Gen Manual Book Neew Type

8/10/2019 Gen Manual Book Neew Type

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CAUTION

The inform ation contained in this book is intended to

assist operating personnel by providing inform ation on

the general characteristics of the purchased equipm ent.

IT D O ES NO T relieve the user of the responsibility of using

accepted engineering practices in the installation,

operation and m aintenance of this equipm ent.


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Contents

2


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1.2 General

1) Type definition

The s upply sc ope of the ma chine designs a vailable is

determined entirely by the data given in the catalogs or

offers. The ma chines o f bas ic design are o pen-circuit

cooled, brushless , low -volta ge, synchronous m ac hines

w ith t op-mounte d excitat ion co ntrol unit.

The ma chines have a sha ft-mounte d exciter on theinboard side of the non-drive endshield.

The three -phas e AC they generat e is rectified a nd fed t o

the rotor winding of the main machine.

The excitation current req uired for the sha ft-mounted

exciter is provided b y the m ain ma chine via a n excitation

control unit placed in the top m ounted hous ing, and via a

thyristor voltag e regulator.

For further information, see the suppleme nta ry

instructions ent itled THYRIPARTexcita tion s yst em on

pa ges 15-25.

Depending on the application, the machines may also be

designed in accordance with the type variant defined in

the table 1-1.

1.1 Component

The brush less A.C. genera tors, a s sh ow n in Figs. 8. 9. 10

a nd 11, (drip-proof t ype, t ota lly-enc losed interna l-coo ling

type) are composed of

a synchronous generator

an A.C. exciter

a Rotary rectifier

static excitation devices.

The brushless ge nerato r, as show n in Figs. 8, 9, 10 and

11, has the exciter and the rota ry rectifier mounted o n

the ge nerato r's rotor shaft. The three-phas e output of the

A.C. exciter is rectified t o D.C. by me ans of the rotary

rectifier, thus ena bling the exciting current t o be supplied,

not through sliding parts, but directly to the field coil of

the generator.

Instruction M anual>> 3

Operating InstructionsSynchronous Generator

3) Degree of protection

The DIN 40050 or IEC 34-5 deg ree of pro te ct ion of b a sic

design ma chines is IP 23. Such mac hines are s uita ble for

operation indoors and m ay b e provided w ith filters or with

pipe conne ctions.

Closed -circuit cooled ma chines com ply w ith degree of

protec tion IP44 a nd IP54.

The de gree of prote ct ion of the ma chine supplied is

shown in the dimension drawing.

4) Type of construction

The ma chines a re normally provided w ith tw o bea rings

(DIN 42950 types of c ons truction B3 or B20) or w ith one

bea ring (DIN 42950 types of c ons truct ion B2 or B16).

The t ype of c onstruction of t he m ac hine supplied is

shown in the dimension drawing.

Fig. 1 Single line diagram for brushless generator

Table 1-1. Type definition

Type Type of construction

HFJ 5, 6, 7

HFC 5, 6, 7

HSR 7

HSJ 7

M achines w ith open-circuit cooling and air-to air

M edium & high voltage m achines w ith closed-

circuit cooling and air-to w ater cooler w ith

provisions for em ergency operation in case of

cooling w ater failure

M edium & high voltage m achines w ith open-circuit

cooling and air-to air

M achines w ith closed-circuit cooling and air-to

w ater cooler w ith provisions for em ergency

operation in case of cooling w ater failure

2) Specification & regulation

The m ac hines comply w ith t he a pplicable DIN standa rds

and with the requirements of VDE 0530.

They ma y have be en a da pted to d ifferent classifica tion

requirements and foreign standards and regulations.

Unless otherwise stated, the rated output for continuous

operation a pplies to a frequency o f 50 Hz, a cooling-air

temperature of 40 and a s ite altitude of up to 1000 m

above sea level.

Construction of Brushless A.C Generator01

5) Cooling and ventilation

The ba sic design ma chines use self-ventilat ion by a sha ft-

mounte d internal fan at the d rive-end.

Cooling air enters the top housing (at the non-drive-end)

and cools the excitation control unit and, subsequently,

the w indings a nd core packs of the exciter and of the ma in

ma chine before leaving the top housing at the d rive-end.


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4 2 kV

Table 1-3. Insulation drying temperatures

Class B Class F Class H

200F

94C

245F*

118C

275F*

135C

Do not discontinue measurement before the final

resistance value is indicated (w ith high-volta ge m ac hines,

this proces s ma y ta ke up to 1minute).

The limit values fo r minimum insula tion resista nce a nd

critical insulation resista nce (for mea surement at a

w inding tem perature of 25) and for mea suring voltage

ca n be derived from the follow ing ta ble depending on the

rated voltage for the machine.

Before comm issioning and afte r long periods of st orage o r

sta ndstill the insulat ion resista nce of the w indings to t he

frame must be meas ured w ith D.C. voltage.

7) Insulation testing

DANGER

Hazardous voltage

W ill cause death, serious injury, electrocution or property

dam age.

Disconnect all pow er before w orking on this equipm ent.

On machines provided w ith air filters at the a ir inlet,

the c lea ning cond ition of t he filter should be monitored.

In m ac hines ha ving closed-circuit cooling, t he air-to-w at er

cooler is placed transverse ly in the to p-mounte d box in

transverse arrangement, in front of the excitation control

unit.

The prima ry cooling air circulat ed b y the interna l fan is re-

cooled in the cooler and passed through the excitation

control unit, the e xciter, and the m ain ma chine.

Given the necessary provisions, the machine can be

ada pted for emergenc y operation w ith open-circuit

cooling in ca se of coo ling w at er failure. See pa ges 46-48.

6) Connecting up

Check the system voltage aga inst the da ta given on the

rating plate. Select the size of the supply cables to match

the particular c urrent rating.

Connect the ma chines in accordance w ith the diagram in

the working drawing.

Before closing the t erminal box, check to se e tha t

Its interior is clean a nd free from any ca ble chippings

All terminal screw s o r bolts a re tight

The m inimum clearanc es in air are ma intained

(>10 mm fo r 500 V, >14 mm for 1 kV a nd > 60 mm

for 6 kV; che ck for a ny project ing wire ends )

Entry openings not in use a re closed off by firmly

sc rew ed-in plugs

For maintaining the particular de gree of protec tion all

sea ling surface s of the terminal box are in order.

The s urfac es of me ta l-to-meta l sea ling joints must be

cleaned and thinly regreased.

Before starting a machine and during operation makesure tha t a ll relevant sa fety regulat ions a re complied w ith.


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Insulation resistance variation to temperature can be

referred to IEEE 43 as shown on fig. 2.

During operation the insulation resista nce o f the w indings

may decrease as result of environmental and operating

conditions.

The c ritical value of the insulation resistance at a w inding

temperature of 25 can be calculated depending on the

rated voltage by multiplying the latter (kV) by the specific

critical resista nce va lue in the ta ble (/kV).

For example: critical resista nce for rate d voltage

660 V: 0.66 kV x 0.5/kV = 0.33

If the mea sured insulat ion resista nce va lue is above t he

ca lculat ed critical figure during opera tion, the ma chine

ca n st ill operate further.

When the m ea sured value reaches or falls below this

critical insulation resista nce figure, how ever, the w indings

must either be dried, or the rotor must be removed and

the w indings thoroughly clea ned a nd dried.

If the mea sured value approache s the c ritical value, the

resistance should subseq uently be checked at

appropriat e s hort intervals.

Insulation resistance measurements on low-voltage

ma chines w ith a me as uring voltage of 1000 V are only

permissible if the insulation resistanc e has previously

been mea sured with a m easuring voltage of a ma ximum

of 500 V and has not fa llen be low the permitted values.

8) Noise emission

The noise level of the ge nerato r w ill not excee d tha t

spe cified in P a rt 9. VDE 0530 (1981).

9) Vibration stability

Reciproca ting engines used a s prime m over impress

vibrations on the alternator because of the pulsating

torque output.Permissible vibration stress measured at the bearing is:

< 10 Hz vibra tion a mplitue S < 0.40 mm-pea k

10-100 Hz vib ra t io n ve lo cit y Ve ff < 18 m m/s -rm s

> 100 Hz a ccelera tion b < 1.6 g

Please inquire if a higher vibration st ress level is e xpected.

