Professional Documents
Culture Documents
2010
Documentation
Table of contents
KAD 30240/E
Edition 04/2010
Read through before initial operation and store carefully for later reference!
Mounting, operating
and maintenance instructions
for series SE and SEH
brushless three-phase synchronous generators
AEM
Anhaltische Elektromotorenwerk Dessau GmbH
Daheimstr. 18
D - 06842 Dessau - Roßlau
After-sales service
Tel.: +49 (0) 340 203 304 / 305
Fax: +49 (0) 340 203 311
e-mail: aem@aemdessau.de
homepage: www.aemdessau.de
ANHALTISCHE
ELEKTROMOTORENWERK
DESSAU GMBH
Danger!
Is used for activities that may cause considerable personal or material damage.
Please read and observe these notes carefully and act particularly cautiously in these
cases. Make other users aware of these notes concerning work safety.
ATTENTION! Concerns the observation of regulations, notes or the correct sequence of working
steps to avoid damaging or destroying the generator, its parts and/or parts of the
equipment.
______________________________________________________________________________________
All work to be carried out on electrical generators such as assembly, connection or maintenance must
only be carried out while the system carries no voltage and is out of operation. Protect the system
against unintended reactivation.
These generators must only be transported, put up, connected, put into operation, maintenanced and operated
by specialized staff being trained to observe the relevant safety and installation regulations. All processes must
be checked by responsible specialized staff. These specialized staff must have been authorized for their activi-
ties by the security system officer (for specialized staff regulations see DIN EN 50110-1 / DIN IEC 60364).
The manufacturer's liability is only maintained if the operating instructions are being observed at any
time!
Table of contents
1 Description................................................................................................................................................... 6
1.1 Regulations and classifications ............................................................................................................ 6
1.2 Design .................................................................................................................................................. 6
1.3 Bearings ............................................................................................................................................... 6
1.4 Cooling system ..................................................................................................................................... 6
1.5 Exciter system ...................................................................................................................................... 6
1.6 Voltage regulator .................................................................................................................................. 7
2 Behaviour during operation and notes on use ............................................................................................ 8
2.1 Excitation, de-excitation ....................................................................................................................... 8
2.2 Setting range for voltages, set-point adjuster ...................................................................................... 8
2.3 Voltage behaviour ................................................................................................................................ 9
2.4 Radio interference suppression ........................................................................................................... 9
2.5 Operational behaviour .......................................................................................................................... 9
2.5.1 Overload capability ....................................................................................................................... 9
2.5.2 Operation with different temperatures of the cooling agent .......................................................... 9
2.5.3 Operation at power factors p.f. < 0.8 .......................................................................................... 10
2.5.4 Underspeed ................................................................................................................................ 10
2.6 Short-circuit behaviour ....................................................................................................................... 10
2.7 Single operation ................................................................................................................................. 10
2.8 Parallel operation ............................................................................................................................... 10
2.8.1 Practical applications .................................................................................................................. 10
2.8.2 Neutral earthing current .............................................................................................................. 11
2.8.3 Synchronisation .......................................................................................................................... 11
2.8.4 Parallel operation with static ....................................................................................................... 11
2.8.5 Parallel operation with compensating line .................................................................................. 12
2.8.6 Parallel network operation with static ......................................................................................... 12
2.9 Emergency operation without regulator ............................................................................................. 12
3 Transport ................................................................................................................................................... 12
3.1 Check after delivery ........................................................................................................................... 13
3.2 Transport locking device .................................................................................................................... 13
3.2.1 Cylindrical roller bearings............................................................................................................ 13
3.2.2 Slide bearings .............................................................................................................................13
3.2.3 Single bearing - and vertical generators ..................................................................................... 13
4 Mounting .................................................................................................................................................... 13
4.1 Installation and connection................................................................................................................. 14
4.2 Electrical connection .......................................................................................................................... 15
4.3 Terminal box and connections ........................................................................................................... 16
