WEG Turbogenerator 10174576 Manual English

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Turbogenerator

S Line

Installation, Operation and Maintenance Manual

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Line S Turbogenerator l 1

Installation, Operation and Maintenance Manual

Document No.: 9300.0050
Model: Line S Turbogenerator
Material: 10174576
Language: English
Revision 1
March, 2010

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2 l Line S Turbogenerators

February 2008

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Dear Customer

Thank you for purchasing a WEG generator. It is a product developed with high levels of
quality and efficiency to ensure excellent performance.
Electric energy plays an outstanding role in the comfort and well-being of humankind. Being
responsible for the production of this energy, the electric generator needs to be identified and
treated as a machine whose characteristics demand special care, particularly with regard to
storage, installation and maintenance procedures.
All efforts have been made to ensure that the information contained in this manual can be
reliably used for setting up and running the WEG generator.
So please read this manual carefully before the installation, operation or maintenance of your
generator for a continuous and safe operation and to ensure that all measures have been
taken for your safety and the safety of your facilities. If any doubts persist, please contact
WEG.
Keep this manual always close to the generator for prompt reference when required.

ATTENTION
1. It is absolutely necessary to follow the procedures contained in this manual for the warranty to be valid.
2. The generator installation, operation and maintenance must be executed by qualified personnel.

NOTES
1. The total or partial reproduction of the information supplied in this manual is authorized, provided that
reference is made to its source;
2. If this manual is lost, an electronic PDF file is available from our website www.weg.net or another
printed copy can be requested.

WEG EQUIPAMENTOS ELTRICOS S.A.

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CONTENTS

1 INTRODUCTION.........................................................................................................................................9
2 GENERAL INSTRUCTIONS.....................................................................................................................10
2.1 QUALIFIED PERSONNEL ....................................................................................................................................... 10
2.2 SAFETY INSTRUCTIONS........................................................................................................................................ 10
3 OPERATING CONDITIONS AND STANDARDS.....................................................................................11
3.1 STANDARDS............................................................................................................................................................ 11
3.2 ENVIRONMENT CHARACTERISTICS................................................................................................................... 11
3.3 OPERATING CONDITIONS.................................................................................................................................... 11
4 RECEIVING AND STORAGE...................................................................................................................12
4.1 RECEIVING............................................................................................................................................................... 12
4.2 STORAGE................................................................................................................................................................. 12
4.2.1 Indoor storage ....................................................................................................................................12
4.2.2 Outside storage ..................................................................................................................................12
5 LONG STORAGE PERIODS....................................................................................................................13
5.1 INTRODUCTION...................................................................................................................................................... 13
5.2 GENERAL................................................................................................................................................................. 13
5.3 STORAGE LOCATION............................................................................................................................................ 13
5.3.1 Indoor storage ....................................................................................................................................13
5.3.2 Outdoor storage .................................................................................................................................13
5.4 SEPARATE PARTS.................................................................................................................................................. 14
5.5 SPACE HEATER...................................................................................................................................................... 14
5.6 INSULATION RESISTANCE.................................................................................................................................... 14
5.7 EXPOSED MACHINED SURFACES...................................................................................................................... 14
5.8 ROLLING BEARINGS.............................................................................................................................................. 14
5.8.1 Grease-lubricated bearing...................................................................................................................14
5.8.2 Oil-lubricated bearing..........................................................................................................................14
5.8.3 Sleeve Bearing....................................................................................................................................14
5.9 TERMINAL BOX....................................................................................................................................................... 15
5.10 PREPARATION FOR OPERATION AFTER LONG STORAGE............................................................................ 15
5.10.1 Cleaning .............................................................................................................................................15
5.10.2 Bearing lubrication ..............................................................................................................................15
5.10.3 Checking the insulation resistance ......................................................................................................15
5.10.4 Others ................................................................................................................................................15
5.11 INSPECTIONS AND RECORDS DURING THE STORAGE................................................................................. 15
5.12 MAINTENANCE PLAN TO BE FOLLOWED DURING THE STORAGE.............................................................. 16
6 HANDLING ...............................................................................................................................................17
7 INSULATION RESISTANCE....................................................................................................................18
7.1 SAFETY INSTRUCTIONS........................................................................................................................................ 18
7.2 GENERAL REMARKS............................................................................................................................................. 18
7.3 STATOR WINDING MEASUREMENT.................................................................................................................... 18
7.4 MEASUREMENT OF THE ROTOR WINDING RESISTANCE, EXCITER WINDING RESISTANCE AND
ACCESSORIES..................................................................................................................................................................... 18
7.5 CONVERSION OF THE MEASURED VALUES..................................................................................................... 19
7.6 MINIMUM INSULATION RESISTANCE.................................................................................................................. 19
7.7 POLARIZATION INDEX............................................................................................................................................ 19
8 CONSTRUCTION CHARACTERISTICS..................................................................................................20
8.1 STATOR.................................................................................................................................................................... 20
8.2 ROTOR..................................................................................................................................................................... 20
8.3 EXCITER................................................................................................................................................................... 20

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8.4 PERMANENT MAGNET GENERATOR (PMG)......................................................................................................20
8.5 DUMPING WINDING...............................................................................................................................................20
8.6 BEARINGS................................................................................................................................................................20
8.7 HEAT EXCHANGER................................................................................................................................................20
9 OPERATION PRINCIPLE........................................................................................................................ 21
9.1 EXCITATION.............................................................................................................................................................21
9.2 DEEXCITATION........................................................................................................................................................21
9.3 VOLTAGE REGULATOR.........................................................................................................................................22
9.4 UNDERFREQUENCY (U/F) PROTECTION............................................................................................................22
10 INSTALLATION....................................................................................................................................... 23
10.1 INSTALLATION SITE................................................................................................................................................23
10.2 PROTECTIONS........................................................................................................................................................23
10.3 DIRECTION OF ROTATION...................................................................................................................................23
10.4 FOUNDATIONS........................................................................................................................................................23
10.5 ANCHOR PLATE SET .............................................................................................................................................24
10.6 ALIGNMENT / LEVELING........................................................................................................................................25
10.7 COUPLING...............................................................................................................................................................25
10.8 ELECTRICAL AND GROUNDING CONNECTIONS.............................................................................................27
10.8.1 Main stator connections (power cables).............................................................................................. 27
10.8.2 Grounding.......................................................................................................................................... 27
10.8.3 Accessories ....................................................................................................................................... 27
10.9 THERMAL PROTECTIONS.....................................................................................................................................27
10.9.1 Protection location ............................................................................................................................. 27
10.9.2 Temperature sensors ......................................................................................................................... 27
10.9.3 Temperature limits for the windings .................................................................................................... 27
10.9.4 Thermal bearing protections............................................................................................................... 28
10.9.5 Alarm and disconnection temperatures .............................................................................................. 28
10.9.6 Ratio between temperature and the ohmic resistance of Pt 100 temperature sensors......................... 28
10.9.7 Space heater ..................................................................................................................................... 29
10.10 PANEL PROTECTIONS...........................................................................................................................................29
10.11 GENERATOR COOLING.........................................................................................................................................29
10.12 WATER RADIATORS...............................................................................................................................................30
11 ELECTRICAL CONNECTIONS AND ACCESSORIES........................................................................... 31
11.1 TERMINAL MARKINGS...........................................................................................................................................31
11.2 WIRING DIAGRAMS................................................................................................................................................31
11.2.1 Thermal protection on main stator winding......................................................................................... 32
11.2.2 Generator cooling system .................................................................................................................. 33
11.2.3 Bearings ............................................................................................................................................ 34
11.2.4 Space heater and exciter ................................................................................................................... 35
11.3 DESCRIPTION OF THE ACCESSORY FUNCTION..............................................................................................35
11.4 ACCESSORIES AND PROTECTIONS...................................................................................................................36
12 START-UP 37
12.1 BEFORE FIRST START-UP.....................................................................................................................................37
12.2 INITIAL MECHANICAL TURN.................................................................................................................................37
12.3 POWERING-UP.......................................................................................................................................................37
12.4 SYNCHRONIZATION AND LOAD..........................................................................................................................37
13 GENERATOR OPERATION.................................................................................................................... 38
13.1 SHAFT LIFTING SYSTEM (JACKING) ....................................................................................................................38
13.2 WATER RADIATORS...............................................................................................................................................38
13.3 BEARINGS................................................................................................................................................................38
13.4 VIBRATION LIMITS..................................................................................................................................................38
13.5 SHAFT VIBRATION LIMITS.....................................................................................................................................38
13.6 STOP 39
14 MAINTENANCE....................................................................................................................................... 40
14.1 GENERAL.................................................................................................................................................................40
14.2 GENERATOR CLEANING.......................................................................................................................................40

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14.3 STATOR, ROTOR AND EXCITER WINDING INSPECTIONS............................................................................... 40
14.4 WINDINGS CLEANING........................................................................................................................................... 40
14.5 INSPECTION AND CLEANING OF RADIATORS................................................................................................. 41
14.6 GENERATOR OUT OF SERVICE........................................................................................................................... 41
15 BEARINGS 42
15.1 SLEEVE BEARINGS................................................................................................................................................ 42
15.1.1 Bearing connections ...........................................................................................................................42
15.1.2 Bearings data .....................................................................................................................................42
15.1.3 Bearings installation and operation......................................................................................................42
15.1.4 Hydrostatic jacking system .................................................................................................................42
15.1.5 Setting of the bearing protections .......................................................................................................42
15.1.6 Lubrication..........................................................................................................................................42
15.1.7 Sealing ...............................................................................................................................................43
15.1.8 Bearing maintenance ..........................................................................................................................43
15.2 OIL BEARINGS......................................................................................................................................................... 43
15.2.1 Lubrication guidelines .........................................................................................................................43
15.2.2 Bearing operations..............................................................................................................................43
15.2.3 Protection device settings...................................................................................................................43
15.3 GREASE BEARINGS............................................................................................................................................... 44
15.3.1 Lubrication guidelines .........................................................................................................................44
15.3.2 Steps for bearing re-lubrication ...........................................................................................................44
15.3.3 Spring device for grease removal ........................................................................................................44
15.3.4 Protection settings..............................................................................................................................44
15.3.5 Bearing replacement...........................................................................................................................45
16 EXCITER 46
16.1 EXCITER................................................................................................................................................................... 46
16.2 DIODES TEST.......................................................................................................................................................... 46
16.3 DIODES REPLACEMENT ....................................................................................................................................... 47
16.4 VARISTORS TEST................................................................................................................................................... 47
16.5 VARISTORS REPLACEMENT................................................................................................................................ 47
17 GENERATOR PARTS..............................................................................................................................48
18 MAINTENANCE SCHEDULE...................................................................................................................49
19 TROUBLESHOOTING..............................................................................................................................50
20 ACCESSORIES AND SPARE PARTS.....................................................................................................52
21 DOCUMENTS...........................................................................................................................................53
22 WARRANTY CONDITIONS OF ENGINEERED PRODUCTS .................................................................54

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1 INTRODUCTION

THE TURBOGENERATOR
The turbogenerator is a machine that operates as an electric power generator when its shaft is driven by a turbine.

THE THERMAL ELECTRIC POWER GENERATION PROCESS
The fuel is burned in a boiler. The boiler heats a water volume, which changes into steam. The steam drives the turbine rotor
that turns the generator shaft. The electromagnetic action inside the generator generates electric power that is supplied to
the consumer network.

TERMINOLOGY

S P W 1250

S GENERATOR LINE

S Line

EXCITATION TYPE

P - Brushless with auxiliary exciter
S - Brushless without auxiliary exciter

COOLING SYSTEM

W - Air-water heat exchanger
A Open, self-ventilated
D - Self-ventilated by ducts, air inlet and outlet
T - Forced ventilation, air inlet and outlet by ducts
V - Forced ventilation, ventilation on the generator
F - Self-ventilated with air-to-air heat exchanger on top of generator
I - Forced ventilation in the internal and external air circuit, air-to-air heat exchanger
L - Air-to-water heat exchanger, forced ventilation in the internal air circuit

IEC FRAME SIZE
Shaft-end height in mm (450 to 5000)

SAFETY WARNINGS IN THE MANUAL

Following safety warnings are used in this manual:

DANGER
The noncompliance with the procedures recommended in this warning may result in death, serious injuries
and considerable material damages.

ATTENTION
The noncompliance with the procedures recommended in this warning may result in material damages.

NOTE
The purpose of this text is to supply important information for the correct and good performance of this
product.

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2 GENERAL INSTRUCTIONS

ATTENTION
All the procedures and rules contained in
this manual must be followed accordingly
to ensure the good operation of the
equipment and safety of the personnel
involved in its operation. The compliance
with these procedures is equally important
to ensure the application of the warranty
terms on the back cover of this manual.
We strongly recommend a detailed reading
of this manual before the generator
installation and operation. However, in
case any doubt persists, please contact
your nearest WEG representative.

For practical reasons, it is impossible to supply in this
manual all the details regarding possible construction
alternatives. In addition, it is impossible to consider all the
imaginable cases of operation or maintenance.
For this reason, this manual contains only the required
information so that qualified and trained personnel may
perform the required services.

2.1 QUALIFIED PERSONNEL

People who, because of their education, experience,
instruction and knowledge of applicable standards and
safety procedures about the corresponding service
conditions, are duly authorized to operate and monitor
the generator. They must also be knowledgeable about
first-aid procedures and be capable of providing these
services if required.
It is assumed, that all commissioning, maintenance and
repair works will only be performed by qualified
personnel.

2.2 SAFETY INSTRUCTIONS

DANGER
During operation of this equipment, there will
be exposed energized or rotating parts with
high voltage or high temperatures.
Thus, its operation with open terminal boxes,
unprotected couplings or erroneous handling,
without considering the operation standards,
may cause serious personal injury and
property damage.

