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H. Cegielski-FSA 09/2005

Contents

1 General Notes and InstructionsSafety precautionsCheck listMaintenance scheduleCustomer contact list & complaint report

2 DrawingsDimension drawing alternator AZ 44914.2Rotor drawing 85874

3 Circuit DiagramCircuit diagram K 811.0.181Legend to circuit diagram K 811.0.181

4 Operating InstructionsThree-phase synchronous electrical machines series DSG 29...144Enclosure to operating instructions

5 Regulator DescriptionsVoltage regulator Cosimat N+

6 Bearings ZollernInstallation and operating instructions for Zollern ZF plain bearingsLubrication for Zollern Z-bearings

7 Spare PartsDrawings nos. 121poE, 221oE, 30NSoW, 401, 60obi

8 Technical DataTechnical data sheetTest report 81 27 280 A002

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General NotesSafety Precautions

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Read this advice as well asthe operating instructionssupplied prior tocommissioning or storage of

the generator.Any works on the generator have to beperformed by qualified and trainedpersonnel only.Any person, working on the generatorhas to read and understand theseoperating instructions.

1. General Notes

1.1 Important notes for users

In the following instructions you will findimportant information and safety advice fortransportation, installation and operationfor AvK generators of the series DSG andDIG.

AvK generators are designed for differentapplications for the use on land as well asoffshore. Series DIG is dimensioned for anominal voltage bigger than 1 kV, DSG fora nominal voltage up to 1 kV. Please referto the rating plate mounted on the

generator for design data and as well as inthe data of the respective order.

Any works on the generator has to beperformed by qualified and trainedpersonnel only. The necessaryqualification can be obtained by training orcourses through the manufacturer.Technicians can obtain a specialgenerator training at AvK Germany.

The installation should preferably be

performed by an AvK service technician orby a specially trained qualified technician.

The operating instructions are to be keptclose to the generator and have to beavailable for the personnel at any time.

Please take notice of the safetyprecautions in chapter 2. Further safetyprecautions are mentioned in therespective chapters.

The order related data of the generator aswell as the operating instructions for

additional parts can be found in thedocumentation.

The documentation, including theoperating instructions, are part of themachine and have to be passed on to thenext user in case the generator is sold ormoved.

1.2 Liability and guarantee

All statements and advice in the operatinginstructions are made under considerationof our present knowledge and experience.

The technical informationand data, described in this

manual, is the correct stateof information at time ofprinting. We reserve the right tochanges due to technical progresswithout changing this operatinginstruction. Accordingly, no claims canbe made from statements anddescriptions in this manual.

We will not be liable for any damages orbreakdowns due to operating mistakes in

disregard of these instruction or improperrepairs.

We particularly point out, that spare partsand additional parts not supplied by AvK,have to be accepted by AvK. AvK willexclude any liability for damages thatresult from the use of spare and additionalparts that have not been accepted by AvK.The installation or use of foreign productsmay possibly change the constructivelygiven design of the electric machine in a

negative way, and may restrict the safetyof persons, machine or other values.

Any unauthorized modifications andchanges on the generator are not allowedfor reasons of safety and will exclude anyliability of AvK for resulting damages. Iftransformers supplied by the customershall be installed in the terminal box, AvKhas to be consulted first.

The preceding notes do not extend theterms of liability and guarantee of thegeneral delivery terms of AvK.

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Manufacturer's Address

AvK Deutschland GmbH & Co. KGBunsenstrae 17D-85053 Ingolstadt

Phone (+49) (0)841 / 792-0FAX (+49) (0)841 / 792-250

All rights reserved. Reprintsor copies - even extracts -need the permission of AvK.

2. Safety Precautions

During transportation, installation,

commissioning and maintenance, certainworks might have to be performed on thegenerator, e.g. on feet support, shaft end,bearings, terminal box, etc. The workingarea and area of danger includes thesurroundings of the generator and theprime mover.During normal operation, the working areashould be limited to the operating andmonitoring devices of the switchboard.

Despite taking into consideration all safety

precautions, the generator may be asource of danger, electrically andmechanically. To avoid damages topersons and values, all safety precautionshave strictly to be followed.

Beside all safety notes in the operatinginstruction the local safety precautions andrules for the prevention of accidents haveto be followed.

2.1 Description of symbols and advice

The following symbols are used in theinstructions to highlight particular pointsand actions:

Warning! Life in danger!

Danger!

Besides these safety notes all local validinstructions for safety and accidentprevention have to be followed.

Follow all warnings andadvice and act very carefullyin these cases. Inform allpersons working on the

generator about all work-safetyregulations.

2.2 Signs on the generator

At particular dangerous points on thegenerator you will find safety notes. Toavoid damages to persons or values these

safety notes have to be followed verystrictly.

Achtung!BetriebsanleitungIm Klemmenkasten!Vor Inbetriebnahme unbedingt lesen.

Caution!Operating instructions are inside theterminal box. These must be read prior to

commissioning.

The documents for the generator are inthe terminal box

Transportsicherungen.Vor Inbetriebnahme entfernen

Transport Safety DevicesRemove prior to commissioning.During transportation the rotor is secured

against shifting. The transport safetydevices have to be removed beforecommissioning.

Maschine nicht betriebsfhig!

Machine out of order

This sign is mounted when the installationof transformers in the terminal box isnecessary. The transformers have to beinstalled prior to commissioning. In this

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After completion of the maintenance work,it must be ensured that all protection andsafety devices are back in place properly.

2.5 Special Dangers

The operator of the machinehas to take care, that therules for fire protection arekept and the equivalent

agents for fire extinction are availablenear the machine and ready for use.

3. Shipping, Handling, Storage

3.1 Safety precautions for transport

Please comply with the localvalid regulations forshipments.

Warning!Never move loads overpersons!

The shipment and the unloading of thegenerator must only be performed bypersonnel, who are familiar with the

lifting cranes and correspondingdevices.

The lifting devices have to be designedfor the weight of the generator(Chapter 3.4).

Follow the shipping instructions(pictographs) on the cover of thegenerator.

The generator must only be supportedon its feet. The support on any otherpart is not permitted. That is why thegenerator is delivered with atransportation construction.

For the lifting of the generator, ringbolts are mounted on the generatorhousing.

Ring bolts, that are mountedon add-on pieces like e.g. the

cooler top, must not be usedto lift the whole machine!

They are only used as mounting devicefor these add-ons.

The ring bolts can only be used for thetransport of the separate machine,they are not designed to lift thecomplete unit (generator and primemover)

For transporting the machine, thefollowing devices are permitted:

- Cable and chains,

that comply with the local regulations,that have a sufficient carrying capacity,that are in an excellent working condition

It is not permitted to usecables that are torn or worn.Cables and chains may not beknotted. Cables and chains

must not touch any sharp edges.

- Lifting devices: cranesoverhead cranes

Moving the machine over roughground e.g. rails, by using a haulage

car is not permitted. This may causedamage to the bearings and thewindings. This is especially importantfor the moving of the machine withinthe factory.

3.2 Packaging

The material used for the packing of thegenerator is made of ozone-friendlymaterial like wood. The packagingdepends on the mode of transport used surface, water or air freight.When the transport time is for a longerperiod, then the generator will be packedin a protective covering against dust orhumidity.

3.3 Checking for Shipping Damage

We recommend checking thegenerator for shippingdamages and complete

delivery by the time ofdelivery.

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If there are damages on the goods (opendamages) report these to the haulagecontractor at take-over. In this case, thereceipt should only be given underreservation with a written statementregarding the estimated amount of thedamage.

If damages that were not noticeable by thetime of delivery (covered damages), aredetected later, they have to be reportedpromptly to AvK, latest 6 days after receiptof the delivery.

3.4 Unloading the generator

The unloading has to be performed in

compliance with the safety precautions fortransport (see chapter 3.1) and the localsafety precautions and rules for theprevention of accidents.

Please refer to the freightpapers and the data of therespective order (Ratingplate) for the weight of the

generator.The weight of the generator is alsowritten on the rating plate.

3.5 Storage of the generator

After unloading, thegenerator and possibleboxes with loose parts haveto be stored until installation,

following the shipping instructions.

Wrapped parts and assessories must notbe unwrapped if the generator is stored fora longer period of time.

The machine and packages have to bestored in a safe place, dust-free and dry(humidity < 75%). Avoid mechanicalvibrations and damages.

If it is planned to store thegenerator for a longer periodof time, please contact AvKfor further information.

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AvK Deutschland GmbH & Co. KGBunsenstrae 1785053 Ingolstadt, GermanyPhone: +49(0)841-792-0Fax: +49(0)841-792-250e-mail: [email protected]

AvK Deutschland GmbH & Co. KGDreieich branchBenzstrae 47-4963303 Dreieich, GermanyPhone: +49(0)6103-5039-0

Fax: +49(0)6103-5039-40e-mail: [email protected] newage-avkseg com

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AvK Checklist to Order No. Page 2

Customer: .............................................................

Order No.: .............................................................

Generator Type: .. ... .. .. ... ... .. .. ... ... .. .. ... ... .. .. ... ... .. .. ... .. .. ... ..

