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MAINTENANCE MANUAL
SYNCHRONOUS GENERATORS
G LINE
Transforming energy
into solutions
GENERATORS SYNCHRONOUS
FOREWARD
9300.0015 I/3
February 2003
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GENERATORS SYNCHRONOUS
TABLE OF CONTENTS
1. NOMENCLATURE.........................................................................................................................5
2. SAFETY INFORMATION...............................................................................................................6
6. INSTALLATION .........................................................................................................................11
6.1. COOLING SYSTEM ............................................................................................................ 11
6.2. ROTATION DIRECTION ..................................................................................................... 11
6.3. DEGREE OF PROTECTION.................................................................................................. 11
6.4. AGGRESSIVE ENVIRONMENT (MARINE DUTY GENERATORS) ................................................ 12
7. MECHANICAL ASPECTS.............................................................................................................13
7.1. BASES / FOUNDATIONS .................................................................................................... 13
7.2. ALIGNMENT/ LEVELING..................................................................................................... 13
7.3. COUPLING ....................................................................................................................... 13
7.3.1. Double Bearing Generators (B5/B3T) ................................................................................... 13
7.3.2. Single Bearing Generators (B15T) ........................................................................................ 14
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1. NOMENCLATURE
G T A . 3 1 5 S I 3 1
Type of Machine
G T A . 3 1 5 S I 3 1
Characteristic
GT A . 3 1 5 S I 3 1
Method of Cooling
A Open Self-ventilated
GTA.315 S I 3 1
Frame IEC
200 to 560
GTA.315 M I 3 1
Frame length
S, M, L, A, B, C, D, E ,F
GTA . 3 1 5 SI 3 1
Application
I Industrial
M Marine
T Telecommunications
N Naval
E Special
GTA.315S I 31
00 to 99
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2. SAFETY INFORMATION
Warning symbols
In case installation and maintenance
manuals are missed, Weg can supply a spare
Safety Warning and copy. If further information is required, this
Warranty can be requested from Weg by providing
generator serial number which can be found
on its nameplate and/or right below of the
Danger drive endshield of the generator.
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3. GENERAL INSTRUCTIONS
3.1. APPLICATION
WEG G line generators have been developed to If any damage is noticed, contact the carrier
meet normal requirements of IEC34.1 and ABNT and Weg.
5117 Standards. Lack of communication will void the warranty.
Special conditions can be met and they should be
specified in the purchase order.
Bearings:
- When generator is storage for a period up to
six months, maintenance is not required;
- From 6 months up to 2 years, rotor must be
Never transport the single bearing generator rotated on a monthly basis (manually) to avoid
without locking the shaft. race spot and hardening of grease;
Neither the generator nor its package should - After 2 years of storage, we recommend to
be dropped or suffer any impact. replace the bearings, when these bearings are
shielded. When not shielded, these must be
disassembled, washed and regreased them
before new operation.
3.3. RECEIVING
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Rm = Un + 1
Where:
This generator is fitted with eyebolts for RM Minimum insulation resistance
lifting purposes. recommended in Mega Ohm with the winding at
These eyebolts are intended to lift only the
a temperature of 40C;
generator. Additional loads are not allowed.
Un Rated voltage of the generator in kV.
Cables and lifting devices must be If the test is performed at a different
appropriated to prevent accidents and
temperature, it is required to correct the reading
damages to the generator or personnel
to 40C by using an insulation resistance variation
injury. Pay attention for correct generator
curve in relation to temperature, given by the
weight.
generator itself. If this curve is not available it is
Lifting and lowering must be done gently.
possible to use an approximate correction given
Never lit the generator by the shaft. by the curve below:
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Voltage
Regulator
Voltage
Regulator
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The electronic voltage regulator is intended to Voltage regulation is made by trimpot P1 on the
keep the voltage as constant independently from own electronic voltage regulator allowing voltage
the type of load. It can be mounted in the regulation in the generator in the range +/- 15%
generator terminal box or in the control panel. of the rated voltage.
An external potentiometer for fine voltage
regulation (5k / 3W) on terminals 6 and 7 of the
regulator.
