Voltage surge protector

6
Description
1 Description
1.1 Regulations and Classifications
The generators are made to comply with the regulations set in DIN EN 60034 / VDE 0530 (Rotating electri-
cal machines), all applicable IEC recommendations and order-specific customized classifications – specially
acc.to the most important marine classifications associations.
1.2 Design
The generators consist of
• one inner-pole main machine with salient or non-salient pole rotor
• one external-pole exciter with rotating rectifiers for transmission of the exciting power and
• one exciter device with electronic voltage regulator .
Generator, exciter and all other components required for excitation and regulation are designed to form one
compact unit. The casing consists of the stator, the end shields and a hood to serve as a cover for the ex-
citer uniton the N side. In the standard design, the terminal box is at the top and can be turned by 180 °.
Both terminal box and casing have specially designated earth connection points.
1.3 Bearings
The system is equipped with spring-loaded deep groove ball bearings, cylindrical roller bearings or plain
bearings as defined in the order.
In case of increased loads on the bearings, a cylindrical roller bearing is installed on the D side while a deep
groove ball bearing is on the N side to serve as counter bearing or, if necessary, a double bearing made up
of a cylindrical roller bearing and a deep groove ball bearing.
Machines in vertical design have an angular contact ball bearing to serve as counter bearing. All bearings
are dust-proof, are permanently lubricated up to shaft center height 315 mm and are provided with relubri-
cation devices with grease quantity regulation on both the D and the N side as from shaft center height 400
mm. Relubrication devices for shaft center height 315 mm are subject to special arrangements.
NOTE For bearing configuration observe “Appendix” and lubrication- and maintenance instructions
observe section 6.2.

1.4 Cooling system

The machines are self-ventilated with the air inlet being axially on the N side. The air outlet is on the D side
through a radial ventilator. In some cases, ventilators depending on the direction of rotation are used to
minimize the air noise.
NOTE Observe section 4.4 "Direction of rotation"!
Generators with higher protection systems (> IP23) are equipped with filters or pipe connection on their D
and N sides (self-ventilation in accordance with IC 31 or external ventilation in accordance with IC 36) or
with air-to-water or air-to-air type heat exchangers (IC 81W7 or IC 81A7).
1.5 Exciter unit
Construction
The exciter unit consists of the following assembly groups (observe appended circuit diagram):
• choke [6]
• current transformer [7]
• stationary rectifier stack [8] with settling resistor r31
• electronic voltage regulator [9]
All units are installed on a panel on the N side end shield. Exciter unit and rotating rectifier stack can be
accessed by taking off the hood and opening the clamps (for instructions on how to take off the hood ob-
serve enclosure "Assembly of bearings”, section 6.6).

NOTE For generator voltages higher 1 kV, an additional transformer with a secondary voltage of 400 V is
built in to separate the AVR from the high-voltage side. The AVR is in a separate connection box.
The exciter unit is protected against unauthorized changes.

Working principle
The remanent voltage produced in the stator winding [1] of the generator causes a small current to flow
through the stator winding [4] of the exciter via choke [6] and rectifier stack [8] thus setting off self-
excitation.

7
 Description
The choke [6] limits the exciter current of the exciter. The exact value depends on the air gap between core
and yoke of the choke. The required air gap is adjusted by adding insulating material.

NOTE For generator voltages higher 1 kV, an additional auxiliary winding is built in into the stator. The
voltage of this auxiliary winding serve as remanent voltage and supply the choke.

The load current flows through the current transformer [7]. When load is put on the generator, the secon-
dary current of the current transformer [7] is added to the choke current. After rectification in the stationary
rectifier stack [8] – a six-pulse bridge circuit –, this alternating exciter current flows to the stator winding [4]
of the exciter. In order to protect the diodes against voltage surges, both the stationary rectifier stack [8] and
the rotating recitifier stack [5] are equipped with varistors [s1], [s2]. Choke current and secondary current of
the current transformer are adjusted such as to permanently maintain a generator voltage of approx. 10 %
above the nominal generator voltage while the generator rotates at its nominal speed and the voltage regu-
lator is disconnected.
Every time the nominal generator voltage is exceeded, the voltage regulator (AVR) [9] periodically
switches on settling resistor r31 that is located in parallel to the stator winding of the exciter [4]. This ensures
that the terminal voltage of the generator is kept at the value set by the set-point adjuster.
NOTE The chosen tappings of the winding to choke and current transformer have been optimally
adjusted to the generator in the manufacturer's test shop. You should therefore always con-
tact the manufacturer prior to making any changes.

1.6 Voltage regulator

Design
The voltage regulator is located in a sealed casing protected against dust and dirt. The casings contains the
potentiometers for setting the various regulator functions.
The potentiometers are equipped with a self-locking multi-speed mandrel drive that is secured against over-
speed by a sliding clutch. The setting range is approximately 20 revolutions.
The following regulator types are used:

R 10-K Standard type providing voltage regulation and staticization for parallel operation. Designed with
smoothing capacitor CK and varistor s2.
R 10-KC In addition to the R 10 K functions, this type provides a cos ϕ - regulation part. It can be used
either as a staticizing regulator or as a cos ϕ - regulator.
R 10-KF In addition to the R 10 K functions, this type provides a cascading, frequency-dependent voltage
regulation.

NOTE Read the enclosed documentation for special modifications of the AVR.

Connectors
The voltage regulator is connected via spring-loaded terminal strips as in Figure 1 and the enclosed wiring
diagram
350 - 450 V at 50 Hz 180 - 250 V at 50 Hz
350 - 490 V at 60 Hz 180 - 290 V at 60 Hz

cable 5 cable 5
U V U V
bl br bl br
R1 R2 R1 R3
AVR AVR

bl – blue br – brown

Figure 1: Connectors for measuring and voltage supply

NOTE For generator voltages higher 500 V, the exciter is connected to tappings of the stator
winding at approx. 400 V. For generator voltages higher 1 kV the AVR is connected to a
special measuring transformer (400 V).

8
Behaviour during operation and notes on use

NOTE Use a current transformer in phase W for current registration. Only some of the parallel
winding branches of the stator winding are put through the converter.
(observe when disassembling the exciter)

1. rotating right 2. rotating left 3. single operation

without static

cable 7 put in cable 7

jumper
k l l k k l
br bl bl br br bl
R4 R5 R4 R5 R4 R5

regulator regulator regulator

Figure 2: Connectors for static transformer

For all other connectors see the enclosed wiring diagram.

2 Behaviour during operation and notes on use

Danger !
Observe during all setting and other work to be carried out on exciter and regulator
that all components supply voltage potential (about 400 V). Only trained specialized
staff are allowed to change settings using a suitable tool.

2.1 Excitation, de-energizing

Excitation
Self-excitation is provided by the remanent voltage.
If self-excitation of the generator does not work, excitation can be induced by briefly applying an external
voltage (6 or 12 V battery) to terminals K3 (battery plus), K4 (battery minus) in the terminal box of the gen-
erator (Figure 3).