The people responsible for the installation safety must
assure that:
Only qualified personnel will perform the installation
and operation of the equipment;
These people will have in hand this manual and other
documents supplied with the generator and will also
perform the works, strictly complying with the service
instructions, standards and the product specific
documentation;
People not qualified will be forbidden to carry out
works on the electric equipment.

The noncompliance with the installation and safety rules
may void the product warranty.
Firefighting equipment and first aid warnings will be
located in the work site in visible and accessible places.

The following should also be observed:
All technical data regarding the allowed applications
(operating conditions, connections and installation
environment) contained in the catalog, purchase order,
operating instructions, manuals and other documents;
The specific determinations and conditions for the local
installation;
The use of proper tools and equipment for handling
and transport;
That the protection devices of the components are
removed little before the installation;
The individual parts must be stored in vibration-free
rooms, preventing falls and assuring that they are
protected against rodents and/or may pose risks to
people safety.

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3 OPERATING CONDITIONS AND STANDARDS

3.1 STANDARDS

WEG turbogenerators are specified, designed, manufactured and tested according to the following standards:

Specification
IEC-60034.1
VDE-0530
NBR 5117
Tests IEC-60034.2 NBR 5052
Degree of protection IEC-60034.5 NBR 6146
Cooling IEC-60034.6 NBR 5110
Mountings IEC-60034.7 NBR 5031
Noise IEC-60034.9 NBR 7565
Mechanical vibration IEC-60034.14 NBR 7094
Mechanical tolerances ISO 286 NBR 6158
Balancing ISO 1940 NBR 8008

Table 3.1: Standards

3.2 ENVIRONMENT CHARACTERISTICS

Turbogenerators are designed to be operated in following ambient conditions:
Ambient temperature: 15C to + 40C;
Altitudes: up to 1,000 m;
Environments without the presence of aggressive agents, such as: sea air, chemicals, etc.;
Environments according to the degree of protection of the generator.

ATTENTION
For turbogenerators fitted with air-to-water heat exchanger, ambient temperature should not be lower than +5C
and the cooling water temperature should be from +5C to +25C.

Special operation conditions can be met upon request and are indicated on the nameplate and data sheet specific for each
machine.

3.3 OPERATING CONDITIONS

The operating conditions of the generator must comply with the nameplate data, applicable standards and codes, as well as
with this manual in order to assure warranty coverage.

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4 RECEIVING AND STORAGE

4.1 RECEIVING

All generators are factory tested and supplied in perfect
operating conditions. The machined surfaces are
corrosion protected. The box or container must be
inspected right after receipt and checked for any damages
that may be caused during the transport.

ATTENTION
Any damage must be reported immediately to
the carrier, the insurance company and WEG.
If such a condition is not reported, the
warranty will be void.

ATTENTION
Parts supplied in additional packages or
volumes must be checked when received
according the complete packing list.

When the package (or container) is lifted, following
items must be checked: hoist components, the weight
indicated on the packaging or on the nameplate, hoist
capacity and operation.
Generators packed in wooden crates must be lifted
always by their own eyebolts or by suitable forklift and
never lifted by its wooden packing box.
Neither the generator nor its packaging should be
dropped or submitted to any impact. Place it on the
ground carefully (without impacts) to prevent bearing
damages.
Do not remove the protecting grease from the shaft end
nor the rubber seals or the plugs from the terminals
boxes.
These protections items must be kept in place until the
final installation has been concluded. After unpacking,
make a complete visual inspection of the generator.
Remove the shaft-lock device and kept it safe for future
transport of the generator.

ATTENTION
If any damage is detected, it must be
photographed, documented and reported
immediately to the carrier company and to

4.2 STORAGE

Any damage to the painting or to the rust protections on
the machined surfaces must be retouched.

ATTENTION
The space heaters must be switched ON
always the generator is not operating.

4.2.1 Indoor storage

When the generator is not unpacked immediately, the box
should be stored in a place protected against moisture,
vapors, sudden change of temperature, rodents and
insects.
The site must be free of vibrations to prevent bearing
damage.

4.2.2 Outside storage

If possible, choose a dry site, free of floods and vibrations.
Repair all damages to the packages before storing the
equipment. This is required to ensure the appropriate
storage conditions.
Store the machines, devices and crates on pallets, wood
beams or foundations that provide protection against
ground moisture.
Prevent the equipment from sinking into the soil. Assure
free airflow under the equipment.
The covering or tarpaulin used to protect the equipment
against the weather should not be in contact with the
equipment surfaces. Assure appropriate air circulation by
placing wooden spacer blocks between the equipment
and the respective covering.

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5 LONG STORAGE PERIODS

5.1 INTRODUCTION

The instructions for long storage periods described below
are valid for generators that are stored during long time
before their commissioning and/or are not operated
during long periods.

5.2 GENERAL

The existing tendency, especially during the plant
construction, of storing generators for long periods
before their commissioning or when only some units are
installed immediately, results in the fact that the generator
is exposed to influences that may not be assessed in
advance for that period.
It is difficult to evaluate the atmospheric, chemical,
thermal and mechanical stresses imposed on the
generator that may occur during the storage, handling,
assembly, initial tests and waiting time until its definitive
commissioning.
Another essential factor is its transport. For example, the
general contractor may transport the generator or a unit
complete with the generator as a joint transport to the
installation site.
The hollow spaces inside the generator, bearings and
terminal box are exposed to the atmospheric air and
temperature fluctuations. Due to air moisture,
condensation of water may occur and, depending on the
type and degree of contamination in the air, aggressive
substances can penetrate the hollow spaces.
As a result, after long storage periods, internal
components such as the bearings, may rust, the
insulation resistance may decrease to values below those
regarded as accepted and the characteristics of the
bearing lubricants are affected adversely. This influence
increases the damage risk before the plant
commissioning.

ATTENTION
To keep the manufacturer's warranty valid,
you must assure that the preventive measures
described in this manual, such as:
construction aspects, preservation,
packaging, storage and inspections are
followed and recorded.

5.3 STORAGE LOCATION

In order to provide the best storage conditions to the
generator during long storage periods, the storage site
should comply strictly with the items below.

5.3.1 Indoor storage

Enclosed storage room with roof;
The storage location must be protected against
moisture, vapors, aggressive fume discharge, rodents
and insects.
Room must be free of corrosive gases, such as:
chlorine, sulfur dioxide or acids;
Location must be free of severe continuous or
intermittent vibrations.
Storage room must be provided with ventilation
system and filter;
Room temperature (5C, > t < 60C), with no sudden
changes in temperature;
Relative air humidity <50%;
Prevention against dirt and dust deposits;
Provided with a fire detection system.
Electric power supply for space heater and illumination
must be provided.

If some of these requirements cannot be provided in the
storage room, WEG suggests that additional protection
measures should be incorporated into the generator
packaging during the storage period as follows:
Storage the generator into a closed wooden box or
similar with electrical installation that allow the
connection of space heaters;
If there is any risk of fungus infestation and formation,
the packaging must be protected in the storage
location by spraying or painting it with appropriate
chemical agents.
The packaging must be prepared carefully by an
experienced person. The company hired for this purpose
shall be responsible for the machine packaging.

5.3.2 Outdoor storage

The outdoor storage of the generator is not
recommended.
If the outdoor storage is unavoidable, pack the generator
into a specific packaging for this condition, as described
below:
For outdoor storage, besides the packaging
recommended for indoor storage, cover the packaging
completely with some protection against dust,
moisture and other foreign matters by using a resistant
canvas or tarpaulin.
Store the packaging on pallets, wood beams or
foundations that provide protection against the ground
moisture.
Prevent the packing from sinking into the soil.
After covering the machine, a shelter must be built to
protect it from direct rain, snow and excessive sun
heat.

ATTENTION
It is recommended to check the storage place
and the generator conditions according to the
maintenance plan for long-term storage as
described in this manual.

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5.4 SEPARATE PARTS

If parts have been supplied separately (terminal boxes,
heat exchanger, endshields, etc.), these parts must be
packed as described above.
The air relative humidity inside the packaging should
not exceed 50% until the machine is unpacked.

5.5 SPACE HEATER

The space heaters installed in the generator must be
energized during the storage period to prevent the
moisture condensation inside the generator, thus
maintaining the winding insulation resistance at
acceptable levels.

ATTENTION
The generator space heater must be
mandatorily energized when the generator is
stored in a place with ambient temperature <
5C and relative air humidity > 50%.

5.6 INSULATION RESISTANCE

During the storage period and before installation, the
insulation resistance of the generator winding should
be measured very 3 months and recorded according
to item 2.3.5 of this manual
Eventual decrease of insulation resistance must be
investigated.

5.7 EXPOSED MACHINED SURFACES

All the exposed machined surfaces (for example, the
shaft end and flanges) are protected at the factory by
temporary protection film (rust inhibitor).
This protective coating must be reapplied at least every
6 months. When this coating is removed and/or
damaged, it must be applied again.

Recommended products:
Name: Dasco Guard 400 TX AZ, Manufacturer: D.A.
Stuart Ltda
Name: TARP, Manufacturer: Castrol

5.8 ROLLING BEARINGS

5.8.1 Grease-lubricated bearing

The bearings are factory lubricated for the performance
of the generator tests.
During the storage period, at every two months, the
shaft-locking device must be removed and the shaft
turned manually to keep the bearing in good lubrication
conditions.
After 6 months of storage and before starting the
operation, the bearings should be relubricated.
If the generator is stored for more than 2 years, the
bearings must be washed, inspected and lubricated
again.
5.8.2 Oil-lubricated bearing
Depending on its mounting position, the generator can
be transported with or without oil in the bearings.
The generator must be stored in its mounting position
with oil in the bearings;
The oil level must be respected, remaining in the sight
glass half.
turned manually to keep the bearing in good lubrication
condition.
After 6 months of storage and before starting the
operation, the bearings should be relubricated.
If the generator is stored for more than 2 years, the
bearings must be washed, inspected and relubricated.

5.8.3 Sleeve Bearing

Depending on the mounting position, the generator
can be transported with our without oil in the bearings
and must be stored in its mounting with oil in the
bearings;
The oil level must be respected, remaining in the sight
glass half.
rotated at 30 rpm to circulate the oil and keep the
sleeve bearing in good lubrication condition.

NOTE
If it is not possible to rotate the generator
shaft, the following procedure should be
adopted to protect the sleeve bearing
internally and the contact surfaces against
corrosion.

Drain all the bearing oil;
Disassemble the bearing following the procedure
described in this manual.
Clean the bearing;
Apply the anticorrosive protection (for example, TECTIL
511, Valvoline or Dasco Guard 400TXAZ) on top and
bottom bearing shell and on the generator shaft
contact surface;
Assemble the sleeve bearing following the procedure
described in this manual;
Close all threaded holes with plugs;
Seal the gaps between the shaft and the bearing seal
by applying a waterproof adhesive tape;
All the flanges (for example, oil inlet and outlet) must
be protected with blind caps;
Remove the bearing top sight glass and spray
anticorrosive protection inside the bearing;
Put some desiccant (silica gel) bags inside the bearing.
The desiccant absorbs moisture and prevents water
condensation inside the bearing;
Close the bearing with the top sight glass.
If the storage period is longer than 6 months:
Repeat the above described procedure;
Place new desiccant (silica gel) bags inside the bearing
If the storage period is longer than 2 years:
Disassemble the bearing;
Preserve and store the bearing parts.

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5.9 TERMINAL BOX

When the generator winding insulation resistance is
checked, the main terminal box and additional
terminal boxes must also be checked, particularly with
regard to the following aspects:
The terminal box inside must be dry and free of any
dust deposit.
The contacts must be free of corrosion.
The seals must be in good condition.
The cable entries must be sealed correctly.
If any of these items is not correct, the parts must be
cleaned or replaced.

5.10 PREPARATION FOR OPERATION AFTER
LONG STORAGE

5.10.1 Cleaning

The machine inside and outside must be free of oil,
water, dust and dirt. The generator inside must be
cleaned with compressed air at reduced pressure.
Remove the rust inhibitor from the exposed surfaces
using a cloth soaked in a petroleum-based solvent.
Remove the existing protection between the grounding
brush and the generator shaft.
Make sure that the bearings and cavities used for
lubrication are free of dirt and that the cavity plugs are
correctly sealed and tightened. Oxidations and marks on
the bearing seats and shaft must be carefully removed.

5.10.2 Bearing lubrication

Use the grease or oil specified for bearing lubrication.
This information is indicated on the bearing nameplate.
The bearings must be lubricated as described in the
"Maintenance" section of this manual according to the
bearing type.

NOTES
Sleeve bearings, where the anticorrosive
protection and desiccant were applied, must
be disassembled according to the procedure
described in this manual. The anticorrosive
protection and the desiccant must be washed
out and removed.
Assemble the bearings as described in this
manual and lubricate them again.

5.10.3 Checking the insulation resistance

Before starting the operation, the insulation resistance
must be checked following the procedure described in
this manual.

5.10.4 Others

NOTE
Follow other procedures supplied in the
"Commissioning" section in this manual
before starting the machine operation.

5.11 INSPECTIONS AND RECORDS DURING
THE STORAGE

The stored generator must be inspected from time to
time and the inspection records must be filed. Check
following aspects:
1. Physical damages.
2. Cleaning.
3. Signs of water condensation.
4. Protective coating conditions.
5. Painting conditions.
6. Signs of worms or insect action.
7. Satisfactory operation of the space heaters. It is
recommended to install a signaling or alarm system in
the storage location to detect any power failure
affecting the space heaters.
8. Record room temperature and the relative air
humidity around the machine, the winding
temperature (using RTDs), the insulation resistance
and the polarization index.
9. Inspect also the storage place that must comply with
the requirements described in the chapter LONG
STORAGE" .