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7. MECHANICAL ASPECTS
7.2. ALIGNMENT/ LEVELING Fig 3.3.3 Combined axial and radial checking
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INCORRECT
For disassembly of pulleys care must be taken to 7.3.2. Single Bearing Generators (B15T)
avoid damage to the key as well as shaft surface.
Always use appropriate tools to perform this G DIMENSION
service. All generators leave the factory already mounted
with discs and flanges according to customers
Operation: Avoid unnecessary radial thrusts on request. G dimension is the distance between
the bearings by ensuring that the shafts are external face of the discs and face of the flange,
parallel and the pulleys perfectly aligned as shown as shown on the drawing below:
below.
Laterally misaligned pulleys, when running,
transmit alternating knobs to the rotor and can
damage the bearing housing. Belt slippage can be
avoided by applying a resin type material such as
rosin.
COUPLING DISC
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STANDARD G DIMENSION
Coupling Disc
PA (mm) G (mm)
(SAE)
241.3 7.5 30.2
263.4 8 61.9
A Flange
314.2 10 53.9 B Shaft end
352.3 11.5 39.6 C Key
466.6 14 25.4 D Coupling bushing
E Coupling disc
517.5 16 15.7
F Hexangle bolt
571.4 18 15.7 G Pressure washer
673.1 21 00 H Support ring
733.4 24 0.0 I Spacing rings
NOTE:
Table of standard coupling dimensions for diesel
- For generators in frames 400 and above, the
group generators.
spacing rings are specific rings with high
thickness, although the change procedure of G
The dimension PA (mm) has a tolerance of
dimensions is the same.
- 0.13 mm.
- To attend to the combination of flange and
necessary coupling disc, also the flange (A)
could be changed.
250 10xM10x1.25 68 to 72
315 12xM12x1.5 119 to 126
400 12xM20x2.50 566 to 595
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Generators usually leave the factory with 12 The Electronic Regulator leaves the factory with
terminals available for connection to 440V. connections made for generator rated frequency
The electronic voltage regulator (located inside the and voltage values.
connection blocks) leaves the factory with jumper For the change of connections, Regulator manual
to operate at 60Hz. must be checked.
To operate at 50Hz, the jumper must be removed,
as per regulator manual.
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Warning
For identify.
of
connection Delta 2
terminals E1
& E3/4
(reference
voltage of
the voltage
regulator).
VOLTAGE ( V )
L-L 380 - 415 440 - 480 220 - 240 220 - 240
60Hz L-N 220 - 240 254 - 277 127 - 139 -
E1 - E3/4 190 - 207 220 - 240 220 - 240 220 - 240
L-L 380 - 400 190 - 200 200 - 220
50Hz L-N 220 - 230 110 - 115 -
E1 - E3/4 190 - 200 190 - 200 200 - 220
DELTA 1
TERMINAL
DELTA 2
BOARD
- E1 and E3/4 Reference Voltage for Voltage Regulator (See Voltage Regulator Manual).
- For Delta connection series 1, regulator reference terminals (E1 and E3/4) connected originally to terminals 7and 9 and
to auxiliary coil lead (4) which is connected to terminal 9, remain in the original position.
- For Delta connection series 2, regulator reference terminals (E1 and E3/4) connected originally to terminals 7 and 9
and to auxiliary coil lead (4) which is connected to terminal 9, must be removed from original position and then
reconnected to terminals 1 and 2 (see diagram above).
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8.2.2. Possible Connections for 6 Terminal Generators 1 Voltage (400 up to 560 frames)
Warning
For identification
of connection
terminals E1, E2
and E3/4
(reference
voltage of the
voltage
regulator).
VOLTAGE (V)
L-L 220 - 240 380 - 415 440 - 480 220 - 240
60Hz L-N 127 - 138 220 - 239 254 - 277 -
E1 - E3/4 220 - 240 (E1) 380 - 415 (E2) 440 - 480 (E2) 220 - 240 (E1)
L-L 380 - 400 190 - 220
50Hz L-N 220 - 230 -
E1 - E3/4 380 - 400 (E2) 190 - 220 (E1)
TERMINAL
BOARD
E1 and E3/4 Reference Voltage for Voltage Regulator (see Voltage Regulator Manual).
