Contents 1
General Notes and Instructions Safety precautions Check list Maintenance schedule Customer contact list & complaint report
2
Drawings Dimension drawing alternator Rotor drawing
3
Circuit Diagram Circuit diagram Legend to circuit diagram
4
AZ 44914.2 85874
K 811.0.181 K 811.0.181
Operating Instructions Three-phase synchronous electrical machines series DSG 29...144 Enclosure to operating instructions
5
Regulator Descriptions Voltage regulator Cosimat N+
6
Bearings Zollern Installation and operating instructions for Zollern ZF plain bearings Lubrication for Zollern Z-bearings
7
Spare Parts Drawings nos. 121poE, 221oE, 30NSoW, 401, 60obi
8
Technical Data Technical data sheet Test report 81 27 280 A002
H. Cegielski-FSA Your order: 8702088 Your project: Szczecin Shipyard B178-I/15,16,17, Poland AvK Order no. 81 27 280 A002
09/2005
General Notes and Instructions
General Notes Safety Precautions
Read this advice as well as the operating instructions supplied prior to commissioning or storage of the generator. Any works on the generator have to be performed by qualified and trained personnel only. Any person, working on the generator has to read and understand these operating instructions. 1. General Notes 1.1 Important notes for users In the following instructions you will find important information and safety advice for transportation, installation and operation for AvK generators of the series DSG and DIG. AvK generators are designed for different applications for the use on land as well as offshore. Series DIG is dimensioned for a nominal voltage bigger than 1 kV, DSG for a nominal voltage up to 1 kV. Please refer to the rating plate mounted on the generator for design data and as well as in the data of the respective order. Any works on the generator has to be performed by qualified and trained personnel only. The necessary qualification can be obtained by training or courses through the manufacturer. Technicians can obtain a special generator training at AvK Germany. The installation should preferably be performed by an AvK service technician or by a specially trained qualified technician. The operating instructions are to be kept close to the generator and have to be available for the personnel at any time. Please take notice of the safety precautions in chapter 2. Further safety precautions are mentioned in the respective chapters. The order related data of the generator as well as the operating instructions for General Notes AH/e-04-2003/A
additional parts can be found in the documentation. The documentation, including the operating instructions, are part of the machine and have to be passed on to the next user in case the generator is sold or moved. 1.2 Liability and guarantee All statements and advice in the operating instructions are made under consideration of our present knowledge and experience. The technical information and data, described in this manual, is the correct state of information at time of printing. We reserve the right to changes due to technical progress without changing this operating instruction. Accordingly, no claims can be made from statements and descriptions in this manual. We will not be liable for any damages or breakdowns due to operating mistakes in disregard of these instruction or improper repairs. We particularly point out, that spare parts and additional parts not supplied by AvK, have to be accepted by AvK. AvK will exclude any liability for damages that result from the use of spare and additional parts that have not been accepted by AvK. The installation or use of foreign products may possibly change the constructively given design of the electric machine in a negative way, and may restrict the safety of persons, machine or other values. Any unauthorized modifications and changes on the generator are not allowed for reasons of safety and will exclude any liability of AvK for resulting damages. If transformers supplied by the customer shall be installed in the terminal box, AvK has to be consulted first. The preceding notes do not extend the terms of liability and guarantee of the general delivery terms of AvK.
page 2
Manufacturer's Address AvK Deutschland GmbH & Co. KG Bunsenstraße 17 D-85053 Ingolstadt Phone (+49) (0)841 / 792-0 FAX (+49) (0)841 / 792-250 All rights reserved. Reprints or copies - even extracts need the permission of AvK. 2. Safety Precautions During transportation, installation, commissioning and maintenance, certain works might have to be performed on the generator, e.g. on feet support, shaft end, bearings, terminal box, etc. The working area and area of danger includes the surroundings of the generator and the prime mover. During normal operation, the working area should be limited to the operating and monitoring devices of the switchboard. Despite taking into consideration all safety precautions, the generator may be a source of danger, electrically and mechanically. To avoid damages to persons and values, all safety precautions have strictly to be followed. Beside all safety notes in the operating instruction the local safety precautions and rules for the prevention of accidents have to be followed. 2.1 Description of symbols and advice The following symbols are used in the instructions to highlight particular points and actions:
Besides these safety notes all local valid instructions for safety and accident prevention have to be followed. Follow all warnings and advice and act very carefully in these cases. Inform all persons working on the generator about all work-safety regulations. 2.2 Signs on the generator At particular dangerous points on the generator you will find safety notes. To avoid damages to persons or values these safety notes have to be followed very strictly. Achtung! Betriebsanleitung Im Klemmenkasten! Vor Inbetriebnahme unbedingt lesen. Caution! Operating instructions are inside the terminal box. These must be read prior to commissioning. The documents for the generator are in the terminal box Transportsicherungen. Vor Inbetriebnahme entfernen Transport Safety Devices Remove prior to commissioning. During transportation the rotor is secured against shifting. The transport safety devices have to be removed before commissioning. Maschine nicht betriebsfähig!
Warning! Life in danger! Machine out of order Danger!
General Notes AH/e-04-2003/A
This sign is mounted when the installation of transformers in the terminal box is necessary. The transformers have to be installed prior to commissioning. In this
page 3
case the installation manual for the transformers is in the terminal box and in the enclosed documents. E-Teile im Klemmenkasten
Unprotected machine parts may cause severe injuries. All safety devices like covers, barriers and protections have to be in place and must be functioning perfectly at all times.
Spare Parts are inside Spare parts that are delivered with the generator are in the terminal box. The spare parts have to be removed. ABSTANDSMAß-PROTOKOLL AM GLEICHRICHTERTÄGER Mounting-distance test-report is inside For the alignment of single bearing machines it is important to keep the mounting distance between rotor and stator on the NDE of the generator. The respective report can be found on the rectifier carrier at the NDE of the generator. ACHTUNG! Vor Inbetriebnahme Öl einfüllen. Menge und Qualität laut Beschreibung Caution! Fill in oil prior to commissioning! Please refer to operating instructions of the sleeve bearing manufacturer for amount and quality. Generators with sleeve bearings need oil to be re-filled before commissioning. The instructions from the sleeve bearing manufacturer are enclosed.
It is not permitted to operate the generator with damaged safety devices! 2.3 Safety at site For operating the electrical machine the responsibilities have to be determined clearly and kept, so that no unclear situation regarding safety may occur. The generator must only be operated when it is in an excellent state and according to the design data. Any change that reduces the safety has to be reported to the responsible person immediately. Modifications on the machine are only allowed in agreement with AvK and these are to be performed under supervision of qualified personnel. The way to the operating and monitoring devices has to be free and must not be obstructed by any objects. Prior to commissioning and during maintenance works, all persons in the danger area have to be warned. They must be ordered to leave the area. After completion of work, the generator must be checked by qualified personnel to ensure it is in a safe working state.
2.2 Safety Devices 2.4 Safety precautions for maintenance Special covers are mounted to protect against mechanical danger (e.g. rotating parts). Protection against electrical danger is provided by covers and devices against over-voltage and over-current. It is not allowed to change or dismount any safety devices or to put them out of order.
General Notes AH/e-04-2003/A
Maintenance should normally only be performed when the generator is out of operation (except for the re-lubrication of anti-friction bearings). The prime mover has to be disconnected.
page 4
After completion of the maintenance work, it must be ensured that all protection and safety devices are back in place properly. 2.5 Special Dangers The operator of the machine has to take care, that the rules for fire protection are kept and the equivalent agents for fire extinction are available near the machine and ready for use. 3. Shipping, Handling, Storage
They are only used as mounting device for these add-ons. •
The ring bolts can only be used for the transport of the separate machine, they are not designed to lift the complete unit (generator and prime mover)
•
For transporting the machine, the following 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
3.1 Safety precautions for transport Please comply with the local valid regulations for shipments. Warning! Never move persons! •
loads
over
The shipment and the unloading of the generator must only be performed by personnel, who are familiar with the lifting cranes and corresponding devices.
•
The lifting devices have to be designed for the weight of the generator (Chapter 3.4).
•
Follow the shipping instructions (pictographs) on the cover of the generator.
•
The generator must only be supported on its feet. The support on any other part is not permitted. That is why the generator is delivered with a transportation construction.
•
For the lifting of the generator, ring bolts are mounted on the generator housing.
It is not permitted to use cables that are torn or worn. Cables and chains may not be knotted. Cables and chains must not touch any sharp edges. -
Lifting devices:
cranes overhead cranes
•
Moving the machine over rough ground e.g. rails, by using a haulage car is not permitted. This may cause damage to the bearings and the windings. This is especially important for the moving of the machine within the factory.
3.2 Packaging
Ring bolts, that are mounted on add-on pieces like e.g. the cooler top, must not be used to lift the whole machine! General Notes AH/e-04-2003/A
The material used for the packing of the generator is made of ozone-friendly material – like wood. The packaging depends on the mode of transport used – surface, water or air freight. When the transport time is for a longer period, then the generator will be packed in a protective covering against dust or humidity. 3.3 Checking for Shipping Damage We recommend checking the generator for shipping damages and complete delivery by the time of delivery.
page 5
If there are damages on the goods (open damages) report these to the haulage contractor at take-over. In this case, the receipt should only be given under reservation with a written statement regarding the estimated amount of the damage. If damages that were not noticeable by the time of delivery (covered damages), are detected later, they have to be reported promptly to AvK, latest 6 days after receipt of the delivery. 3.4 Unloading the generator The unloading has to be performed in compliance with the safety precautions for transport (see chapter 3.1) and the local safety precautions and rules for the prevention of accidents. Please refer to the freight papers and the data of the respective order (Rating plate) for the weight of the generator. The weight of the generator is also written on the rating plate. 3.5 Storage of the generator After unloading, the generator and possible boxes with loose parts have to be stored until installation, following the shipping instructions. Wrapped parts and assessories must not be unwrapped if the generator is stored for a longer period of time. The machine and packages have to be stored in a safe place, dust-free and dry (humidity < 75%). Avoid mechanical vibrations and damages. If it is planned to store the generator for a longer period of time, please contact AvK for further information.
General Notes AH/e-04-2003/A
page 6
AvK Deutschland GmbH & Co. KG Bunsenstraße 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. KG Dreieich branch Benzstraße 47-49 63303 Dreieich, Germany Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40 e-mail:
[email protected] www.newage-avkseg.com
AvK Deutschland GmbH & Co. KG / Service
Date: 22.07.2002
AvK Checklist to Order No.
Page 2
Customer:
.............................................................
Order No.:
.............................................................
Generator Type:
.............................................................
Operation Hours:
.............................................................
Bearing design:
Roller bearing
o
Sleeve bearing
o
Replacement of oil:
YES o
NO o
Bearing inspection performed:
YES o
NO 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
AvK Deutschland GmbH & Co. KG / Service
Date: 22.07.2002
AvK Checklist to Order No.
Page 3
Environmental Conditions:
a) Location:
building
o
marine
o
b) Atmosperic conditions:
dry dust
o o
high humidity salt
c) Ventilation:
unrestricted restricted
o o
o o
o o
adequate inadequate
Operating Conditions:
a) Site duty:
single
o
parallel
o
b) Duty cycle:
24 hours
o
daily
c) Load condition:
inductive
o
non linear
o
d) Operation:
manned
o
unmanned
o
a) Dirt content:
slight dust thick dust
o o
b) Corrosion:
none, very little copper
o
o
idle
occasionally
o
o
standby
Generator Conditions:
c) Engine:
Type: Serial No.: Fuel:
AvK Deutschland GmbH & Co. KG / Service
o o
light layer dirt thick compact dirt
o o
steel/iron severe
o o
(....................)
.................... .................... ....................
Date: 22.07.2002
AvK Checklist to Order No.
I.
Page 4
Electrical Inspection
performed
Complaints see page 11
o
1.1
Examination of cable entry and cable shoes to main terminal box
o
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 to auxiliary terminal box
o
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 Resistance ............. MΩ Voltage ............. V
o
o
b)
Stator winding phase V against ground Resistance ............. MΩ Voltage ............. V
o
o
c)
Stator winding phase W against ground Resistance ............. MΩ Voltage ............. V
o
1.7
Insulation test of stator windings
o
a)
Stator winding phase U against phase V Resistance ............. MΩ Voltage ............. V
o
o
b)
Stator winding phase U against phase W Resistance ............. MΩ Voltage ............. V
o
o
c)
Stator winding phase W against phase V Resistance ............. MΩ Voltage ............. V
o
o
1.8
Resistance measurement of stator
AvK Deutschland GmbH & Co. KG / Service
o
Date: 22.07.2002
AvK Checklist to Order No.
performed
Page 5
Complaints see page 11
o
1.9
Check and re-tightening of all screws and nuts in main terminal box by dynamometric key
o
o
1.10
Cleaning and examination of insulators for cracks
o
o
1.11
Re-tightening of contact screws and nuts on auxiliary terminal strip
o
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 Resistance ............. MΩ Voltage ............. V
o
o
b)
Insulation measurement exciter rotor Resistance ............. MΩ Voltage ............. V
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
Inspection of stator end winding without endoscope
o
Inspection of rotor winding with endoscope
o
Inspection of rotor winding without endoscope
o
o
o o
1.19
AvK Deutschland GmbH & Co. KG / Service
Date: 22.07.2002
AvK Checklist to Order No.
II.
Page 6
Mechanical Inspection
performed
Complaints see page 11
Sleeve Bearing Design
Oil lubrication system installed: o
YES o
NO
o
2.1
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
Inspection of sleeve bearing without endoscope
o
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:
o
AvK Deutschland GmbH & Co. KG / Service
according to ISO VG .................
Date: 22.07.2002
AvK Checklist to Order No.
performed
Page 7
Complaints 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 water
o
AvK Deutschland GmbH & Co. KG / Service
Date: 22.07.2002
AvK Checklist to Order No.
III.
Page 8
Test Run
performed
Complaints see page 11
o
3.1
Check whether earthing switch is disconnected
o
o
3.2
Check of bearing noise
o
o
3.3
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 of alarm and shut down
o
o
3.7
Vibration test / Vibration values (mm/s)
o
DE:
.......... Hor.
.......... Ver.
.......... Axi.
NDE:
.......... Hor.
.......... Ver.
.......... Axi.
Frame:
.............
Output:
............. kW
AvK Deutschland GmbH & Co. KG / Service
Airduct inlet:
.............
Airduct outlet:
.............
Date: 22.07.2002
AvK Checklist to Order No.
Page 9
performed
o
Complaints see page 11
3.8
o
Check of regulator functions at no-load operation a) Exciter current at rated voltage and rated speed: I1-I1':
............. A
b) Exciter current at rated load: I1-I1':
............. A
c) Supply voltage:
d) Under speed protection:
o
3.9
UH1-UH2:
............. V
UH1-WH2:
............. V
WH1-WH2:
............. V
H1 LED off
............. Hz
o
Check of parallel operation Check of distribution of load Statics adjustment
.......... %
o
3.10
Check of overcurrent and short circuit protection trip
o
o
3.11
Check of differential protective trip
o
o
3.12
Check of exciter monitoring system
o
XE2 TO 109/110.1
o
3.13
o o
Check of generator voltage in parallel operation grid voltage min.: grid voltage max.:
AvK Deutschland GmbH & Co. KG / Service
o
............. kV ............. kV
Date: 22.07.2002
AvK Checklist to Order No.
performed
o
Page 10
Complaints see page 11
3.14
Bearing and winding temperature after continuous operation
o
__________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________
AvK Deutschland GmbH & Co. KG / Service
Date: 22.07.2002
AvK Checklist to Order No.
IV.
Page 11
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 any complaints.
o
The alternator must be stopped immediately due to the complaints.
Date: ________________
________________________ (Signature Customer)
________________________ (AvK-Service-Technician)
AvK Deutschland GmbH & Co. KG / Service
Date: 22.07.2002
AvK Deutschland GmbH & Co. KG Bunsenstraße 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. KG Dreieich branch Benzstraße 47-49 63303 Dreieich, Germany Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40 e-mail:
[email protected] www.newage-avkseg.com
AvK Deutschland GmbH und Co. KG
Page 1 of 2
Suggested Maintenance Schedule for AvK Order No.: Customer: Date:
Pos. A
Components
Frequency
Maintenance
General alternator check
12 month
According to AvK Checklist.
Additional components
Frequency
Maintenance
1
Rotor windings
12 month *)
2
Exciter
approx. 25,000 h *)
3 4
Rectifier assembly Stator end winding
approx. 25,000 h *) approx. 25,000 h *)
The insulation resistance must be checked with a megger when the alternator has reached ambient temperature. Remove any accumulated dust from the rotating rectifier and the exciter stator. Check if the electrical connections are secure. Remove dirt adhering to the rectifier unit parts. Inspect and remove deposits of dust, dirt and grease. Do not use any abrassive materials or fluids. Use only electrocleaner.
1
Pos. B
5
Protection equipment
12 month *)
6
Space heater
6 month
Caution: In case of heavy winding contamination please call the AvK Service Department. Check mechanical and electrical connections according to the supplier´s specification / manual. Ensure that the electrical heater is operating to prevent condensation. Check the power supply as well as the insulation resistance.
Carried out by AvK
Carried out by AvK AvK
AvK AvK
AvK Customer
*) Maintenance frequency depends on the operating conditions at site.
Maintenance-e.xls
Service / Steller
Date: 18.04.2000
AvK Deutschland GmbH und Co. KG
Page 2 of 2
Suggested Maintenance Schedule for AvK Order No.: Customer: Date:
Pos. B
Additional components
Frequency
7
Ball and roller bearings
Grease relubrication acc. Check oil or grease for any contamination particles. to supplier´s manual and/or name plate.
