User’s Manual AMG series

Synchronous generator
Generator type: AMG 0500SF04 DAA
Serial number: 8807086-8807089
ABB ref. 1225CA101-104
Project: SPP35B PSV

ABB
 Rev C. Dec 2011

CONTENTS

Chapter 1 Introduction .............................................................................. 1

1.1 General information........................................................................................ 1
1.2 Site conditions ................................................................................................ 1
1.3 Important note ................................................................................................ 1
1.4 Limitation of liability ....................................................................................... 2
1.5 General Safety ................................................................................................ 2
1.5.1 Symbols and decals .................................................................................. 3
1.5.2 Electrical hazard ........................................................................................ 3
1.5.3 Moving parts .............................................................................................. 3
1.5.4 High temperatures ..................................................................................... 3
1.5.5 Electro-Static Devices (ESD) ..................................................................... 3
1.5.6 Magnetic fields........................................................................................... 4
1.5.7 Noise ......................................................................................................... 4
1.6 Safety Instructions ......................................................................................... 4
1.6.1 General...................................................................................................... 4
1.6.2 Intended use .............................................................................................. 4
1.6.3 Transport, storage ..................................................................................... 4
1.6.4 Installation ................................................................................................. 4
1.6.5 Electrical connection.................................................................................. 5
1.6.6 Operation ................................................................................................... 5
1.6.7 Maintenance and servicing ........................................................................ 6
1.7 Disposal and recycling instructions ............................................................. 6
1.7.1 Recycling of material required for transport ............................................... 6
1.7.2 Recycling of the complete machine ........................................................... 6

Chapter 2 Transport and storage ............................................................. 8

2.1 Transport and unpacking ............................................................................... 8
2.1.1 Protective measures prior to transport....................................................... 8
2.1.2 Lifting the machine .................................................................................... 8
2.1.3 Lifting of unpacked machine ...................................................................... 8
2.1.4 Checks upon arrival and unpacking........................................................... 9
2.2 Storage ............................................................................................................ 9
2.2.1 Short term storage (less than 2 months) ................................................... 9
2.2.2 Long term storage (2-6 months) .............................................................. 10
2.2.3 Very long term storage (over 6 months) .................................................. 11
2.2.4 Regular checks during storage ................................................................ 11
2.2.5 Storage and care after installation ........................................................... 12

Chapter 3 Installation and alignment ..................................................... 13

3.1 Preparations for installation ........................................................................ 13
 3.1.1 General.................................................................................................... 13
3.1.2 Removal from storage ............................................................................. 14
3.1.3 Check of foundation................................................................................. 14
3.2 Installation and alignment ........................................................................... 15
3.3 Alignment and coupling with the Engine ................................................... 15
3.3.1 Machines fixed to diesel .......................................................................... 16
3.3.2 One bearing machines ............................................................................ 16
Figure 3-2 Placement of the spirit level ................................................................. 17
Figure 3-3 Supporting the rotor in one bearing machines................................... 17
3.3.3 Two bearing machines ............................................................................ 20
3.3.4 Correction for thermal expansion............................................................. 23
3.4 Final inspection of installation .................................................................... 23
3.4.1 Covers and enclosures ............................................................................ 23

Chapter 4 Mechanical and electrical connections ............................... 24

4.1 General .......................................................................................................... 24
4.2 Mechanical connections .............................................................................. 24
4.2.1 Connection of water pipes ....................................................................... 24
4.3 Electrical connections.................................................................................. 24
4.3.1 General information ................................................................................. 24
4.3.2 Connection of main power cables and neutral cable ............................... 25
4.3.3 Earth connection...................................................................................... 25
4.3.4 Insulation distances of main power connections ..................................... 26
4.3.5 Connection of auxiliaries and instruments ............................................... 26
4.3.6 Automatic Voltage Regulator (AVR) ........................................................ 27
4.3.7 Installation of Automatic Voltage Regulator (AVR) .................................. 27

Chapter 5 Commissioning ...................................................................... 29

5.1 General .......................................................................................................... 29
5.2 Check of mechanical installation ................................................................ 29
5.3 Check of electrical installation .................................................................... 29
5.4 Insulation resistance measurements .......................................................... 30
5.5 Automatic Voltage Regulator (AVR)............................................................ 30
5.6 Starting .......................................................................................................... 31
5.7 Shut down ..................................................................................................... 31
5.8 Greasing of rolling bearings ........................................................................ 31

Chapter 6 Operation ................................................................................ 33

6.1 General .......................................................................................................... 33
6.2 Normal operating conditions ....................................................................... 33
6.3 Protection of synchronous generators....................................................... 33
6.4 Start-up procedure ....................................................................................... 34
6.4.1 Start interlocking ...................................................................................... 34
6.5 Continuous supervision............................................................................... 34
 6.6 Shut down procedures ................................................................................. 35

Chapter 7 Maintenance ........................................................................... 37

7.1 Preventive maintenance............................................................................... 37
7.2 Safety precautions........................................................................................ 37
7.3 Maintenance program .................................................................................. 38
7.3.1 Recommended maintenance program .................................................... 40
7.4 Maintenance of general construction ......................................................... 43
7.4.1 The tightness of fastenings ...................................................................... 43
7.4.2 Vibration and noise .................................................................................. 44
7.4.3 Rotor construction control ........................................................................ 45
7.4.4 Checks during running of the machine .................................................... 45
7.5 Maintenance of bearings.............................................................................. 48
7.5.1 Rolling bearings ....................................................................................... 48
7.5.2 Sleeve Bearings ...................................................................................... 51
7.5.3 Sleeve bearings ....................................................................................... 53
7.5.4 Oil leakage of sleeve bearings ................................................................ 53
7.5.5 Bearing insulation resistance check ........................................................ 58
7.5.6 Bearing clearance measurements ........................................................... 58
7.6 Maintenance of stator and rotor winding ................................................... 59
7.6.1 Particular safety instructions for winding maintenance ............................ 59
7.6.2 Timing of the maintenance ...................................................................... 60
7.6.3 The correct operating temperature .......................................................... 60
7.6.4 Insulation resistance test ......................................................................... 60
7.6.5 Polarization index .................................................................................... 64
7.6.6 High voltage test ...................................................................................... 65
7.6.7 Visual winding inspection ........................................................................ 65
7.6.8 Drying ...................................................................................................... 66
7.6.9 Varnishing of the windings ....................................................................... 67
7.6.10 Other maintenance operations ................................................................ 67
7.7 Maintenance related to electrical performance, excitation, control and
protection ................................................................................................................. 67
7.7.1 Exciter insulation resistance measurement ............................................. 67
7.7.2 Protection trips......................................................................................... 68
7.7.3 Automatic voltage regulator (AVR) .......................................................... 68
7.7.4 Pt-100 resistance temperature detectors ................................................. 68
7.7.5 Insulation resistance measurement for auxiliaries ................................... 68
7.7.6 Diode fault ............................................................................................... 69
7.8 Maintenance related to thermal performance and cooling system .......... 69
7.8.1 Maintenance instructions for air-to-water heat exchanger ....................... 69
7.8.2 Disassembly and remounting of cooling system ...................................... 71

Chapter 8 Troubleshooting..................................................................... 74
8.1 Mechanical performance.............................................................................. 75
8.2 Sleeve bearings and lubrication system .................................................... 76
 8.3 Rolling bearings and lubrication ................................................................. 77
8.4 Thermal performance, water cooling system ............................................. 78
8.5 Thermal performance, direct cooling.......................................................... 79
8.6 Electrical performance and excitation system of generators ................... 80

Chapter 9 After sales and spare parts ................................................... 81

9.1 After sales ..................................................................................................... 81
9.1.1 Site services ............................................................................................ 81
9.1.2 Spare parts .............................................................................................. 81
9.1.3 Warranties ............................................................................................... 81
9.1.4 Support for service centers ...................................................................... 81
9.1.5 After sales contact information ................................................................ 81
9.2 Spare parts .................................................................................................... 81
9.2.1 General spare part considerations........................................................... 81
9.2.2 Periodic part replacement ........................................................................ 82
9.2.3 Need of spare parts ................................................................................. 82
9.2.4 Selection of the most suitable spare part package .................................. 82
9.2.5 Typical recommended spare parts in different sets ................................. 83
9.2.6 Order information..................................................................................... 83

ANNEX 1: TECHNICAL SPECIFICATION

ANNEX 2: MECHANICAL DRAWINGS
ANNEX 3: ELECTRICAL DRAWINGS
ANNEX 4: ACCESSORY INFORMATION
ANNEX 5: COMMISSIONING REPORT
ANNEX 6: CHECK LISTS
ANNEX 7: TEST REPORT
Chapter 1 Introduction

1.1 General information

This User's Manual contains information on the transport, installation, operation and
maintenance of the AMG 0400 - AMG 0630 type of synchronous machine supplied
by ABB.
This manual provides information regarding all aspects of installation, operation,
maintenance and supervision of the machine and shows how to disassemble/assemble
major components, if required. Careful study of the contents of this manual and other
machine related documentation before any actions are taken is necessary to ensure
proper functionality and a long lifetime of the machine.
Actions shown in this manual are only to be performed by trained personnel with
previous experience in similar tasks, and authorized by the owner of the equipment.
ABB constantly strives to improve the quality of the information provided in this
User’s Manual, and will welcome any improvement suggestions. For contact
information, see Chapter 9.1, After sales.
NOTE: These instructions must be followed to ensure safe and proper installation,
operation and maintenance of the machine. They should be brought to the
attention of anyone who installs, operates or maintains this equipment.
Ignoring the instruction invalidates the warranty
Black text is applicable for all machines. Text with color is applied only to certain
type of machines.
1.2 Site conditions
The machinery is to be used on a site with conditions according to Technical
Specifications and Conditions laid down by ABB in their contract with the user, and
nowhere else.
1.3 Important note
The information in this document may sometimes be of a general nature and
applicable to various machines supplied by ABB.
Where a conflict exists between the contents herein and the actual machinery supplied,
the user must either make an informed engineering judgment as to a course of action
or, if any doubt exists, contact ABB.
The safety precautions shown in this chapter and elsewhere in this User’s Manual
must be observed at all times.
Safety is dependent on the awareness, concern and prudence of all those who operate
and service machines. While it is important that all safety procedures will be observed,
care near machinery is essential.
NOTE: To avoid accidents, safety measures and devices required at the installation
site must be in accordance with the instructions and regulations stipulated

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 for safety at work. This applies to general safety regulations of the country
in question, specific agreements made for each work site and safety
instructions included in this manual and separate safety instructions
delivered with the machine.
The information in this document is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this document.
This document and parts thereof must not be reproduced or copied without the
express written permission of ABB, and the contents thereof must not be imparted to
a third party nor be used for any unauthorized purpose.
1.4 Limitation of liability
In no event shall ABB 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 be liable for incidental or consequential damages arising from use of
any software or hardware described in this document.
The warranty issued covers manufacturing and material defects. The warranty does
not cover any damage caused to the machine, personnel or third party by improper
storage, incorrect installation or operating of the machine. The warranty conditions
are in more detail defined according to Orgalime S2000 terms and conditions.
NOTE: The warranty issued is not valid, if the operation conditions of the machine
are changed or any changes in the construction of the machine, or repair
work to the machine have been made without prior written approval from
the ABB factory, which supplied the machine.
NOTE: Local ABB sales offices or third party resellers may hold different warranty
details, which are specified in the sales terms, conditions or warranty terms.
For contact information, see the back page of this User’s Manual. Please remember to
provide the serial number of the machine when discussing machine specific issues.
1.5 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

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 with oil or other substances can constitute a health hazard due to prolonged
contact with the skin, even through underclothing.
b. As far as it 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.
c. Parts of the synchronous machine and its auxiliary equipment can reach high
temperatures. Protective clothing, particularly gloves must be worn at all times.
d. 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.
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 User’s
Manual.
1.5.1 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.
1.5.2 Electrical hazard
The synchronous machine and auxiliary equipment must be disconnected from the
electrical power supply during installation, maintenance or setting-up. All voltage
parts must also be earthed.
1.5.3 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.
1.5.4 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.
1.5.5 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.

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 1.5.6 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.
1.5.7 Noise
Machine rooms can be extremely noisy and damaging to the ears. Ear protection
should always be worn where practicable.
1.6 Safety Instructions
1.6.1 General
General safety regulations, specific agreements made for each work site and safety
precautions shown in this document must be observed at all times.
1.6.2 Intended use
Electric machines have dangerous live and rotating parts and may have hot surfaces.
All operations serving transport, storage, installation, connection, commissioning,
operation and maintenance shall be carried out by responsible skilled persons (in
conformity with EN 50 110-1 / DIN VDE 0105 / IEC 60364). Improper handling may
cause serious personal injury and damage to property.
These machines are intended for industrial and commercial installations as
components as defined in the Machinery Directive (MD) 98/37/EC. Commissioning is
prohibited until conformity of the end product with this directive has been established
(follow particular local safety and installation rules as, for example, EN 60204).
These machines comply with the harmonized series of standards EN 60034 / DIN
VDE 0530. Their use in explosive atmosphere is prohibited unless they are expressly
designed for such use (follow additional instructions).
1.6.3 Transport, storage
Immediately report damage established after delivery to transport company. Stop
commissioning, if necessary. Lifting eyes are dimensioned for the weight of the
machine, do not apply extra loads. Ensure the use of correct lifting eyes. If necessary,
use suitable, adequately dimensioned means of transport (for example, rope guides).
Remove shipping braces (for example, bearing locks, vibration dampers) before
commissioning. Store them for further use.
When storing the machine, make sure that the location is dry, dust and vibration free
(danger of bearing damage at rest). Measure the insulation resistance before
commissioning. At values of ≤ 1 kΩ per volt of rated voltage, dry winding. Follow
the manufacturer's instructions.
1.6.4 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 and listen for abnormal slip noises.
Check direction of rotation in uncoupled state.

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 Make necessary ventilation and cooling system connections. The ventilation must not
be obstructed and the exhaust air, also of neighboring sets, should not be taken in
directly.
1.6.5 Electrical connection
All operations must be carried out only by skilled persons on the machine at rest.
Before starting work, the following 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 neighboring live parts
 De-energize auxiliary circuits (e.g. anti-condensation heating)
Exceeding of limit values of zone A in EN 60034-1 / DIN VDE 0530-1 - voltage ±
5%, frequency ± 2%, waveform and symmetry - leads to higher temperature rise and
affects the electromagnetic compatibility. Note rating plate markings and connection
diagram in the terminal box.
The connection must be made in a way that the permanent safe electrical connection
is maintained. Use appropriate cable terminals. Establish and maintain safe equipotent
bonding.
The clearances between un-insulated live parts and between such parts and earth must
not be below the values of appropriate standards and values possibly given in
manufacturer's documentation.
No presence of foreign bodies, 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
machines with accessories, check satisfactory functioning of these before
commissioning.
The proper installation (for example, segregation of signal and power lines, screened
cables etc.) lies within the installer's responsibility.
1.6.6 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.
If the machine is grease lubricated, grease the bearings during commissioning before
start-up (in case of re-greasable bearings). Re-grease antifriction bearings while the
machine is running. Follow instructions on lubrication plate. Use right kind of grease.
If the machine is oil lubricated, fill the bearing with oil acc to. Bearing plate.
Refer to manufacturer's documentation for noise level and information about the use
of appropriate noise-reducing measures.

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 1.6.7 Maintenance and servicing
Follow the manufacturer's operating instructions. For further details, see Chapter 7,
Maintenance in the User’s Manual. Preserve these safety instructions!
1.7 Disposal and recycling instructions
ABB 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 only guide lines and it is the customer’s responsibility to ensure
that the local legislation is followed.
The material content (average percentage of the mass) which have been used in the
manufacturing the electrical machine is the following:
Steel 85 %
Copper 10 %
Aluminium 2%
Insulation materials 2%
Other 1%

1.7.1 Recycling of material required for transport

After unpacking of the machine, the package has to be removed. The package is made
of wood and can be burned. The plastic material around the machine can be recycled.
After installation of the machine transportation locking have to be removed.
The transportation locking is made of steel and can be recycled. Transportation
locking can also be stored for possible reuse.
The sea trial package to some countries like Australia has special requirements, and is
made of e.g. impregnated wood that must be recycled according to local instructions.
The rust protection material covering the machined surfaces can be removed with
petrol based solvent detergents and the cleaning rags are hazardous waste which has
to be handled according to the local instructions.
1.7.2 Recycling of the complete machine

1.7.2.1 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.

1.7.2.2 Frame, bearing housing, covers and fan

These parts are made of structural steel or cast iron, 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.
Components with electrical insulation

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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 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:
Heat treatment
Temperature: 380…420° C (716…788 F)
Duration: After receiving 90 % of the target temperature the object shall stay a
minimum of five hours at this temperature
After burning of the binder fumes
Temperature: 850…920° C (1562…1688 F)
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 user’s 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 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

1.7.2.3 Hazardous waste

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

1.7.2.4 Landfill waste

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

Page 7
Chapter 2 Transport and storage

2.1 Transport and unpacking

2.1.1 Protective measures prior to transport
The following protective measures are taken before delivery of the machine from the
factory. The same protective measures should be taken, whenever the machine is
moved:
 All synchronous machines delivered as a unit are provided with transport locking
device protecting the machine against damages during transport. The locking
device must be attached whenever the machine is transported.
 Machined metal surfaces, such as the shaft extension, are coated with an anti-
corrosive coating before delivery.
 The cooler is drained.
During shipping the machine should be placed under deck.
2.1.2 Lifting the machine
Before the machine is lifted, ensure that suitable lifting equipment is available and
that personnel are familiar with lifting work. The weight of the machine is shown on
the rating plate, dimension drawing and packing list.
NOTE: Use only the lifting lugs or eyes intended for lifting the complete machine.
Do not use any small additional lifting lugs or eyes available, as they are
there only for service purposes.
NOTE: The center of gravity of machines with the same frame may vary due to
different outputs, mounting arrangements and auxiliary equipment.
NOTE: Check that eyebolts or the lifting lugs integrated with the machine frame are
undamaged before lifting. Damaged lifting lugs must not be used.
NOTE: Lifting eyebolts must be tightened before lifting. If needed, the position of
the eyebolt must be adjusted with suitable washers.
2.1.3 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.
For more details, see the drawing “Transport and Hoist” in Annex 2, Mechanical
Drawings.
NOTE: The machine must be lifted from its frame. Do not attempt to lift the
machine from the top cover!

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 2.1.4 Checks upon arrival and unpacking

2.1.4.1 Check upon arrival

Inspect the machine and the package immediately upon arrival. Any transport damage
must be photographed and reported immediately, i.e. within less than one (1) week
after arrival, if the 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. Use checklists in Annex 5, Commissioning Report.
A machine that is not installed immediately upon arrival must not be left without
supervision or without protective precautions. For more details, see Chapter 2.2,
Storage.

2.1.4.2 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 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.
Recycle packing material acc. to Chapter 1.7.1 Recycling of material required for
transport.
2.2 Storage
2.2.1 Short term storage (less than 2 months)
The machine should be stored in a proper warehouse with a controllable environment.
A good warehouse or storage place has:
 A stable temperature, preferably in the range from 10ºC (50ºF) to 50ºC (120ºF).
If the anti-condensation heaters are energized, and the surrounding air is above 50
ºC (120ºF), make sure that the machine is not overheated.
 Low relative air humidity, preferably below 75 %. The temperature of the
machine should be kept above dew point to prevent moisture from condensing
inside the machine. If the machine is equipped with anti-condensation heaters,
they should be energized. Verify the operation of the anti-condensation heaters
periodically. The anti-condensation heaters shall be de-energised when air
temperature inside the machine enclosure exceeds +40 ºC. Before connecting
power supply to the anti-condensation heater, check the supply voltage and power
in the technical specification or electrical drawings. If the machine is not
equipped with anti-condensation heaters, an alternative method of heating the
machine and preventing moisture from condensing in the machine must be used.
Machine can be e.g. heated by using power supply in the machine main terminals.
Required DC voltage is approx. 5% of the rated voltage and current shall not
exceed 30% of the nominal current.
 A stable support free from excessive vibrations and shocks. If vibrations are
suspected to be too high, the machine should be isolated by placing suitable
rubber blocks under the machine feet.
 Air which is ventilated, clean and free from dust and corrosive gases.

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  Protection against harmful insects and vermin.
If the machine needs to be stored outdoors, the machine must never be left ‘as is’ in
its transportation package. To store the machine outdoors:
 Take the machine out from its plastic wrap.
 Cover the machine to prevent rain from entering it. The cover should allow
ventilation of the machine.
 Place the machine on at least 100 mm (4”) high rigid supports. This prevents
moisture from entering the machine from below.
 Provide with good ventilation. If the machine is left in its transportation package,
make large enough ventilation holes in the package.
 Use anti-condensation heaters or alternative method of heating for heating the
machine and preventing moisture from condensing in the machine
 Protect from harmful insects and vermin.
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), some extra measures need taken.
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 ND-end of the
machine are accessible.
 If the protection made by the manufacturer has been removed, protect the
unpainted surfaces such as shaft extensions, coupling discs, coupling halves and
jacking screws with suitable anti-corrosion agent.
 If the machine has been delivered in fully assembled condition, turn the rotor
approximately 10 revolutions once per every 3 months to maintain a protective oil
film or grease on the bearing surfaces.
 Machines with rolling bearings: Rolling bearings should be well lubricated during
storage. Check the correct grease type in the bearing plate of the machine.
 Machines with sleeve bearings: Fill self-lubricated bearings with protective oil, or
connect flood lubricated bearings to the lubrication system. If this cannot be done,
the bearing shells should be taken out, see Storage outdoors.

Storage outdoors
To store the machine outdoors:
 Take all the measures described in Storage indoors.
 Cover the machine completely with a big enough waterproof cover.

*** Following steps are applicable only with machines with sleeve bearings
 Remove the side and end covers of the machine.

Page 10
  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 (approximately 0.5 mm) until the bearing shells do not carry the
weight of the rotor.
 Turn the lower bearing shells 180 º 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.

2.2.3 Very long term storage (over 6 months)

Clean all the protected surfaces listed in Chapter 2.1, Short term storage (less than 2
months) and Chapter 2.2, Long term storage (2-6 months), and renew the anti-
corrosive treatment every 12 months. Otherwise follow the instructions for shorter
storage periods.
2.2.4 Regular checks during storage
The following checks should be made regularly during storage.
Every month:
 Check that the anti-condensation heaters or alternative method of heating the
machine is working.
 Check that the ventilation works.
Every 3 months:
 Check the insulation resistance, see Chapter 7.6.4 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.
 Turn the rotor as decribed in Chapter 2.2.2 Long Term Storage

*** Following step is applicable only with machines with sleeve bearings
Every 6 months:
 Dismount the bearing housing upper cover and check the shaft and the bearing
housing anti-corrosion protection.

Page 11
2.2.5 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 in Chapter 2.1, Short term storage (less than 2 months) should
be applied. Remember to rotate the shaft 10 revolutions at least every 3 months. Self-
lubricated sleeve bearings must be filled with oil.

Page 12
Chapter 3 Installation and alignment

3.1 Preparations for installation

3.1.1 General
Good planning and preparation results in correct installation, assures safe running
conditions and maximum accessibility.
During installation, general as well as local safety instructions must be followed.
NOTE: Install anti-condensation heaters to keep the machine interior dry when there
is a risk of condensation.
NOTE: Protect the machine against dust and rain.
Tools and materials
Suitable material for set-up and shimming as well as other auxiliary tools for
installation are normally not included in the ABB delivery. Auxiliary tools for
installation are to be supplied by the customer.
The following should be available on site if required:
 attachments for gauges, extension brackets and other alignment tools
 a lever for turning the rotor
 other auxiliary tools and materials for the installation, like hydraulic jacks and
bracket plates with adjusting screws
 for suitable grease / oil qualities, see Chapter 7.5.

*** Following paragraph is applicable only with machines with sleeve bearings
Pouring oil into the bearings
Oil must be poured into the bearing continuously while turning the rotor see Figure 3-
1, Pouring oil into the bearings.

Page 13
 Figure 3-1 Pouring oil into the bearings

General tightening torques

General tightening torques for screws is given in Chapter 7.4.1, The tightness of
fastenings. Use these values if no specific tightening torques are given in this manual
or in the mechanical and electrical drawings.
NOTE: The values in Table 7-2, General tightening torques are general, and do not
apply to various items, such as diodes, support insulators, bearings, cable
terminals or pole fastenings, surge arrester, capacitors, current transformers,
rectifier and thyristor bridges, or if some other value is given elsewhere in
this manual or in the mechanical and electrical drawings, see Annex 2,
Mechanical Drawings and Annex 3, Electrical Drawings.
3.1.2 Removal from storage
When bringing machine from the outside, at a temperature of below 0 °C, do not do
any work on the machine until its temperature has risen sufficiently (5 to 10°C).
The transfer from a cold temperature to ambient temperature can cause condensation
inside machines and may be dangerous for the winding. It is therefore important to
check the winding insulation resistance before the start up (See Chapter 5,
Commissioning).
3.1.3 Check of foundation
The structural design of the foundation is not included in the ABB 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 machine onto the foundation:
 Check that the position of the fixing holes and the height of the foundation are in
agreement with corresponding measurements on outline and foundation drawings
in Annex 2, Mechanical Drawings.

Page 14
  Check that the foundation is flat. If any inclination has been agreed upon, the
permissible inclination must be stated on the installation drawing.
 Sweep or vacuum-clean the foundation.
3.2 Installation and alignment
The machine is normally transported and lifted as one ready assembled unit onto the
foundation; see Annex 2, Mechanical Drawings.
NOTE: The customer is responsible for machine installation (unless mentioned
otherwise in the contract). ABB cannot be hold responsible for damage
which may occur to the machine or to surrounding equipment subsequent to:
 excessive transmitted vibrations
 poor design of foundations and/or structures
 poor installation
 an alignment fault
 poor storage conditions
 non-respect of check instructions before start up
 an incorrect electrical connection
In order to ensure a long and satisfactory lifetime of both the driving and driven
machine, the machines have to be properly aligned to each other. This means that the
radial, as well as the angular deviation between the two shafts of the machine has to
be minimized. The alignment must be performed with great caution because
alignment errors might lead to bearing and shaft damages.
To install and align the machine:
1. Mount the coupling halves, if applicable.
2. Mount the machine on the foundation.
3. Level and align the machine roughly in axial and horizontal directions.
4. Align and couple the rotor with the driven machine.
5. Fasten the machine initially to the foundation.
6. Check air gaps and adjust as necessary.
7. Re-check the alignment. Fine adjust if necessary.
8. Tighten and lock bolts and install dowel pins.
9. Install accessories.
More detailed instructions for installation are given in the following chapters or in
instructions supplied by driven/driving machine manufacturer.
NOTE: Alignment must be performed with great caution. Failure to do so can
result in serious vibrations and damage to both generator and prime
mover.
3.3 Alignment and coupling with the Engine
In order to ensure a long and satisfactory lifetime of both the driving and driven
machine, the machines have to be properly aligned to each other. This means that the

Page 15
 radial, as well as the angular deviation between the two shafts of the machine has to
be minimized. The alignment must be performed with great caution because
alignment errors will lead to bearing and shaft damages.

*** Following steps are applicable only with machines in which engine frame and
generator frame is connected.
3.3.1 Machines fixed to diesel
The generator is designed to fit to diesel and bed plate without any shim plates. The
coupling with the engine has following steps.
 Before alignment remove the transport locking device according to the
instructions in the Transport Locking drawing. The transport locking device is
normally painted red.
 Remove the anti-corrosive coating from metal surfaces that have to be
uncoated during normal operation.
 Assemble the coupling half onto the rotor shaft (in two bearing machines)
 Lift the generator to its position on the bed plate.
 Adjust the generator position according to bell housing
 Couple the flywheel and generator rotor
 Fix the bell housing between prime mover and generator
 Fix the generator to bed frame

*** Following steps are applicable only with one bearing machines in which only
rotor is connected
3.3.2 One bearing machines

3.3.2.1 Rough leveling

To rough level the machine:
1. Check that the distance ET is the same as the value stamped on the D-end of the
generator. See ET dimension from drawing Removing of transport locking and shaft
alignment.
2. Remove the anti-corrosive coating from metal surfaces that have to be uncoated
during normal operation.
3. Lift the machine up and move it onto the bed plate.
4. Align the machine visually and put pieces of sheet metal below the jacking screws
to protect the bed plate surface.
5. Turn the jacking screws until they carry the weight of machine.
Check that the machine is axially leveled by placing a spirit level on the horizontal
surfaces of the rotor shaft as shown in Figure 3-2, Placement of the spirit level. Make

Page 16
adjustments by placing shims under the feet. The machine must be supported by all
feet.

Figure 3-2 Placement of the spirit level

In one bearing machines the rotor is supported at the drive end by a Y-shaped bracket,
see Figure 3-3. The rotor has been aligned at the factory with the leveling screws of
the bracket to the correct radial position. Let the rotor rest on the support and do not
loosen the leveling screws until the shaft flange is coupled with the driven equipment.
As slight misalignment of the air gap may happen during transport, the air gap has to
be checked when performing the final alignment of the machine. See Chapter 3.3.2.3,
Air gap alignment.

Figure 3-3 Supporting the rotor in one bearing machines

3.3.2.2 Rough axial alignment

The rotor is placed in the magnetic center position when the dimension ET is
completed. The dimension has been punched on the D-end of the machine.

3.3.2.3 Air gap alignment

The air gap is aligned when the dimension IV is completed. The dimension has been
punched on the D-end of the machine. See IV dimension from drawing Removing of
transport locking and shaft alignment.

Page 17
 3.3.2.4 Alignment
After the machine has been roughly positioned, as described in Chapter and 3.3.2.2,
Rough axial alignment, the final alignment can start.
NOTE:
Alignment 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, see for example
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 3-4, Definition of misalignment . The corresponding run-out is 0.10 - 0.20 mm
for parallel and angular misalignment, and 0.20 for axial misalignment.

Figure 3-4 Definition of misalignment

Parallel misalignment Δr
Angular misalignment Δb
Axial misalignment Δa
Definite alignment tolerances are impossible to state as many factors influence the
tolerances. Too large tolerances will cause vibration and may possibly lead to bearing
or other damages. Therefore, it is recommended to aim at as narrow tolerances as
possible. Maximum permissible misalignments are shown above. For definitions of
misalignment, see Figure 3-4, Definition of misalignment .
NOTE:
The tolerances given by the coupling manufacturers indicate tolerances
for the coupling, not for the driving-driven machine alignment. The
tolerances given by the coupling manufacturer should be used as a
guideline for the alignment only if they are narrower than the maximum
permissible misalignments shown above.

3.3.2.5 Final alignment

To align the machine:
1. Make sure that the machine stands on its jacking screws.

Page 18
 2. Mount the alignment equipment. If gauges are used, it is practical to
adjust the dial gauge in such a 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 3-5, Alignment check
with gauges.

Figure 3-5 Alignment check with gauges

3. 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. Record the readings in the Commissioning Report.
4. Align the machine vertically by turning the jacking screws or 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 3-6, Vertical positioning of machine foot.
The alignment accuracy of the machine is sometimes affected by the thermal
expansion of its frame. See Chapter 3.3.4, Correction for thermal expansion.

Figure 3-6 Vertical positioning of machine foot

5. Measure the distance between the bottom of the machine feet and the bed plate and
make corresponding solid blocks or wedges or reserve a necessary number of shims.
6. Fit the solid blocks or shims under the stator feet. Slacken the jacking screws and
tighten the fixing bolts.
8. Check the alignment again. Make corrections if necessary.

Page 19
 9. Check the IV and ET dimensions.
10. Re-tighten the nuts and lock them by tack welds or hitting sufficiently hard with a
center punch.

*** Following steps are applicable only with two bearing machines in which only
rotor is connected
3.3.3 Two bearing machines

3.3.3.1 Rough leveling

To rough level the machine:
1. Remove the anti-corrosive coating from metal surfaces that have to be uncoated
during normal operation.
2. Check the coupling instructions and fit. Preheat the coupling hub as necessary and
mount it on the machine shaft.
3. Lift the machine up and move it onto the bed plate.
4. Align the machine visually and put pieces of sheet metal below the jacking screws
to protect the bed plate surface.
5. Turn the jacking screws until they carry the weight of machine.
Check that the machine is axially leveled by placing a spirit level on the horizontal
surfaces of the rotor shaft as shown in Figure 3-2, Placement of the spirit level. Make
adjustments by placing shims under the feet. The machine must be supported by all
feet.

3.3.3.2 Alignment
After the machine has been roughly positioned, as described in Chapter and 3.3.3.1,
Rough axial alignment, the final alignment can start.
NOTE:
Alignment 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, see for example
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 3-4, Definition of misalignment . The corresponding run-out is 0.10 - 0.20 mm
for parallel and angular misalignment, and 0.20 for axial misalignment.

Page 20
Figure 3-4 Definition of misalignment
Parallel misalignment Δr
Angular misalignment Δb
Axial misalignment Δa
Definite alignment tolerances are impossible to state as many factors influence the
tolerances. Too large tolerances will cause vibration and may possibly lead to bearing
or other damages. Therefore, it is recommended to aim at as narrow tolerances as
possible. Maximum permissible misalignments are shown above. For definitions of
misalignment, see Figure 3-4, Definition of misalignment .
NOTE:
The tolerances given by the coupling manufacturers indicate tolerances
for the coupling, not for the driving-driven machine alignment. The
tolerances given by the coupling manufacturer should be used as a
guideline for the alignment only if they are narrower than the maximum
permissible misalignments shown above.

3.3.3.3 Final alignment

To align the machine:
1. Make sure that the machine stands on its jacking screws.
2. Mount the alignment equipment. If gauges are used, it is practical to
adjust the dial gauge in such a 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 3-5, Alignment check
with gauges.

Page 21
 Figure 3-5 Alignment check with gauges
3. 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. Record the readings in the Commissioning Report.
4. Align the machine vertically by turning the jacking screws or 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 3-6, Vertical positioning of machine foot.
The alignment accuracy of the machine is sometimes affected by the thermal
expansion of its frame. See Chapter 3.3.4, Correction for thermal expansion.

Figure 3-6 Vertical positioning of machine foot

5. Measure the distance between the bottom of the machine feet and the bed plate and
make corresponding solid blocks or wedges or reserve a necessary number of shims.
6. Fit the solid blocks or shims under the stator feet. Slacken the jacking screws and
tighten the fixing bolts.
8. Check the alignment again. Make corrections if necessary.
9. Re-tighten the nuts and lock them by tack welds or hitting sufficiently hard with a
center punch.

Page 22
 3.3.4 Correction for thermal expansion
Thermal expansion should be taken into account when aligning the machine. 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 when the
machine is in operation. 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 estimated
using the following formula:
ΔH = a × ΔT × H [mm]
where a = 10 × 10-6 K-1
ΔT = 40 K
H = shaft height [mm]
Due to the thermal expansion of the electrical machine, the vertical movement of the
shaft is approximately 0.1 mm for each 10 °C difference in temperatures as illustrated
in Figure 3-7, The correlation between thermal expansion and machine temperature.

Figure 3-7 The Correlation between thermal expansion and machine temperature
3.4 Final inspection of installation
3.4.1 Covers and enclosures
After the machine has been erected and aligned, check carefully that no tools or
foreign objects have been left inside the enclosures. Clean also any dust or debris.
When installing the covers, check that all sealing strips are intact before mounting
them.
Store alignment and assembly accessories together with the transport locking devices
for future use.

Page 23
Chapter 4 Mechanical and electrical connections

4.1 General
Mechanical and electrical connections are made after the installation and alignment
procedures. The mechanical connections include the connection of air ducts, water
tubes and/or oil supply system where applicable.
The electrical connections include the connection of main and auxiliary cables,
earthing cables and possible external blower motors.
In order to determine proper actions, see Annex 2, Mechanical Drawings and Annex 3,
Electrical Drawings.
NOTE:
When making holes or threads through the terminal box, check always
that no components will be damaged. Metal particles can be hazardous
for the electrical components. Additional installation holes or threads
should never be drilled through the frame.
4.2 Mechanical connections
*** Following chapter is applicable only with machines with water cooling
4.2.1 Connection of water pipes
The cooling water pipes should be laid so that they do not impede service and
maintenance. Install the piping so that only a short part needs to be dismantled to
clean the coolers. The cooler flanges have to be protected against impacts, external
stress and strain. (Caution! These factors may damage the cooler.)
The cooling water pipes should be insulated, and there should be a shut-off valve in
the supply pipe. The pipes to and from the coolers must be cleaned before they are
assembled.
For more detailed information regarding the coolers, refer to Chapter 7.8.1,
Maintenance instructions for air-to-water heat exchanger.
4.3 Electrical connections
4.3.1 General information
The safety information in Chapter 1.5 General Safety and Chapter 1.6 Safety
Instructions must be observed at all times. Study the connection diagrams delivered
with the machine before starting the installation, see Annex 3, Electrical Drawings.
Before you start the installation:
 Verify that the supply voltage and the frequency are the same as the values
indicated on the rating plate of the machine and in Annex 1, Technical
Specification.

Page 24
  Make sure that the sizes of input cables are adequate for the maximum load
current and in accordance with local standards.
 Make sure that cable terminations are of appropriate type and of correct size.
 Check the connections of all devices, such as temperature probes.
NOTE: Prior to installation it is important to check that the incoming cables are not
connected to the supply network. The cables should be grounded.
4.3.2 Connection of main power cables and neutral cable
The main terminal box is typically supplied undrilled as the size and number of the
customer’s cables is unknown. The customer or a third party is therefore responsible
for this.
The stator terminals are marked with the letters U, V and W according to IEC 60034-
8. Stripping, splicing and insulating of the cables must be performed in accordance
with the instructions delivered 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.
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 CCW

U V W U V W

L1 L2 L3 L1 L2 L3
Figure 4-1 Phase sequence (IEC)

(CW = clockwise, CCW = counter clockwise; facing generator drive end, acc. to IEC)
The neutral terminal is marked with the letters N.
4.3.3 Earth connection
The connection point for earthing can be found in a machine frame, see Figure 4-2,
Connection point for earthing cable. There are points for earthing of auxiliary cables
in terminal boxes. The machine earthing is designed so that the machine is safe when
the earthing is done properly.

Page 25
 NOTE:
Do not remove or modify the internal earthings of the machine.
Modificationsmay cause sparking or electric charges that can be
dangerous.

Figure 4-2, Connection point for earthing cable

4.3.4 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 are used.
These distances apply both for insulation distances between two different phases, and
for insulation distances between one phase and the earth. 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).

Main Voltage (V) U  690 V U  1000 V

Air insulation distance [mm] 6 9
Surface insulation distance [mm]
10 14
Even surface
Surface insulation distance [mm]
8 12
Finned surface
Table 4-1 Recommended minimum insulation distances
4.3.5 Connection of auxiliaries and instruments
Connect the instruments and auxiliary equipment according to the connection diagram
in Annex 3, Electrical Drawings.

Page 26
4.3.6 Automatic Voltage Regulator (AVR)

4.3.6.1 General
AVR (Automatic Voltage Regulator) is a device that continuously monitors the
voltage at the voltage regulating point of the system and automatically initiates
corrective actions to maintain the terminal voltage of the generator. AVR also
controls that the synchronous generator operates within pre-set limits.
An auxiliary winding supplies the excitation power to the field winding of the shaft
driven by a three phase exciter under the control of the AVR. A voltage feedback is
supplied by the voltage transformer and a current feedback is provided by the current
transformer. The transformers are installed in the generator.
Operational limits, such as 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 available. The AVR is
equipped with the PC software for the AVR.
More detailed information about the AVR used in the specific generator can be found
in the
following sections:
• AVR manual, see ANNEX 4, Accessory Information
• system description, see ANNEX 1, Technical Specification
• layout and dimensions, see ANNEX 2, Mechanical Drawings and ANNEX 3,
Electrical Drawings.

