Professional Documents
Culture Documents
Synchronous Alternators
G Line
Alternadores Sincrnicos
Lnea G
Alternadores Sncronos
Linha G
Installation, Operation and Maintenance Manual Manual de Instalacin, Operacin y Mantenimiento Manual de Instalao, Operao e Manuteno
www.weg.net
Installation, Operation and Maintenance Manual Manual de Instalacin, Operacin y Mantenimiento Manual de Instalao, Operao e Manuteno
Document # / N do documento: 10680382 Models / Modelos: GTA, GTF, GTW, GTK, GPA, GPF, GPW, GSA, GSF, GSW and GSK Language / Idioma: English / Espaol / Portugus Revision / Revisin / Reviso: 04 May / Mayo / Maio, 2012
10680382 - Synchronous alternators - G line l 3
www.weg.net
www.weg.net
Portugus 5
Espaol
English
www.weg.net
www.weg.net
Dear Customer,
Thank you for purchasing the WEG alternator. It is a product developed with quality and efficiency levels that ensure optimal performance. Electricity plays a role of major importance for the comfort and well-being of humanity. Since the alternator is responsible for generating this energy, this must be identified and treated as a machine whose characteristics include certain care, among them storage, installation, operation and maintenance. All efforts were made to the information contained herein are truthful to the settings and use of the alternator. Thus, we recommend reading this manual carefully before proceeding to installation, operation or maintenance of the alternator to ensure continuous and safe operation of the alternator and ensure your safety and of your facilities. If doubts persist, please refer to WEG. Always keep this manual near the alternator, so it can be consulted whenever necessary.
ATTENTION
1. It is imperative to follow the procedures in this manual for the warranty to be valid; 2. The procedures for installation, operation and maintenance of the alternator should be done by qualified people.
NOTES
1. Reproduction of information in this manual, in whole or in part, is permitted provided that the source is quoted; 2. If this manual is lost, a copy in electronic format may be obtained by contacting www.weg.net or another printed copy may be requested from WEG.
www.weg.net
www.weg.net
INDEX
1 INTRODUCTION...................................................................................................13
1.1 1.2 SAFETY WARNINGS IN THE MANUAL...............................................................................................13 NOMENCLATURE..............................................................................................................................14
3.3
4 INSTALLATION ....................................................................................................22
4.1 4.2 4.3 4.4 4.5 INSTALLATION LOCATION ................................................................................................................22 DIRECTION OF ROTATION ................................................................................................................22 PROTECTION DEGREE .....................................................................................................................22 COOLING ..........................................................................................................................................22 INSULATION RESISTANCE................................................................................................................22 4.5.1 Safety instructions .................................................................................................................22 4.5.2 General considerations..........................................................................................................22 4.5.3 Measurement of the stator winding .......................................................................................22 4.5.4 Measurement in the rotor winding, exciter and accessories...................................................23 4.5.5 Minimum insulation resistance...............................................................................................23 4.5.6 Polarization index ..................................................................................................................23 4.5.7 Conversion of the measured values.......................................................................................24 PROTECTION ....................................................................................................................................24 4.6.1 Thermal protection ................................................................................................................24 4.6.1.1 Temperature limits for the windings........................................................................24 4.6.1.2 Thermal protection for the bearings .......................................................................25
10680382 - Synchronous alternators - G line l 9
4.6
www.weg.net
4.7 4.8
4.9
4.6.1.3 Temperatures for alarm and shutdown.................................................................. 25 Space heater ........................................................................................................................ 25 4.6.2.1 Auxiliary winding protection ................................................................................... 25 4.6.3 Protection of the diodes........................................................................................................ 25 4.6.4 Protection of the voltage regulator ........................................................................................ 26 4.6.4.1 Protection against underfrequency........................................................................ 26 VOLTAGE REGULATOR.................................................................................................................... 26 4.7.1 Maintenance of the short-circuit current ............................................................................... 26 ELECTRICAL FEATURES .................................................................................................................. 26 4.8.1 Electrical connections ........................................................................................................... 26 4.8.1.1 Main connection.................................................................................................... 26 4.8.1.2 Grounding ............................................................................................................. 26 4.8.1.3 Electronic voltage regulator ................................................................................... 27 4.8.1.4 Terminal identification............................................................................................ 27 4.8.2 Connection diagrams ........................................................................................................... 28 4.8.2.1 Three-phase alternators 12 terminals (frames 160 to 355) ............................... 28 4.8.2.2 Three-phase alternators - 6 terminals - (frames 160 to 355) .................................. 29 4.8.2.3 Three-phase alternators with single-phase connection - 12 terminals ................... 30 4.8.2.4 Electrical connections of the voltage regulator....................................................... 30 MECHANICAL FEATURES ................................................................................................................ 