Operation Hours: ..... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

Bearing design: Roller bearing o

Sleeve bearing o

YES NO

Replacement of oil: o o

YES NO

Bearing inspection performed: o o

I. Electrical Inspection

Pos. 1.1 - 1.19

II. Mechanical Inspection

Pos. 2.1 - 2.20

III. Test Run

Pos. 3.1 - 3.14

IV. Maintenance Result

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Environmental Conditions:

a) Location: building o marine o

b) Atmosperic conditions: dry o high humidity o

dust o salt o

c) Ventilation: unrestricted o adequate o

restricted o inadequate o

Operating Conditions:

a) Site duty: single o parallel o idle o

b) Duty cycle: 24 hours o daily o occasionally o standby o

c) Load condition: inductive o non linear o

d) Operation: manned o unmanned o

Generator Conditions:

a) Dirt content: slight dust o light layer dirt o

thick dust o thick compact dirt o

b) Corrosion: none, very little o steel/iron o

copper o severe o (....................)

c) Engine: Type: ....................

Serial No.: ........ ......... ...

Fuel: ....................

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I . Electrical Inspection

performed Complaints

see page 11

o 1.1 Examination of cable entry and cable shoes o

to main terminal box

o 1.2 Examination of strain relief of connecting power cables o

o 1.3 Check of fixation of transformers installed o

o 1.4 Examination of cable entry and cable shoes o

to auxiliary terminal box

o 1.5 Check of strain relief of connection cables o

o 1.6 Insulation test of stator windings o

o a) Stator winding phase U against ground oResistance ............. M Voltage ............. V

o b) Stator winding phase V against ground o

Resistance ............. M Voltage ............. V

o c) Stator winding phase W against ground o


1.7 Insulation test of stator windings

o a) Stator winding phase U against phase V oResistance ............. M Voltage ............. V

o b) Stator winding phase U against phase W o


o c) Stator winding phase W against phase V o


o 1.8 Resistance measurement of stator o

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see page 11

o 1.9 Check and re-tightening of all screws and nuts o

in main terminal box by dynamometric key

o 1.10 Cleaning and examination of insulators for cracks o

o 1.11 Re-tightening of contact screws and nuts on o

auxiliary terminal strip

o 1.12 Resistance measurement of auxiliary windings o

o 1.13 Insulation test of auxiliary windings o

o 1.14 Examination of anti-condensation heater o

............. V ............. A

o 1.15 Insulation resistance measurement of rotor winding

o a) Insulation measurement main rotor o


o b) Insulation measurement exciter rotor o


o 1.16 Resistance measurement of rotor o

o 1.17 Inspection of rotating rectifiers o

o 1.18 Inspection of stator end winding with endoscope o

o Inspection of stator end winding without endoscope o

o 1.19 Inspection of rotor winding with endoscope o

o Inspection of rotor winding without endoscope o

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I I. Mechanical Inspection


see page 11

Sleeve Bearing Design

YES NO

Oil lubrication system installed: o o

o2.1 Check of oil level in sleeve bearing

o

o 2.2 Check for leakage of sleeve bearings o

o 2.3 Inspection of sleeve bearing with endoscope o

o Inspection of sleeve bearing without endoscope o

o 2.4 Check of oil quantity of oil lubrication system o

o 2.5 Check of oil pressure of oil lubrication system: o

.................... mbar

o 2.6 Check of oil temperature of oil lubrication system o

o 2.7 Check of oil pressure inside the bearing housing o

.................... mbar

o 2.8 Check of lubrication ring o

o 2.9 Check for any corrosion on drive side and non-drive side bearing o

o 2.10 Oil viscosity used: according to ISO VG ................. o

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see page 11

Roller/Ball Bearing Design

o 2.11 Relubrication of roller/ball bearing according to operating instructions o

o 2.12 Removal of surplus grease o

o 2.13 Removal of old grease from bearing covers o

Additional Mechanical Checks

o 2.14 Inspection of abrasion of earthing brush o

o 2.15 Inspection of base frame for mechanical deviations o

Mounting of alternator / Check of feet fixation

o 2.16 Visual inspection of the drive coupling o

o 2.17 Check of inlet and outlet airducts for dust and dirt o

o 2.18 Check of inlet and outlet airducts for corrosion o

o 2.19 Cooler / leakage monitoring o

o 2.20 Check of drainage stoppers / drainage for condensation owater

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III. Test Run


see page 11

o 3.1 Check whether earthing switch is disconnected o

o 3.2 Check of bearing noise o

o3.3 SPM bearing analysis: DE: LR .......... HR ..........

o

NDE: LR .......... HR .......... o

o 3.4 Check of oil amount in sleeve bearings during operation o

o 3.5 Effectivity of lubrication ring o

o 3.6 Tripping of temperature protector for check o

of alarm and shut down

o 3.7 Vibration test / Vibration values (mm/s) o

DE: .......... Hor. .......... Ver. .......... Axi.

NDE: .......... Hor. .......... Ver. .......... Axi.

Frame: ............. Airduct inlet: ............. Airduct outlet: .............

Output: ............. kW

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see page 11

o 3.14 Bearing and winding temperature after continuous o

operation

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

__________________________________________

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IV. Maintenance Result

Complaints:

___________________________________________________

___________________________________________________

___________________________________________________

___________________________________________________

___________________________________________________

___________________________________________________

___________________________________________________

___________________________________________________

o The operation of the alternator can be continued without immediate

elimination of the complaints.

o Electrical and mechanical checks were performed without anycomplaints.

o The alternator must be stopped immediately due to the complaints.

Date: ________________ ________________________

(Signature Customer)

________________________

(AvK-Service-Technician)

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AvK Deutschland GmbH & Co. KGBunsenstrae 1785053 Ingolstadt, GermanyPhone: +49(0)841-792-0Fax: +49(0)841-792-250e-mail: [email protected]

AvK Deutschland GmbH & Co. KGDreieich branchBenzstrae 47-4963303 Dreieich, GermanyPhone: +49(0)6103-5039-0

Fax: +49(0)6103-5039-40e-mail: [email protected] newage-avkseg com

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AvK Deutschland GmbH und Co. KG Page 1 of 2

Suggested Maintenance Schedule for AvK Order No.:

Customer:

Date:

Pos. A Components Frequency Maintenance Carried out by1 General alternator check 12 month According to AvK Checklist. AvK

Pos. B Additional components Frequency Maintenance Carried out by1 Rotor windings 12 month *) The insulation resistance must be checked with a megger AvK

when the alternator has reached ambient temperature.

2 Exciter approx. 25,000 h *) Remove any accumulated dust from the rotating rectifier AvK

and the exciter stator. Check if the electrical connections

are secure.

3 Rectifier assembly approx. 25,000 h *) Remove dirt adhering to the rectifier unit parts. AvK

4 Stator end winding approx. 25,000 h *) Inspect and remove deposits of dust, dirt and grease. Do AvK

not use any abrassive materials or fluids. Use only

electrocleaner.

Caution: In case of heavy winding contamination please

call the AvK Service Department.

5 Protection equipment 12 month *) Check mechanical and electrical connections according AvK

to the suppliers specification / manual.6 Space heater 6 month Ensure that the electrical heater is operating to prevent Customer

condensation. Check the power supply as well as the

insulation resistance.

*) Maintenance frequency depends on the operating conditions at site.

Maintenance-e.xls Service / Steller Date: 18.04.2000

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AvK Deutschland GmbH und Co. KG Page 2 of 2

Suggested Maintenance Schedule for AvK Order No.:

Customer:

Date:

Pos. B Additional components Frequency Maintenance Carried out by7 Ball and roller bearings Grease relubrication acc. Check oil or grease for any contamination particles. AvK / Customer

to suppliers manual

and/or name plate.

6 month SPM bearing analysis. AvK

8 Sleeve bearing: Oil ring 6 month Ensure that the oil ring is rotating freely and picking up Customer

enough oil when the shaft is turning.

9 Sleeve bearing: Oil seals 6 month Check for oil leaks. Customer

25,000 h *) The oil seals must be changed. AvK

10 Sleeve bearing: Complete check 50,000 h The bearing check must be done (according to suppliers AvK

manual) and the oil seals must be changed.

11 Oil pipes and flanges 6 month Check for oil leaks. Customer

After the first 500 running hours it is recommended to

tighten the screws of the flanges again.

12 Sleeve bearing: Oil level monthly The oil level must be visible in the viewing glass. Customer

(Approx. one third of the diameter.)

13 Bearing earthing brush 3 month Check the earthing brush for abrasion. Customer

14 Dust filter 3 month *) At the appropriate intervals, the filters must be checked Customer

to establish their degree of contamination with dust and

dirt.15 Cooler 6 month Check the cooler elements and leakage detector. Customer

16 Complete alternator 100,000 h Review with manufacturer for recommendations for full AvK

inspection / overhaul.

*) Maintenance frequency depends on the operating conditions at site.

