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2 Drawings
Dimension drawing alternator AZ 20666 Rev. F
Rotor drawing 83602 Rev. A
Generator Lifting Drawing T67M00300XY
Mounting Drawing 41699.81
3 Circuit Diagram
Circuit diagram K 850.3.261 Rev. A
Circuit diagram K 850.3.261 Z
Legend to circuit diagram K 850.3.261
4 Operating Instructions
Three-phase synchronous electrical machines series DIG 110...191
Enclosure to operating instructions
5 Regulator Descriptions
Voltage regulator Unitrol 1000-15
6 Rotor mounting/dismounting
Description
7 Bearings
RENK Sleeve Bearings: DE: EFNLB / NDE: EFNLQ
RENK Sleeve Bearings Type EF with self lubrication
Recommendation for Synthetic Lubricants for Sleeve Bearings –
Klüber Summit SH 46
Klüber Sales Offices worldwide
8 Spare Parts
Drawings 020, 3001ms, 400oRT, T67M00400XY, T67R00800XY
9 Technical Data
Technical Data
Data sheet for PT 100
EC declaration of conformity
Information to explosion protection device
Test report 8430417A101/B101/C101/D101/E101/F101
Ensure that all personnel operating, servicing, maintaining or Compruebe que todo el personal que utilice, inspeccione, realice
working near this equipment are wearing appropriate Personal tareas de mantenimiento, o trabaje en las proximidades de este
Protective Equipment (PPE) including eye and ear protection alternador lleve puesto el equipo de protección personal (EPP)
and are fully aware of the emergency procedures in case of adecuado, incluidas las protecciones de ojos y oídos, y que conozca
accidents. perfectamente los procedimientos de emergencia que deben
aplicarse en caso de accidente.
Before any maintenance work on the generator is carried out, Antes de llevar a cabo cualquier tarea de mantenimiento en el
please ensure it is isolated from any source of mechanical and alternador, verifique que esté aislado de cualquier fuente de energía
electrical energy. It is recommended that a suitable Lock-Out/ mecánica o eléctrica. Es recomendable adoptar un proceso de
Tag Out process is adopted. desactivación del equipo (Lock-Out/Tag-Out) adecuado.
Note: Before commencing any fault finding procedures Nota: Antes de iniciar cualquier procedimiento de localización de
examine all wiring for broken or loose connections. averías, compruebe el estado del cableado y las conexiones para
asegurarse de que no están sueltos ni rotos.
Caution: As the highly magnetic rotor will attract the stator Precaución: Como el rotor es altamente magnético y tenderá a atraer
core, care must be taken to avoid contact to avoid personal el núcleo del estátor, deberá procurar que no entren en contacto para
injury and potential damage the winding. evitar lesiones personales y posibles daños del devanado.
CAUTION Warning Labels: Warning labels are affixed to the Generator. Etiquetas de advertencia: Las etiquetas de advertencia están
These must not be removed. If removed during painting, it pegadas en el alternador. No se deben quitar. Si se quitan o se pinta
is the genset manufacturer’s responsibility to reaffix warning sobre ellas, es responsabilidad del fabricante del equipo electrógeno
symbols back onto the generator. volver a pegar símbolos de advertencia en el alternador.
Directives: EC Declaration of Conformity: Each generator is supplied Declaración de conformidad CE: Todo alternador se suministra
2004/108/EC Low Voltage Directive with an ‘EC Declaration of Conformity’ in accordance with con una “Declaración de conformidad CE” de acuerdo con las
2006/95/EC EMC Directive the relevant EU directives designed for incorporation into correspondientes directivas de la UE relativas a equipos diseñados
2006/42/EC Machinery Directive an electricity generating set and is CE marked. The stated para su incorporación a un grupo electrógeno, y con la marca CE.
Standards have been applied. Our authorized representative in El equipo cumple las normas indicadas. Nuestro representante
Standards: the Community is Mr Jeffrey Matthews, Director, Engineering, autorizado en la Comunidad Europea es Jeffrey Matthews, Director de
EN 61000-6-1:2007 Cummins Generator Technologies Ltd. Ingeniería de Cummins Generator Technologies Ltd.
EN 61000-6-2:2005
EN 61000-6-4:2007
EN ISO 12100-1:2003
EN ISO 12100-1:2003
EN ISO 14121-1:2007
EN 60034-1:2004
BS ISO 8528-3:2005
BS5000-3:2006
Accertarsi che tutto il personale in servizio, gli addetti Tout le personnel chargé de l’exploitation, de la
all’assistenza e alla manutenzione e tutti coloro che réparation ou de la maintenance de cet équipement, Alle Personen, die dieses Gerät bedienen, warten und
lavorano in prossimità del macchinario indossino gli ainsi que toute personne travaillant à proximité, doit instandhalten bzw. in dessen Nähe arbeiten, müssen
adeguati dispositivi di protezione individuale (DPI), incluso porter un équipement de protection individuelle (EPI) eine geeignete persönliche Schutzausrüstung (PSA),
protezioni per vista e udito, e che conoscano le procedure di adapté, notamment pour la protection des yeux et des einschließlich Augen- und Gehörschutz, tragen sowie
emergenza da seguire in caso di incidenti. di emergenza da oreilles, et avoir pleine connaissance des procédures die Notfallverfahren bei Unfällen kennen.
seguire in caso di incidenti. d’urgence à adopter en cas d’accidents.
Prima di effettuare le operazioni di manutenzione sul Avant toute intervention de maintenance sur Vor der Durchführung von Wartungsarbeiten am
generatore, assicurarsi che sia isolato da qualsiasi l’alternateur, celui-ci doit être isolé de toutes les Generator muss er von allen mechanischen und
fonte di energia meccanica o elettrica. Si raccomanda di sources d’énergie mécanique et électrique. Il est elektrischen Energiequellen getrennt werden. Die
adottare un’adeguata procedura di sicurezza di blocco e recommandé d’adopter une procédure de consignation/ Einführung eines geeigneten Einschaltsicherungs- und
segnalazione. déconsignation appropriée. Spannungsfreischaltungsverfahren wird empfohlen.
Les alternateurs émettent du bruit d’un niveau sonore Generatoren erzeugen Schall. Es muss zu jeder
I generatori emettono rumore. Assicurarsi di indossare
élevé. Une protection adéquate des oreilles doit être Zeit ein Gehörschutz getragen werden. A-bewertete
sempre le protezioni acustiche. I livelli di emissioni pesate
portée en toute circonstance. Le niveau de pression Schallpegel können einen Maximalwert von 104 dB (A)
possono raggiungere 104 db (A). Contattare il sito per
acoustique pondéré A peut atteindre 104 db (A). Pour erreichen. Anlagenspezifische Einzelheiten sind am
informazioni specifiche disponibili per l’applicazione.
des informations plus spécifiques, contactez le site. Einsatzstandort in Erfahrung zu bringen.
ATTENZIONE: non manipolare il PMG (Permanent Magnet AVERTISSEMENT: Ne manipulez pas l’excitatrice PMG VORSICHT! Personen, die Implantate, z.
Generator, generatore a magnete permanente) in caso di si vous portez un dispositif mécanique implanté tel B. Herzschrittmacher, tragen, dürfen keine
presenza di dispositivi impiantati, ad es. pacemaker. qu’un pacemaker. Dauermagnetgeneratoren handhaben.
Avviso: il rotore magnetico, molto potente, attrae il nucleo Attention: Le rotor étant hautement magnétisé, il attire Achtung! Da der stark magnetische Rotor den
dello statore; è necessario, pertanto, fare attenzione per fortement le paquet de tôles stator. Veillez donc à éviter Statorkern anzieht, ist Vorsicht geboten, damit die
evitare contatti che potrebbero danneggiare l’avvolgimento e tout contact entre les deux pour ne pas risquer de vous Wicklung nicht durch eine Berührung beschädigt und
causare lesioni personali. blesser ou d’endommager le bobinage. Verletzungen vermieden werden.
Dichiarazione di conformità CE: Ciascun generatore EG-Konformitätserklärung: Jeder Generator wird mit
Déclaration de conformité CE: Chaque alternateur
è marcato CE ed è corredato dalla “Dichiarazione di einer EG-Konformitätserklärung gemäß den geltenden
fourni est marqué CE et accompagné d’une déclaration
conformità CE” in conformità con le direttive europee EU-Richtlinien für den Einbau in einen Generatorsatz
de conformité aux directives européennes relatives à
applicabili nel settore dei gruppi elettrogeni. Gli standard für die Stromversorgung ausgeliefert und trägt das
l’incorporation dans un groupe électrogène. Il répond
menzionati sono stati applicati. Il nostro rappresentante CE-Kennzeichen. Die aufgeführten Normen wurden
aux normes indiquées. Notre représentant autorisé
autorizzato per la Comunità Europea è Jeffrey Matthews, angewendet. Unser in der Gemeinschaft ansässiger
est M. Jeffrey Matthews, directeur de l’ingénierie de
Direttore responsabile engineering, Cummins Generator Bevollmächtigter ist Herr Jeffrey Matthews, Director,
Cummins Generator Technologies Ltd.
Technologies Ltd. Engineering, Cummins Generator Technologies Ltd.
Any works on the generator has to be We particularly point out, that spare parts
performed by qualified and trained and additional parts not supplied by AvK,
personnel only. The necessary have to be accepted by AvK. AvK will
qualification can be obtained by training or exclude any liability for damages that
courses through the manufacturer. result from the use of spare and additional
Technicians can obtain a special parts that have not been accepted by AvK.
generator training at AvK Germany. The installation or use of foreign products
may possibly change the constructively
The installation should preferably be given design of the electric machine in a
performed by an AvK service technician or negative way, and may restrict the safety
by a specially trained qualified technician. of persons, machine or other values.
Unprotected machine parts may cause After completion of the maintenance work,
severe injuries. it must be ensured that all protection and
safety devices are back in place properly.
• The shipment and the unloading of the • Moving the machine over rough
generator must only be performed by ground e.g. rails, by using a haulage
personnel, who are familiar with the car is not permitted. This may cause
lifting cranes and corresponding damage to the bearings and the
devices. windings. This is especially important
for the moving of the machine within
• The lifting devices have to be designed the factory.
for the weight of the generator
(Chapter 3.4). 3.2 Packaging
• Follow the shipping instructions The material used for the packing of the
(pictographs) on the cover of the generator is made of ozone-friendly
generator. material – like wood. The packaging
depends on the mode of transport used –
• The generator must only be supported surface, water or air freight.
on its feet. The support on any other When the transport time is for a longer
part is not permitted. That is why the period, then the generator will be packed
generator is delivered with a in a protective covering against dust or
transportation construction. humidity.
• For the lifting of the generator, ring 3.3 Checking for Shipping Damage
bolts are mounted on the generator
housing. We recommend checking the
generator for shipping
Ring bolts, that are mounted damages and complete
on add-on pieces like e.g. the delivery by the time of
cooler top, must not be used delivery.
to lift the whole machine!
They are only used as mounting device If there are damages on the goods (open
for these add-ons. damages) report these to the haulage
contractor at take-over. In this case, the
• The ring bolts can only be used for the receipt should only be given under
transport of the separate machine, reservation with a written statement
they are not designed to lift the regarding the estimated amount of the
damage.
Cummins Generator Technologies Germany GmbH Page 5
POD-intro-AvK-eng-safetyprecautions.doc
If damages that were not noticeable by the
time of delivery (covered damages), are
detected later, they have to be reported
promptly to AvK, latest 6 days after receipt
of the delivery.
Customer: .............................................................
Sleeve bearing
YES NO
Replacement of oil:
YES NO
Bearing inspection performed:
I. Electrical Inspection
Environmental Conditions:
Operating Conditions:
Generator Conditions:
I. Electrical Inspection
performed Complaints
see page 11
performed Complaints
see page 11
............. V ............. A
performed Complaints
see page 11
YES NO
Oil lubrication system installed:
.................... mbar
.................... mbar
2.9 Check for any corrosion on drive side and non-drive side bearing
performed Complaints
see page 11
2.17 Check of inlet and outlet airducts for dust and dirt
performed Complaints
see page 11
Output: ............. kW
performed Complaints
see page 11
I1-I1': ............. A
I1-I1': ............. A
UH1-WH2: ............. V
WH1-WH2: ............. V
XE2
TO 109/110.1
performed Complaints
see page 11
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
Complaints:
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
________________________
(AvK-Service-Technician)
BALTIC STATES
DENMARK
FINLAND Fiona Barkhouse +44 (0) 1780 484742
FRANCE Richard Hardy Shay Binder +44 (0) 1780 484744
MARKON ITALY Tel +44 (0) 1780 484771 Bruno Labinjan +44 (0) 1780 484798
STAMFORD NORTH AFRICA Fax +44 (0) 1780 484104 Fax +44 (0) 1780 766074
AvK NORWAY Mobile +44 (0)7801 096641 Mobile +44 (0)771 8339215
SWEDEN email: richard.hardy@cummins.com email: parts.enquires@cummins.com
SWITZERLAND
RUSSIA
UK
Bernard Haje
GERMANY Anita Albrich
MARKON Tel +49 841 792 163
AUSTRIA Tel +49 841 791 192
STAMFORD Fax +49 841 791 195
HUNGARY Fax +49 841 791 103
AvK Mobile +49 171 937 0775
CZECH REPUBLIC email: anita.albrich@cummins.com
email: bernard.haje@cummins.com
Fiona Barkhouse
John Johnson
Tel +44 (0) 1780 484742
MARKON Tel +34 (0) 91-879 1277
SPAIN Fax +44 (0) 1780 766074
STAMFORD Fax +34 (0) 91- 879 1277
PORTUGAL Mobile +44(0)7718339215
AvK Mobile +34 (0)629-183 929
email:
email: john.h.johnson@cummins.com
fiona.barkhouse@cummins.com
Judy Smith
Americas Parts Team
NORTH AMERICA Louie Shar Toll Free Tel (USA and Central
MARKON SOUTH AMERICA Americas Service Team America) 1-800 367 2764 Ext. 5
STAMFORD MEXICO & Toll Free Tel (0) 800 367 2764 1 763 528 7301 Ext. 5
AvK CENTRAL AMERICA Toll Free Fax (0) 800 863 9234 Toll Free Fax (USA and Central
CANADA email: louie.shar@cummins.com America) 1-800 8963 9243
1763 574 5082
email: judy.a.smith@cummins.com
Theo Dragonas Theo Dragonas
MARKON AUSTRALIA Tel +61 (0) 296802299 Tel +61 (0) 296802299
STAMFORD NEW ZEALAND Fax +61 (0) 29680 1545 Fax +61 (0) 29680 1545
AvK SOUTH PACIFIC Mobile +61 (0) 412 886645 Mobile +61 (0) 412 886645
email: theo.dragonas@cummins.com email: theo.dragonas@cummins.com
V Devarajan V Devarajan
BANGLADESH
Tel. +912066246700 Tel. +912066246700
STAMFORD INDIA
Fax. +912066025331 Fax. +912066025331
AvK NEPAL
Mobile No. +91822395641 Mobile No. +91822395641
SRI LANKA
email: v.devarajan@cummins.com email: v.devarajan@cummins.com
Richard Lee Cynthia Chua (STAMFORD /
SINGAPORE Tel.+65 6305 3158 Ext 158 MARKON)
MALAYSIA Fax. +6563053151/2 Tel +65 6305 3169 Ext 169
PHILIPINES Mobile. +65 97595606 Fax. +65 6305 3151/2
MARKON
INDONESIA email: richard.lee@cummins.com email: cynthia.chua@cummins.com
STAMFORD
THAILANAD
AvK
VIETNAM Tay Chek Chuan Cyril Ee (AvK)
JAPAN Tel. +65 6305 3158 Ext 158 Tel: +65 6305 3156 Ext 156
KOREA Fax. +656305 3151/2 Fax. +65 6305 3151/2
Mobile: +6591137511 email: cyril.ee@cummins.com
email: chekchuan.tay@Cummins.com
Ryan Xie
Mike Tami (Japan) Tel: +65 6305 3172 Ext 172
Tel +81 (0) 3 5735 0852 Fax: +65 6305 3151/2
Fax. +81(0) 5735 0788 Mobile: +65 9712 2009
Mobile: +81 (0 )80 5075 2979 email: ryan.xie@cummins.com
email: mike.t.tami@cummins.com
Mike Tami (Japan)
Tel +81 (0) 3 5735 0852
Fax. +81(0) 5735 0788
Mobile: +81 (0) 80 5075 2979
email: mike.t.tami@cummins.com
Jason Xu (Wuxi / Jiangsu)
Jason Xu (Wuxi / Jiangsu)
Tel +86 510 8110 3027 or +86 510
+86 510 8110 3027 or +86 510 8110 Ext 3027
8110 Ext 3027
Fax. +86 510 8521 7673
Fax. +86 510 8521 7673
+86 510 8521 7603
or Fax: +86 510 8521 7603
MARKON Mobile: +86 139 5157 0763
Mobile: +86 139 5157 0763
STAMFORD CHINA email: jason.xu@cummins.com
email: jason.xu@cummins.com
AvK
Jianguo Xu
Jianguo Xu
Tel: +86 510 81103088
Tel: +86 510 81103088
Mobile +86 150 5221 9180
Mobile +86 150 5221 9180
email: jianguo.xu@cummins.com
email: jianguo.xu@cummins.com
Bernard Haje
Tel +49 841 792 163
Fax +49 841 791 195 Anita Albrich
ALL OTHER
Mobile +49 171 937 0775 Tel +49 841 791 192
AvK COUNTRIES
email: bernard.haje@cummins.com Fax +49 841 791 103
WORLDWIDE
email: anita.albrich@cummins.com
24 HOUR HELP DESK: +44 (0)1780 484732
Richard Hardy
Tel +44 (0) 1780 484771
Fax +44 (0) 1780 484104 Fiona Barkhouse
ALL OTHER Mobile +44 (0)7801 096641 Tel +44 (0) 1780 484742
MARKON
COUNTRIES email: service- Fax +44 (0) 1780 766074
STAMFORD
WORLDWIDE engineers@cumminsgeneratortechnologies.com Mobile +44 (0)7718339215
email: parts.enquires@cummins.com
24 HOUR HELP DESK: +44 (0)1780 484732
HEAD OFFICE: Cummins Generator Technologies Ltd ITALY Cummins Generator Technologies Italy s.r.l.