4.3.6.2 Configuration
The voltage regulator with actual value reading and setpoint formation is active in the
automatic mode. The limiter functions which protect the machine against excessive
loads are also active in the automatic mode. In addition to the actual voltage regulator
function, reactive power or power factor regulators are also available. Reactive power
and power factor regulators can be switched on and off.
NOTE: Reactive power and power factor regulators are not available in
island systems.
In the manual mode the actual value is formed from the measurement of the excitation
current and passed with the set-point value to the excitation current regulator. The
output from the regulator is passed to a switch which is used to select the
corresponding mode. This mode is only used for test purposes and as an emergency
regulator in the event of failure of the voltage regulator. The limiter functions are not
active in this mode.
4.3.7 Installation of Automatic Voltage Regulator (AVR)

4.3.7.1 Mechanical installation

If the AVR is delivered as a separate item, the unit should only be installed in indoor
areas which are dry and dust-free and do not contain any gases, acid fumes or similar.

Page 27
4.3.7.2 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 are used for the analog and digital connections.

Page 28
Chapter 5 Commissioning

5.1 General
Commissioning is not 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 trouble
shooting.
NOTE: The commissioning report has to be sent to ABB in order to obtain future
warranty claims.
A recommended commissioning report can be found in Annex 5, Commissioning
Report.
General safety precautions must be followed during commissioning and all work has
to be performed by qualified personnel.
5.2 Check of mechanical installation
Before commissioning:
1. Check that the installation and alignment is made acc. to Chapter 3, Installation
and alignment.
NOTE: The alignment protocol should always be included in the
commissioning report.
2. Check that the machine is properly fixed to the foundation.
3. Check for cracks in the foundation and the general condition of the foundation.
4. Check the tightness of the fixing bolts.
5. Open the machine, and check that the air-gap is free.
6. If possible, turn the rotor by hand and make sure that the rotor turns freely and
that there are no abnormal sounds.
7. Check the assembly of the main terminal box and cooling system.
8. Check the connection of the oil and cooling water pipes. If applicable, check for
leaks when running.
9. Check the pressure and flow for oil and cooling water, if applicable.
10. 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 after the stator insulation resistance has been measured, see Chapter 7.6.4
Insulation resistance test.
Before commissioning, check the connection of power cables:

Page 29
 1. Check that the fixing bolts are tightened with the correct torque.
2. Check that the power cables are suitably routed and do not cause any additional
strain to the terminal bars.
3. Check that the power cables are correctly stress-relieved.
4. Check the connections of the auxiliary equipment.
5. Check the tightness of the cable glands and enclosure sealing.
6. If the cable glands were delivered separately, check that the fixing bolts are
tightened with the correct torque.
5.4 Insulation resistance measurements
Measure the insulation resistances of windings and all auxiliary equipment before
making any electrical connections and applying voltage to the machine.
Measure the insulation of at least the following parts:
 stator and rotor winding
 exciter winding
 anti-condensation heaters (if applicable)
 Pt-100 detectors
 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, Maintenace.
If the insulation resistance is under the specified value, it must be corrected before
starting the machine. See Chapter 7, Maintenace for corrective actions.
Measure the insulation resistance well before the planned first start so you will have
time for any necessary corrective actions.
The winding must be dry during the test. Therefore the anti-condensation heaters
should be active during storage and installation.
5.5 Automatic Voltage Regulator (AVR)
Pre-settings and testing by ABB
The AVR has been tested with the specific generator and all the basic settings have
been modified and saved so that the AVR will also work at site. The correct AVR and
the correct generator can be identified by checking the serial numbers on the test
report. See Test Reports.
Settings used in testing can be found in Test Reports.

Checking at site before first run

All the settings has to be checked once more at the site of the generator. If there is
need to change the settings it must be done by a qualified person such as an ABB or
AVR representative.
NOTE: Settings for the network must also be checked and verified.

Page 30
 NOTE: For detailed information about the settings and commissioning see Test
Reports and the system description in ANNEX 1, Technical Specification.
5.6 Starting
Start-up of the machine
The starting of the machine depends on the application, but main guidelines are:
1. Switch the anti-condensation heaters off if not operated by switchgear.
2. Engage the oil flow to bearings (if applicable)
3. Start to rotate the machine.
4. Maintain rated speed.
5. Switch the machine excitation on (unless self excited automatically).
6. Maintain rated voltage.
7. Check synchronizing parameters (if necessary).
8. Synchronize the machine to the grid (if necessary).
Recommended values for synchronizing are:
 ΔU = 2 %
 Δf = 0.7 %
 phase angle less than 15°
Maximum values ΔU = 4.5 %, Δf = 4.0 % should not be exceeded.
NOTE: Operation of the machine at reduced speed under 75% of rated speed should
be avoided.
5.7 Shut down
The shut-down of the machine depends on the application, but main guidelines are:
1. Reduce the output of the machine to zero.
2. Open the main breaker.
3. Switch the machine excitation off (when applicable).
4. Stop the engine.
5. Stop the oil flow to bearings (if applicable)
6. Switch the anti-condensation heaters on if not automatically done by switchgear.

*** Following chapter is applicable only with machines with rolling bearings
5.8 Greasing of rolling bearings
In case of a newly installed machine or a machine, which has been out of service
for more than 2 months, inject new grease into the bearings immediately after
start-up. New grease must be injected when the machine is running, and is injected
until old grease or excess new grease is discharged through the lubrication channel
in the bottom of the bearing housing, see Figure 5-1 Example of lubrication
channel through bearing arrangement of horizontal machine.

Page 31
Figure 5-1 Example of lubrication channel through bearing arrangement of
horizontal machine

NOTE: The re-lubrication interval will never be longer than 12 months.

The type of original grease used is found on the bearing plate on the machine.
Acceptable types of grease can be found in Chapter 7.5 Maintenance of bearings.

The temperature of the bearings will initially increase because of the excess grease.
After few hours, the excess grease will be discharged through the lubrication valve
and the temperature of the bearing will return to normal running temperature.

If available, and after the machine has been running for several hours, measure the
vibrations or SPM-values from the SPM-nipples, and record the values for future
reference use.

Page 32
Chapter 6 Operation

6.1 General
To ensure trouble-free running, a machine must be looked after and carefully
supervised.
Always before starting up the machine ensure that:
 the bearings are greased with oil to a correct level in accordance with the
manufacturer's technical specifications and the dimensional drawing
 the cooling system is functioning
 no maintenance is ongoing
 personnel and equipment associated with the machine are ready to start up the
machine.
For the start-up procedure see Chapter 5.6, Starting.
In case any deviations from expected normal operation are noticed, for example
elevated temperatures, noise or vibration, shut down the machine and find the reason
for the deviations. If necessary, consult the manufacturer of the machine.
NOTE: The machine may have hot surfaces when running with load.
NOTE: Overloading the machine may cause winding damages.
6.2 Normal operating conditions
The machines supplied by ABB are individually designed to operate in normal
operating conditions according to the IEC standard, technical specifications and
internal ABB standards.
The operation conditions, such as maximum ambient temperature and maximum
operating height, are specified in the performance data sheet. The foundation should
be free from external vibration, and the surrounding air free of dust, salt and corrosive
gases or substances.
6.3 Protection of synchronous generators
Protection of synchronous generators depends e.g. on the generator type and
application. Recommended protections in general are:
 Thermal overload in stator winding; I >
 Network short-circuit, I >>
 Stator interwinding short-circuit, differential protection relay
 Stator earth-fault, earth-fault relay
 Over voltage, over voltage relay
 Unbalanced load or shorted turns in the same phase, I2/In

Page 33
  Under excitation and loss of synchronism, under-reactance relay
 Under voltage and intermittent loss of voltage, under voltage relay
 Temperature supervision of temperature detectors, PT-100 monitoring
 Inlet cooling air temperature high
 Leakage water detection (in water cooled machines)
 Bearing oil flow too low (in sleeve bearings with external oil flow)
Additional protection:
 Frequency disturbance
 Reverse power
 Diode fault
 Vibration level
NOTE: Depending on the scope of the supplied generator, only some of the
protections may be applicable in practice. Necessary level of generator
protection shall be defined by the customer and necessary items shall be
included in the generator scope on request.
6.4 Start-up procedure
Always before starting up the synchronous machine check that:
 Rolling bearings are greased with oil to a correct level in accordance with the
manufacturer's technical specifications and the dimensional drawing
 Sleeve bearings are filled with correct type of oil.
 No shutdown procedures are in operation.
 Personnel and equipment associated to the machine are ready to start up the
machine.
 Cooling water supply to the heat exchangers is in accordance with
manufacturer’s technical specifications and outline drawing data. See ANNEX 1,
Technical Specification and ANNEX 2, Mechanical Drawings for details.
For start-up procedure, see Chapter 5.6, Starting.
6.4.1 Start interlocking
If the lubricating or cooling systems are provided with pressure or flow monitors,
these should 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.
6.5 Continuous supervision
The operating personnel should inspect the synchronous machine at regular intervals.
This means that they should listen to, touch and smell the synchronous machine and
its associated equipment in order to obtain a feeling for normal operating conditions.
The object of the supervision inspection is to thoroughly familiarize personnel with
the equipment. This is essential in order to detect and fix abnormal occurrences in
time.

Page 34
 Data from the supervision inspection should be kept for future reference and can be of
help in maintenance work, trouble shooting and repairs.
It is also recommended that the operational data (generator load, power factor, speed,
voltage and current as a minimum) shall be recorded and stored for future reference.
The difference between supervision and maintenance is rather vague. Normal
supervision of operation includes logging of operating data such as load, temperatures
etc., and the comments are used as a basis for maintenance and service.
 During the first period of operation (- 200 hours) supervision should be intensive.
Bearing and winding temperatures, load, current, cooling, lubrication, and
vibration should 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. If
operation is continuous and stable, the time between inspections may be further
extended.
6.6 Shut down procedures
To stop the synchronous machine:
1. Switch the main breaker open.
2. Switch excitation off (if applicable).
When the synchronous machine is not in operation, anti-condensation heaters must be
switched on to avoid condensation inside the machine.
The cooling water supply must be switched off in order to avoid condensation inside
the machine.
For detailed shut down instructions, see Chapter 5.6, Shut down.

Page 35
Machine type: Serial Number:
Point of Inspection: Date:

Stator current kA
Excitation current A
Bearing temperature, D-end °C
Bearing temperature, ND-end °C
Winding temperature, 1U °C
Winding temperature, 1V °C
Winding temperature, 1W °C
Winding temperature, 2U °C
Winding temperature, 2V °C
Winding temperature, 2W °C
Cold air temperature °C
Hot air temperature °C
Vibration level, D-end / axial Vrms [mm/s]
/ vertical Vrms [mm/s]
/ horizontal (transversal) Vrms [mm/s]
Vibration level, N-end / axial Vrms [mm/s]
/ vertical Vrms [mm/s]
/ horizontal (transversal) Vrms [mm/s]
3
Quantity of coolant m /h
Water leakage (Yes/No)
Fault indication (Yes/No)
Other observations / comments:

Table 6-1 Recommended supervision inspection program

Page 36
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 purpose of maintenance is therefore to:
 Secure that the machine will function reliably without any unforeseen actions or
interventions.
 Estimate and plan service actions in order to minimize down time.
The difference between supervision and maintenance is rather vague. Normal
supervision of operation and maintenance includes logging of operating data such as
load, temperatures, vibrations, as well as measurement of the insulation resistances.
After commissioning or maintenance, the supervision should be intensive.
Temperature of bearings and windings, load, current, cooling, lubrication and
vibration shall be checked frequently.
This chapter presents recommendations regarding maintenance program, and work
instructions how to conduct common maintenance tasks. These instructions and
recommendations should be read carefully and be used as a basis when planning the
maintenance program. Note that the maintenance recommendations presented in this
chapter represent a minimum level of maintenance. By intensifying maintenance and
supervision activities, the reliability of the machine and the long-term availability will
increase.
The data obtained during supervision and maintenance is useful for estimating and
planning additional service. In case some of this data indicates something out of the
ordinary, the trouble shooting guides in Chapter 8, Troubleshooting, will aid in
locating the reason for the trouble. ABB recommends the use of experts in the
creating maintenance programs, as well as in performing the actual maintenance and
possible trouble shooting.
The ABB After Sales organization is happy to assist in these issues. The ABB After
Sales contact information can be found in Chapter 9.1.5, After sales contact
information.
An essential part of the preventative maintenance is to have a selection of suitable
spare parts available. The best way to have access to critical spare parts is to keep
them on stock. Ready-made spare part packages can be obtained from the ABB After
Sales, see Chapter 9.2, Spare parts.
7.2 Safety precautions
Before working on any electrical equipment, general electrical safety precautions are
to be taken into account, and local regulations are to be respected in order to prevent

Page 37
 personnel injury. This should be made according to instructions of the security
personnel.
Personnel performing maintenance on electrical equipment and installations must be
highly qualified. The personnel must be trained in, and familiar with, the specific
maintenance procedures and tests required for rotating electrical machines.
For general safety instructions, see Chapter 1.5 General Safety and Chapter 1.6 Safety
Instructions.
7.3 Maintenance program
This chapter presents a recommended maintenance program for ABB machines. This
maintenance program is of a general nature, and should be considered as a 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.
NOTE: Different types of the generators contain different items to be maintained.
Maintenance program described in this chapter contains references to the accessories
that are not available on all machines. Operator shall create suitable maintenance
program based on basis of this information.
The maintenance program is based on four levels of maintenance, which 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 this
type of maintenance can be found in Chapter 9.2, Spare parts. The recommended
maintenance interval can be seen in Table 7-1, Recommended maintenance program.
The operation hour recommendation in this chapter is 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 * 20
Interval (Eq. h) L1 L2 L3 L4
4000 X
8000 X
12000 X
16000 X
20000 X
24000 X
28000 X
32000 X
36000 X
40000 X
44000 X
48000 X
52000 X
56000 X
60000 X
64000 X
68000 X
72000 X
76000 X
80000 X

Page 38
Table 7-1 Recommended maintenance program

Level 1 (L1)
Level 1 or L1 maintenance consists 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 consist of opening the inspection covers. It is recommended that at least
the operational spare parts package is available when commencing this maintenance.
The first Level 1 maintenance should be performed after 4 000 equivalent operating
hours or six months after commissioning. Subsequently the L1 maintenance should be
performed yearly halfway between Level 2 maintenance, see Table 7-1,
Recommended maintenance program.
Level 2 (L2)
Level 2 or L2 maintenance consists mainly of inspections and tests and small
maintenance tasks. The purpose of this maintenance is to find out 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 (megger). The preparations consist of opening the
inspection covers. Spare parts suitable for this level of maintenance are included in
the recommended spare parts package.
The first Level 2 maintenance should be performed after 8 000 equivalent operating
hours or one year after commissioning. Subsequently the L2 maintenance should be
performed yearly or after every 8 000 equivalent operating hours, see Table 7-1,
Recommended maintenance program.
Level 3 (L3)
Level 3 or L3 maintenance consists of performing extensive inspections, tests and
larger maintenance tasks that have come up during L1 and L2 maintenance. The
purpose of this maintenance is to repair encountered problems and replace parts
subjected to wear.
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
an endoscope and an 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 in the maintenance package.
The Level 3 maintenance should be performed after every 24 000 equivalent
operating hours or at a three to five year interval. When L3 maintenance is conducted
it replaces the L1 or L2 maintenance otherwise scheduled, and it leaves their rotation
unaffected, see Table 7-1, Recommended maintenance program.

Page 39
 Level 4 (L4)
Level 4 or L4 maintenance consists of performing extensive inspections and
maintenance tasks. The purpose of this maintenance is to 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, the rotor
removal equipment. The preparations consist of opening the inspection covers, and
the removal of rotor and exciter, if applicable.
The amount of spare parts required for this level of maintenance is difficult to
determine. At least the recommended spare parts package is recommended, but spare
parts included in the capital spare part package would 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, see Table 7-
1, Recommended maintenance program.
7.3.1 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: Not all options are applicable for all machines.
Maintenance interval
In equivalent operating hours or time
period, which ever comes first
L1 L2 L3 L4
Maintenance 4000 8000 24000 80000
Check / Test
object 3–5
½ year Annual Overhaul
years

7.3.1.1 General construction

Maintenance
L1 L2 L3 L4 Check / Test
object
Starting, shut down,
Machine
V/T V/T V/T V/T vibration measurement,
operation
no-load point
Mounting and
V V/T V/T V/T/D Cracks, rust, alignment
foundation
Exterior V V V V Rust, leakage, condition
Fastenings V V/T V/T V/T Tightness of all

Page 40
 fastenings

7.3.1.2 Cable connection

Maintenance
L1 L2 L3 L4 Check / Test
object
Cabling V V/T V/T V/T/D Wear, fastening
Connections V V/T V/T V/T/D Oxidation, fastening
Terminal box V V V V General condition
Condition of cables
Cable transits V V V V entering the machine
and inside the machine

7.3.1.3 Stator and rotor

Maintenance
L1 L2 L3 L4 Check / Test
object
Stator core V V V V/C Fixing, cracks, welds
Wear, cleanliness,
Stator winding
V V/T V/T/C V/T/C insulation resistance,
insulation
(high voltage test)
Stator coil
V V V V Insulation damages
overhangs
Stator coil Insulation damages,
V V V V
supports tightness
Stator slot wedges V V V V Movement, tightness
Stator terminal
V V V V Fixing, insulation
bars
Stator cable
terminal
V V/T V/T V/T Tightness, condition
fastenings and
crimps
Condition of cables and
Instrumentation V V V V
cable ties
Wear, cleanliness,
Rotor winding
V V/T V/T/C V/T/C insulation resistance,
insulation
voltage drop test
Rotor coil
V V V V Movement, bending
supports
Rotor balancing
V V V V Movement, fixing
weights
Cracks, corrosion, ultra
Damper bars V V/T V/T V/T
sound and knocking test
Shaft V V V V Cracks, corrosion
Air gap V V V V Cleanliness, equality
Connections in Fixing, general
V V V/T V/T
rotor condition
Rotor shaft General condition,
V V V/T V/T
insulation insulation resistance

Page 41
7.3.1.4 Excitation system, control and protection
Maintenance
L1 L2 L3 L4 Check / Test
object
Exciter diode
V V/T/C V/T/C V/T/C Cleanliness, operation
bridge
Exciter
V V/T/C V/T/C V/T/C Operation, fixing
semiconductors
Exciter Fixing, general
V V/T/C V/T/C V/T/C
connections condition
Exciter winding Wear, cleanliness,
V V/T V/T V/T
insulation insulation resistance
Exciter air gap V V/T V/T/D V/T/D Cleanliness, equality
Automatic
Operation, settings,
Voltage Regulator V V/T V/T V/T
stability test
(AVR)
Current
transformer for V V V/T V/T Operation, cleanliness
parallel operation
Voltage
V V V/T V/T Operation, cleanliness
transformer
Differential
V V V/T V/T Operation, cleanliness
transformers
Temperature
V V/T V/T V/T Operation, resistance
detectors
Anti-condensation Operation, insulation
V V/T V/T V/T
heaters resistance
Pt-100 elements
Resistance, insulation
(Stator, cooling V V/T V/T V/T
resistance
air, bearing)
General condition,
Auxiliary
V V/T V/T V/T terminals, wiring
terminals
condition
Exciter stator General condition,
V V V V
fixing cracks

7.3.1.5 Rolling bearings

Maintenance
L1 L2 L3 L4 Check / Test
object
Bearing during General condition,
V V V/T V/T
operation noise, vibration
Waste grease V V/C V/C V/C Condition, purging
According to bearing
Re-greasing V V/R V/R V/R
plate
Seals V V/D V/D V/D Leakage

7.3.1.6 Sleeve Bearings

Maintenance
L1 L2 L3 L4 Check / Test
object
Bearing assembly V V/T V/T V/T Fixing, General

Page 42
 condition
Bearing shells V V/T V/T/D V/T/D General condition, wear
Seals and gaskets V V V/T/D V/T/D Leakage
Condition, insulation
Bearing insulation V V/T V/T/D V/T/D
resistance
Lubrication oil V/R V/R V/R V/R Quality, quantity
Oil supply unit V V/T V/T/D V/T/D Operation

7.3.1.7 Cooling system

Maintenance
L1 L2 L3 L4 Check / Test
object
Leakage, operation,
Heat exchanger V V V V
pressure test
Tubes V V/C V/C V/C Cleanliness, corrosion
Duct V V/C V/C V/C Cleanliness, operations
End cases V V/C V/C V/C Leakage, condition
Seals and gaskets V V/C V/C V/C Leakage, condition
Plate fins V V/C V/C V/C General condition
Vibration
V V V V Condition and profile
dampers
Protective anodes V/C V/C Condition, activity
Operation, general
Fan V V V V
condition, cracks
Water flow
V/T V/T V/T V/T Operation
regulator

7.4 Maintenance of general construction

To ensure a 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 to corrosion and can
affect the cooling of the machine.
7.4.1 The tightness of fastenings
The tightness of all fastenings should be verified regularly. Special focus should be
given to fixing and the rotor parts, which must remain correctly tightened at all times.
Loose fastening in these parts can lead to sudden and severe damage to the entire
machine.

Page 43
 General values for tightening torques are presented in Table 7-2, General tightening
torques.
Tightening Tightening Tightening Tightening
Property class 8.8
torque Nm force kN torque Nm force kN
Screw μ = 0.14 μ = 0.14 μ = 0.16 μ = 0.16
M4 2.7 3.3 3.0 3.3
M5 5.0 5.0 5.5 4.9
M6 9.0 7.5 9.5 7.1
M8 22 14 24 13
M10 44 23 46 21
M12 75 33 80 31
M14 120 45 130 43
M16 180 60 200 59
M20 360 95 390 91
M24 610 140 660 130
M27 900 180 980 170
M30 1200 210 1300 210
M36 2100 310 2300 300
M39 2800 390 3000 370
M42 3400 440 3600 410
M48 5200 580 5600 560
Table 7-2 General tightening torques

NOTE: The values in Table 7-2, General tightening torques are general, and do not
apply to various items, such as diodes, support insulators, bearings, cable
terminals or pole fastenings, surge arrester, capacitors, current transformers,
rectifier and thyristor bridges, or if some other value is given elsewhere in
this manual or in the mechanical and electrical drawings, see Annex 2,
Mechanical Drawings and Annex 3, Electrical Drawings.
7.4.2 Vibration and noise
High or increasing 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, see Chapter 3, Installation and alignment
 Air gap, see Chapter 3, Installation and alignment
 Bearing wear or damage
 Vibration from connected machinery, see Chapter 5, Commissioning
 Loose fastenings, see Chapter 3, Installation and alignment
 Rotor imbalance
 Coupling

Page 44
 7.4.3 Rotor construction control
Particular attention should be paid to rotor construction, because even small damages
in the rotor can lead to severe damages in the stator. In addition, mechanical problems
in the moving parts such as the rotor, have a tendency to develop faster than in the
stationary parts of the machine.
Therefore, rotor construction should be checked yearly, preferably using an
endoscope and ultrasonic equipment. The condition and tightness of the fastenings
should be checked carefully.
7.4.4 Checks during running of the machine
During the first days of running it is important to keep the machine under close
surveillance in case any changes occur in the vibration or temperature levels or there
are abnormal sounds.

7.4.4.1 Normal vibration levels

The following instructions are part of the following two ISO standards:
1. 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
2. ISO 8528-9:1995 Reciprocating internal combustion engine driven alternating
current generating sets: Part 9: Measurement and evaluation of mechanical
vibrations.

7.4.4.1.1 Measurement procedures and operational conditions

General procedures described in ISO 10816-1 are used, subject to the
recommendations listed below.
Measurements are usually made when the rotor and the main bearings have reached
their normal steady-state operating temperatures and the machine running under
specified conditions, for example at rated speed, voltage, flow, pressure and load.
If the measured vibration exceeds the acceptance criteria 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 actions may be necessary to reduce the effect of background vibration.
Measurement equipment
The measurement equipment must be capable of measuring broad-band r.m.s
vibration with flat response over a frequency range of at least 10 Hz to 1000 Hz, in
accordance with ISO 2954. Depending on the vibration criteria, this may require
measurements of displacement or velocity or combinations of these (see ISO 10816-
1).
Measurement location
Use a measurement location that is exposed and accessible during normal operation.
Make sure that there are no local resonances or amplification so that the final
measurements will reasonably represent the vibration of the bearing housing. The
locations and directions of vibration measurements should provide adequate
sensitivity to the machines dynamic forces. Typically, this will require two orthogonal

Page 45
 radial measurement locations on bearing cap or frame. Place the transducers at any
angular position on the bearing cap or frame. Vertical and horizontal directions are
usually preferred for horizontally mounted machines. In some cases it may be
recommended to measure the vibration also in the axial direction. When recording the
results of the measurements, record the specific locations and directions with the
actual values.

7.4.4.1.2 Evaluation of RIC engine generating sets

The main excitation frequencies of the RIC engine (Reciprocating Internal
Combustion) are in the range of 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.
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
(See Table 7-3, Vibration velocity, Vrms below)
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
of the generating set components (see ISO 8528-5:1993, 15.10).
Declared engine Value 1 Value 2
speed [rpm] [mm/s] [mm/s]
≥1300 but <2000 20 28
>720 but <1300 18 22
≤720 15 20
Table 7-3 Vibration velocity, Vrms

Additional information
For more details about vibration measuring, 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

Page 46
7.4.4.2 Temperature levels
The temperatures of the bearings, stator windings and cooling air should be checked
when the synchronous machine is running.
The bearings might not reach a stable temperature until after several (2 - 6) hours,
when running at full speed.
The stator winding temperature depends on the load of the machine. If full load
cannot be reached during or soon after commissioning, the present load and
temperature should be noted and included in the commissioning report.
The settings for temperature detectors can be found on the main connection diagram
in Annex 3, Electrical Drawings.
The temperature alarm levels for resistance temperature detectors (RTD, Pt-100)
should be set as low as possible in order to detect any rapid abnormalities and trend
changes as early as possible. A suitable level can be determined based on the test
results, or preferably based on the observed operating temperatures. It is
recommended that the temperature alarm be set 10K (20°F) higher than the operating
temperature of the machine during maximal loading at the highest coolant
temperature.
1. Recommended procedure for alarm value setting based on site
conditions:
2. Initially set the alarm value according to the Main Connection
Diagram
3. Run the machine for a minimum of 6 hours at the intended operation
point
4. Measure the temperature values related to the alarms and the cooling
media. (i.e. the cooling air or the cooling water or cooling oil)
5. Evaluate the maximum temperature variation in the cooling media
6. Consider other possible sources of higher machine temperatures, such
as higher load, higher speed, different power factor etc.
7. Calculate the alarm value as follows: start with the measured
temperature at the operation point, add in temperature variations in
the cooling material as well as those of other possible sources of
higher machine temperatures. In order to obtain the alarm value, add
an additional 10 degrees C to the previously calculated value
8. Compare the above alarm value to the maximum value given in the
Main Connection Diagram, and choose the lower value as the alarm
set value
NOTE: Do not change the trip limits. If the typical operation point values change,
re-set the alarm values.
Example:
Measured stator Pt-100 value at operation point: 107 degrees C. Potential increase in
ambient air temperature: 7 degrees C. Increase in temperature as a result of lower
power factor: 4 degrees C.

Page 47
 The calculated alarm set point is: 107 + 7 + 4 + 10 = 128 degrees C. As this value is
lower than the value in the Main Connection Diagram, it will be used as the alarm set
point.
7.5 Maintenance of bearings
This section covers the most important maintenance tasks for the bearings. Other
relevant information about bearing and lubrication can be found in Annex 2,
Mechanical Drawings and Annex 4, Accessories.

*** Following part is applicable only with machines with rolling bearings
7.5.1 Rolling bearings
In normal operating conditions, rolling bearings require little maintenance. To ensure
reliable operation, the bearings should be regularly re-greased with high-quality
rolling bearing grease.

7.5.1.1 Bearing Plate

All machines are supplied with bearing plates attached to the machine frame. The
bearing plates provide bearing information, such as:
• Bearing type
• Lubricant used
• Re-greasing interval, and
• Re-greasing amount.
NOTE: It is essential that the information provided on the bearing plate is taken into
account when using and maintaining the machine.

7.5.1.2 Re-greasing intervals

Rolling bearings of electrical machines need to be re-greased at regular intervals. The
re-greasing interval is found on the bearing plate.
NOTE: Regardless of the re-greasing interval, the bearings need to be re-greased at
least once per year.
The re-greasing intervals are calculated for an operating temperature of 70°C (160°F).
If the operating temperature is lower or higher than the assumed, the re-grease
interval has to be altered accordingly. Higher operating temperature decreases the re-
greasing interval.
NOTE: An increase in the ambient temperature raises the temperature of the bearings
correspondingly. The values for the re-greasing interval should be halved for every
15°C (30°F) increase in bearing temperature and may be once doubled for a 15°C
(30°F) decrease in bearing temperature.

7.5.1.3 Re-greasing
All rolling bearings of rotating electrical machines need to be re-greased. The re-
greasing can be performed either manually or by means of an automatic system. In
either case, it has to be verified that a suitable amount of the correct grease is entering
the bearing at suitable intervals.

Page 48
NOTE: Grease can cause skin irritation and eye inflammation. Follow all safety
precautions specified by the grease manufacturer.

Manual re-greasing of the bearings

Machines suited for manual re-greasing are equipped with grease nipples. In order to
prevent debris from entering the bearings, the grease nipples, as well as the
surrounding area has to be cleaned thoroughly before re-greasing.

Manual re-greasing while the machine is running

Re-greasing while the machine is running:

• Verify that the grease to be used is suitable

• Clean the grease nipples and the area around them
• Verify that the lubrication channel is open, if equipped with a handle, open it.
• Press the specified amount and type of grease into the bearing
• Let the machine run 1-2 hours in order to ensure that all excess grease is forced out
of the bearing. The bearing temperature may temporarily increase during this time
• If equipped with a handle, close it.

NOTE: Beware of all rotating parts during the re-greasing.

Manual re-greasing while the machine is at a standstill

Preferably, re-grease the machine while it is running. If this is not possible, or
considered dangerous, the re-greasing has to be carried out while the machine is at a
standstill. In this case:
• Verify that the grease to be used is suitable
• Stop the machine
• Clean the grease nipples and the area around them
• Verify that the lubrication channel is open, if equipped with a handle, open it.
• Press only half the amount of the specified type of grease into the bearing
• Run the machine for a few minutes at full speed
• Stop the machine
• After the machine has stopped, press the specified amount of the correct grease
into the bearing
• Let the machine run 1-2 hours in order to ensure that all excess grease is forced out
of the bearing. The bearing temperature may temporarily increase during this time
• If equipped with a handle, close it.

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7.5.1.4 Bearing grease
It is essential to use grease of good quality and with the correct base soap. This will
ensure a long and trouble free lifetime of the bearings.
Grease used for re-greasing should have the following properties:
• Be special rolling bearing grease
• Be of good quality with a lithium complex soap, and with mineral-, or PAO-oil
• Have a base oil viscosity of 100 to 160 cSt at 40°C (105°F)
• Have a consistency NLGI grade between 1.5 and 3. For vertically or in hot
conditions mounted machines, NLGI grade 2 or 3 is recommended
• Have a continuous temperature range between -30°C (-20°F) and at least +120°C
(250°F).

Grease with the correct properties is available from all major lubricant manufacturers.
If the make of grease is changed and compatibility is uncertain, consult the
manufacturing ABB factory, see Chapter 9.1.5 After Sales contact information.

NOTE: Different makes of grease must not be mixed, unless the compatibility has
been verified.

NOTE: Grease additives are recommended. However, a written guarantee should be

obtained from the lubricant manufacturer stating that the additives do not damage the
bearings or the properties of the grease in the field of the operating temperature. This
is especially important for EP additives.

NOTE: Lubricants containing EP admixtures are not recommended.

Recommended rolling bearing grease

NOTE: Grease type can be found on the bearing plate which is on the frame. Pls do
re-greasing according to bearing plate. If the grease type in the bearing plate is hard to
be found, ABB suggest below grease can be a backup. But the old grease must be
cleaned up, if the other grease is used.
• Mobil Unirex N2, N3 (lithium complex base)
• Shell Albida EMS 2 (lithium complex base)
Re-greasing intervals for greases fulfilling the required properties other than the ones
mentioned above should be halved.
NOTE: Different makes of grease must not be mixed, unless the compatibility has
been verified.

Rolling bearing grease for extreme temperatures

If the bearing operating temperature is above 100°C (210°F), please consult the
manufacturing ABB factory for suitable greases.

Page 50
 7.5.1.5 Bearing maintenance
The lifetime of the bearings is likely to be shorter than the lifetime of the electrical
machine.
Therefore, the bearings will have to be changed periodically.
The maintenance of rolling bearings requires special care, tools and arrangements as
to ensure a long lifetime of newly fitted bearings.
During bearing maintenance, ensure that:
• No dirt or foreign debris is allowed to enter the bearings at any time during the
maintenance
• The bearings are washed, dried and pre-greased with suitable and high quality
rolling bearing grease before assembly
• The disassembly and mounting of the bearings does not damage the bearings. The
bearings must be removed by using pullers and fitted by heating, or using special
tools for the purpose.

If there is a need to change bearings, please contact ABB After Sales. See After Sales
contact information in Chapter 9.1.5 After Sales contact information.

*** Following part is applicable only with machines with sleeve bearings
7.5.2 Sleeve Bearings
The machines are equipped with sleeve bearings that have a very long service life
provided that:
• the lubrication functions continuously
• the oil type and quality are as per ABB recommendations
• the oil change instructions are followed

7.5.2.1 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.

7.5.2.2 Condition of the lubricant

Check the oil with respect to color, smell, turbidity and deposits in a test bottle.
The following requirements must 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.

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 • 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 shortly after commissioning, it can
be used again after removing wear particles by filtering or centrifuging.
In doubtful cases an oil sample can be sent to a laboratory to determine viscosity, acid
number, foaming tendency, etc.

7.5.2.3 Oil qualities

The oils listed below are lubricants based on paraffin that have a high viscosity index
value (VI > 90) and a particularly low fluid temperature. The oils listed below include
the following additives:
• oxidation and rust inhibitor
• anti-foaming agent
• mild EP action, anti-wear additive.
The correct oil type is stated is ANNEX 2: Mechancal drawings – Main dimensions.
The type is also stated in sign next to bearing.

The most commonly used types are:

ISO VG 32, ISO VG 46 and ISO VG 68
The number behind VG means the viscosity cSt at 40 °C

In following section the most common brand names are listed.

Environmentally Benign Oils
BP: Enersyn RC-S 32, 46 or 68
Klüber: Summit SH 32, 46 or 68
Panolin: Turwada Synth 32, 46 or 68
Shell: Corena AS 32, 46 or 68
Mineral Oils
Aral: Degol CL 32, 46 or 68
BP: Energol CS 32, 46 or 68
Castrol: PERFECTO T 32, 46 or 68
Chevron: MECHANISM LPS 32, 46 or 68
DEA: Astron HL 32, 46 or 68
Esso: TERESSO 32, 46 or 68
Klüber: LAMORA HLP 32, 46 or 68
Shell: Tellus Öl C 32, 46 or 68

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 Total: Azolla ZS 32, 46 or 68

7.5.2.4 Oil change schedule for mineral oils

For self-lubricated bearings cleaning intervals with oil changes of approximately 4000
operating hours are recommended and approximately 20000 operating hours for
bearings with oil circulation systems.
Shorter oil change intervals may be necessary in case of frequent start-ups, high oil
temperatures or excessively high contamination due to external influences.
7.5.3 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 ANNEX 4, Accessories.

7.5.3.1 Oil level

The oil level needs to be checked regularly. It can be checked through the sight glass
of the bearing. The possible oil supply unit is equipped with an oil dipper rod for
checking the oil quantity.
If necessary, refill with a suitable lubricant Chapter 7.5.2.3, Oil qualities.

7.5.3.2 Bearing temperature

The bearing temperatures are measured by Pt-100 resistance temperature detectors.
The normal bearing temperature should be 50 - 90 °C. Since a temperature rise above
the alarm limit can be caused either by increased losses in the bearing, or by
decreased cooling capacity, it often indicates a problem somewhere in the machine or
in the lubrication system, and should therefore be closely monitored. The factory set
alarm and trip limits are stated in the Main Connection Diagram, see ANNEX 3,
Electrical Drawings.
The reasons for abnormal bearing temperature vary, but for some possible reason see
Chapter 7.5.1, Lubrication or Chapter 8, Troubleshooting. If the temperature rise is
followed by an increase in vibration levels, the problem might also be related to the
machine's alignment, see Chapter 3, Installation and alignment or to a damage in the
bearing shells in which case the bearing needs to be dismantled and checked, see
ANNEX 4, Accessories.
7.5.4 Oil leakage of sleeve bearings
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.
However, oil leakage can 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
 Re-tighten the bearing housing halves, and the labyrinth seal cover. This is
especially important, if the machine has been stopped for a long time

Page 53
  Measure the vibrations of the leaking bearing in three directions under full
load. 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
 Verify that there is nothing, 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 is no over pressure inside the bearing. Over pressure 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 a flood 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 and below mentioned
things have been checked and verified, please fill in the form Oil Leakage's at RENK
Sleeve Bearings and send it to the after sales and market support department.

7.5.4.1 Oil
In order for the bearings to function as expected, the oil has to meet certain criteria
like viscosity and cleanliness.
Viscosity
The bearings are designed to run with an oil of a certain viscosity, which is mentioned
in the documentation provided with the electrical machine. Incorrect viscosity will
lead to lubrication failures, and can damage the bearings, as well as the shaft.

7.5.4.2 Sleeve bearings

The sleeve bearings used in rotating electrical machines are often 'standard bearings'
used in a number of applications. Therefore, the bearing design in itself is normally
not the cause of bearing leakages, and the reason for the leakage should be found
elsewhere.
However, the bearing is assembled from several parts, and the joints between the parts
can leak due to faulty assembly or lack of sealing compound.
Bearing housing
The bearing housing consists of an upper and lower half, which are joined together. In
addition, labyrinth seals are mounted at the bearing housing entrance of the shaft. This
construction is not completely hermetic, and therefore very small leakages have to be
tolerated.
A tolerable amount of leakage for self-lubricating bearings is such that the bearing
does not need a top-up between the oil change intervals.
The oil can leak from the bearing in two ways:
• Past the labyrinth seals
• Through the split line of the bearing housing.

Page 54
 Sealant
In order to prevent the oil from leaking from the bearing through any split lines,
sealant is applied on the split lines. ABB recommends the Hylomar Blue Heavy
sealing compound. Curil T or other similar compounds can be used as well.

7.5.4.3 Bearing verification

In case the oil leakage is suspected to originate from the bearing housing itself, the
following steps can be taken:
1. Re-tighten the bearing housing
This is especially important during the commissioning of the machine, or if the
machine has been standing still for a longer period, as the parts may set.
If the bearing housing halves are not in a tight fit in respect to each other, the oil
might wash away the sealant from the split line. This in turn will cause oil leakage.
2. Open the bearing housing
The bearing housing can be opened, and new sealant applied on the split lines. Care
has to be taken that no dirt or foreign matter enter the bearing during this procedure.
The split lines have to be completely re-greased before a thin layer of sealant is
applied.