Maintenance-e.xls Service / Steller Date: 18.04.2000

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Customer Contact List

Service and Warranty Claim Handling for Av

Dokumentenname:

Customer contact.doc

Stand: B vom 07.04.05

AvK Deutsch land GmbH & Co. KG

Technical Service on-site (after warranty):

Products Countries Contact E-mail

Al l AvKProducts

UK Sarah Nicholls [email protected] +4

Al l AvKProducts

SpainPortugal

John Johnson [email protected] Mo

Al l AvKProducts

Francefrench speaking North Africa

Rene Moulin [email protected] +3

Al l AvKProducts

ItalyGuiseppe Cinnirella [email protected] +3

Al l AvKProducts

Norway

SwedenDenmarkFinlandBaltic StatesRussia

Jan Jakobsen [email protected] +4

Al l AvKProducts

North AmericaSouth AmericaMexicoCentral AmericaCanada

Gary O`Malley [email protected]

00

Di

TO

Al l AvKProducts

AustraliaNew ZealandSouth Pacific

Theo Dragonas [email protected]+6

Mo

Al l AvK

Products

Switzerland Martin Lderach [email protected]+4Mo

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Customer Contact List

Service and Warranty Claim Handling for Av

Dokumentenname:

Customer contact.doc

Stand: B vom 07.04.05

AvK Deutsch land GmbH & Co. KG

Products Countries Contact E-mail

Al l AvKProducts

SingaporeMalaysiaPhilippinesIndonesiaThailandTaiwanVietnam

Richard Lee,

Anthony Tan

Trisno Sumarlin

(Indonesia)

[email protected]

[email protected]

[email protected]

+6

Mo

+6

Al l AvKProducts

China Jason Xu [email protected]+8Mo

Al l AvKProducts

Japan, Korea Darryl Hanna [email protected]+8Mo

Al l AvKProducts

India, Nepal R.K. Kapur [email protected] +9

Contact for Warranty Claims:

Product Countries Contact E-mail

Al l AvKProducts

Worldwide Norbert Steller [email protected]+4Mo

Issued Approved

am: 30.03.03 30.03.03

von: Norbert StellerService Manager

Emilia SandauAssistant Service Manage

Unterschrift: Norbert Steller Emilia Sandau

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Customer Complaint Report

Kunden- Beanstandungsbericht

FM 7.5-14

Page 1of 1

1.0 General Complaint informationAllgemeine Daten der Beanstandung:

CustomerKunde

Place of ComplainedAlternator Einsatzort

Contact Person CustomerAnsprechpartner Kunde

Customer Fax No.:Kunden Fax Nr.

Customer Phone No.:Kunden Tel. Nr.

Customer Complain No.:Kunden Beanstandungs- Nr.

Customer emailKunden Email

Type of alternator:Generator Typ

AvK Order.- Nr.: AvK Serial No.:AvKMasch.- Nr.:

2.0 Failure description / Fehlerbeschreibung

Defect PartDefektes Bauteil

3.0 Immediate measure by customer/ Sofortmanahme durch den Kunden

Initiated (date) / eingeleitet am:

Successfully completed (date):erfolgreich abgeschlossen am

4.0 Enclosures / Anlagen

Photos / Fotosothers:sonstiges

Distribution List: Customer => AvK Contact person, according to Customer Contact ListDA 7.5-1 or

AvK Hompage www.newage-avkseg.com

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Drawings

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Circuit Diagram

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Seite 1Page 1

Legende zum Schaltbild Nr.K 8**.*.**

Legend to Circuit Diagram No.

K 8* * .* .* *

F1, F2 Schutzschalter fr G3 Protection switch for G3NUR IM STILLSTAND BETTIGEN ONLY SWITCH ON AT STANDSTIL L

G1 Hauptmaschine Main machineG2 Erregermaschine Exciter machineG3 Hilfserregerwicklungen Auxiliary exciter windingsQ1 Schutzschalter Protection switch

NUR IM STILLSTAND BETTIGEN SWITCH ON ONLY AT STANDSTIL L31-32 Meldung 31-32 Signal

R11 Rotierender Varistor Rotating varistor R12 Rotierender Schutzwiderstand Rotating protection resistor R21 Vorwiderstand Serial resistor

T24 Spannungswandler fr Regler Voltage transformer for AVR BEI GEFFNETEM STERNPUNKT VON G1

UNBEDINGT ABKLEMMEN

DISCONNECT I F STARPOINT OF G1 IS

OPENT25-28 Spannungswandler Voltage transformerT30, 31 Spannungswandler fr G3 Voltage transformer for G3T32 Spannungswandler fr G3 mit integriertem

Schutzschalter F1F1 - nur im Stillstand bettigen!

Voltage transformer for G3 with integrated

protection switch F1

F1 - only switch at standstill !

V1 Rotierende Gleichrichter Rotating rectifiers

X1 Hauptklemmen Main terminalsX2-6 Klemmleiste Terminal strip

U1 Spannungsregler Cosimat N Alternator voltage regulator Cosimat N

R3 Unterdrehzahlschutz R3 Underspeed protectionR4 Interner Sollwert R4 Internal voltage settingR1 P-Anteil R1 P-PartS1 I-Anteil S1 I-PartR7 Statikeinstellung R7 Droop adjustmentR6 Statikwandleranpassung R6 Droop transformer adaption

R1 Sollwertpot. Generator Spannung (R = 500 ) Alternator voltage adjuster (R = 500 ) T6 Statikwandler Droop transformer '' ACHTUNG: Bei Regler lose: Regleranschlu CAUT ION: AVR loose supply:AVR connection

Drehrichtung rechts: Rotation clockwise:Leiste X2 Regler Terminal X2 AVRU U U UV V V VW W W WDrehrichtung links: Rotation counter clockwise:Leiste X2 Regler Terminal X2 AVRW U W UV V V VU W U W

Schnellentregung:Brcken UH1-24 und WH1-14 ffnen

Quick de-excitation:

Open bridges UH1-24 and WH1-14

Entregungsschalter: 220 V AC De-excitation switch: 220 V AC(nicht AvK Lieferumfang) 10 A (not AvK supply) 10 A

- - - - Verbindungen auerhalb des Generators Connections outside the alternator

Erstellt am: 12 10 1998 I ssued on: 12 10 1998

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Seite 2Page 2

Legende zum Schaltbild Nr.K 8**.*.**

Legend to Circuit Diagram No.

K 8* * .* .* *

ZUBEHR ACCESSORIESWiderstandsthermometer PT100 Resistance Thermometer PT100

A1-12 Statorwicklung Stator windingPhase U: 1, 4, 7, 10Phase V: 2, 5, 8,11Phase W: 3, 6, 9, 12

Phase U: 1, 4, 7, 10

Phase V: 2, 5, 8, 11

Phase W: 3, 6, 9, 12

A13, 14 Lager, B-Seite Bearing, NDEA15, 16 Lager, A-Seite Bearing, DEA20, 21 Generator Zuluft Alternator air inletA22, 23 Generator Abluft Alternator air outletA24, 26 Statorblechpaket Stator coreA27/28 Sekundr Khlmittel EIN/AUS Secondary Cooling agent inlet / outletAR1-24 berspannungsableiter Overvoltage arrester

C1 Entstrkondensator Interference Suppression Capacitor

Lagerschadendetektor Beari ng damage detectorD1, 2 B-Seite NDED3, 4 A-Seite DE

H, H1-5 Stillstandsheizung Anti condensation heater

L1-4 Leckageanzeiger Khler Leakage detector coolerLW1-4 Luftfilterberwachung Air filter supervision

SR1-6 Schleifring Slip ringSTW1-4 Drehzahlmesser Speed transmittor

Stromwandler Curr ent TransformerT8 fr Stand-by-Regler for Stand-by-unitT14-16 Fr Messung (M), Schutz (P) For Measuring (M), Protection (P)

Kern Nr. 1: X5, 1-6 (M) Core No. 1: X5, 1-6 (M)Kern Nr. 2: X5, 7-12 (P) Core No. 2: X5, 7-12 (P)Kern Nr. 3: X5, 13-18 (P) Core No. 3: X5, 13-18 (P)

T17-22 Messung Measuring

PTC Temperaturfhler PTC Temperatur e SensorTF1, 3 Statorwicklung, Warnung Stator winding, warningTF5, 7 Statorwicklung, Warnung Stator winding, warningTF2, 4 Statorwicklung, Abschaltung Stator winding, shut downTF6, 8 Statorwicklung, Abschaltung Stator winding, shut down

TF11, 13 Lager B-Seite, Warnung Bearing, NDE, WarningTF15, 17 Lager A-Seite, Warnung Bearing, DE, WarningTF12, 14 Lager B-Seite, Abschaltung Bearing, NDE, Shut downTF16, 18 Lager A-Seite, Abschaltung Bearing, DE, Shut down

Thermometer ThermometerTF20, 21 Lager, B-Seite Bearing, NDETF22, 23 Lager, A-Seite Bearing, DETF24, 25 Generator Zuluft Alternator air inletTF26, 27 Generator Abluft Alternator air outlet

WW1-4 Wasserdurchfluwchter Water flow indicatorZ1 Entstrfilter (Funkstrgrad K) Interference filter (R.I.S. degree K)

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Operating Instructions

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Operating instructionsThree-phase synchronous alternators, series DSG 29 ... 144with "COSIMAT C" or "COSIMAT N" voltage regulator

Before installing and starting up this machine, please read these instructions carefully.