UK Barnack Road Via Carducci 125
Stamford Sesto San Giovanni
Lincolnshire PE9 2NB Milan – 20099
Tel: +44 (0) 1780 484000 Tel: +39 (0)2 380 00714
Fax: +44 (0) 1780 484100 Fax: +39 (0)2 380 03664
T32 Spannungswandler für G3 mit integriertem Voltage transformer for G3 with integrated
Schutzschalter F1 protection switch F1
F1 - NUR IM STILLSTAND EINSCHALTEN F1 - SWITCH ON ONLY AT STANDSTILL
V1 Rotierende Gleichrichter Rotating rectifiers
X1 Hauptklemmen Main terminals
X2 Klemmleiste für Regleranschluß Terminal strip for AVR connections
X4 Klemmleiste für Heizung, PT100 Terminal strip for heater, PT100
X5 Klemmleiste für Stromwandler Terminal strip for current transformers
ZUBEHÖR ACCESSORIES
Widerstandsthermometer PT100 Resistance Thermometer PT100
Statorwicklung Stator winding
A1 Phase U Phase U
A2 Phase V Phase V
A3 Phase W Phase W
A4 Phase U Phase U
A5 Phase V Phase V
A6 Phase W Phase W
A13 Lager, B-Seite Bearing, NDE
A15 Lager, A-Seite Bearing, DE
Lift the machine at the crane rings attached to the Clean rust and dirt off the bright metal surfaces
stator housing. Note that crane rings on attached and apply a protective lacquer coating. Make sure
components such as the cooler assembly must that the coating is not porous.
not be used to lift the complete machine. They are
intended only to simplify attachment of these • Bearings
components.
Sleeve bearings
In the case of complete machine sets on a base Drain the oil and apply a corrosion inhibitor to the
frame, use only the lifting facilities provided on the bearing, for instance Tectyl 511 M in the case of
base frame. The crane rings on the electrical ma- sleeve bearings lubricated with mineral oil. If the
chine itself are not rated for lifting the complete bearings are lubricated with a synthetic oil, make
machine set. sure that the bearing materials, the oil content and
the preserving agent are all compatible.
If transported over long distances, it is advisable
to protect the machine against environmental Ball and roller bearings
influences by sealing it in a plastic cover together To prevent brinelling marks caused by vibration
with a quantity of desiccant (moisture indicator), when at a standstill, bearings should either be
so that it remains dust-free and air-tight. pre-loaded with a transit keeper or the rotor
should be turned once a month to alter the posi-
Machines with plain or taper roller bearings, and tion of the balls or rollers. The bearing’s grease
machines in a single bearing design are supplied content should be increased to the maximum.
with shipping brace. This shipping brace should
never be removed until the machine has been set • Cooler
up in its future operating position on site. Install
the shipping brace again if the machine is, for Drain out the cooling water, clean the pipes, flush
instance, to be shipped on or stored as a separate through with clean water and dry the complete
unit after trials. cooler, using warm or pre-dried air.
For transport as a complete machine set, take the Check the efficacy of the protective treatment
necessary safety precautions, for instance support measures once a year. If ambient conditions are
the machine set on anti-vibration elements or particularly unfavourable, check at more frequent
attach transit keepers. intervals. If necessary, repeat the protective treat-
ment.
1.3
cleaning unit. Additives to dislodge grease can be Check the machine’s insulation resistance. If it is
used, provided that they have been checked for below the minimum value (see Chapter 1.12.1,
compatibility with the filter material. After cleaning, Insulation resistance), the machine must be dried
dry the filter elements and if necessary spray the out. The procedure is described in Chapter 1.18.,
with fresh oil. Drying out the machine.
Comply with all relevant environmental protec- • Shaft end, flange and bright metal areas
tion and safety regulations.
Remove the protective lacquer coating with a
Regular cleaning of the filter elements is still suitable solvent. Do not rub it off with emery cloth.
needed even if the electrical machine’s windings Comply with the relevant environmental protection
are protected against overheating by built-in tem- and safety regulations.
perature sensors. Careful attention to this point
will ensure that the machine always runs cool and • Bearings
reliably.
Sleeve bearings
Dismantle and clean the sleeve bearings. The
1.6 Preparations for starting up corrosion inhibiting agent must be removed. (this
is not necessary if Tectyl 511 M was used and the
Pull the protective lacquer coating off the end of
storage period was fairly short, provided that the
the shaft and the flange, or remove it with solvent.
bearing is then lubricated with mineral oil).
Never clean it off with emery cloth. Comply with
Fill the sleeve bearings with oil as stated on the
the relevant regulations on environmental protec-
lubrication plate and in the operating instructions.
tion and safety.
There is a threaded hole on the shaft, to which a
Ball and roller bearings
puller can be attached for installing and removing
Open the bearing housing and remove the addi-
discs or couplings. Hammering is not permitted,
tional quantity of grease which was previously
as this can damage the bearings. If the machine is
added to the bearings so that only the specified
delivered with shipping brace in position, remove
amount remains in the bearing (see chapter on
it.
renewing bearings and lubrication plate).
If the machine is of single bearing design, its rotor
is delivered attached to the shaft flange and the • Cooler
housing by a steel hoop to prevent axial dis-
placement and is located in position radially be- Add water to the cooling circuit and operate it in
tween the shaft and fan housing by an angle accordance with the cooler manufacturer’s operat-
bracket. Both these transit keepers (axial and ing and maintenance instructions.
radial) must be removed.
Make quite sure that the radial transit keepers are 1.7 Machine drive
removed from the gap only after the rotor has 1.7.1 Belt drive
been centred on the drive shaft flange. Failure to
do so can result in damage to the exciter machine If the machine is driven by a belt, the machine
and the NDS (Non-drive-side) bearing. must be ordered specifically with bearings and
bearing lubrication to match the higher loadings.
In the case of machines with a steel disc coupling, Most belt-driven machines have roller bearings on
the radial transit keepers are screws in the flange the input side.
bell. They must be removed after the machine has
been aligned and its position fixed in relation to The rotor must be ordered with balancing by
the drive input. solid key, and the grooved belt pulley must be
dynamically balanced on a smooth mandrel. The
belt must run smoothly, without jerking.
Cummins Generator Technologies Germany GmbH page 5 to 13
POD-geno-AvK-eng-DIG110191.doc
Desired balancing accuracy: ≤ Q 2,5 according to tolerances and clearances included with the ma-
German VDI 2060 standard. chine. For further instructions, see the chapter on
plain bearings.
When flat-type belts or V-belts which have already On machines with a steel disc coupling, radial
been in operation for a fairly long time are re- rotor alignment is by means of centering screws
moved for maintenance purposes, they must be inserted into the centering bell. These screws also
replaced by new ones (in case of hardening). act as transit keepers in a radial direction. They
replace the pressboard inserts otherwise placed in
Important: the air gap. Alignment is checked by measuring
Belts that are tensioned too tightly can put the the distance between the outer rim of the steel
bearings at risk. For this reason, establish the disc coupling and the machined inner diameter of
correct belt tension with the belt manufacturer the centering bell.
or the plant that supplied the machine, and In the case of single-bearing machines with a
have checks carried out on site. divide DS (drive side) end shield, accuracy of
alignment is checked by measuring the air gap.
Note that the rotary field also changes with a re- If current surges or vibration are to be expected,
versal in the direction of rotation. secure the cables with cable clips or racks. If the
plant is set up on flexible mountings, ensure ade-
If the machine is to be used in parallel operation, quate clack in the cables.
the sensing lead plug connections on the regula-
tor (U and W) must be changed over so that con-
nections U V W on the regulator again receive a
right-handed field. The rotary field will change at
the main terminals.
Before starting up any machine, measure the Secondary connections such as measuring con-
insulation resistance of the winding between nections to transformers and all connections to
phases (if the star point is separate) and between regulating, protection or interference suppression
phase and earth. All parts not subjected to the circuits, must be tested separately. Each of these
measuring voltage must be earthed. connections must be checked individually at the
terminal strip. This also register the insulation
When measuring the insulation resistance, all resistance of the terminal strip.
connections (main connection, measuring connec-
tion, connection to regulator and protection or Use a maximum test voltage of 500 V DC for all
suppression circuit) must be disconnected from secondary and measuring connections. Insulation
the winding. resistance should not fall below 5 MΩ.
On low-voltage machines with a nominal voltage The voltage regulator ensures that the voltage
below 1 kV, and in the rotor winding, insulation remains constant as the machine warms up to its
resistance should not be less than 5 MΩ at a normal operating temperature.
winding temperature of 25°C.
Reactive load distribution is determined by the Ensure that machine components which are
electrical machine’s voltage characteristic, accord- live during operation are at zero voltage (by
ing to load. earthing or disconnecting the wiring).
1.13 Interference suppression Apart from the bearings the dust filters (if in-
stalled) and the attached cooler, the machine
The machine comply with radio inteference re- requires no routine maintenance.
quirement "N" as stated in German VDE 0875.
Note that the standard of interference suppression If carbon brushes are installed on the machine in
is related to the quality of earthing. equipment designed to perform various monitoring
functions, they must be checked for wear at regu-
Disconnect suppressor capacitors, measuring lar intervals.
transformers and regulators during high-voltage
insulation tests or if insulation measuring equip- If the machine has add-on equipment, for example
ment is in use (if the test voltage reaches 80% of a cooler, the additional maintenance instructions
the factory’s test voltage). issued by the manufacturers of this equipment
must be complied with.
Re-greasing should be carried out with a grease Type Lubrication Re-lubrication intervals in
gun at the nipples provided on the machine. points* hours for machine running
Quantity in speed of:
A regulator is installed to control grease volume, g
bear-
Double bear-
750-900 min-1
1000-1200
1500-1800
Before re-greasing, clean the nipple so that
Single
-1
min-1
DIG
min
ing
ing
box.
Cable connection acc. to DIN 46200 Using the Protection switches Q1, F1, F2
Elastic parts, such as spring washers, can The purpose of these switches is to protect
be used in the electrical connection, the voltage transformers T24 (Q1) and the
however, only on one side of the clamped auxiliary exciter winding (F1, F2). In case of
conductor. If necessary, additional failure, these switches will lead to a quick
washers are to be used. The other side is de-excitation of the machine.
for current conduction, why only washers
or security locking plates of copper-zinc- These switches are not to be used for de-
alloys must be used. exciting the machine during operation or
maintenance!
By electrical connection with eyelet rings,
the eyelets have to be protected by
washers on both sides against bending. Open star point
Optimum maintenance and care for All brushes and holders must be checked
earthing brushes is the base for smallest for free movement. Blocked brushes may
brush wear. The maintenance of brushes lead to damage.
must take place after certain intervals that
depend on the alternators size as well as Worn out brushes must be renewed in
load and ambient conditions. time, so that damages at the contact
surface on the shaft can be avoided. New
Brushes are subject to wear and tear and earthing brushes do not need grind-in
must be cleaned by air (pressure or (other than slip rings).
suction) from time to time. Routine check
every 3 months is recommended by AvK to Using brushes bigger than the original size
ensure about operational behaviour and is only possible after agreement with the
suitable changing intervals. supplier.
Another possibility is that all bearings of the Control of the anti – condensation heater
NDE aggregate are insulated. should be done that the heater
Description
Insulation material:
pure magnesium oxide, highly compacted
Connection:
threaded bolt M4 with silicon insulated
cable
Tolerances
B 25-1
1
10
a
20
2*Ø7-200
20
3*Ø7-400
=
4*Ø7-600
20*3
5*Ø7-800
L
a
6*Ø7-1000
7*Ø7-1200
=
20
7
10
20 20
Microcellular rubber 10*3
28
glued at installation
1.5
20
R1
ax
10 = = 10
m
38
Product Release
Control: 5.001
Panel: 5.001
CMT1000: 5.000
®
UNITROL 1000 User Manual 3BHS262681 E80 Rev.- v
Terms and Abbreviations
AC Alternating Current
AIO Analog Input and Output
AUTO Automatic Voltage Regulation
(Auto Mode)
AVR Automatic Voltage Regulator
Bat Battery
CB Circuit Breaker
MAIN Main Channel in double channel systems.
REDUNDANT Redundant (Backup) Channel in double channel systems.
CT Current Transformer
DC Direct Current
DIO Digital Input and Output
DSP Digital Signal Processor: referred as the main controller of the
AVR, responsible of regulation, control and communication.
ESD Electrostatic Discharge
EXC Excitation
FCB Field Circuit Breaker
GEN Generator
GFR Ground Fault Relay (Rotor Ground Fault Protection)
HW Hardware
IGBT Insulated Gate Bipolar Transistor
MANUAL Field Current Regulation
(Manual Mode)
PC Personal Computer
PCB Printed Circuit Board
PDF Portable Document Format
PE Protective Earth (Protective Ground)
PF Power Factor
PPE Personal Protective Equipment
PS Power Supply
PT Potential Transformer
Q Reactive Power
SW Software
V/Hz Volt per Hertz (-Limiter)
VDC Voltage Droop Compensation
1.1 General
This advanced-design automatic voltage regulator is used for the excitation of indirectly
excited synchronous machines. This unit is only suitable for this area of application. The
regulator can also be switched over to function as a reactive power-, power factor- or field
current regulator.
SM = Synchronous Machine
Back-up Channel
E = Exciter
PMG = Permanent Magnet UNITROL 1000 UNITROL 1000
R R
Batt.
Generator
Optional:
- Power System Stabilizer (PSS)
SM E
- Synchronization unit
- Diode monitoring
- Changeover to a back-up unit.
- Others
UNITROL 1000
R
SM E
IMPORTANT!
When calling ABB, please leave your name, department and phone
number. This will allow the responsible ABB representative to call back
without delay.
ABB is constantly striving for the best product and service offerings for our
customers. Therefore ABB appreciates your valuable feedback or
suggestions for improvements of UNITROL products.
Please send your comments to "unitrol.feedback@ch.abb.com". Your
information will be forwarded to the responsible persons in order to improve
ABB’s future offerings.
2.1 General
Failure to comply with the safety instructions increases the risk of electric
shock and damage to the equipment. Third parties who approach the
installation are also at risk.
If the scheduled maintenance activities are performed only partially or not
at all, damage may occur with associated expensive repair costs.
2.4.1 General
Signal Word!
Symbol Situation – Type of Hazard Statement
Possible consequence – Consequence Statement
Essential safety measure – Avoidance Statement
DANGER!
This symbol indicates an imminent danger resulting from mechanical
forces or high voltage. Non-observance leads to life-threatening physical
injury or death.
WARNING!
CAUTION!
This symbol indicates a dangerous situation. Non-observance can lead
to physical injury or cause damage to the installation.
NOTICE!
This symbol emphasizes important information. Non-observance can
cause damage to the installation or to objects close to it.
IMPORTANT!
This symbol indicates useful information. Not to be used to indicate
dangerous situations.
2.5.2 Pacemaker
DANGER!
Electrical and magnetic fields.
The system can cause malfunction of pacemakers.
Avoid being close to the excitation system.
Sign Description
Signal word
DANGER
Situation
Hazardous voltage inside.
WARNING, electrical
WARNING This symbol indicates a possible dangerous situation
that could result in serious physical injury or death.
CAUTION, electrical
CAUTION This symbol indicates a possible dangerous situation
that could result in moderate physical injury. This signal
word can also be used for warnings related to
equipment damage.
3.1 General
3.2.1 Introduction
3.3 Hardware
Casing
The device is built into an aluminum casing with
cooling flanges. The connection terminals are
integrated into the front of the circuit boards,
which are arranged on top of one another.
Power electronics
The power part is fitted with an IGBT semi-
conductor. The average value of the output
voltage is always positive. The output is current-
limited and thus short-circuit-proof.
Control elements
The operating keys, the display and the sub-D
connector for the RS-232 interface are located
on the unit cover.
Installation
The site of installation must be dry and free of
Dimensions in mm dust.
/
- !
.*.
")
. 23/
0 " 1
$ 4
' (
-- '( .
*
The UN1000 device can be operated in different ways and from remote locations as
described in the rest of this section.
MAIN
The four-line display and the four keys are
Monitor sufficient to allow a complete operation.
Mode = Auto
Connected: 1
All settings can be carried out directly on the unit
without additional equipment:
• Configuration of inputs and outputs
OK • Parameter setting
• Display of important measuring values.
Parameter configuration and optimization can be done with the user-friendly software
CMT1000 for Microsoft Windows. The CMT1000 can be used to access the UN1000-15
by using a serial connection point-to-point via the RS-232 port or by using an additional
TCP/IP converter gateway, which allows access from remote locations. The connection
options to use CMT1000 are described in Chapter 3.3.9 - Communication ports.
The Remote Access feature allows device access and control from local or remote
locations by using MODBUS as application protocol. The communication can be
performed either via RS485 or TCP/IP using an external gateway over the RS-232 device
interface. More information about the connection possibilities can be found in Chapter
3.3.9 - Communication ports.
The Remote Access is fully interoperable with the CMT1000 software; both interfaces can
access and read from the device at the same moment and control permission (write
parameters) is handled automatically by the AVR microcontroller. The Remote Access
feature is described in detail in Chapter 3.4.9 - Remote Access.