Maintenance
8
Sleeve bearing: Oil ring
6 month 6 month
9
Sleeve bearing: Oil seals
6 month
10
Sleeve bearing: Complete check
25,000 h *) 50,000 h
11
Oil pipes and flanges
6 month
12
Sleeve bearing: Oil level
monthly
13 14
Bearing earthing brush Dust filter
3 month 3 month *)
15 16
Cooler Complete alternator
6 month 100,000 h
SPM bearing analysis. Ensure that the oil ring is rotating freely and picking up enough oil when the shaft is turning. Check for oil leaks. The oil seals must be changed. The bearing check must be done (according to supplier´s manual) and the oil seals must be changed. Check for oil leaks. After the first 500 running hours it is recommended to tighten the screws of the flanges again. The oil level must be visible in the viewing glass. (Approx. one third of the diameter.) Check the earthing brush for abrasion. At the appropriate intervals, the filters must be checked to establish their degree of contamination with dust and dirt. Check the cooler elements and leakage detector. Review with manufacturer for recommendations for full inspection / overhaul.
Carried out by AvK / Customer
AvK Customer Customer AvK AvK Customer
Customer Customer Customer
Customer AvK
*) Maintenance frequency depends on the operating conditions at site.
Maintenance-e.xls
Service / Steller
Date: 18.04.2000
Customer Contact List Service and Warranty Claim Handling for AvK Alternators
DA 7.5-1 1 von 2
Technical Service on-site (after warranty): Products
Countries
Contact
E-mail
Phone
Fax
All AvK Products
UK
Sarah Nicholls
[email protected]
+44-(0)1780-484 ~767
All AvK Products
Spain Portugal
John Johnson
[email protected]
Mobile: +34-(0)629183929
All AvK Products
France french speaking North Africa
Rene Moulin
[email protected]
+33-(0)16074 ~9843
~9844
All AvK Products
Italy
[email protected]
+39-(0)2-38000 ~714
~664
[email protected]
+47-(0)22-9744~37
~45
All AvK Products
All AvK Products All AvK Products All AvK Products
Norway Sweden Denmark Finland Baltic States Russia North America South America Mexico Central America Canada Australia New Zealand South Pacific Switzerland
Guiseppe Cinnirella
Jan Jakobsen
~104
001-763-528-7301-6 Gary O`Malley
[email protected]
Theo Dragonas
[email protected]
Martin Läderach
[email protected]
Direct: 001-763-574 ~5000
~5082
TOLL FREE: (1) 800 ~367-2764
~863-9243
+61-(0)2-9680 ~2299
~1545
Mobile: +61-(0)412-886643 +41 317 408 282 Mobile: +41 7920 17561
+41 317 408 280
Dokumentenname: Customer contact.doc Stand: B vom 07.04.05
AvK Deutschland GmbH & Co. KG
Revisionsstand: B vom 30.03.05
Customer Contact List Service and Warranty Claim Handling for AvK Alternators Products
All AvK Products
All AvK Products All AvK Products All AvK Products
Countries Singapore Malaysia Philippines Indonesia Thailand Taiwan Vietnam China
Contact
[email protected]
+65-(0)6794-3737/5
Anthony Tan
[email protected]
Mobile: +65-(0)979-192-57
[email protected]
+62-214601685
Trisno Sumarlin
India, Nepal
2 von 2
Phone
Richard Lee,
Fax +65-(0)6898-9065
(Indonesia) Jason Xu
Japan, Korea
E-mail
DA 7.5-1
Darryl Hanna R.K. Kapur
[email protected] [email protected] [email protected]
+86-(0)510-521 ~6212 Mobile: +86-(0)139-5157-0763 +81-(0)354-415 ~588 Mobile: +81-(0)906-386-574
~7673 ~590
+91-(0)9811196343
Contact for Warranty Claims: Product All AvK Products
Countries Worldwide
Contact Norbert Steller
am: von: Unterschrift:
E-mail
Phone
[email protected]
+49-(0)841-792 ~163 Mobile: +49-(0)171-221-9453
Issued 30.03.03
Approved 30.03.03
Norbert Steller Service Manager
Emilia Sandau Assistant Service Manager
Norbert Steller
Emilia Sandau
Fax ~195
Dokumentenname: Customer contact.doc Stand: B vom 07.04.05
AvK Deutschland GmbH & Co. KG
Revisionsstand: B vom 30.03.05
Customer Complaint Report
FM 7.5-14
Kunden- Beanstandungsbericht
Page 1 of 1
Distribution List: Customer => AvK Contact person, according to Customer Contact List DA 7.5-1 or AvK Hompage www.newage-avkseg.com
1.0 General Complaint information Allgemeine Daten der Beanstandung:
Customer Kunde
Place of Complained Alternator Einsatzort
Contact Person Customer
Customer Fax No.:
Ansprechpartner Kunde
Kunden Fax Nr.
Customer Complain No.:
Customer Phone No.:
Kunden Beanstandungs - Nr.
Kunden Tel. Nr.
Customer email
Type of alternator:
Kunden Email
Generator Typ
AvK Serial No.:
AvK Order.- Nr.:
AvK Masch. - Nr.:
2.0 Failure description / Fehlerbeschreibung
Defect Part Defektes Bauteil
3.0 Immediate measure by customer/ Sofortmaßnahme durch den Kunden Initiated (date) / eingeleitet am:
Successfully completed (date): erfolgreich abgeschlossen am
4.0 Enclosures / Anlagen Photos / Fotos
others: sonstiges
Dokumentenname: 7_5f14a.doc
Revisionsstand:
AvK Deutschland GmbH & Co. KG
A vom 09.10.03
Drawings
Circuit Diagram
Seite 1 Page 1
Legende zum Schaltbild Nr. K 8**.*.**
Legend to Circuit Diagram No. K 8**.*.**
F1, F2 G1 G2 G3 Q1
Schutzschalter für G3 NUR IM STILLSTAND BETÄTIGEN Hauptmaschine Erregermaschine Hilfserregerwicklungen Schutzschalter NUR IM STILLSTAND BETÄTIGEN 31-32 Meldung
Protection switch for G3 ONLY SWITCH ON AT STANDSTILL Main machine Exciter machine Auxiliary exciter windings Protection switch SWITCH ON ONLY AT STANDSTILL 31-32 Signal
R11 R12 R21
Rotierender Varistor Rotierender Schutzwiderstand Vorwiderstand
Rotating varistor Rotating protection resistor Serial resistor
T24
V1
Spannungswandler für Regler BEI GEÖFFNETEM STERNPUNKT VON G1 UNBEDINGT ABKLEMMEN Spannungswandler Spannungswandler für G3 Spannungswandler für G3 mit integriertem Schutzschalter F1 F1 - nur im Stillstand betätigen! Rotierende Gleichrichter
Voltage transformer for AVR DISCONNECT IF STARPOINT OF G1 IS OPEN Voltage transformer Voltage transformer for G3 Voltage transformer for G3 with integrated protection switch F1 F1 - only switch at standstill! Rotating rectifiers
X1 X2-6
Hauptklemmen Klemmleiste
Main terminals Terminal strip
U1
Spannungsregler Cosimat N R3 Unterdrehzahlschutz R4 Interner Sollwert R1 P-Anteil S1 I-Anteil R7 Statikeinstellung R6 Statikwandleranpassung Sollwertpot. Generator Spannung (R = 500 Ω) Statikwandler ACHTUNG: Bei Regler lose: Regleranschluß Drehrichtung rechts: Leiste X2 Regler U ⇒ U V ⇒ V W ⇒ W Drehrichtung links: Leiste X2 Regler W ⇒ U V ⇒ V U ⇒ W
Alternator voltage regulator Cosimat N R3 Underspeed protection R4 Internal voltage setting R1 P-Part S1 I-Part R7 Droop adjustment R6 Droop transformer adaption Alternator voltage adjuster (R = 500 Ω) Droop transformer CAUTION: AVR loose supply:AVR connection Rotation clockwise: Terminal X2 AVR U ⇒ U V ⇒ V W ⇒ W Rotation counter clockwise: Terminal X2 AVR W ⇒ U V ⇒ V U ⇒ W
Schnellentregung: Brücken UH1-24 und WH1-14 öffnen
Quick de-excitation: Open bridges UH1-24 and WH1-14
Entregungsschalter: 220 V AC (nicht AvK Lieferumfang) 10 A
De-excitation switch: 220 V AC (not AvK supply) 10 A
Verbindungen außerhalb des Generators Erstellt am: 12.10.1998 geprüft von: Diegeler Revision Nr.: 1
Connections outside the alternator Issued on: 12.10.1998 Checked by: Diegeler Revision No.: 1
T25-28 T30, 31 T32
R1 T6 '
----
AvK
Seite 2 Page 2
Legende zum Schaltbild Nr. K 8**.*.**
Legend to Circuit Diagram No. K 8**.*.**
A13, 14 A15, 16 A20, 21 A22, 23 A24, 26 A27/28 AR1-24
ZUBEHÖR Widerstandsthermometer PT100 Statorwicklung Phase U: 1, 4, 7, 10 Phase V: 2, 5, 8,11 Phase W: 3, 6, 9, 12 Lager, B-Seite Lager, A-Seite Generator Zuluft Generator Abluft Statorblechpaket Sekundär Kühlmittel EIN/AUS Überspannungsableiter
ACCESSORIES Resistance Thermometer PT100 Stator winding Phase U: 1, 4, 7, 10 Phase V: 2, 5, 8, 11 Phase W: 3, 6, 9, 12 Bearing, NDE Bearing, DE Alternator air inlet Alternator air outlet Stator core Secondary Cooling agent inlet / outlet Overvoltage arrester
C1
Entstörkondensator
Interference Suppression Capacitor
D1, 2 D3, 4
Lagerschadendetektor B-Seite A-Seite
Bearing damage detector NDE DE
H, H1-5
Stillstandsheizung
Anti condensation heater
L1-4 LW1-4
Leckageanzeiger Kühler Luftfilterüberwachung
Leakage detector cooler Air filter supervision
SR1-6 STW1-4
Schleifring Drehzahlmesser
Slip ring Speed transmittor
T17-22
Stromwandler für Stand-by-Regler Für Messung (M), Schutz (P) Kern Nr. 1: X5, 1-6 (M) Kern Nr. 2: X5, 7-12 (P) Kern Nr. 3: X5, 13-18 (P) Messung
Current Transformer for Stand-by-unit For Measuring (M), Protection (P) Core No. 1: X5, 1-6 (M) Core No. 2: X5, 7-12 (P) Core No. 3: X5, 13-18 (P) Measuring
TF1, 3 TF5, 7 TF2, 4 TF6, 8
PTC Temperaturfühler Statorwicklung, Warnung Statorwicklung, Warnung Statorwicklung, Abschaltung Statorwicklung, Abschaltung
PTC Temperature Sensor Stator winding, warning Stator winding, warning Stator winding, shut down Stator winding, shut down
TF11, 13 TF15, 17 TF12, 14 TF16, 18
Lager B-Seite, Warnung Lager A-Seite, Warnung Lager B-Seite, Abschaltung Lager A-Seite, Abschaltung
Bearing, NDE, Warning Bearing, DE, Warning Bearing, NDE, Shut down Bearing, DE, Shut down
TF20, 21 TF22, 23 TF24, 25 TF26, 27 WW1-4 Z1
Thermometer Lager, B-Seite Lager, A-Seite Generator Zuluft Generator Abluft Wasserdurchflußwächter Entstörfilter (Funkstörgrad “K“)
Thermometer Bearing, NDE Bearing, DE Alternator air inlet Alternator air outlet Water flow indicator Interference filter (R.I.S. degree “K“)
Erstellt am: geprüft von: Revision Nr.:
Issued on: 12.10.1998 Checked by: Diegeler Revision No.: 1
A1-12
T8 T14-16
AvK
12.10.1998 Diegeler 1
Operating Instructions
Operating instructions Three-phase synchronous alternators, series DSG 29 ... 144 with "COSIMAT C" or "COSIMAT N" voltage regulator
Before installing and starting up this machine, please read these instructions carefully. Machine No._____________________________ Circuit diagram No. _______________________
CONTENTS 1. 1.1 1.2 1.3 1.4
1.5 1.6
1.7 1.8 1.9 1.10 1.11 1.12 1.13
1.14 1.15
Operating and maintenance instructions Checking for damage incurred during transit Transport and storage Setting up the machine Cooling the machine 1.4.1 Coolant temperature 1.4.2 Direction of cooling air 1.4.3 Quality of cooling air Preparations prior to starting up Machine drive 1.6.1 Belt drive 1.6.2 Coupling drive 1.6.3 Aligning the machine Changing direction of rotation Electrical connections Starting up 1.9.1 Insulation resistance 1.9.2 Operating speed Interference suppression Operation Maintenance Bearings 1.13.1 Bearing types 1.13.2 Permanently-lubricated bearings 1.13.3 Regreasable bearings 1.13.4 Assembling the bearings 1.13.5 Dismantling the bearings 1.13.6 Monitoring the bearings Dust filters and monitoring of thermal behaviour 1.14.1 Synthetic filter elements 1.14.2 Wire mesh filter elements Drying out the machine 1.15.1 Drying out with integral ventilation system 1.15.2 Drying out by short-circuiting
2.
Faults, causes and remedies for DSG machines with "COSIMAT C" and "COSIMAT N" voltage regulators
3.
Circuit diagram with voltage regulators "COSIMAT C" and "COSIMAT N Note: detailed information on the regulator and circuit diagrams is given in the description and adjusting instructions for "COSIMAT C" and "COSIMAT N".
2
1. Operating and maintenance instructions 1.1 Checking for damage incurred during transit Immediately after receiving the machine, inspect it for damage incurred during transit. The transport or delivering company must be notified of possible complaints immediately, or at the latest within seven days of delivery (covered by warranty).
•
cooling air can enter and exit freely
•
exhaust gas and heated cooling air cannot be drawn in by the machine.
1.4 Cooling the machine 1.4.1 Coolant temperature The machine is normally built to run at a coolant temperature of up to 40°C and at an installation height of up to 1000 meters above mean sea level. Coolant temperatures higher than stated on the machine’s data plate will result in power loss.
1.2 Transport During transit and storage, the machine must not be 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 be protected against sudden impact.
At a coolant temperature of 45°C, up to 96 % of the nominal power can be drawn off; at 50°C up to 92.5 % is permissible.
If transported over long distances, it is advisable to protect the machine against the effects of the weather by sealing it in a plastic cover together with a quantity of desiccant (moisture indicator), so that it remains dust-free and air-tight.
If the machine is ordered to run at coolant temperatures of higher than 40°C, this is shown on its rating plate together with the alteration in power rating. 1.4.2 Direction of cooling air
Machines with plain or taper roller bearings and machines in a stored condition are supplied with additional transit protection.
The machine is cooled by an integral fan dependent on the direction of rotation, mounted on the shaft. It draws cooling air from the non-drive end and expels it at the drive end.
On dual-bearing versions with deep-groove ball bearings, the bearings are pre-loaded and are supplied without an additional transit keeper.
If it is intended to use forced cooling on special versions, either alone or to support the integral fan, the direction of airflow and rotation must be correct here too (see dimensions sheet for data).
This transit keeper should never be removed until the machine has been set up in its future operating position on site. Install the transit protection again if the machine is, for instance, to be shipped on or stored as a separate unit after trials.
Important: The distance between the fan inlet or outlet on the machine and any nearby wall must not be less than the minimum dimension, otherwise ventilation will be obstructed.
For transport as a complete machine set, take the necessary safety precautions, for instance support the machine set on anti-vibration elements or attach transit keepers.
1.3 Setting up the machine
Minimum distance (guide value): 1 x diameter of machine
The installation site must comply with the machine’s enclosure rating and be sufficiently large for cooling and maintenance purposes.
1.4.3 Quality of cooling air
When setting up the machine, make sure that: •
To extend the service life of the machine, and in particular its windings and bearings, it is ex-
the relevant operation and maintenance safety regulations are observed 3
tremely important that neither contaminated nor aggressive cooling air be allowed to enter it.
replaced by new ones (since they will have become too hard for re-use).
An air filter can be installed if requested by the customer, or can be retrofitted provided sufficient space is available.
Important: Belts that are tensioned too tightly can put the bearings at risk. For this reason, establish the correct belt tension with the belt manufacturer or the plant that supplied the machine, and have checks carried out on site.
1.5 Preparations for starting up Pull the protective lacquer coating off the end of the shaft and the flange, or remove it with solvent. Never clean it off with emery cloth. Comply with the relevant regulations on environmental protection and safety. There is a threaded hole on the shaft, to which a puller can be attached for installing and removing discs or couplings. Hammering is not permitted, as this can damage the bearings.
1.6.2 Coupling drive The machine rotor is balanced with a half key. The grooved drive elements must therefore be balanced accordingly.
If the machine is delivered with transit keepers in position, remove them.
The coupling must be dynamically balanced to an accuracy of ≤ Q 2.5 according to VDI 2060.
If the machine is of single bearing design, its rotor is delivered attached to the shaft flange and the housing by a steel hoop to prevent axial displacement and is located in position radially between the shaft and fan housing by an angle bracket. The steel hoop must be removed before assembly.
The sensitive anti-friction bearings require the couplings, belt pulleys etc. to be tightened by special devices. If this is not possible, heat the parts to 80°C. They can then be pushed on easily, provided the bore corresponds to tolerance class "H". Ensure that the drive elements are securely located after tightening. They must be securely clamped against their mechanical stops.
Make quite sure that the angle bracket and/or any keepers are removed from the gap only after the rotor has been centered on the drive shaft flange. Failure to do so can result in damage to the exciter machine and the B-bearing.
If the hub of the drive elements is shorter than the shaft end, this difference must be compensated by a spacer bushing to prevent imbalance and uneven running.
1.6 Machine drive 1.6.1 Belt drive
1.6.3 Aligning the machine
If the machine is driven by a belt, the machine must be ordered specifically with bearings and bearing lubrication to match the higher loads. Most belt driven machines have roller bearings on the input side.
