Technical Documentation

Dolnośląska Fabryka Maszyn
Elektrycznych Sp. z o.o.

ul. Fabryczna 10
53-609 Wrocław; Poland
TECHNICAL DOCUMENTATION
FOR MARINE BRUSHLESS SYNCHRONOUS GENERATOR
TYPE GDBW-1410M/02
DFME Sp. z o.o.

d. DOLMEL
ul.Fabryczna 10
53-609 Wrocław
Poland
Tel. (+48 71) 3565377
Fax. (+48 71) 3565679
ul. Fabryczna 10
TECHNICAL DOCUMENTATION
FOR MARINE BRUSHLESS SYNCHRONOUS GENERATOR
TYPE GDBW-1410M/02
1750 kVA, 450 V, 60 Hz, 720 rpm
LIST OF DOCUMENTS: Document number
1. TECHNICAL DATA SPECIFICATION .....................................................................................................WG4-059625/A

2. OPERATING INSTRUCTIONS FOR MARINE BRUSHLESS SYNCHRONOUS GENERATORS
WITH TWO FLANGED SLEEVE BEARINGS...........................................................................................WG4-023181/A
3. ASSEMBLY DRAWING .......................................................................................................................WG3-011031
4. OUTLINE DRAWING ..........................................................................................................................WG3-031186
5. LIST OF SPARE PARTS .....................................................................................................................WG4-027607/A
6. LIST OF SPECIAL MOUNTING DEVICES ..............................................................................................WG4-029325/A
7. DIAGRAM OF CONNECTIONS .............................................................................................................WG4-049045
8. ANTI-CONDENSATION HEATERS INSTRUCTIONS .................................................................................WG4-023057/A
9. OPERATING INSTRUCTIONS FOR EXCITER..........................................................................................WK4-020031/A
10. SLEEVE BEARING DOCUMENTATION (ZOLLERN):
a. Installation and Operation Instructions ZF .....................................................................................990225/h520
b. Assembly Drawing (ZFNLQ 14-125) .............................................................................................0214.00112
c. Assembly Drawing (ZFNLK 14-160)..............................................................................................0214.00177
11. OPERATING MANUAL OF VOLTAGE CONTROL SYSTEM RNGA-21 ....................................................OG/37/00
DFME Sp. z o.o.

d. DOLMEL WG4-020758/A
ul.Fabryczna 10
53-609 Wrocław
Poland
Tel. (+48 71) 3565377
Fax. (+48 71) 3565679
ul. Fabryczna 10
BRUSHLESS THREE-PHASE SYNCHRONOUS GENERATOR

FOR MARINE APPLICATION
TECHNICAL DATA SPECIFICATION
1. GENERATOR TYPE ............................................................................... GDBW-1410M/02

2. RATED OUTPUT ............................................................................... 1750 kVA / 1400 kW
3. POWER FACTOR ............................................................................................................ 0.8
4. RATED VOLTAGE ............................................................................................... 3 x 450 V
5. RATED FREQUENCY ................................................................................................ 60 Hz
6. RATED STATOR CURRENT .................................................................................. 2245 A
7. RATED SPEED ......................................................................................................... 720 rpm
8. DUTY ............................................................................................................ S1 (continuous)
9. EFFICIENCY: AT P.F.=0.8 AT P.F.=1.0
LOAD 100% ............ 95.4 % .............. 96.1 %
LOAD 75% .............. 95.2 % .............. 96.0 %
LOAD 50% .............. 94.5 % .............. 95.5 %
10. REACTANCES:
DIRECT-AXIS SYNCHRONOUS Xd ....... 139 %
QUADRATURE-AXIS SYNCHRONOUS Xq ....... 79 %
DIRECT-AXIS TRANSIENT X’d ...... 31.7 %
DIRECT-AXIS SUB-TRANSIENT X”d ..... 15.6 %
NEGATIVE PHASE-SEQUENCE X2 ....... 15.4 %
ZERO-PHASE-SEQUENCE Xo ....... 6.2 %
11. DIRECT-AXIS TIME CONSTANTS
TRANSIENT OPEN-CIRCUIT T’do .... 2.4 s
TRANSIENT SHORT-CIRCUIT T’d ...... 0.55 s
SUB-TRANSIENT SHORT-CIRCUIT T”d ...... 0.014 s
APERIODICAL Ta ........ 0.041 s
12. OVERLOAD ....................... 10 % for 1 hour within 6 hours interval; 50 % for 2 minutes
13. PHASE CONNECTION ................................................................................................. star
14. NUMBER OF STATOR TERMINALS ............................................................................. 3
15. CLASS OF INSULATION ................................................................................................. F
16. AMBIENT TEMPERATURE ...................................................................................... 45°C
17. DEGREE OF PROTECTION ACC. TO IEC 34-5 .. machine - IP 23, terminal box - IP 54
18. METHOD OF COOLING ACC. TO IEC 34-6 ........................................................... IC 01
(with filter on air inlet)
19. MOUNTING ARRANGEMENT ACC. TO IEC 34-7 ................................. IM 1101 (B20)
20. BEARINGS ................................................................ two sleeve bearings, self -lubricated
21. ANTI-CONDENSATION HEATERS ...................................................... 220 ÷ 240 V AC
22. TEMPERATURE DETECTORS FOR STATOR WINDING ............................. 2x3 Pt100
(3 operating + 3 reserve)
23. TEMPERATURE DETECTOR OF THE BEARING(S) ........................................ 2xPt100
24. EXCITATION .................................................. brushless exciter mounted in the generator
WG4-059625_A.doc WG4-059625/A
2004-05-24 Page 1/2
ul. Fabryczna 10
25. TECHNICAL DATA OF VOLTAGE CONTROL SYSTEM:

1) VOLTAGE REGULATOR TYPE .......................................... electronic, type RNGA-21
(for mounting in switchboard)
2) VOLTAGE ADJUSTMENT RANGE ........................................................ 90÷105 % UN
3) VOLTAGE REGULATION ACCURACY at load range 0÷100 % IN,
at power factor 0.6÷0.9 lagg and at frequency variation fN ± 5 % ......................... ± 2.5 %
4) VOLTAGE RECOVERY TIME
after switching on/off 60 % IN, at power factor 0.4 lagg .................................... max. 0.5 s
5) VOLTAGE DROP after switching on 55 % IN, at power factor 0.4 lagg ... max. 15 % UN
6) SUSTAINED SHORT CIRCUIT CURRENT ....................................... not less than 3 IN
26. CURRENT TRANSFORMERS FOR DIFFERENTIAL PROTECTION ……… . included
(one set built in + one set for mounting in switchboard)
27. PRIME MOVER .......................................................................................................7L28/32
28. RADIO INTERFERENCE SUPPRESSION ............................................................ class N
29. PARALLEL OPERATION ................ suitable for parallel operation with other generators
(generator with damper winding)
30. LANGUAGE OF DOCUMENTATION AND RATING PLATE ................... acc. to order
31. SPARE PARTS (1 set per ship):
- spare parts for generators (varistor - 3 pcs, diodes - 6 pcs, space heater - 1 pc);
- spare parts for AVR;
- spare bearing shells
32. CABLE GLANDS .............................................................. no. and diameters acc. do order
33. DISMANTLING DEVICES ........................................................................ one set per ship
34. BASIC STANDARD ............................................................................................. IEC 34-1
35. CLASSIFICATION SOCIETY ................................................................................... DNV
36. TECHNICAL DOCUMENTATION ..................... language and no. of copies acc. to order
WG4-059625_A.doc WG4-059625/A
2004-05-24 Page 2/2
OPERATING INSTRUCTIONS
FOR MARINE BRUSHLESS SYNCHRONOUS

GENERATORS
WITH TWO FLANGED SLEEVE BEARINGS
„Dozamel” Sp. z o.o. WG4-023181/A

d. DOLMEL Page 1/18
ul. Fabryczna 10 i 13
53-609 Wrocław
Poland
CONTENTS: PAGE
1. INTRODUCTION ...................................................................................................................................... 3
2. TECHNICAL DESCRIPTION .................................................................................................................... 3
2.1. GENERAL ................................................................................................................................................. 3

2.2. STATOR .................................................................................................................................................... 3
2.3. ROTOR...................................................................................................................................................... 3
2.4. BEARING ARRANGEMENT ..................................................................................................................... 4
2.5. EXCITER .................................................................................................................................................. 4
2.6. DEGREE OF PROTECTION. METHOD OF COOLING ............................................................................ 4
2.7. TEMPERATURE CONTROL .................................................................................................................... 5
2.8. TERMINAL BOX ....................................................................................................................................... 5
2.9. EARTHING TERMINALS .......................................................................................................................... 5
2.10. ANTICONDENSATION HEATERS ........................................................................................................... 5
2.11. AUTOMATIC VOLTAGE REGULATOR .................................................................................................... 6
2.12. SPARE PARTS ......................................................................................................................................... 6
3. PACKING, TRANSPORT AND STORAGE............................................................................................... 6
4. INSTALLATION OF GENERATOR .......................................................................................................... 7
4.1. GENERAL ................................................................................................................................................. 7

4.2. PRELIMINARY PROCEDURES ............................................................................................................... 7
4.3. INSTALLATION PROCEDURES ............................................................................................................... 7
5. STARTING UP. PARALLEL OPERATION ............................................................................................. 8
6. DRYING OF GENERATOR ...................................................................................................................... 9
6.1. GENERAL PRINCIPLES OF DRYING....................................................................................................... 9

6.2. DRYING BY EXTERNAL HEATING......................................................................................................... 10
6.3. DRYING BY SHORT-CIRCUIT CURRENT.............................................................................................. 10
7. OPERATION AND MAINTENANCE........................................................................................................ 11
7.1. LOAD REGULATION............................................................................................................................... 11

7.2. MAINTENANCE....................................................................................................................................... 12
7.3. GENERATOR STANDSTILL.................................................................................................................... 13
8. DISMANTLING OF GENERATOR .......................................................................................................... 13
8.1. DISMANTLING FOR INSPECTION, REPAIR OR REPLACEMENT

