‘Operating and maintenance marae ‘ivian ‘One complete set of ‘operating and main- tenance manuals for Your diosal power station consists of the following binders: 41. Operator's manual A Mechanical & electrical drawings ‘8 Mechanical & electrical drawings C Enclosures 4. 4 4 5.A Electrical system, ‘Operating instructions Component catalogues 5.B Electrical system, ‘Component catalogues for panels 5.C Electrical system, ‘Component catalogues for logic 5. Electrical system, Control system drawings 5.E Electrical system, LV- and HV-system ckawings 5.F Electrical system, ‘Auxiliary panel drawings 5.G Electrical system, PLC- program 1/2 5.H Electrical system , PLC-program 2/2 6. Mechanical auxiliaries 7. Black start unit 8, Logbook and maintenance information‘SYNCHRONOUS GENERATOR HSG 900KS8 INSTRUCTION FOR USE AND MAINTENANCE CONTENTS 41, Technical specification 2. Test report Dimension srawing 50208707 Shaft with rotating masses 50204723, Assembly drawing 50420833, “Transport and hoist 0232182 Removing rotor 50228983 ‘Connection diagram for generator 50205886 Lay-out of connection 150236331 ‘Connection diagram for regulator 50415163 Instruction manual for generator 34HSSE Instruction manual for voltage regulator 34 GXSE Winding maintenance 34 ZU1E1 Exciter rotor with diode bridge 60023168 Dodes ( Semikron } 'SKKD 260/12 \Varistor ( Semikron ) SKVC 20.460 Bearings -Deond Lohmann & Stolteroht — LFZLK 22/225 -Neond Lohmann & Stollerfoht §— LFZLQ 22225 Oil connections 80235211 = Instructions 410. Piotron GR air filters [ABE StrSmberg Drives INSTRUCTIONS FOR GENERATOR Hs 900xs8 wa ciel = a an 93-06-29 MN 1858ne. doe 1‘STROMBERG BRUSHLESS SYNCHRONOUS GENERATOR FOR LAND A2PLTCATION PERFORMANCE DATA (CALCULATED VALUES) re sc RATING: ‘oureut POWER FACTOR 0.80 YOUTAGE 11000 FREQUENCY 50 CURRENT 401 SPEED 750 OVERSPEED 900 MOMENT OF INERTIA (3) 3250 STORED-ENERGY CONSTANT (1) ost 900Ks8 7640 STANDARDS IEC __ ALETTODE z INSULATION CLASS F Ie MH EFFICIENCY TN & + TOAD, POWER FACTOR 0.60 POWER FACTOR 1:00, n108 erat 97:90 REACTANCES IN %D = 202 x9 = 93 xor = 04.20 Qs gprs a3l0 RESISTANCES AT 20 DEGR.-C ‘STATOR WINDING = RL = FIELD WINDING = RF = EXCETER FIELD = RM = 0.0780 0.575 78 [TIME CONSTANTS (SEC,) AT 75 DEGR.-¢ Toor = 3.5. TD! = 0.62 oo"! = orozi TOY’ = 0.016 Ta" SHORD-CIRCUIT RATIO 0.87 SUSTAINED SHORT-CIRCUI? CURRENT ‘RATED EXCITATION WITH VOLTAGE. REGULATOR SUDDEN SHORD-CIRCUTT CURRENT ‘SYHMETRIC RMS. VALE PEAK VADE ALIGHED STARTING-KVA ‘POWER FACTOR VOLTAGE DROP MAX 158 VOUBAGE DROP MAX 208 3680 5000 \WETH SUDDEN CHANGE OF RATED LOAD ‘VOLTAGE. DROP VOLTAGE RISE -20 tas 2008 97-35 97183 “Tgo"" = 0.086, prs/es 5204 DATE 92-12-27 1855 HC 101 REFERENCE No WO /BINTAN CusTOMER OUTLINE DRW No. MOUNTING 1H 1102 PROTECTION TP 23, KVACOOLTNG IC 01 v wexout i x ymin Ran Koma s 21 600 KG. AMBIENT TENP. COOLING WATER TEMP ‘TEMP. RISE sot 96.69 97:53 758 gran 97:80 29.3 26:2 xo = 11.6 XP = 25.7 ome one om TA = 0.23 = 0.022, 0.8 3900 5350 0.8 5350 ' %‘STROMBERG ype ;__ s00xs8 STEADY STATE REACTIVE LOADING ‘AD RATED EXCITATION ‘BE 2ERO EXCITATION 3650 3600 FULL LOAD TORQUE 97500 SUDDEN SHORT-CIRCUIT ATR GAP TORQUES 2-PHASE 565 S-PHASE 520 ExcrTATION NO LOAD KCTTER 2.6 a/ Tea? BEARINGS ‘TYPE: D-eND N-END LIBRICATION WORE OTL REQUIRED SLEEVE SLEEVE aor sé /HIN HEAT EXCHANGER ‘COOLING WATER REQUIRED (COOLING WATER PRESSURE DROP SPACE HEATERS No. OF TEXPERATURE DETECTORS ‘SE-KINOING PP~100 BEARINGS PT-100 00L.MED. PT-100 ADDXTIONAL CONTROL DEVICES! pre/es DATE 92-12-17 HVAR (HD.) KVAR (CAP) & (PEAK VALUE) 3 (BEAK VALUE) FIELD 26.0 V FLOOD LUBRICATED 5-6 BARTESINDURTAY CUSTOMER WARTSILA DIESEL /BINTAN ORDER —PO200II8_—_— TSSSHCION ‘545100 sonst TEST SHEET Ao 1@) isc sooxss par S-PHASE GENERATOR TeAonA St y 750 (a 800) nin EXCITATION. INSULATION CLASS F [AMBIENT TEMP. MAX 50° im si08 ata "20v NR. 4545100 6089080 s0.0He a28 CL VISUAL NSPECTION AND INSPECTION OF BEARINGS FAVE BEEN WADE ECR —30- Sam INSULATION RESISTANCES ‘STATOR WINDING ATAGIENT TEMPERATURE ROTOR WINDING BEFORE TESTS. FIELD WINDING. Tez SPACE HEATERS. PLt00 (STATOR) PLt00 (BEARINGS) | RESISTANCES OF WINDINGS WACFINE [XT AMBIENT TEMPERATURE, UW 0156750 Fedeec UW ose a WW 0458830, Rossa tye lahy [OveRSPEED TEST too amir S050 Ma 000 Maa 0000 Maa 2000 MA. 0000 Ma. 30000 Mak ‘qo00V Bey ‘000 06) ‘000 D0) (g00V Dc) (G00. 0c) (S00V 0c} STE Ww uw w oon. oot a coma 050 [rast Secvence 0 V-= W__ DIRECTION OF ROTATION: <= (COUNTER CLOCKWISE) a uw 47. $20. tare, Hous: ‘72. TNOTOAD CURVE wh 583 307 287 21 {83 800 ‘SHORT-CIROUT CURVE WA IgA eon, 788 wos 557 503 an 2a n= 7501Imi0 Temp. 43°C dLogro ks we Crmanen | APPROVED ON BERALF OF THE CUSTOMER | APPROVED ON BERALF OF THE MANUFACTURER 9646-11RRB TROUSTAY Tas TEST SHEET Ae 2a TiGH VOLTAGE TEST sore, tin [ RSULATION RESISTANCES AFTER TESTS Taare ‘STATOR WINDING 25000 ROTOR WADING "2000 V FeLDWNONG. — 2000 SPACE HEATERS 1500 Prt09 (STATOR) 1600 PLt00 (BEARINGS) S00 ‘STATOR WINDING S000 ROTORWNONG —_3000Ma_ FIELDWINDING 300000 SPACEHEATERS 200000 Prto0 (STATOR) 500000 PLtO0 (BEARINGS) 200080ABB Industry ‘TEST SHEET - POYTAKIRJA Shean AS VIBRATION MEASUREMENT _WARTSILA DIESEL 85540103, HS 900Ks8 4545190 om reo wa |" 13000. so He 3s soe Ld eK 2519 ea VipRATION VELOCITY. ms (nas ‘ane-oid Uy=stt00.v n= 750:mnin Manlng: void on on MEASUREMENT PONTS from bearing rackets oxo Mp4 ND. end hotzontal Nps NO.-end verleal Mp8. ND. -end adal a 038 VIBRATION ANALYSIS. ama | 1 omyTEST SHEET - POYTAKIRJA, ABB Industry aed WARTSILA DIESEL ur Hs oo01s8 mn 4545100, $SSSHC101 peas 8 Saoene f 1999-06-11 OLoyro te mene AT lua ‘J VOLTAGE Manufacture of rut: Regulator ype: eral TOULATOR SETTINGS AND TESTS: Intemational Electic ‘@xcs00PR 888 (MA) 7 otage sang ange |e: Unaereaqney ini cing 3 Beting ampieatan aT Ow 3 noload © Sustained Sareea caret “Ena vatage Bui-up and Topuaion speed at aes spacial iat whoaT Uys stator ineotine votape Uty= 11000 V (tod stator vo Ut” ator coment p ‘etalon cureat speedABB Industry TEST SHEET - POYTAKIRJA ome” __WARTSILA OSE, Pm TGF isc woos mee 1555HCI01 amas 4545400 Rae Senn roe _ 1088.08 oon ens AT |uee XJ Woctate REGULATOR SETTINGS AND TESTS Manufacture of equator: International Elacic Regulator ype Gxe00PR Serato. 193888 (MA) 7 Vargo sng ange De Ow | 2 Unsencegnanay ti tine aR Sag a arpicon 3 “Ea yoga Bun and Topaon Speed at | 600 spec ex haat oad - 5 Sustained Hot area Garon “8 tier vag roqulor U;= stator tineosine votage Uj = 11000 V (ated stator votage) WE stator eureet Uys tection eurent SpeedABB Stréi aT ocd 4 4 LOAt ai 0. fi FSET pe C_Fo0 XS. in = 4208790 Dole 95-00 AR. mberg Drives TEST SHEETABB Industry TEST SHEET - POYTAKIFJA [ese WARTSILA DIESEL a frensare__155SHC101 ave Bx Jae MovoyABB Industry TEST SHEET - POYTAKIFIA WARTSI DIESEL Pe [OF usc vous ssesHo101 Vane 4645100 Se = s Soe Pann 10830648 < han meee Ag luse 22 Iii TEET,-VOLSAGE RE AND REGULATION GPEED AT NO-LOAD eee ax 52x Uovova 1 z I 3 4 8 6 1 8 i — 1950 —————») He ui CENTRE OF GRAVITY 2065 - Bs : X 605 ~ A 359 L R a UNDRILLED — ALUMINIUM u2.ve.w2 N urvi.wi 600 N 2400 8 | Do Fe aes Ret ---- — aa rT 1800 540 600 : Uy | : 300 Lief 7 : l— 200 ; | | | | | -+—_____—. 2860 te o | | #16 PREDRILLED D i 125 | - DOWEL PIN HOLE i i = ¢ + 7 ' f t oo Le | | 1) DIRECTION TO REMOVE FILTER | | el i 2) TERMINALS, SEE DWG 50204715 ; See — 1-6 or cenerator = : po T | | i 4} 210 - - 210 | — | ae 9 a a2 L 250 + | | { t i | BH} rhe fr Sle = 9212-01 "SYNCHRONOUS MACHINE io], BI #16 PREDRILLED : "TF SARAMO yaar ae c DOWEL PIN HOLE LL ips fo Ke ab an et rea Fg Ss an exo PE HYNYNEN 93-03-10] 77300 x6 | SG 900xs8 "mon "AZ fe] ABB Stromberg Drives wcimes [Sar 50204707 lie 7 5 ; T1114 T1111 y | Fi | ;2 3 4 5 6 7 A | EXCITER | \ CENTERLINE m=225k9 CENTERLINE ' OF BEARING OF BEARING ul i 1) |e 8 1 580. 495 990 1230, 475. it . ! i i i | | | - : | | i i | | | | i - i i c en en! H | c gg ij i | SS) | ; | ' | . | | b [I ee | an | | 3 3 a : 3| 2] [S|| 3 i a ail si i 8 8] [8] 8 el ffell] el fel] ie 20 1150 mar 0 300} [150|_ 200 325 _|s0] 1 i | My 3880 [es 1 i Te TOTAL WEIGHT 9600 kg : TOTAL 4 1200 kgm? TORSIONAL STIFFNESS 3x10? Nm/rod I a ar a F [92-12-01 "Sue WITH ROTATING to | ¢ | [PF saRaMo Foay PTe a =| S| ws go208 FS, ar en Le E vwynen 93-03-0[" KG | HG s00xse "im Faz gi ABB Stromberg Drives macmes ["Sarp 50204723 Beant a | 8"ASSEMBLY DRAWING fa PIe fee Py a . HS6900.. KG Stromberg Drives _vacines 9 Sar 50420833 * q 8x c TRANSPORT AND HOIST T a T T HOIST OF SEAWORTHY PACKING WEIGHTS (KG) DIMENSIONS OF SEAWORTHY PACKING 8 POLES 10 POLES TYPE IM A B HEIGHT WIDTH LENGTH | GROSS/NET | GROSS/NET HS_ 710s__| 1305 | 2210 2960 1500/9800 | 10900/10200 HS_710M_ | 1305 | 2410 3160 | 11700711000 | 12100711400 | HS_71oL__ | 1305 | 2610 3360 | 12900/12200 | 13300712600 | Hs_71os__| 1101 | 2210 | 2200 2200 1960 3160 10600/9900 | 11000710300 HS_710M_] tto1 | 2410 3360 | 11800711100 | 12200711500 | | HS_710L__| 1101 | 2610 3560 | 13000712300 } 13400712700 HS_710xX__| 1101 | 2810 3760 | 14300/13600 | 14700/14000 Hs_900s__| 1101 | 2280 3630 | 17200716100 | 17600716500 j Hs_900M__| 1101 | 2480 | 2700 2600 2010 3830 | 20200/19100 | 20600719500 Hs_ 900L__ | 1101 | 2680 4030 | 28200722100 | 23600/22500 | Hs_1120S__ | 1101 | 2280 3730 | 27600/26100 | 28400/26900 | Hs_1120M__| 1101 | 2480 | 3370 3020 2510 3930 | 31600/30100 | 32400730900 Hs_1i20.__ | 1101 | 2680 4130 | 35600734100 | 36000/34500 L 6 ‘ABB STROMBERG DRIVES)" T MACHINES ke IM ee] TRANSPORT AND Horst | 42 ae OF SYNCHR «MACHINE [imme @ pncriw are Po AS HS_710790071120 50232182 A TaRgD-O5-28__J-SARAMO [OWNED eax TEE 9B-O4- 11 E -STLANOERROTOR LAUFER (ae FRAME, STANDER D-END EXTENSION SHAFT AT N-END WELLENVERLAGERUNG eS ) lonve OF ROTORS GRAVITY MODEL TYPE HS710_ HS900_. - -HS1120_ SCHWERPUNKT DES LAUFERS LENGHT LANGE | _K H K H $s 1450 _[ 3400 |" 1600 3700 M 1600 | 3800 | 1750 4100 7: a }00. vewaso VIEW a VON OBEN GESEHEN 3s F ABB STROMBERG DRIVES a T ae MACHINES Ko IM “DIMENSION PRINT ~ REMOVING ROTOR As ae FROM O-END T N-END AUSBAU DES LAUFERS Po as HS710... HS1120 50228983 C mnigy 03-32 T-RETTOLA [CAMEO TAIMAQE [95-05-26 HEGULATOR PLATE (SEE DRAWING 50415163) we ue ot ip ishepo} ee T 6 9 2 8 5 (eee ERO eee a tes Ry lel i i i | uz wr | EEE sos 1 ua ‘CORED core2 P2 PI P2 PI i 13 b a as SPACE HEATER TEMPERATURE sensors Sage BISSAU, SISP aan v 100 | Cwnoincs (SPARE) \ | vw | | | 2 13 4 DIRECTION OF ROTATION D-end, THE GENERATOR CAN BE CONNECTED ONLY IN THE GIVEN DIRECTION OF ROTATION B1 MAIN TERMINAL SPACE AND TRANSFORMER CONNETION B2 TERMINAL BOX FOR ACCESSORIES B3 CONTROL CUBICLE OF CUSTOMER TI VOLTAGE TRANSFORMER 11000V / 110V / 110V , SOHZ SECONDARY 1 110V 3500VA FOR EXCITATION SECONDARY 2 110V 300VA FOR ACTUAL VALUE MEASUREMENT CURRENT TRANSFORMER FOR PARALLEL OPERATION IHDA 500/1A 10VA CLI,0 CURRENT TRANSFORMER FOR EXITATION POWER KOKM 500/5,7A , SOHZ CURRENT TRANSFORMER FOR MEASURING AND PROTECTION KOFA 12 S00/5/5A , 50HZ CORE 1 20VA 5P10 CORE 2 20VA 5P10 +) PERMANENT EXCITATION 24 VOC, <15A / 2 SEC +*) NOT SUPPLIED BY ABB STROMBERG DRIVES. u = oe ALARM °C] TRIPPING °C] ie lee ele wnDnGS [140 ms 155SHC101 eI SHH — HH. ue WARTSILA DIESEL 38 RRRFER ERR “frre | oe = I =| tees To | PF NISSINEN fom PTC MAIN CONNECTION DIAGRAM ae} aI ES” sor len q PA. NSSNEN xo | wSG900xs8— Pa g ABB Strimberg Drives mcmes [Sar 50205686 er 7 T 5 T > T ,..Tt T ‘ T 7 T 2—— r 5 o = ad t = To SECTION A-A 2 A 2 || 2 L| 8 3 ; ql i 5 3) 4 < 4 a — ee 4 URRENT TRANSFORMERS IN NEUTRAL POINT || 1.205 7 L| 3 | 3 2) fe y § ~ = = ERIo 5 q sla @ Pl S $50. | & R = ; = “ak I] | q (2) i) 6) + i 6] | 3 | 5 lo A 4 415 | 4 K [| Iota mn THAT DRAWING CAN USE REFLECTION TOO. 7 | ~—CU-BAR DIRECTION OF THE CONNECTION WILL BE ACCORDING TO OUR OUTLINE DRAWING ~ 5 /— | CURRENT TRANSFORMERS —= VOLTAGE TRANSFORMER | I | 2 2 ‘ABB STROMBERG DRIVES ver eee T MACHINES: wo || z oe jee [ET 4 8 LAY-OUT_OF a2 ae : CONNECTIONS Co 4g Po DA y 7 ee ieee) N-END HsS_900 50236331 B qo > = a L seo 18 BROT Sema F-SARANO [T= 9D-O5- 1B KETTINA feed( AA : VOLTAGE REGULATOR GX 308 PR Joule} infec} |oofor| S| =I} SI [eoieicabeglcoleulcujeulcu| | + 2 " ” ” ” 1% +) NOT SUPPLIED BY ABB STROMBERG DRIVES. PLEASE, SEE ALSO MAIN CONNECTION DIAGRAM OF GENERATOR MA VOLTAGE REGULATOR GX 300 ole} 2jolsalalelsia) = {air no 339) ” 3G B z a Loyer: DE: @25-TEXT EN: 035-TEXT PI R D1 FI KI K2 K3 ovR-1¢ R2 cor 1 D2, D3, D4 RECTIFIER BRIDGE SKD 30/16 CIRCUIT BREAKER PKZMI~16+NHIl1-PKZMI+A-PKZMI (110V, 5QHZ> EXCITATION CONTACTOR OK @G1@/119 VDC + BLOCK OKZAI CONTACTOR OK 0R22/110 VAC + BLOCK OKZA2 CONTACTOR OK @8T22/11@ VOC + BLOCK OKZA2 © OVER VOLTAGE RELAY > 1 KOHM, 25 W INNECTIONS, VOLTAGE ACTUAL VALUE 110V PHASE TO PHASE LL, L2, L3 TO TERMINALS 1, 2, 3 RESPECTIVELY ~ PHASE SEQUENCE OF TERMINALS 1, 2 AND 3 SHALL BE CLOCKWISE enousun EXCITATION POWER SUPPLY 110V OR 165V PHASE TO PHASE EXCITATION OUTPUT < 30@V, < 15 SHORT-CIRCUIT EXCITATION CURRENT SUPPLY 128 AC CURRENT ACTUAL VALUE, 14 RATED CURRENT OF LINE L2 EXCITATION ON/OFF ON = VOC ALARM CONTACT, EXCITATION CONTACTOR ON/OFF ALARM CONTACT FOR CIRCUIT BREAKER OF EXCITATION POWER REMOTE CONTROL VOLTAGE SETTING POTENTIOMETER RI, 18 KOM IW ” REMOTE CONTROL POWER FACTOR SETTING POTENTIOMETER R2, 18 KOHM IW => POTENTIAL FREE CONTACT INFORMATION FOR SWITCHING ON/OFF THE POWER FACTOR CONTROL «>. RF. CONTROL ON WHEN CLOSED CONTACT > CHANGEOVER FROM REGULATOR AA TO REG. MA. MA = 110VDC POSSIBILITY FOR EXTERNAL EXCITATION @ --> 11evoC TERMINALS 338 +, 273 — yoo X3i 1-2 SHORTED AT EXCITATION POWER VOLTAGE l1ev X3: 1-2 OPEN AT EXCITATION POWER VOLTAGE 165V 1S85HC 93-04-30 "AVR connection diagram PF Nissinen 930505" bay FC v1 3} en ie KG 42 ABB Stromberg Drives mowes ‘AEP 50415163 ‘a 7INSTRUCTION MANUAL FOR SYNCHRONOUS GENERATORS HSG 710, HSG 900 AND HSG 1120 TO BE COUPLED TO A DIESEL ENGINE INSTRUCTION MANUAL ABB DrivesINSTRUCTION MANUAL FOR GENERATORS HSG 710, HSG 900 and HSG 1120 IM 1101 GENERAL “This fle contains inetructions for the HSG 710, HSG $00 and HG 1120 generators, tobe coupled wih a diesel engine. Fig 1. Generator HS 900 (Contact information: Acdeoss: ABB Stromberg Drives Oy ‘Synchronous machines P.O.box 186 'SF-00381 Helsink’ Finland Teexchange: — +358-0-5041 Teetex: +358-0-5642675 Teex: +57-12440510 STR SF ABB Strémborg Drives 1962-0600 J. Vas /PTCCONTENTS GENERAL, CONTENTS RECEIPT AND STORAGE Inspection on receipt of the machine Liting and handing ‘Storage and care after unpacking Care after instalation INSTALLATION AND PRE-COMMISSIONING General recommendations Mounting ‘Alignment Flood lubrication il low reguiation Bearing insulation ‘Measuring insulation resistances of windings and sundries Drying the windings ELECTRICAL CONNECTIONS General recommendations Connecting cables and auniiaries REGULAR CHECKING AND ROUTINE MAINTENANCE ‘Checking Est and maintenance records ‘Checking ‘Cleaning Schedule for checking and maintenance ‘Complete over-haut DISMANTLING AND RE-ASSEMBLY Preparation for dismantling ismanting Re-essembly and re-alignment ‘QUICK REFERENCE DAILY CHECKING UST ABB Stromberg Drives | 156.710, Hs 900 AND HOG 1120 1101 INSTRUCTION MANUAL FOR, oT eT 9920649 J. Vara/PTCRECEIPT AND STORAGE Inspection on receipt of the machine ‘Any transport damage should be reported immediately tothe transport company and tothe supple af the machine, After removal ofthe packing, the machine should be inspected to find possible damage which has occured during transportation. Check the packing list for missing parts and accessories and report tothe supple. iting and handing \When fiting the machine, use the lftng batk. Observe thatthe tting luge featened to the top cover ofthe generator are intended for ting the cover only, not the whole machine. ‘Storage and care ater unpacking When necessary, unpacked generator should be stored in a clean and ventiates place, where the relative humidity of the air does not exceed 75 %. Hthere's arisk ot tigher humidity, the space heaters built inside the machine must be lectifed 10 keep the machine dry. Unpainted surfaces Bke shalt extonsions, coupling halves and jacking sorews should be protected using sutable antiust coating. INSTRUCTION MANUAL FOR ABB Stromberg Drives | 36 710,196 900 ANDHSQ 1120 IM 1101 ® me = [a 1902-0600 J. Vats/PTC SMHGSE A“The floor under the ganerstor should be free from excessive vibrations. ths Vibations are suspected to be too large, precautions should be taken to iste the ‘machine ¢.g. placing rubber blocks under the feat. Keeping the bearings of he ‘machine in good condtion requves fushing them with protective oil and turing of the rotor about 10 revolutions every 2:3 months. If the machine fs out of service for &longer period of time, care must be taken to protect the shaft and the seaing points as well es all baring parts against corrosion. ‘The oilin the besring housing is changed to protective ole.g.: Esso: RustBan 623 Gu: Gui No-Rust Engine Oil Grade 2 Mobil: Moblarma 524 Shell; Sho Ensis Engine Oi 20 ‘Tebolt: Teboll Sheter SAE 30 ‘Detaled instructions for maintaiving the windings in good condition during @possibie storage period are describedin a special instruction. Cave after instalation 1f the generator wil nat be in operation for a longer period of time aftr instalation, the measures described earier in the paragraph 1.3 should be applied. is ‘uther ‘recommended to switch the food lubrication on and tu the rotor about 10 ‘evolutions once pet every 2:3 months to maintain good bearing operation. INSTALLATION AND PRE-COMMISSIONING General recommendations “The cooling ir supply to the machine must be ensured in all operating stusions, i the iflowing cooling ails too warm, orf the air low is reduced, the output ofthe ‘machine must be lowered to keep the winding temperature below the it value. ‘Around the machine there should be sufficiont space to allow routine maintenance ‘and contralto be carried out. Sutabl iting equipment should be avalable. 5 INSTRUCTION MANUAL FOR ABB Stromberg Drives | sq 710, #86 900 AND HSG 1120 IME1101 [ce ale or male“The mechenical locking dovice ofthe rotor (ig. 3). needed to ensure transportation, ‘should be removed. Ths parts is painted in 8 special colour (normally red). At-rust ‘costing should be removed trom surfaces where normal operation wil require ‘uncoated metal Fig, 9 Mechanical locking devices (Ver. a and). 22 Mounting For mounting ofthe generator stention should be pald to the following precautions. * Sheet stool material for shimning is avalable + Jacking screws for vertical posoning of the machine 2s ‘well as adjusting sovews or hydraulic Jacks for axal and lateral adjustments are avelable Dial indicator gauges and other measuring instruments, and in eddtion devices for turning the rotor are avaliable CAUTION! Sleeve bearings ere defvered without of they shal be filed wit of ‘connected tothe flood lubrication system and the ol flow shall be on ‘and adjusted before trying to tum the rotor [RTT] remove ne mchaical locking devie ofthe rotor (1 or. 2,693). [2D check te coupling instructions and. Preheat the couping hub as necessary and mount iton the generator shaft [MI] Un up the gonerator accorting to the fig 2 and move over the bed plate. INSTRUCTION MANUAL ABB Strmberg DrWVES | asc 740, HS S00 ANDHSG 1120 M1101 Ys ee = 18020600 4 Vae/PTO[Rl Aton machin eval and pupecns of metal sheet below the Jacking Scrows to protec bed plate sutce. [RIL] Seow packing sews unt ey cay he wag of generator. Aignment ‘The alignment is done in accordance with the recommendations given by the coupling manufacturer. Parallel, angular and axial aignment ofthe machine is Tequired. Some standard puibcations gie recommendations for coupting alignment, f0g. BS 3170:1872 ‘Flexible couplings for power transmission. In acoordence with ‘common practice, paral, angular and axial misalignment should not exceed 0.08 “The alignment accuracy of the machine s sometimes affected by the thermal elongation of frame, Maximum elongation of the frame can be taken as 0.6 men par metre, corresponding to a tempersture rise of °C. In most operating ‘conditions, the temperature rise of tho frame remaine at about 40°C. “Tye alignments performed by rotating the diesel engine 90 degrees steps and measuring the dimensions between the diesel fywheal and generator rotor flange (fg. 4a below). Parallel alignment ‘angular aignmert 2 og Fig. 4a, Alignment scheme INSTRUCTION MANUAL FOR ‘ABB Stubmberg DAVES | gq 710, #56 900 AND HS 1120 1M 1101 ve | me, =~ |" “mm uveTBC] cock ne ec enc oto re rotor by rotting and measuring the oat and center the rotor axially. [E21 Algo the generator by wrenching the jacking screws, the adjustment screws orby aching hycraut jocks. IL Aor agnor, ako measures betwoon the matin fost ends and he base tram (Fig 4b.) and make the corresponding sod blocks or wedges or reserve the necessary shies. 4b,_ Measuring places for solid block di ‘Aor aormert the sold locks or shims under the stato fet. Slesken the Jacking screws and tighten the fixing bolts (8 pcs.) SIL] tech the ie ont and outet pipes. [AST] Alter ightering a fsing bots chack the afgrmert spin. ‘Check the air gap of the machine and the exciter. “The air gap of the generator shal be checked from the points shownin fg. 5. “The centring ofthe rotors adequate, if the deviation of a measured single value from the mean value s less than five per cent. TESTRUCTION MANUAL FOR ABB Stromberg Drives. | sq 710, HsG $00 AND HEG 1120 IM 1101 eS ae = = "199206-00 4. Vart/PTCRemove the covers of the air gap checking holes at D-end (nv.1 Fig.) and ‘check the air gap through the checking holes by a wedge shaped measuring ‘strip at four points using one pote as reference and tuming the rotor 90° ‘between messurements. Remove the ai fiter onside at N-end of stator frame (he. 2, fg. 5) and check the air gap of the machine and the excite. Hf alignment and sir gap checking are ok., provide the stator with tapered ‘guide pins. [BBL] Fixe couping scoring othe recommandason given by the coxping manufac. 24 Flood lubrication “The oil fow has to be on before starting the machine. The size end the location of ol inlets and outlets are indicated on a drawing included in the machine defveyy. needed, the oll connections may be changed from one side ofthe beering housing to the other. SNSTRUCTION MANUAL FOR ‘ABB Stromberg Drives | 14s 710, 156-900 AND H8G 1120. 