8127280a002 GB

Contents
General Notes and Instructions

Safety precautions
Check list
Maintenance schedule
Customer contact list & complaint report
Drawings
Dimension drawing alternator
Rotor drawing
Circuit Diagram
Circuit diagram
Legend to circuit diagram
AZ 44914.2
85874
K 811.0.181
K 811.0.181
Operating Instructions
Three-phase synchronous electrical machines series DSG 29...144
Enclosure to operating instructions
Regulator Descriptions
Voltage regulator Cosimat N+
Bearings Zollern
Installation and operating instructions for Zollern ZF plain bearings
Lubrication for Zollern Z-bearings
Spare Parts
Drawings nos. 121poE, 221oE, 30NSoW, 401, 60obi
Technical Data
Technical data sheet
Test report 81 27 280 A002
H. Cegielski-FSA
Your order: 8702088
Your project: Szczecin Shipyard B178-I/15,16,17, Poland
AvK Order no. 81 27 280 A002
09/2005
General Notes and Instructions
General Notes
Safety Precautions
Read this advice as well as

the operating instructions
supplied
prior
to
commissioning or storage of
the generator.
Any works on the generator have to be
performed by qualified and trained
personnel only.
Any person, working on the generator
has to read and understand these
operating instructions.
1. General Notes
1.1 Important notes for users
In the following instructions you will find
important information and safety advice for
transportation, installation and operation
for AvK generators of the series DSG and
DIG.
AvK generators are designed for different
applications for the use on land as well as
offshore. Series DIG is dimensioned for a
nominal voltage bigger than 1 kV, DSG for
a nominal voltage up to 1 kV. Please refer
to the rating plate mounted on the
generator for design data and as well as in
the data of the respective order.
Any works on the generator has to be
performed by qualified and trained
personnel
only.
The
necessary
qualification can be obtained by training or
courses
through
the
manufacturer.
Technicians can obtain a special
generator training at AvK Germany.
The installation
should preferably be
performed by an AvK service technician or
by a specially trained qualified technician.
The operating instructions are to be kept
close to the generator and have to be
available for the personnel at any time.
Please take notice of the safety
precautions in chapter 2. Further safety
precautions are mentioned in the
respective chapters.
The order related data of the generator as
well as the operating instructions for
General Notes
AH/e-04-2003/A
additional parts can be found in the

documentation.
The
documentation,
including
the
operating instructions, are part of the
machine and have to be passed on to the
next user in case the generator is sold or
moved.
1.2 Liability and guarantee
All statements and advice in the operating
instructions are made under consideration
of our present knowledge and experience.
The technical information
and data, described in this
manual, is the correct state
of information at time of
printing. We reserve the right to
changes due to technical progress
without
changing
this
operating
instruction. Accordingly, no claims can
be made from statements and
descriptions in this manual.
We will not be liable for any damages or
breakdowns due to operating mistakes in
disregard of these instruction or improper
repairs.
We particularly point out, that spare parts
and additional parts not supplied by AvK,
have to be accepted by AvK. AvK will
exclude any liability for damages that
result from the use of spare and additional
parts that have not been accepted by AvK.
The installation or use of foreign products
may possibly change the constructively
given design of the electric machine in a
negative way, and may restrict the safety
of persons, machine or other values.
Any unauthorized modifications and
changes on the generator are not allowed
for reasons of safety and will exclude any
liability of AvK for resulting damages. If
transformers supplied by the customer
shall be installed in the terminal box, AvK
has to be consulted first.
The preceding notes do not extend the
terms of liability and guarantee of the
general delivery terms of AvK.
page 2
Manufacturer's Address
AvK Deutschland GmbH & Co. KG
Bunsenstrae 17
D-85053 Ingolstadt
Phone (+49) (0)841 / 792-0
FAX (+49) (0)841 / 792-250
All rights reserved. Reprints
or copies - even extracts need the permission of AvK.
2. Safety Precautions
During
transportation,
installation,
commissioning and maintenance, certain
works might have to be performed on the
generator, e.g. on feet support, shaft end,
bearings, terminal box, etc. The working
area and area of danger includes the
surroundings of the generator and the
prime mover.
During normal operation, the working area
should be limited to the operating and
monitoring devices of the switchboard.
Despite taking into consideration all safety
precautions, the generator may be a
source of danger, electrically and
mechanically. To avoid damages to
persons and values, all safety precautions
have strictly to be followed.
Beside all safety notes in the operating
instruction the local safety precautions and
rules for the prevention of accidents have
to be followed.
2.1 Description of symbols and advice
The following symbols are used in the
instructions to highlight particular points
and actions:
Besides these safety notes all local valid

instructions for safety and accident
prevention have to be followed.
Follow all warnings and
advice and act very carefully
in these cases. Inform all
persons working on the
generator
about
all
work-safety
regulations.
2.2 Signs on the generator
At particular dangerous points on the
generator you will find safety notes. To
avoid damages to persons or values these
safety notes have to be followed very
strictly.
Achtung!
Betriebsanleitung
Im Klemmenkasten!
Vor Inbetriebnahme unbedingt lesen.
Caution!
Operating instructions are inside the
terminal box. These must be read prior to
commissioning.
The documents for the generator are in
the terminal box
Transportsicherungen.
Vor Inbetriebnahme entfernen
Transport Safety Devices
Remove prior to commissioning.
During transportation the rotor is secured
against shifting.
The transport safety
devices have to be removed before
commissioning.
Maschine nicht betriebsfhig!
Warning! Life in danger!

Machine out of order
Danger!
General Notes
AH/e-04-2003/A
This sign is mounted when the installation

of transformers in the terminal box is
necessary. The transformers have to be
installed prior to commissioning. In this
page 3
case the installation manual for the

transformers is in the terminal box and in
the enclosed documents.
E-Teile im Klemmenkasten
Unprotected machine parts

may cause severe injuries.
All safety devices like covers, barriers and
protections have to be in place and must
be functioning perfectly at all times.
Spare Parts are inside

Spare parts that are delivered with the
generator are in the terminal box. The
spare parts have to be removed.
ABSTANDSMA-PROTOKOLL
AM GLEICHRICHTERTGER
Mounting-distance test-report is inside
For the alignment of single bearing
machines it is important to keep the
mounting distance between rotor and
stator on the NDE of the generator.
The respective report can be found on the
rectifier carrier at the NDE of the
generator.
ACHTUNG!
Vor Inbetriebnahme l einfllen.
Menge und Qualitt laut Beschreibung
Caution!
Fill in oil prior to commissioning!
Please refer to operating instructions of
the sleeve bearing manufacturer for
amount and quality.
Generators with sleeve bearings need oil
to be re-filled before commissioning. The
instructions from the sleeve bearing
manufacturer are enclosed.
It is not permitted to operate

the generator with damaged
safety devices!
2.3 Safety at site
For operating the electrical machine the
responsibilities have to be determined
clearly and kept, so that no unclear
situation regarding safety may occur.
The generator must only be operated
when it is in an excellent state and
according to the design data. Any change
that reduces the safety has to be reported
to the responsible person immediately.
Modifications
on
the
machine are only allowed in
agreement with AvK
and
these are to be performed
under
supervision
of
qualified
personnel.
The way to the operating and monitoring
devices has to be free and must not be
obstructed by any objects.
Prior to commissioning and
during maintenance works, all
persons in the danger area
have to be warned. They must
be ordered to leave the area.
After completion of work, the generator
must be checked by qualified personnel to
ensure it is in a safe working state.
2.2 Safety Devices

2.4 Safety precautions for maintenance
Special covers are mounted to protect
against mechanical danger (e.g. rotating
parts). Protection against electrical danger
is provided by covers and devices against
over-voltage and over-current. It is not
allowed to change or dismount any safety
devices or to put them out of order.
General Notes
AH/e-04-2003/A
Maintenance should normally

only be performed when the
generator is out of operation
(except for the re-lubrication
of anti-friction bearings). The prime
mover has to be disconnected.
page 4
After completion of the maintenance work,

it must be ensured that all protection and
safety devices are back in place properly.
2.5 Special Dangers
The operator of the machine
has to take care, that the
rules for fire protection are
kept and the equivalent
agents for fire extinction are available
near the machine and ready for use.
3. Shipping, Handling, Storage
They are only used as mounting device

for these add-ons.
The ring bolts can only be used for the

transport of the separate machine,
they are not designed to lift the
complete unit (generator and prime
mover)
For transporting the machine, the

following devices are permitted:
Cable and chains,

that comply with the local regulations,
that have a sufficient carrying capacity,
that are in an excellent working condition
3.1 Safety precautions for transport

Please comply with the local
valid
regulations
for
shipments.
Warning!
Never move
persons!
loads
over
The shipment and the unloading of the

generator must only be performed by
personnel, who are familiar with the
lifting
cranes and corresponding
devices.
The lifting devices have to be designed

for the weight of the generator
(Chapter 3.4).
Follow the shipping instructions

(pictographs) on the cover of the
generator.
The generator must only be supported

on its feet. The support on any other
part is not permitted. That is why the
generator is delivered with a
transportation construction.
For the lifting of the generator, ring

bolts are mounted on the generator
housing.
It is not permitted to use

cables that are torn or worn.
Cables and chains may not be
knotted. Cables and chains
must not touch any sharp edges.
-
Lifting devices:
cranes
overhead cranes
Moving the machine over rough

ground e.g. rails, by using a haulage
car is not permitted. This may cause
damage to the bearings and the
windings. This is especially important
for the moving of the machine within
the factory.
3.2 Packaging
Ring bolts, that are mounted

on add-on pieces like e.g. the
cooler top, must not be used
to lift the whole machine!
General Notes
AH/e-04-2003/A
The material used for the packing of the

generator is made of ozone-friendly
material like wood. The packaging
depends on the mode of transport used
surface, water or air freight.
When the transport time is for a longer
period, then the generator will be packed
in a protective covering against dust or
humidity.
3.3 Checking for Shipping Damage
We recommend checking the
generator
for
shipping
damages
and
complete
delivery by the time of
delivery.
page 5
If there are damages on the goods (open

damages) report these to the haulage
contractor at take-over. In this case, the
receipt should only be given under
reservation with a written statement
regarding the estimated amount of the
damage.
If damages that were not noticeable by the
time of delivery (covered damages), are
detected later, they have to be reported
promptly to AvK, latest 6 days after receipt
of the delivery.
3.4 Unloading the generator
The unloading has to be performed in
compliance with the safety precautions for
transport (see chapter 3.1) and the local
safety precautions and rules for the
prevention of accidents.
Please refer to the freight
papers and the data of the
respective
order
(Rating
plate) for the weight of the
generator.
The weight of the generator is also
written on the rating plate.
3.5 Storage of the generator
After
unloading,
the
generator
and
possible
boxes with loose parts have
to be stored until installation,
following the shipping instructions.
Wrapped parts and assessories must not
be unwrapped if the generator is stored for
a longer period of time.
The machine and packages have to be
stored in a safe place, dust-free and dry
(humidity < 75%). Avoid mechanical
vibrations and damages.
If it is planned to store the
generator for a longer period
of time, please contact AvK
for further information.
General Notes
AH/e-04-2003/A
page 6

Bunsenstrae 17
85053 Ingolstadt, Germany
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250
e-mail: infoavkin@newage-avkseg.com
www.newage-avkseg.com

Dreieich branch
Benzstrae 47-49
63303 Dreieich, Germany
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
e-mail: infoavkdr@newage-avkseg.com
AvK Deutschland GmbH & Co. KG / Service
Date: 22.07.2002
AvK Checklist to Order No.
Page 2
Customer:
.............................................................
Order No.:
.............................................................
Generator Type:
.............................................................
Operation Hours:
.............................................................
Bearing design:
Roller bearing
Sleeve bearing
Replacement of oil:
YES
o
NO
o
Bearing inspection performed:
YES
o
NO
o
I.
Electrical Inspection
Pos. 1.1 - 1.19
II.
Mechanical Inspection
Pos. 2.1 - 2.20
III.
Test Run
Pos. 3.1 - 3.14
IV.
Maintenance Result
Date: 22.07.2002
Page 3
Environmental Conditions:
a) Location:
building
marine
b) Atmosperic conditions:
dry
dust
o
o
high humidity
salt
c) Ventilation:
unrestricted
restricted
o
o
o
o
o
o
adequate
inadequate
Operating Conditions:
a) Site duty:
single
parallel
b) Duty cycle:
24 hours
daily
c) Load condition:
inductive
non linear
d) Operation:
manned
unmanned
a) Dirt content:
slight dust
thick dust
o
o
b) Corrosion:
none, very little

copper
idle
occasionally
standby
Generator Conditions:
c) Engine:
Type:
Serial No.:
Fuel:
o
o
light layer dirt

thick compact dirt
o
o
steel/iron
severe
o
o
(....................)
....................
....................
....................
Date: 22.07.2002
I.
Page 4
Electrical Inspection
performed
Complaints
see page 11
1.1
Examination of cable entry and cable shoes

to main terminal box
1.2
Examination of strain relief of connecting power cables
1.3
Check of fixation of transformers installed
1.4
Examination of cable entry and cable shoes

to auxiliary terminal box
1.5
Check of strain relief of connection cables
1.6
Insulation test of stator windings
a)
Stator winding phase U against ground

Resistance ............. M
Voltage ............. V
b)
Stator winding phase V against ground

Voltage ............. V
c)
Stator winding phase W against ground

Voltage ............. V
1.7
Insulation test of stator windings
a)
Stator winding phase U against phase V

Voltage ............. V
b)
Stator winding phase U against phase W

Voltage ............. V
c)
Stator winding phase W against phase V

Voltage ............. V
1.8
Resistance measurement of stator
Date: 22.07.2002
performed
Page 5
Complaints
see page 11
1.9
Check and re-tightening of all screws and nuts

in main terminal box by dynamometric key
1.10
Cleaning and examination of insulators for cracks
1.11
Re-tightening of contact screws and nuts on

auxiliary terminal strip
1.12
Resistance measurement of auxiliary windings
1.13
Insulation test of auxiliary windings
1.14
Examination of anti-condensation heater
............. V ............. A
1.15
Insulation resistance measurement of rotor winding
a)
Insulation measurement main rotor

