Escolar Documentos
Profissional Documentos
Cultura Documentos
KAD 30240/E
Issue 08/01
Mounting and
operating instructions
for series SE and SEH
brushless three-phase synchronous generators
AEM
Anhaltische
Elektromotorenwerk
Dessau GmbH After-sales service
Thomas-Müntzer-Straße 32 Tel.: +49 (0) 340 203304/305
06842 Dessau Fax.: +49 (0) 340 8501482
General safety instructions
Danger !
Is used for activities that may cause considerable personal or material damage.
Please read and observe these notes carefully and act particularly cautiously in these
cases. Make other users aware of these notes concerning work safety.
ATTENTION! Concerns the observation of regulations, notes or the correct sequence of working
steps to avoid damaging or destroying the machine, its parts and/or parts of the
equipment.
All work to be carried out on electrical machines such as assembly, connection or maintenance must only
be carried out while the system carries no voltage and is out of operation. Protect the system against
unintended reactivation.
These machines must only be transported, put up, connected, put into operation, maintenanced and oper-
ated by specialized staff being trained to observe the relevant safety and installation regulations. All proc-
esses must be checked by responsible specialized staff. These specialized staff must have been authorized
for their activities by the security system officer (for specialized staff regulations see
DIN VDE 015 or VDE 364).
The manufacturer's liability is only maintained if the operating instructions are being observed at
any time!
3
Table of contents
1 Description............................................................................................................................................ 7
1.1 Regulations and Classifications...................................................................................................... 7
1.2 Design ........................................................................................................................................... 7
1.3 Bearings......................................................................................................................................... 7
1.4 Cooling system .............................................................................................................................. 7
1.5 Exciter unit..................................................................................................................................... 7
1.6 Voltage regulator............................................................................................................................ 8
2 Behaviour during operation and notes on use........................................................................................ 9
2.1 Excitation, de-energizing................................................................................................................ 9
2.2 Setting range for voltages, set-point adjuster................................................................................ 10
2.3 Voltage response ......................................................................................................................... 10
2.4 Radio noise suppression .............................................................................................................. 10
2.5 Operation..................................................................................................................................... 10
2.5.1 Overload resistance .............................................................................................................. 10
2.5.2 Operation with different temperatures of the cooling agent .................................................... 11
2.5.3 Operation at power factors cos ϕ < 0.8 .................................................................................. 11
2.5.4 Maintenance at the drive and underspeed ............................................................................. 11
2.6 Short-circuit response .................................................................................................................. 11
2.7 Single operation ........................................................................................................................... 11
2.8 Parallel operation ......................................................................................................................... 11
2.8.1 Practical applications ............................................................................................................ 11
2.8.2 Neutral earthing current......................................................................................................... 12
2.8.3 Synchronization .................................................................................................................... 12
2.8.4 Parallel operation with statics ................................................................................................ 13
2.8.5 Parallel operation with compensating line.............................................................................. 13
2.8.6 Parallel network operation with statics................................................................................... 14
2.9 Emergency operation without regulator ........................................................................................ 14
3 Transport ............................................................................................................................................ 15
3.1 Check after delivery ..................................................................................................................... 15
3.2 Transport security device ............................................................................................................. 15
3.2.1 Cylindrical rolling bearings .................................................................................................... 15
3.2.2 Single bearing - and vertical generators ................................................................................ 15
4 Mounting............................................................................................................................................. 16
4.1 Installation and connection........................................................................................................... 16
4.2 Electrical connection .................................................................................................................... 17
4.3 Terminal box and connectors ....................................................................................................... 18
4.4 Direction of rotation...................................................................................................................... 18
5 First startup......................................................................................................................................... 18
5.1 Electrical check............................................................................................................................ 18
5.2 Measuring of the insulation value ................................................................................................. 19
5.3 Mechanical check ........................................................................................................................ 20
6 Maintenance ....................................................................................................................................... 20