10) Transport

The rot or of ma chines w ith cylindrical roller be arings,

angular-conta ct ba ll bearings, or double sleeve be aring

are locked in position for trans port by a s haft block to

protect the bearings.

Do not remove this block until the trans mission eleme nt

is fitte d.

Should the machine have to be transported a fter the

transmission element is fitted, other suitable measures

have to be ta ken.

If the ma chine is not put into service immed iat ely after

arrival, store it in a dry, vibration-free room.



WARNING

Im proper handling can cause severe injury or property

dam age.

W hen lifting generator,

1. Lift only at designated locations.

2. Use spreader for lifting.

3. Apply tension gradually to slings.

4. Do not jerk or attem pt to m ove unit suddenly.

5. Do not use cover lugs w hen lifting.

Fig. 2 Insulation resistance variation to temperature

-10 0 10 20 5030 40 60 9070 80 100

0.05

0.1

0.5

1

5

10

50

100

Insulation

ResistanceC

oefficient,Kt

W inding Tem perature,

To Convert O bserved Insu lation Resistance (Rt) to 40M ultiply by the Tem perature Coefficient Kt.

Rc = Kt x Rt

1. Rc : Insulation Resistance (in m egaohm s) corrected to 402. Rt : M easured Insulation Resistance (in m egaohm s) at Tem perature t

3. Kt : Insulation Resistance Tem perature Coefficient at Tem perature t


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15) Inspection

The first inspe ction sh ould be ca rried out a fter

approximately 500 hours.

The following che cks should a lso be ca rried out:

Running smoothness of machine satisfactory

Rotor a lignment w ithin toleranc es

No subs idence or cracks in the foundat ion

All fixing bolts of mechanical and electrical joints tightInsulation resista nce of w indings sat isfac tory

(compa re w ith previous rea ding and record)

No bridging of any bearing insulation

Any excess ive deviations or change s a scerta ined during

the checks must be corrected immediately.

Damaged or used locked elements from released bolted

joints must be renew ed.

The ba sic intervals betw een inspections a re approxima t-

ely 4000 hours, 1000 switching operations or 1 year for

intermittent operation a nd a pproximately 16,000 hoursor 2 years for continuous operation, depending on w hich

occurs first.

The clea ning of a ll parts be coming fouled b y the flow of

cooling a ir depends on the intervals decided a fter the first

inspection acco rding to t he rat e of fouling w hich occ urs

locally.

Clea ning should be c arried out w ith dry compressed a ir.

Information on o il changes , regreas ing, etc. is given on

the lubrica tion instruction plat e on the m ac hine or in the

suppleme nta ry instructions for bea rings.

The c hecks st at ed for the first inspection afte r 500 hours

should be performed during thes e inspections a lso.

When a ma chine is disma ntled, the follow ing checks

should be ma de:

Slot wedges in stator and rotor cores tight

Windings, conne ction leads , a nd insulating parts in

sa tisfactory condition with no discolorat ion

After reas sem bly, aga in follow t he instructions given for

installation.

16) Spare parts

Spare pa rts sha ll be normally supplied in acc ordance w ith

the clas sifica tion societies req uirement.

Independa nt of the clas sifica tion societies req uirements ,

w e recommend the follow ing sets of spares be ordered

w ith the generators

1 set of bea rings o r bea ring she lls for sleeve be aring

1 set of rota ting rectifiers

1 set of rectifiers for the c onsta nt-volta ge unit

1 regulator (AVR)

1.3 Composition

1) Stator frame and winding

The st at or fram e is of w elded des ign.

The sta tor core is ce ntred in the fram e a nd locked a ga inst

rotat ion a nd shifting.

The st at or w inding is of a tw o-laye r coil design w ith

insulat ion class F.

This insulat ion is m ade in a special w ay and is comprised

of integrated-mica &enamel coated insulating material

impregnated w ith ca st resin.

It is cha racte rized by high dielectric strength, resistance

to moisture, aggressive ga ses a nd vapours, a s w ell as

rigidity a nd long life.

2) Rotor and windings

The sha ft for ma chines cons truction type B3 and B20

is designed w ith a normal cylindrica l shaft exte nsion for

tw o bea rings. In the cas e of types B2 and B16, the shaft

is fitte d w ith a flang e.

The rotor core of the ma in ma chine is mo unted o n the

shaft, tensioned axially, and supports the field and damper

w indings. The da mper w inding ba rs lie in the s lots o f the

rotor core and are welded to the rings.

The rotor core of the exciter is mo unted on the s haft a nd

supports the three-phas e exciter w inding.

The rect ifier supporting w heel is mounte d on the sha ft

between the two laminated cores.

The roto r is ba lance d dyna mica lly.



14) Maintenance

Before sta rting any w ork on a machine, make sure that it

has been disconnected from the pow er supply and tha t

unintentional sta rting is sa fely prevented .

Clea n the co oling air passa ges a t regular intervals,

matching the degree of pollution and using oil-free

compressed air, for example.

The inside of tota lly-enc losed fa n-coo led ma chines ne ed

only be cleane d during norma l overhauls.

If dust or moisture has penetrated into the terminal

compa rtment, it should be ca refully cleaned a nd dried,

in particular the surface s of the insulat ing parts .

Check the seals and eliminate the leak.


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10) Rotor locking device

The follow ing inst ructions supplem ent ing and m odifying

the b as ic operating instructions apply to single be aring

genera tors of type o f construction B2 or B16 which a re

coupled w ith diese l engines or turbines.

See t he instruction manua l on pages 38-39.



11) Insulation for the prevention of shaft current

(high voltage and large machines)

To prevent the sha ft current ca used by t he unba lanc e of

ma gnetic resistance of ma gnetic circuits, the insulat or is

provided at the no n-drive-end s hield as sho w n in Fig. 6.

The s haft volta ge is a high-frequency voltag e of usually

1 volt or less a nd rarely several volts.

When a s haft current flow s, by this volta ge the s haft a nd

journal part are ta rnished. In the w orst condition, sparking

results in minute b lac k spots.

There is a poss ibility t ha t t he o il film is b roken loca lly,

developing burn-out trouble.

When disass embling or as sem bling, be s ure to mea sure

the insulation resistance.

The va lue of 1 to 3 w ill be sa tisfacto ry.

It is gene rally sa id that sha ft voltage for bea rings is limited

as follow s.

1,000 m V Be arings ma y be da ma ge d in a w e ek

to a year

(unless insulation is provided ). Fig. 5 Rotor locking device

End shield AS Flanged shaft Retaining ring half Fixing screw for 1 Shaft supporting ring Fixing screw for 3

Fig. 6 Insulation for the preventation of shaft current

NOTE

Insulated Bearing

A ny connection to this bearing m ust be insulated from it

to prevent bearing current.12) Thermometer

For checking the be aring temperat ure, a thermom eter is

provided for ea ch be aring.

In order to prevent the a ccumulation of moisture and

condensation while the generator is idle, space heaters

are provided within the stator frame.

The spa ce hea ters ca n be ea sily removed from outside

the enclosure.

The hea ter is comprised of st ainless-sheat hed nichrome,filled w ith insulators in the she at h a nd is U-sha ped a s

sho w n in Fig. 7.

13) Space heater

DANGER

Hazardous voltage


dam age.



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10


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Fig. 9 Sectional drawing for HF. 5, 7 & HS. 7 type generator (single sleeve bearing)

HFJ 5, 7 & HSJ 7 (air to w ater cooling)

HFC 5, 7 & HSR 7 (air to air cooling)

Stator and stator w indings assem bly

Rotor and w indings assem bly

A.C exciter assem bly

Rectifier assem bly (Fig. 9-1)

Excitation equipm ent

Shaft

Bearing

Cooling fan

End shield D E/N-DE

Rotor lockage device

Insulation for prevention of shaft current (Fig. 6)

Therm om eter

Space heater

Cooler

Term inal box

Fig. 9-1 Rectifier assembly

Varistor m odule Connector rings Hub Rectifier m odule


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Fig. 11 Sectional drawing for HF. 6, 7 & HS. 7 type generator (single sleeve bearing)

HFJ 6, 7 & HSJ 7 (air to w ater cooling)

HFC 6, 7 & HSR 7 (air to air cooling)

Stator fram e and stator w indings assem bly

Rotor and w indings assem bly

AC exciter assem bly

Rectifier assem bly (Fig. 11-1)

Excitation equipm ent

Shaft

Bearing

Cooling fan

End shield D E/N-DE

Rotor lockage device

Insulation for prevention of shaft current (Fig. 6)

Therm om eter

Space heater

Cooler

Term inal box

Fig. 11-1 Rectifier assembly

Varistor m odule Connector rings Hub Rectifier m odule


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2.1 Mode of Operation (SPRESY 15)

1) Description

Brushless synchronous generators consist of the main

and exciter machine.

