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INSTALLATION AND

MAINTENANCE MANUAL
SYNCHRONOUS GENERATORS
G LINE

Transforming energy
into solutions
GENERATORS SYNCHRONOUS

FOREWARD

Weg is pleased to present you the Installation and Maintenance Manual


for the G line Generators.
For a satisfactory operation of the generator, and before running it,
Weg strongly recommends to read this Manual carefully.

All installation, operation and maintenance details must be followed accordingly.


In case of any further doubt,
please contact Weg.

These operations specific care so as to guarantee perfect operation of the equipment


along with extended life time.

The INSTALLATION AND MAINTEANCE MANUAL FOR G LINE GENERATORS


is intended to assist those who deal with electric machines making their task easier
and preserving the operator from any eventual trouble.

WEG INDSTRIAS S.A. Mquinas

---- IMPORTANT ----


READ CAREFULLY ALL INSTRUCTIONS INCLUDED IN THIS MANUAL TO
ENSURE SAFE AND CONTINUOUS OPERATION TO THE EQUIPMENT.

9300.0015 I/3
February 2003

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GENERATORS SYNCHRONOUS

TABLE OF CONTENTS

1. NOMENCLATURE.........................................................................................................................5

2. SAFETY INFORMATION...............................................................................................................6

3. GENERAL INSTRUCTIONS ..........................................................................................................7


3.1. APPLICATION..................................................................................................................... 7
3.2. TRANSPORTATION ............................................................................................................. 7
3.3. RECEIVING ........................................................................................................................ 7
3.4. STORAGE .......................................................................................................................... 7
3.5. HANDLING......................................................................................................................... 8
3.6. INSULATION RESISTANCE ................................................................................................... 8

4. OPERATION PRINCIPLE .............................................................................................................9

5. VOLTAGE REGULATOR ..............................................................................................................10


5.1. VOLTAGE REGULATION..................................................................................................... 10
5.2. MAINTENING SHORT-CIRCUIT CURRENT ............................................................................ 10

6. INSTALLATION .........................................................................................................................11
6.1. COOLING SYSTEM ............................................................................................................ 11
6.2. ROTATION DIRECTION ..................................................................................................... 11
6.3. DEGREE OF PROTECTION.................................................................................................. 11
6.4. AGGRESSIVE ENVIRONMENT (MARINE DUTY GENERATORS) ................................................ 12

7. MECHANICAL ASPECTS.............................................................................................................13
7.1. BASES / FOUNDATIONS .................................................................................................... 13
7.2. ALIGNMENT/ LEVELING..................................................................................................... 13
7.3. COUPLING ....................................................................................................................... 13
7.3.1. Double Bearing Generators (B5/B3T) ................................................................................... 13
7.3.2. Single Bearing Generators (B15T) ........................................................................................ 14

8. ELECTRICAL ASPECTS ..............................................................................................................16


8.1. CONNECTION................................................................................................................... 16
8.1.1. Main Connection ............................................................................................................... 16
8.1.2. Electronic Voltage Regulator ............................................................................................... 16
8.1.3. Protection and Accessories ................................................................................................. 16
8.1.4. Identification of terminals................................................................................................... 16
8.1.5. Connection Diagrams......................................................................................................... 16
8.2. MAIN CONNECTION DIAGRAMS ......................................................................................... 17
8.2.1. Possible Connections for Three-phase 12 Terminal Generators 3 Voltages (200 up to 315
frames) .................................................................................................................................... 17
8.2.2. Possible Connections for 6 Terminal Generators 1 Voltage (400 up to 560 frames)...................... 18
8.2.3. Possible Single phase Connections for 12 Terminal Three-phase Generators .............................. 19
8.2.4. Connection diagrams for generator fitted with auxiliary coil (standard)...................................... 20
8.2.5. Connection Diagram for Generator with Auxiliary Exciter (Special on request).......................... 20
8.2.6. Connection diagram for generator without auxiliary coil .......................................................... 21

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GENERATORS SYNCHRONOUS

9. GENERATOR PROTECTIONS .....................................................................................................22


9.1. THERMAL PROTECTIONS................................................................................................... 22
9.2. SPACE HEATERS............................................................................................................... 22
9.3. AUXILIARY COIL PROTECTIONS......................................................................................... 23
9.4. DIODE PROTECTIONS....................................................................................................... 23
9.5. PANEL PROTECTIONS ....................................................................................................... 23
9.6. REGULATOR PROTECTIONS............................................................................................... 23
9.7. CONNECTION DIAGRAMS FOR PROTECTIONS ..................................................................... 24

10. COMMISSIONING ...................................................................................................................25


10.1. PRELIMINARY INSPECTION.............................................................................................. 25
10.2. FIRST START-UP............................................................................................................. 25
10.3. START-UP ...................................................................................................................... 25
10.4. SHUTDOWN PROCEDURE ................................................................................................ 26
10.5. PARALLEL OPERATION .................................................................................................... 26
10.5.1. Generators between them and/or with the power supply....................................................... 26

11. MAINTENANCE .......................................................................................................................27


11.1. EMERGENCY SETS .......................................................................................................... 27
11.2. CLEANING...................................................................................................................... 27
11.3. NOISE LEVEL.................................................................................................................. 27
11.4. VIBRATION .................................................................................................................... 27
11.5. BEARINGS...................................................................................................................... 27
11.5.1. Lubrication ..................................................................................................................... 27
11.5.2. Replacement of bearings .................................................................................................. 28
11.6. RECTIFIERS ................................................................................................................... 28
11.6.1. Rectifier Tests................................................................................................................. 28
11.6.2. Replacement of rectifiers .................................................................................................. 28
11.7. AIR FLOW ...................................................................................................................... 29
11.8. COMPLETE MAINTENANCE............................................................................................... 29
11.9. DRYING OF WINDINGS ................................................................................................... 29
11.10. MAINTENANCE SCHEDULE ............................................................................................. 30

12. SPARE PART LIST ...................................................................................................................31


12.1. SINGLE BEARING GENERATORS (B15T) - STANDARD ......................................................... 31
12.2. DOUBLE BEARING GENERATOR (B5/B3T).......................................................................... 31
12.3. SINGLE BEARING GENERATOR AND AUXILIARY EXCITER (SPECIAL) .................................... 32

13. TROUBLEHOOTING .................................................................................................................33

WARRANTY TERMS FOR ENGINEERING PRODUCTS ....................................................................35

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1. NOMENCLATURE

G T A . 3 1 5 S I 3 1

Type of Machine

G Standard Synchronous Machine

G T A . 3 1 5 S I 3 1

Characteristic

T Brushless Generator with Auxiliary Coil

P Brushless Generator with Auxiliary


Exciter

GT A . 3 1 5 S I 3 1

Method of Cooling

A Open Self-ventilated

GTA.315 S I 3 1

Frame IEC
200 to 560

GTA.315 M I 3 1
Frame length

S, M, L, A, B, C, D, E ,F

GTA . 3 1 5 SI 3 1

Application
I Industrial
M Marine
T Telecommunications
N Naval
E Special

GTA.315S I 31

Lamination Core Code

00 to 99

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2. SAFETY INFORMATION

Warning symbols
In case installation and maintenance
manuals are missed, Weg can supply a spare
Safety Warning and copy. If further information is required, this
Warranty can be requested from Weg by providing
generator serial number which can be found
on its nameplate and/or right below of the
Danger drive endshield of the generator.