Precise, careful alignment of the machine ensures that it runs with a minimum of vibration, thus extending the service life of the machine and in particular of the bearings. Only flexible couplings of low radial rigidity should be used.
The rotor must be ordered with balancing by half key, and the grooved belt pulley must be dynamically balanced on a smooth mandrel. The belt must run smoothly, without jerking.
Even slight errors of alignment can rapidly result in damaged bearings. It is vital that all the feet are fully in contact. Uneven surfaces cause stresses in the bearings and must be compensated for by attaching sheet metal strips. Once the machine is aligned correctly, secure it with dowel pins.
Desired balancing accuracy: ≤ Q 2.5 according to German VDI 2060 standard. When flat-type belts or V-belts which have already been in operation for a fairly long time are removed for maintenance purposes, they must be
4
When aligning a machine of single bearing design which is not flanged onto the drive motor, it is important to comply with the reference dimen-
sions specified on the dimension sheet. This will ensure a uniform air gap beneath all poles and the correct axial position of the rotor.
•
Local electricity supplier’s guidelines regarding protective measures
•
Phase sequence or direction of rotation of machine field as stated on rating plate.
When connecting the cable, make sure that no mechanical forces can act on the machine’s connecting terminals.
To prevent damage to the crankshaft or drive motor’s plain bearings, it is essential to observe the manufacturer’s assembly instructions.
Unused cable sockets in the terminal box must be protected against dust and moisture, and closed so that they cannot turn. Take up slack at all screw contacts and nuts.
1.7 Changing direction of rotation The machine’s fan is of a directional pattern.
If current surges or vibration are to be expected, secure the cables with cable clips or racks. If the plant is set up on flexible mountings, ensure adequate slack in the cables.
Note that the rotary field also changes with a reversal in the direction of rotation. If the machine is to be used in parallel operation, the plug connections for measuring lines U and W on the "COSIMAT C" and "COSIMAT N" regulator must be changed over. The rotary field will change at the main terminals.
1.9 Starting up
1.8 Electrical connections
We recommend that the bearings be regreased before the machine is started up.
1.9.1 Insulation resistance After a long period out of use or in storage, the machine’s insulation resistance must be measured.
The machine must be connected up according to the accompanying circuit diagram. Installation is permitted by a qualified electrician only.
Before starting up, measure the insulation resistance of the winding between phases (if the star point is separate) and between phase and earth. All parts not subjected to the measuring voltage must be earthed.
Comply with the following points: •
VDE safety regulations or those of the local safety authorities 5
When measuring the insulation resistance, all connections (main connection, measuring connection and protection or suppression circuit) must be disconnected from the winding. The suppression elements and measuring leads must be disconnected during high-voltage insulation tests and tests with insulation measuring appliances.
1.10 Interference suppression The machines comply with radio interference requirement "N" as stated in German VDE 0875. Note that the standard of interference suppression is related to the quality of earthing.
Do not drop below the following specific insulation resistance values (at 25°C) on windings that have been in operation for lengthy periods:
1.11 Operation During operation, current-conducting and rotating parts must be sealed with the covers provided for this purpose.
With nominal voltage < 1000 V Insulation resistance ≥ 0.5 MΩ/kV Measurement must be carried out using 500 V direct voltage or a crank indicator with a direct voltage output. Due to the capacitive charge in the winding, the measuring unit indicates the correct insulation resistance value only after several seconds have elapsed.
Increased vibration may result from insufficiently accurate alignment, poorly fitted foundations or frame, or weak mountings.
1.12 Maintenance
Earth the winding immediately after the measuring voltage has been switched off.
Before starting work on the machine, make sure that it is switched off and take action to prevent it from being switched on again. All work must be performed by qualified staff only.
If the insulation values are too low, first check the terminal insulation for dirt and moisture. Clean or dry them as the case may be, and repeat the measurement. Damp windings can lead to current leakage, flash-over or breakdown.
If there is moisture or dust in the terminal box, it must be removed above all from the surface of the insulating parts. The reason for the accumulation of moisture or dust must then be established and rectified.
If insulation resistance on new, cleaned or repaired windings is less than that stated below, drying out is needed (see Item 1.15, Drying out the machine).
Brushless machines are maintenance-free apart from their regreasable bearings and the dust filters, if fitted.
On low-voltage machines with a nominal voltage below <1000 V, insulation resistance should not be less than the following values:
However, make sure that the air inlets and outlets are not obstructed during operation.
4 MΩ at a coil temperature of 25°C 1.5 MΩ at a coil temperature of 80°C
Like any other machine, the alternator should be handled with care.
1.9.2 Operating speed The machine’s speed must correspond to the value stated on its rating plate. The machine must run smoothly, both at no-load and when under load. If the drive machine runs at reduced speed, the voltage regulator’s underspeed protection cuts in and de-excites the machine.
1.13 Bearings 1.13.1 Type of bearings The standard version of the alternator is fitted with deep-groove ball bearings. High capacity roller bearings or a combination of them. The B-side has a fixed bearing, the A-side a floating bearing.
Irregular running will lead to deviations from the nominal ratings. The machine is voltage-regulated and maintains a voltage accurate to ± 1,5% for the "COSIMAT C" and to ± 1% for the "COSIMAT N" in any condition between no load and full load, even if its speed fluctuates by ± 5%.
The deep-groove ball bearings are axially preloaded in relation to each other by spring elements; this ensures smoother running and reduces the negative effects of external sources of vibration on the bearings. This does not apply to roller bearings. 6
1.13.2 Permanently lubricated bearings
Initial greasing quantity and regreasing quantity at each lubrication point in grams (guide values only:)
Size 52, 62, 74, 86, 99, 114, 125 and 144 machines 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 bearing grease
1500-1800 min-1
1000-1200 min-1
750-900 min-1
52 30 3100 2500 2000 1300 62 40 2800 2200 1800 1100 74 70 2600 2000 1600 1000 86 70 40 2500 2000 1500 1000 99 80 60 2500 1500 1200 800 114 100 60 2000 1500 800 600 125 100 60 2000 1000 800 600 144 100 60 1800 900 700 500 * In the case of double bearing the amount of grease stated in the “double bearing” column is to be injected into each of the grease nipples.
1.13.3 Regreasable bearings
•
Re-Lubrication intervals in hours for machine running speed of:
500-600 min-1
DSG
The expected operating life is approx. 25,000 operating hours at a machine speed of 1500 rpm. The bearings are lubricated for life. On machines of a single-bearing design, bearing operating life must be expected to be 30% shorter.
Lubrication points Quantity in g
Double bearing
Type
Single bearing
Size 29, 36 and 43 machines are normally fitted with deep-groove ball bearings acc. to DIN 625, version 2 Z, on both sides. The bearings are filled with high grade bearing grease by the bearing manufacturer and sealed on each side with two cover plates.
Before regreasing, clean the nipple so that dirt cannot enter the bearings.
Type of anti-friction bearing grease
Using a medium-sized manual grease gun (approx. capacity 500 g), approx. 1 g of grease can be fed in per stroke at the tapered lubrication nipple (AM 8 x 1 DIN 71427).
On delivery, the bearings are lubricated with high-grade, lithium-soap grease of grade 3 consistency (NLGI-KL anti-friction bearings). The grease channels between the lubricating nipple and bearings are filled with anti-friction bearing grease before leaving the factory.
Where possible, apply grease when the machine is running, unless this represents a hazard for the operating personnel.
Alternatively, the following types of lithium-soap anti-friction bearing grease can be used:
Regreasing interval
•
Shell Alvania
G3
Bearings must be regreased in accordance with the regreasing interval stated on the alternator plate, but at least once a year.
•
SKF/Alfalub
LGMT 3
•
Esso Unirex
N3
•
Mobil Mobilgrease
532
•
Texaco (DEA)
EP 3
Relubricating quantity A- and B-side bearings must each be regreased with the amount of grease stated.
These greases are of grade 3 consistency and comply with DIN 51 825.
After about three regreasing operations, remove expelled grease.
Recommendation: Always regrease the bearings with the same selected brand of grease.
After about five regreasing operations, keep applying more grease until fresh grease is visible at the outlets. Then run the machine if possible at half speed for one hour and then at the nominal speed. Check the temperature of the bearings and compare with those temperatures obtained before regreasing.
1.13.4 Assembling the bearings Bearings must only be renewed by a qualified person working in a dust-free environment, on a clean surface and using clean tools. The grease and bearings 7
must be kept free of impurities, otherwise they will wear out faster and possibly even fail. The bearing components must be arranged as shown in the illustration (see spare part drawing). The grease regulating disk should be rigidly attached to the shaft.
1.14 Dust filters and monitoring of thermal behaviour To prevent the windings from overheating when the filters are dirty, three temperature sensors are installed in the stator winding. Their trip mechanism must be installed in the switch cabinet.
When changing bearings, install type-approved bearings only, and maintain the correct amount of bearing play (usually "C3"). Do not remove new bearings from their packs until just before they are installed. Do not wash the bearings, as the anti-corrosion agent applied to them is intended to mix with the similar agent in the anti-friction bearing grease. Clean the old grease off the parts of the bearing that are to be re-installed.
In addition, probes can be installed to allow the degree of contamination at the filters to be measured directly. Their trip mechanism must be installed in the switch cabinet. Cleaning must be performed at regular intervals even if the machine is protected against excessive temperatures by integral coil temperature monitoring devices.
When fitting the bearing, heat it to about 80 100°C in an oil bath, oven or by an inductive method. Make absolutely sure that it is located centrally and remains in positive contact with the shaft shoulder.
On machines with integral dust filters, please note the following: 1.14.1 Synthetic filter elements These are dry filters and must be cleaned at regular intervals. These intervals vary depending on the rate at which dirt accumulates. Cleaning may be performed using compressed air, water at temperatures up to 50°C, or cleaning fluid. Comply with the relevant environmental and safety regulations. However, it is often more economical to change the filter mat.
Once they have cooled down, pack the bearings with grease. The inner and outer bearing covers must each be filled 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 to particularly stringent quality control. This is essential to maintain the accuracy of shape needed to keep the bearings fully operational.
1.14.2 Wire mesh filter elements These are wet filters and are supplied dry. Before starting up, apply a thin film of oil or "Viscinol" to the filter plates. Dirty wire mesh filters should be cleaned using compressed air or suitable washing agents (soda or "Purinol") and wetted again when dry.
When dismantling the bearings and bearing rings, it is therefore important to handle the bearings and bearing rings with particular care, otherwise the bearing seats on the shaft could become damaged. Use a puller to remove. Heat the parts evenly to a temperature of app. 80°C all round.
1.15 Drying out the machine
1.13.6 Monitoring the bearings
If the insulation value between the winding and the core or between windings is less than that stated in Item 1.9.1, the machine needs drying.
The first indication of damaged bearings is usually a notice-able change in running behaviour, or noise, vibration or temperature if bearing damage has reached an advanced stage.
1.15.1 Drying out with integral ventilation system In many cases it can be dried suitably using its own ventilation system, but it should not be live while this is being carried out. On the "COSIMAT C", the plugs should be disconnected at terminals UH1 and WH1. On the "COSIMAT N" voltage regulator, the connections UH1-UH1’ and WH1-WH1’ must be opened. If no improvement in the insulation resistance is registered after a running period of app. two hours, the alternator must be dried out by shorting.
Recommendation: Monitor the bearings by measuring transmitted noise and vibration at regular intervals, and compare the readings with those taken on previous occasions.
8
1.15.2 Drying out by short-circuiting
on the "COSIMAT C" or at terminals I1 and K1 on the "COSIMAT N".
a) Short the main terminals U, V and W via a current transformer and current meter (for app. 1.2 x nominal current) while the machine is at a standstill.
Important: connect the positive pole to I1 and the negative pole to K1. d) Run the alternator at its nominal speed and adjust the short circuit current at the rheostat to app. 1.2 x nominal current (see performance data plate).
b) Pull off plugs at terminals I1 and K1 as well as UH1 and WH1 on the "COSIMAT C". Open bridges I1-I1’ and K1-K1’ as well as UH1-UH1’ and WH1-WH1’ at the "COSIMAT N" voltage regulator.
Continue to dry the machine until its insulation resistance has risen to a sufficient level. We recommend measuring at approx. 2-hour intervals.
c) Use a 12 V or 24 V battery and rheostat to feed in exciter current at terminals I1 and K1
9
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 regulator lights up. If it does so, then the underspeed protection has tripped; increase the speed until the LED goes out.
2.
Nominal voltage does not respond to adjustment at R1.
2.1 Setpoint potentiometer is defective.
Check voltage setpoint potentiometer at terminal s/t for signs of interruption. Rectify the interruption.
2.2 Sensing leads wrongly connected.
Examine sensing lead connections U, and W on "COSIMAT C" or U, V and W on "COSIMAT N". Check whether the machine’s nominal voltage lies within the rated voltage range.
3.1 Setpoint potentiometer is defective.
Examine the voltage setpoint potentiometer for a short circuit. Renew the setpoint potentiometer. Check the potentiometer leads for a short circuit. Rectify the short circuit.
3.2 A sensing lead is broken.
Rectify the fault.
4.1 Input speed drops under load.
Check the regulator of the drive machine.
4.2 One of the fuses on the cooling body is defective on the "COSIMAT N".
Check the fuse on the inside of the cooling body; renew if necessary (10 A super quick acting).
4.3 Rotating diodes are defective.
Check rotating diodes V1 and overvoltage conductor V3; renew if necessary.
5.1 Input speed too low. Less than 50 % of nominal speed.
Check the speed regulator of the drive motor. Check the power transmission to 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 at I1 and negative pole at K1.
5.3 No voltage at auxiliary exciter winding UH1-UH2 or WH1WH2.
Check whether windings UH1-UH2 and WH1-WH2 are interrupted in the stator of the auxiliary exciter. Rectify the interruption.
5.4 Fault in regulator circuit.
Check whether the external connections on terminals I1, K1 UH1 and WH1 are in place. On the "COSIMAT N", check the bridges also.
5.5 Fault at regulator connections.
Check input and output connections of regulator.
3.
4.
5.
Alternator voltage too high, cannot be brought down by adjustment at R1.
Severe voltage collapse when under load.
Alternator does not respond to excitation.
10
Fault at alternator
Cause
Remedy
5.6 Regulator fuse has blown on "COSIMAT N".
Check the regulator fuse on the inside of the cooling body and renew if necessary (10 A super quick-acting).
5.7 Power stage transistor is defective.
On the "COSIMAT N", replace the regulator’s power stage. On the "COSIMAT C", replace the entire regulator.
5.8 Regulator is defective.
Replace the regulator
5.9 Rotating rectifier is defective.
Check rotating diodes V1 and overvoltage conductor V3; renew if necessary.
6.
Oscillating voltage in separate operation.
6.1 I-share too low.
Set switch S1 to a higher number, and move R1 slightly in a clockwise direction if necessary.
7.
Alternator voltage fluctuates at irregular intervals.
7.1 Loose contact in one regulator input lead.
Check the leads that connect the regulator. Check the connections on the machine’s terminal board. Re-tighten nuts.
7.2 Blockage at mechanical regulator on drive machine.
Check the speed regulator on the drive motor. Rectify the fault.
8.
Oscillating reactive output in parallel operation.
8.1 Droop setting is too low.
Move R7 slightly in a clockwise direction.
9.
Excessively high reactive current output 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 direction.
Open the bridge. 9.2 Transformer connections k/l are incorrect, e.g. bridged by switch. 9.3 Are the secondary connections at Swap over the k/l connections, "k" terminals k/l correct or not? must be the white lead. 9.4 Droop transformer not installed in phase "V".
Install droop transformer in phase "V", check direction of rotation.
9.5 If "COSIMAT C" is installed separately, sensing leads U/W may be wrongly positioned (U/V/W on "COSIMAT N").
Check the sensing lead. There must be a right-handed field on "COSIMAT N".
10. Excessively low reactive current output in parallel operation.
10.1 Droop setting is too high.
Move R7 slightly in an anti-clockwise direction.
11. Active load not equally distributed.
Check the drive motor (regulator, fuel 11.1 This is affected by the drive masupply etc.). chine only, i.e. determined by the drive machine regulator. The alternator’s regulator affects only the reactive output and therefore the distribution of the reactive load (see 8., 9. and 10).