The m ain ma chine s field w inding is pow ered from the

exciter rotor w inding via a rotat iona ry, three-phas e bridge-

connected rectifier set.

The e xcite r is pow ere d from THYRIPARTe xcita tion

equipment.

Excitation equipment a nd thyristor volta ge regulator a re

com bined in the THYRIPARTexcita tion s yst em .

The exc itat ion current req uired is supplied to t he ma in

machine via the excitation equipment which is

ad justed to de liver a field current res ulting in a genera toroutput voltage above the maximum reference value over

the e ntire load range w hen the voltage controller is

inactive.

The a ctua l function of the volta ge regulator is t o provide a

bypas s for a va riable portion of the current supplied by t he

excitation eq uipment for controlling the genera tor volta ge.

The thyristor regulat or module consists o f tw o as sem blies:

the regulat or module and the firing mo dule w ith thyristor in

buck circuit.

The three-phase ge nerato r volta ge, ha ving bee n reduced

to 24V by the measuring-circuit transformers, is applied

to tem inals 17,18 and 19.

A direct vo ltage of a pprox. 30 V (te minal 20 to t ermina l 13

or 14) is produced at the output of the rectifier bridge

under the rated voltage of the generator.

This rectified volta ge provides th e a ctua l pulse signa l a nd

the supply voltage the control am plifier.

The regulat or module supplies output t ermina l 15 w ith a

control voltage of approx. 1 to 10 V, which is proportional

to the control deviat ion.

Depending on the reference potent ial of te rminal 16,

terminal 12 of the compa rator point of the control

am plifier can be given a n a dditiona l D.C. pulse, e.g for

react ive pow er cont rol in pa rallel operation.

For tuning to the signal level, a rheosta t must be so ldered

onto the a vailable so ldering pins.

The pow er supply for the g at e co ntrol mod ule(s) is

available from terminal 11.

In the control circuit of the firing module, a time

adjustable firing impulse for the thyristor is formed from

the c ontrol voltage o f terminal 15 in compa rison w ith a

saw tooth voltage.

The overvolta ge protect or operates at volta ges o ver

600 V betw een te rminals 1 and 5, then sw itches the

thyristor through.

The exc itat ion current is norma lly bucked w ith a single

pulse.

If higher excita tion is required, t w o firing modules for tw o-

pulse " buck" operation w ill be provided.



Excitation System (Operation)02

Fig. 14 Block diagram of voltage regulator; SPRESY 15

Fig. 13 Voltage regulator; SPRESY 15

Six-pulse recifier bridge

Referance/actual value com parator

Pow er supply

Control am plifier

Firing pulse control

Thyristor in buck circuit

O vervoltage protector

Auxilary pow er thyristor


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Excitation System (Operat ion)02

16


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2) Installation

The excitation eq uipment, thyristor volta ge regulat or,

ma in machine and e xciter are all fact ory-w ired.

If necessary, the mains leads and the reference-value

selector should be connected to the terminals in the

terminal box according to the connection diagram

supplied w ith the ma chine.

2.2 Operation (SPRESY 15)

1) Thyristor voltage regulator

When t he ge nerato r is o perating by itself, the thyristor

voltage regulator controls the generator voltage to the

preset reference value.Frequency cha nges due to the droop characteristics of

the prime m over do not influence the ac curacy of the

generator output voltage.

Design and adjustment of the main machine, exciter,

excitation eq uipment, t hyristor voltage regulator and

reference-value selector permit gradual cha nges in the

genera tor output voltage from 95%to 105%rated voltage

via pot entiomete r Usoll under stea dy-sta te co nditions a nd

at loads varying betw een no load to rated load a nd power

factors between 0.8 and unity, unless otherwise specified

on the rating plate.

If the generators are operated at less than 95%or more

than 105%rated voltage, their output must be reduced.

Unrest ricted operation w ith no load (opened generat or

breaker) and partial speeds is permissible.

During operation, the e xcita tion circuit must not be

interrupted since t his w ould give rise t o voltage s urges.

If the gene rator must b e de-excited, t his can be

ac complished by sho rt-circuiting se conda ry side of

rec tifie r tra ns form er (T6) (Fig. 14).

2) Transformer adjustment

The ta ppings used on t he trans fomers are recorded a t

tes t report. It is strongly recomme nded tha t the o riginal

adjustments be left unchanged.

No responsibility ca n be as sumed by the supplier for any

da ma ge or incorrect operat ion resulting from a cha nge in

the o riginal adjustme nts.

In th e c as e o f identica l plan ts , th e THYRIPARTexcita tion

system or single parts may be interchanged if necessary;

those transformer tappings must a lw ays be used inaccordance with the original ones.



3) Direction of rotation of the generator

The ge nerato rs are g enerally suitable for clockw ise and

anti-clock-wise operation.

Generat ors must run only in the co rresponding direction

of rotation as on the data plate of rotating (arrow mark).

To cha nge t he direction of rotat ion it is neces ssry to

change t he connections according to t he connection

diagram e .g. phase rotation check and to check w hether

only one definite direction of rotation is permissible for

mechanical reasons (e.g. fan with curved fan blades).

4) Regulator gain setpoint of voltage integral

action

The regulator m odule includes the three pot entiomete rs

Uso ll, Vr a nd Tn.

The gene rator rate d voltage is a djusted in the fact ory

on potentiometer Usoll and the transient response

cha racte ristic of the regulator on pot entiomete rs Vr

a nd Tn.

The regulat or gain is adjuste d on the po ten tiome ter Vr,

but the integral action time and the optimum transient

response characteristic are adjusted on the

pote ntiome ter Tn.

Turning t he knob of Vr in the direction of d es cen ding

numerals a nd tha t of Tn in the direction of as cending

numerals norma lly stab ilizes the control circuit and

reduces the control rate.

The se tpoint of the ge nerato r volta ge ca n be s hifted via

potentiometer Usoll and via a supplementary external

referenc e-va lue select or (R = 1.5 , P 1 W) to be

connected to auxillary terminals 20 and 21 (Fig. 14)

with the above potentiometer set to mid-position.

The new ad justme nt of the potent iometer must be fixed

w ith the aid of the set screw .


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The t hyristor voltage regulat or provides a bypas s for a

variable portion of t he current supplied b y the excitation

unit for co ntrolling the ge nerato r volta ge.

The volta ge regula tor 6 GA 2492 is co mprised o f the

volta ge regulator 6 GA 2491 and the pow er module

(rect ifier, thyristor in "b uck" circuit, a nd resist or in

" buck" circuit).



Fig. 18 Block diagram of voltage regulator "6 GA 2491"

Fig. 16 Voltage regulator "6 GA 2491"(for generator top mounting)

Fig. 17 Voltage regulator "6 GA 2491"(for panel mounting)

V29 Excitation rectifiers S Droop potentiom eter Pow er supply Control am plifierU Reference value potentiom ete K Potentiom eter, controller gain Pulse unit O vervoltage protectorT Potentiom enter, reset tim e R47 Potentiom eter, disturbance feedforw ard External reference value setterV28 Thyristor in "buck" circuit R48 Resistor in "buck" circuit


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21/56



Fig. 20 Connection diagram of generator (for generator top mounted AVR): 450 Fr~

U : Varistor

V29

+F1Generator side

G 1 U

G 2

+ V2 1 C2 1

C122 C32

U2 W 2V2

1

V

X6

+F1 -F2

X7-F2

G 2

+ W -

UX4/F2

R48

AG

V28K5

K G

G:Sm aller pin size

A

GK A

K : Cathod eG : G ate

V28 : ThyristorA : Ano de

5

2.1

1.1

2.2

1.2

T4

Generator control panel side

4

W 1U1 V1

L1

1

1V11U1

3

1W 1

3 3

(1N)

TSR

U V W

VC B BreakerM ain

450V

3

2W 12U1 2V1

3

T6 654

87

(2N)

1

2.2

X35 63

8

124

6

X2

A3

1

2.1

2.2 2.254

54

54

2.12.13 3 3

T3T2T1

5

19

A12

10

27

A1

S1/1X1

11

S1/3S1/2

51

3

T1...T3 : Current transform erT4 : Current transform er for droop com p.

