CAUTION

The information contained in this book is intended to

assist operating personnel by providing information on
the general characteristics of the purchased equipment.
IT DOES NOT relieve the user of the responsibility of using
accepted engineering practices in the installation,
operation and maintenance of this equipment.
 Contents

1. Construction of Brushless A.C Generator (Safety Notes) 2

1.1 Component
1.2 General
1.3 Composition

2. Excitation System (Operation) 15

2.1 Mode of Operation (SPRESY 15)
2.2 Operation (SPRESY 15)
2.3 Maintenance (SPRESY 15)
2.4 Mode of Operation (6 GA 2491)
2.5 Operation (6 GA 2491)
2.6 Maintenance (6 GA 2491)

3. Maintenance 25
3.1 Installation & Inspection Check List
3.2 Flange-Type Sleeve Bearing (for ring lubrication system)
3.3 Flange-Type Sleeve Bearing (forced lubrication system)
3.4 Rolling-Contact Bearings (series 02 and 03)
3.5 Coupling A-Type (single-bearing generators with flanged shaft and one-part fan wheel)
3.6 Coupling B-Type (single-bearing generators with flanged shaft)
3.7 Coupling (double bearing generator)
3.8 Air Filters
3.9 Terminal Box
3.10 Disassembly of A.C. Generator (Fig. 39 and 40)
3.11 Cooler
3.12 Cooling-Water Failure Emergency Operation

4. Trouble Shooting 46
4.1 Excitation Part for SPRESY 15
4.2 Excitation Part for 6 GA 2491
4.3 Main Machines and Exciters (HF. 5 and 6)
4.4 Bearing Part
4.5 Operating Procedure & Check Sheet for Trouble Shooting

01 Construction of Brushless A.C Generator

Safety Notes NOTE

The warnings DANGER, WARNING, CAUTION, NOTICE, This warning is used when an operation, procedure, or
NOTE are used to draw the user’s attention different delicate installation requires clarification.
points:

DANGER
This warning is used when an operation, procedure, or 1.1 Component
use may cause personal injury or loss of life.
The brushless A.C. generators, as shown in Figs. 8. 9. 10
and 11, (drip-proof type, totally-enclosed internal-cooling
WARNING
type) are composed of
This Warning is used when an operation, procedure, or a synchronous generator
use may cause a latently dangerous state of personal
an A.C. exciter
injury or loss of life.
a Rotary rectifier
static excitation devices.
CAUTION

This warning is used when an operation, procedure, or

The brushless generator, as shown in Figs. 8, 9, 10 and
use may cause damage to or destruction of equipment
11, has the exciter and the rotary rectifier mounted on
and a slight or serious injury.
the generator's rotor shaft. The three-phase output of the
A.C. exciter is rectified to D.C. by means of the rotary
NOTICE
rectifier, thus enabling the exciting current to be supplied,
This warning is used when an operation, procedure, or
not through sliding parts, but directly to the field coil of
use may cause damage to or destruction of equipment.
the generator.

2 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

Fig. 1 Single line diagram for brushless generator Unless otherwise stated, the rated output for continuous
operation applies to a frequency of 50 Hz, a cooling-air
temperature of 40 and a site altitude of up to 1000 m
above sea level.

3) Degree of protection
The DIN 40050 or IEC 34-5 degree of protection of basic
design machines is IP 23. Such machines are suitable for
operation indoors and may be provided with a built-in
filter box or with pipe connections.
Closed-circuit cooled machines comply with degree of
1.2 General protection IP 54.
The degree of protection of the machine supplied is
1) Type definition shown in the dimension drawing.
The supply scope of the machine designs a vailable is
determined entirely by the data given in the catalogs or
offers. The machines of basic design are open-circuit 4) Type of construction
cooled, brushless, low-voltage, synchronous machines The machines are normally provided with two bearings
with top-mounted excitation control unit. (DIN 42950 types of construction B3 or B20) or with one
bearing (DIN 42950 types of construction B2 or B16).
The machines have a shaft-mounted exciter on the The type of construction of the machine supplied is
inboard side of the non-drive endshield. shown in the dimension drawing.
The three-phase AC they generate is rectified and fed to
the rotor winding of the main machine.
5) Cooling and ventilation
The excitation current required for the shaft-mounted The basic design machines use self-ventilation by a shaft-
exciter is provided by the main machine via an excitation mounted internal fan at the AS-end.
control unit placed in the top mounted housing, and via a Cooling air enters the top housing (at the BS-end) and
thyristor voltage regulator. cools the excitation control unit and, subsequently, the
windings and core packs of the exciter and of the main
For further information, see the supplementary machine before leaving the top housing at the BS-end.
instructions entitled THYRIPART excitation system on
pages 15-24. On machines provided with air filters at the air inlet,
Depending on the application, the machines may also be the loading condition of the filter should be monitored.
designed in accordance with the type variant defined in
the table below. In machines having closed-circuit cooling, the air-to-water
cooler is placed transversely in the top-mounted box in
Table 1-1. Type definition
transverse arrangement, in front of the excitation control
Type Type of construction
unit.
Machines with closed-circuit cooling and air-to- The primary cooling air circulated by the internal fan is re-
HFJ 5, 6 water cooler with provisions for emergency cooled in the cooler and passed through the excitation
operation in case of cooling water failure control unit, the exciter, and the main machine.
HFC 5, 6 Machines with open circuit cooling and air-to-air
High voltage machines with open or closed circuit Given the necessary provisions, the machine can be
HSR
cooling adapted for emergency operation with open-circuit
cooling in case of cooling water failure. See pages 44-45.

2) Specification & regulation

6) Connecting up
The machines comply with the applicable DIN standards
Check the system voltage against the data given on the
and with the requirements of VDE 0530.
rating plate. Select the size of the supply cables to match
They may have been adapted to different classification
the particular current rating.
requirements and foreign standards and regulations.

>>
Instruction Manual 3
 01 Construction of Brushless A.C Generator

Connect the machines in accordance with the diagram in Dry new windings have insulation resistance values
the working drawing. between 100 and 2000 or higher.
If the insulation resistance value is in the region of the
Before closing the terminal box, check to see that minimum value, dampress and or dirt could be the cause.
If the insulation resistance value falls below this minimum
Its interior is clean and free from any cable chippings figure, the cause must be established and the winding
All terminal screws or bolts are tight dried.
The minimum clearances in air are maintained
(>10 mm for 500 V, >14 mm for 1 kV and >60 mm In case of drying by warm air oven.
for 6 kV; check for any projecting wire ends) Remove bearing housings
Entry openings not in use are closed off by firmly Remove rotor
screwed-in plugs Remove diode varistor is excitation equipment part
For maintaining the particular degree of protection all
sealing surfaces of the terminal box are in order. Bake in oven at temperatures per below table.
The surfaces of metal-to-metal sealing joints must be The heat should be applied slowly so the desired
cleaned and thinly regreased. temperature will not be obtained in less than six hours.
Insulation resistance should be measured before the heat
Before starting a machine and during operation make is applied, and every six to eight hours thereafter.
sure that all relevant safety regulations are complied with.
Table 1-3. Insulation Drying Temperatures*
Class “B” Class “F” Class “H”
7) Insulation testing
200 F 245 F* 275 F*
94 C 118 C 135 C
DANGER
* Class “F” and “H” insulated units should be baked at 70% specified
Hazardous voltage temperature (to avoid steam inside winding) for about six hours,
before temperature is raised to drying temperature.
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.
The insulation resistance for clean windings is largely
dependent on temperature: for each 10K rise in
Before commissioning and after long periods of storage or temperature it falls by half, i.e. with a temperature rise of
standstill the insulation resistance of the windings to the 50K (e.g. from 25 to 75 ) it falls to about 1/30 of the
frame must be measured with D.C. voltage. initial value.
Do not discontinue measurement before the final
resistance value is indicated(with high-voltage machines, During operation the insulation resistance of the windings
this process may take up to 1minute). may decrease as result of environmental and operating
The limit values for minimum insulation resistance and conditions.
critical insulation resistance (for measurement at a The critical value of the insulation resistance at a winding
winding temperature of 25 ) and for measuring voltage temperature of 25 can be calculated depending on the
can be derived from the following table depending on the rated voltage by multiplying the latter (kV) by the specific
rated voltage for the machine. critical resistance value in the table ( /kV).

Table 1-2. Insulation testing

For example: critical resistance for rated voltage
Limit values at rated voltage
660 V: 0.66 kV x 0.5 /kV = 0.33
Rated voltage Rated voltage
< 2 kV > 2 kV If the measured insulation resistance value is above the
500 V DC 500 V DC calculated critical figure during operation, the machine
Measuring voltage
(min.100 V DC) (max.1000 V DC) can still operate further.

Minimum insulation
resistance with new machine. 10 100 When the measured value reaches or falls below this
Cleaned of repaired windings critical insulation resistance figure, however, the windings
must either be dried, or the rotor must be removed and
Critical specific insulation
the windings thoroughly cleaned and dried.
resistance after long 0.5 /kV 5 /kV
period of operation

4 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

If the measured value approaches the critical value, the 11) Storage
resistance should subsequently be checked at
appropriate short intervals. WARNING

Can cause severs injury or property damage.

Insulation resistance measurements on low-voltage When lifting generator.
machines with a measuring voltage of 1000 V are only 1. Lift only at designated locations.
permissible if the insulation resistance has previously 2. Use spreader for lifting.
3. Apply tension gradually to slings.
been measured with a measuring voltage of a maximum
4. Do not jerk or attempt to move unit suddenly.
of 500 V and has not fallen below the permitted values.
5. Do not use cover lugs when lifting.

8) Noise emission The location for storage should be dry and clean.
There should be no fever min that could attack the
The noise level of the generator will not exceed that
winding.
specified in Part 9. VDE 0530 (1981).
The machined surfaces (coupling part, foots part, etc).
are coated with rust-resistant grease.
If the coating is broken, immediately remover the rust or
9) Vibration stability
moisture and recoat with grease for rust prevention.
Reciprocating engines used as prime mover impress
vibrations on the alternator because of the pulsating
If the machine is to be stored for some time, apply all
torque output.
openings with waterproof paper, wooden, or metallic
Permissible vibration stress measured at the bearing is:
covers.
It is necessary, to protect from the machine wind and rain
during trans-portation and storage and to select less
< 10 Hz vibration amplitue S < 0.40 mm-peak
humid place for storage.
10-100 Hz vibration velocity Veff < 18 mm/s-rms
For storage for a long-term or in the rainy season, it is
> 100 Hz acceleration b < 1.6 g
best to insert heaters to remove moisture or prevent its
condensation.
Please inquire if a higher vibration stress level is expected.

To keep the coil dry, maintain the coil temperature

several degrees above room temperature by arranging
10) Transport
heaters appropriately under the machine part to warm
the coils.
WARNING

Improper handling can cause severs injury or property For long time storage, a space heater is placed inside the
damage.
generator. Its specification is described in the generator
When lifting generator.
final specification and on the nameplate attached to the
1. Lift only at designated locations.
2. Use spreader for lifting. generator.
3. Apply tension gradually to slings.
4. Do not jerk or attempt to move unit suddenly.
5. Do not use cover lugs when lifting. 12) Installation

The rotor of machines with cylindrical roller bearings, NOTE

angular-contact ball bearings, or double sleeve bearing
Experience has shown that any base mounted assemblies
are locked in position for transport by a shaft block to of generator and driven units temporarily aligned at the
protect the bearings. factory, no matter how rugged or deep in section may
twist during shipment.
Do not remove this block until the transmission element Therefore, alignment must be checked after mounting.
is fitted.
Should the machine have to be transported after the The lubrication measures for normal bearings to be
transmission element is fitted, other suitable measures carried out before or during erection of the machines are
have to be taken. specified in the instructions "Rolling Contact Bearings and
If the machine is not put into service immediately after Sleeve Bearings" on pages from 27-36.
arrival, store it in a dry, vibration-free room.