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Single phase Low Zig-zag Single phase Hi Zig-zag Single phase Delta
Warning
for identify.
of terminals
E1 and E3/4 E2
(ref. Voltage
of the
voltage
regulator).
VOLTAGE (V)
L-L 200 - 240 440 - 480 220 - 240
60Hz
E1 or E2-E3/4 200 - 240 440 - 480 220 - 240
L-L 190 - 220 380 - 400 190 - 220
50Hz
E1 or E2-E3/4 190 - 220 380 - 400 190 - 220
TERMINAL
BOARD
E1 and E3/4 Reference Voltage for Voltage Regulator (see Voltage Regulator Manual).
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8.2.4. Connection diagrams for generator fitted with auxiliary coil (standard)
CONNECT E1 OR E2, ACCORDING TO
REFERENCE VOLTAGE DESCRIBED
BELOW
ROTATING PART
STATOR
N
P1 P2
S
S1 S2
MAIN EXCITER
FUSE
1 2 3 E3/4 E2 E1
AUXILIARY COIL
F+ VOLTAGE
F- REGULATOR
8.2.5. Connection Diagram for Generator with Auxiliary Exciter (Special on request)
AUXILIARY EXCITER
(OPTIONAL) ROTATING PART
STATOR
N
N-S P1 P2
S
S1 S2
T
MAIN EXCITER
FUSE
1 2 3 E3/4 E2 E1
F+
VOLTAGE
F- REGULATOR
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ROTATING PART
STATOR
N
P1 P2 S
S1 S2
MAIN EXCITER
1 2 3 E3/4 E2 E1
F+ VOLTAGE
F- REGULATOR
Important notes:
- To use a generator with voltage of 320 to 600V and without auxiliary coil, you must connect E2 to phase
R and terminal 3 to Neutral. For this condition, terminal 3 can not be connected to E2.
- Weg Standard G line generators are fitted with auxiliary coil and without auxiliary exciter.
- It is not recommended to use generator without auxiliary coil due to generator power supply problems in
case of short-circuit or overloads. This diagram should only be used in case of faulty auxiliary coil.
- Generators fitted with auxiliary exciter are special and must be produced on request.
- When transformer is used to adjust reference voltage of the voltage regulator, this transformer can not
be installed inside the generator main terminal box.
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9. GENERATOR PROTECTIONS
Whenever requested by the customer, Weg NOTE: Alarm and tripping values can be
generators can be supplied with overheating defined based on experience. However, the
protection devices installed in the stator windings can not exceed those given previously.
or in the bearings, as described below:
Thermo-Resistance (Type PT100-RTD): When generators are fitted with space heaters to
The thermo-resistance is a resistance thermal avoid water condensation during long periods o
detector (RTD) usually made of platinum, and its standstill, these devices must be kept switched-
electric resistance varies linearly with the on. As soon as generator is restarted, space
temperature. heaters must be de-energized immediately.
The temperature of PT100 can be obtained A dimensional drawing and a specific nameplate
through the following formula: attached to the generator indicate the supply
voltage and the characteristics of the space
C : - 100 heaters installed.
0.385 If space heaters remain energized while machine
is in operation, winding can get damaged.
= resistance measured on the PT100
C = absolute temperature locally PT100 Connection Diagram for Space Heaters
NOTES:
1) Besides the protection devices indicated
herewith, other devices must be used, if
required by the application.
2) All thermal protectors must be duly connected
to control system and these should be in
perfect operation. Even being fitted with
temperature detectors, generator will not be
protected if devices are incorrectly connected.