31 4.9.1 Bases and foundations ......................................................................................................... 31 4.9.2 Alignment and leveling .......................................................................................................... 31 4.9.2.1 Alternators with double bearing (B35T or B3T) ...................................................... 31 4.9.2.2 Alternators with single bearing (B15T) ................................................................... 31 4.9.3 Coupling ............................................................................................................................... 31 4.9.3.1 Alternators with double bearing (B35T / B3T) ........................................................ 31 4.9.3.1.1 Direct coupling .................................................................................... 31 4.9.3.1.2 Coupling by pulleys and belts.............................................................. 32 4.9.3.2 Alternator with single bearing (B15T) ..................................................................... 32 4.9.3.2.1 Measure G........................................................................................ 32 4.9.3.2.2 Change of measure G ......................................................................... 32 4.6.2
5 COMMISSIONING ................................................................................................ 34
5.1 5.2 5.3 5.4 PRELIMINARY TEST.......................................................................................................................... 34 INITIAL OPERATION.......................................................................................................................... 34 SHUTDOWN ..................................................................................................................................... 34 ALTERNATORS IN PARALLEL .......................................................................................................... 34 5.4.1 With each other and / or with the network ............................................................................ 34
6 MAINTENANCE ................................................................................................... 36
6.1 6.2 6.3 6.4 6.5 EMERGENCY GENERATOR SETS .................................................................................................... 36 CLEANING ........................................................................................................................................ 36 NOISE ............................................................................................................................................... 36 VIBRATION........................................................................................................................................ 36 BEARINGS ........................................................................................................................................ 36 6.5.1 Lubrication............................................................................................................................ 36 6.5.1.1 Type and amount of grease .................................................................................. 36 6.5.1.2 Instructions for lubrication ..................................................................................... 37 6.5.1.3 Procedures for relubrication of bearings ................................................................ 37 6.5.2 Exchange of Bearings........................................................................................................... 37 6.5.2.1 Alternator with single bearing - B15T..................................................................... 37 6.5.2.2 Alternator with double bearing - B35T................................................................... 37 6.5.2.3 Replacement of the bearing .................................................................................. 37 MAINTENANCE OF THE EXCITER..................................................................................................... 38 6.6.1 Exciter .................................................................................................................................. 38 6.6.2 Test on the diodes................................................................................................................ 38 6.6.3 Replacement of the diodes................................................................................................... 38 6.6.4 Test on varistor..................................................................................................................... 38 6.6.5 Replacement of the varistor .................................................................................................. 38
10680382 - Synchronous alternators - G line
6.6
10 l
www.weg.net
6.6.6 Test on the capacitor ............................................................................................................39 6.6.7 Replacement of the capacitor................................................................................................39 AIR FLOW ..........................................................................................................................................39 COMPLETE INSPECTION ..................................................................................................................39 DISASSEMBLY, ASSEMBLY AND LIST OF PARTS - GTA160 ............................................................40 DISASSEMBLY, ASSEMBLY AND LIST OF PARTS - GTA200 ............................................................41 DISASSEMBLY, ASSEMBLY AND LIST OF PARTS - GTA250 ............................................................42 DISASSEMBLY, ASSEMBLY AND LIST OF PARTS - GTA315 TO GTA400 ..........................................43 DISASSEMBLY OF THE EXCITER ROTOR GTA315 TO GTA400 .........................................................44 MAINTENANCE PLAN........................................................................................................................44
11
www.weg.net
12 l
www.weg.net
1 INTRODUCTION
This manual aims the assistance of the alternators G line. Alternators with specialties can be provided with specific documents (drawings, wiring diagrams, curve features, etc.). These documents must be carefully evaluated with this manual before proceeding with the installation, operation or maintenance of the alternator. Refer to WEG if there is a need for some additional clarification. All procedures and standards contained in this manual should be followed to ensure the smooth operation of the alternator and safety of professionals involved in its operation. Observing these procedures is also important to ensure the warranty on the alternator. Therefore, we recommend reading this manual thoroughly before installation and operation of the alternator. If doubts persist, please refer to WEG.
ATTENTION
In case of exchange of the components mentioned in this manual the manufacturing date of the alternator must be observed in relation to the date of review of the manual.
DANGER
Failure to observe the procedures recommended in this warning may result in substantial property damage, serious injury or death.
ATTENTION
Failure to observe the procedures recommended in this warning may result in property damage.