6 - 12 V

250 V
10A

K1 K2 K3 K4 K5 K6 K1 K2 K3 K4 K5 K6

excitation de-energizing
Figure 3: Generator excitation and de-energizing circuit

Danger !
Measure the generator voltage during the excitation process. Remove the external
voltage source immediately, when the generator voltage rises. Danger of inverse
voltage!

De-energizing
Use a contactor or suitable switch to produce a short-circuit between terminals K3 and K4.
Current load on the contacts is < 10 A (Figure 3).

Danger !
After de-energizing and while the drive is running, there is a residual voltage of up to
10 % of the mains voltage on the generator terminals Special notice for machines
with voltage more than 1 kV.

9
 Behaviour during operation and notes on use

2.2 Setting range for voltages, set-point adjuster

Use the "Voltage" potentiometer of the regulator to set the terminal voltage in a range of approx. ± 8 % of
the nominal value. You may connect an external set-point adjuster to terminals K1 and K2 in the terminal
box of the generator (rotary resistor 2.5 or 5 kΩ, load limit approx. 1 W, test voltage > 2000 V). On the
regulator, put jumper R7 - R8 to R6 - R7. Use the external set-point adjuster to set the terminal voltage in a
range of approx. ± 5 % of the nominal value.

put in jumper R6 - R7

R6 R7 R8 K1 K2 K3 K4 K5

regulator R 10-K shielding

external
potentiometer set-point adjuster
_ _ 2,5 kΩ / ≥ 1 W
+ +

voltage stability
staticization
Figure 4: Connectors for external set-point adjuster

NOTE We recommend using shielded cables!

Put the jumper back to connect R7-R8 if you are working without external set-point adjuster.
Danger !
Incorporate the external set-point adjuster in the protective measures against high
contact voltage.

2.3 Voltage response

Static voltage response
The voltage regulator maintains the set terminal voltage between idle and nominal current for power factors
in a range of cos ϕ = 0.5 (over-excited) to 1.0 with a tolerance value of under ± 1 %. This constant voltage
works for operation without staticization and independent of the generator temperature. Valid speed in-
creases of the generator drive are up to 105 % of the nominal speed between nominal output and idle op-
eration.
Dynamic voltage response
Adding a nominal load of a power factor of cos ϕ = 0.8 causes a voltage drop by approx. 12 to 15 %. Regu-
lation compensation takes about 0.3 to 0.5 sec. Both nominal values depend on the generator output and its
number of poles. Greater additional loads are possible. However, in this case the voltage drops by up to
30 %. Please contact the manufacturer for further information.
Voltage stability
The regulator is delivered with optimal settings for static and dynamic voltage response. If the output volt-
age oscillates, slowly turn potentiometer "Stability" (Figure 4) clockwise until the output voltage is stable
again.
2.4 Radio noise suppression
Radio noise suppression corresponds to limiting value curve N in accordance with VDE 0875 unless any
other arrangements were made with the manufacturer. Capacitor unit [10] provides noise suppression. This
unit is connected inside the terminal box or to the exciter by a three-phase connection and connected to
generator ground via a cable used by both elements.
2.5 Operation
2.5.1 Overload resistance
Valid current overloads of the generator at cos ϕ = 0.5 are 10 % for an hour (once within 6 hours) or 50 %
for 2 minutes. Brief overloads at motor starting operations are admissible. During overload conditions, the
voltage tolerance of ± 1 % is no longer valid.

10
Behaviour during operation and notes on use
2.5.2 Operation with different temperatures of the cooling agent
The nominal output stated on the type label is only valid in conjunction with the stated temperature of the
cooling agent. For other temperatures, the following output changes apply:

T / °C 30 35 40 45 50 55 60
P / PN 1,06 1,03 1,00 0,96 0,92 0,88 0,84

ATTENTION! Operation in ambient temperatures above 60 °C require manufacturer approval.

2.5.3 Operation at power factors cos j < 0.8

For power factors cos ϕ < 0.8, the apparent generator power must be reduced in relation to the power factor.
cos ϕ 0,7 0,6 0,5 0,4 0,0
P / PN 0,95 0,89 0,85 0,82 0,78

2.5.4 Maintenance at the drive and underspeed

No particular protection of the generator, the exciter or the regulator against underspeed of the generator
drive (e.g. during warm-up) is not required. Voltages are maintained constant down to speeds of approx.
90 % of the nominal speed. Below this value, the voltage is reduced approximately proportionally to the
speed so that every speed is admissible during no-load operation without time limitation.

NOTE Medium-high-voltage generators (type SEH) have to be shortcircuited by an earth-leakage circuit

breaker in case of maintenance. The generator will be damaged if it will be driven inthis operation
because it can be excited up to sustained short-circuit current.

Danger ! In case of maintenance at the drive the short-circuited generators have to be

de-excitated absolutely according to section 2.1 by short-circuiting of the terminals
x100:3,"+" and x100:4,"-". Earth-leakage circuit breaker and terminals for de-
excitation should be i nterlocked.
2.6 Short-circuit response
The current surge (15 - 21 x IN) occurring during short-circuit conditions goes down to the permanent short-
circuit current after about 60 to 100 ms. Stable permanent short-circuit current of up to three times the nomi-
nal generator current is guaranteed for up to 5 sec. Please refer to the appendix for all other values. The
permanent short-circuit current on one pole is approx. 5 - 6 x IN.
2.7 Single operation
To ensure single operation, the statics converter can be deactivated by putting in a jumper between termi-
nals R4 - R5 (Figure 2). This guarantees optimally constant voltage values for the generator.
NOTE Single operation is possible without limitations if there is no jumper between R4 and R5
(parallel operation circuit). In this case, voltage tolerances are determined by the statics set-
ting and they are above 2 %.

2.8 Parallel operation

2.8.1 Practical applications
Brushless generators are designed for parallel operation. They are equipped with damper winding, connec-
tion for compensator circuit, statics device and set-point voltage adjuster.
The following variations of parallel operation are possible:
• Parallel operation with statics with other generators as long as these provide parallel operation
features and if practically the same static voltage curves with falling characteristics can be set for all
generators;
• Parallel operation with compensator circuits of generators of the same type;
• Parallel network operation either via statics and non-regulated power factor or using regulator
R 10-KC with power factor regulation.
For parallel operation of several generators, reactive power distribution as well as current and power output
variations must be within the range of applicable regulations. Prerequisites for this kind of operation are that
generator drives, and their speed governors in particular, are designed correspondingly providing the same
P range (speed drop between idle and full load operation) or that a non-inductive load distribution propor-
tional to the power output is ensured by an automatic non-inductive load distribution installation.