>>
Instruction Manual 5
 01 Construction of Brushless A.C Generator

Install the machines so that the cooling air has free 14) Maintenance
access and can escape unobstructed. Before starting any work on a machine, make sure that it
Warm exhaust air must not be drawn in again. has been disconnected from the power supply and that
unintentional starting is safely prevented.
Louver openings must face downwards to maintain the
particular degree protection. Clean the cooling air passages at regular intervals,
Remove the shaft block (where applicable). matching the degree of pollution and using oil-free
Follow the instructions attached to the shaft extension or compressed air, for example.
shown in the terminal box.
The inside of totally-enclosed fan-cooled machines need
The rotors are normally balanced dynamically by means only be cleaned during normal overhauls.
of a half feather key placed in the shaft extension.
Align the machines carefully and accurately balance the If dust or moisture has penetrated into the terminal
elements to be fitted on the shaft to ensure smooth and compartment, it should be carefully cleaned and dried,
vibration-free running. in particular the surfaces of the insulating parts.
Check the seals and eliminate the leak.
Place shims under the feet of the machines if necessary
to prevent them from being stressed mechanically. Before forcing off a part, replace two upper fixing screws
Transmission elements may be fitted and removed only with longer screws or threaded bolts to support the part
by means of a suitable tool. after forcing it out of its central facility.
The feather keys in the shaft extensions are only secured
to prevent them from falling out during shipment.
A machine must not be commissioned without its 15) Inspection
transmission element having been fitted.
The first inspection should be carried out after
approximately 500 hours.
The rate of fouling should be assessed and appropriate
13) Operation
periods for cleaning the cooling air ducts decided upon.

WARNING
The following checks should also be carried out:
Do not operate equipment beyond design limitations.
Running smoothness of machine satisfactory
Can cause personal injury or damage to equipment.
Operate in accordance with instructions in the manual Rotor alignment within tolerances
and nameplate ratings. No subsidence or cracks in the foundation
All fixing bolts of mechanical and electrical joints tight
Insulation resistance of windings satisfactory
NOTICE
(compare with previous reading and record)
In case of cooling system of IP44 (air to water), check the No bridging of any bearing insulation
flow of cooling water for sure before starting.
Any excessive deviations or changes ascertained during
Internal temprature rise may cause fatal damage to the
generator. the checks must be corrected immediately.
Damaged or used locked elements from released bolted
joints must be renewed.
NOTICE
Before starting, check if the bearing oil is filled with or, not The basic intervals between inspections are approximat-
to the sufficient oil level. ely 4000 hours, 1000 switching operations or 1 year for
intermittent operation and approximately 16,000 hours
Covers fitted to prevent access to rotating and current or 2 years for continuous operation, depanding on which
carrying parts or to correct the air flow for better cooling occurs first.
must not be open in operation. The cleaning of all parts becoming fouled by the flow of
If machine application is abnorma (high temperature, cooling air depends on the intervals decided after the first
extreme vibration, etc.) consult HHi for special inspection according to the rate of fouling which occurs
instructions. locally.

6 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

Cleaning should be carried out with dry compressed air. 2) Rotor and windings
Information on oil changes, regreasing, etc. is given on The shaft for machines construction type B3 and B20
the lubrication instruction plate on the machine or in the is designed with a normal cylindrical shaft extension for
supplementary instructions for bearings. two bearings. In the case of types B2 and B16 the shaft
The checks stated for the first inspection after 500 hours is fitted with a flange.
should be performed during these inspections also. The rotor core of the main machine is mounted on the
When a machine is dismantled the following checks shaft, tensioned axially, and supports the field and damper
should be made: windings. The damper winding bars lie in the slots of the
Slot wedges in stator and rotor cores tight rotor core and are welded to the rings.
Windings, connection leads, and insulating parts in The rotor core of the exciter is mounted on the shaft and
satisfactory condition with no discoloration supports the three-phase field winding.
The rectifier supporting wheel is mounted on the shaft
After reassembly, again follow the instructions given for between the two laminated cores.
installation. The rotor is balanced dynamically.

16) Spare parts 3) AC exciter

The classification societies normally specify sets of spares The AC exciter is composed for revolving-armature type,
as follows: three-phase, synchronous generators.
In revolving-armature type generators, unlike ordinary
Table 1-4. Spare parts ones, the stator and rotor are in reverse relation.
Classification society
Spares
KR ABS BV GL LRS NV RINA NK The armature is installed at the shaft end on the non-
connection side where AC power is generated, and the
1 set of bearing shells for
sleeve bearings with oil output of the static excitation device for control is
ring connected to the field winding installed on the fixed side
1 complete rectifier as shown in Fig. 2.
1 electronic regulator
Fig. 2 Single line diagram for AC exciter
Independant of the classification societies requirements,
we recommend the following sets of spares be ordered
with the alternators:

1 set of bearings or bearingshells for sleeve bearing

1 set of rotating rectifiers
1 set of rectifiers for the constant-voltage unit
1 regulator (AVR)

1.3 Composition
4) Rotating rectifier
1) Stator frame and winding
The rotating rectifier is a silicon rectifier which is
The stator frame is of welded design. connected so as to compose a three-phase full-wave
The stator core is centred in the frame and locked against rectification circuit as shown in Fig. 3 and is mounted on
rotation and shifting. the rotor shaft of generator in Fig. 8-1.
The stator winding is of a two-layer coil design with
insulation class F. The mounting screws are between 4.5 Nm and 5.5 Nm
This insulation is made in a special way and is comprised The contact screws are between 2.5 Nm and 3.5 Nm
of integrated-mica & enamel coated insulating material
impregnated with cast resin. CAUTION
It is characterized by high dielectric strength, resistance
The rotating diode fastening screws must be tightened to
to moisture, aggressive gases and vapours, as well as the recommended torque.
rigidity and long life.

>>
Instruction Manual 7
 01 Construction of Brushless A.C Generator

Fig. 3 Single line diagram for rotating rectifier It is a one-way ventilating system which takes in air from
the opposite side of the prime mover and lets out exhaust
air at the prime mover's side.
We have taken into consideration that the engine's oil
vapor should not be sucked into the machine.

9) End shield AS/BS

Both end shields are designed as flat plates and can take
either a bearing or a shaft extension in accordance with
the particular type of machine construction.

The exciter yoke ring in which the exciter poles are bolted
in regular distribution, is welded to the BS-end shield.

5) Excitation system 10) Rotor locking device

The combination of an excitation unit with a thyrist or The following instructions supplementing and modifying
voltage regulator is called a THYRIPART-excitation system. the basic operating instructions apply to single bearing
The excitation unit supplies a load-dependent field current generators of type of construction B2 or B16 which are
slightly higher than would be required for producing the coupled with diesel engines or turbines.
rated voltage. See the instruction manual on pages 37-38.

The regulator variably reduces the field current as Fig. 4 Rotor locking device

necessary to obtain constant alternator voltage.

This method of load-dependent excitation (compounding)
results in excellent dynamic response to load switching
applications and short-circuits.
A block diagram is shown in Figs. 14, 15, 19 & 20.

6) Shaft
Concerning the generator shaft, the ship's classification
certified forged steel should be applied and designed with
ample strength for coupling with the prime mover.
End shield AS Flanged shaft
Retaining ring half Fixing screw for 1
Shaft supporting ring Fixing screw for 3
7) Bearing
Depending on the design and the operating conditions
specified in the order, the machines are fitted with
grease-lubricated rolling-contact bearings or with sleeve 11) Insulation for the prevention of shaft current
bearings with or without forced-oil lubrication. (high voltage and large machines)
For a full description and special instructions, reference
NOTE
should be made to the supplementary instructions.
Insulated Bearing
Any connection to this bearing must be insulated from it
8) Cooling fan to prevent bearing current.

To let the required amount of cooling air pass through, a

fan of either cast iron or welded steel plate construction To prevent the shaft current caused by the unbalance of
is provided. magnetic resistance of magnetic circuits, the insulator is
Concerning the site of its installation, in either case, the provided at the end shield BS side as shown in Fig. 5.
for it is to be arranged on the prime mover's side of the The shaft voltage is a high-frequency voltage of usually
generator. 1 volt or less and rarely several volts.

8 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

When a shaft current flows, by this voltage the shaft and 13) Space heater
journal part are tarnished. In the worst condition, sparking
results in minute black spots. DANGER

Hazardous voltage
There is a possibility that the oil film is broken locally, Will cause death, serious injury, electrocution or property
developing burn-out trouble. damage.
When disassembling or assembling, be sure to measure Disconnect all power before working on this equipment.
the insulation resistance.

In order to prevent the accumulation of moisture and

The value of 1 to 3 will be satisfactory.
condensation while the generator is idle, space heaters
It is generally said that shaft voltage for bearings is limited
are provided within the stator frame.
as follows.

The space heaters can be easily removed from outside

<300 mV Harmless.
the enclosure.
The heater is comprised of stainless-sheathed nichrome,
500 to 1,000 mV A detrimental shaft current may
filled with insulators in the sheath and is U-shaped as
possibly flow.
shown in Fig. 6.

>1,000 mV Bearings may be damaged in a week

Fig. 6 Space heater
to a year
(unless insulation is provided).

Fig. 5 Insulation for the preventation of shaft current

14) Air/water cooler

If required, HFC6. and HFC5. alternators can be supplied
with a top-fitted air/water cooler as special requirement.

The cooler can be used for fresh water or sea water and
can be of the double-tube type.

The type designation for the alternators is changed from

HFC to HFJ.
Due to the closed-circuit cooling system the degree of
protection has been upgraded from IP 23 to IP 44 and
IP 54.

12) Thermometer
The electrical version of the alternator remains unchanged.
For checking the bearing temperature, a mercury
The alternators HFJ can easily be converted for emergency
thermometer is provided.
operation as an open-circuit aircooled machine if the
U-shaped as shown in Fig. 6.
coolant system or the cooling element fails.

>>
Instruction Manual 9
 01 Construction of Brushless A.C Generator

In this case the degree of protection is IP 23 with the rated 15) Terminal box
output as shown on pages 44-45.
DANGER
Please provide the following information with any inquiry:
Hazardous voltage
Will cause death, serious injury, electrocution or property
Alternate rated output damage.
Classification society Disconnect all power before working on this equipment.
Coolant temperature (air)
Cooling water inlet temperature
Cable entry to the 3 main connections, (U.V.W.) and to the
Fresh water or sea water
2 field terminals +F1, -F2 can be from the left or right, as
required.
The cable entry plates are supplied undrilled or drilled
with cable gland as required.
See Fig. 7.