If more information is steel required including


specific data about the product, WEG can provide
it through its authorized service agents or local
distributors.
To perform such service within technical
All fundamental works covering installation standards and accurately, generator serial number
plan as well as handling, storage, mounting, attached to the nameplate is required.
installation, commissioning and repair Aiming at performing suitable product
operations must be carried out by qualified performance, we suggest that planning,
personnel. mounting, commissioning and start up services be
To pay attention to the following points is also performed in conjunction with WEG technicians.
important:
- All data referring to product use, mounting
conditions, connections, installation
environment, service, catalogs, order
documents, manuals and other
corresponding documents;
To avoid generator damage it is required
- Determination and specific installation and
that qualified service personnel perform
site conditions;
regular maintenance services indicated in the
- Correct use of tools, handling and
Generator Installation, Operation and
transportation equipment;
Maintenance Manual. If any eventual
- Use of protection and safety equipment;
abnormal situation occurs such as increase in
- Individual equipment parts must be duly
temperature, noise, abnormal smell, tripping
protected until completely mounted.
or alarm which are the first signs to
- It is not always possible to foresee all
occur, maintenance people must be
required and detailed information of any
informed immediately to avoid
eventual constructive variable. Due to that,
personnel injury or material damage.
service instructions include essential
information so as to ensure that qualified
personnel can perform the service.

When the equipment is installed out of an


industrial facility (condominium, homes,
hospitals and others), the end user is
QUALIFIED PERSONNEL, are those people responsible for correct mounting and
who due to their education, experience, protection for further safety of people during
background and knowledge of applicable normal generator operation.
standard and safety procedures about service
conditions are duly authorized to operate the
generator. They must also know about first aid
procedures.

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3. GENERAL INSTRUCTIONS

3.1. APPLICATION

WEG G line generators have been developed to If any damage is noticed, contact the carrier
meet normal requirements of IEC34.1 and ABNT and Weg.
5117 Standards. Lack of communication will void the warranty.
Special conditions can be met and they should be
specified in the purchase order.

Normal conditions include the following items:


1. Temperature - 20C to + 40C. 3.4. STORAGE
2. Altitudes up to 1000masl.
3. Environment with no aggressive agents such Generator:
as sea effect, chemical products. When the generator is not installed immediately
4. Ambient meeting generator degree of after receiving, the package should be stored in a
protection. dry temperature place free of humidity, vapors,
sudden change of temperature, rodents and
insects.
3.2. TRANSPORTATION This site must be free of vibrations to avoid
bearing damage. If painting has suffered any
Single bearing generators are supplied with locked damage, it should be recoated, and the machined
shaft. All machined surfaces are protected against parts must be recoated with grease or a similar
corrosion. product.

Bearings:
- When generator is storage for a period up to
six months, maintenance is not required;
- From 6 months up to 2 years, rotor must be
Never transport the single bearing generator rotated on a monthly basis (manually) to avoid
without locking the shaft. race spot and hardening of grease;
Neither the generator nor its package should - After 2 years of storage, we recommend to
be dropped or suffer any impact. replace the bearings, when these bearings are
shielded. When not shielded, these must be
disassembled, washed and regreased them
before new operation.
3.3. RECEIVING

Box or container must be checked right after it is


received to see if any damage has occurred
during transportation.
When generators are fitted with space
heaters, these must kept switched-on when
generators are off, and switched-o when
generator is on.
Do not remove the protecting grease from
machined surfaces, shaft end nor the plugs
from terminal box openings.
These devices should only be removed at the
final installation.

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GENERATORS SYNCHRONOUS

3.5. HANDLING The minimum allowable value for the RM


insulation resistance is given by the formula:

Rm = Un + 1
Where:
This generator is fitted with eyebolts for RM Minimum insulation resistance
lifting purposes. recommended in Mega Ohm with the winding at
These eyebolts are intended to lift only the
a temperature of 40C;
generator. Additional loads are not allowed.
Un Rated voltage of the generator in kV.
Cables and lifting devices must be If the test is performed at a different
appropriated to prevent accidents and
temperature, it is required to correct the reading
damages to the generator or personnel
to 40C by using an insulation resistance variation
injury. Pay attention for correct generator
curve in relation to temperature, given by the
weight.
generator itself. If this curve is not available it is
Lifting and lowering must be done gently.
possible to use an approximate correction given
Never lit the generator by the shaft. by the curve below:

3.6. INSULATION RESISTANCE

When generator is not immediately put into


operation, it should be protected against
moisture, high temperatures and impurities to
avoid damage to insulation. The winding
insulation resistance must be measured before
operating the generator. If the ambient contains
high humidity, a periodical inspection is
recommended during storage. It is difficult to
determine rules for the actual insulation
resistance value of a generators as the resistance
varies according to environmental conditions
(dust, oil, grease, dirt) and condition of the
insulating material used and method of
construction of the generator.
The following guidelines show the approximate
insulation resistance values that can be expected
from a clean and dry generator at 40C
temperature ambient, when test voltage (1000V)
is applied for a period of one minute.

Guiding limits for insulation resistance of


electrical machines:
Insulation resistance
Insulation level
value
2 or lower Bad
< 50 Dangerous
50...100 Abnormal
100...500 Good
500...1000 Very Good The insulation resistance is usually measured with
> 1000 Excellent
a MAGOMETER.
If the insulation resistance is lower than the
Polarization Index (ratio between 1 and 10
minutes): values obtained by the above given formula,
Polarization Index Insulation Level generator must be submitted to a drying process,
1 or lower Bad as described under item DRYING OF
< 1.5 Dangerous WINDINGS.
1.5 to 2.0 Abnormal IMPORTANT
2.0 to 3.0 Good Disconnect all the wires from the voltage
3.0 to 4.0 Very Good regulator before measuring the insulation
> 4.0 Excellent resistance.

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GENERATORS SYNCHRONOUS

4. OPERATION PRINCIPLE terminal voltage or from load variations that may


occur.
The self excitation starts through the residual Fed by the auxiliary coil, the voltage regulator
voltage of the machine which is provided by supplies power to the main machine exciter. It
permanent magnets on the poles of the main also makes compensation between its theoretical
exciter stator. The residual voltage value varies value and the reference voltage. This allows
from machine to machine. The auxiliary coil is control of the generation excitation keeping
responsible for the power supply to the voltage voltage at the required value.
regulator independently from the generator

GTA Line Generator with Auxiliary Coil (Standard)

Voltage
Regulator

GPA Line Generator with Auxiliary Exciter (special - on request)

Voltage
Regulator

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GENERATORS SYNCHRONOUS

5. VOLTAGE REGULATOR 5.1. VOLTAGE REGULATION

The electronic voltage regulator is intended to Voltage regulation is made by trimpot P1 on the
keep the voltage as constant independently from own electronic voltage regulator allowing voltage
the type of load. It can be mounted in the regulation in the generator in the range +/- 15%
generator terminal box or in the control panel. of the rated voltage.
An external potentiometer for fine voltage
regulation (5k / 3W) on terminals 6 and 7 of the
regulator.