11
 Behaviour during operation and notes on use

Effect during single Main effect during parallel

Preset generator voltage
value
Generator statics
Preset generator voltage
value
Generator statics
Preset speed value of drive
Preset speed value of drive
operation operation
é increased generator voltage generator provides more reactive
power
ê ------------------------
ê reduced generator voltage generator provides less reactive
power
é ------------------------
é higher frequency gen. provides more non-inductive
power
ê lower frequency gen. provides less non-inductive
power

NOTE Wrong distributions of non-inductive power (kW indicator not proportional to power output) is
always caused by the speed regulation of the generator drives. Wrong reactive power distri-
bution (kW distribution o.k., different current distribution) is caused by the voltage and stat-
ics settings of the regulator

2.8.2 Neutral earthing current

In parallel operation there aren`’t neutral-earthing currents normally while using of equal generator types of
one manufacturer.
Connecting the generator star point to the star points of generators of another type or to the mains' earthed
neutral can cause compensation currents of mainly three times the mains' frequency to flow in the neutral
earth conductor that have been caused by different voltage curve lines of generators and mains network.
Neutral currents of up to 40 % of the nominal current are admissible unless other values have been defined.
Reducing the neutral current can be achieved by inserting a special type of choke coil in the switching circuit
(please contact the manufacturer).
2.8.3 Synchronization
The generators can be synchronized by manual synchronization, quick synchronization or startup synchroni-
zation (please contact the manufacturer).
The following prerequisites must be observed for synchronization processes:
• almost identical frequency of the two voltage systems ∆f ≤ 0.2 Hz
• almost identical terminal voltage of the generator and mains network, admissible difference < 6 %
• identical phase sequence of the two voltage systems
• closing of switching contacts at a phase angle of < 15 degrees in relation to the zero crossover of
the difference voltage of the two voltage systems.
ATTENTION ! Wrong synchronization causes extremely high electrical and mechanical loads on the
generator which must be avoided under all circumstances.

Manual synchronization
Use the set-point adjuster to set the generator voltage to the mains voltage. After setting smallest frequency
and phase differences possible by means of a synchronoscope, the generator can be switched on. To avoid
the occurrence of inverse power after switching on the generator, the generator frequency should be about
0.2 Hz above the mains frequency.
Quick synchronization
Use an electronic synchronization device to automatically adjust the system to smallest possible voltage,
frequency and phase differences that also takes switching delay times in the zero crossover range of the
difference voltage into account for switching on.

12
Behaviour during operation and notes on use

2.8.4 Parallel operation with statics

ATTENTION ! Check whether the jumper between terminals R4 and R5 of t he regulator have been
removed.
Depending on current and power factor, the generator voltage characteristics have a decline. The voltage
drop can be set by the "Statics" potentiometer on the regulator (Figure 4). The voltage drop is increased by
turning the regulator clockwise. In the factory, the statics is set to approx. 2 % (in relation to idle voltage) at
nominal current and a power factor of cos ϕ = 0.8. Constant voltage during parallel operation depends on
the statics setting. If statics setting and static characteristics are nearly the same, the reactive power (in
relation to the nominal power of the corresponding generator) is distributed proportionally.
ATTENTION ! Make sure to do a generator adjustment before starting operation.
Check whether all drives have the same percentage value for speed drop between
idle speed and full speed while in single operation.
Use the set-point adjuster to adjust the idle voltages of all generators.
Put nominal load at nominal power factor on the generators in single operation if
possible and check whether an almost identical voltage drop can be observed for all
generators.

If you find larger differences, the statics resistors must be readjusted. Statics values of 2 - 3 % at nominal
load and nominal power factor are sufficient for stable parallel operation. This test must not be made with
just using non-inductive load as this renders the statics inefficient.
NOTE Proceed as follows to make a supplementary test if only non-inductive load operation is
possible when changing the setting:
1. Connect the blue cable from phase U to W and the brown cable from phase V to
phase U of cable 5 on the choke terminal strip [6.1].
2. Put load on the generators.
3. The voltage drop corresponds to statics setting at cos ϕ = 0.8 and normal switching
conditions.
4. Reconnect all devices after the setup procedure.
cable 5 cable 5

br bl bl br
W V U W V U
choke terminal
strip [6.1]

choke [6]

normal switching conditions circuit for non-inductive load

Figure 5: Terminal connection for statics setting at non-inductive load

ATTENTION ! Only specialized staff must do these steps.

2.8.5 Parallel operation with compensating line

Generators with the same exciter voltage can work in parallel if there is a compensating line. The genera-
tors are running in this case without static. The voltage is constant for all load. For speciall informations
please consult the manufacturer.

13
Behaviour during operation and notes on use

2.8.6 Parallel network operation with statics

A prerequisite for parallel operation of an electric device in a fixed network is that overload conditions in
varying network situations are avoided. On the power output side this is ensured by a speed regulator or an
electronic load distribution. On the reactive load side, this condition must be ensured by implementing a
load-dependent modification of the internal generator voltage. This generator voltage adjustment can be
realized either by the statics device or by a regulation that depends on the power factor (cos ϕ-regulation).

The statics installation lowers the generator voltage if the reactive power increases. Greater statics causes
small current changes if the mains voltage changes. We recommend setting the open-circuit voltage higher
than the highest mains voltage occurring at the feeding point to avoid reactive power consumption by the
generator from the mains.
ATTENTION ! Observe the neutral earthing current described in section 2.8.2 and synchronization
conditions in section 2.8.3.

2.9 Emergency operation without regulator

If the voltage regulator is defect and if no supplementary regulator is available, it is possible to go into
emergency mode. To do so, simply disconnect connectors R1, R2 (or R3 resp.), R10.
ATTENTION ! Attach and insulate cable ends.
Connect an adjustable resistor of approx. 100 Ω and a load resistance of approx. 2 A to terminals K3, K4 in
the generator terminal box. The resistor can be used to set the nominal generator voltage while the machine
is idling.

Danger !
The resistor is under mains potential and must therefore be protected against co n-
tact.

The voltage can be kept in the required range by readjustment under load.
The voltage tolerance value is approx. -5 % without readjustment.

14
 Transport / Mounting
3 Transport
ATTENTION ! Only use suitable attachment devices (ring bolts, eye bolts) for transportation. The
attachment elements that are part of the machine are only made to carry the m a-
chine's own weight.
Check whether screw-type eye bolts are firmly screwed in.
It is not allowed to sling parts of the transport gear around shaft ends, pillow blocks,
sleeves, hoods or similar elements as this could cause considerable damage.
If a machine or unit is transported on its baseplate you must use the attachment d e-
vices provided in the baseplate. Units that must not be transported in one piece are
marked by a corresponding notice on the baseplate.
NOTE When transporting parts of disassembled machines ropes for lifting armatures should not be
slung around the shaft bearings. If no other way of transporting the element is possible, the
bearings must be sufficiently protected.

3.1 Check after delivery

Check the machine for any damages that might have occurred during transportation.
Transport company and manufacturer must be informed immediately of any transport damages.

3.2 Transport security device

To avoid transport damages to bearings the armature of machines with cylindrical roller bearings is
equipped with a transport security device. This must only be removed when commissioning the machine
and reused if the machine is transported again. Machines with spring-loaded groove ball bearings need no
transport protection.

ATTENTION ! Remove the transport security device before putting the machine into operation for
the first time.