The UN1000 can be controlled by means of digital and analog inputs and can therefore
set up several configurations to fulfill most target applications. All devices' terminals are
located in the Terminal Block of the UN1000-15 which is shown in Figure 3-1.
serial port
DGND
DGND
+Vdig
+Vdig
+Vref
+AI 1
+AI 2
-Vref
-AI 1
-AI 2
DI 5
DI 6
DI 7
DI 8
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
I M2 485 CAN
AGND
DIO 1
DIO 2
DIO 3
DIO 4
+Vdig
+Vdig
+Vref
AO 2
+AI 3
AO 1
-Vref
-AI 3
gnd
S1 S2 + - -
+
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 50 51 52 53 54 55
L1
UML2 L3 L1
U NET L3 NC +
Ie - L1(+)
U PWR
L2(-) L3 L1(+)
U AUX
L2(-) L3
1 2 3 4 5 46 7 8 49 10 11 12
4 13 14 15
4
J2 J4
RS-485 CAN
/
' )( ) & ' ( *
' )( ) & 2
' .2 )( ) , .' ( " %
* /
7 "5 +
+5 +
' ( 3
.'(
. * 8
/
=. 23/
.
+ 23/ /
. . +1
* * /.
6 , /*
0 " /2
. 7 . 0 "
1
+ =2
.
2 //
-
/ *
6 ' 0 (
.*. 8
*.
** "
" .*
*2 " < .2
" . "
*/ ) &
" "5 + ./
*6 ".
*7 ".
*3 ) & < ; 9
*8 ) , .6
+ .7
3 ) & + . .3 + ;
8 .8 +
"* ; :9 ) ,
. "* ; :9 + * *
"
. ) & < + 2 *
..
; 9
2 +5 +
2 ) ,
2. +/ 9
2* +6
+
22 ) ,
2/ +7
26 +3 :9
27 +5 +
Single-phase: Single-phase:
L1 = 1, L3 = 3 - Machine current IM2
" ! 9 )"
S1 = 16, S2 = 17 .
.
or >
Single-phase: -#
/
- Machine voltage UM
*
or
> # 9 / ) ! 9. )"
-#
Three-phase with ground /
1k
out
Digital outputs
DIO1 … DIO4
UN1000-15 External
24 V DC
Caution: +Vdig
Configured as outputs, DIO1
… DIO4 must not be in
connected directly with +Vdig
(causes short circuit via DIO
internal transistor)
out
1k
Note: The internal 24 V supply can be loaded with a maximum of 300 mA by all used
digital inputs and outputs.
External
UN1000-15
max. ±10 V
+AI + 100k
+
47k
-AI -
-
100k
47k
Shielded cable: - 55 2
CAN_L
2
2x 2x 0.34 mm , 120R 52 3
Impedance 120 , J4
CAN_SHIELD
+ 54 4
CAN_H
Length of cable < 30 m 5
CAN_POWER
Earth: = 52
3.3.5.1 Polarity
Polarity can be configured for all digital input/output ports (DIO) 1 to 4 separately, and
each one has a separate polarity configuration when configured as input or output. Each
DIO port can be configured as only input or only output at the same time.
24 V DC 24 V DC
inverted
DIO1 to 4 DIO1 to 4
DI5 to 8 DI5 to 8
normal DI9 to 14 DI9 to 14
Each digital input signal can be set to a predefined value (i.e. active/not active) by means
of configuration, without the need to make connections at the device's terminals; this
process is also known as forcing.
Forcing a digital input terminal can be done by configuring the Polarity parameter of an
input to Normal or Inverted. When Polarity is set to Normal, the digital input is set to not
active, i.e. false or logical 0. When it is set to Inverted, the input is set to active, i.e. true
or logic al 1. It is a must that the intended digital input, which is being configured, shall
not have connections at its device terminals. For more information about configuration
see Chapter 6 - Operation.
Note: When configuring an external setpoint from the analog input list shown above, the
"Remote SP Enable" digital input should be also configured. For more information see
Chapter 3.3.5 - Digital Inputs.
Setpoint min
Ext. Setpoint Auto
-10 10 [V]
Uin0% Uin100%
UM Aux [%]
Input to the summing 10
point max
Uin0% Analog in
-10 10 [V]
min Uin100%
-10
DI9 = 1
Aout [V]
10
Uout 100%
Fbias
Uout 0% Fbias
-10 10 [Hz]
Fbias 0% Fbias 100%
-10
Aout [V]
10
Uout 100%
PWM Output
Uout 0% PWM
100 [%]
-10
?> ?>
' ( ' #(
" @)C
Active Power
?
' #(
" : 4
. @?C
?
' (
" : 4 ?
' #(
Note: The full voltage range runs from –10 V to 10 V at a resolution of 10 bits.
The UN1000 has three main communication ports to share several features which can be
used in combination to cover the requirements of an application.
• RS-232 is a point-to-point interface that can be used to connect with a PC and is
used by the CMT1000 software to control the device. As an alternative, the
interface port can be connected via a TCP/IP gateway to create a multi-point
Ethernet network and allows the connection to both CMT1000 and Remote
Access.
• RS-485 is a multi-point interface that could be used for Remote Access or VDC;
only one feature can be used at the same time.
• CAN is a multi-point interface used to connect an UN1000-PM40 module and
uses the Double Channel feature; both cannot share the CAN bus and they are
only partially compatible to operate together in the same device.
This section describes the hardware and wiring requirements for the communication
interfaces. The software features that use these communication interfaces are explained
in Chapter 3.4 Software.
The UN1000 integrates a RS232 serial port with MODBUS capability to communicate
with the CMT1000 software and a remote terminal using Remote Access.
The serial RS232 port of UN1000 can be used to connect a PC, which runs a CMT1000
software (see Figure 3-2). If the application requires a TCP/IP connection or access from
remote locations, a TCP/IP gateway can be used to create a multi-point network (Modbus
TCP) as shown in Figure 3-3. The use of a TCP/IP gateway on the RS-232 interface is
further referred to as RS232 TCP/IP connection.
# D ,E *
D : .*.
' F F (
0
0 ! 5 4 $
D : .*. D 0 : -E
4 G
' F F ( ' F (
# ,E *
The RS232 TCP/IP connection allows the device to be monitored and controlled from a
remote location. It also offers the possibility to have max. one CMT1000 connection and
one Remote Control accessing the AVR at the same moment. This solution can be
suitable for applications that, for instance, require control or monitoring from remote
location, a custom control software, MODBUS TCP as communication interface or a
single CMT1000 software that accesses several AVRs. More information about these
software features and configuration can be found in Chapters 3.4.9 Remote Access and
6.4 PC Software tool.
The UN1000 serial cable provided by ABB (see Figure 3-4) should be connected in order
to use the CMT1000 software. The cable should be connected between the RS232 port
from the AVR and the serial port from the PC where the CMT1000 is installed (see Figure
3-2); USB to RS232 converters can be used on the PC side.
If the UN1000 serial cable provided from ABB is not available, a replacement cable can
be used as long as it fulfils the following requirements:
The TCP/IP gateway converts Modbus RTU to Modbus TCP data and vice versa. There
are several TCP/IP gateways available which can be used with UN1000. ABB have
tested the UN1000 operation with the NetBiter® Modbus RTU-TCP Gateway from
IntelliCom Innovation AB, Mgate MB3170 and Mgate MB3180 from MOXA.
The NetBiter® TCP/IP Gateway product datasheet and user manual can be found at the
manufacturer Internet address: http://www.netbiter.com. When using Mgate MB3170 or
MB3180 from MOXA, the Modbus TCP Exception capability should be enabled, the Initial
Delay 10 msec. and the Response Time-out 200 msec.
Other TCP/IP Gateways can be used whenever it fulfills the following requirements:
The UN1000 provides a RS485 interface for both VDC and Remote Access; however
only one should be activated and both can not use the bus simultaneously. If both
features are required and must be activated, the solution is the usage of Remote Access
over Modbus TCP (using a TCP/IP gateway) and VDC over RS485 (Figure 3-5). More
information about hardware connections over RS232 can be found in Chapter 3.3.9.1
RS232 interface.
D 0 '- E (
0 ! 5 4 $ 0 ! 5 4 $
)+0 : 23/
Figure 3-5 ABB solution if both Remote Access and VDC features are
required.
The electrical connections of the RS485 bus should be performed according to EIA485
standard specification. The 120 ohm resistor normally used to terminate a RS485 bus is
already included in UN1000 and should be used by placing a jumper bridge over the J2
terminals. The J2 location is shown in Chapter 3.3.2.4 Terminal block.
The cable shielding shall be grounded as closely as possible to the device's terminals as
shown in Figure 3-6.
23/ 0 "
,
/ / /. /* /2 //
=. =2
23/ 0 "
#9
*
E ,
E D
, 9
Figure 3-6 Shielding and wiring recommendation when using the RS-
485 interface.
When using Remote Access over the RS-485 bus, a jumper bridge over J2 terminals
should be placed whenever the AVR is located at the end of the bus. There should not be
any resistor placed externally, i.e. on the other terminals of the device, if a jumper bridge
over J2 is already being placed. The Remote Access software configuration is explained
in Chapter 3.4.9 Remote Access.
When configuring the RS485 interface for VDC, a jumper bridge should be placed over
the J2 terminals of each AVR located at the end of the bus; and it should be removed
from those not located at the end (see Figure 3-7). No resistor should be placed
externally, i.e. on the device's terminals, when the jumper bridge of the UN1000 is
already being used.
Figure 3-7 RS-485 wiring and jumper settings to use VDC on a set of four AVRs.
As shown in Figure 3-7 the topology of the bus should be as "one line" with two endings,
and not as a "star". The recommendations described in Chapter 3.3.9.2 RS485 interface
should be strictly followed. The total length of the cable from end-to-end should not
exceed 250 meters. The VDC feature operates only over RS485 and could not work
properly if there is any other device incompatibly connected to the same bus.
The VDC software should be configured in each device prior to use. The configuration is
described in Chapter 3.4.3 Voltage droop compensation (VDC).
A CAN interface is provided for both Double Channel (connection with a second channel)
and UN1000-PM; however both cannot use the bus simultaneously. As explained in
Chapter 3.4.8 - Double Channel (DCH), the DCH Supervision can be used together with
a UN1000-PM connected to the AVR since the CAN communication is not needed for the
operation of the monitoring functions. However, the remaining functions from Double
Channel are not compatible with the UN1000-PM. For more information see Chapter
3.4.8.5 - DCH communication: configuration and compatibility.
The CAN connections between UN1000-15 and UN1000-PM40 are indicated in Figure
3-8. For more information refer to the UN1000-PM40 User Manual.
Shielded cable: - 55 2
CAN_L
2
2x 2x 0.34 mm , 120R 52 3
Impedance 120 , J4
CAN_SHIELD
+ 54 4
CAN_H
Length of cable < 30 m 5
CAN_POWER
When using Double Channel, the CAN connections should be performed as shown in
(Figure 3-9). The cable used for the CAN communication shall be connected only
between the two channels, i.e. Main and Redundant, and not to any other device. To
properly terminate the bus, there should be one jumper bridge placed over the J4
terminals of each device.
The Double Channel is an optional feature that should be previously available in the
device (by password or product rubric), configured and the communication activated. For
more information refer to Chapter 3.4.8- Double Channel (DCH).
,
/ / /. /* /2 // / / /. /* /2 //
=. =2 =. =2
0 E 23/ 0 " 0 E . 23/ 0 "
0 " H 0 " H
0 " HA 0 " HA
E , E ,
+ D 0 E 0 " 0
3.4 Software
There is a bumpless changeover between all modes performed by the Channel Follow-up
function. For more information see Chapter 3.4.2 - Channel Follow-up. Tuning and other
parameters are described in Chapter 3.4.11 Description of parameters.
Note:
Current measurement for compensation /
droop
SM E
PF
MVar
SM E
Note:
No limiters are active as long as this
mode is active.
SM E
UNITROL 1000 offers a special feature called Voltage Droop Compensation or VDC. This
feature equally shares the amount of reactive power between generators connected in
parallel to the same bus (see Figure 3-10), by using the RS485 bus for communication
between AVRs. The wiring connections of the RS485 bus are explained in Chapter
3.3.9.2 RS485 interface.
During VDC mode all AVRs operate in Auto mode with a voltage droop control. Each
AVR has to be configured with a unique AVR-ID number which identifies itself among the
others on the bus. Each AVR sends the value of its own amount of reactive power over
the RS-485 bus, while the other AVRs take this information to calculate a common
average MVAR setpoint and compensate the effect of the voltage droop. The setpoints
are calculated to maintain the voltage level on the busbar at 100% (not adjustable).
" 1
23/
$
$
$ .
Figure 3-10 VDC application example of four machines and two nets.
The VDC software supports the network to be divided into smaller entities. Each AVR can
operate in one of two pre-determined island grids called Primary and Secondary Nets.
The Primary Net is selected by default if the Secondary is not configured.
When the Secondary Net is required, it should be configured using a digital input. This
input determines whether the AVR uses data for VDC calculation from the devices
configured in the Primary or Secondary Net. When the Secondary Net digital input is
active (logical high), the AVR is selected to operate in the Secondary Net and shares
reactive power between those from Secondary Net only; information from the Primary
Net's AVRs is ignored. On the other hand, if Secondary Net digital input is low or not
configured, the AVR operates in Primary Net and shares reactive power data only with
the others which operate in Primary Net as well.
Normally the digital input for Secondary Net is configured (appears in the DI port list) only
on the AVRs intended to operate in Primary and Secondary Net (see Figure 3-10). On
the other AVRs, the Secondary Net digital input is not normally configured in the DIO
section, which causes the parameter value to be internally assigned to logical zero;
therefore the device only operates in Primary Net.
3.4.3.1 Configuration
Important:
The Compensation Droop Kq shall be set at -5% (negative value) if VDC mode is used.
The AVR-ID number is used to identify the generator among the others and it should be
configured before using VDC. The AVR-ID shall be set as a number between 1 and 31
and it shall be a different number for each machine. In dual channel system, both AVRs
from the same machine (i.e. Main and Redundant) shall be configured with the same
AVR-ID number.
The Primary and Secondary Net ID numbers should be different from each other and
unique for each island grid.
3.4.3.2 Communication
The VDC communication refers to the data transmitted over the RS485 bus whereas the
VDC operating mode refers to whether this data is used for compensation of the reactive
power or not. The AVR enables the VDC communication (i.e. transmit data over the bus)
as soon as the "Gen CB Closed status" input is active (logical one) and VDC software is
available in the device; except during Standby or when Remote Access via the RS485 is
active. As long as the AVR is in Standby or Remote Access via RS485 is active, the VDC
communication is disabled and will not be transmitted over the bus. Once the VDC
communication is enabled, the data available on the bus is taken and used for the
regulation only when the AVR is switched to VDC operating mode (i.e. by VDC Enable
digital input).
The availability of the VDC communication disregarding the operation mode (even during
Excitation Off), allows the cabling connections and communication quality to be easily
tested. The testing is performed by forcing the "Gen CB Closed status" input signal and
monitoring the status of the communication using the VDC Monitor tool included in the
CMT1000. The VDC Monitor allows checking whether the cabling connections are ok or
not, but it does not distinguish if the VDC operating mode is enabled in the device or not;
this can be checked by connecting the CMT1000 or by Remote Access to each AVR. For
more information about VDC Monitor refer to Chapter 6.4.4.5 Communication Menu.
3.4.3.3 Activation
The VDC operation mode can be activated via a digital input (i.e. VDC Enable signal) or
Remote Access. For more information refer to Chapter 3.3.5 Digital Inputs, 3.4.9 Remote
Access and 6.4.4 Menu structure of CMT 1000.
(Optional)
The automatic synchronization of a synchronous machine with the Line is achieved using
the optional integrated synchronizing function. By setting few simple parameters,
UNITROL 1000 supplies the corresponding control signals for the speed governor and
closes the circuit breaker.
Analog speed correction Fbias is given out from the UNITROL 1000-15 analog output to
the speed governor control summing point (not as pulse). This signal represents the
difference of network NOMINAL and network ACTUAL frequency. The reference
(setpoint) value for the speed governor must be nominal (50 or 60 Hz) and the Fbias
given by UNITROL 1000 will drive the speed close to actual network frequency.
Note that the speed control is not with INC/DEC pulses, and that it is not possible to
derive such pulses from the Fbias signal. Also, the configuration possibilities of PTs
(machine/net) are very limited. Other functions, like dead bus synchronizing, etc. are also
missing. The circuit breaker closing command type is traditional with no specialties (for
one breaker).
UNET UN 1000-15
Setpoint fSP = fNom Synchrocheck
Command
CB
Fbias Sync
Speed Controller
Setpoint
UM
Regulator
T SM E
CAUTION!
Synchronization should never be performed by calculation only. All
measurements shall be confirmed on site before synchronization takes
place.
Power circuit breaker (CB) must not be closed unless both voltages
are at least approximately synchronous (coincident).
Otherwise, this may result in faults in line operation, loading of the
synchronous machine and, in extreme cases, damage to the
synchronous machine.
A separate synchrocheck relay must be used to secure the right
operation. For further information please contact ABB.
The values are obtained by the two measurement signals UNET and UM
• Voltage difference (amplitude)
• Slip (frequency difference)
• Phase-angle difference
The voltage matching function gives the adjusting value to the internal voltage regulator
and the frequency matching function sends the analog signal Fbias to the turbine
regulator.
The command to close the breaker (CB) is released if all conditions are fulfilled.
3.4.4.1 Configuration
-10.0
-1.00 -0.40 0
Maximum Minimum
Angle = 10 -10
0
20 -20
Max Delta Angle Max Delta Angle [deg] 40 -20 -40
[deg] 60 -60
80 -80
Tot CB CloseTime Time between closing command and closed breaker (see data
[ms] sheet of the breaker).
Angle Offset [deg] Phase correction factor between UM and UNET. Delta angle is
calculated as follows:
Delta Angle = PhaseNET – PhaseM + Angle Offset
Example
Situation: Due to a step-up transformer between machine and
grid, UNET is delayed 30º with respect to UM.
Correction needed: Angle Offset = + 30º (positive).
SYNC When set to False (default), this enables the monitoring of Gen
DisableCBCheck CB Closed Status input during Synchronization (only): if Gen CB
[True / False] Closed Status is active, Voltage Matching is not performed.
When set to True, this disables the monitoring of Gen CB Closed
Status during Synchronization (only): Voltage Matching is
performed disregarding the Gen CB Closed Status input (not
recommended in most applications).
Important: Leave this parameter in False for backwards
compatibility with releases 4.401 or earlier.