Fig. 7 Internal arrangement for terminal box

( HF. 6 type ) ( HF. 5 type )

10 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

Fig. 8 Sectional drawing for HF. 5 type generator (single sleeve bearing)

HFJ 5 (air to water cooling)

HFC 5 (air to air cooling)

Stator and stator windings assembly

Rotor and windings assembly Fig. 8-1 Rectifier assembly
A.C exciter assembly
Rectifier assembly (Fig. 8-1)
Excitation equipment
Shaft
Bearing
Cooling fan
End shield AS/BS
Rotor lockage device
Insulation for prevention of shaft current (Fig. 5)
Thermometer
Space heater
Cooler
Terminal box
Varistor module Connector rings
Hub Rectifier module

>>
Instruction Manual 11
 01 Construction of Brushless A.C Generator

Fig. 9 Sectional drawing for HF. 5 type generator (double sleeve bearing)

HFJ 5 (air to water cooling)

HFC 5 (air to air cooling)

Stator and stator windings assembly

Rotor and windings assembly Fig. 9-1 Rectifier assembly
AC exciter assembly
Rectifier assembly (Fig. 9-1)
Excitation equipment
Shaft
Bearing
Cooling fan
End shield AS/BS
Terminal box
Insulation for prevention of shaft current (Fig. 5)
Thermometer
Space heater
Cooler

Varistor module Connector rings

Hub Rectifier module

12 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

Fig. 10 Sectional drawing for HF. 6 type generator (single sleeve bearing)

HFJ 6 (air to water cooling)

HFC 6 (air to air cooling)

Stator frame and stator windings assembly

Rotor and windings assembly Fig. 10-1 Rectifier assembly
AC exciter assembly
Rectifier assembly (Fig. 10-1)
Excitation equipment
Shaft
Bearing
Cooling fan
End shield AS/BS
Rotor lockage device
Insulation for prevention of shaft current (Fig. 5)
Thermometer
Space heater
Cooler
Terminal box
Varistor module Connector rings
Hub Rectifier module

>>
Instruction Manual 13
 01 Construction of Brushless A.C Generator

Fig. 11 Sectional drawing for HF. 6 type generator (double sleeve bearing)

HFJ 6 (air to water cooling)

HFC 6 (air to air cooling)

Stator frame and stator windings assembly

Rotor and windings assembly Fig. 11-1 Rectifier assembly
AC exciter assembly
Rectifier assembly (Fig.11-1)
Excitation equipment
Shaft
Bearing
Cooling fan
End shield AS/BS
Terminal box
Insulation for prevention of shaft current (Fig. 5)
Thermometer
Space heater
Cooler

Varistor module Connector rings

Hub Rectifier module

14 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator
02 Excitation System (operation)

2.1 Mode of Operation (SPRESY 15) Depending on the reference potential of terminal 16,
terminal 12 of the comparator point of the control
1) Description amplifier can be given an additional D.C. pulse, e.g for
Brushless synchronous generators consist of the main reactive power control in parallel operation.
machine and of exciter.
The main machine field winding is powered from the For tuning to the signal level, a rheostat must be soldered
exciter rotor winding via a rotating, three-phase bridge- onto the available soldering pins.
connected rectifier set. The power supply for the gate control module(s) is
The exciter is THYRIPART-excited. available from terminal 11.

Fig. 12 Voltage regulator; SPRESY 15

Excitation equipment and thyristor voltage regulator are
combined in the THYRIPART excitation system.
The excitation current required is supplied by the main
machine proper via the excitation equipment which is
adjusted to deliver a field current resulting in a generator
output voltage above the maximum reference value over
the entire load range when the voltage controller is
inactive.

The actual function of the voltage regulator is to provide a

bypass for a variable portion of the curent supplied by the
excitation equipment for controlling the generator voltage.
The thyristor regulator module consists of two
subassemblies: the regulator module and the firing module
with thyristor in buck circuit.

The three-phase generator voltage, having been reduced

to 24V by the measuring-circuit transformers, is applied In the control circuit of the firing module, a time
to teminals 17,18 and 19. adjustable firing impulse for the thyristor is formed from
A direct voltage of approx 30 V (teminal 20 to terminal 13 the control voltage of terminal 15 in comparison with a
or 14) is produced at the output from the rectifier bridge saw tooth voltage.
at the rated voltage of the generator. The overvoltage protector, which operates at voltages
This rectified voltage provides the actual value pulse and over 600 V between terminals 1 and 5, then switches the
the supply to the control amplifier. thyristor through.
The regulator module supplies output terminal 15 with a The excitation current is normally bucked with a single
control voltage of approx. pulse.
1 to 10 V, which is proportional to the control deviation. If higher excitation is required two firing modules for two-
pulse "buck" operation will be provided.

Fig. 13 Block diagram of voltage regulator; SPRESY 15

Six-pulse recifier bridge

Referance/actual value comparator
Power supply
Control amplifier
Firing pulse control
Thyristor in buck circuit
Overvoltage protector
Auxilary power thyristor

>>
Instruction Manual 15
 02 Excitation System (operation)

Fig. 14 Connection diagram of generator (for generator top mounted AVR)

Fig. 15 Connection diagram of generator (for panel mounted AVR)

16 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

2) Installation 3) Direction of rotation of the generator

The excitation equipment, thyristor voltage regulator, The generators are generally suitable for clockwise and
main machine and exciter are supplied factory-wired. anti-clock-wise operation.
If necessary, the mains leads and the reference-value Generators which must run only in a definite direction of
selector, if should be connected to the terminals in the rotation, have the rating plate marked with a
terminal box according to the connection diagram corresponding direction arrow and with the addition
supplied with the machine. "only".

If only one direction of rotation is permissible for electrical

reasons, the excitation system is connected in the works
2.2 Operation (SPRESY 15) for the direction of rotation given in the order.
To change the direction of rotation it is necesssry to
1) Thyristor voltage regulator change the connections according to the connection
When the generator is operating by itself, the thyristor diagram and to check whether only one definite direction
voltage regulator controls the generator voltage to the of rotation is permissible for mechanical reasons (e.g. fan
preset reference value. with curved fan blades).
Frequency changes due to the droop characteristics of
the prime mover do not influence the accuracy of the
generator output voltage. 4) Regulator gain setpoint of voltage integral
action
Design and adjustment of the main machine, exciter, The regulator module includes the three potentiometers
excitation equipment, thyristor voltage regulator and Usoll, Vr and Tn.
reference-value selector permit gradual changes in the The generator rated voltage was adjusted in the works
generator output voltage from 95% to 105% rated voltage on potentiometer Usoll and the transient response
via potentiometer Usoll under steady-state conditions and characteristic of the regulator on potentiometers Vr
at loads varying between no load to rated load and power and Tn.
factors between 0.8 and unity, unless otherwise specified The regulator gain is adjusted on the potentiometer Vr,
on the rating plate. but the integral action time and the optimum transient
If the generators are operated at less than 95% or more response characteristic are adjusted on the
than 105% rated voltage, their output must be reduced. potentiometer Tn.
Unrestricted operation with no load (opened generator
breaker) and partial speeds is permissible. Turning the knob of Vr in the direction of descending
numerals and that of Tn in the direction of ascending
During operation the excitation circuit must not be numerals normally stabilizes the control circuit and
interrupted since this would give rise to voltage surges. reduces the control rate.
If the generator must be de-excited this can be
accomplished by short-circuiting the field winding of the The setpoint of the generator voltage can be shifted via
exciter (terminals +F1 and -F2) (Fig.13). potentiometer Usoll and via a supplementary external
In this case, a dangerously high voltage may develop at reference-value selector (R = 1.5 ,P 1 W) to be
the generator terminals as a result of residual magnetism. connected to auxillary terminals 20 and 21 (Fig. 13)
with the above potentiometer set to mid-position
(Subsequent extention of the setting range specified
2) Transformer adjustment in the order-particularly for full output-is only possible
The tappings used on the transfomers are marked at test following consultation).
report. It is strongly recommended that the original
adjustments be left unchanged. The new adjustment of the potentiometer must be fixed
No responsibility can be assumed by the supplier for any with the aid of the set screw.
damage or incorrect operation resulting from a change in
the original adjustments.
In the case of identical plants, the THYRIPART excitation
system or single parts may be interchanged if need arises;
those transformer tappings must always be used which
conform to the original transformer.

>>
Instruction Manual 17
 02 Excitation System (operation)

5) Parallel operation, droop compensating 2.3 Maintenance (SPRESY 15)

equipment
When provided with droop compensation, a brushless DANGER

synchronous generator is suitable for operating in parallel Hazardous voltage

with other generators or with a supply system. Will cause death, serious injury, electrocution or property
The kW output is adjusted through the governor of the damage.
prime mover. Disconnect all power before working on this equipment.

The speed characteristic of the prime mover should be

linear and rise by a min. of 3% and a max. of 5% between No periodic maintenance inspections of the THYRIPART
rated load and no load. excitation equipment are required.
Excessive dust deposits should, however, be removed
The droop compensating equipment ensures uniform using dry, compressed air.
distribution of the reactive power and reduces the In the case of faults it is advisable to the check voltage
generator output voltage in linear with the increase in regulator, excitation equipment, and main machine with
reactive current. exciter separately.
The droop compensating circuit is adjusted to provide a
generator voltage droop of 6% at zero p.f. and no voltage For troubleshooting in the thyristor voltage regulator, all
droop at unity p.f. between no load and rated load as a the leads connecting excitation equipment and thyristor
function of the generator current. voltage regulator must be disconnected and, if fitted,
With this setting, a voltage droop of 3.6% is obtained at the intermediate transformers of the droop-compensating
0.8 p.f. equipment secondaries short-circuited.
In this case the generator voltage must rise above the
When operated by it self or in parallel with generators maximum reference value as given under "Description".
having the same voltage characteristic, a voltage
accuracy of 1.8% is thus obtained if the rated voltage is In this case the thyristor voltage regulator is defective.
adjusted by means of the setpoint potentiometer at 50% Trouble shooting should be continued according to
generator load. table 4-2 on page 46.
With the generator operating by itself, no droop
compensating equipment is required.

It can be deactivated by short-circuiting the secondary 2.4 Mode of Operation (6 GA 2491)

side of the intermediate transformers.
If the neutrals of alternators in a system are 1) Description
interconnected and/or connected directly to those of Brushless synchronus generators consist of the main
transformers and loads, balancing currents of three times machine and the exciter.
system frequency can occur. The main machine field winding is powered from the
exciter rotor winding via a rotating, three-phase bridge-
Their magnitude must be measured in the alternator connected rectifier set.
neutral conductors under all possible load conditions to
be met in service. The exciter is THYRIPART-excited.
The excitation equipment and the thyristor voltage
To prevent the alternators from overheating, these regulator are combined in the THYRIPART excitation
currents of three times system frequency must not system.
exceed approximately 50% of the respective alternator The field current required is supplied by the main machine
current. via the excitation unit.
Excessive currents should be limited, e.g. by means of
neutral reactors or similar fitted on the plant side. This is adjusted in such a manner that the generator
A specific enquiry is necessary for these items. voltage which is above the maximum setpoint value
develops over the entire load range when the voltage
regulator is inactive (open plug connection X1).

18 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

The thyristor voltage regulator provides a bypass for

part of the current supplied by the excitation unit for
controlling the generator voltage.
The voltage regulator 6 GA 2492 is comprised of the
voltage regulator 6 GA 2491 and the power module
(rectifier, thyristor in "buck" circuit, and resistor in
"buck" circuit).

Fig. 16 Voltage regulator "6 GA 2491" Fig. 17 Voltage regulator "6 GA 2491"
(for generator top mounting) (for panel mounting)

Fig. 18 Block diagram of voltage regulator "6 GA 2491"

V29 Excitation rectifiers S Droop potentiometer Power supply Control amplifier

U Reference value potentiomete K Potentiometer, controller gain Pulse unit Overvoltage protector
T Potentiomenter, reset time R47 Potentiometer, disturbance feedforward External reference value setter
V28 Thyristor in "buck" circuit R48 Resistor in "buck" circuit

>>
Instruction Manual 19
 02 Excitation System (operation)

Fig. 19 Connection diagram of generator (for generator top mounted AVR): 35 Fr~40 Fr

Fig. 19-1 Connection diagram of generator (for generator top mounted AVR): 45 Fr~56 Fr

20 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

Fig. 20 Connection diagram of generator (for panel mounted AVR): 35 Fr~40 Fr

Fig. 20-1 Connection diagram of generator (for panel mounted AVR): 45 Fr~56 Fr

>>
Instruction Manual 21
 02 Excitation System (operation)

2) Mode of operation of regulator 3) Installation

The generator voltage is fed to the regulator via plug The excitation equipment, thyristor voltage regulator,
connector X1 in a single-phase, two-circuit arrangement. main machine, and exciter are supplied factory-wired.
Transformer T1 steps down the generator voltage which If necessary the main leads and the reference-value
is then rectified by the load-side rectifier bridge V1, V4. selector must be connected to the terminals in the
This rectified voltage provides the actual pulse signal "Uist" terminal box according to the connecting diagram
the setpoint voltage Usoll and the supply voltage for supplied with the machine.
the regulator.