4.4 Direction of rotation ............................................................................................................................ 16
5 First start up............................................................................................................................................... 16
5.1 Electrical check .................................................................................................................................. 16
5.2 Measuring of the insulation resistance ............................................................................................... 16
5.3 Mechanical check ............................................................................................................................... 17
6 Maintenance .............................................................................................................................................. 17
6.1 General information ............................................................................................................................ 17
6.1.1 Insulation value and standstill heater.......................................................................................... 17
6.1.2 Maintenance work at the drive .................................................................................................... 18
6.1.3 Preventive maintenance ............................................................................................................. 18
6.2 Lubrication and maintenance instructions for antifriction bearings .................................................... 18
6.2.1 Lubricant information .................................................................................................................. 18
6.2.2 Bearings with relubrication device .............................................................................................. 18
6.2.3 Removing used grease ............................................................................................................... 19
6.2.4 Bearings without relubrication device ......................................................................................... 19
6.2.5 Maintenance instructions ............................................................................................................ 19
6.3 Lubricating and maintenance instructions for slide bearings ............................................................. 19
6.3.1 Oil renewal .................................................................................................................................. 19
6.3.2 Inspection of bearings ................................................................................................................. 19
6.4 Cleaning ............................................................................................................................................. 19
6.5 Drying the winding ..............................................................................................................................20
6.6 Assembly of bearings ......................................................................................................................... 20
7.1
11 R R31
6.1 7
9.2
8
9
6
S1
10
5
Description of view
1 Description
1.1 Regulations and classifications
The generators are made in compliance with the regulations of DIN EN 60034 / VDE 0530 (Rotating electri-
cal machines), all applicable IEC recommendations and the harmonized EG-standards and order-specific
customized classifications – specially acc. to the most important marine classifications associations.
1.2 Design
The generators consist of
• one inner-pole main machine with salient pole or non-salient pole rotor
• one external-pole exciter with rotating rectifiers for transmission of the exciting power and
• one exciter device with electronic voltage regulator.
Generator, exciter and all other components required for excitation and regulation are designed to form one
compact unit. The casing consists of the stator, the end shields and a hood to serve as a cover for the exciter
unit on the N side. In the standard design, the terminal box is at the top and can be turned by 180°. Both
terminal box and casing have specially designated earth connection points.
1.3 Bearings
The system is equipped with spring-loaded deep groove ball bearings (standard mode), cylindrical roller
bearings or plain bearings as defined in the order.
In case of increased loads on the bearings, a cylindrical roller bearing is installed on the D side while a deep
groove ball bearing is on the N side to serve as counter bearing or, if necessary, a double bearing made up
of a cylindrical roller bearing and a deep groove ball bearing.
Generators in vertical design have an angular contact ball bearing to serve as counter bearing. All bearings
are dust-proof, are permanently lubricated up to shaft centre height 315 mm and are provided with relubrica-
tion devices with grease quantity regulation on both the D and the N side as from shaft centre height
400 mm. Relubrication devices for shaft centre height 315 mm are subject to special arrangements.
NOTE For bearing configuration observe Data sheet “Bearings” and lubrication- and maintenance
instructions observe section 6.2.
The load current flows through the current transformer [7]. When load is put on the generator, the secon-
dary current of the current transformer [7] is added to the choke current. After rectification in the stationary
rectifier stack [8] – a six-pulse bridge circuit –, this alternating exciter current flows to the stator winding [4] of
the exciter.
In order to protect the diodes against voltage peaks, both the stationary rectifier stack [8] and the rotating
rectifier stack [5] are equipped with varistors [S1], [S2].
Choke current and secondary current of the current transformer are adjusted such as to permanently main-
tain a generator voltage of approx. 10 % above the rated generator voltage while the generator rotates at its
rated speed and the voltage regulator is disconnected.
Every time the rated generator voltage is exceeded, the voltage regulator (AVR) [9] periodically switches on
step-down resistor R31 that is located in parallel to the stator winding of the exciter [4]. This ensures that the
teminal voltage of the generator is kept at the value set by the set-point adjuster.
NOTE The chosen tappings of the winding to choke and current transformer have been optimally
adjusted to the generator in the manufacturer's test shop. You should therefore always con-
tact the manufacturer prior to making any changes.
R10-K Standard type providing voltage regulation and static device for parallel operation. Designed with
smoothing capacitor CK and varistor S2.
R10-KC In addition to the R10-K functions, this type provides a p.f. - regulation part. It can be used either
as a voltage regulator with static or as a p.f. - regulator.
R10-KF In addition to the R10-K functions, this type provides a cascading, frequency-dependent voltage
regulation.
NOTE Read the enclosed documentation for special modifications of the AVR.
Connections
The voltage regulator is connected via spring-loaded terminal strips. The generator voltage is connected as
in figure 1 and the enclosed wiring diagram.