OF EXCITER ROTOR AND STATOR...................................................................................................... 13
8.2. TOTAL DISMANTLING ........................................................................................................................... 15
8.3. DISMANTLING OF SLEEVE BEARING ................................................................................................. 16
9. SAFETY PRESCRIPTIONS .................................................................................................................... 16
10. TROUBLE SHOOTING ........................................................................................................................... 17
WG4-023181/A
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1. INTRODUCTION
This instructions contain information relating to design features, storage, installation, starting
up and operational use of synchronous, brushless marine generators, by personnel specialised
in operating electrical machines.
Information relating to design and operational use of the bearing, anti-condensation heater,
thermistors (when provided), exciter and automatic voltage regulator is given in separate in-
structions included in the Technical Documentation of the generator.
2. TECHNICAL DESCRIPTION
2.1. GENERAL
The generators meet the requirements of Classification Society regulations specified in the or-
der and are designed for operation with diesel engines in diesel-electric gensets. Mounting ar-
rangement of the generator, its overall and installation dimensions are given in the outline
drawing appended to the Technical Documentation. General design of the generator is pre-
sented in the appended assembly drawing.
2.2. STATOR
The generator frame is of welded construction. The core packs are made of cold-rolled electri-
cal sheet steel coated with an insulating varnish. The stator winding consists of double-layer,
form-wound, short-pitched coils fitted into open slots. Winding overhangs are reliably fastened
to ensure winding resistance to vibrations and shock stresses and also to hazards caused by
short-circuits. After wedging into the slots, the winding is impregnated. The stator winding is of
insulation class F. The insulation system is resistant to marine and tropical climate conditions.
2.3. ROTOR
The shaft is made of high-quality forged steel. Depending on the machine type, the poles are
fixed directly to the shaft or to a rotor spider mounted on the shaft. The core of poles are lami-
nated of thin sheet steel. The field coil is a multilayer coil made of rectangular copper wire in-
sulated with glass fibre. After winding, the coil is pressed and baked. Between the pole core
and the coil, there are special liners and distance pieces forming ventilating ducts through
which the flowing air cools the coil from the inside. The coil insulation is of class F.
WG4-023181/A
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In the pole shoes, there are round copper bars of the damping cage. These bars are welded to
segments forming closed rings. The cage is designed to improve running stability during paral-
lel operation of machines.
2.4. BEARING ARRANGEMENT

The generator has two sleeve self-lubricated bearings. Bearing cooling is natural. For bearing
lubrication, use machine or turbine oil of viscosity class ISO VG46 (cinematic viscosity
2
41÷51 mm /s at 40°C). Admissible bearing temperature: 90°C (measured by means of em-
bedded Pt100 sensor).
Details of bearing design and further information concerning the bearing operation are given in
the bearing documentation being a part of the generator Technical Documentation.
2.5. EXCITER
The generator field winding is supplied by a brushless exciter having rotating diodes mounted
inside the generator at the non-drive end. The exciter stator with control winding, whose ter-
minals are marked F1 and F2, is bolted to the bearing endshield. The exciter rotor is mounted
directly onto the generator shaft and its leads are brought out via a rectifier bridge and con-
nected to the generator field winding.
Further information concerning the exciter is given in the appended Operating Instructions of
exciter.
.
2.6. DEGREE OF PROTECTION. METHOD OF COOLING
The generators have degree of protection IP23 according to IEC 34-5, and are protected
against the entry of solids larger than 12 mm and against water falling at an angle of 60° from
the vertical.
The IC01 cooling system acc. to IEC 34-6 is used, i.e open-circuit ventilation with ambient air.
Air circulation is forced by a fan mounted on the generator shaft and suitable for one direction
of rotation (marked by an arrow on the N-end cover).
A filter is installed at the cooling air intake. The filter can be reconditioned several times by
washing in normal detergents. It should be taken into consideration that the air leaving the
generator carries away the generator heat losses into the surroundings. To maintain the tem-
perature of the ambient air below the value given on the rating plate, adequate ventilation of
the room in which the generator is installed, should be provided.
WG4-023181/A
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2.7. TEMPERATURE CONTROL
Temperature sensors Pt100 or thermistors are provided (depending on the customer’s re-
quirements) for thermal protection of the stator winding. The sensors Pt100 are embedded into
the slots and are provided for remote monitoring of temperature and for alarming/tripping. The
thermistors are mounted on coil ends for alarming/tripping if admissible temperature is ex-
ceeded. The terminals of these sensors are shown on the diagram of connection appended to
the Technical Documentation of the generator.
Further information concerning thermistors (if provided) is given in a separate instructions ap-
pended to the Technical Documentation.
For remote temperature monitoring of the sleeve bearing a Pt100 sensor is provided and a liq-
uid thermometer is installed for visual check of oil temperature.
2.8. TERMINAL BOX

Location of the terminal box is shown on the outline drawing of the generator. In the terminal
box, there are generator stator winding terminal bars (U, V, W), exciter control winding termi-
nals (F1, F2), terminals of the anticondensation heaters and of the temperature sensors Pt100
or thermistors. All terminals located in the terminal box are shown on the diagram of connec-
tions. The quantity and dimensions of cable glands fitted are adapted to customer’s require-
ments.
2.9. EARTHING TERMINALS

The earthing terminal of the generator is located on a support of the frame foot at the same
side as the plate with cable glands. This terminal should be connected to the common earth
bar in compliance with the regulations in force. An earthing terminal is also located inside the
terminal box.
The terminals enclosure is connected to generator frame by means of earthing conductors.
2.10. ANTICONDENSATION HEATERS

To prevent water condensation on the windings after generator shutdown, pipe-type anticon-
densation heaters are mounted inside the stator frame (at N-end). Rating of heaters and ter-
minals marking are given on the diagram of connection. Further information concerning the
system of heaters is given in a separate instruction appended to the Technical Documenta-
tion.
WG4-023181/A
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2.11. AUTOMATIC VOLTAGE REGULATOR (AVR)
The purpose of the AVR is to keep a constant voltage value at the generator terminals (within
set tolerance limits), to regulate it during transient conditions and also to provide proportional
reactive power sharing during parallel operation of generators. The AVR keeps the generator
parameters at a set level by supplying the exciter control winding.
Detailed information dealing with the design and operation of the AVR is given in a separate
Operating Manual.
2.12. SPARE PARTS

The set of spare parts delivered with the generator is specified in the Spare Parts List ap-
pended to the Technical Documentation. The set of spare parts for the Automatic Voltage
Regulator is given in its Operating Manual.
3. PACKING, TRANSPORT AND STORAGE
Generators are shipped from the manufacturer completely assembled and in an appropriate
packing according to applicable instructions. The customer should check that the supply is
complete as per the shipment specification, and also check the state of equipment delivered.
For lifting the generator there are holes provided in the frame above the feet. When lifting the
generator, care should be taken that the slings do not abut against the terminals enclosure,
to avoid damage of them. It is recommended to place the generator crosswise to the travel
direction of the transport means. During transportation and storage, the generator should be
set on its feet in such a manner that the bottom part of the frame is raised above the floor.
If after delivery, the generator is not to be installed immediately, it should be stored together
with spare parts in a closed, dry and clean room. The temperature in the storage room should
not be lower than +5°C. The anticondensation heaters built into the generator can be
switched on.
When the generator is stored longer than 12 months, repeat application of anti-corrosion pro-
tection measures.
Remark:
Once a month check the state of humidity indicator (when provided) located inside the gen-
erator package and proceed as follows:
30 – colour pink – shorten frequency of the inspection
40 – colour pink – replace the humidity indicator
WG4-023181/A
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50 – colour pink – check the state of package interior and replace the humidity indicator
4. INSTALLATION OF GENERATOR
4.1. GENERAL
The generator should be installed on a sufficiently rigid foundation plate. The mounting sur-
face of the foundation plate shall be machined. A proper distance between the foundation
plate and the generator feet shall be provided, to enable inserting of adjusting shims under
the generator feet.
4.2. PRELIMINARY PROCEDURES

Before commencing the generator installation, study the Technical Documentation supplied
by the manufacturer, and especially the following documents :
a) this Instructions,
b) Bearing Operation Instructions,
c) Operating Instructions for Exciter,
d) Assembly Drawing of Generator,
e) Outline Drawing and other drawings appended.
4.3. INSTALLATION PROCEDURES
The protective anticorrosive agent shall be removed from the shaft flange. Damaged or cor-
rosion-attacked spots shall be scraped flash and polished by means of slightly greased em-
ery cloth.
If the generator was stored over an extensive period, it is recommended to inspect the ac-
cessible interior of the generator and blow it through with clean compressed air at pressure
not exceeding 200 kPa.
The generator rotor has been balanced in the plant together with a key half mounted in the
shaft end and hence the coupling half should also be balanced with a key half, before mount-
ing.
Use the proper procedure and appropriate tools while mounting the coupling half onto the
shaft. Note that impacts while mounting the coupling half can damage the generator bear-
ings.
After setting the generator on the foundation plate, align the prime mover and generator shaft
axes by following the relevant directions of the prime mover and coupling manufacturer, and
WG4-023181/A
Page 7/18
also have the locating bearing in the generator on the side of the drive. Vertical position of
the generator on the fundation plate is set with the adjusting bolts screwed into the stator
feet.
After aligning the shaft axes, screw the mounting bolts of the generator into the foundation
plate. Fill the gap between the stator feet and the foundation plate with adjusting shims of
appropriate thickness and shape. Ease the adjusting bolts in the stator feet. Tighten the bolts
securing the generator to the foundation plate, taking particular care not to disturb the gen-
erator position. Recheck for true alignment and correct if necessary.
The air gap between the generator stator and rotor has been set in at the manufacturer’s
plant.
When the generator is correctly set, mount the bearing front cover and secure generator po-
sition by means of dowel pins.
The final installation procedures comprise connecting the cables and earthing the generator.
Connect the external cables through the cable glands to the busbars in the terminal box (the
tighteninig moment of the bushbars bolts – 62Nm). This box also contains the terminals of
the anticondensation heaters, stator winding temperature sensors and voltage adjuster.
5. STARTING UP. PARALLEL OPERATION
Prior to starting up for the first time after installation check the readiness for start up, in par-
ticular :
• correct installation and securing to the foundation plate,
• earthing,
• oil level in bearing,
• operation of bearing temperature control circuit,
• correctness of electrical connections,
• cleanliness around the generator,
• windings insulation condition.
The stator winding insulation resistance at 40oC should not be less than 3 MΩ.
The rotor winding insulation resistance should not be less than 1 MΩ.
Use a 500 V megger for measuring the insulation resistance.
Remark: if, by any reason, a >500 V megger is used the F1, F2 terminals and the AVR fuses
have to be disconnected.
WG4-023181/A
Page 8/18
If the above criteria concerning insulation resistance are not satisfied, dry the generator. The
recommended drying methods are given in the next chapter.
It should be borne in mind that the value of insulation resistance decreases as the winding
temperature increases. Approximately, it can be assumed that the value of insulation resis-
tance is halved resp. doubled for every 20°C.
Immediately after starting up, check if the direction of rotation of generator rotor is correct
and if bearing oil ring rotates.
The method of setting the generator voltage level is given in the voltage regulator Operating
Manual. While measuring the current and voltage and taking into account the power factor,
the generator parameters should be so adjusted that no limiting value specified on the rating
plate is exceeded in any phase.
The connection diagram for parallel operation and the procedures for switching to parallel
operation are given in the voltage regulator Operating Manual. It should be pointed out here
that generators of the same series but of different power ratings can be operated in parallel,
whereas parallel operation of generators of this series with generators made by other manu-
facturers requires analysis and consultation with the manufacturer. During parallel operation,
the voltage regulator only affects the reactive power sharing by the respective generators,
whereas the active power sharing depends on the performance of speed governors of the
driving engines.
If the generator is designed for operation with grounded stator winding neutral, a neutral
grounding resistor should be installed.
6. DRYING OF GENERATOR
During generator operation or during standstill with anticondensation heaters on, the insula-
tion of windings does not get moistened. Insulation moistening may occur during extended
storage period.
External heating or short-circuit current drying is recommended.
6.1. GENERAL PRINCIPLES OF DRYING