IMPORTANT!
After the power circuit breaker has been closed, the Synchronize
command must be deactivated.
The setpoint of the speed controller must have the nominal value of 50
resp. 60 Hz for the synchronization.
Examples
@?C "
Voltage matcher
#
3.4.4.2 Activation
The Synchronization can be activated via digital input or Remote Access. For more
information refer to Chapter 3.3.5 Digital Inputs, Chapter 3.4.9 Remote Access and 6.4.4
Menu structure of CMT 1000.
The Synchronization and Voltage Matching are features that are activated using the
same activation signal, called Synchronize. When the Synchronization SW is not
available in the AVR (i.e. blocked), only Voltage Matching will be activated when
Synchronize digital input is set to high. On the other hand, when Synchronization SW is
available (i.e. unblocked in the SW Options section of the CMT1000), Synchronize input
will fully activate the Synchronization feature, which also includes the capability of voltage
matching and the Fbias output. For more information about Voltage Matching see
Chapter 3.4.5 Voltage matching (VM).
Voltage Matching is a function from the Synchronization software (Chapter 3.4.4) but
included in the AVR basic software package. When Voltage Matching is activated, the
generator voltage setpoint is adjusted to match UGEN with UNET, also during
Synchronization; however there is no Fbias output. More information about Voltage
Matching can be found in Chapter 3.4.4 - Synchronization (SYNC).
3.4.5.1 Activation
The Synchronization and Voltage Matching are features that are activated using the
same activation signal, called Synchronize. When the Synchronization SW is not
available in the AVR (i.e. blocked), only Voltage Matching will be activated when
Synchronize digital input is set to high. On the other hand, when Synchronization SW is
available (i.e. unblocked in the SW Options section of the CMT1000), Synchronize input
will fully activate the Synchronization feature, which includes also the capability of voltage
matching and the Fbias output.
(Optional)
Regulator
Ie
RDM parameters
The device evaluates the alternating current induced in the field circuit of the exciter in
the event of a fault in the rotating rectifier.
The ALARM is triggered in the event of a broken branch in the rotating exciter.
The TRIP is triggered in the event of a branch short-circuit in the rotating exciter.
(Optional)
The PSS is used to improve the damping of possible oscillations in large transmission
networks by adding a signal to the voltage regulator of the existing excitation system.
It is also used to attenuate local rotor oscillations in synchronous generators through
additional influencing of the excitation. The main application is in excitation systems in
single or multi-machine power plants.
• Local oscillations between a unit and the rest of the generating station and
between the latter and the rest of the power system. Their frequencies typically
range from 0.8 to 2.0 Hz.
• Inter-plant oscillations between two electrically close generation plants.
Frequencies may vary from 1 to 2 Hz.
• Inter-area oscillations between two major groups of generation plants.
Frequencies are in a typical range of 0.2 to 0.8 Hz.
• Global oscillation characterized by a common in-phase oscillation of all
generators as found on an isolated system. The frequency of such a global mode
is typically under 0.2 Hz.
The IEEE Std. 421.5-1995 PSS 2A/2B type model functionally represents the PSS. This
model is shown in Figure 3-13.
The object of power system stabilizing (PSS) equipment is to increase the generator
exciter‘s contribution to improving the stability to the highest possible operating range of
the generator. The PSS derives additional signals from the generator internal frequency,
which considerably improves the stability of the power transmission.
Figure 3-14 shows a simplified diagram of the PSS and related functions
PSS MAX
KS3
Frequency
UM Calc
f
PSS
UM Power
IM2 Calc
Pe
Due to the PSS function implementation and structure of UNITROL 1000 AVR, there are
some points to be noticed when using this PSS. The following elements limit the
maximum performance of the PSS:
PSS Parameters
The PSS function can be activated by the PSS_SELECT configuration, if the PSS feature
is available.
The parameters are not explained here. They can be calculated by ABB Switzerland. For
further information please see the Functional Description of UNITROL 1000, Power
System Stabilizer, and document number 3BHS213239 E01.
(Optional)
The Double Channel (DCH) is an optional feature which integrates supervision functions
and redundant channel support to build robust and flexible double channel systems.
3.4.8.1 Overview
The Double Channel feature has the following main components (Figure 3-15):
1. DCH Supervision
The Double Channel Supervision is a feature with 12 monitoring functions that
can be used to trigger an Alarm and/or a Trip outputs from the AVR. The
configuration is performed using a so called Configuration Matrix.
In addition to the configuration of the 12 monitoring functions defined within the
Double Channel SW scope, the Configuration Matrix allows Alarm and Trip to be
triggered from five other monitoring functions, e.g. Diode Monitoring. The flexibility
to combine multiple statuses in one or two signals like Alarm and Trip can be used
to save the number of digital outputs necessary to indicate a problem in the AVR.
The features included in the Redundant Channel support (channel changeover, follow-up
and communication) are in operation and active as long the DCH CAN communication is
enabled and error-free. However, DCH Supervision can be used disregarding of the
existence of a second channel, and therefore, suitable also for single channel
applications. DCH Supervision does not depend of the DCH CAN communication.
The Double Channel software must be available in the AVR (i.e. unblocked) before the
use of DCH Supervision and/or functions from Redundant Channel support. Otherwise
the configuration is not possible and Alarm, Trip and Changeover digital output are
unconditionally set to logical zero (i.e. not active). The schema in Figure 3-15 shows the
relationship between the main functions described.
+0 A :
0 &, #
' E(
+0 A
, .
I *
' .(
9 9
,
9 9
9 9
"
E
I
'/( 6
D$
&,
+
D$
" &,
0 E
0 E 0 E , :
+0 A I 4 'D G E 4 (
+0 A 0
. 90 E "
. 90 E 0 E
+
0 E , : 4 E :
0 9 ,
+0 A 0 " & 4
;
J
E
E D $ +0 A 0
I 4 &
The DCH Supervision has a total of 17 status signals from different monitoring functions
which can be configured to generate a (global) Alarm and/or a (global) Trip. As shown in
Figure 3-16, Alarm and Trip status signals are configured by a so called Configuration
Matrix. Alarm and Trip are independent from each other and they can be configured
different.
The Configuration Matrix allows the user to select which monitoring function will produce
an Alarm and/or a Trip at the output of the Supervision function. For instance, as soon a
monitoring function, which is configured to produce an Alarm, report a failure, the Alarm
status at the output of the Configuration Matrix will be set to active (logical true). The
same could happen to the Trip status if the monitoring function is configured to produce a
Trip. The configuration of Alarm and Trip are handled independent from each other and
therefore it provides great flexibility when engineering a project specific system.
Each monitoring function that can be configured in the Configuration Matrix, has a status
which is used to detect the failure and then, to trigger Alarm and/or Trip according to the
configuration. The status from each monitoring function is implemented with a latch
memory, which makes the value remaining as active (logical true) even after the failure
have been diminished and the monitoring function reports no failure anymore. Therefore,
it is possible to determine which monitoring function cause an Alarm or Trip even after
de-excite the machine. The latch memory of all monitoring function statuses can be
cleared by the digital input "Reset Alarm" (only if the failure has been already diminished)
or by powering off the device (Figure 3-16).
+0 A :
0 &, #
' E(
+0 A
, .
I
' .( *
9 9
,
E 9 9
I
'/( 9 9
"
6 " " $ D
$ D & &,
' , ( E 7 E & , E
E $ 4 E E 0 E D$
& E ,&
$ && , 9
D$
- E , E &,
+
4 E , , D$
' , ( " &,
Both Alarm and Trip statuses are the outputs from the Configuration Matrix and they can
be monitored using the CMT1000 and Remote Access. Alarm and Trip Status can be
configured as digital outputs (DO), however as shown in Figure 3-16 they are not directly
connected to the output but to the Standby Configuration boxes. The Standby
Configuration boxes, shown in Figure 3-16, prevent Alarm and Trip to output their status
values to the DO port during Standby mode; and this function can be used to prevent
undesired alarms as long as the Channel is in Standby. When the Standby Configuration
blocks the status of Alarm and/or Trip, the value transferred to the DO port is logical zero.
A list with all the DCH monitoring functions (12) is shown in Table 3-1. Following, Table
3-2 shows the 5 status signals from other UN1000 functions which can also be
configured with the Configuration Matrix.
Detection
Status signal Description
time
1. SW-Alarm DSP Watchdog failure. -
MODBUS Comm. Alarm
Supervision of MODBUS keep alive Remote
2. On CMT1000: "Loss of 1 sec.
Access feature.
Remote Control".
3. FCB Alarm Supervision of field current breaker. 1 sec.
Rotating diode monitoring alarm.
4. Diode Alarm 1 sec.
Requires RDM software (optional).
Supervision of diode monitoring trip status.
5. Diode Trip 1 sec.
Requires RDM software (optional).
Table 3-2 Other function statuses that can be configured with the
Configuration Matrix.
As shown in Figure 3-17, the Changeover status is the output of the AND-gate which
depends on the Alarm and Trip Status from the current channel, Alarm and Trip Status
from the Second Channel and the DCH Communication Status which is an indication of
the communication quality between both channels.
The DCH Communication refers to the data transmitted over CAN between the two
channels, and it contains setpoint information, measurements, status signals (including
Alarm and Trip) and others. The status of this communication is logical one (good) when
data coming from Double Channel feature is received well and free of errors (CRC
check). On the other hand, the Communication Status is logical zero (bad) when the data
received had errors, the communication is not enabled (no data received) and/or the
configuration is not set properly. Alarm and Trip from the Second Channel should be
configured using the DCH Supervision in the other channel.
To increase the flexibility, the Changeover dependency on Alarm and Trip status is
configurable; i.e. checkboxes allowing to configure whether these signals are part of the
AND and OR gate inputs of the logic decision (Figure 3-17). Each checkbox output is
determined according to the rules shown in Figure 3-18. An important setting is the
checkbox connected to the DCH Communication Status, which additionally lets the signal
pass through until the input of the AND gate. It also enables the DCH Communication
over CAN. The DCH Communication should be enabled to use the Changeover
functionality; otherwise the Changeover Status will be zero all the time (see Figure 3-17
and Figure 3-18).
The decision logic from Figure 3-17 shows that once the DCH Communication is
enabled, the dependency of Changeover Status is defined according to the checkbox
configuration and the Alarm and Trip status from both channels. When, for instance, the
checkboxes are configured according to Figure 3-17, the Changeover Status will be
logical one when: the Trip Status from the current channel is equal to one, the Trip Status
from the Second Channel is equal to zero (i.e. no trip in the Second Channel and it is
ready to takeover) and the Communication Status is equal to one (data from the Second
Channel is being received correctly).
The Changeover status value is latched (retains the value) when the AND gate output
changes from zero-to-one. The latched value may be cleared (to zero) using the Reset
command only if the output of the AND gate is already zero as well.
The Changeover status can be assigned to a digital output signal from the AVR. When
compared with Alarm and Trip DO signals, the DO assigned for Changeover always
outputs the Changeover Status disregarding whether the channel is Standby or Active;
for Changeover DO, this cannot be configured as it is for Alarm and Trip.
0 E , : ,
"
. 90 E " +
" + 4 E :
. 90 E
4 E : E
+0 A 0 9 4 E , & B
' , (
- D +0 A 0
0 ' B ( E E
4 E
4 E : $ & E
" + B 9
+0 A 0 " & 4
J
E
0
. 90 E J
J 4 D : D & +0 A 0 9
& +0 A I 4 D & +0 A 0 9
& G K B '9 9D K $ (9
" ' , (
0 E G D # & +0 A
" + " +
' D ( ' D (
+0 A +0 A
J J
0 0
The Changeover output is intended to be used together with the Standby input, in order
to activate the Redundant channel and deactivate the Main one. The Standby status can
be set via Remote Access or via a digital input (common case). Figure 3-19 shows a
typical example for the use of Changeover output to set the Redundant Channel to
Standby or Active mode. As also shown in Figure 3-19, the ResetAlarm input is normally
used to clear the latch memory of Changeover output and bring the Main Channel back
to Active (and the Redundant back to Standby) once the failure has been diminished or
fixed.
0 E 0 E
+ 4 E : + D$
+ D$
+ " + "
0 " &
The DCH Follow-up is an automatic function that runs in the Standby channel, following
the actual setpoint used by the Active channel, in order to perform a bumpless transfer
during changeover. The DCH Follow-up is different from Channel Follow-up, which is
used to have bumpless between operating modes within the same Channel and could be
also used on systems without Double Channel software support. For more information
about Channel Follow-up see Chapter 3.4.2 - Channel Follow-up.
The DCH Follow-up uses the setpoint information from the Active channel over the CAN
interface. During DCH software operation, the Active channel sends the setpoints of the
current operation mode and the one for Manual mode through the CAN interface. These
two values are setpoints delayed and calculated out from the measurements of the Active
channel; the delaying method minimizes the influence of failures on the setpoint
calculation (e.g. wrong measurement due to PT failure) and improves the bumpless
characteristic at the moment of changeover.
At the moment of changeover, the Standby channel decides whether to take the setpoint
from the Active channel (over the CAN interface) or from its current measurements,
before goes to Active. The decision depends on the operation mode of both channels
according to the following:
• If operation modes on both channels are the same (except OpenLoop), the
setpoint is taken from the Active channel, i.e. delayed setpoint over CAN.
• If Standby channel has Manual mode enabled, the setpoint is taken from the
Active channel, i.e. delayed setpoint over CAN.
• If Standby channel has Open Loop mode enabled, the setpoint after changeover
is set to zero.
• For all other possibilities not described above, the setpoint will be calculated from
the current measurements of the Standby channel; i.e. not from CAN. Under
these conditions, the setpoint is calculated based on delayed measurements from
the own channel; the delaying method minimize the influence of failures on the
setpoint calculation and improves the bumpless characteristic.
Mode Auto
Manual SP
Calculated Calculated
Sync Auto SP of from from
of Active SP = 0%
VDC Active AVR Standby AVR Standby AVR
AVR
Measurements Measurements
Active Manual Calculated
Manual SP
Calculated Calculated
from from from
of Active SP = 0%
Standby AVR Standby AVR Standby AVR
AVR
Measurements Measurements Measurements
AVR PF Calculated
Manual SP
Calculated
from PF SP of from
of Active SP = 0%
Standby AVR Active AVR Standby AVR
AVR
Measurements Measurements
VAR Calculated Calculated
Manual SP
from from VAR SP of
of Active SP = 0%
Standby AVR Standby AVR Active AVR
AVR
Measurements Measurements
Openloop Calculated Calculated Calculated
Manual SP
from from from
of Active SP = 0%
Standby AVR Standby AVR Standby AVR
AVR
Measurements Measurements Measurements
Table 3-3 Setpoint follow-up logic Note: SP = Setpoint.
The grey boxes show the setpoint follow-up taken from the CAN Interface (more reliable)
Limitations
DCH Follow-up is not supported during synchronization. If a double channel system is
engineered, the option Synchronization should be available only from one channel.
Remote Setpoint via analog inputs should be avoided when using any feature from
Redundant Channel support since it influences on the DCH Follow-up functionality, and
as a result, the latter could not work properly.
Activation
DCH Follow-up is automatically activated as long the channel is in Standby mode, DCH
CAN communication is enabled and error-free and DCH software is available (un-
blocked). If those conditions are not fulfilled and the channel is set to Standby, the DCH
Follow-up will not be activated. Instead the Channel Follow-up will be activated. For
more information about Channel Follow-up refer to Chapter 3.4.2 - Channel Follow-up.
The Double Channel software is only partially compatible with the UN1000-PM40
module. The DCH Supervision can be used together with UN1000-PM40, because it
does not depend on the CAN communication status and activation. However, a PM40
module cannot be used in the same device, where Changeover and/or DCH Follow-up
features are also required. Even whenever DCH Communication can be enabled, the
operation of the UN1000-PM40 has a higher priority and the DCH data transmission will
be stopped as soon as the AVR detects an UN1000-PM40 on the CAN bus. This priority
order is fixed in the AVR and not configurable.
Even without functions from Redundant Channel support, a double channel system with
UN1000-PM40 can be built using analog and digital inputs and outputs as communication
interface between the AVRs. Furthermore, Alarm and Trip output signals from DCH
Supervision could be used to extend the functionality to some extent.
The AVR-ID should be configured with the same number in both channels. One channel
should be configured as Main and the other as Redundant. The channel identification can
be configured using the CMT1000 or Remote Access. Only one channel should be Active
while the other is Standby. The use of interlocked contacts (connected externally) is a
recommended practice to assure this situation. The Standby/Active status of both
channels can be monitored using the CMT1000. For more information refer to Chapter
6.4 PC Software tool.
A redundant system with no Double Channel software can be built using analog and
digital inputs and outputs as communication interface between the AVRs. However, due
to the limited number of DO ports in each AVR, it could be possible that there are not
enough digital outputs to use all functions required by an application (e.g. diode
monitoring alarm, etc.).
In case of a failure in
channel 1, the back-up
channel is activated 1 G E
and the defective /! /!.
channel goes off.
Changeover to , ,
channel 1 can be
controlled by an alarm
-
signal or with an
" D$
external control signal.
Remote Access is a feature that allows monitoring and control of the AVR using the
MODBUS protocol. It can be suitable for applications where the control from remote
locations is preferred (i.e. offshore) and/or a custom user interface is required.
The following sections explain the Remote Access software and configuration. The
electrical connections are described in Chapter 3.3.9 Communication ports. It is
recommended to read Chapter 3.4.10 Access Levels prior to this section, in order to fully
understand the software capabilities.
3.4.9.1 Overview
A remote terminal configured as MODBUS master can access the device through RS485
or Ethernet TCP/IP (via RS232) using Remote Access. The communication choice is up
to the application requirements but since VDC needs a dedicated RS485 connection,
Ethernet TCP/IP is then the only choice when VDC is used. When VDC is not needed,
Remote Access can be performed using the RS485 interface. More information about
the communication interfaces can be found in 3.3.9 Communication ports.