For all other connections see the wiring diagram of the generator.
Danger!
Only trained specialized staff are allowed to change settings using a suitable tool.
Observe during all setting and other work to be carried out on exciter and regulator
that all components supply voltage potential.
Danger!
Measure the generator voltage during the excitation process. Remove the external
voltage source immediately, when the generator voltage rises. Danger of inverse volt-
age!
If self-excitation of the generator does not work, excitation can be induced by briefly applying an external
voltage (6 or 12 V battery) to terminals X100:3/+ (battery plus), X100:4/- (battery minus) in the terminal box
of the generator (figure 3).
Danger!
After de-excitation and while the drive is running, there is a residual voltage of up to
10 % of the network voltage on the generator terminals. Special notice for generators
with voltage more than 1 kV.
Use a contactor or suitable switch to produce a short-circuit between terminals X100:3/+ and X100:4/-.
Current load on the contacts is < 10 A (figure 3).
Danger!
Incorporate the external set-point adjuster in the protective measures against high
contact voltage.
You may connect an external set-point adjuster to terminals 6 an 8 at the regulator or X100:1 and X100:2 in
the terminal box of the generator (rotary resistor 2.5 kΩ (to 5 kΩ admissible), load limit approx. 1 W, test
voltage > 2000 V). On the regulator, put jumper 7 - 8 to 6 - 7.
T / °C 30 35 40 45 50 55 60
PS / PN 1.06 1.03 1.00 0.96 0.92 0.88 0.84
2.5.4 Underspeed
Particular protection of the generator, the exciter or the regulator against underspeed of the generator drive
(e.g. during warm-up) is not required. Voltage is maintained constant down to speeds of approx. 90 % of the
rated speed. Below this value, the voltage is reduced approximately proportionally to the speed so that every
speed is admissible in no-load without time limitation.
NOTE Wrong distribution of active power (kW indicator not proportional to power output) is always
caused by the speed regulation of the generator drives.
Wrong distribution of reactive current (kW distribution o.k., different current distribution) is
caused by the voltage and static settings of the regulator.
2.8.2 Neutral earthing current
In parallel operation there are not neutral-earthing currents normally while using of same generator types of
one manufacturer.
Connecting the generator star point to the star points of generators of another type or to the network earthed
neutral can cause compensation currents of mainly three times the network frequency to flow in the neutral
earth conductor that have been caused by different voltage curve lines of generators and mains network.
Neutral currents of up to 40 % of the rated current are admissible unless other values have been defined.
Reducing the neutral current can be achieved by inserting a special type of choke coil in the network
switchboard (please contact the manufacturer).
2.8.3 Synchronisation
The generators can be synchronized by manual synchronisation, automatically quick synchronisation or start
up synchronisation (please contact the manufacturer).
The following conditions must be observed for synchronisation processes:
• almost identical frequency of the two voltage systems Δf ≤ 0.2 Hz
• almost identical terminal voltage of the generator and mains network, admissible difference < 6 %
• identical phase sequence of the two voltage systems
• closing of switching contacts at a phase angle of < 15 degrees in relation to the zero crossover of the dif-
ference voltage of the two voltage systems.
ATTENTION! Wrong synchronisation causes extremely high electrical and mechanical loads on the
generator which must be avoided under all circumstances.
Manual synchronisation
Use the set-point adjuster to set the generator voltage to the network voltage. After setting smallest fre-
quency and phase differences possible by means of a synchronoscope, the generator can be switched on.
To avoid the occurrence of inverse power after switching on the generator, the generator frequency should
be about 0.2 Hz above the network frequency.
Quick synchronisation
Use an electronic synchronisation device to adjust the system to smallest possible voltage, frequency and
phase differences automatically. The generator will be switched on considering that time element (switch) is
in zero crossover range of the difference voltage.
2.8.4 Parallel operation with static
ATTENTION! Check whether the jumper between terminals 4 and 5 of the regulator have been re-
moved.
Depending on current and power factor, the generator voltage characteristics have a decline. The voltage drop
can be set by the "Static" potentiometer on the regulator (max. 8 % at p.f. = 0) (figure 4). The voltage drop is
increased by turning the potentiometer clockwise. In the factory, the static is set to approx. 2 % (in relation to
no-load voltage) at rated current and a power factor of p.f. = 0.8. Constant voltage during parallel operation de-
pends on the static setting. If static setting and static voltage characteristics are nearly the same, the reactive
power (in relation to the rated power of the corresponding generator) is distributed proportionally.