6.1 General information ..................................................................................................................... 20
6.2 Lubrication and maintenance instructions..................................................................................... 21
6.2.1 Lubricant informations........................................................................................................... 21
6.2.2 Bearings with relubrication device ......................................................................................... 21
6.2.3 Removing used grease ......................................................................................................... 22
6.2.4 Bearings without relubrication device .................................................................................... 22
6.2.5 Maintenance ......................................................................................................................... 22
6.3 Slide Bearings.............................................................................................................................. 22
6.3.1 Oil renewal............................................................................................................................ 22
6.3.2 Inspection of bearings ........................................................................................................... 22
6.4 Cleaning ...................................................................................................................................... 23
6.5 Drying the winding........................................................................................................................ 23
6.6 Assembly of bearings................................................................................................................... 24
7 Supplementary installations ................................................................................................................ 24
7.1 Temperature monitoring............................................................................................................... 24
7.2 Standstill heater ........................................................................................................................... 25
7.3 Air filter ........................................................................................................................................ 25
7.4 Additional protection and measuring transformers........................................................................ 25
8 Storage instructions ............................................................................................................................ 25
9 Troubleshooting .................................................................................................................................. 26
4
9.1 Thermal and mechanical problems .............................................................................................. 26
9.2 Voltage problems ......................................................................................................................... 26
9.3 Checking and replacing the rectifier diode.................................................................................... 27
9.4 Testing varistors........................................................................................................................... 27
9.5 Replacing the regulator ................................................................................................................ 27
9.6 Problems overview ...................................................................................................................... 28
10 Spare parts...................................................................................................................................... 30
11 Appendix ......................................................................................................................................... 30
5
View of generator N side
Description of view
6
Description
1 Description
1.1 Regulations and Classifications
The generators are made to comply with the regulations set in DIN EN 60034 / VDE 0530 (Rotating electri-
cal machines), all applicable IEC recommendations and order-specific customized classifications – specially
acc.to the most important marine classifications associations.
1.2 Design
The generators consist of
• one inner-pole main machine with salient or non-salient pole rotor
• one external-pole exciter with rotating rectifiers for transmission of the exciting power and
• one exciter device with electronic voltage regulator .
Generator, exciter and all other components required for excitation and regulation are designed to form one
compact unit. The casing consists of the stator, the end shields and a hood to serve as a cover for the ex-
citer uniton the N side. In the standard design, the terminal box is at the top and can be turned by 180 °.
Both terminal box and casing have specially designated earth connection points.
1.3 Bearings
The system is equipped with spring-loaded deep groove ball bearings, cylindrical roller bearings or plain
bearings as defined in the order.
In case of increased loads on the bearings, a cylindrical roller bearing is installed on the D side while a deep
groove ball bearing is on the N side to serve as counter bearing or, if necessary, a double bearing made up
of a cylindrical roller bearing and a deep groove ball bearing.
Machines in vertical design have an angular contact ball bearing to serve as counter bearing. All bearings
are dust-proof, are permanently lubricated up to shaft center height 315 mm and are provided with relubri-
cation devices with grease quantity regulation on both the D and the N side as from shaft center height 400
mm. Relubrication devices for shaft center height 315 mm are subject to special arrangements.
NOTE For bearing configuration observe “Appendix” and lubrication- and maintenance instructions
observe section 6.2.
NOTE For generator voltages higher 1 kV, an additional transformer with a secondary voltage of 400 V is
built in to separate the AVR from the high-voltage side. The AVR is in a separate connection box.
The exciter unit is protected against unauthorized changes.
Working principle
The remanent voltage produced in the stator winding [1] of the generator causes a small current to flow
through the stator winding [4] of the exciter via choke [6] and rectifier stack [8] thus setting off self-
excitation.
7
Description
The choke [6] limits the exciter current of the exciter. The exact value depends on the air gap between core
and yoke of the choke. The required air gap is adjusted by adding insulating material.
NOTE For generator voltages higher 1 kV, an additional auxiliary winding is built in into the stator. The
voltage of this auxiliary winding serve as remanent voltage and supply the choke.
The load current flows through the current transformer [7]. When load is put on the generator, the secon-
dary current of the current transformer [7] is added to the choke current. After rectification in the stationary
rectifier stack [8] – a six-pulse bridge circuit –, this alternating exciter current flows to the stator winding [4]
of the exciter. In order to protect the diodes against voltage surges, both the stationary rectifier stack [8] and
the rotating recitifier stack [5] are equipped with varistors [s1], [s2]. Choke current and secondary current of
the current transformer are adjusted such as to permanently maintain a generator voltage of approx. 10 %
above the nominal generator voltage while the generator rotates at its nominal speed and the voltage regu-
lator is disconnected.