NOTE
The text with this warning is intended to provide important information for the correct understanding and proper functioning of the product.
13
www.weg.net
1.2 NOMENCLATURE G T A 16 1 A
G - Synchronous Machine - G Line EXCITATION CHARACTERISTIC T - Brushless alternator with auxiliary coil P - Brushless alternator with auxiliary exciter (PMG) S - Brushless alternator without auxiliary coil and without auxiliary exciter TYPE OF COOLING A - Open self-ventilated F - Closed with heat exchanger air-air W - Closed with heat exchanger air-water K - Closed with finned frame FRAME - IEC 16 - frame 160 20 - frame 200 ... FRAME LENGTH 1 - Short frame 2 - Medium frame 3 - Long frame VOLTAGE A - Three-phase - 12 terminals - 480/240V - 440/220V - 380/190V - 208V (60 Hz) Aaaaaaaaaaaaaaaaaaaaaaaa 400/200V, 380/220/190V , 50Hz) B - Three-phase - 6 terminals - 220V/60Hz or 190V/50Hz C - Three-phase - 6 terminals - 380V/60Hz D - Three-phase - 6 terminals - 440V/60Hz or 380V/50Hz E - Three-phase - 6 terminals - 480V/60Hz or 400V/50Hz F - Three-phase - 6 terminals - 600V/60Hz or 575V/60Hz G - Three-phase - 6 terminals - 208V/60Hz H - Three-phase - 6 terminals - 415V/50HZ I - Three-phase - 6 terminals - 2300V/60Hz J - Three-phase - 6 terminals - 4160V/60HZ K - Three-phase - 6 terminals - 6600V/60Hz L - Three-phase - 6 terminals - 13800V/60Hz M - Three-phase - 6 terminals - 3300V/50Hz N - Three-phase - 6 terminals - 6000V/50Hz O - Three-phase - 6 terminals - 11000V/50Hz P - Three-phase - 12 terminals - 415/240/208/120V (50Hz) Z - Another Voltage APPLICATION I - Industrial M - Marine T - Telecommunications N - Naval E - Special COMPLEMENTARY CODE Code referent to alternator power
I SR
14 l
www.weg.net
2 GENERAL INSTRUCTIONS
Professionals who work with electrical installations, either in assembly, operation or maintenance, should be continuously updated and be informed about rules and safety regulations governing the service and are advised to observe them strictly. Before the initiation of any work, the responsible person must ensure that everything was properly noticed and alert operators to the dangers inherent in the task to be performed. Alternators of this type, if used improperly or receive poor maintenance, or when people do not receive the intervention of not qualified personnel may cause serious personal injury and/or material damage. It is therefore recommended that these services be always performed by qualified people.
2.3 STANDARDS
Alternators are specified, designed, manufactured and tested according to the following standards:
Table 2.1: Applicable standards IEC Specification Dimensions Tests Protection degrees Cooling Mounting Noise 60034-1 60072 60034-4 60034-5 60034-6 60034-7 60034-14 NBR 5117 5432 5052 9884 5110 5031 5117 8528 ISO
ATTENTION
For use of alternators with water cooling at temperatures below 0C, antifreeze additives must be added in water.
2.4.1
The industry standard alternator should not be used in harsh environments, because this action is subject to weather that can cause corrosion of mechanical parts and decrease the insulation resistance of the windings and consequently the burning of the alternator. In these situations, WEG is not responsible for damage that may occur on the alternator, depriving the product warranty according to the warranty terms.
15
www.weg.net
NOTE
Alternators applied in harsh environments should be equipped with additional protection against corrosion and poor insulation, ensuring, when requested, to guarantee performance of the product. Is considered harsh environment: marine environment or with high concentration of salinity and / or high humidity, materials in suspension that can be abrasive, and naval application with high ambient temperature variation. In these cases, please refer to WEG for correct specification of the alternator to the required application.
16 l
www.weg.net
3.2.2
ATTENTION
Any damage must be photographed, documented and reported immediately to the carrier, the insurer and to WEG. The lack of notice will void the warranty.
The alternator should be stored in dry place, free from floods and vibration. Repair any damage in the package before storing the alternator, which is needed to ensure proper storage conditions. Place the alternator on platforms or foundations that ensure protection against soil moisture and prevent it from sinking into the ground. Free movement of air underneath the alternator should be ensured. The cover or tarpaulin used to protect the alternator against the weather should not be in contact with its surfaces. To ensure the free circulation of air between the alternator and the the coverage, put wooden blocks as spacers.
ATTENTION
Additional parts supplied in packages should be checked on receipt.
3.2.3
Longer storage