If the system uses a reactive current compensator,

current trans-former T15 or interposing transformer T4 2.5 Operation (6 GA 2491)
of the excitation unit is connected to load resistor R1 via
plug-in contacts X2/5 and X2/9. 1) Thyristor voltage regulator
In this operating mode the actual voltage is composed The voltage regulates the voltage so that it complies
of the secondary voltage of transformer T1 and the with the setpoint selected.
voltage of load resistor R1. Frequency changes due to the droop characteristics of
the prime mover do not affect the voltage accuracy.
The magnitude of the resulting reduction in generator
voltage can be set with potentiometer S. The design and adjustment of the generator and the
If an external set point selector is used, this is connected excitation equipment permit continuous changes of the
by contacts X2/1 (A1) and X2/3 (A3). terminal voltage in the range of 5% rated voltage via
In this case microswitch S1/3 of the regulator must be the setpoint selector under steady-state conditions and
opened. at loads varying from no load to rated load, and power
factors from 0.8 to unity unless specified otherwise on
A DC voltage of 0 to 10 V can be fed in via plug-in the rating plate.
contacts X2/6 and X2/2. If several rated voltages and frequencies are indicated on
This voltage acts on the comparator point of the control the rating plate, the above data apply to each of the rated
amplifier. voltages stated.
The setpoint can thus, for instance, be preset by higher- If the generators are operated at voltages exceeding un
level equipment. 5% the generator output must be reduced.
Unrestricted operation at no load is permitted if the speed
Control amplifier (proportional again adjustable by is reduced.
potentiometer K and reset time by potentiometer T)
outputs a DC voltage which is converted into a time- During operation the excitation circuit must not be
adjustable firing pulse for thyristor V18 or V28 via the interrupted since this would give rise to voltage surges.
loadside pulse unit . If the generator must be deexcited, this can be
accomplished by short-circuiting the field winding of the
The generator excitation circuit is fed from rectifier exciter terminals +F1, -F2.
bridge V29.
Resistor R48 and thyristor V28 form a parallel bypass NOTE
circuit to the field winding through which part of the In this case a remnant voltage of approx.
current supplied by the excitation unit flows. 5% to 10% rated voltage may develop at the generator
This method provides for generator voltage control. terminals.
In order to optimize the correcting action, a disturbance
variable is injected into the control amplifier via resistor
R47.
2) Transformer adjustment
The tappings used on the transformers are shown in the
Overvoltages above DC 600 V in the excitation circuit
test report.
cause the overvoltage protector to operate and
It is strongly advised not to change the original
continuously fire the thyristor.
adjustments.
Protection is thus provided for the stationary excitation
No responsibility can be assumed by the supplier for any
circuit of the generator.
damage or incorrect operation resulting from a change in
the original adjustments.

22 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

In the case of identical plants, the THYRIPART excitation Parallel connection on the exciter side or droop
system or the individual components can be interchanged compensation equipment ensures uniform distribution
if the need arises. of the reactive power and reduces the generator output
The transformer tapings, however must be used which voltage in linear proportion to the increasing reactive
are shown in the circuit diagram of the generator and current.
which correspond to those of the original transformer.
Regarding generators with current transformer for droop
compensaton, potentiometer S in the regulator is
3) Regulator gain, setpoint voltage integral action adjusted so that there is no reduction in the generator
The control module comprises potentiometers U, K, T, voltage at unity p.f. but a 6% reduction at zero p.f.
R47 and S. The corresponding voltage reduction at 0.8 p.f. is 3.6%.
The rated generator voltage has been adjusted in the In isolated operation and at any loading condition of the
works on potentiometer U, and the dynamic behaviour generator, the droop compensation provided for the
of the regulator on potentiometers K, T and R47. generator voltage can be checked with the following
The settings are shown in the test certificate. relationship:

Potentiometer K is used to adjust the controller gain and Ust = 6% 1-cos2 IB/IN (%)
potentiomter T is used to adjust the integral action time,
whereas potentiomter R47 is used to inject a disturbance e. g. at 0.8 pf, IB/IN = 1,
variable into the comparator point of the control amplifier
in order to adjust dynamic behaviour. Ust = 6% 1-0.82 1 = 3.6 (%)
Turning the knob of K and R47 in the direction of
descending numerals and that of T in the direction of
ascending numerals normally stabilizes the control circuit If the generator is to operate by it self, droop
and reduces the control rate. compensation equipment is not required.
The stability of the control circuit can also be improved by It can be deactivated by short-circuiting the associated
increasing the bucking resistance, but the voltage setting current transformer on the secondary side or setting
range of the regulator then is reduced at the lower end. potentiometer S on the regulator to the left-hand stop.
If the neutral points of several generators are
The setpoint of the generator voltage can be shifted via interconnected or connected direct with the neutral
potentiometer U or an additional external setpoint points of transformers and loads, currents at 300%
selector (R = 4.7 , P greater than 1 W) can be connected frequency may occur.
to terminals A1 and A3.
Potentiometer U should be set to the centre position, and Their magnitude should be checked by measurements in
microswitch S 1/3 on the printed-circuit board should be the neutral conductors of the generators under all load
opened. conditions occurring.

To avoid overheating the generators, these currents must

4) Parallel operation droop compensation not exceed a value equal to about 50% of the rated
equipment generator current.
When provided with droop compensation equipment, Higher currents should be limited by installing neutral
brush less synchronous generators are suitable for reactors or similar means.
operating in parallel with each other or with a supply
system.
The KW output is adjusted by the governor of the prime
mover.
The speed characteristic of the prime mover should be
linear and rise by at least 3% and not more than 5%
between rated load and no load.

>>
Instruction Manual 23
 02 Excitation System (operation)

Fig. 21 Droop characteristic curve

2.6 Maintenance (6 GA 2491)

DANGER Excessive dust deposits should, however, be removed

using dry, compressed air.
Hazardous voltage
Will cause death, serious injury, electrocution or property
damage. For maintenance or the other parts of the generater refer
Disconnect all power before working on this equipment. to trouble-shooting table 4-3, as shown on page 47.

When ordering spare parts, please state the type and

No periodic maintenance inspections of the THYRIPART
serial number of the generator as specified on the
excitation equipment are required.
rating plate.

Fig. 22 Position of potentiometers on the voltage regulator

24 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator
03 Maintenance

3.1 Installation & Inspection Check List The purpose of this checklist is to ensure that all
installation and inspection work is fully carried out.
DANGER
It is therefore essential for the list to be filled in carefully.
Hazardous voltage
Will cause death, serious injury, electrocution or property The number of relevant questions will depend on the
damage. scope of the work to be carried out,
Disconnect all power before working on this equipment.
In the "Answer" column, "yes" or "no" or "n/a" (for "not
applicable") should therefore be checked off in each case.
NOTICE
In some lines, additional data or information must be
Before the initial starting for in-sevice, check the items on entered or irrelevant items deleted.
table 3-1 for sure. If any further explanations are necessary they should be
If not, may cause fatal damage in generator.
placed in the report or final spec of the generator.

Table 3-1. Installation & inspection check list

Condition of machines Answer Three-phase A.C. machines Answer

Installation Installation
before installation Yes N0 n/a Standard checks Yes N0 n/a

Packing of all machine Insulation resistance values

components undamaged? at winding temperature

Paintwork undamaged? 3 phases/earthed frame:

phase/phase:
Stator Measuring voltage: V
General (usually 500 V, DC)

Winding guards properly fixed

and locked? Rotor

All parts of the enclosure Insulation resistance values

properly assembled? at winding temperature

Stator foot bolts tightened Rotor winding/earthed shaft:

properly? Measuring voltage: V
(always 500 V, DC)
Stator dowel-pinned?

Earthing or protective conductor Electrical connections

connected?
HV machines must be connected Cables/bars properly connected?
to the earth bus
by a conductor of equal Cable strain-relief connected?
cross-section.

LV machines are to be included

in the protection
arrangements by the connection
of the green-yellow
protective conductor or the
concentric conductor of the
cable to the protective
conductor connecting terminal.

>>
Instruction Manual 25
 03 Maintenance

Table 3-2. Installation & inspection check list

Bearings Answer Oil flow rates reference Answer

Installation Installation
Yes N0 n/a Yes N0 n/a
Drive-end
Journal bearings journal bearing /min
(Lubricating oil used)
Non-drive-end
Oil grade journal bearing /min
Viscosity at
Condition of bearings and shaft The specified oil flow rates are
indicated on the bearing instruc-
Have any shipping bearing shells tion plate. With the specified
and/or shaft blocks been flow rates, about half the clear
removed? cross-sections of the oil drain
pipes are filled with oil.
Anti-rust coating removed?
shaft journals satisfactory? Rolling bearings
Oil rings fitted in the bearings?
Circularity of oil rings Grease lubrication
satistactory?
Oil-ring slots of bearings Type of grease
shells deburred and rounded
off?
Joint locked? General

Bearing sealing rings properly Check the flow of cooling water

fitted? (IP44):
Bearing thermometers fitted?
All bearing bolts properly Check the safety device in
tightened and locked? service or. not?
Bearing filled with oil to
centre marks of oil-level sight
glasses?
Running of oil rings checked?

Oil circulation system

Oil pipework cleaned and

pickled?

Pressure reducer fitted?

1) Inspection schedule
Daily Monthly
Check bearing. Check insulation resistance.
L.O. condition. Caution: Before checking insulation resistance,
Oil ring. disconnect and earthed the leads from A.V.R.
Noise. Bolts and nuts.
Vibration.
Temperature. Tighten all bolts and nuts.
Check electric circuit. Check ventilation openings.
Earth fault by earth lamp. Check air intake opening and its air filter, clean or
Check loading condition. replace the filter if necessary.
Voltage, output kW, current.

26 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

Every 6 Before the machines are aligned and commissioned,

Monthly the bearings should be filled with lubricating oil Since
Change lubrication oil and clean bearing. the machines are delivered without oil in the bearings
At the same time, check fitting or seating of bearing. (oil type is indicated on the name plate of the bearing).
Clean generator.

CAUTION 2) Operating description

Flying dirt, dust or other particles.

NOTICE
May cause eye injury.
Wear safety glasses and dust mask when using Before starting, check if the bearing is filled with oil or not
compressed air. to the sufficient oil level.

Upon stopping, the shaft rests on the lower bearing; there

Inspect generator winding and air filters for dirt, dust, oil,
is metal-to-metal contact.
and salt vapor accumulation.
Blow off contamination by dry and oil free compressed air.
During the start-up phase, the shaft rubs against the anti-
Wipe off accumulated vapor with a lint free colth and
friction metal of the bearing. Oil lubrication is used.
adequate solvent.
Check electrical connection.
After having reached its transition speed, the shaft
creates its oil film.
DANGER
At this point there is no further contact between the shaft
Hazardous voltage and bearing.
Will cause death, serious injury, electrocution or property
damage.
CAUTION
Disconnect all power before working on this equipment.
Prolonged operation at extremely slow rotation speeds
(several rpm) without lubrication could seriously damage
Inspect for loose electrical connection. the service life of the bearing.
Inspect cracked, frayed or oil soaked insulation.
Tighten or replace if neccessary.
CAUTION

If the bearing temperature exceeds the normal operating

value of 15 K stop the machine immediately.
3.2 Flange-Type Sleeve Bearing Inspect the bearing and determine the causes.
(for ring lubrication system)

1) Mounting 3) Oil change

The flange-type sleeve bearings of electrical machines Check the bearing temperature regularly.
are of the split type. The governing factor is not the temperature rise itself,
They are ring-lubricated (Fig. 24) and are subject to the but the temperature variations over a period of time.
following instructions supple menting and modifying the If abrupt variations without apparent cause are noticed,
operating instructions of the machine: shut down the machine and renew the oil.