Moistening level of the insulation system is indicated by the value of insulation resistance
across the windings and the frame.
The value of stator windings insulation resistance at temperature 40°C should be at least
3 MΩ, and for rotor insulation it must be at least 1 MΩ. Do not carry out the drying process
too rapidly. At the beginning of drying, the temperature rise shall not exceed 5°C/hour, and at
WG4-023181/A
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the end 10°C/hour, so that after 8 hours the temperature does not exceed 65°C. The maxi-
mum temperature at the hottest spot of the stator winding should not exceed 80°C. The
maximum temperature may be obtained after 10 hours after commencement of drying.
Continuous temperature control during drying process should be ensured.
Measure the insulation resistance with a 500 V megger. Measure the temperature with ther-
mometers located in the winding. During the drying procedure, the insulation resistance usu-
ally decreases at first, then it gradually increases and finally stabilises. When the above
mentioned criteria are met at a stable temperature, the drying process can be considered as
completed. Measure the insulation resistance with the heating current switched off. Damp
machines whose insulation resistance has dropped below 0.1 MΩ, should not be dried by
means of electric current.
6.2. DRYING BY EXTERNAL HEATING

Drying by means of external heating can be applied to all kinds of electrical machines and
particularly when they show too low insulation resistance. Heating can be done by means of
infrared lamps or hot air from blowers. Hot air temperature for winding drying should not ex-
ceed 100°C. While drying with external heating, temperature of winding of 90°C is admissi-
ble. During drying procedures, air exchange should be ensured in the generator to carry
away the moisture.
6.3. DRYING BY SHORT-CIRCUIT CURRENT

To avoid overheating the rotor circuits due to a negative sequence field generated while dry-
ing with short-circuit current and to obtain equal current in all phases, the stator winding must
be short-circuited via 3 ammeters having equal internal resistance.
Supply the field current to the exciter control winding terminals F1, F2 from a separate power
source. Allow the generator to rotate at a lower speed appropriate for obtaining the proper
temperature. Adjust the field current so that the stator current at the beginning of drying is
50% of the rated value specified on the rating plate, and then gradually increase it until, in the
final stage of drying, such a value is obtained at which the stator winding temperature is close
to 80°C. While drying, follow the instructions given above, taking care that :
a) the stator winding temperature does not exceed 80°C,
b) the stator current does not exceed the rated value,
c) the outlet air temperature does not exceed 50°C.
WG4-023181/A
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The above conditions can be ensured by appropriate regulation of the field current and the
generator speed.
7. OPERATION AND MAINTENANCE
Remark: Information concerning operation and maintenance of:

- bearing,
- anticondensation heaters,
- thermistors (if provided),
- exciter,
- automatic voltage regulator,
are given in the relevant instructions appended to the Technical Documentation.
7.1. LOAD REGULATION

The generator is designed for continuous duty at the data given on the rating plate. The tem-
perature specified on this plate refers to the ambient temperature. At variations of the ambi-
ent temperature with respect to the rated temperature of 45°C, the permissible continuous
output of the generator expressed as percentage of the rated output, varies as follows:
Ambient temperature, °C 30 40 45 50 55
Generator output as % of rated output 106 103 100 95 90
The active power output of the generator is determined from the relationship:
P = S × cosϕ, where: P - active power, in kW;
S - apparent power, in kVA;
cos ϕ - power factor
The rated apparent power in kVA and the rated cosϕ are given on the generator rating plate.
If the generator is only loaded with active power at cosϕ=1.0, the continuous active power
can be increased by 10% with respect to the active power determined from the above rela-
tionship at cosϕ=0.8, provided that the driving engine allows the load increase. If the genera-
tor operates at cosϕ lower than the rated value, the load should be so regulated that the
rated values of the generator stator current and the exciter control current are not exceeded
over longer periods than those given for permissible overloads.
Permissible overloads :
WG4-023181/A
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• 10% above the rated output during 1 hour within a period of 6 hours, at the rated voltage
and rated speed,
• 50% above the rated current during 2 minutes, at cosϕ=0.6 and at voltage and frequency
values as close as possible to the rated ones.
The method of regulating the reactive power is given in the voltage regulator Operating Man-
ual.
7.2. MAINTENANCE
During generator operation, keep the surrounding area clean. Eliminate any oil leakage. By
means of the measuring and monitoring systems applied for the given generator, control its
correct operation, in particular :
1) Bearing temperature (measured by means of embedded Pt100 sensor).
If the temperature of 90°C is exceeded, stop the generator and eliminate the cause of ex-
cessive bearing heating.
2) Stator winding temperature.
In case the temperature of 140°C is exceeded:
- check the generator load; if the generator is overloaded, reduce the load
- check the ambient temperature near the air intake to the generator.
If the ambient temperature is higher than that given on the generator rating plate, de-
crease the generator load according to the ambient temperature using the relationship
given in point 7.1.
Improvement of ventilation in the room where the generator operates should be envis-
aged.
- check the state of the filter at the air intake. If the filter is dirty, it should be washed in wa-
ter with a detergent added. It is recommended to wash the filter at least 2-3 months. Gen-
erator overheating can also be caused by dirtying of its interior, particularly the ventilating
ducts.
Thorough cleaning of the machine interior shall be carried out during periodic overhauls.
The machine shall be blown through with clean air of a pressure not exceeding 200 kPa.
The rubber hose for air supply must have a rubber or plastic nozzle. A metal nozzle shall
not be used because it could damage the winding. The active iron and end windings shall
be wiped with rags soaked in white spirit. It is forbidden to wash the inner generator sur-
faces with plain petrol, kerosene or thinner. It is allowed, but not more frequently than once
WG4-023181/A
Page 12/18
a year, to wash the machine interior with spirit or tetrachloroethylene. However, these
means shall be used cautiously since they dissolve to some extent the varnishes and
enamels applied to the winding surfaces.
7.3. GENERATOR STANDSTILL

In case of generator standstill for an extended period, the anti-condensation heaters should
be switched on.
8. DISMANTLING OF GENERATOR
During operational use of the generator, circumstances may occur which require partial or to-
tal dismantling of the generator. If the engine room does not have sufficient space for
carrying out the required scope of disassembly, the generator should be moved to an appro-
priate place enabling the disassembly. Before any disassembly, study the generator assem-
bly drawing and other drawings appended to the Technical Documentation.
Dismantling should be carried out carefully, with all applicable work safety regulations ob-
served.
Remark: the shaft extension and guide bolts recommended for use during dismantling can
be supplied by the manufacturer according to the scope of supply agreed in the contract for
supply of generators.
8.1. DISMANTLING FOR INSPECTION, REPAIR OR REPLACEMENT OF EXCITER ROTOR AND STATOR
Given below is the scope of dismantling without disconnecting the coupling, assuming that
the place of installation has sufficient space for this procedure.
1. Dismount the covers opposite the exciter from both sides of the stator frame.
2. Disconnect exciter stator cables from the terminals on the inside of the bearing endshield.
3. Dismount the front cover and top part of the bearing housing on the exciter side; remove
the temperature sensor from the bearing.
Remark: for details of dismantling and mounting of bearing parts - see bearing documenta-
tion.
4. Mount a shaft extension of appropriate length and support it at the end.
5. Remove the bearing labyrinth seal and bearing shell from the bearing housing.
6. Unscrew the bolts securing the bearing endshield. To protect the exciter windings against
possible damage, screw 4 guide bolts of length enabling shifting of the endshield to such a
WG4-023181/A
Page 13/18
distance that the exciter stator gets shifted from its rotor, via the bearing endshield into the
holes in the frame.
7. While moving out the bearing endshield use the jacking bolts screwed into the endshield
and the eye-bolts screwed into the bearing housing.
8. Slide the endshield out together with the exciter stator and the bearing housing to the end
of the shaft extension. Perform this task very carefully. Until the exciter stator is shifted out
of the rotor, the radial movements of the endshield with respect to the generator axis can
not exceed 1 mm.
9. Perform the inspection and any possible repairs of the exciter. In case of necessity of
removing the exciter rotor from the shaft, carry out also the following operations:
a) disconnect the generator rotor cables from the rectifier;
b) put a pressboard insert of appropriate thickness between the generator stator and rotor;
c) support the shaft extension in its mid-section located between the bearing endshield
(shifted out) and the generator stator; remove the shaft extension end support;
d) remove the bearing endshield together with the bearing housing and exciter stator from
the shaft extension and dismount the shaft extension; perform the inspection and any nec-
essary repair of the exciter stator;
e) remove the locking insert fixing the exciter rotor on the shaft after removing the securing
weld.
For dismounting the exciter rotor use an appropriate puller, using the holes in the rotor of ex-
citer.
Reassembly of the generator is carried out basically in the reverse sequence of operations
carried out during dismantling, but the exciter rotor should be heated to the temperature of
120÷140°C before mounting onto the shaft. Prior to heating, dismount or protect the diodes
against overheating in the high temperature. After mounting the rotor, assemble the locking
insert fixing the rotor on the shaft and weld it with the exciter. Besides this, remember to re-
move the insert from between the generator stator and rotor and to connect the cables to the
exciter rectifier and to the exciter stator terminals. Observe also the relevant requirements
given in the bearing Maintenance Instructions.
Remark: If the place of installation does not have sufficient space for performing the above
mentioned scope of disassembly, transfer the generator to an appropriate place enabling the
disassembly. In this case, operations specified at the beginning of cl.8.2 have to be carried
out.
WG4-023181/A
Page 14/18
8.2. TOTAL DISMANTLING
For total dismantling (i.e. removal of the rotor from the stator), transport the generator to a
place enabling such operation. Prior to that, following steps have to be completed:
- uncouple the shafts,
- disconnect all external cables from the terminals,
- unbolt the stator from the foundation plate,
- remove the dowel pins.
After moving the generator to the place of dismantling, the sequence of dismantling is as fol-
lows:
1. Perform the tasks as per cl.8.1.-1÷8.
2. Support the shaft extension at its mid-section. Remove the shaft extension end support.
Remove the bearing endshield together with the bearing housing and the exciter stator.
3. Support the shaft at the coupling end.
4. From the bearing at the drive end, dismount the top cover, layrinth sealing, sleeve and
thermometer
5. Screw an eye-bolt into the bottom section housing dismount it.
6. Unscrew the bolt securing the bearing endshield. Screw the jacking screws into the end-
shield holes and suspend the endshield on slings. Remove the bearing endshield if the di-
mensions of the the coupling permit this. If it is not possible, secure the endshield to the
shaft and coupling in such a way that it does not slide while removing the rotor.
7. Put a 2 mm thick pressboard insert between the stator and the rotor.
8. Mount hemp slings at the end of the shaft extension and at the end of coupling and cau-
tiously move out the rotor as far as possible towards the coupling.
Support the rotor in this position and transfer the slings to the pole part near the centre of
gravity of the rotor and remove the rotor from the stator.
Generator reassembly after total dismantling is carried out in the reverse sequence of opera-
tions to those performed during dismantling. Also the relevant requirements given in the
bearing Operating Instructions and the recommendations relating to generator installation
given in cl.4.3 should be taken into account.
WG4-023181/A
Page 15/18
8.3. DISMANTLING OF SLEEVE BEARING
For dismantling the bearing, use the drawings and information given in the bearing Operating
Instructions appended to the Technical Documentation.
9. SAFETY PRESCRIPTIONS
• Operating personnel should have adequate qualifications.