Correct connection diagram should be


check in the regulator Manual. A wrong
connection can result in complete
generator and/or generator winding The use of an external regulation
burn out. potentiometer is optional and it can not be
Any of these cases are not considered installed in the generator terminal box.
warranty. To make the remaining regulations, check the
Electronic Voltage Regulator Manual.
Check generator reference voltage and
maximum allowable reference voltage.
In some cases, a potential transformer For further technical details, operation,
is required, which must be installed in functions, connections, regulations,
the panel and never directly in the troubleshooting, etc, contact the specific
generator terminal box. Check Voltage Regulator Manual.
connection diagrams in this Manual or in
the Regulator Manual.
5.2. MAINTENING SHORT-CIRCUIT
CURRENT
Adjustment Trimpots:
P1: Voltage adjustment Weg G line generators are produced with an
P2: Adjustment of reactive compensation range auxiliary coil consisting of groups of coils inserted
(Droop) Used with parallel connected in the main stator slots, which are insulated in the
generators. main winding. The auxiliary coil is the power
P3: Stability Adjustment 2 source for the voltage regulator and keeps the
P4: Stability Adjustment 1 generator short-circuit up to 3.0 x In.
P5: Sub-frequency Adjustment
NOTES:
Description of Connection Terminals: 1) As the generator maintains high Idc, an
E1: Reference voltage connection 160 to 300Vac overload relays should be provided so as to
E2: Reference voltage connection 320 to 600Vac trip the main circuit breaker within 20s
1 and 2: Connection for CT with In/5A ratio, maximum to avoid generator burn out.
phase S of the generator (used with parallel 2) To maintain Short-Circuit Current above 3.0
connected generators). xln, Weg must be consulted.
6 and 7: Connection for external voltage
adjustment potentiometer (5k /W) of wire or
jumper (not supplied by Weg)
F+ and F-: Connection for generator Filed
3 and E3/4: Connection for Regulator Feeding
through the Auxiliary Coil or Auxiliary Exciter.
J1: With jumper 60Hz, without jumper 50Hz.

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GENERATORS SYNCHRONOUS

6. INSTALLATION We recommend to check rotation direction and


phase sequence before operating the generator.
Electric machines should be installed in locations
of easy access allowing periodical inspections and
removal of equipment while performing
maintenance services, if required.
Fresh and clean air should be available to cool the
generator along with easy flow out of exhausting Important:
air (out of the equipment room) avoiding to use Wrong phase sequence can result in damage
such air for recooling purposes. to other equipment connected to the
Sucking diesel air can damage the generator once generator.
soot conducts electricity. In case of parallel operation of 2 or more
Enclosed rooms will cause overheating which may generators , or generators operating in
reduce insulation life time and leading to possible parallel with the power supply, same phase
generator burn out. sequence is required.
Generators fitted with single bearings must have
the shaft locking device removed (this device is
used to protect rotor/stator set against
transportation damages) before final mounting. 6.3. DEGREE OF PROTECTION

To ensure good performance and durability to the


6.1. COOLING SYSTEM generator it is essential to match the degree of
protection of such equipment to the installation
The fan is mounted on the drive-end side environment.
attached to the rotor. The cooling air is sucked G line of Weg generators have Degree of
from the non-drive end side and goes out through Protection IP21. This means they are protected
the radial openings placed on the drive-end against penetration of solid particles with
endshield/flange. dimensions exceeding 12mm and against dripping
water vertically.

6.2. ROTATION DIRECTION

Weg G line generators are suitable for CW and


CCW rotation directions. However, phase
sequence is set for CW rotation (viewed from
generator shaft end - Drive-end side). As per VDE
0530 ABNT NBR 5117 Standards, generator
terminals are identified in such a way that the
connector sequence 1,2 and 3 (R,S,T) match the
phase sequence, when rotation direction is CW.

If a generator requires CCW rotation direction,


phase sequence must be exchanged (if required).

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6.4. AGGRESSIVE ENVIRONMENT


(MARINE DUTY GENERATORS)

The application of generators along the


coast requires extra protection against
corrosion and marine attack (Degree of
Protection IPW21 or IPW23). On these
cases, WEG Sales Department should be
informed when placing the purchase order
for the generator.
If IP21 generators are used near the ocean
without extra protection, these will be
subject to corrosion and rust on power
cables. On these cases, Weg will not be
responsible as stated on the Warranty
Terms included herewith. The same
applies to installations where chemical
products are present which can affect the
machine due to excess of dust and other
materials affecting the cooling system or
heat exchange.

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GENERATORS SYNCHRONOUS

7. MECHANICAL ASPECTS

7.1. BASES / FOUNDATIONS

- Base design must be made in such a way


to ensure a tough structure so as to
avoid vibrations to the whole set. Such
Fig. 3.3.2 Radial checking (concentricity)
base must be completely flat in order to
avoid deformation to generator frame.
- The base must always be level in
reference to the ground (floor). Correct
leveling is obtained by fitting metallic
plates between base and floor.

7.2. ALIGNMENT/ LEVELING Fig 3.3.3 Combined axial and radial checking

The generator must be accurately aligned with


the driven machine, particularly in cases of direct Single Bearing Generators (B15T):
coupling. The base must be flat allowing correct
positioning on it. Whenever possible, vibration
An incorrect alignment can cause bearing isolators (mufflers) should be applied between
damage, vibrations and shaft breaking. generator + motor and the base so as to minimize
transmission of vibration. When this is not
Double Bearing Generators (B5/B3T) possible, the isolator should be used between the
A good way to ensure correct alignment is to use base and the ground. One of the configurations is
dial indicators placed on each coupling half, one recommended to avoid high vibration level
reading radially and the other axially. In this way, operation.
simultaneous deviation of parallelism and
concentricity can be obtained when making a
complete shaft turn (Figure 2). These dial 7.3. COUPLING
indicators should not exceed 0.05 mm.
A measurement at 4 different points of the 7.3.1. Double Bearing Generators (B5/B3T)
circumference should not give a reading
difference above 0.03mm a) Direct Coupling:
Direct coupling should be always preferred due to
On the alignment/leveling it is important to take low cost, reduced space required, no slippage
into consideration he different expansion levels of (belts) and less risk of accidents.
the coupled machines as they can modify the Gearbox is also used when speed ratio is required.
alignment/leveling during machine operation.
Cares: Carefully align shaft ends, using flexible
coupling, whenever possible.

Recommended clearance values for


direct coupling
Clearance
Radial 0.05mm
Axial 3 to 4mm

Fig. 3.3.1 Axial checking (parallelism). Angular 0.10mm

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b) Belt and pulley coupling:


CORRECT
Belt transmission is the most commonly used
when a speed ratio is required.

INCORRECT

The coupling of the generator to the drive


machine is for end users responsibility and
this service should be made by qualified
personnel. INCORRECT

The assembly of pulleys on shafts having keyway


and threaded hole must be done by inserting it
halfway up to the keyway merely by manual
pressure.
On shafts without threaded hole it is
recommended to heat up the pulley to about
80C.
Generators supplied with double
Correct pulley position is shown below:
bearings as standard are always
manufactured for direct coupling
applications.
When used with belt / pulley
arrangements, Weg must be contacted
about forces that can be applied to the
shaft and bearings.
WRONG WRONG CORRECT

For disassembly of pulleys care must be taken to 7.3.2. Single Bearing Generators (B15T)
avoid damage to the key as well as shaft surface.
Always use appropriate tools to perform this G DIMENSION
service. All generators leave the factory already mounted
with discs and flanges according to customers
Operation: Avoid unnecessary radial thrusts on request. G dimension is the distance between
the bearings by ensuring that the shafts are external face of the discs and face of the flange,
parallel and the pulleys perfectly aligned as shown as shown on the drawing below:
below.
Laterally misaligned pulleys, when running,
transmit alternating knobs to the rotor and can
damage the bearing housing. Belt slippage can be
avoided by applying a resin type material such as
rosin.