11
Please contact our Service Department if you have any problems. Our experienced specialists will be glad to help you. If possible, inform us of your findings by telefax or telephone. Telefax: +49 (0) 841/792-195
Telephone: +49 (0) 841/792-163
12
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)
13
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. )
14
Schutzschalter für G3
F1
Protection switch for G3
NUR IM STILLSTAND BETÄTIGEN
ONLY SWITCH ON AT STANDSTILL
G1 G2 G3
Hauptmaschine Erregermaschine Hilfserregerwicklungen
Main machine Exciter machine Auxiliary exciter windings
R11
Rotierender Varistor
Rotating varistor
V1
Rotierende Gleichrichter
Rotating rectifiers
X1 X2-6
Hauptklemmen Klemmleiste
Main terminals Terminal strip
U1
Spannungsregler Cosimat N R3 Unterdrehzahlschutz R4 Interner Sollwert R1 P-Anteil S1 I-Anteil R7 Statikeinstellung R6 Statikwandleranpassung Sollwertpot. Generator Spannung (R = 500 Ω) Statikwandler
Alternator voltage regulator Cosimat N R3 Underspeed protection R4 Internal voltage setting R1 P-Part S1 I-Part R7 Droop adjustment R6 Droop transformer adaption Alternator voltage adjuster (R = 500 Ω) Droop transformer
ACHTUNG: Bei Regler lose: Regleranschluß Drehrichtung rechts:
CAUTION: AVR loose supply:AVR connection Rotation clockwise:
Leiste X2 U ⇒ V ⇒ W ⇒
Terminal X2 ⇒ U ⇒ V ⇒ W
R1 T6 '
Regler U V W
AVR U V W
Drehrichtung links:
Rotation counter clockwise:
Leiste X2 W ⇒ V ⇒ U ⇒
Terminal X2 ⇒ W ⇒ V ⇒ U
Regler U V W
AVR U V W
Schnellentregung: Brücken UH1-24 und WH1-14 öffnen
Quick de-excitation:
Entregungsschalter: 220 V AC (nicht AvK Lieferumfang) 10 A
De-excitation switch: 220 V AC (not AvK supply) 10 A
Zubehör Widerstandsthermometer PT100
Accessories Resistance Thermometer PT100
A13, 14
Statorwicklung Phase U: 1, 4, 7, 10 Phase V: 2, 5, 8,11 Phase W: 3, 6, 9, 12 Lager, B-Seite
Stator winding Phase U: 1, 4, 7, 10 Phase V: 2, 5, 8, 11 Phase W: 3, 6, 9, 12 Bearing, NDE
H
Stillstandsheizung
Anti condensation heater
----
Verbindungen außerhalb des Generators
Connections outside the alternator
A1-12
15
Open bridges UH1-24 and WH1-14
Bunsenstraße 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. KG Dreieich branch Benzstraße 47-49 63303 Dreieich, Germany Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40 e-mail:
[email protected] www.newage-avkseg.com
16
OI_DSG29_144/en-06-2004/A
AvK Deutschland GmbH & Co. KG
Enclosure to Operating Instructions Advise for Commissioning
Generator with vibration absorbers 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.
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.
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. AnB / e / 20-10-2003 / B
Page 2
Generator with vibration absorbers 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 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.
AnB / e / 20-10-2003 / B
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.
Page 3
Connections
Using the Protection switches Q1, F1, F2 Cable connection acc. to DIN 46200 Elastic parts, such as spring washers, can be used in 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.
AnB / e / 20-10-2003 / B
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.
Page 4
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.
AnB / e / 20-10-2003 / B
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 grindin (other than slip rings). Using brushes bigger than the original size is only possible after agreement with the supplier.
Page 5
Maintenance of Earthing Fault Monitoring
Optimum maintenance and care of ht e 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 originally mounted is only possible after agreement with the supplier.
AnB / e / 20-10-2003 / B
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.
Page 6
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
AnB / e / 20-10-2003 / B
Page 7
AnB / e / 20-10-2003 / B
Page 8
Bolting torque for fixing screws If no further indications are made , use the following bolting torque for connections of fixing screws and fixing nuts:
M4 M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 M42
screws property class 8.8 3,0 3,5 9,0 18 45 50 110 250 440 980 1730 2700
screws property class 4.6 1,1 2,2 3,7 9,0 18 31 75 150 255 510 890 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 µ ges = 0,125
AnB / e / 20-10-2003 / B
Page 9
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 EU2
according to DIN 24185 / part 100 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
AnB / e / 20-10-2003 / B
Page 10
AnB / e / 20-10-2003 / B
Page 11
AvK Deutschland GmbH & Co. KG Bunsenstraße 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. KG
AnB / e / 20-10-2003 / B
Dreieich branch Benzstraße 47-49 63303 Dreieich, Germany Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40 e-mail:
[email protected] www.newage-avkseg.com
Page 12
Regulator Descriptions
Description and adjustment instructions ”COSIMAT N+” voltage regulator for DSG and DIG alternators
Description of ”COSIMAT N +” 1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.
Brief 2.1 2.2 2.3 2.4
3.
Functional description . . . . . . . . 3.1 Block diagram . . . . . . . . . . 3.2 Power supply . . . . . . . . . . . 3.3 Monitoring alternator voltage . . . . 3.4 Desired value . . . . . . . . . . . 3.5 Droop . . . . . . . . . . . . . . 3.6 Control amplifier . . . . . . . . . 3.7 Additional functions of the ”COSIMAT 3.7.1 Underspeed protection . . . . . . 3.7.2 Protection functions . . . . . . . . 3.8 Power stage . . . . . . . . . . .
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Transfer function of the ”COSIMAT N+” . . . . . . . . . . . . . . . . . . . . . . 12
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Special functions and additional equipment . . . . . . . . . . . . . . . . . . . . 13 5.1 Stand-by and emergency manual switchover . . . . . . . . . . . . . . . . . . . . . 13 5.2 Additional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.
Diagrams of connections . . . . . . . . . . . . . . . . . . 8.1 Assembly for DSG alternators 52 – 74 . . . . . . . . . . . 8.2 Assembly for DSG alternators 86 – 125 . . . . . . . . . . . 8.3 Assembly for DIG medium-voltage alternators with UN ≤ 11.5 kV 8.4 Assembly for DIG medium-voltage alternators with UN > 11.5 kV 8.5 De-excitation circuit on the ”COSIMAT N+” . . . . . . . . . 8.6 Monitoring field current and voltage on the ”COSIMAT N+” . .
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Connections, adjusting 9.1 Connections . . . 9.2 Adjusting elements 9.3 Displays . . . . .
10.
Start-up of the ”COSIMAT N+” 10.1 Basic setting and visual check 10.2 Desired value setting range . 10.3 Regulating parameters . . . . 10.4 Underspeed protection . . . 10.5 Droop adjustment . . . . . .
summary . . . . . . . . . . . General diagram . . . . . . . . Adjusting elements and their effects Start-up . . . . . . . . . . . . Optimising the regulator . . . . .
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11. Important notes . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Protection concept for external mounting of regulator . . . . . . 11.2 Mounting the regulator . . . . . . . . . . . . . . . . . . . . 11.3 Excitation build-up . . . . . . . . . . . . . . . . . . . . . . 11.4 Code switch S2 . . . . . . . . . . . . . . . . . . . . . . 11.5 Droop switch . . . . . . . . . . . . . . . . . . . . . . . . 11.6 Changing the direction of rotation . . . . . . . . . . . . . . . 11.7 Synchronous motors . . . . . . . . . . . . . . . . . . . . . 11.8 Protection fuses . . . . . . . . . . . . . . . . . . . . . . . 11.9 Drying out the alternator . . . . . . . . . . . . . . . . . . . 11.10 External power supply . . . . . . . . . . . . . . . . . . . . 11.11 400 Hz alternators and converters . . . . . . . . . . . . . . 11.12 Checking the insulation voltage of the electric machine . . . . . 11.13 Exchange/replacement; ”COSIMAT N/N3” by ”COSIMAT N+” 11.14 Malfunctions, causes and remedies . . . . . . . . . . . . . .
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1. General The ”COSIMAT N+” is a compact voltage regulator designed to control synchronous alternators both in single and parallel operation. In single operation, the alternator voltage is held constant irrespective of power, frequency and temperature. When operated in parallel with the mains or with other alternators, a stable reactive power is produced.
With the use of additional modules it is possible to intervene in set-point and actual value formation via the ”COSIMAT N+” signal inputs: There are a large number of additional modules available for a wide variety of control applications e.g. ●
or ●
Via its power stage, the ”COSIMAT N+” adjusts the excitation current to match the operating conditions.
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Integrated measuring transformers for three-phase measurement of the alternator voltage up to 500 V AC (external conductor voltage).
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Stable reactive power thanks to current-voltage vector measuring system (droop). A load-relieved current transformer is required in alternator phase ”V”.
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Internal and external alternator voltage set-point adjustment.
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PID control amplifier with large adjustment range.
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Disproportionate drop in desired value when alternator operates at underfrequency.
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Permanent monitoring of the actuator and time limit on the max. possible excitation current.
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Internal protection devices trip whenever a fault occurs, thus separating the excitation field from its energy source.
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Compact construction with interchangeable power stage.
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Fully potted in to protect it from environmental effects.
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Long life thanks to high-quality components.
Limitation of start-up current when connecting up a large asynchronous motor to the alternator
or
The main features of the ”COSIMAT N+” are: ●
cos phi regulation of a synchronous alternator or motor
Cable compensation via load current detection or measured value of the external alternator voltage.
Its additional modules make the "COSIMAT N+" suitable for various applications on test rigs, in power-train technology etc. (see 5.2 Additional modules).
2
2. Brief summary 2.1 General-arrangement diagram
Figure 1 – General-arrangement diagram
3
2.2 Adjusting elements and their effects
Figure 2 – Adjusting elements
4
2.3 Start-up
Figure 3 - Start-up
5
2.4 Optimisation of the regulator To optimise regulation, it is necessary to connect loads to the alternator. To allow the trend of the control property following a change in the P or I parameter to be evaluated, the load connected must be reproducible. The factor with the greatest general significance in achieving an optimum regulating system is an overshoot amplitude xm which is as small as possible. The essential criterion in the evaluation of the regulating process with respect to time is the settling time taus.
It is not necessary to adjust the D parameter in order to optimise the control properties. It is generally determined just once, in accordance with the size of the alternator. In the case of alternators > 1 MVA, switch S2.4 is switched to the ON position. To decide whether the D parameter should be increased beyond this, it is necessary to take specific measurements of the alternator voltage and at the output of the regulator. Satisfactory optimisation of the regulator will normally be achieved by the free adjustment of the P and I parameters.
To follow the trend of the control property, use an oscilloscope to monitor the manipulated variable. The "COSIMAT N+" regulator allows ”free” adjustment of the P and I parameters. The D parameter can be switched over in two stages using code switch S2.4.
Figure 4 – Characteristic quantities of the regulating system
Figure 5 – Trend of the control property
6
3. Functional description 3.1 Block diagram
Figure 6 – Block diagram
7
3.2 Power supply
3.3 Monitoring alternator voltage
Power is supplied to the "COSIMAT N+" by means of so-called auxiliary excitation voltages, which are produced in the alternators. The excitation energy and the supply voltage for the "COSIMAT N+" are derived from the auxiliary excitation voltages.
The "COSIMAT N+" measures alternator voltages from 90 to 500 V AC (external conductor voltage) within two selectable ranges by means of an internal three-phase measuring transformer.
In the case of AvK alternators in Series DSG and DIG with UN ≤ 11.5 kV, the "COSIMAT N+" is supplied with power via two single-phase auxiliary windings, which are inserted into the main stator. The windings are designated UH1/UH2 and WH1/WH2. The voltages UH1 and UH2 are offset by 90° with respect to WH1 and WH2 and are 80 V AC ± 20 % at the nominal voltage of the alternator. In the case of AvK alternators belonging to Series DIG with UN > 11.5 kV, the "COSIMAT N+" is supplied with power via a two-phase auxiliary exciter machine. The windings are designated UH1, UH2, UH3 and WH1, WH2. The voltages UH1 and UH2 are offset by 90° with respect to WH1 and WH2 and are 80 V AC ± 20 % at the nominal speed of the machine. The above-mentioned auxiliary exciter windings UH1 and UH2 and WH1 and WH2 are plugged into the correspondingly designated terminals of the "COSIMAT N+":
To measure higher voltages, corresponding voltage transformers must be connected in series. Signal input N allows intervention into the internal formation of the actual value. The secondary AC measurement voltage of the measuring transformer is converted into a DC voltage, smoothed, conditioned and output as an actual value to the regulator circuit. The measured value which is produced corresponds to the arithmetic mean of the rectified three-phase AC measurement voltage. Three-phase measurement allows for asymmetric loads.
Note: For non-linear loads (static thyristor converter or rectifier), additional module TF (RC – low-pass filter) is recommended as a measuring adapter. High non-linear loads may require overdimensioning of the alternator. 3.4 Desired value
Special application Three-phase auxiliary exciter machine If a three-phase auxiliary exciter machine is used, the winding terminals are designated UH1-VH1-WH1. The external conductor voltage is 3 x 75 V AC ± 20 % at the nominal speed of the machine. Special application External power supply The "COSIMAT N+" can also be operated with a constant external voltage. It is generally supplied via a three-phase transformer (Yy 0) with a secondary voltage of 3 x 75 V AC ± 20 %. The nominal power should be at least 500 VA.
Caution: If the auxiliary excitation voltage is taken from a constant "external" power source (e.g. the mains), the supply must be switched on only after the alternator has been started. When switching off the alternator, the supply should be switched off before the machine comes to a halt (see 11.10 External power supply).
The desired value for the "COSIMAT N+" is taken from a temperature-compensated reference source. The signal input ”n” allows intervention in the internal formation of the desired value. The reference voltage reaches the set-point potentiometer R 4 mounted on the front end of the "COSIMAT N+". This potentiometer allows coarse adjustment of the alternator voltage over a wide range (= ”approximate” desired value). In parallel operation of the alternator, the reference voltage is influenced by the droop-measuring system (see 3.5 Droop) and, in the case of underfrequency, by the underspeed protection. A set-point potentiometer can be connected to the "COSIMAT N+" for external adjustment of the desired value. This potentiometer is used for fine adjustment of the alternator voltage (= ”exact” desired value). The adjustment range is limited to ± 5 % to ± 10 % around the nominal value, depending on the potentiometer used. The ES additional module allows the adjustment range of the external set-point potentiometer to be extended from remanence to the nominal voltage.
8
If the ES module is used on AvK alternators, the regulator system must be provided with an external power supply. This must be decided on a case by case basis, depending on the application and the excitation system used (auxiliary excitation windings or auxiliary excitation machine?) 3.5 Droop Once 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 would lead to the alternator producing reactive current > IN. To stabilise the alternator reactive current it is therefore necessary to have a measured variable which is dependent on the reactive current and incorporates the magnitude of the current and the reactive power (inductive or capacitive). This measured variable is introduced at the addition point (comparison point of the desired value and the actual value) of the control amplifier circuit.
If, when the alternator is connected in parallel, the fixed mains forces it down to a figure which is 6 % lower, the reactive current is inductive and equivalent to 100 % of the nominal alternator current. In parallel operation, regulation of the synchronous alternator is made possible by the droop sensing signal. For stand-alone operation, adjustment is performed on the test rig using a reactive load. The droop effect is set to 3 %. The droop sensing signal in the "COSIMAT N+" influences the desired value and is produced by means of a geometrical addition of the external conductor voltage U-W and a current-dependent voltage signal from the V phase. In AvK synchronous machines, the corresponding current transformer is located in phase V. The K side of the transformers points towards the alternator’s main winding (see Figure 6 – Block diagram). Internally load-relieved bushing-type transformers are used.
This produces a static droop control characteristic, which represents the relationship between:
The outlet end of the secondary connections ( = potted end of the transformer) is the primary-side K point (= current input).
the change in the alternator voltage in relation to the nominal voltage and the change in the alternator reactive current in relation to the nominal current.
The wire marked in white is the secondary-side k point.
The droop is represented by the slope of the characteristic curve produced i.e. is the quotient of the above ratio. In the "COSIMAT N+" a linear droop characteristic is generated. The droop effect can be adjusted from 0 to 6 % using the potentiometer R 7. Example: In the case of an inductive reactive current of 100 % of the nominal current of the alternator and with the droop set to 6 %, the alternator voltage is reduced by 6 %.
The secondary connections k and I of the droop current transformer should be plugged into the correspondingly marked terminals of the "COSIMAT N+". In the case of alternators for parallel and stand-alone operation, the measuring input k – I can be short-circuited by means of a switch for stand-alone operation. This gives better voltage stability (see 8. Diagrams of connections, 11.5 Droop switch). The droop sensing system of the "COSIMAT N+" is matched to the nominal current of the alternator by means of potentiometer R 6.
Caution: For the droop sensing system to function correctly, the "COSIMAT N+" requires a clockwise rotating field at its measurement voltage terminals. If the direction of rotation is reversed, measuring leads U and W should be interchanged.
3.6 Control amplifier The control amplifier of the "COSIMAT N+" has a PID characteristic. The parameter of the I section can be varied in steps from 1 to F using switch S 1. During this process, the integration time constant increases. Figure 7 – Droop characteristic
9
Caution:
kink point” is set to 0.95 x fN. Above the kink point, voltage regulation is constant.
Switch position 0 is not allowed; never pass through 0.
The voltage reduction is delayed by about 2 seconds to eliminate the effect of transient drops in the speed of the drive machine.
The parameter of the P section can be varied by means of potentiometer R 1. During this process, the adjustment range shown in Figure 8 should not be exceeded.
In exceptional circumstances, the underspeed protection function can be deactivated by means of code switch S2.2 (see 9.2 Adjusting elements).
Caution: For standard applications of the "COSIMAT N+", the underspeed protection function must be active and correctly set. Code switch S2.2 must be in the ”ON” position. The underspeed protection function is active on 50/60 Hz alternators. For other nominal frequencies, the UF module should be used or the alternator should be deexcited when being shut down. Figure 8 – P adjustment range Further adjustment in the clockwise direction leads to hunting, while further adjustment in the anticlockwise direction leads to control errors. The D parameter can be changed by switching code switch S2.4 to the ”ON” position. This increases the effect of the D parameter, as required by larger alternators (DIG and DSG 74 ... 125). The D parameter can furthermore be varied at the ”D-Opt.” optimisation points. At the specified polarity, a capacitor can additionally be soldered in. When installing additional D-section capacitors, it is important to note their polarity (electrolyte capacitor) and nominal voltage (= 35 V DC). The maximum recommended value is 150 µF. Figure 9 – Underspeed protection 3.7 Additional functions of the "COSIMAT N+" 3.7.2 Protective functions 3.7.1 Underspeed protection While a drive machine (motor or turbine) is warming up, the alternator is operated at underfrequency. To prevent overexcitation and thermal damage in the exciter system, the "COSIMAT N+" allows frequency-dependent reduction of the regulator’s desired value or alternator voltage in accordance with a linear function (see Figure 9 – Underspeed protection).