Machine No._____________________________

Circuit diagram No. _______________________

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CONTENTS

1. Operating and maintenance instructions

1.1 Checking for damage incurred during transit1.2 Transport and storage1.3 Setting up the machine1.4 Cooling the machine

1.4.1 Coolant temperature1.4.2 Direction of cooling air1.4.3 Quality of cooling air

1.5 Preparations prior to starting up1.6 Machine drive

1.6.1 Belt drive1.6.2 Coupling drive1.6.3 Aligning the machine

1.7 Changing direction of rotation1.8 Electrical connections1.9 Starting up

1.9.1 Insulation resistance1.9.2 Operating speed

1.10 Interference suppression1.11 Operation1.12 Maintenance1.13 Bearings

1.13.1 Bearing types1.13.2 Permanently-lubricated bearings1.13.3 Regreasable bearings1.13.4 Assembling the bearings

1.13.5 Dismantling the bearings1.13.6 Monitoring the bearings

1.14 Dust filters and monitoring of thermal behaviour1.14.1 Synthetic filter elements1.14.2 Wire mesh filter elements

1.15 Drying out the machine1.15.1 Drying out with integral ventilation system1.15.2 Drying out by short-circuiting

2. Faults, causes and remedies for DSG machines with "COSIMAT C" and "COSIMATN" voltage regulators

3. Circuit diagram with voltage regulators "COSIMAT C" and "COSIMAT NNote: detailed information on the regulator and circuit diagrams is given in the de-scription and adjusting instructions for "COSIMAT C" and "COSIMAT N".

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1. Operating and maintenance instructions

1.1 Checking for damage incurred duringtransit

Immediately after receiving the machine, inspect itfor damage incurred during transit. The transport ordelivering company must be notified of possiblecomplaints immediately, or at the latest within sevendays of delivery (covered by warranty).

1.2 Transport

During transit and storage, the machine must notbe supported on the terminal box or air entry hood,or exposed to any sources of damage.

Store preferably at a constant temperature in a dry,well ventilated room where the machine will beprotected against sudden impact.

If transported over long distances, it is advisable toprotect the machine against the effects of theweather by sealing it in a plastic cover together witha quantity of desiccant (moisture indicator), so thatit remains dust-free and air-tight.

Machines with plain or taper roller bearings andmachines in a stored condition are supplied with

additional transit protection.

On dual-bearing versions with deep-groove ballbearings, the bearings are pre-loaded and aresupplied without an additional transit keeper.

This transit keeper should never be removed untilthe machine has been set up in its future operatingposition on site.

Install the transit protection again if the machine is,for instance, to be shipped on or stored as a sepa-rate unit after trials.

For transport as a complete machine set, take thenecessary safety precautions, for instance support themachine set on anti-vibration elements or attach tran-sit keepers.

1.3 Setting up the machine

The installation site must comply with the machinesenclosure rating and be sufficiently large for coolingand maintenance purposes.

When setting up the machine, make sure that:

the relevant operation and maintenance safety

cooling air can enter and exit freely

exhaust gas and heated cooling air cannotbe drawn in by the machine.

1.4 Cooling the machine

1.4.1 Coolant temperature

The machine is normally built to run at a cool-ant temperature of up to 40C and at an instal-lation height of up to 1000 meters above meansea level. Coolant temperatures higher thanstated on the machines data plate will result in

power loss.

At a coolant temperature of 45C, up to 96 %of the nominal power can be drawn off; at 50Cup to 92.5 % is permissible.

If the machine is ordered to run at coolant tem-peratures of higher than 40C, this is shown onits rating plate together with the alteration inpower rating.

1.4.2 Direction of cooling air

The machine is cooled by an integral fan de-pendent on the direction of rotation,mounted on the shaft. It draws cooling air fromthe non-drive end and expels it at the drive end.

If it is intended to use forced cooling on specialversions, either alone or to support the integralfan, the direction of airflow and rotation mustbe correct here too (see dimensions sheet fordata).

Important:

The distance between the fan inletor outlet on the machine and anynearby wall must not be less thanthe minimum dimension, otherwise

ventilation will be obstructed.

Minimum distance (guide value):1 x diameter of machine

1.4.3 Quality of cooling air

To extend the service life of the machine, and inparticular its windings and bearings, it is ex-

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tremely important that neither contaminated noraggressive cooling air be allowed to enter it.

An air filter can be installed if requested by thecustomer, or can be retrofitted provided sufficientspace is available.

1.5 Preparations for starting up

Pull the protective lacquer coating off the end of theshaft and the flange, or remove it with solvent.Never clean it off with emery cloth. Comply with therelevant regulations on environmental protectionand safety.

There is a threaded hole on the shaft, to which apuller can be attached for installing and removingdiscs or couplings. Hammering is not permitted, asthis can damage the bearings.

If the machine is delivered with transit keepers inposition, remove them.

If the machine is of single bearing design, its rotoris delivered attached to the shaft flange and thehousing by a steel hoop to prevent axial displace-ment and is located in position radially between theshaft and fan housing by an angle bracket. Thesteel hoop must be removed before assembly.

Make quite sure that the angle bracket and/or any

keepers are removed from the gap only after therotor has been centered on the drive shaft flange.Failure to do so can result in damage to the excitermachine and the B-bearing.

1.6 Machine drive

1.6.1 Belt drive

If the machine is driven by a belt, the machine mustbe ordered specifically with bearings and bearing

lubrication to match the higher loads. Most beltdriven machines have roller bearings on the inputside.

The rotor must be ordered with balancing byhalf key, and the grooved belt pulley must bedynamically balanced on a smooth mandrel. Thebelt must run smoothly, without jerking.

Desired balancing accuracy: Q 2.5 according toGerman VDI 2060 standard.

When flat-type belts or V-belts which have already

been in operation for a fairly long time are re-moved for maintenance purposes, they must be

replaced by new ones (since they will have be-come too hard for re-use).

Important:Belts that are tensioned too tightlycan put the bearings at risk. For thisreason, establish the correct belttension with the belt manufactureror the plant that supplied the ma-chine, and have checks carried outon site.

1.6.2 Coupling drive

The machine rotor is balanced with a halfkey. The grooved drive elements must thereforebe balanced accordingly.

The coupling must be dynamically balanced toan accuracy of Q 2.5 according to VDI2060.

The sensitive anti-friction bearings require thecouplings, belt pulleys etc. to be tightened byspecial devices. If this is not possible, heat theparts to 80C. They can then be pushed oneasily, provided the bore corresponds to toler-

ance class "H". Ensure that the drive elementsare securely located after tightening. They mustbe securely clamped against their mechanicalstops.

If the hub of the drive elements is shorter thanthe shaft end, this difference must be compen-sated by a spacer bushing to prevent imbalanceand uneven running.

1.6.3 Aligning the machine

Precise, careful alignment of the machine en-

sures that it runs with a minimum of vibration,thus extending the service life of the machineand in particular of the bearings. Only flexiblecouplings of low radial rigidity should be used.

Even slight errors of alignment canrapidly result in damaged bearings.

It is vital that all the feet are fully in contact.Uneven surfaces cause stresses in the bearingsand must be compensated for by attachingsheet metal strips. Once the machine is alignedcorrectly, secure it with dowel pins.

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When aligning a machine of single bearing designwhich is not flanged onto the drive motor, it is im-portant to comply with the reference dimen-

sions specified on the dimension sheet.This will ensure a uniform air gap beneath all polesand the correct axial position of the rotor.

To prevent damage to the crankshaft or drive mo-

tors plain bearings, it is essential to observe themanufacturers assembly instructions.

1.7 Changing direction of rotation

The machines fan is of a directional pat-tern.

Note that the rotary field also changes with a rever-sal in the direction of rotation.

If the machine is to be used in parallel operation,the plug connections for measuring lines U and Won the "COSIMAT C" and "COSIMAT N" regulatormust be changed over. The rotary field will changeat the main terminals.

1.8 Electrical connections

The machine must be connected up according tothe accompanying circuit diagram. Installation ispermitted by a qualified electrician only.

Comply with the following points:

VDE safety regulations or those of the local

Local electricity suppliers guidelines re-garding protective measures

Phase sequence or direction of rotation ofmachine field as stated on rating plate.

When connecting the cable, make sure that no

mechanical forces can act on the machinesconnecting terminals.

Unused cable sockets in the terminal box mustbe protected against dust and moisture, andclosed so that they cannot turn. Take up slack atall screw contacts and nuts.

If current surges or vibration are to be expected,secure the cables with cable clips or racks. If theplant is set up on flexible mountings, ensureadequate slack in the cables.

1.9 Starting up1.9.1 Insulation resistance

After a long period out of use or in storage, themachines insulation resistance must be meas-ured.

We recommend that the bearings be regreasedbefore the machine is started up.

Before starting up, measure the insulation resis-tance of the winding between phases (if the starpoint is separate) and between phase and earth.

