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Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. ABB ref. Project: 4577169 3020HE401 Grupo Punta Cana

July 2004

ABB

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana Synchronous Machine AMG 1120MM10DSE 4577169 Serial no. 3020HE401 ABB ref. Grupo Punta Cana Project: Synchronous Machine AMG 1120MM10DSE 4577169 Serial no. 3020HE401 ABB ref. Grupo Punta Cana Project: Synchronous Machine AMG 1120MM10DSE 4577169 Serial no. 3020HE401 ABB ref. Grupo Punta Cana Project:

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

Contents Introduction .............................1 Certificates ..............................2 Technical Specification ...........3 Mechanical Drawings ..............4 Electrical Drawings..................5 Manual ....................................6 Accessory Information.............7 Test Reports............................8 Check Lists..............................9 Additional Information ...........10

ABB

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

1.
Introduction

ABB

Synchronous Machine AMG 1120MM10DSE Section 1 - Introduction

Introduction

1. General information
This is the Users Manual for the AMG 1120MM10DSE Synchronous Machine manufactured for project Grupo Punta Cana and forms the main documentation for this machine. The purpose of this manual is to provide information for all aspects of installation, operation and maintenance of the machinery and shows how to disassemble/assemble major components, if required. Actions shown in this manual are only to be performed by trained personnel authorized by the user.

2. Site conditions
The machinery is to be used on a site with conditions according to Technical Specifications and Conditions laid down by ABB Oy in their contract with the user, and nowhere else.

3. Important Note
The information in this document is subject to change without notice and should not be construed as a commitment by ABB Oy. ABB Oy assumes no responsibility for any errors that may appear in this document. In no event shall ABB Oy be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB Oy be liable for incidental or consequential damages arising from use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without the express written permission of ABB Oy, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.

4. General Safety
Carrying out certain operations, maintenance procedures and some handling procedures can be dangerous or harmful if the correct safety precautions are not observed. While it is important that these recommended safety procedures are observed, care near machinery is always necessary: no list can be exhaustive, always be on your guard! It is important that personnel are aware of the hazards that exist within their working environment. Not only should they be able to identify these hazards, but they should be able to deal quickly and efficiently with the situation by carrying out recognized safety procedures. They should also be able to recognize warning signs (decals) and visual or audio signals. The following recommendations are for general guidance: a. Always wear correctly fitted protective clothing, headwear and footwear. Loose or baggy clothing can be lethal when working on or near rotating machinery. Clothing should be laundered regularly. Clothing which becomes impregnated with oil or other substances can constitute a health hazard due to prolonged contact with the skin, even through underclothing.

Synchronous Machine AMG 1120MM10DSE Section 1 - Introduction

b.

As far as is practicable, work on or close to machinery only when they are stopped. If this is not possible, keep tools, test equipment and all parts of your body well away from the moving parts of the machinery. Parts of the synchronous machine and its auxiliary equipment can reach high temperatures. Protective clothing, particularly gloves must be worn at all times. Many liquids used in machinery are harmful if swallowed or splashed into the eyes. In the event of accidentally swallowing a potentially dangerous fluid, do NOT encourage vomiting and OBTAIN MEDICAL ASSISTANCE IMMEDIATELY. Wear protective goggles when handling liquids which are harmful to the eyes. If any liquid is splashed into the eyes, wash out immediately and OBTAIN MEDICAL ASSISTANCE IMMEDIATELY.

c. d.

Safety is dependent on the awareness, concern and prudence of all those who operate and service machines. The machinery may cause severe injury if incorrectly used. Personnel must be aware of the potential hazards that exist when operating or maintaining synchronous machines. Before attempting to set up, operate or adjust synchronous machines, operators and maintenance people must be technically qualified and must have received the appropriate training. Personnel must be familiar with the recommended procedures detailed in the Installation, Operation and Maintenance chapters of the Section 6, Manual.

4.1 Symbols and decals


Personnel must be familiar with all the warning symbols and decals fitted to the machinery. Failure to recognize a warning and read the associated safety instructions may result in injury or death.

4.2 Electrical hazard


The synchronous machine and auxiliary equipment must be disconnected from the electrical power supply during installation, maintenance or setting-up. All high-voltage parts must also be earthed.

4.3 Moving parts


Covers must only be removed by qualified personnel when instructed as part of an installation, maintenance or setting-up procedure. They must be re-fitted as soon as possible. Keep hands and loose clothing clear of all moving parts.

4.4 High temperatures


Parts of the machinery and its auxiliary equipment will reach high temperatures. Avoid contact with them. Always wear protective gloves when working in the vicinity.

4.5 Electro-Static Devices (ESD)


Precautions must be taken to prevent damage to the electronic control devices of the synchronous machine. Ensure that the operating environment is protected against ESD. Do not touch electronic circuits while unpacking.

Synchronous Machine AMG 1120MM10DSE Section 1 - Introduction

4.6 Magnetic fields


There is a magnetic field presence in the immediate area surrounding rotating machinery. Ensure that devices that can be influenced or wiped (e.g. magnetic disks, credit cards, watches etc.) by the effects of electro-magnetism are removed from the area.

4.7 Noise
Machine rooms can be extremely noisy and damaging to the ears. Ear protection should always be worn where practicable.

5. Safety Instructions (High-voltage AC Machines) 5.1 General


High-voltage machines rated at more than 1 kV have dangerous live and rotating parts and may have hot surfaces. All operations serving transport, connection, putting into service and maintenance shall be carried out by responsible skilled persons (in conformity with prEN 50 110-1 / DIN/VDE 0105 / IEC 364). Improper handling may cause serious personal injury and damage to property.

5.2 Intended use


These high-voltage machines are intended for industrial installations. They comply with the harmonized standards of the series EN 60034 / DIN VDE 0530. Their use in hazardous areas is prohibited unless they are expressly designed for such use (follow supplementary instructions). On no account, use degrees of protection IP 23 outdoors. Air-cooled models are designed for ambient temperatures of -20C up to 50C and altitudes of 1000 m above sea level. Ambient temperature for air-/water-cooled models should be not less than +5C (for sleeve-bearing machines, see manufacturer's documentation). By all means, take note of deviating information on rating plate. Field conditions must conform to all rating plate particulars. High-voltage machines are components for installation in machinery within the meaning of the Machinery Safety Directive (MSD) 89/392/EEC. Putting into service is prohibited until conformity of the end product with this directive has been established (follow particular local safety and installation rules as e.g. EN 60204).

5.3 Transport, storage


Immediately report damage established after delivery to transport company. If appropriate, prevent commissioning of the synchronous machine. Lifting points are dimensioned for the weight of the high-voltage machine, do not apply additional loads. If necessary, use suitable, adequately dimensioned means of transport (e.g. rope guides). Remove shipping brace (e.g. Roller or sleeve bearing locks, vibration dampers) before commissioning. Reuse the brace for further transports. When storing high-voltage machines, make sure of dry, dust-free and low-vibration (Vrms 0.2 mm/s) location (danger of bearing damage at rest). Measure insulation resistance before commissioning. Always use space heaters in order to prevent humidity and condensation inside of the machine. Follow manufacturer's recommendations.

Synchronous Machine AMG 1120MM10DSE Section 1 - Introduction

5.4 Installation
Make sure of even support, solid foot or flange mounting and exact alignment in case of direct coupling. Avoid resonances with rotational frequency and double mains frequency as a result of assembly. Turn rotor, listen for abnormal slip noises. Check direction of rotation in uncoupled state. Mount or remove couplings or other drive elements only with appropriate means and cover them with touch guard. Avoid excessive radial and axial bearing loads (see manufacturer's documentation). The balance of the machine is done with half key as standard. The coupling must also be balanced accordingly. In case of protruding, visible part of key, establish mechanical balance. Make necessary ventilating pipe connections. Models with shaft ends pointing upward are to be provided with cover by customer. The ventilation must not be obstructed and the exhaust air, also of neighbouring sets, should not be taken in directly.

5.5 Electrical connection


All operations must be carried out only by skilled persons on the high-voltage machine at rest. Before starting work, the following five safety rules must be strictly applied: De-energize! Provide safeguard against reclosing! Verify safe isolation from supply! Connect to earth and short! Cover or provide barriers against neighbouring live parts!

De-energize auxiliary circuits (e.g. anti-condensation heating). Exceeding the limit values of zone A in EN 60034-1 / DIN VDE 0530-1 - voltage 5%, frequency 2%, form and symmetry - leads to higher temperature rise. Note rating plate particulars and connection diagram in terminal box. The connection must be made thus, that permanently safe electrical continuity is maintained. Use appropriate cable terminations. Establish and maintain safe equipotential bonding. The clearances between uninsulated, live parts and between such parts and earth must be according to IEC standard. No presence of foreign objects, dirt or moisture is allowed in the terminal box. Close unused cable entrance holes and the box itself in a dust- and watertight manner. For trial run without output elements, lock fitting key. For high-voltage machines with accessories, check satisfactory functioning of these accessories before commissioning. The proper installation (e.g segregation of signal and power lines, screened cables etc.) lies within the installer's responsibility.

Synchronous Machine AMG 1120MM10DSE Section 1 - Introduction

5.6 Operation
Acceptable vibration values have to be determined according to application and corresponding ISO standard. In case of deviations from normal operation - e.g elevated temperature, noises, vibrations - disconnect the synchronous machine, if in doubt. Establish cause and consult the manufacturer, if necessary. Do not defeat protective devices, not even in trial run. In case of heavy dirt deposits, clean cooling system at regular intervals. From time to time, open closed condensation drain holes, if any. Regrease antifriction bearing with relubricating device while high-voltage machine is running. Follow instructions on lubricating plate. In case of sleeve-bearing machines, observe the time limit for oil change. Refer to manufacturer's documentation for noise level and information about the use of appropriate noise-reducing measures.

5.7 Maintenance and servicing


Always follow manufacturer's instructions in Section 6, Manual.

6. Disposal and recycling instructions


ABB Oy is committed to its environmental policy. We strive continuously to make our products environmentally more sound by applying results obtained in recyclability and life cycle analyses. Products, manufacturing process as well as logistics have been designed taking into account the environmental aspects. Our environmental management system, certified to ISO 14001, is the tool for carrying out our environmental policy. These instructions are trendsetting and it is on the customers responsibility to ensure that local the legislation is followed. The material content (average percentage of the mass) which have been used in the manufacturing the electrical machine is the following: Fabricated steel frame synchronous machines (AMG and AMZ) Steel Copper Cast iron Insulation materials Other 81 % 13 % 2% 3% 1%

Synchronous Machine AMG 1120MM10DSE Section 1 - Introduction

6.1 Recycling of material required for transport


After receiving the machine into the site, the package and the transportation locking have to be removed. The transportation locking is made of steel and can be recycled. The package is made of wood and can be burned. The sea trial package to some countries like Australia have special requirements, and is made of impregnated wood that must be recycled according to local instructions. The plastic material around the machine can be recycled. The rust protection material covering the machined surfaces can be removed with petrolbased solvent detergents and the cleaning rags are hazardous waste which have to be handled according to the local instructions.

6.2 Recycling of the complete machine 6.2.1 Dismantling of the machine


Because of the weight of the components, the person who does the dismantling has to have adequate skills to handle heavy components to prevent dangerous situations.

6.2.2 Frame, bearing housing, covers and fan


These parts are made of structural steel, which can be recycled according to local instructions. All the auxiliary equipment, cabling as well as bearings have to be removed before melting the material.

6.2.3 Components with electrical insulation


The stator and the rotor are the main components, which include electrical insulation materials. There are, however, auxiliary components which are constructed of similar materials and which are hence dealt with in the same manner. This includes various insulators used in the terminal box, excitation machine, voltage and current transformers, power cables, instrumentation wires, surge arrestors and capacitors. Some of these components are used only in synchronous machines and some are used only in very limited number of machines. All these components are in an inert stage once the manufacturing of the machine has been completed. Some components, in particular the stator and the rotor, contain a considerable amount of copper which can be separated in a proper heat treatment process where the organic binder materials of the electrical insulation are gasified. To ensure a proper burning of the fumes the oven shall include a suitable after burning unit. The following conditions are recommended for the heat treatment and for the after burning to minimize the emissions from the process: 1) Heat treatment Temperature: 380420 C (716788 F) Duration: After receiving 90 % of the target temperature the object shall stay a minimum of five hours at this temperature 2) After burning of the binder fumes Temperature: 850920 C (15621688 F)

Synchronous Machine AMG 1120MM10DSE Section 1 - Introduction

Flow rate: The binder fumes shall stay a minimum of three seconds in the burning chamber NOTE: The emission consists mainly of O2-, CO-, CO2-, NOx-, CxHy-gases and microscopic particles. It is on the users responsibility to ensure that the process complies with the local legislation. NOTE: The heat treatment process and the maintenance of the heat treatment equipment require special care in order to avoid any risk for fire hazards or explosions. Due to various installations used for the purpose it is not possible for ABB Oy to give detailed instructions of the heat treatment process or the maintenance of the heat treatment equipment and these aspects must be taken care by the customer

6.2.4 Hazardous waste


The oil from the lubrication system is a hazardous waste and has to be handled according to local instructions

6.2.5 Landfill waste


All insulation material can be handled as a land fill waste.

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

2.
Certificates

ABB

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

Contents Certificates

ABB

Synchronous Machine AMG 1120MM10DSE Section 2 - Certificates

Declaration of Incorporation

Article 4(2) of Directive 89/392/EEC, as amended

The manufacturer

ABB OY P.O. Box 186 FIN-00381 Helsinki Finland

hereby declares that the product described below

Synchronous Machine

AMG 1120MM10DSE

may not be put into service before the machinery into which it will be incorporated is declared to comply with the provisions of Directive 89/392/EEC, as amended, and with the regulations transposing it into national law.

Helsinki, 2 July 2004

ABB Oy Electrical Machines

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

3.
Technical Specification

ABB

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

Contents Technical Specification


Technical Specification .....................................1

ABB

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. ABB

TECHNICAL SPECIFICATION
Project name: Our reference number: Customers reference number: Customer: Final customer: Application: Type designation: Grupo Punta Cana 3020HE401 P/04007-Grupo Punta Cana WRTSIL FINLAND OY Diesel/Gas engine AMG 1120MM10 DSE

NOTES

CONTENTS
SECTION: 1 2 3 PERFORMANCE DATA ( Calculated values) CONFIGURATION AND SCOPE OF SUPPLY ACCESSORIES 2 4 6

Prep. Appr. Resp. dept.

Helena Krivetz/PTD PTD PTD ABB Oy / Machines

17.3.2004 TECHNICAL SPECIFICATION Project


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PERFORMANCE DATA ( Calculated values)

TYPE Type designation: RATINGS Output: Duty: Voltage: Current: Power factor: Frequency: Speed: Overspeed: 8713 S1 12470 403 0,80 60 720 864 kVA V A Hz rpm rpm Direction of rotation (Facing drive end): Stored energy constant (Rotative energy divided by rated effect): Weight: Inertia: Protection by enclosure: Cooling method: Mounting arrangement: CCW AMG 1120MM10 DSE

0,78 26500 2400 IP23 IC0A1 IM1101

s kg kgm^2

STANDARDS Applicable standard: Marine classification: Hazardous area classification: Temperature rise stator / rotor: Insulation class: ENVIRONMENTAL CONDITIONS Ambient temperature: Coolant temperature: ASSUMED DATA Driving equipment: Appr. mec. power: EFFICIENCY in % load: Efficiency @ power factor Efficiency @ power factor REACTANCES IN % XD (U): XQ (U): X1 (U): 165,2 84,1 14,7 XD (S): 29,2 XQ (S): 17,3 XD (S): 17,2 X2 (S): 17,3 (S) = Saturated value, (U) = Unsaturated value X0 (U): XP (S): 10,9 24,1 0,80 1,00 110 97,30 98,09 % 100 97,31 98,08 % 75 97,19 97,94 % 50 96,63 97,46 % 25 94,44 95,66 % Wrtsil 16V32 7165 kW 50 C C Altitude: Location: 1000 masl IEC None None F/F F

TIME CONSTANTS (SEC.) AT 75 C TD0: TD0: 5,819 0,02679 TD: TD: 1,131 0,01605 TQ0: TQ: 0,1059 0,0239 TA: 0,103

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RESISTANCES AT 20 C Stator winding: Excitation winding: SHORT CIRCUIT Short circuit ratio: Sustained short circuit current: Sudden short circuit current: 0,74 1,9 > 2.5 2350 5950 p.u. (rated excitation) p.u. (voltage regulator) A (symmetric RMS) A (peak value) 0,0716 5,9 Field winding: 0,8242

VOLTAGE VARIATION Maximum allowed amount of starting load: Maximum voltage drop 15 % 15 % 15 % 20 % 20 % Power factor 0.1 0.4 0.8 0.1 0.4 19 25 Load 4400 4700 6500 6100 6500 kVA kVA kVA kVA kVA % %

Voltage drop at sudden increase of rated load: Voltage rise at sudden drop of rated load: REACTIVE LOADING Steady state reactive loading at rated excitation: Steady state reactive loading at zero excitation: TORQUE Rated load torque (Calculated of rated output in kVA):

7150 4050

kVAR kVAR

115600

Nm 520 %

The peak values of sudden short circuit air gap torques: 2-phase short circuit: 710 % 3-phase short circuit: TERMINAL CONNECTIONS Direction of main connection: Direction of zero connection: EXCITATION No load: Rated load: Exciter field 3,7 A 8,4 A 27,7 63,4 V V Right down Left down

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CONFIGURATION AND SCOPE OF SUPPLY

GENERAL The generator is designed to operate together with a diesel engine. CONSTRUCTION The stator frame is a rigid welded steel structure construction. The stator core is built of thin electric sheet steel laminations which are insulated on both sides with heat-resistant inorganic resin. The radial cooling ducts in the stator core insure uniform and effective cooling of the stator. The rotor consists of a shaft poles fixed on the shaft, exciter and a fan(s). The shaft is machined of steel forging. The poles are manufactured of 2 mm sheet steel and bolted from the top to the shaft. The pole laminations are pressed together with steel bars which are welded to the end plates. The exciter rotor and the fan are shrink fitted onto the shaft and secured with a key. All windings are completely vacuum pressure impregnated with high quality epoxy resin. The windings are provided with very strong bracing which withstands all expected mechanical and electrical shocks and vibrations as well as chemicals. For more information ask for brochure "MICADUR-Compact Industry Insulation System". The stator frame, core support and endshields are made of fabricated steel and welded together. The stator frame is closed with steel panels that guide the ventilation air and provide the degree of protection required. The flange mounted bearings are bolted to the endshields. According to IM1101 the machine has 2 bearings. The feet are raised. The shaft end is cylindrical. FOUNDATION The machine can be mounted using shimming, machined blocks, chock fast or on grouted sole plates or bed plate. Before using other mountings, contact us. COOLING The machine has a shaft mounted fan inside. The surrounding air is used for cooling. The cooling air is drawn in through air filters (self charging electrostatic panels) and blown out to the surrounding environment. CONTROL SYSTEMS A three phase transformer supplies the excitation power to the field winding of the shaft driven three phase exciter under the control of the digital automatic voltage regulator (AVR) type ABB UNITROL 1000. A three phase voltage feedback is supplied by the voltage transformer. A current feedback is provided by the current transformer. The transformers are installed in the generator. In addition to voltage control mode UNITROL 1000 AVR can be used in P.F., Var or field current control modes. Operational limits, like over and under excitation, machine voltage and Volts/Hz are implemented in the AVR. Static reactive power compensation in parallel operation and several other software functions are also included. The AVR-plate is supplied as
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a loose item for installation in the control cubicle. Thanks to a permanent magnet pole in the exciter no external power source is required for initial excitation at start-up. The permanent magnet pole is already magnetised by the generator manufacturer. Should the re-magnetisation of the permanent magnet be necessary, rated values for re-magnetisation given on the main connection diagram of the generator are used. Thanks to Soft Start function it is possible to avoid over shooting at start-up. Excitation power at short circuit is supplied by the CTs through rectifier. At normal voltage the contactor is shorting the output of CTs (and preventing over excitation from these CTs). At a line short circuit AVR will notice the voltage drop and connect CTs to give full short circuit excitation. The CTs are rated for sustaining a short circuit current at least 250 % of rated current. The circuit breaker protects the field circuit and the AVR against thermal overload and short circuit. The over voltage relay will trip the circuit breaker in excess of pre-set limit of over voltage and thus interrupt the supply of the excitation power to the AVR. Auxiliary supply can be 9 to 250 Vac (3-phase), 50 to 250 Vac (1-phase) or 18 to 300 Vdc. UNITROL 1000 AVR can be operated using digital and analogue I/O signals, from local panel or with PCTools software. PCTools is a commissioning and maintenance tool running under Microsoft Windows. With PCTools the tuning of the AVR can be done easily, also by using preset parameter files. The operation of a synchronous machine can be monitored and controlled by an on-line power chart, four channel oscilloscope and by several measurements and status indications with trending and memory functions. Measured data and parameters can be saved to a file for future use and analysis. TESTING Testing is according to IEC and ABB internal requirements. The test may be observed by the customer without extra charges. The test procedures is described in the following PIF -files: PIF 3a-315, PIF 3a-316. These are available upon request. Other tests to be agreed separately. Estimated vibration level is 2,3 mm/s SURFACE TREATMENT Colour: RAL 5019 Grade: C1 - Default

The surface treatment of the machines is based on epoxy paint system, which includes solvent free topcoat. This paint system is suitable especially for urban and industrial atmospheres with moderate corrosive attack (ISO 12944-2, C2 and C3 without direct UV-radiation). Total film thickness is 180 um. DOCUMENTATION User's Manual in electronic format. Documentation language is English.

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ACCESSORIES
Item Drive-end sleeve bearing Side flange mounted sleeve bearing for AMG/Z 1120 in land application. D-end. Normal end float +/- 2.5 mm or +/- 1/8 inch Max. axial force 2 kN. Machine seal on machine side IP44. Floating labyrinth seal on outer side IP44. Non-drive-end sleeve bearing Side flange mounted sleeve bearing Insulation between bearing housing and shell PT100 for stator winding - PYR PT100LG7/3 - 60042012 PT100 for sleeve bearings Anticondensation heater - RER 1-800W/490V - 9871215 Voltage 380-480 V, power 2x500-800 W Voltage transformer for exc.power & actual value measurement - KSG 3PU180/63/E 70006553 12470/110/110 V, 60 Hz Secondary 1: 110 V 3200VA for excitation Secondary 2: 110 V 300VA for actual value measurement Current transformer for actual value measurement - KSG 0500T2 - 9872228 500/1A, 5 VA, CL 0.5, 60 Hz Current transformer for differential protection - ACI-17 - 9877349 500/5/5 A, 60 Hz Core 1: 20VA, 5P10 Core 2: 20VA, 5P10 Coupling half, Mounting of machined coupling half The machined coupling half must be delivered latest 2 weeks before testing to our factory. Current transformer for short circuit exc.power - KSG IFJ-3-500T3 - 9874480 500/7.0 A, CL 3/10P2.5, 60 Hz Automatic Voltage Regulator with plate - Unitrol 1000 Multidiameter cable entry seals (Rox System) for main cables Diode module - LNM 260A/2000V - MITTA ABB Stock code: 9877911

No pc/pcs 1

6 2 2

1 2 3

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Synchronous Machine AMG 1120MM10DSE Section 3 - Technical Specification

Protection for Synchronous Generators


Subject: standard generators Applicable for voltage 1 - 15 kV and power 3 - 40 MVA

Recommended protection For generator itself 1. 2. 3. 4. 5. 6. 7. 8. 9. Thermal overload in stator winding; I > Network short-circuit; I >> Stator interwinding short-circuit; Differential protection relay Stator earth-fault; Earth-fault relay Overvoltage; Over voltage relay Unbalance load or shorted turns in the same phase; I2 / In Underexcitation and loss of synchronism; Under reactance relay Undervoltage and intermittent loss of voltage; Under voltage relay Temperature supervision of temperature detectors; Pt-100-monitoring

Additional protection Essential rather for prime mover than for generator 1. 2. Frequency disturbance Reverse power

Synchronous Machine AMG 1120MM10DSE Section 3 - Technical Specification

Max. Allowed Unbalanced Load for Standard Generators


Subject: standard generators

500

400

300

200

100

0 0 10 20 30 40 50 se c 60 70 80 90 100

I2 is a counter rotating component of stator current In Max. continuous rate of I2 is 8%

Synchronous Machine AMG 1120MM10DSE Section 3 - Technical Specification

Underfrequency Withstanding Capability After Continuous Operation at Rated Output


Subject: standard generators Frequency % 100 96 95 92.5 90 87.5 85 Load at rated voltage P.F.=0.8 P=Pn cont. cont. 30 min 2 min P.F.=1.0 P=Pn cont. cont. cont. 30 min 2 min No load P=0 cont. cont. cont. cont. cont. 30 min 2 min

Synchronous Machine AMG 1120MM10DSE Section 3 - Technical Specification

Current Through Stator Core Lamination Versus Time


Subject: standard generators

70

60

50

40 I/A 30

20

10

B A

0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

t/sec

A = NEGLIGIBLE ARC BURNING B = SLIGHT BURNING C = SEVERE DAMAGE

10

Synchronous Machine AMG 1120MM10DSE Section 3 - Technical Specification

Overcurrent Limit for Standard Generators


Subject: standard generators

11 10 9 8 7 6 5 4 3 2 1 0 2 4 6 8 10 se c 12 14 16 18 20

150 % for 2 minutes 125 % for 15 minutes 110 % for 1 hour In = Rated current I = Max. allowed current at six-hour intervals

11

Synchronous Machine AMG 1120MM10DSE Section 3 - Technical Specification

Loadability of Standard Generators


Subject: standard generators

1 ,6

1 ,5

1 ,4

1 ,3

1 ,2

1 ,1

0 ,9 0 10 20 30 m in 40 50 60

110 % for 1 hour 100 % continuously Sn = Rated output S = Output with rated p.F. at six-hour intervals

12

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

4.
Mechanical Drawings

ABB

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

Contents Mechanical Drawings


Main Dimensions ..................................5135523 Assembly Drawing ................................5122349 Rotor Drawing .......................................5135510 Transport and Hoist ................................530650 Removing of Transport Locking ............5122342 ET-dimension........................................5122341 Removing Rotor ....................................5122343 D-end Bearing.......................................9874569 N-end Bearing.......................................9872686

ABB

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

5.
Electrical Drawings

ABB

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

Contents Electrical Drawings


Main Connection Diagram ....................5132715 Layout of Connection ............................5133125 Terminal Box for Accessories ...............5122340 Exciter Rotor with Diode Bridge ............5122347 Unitrol 1000 Wrtsil..............3BHS116994 E01 Unitrol 1000 Circuit Diagram..3BHS116747 E20

ABB

DI 5

DI 6

DI 7

- AI 1

- AI 2

+ AI 1

+ Vref

- Vref

+ Vdig

+ AI 2

DGND

+ Vdig

DI 8

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
AO 1 AO 2 DIO 1 DIO 2 DIO 3 - AI 3 - Vref + Vref + AI 3 AGND + Vdig S1 S2 + Vdig DIO 4

DGND

UNITROL

1000

OK

ESC

serial port

I M2 UM
L1 L2 L3 L1

EIA-485 - + + 50 51 52 53 54 55

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

U NET
L2 L3

Ie
2 3 4 5 6 7 + 8

U PWR
L1(+) L2(-) L3

U AUX
L1(+) L2(-) L3

10

11

12

13

14

15

A01

UNITROL 1000 WRTSIL


DGND PFrem AGND ON/off f/sync +Vdig +Vdig
boost ctr

GCB/

+Vref

close ctr

+Vref

-Vref

GCB

+ PF

-Vref

If/pv

- PF

status

L1 4

L2 5

L3 L1 6 1

L2 2

L3 3

+ 8

L1(+) L2(-) 10 11

L3 L1(+) L2(-) 12 13 14

L3 S1 S2 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

F01 1
B

2.5mm2 black

24 + B

OVER VOLTAGE

IG

21

3 RELAY

2.5mm2 black + V01 -

4 V02 + 6

Ik/

DGND

SYNC

+Vdig

+Vdig

DEC

U-droop

PWG

PF/

U-droop

status

active

VDC

INC

U busbar

U generator

I field

U power

U AUX

I L2

A2 2.5mm2 black F02 ECL-10 9 10 11 12 4 5 6 7 8 9 10 11 12 1 2 3 4 11 A1 K01 A2 1L1 3L2 5L3 13 13 14 13 14 3 2 1 2.5mm2 black 2T1 4T2 6T3 14 U01 13 14 13 14 U02 R03 R04 13 14 13 14 U03 4mm2 yellow/green PE
E

K02 A1 A1 K03 A2

14

4mm2 yellow/green

A1 A2 65 79 80 71 A2

A1 A2 72 A2 68 66 67 76 77 Ref. Input Range -0,75...1...+0,75 OFF ON

A1 A2 78 A2 Select Remote 70 69 PE

-X1

61

62

63

73

74

75

64

Reference Increase

Reference Decrease

UG

IG

GENERATOR FIELD

POWER SUPPLY

EXCITATION ON/OFF
issued: 26.07.2002 Rietmann Ehlen Ehlen change E 13291 scale: % X checked: 26.07.2002 no sep. parts list sep. PL same no. sep. PL another no. 3BHE006720R0001

ALL WIRES WITHOUT INDICATION: 1.0mm black


F
We reserve all rights in this document and in the information contained

released: 26.07.2002 dervd. from: replaces:

WRTSIL UN1000

recei. office:

CIRCUIT DIAGRAM WRTSIL 11012512


doc.-type format

3BHS116747_E20
1

therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

General tolerances linear and angular tolerances <<medium>> HZN 401 638; DIN 7168 T.1; <<course>> ISO 2768 Geometrical tolerances DIN 7168 T.2:..

office resp.: ATPE

ZAB
7

A2

3BHS116747_E20
8

ASEA BROWN BOVERI 1999

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

6.
Manual

ABB

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Chapter 1 - Introduction
1.1 1.2 1.3 General information............................................................................................... 1 Important note........................................................................................................ 1 Site conditions........................................................................................................ 1

Chapter 2 - Transport and Storage


2.1 Transport and unpacking........................................................................................ 1 2.1.1 Protective measures prior to transport .................................................. 1 2.1.2 Lifting the machine package................................................................. 1 2.1.3 Check upon arrival................................................................................ 1 2.1.4 Unpacking............................................................................................. 1 2.1.5 Lifting of unpacked machine ................................................................ 2 Storage ................................................................................................................... 3 2.2.1 Short term storage (less than 2 months)................................................ 3 2.2.2 Long term storage (2-6 months) ........................................................... 3 2.2.3 Very long term storage (over 6 months) ............................................... 4 2.2.4 Storage and care after installation......................................................... 5

2.2

Chapter 3 - Installation and Alignment


3.1 Preparations for installation ................................................................................... 1 3.1.1 General.................................................................................................. 1 3.1.2 Check of foundation.............................................................................. 2 Installation ............................................................................................................. 2 Rough levelling and alignment .............................................................................. 2 3.3.1 Rough levelling..................................................................................... 3 3.3.2 Rough axial alignment .......................................................................... 3 Alignment and air gap checking ............................................................................ 4 3.4.1 Air gap check ........................................................................................ 4 3.4.2 Alignment ............................................................................................. 5 3.4.3 Correction for thermal expansion ......................................................... 8 Final inspection and installation ............................................................................ 9 3.5.1 Covers and enclosures .......................................................................... 9

3.2 3.3

3.4

3.5

Chapter 4 - Mechanical and Electrical Connections


4.1 Electrical connections ............................................................................................ 1 4.1.1 General information.............................................................................. 1 4.1.2 Connection of main power cables......................................................... 1 4.1.3 Earth connection ................................................................................... 2 4.1.4 Insulation distances of main power connections .................................. 2 4.1.5 Connection of auxiliaries and instruments............................................ 3

Chapter 5 - Commissioning
5.1 5.2 5.3 General................................................................................................................... 1 Check of mechanical installation........................................................................... 1 Check of electrical installation .............................................................................. 1

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

5.4 5.5 5.6

5.7

Insulation resistance measurements....................................................................... 2 Starting................................................................................................................... 2 Checks during running of the machine .................................................................. 3 5.6.1 Normal vibration levels ........................................................................ 3 5.6.1.1 Measurement procedures and operational conditions .... 3 5.6.1.2 Evaluation of RIC engine generating sets...................... 4 5.6.2 Temperature levels ................................................................................ 5 Shut down .............................................................................................................. 6

Chapter 6 - Operation
6.1 6.2 6.3 Start up procedure .................................................................................................. 1 6.1.1 Start interlocking................................................................................... 1 Continuous supervision.......................................................................................... 1 Shut down procedures............................................................................................ 1

Chapter 7 - Maintenance
7.1 7.2 7.3 Preventive maintenance ......................................................................................... 1 Safety precautions.................................................................................................. 1 7.2.1 Particular safety instructions for winding maintenance........................ 1 Maintenance of general construction..................................................................... 2 7.3.1 The tightness of fastenings ................................................................... 2 7.3.2 Vibration and noise ............................................................................... 3 Maintenance of lubrication system and bearings................................................... 4 7.4.1 Lubrication............................................................................................ 4 7.4.1.1 Lubrication oil temperature............................................ 4 7.4.1.2 General characteristics of the listed oil qualities ........... 4 7.4.1.3 Condition of the lubricant .............................................. 4 7.4.1.4 Oil qualities .................................................................... 5 7.4.1.5 Oil change schedule for mineral oils.............................. 5 7.4.2 Sleeve bearings ..................................................................................... 5 7.4.2.1 Oil level.......................................................................... 6 7.4.2.2 Oil leakage ..................................................................... 6 7.4.2.3 Bearing temperature ....................................................... 6 7.4.3 Bearing insulation resistance check...................................................... 7 7.4.3.1 Procedure ....................................................................... 7 Maintenance of stator and rotor winding............................................................... 8 7.5.1 The timing of the maintenance ............................................................. 9 7.5.2 The correct operating temperature........................................................ 9 7.5.3 Insulation resistance test ....................................................................... 9 7.5.3.1 Conversion of measured insulation resistance values.... 9 7.5.3.2 General considerations ................................................. 10 7.5.3.3 Minimum values for insulation resistance ................... 11 7.5.3.4 Stator winding insulation resistance measurement ...... 12 7.5.3.5 Rotor field winding insulation resistance measurement ................................................................ 13

7.4

7.5

ii

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

7.6

7.7

7.8

7.9

7.10

The polarization index ........................................................................ 13 High voltage test ................................................................................. 14 7.5.5.1 High voltage test for stator winding............................. 14 7.5.6 Fault searching methods ..................................................................... 14 7.5.6.1 Voltage drop test (Rotor winding impedance test) ....... 14 7.5.7 Tan delta-measurements ..................................................................... 14 7.5.8 Visual winding inspection................................................................... 15 7.5.8.1 Corrective actions based upon the observations .......... 15 7.5.9 Cleaning the windings ........................................................................ 16 7.5.9.1 Cleaning methods......................................................... 16 7.5.9.2 Cleaning agents ............................................................ 17 7.5.10 Drying ................................................................................................. 19 7.5.11 Varnishing of the windings ................................................................. 19 7.5.12 Other maintenance operations ............................................................ 20 Maintenance related to electrical performance, excitation, control, and protection ...................................................................................................... 20 7.6.1 Exciter insulation resistance measurement ......................................... 20 7.6.2 Protection trips.................................................................................... 21 7.6.3 Automatic voltage regulator (AVR).................................................... 21 7.6.4 Pt-100 resistance temperature detectors ............................................. 21 7.6.4.1 Pt-100 temperature detector retrofitting....................... 22 7.6.5 Insulation resistance measurement for auxiliaries .............................. 24 7.6.6 Diode fault .......................................................................................... 24 Maintenance related to thermal performance and cooling system ...................... 25 7.7.1 Cooling System................................................................................... 25 7.7.1.1 Cleaning ....................................................................... 26 Maintenance program .......................................................................................... 26 7.8.1 Recommended maintenance program................................................. 29 7.8.1.1 General construction .................................................... 29 7.8.1.2 High voltage connection .............................................. 30 7.8.1.3 Stator and rotor............................................................. 30 7.8.1.4 Excitation system, control and protection.................... 31 7.8.1.5 Lubrication system and bearings.................................. 32 7.8.1.6 Cooling system............................................................. 32 Spare parts............................................................................................................ 32 7.9.1 General considerations........................................................................ 32 7.9.2 Wearing parts subjected to mechanical wear ...................................... 33 7.9.3 Other wearing parts............................................................................. 33 7.9.4 Selection of the most suitable spare part package .............................. 33 7.9.5 Typical recommended spare parts in different sets............................. 34 7.9.5.1 Safety package ............................................................. 34 7.9.5.2 Maintenance package ................................................... 34 7.9.6 Order information ............................................................................... 35 Troubleshooting ................................................................................................... 36 7.10.1 Mechanical performance..................................................................... 37

7.5.4 7.5.5

iii

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

7.10.2 7.10.3 7.10.4

Lubrication system and bearings ........................................................ 38 7.10.2.1 Lubrication system and sleeve bearings....................... 38 Thermal performance.......................................................................... 39 7.10.3.1 Thermal performance, open air cooling system........... 39 Electrical performance........................................................................ 40 7.10.4.1 Electrical performance and excitation system of generators................................................................. 41

Chapter 8 - Dismantling and Reassembly


8.1 8.2 8.3 8.4 8.5 8.6 General................................................................................................................... 1 Preparation for dismantling ................................................................................... 1 Dismantling............................................................................................................ 1 Removing the rotor ................................................................................................ 2 Reassembly and Realignment................................................................................ 4 Stator Shift ............................................................................................................. 4

Chapter 9 - After Sales and Market Support

iv

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Chapter 1 Introduction

1.1 General information


The following chapters contain information on the transporting, installing, operating and maintaining of the AMG 1120MM10DSE synchronous machine manufactured for project Grupo Punta Cana. The purpose of this manual is also to provide information for all aspects of removal and assembly of components. Actions shown in this manual are only to be performed by trained personnel authorized by the user.

1.2 Important note


The information in this document may sometimes be of a general nature and applicable to the various machines produced by ABB Oy. Where a conflict exists between the contents herein and the actual machinery supplied, the user must either make an informed engineering judgement as to a course of action or, if any doubt exists, contact ABB Oy. In no event shall ABB Oy be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB Oy be liable for incidental or consequential damages arising from use of any software or hardware described in this document. The safety precautions shown in Section 1, Introduction must be observed at all times. This document and parts thereof must not be reproduced or copied without the express written permission of ABB Oy, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.

1.3 Site conditions


This machine is to be used on a site with environmental conditions according to the ABB Oy specifications (listed in Section 1, Introduction and Section 3, Technical Specification). Please refer to the applicable certificate in Section 2, Certificates. Special conditions stipulated in the certificate must be strictly followed.

Introduction - 1

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Chapter 2 Transport and Storage

2.1 Transport and unpacking 2.1.1 Protective measures prior to transport


All synchronous machines delivered as a unit are provided with an axial movement locking device protecting the bearings against damages during the transport. Therefore it is important that the locking device is attached whenever the machine is transported. Machined metal surfaces, such as the shaft extension, are provided with an anti-corrosive coating before delivery. The bearings are flooded with oil during the tests prior to delivery. This gives sufficient protection against corrosion. During shipping the machine should be placed under deck.

2.1.2 Lifting the machine package


The package has marks that have to be observed, i.e. showing where the lifting wires are to be applied. Lifting must be performed with great care and using long enough slings. . For details, see the lifting drawing in Section 4, Mechanical Drawings. NOTE: Do not attempt to lift the machine from the red attaching points! NOTE: If the ambient temperature is below -20 C, the machine may not be lifted or operated without permission from the manufacturer.

2.1.3 Check upon arrival


The machine and the package must be inspected immediately upon arrival. Any transport damage must be reported within less than one (1) week after arrival if transport insurance is to be claimed. It is therefore important that evidence of careless handling is checked and reported immediately to the transport company and the supplier. A machine which is not to be installed immediately upon arrival must not be left without supervision or without protective precautions. For more details, see Chapter 2.2 Storage.

2.1.4 Unpacking
Place the synchronous machine so that it does not hinder the handling of any other goods and on a flat, vibration-free surface. When the package has been removed, a check should be made to see that the synchronous machine is not damaged and that all accessories are included. Tick off the accessories on the packing list which is enclosed. If there is any damage, suspected damage, or if accessories are missing, please report this immediately to the supplier.

Transport and Storage - 1

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

2.1.5 Lifting of unpacked machine


Lifting must be performed with great care and using slings long enough to assure the lifting angle requirements. If the requirements are not met, there is a risk of damage. See Figure 2-1 Lifting an unpacked machine. For more details, see the lifting drawing in Section 4, Mechanical Drawings. NOTE: The machine must be lifted from its frame. Do not attempt to lift the machine from the top cover!