Every time the nominal generator voltage is exceeded, the voltage regulator (AVR) [9] periodically
switches on settling resistor r31 that is located in parallel to the stator winding of the exciter [4]. This ensures
that the terminal voltage of the generator is kept at the value set by the set-point adjuster.
NOTE The chosen tappings of the winding to choke and current transformer have been optimally
adjusted to the generator in the manufacturer's test shop. You should therefore always con-
tact the manufacturer prior to making any changes.
R 10-K Standard type providing voltage regulation and staticization for parallel operation. Designed with
smoothing capacitor CK and varistor s2.
R 10-KC In addition to the R 10 K functions, this type provides a cos ϕ - regulation part. It can be used
either as a staticizing regulator or as a cos ϕ - regulator.
R 10-KF In addition to the R 10 K functions, this type provides a cascading, frequency-dependent voltage
regulation.
NOTE Read the enclosed documentation for special modifications of the AVR.
Connectors
The voltage regulator is connected via spring-loaded terminal strips as in Figure 1 and the enclosed wiring
diagram
350 - 450 V at 50 Hz 180 - 250 V at 50 Hz
350 - 490 V at 60 Hz 180 - 290 V at 60 Hz
cable 5 cable 5
U V U V
bl br bl br
R1 R2 R1 R3
AVR AVR
bl – blue br – brown
NOTE For generator voltages higher 500 V, the exciter is connected to tappings of the stator
winding at approx. 400 V. For generator voltages higher 1 kV the AVR is connected to a
special measuring transformer (400 V).
8
Behaviour during operation and notes on use
NOTE Use a current transformer in phase W for current registration. Only some of the parallel
winding branches of the stator winding are put through the converter.
(observe when disassembling the exciter)
Danger !
Observe during all setting and other work to be carried out on exciter and regulator
that all components supply voltage potential (about 400 V). Only trained specialized
staff are allowed to change settings using a suitable tool.
6 - 12 V
250 V
10A
K1 K2 K3 K4 K5 K6 K1 K2 K3 K4 K5 K6
excitation de-energizing
Figure 3: Generator excitation and de-energizing circuit
Danger !
Measure the generator voltage during the excitation process. Remove the external
voltage source immediately, when the generator voltage rises. Danger of inverse
voltage!
De-energizing
Use a contactor or suitable switch to produce a short-circuit between terminals K3 and K4.
Current load on the contacts is < 10 A (Figure 3).
Danger !
After de-energizing and while the drive is running, there is a residual voltage of up to
10 % of the mains voltage on the generator terminals Special notice for machines
with voltage more than 1 kV.
9
Behaviour during operation and notes on use
put in jumper R6 - R7
R6 R7 R8 K1 K2 K3 K4 K5
voltage stability
staticization
Figure 4: Connectors for external set-point adjuster
10
Behaviour during operation and notes on use
2.5.2 Operation with different temperatures of the cooling agent
The nominal output stated on the type label is only valid in conjunction with the stated temperature of the
cooling agent. For other temperatures, the following output changes apply:
T / °C 30 35 40 45 50 55 60
P / PN 1,06 1,03 1,00 0,96 0,92 0,88 0,84
11
Behaviour during operation and notes on use
NOTE Wrong distributions of non-inductive power (kW indicator not proportional to power output) is
always caused by the speed regulation of the generator drives. Wrong reactive power distri-
bution (kW distribution o.k., different current distribution) is caused by the voltage and stat-
ics settings of the regulator
Manual synchronization
Use the set-point adjuster to set the generator voltage to the mains voltage. After setting smallest frequency
and phase differences possible by means of a synchronoscope, the generator can be switched on. To avoid
the occurrence of inverse power after switching on the generator, the generator frequency should be about
0.2 Hz above the mains frequency.
Quick synchronization
Use an electronic synchronization device to automatically adjust the system to smallest possible voltage,
frequency and phase differences that also takes switching delay times in the zero crossover range of the
difference voltage into account for switching on.
12
Behaviour during operation and notes on use
If you find larger differences, the statics resistors must be readjusted. Statics values of 2 - 3 % at nominal
load and nominal power factor are sufficient for stable parallel operation. This test must not be made with
just using non-inductive load as this renders the statics inefficient.