All parts not subjected to the measuring voltagemust be earthed.

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When measuring the insulation resistance, all con-nections (main connection, measuring connectionand protection or suppression circuit) must be dis-connected from the winding. The suppression ele-ments and measuring leads must be disconnectedduring high-voltage insulation tests and tests with

insulation measuring appliances.

Do not drop below the following specificinsulation resistance values (at 25C) on

windings that have been in operation forlengthy periods:

With nominal voltage < 1000 VInsulation resistance 0.5 M/kV

Measurement must be carried out using 500 Vdirect voltage or a crank indicator with a directvoltage output. Due to the capacitive charge in thewinding, the measuring unit indicates the correct

insulation resistance value only after several se-conds have elapsed.

Earth the winding immediately after the measuringvoltage has been switched off.

If the insulation values are too low, first check theterminal insulation for dirt and moisture. Clean ordry them as the case may be, and repeat the meas-urement. Damp windings can lead to current leak-age, flash-over or breakdown.

If insulation resistance on new, cleaned or

repaired windings is less than that statedbelow, drying out is needed (see Item1.15, Drying out the machine).

On low-voltage machines with a nominal voltagebelow

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1.13.2 Permanently lubricated bearings

Size 29, 36 and 43 machines are normally fittedwith deep-groove ball bearings acc. to DIN 625,version 2 Z, on both sides. The bearings are filledwith high grade bearing grease by the bearing

manufacturer and sealed on each side with twocover plates.

The expected operating life is approx. 25,000 op-erating hours at a machine speed of 1500 rpm.The bearings are lubricated for life. On machinesof a single-bearing design, bearing operating lifemust be expected to be 30% shorter.

1.13.3 Regreasable bearings

Size 52, 62, 74, 86, 99, 114, 125 and 144 ma-chines with relubricating devices normally bear a

plate on which the following information is stated:

Relubricating interval in hours of operation

Type or specification of anti-friction bearinggrease

Before regreasing, clean the nipple sothat dirt cannot enter the bearings.

Using a medium-sized manual grease gun (approx.capacity 500 g), approx. 1 g of grease can be fedin per stroke at the tapered lubrication nipple (AM 8x 1 DIN 71427).

Where possible, apply grease when the machine isrunning, unless this represents a hazard for theoperating personnel.

Regreasing interval

Bearings must be regreasedin accordance withthe regreasing interval stated on the alternatorplate, but at least once a year.

Relubricating quantity

A- and B-side bearings must each be regreasedwith the amount of grease stated.

After about three regreasing operations, removeexpelled grease.

After about five regreasing operations, keep apply-ing more grease until fresh grease is visible at theoutlets. Then run the machine if possible at halfspeed for one hour and then at the nominal speed.

Check the temperature of the bearings and com-pare with those temperatures obtained before re-greasing.

Initial greasing quantity and regreasing quantityat each lubrication point in grams (guide valuesonly:)

Type Lubrication

pointsQuantity in g

Re-Lubrication intervals in hours

for machine running speed of:

DSG

Singlebea-

ring

Double

bearing

500-6

00

min-1

750-9

00

min-1

1000-1

200

min-1

1500-1

800

min-1

52 30 3100 2500 2000 130062 40 2800 2200 1800 110074 70 2600 2000 1600 100086 70 40 2500 2000 1500 100099 80 60 2500 1500 1200 800

114 100 60 2000 1500 800 600125 100 60 2000 1000 800 600144 100 60 1800 900 700 500

* In the case of double bearing the amount of greasestated in the double bearing column is to be injected intoeach of the grease nipples.

Type of anti-friction bearing grease

On delivery, the bearings are lubricated withhigh-grade, lithium-soap grease of grade 3consistency (NLGI-KL anti-friction bearings). The

grease channels between the lubricating nippleand bearings are filled with anti-friction bearinggrease before leaving the factory.

Alternatively, the following types of lithium-soapanti-friction bearing grease can be used:

Shell Alvania G3

SKF/Alfalub LGMT 3

Esso Unirex N3

Mobil Mobilgrease 532

Texaco (DEA) EP 3

These greases are of grade 3 consistency andcomply with DIN 51 825.

Recommendation:Always regrease the bearings with the sameselected brand of grease.

1.13.4 Assembling the bearings

Bearings must only be renewed by a

qualified person working in a dust-freeenvironment, on a clean surface andusing clean tools. The grease and bearings

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must be kept free of impurities, otherwise they willwear out faster and possibly even fail. The bearingcomponents must be arranged as shown in theillustration (see spare part drawing). The greaseregulating disk should be rigidly attached to theshaft.

When changing bearings, install type-approvedbearings only, and maintain the correct amount ofbearing play (usually "C3"). Do not remove newbearings from their packs until just before they areinstalled. Do not wash the bearings, as the anti-cor-rosion agent applied to them is intended to mix withthe similar agent in the anti-friction bearing grease.Clean the old grease off the parts of the bearingthat are to be re-installed.

When fitting the bearing, heat it to about 80 -100C in an oil bath, oven or by an inductive

method. Make absolutely sure that it is lo-cated centrally and remains in positivecontact with the shaft shoulder.

Once they have cooled down, pack the bearingswith grease.

The inner and outer bearing covers must each befilled with grease to 2/3 of their full capacity.

1.13.5 Dismantling the bearings

During shaft production, the bearing seat and the

bearing stop shoulder on the shaft are subject toparticularly stringent quality control. This is essentialto maintain the accuracy of shape needed to keepthe bearings fully operational.

When dismantling the bearings and bearing rings, itis therefore important to handle the bearings andbearing rings with particular care, otherwise thebearing seats on the shaft could become damaged.Use a puller to remove. Heat the parts evenly to atemperature of app. 80C all round.

1.13.6 Monitoring the bearings

The first indication of damaged bearings is usuallya notice-able change in running behaviour, ornoise, vibration or temperature if bearing damagehas reached an advanced stage.

Recommendation:Monitor the bearings by measuring transmittednoise and vibration at regular intervals, and com-pare the readings with those taken on previousoccasions.

1.14 Dust filters and monitoring ofthermal behaviour

To prevent the windings from overheating whenthe filters are dirty, three temperature sensorsare installed in the stator winding. Their trip

mechanism must be installed in the switch cabi-net.

In addition, probes can be installed to allow thedegree of contamination at the filters to bemeasured directly. Their trip mechanism must beinstalled in the switch cabinet. Cleaning must beperformed at regular intervals even if the ma-chine is protected against excessive tempera-tures by integral coil temperature monitoringdevices.

On machines with integral dust filters, please

note the following:

1.14.1 Synthetic filter elements

These are dry filters and must be cleaned atregular intervals. These intervals vary dependingon the rate at which dirt accumulates. Cleaningmay be performed using compressed air, waterat temperatures up to 50C, or cleaning fluid.Comply with the relevant environmental andsafety regulations. However, it is often moreeconomical to change the filter mat.

1.14.2 Wire mesh filter elements

These are wet filters and are supplied dry. Be-fore starting up, apply a thin film of oil or "Visci-nol" to the filter plates. Dirty wire mesh filtersshould be cleaned using compressed air orsuitable washing agents (soda or "Purinol") andwetted again when dry.

1.15 Drying out the machine

If the insulation value between the winding andthe core or between windings is less than thatstated in Item 1.9.1, the machine needs drying.

1.15.1 Drying out with integral ventilation sys-tem

In many cases it can be dried suitably using itsown ventilation system, but it should not be livewhile this is being carried out. On the "COSI-MAT C", the plugs should be disconnected atterminals UH1 and WH1. On the "COSIMAT N"voltage regulator, the connections UH1-UH1and WH1-WH1 must be opened. If no im-provement in the insulation resistance is regis-tered after a running period of app. two hours,th lt t t b d i d t b h ti

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1.15.2 Drying out by short-circuiting

a) Short the main terminals U, V and W via acurrent transformer and current meter (for app.1.2 x nominal current) while the machine is ata standstill.

b) Pull off plugs at terminals I1 and K1 as wellas UH1 and WH1 on the "COSIMAT C".

Open bridges I1-I1 and K1-K1 as well asUH1-UH1 and WH1-WH1 at the "COSIMATN"voltage regulator.

c) Use a 12 V or 24 V battery and rheostat tofeed in exciter current at terminals I1 and K1

on the "COSIMAT C" or at terminals I1 andK1 on the "COSIMAT N".

Important: connect the positive poleto I1 and the negative pole to K1.

d) Run the alternator at its nominal speedand adjust the short circuit current at therheostat to app. 1.2 x nominal current (seeperformance data plate).

Continue to dry the machine until its insulationresistance has risen to a sufficient level. Werecommend measuring at approx. 2-hour inter-vals.

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2. Faults, causes and remedies for DSG alternators with "COSIMAT C" or "COSIMAT N"voltage regulator

Fault at alternator Cause Remedy

1. Voltage too low. 1.1 Input speed too low. Check whether LED H2 on regulatorlights up. If it does so, then the under-speed protection has tripped; increasethe speed until the LED goes out.