Figure 2-1

Lifting an unpacked machine

Figure 2-2

Lifting an unpacked machine

Transport and Storage - 2

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

2.2 Storage 2.2.1 Short term storage (less than 2 months)


The machine should never under any circumstances, not even in transportation package, be left outdoors as it is. If the ground is wet, the package needs to be placed on supports so that there is at least 100 mm between the wet level and package bottom. If the package needs to be stored outdoors, it has to be provided with a big enough cover that protects it completely from rain, but allows ventilation. The machine must be placed in a clean and dry place. The temperature, dew point, dust, shock and vibration should be controllable. The storage temperature should preferably range from 10C to 50C with a maximum air humidity of 75%. If air humidity is more than 75%, good internal ventilation must be arranged. Anticondensation heaters must be energised to keep the machine above the dew point of the ambient air to prevent condensation of moisture. When surrounding air temperature is higher than 50C ventilation is necessary to prevent overheating of the electrical equipment, especially when the anticondensation heaters are energised. The floor under the machine should be free from excessive vibrations. If the vibrations are suspected to be too large, precautions should be taken to isolate the machine by e.g. placing rubber blocks under the machine.

2.2.2 Long term storage (2-6 months)


In addition to the measures described in Chapter 2.2.1 Short term storage (less than 2 months) above, the following should be done Storage indoors If the machine is stored in its transportation package, make big enough holes on the sides of the transportation package so that the D-end and N-end of the machine are accessible. Protect the shaft and the sealing points as well as all bearing parts against corrosion. Shaft and bearing seals should be treated with an anti-corrosive agent (e.g. LPS 3, Holt Lloyd, USA). The bearing should be filled with protective oil, e.g. Esso: Rust-Ban 623 Gulf: Gulf No-Rust Engine Oil Grade 2 Mobil: Mobilarma 524 Shell: Shell Ensis Engine Oil 20

If the protection made by the manufacturer has been removed, protect the unpainted surfaces such as shaft extensions, coupling halves and jacking screws with suitable anti corrosion agent. If the machine has been delivered in fully assembled condition, the rotor shall be turned approximately 10 revolutions once per every 2-3 months to maintain protective oil film on bearing surfaces. The self-lubricated bearings must be filled with oil, and flood lubricated bearings must be connected to the lubrication system. If this cannot be done, the bearing shells should be taken out, see chapter Storage outdoors .

Transport and Storage - 3

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Storage outdoors For outdoor storage in addition to the measures described in chapter Storage indoors , the following should be done. Make sure that the machine is completely covered with a big enough waterproof cover. Remove the side and end covers of the machine. Push strong cardboard pieces into the air gap between the main machine stator and rotor so that the rotor may be supported by the stator. Dismount the bearing instruments. Dismount the seals and the upper parts of the bearing housings. Remove the upper parts of the bearing shells and dismount the eventual oil rings. Lift the rotor up (approx. 0.5 mm) until the bearing shells do not carry the weight of the rotor. Turn the lower bearing shells 180 over the shaft and remove them. Lower the rotor so that it rests on the stator (cardboard pieces in between). Protect the bare shaft surfaces and shells with anti corrosive agent. Mount the bearing housings and seals (seals have to be loosened) and protect the seals with anti-corrosion agent. Store the bearing shells in a clean and dry place.

NOTE: Do not damage the seals or the bearings.

2.2.3 Very long term storage (over 6 months)


All the protected surfaces mentioned in the previous list in Chapter 2.2.1 Short term storage (less than 2 months) and Chapter 2.2.2 Long term storage (2-6 months) should be cleaned and the anti-corrosive treatment should be renewed every 12 months. Otherwise the instructions for shorter storage periods should be followed.

Regular checkings during storage Every month Check that the anticondensation heaters are working. Check that the ventilation works.

Every 3 months Check the insulation resistance, see Chapter 7.5.3 Insulation resistance test. Check that there is no corrosion on the surfaces. If corrosion is observed, remove the corrosion and protect the surfaces. Check that the anti-corrosion agents have not cracked.

Every 6 months Dismount the bearing housing upper cover and check the shaft and the bearing housing anti-corrosion protection.

Transport and Storage - 4

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

2.2.4 Storage and care after installation


If the machine will not be in operation for a longer period of time after installation, the same measures as above in Chapter 2.2.1 Short term storage (less than 2 months) should be applied. Remember to rotate the shaft 10 revolutions at least every 2-3 months. The self-lubricated bearings must be filled with oil.

Transport and Storage - 5

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Chapter 3 Installation and Alignment

3.1 Preparations for installation 3.1.1 General


Good planning and preparation result in simple and correct installation and assure safe running conditions and maximum accessibility. During installation, general as well as local work safety instructions must be followed. Auxiliary tools for the installation should be made available on site if required: Suitable material for set-up and shimming as well as other auxiliary tools for installation are normally not included in ABB Oy delivery. Auxiliary tools for installation, like hydraulic jack and bracket plates with adjusting screws are to be supplied by the customer. Attachments for gauges, extension brackets and other alignment tools are to be made. Before the rotor is turned, oil must be poured into the bearings. A lever is needed for turning the rotor. While turning the rotor, oil must be continuously poured into the funnels at both ends of the machine, see Figure 3-1 Pouring oil into the bearings. For suitable oil qualities, see Chapter 7.4.1 Lubrication.

Figure 3-1. Pouring oil into the bearings. NOTE: Anti-condensation heaters must be provided for keeping the machine interior dry when there is a risk of condensation. The machine must be protected against dust and rain. The general tightening torques for screws are given in Chapter 7.3.1 The tightness of fastenings. These values are applicable if no specific tightening torques are given in this manual or in the

Installation and Alignment - 1

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

mechanical and electric drawings, see Section 4, Mechanical Drawings and Section 5, Electrical Drawings.

3.1.2 Check of foundation


The structural design of the foundation is not included in the ABB Oy scope and the customer or a third party is therefore responsible for this. The installation of the machine should be planned as early as possible. Before lifting the synchronous machine onto the foundation a check should be made to ensure that the foundation fulfills the following requirements: Check that the position of the anchoring or fixing holes and the height of the foundation are in agreement with corresponding measurements on outline and foundation drawings in Section 4, Mechanical Drawings. The foundation must be flat. If any inclination has been agreed upon the permissible inclination must be stated on the installation drawing. The foundation must be carefully cleaned by sweeping or vacuum-cleaning for some days before the testing is performed. Use of non-shrinking concrete.

3.2 Installation
The machine is normally transported and lifted as one ready assembled unit onto the foundation, see Section 4, Mechanical Drawings. Main steps of the installation procedure are: 1. 2. 3. 4. 5. 6. 7. 8. 9. Mount the coupling halves, if applicable. Mount the machine on the foundation. Level and align the machine roughly in axial and horizontal directions. Align and couple the rotor with driven equipment. Fasten the machine initially to the foundation. Check air gaps and adjust as necessary. Re-check the alignment. Fine adjust if necessary. Tighten and lock bolts and install dowel pins. Install accessories.

More detailed instructions for installation are given in following chapters or in instructions supplied by driven/driving machine manufacturer.

3.3 Rough levelling and alignment


Before alignment remove the transport locking device according to instructions in Transport Locking drawing in Section 4, Mechanical Drawings. The transport locking device is normally painted red.

Installation and Alignment - 2

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

3.3.1 Rough levelling


1. Center the rotor (axially) to the middle of the end float of the drive end bearing. Check also that the distance ET is the same as the value stamped above the D-end bearing. See Figure 3-3 Typical marking of ET dimension and Section 4, Mechanical Drawings. Remove the anti-corrosive coating from surfaces requiring uncoated metal surfaces during normal operation. Check the coupling instructions and fit. Preheat the coupling hub as necessary and mount it on the machine shaft. Lift the machine up and move it over the bed plate. Align the machine visually and put pieces of sheet metal below the jacking screws to protect bed plate surface. Turn the jacking screws until they carry the weight of machine.

2. 3. 4. 5. 6.

Check that the machine is radially and axially leveled. Place a spirit level on the horizontal surfaces of the frame and rotor shaft as shown in Figure 3-2 Placement of the spirit level and make adjustments by placing shims under the feet. The machine must be supported by all feet.

Figure 3-2. Placement of the spirit level

3.3.2 Rough axial alignment


Correct axial position of the rotor is shown by the magnetic center indicator above the shaft. Position is correct when the tip of the indicator is in line with the machined groove on the shaft The rotor is placed in the magnetic center position when the dimension ET is fulfilled. Read the correct distance in the inspection and test record in Section 8 under ET Dimension. The dimension has also been punched on the D-end of the machine, see Figure 3-3 Typical marking of ET dimension and Section 4, Mechanical Drawings for details. If the rotor has axial float, check the mechanical center position of the rotor.

Installation and Alignment - 3

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

The running center is not the same as magnetic center due to the fact that the machine has a radial fan for cooling and the fan has an axial component that will affect the rotor running position. If there is no thrust bearing, the machine cannot withstand any axial force from the driven machine. The axial force must be carried by the driven machine. The coupling must be of limited axial float type. If there is an axially locating bearing on the machine, make sure that continuous free axial movement is possible between the coupling halves (excluding rigid couplings) in order to permit thermal expansion of the machine shaft without damaging the bearings. When the machine stands axially in its right position, leave all adjusting jacking screws only lightly tightened.

ET dimension

Figure 3-3. Typical marking of ET dimension

3.4 Alignment and air gap checking 3.4.1 Air gap check
Check the air gap of the electrical machine between the stator and the rotor. Remove the side covers, or where applicable, the end covers of the machine frame. Push a wedge-shaped measuring strip in the air gap at the middle of one pole in four symmetrically chosen rotor positions. Turn the rotor correspondingly. Where applicable, there is a hole in the fan through which the measuring can be done. Make sure that the bearings are filled with oil before turning the rotor. NOTE: Centering of the rotor, i.e. the air gap, is adequate when a single measured value does not deviate more than 10 percent from the mean value. The air gap of the stator and the rotor of the electrical machine is adjusted by loosening the bolts retaining the end shield, removing the dowel pins, and moving the complete end shield by turning the two adjustment screws situated on each side of the end shield.

Installation and Alignment - 4

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

After the air gap of the stator and the rotor of the electrical machine has been checked and adjusted, the air gap between the exciter stator and rotor, at the N-end of the machine, has to be checked in four symmetrically chosen positions. The exciter air gap is adjusted by moving the exciter stator.

Exciter air gap

Air gap

Figure 3-4. Air gap between stator and rotor After the adjustment of the air gap, all the fastening bolts are tightened, see Table 7-1 General tightening torques (combined stress 0.75 times yield stress). The air gap is then verified once more, where appropriate dowel pins are inserted.

3.4.2 Alignment
General After the machine has been roughly positioned, as described in Chapter 3.3 Rough levelling and alignment, the final alignment can start. This step must be performed with great caution. Failure to do so can result in serious vibrations and damage to both driving and driven machine. The alignment is done in accordance with the recommendations given by the coupling manufacturer. Parallel, angular and axial alignment of the machine is required. Some standard publications give recommendations for coupling alignment, e.g. BS 3170:1972 "Flexible couplings for power transmission". In accordance with common practice, parallel and angular misalignment should not exceed 0.05-0.10 mm and axial misalignment should not exceed 0.10 mm, see Figure 3-5 Definition of misalignment. The corresponding run-out is 0.10-0.20 mm for parallel and angular misalignment, and 0.20 for axial misalignment.

Installation and Alignment - 5

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Parallel misalignment Angular misalignment Axial misalignment

r b a

Figure 3-5. Definition of misalignment The tolerances given by the coupling manufacturers must not be used in deciding how accurate the alignment should be, because these tolerances indicate what the coupling can accept. Excessive tolerances will give rise to vibrations, bearing damage etc. and therefore tolerances as narrow as recommended above should be aimed at. Alignment The alignment of the machine is performed according to these guidelines. 1. 2. The machine should stand on its jacking screws. Rotate the rotor and check the axial end float, see Chapter 3.3.2 Rough axial alignment. Lubricate the bearings at regular intervals during the final alignment in accordance with Chapter 3.1 Preparations for installation. 3. Mount the alignment equipment. If gauges are used, it is practical to adjust the dial gauge in such way that approximately half of the scale is available in either direction. Check the rigidity of the gauge brackets in order to eliminate the possibility of sag, see Figure 3-6 Alignment check with gauges.

Installation and Alignment - 6

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Radial alignment

Angular alignment

Figure 3-6. Alignment check with gauges 4. Measure and note readings for parallel, angular and axial misalignment in four different positions: top, bottom right and left, i.e. every 90, while both shafts are turned simultaneously. Readings are recorded in the Commissioning Report in Section 9. Align the machine vertically by turning the jacking screws, the adjustment screws or by jacking with hydraulic jacks. To facilitate the alignment in the vertical plane, jacking screws are fitted to the feet of the horizontal machine. See Figure 3-7 Vertical positioning of machine foot. The alignment accuracy of the machine is sometimes affected by the thermal expansion of its frame. The maximum thermal expansion of the frame can be taken as 0.5 mm per meter, corresponding to a temperature rise of 50C. In most operating conditions, the temperature rise of the frame remains at about 40C with a corresponding thermal expansion of 0.4 mm per meter. See Chapter 3.4.3 Correction for thermal expansion.

5.

Machine foot Shim

Foundation

Fixing bolt

Jacking screw

Figure 3-7. Vertical positioning of machine foot

Installation and Alignment - 7

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

6. 7. 8. 9.

Measure the distance between the bottom of the machine feet and the bed plate and make corresponding solid blocks or wedges or reserve necessary amount of shims. Fit the solid blocks or shims under the stator feet. Slacken the jacking screws and tighten the fixing bolts. Check the alignment again. Check the air gap of the machine and the exciter.

10. Draw up a record for future checks (Section 9, Check Lists). 11. Re-tighten nuts and lock the nuts by tack welds or hitting sufficiently hard with a center punch.

3.4.3 Correction for thermal expansion


Temperatures have a considerable influence and should be considered during the alignment. The temperature of the machine is lower during installation than it will be during operating conditions. For this reason the shaft centre is going to lie higher during operating conditions. Depending on the type of coupling, the distance between the machine and the driven equipment may have to be compensated because of thermal expansion. The upward thermal expansion of the electrical machine can be approximated according to the following formula: H where T H = = = = T H [mm] 10 10-6 K-1 40 K shaft height [mm]

Due to the thermal expansion of the electrical machine, the vertical movement of the shaft is of the magnitude of 0.1 mm for each 10oC difference in temperatures as illustrated in Figure 3-8 The correlation between thermal expansion and machine temperature.

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Figure 3-8. The correlation between thermal expansion and machine temperature

3.5 Final inspection and installation 3.5.1 Covers and enclosures


After the machine has been erected, aligned and its accessories are installed, check carefully that no tools or foreign objects have been left inside of the enclosure. Clean also any dust or debris. When installing the covers, check that all sealing strips are intact before mounting them on. Store alignment and assembly accessories together with the transport locking devices for future use.

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Chapter 4 Mechanical and Electrical Connections

4.1 Electrical connections 4.1.1 General information


The safety information in Section 1, Introduction Chapter 6 Safety Instructions (High-voltage AC Machines) must be observed at all times. Connection diagrams received with the machine have to be studied before starting the installation work, see Section 5, Electrical Drawings. It is important to verify that the supply voltage and the frequency are the same as the values indicated on the rating plate of the machine and in Section 3, Technical Specification. The sizes of input cables have to be adequate for the maximum load current and in accordance with local standards. The cable terminations have to be of appropriate type and of correct size. The connection of all devices, such as temperature probes, has to be checked. NOTE: Prior to installation work it is important to check that the incoming cables are separated from the supply network. The cables should be grounded.

4.1.2 Connection of main power cables


The stator terminals are marked with letters U, V and W according to IEC 34-8 or T1, T2, and T3 according to NEMA. Stripping, splicing and insulating of the high-voltage cables must be performed in accordance with instructions by the cable manufacturer. The lugs should not be permanently tightened by busbars, but only attached (for checking of insulation resistance). The cables must be supported so that no stress is applied to the busbars in the terminal box, see connection diagram in Section 5, Electrical Drawings. When three-phase cables are used, the prescribed distance must be maintained between the leads at intersections. Bracing and spacers should be used if necessary. Check the phase sequence, see Figure 4-1 Phase sequence (IEC) (CW = clockwise, CCW = counter clockwise) and Figure 4-2 Phase sequence (NEMA) (CW = clockwise, CCW = counter clockwise).

Rotation CW

Rotation CCW

(viewed from drive end) U V W U V W

L1 L2 L3
Figure 4-1

L3 L2 L1

Phase sequence (IEC) (CW = clockwise, CCW = counter clockwise)

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Rotation CW

Rotation CCW

(viewed from non-drive end) T1 T2 T3 A


Figure 4-2

T1 T2 T3 C B A

Phase sequence (NEMA) (CW = clockwise, CCW = counter clockwise)

4.1.3 Earth connection


The ground cable may be connected either inside or outside the terminal box and for connection points on the synchronous machine, see outline and terminal box drawings. See Section 5, Electrical Drawings.

4.1.4 Insulation distances of main power connections


The connections of the main power cables are designed to withstand demanding operation conditions where the insulators can be subjected to dirt, humidity and surge voltages. In order to ensure lasting and trouble free running, it is therefore important that local requirements or other applicable standards for the insulation distances are met. If no local requirements or other applicable standards are available, it is suggested that the minimum insulation distances mentioned in Table 4-1 Recommended minimum insulation distances be used. These distances apply both for insulation distances between two different phases, and for insulation distances between one phase and earth. Values for voltages not mentioned can be obtained by interpolating. The air insulation distance is the shortest distance through air between two points with different electrical potential (voltage). The surface insulation distance is the shortest distance along surfaces next to each other between two points with different electrical potential (voltage).

Table 4-1. Recommended minimum insulation distances Main voltage (V) Air insulation distance(mm) Surface insulation distance (mm) Even surface 690 1000 2000 6 9 17 10 14 27 Finned surface 8 12 24

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Table 4-1. Recommended minimum insulation distances 3000 3300 3600 4160 6000 6600 7200 10000 11500 13800 15000 26 28 31 36 50 54 59 80 92 110 120 41 45 49 57 80 89 98 140 163 198 217 36 39 43 50 70 77 85 120 140 170 186

4.1.5 Connection of auxiliaries and instruments


Connect the instruments and auxiliary equipment according to the connection diagram in Section 5, Electrical Drawings. The locations of auxiliary terminal boxes are shown on drawings in Section 4, Mechanical Drawings.

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Chapter 5 Commissioning
5.1 General
Commissioning is not to be considered finalized before a commissioning report has been made and distributed to all concerned parties (customer and supplier). A commissioning report is a vital tool for future service, maintenance and fault finding. The commissioning report has to be sent to ABB Oy in order to obtain future warranty claims. Recommended commissioning report can be found in Section 9, Check Lists of this manual. General safety precautions must be followed during commissioning and all work has to be performed by qualified personnel.

5.2 Check of mechanical installation


Check alignment of the machine prior to commissioning. Go through the alignment report and ensure that the machine is accurately aligned according to ABB Oy alignment specifications in Chapter 3. The alignment protocol should always be included in the commissioning report.

Check that the machine is properly anchored to the foundation. Check for cracks in the foundation and the general condition of the foundation. Check the tightness of the fixing bolts.

Additional checks Open the machine, and check that the air-gap is free. See Figure 3-4 Air gap between stator and rotor and Chapter 3.4.1 Air gap check. Check that the lubrication system is commissioned and is running before the rotor is turned. If possible, turn the rotor by hand and make sure that the rotor turns freely and that no abnormal sound can be heard. Check the assembly of the main terminal box and cooling system. Check the connection of oil and cooling water pipes and check for leaks when running, if applicable. Check pressure and flow for oil and cooling water, if applicable. Check that all transport locking devices are removed.

5.3 Check of electrical installation


The power cables can be permanently connected to the terminals in the main terminal box when the stator insulation resistance has been measured, see Chapter 7.5 Maintenance of stator and rotor winding. Check connection of power cables: Check that the fixing bolts are tightened with proper torque

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Check that the power cables are suitably routed and do not cause any additional strain to the terminal bars. Check that the power cables are stress-relieved in a proper way. Check the connections of the auxiliary equipment. Check the tightness of the cable glands and enclosure sealing. Check that the fixing bolts are tightened with proper torque.

If the cable glands are delivered separate:

5.4 Insulation resistance measurements


A comprehensive measurement of winding insulation resistances and of all auxiliary devices has to be carried out before making electrical connections and before applying voltage to the machine. The insulation of at least the following parts should be measured: Stator and rotor winding, exciter winding, bearing insulation (if both bearings are insulated), Pt-100 detectors, and space heaters. The measured values indicate the condition of the insulation between the winding (or other circuit to be tested) and the frame of the machine. For detailed information on how to conduct these measurements see Chapter 7 Maintenance. If the insulation resistance is under the specified value, actions must be taken to correct it prior to starting the machine. See Chapter 7 for corrective actions. Carry out the insulation resistance measurements in good time before the first start so you will have time for any necessary actions. The winding has to be dry during the test and therefore the anticondensation heaters should be active during the storage and installation phase before the testing is performed.

5.5 Starting
Start-up of the machine The starting of the machine depends on the application, but main guidelines are: 1. 2. 3. 4. 5. 6. 7. Switch the space heaters off if not operated by switchgear. Start to rotate the machine. Maintain rated speed. Switch the machine excitation on. Maintain rated voltage. Check sychronizing parameters. Synchronize the machine to the grid. U = 2 % f = 0.7 % phase angle less than 15

Recommended values for syncronizing are:

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Maximum values U = 4.5 %, f = 4.0 % should not be exceeded. NOTE: Operation of the machine at reduced speed under 75% of rated speed should be avoided.

5.6 Checks during running of the machine


During the first days of running it is important to keep a close surveillance of the machine in case of any changes in vibration or temperature levels or abnormal sounds should occur.

5.6.1 Normal vibration levels


The following instructions are part of the following two ISO standards: ISO 10816-3:1998 Mechanical vibration - Evaluation of machine vibration by measurements on non-rotating parts: Part 3: Industrial machines with nominal power above 15 kW and nominal speeds between 120 r/min and 15 000 r/min when measured in situ and ISO 8528-9:1995 Reciprocating internal combustion engine driven alternating current generating sets: Part 9: Measurement and evaluation of mechanical vibrations.

5.6.1.1 Measurement procedures and operational conditions


The general procedures described in ISO 10816-1 shall be used, subject to the recommendations set out below. Measurement equipment The measurement equipment shall be capable of measuring broad-band r.m.s. vibration with flat response over a frequency range of at least 10 Hz to 1 000 Hz, in accordance with the requirements of ISO 2954. Depending on the vibration criteria, this may require measurements of displacement or velocity or combinations of these (see ISO 10816-1). However, for machines with speeds approaching or below 600 r/min, the lower limit of the flat response frequency range shall not be greater than 2 Hz. NOTE. If the measurement equipment is also to be used for diagnostic purposes, an upper frequency limit higher than 1 000 Hz may be necessary. Care should be taken to ensure that the measuring system is not influenced by environmental factors such as: temperature variations; magnetic fields; sound fields; power source variations; transducer cable length; transducer orientation.

Particular attention should be given to ensure that the vibration transducers are correctly mounted and that such mountings do not degrade the accuracy of the measurements. Measurement locations Measurements will usually be taken on exposed parts of the machine that are normally accessible. Care shall be taken to ensure that measurements reasonably represent the vibration

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of the bearing housing and do not include any local resonances or amplification. The locations and directions of vibration measurements shall be such that they provide adequate sensitivity to the machine dynamic forces. Typically, this will require two orthogonal radial measurement locations on each bearing cap or pedestal, as shown in Figure 5-1 Measuring points. The transducers may be placed at any angular position on the bearing housings or pedestals. Vertical and horizontal directions are usually preferred for horizontally mounted machines. For vertical or inclined machines, the location that gives the maximum vibration reading, usually in the direction of the elastic axis, shall be one of those used. In some cases it may be recommended to measure also in the axial direction. The specific locations and directions shall be recorded with the measurement. Operational conditions Measurements shall be carried out when the rotor and the main bearings have reached their normal steady-state operating temperatures and with the machine running under specified conditions; for example at rated speed, voltage, flow, pressure and load. On machines with varying speeds or loads, measurements shall be made under all conditions at which the machine would be expected to operate for prolonged periods. The maximum measured value under these conditions shall be considered representative of vibration severity. If the measured vibration is greater than the acceptance criteria allowed and excessive background vibration is suspected, measurements should be made with the machine shut down to determine the degree of external influence. If the vibration with the machine stationary exceeds 25 % of the value measured when the machine is running, corrective action may be necessary to reduce the effect of background vibration.

Figure 5-1

Measuring points

5.6.1.2 Evaluation of RIC engine generating sets


The main excitation frequencies of the RIC engine (Reciprocating Internal Combustion) itself are found in the range 2 Hz to 300 Hz. However, when considering the overall generating set structure and components, a range of 2 Hz to 1000 Hz is required to evaluate the vibration. Additional testing may be necessary to ensure that no local structural resonances contribute to the measurement result.

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Assessment of the potential effects of the vibration are made by reference to Table 5-1. Vibration velocity, Vrms which gives rms values of vibration displacement, velocity and acceleration. These values can be used as guidelines for evaluating the measured vibration levels. Experience has shown that with a standard design of generating set structure and components, damage would not be expected if vibration levels remain below value 1. If the vibration levels fall between values 1 and 2, assessment of the generating set structure and components may be required along with an agreement between the generating set manufacturer and the component supplier in order to ensure reliable operation. In some cases vibration levels can be above value 2 but only if individual special designs of generating set structure and components are applied. In all cases the generating set manufacturer remains responsible for the compatibility with each other of the generating set components (see ISO 8528-5:1993, 15.10).

Table 5-1. Vibration velocity, Vrms Declared engine speed [rpm] >1300 but <2000 >720 but <1300 Value 1 [mm/s] 20 18 15 Value 2 [mm/s] 28 22 20

<720
Additional information

For more details about vibration measuring, please see the following International Standards where applicable: ISO 2954 Mechanical vibration of rotating and reciprocating machinery - Requirements for instruments for measuring vibration severity ISO 5348 Mechanical vibration and shock - Mechanical mounting of accelerometers ISO 7919 Mechanical vibration of non-reciprocating machines - Measurements on rotating shafts and evaluation criteria ISO 8528 Reciprocating internal combustion engine driven alternating current generating sets ISO 10816 Mechanical vibration - Evaluation of machine vibration by measurements on non-rotating parts.

5.6.2 Temperature levels


The temperatures of the bearings, stator windings and cooling air should be checked when the synchronous machine is running. The bearings may not reach a stable temperature until after several (2-6) hours, when running at full speed.

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

The stator winding temperature depends on the load of the machine. If full load cannot be obtained during or soon after commissioning, the present load and temperature should be noted and included in the commissioning report. Recommended settings for alarm and trip levels, see main connection diagram in Section 5, Electrical Drawings.

5.7 Shut down


Shut-down of the machine The shut-down of the machine depends on the application, but main guidelines are: 1. 2. 3. 4. 5. Reduce the output of the machine to zero. Open the main breaker. Switch the machine excitation off. Stop the engine. Switch the space heaters on if not automatically done by switchgear.

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Chapter 6 Operation

6.1 Start up procedure


Always before starting up the synchronous machine it has to be ensured that: Bearings are filled with oil to correct level in accordance with manufacturers technical specifications and machine outline drawing data. See Section 3, Technical Specification and Section 4, Mechanical Drawings for details. No shutdown means are in operation. Personnel and equipment associated to the machine are ready to start up the machine. For start-up procedure, see Chapter 5.5 Starting.

6.1.1 Start interlocking


If the lubricating or cooling systems are provided with pressure or flow monitors, these shall also be included in the start interlocking. A counter for the number of starts and a duty time meter should be included in the system.

6.2 Continuous supervision


The operating personnel should inspect the synchronous machine at regular intervals. This means that they should listen, feel and smell the synchronous machine and its associated equipment in order to obtain a feeling for normal operating condition. The object of the supervision inspection is to thoroughly familiarise personnel with the equipment. This is essential in order to detect and fix abnormal occurrences in time. It is therefore recommended that a supervision inspection sheet, preferably like the one in Table 6-1 Recommended supervision inspection program.is filled in. Data from a supervision inspection should be kept for future reference and can be of help at maintenance work, troubleshooting and repairs. The difference between supervision and maintenance is rather diffuse. Normal supervision of operation includes logging of operating data such as load, temperatures etc., and the comments made are used as a basis for maintenance and service. During the first period of operation (- 200 hours) supervision should be intensive. Temperature of bearing and windings, load, current, cooling, lubrication and vibration shall be checked frequently. During the following duty period (200 - 1000 hours) a check-up once a day is sufficient. A record of supervision inspection should be used and filed with the customer. There after the time between inspections may be further extended if operation is continuous and stable.

6.3 Shut down procedures


The synchronous machine is stopped by switching the main breaker open. Excitation shall be switched off.

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

When the synchronous machine is not in operation, anticondensation heaters have to be switched on. This is to avoid condensation effect inside the machine. For detailed shut down instructions, see Chapter 5.7 Shut down

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Table 6-1. Recommended supervision inspection program. Machine type: Point of inspection Stator current Excitation current Bearing temperature, D-end Bearing temperature, N-end Serial number: Date: kA A
o

oC o o

C C

Winding temperature, 1U Winding temperature, 1V Winding temperature, 1W Winding temperature, 2U Winding temperature, 2V Winding temperature, 2W Cold air temperature, D-end Cold air temperature, N-end Hot air temperature, D-end Hot air temperature, N-end Vibration level, D-end / axial /vertical / horizontal Vibration level, N-end / axial / vertical / horizontal Quantity of coolant Water leakage Oil flow/oil pressure Oil leakage Fault indication Other observations / comments:

oC o o o

C C C

oC o o

C C

oC oC o

Vrms [mm/s] Vrms [mm/s] Vrms [mm/s] Vrms [mm/s] Vrms [mm/s] Vrms [mm/s] m3/h (YES/NO) l/min / bar (YES/NO) (YES/NO)

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Chapter 7 Maintenance

7.1 Preventive maintenance


A synchronous machine often forms an important part of a larger installation and if it is supervised and maintained properly it will be reliable in operation and guarantee a normal life time. The difference between supervision and maintenance is rather diffuse. Normal supervision of operation includes logging of operating data such as load, temperatures, bearing lubrications etc., and the comments made are used as a basis for maintenance and service. After commissioning or maintenance supervision should be intensive. Temperature of bearing and winding, load, current, cooling, lubrication and vibration shall be checked frequently. In this section you can find our recommendations regarding maintenance program and work instructions how to conduct common maintenance tasks. Read these instructions and recommendations carefully and use them a basis when planning the actual maintenance program most suitable the local conditions. Note that the recommendations should be viewed to form the minimum level of maintenance. By intensifying maintenance activities the machine's reliability and the long-term availability increase also. We recommend also using experts in the creation of the maintenance program as well as in performing the actual maintenance. ABB After Sales organisation would be glad to assist on both of these issues. The ABB After Sales' contact information can be found in Chapter 9. An essential part of the preventative maintenance is to have a selection of spare parts available. The quickest way to have access to the spare parts is to keep the often needed and most crucial parts at your own stock. Ready made spare part packages can be bought from the ABB After Sales.

7.2 Safety precautions


Before working on any electrical equipment, general electrical safety precautions are to be taken and local regulations are to be respected in order to prevent personnel accidents. This should be done according to instructions of the customer's personnel in charge of security. Employees who perform maintenance on electrical equipment and installations shall be qualified persons as required and shall be trained in and familiar with the specific maintenance procedures and tests required for medium voltage rotating machines. For general safety instructions, see Section 1, Introduction.

7.2.1 Particular safety instructions for winding maintenance


Some of the hazardous works of the winding maintenance include: handling hazardous solvents, varnishes, and resins. Some hazardous substances are required for cleaning and revarnishing the windings. These substances can be dangerous if inhaled, swallowed or in any contact with skin or other organs. Seek proper medical care if accidents occur. dealing with flammable solvents and varnishes. Handling and use of these substance

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should always happen by authorized personnel and proper safety procedures should be followed. testing at high voltage (HV). High voltage test should be conducted only by authorized personnel and proper safety procedures should be followed.

Some dangerous substances are: white spirit: solvent 1.1.1-trichloroethane: solvent finishing varnish: solvent and resin adhesive resin: epoxy resin

There are special instructions for handling dangerous substances during maintenance work. Important handling instructions can also be found on warning labels of the packing. Some general safety measures are as follows: Avoid breathing air fumes; ensure proper air circulation at the work site or use respiration masks. Wear safety gear such as glasses, shoes, hard hat and gloves and suitable protective clothing to protect the skin. One should always use protective creams. Spray-varnish equipment, the frame of the machine, and the windings should be earthed during spray-varnishing. Do not smoke, eat, or drink at the work site. Take necessary precautions when working in pits and cramped places. Only people trained to do high voltage work can carry out a voltage test.

For a test record for winding maintenance, see Chapter 9, Check Lists

7.3 Maintenance of general construction


To ensure long life span for the general construction of the machine, the machine exterior should be kept clean and should periodically be inspected for rust, leaks and other defects. Dirt on the machine exterior exposes the frame for corrosion and can also affect the cooling of the machine.

7.3.1 The tightness of fastenings


The tightness of all fastenings should also be checked regularly. Special care should be focussed to the grouting, anchored bolts and rotor parts, that should remain correctly tightened at all times. Loose fastening in these parts can lead to sudden and severe damage to the whole machine. General values for tightening torques is presented in Table 7-1 General tightening torques (combined stress 0.75 times yield stress). NOTE: These values do not apply for diodes, support insulators, bearings, cable terminals or pole fastenings, bus bar terminals, surge arrestors, capacitors, current transformers, rectifier and thyristor bridges or if some other value is given elsewhere in this manual

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or in the mechanical and electrical drawings, see Section 4, Mechanical Drawings and Section 5, Electrical Drawings. Tightening torque / Nm (Property class 8.8) Size M4 M5 M6 M8 M 10 M 12 M 14 M 16 M 20 M 24 M 27 M 30 M 36 M 39 M 42 M 48 Oiled (=0.14) 2,7 5,0 9 22 44 75 120 180 360 610 900 1200 2100 2800 3400 5200 Dry (=0.16) 3,0 5,5 9,5 24 46 80 130 200 390 660 980 1300 2300 3000 3600 5600

Table 7-1. General tightening torques (combined stress 0.75 times yield stress)

7.3.2 Vibration and noise


High or increasing in vibration levels indicate changes in the machine's condition. Normal levels vary greatly depending on the application, type and foundation of the machine. The vibration measurements and levels are discussed in detail in Chapter 5 Commissioning. Some typical reasons that might cause high noise or vibration levels are: Alignment and air gap, see Chapter 3 Alignment Bearing wear or damage, see Section 7, Accessory Information Vibration from connected machinery, see Chapter 5 Commissioning Loose fastenings or anchor bolts, see Chapter 3 Alignment Rotor imbalance Coupling

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7.4 Maintenance of lubrication system and bearings


This section covers the most important maintenance tasks in the bearings and in the lubrication system. Other relevant information about bearing and lubrication can be found in Section 7, Accessory Information and Section 4, Mechanical Drawings.

7.4.1 Lubrication
The machines are equipped with sleeve bearings with a very long service life provided that the lubrication functions continuously and that the oil type and quality are as per ABB recommendations and that oil change instructions are followed, see Main Dimension Drawing in Section 4, Mechanical Drawings.

7.4.1.1 Lubrication oil temperature


The correct lubrication oil temperature is essential in keeping the bearing at the correct operating temperature and in ensuring sufficient lubrication effect and the correct viscosity of the lubrication oil. For machines equipped with oil supply the poor operation of oil cooler or heater and incorrect oil flow can cause oil temperature problems. For all bearings the correct oil quality and quantity need to be checked if temperature problems appear. For more information see Chapter 7.4.1.3 Condition of the lubricant and Chapter 7.4.1.4 Oil qualities.

7.4.1.2 General characteristics of the listed oil qualities


The oil is a lubricant based on paraffin having high viscosity index value (VI>90) and a particularly low fluid temperature. It includes the following additives: oxidation and rust inhibitor anti-foaming mild EP action, anti-wear additive

7.4.1.3 Condition of the lubricant


Check the oil with respect to color, smell, turbidity and deposits in a test bottle. The following requirements shall be fulfilled: The oil should be free from debris, and its cleanliness according to ISO 4406 class 18/15, or NAS 1638 class 9. The quantity of metal impurities should be less than 100 PPM. The oil should be clear or negligibly turbid. The turbidity may not be caused by water. Strong acid or burnt smell is not acceptable.

The original viscosity must be maintained within a tolerance of 10-15%. The original acid number should not be exceeded by more than 1 mg KOH pergram oil. An oil check should be performed a few days after the first test run of the machine and subsequently as required. If the oil is changed just after the commissioning, it can be used again after removing wear particles by filtering or centrifuging. In doubtful cases an oil sample may be sent to the laboratory to determine viscosity, acid number, foaming tendency, etc.

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

7.4.1.4 Oil qualities


Unless otherwise stated on ABB Oy drawings, the bearings are designed for any of the following oil qualities: ISO VG 46 Viscosity 46 cSt at 40 C Environmentally Benign Oils: Esso: Mobil: Shell: Mineral Oils: Aral: BP: Castrol: Chevron: DEA: Esso: Fuchs: Klber: Mobil: Shell: Total: Degol CL 46 Energol CS 46 PERFECTO T 46 MECHANISM LPS 46 Astron HL 46 TERESSO 46 RENOLIN DTA 46 LAMORA HLP 46 Mobil DTE Oil Medium Tellus l C 46 Azolla ZS 46 HYDRAULIKOEL HE 46 EAL Syntraulic 46 Naturelle HF-E 46

7.4.1.5 Oil change schedule for mineral oils


For self-lubricated bearings cleaning intervals with oil changes of approx. 4000 operating hours are recommended and approx. 20000 operating hours for bearings with oil circulation systems. Shorter intervals may be necessary in case of frequent start-ups, high oil temperatures or excessively high contamination due to external influences.

7.4.2 Sleeve bearings


In normal operating conditions sleeve bearings require little maintenance. To ensure reliable operation the oil level and the amount of oil leakage should be regularly checked. For more detailed information about the bearings see Section 7, Accessory Information.

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7.4.2.1 Oil level


The oil level of a self-lubricated sleeve bearing needs to be checked regularly. The minimum oil level is the bottom of the oil sight glass, the maximum oil level is in the top of the oil sight glass and normal level is in the middle of the sight glass. If necessary, refill with suitable lubricant, see Section 4, Mechanical Drawings and Chapter 7.4.1.4 Oil qualities.

7.4.2.2 Oil leakage


The construction of a sleeve bearing is such that it is very difficult to avoid oil leakage completely, and therefore small amounts of leakage should be tolerated. Oil leakage can, however, also appear because of reasons other than the bearing design such as incorrect oil viscosity, over pressure inside the bearing, under pressure outside the bearing, or high vibration levels at the bearing. If excessive oil leakage is noted, please check/verify the following: Verify that the oil used is according to specifications, see Section 4, Mechanical Drawings and Chapter 7.4.1 Lubrication. Re-tighten the bearing housing halves, and the labyrinth seal cover. This is especially important if the synchronous machine has been stopped for a long time, see Section 7, Accessory Information. Measure the vibrations of the leaking bearing in three directions under full load, see Chapter 7.4.1 Lubrication. If the vibration level is high, the bearing housing might "loosen" just enough to permit the oil to wash away the sealant between the housing halves. Open the bearing, clean the surfaces and apply new sealant between the bearing housing halves, see Section 7, Accessory Information. Verify that there isn't anything, which might cause low pressure next to the bearing. A shaft or coupling cover can for instance be designed so that it will cause low pressure near the bearing. Verify that there isn't overpressure inside the bearing. Overpressure may be entering the bearing through the oil outlet piping from the oil lubrication unit. Apply breathers or vents to the bearing housing as to relieve the over pressure from the bearing. In case of forced bearing lubrication system, check that the slope of the oil outlet pipes is sufficient.

If excessive oil leakage is found even after all of the above mentioned things have been checked and verified, please fill in the form Oil Leakage's at RENK Slide Bearings in Section 9, Check Lists, and send it to the after sales and market support department, see Chapter 9 After Sales and Market Support.

7.4.2.3 Bearing temperature


The bearing temperatures are measured by Pt-100 resistance temperature detectors. The normal bearing temperature should be 65 - 85 C. Since temperature rise is caused either by increased losses in the bearing or decreased cooling capacity, it often indicates a problem somewhere in the machine or in the lubrication system and should be therefore closely monitored. The factory

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

set alarm and trip limits are stated in the Main Connection Diagram, see Section 5, Electrical Drawings. The reasons for abnormal bearing temperature vary, but for some possible reason see Chapter 7.4.1 Lubrication or Chapter 7.10 Troubleshooting. If the temperature rise is followed by an increase vibration levels the problem might also be related to the machine's alignment, see Chapter 3 Alignment or to a damage in the bearing shells in witch case the bearing needs to be dismantled and checked, see Section 7, Accessory Information.