3.2.1 Cylindrical rolling bearings

Refer to the illustration or the information given inside the terminal box to learn about how to remove the
transport security device.
Machines with transport security devices are marked by a corresponding sign. Transport security is realized
on the D side by two fixing screws. To remove it unscrew both hexagonal screws M12x60 (Figure 6 [1]) by
approx. 8 - 10 mm and secure against unintended screwing-in by attaching the counter nuts (Figure 6 [2]).
After removing the transport security devices, you should race the machine manually if at all possible.

Figure 6: Transport security device on D-side

3.2.2 Single bearing - and vertical generators

The transport security for this machines is described in a special mounting instruction (See documentation!)
Pay attention to absolutely !

15
Mounting
4 Mounting

Danger!
Observe general security information

4.1 Installation and connection

Installation conditions
• The machine was designed for temperatures of the cooling agent between -25 °C and + 40 °C and a
mounting location up to a height of 1000 m. Any other information on the performance label must be
observed.
• Never install machines labelled as IP 23 degree of protection outside. The degree of protection of
the machine must match the local conditions at the point of installation.
• Make sure to let the cooling air get in trough the air inlets and out again through the air outlets with-
out obstructions or being sucked back in.
• If you are working with external air cooling, make sure to provide the air quantity indicated on the
performance label.
• Install the machine on a low-vibration foundation. Avoid tension due to fixing the screws on uneven
surfaces.
• Use taring screws for aligning the machine. The final installation position is to be fixed by sheet
metal put underneath the machine. Bolt the machine up if necessary (holes are drilled into place al-
ready).
• When assembling machines that come to you in several pieces, you have to make sure only to use
parts that have been marked as belonging together.
• The machine must only be assembled and operated according to design (see rating plate).
• Always observe the connection conditions for water quantity, pressure and temperature at the inlet
given in the data sheet for water coolers (see appendix).
• If you are working with a pipe connection with self-ventilation, the pressure drop indicated by the
manufacturer must in no case be exceeded due to length and layout of piping.
• Make sure to keep sufficient distance to walkways and operating stands as the temperatures of ex-
haust air or surface can be up to 80 °C.
ATTENTION ! Provide information signs or protective railing.

Coupling
The generator and bearings have been carefully mounted, aligned and completely tested by the manufac-
turer.
NOTE The rotor is dynamically balanced. The balancing state is marked in accordance with
DIN ISO 8821 at the D-side shaft-end.
Coupling of generators in double-bearing design to the drive unit should be realized by an
elastic clutch.
NOTE Coupling of generators in single-bearing design: Observe the special documentations in
appendix!

Putting on couplings or pulleys

It is not necessary to remove the corrosion protection at the shaft ends during installation.
ATTENTION ! Make sure to use a mounting device for mounting couplings or pulleys.

A suitable means for this is the centering drillhole in the shaft end. When putting in the clutch you have to
make sure that the shaft of the drive mechanism and the shaft of the machine to be driven are perfectly
aligned. Misalignment must be not greater than 0.05 mm. To avoid angle errors, the gap between the two
halves of the clutch must be measured at a 90 °C offset. The difference must be no greater than 0.05 mm.
If elastic bolts or denture clutches are used you must make sure to have congruent separations of the two
halves of the clutch. Changing the half clutches round is not allowed.
ATTENTION ! Because of the danger of damages occurring on the bearings, hammering or knoc k-
ing the driving elements on is not allowed.

16
Mounting
Pulleys are only allowed for machines of the type IM C2 as special feature design; they too must be dy-
namically balanced. Furthermore you must make sure to carefully align the two disks making up one pulley,
i.e. both shafts must be parallel to each other and the connecting line between the two disk centres must be
at a right angle to the shafts.
ATTENTION ! Check the pull of the belt. For information about the max. admissible belt tension
please contact the manufacturer. Increasing the pull of the belt shortens the servic e-
able machine life.

ATTENTION ! In any mounting work, this setting must be strictly adhered to. To adjust the rotor at
the magnetic centre, the dimension X is given on the bearings.

Figure 7: Dimension X

This dimension (see figure 7) must be checked after the coupling has been mounted, and if necessary the
alignment of the coupling and machine must be corrected.
4.2 Electrical connection
ATTENTION ! Only have specialized sta ff set up the electrical connection in accordance with appl i-
cable safety regulations.
Observe all applicable national and international regulations. Connect the machine up according to the in-
formation given on the wiring diagram stuck on inside the terminal box. Refer to the wiring diagram for the
terminal points to connect the temperature winding protection, the bearing monitoring device, the speed
control device, the standstill heating system, the exciter connectors and additional transducers.
ATTENTION ! Connect the machines to earth using the corresponding protective earth terminals
inside the terminal box and on the foot of the machine stand.
Tightly set all connectors to avoid high transitory resistances. At the same time permissible tightening tor-
ques have to be held:

Thread M 10 M 12 M 16 M 20
Tightening torque in Nm 10 15,5 30 52

Align the cable lugs at the largest possible distance to other connecting points and to the casing.

ATTENTION ! Do not fall below the following distances between live c omponents and to the case:
Nominal voltage UN in V 550 725 1000 6000
minimal distance in mm 8 10 14 60

17
 Mounting / First startup
Round terminal bolts of low voltage machines (< 1kV) have not been designed to serve as conductors for
the rating current. You must therefore always make sure to put cable lug on cable lug (Figure 8). If more
than three cable lugs are connected to one terminal, you should use a flat nut in between. Arrangement of
cable lugs, nuts and counternuts is to be made according to the illustration below.

Figure 8: Cable lug arrangement inside the terminal box.

4.3 Terminal box and connectors

The terminal box of low voltage machines (< 1 kV) contains the connectors of the stator winding and all
other additional terminals required for generator operation and monitoring. Water-proof cable sleeves have
been provided for inserting the cables. The terminal box can be turned by 180 ° in relation to the insertion
opening. Prior to doing so you have to remove the additional terminal strip and attach to the opposite side.

For generator voltages higher 1 kV, the generators have got separate terminal boxes for the main connec-
tions and for the auxiliary and measuring connections.
4.4 Direction of rotation
The terminals are obligatorily marked in accordance with EN 60034-8 / IEC 34 Part 8. If rotating right, i.e. a
clockwise direction of rotation seen from the drive unit side, a right revolving magnetic field occurs on ter-
minals U, V, W. If rotating left, the magnetic field revolves to the left unless something else has been
agreed. If you want to operate the generator as described above, you must connect the static current con-
verter leads (Cable 7) to the regulator to terminals R4, R5 as shown in Figure 2. Should the network operate
with right rotating magnetic field two phases have to be changed on panel connection.

NOTE Machines that have been made to work only in one direction of rotation, this direction is
marked by an arrow on the machine, the ventilator or on the rating plate.
Contact the manufacturer if you want to change the direction of rotation of this typ of
machine!
Direction of rotation Rotation right only Rotation left only
Direction symbol è ç

5 First startup
When putting the machine into operation for the first time or after long downtimes, the following checks
have to be made.