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5.12 MAINTENANCE PLAN TO BE FOLLOWED DURING THE STORAGE

During the storage period, the generator maintenance must be performed and recorded according to the plan described in
the table 5.1:

Monthly
Every 2
months
Every 6
months
Every
2 years
Before
operation
Note
Storage Location
Inspect the cleaning conditions X X

Inspect moisture conditions and the
temperature
X

Check for insect infestation signs X

Measure the vibration level X

Packaging
Inspect for physical damages X
Inspect the inner relative humidity X

Change the desiccant in the packaging
(if any)
X When required
Space heater
Check the operating conditions X

Complete Generator
Clean generator outside X X
Check painting conditions X
Check the oxidation inhibitor on the
exposed parts
X
Replace the oxidation inhibitor X
Windings
Measure insulation resistance X X

Measure polarization index X X

Terminal box and grounding terminals
Clean box inside X X

Inspect the seals and gaskets

Roller bearings, grease or oil lubricated
Rotate the shaft X

Relubricate the bearing X X

Disassemble and clean the bearing X

Sleeve bearing
Rotate the shaft X

Apply rust inhibitor and desiccant X

Clean and relubricate the bearings X

Disassemble and store the parts X

Table 5.1: Storage plan

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6 HANDLING
Figure 6.1: Lifting the generator by its eyebolts Figure 6.2: Lifting the generator by the base eyebolts

To lift the generator, use only the eyebolts on the top or at base of the generator provided for this purpose, as shown in
the figure 6.1 and 6.2.
Consider the generator weight. Lift the generator smoothly and do not place it abruptly on the base to prevent bearing
damages.
The eyebolts on the heat exchanger, covers, bearings, radiator, terminal boxes, exciter, etc., were designed only to lift
these components.
Never use the shaft to lift the generator by means of cables, etc.
To move the generator, its shaft must be locked using the locking device supplied with the generator

ATTENTION
Ropes, rings and lifting equipment must be capable to support the generator weight.

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7 INSULATION RESISTANCE

7.1 SAFETY INSTRUCTIONS

DANGER
Before insulation resistance is measured,
machine must be switched off and stopped.
The winding under test must be connected to
the housing and the ground for a period until
all residual electrostatic charge has been
removed. Ground the capacitors (if supplied)
before disconnecting the lead terminals.
The noncompliance with these procedures
may result in personal injuries.

7.2 GENERAL REMARKS

When the generator is commissioned immediately after
receipt, it should be protected against moisture, high
temperature and dirt, thus preventing damages on the
insulation resistance.
The winding insulation resistance must be measured
before the generator operation.
If the ambient is very wet, the winding resistance must be
measured from time to time during the storage period. It is
difficult to prescribe fixed rules for the machine insulation
resistance values, since they change according to the
environment conditions (temperature, moisture), machine
cleaning conditions (dust, oil, grease, and dirt), quality and
conditions of the used insulating material. A considerable
dose of common sense, resulted from experience, must
be applied to conclude when a machine is or is not
suitable for service. Periodic records are useful for this
conclusion.

NOTE
The insulation resistance must be measured
using a MEGOHMMETER.

7.3 STATOR WINDING MEASUREMENT

The stator winding test voltage must comply with the table
7.1 according to IEEE43 standard.

Rated winding
voltage (V)
Insulation resistance test
(Continuous voltage) (V)
< 1000 500
1000 - 2500 500 -1000
2501 - 5000 1000 - 2500
5001 - 12000 2500 - 5000
> 12000 5000 - 10000

Table 7.1: Insulation resistance test voltage.

Before measuring the stator winding, check following:
If the CT secondary connections are not open;
If all the power cables are disconnected;
If the generator frame and the not measured windings
are grounded;
If the winding temperature has been measured;
If all the temperature sensors are grounded;

The stator winding insulation resistance must be
measured in the main terminal box
The megohmmeter must be connected between the
generator frame and the winding. The frame must be
grounded.

Figure 7.1: Megohmmeter connection

If the winding total measurement shows a value below the
recommended one, the neutral connections must be open
and the insulation resistance of each phase must be
measured separately.

7.4 MEASUREMENT OF THE ROTOR
WINDING RESISTANCE, EXCITER
WINDING RESISTANCE AND
ACCESSORIES

Measurement of the rotor winding resistance:
Disconnect the rotor cables from the diode set;
Record the winding temperature supplied by the
PT 100;
Connect the megohmmeter between the rotor winding
and the generator shaft. The measured current cannot
flow through the bearings.

Measurement of the stator winding resistance of the
exciter:
Disconnect the exciter power supply cables;
Connect the megohmmeter between the exciter stator
winding (I and K terminals) and the generator frame.

Measurement of the rotor winding resistance of the
exciter:

Disconnect the exciter rotor cables from the diode set;
Connect the megohmmeter between the rotor winding
and the generator shaft. The measured current can not
flow through the bearings
Measurement of the stator winding resistance of the PMG
- SP model generators --_:
Disconnect the cables that connect the PMG to the
voltage regulator
Connect the megohmmeter between PMG stator
winding (terminals 13, 14 and 15) and the generator
frame.

ATTENTION
After insulation resistance has been measured,
ground the tested winding to discharge it.
The test voltage for the rotor, exciter, PMG and
space heater must be 500 Vdc. The test
voltage for the accessories is 100 Vdc.
It is not recommended to measure the
insulation resistance of thermal protectors.

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7.5 CONVERSION OF THE MEASURED
VALUES

If the test is conducted at a different temperature, the read
values must be corrected to 40C by using an insulation
resistance variation curve according to the temperature
measured on the machine under test. If this curve is not
available, you can an approximate correction, as indicated
by the curve in Figure 7.2 as per NBR 5383 / IEEE43.

Figure 7.2: Coefficient of insulation resistance variation with
temperature.

With old machines, during longer time in service, the read
values for the winding resistance will be usually higher.
The comparison with values measured in previous tests on
the same machine with similar load, temperature and
moisture conditions is regarded as a better indication of
the insulation conditions than the value obtained in a
single test. Any great or sudden reduction is regarded as
suspect.

Insulation resistance Insulation evaluation
2M or less Bad
< 50M Dangerous
50...100M Regular
100...500M Good
500...1000M Very Good
> 1000M Optimum

Table 7.2: Orientative limits for the insulation resistance of
electrical machines.

7.6 MINIMUM INSULATION RESISTANCE

If the measured insulation resistance is lower than 100
M at 40C, the windings must be dried according to
the procedure below before the machine starts
operating:
Disassemble the generator by removing the rotor and
the bearings;
Take the housing with the stator winding to an oven
and heat it up to a temperature of 130C, leaving it at
this temperature for at least 8 hours. For large machines
(above IEC 630 frame size or 104XX NEMA series, a
dry time on oven of at least 12 hours may be required).
Check if the measured insulation resistance is within the
acceptable values as shown in table 7.2. Otherwise,
please contact WEG.

7.7 POLARIZATION INDEX

The polarization index is traditionally defined as the ratio
between the insulation resistance measured in 10 minutes
and the insulation resistance measured in 1 minute at a
relatively constant temperature.
Through the polarization index, it is possible to assess the
generator insulation conditions as per the table 7.3:

Polarization index Insulation evaluation
1 or less Bad
< 1.5 Dangerous
1.5 to 2.0 Regular
2.0 to 3.0 Good
3.0 to 4.0 Very Good
> 4.0 Optimum

Table 7.3: Polarization index (ratio between 10 and 1 minute).

DANGER
Right after measuring the insulation
resistance, ground the winding to prevent
accidents.

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8 CONSTRUCTION CHARACTERISTICS

8.1 STATOR

The stator lamination package, formed by silicon steel
laminations with insulation on both faces and low electric
losses, is pressed and fixed by metal beam or spar
system.
The windings of the high-voltage generators are
constructed with prefabricated rectangular wire coils with
class-F insulation resin and coated with mica tape
insulation that, after heat treatment process, provides
high mechanical resistance to the winding.
The coils are inserted into the stator slots and fixed by
fiberglass or magnetic wedges. The fixation of these
wedges is assured by the dovetail in slot and by using
expandable fiberglass lamination.
Highly absorbing materials are used for binding the coil
heads, thus ensuring the mechanical stiffness required to
withstand to the most severe operating conditions.
The high-voltage stators are then impregnated by the
epoxy VPI-impregnation system.

8.2 ROTOR

The rotor accommodates the field winding whose poles
are made of steel laminations.
A squirrel cage winding for absorbing purposes
compensates for parallel services and abnormal load
operation.
The rotor is dynamically balanced and designed to
withstand to the electrical and mechanical effects of
overspeed as required by the applicable standard and of
the triggering according to the design.
Manufactured with non-salient poles, the rotor has a
constant air gap along the whole iron core periphery. The
rotor has a cylindrical shape in whose periphery slots is
inserted the excitation winding. The field coils are made of
bars, wires or copper laminations insulated with a class-H
insulating material.
The non-salient pole rotor of the turbogenerator is
practically a monobloc with no overhangs or recesses. As
a result, it becomes sturdier and more resistant to
overspeed and coil triggering.

8.3 EXCITER

Installed at the non-drive end side of the generator, the
exciter is formed by fixed poles that accommodate the
excitation field coils, the armature and the rotating rectifier
bridge. Its purpose is to supply direct voltage to exciter
rotor. It supplies direct current controlled by the voltage
regulator according to the load requirements, thus
maintaining constant voltage for the main generator.

Exciter Stator
The poles accommodate the field coils which are series
connected, their ends being connected to the terminal
block (I(+) and K(-)). Its purpose is to supply the flux to the
exciter rotor. It is supplied with a direct current controlled
by the voltage regulator according to the load
requirements, thus keeping the main generator voltage
constant.

Exciter Rotor
The exciter rotor is mounted on the main shaft of the
machine. The rotor is formed by laminations with slots that
accommodate a star-connected three-phase winding.
The phases are connected to the rotating rectifying diode
set.
The rotor is induced by the flux from the exciter stator
using a three-phase AC voltage that is rectified in full wave
by the rotating rectifier.
Two wires come from the rectifier to feed the main
machine rotor (field).

NOTE
The rectifier is made up of six diodes and a
set of varistors for protection against reverse
overvoltage in the diodes.

8.4 PERMANENT MAGNET GENERATOR
(PMG)

(Only for the SP_ model generator)
Installed at the non-drive end side of the generator, the
PMG generates alternate voltage for supplying the voltage
regulator power circuit.
The rotor is formed by permanent magnet poles inserted
into the lamination package mounted on the main
generator shaft.
The stator is formed by a lamination package and a three-
phase winding that generates the voltage to supply the
power circuit of the electronic voltage regulator.

8.5 DUMPING WINDING

The dumping winding is constructed along the whole rotor
periphery, which is of fundamental importance for handling
sudden loads, such as motor starts, OFF/ON procedures
of heavy loads. The dumping winding has following
functions:
1. Dumping of load input and output at generator
terminals.
2. In case of an infinite busbar, the machine becomes
more stability against abrupt voltage variations.
3. Absorption of zero sequence and negative sequence
currents caused by load unbalance.
4. Loads with harmonic distortion of currents will also be
absorbed by dumping bars according to standard.
5. They increase the abrupt short-circuit at the machine
terminals.

8.6 BEARINGS

The bearings are mounted at the frame ends and their
purpose is to support the rotor mass and allow it to turn.
Sleeve bearings are lubricated with oil and the rolling
bearings can be lubricated with grease or oil.
Correct storage, operation and maintenance procedures
are determinant for their performance and useful life.

8.7 HEAT EXCHANGER

SPW and SSW turbo-generators are provided with an air-
to-water exchanger installed at the bottom or top section
of the generator. The SPF and SSF models are provided
with air-to-air heat exchanger, normally installed on top
side of the generator (see in this Manual the item "Cooling" ).

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9 OPERATION PRINCIPLE

Figure 9.1: Internal electrical circuits of the SP_ model generator

9.1 EXCITATION

After the primary machine is driven and reaches is rated
speed, starts the excitation process in the generator and
the voltage generated by PMG supplies the voltage
regulator power circuit.
When the voltage regulator is enabled, it rectifies this
voltage and supplies direct current to the stator of the
generator exciter.
The alternate current generated by the exciter rotor is
rectified by the rotating diodes and supplied to the main
rotor poles.
The generator voltage increases as ramp automatically
from its residual value up to the pre-established rated
voltage that is regulated by monitoring the reference
voltage in the electronic voltage regulator.
The reference voltage for the voltage regulator must be
obtained through reference TPs connected to the main
terminals of the generator.
The SS_ model turbogenerators (Shunt) are not provided
with PMG and the voltage regulator power circuit is
supplied by the generator output voltage using power
TPs.

ATTENTION
To start the shunt generator excitation
process, it may be necessary to use an
external pre-priming circuit (DC power
supply), since the residual generator
magnetism may not be sufficient for the
priming.
Check the procedures in the voltage regulator
manual for enabling this function during the
excitation process.

DANGER
When operated at no load with nominal speed
and without excitation voltage there is a
residual voltage present in the synchronous
generator terminals due to residual magnetism
in the exciter magnetic core.
These voltage levels can cause serious
accidents with risk of death. It is unwise to
manipulate the machine while the rotor is
turning.
Generators with rated voltage of 440V,
usually present 180V of residual voltage;
Generators with rated voltage of 13800V
easily present 1000V of residual voltage.

9.2 DEEXCITATION

The generator full deexcitation is performed by the
generator stoppage or voltage regulator shutdown.
When the voltage regulator is shut down, the generator
deexcitation is performed by a free-wheel circuit installed
in the voltage regulator panel. The excitation current flows
through a discharge resistance that promotes a faster
deexcitation of the main machine.
During the maintenance services, the machines must be
stopped, since the deexcitation alone is not enough.

AVR: Automatic Voltage Regulator
EPT: Main three-phase exciter
PMG: Exciter with permanent magnets

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9.3 VOLTAGE REGULATOR

The purpose of the electronic voltage regulator is to keep
the generator voltage constant, regardless of the load.
The generator excitation process starts from the moment
the voltage regulator is activated. This must always be
done when the generator reaches at least 90% of its rated
speed, thus preventing overcurrent in the generator
excitation windings.