ATTENTION! Make sure to do a generator adjustment before starting operation.
Only specialized staff must do these steps.
Check whether all drives have the same percentage value for speed drop between no-
load speed and full speed while in single operation.
Use the set-point adjuster to adjust the equal values of no-load voltages (±1 V) at all
generators. For this setting please use the same meter.
Put rated power at rated power factor on the generators in single operation if possible
and check whether an almost identical voltage drop can be observed for all generators.
If you find larger differences, the static potentiometer must be readjusted. Static values of 2 – 3 % at rated
power and rated power factor are sufficient for stable parallel operation. This test must not be made with just
using active power as this renders the static inefficient.
NOTE Proceed as follows to make a supplementary test if only active power operation is possible
when changing the setting:
1. Connect the blue cable from phase U to W and the brown cable from phase V to
phase U on the choke terminal strip [6.1].
2. Put load on the generators.
3. The voltage drop corresponds to static setting at p.f. = 0.5 and normal switching condi-
tions.
4. While corrections of the static adjustment using the equivalent circuit is to be noted that
the static adjustment is made with p.f. = 0.5. The static adjustment will be accordingly
smaller with p.f. = 0.8 therefore.
5. Reconnect all devices after the setup procedure.
Danger!
The resistor is under network potential and must therefore be protected against touch-
ing.
The resistor can be used to set the rated generator voltage in the no-load of generator.
The voltage can be kept in the required range by readjustment under load. The voltage tolerance value is
approx. –5 % without readjustment.
3 Transport
ATTENTION! Only use suitable attachment devices (ring bolts, eye bolts) for transportation. The at-
tachment elements that are part of the generator are only made to carry the genera-
tor's own weight.
4 Mounting
Danger!
Observe general security information (see page 2)!
• Use taring screws for aligning the generator. The final installation position is to be fixed by sheet metal
put underneath the generator. Bolt the generator up if necessary (holes are drilled into place already).
• When assembling generators that come to you in several pieces, you have to make sure only to use
parts that have been marked as belonging together.
• The generator must only be assembled and operated according to design (see rating plate).
• Always observe the connection conditions for water quantity, pressure and temperature at the inlet given
in the data sheet for water coolers (see appendix).
• If you are working with a pipe connection with self-ventilation, the pressure drop indicated by the manu-
facturer must in no case be exceeded due to length and layout of piping.
• Make sure to keep sufficient distance to walkways and operating stands as the temperatures of exhaust
air or surface can be up to 80 °C.
ATTENTION! Provide information signs or protective railing.
Coupling
The generator and bearings have been carefully mounted, aligned and completely tested by the manufacturer.
NOTE The rotor is dynamically balanced. The balancing state is marked in accordance with DIN
ISO 8821 at the D-side shaft-end.
Coupling of generators in two-bearing design to the drive unit should be realized by an elastic clutch.
Coupling of generators in single-bearing design: Observe the special documentations in appendix!
Pay attention to absolutely!
Putting on couplings or pulleys
It is not necessary to remove the corrosion protection at the shaft ends during installation.
ATTENTION! Make sure to use a mounting device for mounting couplings or pulleys.
A suitable means for this is the centring drill hole in the shaft end. When putting in the clutch you have to
make sure that the shaft of the drive mechanism and the shaft of the machine to be driven are perfectly
aligned. Misalignment must be not greater than 0.05 mm. To avoid angle errors, the gap between the two
halves of the clutch must be measured at a 90° offset. The difference must be no greater than 0.05 mm.
If elastic bolts or denture clutches are used you must make sure to have congruent separations of the two
halves of the clutch. Changing the half clutches round is not allowed.
ATTENTION! Because of the danger of damages occurring on the bearings, hammering or knocking
the driving elements on is not allowed.
Pulleys are only allowed for generators of the type IM C2 as special feature design; they too must be dy-
namically balanced. Furthermore you must make sure to carefully align the two disks making up one pulley,
i.e. both shafts must be parallel to each other and the connecting line between the two disk centres must be
at a 90° angle to the shafts.
ATTENTION! Check the pull of the belt. For information about the max. admissible belt tension
please contact the manufacturer. Increasing the pull of the belt shortens the service-
able generator life.