• Coupling and other rotating parts should be shielded.
• Dismantling and reassembly should be carried out in compliance with relevant safety rules.
• Safety rules appropriate for the voltage level of the generator and related equipment should
be observed.
• Fire safety rules should be observed.
WG4-023181/A
Page 16/18
10. TROUBLE SHOOTING
Malfunction Possible causes Action
Connection break between Check the connection.

exciter and generator rotor. Eliminate the break.
Connection break between Check the connection.

At rated speed, exciter control winding and Eliminate the break.
generator is not regulator.
excited or gener-
ates too low Damaged exciter. Proceed as recommended in the ap-
voltage. pended Operating Instructions of exciter.
Proceed as recommended in the ap-

Damaged voltage regulator. pended voltage regulator Operating
Manual.
Excessive voltage Generator overloaded Check the power output and reduce the
drop on load. current value if necessary.
Generator overloaded Check the generator current value and

reduce it if necessary.
Ambient temperature ex- Decrease the generator load.

Generator over- ceeded Lower the ambient temperature, improve
heats. ventilation of generator room.
Dirty filter at air inlet Wash the filter.
Generator interior polluted. Blow generator interior through with

compressed air.
WG4-023181/A
Page 17/18
Malfunction Possible causes Action
Inappropriate coupling of Check the coupling of the shafts and if

generator shaft with prime necessary correct it.
mover
Inappropriate foundation Measure the vibrations of the genset,

plate. calculate the rigidity of the foundation
plate and if necessary, change its de-
sign.
Excessive vibra- Damaged bearing. Check the state of bearing and if neces-
tions. sary repair it.
Loading of stator phases too Check the value of current in the phases
asymmetric. and the voltage between the phases.
Reduce the loading asymmetry to the
admissible values.
Magnetic asymmetry due to Measure the impedance of each field

short-circuited turns in field coil and if necessary repair or replace
coils. the damaged coil.
Deterioration of the rotor Check the rotor balancing and if neces-

balancing. sary re-balance the rotor.
Remarks:
1. Further information regarding causes of malfunctioning concerning electrical parameters
and their elimination is given in the voltage regulator Operating Manual.
2. Information on bearing operation is given in the bearing Operating Instructions.
WG4-023181/A
Page 18/18
Spare parts list WCZ
Below listed spares are assigned for 1 ship.
Item Description No off Drawing or specification No Remarks
1 Space heater 1 WG4-693033

2 Diode D51-100-16-NO 6 catalogue
3 Varistor 3 WW4-229019
4 Bearing shell for ZFNLQ 14-125 1 WG4-089392 item 3
5 Bearing shell for ZFNLK 14-160 1 WG4-089392 item 4
Designed 06-2003 W. Pilat WG4-027607/A

Checked: 06-2003 J. Tokar Pages: 1 Page: 1
Specification for special WCM
mounting devices
Below specifed devices could be used to all alternators instaled in ship.
Item Description No off Drawing or standard No Remarks
1 Shaft extension 1 WG3-939013 RII

2 Bolt M16x45-8.8-B 4 PN/M-821105
3 Leading bolt 4 WG5-939003
Designed: 98-10 W. Piłat WG4-029325/A

Checked: 98-10 J. Tokar Pages: 1 Page: 1
ANTI-CONDENSATION HEATERS - INSTRUCTION
The anti-condensation heaters are supplied as special equipment of generator for standstill
period and consist of heating elements built-in in the generator housing. The system is
intended to maintain the generator internal temperature at a higher level than ambient
temperature what is aimed to prevent steam condensation within the generator housing in
case of generator switching off or at sudden ambient temperature fluctuations.
Steam condensation in such a case is caused by lower ability of cold air to disperse steam
particles than that of warm air.
The use of heating elements being switched-on during standstill brings about continuous air
circulation between the generator interior and surroundings, what causes on the one hand that
machine elements reach the ambient temperature more quickly and on the other hand the air
from the surroundings after getting into the machine interior, is warmed up and gets higher
ability to disperse steam particles, where by additional protection against condensate
generation is obtained.
It is to be pointed out, that to drain the condensate, possible at anti-condensation heaters
failure, at the stator housing bottom, appropriate drain holes are provided.
The heating elements are fixed at one stator end, above the endwindings.
The heating-up system is to be switched on immediately after generator being put out of
operation-preferably automatically, by means of main circuit breaker auxiliary contact, as
show, by way of an example, in Fig.1.
Fig. 1.
1 - Main circuit breaker auxiliary contact

2 - Heating elements
"Dozamel" Sp. z o.o. WG4-023057/A

d. DOLMEL Page 1/1
53-609 Wroclaw
Poland
INSTRUCTION MANUAL
of
EXCITER
with Rotating Rectifer
type
APOc-740
"Dozamel" Sp. z o.o. WK4-020031/A

d. DOLMEL Page 1/6
53-609 Wroclaw
Poland
1. Exciter Specifications
Rated data
Exciter type Output Voltage Current
kW V A
APOc-740-60-20W 9 90 100
APOc-740-80-20W 11 110 100
APOc-740-110-20W 15 150 100
APOc-740-160-20W 22 220 100
2. Exciter Electrical diagram
F1
F2
Varistor
WK4-020031/A
Page 2/6
3. Exciter Construction
The rotating rectifier exciter is mounted inside a synchronous generator. It is a synchr o-

nous five-phase alternating current generator, which supplies via silicon diodes the field
winding of the main synchronous generator. The double-layer exciter armature winding is
located in the rotor iron slots and together with rectifier diodes forms the star connection.
The star neutral point is connected directly with one end of synchronous generator field
winding, whereas the remaining phase ends of exciter armature are connected via diodes
with the collecting ring of the carrier, to which there is bolted the second end of the field
winding. The rotor core is located on the generator shaft at the non-drive end. The diode
carrier is fixed directly to the rotor core by means of insulated bolts,. Single layer, concentric
field winding, called also a control winding, is located in the stator core slots. Stator core
plates are mounted on special support structure and it is centred with respect to the ge n-
erator bearing shield bore. The control winding is supplied by the stabilized generator vol t-
age, at exciter open-circuit, the control winding generates triangle-shaped field in a gap.
Under load, the field gap b ecomes similar to the trapezium.
Diodes are protected against overvoltage by varistors built in the diode carrier ring.
4. Directions Regarding Non- damaged Exciter Maintenance
Before the first starting of the synchronous generator and during periodical inspections, a t-
tention should be paid to proper fixing of diodes to the carrier. During measuring the resi s-
tance of the main generator rotor winding insulation by means of measuring instruments
supplied by voltages greater than 100V, the diodes should be protected against possible
damage by connecting all their inputs to a cable of small resistance and connecting this c a-
ble to the diodes carrier mass.
Other maintenance operations should be carried out in the way as in case of generators.
5. Servicing a Damaged Exciter
The most typical is the exciter armature damage caused by short circuit of rectifier diodes or
by interturn short circuit in the armature phase windings. Such damages symptoms are fo l-
lows: considerable increase of the control winding current, in extreme cases even do-
energizing the synchronous generator and very high rise of the exciter stator core plates
temperature.
WK4-020031/A
Page 3/6
This symptom is very characteristic, because in the case of non-damaged exciter, the s ta-
tor core plates temperature does not differ far from the ambient temperature.
In order to identify the damage, after dismantling the covers opposite the exciter from both
sides of the stator frame, the exciter armature shall be disconnected from the field winding
(mounted on poles), by unscrewing the screws fixing the conductor end to the diodes ca r-
rier.
Then, the resistance of the rectifier circuit in the barrier direction should be measured by
means of low-voltage resistance measuring instrument.
To do the connect the „plus” terminal of the measuring instrument to the carrier mass and
the „minus” terminal - to one of the diodes input.
If the barrier resistance value is nearly zero ( the barrier resistance of the „efficient” silicon
diodes is normally greater than 1 MOhm ) at least one of the diodes must be damaged.
In order to detect the damaged diode, the barrier resistance of the circuit diodes should be
measured individual. To do the all ends of the exciter armature phase windings should be
disconnected from the diodes.
The damaged diode or diodes should be replaced by efficient diodes of the same type, and
the collecting ring should be connected again to the field winding. If however the rectifier
barrier circuit resistance is excessive eliminating thus the possibility of their damage and
the symptoms are the same as before then it becomes apparent that the interturn or even
the main insulation of at least one of the exciter armature phase windings is da maged.
In order to repair that, the bearing shield of the generator must be dismantled, the exciter
rotor must be pulled off by means of a special puller and the spare rotor should be mounted
or the damaged one should be rewound.
6. Dismantling the Exciter
Dismantling the bearing shield and the exciter should be carried out only in justified cases,
when it is impossible to repair the exciter after dismantling the covers opposite the exciter
from both sides of the stator frame.
The general order of dismantling is as follows:
6.1. Dismantling the exciter stator in case the generator is provided with sleeve bearings
1. Dismantle the bearing according to the Instruction Manual supplied with the generator
without removing the bearing housing from the shield bracket.
WK4-020031/A
Page 4/6
2. Take off the labyrinth cover at the bearing shield and disconnect the field circuit term i-
nals located at the inner side of the bracket.
3. Remove the screws fixing the bearing shield. To protect the exciter windings against a
damage it is recommended to screw over the shield circumference into the frame holes,
4 adjusting screws ( approx. 300mm long ).
4. Screw in the eye bolts in the bearing pedestal holes ( for fixing the bearing cover ).
Move cautiously the shield together with the bearing pedestal until the exciter stator is
pulled off the exciter rotor the shield radial movements cannot exceed 1mm with respect
to the generator axis.
For displacing the shield, use the jacking holes in a shield, the adjusting bolts screwed in
the frame and eye bolts screwed in the boaring pedestal.
5. Remove the shield together with the bearing pedestal until the exciter stator will be fully
opened.
6. When the exciter stator must be removed, displace the shield up to the end of the shaft
extension. Place the 2mm thick prossboard insert in the gap between the stator and the
rotor of the generator and take the bearing shield off the shaft extension. Support again
the shaft extension end, retaining the previous shaft position.
Disconnect the exciter stator leads from the terminals in the bearing shield. Remove the
exciter stator.
6.2. Dismantling the exciter stator in case the generator is provided with rolling bearings
1. Remove the bearing outer cover.