Automatic operation mode

The voltage regulator is intended to keep the generator
output voltage equal to the previously programmed
reference value. To perform this function, the regulator
must be operated in automatic mode, where the generator
output voltage is used as feedback.
During the automatic operation mode, the reference
voltage can be used by other controls, such as:
acceleration Ramp, F/U Operation, PF/Q Correction and
others.

Manual operation mode

In this operation mode, the generator excitation is
conducted through the excitation voltage variation.
This operation mode is selected through a selector switch
(automatic/manual = open) and is used during the
generator commissioning tests.
For technical details, operation, functions, connections,
adjustments, abnormalities, etc., see the voltage
regulator manual.
The regulators are generally microprocessed and allow
parallel operation between two machines and with the
network. In this case, with power factor correction.

ATTENTION
Check for the correct wiring diagram in the
regulator manual.
An erroneous connection may burn the
regulator and / or the generator windings.

9.4 UNDERFREQUENCY (U/F) PROTECTION

When the generator frequency drops below the
programmed value for U/F in the voltage regulator, the
generator output voltage will decrease as programmed by
the Volt/Hz ratio.

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10 INSTALLATION

10.1 INSTALLATION SITE

Electric machines must be installed in locations of ease
access, allowing periodic inspections, local maintenance
services and, if required, the removal of equipment for
external maintenance services.
The following environmental characteristics must be
ensured:
Clean and well-ventilated place;
The installation of other equipment or walls should not
obstruct generator cooling;
The space around and above the generator must be
sufficient for its maintenance and handling;
The environment must comply with the generator
protection class.

10.2 PROTECTIONS

The generator is supplied with a shaft-locking device to
prevent damages to the bearings during the transport.
This locking device must be removed before the generator
installation.

ATTENTION
The shaft locking device must be used
whenever the generator is removed from its
base (decoupling from the drive machine) and
so prevent bearing damages during the
transport.
The shaft end is protected by a protective
grease coat. During the generator installation,
remove this shaft protection from the race
where the shaft grounding brush contacts it.

10.3 DIRECTION OF ROTATION

The generators are normally designed to operate in a
single direction of rotation as indicated by the arrow on
the frame at the drive end side.

Figure 10.1: Direction of Rotation
When generator rotation direction is changed, the phase
sequence will be changed too and the reversal of the two
phases will be required. Check the direction of rotation
and the phase sequence before operating the generator.

ATTENTION
Generators supplied with single direction of
rotation can only be operated in the specified
direction of rotation. If inversion of the
direction of rotation is desired, you must
contact the factory through your nearest WEG
representative.

10.4 FOUNDATIONS

The foundation or structure where the generator is to be
installed must be must be stiff enough, flat, free of
external vibrations and able to withstand to the
mechanical efforts to which it will be submitted during
the start-up or in case of generator short-circuits.
The type of foundation chosen depends on soil
condition or on the floor resistance.
If the foundation dimensions are not executed
accurately, serious vibration problems may occur with
the generator and drive machine as a whole.
The dimensioning of the foundation structure must be
executed by considering the dimensional drawing and
the information about the mechanical efforts on the
foundation, the anchoring procedures and the heat
exchanger details (if any).

ATTENTION
Provision must be made for a minimum
clearance of 2 mm between the anchor plate
and the generator feet for inserting the
compensation plates (wedges) used for the
alignment adjustment.

NOTE
The user is responsible for the foundation
dimensioning and construction.

DIRECTION OF
ROTATION

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10.5 ANCHOR PLATE SET

The anchor plate set comprises anchor plate, leveling bolts, leveling wedges, alignment bolts and anchor bolts.

Procedure for the assembly, leveling and grouting of the anchor plates

Step 1
Construct the foundation (1) using anchor bars (2)
as per the dimensional drawing, considering the
efforts to which this base will be submitted as
shown in the drawing.

Step 2
Position the anchor bolts (3) in the anchor bars
and the leveling bolts on the primary concrete
surface.

Step 3
Place the anchor plates (5) on the leveling bolts.

Step 4
Level the anchor plates by using the required
instruments. Please consider a 2 mm clearance
between the anchor plates and the generator
base for inserting the leveling wedges required for
the generator alignment.

Step 5
After the anchor plates have been leveled, they
must be grouted (6) together with the anchor
bolts for their definitive fixation.

Step 6
After the grout cure, place the generator on the
anchor plates, align it by using the horizontal
alignment bolts (7 and 8) and fix it in place
through it base holes and anchor bolts.

Figure 10.2: Anchor Plate

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Leveling and grouting with the anchor plates fixed the
generator

Figure 10.3: The anchor plate and the generator

The anchor plates can be leveled and grouted after they
have been fastened to the generator base with the 2 mm
wedges between the generator base and the anchor
plates.
For this purpose, place the generator with the anchor
plates on the leveling cap bolts, level off the base using
these leveling cap bolts and pre-align the generator using
the alignment bolts (7 and 8).
Secure the generator in place using the anchor bolts and
grout the anchor plate and anchor bolts for its definitive
fixation.

10.6 ALIGNMENT / LEVELING

The generator must be aligned correctly with the driving
machine, particularly in case of direct coupling.
An incorrect alignment may cause bearing damages,
vibrations and even the shaft rupture.
The alignment must be made according to the
recommendations of the coupling manufacturer.
It is necessary to make the machine parallel and angular
alignment as follows:

Parallel Alignment

Figure 10.4: Parallel misalignment

Figure 10.4 shows the parallel misalignment of the two
shaft ends and a practical way for making the
measurements is by using proper dial indicators.
The measurement is made at 4 points at 90 with two
half-couplings rotating together in order to eliminate the
effects caused by contact irregularities of the dial
indicators. Choosing the vertical top point 0, half of the
measuring difference of the dial indicator at the positions
of 0 and 180 represents the vertical coaxial error. This
error must be corrected properly by adding or removing
the assembly wedges. Half of the difference of the dial
indicator measurement at the positions of 90 and 270
represents the horizontal coaxial error.
This provides an indication when leveling (raising or
lowering) or moving to the right or to the left at the drive
end side is required to eliminate the coaxial error.
The half of the maximum difference of the dial indicator
measurement in a full revolution represents the maximum
eccentricity.
The maximum allowed eccentricity for rigid or semi-rigid
coupling is 0.03 mm.
When flexible couplings are used, values higher than those
above are acceptable, however the value defined by the
coupling manufacturer should not be exceeded.
We recommend keeping a safety margin for these values.

Angular Alignment

Figure 10.5: Angular misalignment

Figure 10.5 shows the angular misalignment and a
practical way for making the respective measurement.
The measurement is made at 4 different points displaced
by 90 each other with two half-couplings rotating
together in order to eliminate the effects caused by the
irregularities of the dial indicators on the contact surface.
Choosing the vertical top point 0, half of the measuring
difference of the dial indicator at the positions of 0 and
180 represents the vertical misalignment. This error must
be corrected properly by adding or removing the assembly
wedges. Half of the difference of the dial indicator
measurement at the positions of 90 and 270 represents
the horizontal misalignment.
This must be properly corrected by side/angular moving of
the generator.
Half of the maximum difference in the comparison clock
measurement in a full rotation represents the maximum
angular misalignment.
Half of the difference of the dial indicator measurement
during a complete revolution represents the maximum
angular misalignment.
The maximum allowed misalignment for the rigid or semi-
flexible coupling is 0.03 mm
When flexible couplings are used, values higher than those
above are acceptable, however the value defined by the
coupling manufacturer should not be exceeded.
We recommend keeping a safety margin for these values.
During the alignment/leveling procedures, consider the
temperature effects of the generator and the driving
machine. Different expansion levels of the coupled
machines can change the alignment/leveling during the
operation

10.7 COUPLING

Use only suitable couplings able to transmit pure torques
without generating transverse forces.
The generator shaft and the driving machine centers must
be in a single line, both for the elastic and rigid couplings.
The elastic coupling are intended for mitigating the
residual misalignment effects and preventing the vibration
transfer between the coupled machines, which is not the
case when rigid couplings are used.
The coupling must be assembled or removed only with the
use o appropriate devices and never by means of rustic
devices (hammer, mallet, etc.).

Radial measurement

Axial measurement

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Generators fitted with sleeve bearings

Figure 10.6: Sleeve Bearing

The generators fitted with sleeve bearings must be
coupled direct to the driving machine or by means of
reducer.
The coupling by belts and pulleys is not allowed.
The shaft end has three markings, the central mark (red
painted) is an indication of the magnetic center and the
two external markings indicate the limits of the rotor axial
movement.

Figure 10.7: Magnetic center marking

For the correct coupling of the generator, the following
factors should be considered:
Bearing axial play;
The axial displacement of the machine coupled to the
generator (turbine);
The maximum axial play of the opening allowed for the
coupling.

ATTENTION
Displace the shaft fully to the front side to
make correct measurement of the axial
play;
Align the shaft ends carefully by using a
flexible coupling whenever possible,
allowing a minimum axial play of 3 to 4
mm between the couplings.

Figure 10.8: Coupling axial play.

NOTE
If the shaft cannot be turned, consider the
shaft position, the shaft forward displacement
(according to the shaft markings) and the axial
play recommended for the coupling.

Before starting the operation, check if generator shaft
allows the free axial movement in the above play
conditions.
During the operation, the arrow must be positioned on
the central mark (red) that indicates that the rotor is at
the magnetic center.
At the start-up or even during the operation, the
generator will be allowed to move freely between the
two markings.

Under no circumstance, the generator will be allowed
to operate constantly with axial effort on the bearing.
The used sleeve bearings are not designed to withstand
constant axial efforts.

After the machine set has been aligned and checked ( in
cold and hot operating conditions) the generator must
be secured in place on the anchor plate as shown in the
figure below:

Figure 10.9: Pin fastening of the generator to the anchor plate

ATTENTION
The pins, nuts, washers and leveling wedges
may be delivered with the generator upon the
customer request.

NOTES
The user is responsible for the generator
installation.
WEG shall not be responsible for damages to
the generator, associated equipment and
installation occurred as a result of:
Excessive transmitted vibrations;
Precarious installations;
Alignment failures;
Improper storage conditions;
Noncompliance with the pre-operation
instructions;
Incorrect electrical connections.

Welding at four points

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10.8 ELECTRICAL AND GROUNDING
CONNECTIONS

ATTENTION
Make a careful analysis of the electric wiring
diagram delivered with the generator before
connecting the power and ground cables as
well as the accessories.
For the electrical connection of the auxiliary
equipment (voltage regulator, hydraulic unit,
etc.), please refer to the specific manuals of
these items.

10.8.1 Main stator connections (power cables)

The power cables are connected to insulator terminals in
the terminal box or to copper terminals, depending on the
generator design.
The location of the power and neutral terminals is
identified in the specific dimensional drawings of each
generator.
The stator terminal connections must comply with the
stator wiring diagram specific for that generator.
Make sure that the connection cable cross-section and
connection cable insulation class are appropriate to the
generator current and voltage.
The stator terminal markings and their connections are
shown in the specific wiring diagram of each generator, in
compliance with IEC60034-9 or NEMA MG1 standards.
The phase sequence can be changed by inverting any two
connections, however the generator must turn in the
direction of rotation specified in the wiring diagram and by
the indication arrow as viewed onto the shaft end to be
coupled.
Generators with a single direction of rotation must turn
only in the indicated direction since fans and other devices
allow only single direction of rotation.
If the generator should be operated in opposite direction
of rotation to the shown one, contact the factory through
Before making the electrical connections between the
generator and the user power supply, check the winding
insulation resistance and the phase sequence carefully.

10.8.2 Grounding

The generator grounding terminal is located on the
generator frame or on its base and inside the main
terminal box or on the terminal strip.
These terminals should be used for connecting the
grounding cables and the shield as required by local
standards.

10.8.3 Accessories

The main accessories supplied with turbogenerators are:
Stator winding temperature sensors;
Bearing temperature sensors;
Space heater;
Water leak detector;
Water flow sensors;
Oil flow sensors;
Other accessories (if requested) are listed in the specific
WIRING DIAGRAM of the involved generator.
The accessories are connected to the connection strips
located inside the terminal box for accessories according
to the cable markings as shown in the generator-wiring
diagram.

10.9 THERMAL PROTECTIONS

10.9.1 Protection location

The turbogenerators are fitted with overtemperature
protection devices installed in the main stator, on the
bearings and other components that require temperature
monitoring and thermal protection.
These devices must be connected to an external
temperature monitoring and protection system.

10.9.2 Temperature sensors

The Resistance Temperature Detector (RTD) is a
calibrated resistance element. Its operation is based on
the principle that the electrical resistance of a metal
conductor varies linearly with the temperature. The
detector terminals must be connected to a control panel,
which includes a temperature meter.

NOTE
The Resistance Temperature Detector (RTD)
can be monitored according to the absolute
temperature supplied by its instantaneous
resistance value. Based on this information,
the relay can read the temperature and
define the alarm and disconnection
parameters based on predefined
temperatures.

10.9.3 Temperature limits for the windings

The temperature of the winding hottest-spot must be kept
below the thermal class limit. The total temperature is
equal to the sum of the room temperature with the
temperature rise (T) plus the difference that exists between
the winding average temperature and the hottest spot.
According to the applicable standard, the maximum room
temperature is 40C. Above that temperature, operating
conditions are regarded as special.
Table 10.1 shows the numeric values and the admissible
temperature composition for the hottest spot:

Insulation class F H
Ambient temperature C 40 40
T = temperature rise (resistance method) C 100 125
Difference between the hottest spot and the
average temperature
C 15 15
Total: hottest spot temperature C 155 180

Table 10.1: Insulation Class

ATTENTION
If the generator operates with winding
temperatures above thermal class limits, the
insulation and, consequently, the generator
useful life will be reduced significantly. This
may even result in the generator burnout.

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10.9.4 Thermal bearing protections

The temperature sensors installed on the bearings are
used to protect them against damages caused by an
overtemperature operation.