5.1 Electrical check

• Check whether all terminals are firmly connected and connections made to wiring diagram!
• Check condition of exciter and regulator connectors!
• Check whether all monitoring devices are connected and set correctly!
• Check the system for proper earthing and for protection lead connection!
• Check whether voltage, frequency and rotary field of generator and mains coincide before switching
the system on for the first time!
• Check the insulation resistances between winding and earth and between the parts of the winding.
Measurements to be made by specialized staff only!

18
Maintenance

5.2 Measuring of the insulation value

Danger !
Protect the system against unintended reactivation!
Earth the windings before and after the measuring of insulation at least 10 s.
Don’t touch the windings before!

Measuring instrument: The measurement should be effected by a standard measuring instrument. Ob-
serve exactly the operating instruction.
Measuring voltage: Observe the table.
Measuring time: The measuring time should 1 min at least.

ATTENTION ! Disconnect the internal radio interference protection capacitors [10] before measu r-
ing.
The capacitors are attached to the exciter and connected to the generator frame via a cable. Disconnect this
lead and re-connect it after measuring. The test voltage of the measuring instrument used must be no
higher than 1000 V.
Insulation resistance
The following table serve to estimate the insulation resistance. Always estimate the insulation resistance
(Ris) of the cold machine, i.e. on room temperature (approx. 25°C). “Warm-values“ are not to comprehend
clearly.
The minimum insulation resistance on room temperature of a brand new machine or a repaired machine
with a new winding you find under item 1.

This value can drop by virtue of transportation and storage under bad environmental conditions. In this case
the insulation is not damaged. Machines, which stand still under bad environmental conditions for a long
time and do not have a standstill heater (dew on the windings), can be started-up, so long as the insulation
resistance of the cold machine do not drop under the values like shown in item 2.

Drop the insulation resistance under values of item 2, the windings must be dried. Under special operating
conditions the windings must be cleaned before drying (for that look to the item “Drying the winding“). The
insulation resistance must rise after a short operation of the machine.
Under normal transportation, storage and operating conditions the insulation resistance of the cold machine
must not drop under the values in item 2.

Table: Insulating resistances

generator voltage rated voltage < 1,5 kV rated voltage > 1,5 kV
measuring voltage > 100 V : max. 500V 1000 V
1. winding new or repaired
Ris > 50 MΩ Ris > 100 MΩ
dry, 25 °C
2. winding after long period of operation
Ris > 1 MΩ Ris > 5 MΩ / kV
condition unknown, 25 °C

19
Maintenance

5.3 Mechanical check

• Make sure that the machine is clean and free from dust! Are removed all strange parts and tools?
• Check whether air inlets and outlets are clean, making sure that the air can enter and exit
unobstructed!
• Check the temperature of the coolant!
• If you are working with a water-cooled machine, make sure that the cooling water circuit is properly
connected and operating!
• Check whether the machine and all screws fastening are connected correctly !
• Check whether the terminal box is closed and all wire entry sleeves properly sealed!
• Check the belt tension of belt-driven machines.
• In machines equipped with transport security devices – marked by a special notice plate – check
whether the device has been removed.
• After longer storage periods, check the lubrication of the bearings (see enclosure “Bearings”).
• We recommend first of all running every machine without load for at least one hour. The machine is
operating properly if it does not shake and if the noise of the bearings is even.
ATTENTION ! Remove the transport security device before starting operation.
Then race every machine manually and listen to monitor i
Before commissioning, it is essential to fill the bearings with the required oil quantity
(see data sheet)! Make sure that the oil has the correct viscosity! A list of reco m-
mended oils is part of the documentation.

6 Maintenance
6.1 General information
Maintenance activities include bearings, cleaning the machine and the cooling air filters, if exist.
The following must be done according to operating condition but at least once every year:
• check the terminal boxes and terminals for cleanliness and corrosion
• check the electrical connectors for tight fit
• check the bearings for leckages of grease or oil
• check the cooling air circuit for cleanliness and sufficient operability.

Use a vacuum cleaner or bellows to remove dust from the machines, do not use pressurized air containing
oil or water. Make sure not to blow any dirt or dust into the inside of the machine. Do not use sharp tools for
cleaning.
If the winding is very dirty (oil vapours or grease squelching out of the bearings), use industrial solvent-
based cleaners (petroleum ether or diluter on petrol basis) or other aqueous industrial cleaners or emulsion
cleaners to remove the dirt. Make sure that the cleaners do not dissolve paint coats or plastic materials.
ATTENTION ! Provide sufficient ventilation when cleaning the machine and make sure not to let
any cleaning agents get into the waste water. Observe the environmental protection
regulations.

Insulation value and standstill heater

Regularly check the insulation value of machines that are not used permanently or used in particularly damp
environments (see section 5.2 "Measuring the insulation value").
If the machine is equipped with a standstill heater, then the heater bands and corresponding switching ele-
ments must be checked every six months.
Preventive maintenance
Depending on operating conditions, preventive maintenance is to be carried out every 15,000 to 24,000 hrs
by experienced and specialized staff. Maintenance activities include cleaning the inside of the machine,
checking bearings and close fitting of the end-wire binding bands and, if necessary, applying a new coat of
finishing varnish.
Check the alignment of machines and the safe connection of all screws.

20
 Lubrication and maintenance

6.2 Lubrication and maintenance instructions

6.2.1 Lubricant informations
The manufacturer lubricates the machine in the factory using Bechem / Ceritol HIGH LUB LM 3 EP, a
lithium-based multigrade grease of consistency class 3 and a temperature range of -40 °C to +140 °C.
We recommend also using this type of grease for relubrications. This is a sure way of avoiding damages to
the bearings due to wrong lubricants. The following lubricants can replace each other without limitations due
to useful characteristics or lubrication intervals.

Lubricant Manufacturer Lubricant Manufacturer

HL 3 Aral Energrease LS 3 BP
Epexa 3 Elf MM - EP2 BP
Centoplex 3 Klüber Mobilux 3 / EP 3 Mobil
Alvania RL3 Shell Unirex 3 Esso
Total Multic EP3 Total Turmoplex 3 EP Lubcon
Glissandro EP2-3 DEA SPEEROL AP3 Castrol

If new sort of grease will be used (with same consistency class and saponification also) the bearings should
be regreased 3 times with shorten regreasing periods.
In case of longer downtimes or storage please remember that the maximum storage time of these greases
is 36 months. So we recommend to regrease brandnew machines too with shorten regreasing periods after
longer standstill time.
Check the proper functioning of the machine before and after each lubrication.