3) We recommend that all relays (when
generator is protected with thermo resistance)
should be set as indicated below:
Temperature (C)
Class Alarm Tripping
F 140 155
Stator
H 155 180
Bearings 90 100
Table 4
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FUSE (series connected with auxiliary coil): Model SIOV-S20K550 MKP 1.44/2
Weg generators are fitted with an automatic Weg Item 0018.1588 0018.0745
protection fuse of 5A, which is series connected
with auxiliary coil for its protection. 1,0W, Ueff 550V, 0.1mF,
Features Umax, Umax 2000Vdc,
990V 630Vac
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R S T
54 60 Frequency (Hz)
Application at 50Hz
52D TRIPPING
53D
Voltage (V)
Un
Bearing Thermostats
U/f
1 per bearing
45 50 Frequency (Hz)
76 77 78 79
9.7. CONNECTION DIAGRAMS FOR DRIVE END BEARING NON-DRIVE END BEARING
PROTECTIONS
Thermoresistances (PT100)
Winding Thermostats
In the stator (1 per phase)
In the stator (1 per phase)
R S T R S T
20 21 22 23 24 25
52 53 54 55 56 57
In the stator (1 per phase with 3 wires)
In the stator (1 per phase series connected)
R S T
R S T
20 20 21 22 22 23 24 24 25
52A 53A 54A 55A 56A 57A In the Bearings (1 per bearing with 3 wires)
ALARM
R S T
68 68 69 70 70 71
DRIVE END BEARING NON-DRIVE END BEARING
52D 53D 54D 55D 56D 57D
TRIPPING NOTE:
1) For PTC sensors, numbering is changed, as per
caption of item Identification of Terminals.
2) When 2 sensors per phase are used, suffixes A
for alarm and D for tripping are added.
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Weg generators leave the factory with some Once all above items have been entirely
safety measures for transportation. Therefore, accomplished, generator is then ready for start
before operating them, these protections (if any) up. While in operation, the automatic excitation
should be removed. starts operating and, under rated speed,
Usually, generators leave the factory connected generator can take load.
for 440V and the regulator with Jumper for 60Hz The ideal adjustment of the rated voltage must be
operation (to operate at 50Hz, remove the done through the adjusting potentiometer of the
Jumper, as per Regulator Manual). theoretical value on the regulator.
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GENERATORS SYNCHRONOUS
d. Having followed all procedures described a. The load must be disconnected from the
above and having solved eventual problems generator power supply before switching-off to
occurred (see abnormal situations/solutions), avoid eventual damages to it due to voltage
disconnect the set. Complete stop, connect reduction during the stop.
voltage regulator, operate the set and make
b. If the generator is fitted with space heaters,
adjustments required to the regulator. The
regulator manual describes the procedures for make sure they are energized.
the adjustments available (stability, voltage,
U/F constant).
10.5. PARALLEL OPERATION
e. Apply load and monitor generator current
making sure it will remain within specified 10.5.1. Generators between them and/or
figures for the machine in question. with the power supply
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The following maintenance procedures must be The maximun vibration level to the generator in
followed to ensure a good performance of the load is 20mm/s (RMS).
equipment and extension of its life time.
Inspection cycles depend essentially on the
application site conditions and on the service 11.5. BEARINGS
duty.
Bearing temperature control is also part of a
routine maintenance.
Temperature rise should not exceed 60 C,
measured at the external bearing cap.
Constant temperature control can be made by
The non observation of one of the items listed means of external thermometers or by embedded
below can reduce generator life time, thermo-elements (optional) .
unexpected stops and/or installation damages. Alarm and tripping temperatures for ball bearings
can be set respectively for 90 C and 100 C.
Generators used on supplying and emergency Generators built up to frame 315 (inclusive) are
sets must be, based on the humidity level of the fitted with permanent lubrication bearings, hence
installation site, operated from 2 to 3 times a not requiring relubrication.
month. At the time lubricant becomes deteriorated,
bearings must be replaced.
Generators built in frame size above 315, bearings
11.2. CLEANING need to be relubricated. On this case, lubrication
instructions must be followed strictly (cycle time,
Frame, vents, screens and fan cover must be kept amount and type of grease), according to the
clean, free of dust, dirt on the outside so as to table below:
make the cooling process easier.