V2 : Rotating rectifierX1...X4 : Plug conn ection

V29 : Rectifier m oduleR48 : By-pass resistor

T6 : Rectifier transform er

4 Current transform er for droop com p.N ecessary for parallel op eration

X6...X7 : Term inal strip

1.0SQ

20Vac

2

-

A1 : Vo ltage regulator

+

G 2 : ExciterL1 : Re actor

C1...C3 : CapacitorG1 : M ain m achine

2

3230V1

5

3

1.25SQ600V

Shield cable

3 400V

1 Con nections are determ ined in the test field.2 W hen reference value setter fitted circuit breake r S 1/3 off

A1

A3 setter(VR)Reference value

-

+

A3

A1

A3

A1

2W2V

2V 2W

1.1.W

1.1.V

1.1.U

G1U2

U1

V2

V1

1.2

T1

1.2

T2

1.1 1.1

W 2

W 1

1.2

T3

1.1

-

T10

Shortnotinuse

C12

C32C22

C21C11

C31

L

K

T12T11l

k 187X2187X3

187X1 187X1

187X3187X2

187X6

250Vac1.25sq

decreased b y this short circuiting of exciting current.

w ill be sh orted by "A " contact of 187X relay.

w ill be energized and exciting current of generator

If generator winding is faulty, the 187X relay

Then term inal voltage of generator w ill be im m ediately

(Supp lied b y sw itch board m aker)

Note for 187X6

from panel side(150Vac, 10Aac)

T11 Differential protection C /T

187X : D.E-M agnetizing contact

T10

T12

O ptional

Fig. 20-1 Connection diagram of generator (for panel mounted AVR): 450 Fr~

Generator control panel side

G 1

Generator side

U

G 2

V2

+

U2

V2 1

W 2

V

+ F1 + F1

+

-F2

G2

-F2

W -

2

V29

C3

C222

1 U

C1

1

R48

X4/F2

R48/1

U2

G1

U1

V2

V1

1.2

T1

1.1

T2

1.1

R S

U V

1V1

V1W 2

W 1

U1

L1

W 1 1

1U1

3

T3

1.1

T44

1W 1

3 3

(1N)

2U1 2V1

T6

1.2

(2N)

2.2

2W 1

3

6

45

78 1

T3

2.22.2

1.12.1

2.2

45

45

2.1 2.13

2.13

T1 T2

145

X2/9

X2/5

3

T

W

M ainbreaker

G : G ateK : CathodeA : Anod e

U : VaristorN ecessary for parallel op eration

4 Current transform er for droop com p.

V28 : Thyristor

1.25sq

250Vac

R48/1

F2

A5

K V28

G

5

G:Sm aller pin size

K G

AG

A

K

T6 : Rectifier transform er

R48 : By-pass resistorV29 : Rectifier m od ule

circuit breake r S 1/3 off2 W hen reference value setter fitted1 Connection s are determ ined in the test field.

X1...X4 : Plug con nectionV2 : Rotating rectifier

T1...T3 : Current transform erT4 : Current transform er for droop com p.

L1 : ReactorG 2 : ExciterG 1 : M ain m achine

C1...C3 : CapacitorA1 : Vo ltage regulator

450V

250Vac

1.25sq

X35

X2/5

X2/9

X1

3

3 6

A3

8

X2124

6

A1

5

19 22

107

A1

S1/1S1/2S1/3

11

15 3

2

3

Shield cable

600V1.25SQ

3 400V

A3

A1

513

230V

-

+ Reference value

-

+

2

20Vac1.0SQ

setter (VR)

1.2 1.2

X6

X7

VC B

X6...X7 : Term inal strip

1.1.U

1.1.V

1.1.W

-

Shortnotinuse

T11T10kK

C12

C32C22

lL

C21C11

C31

T12187X2187X3

187X1187X

187X2187X3

187X1

6

decreased by this short circuiting of exciting current.

w ill be shorted b y "A" co ntact of 187X relay.w ill be energized and exciting current of generatorIf generator winding is faulty, the 187X relay

Then term inal voltage of generator will be im m ediately

(Supp lied by sw itch board m aker)

Note for 187X6

from panel side(150Vac, 10Aac)

T11 Differen tial protection C /T

187X : D.E-M agnetizing contact

T10

T12

O ptional


22/56


22


23/56



2) Mode of operation of regulator

The ge nerato r volta ge is fed to the regulat or via plug

connec tor X1 in a single-phase , tw o-circuit arrangem ent.

Transformer T1 steps dow n the genera tor voltage w hich

is the n rect ified by t he loa d-side rec tifier bridge V1, V4.

This rect ified volta ge provides the ac tual pulse signal " Uist"

the s etpoint volta ge Usoll and t he supply volta ge fo r

the regulator.

If the system uses a reactive current compensa tor,

current tra nsform er T15 or interposing t rans former T4

of the excitation unit is c onnecte d to loa d resistor R1 via

plug-in c ont a ct s X2/5 a nd X2/9.

In this operating mode the actual voltage is composed

of the s econda ry volta ge of tra nsformer T1 and t he

volta ge of load resistor R1.

The m agnitude of the resulting reduction in genera tor

voltage can be set w ith potentiometer S.

If an exte rnal set point selector is used , this is conne cted

by co nt a ct s X2/1 (A1) and X2/3 (A3).

In this ca se microswitch S1/3 of the regulator m ust b e

opened.

A DC voltage of 0 to 10 V ca n be fed in via plug-in

co nta ct s X2/6 and X2/2.

This voltage a cts o n the co mpa rator point of the control

amplifier.

The se tpoint can thus, for instance , be prese t by higher-

level equipment.

Cont rol am plifier (proportional ag ain a djusta ble by

potentiomet er K and rese t t ime by pot entiomete r T)

outputs a DC voltage which is converted into a time-

a djusta ble firing pulse for thyristo r V18 or V28 via the

loadside pulse unit .

The ge nera tor exc itat ion circuit is fed from rect ifier

bridge V29.

Resistor R48 and thyristor V28 form a parallel bypass

circuit to the field w inding through w hich part of the

current supplied by the excitation unit flow s.

This met hod provides for genera tor voltage control.

In order to optimize the co rrecting ac tion, a disturbance

variable is injected into the control amplifier via resistor

R47.

Overvoltages above DC 600 V in the excitation circuit

cause the overvoltage protector to operate a nd

continuously fire the thyristor.Protect ion is thus provided for the st at iona ry excita tion

circuit of the gene rator.

3) Installation

The e xcitation eq uipment, thyristor voltag e regulat or,

main machine, and exciter are factory-wired.

If necess ary, the m ain lea ds a nd the reference-value

selector must be connected to the terminals in the

terminal box according to the connecting diagram

supplied w ith the ma chine.

2) Transformer adjustment

The ta ppings used on the t ransformers a re show n in the

test report.

It is strongly advised not t o cha nge the original

adjustments.

No respons ibility ca n be as sumed by the supplier for any

da ma ge or incorrect operat ion resulting from a cha nge in

the original ad justme nts.

In th e c a se of ident ical plant s, the THYRIPARTexcita tionsystem or the individual components can be interchanged

if necessary.

The trans former tappings, how ever, must b e use d in

accordance with the original ones.

2.5 Operation (6 GA 2491)

1) Thyristor voltage regulator

The voltage regulat es t he voltage so t hat it com plies

w ith the setpoint selected.

Frequency cha nges due to the droop characteristics ofthe prime m over do not a ffect t he voltage accuracy.