The Remote Access allows the user to read and write registers (measurements, setpoint
and other information) from the AVR. The document that describes the MODBUS
Registers Table is normally inside the CD-ROM that comes with new devices. It can also
be ordered from ABB. The manufacturer details and contact information can be found in
Chapter 1.4 - Manufacturer’s Address.
The feature supports up to one MODBUS remote terminal and it must be assured that
requests are sent from only one remote terminal using the same communication interface
(RS485 or Ethernet TCP/IP). If more than one request comes from different interfaces,
they might be answered via the same interface from where they come. This method is
however not recommended and should not be used.
In order to communicate with the device, the remote terminal should gain a determined
access level in the AVR according to the operation desired: Monitor Access for reading
only and Control Access for reading and writing to registers. More information about
Access Levels can be found in Chapter 3.4.10 - Access Levels.
3.4.9.2 Compatibility
The Remote Access feature over RS485 cannot be used together with VDC. If both
Remote Access and VDC are required, Remote Access should be used via TCP/IP using
an external gateway. When VDC mode is not required, Remote Access can be used via
either RS485 or Ethernet. For more information see Chapter 3.3.9 - Communication
ports.
3.4.9.3 Configuration
Remote Access over RS485 has a number of parameters that should be configured:
Protocol (Modbus RTU or TCP), Activation (of the feature over RS485), Baud Rate,
Answer delay and others shown in Chapter 6.4.4.5 Communication Menu.
When using Remote Access over Ethernet, the protocol used between the RS232 port
and the TCP/IP gateway is Modbus RTU; which is fixed and not configurable in the AVR.
Additionally, Remote Access through RS232 is always activated (i.e. there is no
activation parameter) and it uses the following communication settings, which are fixed
and not configurable in the AVR:
• Protocol: Modbus RTU
• Baud rate: 57600 bps
• Character format: No Parity
• Stop Bits: 1
The Modbus Slave ID value is used for both Remote Access over RS485 and RS232
(and TCP/IP); there is no differentiation of the physical interface. This number can be
configured between 1 and 247; the latter being the default value. A restriction applies
when the number is configured between 1 and 63 (except 32) and matches with the
Modbus Slave ID used for communication with the CMT1000; in these situations, the
AVR will change the Remote Access Slave ID to 247 upon restart. The Modbus Slave-ID
for Remote Access can be configured between 64 and 247 without restrictions; being the
range, the recommended for most applications.
The Modbus ID used for CMT1000 access is a number between 1 and 63, which
depends on the AVR-ID and the Channel Identification (Main or Redundant), even if
Double Channel feature is not being used. When the parameterization is done using the
CMT1000, the Modbus ID used for CMT1000 is shown in the MODBUS Supervision
window. This number should not be used as Modbus Slave ID for Remote Access. For
further information refer to Chapter 6.4.4.5 Communication Menu.
The UN1000 device can be accessed from three different operators: front Panel,
CMT1000 or Remote Access. While all operators can read data simultaneously, only one
of them can have control access and is allowed to write or change parameters in the
AVR. This concurrence is managed in the AVR main controller by assigning, to each
operator, a determined Access Level or privilege:
• Offline or disconnected (no access)
When the status of an operator is Offline, the AVR microcontroller considers the
operator as not connected to the UN1000 and, therefore, there is mainly no data
exchange with the AVR. Only when using the CMT1000 as operator and the
presence of a compatible AVR is detected, a small quantity of data is exchanged to
provide and display the AVR-ID information on the main window of the software.
• Monitor (read access)
When an operator has Monitor Access, it is only possible to read data from the
device (i.e. measurements, parameters, etc.); and data cannot be changed or
modified in the AVR during this access mode. All the operators, i.e. Panel,
CMT1000 and Remote Access, can have Monitor access to the AVR at the same
time; all of them can read simultaneously from the same AVR.
• Control (read and write, full access)
If an operator has Control Access, this means that it has full control of the device
(write and read data). All operators are able to request Control access, but the
access will be granted to only one at the same time, based on the operator's
priority. The operator's priority is explained later in this section.
The Access Level status of each operator is stored in the AVR main controller and used
to grant and deny access requests. An operator can request the change of its Access
level to the AVR main controller, i.e. from Monitor to Control. Access changes to Monitor
are normally granted without restrictions since all sources can read simultaneously from
the AVR. Access changes to Monitor and/or Control are granted based on the following
operators' priority:
• Panel / CMT1000 access (highest priority)
The Panel and CMT1000 priority access are not differentiated from each other
since only one of them can be physically connected to the same AVR at the same
time. Whenever the CMT1000 or the Panel requests an access change to Control,
the change is granted disregarding the status of other sources (i.e. Remote
Access). If the Access status of Remote Access is Control at the time of the
request, it will be immediately changed to Monitor after the user confirms the action
from the Panel keypad. Remote Access can detect the change by reading back its
access status from the AVR.
• Remote Access (lowest priority)
Remote Access has the lowest priority during Access Level changes; a change to
Control is only granted when neither the Panel nor the CMT1000 have Control
Access to the AVR controller.
An Access Level changing request can be denied when more than one CMT1000 and/or
more than one Remote Access are trying to establish a connection to the same AVR. The
UN1000 supports a simultaneous connection of one CMT1000 and one Remote Access
per device (maximum). When those limitations are surpassed, one or all operators
connected can lose their accesses and go Offline; this practice is not recommended by
ABB. The method to change Access Levels from Panel, CMT1000 and Remote Access
are explained in the following sections. For more details about UN1000 user interfaces
refer to Chapter 6 - Operation.
3.4.10.1 Panel
The Panel has Offline status as long as the communication with the main AVR is not
established or if another device is connected to the RS232 port (PC or a TCP/IP
Gateway). If there is no other device connected to the RS232 port and the
communication between Panel and the AVR main controller has just been established,
the Panel has Monitor Access and it remains in this access level as long as the user does
not modify any parameters using the keyboard. When a parameter is changed, the Panel
automatically requests Control Access, changes the parameter's value and then,
requests the change back to Monitor; the process may ask for a confirmation from the
user only if a remote terminal has Control Access to the AVR.
3.4.10.2 CMT1000
The CMT1000 manages the Access changing requests: Offline, Monitor and Control by
using a graphic slide-bar displayed in the software's main window. The slide-bar shows
the CMT1000 current access status from the AVR and allows the user to simply change it
by sliding up and down. For more information about the user interfaces see Chapter 6 -
Operation.
IMPORTANT!
If there is a block transformer with any circuit configuration between
PTGEN and PTNET, the phase shift must be compensated. The phase can
be compensated as described in Chapter 3.4.4 Synchronization (SYNC).
Excitation ON Input
1s
Close FCB Command Output
1s
Open FCB Command Output
PWM-Control
Machine voltage
- Off Level Off Level [%] [%]
Signal field flashing
Setting the Off Level to 0% disables field Field flashing off level
flashing. Soft start level
[s]
Excitation ON
5 0 1 0 :
,, $ E &
Note: Soft Start is available only in Auto mode.
3.4.11.5 Limiters
V/Hz Limiter E : ,
@?C
- V/Hz knee point fknee [Hz]
frequency
- Slope Slope [%]
@AB C
&G
UM2
MOTOR
Xq
IM Limiter
- Limiting value of the maximum machine current Maximum [%]
- Time Multiplier according to IEC 60255-3, Table 1,
Col. B, very inversed characteristic Time Multiplier K
- Limiter active Maximum Active = True/False
Boost = 0 1 0
Voltage Relay= 1 0 1 0 1
IM Limiter
E
@?C
T1 at Max IM T1 [°]
T2 at IM th2 T2 [°] #
T3 at IM th3 T3 [°] HE. .
T4 at IM = 0 A T4 [°] HE* *
Machine current level IM th2[%] ./
Machine current level IM th3[%] 2 0 , 9
. 2 . * 2 @LC
Ie Limiter -# @?C
T2 at Ie th2 T2 [°]
T3 at Ie th3 T3 [°] HE. .
T4 at Ie = 0 A T4 [°] HE* *
./
2 0 , 9
Excitation current level Ie th2 [%]
@LC
Excitation current level Ie th3 [%] . 2 . * 2
Auto, Manual and Open Loop also have the following parameters
- Initial Setpoint
Integration Time Ta
- Integral time [s]
constant ! ! D ./7 M@ ! C
Reactive current
[%]
Motor
All parameters should be stored in the EEPROM non-volatile memory after they are
configured. Store to EEPROM can be done via CMT1000, Panel or Remote Access. For
more information refer to the appropriate sections.
4.1 General
NOTICE!
First read and understand the general safety instructions in Chapter
2 - Safety Instructions before starting to work with the excitation
system.
NOTICE!
Converter components can be damaged while transporting the
excitation system.
4.3 Unpacking
The unit should be unpacked with the maximum degree of care, without
the use of force and using suitable tools.
The unit should be inspected visually to check for any damage caused
during transport. Complaints regarding defects resulting from
inappropriate transport are to be addressed immediately to the receiving
station or the last carrier.
NOTICE!
The unit is visibly damaged:
• Safe operation is not possible.
• The unit must not be installed and taken into operation.
7 7
The unit is mounted by means of four screws.
See dimensional diagram for fixing holes and spacing.
Mounting instructions see Chapter 3.3 - Hardware
The unit should only be installed in indoor areas which
are dry and dust-free and which do not contain any
.
gases, acid fumes or similar.
Mounting
2.
NOTICE!
Electrostatic discharge (ESD) can damage electronic boards and
components!
• Do not touch printed circuit boards or other sensitive
components without taking static-sensitive handling
precautions.
• Do not touch the components without wearing a wrist
grounding strap.
• Put the board or component on a grounded working surface
which is protected against electrostatic discharges.
• Hold a board only at the edge.
• Handle a faulty board with care.
2
Cross sections - Power electronics, terminal numbers 1 to 15 0.2 to 4 mm (AWG 10 to 30)
2
- Electronic sections, terminal numbers 16 to 55 0.2 to 2.5 mm (AWG 12 to 30)
4.6 Storage
4.6.2 Disposal
5.1 General
WARNING!
WARNING!
After the unit has been switched off, it must be ensured by measurement
that no measuring voltages or control voltages >50 V are present at the
terminals. At an interrupted field circuit the input capacitor is slowly
discharged through internal circuits.
In order to prevent unintentional closing of open voltage circuits by third
parties, the circuits in question should be identified at the point of
interruption (e.g. by means of a warning sign).
Before switching on, check whether the connection terminals are wired up
according to the plant schematic.
The following section describes how to determine the Ceiling Factor in two different ways.
We recommend the measuring method.
Measuring method
Definition: The ceiling factor Kceil determines the relationship between the maximum
output voltage of the regulator and the exciter voltage, which is required for no-load
excitation and is thus a measure for the possible overexcitation of the machine.
Example: Regulator output signal (PWM) at no load shows 20% at nominal voltage
100
K ceil = =5
20
Calculating method
Power electronics supply: Three-phase: Uemax = 1.40 * UPWR – 8 V
Single-phase: Uemax = 1.25 * UPWR – 8 V
DC: Uemax = 0.98 * UPWR – 8 V
Example
Specifications: Power electronics supply UPWR = 240 V, single-phase
No-load exciter voltage Ueo = 50V
There are no limiters active in the mode Manual and Open loop.
The limiting values of the UM limiter are, as a rule, set equally, like the setpoint range of
the voltage regulator (Auto mode).
The operating mode is selected via the digital inputs. For this purpose, a maximum of
10 inputs have to be occupied by the following signals:
The machine frequency must always be higher than the network frequency and cannot be
synchronized by a positive slip.
The Nominal Exciter Frequency has to be adjusted; for the others, the default value has to
be kept.
Nominal Exciter Frequency = p x n/60
p = Number of pole pairs [.]
n = Revolutions per minute [U/min].
The parameters can be calculated by ABB Switzerland. For further information please see
the Functional Description of UNITROL 1000, Power System Stabilizer, and document
number 3BHS213239 E01.
See manufacturer’s details, Chapter 1.4 - Manufacturer’s Address.
The configuration of Double Channel depends on the application and connections. For
detailed information about configuration, refer to 3.4.8 Double Channel (DCH).
If several operating modes are selected simultaneously by the digital inputs, then the
following order of priority applies:
The following settings can be pre-set on the basis of the machine data.
Proportional gain Vp
This most important setting value depends primarily on the controlled system.
If the ceiling factor Kceil has been set correctly, values between 10 and 40 should result in
stable regulation of the machine.
Example
Step-up transformer Reactance = 12%
Compensation Kq = +6%
The RS485 port is shared between VDC mode and MODBUS. With factory settings,
MODBUS is disabled.
To use MODBUS, the parameter MB_Enable must be set to true, then the parameters
have to be written to the EEPROM. Afterwards, the UNITROL 1000 must be restarted.
This procedure has to be followed for any change to MODBUS related parameters to take
effect. It serves as a protection against inadvertently overwriting the setup by MODBUS
itself and therefore losing connection to the UNITROL 1000.
Slave ID
Zero and values higher than 247 are reserved, so the valid range for the slave ID is 1 to
247; 247 is the default. Recommended range is 64 to 247 due to the possible influence
with the Modbus ID used for CMT1000 access. For more information consult Chapter
3.4.9 - Remote Access.
Keep-alive time
The parameter “MB_KeepAliveTime” defines, in which time-period the “Keep Alive Bit” in
control word 1 must be changed. Valid settings are 1 to 120 seconds and 0 to disable the
connection monitoring.
Keep-alive action
If the timer reaches the supervision time, a “Modbus Communication Alarm” will appear
and one of the events can be selected with the “MB_KeepAliveAction”.
For more information, please refer to the UN1000 Modbus Reference document.
Preliminary Checks
• Wiring check, compare connections with schematics.
CAUTION!
Check the insulation strength of the plant with the insulation tester
During the test, the equipment could be damaged by the testing voltage.
Disconnect cables to the UNITROL 1000
• Optimize PQ Limiter
The setting of the PQ limiter must be coordinated with the settings of the generator
protection. As a rule, the limiter should be set at least 5% lower.
5.5.3 Synchronization
Isolator
SM
• „Blind“ synchronization
Monitor the Synchronoscope (Monitor\Sync Diagram) by disconnecting the trigger of
the circuit breaker.
• „Live“ synchronization
Record the event with a Synchronoscope.
CAUTION!
The synchronoscope must stand at “twelve o’clock “. If the
synchronoscope stands at “six o’clock“, one voltage is incorrectly
connected. In other positions, either measuring is being carried out on
incorrect phases or a phase shift caused by the connection group of a
step-up transformer has not been compensated.
CAUTION!
In this status, the phase-angle difference must be 0 deg. Otherwise the
measuring cable is incorrectly connected. Incorrect polarity cannot be
detected by the UNITROL 1000. Paralleling with incorrect polarity can
lead to serious damage.
A phase shift caused by one of both measuring transformers or by the
connection group of a step-up transformer must never take place.
6.1 General
NOTICE!
ABB recommends periodical training for operating personnel
DANGER!
Dangerous voltage.
There is a danger of electric shock.
NOTICE!
Before operating the excitation system the general safety instructions in
Chapter 2 - Safety Instructions must be read and understood.
CAUTION!
Parameters are set during commissioning of the device and must not be
changed afterwards without taking into consideration the consequences
they can produce.
Running the excitation system with incorrect data can result in improper
operation, reduction in control accuracy and damage to the equipment.
Only qualified and certified personnel are allowed to operate the device,
i.e. personnel who are familiar with the excitation system and the
hazards involved.
The Panel of the UN1000-15 allows the configuration of most of the parameters, with the
exception of Double Channel parameter and others, which can be configured using
Remote Access or the CMT1000. The parameters that can be configured with the Panel
are shown in Chapter 6.3.4 Menu structure.
The Panel is operated using the buttons from the keypad installed in the front. The Panel
can even be used to read measurements and/or change parameters when there is a
Remote Access connection over RS485. In this case, the functionality explained in
Chapter 3.4.10 Access Levels comes into operation, in order to establish rights to change
parameter values in both Panel and Remote Terminal.
After powering up the device (UAUX power) the Panel performs an initialization stage to
establish the communication with the AVR main controller. The serial cable should be
disconnected from the RS232 serial port in order to operate the Panel and Keypad.
OK Select mode: Selects sub-menu in the line marked with the cursor
On parameter level, the cursor disappears and the following text is
displayed:
OK to write value => Accept new value, not yet saved in EEPROM
ESC to cancel => Retain old value
Parameter setting: Accept new value
ESC Select mode: Back to next-higher menu
Parameter setting: Retain saved value
ESC + Keys are locked if both are pressed during 2 seconds.
ESC + Keys are unlocked if both are pressed during 2 seconds.
5x DI5
→ DI6
6. Select sub-menu 4, DI6
OK ∗∗∗ DI6 ∗∗∗
→ Din = None
Polarity = Normal
Connected: 1 MAIN
→ Setup
• The above procedure only changes the parameters in the volatile memory. To make
the modification permanent, you have to save the entire parameter set.
• Save parameters: Start menu MAIN, Write EEPROM, OK, OK.
∗ANALOG INPUTS
AI1
AI2
AI3
UM Aux
Ie Ext
ANALOG OUTPUTS
AO1
AO2
Ie Range
Fbias Range
PSS
Active =FALSE
PSS Settings
PSS Time Consts
∗COMMUNICATION
AVR ID = 1 MAIN
Modbus Setup
A number of limiter and alarm indications can be monitored from the Panel screen. The
message indications are shown in the first line of the screen, by toggling between the title
of the Panel menu and the message indication each for one second.
1. Initial screen:
* * * M A I N * * * *
M o n i t o r
M o d e = A u t o
C o n n e c t e d : 1 M A I N
If more than one alarm or limiter is active at the same time, they are displayed one by one
after one second each.