The same applies to the inside of the generator Lubrication Quantity of
Frame Bearing
which should be free of dust, dirt and oil. Soft Interval (h) grease (g)
brush or clean cotton rags should be used to LA 6313 2RS --- ---
clean the generators. A jet of compressed air 200
LOA 6210 2RS --- ---
should be used to remove non-abrasive dust from
the fan cover and any accumulated grime from LA 6318 2RS-C3 --- ---
250
the fan and cooling fins (frame). LOA 6214 2RS --- ---
Oil or damp impregnated impurities can be LA 6320 2RS-C3 --- ---
removed with rags soaked in a suitable solvent. 315
LOA 62162RS-C3 --- ---
Their terminals should be free of oxidation, in
LA 6324 -C3 2900 72
perfect mechanical condition and all unused space 400
dust-free. LOA 6226-C3 2300 46
LA 6324 -C3 2900 72
450
LOA 6226-C3 2300 46
11.3. NOISE LEVEL * For the other frames refer to Weg.
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GENERATORS SYNCHRONOUS
On single bearing generators, bearings are Conduction of current should occur only from
replaced by removing the vent and ND endshield anode to cathode, that is, on the direct
providing free access to the bearing. Using a 3 polarization condition.
grip extractor, bearing can be easily removed.
For safety reasons, replacement of bearings
should be made with the generator uncoupled
from the drive machine.
Generators fitted with double bearings need to be
uncoupled completed for replacement of bearings.
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Rectifier base Torquemeter Mounting Drain the condensed water and clean the inside
thread (mm) (mm) torque (Nm) of the terminal boxes;
Measure the insulation resistance or polarization
M6 11 2
index as per tables given in item Insulation
M8 17 4 Resistance.
M12 24 10
M16 32 30
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1
Lubricate the bearings
2
Change the bearings
1- Verify the lubrication interval and quantity of grease in the item Lubrication of this manual.
2- The change of the bearings must be effected to each 20000 hours or when present defect.
NOTE: The verifications and tasks described in the table above must be executed in agreement with the
item Maintenanance of this manual.
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Below are listed the main generator components. To order any of these components, or any other not
included herewith, please contact Service Department of WEG Mquinas or one of our
representatives/distributors.
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13. TROUBLEHOOTING
We are listing below some abnormal situations that can occur during generator operation along with
identifying probable cause(s) as well as some suggested corrective measures.
- External voltage adjusting potentiometer broken - Check connections of terminals 11-12 as well as
or connection interrupted. the potentiometer.
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GENERATORS SYNCHRONOUS
- Feeding voltage of the regulator is not in - Remake the connections. Check the Voltage
accordance with the outlet voltage required. Regulator Manual.
IMPORTANT
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These products, when operated under the conditions stipulated by WEG in the operating manual for such
product, are warranted against defects in workmanship and materials for twelve (12) months from start-up
date or eighteen (18) months from manufacturer shipment date, whichever occurs first.
However, this warranty does not apply to any product which has been subject to misuse, misapplication,
neglect (including without limitation, inadequate maintenance, accident, improper installation, modification,
adjustment, repair or any other cases originated from inadequate applications).
The company will neither be responsible for any expenses incurred in installation, removal from service,
consequential expenses such as financial losses nor transportation costs as well as tickets and
accommodation expenses of a technician when this is requested by the customer.
The repair and/or replacement of parts or components, when effected by WEG within the Warranty period
do not give Warranty extension, unless otherwise expressed in writing by Weg.
This constitutes WEG' s only warranty in connection with this sale and is in lieu of all other warranties,
expressed or implied, written or oral.
There are no implied warranties of merchantability or fitness for a particular purpose that apply to this sale.
No employee, agent, dealer, repair shop or other person is authorized to give any warranties on behalf of
WEG nor to assume for WEG any other liability in connection with any of its products.
In case this happens without Weg' s authorization, Warranty is automatically cancelled.
LIABILITY
Except as specified in the foregoing paragraph entitled "Warranty Terms for Engineering Products", the
company shall have no obligation or liability whatsoever to the purchaser, including, without limitation, any
claims for consequential damages or labor costs, by reason of any breach of the express warranty described
therein.
The purchaser further hereby agrees to indemnify and hold the company harmless from any causes of action
(other than cost of replacing or repairing the defective product as specified in the foregoing paragraph
entitled "Warranty Terms for Engineering Products", arising directly or indirectly from the acts, omissions or
negligence of the purchaser in connection with or arising out of the testing, use, operation, replacement or
repair of any product described in this quotation and sold or furnished by the company to the purchaser.
1013.02/0295
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