Figure 7: Dimension X
Thread M 10 M 12 M 16 M 20
Tightening torque in Nm 10 15.5 30 52
Align the cable lugs at the largest possible distance to other connecting points and to the casing.
ATTENTION! Do not fall below the following distances between live components and to the case:
Round terminal bolts of low voltage generators (<1 kV) have not been designed to serve as conductors for
the rating current. You must therefore always make sure to put cable lug on cable lug (figure 8). If more than
three cable lugs are connected to one terminal, you should use a flat nut in between. Arrangement of cable
lugs, nuts and counter nuts is to be made according to the illustration below.
Terminal bridge
Wrong!
Figure 8: Cable lug arrangement inside the terminal box.
5 First start up
When putting the generator into operation for the first time or after long downtimes, the following checks
have to be made.
Danger!
Protect the system against unintended reactivation!
Earth the windings before and after the measuring of insulation at least 10s.
Don’t touch the windings before!
Measuring instrument: The measurement should be effected by a standard measuring instrument. Observe
exactly the operating instruction.
Measuring voltage: Observe the table below.
Measuring time: The measuring time should be 1 min at least.
ATTENTION! Disconnect the internal radio interference protection capacitors [10] before measuring
of the insulation resistance value.
The capacitors are attached to the exciter and connected to the generator frame via a cable. Disconnect this
line and re-connect it after measuring.
The following table serve to estimate the insulation resistance. Always estimate the insulation resistance (Ris) of
the cold generator, i.e. on room temperature (approx. 25 °C). “Warm-values“ are not to comprehend clearly.
The minimum insulation resistance on room temperature of a brand new generator or a repaired generator
with a new winding you find under item 1. of the next table.
This value can drop by virtue of transportation and storage under bad environmental conditions. In this case
the insulation is not damaged. Generators, which stand still under bad environmental conditions for a long
time and do not have a standstill heater (dew on the windings), can be started-up, so long as the insulation
resistance of the cold generator do not drop under the values like shown in item 2. of the next table.
Drop the insulation resistance under values of item 2, the windings must be dried. Under special operating
conditions the windings must be cleaned before drying (for that look to the section 6.5 “Drying the winding“).
The insulation resistance must rise after a short operation of the generator. Under normal transportation,
storage and operating conditions the insulation resistance of the cold generator must not drop under the val-
ues in item 2.
6 Maintenance
6.1 General information
Maintenance activities include bearings, cleaning the generator and the cooling air filters, if exist.
The following must be done according to operating condition but at least once every year:
• check the terminal boxes and terminals for cleanliness and corrosion
• check the electrical connections for tight fit. Maximal torques see section 4.2
• check the bearings for leckages of grease or oil
• check the cooling air circuit for cleanliness and sufficient operability.
6.1.1 Insulation value and standstill heater
Regularly check the insulation value of generators that are not used permanently or used in particularly
damp environments (see section 5.2 "Measuring of the insulation resistance").
If the generator is equipped with a standstill heater, then the heater bands and corresponding switching ele-
ments must be checked every six months.
6.1.2 Maintenance work at the drive
Danger!
In case of maintenance at the drive the short-circuited generators have to be de-ex-
citated absolutely according to section 2.1 by short-circuiting of the terminals
X100:3,"+" and X100:4,"-".
Earth-leakage circuit breaker and terminals for de-excitation should be interlocked.
NOTE Medium-high-voltage generators (type SEH) have to be short-circuited by an earth-leakage
circuit breaker in case of maintenance. The generator will be damaged if it will be driven in
this operation because it can be excited up to sustained short-circuit current.
6.1.3 Preventive maintenance
Depending on operating conditions, preventive maintenance is to be carried out every 15 000 to 24 000 h by
experienced and specialized staff.
Maintenance activities include cleaning the inside of the generator, checking bearings and close fitting of the
end-wire binding bands and, if necessary, applying a new coat of finishing varnish.
Check the alignment of generators and the safe connection of all screws.
If new sort of grease will be used (with same consistency class and saponification also) the bearings should
be regreased 3 times with half regreasing periods.
In case of longer downtimes or storage please remember that the maximum storage time of these greases
is 36 months. So we recommend to regrease brand new generators too with half regreasing periods after
longer standstill time.
Check the proper functioning of the generator before and after each lubrication.