7.4.3 Bearing insulation resistance check


Bearing insulation resistance check is a maintenance operation done primarily in the factory during final assembly and tests. It should also be done during all comprehensive overhauls of the machine. Good insulation is necessary in order to eliminate the possibility of circulating bearing currents, that might be induced by shaft voltages. Insulation of non-drive-end bearing cuts the path of the bearing current and thus eliminating the risk of bearing damages due to bearing currents. The drive-end shaft of an electrical machine must be earthed, because an unearthed shaft would have an unknown electrical potential compared to the surroundings and would therefore be a potential source of injury. However, to make the testing of the non-drive-end bearing insulation easier the drive-end bearing is also often insulated. This insulation is then short circuited by an earthing cable during normal operation. See Figure 7-1 D-end bearing earthing cable.

7.4.3.1 Procedure
For machines with an insulated drive-end bearing, the short-circuit earth cable in drive-end bearing must be removed prior of commencing the non-drive-end bearing insulation resistance test. If the drive-end bearing is not insulated, the non-drive-end bearing insulation resistance test requires the removal of drive-end bearing shells or removal of the bearing housing cover and lifting of the shaft, so that there is not contact between with the lower bearing housing half and the shaft. Therefore, when the drive-end bearing is non-insulated, the measurement of the nondrive-end bearing should only be conducted by qualified personnel.

Figure 7-1. D-end bearing earthing cable

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

For all machines the optional shaft earthing brush, rotor earth fault brush and coupling (if it's made out of conductive material) must also be removed. Measure the insulation resistance from the shaft to the ground using no more than 100 VDC. See Figure 7-2 The testing of bearing insulation resistance. Insulation resistance is acceptable if the resistance value is more than 10 k.

Figure 7-2. The testing of bearing insulation resistance

7.5 Maintenance of stator and rotor winding


The windings of rotating electrical machines are subject to electrical, mechanical and thermal stresses. The windings and insulation gradually age and deteriorate due to these stresses. Therefore, the service life of the machine often depends on the insulation durability. Many processes leading to damages can be prevented or at least slowed down with appropriate maintenance and regular testing. This chapter offers a general description on how to perform basic maintenance and tests. In many countries ABB Service also offers complete service maintenance packages, that include comprehensive testing. Before conducting any maintenance work on the electrical windings general electrical safety precautions are to be taken and local regulations are to be respected in order to prevent personnel accidents. See Chapter 7.2 Safety precautions for more information. Independent test and maintenance instructions can also be found in the following international standards: 1. 2. 3. IEEE Std. 43-2000, IEEE Recommended Practice for Testing Insulation Resistance of Rotating Machines IEEE Std. 432-1992, IEEE Guide for Insulation Maintenance for Rotating Electrical Machinery (5 hp to Less Than 10 000 hp) IEEE Std. 522-1992. IEEE Guide for Testing Turn-to-Turn Insulation on Form Wound Stator Coils for Alternating-Current Rotating Machines

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

7.5.1 The timing of the maintenance


There are three main principles for timing the winding maintenance: Maintenance of the windings should be arranged according to other machine maintenance. Maintenance only when necessary. Important machines should be serviced more often than the less important ones. This also applies to windings that become contaminated rapidly and to heavy drives.

As a thumb rule an insulation resistance test should be done once a year. This should suffice for most machines in most operating conditions. Other tests should only be conducted if problems arise. A maintenance program for the complete machine, including windings, is presented in Chapter 7.8 Maintenance program. This maintenance program should, however, be adapted to customer's particular circumstances i.e. servicing of other machines and operating conditions as long as recommended servicing intervals are not exceeded.

7.5.2 The correct operating temperature


The correct temperature of the windings is ensured by keeping the exterior surfaces of the machine clean, by seeing to the correct operation of the cooling system and by monitoring the temperature of the cooling agent. If the cooling agent is too cold, water may condense inside the machine. This can wet the winding and deteriorate the insulation resistance.

7.5.3 Insulation resistance test


During general maintenance work and before the machine is started up for the first time or after long standstill period, the insulation resistance of stator and rotor windings must be measured. The insulation resistance measurement provides information about the humidity and dirtiness of the insulation. Based upon this information, correct cleaning and drying actions can be determined. For new machines with dry windings the insulation resistance is very high. The resistance can, however, get extremely low if the machine has been subjected to incorrect transportation and storage conditions and humidity or if the machine is operated incorrectly. The insulation resistance readings should be taken after the test voltage has been applied for one (1) minute. The measured values should be recorded for reference. The winding temperature should also be recorded.

7.5.3.1 Conversion of measured insulation resistance values


According to normal standards the winding insulation resistance is to be stated at a winding temperature of 40C. The value measured is therefore converted to a corresponding 40C value, with the help of the following diagram in Figure 7-3 Correlation between the insulation resistance and the temperature. The use of this diagram should be limited to temperatures fairly near to the standard value of 40C, since large deviations from it could result in errors.

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Figure 7-3. Correlation between the insulation resistance and the temperature R = Insulation resistance value at a specific temperature R40 = Equivalent insulation resistance at 40C R40 = k x R Example: R = 30 M measured at 20C k = 0.25 R40 = 0.25x30=7.5 M
oC o

0 32

10 50

20 68

30 86

40 104

50 122

60 140

70 158

80 176

90 194

100 212

110 230

Table 7-2. Temperature values in degrees Celsius (C) and degrees Fahrenheit (F)

7.5.3.2 General considerations


The following consideration should be noted, before making deciding any actions based upon the insulation resistance tests:

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If the measured value is considered too low the winding must be cleaned and/or dried, see Chapters 7.3.3.9 and 7.3.3.10 for details. If these measures are not sufficient expert help should be acquired. Machines, that are suspected to have moisture problem, should be dried carefully independent on the measured insulation resistance value. The insulation resistance value will decrease when the winding temperature rises. The resistance is halved for every 10 ... 15 K temperature rise. The value is dependant of the measurement equipment.

The insulation resistance indicated in the test report is normally considerably higher than the values measured on site.

7.5.3.3 Minimum values for insulation resistance


The minimum values for safe starting The machine can be safely started if the insulation resistance values at 40 C exceed the following values: Rotor R(40)> 1,5 M Stator R(40)> U+1 M Where R(40)= Equivalent insulation resistance at 40 C. U = The rated machine voltage in kV. Even though, the machine can be safely started at these values, a low insulation resistance in the stator winding may indicate severe moisture or other problems in the winding. Criteria for windings in a normal condition Generally the insulation resistance values for dry windings should exceed the minimum values significantly. Definite values are impossible to give, because resistance varies depending on i.e. the machine type and local conditions. Also the insulation resistance is affected by the age and usage of the machine. Therefore, the following values can only be considered as guidelines. Rotor For new rotors: R(40)> 10 M For used rotors: R(40)> 1,5 M Stator For new stators: R(40)> 1000 M For used stators: R(40)> 100 M

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7.5.3.4 Stator winding insulation resistance measurement


The insulation resistance is measured using a special DC tester. The test voltage for the stator winding insulation resistance is 1000 VDC. Before the insulation resistance test is conducted, the following actions must be taken: Check that the secondary connections of the current transformers (CT's), including spare cores are not open. See Figure 7-4 a). All power supply cables are disconnected. The frame of the machine and the stator windings not been tested are earthed. All resistance temperature detectors are earthed. Winding temperature is measured. Possible earthing of voltage transformers (not common) must be removed. Measured insulation resistance values are compared to values given in the test report. See Section 9, Test Reports.

The measuring should be carried out in the terminal box and from the synchronising circuit breaker. The test usually performed to the whole winding as a group, in which case the tester is connected between the frame of the machine and one winding (or circuit). The frame is earthed and the three phases of the stator winding remain connected at the neutral point, see part A of Figure 7-4 Connection for main machine stator winding insulation resistance test. In the figure M represents insulation resistance tester. If the measured insulation resistance of the whole winding is lower than specified, and the phase windings can easily be disconnected from each other, each phase can also be measured separately. This is not possible in all the machines. In this measurement the tester is connected between the frame of the machine and one of the windings. The frame and the two phases not measured are earthed, see part B of Figure 7-4 Connection for main machine stator winding insulation resistance test. In the figure M represents insulation resistance tester. NOTE: When phases are measured separately, all star-points of the winding system must be removed. If the star-point of the component cannot be removed, as in typical triphase voltage transformer, the whole component must be removed.

Figure 7-4. Connection for main machine stator winding insulation resistance test

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NOTE: After the insulation resistance measurement the winding phases must be earthed to discharge them

7.5.3.5 Rotor field winding insulation resistance measurement


The test voltage for the rotor windings should be 500 VDC. When testing the insulation resistance of the rotor, begin by disconnecting (lifting) the rotor earth fault brushes from slip ring, if applicable. See Figure 7-5 Connection for main machine field winding insulation resistance test, where M represents insulation resistance tester. Insulation resistance measurement should be performed at the slip ring for rotor earth fault brush or rectifier bridge connection to the main rotor. NOTE: If the machine is equipped with a rectifier, the rectifier has to be short circuited before measuring.

Figure 7-5. Connection for main machine field winding insulation resistance test NOTE: After the insulation resistance measurement the winding phases must be earthed to discharge them.

7.5.4 The polarization index


For the polarization index test the insulation resistance is measured after the voltage has been applied for 15 seconds and 1 minute (or 1 minute and 10 minutes). The polarization index test is less dependent on the temperature than the insulation resistance. When the winding temperature is below 50C (122F), it may be considered independent of temperature. High temperatures can cause unpredictable changes in the polarization index, so it should not be used above 50C (122F). The dirt and humidity accumulating in the winding normally reduce the insulation resistance and the polarization index as well as their dependence on temperature. Thus, the line in Figure 7-3 Correlation between the insulation resistance and the temperature becomes less steep. Windings with open creepage distances (e.g. from squirrel cage) are very sensitive to the effects of dirt and humidity. There are several rules for determining the lowest acceptable value with which the machine can be safely started. For the polarization index (PI), the values usually range between 1 and 4. Values close to 1 indicate that the windings are humid and dirty. As a thumb rule the following minimum values may be applied to the PI: Maintenance - 13

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

for class A machines PI = 1,5 for class B-F machines PI = 2,5

where PI =

R1 min R10 min or R15 s R1 min

The use of PI-values has lessened because it occasionally gives misleading values. For instance, some very low PI values have been measured with modern epoxy-mica insulations although the windings have been dry and the insulation resistance high (thousands of M). When estimating a machine's ability to start after a standstill, the insulation resistance is more important than the polarization index.

7.5.5 High voltage test


A voltage test is used to check for electrically weak spots in the windings that may lead to insulation failure during servicing. It is carried out with major inspections, trouble shooting and repairs. DC or AC voltage is used for the over voltage test. DC voltage tests, although seldom performed, use 1,6 times the root-mean-square value of the machine's rated AC voltage or 2,5 times the DC voltage.

7.5.5.1 High voltage test for stator winding


AC voltage tests use the following test voltages: for service and repair: 1,2 U + 400[V] for periodical tests: 1,5 U[V]

where U = main voltage [V]. NOTE: The higher voltage test is always used for modern epoxy-mica insulations.

7.5.6 Fault searching methods


7.5.6.1 Voltage drop test (Rotor winding impedance test)
The main rotor field winding can be tested by applying 100-200 VAC over the entire rotor winding. The voltage drop across the total winding and each pole winding is measured. The voltage drop over each pole winding should be the test voltage divided by the number of poles in series. If the voltage drop measured over the pole windings varies significantly, it may be an indication of a possible turn-to-turn short circuit, connection error or broken lead.

7.5.7 Tan delta-measurements


Tan delta, representing the dielectric and discharge energy losses, is measured in steps of 0.2 U up to the main voltage U. The rate of rise of tan delta as a function of voltage describes the average partial discharge level both inside and on the surface of the insulation. This makes it difficult to determine the condition inside the insulation. It is emphasized that tan delta measurements can not estimate the age or predict failure of the insulation. Only regular trend measurements can reveal more information.

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7.5.8 Visual winding inspection


Winding inspections reveal information about: the rate of contamination; presence of dirt and humidity radiator condensation and leakage stability of bracings, vibration marks, and cracking marks of overheating marks of movement tightness of the slot wedges especially information about winding overhangs and their supports

All inspections should be recorded on the check list supplied in Section 9, Check lists. When examining the contamination, particular attention should be paid to the open creepage surfaces, as the insulation resistance is easily affected by the dirt accumulating there. Open creepage surfaces exist e.g. in brush gear and in connections. Accumulating dirt blocking coil gaps and air ducts diminishes the cooling capacity of the machine. As a result, the winding temperature increases, and the ageing may speed up considerably. Mechanical strain, vibration, and shocks may produce cracks on the edges of the supports, tyings, and around slot ends. Loose supports and slot wedges are signs of further deterioration. Abrasion marks and powder near the supports, tyings, and at the slot ends, must be checked. Complete loosening of the slot wedges and bent coils are serious problems that must be rectified immediately. Hair cracks and fractures in metal parts such as supporting bolts and squirrel cage windings are also signs of deterioration, but they take longer to develop a failure. Humidity in the winding is often shown by the marks it leaves behind: rust on iron, drop marks, dripping, and wetting marks on dirt layers. Bush-like patterns, often charred and left behind by the tracking currents, warn of an approaching failure. In rare cases, conductors are corroded. Marks of the electrical effects (apart from tracking current marks), are usually hidden inside the slot and conductor insulations. Short period over temperatures can leave marks all over the machine. Copper in the squirrelcage windings grows darker (darkening may also be due to the gases in the environment), and it oxidizes. Core laminations of the rotor become blue (over 350C [662F]) if the temperature rises due to a jam or an exceedingly heavy start. Colour differences in the fastening bolts of synchronous machines are a sign of overheating. Insulation may shrink or split (usually over 200C [392F]), tyings may crack (over 220C [428F]), and polyester film or fibers may melt (over 250C [482F]). Swelling of the slot insulation is also possible. Prolonged period over temperatures cause premature ageing. The insulating materials become brittle and darken in the early stages, especially varnishes containing cellulose. As a result, the windings split, disintegrate, and fracture.

7.5.8.1 Corrective actions based upon the observations


According to the observations the following conclusions can be drawn for necessary actions:

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Observation Degree of contamination: - a lot of dirt, cooling ducts about to be clogged - conductive dirt, low insulation resistance - humidity, low insulation resistance Finishing varnish: - mat, worn, cracked - coming off Supporting parts: - loose slot wedges - vibration marks - bent coils Ageing: - darkening, slight embrittlement - embrittlement, loose insulation layer - tightening *

Action

- cleaning and drying, if necessary - cleaning and drying, if necessary - drying

- cleaning and revarnishing - removing old varnish and revarnishing

- tightening, strengthening and revarnishing * - strengthening or rewinding *

- cleaning and revarnishing - rewinding * = A statement from an expert is needed.

7.5.9 Cleaning the windings


Accumulating dirt in the open creepage surfaces should be removed. This is especially important when re-varnishing the windings because a new varnish coat will trap any existing dirt beneath the new coat.

7.5.9.1 Cleaning methods


Blowing and vacuuming Blowing and vacuuming are used if the dirt is dry and can be removed easily. Vacuuming is recommended, since blowing tends to redistribute the dirt or move it deeper between the insulation layers. Wiping Wiping is used when spray-wash is not possible. Surfaces easily reached are wiped clean with a cloth dampened with detergent. In cramped areas of the windings, a special brush may be more effective. Low insulation resistance is often caused by dirty slip rings and brush gear, so the creepage surfaces on these components should be carefully cleaned.

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Spray wash A spray wash is carried out with an airless high-pressure spray or a conventional spray. The high-pressure spray is more effective in removing dirt. The detergent used should remove the dirt without softening or damaging the insulation. Use excessive amounts of the cleaning agent. Dip wash A dip wash can be used if the detergent does not soften or damage the insulation. Since the dirt is not removed mechanically in this method, a very effective cleaning and scouring agent is needed. A long dipping time may be required. Water wash A water wash involves rinsing with water to prevent the detergents from penetrating into places where they can not be removed. A water wash is done if needed following the instructions given above for wiping, dip wash, or spray wash. The detergents used are described in Chapter 7.5.9.2 Cleaning agents. After washing, the windings are rinsed with pure water several times. It is recommended to use distilled or deionized water for the last rinse. Drying after the water wash is necessary.

7.5.9.2 Cleaning agents


Some features of the detergents are described in Table 7-3 Features of the detergents for the winding. Before any cleaning agent is used, its damaging effect on the old winding surface should be checked. A suitable test can be performed as follows: Using a cloth wet with the cleaning agent, rub the surface to be tested for five minutes. Make sure that the surface remains completely wet during this time. After rubbing, try to remove the finishing varnish by thumb nail. For comparison, do the same thing to a dry part of the surface. If the surface layer is soft or removed easily, the cleaning agent is too strong. For minimal environmental loading, water or water-detergent mixtures should be used when possible. If the dirt contains water soluble agents, water must be used. Substances that improve the cleaning power should be added to the water to dissolve greasecontaining dirt. These detergents should not leave electrically conductive residues on the surfaces. Water soluble solvents such as acetone and isopropyl alcohol can also be used to improve the cleaning effect. Note that such solvents increase the flammability of the mixture. If organic solvents must be used, cleaning agents based on aliphatic hydrocarbons are recommended. Several manufacturers of cleaning solvent mixtures are presently developing such halogen-free cleaning agents to replace the chlorinated solvent mixtures used in the past. White spirit is the most common organic solvent. It is a good solvent for greases but quite inefficient for pitch-like dirt on the windings (produced by coal and burning residues of diesel oil and humidity). White spirit is also flammable (flash point 30...40 C [86...104F]). The cleaning capacity of white spirit can be improved by adding 1.1.1-trichlorethane to the solvent, however, the use of chlorinated solvents is no longer recommended.

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DIRT Dissolving or reducing effect Dissolving or softening effect

Allowed concentration in air, ppm or cm3/m3 VARNISH OR RESIN

Detergent Salts Normal dust Silicone rubber Greasy coaldust Greasy woodpulp Epoxy and polyester resin Pitched diesel grime, fats, oils Red finishing varnish (epoxy, alkyd) 3 2 3 3 3 1

Proportion /

Consistency

Class of flammable liquids

Water (hot) 3 2

Incombustible

3 3

1-3

Water (hot) + detergent 1:20 (volume) Incombustible 1 I II I II 1000 100 200 400

1 2

3 3 3

Isopropylenealcohol

3 3

White spirit 140/200

3 2

Acetone

3 2

Table 7-3. Features of the detergents for the winding 2 2 3 3 200 Incombustible Not recommended 1:1 (volume) EXPLANATIONS II 200 Not recommended 2 3 3 1 Empty: Does not clean 1: Removes dirt poorly 2: Cleans reasonably 3: Cleans well

Xylene

3 2

1.1.1-trichloroethane

2 3 2

White spirit + 1.1.1-trichloroethane

Empty: Does not resist the solvent 1: Poor resistance of solvent 2: Satisfactory resistance of solvent 3: Good resistance of solvent

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7.5.10 Drying
The windings must be dried after washing (especially a water wash and rinse) or if they have become humid in use or during a standstill. The drying should always be started with an external blower or warm air. Other means should be attempted, only if blower and warm air do not suffice. The rate of temperature rise of the winding should not exceed 5 K (9F) per hour, and the final temperature should not exceed 105C (220F). A sudden temperature rise or a too high final temperature can cause steam to be formed in the cavities of the windings, which in turn can destroy the windings. During the drying process, the temperature should be monitored periodically, and the insulation resistance should be measured at regular intervals. A very wet machine should be dismantled and the winding dried in the oven. Every part should be checked. If the machine is not very wet, the winding can be dried by passing a current through it. If the winding is dried by passing current through it, the source of electricity could be i.e. a welding machine or a similar device. NOTE: Direct current or alternate current can be used. Current cannot exceed 25% of the value of the nominal current, which is indicated on the rating plate on the machine. The winding temperature must also be continuously monitored. When drying in an oven, the temperature rise and the maximum temperature should be monitored carefully. The oven temperature should be around 90C (194F) for 12 to 16 hours and then 105C (220F) for six to eight hours. This time can vary and the correct time should be monitored by insulation resistance test. Effective drying is achieved with the proper balance of heat and ventilation. The air inside the machine should be circulated in the most effective way. Drying in an oven with good ventilation is the most effective technique. Unfortunately, this is not usually possible at the machine's operating site. Therefore, either hot-air-blow or heating the windings with current should be used. Adequate fresh-air exchange is essential, whatever heating method is used. The drying of the windings should be followed by insulation resistance tests. At the beginning of the drying treatment, the insulation resistance decreases due to the temperature rise. As the drying continues, however, the insulation resistance increases until it reaches a stable value.

7.5.11 Varnishing of the windings


A finishing varnish is a varnish or a resin coat that is sprayed or brushed on the insulation. It is a protective layer that seals the windings, improves tracking resistance somewhat and makes cleaning easier. In new machines finishing varnish treatment is made optionally. The finishing varnish may after long operating time crack or peel off to certain extent. This can be corrected by giving the windings a new coat of finishing varnish. Re-varnishing is necessary when: the old finishing varnish flakes, cracks or peels off. the surface of the winding is rough (dirt sticks to it easily). the materials on the surface of the insulation or tyings have moved.

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The windings should be cleaned with utmost care before a new coat of varnish is given so that no dirt will be left under this new coat of varnish. Old finishing varnish that can come off easily should be removed. Varnish is usually applied with a spray (one or two coats suffices). If the windings are still warm after drying, the temperature should be less than 40C (104F). One should try to apply the varnish between the coils and other parts that are not easily reached. Thick coats of varnish should be avoided as they dry slowly. Rotating parts should be left to dry at least 24 hours at room temperature before bringing them into use. Solvent fumes from the varnishes are generally poisonous and flammable, so safety at work should be taken into account.

7.5.12 Other maintenance operations


Usually, ABB made winding are trouble free and in addition to periodical monitoring they require only occasional cleaning and drying as described above. If extraordinary circumstances occur and other maintenance is required, it is best to acquire professional help. ABB After Sales organization is eager to assist in question regarding maintenance of electrical machine winding, for contact information see Chapter 9, After Sales and Market Support.

7.6 Maintenance related to electrical performance, excitation, control, and protection


The electrical performance of a synchronous machine is mostly defined by the condition of rotor and stator windings and the operation of excitation system. The main machine winding maintenance is described in Chapter 7.5 Maintenance of stator and rotor winding. In this chapter the focus is on the maintenance of the excitation and the control and protection systems.

7.6.1 Exciter insulation resistance measurement


The insulation resistance in the exciter can be tested with winding insulation resistance test. The procedure is described in detail in Chapter 7.5 Maintenance of stator and rotor winding. The test voltage for the exciter stator should be 500 VDC and the test should be performed in the terminal box after the cables have been disconnected. The connection is shown in Figure 7-6. The exciter rotor is usually measured jointly with the rotor of the main machine, see Chapter 7.5.3.5 Rotor field winding insulation resistance measurement. The exciter rotor can also be measured separately, but this requires special arrangement.

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Figure 7-6. Connection for exciter stator insulation resistance test (M represents insulation resistance tester)

7.6.2 Protection trips


The synchronous machine needs to be protected with alarms and trips for abnormal running conditions, both electrical and mechanical. Some of these protections can be reset and the machine restarted directly as the fault is located Examples of protections that if they give an alarm or trip, may need further investigations: Diode fault protection, see later this chapter. High temperature in bearing, see Chapter 7.4 Maintenance of lubrication system and bearings. High temperature in winding or in cooling air, see Chapter 7.5 Maintenance of stator and rotor winding and Chapter 7.6 Maintenance related to electrical performance, excitation, control, and protection. Over current, current unbalance, bus bar voltage. Vibration protection, see Chapter 5 Commissioning.

7.6.3 Automatic voltage regulator (AVR)


The automatic voltage regulator (AVR) is an important part in the control and protection of the machine and problems in connections or settings of the AVR might lead to different types of operational faults. These include i.e. performance deviations and lost of excitation. For detailed information about AVR connection and settings see Section 5, Electrical Drawings and Section 7, Accessory Information. For AVR factory setting, see Section 8, Test Reports.

7.6.4 Pt-100 resistance temperature detectors


Pt-100 resistance temperature detectors are an essential part in the machine's condition monitoring and protection system. They are used to measure temperatures in the windings, bearings and in the cooling air. The Pt-100 detector use a fine platinum filament for the temperature measurement, which can be damaged i.e. by incorrect handling or excessive vibration. The following symptoms might suggest a problem in a Pt-100-detector:

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Infinite or zero resistance over the detector. Disappearance of measurement signal during or after start up. A significantly different resistance value in a single detector.

If a Pt-100 failure is suspected the findings should always be confirmed from the connection box, by measuring the resistance over the detector. The findings should also by registered. For the correct measuring current and resistance values at different temperatures see Section 7, Accessory Information and the appropriate Pt-100 detector. There are two possible remedies for a Pt-100 detector damage. If there are operational spare detectors remaining in the stator core, they can be taken into use. If all the working factory assembled detectors are in use a new detector can be retrofitted in the winding end, see Chapter 7.6.4.1 Pt-100 temperature detector retrofitting.

7.6.4.1 Pt-100 temperature detector retrofitting


Introduction The temperature detectors for form wound stator windings are typically installed between the two coils in the stator slot. This is why these detectors are not replaceable, and additional identical temperature detectors cannot be added. See Section 7, Accessory Information and the Pt-100 elements. However, in some cases additional temperature detectors of a different design may be needed and installed. This instruction describes how to add extra detectors to the stator winding head area. Installation place The copper lead in the stator winding is fully insulated through the whole coil, and the surface potential of the coil inside the stator core is very close to the potential of the stator core. However, the surface potential of the stator winding increases rather rapidly after the coil exits the stator core, and therefore it is important to try to place the temperature detector as close to the stator core as possible. If the nominal voltage of the stator winding is 1 kV or more, the temperature detector should preferably be installed on the coil, which is electrically close to the stator winding star point. This is particularly important when the nominal voltage of the stator windings is 10 kV or more. Installation Before installing a temperature detector, the function of it is verified. The temperature detector, e.g. Pt-100, should be installed near the stator core, see Figure 7-7 Temperature detector installation place.

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Figure 7-7. Temperature detector installation place Choose a coil of preferred phase, and which is electrically near the stator winding start point. If the nominal stator voltage is more than 4.2. kV, scratch the red and/or brown surface tape slightly so that the black conductive tape ends, or the grey semiconductive tape start point is visible. Paint a small area, approximately 30 mm with conductive paint. The overlap of the paint with the conducive tape should be at least 5 mm, see Figure 7-8 Conductive painting.

Figure 7-8. Conductive painting Contact with the winding A good contact between the coil and the detector is essential when the temperature detector is placed on the stator winding, as the purpose of the temperature detector is to monitor the temperature of the coil, not the surrounding air. Therefore the temperature detector should be placed as close to the coil surface as possible. The temperature detector should be placed on the coil using silicone padding 10 mm around the detector. The temperature detector is then covered with polyester felt with a total thickness of approximately 6 mm in order to make sure that the detector is not cooled by the ambient airflow. The felt is bound and impregnated using glass or Terylene tape and air-dry polyester or epoxy resin, see Figure 7-9 Temperature detector and cover should be impregnated and bounded tightly.

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Figure 7-9. Temperature detector and cover should be impregnated and bounded tightly

7.6.5 Insulation resistance measurement for auxiliaries


To ensure correct operation of the machines protections and other auxiliaries, their condition can be determined by an insulation resistance test. The procedure is described in detail in Figure 7.5 Maintenance of stator and rotor winding. The test voltage for the space heater should be 500 VDC and for other auxiliaries 100 VDC. The insulation resistance measurement for Pt-100 detectors is not recommended.

7.6.6 Diode fault


In case any of the diodes in the rotating rectifier should fail, the generator must be tripped. To determine and locate a faulty diode, open the covers at the non-drive end of the machine and measure the insulation resistance with an ohm-meter over one of the diodes. If diode failure is detected, disconnect all diodes and test them separately to locate the faulty diode. Do not open the service covers or end shields unless it is certain that the machine is isolated from its driving source. 1. 2. 3. 4. 5. 6. 7. 8. Open the service doors at N-end shield of the machine. Disconnect the wires connected to the diodes and exciter winding connection cables. See diode bridge/thyristor bridge drawing in Section 5, Electrical Drawings. Check condition of diodes by measuring resistance over a diode in both directions. Replace the damaged diode(s). Clean the contact surfaces, and apply electric joint compound. Fasten diode(s). Bind the connection leads of the diodes as on original assembly. Check fastening and locking of all rectifier bridge components. Make sure that no tools etc. are inside the machine and close the service covers.

After replacing the diodes, the condition of the diodes can be checked by comparing no-load excitation current to commissioning values. A diode failure results as a significant increase in excitation current.

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7.7 Maintenance related to thermal performance and cooling system


There are always two fundamental reasons that might cause an increase in the machine's temperature: The effect of the cooling system has declined The machine is producing excessive amount of heat

If the machine temperature exceed normal values, measures should be taken to determine which of these two causes is dominant in that particular incident. Excessive heat production might be caused i.e. by a winding problem or by network unbalance and in these cases corrective actions on the cooling system would be ineffective or harmful.

7.7.1 Cooling System


The machine is cooled with a shaft mounted fan. The cooling air is taken in from the surroundings through air filters situated at the non-drive end and it is blown out from the top and the sides of the machine at the drive end (IC 0A1). The cooling air should be as clean as possible because the dirt which drifts into the machine causes contamination and reduces the efficiency of the cooling. The air filters are self charging electrostatic panels of type Pliotron CR. They are constructed of washable, woven polyethylene fiber and incorporate a non-woven synthetic fiber mat. They are enclosed in a rust-resistant galvanized steel-frame and they are reinforced by 1/2" mesh galvanized steel hardware cloth. Their maximum operation temperature is +100C. If winding or cooling air temperature detectors show an abnormal temperature, a check of the cooling system has to be made. The two maintenance issues are to check the condition of air filters and to ensure good air circulation inside the machine. The machine interior should be cleaned and checked during overhauls or if problems arise. Other possible causes for poor cooling system performance might include elevated ambient temperature or high intake air temperature. In addition lubrication or bearing malfunction might lead to high bearing temperature. A seemingly high temperature might also be caused by a problem in the temperature measurement system, see Chapter 7.6.4 Pt-100 resistance temperature detectors.

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Figure 7-10. Air cooling

7.7.1.1 Cleaning
The filters should be cleaned on an established basis. When the temperature detectors in the winding show abnormal temperature or approach the alarm level, the filters have to be cleaned. If a pressure manometer is used, the filters have to be cleaned when the pressure drop has doubled. Remove the air filters for cleaning. They should regularly be cleaned by vacuuming first from the upstream side, then on the discharge side. Periodically, a thorough wash with clean water is recommended to release any dirt not removed by vacuuming. When heavy grease concentrations are encountered, the filters should be washed with a detergent solution. This solution should be rinsed thoroughly before returning the filter to service. Be careful to install the air filters back the right side out (arrows on the air filter frame indicate the direction of air flow). Refer also to air filter manufacturer information.

7.8 Maintenance program


In this chapter is presented a recommended maintenance program for ABB synchronous machines. This program is general in nature and should be considered as the minimum level of maintenance. Maintenance should be intensified when local conditions are demanding or very high reliability is required. It should also be noted that even when following this maintenance program normal supervision and observation of the machine's condition is required. Please note that even though we have customized the maintenance program to match your machine, it might contain references to accessories that you do not have.

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

The maintenance program is based on four levels of maintenance, that rotate according to operating hours. The amount of work and down time vary, so that level 1 includes mainly quick visual inspections and level 4 more demanding measurements and replacements. More information about the spare part packages suitable for these maintenances can be found in Chapter 7.9. The recommended maintenance interval can be seen in Table 7-4 Recommended maintenance program (one complete cycle). The operation hour recommendation in this chapter are given as equivalent operating hours (Eq. h), that can be counted by the following formula: Equivalent operating hours (Eq. h) = Actual operating hours + Number of starts x 20 Level 1 (L1) Level 1 or L1 maintenance consist of visual inspections and light maintenance. The purpose of this maintenance is to do a quick check whether problems are beginning to develop before they cause failures and unscheduled maintenance breaks. It gives also suggestions what maintenance issues must be performed in the next larger overhaul. The maintenance can be estimated to last approximately 4 - 8 hours, depending on the type and installation of the machine and the depth of the inspections. Tools for this maintenance include normal servicing tools i.e. wrenches and screw drives. The preparations consists of opening the inspection covers. It is recommended that at least the safety package spare parts are available when commencing this maintenance. The first Level 1 maintenance should be performed after 4 000 equivalent operating hour or after six months after commissioning. Subsequently the L1 maintenance should be done yearly halfway between Level 2 maintenances. Level 2 (L2) Level 2 or L2 maintenance consist mainly of inspections and tests and small maintenance tasks. The purpose of this maintenance is to test whether there are problems in the operation of the machine and to do small repairs to ensure uninterrupted operation. The maintenance can be estimated to last approximately 8 - 16 hours, depending on the type and installation of the machine and the amount of servicing to be done. Tools for this maintenance include normal servicing tools, multimeter, torque wrench and insulation resistance tester. The preparations consist of opening the inspection covers and bearings if necessary. Spare parts suitable for this level of maintenance are included the maintenance package. The first Level 2 maintenance should be performed after 8 000 equivalent operating hour or one year after commissioning. Subsequently the L2 maintenance should be done yearly or after every 8 000 equivalent operating hours. Level 3 (L3) Level 3 or L3 maintenance consist of performing extensive inspections and tests and larger maintenance tasks that have come up during L1 and L2 maintenances. The purpose of this maintenance is to repair encountered problems and replace parts subjected to wearing. The maintenance can be estimated to last approximately 16 - 40 hours, depending on the type and installation of the machine and the amount of repairs and replacements to be done. Tools for this maintenance include the same tools as for L2 and in addition a borescope (endoscope) and oscilloscope. The preparations consist of opening the inspection covers, the bearings and the water cooler, if applicable. Spare parts suitable for this level of maintenance are included the maintenance package.

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

The Level 3 maintenance should be performed after every 24 000 equivalent operating hour or at three to five year interval. When a L3 maintenance is conducted it replaces the L1 or L2 maintenance otherwise scheduled and it leaves their rotation unaffected, see Table 7-4 Recommended maintenance program (one complete cycle) for more information. Level 4 (L4) Level 4 or L4 maintenance consist of performing extensive inspections and maintenance tasks. The purpose of this maintenance is restore the machine into a reliable operating condition. The maintenance can be estimated to last approximately 40 - 80 hours, depending mostly on the condition of the machine and the needed reconditioning actions. Tools for this maintenance include the same tools as for L3 and in addition rotor removal equipment. The preparations consist of opening the inspection covers, the bearings and the water cooler, if applicable, and the removal of rotor and exciter. The amount of spare parts required for this level of maintenance are difficult to determine. At least the maintenance package is recommended, but spare parts included in the capital spare part package would better ensure a fast and successful execution of this maintenance. The Level 4 maintenance should be performed after every 80 000 equivalent operating hour. When a L4 maintenance is conducted it replaces the L1, L2 or L3 maintenance otherwise scheduled and it leaves their rotation unaffected. Interval (Eq. h) 4000 8000 12000 16000 20000 24000 28000 32000 36000 40000 44000 48000 52000 56000 60000 64000 68000 72000 X X X X X X X X X X X X X X X X L1 X X L2 L3 L4

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

76000 80000

X X

Table 7-4. Recommended maintenance program (one complete cycle)

7.8.1 Recommended maintenance program


Abbreviation used in maintenance program: V = Visual checking C = Cleaning D = Disassembling and assembling R = Reconditioning or replacement T = Testing and measurement

NOTE: All options are not applicable for all machines.

MAINTENANCE INTERVAL In equivalent operating hours or time period, which ever comes first L1 4000 Eq. h Maintenance object year L2 8000 Eq. h Annual L3 L4

24000 Eq.h 80000 Eq. h 3 - 5 years Overhaul Check / Test

7.8.1.1 General construction

Maintenance object Machine operation Mounting and foundation Exterior Fastenings Anchor bolts

L1 V/T V V V V

L2 V/T V/T V V/T V

L3 V/T V/T V V/T V/T

L4 V/T V/T/D V V/T V/T

Check / Test Starting, shut down, vibration measurement, no-load point Cracks, rust, alingment Rust, leakage, condition Tightness of all fastenings Fastening, condition

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

7.8.1.2 High voltage connection

Maintenance object High voltage cabling High voltage connections Terminal box accessories, i.e. surge capacitors and arresters Cable transits

L1 V V V

L2 V/T V/T V

L3 V/T V/T V

L4 V/T/D V/T/D V

Check / Test Wear, fastening Oxidation, fastening General condition

Condition of cables entering the machine and inside the machine

7.8.1.3 Stator and rotor

Maintenance object Stator core Stator winding insulation Stator coil over hangs Stator coil supports Stator slot wedges Stator terminal bars Stator cable terminal fastenings and crimps Instrumentation Rotor poles Rotor winding insulation Rotor coil supports Rotor balancing weights Damper bars Shaft and rotor center Air gap Connections in rotor

L1 V V V V V V V V V V V V V V V V

L2 V V/T V V V V V/T V V V/T V V V/T V V/T V

L3 V V/T/C V V V V V/T V V V/T/C V V V/T V V/T V/T

L4 V/C V/T/C V V V V V/T V V V/T/C V V V/T V V/T/D V/T

Check / Test Fixing, cracks, welds Wear, cleanliness, insulation resistance, turn insulation test, (high voltage test) Insulation damages Insulation damages Movement, tightness Fixing, insulation Tightness, condition Condtion of cables and cable ties Movement, tightness, fixing Wear, cleanliness, insulation resistance, voltage drop test Movement, bending Movement Cracks, corrosion, ultra sound and knocking test Cracks, corrosion Equality Fixing, general condition

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Maintenance object Earthing brushes Rotor shaft insulation

L1 V V

L2 V V

L3 V V/T

L4 V V/T

Check / Test Operation and general codition General condition, insulation resistance

7.8.1.4 Excitation system, control and protection

Maintenance object Exciter diode bridge Exciter semiconductors Excitation connections Exciter winding insulation Exciter air gap AVR unit AVR board PMG Voltage transformer (VT) Short circuit current transformer (CT) Actual value CT Measurement and protection CTs Pt-100 elements (stator, cooling air, bearing) Anticondensation heaters Auxiliary terminal boxes Exciter stator fixing

L1 V V V V V V V V V V V V V V V V

L2 V/T/C V/T/C V/T/C V/T V/T V/T V/T V V/T V V V V/T V/T V/T V

L3 V/T/C V/T/C V/T/C V/T V/T/D V/T V/T V/T V/T V/T V/T V/T V/T V/T V/T V

L4 V/T/C V/T/C V/T/C V/T V/T/D V/T V/T V/T V/T V/T V/T V/T V/T V/T V/T V

Check / Test Cleanliness, operation Operation, fixing Fixing, general condition Wear, cleanliness, insulation resistance Equality Operation, settings, stability test Operation, connections Operation, connections Operation, cleanliness Operation, cleanliness Operation, cleanliness Operation, cleanliness Resistance, insulation resistance Operation, insulation resistance General condition, terminals, wiring condition General condition, cracks

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

7.8.1.5 Lubrication system and bearings

Maintenance object Bearing assembly Bearing shells Seals and gaskets Bearing insulation Lubrication piping Lubrication oil Oil ring Oil flow regulator Oil tank Jack-up system Oil cooler / heater

L1 V V V V V V/R V V V V T

L2 V/T V V V/T V V/R V V/T V/C V/T T

L3 V/T V/T/D V/T/D V/T/D V/T/D V/R V V/T V/C V/T T

L4 V/T V/T/D V/T/D V/T/D V/T/D V/R V V/T/D V/C V/T T

Check / Test Fixing, general condition General condition, wear Leakage Condition, insulation resistance Leakege, operation Quality, quantity, flow Operation Operation Cleanliness, leakage Operation Oil temperature

7.8.1.6 Cooling system

Maintenance object Fan(s) Filters Air ways

L1 V V/C V

L2 V V/C V/C

L3 V V/C/R V/C

L4 V V/C/R V/C

Check / Test Operation, condition Cleanliness, operation Cleanliness, operation

7.9 Spare parts 7.9.1 General considerations


The machines manufactured by ABB are designed and manufactured to provide reliable and trouble free operation for many years. This requires, however, that the machines are properly maintained and operated. This maintenance includes changing of parts subjected to normal wear. There is always an inevitable amount of uncertainty related to wearing. The wear rates of these parts vary greatly according to application, environment and particular conditions. Therefore, the condition of these parts should be checked regularly and a sufficient amount of spare parts should be kept in stock. These spares help to minimize down time if the need appears. The extent of the stock should be decided based upon the importance of the application, the availability of the particular spare part and the expertize of the local maintenance personnel.

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

7.9.2 Wearing parts subjected to mechanical wear


There is always mechanical wearing when two moving surfaces are in contact with each other. In electrical machines most of the mechanical wearing occurs between the rotating shaft and stationary parts. The bearing parts such as bearing shells and oil rings in sleeve bearings will eventually wear out and need to be replaced, even if correct lubrication is maintained. Other wearing parts include seals, that are in constant contact with the rotating shaft, and the brushes, brush gears and slip rings of the slip ring unit. The parts listed above are an extensive, but not complete, list of the mechanically wearing parts. These parts have an estimated life span, but as mentioned earlier, their actual durability can vary significantly. For this reason, at least these parts should be kept in stock. It should also be noted that the replacement of these parts, due to normal wearing is not covered by the warranty.