The design and a djustme nt of the gene rator and t he

excitation equipment permit continuous changes of the

terminal volta ge in the range of 5%rat ed voltage via

the setpoint selector under steady-state conditions and

at loads varying from no load to rated load, and pow er

fact ors from 0.8 to unity unless specified ot herw ise o n

the rating plate.

If several rated voltages and frequencies are indicated on

the rating plate, t he above da ta apply to each of the rate d

voltages stated.

If the generators a re operated at voltages exceeding

5%, the ge nerato r output must be reduced .

Unrestricted opera tion at no load is permitted if the speed

is reduced .

During opera tion, the e xcitation circuit must no t be

interrupted since this w ould give rise t o voltage s urges.

If the generator must be de-excited, this can be

ac complished by short-circuiting the s econd ary side of

rec tifie r tra ns form er (T6) (Fig. 14).


24/56


25/56



Excessive dust deposits should, however, be removed

using dry, com pressed a ir.

For the maintenance of generator of its related parts,

refer to trouble-shoot ing table 4-3, as s how n on pa ge 51.

When ordering spare pa rts, plea se st at e the type a nd

serial number of the generator as specified on the

rating plat e.

No periodic ma intena nce inspect ions o f th e THYRIPART

excitation equipment are required.

2.6 Maintenance (6 GA 2491)

Fig. 22 Droop characteristic curve

Fig. 23 Position of potentiometers on the voltage regulator

DANGER

Hazardous voltage


dam age.

D isconnect all pow er before w orking on this equipm ent.


26/56

Maintenance03

26


27/56



1) Inspection schedule

Daily

Check bea ring.

L.O. c ondition.

Oil ring.

Noise.

Vibration.

Tem pera ture.

Check electric circuit.

Earth fa ult by ea rth lam p.

Check loading condition.

Volta ge, output kW, current .

Monthly

Check insulation resista nce.

Caution: Before che cking insulat ion resista nce,

disconnect and ea rthed the leads from A.V.R.

Bolts a nd nuts.

Tighten a ll bolts a nd nut s.

Check ventilat ion openings.

Check air intake opening and its air filter, clean orreplac e t he filter if necess ary.

Table 3-2. Installation & inspection check list

Bearings

Journal bearings

(Lubricating oil used)

O il grade

Viscosity at

Condition of bearings and shaft

Have any shipping bearing shells

and/or shaft blocks been

rem oved?

Anti-rust coating rem oved?

shaft journals satisfactory?

O il rings fitted in the bearings?

Circularity of oil rings

satistactory?

O il-ring slots of bearings

shells deburred and rounded

off?

Joint locked?

Bearing sealing rings properly

fitted?

Bearing therm om eters fitted?

All bearing bolts properly

tightened and locked?

Bearing filled w ith oil tocentre m arks of oil-level sight

glasses?

Running of oil rings checked?

Oil circulation system

O il pipew ork cleaned and

pickled?

Pressure reducer fitted?

Oil flow rates reference

Drive-endjournal bearing /m in

N on-drive-end

journal bearing /m in

The specified oil flow rates are

indicated on the bearing instruc-

tion plate. W ith the specified

flow rates, about half the clear

cross-sections of the oil drain

pipes are filled w ith oil.

Rolling bearings

Grease lubrication

Type of grease

General

Check the flow of cooling w ater

(IP44):

Check the safety device in

service, or not?

Answ er

Yes N 0 n/aInstallation

Answ er

Yes N 0 n/aInstallation


28/56

Maintenance03

28


29/56



Pour in the kerosene and oil through the top s ight-glass

hole.

Lea ve the d rain open until all the kerosene has been

removed a nd clean oil runs out.

Now , plug the drain and fill the bea ring w ith oil up to the

centre of the lateral inspect ion glas s.

When the ma chine has run up to speed, c heck the oil ring

through the top inspection glass to see that it rotates

correctly, and check the bearing temperature.

Should the bearing temperature not drop to the normal

value after the oil change, it is recommended that the

surfaces of the bearing shells be inspected.

If the bea rings a re fitted w ith thermomet ers for checking

the b ea ring tem perature, fill the thermom eter w ell in the

upper bea ring she ll for thermo feeler w ith oil to improve

hea t trans fer and top up w ith oil every time the

lubricating oil is changed.

Recom mende d oil changing intervals a re ab out 3000

and 6000 operating hours in the ca se of intermittent a nd

continuous duty.

When c lea ning, first flush the bea rings w ith kerosene

and then with oil.

NOTE

If the lubrication oil contains unusual residues or its color

looks changed, bearings shall be inspected.When disma ntling the ma chine, the low er part of the

bearing housing need not be unscrew ed from the end

shield. When o pening the b ea ring housing, locat e

which side of the machine the adjusting shims

(upper and lower pa rts) are insta lled.

These s hims must be insta lled in the sam e place w hen

ass embling the machine.

Exceptions are possible if the stator core was changed.

Drain the oil, ta ke off the upper part o f the bea ring

housing and the upper bearing shell, lift the s haft very

slightly and turn out t he low er bea ring she ll and the

sealing rings in a peripheral direction.

The oil ring ca n be w ithdraw n by holding it at a n inclined

position to the shaft.

4) Dismantling, assembling

CAUTION

W hen insulated shaft current is applied, the accessories in

contact w ith the bearing housing m ust be electrically

insulated.

Fig. 24 Oil pockets and oil grooves

flattened to running face


30/56

Maintenance03

30


31/56



3.3 Flange-Type Sleeve Bearing

(forced lubrication system)

1) Mounting

The flange be arings of these electrica l machines a re of

the split type.

They a re lubrica ted by a n oil ring a nd provided

a dditiona lly for force d lubrication (Fig. 27)

They a re subject t o the follow ing inst ructions s upple-

ment ing and mo difying the operation instructions of t he

machine:

Corresponding to the o perating conditions, the sleeve

bearings of new machines have a favorable bea ring

clearance w hich should not be changed.

Scraping (spot-grinding) is no t a llowed not t o m ake w orse

the ant ifrictional q ualities.

It is recommended that the contour of the transmission

element rem ains w ithin the ha tched range (see Fig. 27)

to remove t he upper part of the bea ring housing for

maintenance without removing the transmission element.

Before the machines are aligned,the bearings should be

filled w ith lubricat ing oil (oil type is indica ted on t he na me

plat e of the bea ring) since the m ac hines a re delivered

w ithout oil in the bea rings.

Connect t he bea rings to t he oil pump, oil ta nk and cooler

before commissioning the machines.

No reducers m ust b e fitted in the piping.

Install a regulating orifice on the oil supply line to protect

the bea ring from flooding.

If the oil pump fails, the lubrication maintained by the oil

ring is effect ive for a bout 15 to 30 minutes, provided the

oil contained in the bearing does not drain away.

To prevent this, connec t the oil discharge tube on tha t

side w here the oil ring moves dow nw ard into the oil.

In addition to this, install a non-return valve in the oil

supply line.

As a n a lternative raise the level of the oil in the bea ring

to 100 mm.

Oil discha rge tubes must terminate flush w ith the inside

surface of the bea ring housing to prevent the oil rings

from rubbing against the tubes.

Fill the oil tank with the lubricating oil indicated on the

data plate.

This oil is use d for sta rting up the ma chine at an am bient

temperature of above + 5.At lowe r temperat ures, preheat t he oil.

It is recommended to use a control system adjusted in

such a manner to have an oil temperature of 15 to 20

in the tank and to have a preheated oil flow through the

cold bea rings for 5 to10 minutes b efore sta rting up the

machine.

Do not m ix oils o f different g rades .

The nec essa ry pressure o f the o il entering the be arings

and the oil flow rate a re indicate d on the da ta plate.

Adjust these values when starting up the machine for the

first time a nd correct them w hen the bea ring has atta ined

its normal running te mperat ure.

The oil in the bea ring housing must not a scend over the

cente r of the lat eral inspect ion glas s.

If the bea rings a re fitted w ith thermomete rs for checkingthe be aring tempera ture, fill the thermom eter w ell in the

upper bea ring s hell for the t hermofeeler w ith oil to

improve hea t trans fer and top up w ith oil every time t he

lubricating oil is changed.