6.2.2 Bearings with relubrication device
ATTENTION! Lubricate the bearings only with the generator running.
Relubrication is done via the button head lubricating nipple in accordance with DIN 3404. All lubrication
points are marked on the generator. Information plates and the data sheet „Antifriction bearings” tell you
about lubrication dates and grease quantities.
In case the grease indicated for generators to be relubricated or another grease of the same type of saponi-
fication is not available, open the bearing covers and remove the grease. Then clean the bearing and relu-
bricate using a grease of a similar quality.
NOTE Avoid mixing greases of different type of saponification for roller bearing lubrication, because
the greases decrease their lubricity in this case.
NOTE Extending the recommended lubrication periods causes danger to the bearings and may lead to
a loss of bearing sealing usually provided by the grease thus allowing dust to enter the bearing.
By generators with low operation periods (e.g. emergency generators) it will be recommend
to regrease yearly with reduced grease quantity. A periodical putting into operation, at least
every three months, is important that grease in bearing will be worked through.
The used grease is automatically collected in a chamber underneath the bearing. The grease collector must
be emptied after three lubrication cycles unless otherwise stated. The grease collectors are marked by par-
ticular signs on the generator.
6.2.3 Removing used grease
Danger!
Remove the used grease only while the generator is standing still.
• It is mandatory to observe the dates for removing the used grease, because too much increased grease
quantities would lead to an impermissible warming-up of the bearings.
• In some generator types, the used grease comes out of a covered gap in the bearing lid, accumulates
around the end shield and must be removed from there after several lubrication cycles.
• Generators of type V1 are equipped with grease pipes on the D and the N side. To clean these, you re-
move the plugs on either side and push the used grease out to the left or right using a round stick
(Ø approx. 25 mm).
ATTENTION! Make sure to dispose of the used grease in an environmentally friendly way.
6.2.4 Bearings without relubrication device
Unless otherwise marked or agreed, generators up to type 250 are equipped with bearings with lifetime lubri-
cation. The bearing producer calculate (appr. 20 000 h as life time. This value can fluctuate very much de-
pending on operating case (pollution, vibrations, temperature). So it will be recommended to open bearing
covers after 2 years operation and remove waste grease. The bearings have to be regreased.
For the bearings used see the Data sheet “Antifriction bearings”.
6.2.5 Maintenance instructions
Bearings have to be checked regarding to unusual sounds and admissible bearing temperatures periodically.
If there are SPM measuring nipples or vibration pickups, then the values measured must be analysed at the
same time intervals. To remove the hood or the end shield of bearings with relubrication device, you have to
separate the lubrication tube from the screw connection (see 6.6 “Assembly of bearings”).
6.4 Cleaning
Use a vacuum cleaner or bellows to remove dust from the generator, do not use pressurized air containing
oil or water. Make sure not to blow any dirt or dust into the inside of the generator. Do not use sharp tools
for cleaning!
If the winding is very dirty (oil vapours or grease squelching out of the bearings), use industrial solvent-based
cleaners (petroleum ether or diluter on petrol basis) or other aqueous industrial cleaners or emulsion clean-
ers to remove the dirt. Make sure that the cleaners do not dissolve paint coats or plastic materials.
ATTENTION! Provide sufficient ventilation when cleaning the generator and make sure not to let
any cleaning agents get into the waste water. Observe the environmental protection
regulations.
2. Pull Aassembly:
Push tube right in
Lubricating tube
• Disconnect the cables connected to terminals X100:1 to X100:6 inside the terminal box and pull the ca-
ble through and in.
• Disconnect cables U, V, W from choke terminal strip or rectifier plate for exciter supply.
• Disconnect the primary winding cables of the current transformer.
• Carefully mark the primary cable of the static current transformer; during assembly observe direction K-L
of current flow (see functional diagram).
• Disconnect cables of the rotating rectifier stack.
• Loosen carrier disk and remove the rotating rectifier stack.
• Line the generator air gap.
NOTE Set the rotor such that one pole points down
• Disassembly the bearing components, bearing lid, labyrinth box, excenter and remove the end shield in-
cluding the entire exciter unit after unscrewing the screws in the ring around the stator casing.
NOTE Use the attachment screws to remove the end shield from the centring device by screwing
them into the threads provided for this purpose.
• Pull out the old bearing and put in the new one after warming it up to 100 °C (water test).