7.9.3 Other wearing parts


Other types of wearing occur due to i.e. elevated temperatures, electrical disturbances and chemical reactions. The wearing of the diodes in the rectifier bridge is usually related to abnormal electrical operating conditions. It is usually a slow process, but it is strongly dependent on the operation conditions of the machines and system disturbances. Air filters, that protect the machine interior from contamination get them selves saturated with air impurities and need to be replaced to ensure the correct operation of the cooling unit and the continuous protection of sensitive machine parts. The electrical windings of the ABB machines have good protection against wearing, but only if correct maintenance and operating conditions are followed. The correct operating temperature must not be exceeded and the windings must be cleaned from dirt regularly. The winding can also be subjected to accelerated wear due to a number of electrical disturbances. There are Pt100 temperature detectors located inside the stator core slots and they are impossible to replace. Therefore the ABB practice is to add spare Pt100 detectors in the stator core. These detectors are not be considered as regular spare parts, because they are intended to be used as a replacement in case of a stator Pt100 element failure during commissioning. However, these elements can be taken into use also during operation if the primary detector fails. If even the spare element should fail, the possible corrective action is to add Pt100 elements into the stator winding end. See Chapter 7.6.4.1 Pt-100 temperature detector retrofitting.

7.9.4 Selection of the most suitable spare part package


ABB provides three level of ready made spare part packages. The personnel best informed of the machine's operational conditions should select the most suitable package based on criticality of the application and on the financial risk related to the duration of downtime and loss of production. Safety parts for commissioning and to ensure usability These are the most essential spare parts that you should have always available

Maintenance parts for trouble shooting and scheduled maintenance These parts enable should be available while doing medium term maintenance. These parts also enable fast recovery in case of failure in the most of the accessories.

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Capital spare parts to reduce repair time in case of serious damage These spare parts are recommended when the machine is a part of an essential processes. These spare parts enable fast recovery even in case of a serious damage.

7.9.5 Typical recommended spare parts in different sets


The following chapters present a general ABB recommendation of the typical spare parts for different packages. To get an offer of specific parts for your machine, please contact ABB After Sales organization. Please note that even though we have customized the spare part sets to match your machine, they might contain references to accessories that you do not have.

7.9.5.1 Safety package


Spare part Automatic voltage regulator (AVR) Rectifier diodes Varistor Air filters Pt-100 for cooling air Bearing RTD Bearing labyrinth seal Bearing shell, for D-end and NE-end Bearing oil ring Amount 1 pc. 3 pcs. 1 pc. Set 1 pc. 1 pc. 2 pcs. 1 pc. 1 pc.

7.9.5.2 Maintenance package


Spare part Safety package (without AVR) AVR with board Voltage transformer Short circuit current transformers Actual value current transformer Stator current measurement transformers Space heater Amount 1 pc. 1 pc. 1 pc. 3 pcs. 1 pc. 3 pcs. 1 pc.

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Capital spare parts Spare part Exciter rotor Exciter stator Rectifier bridge Rotor pole Rotor (complete) Stator with frame Water cooler element Amount 1 pc. 1 pc. 1 pc. 2 pcs. 1 pc. 1 pc. 1 pc.

7.9.6 Order information


To ensure fast and correct spare part ordering and delivery, our After Sales personnel should be provided with at least the type and serial number of the machine in question. This information is given i.e. on the front page of this manual and it can also be found on rating plate fixed to the machine frame. In addition they require specific information about the parts to be ordered. For most parts, this can be found in Section 7, Accessory Information. The contact information of our After Sales organization can be found in Chapter 9, After Sales and Market Support.

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

7.10 Troubleshooting
This chapter is intended to help in the event of an operational failure with ABB delivered machine. The trouble shooting charts given below can assist in locating and repairing mechanical, electrical and thermal problems and problems with lubrication system. The checks and corrective actions mentioned should always be conducted by qualified personnel. If in doubt, ABB After Sales should always be contacted. They can provide more information or technical assistance for trouble shooting and maintenance.

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

7.10.1 Mechanical performance

Troubleshooting
Mechanical performance

Experienced malfunction

Vibration

Noise

#
Possible cause
Lubrication malfunction Bearing malfunction Faulty cooling fan(s) Damaged bearing parts Faulty bearing assembly

Corrective action
Check lubricant quality and quantity and lubrication system function Check bearing condition and replace bearing parts Open and readjust the bearing Inspect and repair cooling system Inspect and repair excitation system Check machine alignment Rebalance rotor Check rotor wedges, poles etc., repair and rebalance rotor Check the balance of connected machinery and coupling type Check alignment and coupling function and type Check coupling function Reinforce foundation as per ABB instructions Check main machine and excitation machine windings Check that network balance fulfils requirements Check bearing pedestal alignment Check and clean machine interior, dry windings Measure and adjust airgap

Imbalanced or damaged fan(s) Check and repair cooling fan(s)

Malfunctioning cooling system Malfunctioning excitation system Machine misalignment Rotor or shaft imbalance Loose parts in rotor Vibration coming from connected machinery Axial load coming from connected machinery Faulty or incorrectly assembled coupling Insufficient foundation strength Main machine or excitation machine winding fault Excessive network unbalance Bearing misalignment Foreign material, moisture or dirt inside the machine Airgap not uniform

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

7.10.2 Lubrication system and bearings


7.10.2.1 Lubrication system and sleeve bearings

Troubleshooting
Lubrication system and sleeve bearings
self lubrication

Experienced malfunction
Bearing noise or vibration High bearing temperature Visibly poor oil quality Oil inside the machine

Oil leaks

#
Possible cause
Insufficient lubrication Unsuitable oil quality Oil quality is reduced Excessive axial load Machine misalignment Incorrectly assembled bearing Excessive amount of oil Oil impurities Bearing currents Damaged bearing shells Complete bearing failure Normal wearing Operating speed too low Faulty instrumentation External vacuum Internal over pressure Damaged machine seal Poor oil ring or disc operation Foreign matter inside the bearing Faulty temperature detector Rotating equipment nearby Pressure compensation failure Damaged or worn-out bearing seals Incorrect oil change period Faulty coupling or mounting Low oil level

Corrective action
Check bearing for leakage, add oil Check ABB oil recommendations Clean bearing and change oil Check coupling, mounting and alignment Realign machine Verify correct bearing assemblage and adjustments Clean bearing and add correct amount of lubricant Change oil, check bearing condition, replace bearing shells Restore bearing insulation, replace bearing shells Replace bearing parts Replace bearing shells Check the operating speed range of bearing Check bearing temperature measurement system Replace bearing seals Check pressure levels, relocate rotating equipment Remove cause for internal over pressure Replace or repair machine seal Open bearing and adjust operation Clean bearing and check seal condition

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

7.10.3 Thermal performance


7.10.3.1 Thermal performance, open air cooling system

Troubleshooting
Thermal performance
open air cooling system

Experienced malfunction
High cooling air temperature High winding temperature

#
Possible cause
Ambient temperature too high High intake air temperature Exiting air is pulled back in Heat source nearby Dirty machine interior Faulty air flow Faulty cooling arrangement Air intakes are blocked Air filter is clogged Damaged cooling fan(s) Cooling fan rotating in the wrong direction Overload Overspeed Network unbalance Faulty instrumentation or measurement system Main machine or excitation machine winding fault Control system setting

Corrective action
Add ventilation to decrease ambient temperature Ensure sufficient clear distances surrounding the machine Place heat sources further away, check ventilation Clean machine parts and air gaps Inspect cooling arrangement condition and correct assembly Clear air intakes of debris Clean or replace air filters Replace fan(s) Replace fan(s) or change rotating direction of external fan Check machine controls, eliminate overload Check actual speed and ABB speed recommendations Check that network balance fulfils requirements Check measurements, sensors and wiring Check main machine and excitation machine windings

Note: For high bearing temperature see: Trouble shooting, Lubrication system and bearings

Maintenance - 39

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

7.10.4 Electrical performance

Troubleshooting
Electrical performance and excitation system of variable speed motors
with brushless excitation

Experienced malfunction
Malfunction during starting Operation not adjustable Asynchronous operation Performance deviation Excitation failure

#
Possible cause
Faulty drive system Faulty excitation supply unit Main motor winding fault Excitation field winding fault Excitation machine winding fault Faulty rotating rectifier Electrical fault in excitation system Excitation equipment fault Encoder malfunction Control cubicle equipment Faulty settings Faulty wiring

Corrective action
Check variable speed equipment and setting Check excitation panel relay and voltage regulator setting Check connection between excitation panel and motor Check main machine winding and insulation resistances Check field winding and insulation resistances Check excitation machine winding condition Check rectifier component and ignition system conditions Check electrical connections in excitation system Check and repair excitation equipment in control cubicle Check condition of speed and position encoders

Maintenance - 40

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

7.10.4.1 Electrical performance and excitation system of generators

Troubleshooting
Electrical performance and excitation system of generators
with transformer excitation

Experienced malfunction
Increase in excitation current Malfunction during start-up Operation not adjustable Faulty parallel operation Performance deviation

Lost excitation

#
Possible Cause
Abnormal speed Network phase unbalance Speed variation of operating machine Faulty settings Field application failure Faulty wiring Faulty speed control

Corrective action
Check speed control of operating machine Check that network balance fulfils requirements Check speed control of operating machine Check excitation panel relay and voltage regulator setting Check excitation panel control cubicle and generator Check transformer winding insulation resistance and connections Check transformer winding insulation resistance and connections Check transformer winding insulation resistance and connections Check operation of short circuit excitation system Check main machine winding and insulation resistances Check exciter winding and insulation resistances Check connection and condition of rectifier components Check electrical connections in excitation system Check and replace excitation panel equipment Check and adjust voltage regulator settings

Demagnetised excitation magnet See main connection diagram to restore permanent magnet excitation Defective voltage transformer Defective parallel operation transformer Defective current transformer Short circuit excitation system failure Main generator winding fault Excitation system winding fault Faulty rotating rectifier Faulty wiring in excitation system Excitation equipment fault Excitation panel equipment Faulty AVR settings

Bad AVR tuning parameters Voltage oscillation, poor response Check AVR tuning (PID parameters) Check and replace voltage regulator Defective AVR Faulty AVR wiring or incorrect connections Power factor variation over permitted values Faulty external voltage reference system No actual value information for AVR Check AVR wiring and connections Check AVR condition Check connections and condition of voltage reference Check actual value measurement system and electrical connections

Note: AVR = Automatic Voltage Regulator

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Chapter 8 Dismantling and Reassembly

8.1 General
For complete overhaul, cleaning and possible revarnishing, the machine must be dismantled so that the rotor and the stator are separated. How often a thorough cleaning should be made can be judged from the state of uncleanness observed in the annual inspections. If the machine is not subjected to more than normal contamination, an inspection interval of five to ten years is recommended.

8.2 Preparation for dismantling


Observe that most of the inspection and maintenance work can be done after removing the covers, and by using the existing maintenance doors and air intake and outlet openings. Ensure that there is no risk of electrical or mechanical accident. The machine should be electrically, and if necessary mechanically disconnected, and earthed. Main supply cables or busbars and auxiliary cables should be disconnected and identified for reconnection. All necessary safety precautions should be taken. The complete machine should if possible be removed from its site to a dry and dust-free location. Shims placed under the feet of the machine as well as dowel pins should be identified and retained for later reassembly. Shaft coupling halves should be marked.

8.3 Dismantling
Construction drawings of the machine and the bearings should be used to guide the dismantling work, see Section 4 Mechanical Drawings, and Section 5 Electrical Drawings. Remove the side covers. Turn the shaft into a position where it can firmly rest on the stator laminations. Push strong plywood pieces into the air gap under the rotor from the N-end, see Figure 8-1 Plywood pieces supporting the rotor. Where applicable, also put pieces of strong plywood between the exciter rotor and stator. Dismount the instruments, the seals and the bearing housing upper parts. Tighten the two end shield jacking screws on both ends of the machine, and then remove the end shield dowel pins. Loosen the end shield fixing bolts until the jacking screws carry the weight of the rotor, the bearings and the end shields. Remove all end shield-fixing bolts except two on both sides of the bearing. Turn the jacking screws counter-clockwise until the rotor is supported by the plywood pieces previously inserted between the rotor and the stator. Direct contact between stator and rotor must be avoided. Remove the upper part of the bearing shells and the oil rings. Loosen the end shield jacking screws until the bearing shell moves easily. Turn the shell 180 over the shaft and remove it. Remove the N-end end shield with the exciter stator and the bearing housing by moving it carefully along the axis of the rotor. Use a crane and an additional tackle to balance the end shield as to avoid damaging the exciter windings. Dismount the D-end bearing housing. On some cases the rotor must be moved 10 mm towards D-end to remove the D-end bearing housing. This is carried out by using the same principle as when the rotor is removed out of the stator. Remove the D-end end shield by moving it carefully along the rotor axis towards the Dend. Where applicable, remove the fan.

Dismantling and Reassembly - 1

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

When removing the rotor from the stator, a special piece of tubing is used for elongation of the shaft. Great care should be taken in order not to scratch or otherwise damage the windings.

PLYWOOD PIECES
Figure 8-1 Plywood pieces supporting the rotor

8.4 Removing the rotor


A special extension shaft is fitted to the end of the rotor. The rotor is supported from the end of the extension shaft and the other end of the rotor. The rotor is carefully moved outward. When the center of gravity of the rotor is outside the stator frame, move the support from the end of the extension shaft next to the center of gravity of the rotor. Move the rest of the rotor carefully out from the stator frame. If there is not enough space to remove the rotor directly out, it can be turned to either side. Great care has to be taken in order not to damage the windings, see Figure 8-2 Typical rotor removal procedure and Figure 8-3 Typical rotor removal procedure (continued).

Dismantling and Reassembly - 2

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Figure 8-2

Typical rotor removal procedure

Dismantling and Reassembly - 3

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Figure 8-3

Typical rotor removal procedure (continued)

8.5 Reassembly and Realignment


For reassembly and realignment work the same instructions are generally valid as for original assembly and alignment work. Construction drawings and special mounting instructions should be employed. When reassembling the covers, air ducts and terminal boxes, the gaskets should be examined and renewed if necessary.

8.6 Stator Shift


Introduction It is normally not necessary to remove the rotor from a synchronous machine. However, if a need to remove or inspect the rotor turns up, it can for instance be done by stator shift. This method requires a minimum of equipment.

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Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Stator Shift Procedure 1. 2. 3. 4. 5. 6. 7. 8. 9. Temporarily remove the electrical and mechanical connections Open the coupling between the synchronous machine, and the driving/driven machine Add additional frame at the non-drive end of the common frame Slide the synchronous machine away from the driving/driven machine Support the rotor inside the stator core Remove coupling half, bearings, end shields, exciter stator and fan Add extension shaft in drive end Support extension shaft and rotor on additional supports Slide synchronous machine towards driving/driven machine

Inspection The complete synchronous machine can now be inspected, or dismantled if required. The rotor can be removed by the use of only one crane. Reassembly of Synchronous Machine In order to reassemble the synchronous machine, the stator shift procedure is reversed.

Dismantling and Reassembly - 5

Synchronous Machine AMG 1120MM10DSE Section 6 - Manual

Chapter 9 After Sales and Market Support


After Sales and Market Support for Rotating Electrical Machines manufactured by ABB , and Strmberg in Helsinki, Finland since 1889. Site Services and Spare Parts Provides commissioning and erection supervision, co-ordinates spare parts packages delivered with the machine, sells spare parts after the delivery of the machine. Warranties Manages complaints and warranty questions concerning the machines. Support for Service Centers Supports in questions concerning the mechanical construction as well as in electromagnetic and insulation technology issues. Contact the After Sales department by: Phone 7:00 am - 5:30 pm (GMT+2) Fax e-mail 24 hour emergency service +358 (0)10 22 2000 +358 (0)10 22 22544 aftersales.machines@fi.abb.com +358 (0)10 22 21999

After Sales and Market Support - 1

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

7.
Accessory Information

ABB

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

Contents Accessory Information Delivered with Machine


Resistance Temperature Detector PYR_L_/_..........................................................1 Resistance Temperature Detector PYR_R_0_ ........................................................4 Anti-condensation Heater RER 800/490 V .......6 Pliotron CR Air Filter .........................................8 Voltage Transformer T1 type 3PU180/63/E....11 Current Transformer T2 KSG..........................15 Current Transformer T3 IFJ-3 Arteche............18 Current Transformer T4 ACI-17 Arteche.........20 Silicon Diode LNM SKKD 260/20....................22 Varistor Module SXV 40K550 C......................23 Roxtec Cable Glands ......................................25 Excitation Current Limiter ECL-10 ..................29 UNITROL 1000 AVR Instruction Manual Bearing Documentation by Renk AG Other Documentation

ABB

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Resistance Temperature Detector - PYR_L_/_

Use To be fitted in stator slot of form wound stators for measuring the temperature of stator. Voltage area U 15 kV. Sensor with length 50 mm is not suitable for NEMA machines. Description The detector is manufactured to the standard specification IEC 751 class B Marking PYR abLcd/ef a = resistance material b = resistance [] at 0C L = slope type sensor c = length of sensor [code] d = length of cable [m] e = wires (pcs) f = armouring (X), shielded (Z), either (empty) e.g. PYR PT100LG4/4 Refer to the Technical Specification in Section 3 for correct Type Designation Code. Requirements Dielectric strenght min 1 kV (50 or 60 Hz) for 1 minute Order Information Stock unit : pcs Order unit : pcs Weight per unit : approximately 16 g Further Information Teflon insulated flexible Cu-wires 0.25 mm2 (AWG#24), not twisted (flat cable 2 x 5 mm) or twisted {see table} contained in a common teflon jacket Max. thickness of the teflon jacket {see table} mm Not halogen free Cable ends sealed with epoxy (appr. 100 mm) Usable temperature: 60C 180C (normal), 20C 180C (Ex) Measuring current max 10 mA

Resistance Temperature Detector - PYR_L_/_ - 1

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Code

Type designation

Dielectric strenght [kV]

Twisted wire No No No Yes No No No No Yes Yes Yes Yes

[mm] 2 2 2 3 2 2 2 2 2,8 3 2,8 2,8

L1 [mm] 3000 3000 4000 4000 4000 4000 4000 4000 7000 7000 7000 18000

L2 [mm] 50 50 200 200 200 200 200 200 200 200

Ex approved [EEx e II] PTB Nr: Ex-87.D.2021U KEMA Nr: Ex-96.D.1529U PTB Nr: Ex-96.D.3139U KEMA Nr: Ex-96.D.1529U -

9872265 6013601 6017515 9872735 9872555 9872546 9872557 9872556 6004202 9874084 9870614 9872008

PYR PT1000LC3/4 PYR PT100LC3/4EX PYR PT100LG4/4EX PYR PT100LG4/4Z PYR PT120LG4/4 PYR PT1000LG4/4 PYR CU10LG4/4 PYR NI120LG4/4 PYR PT100LG7/3 PYR PT100LG7/2Z PYR PT100LG7/3EX PYR PT100LG18/3

5 5 5 3,2 5 5 5 5 3,2 3,2 3,2 3,2

PTB Nr: Ex-87.D.2021U 200 200 PTB Nr: Ex-97.D.2239U KEMA Nr: Ex-96.D.1529U -

Resistance Temperature Detector - PYR_L_/_ - 2

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Figure 1. Sensor with cable without armouring

Figure 2. Sensor with shielded cable

Resistance Temperature Detector - PYR_L_/_ - 3

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Resistance Temperature Detector - PYR_R_0/_

Use To be fitted in the shell of sleeve bearings for measuring the temperature of the bearing. Used also in controlling the temperature of the cooling air. Description The detector is manufactured to the standard specification IEC 751 class B Marking PYR abcRd0/e a = number of the detectors = 1 detector 2 = 2 detectors b = resistance material (PT = platinum) c = resistance () at 0C d = length code of the detector e = number of the wires Refer to the Technical Specification in Section 3 for correct Type Designation Code. Requirements Dielectric strength min 1 kV ( 50 or 60 Hz ) for 1 minute Degree of protection IP54 Order Information Stock unit : pcs Order unit : pcs Further Information Usable temperature -60C +180C Small terminal head, DIN 43 729 Form P Big terminal head, DIN 43 729 Form B Measuring current max 10 mA

Resistance Temperature Detector - PYR_R_0/_ - 4

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Code 9873253 9873692 60129126 99869699 99869697 60129134 99869698 99869696 9870430 9870431

Marking PYR PT100RC0/4 PYR 2PT100RC0/4 PYR PT100RG0/4 PYR 2PT100RG0/4 PYR 2PT100RG0/2 PYR PT100RJ0/4 PYR 2PT100RJ0/4 PYR 2PT100RJ0/2 PYR PT100RL0/4 PYR PT100RP0/4

Form P B P B P P B P P P

L1/mm 50 50 200 200 200 300 300 300 400 550

L2/mm max. 55 85 55 85 55 55 85 55 55 55

H1/mm 25 38 25 38 25 25 38 25 25 25

H2/mm 30 49 30 49 30 30 49 30 30 30

Weight/g 210 260 213 263 213 220 270 220 280 300

T Pg 9 Pg 16 Pg 9 Pg 16 Pg 9 Pg 9 Pg 16 Pg 9 Pg 9 Pg 9

Resistance Temperature Detector - PYR_R_0/_ - 5

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Tubular Heating Element 800W/490V

Marking RER 1-a/b (a = nominal power, b = nominal voltage). Use As a standstill heating element for AM_ synchronous machines. Specification Code Type Nom. power [W] Power [W] Nominal voltage[V] Voltage [V]

9871212 9871213 9871214 9871215

RER 1-800W/115V RER 1-800W/235V RER 1-800W/400V RER 1-800W/490V

800 800 800 800

720-870 700-900 720-970 760-840

115 235 400 490

110-120 220-250 380-440 480-500

Technical requirements Material of the tubular heating element: AISI 304. Material of the attachment ear: AISI 304. Operating temperature of the connection cables: 100 C. Operating voltage of the connection cables: 500 V. Cross section area of the connection cables: 1.0 - 2.0 mm2. Connection of the connection cables with a connecting clamp: 6.3. Halogenous free connection cables. Test voltage: 1500 VAC.

Further Information Information stamped on the tube of the heating element: Manufacturer, power, voltage, manufacturing number, mont and year of manufacture. Order related information Stock unit: pcs Order unit: pcs Weight per unit: 1.0 kg

Tubular Heating Element 800W/490V - 6

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Tubular Heating Element 800W/490V - 7

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Pliotron CR Air Filter

Purpose Pliotron CR Air Filters are designed to remove atmospheric dust including sub-visible particles down to the particle range of 10 microns and less. Sub-visible particles are the predominant cause of extended surface soilage as well as dirt generated electrical circuitry failure.

Description The Pliotron CR (Commercial/Residential) is a permanent, self charging, electrostatic panel air filter. It is contructed of washable, woven polyethylene fibre and incorporates a non-woven, synthetic fibre mat, both of which are enclosed in a rust resistant, galvanized steel frame and reinforced by 0.5 mesh galvanized steel hardware cloth. The filter can withstand temperatures up to 100C (212F). The polyethylene media is chemically inert to the majority of contaminants encountered in ventilation systems.

Pliotron CR Air Filter - 8

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Principle of Operation Polyethylene, a high-dielectric plastic, has an inherent capability to generate both positive and negative surface charges in close proximity. Residual surface charges are always present on polyethylene, and combined with the frictional forces of an air stream substantially increases the voltage of these charges. As no external electrical energy is required, polyethylene can be considered as self charging. As airborne dust particles are of either positive or negative charge, they are both attracted and retained by the opposite charges on the filter media. This electro-static arresting greatly enhances the normal mechanical action of the filter. Maintenance The filter should be cleaned on an established regular basis to obtain maximum efficiency ensuring longer life and long term low running costs. The filter may be cleaned either by simply using a vacuum, firstly on the upstream side, then repeated on the discharge side. This will assist in maintaining peak performance. Periodically (to be established and maintained) a thorough flush through with clean water, either by immersion or with a fine spray in the opposite direction to the air flow. If contaminated by oily or greasy substances, a detergent solution should be used, after which the filter must be rinsed with clean water. Marking WJFA a x b x c a=width (mm) b=length (mm) c=thickness (mm) (e.g. WJFA 500 x 725 x 24) Specification

Code 88319206 10209072 88157001 88319605 10209510 10209013 10208181

Net face Pressure velocity m/s loss Pa 3 3 3 3 3 3 3 98 98 98 98 98 98 98

Airflow m3/s 0.300 0.600 0.511 0.631 0.811 0.811 0.961

Net area of filter m2 0.10 0.20 0.17 0.21 0.27 0.27 0.32

A 245 375 400 400 425 500 500

B 500 625 500 625 725 625 725

Pliotron CR Air Filter - 9

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Order related information Airfilter PLIOTRON CR, Width (a) x Length (b) x Thickness (c). This factory standard must be attached to the order. Stock unit: Order unit Designation CR pcs pcs

Pliotron CR Air Filter - 10

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Voltage Transformer T1 type 3PU180/63/E

TECHNICAL DATA FOR VOLTAGE TRANSFORMER T1 Three phase voltage transformer for excitation power and to measure actual voltage of synchronous generator. Required one for each generator. Primary winding Voltage: Un V / Fn Hz Connection: Y Terminal marking: A , B , C Insulation level: Test voltage (winding to case) (2 x Un + 3 kV) x 1.15 Cables 1.5 mm2, L = 2.5 m, tightly fitted silicone insulation 5 mm for Ux < 11.6 kV, 7 mm for Ux > 11.5 kV Distance between connection cables and case and between individual cables > 30 mm 1st secondary winding Voltage: u1 V Output: S1 = 3.2 kVA continuously , 5.5 kVA 2 min Connection : yn0 Terminal marking: a , b , c ,F11 Insulation level: Test voltage 2.5 kV / 50 Hz / 1 min Terminals are provided with short circuit breaker: main contacts: 25 A, when 110 V type S 260-B 25 (ABB Stotz), breaking capacity 6 kA main contacts: 16 A, when 165 V type S 260-B 16, breaking capacity 6 kA auxiliary contacts: NO+NC type S2-H11 cable: 2.5 mm2, length 2.5 m. If generator frame size is 1250, 1600 or 2000, length 6.0 m (marked in order)

2nd secondary winding Voltage: u2 V Output: S2 = 300 VA continuously Connection : yn0 Terminal marking: 2a , 2b , 2c ,F12 Insulation level: Test voltage 2.5 kV / 50 Hz / 1 min Terminals are provided with short circuit breaker: main contacts: 2 A type S 263-C 2 (ABB Stotz), breaking capacity 6 kA auxiliary contacts: NO+NC type S2-H11

Voltage Transformer T1 type 3PU180/63/E - 11

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

cable: 2.5 mm2, length 2.5 m. If generator frame size is 1250, 1600 or 2000, length 6.0 m (marked in order)

Rating of auxiliary contacts VDE 0660 Ith = 25 A, IGr C / 500 V AC11 Ue/Ie 415 V / 2 A, 240 V / 6 A DC11 Ue/Ie 250 V / 1 A, 110 V / 1.5 A, 60 V / 2 A, 24 V / 4 A Environmental limits Vibration: amplitude 0-peak 0.8 mm, when f 8 Hz speed Veff acceleration shock Operation temperature: Storage temperature: Humidity: Further data Protection class: Temperature rise: Weight: ORDER INFORMATION Voltage transformer T1, type 3 PU 180/63/E according to this standard and to the order-specific information given in the order form. IP-00 B-class 78 kg 30 mm/s, when 8 < f < 100 Hz 2.5 g, when f 100 Hz 5g 0 - 60 C -30 - +75 C 95 % / +40 C

Voltage Transformer T1 type 3PU180/63/E - 12

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Voltage Transformer T1 type 3PU180/63/E - 13

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Voltage Transformer T1 type 3PU180/63/E - 14

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Current Transformer T2 KSG

Use Normal use for current sensing for AVR. Marking KSG Ipn T2 Ipn = primary current (A) Refer to the Technical Specification in section 3 for correct Type Designation Code. Specification Insulation level: Terminal marking: Frequency: Primary currents, see table: Rated thermal current: Short-time withstand current Ith 1s: Peak withstand current Idyn: Secondary current: Accuracy class: Burden, see table Operating temperature range: Window: Screw of secondary terminal: Weight approximately: Delivery without foot and terminal cover Dimension according to enclosed drawing -30C ... +60C 70 mm M5 2.5 kg 1/6/ - kV P1, P2, S1, S2 50 - 60 Hz Ipn Ext. = 120% 60 * Ipn 2.5 * Ith Isn = 1 A 0.5

Current Transformer T2 KSG - 15

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Requirements Code 9872221 9872222 9872223 9872224 9872225 9872226 9872227 9872228 9872229 9872230 9872231 9872232 9872233 9872234 Type KSG 0100T2 KSG 0125T2 KSG 0150T2 KSG 0200T2 KSG 0250T2 KSG 0300T2 KSG 0400T2 KSG 0500T2 KSG 0600T2 KSG 0800T2 KSG 1000T2 KSG 1250T2 KSG 1500T2 KSG 2000T2 Primary current A 100 125 150 200 250 300 400 500 600 800 1000 1250 1500 2000 Rated burden VA 3 4 4 4 5 5 5 5 5 5 5 5 5 5

Current Transformer T2 KSG - 16

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Typical Dimensions

Connection

Current Transformer T2 KSG - 17

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Current Transformer T3IFJ-3 Arteche

Use Excitation power during generator short circuit. 3 pcs / each generator. Marking KSG IFJ- IpnT3 Arteche Specification Standard: Insulation level: Terminal marking: Rated thermal current: Short-time withstand current Ith 1s: Peak withstand current Idyn: Operating temperature range: Window: Screw of secondary terminal: Delivery without foot and terminal cover Dimension according to enclosed drawing IEC 185 1/6/ - kV P1, P2, S1, S2 Ext. = 120% 60 * Ipn 2.5 * Ith -30C ... +60C 70 mm M5

Current Transformer T3IFJ-3 Arteche - 18

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Current Transformer T3IFJ-3 Arteche - 19

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Current Transformer ACI-17 Arteche

Description The primary winding of the transformer are encapsulated in cast-resin. Order specifications: - Quantity - Type - System voltage - Frequancy - Rated primary and secondary current - Short time currents Ith (1 sec.) and Idyn - Rated burden and accuracy class for each core - Ambient temperature other than IEC (-5 C...+60 C) - Special requirements, if any - Test report, if required, language specified Environment: The ACI transformers are made for indoor mounting. The transformers must be protected against unusually heavy deposits of dust or similar pollution, as well as against direct sunshine. See technical specification in Section 3 of this manual for details.

Current Transformer ACI-17 Arteche - 20

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Current Transformer ACI-17 Arteche - 21

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Silicon Diode LNM SKKD 260/20


Power Semiconductor Module Marking LNM SKKD260/20 Order Power semiconductor module, isolated metal base. Semipack LNM SKKD 260/20. Further information IF(AV) = 260 A, IF max = 410 A, VRMM = 2200 V Isolation 2500 V AC Weight per unit 0.9 kg Use For rotating rectifier of a synchronous machine.

Silicon Diode LNM SKKD 260/20 - 22

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Varistor Module SXV 40K550 C

Marking: SXV 40K550 C Purpose: For rotating rectifier of a synchronous machine. Specification: Varistor Type: Marking: Manufacturer: Capacitor Type: Marking: Manufacturer: Box Type: Manufacturer: Type: Manufacturer: Further information: Varistor module and capacitor in parallel Polarity does not matter Can be connected between + and poles in both directions Connection diagram shall be fixed on the module SKB 33 Semikron Oy 25303 14/19 VA, 1,941 mm2, length: 250 mm and 500 mm Teflontalo Irpala Oy MKP 0,1 F +-10%. 600Vac, 100 Vdc Fischer & Tausche LS40K550QPK2 VRMS 550 V, VDC 745V, Imax (8/20) s 40000 A Siemens

Teflon FEP-insulated cable

Order information: Design unit : pcs Order unit : pcs Weight per unit : 0.18 kg

Varistor Module SXV 40K550 C - 23

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Varistor Module SXV 40K550 C - 24

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Roxtec Cable Glands

Assembly instructions - using ROX Wedge

1. 2. 3. 4. 5. 6.

Remove any dirt inside the frame. Lubricate the inside faces of the frame. Adapt those modules which are to hold cables or pipes by peeling off layers. Try to achieve a 0-1 mm gap between the two halves when held against the cable/pipe. Lubricate the modules thoroughly with ROX lubricant, both the inside and outside faces. Insert the modules according to your transit plan. Start with the largest modules. Insert a stayplate on top of every finished row of modules.

7. 8. 9.

Continue to fill the packing space with cables, modules and stayplates Before inserting the final row of modules, insert two stayplates Separate the two stayplates.

10. Insert the final row of modules between the stayplates. 11. Tip: Put the last two modules together like a "" and insert with the point first between the other modules.

Roxtec Cable Glands - 25

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

12. Drop the upper stayplate on top of the modules.

13. Lubricate and insert the ROX Wedge in top of the frame (standard position). 14. Tighten the bolts until stop (max. 20 Nm). 15. Tip: An additional row of RM 10/0 (below the last stayplate) increases the compression in the frame. 16. Optional: The wedge can be inserted in the middle or bottom of the frame. Be sure to place a stayplate only on the marked side of the wedge. Assembly instructions - using Roxkit First follow above steps 1-7.

17. Lubricate and insert the compression plate directly over the final row of modules (no stayplate). Tighten the compression plate bolt until the top-packing fits in. 18. Lubricate and insert the top-packing's middle piece around the bolt. 19. Turn the middle piece 180. 20. Lubricate and insert the top-packing. 21-22. Tighten the nuts of the top-packing until 10-15 mm of thread protrudes from the nuts.

Roxtec Cable Glands - 26

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Assembly instructions for R round frames

23. Push the front fittings of the frame to the sides and lubricate the inside of the frame. 24. Adjust, lubricate and insert the modules according to your transit plan. 25. Pull the fittings back towards the centre of the frame and tighten the nuts until approx. 15 mm of thread protrudes. Assembly instructions - for RS round single penetrations 26. Adjust the centre core of the RS seal to fit the cable by peeling off layers. 27. Lubricate the contact faces between the two transit halves and also the face of the last upper sheet of the core. 28. Insert the two halves into the hole around the cable. Tighten the bolts on the fittings until a seal is achieved. Disassembly - reopening a ROX wedge transit

29. Turn the two bolts counterclockwise and the ROX Wedge releases itself. 30. Now simply remove the wedge. 31. Lift the upper stayplate. 32. Use fingers or a screwdriver to make the modules come loose. Remove the modules.

Roxtec Cable Glands - 27

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

33. Remove the two stayplates. 34. Now you can route new cables, adapt modules and reassemble the transit. Using the ROX Top-packing puller

35. Remove the nuts and the front fittings from the top-packing. Turn the inner larger nuts of the puller counterclockwise until they are fairly close to the smaller outer bolts. 36. With its crossbar pointing down attach the puller to the two bolts of the top-packing. Try to attach evenly to the two bolts. 37. When firmly attached turn any of the two larger nuts on the puller in clockwise direction . The top-packing will now start to pull out from the frame.

Roxtec Cable Glands - 28

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Excitation Current Limiter ECL-10

Excitation Current Limiter ECL-10 - 29

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

1 Principle of the excitation current limiter


Figure 1-1 presents a case of generator line short circuit. The redundant current transformers T3 supply during the short circuit excitation power. The ceiling value of excitation current is limited by an excitation current limiter. The limiter consists of a filter, two triggers and four thyristors. The filter damps high voltage peaks induced due to the combination of current transformer and rectifier. The trigger triggs the associated thyristor, when the voltage between lines intends to exceed a preset level. Thus the current Im through the exciter field remains at constant ceiling value (Figure 1-2, line 3). The desired trigger value is selected by means of jumpers.The curves 1a and 1b present currents supplied by cts T3 in cold and warm conditions, respectively.

Figure 1-1

Excitation Current Limiter ECL-10 - 30

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

Figure 1-2

2 Specification
2.1 Description
The ECL-10 is inteded to limit excitation current in case of a synchronous generator output is shorted. It is recommended to mount on a AVR mounting plate. During normal operation the ecitation current limiter has no role in the excitation system, because its terminals are shorted. The operation of ECL-10 will take place only occasinally and with duration of few seconds in case of generator short circuit, when the line voltage is dropped somewhere below 80% of the rated value. This level is determined by an AVR or some other device.

2.2 Inputs
There are three input terminals: L1, L2, L3. Screw connectors 4 mm2. The terminals should be connected between the cables from the current transformers T3. Max. 3-ph voltage 230 V / 10 sec.

2.3 Settings
The trigger level is set by means of jumpers. Therefore there are 10 screws, each 4 mm2. See Chapter 3 Trigger setting.

2.4 Ambient values


Operating temperature 0 . 60 oC Relative humidity max. 90 %

Excitation Current Limiter ECL-10 - 31

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

2.5 Mechanical data


Weight: 700 g Protection class: IP20 Bottom mounting with two M6 screws.

3 Trigger setting
Sustained short circuit current in line shall exceed a certain level in order to ensure a appropriate over current relay function. On the other hand excessive line current in a case of short circuit may destroy the generator. Thats why there is a max limit for short circuit current as well. In general the desired short ciruit current is approximately 3,5 * rated current. To find the right position for jumper setting, it is needed to carry a couple of short circuit tests with generator .
The default position bases on the rated excitation voltage Um. Ummax is approx. 1,4 * Um. So in the table below you select the assosiated setting on the same line with the Ummax. ***)

Excitation Current Limiter ECL-10 - 32

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

TRIGGER SETTING FOR ECL-10 A - trigger B - trigger


Pos
4-5

Ummax
approx. 12-13

Terminals
5-6 6-7 7-8 9-10

Terminals
10-11 11-12

V
**) 75 81 86 92 97 103 108 114 119 125 130 136 141 147 152 158 163 169 174 180 185 191 196 202 207 213 218 224 229 235 240

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

*) C C C C C C C C C C C C C C C C Open Open Open Open Open Open Open Open Open Open Open Open Open Open Open

*) C C C C C C C C Open Open Open Open Open Open Open Open C C C C C C C C Open Open Open Open Open Open Open

*) C C C C Open Open Open Open C C C C Open Open Open Open C C C C Open Open Open Open C C C C Open Open Open

*) C C Open Open C C Open Open C C Open Open C C Open Open C C Open Open C C Open Open C C Open Open C C Open

*) C C C C C C C C C C C C C C C Open Open Open Open Open Open Open Open Open Open Open Open Open Open Open Open

*) C C C C C C C Open Open Open Open Open Open Open Open C C C C C C C C Open Open Open Open Open Open Open Open

*) C C C Open Open Open Open C C C C Open Open Open Open C C C C Open Open Open Open C C C C Open Open Open Open

*) C Open Open C C Open Open C C Open Open C C Open Open C C Open Open C C Open Open C C Open Open C C Open Open

* ) C = closed ** ) Default for first test Ummax = 1,4 * Umn


In final setting Ik = rated speed / test speed * Ik measured / I rated = 3,2 - 3,6

***) Ummax values are as yet preliminary

Excitation Current Limiter ECL-10 - 33

Synchronous Machine AMG 1120MM10DSE Section 7 - Accessory Information

4 Dimensions

Excitation Current Limiter ECL-10 - 34

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. Copyright 2002 ABB. All rights reserved.

UNITROL 1000
Users Manual

Automatic Voltage Regulator


Compact voltage regulator for synchronous machines up to 15 A exciter current

Revision Control: Panel: PCTools:

3.xxx 3.xxx 3.xxx

Prep. Appr. Resp. dept.

Peter Moor Sami Karttunen ATPE

02-03-10 Users Manual 02-03-10 UNITROL 1000


Document number Lang. Rev. ind.

No. of p.

77
Page

ABB Switzerland Ltd

3BHS124245 E80

en

Important Notice
Our experience has shown that, if the information and recommendations contained in this Operating Instructions are observed, the best possible reliability of our products is assured. The data contained herein purports solely to describe the product and is not a warranty of performance or characteristics. It is with the best interests of our customers in mind that we constantly strive to improve our products and keep them abreast of advances in technology. This may, however, lead to discrepancies between a product and its "Technical Description" or " Operating Instructions". This document has been carefully prepared and reviewed, however should in spite of this the reader find an error, he is requested to inform us at his earliest convenience. It is scarcely possible for the operating instructions for technical equipment to cover every eventuality which can occur in practice. We would therefore request you to notify us or our agent in the case of all unusual behaviour, which does not appear to be covered by these operating instructions. It is pointed out that all local regulations must be observed when connecting and commissioning this equipment in addition to these operating instructions. We cannot accept any responsibility for damage incurred as a result of mishandling the equipment regardless of whether particular reference is made in these operating instructions or not. We lay particular stress on the fact that only genuine spare parts should be used for replacements. All rights with respect to this document, including applications for patent and registration of other industrial property rights, are reserved. Unauthorized use, in particular reproduction or making available to third parties, is prohibited.