Disconnect the field circuit terminals. Bolt the shaft extension to the generator shaft end.
By means of a crane or a hoist, lift slightly the shaft extension end until a clearance in the
upper part of the bearing between the barrels and the outer ring will be cancelled.
Support the extension end in that position and loosen the crane or hoist.
2. Unscrew bolts fixing the bearing shield. To protect the exciter windings against damage it
is recommended to screw 4 adjusting bolts into the frame holes evenly spaced over the
shield circumference ( the bolts are supplied as erection parts ).
3. To remove the bearing shield from the from spigot there could be used jacking screws
which should be bolted into tapped holes in the bearing shield. The shield shall be di s-
placed very continuously until the exciter stator will be pushed of the exciter rotor.
WK4-020031/A
Page 5/6
Radial movements of the shield with respect to the generator axis shall not exceed 1mm.
If there will arise the necessity of the exciter stator removal, proceed in the same manner
as given in the cl. 6.1.6.
6.3. Dismantling the exciter rotor
1. If it becomes necessary to repair the exciter rotor, which could not be carried out by o b-
taining access through the revision windows, the bearing shield together with the exciter
stator shall be dismantled as described in the cl.6.2 (in case of rolling bea rings ).
2. If the exciter rotor repair requires its removal from the shaft, then the soldered connection
of the exciter rotor leads with the generator rotor coil ends shall be disconnected, after
that the exciter rotor shall be removed utilizing 3 tapped holes M16 in the rotor at the
bearing shield side.
6.4. Assembling the exciter stator and rotor
1. Assembling the exciter stator and rotor shall be carried out in a reverse sequence with
respect to the dismantling procedures.
2. The correctness of exciter assembling shall be inspected by measuring in several
planes the air gaps between the exciter stator and rotor.
The readings shall not differ from those given in the Factory Certificate by more than
±10%.
WK4-020031/A
Page 6/6
Power transmission
Plain bearings
Installation and Operating Instructions ZF
990225/h520
Parts List for Flange Mounted Bearing ZF
1.1 Upper bearing housing* 15.1 Seal carrier

1.2 Lower bearing housing* 15.2 Seal carrier retaining screws*
1.3 Bearing housing retaining screws* 20.1 Floating labyrinth seal*
1.5 Sealing plug with seal* (Oil inlet for circulated oil) 20.2 Spring key for floating labyrinth seal*
1.6 Sealing plug with seal*(Temperature sensor port) 21.1 Floating labyrinth seal (machine side)*
1.7 Sealing plug with seal* 21.2 Spring key for floating labyrinth seal (machine
(Connection for heater, sump thermometer or cooler) side)*
1.8 Sealing plug with seal* (drain) 25.1 Bolt on baffle
1.9 Sealing plug with seal* (oil fill) 25.2 Bolt on baffle retaining screws*
1.10 Oil level sight gauge (or oil outlet for circulated oil) 30.1 Machine seal
1.11 Oil sight window* 30.2 Machine seal strip
1.12 Eye Bolt* 30.3 Machine seal retaining screws*
5.1 Bearing shell upper half* 40.1 Upper bearing housing retaining screws
5.2 Bearing shell lower half* 40.2 Lower bearing housing retaining screws
5.3 Anti-rotation pin* 45 Machine shield
10 Loose oil ring
*These parts can only be supplied as sub-assemblies. Spares parts are listed in section 11
990225/h520
2
1 Safety Recommendations
Zollern flange bearings (type ZF) are incorporated into various types of machinery, any safety regulations specific to the
machinery must be observed.
During bearing operation, assembly, maintenance and repair, accidents and injuries must be avoided at all costs. The following
points require special attention:
?? During maintenance and repair ensure that rotating machinery is at a standstill, isolated from electrical supply with
interlocks such the supply cannot be resumed unintentionally.
?? Loads and speeds must not exceed those specified in Zollern’s data sheets, drawings or calculation sheets.
?? Rotating parts must be fixed so that accidental movement is not possible.
?? BEWARE: after use bearings will be hot, there is a danger from burning during repairs and maintenance if the bearing is
not allowed to cool.
?? The shaft tolerances set out in our specifications and drawings may not be exceeded.
?? The bearing may become detached if screws are allowed to loosen. Tighten the screws to the specified torque.
Alterations to the ZF bearing may only be carried out with the express permission of Zollern, who must also be consulted in the
event of load specifications being exceeded. Our qualified team of fitters can carry out repairs and service if required avoiding
errors caused by untrained personnel.
2 Bearing Types and Designations