The auxiliary exciter windings (see 3.2 Power supply) have a very high short-circuit capacity. If the actuator is faulty, the high short-circuit power involved may cause severe damage. To prevent this damage, the "COSIMAT N+" has two protective functions which monitor its actuator and prevent overloading of the exciter system:
The point at which the voltage drops is defined by a corresponding frequency value set by means of R3. The reduction for underspeed is indicated by H1. Before delivery, the ”U/f
10
Time limitation of the maximum excitation current When the actuator is fully on, the excitation current reaches a maximum. If this state is allowed to continue, the exciter system will be damaged. However, the fully-on state only occurs in the case of compensating processes or short circuits at the main terminals of the alternator. The monitoring system of the "COSIMAT N+" limits maximum excitation to 8 to 10 seconds. After this, the protection circuit isolates the exciter field from the source of excitation energy by tripping the protection fuses. Checking the direction of action of the control amplifier and the actuator This feature monitors the positioning transistor for short circuits. Short-circuiting of the positioning transistor leads to maximum excitation. The control amplifier tries to counteract this but has no effect on the faulty actuator. The actuator and the control amplifier act in opposite directions and the fuses trip immediately. The following circumstances also lead to maximum excitation and can trip the fuses: ●
Faulty sensor leads
●
Deactivated or incorrectly adjusted underspeed protection function
●
Short circuit in the I1 / K1 exciter lead
●
Faulty exciter rectifier in the "COSIMAT N+"
●
Extreme overloading of the alternator (short circuit) if this has not been switched off after 8 to 10 seconds.
The protection device integrated into the "COSIMAT N+" responds to a large number of defects and faults.
Note: Additional module ER1 can be used to limit the excitation current when the alternator is operated in parallel.
11
3.8 Power stage The power stage of the "COSIMAT N+" provides an excitation current that corresponds to the output signal of the control amplifier. A MOSFET transistor is used as the actuator, with pulse width modulation, i.e. the turn-on time varies but the switching frequency remains constant. The excitation energy is taken from the rectified supply voltage, the rectifier circuit being located in the power stage. It allows the rectification of two single-phase or three-phase supply voltages (see 3.2 Power supply). There is a short-circuit thyristor in the DC circuit. The protective circuit of the "COSIMAT N+" switches this thyristor on if faults occur in the control circuit. The resulting short-circuit current trips the two protection fuses on the front plate of the "COSIMAT N+" and the exciter field is isolated from the source of excitation energy. Fuse: 10 A super quick-acting 32 mm x 6.3 mm ø IEC G 144.400
Caution: Replacement fuses must be of the above type. The power stage may suffer permanent damage if the wrong type of fuse is used. The power stage is located on a profiled heat sink. It is plugged into the regulator and screwed into the substructure of the "COSIMAT N+". To ensure adequate cooling for the power semi-conductors in the power stage, you must follow the instructions in Chapter 11.2 Mounting the regulator.
4. Transfer function of the "COSIMAT N+"
Figure 10 – Equivalent control circuit diagram There are three ways of influencing the control parameters in the "COSIMAT N+”:
The time constant of the input low-pass filter is: TP1
Potentiometer R1 (500 kΩ) for changing the P parameter. At the right-hand stop, R1 is 0Ω. Switch S1 for changing the I parameter in 15 steps (from 0.22 to 3.85 µF) each of 0.22 µF (C1).
= 3.62 ms
The time constant of the output low-pass filter is: TP2
= 0.268 x T2
Code switch S2.4 for increasing the D parameter from 10.1 µF (S2.4 = OFF) to 32.1 µF (S2.4 = ON) (C2). The individual parameters in the equivalent circuit diagram (see Figure 10 – Equivalent control circuit diagram) can be calculated as follows: T1 T2 T3
= R1 x C1 = 6,8 kΩ x C2 = 22 kΩ x C1
TI
= T1 + T2
TD
= T1 x T2 T1 + T2
K1
=2,56
K2
= 716,1 ms x K1 Tl
K3
= 1 = 0,066 15
T1 + T2 T3
12
5. Special functions and additional equipment 5.1 Stand-by and emergency manual switchover Where higher availability is required, there are ”stand-by” circuits. Stand-by circuits contain two "COSIMAT N+" voltage regulators. The alternator is regulated by one of these regulators (main regulator). If this regulator is defective, it is possible to switch to the second (stand-by) regulator. Stand-by circuits are available in either manual or automatic form. Manual stand-by circuit (SB1) In the event of a malfunction, a changeover switch permits the stand-by regulator to be selected. The changeover switch switches over all the signals apart from the sensing voltage and supply connections UH2 (VH1) and WH2. Automatic stand-by circuit (SB2) The stand-by circuit monitors the main regulator. Common operating variables with respect to the response of the regulator allow fault detection and switchover to the stand-by regulator. The stand-by regulator operates in simulated control mode and is likewise monitored. The switch between the two regulators can take place during the operation of the alternator and can be performed manually, by means of a test function or, in the case of a malfunction, automatically.
13
5.2 Additional modules The following list provides a summary of the various additional modules for the "COSIMAT N+". COS cos phi regulator FUNCTION: The power factor (cos phi) is held constant irrespective of fluctuations in system voltage or load changes. APPLICATION: Parallel operation with fluctuating mains. Limitation of the excitation current by means of ER1 additional module.
Figure 11 – Additional module COS
QPF Reactive power regulator with single-phase measurement FUNCTION: The reactive power is held constant irrespective of fluctuations in system voltage or load changes.
QPF
APPLICATION: Parallel operation with constant reactive power output.
Figure 12 – Additional module QPF A
QPF cos phi trimmer FUNCTION: The power factor of the regulated alternator is the same as that of the total current or of the currents of the other alternators (depending on current transformer connection). APPLICATION: Parallel operation with alternators without linear voltage droop. Figure 13 – Additional module QPF B
QPF Reactive power trimmer with single-phase measurement FUNCTION: The reactive power of the regulated alternator is the same as that of the other alternator. APPLICATION: Parallel operation with alternators without linear voltage droop.
Figure 14 – Additional module QPF C
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SB2 Automatic stand-by switchover (see 5.1 Stand-by and emergency manual switchover) FUNCTION: Automatic switchover to the stand-by regulator in the event of regulator faults. APPLICATION: Requirement for higher availability and operating reliability (e.g. on ships).
Figure 15 – Additional module SB2
TF/TF1 RC – low-pass filter (Type TF1-50 for 50/60 Hz) FUNCTION: Reducing the ripple effect in the voltage sensing signal of the "COSIMAT N+". APPLICATION: Non-linear alternator loading by rectifier bridges or static converters.
Figure 16 - Additional module TF1
ES Extended adjustment range (incl. 10 x potentiometer) FUNCTION: External adjusting range from remanence to nominal voltage. APPLICATION: Various test applications in the construction of transformers and electrical machines, run-up of large electric motors (pump motor). Figure 17 – Additional module ES
UF U/f characteristic module FUNCTION: Frequency-dependent regulation of the alternator voltage in accordance with a linear function. Different gradients can be selected. APPLICATION: Variable-frequency operation of shaft alternators on ships. Reduces the speed dip when there is a jump in the active load. Figure 18 – Additional module UF
15
UF3 U/f characteristic module with extension FUNCTION: Frequency-dependent control of the alternator voltage in accordance with freely selectable function. Operation with controlled inner field voltage down to 0 Hz. APPLICATION: Control of the alternator voltage as a function of any measured variable (using standardised measured-value signal) and freely selectable characteristics. Used for driving asynchronous winding motors and for testing transformers. Figure 19 – Additional module UF3
SR2 Current limitation FUNCTION: Limitation of alternator current to predetermined value. APPLICATION: Run-up of large electric motors. Note: No effect on the switch-on peak in the case of direct switch-on of motors or transformers.
Figure 20 – Additional module SR2
EI External actual value detection FUNCTION: Regulation to externally measured voltage. If the measuring lead breaks, it switches over to voltage measurement at the alternator terminal. APPLICATION: Providing the consumer with highly accurate voltages over long input leads.
Figure 21 – Additional module EI
UDC2 Detection of DC voltage actual value FUNCTION: Electrically isolated measurement of a DC voltage actual value. APPLICATION: Voltage regulation of a synchronous alternator to the rectification value of an output-side bridge-type rectifier.
Figure 22 – Additional module UDC2
16
KP Cable compensation FUNCTION: Raising the alternator voltage as a function of the current. APPLICATION: Compensation of cable voltage losses by way of the load current, specifically when there is no possibility of access to the external measuring point.
Figure 23 – Additional module KP
ER1 Controlling exciter current limiter FUNCTION: Secondary regulation of the exciter current to a selected over- and under-excitation value. APPLICATION: Protects the alternator in cos phi-regulated parallel operation with a ”soft” mains when using "COSIMAT N+" and COS module. When used with QPF, controlling limitation of the exciter current cannot be used. In that case, it would be necessary to employ contact indication in the event of the exciter current limits being over- or undershot.
17
Figure 24 – Additional module ER1
6. Technical data GENERAL DATA
Type Maintenance Rated switch-on time Installation position Installation clearance
MEASURING CIRCUITS
Alternator voltage Nominal voltage Frequency Power consumption Droop current sensing (Voltage input) Voltage at IN Power consumption
AUXILIARY CIRCUITS
Supply voltage Power consumption Nominal frequency
OUTPUT CIRCUITS
Actuator Intermediate circuit voltage UZK Continuous excitation current Minimum field resistance RIK Minimum required field time constant τIK Short circuit exciter current Protective fuse
: : : :
fully potted aluminium housing incl. power stage maintenance-free continuous operation mount with longitudinal axis vertical at convectional cooling or longitudinal axis in air flow direction at fan cooling : 3 cm all round (see 11.2 Mounting the regulator)
: 90 ... 250 V AC / 250 ... 500 V AC : 50 ... 400 Hz : 4 VA / 6 VA
3 ... 7 V AC : 0.15 ... 0.35 W
:
: 2 x single-phase 80 V AC ±20 % or 1 x three-phase 75 V AC ±20 % : depending on excitation requirement : 50 ... 1200 Hz : 85 to 130 V DC (dependent on the supply voltage) : 7 ADC (continuous) : 5Ω (cold) : 0.06 s : 20 ADC for 5 seconds (at RIK = Ω5 and UZK = 100 VDC) : 10 A-FF / 250 V – 6.3 x 32
ACCURACY
Control accuracy
: ±1 % at 0 to 60 °C ±5 % speed fluctuations and apparent power 0 ... 100 %
TESTS
Vibration test EMV
: German Lloyd category 2 : CE-compliant in accordance with EN50081 and EN50082
AMBIENT CONDITIONS
Storage temperature Operating temperature
: - 40 ... + 70 °C : -25 ... + 70 °C (Special version "COSIMAT N+T" - 55 ... + 70 °C)
Height x width x depth Fixing Weight
: 121 x 115 x 162.5 mm : 4 M6 bolts, washers and circlips : 2 kg
HOUSING, DIMENSIONS, WEIGHT AND INSTALLATION
18
7. Dimensions
Figure 25 – Dimensions
19
8. Diagrams of connections Legend for diagrams of connections F1
Circuit breakers for G3 Operate only when stationary
G1
Main machine
G2
Exciter/excitation windings
G3
Auxiliary windings/Auxiliary exciter machine
R11/V3 Rotating varistor T24
Voltage transformer for regulator Must be disconnected if the star point of G1 is open
T32
Voltage transformer for G3 with integrated circuit breaker F1 Operate F1 only when stationary!
V1
Rotating rectifier
X1
Main terminals
X2 – 6 Terminal strip U1
"COSIMAT N+" voltage regulator R3 Underspeed protection R4 Internal desired value R1 P component S1 I component R7 Droop adjustment R6 Droop transformer matching
R1
Desired value potentiometer alternator voltage (R = 500Ω)
T6
Droop transformer
20
8.1 Assembly for DSG alternators 52 - 74
Figure 26 – Internal mounting, DSG alternators 52 – 74
Figure 27 – External mounting, DSG alternators 52 – 74
21
8.2 Assembly for DSG alternators 86 – 125
Figure 28 – Internal mounting, DSG alternators 86 – 125
Figure 29 – External mounting, DSG alternators 86 – 125
22
8.3 Assembly for DIG medium-voltage alternators with UN ≤ 11.5 kV
Figure 30 - Internal mounting, DIG medium-voltage alternators with U N ≤ 11.5 kV
Figure 31 - External mounting, DIG medium-voltage alternators with UN ≤ 11.5 kV
23
8.4 Assembly for DIG medium-voltage alternators with UN >11.5 kV
Figure 32 - Internal mounting, DIG medium-voltage alternators with U N > 11.5 kV
Figure 33 - External mounting, DIG medium-voltage alternators with UN > 11.5 kV
24
8.5 De-excitation circuit on the "COSIMAT N+" If a de-excitation circuit is fitted, the bridges on the double terminals UH1/UH1’ and WH1/WH1’ should be removed. Switch contacts should be connected to the double terminals to de-excite the alternator when they open (see Figure 34 – De-excitation circuit). These de-excitation contacts must meet the following specification: Current carrying capacity:10 AAC Voltage carrying capacity:160 V AC The switch elements used must have dust-protected contact chambers. Ensure that contact resistance is low – the contacts must be sensitive to low-level signals.
Note: One of the factors which determines the build-up of excitation is the quality of these contacts. On AvK alternators (DSG 86 – 125, DIG), connecting terminals for de-excitation are provided in the auxiliary terminal box (see legend of the order-specific circuit diagram).
Figure 34 - De-excitation circuit
Figure 35 - Field current/field voltage monitoring
25
8.6 Monitoring field current and voltage on the "COSIMAT N+" The "COSIMAT N+" is provided with double terminals I1/I1’ and K1/K1’ to allow the exciter field to be connected. Bridge I1/I1’ must be removed to allow the field current and voltage to be monitored (see Figure 35 – Field current/field voltage monitoring). The measuring range for field voltage monitoring is 150 VDC; for field current monitoring it is 10 ADC. Rotary coil or moving-iron instruments are recommended. Under certain conditions, digital instruments may give false readings.
Note: In the case of AvK alternators (DSG 86 – 125, DIG), there are connecting terminals for monitoring the field current and voltage on terminal strip X2.
9. Connections, adjusting elements and displays
Monitoring droop current:
9.1 Connections
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm Ø screw terminals
Voltage supply: UH1 UH2 (VH1) WH1 WH2
Caution:
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4mm Ø screw terminals Supply can be 2 x single-phase (80 V AC ± 20 %) or three-phase (75 V AC ± 20 % external conductor voltage). 2 x single-phase = three-phase =
k–I
UH1-UH2, WH1-WH2 UH1-VH1-WH1
For de-excitation circuits, the bridges on the double terminals must be removed (see 8.5 De-excitation circuit or order-specific circuit diagram). Caution: If there is an external power supply (e.g. from the mains), it must not be switched on until after the alternator has run up. It should be switched off before the machine has come to a halt (see 11.10 External power supply).
Measuring input k – I is not a current input; standard transformers should be load-relieved accordingly.
The droop current transformer must be installed in the "V" phase of the alternator. Internally load-relieved droop current transformers are used in AvK alternators. At the nominal current of the alternator, a voltage of 3 to 7 V AC is required at the terminals k – I (see 3.5 Droop and 6. Technical Data). Connecting leads to the transformer must be shielded if the regulator is installed externally. Connecting leads to the short-circuit droop switch (see 11.5 Droop switch) should be shielded in all cases. The shield should be earthed at one end on the "COSIMAT N+" (see 8. Diagrams of connections). Exciter field: I1 – K1
Measuring alternator voltage: U-V-W 250 to 500 V AC U-V-W 90 to 250 V AC 6.3 x 0.8 mm flat plugs Caution: A clockwise rotary field is required. If the alternator rotates anticlockwise, U and W should be interchanged (see 3.5 Droop). The specified voltage ranges relate to the nominal external conductor voltage of the alternator. For higher voltages, appropriate measuring transducers with a design rating of 10 VA should be connected on the input side (see 3.3 Monitoring alternator voltage). The applicable voltage range should be taken from the order-specific circuit diagram. For DIG alternators with UN >1 kV, the range 90 – 250 V AC is generally chosen. Consult AvK before initial start-up if required.
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm Ø screw terminals as double terminal. If the regulator is mounted externally, the I1/K1 field leads to the alternator must be run through a separately shielded cable (LSYCY or LIYCY). The shield should be earthed at one end on the "COSIMAT N+" (see 8. Diagrams of connections). External set-point potentiometer s–t 4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm Ø screw terminals as double terminal. The value of the set-point potentiometer determines the adjustment range: 250 Ω = about ± 5 % 500 Ω = about ± 10 %
26
The rated power of the potentiometer must be at least 1 W. A multiple-turn potentiometer must be used (see 3.4 Desired value). If the regulator or the set-point potentiometer is mounted externally, the set-point lead must be provided with its own separate shield. The shield should be earthed at one end on the "COSIMAT N+". If the regulator is mounted externally and the set-point leads are longer than >10 m, a motor-actuated potentiometer should be used near to the "COSIMAT N+".
This potential is not connected when the "COSIMAT N+" is used for standalone operation. 9.2 Adjusting elements Underspeed protection R3 25-gang trim potentiometer Function: Adjustment of the frequency-dependent lowering of alternator voltage (see 3.7.1 Underspeed protection).
Control inputs: N M/m n
Direction of action: Left-hand stop = beginning of reduction at >50/60 Hz. Right-hand stop = beginning of reduction only after about > 30 Hz.
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm Ø screw terminals.
In special cases, the underspeed protection can be deactivated by means of switch S2.2 (see 9.2 Adjusting elements).
A number of additional modules from the "COSIMAT N+" equipment range can be connected to these control inputs (see 5.2 Additional modules).
This is necessary when regulating a DC voltage by way of additional module UDC or in some cases when using external UF modules.
Caution: Only AvK additional modules must be used at the control inputs. 20 mA standard signals must not be used at these inputs.