7.5.4.4 Use
Causes for bearing leakages, apart from being installation-related, some causes are
'use' related.
Oil temperature
The correct lubrication oil temperature is essential in keeping the bearing at the
correct operating temperature, in ensuring sufficient lubrication effect, and correct
viscosity of the lubrication oil, see Chapter 7.5.1.1, Lubrication oil temperature.
Vibrations
All machines are subjected to, and designed to withstand vibrations. Large vibrations
might cause the various parts in the bearing to function different as intended.
Heavy vibrations can cause different phenomena in the oil film between the shaft and
the white metal, but this will rather seldom lead to oil leakages. Instead, vibrations
might cause bearing failures.
Heavy vibrations can cause the bearing housing parts to set, or to 'loosen up' just
enough to allow the oil to enter the split surface between the upper and the lower
bearing housing halves. The vibrations will cause the bearing housing parts to move
in respect of each other. This can cause a 'pumping' effect in such a way, that oil will
be pumped in and out from the split surface. This will eventually remove the sealant,
and cause the bearings to leak.
Over pressure inside the bearing
The bearing housing is not a hermetic compartment, and therefore any over pressure
inside the bearing housing will escape the bearing housing via the labyrinth seals. In
escaping, the air will bring oil mist with it, thus causing the bearing to leak.

Page 55
 Over pressure inside the bearing is normally caused by other components than the
bearing itself. The most common reason for over pressure inside the bearing is over
pressure in the oil return piping.
Under pressure outside the bearing
Similar to over pressure inside the bearing, under pressure outside the bearing will
'suck' air out from inside the bearing, thus bringing oil with it, and causing the bearing
to leak oil.
Under pressure inside the bearing is normally not caused by the bearing itself, but by
parts outside the bearing.
Under pressure near the bearing housing is caused by rotational parts moving the air
next to them in such a way that a local under pressure is formed next to the exit of the
shaft of the bearing.

7.5.4.5 Use verification

Oil
The oil quality must be verified.
Vibrations
Vibration readings of the bearing housings should be taken in three directions: axial,
transversal (horizontal) and vertical.
Air pressure inside the bearing
The air pressures inside and outside the bearings should be verified.
The best way to measure the pressure inside a bearing, is from the oil fill entrance or
the inspection glass on top of the bearing.
Air pressure outside the bearing
The air pressure near the exit of the shaft from the bearing needs to be verified. This
is especially important if the bearing is flange mounted to the machine, or if the shaft
is mounted inside a cover or other construction which might form a 'centrifugal fan'
together with the shaft.
Flange bearings have two canals between the bearing housing and the flange, which
normally are enough to compensate for any under pressure near the exit of the shaft
from the bearing housing. However, if for some reason a very large under pressure is
present near this area, the two canals might not be enough, and some air is
additionally sucked from inside the bearing. This is especially likely to happen to
sleeve bearings with axial thrust pads, as the oil flow in these bearings is larger than
in pure radial bearings.
If a large under pressure is noticed or suspected, the air pressure has to be measured
near the exit of the shaft from the bearing housing.
In order to verify that the under pressure outside the bearing can cause the leakage,
the pressure outside the bearing (p0) inside the bearing (p2), and the pressure in the
area between the end shield and the machine seal (p1) must be measured as well.
When measuring (p1), the tube has to be inserted as deep as possible, and the canals
must be temporarily closed, see Figure 7-2, Verification of air pressure inside and
outside of a sleeve bearing.

Page 56
In order to analyze the situation, p1 and p2 have to be compared with p0, which has to
be measured free from any disturbances or turbulence near the machine. The
following situations can appear:
• p0 = p1 = p2. If all pressure readings are the same, the leakage is not caused by
pressure differences. However, bear in mind what has been stated about diesel
engines earlier
• p2 > p1(= p0). If the pressure inside the bearing is larger than the outside pressure,
there is only a situation with over pressure inside the bearing
• p2 (= p0) > p1. If the pressure outside the bearing is smaller than the pressure
elsewhere, there is under pressure near the bearing
• p2 > p0 > p1. If all pressure readings are different, there might be a situation where
both over pressure inside the bearing, and under pressure outside the bearing are
present.

Figure 7-1. Verification of air pressure inside and outside of a sleeve bearing

Page 57
 If a large under pressure is found to be inside the machine, e.g. between the end shield
and the machine seal, the situation is tricky; it is normally very difficult to remove the
machine seal, and to re-seal it.
NOTE: In no case should a breather be installed to remedy under pressure in the
bearing, as it will only make the leakage worse.
7.5.5 Bearing insulation resistance check
The bearing insulation resistance check is a maintenance operation done primarily in
the factory during the final assembly and testing. It should also be made during all
comprehensive overhauls of the machine. Good insulation is necessary in order to
eliminate the possibility of circulating bearing currents, which might be induced by
shaft voltages. The insulation of the non-drive end bearing cuts the path of the bearing
current and thus eliminates the risk of bearing damages due to bearing currents.
If the drive end bearing is not insulated, the non-drive end bearing insulation
resistance test requires the removal of the drive end bearing, or the removal of the
bearing housing cover, and lifting of the shaft, so that there is no electrical contact
between the shaft and any other part, for example frame or bearing housing. Therefore,
when the drive end bearing is insulated, the measurement of the non-drive end
bearing should only be conducted by qualified personnel.
Insulation resistance is acceptable if the resistance value is more than 10 kΩ.
7.5.6 Bearing clearance measurements
The bearing clearance is measured by opening the upper bearing shell, which makes it
possible to measure the clearance with for example a lead wire at the top and at the
sides of the shaft. The measuring at the top of the shaft is carried out by placing
40...50 mm pieces of about 1 mm thick lead wire on top of the shaft and on the split
surfaces at both sides of the lower bearing shell. The upper bearing shell is then
lowered to rest on the wires and pressed lightly. The thickness of the pressed wires is
measured with a micrometer.
The bearing clearance is calculated from the formula:
S = A - [(B1 + B2) ÷ 2]
where S = bearing clearance (mm)
A = thickness of lead wire on top of shaft (mm)
B1 = thickness of lead wire on split surface (mm)
B2 = thickness of lead wire on split surface (mm)
The clearance values are given on the dimension drawing or they can be roughly
estimated from the formula:
¼
S = (n × D) × (D ÷ 14500)
where S = bearing clearance (mm)
D = shaft diameter at the bearing (mm)
n = rotating speed (r/min)

Page 58
7.6 Maintenance of stator and rotor winding
The windings of rotating electrical machines are subjected 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,
which 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. IEEE Std. 43-2000, IEEE Recommended Practice for Testing Insulation
Resistance of Rotating Machines
2. IEEE Std. 432-1992, IEEE Guide for Insulation Maintenance for Rotating
Electrical Machinery (5 hp to Less Than 10 000 hp)
7.6.1 Particular safety instructions for winding maintenance
Some of the hazardous works of the winding maintenance include:
 Handling of hazardous solvents, varnishes, and resins. Hazardous substances are
required for cleaning and re-varnishing windings. These substances can be
dangerous if inhaled, swallowed or in any contact with skin or other organs. Seek
proper medical care if an accident occurs.
 Dealing with flammable solvents and varnishes. Handling and use of these
substances should always be by authorized personnel and proper safety
procedures must be followed.
 Testing at high voltage (HV). High-voltage tests should only be conducted by
authorized personnel and proper safety procedures must be followed.
Dangerous substances used in winding maintenance are:
 White spirit: solvent
 Trichloroethane: solvent
 Finishing varnish: solvent and resin
 Adhesive resin: epoxy resin
NOTE: 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 during winding maintenance are as follows:
 Avoid breathing air fumes; ensure proper air circulation at the work site or use
respiration masks.

Page 59
  Wear safety gear such as glasses, shoes, hard hat and gloves and suitable
protective clothing to protect the skin. Protective creams should always be used.
 Spray-varnish equipment, the frame of the machine, and the windings should be
earthed during spray-varnishing.
 Take necessary precautions when working in pits and cramped places.
 Only personnel trained to do high voltage work can carry out a voltage test.
 Do not smoke, eat, or drink at the work site.
For a test record for winding maintenance, see Annex 6, Check Lists.
7.6.2 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 should be performed 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.
NOTE: As a rule of thumb, 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 7.3, Maintenance program. This maintenance program however, should be
adapted to the customer's particular circumstances, i.e. servicing of other machines
and operating conditions as long as recommended servicing intervals are not exceeded.
7.6.3 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.
7.6.4 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, be extremely low if the machine has been subjected to
incorrect transportation and storage conditions and humidity, or if the machine is
operated incorrectly.
NOTE: Windings should be earthed briefly immediately after measurement in order
to avoid risk of electric shock.

Page 60
7.6.4.1 Conversion of measured insulation resistance values
In order to be able to compare measured insulation resistance values, the values are
stated at 40 °C. The actual measured value is therefore converted to a corresponding
40 °C value with the help of the following diagram (see 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 40 °C, since
large deviations from it could result in errors.

Figure 7-1 Correlation between the insulation resistance and the temperature

R = Insulation resistance value at a specific temperature

R40 = Equivalent insulation resistance at 40 °C
R40 = k x R
Example:
R = 30 MΩ measured at 20 °C
k = 0.25
R40 = 0.25 x 30 = 7.5 MΩ
°C 0 10 20 30 40 50 60 70 80 90 100 110
°F 32 50 68 86 104 122 140 158 176 194 212 230
Table 7-4 Temperature values in degrees Celsius (°C) and degrees Fahrenheit
(°F)

7.6.4.2 General considerations

The following consideration should be noted, before deciding any actions based upon
the insulation resistance tests:
 If the measured value is considered too low, the winding must be cleaned and/or
dried, see Chapter 7.6.8, Drying for details. If these measures are not sufficient,
expert help should be acquired.

Page 61
 Machines, that are suspected to have a moisture problem, should be dried
carefully independent of 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.
NOTE: The insulation resistance indicated in the test report is normally
considerably higher than the values measured on site.

7.6.4.3 Minimum values for insulation resistance

The following criteria apply to 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 the machine type and local conditions. In addition, the
insulation resistance is affected by the age and usage of the machine. Therefore, the
following values can only be considered as guidelines.
The insulation resistance limits, which are given below, are valid at 40 °C, and when
the test voltage has been applied for 1 minute or longer.
Rotor
For rotors: R(1 - 10 min at 40 °C) > 1.5 MΩ
Carbon dust on naked copper surfaces lower the insulation resistance values of the
rotor.
Stator
For new stators: R(1 - 10 min at 40 °C) > 1000 MΩ
For used stators: R(1 - 10 min at 40 °C) > 100 MΩ
If the values indicated here are not reached, the reason for the low insulation
resistance should be determined. A low insulation resistance value is often caused by
excess humidity or dirt, the actual insulation being intact.

7.6.4.4 Stator winding insulation resistance measurement

The insulation resistance is measured using an insulation resistance meter. The test
voltage is 1000 VDC. The test time is 1 minute, after which the insulation resistance
value is recorded. Before the insulation resistance test is conducted, check that:
 The secondary connections of the current transformers (CT's), including spare
cores are not open. See Figure 7-4, Connection of the stator windings for
insulation resistance measurements, part a.
 All power supply cables are disconnected.
 The frame of the machine and the stator windings not being tested are earthed.
 All resistance temperature detectors are earthed.
 Possible earthing of voltage transformers (not common) must be removed.
The insulation resistance measuring should be carried out in the terminal box. The test
is usually performed to the whole winding as a group, in which case the meter is
connected between the frame of the machine and the winding. See part a and part b
of Figure 7-6, Connection of the stator windings for insulation resistance
measurements. The frame is earthed and the three phases of the stator winding remain

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connected at the neutral point, see part A of Figure 7-4, Connection of the stator
windings for insulation resistance measurements. In the figure MΩ represents the
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 c of
Figure 7-4, Connection of the stator windings for insulation resistance measurements.
In the figure MΩ represents the 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 a typical 3-phase voltage transformer, the whole component must be
removed.

Figure 7-2 Connection of the stator windings for insulation resistance

measurements
a. Insulation resistance measurement for star connected winding
b. Insulation resistance measurement for delta connected winding
c. Insulation resistance measurement for one phase of the winding. MΩ
represents insulation resistance meter

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

7.6.4.5 Insulation resistance measurements of the rotor field

winding and excitation machine
The test voltage for the rotor windings and excitation machine is 500 VDC.
When testing the windings of the rotors:
 Short circuit the rectifier before measuring.
 Measure the rotor winding temperature if possible or estimate otherwise
measurement temperature of the rotor winding..
 Connect the insulation resistance meter between the rotor windings and the shaft
of the rotors as shown in Figure 7-5, Connections for insulation resistance
measurements. The measurement current must not go through the bearings.
 After the insulation resistance measurement, discharge the windings by earthing
them.
When testing the stator winding of the excitation machine:

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  Disconnect the power supply cables from the voltage source.
 Connect the insulation resistance meter between the stator winding and the frame
of the machine as shown in Figure 7-5, Connections for insulation resistance
measurements.

Figure 7-3 Connections for insulation resistance measurements

1. Measurement of windings of the rotors
2. Measurement of the stator winding of the excitation machine. MΩ
represents the insulation resistance meter
7.6.5 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 50 °C (122 °F), it may be
considered independent of temperature. High temperatures can cause unpredictable
changes in the polarization index; therefore the test should not be used in
temperatures above 50 °C (122 °F).
Dirt and humidity accumulating in the winding normally reduces 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 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.
The minimum PI value for class H stator winding is more than 2 where
R1 min R
PI  or 10 min
R15 s R1 min
NOTE: If the insulation resistance of the winding is in the range of several
thousands of MΩ, the polarization index is not a meaningful criterion of the
condition of the insulation, and it can be disregarded.

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7.6.6 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 during major inspections,
troubleshooting and repairs.
AC voltage is used for the high voltage test and the test voltage is 1500 V.
7.6.7 Visual winding inspection
Winding inspections give information on:
 the rate of contamination; presence of dirt and humidity
 stability of bracings, vibration marks, and cracking
 marks of overheating
 marks of movement
 tightness of the slot wedges
 winding overhangs and their supports
The results of all inspections should be recorded in the check list supplied in Annex 6,
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.
Accumulating dirt blocks the coil gaps and air ducts, and thus diminishes the cooling
capacity of the machine. As a result, the winding temperature rises, and aging may
speed up considerably.
Mechanical strain, vibration, and shocks may cause cracks on the edges of the
supports, tyings, and around slot ends. Loose supports and slot wedges are signs of
further deterioration. Check for abrasion marks and powder near the supports, tyings,
and at the slot ends. 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 into a failure.
Humidity in the winding often causes for example rust on iron, drop marks, dripping,
and wetting marks on dirt layers. Bush-shaped patterns, often charred and left behind
by the tracking currents, warn of an approaching failure. In rare cases, the conductors
are corroded.
Marks of the electrical effects (apart from tracking current marks), are usually hidden
inside the slot and conductor insulations.
Over temperatures that last only for a short period of time can leave marks all over the
machine.
The following are marks of overheating:
 Copper in the damper 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 350 °C [662 °F])
 There are color differences in the fastening bolts of synchronous machines.

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  Insulation may shrink or split (usually over 200 °C [392 °F]), tyings may crack
(over 220 °C [428 °F]), and polyester film or fibers may melt (over 250 °C
[482 °F]).
 Swelling of the slot insulation is also possible.
Prolonged periods over temperatures cause premature ageing. The insulating
materials become brittle and darken in the early stages. As a result, the windings split,
disintegrate, and fracture.
7.6.8 Drying
The windings must be dried:
 After washing (especially a water wash and rinse)
 If they have become humid in use or during a standstill.
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.
During drying, the rate of temperature rise of the winding should not exceed 5 K (9 °F)
per hour, and the final temperature should not exceed 105 °C (220 °F). 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 windings dried in an 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 a current through it, the source of electricity can be
for example a welding machine or a similar device.
NOTE: Direct current or alternate current can be used. The current must not exceed
25 % of the nominal current, which is indicated on the rating plate on the
machine. The winding temperature should 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 90 °C (194 °F) for 12
to 16 hours and then 105 °C (220 °F) for six to eight hours. These times can vary, and
the correct time should be monitored with and insulation resistance test.
Effective drying is achieved with the right balance of heat and ventilation. The air
circulation inside the machine should be as effective as possible.
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 circulation is essential, whatever heating method is used.
An insulation resistance test should be performed after drying the windings. When
drying is started, the insulation resistance decreases due to the temperature rise. As
the drying continues, however, the insulation resistance increases until it reaches a
stable value.

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 7.6.9 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
and makes cleaning easier. In new machines a finishing varnish treatment is optional.
The finishing varnish can crack or peel after a long operating time. 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 windings should be cleaned carefully before a new coat of varnish is applied, so
that no dirt will be left under the new coat. Old finishing varnish that can come off
easily should be removed before re-varnishing.
Varnish is usually applied with a spray (one or two coats suffices). If the windings are
still warm after drying, wait until the temperature of the windings is below 40 °C
(104 °F). Apply the varnish between the coils and other parts that are not easily
reached. Avoid thick coats of varnish as they dry slowly. Rotating parts should be left
to dry for 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.
7.6.10 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. The ABB After Sales organization is happy to assist in question
regarding maintenance of electrical machine windings, for contact information see
Chapter 9, After sales and spare parts.
7.7 Maintenance related to electrical performance, excitation,
control and protection
The electrical performance of a synchronous machine is mostly defined by the
condition of the rotor and stator windings and the operation of the excitation system.
The main machine winding maintenance is described in Chapter 7.6, Maintenance of
stator and rotor winding. In this chapter the focus is on the maintenance of the
excitation system and the control and protection systems.
7.7.1 Exciter insulation resistance measurement
The insulation resistance in the exciter can be tested with the winding insulation
resistance test. The procedure is described in detail in Chapter 7.6, 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 resistance of the exciter rotor is usually measured jointly with the rotor of the
main machine, see Chapter 7.6.4.5, Insulation resistance measurements of the rotor
field winding and excitation machine. The resistance of the exciter rotor can also be
measured separately, but this requires special arrangements.

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7.7.2 Protection trips
The synchronous machine needs to be protected with alarms and trips in case of
abnormal running conditions, both electrical and mechanical. Some of these
protections can be reset and the machine restarted directly as the fault is located.
Alarms or trips in the following protections should be further investigated:
• Diode fault protection, see Chapter 7.7.6, Diode fault.
• High temperature in bearing, see Chapter 7.5, Maintenance of lubrication system
and bearings.
• High temperature in winding or in cooling air, see Chapter 7.6, Maintenance of
stator and rotor winding and Chapter 7.7, Maintenance related to electrical
performance, excitation,control, and protection.
• Over current, current unbalance, bus bar voltage.
• Vibration protection, see Chapter 5, Commissioning.
7.7.3 Automatic voltage regulator (AVR)
The automatic voltage regulator (AVR) is important in controlling and protecting the
machine, and problems in connections or settings of the AVR might lead to different
types of operational faults. These include for example performance deviations and
loss of excitation. For detailed information about AVR connection and settings see
Annex 3, Electrical Drawings and Annex 4, Accessory Information. For AVR factory
setting, see generator test report.
7.7.4 Pt-100 resistance temperature detectors
Pt-100 resistance temperature detectors are an essential part of the machine's
monitoring and protection system. They are used to measure the temperature of the
windings, bearings and the cooling air. The Pt-100 detectors use a fine platinum
filament for measuring the temperature. They should be handled carefully as they can
be damaged for example by incorrect handling or excessive vibration.

The following symptoms might suggest a problem in a Pt-100-detector:

• Infinite or zero resistance over the detector.
• Disappearance of measurement signal during or after start up.
• A significantly different resistance value one of the detectors.

If a Pt-100 failure is suspected, always confirm the finding from the connection box.
This can be done by measuring the resistance over the detector. In ANNEX 6, Check
lists a Pt-100 detector failure inspection protocol can be found.
7.7.5 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 Chapter 7.6, 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.

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 7.7.6 Diode fault
If a diode in the rotating rectifier fails, 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.
NOTE: Do not open the service covers or end shields unless it is certain that the
machine is isolated from its driving source.
To replace faulty diodes:
 Open the service doors at N-end shield of the machine.
 Disconnect the wires connected to the diodes and exciter winding connection
cables.
 Check the condition of the diodes by measuring the resistance over a diode in
both directions.
 Replace the damaged diode(s).
 Clean the contact surfaces, and apply electric joint compound.
 Fasten the 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.
7.8 Maintenance related to thermal performance and cooling
system
An increase in the machine's temperature is usually caused by:
 A decline in the effect of the cooling system or
 Excessive amounts of heat produced by the machine.
If the machine temperature exceeds normal values, determine which of these two
causes is responsible for the increase in the temperature. Excessive heat production
might be caused for example by a winding problem or by network unbalance and in
these cases corrective actions on the cooling system would be ineffective or harmful.

*** Following part is applicable only with water cooled machines

7.8.1 Maintenance instructions for air-to-water heat exchanger
If the temperature detectors show normal temperature, and the leakage detectors
indicate no leaks, no additional supervision is required for the cooling system. If the
coolers have to be cleaned, see instructions in Chapter 7.8.1.3, Cleaning.

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If the winding or cooling air temperature detectors show an abnormal temperature, the
cooling system has to be checked. Either of the following two reasons could be
causing the problem in the cooling system:
• incorrect operation of the heat exchanger
Ensure that the operation of the heat exchanger is uninterrupted and correct. The
heat exchanger should be cleaned periodically and it should be checked for
leakage. For more information see Chapter 7.8.1.3, Cleaning. Check also that air
flow through the heat exchanger is uninterrupted.
• problems in the primary cooling circuit
Ensure good air circulation in the primary cooling circuit inside the machine. The
machine interior should be cleaned and checked during overhauls or if problems
arise.
Other possible causes for poor heat exchanger performance include elevated ambient
temperature, coolant water flow or temperature abnormality.

7.8.1.1 Installation
The cooler can be installed both for vertical and horizontal air flow. The cooler is a
standard design with a crossflow water circuitry. The direction of air flow is not
relevant.

7.8.1.2 Starting up
The supply and return pipes should be flushed before they are connected to the
cooling element.
If the pipework is pressure tested with the cooling element connected, the test
pressure should not exceed the value specified on the rating plate of the cooling
element.
During pressure testing and when starting up the system, back off the vent plugs to
release any air in the pipework. Venting should be carried out frequently during the
initial period of operation.
Adjust the water flow to the required level. If the flow is too low, the cooling capacity
of the coil will be impaired and deposits may occur on the insides of the tubes. If the
flow is too high, the cooling capacity will be increased, but erosion may occur on the
insides of the tubes.

7.8.1.3 Cleaning
Even if air and water filters are used, some fouling of the cooling surface and the tube
wall will occur. This fouling reduces the cooling capacity. The cooling element
should therefore be cleaned at regular intervals, to be determined from case to case,
depending on the quality of the air and water. During the initial period of operation,
the coil should be inspected frequently.
To clean the water side:
1. Drain the cooling element thoroughly.
2. Remove the cooling element from the system if this will make cleaning easier.
3. Remove the chambers and mark up the location of the chamber to ensure correct
mounting.

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 4. Clean the inside of the tubes using a brush. Flush with water.
5. Remove the old gasket and clean the inside of the chamber.
6. A new self-adhesive gasket (QLKZ-01) can be stuck on the chamber. The gasket is
made of EPDM cellular rubber 9x3 mm. (neoprene rubber).
7. Mount the chamber to a correct location.
8. Tighten the screw joint with a torque wrench.
- Torque: 80 Nm
- (8 kmp or 708 Lbf.in)
To clean the air side:
1. Blow the cooling element clean with compressed air or flush it carefully with water.
2. Add detergent to the water if the surface is coated with fatty deposits.

7.8.1.4 Risk of freezing

If a water-filled coil is not in service and the temperature drops below freezing point,
the finned tubes may burst and the chambers may be deformed.
If there is a risk of freezing, all water should be drained from the coil by removing the
drain and bent plugs.

7.8.1.5 Inoperative coils

A cooling element that is not in use should be completely drained of water to prevent
damage due to corrosion or freezing. This is particularly important if coils with cupro-
nickel tubes are used, since this material is particularly susceptible to corrosion
caused by deposits.
Do not refit the drain plugs after the cooling element has been drained, since the shut-
off valves may leak and fill the coil with water.
To ensure that the cooling element is completely drained, remove one water box.
When the cooler is installed for vertical air flow, the bottom row of tubes cannot be
completely drained. In order to avoid the risk of freezing when the cooling element is
out of operation, one of the chambers should always be removed.
7.8.2 Disassembly and remounting of cooling system
The cooling unit should be disassembled following these steps:
 Turn off the cooling water circulation in the cooling unit.
 Disconnect the water pipes from the heat exchanger.
 Remove cable gland plates from the end of the side cover.

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Figure 7-5 Cable gland plates of the side cover

 Empty the heat exchanger.

 Disconnect the leakage water sensors from the cooling unit.

Figure 7-6 Leakage water sensor connections

 Remove side covers, top plate, and d-end cover

Page 72
Figure 7-7 Cover parts of the D-end

 Unscrew mounting screws, lift and remove the cooling unit.

Figure 7-8 Mounting screws of the cooling unit

 The cooling unit should be reinstalled following same steps backwards.

NOTE! If it is needed also half of top module is able to disassembly from the top
module.

Page 73
Chapter 8 Troubleshooting

This chapter is intended as a help in the event of an operational failure with an ABB
delivered machine. The troubleshooting charts given below can aid in locating and
repairing mechanical, electrical and thermal problems and problems associated with
the lubrication system. The checks and corrective actions mentioned should always be
conducted by qualified personnel. If in any doubt, the After Sales of ABB should be
contacted for more information or technical assistance regarding troubleshooting and
maintenance.

Page 74
8.1 Mechanical performance
Troubleshooting
Mechanical performance
Experienced
malfunction
Vibration

Noise

Possible cause Corrective action

Check lubricant quality and quantity and
x x Lubrication malfunction
lubrication system function
Check bearing condition and replace bearing
x x Damaged bearing parts
parts
Bearing malfunction
Faulty bearing
x x Check alignment
assembly
Imbalanced or
x x Faulty cooling fan(s) Check and repair cooling fan(s)
damaged fan(s)
x Malfunctioning cooling system Inspect and repair cooling system
x Malfunctioning excitation system Inspect and repair excitation system
x x Machine misalignment Check machine alignment
x x Rotor or shaft imbalance Rebalance rotor
Check rotor wedges, poles etcx, repair and
x x Loose parts in rotor
rebalance rotor
Check the balance of connected machinery and
x x Vibration coming from connected machinery
coupling type
x x Axial load coming from connected machinery Check alignment and coupling function and type
x x Faulty or incorrectly assembled coupling Check coupling function
x Insufficient foundation strength Reinforce foundation as per ABB instructions
x
Main machine or excitation machine winding Check main machine and excitation machine
fault windings
x x Excessive network unbalance Check that network balance fulfils requirements
Foreign material, moisture or dirt inside the
x Check and clean machine interior, dry windings
machine
x x Airgap not uniform Measure and adjust airgap

Page 75
 8.2 Sleeve bearings and lubrication system
Troubleshooting
Lubrication system and sleeve bearings
Experienced
malfunction
Bearing noise or vibration
High bearing temperature

Visibly poor oil quality

Oil inside the machine
Oil leaks

Possible cause Corrective action

Insufficient
x x x Insufficient amount of oil Check bearing for leakage, add oil
lubrication
x x x x Unsuitable oil quality Check ABB oil recommendations
Oil quality is Incorrect oil change
x x Clean bearing and change oil
reduced period
Excessive axial Faulty coupling or
x x x x Check coupling, mounting and alignment
load mounting
x x x Machine misalignment Realign machine
Verify correct bearing assemblage and
x x Incorrectly assembled bearing
adjustments
Clean bearing and add correct amount of
x x x Excessive amount of oil
lubricant
Change grease, check bearing condition,
x x x Oil impurities
replace bearing shells
Restore bearing insulation, replace bearing
x x Bearing currents
Damaged shells
x x bearings Complete bearing failure Replace bearing parts
x x Normal wearing Replace shells
Check the operating speed range of
x x Operating speed too low
bearing
x
Faulty Faulty temperature Check bearing temperature measurement
instrumentation detector system
x Damaged or worn-out bearing seals Replace or repair bearing seals
Rotating equipment Check pressure levels, relocate rotating
x External vacuum
nearby equipment
Internal over Pressure compensation
x x Remove cause for internal over pressure
pressure failure
x Damaged machine seal Replace or repair machine seal
x x Foreign matter inside the bearing Clean bearing and check seal condition
x
Faulty assembled or maintained lubrication Check hoses, connections and oil filter
hosing tightness

Page 76
 8.3 Rolling bearings and lubrication

Experienced
malfunction
Bearing noise or vibration
High bearing temperature

Lubrication leaks

Possible cause Corrective action

Insufficient Insufficient amount of
x x Check bearing condition, add grease
lubrication grease
x x x Unsuitable grease quality or viscosity Check ABB recommendations, change grease
Incorrect re-greasing
x x Check ABB recommendations, re-grease
Oil quality is period
reduced Check ABB operating and grease
x x Faulty operating conditions
recommendations
Excessive axial Faulty coupling or
x x Check coupling, mounting and alignment
load mounting
Verify correct bearing assemblage and
x x Incorrectly assembled bearing
adjustments
Clean bearing and add correct amount of
x x Excessive amount of grease
lubricant
x x Grease impurities Change grease, check bearing condition
Damaged bearings
x x Complete bearing failure Replace bearing parts
x x Normal wearing Replace worn bearing parts
x
Faulty Faulty temperature Check bearing temperature measurement
instrumentation detector system
x Damaged or worn-out bearing seals Replace or repair bearing seals
Clean bearing and check seal condition and
x Foreign matter inside the bearing
replace bearing

Page 77
 8.4 Thermal performance, water cooling system
Experienced
malfunction
High cooling air
High winding
temperature
temperature
x x
x x
x x
x x
x x
x x
x x
x Overload
x x
x Network unbalance
x x
x
Troubleshooting
Thermal performance, water cooling system
Possible cause
Coolant pipes are blocked
Faulty coolant pump
Low water Leaking cooler heading
cooler Air inside the cooler
performance Emergency cooling hatch
open
Faulty flow regulator
settings
Dirty machine interior
Low air flow Faulty cooling arrangement
Damaged cooling fan(s)
Cooling fan rotating in the wrong direction
Control system setting
Overspeed
Faulty instrumentation or measurement
system
Main machine or excitation machine
winding fault
Page 78
Corrective action
Open cooler and clean pipes
Check and repair the pump
Replace the cooler header
Bleed the cooler through bleeder screw
Close emergency cooling hatch quality
Check and adjust the coolant flow
Clean machine parts and air gaps
Inspect cooling arrangement condition and
correct assembly
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
 8.5 Thermal performance, direct cooling
Experienced
malfunction
High cooling air
High winding
temperature
temperature
X x
X x
X x
X x
X x
X Overload
X x
X Network unbalance
X x
X
Troubleshooting
Thermal performance, water cooling system
Possible cause Corrective action
Dirty machine interior Clean machine parts and air gaps
Dirty air filters Clean or change the air filters
Low air flow
Inspect cooling arrangement condition and
Faulty cooling arrangement
correct assembly
Damaged cooling fan(s) Replace fan(s)
Replace fan(s) or change rotating direction of
Cooling fan rotating in the wrong direction
external fan
Control system setting Check machine controls, eliminate overload
Check actual speed and ABB speed
Overspeed
recommendations
Check that network balance fulfils
requirements
Faulty instrumentation or measurement
Check measurements, sensors and wiring
system
Main machine or excitation machine Check main machine and excitation machine
winding fault windings
Page 79
 8.6 Electrical performance and excitation system of generators
Troubleshooting
Electrical performance and excitation system of generators with transformer excitation
Experienced
malfunction
Malfunction during start-up

Operation not adjustable

Faulty parallel operation
Performance deviation
Increase in excitation
Lost excitation

current

Possible Cause Corrective action

x x Abnormal speed Faulty speed control Check speed control of operating machine
x x Network phase unbalance Check that network balance fulfils requirements
x Speed variation of operating machine Check speed control of operating machine
Check excitation panel relay and
x x Faulty settings
voltage regulator setting
Field application
x x Faulty wiring Check excitation panel control cubicle and generator
failure
Demagnetised excitation See main connection diagram to restore
x x
magnet permanent magnet excitation
Check transformer winding insulation resistance and
x x x x Defective voltage transformer
connections
Check transformer winding insulation resistance and
x x x x x Defective parallel operation transformer
connections
Check transformer winding insulation resistance and
x x Defective current transformer
connections
x x Short circuit excitation system failure Check operation of short circuit excitation system
x Main generator winding fault Check main machine winding and insulation resistances
x x Excitation system winding fault Check exciter winding and insulation resistances
x x x x x Faulty rotating rectifier Check connection and condition of rectifier components
x x x x Faulty wiring in excitation system Check electrical connections in excitation system
Excitation
x x Excitation panel equipment Check and replace excitation panel equipment
equipment fault
x x x x x x Faulty AVR settings Check and adjust voltage regulator settings
Bad AVR tuning Voltage oscillation, poor
x Check AVR tuning (PID parameters)
parameters response
x x x x x x Defective AVR Check and replace voltage regulator
x x x x x x Faulty AVR wiring or incorrect connections Check AVR wiring and connections
x Power factor variation over permitted values Check AVR condition
x x x Faulty external voltage reference system Check connections and condition of voltage reference
Check actual value measurement system and electrical
x x No actual value information for AVR
connections

Page 80
Chapter 9 After sales and spare parts

9.1 After sales

The after sales support for rotating electrical machines manufactured by ABB.
9.1.1 Site services
The Site services department provides:
 Installation and commissioning
 Maintenance and inspections
 Trouble shooting and service
 Upgrading and modifications.
9.1.2 Spare parts
Co-ordinates spare parts packages delivered with the machine
Sells genuine spare parts after the machines has been delivered.
9.1.3 Warranties
The Warranties department handles warranty issues regarding the machines.
9.1.4 Support for service centers
The Service center support provides help for Service centers in questions concerning
the mechanical construction as well as in electromagnetic and insulation technology
issues.
9.1.5 After sales contact information
Contact the technical department by:
Phone 7:30 am - 5:30 pm +86 791 811 5180
(GMT+8)
Fax +86 791 811 2381
e-mail: aftersales.generator@cn.abb.com
9.2 Spare parts
9.2.1 General spare part considerations
The machines manufactured by ABB are designed and manufactured to provide
reliable and trouble free operation for decades. 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

Page 81
 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 expertise of the local maintenance personnel.
9.2.2 Periodic part replacement
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 will eventually wear out and
need to be replaced, even if correct greasing is maintained. Other wearing parts are
the seals that are in constant contact with the rotating shaft.
The parts mentioned above make an extensive, but not a 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.
9.2.3 Need of spare parts
Other types of wear occur due to elevated temperatures, electrical disturbances and
chemical reactions. The wear 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.
The electrical windings of the ABB machines have good protection against wear, 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.
9.2.4 Selection of the most suitable spare part package
ABB provides three levels 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.
Operational spare parts for commissioning and to ensure usability
These are the most essential spare parts that you should have always available.
Recommended 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.
Capital spare parts to reduce repair time in case of serious damage
These spare parts are recommended when the machine is a part of essential processes.
These spare parts enable fast recovery even in case of a serious damage.

Page 82
9.2.5 Typical recommended spare parts in different sets
Below is presented a general recommendation of the typical spare parts for different
packages. To receive a quotation for specific parts for a specific machine, please
contact the ABB After sales organization.
Please note that even though ABB has customized the spare part sets to match the
machine, they might contain references to accessories not found on all machines.

9.2.5.1 Operational spare parts package

Spare part Amount
Automatic voltage regulator (AVR) 1 pc
Rectifier diodes 6 pcs
Varistor 1 pc
PT-100 for cooling air 1 pc
Rolling bearings 1 set
Sleeve bearing shells 1 set
Bearing RTD 1 pc
Leakage water detector 1 pc

9.2.5.2 Recommended spare parts package

Safety package plus following spare parts:

Spare part Amount

Voltage transformer 1 pc
Anti-condensation heater 1 pc
Stator current meas. transformers 3 pcs
Actual value current transformer 1 pc

9.2.5.3 Capital spare parts package

Spare part Amount
Exciter rotor 1 pc
Exciter stator 1 pc
Rectifier bridge 1 pc
Rotor (complete) 1 pc
Stator with frame 1 pc
Water cooler element 1 pc
9.2.6 Order information
To ensure fast and correct spare part order and delivery, our After sales personnel
should be provided with the serial number of the machine in question. The serial
number can be found either on the rating plate fixed to the machine frame, or stamped
on the machine frame, and is also given in this manual.

Page 83
In addition, provide specific and detailed information about the parts ordered (in most
cases this information can be found in Annex 4, Accessory Information. The contact
information of ABB's After sales organization can be found in Chapter 9, After sales
and spare parts.

Page 84
 ANNEX 1 –

Technical specification
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 2010 ABB

TECHNICAL SPECIFICATION

Project name: SPP35B PSV

Our reference number: 1225CA101-148
Customer’s reference number:
Customer:
Final customer:
Application: Diesel/Gas engine
Type designation: AMG 0500SF04 DAA

NOTES

CONTENTS

SECTION:

1  PERFORMANCE DATA (Calculated values) 2 

2  CONFIGURATION AND SCOPE OF SUPPLY 4 

3  ACCESSORIES 6 

No. of sh.
Prep. Jerry-LiangLiang Zhu/CNGEN 21.9.2011 TECHNICAL SPECIFICATION
Appr. Linda-XuelanYuan/CNGEN 22.9.2011 6
Resp. dept. PT
Document identification Lang. Rev. ind. Sheet

ABB Generators Ltd. en B 1

TEMPLATE: TECHNICALSPECIFICATION.DOT; FILENAME: TECH SPEC FOR LSH_B.DOC; PRINTDATE: 9/22/2011 9:13:00 AM; SAVEDATE: 9/22/2011 9:13:00 AM
1 PERFORMANCE DATA (Calculated values)

TYPE
Type designation: AMG 0500SF04 DAA

RATINGS
Output: 1700 kVA Direction of rotation
Duty: S1 (Facing drive end): CCW
Voltage: 440 V Weight: 5650 kg
Current: 2231 A Inertia: 60 kgm^2
Power factor: 0.80 Protection by enclosure: IP23
Frequency: 60 Hz Cooling method: IC0A1
Speed: 1800 rpm Mounting arrangement: IM1101
Overspeed: 2160 rpm

STANDARDS
Applicable standard: IEC
Marine classification: Bureau Veritas
Hazardous area classification: None
Temperature rise stator / rotor: F/F
Insulation class: H

ENVIRONMENTAL CONDITIONS (max. values)

Ambient temperature: 45 °C Altitude: 1000 masl
Coolant temperature: °C

ASSUMED DATA
Driving equipment:
Appr. mec. power: 1430 KW

EFFICIENCY in %
load: 110 % 100 % 75 % 50 % 25 %
Efficiency @ power factor 0.80 95.08 95.17 95.17 94.55 91.56
Efficiency @ power factor 1.00 96.24 96.29 96.28 95.77 93.30

REACTANCES in %
XD (U): 285.4 XD’ (S): 19.8 XQ’’ (S): 18.5 X0 (U): 8.1
XQ (U): 121.2 XD’’ (S): 15.6 X2 (S): 17.1 XP (S): 16.3
X1 (U): 11.5 (S) = Saturated value, (U) = Unsaturated value

TIME CONSTANTS (SEC.) AT 75 °C

TD0’: 4.644 TD’: 0.354 TQ0’’: 0.0838 TA: 0.035
TD0’’: 0.00497 TD’’: 0.00369 TQ’’: 0.0140

Document identification Lang. Rev. ind. Sheet

ABB Generators Ltd. en B 2

TEMPLATE: TECHNICALSPECIFICATION.DOT; FILENAME: TECH SPEC FOR LSH_B.DOC; PRINTDATE: 9/22/2011 9:13:00 AM; SAVEDATE: 9/22/2011 9:13:00 AM
 RESISTANCES AT 20 °C
Stator winding: 0.0013  Field winding: 0.9451 
Excitation winding: 11.8 

SHORT CIRCUIT
Short circuit ratio: 0.40
Sustained short circuit current: 1.4 p.u. (rated excitation)
> 3.0 p.u. (voltage regulator)
Sudden short circuit current: 14250 A (symmetric RMS)
36300 A (peak value)

VOLTAGE VARIATION
Voltage drop at sudden increase of rated load: <15 %
Voltage rise at sudden drop of rated load: <20 %

REACTIVE LOADING
Steady state reactive loading at rated excitation: 1500 KVAR (lagging)
Steady state reactive loading at zero excitation: 400 KVAR (leading)

TORQUE
Rated load torque (Calculated of rated output in kVA): 9000 Nm
The peak values of sudden short circuit air gap torques:
2-phase short circuit: 745 % 3-phase short circuit: 520 %

BEARINGS
D-end: Rolling, w/ grease, locked N.D-end: Rolling, w/ grease, free
Lubrication system:
Inclination
Fore-Aft static: 10 Degrees Fore-Aft dynamic: 15 degrees
Athwards static: 15 Degrees Athwards dynamic: 22.5 degrees

TERMINAL CONNECTIONS (Defined facing drive end)

Direction of main connection: According to drawing 5862313-main dimension.