COUPLING DISC

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GENERATORS SYNCHRONOUS

Procedures to change G Dimension


(If required)
To change G dimension, position of coupling discs
in the bushing needs to be changed. To do that,
NOTE: All generators leave the factory with you only need to remove or add spacing rings
G dimension meeting table values given (Letter I), as shown on the drawing below:
above.
The personnel who will mount the generator
G Dimension
set is responsible to check whether the
bushing and coupling disc position complies
with diesel motor used.
If G dimension is not respected, diesel
motor and generator can get damaged or, in
some case, it will not be possible to couple
the generator to the diesel motor.

STANDARD G DIMENSION
Coupling Disc
PA (mm) G (mm)
(SAE)
241.3 7.5 30.2
263.4 8 61.9
A Flange
314.2 10 53.9 B Shaft end
352.3 11.5 39.6 C Key
466.6 14 25.4 D Coupling bushing
E Coupling disc
517.5 16 15.7
F Hexangle bolt
571.4 18 15.7 G Pressure washer
673.1 21 00 H Support ring
733.4 24 0.0 I Spacing rings

NOTE:
Table of standard coupling dimensions for diesel
- For generators in frames 400 and above, the
group generators.
spacing rings are specific rings with high
thickness, although the change procedure of G
The dimension PA (mm) has a tolerance of
dimensions is the same.
- 0.13 mm.
- To attend to the combination of flange and
necessary coupling disc, also the flange (A)
could be changed.

Fastening torque for fixation of discs to


single bearing generator shaft:
Fastening
Frame Fixation
torque (Nm)
200 10xM10x1.25 68 to 72

250 10xM10x1.25 68 to 72
315 12xM12x1.5 119 to 126
400 12xM20x2.50 566 to 595

For larger frames, contact Weg.

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GENERATORS SYNCHRONOUS

8. ELECTRICAL ASPECTS 8.1.2. Electronic Voltage Regulator

Generators usually leave the factory with 12 The Electronic Regulator leaves the factory with
terminals available for connection to 440V. connections made for generator rated frequency
The electronic voltage regulator (located inside the and voltage values.
connection blocks) leaves the factory with jumper For the change of connections, Regulator manual
to operate at 60Hz. must be checked.
To operate at 50Hz, the jumper must be removed,
as per regulator manual.

8.1. CONNECTION Voltage regulation is made with the generator


at no load and at rated frequency.
The electrical connection is for customers
responsibility and must be provided by qualified
personnel.
The possible connection diagrams of the generator
are included in the chapter Connection Diagrams.

When there is a change in the connection of


8.1.1. Main Connection the generator main terminals in order to
change voltage, reconnect the regulator
The main terminal connections must be made reference voltage cables, as per specific
based on the diagrams included in this manual. connection diagram.
The connections must be made with fastened
torque, as per table below:
8.1.3. Protection and Accessories
Fastening Torque
Thread Diameter The connections of the generator protections,
(Nm)
M8 15.4 protection on the panel and accessories must be
made based on the instructions of this manual to
M10 30.0 avoid damage to the generator in case of any
M12 53.0 trouble.
M16 129.0
8.1.4. Identification of terminals

Grounding: Generators must be always 1 to 12,N Stator (power terminals)


connected to ground using a suitable gauge cable E3/4, E1 or E2 Reference voltage
which is available on one of their feet. 3 and 4 Auxiliary coil phases (power
regulator)
F+ and F- Main exciter field
16 to 19 Space heaters (with or without
thermostat)
20 to 35 Stator thermosensors (PT100)
36 to 51 Stator thermistors (PTC)
52 to 67 Stator thermostats (Klixon,
Compela)
68 to 71 Bearing Thermosensors
to 71 Bearing Thermosensors
72 to 75 Bearing Thermistors
76 to 79 Bearing Thermostats
80 to 82 Tachogenerators
88 to 91 Thermometers
94 to 99 Current Transformers

8.1.5. Connection Diagrams

See below all possible connection diagrams of the


main terminals (power), accessories and
protections.

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GENERATORS SYNCHRONOUS

8.2. MAIN CONNECTION DIAGRAMS

8.2.1. Possible Connections for Three-phase 12 Terminal Generators 3 Voltages (200 up to


315 frames)

HI WYE LOW WYE Delta 1


(access to neutral) (access to neutral)

Warning
For identify.
of
connection Delta 2
terminals E1
& E3/4
(reference
voltage of
the voltage
regulator).

VOLTAGE ( V )
L-L 380 - 415 440 - 480 220 - 240 220 - 240
60Hz L-N 220 - 240 254 - 277 127 - 139 -
E1 - E3/4 190 - 207 220 - 240 220 - 240 220 - 240
L-L 380 - 400 190 - 200 200 - 220
50Hz L-N 220 - 230 110 - 115 -
E1 - E3/4 190 - 200 190 - 200 200 - 220

DELTA 1

TERMINAL

DELTA 2

BOARD

- E1 and E3/4 Reference Voltage for Voltage Regulator (See Voltage Regulator Manual).
- For Delta connection series 1, regulator reference terminals (E1 and E3/4) connected originally to terminals 7and 9 and
to auxiliary coil lead (4) which is connected to terminal 9, remain in the original position.
- For Delta connection series 2, regulator reference terminals (E1 and E3/4) connected originally to terminals 7 and 9
and to auxiliary coil lead (4) which is connected to terminal 9, must be removed from original position and then
reconnected to terminals 1 and 2 (see diagram above).

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GENERATORS SYNCHRONOUS

8.2.2. Possible Connections for 6 Terminal Generators 1 Voltage (400 up to 560 frames)

LOW WYE Delta

Warning
For identification
of connection
terminals E1, E2
and E3/4
(reference
voltage of the
voltage
regulator).

VOLTAGE (V)
L-L 220 - 240 380 - 415 440 - 480 220 - 240
60Hz L-N 127 - 138 220 - 239 254 - 277 -
E1 - E3/4 220 - 240 (E1) 380 - 415 (E2) 440 - 480 (E2) 220 - 240 (E1)
L-L 380 - 400 190 - 220
50Hz L-N 220 - 230 -
E1 - E3/4 380 - 400 (E2) 190 - 220 (E1)

TERMINAL

BOARD

E1 and E3/4 Reference Voltage for Voltage Regulator (see Voltage Regulator Manual).

18
GENERATORS SYNCHRONOUS

8.2.3. Possible Single phase Connections for 12 Terminal Three-phase Generators

Single phase Low Zig-zag Single phase Hi Zig-zag Single phase Delta

Warning
for identify.
of terminals
E1 and E3/4 E2
(ref. Voltage
of the
voltage
regulator).

VOLTAGE (V)
L-L 200 - 240 440 - 480 220 - 240
60Hz
E1 or E2-E3/4 200 - 240 440 - 480 220 - 240
L-L 190 - 220 380 - 400 190 - 220
50Hz
E1 or E2-E3/4 190 - 220 380 - 400 190 - 220
TERMINAL

BOARD

E1 and E3/4 Reference Voltage for Voltage Regulator (see Voltage Regulator Manual).

19
GENERATORS SYNCHRONOUS

8.2.4. Connection diagrams for generator fitted with auxiliary coil (standard)
CONNECT E1 OR E2, ACCORDING TO
REFERENCE VOLTAGE DESCRIBED
BELOW

ROTATING PART
STATOR
N

P1 P2
S
S1 S2

MAIN EXCITER
FUSE

1 2 3 E3/4 E2 E1
AUXILIARY COIL
F+ VOLTAGE
F- REGULATOR

CT for parallel operation (optional). E1 Connection for 160 to 300 Vac.