Desired value: R4
The inputs have the following functions:
25-gang trim potentiometer
N M/m n
Function: Adjusting the alternator voltage (see 4.3 Desired value, 10.2 Desired value adjustment range).
Access to the internal actual value circuit Reference point for additional equipment Access to the internal desired value circuit
Direction of action: Left-hand stop = minimum alternator voltage Right-hand stop = maximum alternator voltage
Circuit earth: The circuit earth is likewise used as reference potential for a number of ”controlling” additional modules. This potential is not connected when the "COSIMAT N+" is used for stand-alone operation. Load earth:
Caution: Before the "COSIMAT N+" is started up, R4 must be turned to the left-hand stop position (see 10. Starting up the "COSIMAT N+"). A regulator which is checked and delivered together with an alternator is already preset.
Z The load earth is used for connecting the internal intermediate circuit capacitors. Additional external capacitors can be connected between the second Z connection tab (MINUS) and terminal I1 (PLUS).
27
P component: R1 1-gang trim potentiometer
Function: Varying the proportional component of the control characteristic.
Direction of action: Left-hand stop = maximum compensation value Right-hand stop = minimum compensation value
Direction of action: Anticlockwise = small P component Clockwise = large P component
At nominal alternator current, R6 should be used to carry out trimming to 2.5 V AC at the measuring points ”MP-STATIK – DROOP”. If the alternator load current is less than the nominal current, this may be trimmed to a proportional voltage value.
The recommended adjustment range shown in Fig. 8 – P adjustment range must not be exceeded (see 10.3 Regulating parameters).
Code switch: I component:
S2
S1
4-pole dip switch Function:
Caution: Switch position ”0” is not permitted.
Switch
FUNCTION
ON
OFF
S2.1
none
./.
./.
S2.2
Activation and deactivation of underspeed protection
Active
Not active
S2.3
Reduction of actual value smoothing
Nominal
Reduced
S2.4
Increasing the D-parameter
Increased
Nominal
16-stage code switch Function: Varying the I component in the regulating characteristic (see 10.3 Regulating parameters). Direction of action: Left (1 <- F) = small I component Right (1 -> F) = large I component Droop:
Required basic setting:
R7
AvK DSG alternators up to size 62: 1-gang trim potentiometer
S2.1 S2.2 S2.3 S2.4
Function: Adjustment of the droop effect. Direction of action: Left-hand stop = no droop effect (0 %) parallel operation not possible. Right-hand stop = droop effect 6 %
no function ON (underspeed protection) ON (actual value smoothing) OFF (D parameter)
AvK DIG, DSG 74 – 125 alternators S2.1 S2.2 S2.3 S2.4
If the direction of rotation is reversed, sensing voltage connections U and W must be interchanged. Droop matching:
= = = =
= = = =
no function ON (underspeed protection) ON (actual value smoothing) ON (D parameter)
9.3 Displays Underspeed protection:
R6 25-gang trim potentiometer Function: Matching the various alternator nominal currents and current transformer ratios to the droop monitoring system.
H1 yellow 5 mm Ø LED
28
H 1 lights up when the desired value or lowering of alternator voltage in the case of underfrequency is active (3.7.1 Underspeed protection)
g) Is the field connected with the correct polarity? 10.2 Desired value setting range
Caution: The regulator is set during the testing of the alternator at the factory. See test protocol and order-specific circuit diagram.
Once all the basic settings and visual checks have been carried out, the alternator can be started up. a) Run up alternator to nominal speed. b) Set external set-point potentiometer to the central position. c) Adjust nominal voltage using R4.
10. Starting up the "COSIMAT N+" 10.1 Basic setting and visual check
d) The alternator voltage can be adjusted around its nominal value using the external set-point potentiometer.
Before start-up, the following basic settings of the "COSIMAT N+" voltage regulator must be checked:
10.3 Regulating parameters
R3 R4 R1
a) If the basic settings of R1 and S1 (see 10.1 Basic setting and visual check) lead to continuous periodic fluctuations (stability limit), adjust R1 slowly to the left.
S1 S2
R7 R6
right-hand stop position left-hand stop position central position (in the case of DIG, DSG alternators, 1/4 rotation anticlockwise from the central position) Pos. 4 (in the case of DIG, DSG alternators Pos. 6, at 600/750 rpm Pos. 9) S2.1 = no function S2.2 = ON S2.3 = ON S2.4 = OFF (ON in the case of DIG and DSG alternators from size 74) Central position Left-hand stop
b) If there is temporarily a tendency towards weakly damped hunting in the event of load surges, adjust S1 one or two positions to the right. 10.4 Underspeed protection a) 50/60 Hz alternators to 0.95 x fN. b) In the case of 50/60 Hz alternators, turn R3 slowly in the anticlockwise direction starting from the right-hand stop position until H1 lights up. Then turn it slowly in the clockwise direction until H1 goes out.
After basic setting, the following visual checks must be carried out:
c) Run the alternator up to nominal speed.
a) Have the sensing voltage connections (U, V, W 90...250 / 250...500) been correctly selected?
10.5 Droop adjustment
b) Do the sensing voltage connections possess a clockwiserotating field? (If rotation is anticlockwise, interchange U and W). c) Is the supply voltage correctly connected (2 x singlephase UH1/UH2 and WH1/WH2; three-phase UH1, VH1, WH1)? d) Is the excess current circuit breaker in the alternator switched on? e) Is the droop transformer installed in the V phase? f) Is the k – I phase position of the droop current transformer correctly connected? (In the case of external installation, check from the alternator to the regulator).
29
a) Load the alternator with nominal current. Measure the AC voltage at the droop sensing points ”MP-STATIK-DROOP”. Adjust to 2.5 V AC using potentiometer R6. b) For partial loading, the calibration value can be reduced proportionately. c) If a stronger droop effect is required, R7 (percentage droop) should be turned clockwise starting from its central position.
Note: Where a number of alternators are run in parallel, the droop device must be at the same setting in all the "COSIMAT N+" regulators and be active!
Recommended droop settings: 3%
Parallel to the mains (If the mains supply is not stable, the setting may have to be increased).
2%
Parallel operation with identical alternators.
6%
Parallel operation with different alternators whose regulators do not have a linear droop.
1%
Parallel operation with different alternators which also have "COSIMAT N” or ”N+" regulators.
to flow freely through its power stage. Note the installation position marking ”UNTEN” (= BOTTOM) (connecting leads towards the power stage). At fan cooling, the longitudinal axis of the "COSIMAT N+" has to be in air flow direction. Deviating mounting is only suitable after checking by AvK. There must be a 3 cm clearance all the way round between the "COSIMAT N+" and any structural elements that might hinder flow (cable ducts, plates). This rule does not apply to laterally mounted additional modules. 11.3 Excitation build-up
11. Important notes 11.1 Protection concept for external mounting of regulator The following protective measures must be taken if the regulator is installed externally in the switching station: The sensing line U-V-W is to be laid using short-circuit-proof cable (1.5 mm2) from the alternator terminal strip X2 to the switching station. AvK recommends the installation of a three-phase circuit breaker with a thermal tripping current of approximately 0.5 A. If this circuit breaker is tripped, the alternator must be de-excited and stopped immediately. If the regulator is installed externally, the connecting leads for the external set-point potentiometer, the droop current transformer, the droop switch and the I1/K1 exciter line are to be provided with separate shielding. The shields must be earthed at one end on the "COSIMAT N+". Protection concept: The exciter system should be protected from excessive exciter currents and voltages by a field discharge switch or relay. This switch or relay should be connected as shown in the relevant order-specific circuit diagram. The tripping criteria will be determined by the protection required by the alternator. Where the alternator is operated in stand-alone mode, an overvoltage protection system must be installed in the switching station. In the case of operation in parallel with the mains or other alternators, an overcurrent protection system is to be added. DSG/DIG alternators with auxiliary windings: DSG and DIG alternators with auxiliary windings are fitted with an excess-current circuit breaker F1. This protects the auxiliary windings from excessively high thermal loading e.g. as the result of an external short circuit involving the auxiliary exciter voltage UH1-UH2 or WH1-WH2.
At the nominal speed, the auxiliary excitation windings on DSG and DIG alternators must produce a remanent voltage of at least 10 V AC in order to ensure a satisfactory excitation build-up. However, problems with excitation build-up may also be caused by dirty de-excitation contacts or a field connection of incorrect polarity. In the case of alternators which have been stationary for a prolonged period, it may be necessary to introduce an external excitation voltage. To do this, a 4.5 V or 6 V battery is briefly connected by its positive terminal to I1 and by its negative terminal to K1 at nominal speed. In the case of two-phase auxiliary excitation machines, the battery should be connected to I2(POSITIVE)/K2(NEGATIVE). 11.4 Code switch S2 For standard applications of the "COSIMAT N+", the following basic settings must be made before start-up at code switch S2 (see 9.2 Adjusting elements): AvK DSG alternators up to size 62 S2.1 = no function S2.2 = ON (underspeed protection) S2.3 = ON (actual value smoothing) S2.4 = OFF (D parameter) AvK DIG and DSG 74 – 125 alternators: S2.1 = no function S2.2 = ON (underspeed protection) S2.3 = ON (actual value smoothing) S2.4 = ON (D parameter) Any differences from these settings must be agreed with the manufacturer beforehand and taken into account in the way the alternator is operated. 11.5 Droop switch
11.2 Mounting the regulator The "COSIMAT N+" must be mounted with its longitudinal axis vertical in case of convectional cooling to allow the air
If alternators are to be used for both single and parallel operation, better voltage stability can be achieved in single
30
operation if the k – I inputs of the "COSIMAT N+" are short-circuited (see 8. Diagrams of connections). The lead between the droop switch and the regulator must be screened.
it is installed in the synchronous machine and the way the droop current transformer is connected to the "COSIMAT N+" remains the same (see 8. Diagrams of connections). For motor control, a cos phi controller (COS module) is required additionally.
The screen must be earthed at one end on the "COSIMAT N+". Caution: In parallel operation, the switch must be opened.
11.6 Changing the direction of rotation To enable the droop sensing system to exercise the correct effect, the "COSIMAT N+" requires a clockwise-rotating field at its measuring voltage connections. Caution: If the direction of rotation is reversed, interchange sensing leads U and W.
Note: The desired direction of rotation should be specified when ordering the alternator. This is important with regard to ventilation. 11.7 Synchronous motors Synchronous motors operate in a similar way to synchronous alternators in parallel operation. The direction of the active power is rotated through 180° relative to the alternator (see Figure 36 – Operation of the synchronous machine).
Figure 36 – Modes of operation of a synchronous machine 11.8 Protective fuses When the protective fuses are tripped, they must be replaced with fuses of the same type. Fuse type: 10 A super quick-acting IEC G 144.400 Caution:
Starting from cos phi = 1, this has the following implications for the reactive power: ●
Given a rising exciter current (overexcitation), the synchronous machine becomes a source of reactive power.
The power stage may be permanently damaged if slow or medium time-lag fuses with a rating equal to or higher than 10 A are used!
●
Given a falling exciter current (underexcitation), the synchronous machine becomes an acceptor of reactive power.
Two spare fuses are mounted on the underside of the "COSIMAT N+" (see 7. Dimensions).
When used as a generator, the synchronous machine is taken as the reference point; where it is used as a motor, the mains are taken as the reference point.
11.9 Drying out the alternator
When used as a generator, the synchronous machine supplies ”inductive” reactive power to the mains when overexcited.
If, because of inadequate insulation resistance, the alternator has to be dried out at nominal current by the short-circuit method, the "COSIMAT N+" should be disconnected from the supply and exciter field connections.
When used as a motor, the synchronous machine draws ”inductive” reactive power from the mains when underexcited. The droop system in the "COSIMAT N+" operates with the correct direction of action whether the machine is being operated as a motor or a generator. The direction in which
31
The alternator is dried out by applying an external source of excitation. Further information on how to dry out the alternator can be found in the alternator instructions.
11.10 External power supply
must be connected to the correspondingly named connecting terminal of the "COSIMAT N+".
If the auxiliary exciter voltage is taken from a different, ”external” source (e.g. the mains), the supply must not be switched on until the alternator has started up. When shutting down the alternator, the supply must be switched off before the machine comes to a halt. The switch-on and switch-off point of the supply should be set to 0.95 x fN using a frequency relay (BF1). The double terminals at connections UH1 and WH1 can be used to switch the supply on and off (see 8.5 De-excitation circuit). Caution: When the alternator is stationary and an auxiliary exciter voltage is applied, the exciter current flowing is at its maximum! The protective circuit of the "COSIMAT N+" will trip the protection fuses on the front plate after about 8 seconds.
11.11 400 Hz alternator/converter On 400 Hz alternators < 100 kVA (as single machines or converters), switch S2.3 must be set to the "OFF" position. 11.12 Checking the insulation voltage of the electric machine Before checking the insulation voltage of the electric machine, the following connections of the "COSIMAT N+" must be disconnected: Measuring voltage Supply Exciter field
U, V, W UH1-UH2, WH1-WH2 I1-K1
The supply and measurement connections of additional regulator components must also be disconnected. All disconnected or interrupted connections should be isolated in the appropriate manner. 11.13 Exchange/replacement; "COSIMAT N/N3" by "COSIMAT N+" On AvK alternators of series DSG, DIDBN, DIDBH and DIG, sizes ...74-86-99-114-125, switch S2.4 on the "COSIMAT N+" should be switched to the ”ON” position. Switches S2.2 and S2.3 should be switched to the ”ON” position. Switch S2.1 should be set to the ”OFF” position. The sequence of terminals WH1 and WH1’ has been reversed on the "COSIMAT N+". The connecting cable WH1
32
11.14 Malfunctions, causes and remedies Malfunction
Cause
Remedy
Alternator voltage is too low.
Input speed too low.
Check whether LED H1 on regulator lights up. If so, underspeed protection device has been activated, run up alternator to nominal speed.
Measuring leads incorrectly connected.
Check measuring-lead connections U, V, W on the regulator. Check whether the nominal voltage of the alternator is within the voltage range indicated on the "COSIMAT N+".
Alternator voltage is too low and cannot be adjusted with the set-point potentiometer.
Set-point potentiometer or its connecting leads are disconnected/interrupted.
Check set-point potentiometer or its connecting leads. Rectify fault.
Alternator voltage is too high.
Broken measuring lead.
Rectify fault.
Measuring leads incorrectly connected.
Check measuring lead connections U, V, W on the regulator. Check whether the nominal voltage of the alternator is within the voltage range indicated on the "COSIMAT N+".
Alternator voltage is too high and cannot be adjusted with the set-point potentiometer.
Set-point potentiometer or its connecting leads have a short circuit.
Check set-point potentiometer for short circuit. Change potentiometer. Check set-point leads for short circuits. Eliminate short circuit.
Severe voltage dip upon loading.
Input speed falls upon loading.
Check regulator of driving machine.
Defective protection fuse.
Check protection fuse on the regulator and exchange if necessary.
Rotating diodes defective.
Check rotating diodes V1 and surge voltage protector V3 and R11 and exchange if necessary.
Input speed too low. Less than 0,5 x nN.
Check the speed regulator of the input machine. Check the power transmission to the alternator.
Exciter protection switch has tripped.
Switch on the protective switch again. If it trips once more, search for the fault and repair it.
Alternator does not respond to excitation.
33
Malfunction
Cause
Remedy
Alternator does not respond to excitation.
Remanence too low.
Alternator with auxiliary winding: Briefly connect positive terminal of 4.5 or 6 V battery to I1 and negative terminal to K1 (at nominal speed). Alternator with two-phase auxiliary exciter machine: Briefly connect positive terminal of 4.5 or 6 V battery to I2 and negative terminal to K2 (at nominal speed).
DSG, DIG alternators: Interruption in the auxiliary exciter windings.
With alternator standing still! Check windings UH1/UH2 and WH1/WH2 for interruptions using an ohmmeter. Eliminate faults.
DIG alternators (UN ≤ 11,5kV): Interruption in the auxiliary exciter machine windings.
With alternator standing still! Check windings WH1/WH2 and UH2/UH1/UH3 for interruptions using an ohmmeter. Eliminate faults.
DSG, DIG alternators: Interruption in exciter windings I1/K1.
With alternator standing still! Check windings I1/K1 for interruptions using an ohmmeter. Eliminate faults.
DIG alternators (UN > 11.5 kV): Interruption in exciter windings I1/K1 and/or I2/K2.
With alternator standing still! Check windings I1/K1 and I2/K2 for interruptions using an ohmmeter. Eliminate faults.
Fault in regulator.
Check protective fuses and exchange if necessary. Is the regulator receiving excitation release and are the bridges present at the double terminals I1/I1’, K1/K1’, UH1/UH1’ and WH1/WH1’? Check and eliminate fault.
Fault in the regulator connections.
Check all regulator connections, input and output leads. Eliminate faults.
Regulator defective.
Exchange regulator.
Rotating diodes defective.
Check rotating diodes V1 and voltage surge protector V3 and R11 and exchange if necessary.
Incorrect regulator setting.
Adjust R1 carefully in the anticlockwise direction and turn S1 one or two steps to the right.
Periodic fluctuations in the alternator voltage when operated singly (stability limit)!
34
Malfunction
Cause
Remedy
Alternator voltage fluctuates at irregular intervals.
Temporary interruption in one of the regulator supply leads.
Check connecting leads to the regulator. Check connections at the terminal board of the alternator. Tighten all contact screws and nuts.
Mechanical regulator of the driving machine is sticking.
Check speed regulator of the driving machine. Eliminate fault.
Droop set too low.
Adjust R7 slightly in the clockwise direction on the "COSIMAT N+".
Transformer connections k/I have been bridged by the droop switch.
Open bridge.
Phase angle connection (k/I) of the droop current transformer has been wrongly positioned.