Corresponding to the operating conditions the sleeve The lubrication oil indicated on the data plate is used for
bearings of new machines have a favorable bearing starting up the machines at an ambient temperature of
clearance which should not be changed. above +5 .
Scraping (spot-grinding) is not allowed not to make worse
the antifrictional qualities. At lower temperatures (to about -20 ) it is sufficient to
preheat the oil.
It is recommended that the contour of the transmission If the ambient temperature is below -20 another type of
element remain within the hatched range (see Fig. 24) oil according to the special conditions is used.
to remove the upper part of the bearing housing for Do not mix oils of different grades.
maintenance without removing the transmission element.

>>
Instruction Manual 27
 03 Maintenance

Recommended oil changing intervals are about 3000 4) Dismantling, assembling

and 6000 operating hours in the case of intermittent and
continuous duty. CAUTION
When cleaning, first flush the bearings with kerosene
When insulated shaft current is applied the accessories in
and then with oil. contact with the bearing housing must be electrically
insulated.
NOTE
If the lubricating oil contains unusual residues or is visibly When dismantling the machine the lower part of the
changed, an inspection.
bearing housing need not be unscrewed from the end
shield. When opening the bearing housing, locate
Pour in the kerosene and oil through the top sight-glass which side of the machine the adjusting shims
hole. (upper and lower parts) are installed.
Leave the drain open until all the kerosene has been
removed and clean oil runs out. These shims must be installed in the same place when
Now, plug the drain and fill the bearing with oil up to the assembling the machine.
centre of the lateral inspection glass.
Exceptions are possible if the stator core was changed.
When the machine has run up to speed, check the oil ring Drain the oil, take off the upper part of the bearing
through the top inspection glass to see that it rotates housing and the upper bearing shell, lift the shaft very
correctly, and check the bearing temperature. slightly and turn out the lower bearing shell and the
sealing rings in a peripheral direction.
Should the bearing temperature not drop to the normal
value after the oil change, it is recommended that the The oil ring can be withdrawn by holding it at an inclined
surfaces of the bearing shells be inspected. position to the shaft.

If the bearings are fitted with thermometers for checking

the bearing temperature, fill the thermometer well in the
upper bearing shell for thermofeeler with oil to improve
heat transfer and top up with oil every time the
lubricating oil is changed.

Fig. 23 Oil pockets and oil grooves

flattened to running face

28 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

If only slight damage has occurred to the bearing The replacement bearing shells are delivered by the
surface, it may be re-conditioned by scraping, as long as works with a finished inner diameter.
the cylindrical shape of the bore is maintained, so that a Oil rings which have become bent through careless
good oil film can form. handling will not turn evenly.
The lining must be renewed if more serious damage is
found. Straighten or replace such rings.
The oil pockets and grooves of the new lining or scraped Replace any damaged sealing rings.
shell should be cleaned and finished with
particular care (Fig. 23).

Fig. 24 Ring-lubricated flange-type sleeve bearings (examples, delivered design may deviate in details)

a 2 14
45

25 1
26 3
4
d1

18
d2

6
19
27
32
15
Limiting range for
transmission element 8
1. Screw plug 20
(thermometer mounting and oil filling point)
1 2. Inspection glass
2 3. Sealing ring for 2
3 4. Sealing ring for 1 21
4 14 5. Bearing housing, upper part, drive end
6. Cylindrical pin
5 7. Sealing ring, upper half, drive end
8. Guide pin to prevent twisting
6 9. Upper bearing shell, drive end 22
7 10. Oil ring, drive end
11. Lower bearing shell, drive end
8
12. Bearing ring, lower half, drive end
15 23
9 13. Sealing ring, lower half, drive end
14. Taper pin
15. Guide pin to fix bolted parts 24
16. Sealing ring for 17 3
17. Drain plug 2
10 18. Bearing housing, upper part, non-drive end 16
19. Sealing ring, upper half, non-drive end 17
20. Upper bearing shell, non-drive end
21. Oil ring, non-drive end
22. Lower bearing shell, non-drive end
23. Bearing housing, lower part, non-drive end 28
11 24. Sealing ring, lower half, non-drive end 29 31
25. Upper adjusting shim, drive end
26. Sealing cover, drive end
12 27. Lower adjusting shim, drive end
28. Upper adjusting shim, non-drive end
29. Sealing cover, non-drive end
13 30. Lower adjusting shim, non-drive end
3 30
2 31. Protective cap
32
32. Pressure compensation opening

16
17 d1 (mm) 80 100 120 150 180 215
d2 (mm) 140 160 170 190 210 245
a (mm) 8 8 10 15 18 22

>>
Instruction Manual 29
 03 Maintenance

3.3 Flange-Type Sleeve Bearing It is recommended to use a control system adjusted in

(forced lubrication system) such a manner to have an oil temperature of 15 to 20
in the tank and to have a preheated oil flow through the
1) Mounting cold bearings for 5 to10 minutes before starting up the
The flange bearings of these electrical machines are of machine.
the split type. Do not mix oils of different grades.
They are lubricated by an oil ring and are provided for by
additional forced lubrication (Fig. 26). The necessary pressure of the oil entering the bearings
They are subject to the following instructions supple and the oil flow rate are indicated on the data plate.
menting and modifying the operation instructions of the Adjust these values when starting up the machine for the
machine: first time and correct them when the bearing has attained
Corresponding to the operating conditions the sleeve its normal running temperature.
bearings of new machines have a favorable bearing The oil in the bearing housing must not ascend over the
clearance which should not be changed. center of the lateral inspection glass.
Scraping (spot-grinding) is not allowed not to make worse
the antifrictional qualities. If the bearings are fitted with thermometers for checking
the bearing temperature, fill the thermometer well in the
It is recommended that the contour of the transmission upper bearing shell for the thermofeeler with oil to
element remains within the hatched range (see Fig. 26) improve heat transfer and top up with oil every time the
to remove the upper part of the bearing housing for lubricating oil is changed.
maintenance without removing the transmission element.
In the case of insulated bearings, make sure that the
Before the machines are aligned,the bearings should be insulation is not bridged by the tubes.
filled with lubricating oil (oil type is indicated on the name Interrupt the electrical conductivity of the tubes near the
plate of the bearing) since the machines are delivered bearings, e.g. by installing oil-resistant fittings of plastic
without oil in the bearings. material or hoses of rubber or plastic material.

Connect the bearings to the oil pump, oil tank and cooler
before commissioning the machines. 2) Operating description
No reducers must be fitted in the piping.
NOTE
Install a regulating orifice on the oil supply line to protect
the bearing from flooding. Before starting, check if the bearing is filled with oil or not
If the oil pump fails, the lubrication maintained by the oil to the sufficient oil level.

ring is effective for about 15 to 30 minutes, provided the

oil contained in the bearing does not drain away. Upon stopping, the shaft rests on the lower bearing; there
is metal-to-metal contact.
To prevent this, connect the oil discharge tube on that
side where the oil ring moves downward into the oil. During the start-up phase, the shaft rubs against the anti-
In addition to this, install a non-return valve in the oil friction metal of the bearing.
supply line. Oil lubrication is used.
As an alternative raise the level of the oil in the bearing
to 100 mm. After having reached its transition speed, the shaft
Oil discharge tubes must terminate flush with the inside creates its oil film.
surface of the bearing housing to prevent the oil rings At this point there is no further contact between the shaft
from rubbing against the tubes. and bearing.

CAUTION
Fill the oil tank with the lubricating oil indicated on the
data plate. Prolonged operation at extremely slow rotation speeds
This oil is used for starting up the machine at an ambient (several rpm) without lubrication could seriously damage
temperature of above +5 . the service life of the bearing.

At lower temperatures preheat the oil.

30 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

CAUTION 4) Dismantling, assembling

If the bearing temperature exceeds the normal operating

value of 15 K stop the machine immediately. CAUTION
Inspect the Bearing and determine the causes. When insulated shaft current is applied the accessories in
contact with the bearing housing must be electrically
insulated.
Switch on the oil pump before starting up the machine.
The use of a pump driven from the shaft of the main
machine is permitted only in special cases, such as when When dismantling the machine the lower part of the
the acceleration and coasting times are short. bearing housing need not be unscrewed from the end
shield.
When opening the bearing housing, locate on which side
3) Oil change of the machine the adjusting shims (upper and lower parts)
Check the bearing temperature regularly. are installed.
The governing factor is not the temperature rise itself, but
the temperature variations over a period of time. These shims must be installed in the same place when
If abrupt variations without apparent cause are noticed, assembling the machine.
shut down the machine and renew the oil. Exceptions are possible, if the stator core was changed.
Drain the oil, take off the upper part of the bearing housing
Recommended oil changing intervals are about 20,000 and the upper bearing shell, lift the shaft very slightly and
operating hours. turn out the lower bearing shell and the sealing rings in a
peripheral direction.
After the machine has come to a stand-still and the old oil The oil ring can be withdrawn by holding it at an inclined
is drained out of the bearings and oil tank operate the oil position to the shaft.
pump with kerosene for a short time and then with oil to
clean the bearings. If only slight damage has occurred to the bearing surface,
it may be reconditioned by scraping as long as the
For the oil pump, the oil tank, the cooler and the pipe cylindrical shape of the bore is maintained, so that a good
lines: Pour in the kerosene and then the oil through the oil film can form.
filling opening of the oil tank. The lining must be renewed if more serious damage
Leave the drains open from time to time until all the is found.
kerosene has been removed and clean oil runs out of the The oil pockets and grooves of the new lining or scraped
bearings and oil tank. shell should be cleaned and finished with particular care
Then plug the drains and fill the tank with oil. (Fig. 25).
Should the bearing temperature not drop to the normal
value after the oil change, it is recommended that the The replacement bearing shells are delivered by the works
surfaces of the bearing shells be inspected. with a finished inner diameter.
Oil rings which have become bent through careless
handling will not turn evenly.
Straighten or replace such rings.
Replace any damaged sealing rings.

Fig. 25 Oil pockets and oil grooves

flattened to running face

>>
Instruction Manual 31
 03 Maintenance

Fig. 26 Flange-type sleeve bearing for forced-oil lubrication (examples, delivered design may deviate in details)

1. Screw plug
(thermometer mounting and oil filling point)
2. Inspection glass
3. Sealing ring for 2
4. Sealing ring for 1
2 14
5. Bearing housing, upper part, drive end 1
1 6. Cylindrical pin 3
2 4
7. Sealing ring, upper half, drive end
3
4 8. Guide pin to prevent twisting
14 18
9. Upper bearing shell, drive end
10. Oil ring, drive end 6
5
11. Lower bearing shell, drive end 19
12. Bearing housing, lower part, drive end
6
13. Sealing ring, lower half, drive end 15
7
14. Taper pin
8
15. Guide pin to fix bolted parts
8 15 20
16. Sealing ring for 17
9
17. Drain plug
18. Bearing housing, upper part, non-drive end
19. Sealing ring, upper half, non-drive end 21
20. Upper bearing shell, non-drive end
10 21. Oil ring, non-drive end
22. Lower bearing shell, non-drive end
23. Bearing housing, lower part, non-drive end
24. Sealing ring, lower half, non-drive end 22
25. Upper adjusting shim, drive end
26. Sealing cover, drive end
11
27. Lower adjusting shim, drive end 23
28. Upper adjusting shim, non-drive end
29. Sealing cover, non-drive end
12 24
30. Lower adjusting shim, non-drive end 3
31. Protactive cap 2
13 32. Pressure compensation opening
3 16
33. Oil supply tube with orifice
2 17
34. Oil discharge tube with sight glass

16
17 28
29 31
a 25
45

26
100mm
d1
d2

30
33
32
34
27
32
Limiting range for
transmission element

d1 (mm) 80 100 120 150 180 215

d2 (mm) 140 160 170 190 210 245
a (mm) 8 8 10 15 18 22

32 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

3.4 Rolling-Contact Bearing (series 02 and 03) Initial lubrication of the bearings is normally carried out in
the works with an Alvania #2 grease satisfying the
1) Mounting conditions of the running test at a test temperature of
Electrical machines fitted with rolling-contact bearings 120 to DIN 51 806.
mentioned above are subject to the following If a different type of grease is required, this is indicated on
instructions supplementing and modifying the operating the data plate, provided that the particular operating
instructions of the machine: conditions were given in the order.