E2 Connection for 320 to 600 Vac.
* For regulator AVC63-7 (Basler) with reference voltage of
Capacitor + Varistor. 320 to 600, a transformer between E2 and E3/4 is required
Used only in frames. (See Voltage Regulator Installation and Maintenance
400,450,500 and 560. Others, on request. Manual).
a) Capacitor 0.1F, 2000Vdc, 630Vac.
b) Varistor 1.0W, Ueff 550V, Umax 990V.

8.2.5. Connection Diagram for Generator with Auxiliary Exciter (Special on request)

CONNECT E1 OR E2, ACCORDING TO


REFERENCE VOLTAGE DESCRIBED
BELOW

AUXILIARY EXCITER
(OPTIONAL) ROTATING PART
STATOR
N

N-S P1 P2
S
S1 S2

T
MAIN EXCITER

FUSE
1 2 3 E3/4 E2 E1

F+
VOLTAGE
F- REGULATOR

CT for parallel operation (optional). E1 Connection for 160 to 300 Vac.


E2 Connection for 320 to 600 Vac.
* For regulator AVC63-7 (Basler) with reference voltage of
Capacitor + Varistor. 320 to 600, a transformer between E2 and E3/4 is required
Used only in frames. (See Voltage Regulator Installation and Maintenance
400,450,500 and 560. Others, on request. Manual).
a) Capacitor 0.1F, 2000Vdc, 630Vac.
b) Varistor 1.0W, Ueff 550V, Umax 990V.

20
GENERATORS SYNCHRONOUS

8.2.6. Connection diagram for generator without auxiliary coil

CONNECT E1 OR E2, ACCORDING TO


REFERENCE VOLTAGE DESCRIBED
BELOW

ROTATING PART
STATOR
N

P1 P2 S
S1 S2

MAIN EXCITER

1 2 3 E3/4 E2 E1

F+ VOLTAGE
F- REGULATOR

CT for parallel operation (optional). E1 Connection for 160 to 300 Vac.


E2 Connection for 320 to 600 Vac.
* For regulator AVC63-7 (Basler) with reference voltage of 320
to 600, a transformer between E2 and E3/4 is required (See
Capacitor + Varistor. Voltage Regulator Installation and Maintenance Manual).
Used only in frames.
400,450,500 and 560. Others, on request.
a) Capacitor 0.1F, 2000Vdc, 630Vac.
b) Varistor 1.0W, Ueff 550V, Umax 990V .

Important notes:

- To use a generator with voltage of 320 to 600V and without auxiliary coil, you must connect E2 to phase
R and terminal 3 to Neutral. For this condition, terminal 3 can not be connected to E2.

- Weg Standard G line generators are fitted with auxiliary coil and without auxiliary exciter.

- It is not recommended to use generator without auxiliary coil due to generator power supply problems in
case of short-circuit or overloads. This diagram should only be used in case of faulty auxiliary coil.

- Generators fitted with auxiliary exciter are special and must be produced on request.

- When transformer is used to adjust reference voltage of the voltage regulator, this transformer can not
be installed inside the generator main terminal box.

21
GENERATORS SYNCHRONOUS

9. GENERATOR PROTECTIONS

9.1. THERMAL PROTECTIONS

Whenever requested by the customer, Weg NOTE: Alarm and tripping values can be
generators can be supplied with overheating defined based on experience. However, the
protection devices installed in the stator windings can not exceed those given previously.
or in the bearings, as described below:

Thermostat (Bimetallic): NOTE: When accessory terminal box is required,


These are bimetallic thermal detectors and are connection terminals for thermal protectors and
used for tripping. They are limited at a maximum other accessories are placed in this terminal box.
current of 2.5A. If this box is not foreseen, terminals will be placed
in the main terminal box.
Thermistors (Type PTC or NTC):
These are thermal detectors consisting of semi-
conductors which sharply vary their resistance 9.2. SPACE HEATERS
when reaching a set temperature. (Optional)

Thermo-Resistance (Type PT100-RTD): When generators are fitted with space heaters to
The thermo-resistance is a resistance thermal avoid water condensation during long periods o
detector (RTD) usually made of platinum, and its standstill, these devices must be kept switched-
electric resistance varies linearly with the on. As soon as generator is restarted, space
temperature. heaters must be de-energized immediately.
The temperature of PT100 can be obtained A dimensional drawing and a specific nameplate
through the following formula: attached to the generator indicate the supply
voltage and the characteristics of the space
C : - 100 heaters installed.
0.385 If space heaters remain energized while machine
is in operation, winding can get damaged.
= resistance measured on the PT100
C = absolute temperature locally PT100 Connection Diagram for Space Heaters

NOTES:
1) Besides the protection devices indicated
herewith, other devices must be used, if
required by the application.
2) All thermal protectors must be duly connected
to control system and these should be in
perfect operation. Even being fitted with
temperature detectors, generator will not be
protected if devices are incorrectly connected.
3) We recommend that all relays (when
generator is protected with thermo resistance)
should be set as indicated below:

Temperature (C)
Class Alarm Tripping
F 140 155
Stator
H 155 180
Bearings 90 100
Table 4

4) For thermostats and thermistors, alarm and/or


tripping are not adjustable.

22
GENERATORS SYNCHRONOUS

9.3. AUXILIARY COIL PROTECTIONS Varistor Capacitor

FUSE (series connected with auxiliary coil): Model SIOV-S20K550 MKP 1.44/2
Weg generators are fitted with an automatic Weg Item 0018.1588 0018.0745
protection fuse of 5A, which is series connected
with auxiliary coil for its protection. 1,0W, Ueff 550V, 0.1mF,
Features Umax, Umax 2000Vdc,
990V 630Vac

9.5. PANEL PROTECTIONS


If incorrect fuse is used, the auxiliary coil can
get damaged along with complete stator Protections in the panel are defined by the
winding burn out. This will not be considered customer/end user based on his needs. However,
as warranty. some protections are actually required and must
be provided in the panel.
In table 5, we list the most common protections
In case of fuse operation, this must be replaced in the control and protection panels. We also list
by another of same value so as to ensure safe herewith the indispensable protections in the
and protected operation to the machine. control and protection panels:

The fuse protects the machine and voltage


POWER PROTECTIONS
regulator on the following situations:
1) Lack of reference (refeeding) of the voltage Up to 150kVA
52 - 59
regulator; Low voltage
2) Connection of auxiliary coil cables in short- From 150 to 512kVA 27, 32, 40, 46, 49, 52,
circuit made on the coil outlet leads or through Low voltage 59, 81, 87
incorrect connection on the voltage regulator; From 512 to 2000kVA 27, 32, 40, 46, 49, 52,
3) Connection of the voltage regulator outlet Low voltage 59, 81, 87
terminals in short-circuit;
Up to 2000 kVA 52.59 (*)
4) Low speed operation (used to warm up diesel
generator), mainly with U/F disabled function Up to 2000kVA
32, 49, 59 e 52 (*)
of the voltage regulator: there will be Operating in parallel
protection depending on the operation Table 5
condition (speed, regulator adjustment...).
5) In case voltage regulator is damaged (burn out Nomenclature:
27 Under-voltage 52 Circuit-breaker
of power element or internal reference failure
32 Reverse power 81 Frequency
on the comparing circuits).
46 Current unbalance 87 Differential
6) Fuse will not operate in case of short-circuit.
49 Overload 40 Field run away
So protection must be provided with the use of
a relay allowing motor starting and protection 59 Over-voltage
sensitivity.