Voltage ............. V
b)
Insulation measurement exciter rotor

Voltage ............. V
1.16
Resistance measurement of rotor
1.17
Inspection of rotating rectifiers
1.18
Inspection of stator end winding with endoscope
Inspection of stator end winding without endoscope
Inspection of rotor winding with endoscope
Inspection of rotor winding without endoscope
o
o
1.19
Date: 22.07.2002
II.
Page 6
Mechanical Inspection
performed
Complaints
see page 11
Sleeve Bearing Design
Oil lubrication system installed: o
YES
o
NO
2.1
Check of oil level in sleeve bearing
2.2
Check for leakage of sleeve bearings
2.3
Inspection of sleeve bearing with endoscope
Inspection of sleeve bearing without endoscope
2.4
Check of oil quantity of oil lubrication system
2.5
Check of oil pressure of oil lubrication system:
.................... mbar
2.6
Check of oil temperature of oil lubrication system
2.7
Check of oil pressure inside the bearing housing
.................... mbar
2.8
Check of lubrication ring
2.9
Check for any corrosion on drive side and non-drive side bearing
2.10
Oil viscosity used:
according to ISO VG .................
Date: 22.07.2002
performed
Page 7
Complaints
see page 11
Roller/Ball Bearing Design

o
2.11
Relubrication of roller/ball bearing according to operating instructions
2.12
Removal of surplus grease
2.13
Removal of old grease from bearing covers
Additional Mechanical Checks
2.14
Inspection of abrasion of earthing brush
2.15
Inspection of base frame for mechanical deviations
Mounting of alternator / Check of feet fixation
2.16
Visual inspection of the drive coupling
2.17
Check of inlet and outlet airducts for dust and dirt
2.18
Check of inlet and outlet airducts for corrosion
2.19
Cooler / leakage monitoring
2.20
Check of drainage stoppers / drainage for condensation

water
Date: 22.07.2002
III.
Page 8
Test Run
performed
Complaints
see page 11
3.1
Check whether earthing switch is disconnected
3.2
Check of bearing noise
3.3
SPM bearing analysis:
DE:
LR .......... HR ..........
NDE:
LR .......... HR ..........
3.4
Check of oil amount in sleeve bearings during operation
3.5
Effectivity of lubrication ring
3.6
Tripping of temperature protector for check

of alarm and shut down
3.7
Vibration test / Vibration values (mm/s)
DE:
.......... Hor.
.......... Ver.
.......... Axi.
NDE:
.......... Hor.
.......... Ver.
.......... Axi.
Frame:
.............
Output:
............. kW
Airduct inlet:
.............
Airduct outlet:
.............
Date: 22.07.2002
Page 9
performed
Complaints
see page 11
3.8
Check of regulator functions at no-load operation

a) Exciter current at rated voltage and rated speed:
I1-I1':
............. A
b) Exciter current at rated load:

I1-I1':
............. A
c) Supply voltage:
d) Under speed protection:
3.9
UH1-UH2:
............. V
UH1-WH2:
............. V
WH1-WH2:
............. V
H1 LED off
............. Hz
Check of parallel operation

Check of distribution of load
Statics adjustment
.......... %
3.10
Check of overcurrent and short circuit protection trip
3.11
Check of differential protective trip
3.12
Check of exciter monitoring system
XE2
TO 109/110.1
3.13
o
o
Check of generator voltage in parallel operation

grid voltage min.:
grid voltage max.:
............. kV
............. kV
Date: 22.07.2002
performed
Page 10
Complaints
see page 11
3.14
Bearing and winding temperature after continuous

operation
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
Date: 22.07.2002
IV.
Page 11
Maintenance Result
Complaints:
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
The operation of the alternator can be continued without immediate

elimination of the complaints.
Electrical and mechanical checks were performed without any

complaints.
The alternator must be stopped immediately due to the complaints.
Date: ________________
________________________
(Signature Customer)
________________________
(AvK-Service-Technician)
Date: 22.07.2002

Bunsenstrae 17
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250

Dreieich branch
Benzstrae 47-49
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
AvK Deutschland GmbH und Co. KG
Page 1 of 2
Suggested Maintenance Schedule for AvK Order No.:

Customer:
Date:
Pos. A
Components
Frequency
Maintenance
General alternator check
12 month
According to AvK Checklist.
Additional components
Frequency
Maintenance
Rotor windings
12 month *)
Exciter
approx. 25,000 h *)
3
4
Rectifier assembly
Stator end winding
approx. 25,000 h *)
approx. 25,000 h *)
The insulation resistance must be checked with a megger

when the alternator has reached ambient temperature.
Remove any accumulated dust from the rotating rectifier
and the exciter stator. Check if the electrical connections
are secure.
Remove dirt adhering to the rectifier unit parts.
Inspect and remove deposits of dust, dirt and grease. Do
not use any abrassive materials or fluids. Use only
electrocleaner.
Pos. B
Protection equipment
12 month *)
Space heater
6 month
Caution: In case of heavy winding contamination please

call the AvK Service Department.
Check mechanical and electrical connections according
to the suppliers specification / manual.
Ensure that the electrical heater is operating to prevent
condensation. Check the power supply as well as the
insulation resistance.
Carried out by
AvK
Carried out by
AvK
AvK
AvK
AvK
AvK
Customer
*) Maintenance frequency depends on the operating conditions at site.
Maintenance-e.xls
Service / Steller
Date: 18.04.2000
AvK Deutschland GmbH und Co. KG
Page 2 of 2
Suggested Maintenance Schedule for AvK Order No.:

Customer:
Date:
Pos. B
Additional components
Frequency
Ball and roller bearings
Grease relubrication acc. Check oil or grease for any contamination particles.
to suppliers manual
and/or name plate.
Maintenance
Sleeve bearing: Oil ring
6 month
6 month
Sleeve bearing: Oil seals
6 month
10
Sleeve bearing: Complete check
25,000 h *)
50,000 h
11
Oil pipes and flanges
6 month
12
Sleeve bearing: Oil level
monthly
13
14
Bearing earthing brush

Dust filter
3 month
3 month *)
15
16
Cooler
Complete alternator
6 month
100,000 h
SPM bearing analysis.

Ensure that the oil ring is rotating freely and picking up
enough oil when the shaft is turning.
Check for oil leaks.
The oil seals must be changed.
The bearing check must be done (according to suppliers
manual) and the oil seals must be changed.
Check for oil leaks.
After the first 500 running hours it is recommended to
tighten the screws of the flanges again.
The oil level must be visible in the viewing glass.
(Approx. one third of the diameter.)
Check the earthing brush for abrasion.
At the appropriate intervals, the filters must be checked
to establish their degree of contamination with dust and
dirt.
Check the cooler elements and leakage detector.
Review with manufacturer for recommendations for full
inspection / overhaul.
Carried out by
AvK / Customer
AvK
Customer
Customer
AvK
AvK
Customer
Customer
Customer
Customer
Customer
AvK
*) Maintenance frequency depends on the operating conditions at site.
Maintenance-e.xls
Service / Steller
Date: 18.04.2000
Customer Contact List

Service and Warranty Claim Handling for AvK Alternators
DA 7.5-1
1 von 2
Technical Service on-site (after warranty):

Products
Countries
Contact
E-mail
Phone
Fax
All AvK
Products
UK
Sarah Nicholls
Sarah.nicholls@newage-avkseg.com
+44-(0)1780-484 ~767
All AvK
Products
Spain
Portugal
John Johnson
John.johnson@newage-avkseg.com
Mobile: +34-(0)629183929
All AvK
Products
France
french speaking North Africa
Rene Moulin
Rene.moulin@newage-avkseg.com
+33-(0)16074 ~9843
~9844
All AvK
Products
Italy
Joseph.cinnirella@newage-avkseg.com
+39-(0)2-38000 ~714
~664
J.Jakobsen@newage.no
+47-(0)22-9744~37
~45
All AvK
Products
All AvK
Products
All AvK
Products
All AvK
Products
Norway
Sweden
Denmark
Finland
Baltic States
Russia
North America
South America
Mexico
Central America
Canada
Australia
New Zealand
South Pacific
Switzerland
Guiseppe Cinnirella
Jan Jakobsen
~104
001-763-528-7301-6
Gary O`Malley
Gary.b.omalley@newage-avkseg.com
Theo Dragonas
Theo.dragonas@newage-avkseg.com
Martin Lderach
laederach_interplan@bluewin.ch
Direct: 001-763-574 ~5000
~5082
TOLL FREE: (1) 800 ~367-2764
~863-9243
+61-(0)2-9680 ~2299
~1545
Mobile: +61-(0)412-886643
+41 317 408 282
Mobile: +41 7920 17561
+41 317 408 280
Dokumentenname:
Customer contact.doc
Stand: B vom 07.04.05
Revisionsstand:
B vom 30.03.05
Customer Contact List

Service and Warranty Claim Handling for AvK Alternators
Products
All AvK
Products
All AvK
Products
All AvK
Products
All AvK
Products
Countries
Singapore
Malaysia
Philippines
Indonesia
Thailand
Taiwan
Vietnam
China
Contact
Richard.lee@newage-avkseg.com
+65-(0)6794-3737/5
Anthony Tan
Anthony.tan@newage-avkseg.com
Mobile: +65-(0)979-192-57
Trisno13@cbn.net.id
+62-214601685
Trisno Sumarlin
India, Nepal
2 von 2
Phone
Richard Lee,
Fax
+65-(0)6898-9065
(Indonesia)
Jason Xu
Japan, Korea
E-mail
DA 7.5-1
Darryl Hanna
R.K. Kapur
Jason.xu@newage-avkseg.com
Darryl.hanna@newage-avkseg.com
Avkpower@del3.vsnl.net.in
+86-(0)510-521 ~6212
Mobile: +86-(0)139-5157-0763
+81-(0)354-415 ~588
Mobile: +81-(0)906-386-574
~7673
~590
+91-(0)9811196343
Contact for Warranty Claims:

Product
All AvK
Products
Countries
Worldwide
Contact
Norbert Steller
am:
von:
Unterschrift:
E-mail
Phone
n.steller@newage-avkseg.com
+49-(0)841-792 ~163
Mobile: +49-(0)171-221-9453
Issued
30.03.03
Approved
30.03.03
Norbert Steller
Service Manager
Emilia Sandau
Assistant Service Manager
Norbert Steller
Emilia Sandau
Fax
~195
Dokumentenname:
Customer contact.doc
Stand: B vom 07.04.05
Revisionsstand:
B vom 30.03.05
Customer Complaint Report
FM 7.5-14
Kunden- Beanstandungsbericht
Page 1 of 1
Distribution List: Customer => AvK Contact person, according to Customer Contact List DA 7.5-1 or
AvK Hompage www.newage-avkseg.com
1.0 General Complaint information

Allgemeine Daten der Beanstandung:
Customer
Kunde
Place of Complained
Alternator Einsatzort
Contact Person Customer
Customer Fax No.:
Ansprechpartner Kunde
Kunden Fax Nr.
Customer Complain No.:
Customer Phone No.:
Kunden Beanstandungs - Nr.
Kunden Tel. Nr.
Customer email
Type of alternator:
Kunden Email
Generator Typ
AvK Serial No.:
AvK Order.- Nr.:
AvK Masch. - Nr.:
2.0 Failure description / Fehlerbeschreibung
Defect Part
Defektes Bauteil
3.0 Immediate measure by customer/ Sofortmanahme durch den Kunden

Initiated (date) / eingeleitet am:
Successfully completed (date):

erfolgreich abgeschlossen am
4.0 Enclosures / Anlagen

Photos / Fotos
others:
sonstiges
Dokumentenname:
7_5f14a.doc
Revisionsstand:
A vom 09.10.03
Drawings
Circuit Diagram
Seite 1
Page 1
Legende zum Schaltbild Nr.

K 8**.*.**
Legend to Circuit Diagram No.

K 8**.*.**
F1, F2
G1
G2
G3
Q1
Schutzschalter fr G3
NUR IM STILLSTAND BETTIGEN
Hauptmaschine
Erregermaschine
Hilfserregerwicklungen
Schutzschalter
31-32 Meldung
Protection switch for G3

ONLY SWITCH ON AT STANDSTILL
Main machine
Exciter machine
Auxiliary exciter windings
Protection switch
SWITCH ON ONLY AT STANDSTILL
31-32 Signal
R11
R12
R21
Rotierender Varistor
Rotierender Schutzwiderstand
Vorwiderstand
Rotating varistor
Rotating protection resistor
Serial resistor
T24
V1
Spannungswandler fr Regler
BEI GEFFNETEM STERNPUNKT VON G1
UNBEDINGT ABKLEMMEN
Spannungswandler
Spannungswandler fr G3
Spannungswandler fr G3 mit integriertem
Schutzschalter F1
F1 - nur im Stillstand bettigen!
Rotierende Gleichrichter
Voltage transformer for AVR

DISCONNECT IF STARPOINT OF G1 IS
OPEN
Voltage transformer
Voltage transformer for G3
Voltage transformer for G3 with integrated
protection switch F1
F1 - only switch at standstill!
Rotating rectifiers
X1
X2-6
Hauptklemmen
Klemmleiste
Main terminals
Terminal strip
U1
Spannungsregler Cosimat N
R3 Unterdrehzahlschutz
R4 Interner Sollwert
R1 P-Anteil
S1 I-Anteil
R7 Statikeinstellung
R6 Statikwandleranpassung
Sollwertpot. Generator Spannung (R = 500 )
Statikwandler
ACHTUNG: Bei Regler lose: Regleranschlu
Drehrichtung rechts:
Leiste X2
Regler
U
U
V
V
W
W
Drehrichtung links:
Leiste X2
Regler
W
U
V
V
U
Alternator voltage regulator Cosimat N

R3 Underspeed protection
R4 Internal voltage setting
R1 P-Part
S1 I-Part
R7 Droop adjustment
R6 Droop transformer adaption
Alternator voltage adjuster (R = 500 )
Droop transformer
CAUTION: AVR loose supply:AVR connection
Rotation clockwise:
Terminal X2
AVR
U
U
V
V
W
W
Rotation counter clockwise:
Terminal X2
AVR
W
U
V
V
U
Schnellentregung:
Brcken UH1-24 und WH1-14 ffnen
Quick de-excitation:
Open bridges UH1-24 and WH1-14
Entregungsschalter: 220 V AC
(nicht AvK Lieferumfang) 10 A
De-excitation switch: 220 V AC

(not AvK supply) 10 A
Verbindungen auerhalb des Generators

Erstellt am:
12.10.1998
geprft von:
Diegeler
Revision Nr.: 1
Connections outside the alternator

Issued on:
12.10.1998
Checked by: Diegeler
Revision No.: 1
T25-28
T30, 31
T32
R1
T6
'
----
AvK
Seite 2
Page 2
Legende zum Schaltbild Nr.

K 8**.*.**
Legend to Circuit Diagram No.