CAUTION
The locating bearings are deep-groove ball bearings for
horizontally mounted machines. Do not mix grease of different soapbases.
These bearings may also be in pairs with cylindrical roller When changing the type of grease, clean the bearing
beforehand using a brush with solvent.
bearings in the case of bearings is not guide radially and
is prevented from rotating by compression springs.
NOTE
The locating bearings for vertically mounted machines are The most widely-used solvent is gasoline: white spirit is
angular-contact ball bearings of type range 72 or 73 acceptable.
(angular-contact ball bearings with increased axial fixation
see suplementary operating instructions).
DANGER
The floating bearings are deep-groove ball bearings or
The prohibited solvents are:
cylindrical roller bearings.
Chlorinated solvent (trichlorethylene, trichloroethane)
In the case of deep-groove ball bearings as floating which becomes acid.
bearings, the axial play is compensated by means of Fuel-oil (evaporates too slowly).
compression springs. Gasoline containing lead.
Benzine (toxic)

2) Regreasing For regreasing, clean the lubricating nipple and press in

the grease quantity indicated on a data plate, using a
NOTE grease gun.
A common mistake is over-lubrication of bearings. When Keep the new grease meticulously clean.
grease is added without removing the drain plug, the
excess grease must go somewhere and usually it is forced
into and through the inner bearing cap and is then thrown
into the windings. Proper lubrication is desired, but some
under-lubrication is less dangerous than over-lubrication.

Fig. 27 Examples for bearing combinations

Deep-groove ball bearing

Cylindrical roller bearing
Angular contact ball bearing

>>
Instruction Manual 33
 03 Maintenance

The shaft should rotate during regreasing, hence the 4) Dismantling, assembling
machines need not be stopped. For working on the locating bearing in the vertical
After regreasing, the bearing temperature will rise by a position of the machine, support or discharge the rotor.
few degrees and will drop to the normal value when the
grease has reached its normal service viscosity and the It is recommended that new rolling bearings be installed
excess grease has been forced out of the bearing. as follows: Heat the ball bearings or the inner ring of the
roller bearings in oil or air to a temperature of approx 80
It is recommended that the lubricating instructions be and slip them onto the shaft.
strictly followed. Heavy blows may damage the bearings and must be
Special cases may require lubrication according to special avoided.
instructions, e.g. where there is an extreme coolant
temperature oraggressive vapours. When installing single angular-contact ball bearings, make
sure that the broad shoulder of the inner ring (and the
The old grease from several regreasing operations gathers narrow shoulder of the outer ring) in operating
in the space inside the outer bearings caps. position points upwards, i.e. in a direction opposite to
Remove the old grease when overhauling the machines. that of the axial thrust.

The model of bearing is favorably chosen for direction and When assembling the machines, avoid damage to the
size of load (type of construction, forces acting on the sealing rings.
shaft) and therefore it should not be hung. Rubber sealing rings (V-rings) should be carefully fitted
The permissible values of axial and radial forces may be over the shaft as shown the illustration.
taken from the list of machine or may be inquired about.
New felt sealing rings should be so dimensioned that the
The machines should operate in only one type of shaft can run easily while proper sealing is still effected.
construction as shown on the rating plate, because Before fitting new rings, soak them thoroughly in highly
another type of construction requires perhaps further viscous oil (normal lubricating oil N68 to DIN 51 501)
measures in addition to a modification of the model of having a temperature of approx 80 .
bearing.
In this case an inquiry is always necessary.
5) Locating faults
The trouble shooting table 4-6 helps to trace and remove
3) Lubrication
the causes of faults as shown on page 49.
Regrease the bearings if the machines have been Sometimes it is difficult to assess damage to the bearings.
unused/stored for longer than 2 years. In this case, renew the bearings.

34 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

Fig. 28 Floating bearings (examples, delivered design may deviate in details)

Cylindrical roller bearing

Deep-groove ball bearing

with compensation of
axial play

Deep-groove ball bearing

with compensation of
axial play, with bearing
housing brush and
intermediate ring

V-ring 1) Deep groove ball bearing (floating-bearing)

Outer bearing cap 1) Compression spring 1)
Circlip 1) Bearing housing ring
Grease slinger 1) Bearing housing brush
Bearing housing 1) Cylindrical pin
Lubricating nipple
Cylindrical roller bearing 1)
Inner bearing cap with felt sealing rings 1) 1)
floating bearing side

>>
Instruction Manual 35
 03 Maintenance

Fig. 29 Locating bearings (examples, delivered design may deviate in details)

Single bearing, shaft

does not pass through
the outer bearing cap

Single bearing, shaft

passes through the
outer bearing cap

Duplex bearing, shaft

does not pass through
the outer bearing cap

Angular-contact ball Angular-contact ball

bearing placed below bearing placed below

Duplex bearing, shaft

passes through the
outer bearing cap

Lubricating nipple
Inner bearing cap with felt sealing rings 2) Fig. 30 Fitting instructions for V-ring and oil seal for shaft
Angular-contact ball bearing
Bearing slinger 2)
Grease slinger 2)
Circlip 2)
Outer bearing cap 2)
V-ring 2)
Deep-groove ball bearing (locating bearing)
or angular-contact ball bearing
Compression spring 2)
Cylindrical roller bearing 2)
Cylindrical roller bearing 2)
Oil seal for shaft 1) 2) 3)

1)
floating bearing side
2)
locating bearing side
3)
special operating conditions only Single bearing, shaft does not pass through the outer bearing cap

36 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

3.5 Coupling A-type (single-bearing generators Insert shims underneath the mounting feet until the
with flanged shaft and one-part fan wheel) centering faces of the generator flange and engine
(flywheel) or gear flange are in line with the flanges being
1) Transport, storage parallel to each other.
The following instructions supplementing and modifying
the basic. Experience shows that less shims are required at the non-
Operating Instructions apply to single-bearing drive end than at the drive end, since the engine coupling
generators of type of construction B2 or B16 which are flange is inclined by the weight of the flywheel.
coupled with diesel engines or turbines: Bolt the coupling flanges together while re-pressing the
generator axially, lightly tighten the foot bolts, and undo
For transport and assembly, the generator rotor is the retaining-ring halves.
centered radially and fixed axially by means of bolted
retaining-ring halves fitted between the end shield AS
3) Checking the air gap (Fig. 33)
(unsplit) and the shaft supporting ring (Fig. 31).
The ring halves should therefore not be detached before Check the air gap between the shaft supporting ring and
the generator is assembled with the diesel engine or the end shield AS.
turbine. The gap should be uniform all around.
If the maximum difference between the measured
Fig. 31 Rotor locking device (example, delivered values "a max-a min" exceeds 0.3 mm, correct the gap
design may deviate in details)
by inserting or removing shims underneath the
mounting feet.

Experience indicates that the number of shims to be

inserted or removed at the non-drive end is only 50%
of the number at the drive end.
Tighten the holding-down bolts and check the web
clearance of the diesel engine.
It may be necessary to correct the air gap and the web
clearance several times.

Fig. 32 Aligning the coupling flanges

End shield AS Flanged shaft
Retaining ring half Fixing screw for 1
Shaft supporting ring Fixing screw for 3

2) Aligning the coupling flanges (Fig. 32)

Careful alignment of the coupled machines prevents
additional bearing and shaft stresses, in acklition to
uneven and noisy running.
It is particularly important to achieve a uniform air gap.
The machine may be installed on a concrete foundation or
a baseframe.
Fig. 33 Checking the air gap and the position of the rotor

Check to see that the machine seating surfaces have

been made in accordance with the drawings.
The generator should be aligned with the diesel engine or
the turbine with gearing (the prime mover should have
already been installed and aligned in accordance with the
manufacturer's instructions).
The generators are aligned and coupled as follows: Place
the generator onto the concrete foundation or baseframe.

>>
Instruction Manual 37
 03 Maintenance

Fig. 34 Fixing of the retaining-ring halves after Fig. 35 Rotor locking device (example, delivered
assembling with prime mover design may deviate in details)

Indicator for magnetic center Washer

Piece for air gap adjustment End shield AS
Support plate
4) Position of rotor in longitudinal direction (Fig. 33)
Originally, the generator rotor had been located axially
in the correct position by the bolted-on retaining-ring
2) Aligning the coupling flanges (Fig. 36)
halves.
Careful alignment of the coupled machines prevents
Since single-bearing generators have a floating (rolling or
additional bearing and shaft stresses, also uneven and
sleeve) bearing at the non-drive end, the axial position of
noisy running.
the rotor may have been changed during alignment.
It is particularly important to achieve a uniform air gap.
The machine may be installed on a concrete foundation
A check should therefore be made to ensure that the axial
or a baseframe.
clearance of (6 0.8)mm between the flange faces
of the end shield AS and the shaft supporting ring has
Check to see that the machine seating surfaces have
been maintained.
been made in accordance with the drawings.
Otherwise the stator frame should be shifted axially.
The generator should be aligned to the diesel engine i.e.
the prime mover had already been installed and aligned
5) Fixing the retaining-ring halves in accordance with the manufacturer's instrutions.
The generators are aligned and coupled as follows: Place
Thereupon, screw the retaining-ring halves to the end
the generator onto the concrete foundation or baseframe.
shield AS as shown in Fig. 34.
Insert shims underneath the mounting feet until the
The ring joint should be vertical.
centering faces of genertor flange and engine (flywheel)
Close off the threaded holes in the retaining-ring halves
are in line with the flanges being parallel to each other.
by means of the screws supplied, and lock the screws
with spring washers.
Experience shows that less shims are required at the non-
drive end than at the drive end, since the engine coupling
flange is inclined by the weight of the flywheel.
3.6 Coupling B-type (single-bearing generators Bolt the coupling flanges together while re-pressing the
with flanged shaft) generator axially, lightly tighten the foot bolts and remove
the pieces for air gap adjustment.
1) Transport, storage (Fig. 35)
The following instructions supplementing and modifying
3) Checking the air gap (Fig. 37)
the basic.
Operating instructions apply to single-bearing generators Check the air gap between the shaft and the end shield AS.
of type of construction B2 or B16 which are coupled with The gap should be uniform all around.
diesel engine. For transport and assembly, the generator rotor is
centered radially and fixed axially by means of bolted.
supporting plate fitted between the sleeve bearing and
the shaft. If the maximum difference between the measured values
The support plate must be detached during the coupling "a max-a min" exceeds 0.3 mm, correct the gap by
work on the common bed with engine and generator. inserting or removing shims underneath the mounting feet.
(Fig. 35-item 3)

38 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

Experience indicates that the number of shims to be 3) With axial end play at bearing
inserted or removed at the non-drive end is only 50% of In this case, the axial position of the rotor assembly was
the number at the drive end. Tighten the foot bolts and adjusted during the initial test at the factory.
the web clearance of the diesel engine.
It may be necessary to correct the air gap and the web The generators are delivered with a magnetic center
clearance several times. gauge an the drive bearing side with a groove on the
shaft and must be kept in the rotor position during the
Fig. 36 Aligning the coupling fanges
alignment with the prime mover.