9.6. REGULATOR PROTECTIONS


9.4. DIODE PROTECTIONS
Protection against under-voltage (low
Generator built in frame 315 and above are fitted speed): Before operating the generator,
with a varistor and a capacitor parallel protection against under-frequency must be set at
connected and operate as protection to diodes. 90% of the rated frequency (generator already
When these components get burned, they should leaves the factory with such setting) or keep the
be replaced immediately. regulator switched-off until generator get the
rated speed to avoid over-currents in the auxiliary
coil bearings and generator excitation. This
protection operates instantaneously and it
reduces the voltage every time the frequency
remains below 90% of the rated value (Un).

23
GENERATORS SYNCHRONOUS

Application at 60Hz In the stator (2 per phase series connected)


Voltage (V) R S T
Un

U/f 52A ALARM 53A

R S T

54 60 Frequency (Hz)
Application at 50Hz
52D TRIPPING
53D
Voltage (V)
Un
Bearing Thermostats
U/f
1 per bearing

45 50 Frequency (Hz)
76 77 78 79
9.7. CONNECTION DIAGRAMS FOR DRIVE END BEARING NON-DRIVE END BEARING
PROTECTIONS
Thermoresistances (PT100)
Winding Thermostats
In the stator (1 per phase)
In the stator (1 per phase)
R S T R S T

20 21 22 23 24 25
52 53 54 55 56 57
In the stator (1 per phase with 3 wires)
In the stator (1 per phase series connected)
R S T
R S T
20 20 21 22 22 23 24 24 25

52 53 In the Bearings (1 per bearing)

In the stator (2 per phase)


R S T 68 69 70 71
DRIVE END BEARING NON-DRIVE END BEARING

52A 53A 54A 55A 56A 57A In the Bearings (1 per bearing with 3 wires)
ALARM

R S T
68 68 69 70 70 71
DRIVE END BEARING NON-DRIVE END BEARING
52D 53D 54D 55D 56D 57D
TRIPPING NOTE:
1) For PTC sensors, numbering is changed, as per
caption of item Identification of Terminals.
2) When 2 sensors per phase are used, suffixes A
for alarm and D for tripping are added.

24
GENERATORS SYNCHRONOUS

10. COMMISSIONING 10.2. FIRST START-UP

Weg generators leave the factory with some Once all above items have been entirely
safety measures for transportation. Therefore, accomplished, generator is then ready for start
before operating them, these protections (if any) up. While in operation, the automatic excitation
should be removed. starts operating and, under rated speed,
Usually, generators leave the factory connected generator can take load.
for 440V and the regulator with Jumper for 60Hz The ideal adjustment of the rated voltage must be
operation (to operate at 50Hz, remove the done through the adjusting potentiometer of the
Jumper, as per Regulator Manual). theoretical value on the regulator.

10.1. PRELIMINARY INSPECTION 10.3. START-UP

Before starting the generator for the first time or


after a long period of standstill, check the
following items:
1) Is the generator clean? Were all packing
materials and protection elements removed?
2) Are coupling elements in perfect condition (See item Safety Information).
and duly fastened and greased, wherever When the generator is operated for the first
required? time, the following steps must be followed:
3) Is generator aligned (as per item Alignment
of this Manual)?
4) Are bearings duly lubricated or OK for use? a. Make sure the generator terminals are
(See item Lubrication) disconnected from the load through removal of
5) Are thermal protector grounding and surface panel fuses or placing the switch or circuit
heaters leads duty connected (if any)? breaker in the OFF position;
6) Is winding insulation resistance within b. If generator is fitted with space heaters, these
prescribed values, as per item Insulation must be de-energized while machine is in
Resistance? operation;
7) Were all objects such as tools, measuring c. Disconnect the voltage regulator (removing
instruments and alignment devices removed the series connected fuse with the auxiliary
from generator operating area? coil).
8) Is generator fixed correctly?
9) Are all connections made according to the
generator connection diagram?
10) Is voltage regulator correctly connected
according to its installation manual?
The content of items A, B and C is actually
11) Are power supply connectors duly connected
required to detect any eventual abnormal
to main terminals in order to avoid short
situation that may affect load or the
circuit or get them loose?
regulator.
12) Is generator duly grounded?
13) Rotate manually the generator set to see if
there is any air gap interference. When
generator is started at no load, it should
rotate freely without abnormal noise.
14) Is generator cooling system OK? Is air inlet
as specified? The generator leaves the factory with U/F
15) Was G dimension followed (for single function as constant (for the regulator)
bearing generators)? already set. However, as additional safety
measure, it is recommended to disconnect
the regulator.

25
GENERATORS SYNCHRONOUS

d. Having followed all procedures described a. The load must be disconnected from the
above and having solved eventual problems generator power supply before switching-off to
occurred (see abnormal situations/solutions), avoid eventual damages to it due to voltage
disconnect the set. Complete stop, connect reduction during the stop.
voltage regulator, operate the set and make
b. If the generator is fitted with space heaters,
adjustments required to the regulator. The
regulator manual describes the procedures for make sure they are energized.
the adjustments available (stability, voltage,
U/F constant).
10.5. PARALLEL OPERATION
e. Apply load and monitor generator current
making sure it will remain within specified 10.5.1. Generators between them and/or
figures for the machine in question. with the power supply

Minimum conditions for operation of generators


without including control of the driven machine:

1) The machines must have the same operating


See item (trouble shooting/solutions) for voltage;
solution and eventual problems. 2) Check if voltage regulator is suitable for
parallelism with another generator and power
supply;
3) Add a CT of rated current (In/5) from 5 to 10
f. Check the vibration levels of the generator set VA on phase No. 2 and check the regulator
and monitor the measuring instruments manual.
(current, voltage and frequency). In case there
4) To have a panel suitable for its protection and
is a sudden variation in vibration between
operation.
initial condition and after reaching thermal
5) Synchronism and active power adjustment to
stability, it is required to analyze the
be imposed by the machine control.
alignment/leveling of the whole set
If high neutral current will occur, then use a
grounding coil or open neutral connection of one
of the generators. This occurs mainly when
generators are not identical or when there will be
high harmonic content loads.
All measuring and control instruments must be
checked on a permanent basis to detect any
eventual change in the operation and solve the
cause.

1) Whenever possible, contact a skilled team


10.4. SHUTDOWN PROCEDURE to perform these installations.

2) For parallel transient operation (ex: load


ramp), where the motor will operate after
parallel period, the parallelism CT must be
short-circuited once this is not required on
such operation.
Even after the de-excitation, voltage still goes
through the machine terminals. For this
reason, any service should only be carried out
on the machine when it is completely
stopped.
The not observation of this recommendation
can cause injury to personnel life!

26
GENERATORS SYNCHRONOUS

11. MAINTENANCE 11.4. VIBRATION

The following maintenance procedures must be The maximun vibration level to the generator in
followed to ensure a good performance of the load is 20mm/s (RMS).
equipment and extension of its life time.
Inspection cycles depend essentially on the
application site conditions and on the service 11.5. BEARINGS
duty.
Bearing temperature control is also part of a
routine maintenance.
Temperature rise should not exceed 60 C,
measured at the external bearing cap.
Constant temperature control can be made by
The non observation of one of the items listed means of external thermometers or by embedded
below can reduce generator life time, thermo-elements (optional) .
unexpected stops and/or installation damages. Alarm and tripping temperatures for ball bearings
can be set respectively for 90 C and 100 C.