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Page

ABB Switzerland Ltd

3BHS124245 E80

en

Contents
1
1.1 1.2 1.3 1.4

GENERAL INFORMATION ......................................................................................5


Introduction ............................................................................................................................... 5 Marking of sections of text........................................................................................................ 5 Manufacturers address ............................................................................................................ 5 Area of use ............................................................................................................................... 6

2
2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.2 2.2.1 2.2.2

DEVICE DESCRIPTION...........................................................................................7
Hardware .................................................................................................................................. 7 Control elements and interfaces............................................................................................... 8 Overview of the device connections ......................................................................................... 9 Device connections ................................................................................................................ 10 Digital inputs ........................................................................................................................... 13 Digital outputs ......................................................................................................................... 15 Analog inputs .......................................................................................................................... 17 Analog outputs........................................................................................................................ 18 Software.................................................................................................................................. 19 Operating modes .................................................................................................................... 19 Description of the parameters ................................................................................................ 22

3
3.1 3.2 3.3

INSTALLATION AND DISPOSAL..........................................................................29


Mechanical installation ........................................................................................................... 29 Earthing and wiring ................................................................................................................. 29 Disposal .................................................................................................................................. 29

4
4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6

OPERATION ..........................................................................................................31
Operation on the unit .............................................................................................................. 31 Keypad.................................................................................................................................... 31 Display .................................................................................................................................... 31 Example of parameter setting................................................................................................. 32 Menu structure of display ....................................................................................................... 33 Fault message on the display................................................................................................. 38 PC-Software ........................................................................................................................... 39 Operation using the software.................................................................................................. 40 Example of parameter setting using PCTools ........................................................................ 41 Menu structure of PCTools..................................................................................................... 42 Save parameter file ................................................................................................................ 53 Evaluation of the waveform .................................................................................................... 54 Error message ........................................................................................................................ 56

5
5.1 5.2 5.3 5.4

COMMISSIONING..................................................................................................57
Safety regulations ................................................................................................................... 57 Setting aids ............................................................................................................................. 58 Work carried out while machine is at a standstill.................................................................... 62 Work carried out while machine is running............................................................................. 62

6
6.1 6.2 6.3

MAINTENANCE AND FAULTS .............................................................................65


Maintenance ........................................................................................................................... 65 Trouble shooting ..................................................................................................................... 65 Repair ..................................................................................................................................... 68

7
7.1 7.2 7.3

APPENDIX .............................................................................................................69
General Data .......................................................................................................................... 69 Settings record for UNITROL 1000 ........................................................................................ 71 Parameter settings, default values ......................................................................................... 72

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1 GENERAL INFORMATION
1.1 Introduction
UNITROL 1000 is an automatic voltage regulator of the latest design for synchronous generators and synchronous motors. The use of the most advanced microprocessor technology together with IGBT semiconductor technology (Insulated Gate Bipolar Transistor) allows it to be used in a wide area of applications. A practical and simple-to-operate panel on the unit is used for all control operations. In addition, a user-friendly software facilitates commissioning and allows optimisation of operation. The unit complies with all relevant international standards. The mechanical construction is extremely compact and robust. This user`s manual provides the necessary information on installing, commissioning and operating the UNITROL 1000. It is aimed at trained operating personnel who possesses a good knowledge of electrical engineering and electronics.

1.2 Marking of sections of text


Dangerous voltages This symbol indicates that dangerous voltages occur during handling which can cause fatal or serious injury. Caution Note Caution indicates sections of text which contain information in which failure to comply with regulations can lead to material damage or device failure. Sections of text marked with Note provide additional information. This information must be taken into account in order to avoid malfunctions.

1.3 Manufacturers address


ABB Switzerland Ltd Excitation Systems Voltage Regulators and Synchronizing Equipment CH-5300 Turgi / Switzerland Telephone: Fax: Email: Internet: +41 58 589 24 86 +41 58 589 23 33 pes@ch.abb.com www.abb.com/unitrol +41 844 845 845

24 h - Hotline for urgent service inquiries:

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1.4 Area of use


This advanced-design automatic voltage regulator is used for the excitation of indirectly excited synchronous machines. The regulator can also be switched over to function as a reactive power-, power factor- or field current regulator. It is characterised by wide ranges for input voltage and operating frequency.

Dual Channel

SM = Synchronous Machine E = Exciter PMG = Permanent-Magnet-Generator Shunt excitation with : - optional short circuit support - Synchronization unit - Change over to a redundant unit.

Batt.

Abb

UNITROL 1000
R

Abb

UNITROL 1000
R

SM

Abb

UNITROL 1000
R

Generator or motor excitation with PMG or external supply.


PMG

SM

Abb

UNITROL 1000
R

Replacement of voltage regulators for generators or motors with direct-current excitation machines.
SM =

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2 DEVICE DESCRIPTION
2.1 Hardware
Structure: The device is built into an aluminium casing with cooling flanges. The connection terminals are integrated into the front of the circuit boards, which are arranged on top of one another. Power electronics: The power part is fitted with an IGBT semiconductor. The average value of the output voltage is always positive. The output is current-limited and thus shortcircuit-proof. Control elements: The operating keys, the display and the sub-D connector for the RS-232 interface are located on the unit cover. Dimensions in mm Rack mounting Wall mounting
Abb
UNITROL 1000
R

Installation: The site of installation must be dry and free of dust (IP20).

Mounting: The UNITROL 1000 is designed for rack or wall mounting.

142

Connection diagram:
Digital in- and outputs Analog in- and outputs Auxiliary supply UAUX for control electronics L1 L2 L3 (+) (-)

UN1000
UNET UM IM2 Measurement and control inputs

~/=
AVR RS-232 RS-485

PWM Supply power electronics UPWR Ie

SM

E E

(+) L1 (-) L2 L3

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2.1.1 Control elements and interfaces


MAIN Monitor Mode = Auto Connected: 1

Carrying out settings on the unit The four-line display and the four keys are sufficient to allow complete operation. All settings can be carried out directly on the unit without additional equipment: Configuration of inputs and outputs Parameter setting Display of important measuring values.

OK ESC

Interface with PC
Abb
UNITROL 1000
R

Parameter setting and also optimisation is possible using the user-friendly software PC tool for Microsoft Windows. Connection cable, sub-D, 9 pol (female) Configuration of inputs and outputs Parameter setting Trending function for optimisation of the controller (Oscilloscope, Power chart) Display of important measuring values Parameter File upload or download.

Terminal block
DGND DGND +Vdig +Vdig

+Vref

+AI 1

+AI 2

-Vref

-AI 1

-AI 2

DI 5

DI 6

DI 7

AGND

32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
DIO 1 DIO 2 DIO 3
S1 S2

DIO 4

+Vdig

+Vdig

+Vref

+AI 3

AO 1

-Vref

AO 2

-AI 3

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
L1

50 51 52 53 54 55
L3 L1(+)

UM
L2

L3

L1

U NET
L3

NC

Ie

L1(+)

U PWR
L2(-)

U AUX
L2(-)

L3

6 4

9 4

10 11 12 4 13 14 15 4

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I M2

DI 8

serial port EIA-485


+ +

Rev. ind.

Page

2.1.2 Overview of the device connections


UN1000 (+10V) +Vref (-10V) -Vref (+24V) +Vdig AGND DGND L1(+) L2 (-) L3 L1 L2 L3 S1 S2 L1 L3 (NC) L1(+) L2(-) L3
13 14 15

UAUX

10

+ -

UPWR

11 12

Ie
9

UM

2 3 16

PID

EIA 485

+ 50
51

- 52 + 53
54

IM2

17 4

DSP RS232

- 55

UNET

5 6

9 pol

32 33 34 35 36 37 38 39 18 19 20 21 22 40 41 42 43 44 45 46 47

AIN

+AI1 -AI1 +Vref +AI2 -AI2 -Vref

~
#

~
in, norm.

AO1 AO2 AGND

23 24 25

AOUT

AIN

+Vref +AI3 -AI3 -Vref

~
#

in, inv. out, inv.

+Vdig DIO1 DIO2 +Vdig DIO3 DIO4

26 27 28 29 30 31

DIN, DOUT

DIN

DGND +Vdig DI5 DI6 +Vdig DI7 DI8 DGND

out, norm.

norm.

inv.

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2.1.3 Device connections Terminal designation L1(+) = 13 L2(-) = 14 L3 = 15 Signal Auxiliary supply UAUX - AC input voltage three-phase or - AC input voltage single-phase or - DC input voltage Power electronics supply UPWR - AC input voltage three-phase, AC input voltage single-phase and excitation current < 10 A or - DC input voltage or - AC input voltage single-phase and excitation current >10 A Diode D: 20 A, 600 V Capacitor: C = 1000 F, 600 V Measurements inputs Three-phase: - Machine voltage UM
External 9 to 250 V~

Circuit
UN1000

3~ 1~ 2=

L1,L2,L3 L1,L2 L1(+),L2(-)

50 to 250 V~

18 to 300 V=

L1(+) = 10 L2(-) = 11 L3 = 12

External 0 to 250 V~

3~ 2=

UN1000

L1,L2,L3 L1(+),L2(-)
UN1000

0 to 300 V=

External

D
0 to 250 V~

L1 L2

Three-phase: L1 = 1, L2 = 2, L3 = 3 S1 = 16, S2 = 17 Single-phase: L1 = 1, L3 = 3 S1 = 16, S2 = 17

External

L1 L2 L3

UN1000 UM

max. 250 V / 0.2 VA

SM
Single-phase: - Machine current IM2 or Single-phase: - Machine voltage UM or Three-phase with ground (Three ph gnd) - Machine voltage UM
IM2

S1 S2 L1 L3

1 A / 0.1 VA

External

UN1000 UM

max. 150 V / 0.2 VA External

L1 L2 L3

UN1000 UM

L1 L2 L3
External

max. 150 V / 0.2 VA

L1 = 4, L3 = 5

Single-phase: Line voltage measurement UNET Excitation current output Ie

L1 L3
External

UN1000 UNET

max. 150 V / 0.2 VA

+ -

=8 =9

UN 1000

0 to 300 V= 15 A =

+ -

Earth connection = 7

Earth connection
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Terminal designation DIO1 DIO2 DIO3 DIO4 +Vdig = 27 = 28 = 30 = 31 = 26, 29

Signal Digital inputs DIO1 to DIO4 DIO1 to DIO4 can be operated either as inputs or outputs.

Circuit
External 24 V DC UN1000

+Vdig
24 mA in

DIO1 to 4
1k out

Digital outputs DIO1 to DIO4 Caution: Configured as outputs, DIO1 to DIO4 must not be connected directly with +Vdig (causes short circuit via internal transistor)

UN1000

24 V DC

External

+Vdig
in

DIO1 to 4
out

DI5 DI6 DI7 DI8 +Vdig DGND

= 42 = 43 = 45 = 46 = 41, 44 = 40, 47

Digital inputs DI5 to DI8 Controlled from potential-free contacts

External

24 V DC

UN1000

+Vdig
24 mA

DI5 to 8 1k

Controlled from potentialdependent contacts R = 1 k, 4 W at 48 V R = 3.9 k, 10 W at 110 V R = 8.2 k, 20 W at 220 V

External

UN1000

DI5 to 8 1k

DGND

Caution

The internal 24 V supply may be loaded with a maximum of 300 mA by all used digital inputs and outputs.

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Terminal designation +AI1 = 33, -AI1 = 34 +AI2 = 36, -AI2 = 37 +AI3 = 19, -AI3 = 20 +Vref = 18, 35 -Vref = 21, 38 AGND = 25 Earth = 22,32,39

Signal Analog inputs AI1 to AI3 R = 10 k, 1 W

Circuit
External 10 V DC 4.7k 100k 47k 100k 4.7k AGND -10 V DC UN1000 100k 47k 100k UN1000

+Vref +AI1 to 3 R -AI1 to 3 AGND -Vref


External max. 10 V

+ 47k

+AI1 to 3 + -AI1 to 3 -

+ 47k

+AI1 = 33, -AI1 = 34 +AI2 = 36, -AI2 = 37 +AI3 = 19, -AI3 = 20 +Vref = 18, 35 -Vref = 21, 38 +Vdig = 26, 29, 41, 44 AGND = 25 DGND = 40, 47 Earth = 22,32,39

Analog inputs digitally assigned AI1 to AI3 (DI9 to DI14)

UN1000 External 1k

+Vdig +Vref +AI1 to 3 -AI1 to 3

24 V DC 10 V DC 4.7k 100k 47k 100k 47k

+ -

Ain

DGND
DGND

AO1 = 23 AO2 = 24 AGND = 25

Analog outputs AO1 to AO2

UN1000

12 V

100R

External max. 10 V max. 20 mA

AO1 to 2
AGND

Serial port: Sub-D, 9 pol, Male EIA-485: + = 50, - = 52 + = 53, - = 55 Earth = 51, 54

Serial interface RS 232

RX =2 TX =3 GND = 5
External UN1000
out in

Serial interface RS 485

External

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2.1.4 Digital inputs Input function None Excitation ON active Description Input not assigned Excitation ON demand active: - Field flashing begins if Off Level > 0% - Soft start begins after the Off Level has been reached (Auto mode) Excitation ON demand not active: All setpoints are immediately set to the following values and remain fixed there. Mode Manual Open Loop PF Var Auto Preset value 0A 0% 1.0 0% 100%

Excitation ON not active

Gen CB Closed Status active

Circuit-breaker closed status active: - Activates current measurement - This message triggers immediately the ramp of the soft start as if still the hold time Circuit-breaker closed status changes from active to not active: All setpoints are immediately set to the following values. Mode Manual Open Loop Auto Final value 90% Ie NoLoad 90% 1/Kceil 100%

Gen CB Closed Status no longer active

Parallel with Grid Status

Parallel with grid status active: - Enables together with Gen CB Closed possibility to change over to PF and Var modes. - Disables VDC mode. Increase setpoint of active regulator Decrease setpoint of active regulator Status reset setpoint is active: The setpoint of the active regulator goes to the following value at ramp speed. Mode Manual Open Loop PF Var Auto Final value Ie NoLoad 100% 1/Kceil 1.0 0% 100%

Increase Decrease Reset Setpoint

Remote SP Enable PF Enable Var Enable Manual Enable Open Loop Enable

Control signal for remote setpoint setting. The setpoints are controlled by analog inputs. Power factor regulation active Reactive power regulation active Manual active, field current regulation Open loop, direct control of power transistor active

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Input function Synchronize VDC Enable Secondary Net Reset Alarm

Description Synchronize demand active Voltage droop compensation control active Net 2 on island operation Clear the following alarms: - SystemOK (optional) - SW Alarm Standby demand active: - The output of the AVR is turned off - Boost is disabled - Field flashing is off - Integrator is kept in 1/Kceiling - All limits are disabled - There will be no data transmission to the EIA-485 bus - Mode is standby - All setpoints are following the corresponding actual value

Standby

The assignment of the digital inputs to the terminals DIO1 to 4, DI5 to 8, (DI9 to 14) can be selected freely.

Level of the digital input Setting range: 0 to 28 V DC


High Level Low Level logical 1 0 1

Polarity of the digital input Software setting


24 V DC

24 V DC

inverted
DIO1 to 4 DI5 to 8 DI9 to 14

normal

DIO1 to 4 DI5 to 8 DI9 to 14

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2.1.5 Digital outputs Output function None Boost Field Flashing *) Description Output not assigned Status signal boost is active Boost supports excitation in the event of line short circuit or heavy load. The boost function is blocked during field flashing and soft start. Field flashing (voltage built up) active, if Excitation ON The next field flashing can only be started after Excitation ON or after the power has been switched off. During field flashing the output of the regulator is blocked in all operation modes. In preparation One of the limiters (V/Hz, Ie, PQ or UM) is active or setpoint limit has been reached (min. - or max. position) V/Hz limiter active Setpoint limit has been reached Minimum setpoint has been reached Maximum setpoint has been reached Ie, PQ or UM limiter active Ie minimum current limiter active Ie maximum current limiter active PQ limiter active Limit value for minimum machine voltage is fallen below, voltage limiter active Limit value for maximum machine voltage is exceeded, voltage limiter active active = machine voltage below boost threshold inactive = boost threshold and hysteresis exceeded Not dependent on signal Excitation ON.

SystemOK (optional) Limit Active V/Hz Limit Active SP Limit Reached SP Minimum Reached SP Maximum Reached Operational Limit Active Min Ie Active Max Ie Active Min PQ Active Min UM Active Max UM Active Voltage Relay

*) see also description of parameters in section 2.2.2

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Output function Sync Check

Description Sync Check demand active: - Generator circuit breaker is open - Machine voltage is more than 50% - Synchronization is possible (unit with Sync-Option) - Synchronize is enabled - Slip is between minimum slip and maximum slip - Machine voltage is deviating from network voltage maximum Delta U - Angle is between -maximum delta angle and +maximum delta angle The command is released: - Angle is in a value where it would take the Total CB Closing time for the breaker to close at zero degrees with current speed and acceleration. - Sync Check demand active - The command is so long active as the command Sync Check is active Software program process is out of order

Close CBCommand

SW Alarm

The assignment of the digital outputs to the 4 terminals DIO1 to 4 can be selected freely.

Polarity of the digital output Software setting

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2.1.6 Analog inputs Input function None Auto Remote Setpoint PF Remote Setpoint Var Remote Setpoint Manual Remote Setpoint Open Loop Remote SP UMaux Reserved2 to 5 Digital Input 9(+) & 10(-) Digital Input 11(+) & 12(-) Digital Input 13(+) & 14(-) Description Input not assigned External setpoint input to Auto regulator External setpoint input to PF regulator External setpoint input to Var regulator External setpoint input to Manual regulator External setpoint input to open loop Auxiliary supply to the summing point of Auto regulator Reserved for later function expansion Assign digital inputs Assign digital inputs Assign digital inputs

The assignment of the analog inputs to the 3 terminals AI1 to 3 can be selected freely.

External setpoint input

Internal signal value Setpoint max = 110 Setpoint min = 90

[%]

Ext. Setpoint Auto -10 2 Ain0% UMaux 10 max = 6 -6 -10 [%] Analog in 8 10 Ain100% [V] 8 10 Ain100% [V]

Input to the summing point


Ain0% min= -10

+AI1 to 3 -AI1 to 3

AI

Ain

Ain +Ain100% +Ain0% -Ain0% -Ain100%


Din9=0 Din10=0 Din9=1 Din10=0 Din9=0 Din10=0 Din9=0 Din10=1

Two digital signals can be generated from an analog signal. AI = pos. AI = neg. -> Ain = -> Ain =

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2.1.7 Analog outputs Output function None Excitation Current PWM Fbias Description Output not assigned Excitation current Pulse width modulation, control value Analog continuous signal presenting difference between UNET and UM Fbias = fNET fNOM (Slipmax Slipmin)/2 Output signal Fbias is forced to zero: - Not in Sync mode - Synchronization function not enabled (unit without Sync-Option) - Network frequency is not between 45 to 66 Hz

The assignment of the analog outputs to the 2 terminals AO1 to 2 can be selected freely. Level of the analog outputs Excitation Current Caution: Ie0% must be less than Ie100%
Aout % 10 Aout 100% 8 Aout 0% 2 5 -10 Ie 0% Ie100% Aout % [V] 10 8 2 -3 Fbias0% Aout % 10 Aout 100% 8 Aout 0% 2 100 -10 [V] 3 Fbias100% 15 [V]

Ie 30 [A]

Fbias
Aout 100% Aout 0%

Fbias [Hz]

-10

PWM Output

PWM [%]

The full voltage range runs from 10 V to 10 V at a resolution of 10 bits.


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2.2 Software
2.2.1 Operating modes Automatic voltage regulation (Auto) Regulates the terminal voltage of the synchronous machine. Note: Current measurement for compensation / droop
SM E
UN 1000 PID Regulator

UN 1000

Manual control Regulates the field current of the excitation machine. Note: No limiters will be active.
SM E

PI Regulator

UN 1000

PF or Var regulation (PF, Var) Regulates the power factor or reactive power of the synchronous machine.
SM

PI Regulator PF MVar

Open loop Manual control with a fixed output signal. Note: No limiters will be active.
SM E

UN 1000

Note

Bumpless changeover between all modes of operation

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Voltage droop compensation control and reactive power allocation

(VDC)

In order to share equally the amount of reactive power between parallel connected generators UNITROL 1000 offers a special feature, called voltage droop compensation control. Units are connected together with RS-485 bus. In VDC mode, actually, all AVRs operate in Auto mode with voltage droop. However, each AVR (with its own ID number) writes the value of its own amount of reactive power to the RS-485 bus. Each unit reads these values and calculates a common average Mvar setpoint, and compensates the effect of voltage droop. Therefore, voltage level on the busbar is always kept at 100% (not adjustable).
Load A Load B

RS 485

SM

AVR 1

SM

AVR 2

SM

AVR 3

SM

AVR 4

Prim. Net = 1 Din= Secondary Net

Prim. Net = 1 Sec. Net = 2

Synchronization

(Sync)

Power circuit breaker (CB) may only be closed if both voltages are at least approximately synchronous (coincident). Otherwise, faults in line operation, loading of the generators and, in extreme cases, damage to the generators can result. Measuring: The values are formed from the two measurement signals UNET and UM - Voltage difference (amplitude) - Slip (frequency difference) - Phase-angle difference Matching: The voltage matching function gives the adjusting value to the internal voltage regulator and the frequency matching function send the analog signal Fbias to the turbine regulator. Monitoring and command generation: The command to close the breaker (CB) is released if all conditions are fulfilled.

UNET Setpoint fSP = fNom CB


Speed Controller

UN 1000

Command Fbias Sync Setpoint UM Regulator

SM

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Dual channel system

(Standby)

In case of a failure in channel 1, the redundant channel 2 is activated and the defective channel switched off. Change over to channel 1 can be controlled by alarm signal or with an external control signal.

Dual channel UN 1000 / 1 UN 1000 / 2

Regulator

Regulator

SM

E
Alarm Standby

Operating modes are chosen by activating the predefined digital inputs. See section 5.2.

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2.2.2 Description of the parameters

System Data
- Nominal voltage of the machine - Measuring voltage three- or singlephase - Potent. transformer, primary voltage - Potent. transformer, sec. voltage - Nominal machine current - Current transformer primary current - Current transformer sec. current - No load excitation current - Ceiling factor - Machine reactance - Line voltage measurement (UNET) UMNominal [kV] PT [Single Ph] [Three Ph] [Three ph gnd] [kV] UMPrimary UMSecondary [V] [A] IM2Nominal [A] IM2Primary IM2Secondary [A] Ie NoLoad [A] Kceil [V/V] Xq [p.u.] No scaling
PTNET

UNET

UMPrimary IM2Primary

PTM

UMSecondary

Regulator

IM2Secondary IM2Nominal UMNominal

SM
Xq

Ie NoLoad

Caution The line voltage measurement cannot be scaled. A phase shift between the both measuring transformers PTNET an PTM is not allowed.

Field Flashing
- Off Level Off Level [%]
Machine voltage [%] Signal field flashing

By setting Off level to 0% the field flashing is disabled


Field flashing off level Soft start level [s] Excitation ON

Soft Start
Machine voltage

- Starting voltage - Delay until ramp - Ramp time

Start Level Hold Time Ramp Time

[%] [s] [s]

[%]

UMNominal

A soft start is done only in the Auto mode

Start level [s] Hold time Ramp

Gen CB Closed Status = active Trigger immediately the soft start

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Limiters
V/Hz Limiter - V/Hz knee point frequency - Slope fknee [Hz] Slope [% / fknee]
[%] 100 Machine voltage

[Hz] fknee

IeMinimum current limiter - Minimum limit - Limiter active

Minimum [A] Active = True/False

underexcited Limitercharacteristics

P [W] Active power overexcited GENERATOR Reactive power Q+ [var]

Iemin
Q-

UM2 Xq

MOTOR

IeMaximum current limiter


[A]

Excitation current

- 1st limit - Hold time - 2nd limit delay - Hold time - Continuous current - Limiter active

Maximum Hold Time Delayed Hold Time

[A] [s] [A] [s]

1st limit 2nd limit Contin. current [s]

Hold time

Hold time

Continuous [A] Active = True/False

PQ Limiter The characteristic is determined by 5 points - Q limit at P= 0% - Q limit at P= 25% - Q limit at P= 50% - Q limit at P= 75% - Q limit at P= 100% - Voltage dependency active - Limiters active Q( 0%) [%] Q( 25%) [%] Q( 50%) [%] Q( 75%) [%] Q( 100%) [%] Volt.Depend=True/False Active =True/False

P [W] underexcited
P=100% P=75% P=50% P=25%

Active power overexcited

Generator Reactive power Q+ [var]

Q-

P=0% P=25% P=50%

P=75%

Motor

P=100%

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UM Limiter - Limiting value of the minimum machine voltage - Limiting value of the maximum machine voltage - Limiter active - Limiter active Caution Minimum [%] Maximum [%] MinActive =True/False MaxActive =True/False

In PF/Var mode, the Auto regulator takes over in the event of extreme line disturbances.

Boost-Output - Pick-up volt. to generate boost command - Time boost output is active - Hysteresis for the reset of boost output Threshold [%] Hold Time [s] Hysteresis [%]
100%

Machine voltage Soft start Excitation ON Excitation ON not active

Voltage drop

Hysterese Threshold t Hold time Boost = Voltage Relay= 1 0 0 1 1 0 0 [s]

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Setpoint setting for the regulator


- Auto - PF, Var - Manual, - Open Loop - UMaux Minimum [ ] Maximum [ ] Ramp Rate [ ] Minimum [ ] Maximum [ ] to voltage regulator to power factor, reactive power regulator to manual regulator to open loop regulation circuit Auxiliary supply to the summing point of Auto regulator

Mode Level of the setpoint if the digital Input Excitation ON is not active. Manual Open Loop PF Var Auto

Preset value 0A 0% 1.0 0% 100%

The limits and rise time can be set separately for each operating mode. The setpoints of the non-active regulators follow the relevant operating point. For example, for reactive power regulation (Var) the setpoint of the auto-regulator follows the current machine voltage. Thus allows surge-free switching between operating modes if the new setpoint is within the setpoint limit. Particulars to the setpoint in Sync mode - No Load: Regulator works in AUTO mode. Setpoint follows line voltage and the ramp rate corresponds with the increase- resp. decrease command. - Gen CB Closed Status active: Works in AUTO mode, but the setpoint will be changed in such a manner that the reactive power always goes to zero.

Voltage Droop Compensation Control (VDC)


- Primary Net ID - Secondary Net ID - Ramp Time Net ID Net ID Ramp Time
Machine voltage

[s]

100

Ramp time to get machine voltage to 100% and Var equal between machines after VDC is activated.
Reactive current Var SPmin Var SPmax [%]

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Synchronisation
- Minimum Slip - Maximum Slip - Max. voltage difference Note: fM > fNET Slip always negative Minimum Slip Maximum Slip Maximum Delta U [Hz] [Hz] [%]
(Delta U) UM -UNET [%] 10,0 5,0 Slip [Hz] -5,0 -10,0 -0,40 0 Maximum Minimum

-1,00

Angle = 10

-10
0 -20
-20

Delta Angle

Maximum Delta Angle [deg]


20 40 60

-40 -60

Time between closing Total CB Closing Time [ms] command and closed breaker (see data sheet of the breaker)
[%] Setpoint AUTO Maximum UNET Ramp = constant UM Minimum

Voltage matcher The machine voltage is raised to the level of the line voltage. Ramp Rate has to be adjusted in the menu Setpoint AUTO

110 103 100 98 90 [Hz] 3 Fbias

Frequency matcher Example: fNOM = 50 Hz (45 Hz < fNET 54 Hz, 50 Hz) (54 Hz < fNET < 66 Hz, 60 Hz)

-0,8 -3 [Hz] fSP 50 fNOM 49 fNET 48 47 fSP

= 49 Hz fNET = 47 Hz fM = 47 Hz (Setpoint turbine) fSP fSP = 50 Hz (Setpoint turbine for synchronization) Slipmax = -0,4 Hz Slipmin = 0 Hz = fNET -fNOM -(Slipmax-Slipmin)/2 = -0,8 Hz Fbias fSP+Fbias= 49,2 Hz

[Hz] 50 fNOM 49,2 49 fNET 48 47 fSP + Fbias fM

0,4

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Regulator
Auto [Voltage control] - Proportional gain - Integral time constant - Derivative time constant

Tune
Gain [p.u.]

Vp Ta Tb

[p.u.] [s] [s]

150 Vp

1/Ta

1/Tb

1257

[rad/s]

Machine voltage

- Compensation or droop

Kq

[%]

[%]

nsation Compe

Kq= 20% (max. compensation) Kq= 0.00 (no effect)

Droop

Kq= -20% (max. droop) Reactive current [%]

PF or Var Control and PQ Limiter

P [W] underexcited

Active power overexcited Var PF Reactive power Q+ [var]

Vp Ta

[p.u.] [s]

PF

Generator

Q-

Motor

Manual Field current control and Ie Limiter

Gain [p.u.]

Vp Ta

[p.u.] [s]

Vp

1/Ta

1257

[rad/s]

Communication Write EEPROM


Electrically Erasable Programmable Read Only Memory

ID unit number: AVR ID Saves the parameters in the devices EEPROM

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3 INSTALLATION AND DISPOSAL


Caution The safe operation of the unit depends on appropriate transport and correct storage, installation and mounting.

The unit should be packed and unpacked with the usual degree of care, without the use of force and using suitable tools. The unit should be inspected visually to check for any damage caused during transport. Complaints regarding defects resulting from inappropriate transport are to be addressed immediately to the receiving station or the last carrier. The unit should only be installed in indoor areas which are dry and dust-free and which do not contain any gases, acid fumes or similar (IP20).
O7 170
Abb
UNITROLR 1000

3.1 Mechanical installation


The unit is fixed in place by means of four screws. See dimensions diagram for fixing holes and spacing.
200

Dimensions in mm

3.2 Earthing and wiring


The emission limits in accordance with standard EN 50081-2 (1993) will only be complied with if the connections for the power electronics supply and the field output are made using shielded cables earthed at each end. We also recommend that shielded cables be used for the analog and digital connections. The connection terminals are fitted on the front side of the unit, on three levels: Maximum cross sections: - Power electronics, terminals numbers 1 - 15: 4 mm2 - Electronics section, terminals numbers 16 - 55: 2.5 mm2 The casing must be earthed at terminal 7 with 4 mm2. Additional earth terminals are provided for the shielded cables. The earth connection should be kept as short as possible.

3.3 Disposal
Improper disposal of electrical devices can lead to environmental damage. It is therefore important that the disposal of electronic equipment is carried out by qualified personnel. The metallic casing does not present any risk to the environment and can be recycled. UNITROL 1000 is of environmentally friendly design. The printed circuit boards are simple to remove. The printed circuit boards must be removed and should be disposed of by a licensed disposal company. Environmentally hazardous elements such as capacitors must be separated from the boards.
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4 OPERATION
4.1 Operation on the unit
4.1.1 Keypad The keypad consists of four keys with the following functions: Keys , Commands Select mode: Parameter setting: OK Select mode: Moves the cursor up or down Horizontal arrow cursor marks the active line Increases or reduces value Selects sub-menu in the line marked with the cursor On parameter level, the cursor disappears and the following text is displayed: OK to write value => Accept new value, not yet saved in EEPROM ESC to cancel => Retain old value Parameter setting: ESC Select mode: Parameter setting: Accept new value Back to next-higher menu Retain saved value

4.1.2 Display After auxiliary voltage supply UAUX is applied the version numbers of both the unit and the panel are shown on the display for a few seconds. Then the start menu MAIN lights up. All the sub-menus are called up from the MAIN start menu The vertical arrow ( ) indicates whether other lines are available using the up () or down () keys. The horizontal arrow cursor () marks the active line. "MAIN" start menu The title and three lines are displayed - Online measurement of machine and field values - Current operating mode, in this place only a information - Set ID number of the unit, in this place only a information - Set parameters - Set regulator parameters - Set ID number - Save parameters in UNITROL 1000

key key key key

MAIN Monitor Mode = Auto Connected: 1 Setup Tune Communication Write EEPROM

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4.1.3 Example of parameter setting Example: Assigning Parallel wGrid to input DI6 Operating Display after auxiliary voltage is applied Key Resulting display
MAIN Monitor Mode = Auto Connected: 1

In the start menu, use key to move down to setup

3x OK, 7x OK, 1x OK, 5x OK OK 3x OK 4x ESC

MAIN Mode = Auto Connected: 1 Setup SETUP Setpoints Volt.Droop Comp. Digital I/Os DIGITAL I/Os Hysteresis I/Os Din from Ain DIGITAL I/Os DIO4 DI5 DI6 DI6 Din= None Polarity =Normal DI6 Din= None - OK to write value - ESC to cancel DI6 Din=Parallel wGrid - OK to write value - ESC to cancel DI6 Din=Parallel wGrid Polarity =Normal MAIN Mode = Auto Connected: 1 Setup

Select sub-menu 1, setup, and use key to move down to digital I/Os Select sub-menu 2, digital I/Os, and use key to move down to I/Os Select sub-menu 3, digital I/Os, and use key to move down to DI6 Select sub-menu 4, DI6

Select parameter DI Cursor disappears, text OK/ESC appears instead Use key to select assignment

Press OK key to save

Press ESC key to return to start menu

Caution

The above procedure only changes the parameters in the volatile memory. To make the modification permanent, you have to save the entire parameter set: Save parameters: Start menu MAIN, Write EEPROM, OK, OK.

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4.1.4 Menu structure of display


Start menu MAIN Monitor Mode = Auto Connected: 1 Setup Tune Communication Write EEPROM Sub-menu 1 Sub-menu 2 Sub-menu 3

MONITOR UM = kV UM rel = % IM2 = A IM2 rel = % Q = kVar Q rel = % P = kW P rel = % Ie = A freq = Hz SETUP System Data Field Flashing Soft Start Limiters Synchronization Setpoints Volt. Droop Comp. Digital I/Os Analog Inputs Analog Outputs

MAIN

SYSTEM DATA UMNom = kV PT = UMPrim = UMSecond = IM2Nom = IM2Prim = IM2Sec = Ie NoLoad = Kceil = Xq = kV V A A A A V/V PT: Three phase Single phase 3 phase gnd

MAIN, SETUP

FIELD FLASHING Off Level = %

MAIN, SETUP

SOFT START Start Lvl = % Hold Time = s Ramp Time = s

MAIN, SETUP

LIMITERS V/Hz Limiter IeMin Limiter IeMax Limiter PQ Limiter UM Limiter Boost

V/Hz LIMITER fknee = Hz Slope = %

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Sub-menu 2

Sub-menu 3

MAIN, SETUP,

LIMITERS

IeMin LIMITER Minimum = A Active =

MAIN, SETUP,

LIMITERS

IeMax LIMITER Maximum = A Hold Time = s ---------------------Delayed = A Hold Time = s ---------------------Continuous = A Active = PQ LIMITER Q( 0%) = Q( 25%) = Q( 50%) = Q( 75%) = Q(100%) = Volt.Depend = Active = % % % % %

MAIN, SETUP,

LIMITERS

MAIN, SETUP,

LIMITERS

UM LIMITER Minimum = % Maximum = % MinActive = MaxActive = BOOST Threshold = % Hold Time = s Hysteresis = %

MAIN, SETUP,

LIMITERS

MAIN, SETUP

SYNCHRONIZATION

Min Slip = Max Slip = Max dU = Max Angl= TotCBCtime =

Hz Hz % deg ms

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Sub-menu 2

Sub-menu 3

MAIN, SETUP

SETPOINTS Auto PF Var Manual Open Loop

AUTO PF SP Var SP MANUAL SP OPEN LOOP SP Minimum = % Maximum = % Ramp Rate = %/s

UM AUX Minimum = % Maximum = %

MAIN, SETUP

VDC Prim.NetID = Sec.NetID = Ramp Time = s

MAIN, SETUP

DIGITAL I/Os Hysteresis I/Os Din from Ain

HYSTERESIS Low Level = V High Level = V

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Sub-menu 2

Sub-menu 3

Sub-menu 4 Direction: Input Din None, Excitation ON, Gen CB cl. st., Parallel wGrid, Increase, Decrease, Reset Setpoint, Remote SP Ena., PF Enable, Var Enable, Manual Enable, Open Loop Ena., Sync, VDC Enable, Secondary Net DIO1 DIO2 DIO3 DIO4 Direction = Din = Dout = Polarity =

DIGITAL I/Os DIO1 DIO2 DIO3 DIO4 DI5 DI6 DI7 DI8

DI5 DI6 DI7 DI8 Din = Polarity =

Direction:

Output Dout None, Boost, Field Flashing, SystemOK Limit Active, V/Hz Lim. Act., SP Lim. Reach., SP Min. Reach., SP Max. Reach., Oper. Lim. Act., Min Ie Act., Max Ie Act., Min PQ Act., Min UM Act., Max UM Act., Voltage Relay, Close CB Comd, Sync Check, SW Alarm

Sub-menu 4 DI09 DI10 DI11 DI12 DI13 DI14 from AI Din = Polarity =

DIN from AIN DI9 from +AI DI10 from -AI DI11 from +AI DI12 from -AI DI13 from +AI DI14 from -AI

Polarity:

Normal, Inverted

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Sub-menu 1 Ain:

Sub-menu 2 None, Auto Remote SP, PF Remote SP, Var Remote SP, Manual Rem SP, OpenLoop R SP, UMaux, Reserved2, Reserved3, Reserved4, Reserved5, DI9(+)&10(-), DI11(+)&12(-), DI13(+)&14(-)

Sub-menu 3

MAIN, SETUP

ANALOG INPUTS AI1 AI2 AI3

AI1 AI2 AI3 Ain = Uin0% = Uin100% =

V V

Aout:

None, Exc. Current, PWM Fbias

AIN, SETUP

ANALOG OUTPUTS

AO1 AO2 Ie Range Fbias Range

AO1 AO2 Aout = Uout0% = Uout100% =

V V

MAIN, SETUP,

ANALOG OUTPUTS

Ie RANGE Fbias RANGE Fbias0% = % Fbias100%= %

MAIN

TUNE Auto PF/Var/PQ Limiter Manual/Ie Limiter Open Loop

AUTO Setpoint = Vp = Ta = Tb = Kq = Step = Do Step


Document number

% s s % %
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Sub-menu 1

Sub-menu 2

MAIN, TUNE

PF/Var/PQ LIMITER

SP PF = SP Var = Vp = Ta = PF-Step = Var-Step = Do PF-Step Do Var-Step MAIN, TUNE

% s

MANUAL/Ie LIMITER

Setpoint Vp Ta Step Do Step MAIN, TUNE

= = = =

A s A

OPEN LOOP Setpoint = % Step = % Do Step =

MAIN

COMMUNICATION AVR ID =

MAIN

MAIN Write EEPROM -OK to write value -ESC to cancel

4.1.5 Fault message on the display In certain circumstances it could appear the following fault messages on the display: XIRQ, SI or SYSTEM HALTED The regulator continues to work faultless and has not to be taken out of service. But, no parameters can be entered or changed. The display is reseted when the unit is taken out of service and the auxiliary power is disconnected for a short-time. A defective unit should be sent in for repair. See manufacturers details in section 1.3.

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4.2 PC-Software
The delivered PC software is called PCTools for UNITROL 1000. System requirements: - at least Pentium II (200MHz) processor - 256 MB RAM - 4-speed CD-ROM drive - Microsoft WindowsTM 95/98, NT or 2000

Installing PCTools 3.0 software To install the PCTools software please carry out the following steps: Place the PCTools CD in your CD-ROM drive Open the Windows File Manager or Explorer Display the CD root directory Double-click Visa201.exe from the directory PCTools \ Installer \ Disks Double-click Setup.exe from the directory PCTools \ Installer \ Disks Follow the instructions that appear on the screen. The Setup loads the PCTools program into your hard disk.

The application program is now installed. To start the program: Open the user interface via Start button, Programs, UNITROL 1000 and Double-click the shortcut icon PCTools.

Distribution rights: PCTools was developed with the LabVIEW software and is distributed free of license charges and costs. The copyright to LabVIEW is owned by the company National Instruments International Distribution (NIID). Copyright [02-03-10] National Instruments Corporation.

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4.2.1 Operation using the software The window PCTools is the graphic user interface of the program. The other sub-menus are called up from the menu bar: - File: Load/save parameters - Monitor: Online measuring - Setup: Set parameters - Com.: Set ID number - Tune: Tune regulator - Help: Software information
+

PCTools
File Monitor Setup Communication menu bar, start menu Tune Help

OFF LINE Connected to:

ID-Number

AVR1

EEPROM

ABB

PCTools for UNITROL 1000

Display on the unit: After the connection cable has been connected, the unit display reads REMOTE CONTROL.

REMOTE CONTROL

Note

It is possible to connect or disconnect the cable while the unit is in operation.

To make the communication between PCTools and the unit:


+

PCTools
Setup Communication Tune OFF LINE ON LINE Connected to: Reading Parameters from AVR 100.0%+Ready
AVR1

File Monitor

Help

Click the button OFF LINE

k clic
Button lights up green LED lights up green

Caution: This button is shaded, if PCTools can not communicate with the unit. Press the button Continue to accept the reading of the parameters.