1 2 902.0609 J. Vara/PTC‘Speciel care should be taken to secure the flood lubrication system, which must shut ‘down the machine if the ol fow is reduced 30 % ofthe sat value ‘Ol rings for emergency lubricstion allow safe machine shut down. CO supplied to the besring must be fitered, temperature being > + 10°C end oll pressure constant. Recommended ftering grade s 25 wm and normal ol pressure oproximately 00..400 kPa. The oiinlet pipe shallbe dimensioned so tht the low ratois < 2m/s, OL GURY ‘CET TEMPERATURES al rx [soe soe oC <9 'SOVG 180 $556 SOVG 270 ee PRESSURE Taser TESTO FSH Tear ‘The oll outet pipe shall have an adequate slope dawnwerds (rin, incination 1:20 or 25°) end ft shall be cimensioned 0 that the flow rate fs < 0.2 m/s and ro si looks ‘re formed. The ol return pipe shall continue below the of surface inthe angine oll ‘sump. This is important In order to avoid overiowing of bearing and ol feakages through shaft sels. In marine applications itis recommended to ft an of outet pipe ‘on both sides of bearing. Oil fow regulation -The ol flow reguiation is separately adjusted for each bearing before the ist starting. “The oll infos normaly fitted with the regulating equipment shown in fig. 6. ‘After the starting ofthe ol croulation system the manometer (2, fg. 6) is cjusted by means ofthe regulating valve (1, fg. 6) to Indicate the value 125:+25 kPa. Then the ol ‘ow to the bearing through the plate orifice (2, 9.6) conforms to the reference value. INSTRUCTION MANUAL FOR ABB Stiimberg Drives | 5c 730, HS 900 AND H9G 1120 M1101“The prope function a the besrng requires that the ol aw trough the bearng such as wil keep the boarng temperature at a sutaba level e “The agjustments checked while the machine is running when the beering and oi have reached operating temperature, nacessary, ol tow is inreased/decreased bby means ofthe regulating vate (1, fg. 6). The ol pressure given fs & estimate only, and ts quite applicable when the temperature of he of coming to the bearings approx +45°C. 1) regulating vate C 2)manometer 3) plate orice « Fig 6. Oi fow regulating equipment fender "7 STRUCTION MANUAL FOR aed ABB Stromberg Drives | sq 70, HG e00 ANDHSO 1120 mH sa e We | ms. ca vwon0cda .varejere | ‘ora2.6 Bearing insulation ‘Tre N-end beeringis insulated to prevent the shatt currents that might damage the bearing surtaces. The insulation is based on a efon fim thet is xed to the inner surface of the bearing housing (ig. 7). Check the insulation visually aways whan the bearing is dismounted and take care thatthe teflon fim doesn't get any scratches, “Tre temperature measuring instruments ofthe bearing are elso insulated. Measuring insulation resistances of windings nd audiaries “The insulation resistances ofthe windings and aunliary devices should be moesured before electrical connections are made and belore any votage is applied te the (generator. The measured value ofthe Insulation resistance wil tll the condition of the winding the insulation resistance is too low, measures must be taken ‘0 bring toan adequate level. Make the insulation resistance measurements early so you Wall ewe time to dry the windings ifnecessary. ‘The insulation resistance is measured using a special dc. tester or “mega. The testar should be connected at atime between one winding and the frame ofthe ‘machine, all other windings (phases) connected tothe frame and earthed, £9 8. INSTRUCTION MANUAL FOR, ABB Stromberg Drives | 454730, HSG 900 AND HSG 1120 M1101Fig. 8. Connection for insulation resistence test “The neoded test voltage for high vottage windings (@ KV operating voltage or over) is 2800 V. For cther windings and forthe reciying bridge, the test voltage shall be 1000 V. For euxiiary devices other than Pt-100 temperature detectors, S00V should be used, Pt-100 detectors should be tasted with 100 V. The reacings shall be taken ater the test vokage has been applied for one minute. The measured values shallbe recorded for reference. “Tre minimum acceptable value ofthe insulation resistance ofa winding st rom temperature (25°C) is calculated as (Fated vohage ofthe winding in kV) + 1 Megobms: “Te insulation resistance is versely proportional to the winding temperature. iis halved for every 10..15°C temperature rise. Fer safety reasons, the frame and windings not being tested should be earthed cling the insulation resistance test. Diodes and thyristors inthe rectiterbriige must be short circuited witha piece of copper conductor during the tast. To evo that ‘electrical charges remain in tested windings, the windings must be earthed immediately after the test. a INSTRUCTION MANUAL FOR ‘ABB Strdmberg Drives | sq 710, SG 900 AND HSG 1120 1101 [“e [me. 802.0609 J. Vate/PTC28 Drying the windings I1the insulation resistance of @ winding is t00 low, the terminal insuation should first be examined. The Insulation surfaces may be covered by dust, dit and moisture. ster cleaning the sustaces, 8 low value of the insulation resistence is messured, ori ‘no contamination is found, there is most tkely moisture in the winding insulation. Dying the windings wil require heating. The space heaters inside the machine can 'be safely used forthe purpose, but the heating effect may be too low. The ise of ‘the machine may be heated by hot air blowers. The windings themselves may be heeted by d.c. current amounting about 20 per cent ofthe rated current. The ‘empecalure rise of the windinge should be monitored during the drying process. Move than 5°C per hour is not allowed, the maximum temperature being 85..90°C. “That way, the escaping vapour wall nat damage the insulation |When heating the windings using d.e. current, moisture shal be allowed to get out easily. Dry air should be supplied to the machine. Covers on the upper and ber parts ofthe machine should be removed to cause a free a flow. Moisture wll usually scape through the end windings of the machine, so blowing dry er over them is fective. 3. ELECTRICAL CONNECTIONS 3.1. General recommendations ‘Belore beginning electrical connection work, make sure you have corefuly studied all the connection diagrams supplied with the machine. Ensure thet supply voltage and ‘requency correspond with he values given on the generator rating pte. Check that the incoming cable cross section is suitable forthe ful oad current of the machine. ‘Check thatthe cable glands and other accessories ae ofthe right type and size, ‘Check thatthe supply i isolated and the incorning cables earthed as required. See ‘that all safety precautions have been observed. INSTRUCTION MANUAL FOR ‘ABB Strémberg Drives | sq 740, #5 S00 AND HS@ 1120 IM 1101 #80 i wa om vr ecco s.vare/erc | ene bead3.2 Comecting cables and auxiiaries “The connections should be performed according to connection diagrams. Comect he cables of 10 laments Connect ha cables ofthe automat vohage regain systom AVR) [GB connect cals of ne space haaters. Fath main trminls anc connect cable. ‘shoo fow according to secon 26 REGULAR CHECKING AND ROUTINE MAINTENANCE, Checking Ist and maintenance records tis recommended to check regulary the operating condtions of the generator lke toed, cooling and bearing functions. Any maintenance and repair performed should be recorded in a Maintenance Record Card or in a corresponding computer fle, ‘During he fest wocks of service these checkings are most important. Misalgnment ‘and other faulty circumstances are more Kkely to cause rouble just during his period in which the moving parts of the machine ere setting down to working stresses and temperatures. Checking ‘Check thatthe reacings ofthe temperature indicators for windings and besrings stay vl under the given maximum values. ‘Compare the load current, electric power, power factor and excitation current with the rated values on the rating plete or in the specications ofthe generator. When stating the generator, check thet sutematic excitation and synchrorization systems are functioning smoothly. ‘Cteck that cooting air intake and outlets are free from any obstactes. Check thatthe sirfitering units are clean. ‘ABB Strémberg Drives | 459 710, 180.900 ANOHSG 1120 1M 101 | | m4. _ i |™ ge 9. Vuis/PTC = SAHSSE AFor flood lubricated beerings, check the oll pressure. Check that there is.n@ ‘overocsing of the bearings and check the gaskets for possible of leakage. It nacessary, measure the vibration levels of the bearing housings and of the frame of themachine, Vibration should be measured in horizontal as wel as in vertical clirection. Compare the results with the values given in the commissioning report. Rising vibration level is often a sign of unbalance in the generator or inthe prime ‘mover. Iimay be af indication of some changes In alignment or in operaticn of the coupling. [Check thet the fixing bots, couplings, incoming cables and other parts are securely {astened. Keep the machine and its surroundings es clean es possible, especialy ait inteke and outot areas. (Cleaning \Mosture, dust, din, oil and grease may be harmful to the electrical insutations of the ‘machine. Cooling system may also be blocked or corroded, ‘Clean the ai fiters by vacuuming. Vacuum the upstream side fret, then repeat onthe ischarge side. necessary, wash them with a mix of water and detergent. (Cleaning and deying the windings ofthe machine is explained in special instructions. ‘Schedule for checking and mantenance ‘Asschedue for checking and maintenance of the generator should be eet up In ‘accordance with the operation requirements and wah the site conditions. The ‘mantenance program ofthe whole plant must be paid attention to. The fine ‘schedule for checking end meintenance should be confirmed when experience has been gained during 3 to 12 months. “The maintenance of windings and bearings is described in special instructions. A INSTRUCTION MANUAL FOR, ‘ABB Strémberg DriveS | j45q 710,56 900 AND HSG 1120 M 1101 me ees. = | 1902.0609 J. Var/PTC‘SCHEDULE FOR REGULAR CHECKINGS: ql TORY | sussect Power Gurren BF. Excaien care Winding npn Bearing Wipers [-cootng st tomperauee OF press Boating vor Diode bilge eat tango Contamiation Garis fie pts ibe acting ‘Goanines of dds and doo Bdge ‘Condionand suport of windings okngs Posskie sing the slot wedges ‘Cnitlon fhe wg dation are eng wari | Bosstie siting oooseing ofthe al woos [insuring resistances ofthe windngs Condienof tw an Lockingstn comer wie etn ars Paling and pestocton against eoroson ‘Checking te sons proveding te ngess ‘Chockig the pefamancos of contol and region | equprner ae wo a prtectve rly heching oft esed by vibration 00 sor cme Cechng th condion of rte winding mupors ‘Grek the slings and posse broken bas of ha rior damper viding Seating and boning so 4.5 Complete over-hat Fr complete over-haul, cleaning end possible revamishing, the machine must be ‘smantied so thatthe rotor and the stator are seperated. How often a thorough cleaning should be made can be judged from the stite of Uuncleantness observed in annual inspections. if the machine isnot subjected fo ‘more than normal contamination, en inspection interval fve to ten years is recommended. TNSTRUCTION MANUAL FOR ‘ABB Strmberg Drives | 459 710, 1S 900 AND HSG 1120 BA 1101 cr eo 1902 0599 J. Vrs/PTC aireeel5 DISMANTLING AND RE-ASSEMBLY 5.1. Preparation for dismanting ‘Observe that most ofthe inspection and maintenance work can be done using the testing maintenance covers or ar intake and outlet openings ater removing the ‘covers only. See that no risk of electrical or mechanical sccident ls present. I cismanting is necessary, the machine should be isolated from the electrical supply. Main supply cables or busbars and avadlary cables should be disconnected ‘ang identfied for reconnection. Al necessary safety precautions should be isken, “The complete machine should be removed from its she o a dry and dust ree locaton. ‘Shims placed under the feet of the machine, as well as gude pins should be identifed and retained for later reassemble, Shaft coupling halves should be marked. 