10.9.5 Alarm and disconnection temperatures

The temperature level for the alarm and trip functions
should be set as low a possible. This level can be
determined by using the test results as reference or the
generator operating temperature.
The alarm temperature can be set to 10C above the
machine operation temperature at full load considering the
highest ambient temperature.
The temperature set for the trip function should not
exceed the maximum allowed temperatures for the stator
winding (according to the insulation class) and for the
bearings (according to the used lubrication system).

STATOR WINDING
Maximum temperatures for
protection adjustments (C)
Temperature
Class
Alarm Trip
F 140 155
H 155 180

Table 10.2: Maximum stator temperature

BEARINGS
Maximum temperatures for protection adjustments (C)
Alarm Trip
110 120

Table 10.3: Maximum bearing temperature

ATTENTION
The alarm and trip values can be defined
through experience, but they should never
exceed the above ones.

The generator protection devices are listed in WEG Wiring
Diagram, specific for each generator.
The nonuse of these devices is the user's responsibility,
and in case of damages, may void the warranty.

10.9.6 Ratio between temperature and the
ohmic resistance of Pt 100 temperature
sensors

The table 10.4 shows the temperature values as function
of the ohmic resistance measured for Pt 100 temperature
sensors.

C 0 1 2 3 4 5 6 7 8 9
0 100.00 100.39 100.78 101.17 101.56 101.95 102.34 102.73 103.12 103.51
10 103.90 104.29 104.68 105.07 105.46 105.95 106.24 106.63 107.02 107.40
20 107.79 108.18 108.57 108.96 109.35 109.73 110.12 110.51 110.90 111.28
30 111.67 112.06 112.45 112.83 113.22 113.61 113.99 114.38 114.77 115.15
40 115.54 115.93 116.31 116.70 117.08 117.47 117.85 118.24 118.62 119.01
50 119.40 119.78 120.16 120.55 120.93 121.32 121.70 122.09 122.47 122.86
60 123.24 123.62 124.01 124.39 124.77 125.16 125.54 125.92 126.31 126.69
70 127.07 127.45 127.84 128.22 128.60 128.98 129.37 129.75 130.13 130.51
80 130.89 131.27 131.66 132.04 132.42 132.80 133.18 133.56 133.94 134.32
90 134.70 135.08 135.46 135.84 136.22 136.60 136.98 137.36 137.74 138.12
100 138.50 138.88 139.26 139.64 140.02 140.39 140.77 141.15 141.53 141.91
110 142.29 142.66 143.04 143.42 143.80 144.17 144.55 144.93 145.31 145.68
120 146.06 146.44 146.81 147.19 147.57 147.94 148.32 148.70 149.07 149.45
130 149.82 150.20 150.57 150.95 151.33 151.70 152.08 152.45 152.83 153.20
140 153.58 153.95 154.32 154.70 155.07 155.45 155.82 156.19 156.57 156.94
150 157.31 157.69 158.06 158.43 158.81 159.18 159.55 159.93 160.30 160.67

Table 10.4: Temperature X resistance (PT100)

Formula: - 100 = C
0.386

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10.9.7 Space heater

The space heaters in the generators are intended for
preventing water condensation when generators are not
operated for long periods.
These resistances must always be energized during the
generator storage period and when the generator
remains at standstill and switched off before the
generator operation is started again.
The specific WEG Wiring Diagram and the nameplate on
the generator frame show the supply voltage and the
rated power of the installed resistances, as well as show
the terminal markings.

10.10 PANEL PROTECTIONS

In addition to the protection devices listed here, other
protection devices should installed in panel.
The panel protections are defined by the customer
according to his requirements. The table 10.5 lists the
usual protections devices for the control panels:

POWER PROTECTIONS
Up to 3000 kVA Medium
Voltage
CP-PR-27-32-49-50G-51V-
52-59
3000 to 7500kVA Medium
Voltage
CP-PR-32-40-46-49-50G-
51V-52-59-87
Over 7500kVA Medium
Voltage
CP-PR-27-32-40-46-49-50G-
51V-52-59-78-81-87

Table 10.5: Panel protections.

Symbols:

CP - Capacitor
PR - Lightning arrester
27 - Undervoltage
32 - Inverse power
40 - Field loss
46 - Current unbalance
49 - Overload
50G - Ground overcurrent
50 - Instantaneous Overcurrent
51 - Timed overcurrent
51V - Overcurrent with voltage locking
52 - Circuit Breaker
59 - Overvoltage
64 - Field ground
87 - Differential
78 - Phase Angle
81 - Frequency
86 - Blocking Relay

ATTENTION
Protection 59 (Overvoltage) is mandatory to
prevent damages to the generator and the
supplied load.

10.11 GENERATOR COOLING

D5 and D6 Constructive Form
Bottom heat exchanger
Two internal fans and one or two water radiators that
are supplied with the generator and must be installed
according to its specific dimensional drawing provide
the generator cooling.

The cooling air is provided by the internal (front and rear)
fans, crosses the internal windings and exits through the
lower section of the generator where the radiator or the
water radiators is(are) located.
The hot air passes through these radiators, is cooled and
returns to the inside of the generator.
Figure 10.10: Cooling by bottom heat exchanger (D5 and D6).

D5 and D6 Constructive Form:
Top heat exchanger
The generator cooling consists of two internal fans and
one or two water radiators installed in the air-to-water
heat exchanger on top of the generator.
The cooling air is provided by the internal (front and rear)
fans, crosses the internal windings and exits through the
top section of the generator where the radiator or the
water radiators is(are) located.
The hot air passes through these radiators, is cooled and
returns to the inside of the generator.

Figure 10.11: Cooling by top heat exchanger (D5 and D6).
Air
Outlet
Warm Air
Outlet
Cold
Air
Cold
Air
I l t
Radiators

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Constructive Form B3:

The generator cooling is provided by internal axial fans
and the air-to-water heat exchanger located on top of the
generator.
The ventilation provided by the internal fans, crosses the
windings and exits through the generator upper section
where the heat exchanger radiators are located. The hot
air passes through the radiators, is cooled, and returns to
the inside of the generator.

Figure 10.12: Cooling with the top heat exchanger (B3).

NOTE
The usual types of turbogenerator cooling are
shown above. Other cooling types may be
used according to the user's requirements.

10.12 WATER RADIATORS

The radiator is a surface heat transmitter, designed to
dissipate heat from electrical or other components
indirectly, that is, the air in a closed circuit is cooled by
the radiator after the heat removal from the equipment
that must be cooled.
Clean water with the following characteristics must be
used as a cooling fluid:
pH : from 6 to 9
Chlorides: maximum 25.0 mg/l
Sulfates: maximum 3.0 mg/l
Manganese: maximum 0.5 mg/l
Solids in suspension: maximum 30.0 mg/l
Ammonia: with no traces

The heat transmission is from the equipment to the air
and from the air to the water.

ATTENTION
To prevent premature corrosion in case of
cooling with seawater, the materials that get in
contact with water (pipes and tube sheets)
must be corrosion-resistant.
In addition, the radiators must be fitted with
sacrificial anodes (for example, Zinc or
Magnesium), which are corroded during the
exchanger operation and so protect the
heads. As a result, these anodes must be
replaced from time to time according to the
corrosion degree shown, thus keeping the
head integrity.

The cooling system protection devices must be
monitored from time to time.

The air-to-water inlets and outlets should not be
obstructed. Otherwise, they can cause overheating
and even the generator burnout.

ATTENTION
The data of the radiators that form the air-to-
water heat exchanger are indicated on the
radiator nameplate and in the generator
dimensional drawing.
The data should be followed for correct
operation of the generator ventilation system
and to prevent overheating.

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11 ELECTRICAL CONNECTIONS AND ACCESSORIES

11.1 TERMINAL MARKINGS

U1, V1 and W1 Phases of main stator
U2, V2 and W2 Neutral cables of main stator
UR, VR, WR and N Reference voltage and power supply of voltage regulator.
13, 14 and 15 Phases of the PMG or auxiliary coil.
I and K Stator of main exciter I(+) and K(-)
16 to 19 Space heater
20 a 25 Temperature sensor (Pt 100) on stator winding.
26 - 27 Moisture sensor
68 to 69 Temperature sensor (Pt 100) on DE bearing.*
70 to 71 Temperature sensor (Pt 100) on NDE bearing.*
60 a 63 Thermometer for water
64 to 65 Diodes fault detector.
66 to 77 Current transformer.
88D to 91D Thermometer on DE bearing
88T to 91T Thermometer on NDE bearing
525 a 527 Water flow sensor
500 - 501 Water leak detector
579 to 586 Thermometer at water inlet and water outlet
636 to 643 Thermometer at air inlet and air outlet

ADDITIONAL ACCESSORIES In generators fitted with more than 1 Pt 100 on each bearing, the additional temperature
sensors are identified by the number 1 that corresponds to the first Pt 100 (1 for the first additional Pt 100) or 2 (for the
second additional Pt 100) and so on.
Example: NDE bearing fitted with 2 three-wires Pt 100 the first Pt 100 is identified by the numbers 70 - 70 - 71 and the
second one with the numbers 170 - 170 - 171.
Note: The terminal markings may differ from previous ones upon customer request or for special designs.
In addition to this manual, we recommend to refer also to the wiring diagrams supplied with generator.

11.2 WIRING DIAGRAMS

1. Following wiring diagram should be used or the electrical connections of the turbogenerator.
2. Terminal numbering refers to specific accessories.
3. The installed accessories as well as the number of accessories depend on the generator size and its application.

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11.2.1 Thermal protection on main stator winding

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11.2.2 Generator cooling system

WATER LEAK DETECTION RELAY
TO BE I NSTALLED IN PANEL
WATER FLOW SWI TCH HUMI DI TY DETECTOR

THERMOMETERS (WATER) THERMOMETERS (AIR)

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11.2.3 Bearings

THERMAL PROTECTI ONS OIL FLOW SWI TCH

THERMOMETERS (OIL)

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11.2.4 Space heater and exciter

11.3 DESCRIPTION OF THE ACCESSORY FUNCTION

In order to get right understand of this description you
should check the wiring diagrams found in the previous
chapter.

1. PT 100 Temperature sensor with terminal numbers 20-
20-21, 22-22-23 and 24-24-25 are the main
sensors for measuring temperature and protecting
the generator stator winding and they should present
the following actuation point:
Alarm: 130C
Shutdown: 155C
Pt 100 temperature sensors with terminal numbers
20R-20R-21R, 22R-22R-23R and 24R-24R-25R
are reserve sensors and they will be activated in case
of failure of the main sensors.

2. Pt 100 temperature sensors with terminal number
68-68-69 and 168-168-169 are sensors for
measuring the temperature and protecting the DE
bearing, and the sensor with the numbers 70-70-71
and 170-170-171 are for measuring the
temperature and protecting the NDE bearing and
should be activated with following temperatures:
Alarm: 110C
Shutdown: 120C

3. The terminal with numbers 500-501 are connected to
the electrode of the water leak detectors and to the
bottom plate of water trough of the radiator support.
These terminals should be connected to the terminals
that have the same numbering of the water leak
detector in the generator protection panel. The
generator shutdown sequence should be executed
immediately after a leakage in the heat exchanger is
detected.

4. The terminal with numbers 525-526-527 are related
to water flow sensor of radiators.
This sensor monitors the water flow and deactivates
the generator drive as soon as the lack of water flow
is detected. If water shortage is detected in system
during the generator operation, the generator
shutdown sequence should be started immediately.

5. The terminals 26 and 27 are related to moisture
sensor. They are installed in some generators as an
additional device for detecting water leak in the
radiator by means of the presence of moisture.

6. The terminals 88D-88D-90D-91D are connected to
the thermometer that contacts the DE bearing. The
terminals 88T-88T-90T-91T are connected to the
thermometer that contacts the NDE bearing.

7. The terminals 636-637-638-639 are connected to
the thermometer that contacts the generator air inlet.
The terminals 640-641-642-643 are connected to
the thermometer that contacts installed the generator
air outlet.

8. The terminals 579-580-581-582 are connected to
the thermometer that contacts the water inlet of front
radiator. The terminals 583-584-585-586 are
connected to the thermometer that contacts the
water outlet of front radiator.

9. The switches with terminals 534-535 and 536-537
corresponds to the contacts of oil flow sensor at the
oil inlet piping that lubricates and cools the DE and
NDE bearings, respectively. These sensors detect the
presence or the lack of oil flow in these piping.
In case of oil shortage in inlet piping for one or both
bearings during or after star-up procedure, the
equipment shutdown sequence should be executed
immediately in order to adopt the required corrective
actions.

The bearings cannot be without lubrication under
any circumstances while the shaft of generating
unit is operating, which may result in irreversible
damage to these bearings.

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10. The terminals 16-17 supply the space heaters,
ensure moist removal inside the generator and
maintains the temperature inside the generator. The
space heaters should always be switched On during
longer standstills in order to ensure that temperature
inside the generator remains always higher than the
ambient temperature.

11. The terminals I - K correspond to the main exciter
stator and should always be powered by the
electronic voltage regulator.
The main exciter generates a three-phase voltage in
rotor that is rectified by diodes in the rotating rectifier
and supplies the main field of generator (main rotor).
12. The terminals 13-14-15 match PMG stator of
the turbogenerator Model SP_ and supply the power
circuit of voltage regulator.

11.4 ACCESSORIES AND PROTECTIONS

In order to get right understand of this description, check the generator wiring diagram.