EXCITATION
Exciter field
No load: A V
Rated load: A V

OTHER
Stored energy constant (rotative energy divided by rated effect): 0.58 s
Earth capacitance (1-phase): 0.03 µF

Document identification Lang. Rev. ind. Sheet

ABB Generators Ltd. en B 3

TEMPLATE: TECHNICALSPECIFICATION.DOT; FILENAME: TECH SPEC FOR LSH_B.DOC; PRINTDATE: 9/22/2011 9:13:00 AM; SAVEDATE: 9/22/2011 9:13:00 AM
2 CONFIGURATION AND SCOPE OF SUPPLY

GENERAL
The generator is designed to operate together with a diesel or gas 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 ensure uniform and effective cooling of the
stator.

The rotor consists of a shaft and star shaped, laminated polestructure, exciter and a fan(s).
The shaft is machined of steel forging. The polestructure is manufactured of 2 mm sheet steel
and is shrink fitted onto 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 end-shields 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 end-shields.

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 the Factory.
Compliance with the maximum vibration level of the genset to be verified by the genset
manufacturer who is responsible for the full compatibility of all components of the genset
according to ISO 8528-5:1993,15.10.

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
Brushless excitation. The excitation system includes following components: Automatic Voltage
Regulator, Basler DECS100,current transformers for actual value measurement, parallel
operation and differential protection, voltage transformer for measurement and auxiliary
winding for power supply. Permanent Magnet Insertion(PMI) in the exciter stator ensures
voltage build up.

TESTING

Document identification Lang. Rev. ind. Sheet

ABB Generators Ltd. en B 4

TEMPLATE: TECHNICALSPECIFICATION.DOT; FILENAME: TECH SPEC FOR LSH_B.DOC; PRINTDATE: 9/22/2011 9:13:00 AM; SAVEDATE: 9/22/2011 9:13:00 AM
 Testing is according to IEC and ABB internal requirements. The test may be observed by the
customer without extra charges. The test procedures are described in the following documents
which are available on request:
- Routine tests: MDD 8006327 (for all machines)
- Type tests: MDD 8006328 (Optional, to be agreed separately).
- Special tests: MDD 8006329 (Optional, to be agreed separately)
Compliance with the voltage drop requirements to be verified by the client (depends on the
size of electrical motors to be started).
Compliance with the max harmonic distortion requirements to be verified by the client
(depends on the actual operating conditions, e.g. the amount and type of frequency converters
in the system).

SURFACE TREATMENT
Colour: Caterpillar yellow Grade: C3
Surface treatment C3 according to the ISO 12944 standard, for standard industrial
environment

DOCUMENTATION
User's Manual in electronic format. Documentation language is English.
Also provide with 6pcs/vessel

DOCUMENTATION
BV GENERATOR CERTIFICATE (1 original+4 copies) should be supplied.

Document identification Lang. Rev. ind. Sheet

ABB Generators Ltd. en B 5

TEMPLATE: TECHNICALSPECIFICATION.DOT; FILENAME: TECH SPEC FOR LSH_B.DOC; PRINTDATE: 9/22/2011 9:13:00 AM; SAVEDATE: 9/22/2011 9:13:00 AM
3 ACCESSORIES

No pc/pcs Item
6 PT100 for stator winding

1 PT100 for cold cooling air

1 PT100 for warm cooling air

Including an extension part for the PT100 element mounting

2 PT100 element for antifriction bearing

1 / bearing

1 Automatic Voltage Regulator system

Basler DECS-100,mounted in the switchboard

1 1PT - Voltage transformer for actual value measurement

690-450-400 / 220V, 50-60Hz
20 VA, CL0.5

1 2CT - Current transformer for actual value measurement

2500/1A, 5VA, CL0.5, 50/60Hz

6 4CT - Current transformer for differential protection

2500/1A, 5VA, 5P25, 50/60Hz
3pcs mounted in generator
3pcs mounted in MSB

1 Sinter plugs for frame bottom holes

1 Anticondensation heater
Voltage 230 VAC, power 500 W

1 Auxiliary terminal box B3A

1 Multidiameter cable entry seals (Rox System) for main cables

(Roxtec assembly & Roxframe)

1 Cable glands for auxiliary terminal boxes

Undrilled plates

1 Main terminal space B1, integrated

Main and neutral terminals integrated into top enclosure of the machine

1 Special cable design: Halogen free cable

1 Internal protective varnish

Stator and rotor varnish (insulating varnish)

1 Voltage adjust switch

Document identification Lang. Rev. ind. Sheet

ABB Generators Ltd. en B 6

TEMPLATE: TECHNICALSPECIFICATION.DOT; FILENAME: TECH SPEC FOR LSH_B.DOC; PRINTDATE: 9/22/2011 9:13:00 AM; SAVEDATE: 9/22/2011 9:13:00 AM
 ANNEX 2 –

Mechanical Drawings
 Document kind Document identity Revision

Technical description 3AFP5808646 A

Owner organization Document type Date of revision (yyyy-mm-dd) Status Page(s)

Motors and Generators Cross section 2011-01-31 Valid 1(1)

Division/Department Prepared by Approved by Security level

DM/PTS Janne Kamppuri Ari Saarinen External

Cross section: AMG ____ DA_

1) Shaft
2) Rotor core
3) Exciter and rotating rectifier
4) Radial fan
5) Bearing (N-end)
6) Bearing (D-end)
7) Stator core
8) Terminal space

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 2011 ABB.
 Document kind Document identity Revision

Technical description 3AFP5806251 B

Owner organization Document type Date of revision (yyyy-mm-dd) Status Page(s)

Motors and Generators Machine description 2011-04-13 Ready 1(1)

Department Prepared by Approved by Security level

PGD Tuominen Asta Kamppuri Janne External

AMG 0500 – Antifriction bearing assembly

Revision history
Rev. Date Prepared by Division/ Description
(yyyy-mm-dd) Department
A 2010-04-19 ASTU PTS100 Original version
B 2011-04-13 A.Tuominen DMMG/PGD N-end bearing changed and header text updated.

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 2011 ABB.
 ANNEX 3 –

Electrical Drawings
 ANNEX 4 –

Accessory Information
 INSTRUCTION MANUAL
FOR
DIGITAL EXCITATION CONTROL SYSTEM
DECS-100

Publication: 9287500991
Revision: F 05/05
 INTRODUCTION
This instruction manual provides information about the operation and installation of the DECS-100 Digital
Excitation Control System. To accomplish this, the following information is provided:

• General Information and Specifications

• Controls and Indicators
• Functional Description
• Installation
• Maintenance and Troubleshooting

WARNING!
To avoid personal injury or equipment damage, only qualified personnel should
perform the procedures in this manual.
Lethal voltage is present at the rear panel when the unit is energized. Rear panel
connections should be made only when the unit id de-energized.

CAUTION
The Manual mode excitation level must be evaluated prior to enabling this
feature. If the level of excitation current is inappropriate for the generator, severe
damage to the generator may occur.
Improper PID numbers will result in poor system performance or system damage.
When applying operating power for programming purposes, observe the
precautions called out in Section 4, Installation, Preliminary Setup.
When programming the DECS-100 without the generator spinning, the
connections to DECS-100 terminals F+ and F– should be removed.
Before uploading a settings file, remove operating power from the DECS-100,
disconnect the field wiring from terminals F+ and F–, and re-apply operating
power to the DECS-100.

NOTE
Be sure that the relay is hard-wired to earth ground with no smaller than 12 AWG
copper wire attached to the ground terminal on the rear of the unit case. When
the relay is configured in a system with other devices, it is recommended to use a
separate lead to the ground bus from each unit.

DECS-100 Introduction i
 First Printing: March 2001

Printed in USA

© 2001–2005 Basler Electric, Highland Illinois 62249 USA

All Rights Reserved

May 2005

CONFIDENTIAL INFORMATION
of Basler Electric, Highland Illinois, USA. It is loaned for confidential use, subject
to return on request, and with the mutual understanding that it will not be used in
any manner detrimental to the interest of Basler Electric.

It is not the intention of this manual to cover all details and variations in equipment, nor does this manual
provide data for every possible contingency regarding installation or operation. The availability and design
of all features and options are subject to modification without notice. Should further information be
required, contact Basler Electric.

BASLER ELECTRIC
ROUTE 143, BOX 269
HIGHLAND IL 62249 USA
http://www.basler.com, info@basler.com
PHONE +1 618.654.2341 FAX +1 618.654.2351
ii Introduction DECS-100
 REVISION HISTORY
The following information provides a historical summary of the changes made to the DECS-100 hardware,
firmware, and software. The corresponding revisions made to this instruction manual (9287500991) are
also summarized. Revisions are listed in chronological order.

Hardware
Version and Date Change
E, 01/01 • Initial release
F, 05/01 • Deepened potting shell
G, 10/01 • Began supplying mounting screws
H, 02/02 • SIL-PADS were added between power components and the heat sinks
• Added manufacturing origin to the rear label
J, 07/02 • Revised EEPROM
K, 02/03 • Replaced transistor Q8B1 with an improved part
L, 03/03 • Incremental improvements to firmware and BESTCOMS
M, 01/04 • Improved flash memory retention
N, 05/05 • Redesigned current transformer
• Added front panel Underexcitation Limiting indicator
• Enhanced EMI/RFI immunity

Firmware
Version and Date Change
1.09.XX, 01/01 • Initial release
1.11.XX, 07/01 • Enabled the protection function during the first 5 seconds of operation
• Modified the OEL setpoint scale factor to be compatible with BESTCOMS
version 1.03.XX
• Added the scale factor for per-unit gain
• Established minimum voltage regulation at 30% of nominal sensing voltage
1.12.XX, 03/02 • Added register to detect CT type
2.13.XX, 05/05 • Added underexcitation limiting
• Added takeover-style excitation limiting
• Added bus voltage matching provisions

BESTCOMS for
®
Windows OS
Version and Date Change
1.02.XX, 02/01 • Initial Release
1.03.XX, 08/01 • Changed OEL scale from 100 to 1,000 to match the change in firmware
version 1.11.01
• Changed OEL default setting from 1 to 15
• Changed the default for all protection functions to enabled
• Add support for French regional settings
1.04.XX, 04/02 • Made BESTCOMS compatible with older firmware versions
• Added support for all regional settings
• Enabled reading of secondary CT value for units with firmware version
1.12.01 and higher
• Simplified the Analysis screen
• Added feature to calculate and send voltage matching reference for
different generator and bus PT ratios
• Changed minimum Ki setpoint from 0 to 0.01
1.05.XX, 05/05 • Added underexcitation limiting capability
• Added ability to select either summing point or takeover style OEL
• Added provisions for bus voltage matching

DECS-100 Introduction iii

 BESTCOMS for
®
Palm OS
Version and Date Change
1.01.XX, 01/01 • Initial Release
1.02.XX, 08/01 • Added a Check for New Version button to the Contact Basler screen
• Added a date/time stamp to the “Save to File” names
• Added version checking
1.03.XX, 04/02 • Added password protection
• Improved version checking function
NOTE • BESTCOMS for Palm OS is compatible only with firmware versions
1.12.XX and earlier

Manual
Revision and Date Change
—, 03/01 • Initial release
A, 03/01 • In Section 5, BESTCOMS Software for the Windows® Operating System
and Section 6, BESTCOMS Software for the Palm OS® Platform, Step 2 of
Installing BESTCOMS was revised to reflect the addition of an auto-start
utility for the DECS-100 CD-ROM
B, 08/01 • Added Embedded Software subsection to Section 5, BESTCOMS Software
for the Windows® Operating System
• Corrected various minor errors throughout manual
C, 05/02 • Revised the torque specification for the mounting screws supplied with unit
• In Section 5, BESTCOMS Software for the Windows® Operating System
and Section 6, BESTCOMS Software for the Palm® OS Platform, text and
illustrations were revised to accommodate software enhancements
D, 01/03 • Revised Voltage Matching Time Adjustment Range from 0 to 300 seconds
to 1 to 300 seconds throughout manual
• Corrected figure number references in Sections 5 and 6
E, 03/04 • Added Operating Power Considerations During DECS-100 Programming to
Section 4, Installation, Preliminary Setup
• Added caution box regarding application of operating power during DECS-
100 programming to Section 5, BESTCOMS for Windows® OS and
Section 6, BESTCOMS for Palm OS®
• Corrected CT ratio setting range stated in Section 5
F, 05/05 • Added material covering added UEL capability
• Revised all drawings to show new front panel with UEL indicator
• Updated all illustrations of rear panel to show revised CT
• Added discussion of summing point and takeover style OEL limiting
• Revised voltage matching description to cover Maintain and Revert modes
• Corrected the hole drilling diameter shown in Figure 4-2
• Added illustration/description for using the ICRM-7 with the DECS-100
• Removed Section 6, BESTCOMS Software for the Palm® OS Platform and
moved Maintenance and Troubleshooting to Section 6
• Added troubleshooting procedure for a UEL annunciation

iv Introduction DECS-100
 CONTENTS
A detailed table of contents is provided at the start of each manual section. The manual sections are
ordered as follows.

Section 1 General Information................................................................................................... 1-1

Section 2 Human-Machine Interface ......................................................................................... 2-1
Section 3 Functional Description............................................................................................... 3-1
Section 4 Installation ................................................................................................................. 4-1
Section 5 BESTCOMS Software ............................................................................................... 5-1
Section 6 Maintenance and Troubleshooting ............................................................................ 6-1

DECS-100 Introduction v
 This page intentionally left blank.

vi Introduction DECS-100
SECTION 1 • GENERAL INFORMATION
TABLE OF CONTENTS
SECTION 1 • GENERAL INFORMATION................................................................................................. 1-1
INTRODUCTION .................................................................................................................................... 1-1
FEATURES ............................................................................................................................................ 1-1
MODEL AND STYLE NUMBER ............................................................................................................. 1-1
Style Number ...................................................................................................................................... 1-1
SPECIFICATIONS ................................................................................................................................. 1-2
Operating Power................................................................................................................................. 1-2
Generator Voltage Sensing ................................................................................................................ 1-2
Generator Current Sensing................................................................................................................. 1-2
Bus Voltage Sensing (Optional) ......................................................................................................... 1-2
Accessory Input .................................................................................................................................. 1-3
Communication Port ........................................................................................................................... 1-3
Contact Input Circuits ......................................................................................................................... 1-3
Common Alarm Output ....................................................................................................................... 1-3
Field Output ........................................................................................................................................ 1-3
AVR Operating Mode.......................................................................................................................... 1-3
FCR (Manual) Operating Mode .......................................................................................................... 1-4
Var Operating Mode (Optional) .......................................................................................................... 1-4
PF Operating Mode (Optional) ........................................................................................................... 1-4
Parallel Compensation........................................................................................................................ 1-4
Field Overvoltage Protection .............................................................................................................. 1-4
Generator Overvoltage Protection...................................................................................................... 1-4
Overexcitation Limiter ......................................................................................................................... 1-5
Underexcitation Limiter ....................................................................................................................... 1-5
Soft Start Function (AVR Mode Only)................................................................................................. 1-5
Voltage Matching ................................................................................................................................ 1-5
Metering (BESTCOMS) ...................................................................................................................... 1-5
Environment........................................................................................................................................ 1-6
Type Tests .......................................................................................................................................... 1-6
Physical............................................................................................................................................... 1-6
Agency Recognition............................................................................................................................ 1-6
CE Compliance................................................................................................................................... 1-6
Patent.................................................................................................................................................. 1-7

Figures
Figure 1-1. DECS-100 Style Chart.............................................................................................................1-2
Figure 1-2. Typical V/Hz Curves ................................................................................................................1-4

DECS-100 General Information i

 This page intentionally left blank.

ii General Information DECS-100

SECTION 1 • GENERAL INFORMATION
INTRODUCTION
The Basler Digital Excitation Control System (DECS-100) is an electronic, solid-state, microprocessor
based control device. The DECS-100 regulates the output voltage of a brushless, ac generator by
controlling the current into the generator exciter field. Input power to the DECS-100 can be from a multi-
pole, high-frequency, permanent magnet generator (PMG) or from the generator output when used as a
conventional, shunt-excited, excitation system.
The DECS-100 is supplied in an encapsulated package designed for behind-the-panel mounting. The
DECS-100 is held in place by thread-forming screws that thread into its plastic shell. Front panel
indicators (LEDs) annunciate DECS-100 status and system conditions. DECS-100 connections are made
through quarter-inch, quick-connect terminals on the rear panel. A 9-pin DB-9 type connector on the rear
panel provides communication between the DECS-100 and an IBM compatible PC.

FEATURES
DECS-100 units have the following features and capabilities:
• Four control modes: automatic voltage regulation (AVR), manual or field current regulation (FCR),
power factor (PF) regulation, and reactive power (var) regulation.
• Programmable stability settings.
• Soft start and voltage buildup control with an adjustable ramp in AVR control mode.
• Overexcitation limiting (OEL) and underexcitation limiting (UEL) in AVR, Var, and PF control modes.
• Underfrequency (volts/hertz) regulation.
• Three-phase or single-phase generator voltage (rms) sensing/regulation in AVR mode.
• Single-phase bus voltage (rms) sensing.
• Single-phase generator current sensing for metering and regulation purposes.
• Field current and field voltage sensing.
• One analog input for proportional remote control of the setpoint.
• Five contact sensing inputs for system interface.
• One common output relay for alarm indication and trip functions.
• Three protection functions: field overvoltage, generator overvoltage, and loss of sensing.
• Generator paralleling with reactive droop compensation and reactive differential compensation.
• Rear RS-232 communication port for personal computer communication using BESTCOMS
Windows® based software for fast, user-friendly, setup and control.

MODEL AND STYLE NUMBER

The model number, together with the style number, describe the options included in a specific device, and
appear on a label affixed to the rear panel. Upon receipt of a DECS-100, be sure to check the style
number against the requisition and the packing list to ensure that they agree.

Style Number
DECS-100 electrical characteristics and operational features are defined by a combination of letters and
numbers that make up the style number. The DECS-100 style number chart is shown in Figure 1-1.
Style Number Example
For example, a DECS-100 with a style number of A15 would have the following characteristics and
operating features.
A ------- No var or power factor control
1-------- Voltage matching
5-------- 5 ampere current sensing

DECS-100 General Information 1-1

 Figure 1-1. DECS-100 Style Chart

SPECIFICATIONS
DECS-100 specifications and qualifications are listed in the following paragraphs.

Operating Power
Refer to Section 4, Installation for special requirements concerning the application of operating power
during DECS-100 programming and the application of station power.
Voltage: 88 to 250 Vac, single-phase or three-phase (L-L)
Frequency: 50 to 400 Hz
Burden: 650 VA
Voltage Buildup: ≥6 Vac
Terminals: 3, 4, 5

Generator Voltage Sensing

Type: 1-Phase/3-Phase, 4 ranges
Burden: <1 VA per phase
Terminals: E1, E2, E3
50 Hertz Sensing
Range 1: 100 Vac (85 to 132 Vac)
Range 2: 200 Vac (190 to 220 Vac)
Range 3: 400 Vac (380 to 440 Vac)
Range 4: N/A
60 Hertz Sensing
Range 1: 120 Vac (85 to 132 Vac)
Range 2: 240 Vac (170 to 264 Vac)
Range 3: 480 Vac (340 to 528 Vac)
Range 4: 600 Vac (540 to 660 Vac)

Generator Current Sensing

Type: 1-phase (B-phase), 50/60 Hz
Style XX1: 1 Aac maximum continuous
Style XX5: 5 Aac maximum continuous
Burden: <0.1 VA
Terminals: CT1, CT2

Bus Voltage Sensing (Optional)

Type: 1-phase, 4 ranges
Burden: <1 VA per phase
Terminals: B1, B3
50 Hertz Sensing
Range 1: 100 Vac (85 to 132 Vac)
Range 2: 200 Vac (190 to 220 Vac)
1-2 General Information DECS-100
Range 3: 400 Vac (380 to 440 Vac)
Range 4: N/A
60 Hertz Sensing
Range 1: 120 Vac (85 to 132 Vac)
Range 2: 240 Vac (170 to 264 Vac)
Range 3: 480 Vac (340 to 528 Vac)
Range 4: 600 Vac (540 to 660 Vac)

Accessory Input
Voltage Range: –3 Vdc to +3 Vdc
Setpoint Range: –30% to +30% shift
Burden: 1 kΩ
Terminals: A, B

Communication Port
Interface: Full duplex RS-232
Connection: Rear panel DB-9 connector
Baud: 4800
Data Bits: 8
Parity: None
Stop Bit: 1

Contact Input Circuits

Type: Dry contacts
Interrogation Voltage: 13 Vdc (supplied by DECS-100)
Terminal Assignments for Standard Functions
Raise: 6U, 7
Lower: 6D, 7
Var/PF Enable: 52J, 52K
Parallel Control: 52L, 52M
Voltage Matching: VM, VMC

Common Alarm Output

Type: Form A
Rated Load: 7 Aac/Adc continuous
Make: 30 Aac/Adc, carry for 0.2 sec
Break: 7 Aac/0.1 Adc
Operating Voltage: 240 Vac/250 Vdc maximum
Terminals: AL1, AL2

Field Output
Continuous Rating: 63 Vdc, 7 Adc
Field Resistance: 5 Ω minimum
Terminals: F+, F–
10 Second Forcing Rating
200 Vac Power Input: 135 Vdc, 15 Adc
110 Vac Power Input: 90 Vdc, 10 Adc (9Ω field)
75 Vdc, 15 Adc (5Ω field)

AVR Operating Mode

Adjustment Range:
Voltage Regulation:
Temperature Drift:
DECS-100
See Generator Voltage Sensing
±0.25% over load range at rated power factor and constant generator
frequency.
±0.5% with 3-phase sensing and shunt power at 40% THD of the voltage
waveform (due to a six SCR load).
±0.5% for a 40°C change
General Information 1-3
V/Hz Characteristic: Slope from 0 to 3PU is adjustable in 0.01PU increments. Transition
(Corner) frequency is adjustable from 40 to 65 Hz. See Figure 1-2 for the
V/Hz curves.
Response Time: Within 1 cycle

Figure 1-2. Typical V/Hz Curves

FCR (Manual) Operating Mode

Adjustment Range: 0 to 7 Adc
Increment: 0.1 Adc

Var Operating Mode (Optional)

Adjustment Range: –100 to 100%
Increment: 0.1%

PF Operating Mode (Optional)

Adjustment Range: 0.6 lag to 0.6 lead
Increment: 0.001

Parallel Compensation
Modes: Reactive Droop and Reactive Differential (cross-current)∗
Droop Adjust Range: 0 to 10%
Increment: 1%
∗ Burden can exceed 1 VA if external resistors are added to the CT circuit.

Field Overvoltage Protection

Pickup Range: 0 to 250 Vdc
Time Delay: 10 s (fixed)

Generator Overvoltage Protection

Pickup
Range: 100 to 120% of system voltage setting
Increment: 1.0%

1-4 General Information DECS-100

Alarm Time Delay
Range: 0 to 10 s
Increment: 1s

Overexcitation Limiter
Pickup
Range: 0 to 15 Adc
Increment: 0.001 Adc
Alarm Time Delay
Range: 0 to 10 s
Increment: 1s

Underexcitation Limiter
Pickup
Range: 0 to 100% of rated vars
Increment: 1%
Alarm Time Delay
Range: 0 to 10 s
Increment: 1s

Soft Start Function (AVR Mode Only)

Time Adjust Range: 1 to 7,200 s
Increment: 1s

Voltage Matching
Accuracy: Generator rms voltage is matched with the bus rms voltage to within
±0.5% of the generator voltage.
Time Adjustment
Range: 1 to 300 s
Increment: 0.01 s

Metering (BESTCOMS)
Generator Voltage
Range: 10 V to 79 kV
Accuracy: ±0.5% (at 25°C)
Generator Current
Range: 0.04 to 3,000 Aac for 1 A CT (Not to exceed nominal CT rating)
0.2 to 15,000 Aac for5 A CT (Not to exceed nominal CT rating)
Accuracy: ±0.5% (at 25°C)
Frequency
Range: 40 to 65 Hz
Accuracy: ±0.2 Hz (at 25°C)
Field Voltage
Range: 0 to 200 Vdc
Accuracy: ±5.0% (at 25°C)
Field Current
Range: 0 to 20 A
Accuracy: ±0.5% (at 25°C)
Bus Voltage
Range: 10 V to 79 kV
Accuracy: ±0.5% (at 25°C)
DECS-100 General Information 1-5
Auxiliary DC Input
Range: –3 V to +3 V
Accuracy: ±0.5% (at 25°C)
Power (Apparent, Real, and Reactive)
Range: 0 to 99 MVA, MW, Mvar
Accuracy: ±3.0% (at 25°C)
Power Factor
Range: –1.0 to –0.6, +0.6 to +1.0
Accuracy: ±0.02 at rated current (25°C), CT input ≥10% nominal rating
Phase Angle
Range: 0 to 360 degrees
Accuracy: ±2.0 degrees (at 25°C), CT input ≥10% nominal rating

Environment
Operating Temperature
DECS-100: –40 to 70°C (–40 to 158°F)
Storage Temperature
DECS-100: –40 to 85°C (–40 to 185°F)
CD-ROM: 0 to 50°C (32 to 122°F)

Type Tests
Shock: Withstands 20 G in three perpendicular planes
Vibration: Withstands 1.2 G at 5 to 26 Hz
Withstands 0.914 mm (0.036 in) double amplitude at 27 to 52 Hz
Withstands 5 G at 53 to 500 Hz
Salt Fog: Qualified per MIL-STD-810E

Physical
Weight
Unit: 1.10 kg (2.42 lb)
Shipping: 1.31 kg (2.88 lb)
Shipping Carton Dimensions (W x H x D)
Single Unit: 299 x 79 x 146 mm (11.75 x 3.125 x 5.75 in)
48 Units: 841 x 653 x 352 mm (33.13 x 25.69 x 13.88 in)

Agency Recognition
cURus recognition per UL Standard 508 and CSA Standard C22.2 No. 14
Certified per DNV Standard 2.4

CE Compliance
Emissions
CISPR11/EN55011, Level A
Electrostatic Discharge (ESD)
IEC 1000-4-2/EN 61000-4-2, Level B
Radiated Susceptibility
IEC 1000-4-3/EN 61000-4-3, Level A
Electrical Fast Transient
IEC 1000-4-4/EN 61000-4-4, Level B
Radio Frequency–Conducted
IEC 1000-4-6/EN 61000-4-6, Level A
1-6 General Information DECS-100
Power Frequency–Magnetic
IEC 1000-4-8/EN 61000-4-8, Level A
Dielectric
IEC 255
Surge Immunity
IEC 1000-4-5/EN 61000-4-5, Level B
Voltage Dips, Interruptions, and Variations Immunity
IEC 1000-4-11/EN 61000-4-11, Level C

Patent
U.S. Patent Number 5294879

DECS-100 General Information 1-7

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1-8 General Information DECS-100

SECTION 2 • HUMAN-MACHINE INTERFACE
TABLE OF CONTENTS
SECTION 2 • HUMAN-MACHINE INTERFACE........................................................................................ 2-1
INTRODUCTION .................................................................................................................................... 2-1
FRONT PANEL INDICATORS ............................................................................................................... 2-1
Overexcitation Shutdown.................................................................................................................... 2-1
Generator Overvoltage ....................................................................................................................... 2-1
Loss of Generator Sensing ................................................................................................................. 2-1
Overexcitation Limiting ....................................................................................................................... 2-2
Underexcitation Limiting ..................................................................................................................... 2-2
Var/P.F. Mode Active.......................................................................................................................... 2-2
Manual Mode Active ........................................................................................................................... 2-2
Underfrequency Active ....................................................................................................................... 2-2
COMMUNICATION PORT ..................................................................................................................... 2-2

Figures
Figure 2-1. DECS-100 Front Panel Indicators ...........................................................................................2-1
Figure 2-2. DECS-100 Communication Port Location ............................................................................... 2-2

DECS-100 Human-Machine Interface i

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ii Human-Machine Interface DECS-100

SECTION 2 • HUMAN-MACHINE INTERFACE
INTRODUCTION
The DECS-100 human-machine interface (HMI) consists of front panel indicators and a rear-panel
communication port.

FRONT PANEL INDICATORS

DECS-100 front panel indicators consist of eight red LEDs. The indicators are shown in Figure 2-1 and
described in the following paragraphs.

Figure 2-1. DECS-100 Front Panel Indicators

Overexcitation Shutdown
This LED lights when the Overexcitation Protection feature is enabled and the field voltage exceeds the
adjustable setpoint for 10 seconds. The DECS-100 will shutdown when an overexcitation condition is
detected. The Overexcitation Shutdown LED will light for 5 seconds when the DECS-100 is powered up
following an overexcitation shutdown.

Generator Overvoltage
This LED lights when generator output voltage exceeds the adjustable setpoint for 0.75 seconds. When a
generator overvoltage condition exists, the DECS-100 output contacts close and the DECS-100 shuts
down (if hardware shutdown is enabled). The Generator Overvoltage LED will light for 5 seconds when
the DECS-100 is powered up following a generator overvoltage shutdown.

Loss of Generator Sensing

This LED lights when a loss of generator sensing voltage is detected. When a loss of sensing condition
occurs, the DECS-100 output contacts close. Depending on the protective action selected, the DECS-100
will either shutdown or transfer to Manual mode. The Loss of Generator Sensing LED will flash for 5
seconds when the DECS-100 is powered up following a loss of generator sensing shutdown.

DECS-100 Human-Machine Interface 2-1

Overexcitation Limiting
This LED lights when the field current exceeds the programmed overexcitation limit. It stays lit until the
overexcitation condition ceases or the overexcitation time delay expires and the DECS-100 shuts down.
The Overexcitation Limiting LED will flash for 5 seconds when the DECS-100 is powered up following an
overexcitation limiting shutdown.

Underexcitation Limiting
This LED lights when the sensed, reactive power (leading vars) decreases below the programmed
underexcitation limit. It stays lit until the underexcitation condition ceases or the underexcitation time
delay expires and the DECS-100 shuts down. The Underexcitation Limiting LED will flash for 5 seconds
when the DECS-100 is powered up following an underexcitation limiting shutdown.

Var/P.F. Mode Active

This LED lights to indicate that the DECS-100 is operating in the optional Var or Power Factor mode of
control. Var/Power Factor control is enabled through BESTCOMS software and when the 52J/K contact
input is open.

Manual Mode Active

This LED lights when the DECS-100 is operating in Manual mode. Manual mode is enabled through
BESTCOMS software.

Underfrequency Active
This LED lights when the generator frequency decreases below the underfrequency setpoint and the
DECS-100 is regulating on the selected volts per hertz curve.

COMMUNICATION PORT
The communication port is located on the rear panel and
consists of a female, RS-232 (DECS-B-9) connector. The
communication port serves as an interface for programming
(setup) of the DECS-100. Figure 2-2 illustrates the location of
the communication port.
Programming requires a standard, nine-pin, serial
communication cable connected between the DECS-100 and
an IBM-compatible PC operating with BESTCOMS software.
BESTCOMS software is a Microsoft Windows®-based
communication software package that is supplied with the
DECS-100. A detailed description of BESTCOMS is provided
in Section 5, BESTCOMS Software.

WARNING!
Lethal voltage is present at the rear panel when the unit is
energized. Rear panel connections should be made only
when the unit is de-energized.

Figure 2-2. DECS-100

Communication Port Location

2-2 Human-Machine Interface DECS-100

SECTION 3 • FUNCTIONAL DESCRIPTION
TABLE OF CONTENTS
SECTION 3 • FUNCTIONAL DESCRIPTION............................................................................................ 3-1
INTRODUCTION .................................................................................................................................... 3-1
DECS-100 FUNCTION BLOCKS ........................................................................................................... 3-1
Analog Input Circuits........................................................................................................................... 3-1
Bus Voltage ..................................................................................................................................... 3-1
Generator Voltage........................................................................................................................... 3-1
B-Phase Line Current...................................................................................................................... 3-2
Accessory Input (Auxiliary Adjust) .................................................................................................. 3-2
Field Voltage ................................................................................................................................... 3-2
Field Current ................................................................................................................................... 3-2
Contact Input Circuits ......................................................................................................................... 3-2
Raise ............................................................................................................................................... 3-2
Lower............................................................................................................................................... 3-2
Var/Power Factor Control (52J/K) Option ....................................................................................... 3-2
Parallel Generator Compensation (52L/M) ..................................................................................... 3-2
Voltage Matching Control Option .................................................................................................... 3-3
RS-232 Communication Port.............................................................................................................. 3-3
Microprocessor ................................................................................................................................... 3-3
Power Input Stage .............................................................................................................................. 3-3
Power Supply...................................................................................................................................... 3-3
Power Amplifier Stage ........................................................................................................................ 3-3
Front Panel Indicators......................................................................................................................... 3-3
Relay Output ....................................................................................................................................... 3-3
DECS-100 OPERATING FEATURES.................................................................................................... 3-3
Operating Modes ................................................................................................................................ 3-3
Automatic Voltage Regulation Mode............................................................................................... 3-3
Manual Mode .................................................................................................................................. 3-4
Var Control Mode (Optional) ........................................................................................................... 3-4
Power Factor Control Mode (Optional) ........................................................................................... 3-4
Reactive Droop Compensation........................................................................................................... 3-4
Underfrequency .................................................................................................................................. 3-4
Protection............................................................................................................................................ 3-5
Generator Overvoltage.................................................................................................................... 3-5
Loss of Sensing Voltage ................................................................................................................. 3-5
Field Overvoltage (Overexcitation Shutdown) ................................................................................ 3-5
Limiters ............................................................................................................................................... 3-6
Overexcitation Limiting.................................................................................................................... 3-6
Underexcitation Limiting.................................................................................................................. 3-6
Soft Start ............................................................................................................................................. 3-6
Voltage Matching (Optional) ............................................................................................................... 3-6

Figures
Figure 3-1. Simplified DECS-100 Block Diagram ......................................................................................3-1

DECS-100 Functional Description i

 This page intentionally left blank.

ii Functional Description DECS-100

SECTION 3 • FUNCTIONAL DESCRIPTION
INTRODUCTION
This section describes how the DECS-100 functions and explains its operating features. To ease
understanding, DECS-100 functions are illustrated in the block diagram of Figure 3-1. A detailed
description of each function block is provided in the paragraphs under the heading of DECS-100 Function
Blocks.
DECS-100 operating features include four operating modes, four protective functions, startup provisions,
reactive droop compensation, underfrequency compensation, and optional voltage matching. A detailed
description of each operating feature is provided in the paragraphs under the heading of DECS-100
Operating Features.

Figure 3-1. Simplified DECS-100 Block Diagram

DECS-100 FUNCTION BLOCKS

The following paragraphs describe each of the function blocks illustrated in Figure 3-1. The function of
each block is explained along with the operation of all function block inputs and outputs.

Analog Input Circuits

Seven analog voltages and current may be sensed and applied to the DECS-100.
Bus Voltage
C-phase and A-phase bus voltages are monitored at terminals B3 and B1 on units that include voltage
matching. Nominal voltages of up to 600 Vac may be sensed at these terminals. Voltage monitored at this
input is scaled and conditioned before being applied to the input of the analog-to-digital converter (ADC).
This bus voltage signal applied to the ADC is used to calculate the rms value of the bus voltage across
phases C and A (Bus VC-A).
Generator Voltage
Generator voltage is monitored at terminals E1 (A-phase), E2 (B-phase), and E3 (C-phase). Nominal
voltages of up to 600 Vac may be sensed at these terminals. Voltage applied to these inputs is scaled
DECS-100 Functional Description 3-1
and conditioned before being applied to the input of the ADC. The voltage signal from phase C and A
(VC-A) of the generator is used by the ADC to calculate the rms value of generator voltage across phases
C and A. Likewise, the voltage signal from phase C and B (VC-B) of the generator is used by the ADC to
calculate the rms value of generator voltage across phases C and B. The rms value of generator phase B
to phase A voltage (VB-A) is calculated by the microprocessor from the phase C to phase A signal (VC-A)and
the phase C to phase B (VC-B) signal.
Additionally, the generator phase C to phase A (VC-A) signal is applied to a filtered, zero-cross detector
circuit. This signal is applied to the microprocessor and is used to calculate generator frequency.
B-Phase Line Current
The phase B line current (IB) signal is developed through a customer supplied current transformer (CT)
and monitored through terminals CT1 and CT2. Depending on the option selected, current up to 1 ampere
(style number xx1) or 5 amperes (style number xx5) rms may be monitored at these terminals. The
current monitored at these terminals is scaled and conditioned by an internal current transformer and
active circuitry for use by the ADC. The signal applied to the ADC is used to calculate the rms value of
phase B line current.
Additionally, the phase angle between phase B line current and phase C to phase A generator voltage is
calculated for use during droop and var/power factor operation.
Accessory Input (Auxiliary Adjust)
This input allows adjustment of the DECS-100 regulation setpoint by the application of a positive or
negative dc voltage across terminals A and B. Positive voltage applied to terminal A with respect to
terminal B will cause the active mode setpoint to increase. Voltage from –3 to +3 Vdc may be applied to
this input. The circuit induces a 1,000-ohm burden on the dc source. The Application of a ±3 Vdc signal
corresponds to a ±30 percent change in setpoint.
Field Voltage
Voltage (VFIELD) across the regulator field output terminals, F+ and F–, is monitored, scaled, and
conditioned before being applied to the ADC. This signal is used to calculate the dc value of field voltage
for use in system protection.
Field Current
Current (IFIELD) through the main power output switch is converted to a proportional voltage level. This
voltage signal is scaled and conditioned before being applied to the input of the ADC. The result is used
to calculate the dc value of field current for use in the Manual mode of operation as well as protection of
the system.