• Lubricate the bearing. Completely fill the bearings to the rim with grease.
• Fill the gap between bearing lid and shaft with grease leaving the bearing lid empty.
Proceed in opposite direction for assembly making sure in particular to carefully connect all cables according
to the enclosed wiring diagram.
D-side
• Line the generator air gap from the N-side.
• Disassemble all bearing components and the end shield and change bearings as described for the N-side.
7 Supplementary installations
These only exist in customized solutions upon special request.
A typical stator winding has one PTC thermistor per phase. The stranded hook-up wires of these three ther-
mistors are series connected. It is possible to install a second set of thermistors which is then used in con-
junction with a second module either as reserve, for two separate windings or for thermal warning.
7.1.5 Platinum measuring resistors (Pt100 sensors in acc. to DIN EN 60751)
In this case, temperature monitoring is based on the linear change of Pt100 sensor resistances in a wide
temperature range. In conjunction with suitable temperature limit switches or Pt100 temperature measuring
circuits they can be used for both automatic triggering at certain preset temperatures or for permanent
measurement, control or indication of temperatures.
Pt100 sensors can be installed in windings like thermistors.
Each sensor is connected separately to the terminal panel and must be analyzed separately.
Special Pt100 slot resistance thermometers can be installed in the generator slots according to agreement.
This allows very precise checking of the winding temperature and the sheet metal package even in very in-
accessible places.
Temperature control of components, cables and bearings in particular is possible by using surface sensors.
NOTE Create a four-wire connection by later adding two additional terminals in conjunction with a
terminal bridge or parallel terminals for the current and voltage wires (figure 10).
KTY sensors may be replaced by the same types only. If you inform us of the generator number, we will no-
tify you of the precise KTY type designation.
Danger!
Switch off the standstill heater via the control centre before opening the terminal box!
Check whether the system is in a voltage-free condition.
Shaft centre height in mm 225 - 250 315 - 400 450 - 500 560 / 630 710
Heating output in W 84 150 300 520 780
The connecting terminals are marked and located in the generator's terminal box.
The supply voltage is 220 / 230 V unless otherwise agreed. Connect the standstill heater to the relevant ter-
minals in the terminal box according to the current switching diagram.
Î For specific heater output and voltage : see information sign in the terminal box
ATTENTION! Activate the standstill heater only after switching off the generator.
Provide suitable means to avoid unintentional operation of the standstill heater while
the generator is running (locking mechanism).
8 Storage instructions
The generators should be stored vibration-free in a dry room free of dust. In this case, special packaging is
not required. Otherwise, the generators must be kept in plastic foil with humidity absorbing material. Provide
covers to protect it against rain and sun.
ATTENTION! Manually race the armature at regular intervals to avoid damage to the bearing.
NOTE Armatures of generators provided with transport locking devices are not raced as long as the
transport locking device is applied and functional. Observe the instructions given in section 5
prior to first operation
9 Troubleshooting
ATTENTION! Immediately switch off the drive if a failure occurs.
Carefully inspect the generator while in a voltage-free condition.
Danger!
While measuring or setting parameters with the generator running, you must be aware
of the fact that all unprotected terminals may carry very dangerous voltages and that
they are in immediate proximity to rotating parts. The generator must therefore be
locked to avoid contact by unauthorized persons.
ATTENTION! Check-ups of exchanging of parts must only be carried out by trained specialized staff
in accordance with IEC 60364 observing all applicable regulations of health care,
safety at work and fire protection.
The references to components correspond to the connection diagram of the generator.
Screws: 5 Nm
Terminals: 3 Nm
Figure 11: Test instrument setting for stat. rectifier Figure 12: Test instrument setting for rot. rectifier
Problem: Generator voltage too high or too low when putting into operation
Action Consequence Cause of failure, further actions
Check speed of drive system
Voltage o.k.