82. Disnanting Construction drewings of the generator and of ts bearings shall be used to guide the ismanting work. Remove the side covers and er fters of the machine. Push pressboard pesces from [Neend into the eir gep according to fig. 9. Disrmount instruments, seals and he pearing housing upper parts. Remove the ol rings. Tighten the end shield Jacking sofews (2 pes. on both ends of the machine). Remove the end shield guide pins. {Loose the end shiald fixing bots until jacking screws cary the weight of rotor, bearings and the endshield. Remove all end shield fixing bolts except two on both ‘idse of the bearing. Turn the jacking screws counter- | = AraxoneNpoc “B46 Permanent Magnet Generator (PMG) PMG is the most reliable excitation power source for a synchronous generator. PMG shall be rated to match the caling excitation voltage of the generator, Transformer In case a PMG can not be used, ¢.9. when the main generator is a very slow-running machine, a tnee-phase lansformer connected to the terminals of tho gonerator cen be ‘applied. in most eases, the transformer is mounted inthe terminal space of the generator. ‘The rating ofthe transformer shall match the celling excitation requirements. - AS an ‘option, the transformer can be furnished with an auxiliary 110 V winding supplying the texminal vollage signal to the AVR. Independent source ‘Assecured a2 power souree, or a battery-based source can be used for brushless {generator excitation. In case of a dual-channel system, it may be of particular edventage if €n independent power source is provided for the stand-by AVR, 41.4 Specification of the AVR. (Terminal numbers are refering to fig. 4 and 5) 1.441 Inputs 2) Generator voltage signal Three phaso 110V oF 100V frminals 1, 2 and 3 from a potential transformer. Terminals for 220 V, 400 V, 450 V and 660 V are provided. Adjustable + 10 % Loading: 1 VA ) Excitation source 4190 V (250 V max) from PMG, to terminals 4, § and 6 ‘ranstormer or independent source ©) Current signal +A trom current trane- to terminals 9 and 10 former in phase V (12). Loading 0,3 VA (GX 300 P) 2,6 VA (GX 300 PR) 1.42 Output Excitation voltage from terminals 7 and 8 - ceiling vollage at 220 V AC input‘ABE Stromberg Drives Oy [=== Saxe, machines - Prov MNissinen 19921029 en _Eviiko &+ 7 Wi tissinen A Leal Sreemrennoc wa e maximum field current output continuously 4 minutes 10 seconds. 158, 20A 308, Upper limit of excitation current can be set by a resistor in the basic AVR (terminals 15 ‘and 16). Both lower and upper current mits can be set by potentiometers located on the auxiliary card GE 10. 1.43 Operation Seiting range of generator voltage = with potentiometer located in the AVR or + with external potentiometer connected to torminals 12, 13 and 14 (Rt } Regulation accuracy Salting range of voltage droop = with potentiometer located in the AVR, Frequency range frequency falloff point can be adjusted with potentiometer located in the AVR. in a range -15 % 10 0% Power factor control setting range - with potentiometer P3 “with external potentiometer connected terminals 18, 19, 20( R2) Regulator response + recovery time after a sudden change of terminal voltage; not more than gain setting potentiometer in the AVR; ‘additional capactors can be soldered to pins on the pic. cards for setting of integral snd differential time-constantants. 1.4.4 Ambient conditions - cooling air temperature * storage temperature + relative humidity, not more than + vibration endurance: Installation in the generator control panel s preferred, but the AVR can be ‘mounted on the generator peak transient voltage (10 ms) phase to phaso £10% 10k0, 05 W 1% 0.10% 35..65 Hz 45,55 Hz, oF 55.65 Hz 49° (PF.= -0,988..0..10,988) when R2=10 kA # 90° (P.F.=-0..1..10) when R255 KA # 60° PF.=-0,6..1..10,5) 0.8 second 0,445", +60°C forced 40,175 °C, 93 % at +40 °C 1000 V‘ABB Stromberg Drives Oy |" Mexse Machin [PTC 7M, Nisinen en Evinko ©. 27 MC Nissinen 3AFGX300-EN.00C high potential test ‘phase terminal to frame 2500 V ac radio interference VDE class N CISPR Recommendation no. 54 ~ degree of protection P20 heat dissipation max 45W 4.4.8 Mechanical construction ‘The AVR is buil in a case made of U-formed aluminium profil, see fig. 2 and 3. The ‘weight of the regulator is § kilograms. 1 Circuit board GO-11 2 Circuit board GP-11 3 Gircuit board GT-11 4 Transistor module 5 Diode bridge 6 Diode bridge 7 Capasitor 8 Terminal Fig, 2 Mechanical construction of the AVR type GX 300a [ABS Stromberg Drives Gy [=== ose Ervine ©. Wetissinen if L Fig, 3 Dimension drawings of the AVR type GX 300 = BAFGKQOD.ENDOC "B78 ca 200, \ i¢——_140_py ae *| ! — y | ? f iB 2 yl let ly ma‘ABB Sirémberg Drives Oy |=" Machines $n JE Fie Tiieamn Tiasoze we Eno 27 WNionen = BAFGX300-£N.000_ mn S4GX3E 1.46 Terminals (oxs00F = Af a] 3] af | of 2} 6] of softs} 12} 23) val a5] t6 17 (Gx 300 PR la Je] af a] af 4} sf | a} af of) sn} 22} 20) safer] 10] a) 20] 2420] 2] a] 25] 2627 ‘Ausary vokage _(GX300P : terminals 4 end 5) ‘tual votlage (1 =U, 212, 313) Excitation suply (3-2h volege from vatage transformer , PMG or network) Excision ouput (7 = +) Curent actual value ofL2 ( max 1A ,8VA, 9= St 10552) Yolige sting potentiometer (10 kot 08 W) Earhing case Power fair setng potentiometer (10 koh. 05 W ) RRegulaton mode U or PF. (Terminals oped U, terminals shorted P29) ‘Contr sgnal for autotoow on/off (teinals open = on shored af) ‘Avtofolow out (terminal 26 of another regusor) ‘Auofotow in (rom terminal 25 of anather regulator) ring ease In GX 300 the interna! petenlometerP4 canbe used fer Uset as well, thus ihe enteral Use poteritometer isnot necessary The bridge shel be removed when evi is connecod te these terminals‘ABB Strémberg Drives Oy [== 5 ox se Machines PRCT AC is {00-10-20 MNase Ml if! Wrecmeicc “s “se | @ 1.5 Standard scope of supply Regulators: 2) Basic AVR type GX 300 P for generator voltage contro, with voltage droop feature as 1o08e item, or b) Basic AVR type GX 300 PR, including euxliary card GE 101 for addtional power factor contro feature, or ‘¢) Basic AVR type GX 300 PR, including auxilary card GE 10 q for edditionel reactive volt-amperes control feature Excitation current sources: e 4) Permanent magnet generator (PMG) mounted on the generator, «) Excitation power transformer installed in the terminal space of the gonerater, and any ‘appropriate voltage relay, contactors, diode and resistor. The auxiliaries are mounted on ‘4 commen base plato with the AVR. Auxiliaries #) Current transformers and diode bridge for shor circult excitation when requested (only whan required) 9) Contactor for excitation current, and protective circull breaker 41.8 Optional scope of supply e itis assumed that the AVR is shipped as a loose item for installation in the generator panel of another manufacture, and that the acosssories can be supplied by the pane! manufacturer 2) External potentiometer for satting of voltage, of power factor, or of reactive volt- ‘amperes. The potentiometer can be manually or motor operated, ») Current transformers for sensing generator current (rated generator curren 1 A), ) Excitation power transformer furnished with an auxiliary secondary winging for voltage sensing (8x 110 V, 1 VA) 4) Voltage transformer in the cases when excitation power is supplied from PMG or from. an independent source‘ABB Strémberg Drives Oy [= Ie fe /MNissinen 1962-1029 en Vino ©. 2” A Nissinen iA A. SAFGxao0-enp0c “6 2. OPERATING PRINCIPLES. 2.4 General ‘The basic automatic voltage regulator (AVR) type GX 300 P (s86 the conection diagrams, fig. 4 and 8) The function ofthe basic AVR is to keep the terminal voltage of a synchronous generetor constant at ¢ pre-set level under various load conditions in @ power system. The basic, AVR is furnished with voltage droop circuit for stable parallel operation of two or mare ‘generators, as well as with frequency falloff feature for protection of sensitive load ‘2quipment against overheating of magnelic components, see fig.4 and 8. 2.2 Actual values of input signals ‘Voltage signal The potential transformer T1 is connected to the main terminals of the generator. At rated voltage of the generator, the secondary ofthe transformer wil supply 110 V (or 100 V) ae to the AVR. This voltage is rectified to produce a signal proportional to the average value lof the three phase voltages. The signal is fed to the main control amplifier (A2). “The ac voltage from the potential transformer T1 is also fed to @ circuits, which yield signals proportional ta the reactive amperes (AA) and for lowering of voltage beneeth the st knee freguency (AS) Current signal ‘The secondary ofthe current transformer T2 delivers an output signal, which is. proportional to the phase current of the generator. 1 A secondary current corresponds to the rated current of the generator. In the basic AVR, the current signal is applied tc the reactive amperes resolving circuit (AA),‘ABB Strimberg Drives Oy Wriesinen SAFGxa00-£n DOC Fig, 4 Voltage regulator wih PMG power supply‘ABB Strémberg Drives Oy Machines ™ 34 GX3E TMissnen 1982.10.20 en E-Vikko &. Wi Risinon 3iFesa00-en000 Fig, 5 Voltage regulator with transformer supply and excit boost‘ABB Strémberg Drives Oy [== Soy ae BTCTM Nssinen 1992-10-29 90 0°10 0 10 ‘VOLTAGE AMPLIFICATION DROP. ©] P4 Pt PS P2 Fig. 6 Setting potentiometers 2.8 Reference values. (set-points) Vottage reference ‘The voltage reference is sot with the potentiometer Pé placed in the AVR. An external Potentiometer (Rt) can also be used, see fig. 4. The setting range is + 10%. ran ‘external potentiometer is connected, potentiometer P4 shall be set in mic-position, Setting of voltage droop In case the load is supplied by two or more generators operating in parallel, orf the ‘generator is connected to a larger power system, the voltage regulator must include @ voltage droop control. To grant stable operation, terminal voltage of the generator shall be ‘somewhat iowered with increasing reactive load current. This is called voltage droop feature, ‘The percentage of the voltage droop is set withthe potentiometer P2 in the AVR. The selting range is 0..10 %. The scale ofthe potentiometer is valid when the rated current of the generator is equal tothe rated primary current of the current vansformer T2,BECTM Nissen T9e2-10-29 en _E-vVibkko_&+ Mi Nino SAFGxs00-eN Doc tea. a Fig, 7 Voltage droop Selling of frequency falloff point ‘Components in sensitive load equipment can be overheated due to magnetic saturation, if the generator is operated longer times at decreased frequency, s0@ fig. 8. To avoid saturation, te knee point where the voltage of the generator begins to decrease at descending frequency, can be set wth help ofthe potentiometer P1 on the GC card. Wa 35He 45 He Uayke (He Fig. 8 Frequency faltof‘ABB Stromberg Drives Oy [""™"" ae ines 1 KBE Pic/M Hsien fwa21029 en Evite © 7 ‘Ma Wasson 24 Control circuits Voltage contro! “The main control amplifier (A2) is @ PID amplifier where the voltage signal from the terminals ofthe generator is compared with the voltage reference. The diference is the Control voltage for the PWM cicuit (U1), which regulates the excitation current over the power transistor (V1) in the end stage of the AVR. The integral functicn provided will climinate the steaty state error. The derivated function wil decrease the recovery time after a sudden change of voltage signal. The influence is depending upon the time Constants ofthe generator and of the exciter. ‘To maintain constant voltage atthe terminals of the generator under ell specified conditions, the voltage signal