NOTE Proceed as follows to make a supplementary test if only non-inductive load operation is
possible when changing the setting:
1. Connect the blue cable from phase U to W and the brown cable from phase V to
phase U of cable 5 on the choke terminal strip [6.1].
2. Put load on the generators.
3. The voltage drop corresponds to statics setting at cos ϕ = 0.8 and normal switching
conditions.
4. Reconnect all devices after the setup procedure.
cable 5 cable 5
br bl bl br
W V U W V U
choke terminal
strip [6.1]
choke [6]
13
Behaviour during operation and notes on use
The statics installation lowers the generator voltage if the reactive power increases. Greater statics causes
small current changes if the mains voltage changes. We recommend setting the open-circuit voltage higher
than the highest mains voltage occurring at the feeding point to avoid reactive power consumption by the
generator from the mains.
ATTENTION ! Observe the neutral earthing current described in section 2.8.2 and synchronization
conditions in section 2.8.3.
Danger !
The resistor is under mains potential and must therefore be protected against co n-
tact.
The voltage can be kept in the required range by readjustment under load.
The voltage tolerance value is approx. -5 % without readjustment.
14
Transport / Mounting
3 Transport
ATTENTION ! Only use suitable attachment devices (ring bolts, eye bolts) for transportation. The
attachment elements that are part of the machine are only made to carry the m a-
chine's own weight.
Check whether screw-type eye bolts are firmly screwed in.
It is not allowed to sling parts of the transport gear around shaft ends, pillow blocks,
sleeves, hoods or similar elements as this could cause considerable damage.
If a machine or unit is transported on its baseplate you must use the attachment d e-
vices provided in the baseplate. Units that must not be transported in one piece are
marked by a corresponding notice on the baseplate.
NOTE When transporting parts of disassembled machines ropes for lifting armatures should not be
slung around the shaft bearings. If no other way of transporting the element is possible, the
bearings must be sufficiently protected.
ATTENTION ! Remove the transport security device before putting the machine into operation for
the first time.
15
Mounting
4 Mounting
Danger!
Observe general security information
Coupling
The generator and bearings have been carefully mounted, aligned and completely tested by the manufac-
turer.
NOTE The rotor is dynamically balanced. The balancing state is marked in accordance with
DIN ISO 8821 at the D-side shaft-end.
Coupling of generators in double-bearing design to the drive unit should be realized by an
elastic clutch.
NOTE Coupling of generators in single-bearing design: Observe the special documentations in
appendix!
A suitable means for this is the centering drillhole in the shaft end. When putting in the clutch you have to
make sure that the shaft of the drive mechanism and the shaft of the machine to be driven are perfectly
aligned. Misalignment must be not greater than 0.05 mm. To avoid angle errors, the gap between the two
halves of the clutch must be measured at a 90 °C offset. The difference must be no greater than 0.05 mm.
If elastic bolts or denture clutches are used you must make sure to have congruent separations of the two
halves of the clutch. Changing the half clutches round is not allowed.
ATTENTION ! Because of the danger of damages occurring on the bearings, hammering or knoc k-
ing the driving elements on is not allowed.
16
Mounting
Pulleys are only allowed for machines of the type IM C2 as special feature design; they too must be dy-
namically balanced. Furthermore you must make sure to carefully align the two disks making up one pulley,
i.e. both shafts must be parallel to each other and the connecting line between the two disk centres must be
at a right angle to the shafts.
ATTENTION ! Check the pull of the belt. For information about the max. admissible belt tension
please contact the manufacturer. Increasing the pull of the belt shortens the servic e-
able machine life.
ATTENTION ! In any mounting work, this setting must be strictly adhered to. To adjust the rotor at
the magnetic centre, the dimension X is given on the bearings.
Figure 7: Dimension X
This dimension (see figure 7) must be checked after the coupling has been mounted, and if necessary the
alignment of the coupling and machine must be corrected.
4.2 Electrical connection
ATTENTION ! Only have specialized sta ff set up the electrical connection in accordance with appl i-
cable safety regulations.