Contact Input Circuits

Five contact input circuits powered from an internal 13 Vdc power supply provide input control from user-
supplied, isolated, dry-type contacts.
Raise
Closing a contact across terminals 6U and 7 causes the active operating setpoint to increase. This
function is active as long as the contact is closed.
Lower
Closing a contact across terminals 6D and 7 causes the active operating setpoint to decrease. This
function is active as long as the contact is closed.
Var/Power Factor Control (52J/K) Option
Closing a contact across terminals 52J and 52K disables var/power factor control. An open contact
enables the DECS-100 to control the generator reactive power in either the var or the power factor mode.
The contact has no effect when this function is not enabled in the software. For more information, see
Parallel Generator Compensation (52L/M) and Voltage Matching Control Option.
Parallel Generator Compensation (52L/M)
Closing a contact across terminals 52L and 52M disables parallel operation. An open contact enables
parallel operation and the DECS-100 operates in reactive droop compensation mode.

3-2 Functional Description DECS-100

If the Var/Power Factor Control option is present and is enabled in the software, the 52J/K input has
priority. Therefore, if the 52J/K and the 52L/M inputs are both open, the system operates in var/power
factor mode. For more information, see Voltage Matching Control Option.
Voltage Matching Control Option
If the Voltage Matching option is enabled in the software, closing a contact across terminals VM and VMC
causes the DECS-100 to operate in the voltage matching mode. An open contact disables voltage
matching. Voltage matching is also disabled when either the 52J/K or 52L/M inputs are open.

RS-232 Communication Port

The communication port provides the interface for user programming (setup) of the DECS-100.
Connection is made to the female RS-232 (DB-9) connector with a user-supplied, standard 9-pin cable.
The communication port is optically isolated and is powered from a transformer-isolated supply.

Microprocessor
The microprocessor is the heart of the DECS-100 and performs measurement, computation, control, and
communication functions by the use of its embedded programming and the nonvolatile settings stored in
its memory.

Power Input Stage

Input power applied to terminals 3, 4, and 5 is rectified and filtered before being applied to the power
amplifier and the power supply. Input power may be single-phase or three-phase in the range of 88 to 250
Vac at a frequency of 50 to 400 hertz.
The input power source should be properly fused for the application.

Power Supply
The internal switch-mode power supply receives power from the power input stage and supplies power at
the required dc voltage levels to the internal circuitry of the DECS-100.

Power Amplifier Stage

The power amplifier receives power from the power input stage and supplies a controlled amount of
power to the exciter field via terminals F+ and F–. The amount of power supplied to the exciter field is
based on gating pulses received from the microprocessor. The power amplifier uses a solid state power
switch to provide the required power to the exciter field. Power amplifier output to the field is rated up to
63 Vdc at 7 Adc continuous and 135 Vdc at 15 Adc for 10 seconds.

Front Panel Indicators

Eight front-panel LED indicators light to indicate various protective functions and operating modes.
Section 2, Human-Machine Interface provides more information about the front panel indicators.

Relay Output
A common alarm output contact is provided through terminals AL1 and AL2. This normally open, form A
contact annunciates alarm or trip conditions. The relay output is non-latching.

DECS-100 OPERATING FEATURES

The following paragraphs describe the characteristics of each DECS-100 operating feature.

Operating Modes
The DECS-100 provides up to four modes of operation selectable through BESTCOMS software.
Automatic voltage regulation mode and Manual mode are standard features. Var and Power Factor
modes are an option.
Automatic Voltage Regulation Mode
In Automatic Voltage Regulation (AVR) mode, the DECS-100 regulates rms generator output voltage.
This is accomplished by sensing generator output voltage and adjusting dc output excitation current to
maintain voltage at the regulation setpoint. The regulation setpoint is adjusted by the Raise and Lower

DECS-100 Functional Description 3-3

contact inputs, the Accessory input, or through BESTCOMS software. The regulation point may also be
modified by the Droop function or the Underfrequency function under certain conditions.
Manual Mode
In Manual mode, also known as Field Current Regulation (FCR) mode, the DECS-100 maintains dc
excitation current at a set level. The current-level setpoint is adjustable from 0 to 7 Adc in 0.1 Adc
increments by the Raise and Lower contact inputs, the optional Accessory input, or through BESTCOMS
software.

CAUTION
The Manual mode excitation level must be evaluated prior to enabling this
feature. If the level of excitation current is inappropriate for the generator, severe
damage to the generator may occur.

Var Control Mode (Optional)

In Var Control mode, the DECS-100 maintains generator vars (volt-amperes, reactive) at a set level when
paralleling with an infinite bus. The DECS-100 calculates generator vars by using the sensed generator
output voltage and current quantities. It then adjusts the dc excitation current to maintain vars at the
setpoint. Var control is enabled and disabled through BESTCOMS software. When the software is turned
on, var control is enabled or disabled through the Var/Power Factor Control (52J/K) contact input circuit.
The var setpoint is adjustable from 100 percent absorb to 100 percent generate through the Raise and
Lower contact inputs, the optional Accessory input, or through BESTCOMS software.
Power Factor Control Mode (Optional)
In Power Factor Control mode, the DECS-100 maintains generator power factor at a set level when
paralleling with an infinite bus. The DECS-100 calculates generator power factor using the sensed
generator output voltage and current quantities and then adjusts the dc excitation current to maintain
power factor at the setpoint. Power factor control is enabled or disabled through BESTCOMS software.
When the software is turned on, it is enabled or disabled through the Var/Power Factor Control (52J/K)
contact input circuit. The power factor setpoint is adjustable between 0.6 lag and 0.6 lead through the
Raise and Lower contact inputs, the optional Accessory input, or through BESTCOMS software.

Reactive Droop Compensation

The DECS-100 provides a reactive droop compensation feature to assist in the sharing of reactive load
during parallel generator operation. When this feature is enabled, the DECS-100 calculates the reactive
portion of the generator load using the sensed generator output voltage and current quantities and then
modifies the voltage regulation setpoint accordingly. A unity power factor generator load results in almost
no change in generator output voltage. A lagging power factor generator load (inductive) results in a
reduction of generator output voltage. A leading power factor generator load (capacitive) results in an
increase of generator output voltage. Droop is adjustable up to 10 percent with rated, nominal B-phase
line current (1 ampere or 5 amperes applied through terminals CT1 and CT2) and 0.8 power factor. The
droop feature is enabled and disabled through the Parallel Generator Compensation contact input circuit
(terminals 52L and 52M). Droop is also disabled when operating in var or power factor control modes.

Underfrequency
When generator frequency drops below the selected knee frequency setpoint, the voltage setpoint is
automatically adjusted by the DECS-100 so that generator voltage follows the selected PU (per unit) V/Hz
curve. When operating on the selected PU V/Hz curve, the Underfrequency Active indicator lights on the
front panel and in BESTCOMS. Underfrequency control is disabled below 12 hertz. The knee frequency is
adjustable from 40 to 65 hertz in 0.1 hertz increments and the PU V/Hz curve may be set at a slope of 0
to 3 in 0.01 steps through BESTCOMS software. A slope of 0 effectively disables the underfrequency
function. The DECS-100 has a minimum regulation point of approximately 30 percent of the nominal
setpoint.

3-4 Functional Description DECS-100

Protection
The DECS-100 includes three protective functions: generator overvoltage, loss of sensing voltage, and
field overvoltage. Each protective function has a corresponding front panel indicator that lights when the
function is active. An active protective function is also annunciated through BESTCOMS.
Generator Overvoltage
A generator overvoltage condition can be configured (in BESTCOMS) to close the DECS-100 relay
output, disable the DECS-100, initiate both actions, or initiate neither action. When the sensed generator
voltage increases above the adjustable voltage level setpoint for the duration of the adjustable alarm time
delay, the DECS-100 initiates the selected action.
If the DECS-100 is configured to close the relay output, a generator overvoltage condition will light the
front panel and BESTCOMS Generator Overvoltage indicator and close the relay output at terminals AL1
and AL2.
If the DECS-100 is configured for hardware shutdown, a generator overvoltage condition will disable the
DECS-100 after the alarm time delay expires. When the DECS-100 is powered up following a generator
overvoltage shutdown, the Generator Overvoltage indicator will light for five seconds.
The voltage level setpoint is adjustable from 100 to 120 % of the system voltage setting. The alarm time
delay is adjustable from 0 to 10 seconds.
Loss of Sensing Voltage
The DECS-100 monitors the sensed generator output voltage and takes protective action if a loss of
sensing voltage is detected. A loss of sensing voltage is detected during the following conditions.
• The sensed voltage is less than 50 percent of the rated voltage (one-phase or three-phase sensing).
• A total loss of any phase occurs (three-phase sensing).
• The voltage difference between any phase (line-to-line) and the three-phase average exceeds 20
percent of nominal (three-phase sensing).
A time delay of 0 to 25 seconds is adjustable through BESTCOMS software. This delays the protective
action in order to allow field forcing in applications that do not sense B-phase generator current. The
default time delay setting is 10 seconds.
BESTCOMS software allows the selection of one of two protective actions for a loss of sensing. Either a
complete shutdown or a transfer to Manual mode may be selected.
If shutdown is selected and a loss of sensing occurs, the Loss of Generator Sensing indicator on the front
panel and in BESTCOMS lights, the relay output closes, and the DECS-100 shuts down after the
adjustable time delay expires. When the DECS-100 is powered up following a loss of generator sensing
shutdown, the Loss of Generator Sensing indicator will light for five seconds. However, if the loss of
sensing conditions still exists, the DECS-100 will not shut down due to loss of sensing until the soft-start
time delay and the loss of sensing time delay expires.
If transfer to Manual is selected and a loss of sensing occurs, the relay output closes, and the DECS-100
transfers to the Manual mode of operation after the adjustable time delay expires. The DECS-100 will
remain in this mode of operation until switched via BESTCOMS. Prior to selecting transfer to Manual on
loss of sensing, it is necessary to determine an appropriate Manual (FCR) mode setpoint level to be
transferred to. An inappropriate excitation level could result in severe damage to equipment.
This function is disabled when the frequency decreases below 12 hertz or when a generator short circuit
condition is detected. A generator short-circuit is determined when the B-phase CT current exceeds three
times the per unit value. Loss of sensing shutdown or transfer is not active during the soft-start time.
Field Overvoltage (Overexcitation Shutdown)
A field overvoltage condition can be configured (in BESTCOMS) to close the DECS-100 relay output,
disable the DECS-100, initiate both actions, or initiate neither action. When the field voltage increases
above the adjustable voltage level setpoint for the fixed duration of 10 seconds, the DECS-100 initiates
the selected action.
If the DECS-100 is configured to close the relay output, a field overvoltage condition will light the front
panel and BESTCOMS Overexcitation Shutdown indicator and close the relay output at terminals AL1
and AL2.
If the DECS-100 is configured for hardware shutdown, a field overvoltage condition will disable the DECS-
100 after the 10 second time delay expires. When the DECS-100 is powered up following a field
overvoltage shutdown, the Overexcitation Shutdown indicator will light for five seconds.
DECS-100 Functional Description 3-5
The voltage level setpoint is adjustable from 0 to 250 Vdc. The field overvoltage time delay is fixed at 10
seconds.

Limiters
DECS-100 limiters consist of an overexcitation limiter (OEL) triggered by an increase in field current and
an underexcitation limiter (UEL) triggered by excessive leading vars.
Overexcitation Limiting
The DECS-100 provides two types of overexcitation limiting: summing point and takeover.
Summing Point OEL. When the level of field current increases above the adjustable current level setpoint,
the front panel and BESTCOMS Overexcitation Limiting indicators light. If the overexcitation condition
persists for the duration of the user-adjustable alarm time delay, the relay output at terminals AL1 and
AL2 closes.
The advantage of a summing-point type of OEL is that it can provide a smooth transition into and out of
the limit. Its drawback is that it does not control field current directly, but has to work through the normal
voltage regulator, and may be influenced by changes in terminal voltage.
Takeover OEL. When takeover-style overexcitation limiting is used, the level of field current at which
limiting occurs is determined by an adjustable current level setpoint. If the field current increases above
the adjustable current level setpoint, the front panel and BESTCOMS Overexcitation Limiting indicators
light and the field current is limited and forced to follow the inverse time curve.
The advantage of a takeover type of OEL is that it provides direct control of the exciter field current
without relying on the normal voltage regulator’s control action. Its drawback is that it may not provide a
smooth transition into and out of the limit.
If hardware shutdown is enabled, the DECS-100 will be disabled when the time delay expires. When the
DECS-100 is powered up following a shutdown triggered by overexcitation limiting, the Overexcitation
Limiting indicator will light for five seconds.
The current level setpoint is adjustable from 0 to 15 Adc. The alarm time delay is adjustable from 0 to 10
seconds.
Underexcitation Limiting
When the level of leading vars increases above the adjustable var level setpoint, the front panel and
BESTCOMS Underexcitation Limiting indicators light. If the underexcitation condition persists for the
duration of the adjustable alarm time delay, the relay output at terminals AL1 and AL2 closes.
If hardware shutdown is enabled, the DECS-100 will be disabled when the time delay expires. When the
DECS-100 is powered up following a shutdown triggered by underexcitation limiting, the Underexcitation
Limiting indicator will light for five seconds.

The var level setpoint is adjustable from 0 to 100% of the rated vars. The rated var level is determined by
the following equation:
rated var level = V AVG × I B × 3
where IB is the DECS-100 nominal current sensing rating (1 Aac or 5 Aac)
The alarm time delay is adjustable from 0 to 10 seconds.

NOTE
The UEL function is active only during parallel operation when the 52J/K contact
input or 52L/M contact input is open.

Soft Start
The DECS-100 also incorporates an adjustable soft start feature that controls the time for generator
voltage or field current to ramp to the regulation setpoint. The ramp rate is adjustable from 1 to 7,200
seconds in 1 second increments through BESTCOMS. The underfrequency feature is also active during
soft start and takes priority in control of the generator voltage in an effort to minimize voltage overshoot.

3-6 Functional Description DECS-100

Voltage Matching (Optional)
Voltage matching is useful when the PT ratios in an application are not matched exactly. Using
BESTCOMS to enter the generator PT ratio and bus PT ratio will automatically compensate for the offset.
The DECS-100 voltage matching option automatically matches the rms generator output with the rms bus
voltage prior to synchronizing. The DECS-100 compares and matches the generator voltage with the bus
voltage by adjusting the dc excitation current. Voltage matching is enabled when the bus voltage is within
10% of the nominal sensing range selected. As long as the values of generator and bus voltage (applies
to the DECS-100 voltage sensing inputs) are within the acceptable range, voltage matching can be
achieved.
The rate at which the DECS-100 matches the generator input level with the bus input level is controlled by
a voltage matching speed setting. this setting is adjustable from 1 to 300 seconds in 0.01 second
increments.
Voltage matching can be disabled by the state of the DECS-100 contact inputs. In BESTCOMS, the
52J/K contact input, 52L/M contact input, or both contact inputs can be configured to enable and disable
voltage matching. To enable bus voltage matching, select 52J/K. This will allow droop to remain active.
When the utility tie breaker closes, voltage matching will be disabled automatically (via the 52J/K contact
input) and var/power factor control will be enabled.
Two voltage matching modes are available: Maintain and Revert. When Maintain mode is implemented,
the DECS-100 setpoint is maintained at the bus voltage level even when the generator or utility breaker is
open. When Revert mode is implemented, the DECS-100 setpoint reverts to its original level when the
generator or utility breaker opens. Revert is the default voltage matching mode.

DECS-100 Functional Description 3-7

 This page intentionally left blank.

3-8 Functional Description DECS-100

SECTION 4 • INSTALLATION
TABLE OF CONTENTS
SECTION 4 • INSTALLATION................................................................................................................... 4-1
INTRODUCTION .................................................................................................................................... 4-1
MOUNTING ............................................................................................................................................ 4-1
CONNECTIONS ..................................................................................................................................... 4-4
DECS-100 Terminations..................................................................................................................... 4-4
Bus Voltage Sensing Inputs (Optional)............................................................................................... 4-5
Generator Voltage Sensing Inputs ..................................................................................................... 4-5
Phase B Line Current Sensing Input .................................................................................................. 4-5
Accessory Input .................................................................................................................................. 4-5
Raise and Lower Contact Inputs ........................................................................................................ 4-5
Var/Power Factor Control Contact Input (Optional)............................................................................ 4-5
Parallel Generator Compensation ...................................................................................................... 4-5
Parallel Control and Var/PF Control Inputs ........................................................................................ 4-6
Voltage Matching (Optional) ............................................................................................................... 4-6
Power Supply Inputs........................................................................................................................... 4-6
Chassis Ground .................................................................................................................................. 4-6
Power (Field) Output........................................................................................................................... 4-6
Relay Output (Alarm) .......................................................................................................................... 4-6
Communication Port ........................................................................................................................... 4-7
DECS-100 Connections for Typical Applications ............................................................................... 4-7
INSTALLATION FOR CE COMPLIANCE ............................................................................................ 4-13
Mounting ........................................................................................................................................... 4-13
Wiring................................................................................................................................................ 4-13
PRELIMINARY SETUP ........................................................................................................................ 4-13
Operating Power Considerations During DECS-100 Programming ................................................. 4-14
ADJUSTMENTS ................................................................................................................................... 4-14

Figures
Figure 4-1. DECS-100 Dimensions ...........................................................................................................4-2
Figure 4-2. Cutout and Drilling Dimensions ...............................................................................................4-3
Figure 4-3. DECS-100 Terminals ..............................................................................................................4-4
Figure 4-4. RS-232 Port Pin Assignments.................................................................................................4-7
Figure 4-5. Personal Computer to DECS-100 Connections ......................................................................4-7
Figure 4-6. Typical Connections for PMG Application with ABC Rotation and Three-Phase Sensing .....4-8
Figure 4-7. Typical Connections for PMG Application with ABC Rotation and Single-Phase Sensing.....4-9
Figure 4-8. Typical Connections for Shunt Application with ABC Rotation and Three-Phase Sensing ..4-10
Figure 4-9. Typical Connections for Shunt Application with ABC Rotation and Single-Phase Sensing..4-11
Figure 4-10. Typical Connections for Station Power Application and Three-Phase Sensing .................4-12
Figure 4-11. Cross-Current (Reactive Differential) Connections .............................................................4-13
Figure 4-12. Operating Power Connections for DECS-100 Programming (Input Voltage >120 Vac) .....4-14

Tables
Table 4-1. Bus Voltage Sensing Terminals ...............................................................................................4-5
Table 4-2. Generator Voltage Sensing Terminals .....................................................................................4-5
Table 4-3. 52L/"M" and 52J/K Control Modes ...........................................................................................4-6
Table 4-4. Communication Port Pin Functions ..........................................................................................4-7

DECS-100 Installation i
 This page intentionally left blank.

ii Installation DECS-100
SECTION 4 • INSTALLATION
INTRODUCTION
DECS-100 Digital Excitation Control Systems are delivered in sturdy cartons to prevent shipping damage.
Upon receipt of a system, check the part number against the requisition and packaging list for agreement.
Inspect for damage, and if there is evidence of such, immediately file a claim with the carrier and notify
the Basler Electric Regional Sales Office, your Sales Representative or a Sales Representative at Basler
Electric, Highland, Illinois.
If the unit is not installed immediately, store it in the original shipping package in a moisture and dust free
environment.

MOUNTING
The DECS-100 is normally located in the generator conduit box. It is designed for behind the panel
mounting and requires a cutout for front panel viewing. Supplied mounting hardware consists of six #12
thread-forming screws that pass through mounting holes in the conduit box and thread into the plastic
shell of the DECS-100. The recommended torque range for the steel mounting screws is 4.07 to 4.52
newton-meters (36 to 40 inch-pounds). The unit must be mounted where the ambient temperature does
not exceed the allowable environmental conditions called out in Section 1, General Information,
Specifications. DECS-100 package dimensions are shown in Figure 4-1. Cutout and drilling dimensions
are shown in Figure 4-2. Drawing dimensions are shown in inches and millimeters (in parenthesis).

DECS-100 Installation 4-1

 Figure 4-1. DECS-100 Dimensions

4-2 Installation DECS-100

 Figure 4-2. Cutout and Drilling Dimensions
DECS-100 Installation 4-3
CONNECTIONS
DECS-100 connections are dependent on the application and excitation scheme. Incorrect wiring may
result in damage to the unit. Check the part number to ensure that you have the correct unit before
connecting and applying power.

NOTE
Be sure that the DECS-100 is hard-wired to earth ground with no smaller than 12
AWG copper wire attached to the ground terminal on the rear of the unit case.
When the unit is configured in a system with other devices, connect a separate
lead from the ground bus to each DECS-100 unit.

DECS-100 Terminations
DECS-100 units have two types of interface terminals (Figure 4-3). One type is quarter-inch, quick-
connect terminals and the other is a 9-pin DB9 connector. All terminals are located on the rear of the unit.
The quarter-inch, quick-connect terminal labels are located on the rear of the case. Wires performing
common functions, such as voltage sensing leads, should be grouped together. The 9-pin DB-9 type
connector is used for temporary interface with both IBM compatible PCs and hand-held computers.
Figure 4-3 shows the terminal connections located on the rear panel of the DECS-100. Except as noted
above, connections should be made with minimum wire size of 14 AWG.

Figure 4-3. DECS-100 Terminals

4-4 Installation DECS-100

Bus Voltage Sensing Inputs (Optional)
The bus voltage sensing terminals are labeled B1 and B3. These terminals are used only on units that
include the Voltage Matching option. The bus input is not phase sensitive to generator sensing. Table 4-1
lists the terminal assignments for bus voltage sensing.
Table 4-1. Bus Voltage Sensing Terminals
Bus Voltage Phase Terminal
A B1
C B3

Generator Voltage Sensing Inputs

The generator voltage sensing terminals are labeled E1, E2, and E3. The DECS-100 comes equipped for
three-phase sensing as standard. Single-phase sensing is obtained by connecting the C-phase sensing
input to terminals E2 and E3. Table 4-2 lists the terminal assignments for three-phase and single-phase
generator voltage sensing.
Table 4-2. Generator Voltage Sensing Terminals
Generator
Sensing Phase Terminal
A E1
3-Phase B E2
C E3
A E1
1-Phase
C E2, E3

Phase B Line Current Sensing Input

Generator line current is stepped down through a user-supplied current transformer (CT). Secondary
current from that transformer is applied to terminals labeled CT1 and CT2.

Accessory Input
The accessory input voltage terminals are labeled A and B and accept a maximum signal of ±3 Vdc.
Positive voltage applied to terminal A with respect to terminal B causes the active mode setpoint to
increase. For every ±1 Vdc change, a ±10% change in the active mode setpoint is achieved.

Raise and Lower Contact Inputs

Remote setpoint adjustment may be accomplished by connecting a single-pole, double-throw (SPDT),
spring return, center-off switch to the terminals labeled 6U, 7, and 6D. To connect this switch, the center
pole, or common terminal, must be connected to terminal 7. The other two terminals are connected to
terminals 6U and 6D.
This remote adjust switch may be mounted up to 150 feet away from the DECS-100 when using twisted,
shielded cable. Only dry, ungrounded switching contacts should be applied to the Raise and Lower
contact inputs.

Var/Power Factor Control Contact Input (Optional)

A customer-supplied enable/disable contact for this function connects to the terminals labeled 52J and
52K.
Only dry, ungrounded switching contacts should be applied to the Var/Power Factor Control contact input.

Parallel Generator Compensation

A customer-supplied enable/disable contact for this function connects to the terminals labeled 52L and
52M.
DECS-100 Installation 4-5
Only dry, ungrounded switching contacts should be applied to the Parallel Generator Compensation
contact input.

Parallel Control and Var/PF Control Inputs

User-supplied contacts at terminals 52L and 52M determine whether AVR or Droop mode is active.
Terminals 52L and 52M typically connect to a 52b auxiliary contact of the generator breaker. User-
supplied contacts at terminals 52J and 52K control whether var or power factor correction is active or
disabled. Terminals 52J and 52K typically connect to the auxiliary contacts of the utility tie breaker. Table
4-3 lists the operating modes achieved for the different 52L/M and 52J/K contact states. A closed state
indicates a continuous contact closure and an open state indicates a continuous open-circuit.
Table 4-3. 52L/M and 52J/K Control Modes
DECS-100 Operating Mode 52L/M 52J/K Generator Operating Mode
AVR mode active, no droop, optional Closed Closed Single unit/stand-alone
var/PF mode disabled
Droop mode active, optional var/PF Open Closed Paralleled to the utility grid (droop) or
mode disabled two or more generators islanded
(droop or CCC)
Var/PF mode active Open Open Paralleled to utility grid

Voltage Matching (Optional)

A customer-supplied enable/disable contact for this function connects to the terminals labeled VM and
VMC. Only dry, ungrounded switching contacts should be applied to the Voltage Matching contact input.
Voltage matching is also enabled/disabled by the state of the 52J/K and/or 52L/M contact inputs. In
BESTCOMS, voltage matching can be configured to be disabled when the 52J/K or 52L/M contact input is
open or just the 52J/K contact input is open.

Power Supply Inputs

Power input terminals are labeled 3, 4, and 5. Single-phase or three-phase power may be applied. Single-
phase power may be applied to any two of the three terminals.
The DECS-100 can be powered directly from a variety of sources as long as the DECS-100 input power
specifications are followed (see Section 1, General Information, Specifications).
Examples of DECS-100 operating power sources are:
• Generator (shunt fed)
• Permanent magnet generator (PMG)
• Auxiliary winding
When powering the DECS-100 from a low-impedance power source, special provisions must be made to
avoid damage to the DECS-100. Examples of a low-impedance power source include a station service
source or power outlet. An Inrush Current Reduction Module, ICRM-7, must be connected between the
power source and DECS-100 input power terminals (see Figure 4-10). The ICRM-7 prevents DECS-100
damage by minimizing the level of inrush current. The ICRM-7 can also be used when programming the
DECS-100. However, the Preliminary Setup paragraphs illustrate an alternate method for temporarily
powering the DECS-100 for programming.
More details about the ICRM-7 are available in Basler Electric publication 9387900990.

Chassis Ground
The chassis ground terminal is labeled GND.

Power (Field) Output

The field output terminals for connection to the generator exciter field are labeled F+ and F–.

Relay Output (Alarm)

The common alarm relay output contact may be accessed at the terminals labeled AL1 AND AL2.

4-6 Installation DECS-100

Communication Port
The RS-232 port on the rear panel uses a DB-9
female connector. Figure 4-4 Illustrates the pin
assignments of the communication port and
Table 4-4 Identifies the RS-232 connector pin
functions. A standard communication cable
terminated with a DB-9 male connector is used
for PC interface with the DECS-100 as shown in
Figure 4-5. Figure 4-4. RS-232 Port Pin Assignments

Table 4-4. Communication Port Pin Functions

Pin Function Name Direction
1 N/C — N/A
2 Transmit data TXD From DECS-100
3 Receive data RXD To DECS-100
4 N/C — N/A
5 Signal ground GND N/A
6 N/C — N/A
7 N/C — N/A
8 N/C — N/A
9 N/C — N/A

Figure 4-5. Personal Computer to DECS-100 Connections

DECS-100 Connections for Typical Applications

Figures 4-6 through 4-10 illustrate typical applications using the DECS-100. Figure 4-6 shows an
application where DECS-100 operating power is derived from a permanent magnet generator (PMG) and
three-phase voltage sensing is applied to the DECS-100. Figure 4-7 shows another PMG application but
with single-phase voltage sensing. Figure 4-8 shows an application where DECS-100 operating power is
derived from the generator output (shunt application) and three-phase voltage sensing is applied to the
DECS-100. Figure 4-9 shows another shunt application but with single-phase sensing. Figure 4-10 shows
a DECS-100 powered by single-phase station power in a three-phase sensing application.
Figure 4-11 shows a typical connection diagram for two paralleled generators operating in cross-current
compensation (reactive differential) mode. The resistors shown have a value of 0.1 ohms. This is a typical
value that can be used to set the burden. (Ensure that the resistor power rating is adequate for the
installation.)

DECS-100 Installation 4-7

4-8
DECS-100 WITH VOLTAGE MATCHING
FIELD INPUT SENSING VAR/PF PARALLEL EXTERNAL AUX. VOLTAGE
OUTPUT POWER CTB VOLTAGE GROUND BUS CONTROL CONTROL ADJUST ALARM ADJUST MATCHING
F- F+ 3 4 5 CT1 CT2 E3 E2 E1 GND B1 B3 52J 52K 52L 52M 6D 7 6U AL 1 AL 2 A B VM VMC

4 5
10 10

52b S3
S2 S1

A B C
1 2 10 9 10
7
3
10
NOTES:
6
7 1 Required only for optional Var/PF control. Var/PF is active with
8
10
52b open. Var/PF is inactive with 52b closed.
10
2 Parallel control and droop active with S2 open, inactive with S2
closed.
3

Installation
S1 (SPDT, spring-return to center-off position) adjusts DECS-
PMG
10 52 100 setpoint.
+ 4 Normally-open output contact closes for customer alarm or trip.
A
10 CTB
GEN B 5 Analog input voltage between +/- 3 Vdc provides adjustment of
11 voltage sepoint (optional feature).
C
D2881-09 6 External fuses should be Bussman type KTK-10 or equivalent.
05-10-02
Generator Utility
Side Side 7 Sensing potential transformer is required if line voltage exceeds
660 Vac.
8 3-phase PMG is shown. For 1-phase PMG, omit B-phase
connection.
9 Optional voltage matching control input. Voltage matching is
active with S3 closed, inactive with S3 open.
10 Item not supplied by Basler Electric.

11 When generator rotation is ACB, the connections shown for

Figure 4-6. Typical Connections for PMG Application with ABC Rotation and Three-Phase Sensing
CTB should be reversed.

DECS-100
 DECS-100 WITH VOLTAGE MATCHING
FIELD INPUT SENSING VAR/PF PARALLEL EXTERNAL AUX. VOLTAGE

DECS-100
OUTPUT POWER CTB VOLTAGE GROUND BUS CONTROL CONTROL ADJUST ALARM ADJUST MATCHING
F- F+ 3 4 5 CT1 CT2 E3 E2 E1 GND B1 B3 52J 52K 52L 52M 6D 7 6U AL 1 AL 2 A B VM VMC

4 5
10 10

52b S3
S2 S1
A B C
1 2 10 9 10
7
3
10
6 NOTES:
7
8 1 Required only for optional Var/PF control. Var/PF is active with
10 52b open. Var/PF is inactive with 52b closed.
10
2 Parallel control and droop active with S2 open, inactive with S2
closed.

PMG 3 S1 (SPDT, spring-return to center-off position) adjusts DECS-

10 52 100 setpoint.

Installation
+ 4 Normally-open output contact closes for customer alarm or trip.
A
10 CTB
GEN B 5 Analog input voltage between +/- 3 Vdc provides adjustment of
voltage sepoint (optional feature).
C
D2881-11 6 External fuses should be Bussman type KTK-10 or equivalent.
05-10-02
Generator Utility
Side Side 7 Sensing potential transformer is required if line voltage exceeds
660 Vac.
8 3-phase PMG is shown. For 1-phase PMG, omit B-phase
connection.
9 Optional voltage matching control input. Voltage matching is
active with S3 closed, inactive with S3 open.
10 Item not supplied by Basler Electric.

11 When generator rotation is ACB, the connections shown for

Figure 4-7. Typical Connections for PMG Application with ABC Rotation and Single-Phase Sensing
CTB should be reversed.

4-9
4-10
DECS-100 WITH VOLTAGE MATCHING
FIELD INPUT SENSING VAR/PF PARALLEL EXTERNAL AUX. VOLTAGE
OUTPUT POWER CTB VOLTAGE GROUND BUS CONTROL CONTROL ADJUST ALARM ADJUST MATCHING
F- F+ 3 4 5 CT1 CT2 E3 E2 E1 GND B1 B3 52J 52K 52L 52M 6D 7 6U AL 1 AL 2 A B VM VMC

4 5
10 10

52b S3
S2 S1
A B C
1 2 10 9 10
7
6 3
10
NOTES:
8
1 Required only for optional Var/PF control. Var/PF is active with
7
10 52b open. Var/PF is inactive with 52b closed.
11 10 2 Parallel control and droop active with S2 open, inactive with S2
closed.
3 S1 (SPDT, spring-return to center-off position) adjusts DECS-
100 setpoint.

Installation
10 52 4 Normally-open output contact closes for customer alarm or trip.
+
A
10 CTB 5 Analog input voltage between +/- 3 Vdc provides adjustment of
GEN B voltage sepoint (optional feature).
12
C 6 External fuses should be Bussman type KTK-10 or equivalent.
D2881-10
05-10-02
Generator Utility 7 Sensing potential transformer is required if line voltage exceeds
Side Side 660 Vac.
8 3-phase transformer is shown. For 1-phase transformer, omit B-
phase connection.
9 Optional voltage matching control input. Voltage matching is
active with S3 closed, inactive with S3 open.
10 Item not supplied by Basler Electric.

11 Power potential transformer is required if line voltage exceeds

the specified power input limits.
12 When generator rotation is ACB, the connections shown for

Figure 4-8. Typical Connections for Shunt Application with ABC Rotation and Three-Phase Sensing
CTB should be reversed.

DECS-100
 DECS-100 WITH VOLTAGE MATCHING
FIELD INPUT SENSING VAR/PF PARALLEL EXTERNAL AUX. VOLTAGE
OUTPUT POWER CTB VOLTAGE GROUND BUS CONTROL CONTROL ADJUST ALARM ADJUST MATCHING

DECS-100
F- F+ 3 4 5 CT1 CT2 E3 E2 E1 GND B1 B3 52J 52K 52L 52M 6D 7 6U AL 1 AL 2 A B VM VMC

4 5
10 10

52b S3
S2 S1
A B C
1 2 10 9 10
7
6 3
10 NOTES:
8
1 Required only for optional Var/PF control. Var/PF is active with
7
10 52b open. Var/PF is inactive with 52b closed.
11 10
2 Parallel control and droop active with S2 open, inactive with S2
closed.
3 S1 (SPDT, spring-return to center-off position) adjusts DECS-
100 setpoint.
10 52 4 Normally-open output contact closes for customer alarm or trip.
+

Installation
A
10 CTB 5 Analog input voltage between +/- 3 Vdc provides adjustment of
GEN B voltage sepoint (optional feature).
12
C 6 External fuses should be Bussman type KTK-10 or equivalent.
D2659-18
05-10-02
Generator Utility 7 Sensing potential transformer is required if line voltage exceeds
Side Side 660 Vac.
8 3-phase transformer is shown. For 1-phase transformer, omit B-
phase connection.
9 Optional voltage matching control input. Voltage matching is
active with S3 closed, inactive with S3 open.
10 Item not supplied by Basler Electric.

11 Power potential transformer is required if line voltage exceeds

the specified power input limits.
12 When generator rotation is ACB, the connections shown for

Figure 4-9. Typical Connections for Shunt Application with ABC Rotation and Single-Phase Sensing
CTB should be reversed.

4-11
4-12
DECS-100 WITH VOLTAGE MATCHING
FIELD INPUT SENSING VAR/PF PARALLEL EXTERNAL AUX. VOLTAGE
OUTPUT POWER CTB VOLTAGE GROUND BUS CONTROL CONTROL ADJUST ALARM ADJUST MATCHING
F- F+ 3 4 5 CT1 CT2 E3 E2 E1 GND B1 B3 52J 52K 52L 52M 6D 7 6U AL 1 AL 2 A B VM VMC

4 5
10 10

52b S3
S2 S1
6

ICRM-7 8
1 2 10 9 10
7
12 3
10 NOTES:
7 1 Required only for optional Var/PF control. Var/PF is active with
52b open. Var/PF is inactive with 52b closed.
10
STATION 2 Parallel control and droop active with S2 open, inactive with S2
POWER closed.
3 S1 (SPDT, spring-return to center-off position) adjusts DECS-
100 setpoint.

Installation
10 52
4 Normally-open output contact closes for customer alarm or trip.
+
A
10 CTB
GEN 5 Analog input voltage between +/- 3 Vdc provides adjustment of
B
11
voltage sepoint (optional feature).
C 6 External fuses should be Bussman type KTK-10 or equivalent.
P0028-08
03-01-05
Generator Utility
7 Sensing potential transformer is required if line voltage exceeds
Side Side 660 Vac.
8 1-phase power is shown. For 3-phase power, add missing
connection.
9 Optional voltage matching control input. Voltage matching is
active with S3 closed, inactive with S3 open.
10 Item not supplied by Basler Electric.

11 When generator rotation is ACB, the connections shown for

Figure 4-10. Typical Connections for Station Power Application and Three-Phase Sensing
CTB should be reversed.
12 Optional accessory for station power applications.

DECS-100
 CT
GEN 1

0.1
CTB1

CTB2

DECS-100
CCC LOAD
DECS-100 ENABLE
0.1 CONTACT
CTB1

CTB2

D2880-16
05-19-00
GEN 2
CT

Figure 4-11. Cross-Current (Reactive Differential) Connections

INSTALLATION FOR CE COMPLIANCE

The following paragraphs describe the mounting and wiring requirements for a CE (European
Community) compliant installation.

Mounting
The DECS-100 must be mounted inside a grounded, metal enclosure (conduit box). An access panel
should cover the opening for the front panel display.

Wiring
Wiring connected to the terminals listed below must be shielded. Each shield should be terminated to
ground on the outside of the conduit box.
• Current sensing terminals CT1 and CT2
• Relay output terminals AL1 and AL2
• Var/Power Factor control contact input terminals 52J and 52K
• Parallel generator compensation terminals 52L and 52M
• Raise and lower contact input terminals 6U, 6D, and 7
• Accessory input voltage terminals A and B
• Voltage matching contact input terminals VM and VMC

PRELIMINARY SETUP
Before starting the generator and DECS-100 for the first time, proceed as follows.

WARNING!
Lethal voltage is present at the rear panel when the unit is energized. Rear panel
connections should be made only when the unit is de-energized.

1. Tag and disconnect all wiring to the DECS-100. Be sure to insulate the wire terminals to prevent a
short circuit.
2. Start the prime mover and perform all engine governor adjustments.
3. After all initial governor adjustments have been made, shut down the prime mover.
DECS-100 Installation 4-13
4. Connect only the DECS-100 power input terminals to an auxiliary power source. Before applying
DECS-100 operating power, observe the precautions noted in Operating Power Considerations
During DECS-100 Programming.
5. Perform all initial DECS-100 settings by connecting a PC operating with BESTCOMS to the rear
communication port of the DECS-100 and save all new settings.
6. Remove power from the DECS-100.
7. Connect the rest of the DECS-100 leads using the tagged identification.
8. Start the prime mover/generator and perform the final adjustments at rated speed and load.
9. After the initial startup, the DECS-100 should not require any further adjustments unless there is a
change in the system.

Operating Power Considerations During DECS-100 Programming

Due to its pulse-width modulated (PWM) power stage, the DECS-100 operating power input has a
substantial amount of capacitance. High inrush current can be experienced upon DECS-100 power-up
when a "solid" power source is used. When powering the DECS-100 for programming with voltage
greater than 120 Vac, high inrush current may damage the unit. Therefore, during programming, DECS-
100 operating power should be within the range of 30 to 120 Vac (50/60 Hz).

CAUTION
When programming the DECS-100 without the generator spinning, the
connections to DECS-100 terminals F+ and F– should be removed.