K 8**.*.**
A13, 14
A15, 16
A20, 21
A22, 23
A24, 26
A27/28
AR1-24
ZUBEHR
Widerstandsthermometer PT100
Statorwicklung
Phase U: 1, 4, 7, 10
Phase V: 2, 5, 8,11
Phase W: 3, 6, 9, 12
Lager, B-Seite
Lager, A-Seite
Generator Zuluft
Generator Abluft
Statorblechpaket
Sekundr Khlmittel EIN/AUS
berspannungsableiter
ACCESSORIES
Resistance Thermometer PT100
Stator winding
Phase U: 1, 4, 7, 10
Phase V: 2, 5, 8, 11
Phase W: 3, 6, 9, 12
Bearing, NDE
Bearing, DE
Alternator air inlet
Alternator air outlet
Stator core
Secondary Cooling agent inlet / outlet
Overvoltage arrester
C1
Entstrkondensator
Interference Suppression Capacitor
D1, 2
D3, 4
Lagerschadendetektor
B-Seite
A-Seite
Bearing damage detector

NDE
DE
H, H1-5
Stillstandsheizung
Anti condensation heater
L1-4
LW1-4
Leckageanzeiger Khler
Luftfilterberwachung
Leakage detector cooler

Air filter supervision
SR1-6
STW1-4
Schleifring
Drehzahlmesser
Slip ring
Speed transmittor
T17-22
Stromwandler
fr Stand-by-Regler
Fr Messung (M), Schutz (P)
Kern Nr. 1: X5, 1-6 (M)
Kern Nr. 2: X5, 7-12 (P)
Kern Nr. 3: X5, 13-18 (P)
Messung
Current Transformer
for Stand-by-unit
For Measuring (M), Protection (P)
Core No. 1: X5, 1-6 (M)
Core No. 2: X5, 7-12 (P)
Core No. 3: X5, 13-18 (P)
Measuring
TF1, 3
TF5, 7
TF2, 4
TF6, 8
PTC Temperaturfhler
Statorwicklung, Warnung
Statorwicklung, Warnung
Statorwicklung, Abschaltung
Statorwicklung, Abschaltung
PTC Temperature Sensor

Stator winding, warning
Stator winding, warning
Stator winding, shut down
Stator winding, shut down
TF11, 13
TF15, 17
TF12, 14
TF16, 18
Lager B-Seite, Warnung

Lager A-Seite, Warnung
Lager B-Seite, Abschaltung
Lager A-Seite, Abschaltung
Bearing, NDE, Warning

Bearing, DE, Warning
Bearing, NDE, Shut down
Bearing, DE, Shut down
TF20, 21
TF22, 23
TF24, 25
TF26, 27
WW1-4
Z1
Thermometer
Lager, B-Seite
Lager, A-Seite
Generator Zuluft
Generator Abluft
Wasserdurchfluwchter
Entstrfilter (Funkstrgrad K)
Thermometer
Bearing, NDE
Bearing, DE
Alternator air inlet
Alternator air outlet
Water flow indicator
Interference filter (R.I.S. degree K)
Erstellt am:
geprft von:
Revision Nr.:
Issued on:
12.10.1998
Checked by: Diegeler
Revision No.: 1
A1-12
T8
T14-16
AvK
12.10.1998
Diegeler
1
Operating Instructions
Operating instructions
Three-phase synchronous alternators, series DSG 29 ... 144
with "COSIMAT C" or "COSIMAT N" voltage regulator
Before installing and starting up this machine, please read these instructions carefully.
Machine No._____________________________
Circuit diagram No. _______________________
CONTENTS
1.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
Operating and maintenance instructions

Checking for damage incurred during transit
Transport and storage
Setting up the machine
Cooling the machine
1.4.1 Coolant temperature
1.4.2 Direction of cooling air
1.4.3 Quality of cooling air
Preparations prior to starting up
Machine drive
1.6.1 Belt drive
1.6.2 Coupling drive
1.6.3 Aligning the machine
Changing direction of rotation
Electrical connections
Starting up
1.9.1 Insulation resistance
1.9.2 Operating speed
Interference suppression
Operation
Maintenance
Bearings
1.13.1 Bearing types
1.13.2 Permanently-lubricated bearings
1.13.3 Regreasable bearings
1.13.4 Assembling the bearings
1.13.5 Dismantling the bearings
1.13.6 Monitoring the bearings
Dust filters and monitoring of thermal behaviour
1.14.1 Synthetic filter elements
1.14.2 Wire mesh filter elements
Drying out the machine
1.15.1 Drying out with integral ventilation system
1.15.2 Drying out by short-circuiting
2.
Faults, causes and remedies for DSG machines with "COSIMAT C" and "COSIMAT
N" voltage regulators
3.
Circuit diagram with voltage regulators "COSIMAT C" and "COSIMAT N

Note: detailed information on the regulator and circuit diagrams is given in the description and adjusting instructions for "COSIMAT C" and "COSIMAT N".
1. Operating and maintenance instructions

1.1 Checking for damage incurred during
transit
Immediately after receiving the machine, inspect it
for damage incurred during transit. The transport or
delivering company must be notified of possible
complaints immediately, or at the latest within seven
days of delivery (covered by warranty).
cooling air can enter and exit freely
exhaust gas and heated cooling air cannot

be drawn in by the machine.
1.4 Cooling the machine

1.4.1 Coolant temperature
The machine is normally built to run at a coolant temperature of up to 40C and at an installation height of up to 1000 meters above mean
sea level. Coolant temperatures higher than
stated on the machines data plate will result in
power loss.
1.2 Transport
During transit and storage, the machine must not
be supported on the terminal box or air entry hood,
or exposed to any sources of damage.
Store preferably at a constant temperature in a dry,
well ventilated room where the machine will be
protected against sudden impact.
At a coolant temperature of 45C, up to 96 %

of the nominal power can be drawn off; at 50C
up to 92.5 % is permissible.
If transported over long distances, it is advisable to

protect the machine against the effects of the
weather by sealing it in a plastic cover together with
a quantity of desiccant (moisture indicator), so that
it remains dust-free and air-tight.
If the machine is ordered to run at coolant temperatures of higher than 40C, this is shown on
its rating plate together with the alteration in
power rating.
1.4.2 Direction of cooling air
Machines with plain or taper roller bearings and

machines in a stored condition are supplied with
additional transit protection.
The machine is cooled by an integral fan dependent on the direction of rotation,

mounted on the shaft. It draws cooling air from
the non-drive end and expels it at the drive end.
On dual-bearing versions with deep-groove ball

bearings, the bearings are pre-loaded and are
supplied without an additional transit keeper.
If it is intended to use forced cooling on special

versions, either alone or to support the integral
fan, the direction of airflow and rotation must
be correct here too (see dimensions sheet for
data).
This transit keeper should never be removed until

the machine has been set up in its future operating
position on site.
Install the transit protection again if the machine is,
for instance, to be shipped on or stored as a separate unit after trials.
Important:
The distance between the fan inlet
or outlet on the machine and any
nearby wall must not be less than
the minimum dimension, otherwise
ventilation will be obstructed.
For transport as a complete machine set, take the

necessary safety precautions, for instance support the
machine set on anti-vibration elements or attach transit keepers.
1.3 Setting up the machine
Minimum distance (guide value):

1 x diameter of machine
The installation site must comply with the machines

enclosure rating and be sufficiently large for cooling
and maintenance purposes.
1.4.3 Quality of cooling air
When setting up the machine, make sure that:
To extend the service life of the machine, and in

particular its windings and bearings, it is ex-
the relevant operation and maintenance safety

regulations are observed
3
tremely important that neither contaminated nor

aggressive cooling air be allowed to enter it.
replaced by new ones (since they will have become too hard for re-use).
An air filter can be installed if requested by the

customer, or can be retrofitted provided sufficient
space is available.
Important:
Belts that are tensioned too tightly
can put the bearings at risk. For this
reason, establish the correct belt
tension with the belt manufacturer
or the plant that supplied the machine, and have checks carried out
on site.
1.5 Preparations for starting up

Pull the protective lacquer coating off the end of the
shaft and the flange, or remove it with solvent.
Never clean it off with emery cloth. Comply with the
relevant regulations on environmental protection
and safety.
There is a threaded hole on the shaft, to which a
puller can be attached for installing and removing
discs or couplings. Hammering is not permitted, as
this can damage the bearings.
1.6.2 Coupling drive

The machine rotor is balanced with a half
key. The grooved drive elements must therefore
be balanced accordingly.
If the machine is delivered with transit keepers in

position, remove them.
The coupling must be dynamically balanced to

an accuracy of Q 2.5 according to VDI
2060.
If the machine is of single bearing design, its rotor

is delivered attached to the shaft flange and the
housing by a steel hoop to prevent axial displacement and is located in position radially between the
shaft and fan housing by an angle bracket. The
steel hoop must be removed before assembly.
The sensitive anti-friction bearings require the

couplings, belt pulleys etc. to be tightened by
special devices. If this is not possible, heat the
parts to 80C. They can then be pushed on
easily, provided the bore corresponds to tolerance class "H". Ensure that the drive elements
are securely located after tightening. They must
be securely clamped against their mechanical
stops.
Make quite sure that the angle bracket and/or any

keepers are removed from the gap only after the
rotor has been centered on the drive shaft flange.
Failure to do so can result in damage to the exciter
machine and the B-bearing.
If the hub of the drive elements is shorter than

the shaft end, this difference must be compensated by a spacer bushing to prevent imbalance
and uneven running.
1.6 Machine drive

1.6.1 Belt drive
1.6.3 Aligning the machine
If the machine is driven by a belt, the machine must

be ordered specifically with bearings and bearing
lubrication to match the higher loads. Most belt
driven machines have roller bearings on the input
side.
Precise, careful alignment of the machine ensures that it runs with a minimum of vibration,
thus extending the service life of the machine
and in particular of the bearings. Only flexible
couplings of low radial rigidity should be used.
The rotor must be ordered with balancing by

half key, and the grooved belt pulley must be
dynamically balanced on a smooth mandrel. The
belt must run smoothly, without jerking.
Even slight errors of alignment can

rapidly result in damaged bearings.
It is vital that all the feet are fully in contact.
Uneven surfaces cause stresses in the bearings
and must be compensated for by attaching
sheet metal strips. Once the machine is aligned
correctly, secure it with dowel pins.
Desired balancing accuracy: Q 2.5 according to

German VDI 2060 standard.
When flat-type belts or V-belts which have already
been in operation for a fairly long time are removed for maintenance purposes, they must be
When aligning a machine of single bearing design

which is not flanged onto the drive motor, it is important to comply with the reference dimen-
sions specified on the dimension sheet.

This will ensure a uniform air gap beneath all poles
and the correct axial position of the rotor.
Local electricity suppliers guidelines regarding protective measures
Phase sequence or direction of rotation of

machine field as stated on rating plate.
When connecting the cable, make sure that no

mechanical forces can act on the machines
connecting terminals.
To prevent damage to the crankshaft or drive motors plain bearings, it is essential to observe the
manufacturers assembly instructions.
Unused cable sockets in the terminal box must

be protected against dust and moisture, and
closed so that they cannot turn. Take up slack at
all screw contacts and nuts.
1.7 Changing direction of rotation

The machines fan is of a directional pattern.
If current surges or vibration are to be expected,

secure the cables with cable clips or racks. If the
plant is set up on flexible mountings, ensure
adequate slack in the cables.
Note that the rotary field also changes with a reversal in the direction of rotation.
If the machine is to be used in parallel operation,
the plug connections for measuring lines U and W
on the "COSIMAT C" and "COSIMAT N" regulator
must be changed over. The rotary field will change
at the main terminals.
1.9 Starting up
1.8 Electrical connections
We recommend that the bearings be regreased

before the machine is started up.
1.9.1 Insulation resistance

After a long period out of use or in storage, the
machines insulation resistance must be measured.
The machine must be connected up according to

the accompanying circuit diagram. Installation is
permitted by a qualified electrician only.
Before starting up, measure the insulation resistance of the winding between phases (if the star
point is separate) and between phase and earth.
All parts not subjected to the measuring voltage
must be earthed.
Comply with the following points:
VDE safety regulations or those of the local

safety authorities
5
When measuring the insulation resistance, all connections (main connection, measuring connection
and protection or suppression circuit) must be disconnected from the winding. The suppression elements and measuring leads must be disconnected
during high-voltage insulation tests and tests with
insulation measuring appliances.
1.10 Interference suppression

The machines comply with radio interference
requirement "N" as stated in German VDE
0875.
Note that the standard of interference suppression is related to the quality of earthing.
Do not drop below the following specific

insulation resistance values (at 25C) on
windings that have been in operation for
lengthy periods:
1.11 Operation
During operation, current-conducting and rotating parts must be sealed with the covers provided for this purpose.
With nominal voltage < 1000 V

Insulation resistance 0.5 M/kV
Measurement must be carried out using 500 V
direct voltage or a crank indicator with a direct
voltage output. Due to the capacitive charge in the
winding, the measuring unit indicates the correct
insulation resistance value only after several seconds have elapsed.
Increased vibration may result from insufficiently

accurate alignment, poorly fitted foundations or
frame, or weak mountings.
1.12 Maintenance
Earth the winding immediately after the measuring

voltage has been switched off.
Before starting work on the machine, make sure

that it is switched off and take action to prevent
it from being switched on again. All work must
be performed by qualified staff only.
If the insulation values are too low, first check the

terminal insulation for dirt and moisture. Clean or
dry them as the case may be, and repeat the measurement. Damp windings can lead to current leakage, flash-over or breakdown.
If there is moisture or dust in the terminal box, it

must be removed above all from the surface of
the insulating parts. The reason for the accumulation of moisture or dust must then be established and rectified.
If insulation resistance on new, cleaned or

repaired windings is less than that stated
below, drying out is needed (see Item
1.15, Drying out the machine).
Brushless machines are maintenance-free apart

from their regreasable bearings and the dust
filters, if fitted.
On low-voltage machines with a nominal voltage

below <1000 V, insulation resistance should not
be less than the following values:
However, make sure that the air inlets and outlets are not obstructed during operation.
4 M at a coil temperature of 25C