Observe all applicable national and international regulations. Connect the machine up according to the in-
formation given on the wiring diagram stuck on inside the terminal box. Refer to the wiring diagram for the
terminal points to connect the temperature winding protection, the bearing monitoring device, the speed
control device, the standstill heating system, the exciter connectors and additional transducers.
ATTENTION ! Connect the machines to earth using the corresponding protective earth terminals
inside the terminal box and on the foot of the machine stand.
Tightly set all connectors to avoid high transitory resistances. At the same time permissible tightening tor-
ques have to be held:
Thread M 10 M 12 M 16 M 20
Tightening torque in Nm 10 15,5 30 52
Align the cable lugs at the largest possible distance to other connecting points and to the casing.
ATTENTION ! Do not fall below the following distances between live c omponents and to the case:
Nominal voltage UN in V 550 725 1000 6000
minimal distance in mm 8 10 14 60
17
Mounting / First startup
Round terminal bolts of low voltage machines (< 1kV) have not been designed to serve as conductors for
the rating current. You must therefore always make sure to put cable lug on cable lug (Figure 8). If more
than three cable lugs are connected to one terminal, you should use a flat nut in between. Arrangement of
cable lugs, nuts and counternuts is to be made according to the illustration below.
For generator voltages higher 1 kV, the generators have got separate terminal boxes for the main connec-
tions and for the auxiliary and measuring connections.
4.4 Direction of rotation
The terminals are obligatorily marked in accordance with EN 60034-8 / IEC 34 Part 8. If rotating right, i.e. a
clockwise direction of rotation seen from the drive unit side, a right revolving magnetic field occurs on ter-
minals U, V, W. If rotating left, the magnetic field revolves to the left unless something else has been
agreed. If you want to operate the generator as described above, you must connect the static current con-
verter leads (Cable 7) to the regulator to terminals R4, R5 as shown in Figure 2. Should the network operate
with right rotating magnetic field two phases have to be changed on panel connection.
NOTE Machines that have been made to work only in one direction of rotation, this direction is
marked by an arrow on the machine, the ventilator or on the rating plate.
Contact the manufacturer if you want to change the direction of rotation of this typ of
machine!
Direction of rotation Rotation right only Rotation left only
Direction symbol è ç
5 First startup
When putting the machine into operation for the first time or after long downtimes, the following checks
have to be made.
18
Maintenance
Danger !
Protect the system against unintended reactivation!
Earth the windings before and after the measuring of insulation at least 10 s.
Don’t touch the windings before!
Measuring instrument: The measurement should be effected by a standard measuring instrument. Ob-
serve exactly the operating instruction.
Measuring voltage: Observe the table.
Measuring time: The measuring time should 1 min at least.
ATTENTION ! Disconnect the internal radio interference protection capacitors [10] before measu r-
ing.
The capacitors are attached to the exciter and connected to the generator frame via a cable. Disconnect this
lead and re-connect it after measuring. The test voltage of the measuring instrument used must be no
higher than 1000 V.
Insulation resistance
The following table serve to estimate the insulation resistance. Always estimate the insulation resistance
(Ris) of the cold machine, i.e. on room temperature (approx. 25°C). “Warm-values“ are not to comprehend
clearly.
The minimum insulation resistance on room temperature of a brand new machine or a repaired machine
with a new winding you find under item 1.
This value can drop by virtue of transportation and storage under bad environmental conditions. In this case
the insulation is not damaged. Machines, which stand still under bad environmental conditions for a long
time and do not have a standstill heater (dew on the windings), can be started-up, so long as the insulation
resistance of the cold machine do not drop under the values like shown in item 2.
Drop the insulation resistance under values of item 2, the windings must be dried. Under special operating
conditions the windings must be cleaned before drying (for that look to the item “Drying the winding“). The
insulation resistance must rise after a short operation of the machine.
Under normal transportation, storage and operating conditions the insulation resistance of the cold machine
must not drop under the values in item 2.
19
Maintenance
6 Maintenance
6.1 General information
Maintenance activities include bearings, cleaning the machine and the cooling air filters, if exist.
The following must be done according to operating condition but at least once every year:
• check the terminal boxes and terminals for cleanliness and corrosion
• check the electrical connectors for tight fit
• check the bearings for leckages of grease or oil
• check the cooling air circuit for cleanliness and sufficient operability.