6.2.2 Bearings with relubrication device

Relubrication is done via the button head lubricating nipple in accordance with DIN 3404. All lubrication
points are marked on the machine. Information plates and the appendix „Bearing configuration“tell you
about lubrication dates and grease quantities.
In case the grease indicated for machines to be relubricated or another grease of the same type of saponifi-
cation is not available, open the bearing covers and remove the grease. Then clean the bearing and relubri-
cate using a grease of a similar quality.
NOTE Avoid mixing greases of different type of saponification for rolling bearing lubrication, be-
cause the greases loose their lubricity in this case.
ATTENTION ! Lubricate the machine only with the machine running.
NOTE Extending the recommended lubrication periods causes danger to the bearings and may
lead to a loss of bearing sealing usually provided by the grease thus allowing dust to enter
the bearing.
By machines with low operation periods (e.g. emergency generators) if will be recommend
to regrease yearly with reduced grease quantity. A periodical putting into operation is im-
portant that grease in bearing will be worked through.

The used grease is automatically collected in a chamber underneath the bearing. The grease collector must
be emptied after three lubrication cycles unless otherwise stated. The grease collectors are marked by par-
ticular signs on the machine.

21
 Lubrication and Maintenance

6.2.3 Removing used grease

Danger!
Remove the used grease only while the machine is standing still.

• It is mandatory to observe the dates for removing the used grease, because too much increased
grease quantities would lead to an impermissible warming-up of the bearings.
• In some machine types, the used grease comes out of a covered gap in the bearing lid, accumu-
lates around the end shield and must be removed from there after several lubrication cycles.
• Machines of type V1 are equipped with grease pipes on the D and the N side. To clean these, you
remove the plugs on either side and push the used grease out to the left or right using a round stick
( Ø approx. 25 mm).
ATTENTION ! Make sure to dispose of the used grease in an environmentally friendly way.

6.2.4 Bearings without relubrication device

Unless otherwise marked or agreed, machines up to typ 315 are equipped with bearings with lifetime lubri-
cation.
The bearing producer name appr. 20 000 h as life time. This value can fluctuate very much depending on
operating case (pollution, vibrations, temperature). So it will be recommended to open bearing covers after
2 year operation and remove waste grease. The bearings have to be regreased.
For the bearings used see the appendix.

6.2.5 Maintenance
Bearings have to be checked regarding to unusual sounds and admissible bearing temperatures periodi-
cally. If there are SPM measuring nipples or vibration pickups, then the values measured must be analysed
at the same time intervals. To remove the hood or the end shield of bearings with relubrication device, you
have to separate the lubrication tube from the screw connection (see 6.6 Assembly of bearings).

6.3 Slide Bearings

The basis for the commissioning and maintenance of sliding bearings is the enclosed original documenta-
tion of the bearing manufacturer.
ATTENTION! The documentation must be carefully read before commissioning. Only strict and
careful adherence to these regulations ensures operation without faults!

6.3.1 Oil renewal

For this use the oil drain screw below the slide bearing.
NOTE: It is recommend to exhaust the used waste oil. For that the screw is to remove above the oil
flow indicator (inspection glass)

6.3.2 Inspection of bearings

To carry out the prescribed inspection of the bearings, the machine shaft must be lifted in this way, that the
lower bearing shell is unloaded and rotatable.
As there is no suitable support surface on the N side behind the aggregate frame or a lifting tackle can't be
used, a cross bar can be screwed on the end shield as a mounting aid (tapped holes exist for that).
ATTENTION ! At first the rotating rectifier[5] is to disassemble.
NOTE: For machines with water coolers, the cover on the N side can be dismantled without re-
moving the cooler cover.

22
Maintenance

6.4 Cleaning
Cleaning cooling air filters
The filtering effect of the filter is achieved by a metal filter or layer of fiber filter element on the air inlet side.
Corresponding to operating conditions, clean the filter at regular intervals or after the thermal safety device
has reacted
•
• Remove filter plate
• Shake or blow off loose dirt
• Wash the layer of fiber filter elements using water and solvent-free agents, then dry
• Wash metal filters with petroleum ether, blow through with air and then lubricate with filter oil.
ATTENTION ! Observe environmentally friendly disposal.

6.5 Drying the winding

Selection of the drying method depends on the type of machine and the possibilities provided at the loca-
tion. Redrying can be achieved by warming up the winding using direct current (e.g. welding machine). The
current intensity used should not exceed 60 % of the nominal current indicated on the performance plate.
Ensure power feed to two phases. Minimum drying time is 1 hour.
Machines with enclosed ventilation (IP 23) can be dried with warm air ventilators. Required drying time is
several hours. Generators can be dried while the machine is running and after short-circuiting the stator
winding. The short-circuit can be produced immediately via the switch on the switching panel such that the
stator current can be monitored by an ammeter. Otherwise you have to measure the current in the machine
directly. To do so produce external excitation of the generator by an adjustable DC source.
Connection is made to terminals K3 (+pole) and K4 (-pole) inside the terminal box. Required setting ranges
are up to approx. 24 V for machines up to type 315 and up to approx. 48 V for machines up to type 630.
Required current intensity is < 5 A.
ATTENTION ! Check the heating up of the casing or measure the temperature of the winding by
thermo-elements or a thermometer.
Only to be carried out by specialized staff.
After drying you must measure the insulation resistance.
Drying conditions
• Always dry the machine slowly and thoroughly.
• The maximum drying temperature is 75° C.
• Continue the drying process until the insulation resistance increases considerably and arrives at the
minimum value. Keep check-up records with values measured!
• Ensure condensation drain in enclosed machines (IP 44 degree of protection or higher) by opening
terminal box and / or covers.
• Put the machine back into a normal operating state after drying.

23
Maintenance /.Supplementary installations

6.6 Assembly of bearings

N-side
Replacing a bearing on the N-side required removing the end shield including the exciter enclosed in it.
Proceed as follows:
• Disassembly of lubricating tube (see fig. 9)

Screw connection Disassembly:

Thrust collar
1. Push thrust collar against screw
1. push connection
2. pull at the tube at the same time

2. pull Assembly:
Push tube right in.
lubricating tube

Figure 9: Disassembly of lubricating tube

• Disconnect the leads connected to terminals K1 to K6 inside the terminal box and pull the leads
through and in.
• Disconnect leads U, V, W from choke terminal strip or rectifier plate for exciter supply.
• Disconnect the primary winding leads of the current transformer.
• Carefully mark the primary cable of the static converter; during assembly observe direction K-L of
current flow (see functional diagram).
• Disconnect leads of the rotating rectifier stack.
• Loosen carrier disk and remove the rotating rectifier stack.
• Line the generator air gap.
NOTE Set the armature such that one pole points down
• Disassemble the bearing components, bearing lid, labyrinth box, excenter and remove the end
shield including the entire exciter unit after unscrewing the screws in the ring around the stator cas-
ing.
NOTE Use the attachment screws to remove the end shield from the centering device by screwing
them into the threads provided for this purpose.
• Pull out the old bearing and put in the new one after warming it up to 100 °C (water test).
• Lubricate the bearing. Completely fill the bearings to the rim with grease.
• Fill the gap between bearing lid and shaft with grease leaving the bearing lid empty.
Proceed in opposite direction for assembly making sure in particular to carefully connect all leads according
to the enclosed wiring diagram.
D-side
• Line the generator air gap from the N-side.
• Disassemble all bearing components and the end shield and change bearings as described for the
N-side.