3.8 Air Filters

1) Air filter cleaning period

The cleaning period depends on the site conditions and
can change.
The cleaning of the filter is requested if the record of the
stator winding temperature (using the stator winding
sensors) indicates an abnormal increase in temperature.
Fig. 37 Checking the air gap and the position of the rotor

2) Air filter cleaning procedure

The filter element (flat or cylindrical) is immersed in a
tank of cold or warm water (temperautre less than 50 ).
Use water with detergent added.
Shake the filter gently to ensure that the water flows
through the filter in both directions.

Fig. 38 Installation for air filter

Fixing of the piece for air gap adjustment after assembling

with the prime mover.

3.7 Coupling (double bearing generator)

1) Fitting the coupling element

The coupling element must be balanced separately
before fitting the machine shaft.
A residual unbalance of coupling element should be
less than class G 2.5 grade to ISO standard.

2) Without axial end play at bearing

The alignment must take the tolerance of the coupling
element into account.
The axial, radial and angle tolerance are to be acceptable
by coupling element property.

Filter unit, complete Inner filter holder with frame

Outer filter holder Cover
Filter mat

>>
Instruction Manual 39
 03 Maintenance

When the filter is clean, rinse it with clear water. The supply leads should be matched to the rated current
Drain the filter properly (there must be no more formation in line with VDE0100 and their cross section must not be
of droplets). excessive.
The main circuit is normally connected at both sides of
Refit the filter on the machine. the circuit bars with conductor cross sections of max.
300 and may be made by cable lugs or when
CAUTION connecting parts used in hazardous locations which are
Do not use water with a temperature higher than 50 , present without any lugs.
do not use solvents.
The ends of the conductors should be stripped in such a
Do not clean the filter using compressed air. way that the remaining insulation almost reaches up to
This procedure would reduce filter efficiency. the lug or terminal ( 5 mm).
In the case of cable lugs with long sleeves, it may be
necessary to insulate the latter to maintain the proper
clearances in air.
3.9 Terminal Box If using cable lugs, see that the dimension of the cable
lugs and its fastening elements (normally M12) agree with
DANGER the holes in the copper bus bar.
High voltage Use hexagon-head screws with a min. breaking point of
Power source must be disconnected before working on 500 N/ , hexagon nuts and spring elements which are
equipment.
protected against corrosion according to DIN 43673.
Failure to disconnect power source could result in injury
or death.
Terminal box only to be opened by skilled personnel. The connection of accessories is achieved by terminal
strips.
Use a 5 mm maximum screwdriver to work on the
1) Description
blocking screws.
Use the attached terminal box drawing in the final
See the terminal connection diagram in the final
specification.
specification.
The main terminal box of the machine is located on the
top of the machine.
The supply leads particularly the protective conductor
The neutral and phase wires are connected to the copper
should be laid loosely in the terminal box with an extra
bus bar-one copper bus bar per phase and one copper
length for protecting the cable insulation against splitting
bus bar per neutral line (option).
and to prevent the terminals and circuit bars from the
See terminal box diagram in the final specification.
tension load of the leads.
The openings provide access to the terminals.
The gland plates are made of non-magnetic materials in
They should be introduced into the terminal box through
order to avoid circulating currents if needed.
cable entry fittings and sealed.
Protected fittings with strain relief cleats should be used
Compare the supply voltage with the data on the rating
for loose leads to prevent them from becoming twisted.
plate. Connect the supply leads and the links in
Close off any unused cable-entry openings.
accordance with the circuit diagram on the inside of the
terminals box.
Pay attention to the right direction of rotation (phase
sequence in the case of three phase and polarity in the
case of direct current).

40 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

3.10 Disassembly of A.C. Generator (Fig. 39 and 40)

Fig. 39 For single bearing type A.C. generator

{ }

1. Take away bolts ,

2. Take away support ring (upper part)
3. Take away bolts ,
Coupling Anti-coupling
4. Take away bearing upper part
side side
5. Take away bearing shell and oil ring
6. Take away bolts and support ring under
part
7. Take away bolts and bearing under part
8. Take away endshield ,

{ }

9. Insert protective sheet

10. Take away bolts
11. Draw out fan

{ }

12. Hang the shaft end with rope both side.

13. Shift the rotor toward anti-coupling side.
(shaft journal should be protected from
any damages by wrapping in cloth)

{ }

14. Shift the rotor assembly to anti-coupling

side as left description.
15. Hang the rotor assembly at its center
position by the rope.
16. Take away the rope of coupling side.

{ }

17. Take away the rotor out of the stator.

>>
Instruction Manual 41
 03 Maintenance

Fig. 40 For double bearing type A.C. generator

{ }

1. Take away bolts

2. Take away bolts
Coupling Anti-coupling
3. Take away bearing upper part
side side
4. Take away bearing shell and oil ring
5. Take away bolts and bearing under
part
6. Take away endshield

{ }

7. Insert protective sheet

8. Take away bolts
9. Draw out fan

{ }

10. Hang the shaft end with rope both side.

(shaft journal should be protected from
any damages by wrapping in cloth )
11. Shift the rotor toward anti-coupling side.

{ }

12. Shift the rotor assembly to anti-coupling

side as left description.
13. Hang the rotor assembly at its center
position by the rope.
14. Take away the rope of coupling side.

{ }

15. Take away the rotor out of the stator.

42 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

3.11 Cooler 3) Stop the machine

Leak detection for a double-tube exchanger:
1) General points If a leak is detected, cut off the power supply of the water
The purpose of the cooler is to remove machine heat in/outlet lines and change to emergency operations
losses (mechanical, ohmic etc). according to Fig. 44 and 46 immediately.
The exchanger is located on the top of the machine. The problem must be ascertained and repaired.
Remove the two water boxes, apply a slight positive
Normal operation: pressure in the leakage chamber and thus between the
The air is pulsed by a fan fixed to the synchronous two tubes (only concerns double-tue coolers).
machine shaft. If a tube is damaged, plug it at both ends.
Use a tapered plug.
Description of air-water double tube exchanger Preferably the plug should be made of salt-water
The double-tube technique keeps the cooling circuit from resistant aluminium bronze or a synthetic material.
being affected by possible water leakage.
The double tube provides a high safety level.
In case of leakage, the water goes from the inside of the 4) Leak detection (float system)
internal tube to the coaxial space between the two tubes. A magnet float activates a switch located in the float
The water is drained axially to a leakage chamber where guiding rod.
it may activate a sensor.
Fig. 41 Leakage detector
An exchanger comprises a fin-tube block containing:
a steel frame.
a fin-tube block expanded mechanically to the tubes.
The tube bundle is roll-expanded in the end plates.
The water distribution in the tubes is provided by two
removable water boxes.
A water box is equipped with collars for fitting the inlet
and outlet lines.
Neoprene seals ensure watertightness between the water
boxes and the end plates.

2) Cleaning
The frequency of cleaning operations depends essentially
on the purity of the water used.
We recommend a minimum of one inspection per year. 5) Cooler removal
The life of zinc block for anti-corrosion is about a year. The cooler unit is slid into its housing.
Therefore replace it with a new one every year. It is possible to remove the cooler from the housing
Cut off the water supply by isolating the inlet and outlet without removing the water boxes as shown in Fig. 42.
lines, and drain the water. The cooler is fastened to the housing via a series of
screws on the housing.
Disconnect the leak sensor (option with double-tube Remove the supply and return pipes.
cooler), and make sure that there are no leaks. Provide two eye-bolts to hold the cooler when it comes
Remove the water boxes on each side of the machine. out of its housing.
Rinse and brush each water box. Remove the cooler using slings that can be attached to
the connecting flanges.
NOTE

Do not use a hard wire brush as this will remove the

protective tar-epoxy layer which has formed on the 6) Cooler re-assembly
surfaces of the water boxes.
Carry out the operations of the "Cooler Removal" Fig. 42
Clean each tube with a metal scraper.
in the reverse order. Be careful to push the cooler
Rinse in soft water.
Keep the leakage chamber dry (double-tube water-cooler completely into its housing before tightening the
only) fastening screws of the cooler to the casing.

>>
Instruction Manual 43
 03 Maintenance

3.12 Cooling-Water Failure Emergency Operation The following supplements the machine description and
the module for the closed-circuit cooling.
1) HFJ 5. Type Should the cooling water supply for the electrical machine
(1) Changing over to oepn-circuit cooling fail, the machine can be changed over to an open cooling
The electrical machine has a facility for emergency circuit (Fig. 44), as follows:
operation if the cooling water supply fails. The electrical version of the alternator remains
unchanged.
Fig. 42 Cooler removal
Open the air vents at the BS-end for the air inlet and
at the AS-end for the air outlet (Figs. 43 and 44 - No.
3 & 5),
Remove enclosure or cover 2 (Fig. 43)
Insert air cut-off plate 6 (Fig. 44) into the slot in the
raised section on the housing on the hot air side of
the cooler and secure.

(2) Changing over to closed-circuit cooling

Operation should be changed back from emergency to
normal operation with air-to-water closed-circuit cooling
as soon as possible by reversing the sequence described
Cover Gasket for 5
Gasket for 1 Air to water cooling element as below.
Cooler housing

Fig. 43 Normal operation with air-to-water Fig. 44 Emergency operation with open cooling circuit
closed-circuit cooling following failure of the cooling water supply

Air vent with cover AS-end, closed. Air vent with cover AS-end, open.
Enclosure or cover. Air cut-off plate before insertion.
Air vent with cover BS-end, closed. Air cut-off plate, inserted and screwed tight.
Air-to-water cooler. Air vent with cover BS-end, open.

44 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

2) HFJ 6, Type Detach the cover (part 2) from the side opposite the
(1) Changing over to open-circuit cooling cooling water connections, insert the air-stop plate
On failure of the cooling-water flow the following (part 3) which was supplied loose, and secure with the
operations are required to convert the generator for screws provided.
emergency operation with internal cooling.
The electrical version of the alternator remains (2) Changing over to closed-circuit cooling
unchanged. Air-to-water colling element
Detach louvered covers (parts 4) together with the Cover for No. 1
closure plates (parts 5) at the drive and nondrive ends, Air-stop plate (emergency operation)
remove closure plates and attach louvered covers in Louvered cover (emergency operation)
their original positions. Closure plate

Fig. 45 Normal operation with air-to-water closed-circuit cooling

Cover for No 1.
Louvered cover (emergency operation).
Closure plate.

Fig. 46 Emergency operation with open cooling circuit following failure of the cooling water supply

Air-to-water cooling element.

Air-stop plate (emergency operation).
Louvered cover (emergency operation).