1.5 M at a coil temperature of 80C
Like any other machine, the alternator should be

handled with care.
1.9.2 Operating speed

The machines speed must correspond to the value
stated on its rating plate. The machine must run
smoothly, both at no-load and when under load. If
the drive machine runs at reduced speed, the voltage regulators underspeed protection cuts in and
de-excites the machine.
1.13 Bearings
1.13.1 Type of bearings
The standard version of the alternator is fitted
with deep-groove ball bearings. High capacity
roller bearings or a combination of them. The
B-side has a fixed bearing, the A-side a floating
bearing.
Irregular running will lead to deviations from the

nominal ratings.
The machine is voltage-regulated and maintains a
voltage accurate to 1,5% for the "COSIMAT C"
and to 1% for the "COSIMAT N" in any condition
between no load and full load, even if its speed
fluctuates by 5%.
The deep-groove ball bearings are axially preloaded in relation to each other by spring elements; this ensures smoother running and reduces the negative effects of external sources of
vibration on the bearings. This does not apply to
roller bearings.
6
1.13.2 Permanently lubricated bearings
Initial greasing quantity and regreasing quantity

at each lubrication point in grams (guide values
only:)
Size 52, 62, 74, 86, 99, 114, 125 and 144 machines with relubricating devices normally bear a
plate on which the following information is stated:
Relubricating interval in hours of operation
Type or specification of anti-friction bearing

grease
1500-1800
min-1
1000-1200
min-1
750-900
min-1
52
30
3100
2500
2000
1300
62
40
2800
2200
1800
1100
74
70
2600
2000
1600
1000
86
70
40 2500
2000
1500
1000
99
80
60 2500
1500
1200
800
114 100
60 2000
1500
800
600
125 100
60 2000
1000
800
600
144 100
60 1800
900
700
500
* In the case of double bearing the amount of grease
stated in the double bearing column is to be injected into
each of the grease nipples.
1.13.3 Regreasable bearings
Re-Lubrication intervals in hours

for machine running speed of:
500-600
min-1
DSG
The expected operating life is approx. 25,000 operating hours at a machine speed of 1500 rpm.
The bearings are lubricated for life. On machines
of a single-bearing design, bearing operating life
must be expected to be 30% shorter.
Lubrication
points
Quantity in g
Double
bearing
Type
Single bearing
Size 29, 36 and 43 machines are normally fitted

with deep-groove ball bearings acc. to DIN 625,
version 2 Z, on both sides. The bearings are filled
with high grade bearing grease by the bearing
manufacturer and sealed on each side with two
cover plates.
Before regreasing, clean the nipple so

that dirt cannot enter the bearings.
Type of anti-friction bearing grease
Using a medium-sized manual grease gun (approx.

capacity 500 g), approx. 1 g of grease can be fed
in per stroke at the tapered lubrication nipple (AM 8
x 1 DIN 71427).
On delivery, the bearings are lubricated with

high-grade, lithium-soap grease of grade 3
consistency (NLGI-KL anti-friction bearings). The
grease channels between the lubricating nipple
and bearings are filled with anti-friction bearing
grease before leaving the factory.
Where possible, apply grease when the machine is

running, unless this represents a hazard for the
operating personnel.
Alternatively, the following types of lithium-soap

anti-friction bearing grease can be used:
Regreasing interval
Shell Alvania
G3
Bearings must be regreased in accordance with

the regreasing interval stated on the alternator
plate, but at least once a year.
SKF/Alfalub
LGMT 3
Esso Unirex
N3
Mobil Mobilgrease
532
Texaco (DEA)
EP 3
Relubricating quantity
A- and B-side bearings must each be regreased
with the amount of grease stated.
These greases are of grade 3 consistency and

comply with DIN 51 825.
After about three regreasing operations, remove

expelled grease.
Recommendation:
Always regrease the bearings with the same
selected brand of grease.
After about five regreasing operations, keep applying more grease until fresh grease is visible at the
outlets. Then run the machine if possible at half
speed for one hour and then at the nominal speed.
Check the temperature of the bearings and compare with those temperatures obtained before regreasing.
1.13.4 Assembling the bearings

Bearings must only be renewed by a
qualified person working in a dust-free
environment, on a clean surface and
using clean tools. The grease and bearings
7
must be kept free of impurities, otherwise they will

wear out faster and possibly even fail. The bearing
components must be arranged as shown in the
illustration (see spare part drawing). The grease
regulating disk should be rigidly attached to the
shaft.
1.14 Dust filters and monitoring of

thermal behaviour
To prevent the windings from overheating when
the filters are dirty, three temperature sensors
are installed in the stator winding. Their trip
mechanism must be installed in the switch cabinet.
When changing bearings, install type-approved

bearings only, and maintain the correct amount of
bearing play (usually "C3"). Do not remove new
bearings from their packs until just before they are
installed. Do not wash the bearings, as the anti-corrosion agent applied to them is intended to mix with
the similar agent in the anti-friction bearing grease.
Clean the old grease off the parts of the bearing
that are to be re-installed.
In addition, probes can be installed to allow the

degree of contamination at the filters to be
measured directly. Their trip mechanism must be
installed in the switch cabinet. Cleaning must be
performed at regular intervals even if the machine is protected against excessive temperatures by integral coil temperature monitoring
devices.
When fitting the bearing, heat it to about 80 100C in an oil bath, oven or by an inductive
method. Make absolutely sure that it is located centrally and remains in positive
contact with the shaft shoulder.
On machines with integral dust filters, please

note the following:
1.14.1 Synthetic filter elements
These are dry filters and must be cleaned at
regular intervals. These intervals vary depending
on the rate at which dirt accumulates. Cleaning
may be performed using compressed air, water
at temperatures up to 50C, or cleaning fluid.
Comply with the relevant environmental and
safety regulations. However, it is often more
economical to change the filter mat.
Once they have cooled down, pack the bearings

with grease.
The inner and outer bearing covers must each be
filled with grease to 2/3 of their full capacity.
1.13.5 Dismantling the bearings
During shaft production, the bearing seat and the
bearing stop shoulder on the shaft are subject to
particularly stringent quality control. This is essential
to maintain the accuracy of shape needed to keep
the bearings fully operational.
1.14.2 Wire mesh filter elements

These are wet filters and are supplied dry. Before starting up, apply a thin film of oil or "Viscinol" to the filter plates. Dirty wire mesh filters
should be cleaned using compressed air or
suitable washing agents (soda or "Purinol") and
wetted again when dry.
When dismantling the bearings and bearing rings, it

is therefore important to handle the bearings and
bearing rings with particular care, otherwise the
bearing seats on the shaft could become damaged.
Use a puller to remove. Heat the parts evenly to a
temperature of app. 80C all round.
1.15 Drying out the machine
1.13.6 Monitoring the bearings
If the insulation value between the winding and

the core or between windings is less than that
stated in Item 1.9.1, the machine needs drying.
The first indication of damaged bearings is usually

a notice-able change in running behaviour, or
noise, vibration or temperature if bearing damage
has reached an advanced stage.
1.15.1 Drying out with integral ventilation system

In many cases it can be dried suitably using its
own ventilation system, but it should not be live
while this is being carried out. On the "COSIMAT C", the plugs should be disconnected at
terminals UH1 and WH1. On the "COSIMAT N"
voltage regulator, the connections UH1-UH1
and WH1-WH1 must be opened. If no improvement in the insulation resistance is registered after a running period of app. two hours,
the alternator must be dried out by shorting.
Recommendation:
Monitor the bearings by measuring transmitted
noise and vibration at regular intervals, and compare the readings with those taken on previous
occasions.
1.15.2 Drying out by short-circuiting
on the "COSIMAT C" or at terminals I1 and

K1 on the "COSIMAT N".
a) Short the main terminals U, V and W via a

current transformer and current meter (for app.
1.2 x nominal current) while the machine is at
a standstill.
Important: connect the positive pole

to I1 and the negative pole to K1.
d) Run the alternator at its nominal speed
and adjust the short circuit current at the
rheostat to app. 1.2 x nominal current (see
performance data plate).
b) Pull off plugs at terminals I1 and K1 as well

as UH1 and WH1 on the "COSIMAT C".
Open bridges I1-I1 and K1-K1 as well as
UH1-UH1 and WH1-WH1 at the "COSIMAT
N" voltage regulator.
Continue to dry the machine until its insulation

resistance has risen to a sufficient level. We
recommend measuring at approx. 2-hour intervals.
c) Use a 12 V or 24 V battery and rheostat to

feed in exciter current at terminals I1 and K1
2. Faults, causes and remedies for DSG alternators with "COSIMAT C" or "COSIMAT N"
voltage regulator
Fault at alternator
Cause
Remedy
1.
Voltage too low.
1.1 Input speed too low.
Check whether LED H2 on regulator

lights up. If it does so, then the underspeed protection has tripped; increase
the speed until the LED goes out.
2.
Nominal voltage does not respond to adjustment at R1.
2.1 Setpoint potentiometer is defective.
Check voltage setpoint potentiometer

at terminal s/t for signs of interruption.
Rectify the interruption.
2.2 Sensing leads wrongly connected.
Examine sensing lead connections U,

and W on "COSIMAT C" or U, V and
W on "COSIMAT N". Check whether
the machines nominal voltage lies
within the rated voltage range.
3.1 Setpoint potentiometer is defective.
Examine the voltage setpoint potentiometer for a short circuit. Renew the
setpoint potentiometer. Check the
potentiometer leads for a short circuit.
Rectify the short circuit.
3.2 A sensing lead is broken.
Rectify the fault.
4.1 Input speed drops under load.
Check the regulator of the drive machine.
4.2 One of the fuses on the cooling

body is defective on the "COSIMAT N".
Check the fuse on the inside of the

cooling body; renew if necessary (10 A
super quick acting).
4.3 Rotating diodes are defective.
Check rotating diodes V1 and overvoltage conductor V3; renew if necessary.
5.1 Input speed too low. Less than

50 % of nominal speed.
Check the speed regulator of the drive

motor. Check the power transmission
to the alternator.
5.2 Remanence voltage of auxiliary

exciter is too low (less than 6 %
nominal voltage)
Briefly excite the machine by attaching

a 4.5 V battery with its positive pole at
I1 and negative pole at K1.
5.3 No voltage at auxiliary exciter

winding UH1-UH2 or WH1WH2.
Check whether windings UH1-UH2

and WH1-WH2 are interrupted in the
stator of the auxiliary exciter. Rectify
the interruption.
5.4 Fault in regulator circuit.
Check whether the external connections on terminals I1, K1 UH1 and

WH1 are in place. On the "COSIMAT
N", check the bridges also.
5.5 Fault at regulator connections.
Check input and output connections of

regulator.
3.
4.
5.
Alternator voltage too high, cannot be brought down by adjustment at R1.
Severe voltage collapse when

under load.
Alternator does not respond to

excitation.
10
Fault at alternator
Cause
Remedy
5.6 Regulator fuse has blown on

"COSIMAT N".
Check the regulator fuse on the inside

of the cooling body and renew if necessary (10 A super quick-acting).
5.7 Power stage transistor is defective.
On the "COSIMAT N", replace the

regulators power stage. On the "COSIMAT C", replace the entire regulator.
5.8 Regulator is defective.
Replace the regulator
5.9 Rotating rectifier is defective.
Check rotating diodes V1 and overvoltage conductor V3; renew if necessary.
6.
Oscillating voltage in separate

operation.
6.1 I-share too low.
Set switch S1 to a higher number, and

move R1 slightly in a clockwise direction if necessary.
7.
Alternator voltage fluctuates at

irregular intervals.
7.1 Loose contact in one regulator

input lead.
Check the leads that connect the regulator. Check the connections on the
machines terminal board. Re-tighten
nuts.
7.2 Blockage at mechanical regulator on drive machine.
Check the speed regulator on the drive

motor. Rectify the fault.
8.
Oscillating reactive output in

parallel operation.
8.1 Droop setting is too low.
Move R7 slightly in a clockwise direction.
9.
Excessively high reactive current

output in parallel operation.
8.2 I-share too low.
Set switch S1 to a higher number.
9.1 Droop setting is too low.
Move R7 slightly in a clockwise direction.
Open the bridge.

9.2 Transformer connections k/l are
incorrect, e.g. bridged by switch.
9.3 Are the secondary connections at Swap over the k/l connections, "k"
terminals k/l correct or not?
must be the white lead.
9.4 Droop transformer not installed
in phase "V".
Install droop transformer in phase "V",

check direction of rotation.
9.5 If "COSIMAT C" is installed separately, sensing leads U/W may

be wrongly positioned (U/V/W
on "COSIMAT N").
Check the sensing lead. There must be

a right-handed field on "COSIMAT
N".
10. Excessively low reactive current

output in parallel operation.
10.1 Droop setting is too high.
Move R7 slightly in an anti-clockwise

direction.
11. Active load not equally distributed.
Check the drive motor (regulator, fuel

11.1 This is affected by the drive masupply etc.).
chine only, i.e. determined by
the drive machine regulator. The
alternators regulator affects
only the reactive output and
therefore the distribution of the
reactive load (see 8., 9. and
10).
11
Please contact our Service Department if you have any problems. Our experienced specialists will be glad to help you. If possible, inform us of your findings by telefax or telephone.
Telefax: +49 (0) 841/792-195
Telephone: +49 (0) 841/792-163
12
3. Circuit diagrams
Circuit diagram for DSG 29 and 36 with "COSIMAT C" voltage regulator (No. Z 2811.001)
3.2 Circuit diagram for DSG 43 with "COSIMAT C" voltage regulator (No. Z 2811.003)
13
3.3 Circuit diagram for DSG 43...74 with "COSIMAT N" voltage regulator (No. Z 2817.001)
3.4 Circuit diagram for DSG 86...144 with "COSIMAT N" voltage regulator (No. )
14
Schutzschalter fr G3
F1
Protection switch for G3
ONLY SWITCH ON AT STANDSTILL
G1
G2
G3
Hauptmaschine
Erregermaschine
Hilfserregerwicklungen
Main machine
Exciter machine
Auxiliary exciter windings
R11
Rotierender Varistor
Rotating varistor
V1
Rotating rectifiers
X1
X2-6
Hauptklemmen
Klemmleiste
Main terminals
Terminal strip
U1
R3 Unterdrehzahlschutz
R4 Interner Sollwert
R1 P-Anteil
S1 I-Anteil
R7 Statikeinstellung
R6 Statikwandleranpassung
Sollwertpot. Generator Spannung (R = 500 )
Statikwandler
Alternator voltage regulator Cosimat N

R4 Internal voltage setting
R1 P-Part
S1 I-Part
R7 Droop adjustment
R6 Droop transformer adaption
Alternator voltage adjuster (R = 500 )
Droop transformer
ACHTUNG: Bei Regler lose: Regleranschlu

Drehrichtung rechts:
CAUTION: AVR loose supply:AVR connection

Rotation clockwise:
Leiste X2
U
Terminal X2
R1
T6
'
Regler
U
V
W
AVR
U
V
W
Drehrichtung links:
Rotation counter clockwise:
Leiste X2
W
Terminal X2
Regler
U
V
W
AVR
U
V
W
Schnellentregung:
Brcken UH1-24 und WH1-14 ffnen
Quick de-excitation:
Entregungsschalter: 220 V AC
(nicht AvK Lieferumfang) 10 A
De-excitation switch: 220 V AC