2. Nominal voltage does not re-spond to adjustment at R1.

2.1 Setpoint potentiometer is defec-tive.

Check voltage setpoint potentiometerat terminal s/t for signs of interruption.Rectify the interruption.

2.2 Sensing leads wrongly con-nected.

Examine sensing lead connections U,and W on "COSIMAT C"or U, V andW on "COSIMAT N". Check whether

the machines nominal voltage lieswithin the rated voltage range.

3. Alternator voltage too high, can-not be brought down by adjust-ment at R1.

3.1 Setpoint potentiometer is defec-tive.

Examine the voltage setpoint potenti-ometer for a short circuit. Renew thesetpoint potentiometer. Check thepotentiometer leads for a short circuit.Rectify the short circuit.

3.2 A sensing lead is broken. Rectify the fault.

4. Severe voltage collapse whenunder load.

4.1 Input speed drops under load. Check the regulator of the drive ma-chine.

4.2 One of the fuses on the coolingbody is defective on the "COSI-MAT N".

Check the fuse on the inside of thecooling body; renew if necessary (10 Asuper quick acting).

4.3 Rotating diodes are defective. Check rotating diodes V1 and over-voltage conductor V3; renew if neces-sary.

5. Alternator does not respond toexcitation.

5.1 Input speed too low. Less than50 % of nominal speed.

Check the speed regulator of the drivemotor. Check the power transmissionto the alternator.

5.2 Remanence voltage of auxiliary

exciter is too low (less than 6 %nominal voltage)

Briefly excite the machine by attaching

a 4.5 V battery with its positive pole atI1 and negative pole at K1.

5.3 No voltage at auxiliary exciterwinding UH1-UH2 or WH1-WH2.

Check whether windings UH1-UH2and WH1-WH2 are interrupted in thestator of the auxiliary exciter. Rectifythe interruption.

5.4 Fault in regulator circuit. Check whether the external connec-tions on terminals I1, K1 UH1 andWH1 are in place. On the "COSIMATN", check the bridges also.

5.5 Fault at regulator connections. Check input and output connections of

regulator.

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Fault at alternator Cause Remedy

5.6 Regulator fuse has blown on"COSIMAT N".

Check the regulator fuse on the insideof the cooling body and renew if nec-essary (10 A super quick-acting).

5.7 Power stage transistor is defec-tive. On the "COSIMAT N", replace theregulators power stage. On the "CO-SIMAT C", replace the entire regulator.

5.8 Regulator is defective. Replace the regulator

5.9 Rotating rectifier is defective. Check rotating diodes V1 and over-voltage conductor V3; renew if neces-sary.

6. Oscillating voltage in separateoperation.

6.1 I-share too low. Set switch S1 to a higher number, andmove R1 slightly in a clockwise direc-tion if necessary.

7. Alternator voltage fluctuates atirregular intervals.

7.1 Loose contact in one regulatorinput lead.

Check the leads that connect the regu-lator. Check the connections on themachines terminal board. Re-tightennuts.

7.2 Blockage at mechanical regula-tor on drive machine.

Check the speed regulator on the drivemotor. Rectify the fault.

8. Oscillating reactive output inparallel operation.

8.1 Droop setting is too low. Move R7 slightly in a clockwise direc-tion.

9. Excessively high reactive currentoutput in parallel operation.

8.2 I-share too low. Set switch S1 to a higher number.

9.1 Droop setting is too low. Move R7 slightly in a clockwise direc-tion.

9.2 Transformer connections k/l areincorrect, e.g. bridged by switch.

Open the bridge.

9.3 Are the secondary connections atterminals k/l correct or not?

Swap over the k/l connections, "k"must be the white lead.

9.4 Droop transformer not installedin phase "V".

Install droop transformer in phase "V",check direction of rotation.

9.5 If "COSIMAT C"is installed sepa-

rately, sensing leads U/W maybe wrongly positioned (U/V/Won "COSIMAT N").

Check the sensing lead. There must be

a right-handed field on "COSIMATN".

10. Excessively low reactive currentoutput in parallel operation.

10.1 Droop setting is too high. Move R7 slightly in an anti-clockwisedirection.

11. Active load not equally distrib-uted.

11.1 This is affected by the drive ma-chine only, i.e. determined bythe drive machine regulator. Thealternators regulator affectsonly the reactive output andtherefore the distribution of thereactive load (see 8., 9. and

10).

Check the drive motor (regulator, fuelsupply etc.).

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Please contact our Service Department if you have any problems. Our experienced spe-cialists will be glad to help you. If possible, inform us of your findings by telefax or tele-phone.

Telefax: +49 (0) 841/792-195 Telephone: +49 (0) 841/792-163

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3. Circuit diagrams

Circuit diagram for DSG 29 and 36 with "COSIMAT C" voltage regulator (No. Z 2811.001)

3.2 Circuit diagram for DSG 43 with "COSIMAT C" voltage regulator (No. Z 2811.003)

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3.3 Circuit diagram for DSG 43...74 with "COSIMAT N" voltage regulator (No. Z 2817.001)

3.4 Circuit diagram for DSG 86...144 with "COSIMAT N" voltage regulator (No. )

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F1 Schutzschalter fr G3 Protection switch for G3NUR IM STILLSTAND BETTIGEN ONLY SWITCH ON AT STANDSTILL

G1 Hauptmaschine Main machineG2 Erregermaschine Exciter machineG3 Hilfserregerwicklungen Auxiliary exciter windings

R11 Rotierender Varistor Rotating varistor

V1 Rotierende Gleichrichter Rotating rectifiers

X1 Hauptklemmen Main terminalsX2-6 Klemmleiste Terminal strip

U1 Spannungsregler Cosimat N Alternator voltage regulator Cosimat NR3 Unterdrehzahlschutz R3 Underspeed protectionR4 Interner Sollwert R4 Internal voltage settingR1 P-Anteil R1 P-PartS1 I-Anteil S1 I-PartR7 Statikeinstellung R7 Droop adjustment

R6 Statikwandleranpassung R6 Droop transformer adaptionR1 Sollwertpot. Generator Spannung (R = 500 ) Alternator voltage adjuster (R = 500)T6 Statikwandler Droop transformer' ACHTUNG: Bei Regler lose: Reg leransch lu CAUTION: AVR loose supply:AVR connection

Drehrichtung rechts: Rotation clockwise:Leiste X2 Regler Terminal X2 AVR

U U U U

V V V V

W W W WDrehrichtung links: Rotation counter clockw ise:Leiste X2 Regler Terminal X2 AVR

W U W U

V V V V

U W U W

Schnellentregung:Brcken UH1-24 und WH1-14 ffnen

Quick de-excitation:Open bridges UH1-24 and WH1-14

Entregungsschalter: 220 V AC De-excitation switch: 220 V AC(nicht AvK Lieferumfang) 10 A (not AvK supply) 10 A

Zubehr AccessoriesWiderstandsthermometer PT100 Resistance Thermometer PT100

A1-12 Statorwicklung Stator windingPhase U: 1, 4, 7, 10Phase V: 2, 5, 8,11

Phase W: 3, 6, 9, 12

Phase U: 1, 4, 7, 10Phase V: 2, 5, 8, 11

Phase W: 3, 6, 9, 12A13, 14 Lager, B-Seite Bearing, NDE

H Stillstandsheizung Anti condensation heater

- - - - Verbindungen auerhalb des Generators Connections outside the alternator

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AvK Deutschland GmbH & Co. KGBunsenstrae 17

85053 Ingolstadt, GermanyPhone: +49(0)841-792-0Fax: +49(0)841-792-250e-mail: [email protected]

AvK Deutschland GmbH & Co. KGDreieich branchBenzstrae 47-4963303 Dreieich, GermanyPhone: +49(0)6103-5039-0Fax: +49(0)6103-5039-40e-mail: [email protected] OI_

DSG29_

144/en-06-2004/A

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Enclosure to Operating InstructionsAdvise for Commissioning

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Generator with vibrationabsorbers on foundation

By connection of the cables it must be ensured that

no forces have an effect on the machine connection

terminals. The same counts for the time during

assembly.

If shock load or vibrations are to be expected, the

cables should be fixed over the cable clips and the

cable platform.

By elastic mounted gen-sets (see picture above)

sufficient 'free cable length' should be ensured to

compensate the movements of the diesel/gas motor.

In order to ensure that the movements do not have

a negative influence on the connection terminals,

the cable must be fixed with max. 300 mm distance

from the terminal box screw fitting. This cable fixing

has to be connected rigidly to the gen-set in order

to avoid relative movements between the cable

fixing and the terminal box.

The relative movements between the gen-set and

the foundation have to be compensated for by a

sufficiently long free cable length between the cable

fixing on the gen-set and the foundation.

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Generator with vibrationabsorbers on frame base

By connection of the cables it must be ensured that

no forces have an effect on the machine connection

terminals. The same counts for the time duringassembly.

If shock load or vibrations are to be expected, the

cables should be fixed over the cable clips and the

cable platform.

By elastic mounted gen-sets (see picture above)

sufficient 'free cable length' should be ensured to

compensate the movements of the diesel/gas motor.