Use a vacuum cleaner or bellows to remove dust from the machines, do not use pressurized air containing
oil or water. Make sure not to blow any dirt or dust into the inside of the machine. Do not use sharp tools for
cleaning.
If the winding is very dirty (oil vapours or grease squelching out of the bearings), use industrial solvent-
based cleaners (petroleum ether or diluter on petrol basis) or other aqueous industrial cleaners or emulsion
cleaners to remove the dirt. Make sure that the cleaners do not dissolve paint coats or plastic materials.
ATTENTION ! Provide sufficient ventilation when cleaning the machine and make sure not to let
any cleaning agents get into the waste water. Observe the environmental protection
regulations.
20
Lubrication and maintenance
If new sort of grease will be used (with same consistency class and saponification also) the bearings should
be regreased 3 times with shorten regreasing periods.
In case of longer downtimes or storage please remember that the maximum storage time of these greases
is 36 months. So we recommend to regrease brandnew machines too with shorten regreasing periods after
longer standstill time.
Check the proper functioning of the machine before and after each lubrication.
The used grease is automatically collected in a chamber underneath the bearing. The grease collector must
be emptied after three lubrication cycles unless otherwise stated. The grease collectors are marked by par-
ticular signs on the machine.
21
Lubrication and Maintenance
Danger!
Remove the used grease only while the machine is standing still.
• It is mandatory to observe the dates for removing the used grease, because too much increased
grease quantities would lead to an impermissible warming-up of the bearings.
• In some machine types, the used grease comes out of a covered gap in the bearing lid, accumu-
lates around the end shield and must be removed from there after several lubrication cycles.
• Machines of type V1 are equipped with grease pipes on the D and the N side. To clean these, you
remove the plugs on either side and push the used grease out to the left or right using a round stick
( Ø approx. 25 mm).
ATTENTION ! Make sure to dispose of the used grease in an environmentally friendly way.
6.2.5 Maintenance
Bearings have to be checked regarding to unusual sounds and admissible bearing temperatures periodi-
cally. If there are SPM measuring nipples or vibration pickups, then the values measured must be analysed
at the same time intervals. To remove the hood or the end shield of bearings with relubrication device, you
have to separate the lubrication tube from the screw connection (see 6.6 Assembly of bearings).
22
Maintenance
6.4 Cleaning
Cleaning cooling air filters
The filtering effect of the filter is achieved by a metal filter or layer of fiber filter element on the air inlet side.
Corresponding to operating conditions, clean the filter at regular intervals or after the thermal safety device
has reacted
•
• Remove filter plate
• Shake or blow off loose dirt
• Wash the layer of fiber filter elements using water and solvent-free agents, then dry
• Wash metal filters with petroleum ether, blow through with air and then lubricate with filter oil.
ATTENTION ! Observe environmentally friendly disposal.
23
Maintenance /.Supplementary installations
2. pull Assembly:
Push tube right in.
lubricating tube
• Disconnect the leads connected to terminals K1 to K6 inside the terminal box and pull the leads
through and in.
• Disconnect leads U, V, W from choke terminal strip or rectifier plate for exciter supply.
• Disconnect the primary winding leads of the current transformer.
• Carefully mark the primary cable of the static converter; during assembly observe direction K-L of
current flow (see functional diagram).
• Disconnect leads of the rotating rectifier stack.
• Loosen carrier disk and remove the rotating rectifier stack.
• Line the generator air gap.
NOTE Set the armature such that one pole points down
• Disassemble the bearing components, bearing lid, labyrinth box, excenter and remove the end
shield including the entire exciter unit after unscrewing the screws in the ring around the stator cas-
ing.
NOTE Use the attachment screws to remove the end shield from the centering device by screwing
them into the threads provided for this purpose.
• Pull out the old bearing and put in the new one after warming it up to 100 °C (water test).
• Lubricate the bearing. Completely fill the bearings to the rim with grease.
• Fill the gap between bearing lid and shaft with grease leaving the bearing lid empty.
Proceed in opposite direction for assembly making sure in particular to carefully connect all leads according
to the enclosed wiring diagram.
D-side
• Line the generator air gap from the N-side.
• Disassemble all bearing components and the end shield and change bearings as described for the
N-side.
7 Supplementary installations
These only exist in customized solutions upon special request.