The following alarms and limiters can be monitored from the Panel:
* I e
H i g h A c t i v e *
* U M
H i g h A c t i v e *
* * V / H z A c t i v e * *
* I M H i g h A c t i v e *
* * F C B A l a r m * *
* * I e L o w A c t i v e * *
* * U M L o w A c t i v e * *
* * I q L o w A c t i v e * *
* * I q M a x A c t i v e * *
* E x t e r n a l A l a r m *
* * M B C o m A l a r m * *
* * D i o d e A l a r m * *
* * D i o d e T r i p * *
* * S W A l a r m * *
M i n I M a x S P R e a c h e d
* * C o m m E r r o r * *
* * S p r v A l a r m * *
* * S p r v T r i p * *
* * S w i t c h O v e r * *
In certain circumstances the following fault messages could appear on the display:
XIRQ, SI, SYSTEM HALTED or COMM ERROR
The regulator could continue to work faultlessly and needs not be taken out of service.
However, no parameters can be entered or changed. The display is reset when the unit is
taken out of service and the auxiliary power is disconnected for a short time.
A defective unit should be sent for repair with a failure report attached to it. For contact
information, please refer to Chapter 1.4 Manufacturer’s Address.
The PC software tool used with UNITROL 1000 is called CMT1000. The CMT1000 release
5 is not compatible with earlier releases of the product, release 4 and below.
To install the CMT 1000 software, please carry out the following steps:
Distribution rights:
CMT 1000 was developed with the Lab VIEW software and is distributed free of license
charges and costs. The copyright to Lab VIEW is owned by the company National
Instruments International Distribution (NIID).
The CMT1000 communicates with the AVR via the RS232 port. The UN1000 serial cable
provided by ABB should be used to connect the RS232 port from the AVR to the PC (using
an USB adaptor if necessary) or to a TCP/IP gateway. For more information about the
hardware connections refer to chapter 3.3.9 Communication ports.
In case the appropriated COM port is not found, check whether the required COMx is
correctly configured in the operating system or being used by another application.
Port settings normally used for COM:
Base I/O Port address: 3f8
Interrupt Request Line (IRQ): 4
The main window of the CMT1000 is shown in Figure 6-15 and is the starting point to access
all software features. The software features are accessed from the menu and each menu
item is grouped according to functionality.
The following sections describe the CMT1000 menu organization and window contents.
IMPORTANT!
All software windows shown in this User Manual were taken with
standard style of Microsoft Windows (R) XP and most of them can be
closed by using the mouse and clicking on the cross in the upper right
corner. If the cross button is not available, the information in the window
explains how to close it.
About CMT1000
AVR S/N: Unit’s serial number
Control: DSP software version
Panel: Panel software version
Revision: CMT1000 version
Configuration: ABB or Custom
Click on the window to close it.
Note: the serial number of the AVR is
shown in the window of Figure 6-16 and
it should be provided when an optional
software is requested from ABB.
>9 ' 4 , , D 4(
: E E 0 E G
: E E : N --
&
D & ' 4 K (
E
When "Save Parameter File" is executed during Offline, it allows the user to create a
preconfigured file for further download to one or more AVRs. Once the CMT1000 is
started, all parameters are normally set to default values and they can be modified during
Offline Access. After they have been modified and the command "Save Parameter File" is
selected, all parameter values are stored in an INI file whose name is specified by the user
during the file creation process. The resulting INI file can be downloaded to an AVR by
using the command "Open Parameter File".
When "Save Parameter File" is executed during Monitor or Control mode, all parameter
values written in the configuration INI file are read directly from the connected AVR; i.e. the
created INI file reflects the actual configuration of the AVR. During Monitor or Control
mode, this command can be used when a device must be replaced by a spare unit.
Customer setup
Option for user defined application
only (password protected).
SW-Options
It allows the user to enable (un-block) optional software in the AVR. A password code is
required and should be provided by ABB.
Close
Exit the CMT1000 software.
' 0 E (
& $ E B
& : B
& E 0 E
9 & & E
9 & & -#
Measurements
Monitor \ Measurements
• Network Voltage (UNet) [% and kV]
• Machine Voltage (UM) [% and kV]
• Machine Real Power (P) [% and kW]
• Excitation Current (Ie) [A]
• Machine Current (IM2) [% and A]
• Machine Reactive Power (Q) [% and kVar]
• Network Frequency (fNet) [Hz]
• Machine Frequency (fM) [Hz]
• Power Factor (PF) --
Oscilloscope
Monitor \ Oscilloscope
Measurements and transients can be visualized, analyzed and stored to the hard disk
using the Oscilloscope tool of CMT1000. Up to 4 different measurements channels are
possible to be visualized simultaneously on the black box of the Oscilloscope window (see
Figure 6-23). The signal or measurement to be displayed is configured on the right end
side of the Oscilloscope window with the options shown in Figure 6-23.
The Buffer Length defines the length of the buffer size used to record the transient data
and display them on the display, i.e. the size of the black box of the Oscilloscope. The
selection can be performed at predefined values: 1, 2, 5, 10, 20, 50, 100 and higher up to
500 seconds. Each time the Buffer Length value is changed by the user, the black box is
resized in order to match with the new value selected. The transient shown on the black
box is possible to store to the hard disk afterwards; the transient data that could already
pass-through the black box and not shown anymore are lost (there is no additional
memory or buffer).
When a set of consecutives data measurements are received with errors (i.e. due to
cabling or communication problems) the Out of Frame LED indication should light-up.
Under these circumstances it is recommended to check the cabling and configuration
between CMT1000 and UN1000, in order to solve the problem. During the Out of Frame
indication, the Oscilloscope freezes and displays the last correct (error free) measurement
for each channel, until the failure is solved and the indication LED goes off (see Figure
6-23).
The Oscilloscope window menu and the function description of each item are explained in
Figure 6-24. The Oscilloscope can be started and stopped as explained in Figure 6-25.
0 E 4 4
Figure 6-24 Menu structure of the Oscilloscope tool window and function
of each item.
O E O , $ , E 9
E E , & G 9
I B : & O E O , & B 9
E E , & G 9
Figure 6-25 The Oscilloscope is started and stopped using the "Start" /
"Freeze Waveform" button located in the menu of the window.
IMPORTANT!
Previous waveform files saved with CMT1000 releases 4.xxx or 3.xxx
are not compatible with CMT1000 release 5.
The user is kindly asked to use the appropriate version of CMT1000 to
open older waveform files than release 5.
they are placed (Figure 6-26). If the instantaneous value from another Channel is object of
interest, the channel selection for the cursors A and/or B can be changed on the
Oscilloscope window itself (see Figure 6-26).
The temporal buffer of the UN1000 can be used for troubleshooting by allowing retrieval of
data history recorded during the AVR operation time. As long as the CMT1000 is Offline,
the cursor A can be used to observe measurements and data stored on the temporal
buffer but on the Instrument windows. When instruments such as Measurements, Setpoint
Adjust, PQ Monitor and/or others are open when the cursor A is displaced along a curve in
the Oscilloscope window, the Instruments will show measurements reading from the AVR
at the time the temporal buffer was recorded (Figure 6-26). This additional information is
also stored in the temporal buffer but (some of them) are not shown in the Oscilloscope
window.
Notice that the cursors moved along the temporal buffer will show historical data on the
Instrument only if the CMT1000 is Offline; otherwise the Instruments show actual
measurements and reading from the AVR (and the system).
Close
Measurements
Close
25 1.067 [kV] x
0
106.7 [%]
0 x
Zoom -300 -275 -250 -225 -200 -175 -150 -125 -100 -75 -50 -25 0 25 50 75 100
File Edit Start
Freeze Waveform
Channel 1
UM Relative
1 100.0 %/div
0.0 %
Channel 2
1 Iq Relative
100.0 %/div
2 2
0.0 Hz
B Channel 3
4 Combined Limit
1.0 /div
0.0
Channel 4
A 3 3 Gen. State
2.0 /div
4
0.0
Cursors A, B
A B
Channel 3 Channel 3
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 0 3
20.0 s 30.0 s
time / s Sweep Buffer
Buffer Length 50.0 s dt = 10.0 s
1/dt = 0.010Hz
A feature called Sweep Buffer can be used to displace the cursor A along the transient
curve at real time speed, and so, to observe the variations of measurements and data as
they might have been gathered during operation of the AVR.
When Sweep Buffer is enabled from the menu, a vertical line replaces the pointer A and
runs along the transient curve starting from the cursor A until the end of the transient at
real time speed (i.e. one second of cursor movement is equal to one second of operation
with the AVR). During the time the vertical line runs, the instantaneous value of the curve
is displayed on the Oscilloscope window, under the cursor A information. If an Instrument
window is opened during this process, the instantaneous data is also updated and shown
in the window. The Sweep Buffer is intended to be used together with Instruments
windows, and therefore, it is only available when the CMT1000 is Offline. It can only be
activated from the menu when the cursors were already enabled as well.
Examples
Notes
• The window in "Tune" can also be opened to set the regulators.
• The setpoint step is simulated in “Tune Setpoint Adjust“.
• The buffer length can be adjusted from 1 s, 2 s, 5 s, 20 s, 50 s to 100 s.
• The time scale can be adjusted in the bar above the waveform (Zoom).
There are 4 quasi analog signals which can be used to represent status changes on the
oscilloscope. The decoding of those signals is explained as follows:
0 D
# " : )!AB *9
# " : )!AB .9
K " : )!AB 9
" : )!AB 9
" : )!AB 89
)!AB " : 39
3
# " : /9
3
# " : 29
K " : *9
" : .9
" : 9
Window PQ Diagram
Monitor \ PQ Diagram (Power chart)
IM or Ie Temperature Monitor
Monitor \ Temp Influence
IM Temperature
Monitor
Ie Temperature
Monitor
0 &, & $
&
I & E , &,
&,
&,
)+0 &4 &,
+, ! &,
" , &,
" , &,
$ E B
,+ , ,
4 $ D B
+ D 0 E :
) ! AB &,
P ; ; &,
E
" &,
I &,
)" &,
&,
&,
Note: Some menu items may be shaded and are not accessible when the CMT1000 has
Monitor or Control Access and/or the AVR has optional software which is not available. All
menu items are accessible when the CMT is Offline.
Setup \ Setpoints \ PF
Example of configuration of the input signals with the CMT1000 software tool
1. Select the analog input AI1 2. Select one or two digital signals
(or AI2 or AI3) and adjust the DI9 from +AI
input range [Setup \ Analog DI10 from –AI
Inputs] [Setup \ Digital I/Os]
When using AI pins for DI signals, both inputs should not be active at the same time.
The above procedure only changes the parameters in the volatile memory.
To make the modification permanent (even after restarting the AVR), all the parameters
have to be stored in the non-volatile EEPROM.
Adjust Synchronization
Setup \ Synchronization
Adjust PSS
Setup \ PSS
The window is only
shown when the
CMT1000 is
OFFLINE and/or the
Power System
Stabilizer SW
(optional) is available
in the device.
Port configuration
Communication \ Port configuration
VDC Monitor
Communication \ VDC Monitor
VDC Monitor is a tool to analyze the VDC communication between the AVRs connected to
the same RS485 bus.
The VDC communication should be enabled before using this tool. For more
information refer to 3.4.3.2 Communication.
3. The VDC data received from a specific AVR can be retrieved by specifying the AVR-
ID = "y" of the device.
4. The VDC data that is read from the bus and coming from the AVR whose AVR-ID =
"y" (from item 3) can be observed in Figure 6-30.
Net ID shows the Primary or Secondary Net number depending on the Net the AVR-
ID "y" is currently in operation. A special case may occur when Net ID is equal to
cero, which means the VDC data for the AVR-ID "y" had CRC errors or the
communication is not established; under these circumstances the LED "y" is dark.
IM Nominal refers to the Nominal Machine Current and Iq Rel to the Reactive
Current in p.u. units (both read from the RS485 bus).
Q ;
& " ' +( RK +
& I; )" P ' (
& ' (
1. Displays the generator state condition, according to the Gen CB Closed and
Parallel with Grid status signals. Prim. Net and Sec. Net are used during VDC
operation mode.
2. Displays the actual operating mode of the AVR. Some modes may be shaded
(disabled) if an optional feature is not available or due to system conditions or
configuration. For more information about the software feature and operation
modes consult Chapter 3.4 Software.
3. Displays Limiters status.
4. Displays AVR Alarms status. Not all alarms statuses are shown when an
optional feature is not available in the AVR.
5. The actual setpoint can be adjusted with the upper Up and Down buttons (if
the adjustment is not performed via analog or digital inputs). A step response
can be performed by specifying the Step value and then pressing the lower
Up (actual setpoint + Step) and Down (actual setpoint – Step) buttons.
0 /
0
" --
A G I II - --
: I
!
0
After switching from OFF LINE to MONITOR/CONTROL, CMT 1000 reads the parameters
from the device‘s RAM. Now, all parameter changes carried out using CMT 1000 are
written directly into the device‘s RAM.
- Write Parameters to EEPROM: The parameters in the RAM are stored in the device (only
possible during CONTROL Access).
- Save Parameter File: The parameters are saved on the hard disk as an INI file.
- Open Parameter File: The INI file is loaded into CMT 1000 and the RAM is
overwritten again (only possible during CONTROL
Access).
When opening a parameter file from disk, the old parameter file is immediately overwritten in the
RAM (only possible during CONTROL Access).
Any parameter changes carried out in CMT 1000 are not transferred into the device.
7.1 General
NOTICE!
ABB recommends periodical training for the maintenance personnel.
WARNING!
!
The secondary voltage of the excitation transformer and the voltage of
the excitation field are fed into the excitation cabinet.
These components present a great danger of electric shocks.
The control elements and the PC interface on the front plate of the
UNITROL 1000 unit are to be touched and/or attached only with
caution.
When the system is at a standstill, the screwed terminals, which can get
loose due to vibrations, should be checked for tightness. Dusty cooling
flanges should also be cleaned.
8.1 General
Field flashing current too high Check design of the field flashing circuit.
Field flashing should deliver 10 to 15% of the no
load excitation current
8.4 Repair
The unit must not be opened. A defective unit should be sent in for repair
with failure description and, if possible, trending of failure.
See manufacturer’s details on Chapter 1.4 Manufacturer’s Address.
9.1 General
Weight 5 kg
Protection class IP20
Dimensions (HxWxD) 245x190x142 mm
Test voltage:
Power electronics supply UPWR against case and auxiliary supply UAUX 2830 V DC, 2 s
Auxiliary supply UAUX against case and power electronics supply UPWR 2830 V DC, 2 s
Voltage measurement inputs UM, UNET: High impedance voltage input without galvanic separation
According to (USA, Canada) UL specification:
The screw-type terminals for inputs and outputs are approved for maximum voltage 150 V
Plant:
Order No.:
Plant Schematic No.:
Device Identification:
Type Plate:
Delivery Date:
Software Revision: Control:
Panel:
CMT 1000:
Remarks:
Name: Company:
Signal name:
Digital inputs +
Digital outputs
+
DIO1 to 4 DIO1 to 4
DI5 to 8
(DI9 to14)
IMPORTANT!
Parameter values should be stored in the device's EEPROM after
configuration.
Panel: Start menu MAIN => Write EEPROM => OK => OK
CMT1000: Main Menu => File => Write Parameters to EEPROM
CMT1000 must be in Control mode.
For additional information refer to Chapter 6 - Operation.
CONTENTS:
• INSTRUCTION FOR ROTOR DISMOUNTING AND MOUNTING,
MOUNTING, SIDES 1-
1-2
• ASSEMBLY DRAWINGS:
DRAWINGS: T67M00600XY,
T67M00600XY, T67M00100XY SIDES 1-
1-3
• ASSEMBLY DEVICE DRAWINGS: T67M00101XY, T67M00102XY, T67M00103XY,
T67M00104CY,
T67M00104CY, T67M00104FY, T67M00110XY,
T67M00120XY,
Instruction for Rotor Dismounting
and Mounting Before dismounting the
bearings, disconnect PT100
The following instruction refers to the attached on bearing housing (16)(20).
drawing T67M00100XY sheet 1-3 respectively
as well as table of torques. (i) Lift upper part of bearing housing (9) on
DE after loosening the screws (10).
The assembly works must be
carried out carefully by trained (j) Lift upper part of bearing housing (11) on
staff only. Before starting the NDE after loosening the screws (12).
works, read the complete
instruction. (k) Dismount upper part of bearing shell (13)
on DE.
Please observe the following
recommendations: (l) Dismount upper part of bearing shell (14)
- Use only suitable tools on NDE.
- Windings and bearing surfaces must
be protected against damages (m) Slightly lift rotor on DE (for discharging).
- Apply generator stable on stator core Dismount from lower bearing shell (15) as
as shown in T67M00100XY sheet 1. well as bearing housing (16) by loosening
Support only on longitudinal rips, of the fixing bolts (17).
where screws are mounted.
(n) Lower rotor and support it on sleeve
Please pay attention to the additionally bearing cover (18).
enclosed installation manuals.
(o) Unscrew the lower part of the bearing shell
Further, please observe additional mounting (19) on NDE by slight lifting (discharging).
and dismounting instructions of our sleeve
bearing manufacturer. (p) Remove the lower part of the bearing
housing (20) after loosening the fixing
bolts (21).
1. Rotor Dismounting
(q) Lower rotor on sleeve bearing cover (22).
(a) Dismount assembly cover (1) on NDE by
loosen screws (2). (r) Dismount air outlet box (23) by loosening
the screws (24).
(b) Drain the oil of the bearings on DE and
NDE. (s) Lift the rotor on DE for discharging.
After loosening the fixing bolts (25) the
(c) Dismount axial air filters (30) on NDE. bearing shield (26) has to be removed
towards DE together with the sleeve
(d) Insert Pertinax and respectively HGW- bearing cover (18) and with the help of the
sheets (at two positions at lower range existing jack bolts and the pipe (27) on the
through the whole core length) into air gap DE bearing shield. Change the support
and fix it (air gap is about 10 mm on 8-pole any time if necessary. Dispose rotor
rotors and 9 mm on 10-pole rotors). carefully on protection sheets mounted on
item (d). Then take of the bearing shield
(e) Mark the cables on the rotating rectifiers (26).
(3) and disconnect them.
(t) After loosening the fixing bolts (28), also
(f) Dismount the rectifier carrier incl. rotating dismount and deposit the fan (29) towards
rectifier (4). DE.