EEPROM

Cancel Parameters Read OK Continue

2nd

c lic k

The button is now with ON LINE labelled and lights up green The parameters have been loaded from the unit to PCTools (EEPROM LED lights up green)

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4.2.2 Example of parameter setting using PCTools Example: Assigning Parallel with Grid Status to input DI6 Make ON-LINE connection to the unit
+

PCTools File Monitor Setup Communication Tune Help

Menu bar PCTools, start menu - Select setup

click

- Select digital I/Os

click

System Data Soft Start Field Flashing Limiters Setpoints Voltage Droop Composition Digital I/Os Analog Input Analog Output Synchronization

Digital I/Os Close Direction DIO1 In Digital Input/Output None Polarity Normal

DI5

None None

Normal

- Open input DI6 withmenu

DI6

k ic cl

Normal

- Select input

click

None Excitation ON Gen CB Closed Status Parallel with Grid Status Increase Decrease Reset Setpoint Remote SP Enable PF Enable Var Enable Manual Enable Open Loop Enable Synchronize VDC Enable Secondary Net Reset Alarm Standby DI6
Parallel with Grid Status

Return to start menu Caution

Normal

The above procedure only changes the parameters in the volatile memory. To make the modification permanent, you have to save the entire parameter set. Save parameters in ON LINE status: - Unit: Menu bar PCTools \ File \ Write Parameters to EEPROM - Harddisk: Menu bar PCTools \ File \ Save Parameter File
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4.2.3 Menu structure of PCTools


+

PCTools
Monitor Setup Communication Tune Help About PCTools Software information

File

About PCTools
+

Control: Panel: Revision:

Software revision unit Software revision panel Software revision PCTools

ABB
Connected AVR Software Revisions Control: X.XXX Panel: X.XXX

PCTools

for UNITROL 1000 Revision: X.XXX

Click window to continue

Click window to continue

File

Monitor

Setup

Communication *.ini

Tune

Help

Open Parameter File Save Parameter File

Write Parameters to EEPROM Close close the application

File

Monitor

Setup

Communication

Tune

Help

Measurements Oscilloscope PQ Diagram Sync Diagram

Online measurement of the machine and field values Online measurement Online measurement Online measurement

Window measuring instruments Monitor \ Measurements


+

Measurements

Close

- Network Voltage (UNET) - Machine Voltage (UM) - Machine Real Power (P) - Field Current (Ie) - Machine Current (IM2) - Machine Reactive Power (Q) - Network Frequency (fNET) - Machine Frequency (fM) - Power Factor (PF)

[% and kV] [% and kV] [% and kW] [A] [% and A] [% and kVar [Hz] [Hz] --

Machine Voltage (UM) 50 75 100 125 150

25 0

0.0 0.000

% kV

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Oscilloscope Monitor \ Oscilloscope


File Edit Ctrl+O Start open the waveform (is saved as ASCII table, *.xls) open settings of oscilloscope (*. cfg) save measurements as ASCII table (*.xls) save oscilloscope settings (*. cfg) Ctrl+B Ctrl+Q Edit Cursors Sweep Buffer File Edit save waveform in a BMP File close application Start Ctrl+C Ctrl+S Start Start Freeze Waveform
File Edit Start

Open Waveform Recall Setup Save Waveform Save Setup Print Bitmap to File Close File

show / hide cursors, Cursor appear on the left side of the screen Run through recording from Cursor A

start the record (appears menu point Freeze Waveform) stop the record (appears menu point Start)

B A, s r rso Cu

Channel 1 UM Relative 0.0

cl ic k k ic cl

Zoom

50.0 %/div %

Channel 2 f Machine 50.0 Hz/div 0.0 Channel 3 Ie 10.0 0.0 Channel 4 PWM 100.0 %/div 0.0 A Channel 1 0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 time / s Buffer Length Sampling rate = 20 Samples / Second 50.0 s 0.0 % 0.0 s % A/div A Hz

Generator State Mode Combined Limit ------------PWM Ie UM Relative IM2 Relative f Machine P Relative Q Relative cosphi Iq Relative Iq Relative Slow Limit PQ Min Limit Ie Max UM Step PF Step Var Step Ie Step

Gain Offset Cursors A, B

B Channel 1

dt = 0.0 s 1/dt = Inf Hz

Channel 1 Channel 2 Channel 3 Channel 4

Measurement: Define buffer length (max. length = 100 s) Start, stop and save record The assignment of the signal, gain, offset can be chosen afterwards. Note: A reduced buffer length improves considerably the performance of the PC.

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Window PQ Diagram Monitor \ PQ Diagram (Power chart)


Close
125
100

100
75

x x
50

Limiter characteristics

75 50
25

Operating points

x
0

25 0 -300 -275 -250 -225 -200 -175 -150 -125 -100 -75

x
-25 0 25 50 75 100

x
-50

Window Synchonization Diagram Monitor \ Sync Diagram Synchronoscope

Close command Close Angle


20 40 60 80 100 120 140 160 180 -160 0 -20
-20

Differential voltage machine to network UM - UNET [%]

Frequency/Voltage
10.0 8.0 -40 -60 -80 -100 -120 -140 6.0 4.0 2.0 0.0 -2.0 -4.0 -6.0 -8.0 -10.0 -0.8 -0.6 -0.4 -0.2 0.0 0.2 0.4

Synchronization x

Slip fM -fNET [Hz]

0,05 Hz

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File

Monitor

Setup

Communication

Tune

Help Setting of the system and unit parameters System Data Soft Start Field Flashing Limiters Setpoints Voltage Droop Compensation Control Digital I/Os Analog Inputs Analog Outputs Synchronization

System Data Soft Start Field Flashing Limiters Setpoints Voltage Droop Compensation Digital I/Os Analog Inputs Analog Outputs Synchronization

Limiters V/Hz Limiter Operational Limits Boost

PQ, Ie und UM limiter Line short circuit support

Setpoints Auto PF Var Manual Open Loop UMaux

Min., max. and ramp

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Adjust System Data Setup \ System Data


Close

Ie No Load 5.0 A Kceiling 5.00 V/V Xq 1.50

UM Nominal 1.000 kV

IM2 Nominal 500 A

S Nominal 0.87 MVA

Potential Transformer PT Three Phase

k ic cl

Three Phase Single Phase Three ph gnd

Current Transformer Primary Secondary 500 A : 1.000 A

Primary Secondary 1.000 kV : 110.00 V

UM Nominal @ AVR 110.00 V

IM2 Nominal @ AVR 1.000 A

Configure Soft Start Setup \ Soft Start


Close
110 100 80

Start Level 0.0 % Hold Time 0.0 s Ramp Time 10.0 s

60 40 20 0 0.0 0.0 2.02.0 4.04.0 6.06.08.08.0 10.0 10.0 12.0 12.0 14.0 14.0 16.0 16.0 18.0 18.0 20.0 20.0

Adjust Field Flashing Setup \ Field Flashing


Close

Field Flashing Off Level

0.0 %

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Adjust V/Hz Limiter Setup \ Limiters \ V/Hz Limiter


Close

f knee Slope

48.0 Hz 100.0 %/fknee

Adjust Ie, UM and PQ Limiter Setup \ Limiters \ Operational Limits \ Limiter Setup
Ie Limiter Close Max Min Close

Max Ie Min Ie

Max UM Min UM Min Q

Max Ie Min Ie

Max UM Min UM Min Q

Active Max Ie = Min Q A for Min Q s 30.0 10.0 Max delayed Ie = Min Q A for Min Q s 12.0 60.0 Max continous Ie = Min Q A 10.0
UM Limiter Max Min

Active Min Ie = Min Q A 0.0

Max Ie Min Ie

Max UM Min UM Min Q

Max Ie Min Ie

Max UM Min UM Min Q

Active Max UM =
PQ Limiter
Close Max Ie Min Ie Max UM Min UM Min Q

Active Min UM = Min Q % 90.0

Min Q % 110.0

Active Voltage dependency Min Q5 = Min Q %, when P = 100% -20.0 Min Q4 = Min Q %, when P = 75% -25.0 Min Q3 = Min Q %, when P = 50% -30.0 Min Q2 = Min Q %, when P = 25% -35.0 Min Q1 = Min Q %, when P = 0% -40.0

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Adjust short circuit support Setup \ Limiters \ Boost


Close Threshold Hold Time Hysteresis 40.0 % 3.0 s 15.0 %

Adjust Setpoint Range Setup \ Setpoints \ AUTO


Close Minimum Maximum Ramp Rate 90.0 % 110.0 % 0.30 %/s

The setpoints PF, Var, Manual, Open loop and UMaux are entered in identical input fields.

Adjust Voltage Droop Compensation Control Range Setup \ Voltage Droop Compensation
Close Primary Net ID Secondary Net ID VDC Ramp Time 1 2 10.0 s

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Configure Digital I/O Setup \ Digital I/Os


Close Direction DIO1 DIO2 DIO3 DIO4 DI5 DI6 DI7 DI8 DI9 from +AI DI10 from -AI DI11 from +AI DI12 from -AI DI13 from +AI DI14 from -AI In In In In Digital Input/Output None None Out None None None None None None None None None None None None Polarity Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Low Level 4.0 V High Level 10.0 V

Direction = In None Excitation ON Gen CB Closed Status Parallel with Grid Status Increase Decrease Reset Setpoint Remote SP Enable PF Enable Var Enable Manual Enable Open Loop Enable Synchronize VDC Enable Secondary Net Reset Alarm Standby

ABB Switzerland Ltd

cl k ic

ic cl k
Inverted

cl

k ic
Direction = Out None Boost FieldFlashing SystemOK Limit Active V/Hz Limit Active SP Limit Reached SP Minimum Reached SP Maximum Reached Operational Limit Active Min Ie Active Max Ie Active Min PQ Active Min UM Active Max UM Active Voltage Relay CloseCBCommand Sync Check SW Alarm

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Configure Analog Inputs Setup \ Analog Inputs


Close Analog Input AI1 AI2 AI3 None None None 0% 0.0 V 0.0 V 100% 10.0 V 10.0 V 10.0 V

None Auto Remote Setpoint PF Remote Setpoint Var Remote Setpoint Manual Remote Setpoint Open Loop Remote Setpoint UMaux Reserved2 Reserved3 Reserved4 Reserved5 Digital Input 9(+) & 10(-) Digital Input 11(+) & 12(-) Digital Input 13(+) & 14(-)

k ic cl

0.0 V

Configure Analog Outputs Setup \ Analog Outputs


Close min Ie Range PWM Fbias Range Analog Output AO1 AO2 None Excitation Current PWM Fbias None None 0.0 V 10.0 V 10.0 V 0.0 A 0.0 % -3.0 Hz max 30.0 A 100.0 % 3.0 Hz

k ic cl

0.0 V

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Adjust Synchronization Setup \ Synchronization


Close Minimum Slip Maximum Slip Maximum Delta U Maximum Delta Angle Total CB Closing Time 0.00 Hz -0.40 Hz 5.00 % 10 deg 90 ms

File

Monitor

Setup

Communication ID Definition

Tune

Help Set ID number

Set ID Number Communication \ ID Definition Note: Required in VDC mode to be set unique

Close

ID

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File

Monitor

Setup

Communication

Tune

Help Automatic voltage regulation PF, Var regulation and PQ Limiter Manual control and Ie Limiter

Setpoint Adjust Auto PF/Var/PQ Limiter Manual/Ie Limiter

Adjust Setpoint, Trigger Setpoint, Status Displays Tune \ Setpoint Adjust


Close Generator State Active Mode Limiter State Setpoint
100.0 95.0 105.0

Standby Sync Grid Sec. Net Prim. Net NoLoad Manual Open Loop Pf Var VDC AUTO

Ie High UM High IM High


90.0

A setpoint jump can also be triggered in this window.

110.0

V/Hz

DOWN

UP 100.0 %

Adjust setpoint

Ie Low UM Step UM Low Iq Low DOWN 0.0 % UP

Set step height Trigger setpoint jump

Parameter Setting Range Tune \ Auto


Close

Vp (Proportional Gain)
75 50 25 0 100 125 150 175 200

Ta (Integration Time)
10.00 5.00 15.00

- Tune \ PF/Var/PQ Limiter - Tune \ Manual/Ie Limiter


Close

Vp (Proportional Gain)
0.01 20.00

Ta (Integration Time)
10.00

20.0 Kq (Droop)
-5 -10 -15 -20 20 0 5 10 15 0.01 1.00

1.00 s
50

75

100

125 150 175 5.00

15.00

Tb (Derivation Time)
2.00 3.00 4.00

25 0

200

0.01

20.00

20.0

1.00 s

5.00

0.0 %

0.35 s

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4.2.4 Save parameter file

PC
PCTools

UN 1000
RAM Parameters Write Parameters to EEPROM EEPROM Parameters

Harddisk

Open Parameter File Save Parameter File

OFF LINE

ON LINE EEPROM LED lights up, if data RAM = EEPROM (ON LINE)

Status ON-LINE After switching from OFF LINE to ON LINE, PCTools reads the parameters from the devices RAM. Now, all parameter changes carried out using PCTools are written directly into the devices RAM. - Write Parameters to EEPROM: - Save Parameter File: - Open Parameter File: The parameters in the RAM are stored in the device. The parameters are saved onto the hard disk as an INI file. The INI file is loaded into PCTools and the RAM is overwritten again. Caution: The old parameter file is immediately overwritten in the RAM!

Status OFF-LINE Any parameter changes carried out in PCTools are not transferred into the device. - Write Parameters to EEPROM: - Save Parameter File: - Open Parameter File: No effect, since there is no communication between PCTools and the device. The parameters are saved onto the hard disk as an INI file. The INI file is only loaded into PCTools. Caution: If you now switch to ON-LINE, PCTools loads the old data from the RAM again!

Editing the Parameter file: The INI file can be opened using an editor (Word, Note- or Wordpad) or by double-clicking on the filename and the parameters can be edited directly and printed out. Caution When entering the parameters, it should be ensured that the permissible ranges of values are not exceeded and that the specified syntax is observed. If the parameters in *.ini file are not correct, serious damage can be caused on the plant!

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4.2.5 Evaluation of the waveform The curves for the current and stored data can be viewed using the oscilloscope, PQ diagram and the instruments. (Monitor toolbar)
+

Close Measurements
Close

125 Voltage [UM] Machine


100

100
25 0

50

75

100 125 150 75

x x
50

limiter characteristics

75 50

x
25 106.7 1.067 [%] [kV] 0

PQ Limiter is active

25 0

x
-25 0 25 50 75 100

x
-75 -50

Zoom
File Edit Start

-300 -275 -250 -225 -200 -175 -150 -125 -100 Freeze Waveform

Channel 1 UM Relative 1 50.0 %/div 0.0 %

1 2 2

Channel 2 Iq Relative 100.0 %/div 0.0 Hz

Channel 3 Combined Limit 1.0 0.0 /div

3 4

Channel 4 Gen. State 2.0 0.0 A Channel 3 /div

Cursors A, B
B Channel 3 0.0 % 34.3 s

0.0

5.0

10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 time / s

Sweep Buffer
Buffer Length 50.0 s

0.0 % 24.0 s

dt = 10.3 s 1/dt = 0.097Hz

Status OFF LINE File \ Open Waveform: Open stored waveform file. Edit \ Cursors: Assign channel with buttons A and B, use left mouse button to drag cursor A to the desired point on the signal curve. The measured values can be measured on the oscilloscope, instruments or PQ diagram. Edit \ Sweep Buffer: The curves are run through from cursor point A using the scanning bar. Status ON LINE Start: Freeze Waveform: File \ Save Waveform: File \ Save Setup: The recording of the waveform is started. The recording is stopped. Save waveform. Save oscilloscope settings.

The window in "Tune can also be opened to set the regulators. The setpoint step is simulated in "Tune Setpoint Adjust. The buffer length can be adjusted from 1 s, 2 s, 5 s, 20 s, 50 s to 100 s. The time scale can be adjusted in the bar above the waveform (Zoom).

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Monitor \ oscilloscope, status display There are 3 quasi analogue signals which can be used to represent status changes on the oscilloscope. Decoding of the signals Generator State, Mode and Combined Limit.
Generator State Mode Combined Limit ------------PWM Ie UM Relative IM2 Relative f Machine P Relative Q Relative cosphi Iq Relative Angle UNetRelative Slip UM Step PF Step Var Step Ie Step

signal value Generator State: 0 = 1= 2= 3= 4= 5= 6= 7= 8= Mode: 0= 1= 2= 3= 4= 5= 6= 7= 0= 1= 2= 3= 4= 5= +8 =

state Idle (NoLoad) Change NoLoad -> Net1 Net 1 Change Net1 <-> Net2 Net 2 Change Net2 -> NoLoad Net1 or Net2 -> Grid ON Grid ON => see channel 4, picture previous page Grid ON -> Net1 or Net2 Auto Var PF Manual Open Loop VDC Sync Standby None Ie Min UM Min PQ Min => see channel 3, picture previous page Ie Max UM Max V/Hz *)

Combined Limit:

*) Each time a limiter is tripped, the V/Hz-Limiter can also occur and be displayed in the status signal of the limiters. All other collective signals only allow one display . Summary of the limiter status:
Combined Limit 1.0/div UM Max +V/Hz Ie Max +V/Hz PQ Min +V/Hz UM Min +V/Hz Ie Min +V/Hz V/Hz UM Max Ie Max PQ Min UM Min Ie Min None 13.0 12.0 11.0 10.0 9.0 8.0 +8 5.0 4.0 3.0 2.0 1.0

+8 s

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4.2.6 Error message

Error message during the reading of the parameters

The following message appears if the connection is interrupted during the reading of the parameters.
+

Error 0 occurred at Time Out. Possible reasons: FieldPoint: IAK operation was successful. or IA Servers: IAK operation was successful. or + PCTools Reading Parameters from AVR NI-488: Error connecting to driver or device. Help File Monitor Setup Communication Tune 100.0% Ready Continue Cancel ON LINE

Acknowledge by clicking on the Continue button. Check connection between PC and device and click OFF LINE button again.

Error message at assigning of the digital input with the signal Synchronize
+

The Error message appears, when the relevant unit does not include the option Synchronization.

Synchronization is not possible with this unit OK

Note

You can ask for information directly from the manufacturer, in case the option Synchronization is required to this unit. See manufacturers details in section 1.3.

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5 COMMISSIONING
5.1 Safety regulations
UNITROL 1000 units operate with dangerous voltages of up to 250 V AC. Manipulation of live parts can lead to death or injury to the persons involved or damage to the surroundings. Possible risks are largely excluded if the unit is handled properly in accordance with these instructions. All relevant regulations must be complied with during commissioning. It is essential that these safety regulations are read before starting any work on the UNITROL 1000 equipment. After the unit has been switched off, it must be ensured by measurement that no measuring voltages or control voltages >50 V are present at the terminals. At an interrupted field circuit the input capacitor is slowly discharged through internal circuits. In order to prevent unintentional closing of open voltage circuits by third parties, the circuits in question should be identified at the point of interruption (e.g. by means of a warning sign).

If work is being carried out in the vicinity of the UNITROL 1000, all voltages greater than 50 V leading to the system must be switched off.

Caution

Before switching on, always check whether the connection terminals are wired up according to the plant schematic.

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5.2 Setting aids


At the first commissioning all parameters have to be controlled. For this see description of the parameters in section 2.2.2 and settings recorded in section 7.3. Overview of parameter blocks Setup: - System Data - Field Flashing - Soft Start - Limiters - Synchronization - Setpoints - Voltage Droop Compensation Control - Digital I/O - Analog I/O

Tune: Controller Communication: ID unit number.

Setting aids Setup \ System Data, Ceiling Factor Kceil


U PWR

K ceil

Ue max = Ueo
Regulator U emax U eo

Uemax: maximum output voltage Ueo: output voltage at nominal voltage of the machine (machine in no-load operation)

SM

Definition: The ceiling factor Kceil determines the relationship between the maximum output voltage of the regulator and the exciter voltage which is required for no-load excitation and is thus a measure for the possible overexcitation of the machine. The greater the ceiling factor, the faster the regulator can react drops in the machine voltage and/or reactive power. On the other hand the smaller the ceiling factor, the faster the regulator can react load off. The ceiling factor is dependent on the available supply voltage UPWR. Power electronics supply: three- phase: Uemax = 1.40 * UPWR 8 V single-phase: Uemax = 1.25 * UPWR 8 V DC: Uemax = 0.98 * UPWR 8 V Example: Specifications: Calculation: Power electronics supply UPWR = 240 V, single-phase No-load exciter voltage Ueo = 150 V Uemax = 1.25 * 240 V 8 V = 292 V Kceil = 292 V/150 V = 1.95 p.u.

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Setup \ System Data, Machine Reactance Xq - Salient pole machine: Xq 0.7 to 0.5 Xd - Cylindrical-rotor machine (Turbo): Xq Xd Setup \ Limiter, Manual und Open Loop There are no limiters active in the mode Manual and Open loop. Setup \ Limiter, UM Limiter The limiting values of the UM limiter are, as a rule, set equally, like the setpoint range of the voltage regulator (Auto mode). Setpoint Auto Minimum Maximum UM Limiter = Minimum = Maximum Example 90% 110%

Setup \ Synchronization Caution The machine frequency has to be always greater than network frequency. It can not be synchronized by a positive slip.

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Setup \ Digital I/Os, configuration Software configuration of the digital I/Os: Check switching threshold of the inputs. Default values apply to internal 24 V supply. Define terminal as input or output Assign terminal to desired signal Select polarity Setup \ Analog inputs / outputs, configuration Software configuration of the analog inputs: Assign terminal to desired signal Define signal level of the input signal [Uin0% Uin100%] If the input is used as a digital input, the desired signal name is to be assigned in the menu Digital I/Os. Software configuration of the analog outputs: Assign terminal to desired signal Define signal level of the output signal [Uin0% to Uin100%] Define signal level of the field current [Ie0% to Ie100%]

Setup \ Digital I/Os, selection of operating mode The operating mode is selected via the digital inputs. For this purpose, a maximum of 10 inputs have to be occupied by the following signals: Mode
Exc. ON OFF Standby Sync Manual Open Loop VDC PF Var Auto 0V 24 V 24 V 24 V 24 V 24 V 24 V Stand by X 24 V 0V 0V 0V 0V 0V

Digital inputs which are to be assigned


SYN Gen CB Closed Status X X X X X 24 V 24 V 24 V 0V 24 V Parallel with Grid Status X X X X X 0V 24 V 24 V X X Manual Enable X X X 24 V 0V 0V 0V 0V 0V 0V Open Loop Enable X X X X 24 V 0V 0V 0V 0V 0V VDC Enable X X X X X 24 V 0V 0V X 0V PF Enable X X X X X X 24 V 0V X 0V Var Enable X X X X X X X 24 V X 0V

X X 24 V 0V 0V 0V 0V 0V 0V 0V

24 V 0V 24 V 0V with *) 24 V 0V *) with droop or compensation

X 0V

= not relevant = 0 V or open

Note: If an input is to be continuously active (24 V), then it should only be inverted by software means. The input then naturally counts as being occupied. The inputs DI9 to DI14 can be used as virtual digital inputs even if they are not defined in Analog Inputs as Digital Inputs.

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Tune \ Setpoint Adjust, Step Mode Maximum adjustable setpoint jump during 10 s Manual 5 A Open Loop 20% PF 0.2 Var 50% Auto 20% Tune, Order of priorities If several operating modes are selected simultaneously by the digital inputs, then the following order of priority applies. This is also shown in the tables Selection of operating mode on the preceding page. (Fields with X = not relevant) Priority 1. resp. top 2. 3. 4. 5. 6. 7. 8. 9. resp. lowest Mode OFF Standby Sync Manual Open Loop VDC PF Var Auto Remark

Only active, if Gen CB Closed status is there and Parallel with Grid status is there Only active, if Parallel with Grid status is there Only active, if Parallel with Grid status is there active, if no other operation mode is active

Tune, Auto The following settings can be pre-set on the basis of the machine data. Integral time constant Ta This lies within the range of Td of the main machine. Setting: Ta = Td Derivative time constant Tb This approximately compensates the load time constant TE of the exciter machine. Setting: Tb = 0.7 to 1.0 * TE Proportional gain Vp This most important setting value depends primarily on the controlled system. If the ceiling factor Kceil has been set correctly, values between 10 and 40 should result in stable regulation of the machine. A default value of 20 is set for the first excitation. Reactive power influence Kq In the case of machines which, without step-up transformers, are connected with the fixed grid or, via a busbar, with other synchronous machines, it is essential that the droop Kq is set to a negative value of 5 to 20%. A higher negative value makes the machine more independent of voltage fluctuations in the grid; the reactive power output or consumption stabilises. At low negative values, the machine will support the grid or busbar voltage. In the case of machines with step-up transformers, the voltage drop of the transformer can be partly compensated with positive values of Kq. Example: Step-up transformer Reactance = 12% Compensation Kq = +6%
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5.3 Work carried out while machine is at a standstill


Preliminary checks:

Wiring check, compare connections with schematic Caution Caution Unit connection terminal 7 has to be earthed. Disconnect cables before the meggers (with the insulation tester) on the unit. The unit could be damaged.

Switch on auxiliary voltage UAUX Adjust parameters Check measuring voltage and current transformer circuits Measure field resistance Low-load test: external supply of power electronics (3x <250 V AC) - Open loop mode, polarity - Optimise Ie regulator

Adjust limiter settings on the basis of customers power chart

Reminder, generator: short circuit and no-load tests.

5.4 Work carried out while machine is running


No-load tests: (nominal speed, not synchronized)

Field flashing, discharge and in Auto and Manual mode Soft start in Auto mode Adapt setpoint range, optimise voltage regulator V/Hz limiter: The actuation point fknee is set to 48 Hz by default Caution For 60 Hz machines this value must be set to approximately 58 Hz.

Reminder, synchronization: First synchronization with voltage regulator.

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Tests under load:

Stator current measurement, internal P- and Q-measurement, droop/compensation Caution The droop/compensation is set to 0% by default. If the machine is paralleled directly with the rigid grid or, via a busbar, with other synchronous machines, it is essential that the droop Kq is set to a value of approx. 10% before the first synchronization. The reactive current must be monitored carefully during the first paralleling. If it increases uncontrollably following the first synchronization, then the current direction of the IM2 measurement is incorrect or the CT phase position is wrong.

Load rejection overexcited and underexcited Optimise Iemin / Iemax Llimiter Optimise PQ Limiter Caution The setting of the PQ limiter must be co-ordinated with the settings of the generator protection. As a rule, the limiter should be set at least 5% lower.

PF and Var regulator, stability, setpoint range. Note: To enable correct operation of PQ Limiter, the PF / Var regulator must be tuned, even if these modes are not used.

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Synchronization: It is a prerequisite for the correct functioning of the synchronization that the measured machine and network voltages are in phase, display the correct values and are tuned with the circuit breaker closed.

UN 1000 UNET CB UM Isolator AVR

Measurement of the phase angle of the voltages UNET and UM: - open the isolator, close the circuit breaker (CB) For reasons of safety has to be measured not only in the menu Monitor\Oscilloscope or Monitor\Sync Diagram but also with an oscilloscope. Blind synchronization: Watch the event with synchronoscope (Monitor\Sync Diagram) by disconnected trigger of the circuit breaker. Live synchronization: Record the event with synchronoscope

SM

About the measurement: Caution In this status, the phase-angle difference must be 0 deg. Otherwise the measuring cable are incorrectly connected. Incorrect polarity cannot be detected by the UNITROL 1000. There must not occur a phase shift caused by one of the both measuring transformer or by the connection group of a step-up transformer. Paralleling with incorrect polarity can lead to serious damage.

Note: The synchronoscope must stand at twelve oclock . If the synchronoscope stands at six oclock, one voltage is incorrectly connected. In other positions, either measuring is being carried out on incorrect phases or a phase shift caused by the connection group of a step-up transformer has not been compensated.

Concluding work:

Saving the parameter and write the parameter settings section 7.3 or printing out the INI file. The INI file can be opened using an editor (Word, Note- or Wordpad) and printed out.

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6 MAINTENANCE AND FAULTS


6.1 Maintenance
When the system is at a standstill, the screwed terminals which can loosen due to vibrations should be checked for tightness. Dusty cooling flanges should also be cleaned.

6.2 Trouble shooting


The following instructions are intended to assist in localising a fault within the excitation system as a whole. However, it is not possible to deal with all eventualities in full. If a fault occurs in the unit, then the reserve unit should first be installed and commissioned in accordance with section 5. List of possible faults Possible causes Machine is not excited

Checks, action

Field circuit interrupted Field circuit-breaker doesnt close

Check wiring for break Check field circuit-breaker Check field flashing circuit Measure auxiliary supply UAUX Check for tripped protective circuit-breaker Measure power electronics supply UPWR Check for tripped protective circuit-breaker Measure auxiliary supply UAUX, Measure power electronics supply UPWR Check field flashing Off level Check operating mode. For field flashing normally Auto is used Check field flashing Off level Check setpoint Measure power electronics supply UPWR If all supplies and setpoints are correct change unit Check operating mode. For field flashing normally Auto is used Check setpoint Measure output voltage at terminals 8,9 (Osc.) -> positive Measure voltage UPWM (PCTools, Monitor) -> positive rising
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Shunt: Field flashing does not work


No electronics supply UAUX

No control element supply UPWR

Shunt: Machine is only excited to the value supplied by the field flashing

Machine is first excited then discharges again

Setpoint error

Regulator error

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Possible causes Overvoltage during build-up

Checks, action

Overvoltage caused by voltage regulator

Machine voltage UM present Check system data Check operating mode. For field flashing normally Auto is used Check setpoint Check thresholds of UM Limiter Check regulator settings Check design of the field flashing circuit. Field flashing should deliver 10 to 15% of the no load excitation current

Field flashing current too high

Machine voltage not stable in no-load operation

Regulator error

Check operating mode. For field flashing normally Auto is used Check setpoints Check parameters of Auto regulator Higher, lower inputs unstable Externally input setpoint unstable Check wiring, loose contact UM, Ie

Setpoint error

Control element fault

Parallel operation with grid unstable. Periodic oscillation of reactive and possibly active power

Regulator settings incorrect

Were changes made to the grid configuration? Additional outputs, loads etc. installed?
Yes: re-set regulator No: check parameters of Auto and PF, Var regulator

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Possible causes

Checks, action

Irregular instability, i.e. sporadic over- or underexcitation which is not caused by grid

Droop influence of the voltage regulator ineffective or Iq measurement defective Machine within inadmissible operating range (normally protected by limiters)

Check droop/compensation setting Check external current transformer circuit Bring machine into normal operating range by adjusting the setpoint. Check setting of limiters

Regulator fault

Measure output voltage at terminals 8,9 (oscilloscope) Measure voltage UPWM (PCTools, Monitor)
Signals in phase opposition: unit defective Signals in phase: disturbance possibly caused by the driving side of the machine or by disturbances from the grid

Operating point cannot be adjusted

Setpoint error

Check operating mode. For field flashing normally Auto is used Check setpoint Bring machine into normal operating range by adjusting the setpoint. Check setting of limiters

Limiter active

Excitation with compounding and boost circuit: Excitation is only supplied by the series compounding

No control element voltage Regulator fault

Measure power electronics supply UPWR Check for tripped protective circuit-breaker Check operating mode. For field flashing normally Auto is used Check setpoint Check parameters of Auto regulator

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Possible causes External controls faulty


Checks, action

No external control voltage

Measure control voltage check wiring Measure internal control voltages Check configuration

No internal control voltages Vdig, Vref Configuration of the digital or analog inputs or outputs is not correct

6.3 Repair
The unit may not be opened. A defective unit should be sent in for repair. See manufacturers details in section 1.3.

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7 APPENDIX
7.1 General Data
Ordering information Device designation Order number with Synchronization without Synchronization Mechanical data Weight Protection class Dimensions (LxWxH) Climatic stability Temperature range for operation Temperature range for storage Vibration Shock UNITROL 1000 3BHE005774 R0004 3BHE005774 R0003

5 kg IP20 245x190x142 mm

0 to 60 C -20 to +75 C 2 mm f<15 Hz, 0.7 g f>15 Hz 5 g, 11 ms pulse

Electrical data Auxiliary supply UAUX: Maximum power consumption 25 W DC, 40 to 600 Hz Power electronics supply UPWR: Frequency Excitation output IM2: - Maximum continuous current 15 A 1 A /degree - Current reduction for ambient temperatures >50 C - Overload (maximum 10 s) 30 A DC - Overload (maximum 4 min) 20 A DC Frequency range of measuring values UM and IM2 Accuracy: Test voltage: Voltage regulation Power electronics supply and auxiliary supply against case Voltage measurement inputs UM, UNET against case 10 to 100 Hz <0.1% 2 kV, 1 min 500 V, 1 min

Relevant standards, CE conformity EMC directive: Generic emission standard Generic immunity standard Ordering information connection cable PC to UNITROL 1000 Series standard cable (terminals 2 and 3 crossed)

89/336/EEC EN 50081-2 (IEC 61000-6-4) IEC/EN 61000-6-2

DB9 f/f/ 3 m

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This page is intentionally blank.

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7.2 Settings record for UNITROL 1000


Name and address of customer: ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ Plant: Order no.: Plant schematic no.: Device identification: Type plate: Delivery date: Software revision: - Control: - Panel: - PCTools: Remarks: ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________

Place and date of commissioning: Name: Company:

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7.3 Parameter settings, default values


Parameter System Data
- Nominal voltage of the machine - Measuring voltage, three- or single-phase - Potential transformer, primary voltage - Pot. transformer, secondary voltage 3-Ph 1-Ph 3-Ph gnd - Nominal machine current - Current transformer primary current - Current transformer secondary current - No-load current - Ceiling factor - Machine reactance UMNominal PT UMPrimary UMSecondary IM2Nominal IM2Primary IM2Secondary Ie NoLoad Kceiling Xq 1.000 three-Phase 1.000 110.00 500 500 1.000 5.0 5.00 1.5 0.010 to 32.000 1-/3-Phase/3-Ph gnd 0.010 to 32.000 60.00 to 250.00 60.00 to 150.00 60.00 to 150.00 1 to 32000 1 to 32000 0.500 to 1.500 0 to 10.0 1.00 to 100.00 0.20 to 4.00 kV -kV V V V A A A A p.u. p.u.

Abbreviation

Standard value

Setting range

Set

Unit

Field Flashing
- reached voltage off level Off Level 0.0 0 to 100.0 %

Soft Start
- Starting voltage - Delay until ramp - Ramp time Start Lvl Hold Time Ramp Time 0.0 0.0 10.0 0 to 100.0 0 to 327.0 0 to 327.0 % s s

Limiters V/Hz Limiter:


- Cut-off frequency - Slope fknee Slope 48.0 100.0 10.0 to 200.0 0 to 327.0 Hz
%/fknee

IeMin Limiter:
- Minimum limit - Limiter active Minimum Active 0.0 FALSE 0 to 15.0 FALSE / TRUE A --

IeMax Limiter:
- 1 limit - Delay time nd - 2 limit - Delay time - Continuous current - Limiter active
st

Maximum Hold Time Delayed Hold Time Continuous Active

30.0 10.0 12.0 60.0 10.0 TRUE

0 to 30.0 0 to 327.0 0 to 20.0 0 to 327.0 0 to 15.0 FALSE / TRUE

A s A s A --

PQ Limiter:
- Q Limiter at P = 0% - Q Limiter at P = 25% - Q Limiter at P = 50% - Q Limiter at P = 75% - Q Limiter at P = 100% - Voltage dependency active - Limiter active P at 0% P at 25% P at 50% P at 75% P at 100% Volt.Depend Active -40.0 -35.0 -30.0 -25.0 -20.0 TRUE TRUE -400.0 to -0.5 -400.0 to 0 -400.0 to 0 -400.0 to 0 -400.0 to 0 FALSE / TRUE FALSE / TRUE % % % % % ---

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0 Parameter UM Limiter:
- Limiting value minimum machine voltage - Limiting value maximum machine voltage - Limiter low level - Limiter high level

Abbreviation
Minimum Maximum MinActive MaxActive

Standard value
90.0 110.0 TRUE TRUE

Setting range
0 to 150.0 0 to 150.0 FALSE / TRUE FALSE / TRUE

Set

Unit
% % ---

Boost:
- Minimum machine voltage - Time boost output is active - Hysteresis Threshold Hold Time Hysteresis 40.0 3.0 15.0 0 to 100.0 0 to 32.7 0 to 100.0 % s %

Synchronization
- Minimum slip - Maximum slip - Maximum voltage difference - Maximum delta angle - Total CB closing time Minimum Slip Maximum Slip Max. Delta U Max.Delta Angle Tot.CB Cl. Time 0,00 -0.40 5.00 10 90 -1,00 to 0,00 -1,00 to 0,00 -10,00 to +10,00 0 to 72 0 to 630 Hz Hz % deg ms

Range of Setpoints Auto: - Minimum value


- Maximum value - Ramp Rate

Minimum Maximum Ramp Rate Minimum Maximum Ramp Rate Minimum Maximum Ramp Rate Minimum Maximum Ramp Rate Minimum Maximum Ramp Rate Minimum Maximum

90.0 110.0 0.30 -0.8500 +0.8500 0.0050 0.0 100.0 1.00 0.0 15.0 0.25 0.0 100.0 1.00 -10 +10

0 to 150.0 0 to 150.0 0.01 to 100.00 -0.2500 to +0.2500 -0.2500 to +0.2500 0.0001 to 0.1000 -200.0 to +200.0 -200.0 to +200.0 0.02 to 100.00 0 to 5.0 1.0 to 15.0 0.01 to 10.00 0 to 100.0 0 to 100.0 0.01 to 80.00 -10 to +10 -10 to +10 ----

% % %/s --/s % % %/s A A A/s % % %/s % %

PF:

- Minimum value - Maximum value - Ramp Rate - Minimum value - Maximum value - Ramp Rate - Minimum value - Maximum value - Ramp Rate - Minimum value - Maximum value - Ramp Rate - Minimum value - Maximum value

Var:

Manual:

Open Loop:

UMaux:

Voltage Droop Compensation Control


- ID-Nr. Primary Net - ID-Nr. Secondary Net - Ramp Time Primary NetID Second. NetID Ramp Time 1 2 10.0 1 to 31 1 to 31 0.1 to 60.0

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Parameter Digital I/Os Hysteresis: DIO1:


- Low Level - High Level - Input or Output - Signal name - Polarity - Input or Output - Signal name - Polarity - Input or Output - Signal name - Polarity - Input or Output - Signal name - Polarity - Signal name - Polarity - Signal name - Polarity - Signal name - Polarity - Signal name - Polarity

Abbreviation
Low Level High Level Direction Din / Dout Polarity Direction Din / Dout Polarity Direction Din / Dout Polarity Direction Din / Dout Polarity Din Polarity Din Polarity Din Polarity Din Polarity

Standard value
4.0 10.0 Input None Normal Input None Normal Input None Normal Input None Normal None Normal None Normal None Normal None Normal

Setting range
0 to 28.0 1.0 to 28.0 Input / Output Signal name Normal / Inverted Input / Output Signal name Normal / Inverted Input / Output Signal name Normal / Inverted Input / Output Signal name Normal / Inverted Signal name Normal / Inverted Signal name Normal / Inverted Signal name Normal / Inverted Signal name Normal / Inverted

Set

Unit
V V ---------------------

DIO2:

DIO3:

DIO4:

DI5: DI6: DI7: DI8:

Assign analog input to digital signal


DI9 from +AI1: - Signal name - Polarity - Signal name - Polarity - Signal name - Polarity - Signal name - Polarity - Signal name - Polarity - Signal name - Polarity Din Polarity Din Polarity Din Polarity Din Polarity Din Polarity Din Polarity None Normal None Normal None Normal None Normal None Normal None Normal Signal name Normal / Inverted Signal name Normal / Inverted Signal name Normal / Inverted Signal name Normal / Inverted Signal name Normal / Inverted Signal name Normal / Inverted -------------

DI10 from -AI1:

DI11 from +AI2:

DI12 from AI2:

DI13 from +AI3:

DI14 from AI3:

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Parameter Analog Inputs AI1:


- Signal name - Input voltage range Low level High Level

Abbreviation

Standard value
None 0.00 +10.00

Setting range
Signal name -10.00 to +10.00 -10.00 to +10.00

Set

Unit

Ain Uin0% Uin100%

V V

AI2:
- Signal name - Input voltage range Low level High Level Ain Uin0% Uin100% None 0.00 +10.00 Signal name -10.00 to +10.00 -10.00 to +10.00 V V

AI3:
- Signal name - Input voltage range Low level High Level Ain Uin0% Uin100% None 0.00 +10.00 Signal name -10.00 to +10.00 -10.00 to +10.00 V V

Analog Outputs AO1:


- Signal name - Output voltage range Ie / PWM Low level High Level Aout Uout0% Uout100% None 0.0 +10.0 Signal name -10.0 to +10.0 -10.0 to +10.0 -V V

AO2:
- Signal name - Output voltage range Ie / PWM Low level High Level Aout Uout0% Uout100% None 0.0 +10.0 Signal name -10.0 to +10.0 -10.0 to +10.0 -V V

Ie Range:
- Output voltage range Low level High Level Ie 0% Ie 100% 0.0 15.0 0.0 to 30.0 0.0 to 30.0 A A

Fbias Range:
- Offset signal Low level High Level Fbias 0% Fbias 100% -3.00 3.00 -3.00 to +3.00 -3.00 to +3.00 Hz Hz

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Parameter Controller Auto:


- Setpoint - Proportional gain - Integral time constant - Derivative time constant - Reactive current influence

Abbreviation

Standard value
-20 1.00 0.35 0.00

Setting range
Min to Max 1 to 200 0.01 to 20.00 0.01 to 5.00 -20.00 to +20.00

Set

Unit

Setpoint Vp Ta Tb Kq

% p.u. s s %

PF / Var / PQ Limiter:
- Setpoint PF - Setpoint Var - Proportional gain - Integral time constant Setpoint PF Setpoint Var Vp Ta --10 3.00 Min to Max Min to Max 0.01 to 200.00 0.01 to 20.00 % % p.u. S

Manual / Ie Limiter:
- Setpoint - Proportional gain - Integral time constant Setpoint Vp Ta -20 1.00 Min to Max 1 to 200 0.01 to 20.00 A p.u. s

Open Loop:
Only for commissioning

AVR ID

1 to 31

--

Communication
ID unit number

Caution

Values have to be saved in the unit. Display: Start menu MAIN, Write EEPROM, OK, OK PCTools: - Unit: Menu bar PCTools \ File \ Write Parameters to EEPROM - Harddisk: Menu bar PCTools \ File \ Save Parameter File

The saved INI file can be opened using an editor (Word, Note- or Wordpad) or by double-clicking on the filename and the parameters can be directly printed out.