and the cucrent signal, eventually supplemented by the frequency fall-of signal, are conditioned to provide the input for the main amplifier. ‘The main control amplifier includes ctcults and adjustments for stabilizing the control action, Voltage droop contro! ‘The circuitry sensing generator current wll resolve the reactive component of the current signal using the voltage signal as 2 reference, The reactive curent signal isthe input for the droop amplifier (Ad). This input is compared with the voltage droop setting. The output of the amplifier will change the main amplifier reference with a pre-set amount related to the reactive current Frequency fall-off ‘Acircuit yielding a rising de voltage with decreasing generator frequency is used for realization ofthe frequency fall-off feature ofthe AVR. The part of this voltage in excess of the voltage corresponding tothe knee point frequency Is amplified and fed as a bias to the main ampifie for reducing the terminal voltage of the generator. The default setting is such that when the frequency has dropped to 60 % of the rated value, the voltage of the generator has dropped to 75 %, 2.5 Additional features of the AVR type 300 PR ‘The basic AVR equipped with additional card type GE 10 resp. GE 104 For controling power factor o° reactive volt-amperes of a generator connected to a larger ppowor system, the basic AVR is provided with an additional pc. card as stated above, see fig. 10. The additional cards are also equipped with circutsfaciitating autofollow function in dual channel systems. NOTE: The regulator can be switched over to reactive current or power factor control only, ‘when the generator is connected to a larger power system, where the system voltage is determined by the network‘ABB Stromberg Drives Oy Fic TM iiss nog et Evauo €.2) — Miomen 7 fa SAFGX300.EN.00¢ ies Phase angle signal Inthe AVR type GX 300 PR, the voltage and current signals are fed into the amplifer AS for deriving a signal proportional tothe phase angle between vollage and current of the generator, Power factor reference ‘The power factor reference is set with the potentiometer P3 on the p.c. card GC-11 ‘Often, an exernal setting potentiometer R2 is connected over a cable for more convenient ‘operation, In this case, the potentiometer R2 is set to mid-position (to read = 1). Then the internal potentiometer P3 is adjusted unl the measured power facior ofthe loaded {generator is = 1.0.- The power angle scale of the potentiometer P3 is linear, but the ‘setting accuracy increases toward unity power factor, which isan advantage forthe cperator. Reactive volt-ampores reference ‘The reference for reactive volt-ampores is set with the potentiometer P3 on the GC card in the AVR. itis also possible to connect an external potentiometer R2 for the purpose. Control of power factor For phase angle (power factor) contro, the AVR Is equipped withthe additional card GE 10, When the AVR is switched over to P.F. control by closing the external contact 1, the phase angle amplifier (A6) will yield a signal proportional to the diference ‘between the actual value and the reference value of the phase angle. The output ct the phase angle amplifier is connected tothe input of the main amplifier. The voltage signal input tothe main amplifier is switched to a fixed value. The oulput of the droop amplifier is shorted, ‘Adjustment ‘When the regulator isin P.F.-mode, the output voltage of the phase angle ample: must bbe zer0 ( ICT, pin, on the GE10 card ). H not, adjust it to zero using the potentioneter 6, (The potentiometer P must be in the mid position.) After adjustment do not change the settings ofthe potentiometers P4 and PS, For the voltage adustment do use only the ‘external potentiometers Rt Control of reactive current For control cf the reactive current, the AVR is equipped with the additional p.c. card GE 10, When the AVR is switched over to reactive current contol by ciesing the external contact $1, the droop amplifier Ad is connected for controlling the reactive ‘current ofthe generator. The output ofthe droop amplifier is now the input for the main ‘amplifier. The voltage signal is switched over toa fixed voltage input ‘Adjustment ‘When the regulator is in 'g-mode, the output voltage of the droop amplifier must be 260 {test point 27). I not, adjust it to zero using the potentiometer P6 (the potentiometer Pa"ABB Stromberg Drives Oy Machi PICTM Nissen 90210.20 _en_ BAFGX300.EN DOC. ‘must be in the mid position) After adjustment do not change the settings of the potentiometers P4 and PS. For the voltage adjustment do use only the external potentiometer Ri. 2.6 Dynamics of voltage control ‘When the load ofthe gonerator is switched on or off, the terminal vliage will momentarily sink or rise before the regulator will catch the control again. The typical voltage variations ‘are show in fig. 9. The correcting action wll take some time due tothe feld time Constants of the exciter and of the main machine. Both time constants amount some tenths of a second. Thelr combined effect is shown in figure 8 ‘The recovery of correct terminal voltage shall be achieved as fast as possible without oscillations. For that purpose, PID control circuits are built in the reguiator. The circuts fare adjusted at factory for optimum performance. if stability problems will appear, the ‘adjustments can be changed by soldering the jumpers of additional capacitors tothe studs provided on the printed circuit card Load on Load off 1 | v Ll “ (OTT RATT No load Rated load Noload Fig. 9 Dynamics of voltage controt| ABB Strémberg Drives Oy 34GX3E | Machines | t I Zz par a roast 2.7 Output current tims Basic regulator GX 300 P ‘The high limi ofthe fiald current can be set by connecting a resistor Rx to the terminals 15 and 16 on the GP card. Resistance values are listed below. braw/A Resistance! 30 no resistor Py 1470 20 1590 6 301 46 a7 5 56 For adjusting ofthe high limit of the fold current, its also possible to change the value of the resistor R 91 on the GC card. And for adjusting ofthe minimum value of the fild ‘current itis possible to change the value ofthe resistor R94 on the GC card Regulator Gx 300 PR The AVR is provided with the additional card GE 10, which is equipped with potentiometers Pt and P2 for adjusting the pulse ratio limits of the PWM. P1 is for setting the low limit ofthe field current and P2 forthe high mt. The high limit may also be adjusted by changing the resistor Rx as explained above. 2.8 Power sage Driver eireuit The output signal of the main amplifier controls the pulse width ratio of the pulse width modulator (PWM), The PWM operates at a constant frequency of about 1 kHz, The pulse ‘width ratio is the conducting ime periad divided by the fll pulse time, The pulse rallo can bbe measured by measuring the output voltage (between the terminals 7 and 8) with the osclloscope Power transistor circuit ‘The output fiom the PWM is over optoisolators. connected to preamplifiers, which control the power transistors in the end stage. The transistors feed the fleld winding of the excite. The voltage control loop is thus closed 2.9 Internal power supply ‘The power supplying the internal circuits of the AVR is crawn from the terminals 4 and 5, which are connected to the excitation power supply, either to PMG or to excitation power transformer T1. The several voliage levels needed for energizing different circuits are Created and stabilized in the circuitry G9. - In the AVR's type GX 300 PR, the internal34GX3E een Evin EY Wisin /72 ‘SAFGxs00-8.000 _“B Machines ‘ABB Strémberg Drives Oy | PrCT i Nissinen “7e28 power supply is connected to separate terminals A and B, The power for he regulator may be drawn from an independent source when required, 2.10 Startup excitation The generator is provided by PMG or by Independent excitation source ‘When the generator has been started and has come up to 80...90 % of fll speed, the excitation supply contactor is closed, Power for excitation and for internal circuits of the AVR are then readily available. The generator can deliver full output. Power for excitation is provided by a transformer Even at full rotating speed, a remanence voltage high enough to feed internal circuits of the regulator, and to deliver excitation current to the generator itself, ls usually not achieved. For reliable start-up excitation, field flashing is applied, Fo: some seconds and ‘until the terminal voltage of the generator has risen enough, the exitation current is taken {from the transformer T1 through the diode bridge and the relay Kz is connected to the field winding ofthe excite. In a few seconds after closing the excitation contactor K1, terminal voltage of the generator will rise high enough for operation of the AVR. The field flashing connection is then opened and the AVR will take over the ccnieo ofthe generator voltage, ‘The additional devices required are a voltage relay K2, controlling an auxlisry relay with dolayed tripping, and a by-pass contactor. Ifthe generator excter is equipped with @ permanent magnet pole, the DC-battery for inital voltage build-up is not necessary and in that case a 24V DC-supply is used only for remagnetising in case normal voltage bulld-up isnot successful 2.11. Shot circuit excitation To enable a selective overcurrent protection for the synchronous gererator, enough ‘excitation must be provided algo in short circuit conditions, When excitation current is delivered by a PMG, or when an independent power source is used for excitation, sufficient current is available even ifthe terminal voltage ofthe generator drops very low, In case the power for excitation is supplied from the terminals of the generator over @ transformer, sufficient shor circuit current is not readily generated. Then, the generator Is provided with two or three saturable current transformers for delivering an excitation ‘current required to maintain at least 250 % fault curent for 3 soconds ‘The contactor also connects the battery for field flashing when applied for start-up excitation. When the terminal voltage of the generator drops below s pre-set limit value, the short circuit is opened to get boosted excitation.‘ABB Stromberg Drives Oy [=== Machines 34GX3E. Bro/MNissnen —o92-10-20 en E Vakko ©. 7 MW Nssinen 74 4/4 SAEGx00.ENDOC "B2025 2.12 Gireut protection For thermal and short circuit protection ofthe AVR and of the exciter field winding @ ‘manually operated circuit breaker is provided in the generator control panel. The auxiliary Contact ofthe circuit breaker is recommended to be used for indication and tripping, The contactor Kt connecting the AVR to the excitation supply is to be used as fel breaker, e.g I shail be tripped by the aferential relays. Depending on the length of cables, and on local conditions, it might be necessary to provide the outgoing cables for the voltage signal, for battery supply and forthe eventual ‘secured independent power supply with adequate protective devices, &faultin the voltage sigral circuit, or disconnection of the cable should always trip the field contactor. 