(g) Dismount seal carrier (5) after loosening (u) Dismount the cover of terminal box (31).
the screws (6). Mark the cables, wired between NDE-
shield and terminal box, and disconnect
(h) Remove seal carrier (7) after loosening the them.
screws (8).
2. Rotor – Removal
When depositing the rotor,
With the help of the removing devices support on the shaft. Never lay
- alignment part DE (50) down the rotor on core!
- alignment part NDE (51)
- two half shells DE c/d/e-size (52)
- two half shells DE f/g/h-size (53) 2.2 Dismounting from NDE to DE
- one bushing NDE (54)
- two adapter pipes (55) As per description from DE to NDE, only the
- one connection pipe (56) reverse direction.
- Bolt EN 24017 M16x60 (57)
- Bolt EN 24017 M8x25 (58) 3. Rotor Mounting Respectively
- Bolt EN 24017 M16x40 (59) Bearing Shield: In Reverse Order
- Bolt EN 24017 M8x40 (60)
Table of torques
which are part of generator manufacturer
supply. (optional equipment) Torques for bolts used for rotor dismounting
and mounting:
Pay attention to the drawings of
T67M00100XY sheet 2! A secure
handling of the rotor with help 1. Bearing bolts: s. table respectively
of the extension pipes is only description in the documents of Firm Renk
warranted if mounted as shown. 2. Fixing bolts bearing shield of generator
Differences could cause damages on the Housing, support of the exciter.
rotor or lead to severe injuries caused by Fastening housing of exciter on support
accident.
RH EFEWI E – 7.02
Maintenance and Inspection
RENK AKTIENGESELLSCHAFT
Werk Hannover
Weltausstellungsallee 21
D 30539 Hannover
Telephone: (0511) 86010
Telefax: (0511) 8601266
email: renk_hannover@renk.de
http:\\www.renk.de
All rights reserved. Copy or reproduction without prior permission of RENK Aktiengesellschaft Hannover
prohibited.
Contents
Bearing Coding
Type Housing Heat Dissipation Shape of Bore and Type of Thrust part Size Diameter
Lubrication
E F flange mounted N natural cooling L plain cylindrical bore with Q without thrust part 9 80£D£100
bearing loose oil ring (nonlocating bearing )
W water cooling 11 100£D£125
(finned cooler in oil sump ) B plain sliding surfaces with oil
grooves (locating bearing) 14 125£D£160
E F N L Q 22200 Type E slide bearing with flange mounted housing, natural cooling
plain cylindrical bore with loose oil ring, non locating bearing without thrust part,
size 22, diameter 200.
Slide Bearing EF
4
10
11
3 12
13
2
14
15
1
16
17
xxx
x
18
xxx
19
20
21
22
23
24
27 26 25
1 Top half of the housing
2 Hole for positioning pin
3 Pin for positioning shell
4 Oil filling hole
5 Top sight glass
6 Eye bolt
7 Screw (not included in delivery)
8 Screw
9 Tapped hole ( in the top and bottom halves of the shell, up size 14 )
10 Machine seal
11 Top half of the shell
12 Screw (split line of the housing)
13 Bottom half of the shell
14 Spherical seating
15 Engraved number shell
16 Spigot
17 Tapped hole
18 Screw (not included in delivery)
19 Screw (split line of the shell)
20 Engraved numbers housing
21 Bottom half of the housing
22 Tapped hole for journal bearing temperature measurement
23 Oil sight glass
24 Tapped hole for oil sump temperature measurement
25 Outlet/Inlet cooling water (Type E.T..)
26 Cooler ( Type E.T..)
27 Hexagon head plug (Oil drain plug)
self lubrication
34
35
36
33 Loose oil ring
34 Dowel pin
35 Hole
36 Screw
self lubrication
38
43
42
39
41
40
Outer view
47 44
46
45
37 Seal carrier top half
38 Garter spring
39 Groove
40 Seal carrier bottom half
41 Bottom half of the seal
42 Top half of the seal
43 Anti rotation pin
44 Screw
45 Engraved number
46 Groove ( Type 11 )
47 Engraved number
self lubrication
54
50 (2x)
51
53
52
48 Rigid labyrinth seal top half
49 Screw
50 Screw (split line)
51 Groove ( Type 21 )
52 Rigid labyrinth seal bottom half
53 Engraved number
54 Engraved number
self lubrication
General Drawing
Baffle
56
57
55 Baffle top half
56 Screw
57 Baffle bottom half
self lubrication
Dust Flinger
59 (2x)
58 Dust flinger
59 Screw (split line)
EF with self lubrication
The instructions for maintenance and inspection are addressed to qualified technical personnel
(fitters, mechanic installers, mechanical engineers).
Slide bearings of type EF are almost universally used in the engineering industry. Therefore it is not
possible to provide detailed information on all possible types and range of applications for these
bearing types. For instance, the position of the connection points for supply and monitoring
equipment is determined by the place of application ( in the following called " installation " ).
Please keep ready the guidelines with the technical documentation before starting assembly and
operation of the slide bearings.
Additional technical documentation with detailed information is supplied in the case of special
design bearings. Please contact RENK Export or Domestic Department for supplementary
information on bearings. Please indicate the bearing coding and the full reference number, too.
Caution !
Warning of dangers for personnel.
Example: Warning of injury
Attention!
Warning of damage for the bearing or installation.
EFW.. This is how chapters, instructions or recommendations are marked when referring to a single type
or size of a bearing.
Example: Slide bearing type EF with water cooler
Instruction follows.
· Beginning of an enumeration.
( ) This is how the different parts of a bearing as described in the general drawings ( numbers )
are marked in the text.
- Use the enclosed checklist before starting assembly or operation. Copies available on request.
- The check list provides the experienced mechanical fitters of RENK bearings with the
necessary instructions for installation and operation.
2 Safety Instructions
Danger!
The maintenance and inspection of the slide bearings should be carried out by:
· persons nominated by the safety representative
· persons correspondingly trained and instructed
· persons with knowledge on appropriate standards, regulations and accident
. prevention rules
· persons with knowledge on firstaid measures and local rescue centers.
Warning of injury!
Before starting work on the bearing:
Switch off the installation.
Make sure the installation is not in operation.
Never lift or transport machines, etc.by the bearing eye bolts. These are only intended
for assembly and dismantling of the bearing !
Warning of injury!
Do not grab such heavy bearing parts as the housing during assembly or dismantling
work. This could result in bruising or injury to hands !
Attention!
All metal parts of a slide bearing consisting of top and bottom half such as the housing, shells,
shaft seals are marked by engraved numbers. Fit together only the parts with the same number.
Attention!
In case · the admissible bearing temperature exceeds 15 K
· inadmissible vibrations occur
· unusual noises or odours are noticed
· monitoring equipment triggers alarm
shut down the installation and inform the maintenance personnel in charge.
Attention!
Do not operate the bearing below the transition speed values indicated in the bearing calculation,
thus avoiding inadmissible operating conditions, which could lead to damage to the bearing.
Attention!
Please observe our leaflet Technical Information No. 85 which refers to various sealing compounds
for extended technical applications.
- Clean the external parts of the bearing. Dust and dirt impede the radiation of the heat.
- Check with the instructions for the use of the lubricating oil if an oil change is necessary.
Depending on the duration of the standstill an oil change is either prescribed or recommended.
Carry out the oil change as indicated in Chapter 5.
- Check the oil level
- If necessary, refill with lubricant by using the oil filling hole (4).
The refilling oil should be of the same type as already used.
The oil level limits are as follows:
minimum oil level: bottom of the oil sight glass
maximum oil level: top of the oil sight glass
- Retighten the and screws (12), (8), (18) to the following torque rates:
Bearing Size 9 11 14 18 22 28
4 Maintenance Schedule
5 Oil Change
Risk of pollution!
Please observe the instructions for the use of the lubricating oil. The manufacturer can provide
information on waste oil disposal.
Attention!
In case the lubricating oil contains unusual residues or is visibly changed, eliminate the causes. If
necessary, carry out an inspection.
- Tighten the hexagon head plug (27) to the following torque rates:
Bearing size 9 11 14 18 22 28
Torque [Nm] 30 30 30 40 60 60
- Remove the screw plug from the oil filling hole (4).
Attention!
Make sure that no impurities get into the bearing.
- Use a lubricant with the viscosity indicated on the bearing type plate. Fill the lubricant through
the oil filling hole (4) up to the middle point of the oil sight glass (23).
The oil level limits are as follows:
minimum oil level: bottom of the oil sight glass
maximum oil level: top of the oil sight glass
Attention!
· Not enough lubricant leads to temperature rises and thus to damage to the bearing.
· Too much lubricant leads to leakages. In the case of bearings with lubrication by loose oil
ring too much lubricant could have a considerable breaking effect on the oil rings,
thus leading to damage to the bearing.
- Tighten the screw plug into the oil filling hole (4) to the following torque rates:
Bearing size 9 11 14 18 22 28
Torque [Nm] 30 30 30 40 60 60
Risk of injury!
Before transport or lifting check if the eye bolts are tight! Insecure eye bolts could
result in bearing becoming loose.
Before moving the bearing by the eye bolts make sure that the screws at the split line
are tightened, otherwise the bottom half of the bearing could become detached.
Make sure that the eye bolts are not exposed to bending stress, otherwise the bolts
could break.
Follow exactly the instructions for the use of the lifting equipment.
Transport/Assembly of: Use lifting equipment for the following bearing sizes
Shells 1428
Bearing size 9 11 14 18 22 28
Bearing size 9 11 14 18 22 28
Tapped hole M 12 M 12 M 16 M 20 M 24 M 30
Shells
- Screw two eye bolts or screw hooks with suitable threads tight into the tapped holes (9):
Bearing size 14 18 22 28
Tapped hole M8 M 12 M 12 M 16
Attention!
Make sure that the work place is clean. Contamination and damages to the bearing, especially of
the working surfaces, have a negative influence on the operating quality and could lead to
premature damage.
Attention!
Do not use any violence or force!
Risk of pollution!
Please observe the instructions for the use of the lubricating oil. The manufacturer can provide
necessary information on waste oil disposal.
- Tighten the hexagon head plug (27) to the following torque rates
Bearing size 9 11 14 18 22 28
Torque (Nm] 30 30 30 40 60 60
Warning of injury!
During dismantling of the floating labyrinth seal hold tight the garter spring (38) which
is under tension and could bounce back and lead to injury.
- Open the garter spring (38) and remove the bottom half of the seal (41) from the shaft.
Type 6.4.2 Floating labyrinth seal with dust flinger (Type 11)
11
- Dismantle the dust flinger (58). Loosen the screws (59) and take out the dust flinger (58) from
the groove (46) of the seal carrier. Remove both halves of the dust flinger.
- Go on as indicated for type 10 (see Chapter .4.1).
Type
6.4.3 Floating labyrinth seal with baffle (Type 12)
12
- Unscrew both top (55) and bottom (57) halves of the baffle by untightening the screws (56).
- Go on as indicated for type 10 (see Chapter 6.4.1).
Type 6.4.5 Rigid labyrinth seal with dust flinger (Type 21)
21
- Dismantle the dust flinger (58). Loosen the screw (59) and take out the dust flinger (58) from the
groove (51) of the rigid seal. Remove both halves of the dust flinger.
- Go on as indicated for type 20 (see Chapter 6.4.4).
Type 6.4.6 Rigid labyrinth seal with baffle (Type 22)
22
- Unscrew the top half (55) and the bottom half (57) of the baffle by untightening the screws (56).
- Go on as indicated for type 20 (see Chapter 6.4.4).
- Unscrew the screws (19) and lift the top half of the shell (11).
Attention!
Do not damage the thrust and radial working surfaces.
Attention!
In the case of insulated housings (white plastic insulating foil) avoid any jamming of the top half of
the shell when you lift it up
Jamming could lead to damage of the insulating foil in the bottom half of the housing.
- Open both split lines of the loose oil ring (33) by untightening and taking out the screws (36).
Separate both halves of the loose oil ring (33) carefully without using any tools or other devices.
I II
33
33 33
36
To check the geometry of the loose oil ring put it together as follows:
- Press the positioning pin (34) into the hole (35).
- Adjust both halves of the loose oil ring till the split lines match each other.
- Tighten the screws (36).
- Shift a little (about 20 mm) the top half (42) of the seal. Tilt it over carefully until the garter spring
(38) unbends.
Warning of injury!
During dismantling of the floating labyrinth seal hold tight the garter spring (38) which
is under tension and could bounce back and lead to injury.
- Open the garter spring (38) and turn the bottom half of the seal (41) in opposite direction from
the antirotation pin out of the integrated seal groove of the bottom half of the housing.
Attention!
Make sure that all bearings mounted on a shaft line are opened. Loosen the screws at the split line
of the housings.
Attention!
The lifting equipment should not come into contact with the seal and working surfaces of the shaft.
- Lift the shaft up to the point where shaft and bottom half of the shell (13) do not touch each
other any more. Protect the shaft against unintended movement.
- Turn the bottom half of the shell (13) out of the bottom half of the housing (21) and remove it
from the shaft.
Attention!
If the bottom half of the shell (13) is provided with metal tabs (28) do not remove them. They
regulate the oil level in the oil pockets.
Usually it is not necessary to dismantle the machine seal (10) if maintenance works are carried out.
If due to certain reasons the split machine seal must be dismantled please observe that this
operation can be carried out only from the inner part of the machine. Loosen the screws at the
split line of the machine seal and remove the screws (7).
Nonsplit machine seals can be dismantled only after dismantling the machine shield or the shaft
completely.
In the case the machine seal is equipped with a hamp packing, some visible changes can be
noticed, such as : tallow excess, black colour of the seal due to temperature development. Even in
such cases it is not necessary to renew the hamp packing. Colour changes will appear with a new
hamp packing too, until the seal clearance adjusts during operation.
Attention!
Use only nonaggressive detergents such as for instance
· VALVOLINE 150
· Alcaline cleaning compounds (pH-value 6 to 9, short reaction time).
Warning of injury!
Please observe the instructions for the use of the detergents.
Attention!
Never use cleaning wool or cloth. Residues of such materials left in the bearing could lead to
excessive temperatures.
- Carry out a visual check of the wear condition of all bearing parts. The following graph provides
information on the parts that must be replaced in case of wear.The right evaluation of the wear
condition, especially of the working surfaces of the shell, implies a lot of experience. If in doubt,
replace the worn part with new ones.
Loose oil ring Geometrical form ( roundness, New loose oil ring
flatness ) visibly changed
Size - Check the projection of the positioning pin (3) according to the values indicated below:
914
Bearing size 9 11 14 18 22 28
Projection of the 7 8 10 12 14 16
positioning pin (4) mm
insulated - Check the insulating layer of the spherical seating (14) of the top half (1) and bottom half (21) of
bearings
the housing. In case of damage contact the RENKsales agency in charge.
Attention!
Remove all impurities or other objects such as screws, nuts, etc. from inside the bearing. If left
inside they could lead to damage of the bearing. Cover up the opened bearing during work breaks.
Attention!
Carry out all assembly operations without making use of force.
Attention!
Secure all screws of the housing, flange and at the split line with a liquid screw locking compound
(e.g.LOCTITE 242).
EF..E Attention!
Mounting the bottom half of the shell (not marked with an arrow) correctly will ease the assembly
of the top half shell (marked with an arrow) (see chapter 8.4).
- Apply some lubricant to the spherical seating (14) in the bottom half of the housing (21) and to
the working surfaces of the shaft. Use the same type of lubricant as indicated for bearing
operation
( see type plate ).
- Place the bottom half of the shell (13) on the working surface of the shaft. Turn the bottom half
of the shell (13) into the bottom half of the housing (21) with the split line surfaces of both halves
in true alignment.
In case the bottom half of the shell doesn’t turn in easily, check the position of the shaft and the
alignment of the housing
EF..B, Attention!
EF..K, These operations should be carried out most carefully. The thrust parts of the bottom shell must
EF..E not be damaged.
- Lower down the shaft till it sits on the bottom half of the shell (13).
The machineside shaft seal is, as standard, a floating labyrinth seal. The integrated seal groove is
in the top and bottom halves of the housing.
Warning of injury!
During assembly hold the garter spring ends (38) securely to avoid them suddenly
releasing and causing possible injury!
Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing:
- Put the garter spring (38) around the shaft and hook both ends into each other.
- Put both halves of the seal (41), (42) in their place on the shaft.
- Put the garter spring (38) into the groove (39).
- Turn the floating labyrinth seal on the shaft.
Attention!
The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating
during operation and even to shaft wear.
If the floating labyrinth seal jams,
dismantle the seal and
remove the worn parts of the seal carefully, by using emery paper or a plain scraper.
- Apply a uniform layer of sealing compound to the seal surfaces and to the split line surfaces of
both halves of the seal (41), (42).
- Place the bottom half of the seal (41) with the labyrinths onto the shaft.
- The oil return holes at the bearing side must be clear and open.
- Turn the seal in opposite direction from the antirotation pin into the groove of the housing until
the split lines of the bottom half of the housing and the bottom half of the seal match each
other.
- Remove the rests of sealing compound.
- Push the garter spring into the integrated seal groove between the bottom half of the housing
and the seal until both ends jut out from the split line.
- Place the top half of the seal with the cam facing the inside of the bearing on the bottom half of
the seal.
- Stretch the garter spring till both ends can be hooked.
I II
33
33 33
36
- Place both halves of the loose oil ring into the shell groove (13) around the shaft. Press the
positioning pin (34) of each split line into the corresponding hole (35).
- Adjust both halves of the loose oil ring till the split lines match each other.
21
34
33
33 13
Bearing size 9 11 14 18 22 28
Attention!
An incorrectly placed shell could jam the shaft thus leading to the damage of both shaft and
bearing.
EF..B, Attention!
EF..K, Place the top half of the shell carefully on the shaft. The thrust parts of the top half of the shell
EF..E should not be damaged.
insulated In the case of bearings arranged for insulation monitoring, connect the black cable for insulation
bearings monitoring to the shell.