Document number

Lang.

Rev. ind.

Page

ABB Switzerland Ltd

3BHS124245 E80

en

76

REVISION Rev. Page (P) ind. Chapt. (C)

Description (or number of revision)

Date Dept./Init.

Document number

Lang.

Rev. ind.

Page

ABB Switzerland Ltd

3BHS124245 E80

en

77

ABB UNITROL 1000 AVR problem claim form


Please fill in this form for problem claim.

1. Serial number of ABB UNITROL 1000 AVR you are claiming: Serial number of ABB generator where it is installed: 2. What kind of problem have you noticed in AVR? Please describe the problem detailed. All information of it is welcomed to us!

2.1 Which operation condition is concerned?


Standstill Start No load Load Stop Change Not relevant

2.2 Which operation mode is concerned?


Manual Auto P.F. Var (Q) Stop Change Not relevant

If you are interested in assisting us in trouble shooting process please fill in spare unit check list. Telephone support, ABB Switzerland, Mr. Martin Affolter, tel +41 58 589 3860, fax +41 58 589 2333. For further information, please refer to Users Manual or E-Learning in the internet: www.abb.com/unitrol. ABB Electrical machines warranty contact information: warranties.machines@fi.abb.com fax: + 358 10 22 22544 Thank you very much for your co-operation!

UNITROL 1000 Spare unit installation check list


for Wrtsil Please fill in this formula for trouble shooting support / warranty claim handling. Mark N/A in irrelevant fields. Telephone support, ABB Switzerland, Mr. Martin Affolter, tel +41 58 589 3860, fax +41 58 589 2333. For further information, please refer to Users Manual or E-Learning in the internet: www.abb.com/unitrol.

General information Country: ___________________ Plant: ___________________ Generator Serial No: __________

Tech. Contact Person:__________________ Telephone No.: __________________ Email address: __________________

AVR Data ID-Number: 3BHE_____________ Serial Number: _____________ Control Software: _____________ Panel Software: _____________ Status:_______ Sub-Status _______ Date of failure _____________ PCTools Provided Yes No PCTools Software version: _________ Under guarantee Yes No Running hours ________

Commissioning: Made by: ____________________ Date: __________________

1.0

Fault description

1.1. What kind of problem have you noticed in AVR? ____________________________________________________ ____________________________________________________ ____________________________________________________ 1.2. When (always/from time to time/how often/ Special situations) ____________________________________________________ 1.3. Special events before the failure (over voltage, mechanical harm, etc.) ____________________________________________________ 1.4. Special events after the failure (protection device active, etc.) ____________________________________________________

2.0

Which operation condition is concerned?


Load Stop Not relevant Change over from ______ to ______ Remarks: __________________ _________________

Standstill Start No Load

3.0

Which operation mode is concerned?


Var (Q) Stop Not relevant Change over from ______ to ______ Remarks: __________________ _________________

Manual Auto P.F.

5.0

Checking of the measurement circuits

5.1.Which measurement in the AVR is concerned? UM IM2 Ie P/Q/S Others: _____________ Please carry out the relevant measurements in (5.3-5.8) 5.2. Fault description: __________________________________________ __________________________________________ __________________________________________ 5.4. Measurement on the Panel abs: ________ %: _________

5.3. Measurement with the PCTools abs: ________ %: _________ 5.5 UM Measurement at terminals 1 2 3 U12: _________V U23: _________V
U12 U23

2 U13

U13: _________V

5.6 IM2

Measurement at terminals
16

IM2 : ___________A

NOTE: Never open a running CT!!

5.6.1. Signal Gen CB Closed Status OK (Panel / PCTools)? Terminal voltage / Relay Yes No Not known Voltage at corresponding terminal (to GND): ____________V 5.7 Ie Measurement at shunt resistor (if available) Ie: __________ 5.8 P/Q/S IM2 measuring OK? UM Measuring OK? Yes Yes No No

6.0

Checking In- and Outputs


Number: ______ Function: ____________________ ________V

6.1 Which In- Output

6.2 Measurement at terminals at corresponding Terminal (against GND) 6.3 Corresponding relay is working (if any) Yes No

Not known

7.0 To check (If the problem was not mention above):


7.1 Field resistance 7.2 UPWR 7.3 UAUX 7.4 +Vdig 7.5 +Vref 7.6 -Vref Terminal 8/9: Terminal 10/11/(12) Terminal 13/14/(15) Terminal 44/47 Terminal 18/25 Terminal 21/25 _______ U10/11 ______ U11/12______ U10/12_______ _______V _______V _______V _______V

Additional points to check: Fault message on the display: _________________________________________________ When failure occurs: _________________________________________________ Does other units have this problem too: ______________________________________ Display before failure: ________________________________________________ Display after failure: ________________________________________________ What additional measurements were done: ______________________________________ Can the field breaker be closed: ______________________________________ All MCBs OK (e.g. -Q10, -Q11): ______________________________________ All connections and wires controlled: ______________________________________ Sketch of the relevant failure signals:

8.0 Plant Data (if not documented elsewhere)


Machine nominal voltage, UMn ______ Machine nominal current, IMn _______ Machine nominal power, SMn ________ No load field current, Ieo ___________ Nominal field current, Ien Field resistance, Rf Nominal field voltage Uen No load field voltage Ueo ________ ________ ________ ________

9.0 Settings of the System Parameters


Please attach Parameter file (.ini) from PCTools, saved online. If PCTools can not be used, please fill in the parameter list, found in Users Manual. Please send following documents, if available Hardware Drawings UN1000 Recordings from PCTools Oscilloscope Oscillograms /Event list from plant monitoring system Commissioning Report Single line diagram of the plant

Thank You for your cooperation!

Instructions for Maintenance and Inspection

Slide Bearings Type EF with self lubrication

RH - EFEWI - E 11.00

Maintenance and Inspection

RENK AKTIENGESELLSCHAFT Werk Hannover Weltausstellungsallee 21 D - 30539 Hannover Telephone: (0511) 8601-0 Telefax: (0511) 8601-266 e-mail: renk_hannover@renk.de http:\\www.renk.de All rights reserved. Copy or reproduction without prior permission of RENK Aktiengesellschaft Hannover prohibited.

RH-EFEWI-E Version: 6 November, 2000

RENK AG Werk Hannover

EF with self lubrication

Contents Bearing Coding................................................................................................................................................ 5 General Drawing of the Slide Bearing EF with self lubrication........................................................................ 7 General Drawing of the Loose Oil Ring ........................................................................................................... 9 General Drawing of the Floating Labyrinth Ring with Seal Carrier................................................................ 11 General Drawing of the Rigid Labyrinth Seal ................................................................................................ 13 General Drawing of the Baffle ....................................................................................................................... 15 General Drawing of the Dust Flinger ............................................................................................................. 17 1 2 3 4 5 6 Considerations for Use .......................................................................................................................... 19 Safety Instructions.................................................................................................................................. 20 Operating Instructions after Standstill ................................................................................................. 21 Maintenance Schedule........................................................................................................................... 22 Oil Change ............................................................................................................................................... 23 Dismantling of the Bearing .................................................................................................................... 24 6.1 6.2 6.3 6.4 Tools and equipment......................................................................................................................... 24 Use of lifting equipment .................................................................................................................... 24 Preparation for dismantling ............................................................................................................... 26 Dismantling of the shaft seal - outboard side ................................................................................... 27 Floating labyrinth seal (Type 10)................................................................................................. 27 Floating labyrinth seal with dust flinger (Type 11) ...................................................................... 27 Floating labyrinth seal with baffle (Type 12) ............................................................................... 27 Rigid labyrinth seal (Type 20) ..................................................................................................... 27 Rigid labyrinth seal with dust flinger (Type 21)........................................................................... 27 Rigid labyrinth seal with baffle (Type 22).................................................................................... 27

6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.5 6.6

Dismantling of the top half of the housing ........................................................................................ 28 Removal of the top half of the shell................................................................................................... 28 Dismantling of the loose oil ring ................................................................................................. 28 Dismantling the machine side shaft seal.................................................................................... 29

6.6.1 6.6.2 6.7 6.8 7

Removal of the bottom half of the shell ............................................................................................ 29 Dismantling of the machine seal ....................................................................................................... 29

Cleaning and Checking of the Bearing ................................................................................................. 30

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

Maintenance and Inspection

Assembly of the Bearing ........................................................................................................................ 32 8.1 8.2 8.3 8.4 8.5 8.6 Fitting in the bottom half of the shell ................................................................................................. 32 Assembly of the shaft seal - machine-side ....................................................................................... 33 Installation of the loose oil ring.......................................................................................................... 35 Fitting in the top half of the shell ....................................................................................................... 36 Closing of the bearing ....................................................................................................................... 37 Assembly of the Seals - Outboard Side ............................................................................................ 39 Floating labyrinth seal (Type 10)................................................................................................. 39 Floating labyrinth seal with dust flinger (Type 11) ...................................................................... 43 Floating labyrinth seal with baffle (Type 12) ............................................................................... 44 Rigid labyrinth seal (Type 20) ..................................................................................................... 44 Rigid labyrinth seal with dust flinger (Type 21)........................................................................... 46 Rigid labyrinth seal with baffle (Type 22).................................................................................... 46

8.6.1 8.6.2 8.6.3 8.6.4 8.6.5 8.6.6 9

Starting Operation after Inspection ...................................................................................................... 47

10 Corrosion Protection for Longer Standstill Periods............................................................................ 48 11 Transport Protection .............................................................................................................................. 48 12 Glossary................................................................................................................................................... 49

RH-EFEWI-E Version: 6 November, 2000

RENK AG Werk Hannover

EF with self lubrication

Bearing Coding

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

Maintenance and Inspection

Type

Housing

Heat Dissipation

Shape of Bore and Type of Lubrication

Thrust part

Size - Diameter

F - flange mounted bearing

N - natural cooling W - water cooling (finned cooler in oil sump )

L - plain cylindrical bore with loose oil ring

Q - without thrust part (non-locating bearing )

80D100 100D125 125D160 160D200 200D250 250D315

11 B - plain sliding surfaces with oil 14 grooves (locating bearing) E - taper land faces for one sense of rotation (locating bearing) K - taper land faces for both senses of rotation (locating bearing) 18 22 28

Example for bearing coding:

22-200 Type E slide bearing with flange mounted housing, natural cooling plain cylindrical bore with loose oil ring, non locating bearing without thrust part, size 22, diameter 200.

Shaft seals

Type 10 - floating labyrinth seal (IP 44) Type 11 - floating labyrinth seal with dust flinger (IP 54) Type 12 - floating labyrinth seal with baffle (IP 55) Type 20 - rigid labyrinth seal (IP 44) Type 21 - rigid labyrinth seal with dust flinger (IP 54) Type 22 - rigid labyrinth seal with baffle (IP 55)

RH-EFEWI-E Version: 6 November, 2000

RENK AG Werk Hannover

self lubrication

General Drawing of the Slide Bearing EF with self lubrication

RENK AG Werk Hannover

RH-EFEE/WI-E Version: 6 November, 2000

10 11

3 2

12 13 14

15 16 17
xxx x

18 19

xxx

20 21 22 23

24

27

26

25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Top half of the housing Hole for positioning pin Pin for positioning shell Oil filling hole Top sight glass Eye bolt Screw (not included in delivery) Screw Tapped hole ( in the top and bottom halves of the shell, up size 14 ) Machine seal Top half of the shell Screw (split line of the housing) Bottom half of the shell Spherical seating Engraved number - shell Spigot Tapped hole Screw (not included in delivery) Screw (split line of the shell) Engraved numbers - housing Bottom half of the housing Tapped hole for journal bearing temperature measurement Oil sight glass Tapped hole for oil sump temperature measurement Outlet/Inlet cooling water (Type E.T..) Cooler ( Type E.T..) Hexagon head plug (Oil drain plug)

self lubrication

General Drawing of the Loose Oil Ring

RENK AG Werk Hannover

RH-LSEE/WI-E Version: 6 November, 2000

33 34 35 36

33 34 35 36

Loose oil ring Dowel pin Hole Screw

self lubrication

General Drawing of the Floating Labyrinth Seal with Seal Carrier

RENK AG Werk Hannover

RH-SSEE/WI-E Version: 6 November, 2000

11

Bearing side 37

43 42

38

39 41 40

47

Outer view

44

46

45

37 38 39 40 41 42 43 44 45 46 47

Seal carrier - top half Garter spring Groove Seal carrier - bottom half Bottom half of the seal Top half of the seal Anti - rotation pin Screw Engraved number Groove ( Type 11 ) Engraved number

self lubrication

General Drawing of the Rigid Labyrinth Seal

RENK AG Werk Hannover

RH-KDEE/WI-E Version: 6 November, 2000

13

48 49

54

50 (2x)

51

53

52

48 49 50 51 52 53 54

Rigid labyrinth seal - top half Screw Screw (split line) Groove ( Type 21 ) Rigid labyrinth seal - bottom half Engraved number Engraved number

self lubrication

General Drawing Baffle

RENK AG Werk Hannover

RH-DSEE/WI-E Version: 6 November, 2000

15

55

56

57

55 56 57

Baffle - top half Screw Baffle - bottom half

self lubrication

General Drawing of the Dust Flinger

RENK AG Werk Hannover

RH-LREE/WI-E Version: 6 November, 2000

17

58

59 (2x)

58 59

Dust flinger Screw (split line)

EF with self lubrication

Considerations for Use

The instructions for maintenance and inspection are addressed to qualified technical personnel (fitters, mechanic installers, mechanical engineers). Read these instructions carefully before starting assembly. Slide bearings of type EF are almost universally used in the engineering industry. Therefore it is not possible to provide detailed information on all possible types and range of applications for these bearing types. For instance, the position of the connection points for supply and monitoring equipment is determined by the place of application ( in the following called " installation " ). Please keep ready the guidelines with the technical documentation before starting assembly and operation of the slide bearings. Additional technical documentation with detailed information is supplied in the case of special design bearings. Please contact RENK Export or Domestic Department for supplementary information on bearings. Please indicate the bearing coding and the full reference number, too. Following indications should be observed when reading these instructions. Safety instructions are marked as follows: Caution ! Warning of dangers for personnel. Example: Warning of injury

Attention! Warning of damage for the bearing or installation.

Useful recommendations and additional information are framed. EFW.. This is how chapters, instructions or recommendations are marked when referring to a single type or size of a bearing. Example: Slide bearing type EF with water cooler Instruction follows. Beginning of an enumeration. This is how the different parts of a bearing as described in the general drawings ( numbers ) are marked in the text.

( )

Use the enclosed check-list before starting assembly or operation. Copies available on request. The check list provides the experienced mechanical fitters of RENK bearings with the necessary instructions for installation and operation.

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

19

Maintenance and Inspection

Safety Instructions Danger! The maintenance and inspection of the slide bearings should be carried out by: persons nominated by the safety representative persons correspondingly trained and instructed persons with knowledge on appropriate standards, regulations and accident . prevention rules persons with knowledge on first-aid measures and local rescue centers.

Warning of injury! Before starting work on the bearing: - Switch off the installation. - Make sure the installation is not in operation. Never lift or transport machines, etc.by the bearing eye bolts. These are only intended for assembly and dismantling of the bearing !

Warning of injury! Do not grab such heavy bearing parts as the housing during assembly or dismantling work. This could result in bruising or injury to hands !

Attention! All metal parts of a slide bearing consisting of top and bottom half such as the housing, shells, shaft seals are marked by engraved numbers. Fit together only the parts with the same number.

Attention! In case the admissible bearing temperature exceeds 15 K inadmissible vibrations occur unusual noises or odours are noticed monitoring equipment triggers alarm shut down the installation and inform the maintenance personnel in charge.

Attention! Do not operate the bearing below the transition speed values indicated in the bearing calculation, thus avoiding inadmissible operating conditions, which could lead to damage to the bearing.

20

RH-EFEWI-E Version: 6 November, 2000

RENK AG Werk Hannover

EF with self lubrication

Operating Instructions after Standstill

Clean the external parts of the bearing. Dust and dirt impede the radiation of the heat. Check with the instructions for the use of the lubricating oil if an oil change is necessary. Depending on the duration of the standstill an oil change is either prescribed or recommended. Carry out the oil change as indicated in Chapter 5. Check the oil level If necessary, refill with lubricant by using the oil filling hole (4). The refilling oil should be of the same type as already used. The oil level limits are as follows:
minimum oil level: maximum oil level: bottom of the oil sight glass top of the oil sight glass

Retighten the and screws (12), (8), (18) to the following torque rates:
Bearing Size Torque [Nm] for tot = 0,1 (lightly oiled) 9 69 11 69 14 170 18 330 22 570 28 1150

Check the firm position of the top sight glass (5). Check the firm position of the oil sight glass (23).
In case a thermo sensor or/and an oil sump thermometer are used:

Check if they are well fitted (see also the manufacturer's instructions). Retighten all screw plugs in the tapped holes (4), (22), (24) (27) to the necessary torque rates:
Screw plug threads Torque [Nm] for plugs with moulded on plastic seal Torque [Nm] for plugs with elastic seal G 3/8 30 G 1/2 40 G 3/4 60 G1 110 G 1 1/4 G 1 1/2 160 230 G2 320 G 2 1/2 500

34

60

85

130

240

300

330

410

Check the functioning of the temperature monitoring equipment.


EFW..

Check the functioning of the cooler.


The bearing is now ready to work.

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

21

Maintenance and Inspection

Maintenance Schedule Deadline every 100-1000 hours Bearing in reversing operation every 5000 operating hours. Bearing in continous operation every 8.000 operating hours (please observe also the indications for the use of the lubricating oil). During prevention maintenance work for the installation. Immediately if:

Maintenance work Exterior cleaning of the bearing Oil change

Bearing inspection

the bearing temperature exceeds 15 K over the indicated value (see the EDP-calculations) unusual operating noises occur unusual changes of the lubricating oil become visible increased oil level in the case of bearing type EFW....

22

RH-EFEWI-E Version: 6 November, 2000

RENK AG Werk Hannover

EF with self lubrication

Oil Change

Risk of pollution! Please observe the instructions for the use of the lubricating oil. The manufacturer can provide information on waste oil disposal.

Shut down the installation and secure it against unintended operation. Take all necesarry measures to collect the whole quantity of the lubricating oil. Drain off the lubricating oil in still warm condition. Impurities and residues will thus be scavenged. Unscrew the hexagon head plug (27). Drain off the lubricating oil and collect it.
Attention! In case the lubricating oil contains unusual residues or is visibly changed, eliminate the causes. If necessary, carry out an inspection.

Tighten the hexagon head plug (27) to the following torque rates:
Bearing size Torque [Nm] 9 30 11 30 14 30 18 40 22 60 28 60

Remove the screw plug from the oil filling hole (4).
Attention! Make sure that no impurities get into the bearing.

Use a lubricant with the viscosity indicated on the bearing type plate. Fill the lubricant through the oil filling hole (4) up to the middle point of the oil sight glass (23). The oil level limits are as follows:
minimum oil level: maximum oil level: bottom of the oil sight glass top of the oil sight glass

Attention! Not enough lubricant leads to temperature rises and thus to damage to the bearing. Too much lubricant leads to leakages. In the case of bearings with lubrication by loose oil ring too much lubricant could have a considerable breaking effect on the oil rings, thus leading to damage to the bearing.

Tighten the screw plug into the oil filling hole (4) to the following torque rates:
Bearing size Torque [Nm] 9 30 11 30 14 30 18 40 22 60 28 60

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

23

Maintenance and Inspection

6 6.1

Dismantling of the Bearing Tools and equipment

Following tools and equipment are necessary:


Allan key set Wrenching key set Open-jawed spanner set Feeler gauges (up 0,05mm) Caliper gauge Emery paper, plain scraper Oil stone Lifting equipment Permanent sealing compound (e.g. Curil T) Clean (close weave) rags Oil with the viscosity indicated (see bearing type plate) Detergents Liquid screw locking compound (e.g.LOCTITE 242) Liquid sealing compound and Teflon tape.

6.2

Use of lifting equipment Risk of injury! Before transport or lifting check if the eye bolts are tight! Insecure eye bolts could result in bearing becoming loose. Before moving the bearing by the eye bolts make sure that the screws at the split line are tightened, otherwise the bottom half of the bearing could become detached. Make sure that the eye bolts are not exposed to bending stress, otherwise the bolts could break. Follow exactly the instructions for the use of the lifting equipment.

Use lifting equipment for following assembly and transport works:


Transport/Assembly of: Whole bearing unit Top half of the housing Bottom half of the housing Shells Use lifting equipment for the following bearing sizes 9-28 14-28 11-28 14-28

24

RH-EFEWI-E Version: 6 November, 2000

RENK AG Werk Hannover

EF with self lubrication

Following steps are to be observed before using the lifting equipment: Whole bearing unit

Check if the screws are tight (12):


Bearing size Torque [Nm] for tot = 0,1 (lightly oiled) 9 69 11 69 14 170 18 330 22 570 28 1150

Check if the eye bolts are tight (6). Connect the lifting equipment to the eye bolts (6).
Top half of the housing

Check if the eye bolts are tight (6). Connect the lifting equipment to the eye bolts (6).
Bottom half of the housing

Screw two eye bolts (6) with suitable threads tight into the cross-placed opposite tapped holes (17).
Bearing size Tapped hole 9 M 12 11 M 12 14 M 16 18 M 20 22 M 24 28 M 30

Connect the lifting equipment to the eye bolts (6).


Shells

Screw two eye bolts or screw hooks with suitable threads tight into the tapped holes (9):
Bearing size Tapped hole 14 M8 18 M 12 22 M 12 28 M 16

Connect the lifting equipment to the screw hooks.

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

25

Maintenance and Inspection

6.3

Preparation for dismantling

Attention! Make sure that the work place is clean. Contamination and damages to the bearing, especially of the working surfaces, have a negative influence on the operating quality and could lead to premature damage.

Attention! Do not use any violence or force!

EFW..

Shut down the installation and ensure it against unintended operation. Interrupt the cooling water supply. Dismantle all thermo sensors from the connection holes. Take all necessary measures to collect the lubricating oil. Unscrew the hexagon head plug (27) and collect the lubricating oil.
Risk of pollution! Please observe the instructions for the use of the lubricating oil. The manufacturer can provide necessary information on waste oil disposal.

Tighten the hexagon head plug (27) to the following torque rates
Bearing size Torque (Nm] 9 30 11 30 14 30 18 40 22 60 28 60

26

RH-EFEWI-E Version: 6 November, 2000

RENK AG Werk Hannover

EF with self lubrication

6.4

Dismantling of the shaft seal - outboard side

Dismantle the outboard side seals of the bearing. Proceed correspondingly to the seal type: Floating labyrinth seal (Type 10) Floating labyrinth seal with dust flinger (Type 11) Floating labyrinth seal with baffle (Type 12) Rigid labyrinth seal (Type 20) Rigid labyrinth seal with dust flinger (Type 21) Rigid labyrinth seal with baffle (Type 22)
Type 10 6.4.1 Floating labyrinth seal (Type 10) Chapter 6.4.1 Chapter 6.4.2 Chapter 6.4.3 Chapter 6.4.4 Chapter 6.4.5 Chapter 6.4.6

Loosen all screws (44) and turn them off. Remove simultaneously in axial direction both top half (37) and bottom half (40) of the seal carrier from the housing. Shift a little (about 20 mm) the top half (42) of the seal. Tilt it over carefully until the garter spring (38) unbends.
Warning of injury! During dismantling of the floating labyrinth seal hold tight the garter spring (38) which is under tension and could bounce back and lead to injury.

Open the garter spring (38) and remove the bottom half of the seal (41) from the shaft.
Type 11 6.4.2 Floating labyrinth seal with dust flinger (Type 11)

Dismantle the dust flinger (58). Loosen the screws (59) and take out the dust flinger (58) from the groove (46) of the seal carrier. Remove both halves of the dust flinger. Go on as indicated for type 10 (see Chapter .4.1).
6.4.3 Floating labyrinth seal with baffle (Type 12)

Type 12

Unscrew both top (55) and bottom (57) halves of the baffle by untightening the screws (56). Go on as indicated for type 10 (see Chapter 6.4.1).
Type 20 6.4.4 Rigid labyrinth seal (Type 20)

Loosen all screws (49) and take them out. Take out the screws (50). Remove simultaneously in axial direction both top (48) and bottom (52) halves of the rigid labyrinth seal.
6.4.5 Rigid labyrinth seal with dust flinger (Type 21)

Type 21

Dismantle the dust flinger (58). Loosen the screw (59) and take out the dust flinger (58) from the groove (51) of the rigid seal. Remove both halves of the dust flinger. Go on as indicated for type 20 (see Chapter 6.4.4).
6.4.6 Rigid labyrinth seal with baffle (Type 22)

Type 22

Unscrew the top half (55) and the bottom half (57) of the baffle by untightening the screws (56). Go on as indicated for type 20 (see Chapter 6.4.4).

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

27

Maintenance and Inspection

6.5

Dismantling of the top half of the housing

Remove the screws (8). Remove the screws (12). Lift the top part of the housing (1) until the top part of the housing can be moved in axial line over the shell, without touching it.

6.6

Removal of the top half of the shell

Unscrew the screws (19) and lift the top half of the shell (11).
Attention! Do not damage the thrust and radial working surfaces.

Attention! In the case of insulated housings (white plastic insulating foil) avoid any jamming of the top half of the shell when you lift it up Jamming could lead to damage of the insulating foil in the bottom half of the housing.

6.6.1

Dismantling of the loose oil ring

Open both split lines of the loose oil ring (33) by untightening and taking out the screws (36). Separate both halves of the loose oil ring (33) carefully without using any tools or other devices.
I II

33

33

33

36

Illustration 1:

Opening of the loose oil ring

To check the geometry of the loose oil ring put it together as follows:

Press the positioning pin (34) into the hole (35). Adjust both halves of the loose oil ring till the split lines match each other. Tighten the screws (36).

28

RH-EFEWI-E Version: 6 November, 2000

RENK AG Werk Hannover

EF with self lubrication

6.6.2

Dismantling the machine side shaft seal

Shift a little (about 20 mm) the top half (42) of the seal. Tilt it over carefully until the garter spring (38) unbends.
Warning of injury! During dismantling of the floating labyrinth seal hold tight the garter spring (38) which is under tension and could bounce back and lead to injury.

Open the garter spring (38) and turn the bottom half of the seal (41) in opposite direction from the anti-rotation pin out of the integrated seal groove of the bottom half of the housing.

6.7

Removal of the bottom half of the shell

Attention! Make sure that all bearings mounted on a shaft line are opened. Loosen the screws at the split line of the housings.

Attention! The lifting equipment should not come into contact with the seal and working surfaces of the shaft.

Lift the shaft up to the point where shaft and bottom half of the shell (13) do not touch each other any more. Protect the shaft against unintended movement. Turn the bottom half of the shell (13) out of the bottom half of the housing (21) and remove it from the shaft.
Attention! If the bottom half of the shell (13) is provided with metal tabs (28) do not remove them. They regulate the oil level in the oil pockets.

6.8

Dismantling of the machine seal

Usually it is not necessary to dismantle the machine seal (10) if maintenance works are carried out. If due to certain reasons the split machine seal must be dismantled please observe that this operation can be carried out only from the inner part of the machine. Loosen the screws at the split line of the machine seal and remove the screws (7). Non-split machine seals can be dismantled only after dismantling the machine shield or the shaft completely. In the case the machine seal is equipped with a hamp packing, some visible changes can be noticed, such as : tallow excess, black colour of the seal due to temperature development. Even in such cases it is not necessary to renew the hamp packing. Colour changes will appear with a new hamp packing too, until the seal clearance adjusts during operation.

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

29

Maintenance and Inspection

Cleaning and Checking of the Bearing

Attention! Use only non-aggressive detergents such as for instance VALVOLINE 150 Alcaline cleaning compounds (pH-value 6 to 9, short reaction time).

Warning of injury! Please observe the instructions for the use of the detergents.

Attention! Never use cleaning wool or cloth. Residues of such materials left in the bearing could lead to excessive temperatures.

Clean the following parts thoroughly: top half of the housing (1) bottom half of the housing (21) top half of the shell (11) bottom half of the shell (13) sealing surfaces of the top half (37) and bottom half (40) of the seal carrier or of the rigid labyrinth seal loose oil ring (33).
EFW..

Check the condition of the cooler (26).


In cases where the cooler (26) is incrusted with oil sludge:

Dismantle the cooler. Remove the incrustation by using for instance a wire brush. Install the cooler (26) into the bearing.

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Carry out a visual check of the wear condition of all bearing parts. The following graph provides information on the parts that must be replaced in case of wear.The right evaluation of the wear condition, especially of the working surfaces of the shell, implies a lot of experience. If in doubt, replace the worn part with new ones.
Bearing part Wear condition Maintenance procedures

Shell

Scoring

Bearing temperature before inspection: not increased - no new shells increased - new shells New shell New shells New shaft seal

White metal lining damaged Bow wave ridges Shaft seal Baffles broken or damaged

Loose oil ring

Geometrical form ( roundness, flatness ) visibly changed

New loose oil ring

Size 9-14

Check the projection of the positioning pin (3) according to the values indicated below:
Bearing size Projection of the positioning pin (4) mm 9 7 11 8 14 10 18 12 22 14 28 16

In case the projection is less than indicated,

drive the positioning pin (3) into the top half of the housing (1) until the indicated value is reached.
insulated bearings

Check the insulating layer of the spherical seating (14) of the top half (1) and bottom half (21) of the housing. In case of damage contact the RENK-sales agency in charge.

RENK AG Werk Hannover

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31

Maintenance and Inspection

Assembly of the Bearing

Attention! Remove all impurities or other objects such as screws, nuts, etc. from inside the bearing. If left inside they could lead to damage of the bearing. Cover up the opened bearing during work breaks.

Attention! Carry out all assembly operations without making use of force.

Attention! Secure all screws of the housing, flange and at the split line with a liquid screw locking compound (e.g.LOCTITE 242).

8.1 EF..E

Fitting in the bottom half of the shell

Attention! Mounting the bottom half of the shell (not marked with an arrow) correctly will ease the assembly of the top half shell (marked with an arrow) (see chapter 8.4).

Apply some lubricant to the spherical seating (14) in the bottom half of the housing (21) and to the working surfaces of the shaft. Use the same type of lubricant as indicated for bearing operation ( see type plate ). Place the bottom half of the shell (13) on the working surface of the shaft. Turn the bottom half of the shell (13) into the bottom half of the housing (21) with the split line surfaces of both halves in true alignment.
In case the bottom half of the shell doesnt turn in easily, check the position of the shaft and the alignment of the housing

EF..B, EF..K, EF..E

Attention! These operations should be carried out most carefully. The thrust parts of the bottom shell must not be damaged.

Lower down the shaft till it sits on the bottom half of the shell (13).

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8.2

Assembly of the shaft seal - machine-side

The machine-side shaft seal is, as standard, a floating labyrinth seal. The integrated seal groove is in the top and bottom halves of the housing. Warning of injury! During assembly hold the garter spring ends (38) securely to avoid them suddenly releasing and causing possible injury!

Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing:

Put the garter spring (38) around the shaft and hook both ends into each other. Put both halves of the seal (41), (42) in their place on the shaft. Put the garter spring (38) into the groove (39). Turn the floating labyrinth seal on the shaft.

Attention! The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating during operation and even to shaft wear. If the floating labyrinth seal jams, - dismantle the seal and - remove the worn parts of the seal carefully, by using emery paper or a plain scraper.

Dismantle the floating labyrinth seal. Apply Curil T to the guide surfaces of the integrated seal groove in the bottom half of the housing.

21

Illustration 2:

Applikation of Curil T to the integrated seal groove

RENK AG Werk Hannover

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Maintenance and Inspection

Apply a uniform layer of Curil T to the seal surfaces and to the split line surfaces of both halves of the seal (41), (42).

41

Illustration 3:

Application of Curil T to the floating labyrinth seal

Please observe the instructions for the use of Curil T.

Place the bottom half of the seal (41) with the labyrinths onto the shaft. The oil return holes at the bearing side must be clear and open. Turn the seal in opposite direction from the anti-rotation pin into the groove of the housing until the split lines of the bottom half of the housing and the bottom half of the seal match each other. Remove the rests of Curil T. Push the garter spring into the integrated seal groove between the bottom half of the housing and the seal until both ends jut out from the split line. Place the top half of the seal with the cam facing the inside of the bearing on the bottom half of the seal. Stretch the garter spring till both ends can be hooked.

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8.3

Installation of the loose oil ring

Open both split lines of the loose oil ring (33) by untightening and removing the screws (36). Separate both halves of the loose oil ring (33) carefully without using any tools or other devices.
I II

33

33

33

36

Illustration:4

Opening of the loose oil ring

Place both halves of the loose oil ring into the shell groove (13) around the shaft. Press the positioning pin (34) of each split line into the corresponding hole (35). Adjust both halves of the loose oil ring till the split lines match each other.

21 34 33

33

13
Installation of the loose oil ring

llustration 5:

Tighten the screws (36) to the following torque rates:


Bearing size Torque [Nm] 9 1,4 11 1,4 14 1,4 18 2,7 22 2,7 28 2,7

RENK AG Werk Hannover

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Maintenance and Inspection

8.4

Fitting in the top half of the shell

Apply some lubricant to the working surfaces of the shaft. Use the same type of lubricant as indicated for bearing operation (see type plate). Check if the engraved numbers (15) on the bottom and top halves of the shell correspond. Place the top half of the shell (11) on the shaft; both engraved numbers (15) should be on the same side.
Attention! An incorrectly placed shell could jam the shaft thus leading to the damage of both shaft and bearing.

EF..B, EF..K, EF..E


insulated bearings

Attention! Place the top half of the shell carefully on the shaft. The thrust parts of the top half of the shell should not be damaged. In the case of bearings arranged for insulation monitoring, connect the black cable for insulation monitoring to the shell. According to the bearing type, there are two possibilities of connection. 1. The black cable is provided with a cable connector.

Plug the cable with the cable connector into the counterpart available on the top of the shell. Lead the cable through the cable gland in the bottom half of the housing and out of the bearing. Tighten the cable gland oil-tight.
2. The black cable is provided with an eyelet.

Fasten the cable with the eyelet to the split line of the shell, by using one of the shell joint bolts. Lead the cable through the cable gland in the bottom half of the housing and out of the bearing. Tighten the cable gland oil-tight. Tighten up the screws (19) to the following torque rates:
Bearing size Torque [Nm] 9 8 11 8 14 20 18 69 22 69 28 170

Check the split line of the shell by using a feeler gauge. The split line gap should be less than 0,05 mm. If the split line is greater than this, dismantle both top and bottom (11),(13) halves of the shell. Rework the split line surfaces of the top half (11) and bottom half (13) of the shell with an oil stone. Check the mobility of the loose oil ring (33).
EF.L.
Marine Bearing

A guide bush in the top half of the shell secures the function of the loose oil ring.

Check the mobility of the loose oil ring (33) in the guide bush.

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EF..E

Shells with taper land faces suitable only for one direction of rotation are marked with an arrow on the top half shell, which indicates the sense of rotation of the shaft. The arrow indicates the allowed direction of shaft rotation after completion of the bearing assembly.

Before mounting the top half of the housing check that the proposed direction of rotation of the shaft corresponds to the direction indicated by the arrow on the top half of the shell. If the directions match, continue the assembly of the bearing. If the directions do not match, the shell must be disassembled, re-aligned and mounted again.
Attention! A wrongly placed shell, without observance of the direction of rotation of the shaft, impairs the operational safety of the bearing.

8.5

Closing of the bearing

Check the true alignment of the shell (11), (13) and bottom half (21) of the housing.
The positioning pin (3) in the top half of the housing fits in the corresponding hole (2). The shell is thus placed into its right position.

Check if the engraved numbers (20) on the top and bottom halves of the housing correspond. Clean the split line surfaces of the top and bottom halves (1), (21) of the housing. Apply Curil T over the whole surface of the split line of the bottom half (21) of the housing.
Please observe the instructions for the use of Curil T.

Place the top half of the housing carefully into the machine shield, without touching the seals or the shell. Lower the top half of the housing (1) vertically on the bottom half of the housing (21). Lower the top half of the housing (1) till the split line of the housing is not visible any more. Gently hit the bottom half of the housing (21) with a nylon hammer, thus ensuring the alignment of the spherical seating. Insert the screws (12). Tighten them hand-tight. Insert the screws (8). Tighten them to the following torque rates:
Bearing size Torque [Nm] tot = 0,1 (lightly oiled) 9 69 11 69 14 170 18 330 22 570 28 1150

Tighten the screws (12) of the housing crosswise to the same torque rates.

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

37

Maintenance and Inspection

insulated bearings

Insulation monitoring In the case of electric insulated bearings provided with insulation monitoring, the cable coming out of the housing must be connected in a professional manner. According to the type supplied, please follow the assembly instructions given below. a) The cable is very short and provided with a further cable connector at the end of it. This cable is ready for connection to the housing. The bottom half of the housing is provided with the counterpart.

Plug the cable connector into the counterpart.


Attention! This connection bypasses the electrical insulation of the bearing. In the case of electric machines, make sure at least one bearing is electrically insulated. To check the electrical insulation, interrupt the connection cable - housing. Check the electrical resistance with a suitable measuring instrument. Make sure that both bearings and the coupling are electrically insulated. b) The cable has a free end. In this case the customer has to make the connection. Attention! If only one bearing is insulated, the end of the cable must not be earthed. Any further connection depends on the customers requirements related to the insulation monitoring and can not therefore be described here.

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8.6

Assembly of the Seals - Outboard Side

Assemble the outboard side seals. Proceed according to the seal type used: Floating labyrinth seal (Type 10) Floating labyrinth seal with dust flinger (Type 11) Floating labyrinth seal with baffle (Type 12) Rigid labyrinth seal (Type 20) Rigid labyrinth seal with dust flinger (Type 21) Rigid labyrinth seal with baffle (Type 22)
Type 10 Chapter 8.6.1 Chapter 8.6.2 Chapter 8.6.3 Chapter 8.6.4 Chapter 8.6.5 Chapter 8.6.6

8.6.1

Floating labyrinth seal (Type 10) Warning of injury! During assembly hold the garter spring ends (38) securely to avoid them suddenly releasing and causing possible injury!

Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing.

Put the garter spring (38) around the shaft and hook both ends into each other. Put both halves of the seal (41), (42) in their place on the shaft. Put the garter spring (38) into the groove (39). Turn the floating labyrinth seal on the shaft.

Attention! The floating labyrinth seal should turn easily on the shaft. A jammed seal could lead to overheating during operation and even to shaft wear. If the floating labyrinth seal jams, - dismantle the seal and - remove the worn parts of the seal carefully, by using emery paper or a plain scraper.

Dismantle the floating labyrinth seal.

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

39

Maintenance and Inspection

Apply a uniform layer of Curil T to the guide surfaces and to the split line surfaces of both halves of the seal (41), (42).
Please observe the instructions for the use of Curil T.

41

Illustration 6:

Application of Curil T to the floating labyrinth seal

Press the bottom half of the seal (41) against the shaft. Place the top half of the seal (42) on the shaft and align both halves of the seal to each other. Place the garter spring (38) into the groove (39) and stretch until both ends can be hooked.

43

42

38

41

21

Illustration 7:

Assembly of the floating labyrinth seal

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Place in true alignment the split line of the floating labyrinth seal and the split line of the seal carrier. Check that both engraved numbers (45) and (47) on top and bottom halves of the seal carrier (37), (40) correspond. Clean the following parts: the seal surfaces of the top (37) and bottom (40) half of the seal carrier (the groove of the floating labyrinth seal, the flange surfaces) the split line surfaces of the top (37) and bottom (40) half of the seal carrier the flange surfaces of the housing. Apply a uniform layer of Curil T to: the lateral surfaces of the groove at the top (37) and bottom (40) half of the seal carrier the flange surfaces of the top (37) and bottom (40) half of the seal carrier the split line surfaces of the bottom half of the seal carrier (40).
Please observe the instructions for the use of Curil T.