Check connecting leads from the alternator to the regulator. Interchange k/I if necessary. The white secondary connection of the droop current transformer is ”k”.
Droop switch is not in alternator phase ”V”.
Install droop transformer in phase ”V”.
Measuring voltage connections U, V, W wrongly positioned.
Check the sensing lead. "COSIMAT N+" requires a clockwise-rotating field. Interchange U and W if necessary (in the case of anticlockwise rotation).
Droop set too high.
Adjust R7 slightly in the anticlockwise direction on the "COSIMAT N+".
Measuring voltage connections U, V, W wrongly positioned
Check the sensing lead. "COSIMAT N+" requires a clockwise-rotating field. Interchange U and W if necessary (in the case of anticlockwise rotation).
This is affected by the driving machine only. The "COSIMAT N+" affects only the reactive power.
Check the drive motor and its regulator.
Reactive power output too high in parallel operation.
Reactive power output too low in parallel operation.
Active load not equally distributed.
We reserve the right to make technical changes.
35
12. List of figures
Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36
General arrangement diagram . . . . . . . . . . . . . . . . . . Adjusting elements . . . . . . . . . . . . . . . . . . . . . . . Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . Characteristic quantities . . . . . . . . . . . . . . . . . . . . . Trend of the control property . . . . . . . . . . . . . . . . . . . Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . Droop characteristic . . . . . . . . . . . . . . . . . . . . . . . P adjustment range . . . . . . . . . . . . . . . . . . . . . . . Underspeed protection . . . . . . . . . . . . . . . . . . . . . Equivalent control circuit diagram . . . . . . . . . . . . . . . . . Additional module COS . . . . . . . . . . . . . . . . . . . . . Additional module QPF A . . . . . . . . . . . . . . . . . . . . Additional module QPF B . . . . . . . . . . . . . . . . . . . . Additional module QPF C . . . . . . . . . . . . . . . . . . . . Additional module SB2 . . . . . . . . . . . . . . . . . . . . . Additional module TF1 . . . . . . . . . . . . . . . . . . . . . Additional module ES . . . . . . . . . . . . . . . . . . . . . . Additional module UF . . . . . . . . . . . . . . . . . . . . . . Additional module UF3 . . . . . . . . . . . . . . . . . . . . . Additional module SR2 . . . . . . . . . . . . . . . . . . . . . Additional module EI . . . . . . . . . . . . . . . . . . . . . . Additional module UDC2 . . . . . . . . . . . . . . . . . . . . Additional module KP . . . . . . . . . . . . . . . . . . . . . . Additional module ER1 . . . . . . . . . . . . . . . . . . . . . Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal mounting, DSG alternators 52 – 74 . . . . . . . . . . . . External mounting, DSG alternators 52 – 74 . . . . . . . . . . . . Internal mounting, DSG alternators 86 – 125 . . . . . . . . . . . External mounting, DSG alternators 86 – 125 . . . . . . . . . . . Internal mounting, DIG medium-voltage alternators with UN ≤ 11.5 kV External mounting, DIG medium-voltage alternators with UN ≤ 11.5 kV Internal mounting, DIG medium-voltage alternators with UN > 11.5 kV External mounting, DIG medium-voltage alternators with UN > 11.5 kV De-excitation circuit . . . . . . . . . . . . . . . . . . . . . . . Field current/field voltage monitoring . . . . . . . . . . . . . . . Modes of operation of a synchronous machine . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 3 . 4 . 5 . 6 . 6 . 7 . 9 . 10 . 10 . 12 . 14 . 14 . 14 . 14 . 15 . 15 . 15 . 15 . 16 . 16 . 16 . 16 . 17 . 17 . 19 . 21 . 21 . 22 . 22 . 23 . 23 . 24 . 24 . 25 . 25 . 31
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AvK Deutschland GmbH & Co. KG Bunsenstraße 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. KG Dreieich branch Benzstraße 47-49 63303 Dreieich, Germany Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40 e-mail:
[email protected] www.newage-avkseg.com
Bearings Zollern
Power transmission Plain bearings Installation and Operating Instructions ZF
Parts List for Flange Mounted Bearing ZF
1.1 1.2 1.3 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 5.1 5.2 5.3 10
Upper bearing housing* Lower bearing housing* Bearing housing retaining screws* Sealing plug with seal* (Oil inlet for circulated oil) Sealing plug with seal*(Temperature sensor port) Sealing plug with seal* (Connection for heater, sump thermometer or cooler) Sealing plug with seal* (drain) Sealing plug with seal* (oil fill) Oil level sight gauge (or oil outlet for circulated oil) Oil sight window* Eye Bolt* Bearing shell upper half* Bearing shell lower half* Anti-rotation pin* Loose oil ring
15.1 15.2 20.1 20.2 21.1 21.2 25.1 25.2 30.1 30.2 30.3 40.1 40.2 45
Seal carrier Seal carrier retaining screws* Floating labyrinth seal* Spring key for floating labyrinth seal* Floating labyrinth seal (machine side)* Spring key for floating labyrinth seal (machine side)* Bolt on baffle Bolt on baffle retaining screws* Machine seal Machine seal strip Machine seal retaining screws* Upper bearing housing retaining screws Lower bearing housing retaining screws Machine shield
*These parts can only be supplied as sub-assemblies. Spares parts are listed in section 11
990225/h520
2
1
Safety Recommendations
Zollern flange bearings (type ZF) are incorporated into various types of machinery, any safety regulations specific to the machinery must be observed. During bearing operation, assembly, maintenance and repair, accidents and injuries must be avoided at all costs. The following points require special attention: During maintenance and repair ensure that rotating machinery is at a standstill, isolated from electrical supply with interlocks such the supply cannot be resumed unintentionally. Loads and speeds must not exceed those specified in Zollern’s data sheets, drawings or calculation sheets. Rotating parts must be fixed so that accidental movement is not possible. BEWARE: after use bearings will be hot, there is a danger from burning during repairs and maintenance if the bearing is not allowed to cool. The shaft tolerances set out in our specifications and drawings may not be exceeded. The bearing may become detached if screws are allowed to loosen. Tighten the screws to the specified torque. Alterations to the ZF bearing may only be carried out with the express permission of Zollern, who must also be consulted in the event of load specifications being exceeded. Our qualified team of fitters can carry out repairs and service if required avoiding errors caused by untrained personnel.
2
Bearing Types and Designations
Type
Z
Bearing for horizontal mounted shaft
Housing
F
Finned end flange bearing
Cooling
N
Natural convection
Z
Forced oil with external cooling
W
Water cooler in oil sump
Lubrication
L
Cylindrical bore with loose oil ring
Thrust bearing
B
Plain white metal with oil grooves
K
Tapered pad for bi-directional rotation
D
Tapered pad for uni-directional rotation
A
Round tilted pads, spring supported
Q
Without thrust bearing
Note
Insulated bearing shells are designated ‘insulated’
Example :
Finned end flange bearing with forced oil lubrication externally cooled having plain cylindrical bore with loose oil ring. Tapered thrust pad for bi-directional rotation size 9, shaft diameter 90mm
ZFZLK 9-90
3
Introduction
Please pay careful attention to all points covered by this manual to ensure the safe and efficient operation of the bearing. Care needs to be taken to keep all bearing parts and the workplace clean. Provision is made for thermometers (1.6, 1.7), oil level gauges (1.10), oil inlet (1.5) and outlets to be fitted to either side of the bearing. These devices can be fitted to either left or the right as required. Where a bearing is force oil lubricated, the oil outlet pipe is fitted into the tapping for the oil level gauge (1.10). The oil drain plug (1.8), which can also act as an oil flow connection, is positioned at the centre underneath the bearing. With electrically insulated bearings, there is a non-conductive layer on the spherical seat of the bearing housing. This layer is both wear-resistant and temperature-resistant. The shaft seals (see chapter 6 - “shaft seals”) and the anti-rotating pins (5.3) are manufactured from non-conductive material and prevent any spark erosion of either bearing shell or. Any temperature control instrumentation installed by the user should be insulated using appropriate measures, such as isolated protective piping and plastic screws. Zollern can, of course, provide help as and when required. Eyebolts are fastened to the upper part of the bearing to assist handling of the complete and assembled bearing. It is important to remember that they are not suitable for the handling of the assembled machine and that the eyebolts are only to be used as tension elements.
4
Packing
All bearings are delivered fully assembled without oil. The oil ring (10) and other accessories are packed as separate items. The bearings are protected against corrosion and other influences by a preserving film, according to individual application.
3
5
Installation
Once the upper housing (1.1), the seal carrier (15.1), the shaft seals (20.1) and the bearing seal (5.1 and 5.2) have been dismantled, carefully clean the interior of the bearing and the bearing shell and check for any damage caused during transport. Ensure that the shaft is clean and that dimensions and tolerances correspond to our recommendations. We recommend that the appearance of the bearing surface on the shaft is checked and that it is checked that non-moving seals have not become jammed in the shaft (see chapter 6 “shaft seals”). Proceed with installation as follows: Align the cleaned lower part of the housing (1.2) with the machine frame and fasten. Secure the machine seal (30.1) inside the machine housing (the machine seal is not supplied as standard and must therefore be ordered separately). Apply a film of oil to both the spherical seats in the lower part of the bearing housing and to the lower part of the bearing shell (5.2) (use the same oil as is to be used during operation of the bearing). Place the lower part of the bearing shell onto the shaft seat and turn it to the correct position in the lower part of the housing. Take care that thrust bearing surfaces are not damaged whilst the shell is turned. Align the surface of the shell with that of the housing. Now follows assembly of the loose oil ring (10), which must first be disassembled. Position both halves of the oil ring on the shaft and around the lower half of the shell using the notch provided, then press both halves together on the dowel pins. Following this, tighten the fixing screws to the following torque values:
Bearing Size
09 - 14
18 - 28
Torque (Nm)
1.4
2.7
Apply a film of oil to both the shaft seat and the upper part of the bearing shell (5.1). Lower the shaft into the lower part of the shell (5.2) and place the upper part of the shell onto the lower part (it is impossible to turn both halves of the shell together as they would become misaligned). Insert the flange-side seal (21.1), this is usually a floating labyrinth seal (see chapter 6: “shaft seals”). Coat the surface of the split line in the lower part of the bearing housing with a thin film of non-hardening sealing compound. Very slowly lower the upper part of the housing (1.1), rotate it in the machine frame and position it on the flange. Ensure that during lowering the already assembled flange-side seal slides locate into the groove provided. Avoid jamming at all costs. The upper part must be correctly aligned (to ensure this one possibility is to pass a rod through the upper through hole and align accordingly). Tighten the cover screws (1.3) crossways and then tighten the flange screws (40.1) to the following torque values :
Bearing size
9
11
14
18
22
28
Torque (Nm)
89
89
215
420
725
1450
The cover screws (1.3) are to be tightened crossways as follows:
Bearing size
9
11
14
18
22
28
Torque (Nm)
71
71
172
336
580
1160
With machines that are prone to vibration, it is essential that measures be taken to prevent screws from loosening. To this end secure with Loctite or similar thread locking compound. Prepare the exterior floating labyrinth seal (20.1) for assembly in the same way as the flange-side seal and attach to the shaft before fastening the seal carrier (15.1) to the housing as follows. Coat the split lines and flange surfaces of the seal carrier with non-hardening sealing compound. Place the seal carrier around the floating labyrinth seal, push both into the bearing housing and tighten the seal carrier screws (15.2) to the following torque values :
Bearing Size
09 - 14
18 - 28
Torque (Nm)
10.5
26
4
5.1
Additional Information for Bearings with External Oil Supply
When using an external oil supply the pipe diameters should be chosen such that the inlet flow does not exceed 1.5 m/s and the outlet flow 0.15m/s. If the inclination of the oil outlet pipes for structural or design reasons cannot be set to 15° , pipes with correspondingly larger diameters need to be used. Pipes with inclinations or diameters which are too small may create back-flow, which could in turn lead to overflowing or leakage. Heat-treated (welded or hot-worked) pipes and/or those showing any signs of rust or dirt must be scoured and cleaned prior to assembly. Following assembly of the pipes the entire oil circulating system must be flushed to prevent dirt entering the bearing or fittings. Prior to cleaning all measuring and switch fittings (pressure control, flow gauge) and their connections must be removed. The bearings must not be left intact during cleaning, and following cleaning all filters must be rinsed. All connections to the bearing must be free of vibration and tension.
5.2
Additional Information for Bearings with Water Cooler in the Oil Sump
When attaching the water cooler care must be taken to ensure that there are no leaks from the cooler or its connecting pipes. The joint seals must not be damaged. During fitting a stop tap or valve should be provided in the inlet. Any oil should be free to drain from the housing (no pressure should be required). The cooling flow can be in either direction.
6
Shaft Seals
Zollern bearings can be supplied with various seal types or seal systems depending on the required application, with seals conforming to DIN 40050 or IEC 529. Special seals can be supplied for particular applications on request.
6.1
Floating Labyrinth Seals
For standard applications ZF bearings are equipped with floating labyrinth seals (see fig. 2) which achieve IP44. The labyrinth seals float on the shaft at circumferential speeds above 100 m/s. They are manufactured from a rigid, unbreakable and temperature resistant polymer. The seals are seated within a seal carrier or directly seated in the housing such that they are not subject to loadings due to radial shaft displacements.
Oil drain holes are provided in the lower part of the floating labyrinth seal. An anti rotation pin on the split line prevents the seal from being assembled incorrectly and damaged. Build the seals up prior to bearing assembly so that the hook and eye of the spring key (20.2 & 21.2) are separated. Prepare the seal for installation and coat the surface of the split line and the exterior of the spring guide (see fig. 2) with a thin layer of non-hardening sealing compound. Place the lower part of the seal onto the shaft and turn it into the correct position (the oil drain holes in the seal must be facing towards the bearing and the anti rotating pin must sit in the groove of the split line). Place the upper part of seal onto the lower Insert the spring key through the sealing groove and lock into place. Check the alignment of the seal and housing split line
6.2
Floating Labyrinth Seal with Bolt on Baffle
The bolt on baffle can be combined with either a floating labyrinth seal (chapter 6.1) or a rigid seal (chapter 6.4) to achieve IP55. The inserted seal strip is temperature resistant withstanding high circumferential speed. The coefficient of friction is minimal as is the ‘stick/slip’ coefficient. The electrical insulation properties are very good and independent of temperature and environmental influences.
5
Insertion to be done as follows: Spread the sealing compound onto the surface of the split line and coat the movement surface with the seal carrier of the floating labyrinth seal (fig. 3) Next gently press the lower part (recognised by the drain hole) from underneath against the shaft and tighten the fixing bolts equally. Finally position the upper part, align on the split line and attach with the bolts.
6.3
Floating Labyrinth Seal with Labyrinth Ring
The labyrinth is clamped onto the shaft and inserted into a groove in the seal carrier of the floating labyrinth seal (fig. 4), thus preventing dirt and water from entering the bearing. The groove can be filled with grease where necessary.
After placing onto the shaft the labyrinth ring must be so placed that it is not possible for it to run into the groove. The thrust movement of the shaft is limited.
6.4
The Rigid Seal
Fig. 5 shows a rigid seal with two separate labyrinth systems. Where axial movement is minimal a shaft collar can be provided between the labyrinths.
A thin layer of sealing compound initially retains the rigid seal. During assembly the lower half of the seal is lightly pressed onto the shaft from below and the screws then tightened (during operation the shaft is raised). ATTENTION The baffles must be removed during assembly and disassembly of the shaft or damage to the shaft may ensue.
6
7
Commissioning
Having removed the oil sight glass (1.11) or the plug (1.9) fill to level with the recommended oil grade. The oil is at the correct level when it reaches the middle of the oil level glass (1.10). The minimum oil level is when the oil only reaches the lower part of the sight level glass when the machine is stationary. WARNING Insufficient oil level will lead to ineffective lubrication, bearing overheating and subsequent damage leading to failure. Too high a level of oil will not hinder the operation of the bearing, but could lead to leakage at the seals. Prior to commissioning of the bearing it must be checked for leaks. All oil port plugs and securing screws are correctly fitted and tightened. ATTENTION Should, at any time during commissioning or operation, the bearing temperature exceed that specified by Zollern the machine should be stopped and the causes investigated.
8
Maintenance
The oil level must be checked at regular intervals with the machine at standstill. The minimum oil level is when the oil only reaches the lower part of the sight level glass. The bearing housing must be kept clean as heat transfer can be hindered by dirt and dust leading to bearing overheating and subsequent damage leading to failure. Should, during operation, there be unusual variations in bearing temperature or oil level the causes must be investigated. Our technicians are available should any assistance be required.
8.1
Oil change intervals
For self contained and bearings using mineral oils we recommend flushing and oil change after 8000 operating hours, for forced oil lubricated bearings we recommend an interval of 20000 hours. Longer intervals may be possible subject to Zollern approval. Shorter intervals are necessary where there is frequent starting or where oil temperatures are high or where there is an excessively dirty environment. To change the oil, take out the oil drain port which is positioned at the centre beneath the bearing (allow the oil to drain whilst hot). Should unusual oil discoloration or smell be apparent the causes must be investigated. Should any chemical cleaning compounds be used these must be thoroughly flushed away prior to further operation. The oil is refilled through the oil sight glass (1.11) or plug (1.9). Use only the recommended oil grade as shown by the manufacturer’s plate. The oil is at the correct level when it reaches the middle of the oil level glass (1.10). There is always a possibility of overfilling - too high a level of oil will hinder the operation of the bearing. WARNING If regular checks are not made there is a chance of insufficient oil leading to ineffective lubrication, bearing overheating and subsequent damage leading to failure.
8.2
Inspection
Should unusual oil colour changes or increases in temperature be apparent an inspection must be made. Remove the upper half of the bearing housing (1.1) leaving the lower half in place. Prior to disassembly thoroughly clean the bearing casing such that no dirt can accidentally enter the bearing itself.