In the case of insulated bearings, make sure that the

insulat ion is not bridged by the t ubes.

Interrupt the electrica l conductivity of the tubes nea r the

bearings, e.g. by installing oil-resistant fittings of plastic

ma terial or hoses of rubber or plas tic mat erial.

Upon stopping, the shaft rests on the lower bearing; there

is metal-to-metal contact.

During the start-up phase, the shaft rubs against the anti-

friction met al of the bea ring.Oil lubricat ion is use d.

After having rea ched its trans ition speed , the sha ft

creates its oil film.

At this point, there is no further contact between the

shaft a nd bearing.

2) Operating description

NOTE

Before starting, check if the bearing is filled w ith oil or not

to the sufficient oil level.

CAUTION

Prolonged operation at extrem ely slow rotation speeds

(several rpm ) w ithout lubrication could seriously dam age

for the service life of the bearing.


32/56

Maintenance03

32


33/56



Fig. 27 Flange-type sleeve bearing for forced-oil lubrication (examples, delivered design may deviate in details)

1. Screw plug

(therm om eter m ounting and oil filling point)

2. Inspection glass

3. Sealing ring for 2


5. Bearing housing, upper part, drive end

6. Cylindrical pin

7. Sealing ring, upper half, drive end

8. Guide pin to prevent tw isting

9. Upper bearing shell, drive end

10. O il ring, drive end

11. Low er bearing shell, drive end

12. Bearing housing, low er part, drive end

13. Sealing ring, low er half, drive end

14. Taper pin

15. Guide pin to fix bolted parts


17. Drain plug

18. Bearing housing, upper part, non-drive end

19. Sealing ring, upper half, non-drive end

20. Upper bearing shell, non-drive end

21. O il ring, non-drive end

22. Low er bearing shell, non-drive end

23. Bearing housing, low er part, non-drive end

24. Sealing ring, low er half, non-drive end

25. Upper adjusting shim , drive end

26. Sealing cover, drive end

27. Low er adjusting shim , drive end

28. Upper adjusting shim , non-drive end

29. Sealing cover, non-drive end

30. Low er adjusting shim , non-drive end

31. Protactive cap

32. Pressure com pensation opening

33. O il supply tube w ith orifice

34. O il discharge tube w ith sight glass

35. Lubrication oil cooler

1

2

34

5

6

7

8

9

10

11

12

13

14

2134

18

6

19

8

20

21

22

23

24

14

15

3

2

16

17

31

28

29

30

32

15

3

2

1617

d1 (m m ) 80 100 120 150 180 215

d2 (m m )

a (m m ) 8 8 10 15 18 22

140 160 170 190 210 245

Front a nd rear cha mbers of lubrica tion oil cooler can be

disass embled in cas e of w ater leakage.

How ever, lubrica tion oil cooler do not need any o verhaul

works unless oil or water leakage happen because it

requires additional compression test when those

chambers a re disass embled.

Lim iting range for

transm ission elem ent

100m

m

d1

d2

a

4525

26

27

32

3334

35

Cooling w ater supply

Cooling w ater discharge

5) Lubrication oil cooler for generator bearings

Forced lubrica tion syste m m ay have lubrica tion oil cooler

for technical reason.


34/56

Maintenance03

34


35/56



The sha ft should rotate during regreas ing, hence the

mac hines need not be stopped.

After regreasing, the bea ring te mperat ure w ill rise by a

few degrees and w ill drop to the normal value when the

grease has reached its normal service viscosity and the

excess grease has been forced out of the bearing.

It is recomme nded t hat the lubrica ting instructions be

strictly followed .

Special cases ma y require lubrica tion acco rding to spe cial

instructions, e.g. where there is an extreme coolant

temperature or aggressive vapours.

The old greas e from seve ral regrea sing operations ga thers

in the space inside the outer bearings caps.

Remove the old grease when overhauling the machines.

The m odel of be aring is fa vorably chosen for direction a nd

size of load (type of cons truction, forces ac ting on the

sha ft) and t herefore it should not be hung.

The permissible va lues of a xial a nd ra dial forces ma y be

ta ken from the list of ma chine or may be inquired a bout.

The m ac hines should operate in only one type of

construction as show n on the rating plate , because

ano ther type of const ruction requires perha ps further

measures in addition to a modification of the model of

bearing.

In this case an inquiry is always necessary.

3) Lubrication

Regrease t he bea rings if the machines have bee n

unused/stored for longer tha n 2 yea rs.

5) Locating faults

The t rouble s hooting ta ble 4-6 helps to trace and remove

the causes of faults a s show n on page 53.

Sometimes, it is difficult to assess damage to the

bearings. In this case, renew the bearings.

4) Dismantling, assembling

For working on the loca ting bea ring in the vertica l

position of the ma chine, support or discharge the rotor.

It is recomme nded t hat new rolling bea rings be insta lled

as follows: Hea t the ball bearings or the inner ring of the

roller bearings in oil or air to a temperature of approx 80

and s lip them onto t he shaft.

Heavy blow s ma y dama ge the bearings and must be

avoided.

When insta lling single ang ular-cont a ct ba ll bea rings , ma ke

sure tha t the broad s houlder of the inner ring (and the

narrow shoulder of the outer ring) in operating

position points upw ards, i.e. in a direction opposite t o

that of the axial thrust.

When as sem bling the ma chines, avoid dama ge to the

sealing rings.

Rubbe r se aling rings (V-rings) sho uld be ca refully fitte d

over the shaft as shown the illustration.

New felt se aling rings sho uld be s o dimensioned tha t the

sha ft ca n run ea sily w hile proper sea ling is s till effected.

Before fitting new rings, s oa k them thoroughly in highly

viscous oil (normal lubricating oil N68 to DIN 51 501)

having a te mperat ure of approx 80.


36/56

Maintenance03

36


37/56



Fig. 30 Locating bearings (examples, delivered design may deviate in details)

Lubricating nipple Inner bearing cap w ith felt sealing rings 2)

Angular-contact ball bearing Bearing slinger 2)

Grease slinger 2)

Circlip 2)

O uter bearing cap 2)

V-ring 2)

Deep-groove ball bearing (locating bearing)or angular-contact ball bearing

Com pression spring 2)

Cylindrical roller bearing 2)

Cylindrical roller bearing 2)

O il seal for shaft1) 2) 3)

1)floating bearing side2)locating bearing side3)special operating conditions only

Fig. 31 Fitting instructions for V-ring and oil seal for shaft

Single bearing, shaft does not pass through the outer bearing cap

Angular-contact ballbearing placed below

A ngular-contact ballbearing placed below

Single bearing, shaftdoes not pass throughthe outer bearing cap

Single bearing, shaftpasses through theouter bearing cap

D uplex bearing, shaftdoes not pass throughthe outer bearing cap

D uplex bearing, shaftpasses through theouter bearing cap


38/56

Maintenance03

38


39/56



4) Position of rotor in longitudinal direction (Fig. 34)

Originally, the genera tor rotor had been loca ted axially

in the correct position by the bolted-on retaining-ring

halves.

Since single-bearing generators have a floating (rolling or

sleeve) bea ring a t the non-drive end, the axial position of

the rotor may have been changed during alignment.

A check should therefore be made to ensure that the axial

clearanc e of (60.8)mm be tw een the flange faces

of the drive-end shield and the s haft s upporting ring has

been maintained.

Otherwise the s ta tor frame sho uld be shifted a xially.

5) Fixing the retaining-ring halves

Thereupo n, scre w the ret a ining-ring halves to t he drive-

end s hield a s s how n in Fig. 35.

The ring joint s hould be vertica l.

Close off the thread ed holes in the retaining-ring ha lves

by mea ns of the screw s supplied, and lock the screws

w ith spring w ashers.

3.6 Coupling B-type (single-bearing generatorswith lamination plate)

1) Transport

The following instructions apply to the genera tors c oupled

w ith e ngine using lam ination type co upling.

For transportation and assembly, the generator rotor is

cente red radially and fixed a xially by mea ns of the holding

devices fitted betw een generator frame and lamination

plates or fan assembled (Fig. 36).