If it is necessary to perform programming with applied operating power over 120 Vac, a current-limiting
resistor must be connected between the power source and DECS-100 (Figure 4-12). A resistor rated at
20 ohms and 20 watts may be used to limit the inrush current to a safe level. During the duration of the
inrush current (about one cycle), the resistor power rating will be exceeded. Once the inrush has passed,
the resistor power dissipation level will be minimal. If desired, a 10 ohm, 50 watt resistor may be used
instead.

Figure 4-12. Operating Power Connections for DECS-100 Programming (Input Voltage >120 Vac)
These special operating considerations are to be observed only during DECS-100 programming.
Applications where the DECS-100 is powered from the generator output (shunt powered) or a permanent
magnet generator (PMG) are still valid within the constraints given in Section 1, General Information,
Specifications. In applications where station power is used to power the DECS-100, the DECS-100
should be protected by an Inrush Current Reduction Module (ICRM-7). See Power Supply Inputs for more
information.

ADJUSTMENTS
All adjustments are made using external switching, or with BESTCOMS software via the rear panel
communication port. See Sections 5 and 6 for more information regarding setting adjustments with
BESTCOMS software.

4-14 Installation DECS-100

SECTION 5 • BESTCOMS SOFTWARE
TABLE OF CONTENTS
SECTION 5 • BESTCOMS SOFTWARE................................................................................................... 5-1
INTRODUCTION .................................................................................................................................... 5-1
INSTALLATION ...................................................................................................................................... 5-1
Installing BESTCOMS ........................................................................................................................ 5-1
Connecting the DECS-100 and PC .................................................................................................... 5-1
STARTING BESTCOMS ........................................................................................................................ 5-1
Establishing Communication .............................................................................................................. 5-2
CHANGING SETTINGS ......................................................................................................................... 5-2
SENDING AND RECEIVING SETTINGS .............................................................................................. 5-3
Sending Settings................................................................................................................................. 5-3
Receiving Settings .............................................................................................................................. 5-3
Saving Settings to DECS-100 Memory .............................................................................................. 5-3
SETTING DEFINITIONS ........................................................................................................................ 5-3
System Configuration ......................................................................................................................... 5-3
System Settings .............................................................................................................................. 5-3
Setting Adjustments............................................................................................................................ 5-4
Setpoint Tab.................................................................................................................................... 5-4
Startup Tab ..................................................................................................................................... 5-5
Control Gain........................................................................................................................................ 5-6
Control Gain Tab............................................................................................................................. 5-6
Analysis............................................................................................................................................... 5-8
AVR Tab.......................................................................................................................................... 5-8
FCR Tab.......................................................................................................................................... 5-9
PF Tab........................................................................................................................................... 5-10
VAR Tab........................................................................................................................................ 5-11
Protection Settings............................................................................................................................ 5-12
Protection Tab............................................................................................................................... 5-12
Limiter Tab .................................................................................................................................... 5-13
Metering, Operation and Alarms....................................................................................................... 5-14
Operation Tab ............................................................................................................................... 5-14
Alarm/Status Tab .......................................................................................................................... 5-17
PID DATA ............................................................................................................................................. 5-18
PID Calculation Based on Input Values............................................................................................ 5-18
Adding to the PID List ....................................................................................................................... 5-19
Removing a PID List Record ............................................................................................................ 5-19
Retrieving Existing Data from the PID List ....................................................................................... 5-19
SETTINGS FILES ................................................................................................................................ 5-19
Printing Settings Files ....................................................................................................................... 5-19
Saving Settings Files ........................................................................................................................ 5-19
Uploading Settings Files ................................................................................................................... 5-20
PASSWORD PROTECTION................................................................................................................ 5-20
Changing the Password.................................................................................................................... 5-20
TERMINATING COMMUNICATION .................................................................................................... 5-21
EMBEDDED FIRMWARE .................................................................................................................... 5-21
Updating the Firmware ..................................................................................................................... 5-21

Figures
Figure 5-1. BESTCOMS Title and Version ................................................................................................5-1
Figure 5-2. Communication Port Menu Selection ......................................................................................5-2
Figure 5-3. Password Dialog Box ..............................................................................................................5-2
Figure 5-4. Communication Initiation Screen.............................................................................................5-2
Figure 5-5. Wait Dialog Box .......................................................................................................................5-2
Figure 5-6. System Configuration Screen..................................................................................................5-4
Figure 5-7. Setting Adjustments Screen, Setpoint Tab .............................................................................5-5
Figure 5-8. Setting Adjustments Screen, Startup Tab ...............................................................................5-6
Figure 5-9. Control Gain Screen ................................................................................................................5-6
DECS-100 BESTCOMS Software i
Figure 5-10. Analysis Screen, AVR Tab ....................................................................................................5-9
Figure 5-11. Analysis Screen, FCR Tab ..................................................................................................5-10
Figure 5-12. Analysis Screen, PF Tab .....................................................................................................5-11
Figure 5-13. Analysis Screen, VAR Tab ..................................................................................................5-12
Figure 5-14. Protection Settings, Protection Tab.....................................................................................5-13
Figure 5-15. Protection Settings Screen, Limiter Tab..............................................................................5-14
Figure 5-16. Metering, Operation, and Alarms Screen, Operation Tab...................................................5-15
Figure 5-17. Metering, Operation, and Alarms Screen, Alarm/Status Tab ..............................................5-17
Figure 5-18. PID Window.........................................................................................................................5-18
Figure 5-19. Settings Upload Dialog Box.................................................................................................5-20
Figure 5-20. Password Dialog Box ..........................................................................................................5-20
Figure 5-21. Software Uploading Advisory Dialog Box............................................................................5-21
Figure 5-22. DECS-100 Embedded Program Loader..............................................................................5-22
Figure 5-23. Retrieved DECS-100 Information........................................................................................5-22
Figure 5-24. Settings File Reminder Dialog Box......................................................................................5-22
Figure 5-25. Open Dialog Box .................................................................................................................5-23
Figure 5-26. File Transfer Progress .........................................................................................................5-23
Figure 5-27. DECS-100 Information After Upload ...................................................................................5-23

Tables
Table 5-1. DECS-100 Stability Range Settings .........................................................................................5-7
Table 5-2. Analysis Screen Tab Combinations..........................................................................................5-8

ii BESTCOMS Software DECS-100

SECTION 5 • BESTCOMS SOFTWARE
INTRODUCTION
BESTCOMS-DECS100 software provides the communication link between the DECS-100 and the user.
All DECS-100 settings are entered through BESTCOMS and all metering values (updated about once
every second) are read through BESTCOMS. Software within BESTCOMS enables the user to establish
proper PID (proportional + integral + derivative) parameters based on a specified generator and/or exciter
time constants. Within BESTCOMS, DECS-100 settings can be saved in a computer file and used later to
configure other units with the same settings.

INSTALLATION
BESTCOMS software for the DECS-100 operates with IBM-compatible personal computers (PCs)
operating with Microsoft® Windows® 98, Me, 2000, and Windows® NT®. The minimum recommended
operating requirements are:
• IBM compatible PC, 486DX2 or faster (100 MHz or higher microprocessor is recommended)
• CD-ROM Drive
• One available serial port

Installing BESTCOMS
BESTCOMS software contains a setup utility that installs the program on your PC. An uninstall utility is
loaded with the program that can be used to remove BESTCOMS from your PC if desired. Use the
following procedure to install BESTCOMS.
1. Insert the CD-ROM into the PC CD-ROM drive.
2. When the DECS-100 Setup and Documentation CD menu appears, click the Install button for the
BESTCOMS PC Program. The setup utility automatically installs BESTCOMS on your PC.
When BESTCOMS is installed, a Basler Electric folder is added to the Windows® program menu. This
folder is accessed by clicking the Start button and pointing to Programs. The Basler Electric folder
contains icons for the BESTCOMS-DECS100 program and a utility to remove BESTCOMS.

Connecting the DECS-100 and PC

Connect a communication cable between the rear RS-232 connector of the DECS-100 and the
appropriate communication port of the PC. Refer to Figure 2-2 for the location of the DECS-100 RS-232
connector and Figure 4-5 for the required connections between the DECS-100 and a PC.

CAUTION
When applying operating power to the DECS-100 for programming purposes,
observe the precautions called out in Section 4, Installation, Preliminary Setup.

STARTING BESTCOMS
BESTCOMS is started by clicking the Windows® Start
button, pointing to Programs, the Basler Electric folder,
and then clicking the BESTCOMS-DECS100 icon. At
startup, a dialog box with the program title and version
number is displayed briefly (Figure 5-1). After this dialog
box is displayed, the System Configuration screen is
displayed.

Figure 5-1. BESTCOMS Title and Version

DECS-100 BESTCOMS Software 5-1

Establishing Communication
Communication between BESTCOMS and the
DECS-100 must be established before viewing
metering values or reading or changing settings.
BESTCOMS screen settings are updated only
after communication is opened or the
communication settings have been changed.
Open the DECS-100 communication port by
clicking on Communications on the menu bar,
hovering the mouse pointer over Open Comm
Figure 5-2. Communication Port Menu Selection
Port, and clicking RS-232 Port. Figure 5-2
illustrates the menu selections for opening the
DECS-100 communication port.
When RS-232 Port is selected, the Password dialog box of Figure 5-3 appears and prompts you to enter
a password. Each DECS-100 is delivered with "decs" as the default password. See the Password
Protection sub-section for information about changing the password.
After the correct password is entered, the Communication Initiation screen of Figure 5-4 is displayed.
Select Comm 1, Comm 2, Comm 3, or Comm 4 as the active communication port on your PC and click
the Initialize button. BESTCOMS initializes communication by obtaining the configuration settings from
the DECS-100.

Figure 5-3. Password Dialog Box
NOTE
BESTCOMS may display the dialog box of
Figure 5-5 when initializing DECS-100 commu-
nication, obtaining DECS-100 configuration set-
tings, or performing other tasks. It's important to
wait until the box disappears before trying to
execute communication commands. Issuing
commands while the Wait dialog box is present
may disrupt communication between the DECS-
100 and BESTCOMS.

Figure 5-5. Wait Dialog Box

Figure 5-4. Communication Initiation Screen

CHANGING SETTINGS
Settings are arranged into six groups.
• System Configuration • Analysis
• Setting Adjustments • Protection/Relay
• Control Gain • Metering/Operation
Each setting group has a corresponding toolbar button that can be selected to access that group of
settings. The six setting groups can also be accessed by clicking Screens on the menu bar and then
selecting the desired setting group from the list. Once a setting group is accessed, the individual settings
of the group can be viewed and changed.
A setting is changed by clicking within the setting field and typing the new setting. The range limits of a
setting can be viewed by double-clicking the setting. Once all desired setting changes have been made
on a setting group screen, the settings must be sent to the DECS-100 before viewing other screens.
Otherwise, the settings changes will be lost. Settings changes can be sent to the DECS-100 by clicking
the SendToDECS button. Settings can also be sent to the DECS-100 by clicking Communications on
the menu bar and clicking Send To DECS.

5-2 BESTCOMS Software DECS-100

SENDING AND RECEIVING SETTINGS
When communication is enabled, DECS-100 settings can be sent or received through BESTCOMS.

Sending Settings
Settings changes are sent to the DECS-100 by clicking the SendToDECS button. This causes the
selected setting displayed on the current settings screen to become the DECS-100 setting. Settings can
also be sent to the DECS-100 by clicking Communications on the menu bar and clicking Send To
DECS. Additionally, a setting can be sent by pressing the Enter key after the new value is typed in. The
SendToDECS button must be clicked or the Enter key must be pressed after each setting change to
ensure that all settings are sent to the DECS-100. See Saving Settings to DECS-100 Memory for
information about retaining DECS-100 settings after operating power is removed.

Receiving Settings
DECS-100 settings are retrieved by clicking the GetFromDECS button. This causes the current settings
of the DECS-100 to be displayed on the settings screen. Settings can also be received from the DECS-
100 by clicking Communications on the menu bar and clicking Get From DECS.

Saving Settings to DECS-100 Memory

Settings are saved in nonvolatile memory (EEPROM). In the event of a power loss, these are the settings
that are active at power up. If settings are changed and sent to the DECS-100, but not sent to EEPROM,
the changed settings are lost if DECS-100 operating power is lost. When exiting BESTCOMS or closing
communication, you are asked if you want to save the settings to EEPROM. This question is asked even
if no settings changes were made.
When communication is enabled, setting changes are saved to EEPROM by clicking the EEPROM
button. The opportunity to save settings to EEPROM is also given through a dialog box when exiting
BESTCOMS or closing communication.

SETTING DEFINITIONS
Each of the six setting groups has a corresponding BESTCOMS screen. The settings of each screen are
categorized by one or more tabs. In the following paragraphs, settings are arranged and defined
according to the organization of the BESTCOMS screens and tabs.

System Configuration
The System Configuration screen consists of one tab labeled System Settings. Click the Configure
button to access the System Configuration screen or click Screens on the menu bar and click System
Configuration.
System Settings
System settings are shown in Figure 5-6 and described in the following paragraphs.
Sensing Voltage. This setting is used to configure the DECS-100 for either single-phase or three-phase
sensing voltage.
Limiter Mode. This setting enables and disables the excitation limiters. Overexcitation limiting (OEL) or
underexcitation limiting (UEL) can be enabled independently, both can be enabled, or neither limiter
enabled.
OEL Type. This setting configures the overexcitation limiter as a summing point limiter or takeover-style
limiter.
Generator Frequency. This setting is used to select a nominal system operating frequency of 50 hertz or
60 hertz.
Regulator Sensing Voltage (V). The nominal, ac generator voltage obtained from the generator sensing
transformer is entered in this setting field. Voltages within the ranges of 100 to 140 Vac, 200 to 280 Vac,
or 400 to 560 Vac may be entered in 0.1 Vac increments. A setting of 600 Vac is also possible.
Regulator Sensing Current (A). This setting field reads and displays the nominal output of the current
transformer (CT) that supplies the DECS-100 with B-phase generator line current. This value (1 or 5)
must be manually entered for units with a firmware version lower than 1.12.01.

DECS-100 BESTCOMS Software 5-3

 Figure 5-6. System Configuration Screen
Version Numbers. These two read-only version numbers indicate the BESTCOMS software version and
the DECS-100 embedded software version. Version numbers are displayed only when communication
between the DECS-100 and BESTCOMS is established.

Style Number. The three, read-only style number fields indicate the electrical characteristics and
operational features of the DECS-100. the style number is displayed only when communication between
the DECS-100 and BESTCOMS is established.
Generator PT Ratio. The ratio of the generator sensing transformer is entered in this setting field. This
ratio allows the voltage displayed through BESTCOMS to match the actual generator output voltage. A
ratio of 1 to 150 may be entered in increments of 0.01.
Generator CT Ratio. The ratio of the generator B-phase current transformer is entered in this setting field.
This ratio allows the current displayed by the DECS-100 to match the actual B-phase generator output
current. A ratio of 1 to 3,000 may be entered in increments of 0.1.
Bus PT Ratio. This setting field is used to enter the bus potential sensing transformer ratio. This ratio
allows the bus voltage to be displayed through BESTCOMS. A ratio of 1 to 150 may be entered in 0.01
increments.

Setting Adjustments
The Setting Adjustments screen consists of two tabs: Setpoint and Startup.
Setpoint Tab
The Setpoint tab settings of the Setting Adjustments screen are shown in Figure 5-7. Each setting of the
Setpoint tab is described in the following paragraphs.
Automatic Voltage Regulator (AVR) - AVR Setpoint (V). This setting field is used to enter the desired
generator output terminal voltage. The AVR setpoint value range depends on the regulator sensing
voltage and band setting.
Fine Voltage Adjustment - Band Setting (%). The Band Setting determines the minimum and maximum
adjustment allowed to the AVR Setpoint (as a percentage of the Regulator Sensing Voltage setting (see
Figure 5-8)). Band Setting values are entered as a percentage of the regulator sensing voltage setting
over a range of 0 to 15%in 0.1% increments.
Droop - Setpoint (%). This setting controls the reactive droop compensation feature of the DECS-100.
The setpoint value determines the amount of change permitted in the generator voltage setpoint when the
DECS-100 responds to a reactive load. The setpoint value is adjustable from 0 to 10% in increments of
0.01%. The setpoint is based on a 0.8 power factor load.
5-4 BESTCOMS Software DECS-100
Field Current Regulator (FCR) - FCR Setpoint (A). This setting defines the field current setpoint when
operating in Manual mode. The FCR Setpoint field accepts a value of 0 to 7 Adc in 0.01 Adc increments.

Figure 5-7. Setting Adjustments Screen, Setpoint Tab

Reactive Power Control (VAR) - VAR Setpoint (% of rated). The VAR Setpoint determines the level of
generator vars maintained by the DECS-100 when operating in Var Control mode. Values from -100 to
+100 percent in 1.0 percent increments may be entered in the VAR Setpoint field.
Power Factor Control (PF) - PF Setpoint. The PF Setpoint determines the level of generator power factor
maintained by the DECS-100 when operating in Power Factor Control mode. PF Setpoint values are
adjustable from -0.6 to -1 (1) or 0.6 to +1 in 0.001 increments.
Startup Tab
The Startup-tab settings of the Setting Adjustment screen are shown in Figure 5-8. Each setting of the
Startup tab is described in the following paragraphs.
Startup Control - Gen Soft Start Time (sec). This setting defines the time limit for the generator soft-start
voltage ramp time. The soft-start time minimizes generator voltage overshoot and can be set from 1 to
7,200 seconds in 1 second increments.
Underfrequency Setting - Corner Frequency (Hz). The Corner Frequency setting defines the value of
frequency that causes the DECS-100 to adjust the voltage setpoint so that the generator voltage follows
the selected volts per hertz slope. A value of 40 to 65 hertz can be entered in this setting field in 0.01
increments.
Underfrequency Setting - Slope (Volts/Hz). The slope for generator underfrequency protection is selected
with this per-unit setting. A slope setting of 0 to 3.00 can be entered in increments of 0.01.
Voltage Matching - Speed (sec). This setting determines how quickly the generator voltage is adjusted by
the DECS-100 to match the bus voltage. The Speed setting is adjustable from 1 to 300 seconds in 0.01
increments.
Voltage Matching – Disable by Contact. This setting selects the DECS-100 contact input used to disable
voltage matching. Selecting “52JK or 52LM” allows either the 52JK or 52LM contact input to disable
voltage matching. Selecting “52JK” allows only the 52JK contact input to disable voltage matching.
Voltage Matching – Mode. The voltage matching mode can be Maintain or Revert. When Maintain is
selected, the DECS-100 setpoint is maintained at the bus voltage level even after the generator or utility
breaker opens. When Revert is selected, the DECS-100 setpoint reverts to its original level when the
generator or utility breaker opens.

DECS-100 BESTCOMS Software 5-5

 Figure 5-8. Setting Adjustments Screen, Startup Tab

Control Gain
The Control Gain screen consists of one tab labeled Control Gain. Click the Gain button to access the
Control Gain screen or click Screens on the menu bar and click Control Gain.
Control Gain Tab
Control gain settings are shown in Figure 5-9 and are described in the following paragraphs.

Figure 5-9. Control Gain Screen

5-6 BESTCOMS Software DECS-100

Stability Range. This setting selects one of 20 preset stability ranges within the DECS-100. A guide for
selecting the stability range is provided in Table 5-1. A setting of 21 enables the entry of custom stability
settings through the BESTCOMS PID window. Information about the PID window is provided later under
the heading of PID Window. When the Stability Range is set at 21, the PID button may be selected to
access the PID window. A Stability Range setting of 1 through 20 disables the PID button and prevents
access to the PID window.
AVR/FCR - Proportional Gain KP. This setting selects the proportional constant (KP) stability parameter.
The DECS-100 supplies a value that is equivalent to KP multiplied by the error between the voltage
setpoint and the actual generator output voltage. KP values of 0 to 1,000 may be entered in increments of
0.01.
Observe the following guidelines when tuning the KP value. If the transient response has too much
overshoot, then KP should be decreased. If the transient response is too slow, then KP should be
increased.
Table 5-1. DECS-100 Stability Range Settings
Generator Time Constants Stability
Size Generator (T’do) Exciter (Texc) Range
SMALL 1.0 0.17 1
1.5 0.25 2
2.0 0.33 3
2.5 0.42 4
3.0 0.50 5
3.5 0.58 6
4.0 0.67 7
4.5 0.75 8
5.0 0.83 9
5.5 0.92 10
6.0 1.00 11
6.5 1.08 12
7.0 1.17 13
7.5 1.25 14
8.0 1.33 15
8.5 1.42 16
9.0 1.50 17
9.5 1.58 18
10.0 1.67 19
LARGE 10.5 1.75 20

AVR/FCR - Integral Gain KI. This setting selects the integral constant (KI) stability parameter. The DECS-
100 supplies a value that is equivalent to KI multiplied by the integral of the error between the voltage
setpoint and the actual generator output voltage. KI values of 0.01 to 1,000 may be entered in increments
of 0.01.
Increasing the value of KI decreases the time required to reach steady state.
AVR/FCR - Derivative Gain KD. This setting selects the derivative constant (KD) stability parameter. The
DECS-100 provides an output value that is equivalent to KD multiplied by the derivative of the error
between the voltage setpoint and the actual generator output voltage. KD values of 0 to 1,000 may be
entered in increments of 0.01.
Increasing the value of KD reduces transient response ringing.
AVR/FCR - AVR<=Loop Gain Kg=>FCR. This setting adjusts the loop-gain level of the PID algorithm.
Loop Gain values of 0 to 1,000 may be entered for AVR and FCR operation in increments of 0.01.
VAR/PF - PF Integral Gain KI. This setting adjusts the integral gain and determines the characteristic of
the DECS-100 dynamic response to a changed PF setting. PF KI values of 0 to 1,000 may be entered in
increments of 0.01.

DECS-100 BESTCOMS Software 5-7

VAR/PF - Var Integral Gain KI. This setting adjusts the integral gain and determines the characteristic of
the DECS-100 dynamic response to a changed var setting. Var KI values of 0 to 1,000 may be entered in
increments of 0.01.
VAR/PF - VAR<=Loop Gain Kg=>PF. This setting adjusts the loop-gain level of the PI algorithm for var or
power factor control. Loop Gain values of 0 to 1,000 may be entered for var and power factor operation in
increments of 0.01.
OEL/UEL – OEL Integral Gain KI. This setting controls the rate at which the DECS-100 responds during
an overexcitation event. KI values of 0 to 1,000 may be entered in increments of 0.01.
OEL/UEL – OEL Loop Gain Kg. This setting adjusts the coarse loop-gain level of the PID algorithm for the
overexcitation limiting function. Loop Gain values of 0 to 1,000 may be entered in increments of 0.01.
OEL/UEL – UEL Integral Gain KI. This setting controls the rate at which the DECS-100 responds during
an underexcitation event. KI values of 0 to 1,000 may be entered in increments of 0.01.
OEL/UEL – UEL Loop Gain Kg. This setting adjusts the coarse loop-gain level of the PID algorithm for the
underexcitation limiting function. Loop Gain values of 0 to 1,000 may be entered in increments of 0.01.

Analysis
Click the Analysis button or click Screens on the Menu bar and click Analysis to view the Analysis
screen. The Analysis screen consists of four tabs: VAR, PF, AVR, and FCR. Each of the tabs displays
four metered sensing values and has six alarm signal indicators. Metered sensing values include Vrms
(rms voltage), Ifd (dc field current), reactive power (vars), and power factor (PF). Alarm signal indicators
include Overexcitation Limiting, Underexcitation Limiting, Generator Overvoltage, Loss of Generator
Sensing, Underfrequency Active, and Overexcitation Shutdown.
The operating status and control mode of the DECS-100 determine which tabs of the Analysis screen are
enabled and can be accessed by the user. Table 5-2 lists the DECS-100 operating status and control
modes that enable the four tabs of the Analysis screen.
Table 5-2. Analysis Screen Tab Combinations
Control Mode Operating Status Tab Enabled
AVR OFF AVR
AVR PF AVR, PF
AVR VAR AVR, VAR
FCR N/A FCR

Control mode and operating status selections are made at the Operation tab of the BESTCOMS Metering
screen and are discussed later in this section.
AVR Tab
Figure 5-10 illustrates the settings, sensing values, and alarm signal indicators of the AVR tab. The
settings of the AVR tab make it possible to increment and decrement the AVR setpoint of the DECS-
100.The sensing values and alarm signal indicators of the AVR tab are also displayed by the other tabs of
the Analysis screen.
Voltage Step Response - AVR Setpoint (V) (Nominal). This read-only field indicates the AVR setpoint.
(The AVR setpoint is set by using the Setpoint tab of the Setting Adjustments screen). The voltage
displayed in the AVR Setpoint field is selected by clicking the adjacent button. Clicking this button sends
the AVR Setpoint value to the DECS-100 and changes the color of the button from gray to red.
Voltage Step Response - Increment of AVR Setpoint (V). These two fields indicate the increase that
occurs to the AVR setpoint when the corresponding Increment button is clicked. The "% increase" field is
used to set and indicate the percentage that the AVR setpoint is increased when the Increment button is
clicked. The "AVR Setpoint =" field indicates the value of voltage that corresponds to the "% increase"
field. Any setpoint value within range or higher than the setpoint value can be typed into the "AVR
Setpoint ="field, which updates the "% increase" field. The AVR setpoint changes to this value when the
adjacent button is clicked. When clicked, the Increment button changes from gray to red to indicate that
the AVR setpoint has increased to the value in the "AVR Setpoint =" field.

5-8 BESTCOMS Software DECS-100

 Figure 5-10. Analysis Screen, AVR Tab
Voltage Step Response - Decrement of AVR Setpoint (V). These two fields indicate the change that will
occur to the AVR setpoint when the corresponding Decrement button is clicked. The "% decrease" field is
used to set and indicate the percentage (0 to 10%) that the AVR setpoint is decreased when the
Decrement button is clicked. The "AVR Setpoint =" field indicates the value of voltage that corresponds to
the "% decrease" field. Any setpoint value within range or lower than the setpoint value can be typed into
the "AVR Setpoint =" field, which updates the "% decrease" field. The AVR setpoint changes to this value
when the adjacent button is clicked. When clicked, the Decrement button changes from gray to red to
indicate that the AVR setpoint has decreased to the value in the "AVR Setpoint =" field.
Voltage Step Response - Meter Value. This field and the dial pointer indicate the value of the selected
AVR setpoint. When the AVR setpoint is changed by clicking the increment, decrement, or setpoint
button, the meter value field and dial pointer indicate the new setpoint value. A new AVR setpoint can be
typed directly into the Meter Value field or selected by dragging the dial pointer to the desired value. The
new value is sent to the DECS-100 by clicking the Send button.
Voltage Step Response - Current Setpoint. The active DECS-100 setpoint (adjusted by using any of the
previously mentioned methods) is displayed in this field. To return the AVR setpoint to the nominal
setting, the button adjacent to the "AVR Setpoint (V) (Nominal)" field should be clicked. If the AVR tab is
left to view other tabs or screens without returning the AVR setpoint to nominal, an AVR dialog box
appears. Clicking the Yes button returns the AVR setpoint to nominal. Clicking No maintains the AVR
setpoint at the current value.
FCR Tab
Figure 5-11 illustrates the settings, sensing values, and alarm signal indicators of the FCR tab. The
settings of the FCR tab make it possible to increment and decrement the FCR setpoint of the DECS-100.
The sensing values and alarm signal indicators of the FCR tab are also displayed by the other tabs of the
Analysis screen.
Field Current Step Response - FCR Setpoint (A). This read-only field indicates the FCR setpoint. (The
FCR setpoint is set by using the Setpoint tab of the Setting Adjustments screen). The current displayed in
the FCR Setpoint field is selected by clicking the adjacent pushbutton. Clicking this button sends the FCR
Setpoint value to the DECS-100 and changes the color of the pushbutton from gray to red.
Field Current Step Response - Increment of FCR Setpoint (A). These two fields indicate the increase that
occurs to the FCR setpoint when the corresponding Increment button is clicked. The "% increase" field is
used to set and indicate the percentage (0 to 10%) that the FCR setpoint is increased when the
Increment button is clicked. The "FCR Setpoint =" field indicates the value of current that corresponds to
the "% increase" field. Any setpoint value within range or higher than the setpoint value can be typed into
DECS-100 BESTCOMS Software 5-9
the "FCR Setpoint =" field, which updates the "% increase" field. The FCR setpoint changes to this value
when the adjacent button is clicked. When clicked, the Increment button changes from gray to red to
indicate that the FCR setpoint has increased to the value in the "FCR Setpoint =" field.

Figure 5-11. Analysis Screen, FCR Tab

Field Current Step Response - Decrement of FCR Setpoint (A). These two fields indicate the change that
will occur to the FCR setpoint when the corresponding Decrement button is clicked. The "% decrease"
field is used to set and indicate the percentage that the FCR setpoint is decreased when the Decrement
button is clicked. The "FCR Setpoint =" field indicates the value of current that corresponds to the "%
decrease" field. The FCR setpoint changes to this value when the adjacent button is clicked. When
clicked, the Decrement button changes from gray to red to indicate that the FCR setpoint has decreased
to the value in the "FCR Setpoint =" field.
Field Current Step Response - Meter Value. This field and the dial pointer indicate the value of the
selected FCR setpoint. When the AVR setpoint is changed by clicking the increment, decrement, or
setpoint button, the meter value field and dial pointer indicate the new setpoint value. A new FCR setpoint
can be typed directly into the "Meter Value" field or selected by dragging the dial pointer to the desired
value. The new value is sent to the DECS-100 by clicking the Send button.
Field Current Step Response - Current Setpoint. The active DECS-100 setpoint (adjusted by using any of
the previously mentioned methods) is displayed in this field. To return the FCR setpoint to the nominal
setting, the button adjacent to the "FCR Setpoint (A) (Nominal)" field should be clicked. If the FCR tab is
left to view other tabs or screens without returning the FCR setpoint to nominal, an FCR setpoint dialog
box appears. Clicking the Yes button returns the AVR setpoint to nominal. Clicking No maintains the AVR
setpoint at the current level.
PF Tab
Figure 5-12 illustrates the settings, sensing values, and alarm signal indicators of the PF tab. Each setting
of the PF tab is described in the following paragraphs.
Power Factor Step Response - Power Factor Setpoint (Nominal). This read-only field indicates the PF
setpoint. (The PF setpoint is set by using the Setpoint tab of the Setting Adjustments screen.) The value
displayed in the FCR Setpoint field is selected by clicking the adjacent pushbutton. Clicking this button
sends the PF setpoint value to the DECS-100 and changes the color of the pushbutton from gray to red.
Power Factor Step Response - Increment of PF Setpoint. This field indicates the new PF setpoint that is
established when the corresponding increment button is clicked. Any setpoint value within range or higher
than the existing setpoint value can be typed into the "Increase PF Setpoint =" field. The PF setpoint
changes to this value when the adjacent button is clicked. When clicked, the Increment button changes
5-10 BESTCOMS Software DECS-100
from gray to red to indicate that the PF setpoint has increased to the value in the "Increase PF Setpoint ="
field.

Figure 5-12. Analysis Screen, PF Tab

Power Factor Step Response - Decrement of PF Setpoint. This field indicates the new PF setpoint that is
established when the corresponding decrement button is clicked. Any setpoint value within range or lower
than the existing setpoint value can be typed into the "Decrease PF Setpoint =" field. The PF setpoint
changes to this value when the adjacent button is clicked. When clicked, the Decrement button changes
from gray to red to indicate that the PF setpoint has decreased to the value in the "Decrease PF Setpoint
=" field.
Power Factor Step Response - PF Value. This field and the dial pointer indicate the value of the selected
PF setpoint. When the PF setpoint is changed by clicking the increment, decrement, or setpoint button,
the meter value field and dial pointer indicate the new setpoint value. A new PF setpoint can be typed
directly into the "PF Value" field or selected by dragging the dial pointer to the desired value. The new
value is sent to the DECS-100 by clicking the Send button.
Power Factor Step Response - Current Setpoint. The active DECS-100 setpoint (adjusted by using any of
the previously mentioned methods) is displayed in this field. To return the PF setpoint to the nominal
setting, the button adjacent to the PF Setpoint (Nominal) field should be clicked. If the PF tab is left to
view other tabs or screens without returning the PF setpoint to nominal, a PF setpoint dialog box appears.
Clicking the Yes button returns the AVR setpoint to nominal. Clicking No maintains the AVR setpoint at
the current value.
VAR Tab
Figure 5-13 illustrates the settings, sensing values, and alarm signal indicators of the VAR tab. Each
setting of the VAR tab is described in the following paragraphs.
Reactive Power Step Response - VAR Setpoint (%) (Nominal). This read-only field indicates the var
setpoint. (The var setpoint is set by using the Setpoint tab of the Setting Adjustments screen.) The value
displayed in the "VAR Setpoint" field is selected by clicking the adjacent button. Clicking this button sends
the var setpoint value to the DECS-100 and changes the color of the pushbutton from gray to red.
Reactive Power Step Response - Increment of VAR Setpoint (%). This field indicates the increase that
occurs to the FCR setpoint when the corresponding Increment button is clicked. The "Increase VAR
Setpoint =" field is used to set and indicate the percentage that the var setpoint is increased to when the
Increment button is clicked. Any setpoint value (expressed as a percent of nominal) within range or higher
than the existing setpoint value can be typed into the "Increase VAR Setpoint =" field. The var setpoint
changes to the new value when the adjacent button is clicked. Clicking this button sends the var setpoint
value to the DECS-100 and changes the color of the pushbutton from gray to red.
DECS-100 BESTCOMS Software 5-11
 Figure 5-13. Analysis Screen, VAR Tab
Reactive Power Step Response - Decrement of VAR Setpoint (%). This field indicates the decrease that
occurs to the FCR setpoint when the corresponding Decrement button is clicked. The "Decrease VAR
Setpoint =" field is used to set and indicate the percentage that the var setpoint is decreased to when the
Decrement button is clicked. Any setpoint value (expressed as a percent of nominal) within range or lower
than the existing setpoint value can be typed into the "Decrease VAR Setpoint =" field. The var setpoint
changes to the new value when the adjacent button is clicked. Clicking this button sends the var setpoint
value to the DECS-100 and changes the color of the pushbutton from gray to red.
Reactive Power Step Response - Meter Value. These fields and the dial pointer indicate the value of the
selected var setpoint. When the var setpoint is changed by clicking the increment, decrement, or setpoint
button, the meter value fields and dial pointer indicate the setpoint value. A new var setpoint, expressed
as a kvar value or a percentage of nominal, can be typed directly into either Meter Value field or selected
by dragging the dial pointer to the desired value. The new value is sent to the DECS-100 by clicking the
Send button.
Reactive Power Step Response - Current Setpoint (%). The active var setpoint (adjusted by using any of
the previously mentioned methods) is displayed in this field. To return the var setpoint to the nominal
setting, the button adjacent to the "VAR Setpoint (%) (Nominal)" field should be clicked. If the VAR tab is
left to view other tabs or screens without returning the VAR setpoint to nominal, a var setpoint dialog box
appears. Clicking the Yes button returns the var setpoint to nominal. Clicking No maintains the var
setpoint at the current value.

Protection Settings
The Protection Settings screen consists of two tabs: Protection and Limiter. Click the Protection button to
access the Protection Settings screen or click Screens on the menu bar and click Protection Settings.
Protection Tab
Protection settings are shown in Figure 5-14 and are described in the following paragraphs.
Generator Overvoltage - Voltage Level (%). The value of this field is expressed as a percentage of the
nominal generator voltage and determines the level of generator voltage required to initiate a generator
overvoltage condition. An overvoltage percentage value of 100 to 120 percent may be entered in 1
percent increments. A generator overvoltage condition lights the Generator Overvoltage LED on the front
panel.
Generator Overvoltage – Alarm Time Delay (sec). This setting establishes the length of time that a
generator overvoltage condition must exist before the DECS-100 annunciates the condition.

5-12 BESTCOMS Software DECS-100

 Figure 5-14. Protection Settings, Protection Tab
Generator Overvoltage - Hardware Shutdown. Enabling Hardware Shutdown will cause the DECS-100 to
remove field excitation when the generator overvoltage setting is exceeded. Disabling Hardware
Shutdown prevents the DECS-100 from removing excitation during a generator overvoltage condition.
Generator Overvoltage – Alarm. This setting enables and disables closure of the DECS-100 Alarm output
(terminals AL1 and AL2) during generator overvoltage. Disabling the alarm also disables hardware
shutdown.
Field Overvoltage - Voltage Level (Vdc). The value in this field is adjustable from 0 to 250 Vdc and
determines the field voltage level that will cause the DECS-100 to issue an overexcitation limit alarm.
When the field voltage increases above the value of this field for 10 seconds, the Overexcitation
Shutdown LED on the front panel lights.
Field Overvoltage - Alarm. If the Alarm is enabled and a field overvoltage condition exists for 10 seconds,
the DECS-100 Alarm output (terminals AL1, AL2) will close. Disabling the Alarm prevents the Alarm
output from closing when a field overvoltage condition exists. Disabling the alarm also disables hardware
shutdown.
Field Overvoltage - Hardware Shutdown. When Hardware Shutdown is enabled, the DECS-100 will
remove field excitation when a field overvoltage condition exists for 10 seconds.
Loss of Sensing Voltage - LOS Option. One of two DECS-100 responses can be selected for a loss of
sensing voltage condition. Selecting Shutdown Regulator will cause the DECS-100 to remove field
excitation when loss of sensing voltage occurs. Selecting Transfer To FCR will cause the DECS-100 to
transfer to FCR mode when a loss of sensing voltage occurs.
Loss of Sensing Voltage - Time Delay (sec). The value of this field determines the time delay between
when a loss of sensing voltage is recognized and the DECS-100 responds according to the Hardware
Shutdown and LOS Option options selected. A time delay of 0 to 25 seconds may be entered in 1 second
increments.
Loss of Sensing Voltage - Hardware Shutdown. Enabling Hardware Shutdown will cause the DECS-100
to remove field excitation when a loss of sensing voltage occurs. Disabling Hardware Shutdown prevents
the DECS-100 from removing excitation during a loss of sensing voltage.
Limiter Tab
Limiter tab settings are shown in Figure 5-15 and described in the following paragraphs.
OEL - Current Level (A). The value of current in this field determines the excitation level that will cause
the DECS-100 to issue an overexcitation limit alarm. A current level of 0 to 15 A may be entered in 0.01
increments. When the level of field current increases above the value of this field, the Overexcitation
Shutdown LED on the front panel lights and the OEL time delay starts timing down.
DECS-100 BESTCOMS Software 5-13
 Figure 5-15. Protection Settings Screen, Limiter Tab
OEL - Alarm Time Delay (sec). The value of this field determines the time delay between when the
DECS-100 recognizes an overexcitation condition and the DECS-100 Alarm output (terminals AL1, AL2)
closes. A time delay of 0 to 10 seconds may be entered in 1 second increments.
OEL - Hardware Shutdown. If the hardware shutdown feature is enabled and an overexcitation condition
exists for the duration of the Alarm Time Delay, the DECS-100 will stop excitation when the Alarm output
closes.
UEL – VAR Level (%). This setting, expressed as a percentage of the leading var setpoint, determines the
excitation level that will cause the DECS-100 to issue an underexcitation limit alarm. A setting of 0 to
100% may be entered in 1% increments. When the var level decreases below this setting, the
Underexcitation Limiting LED on the front panel lights and the UEL time delay starts timing down.
UEL – Alarm Time Delay (sec). The value of this field determines the time delay between when the
DECS-100 recognizes an underexcitation condition and the DECS-100 Alarm output (terminals AL1, AL2)
closes. A time delay of 0 to 10 seconds may be entered in 1 second increments.
UEL – Hardware Shutdown. If the hardware shutdown feature is enabled and an underexcitation
condition exists for the duration of the Alarm Time Delay, the DECS-100 will stop excitation when the
Alarm output closes.