7 Supplementary installations
These only exist in customized solutions upon special request.
7.1 Temperature monitoring
Connect the temperature sensors for monitoring e.g. the stator winding temperature, bearings or coolant via
the supplementary terminals provided in the terminal box according to the enclosed wiring diagram.
Rules and information given in section 4.2 "Electrical connections" apply.

24
 Supplementary installations /.Storage instructions

7.2 Standstill heater

Standstill heaters are available for using the machines in shipbuilding, in tropical zones or upon request.
The standstill heater consists of heating pipes that are located inside the machine on the D- and N-side.
The following heating output is assigned to the shaft centre heights:

shaft centre height in mm 225, 250 315, 400 450, 500 630 710
heating output in W 84 150 300 520 780

The connecting terminals are marked and located in the machine's terminal box. The supply voltage is
220 / 230 V unless otherwise agreed. Connect the standstill heater to the relevant terminals in the terminal
box according to the current switching diagram.
NOTE For specific heater output and voltage : see information sign in the terminal box
ATTENTION ! Activate the standstill heater only after switching off the machine.
Provide suitable means to avoid unintentional operation of the standstill heater while
the machine is running (locking mechanism).

Danger !
Switch off the standstill heater via the control centre before opening the terminal
box! Check whether the system is in a voltage-free condition.

7.3 Air filter

Observe maintenance instructions as given in section 6.1.
7.4 Additional protection and measuring transformers
Transformers can be put in for protection or measuring purposes upon request or if required by applicable
regulations. The transformers are located on the star point side of the stator winding. The transformer is
connected to the terminal box. Refer to the wiring diagram for measuring, auxiliary and monitoring instru-
ments.
ATTENTION! Transformers that are not connected must be short-circuited

8 Storage instructions
The machines should be stored vibration-free in a dry room free of dust. In this case, special packaging is
not required. Otherwise, the machines must be kept in plastic foil with humidity absorbing material. Provide
covers to protect it against rain and sun.
Manually race the armature at regular intervals to avoid damage to the bearing.
Armatures of machines provided with transport security devices are not raced as long as the security device
is applied and functional. Observe the instructions given in section 5 prior to first operation

25
Troubleshooting

9 Troubleshooting
ATTENTION ! Immediately switch off the drive if a failure occurs.
Carefully inspect the generator while in a voltage-free condition.
ATTENTION ! Check-ups of exchanging of parts must only be carried out by trained specialized
staff in accordance with IEC 364 observing all applicable regulations of health care,
safety at work and fire protection. While measuring or setting parameters with the
machine running, you must be aware of the fact that all unprotected terminals may
carry very dangerous voltages and that they are in immediate proximity to rotating
parts. The machine must therefore be locked to avoid contact by unauthorized pe r-
sons.

9.1 Thermal and mechanical problems

Generator too hot:
• Check cooling air inlet and outlet and air filter and remove obstructions if necessary.
• Check whether the values given on the performance plate are kept (stator current, voltage, per-
formance factor, unbalanced load).
• Check the coolant temperature.

Unsteady generator operation:

• Check alignment of clutch and machine.
• Check clutch status.
• Check temperature of and noise made by bearings.
• Exclude influences caused by the drive (e.g. ignition failures).
• Check whether all armature components are firmly attached.
9.2 Voltage problems
If the generator produces no voltage or unusual voltages, try to find the problem in the exciter, unless a
winding has given up. The first step always is to check all connectors and cables in the terminal box and on
the exciter components for proper connections and safe contacts.
ATTENTION ! Use the wiring diagram for troubleshooting. Observe wire numbers and colours.

26
 Troubleshooting

9.3 Checking and replacing the rectifier diode

The test is made with a continuity check instrument. The diodes must forward the current in one direction
and not do so in the other direction.

Proceed as follows to carry out the check:

• Disconnect all poles of the unit prior to starting the check.
• Carefully pull off the flat-cable plugs.
• Check the through-state.

rotating rectifier stack [5] stationary rectifier stack [8]

The modules are standard components used by most Reverse the polarity of the continuity test
manufacturers. Observe the electrical min. values when instrument for testing diodes 4, 5 and 6 (Fig. 11).
replacing a module .Make sure not to exceed the fol-lowing
torques when reassembling (Figure 10):
Screws: 5 Nm
- + - +
Terminals: 3 Nm

- + -
3 Nm
∼ 1 2 3

∼
5 Nm 1 2 3

∼
4 5 6

+
Figure 10: Test instrument setting for rotating Figure 11: Test instrument setting for stat. recti-
rectifier fier

9.4 Testing varistors

The test is made as described for the diodes, the difference being that varistors must cut off in both direc-
tions. If any current is forwarded, the varistor is defect and needs to be replaced.
9.5 Replacing the regulator
Unscrew the 4 attachment screws and disconnect the wires. Replacing the unit is then possible without any
problems. Use a pen or screwdrive to open the terminals so that you can take out and disconnect the wires.
ATTENTION ! Carefully observe the terminal assignment plan. Wrong connections damage the
generator.
NOTE The system may have to be readjusted (voltage, statics, stability) after replacing the regu-
lator.

27
Troubleshooting
9.6 Problems overview
ATTENTION ! For safety reasons, you must inte rrupt the connection between stationary rectifier [8]
and stator winding [4] of the exciter before measuring the remanent voltage. Do not
touch voltage-carrying parts, as the remanent voltage is usually in the range between
approx. 5 to 10% of the rated voltage.
NOTE For generator voltages > 1 kV measure the remanent voltage on the terminals of au x-
illary winding X 020 only.
Problem: No generator excitation at idling speed
ATTENTION ! Measure the generator voltage before trying to find the problem.
Action Consequence Cause of failure, further actions
Connect battery "+" pole to K3 no generator ex- • check stat. rectifier [8] (section 9.3)
and "-" pole to K4 citation • replace if defect
• check rot. diodes [5] and varistor [s1]
• replace if defect
check current forwarding of rot. exciter winding [2]
on "+" and "-" bar of the rot. exciter [5]
• check current forwarding of exciter winding [4] of
the exciter
• to do so disconnect wire 3 from K3, K4 and
measure between K3 - K4
generator excita- • remanent voltage was too low
tion to nominal • immediately disconnect battery
voltage
without battery • check stat. rectifier [8] (section 9.3)
support voltage • replace if defect
breakdown of
generator voltage check current forwarding of choke [6] between UVW
and XYZ
Problem: Generator voltage too low and not adjustable during operation
Action Consequence Cause of failure, further actions
• Deactivate regulator generator voltage • regulator problem
• Disconnect conductor from is approx. 1.1 x UN • replace reg. or go into emerg. oper. mode
terminal R10 (insulate) and (section 2.9)
run generator at nominal
speed generator voltage • check rectifier stacks [5] and [8] (section 9.3)
does not change • replace if defect
• check the connections of choke [6]
Problem: Generator voltage too high and not adjustable during operation
Action Consequence Cause of failure, further actions
Check connection of external
set-point adjuster
Check function of settling resis- generator voltage • settling resistor r31 or connectors defect
tor r31 is approx. 0.8 x UN • replace resistor, repair lead
generator voltage • regulator problem
does not change • replace reg. or go into emerg.oper.mode
(section 2.9)
• Check air gap of choke [6] If the yoke is loose, set the air gap such that the
• Yoke and shims must be systems sets itself to approx. 1.1 x UN at nominal
firmly attached speed and without voltage regulator (disconnect
lead from terminal R10 and insulate)