11.1. EMERGENCY SETS 11.5.1. Lubrication

Generators used on supplying and emergency Generators built up to frame 315 (inclusive) are
sets must be, based on the humidity level of the fitted with permanent lubrication bearings, hence
installation site, operated from 2 to 3 times a not requiring relubrication.
month. At the time lubricant becomes deteriorated,
bearings must be replaced.
Generators built in frame size above 315, bearings
11.2. CLEANING need to be relubricated. On this case, lubrication
instructions must be followed strictly (cycle time,
Frame, vents, screens and fan cover must be kept amount and type of grease), according to the
clean, free of dust, dirt on the outside so as to table below:
make the cooling process easier.
The same applies to the inside of the generator Lubrication Quantity of
Frame Bearing
which should be free of dust, dirt and oil. Soft Interval (h) grease (g)
brush or clean cotton rags should be used to LA 6313 2RS --- ---
clean the generators. A jet of compressed air 200
LOA 6210 2RS --- ---
should be used to remove non-abrasive dust from
the fan cover and any accumulated grime from LA 6318 2RS-C3 --- ---
250
the fan and cooling fins (frame). LOA 6214 2RS --- ---
Oil or damp impregnated impurities can be LA 6320 2RS-C3 --- ---
removed with rags soaked in a suitable solvent. 315
LOA 62162RS-C3 --- ---
Their terminals should be free of oxidation, in
LA 6324 -C3 2900 72
perfect mechanical condition and all unused space 400
dust-free. LOA 6226-C3 2300 46
LA 6324 -C3 2900 72
450
LOA 6226-C3 2300 46
11.3. NOISE LEVEL * For the other frames refer to Weg.

Noise level of generators should be checked at DE = Drive end.


intervals of 1 to 4 months. In case of any NDE = Non drive end.
abnormal situation, see item Troubleshooting.
NOTE: The estimated useful life for the bearings
is 20.000 hours.

27
GENERATORS SYNCHRONOUS

11.5.2. Replacement of bearings 11.6.1. Rectifier Tests

On single bearing generators, bearings are Conduction of current should occur only from
replaced by removing the vent and ND endshield anode to cathode, that is, on the direct
providing free access to the bearing. Using a 3 polarization condition.
grip extractor, bearing can be easily removed.
For safety reasons, replacement of bearings
should be made with the generator uncoupled
from the drive machine.
Generators fitted with double bearings need to be
uncoupled completed for replacement of bearings.

- G Line WEG generators are supplied with Field excitation circuit


POLIREX EM grease.
ROTOR
MAIN EXCITER FIELD (MAIN
ROTOR MACHINE)

1) A bearing should only be removed from the


shaft when absolutely required; RECTIFIER SET
2) Before mounting a new bearing, shaft (BRIDGE RECTIFIER)
shoulder should be cleaned and slightly
relubricated. Direct polarization of a diode
3) Bearings must be pre-heated at 180C to
turn the mounting easier. NOTE: From here on, the following abbreviations
4) Bearings can not be subject to direct will be used:
blows, shocks, drops, storage with AND - Anode in the frame; (+)
vibrations or excess of humidity once this CTD - Cathode in the frame. (-)
can cause spots to internal races or on the
balls, hence reducing their life time.
5) Grease used for relubrication must be 11.6.2. Replacement of rectifiers
compatible to avoid deterioration and
further damage to bearings. For the replacement of rectifiers, proceed as
follows:
- Remove the back vent;
- Unfasten the support rectifier set;
- Remove the connection of the rectifier with the
11.6. RECTIFIERS exciter rotor;
Each generator is fitted with 3 rectifiers AND and
Failures on rectifier are usually caused by external 3 CTD.
factors (voltage peaks, synchronism error, etc). Fix he support on the vice to remove damaged
When one of the rotating rectifiers burns out, it is rectifiers and mounting new ones.
also required to check the condition of the Place 3 rectifiers of same polarity (AND or CTD)
remaining pieces. Even when the tests indicate on the support. Fasten them with torquemeter
good condition, it is impossible to determine if the following mounting torques of table below;
others are also in good condition. Due to that, Fix the other support on the vice in the same way
and due to the fact that a rectifier set makes part of the previous support;
of the excitation circuit of the synchronous Place on this support of contrary polarity to those
machine, we recommend to replace the whole 3 previous rectifiers (AND or CTD)
rectifier set. This will reduce the risk of new stops Use torquemeter following the mounting torque
originated from a damage of the remaining table.
pieces.

28
GENERATORS SYNCHRONOUS

Rectifier base Torquemeter Mounting Drain the condensed water and clean the inside
thread (mm) (mm) torque (Nm) of the terminal boxes;
Measure the insulation resistance or polarization
M6 11 2
index as per tables given in item Insulation
M8 17 4 Resistance.
M12 24 10
M16 32 30

Lack of complete maintenance on generators


will cause accumulation of dirt inside.
Under such conditions, its life time can be
It is fundamentally important that the torque reduced causing unexpected stops along with
indicated be respected to avoid damage to additional repair costs of the equipment.
rectifiers while mounting them.

11.9. DRYING OF WINDINGS


Commercial
Designation
Frame WEG Designation It is recommended that this task be undertaken
Semikron carefully and by qualified personnel.
The complete drying is done during 4 hours in an
AND SKN 50/12
oven at 60 to 70 degrees C.
DS6
Up to 315 CTD SKR 50/12 During drying process, temperature should be
controlled carefully.
400 and AND SKN 71/12 In the beginning of such process, the insulation
DS8
above CTD SKR 71/12 resistance will decrease due to temperature
increase, and will then increase as the insulation
Chart of diodes used.
is dehumidified.
The drying process should continue until
successive measurements of the insulation
11.7. AIR FLOW
resistance show a constant insulation resistance
which should exceed the minimum specified
Air inlets and outlets must be free so as to
value.
provide improved exchange of heat. In case of
The winding is effectively dried through a warm
poor heat exchange, generator will overheat
air flow.
which can cause damage to its winding (burn of
To ensure that the warm air is dry, a certain
generator).
number of fans must be uniformly placed on the
air inlet side.
In case the humidity level is excessively high,
11.8. COMPLETE MAINTENANCE space heaters should be provided between the
fans and the winding, or use forced ventilation
Maintenance cycles depend on the environment heaters.
conditions where the machines are installed. The It is extremely important to provide a satisfactory
more aggressive the environment is (dirt, oil, ventilation inside the generator during the drying
ocean effect, dust, etc) the shorter the process ensuring removal of the moisture.
maintenance intervals should be. The dehumidifying heat can also be obtained
Clean the dirty windings with a soft brush. energizing the generator space heaters or
Grease, oil and other impurities which adhere on circulating current through the windings being
the windings can be removed with a rag soaked in dehumidified.
alcohol. Dry it with a jet of compressed air.
A jet of compressed air should be also used to Important:
clean air ducts in the stator and rotor laminations Disconnect and remove the Voltage Regulator
as well as bearings. before placing the generator in the oven.
NOTE: Compressed air should be always used
after the cleaning, never before!

29
GENERATORS SYNCHRONOUS

11.10. MAINTENANCE SCHEDULE

Each Each Each


Verifications and tasks of maintenance to execute Daily
250 h 1500 h 4500 h

Observe strange noises with the generator in movement. *

Inspect the ventilation (air flow). *

Verify the Insulation Resistance. *

Verify and retighten the screws and connection terminals. *

Verify the vibration and noise levels. *

Inspecct the bearings. *

Inspect the voltage regulator connections. *

internal and external cleanness of the generator. *

Inspect the functioning and connections of the accessories (space heater ,


*
temperature detectors...)