3. INSTALLATION tis necessary to ascertain that the operating cordiions are in accordance with the specifications ofthe AVR. If vibrations ara suspected to exceed reasonable limits, the amplitudes and frequencies should be measured, ‘To avoid severe vibration, the regulator is most often mounted in the control panel ofthe ‘generator. The ragulator may be isolated from its base using elastic mounts, - Due to the ‘small mass ofthe reguiator, high vibration frequencies are dangerous, especially hose exceeding €5 Hz. Electrical connections of the regulator are arranged in a screw connector block, The cross-section area ofthe connecting wires and cables must be 2.5 sq. mm. atleast, The {grounding erminal of the regulator must be connected to the generator frame or te the frame of the panel, 4, OPERATION OF THE REGULATOR Remark. Continuous operation of the generator al reduced speed under75 % of reted speed shoud be avoided 4.1 Control settings The AVR type GX 300 has some internal immer components, The trimmers havebeen adjusted at ino factory to standardize the characteristics of the regulators, So all the regulators will stay inlerchangeable provided that the adjustments done atthe factory are rot altered The AVR has three setting potentiometers: for adjusting "Voltage", "Amplification" and ‘Voltage dreop”. In addition, three potentiometers are provided for special adjustments, ‘The potentiometers are seaied in the GC card Immediately under the cover of the regulator, see fig. 6, Each potentiometer is furnished wilh @ graduated scale,‘ABB Stromberg Drives Oy Machines STM Nissinen 19021020 en SAFGKSOOENDOG “B28 ‘The nominal voltage should first be selected by the jumper connection on the GC card, Ifthe rated voltage of the generstor differs from the specified value of the regulator. the correct voltage shall be set using the potentiometer PS. Fine adjustment of the generator voltage is done by turing the "Voltage" potentiometer. fan extemal potentiometer for voltage setting is connected, he Voltage” adjustment in the regulator should be set to 100% ‘The "Ampiification* adjustment is scalod from 0 to 10, The scale is not directly proportional to the actual control amplification, but the scale is used fer reference, see the following section, ‘The “Voltage droop" potentiometer is scaled from 0 0.10 %. Itit is necessary to adjust the frequency falloff characteristic, see fig. 8, it ean be done by turning potentiometer Pi 4.2 Setting of amplification ‘The "Ampiification” potentiometer has been set atthe factory In @ postion, which gives a short restoring time of the generator voltage afer a change of load current. For @ medium size gonerator, an initial setting of 5 may be adequate. For a larger machine, a somewhat higher setting may be chosen. Higher seting of the potentiometer wil yield shorter recovery times. If oscillation will cour, the setting shall be lowered. 42 Single generator operation For a single ganerstor supplying a separate load, the regulator shall only maintain the terminal voltage at the pre-set level. The current transformer for sonsing voltage droop is Not necessary. The "Voltage droop" setting in the AVR can be turned to 0 % 44 Operation in paral witha power system e Before connecting the generator to a power system, the no-load voltage is set by the “Voltage"-potentiometer to equal the system voltage, The "Voltage droop'-potentiometor is set to.a position which is adequate forthe reactive current needs, offen o 5.6 % During operation, itmay become necessary to changa the setting ofthe "Voltage". potentiometer. The setting of the "Voltage droop". potentiomater should not be altered, 45 Operation in parallel The "Voltage"-potentiomaters ara adjusted to get the same no-load terminal voitage forall {enerators. The "Voltage droop"-potentiometers are sat to the same percentage, about 3.4% During operation. the reactive load current of each generator should be checked. If there 's a need for adjustment, the "Voltage droop"-potentiometer is used forthe purpose. e Resetting of "Voltage'-potentiometer should nat be done, because that would make the ‘esctive load sharing between ine generators inacourate with changing net voltage.TR ‘ABB Stromberg Drives Oy eTarsel Machines BiGiae Nissen 1062-102 on Evinko ©, 2 Ha Nisinen 14 SaFGxso0-eno0c "6 "235 5. DUAL CHANNEL OPERATION Genoral In some cases, dual channel operation ofthe regulators is requested, This gives the possiblity tat tho AVR can be replaced by a stand-by unit in a very short time. In addition, the stand-by unit shall be abie to take over the control immediately, Le. it shall stay in the same condition as the unit to be replaced, This is called auto follow operation, ‘The auto foliow feature allows the switch-over tothe stand-by AVR taking place smoothly. Auto follow operation Two similar AVRs type GX 300 PR are required to realize the dual channel system, see fig. 10. Both AVR:s are connected to the voltage and current transformers at the i. terminals ofthe generator. The position ofthe selection switch $1 determines, which of the AVR's acts as master regulator. ‘The other AVR is slave regulater, following the state ofthe master but supplying no ‘exciting curent to the main exciter field winding. The master AVR is selected by sviteh 82. Most often the switch is used to test the correct functioning of both AVR's, Both regulators need to be energized all the time during auto follow operation. The slave AVR must be able to take over the contro! immediately, when switch 82 is operated The PWM circuits of both regulators are connected together so that the contrl voltages {or both power stages ere equal. When switching the control over from the eurrent master AVR to the slave AVR, the excitation current output remains constant with minimal fluctuations, ifthe settings ofthe regulators aro equal. The previous slave AVR becomes master AVR and vice versa, ‘The excitation currant outputs of the regulators are connected to the fied winding cf the exciter over diodes, blocking reverse excitation current. ‘The AVR can also be used for contol ofthe power factor. To change the operation mode, Potential free terminals are provided for an auxiliary switch, Remote contra! ofthe regulators can be realized with help of external remote contre! potentiometers, one for voltage selting and one for power factor control, Each regulator will need its own set of potentiometers. The AVR can be operated as a pf. regulalcr only \hen the generator is connected to an external power system,Fig, 10 Connection cagram for dua channel operation e5 SE ‘ABB Stromberg Drives Oy eraxsel PROTA Nissen 902-1029 en _E Vino ©. 27 He Ras ed e SiFexsooen voc “e225 6, MAINTENANCE AND REPAIRS “The AVR nesds no regular maintenance, ‘A defective AVR. should be replaced by a spare regulator. The settings of the polentiometers, jumpers and auxiliary voltage selection in the defective regulator should be noticed. Tha same settings should be used in tho spare regulator, In case of reactive current contol with GX 300 PR, the type of GE-card must also be checked, Localization and repair ofa faut in the AVR circus wil require special skills and suitable measuring struments, @ 7 TROUALE SHOOTING Disturbances in the operation of the AVR appaar in different ways. Some of the indications and their possible causes will be presented in the following list. A Generator voltage does net rise Possible causes: ~ the circuit breaker for the regulator is open * the wing of the regulator is faulty + a fault nthe regulator B. Circuit breaker trips when generator is started Possible causes: @ - stautin ine wising [a feutin the reguatr . Generator voltage t00 low or to0 high and voltage adiusting has no effect ossible caus = a fault inthe regulator = a fault in the wiring D. No-load voltage correct, but voltage rises when generator is loaded Possib uses: e ~ the current transformer for voltage droop sensing is incorrectly wired E. Tho generator s not able to supply enough reactiveBSTMNissinen Too21020 en vinko © Possible cause settings in the regulator are incorrect wiring ofthe currant transformer for voltage droop sensing incorrect 8 faut in the regulator {a faut in the generator (0.9. in the rotating rectifier) F. The generator voltage is oscillating Possible causes: = "Amplification" setting too high + a fault in the regulator List of figures Fig. 1 Basic voltage contr! loop Fig. 2 Mechanical construction ofthe AVR type GX 300, Fig. 3 Dimension drawings of the AVR type GX 300 Fig. 4 Voltage regulator with PMG power supply Fig, S Voltage reguiator with transformer supply and excitation boost Fig. 6 Setting potentiometers Fig. 7 Voltage droop Fig. 8 Frequency fall-off Fig. 9 Dynamics of voltage control Fig. 10 Connection diagram for dual channel operation ‘ABE Strémberg Drives Oy [=== Cn —T Machines of 7 ___—HiNiesnen 14 ifWINDING MAINTENANCE FOR ELECTRICAL MACHINES e AB RD ABB Drives F wD ASEA BROWN BOVER}ConTENTS: 1 NEED AND SCOPE OF MAINTENANCE 2 THE MAINTENANCE PROGRAM 3 EXTEROR INSPECTION 4 MAINTENANCE TESTS 4. Insulation Resistance Test 42 Votage Test 43 Tans. measurements INSPECTION 51 Observations 52 Gondusions of re Actons 8 CLEANING THE WINDINGS 6.1 Cleaning Methoss 62 Clearing Agents 63 Dying 7 VARNISHING OF THE WINDINGS {8 OTHER MAINTENANCE OPERATIONS ‘8 MAINTENANCE OF OLD WINDINGS 40 WORK SAFETY PRINCIPLES WITH WINDING MAINTENANCE.‘ABB Stromberg Drives Oy | agg pee 34.201 18 Sermo oe = = BE] PHETP. Palonomi 1803.01.22 en E Koskinen 2 EPatniem /2———_| _SREWINDINGS 0c. the WINDING MAINTENANCE FOR ELECTRICAL MACHINES 1 NEED AND SCOPE OF MAINTENANCE ‘The windings of rotating electical machines are subject to electrical, mechanical and thernal stresses, Its known that the windings and insulation gradually age and deteriorate due tothese ‘tresses, Therefore the service life ofthe machine often depends on the insulation durebly Many processss leading to damages can be prevented or atleast they can be made slower wth appropriate maintenance \Winkings in amall AC-machines need normaly only some minor msintenence. These insiuctions form the manual for the meintenaneo of windings in, both new and ad large AC- and Dc-machines ‘Addionalinstuctions for commutstors, brushgear, etc, are given foreach machine type. \When planning the maintenance program forthe windings it should be consiaered which machines are worth including Inthe systematical service programme. One example ~ important machines “large machires, especialy HV-machines "Cemachines, 2 THEWAINTENANCE PROGRAM Principies: - Maintenance ofthe windings should be aranged accoraing to other machine maintenance, Maintenance only when necessary. E.9. an important machine should be serviced more often ‘an a less important one. This applies also to windings that become contaminated rapidy, and to heavy cives “Table 1 i an example ofa simple maintenance scheme. Everyone doing service work should owever, plan the malntananco programme sultabe ust for his condons, machines and process. 3 EXTERIOR INSPECTION “The correct temperature forthe windings is ensured by keeping the exterior surfaces ofthe machine clean and also by observing that the tamporature ofthe cooing agent remains inthe ‘correct range Note that tne cooing agent can also be too cold: water may condensate on the cols wateraiator ane mixture of a ana warm aso damp) a mint develo mt Boh these situations can wet the winding and deterir ulation ‘esistance. The amount of rater tnning vough te edtorshele be at te cect Teel, oo tong few might moe the‘ABB Stromberg Drives Oy [Sy a eae achines BHE/P,Palonlems 1093.00.22 en EKeskinon_ 222 PrPatoniemt 27 Skrwnowcs.00c "B28 ‘Checking the temparatues ais includes observation ofthe operating temperatures with resistance temparature detectors. I remarkable changes can be seen batween the tomperatures fof the detectors, it could be a sign of damage developing inthe winding. (Make sure fist hat the ‘changes ara not caused by the iting of the measuring chanel.) ‘Table 1. MAINTENANCE SCHEME. 