(not AvK supply) 10 A
Zubehr
Widerstandsthermometer PT100
Accessories
Resistance Thermometer PT100
A13, 14
Statorwicklung
Phase U: 1, 4, 7, 10
Phase V: 2, 5, 8,11
Phase W: 3, 6, 9, 12
Lager, B-Seite
Stator winding
Phase U: 1, 4, 7, 10
Phase V: 2, 5, 8, 11
Phase W: 3, 6, 9, 12
Bearing, NDE
Stillstandsheizung
Anti condensation heater
----
Verbindungen auerhalb des Generators
Connections outside the alternator
A1-12
15
Open bridges UH1-24 and WH1-14
Bunsenstrae 17
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250

Dreieich branch
Benzstrae 47-49
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
16
OI_DSG29_144/en-06-2004/A
Enclosure to Operating Instructions

Advise for Commissioning
Generator with vibration

absorbers on foundation
By connection of the cables it must be ensured that

no forces have an effect on the machine connection
terminals. The same counts for the time during
assembly.
The relative movements between the gen-set and

the foundation have to be compensated for by a
sufficiently long free cable length between the cable
fixing on the gen-set and the foundation.
If shock load or vibrations are to be expected, the

cables should be fixed over the cable clips and the
cable platform.
By elastic mounted gen-sets (see picture above)
sufficient 'free cable length' should be ensured to
compensate the movements of the diesel/gas motor.
In order to ensure that the movements do not have
a negative influence on the connection terminals,
the cable must be fixed with max. 300 mm distance
from the terminal box screw fitting. This cable fixing
has to be connected rigidly to the gen-set in order
to avoid relative movements between the cable
fixing and the terminal box.
AnB / e / 20-10-2003 / B
Page 2
Generator with vibration

absorbers on frame base
By connection of the cables it must be ensured that

no forces have an effect on the machine connection
terminals. The same counts for the time during
assembly.
If shock load or vibrations are to be expected, the
cables should be fixed over the cable clips and the
cable platform.
By elastic mounted gen-sets (see picture above)
sufficient 'free cable length' should be ensured to
compensate the movements of the diesel/gas motor.
AnB / e / 20-10-2003 / B
In order to ensure that the movements do not have

a negative influence on the connection terminals,
the cable must be fixed with max. 300 mm distance
from the terminal box screw fitting. This cable fixing
has to be connected rigidly to the gen-set in order
to avoid relative movements between the cable
fixing and the terminal box.
The relative movements between the gen-set and
the foundation have to be compensated for by a
sufficiently long free cable length between the cable
fixing on the gen-set and the foundation.
Page 3
Connections
Using the Protection switches Q1, F1, F2

Cable connection acc. to DIN 46200
Elastic parts, such as spring washers, can be used
in the electrical connection, however, only on one
side of the clamped conductor. If necessary,
additional washers are to be used. The other side is
for current conduction, why only washers or security
locking plates of copper-zinc-alloys must be used.
By electrical connection with eyelet rings, the eyelets
have to be protected by washers on both sides
against bending.
De- excitation
Open the bridges UH1-24 and WH1-14 on the
terminal strip X2. De-excitation with extern switch
takes place on these terminals, too.
AnB / e / 20-10-2003 / B
The purpose of these switches is to protect the

voltage transformers T24 (Q1) and the auxiliary
exciter winding (F1, F2). In case of failure, these
switches will lead to a quick de-excitation of the
machine.
These switches are not to be used for de-exciting
the machine during operation or maintenance!
Open star point
The voltage transformer T24 has to be disconnected
and the cables sufficiently insulated! De-excite the
machine as described above.
No tests are to be performed with open star point!
The correct connection of the power cables can be
checked with appropriate equipment.
Page 4
Maintenance for earthing brush
Optimum maintenance and care for earthing

brushes is the base for smallest brush wear. The
maintenance of brushes must take place after
certain intervals that depend on the alternators size
as well as load and ambient conditions.
Brushes are subject to wear and tear and must be
cleaned by air (pressure or suction) from time to
time. Routine check every 3 months is
recommended by AvK to ensure about operational
behaviour and suitable changing intervals.
AnB / e / 20-10-2003 / B
All brushes and holders must be checked for free

movement. Blocked brushes may lead to damage.
Worn out brushes must be renewed in time, so that
damages at the contact surface on the shaft can be
avoided. New earthing brushes do not need grindin (other than slip rings).
Using brushes bigger than the original size is only
possible after agreement with the supplier.
Page 5
Maintenance of Earthing Fault

Monitoring
Optimum maintenance and care of ht e brushes

and slip rings is the base for smallest wear. The
maintenance must take place in certain time
intervals. The frequency of the maintenances
depends on alternator size as well as on load and
ambient conditions.
Brushes are subject to wear and tear and must be
cleaned by air (pressure or suction) from time to
time. Routine checks every 3 months is
recommended by AvK in order to estimate the
necessary time intervals during the actual operation
conditions.
All brushes and holders must be checked for free
movement. Blocked brushes may lead to damage.
Worned out brushes must be replaced in time in
order to avoid damages on the slip rings and to
ensure the perfect function of the Earthing Fault
Monitoring. New brushes need grind-in with the
slip rings. The use of larger brushes than originally
mounted is only possible after agreement with the
supplier.
AnB / e / 20-10-2003 / B
Note:
The Earthing Fault Monitoring is mounted on the
NDE of the machine.
Attention:
Maintenance works must be performed only during
standstill of the machine.
Electrical Machines with two shaft

ends
Bearing currents by electrical machines with two
shaft ends must be avoided.
AvK recommends an insulated coupling mounted
on the NDE.
Another possibility is that all bearings of the NDE
aggregate are insulated.
Page 6
Anti - condensation heater:

The anti condensation heater is to be connected
according to correct rating and supply voltage.
Please refer to rating plate of the machine.
Control of the anti condensation heater should be
done that the heater
-
is switched on after the machine has stopped,

is switched off before starting up the machine.
Tubular heater type RHK T + H art. no.

100870 and 100872
Description
2 heaters type RHK dia. 8, 5mm x 500mm long
assembled into two brackets made of stainless steel
as per our drawing no 31522, heaters wired in
parallel by brass brackets, silicon insulated
connection cable 3000mm long.
Number of heater elements is according to required
heating power.
Technical data of the heaters
Heater sheath:
Chrome-Nickel-Steel AISI 321
Heater wire:
NiCr 8020, Mat. no.: 2.48869
Insulation material:
pure magnesium oxide, highly compacted
Connection:
threaded bolt M4 with silicon insulated cable
Tolerances
Diameter of heaters:
8,5mm 0,15mm
Straight length of
heaters:
500 2 %
Wattage per heater:
500 Watt 10 %
Total wattage (4 heaters):1000 Watt 10 %
Voltage:
230 Volt
Dielectric strength:
1250 V
Final test:
per standard
DIN EN 60 335
AnB / e / 20-10-2003 / B
Page 7
AnB / e / 20-10-2003 / B
Page 8
Bolting torque for fixing screws

If no further indications are made , use the
following bolting torque for connections of fixing
screws and fixing nuts:
M4
M5
M6
M8
M10
M12
M16
M20
M24
M30
M36
M42
screws
property class
8.8
3,0
3,5
9,0
18
45
50
110
250
440
980
1730
2700
screws
property class
4.6
1,1
2,2
3,7
9,0
18
31
75
150
255
510
890
1450
starting torque in Nm
Values according to VDI 2230 calculated
considering the maximal admissible surface
pressure under the screw head and a frictional co
efficient ges = 0,125
AnB / e / 20-10-2003 / B
Page 9
Dust filter made of metal fabric

Description
Design of the filter
The frames and the plates of the filter are fabricated
of:
Constructional steel with zinc coated mesh wire
Stainless steel with stainless steel mesh wire
alternatively
depending
on
application
conditions
Type of filter
B1
EU2
according to DIN 24185 / part 100

according to DIN 24185 / part 2
Medium degree of deposition 65 = 80 %

Maintenance
The maintenance intervals depend on the local dust
accumulation. The dust protective filter plates have
to be cleaned with the usual commercial detergents.
Cleaning with high-pressure cleaning devices is
also possible.
Caution:
Do not wet the filter plates with oil!
Observe the instructions for pollution
control.
The following detergents can be used when
cleaning mechanically:
Calgonit / Somat / Topmat 760 (or equivalent)
If only a manual cleaning is possible, use the
following detergents:
Rivonit / RG 1083 (or equivalent)
Regular checks and cleaning of the dust
protective filter system is indispensable for
the safety in operation of the electrical
machines
AnB / e / 20-10-2003 / B
Page 10
AnB / e / 20-10-2003 / B
Page 11

Bunsenstrae 17
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250
AnB / e / 20-10-2003 / B
Dreieich branch
Benzstrae 47-49
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
Page 12
Regulator Descriptions
Description and adjustment instructions

COSIMAT N+ voltage regulator
for DSG and DIG alternators
Description of COSIMAT N +
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.
Brief
2.1
2.2
2.3
2.4
3.
Functional description . . . . . . . .
3.1
Block diagram . . . . . . . . . .
3.2
Power supply . . . . . . . . . . .
3.3
Monitoring alternator voltage . . . .
3.4
Desired value . . . . . . . . . . .
3.5
Droop . . . . . . . . . . . . . .
3.6
Control amplifier . . . . . . . . .
3.7
Additional functions of the COSIMAT
3.7.1 Underspeed protection . . . . . .
3.7.2 Protection functions . . . . . . . .
3.8
Power stage . . . . . . . . . . .
4.
Transfer function of the COSIMAT N+ . . . . . . . . . . . . . . . . . . . . . . 12
5.
Special functions and additional equipment . . . . . . . . . . . . . . . . . . . . 13

5.1
Stand-by and emergency manual switchover . . . . . . . . . . . . . . . . . . . . . 13
5.2
Additional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.
Diagrams of connections . . . . . . . . . . . . . . . . . .
8.1
Assembly for DSG alternators 52 74 . . . . . . . . . . .
8.2
Assembly for DSG alternators 86 125 . . . . . . . . . . .
8.3
Assembly for DIG medium-voltage alternators with UN 11.5 kV
8.4
Assembly for DIG medium-voltage alternators with UN > 11.5 kV
8.5
De-excitation circuit on the COSIMAT N+ . . . . . . . . .
8.6
Monitoring field current and voltage on the COSIMAT N+ . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
20
21
22
23
24
25
25
9.
Connections, adjusting
9.1
Connections . . .
9.2
Adjusting elements
9.3
Displays . . . . .
10.
Start-up of the COSIMAT N+

10.1 Basic setting and visual check
10.2 Desired value setting range .
10.3 Regulating parameters . . . .
10.4 Underspeed protection . . .
10.5 Droop adjustment . . . . . .
summary . . . . . . . . . . .
General diagram . . . . . . . .
Adjusting elements and their effects
Start-up . . . . . . . . . . . .
Optimising the regulator . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
3
3
4
5
6
. . .
. . .
. . .
. . .
. . .
. . .
. . .
N+
. . .
. . .
. . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
7
7
8
8
8
9
9
10
10
10
11
displays
. . . . .
. . . . .
. . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
26
26
27
28
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
29
29
29
29
29
29
11. Important notes . . . . . . . . . . . . . . . . . . . . . . . . .

11.1 Protection concept for external mounting of regulator . . . . . .
11.2 Mounting the regulator . . . . . . . . . . . . . . . . . . . .
11.3 Excitation build-up . . . . . . . . . . . . . . . . . . . . . .
11.4 Code switch S2 . . . . . . . . . . . . . . . . . . . . . .
11.5 Droop switch . . . . . . . . . . . . . . . . . . . . . . . .
11.6 Changing the direction of rotation . . . . . . . . . . . . . . .
11.7 Synchronous motors . . . . . . . . . . . . . . . . . . . . .
11.8 Protection fuses . . . . . . . . . . . . . . . . . . . . . . .
11.9 Drying out the alternator . . . . . . . . . . . . . . . . . . .
11.10 External power supply . . . . . . . . . . . . . . . . . . . .
11.11 400 Hz alternators and converters . . . . . . . . . . . . . .
11.12 Checking the insulation voltage of the electric machine . . . . .
11.13 Exchange/replacement; COSIMAT N/N3 by COSIMAT N+
11.14 Malfunctions, causes and remedies . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
30
30
30
30
30
30
31
31
31
31
32
32
32
32
33
12.
elements and
. . . . . . . .
. . . . . . . .
. . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1. General
The COSIMAT N+ is a compact voltage regulator designed
to control synchronous alternators both in single and parallel
operation.
In single operation, the alternator voltage is held constant
irrespective of power, frequency and temperature.
When operated in parallel with the mains or with other
alternators, a stable reactive power is produced.
With the use of additional modules it is possible to intervene

in set-point and actual value formation via the COSIMAT N+
signal inputs:
There are a large number of additional modules available for
a wide variety of control applications e.g.
or
Via its power stage, the COSIMAT N+ adjusts the excitation

current to match the operating conditions.
Integrated measuring transformers for three-phase measurement of the alternator voltage up to 500 V AC
(external conductor voltage).
Stable reactive power thanks to current-voltage vector

measuring system (droop). A load-relieved current transformer is required in alternator phase V.
Internal and external alternator voltage set-point adjustment.
PID control amplifier with large adjustment range.
Disproportionate drop in desired value when alternator

operates at underfrequency.
Permanent monitoring of the actuator and time limit on

the max. possible excitation current.
Internal protection devices trip whenever a fault occurs,

thus separating the excitation field from its energy source.
Compact construction with interchangeable power

stage.
Fully potted in to protect it from environmental effects.
Long life thanks to high-quality components.
Limitation of start-up current when connecting up a large

asynchronous motor to the alternator
or
The main features of the COSIMAT N+ are:
cos phi regulation of a synchronous alternator or motor
Cable compensation via load current detection or measured value of the external alternator voltage.
Its additional modules make the "COSIMAT N+" suitable for

various applications on test rigs, in power-train technology
etc. (see 5.2 Additional modules).
2. Brief summary
2.1 General-arrangement diagram
Figure 1 General-arrangement diagram
2.2 Adjusting elements and their effects
Figure 2 Adjusting elements
2.3 Start-up
Figure 3 - Start-up
2.4 Optimisation of the regulator

To optimise regulation, it is necessary to connect loads to the
alternator.
To allow the trend of the control property following a change
in the P or I parameter to be evaluated, the load connected
must be reproducible.
The factor with the greatest general significance in achieving
an optimum regulating system is an overshoot amplitude xm
which is as small as possible. The essential criterion in the
evaluation of the regulating process with respect to time is the
settling time taus.
It is not necessary to adjust the D parameter in order to

optimise the control properties. It is generally determined just
once, in accordance with the size of the alternator. In the case
of alternators > 1 MVA, switch S2.4 is switched to the ON
position.
To decide whether the D parameter should be increased
beyond this, it is necessary to take specific measurements of
the alternator voltage and at the output of the regulator.
Satisfactory optimisation of the regulator will normally be
achieved by the free adjustment of the P and I parameters.
To follow the trend of the control property, use an oscilloscope

to monitor the manipulated variable.
The "COSIMAT N+" regulator allows free adjustment of the
P and I parameters. The D parameter can be switched over
in two stages using code switch S2.4.
Figure 4 Characteristic quantities of the regulating system
Figure 5 Trend of the control property
3. Functional description
3.1 Block diagram
Figure 6 Block diagram
3.2 Power supply
3.3 Monitoring alternator voltage
Power is supplied to the "COSIMAT N+" by means of

so-called auxiliary excitation voltages, which are produced
in the alternators. The excitation energy and the supply
voltage for the "COSIMAT N+" are derived from the auxiliary
excitation voltages.
The "COSIMAT N+" measures alternator voltages from 90 to

500 V AC (external conductor voltage) within two selectable
ranges by means of an internal three-phase measuring transformer.
In the case of AvK alternators in Series DSG and DIG with

UN 11.5 kV, the "COSIMAT N+" is supplied with power
via two single-phase auxiliary windings, which are inserted
into the main stator. The windings are designated UH1/UH2
and WH1/WH2.
The voltages UH1 and UH2 are offset by 90 with respect
to WH1 and WH2 and are 80 V AC 20 % at the nominal
voltage of the alternator.
In the case of AvK alternators belonging to Series DIG with
UN > 11.5 kV, the "COSIMAT N+" is supplied with power
via a two-phase auxiliary exciter machine. The windings are
designated UH1, UH2, UH3 and WH1, WH2.
The voltages UH1 and UH2 are offset by 90 with respect
to WH1 and WH2 and are 80 V AC 20 % at the nominal
speed of the machine.
The above-mentioned auxiliary exciter windings UH1 and
UH2 and WH1 and WH2 are plugged into the correspondingly designated terminals of the "COSIMAT N+":
To measure higher voltages, corresponding voltage transformers must be connected in series.