Therefo re, thos e holding devices m ust be fixed t ightly

inner and oute r sides for sure w hen t ransport. This is for

cente ring the genera tor rotor radially a nd a xially.

3) Checking the air gap

This t ype of coupling doe s not need to c heck a ir gap

because engine flywheel housing/generator frame and

engine flyw heel/genera tor rotor are directly coupled.

2) Aligning the lamination plate coupling (Fig. 36)

Careful alignment of coupled ma chines prevents a dditional

bearing and sha ft stresses a s w ell as uneven and noisy

running. It is particularly importa nt to a chieve a uniform air

gap. The ma chine may be installed on a concrete

foundation or a ba se frame.

Check to see t hat the machine seating surfaces ha ve been

ma de in accorda nce w ith the d iesel engine (the prime

mover should have a lrea dy been insta lled and a ligned in

accordance w ith the manufacturers instructions.

The gene rators a re aligned a nd coupled as follow s:

Place the generator onto the concrete foundation or base

frame. Align the mo unting feet until the cent ering face s of

the generator side and engine flywheel and its housing are

in line w ith lam ination plat es b eing parallel to ea ch othe r.

When coupling the g enerat or w ith the engine, the out er

holding devices (No. 4) shall be removed before inserting

genera tor guide sha ft to flyw heel. After inserting the shaft,

inner holding device (No. 3) shall be removed and furthercoupling works carried our in accordance with standard

instructions of the engine ma ker.

For reference, t his type of coupling doe s not need shim

plate under the generator.

Removed holding devices sha ll be st ored on gene rator foot

afte r coupling for the future t ransporta tion or repairing

works.

Fig. 35 Fixing of the retaining-ring halves afterassembling with prime mover

Fig. 36 Rotor locking device (example, delivereddesign may deviate in details)

2

3

6

43

1

5

4

6

5

Guide

Engine flyw heelhousing

Engineflyw heel

shaftG enerator foot

7

Enerator fram e Lam ination plate Holding devices, inside Holding devices, outside

Screw for Screw for Access cover for


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Maintenance03

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When the filter is clean, rinse it w ith clea r w at er.

Drain the filter properly (there must be no more formation

of droplets ).

Refit the filter on the m ac hine.

Do not clean t he filter using compresse d a ir.

This proced ure w ould reduce filter e fficiency.

1) Description

Use the attached terminal box drawing in the final

specification.The ma in terminal box of the ma chine is locat ed on the

top of the ma chine.

The neutral and phase w ires a re connected t o the copper

bus bar-one copper bus bar per phase and one copper

bus ba r per neut ral line (option).

See t erminal box diagram in the final specifica tion.

The openings provide a cces s to the terminals.

The gland plate s a re ma de of non-magnet ic ma terials in

order to a void circulat ing currents if needed .

Compare the supply voltage w ith the data on the rating

plat e. Connec t the supply leads a nd the links in

accordance with the circuit diagram in the final

specification.

Pa y att ention to the right direction of rota tion (phase

sequence in the ca se of three phas e a nd polarity in the

ca se of direct current).

3.9 Terminal Box

The supply lea ds sho uld be m at ched t o the ra ted c urrent

in line w ith VDE0100 and t heir cross s ect ion must n ot be

excessive.

The ma in circuit is norma lly connec ted at both sides of

the circuit bars with conductor cross sections of max.

300 and ma y be made by ca ble lugs or w hen

connecting parts used in hazardous locations which are

present without any lugs.

The end s of t he co nductors s hould be stripped in such a

w ay tha t the remaining insulation almost reaches up to

the lug or t erminal (5 mm).

In the ca se of ca ble lugs w ith long sleeves , it ma y be

necessary to insulate the latter to maintain the proper

clearance s in air.

If using ca ble lugs, see tha t the d imens ion of the cablelugs a nd its fa stening element s (norma lly M12) agree w ith

the holes in the copper bus ba r.

Use hexagon-head screws with a min. breaking point of

500 N/ , hexagon nuts and s pring elements w hich a re

protected aga inst corrosion a ccording to DIN 43673.

The conne ction of ac cess ories is a chieved by terminal

strips.

Use a 5 mm maximum screwdriver to work on the

blocking screws .

See the terminal connection diagra m in the final

specification.

The s upply lea dsparticularly the protect ive cond uctor

should be laid loose ly in the terminal box w ith a n extra

length for protec ting the c able insulat ion aga inst splitting

and to prevent the t erminals and circuit ba rs from the

tension load of the leads.

They sho uld be introduced into the terminal box through

cable entry fittings and sealed.

Protected fittings with strainrelief cleats should be used

for loose leads to prevent them from becoming twisted.Close off any unused ca ble-entry openings.

CAUTION

D o not use w ater w ith a tem perature higher than 50.

D o not use solvents.

DANGER

High voltage

Pow er source m ust be disconnected before w orking on

equipm ent.

Failure to disconnect pow er source could result in injury

or death.

Term inal box only to be opened by skilled personnel.


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Maintenance03

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Fig. 40 For double bearing type A.C. generator

{}

7. Insert protective sheet

8. Take aw ay bolts

9. Draw out fan

{}

10. Hang the shaft end w ith rope both side.

(shaft journal should be protected from

any dam ages by w rapping in cloth )

11. Shift the rotor tow ard anti-coupling side.

{}

12. Shift the rotor assem bly to anti-coupling

side as left description.13. Hang the rotor assem bly at its center

position by the rope.

14. Take aw ay the rope of coupling side.

{}

15. Take aw ay the rotor out of the stator.

Fig. 40 For double bearing type A.C. generator

Coupling

side

Anti-coupling

side

{}

1. Take aw ay bolts

2. Take aw ay bolts

3. Take aw ay bearing upper part

4. Take aw ay bearing shell and oil ring

5. Take aw ay bolts and bearing under

part

6. Take aw ay endshield


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Maintenance03

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3.11 Cooler

1) General points

The purpose of the cooler is to remove ma chine heat

losses (mec hanical, ohmic et c).

The excha nger is locat ed on the top of the m ac hine.

Normal operation:

The a ir is pulsed by a fan fixed to t he sync hronous

mac hine shaft.

Description of air-water double tube exchanger

The do uble-tube tec hnique kee ps the coo ling circuit from

being a ffected by possible w ater leakage.

The doub le tube provides a high safe ty level.

In ca se of leakage, the w ater goes from the inside of theinternal tube to the coa xial space betw een the tw o tubes.

The w at er is drained a xially to a leakage cha mber w here

it ma y activate a s ensor.

An e xchange r comprises a fin-tube block conta ining:

a st eel frame.

a fin-tube block expanded m echa nica lly to the t ubes.

The tub e bund le is roll-expa nde d in the end plate s.

The w at er distribution in the tubes is provided b y tw o

removable w ater boxes.

A w at er box is eq uipped w ith co llars for fitting the inlet

and outlet lines.

Neoprene sea ls ensure wa ter tightness betw een the

w ater boxes and the end plates .



2) Cleaning

The frequenc y of cleaning operat ions depends ess entially

on the purity of the w ater used.

We recomm end to inspect a nnually at leas t.

The life of z inc block for anti-corrosion is a bout a yea r.

Therefore, replac e it w ith a new one e very year.

Cut off the w at er supply by isolat ing the inlet a nd outlet

lines, a nd drain the w ater.

Disconne ct the leak senso r (option w ith d ouble-tube

cooler), and make sure that there are no leaks.

Remove the w ater boxes on ea ch side of the machine.

Rinse a nd brush each w ater box.

NOTE

D o not use a hard w ire brush as this w ill rem ove the

protective tar-epoxy layer w hich has form ed on the

surfaces of the w ater boxes.

Clean each tube w ith a m etal scraper.

Rinse in soft w ater.

Keep the leakage cham ber dry (double-tube w ater-cooler

only)

3) Stop the machine

Lea k detect ion for a d ouble-tube e xchange r:

If a leak is detected, cut off the power supply of the water

in/outlet lines a nd cha nge to eme rgency operat ions

according to Fig. 45, 47, 49 immediately.

The problem must b e a scerta ined a nd repaired.

Remove the two water boxes, apply a slight positive

pressure in the leakage cham ber and betw een the tw o

tubes (only concerns double-tue coolers).