Metering, Operation and Alarms

The Metering, Operation and Alarms screen is viewed by clicking the Metering button or by clicking
Screens on the Menu bar and clicking Metering/Operation. Information displayed on the Metering,
Operation and Alarms screen can be frozen by clicking the Metering button while viewing the screen or by
clicking Metering on the Menu bar and clicking Disable Metering. Metering can be resumed by clicking the
Metering button or by clicking Metering on the Menu bar and clicking Enable Metering. The Metering,
Operation and Alarms screen consists of two tabs: Operation and Alarm/Status.
Operation Tab
Operation tab metering values, setpoint values, and control functions are illustrated in Figure 5-16.
Gen Voltage (V). These metering values report the status of the VA-B, VC-B, VC-A, and VAVG generator
voltages. The reported values are the product of the voltage sensed at terminals E1, E2, and E3 and the
generator PT ratio. All metering values are updated once each second. When single-phase sensing is
used (System Configuration screen, Sensing Voltage) and the DECS-100 sensing voltage terminals (E1,
E2, and E3) are connected as shown in Figures 4-7 or 4-9, all of the generator voltage metering values
will be identical.
5-14 BESTCOMS Software DECS-100
 Figure 5-16. Metering, Operation, and Alarms Screen, Operation Tab
Gen Current (A). This metering value indicates the level of the B-phase generator current. This value is
the product of the current input to CT1 and CT2 and the CT ratio. Generator current is monitored through
DECS-100 terminals CT1 and CT2.
Gen Frequency (Hz). This metering value indicates the frequency of the monitored generator voltage.
Field Voltage (V). This metering value indicates the value of voltage being supplied from the DECS-100
output (terminals F+ and F-) to the generator field.
Field Current (A). This metering value indicates the amount of current flowing from the DECS-100 output
(terminals F+ and F-) to the generator field.
Bus Voltage (V). This metering value indicates the amount of bus voltage present at the utility side of the
tie circuit breaker. The displayed value is the product of the voltage sensed at terminals B1 and B3 and
the bus PT ratio.
Phase Angle (Degree). This metering value indicates the phase angle difference (in degrees) between the
generator voltage and the generator current.
Aux DC Input (V). This metering value indicates the level of dc control voltage applied from a remote
device to DECS-100 terminals A and B. The displayed value correlates to the generator voltage setpoint.
Apparent Power (VA). This value is the calculated product of the metered generator voltage (VAVG), PT
ratio (entered at the System Configuration screen), metered generator current (Ib), CT ratio (entered at
the System Configuration screen), and the square root of 3. See Equation 5-1.

VA = V AVG × I B × 3
Equation 5-1
Real Power (W). This value is the calculated product of the metered generator voltage(VAVG), PT ratio
(entered at the System Configuration screen), metered generator current (Ib) CT ratio (entered at the
System Configuration screen), square root of 3, and the cosine of the metered phase angle. See
Equation 5-2.

W = V AVG × I B × 3 × cos φ
Equation 5-2

DECS-100 BESTCOMS Software 5-15

Reactive Power (var). This value is the calculated product of the metered generator voltage(VAVG), PT
ratio (entered at the System Configuration screen), metered generator current (Ib) CT ratio (entered at the
System Configuration screen), square root of 3, and the sine of the metered phase angle. See Equation
5-3.

var = V AVG × I B × 3 × sin φ

Equation 5-3
Power Factor. This value is the calculated result of dividing the Real Power (W) value by the Apparent
Power (VA) value. See Equation 5-4.
PF = W ÷ VA
Equation 5-4
Operating Status. The Operating Status controls and indicators include three buttons and three
corresponding indicators. Operating Status buttons are labeled PF, VAR, and OFF. Clicking the PF button
changes the color of the adjacent PF indicator to green and causes the DECS-100 to maintain the
desired power factor regulation point. The power factor regulation point can be set within the range of 0.6
lead to 0.6 lag. Clicking the VAR button changes the color of the adjacent VAR indicator to green and
causes the DECS-100 to maintain the desired var regulation point. The var regulation point can be set
within the range of 100 percent absorb to 100 percent generate. Clicking the OFF button changes the
color of the adjacent OFF indicator to red and disables power factor and var regulation.
Operation of the Operating Status controls is determined by the status of the contacts connected across
the DECS-100 Var/PF Control terminals (52J, 52K). When these contacts are open, the Operating Status
controls are enabled. Closing the contacts at terminals 52J and 52K disables the Operating Status
controls and interrupts regulation of vars or power factor until the contacts are opened again.
Setpoint - Voltage (V). This setting field can be used to enter the desired generator output terminal
voltage. The voltage setpoint can also be entered at the Setting Adjustments screen, Setpoint tab,
Automatic Voltage Regulator (AVR) - AVR Setpoint (V). The background color of this field is green when
operating in AVR mode and power factor and var regulation is disabled.
Setpoint - Current (A). This setting defines the field current setpoint when operating in FCR mode. The
current setpoint can also be entered at the Setting Adjustments screen, Setpoint tab, Field Current
Regulator (FCR) - FCR Setpoint. Current values from 0 to 7 Adc may be entered in increments of 0.01
Adc. The background color of this field is green when operating in FCR mode.
Setpoint - Var (% of nom.). This setting determines the level of generator vars maintained by the DECS-
100 when operating in var mode. The var setpoint can also be entered at the Setting Adjustments screen,
Setpoint tab, Reactive Power Control (VAR) - VAR Setpoint (% of nom.). The background color of this
field is green when the DECS-100 is operating in AVR mode and is regulating the var setpoint.
Setpoint - Power Factor. This setting determines the level of power factor regulation maintained by the
DECS-100. The power factor setpoint can also be entered at the Setting Adjustments screen, Setpoint
tab, Power Factor Control (PF) - PF Setpoint. Power Factor setpoint values are adjustable from -0.6 to -1
(1) or 0.6 to +1 in 0.001 increments. The background color of this field is green when the DECS-100 is
operating in AVR mode and is regulating the power factor setpoint.
Voltage Matching. The Voltage Matching controls and indicators consist of two buttons and two adjacent
indicators. Clicking the ON button changes the color of the adjacent ON indicator to green and enables
voltage matching by the DECS-100. When Voltage Matching is enabled, the DECS-100 automatically
adjusts the field current to match the generator output voltage with the bus voltage prior to synchronizing.
In order for Voltage Matching to be enabled, the following conditions must be met.
• The Parallel Generator Compensation Contacts (terminals 52L and 52M) must be shorted.
• The DECS-100 Voltage Matching input must be shorted (terminals VM and VMC).
• Var/PF control must be disabled by shorting terminals 52J and 52K (open breaker).
• The DECS-100 must be operating in AVR mode.
Clicking the OFF button changes the color of the adjacent OFF indicator to red and disables the voltage
matching function.
Control Mode. Clicking the AVR button changes the color of the adjacent AVR indicator to green and
enables the AVR operating mode. When operating in AVR mode, the DECS-100 regulates the generator
output voltage at the AVR setpoint. Clicking the FCR button changes the color of the adjacent FCR

5-16 BESTCOMS Software DECS-100

indicator to green and enables the FCR operating mode. When operating in FCR mode, the DECS-100
maintains the field current at the FCR setpoint. Enabling the FCR mode turns off Voltage Matching.
Fine Adjustment. Raise and Lower buttons control the fine adjustment of the operating setpoint. These
buttons perform the same function as closing the appropriate set of contacts connected to the External
Adjust terminals (6D and 7 to decrease, 6U and 7 to increase) of the DECS-100. For AVR mode, each
click of the Raise button increases the voltage setpoint 0.01 volts; each click of the Lower button
decreases the voltage setpoint 0.01 volts. The minimum and maximum limits for fine adjustment of the
voltage setpoint are controlled by the Regulator Sensing Voltage setting (System Configuration screen)
and the Fine Voltage Adjustment - Band setting (Setting Adjustments screen). Fine adjustment of the
voltage setpoint can be increased/decreased no higher/lower than the Regulator Sensing Voltage setting
plus/minus the Band setting. For example, a Regulator Sensing Voltage setting of 100 volts and a Band
setting of 10 percent allows the Fine Adjustment function to increase the voltage setpoint to a maximum
of 110 volts and decrease the voltage setpoint to a minimum of 90 volts. For Var, PF, or FCR modes, the
Raise and Lower buttons provide fine adjustment over the entire adjustment range.
Alarm/Status Tab
The Alarm/Status tab indicators provide the status of DECS-100 protection functions, control modes, and
contact inputs. Alarm/Status tab indicators are illustrated in Figure 5-17 and are described in the following
paragraphs.

Figure 5-17. Metering, Operation, and Alarms Screen, Alarm/Status Tab

Protection Alarms. Six protection alarm indicators provide the status of DECS-100 protection functions.
Alarm indicators include Overexcitation Shutdown, Overexcitation Limiting, Underexcitation Limiting,
Generator Overvoltage, Loss of Generator Sensing, and Underfrequency. When a DECS-100 protection
function detects an alarm condition, the appropriate indicator changes from black to red.
Control Status. Two Control Status indicators indicate when the VAR/PF and Manual modes are active.
The Manual Mode Active indicator changes from black to red when the FCR control mode is active. The
VAR/PF Mode Active indicator changes from black to red when the DECS-100 is operating in AVR mode
and correction of power factor or vars is selected.
Switch Status. Three Switch Status indicators indicate when the DECS-100 control inputs are open or
closed. The 52JK switch open indicator changes from black to red when the user-supplied contacts at
terminals 52J and 52K are closed. When this control input is open, selection of PF or VAR mode can be
made on the Operation tab of the Metering, Operation, and Alarms screen. The 52LM switch closed
indicator changes from black to red when the user-supplied contacts at terminals 52L and 52M are
closed. When this control input is closed, parallel control and droop is inactive. The VM switch closed

DECS-100 BESTCOMS Software 5-17

indicator changes from black to red when the user-supplied contacts at terminals VM and VMC are
closed. When this control input is closed, the Voltage Matching function is active.
Metering Signal. The Metering Signal indicator flashes to indicate when metering is active. A number
beside the indicator tracks how many times the metering and status indicators have been updated. When
the Metering button is clicked or Metering on the Menu bar is clicked followed by Disable Metering, the
Metering Signal indicator stops flashing, the metering update counter stops incrementing, and the
metering functions stop being updated.

PID DATA
BESTCOMS enables generator stability to be set through the automatic calculation of PID parameters.
PID stands for Proportional, Integral, Derivative. The word proportional means that the response of the
DECS-100 output is proportional or relative to the amount of change that is observed. Integral means that
the DECS-100 output is proportional to the amount of time that a change is observed. Integral action
eliminates offset. Derivative means that the DECS-100 output is proportional to the required rate of
excitation change. Derivative action avoids excitation overshoot.
BESTCOMS automatically calculates PID values after the user selects the generator frequency,
generator time constant (T'do), and exciter time constant (Texc). With BESTCOMS, the user may
generate new PID numbers, add to a PID list file, and update the AVR gain settings in the Control Gain or
Step Response screens.
The PID window (Figure 5-18) is accessed by clicking the PID button. The PID button can be clicked only
when the Stability Range setting of the Control Gain screen is set at a value of 21. (A setting of 21
enables the entry of custom stability settings through the PID window.) Then, when a field of the Control
Gain screen is changed or selected, the PID button changes from gray to yellow and the button can be
clicked to view the PID window. After the PID numbers are modified, calculated, and updated, the PID
window is closed by clicking the Update Setting Screen button. The modified PID values are then shown
on the Control Gain screen.

Figure 5-18. PID Window

PID Calculation Based on Input Values

The available range for the exciter time constant depends on the value entered for the generator time
constant. (The default value for the exciter time constant is the generator time constant divided by 6.) The
generator time constant value selected must be in the range of 1.00 to 15.00 seconds and in 0.05
increments. When the generator time constant value is 1.00, the available exciter time constant range is
0.03 to 0.50 in 0.01 second increments. When the generator time constant value is 15.00, the available
exciter time constant range is 0.30 to 3.00 in 0.01 second increments.

5-18 BESTCOMS Software DECS-100

For example, when T'do is set at 2.0 seconds, Texc is 0.33. After specifying the input values, a set of PID
parameters (output data) is generated automatically. If T'do is set at 5.00 seconds, then Texc is 0.83
seconds. The calculated KP is 155.47, KI is 138.72, KD is 48, and Kg is 1.
PID parameters can be directly removed from, added to, or modified in the PID List Data. PID parameters
may also be saved into a file (pidlist.dat).

Adding to the PID List

CAUTION
Improper PID numbers will result in poor system performance or system damage.

PID parameters can be added to a list and recalled for operation and comparison. To add to the list, type
a name for the generator (or other appropriate information) in the generator information box. Select the
generator time constant. Observe the PID gain parameters in the Field Output Data fields. If these gain
parameters are appropriate, click the Add to PID List button. Check for the new parameters by pulling
down the PID List (click the down arrow). The new gain and time constant parameters should be
displayed.

Removing a PID List Record

PID parameters can also be removed from the list. To remove a list (record), pull down the PID List and
select the record or list so that the gain and time constant parameters are displayed. Click the Remove
Record button and the listed record is deleted.

Retrieving Existing Data from the PID List

To retrieve existing data, pull down the PID List and select the record or list so that the gain and time
constant parameters are displayed and highlighted. Click the Get from a List button and the listed record
input and output data displays in the boxes.

SETTINGS FILES
BESTCOMS software enables you to print a list of DECS-100 settings, save DECS-100 settings to a file,
and open a settings file and upload those settings to a DECS-100. A settings file may also be opened and
edited within any text editing software.

Printing Settings Files

A printout of DECS-100 settings can be useful for record keeping or comparison purposes. DECS-100
settings are printed by clicking the print icon or clicking File on the Menu bar and then clicking Print.
When the print command is given, a dialog box provides the opportunity to add a title, unit information,
and comments to the settings list. Each entry is limited to a maximum of 54 characters. When OK is
clicked, a print dialog box prompts you to select a printer. Once the printer is selected, the report is
printed.

Saving Settings Files

Saving DECS-100 settings to a file for uploading to other DECS-100 units saves setup time when
configuring multiple units to the same configuration. A settings file can also be created in BESTCOMS
without being connected to a DECS-100. The settings of the desired screens can be changed and these
settings can then be saved to a file. Once a settings file is created, it can be edited using any text editing
software, and then saved for uploading.
A settings file is created by clicking the save icon or by clicking File on the Menu bar and then clicking
Save. When the save command is given, a dialog box provides a choice of saving the settings in a
DECS-100 file or text file.
If “DECS File” is selected, a Save As dialog box appears and enables you to save the settings file. The
file is automatically given a .de1 extension.
If “Text File” is selected, a dialog box provides the opportunity to add a title, unit information, and
comments to the settings. Each entry is limited to a maximum of 54 characters. When OK is clicked, a
Save As dialog box appears and enables you to save the settings file. The file is automatically given a .txt
file extension.

DECS-100 BESTCOMS Software 5-19

Uploading Settings Files
A DECS-100 settings file downloaded from a DECS-100 or created within BESTCOMS can be uploaded
to multiple DECS-100 units. Only a DECS-100 settings file with a .de1 extension can be uploaded to a
DECS-100 unit. Before uploading a file, communication must be initiated with the DECS-100 that is to
receive the settings. Refer to the paragraphs labeled Starting BESTCOMS, Establishing Communication.

CAUTION
Before uploading a settings file, remove operating power from the DECS-100,
disconnect the field wiring from terminals F+ and F–, and re-apply operating
power to the DECS-100.

The upload process is started by clicking the open icon or clicking File on the menu bar and then clicking
Open. A dialog box is then displayed (Figure 5-19) reminding you that the DECS-100 should be off-line
before uploading settings. Clicking Yes loads the settings into DECS-100 memory.

Figure 5-19. Settings Upload Dialog Box

PASSWORD PROTECTION
Password protection guards against unauthorized changing or viewing of DECS-100 settings. A single
password protects all DECS-100 settings. The DECS-100 is delivered with a default password of decs.
Once the password is changed, it should be stored in a secure location. If the user-defined password is
lost or forgotten, BESTCOMS must be reloaded to restore the default password.

Changing the Password

NOTE
A password change can be made only after communication between
BESTCOMS and the DECS-100 is established.

A new password can be programmed by performing the following steps.

1. Click Communications on the menu bar and click
Password Change on the drop-down menu. The Change
Password dialog box of Figure 5-20 appears.
2. Type the current password in the "Enter your access
password" field of the Change Password dialog box and
press the Enter key on your keyboard.
3. Another dialog box will appear with instructions for making
the password change. Click the OK button and type a new
password (8 alphanumeric characters, maximum) in the
"Enter your new password" field.
4. Press the Enter or Tab key on your keyboard to advance the
cursor into the field labeled "Re-enter your new password".
Type the new password again to confirm the changed
password and press the Enter key. When the Enter key is
pressed, the new password is enabled and a dialog box
appears to remind you to keep your password in a secure Figure 5-20. Password Dialog Box
location.

5-20 BESTCOMS Software DECS-100

TERMINATING COMMUNICATION
DECS-100 communication is terminated by clicking on Communications on the menu bar, and clicking
Close Comm Port. You are asked if you want to save the settings to EEPROM. This question is asked
even if no changes were made to the DECS-100 settings. When you execute the Close command (with a
Yes or No to save settings to EEPROM), communication with the DECS-100 is terminated. If you choose
to exit BESTCOMS (by clicking File on the menu bar and then Exit) without first closing communication,
you are still given the opportunity to save the settings to EEPROM.

EMBEDDED FIRMWARE
Embedded firmware is the operating program that controls the actions of the DECS-100. The DECS-100
stores firmware in nonvolatile flash memory that can be reprogrammed through the RS-232
communication port. It is not necessary to replace EPROM chips when replacing the firmware with a
newer version.

Updating the Firmware

Future enhancements to DECS-100 functionality may make a firmware update desirable. DECS-100
embedded firmware can be updated by performing the following steps.

CAUTION
If power is lost or communication is interrupted during file transfer, the DECS-100
will not recover and will cease to be operational.

NOTE
Communication must be closed prior to uploading embedded firmware to the
DECS-100. Refer to the Terminating Communication subsection for information
about closing DECS-100 communication.

1. Connect a communication cable between the rear RS-232 connector of the DECS-100 and the
appropriate communication port of your PC.
2. Click DECSLoad on the BESTCOMS menu bar and click Uploading Embedded Software. If this
menu selection is grayed out, you'll need to close DECS-100 communication. Refer to the
Terminating Communication subsection for information about closing DECS-100 communication.
When Uploading Embedded Software is clicked, a dialog box (Figure 5-21) is displayed that advises
you to disconnect the DECS-100 generator and bus connections and save the DECS-100 settings in a file
before proceeding with firmware uploading. Firmware uploading may replace some user-adjusted settings
with factory-default settings.

Figure 5-21. Software Uploading Advisory Dialog Box

3. Click Yes to proceed with software uploading. When Yes is clicked, the Communication Initiation
screen (Figure 5-4) appears. Select the active communication port for your PC and click the Initialize
button. BESTCOMS obtains the configuration settings from the DECS-100 and saves all settings.
When the saving of settings is complete, the DECS-100 Embedded Program Loader of Figure 5-22
appears.

DECS-100 BESTCOMS Software 5-21

 Figure 5-22. DECS-100 Embedded Program Loader
4. Click the Get Device Information button. The DECS-100 Embedded Program Loader retrieves and
displays the DECS-100 model number, style number, serial number, and application program version
number in the left-hand column (Figure 5-23).

Figure 5-23. Retrieved DECS-100 Information

5. Click the Start Transfer Data button to proceed with software uploading. The dialog box of Figure 5-
24 appears and recommends that your DECS-100 settings be saved in a file that can be uploaded to
the DECS-100 after the embedded firmware is updated.

Figure 5-24. Settings File Reminder Dialog Box

Clicking No allows you to exit the upload process so that a DECS-100 settings file can be created. Refer
to the Settings Files subsection for information about creating a settings file.
Clicking Yes continues with the upload process and displays the Open dialog box of Figure 5-25. The
Open dialog box is used to locate and select the appropriate file for uploading to the DECS-100. Only files
with a .S19 extension are displayed in the Open dialog box.

5-22 BESTCOMS Software DECS-100

 Figure 5-25. Open Dialog Box
6. Select the appropriate file for uploading and click the Open button to start the file transfer. A dialog
box (Figure 5-26) indicating the progress of the file transfer is displayed.

Figure 5-26. File Transfer Progress

Once the transfer is complete, the device information is displayed in the right-hand column of the DECS-
100 Embedded Program Loader (Figure 5-26). The displayed program version number indicates the
version and date of the firmware just loaded.

Figure 5-27. DECS-100 Information After Upload

7. Close the DECS-100 Embedded Program Loader. BESTCOMS loads the default settings, loads the
saved settings, and checks the settings.

DECS-100 BESTCOMS Software 5-23

 This page intentionally left blank.

5-24 BESTCOMS Software DECS-100

SECTION 6 • MAINTENANCE AND TROUBLE-
SHOOTING
TABLE OF CONTENTS
SECTION 6 • MAINTENANCE AND TROUBLE-SHOOTING................................................................... 6-1
PREVENTATIVE MAINTENANCE......................................................................................................... 6-1
TROUBLESHOOTING ........................................................................................................................... 6-1
Generator Voltage Does Not Build ..................................................................................................... 6-1
Low Generator Output Voltage ........................................................................................................... 6-2
High Generator Output Voltage .......................................................................................................... 6-2
Poor Voltage Regulation..................................................................................................................... 6-3
Generator Output Unstable (Hunting)................................................................................................. 6-3
Overexcitation Shutdown Indicator is Annunciating ........................................................................... 6-4
Loss of Generator Sensing Indicator is Annunciating ........................................................................ 6-4
Overexcitation Limiting Indicator is Annunciating ............................................................................... 6-4
Underexcitation Limiting Indicator is Annunciating ............................................................................. 6-4
Underfrequency Active Indicator is Annunciating ............................................................................... 6-5
No Droop ............................................................................................................................................ 6-5
No Voltage Matching .......................................................................................................................... 6-6

DECS-100 Maintenance and Troubleshooting i

 This page intentionally left blank.

ii Maintenance and Troubleshooting DECS-100

SECTION 6 • MAINTENANCE AND TROUBLE-
SHOOTING
PREVENTATIVE MAINTENANCE
The only preventive maintenance required on the DECS-100 is to periodically check that the connections
between the DECS-100 and the system are clean and tight. DECS-100 units are manufactured using
state-of-the-art, surface-mount technology. As such, Basler Electric recommends that no repair
procedures be attempted by anyone other than Basler Electric personnel.

TROUBLESHOOTING
If you do not get the results that you expect from the DECS-100, first check the programmable settings for
the appropriate function. Use the following troubleshooting procedures when difficulties are encountered
in the operation of your excitation system.

Generator Voltage Does Not Build

Step 1. Verify that all wiring is properly connected. Refer to Figures 4-6 through 4-10.
If wiring is improperly connected or loose, reconnect wiring properly.
If wiring connections are correct, proceed to Step 2.
Step 2. Verify that the generator is spinning at rated speed.
If the generator is not up to rated speed, increase generator speed to the rated value.
If the generator is spinning at rated speed, proceed to Step 3.
Step 3. For PMG power, check for correct input power to the DECS-100. Refer to Section 1, General
Information, Specifications for input power requirements.
If voltage is not present, refer to the generator manual for repair procedures (PMG system
only).
If voltage is present, proceed to Step 4.
Step 3a. If the DECS-100 is being shunt powered (non-PMG) mode, verify that the residual voltage
applied to the power input is at least 6 Vac.
If the applied voltage is less than 6 Vac, refer to the generator manual and flash the generator
field.
If the applied voltage is 6 Vac or greater, proceed to Step 4.
Step 4. Verify that no fuses are open.
Replace any open fuses.
If no fuses are open, proceed to Step 4.
Step 5. Verify that the front panel Overexcitation Shutdown indicator is not lit.
If the front panel Overexcitation Shutdown indicator (field voltage) is lit, check the generator
and/or load conditions. Interrupt input power or shut down the generator for a minimum of one
minute.
If the front panel Overexcitation Shutdown indicator is not lit, proceed to Step 6.
Step 6. Verify that the front panel Overexcitation Limiting indicator is not lit.
If the front panel Overexcitation Limiting indicator is lit, check the generator and load conditions.
Also check the field current limit setpoint for the correct level. Interrupt input power or shut
down the generator for a minimum of 1 minute.
If the front panel Overexcitation Limiting indicator is not lit, proceed to Step 7.
Step 7. Verify that the DECS-100 soft start settings are correct. Too long of a soft start setting may give
the appearance of no buildup.
If the soft start settings are incorrect, adjust the settings.
If the soft start settings have no effect, proceed to Step 8.

DECS-100 Maintenance and Troubleshooting 6-1

Step 8. Replace the DECS-100 unit.
If replacing the DECS-100 unit does not correct the malfunction, then the generator is defective.
Consult with the generator manufacturer.

Low Generator Output Voltage

Step 1. Verify that the voltage adjustment is not set too low.
If the voltage adjustment is too low, adjust it to the correct setpoint.
If the voltage adjustment is correct, proceed to Step 2.
Step 2. Verify that the underfrequency knee setpoint is not greater than the generator frequency.
If the underfrequency setpoint is too high, adjust the setpoint below the rated generator
frequency.
If the underfrequency setpoint is correct, proceed to Step 3.
Step 3. Verify that the generator is spinning at rated speed.
If the generator is not up to rated speed, increase the generator speed to the rated level.
If the generator is spinning at rated speed, proceed to Step 4.
Step 4. For PMG power, check for correct input power to the DECS-100. Refer to Section 1, General
Information, Specifications for input power requirements.
If the DECS-100 input voltage is low, refer to the PMG manual for PMG repair (PMG system
only).
If the voltage is at the required level, proceed to Step 5.
Step 4a. If the DECS-100 is being shunt powered (non-PMG), verify that the power potential transformer
(if used) has the correct turns ratio, is sized properly, and is supplying the correct voltage level
to the power input.
If the turns ratio of the power potential transformer is incorrect, is sized too small, or is not
supplying the correct input power, replace the power potential transformer.
If the power potential transformer is correct, proceed to Step 5.
Step 5. Verify that the sensing potential transformer (if used) has the correct turns ratio and is operating
correctly.
If the turns ratio of the sensing potential transformer is incorrect, replace the sensing potential
transformer.
If the sensing potential transformer is operating correctly, proceed to Step 6.
Step 6. Verify that the front panel Overexcitation Limiting indicator is not lit.
If the front panel Overexcitation Limiting indicator is lit, check the generator and/or load
conditions. Also check the field-current limit setpoint for the correct level. Interrupt input power
or shut down the generator for a minimum of one minute.
If the front panel Overexcitation Limiting indicator is not lit, proceed to Step 7.
Step 7. Low generator output voltage may occur when operating in droop mode with an inductive load.
If the low voltage condition is not caused by the droop function, proceed to Step 8.
Step 8. Verify that the voltage setpoint is not being modified by application of voltage to the optional
Accessory Input.
If the low voltage condition is not caused by voltage applied to the Accessory Input, proceed to
Step 9.
Step 9. Replace the DECS-100 unit.

High Generator Output Voltage

Step 1. Verify that the voltage adjustment is not set too high.
If the voltage adjustment is too high, adjust it to the correct setpoint.
If the voltage adjustment is correct, proceed to Step 2.

6-2 Maintenance and Troubleshooting DECS-100

Step 2. Verify that the sensing potential transformer (if used) has the correct turns ratio.
If the turns ratio of the sensing potential transformer is incorrect, replace the sensing potential
transformer with the correct one.
If the sensing potential transformer is correct, proceed to Step 3.
Step 3. High generator output voltage may occur when operating in droop mode with a capacitive load.
If the high voltage condition is not caused by the droop function, proceed to Step 4.
Step 4. Verify that the voltage setpoint is not being modified by application of voltage to the optional
Accessory Input.
If the high voltage condition is not caused by voltage applied to the Accessory Input, proceed to
Step 5.
Step 5. Replace the DECS-100 unit.

Poor Voltage Regulation

Step 1. Verify that the case of the DECS-100 is properly grounded.
If the DECS-100 is not properly grounded, connect a dedicated ground wire to the quarter-inch
fast-on connector labeled GND on the rear of the DECS-100 case.
If the DECS-100 is properly grounded, proceed to Step 2.
Step 2. Check for grounded field leads.
If the field leads are grounded, isolate them from ground.
If the field leads are not grounded, proceed to Step 3.
Step 3. If the DECS-100 is powered from a PMG, check for grounded PMG leads.
If the PMG leads are grounded, isolate them from ground.
If the PMG leads are not grounded, proceed to Step 4.
Step 4. Verify that the generator frequency is not dropping below the DECS-100 underfrequency
setpoint when load is applied to the generator.
If the generator frequency is dropping below the underfrequency setpoint, reduce the setpoint if
possible. Also check the prime mover and generator for proper sizing in relation to the applied
load.
If poor regulation is not related to DECS-100 underfrequency operation, proceed to Step 5.
Step 5. Verify that regulation is not being affected by normal droop operation.
If droop operation is not affecting regulation, proceed to Step 6.
Step 6. Replace the DECS unit.

Generator Output Unstable (Hunting)

Step 1. Verify that the governor for the prime mover is operating properly.
If the governor is not operating properly, troubleshoot using the manufacturer's suggested
procedures.
If the governor is operating properly, proceed to Step 2.
Step 2. Verify that the sensing and input power leads are connected securely.
If the sensing or input power leads are not connected securely, tighten the connections.
If the sensing or input power lead connections are secure, proceed to Step 3.
Step 3. Verify that the DECS-100 Stability Range is set to the proper range.
If the Stability Range setting is incorrect, reset the Stability Range.
If the Stability Range setting is correct, proceed to Step 4.
Step 4. Verify that the Stability Level is properly set.
If the Stability Level is not properly set, reset the Stability Level.

DECS-100 Maintenance and Troubleshooting 6-3

Overexcitation Shutdown Indicator is Annunciating
Step 1. Check for generator overloading.
If the generator is operating with a larger than rated load, shed load.
If the generator is operating with a rated or less than rated load, proceed to Step 2.
Step 2. Verify that the generator exciter field voltage requirements are compatible with the DECS-100.
If the exciter field voltage requirements are not compatible with the DECS-100, contact Basler
Electric Customer Service for recommendations.
If the exciter field voltage requirements are compatible with the DECS-100, proceed to Step 3.
Step 3. Replace the DECS-100.
If replacing the DECS-100 does not correct the malfunction, proceed to Step 4.
Step 4. Refer to the generator manual. Generator is defective.

Loss of Generator Sensing Indicator is Annunciating

Step 1. Verify that the voltage sensing leads are properly connected.
If the sensing leads are not properly connected, correct the connections.
If the sensing lead connections are correct, proceed to Step 2.
Step 2. For single-phase sensing, verify that E2 and E3 are connected.
If E2 and E3 are not connected, connect them both to phase C sensing voltage.
If E2 and E3 are properly connected, proceed to Step 3.
Step 3. Verify that the sensing potential transformer (if used) has the correct turns ratio and is
functioning properly.
If the sensing potential transformer has the wrong turns ratio or is malfunctioning, replace it.
If the sensing potential transformer is correct and functioning properly, proceed to Step 4.
Step 4. Verify that the generator output voltage is present on all phases.
If the generator is missing a phase, refer to the generator manual. Generator is defective.
If generator output voltage is balanced on all phases, proceed to Step 5.
Step 5 Replace the DECS-100.

Overexcitation Limiting Indicator is Annunciating

Step 1. Check for generator overloading.
If the generator is operating with a larger than rated load, shed load.
If the generator is operating with a rated or less than rated load, proceed to Step 2.
Step 2. Verify that the DECS-100 output (field) current limit is not set too low.
If the output current limit setpoint is too low, adjust for the proper setting.
If the output current limit is set properly, proceed to Step 3.
Step 3. Verify that the generator exciter field current requirements are compatible with the DECS-100.
If the generator exciter field current requirements are not compatible with the DECS-100,
contact Basler Electric Customer Service for recommendations.
If the generator exciter field current requirements are compatible with the DECS-100, proceed
to Step 4.
Step 4. Replace the DECS-100.
If replacing the DECS-100 does not correct the malfunction, proceed to Step 5.
Step 5. Refer to the generator manual. Generator is defective.

Underexcitation Limiting Indicator is Annunciating

Step 1. Verify that the DECS-100 generator voltage setpoint is not being driven to a lower level.
The setpoint can be affected by the Raise/Lower contact inputs or by the Auxiliary input.

6-4 Maintenance and Troubleshooting DECS-100

Step 2. Verify that the DECS-100 output (field) current limit is not set too low.
Adjust the field current limit as needed.
Step 3. Use the connection diagrams of Section 4, Installation to verify that the sensing voltage and
current connections to the DECS-100 provide the proper phasing.
Correct the sensing voltage and current connections as needed.
Step 4. Verify that the generator exciter field current requirements are compatible with the DECS-100.
If the generator exciter field current requirements are not compatible with the DECS-100,
contact Basler Electric Technical Sales Support for recommendations.
If the generator exciter field current requirements are compatible with the DECS-100, proceed
to Step 5.
Step 5. Replace the DECS-100.
If replacing the DECS-100 does not correct the malfunction, proceed to Step 6.
Step 6. Refer to the generator manual or contact the generator manufacturer.

Underfrequency Active Indicator is Annunciating

Step 1. Verify that the generator is operating at rated speed.
If the generator is not operating at rated speed, adjust the generator speed.
If the generator is operating at the rated speed, proceed to Step 2.
Step 2. Verify that the underfrequency setpoint is correct.
If the underfrequency setpoint is incorrect, adjust it to the correct value.

No Droop
Step 1. Verify that the DECS-100 52L/M contact input is open.
If the 52L/M contact input is not open, it must be opened to enable the droop function.
If the 52L/M contact input is open, proceed to Step 2.
Step 2. Verify that the DECS-100 52J/K contact input (if present) is closed or the Var/PF function is
disabled via BESTCOMS. Var/PF operation must be disabled for droop operation. If var/PF
operation is disabled, proceed to Step 3.
Step 3. Verify that the DECS-100 droop setting is not adjusted to 0% droop.
If the droop setting is adjusted to 0% droop, increase the setpoint above 0%.
If the droop setting is adjusted to above 0%, proceed to Step 4.
Step 4. Check for an open in the circuit connected to DECS-100 CT1 and CT2.
If there is an open circuit, repair as necessary.
If there is no open circuit, proceed to Step 5.
Step 5. Verify that all connections are correct according to Figures 4-6 through 4-9.
If connections are incorrect, correct the problem.
If connections are correct, proceed to Step 6.
Step 6. Verify that the load being applied to the generator for droop testing is not purely resistive.
If only a resistive load is being applied to the generator, apply an inductive load and retest.
If the load being applied to the generator is inductive, proceed to Step 7.
Step 7. Verify that your DECS-100 is compatible with the current sensing transformer (1 A or 5 A
secondary) being used. For example, a current sensing transformer with a 1 ampere output
rating would produce very little droop if your DECS-100 has a 5 ampere current transformer
input. Refer to Figure 1-1 to check the current transformer input of your DECS-100.
If the current transformer input is incorrect, replace the current sensing transformer or the
DECS-100 for compatibility.
If the current transformer input is correct, proceed to Step 8.
Step 8. If the above steps fail to correct the malfunction, replace the DECS-100 unit.

DECS-100 Maintenance and Troubleshooting 6-5

No Voltage Matching
Step 1. Verify that the Voltage Matching option was purchased and is enabled in the software.
If not enabled, use the BESTCOMS software to turn on voltage matching.
If voltage matching is enabled, proceed to Step 2.
Step 2. Verify that all connections are correct according to Figures 4-6 through 4-9 as required for the
Voltage Matching option of the DECS-100.
If the interconnection is incorrect, reconnect according to the appropriate interconnect diagram.
If the interconnection is correct, proceed to Step 3.
Step 3. Verify that the DECS-100 VM/VMC contact input is closed.
If the VM/VMC contact input is open, it must be closed to enable voltage matching.
If the VM/VMC contact input is closed, proceed to Step 2.
Step 4. Check for correct utility reference voltage on DECS-100 terminals B1 and B3.
If the interconnection is incorrect, reconnect according to the appropriate interconnect diagram.
If the interconnection is correct, check for open system fuses.
Verify that the potential sensing transformer, if used, is connected to DECS-100 terminals B1
and B3.
If potential sensing transformer connections are correct, proceed to Step 5.
Step 5. Verify that the generator output voltage setpoint is within 10 percent of the measured utility bus
voltage.
If the setpoint is too low or too high, adjust the setpoint to the appropriate level.
If the setpoint is correct, proceed to Step 6.
Step 6. If the above steps fail to correct the Voltage Matching malfunction, replace the DECS-100.