8.3
Disassembly Loosen the fixing screws to the upper half of the bearing (40.1) and the split line screws (1.3) and the screws (15.2) on the upper half of the seal carrier. Raise the upper half of the housing such that the bearing is split then completely remove the upper bearing housing from the frame. Remove the upper part of the seal carrier (15.1). Dismantle the floating labyrinth seals (20.1 & 21.1) by raising the upper half and tilting it then open the spring key and dismantle together with the lower half. Carefully raise the upper half of the bearing shell (5.1). Release the loose oil ring (10) screws, separate and remove both parts. Remove any probes or sensors if present. Raise the shaft far enough to give sufficient clearance to turn the lower shell (5.2) half through 180° and lift it away.
8.4
Visual Check
During disassembly check that all bearing surfaces remain in good condition. Bearing in mind the length of bearing service the shell should show consistent polishing of the surface. Any light score marks should be smoothed prior to rebuilding of the bearing. The shaft seals should be changed should they show excessive wear or have broken edges.
7
9
Transport and Storage
During transportation of the machine the bearings should never be subject to shock loading, and must be protected from environmental humidity. Care must be taken to prevent dry sliding within the bearing. Storage facilities must be dry and not subject to severe variations in temperature or humidity. In good conditions the bearings can be stored for up to one year.
10 Troubleshooting 10.1 Increased Bearing Temperature Cause : lack of lubrication Solution : Regularly check the oil level, inspect the bearing surface for score marks. Check that the filter does not restrict oil flow.
10.2 Excessive scoring of the bearing shell Cause : Dirt particles in oil Solution : Change oil (possibly polish out scores on bearing surface). Change oil filter.
11 Ordering Spare Parts Every bearing has a part and order number embossed onto the manufacturer’s plate. In order to ensure the delivery of the correct parts please quote these numbers in all correspondence or return the part to Zollern for repair or replacement. The following parts are supplied as sub-assemblies:
Sub-assembly
Position (fig. 1)
Bearing Shell
5.1 to 5.3
Seal carrier
Bearing housing (sizes 9-28) : 1.1 & 1.2
Loose oil ring
10
Seal Carrier
15.1
Floating labyrinth seal (machine side)
21.1 & 21.2
Floating labyrinth seal (exterior)
20.1 & 20.2
Bolt on baffle with Teflon bronze strips
25.1
Labyrinth ring
N/A
Machine seal with or without Teflon bronze strips
(30.1 & 30.2)
Zollern Vertriebs-GmbH + Co. Werk Herbertingen -GleitlagertechnikHeustr.1 D-88518 Herbertingen Tel.: +49.7586.959-0 Fax: +49.7586.959-715
8
Zollern Vertriebs-GmbH + Co. KG Lagertechnik Heustraße 1 D-88518 Herbertingen
ISO Viskositäts klasse
ISO Viskositäts klasse
Kinematische 2 Viskosität [mm /s] [cSt]
40 ° C Class of viscosity ISO
Schmieröle für ZollernQPF Z-Lager
100 ° C
Kinematische 2 Viskosität [mm /s] [cSt]
40 ° C
Kinematic Viscosity [mm2/s] [cSt]
Class of viscosity ISO
40 ° C
100 ° C
VG 22
22
4,4
FLUID RSL
VG 32
32
5,5
VG 46
46
VG 68
100 ° C
Kinematic Viscosity [mm2/s] [cSt]
TOTAL ELF FINA
40 ° C
100 ° C
VG 22
22
4,3
AZOLLA ZS
FLUID RSL
VG 32
32
5,4
AZOLLA ZS
6,9
FLUID RSL
VG 46
46
6,8
AZOLLA ZS
68
8,8
FLUID RSL
VG 68
68 68
8,7 8,8
AZOLLA ZS CARTER EP
VG 100
100
11,2
FLUID RSL
VG 100
100 100
11,2 11,0
AZOLLA ZS CARTER EP
VG 150
150
14,3
FLUID RSL
VG 150
150
15
CARTER EP
VG 220
220
18,3
FLUID RSL
VG 220
220
19
CARTER EP
AVIA 89003 Ulm 85258 Weichs / München 08451 Chrimmitschau
ISO Viskositäts klasse
Telefon (0731) 3999-0 (08136) 930820 (03762) 7002-0
Kinematische Viskosität [mm2/s] [cSt]
40 ° C Class of viscosity ISO
TOTALFINA Deutschland GmbH Kirchfeldstraße 61 40217 Düsseldorf Tel.: 0211 / 9057-0
ISO Viskositäts klasse
100 ° C
Kinematische Viskosität [mm2/s] [cSt]
40 ° C
Kinematic Viscosity [mm2/s] [cSt]
Class of viscosity ISO
40 ° C
100 ° C
VG 22
22
4,37
Shell Morlina 22
VG 46
46
6,85
VG 68
68
VG 100
100 ° C
Kinematic Viscosity [mm2/s] [cSt]
40 ° C
100 ° C
VG 22
21
4,2
Mobil DTE 22
Shell Morlina 46
VG 32
30
5,3
Mobil DTE Oil Light
8,85
Shell Morlina 68
VG 46
43
6,7
Mobil DTE Oil Medium
100
11,2
Shell Morlina 100
VG 68
64
8,6
Mobil DTE Oil Heavy Medium
VG 150
150
15
Shell Morlina 150
VG 100
84
10
Mobil DTE Oil Heavy
VG 220
220
18,3
Shell Morlina 220
VG 150
143
14
Mobil DTE Oil Extra Heavy
VG 460
460
30
Shell Morlina 460
VG 220
204
18
Mobil DTE Oil BB
Deutsche Shell GmbH Überseering 35 2000 Hamburg 60 Tel.: (040) 6324-0
Mobil Schmierstoff GmbH Neuhöfer Brückenstraße 127 - 152 21107 Hamburg Tel.: 040 / 75191-109
Spare Parts
Ersatzteile: 1.2.1 poE
Spare Parts: 1.2.1 poE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Flange plate (2 parts) Endshield DS Air baffle DS Stator housing Seal Retainer Exciter Stator Endshield NDS Sleeve Bearing Cover for seal carrier PT100 NDS Anti Condensation Heater PT100 DS Brush holder for Rotor Grounding Brusches for Rotor Grounding
Flanschblech 2-teilig Lagerschild AS Luftblende AS Statorgehäuse Maschinendichtung Erreger-Stator Lagerschild BS Gleitlager Abdeckhaube Diodenträger PT100 BS Stillstandsheizung PT100 AS Bürstenhalter für Rotorerdung Kohlen für Rotorerdung
www.newage-avkseg.com infoav
[email protected]
AvK Deutschland GmbH & Co. KG Bunsenstr. 17 85053 INGOLSTADT GERMANY Phone: +49(0)841-792-0 Fax: +49(0)841-792-250
AvK Deutschland GmbH & Co. KG Dreieich branch Benzstr. 47-49 63303 Dreieich GERMANY Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40
Ersatzteile: 2.2.1 oE
1 2 3 4 5 6 7 8 9 10 11 12
Spare Parts: 2.2.1 oE
Ventilator Ventilatorbuchse Passfeder für Ventilatorbuchse Rotor komplett Spulenhalter Wellensicherungsring für Erreger-Rotor Passfeder für Erreger-Rotor Erreger-Rotor Gleichrichterträger Rotierender Gleichrichter Überspannungs-Ableiter Wellensicherungsring für Hilfserreger-RotorBuchse
www.newage-avkseg.com
[email protected]
Fan Fan hub Key for fan hub Rotor complete Coil holder Circlip for Exciter Rotor Key for Exciter Rotor Exciter Rotor Rectifier Carrier Rotating Rectifier Overvoltage Arrestor Circlip for Aux. Exciter Rotor Bushing
AvK Deutschland GmbH & Co. KG Bunsenstr. 17 85053 INGOLSTADT GERMANY Phone: +49(0)841-792-0 Fax: +49(0)841-792-250
AvK Deutschland GmbH & Co. KG Dreieich branch Benzstr. 47-49 63303 Dreieich GERMANY Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40
Ersatzteile: 3.0 NSoW
1 2 3 4 5 6 7 8 9 10
Spare Parts: 3.0 NSoW
Klemmkasten Unterteil Isolator Kupferschiene U1, V1, W1 Kupferschiene Sternpunkt Isolatorbefestigungsbolzen Statik Wandler Klemmenkasten Deckel Muffe Oberteil Abschlussplatte Muffe Unterteil
www.newage-avkseg.com
[email protected]
Terminal Box lower part Insulator Copper Bar U1, V1, W1 Copper Bar Star Point Insulator Fixing Bolts Static Transformer Terminal box cover Bushing upper part Endcover Plate Bushing Lower Part
AvK Deutschland GmbH & Co. KG Bunsenstr. 17 85053 INGOLSTADT GERMANY Phone: +49(0)841-792-0 Fax: +49(0)841-792-250
AvK Deutschland GmbH & Co. KG Dreieich branch Benzstr. 47-49 63303 Dreieich GERMANY Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40
Ersatzteile: 401
Spare Parts: 401
1 2 3 4 5 6 7 8 9 10 11
Auxiliar terminal box Serial resistor Rectifier Fuse for Cosimat N Voltage regulator Cosimat N Power factor regulator Additional module Aux. terminal box cover Terminal in a row U - bar Gland plate
Hilfsklemmenkasten Vorwiderstand Gleichrichter Sicherung für Cosimat N Spannungsregler Cosimat N Cosinus phi – Regler Zusatzbaustein Deckel für Hilfsklemmenkasten Reihenklemmen U-Schiene Abschlussplatte
www.newage-avkseg.com
[email protected]
AvK Deutschland GmbH & Co. KG Bunsenstr. 17 85053 INGOLSTADT GERMANY Phone: +49(0)841-792-0 Fax: +49(0)841-792-250
AvK Deutschland GmbH & Co. KG Dreieich branch Benzstr. 47-49 63303 Dreieich GERMANY Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40
Ersatzteile: 6.0 obi
Spare Parts: 6.0 obi
1 2 3 4 5 6 7 8 9
Copper Bar Copper Bar Copper Bar Copper Bar Over Voltage arrestor Cable link Rotating Rectifier Holding device Rectifier Carrier
Kupferschiene Kupferschiene Kupferschiene Kupferschiene Überspannungsableiter Kabelbrücke Rotierende Gleichrichter Halterung Gleichrichterträger
www.newage-avkseg.com
[email protected]
AvK Deutschland GmbH & Co. KG Bunsenstr. 17 85053 INGOLSTADT GERMANY Phone: +49(0)841-792-0 Fax: +49(0)841-792-250
AvK Deutschland GmbH & Co. KG Dreieich branch Benzstr. 47-49 63303 Dreieich GERMANY Phone: +49(0)6103-5039-0 Fax: +49(0)6103-5039-40
Technical Data
Technische Daten / technical data Nenndaten / nominal data Leistung SN: 1499 kVA
cos ϕ:
rating power
p.f.
Spannung U N:
DSG
L1-10
0,80
Strom IN:
450 V
voltage
99
1923 A
current
Frequenz f:
60 /s
10 polig
frequency
poles
Drehzahl n:
720 /min
speed
Reaktanzen und Zeitkonstanten / reactances and time constants xd: xq: 1,95 p.u. 0,98 p.u.
Td0':
1,86 s
xd':
0,285 p.u.
xq':
0,98 p.u.
Td':
0,27 s
xd'':
0,198 p.u.
xq'':
0,218 p.u.
Td'':
0,017 s
x2:
0,208 p.u.
x0:
0,059 p.u.
T a:
0,045 s
Wirkungsgrad / efficiency 1/4*PN
2/4*PN
3/4*PN
4/4*PN
η [%] p.f.=0.8
93,60
95,30
95,40
95,40
η [%] p.f.=0.9
93,80
95,85
96,10
96,10
η [%] p.f.=1.0
94,00
96,40
96,80
96,80
Kurzschlußdaten / short circuit data p.u.
Ik'':
9713 A
iS:
24722 A
Ik:
5770 A
Mk2:
Anfangskurzschlußwechselstrom (3~) / initial short circuit current ( 3~)
5,05
Stoßkurzschlußstrom (3~) / max. peak current (3~)
12,85
Dauerkurzschlußstrom (3~) / sustained short circuit current (3~)
3,00
130,5 kNm
Stoßkurzschlußmoment (2~) / initial short circuit torque (2~)
6,56
Mf:
280,6 kNm
Max.Fehlsynchronisationsmoment / max. faulty synchron.torque
MSN:
19,88 kNm
Nennscheinmoment / rated kVA torque=
1,00
MN: dU': dSmax.<=
15,91 kNm -22,2 % 789 kVA
Nennmoment / rated torque
0,80
14,11
Transienter Spannungseinbruch bei Nennlaststoß / TVD at rated load application Max. Laststoß bei p.f.0.2 mit dU'<=15% / Max. load application at p.f.0.2 for TVD<=15%
Sonstige Daten / other data 2 204 kgm
Trägheitmoment J:
*
moment of inertia 3 2,0 m /s
Kühlluftmenge Q L: cooling air volume
Schutzart: enclosure
Gewicht m:
6700 kg*
weight
Kühlmitteltemp.:
45 °C
cooling medium temp
IP23 with air inlet filter
Isolationsklasse:
H
insulation class
Bemerkungen / remarks AvK. No. 81 27280-81-82 A002 Temperature rise according to F Voltage/Frequency range according to EN60034-1,zone A Classification GL, 45°C Solas Ch.II-2 03.05.05
*exact values see valid drawing
Identical to AvK No. 81 26493/94/95/96 A002 Identical to AvK. No. 81 26106/107 A002
Ga
Alle Angaben sind gemäß VDE 0530, IEC600 34
All data are in accordance to VDE 0530, IEC600 34
Type:
Technische Daten selbstregelnden Drehstrom-Synchrongenerator 1.1 Rev. 0 technical data for self regulating three phase alternator Projekt: AvK-Order: Cegielski 81 27280-81-82 A002
DSG 99 L1-10
Leistungsdiagramm / Capability diagramm 1 0,9
active power P (p.u.)
0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1
leading Wirkleistung
AvK Deutschland GmbH & Co.KG Bunsenstr.17 85053 Ingolstadt
Cos phi 0,95
reactive power Q (p.u.) Cos phi 0,9
cos phi 0,8
1,20
1,10
1,00
0,90
0,80
0,70
0,60
0,50
0,40
0,30
0,20
0,10
-0,1
0,00
-0,10
-0,20
-0,30
-0,40
-0,50
-0,60
-0,70
-0,80
0
lagging cos phi 0,6
Datum / date :
cos phi 0,4
cos phi 0,2
Kontrolle TBR / controll TBR : 03.05.05
Gamo
2.1
Technische Daten selbstregelnden Drehstrom-Synchrongenerator technical data for self regulating three phase alternator Type:
DSG 99 L1-10
Projekt:
Cegielski
AvK-Order:
Rev. 0
81 27280-81-82 A002
Inversstrom / negative sequence current I2/IN = f(t) 1,5 1,4 1,3 I22 t = 20 p.u.
1,2 1,1
I2 / IN [p.u.]
1 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 I2 (∞) = 0.08 p.u.
0,1 0 100
101
102
103
104
105
106
t [s]
Bemessungsdaten: Type rating for this application and requirements: SN/kVA
1499
Kriterien für Inversstrom:
IN/A
1923
Criterias for negative sequence current:
UN/V
450
fN/Hz
60
Kurzzeitbetrieb Transient operation: Dauerbetrieb Continuous operation:
nN/rpm power factor
720 0,80
Protection
IP23
cooling air °C temp.rise
(I2/IN)2*t <=20s I2/IN <= 0,08 p.u.
45 F
AvK Deutschland GmbH & Co.KG Bunsenstr.17 85053 Ingolstadt
Datum / date : 03.05.05
Kontrolle TBR / controll TBR : Gamo
Technische Daten selbstregelnden Drehstrom-Synchrongenerator technical data for self regulating three phase alternator Type:
DSG 99 L1-10
Projekt:
AvK-Order:
Cegielski
3.1 Rev. 0
81 27280-81-82 A002
Überlastbarkeit / overload capability I/IN = f(t) 5 4,5 4
I / IN
3,5 3 2,5 2 1,5 1 0 10
5s
SN/kVA
1499
IN/A
1923
UN/V
450
fN/Hz nN/rpm
720
power factor
0,80
Protection
IP23
101
30 s
102
103
t [s]
45
temp.rise
F
AvK Deutschland GmbH & Co.KG Bunsenstr 17 85053 Ingolstadt
104
Strom/Zeit Kriterien: Current/time characteristics: 2 (I/IN) *t =45s 1,5*IN für 30s 1,1*IN für 1 h in 6 h
60
cooling air °C
60 min
Datum / date : 03.05.05
Kontrolle TBR / controll TBR : Gamo
Technische Daten selbstregelnden Drehstrom-Synchrongenerator technical data for self regulating three phase alternator Type:
Projekt:
DSG 99 L1-10
Cegielski
AvK-Order:
4.1 Rev. 0
81 27280-81-82 A002
Short circuit decrement curve ( symmetrical short circuit current envelope Ik`` ) 12
10
Ik``/IN [ p.u.]
8
6
4
2
0 0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
t [s]
Bemessungsdaten:
Short circuit decrement curve without AVR
Type rating for this application and requirements:
and with AVR (min. value at 3phase short circuit =300% In for max.5s)
SN/kVA
1499
IN/A
1923
UN/V
450
fN/Hz
60
nN/rpm
720
power factor
0,80
Protection
IP23
cooling air °C
45
temp.rise
F
AvK Deutschland GmbH & Co.KG Bunsenstr.17 85053 Ingolstadt
Datum / date : 03.05.05
Kontrolle TBR / controll TBR : Gamo