7 ‘A. Whan checking the bearings | Check he lampartares and Important and Vibration. Clean te outside it heey crves - hecesss a BTyear ‘Open; inspack, Caan, ighton he ‘supports and rearnish #f necessar z “Ain conjunction wih soma | Check the temperatures an HV-motore ‘ther maitensnce meacures | vibration, Clean the outside f generally (e.g. with every thid check | necessary of the besrngs) 7 — 3105 yoars (0 when | Opanrmepect Gan; Wghien te changingthne bearings) _| supports and re-vamish it necessary. ’A When changing the Brushes [Inspect ‘Gisan if necessary, 3 Occasionaly (eg. wien | Inspect Clean. Re-arish changing the bearings necessary 4 MAINTENANCE TESTS. [ABB Service in many countries oftens & completa service package with several measurements and test 4.1 Insulation Resistance Test Purpose: The insulation resistance values supply information on wetness and degree of contamination in the neulaion, whereby one can prepare the necessary cleening and drying feton Method: wen the neminal voltage ofthe tested machine is loss than or equal to 3 KV the test ‘voltage is usualy between 500 and 1000 V OC. I the nominal vltage ofthe tested machine I higher then 3 KV the test voltage is mostly between 1000 and 2500 V DC, Tha changing of insulation resistance is observed fort to 10 minutes and the values are writan down ater 15. seconds and after one minute (or after one minute and afer 10 minvtes), ‘The Insulation resistance will be the one minute value, R4 rin‘ABB Stromberg Drives Oy [Sa Machines 3420 1E 1B hE Koskinen EPatwniem P22 Shewnnowss.p0c "Bais. @ pete bee The polarization index lis given asthe relation: Bam or Be Rise CR fect of Temgeralure: Insulation resistance usually decreases sharply dus to the temperatura ‘ise. This s shawn by tho coefficient Kein Figure 1. With Ky the measured insuaton resistance in temperature vq, ean be converted to a sulable reference temperature wy (40°C in Fig. 1) 1) R=KxR, © 10 2 30 40 50 80 70 80 90 -100 Winding temperature, Degrees Celsius *C 10 Figure 1. Correlation between the insulation resistance and the temperature polarization index is lass dependent onthe temperature than the insulation resistance, and the temperature being below 50°C, i may be considered nearly independant on the temperature, Higher temperatures may cause unpredictable changes in the polarization index and therefore i should nat be used above S0°C,‘ABB Stromberg Drives Oy) "Sry te 1B Machin Se —— re oa = PRE TE Polonemi (05.0122 en E Keeton BE EBioniens Efecto dt and humidity: The dt and wetness accumulating inthe winding normaly reduce ‘he insulation resistance and the polarization index, and they can algo make the dependence on temperature in Fig, less steep (especialy coal dust). Windings with open creepage distances (@2.sip ring and commutator machines) and old hygroscopic materials ke paper, coton and shellac are very sensitive tothe effocs of wetness and dit Accontable valves: There are several ule of thu forthe lowest insulation resistance values ‘wh which the machine ean st be safely started. Howevor, Ith fo De stated that an absolutely ‘safe value forthe insulation resistance does not exist. The probability of insulation failure increases when the nsuation resistance is deteriorating, but it depends also on other factors and its valve cannet be estimated. Eg. conducting drt collecting on one spot ofthe creepage surface ‘ould cause ariskoffalure though the insulation resistance woul stil berather high. In USA (oference 1) the folowing Eq 2) is used @ Rae +U Mor where U= main voltage kV. “This applies both to new and used machines. Insulation resistance for mactines serviced at ABB Service is usualy at 80°C at least as high as in Eq 2: Ryo 2140 MO whe U= main votage kV. With figure 1 and Ea) the values measured at othartomperatures can be corrected to 40°C. ‘The polarization index varies usually in the range of 1 to 4, With humid and dirty windings Pts approx. 1 Accent trates 2 (ty for dass Amachines —PI= 18 “forclass BF machines PI= 25, Plis nowadays seldom used as it may occasionally ve misleading values. €.g. with modem ‘spoxy.mica insulations some very low Pl values nave occasionally been measured although the windings have bean dey and the insulation resistance high thousands of M2). When estimating mschine's stability after a standstl its insuiation resistance value is more Important than the polriztion index.‘ABB Stromberg Drives Oy [Sa 7y 4c 18 | Srv Poumon itmonz os Evan Fam SREWNDINGE.DOC _ 4.2 Vottage Test ‘An voltage test wal assure thatthe winding does not ha service lead te mulation failure the near Future eecticaly weak spots that might in Votage tests caried out - in connection with greater maintenance work and repalrs- in connection with injection impregnation only old HV machines) -perlodally for important machines (e.g nydro-generator} Direct or alternating currants used forthe overvoktage test. The voltage in seldom used CC voltage test is ‘value ofthe AC volaga. In AC tests the Fellowing value = services, repairs L2xu +400" = perogical tests, Use where U = main votage (V) Test ota (Notel The hig aways 4.3 Tanb.messurements ‘Tané representing dielectric and discharge energy losses is measured stepwise up to the main voltage U, by0.2 xU steps. Rate of ise ofthe tans value as function of voltage describes the average partial ciecharge lveln the insulation (both inside and on the Surtace; his makes it “ficult to estimate the inside condtion of te insulation). Apalcaion cange: large and important high voltage machines (e.g. hyéro-generator). letuiness (On the basis of tané measurements af old windings neither the estination of ageing ofthe insulation nor the prediction of he fallure could be made, S.INSPECTION 5.1 Observations Winding inspections reveal above al! the rata of contaminating; he risk at and humidty at insulation the rector condensation and leakages looseness cf the bracing structure, vibration marks and crackings the marks of considerable overheating Inspections sould be recorded e.9. using the enclosed form which is also the list ofthe fms to bbe checked in a mactine.‘ABB Stromberg Drives Oy |=" PETER ] Machines HEP. Pal Patriot FP PRE IP. Paoniem Shewnoncapoc “e_“ ane When examining the contamination one should pay most attention tothe open creepage surfaces fas the insulation resistance is very easly affected by the dt accumulating there, There are open ‘roopage surfaces for example In commutators, brushgears, pole windings, :ol ends and in ‘connections. [When theres alot of accumutatd dit the coating might become poorer whan the dit blocks the coll gaps and se dues, This eauses an increase in winding temperature and ageing may speed Up considerably Mechanical strain, vibration and shocks cause at an eary stage hair racks on the edges of the supports, supporting parts and tyings and also round the slot ends. Definite oosening ofthe support construction and slot wedges isa sign of a futher deterioration. Abrasion marks and powder near the support, tyings and st the slot ends, complete loosening ofthe slot wedges and Dent cols ae serious, Hale cracks and fractures in the metal pars asin supporting bots and squirel cage windings are ‘also sighs of deterioration which, however, might take a longer time to develop toa fllure, Humidity in the winding is eften shown oniy bythe marks it leaves Behind: on ron there are rustmarks; dropmarks, dipping and waiting marks on the dit layers. Bush-ike pattoms, often ‘charred and left behind by the racking curens, warn ofthe approaching falure. In rare cases conductiors have been coroded Marks ofthe electical effects (apart from tracking current marks mentioned water) are usualy hidden inside th slot insulation and conductor insulation, ‘Short overtemperstures can leave marks all over the machine. Copper inthe squirel-cage ‘windings grows darker (darkening might be due fo gases in he enwronment, too) and oxdizes, ofe laminations ofthe rotor become blue (over 350°C) ifthe temperature rises e.g. due to 8 jam ‘ora too heavy start, Colour differences of the fastening bolts In synchronous machines are a sign ‘of overheating. Insulation may sherk o spt (usually over 200°C), tyings my erack (over 220°C), polyester fim o ites may melt over 250°C), Sweling ofthe slot insultionis also possible. Prolonged overtemoeratutes cause premature ageing. The insulating materals become brite ana carker (at fs), especially varnishes contlning callulose withthe resut of spiting, dfsintegration and fracturing,Machines ‘ABB Strémberg Drives Oy |=" eae Jeez en PREP Patoniem E Koskinen te BPatoniemi LP SAFWINDINGR.DOG “BTiS” 5.2 Conclusions of the Actions According to the observations the following conctustons can be drawn forthe ne ‘Observation ‘Action Tot of dit, cooling ducts about tobe plugged ‘conducive dit (insulation resistance low, te) hurniity iaulation resistance tow, too) leaning, and drying, if necessary desning, and drying, i necessary arying racking snd coming off Condition ofthe supporting pars slot wedges unight cracks, loosening ‘iorauoa marks bent cols | Aacing |= carkoning, sgt embittoment ‘embritement, insulation layers loosening ‘ld HV machine (see point 9) clesning and re-varishing ‘old vamish should be removed and then rewarish the surface tightening » tightening tightening and pemaps strengthening and revarish * closer inspection, strengthening or rewinding 5 ‘deaning and re-varnishing rewinding = sample coll andlor rewinding *) A statement from an expert is needed. 5 CLEANING THE WINDINGS, ‘The dit accumulated in he open creepage surfaces and a majority ofthe dirt impairing the cooling, should be removed by cleaning. Especially when re-vamishing the winging, the daring should be done with care eo that no dit wl remain under the new varish coat where it would be Impossible to remove, 8.1 Cleaning Methods Blowing and vacuuming Blowing and vacuuming are useful only if itis dry and can be removed easly. Vacuuming is. recommended, since blowing tands only to redstibute the ditto somewher ‘deeper between the insulation layers‘ABB Stromberg Drives Oy [Seu 1 eae BHE)P Patient 1905.01.22 on E-Keshinen BBaloniemt — Skewinomcapoc “Bais” Wi Wiping should be used when spray-wash is not possible, e.9 for local cleaning, clearing DC ‘machines of vertical machines, Surfaces easily reached can be wiped claan wth a cioth ‘dampened with detergent. in more cramped parts ofthe winding a sutable form of brush could be more stfective, Cleaning equipments should often be cleaned in detergent or be replaced by new Dity sip rings, commutato: or bush-gear often are the reason for low insulin resistance. CGreepage surfaces on these components should be cleaned carefully, e.g, insulation surfaces between all ngs. Spmy.wash ‘Spray wash is cared out using airless high-pressure spray or conventional spay. The high Dressure spray is more effective in removing die. The dotergent used should remove the dit as ‘thoroughly as possible without softening or damaging the insulations. Excessive smounts of the clearing agent shouid be used, to remove the cit Dipwash Ite detergent does not soften or damage the insulation, algo dlp wash cer be used. Since he dit Is not removes mechanical in tis method, a very affective ieaning and