40

Illustration 8:

Application of Curil T to the seal carrier

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

41

Maintenance and Inspection

Place the top half of the seal carrier (37) on the top half of the seal (42). Press the bottom half (40) of the seal carrier against it. Push the shaft seal completely into the housing.

37

43

42

Illustration 9:

Assembly of the seal carrier

Place in true alignment the split lines of the seal carrier and the housing. Tighten up the screws (44) to the following torque rates:
Bearing size Torque [Nm] 9 8 11 8 14 8 18 20 22 20 28 20

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Type 11

8.6.2

Floating labyrinth seal with dust flinger (Type 11)

Assemble the floating labyrinth seal with dust flinger as described in Chapter 8.6.1, Floating labyrinth seal type 10. Place both halves of the dust flinger (58) in front of the shaft seal around the shaft. Loosely screw in the screws (59).

58

37

46

Illustration 10: Clearance between dust flinger and seal carrier EF..Q

Push the dust flinger (58) into the groove (46) of the seal carrier. Set the clearance "e" at the following figure around the whole unit:
maximum longitudinal extension of the shaft in operation + 1 mm (Parameters indicated in the Technical Documentation of the Installation).

Tighten up the screws (59) to the following torque rates:


Seal diameter [mm] Torque [Nm] EF..B, EF..E, EF..K 80-140 7 >140 18

Push the dust flinger (58) into the groove (46) of the seal carrier. Set the clearance "e" at 1 mm around the whole unit. Tighten the screws (59) to the following torque rates:
Seal diameter [mm] Torque [Nm] 80-140 7 >140 18

RENK AG Werk Hannover

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Maintenance and Inspection

Type 12

8.6.3

Floating labyrinth seal with baffle (Type 12)

Assemble the floating labyrinth seal with baffle as in Chapter 8.6.1, Type 10. Apply a uniform layer of Curil T to the flange surfaces of the top half (55) and bottom half (57) of the baffle. Screw the top half of the baffle (55) onto the top half of the seal carrier (37) the bottom half of the baffle (57) onto the bottom half of the seal carrier (40). Tighten the screws (56) to the following torque rates:
Seal diameter [mm] Torque [Nm] 80-140 4 >140 10

Type 20

8.6.4

Rigid labyrinth seal (Type 20)

Check if the engraved numbers (53) and (54) on the bottom half (52) and top half (48) of the rigid labyrinth seal correspond. Clean the flange surfaces of the top half (48) and bottom half (52) of the rigid labyrinth seal the split line surfaces of the top half (48) and bottom half (52) of the rigid labyrinth seal the flange surfaces of the housing. Apply a uniform layer of Curil T to the following parts: the flange surfaces of the top half (48) and bottom half (52) of the rigid labyrinth seal the split lines of the bottom half (52) of the rigid labyrinth seal.
Please observe the instructions for the use of Curil T.

52

Illustration 11: Application of Curil T to the rigid labyrinth seal

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EF with self lubrication

Place the top half (48) of the rigid labyrinth seal on the shaft and press slightly the bottom half (52) of the rigid labyrinth seal from below against it. Lightly push the rigid labyrinth seal completely into the housing. Tighten the screws (50). Place in parallel alignment the split line of the rigid labyrinth seal and the split line of the housing. Press the rigid labyrinth seal slightly from below against the shaft. Adjust the rigid labyrinth seal in such a way that the clearance "f" between the shaft and the rigid labyrinth seal at both split lines has the same figure.

48

21

52

Illustration 12: Alignment of the rigid labyrinth seal

Tighten the screws (49) to the following torque rates:


Bearing size Torque [Nm] 9 8 11 8 14 8 18 20 22 20 28 20

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

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Maintenance and Inspection

Type 21

8.6.5

Rigid labyrinth seal with dust flinger (Type 21)

Assemble the rigid labyrinth seal with dust flinger as indicated in Chapter 8.6.4, Type 20. Place both halves of the dust flinger (58) round the shaft, in front of the rigid labyrinth seal. Mount the screws (59) loose.

58

48

51

Illustration 13: Clearance between dust flinger and rigid labyrinth seal EF..Q

Push the dust flinger (58) into the groove (51) of the rigid labyrinth seal. Set the clearance "e" at the following figure around the whole unit:
maximum longitudinal extension of the shaft in operation + 1 mm (Parameters are indicated in the Technical Documentation of the Installation).

Tighten the screws (59) to the following torque rates:


Seal diameter [mm] Torque [Nm] EF..B, EF..E, EF..K 80-140 7 >140 18

Push the dust flinger (58) into the groove (51) of the rigid labyrinth seal. Set the clearance "e" at 1 mm around the whole unit. Tighten the screws (59) to the following torque rates:
Seal diameter [mm] Torque [Nm] 80-140 7 >140 18

Type 22

8.6.6

Rigid labyrinth seal with baffle (Type 22)

Assemble the rigid labyrinth seal with baffle as described in Chapter 8.6.4. Apply a uniform layer of Curil T to the flange surfaces of the top half (55) and bottom half (57) of the baffle. Tighten the top half of the baffle (55) to the top half (48) of the rigid labyrinth seal the bottom half of the baffle (57) to the bottom half (52) of the rigid labyrinth seal. Tighten the screws (56) to the following torque rates:
Seal diameter [mm] Torque [Nm] 80-140 4 >140 10

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Starting Operation after Inspection

Fit the thermo sensors for: temperature measurement of the journal part in the tapped holes (22) Retighten all screw plugs in the tapped holes (22), (24), (27), (29) to the following torque rates:
Screw plug threads Torque [Nm] for plugs with moulded on plastic seal Torque [Nm] for plugs with elastic seal G 3/8 30 G 1/2 40 G 3/4 60 G1 110 G 1 1/4 G 1 1/2 160 230 G2 320 G 2 1/2 500

34

60

85

130

240

300

330

410

Check that the top sight glass (5) is tight. Check that the oil sight glass (23) is tight, the screws should be hand-tight. Carry out a visual check of the assembled bearing. Remove the screw plugs from the oil filling hole (4).
Attention! Make sure that no impurities get into the bearing.

Use a lubricant with the viscosity indicated on the bearing type plate. Fill the lubricant through the oil filling hole (4) up to the middle point of the oil sight glass (22). The oil level limits are as follows:
minimum oil level: maximum oil level: bottom of the oil sight glass top of the oil sight glass

Attention! Not enough lubricant leads to temperature rises and thus to damages to the bearing. Too much lubricant leads to leakages. In the case of bearings with lubrication by loose oil ring too much lubricant could have a considerable breaking effect on the oil rings, thus leading to damages to the bearing.

Tighten the screw plug into the oil filling hole (4) to the following torque rates:
Bearing size Torque [Nm] 9 30 11 30 14 30 18 40 22 60 28 60

Check that the temperature monitoring equipment works.


EFW..

Start operating the cooling water supply system and check its functioning.
The bearing is ready for operation.

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

47

Maintenance and Inspection

Supervise the bearing during the trial run ( 5 - 10 operating hours ). Pay special attention to:
oil level bearing temperature sliding noises of the shaft seals tightness occurrence of inadmissible vibrations.

Attention! If the bearing temperature exceeds the calculated value by 15 K (see the EDP-bearing calculations) stop the installation immediately. Carry out an inspection of the bearing and find out the causes.

10

Corrosion Protection for Longer Standstill Periods

If you want to protect the bearing mounted on an installation against corrosion proceed as follows:

Dismantle the bearing (see Chapter 6). Clean the bearing (see Chapter 7). Paint or spray the top half of the shell (11), the bottom half of the shell (13) and the shaft with TECTYL 511. Assemble the bearing (see Chapter 8). Close all tapped holes with screw plugs. Seal the gaps between shaft seal and housing shaft seal and shaft by using a self-adhesive, permanent tape. Remove the top sight glass (5). Spray some anti-corrosive such as TECTYL 511 or VALVOLINE into the bearing. Put a bag of dessicant (silicate gel) inside. The dessicant absorbs the humidity and prevents the formation of condensation water inside the bearing. Close the bearing tight with the top sight glass (5).

In case the standstill period is longer than 1/2 year:

Repeat the preservation procedures. Put a new bag of dessicant into the bearing.

In case the standstill period lasts more years:

Dismantle the shells. Preserve and store the bearing parts.

11

Transport Protection

In case of a machine equipped with slide bearings of type EF:

Carry out the corrosion protection as described in Chapter 10 and apply enough lubricant on the working surfaces of the bearing. Secure the shaft against thrust and radial movements during transportation

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12 Baffle

Glossary With bearing types 10 and 20 the baffles are assembled externally in front of the shaft seals. The baffle, made of reinforced polyamide, protects the bearing from dust and water. The rigid labyrinth seal (type 20) is used with slide bearings type E with high oil throughput.It corresponds to the protective system IP44 and is made of an aluminium alloy. The rigid labyrinth seal is built of two halves, flanged at the housing.The labyrinths that wipe out the lubricant are arranged into two groups.The first two labyrinths , installed inside keep back most of the lubricant. Five further labyrinths protect the bearing from outside.They prevent the lubricant overflow and the ingress of impurities.The overflow lubricant is collected into a chamber between the both groups of labyrinths.Through the return bores the lubricant flows back into the bearing. The spherical seating is a special feature enabling the alignment of the shell in the housing.The shell is seated on two spherical seatings. The advantages of the spherical seating are: easy at assembly good heat transfer from the shell to the housing suitable for such applications with high thrust or journal loads. In the case of bearing types 10 and 20 a light alloy ring is clamped on the shaft in front of the shaft.This ring fits into a groove in the seal carrier or the rigid labyrinth seal, thus building a labyrinth. The labyrinth protects the shaft exit against low pressure that could otherwise " absorb " the lubricant. Low pressure occurs for instance in the case of rotating discs, such as couplings or cooling discs. The floating labyrinth seal (type 10) in the seal carrier is used as a shaft seal in the case of bearings type E operating under normal conditions. It prevents the lubricant and lubricant mist coming out and the ingress of impurities. The floating seal has a high capacity of resistance to wear. It is made of a high-performance, high temperature stability and electrically insulated plastic material.The floating seal consists of two halves held together by a garter spring. Both ends of the spring are hooked together. In the case of slide bearings type EM the floating seal is mounted into a two-piece seal carrier. The groove allows for radial movement of up to 1 mm. The seal is thus insensitive to shaft radial displacement or deflection. The sealing effect is produced by the baffles wiping off the lubricant from the shaft. The lubricant flows back into the bearing via oil return opening. In the case of the flange mounted bearings, the machine seal reduces the influence of positive and negative pressure in the machine thus preventing leakages at the inner seal area. The space between the machine seal and the bearing housing must always be vented to atmospheric pressure. The size of the gap between shaft and machine seal influences the sealing effect.

Rigid labyrinth seal

Spherical seating

Dust flinger

Floating labyrinth seal

Machine seal

RENK AG Werk Hannover

RH-EFEWI-E Version: 6 November, 2000

49

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

8.
Test Reports

ABB

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

Contents Test Reports

ABB

TEST REPORT

Test report for synchronous machines

Customer Order reference Project

WRTSIL FINLAND OY P/04007-Grupo Punta Cana Grupo Punta Cana

Machine Work nr: Serial nr Date

AMG 1120MM10 DSE 3020HE401 4577169 3.6.2004

Approved on the behalf of manufacturer

Jukka Siuko

ABB Oy, Electrical Machines


Visiting Address Strmbergintie 1 HELSINKI Postal Address P.O.Box 186 FIN-00381 HELSINKI Finland Telefax(Group) +358 10 22 22330 Telefax(Test floor) +358 10 22 23692

TEST REPORT
Customer Machine Page

WRTSIL FINLAND OY
Order reference

AMG 1120MM10 DSE


Work nr: Serial nr

2
Revision

P/04007-Grupo Punta Cana


Project

3020HE401
Approved Jukka Siuko

4577169

A
Report rev:

Grupo Punta Cana

RATINGS
Standards Insulation class Temperature class Ambient temp. max Usage Generator Conn Y IEC F F 50 C Sn/Pn[kVA] 8713 Un [V] 12470 Classification society Mounting Protection class Duty In [A] 403 None IM 1101 IP 23 S1

p.f. f [Hz] Um [V] Im [A] Direction n [rpm] 0.80 60.0 63 8.4 <== 720

Table of contents / Test Program 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) Visual inspection Air gap measurement and bearing clearance Insulation resistances before tests Resistance measurement of windings and elements Direction of rotation, checking of phase sequence First running No-load point Short-circuit point No-load and short circuit curve, U1 = f(Im) and I1 = f(Im) Tests with regulator Overspeed test Vibration measurement after overspeed High voltage test Insulation resistances with PI

Appendices: 1) Tests with regulator_Basic settings 2) Tests with regulator_Voltage build up and regulation at no-load

TEST REPORT
Customer Machine Page

WRTSIL FINLAND OY
Order reference

AMG 1120MM10 DSE


Work nr: Serial nr

3
Revision

P/04007-Grupo Punta Cana


Project

3020HE401
Approved Jukka Siuko

4577169

A
Report rev:

Grupo Punta Cana

1)

Visual inspection
Version A Notes OK

2) Air gap measurement and bearing clearance


Airgap Min [mm] Machine Exciter 9.0 2.4 Max [mm] 9.2 3.1 Bearing clearance [mm] D N.D 0.32 0.32 Axial play [mm] 5.00 ET [mm] 40.5

3) Insulation resistances before tests


T = 25C Winding Stator Rotor Exciter Auxiliaries Space heater Temperature detectors Stator Bearing R [Mohm] 5200 25400 57500 U [V] 1000 1000 1000 t1 [s] 60 60

324000 366000 7500

500 500 500

4) Resistance measurement of windings and elements


Resistances of windings T = 20 C Armature windings Ruv [ohm] Stator Rotor Exciter Stator Rotor: 0.13899 0.78771 5.44533 0.01975

Ruw [ohm] 0.13907

Rvw [ohm] 0.13919

0.01976

0.01974

Resistances of detectors and space heaters T = 25.0 C Terminal box Terminals Position B3A 1HE1 - 1HE2 Space heaters B3A 1R1 - 1R2 Stator winding U B3A 2R1 - 1R2 Stator winding V B3A 3R1 - 3R2 Stator winding W B3A 4R1 - 4R2 Stator winding U (spare) B3A 5R1 - 5R2 Stator winding V (spare) B3A 6R1 - 6R2 Stator winding W (spare) B3A 30R1 - 30R2 Bearing D-end B3A 40R1 - 40R2 Bearing N.D-end

R [ohm] 151.2 109.7 109.6 109.6 109.8 109.9 109.8 109.8 109.4

Detector Pt-100 Pt-100 Pt-100 Pt-100 Pt-100 Pt-100 Pt-100 Pt-100

TEST REPORT
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P/04007-Grupo Punta Cana


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3020HE401
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4577169

A
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5) Direction of rotation, checking of phase sequence


Result U-V-W | L3-L2-L1 | <<< (CCW)

6) First running
Notes OK

7) No-load point
n [rpm] T [C] U1 [V] Im [A] Ir [A] 80.0 Uvw [V] 12495

720 65.1 12493 3.00 Voltage balances Uuv [V] Uuw [V] Stator 12499 1 12491 Notes

8) Short-circuit point
n [rpm] T [C] I1 [A] 720 49.4 403.1 Current balances Stator Iu [A] 1 404 Im [A] 3.60 Iv [A] 404 Ir [A] 96.2 Iw [A] 402

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9) No-load and short circuit curve, U1 = f(Im) and I1 = f(Im)


Ratings U1 = 12470 V I1 = 403 A n = 720 rpm No-load curve T = 65.1 C n = 720 rpm Im [A] U1 [p.u.] 16.46 1.35 6.20 1.20 4.14 1.10 3.50 1.05 3.00 1.00 2.62 0.95 2.36 0.90 1.60 0.70 1.31 0.60 1.04 0.50 0.76 0.39 0.65 0.35 0.53 0.30 0.40 0.25 0.00 0.08 Short-circuit curve T = 49.4 C n = 720 rpm Im [A] I1 [p.u.] 5.63 1.50 3.99 1.10 3.60 1.00 2.64 0.75 1.69 0.50 0.75 0.25 0.00 0.05
1.6

1.4

1.2

1.0
U1 [p.u.], I1 [p.u]

0.8

0.6

0.4

0.2

0.0 0 5 10 15 Im [A] U1 I1 20 25

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10) Tests with regulator


Version Position Manufacturer Type Serial nr Drawing nr A

ABB UNITROL 1000 30069127/0004 5132715 B

Sustained short-circuit test I1, max = Im, max = n, min = ECL-10(Pos nr) = Other settings Remanence voltage, U = Voltage transformer Auxliary voltage, Uaux = Pulse Width of UM Direction of Permanent Magnet

1425 A 15.1 A 671 rpm 5

1705.0 V 12470/110/110 110.0 V 11.9 % Ok

11) Overspeed test


n = 864 rpm t = 120 s

12) Vibration measurement after overspeed


Bearing position D-END ND-END U [V] 12470 12470 I [A] No-load No-load n [rpm] 720 720 Horizontal 1.20 0.65 Vertical 0.80 0.24 Axial 0.75 0.45 Unit mm/s mm/s

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13) High voltage test


Winding Stator Rotor Exciter Auxiliaries Space heater Temperature detectors Stator Bearing U [V] 27940 2500 2000 1500 1500 500 t [s] 60 60 60 60 60 60 f [Hz] 50 50 50 50 50 50

14) Insulation resistances with PI


T = 46.0 C Winding Stator Rotor Exciter Auxiliaries Space heater Temperature detectors Stator Bearing R [Mohm] 46800 47200 252000 258000 4720 U [V] 1000 1000 500 500 500 t [s] 600 R2 [Mohm] t2 [s] 4720 60 15000 60 R/R2 9.92

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1)

Tests with regulator_Basic settings

;----------------------------------------; ABB Switzerland Ltd ; PCTools 3.001 ; ; UNITROL 1000 Parameter File ; Saved: 04.06.2004, 07:32 ; AVR Serial Number: 30069127/0004 ; Control Software Version: 3.100 ; Panel Software Version: 3.001 ;----------------------------------------[SYSTEM DATA] Potential Transformer=Three_Phase UM Nominal=12.470kV UM Primary=12.470kV UM Secondary=110.00V IM2 Nominal=1000A IM2 Primary=500A IM2 Secondary=1.000A Ie No Load=3.7A Kceiling=7.08 Xq=0.84 [FIELD FLASHING] Off Level=0.0% [SOFTSTART] Starting Level=25.0% Hold Time=1.0s Ramp Time=5.0s [V/Hz LIMITER] fKnee=54.0Hz Slope=100.0%/fknee [IeMin LIMITER] Minimum=0.0A Active=FALSE [IeMax LIMITER] Maximum=30.0A Maximum Hold Time=10.0s Delayed=12.6A Delayed Hold Time=60.0s Continuous=10.9A Active=TRUE [PQ LIMITER] Minimum Q (P @ Minimum Q (P @ Minimum Q (P @ Minimum Q (P @ 0%)=-25.0% 25%)=-25.0% 50%)=-25.0% 75%)=-25.0%

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Minimum Q (P @ 100%)=-25.0% Voltage Dependency=FALSE Active=TRUE [UM LIMITER] Minimum=90.0% Maximum=110.0% Minimum Active=TRUE Maximum Active=TRUE [BOOST] Treshold=70.0% Hold Time=10.0s Hysteresis=8.0% [AUTO SETPOINT] Minimum=90.0% Maximum=110.0% Ramp Rate=0.30%/s Aux Minimum=-10.0% Aux Maximum=10.0% [PF SETPOINT] Minimum=-0.7500 Maximum=0.7500 Ramp Rate=0.0050/s [Var SETPOINT] Minimum=0.0% Maximum=100.0% Ramp Rate=1.00%/s [MANUAL SETPOINT] Minimum=0.0A Maximum=15.0A Ramp Rate=0.10A/s [OPEN LOOP SETPOINT] Minimum=0.0% Maximum=100.0% Ramp Rate=1.00%/s [VDC] Primary Net ID=1 Secondary Net ID=2 Ramp Up Time=10.0s [DIGITAL I/O HYSTERESIS] Low Level=4.0V High Level=10.0V [DIGITAL I/O 1]

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Input=Excitation_ON Polarity=Normal Output=None Direction=In [DIGITAL I/O 2] Input=Gen_CB_Closed Polarity=Normal Output=None Direction=In [DIGITAL I/O 3] Input=None Polarity=Normal Output=Close_CB_Command Direction=Out [DIGITAL I/O 4] Input=None Polarity=Normal Output=Boost Direction=Out [DIGITAL INPUT 5] Input=Synchronize Polarity=Normal [DIGITAL INPUT 6] Input=Parallel_With_Grid Polarity=Normal [DIGITAL INPUT 7] Input=PF_Enable Polarity=Normal [DIGITAL INPUT 8] Input=VDC_Enable Polarity=Normal [DIGITAL INPUT 9 from +AI] Input=Manual_Enable Polarity=Normal [DIGITAL INPUT 10 from -AI] Input=Reset_Alarm Polarity=Normal [DIGITAL INPUT 11 from +AI] Input=Remote_Setpoint Polarity=Normal [DIGITAL INPUT 12 from -AI]

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Input=Secondary_Net_Selected Polarity=Normal [DIGITAL INPUT 13 from +AI] Input=Increase Polarity=Normal [DIGITAL INPUT 14 from -AI] Input=Decrease Polarity=Normal [ANALOG INPUT 1] Input=PF_Setpoint Uin 0%=2.0V Uin 100%=10.0V [ANALOG INPUT 2] Input=Din11&12 Uin 0%=2.0V Uin 100%=4.0V [ANALOG INPUT 3] Input=Din13&14 Uin 0%=2.0V Uin 100%=4.0V [ANALOG OUTPUT] Output1=Excitation_Current Output2=Fbias Uout1 0%=0.0V Uout1 100%=10.0V Uout2 0%=-3.0V Uout2 100%=3.0V Ie 0%=0.0A Ie 100%=15.0A Fbias 0%=-3.00Hz Fbias 100%=3.00Hz [TUNE AUTO] Proportional Gain (Vp)=58.0 Derivation Time (Tb)=0.20s Integration Time (Ta)=5.80s Droop (Kq)=-4.00% [TUNE PF/Var/PQ LIMITER] Proportional Gain (Vp)=10.0 Integration Time (Ta)=3.00s [TUNE MANUAL/Ie LIMITER] Proportional Gain (Vp)=20.0 Integration Time (Ta)=0.10s

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[COMMUNICATION] AVR ID=1 [SYNCHRONIZATION] Min Slip=0.00Hz Max Slip=-0.40Hz MaxDeltaU=5.00% Max Delta Angle=10deg Tot CB Close Time=90ms

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2)

Tests with regulator_Voltage build up and regulation at no-load

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End of report
Test bay Author GX2 (Dieselgenerator line, test bench no. 2) T.Stenlund, J.Lhde Printed: 23.6.2004 Number of pages 14 Jukka Siuko

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

9.
Check Lists

ABB

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

Contents Check Lists


Commissioning Report Test Record for Winding Maintenance Pt-100 Failure Inspection Protocol Check List for Renk Bearings

ABB

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

COMMISSIONING REPORT
Rating Plate Information: 3 ~ Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 Manufacturer: Address: Telephone: Telefax: Customer: Customer Address: ABB Oy Synchronous Machines P.O. Box 186 FIN-00381 HELSINKI FINLAND +358 (0) 10 22 2000 +358 (0) 10 22 22675

Contact Person: Telephone: Mobile phone: Fax: Email:

Commissioning Report - 1

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

1 Transportation
General: Arrival date of the machine: Inspection date and location: Signature of consignee: Open box inspection: Damages: Packing list: Machine: Package: Accessories: Spare parts + tools: Actions Taken in Response to Damages: Photographed: Reported to the transportation company: Reported to the supplier: Reported to the insurance company: Method of Transportation: Railway Comments: Airfreight Truck Mail Shipped by M/S ___________ Other: no no no no yes, date: yes, to whom: yes, to whom: yes, to whom: date: date: date: no no no no no yes, missing items: yes, what kind of: yes, what kind of: yes, what kind of: yes, what kind of: no yes, done by:

Commissioning Report - 2

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

2 Storage
General: Storage: Storage Time Longer than 6 Months: Person Responsible for Storage: Storage Place: indoors in packing case outdoors protected by a waterproof cover no no yes, begin:_______________end:_____________________ yes

Daily temperature: min/max._______ - _______C Humidity:_______% Storage Actions: Transportation package is ventilated: External heating/fan is used: Machine space heaters are used: Bearings are flushed: Bearing shells are removed: Shaft end anti-corrosion protection checked: Shaft end anti-corrosion protection renewed: The rotor is turned 10 revolutions every two months: There are vibrations in the storage place: There are corrosive gases in the air: Brushes are lifted up: Machine documents are saved and protected for future use: Comments: no no no no no no no no no no no no yes yes, type:______________________________________ yes, voltage:____________________________________ yes, oil type:____________________________________ yes, date:______________________________________ yes, type:______________________________________ yes, date:______________________________________ yes yes, __________mm/s, rms yes, what kind of:__________________________________ yes yes, location:_____________________________________

Commissioning Report - 3

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

3 Mechanical Installation
Foundation is checked according to machine drawing: Possible foundation anchor bolts or sole plates are mounted according to instructions: Air gap is measured: For pedestal bearings, mark values 1-4, and for flanged bearings, values A-D 1 ____________ A ____________ 2 ____________ B ____________ 3 ____________ C ____________ 4 ____________ D ____________ For alignment of the coupling, use either values 1-4 or values A-D 1 ____________ 2 ____________ 3 ____________ 4 ____________ A ____________ B ____________ C ____________ D ____________ D 4 C 3 D 4 C 3 no no yes, drawing number:_____________________________ yes D-end top 1 A 2 B 4 C 3 B D N-end top 1 A 2 4 C 3 B Exciter N-end top D 1 A 2

Radial alignment of coupling top 1 A 2 B

Angular alignment of coupling top D 4 C 3 1 A 2 B

Axial position of the rotor: ET #1:__________mm, ET #2:__________mm Axial distance between shaft ends: __________mm Rotor support distance:

______mm ______mm Crankshaft deflection is checked: Tapered guide pins are used to lock the position of the machine after alignment: Foundations bolts are tightened with torque wrench: Bolt lubrication: Cooling water: Cooling element piping: Transport locking device is removed: Rotor rotates without noise or scraping: no no no dry no flexible no no yes yes Commissioning Report - 4 yes yes yes, bolt size:_____________torque:_______________Nm oil, MoS2 m3/s rigid

yes, amount:

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

4 Lubrication check
4.1 Self lubrication
Bearing oil: The oil quality is the same as recommended : Bearing oil is filled up to the indicated level: Please mark the level in the sight glass circle on the right Lubrication rings rotate freely: no yes Manufacturer:__________________ Type:_________________________ no yes Sight Glass

4.2 Forced lubrication


Bearing oil: The oil quality is the same as recommended: Lubrication rings rotate freely: Force lubrication oil pressure: Oil flow: Rotation of the pumps checked: Jack-up pumps checked: Oil filters checked: Manufacturer:__________________ Type:_________________________ no no yes yes

___________kPa ___________liters/min no no no yes yes, alarm setting:_____kPa, relief valve setting:______kPa yes

4.3 Grease lubricated bearings:


Grease: The grease quality is the same as recommended on the lubrication plate: The first greasing has been done: Comments: Manufacturer:__________________ Type:_________________________ no yes

Date:_______________ Quantity:________g

Commissioning Report - 5

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

5 Electrical installation
Network variation: Space heater operation: Space heater for slip ring unit: no no no yes, voltage:______-______V, frequency:_____-______Hz manual automatic, controlled by:_________________

yes, voltage:_____________V, power:_______________W

5.1 Insulation Resistance Test


Stator winding (1 min.): Stator winding (15 / 60 s. or 1 / 10 min.): Rotor winding (1 min., 500 VDC): Exciter stator (1 min., 500 VDC): Space heater: Temperature detectors: N-end bearing insulation: __________M, tested by________ kV, winding temperature:______C PI =__________, tested by________ kV, winding temperature:______C __________M, tested by________ kV, winding temperature:______C __________M, tested by________ kV, winding temperature:______C __________M (500 VDC) __________M (100 VDC) __________M (100 VDC)

5.2 Accessories resistance test


Stator 1 PT 100: Stator 2 PT 100: Stator 3 PT 100: Stator 4 PT 100: Stator 5 PT 100: Stator 6 PT 100: Bearing PT 100 D-end: Bearing PT 100 N-end: Air temperature 1 PT 100: Air temperature 2 PT 100: Space heater: __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________

Commissioning Report - 6

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

6 Machine protection settings


Overcurrent tripping: Instant overcurrent tripping: Overvoltage setting: Earth fault setting: Reverse power setting: Differential protection setting: Vibration monitoring: Temperature monitoring: - in stator winding - in bearing - in ______________________________ Other protection units: no no no no yes, alarm:__________C, trip:______________C yes, alarm:__________C, trip:______________C yes, alarm:__________C, trip:______________C yes, type: _______________A _________________ s _______________A _________________ s no no no no no yes, setting: yes, setting: yes, setting: yes, setting: yes, alarm:__________mm/s, trip:______________mm/s

Commissioning Report - 7

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

7 Test Run
7.1 First start (a few seconds only)
Note: Check that possible force lubrication is on! Direction of rotation (viewed from D-end): Are there abnormal noises? no CW yes, from: CCW

7.2 Second start (uncoupled, if possible)


Note: Check that possible force lubrication is on! Are there abnormal noises? Does the machine vibrate abnormally? Bearing vibration level measured: Running: no no yes, from: yes, where/how:

D-end:__________ mm/s, rms; N-end:_________ mm/s, rms machine run OK operation stops, why:

Checking schedule and information


Time Bearing temperature D-end h:min 0:00 0:05 0:10 0:15 0:20 Comments: N-end Bearing vibration levels D-end mm/s rms N-end mm/s rms Current A Stator Power Factor cos Excit. Current A Stator winding temperature U V W

Observations:

Commissioning Report - 8

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

8 Test run (with load)


Checking schedule and information
Time Load Bearing temp. D-end h:min 0:00 % N-end Bearing vibration levels D-end mm/s rms N-end mm/s rms Current A Stator Power Factor cos Excit. Current A Stator winding temperature U V W

Vibration spectrum attached: Acceleration time: Cooling air temperature: Cooling water temperature: Comments:

no

yes

__________ s. Inlet: __________ C Inlet: __________ C Outlet:__________ C Outlet:__________ C

9 Machine approval
Machine approved for use Commissioning done by: Approved by: Date:

Commissioning Report - 9

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

Fax Cover Sheet


Date: To: ABB Oy Synchronous Machines Telefax: +358 (0) 10 22 22675

From: Fax number: Phone number: Email: Number of Pages: Message: 1 + 9 + _________

Commissioning Report - 10

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

Test Record for Winding Maintenance

TEST RECORD
Annual inspection Inspection every 4 years Random inspection

Machine type: Use: Voltage/output: Running hours:

No: No: V/ h kW

Distribution: 1. Seals

Date/inspected by: OK Observations:

2. Fixing air guiding plates etc.

OK

Observations:

3. Contamination Total amount of dirt Grease, oil Dry dirt, dust Dampness, rust

Stator Rotor Commutator windings windings brushgear

Air ducts

Cooling radiators

Explanations

End D/N

QUANTITY ESTIMATION 0 = clean 1 = slightly dirty 2 = ducts about to plug 3 = ducts are plugged

ESTIMATION BASIS 1 = dropping 5 = dust, caused by vibration 9 = water marks 13 = battered 17 = condensation 21 = other noises 2 = loosening 6 = swelling 10 = tracking current marks 3 = cracking 7 = darkening 11 = hair cracks 4 = breaking 8 = embrittlement 12 = risen bars 16 = leakages 20 = noise from bearing

14 = knocking: doubtful 15 = corrosion 18 = loose ribs 22 = other flaws 19 = abrasion

Test Record for Winding Maintenance - 1

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

4. WINDINGS
4.1 AC Stator Support Coils Connecting cables Core laminations 4.2 Synchronous rotor Coils, insulations, support Pole, poleshoe, bolts Connection ring 4.3 Asynchronous rotor Ends of squir. cage windings Key of squir. cage ring Core laminations 4.4 DC stator Windings, insulations Fixing the windings Connecting leads 4.5 DC rotor Coils Bandage Core laminations

OK

Observations

D/N

5. FAN 6. COOLING SYSTEM


Visible radiator parts Inner radiator parts Flow-switch

Test Record for Winding Maintenance - 2

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

7. ELECTRICAL CONNECTIONS
Main connection Control gear

8. ELECTRICAL TESTS Insulation resistance to earth R15= Winding temperature: Voltage test 1 min. Operation test of protection Test voltage: Voltage kV, DC voltage AC voltage M, R60= M

Test Record for Winding Maintenance - 3

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

Pt-100 Failure Inspection Protocol


This check list helps to provide ABB with sufficient data to determine the cause of Pt-100 sensor damages. Please mark N/A on points not valid in your case.

1 General
Customer: Azipod Type of machine: Serial number: Project name or order number: Generator Motor

2 Operational information
Start up date (dd/mm/yyyy): Application: Operating hours before failure: Output at the time of failure: Current: A Power: Temperature: Power: kW h kW Speed: rpm

C
Current: A

Normal operating load: Normal operating temperatures: D-end: N-end: Ambient temperature:

C C C C

Stator: Rotor:

C C C

Minimum and maximum ambient temperatures: Service done before damage:

Disturbances before damage (e.g. high vibration):

Pt-100 Failure Inspection Protocol - 1

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

3 Additional information
Where the damaged sensors are and how many sensors are damaged: Stator winding When the damage was discovered: Were several sensors damaged at the same time: Were there other damages in system at the same time: How the damage was discovered: In monitoring system If otherwise, how: Bearing Hot air Cool air

Where were the sensors checked after damage: In junction box

If not, where:

Manufacturer of damaged sensor: Minco Thermo-Est Some other, who:

Resistance between 3-wire Minco sensor wires, if other sensor, update colors: red-blue red-white blue-white

4 Current situation
Where is the machine at the moment:

What has been done so far to the machine due to this damage:

Additional comments:

5 Material to be provided to ABB


Photographs of machine: Temperature trend curves: Other material:

Pt-100 Failure Inspection Protocol - 2

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Serial no. ABB Ref. July 2004 Project:

4577169 3020HE401 Grupo Punta Cana

6 Contact information
Date (dd/mm/yyyy): Place: Signature: Name, title: Company: Phone: Fax: E-mail: Thank you very much for your co-operation!

Pt-100 Failure Inspection Protocol - 3

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Oil Leakages at RENK Slide Bearings?


A Check List for Horizontal Bearings

In case of oil leakage's in the bearing area, this check list may help you to find fail reasons or to set up a detailed fail report to our service department. Your answers of necessary questions will help us to find reasons and solutions to the problems. General informations 1.1 Machine Scheme (designation convention and description)
Bearg.
DE

Bearg. MACHINE

Type of machine: ___________________


NDE

Type of machine: ___________________ coupled to DE 2 Seals 1 1 Seals 2


(Seal position e.g. DE_2 or NDE_1)

(in case of leaking seals mark the desired check-box)

1.2 To read from nameplate of bearing: Bearing Type: RENK Ref. N: Oil viscosity: 1.3. Type of oil applied: (e.g. EFZLA 14-140) (e.g. 446 123) (e.g. ISO VG 46) unknown DE _____________ DE _____________ DE _____________ Manufacturer: Denomination: 1.4 Informations on operational conditions: nominal speed: ________ RPM overspeed: _____________ RPM NDE _____________ NDE _____________ NDE _____________ _________________ _________________

RENK Check List for Horizontal Bearings - 1

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

1.5 Types of mounted seals: DE_1: Typ ___ DE_2: Typ ___ NDE_1: Typ ___ NDE_2: Typ ___
(ad on's to basic types)

Typ 10 Floating Labyrinth S.

Typ 20 Rigid Labyrinth S.

Typ + 1 Dust Flinger

Typ + 2 Bolt-on Baffle

(Typ numbers for basic seals with "ad on": Typ 11 or 12 respective Typ 21 or 22)

2.1 Intensity of oil leakage's: less than 2 drops per day less than 10 drops per day more than 10 drops per day 2.2 Localisation of leakage's: Seals screw connections / pipes split line of bearing housings 3. Is the oil level correct? 4. Foams the oil heavily? 5. Is the foam visible in the sight glass? yes yes yes (please answer questions 3 - 25, 30) (please answer questions 26 - 30) (please answer questions 3 - 8, 14, 22, 29, 30) no no no

6. Normal bearing shell temperature? unknown 7. Oil sump temperature? unknown ____ C ____ C

8. Machine and bearings horizontally aligned? yes sea! no, inclination (axline): ____ axline: ____ across: ____

RENK Check List for Horizontal Bearings - 2

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Shaft Seals - Details 9. Where do the leakage's at seal appear? between seal and shaft between seal and housing difficult to recognise 10. Seals gap to shaft - can you measure the gaps at positions 12, 3, 6 and 9 o'clock positions with view towards bearing; the seal should not be disassembled before? Please note also seals machine-position. If not possible, can you measure alternatively the shaft diameter at seals seat? no | | yes: please note below | | (mm)

(mm)

11. Did you realise gaps in the split line of seals (by means of a feeler / plate gauge)? (In case of Floating Labyrinth Seal: fit the seal with its garter spring - but without the carrier - onto the shaft) no <|> yes: note gap's below <|> (mm)

12. Is there any damaged baffle (at seals)? yes no

13. Are the oil drain holes of seals in the lower half and they are open to bearing housing? yes no 14. Has been applied "Curil T" (or other non-hardening sealant) on all joints, split lines of housings and seals as well as between housing and seals prior to assembly? yes no

15. If Floating Lab. Seal is used, has been applied "Curil T" to the flanks of this seals? yes no

16. Are there deflectors at the shaft - between bearing shell and seal area? yes no

RENK Check List for Horizontal Bearings - 3

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

Differences in Air Pressure / Air Streams 17. Are there components outside the bearing, close to the seal area, which might cause a draught (fans, cooling discs, couplings flywheels, belt drives)? yes no ______ mm

Distance inbetween:

18. Is there a difference in air pressure from inside bearing to outside (low or high pressure differences of more than 30 Pa respective 3 mm WC are of interest; please sign low pressure with minus)? no DE: ____ Pa could not be measured NDE: ____ Pa

19. Are there low or high pressure in front of seals (at machine side of flanged bearings - housings EF or EM - you can measure in the channels respective connections for air pressure compensation)? no DE_1: ____ Pa could not be measured DE_2: ____ Pa

NDE_1: ____ Pa

NDE_2: ____ Pa

20. If there is a breather mounted at the bearing house, is this device (filter) dry and clean? no device yes device mounted no. oil-wet --> or: __

21. In case of pressure differences, did you have any idea of its origin (note it please)? External oil supply If there is only a circulation from oil sump of bearing direct to bearing entry (oil circulation pump at each bearing), please strike out questions 23, 24 and 25. 22. Please note oil throughput + oil pressure + oil temperature at each bearing entry: unknown DE: ____ l/min ____ bar ____ bar ____ C ____ C

NDE: ____ l/min

23. Inclination of oil return pipe between bearing and oil tank: < 10 deg. 10 deg > 15 deg.

24. Nominal diameter of oil return pipe

RENK Check List for Horizontal Bearings - 4

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

________

mm

25. If you found high pressure inside bearing, is it possible that this pressure comes along the oil return pipe (from tank; e.g. produced by pressurised air seals at other components in the oil circulation system)? yes no

Screw connections and Vibrations


26. Which screw connections are leaking? locking screw with plastic seal locking screw with copper gasket oil sight glass connection of oil return pipe - with hexagon nut and lead gasket 27. Are the locking screws tightened according to torque's (Nm) given below? G 1/8: G 1/2: G 1 1/4: G 2 1/2: yes 18 G 1/4: 22 40 G 3/4: 60 160 G 1 1/2: 230 500 no G 3/8: 30 G 1 : ..110 G 2 : ..320

28. Has the screw connection of the oil return pipe in the bearing house been relieved from the tube weight by appropriate fixing devices? yes no

29. Are there vibrations at the oil return pipe? no low strong

30. Did you measure vibrations of the housings and / or of the shaft? no yes, Veff = _____ mm/s amplitude Smax = ____ m

RENK Check List for Horizontal Bearings - 5

Synchronous Machine AMG 1120MM10DSE Section 9 - Check Lists

RENK AG, Werk Hannover (Germany) Dept.: HVA (after sales service) Fax: +49.511.8601 - 288 e-mail: hva_ha@renk.de

RENK Check List for Horizontal Bearings - 6

Users Manual

Synchronous Machine AMG 1120MM10DSE Serial no. 4577169 ABB ref. 3020HE401 Project: Grupo Punta Cana

July 2004

10.
Additional Information

ABB

ABB
ABB Oy Synchronous Machines P.O. Box 186 FIN-00381 HELSINKI FINLAND Telephone + 358 (0)10 22 2000 Telefax + 358 (0)10 22 22675