Type Z Bearing for horizontal mounted shaft
Housing F Finned end flange bearing
Cooling N Natural convection
Z Forced oil with external cooling
W Water cooler in oil sump
Lubrication L Cylindrical bore with loose oil ring
Thrust bearing B Plain white metal with oil grooves
K Tapered pad for bi-directional rotation
D Tapered pad for uni-directional rotation
A Round tilted pads, spring supported
Q Without thrust bearing
Note Insulated bearing shells are designated ‘insulated’
Example : Finned end flange bearing with forced oil lubrication externally cooled having plain
cylindrical bore with loose oil ring. Tapered thrust pad for bi-directional rotation size 9,
ZFZLK 9-90 shaft diameter 90mm
3 Introduction
Please pay careful attention to all points covered by this manual to ensure the safe and efficient operation of the bearing. Care
needs to be taken to keep all bearing parts and the workplace clean. Provision is made for thermometers (1.6, 1.7), oil level
gauges (1.10), oil inlet (1.5) and outlets to be fitted to either side of the bearing. These devices can be fitted to either left or the
right as required. Where a bearing is force oil lubricated, the oil outlet pipe is fitted into the tapping for the oil level gauge (1.10).
The oil drain plug (1.8), which can also act as an oil flow connection, is positioned at the centre underneath the bearing.
With electrically insulated bearings, there is a non-conductive layer on the spherical seat of the bearing housing. This layer is
both wear-resistant and temperature-resistant. The shaft seals (see chapter 6 - “shaft seals”) and the anti-rotating pins (5.3) are
manufactured from non-conductive material and prevent any spark erosion of either bearing shell or. Any temperature control
instrumentation installed by the user should be insulated using appropriate measures, such as isolated protective piping and
plastic screws. Zollern can, of course, provide help as and when required.
Eyebolts are fastened to the upper part of the bearing to assist handling of the complete and assembled bearing. It is important
to remember that they are not suitable for the handling of the assembled machine and that the eyebolts are only to be used as
tension elements.
4 Packing
All bearings are delivered fully assembled without oil. The oil ring (10) and other accessories are packed as separate items. The
bearings are protected against corrosion and other influences by a preserving film, according to individual application.
3
5 Installation
Once the upper housing (1.1), the seal carrier (15.1), the shaft seals (20.1) and the bearing seal (5.1 and 5.2) have been
dismantled, carefully clean the interior of the bearing and the bearing shell and check for any damage caused during transport.
Ensure that the shaft is clean and that dimensions and tolerances correspond to our recommendations. We recommend that the
appearance of the bearing surface on the shaft is checked and that it is checked that non-moving seals have not become
jammed in the shaft (see chapter 6 “shaft seals”).
Proceed with installation as follows:
?? Align the cleaned lower part of the housing (1.2) with the machine frame and fasten.
?? Secure the machine seal (30.1) inside the machine housing (the machine seal is not supplied as standard and must
therefore be ordered separately).
?? Apply a film of oil to both the spherical seats in the lower part of the bearing housing and to the lower part of the bearing
shell (5.2) (use the same oil as is to be used during operation of the bearing).
?? Place the lower part of the bearing shell onto the shaft seat and turn it to the correct position in the lower part of the
housing. Take care that thrust bearing surfaces are not damaged whilst the shell is turned.
?? Align the surface of the shell with that of the housing.
?? Now follows assembly of the loose oil ring (10), which must first be disassembled.
?? Position both halves of the oil ring on the shaft and around the lower half of the shell using the notch provided, then press
both halves together on the dowel pins. Following this, tighten the fixing screws to the following torque values:
Bearing Size 09 - 14 18 - 28
Torque (Nm) 1.4 2.7
?? Apply a film of oil to both the shaft seat and the upper part of the bearing shell (5.1). Lower the shaft into the lower part of
the shell (5.2) and place the upper part of the shell onto the lower part (it is impossible to turn both halves of the shell
together as they would become misaligned).
?? Insert the flange-side seal (21.1), this is usually a floating labyrinth seal (see chapter 6: “shaft seals”).
?? Coat the surface of the split line in the lower part of the bearing housing with a thin film of non-hardening sealing
compound.
?? Very slowly lower the upper part of the housing (1.1), rotate it in the machine frame and position it on the flange. Ensure
that during lowering the already assembled flange-side seal slides locate into the groove provided. Avoid jamming at all
costs. The upper part must be correctly aligned (to ensure this one possibility is to pass a rod through the upper through
hole and align accordingly). Tighten the cover screws (1.3) crossways and then tighten the flange screws (40.1) to the
following torque values :
Bearing size 9 11 14 18 22 28
Torque (Nm) 89 89 215 420 725 1450
?? The cover screws (1.3) are to be tightened crossways as follows:
Bearing size 9 11 14 18 22 28
Torque (Nm) 71 71 172 336 580 1160
With machines that are prone to vibration, it is essential that measures be taken to prevent screws from loosening. To this end
secure with Loctite or similar thread locking compound.
?? Prepare the exterior floating labyrinth seal (20.1) for assembly in the same way as the flange-side seal and attach to the
shaft before fastening the seal carrier (15.1) to the housing as follows.
?? Coat the split lines and flange surfaces of the seal carrier with non-hardening sealing compound.
?? Place the seal carrier around the floating labyrinth seal, push both into the bearing housing and tighten the seal carrier
screws (15.2) to the following torque values :
Bearing Size 09 - 14 18 - 28
Torque (Nm) 10.5 26
4
5.1 Additional Information for Bearings with External Oil Supply
When using an external oil supply the pipe diameters should be chosen such that the inlet flow does not exceed 1.5 m/s and the
outlet flow 0.15m/s.
If the inclination of the oil outlet pipes for structural or design reasons cannot be set to 15°, pipes with correspondingly larger
diameters need to be used. Pipes with inclinations or diameters which are too small may create back-flow, which could in turn
lead to overflowing or leakage.
Heat-treated (welded or hot-worked) pipes and/or those showing any signs of rust or dirt must be scoured and cleaned prior to
assembly. Following assembly of the pipes the entire oil circulating system must be flushed to prevent dirt entering the bearing
or fittings.
Prior to cleaning all measuring and switch fittings (pressure control, flow gauge) and their connections must be removed. The
bearings must not be left intact during cleaning, and following cleaning all filters must be rinsed. All connections to the bearing
must be free of vibration and tension.
5.2 Additional Information for Bearings with Water Cooler in the Oil Sump
When attaching the water cooler care must be taken to ensure that there are no leaks from the cooler or its connecting pipes.
The joint seals must not be damaged. During fitting a stop tap or valve should be provided in the inlet. Any oil should be free to
drain from the housing (no pressure should be required). The cooling flow can be in either direction.
6 Shaft Seals
Zollern bearings can be supplied with various seal types or seal systems depending on the required application, with seals
conforming to DIN 40050 or IEC 529. Special seals can be supplied for particular applications on request.
6.1 Floating Labyrinth Seals

For standard applications ZF bearings are equipped with floating labyrinth seals (see fig. 2) which achieve IP44. The labyrinth
seals float on the shaft at circumferential speeds above 100 m/s. They are manufactured from a rigid, unbreakable and
temperature resistant polymer. The seals are seated within a seal carrier or directly seated in the housing such that they are not
subject to loadings due to radial shaft displacements.
Oil drain holes are provided in the lower part of the floating labyrinth seal. An anti rotation pin on the split line prevents the seal
from being assembled incorrectly and damaged.
?? Build the seals up prior to bearing assembly so that the hook and eye of the spring key (20.2 & 21.2) are separated.
?? Prepare the seal for installation and coat the surface of the split line and the exterior of the spring guide (see fig. 2) with a
thin layer of non-hardening sealing compound.
?? Place the lower part of the seal onto the shaft and turn it into the correct position (the oil drain holes in the seal must be
facing towards the bearing and the anti rotating pin must sit in the groove of the split line).
?? Place the upper part of seal onto the lower
?? Insert the spring key through the sealing groove and lock into place.
?? Check the alignment of the seal and housing split line
6.2 Floating Labyrinth Seal with Bolt on Baffle

The bolt on baffle can be combined with either a floating labyrinth seal (chapter 6.1) or a rigid seal (chapter 6.4) to achieve IP55.
The inserted seal strip is temperature resistant withstanding high circumferential speed. The coefficient of friction is minimal as
is the ‘stick/slip’ coefficient. The electrical insulation properties are very good and independent of temperature and
environmental influences.
5
Insertion to be done as follows:
?? Spread the sealing compound onto the surface of the split line and coat the movement surface with the seal carrier of the
floating labyrinth seal (fig. 3)
?? Next gently press the lower part (recognised by the drain hole) from underneath against the shaft and tighten the fixing
bolts equally.
?? Finally position the upper part, align on the split line and attach with the bolts.
6.3 Floating Labyrinth Seal with Labyrinth Ring

The labyrinth is clamped onto the shaft and inserted into a groove in the seal carrier of the floating labyrinth seal (fig. 4), thus
preventing dirt and water from entering the bearing. The groove can be filled with grease where necessary.
After placing onto the shaft the labyrinth ring must be so placed that it is not possible for it to run into the groove. The thrust
movement of the shaft is limited.
6.4 The Rigid Seal

Fig. 5 shows a rigid seal with two separate labyrinth systems. Where axial movement is minimal a shaft collar can be provided
between the labyrinths.
?? A thin layer of sealing compound initially retains the rigid seal. During assembly the lower half of the seal is lightly pressed
onto the shaft from below and the screws then tightened (during operation the shaft is raised).
ATTENTION The baffles must be removed during assembly and disassembly of the shaft or damage to the shaft may ensue.
6
7 Commissioning
Having removed the oil sight glass (1.11) or the plug (1.9) fill to level with the recommended oil grade. The oil is at the correct
level when it reaches the middle of the oil level glass (1.10). The minimum oil level is when the oil only reaches the lower part of
the sight level glass when the machine is stationary.
WARNING
Insufficient oil level will lead to ineffective lubrication, bearing overheating and subsequent damage leading to failure. Too high a
level of oil will not hinder the operation of the bearing, but could lead to leakage at the seals. Prior to commissioning of the
bearing it must be checked for leaks. All oil port plugs and securing screws are correctly fitted and tightened.
ATTENTION
Should, at any time during commissioning or operation, the bearing temperature exceed that specified by Zollern the machine
should be stopped and the causes investigated.
8 Maintenance
The oil level must be checked at regular intervals with the machine at standstill. The minimum oil level is when the oil only
reaches the lower part of the sight level glass.
The bearing housing must be kept clean as heat transfer can be hindered by dirt and dust leading to bearing overheating and
subsequent damage leading to failure.
Should, during operation, there be unusual variations in bearing temperature or oil level the causes must be investigated.
Our technicians are available should any assistance be required.
8.1 Oil change intervals

For self contained and bearings using mineral oils we recommend flushing and oil change after 8000 operating hours, for forced
oil lubricated bearings we recommend an interval of 20000 hours. Longer intervals may be possible subject to Zollern approval.
Shorter intervals are necessary where there is frequent starting or where oil temperatures are high or where there is an
excessively dirty environment. To change the oil, take out the oil drain port which is positioned at the centre beneath the bearing
(allow the oil to drain whilst hot). Should unusual oil discoloration or smell be apparent the causes must be investigated. Should
any chemical cleaning compounds be used these must be thoroughly flushed away prior to further operation.
The oil is refilled through the oil sight glass (1.11) or plug (1.9). Use only the recommended oil grade as shown by the
manufacturer’s plate. The oil is at the correct level when it reaches the middle of the oil level glass (1.10). There is always a
possibility of overfilling - too high a level of oil will hinder the operation of the bearing.
WARNING
If regular checks are not made there is a chance of insufficient oil leading to ineffective lubrication, bearing overheating and
subsequent damage leading to failure.
8.2 Inspection
Should unusual oil colour changes or increases in temperature be apparent an inspection must be made. Remove the upper
half of the bearing housing (1.1) leaving the lower half in place. Prior to disassembly thoroughly clean the bearing casing such
that no dirt can accidentally enter the bearing itself.
8.3 Disassembly
?? Loosen the fixing screws to the upper half of the bearing (40.1) and the split line screws (1.3) and the screws (15.2) on the
upper half of the seal carrier.
?? Raise the upper half of the housing such that the bearing is split then completely remove the upper bearing housing from
the frame.
?? Remove the upper part of the seal carrier (15.1).
?? Dismantle the floating labyrinth seals (20.1 & 21.1) by raising the upper half and tilting it then open the spring key and
dismantle together with the lower half.
?? Carefully raise the upper half of the bearing shell (5.1). Release the loose oil ring (10) screws, separate and remove both
parts.
?? Remove any probes or sensors if present.
?? Raise the shaft far enough to give sufficient clearance to turn the lower shell (5.2) half through 180° and lift it away.
8.4 Visual Check

During disassembly check that all bearing surfaces remain in good condition. Bearing in mind the length of bearing service the
shell should show consistent polishing of the surface. Any light score marks should be smoothed prior to rebuilding of the
bearing. The shaft seals should be changed should they show excessive wear or have broken edges.
7
9 Transport and Storage
During transportation of the machine the bearings should never be subject to shock loading, and must be protected from
environmental humidity. Care must be taken to prevent dry sliding within the bearing. Storage facilities must be dry and not
subject to severe variations in temperature or humidity. In good conditions the bearings can be stored for up to one year.
10 Troubleshooting
10.1 Increased Bearing Temperature
Cause : lack of lubrication
Solution : Regularly check the oil level, inspect the bearing surface for score marks. Check that the filter does not restrict oil
flow.
10.2 Excessive scoring of the bearing shell

Cause : Dirt particles in oil
Solution : Change oil (possibly polish out scores on bearing surface). Change oil filter.
11 Ordering Spare Parts

Every bearing has a part and order number embossed onto the manufacturer’s plate. In order to ensure the delivery of the
correct parts please quote these numbers in all correspondence or return the part to Zollern for repair or replacement.
The following parts are supplied as sub-assemblies:
Sub-assembly Position (fig. 1)

Bearing Shell 5.1 to 5.3
Seal carrier Bearing housing (sizes 9-28) : 1.1 & 1.2
Loose oil ring 10
Seal Carrier 15.1
Floating labyrinth seal (machine side) 21.1 & 21.2
Floating labyrinth seal (exterior) 20.1 & 20.2
Bolt on baffle with Teflon bronze strips 25.1
Labyrinth ring N/A
Machine seal with or without Teflon bronze strips (30.1 & 30.2)
Zollern Vertriebs-GmbH + Co.