7.1 Temperature monitoring
Connect the temperature sensors for monitoring e.g. the stator winding temperature, bearings or coolant via
the supplementary terminals provided in the terminal box according to the enclosed wiring diagram.
Rules and information given in section 4.2 "Electrical connections" apply.
24
Supplementary installations /.Storage instructions
shaft centre height in mm 225, 250 315, 400 450, 500 630 710
heating output in W 84 150 300 520 780
The connecting terminals are marked and located in the machine's terminal box. The supply voltage is
220 / 230 V unless otherwise agreed. Connect the standstill heater to the relevant terminals in the terminal
box according to the current switching diagram.
NOTE For specific heater output and voltage : see information sign in the terminal box
ATTENTION ! Activate the standstill heater only after switching off the machine.
Provide suitable means to avoid unintentional operation of the standstill heater while
the machine is running (locking mechanism).
Danger !
Switch off the standstill heater via the control centre before opening the terminal
box! Check whether the system is in a voltage-free condition.
8 Storage instructions
The machines should be stored vibration-free in a dry room free of dust. In this case, special packaging is
not required. Otherwise, the machines must be kept in plastic foil with humidity absorbing material. Provide
covers to protect it against rain and sun.
Manually race the armature at regular intervals to avoid damage to the bearing.
Armatures of machines provided with transport security devices are not raced as long as the security device
is applied and functional. Observe the instructions given in section 5 prior to first operation
25
Troubleshooting
9 Troubleshooting
ATTENTION ! Immediately switch off the drive if a failure occurs.
Carefully inspect the generator while in a voltage-free condition.
ATTENTION ! Check-ups of exchanging of parts must only be carried out by trained specialized
staff in accordance with IEC 364 observing all applicable regulations of health care,
safety at work and fire protection. While measuring or setting parameters with the
machine running, you must be aware of the fact that all unprotected terminals may
carry very dangerous voltages and that they are in immediate proximity to rotating
parts. The machine must therefore be locked to avoid contact by unauthorized pe r-
sons.
26
Troubleshooting
- + -
3 Nm
∼ 1 2 3
∼
5 Nm 1 2 3
∼
4 5 6
+
Figure 10: Test instrument setting for rotating Figure 11: Test instrument setting for stat. recti-
rectifier fier
27
Troubleshooting
9.6 Problems overview
ATTENTION ! For safety reasons, you must inte rrupt the connection between stationary rectifier [8]
and stator winding [4] of the exciter before measuring the remanent voltage. Do not
touch voltage-carrying parts, as the remanent voltage is usually in the range between
approx. 5 to 10% of the rated voltage.
NOTE For generator voltages > 1 kV measure the remanent voltage on the terminals of au x-
illary winding X 020 only.
Problem: No generator excitation at idling speed
ATTENTION ! Measure the generator voltage before trying to find the problem.
Action Consequence Cause of failure, further actions
Connect battery "+" pole to K3 no generator ex- • check stat. rectifier [8] (section 9.3)
and "-" pole to K4 citation • replace if defect
• check rot. diodes [5] and varistor [s1]
• replace if defect
check current forwarding of rot. exciter winding [2]
on "+" and "-" bar of the rot. exciter [5]
• check current forwarding of exciter winding [4] of
the exciter
• to do so disconnect wire 3 from K3, K4 and
measure between K3 - K4
generator excita- • remanent voltage was too low
tion to nominal • immediately disconnect battery
voltage
without battery • check stat. rectifier [8] (section 9.3)
support voltage • replace if defect
breakdown of
generator voltage check current forwarding of choke [6] between UVW
and XYZ
Problem: Generator voltage too low and not adjustable during operation
Action Consequence Cause of failure, further actions
• Deactivate regulator generator voltage • regulator problem
• Disconnect conductor from is approx. 1.1 x UN • replace reg. or go into emerg. oper. mode
terminal R10 (insulate) and (section 2.9)
run generator at nominal
speed generator voltage • check rectifier stacks [5] and [8] (section 9.3)
does not change • replace if defect
• check the connections of choke [6]
Problem: Generator voltage too high and not adjustable during operation
Action Consequence Cause of failure, further actions
Check connection of external
set-point adjuster
Check function of settling resis- generator voltage • settling resistor r31 or connectors defect
tor r31 is approx. 0.8 x UN • replace resistor, repair lead
generator voltage • regulator problem
does not change • replace reg. or go into emerg.oper.mode
(section 2.9)
• Check air gap of choke [6] If the yoke is loose, set the air gap such that the
• Yoke and shims must be systems sets itself to approx. 1.1 x UN at nominal
firmly attached speed and without voltage regulator (disconnect
lead from terminal R10 and insulate)
28
Troubleshooting
29
Spare parts / Appendix
10 Spare parts
The following information is required for ordering spare parts:
What ? Where ?