Modify voltage set-point Voltage setting Check connection of external set-point adjuster
range insufficient Check jumpers 6 - 7 on the regulator (figure 4)
Problem: Generator voltage too low and not adjustable during operation
Action Consequence Cause of failure, further actions
- Regulator problem
Generator voltage - Replace regulator or go into emergency operat-
- Deactivate regulator
is approx. 1.1 x UN ion mode (section 2.9)
- Disconnect conductor from termi-
nal 10 (insulate) and run generator - Check rectifier stacks [5] and [8] (section 9.3),
at rated speed Generator voltage replace if defect
does not change - Check the connections of choke [6]
Problem: Generator voltage too high and not adjustable during operation
Action Consequence Cause of failure, further actions
Check connection of external set-
point adjuster
Check function of step-down resis- Generator voltage - Step-down resistor R31 or connections defect
tor R31 is approx. 1.1 x UN - Replace resistor, repair line
- Regulator problem
Generator voltage - Replace reg. or go into emergency operating
does not change mode (section 2.9)
- Check air gap of choke [6] If the yoke is loose, set the air gap such that the
- Yoke and shims must be firmly systems sets itself to approx. 1.1 x UN at rated
attached speed and without voltage regulator (disconnect
cable from terminal 10 and insulate)
10 Spare parts
The following information is required for ordering spare parts:
What? Where?
Name of part Enclosed spare parts list
Generator type Rating plate
Output ”
Voltage ”
Serial number of generator (absolutely necessary!) ”
Carry out dynamic balancing after replacing any rotating parts (with the exception of the rotating rectifier [5]).
Bearing configuration - see data sheet “Bearings”
Spare parts and names of parts - see appendix
KAD 00810/DE
Ausgabe/edition: 27.07.2010
Lageraufbau
KAD 00802 RL KAD 00802 RF
bearing, ready-to-fit
Nachschmierfrist in h
2800 2800
regreasing period in h
Fettmenge in g
70 50
grease amount in g
Die Erstschmierung erfolgt mit dem Schmierfett Bechem / Ceritol HIGH LUB LM 3 EP, einem lithium-
verseiften Mehrbereichsfett der Konsistenzklasse 3 mit einem Temperaturbereich von -40°C bis +140°C.
Die folgenden Produkte können ohne Einschränkung der Gebrauchseigenschaften und Nachschmierfristen im
Austausch eingesetzt werden.
The manufacturer lubricates the machine in the factory first using Bechem / Ceritol HIGH LUB LM 3 EP, a
lithium-based multigrade grease of consistency class 3 and a temperature range of -40°C to +140°C.
The following lubricants can replace each other without limitations due to useful characteristics or lubrication
intervalls.
KAD 00802RL/DE
Ausgabe / Edition: 06/2004
RILLENKUGELLAGER (LOSLAGER)
Druckfeder Rillenkugellager
Lagerdeckel außen
External cap piece of the Lagerdeckel innen
bearing
Internal cap piece of the
bearing
Labyrinthbuchse außen
External labyrinth socket
Labyrinthbuchse, innen
Internal labyrinth socket
Fettsammler
Grease collector
Diese Prinzipdarstellung dient zur Ersatzteilbestellung und muss nicht mit der tatsächlichen Ausführung
übereinstimmen. Änderungen im Sinne des technischen Fortschritts vorbehalten!
This schematic diagram was designed for the order of spare parts and may not comply with the actual
version. It is subject to alteration in terms of technical progres!
Anhang - Lageraufbau RF ANHALTISCHE
ELEKTROMOTORENWERK
Appendix - Bearing arrangement RF DESSAU GMBH
KAD 00802RF/DE
Ausgabe / Edition: 06/2004
RILLENKUGELLAGER (FESTLAGER)
Lagerdeckel, innen
Labyrinthbuchse, außen
Internal cap piece of the bearing
External labyrinth socket
Labyrinthbuchse, innen
Internal labyrinth socket
Fettsammler
Grease collector
Diese Prinzipdarstellung dient zur Ersatzteilbestellung und muss nicht mit der tatsächlichen Ausführung
übereinstimmen. Änderungen im Sinne des technischen Fortschritts vorbehalten!
This schematic diagram was designed for the order of spare parts and may not comply with the actual
version. It is subject to alteration in terms of technical progres.
ANHALTISCHE
Anhang - Ersatzteilliste SE 400 - 710 ELEKTROMOTORENWERK
DESSAU GMBH
KAD 30380/DEPS
Ausgabe 11/2009
Ersatzteilbestellung
Bei der Bestellung sind folgende Angaben erforderlich:
• Bezeichnung des Teiles
• Generatortyp
• Leistung
• Spannung
• Werknummer (unbedingt erforderlich)
Radiallüfter Diodenmodul
Centrifugal fan Diode modul
5. 12.1
Ventilador radial Módulo de diodos
Ventilador radial Mòdulo de diodo