Inspect the retifiers. *

1
Lubricate the bearings

2
Change the bearings

Complete revision of the generator. *

1- Verify the lubrication interval and quantity of grease in the item Lubrication of this manual.
2- The change of the bearings must be effected to each 20000 hours or when present defect.

NOTE: The verifications and tasks described in the table above must be executed in agreement with the
item Maintenanance of this manual.

30
GENERATORS SYNCHRONOUS

12. SPARE PART LIST

Below are listed the main generator components. To order any of these components, or any other not
included herewith, please contact Service Department of WEG Mquinas or one of our
representatives/distributors.

12.1. SINGLE BEARING GENERATORS (B15T) - STANDARD

1. Shaft 5. Main stator 9. Terminal board 13. Rectifier


2. Discs 6. Frame 10. Voltage regulator 14. Non-drive end bearing
3. Flange 7. Main rotor 11. Non drive endshield
4. Fan 8. Terminal box 12. Main exciter stator

12.2. DOUBLE BEARING GENERATOR (B5/B3T)

1. Shaft 5. Main stator 9. Terminal board 13. Rectifier set


2. Drive end bearing 6. Frame 10. Voltage regulator 14. Non-drive end bearing
3. Drive endshield 7. Main rotor 11. Non-drive endshield 15. Flange
4. Fan 8. Terminal box 12. Main exciter stator
31
GENERATORS SYNCHRONOUS

12.3. SINGLE BEARING GENERATOR AND AUXILIARY EXCITER (SPECIAL)

1. Shaft 5. Main stator 9. Terminal board 13. Rectifier set


2. Discs 6. Frame 10. Voltage regulator 14. Non-drive end bearing
3. Flange 7. Main rotor 11. Non-drive endshield 15. Auxiliary exciter rotor
4. Fan 8. Terminal box 12. Main exciter stator 16. Auxiliary exciter stator

32
GENERATORS SYNCHRONOUS

13. TROUBLEHOOTING
We are listing below some abnormal situations that can occur during generator operation along with
identifying probable cause(s) as well as some suggested corrective measures.

Generator is not exciting

ABNORMAL SITUATION CORRECTIVE MEASURE

- Check lead connection of the auxiliary coil at the


- Interruption in the auxiliary winding circuit; connection block until getting to the regulator
- Burn fuse. connection block;
- Replace the auxiliary fuse (as specified).
- Provide an external excitation with a 4.5 Amps,
12 V battery until the excitation starts:
- Negative pole at F-;
- Positive pole at F+.
- Residual voltage excessively low.
- Always disconnect regulator leads to avoid
damage.
Warning: When using a Diesel start battery, this
can not be grounded.
- Measure the speeds. Eventually make new
- Incorrect drive speed.
regulation.
- Check connection of leads F+ and F-;
- Interruption on the main excitation circuit. - Measure all rotating rectifiers; replace defective
rectifiers or replace complete set.

- Defective relay or another regulator component. - Replace voltage regulator.

- External voltage adjusting potentiometer broken - Check connections of terminals 11-12 as well as
or connection interrupted. the potentiometer.

- If defective, replace it; if replacement parts are


- Protection varistor, if any, is defective.
not available, remove it temporarily.

Generator is not exciting up to rated voltage

ABNORMAL SITUATION CORRECTIVE MEASURE

- Defective rotating rectifiers. - Replace the rectifier set.


- Incorrect speed. - Measure the machine speed and adjust it
- Adjust it in the potentiometer, in the regulator or
- Adjustment below the rated level.
in an external potentiometer.
- Feeding voltage of the regulator is not in - Check if the connections are in accordance with
accordance with the outlet voltage required. the Voltage Regulator Manual.

33
GENERATORS SYNCHRONOUS

At no load, generator excites up to rated voltage.


However, it collapses when load is hooked up

ABNORMAL SITUATION CORRECTIVE MEASURE

- Significant voltage drop. - Control diesel selector.

- Defective rotating rectifiers. - Replace rectifier set.

At no load, generator excites by over-voltage

ABNORMAL SITUATION CORRECTIVE MEASURE

- Defective power tiristor; - Replace the Regulator / transformer (Check


- Defective voltage feeding transformer; voltage/operating voltage);

- Feeding voltage of the regulator is not in - Remake the connections. Check the Voltage
accordance with the outlet voltage required. Regulator Manual.

Voltage variations on the generator

ABNORMAL SITUATION CORRECTIVE MEASURE

- Stability poorly adjusted - Adjust regulator stability in the trimpot.

- Frequent variations are originated from the drive


- Speed variations on the drive machine.
machine and these must be eliminated.

Mechanical problems (over-temperature, noise and vibration)

ABNORMAL SITUATION CORRECTIVE MEASURE


- Excessive bearing temperature. - Check bearing, grease and axial clearance.
- Cooling air (inlet and outlet) partially blocked, or
warm air is returning to the generator;
- Excessive generator frame temperature.
- Generator overload;
- Over-excitation.
- Misalignment (coupling);
- Excessive vibration. - Mounting defect;
- Coupling clearance;
Causes:
- Significant voltage drop with further recovery - Adjust stability;
(blinks). - Put CT in short;
- Reduce load.

IMPORTANT

All machines included in this Manual are constantly updated.


For this reason, any information given herewith may change without prior notice.

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GENERATORS SYNCHRONOUS

WARRANTY TERMS FOR ENGINEERING PRODUCTS

These products, when operated under the conditions stipulated by WEG in the operating manual for such
product, are warranted against defects in workmanship and materials for twelve (12) months from start-up
date or eighteen (18) months from manufacturer shipment date, whichever occurs first.
However, this warranty does not apply to any product which has been subject to misuse, misapplication,
neglect (including without limitation, inadequate maintenance, accident, improper installation, modification,
adjustment, repair or any other cases originated from inadequate applications).
The company will neither be responsible for any expenses incurred in installation, removal from service,
consequential expenses such as financial losses nor transportation costs as well as tickets and
accommodation expenses of a technician when this is requested by the customer.
The repair and/or replacement of parts or components, when effected by WEG within the Warranty period
do not give Warranty extension, unless otherwise expressed in writing by Weg.
This constitutes WEG' s only warranty in connection with this sale and is in lieu of all other warranties,
expressed or implied, written or oral.
There are no implied warranties of merchantability or fitness for a particular purpose that apply to this sale.
No employee, agent, dealer, repair shop or other person is authorized to give any warranties on behalf of
WEG nor to assume for WEG any other liability in connection with any of its products.
In case this happens without Weg' s authorization, Warranty is automatically cancelled.

LIABILITY

Except as specified in the foregoing paragraph entitled "Warranty Terms for Engineering Products", the
company shall have no obligation or liability whatsoever to the purchaser, including, without limitation, any
claims for consequential damages or labor costs, by reason of any breach of the express warranty described
therein.
The purchaser further hereby agrees to indemnify and hold the company harmless from any causes of action
(other than cost of replacing or repairing the defective product as specified in the foregoing paragraph
entitled "Warranty Terms for Engineering Products", arising directly or indirectly from the acts, omissions or
negligence of the purchaser in connection with or arising out of the testing, use, operation, replacement or
repair of any product described in this quotation and sold or furnished by the company to the purchaser.

WEG INDSTRIAS S.A. - MQUINAS


Av. Pref. Waldemar Grubba, 3000 89256-900 Jaragu do Sul/SC - BRAZIL
Phone: 55 (047) 372-4000 Fax: 55 (047) 372-4030
So Paulo/SP Phone: 55 (011) 5053-2300 Fax: 55 (011) 5052-4202
www.weg.com.br

1013.02/0295

35