Signal input N allows intervention into the internal formation
of the actual value.
The secondary AC measurement voltage of the measuring
transformer is converted into a DC voltage, smoothed, conditioned and output as an actual value to the regulator circuit.
The measured value which is produced corresponds to the
arithmetic mean of the rectified three-phase AC measurement
voltage.
Three-phase measurement allows for asymmetric loads.
Note:
For non-linear loads (static thyristor converter or rectifier),
additional module TF (RC low-pass filter) is recommended
as a measuring adapter. High non-linear loads may
require overdimensioning of the alternator.
3.4 Desired value
Special application
Three-phase auxiliary exciter machine
If a three-phase auxiliary exciter machine is used, the winding
terminals are designated UH1-VH1-WH1. The external conductor voltage is 3 x 75 V AC 20 % at the nominal speed
of the machine.
Special application
External power supply
The "COSIMAT N+" can also be operated with a constant
external voltage. It is generally supplied via a three-phase
transformer (Yy 0) with a secondary voltage of 3 x 75 V AC
20 %. The nominal power should be at least 500 VA.
Caution:
If the auxiliary excitation voltage is taken
from a constant "external" power source (e.g.
the mains), the supply must be switched on
only after the alternator has been started.
When switching off the alternator, the
supply should be switched off before the
machine comes to a halt (see 11.10 External
power supply).
The desired value for the "COSIMAT N+" is taken from a

temperature-compensated reference source.
The signal input n allows intervention in the internal formation
of the desired value.
The reference voltage reaches the set-point potentiometer R 4
mounted on the front end of the "COSIMAT N+". This
potentiometer allows coarse adjustment of the alternator
voltage over a wide range (= approximate desired value).
In parallel operation of the alternator, the reference voltage
is influenced by the droop-measuring system (see 3.5 Droop)
and, in the case of underfrequency, by the underspeed
protection.
A set-point potentiometer can be connected to the "COSIMAT N+"
for external adjustment of the desired value.
This potentiometer is used for fine adjustment of the alternator
voltage (= exact desired value).
The adjustment range is limited to 5 % to 10 % around
the nominal value, depending on the potentiometer used.
The ES additional module allows the adjustment range of the
external set-point potentiometer to be extended from remanence
to the nominal voltage.
If the ES module is used on AvK alternators, the regulator

system must be provided with an external power supply. This
must be decided on a case by case basis, depending on the
application and the excitation system used (auxiliary excitation windings or auxiliary excitation machine?)
3.5 Droop
Once an alternator has been connected in parallel, voltage
regulation is no longer possible because the system voltage
is fixed. The slightest fluctuation in the system voltage would
lead to the alternator producing reactive current > IN.
To stabilise the alternator reactive current it is therefore
necessary to have a measured variable which is dependent
on the reactive current and incorporates the magnitude of the
current and the reactive power (inductive or capacitive). This
measured variable is introduced at the addition point (comparison point of the desired value and the actual value) of the
control amplifier circuit.
If, when the alternator is connected in parallel, the fixed mains

forces it down to a figure which is 6 % lower, the reactive
current is inductive and equivalent to 100 % of the nominal
alternator current.
In parallel operation, regulation of the synchronous alternator
is made possible by the droop sensing signal.
For stand-alone operation, adjustment is performed on the test
rig using a reactive load. The droop effect is set to 3 %.
The droop sensing signal in the "COSIMAT N+" influences
the desired value and is produced by means of a geometrical
addition of the external conductor voltage U-W and a
current-dependent voltage signal from the V phase.
In AvK synchronous machines, the corresponding current
transformer is located in phase V. The K side of the transformers points towards the alternators main winding (see Figure
6 Block diagram).
Internally load-relieved bushing-type transformers are used.
This produces a static droop control characteristic, which

represents the relationship between:
The outlet end of the secondary connections ( = potted end

of the transformer) is the primary-side K point (= current input).
the change in the alternator voltage in relation to the nominal

voltage and
the change in the alternator reactive current in relation to the
nominal current.
The wire marked in white is the secondary-side k point.
The droop is represented by the slope of the characteristic

curve produced i.e. is the quotient of the above ratio.
In the "COSIMAT N+" a linear droop characteristic is generated. The droop effect can be adjusted from 0 to 6 % using
the potentiometer R 7.
Example:
In the case of an inductive reactive current of 100 % of the
nominal current of the alternator and with the droop set to 6 %,
the alternator voltage is reduced by 6 %.
The secondary connections k and I of the droop current

transformer should be plugged into the correspondingly marked terminals of the "COSIMAT N+".
In the case of alternators for parallel and stand-alone operation, the measuring input k I can be short-circuited by means
of a switch for stand-alone operation. This gives better voltage
stability (see 8. Diagrams of connections, 11.5 Droop
switch).
The droop sensing system of the "COSIMAT N+" is matched
to the nominal current of the alternator by means of potentiometer R 6.
Caution:
For the droop sensing system to function
correctly, the "COSIMAT N+" requires a
clockwise rotating field at its measurement
voltage terminals. If the direction of rotation
is reversed, measuring leads U and W
should be interchanged.
3.6 Control amplifier

The control amplifier of the "COSIMAT N+" has a PID
characteristic. The parameter of the I section can be varied
in steps from 1 to F using switch S 1. During this process, the
integration time constant increases.
Figure 7 Droop characteristic
Caution:
kink point is set to 0.95 x fN. Above the kink point, voltage
regulation is constant.
Switch position 0 is not allowed; never pass

through 0.
The voltage reduction is delayed by about 2 seconds to

eliminate the effect of transient drops in the speed of the drive
machine.
The parameter of the P section can be varied by means of

potentiometer R 1. During this process, the adjustment range
shown in Figure 8 should not be exceeded.
In exceptional circumstances, the underspeed protection function can be deactivated by means of code switch S2.2 (see
9.2 Adjusting elements).
Caution:
For standard applications of the "COSIMAT N+",
the underspeed protection function must be
active and correctly set. Code switch S2.2
must be in the ON position.
The underspeed protection function is active on 50/60 Hz
alternators. For other nominal frequencies, the UF module
should be used or the alternator should be deexcited when
being shut down.
Figure 8 P adjustment range
Further adjustment in the clockwise direction leads to hunting,
while further adjustment in the anticlockwise direction leads
to control errors.
The D parameter can be changed by switching code switch
S2.4 to the ON position. This increases the effect of the D
parameter, as required by larger alternators (DIG and DSG
74 ... 125).
The D parameter can furthermore be varied at the D-Opt.
optimisation points. At the specified polarity, a capacitor can
additionally be soldered in.
When installing additional D-section capacitors, it is important
to note their polarity (electrolyte capacitor) and nominal
voltage (= 35 V DC). The maximum recommended value is
150 F.
Figure 9 Underspeed protection
3.7 Additional functions of the "COSIMAT N+"
3.7.2 Protective functions
3.7.1 Underspeed protection
While a drive machine (motor or turbine) is warming up, the
alternator is operated at underfrequency. To prevent overexcitation and thermal damage in the exciter system, the "COSIMAT N+" allows frequency-dependent reduction of the
regulators desired value or alternator voltage in accordance
with a linear function (see Figure 9 Underspeed protection).
The auxiliary exciter windings (see 3.2 Power supply) have a

very high short-circuit capacity. If the actuator is faulty, the
high short-circuit power involved may cause severe damage.
To prevent this damage, the "COSIMAT N+" has two protective functions which monitor its actuator and prevent overloading of the exciter system:
The point at which the voltage drops is defined by a corresponding frequency value set by means of R3. The reduction
for underspeed is indicated by H1. Before delivery, the U/f
10
Time limitation of the maximum excitation current

When the actuator is fully on, the excitation current
reaches a maximum.
If this state is allowed to continue, the exciter system will
be damaged.
However, the fully-on state only occurs in the case of
compensating processes or short circuits at the main
terminals of the alternator.
The monitoring system of the "COSIMAT N+" limits
maximum excitation to 8 to 10 seconds.
After this, the protection circuit isolates the exciter field
from the source of excitation energy by tripping the
protection fuses.
Checking the direction of action of the control
amplifier and the actuator
This feature monitors the positioning transistor for short
circuits.
Short-circuiting of the positioning transistor leads to maximum excitation. The control amplifier tries to counteract
this but has no effect on the faulty actuator. The actuator
and the control amplifier act in opposite directions and
the fuses trip immediately.
The following circumstances also lead to maximum excitation
and can trip the fuses:
Faulty sensor leads
Deactivated or incorrectly adjusted underspeed protection function
Short circuit in the I1 / K1 exciter lead
Faulty exciter rectifier in the "COSIMAT N+"
Extreme overloading of the alternator (short circuit) if this

has not been switched off after 8 to 10 seconds.
The protection device integrated into the "COSIMAT N+"

responds to a large number of defects and faults.
Note:
Additional module ER1 can be used to limit the excitation
current when the alternator is operated in parallel.
11
3.8 Power stage

The power stage of the "COSIMAT N+" provides an excitation current that corresponds to the output signal of the control
amplifier.
A MOSFET transistor is used as the actuator, with pulse width
modulation, i.e. the turn-on time varies but the switching
frequency remains constant.
The excitation energy is taken from the rectified supply
voltage, the rectifier circuit being located in the power stage.
It allows the rectification of two single-phase or three-phase
supply voltages (see 3.2 Power supply).
There is a short-circuit thyristor in the DC circuit. The protective
circuit of the "COSIMAT N+" switches this thyristor on if faults
occur in the control circuit. The resulting short-circuit current
trips the two protection fuses on the front plate of the "COSIMAT N+" and the exciter field is isolated from the source of
excitation energy.
Fuse:
10 A super quick-acting
32 mm x 6.3 mm
IEC G 144.400
Caution:
Replacement fuses must be of the above type.
The power stage may suffer permanent damage if the wrong type of fuse is used.
The power stage is located on a profiled heat sink. It is
plugged into the regulator and screwed into the substructure
of the "COSIMAT N+".
To ensure adequate cooling for the power semi-conductors in
the power stage, you must follow the instructions in Chapter
11.2 Mounting the regulator.
4. Transfer function of the "COSIMAT N+"
Figure 10 Equivalent control circuit diagram

There are three ways of influencing the control parameters in
the "COSIMAT N+:
The time constant of the input low-pass filter is:

TP1
Potentiometer R1 (500 k) for changing the P parameter. At

the right-hand stop, R1 is 0.
Switch S1 for changing the I parameter in 15 steps (from 0.22
to 3.85 F) each of 0.22 F (C1).
= 3.62 ms
The time constant of the output low-pass filter is:

TP2
= 0.268 x T2
Code switch S2.4 for increasing the D parameter from 10.1 F

(S2.4 = OFF) to 32.1 F (S2.4 = ON) (C2).
The individual parameters in the equivalent circuit diagram
(see Figure 10 Equivalent control circuit diagram) can be
calculated as follows:
T1
T2
T3
= R1 x C1
= 6,8 k x C2
= 22 k x C1
TI
= T1 + T2
TD
= T1 x T2
T1 + T2
K1
=2,56
K2
= 716,1 ms x K1
Tl
K3
= 1 = 0,066
15
T1 + T2
T3
12
5. Special functions and additional

equipment
5.1 Stand-by and emergency manual switchover
Where higher availability is required, there are stand-by
circuits.
Stand-by circuits contain two "COSIMAT N+" voltage regulators.
The alternator is regulated by one of these regulators (main
regulator). If this regulator is defective, it is possible to switch
to the second (stand-by) regulator.
Stand-by circuits are available in either manual or automatic
form.
Manual stand-by circuit (SB1)
In the event of a malfunction, a changeover switch permits
the stand-by regulator to be selected.
The changeover switch switches over all the signals apart
from the sensing voltage and supply connections UH2
(VH1) and WH2.
Automatic stand-by circuit (SB2)
The stand-by circuit monitors the main regulator.
Common operating variables with respect to the response
of the regulator allow fault detection and switchover to
the stand-by regulator.
The stand-by regulator operates in simulated control
mode and is likewise monitored.
The switch between the two regulators can take place
during the operation of the alternator and can be performed manually, by means of a test function or, in the case
of a malfunction, automatically.
13
5.2 Additional modules