Werk Herbertingen
-Gleitlagertechnik-
Heustr.1
D-88518 Herbertingen
Tel.: +49.7586.959-0
Fax: +49.7586.959-715
8
ZAKŁAD REGULACJI
80-870 GDAŃSK, ul. Mikołaja Reja 27, skr.poczt.25 TEL. (058) 3498120, FAX
(058)3417687
No: OG/ 37 /00
VOLTAGE CONTROL SYSTEMS

RNGA-21, RNGA-21r, RNGA-21p, RNGA-21pr.
OPERATING MANUAL
Designer and producer:

Instytut Energetyki Oddział w Gdańsku
ul. Mikołaja Reja 27
80-870 GDAŃSK
tel (+48 58) 349-82-200
fax (+48 58) 341-76 85
e-mail: oge@ien.gda.pl
http://www.ien.gda.pl
Gdańsk, 2000
CONTENS RNGA-21, RNGA-21r, RNGA-21p, RNGA21pr
1 CONTENS
1 Contens ........................................................................................................ 2
2 TECHNICAL DESCRIPTION .......................................................................... 3
3 Description and principle of operation ........................................................ 4

3.1 Construction .................................................................................................... 4
4 MOUNTING AND STARTING-UP ................................................................... 5
4.1 Visual inspection.............................................................................................. 5
4.2 Checking of the Insulation ................................................................................ 5
4.3 Mounting ......................................................................................................... 5
4.4 Starting-up the generator with the control system.............................................. 5
5 SERVICE ....................................................................................................... 6
5.1 Switching the generator on run ......................................................................... 6
5.2 Switching the generator on run using the current limiter function (types RNGA-21r
RNGA-21pr) ............................................................................................................... 6
5.3 Switching the generator off run......................................................................... 6
6 CONTROL SYSTEM MALFUNCTION............................................................. 7
6.1 The generator does not excite .......................................................................... 7
6.2 The generator excites up to the voltage higher than 1,2U gn ................................ 8
6.3 Inappropriate reactive power sharing ................................................................ 8
7 MAINTENANCE ............................................................................................. 9
7.1 Periodical inspections ...................................................................................... 9
7.2 The main inspection ......................................................................................... 9
8 TRANSPORT AND STORAGE ....................................................................... 9
8.1 Transport......................................................................................................... 9
8.2 Storage ........................................................................................................... 9
9 SPARE PARTS ............................................................................................ 10
10 List of regulator RNGA-21... types ........................................................... 10
11 Figures ..................................................................................................... 10
• Voltage regulator RNGA-21. Circuit diagram fig. 3620-30

• Voltage regulator RNGA-21r. Circuit diagram fig. 3620-30r
• Voltage regulator RNGA-21p. Circuit diagram fig. 3620-30p
• Voltage regulator RNGA-21pr. Circuit diagram fig. 3620-30pr
INSTITUTE OF POWER ENGINEERING GDAŃSK DIVISION

2
TECHNICAL DESCRIPTION RNGA-21, RNGA-21r, RNGA-21p, RNGA21pr
2 TECHNICAL DESCRIPTION
The system designation
RNGA-21... systems have been designed for automatic voltage control of

synchronous brushless generators of Zakład Maszyn Elektrycznych „DOZAMEL”, of
2500kVA, 400V or 450V voltage, 50 or 60 Hz frequency.
RNGA-21... systems have been designed for operation on vessels of unlimited
floating range.
Technical data
a) Operation mode continuous S1
b) Ambient conditions
- temperature from 263K to 328K
- maximum relative humidity 75±3% at 318 oK±2 oK
95±3% at 298±2 oK
c) Protection degree RNGA-21, RNGA-21r IP23 or IP00
d) Protection degree RNGA-21p, RNGA-21pr --
e) Insulation class B
f) Voltage setting range from 0.9 to 1.05 Ugn
g) Generator voltage control accuracy in the range
of load change from 0 up to In , power factor
change from 0.7 up to 0.9, and frequency change
from 47.5 up to 52.5Hz:
- at single operation (current compensation switched - off) ± 1%
- at parallel operation ± 2%
h) The generator voltage recovery time after
switching -on or switching – off current of 0.6In
at 0.4 ind power factor, not longer than
0.5 s
i) Steady-state three-phase short-circuit current 3÷6 Ign

3
DESCRIPTION AND PRINCIPLE OF OPERATIONRNGA-21, RNGA-21r, RNGA-21p,
RNGA21pr
3 DESCRIPTION AND PRINCIPLE OF OPERATION

The diagrams of the RNGA-21p system are presented in figures:
• type RNGA-21 - fig. 3620-30
• type RNGA-21r - fig. 3620-30r
• type RNGA-21p - fig. 3620-30p
• type RNGA-21pr - fig. 3620-30pr
The input current of excitation rectifier (3) is a vector sum of:
• current of the circuit with reactor (2) supplied with the generator voltage,
• current proportional to generator load current.
Parameters of the reactor (2) and of current transformers (1) have been chosen in such a
way that the exciter excitation current is higher than that required for the given generator
load conditions. That current is reduced to the required value by cyclic short-circuiting of the
rectifier (3) output by the power transistor (4) operating with pulse width modulation
(PWM).
That control system principle of operation ensures the generator excitation current of the
value appropriate for each generator load, easy self-exiting and causes generator field forcing
when transistor control signal is getting down or is broken.
Current compensation system ensures correct reactive power sharing among operating
in parallel generators. It is due to the appropriate slope of the external generator
characteristics according to its reactive power load. That characteristics slope degree is set by
the potentiometer NQ connected to terminal strip L 24,25,26.
De- excitation of the generator may be performed by the method of short-circuiting the
excitation rectifier supply circuit (3) with the hand-operated switch is optional connected to
18, 19, 20 on the terminal strip “L”.
Generator voltage level setting can be performed by NU which is connected to
terminals 21,22,23 terminal strip L
3.1 CONSTRUCTION
All elements of the RNGA-21 and RNGA-21r voltage control system except of current
transformers (1) are located in the casing.
All elements of the RNGA-21p and RNGA-21pr voltage control system are located on the
plate.

4
MOUNTING AND STARTING-UP RNGA-21, RNGA-21r, RNGA-21p, RNGA21pr
4 MOUNTING AND STARTING-UP
4.1 VISUAL INSPECTION

The control system elements shall be checked regarding at damage or impurity. The
generator type given in the data plate shall be in accordance with the generator type the
system is to operate with.
4.2 CHECKING OF THE INSULATION

The insulation state of the controller units shall be checked before assembling and
starting-up the controller with the generator. Megaohm-meter of 500 V voltage shall be used
for the measurement.
The measurement shall be performed in the following way:
- short-circuit terminals B1 ÷ B3, 18,19,20, and F1,F2
- measure the insulation resistance between this circuit and the earth.
Insulation resistance shall not be less than 5 MΩ. Otherwise the system shall be dried.
4.3 MOUNTING
All elements of the RNGA-21 and RNGA-21r voltage control system has been designed
for mounting in the vertical position in a place ensuring the natural air flow, and with no
additional heat sources raising the environment temperature over 55oC.
All elements of the RNGA-21p and RNGA-21pr voltage control system has been designed
for mounting inside a generator in the horizontal position.
Earth the controller using the earthling clamp, then make the external connections with
the wires in the insulation of the rating voltage of 750 V and cross-sections:
- with terminals F1, F2, B1, B2, B3 (18, 19, 20-optional) 1,5mm2
- with terminals k, l: 1mm2
- with terminals 21÷23, 24÷26 1mm2 in the screen
- with the other terminals: 1,5 mm2
Note! Having made all the connections, the earthling clamp shall be protected against
corrosion with silicone grease or acidic free vaseline.
4.4 STARTING-UP THE GENERATOR WITH THE CONTROL SYSTEM

Start the generator drive. After excitation, the generator voltage shall be within the range
of 0,9 ÷ 1,05 Un at the rotational speed close to the rated value.
Note! When the exciter is excited it is not allowed to disconnect an excitation circuit.
If the generator does not excite, the generator residual voltage value shall be checked, and
if it is lower than 15V, the generator shall be magnetised by connecting battery of 4.5V to
terminals F1 (+) F2(-) of the regulator.
Note! The crossover of the wires connecting terminals F1, F2 of the regulator with the
generator excitation winding in relation to connections existing during
testing at the producer’s, and related to it excitation current direction
change, may be the reason of lack of excitation.

5
SERVICE RNGA-21, RNGA-21r, RNGA-21p, RNGA21pr
5 SERVICE
In normal operation conditions once set-up and checked voltage controller does not
require any service.
Note! When the exciter is excited it is not allowed to disconnect an excitation circuit.
5.1 SWITCHING THE GENERATOR ON RUN

In order to switch the generator on run one shall:
a) start up the generator drive,
b) perform synchronisation.
5.2 SWITCHING THE GENERATOR ON RUN USING THE CURRENT LIMITER

FUNCTION (types RNGA-21r RNGA-21pr)
In order to start the big asynchronous machine it is necessary:
a) trough the separated bus configuration of a switching station connect, equipped with
voltage regulator type RNGA-21r or RNGA-21pr, generator directly to asynchronous
machine,
b) switch off a field breaker,
c) start up a generator drive and while the generator is not excited accelerate it up to
the nominal speed,
d) supply voltage regulator terminal strip L, marked 24V and 0, with +24VDC ,
e) switch on the field breaker – it begins the asynchronous machine start-up. Start-up
current is limited to the value which may be set by P1 adjuster on the PCB regulator
(5). Manufacturer’s set of P1 equals to 1,75Ign (generator rated current). Range of
settings of P1 is 1,5÷2,5 Ign . Setting of P1 should be chosen in the way which
ensures time of starting-up shorter than 15s and the highest drive loading lower than
50% of its rated power (turning the P1 adjuster left causes increase of the value of
the start up current and this way decreasing time of starting up),
f) when the start up is over stop supplying with +24VDC .
Note! During the normal operation of the generator it is not allowet suplly with
+24VDC. Work of the generator together with supplying with 24VDC causes
÷ 6 I gn
that required value of steady-state three phase short circuit current 3÷
can not be reached.
5.3 SWITCHING THE GENERATOR OFF RUN

a) open the generator main switch,
b) stop the generator drive or switch -off the field breaker.