>>
Instruction Manual 45
 04 Trouble Shooting

4.1 Excitation Part for SPRESY 15 If the voltage does not be induced, either the excitation
equipment or the main machine or the exciter can be
In the case of faults it is advisable to check the voltage defective. Troubleshoot according to Table 4-4.
controller, excitation equipment, and main machine with Information concerning voltage values for the thyristor
an exciter separately. regulator module is given overleaf and assists in the
For troubleshooting in the thyristor voltage controller all location of faults.
the leads connecting excitation equipment and thyristor
voltage controller must be disconnected and if present, Table 4-1. Excitation part
the intermediate transformers of the droop-compensating Terminal 20-14 < 30 V > 30 V
equipment secondaries short-circuited. Terminal 15-14 about 1 V about 10 V about 1 V about 10 V
In this case the generator voltage must rise above the Fault Regulator Firing Firing Regulator
location
maximum reference value as given under "Description". module module module module
(Fig.13)
In this case the thyristor voltage controller is defective.
Troubleshooting should be continued according to If the remnant should not be adequate for exciting the
Table 4-2. generator, a D.C. voltage (6 to 24 V) must be connected
to terminals F1 and F2 (+ to F1, - to F2) for a short time.
DANGER
Please note that the terminals F1 and F2 start carrying a
Hazardous voltage voltage as soon as self-excitation sets in.
Will cause death, serious injury, electrocution or property When ordering spare parts please state the type and
damage.
serial number of the generator, as they are shown on the
Disconnect all power before working on this equipment.
rating plate.

Table 4-2. Fault diagnosis chart for thyristor voltage regulators

Parallel (system)
Electric fault symptoms operation
Genetator excitation

Voltage and current

Controller module
Genetator voltage

Genetator voltage

Reactive current

Reactive current
Reactive power

Power thyristor
Active power

defective

defective
too high

too high
hunting

hunting

hunting
too low

too low
Cause
fails

No wiring links
Wiring links in wrong position
Controller Connected improperly
module Wrong setting of potentiometer Usoll
Wrong setting of potentiometer VR or TN
Internal defect
Discontinuity
Power thyristor Blocking failure
Gate electrode failure
Discontinuity
Measuring-circuit
Inter-turn fault
transformer
Connected improperly
Reference-value Discontinuity
selector Short-circuit in leads
Discontinuity
Series resistor Resistance too high
Resistance too low
Discontinuity
Intermediate
Short-circuit
transformer
Connected improperly
Discontinuity
Tandem Resistance too high
potentiometer Resistance too low
Connected improperly

46 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

4.2 Excitation Part for 6 GA 2491

DANGER

Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

Table 4-3. Fault diagnosis chart for thyristor voltage regulators

Genetator voltage <UN,

Genetator voltage >1.1

Fault Fault
UN, not adjustable via
not adjustable via set

Genetator voltage

parallel operation
External set point
set point selector

without function

not proportional
Load sharing in
point selector

current swing
Voltage and
selector
<0.1 UN

Possible cause Remedies

Too high
Drive speed
Too low Check speed control of prime mover.
Speed oscillation
Unsolder diode connections, check diodes in
Rotating rectifier defective
forward and reverse direction, replace diodes.

Check plug connection X 2 (only open X 2 with the

generator at standstill), check terminal strip X 6,
Interruption of exciter circuit
and X 7, check plug connections on rectifier
transformer and reactor.

Exciter remnant no longer Short-time connection of F1(+) and F2(-) with

sufficient Dc source(6 to 24V) via decoupling diode.
Interturn short-circuit or
interruption of the main
machine/exciter winding Check-winding resistances at cold state.
(rotor or stator/winding grade
of excitation unit)
Voltage regulator Control section Replace voltage regulator.
defective Power section Replace modules.
Interruption of actual-value Check plug connection X1 and the leads bet-ween
input on controller terminals V, W and plug connection X1.

Switch closed Open switch S1-3 on the voltage regulator.

S1-3 on During operation without the external reference
controller open value setter, S1-3 on the voltage regulator must be
Fault in PCB closed (solder).
setpoint
selector Short-circuit in the Eliminate short-circuit in the leads connected to the
circuit leads extemal reference value setter.

Interruption in Establish the connection to the external reference value

connection setter leads.

Adjust potentiometers K and T on the voltage

Potentiometers on voltage regulator in accordance with the test report or
regulator maladjusted adapt the voltage regulator to the plant by adjusting
potentiometers K and T.

droop potentiometers Adjust potentiometer S for generators with droop

maladjusted compensation transformer as per test report.

Interruption or short-circuit in Eliminate short-circuit or interruption.

leads between droop Check current transfomer and plug connection
compensation transformer and X2 in the case of interruption
voltage regulator (current transformer without burden).

Resistor in "buck" circuit

R48 to be increased.
maladjusted

>>
Instruction Manual 47
 04 Trouble Shooting

4.3 Main Machines and Exciters (HF. 5 and 6)

DANGER

Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

Table 4-4. Fault diagnosis chart for excitation equipments, main machines and exciters
Voltage Too warm
Electric fault symptoms deviates
from rated Main

Defective rectifier
value Exciter
machine

excitation fails

wing load duty

Transformer
No load follo-

conditions
Genetator

On-load

winding

winding

winding

winding

Reactor
Stator

Stator
Rotor

Rotor
Cause

Incorrect Overload
service
conditions or Speed deviating from set point
duty under
conditions
deviating from Excessive deviation from rated power factor
order Incorrect operation, e.g.paralleling with
specifications 2nd generator in phase opposition
Stator
Main machine
Rotor
Inter-turn fault
Stator
Exciter
Rotor

Stator
Main machine
Rotor
Winding
discontinuity
Stator
Exciter
Rotor

Defective rotating rectifier

No remanence

Inter-turn fault
Transformer
Winding discontinuity

Inter-turn fault
Single-phase
current transformer
Faults on Winding discontinuity
excitation
equipment Inter-turn fault
Reactor
Winding discontinuity

Capacitor Open or short circuit

Defective rectifier

48 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

4.4 Bearing Part

DANGER

Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment.

Table 4-5. Sleeve bearing

Defects

Possible cause Oil Large Remedy

Bearing Bearing Oil in
discolours temperature
overheats leaks machine
quickly variations

Oil aged or dirty Clean bearing housing; renew oil

Oil ring does not rotate evenly Straighten and deburr the ring or renew it
Excessive axial thrust or radial load Check alignment and coupling
Too little crest clearance 1) Rescrape bearing surface
Oil grooves too small or not wedge-shaped Refinish the oil grooves
Oil viscosity too high
Check Viscosity; change oil
Oil viscosity too low
Defective bearing surface Renew lining
Defective seals Renew seals
Incorrect oil discharge from sealing rings Clean return openings and grooves
Bearing too cold during start-up Preheat the bearing or oil
Gap between sealing cover and shaft too large Bush or replace the cover
Pressure compensation opening clogged Clean compensation opening
Forced-lubrication system failure Inspect system
Oil flow too high Readjust the flow rate; check oil discharge
1) Crest clearance = Inside diameter of bearing shells minus diameter of shaft.

Table 4-6. Roller bearing

Defects

Possible cause Bearing Bearing Oil in Remedy

overheats leaks machine

Felt sealing rings pressing on shaft Fit rings better into grooves or replace them
Strain applied from coupling Improve alignment of machine
Excessive belt tension Reduce belt tension
Bearing contaminated Clean or renew bearing, inspect seals
Ambient temperature higher than 40 Use special high-temperature grease
Lubrication insufficient Lubricate according to instructions
Bearing canted Check mounting conditions, install outer ring with lighter fit
Too little bearing play Fit bearing with larger play
Bearing corroded Renew bearing, inspect seals
Scratches on raceways Renew bearing
Scoring Renew bearing, avoid vibration while at a standstill
Excessive bearing play Install bearing with smaller play

>>
Instruction Manual 49
 04 Trouble Shooting

4.5 Operating Procedure & Check Sheet for Exampls)

Trouble Shooting Full load zero (0) power factor = 6 droop.
Full load rated power factor (0.8 P.F) = 3.6 droop.
DANGER Unit power factor (1.0 P.F) = Generator voltage
is not dropped.
Hazardous voltage
Will cause death, serious injury, electrocution or property
damage.
Disconnect all power before working on this equipment. 2) Parallel running (for manual synchronizing)
- After load testing of each generator, start No. 1 single
running and proceed to items , , , and of
1) Single running
4.4.1.
- Start No.1 Engine at its rated speed.
- If the synchro scope indicates a synchronized position,
- Adjust No.1 generator voltage to its rated value at
insert the No. 2 circuit breaker carefully.
no-load using reference value setter (V.R), which is
mounted on control panel side. After adjusting the NOTE
voltage to its rated value, on the check the generator
voltage using a digital tester at switch board side. If synchronization fails, the generator can be damaged by
a transient current.
- Proceed items and of 4.4.1 for No. 2, No. 3 and No.
Please refer to synchronizing instructions of the switch
4 generators. board maker.
- After completion of the no-load setting, read the
indicated value on the panel and record the results
- Increase the load constantly from zero (0) to a rated
according to Table 4-7.
load.
- Circuit breaker 'ON'.
- Record the results according to Table 4-9.
- Increase the load constantly from zero (0) to a rated load
(as much as possible) and record the results according
NOTICE
to Table 4-8.
- Proceed to items and of 4.4.1 for No. 2, No. 3 and A. Parallel running of No. 3 and No. 4 generator:
No. 4 generaters. The method is the same as No. 1 & No. 2.
B. If the, power factor and KVAR are unbalnced after
- In general, the droop compensating method is used for
completion above the procedure, consult the generator
our generators for parallel running.
manufacturer using Table 4-9.
Generator voltage should be dropped in proportion to
the magnitude of the load.

Table 4-7. Single running

Item Ship No. No. 1 No. 2 No. 3 No. 4 Notes
R.P.M. or Hz
Voltage
After match the no-load voltage of each generator, don’t adjust generator voltage (before, during and after parallel running)

Table 4-8. Single running

Item Ship No. kW Volt (V) R.P.M. (Hz) Current (A) Power Factor Notes

EACH
GEN.
(No. 1, 2...)

Table 4-9. Parallel running

Item Ship No. kW Volt (V) R.P.M. (Hz) Current (A) Power Factor Notes
No.1 & No.2, / / /
No.1 & No.3, / / /
No.1 & No.4, / / /
each condition. / / /

, , , , , , , , ,
No.1,
, , , , , , , , ,
No.2,
, , , , , , , , ,
No.3 & No.4,
, , , , , , , , ,

50 << Operating Instructions Synchronous Generator

 Operating Instructions
Synchronous Generator

Memo

>>
Instruction Manual 51
 HHIS-WZ-RE-005-01 ’02.07 Designed by SKYdesign

www.hhi.co.kr
ELECTRO ELECTRIC SYSTEMS

HEAD OFFICE 1 JEONHA-DONG, DONG-GU, ULSAN, KOREA

TEL. 82-52-230-8101~7 FAX. 82-52-230-8100
SEOUL HYUNDAI B/D, 140-2, GYE-DONG, JONGNO-GU, SEOUL, KOREA
TEL. 82-2-746-7589, 7522 FAX. 82-2-746-7648
ORLANDO 3452 LAKE LYNDA DRIVE, SUITE 110. ORLANDO, FLORIDA 32817 U.S.A.
TEL. 1-407-249-7350 FAX.1-407-275-4940
LONDON 11TH FL., ST. MARTIN’S HOUSE, 1 HAMMERSMITH GROVE, LONDON W6 ONB, U.K.
TEL. 44-20-8600-7127 FAX.44-20-8741-5620, 4571
TOKYO 8TH FL., YURAKUCHO DENKI BLDG.1-7-1, YURAKU-CHO, CHIYODA-KU, TOKYO, JAPAN 100-0006
TEL. 81-3-3212-2076, 3215-7159 FAX. 81-3-3211-2093
CAIRO APARTMENT NO. 503, 5TH FL., BLDG. NO. 7 BLOCK 2, 9TH DIVISION, EL-NASR ROAD, NEW MAADI, CAIRO, EGYPT
TEL. 20-2-520-0148~9 FAX. 20-2-754-7528
SOFIA 1271, SOFIA 41, ROJEN BLVD. BULGARIA
TEL. 359-2-381-068 FAX. 359-2-936-0742