scouring agents. heeded. & long sipping time may be needed Water wash ‘watec wash must be started rinsing with pure water (ap water is usually pur enough), to prevent the detargentsto penetrate to such places where it could not be removed. ‘Washing can be made following the instruction for wiping, dip wash or spray wash given above, as appropriate Atr the washing, the winsings must be rinsed with pure water severa!imes, itis recommended tomake the last rinsing win destiled or deionized water Drying after the water wash is necessary. See 6.3 Detergents for water wash: see 82ABB Sirbmberg Drives Oy [-"“""Shoyieu | Machines ee emi 1903.01.22 on EReskinen i PePatoniem 27 _____hrwnnowes.n0c “Bais” 6.2 CLEANING AGENTS: In Table 2, sone ofthe features ofthe detergents ara described. ‘etore any clearing agents used, ts damaging effect onthe old winding suface should be checked. A sutable test can be made as folows: "Rub the surface fo be tested with a cleaning olotn wottod with the cleaning agent forfve ‘minutes, Teke care thatthe surface remains wetted this tie. After rubbing, try fo remove the fishing vamish by thumb nail and fr compenson make the same tral to tho non wetted part of the surface. Ifthe surface layer has get Sof or can easily be removed ihe ‘leaning agents foo strong. For minimum environmental long, water or water-detergent mixtures should be used when possible, Water muet bo ueod, ifthe dirt contains water seluble agents ‘Substances improving the cleaning power should be added into the water to dissolve grease- contsining dit These detergents should leave as ite as possibie electrically conductive, ‘residues on te surfaces. ‘Aso water solible solvents can be used to improve the cleaning effect. Eg. acetone and isopropyl aleahol ean be mixed wih water. Observe that then the lammabiity ofthe midure It organic solvents must be used, then cleaning agents based on alifatic hydrocarbons ae to be recommendes. Several manufacturers of cleaning solvent mixtures are presently developing such hhalogen-toe clearing agents to replace the chionnated solvent mixtures used in the past From the organic solvents white pletis the most common. itis @ good solvent for greases but ‘not $0 good when there is pithke dt on the windings (eroduced by e.g. coal + burning ‘osiduoe of cise! of + humisity), Note that white spc aso flammable (Nash point 30...0 °C). (Cleaning effect of white spirit cen be improved by addition of 1.1.1-tichiorethane, However, the Use of chlorinated solvents is no more recommended.‘ABB Stromberg Drives Oy [satu 16 an Machines. Grey? Paonlem 10550122 en EvKeshinen (1c ErPrieniems 7. SAFWINDINGB DOG. “one ‘Table 2. Features of the detergents forthe winding i ape | 8 Tafel g ale felz it oe beth li PPh tpi) isbe eo PETE ae defen er te wenn (EY al AE. HG | le t —— Hl Fle‘ABB Stromberg Drives Oy [sa sy te 1B Machines _ eee 3 Pe |p Pelonemi fen0-01.22 en EKestnen tc FrPawonieni 2 SAEWINOINGB.DOC. us 83° Drying ‘tera wash, especial after a waterwash and rinse, the windings need drying and also when the windings have become damp in Use or during @ standstl prior to me inspection and ‘The basic factors of drying are heat and ventilation. Drying temperature should be spproxinately 400°C so thatthe drying will be quick. The air inside the machine should be changed in the most effective way, Sometimes the drying can be quickened by cooing the machine to 20...40°. Drying in an oven with good ventilation is normally the most effective way. However, this is hardly possible in the machine's operating site. Therefore either hot-ar-blow or current heating ofthe Windings should be used, Adequate fresh-air exchange is essential, whatever heating metvod is. Used. windings tater diticlt to dry (@.9. poles, DC rotors) and not toa big can be died in @ vacuum. “The drying of he windings should be folowel by insulation resistance tests, At the beginning of the crying the insulation resistance nomaly sinks, due to the rising temperature. When the ying advances the insulation resistance increases, reaching the maximum value wherefrom it wil not fise anymore. With formulas (1) oF (2) make sure that sufficient value for the insulation resistance is achieved, 7 VARNISHING OF THE WINDINGS “The fishing vanish of old windings sometimes begins to crack or even peel of before the insulation is obsolescent. This can be improved by giving the wincings a new coat of finishing vamish, {By the finishing varnish itis meant the varnish or the resin coat that has been sprayed or brushed fon the insulation, Finishing varnish aete ass protective layer making cleaning easier, it sans off the windings, mproves the tacking resistance and slows down ageing, Re-vamishing s necessary when the old fisting varnish ie faking off, cracking or peeing off the surface ofthe winding is rough (din steks toi easly) the materials on the surface ofthe insulation or tings have moved. “The wingings should be cleaned with utmst care before @ new coat of vaish Is given so that no

43sEMIKRON _Frovien' service Fusibles para Fusiveis para semiconductores semicondutores— | “ie | Jou*ttane ata} b 24 r ABB STROMBERG DRIVES | MACHINES LAGER D BEARING D HS_710 700357 74 fer TSORSA 7rn See ME 92-06-06 F Wester T7807 800771 ereazegNestugiareae 0112 ) 5, | = d » 3 ? Mit_Isolation = : Caan with isolation a . ABB STROMBERG DRIVES: =a | ZF T MACHINES — at aaaeee LAGER N oe | a € | T BEARING N = \ be, « | I : UG i pss a ; ae ; ) ea +} Lx tee 70035766 A DE MS 9h 06-08 TT MiffentTonschlager Eee feng be sae be 1722507500174 | = [ HTTJON © OF BEARING | i L 175 ® 60.8 é OIL INLET 63/4" | >| 40 wat 164 NOTE. AFTER THE STARTING OF THE OIL CIRCULATION SYSTEM THE PRESSURE CINDICATEDS BY MANOMETER (b)) 80 & OF BEARING 124 ow! e890 OIL OUTLET ON 50 IS ADJUSTED BY MEANS OF THE REDUCTION VALVE (c) ABB STROMBERG DRIVES fer NETO T TO INDICATE THE VALUE 125225 kPa. 1 MACHINES KG IM THEN THE OTL FLOW TO THE BEARING THROUGH THE [ae T PLATE ORIFICE (ce) CONFORMS TO THE NOMINAL VALUE fo) 1 UpRICATION AS 10 ae PIPE CONNECTIONS [ate ie arr a Po LG cae T Hs_90071120 50235211 A erimiG2-04=0) J SARANO [OWED Gans Mea 90a E TANOER ArBetriebsanleitung Seitenflanschlager Mittenflanschlager RALUS LF/LM 0 MANNESMAN! REXROTH Lohmann + Stolterfoht Operating Instructions Side Flange Bearing Center Flange BearingVerkaut / Sales LOHMANN+STOLTERFOHT GmbH Mannesmannst. 29 Postiach 1960+ 0-5810 Witen Tal. (0 28 2) 877-0 Teax 8 229 005 Telefax (0 2802) 88-148 Kundendienst/ Service LOHMANN#STOLTERFOAT GribH Plerdebachst. 4 Postfach 1860 + 0-5810 Wien “Tel (0 23 02) 877-180 «Telex 8 229 005 ‘Telefax (02302) 877-200Inhaltsverzeichnis 10. Einietung Eintuhrung Sicherhetshinweise Produkibeschreibung Enfhrung Beschreibung LGelerumfang Technische Daten Zeicnnungen und Listen Betrebsmitel Transport / Lagerung Einfanrung Hinweise 2u Transport und Lagerung Konservierung Einbau EiniGhrung Handlungesehite zum Einbau Inbetriebnahme Einfohrung Hanclungssehvite zur nbetrcbnahme (in dosem Handbuch nicht enthaten) Pfloge / Wartung Eintoarung Handungsschrite 2u Ploge und Wartung Wartungsplan ‘Ausbau Einfahnung Handungssctuite zum Ausbay (7 diecam Handbuch rich enthaler) Ersatzclibestellung ‘Anhang A a « D. ‘Technische Daten Angcheiften Zelchnungen Ereatetelliston Table of Contents Preliminary Notes Introduetion Notes on Safety Product Description Introduction Description Scope of Supply ‘Technical Data Drawings and Lists Operating Mecka Haneting / Storage Invoducton ‘Notes on Handing and Storing Preservation Mounting Introduction ‘Mounting Work to be Performed Commissioning Invoduction Commissioning Aciviios {oes not form patois manua) Maintenance / Care Invoduetion Maintenance and Care Acvitos Maintenance Schedule Dismantling Intvoduction Ciemanting Work tbe Performed (oes not form part ofthis maruat 10, Spare Parts Ordering Appendix ‘A. Technical Data B Addresses Drawings D. Spare Parts Lists[ Eintettung 1.1 Einfahrung In der vorfegenden Betiebsanletung finden Sie 1.2. Informabonen zum Einbau, zur nbeviebnanme, {BurPlegaund WarungundzurErsatzeibestelung, Beachter Sie unbedingt dle Sicherheitshinwei- ‘98 dieser Dokumentation. «= Algemeine Sicherbeitshinucise fen Since. teem ersten Kapil = Besondere Hinweise finden Sie jewels am An- fang eines Kapital. Au eine Handlung bezogene Sichecheitshinwei te finden Sie wor dor Beechroibung des Hand. lungsscwies. Die Seitenzahl eden Sie am auBeren Seitenrand, Die Angabe 01-01 /04 z 8 bodoutet: piel 1, Seite 1, das Kapiel umfaBt 4 Seiten, Die Bereiche des Anhangs sind durch Zwischen- blater voeinander otenat und oat versehen mit Hinweisen auf den angesprochenen Leserkvas 4.2 Sicherheltshinweise Die Produkte von OHMANN4STOLTERFOHT ind nach dem aktvelon Stand der Technik avspeiogt ‘Und hergestelt,Dennoch kionen Gefahren ave. ten for = Késper und Gesundheit 1 das Produkt und ce Gesamtanlage. + sonstige Werte \Mitlesem Symbol sind Getahren farkér- ‘per und Gesundhelt gekennzeichnet. Mit diesem Symbol sind Gotahren for das Produkt und die Gesamtanlage gekenn- zeichnel. ‘Mit diesem Symbol sind Getahren fOrson- sige Werte gokemnzeichnet. [Rp Dstt oymettcomatene Hinweise. TH Preliminary Notes 1.1. Introduction ‘The present operating instructions contain information on Insiallaion, stat-up, care and maintenance as well as spare pats ordering. Moke sure the safety instructions given inthis documentation ae carefully observed. General nates on safety are listed inthis frst chapter. Special instructions are given atthe beginning of the individual chapter. «Safely Instructons relertng to actions are given ‘lov the action isl is desorbed. Page numbers are shown at te outer bottom ‘margin. Fer example, 01-01 /04 means: Chapter 1, page 1, the chapter has 4 pages. The various areas of the Append have been separated by sheets and, where considered ‘expedient, provided wid notes on the relevant subjects. 1.2. Notes on Safety ‘The products of LOHMANN+STOLTERFOHT have been designed and manufactured £0 as reflect technologicalsateotho at Noverteless, Reannot be red ut that danger may arse to ~ Heand ib, the product and overal plant, > other assets. ‘This symbol signifies danger to We and tid. ‘Thissymbolsigniesdangertotheproduct and the overall plant. ‘This symbol signifies danger to other assets. ‘This symbol calls attention to notes, oxorso41. | Einleitung GGetanren kinnen iasbesondere dann autreten: ‘wenn unzurechend ausgebietes Personal am Produkt tg st, wenn das Produkt unsachgemad insalien, be Cent und instanogehalion wed, ‘wana das Produkt 2u nicht bestimmungsgema- ‘Bem Gebrauch eingesetzt wid. ‘Ale Personen, ie mitdem Bete der Aniage oder Ges Produtos bela sind, méssen: ‘onbedingt dae Kapil “Sicherhetsinweiss” lesen und vestanden haben, ese Betrebsanletung zumindestin den Telen enon indonen ciejewellige Taigketundzuge haige Gefahvoahinweise beschrieben sind, ‘mit Abschagrozeduren, z. 8. "NOT-AUS’ der ‘ganzen Aniage oder den idrdijewelige Taigkeit ‘wchiigen Ten der Aniage verraut sein, echnisch austeichand ausgebidet und zu der jeweligen TEtgkot betug sein ire Abfgaben und Befugnisse kennen. ‘Sie missen untedingt "alle Handungen untoriassen, ie Gefabren for kKérper und Gesuneheit, Gelahen fOr das Pro: Dokumerason Der gosetzichvorgesctvichone Berdhrungsschutz an uiaulonden Tefen geht nicht zum Lifet- umiang. 2.4 Technische Daten ine Zusarmenstelung dor technischen Daten finden Sie km Anhang A. 2.5. Zelchnungen und Listen

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