6
CONTROL SYSTEM MALFUNCTION RNGA-21, RNGA-21r, RNGA-21p, RNGA21pr
6 CONTROL SYSTEM MALFUNCTION
6.1 THE GENERATOR DOES NOT EXCITE

a) too low generator rotational speed,
b) too low generator residual voltage. Point 4.4 of this documentation shall be followed
c) disconnected or out of order adjuster NU
d) excitation rectifier (3) out of order. The rectifier connector joint shall be
disconnected and each diode of the set shall be checked according to Fig. 6.1. With
the battery B voltage polarity as in the figure lamp L shall burn, with the opposite
polarity it shall not. If it is differently, the rectifier shall be replaced.

Rys 6.1 Układ do sprawdzania diod prostownika (3) B- bateria 4.5V, L- lampka
Fig. 6.1. The system for rectifier (3) diodes checking B – 4.5V battery, L – lamp
Fig. 6.1. Schaltplan zur Prüfung der Drehstrombrucke (3) B – Batterie 4.5V, L - Lamp
e) Transistor module (4) out of order. Dismount transistor module. Check the module
in the system according to Fig. 6.2. With closed switch W lamp L shall burn, with
opened switch it shall not. If it is differently, the regulator PCB (5) shall be
replaced.
Rys. 6.2. Układ do sprawdania modułu tranzystorowego (4) B1 – bateria 4.5V, B2 – bateria 9V, L
– lampka , W - łącznik
Fig. 6.2. The system for transistor module (4) checking B1 – 4.5V battery, B2 – 9V battery, L–
lamp, W - switch
Fig. 6.2. Schaltplan zur Prüfung der Thyristormodul (4) B1 – Batterie 4.5V, batterie 9V,
L – Lampe, W – Schalter

7
CONTROL SYSTEM MALFUNCTION RNGA-21, RNGA-21r, RNGA-21p, RNGA21pr
6.2 THE GENERATOR EXCITES UP TO THE VOLTAGE HIGHER THAN 1,2UGN

a) A break in the voltage measurement circuit. It shall be checked whether voltages at
terminals 1,2,3 of regulator PCB are about 60VAC . If not:
• check the presence and equality of voltages at terminals B1-B2-B3 of strip
L,
• check connections with transformers (11) and (18),
• replace the damaged transformer.
b) Regulator PCB out of order. Voltage at D12 of the regulator PCB (5) shall be
checked. It shall be: UD12 >10VDC („+” at cathode D12). If not, the PCB shall be
replaced.
c) Transistor module (4) out of order. Point 6.1.e) shall be followed.
6.3 INAPPROPRIATE REACTIVE POWER SHARING

a) Bad current compensation set. The following shall be checked and corrected:
• equality of voltages of working in parallel generators at no-load operation
• NQ potentiometer setting.
b) Failure in the measurement circuit of the generator loading. It shall be checked
whether, at loading the generator with the current close to nominal, voltage at
terminals 4-5 of the regulator PCB (5) is U4-5 =0,9÷1VAC . If not:
• check connections,
• check resistor R23 (on PCB),
• check current transformer PI.

8
MAINTENANCE RNGA-21, RNGA-21r, RNGA-21p, RNGA21pr
7 MAINTENANCE
Maintenance consists of periodical system inspections, during which necessary

maintenance treatment and regulator cleaning shall be carried out.
7.1 PERIODICAL INSPECTIONS

Clean the regulator by blowing it with compressed air depending on operation conditions
but no less than once each 12 months. Screw joints shall be checked.
7.2 THE MAIN INSPECTION

It is carried out each 3 years. It is recommended to carry out the system main inspection
together with the generator main inspection. All the wires between the generator and the
regulator, and the earthling wire are to be disconnected.
Having cleaned all the controller parts, the state of all the connections and part fixations
are checked.
Then, the insulation state is checked by the means of megohm-meter of 500 V in the way
given in point 4.2.
Restarting the generator with the system after the main inspection is carried out according
to the principles of the first starting the generator with the system (point 4.).
8 TRANSPORT AND STORAGE
8.1 TRANSPORT
The long-distance transport of the system can take place only by covered and suspension
springed means of transport. The cases shall be fixed in such a way that their movement is
impossible.
The system shall be protected against rain and falling down.
8.2 STORAGE
The system shall be stored in roofed warehouses, well aired, free from dust and harmful
for electric insulation gases. The temperature shall not be less than 0oC, relative humidity
shall not exceed 70%.
It is recommended to keep the system in the original producer’s packing.

9
SPARE PARTS RNGA-21, RNGA-21r, RNGA-21p, RNGA21pr
9 SPARE PARTS
The set of spare parts for one vessel:
For regulators type RNGA-21, RNGA-21r

• Excitation rectifier (3) - module 36MT160 - 1 item.
• Regulator PCB (5) type RNGA-21pr suitable for regulator
RNGA-21, as well RNGA-21r - 1 item.
For regulators type RNGA-21p, RNGA-21pr

• Excitation rectifier (3) - module 36MT160 - 1 item.
• Regulator PCB (5) type RNGA-21pr suitable for regulator
RNGA-21p, as well RNGA-21pr - 1 item.
• Renewable fuses 6.3A, 500V - 3 item.
10 LIST OF REGULATOR RNGA-21... TYPES
Generator and Sn Un fn In PI
L.p
regulator type KVA V Hz A I n/1A
1 GDB-148s/06 1540 450 60 1976 2000/1A
2 GDB-148s/05 1370 450 60 1758 2000/1A
3 GDB-138L/03 1137 450 60 1459 2000/1A
4 GDB-138LL/03 1499 450 60 1923 2000/1A
5 GDB-128M/01 675 450 60 866 1000/1A
6 GYDB-1410M/02 1250 450 60 1604 2000/1A
7 GDB-1410M/02 1490 450 60 1912 2000/1A
8 GDB-138L/01 1210 450 60 1552 2000/1A
9 GDBW-148M/03 1815 450 60 2329 3000/1A
10
11
11 FIGURES

10
FIGURES RNGA-21, RNGA-21r, RNGA-21p, RNGA21pr
12
INSTYTUT ENERGETYKI ODDZIAŁ GDAŃSK
13
14

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Dolnośląska Fabryka Maszyn

Elektrycznych Sp. z o.o.

DFME Sp. z o.o.

LIST OF DOCUMENTS: Document number

1. TECHNICAL DATA SPECIFICATION .....................................................................................................WG4-059625/A

DFME Sp. z o.o.

BRUSHLESS THREE-PHASE SYNCHRONOUS GENERATOR

1. GENERATOR TYPE ............................................................................... GDBW-1410M/02

25. TECHNICAL DATA OF VOLTAGE CONTROL SYSTEM:

FOR MARINE BRUSHLESS SYNCHRONOUS

WITH TWO FLANGED SLEEVE BEARINGS

„Dozamel” Sp. z o.o. WG4-023181/A

2. TECHNICAL DESCRIPTION .................................................................................................................... 3

2.1. GENERAL ................................................................................................................................................. 3

3. PACKING, TRANSPORT AND STORAGE............................................................................................... 6

4. INSTALLATION OF GENERATOR .......................................................................................................... 7

4.1. GENERAL ................................................................................................................................................. 7

5. STARTING UP. PARALLEL OPERATION ............................................................................................. 8

6. DRYING OF GENERATOR ...................................................................................................................... 9

6.1. GENERAL PRINCIPLES OF DRYING....................................................................................................... 9

7. OPERATION AND MAINTENANCE........................................................................................................ 11

7.1. LOAD REGULATION............................................................................................................................... 11

8. DISMANTLING OF GENERATOR .......................................................................................................... 13

8.1. DISMANTLING FOR INSPECTION, REPAIR OR REPLACEMENT

9. SAFETY PRESCRIPTIONS .................................................................................................................... 16

10. TROUBLE SHOOTING ........................................................................................................................... 17

2.4. BEARING ARRANGEMENT

2.8. TERMINAL BOX

2.9. EARTHING TERMINALS

2.10. ANTICONDENSATION HEATERS

2.12. SPARE PARTS

3. PACKING, TRANSPORT AND STORAGE

4.2. PRELIMINARY PROCEDURES

4.3. INSTALLATION PROCEDURES

5. STARTING UP. PARALLEL OPERATION

6.1. GENERAL PRINCIPLES OF DRYING

6.2. DRYING BY EXTERNAL HEATING

6.3. DRYING BY SHORT-CIRCUIT CURRENT

7. OPERATION AND MAINTENANCE

Remark: Information concerning operation and maintenance of:

7.1. LOAD REGULATION

7.3. GENERATOR STANDSTILL

• Operating personnel should have adequate qualifications.

Malfunction Possible causes Action

Connection break between Check the connection.

Connection break between Check the connection.

Proceed as recommended in the ap-

Generator overloaded Check the generator current value and

Ambient temperature ex- Decrease the generator load.

Dirty filter at air inlet Wash the filter.

Generator interior polluted. Blow generator interior through with

Inappropriate coupling of Check the coupling of the shafts and if

Inappropriate foundation Measure the vibrations of the genset,

Magnetic asymmetry due to Measure the impedance of each field

Deterioration of the rotor Check the rotor balancing and if neces-

Below listed spares are assigned for 1 ship.

Item Description No off Drawing or specification No Remarks

1 Space heater 1 WG4-693033

Designed 06-2003 W. Pilat WG4-027607/A

Below specifed devices could be used to all alternators instaled in ship.

Item Description No off Drawing or standard No Remarks

1 Shaft extension 1 WG3-939013 RII

Designed: 98-10 W. Piłat WG4-029325/A

1 - Main circuit breaker auxiliary contact