The following list provides a summary of the various additional
modules for the "COSIMAT N+".
COS
cos phi regulator
FUNCTION: The power factor (cos phi) is held constant
irrespective of fluctuations in system voltage or load changes.
APPLICATION: Parallel operation with fluctuating mains.
Limitation of the excitation current by means of ER1 additional
module.
Figure 11 Additional module COS
QPF
Reactive power regulator with single-phase
measurement
FUNCTION: The reactive power is held constant irrespective
of fluctuations in system voltage or load changes.
QPF
APPLICATION: Parallel operation with constant reactive

power output.
Figure 12 Additional module QPF A
QPF
cos phi trimmer
FUNCTION: The power factor of the regulated alternator is
the same as that of the total current or of the currents of the
other alternators (depending on current transformer connection).
APPLICATION: Parallel operation with alternators without
linear voltage droop.
Figure 13 Additional module QPF B
QPF
Reactive power trimmer with single-phase
measurement
FUNCTION: The reactive power of the regulated alternator
is the same as that of the other alternator.
APPLICATION: Parallel operation with alternators without
linear voltage droop.
Figure 14 Additional module QPF C
14
SB2
Automatic stand-by switchover
(see 5.1 Stand-by and emergency manual switchover)
FUNCTION: Automatic switchover to the stand-by regulator
in the event of regulator faults.
APPLICATION: Requirement for higher availability and operating reliability (e.g. on ships).
Figure 15 Additional module SB2
TF/TF1
RC low-pass filter
(Type TF1-50 for 50/60 Hz)
FUNCTION: Reducing the ripple effect in the voltage sensing
signal of the "COSIMAT N+".
APPLICATION: Non-linear alternator loading by rectifier
bridges or static converters.
Figure 16 - Additional module TF1
ES
Extended adjustment range
(incl. 10 x potentiometer)
FUNCTION: External adjusting range from remanence to
nominal voltage.
APPLICATION: Various test applications in the construction
of transformers and electrical machines, run-up of large
electric motors (pump motor).
Figure 17 Additional module ES
UF
U/f characteristic module
FUNCTION: Frequency-dependent regulation of the alternator voltage in accordance with a linear function. Different
gradients can be selected.
APPLICATION: Variable-frequency operation of shaft alternators on ships. Reduces the speed dip when there is a jump in
the active load.
Figure 18 Additional module UF
15
UF3
U/f characteristic module with extension
FUNCTION: Frequency-dependent control of the alternator
voltage in accordance with freely selectable function. Operation with controlled inner field voltage down to 0 Hz.
APPLICATION: Control of the alternator voltage as a function
of any measured variable (using standardised measured-value
signal) and freely selectable characteristics. Used for driving
asynchronous winding motors and for testing transformers.
Figure 19 Additional module UF3
SR2
Current limitation
FUNCTION: Limitation of alternator current to predetermined
value.
APPLICATION: Run-up of large electric motors.
Note: No effect on the switch-on peak in the case of direct
switch-on of motors or transformers.
Figure 20 Additional module SR2
EI
External actual value detection
FUNCTION: Regulation to externally measured voltage. If the
measuring lead breaks, it switches over to voltage measurement at the alternator terminal.
APPLICATION: Providing the consumer with highly accurate
voltages over long input leads.
Figure 21 Additional module EI
UDC2
Detection of DC voltage actual value
FUNCTION: Electrically isolated measurement of a DC voltage actual value.
APPLICATION: Voltage regulation of a synchronous alternator to the rectification value of an output-side bridge-type
rectifier.
Figure 22 Additional module UDC2
16
KP
Cable compensation
FUNCTION: Raising the alternator voltage as a function of
the current.
APPLICATION: Compensation of cable voltage losses by
way of the load current, specifically when there is no possibility of access to the external measuring point.
Figure 23 Additional module KP
ER1
Controlling exciter current limiter
FUNCTION: Secondary regulation of the exciter current to a
selected over- and under-excitation value.
APPLICATION: Protects the alternator in cos phi-regulated parallel operation with a soft mains when using "COSIMAT N+" and
COS module.
When used with QPF, controlling limitation of the exciter
current cannot be used. In that case, it would be necessary
to employ contact indication in the event of the exciter current
limits being over- or undershot.
17
Figure 24 Additional module ER1
6. Technical data
GENERAL DATA
Type
Maintenance
Rated switch-on time
Installation position
Installation clearance
MEASURING CIRCUITS
Alternator voltage
Nominal voltage
Frequency
Power consumption
Droop current sensing
(Voltage input)
Voltage at IN
Power consumption
AUXILIARY CIRCUITS
Supply voltage
Power consumption
Nominal frequency
OUTPUT CIRCUITS
Actuator
Intermediate circuit voltage UZK
Continuous excitation current
Minimum field resistance RIK
Minimum required
field time constant IK
Short circuit exciter current
Protective fuse
:
:
:
:
fully potted aluminium housing incl. power stage

maintenance-free
continuous operation
mount with longitudinal axis vertical at
convectional cooling or longitudinal axis
in air flow direction at fan cooling
: 3 cm all round
(see 11.2 Mounting the regulator)
: 90 ... 250 V AC / 250 ... 500 V AC

: 50 ... 400 Hz
: 4 VA / 6 VA
3 ... 7 V AC
: 0.15 ... 0.35 W
: 2 x single-phase 80 V AC 20 %
or
1 x three-phase 75 V AC 20 %
: depending on excitation requirement
: 50 ... 1200 Hz
: 85 to 130 V DC
(dependent on the supply voltage)
: 7 ADC (continuous)
: 5 (cold)
: 0.06 s
: 20 ADC for 5 seconds
(at RIK = 5 and UZK = 100 VDC)
: 10 A-FF / 250 V 6.3 x 32
ACCURACY
Control accuracy
: 1 % at 0 to 60 C
5 % speed fluctuations and
apparent power 0 ... 100 %
TESTS
Vibration test
EMV
: German Lloyd category 2

: CE-compliant in accordance with EN50081
and EN50082
AMBIENT CONDITIONS
Storage temperature
Operating temperature
: - 40 ... + 70 C
: -25 ... + 70 C
(Special version "COSIMAT N+T"
- 55 ... + 70 C)
Height x width x depth

Fixing
Weight
: 121 x 115 x 162.5 mm

: 4 M6 bolts, washers and circlips
: 2 kg
HOUSING, DIMENSIONS,
WEIGHT AND INSTALLATION
18
7. Dimensions
Figure 25 Dimensions
19
8. Diagrams of connections
Legend for diagrams of connections
F1
Circuit breakers for G3

Operate only when stationary
G1
Main machine
G2
Exciter/excitation windings
G3
Auxiliary windings/Auxiliary exciter machine
R11/V3 Rotating varistor

T24
Voltage transformer for regulator

Must be disconnected if the star
point of G1 is open
T32
Voltage transformer for G3

with integrated circuit breaker F1
Operate F1 only when stationary!
V1
Rotating rectifier
X1
Main terminals
X2 6 Terminal strip
U1
"COSIMAT N+" voltage regulator

R4 Internal desired value
R1 P component
S1 I component
R7 Droop adjustment
R6 Droop transformer matching
R1
Desired value potentiometer alternator

voltage (R = 500)
T6
Droop transformer
20
8.1 Assembly for DSG alternators 52 - 74
Figure 26 Internal mounting, DSG alternators 52 74
Figure 27 External mounting, DSG alternators 52 74
21
8.2 Assembly for DSG alternators 86 125
Figure 28 Internal mounting, DSG alternators 86 125
Figure 29 External mounting, DSG alternators 86 125
22
8.3 Assembly for DIG medium-voltage alternators with UN 11.5 kV
Figure 30 - Internal mounting, DIG medium-voltage alternators with U N 11.5 kV
Figure 31 - External mounting, DIG medium-voltage alternators with UN 11.5 kV
23
8.4 Assembly for DIG medium-voltage alternators with UN >11.5 kV
Figure 32 - Internal mounting, DIG medium-voltage alternators with U N > 11.5 kV
Figure 33 - External mounting, DIG medium-voltage alternators with UN > 11.5 kV
24
8.5 De-excitation circuit on the "COSIMAT N+"

If a de-excitation circuit is fitted, the bridges on the double
terminals UH1/UH1 and WH1/WH1 should be removed.
Switch contacts should be connected to the double terminals
to de-excite the alternator when they open (see Figure 34
De-excitation circuit). These de-excitation contacts must meet
the following specification:
Current carrying capacity:10 AAC
Voltage carrying capacity:160 V AC
The switch elements used must have dust-protected contact
chambers. Ensure that contact resistance is low the contacts
must be sensitive to low-level signals.
Note:
One of the factors which determines the build-up of
excitation is the quality of these contacts.
On AvK alternators (DSG 86 125, DIG), connecting
terminals for de-excitation are provided in the auxiliary
terminal box (see legend of the order-specific circuit
diagram).
Figure 34 - De-excitation circuit
Figure 35 - Field current/field voltage monitoring
25
8.6 Monitoring field current and voltage on the

"COSIMAT N+"
The "COSIMAT N+" is provided with double terminals I1/I1
and K1/K1 to allow the exciter field to be connected. Bridge
I1/I1 must be removed to allow the field current and voltage
to be monitored (see Figure 35 Field current/field voltage
monitoring).
The measuring range for field voltage monitoring is 150 VDC;
for field current monitoring it is 10 ADC. Rotary coil or
moving-iron instruments are recommended. Under certain
conditions, digital instruments may give false readings.
Note:
In the case of AvK alternators (DSG 86 125, DIG),
there are connecting terminals for monitoring the field
current and voltage on terminal strip X2.
9. Connections, adjusting elements and

displays
Monitoring droop current:
9.1 Connections
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm screw

terminals
Voltage supply:
UH1
UH2 (VH1)
WH1
WH2
Caution:
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4mm screw

terminals
Supply can be 2 x single-phase (80 V AC 20 %) or
three-phase (75 V AC 20 % external conductor voltage).
2 x single-phase =
three-phase
=
kI
UH1-UH2, WH1-WH2
UH1-VH1-WH1
For de-excitation circuits, the bridges on the double

terminals must be removed (see 8.5 De-excitation circuit
or order-specific circuit diagram).
Caution:
If there is an external power supply (e.g.
from the mains), it must not be switched on
until after the alternator has run up. It
should be switched off before the machine
has come to a halt (see 11.10 External
power supply).
Measuring input k I is not a current input;

standard transformers should be load-relieved
accordingly.
The droop current transformer must be installed in the "V"

phase of the alternator.
Internally load-relieved droop current transformers are
used in AvK alternators.
At the nominal current of the alternator, a voltage of 3 to
7 V AC is required at the terminals k I (see 3.5 Droop
and 6. Technical Data).
Connecting leads to the transformer must be shielded if
the regulator is installed externally. Connecting leads to
the short-circuit droop switch (see 11.5 Droop switch)
should be shielded in all cases. The shield should be
earthed at one end on the "COSIMAT N+" (see 8.
Diagrams of connections).
Exciter field:
I1 K1
Measuring alternator voltage:

U-V-W 250 to 500 V AC
U-V-W 90 to 250 V AC
6.3 x 0.8 mm flat plugs
Caution:
A clockwise rotary field is required. If the
alternator rotates anticlockwise, U and W
should be interchanged (see 3.5 Droop).
The specified voltage ranges relate to the nominal external conductor voltage of the alternator. For higher voltages, appropriate measuring transducers with a design
rating of 10 VA should be connected on the input side
(see 3.3 Monitoring alternator voltage).
The applicable voltage range should be taken from the
order-specific circuit diagram. For DIG alternators with
UN >1 kV, the range 90 250 V AC is generally chosen.
Consult AvK before initial start-up if required.
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm screw

terminals as double terminal.
If the regulator is mounted externally, the I1/K1 field leads to
the alternator must be run through a separately shielded cable
(LSYCY or LIYCY).
The shield should be earthed at one end on the "COSIMAT N+"
(see 8. Diagrams of connections).
External set-point potentiometer
st
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm
screw terminals as double terminal.
The value of the set-point potentiometer determines the
adjustment range:
250 = about 5 %
500 = about 10 %
26
The rated power of the potentiometer must be at least 1

W. A multiple-turn potentiometer must be used (see 3.4
Desired value).
If the regulator or the set-point potentiometer is mounted
externally, the set-point lead must be provided with its
own separate shield. The shield should be earthed at one
end on the "COSIMAT N+". If the regulator is mounted
externally and the set-point leads are longer than >10 m,
a motor-actuated potentiometer should be used near to
the "COSIMAT N+".
This potential is not connected when the "COSIMAT N+"

is used for standalone operation.
9.2 Adjusting elements
Underspeed protection
R3
25-gang trim potentiometer
Function:
Adjustment of the frequency-dependent lowering of alternator voltage (see 3.7.1 Underspeed protection).
Control inputs:
N
M/m
n
Direction of action:
Left-hand stop = beginning of reduction at >50/60 Hz.
Right-hand stop = beginning of reduction only after
about > 30 Hz.
4.8 x 0.8 mm flat plugs and/or 2.5 mm2/4 mm

screw terminals.
In special cases, the underspeed protection can be

deactivated by means of switch S2.2 (see 9.2 Adjusting
elements).
A number of additional modules from the "COSIMAT N+"

equipment range can be connected to these control
inputs (see 5.2 Additional modules).
This is necessary when regulating a DC voltage by way

of additional module UDC or in some cases when using
external UF modules.
Caution:
Only AvK additional modules must be used
at the control inputs. 20 mA standard signals must not be used at these inputs.
Desired value:
R4
The inputs have the following functions:
N
M/m
n
Function:
Adjusting the alternator voltage (see 4.3 Desired value,
10.2 Desired value adjustment range).
Access to the internal actual value circuit

Reference point for additional equipment
Access to the internal desired value circuit
Left-hand stop = minimum alternator voltage
Right-hand stop = maximum alternator voltage
Circuit earth:
The circuit earth is likewise used as reference potential
for a number of controlling additional modules.
This potential is not connected when the "COSIMAT N+"
is used for stand-alone operation.
Load earth:
Caution:
Before the "COSIMAT N+" is started up, R4
must be turned to the left-hand stop position
(see 10. Starting up the "COSIMAT N+"). A
regulator which is checked and delivered
together with an alternator is already preset.
Z
The load earth is used for connecting the internal intermediate circuit capacitors.
Additional external capacitors can be connected between
the second Z connection tab (MINUS) and terminal I1
(PLUS).
27
P component:
R1
Function:
Varying the proportional component of the control characteristic.
Left-hand stop = maximum compensation value
Right-hand stop = minimum compensation value
Anticlockwise = small P component
Clockwise
= large P component
At nominal alternator current, R6 should be used to carry

out trimming to 2.5 V AC at the measuring points
MP-STATIK DROOP. If the alternator load current is
less than the nominal current, this may be trimmed to a
proportional voltage value.
The recommended adjustment range shown in Fig. 8

P adjustment range must not be exceeded (see 10.3
Regulating parameters).
Code switch:
I component:
S2
S1
4-pole dip switch

Function:
Caution:
Switch position 0 is not permitted.
Switch
FUNCTION
ON
OFF
S2.1
none
./.
./.
S2.2
Activation and
deactivation
of underspeed
protection
Active
Not
active
S2.3
Reduction of
actual value
smoothing
Nominal
Reduced
S2.4
Increasing the
D-parameter
Increased
Nominal
16-stage code switch

Function:
Varying the I component in the regulating characteristic
(see 10.3 Regulating parameters).
Left (1 <- F)
= small I component
Right (1 -> F)
= large I component
Droop:
Required basic setting:
R7
AvK DSG alternators up to size 62:

S2.1
S2.2
S2.3
S2.4
Function:
Adjustment of the droop effect.
Left-hand stop = no droop effect (0 %)
parallel operation not possible.
Right-hand stop = droop effect 6 %
no function
ON (underspeed protection)
ON (actual value smoothing)
OFF (D parameter)
AvK DIG, DSG 74 125 alternators

S2.1
S2.2
S2.3
S2.4
If the direction of rotation is reversed, sensing voltage

connections U and W must be interchanged.
Droop matching:
=
=
=
=
=
=
=
=
no function
ON (underspeed protection)
ON (actual value smoothing)
ON (D parameter)
9.3 Displays
Underspeed protection:
R6
Function:
Matching the various alternator nominal currents and
current transformer ratios to the droop monitoring system.
H1
yellow 5 mm LED
28
H 1 lights up when the desired value or lowering of alternator

voltage in the case of underfrequency is active (3.7.1 Underspeed protection)
g) Is the field connected with the correct polarity?