6-6 Maintenance and Troubleshooting DECS-100

 ANNEX 5 –

Commissioning report
 Comissioning report

Serial no.
ABB Ref.
Feb 2010 Project:

COMMISSIONING REPORT
Manufacturer: ABB Generators Ltd.
Address: 3088 Zi Yang Avenue
High-Tech Development
Zone
330096 Nanchang
Jiangxi, P.R.China
Telephone: +86 791 835 0800
Telefax: +86 791 835 0814

Customer:
Customer Address:

Contact Person:
Telephone:
Mobile phone:
Fax:
Email:

Commissioning Report - 1
 Comissioning report

Serial no.
ABB Ref.
Feb 2010 Project:

1 Transportation
General:
Arrival date of the machine:
Inspection date and location:
Signature of consignee:
Open box inspection: no yes, done by

Damages:
Packing list: no yes, missing items:
Machine: no yes, what kind of:
Package: no yes, what kind of:
Accessories: no yes, what kind of:
Spare parts + tools: no yes, what kind of:

Actions Taken in Response to Damages:

Photographed: no yes, date:
Reported to the transportation company: no yes, to whom: date:
Reported to the supplier: no yes, to whom: date:
Reported to the insurance company: no yes, to whom: date:

Method of Transportation:
Railway Airfreight Truck Mail Shipped by M/S____________ Other:

Comments:

Commissioning Report - 2
 Comissioning report

Serial no.
ABB Ref.
Feb 2010 Project:

2 Storage
General:
Storage: no yes, begin:__________________ end: __________________
Storage Time Longer than 6 Months: no yes
Person Responsible for Storage:

Storage Place:
indoors outdoors
in packing case protected by a waterproof cover
Daily temperature: min/max. ______ - ______ºC Humidity:______%

Damages:
Transportation package is ventilated: no yes
External heating/fan is used: no yes, type:__________________________________________
Machine space heaters are used: no yes, voltage: _______________________________________
Bearings are flushed: no yes, oil type: _______________________________________
Bearing shells are removed: no yes, date: __________________________________________
Shaft end anti-corrosion protection checked: no yes, type:__________________________________________
Shaft end anti-corrosion protection renewed: no yes, date: __________________________________________
The rotor is turned 10 revolutions every two no yes
months:
There are vibrations in the storage place: no yes, type:_________ mm/s, rms
There are corrosive gases in the air: no yes, what kind of:___________________________________
Brushes are lifted up: no yes
Machine documents are saved and protected no yes, location:_______________________________________
for future use:
Comments:

Commissioning Report - 3
 Comissioning report

Serial no.
ABB Ref.
Feb 2010 Project:

3 Mechanical Installation
Foundation is checked according to machine no yes, drawing number:________________________________
drawing:
Possible foundation anchor bolts or sole plates no yes
are mounted according to instructions:
For alignment of the coupling, use either Radial alignment of coupling Angular alignment of coupling
top top
values 1-4 or values A-D
1_____________ 1 1
D A D A
2_____________
4 2 4 2
3_____________
C B C B
4_____________ 3 3
A_____________ Axial position of the rotor: ET #1:_________mm, ET #2: _________mm
B_____________
Axial distance between shaft ends:_________mm
C_____________ Rotor support distance:
D_____________

_______mm _______mm

Crankshaft deflection is checked: no yes

Foundations bolts are tightened with torque no yes, bolt size: ______________ torque: ______________Nm
wrench:
Bolt lubrication: dry oil, MoS2
Cooling water: no yes, amount: m3/s
Cooling element piping: flexible rigid
Transport locking device is removed: no yes
Rotor rotates without noise or scraping: no yes

Commissioning Report - 4
 Comissioning report

Serial no.
ABB Ref.
Feb 2010 Project:

4 Lubrication check

4.1 Self lubrication

Bearing oil: Manufacturer:_____________________ Type: _____________________
The oil quality is the same as recommended : no yes
Bearing oil is filled up to the indicated level:
Please mark the level in the sight glass circle Sight Glass
on the right
Lubrication rings rotate freely: no yes

4.2 Forced lubrication

Bearing oil: Manufacturer:_____________________ Type: _____________________
The oil quality is the same as recommended : no yes
Lubrication rings rotate freely (if applicable): no yes
Force lubrication oil pressure: ___________kPa
Oil flow: ___________liters/min
Rotation of the pumps checked: no yes
Jack-up pumps checked: no yes, alarm setting:_____ kPa, relief valve setting: _____ kPa
Oil filters checked: no yes

4.3 Grease lubricated bearings:

Grease: Manufacturer:_____________________ Type: _____________________
The grease quality is the same as no yes
recommended on the lubrication plate:
The first greasing has been done: Date:_______________ Quantity:________ g
Comments:

Commissioning Report - 5
 Comissioning report

Serial no.
ABB Ref.
Feb 2010 Project:

5 Electrical installation
Network variation: no yes, voltage:______-______ V, frequency: ______-______Hz
Space heater operation: no manual automatic, controlled by:____________________

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:______ ºC
PI =__________, tested by________ kV, winding temperature:______ ºC
__________M , tested by________ kV, winding temperature:______ ºC
__________M , tested by________ kV, winding temperature:______ ºC
__________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
 Comissioning report

Serial no.
ABB Ref.
Feb 2010 Project:

6 Machine protection settings

Overcurrent tripping: _______________A_______________ s
Instant overcurrent tripping: _______________A_______________ s
Overvoltage setting: no yes, setting:
Earth fault setting: no yes, setting:
Reverse power setting: no yes, setting:
Differential protection setting: no yes, setting:
Vibration monitoring: no yes, alarm setting:_________ mm/s, trip: _________ mm/s
Temperature monitoring:
- in stator winding no yes, alarm:__________ ºC, trip:______________ ºC
- in bearing no yes, alarm:__________ ºC, trip:______________ ºC
- in ________________________ no yes, alarm:__________ ºC, trip:______________ ºC

Lubrication oil flow alarm:__________ l/min, trip:______________ l/min

Other protection units: no yes, type:

Commissioning Report - 7
 Comissioning report

Serial no.
ABB Ref.
Feb 2010 Project:

7 Test Run

7.1 First start (a few seconds only)

Direction of rotation (viewed from D-end): CW CCW

Are there abnormal noises? no yes, from:

7.2 Second start (uncoupled, if possible)

Note: Check that possible force lubrication is on!
Are there abnormal noises? no yes, from:
Does the machine vibrate abnormally? no yes, where/how:
Bearing vibration level measured: D-end:__________ mm/s, rms; N-end:_________ mm/s, rms
Running: machine run OK operation stops, why:

Checking schedule and information

Time Bearing temperature Bearing vibration levels Stator Stator winding temperature
D-end N-end Power Excit.
D-end N-end Current U V W
mm/s mm/s Factor Current
h:min ºC ºC rms rms A cos A ºC ºC ºC
0:00
0:05
0:10
0:15
0:20

Comments:

Observations:

Commissioning Report - 8
 Comissioning report

Serial no.
ABB Ref.
Feb 2010 Project:

8 Test run (with load)

Checking schedule and information
Time Load Bearing temp. Bearing vibration levels Stator Stator winding temperature
D-end N-end Power Excit.
D-end N-end Current U V W
mm/s mm/s Factor Current
h:min % ºC ºC rms rms A cos A ºC ºC ºC
0:00

Vibration spectrum attached: no yes, from:

Acceleration time: __________ s.
Cooling air temperature: Inlet: __________ ºC Outlet:__________ ºC
Cooling water temperature: Inlet: __________ ºC Outlet:__________ ºC
Comments:

9 Machine approval
Machine approved for use Date:
Commissioning done by:
Approved by:

Commissioning Report - 9
 Comissioning report

Serial no.
ABB Ref.
Feb 2010 Project:

Fax Cover Sheet

Date:
ABB Tellhow Generators Ltd.
To:
Telefax: +86 791 835 0814
From:
Fax number:
Phone number:
Email:
Number of Pages: 1 + 9 + _________
Message:

Commissioning Report - 10
ANNEX 6 –

Check Lists
 Check lists

Serial no.
ABB Ref.
Feb 2010 Project:

PT-100 failure inspection protocol

PT-100 failure inspection protocol - 1

Check lists

PT-100 2
Check lists

PT-100 3
ANNEX 7 –

Test Report
ABB GENERATORS
Ltd.
TEST REPORT FOR SOLAS SHEET NO:

Report No.:

TEST REPORT
FOR SOLAS
Date : 10th Dec 2011

Manufacturer(name) : ABB Generators Ltd.

(address) :3088 Zi Yang Avenue High-Tech Development Zone Nanchang

Description of apparatus :Synchronous generator

Atmospheric conditon :Temperature( 14.1 )

THIS IS TO CERTIFY that the above mentioned apparatus has been tested and inspected in
accordance with the standard IEC 529 2nd Edition(1989-11)&SOLAS Amendments 2000
Regulation 10.5.6 and MSC/Cire.913 to show its compliance with Fixed Water-Based Local
Application Fire Fighting Systems(FWBLAFFS).

Type of protection :IP23

Tested and reported by :

Marco-Yuan

ABB Generators Ltd.

ABB GENERATORS
Ltd.
TEST REPORT FOR SOLAS SHEET NO:

Report No.:

1. Name of test :Protection degree test, IP23

2. Test specimen
1) Name: Synchronous Generator( as no load motor operate)
2) Type: AMG0500SF04 DAA (Ser.No.8807086)
3) Degree of protection: IP23
4) Test procedure :Refer to Appendix 5.
5) Construction: Refer to Appendix 6.

3. Applied Standard
1) IEC529,2nd Edition,1988-11
2) SOLAS Amendments 2000 Regulation 10.5.6 and MSC/Cire.913;
Approve of Fixed Water-Based Local Application Fire Fighting System.

6. Test Date : 10th Dec,2011

7. Test Result : Test Specimen satisfied the performance criteria

(Refer to test results of Appendix 1.)

This is to certify that the above mentioned test have been suitably carried out.
ABB GENERATORS
Ltd.
TEST REPORT FOR SOLAS SHEET NO:

Report No.:

Appendix 1.

Test Item Tested Result Remark

.Degree of Protection
(First characteristic numeral)
1. IEC 529 Satisfactory Refer to Appendix 2.
(Second characteristic numeral)
2. IEC 529 Satisfactory Refer to Appendix 3.

. SOLAS 2000 Amendment Satisfactory Refer to Appendix 4.

ABB GENERATORS
Ltd.
TEST REPORT FOR SOLAS SHEET NO:

Report No.:

Appendix 2.

Description of test

1. Degree of protection:
Protection of the equipment inside the enclosure against ingress of solid foreign objects
having a diameter of 12.5 mm and greater.

2. Testing method : Probe test

Probe with diameter of 12.5 mm to be applied to the enclosure of generator with test
force of 30N ±10%

Test results: No penetration.

ABB GENERATORS
Ltd.
TEST REPORT FOR SOLAS SHEET NO:

Report No.:

Appendix 3.

Description of test

1. Degree of protection :
Water sprayed at an angle up to 60 degree on either side of the vertical shall have no
harmful effects; It is to be accordance with IEC 529.

2. Testing method
Using spray nozzle, water will be applied with pressure of 50-150 KPa(or flow rate of 10
liter/min.) for time of 1 min./m2.

-construction of nozzle : IEC standard test nozzle

-delivery rate: 10 liter/min.
-water pressure at the nozzle: appr.50-150 KPa
-test duration m2 of surface area of the machine: 1 min.
-distance from the nozzle to the machine surface: appr. 300-500 mm
-Detailed test method: Refer to Appendix 6.

3. Test results: No harmful effect was found.

1) Visual cheek with covers opened (AMG0500SF04 DAA Type)
Water was noted within none essential area in generator. Water deposits within essential
area of generator were minimal, but complied with code requirement.
2) Insulation Resistance measurement.

Insulation Resistance(M )
AMG0500SF04 DAA type 13500
ABB GENERATORS
Ltd.
TEST REPORT FOR SOLAS SHEET NO:

Report No.:

Appendix 4.

!" ### "$ $

Description of protection

1. Degree of protection:
High pressure of water mist sprayed from top shall have no harmful effects.
It is to be accordance with SOLAS 2000 Amendment.

2. Testing method
Using low pressure water mist nozzle, water will be applied with flow rate of 10
liter/min. at 0.7Mpa .This nozzle is to be supplied by the fire fighting system maker.

-construction of nozzle: Maker JIANGXIJIUJIANGYUANYANGCHUANYONG

FAMENKAIFAZHIZHAOYOUXIANGONGSI standard test
nozzle
Refer to Appendix 7 for detailed construction
-flow rate: 10 liter/min.
- water pressure at the nozzle: appr .0.7Mpa bar at nozzle
- test duration: appr .20 min.
-distance from the nozzle to the machine surface: appr.2400 mm

3. Test results: No harmful effect was found.

1) Visual cheek with covers opened(AMG0500SF04 DAA type)
Water was noted within none essential area in % Water deposits within essential
area of generator were minimal, but complied with code requirement.
2 Insulation Resistance measurement.

Insulation Resistance(M )
AMG0500 type 16300
ABB GENERATORS
Ltd.
TEST REPORT FOR SOLAS SHEET NO:

Report No.:

Appendix 5.

TEST PROCEDURE OF A.C SYNCHRONOUS GENERATORS IP TEST 1/1

No Test Item Procedure Criterion Remarks

1 Verification of Using spray nozzle, water will be applied Insulation Type Test
Degree of with pressure of 50-150KPa (Flow rate of Resistance:
Protection(Water 10 liter /min for about 10min.)according More than 5
Spray Test) to IEC 60529 M

2 Verification of Using water mist nozzle, water will be Insulation Type Test
Degree of applied with flow rate of 10 l/min at Resistance:
Protection(Water pressure of 0.7Mpa for about 20min More than 5
Mist Test) according to SOLAS 2000 Amendment. M
ABB GENERATORS
Ltd.
TEST REPORT FOR SOLAS SHEET NO:

Report No.:

Appendix 6.
ABB GENERATORS
Ltd.
TEST REPORT FOR SOLAS SHEET NO:

Report No.:

Appendix 7.
ABB GENERATORS
Ltd.
TEST REPORT FOR SOLAS SHEET NO:

Report No.:

Appendix 8.
ABB GENERATORS
Ltd.
TEST REPORT FOR SOLAS SHEET NO:

Report No.:

* Picture at test
ABB GENERATORS
Ltd.
TEST REPORT FOR SOLAS SHEET NO:

Report No.:

& '(
 TEST REPORT

Test report for synchronous machines

Customer
Lei Shing Hong Machinery Limited
Order reference
11HK01/ZJ4001/ Main generators

main generator number 1

Project
SPP35B PSV(LSH)
Machine
AMG 0500SF04 DAA
Work nr
1225CA101
Serial nr
8807086
Date
14.12.2011

Approved on the behalf of manufacturer

Marco-Jin Yuan

Witnessed on the behalf of the classification society

ABB Generators Ltd.

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 2
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

Standards: IEC60034,BV Connection: Y

Insulation class: H Sn: 1700kVA

Temperature class: F Un: 440 V

Ambient temp.max: 45 In: 2231 A

IP: 23 p.f: 0.8

IM: 1101 f: 60 Hz

Duty: S1 n: 1800 rpm

Test program
1. Active load temperature rise test
2. Sudden short-circuit test
 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 3
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

1. Active-load temperature rise test (2011- 12- 01 Shanghai ABB test field)
Time U1 I1 P Pf Um Im Ur Ir Inlet Outlet
V A (KW) V A V A air air
( ) ( )
13:30 440.68 2261.35 1365.90 0.80 27.20 2.07 86.50 83.64 16.6 17.5

14:15 440.77 2262.70 1366.20 0.79 27.41 2.11 86.79 83.75 18.5 30.0

14:45 440.32 2251.24 1370.27 0.80 28.40 2.16 91.65 83.29 18.3 35.0

15:15 440.37 2255.80 1372.22 0.80 28.33 2.17 92.67 83.55 18.3 36.7

15:45 440.30 2250.06 1369.94 0.80 28.55 2.17 92.81 83.55 18.5 37.4

16:15 440.23 2248.91 1369.86 0.80 28.45 2.17 92.94 83.26 18.8 37.7

Overload
Time U1 I1 P Pf Um Im Ur Ir Inlet Outlet
V A (KW) V A V A air air
( ) ( )
16:59 446.37 2436.63 1503.60 0.80 29.42 2.28 94.12 89.72 14.8 30.1

17:14 446.32 2439.96 1511.82 0.80 30.33 2.34 99.56 89.71 14.5 33.5

17:29 446.44 2443.02 1510.30 0.80 30.76 2.36 101.34 89.94 16.4 36.1

17:59 445.75 2424.89 1512.09 0.80 30.78 2.35 101.14 88.90 18.5 39.0
 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 4
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

Time Bearing Bearing Stator Stator Stator Stator Stator Stator Ambient
Temp. Temp. U V W U V W ( )
ND-end D-end phase phase phase phase phase phase
( ) ( ) ( ) ( ) ( ) ( ) ( ) ( )
13:30 19.1 17.3 17.8 17.8 17.8 17.9 17.6 17.8 16.8

14:15 21.1 25.3 67.9 54.9 56.1 62.5 64.8 59.0 20.0

14:45 22.2 30.3 75.5 61.5 62.8 69.5 72.2 65.9 21.3

15:15 22.8 33.7 78.2 63.9 65.4 71.8 74.8 68.5 21.7

15:45 23.3 35.5 79.0 64.7 66.2 72.9 75.7 69.4 22.1

16:15 23.5 36.2 79.5 65.1 66.5 73.3 76.0 69.7 23.6

Overload
Time Bearing Bearing Stator Stator Stator Stator Stator Stator Ambient
Temp. Temp. U V W U V W ( )
ND-end D-end phase phase phase phase phase phase
( ) ( ) ( ) ( ) ( ) ( ) ( ) ( )
16:59 21.6 31.2 71.0 57.1 58.8 65.5 67.7 61.8 19.0

17:14 21.0 31.7 81.0 64.6 66.4 73.9 77.3 70.0 19.8

17:29 20.9 32.9 84.5 67.9 69.5 77.5 80.6 73.2 20.5

17:59 21.8 34.7 88.7 71.8 73.3 81.3 84.6 77.0 22.8

Remark: There are 2 pcs pt100 sensor in each phase of stator winding.
From the cooling curve, the temperature rise of stator winding at active-load is 48.5K, rotor winding is
39.9K (Based on inlet air temperature).
 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 5
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

2. Sudden short-circuit test

Main stator current waveform when sudden short-circuit test.
At sudden short-circuit stable period, The main stator RMS current value is 9866A, 10853A,
10804A. (Rated current is 2231A.) Then sudden short-circuit current value>3In and last for
more than 2 seconds.
Aux.voltage is 192V.
 TEST REPORT

Test report for synchronous machines

Customer
Lei Shing Hong Machinery Limited
Order reference
11HK01/ZJ4001/ Main generators

main generator number 1

Project
SPP35B PSV(LSH)
Machine
AMG 0500SF04 DAA
Work nr
1225CA101
Serial nr
8807086
Date
14.12.2011

Approved on the behalf of manufacturer

Marco-Jin Yuan

Witnessed on the behalf of the classification society

ABB Generators Ltd.

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 2
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

Standards: IEC60034,BV Connection: Y

Insulation class: H Sn: 1700kVA

Temperature class: F Un: 440 V

Ambient temp.max: 45 In: 2231 A

IP: 23 p.f: 0.8

IM: 1101 f: 60 Hz

Duty: S1 n: 1800 rpm

Test program
1. Visual inspection
2. Air gap measurement
3. Insulation resistance before tests
4. Resistance measurement of windings and elements
5. High voltage test
6. First running
7. Direction of rotation, checking of phase sequence
8. No-load point
9. Short-circuit point
10. No-load curve, U1=f(Im)
11. Short-circuit curve, I1=f(Im)
12. Vibration measurement
13. Voltage waveform measurement
14. Test with AVR
15. Over current test
 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 3
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

16. Over speed test

17. Insulation resistance after test
18. IPx3 testing
 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 4
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

1. Visual inspection

Notes OK

2. Air gap measurement

Main stator air gap

See from the DE

Position Air gap(mm) Position Air gap(mm)

Up-left 4.75 Up-right 4.80

Down-left 4.80 Down-right 4.75

3. Insulation resistance before tests

Winding R [Mohm] U [V] t1[s] T[ ]

Stator 22100 1000 60 15.1

Rotor 38400 1000 60 15.1

Exciter 395000 1000 60 15.1

Winding of PM 330000 1000 60 15.1

Main auxiliary winding 511000 1000 60 15.1

Spare auxiliary winding 440000 1000 60 15.1

Space heater 320000 500 60 15.1

PT100 (stator) 24500 500 60 15.1

PT100 (others) 24500 500 60 15.1

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 5
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

4. Resistance measurement of windings and elements

Resistance of winding

Armature windings Ru-v [ohm] Ru-w [ohm] Rv-w [ohm] T[ ]

Stator 0.00231 0.00232 0.00231 15.1

Rotor 0.92686 15.1

Exciter

Stator 12.570 15.1

Winding of PM 1.5395 15.1

Rotor 0.02375 0.02377 0.02385 15.1

Main auxiliary winding 0.19295 15.1

Spare auxiliary winding 0.20571 15.1

5. High voltage test

Stator winding 2500 V 60S OK

Rotor winding 2000 V 60S OK

Field winding 2000 V 60S OK

Aux.winding 1500 V 60S OK

Space heater 1500 V 60S OK

PT100(stator) 1500 V 60S OK

PT100(others) 500 V 60S OK

 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 6
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

6. First running

Notes OK

7. Direction of rotation, checking of phase sequence

Result U-V-W >>>L3-L2-L1 (CCW)

8. No-load point
N[rpm] U1(V) Im(A) Um(V)

1800 443.88 0.70 8.92

Voltage balances

Stator Uuv(V) Uuw(V) Uvw(V)

1 443.88 443.87 443.89

9. Short-circuit point
N[rpm] I1(A) Im(A) Um(V)

1800 2224.77 1.67 20.83

Current balances

Stator I1 (A) I2(A) I3(A)

1 2178.20 2271.34 2181.57

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 7
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

10. No-load curve, U1=f(Im)

U1(V) Um(V) Im(A)

592.27 20.82 1.67

528.63 12.77 1.03

482.44 10.53 0.80

461.99 9.84 0.75

443.88 8.92 0.70

416.09 7.84 0.65

397.81 7.40 0.60

302.10 5.62 0.46

265.13 5.08 0.41

216.80 4.30 0.34

173.52 3.66 0.28

REM 23.23 0.03 0.00

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 8
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

11. Short-circuit curve, I1=f(Im)

I1(A) Um(V) Im(A)

3341.23 30.91 2.50

2470.57 23.33 1.85

2224.77 20.83 1.67

1681.10 16.34 1.27

1097.48 10.57 0.86

555.70 5.80 0.46

REM 0.00 0.03 0.00

12. Vibration measurement

At self-excitation, r=1800 RPM, U1=440 V

D-end Horizontal Vertical Axial

1.0 1.1 1.8 mm/s

N.D-end Horizontal Vertical Axial

0.8 0.7 1.3 mm/s

13. Voltage waveform measurement

THD of line voltage waveform 1.90%

THD of phase voltage waveform 4.26%
 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 9
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

14. Test with AVR (DECS100)

Min(V) Max(V)
Line voltage regulate range
396 484

Setting of under frequency limit and function testing

The main voltage level is keep as rated voltage at rated speed.
Reduce the frequency to 55 Hz; regulate the AVR, the main voltage level stays as rated.
Reduce the frequency to 54 Hz, the main voltage drops.
Remark: The function is working.

15. Over current test

Current Time

Over current 150% In 30S

Notes: OK

16. Over speed test

Speed Time

Over speed 2160RPM 2 minutes

Notes OK
 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 10
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

17. Insulation resistance after tests

Winding R [Mohm] U [V] t1[s]

Stator 19800 1000 60

Rotor 36400 1000 60

Exciter 401000 1000 60

Winding of PM 377000 1000 60

Main auxiliary winding 525000 1000 60

Spare auxiliary winding 491000 1000 60

Space heater 308000 500 60

PT100 (stator) 20100 500 60

PT100 (others) 20100 500 60

 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 11
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

18. IPx3 tests

The nozzle position as below figure shown.

The water pressure is adjusted to give a delivery rate of 10L/min (pressure approximately
0.7MPa), generator running as no-load at this condition for 20 minutes.
 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 12
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA101 8807086 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

Test result
1. No water entered the enclosure after IPX3 test.
2. Insulation resistance after IPX3 test as following table, it is ok.
Components Insulation resistance (Mohm)
Stator winding 16300
Rotor winding 10300
Aux winding 394000
Exciter stator winding 522000
Exciter rotor winding 112000
Space heater 213000
 TEST REPORT

Test report for synchronous machines

Customer
Lei Shing Hong Machinery Limited
Order reference
11HK01/ZJ4001/ Main generators

main generator number 2

Project
SPP35B PSV(LSH)
Machine
AMG 0500SF04 DAA
Work nr
1225CA102
Serial nr
8807087
Date
14.12.2011

Approved on the behalf of manufacturer

Marco-Jin Yuan

Witnessed on the behalf of the classification society

ABB Generators Ltd.

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 2
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA102 8807087 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

Standards: IEC60034,BV Connection: Y

Insulation class: H Sn: 1700kVA

Temperature class: F Un: 440 V

Ambient temp.max: 45 In: 2231 A

IP: 23 p.f: 0.8

IM: 1101 f: 60 Hz

Duty: S1 n: 1800 rpm

Test program
1. Visual inspection
2. Air gap measurement
3. Insulation resistance before tests
4. Resistance measurement of windings and elements
5. High voltage test
6. First running
7. Direction of rotation, checking of phase sequence
8. No-load point
9. Short-circuit point
10. No-load curve, U1=f(Im)
11. Short-circuit curve, I1=f(Im)
12. Vibration measurement
13. Voltage waveform measurement
14. Test with AVR
15. Over current test
 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 3
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA102 8807087 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

16. Over speed test

17. Insulation resistance after test
 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 4
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA102 8807087 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

1. Visual inspection

Notes OK

2. Air gap measurement

Main stator air gap

See from the DE

Position Air gap(mm) Position Air gap(mm)

Up-left 4.80 Up-right 4.80

Down-left 4.85 Down-right 4.85

3. Insulation resistance before tests

Winding R [Mohm] U [V] t1[s] T[ ]

Stator 19900 1000 60 19.6

Rotor 45400 1000 60 19.6

Exciter 660000 1000 60 19.6

Winding of PM 467000 1000 60 19.6

Main auxiliary winding 716000 1000 60 19.6

Spare auxiliary winding 606000 1000 60 19.6

Space heater 180000 500 60 19.6

PT100 (stator) 78100 500 60 19.6

PT100 (others) 78100 500 60 19.6

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 5
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA102 8807087 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

4. Resistance measurement of windings and elements

Resistance of winding

Armature windings Ru-v [ohm] Ru-w [ohm] Rv-w [ohm] T[ ]

Stator 0.00233 0.00233 0.00233 19.6

Rotor 0.95186 19.6

Exciter

Stator 12.260 19.6

Winding of PM 1.5077 19.6

Rotor 0.02309 0.02312 0.02315 19.6

Main auxiliary winding 0.19416 19.6

Spare auxiliary winding 0.20387 19.6

5. High voltage test

Stator winding 2500 V 60S OK

Rotor winding 2000 V 60S OK

Field winding 2000 V 60S OK

Aux.winding 1500 V 60S OK

Space heater 1500 V 60S OK

PT100(stator) 1500 V 60S OK

PT100(others) 500 V 60S OK

 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 6
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA102 8807087 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

6. First running

Notes OK

7. Direction of rotation, checking of phase sequence

Result U-V-W >>>L3-L2-L1 (CCW)

8. No-load point
N[rpm] U1(V) Im(A) Um(V)

1800 444.07 0.63 8.12

Voltage balances

Stator Uuv(V) Uuw(V) Uvw(V)

1 444.07 444.05 444.06

9. Short-circuit point
N[rpm] I1(A) Im(A) Um(V)

1800 2265.57 1.63 19.58

Current balances

Stator I1 (A) I2(A) I3(A)

1 2215.48 2315.66 2209.98

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 7
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA102 8807087 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

10. No-load curve, U1=f(Im)

U1(V) Um(V) Im(A)

598.36 20.81 1.70

527.63 11.91 0.96

483.15 8.92 0.74

466.44 8.62 0.69

444.07 8.12 0.63

409.36 7.02 0.55

391.21 6.53 0.53

305.98 4.77 0.38

256.97 4.16 0.32

217.06 3.57 0.27

146.74 2.29 0.17

REM 10.30 0.03 0.00

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 8
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA102 8807087 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

11. Short-circuit curve, I1=f(Im)

I1(A) Um(V) Im(A)

3338.40 30.83 2.44

2468.20 22.08 1.79

2265.57 19.58 1.63

1638.62 14.61 1.17

1122.75 8.73 0.79

576.07 5.06 0.40

REM 0.00 0.03 0.00

12. Vibration measurement

At self-excitation, r=1800 RPM, U1=440 V

D-end Horizontal Vertical Axial

1.0 1.0 2.0 mm/s

N.D-end Horizontal Vertical Axial

0.9 0.7 1.4 mm/s

13. Voltage waveform measurement

THD of line voltage waveform 1.91%

THD of phase voltage waveform 4.26%
 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 9
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA102 8807087 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

14. Test with AVR (DECS100)

Min(V) Max(V)
Line voltage regulate range
396 484

Setting of under frequency limit and function testing

The main voltage level is keep as rated voltage at rated speed.
Reduce the frequency to 55 Hz; regulate the AVR, the main voltage level stays as rated.
Reduce the frequency to 54 Hz, the main voltage drops.
Remark: The function is working.

15. Over current test

Current Time

Over current 150% In 30S

Notes: OK

16. Over speed test

Speed Time

Over speed 2160RPM 2 minutes

Notes OK
 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 10
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA102 8807087 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

17. Insulation resistance after tests

Winding R [Mohm] U [V] t1[s]

Stator 25100 1000 60

Rotor 39800 1000 60

Exciter 521000 1000 60

Winding of PM 495000 1000 60

Main auxiliary winding 687000 1000 60

Spare auxiliary winding 459000 1000 60

Space heater 203000 500 60

PT100 (stator) 65400 500 60

PT100 (others) 65400 500 60

 TEST REPORT

Test report for synchronous machines

Customer
Lei Shing Hong Machinery Limited
Order reference
11HK01/ZJ4001/ Main generators

main generator number 3

Project
SPP35B PSV(LSH)
Machine
AMG 0500SF04 DAA
Work nr
1225CA103
Serial nr
8807088
Date
14.12.2011

Approved on the behalf of manufacturer

Marco-Jin Yuan

Witnessed on the behalf of the classification society

ABB Generators Ltd.

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 2
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA103 8807088 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

Standards: IEC60034,BV Connection: Y

Insulation class: H Sn: 1700kVA

Temperature class: F Un: 440 V

Ambient temp.max: 45 In: 2231 A

IP: 23 p.f: 0.8

IM: 1101 f: 60 Hz

Duty: S1 n: 1800 rpm

Test program
1. Visual inspection
2. Air gap measurement
3. Insulation resistance before tests
4. Resistance measurement of windings and elements
5. High voltage test
6. First running
7. Direction of rotation, checking of phase sequence
8. No-load point
9. Short-circuit point
10. No-load curve, U1=f(Im)
11. Short-circuit curve, I1=f(Im)
12. Vibration measurement
13. Voltage waveform measurement
14. Test with AVR
15. Over current test
 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 3
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA103 8807088 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

16. Over speed test

17. Insulation resistance after test
 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 4
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA103 8807088 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

1. Visual inspection

Notes OK

2. Air gap measurement

Main stator air gap

See from the DE

Position Air gap(mm) Position Air gap(mm)

Up-left 4.80 Up-right 4.75

Down-left 4.80 Down-right 4.85

3. Insulation resistance before tests

Winding R [Mohm] U [V] t1[s] T[ ]

Stator 10800 1000 60 15.9

Rotor 81100 1000 60 15.9

Exciter 89800 1000 60 15.9

Winding of PM 89800 1000 60 15.9

Main auxiliary winding 432000 1000 60 15.9

Spare auxiliary winding 432000 1000 60 15.9

Space heater 521000 500 60 15.9

PT100 (stator) 59600 500 60 15.9

PT100 (others) 59600 500 60 15.9

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 5
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA103 8807088 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

4. Resistance measurement of windings and elements

Resistance of winding

Armature windings Ru-v [ohm] Ru-w [ohm] Rv-w [ohm] T[ ]

Stator 0.00232 0.00233 0.00233 15.9

Rotor 0.94521 15.9

Exciter

Stator 12.105 15.9

Winding of PM 1.4930 15.9

Rotor 0.02321 0.02320 0.02318 15.9

Main auxiliary winding 0.19786 15.9

Spare auxiliary winding 0.20870 15.9

5. High voltage test

Stator winding 2500 V 60S OK

Rotor winding 2000 V 60S OK

Field winding 2000 V 60S OK

Aux.winding 1500 V 60S OK

Space heater 1500 V 60S OK

PT100(stator) 1500 V 60S OK

PT100(others) 500 V 60S OK

 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 6
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA103 8807088 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

6. First running

Notes OK

7. Direction of rotation, checking of phase sequence

Result U-V-W >>>L3-L2-L1 (CCW)

8. No-load point
N[rpm] U1(V) Im(A) Um(V)

1800 441.68 0.63 7.63

Voltage balances

Stator Uuv(V) Uuw(V) Uvw(V)

1 441.73 441.67 441.64

9. Short-circuit point
N[rpm] I1(A) Im(A) Um(V)

1800 2227.11 1.59 19.30

Current balances

Stator I1 (A) I2(A) I3(A)

1 2191.97 2262.25 2165.52

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 7
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA103 8807088 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

10. No-load curve, U1=f(Im)

U1(V) Um(V) Im(A)

593.96 20.01 1.63

528.43 11.71 0.97

484.89 9.01 0.75

460.93 8.20 0.67

441.68 7.63 0.63

416.32 7.01 0.57

394.21 6.46 0.53

308.80 4.81 0.40

263.08 3.95 0.33

216.06 2.89 0.27

174.82 2.71 0.22

REM 10.30 0.03 0.00

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 8
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA103 8807088 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

11. Short-circuit curve, I1=f(Im)

I1(A) Um(V) Im(A)

3374.85 29.91 2.45

2472.13 21.83 1.77

2227.11 19.30 1.59

1646.42 14.45 1.17

1115.92 10.38 0.79

563.28 4.67 0.39

REM 0.00 0.00 0.00

12. Vibration measurement

At self-excitation, r=1800 RPM, U1=440 V

D-end Horizontal Vertical Axial

1.1 1.2 1.7 mm/s

N.D-end Horizontal Vertical Axial

1.2 0.8 1.3 mm/s

13. Voltage waveform measurement

THD of line voltage waveform 1.94%

THD of phase voltage waveform 4.28%
 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 9
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA103 8807088 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

14. Test with AVR (DECS100)

Min(V) Max(V)
Line voltage regulate range
396 484

Setting of under frequency limit and function testing

The main voltage level is keep as rated voltage at rated speed.
Reduce the frequency to 55 Hz; regulate the AVR, the main voltage level stays as rated.
Reduce the frequency to 54 Hz, the main voltage drops.
Remark: The function is working.

15. Over current test

Current Time

Over current 150% In 30S

Notes: OK

16. Over speed test

Speed Time

Over speed 2160RPM 2 minutes

Notes OK
 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 10
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA103 8807088 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

17. Insulation resistance after tests

Winding R [Mohm] U [V] t1[s]

Stator 14500 1000 60

Rotor 65300 1000 60

Exciter 105900 1000 60

Winding of PM 105900 1000 60

Main auxiliary winding 374000 1000 60

Spare auxiliary winding 374000 1000 60

Space heater 493000 500 60

PT100 (stator) 72100 500 60

PT100 (others) 72100 500 60

 TEST REPORT

Test report for synchronous machines

Customer
Lei Shing Hong Machinery Limited
Order reference
11HK01/ZJ4001/ Main generators

main generator number 4

Project
SPP35B PSV(LSH)
Machine
AMG 0500SF04 DAA
Work nr
1225CA104
Serial nr
8807089
Date
14.12.2011

Approved on the behalf of manufacturer

Marco-Jin Yuan

Witnessed on the behalf of the classification society

ABB Generators Ltd.

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 2
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA104 8807089 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

Standards: IEC60034,BV Connection: Y

Insulation class: H Sn: 1700kVA

Temperature class: F Un: 440 V

Ambient temp.max: 45 In: 2231 A

IP: 23 p.f: 0.8

IM: 1101 f: 60 Hz

Duty: S1 n: 1800 rpm

Test program
1. Visual inspection
2. Air gap measurement
3. Insulation resistance before tests
4. Resistance measurement of windings and elements
5. High voltage test
6. First running
7. Direction of rotation, checking of phase sequence
8. No-load point
9. Short-circuit point
10. No-load curve, U1=f(Im)
11. Short-circuit curve, I1=f(Im)
12. Vibration measurement
13. Voltage waveform measurement
14. Test with AVR
15. Over current test
 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 3
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA104 8807089 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

16. Over speed test

17. Insulation resistance after test
 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 4
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA104 8807089 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

1. Visual inspection

Notes OK

2. Air gap measurement

Main stator air gap

See from the DE

Position Air gap(mm) Position Air gap(mm)

Up-left 4.80 Up-right 4.85

Down-left 4.80 Down-right 4.85

3. Insulation resistance before tests

Winding R [Mohm] U [V] t1[s] T[ ]

Stator 9670 1000 60 16.7

Rotor 42600 1000 60 16.7

Exciter 81900 1000 60 16.7

Winding of PM 81900 1000 60 16.7

Main auxiliary winding 246000 1000 60 16.7

Spare auxiliary winding 246000 1000 60 16.7

Space heater 102000 500 60 16.7

PT100 (stator) 28700 500 60 16.7

PT100 (others) 28700 500 60 16.7

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 5
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA104 8807089 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

4. Resistance measurement of windings and elements

Resistance of winding

Armature windings Ru-v [ohm] Ru-w [ohm] Rv-w [ohm] T[ ]

Stator 0.00232 0.00233 0.00232 16.7

Rotor 0.94101 16.7

Exciter

Stator 12.124 16.7

Winding of PM 1.5175 16.7

Rotor 0.02321 0.02311 0.02323 16.7

Main auxiliary winding 0.19657 16.7

Spare auxiliary winding 0.20861 16.7

5. High voltage test

Stator winding 2500 V 60S OK

Rotor winding 2000 V 60S OK

Field winding 2000 V 60S OK

Aux.winding 1500 V 60S OK

Space heater 1500 V 60S OK

PT100(stator) 1500 V 60S OK

PT100(others) 500 V 60S OK

 TEST REPORT
C Customer Machine page
Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 6
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA104 8807089 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

6. First running

Notes OK

7. Direction of rotation, checking of phase sequence

Result U-V-W >>>L3-L2-L1 (CCW)

8. No-load point
N[rpm] U1(V) Im(A) Um(V)

1800 441.86 0.63 7.64

Voltage balances

Stator Uuv(V) Uuw(V) Uvw(V)

1 441.86 441.85 441.86

9. Short-circuit point
N[rpm] I1(A) Im(A) Um(V)

1800 2234.32 1.60 19.46

Current balances

Stator I1 (A) I2(A) I3(A)

1 2197.55 2271.10 2175.53

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 7
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA104 8807089 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

10. No-load curve, U1=f(Im)

U1(V) Um(V) Im(A)

594.97 19.35 1.64

527.91 11.83 0.96

485.27 9.37 0.75

464.62 8.43 0.69

441.86 7.64 0.63

416.17 6.87 0.57

395.72 6.04 0.53

307.41 4.75 0.39

264.45 3.98 0.33

217.13 3.39 0.27

176.44 2.68 0.22

REM 8.95 0.03 0.00

 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 8
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA104 8807089 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

11. Short-circuit curve, I1=f(Im)

I1(A) Um(V) Im(A)

3332.16 29.71 2.41

2460.05 21.50 1.76

2234.32 19.46 1.60

1663.10 14.46 1.18

1104.24 9.30 0.78

557.06 4.46 0.38

REM 0.00 0.00 0.00

12. Vibration measurement

At self-excitation, r=1800 RPM, U1=440 V

D-end Horizontal Vertical Axial

1.0 1.4 1.4 mm/s

N.D-end Horizontal Vertical Axial

0.8 0.4 1.5 mm/s

13. Voltage waveform measurement

THD of line voltage waveform 1.93%

THD of phase voltage waveform 4.29%
 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 9
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA104 8807089 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

14. Test with AVR (DECS100)

Min(V) Max(V)
Line voltage regulate range
396 484

Setting of under frequency limit and function testing

The main voltage level is keep as rated voltage at rated speed.
Reduce the frequency to 55 Hz; regulate the AVR, the main voltage level stays as rated.
Reduce the frequency to 54 Hz, the main voltage drops.
Remark: The function is working.

15. Over current test

Current Time

Over current 150% In 30S

Notes: OK

16. Over speed test

Speed Time

Over speed 2160RPM 2 minutes

Notes OK
 TEST REPORT

C Customer Machine page

Lei Shing Hong Machinery Limited AMG 0500SF04 DAA 10
Order reference Work nr: Serial nr Revision
11HK01/ Main generators 1225CA104 8807089 A
Project Approved Report rev:
SPP35B PSV(LSH) Marco-Jin Yuan A

17. Insulation resistance after tests

Winding R [Mohm] U [V] t1[s]

Stator 17300 1000 60

Rotor 61700 1000 60

Exciter 70400 1000 60

Winding of PM 70400 1000 60

Main auxiliary winding 198000 1000 60

Spare auxiliary winding 198000 1000 60

Space heater 131000 500 60

PT100 (stator) 45800 500 60

PT100 (others) 45800 500 60