According to the bearing type, there are two possibilities of connection.
1. The black cable is provided with a cable connector.
- Plug the cable with the cable connector into the counterpart available on the top of the shell.
- Lead the cable through the cable gland in the bottom half of the housing and out of the
bearing.
- Tighten the cable gland oiltight.
2. The black cable is provided with an eyelet.
- Fasten the cable with the eyelet to the split line of the shell, by using one of the shell joint bolts.
- Lead the cable through the cable gland in the bottom half of the housing and out of the
bearing.
- Tighten the cable gland oiltight.
Bearing size 9 11 14 18 22 28
- Check the split line of the shell by using a feeler gauge. The split line gap should be less than
0,05 mm. If the split line is greater than this, dismantle both top and bottom (11),(13) halves of
the shell. Rework the split line surfaces of the top half (11) and bottom half (13) of the shell with
an oil stone.
- Check the mobility of the loose oil ring (33).
EF.L. A guide bush in the top half of the shell secures the function of the loose oil ring.
Marine
Bearing - Check the mobility of the loose oil ring (33) in the guide bush.
Shells with taper land faces suitable only for one direction of rotation are marked with an arrow on
EF..E
the top half shell, which indicates the sense of rotation of the shaft.
The arrow indicates the allowed direction of shaft rotation after completion of the bearing
assembly.
- Before mounting the top half of the housing check that the proposed direction of rotation of the
shaft corresponds to the direction indicated by the arrow on the top half of the shell.
- If the directions match, continue the assembly of the bearing.
- If the directions do not match, the shell must be disassembled, realigned and mounted again.
Attention!
A wrongly placed shell, without observance of the direction of rotation of the shaft, impairs the
operational safety of the bearing.
- Check the true alignment of the shell (11), (13) and bottom half (21) of the housing.
The positioning pin (3) in the top half of the housing fits in the corresponding hole (2). The shell is
thus placed into its right position.
- Check if the engraved numbers (20) on the top and bottom halves of the housing correspond.
- Clean the split line surfaces of the top and bottom halves (1), (21) of the housing.
- Apply sealing compound over the whole surface of the split line of the bottom half (21) of the
housing.
- Place the top half of the housing carefully into the machine shield, without touching the seals or
the shell.
- Lower the top half of the housing (1) vertically on the bottom half of the housing (21). Lower the
top half of the housing (1) till the split line of the housing is not visible any more.
- Gently hit the bottom half of the housing (21) with a nylon hammer, thus ensuring the alignment
of the spherical seating.
- Insert the screws (12). Tighten them handtight.
- Insert the screws (8). Tighten them to the following torque rates:
Bearing size 9 11 14 18 22 28
- Tighten the screws (12) of the housing crosswise to the same torque rates.
Attention!
This connection bypasses the electrical insulation of the bearing.
In the case of electric machines, make sure at least one bearing is electrically insulated.
To check the electrical insulation, interrupt the connection cable housing. Check the electrical
resistance with a suitable measuring instrument. Make sure that both bearings and the coupling
are electrically insulated.
b) The cable has a free end. In this case the customer has to make the connection.
Attention!
If only one bearing is insulated, the end of the cable must not be earthed.
Any further connection depends on the customer’s requirements related to the insulation
monitoring and can not therefore be described here.
Warning of injury!
During assembly hold the garter spring ends (38) securely to avoid them suddenly
releasing and causing possible injury!
Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing.
- Put the garter spring (38) around the shaft and hook both ends into each other.
- Put both halves of the seal (41), (42) in their place on the shaft.
- Put the garter spring (38) into the groove (39).
- Turn the floating labyrinth seal on the shaft.
Attention!
The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating
during operation and even to shaft wear.
If the floating labyrinth seal jams,
dismantle the seal and
remove the worn parts of the seal carefully, by using emery paper or a plain scraper.
- Apply a uniform layer of sealing compound to the guide surfaces and to the split line surfaces
of both halves of the seal (41), (42).
- Press the bottom half of the seal (41) against the shaft.
- Place the top half of the seal (42) on the shaft and align both halves of the seal to each other.
- Place the garter spring (38) into the groove (39) and stretch until both ends can be hooked.
43 42 1
38 41 21
- Place in true alignment the split line of the floating labyrinth seal and the split line of the seal
carrier.
- Check that both engraved numbers (45) and (47) on top and bottom halves of the seal carrier
(37), (40) correspond.
- Clean the following parts:
· the seal surfaces of the top (37) and bottom (40) half of the seal carrier (the groove of the
floating labyrinth seal, the flange surfaces)
· the split line surfaces of the top (37) and bottom (40) half of the seal carrier
· the flange surfaces of the housing.
- Apply a uniform layer of sealing compound to:
· the lateral surfaces of the groove at the top (37) and bottom (40) half of the seal carrier
· the flange surfaces of the top (37) and bottom (40) half of the seal carrier
· the split line surfaces of the bottom half of the seal carrier (40).
- Place the top half of the seal carrier (37) on the top half of the seal (42). Press the bottom half
(40) of the seal carrier against it. Push the shaft seal completely into the housing.
37
43
42
- Place in true alignment the split lines of the seal carrier and the housing.
- Tighten up the screws (44) to the following torque rates:
Bearing size 9 11 14 18 22 28
Torque [Nm] 8 8 8 20 20 20
Type 8.6.2 Floating labyrinth seal with dust flinger (Type 11)
11
- Assemble the floating labyrinth seal with dust flinger as described in Chapter 8.6.1, Floating
labyrinth seal type 10.
- Place both halves of the dust flinger (58) in front of the shaft seal around the shaft. Loosely
screw in the screws (59).
58 37
e 46
EF..Q - Push the dust flinger (58) into the groove (46) of the seal carrier.
- Set the clearance "e" at the following figure around the whole unit:
maximum longitudinal extension of the shaft in operation + 1 mm
(Parameters indicated in the Technical Documentation of the Installation).
- Tighten up the screws (59) to the following torque rates:
Torque [Nm] 7 18
EF..B, - Push the dust flinger (58) into the groove (46) of the seal carrier.
EF..E, - Set the clearance "e" at 1 mm around the whole unit.
EF..K - Tighten the screws (59) to the following torque rates:
Torque [Nm] 7 18
Torque [Nm] 4 10
- Place the top half (48) of the rigid labyrinth seal on the shaft and press slightly the bottom half
(52) of the rigid labyrinth seal from below against it. Lightly push the rigid labyrinth seal
completely into the housing.
- Tighten the screws (50).
- Place in parallel alignment the split line of the rigid labyrinth seal and the split line of the
housing. Press the rigid labyrinth seal slightly from below against the shaft. Adjust the rigid
labyrinth seal in such a way that the clearance "f" between the shaft and the rigid labyrinth seal
at both split lines has the same figure.
1 48
f f
21 52
Bearing size 9 11 14 18 22 28
Torque [Nm] 8 8 8 20 20 20
Type 8.6.5 Rigid labyrinth seal with dust flinger (Type 21)
21
- Assemble the rigid labyrinth seal with dust flinger as indicated in Chapter 8.6.4, Type 20.
- Place both halves of the dust flinger (58) round the shaft, in front of the rigid labyrinth seal.
Mount the screws (59) loose.
58 48
e
51
Illustration 13: Clearance between dust flinger and rigid labyrinth seal
EF..Q - Push the dust flinger (58) into the groove (51) of the rigid labyrinth seal.
- Set the clearance "e" at the following figure around the whole unit:
maximum longitudinal extension of the shaft in operation + 1 mm
(Parameters are indicated in the Technical Documentation of the Installation).
- Tighten the screws (59) to the following torque rates:
Torque [Nm] 7 18
EF..B, - Push the dust flinger (58) into the groove (51) of the rigid labyrinth seal.
EF..E, - Set the clearance "e" at 1 mm around the whole unit.
EF..K - Tighten the screws (59) to the following torque rates:
Torque [Nm] 7 18
Torque [Nm] 4 10
Attention!
Make sure that no impurities get into the bearing.
- Use a lubricant with the viscosity indicated on the bearing type plate. Fill the lubricant through
the oil filling hole (4) up to the middle point of the oil sight glass (22).
The oil level limits are as follows:
minimum oil level: bottom of the oil sight glass
maximum oil level: top of the oil sight glass
Attention!
· Not enough lubricant leads to temperature rises and thus to damages to the bearing.
· Too much lubricant leads to leakages. In the case of bearings with lubrication by loose oil
ring too much lubricant could have a considerable breaking effect on the oil rings,
thus leading to damages to the bearing.
- Tighten the screw plug into the oil filling hole (4) to the following torque rates:
Bearing size 9 11 14 18 22 28
Torque [Nm] 30 30 30 40 60 60
EFW.. - Start operating the cooling water supply system and check its functioning.
Attention!
If the bearing temperature exceeds the calculated value by 15 K (see the EDPbearing
calculations) stop the installation immediately. Carry out an inspection of the bearing and find out
the causes.
If you want to protect the bearing mounted on an installation against corrosion proceed as follows:
- Dismantle the bearing (see Chapter 6).
- Clean the bearing (see Chapter 7).
- Paint or spray the top half of the shell (11), the bottom half of the shell (13) and the shaft with
TECTYL 511.
- Assemble the bearing (see Chapter 8).
- Close all tapped holes with screw plugs.
- Seal the gaps between · shaft seal and housing
· shaft seal and shaft
by using a selfadhesive, permanent tape.
- Remove the top sight glass (5). Spray some anticorrosive such as TECTYL 511 or VALVOLINE
into the bearing.
- Put a bag of dessicant (silicate gel) inside. The dessicant absorbs the humidity and prevents the
formation of condensation water inside the bearing.
- Close the bearing tight with the top sight glass (5).
11 Transport Protection
12 Glossary
Baffle With bearing types 10 and 20 the baffles are assembled externally in front of the shaft
seals. The baffle, made of reinforced polyamide, protects the bearing from dust and
water.
Rigid labyrinth seal The rigid labyrinth seal (type 20) is used with slide bearings type E with high oil
throughput.It corresponds to the protective system IP44 and is made of an aluminium
alloy.
The rigid labyrinth seal is built of two halves, flanged at the housing.The labyrinths that
wipe out the lubricant are arranged into two groups.The first two labyrinths , installed
inside keep back most of the lubricant. Five further labyrinths protect the bearing from
outside.They prevent the lubricant overflow and the ingress of impurities.The overflow
lubricant is collected into a chamber between the both groups of labyrinths.Through
the return bores the lubricant flows back into the bearing.
Spherical seating The spherical seating is a special feature enabling the alignment of the shell in the
housing.The shell is seated on two spherical seatings. The advantages of the spherical
seating are:
· easy at assembly
· good heat transfer from the shell to the housing
· suitable for such applications with high thrust or journal loads.
Dust flinger In the case of bearing types 10 and 20 a light alloy ring is clamped on the shaft in front
of the shaft.This ring fits into a groove in the seal carrier or the rigid labyrinth seal, thus
building a labyrinth. The labyrinth protects the shaft exit against low pressure that could
otherwise " absorb " the lubricant. Low pressure occurs for instance in the case of
rotating discs, such as couplings or cooling discs.
Floating labyrinth The floating labyrinth seal (type 10) in the seal carrier is used as a shaft seal in the case
seal of bearings type E operating under normal conditions. It prevents the lubricant and
lubricant mist coming out and the ingress of impurities. The floating seal has a high
capacity of resistance to wear. It is made of a highperformance, high temperature
stability and electrically insulated plastic material.The floating seal consists of two
halves held together by a garter spring. Both ends of the spring are hooked together. In
the case of slide bearings type EM the floating seal is mounted into a twopiece seal
carrier. The groove allows for radial movement of up to 1 mm. The seal is thus
insensitive to shaft radial displacement or deflection. The sealing effect is produced by
the baffles wiping off the lubricant from the shaft. The lubricant flows back into the
bearing via oil return opening.
Machine seal In the case of the flange mounted bearings, the machine seal reduces the influence of
positive and negative pressure in the machine thus preventing leakages at the inner
seal area. The space between the machine seal and the bearing housing must always
be vented to atmospheric pressure. The size of the gap between shaft and machine
seal influences the sealing effect.
Beide Gleitlager der Maschine sind für Both sleeve bearings of the machine are
synthetische Schmierstoffe geeignet. designed for synthetic lubricants.
Gleitlager werden ab Werk ohne Sleeve bearings are delivered without oil
Ölfüllung ausgeliefert und sind mit filling and are protected against
Korrosionsschutz versehen. corrosion by the manufacturer. There is
Korrosionsschutz braucht vor no need to remove the protective coat
Inbetriebnahme nicht entfernt zu before commissioning.
werden.
Die Lager sollen vor Inbetriebnahme bis The bearings should be filled with oil, up
etwa Mitte des Schauglasses mit Öl to about half of the sight glass prior to
gefüllt sein. commissioning.
Schmierstoffempfehlung: Recommendation:
Esso und Mobil Lubricants, Hamburg Esso und Mobil Lubricants, Hamburg
www.mobil-oil.com www.mobil-oil.com
____________________________________________________________________________________________________________________________________________________
____________________________________________________________________________________________________________________________________________________
____________________________________________________________________________________________________________________________________________________
Cummins Generator Technologies Germany GmbH Cummins Generator Technologies Germany GmbH
Ingolstadt Branch Dreieich Office
Bunsenstraße 17 Benzstraße 47-49
85053 Ingolstadt 63303 Dreieich
Germany Germany
www.cumminsgeneratortechnologies.com Phone: +49(0)841-792-0 Phone: +49(0)6103-5039-0
info@cumminsgeneratortechnologies.com Fax: +49(0)841-792-250 Fax: +49(0)6103-5039-40
Ersatzteile: 3.0.0.1 ms Spare Parts: 3.0.0.1 ms
Cummins Generator Technologies Germany GmbH Cummins Generator Technologies Germany GmbH
Ingolstadt Branch Dreieich Office
Bunsenstraße 17 Benzstraße 47-49
85053 Ingolstadt 63303 Dreieich
Germany Germany
www.cumminsgeneratortechnologies.com Phone: +49(0)841-792-0 Phone: +49(0)6103-5039-0
info@cumminsgeneratortechnologies.com Fax: +49(0)841-792-250 Fax: +49(0)6103-5039-40
Ersatzteile: 4.0.0 oRT Spare Parts: 4.0.0 oRT
Cummins Generator Technologies Germany GmbH Cummins Generator Technologies Germany GmbH
Ingolstadt Branch Dreieich Office
Bunsenstraße 17 Benzstraße 47-49
85053 Ingolstadt 63303 Dreieich
Germany Germany
www.cumminsgeneratortechnologies.com Phone: +49(0)841-792-0 Phone: +49(0)6103-5039-0
info@cumminsgeneratortechnologies.com Fax: +49(0)841-792-250 Fax: +49(0)6103-5039-40
Technical Data
Technical Data Sheet for AvK-Alternators FM 7.3-5
Cummins Generator Technologies Germany GmbH Cummins Generator Technologies Germany GmbH
Ingolstadt Branch Dreieich Office
Bunsenstraße 17 Benzstraße 47-49
85053 Ingolstadt 63303 Dreieich
Germany Germany
www.cumminsgeneratortechnologies.com Phone: +49(0)841-792-0 Phone: +49(0)6103-5039-0
info@cumminsgeneratortechnologies.com Fax: +49(0)841-792-250 Fax: +49(0)6103-5039-40
EC Declaration of Conformity
This synchronous a.c. generator is designed for incorporation into an electricity generating-set and fulfils all the relevant
provisions of the following EC Directive(s) when installed in accordance with the installation instructions contained in the
product documentation:
2006/95/EC Low Voltage Directive
and that the standards and/or technical specifications referenced below have been applied:
EN 61000-6-1:2007 Electromagnetic compatibility (EMC). Generic standards - Part 6-1: Immunity for residential,
commercial and light-industrial environments
EN 61000-6-2:2005 Electromagnetic compatibility (EMC). Generic standards - Part 6-2: Immunity for industrial
environments
EN 61000-6-4:2007 Electromagnetic compatibility (EMC). Generic standards - Part 6-4: Emission standard for
industrial environments
EN ISO 12100-1:2003 Safety of machinery - Basic concepts, general principles for design - Part 1: Basic
terminology, methodology
EN ISO 12100-1:2003 Safety of machinery - Basic concepts, general principles for design -Part 2: Technical
principles
BS 5000-3:2006 Rotating electrical machines of particular types or for particular applications - Part 3:
Generators to be driven by reciprocating internal combustion engines - Requirements for
resistance to vibration
The manufacturer’s authorised representative in the Community and person empowered to draw up this declaration and to
compile the relevant technical documentation, on behalf of the manufacturer is:
Das Explosionsschutzblech ist ein Schutzsystem The explosion protection device is a protective
zur Druckentlastung, das den Schaden im Falle system for decompression that limits the damage
einer Explosion im Klemmkasten örtlich begrenzt. caused by an explosion in the terminal box and
Eine Explosion kann im Fehlerfall durch einen keeps the effect local. A spark-over in the terminal
Überschlag im Klemmenkasten entstehen. Hierbei box can - in case of an failure - lead to an explo-
werden Luft und andere Materialien, aufgrund der sion. Due to extreme high temperatures, air and
extrem hohen Temperatur, schlagartig um ein other materials expand to a multiple of their nor-
vielfaches des Ausgangsvolumens ausgedehnt. mal volume.
Es wird versucht, den aus dieser Reaktion entste- Pre-determined breaking points are designed for
henden Druck gezielt durch Sollbruchstellen so reducing the occurring pressure so that the con-
abzubauen, dass die Auswirkungen der Explosion sequences of an explosion can be minimized.
minimiert werden kann. Primäres Ziel ist, dass Primary target is to eliminate the risk of danger to
eine Personengefährdung nahezu ausgeschlos- staff and other persons.
sen werden kann.
issued approved
Date 14.02.2008 14.02.2008
Position Mechanical Design Mechanical Design
Engineer Manager
Signature Andreas Bachhuber Thomas Koerner
Explosionsschutzblech
Explosion protection device