Name of part enclosed spare parts list
Generator type rating plate
Output ”
Voltage ”
Serial number of generator (absolutely necessary! ) ”
Carry out dynamic balancing after replacing any rotating parts (with the exception of the rotating
rectifier [5]).
Bearing configuration - see appendix
spare parts and names of parts - see appendix
11 Appendix
Bearing configuration
Terminal connecting plan
Spare parts and names of parts
Wiring diagram
cos ϕ- regulator
U / f-regulator
Temperature monitoring
Special mounting instructions - water cooler
Special mounting instructions - pony motor
Lubrication and maintenance instructions for bear-
ings
30
Internes Betriebsmittel / Klemmen-/
int. electrical equipment terminal Externes Betriebsmittel /
Mess- Kabel- Ziel- Typ Leiste external electrical equipment
fühler farbe klemme
cable- type strip Anschlusswerte/
sensor destination
color techn.parameter
c -X100 Erregergerät / exciting device
W8 br -R:6 a 1 ext. Spannungseinsteller /
2,5 k Ω 1W
bl -R:8 a 2 ext. voltage adjuster
br -R:12 d 3 + Erregung / excition 12 V DC 1 A
W4 br -G+4:F1 Entregung / de-energizing
250 V DC 10 A
bl -G+4:F2 d 4 Notbetrieb / emergency
W3 100 Ω 2A
bl -R:9 − operation
a 5
sw -R:11 a 6
c -X110 W icklungsüberwachung / monitoring of windings
↑↑ a 1
B110 ϑ Pt 100- Messfühler / sensor Phase U
a 2
a 3 TLimit =
B111 ϑ↑ ↑ Pt 100- Messfühler / sensor Phase V
a 4 130°C
a 5
B112 ϑ↑ ↑ Pt 100- Messfühler / sensor Phase W
a 6
↑↑ a 7
B113 ϑ Pt 100- Messfühler / sensor Phase U
a 8
↑↑ a 9 TLimit =
B114 ϑ Pt 100- Messfühler / sensor Phase V
a 10 130°C
a 11
B115 ϑ↑ ↑ Pt 100- Messfühler / sensor Phase W
a 12
c -X130 Lagerüberwachung / monitoring of bearing
a 1 Pt 100- Messfühler N-Seite/
B130 ϑ ↑↑
TLimit = 90°C
a 2 sensor N-side
a 3 Pt 100- Messfühler D-Seite/
B131 ϑ
↑↑
TLimit = 90°C
a 4 sensor D-side
c -X150 Kühlerüberwachung / monitoring of cooling
a 1 Pt 100- Messfühler Kaltluft /
B150 ϑ↑ ↑ TLimit = 45°C
a 2 sensor cold air
a 3 Pt 100- Messfühler Warmluft /
B151 ϑ↑ ↑ TLimit = 80°C
a 4 sensor hot air
bl :BU a 5
B153
br :BN a 6 Leckage-Messfühler / leakage sensor
sw :BL a 7
c -X160 Mess-,Schutzwandler / measuring, protecting transformers
S1/k
br -T1.U:S1 a 1 Achtung! /
T1.U Phase U 2000 / 1 A
S2/l bl -T1.U:S2 a 2 Attention!
S1/k
br -T1.V:S1 a 3 Bei Auslieferung
T1.V
kurzgeschlossen. / Phase V 45 VA
S2/l bl -T1.V:S2 a 4
S1/k
br -T1.W:S1 a 5 Short-circuited
T1.W
bl a
Phase W Kl.0,5
S2/l -T1.W:S2 6 by delivery
c -X200 Stillstandsheizung / anti-condensation heater
d 1
230 V
E200
d 2 max. 3 A