Description Location Operation point
Mea-
sured
value
Function
STATOR
Thermal resistance Pt -100 (Phase
U)
Stator Winding
Alarm=130C
Shutdown = 311.00F

Measures stator temperature
(phase U)
Temperature sensor Pt 100 (Phase
V)
Stator Winding
Alarm=130C
Shutdown = 311.00F

(phase V)
Temperature sensor Pt 100 (Phase
W)
Stator Winding
Alarm=130C
Shutdown = 311.00F

(phase W)
FRONT AND REAR BEARING
Temperature sensor Pt 100 DE bearing
Alarm=110C
Shutdown = 248.00F

Measures bearing temperature
and protects against
overtemperature
Contact thermometer Bearing oil reservoir
Alarm=60C
Shutdown = 80C

Measures bearing oil
temperature and protects
against overtemperature
Oil flow switch Oil piping
_
Detects oil flow on bearings
COOLING SYSTEM
Thermometer (water inlet) Water circuit
_ Measures water inlet
temperature in radiator
Thermometer (water outlet) Water circuit
_ Measures water outlet
temperature in radiator
Thermometer (air inlet) Heat exchanger
_ Measures air inlet temperature in
heat exchanger
Thermometer (air outlet) Heat exchanger
_ Measures air outlet temperature
in heat exchanger
Water leak detector In each radiator _
Detects water leakage in
radiators
Relay of water leakage detector
In the generator control
panel
_
Detects water leakage in
radiators
Water flow sensor Water circuit _
Detects water flow in the cooling
system
Moisture Sensor _
Detects the presence of
moisture inside generator
OTHERS ACCESSORIES
Space heater
Inside the chamber or
generator enclosure
Turn on when generator is
at standstill

Maintains winding temperatures
and prevents water
condensation
CT for protection
Terminal box of neutral
conductor or panel
(separate supply)
_
Differential protection
CT for measuring
Main Terminal box
or panel (separate supply)
_
Measures the current
Lightning arrester
conductor and surge cell
_ Surge protection
Capacitors
conductor and surge cell
_ Surge protection

Table 11.1: Accessories and shields

The alarm temperature of bearings and stator windings should be set to 10C higher than rated operating temperature and
should not exceed the values indicated in the table 11.1.

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12 START-UP

12.1 BEFORE FIRST START-UP

Before first start-up of generator or after long standstill
periods, check following items:
1. Generator fixing bolts should be tightened. Feet
should be anchored and pinned;
2. Measure the winding insulation resistance. Assure that
the insulation resistance is according to specified
value;
3. Check if generator is clean and if package, measuring
instruments and alignment devices have been
removed from generator working area;
4. The couplings should be in good conditions, properly
tightened and lubricated, if required;
5. The generator should be aligned correctly;
6. Check if bearings are properly lubricated. Lubricant
should be as specified on nameplate. Check oil level
of the generators fitted with oil lubricated bearings.
Bearing with forced lubrication should have oil
pressure and flow as indicated on the nameplate;
7. Inspect connections of accessory cables (thermal
protectors, space heaters, etc.) and how they act on
control panel;
8. Check if all electrical connections meet the generator
wiring diagram;
9. Check if connections and parameter settings of the
electronic voltage regulator are in accordance with the
Installation Manual;
10. The line cables connected to main terminals should be
proper tightened in order to prevent short-circuit or
loosening;
11. Check cooling system. On machines with water
cooling system, check the operation of water supply
system in the radiators;
12. Assure that generator air inlet/outlet are not obstructed;
13. Moving parts of generator should be protected in
order to avoid accidents;
14. The terminal box covers should be fixed correctly;
15. Test operation of shaft oil pressure operated lifting
system (hydrostatic jacking), if any, and assure that it
operates correctly.

12.2 INITIAL MECHANICAL TURN

After checking all items mentioned above the following
procedures should be carried out to get generator initial turn:
1. Switch Off space heater;
2. Set circuit breaker to test position;
3. Set voltage regulator parameters according to manual;
4. Turn on oil pressure pump for raising hydrostatic
jacking (if any) of the bearings;
5. Check oil level of oil lubricated bearings;
6. If bearings are fitted with forced lubrication system,
turn oil circulation system on and check the level, oil
flow and oil pressure making sure that they meet the
nameplate data.
7. If system is fitted with oil flow sensors, wait for flow
return signal of the oil circulation system of both
bearings that ensure that the oil get into bearings;
8. Turn on industrial cooling water system, check
required water flow and water pressure (generators
fitted with air-to-water heater exchange);
9. Rotate the generator shaft slowly to make sure that there is
no dragging part or abnormal noises;
After this procedure has been completed, proceed with the
following steps for the generator start-up sequence;
10. Increase speed up to the rated speed so the oil film on
bearings is formed readily.
11. The hydraulic jacking system, if any, should be turned off
when the acceleration of the generator set reaches 80 rpm.
12. Keep generator operating at rated speed and record
the temperatures of the bearings in 1-minute intervals
until the temperature becomes constant. Any sudden
increase of bearing temperature indicates abnormality
for the bearing lubrication or bearing contact surface.
13. Monitor temperature, oil level of bearings and vibration
level. If there is a significant change, stop generator
start-up in order to evaluate possible causes.
14. When temperatures on bearings become constant you can
proceed with the next steps of the generator operation.

12.3 POWERING-UP

With generator at rated speed, assure that all protection
devices have been tested and are operating properly, and
in case of some fault, they act immediately.
Generator is powered-up by setting the voltage regulator
to the automatic mode.
The voltage regulator maintains the output voltage of
generator at reference voltage.

In manual operation mode, the generator can be
powered up in steps until the rated voltage is reached.
This operation mode is usually selected by the
automatic/manual selector switch and is used only for
generator commissioning tests.
Refer to the manual of voltage regulator for correct use of
this operation mode as well as to know the protections
that are not enabled for this- operation.

NOTE
All measuring and control instruments should
be watched in all times in order detect any
change and adopt the prompt corrective
actions.

12.4 SYNCHRONIZATION AND LOAD

To synchronize generator with network bus:
1. Turn on voltage regulator and allow it controls
machine voltage, making the required settings.
2. To connect generator to power system, the voltage
signal, frequency and phase sequence should be
equivalent.
3. Set the circuit breaker to original position and execute
the synchronization and the line connection.

THE ACTIVE POWER CONTROL (kW) OF
GENERATOR IS MADE BY TURBINE POWER
VARIATION.
GENERATOR REACTIVE POWER CONTROL (kVAR)
AND ITS POWER FACTOR ARE CONTROLLED BY
VARIATION OF THE EXCITATION CURRENT.

NOTE
These functions can be parameterized by the
voltage regulator.
For the parameter setting, refer to the Voltage
Regulator Manual.

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13 GENERATOR OPERATION

The operation procedures vary significantly due
machine application and used control equipment.
This section describes only the general procedures.
For operation procedures of control system and
voltage regulator, refer to the specific manuals of each
equipment.
All measuring and control instruments should be
watched in all times in order detect any change and
adopt the prompt corrective actions.

13.1 SHAFT LIFTING SYSTEM (JACKING)

Turbogenerator bearings fitted with jacking option during
the start-up or stop process by oil pressure, this system
is driven by an external oil pump and following
procedures should be adopted:

ATTENTION
The oil pressure system for jacking should
be turned on before start-up (speed = 0 rpm)
and turned off only after machine exceeds
80 rpm. This oil pressure system should be
turned on during the deceleration process
after the machine reaches 80 rpm and
turned off after stop (speed = 0 rpm).

13.2 WATER RADIATORS

Control the water temperature at radiator inlet/outlet and
correct the water flow, if required. Regulate the water
pressure only if necessary to overcome the resistance in
radiator pipes.
For operation control, provide thermometer at the
radiator air/water inlet/outlet and record the temperatures
in determined intervals. During the thermometer
installation, also signaling or recording instruments
(horns, lamps) can be installed at specific locations.

13.3 BEARINGS

Watch closely the system start-up as well as its first
operating hours.

Before start-up, check:
If the jacking system (if any) of is turned on.
If the external lubrication system (if any) is On.
If the used lubricant meets the specification.
The lubricant characteristics.
The oil level (oil lubricated bearings).
The trip and alarm temperature set for the bearings.
During first start-up, pay attention to vibrations and
noises.
If bearings do not run smoothly and uniformly, turn the
generator OFF immediately.
The generator must operate during several hours until
the temperature in bearings stabilizes and remains
within the temperature limits mentioned previously.
In case of overtemperature, switch the generator OFF
immediately and check bearing temperature and
temperature sensors.
After bearings have reached the operating temperature,
check plugs, joints and shaft end for leakage.
13.4 VIBRATION LIMITS

WEG generators are factory balanced and meet the
vibration limits specified in the standards IEC60034-14,
NEMA MG1 - Part 7 and NBR 11390 (unless different
values have been agreed in the Purchase Agreement).

The vibration are measured on the DE and NDE, in
horizontal and axial directions.

When costumer sends half-sleeve coupling to WEG, the
generator is balanced with half-sleeve mounted on shaft.
Otherwise, according to standards mentioned above,
generator is balanced with half shaft key (i. e., key slot is
filled out during balancing procedure with a bar of the
same width, thickness and high as the key slot).

Maximum vibration levels recommended by WEG for
generators during operation are indicated in the table
13.1. These values are only general orientative values so
specific conditions should be considered for each
application:

Vibration Levels (mm/s RMS)
Rated speed
(rpm)
Frame size < 355
355 a
630
> 630
Alarm 4,5 4,5 5,5
600 n 1800
Shutdown 7,0 7,0 8,0
Alarm 3,5 4,5 5,5
1800 < n 3600
Shutdown 5,5 6,5 7,5

Table 13.1: Vibration (RMS)

The most common vibration causes in field are:
Misalignment between generator and driving machine;
Improper fixation of the generator onto the base with
loose wedges under one or more feet of the
generator and loose securing bolts;
Improper base with poor stiffness;
External vibration transmitted by other equipment.

ATTENTION
Generator operation at higher vibration levels
than specified above may impair its useful life
and/or performance).

13.5 SHAFT VIBRATION LIMITS

Generators fitted with proximity sensor or with provision
for the installation of these devices (normally used in
generator with sleeve bearings), the shaft surfaces are
machined with special finishing in the areas adjacent to
bearings in order to assure correct measurement of shaft
vibration.
The measured shaft vibration should meet IEC 34-14 or
NEMA MG 1 standard.
The alarm and shutdown values in table 13.2 specify the
maximum allowable vibration levels for electrical machine
coupled according to ISO7919-3 standard.

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These values above are only indicative and for each
application should be considered the specific site
conditions, such as the diametric clearance between
shaft and bearing.

Shaft Vibration (m - peak-to-peak)
Rated speed
(rpm)
Frame size
280 e
315
355 a
450
> 450
Alarm 110 130 150
1800
Shutdown 140 160 190
Alarm 85 100 120
3600
Shutdown 100 120 150

Table 13.2: Shaft vibration

Generator operation with shaft vibration in the area of
alarm or shutdown levels may cause damage to the
bearing shell.
Main causes for increase of the shaft vibration are:
Unbalance, coupling or other problems that have an
indirect influence on the machine vibration;
Shaft machining problems during the manufacturing
process;
Stress or residual magnetism on the shaft surface
where measurements are made;
Scratches, knockings or variations in shaft finishing at
the measuring area.

13.6 STOP

(manual mode local)
To stop the generator:
1. Reduce generator load up to 5 - 10% of rated
current;
2. Open armature circuit breaker;
3. Disable voltage regulator;
4. Shutdown the primary machine;
5. Enable the bearing jacking system (if any) when
speed reaches 80 rpm;
6. After generator is stopped, shutdown jacking
system (if any), close cooling water valve (if any) and
turn off bearing oil circulation system.
7. Turn on space heater if generator will be idle by
extended time.

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14 MAINTENANCE

14.1 GENERAL

The maintenance of generators applied correctly should
consider following procedures:
Keep generator and associated devices clean;
Check insulation levels periodically;
Check overtemperature periodically (windings and
bearings);
Check wears, lubrication and useful life of bearings;
Check ventilation system and ensure correct air flow;
Inspect heat exchanger;
Check machine vibration levels;
Inspect associated equipments (hydraulic unit, oil
pressure system jacking, voltage regulator);
Inspect all accessories and generator protection
devices ensuring correct operation and connections.
Non-observance of one of the item above could result in
unexpected stops of the equipment. The required
inspection frequency depends on the local condition of
the application.

If repair, recondition or overhaul of the generator or some
part is required, please contact WEG.
In addition to its well-trained service centers, WEG
supplies all factory and engineering services in order to
provide full-service to your company.

14.2 GENERATOR CLEANING

Maintain generator enclosure clean, free of oil and dust
and so improve the machine heat exchange to the
surrounding medium.
Clean inner surfaces of the generator, removing dusts,
debris and oils.
Use for cleaning always clean cotton cloth. If the dust
is not abrasive, industrial vacuum cleaner can be used
for the cleaning procedure. Remove all dirt and dust
from the fan cover, fan blades and generator housing.
Oil impregnated debris and moisture can be removed
with cloth soaked in properly solvent.
Clean also the terminal boxes. Maintain terminals and
connectors clean and free of oxidation and in good
conditions. Avoid grease or verdigris on connection
components.

NOTE
If generators are used for no-breaks supplying,
they must be operated from 2 to 3 hours each
month, depending on the moisture at the
installation site.

14.3 STATOR, ROTOR AND EXCITER
WINDING INSPECTIONS

Stator, rotor and exciter winding insulation should be
measured in regular intervals, specially in wet weather or
after extended generator standstill.
Inspect windings visually in regular intervals, record and
repair all detected damages.
Low measured values or sudden variations of insulation
resistance should be investigated carefully.
The insulation resistance could be increased to proper
values when it is low (due to dust and excessive
moisture) by cleaning and drying it for removing dust and
moisture.

14.4 WINDINGS CLEANING

In order to ensure high performance and longer useful life
for the machine, maintain windings free of dirt, oil, metal
dust, contaminants, etc.
Ensure that operation site is clean, make periodical
inspections and clean the machine and if required
impregnate the winding again (for this procedure contact
WEG ).
The windings may be cleaned with industrial vacuum
cleaner with fine and non-metallic tips or by rubbing with
dry cloth.
For extreme dust conditions it can be necessary to clean
with proper liquid solvent. This cleaning procedure should
executed as fast as possible to not expose windings to
solvent action for long times.
After cleaning with solvent, windings should be dried
thoroughly. Measure insulation resistance and
polarization index to determine if windings are dried
thoroughly.
Time required for winding drying process varies to
weather conditions such as temperature, moisture, etc.