In order to ensure that the movements do not have

a negative influence on the connection terminals,

the cable must be fixed with max. 300 mm distancefrom the terminal box screw fitting. This cable fixing

has to be connected rigidly to the gen-set in order

to avoid relative movements between the cable

fixing and the terminal box.

The relative movements between the gen-set and

the foundation have to be compensated for by a

sufficiently long free cable length between the cable

fixing on the gen-set and the foundation.

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Connections

Cable connection acc. to DIN 46200

Elastic parts, such as spring washers, can be usedin the electrical connection, however, only on one

side of the clamped conductor. If necessary,

additional washers are to be used. The other side is

for current conduction, why only washers or security

locking plates of copper-zinc-alloys must be used.

By electrical connection with eyelet rings, the eyelets

have to be protected by washers on both sides

against bending.

De-excitation

Open the bridges UH1-24 and WH1-14 on the

terminal strip X2. De-excitation with extern switch

takes place on these terminals, too.

Using the Protection switches Q1, F1, F2

The purpose of these switches is to protect the

voltage transformers T24 (Q1) and the auxiliary

exciter winding (F1, F2). In case of failure, these

switches will lead to a quick de-excitation of the

machine.

These switches are not to be used for de-exciting

the machine during operation or maintenance!

Open star point

The voltage transformer T24 has to be disconnected

and the cables sufficiently insulated! De-excite the

machine as described above.

No tests are to be performed with open star point!

The correct connection of the power cables can be

checked with appropriate equipment.

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Maintenance for earthing brush

Optimum maintenance and care for earthing

brushes is the base for smallest brush wear. The

maintenance of brushes must take place after

certain intervals that depend on the alternators size

as well as load and ambient conditions.

Brushes are subject to wear and tear and must be

cleaned by air (pressure or suction) from time to

time. Routine check every 3 months is

recommended by AvK to ensure about operational

behaviour and suitable changing intervals.

All brushes and holders must be checked for free

movement. Blocked brushes may lead to damage.

Worn out brushes must be renewed in time, so that

damages at the contact surface on the shaft can be

avoided. New earthing brushes do not need grind-

in (other than slip rings).

Using brushes bigger than the original size is only

possible after agreement with the supplier.

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Maintenance of Earthing Fault

Monitoring

Optimum maintenance and care of the brushes

and slip rings is the base for smallest wear. The

maintenance must take place in certain time

intervals. The frequency of the maintenances

depends on alternator size as well as on load and

ambient conditions.

Brushes are subject to wear and tear and must be

cleaned by air (pressure or suction) from time to

time. Routine checks every 3 months is

recommended by AvK in order to estimate the

necessary time intervals during the actual operation

conditions.

All brushes and holders must be checked for free

movement. Blocked brushes may lead to damage.

Worned out brushes must be replaced in time in

order to avoid damages on the slip rings and to

ensure the perfect function of the Earthing Fault

Monitoring. New brushes need grind-in with the

slip rings. The use of larger brushes than originallymounted is only possible after agreement with the

supplier.

Note:

The Earthing Fault Monitoring is mounted on the

NDE of the machine.

Attention:

Maintenance works must be performed only during

standstill of the machine.

Electrical Machines with two shaft

ends

Bearing currents by electrical machines with two

shaft ends must be avoided.

AvK recommends an insulated coupling mounted

on the NDE.

Another possibility is that all bearings of the NDE

aggregate are insulated.

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Anti - condensation heater:

The anti condensation heater is to be connected

according to correct rating and supply voltage.

Please refer to rating plate of the machine.

Control of the anti condensation heater should be

done that the heater

- is switched on after the machine has stopped,

- is switched off before starting up the machine.

Tubular heater type RHK T + H art. no.

100870 and 100872

Description

2 heaters type RHK dia. 8, 5mm x 500mm long

assembled into two brackets made of stainless steel

as per our drawing no 31522, heaters wired in

parallel by brass brackets, silicon insulated

connection cable 3000mm long.

Number of heater elements is according to required

heating power.

Technical data of the heaters

Heater sheath: Chrome-Nickel-Steel AISI 321

Heater wire: NiCr 8020, Mat. no.: 2.48869

Insulation material:

pure magnesium oxide, highly compacted

Connection:

threaded bolt M4 with silicon insulated cable

Tolerances

Diameter of heaters: 8,5mm 0,15mm

Straight length of

heaters: 500 2 %

Wattage per heater: 500 Watt 10 %

Total wattage (4 heaters):1000 Watt 10 %

Voltage: 230 Volt

Dielectric strength: 1250 V

Final test: per standard

DIN EN 60 335

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Bolting torque for fixing screws

If no further indications are made , use the

following bolting torque for connections of fixing

screws and fixing nuts:

screws

property class

8.8

screws

property class

4.6

M4 3,0 1,1

M5 3,5 2,2

M6 9,0 3,7

M8 18 9,0

M10 45 18

M12 50 31

M16 110 75M20 250 150

M24 440 255

M30 980 510

M36 1730 890

M42 2700 1450

starting torque in Nm

Values according to VDI 2230 calculated

considering the maximal admissible surface

pressure under the screw head and a frictional co

efficient ges = 0,125

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Dust filter made of metal fabric

Description

Design of the filter

The frames and the plates of the filter are fabricated

of:

Constructional steel with zinc coated mesh wire

Stainless steel with stainless steel mesh wire

alternatively depending on application

conditions

Type of filter

B1 according to DIN 24185 / part 100

EU2 according to DIN 24185 / part 2

Medium degree of deposition 65 = 80 %

Maintenance

The maintenance intervals depend on the local dust

accumulation. The dust protective filter plates have

to be cleaned with the usual commercial detergents.

Cleaning with high-pressure cleaning devices is

also possible.

Caution:

Do not wet the filter plates with oil!Observe the instructions for pollution

control.

The following detergents can be used when

cleaning mechanically:

Calgonit / Somat / Topmat 760 (or equivalent)

If only a manual cleaning is possible, use the

following detergents:

Rivonit / RG 1083 (or equivalent)

Regular checks and cleaning of the dust

protective filter system is indispensable for

the safety in operation of the electrical

machines

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AvK Deutschland GmbH & Co. KGBunsenstrae 17

85053 Ingolstadt, Germany

Phone: +49(0)841-792-0

Fax: +49(0)841-792-250

e-mail: [email protected]

www.newage-avkseg.com

AvK Deutschland GmbH & Co. KGDreieich branch

Benzstrae 47-49

63303 Dreieich, Germany

Phone: +49(0)6103-5039-0

Fax: +49(0)6103-5039-40

e mail infoa kdr@ne age a kseg com

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Regulator Descriptions

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Description and adjustment instructionsCOSIMAT N+ voltage regulatorfor DSG and DIG alternators

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Description of COSIMAT N +

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. Brief summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.1 G eneral diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.2 Adjusting elem ents and their effects . . . . . . . . . . . . . . . . . . . . . . . . . 42.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.4 O ptim ising the regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.1 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.2 Pow er supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.3 M onitoring alternator voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.4 Desired value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.5 Droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.6 C ontrol am plifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.7 Additional functions of the C O SIM AT N + . . . . . . . . . . . . . . . . . . . . . 103.7.1 U nderspeed protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.7.2 Protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.8 Pow er stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4. Transfer function of the COSIMAT N+ . . . . . . . . . . . . . . . . . . . . . . 12

5. Special functions and additional equipment. . . . . . . . . . . . . . . . . . . . 135.1 Stand-by and em ergency m anual sw itchover . . . . . . . . . . . . . . . . . . . . . 135.2 Additional m odules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8. Diagrams of connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208.1 Assem bly for DSG alternators 52 74 . . . . . . . . . . . . . . . . . . . . . . . 218.2 Assem bly for DSG alternators 86 125 . . . . . . . . . . . . . . . . . . . . . . . 22

8.3 Assem bly for DIG m edium -voltage alternators w ith U N 11.5 kV . . . . . . . . . . . . 238.4 Assem bly for DIG m edium -voltage alternators w ith U N > 11.5 kV . . . . . . . . . . . . 248.5 De-excitation circuit on the C O SIM AT N +. . . . . . . . . . . . . . . . . . . . . 258.6 M onitoring field current and voltage on the C O SIM AT N +. . . . . . . . . . . . . . 25

9. Connections, adjusting elements and displays. . . . . . . . . . . . . . . . . . . 269.1 C onnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269.2 Adjusting elem ents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279.3 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

10. Start-up of the COSIMAT N+ . . . . . . . . . . . . . . . . . . . . . . . . . . . 2910.1 Basic setting and visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2910.2 Desired value setting range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2910.3 Regulating param eters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

10.4 Underspeed protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2910.5 Droop adjustm ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

11. Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3011.1 Protection concept for external m ounting of regulator . . . . . . . . . . . . . . . . . 3011.2 M ounting the regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3011.3 Excitation build-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3011.4 C ode sw itch S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3011.5 Droop sw itch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3011.6 C hanging the direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . 3111.7 Synchronous m otors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3111.8 Protection fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3111.9 Drying out the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

11.10 External pow er supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3211.11 400 H z alternators and converters . . . . . . . . . . . . . . . . . . . . . . . . . 3211.12 C hecking the insulation voltage of the electric m achine . . . . . . . . . . . . . . . . 32

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1. General

TheC O SIM AT N +is a com pact voltage regulator designed

to control synchronous alternators both in single and parallel

operation.