28
 Troubleshooting

Problem: Generator voltage drops considerably under load

Action
Check speed of drive system
Check rectifier stacks [5] and [8]
(section 9.3)
Check transformer [7] and cable 2
Check statics settings: put in jumper generator voltage remove jumper for parallel operation and read-
between R4 and R5 and put load on must remain
generator
Problem: Generator voltage rises under load
Action
Check connector of transformer [11]
and direction of rotation (Figure 2)
Problem: Irregular generator voltage
Action
Check speed of drive system
Change "Stability" potentiometer of
the regulator
Problem: Generator voltage too high or too low when putting into operation
Action
Check speed of drive system
Modify set-point voltage value
Problem: Wrong current distribution in parallel operation
Action
Check connector of transformer [11]
and direction of rot. (Figure 2)
Measure transformer current under
load
Check performance-dependent dis-
tribution of non-inductive load
Check setting of idling speed voltage
of all generators
Check whether statics setting is even
For operation with compensating
line: check the connection between
generator terminal K3 - K4 and com-
pensating line
Consequence Cause of failure, further actions
adjust speed regulator
replace defect elements
• hand in to service if winding damaged
• repair connectors
just "Statics" potentiometer
constant
Consequence Cause of failure, further actions
connect-up properly
Consequence Cause of failure, further actions
adjust speed regulator
voltage continues • regulator defect
to be irregular • replace regulator
• loose terminal
• check connectors
Consequence Cause of failure, further actions
voltage o.k.
voltage setting check connector of external set-point adjuster
range insufficient check jumpers R6-R7 on the regulator (Figure 4)
Consequence Cause of failure, further actions
remove jumper between R4 and R5 if it is in
connect up properly
current = 0 replace transformer [11]
readjust speed regulator
use "Voltage" potentiometer or external set-point
adjuster
• use "Statics" potentiometer to readjust gen-
erator
• Observe in any case : if one generator ac-
cepts too much reactive load during parallel
operation with statics and increasing load,
then you must increase its statics setting or
reduce that of the other generators (do not
fall below about 2 % at nominal current and
cos ϕ=0.8) ! (Section 2.8.4)
check switch contact

29
Spare parts / Appendix
10 Spare parts
The following information is required for ordering spare parts:

What ? Where ?
Name of part enclosed spare parts list
Generator type rating plate
Output ”
Voltage ”
Serial number of generator (absolutely necessary! ) ”

Carry out dynamic balancing after replacing any rotating parts (with the exception of the rotating
rectifier [5]).
Bearing configuration - see appendix
spare parts and names of parts - see appendix

11 Appendix

The following are enclosed in the appendix:

Bearing configuration
Terminal connecting plan
Spare parts and names of parts
Wiring diagram
cos ϕ- regulator
U / f-regulator
Temperature monitoring
Special mounting instructions - water cooler
Special mounting instructions - pony motor
Lubrication and maintenance instructions for bear-
ings

30
 Internes Betriebsmittel / Klemmen-/
int. electrical equipment terminal Externes Betriebsmittel /
Mess- Kabel- Ziel- Typ Leiste external electrical equipment
fühler farbe klemme
cable- type strip Anschlusswerte/
sensor destination
color techn.parameter
c -X100 Erregergerät / exciting device
W8 br -R:6 a 1 ext. Spannungseinsteller /
2,5 k Ω 1W
bl -R:8 a 2 ext. voltage adjuster
br -R:12 d 3 + Erregung / excition 12 V DC 1 A
W4 br -G+4:F1 Entregung / de-energizing
250 V DC 10 A
bl -G+4:F2 d 4 Notbetrieb / emergency
W3 100 Ω 2A
bl -R:9 − operation
a 5
sw -R:11 a 6
c -X110 W icklungsüberwachung / monitoring of windings
↑↑ a 1
B110 ϑ Pt 100- Messfühler / sensor Phase U
a 2
a 3 TLimit =
B111 ϑ↑ ↑ Pt 100- Messfühler / sensor Phase V
a 4 130°C
a 5
B112 ϑ↑ ↑ Pt 100- Messfühler / sensor Phase W
a 6
↑↑ a 7
B113 ϑ Pt 100- Messfühler / sensor Phase U
a 8
↑↑ a 9 TLimit =
B114 ϑ Pt 100- Messfühler / sensor Phase V
a 10 130°C
a 11
B115 ϑ↑ ↑ Pt 100- Messfühler / sensor Phase W
a 12
c -X130 Lagerüberwachung / monitoring of bearing
a 1 Pt 100- Messfühler N-Seite/
B130 ϑ ↑↑
TLimit = 90°C
a 2 sensor N-side
a 3 Pt 100- Messfühler D-Seite/
B131 ϑ
↑↑
TLimit = 90°C
a 4 sensor D-side
c -X150 Kühlerüberwachung / monitoring of cooling
a 1 Pt 100- Messfühler Kaltluft /
B150 ϑ↑ ↑ TLimit = 45°C
a 2 sensor cold air
a 3 Pt 100- Messfühler Warmluft /
B151 ϑ↑ ↑ TLimit = 80°C
a 4 sensor hot air
bl :BU a 5
B153
br :BN a 6 Leckage-Messfühler / leakage sensor
sw :BL a 7
c -X160 Mess-,Schutzwandler / measuring, protecting transformers
S1/k
br -T1.U:S1 a 1 Achtung! /
T1.U Phase U 2000 / 1 A
S2/l bl -T1.U:S2 a 2 Attention!
S1/k
br -T1.V:S1 a 3 Bei Auslieferung
T1.V
kurzgeschlossen. / Phase V 45 VA
S2/l bl -T1.V:S2 a 4
S1/k
br -T1.W:S1 a 5 Short-circuited
T1.W
bl a
Phase W Kl.0,5
S2/l -T1.W:S2 6 by delivery
c -X200 Stillstandsheizung / anti-condensation heater
d 1
230 V
E200
d 2 max. 3 A

Klemmenlegende / Kabelfarbe / cable- Verteiler

color Anschlussplan / connection diagramm
terminalcode 1,6,7,8,12
Typ/ Bezeichner Hersteller/ Abk.
manufacturer abbr. Farbe /
type
a-33
designation
264-711 WAGO br braun/brown
color
338-01-1
b-00 264-737 WAGO bl blau/blue Auftrag / Datum Name Blatt/page
order Anhaltische
c-06 249-116 WAGO sw schwarz/black Bearb. 07.03.03 Reimann 1 von/of 1 Elektromotorenwerk
d-04 264-731 WAGO Ers.f. Dessau GmbH