DANGER
Most cleaning solvents are very toxic and
flammable.
Solvents should not be used on straight
parts of coil since the protection against
corona effect may be damaged.

Inspections

Make following inspections after carefully cleaning of the
windings:
Check insulations of windings and connections.
Check fastening of spacers, winding head lashing, slot
wedges, bandages and supports.
Assure that there is no cable breakage, poor welding,
or short-circuit between turns, against mass or
connections. If some is detected, contact WEG
Authorized Repair Shops.
Assure that cables are connected properly and
terminals are well tightened. Retighten, if required

Reimpregnation

If winding insulation (resin layer) has been damaged
during cleaning or inspection process, retouch the
damaged parts by using proper insulation resin (contact
WEG).

Insulation resistance

The insulation resistance should be measured after all
maintenance procedures are completed.

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ATTENTION
Measure the insulation resistance of the
stator, rotor and exciter windings when
generator was out of operation for longer
time and before it is powered-up again.
Ensure that measured values met the
specified ones.

14.5 INSPECTION AND CLEANING OF
RADIATORS

Guidelines for heat exchanger removal and
maintenance
Proceed as follows for removing the heat exchanger:
1. Close all water inlet and outlet valves after stopping
ventilation;
2. Drain water from radiator through the drain plugs;
3. Unscrew the heads retaining cap screws, nuts and
washers;
4. Scrub pipe inside surface of the pipes by using nylon
brushes for removing all scales. If during the cleaning
process damages are detected in the radiator pipes,
repair them.

Radiator storage after operation

When radiator is maintained out of operation during long
periods for maintenance procedures, drain out all water
and then dry it. Drying may be carried out with pre-
heated compressed air. During the winter, when the
water in the radiator pipes can freeze, drain all water out
even for short standstill periods, in order to avoid pipe
deformation and damages.

NOTE
During short stops, when water is not drained
from radiator, maintain low water flow
circulating through the radiator pipes to
ensure that the harmful products such as
ammonia and hydrogen sulfates compounds
are purged out from the radiator.

Radiator maintenance

Radiator can be operated during many years without
requiring any cleaning when supplied by clean water.
When radiator is supplied by dirty water, a complete
cleaning is required every 12 months.
The increase of the air temperature may be a sign that
radiator is dirty.
When cold air temperature, at the same operation
condition, exceeds the specified value, you can assume
that pipes are dirty.
If any corrosion is detected, proper corrosion protection
(for example, zinc anode, plastic, epoxy covering or
covering by similar products) is required, in order to
prevent more damages to the affected parts.
The external coatings of all radiator parts should be
maintained in good conservation conditions.

Radiator operation and performance

To control the generator operation we recommend that
water and air temperatures at radiator inlet and outlet are
measured and recorded periodically.
The radiator performance is expressed by the
temperature differences between cold water and cold air
during regular operation. This difference should be
controlled periodically. If this temperature difference
increases after a longer period of regular operation, this
is a sign that the radiator should be cleaned.
Performance decrease or radiator damage may also be
caused due to the accumulation of air inside the radiator.
In this case, a deaeration of radiator and water piping
may correct this problem.
The water pressure difference at the water inlet and outlet
can be a sign that radiator cleaning is required.
Measure and record the water pressure difference at the
water inlet and outlet. Compare periodically the
measured values with the first measured value. An
increase of the pressure difference indicates that radiator
cleaning is required.

14.6 GENERATOR OUT OF SERVICE

The following procedures should be adopted when
generator remains long periods out of service:
Turn the space heater on to ensure a slightly higher
temperature inside generator than the ambient
temperature, thus preventing water condensation and
consequent insulation resistance drop of the windings
and oxidation of metal parts.
All water pipes should be drained in order to reduce
corrosion and deposition of suspended matter of the
cooling water.
Follow also the procedures mentioned in chapter 5 of this
Manual Extended Storage

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15 BEARINGS

15.1 SLEEVE BEARINGS

1
2
3
4
5

Figure 15.1: Sleeve bearing

15.1.1 Bearing connections

1. Oil inlet pipe of the hydrostatic jacking system, if any.
2. Bearing oil inlet pipe.
3. Connection of the temperature sensor on bearing
shell.
4. Oil outlet pipe/Sight glass of oil level.
5. Connection of the oil thermometer.

15.1.2 Bearings data

Characteristic data: type, size and oil flow rate are
indicated on the DE and NDE bearing nameplate and
must be followed strictly in order to prevent bearing
overheating and damage.
Hydraulic installation and generator bearing oil supply is
users responsibility.

15.1.3 Bearings installation and operation

For parts list, assembling and disassembling guidelines,
maintenance details, refer to bearing Installation,
Operation and Maintenance Manual.

15.1.4 Hydrostatic jacking system

Due to application and technical features of some
generators, the use of an auxiliary Hydrostatic Jacking is
required for providing an oil film during generator start-up
and deceleration process, or when generator is running
for long periods at low speed.
The installation and operation of the hydraulic pump for
the shaft jacking system is users responsibility.

ATTENTION
Ensure correct speed for the jacking pump, if
any (see chapter START-UP).

15.1.5 Setting of the bearing protections

Each bearing is fitted with temperature sensors. These
devices should be connected to a control panel that
gives information on the bearing temperature and
prevents bearing damage due to overheating.

ATTENTION
Following temperatures should be set for the
bearing protection system:
ALARM 110C
SHUTDOWN 120C
The alarm temperature should be set 10 C
higher than rated operation temperature,
however should not exceed the limit of
110C.

NOTE
At no circumstance, water can leak into the
oil reservoir, since water results in oil
contamination.

15.1.6 Lubrication

Oil should be changed every 20.000 operation hours
when bearings are fitted with forced lubrication system
and every 8.000 operation hours when bearing are self-
lubricated, or always when the oil characteristics
changed. Check periodically the oil viscosity and pH.

NOTE
Check oil level daily and maintain the oil level
about center of the of sight glass.

Bearings should be lubricated with the specified oil
considering the flow rates indicated on the nameplate.
All unused screwed hole should be closed with plugs and
no connection may present any leakage.
Oil level is reached when lubricant is at the center of the
sight glass. The addition of more oil than required does
not damage the bearings, but may cause oil leakage
through the shaft sealing.

ATTENTION
Cares to be taken during the lubrication
process will determine the bearing lifetime
and generator operation safety. Thus
consider following guidelines:
The selected elected should have suitable
viscosity for bearing operation
temperature. This should be checked
during oil change or during periodical
maintenance procedures.
Machine operation with too low oil level
means lack of lubricant and could damage
bearing sleeves.
Minimum required oil level is reached
when lubricant reaches the bottom part of
sight glass with generator at standstill.

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15.1.7 Sealing

After bearing maintenance, both halves of seal labyrinth
should be fixed together by a circlip ring.
They must be inserted into the ring seat, so the locking
pin is fitted into the undercut of the upper half part of
housing. Poor installation damages the sealing.
Before seal assembling, clean carefully the contact
surfaces of the ring and seating and coat the contact
area with soft sealing compound. Drain holes at bottom
half of the ring should be cleaned and cleared. When
installing this halve of the sealing ring, press it slightly
against bottom shaft side.

15.1.8 Bearing maintenance

Sleeve bearing maintenance:
Check periodically lubricant level and conditions;
Check noise levels and bearing vibration,
Follow up and record operation temperature and
retighten all fixing bolts.
Clean generator frame. Remove dust and oil from the
frame outside to improve the heat exchange with the
environment.
NDE bearing is electrically isolated. The spherical seat
of the bearing shell is covered by an insulation material.
The locking pin is insulated and the seals are made of
non-conductive material.
The temperature control devices that contact the
bearing shells are also insulated.

15.2 OIL BEARINGS

1. Oil inlet pipe

2. Oil sight glass

3. Oil outlet

4. Temperature
sensor.

Figure 15.2: Oil bearings

15.2.1 Lubrication guidelines

Oil removal: When oil change is required, remove the
plug from the oil outlet pipe (3) and drain all oil.
For oil filling proceed as follows:
Close oil outlet pipe with plug (3).
Remove plug from oil inlet pipe of filter (1) (if any).
Add specified oil up to the level indicated in sight
glass.

NOTES
1. All unused screwed holes should be
closed with plugs and no connection
may leak.
2. Oil level is reached when lubricant is in
the middle of sight glass.
3. Addition of more oil than recommended
does not damage the bearings, but may
result in oil leakage through shaft sealing.

Oil type: Type and quantity of oil to be used are indicated
on the nameplate fixed on generator next to bearing.
Oil change: Bearing oil change should be carried out at
following intervals considering the bearing operation
temperatures, as shown in table below:
Below 75C = 20.000 hours
Between 75 and 80C = 16.000 hours

ATTENTION
Bearing lifetime depend on generator
operation conditions, environment conditions
and preventive procedures adopted by the
maintenance people.
The following guidelines should be followed:
The selected oil for the application should
has proper viscosity for expected bearing
operation temperature. The type of oil
recommended by WEG already considers
these criteria.
Insufficient amount of oil may damage
bearing.
Minimum level of oil is reached when
lubricant reaches the bottom part of sight
glass with generator at standstill.

ATTENTION
Oil level should be inspected daily and
maintained in the middle of oil sight glass.

15.2.2 Bearing operations

The system start-up should be watched carefully
during the first hours of operation.
Before start-up check:
If used oil meets the specification on nameplate.
The lubricant characteristics.
Oil level.
The bearing temperatures set for shutdown and alarm.
During first start-up check if the are abnormal vibrations
and noises. If bearings do not run smoothly and quietly,
stop generator immediately.
The generator must operate during several hours until the
bearing temperature stabilizes within the temperature
limits mentioned above. If an overtemperature is
detected, stop the generator and check bearings and
temperature sensors.
After operating temperature has been reached, check
plugs, joints and shaft seals for oil leakage.

15.2.3 Protection device settings

The temperature sensors installed on bearings should be
connected to a control panel to monitor bearing
overheating and so protecting the bearings against
damage due overtemperature during operation.

1
2
3
4

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ATTENTION
Following temperatures should be set for the
ALARM 110C
SHUTDOWN 120C
The alarm temperature should be set 10C
higher than normal operation temperature,
however should not exceed the limit of
110C.

15.3 GREASE BEARINGS

Figure 15.3: Grease-lubricated bearings

15.3.1 Lubrication guidelines

Lubrication system has been so designed that during
lubrication procedures the old grease is removed from
bearing race and expelled through drain hole that
prevents the ingress of dust or other harmful
contaminants into bearing.
This drain hole prevents bearing damage due to
overgreasing.
Grease bearings with running generator in order to
ensure grease renewal in the bearing housing.
If this is not possible due to rotating parts next to the
grease nipples (pulleys, etc.) that can injure the
maintenance people, proceed as follows:
With grease gun, apply about the half of total specified
amount of grease and operate the generator around 1
minute at full speed;
Stop generator and apply the remaining grease.

The injection of total amount of grease at one time with
the generator at standstill can cause lubricant penetration
into the generator inside through internal bearing seal.

ATTENTION
Clean grease nipples before greasing
procedure in order to prevent that foreign
matter are drawn into the bearings with the
grease.
For lubricating, use manual grease gun only.

15.3.2 Steps for bearing re-lubrication

1. Remove drain plug.
2. Clean the area around the grease nipple with cotton
cloth.
3. With running rotor, add grease with manual grease gun
until grease comes out the drain hole or until the total
amount of grease as specified in the table has been
applied.
4. Run the generator for a longer time in order to drain all
grease excess.
5. Check the bearing temperature in order ensure that no
significant temperature changes have occurred.

15.3.3 Spring device for grease removal

When operator cannot access grease relief valve, some
generators are fitted with an extended spring device for
grease removing during bearing relubrication procedures.

Steps for lubrication:
1. Clean grease nipple with cotton cloth before starting
bearing lubrication procedure;
2. Remove dipstick with spring, clean spring and insert it
again;
3. With rotor running, add quantity of grease specified on
bearings nameplate using manual grease gun.
4. Grease excess is expelled through bottom drain hole
and deposits on spring.
5. Operate generator during certain time so all grease
excess is expelled through bottom drain hole and
deposits on spring.
6. Remove this grease excess by removing the dipstick
with the spring remove the grease from the spring.
Repeat this procedure as necessary so often as
required till no grease is deposit on the spring.
7. Check bearing temperature to ensure that no
significant temperature changes have occurred.

15.3.4 Protection settings

ATTENTION
Following temperatures should be set at
ALARM 110C
SHUTDOWN 120C
The alarm temperature should be set 10C
higher than rated operation temperature,
however should exceed the limit of 110C.

Grease nipple
Grease drain hole

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15.3.5 Bearing replacement

In order to avoid damages to steel laminations, insert
cardboard shims in the air gap in the same thickness of
the air gap after endshield removal.
Bearing disassembly is very easy provided suitable tools
are used (with 3 grips according to figure15.4).

Figure 15.4: Bearing extractor.

The extractor grips must be applied on sidewall on the
inner ring to be stripped, or on an adjacent part.
In order to assure good operation and avoid bearing
damages, it is essential that assembly of bearing is
carried out under complete cleanliness and skilled
personnel.
New bearings should be removed only from packaging
just before the assembly. Before installing the new
bearing, remove any burrs and correct any knocks on
bearing seat onto the shaft.
During bearing assembly procedures do not apply direct
blows by hammer. We recommend to heat the bearing
by inductive heater in order expand the bearing inner ring
and thus facilitate the bearing assembly onto the shaft.
The press support should be applied on the inner ring.