In single operation, the alternator voltage is held constant

irrespective of pow er, frequency and tem perature.

W hen operated in parallel w ith the m ains or w ith other

alternators, a stable reactive pow er is produced.

Via its pow er stage, the C O SIM AT N +adjusts the excitation

current to m atch the operating conditions.

The m ain features of the C O SIM AT N +are:

Integrated m easuring transform ers for three-phase m eas-

urem ent of the alternator voltage up to 500 V AC

(external conductor voltage).

Stable reactive pow er thanks to current-voltage vector

m easuring system (droop). A load-relieved current trans-

form er is required in alternator phase V.

Internal and external alternator voltage set-point ad-

justm ent.

PID control am plifier w ith large adjustm ent range.

Disproportionate drop in desired value w hen alternator

operates at underfrequency.

Perm anent m onitoring of the actuator and tim e lim it onthe m ax. possible excitation current.

Internal protection devices trip w henever a fault occurs,

thus separating the excitation field from its energy source.

C om pact construction w ith interchangeable pow er

stage.

Fully potted in to protect it from environm ental effects.

Long life thanks to high-quality com ponents.

W ith the use of additional m odules it is possible to interven

in set-point and actual value form ation via the C O SIM AT N

signal inputs:

There are a large num ber of additional m odules available f

a w ide variety of control applications e.g.

cos phi regulation of a synchronous alternator or m oto

or

Lim itation of start-up current w hen connecting up a larg

asynchronous m otor to the alternator

or

C able com pensation via load current detection or m e

sured value of the external alternator voltage.

Its additional m odules m ake the "C O SIM AT N +"suitable f

various applications on test rigs, in pow er-train technologetc. (see 5.2 Additional m odules).

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2. Brief summary

2.1 General-arrangement diagram

Figure 1 G eneral-arrangem ent diagram

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2.2 Adjusting elements and their effects

Figure 2 Adjusting elem ents

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2.3 Start-up

Figure 3 - Start-up

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2.4 Optimisation of the regulator

To optim ise regulation, it is necessary to connect loads to the

alternator.

To allow the trend of the control property follow ing a change

in the P or I param eter to be evaluated, the load connected

m ust be reproducible.

The factor w ith the greatest general significance in achieving

an optim um regulating system is an overshoot am plitude xmw hich is as sm all as possible. The essential criterion in the

evaluation of the regulating process w ith respect to tim e is the

settling tim e taus.

To follow the trend of the control property, use an oscilloscope

to m onitor the m anipulated variable.

The "C O SIM AT N +"regulator allow s freeadjustm ent of the

P and I param eters. The D param eter can be sw itched over

in tw o stages using code sw itch S2.4.

Figure 4 C haracteristic quantities of the regulating system

Figure 5 Trend of the control property

It is not necessary to adjust the D param eter in order

optim ise the control properties. It is generally determ ined ju

once, in accordance w ith the size of the alternator. In the ca

of alternators > 1 M VA, sw itch S2.4 is sw itched to the O

position.

To decide w hether the D param eter should be increase

beyond this, it is necessary to take specific m easurem ents

the alternator voltage and at the output of the regulator.

Satisfactory optim isation of the regulator w ill norm ally b

achieved by the free adjustm ent of the P and I param eters

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3. Functional description

3.1 Block diagram

Figure 6 Block diagram

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3.2 Power supply

Pow er is supplied to the "C O SIM AT N +" by m eans of

so-called auxiliary excitation voltages, w hich are produced

in the alternators. The excitation energy and the supply

voltage for the "C O SIM AT N +"are derived from the auxiliary

excitation voltages.

In the case of AvK alternators in Series DSG and DIG w ith

U N 11.5 kV, the "C O SIM AT N +"is supplied w ith pow er

via tw o single-phase auxiliary w indings, w hich are inserted

into the m ain stator. The w indings are designated UH 1/U H 2

and W H 1/W H 2.

The voltages UH 1 and U H 2 are offset by 90 w ith respect

to W H 1 and W H 2 and are 80 V AC 20 % at the nom inal

voltage of the alternator.

In the case of AvK alternators belonging to Series D IG w ith

U N > 11.5 kV, the "C O SIM AT N +"is supplied w ith pow er

via a tw o-phase auxiliary exciter m achine. The w indings aredesignated UH 1, UH 2, U H 3 and W H 1, W H 2.

The voltages UH 1 and U H 2 are offset by 90 w ith respect

to W H 1 and W H 2 and are 80 V AC 20 % at the nom inal

speed of the m achine.

The above-m entioned auxiliary exciter w indings U H 1 and

U H 2 and W H 1 and W H 2 are plugged into the correspon-

dingly designated term inals of the "C O SIM AT N +":

Special applicationThree-phase auxiliary exciter machine

If a three-phase auxiliary exciter m achine is used, the w indingterm inals are designated UH 1-VH 1-W H 1. The external con-

ductor voltage is 3 x 75 V AC 20 % at the nom inal speed

of the m achine.

Special applicationExternal power supplyThe "C O SIM AT N +" can also be operated w ith a constant

external voltage. It is generally supplied via a three-phase

transform er (Yy0) w ith a secondary voltage of 3 x 75 V AC

20 % . The nom inal pow er should be at least 500 VA .

3.3 Monitoring alternator voltage

The "C O SIM AT N +"m easures alternator voltages from 90

500 V AC (external conductor voltage) w ithin tw o selectab

ranges by m eans of an internal three-phase m easuring tran

form er.

To m easure higher voltages, corresponding voltage transfo

m ers m ust be connected in series.

Signal input N allow s intervention into the internal form atio

of the actual value.

The secondary AC m easurem ent voltage of the m easurin

transform er is converted into a DC voltage, sm oothed, cond

tioned and output as an actual value to the regulator circui

The m easured value w hich is produced corresponds to th

arithm etic m ean of the rectified three-phase AC m easurem e

voltage.

Three-phase m easurem ent allow s for asym m etric loads.

Note:

For non-linear loads (static thyristor converter or rectifie

additional m odule TF (RC low -pass filter) is recom m ende

as a m easuring adapter. H igh non-linear loads m a

require overdim ensioning of the alternator.

3.4 Desired value

The desired value for the "C O SIM AT N +" is taken from

tem perature-com pensated reference source.

The signal input nallow s intervention in the internal form atio

of the desired value.

The reference voltage reaches the set-point potentiom eter R

m ounted on the front end of the "C O SIM AT N +". Th

potentiom eter allow s coarse adjustm ent of the alternat

voltage over a w ide range (= approxim atedesired value

In parallel operation of the alternator, the reference voltag

is influenced by the droop-m easuring system (see 3.5 D roo

and, in the case of underfrequency, by the underspee

protection.

A set-point potentiom eter can be connected to the "C O SIM AT N

for external adjustm ent of the desired value.

This potentiom eter is used for fine adjustm ent of the alternat

voltage (= exactdesired value).

The adjustm ent range is lim ited to5 % to 10 % aroun

the nom inal value, depending on the potentiom eter used.

The ES additional m odule allow s the adjustm ent range of th

external set-point potentiom eter to be extended from rem anenc

to the nom inal voltage.

Caution:

If the auxiliary excitation voltage is takenfrom a constant "external" power source (e.g.the mains), the supply must be switched ononly after the alternator has been started.When switching off the alternator, thesupply should be switched off before themachine comes to a halt (see 11.10 Externalpower supply).

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If the ES m odule is used on A vK alternators, the regulator

system m ust be provided w ith an external pow er supply. This

m ust be decided on a case by case basis, depending on the

application and the excitation system used (auxiliary excitati-

on w indings or auxiliary excitation m achine?)

3.5 Droop

O nce an alternator has been connected in parallel, voltage

regulation is no longer possible because the system voltage

is fixed. The slightest fluctuation in the system voltage w ould

lead to the alternator producing reactive current > IN .

To stabilise the alternator reactive current it is therefore

necessary to have a m easured variable w hich is dependent

on the reactive current and incorporates the m agnitude of the

current and the reactive pow er (inductive or capacitive). This

m easured variable is introduced at the addition point (com -

parison point of the desired value and the actual value) of the

control am plifier circuit.

This produces a static droop control characteristic, w hich

represents the relationship betw een:

the change in the alternator voltage in relation to the nom inal

voltage and

the change in the alternator reactive current in relation to the

nom inal current.

The droop is represented by the slope of the characteristic

curve produced i.e. is the quotient of the above ratio.

In the "C O SIM AT N +"a linear droop characteristic is gene-rated. The droop effect can be adjusted from 0 to 6 % using

the potentiom eter R 7 .

Exam ple:

In the case of an inductive reactive current of 100 % of the

nom inal current of the alternator and w ith th

DOC_8127280A002_GB

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