If a tube is damaged, plug it at both ends.

Use a tapered plug.

Preferably the plug should be made of salt-water

resistant a luminium bronze or a s ynthetic ma terial.

Fig. 42 Leakage detector

4) Leak detection (float system)A magnet float activates a sw itch located in the float case.

5) Cooler removal

The c ooler unit is s lid into its ho using.

It is poss ible to remo ve the cooler from t he housing

without removing the water boxes as shown in Fig. 43.

The coo ler is fa ste ned to the hous ing via a series of

screws on the housing.

Remove t he w at er supply and return pipes.

Provide two eye-bolts to hold the cooler when it comes

out of its ho using.

Remove the cooler using slings tha t ca n be a ttached to

the connecting flanges.

6) Cooler re-assembly

Carry out the operat ions of the " Cooler Remova l" Fig. 43in the reverse order. Be ca reful to push t he coo ler

completely into its housing before t ightening the

fastening screw s of the cooler to the ca sing.


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Maintenance03

46


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The elect rica l version of the alte rnat or rema ins

unchanged.

[Type I]

Open the air vents a t the non drive end for the air inlet

and at the drive end for the a ir outlet (Figs. 44 and 45 -

No. 3 &5),

Rem ove e nclosure o r cover 2 (Fig. 44)

Inse rt a ir cut -off plate 6 (Fig. 45) into th e s lot in the

raised sec tion on the housing on the hot a ir side of

the cooler and secure.

[Type II]

Open the air vents a t the drive end for a ir inlet a nd a t

the non d rive e nd for a ir outlet (Fig. 46, No. 1 &2)

Remove the access cover (Fig. 47, No. 7)Insert air cut-off plate (No. 4) and secure inside of

cooler housing

(2) Changing over to closed-circuit cooling

Operation should be changed back from emergency to

norma l opera tion w ith air-to-wa ter closed -circuit cooling

as soon a s possible in the reverse s equence de scribed

above.



Fig. 46 Normal operation with air-to-waterclosed-circuit cooling

12

4

3

4

Air vent w ith cover, closed Air vent w ith cover, closed Air-to-w ater cooler Air cut-off plate

Drive end Non drive end

Fig. 47 Emergency operation with open cooling circuitfollowing failure of the cooling water supply

5 6

7

4

4

Air vent, open Air vent, open Access cover for

Drive end Non drive end


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Maintenance03

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4.1 Excitation Part for SPRESY 15

In the ca se of fa ults, it is advisable to chec k the volta ge

controller, excitation equipment, and main machine with

an exciter separately.

For troubleshooting in the thyristor voltage controller, all

the leads connecting excitation equipment and thyristor

voltage controller must be disconnected, and if present,

the intermediate transformers of the droop-compensating

eq uipment seco nda ries short-circuited.

In this case, the generator voltage must rise above the

ma ximum reference value as given under "Desc ription".

In this ca se, the t hyristor voltage controller is defective.

Troubleshoo ting should be continued a ccording to

Ta ble 4-2.

If the voltage is not induced, e ither the excitation

equipment, the main machine or the exciter can be

defe ctive. Troublesho ot a cco rding to Ta ble 4-4.

Information conc erning voltage values for the t hyristor

regulat or module is given overlea f and as sists in the

location of faults.

Troublesho oting sha ll be ca rried out a cco rding to

Ta ble 4-3.

If the remnant should not be adequate for exciting the

genera tor, a D.C. voltage (6 to 24 V) must be c onnect ed

to t ermina ls F1 an d F2 (+ to F1, - to F2) for a s hort t ime.

Please note that the terminals F1 and F2 start carrying a

voltage as soon as self-excitation sets in.

When ordering spare pa rts plea se, st at e the type a nd

serial number of the generator, as they are show n on the

rating plat e.

DANGER

Hazardous voltage


dam age.


Table 4-1. Excitation part

Term inal 20-14 < 30 V > 30 V

Term inal 15-14

Faultlocation(Fig.14)

Regulator

m odule

Firing

m odule

Firing

m odule

Regulator

m odule

about 1 V about 10 V about 1 V about 10 V

Trouble Shooting04

4.2 Excitation Part for 6 GA 2491

DANGER

Hazardous voltage


dam age.



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Trouble Shooting04

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Table 4-3. Fault diagnosis chart for thyristor voltage regulators

Fault

H

ighvoltage

Low

voltage

Voltage

&

currenthuntin

g

kW

hunting

kVA

rhunting

C

rculation

currentunder

lowe

rload

Excessivereactivecurre

nt

Low

erreactivecurrent

D

ifferentP.F

D

efectw

ithcontrolm

od

ule

D

efectw

ith

thyristor

Voltagecontrolim

possib

le

Low

erm

ax.voltage

H

alfvoltage

H

igherdroop

&

PF

drop

Voltageincreasew

ith

lo

ad

Voltagehunting

N

ovoltage

builtup

N

arrow

voltagecontrolrange

Excessivevoltagedropw

ith

load

Possible cause

AVR

Pow er thyrister

M easuring

transform er

(AVR inside)

Reference value

setter [VR]

Series resister

[R48]

Interm ediate

transform er [T4]

Potentiom eter

(AVR inside) [S]

Reactor [L1]

Rectifier

transform er [T6]

Rotating rectifier

[V2]

Varistor

Current

transform ers

[T1, T2, T3]

+F1 & -F2

N o w iring link

W iring link w rong point

U w rong setting

K, T, R47 w rong setting

Internal defect

Discontinuity

Blocking fail

Gate electrode fail

Discontinuity

Internal defect


Discontinuity


Incorrect no-load setting

Short circuit in leads

Im proper contact at T/B

Discontinuity

Excessive resistance

Low er resistance

Discontinuity

Short circuit in leads


Discontinuity

Excessive resistance

Low er resistance

Different resistances


Discontinuity

Sm aller reactor gap

Discontinuity

Im proper tap setting

Discontinuity

Burnt or internal defect

Internal short circuit

Discontinuity


Internal defect

Setting to low er pow er

W rong polarity

Parallel operation

N ote: w ith high possibility, check first


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Trouble Shooting04

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4.4 Bearing Part



DANGER

Hazardous voltage


dam age.


Table 4-5. Sleeve bearing

Defects

Possible cause Bearing

overheats

Bearing

leaks

O il in

m achine

Large

tem perature

variations

Rem edy

O il aged or dirtyO il ring does not rotate evenly

Excessive axial thrust or radial load

Too little crest clearance 1)

O il grooves too sm all or not w edge-shaped

O il viscosity too high

O il viscosity too low

Defective bearing surface

Defective seals

Incorrect oil discharge from sealing rings

Bearing too cold during start-up

Gap betw een sealing cover and shaft too large

Pressure com pensation opening clogged

Forced-lubrication system failure

O il flow too high

Clean bearing housing; renew oilStraighten and deburr the ring or renew it

Check alignm ent and coupling

Rescrape bearing surface

Refinish the oil grooves

Check Viscosity; change oil

Renew lining

Renew seals

Clean return openings and grooves

Preheat the bearing or oil

Bush or replace the cover

Clean com pensation opening

Inspect system

Readjust the flow rate; check oil discharge

1) Crest clearance = Inside diam eter of bearing shells m inus diam eter of shaft.

Table 4-6. Roller bearing

Defects

Possible cause Bearingoverheats

Bearingleaks

O il inm achine

Rem edy

Felt sealing rings pressing on shaft

Strain applied from coupling

Excessive belt tension

Bearing contam inated

Am bient tem perature higher than 40

Lubrication insufficient

Bearing canted

Too little bearing play

Bearing corroded

Scratches on racew ays

ScoringExcessive bearing play

Fit rings better into grooves or replace them

Im prove alignm ent of m achine

Reduce belt tension

Clean or renew bearing, inspect seals

Use special high-tem perature grease

Lubricate according to instructions

Check m ounting conditions, install outer ring w ith lighter fit

Fit bearing w ith larger play

Renew bearing, inspect seals

Renew bearing

Renew bearing, avoid vibration w hile at a standstillInstall bearing w ith sm aller play

O il

discoloursquickly


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Trouble Shooting04

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Memo


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www.hyundai-elec.com

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