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16 EXCITER

EXCITER DIODES SET

Figure 16.1: Exciter of Turbogenerator SP_

1. Pilot exciter with permanent
magnets (PMG)
2. Fan
3. Stator of auxiliary exciter
4. Rotor of main exciter
5. Stator of main exciter
6. Exciter housing
7. NDE endshield of the exciter
8. Diodes set
9. Heat sink
10. Varistor wiring bridge
11. Varistor
12. Diode
13. Heat sink
14. Stranded cable

16.1 EXCITER

For good performance of its components, the
compartment of generator exciter should be cleaned.
Perform periodic cleaning according to procedures
mentioned on item 14.3 of this manual.

Windings
Check periodically insulation resistance of main and pilot
exciter windings to determine their insulation conditions
following procedures in item 7.4 of this manual.

16.2 DIODES TEST

Rotary rectifier bridge housed on diode wheel is formed
by 3 anode diodes and e 3 cathode diodes.
These diodes are components that have higher durability
and not require frequent tests.
If generator shows any fault that indicates diodes
damages, for example an increase of field current for
same load condition, then these diodes should be tested
according to following procedure:
1. Remove rear cover of exciter (7) to access diodes;
2. Loose flex cables of all 6 diodes;
3. With ohmmeter measure each diode resistance in both
directions.
Diode is in good condition when presents low ohmic
resistance (until 100) in its direct direction and high
resistance (approx. 1 M) in the reverse direction.
Faulty diodes will present ohmic resistance of 0 or
higher than 1 M in both measured directions.

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16.3 DIODES REPLACEMENT

For replacing any diode WEG recommends you to follow
following procedures:
1. Replace damaged diodes by new ones considering the
position of each diode anode and diode cathode.
2. Diodes are supplied with stranded insulated
connection cable (13) and connection terminal;
3. Clean carefully heat sink (9 and 12) around the
mounting holes of diode.
4. Ensure that mounting area is free of burrs than prevent
perfect diode insertion into the heat sink.
5. Check diode thread to make sure it is clean and free of
burrs.
6. Install diode in its correct position by using torque
wrench and tighten it according to the torques
recommended in the table 16.1:

Diode Base
Thread
(mm)
Torque Meter
Wrench
(mm)
Tightening
Torque
(Nm)
M12 24 10
M16 32 30
M24 41 60

Table 16.1: Diodes Tightening Torque.

ATTENTION
It is important that specified tightening
torques are applied in order to not damage
diodes during assemble procedures.

1. After diodes have been fixed, connected stranded
cables as shown in figure above.

NOTE
Diode polarity is indicated by an arrow on its
housing. During diode replacement, ensure
that they are installed on the heat sink with
correct polarity.

Current conduction should
occur only in the anode-
cathode direction, i.e., in direct
polarization condition.

16.4 VARISTORS TEST

Varistors are devices installed between both halves of
rectifier bridge disk where are installed diodes and their
purpose is to protect diodes against overvoltage.
In case of fault of these components, replace them.
An ohmmeter can be use to test varistor conditions.
The resistance of varistor should be very high (20.000
ohms).
If varistor damage is detected or if its resistance is too
low replaced it.

16.5 VARISTORS REPLACEMENT

For replacing any varistor, WEG recommends to follow
the guidelines below:
1. Replace damaged varistors by new ones according to
generator manufacturer specification.
2. For replacing the varistor loose the bolts that fix it to
the heat sink and the bolt that fixes varistor wiring
bridge (10) to heat sink.
3. When removing varistor note how components are
assembled in order to install the new varistor in the
same way.
4. Before mounting new varistor, ensure that all
component contact surfaces (heat sink, wedges,
insulations and varistor) are leveled and smooth so that
allow perfect contact.
5. Secure the new varistor, tighten the bolt hat fixes it to
the heat sink by applying only sufficient tightening
torque to ensure good electrical connection. Excessive
tightening torque may cause varistor cracks and
damage.
6. Tighten also the bolt that fixes the varistor wiring bridge
to heat sink.

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17 GENERATOR PARTS

Figure 17.1: Parts of model SP_ turbogenerator _

1. DE bearing
2. Shaft
3. DE seal
4. Closing of DE endshield/frame
5. Internal DE fan
6. Stator winding
7. DE endshield
8. Stator winding
9. DE fan cover
10. Rotor core
11. Stator core
12. Frame
13. Equalizer winding
14. NDE fan cover
15. NDE endshield
16. Internal NDE fan
17. Closing of NDE endshield/frame
18. NDE seal
19. Exciter fan
20. Pilot exciter (PMG)
21. Exciter compartment
22. Main exciter
23. Rotary rectifier set
24. Exciter cover
25. Anchor plate set
26. Accessory terminal box
27. Intermediate base
28. Alignment cap screws
29. Anchor bolts

NOTES
Parts identification and location may vary depend on turbogenerator model and mounting;
SS_ model Turbogenerators are not fitted with pilot exciter (PMG)
Turbogenerators for mounting B3_ have bearings fixed on DE and NDE endshields;
Heat exchanger can be installed on top or bottom side of generator as required by the costumer.

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18 MAINTENANCE SCHEDULE

The following maintenance schedule is a guideline and intervals between each maintenance procedure may vary according
to conditions and location of equipment operation.
For associated equipment such as hydraulic unit and voltage regulator we recommend to also refer their specific manuals.

EQUIPMENT Weekly Monthly
Every 3
month
Every 6
month
Yearly
Every 3
Years
Note
STATOR
Visual inspection of stator x
Cleaning control x
Inspection of the slot wedges x
Stator terminal control x
Measure wing insulation resistance x
ROTOR
Cleaning control
x

Check connection of poles and dumping
winding

x
Visual inspection and measurement of pole
insulation resistance

x

EXCITER
Cleaning control x
Test diodes and varistors x
Inspect windings x
BEARINGS
Noise, vibration, oil flow, leakage and
temperature control
x
Checking of high pressure system (jacking) x
Oil quality control x
Inspection of sleeve shells and shaft race
(sleeve bearings)
x
Change lubricant
As indicated on
bearing nameplate
HEAT EXCHANGER
Radiator inspection x
Radiator cleaning x
Inspection of the radiators sacrificial anodes
(if any)
x
Sacrificial anodes
are used in
radiators that uses
salt water
CONTROL AND PROTECTION EQUIPMENTS
Performance inspection x
Value records x
Disassemble and test the operation
performance
x
COUPLING
Alignment inspection x
Check after the first
week of operation
Fixation inspection x
Check after first
week of operation
COMPLETE GENERATOR
Noise and vibration control x
Drain condensed water x
Retighten cap screws x
Clean terminal box x
Retighten electrical and ground
connections
x

Table 18.1: Maintenance Schedule

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19 TROUBLESHOOTING

Please find below a list of some abnormal conditions that can occur during generator as well some procedures for checking
and correcting these faults.

Generator does not excite or prime

ANOMALY PROCEDURE
Activated protection
Check the main panel and regulators modules for
signalization of the activated protection.
Excitation switch, if any, is not operating.
nterruption in power supply circuit of voltage
regulator.
Check excitation switch.
Check cable connection of the pilot exciter and voltage
regulator to the terminal block.
Incorrect drive speed.
Measure generator speed and if required make new
settings.
Check if underfrequency protection is not activated.
Interruption of main excitation circuit.
Measure all rotary diodes; replace damaged diodes or
replace whole diode set.
Check wiring between main rotor and diode disc.
Relay or other regulator component
damaged.
Set to manual mode.
Replace voltage regulator.
Voltage reference set too low Reset parameterization.
Varistor of diodes protection is defective.
If defective replace it. If there is no spare part remove it
temporally.

Generator do not excite, until to rated voltage

ANOMALY PROCEDURE
Rotating rectifiers defective.
Measure each rotating diode; replace damaged diode;
eventually replace the whole set.
Speed below to parameterized setting for U/F
function of the voltage regulator.
Check if the U/F function of voltage regulator is enabled.
If U/F function is set above rated frequency, reset to 5%
lower.
Measure and set the speed.
Voltage reference set too low. Set the voltage reference.
Remote setting of voltage lower than the
rated.
Reset the remote pushbutton to correct value.

Generator does not excite up to the rated voltage

ANOMALY PROCEDURE
Power supply voltage of the voltage regulator
lower the desired voltage resulting in an
output voltage lower than required.
Check if wiring is according to Voltage Regulator Manual.

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At no load generator excites up to until rated voltage, but collapses under load

ANOMALY PROCEDURE
Rotating diodes are defective.
Measure each rotating diode; replace damaged diode;
eventually replace the whole set.
Protection activation: overcurrent, overexcitation,
overvoltage.
Check if parameters are not set wrong and so activate
the protection in normal operation condition.
Activation of excitation current limit. Check the parameter settings.
Strong speed drop with enabling of U/F function or
not.
Check turbine speed control.
Check U/F function setting.

The generator, at no load, excites by overvoltage

ANOMALY PROCEDURE
For momentary overvoltage with immediate
shutdown: opening of signal transformer circuit.
Check fuse and wiring.
In remote mode: parameter setting errors by remote
pushbutton, with shutdown after a period of time
(also adjusted with parameter setting).
Reset reference voltage.
On manual mode: parameter setting errors of the
reference voltage: protection will no be activated.
In local mode: parameter setting errors of reference
voltage, with shutdown after a period (also adjusted
with parameter setting).

Generator voltage oscillations

ANOMALY PROCEDURE
Manual Mode: Poor adjusted stability. Adjust on parameterization of voltage regulator.
Automatic mode: Poor adjusted stability. Adjust on parameterization of voltage regulator.
Load variation. Check causes of variations.
Variations of the turbine speed. Check turbine speed control.

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20 ACCESSORIES AND SPARE PARTS

WEG recommend maintaining following spare in stock:

SPARE PARTS

Quant. Description
01 Sleeve bearing shell (upper and bottom) for the DE bearing with hydrostatic jacking (if any)
01 Sleeve bearing shell (upper and bottom) for the NDE bearing with hydrostatic jacking (if any)
03 Anode SKR Diode
03 Cathode SKN Diode
02 Space heater

Accessories listed below are standard supply for WEG turbogenerators.
Others accessories can be installed upon costumer request.

ACCESSORIES

Quantities
Cooling with 1
radiator
Cooling with 2
radiators
Description
03 03 Air thermometer
02 04 Water thermometer
01 02 Water flow sight glass
02 02 Contactless thermometer for bearing
04 04 Space heater - Pt 100 - 3 wires - for bearing
1, 2 or 3 per phase Temperature sensor - Pt 100 - 3 wires - for coils*
01 02 Level indicator relay for water leak sensor in radiator
01 02 Rod electrode for water leakage sensor in radiator
01 02 Water fluxostat
02 02 Oil fluxostat
01 02 Water pressure relief valve
01 01 Shaft grounding brush

* Winding temperature sensors can not be replaced. This accessory can be replaced only during stator rewinding.

HOW TO PURCHASE:

For purchasing spare parts and accessories, user must inform to WEG the generator serial number.

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21 DOCUMENTS

For correct installation, operation and maintenance of generator, WEG recommends that in addition to recommendations
mentioned in this manual, following specific documents must be considered:

Generator connection diagram;

Generator dimensional drawing;

Pump drawing (Jacking pump), if any;

Bearings installation and operation manual;

Water radiators maintenance manual;

Voltage regulator manual;

Manual of the hydraulic unit for the bearing lubrication.

ATTENTION
All machines included in this manual are updated constantly, so any information given herewith my be changed
without prior notice.
More information about the parameter setting can be found in the voltage regulator manual.

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22 WARRANTY CONDITIONS OF ENGINEERED PRODUCTS

These products, when operated under the conditions stipulated by WEG in the operating manual for such
product, are warranted against defects in workmanship and materials for twelve (12) months from start-up date
or eighteen (18) months from manufacturer shipment date, whichever occurs first.
However, this warranty does not apply to any product which has been subject to misuse, misapplication,
neglect (including without limitation, inadequate maintenance, accident, improper installation, modification,
adjustment, repair or any other cases originated from inadequate applications).
The company will neither be responsible for any expenses incurred in installation, removal from service,
consequential expenses such as financial losses nor transportation costs as well as tickets and accommodation
expenses of a technician when this is requested by the customer.
The repair and/or replacement of parts or components, when effected by WEG within the Warranty period do
not give Warranty extension, unless otherwise expressed in writing by WEG.
This constitutes WEG's only warranty in connection with this sale and is in lieu of all other warranties, expressed
or implied, written or oral.
There are no implied warranties of merchantability or fitness for a particular purpose that apply to this sale.
No employee, agent, dealer, repair shop or other person is authorized to give any warranties on behalf of WEG
nor to assume for WEG any other liability in connection with any of its products.
In case this happens without WEG's authorization, Warranty is automatically cancelled.

LIABILITY

Except as specified in the foregoing paragraph entitled "Warranty Terms for Engineering Products", the
company shall have no obligation or liability whatsoever to the purchaser, including, without limitation, any
claims for consequential damages or labor costs, by reason of any breach of the express warranty described
therein.
The purchaser further hereby agrees to indemnify and hold the company harmless from any causes of action
(other than cost of replacing or repairing the defective product as specified in the foregoing paragraph entitled
"Warranty Terms for Engineering Products"), arising directly or indirectly from the acts, omissions or negligence
of the purchaser in connection with or arising out of the testing, use, operation, replacement or repair of any
product described in this quotation and sold or furnished by the company to the purchaser.

WEG Equipamentos Eltricos S.A.
International Division
Av. Prefeito Waldemar Grubba, 3000
89256-900 - Jaragu do Sul - SC - Brazil
Phone: 55 (47) 3276-4002
Fax: 55 (47) 3276-4060
www.weg.net

1013.03/0709

www.weg.net

NOTES

www.weg.net


WEG Equipamentos Eltricos S.A.
Internation Division
AV. Prefeito Waldemar Grubba, 3000
89256-900 - Jaragu do Sul - SC - Brasil
Phone: 55 (47) 3276-4002
Fax: 55(47) 3276-4060
www.weg.net

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