10.2 Desired value setting range
Caution:
The regulator is set during the testing of the
alternator at the factory. See test protocol
and order-specific circuit diagram.
Once all the basic settings and visual checks have been
carried out, the alternator can be started up.
a) Run up alternator to nominal speed.
b) Set external set-point potentiometer to the central position.
c) Adjust nominal voltage using R4.
10. Starting up the "COSIMAT N+"

10.1 Basic setting and visual check
d) The alternator voltage can be adjusted around its

nominal value using the external set-point potentiometer.
Before start-up, the following basic settings of the "COSIMAT N+"

voltage regulator must be checked:
10.3 Regulating parameters
R3
R4
R1
a) If the basic settings of R1 and S1 (see 10.1 Basic setting

and visual check) lead to continuous periodic fluctuations
(stability limit), adjust R1 slowly to the left.
S1
S2
R7
R6
right-hand stop position

left-hand stop position
central position
(in the case of DIG, DSG alternators, 1/4
rotation anticlockwise from the central position)
Pos. 4
(in the case of DIG, DSG alternators Pos. 6,
at 600/750 rpm Pos. 9)
S2.1 = no function
S2.2 = ON
S2.3 = ON
S2.4 = OFF (ON in the case of DIG and DSG
alternators from size 74)
Central position
Left-hand stop
b) If there is temporarily a tendency towards weakly

damped hunting in the event of load surges, adjust S1 one
or two positions to the right.
10.4 Underspeed protection
a) 50/60 Hz alternators to 0.95 x fN.
b) In the case of 50/60 Hz alternators, turn R3 slowly in
the anticlockwise direction starting from the right-hand stop
position until H1 lights up. Then turn it slowly in the clockwise direction until H1 goes out.
After basic setting, the following visual checks must be carried

out:
c) Run the alternator up to nominal speed.
a) Have the sensing voltage connections (U, V, W

90...250 / 250...500) been correctly selected?
10.5 Droop adjustment
b) Do the sensing voltage connections possess a clockwiserotating field? (If rotation is anticlockwise, interchange U
and W).
c) Is the supply voltage correctly connected (2 x singlephase UH1/UH2 and WH1/WH2; three-phase UH1,
VH1, WH1)?
d) Is the excess current circuit breaker in the alternator
switched on?
e) Is the droop transformer installed in the V phase?
f) Is the k I phase position of the droop current transformer
correctly connected? (In the case of external installation,
check from the alternator to the regulator).
29
a) Load the alternator with nominal current. Measure the AC

voltage at the droop sensing points MP-STATIK-DROOP.
Adjust to 2.5 V AC using potentiometer R6.
b) For partial loading, the calibration value can be reduced
proportionately.
c) If a stronger droop effect is required, R7 (percentage
droop) should be turned clockwise starting from its central
position.
Note:
Where a number of alternators are run in parallel, the
droop device must be at the same setting in all the
"COSIMAT N+" regulators and be active!
Recommended droop settings:

3%
Parallel to the mains (If the mains supply is not

stable, the setting may have to be increased).
2%
Parallel operation with identical alternators.
6%
Parallel operation with different alternators whose

regulators do not have a linear droop.
1%
Parallel operation with different alternators which

also have "COSIMAT N or N+" regulators.
to flow freely through its power stage. Note the installation

position marking UNTEN (= BOTTOM) (connecting
leads towards the power stage). At fan cooling, the longitudinal axis of the "COSIMAT N+" has to be in air flow
direction. Deviating mounting is only suitable after checking
by AvK.
There must be a 3 cm clearance all the way round between
the "COSIMAT N+" and any structural elements that might
hinder flow (cable ducts, plates). This rule does not apply to
laterally mounted additional modules.
11.3 Excitation build-up
11. Important notes

11.1 Protection concept for external mounting
of regulator
The following protective measures must be taken if the regulator is installed externally in the switching station:
The sensing line U-V-W is to be laid using short-circuit-proof
cable (1.5 mm2) from the alternator terminal strip X2 to the
switching station. AvK recommends the installation of a
three-phase circuit breaker with a thermal tripping current of
approximately 0.5 A. If this circuit breaker is tripped, the
alternator must be de-excited and stopped immediately.
If the regulator is installed externally, the connecting leads for
the external set-point potentiometer, the droop current transformer, the droop switch and the I1/K1 exciter line are to be
provided with separate shielding. The shields must be earthed
at one end on the "COSIMAT N+".
Protection concept:
The exciter system should be protected from excessive exciter
currents and voltages by a field discharge switch or relay.
This switch or relay should be connected as shown in the
relevant order-specific circuit diagram. The tripping criteria
will be determined by the protection required by the alternator.
Where the alternator is operated in stand-alone mode, an
overvoltage protection system must be installed in the switching station. In the case of operation in parallel with the
mains or other alternators, an overcurrent protection system is
to be added.
DSG/DIG alternators with auxiliary windings:
DSG and DIG alternators with auxiliary windings are fitted
with an excess-current circuit breaker F1. This protects the
auxiliary windings from excessively high thermal loading e.g.
as the result of an external short circuit involving the auxiliary
exciter voltage UH1-UH2 or WH1-WH2.
At the nominal speed, the auxiliary excitation windings on

DSG and DIG alternators must produce a remanent voltage
of at least 10 V AC in order to ensure a satisfactory excitation
build-up.
However, problems with excitation build-up may also be
caused by dirty de-excitation contacts or a field connection
of incorrect polarity.
In the case of alternators which have been stationary for a
prolonged period, it may be necessary to introduce an
external excitation voltage. To do this, a 4.5 V or 6 V battery
is briefly connected by its positive terminal to I1 and by its
negative terminal to K1 at nominal speed. In the case of
two-phase auxiliary excitation machines, the battery should
be connected to I2(POSITIVE)/K2(NEGATIVE).
11.4 Code switch S2
For standard applications of the "COSIMAT N+", the following
basic settings must be made before start-up at code switch S2
(see 9.2 Adjusting elements):
AvK DSG alternators up to size 62
S2.1
= no function
S2.2
= ON (underspeed protection)
S2.3
= ON (actual value smoothing)
S2.4
= OFF (D parameter)
AvK DIG and DSG 74 125 alternators:
S2.1
= no function
S2.2
= ON (underspeed protection)
S2.3
= ON (actual value smoothing)
S2.4
= ON (D parameter)
Any differences from these settings must be agreed with the
manufacturer beforehand and taken into account in the way
the alternator is operated.
11.5 Droop switch
11.2 Mounting the regulator

The "COSIMAT N+" must be mounted with its longitudinal
axis vertical in case of convectional cooling to allow the air
If alternators are to be used for both single and parallel

operation, better voltage stability can be achieved in single
30
operation if the k I inputs of the "COSIMAT N+" are

short-circuited (see 8. Diagrams of connections).
The lead between the droop switch and the regulator must be
screened.
it is installed in the synchronous machine and the way the

droop current transformer is connected to the "COSIMAT N+"
remains the same (see 8. Diagrams of connections).
For motor control, a cos phi controller (COS module) is
required additionally.
The screen must be earthed at one end on the "COSIMAT N+".

Caution:
In parallel operation, the switch must be
opened.
11.6 Changing the direction of rotation

To enable the droop sensing system to exercise the correct
effect, the "COSIMAT N+" requires a clockwise-rotating field
at its measuring voltage connections.
Caution:
If the direction of rotation is reversed, interchange sensing leads U and W.
Note:
The desired direction of rotation should be specified
when ordering the alternator. This is important with
regard to ventilation.
11.7 Synchronous motors
Synchronous motors operate in a similar way to synchronous
alternators in parallel operation. The direction of the active
power is rotated through 180 relative to the alternator (see
Figure 36 Operation of the synchronous machine).
Figure 36 Modes of operation of a synchronous machine

11.8 Protective fuses
When the protective fuses are tripped, they must be replaced
with fuses of the same type.
Fuse type:
10 A super quick-acting IEC G 144.400
Caution:
Starting from cos phi = 1, this has the following implications

for the reactive power:
Given a rising exciter current (overexcitation), the synchronous machine becomes a source of reactive power.
The power stage may be permanently damaged if slow or medium time-lag fuses
with a rating equal to or higher than 10 A
are used!
Given a falling exciter current (underexcitation), the synchronous machine becomes an acceptor of reactive power.
Two spare fuses are mounted on the underside of the "COSIMAT N+" (see 7. Dimensions).
When used as a generator, the synchronous machine is taken

as the reference point; where it is used as a motor, the mains
are taken as the reference point.
11.9 Drying out the alternator
When used as a generator, the synchronous machine supplies

inductive reactive power to the mains when overexcited.
If, because of inadequate insulation resistance, the alternator

has to be dried out at nominal current by the short-circuit
method, the "COSIMAT N+" should be disconnected from
the supply and exciter field connections.
When used as a motor, the synchronous machine draws

inductive reactive power from the mains when underexcited.
The droop system in the "COSIMAT N+" operates with the
correct direction of action whether the machine is being
operated as a motor or a generator. The direction in which
31
The alternator is dried out by applying an external source of

excitation.
Further information on how to dry out the alternator can be
found in the alternator instructions.
11.10 External power supply
must be connected to the correspondingly named connecting

terminal of the "COSIMAT N+".
If the auxiliary exciter voltage is taken from a different,

external source (e.g. the mains), the supply must not be
switched on until the alternator has started up.
When shutting down the alternator, the supply must be
switched off before the machine comes to a halt.
The switch-on and switch-off point of the supply should be set
to 0.95 x fN using a frequency relay (BF1).
The double terminals at connections UH1 and WH1 can be
used to switch the supply on and off (see 8.5 De-excitation
circuit).
Caution:
When the alternator is stationary and an
auxiliary exciter voltage is applied, the
exciter current flowing is at its maximum!
The protective circuit of the "COSIMAT N+"
will trip the protection fuses on the front
plate after about 8 seconds.
11.11 400 Hz alternator/converter

On 400 Hz alternators < 100 kVA (as single machines or
converters), switch S2.3 must be set to the "OFF" position.
11.12 Checking the insulation voltage of the
electric machine
Before checking the insulation voltage of the electric machine,
the following connections of the "COSIMAT N+" must be
disconnected:
Measuring voltage
Supply
Exciter field
U, V, W
UH1-UH2, WH1-WH2
I1-K1
The supply and measurement connections of additional regulator components must also be disconnected.
All disconnected or interrupted connections should be isolated
in the appropriate manner.
11.13 Exchange/replacement; "COSIMAT N/N3"
by "COSIMAT N+"
On AvK alternators of series DSG, DIDBN, DIDBH and DIG,
sizes ...74-86-99-114-125, switch S2.4 on the "COSIMAT
N+" should be switched to the ON position. Switches S2.2
and S2.3 should be switched to the ON position. Switch
S2.1 should be set to the OFF position.
The sequence of terminals WH1 and WH1 has been
reversed on the "COSIMAT N+". The connecting cable WH1
32
11.14 Malfunctions, causes and remedies

Malfunction
Cause
Remedy
Alternator voltage is too low.
Input speed too low.
Check whether LED H1 on regulator

lights up. If so, underspeed protection
device has been activated, run up alternator to nominal speed.
Measuring leads incorrectly connected.
Check measuring-lead connections U,

V, W on the regulator. Check whether
the nominal voltage of the alternator is
within the voltage range indicated on
the "COSIMAT N+".
Alternator voltage is too low and cannot be adjusted with the set-point potentiometer.
Set-point potentiometer or its connecting leads are disconnected/interrupted.
Check set-point potentiometer or its

connecting leads. Rectify fault.
Alternator voltage is too high.
Broken measuring lead.
Rectify fault.
Measuring leads incorrectly connected.
Check measuring lead connections U,

V, W on the regulator. Check whether
the nominal voltage of the alternator is
within the voltage range indicated on
the "COSIMAT N+".
Alternator voltage is too high and cannot be adjusted with the set-point potentiometer.
Set-point potentiometer or its connecting leads have a short circuit.
Check set-point potentiometer for short

circuit. Change potentiometer. Check
set-point leads for short circuits. Eliminate short circuit.
Severe voltage dip upon loading.
Input speed falls upon loading.
Check regulator of driving machine.
Defective protection fuse.
Check protection fuse on the regulator

and exchange if necessary.
Rotating diodes defective.
Check rotating diodes V1 and surge

voltage protector V3 and R11 and
exchange if necessary.
Input speed too low. Less than 0,5 x nN.
Check the speed regulator of the input

machine. Check the power transmission to the alternator.
Exciter protection switch has tripped.
Switch on the protective switch again.

If it trips once more, search for the fault
and repair it.
Alternator does not respond to excitation.
33
Malfunction
Cause
Remedy
Alternator does not respond to excitation.
Remanence too low.
Alternator with auxiliary winding:

Briefly connect positive terminal of 4.5
or 6 V battery to I1 and negative
terminal to K1 (at nominal speed).
Alternator with two-phase auxiliary
exciter machine:
Briefly connect positive terminal of 4.5
or 6 V battery to I2 and negative
terminal to K2 (at nominal speed).
DSG, DIG alternators:

Interruption in the auxiliary exciter windings.
With alternator standing still!

Check windings UH1/UH2 and
WH1/WH2 for interruptions using an
ohmmeter. Eliminate faults.
DIG alternators (UN 11,5kV):

Interruption in the auxiliary exciter
machine windings.

Check windings WH1/WH2 and
UH2/UH1/UH3 for interruptions
using an ohmmeter. Eliminate faults.
DSG, DIG alternators:

Interruption in exciter windings I1/K1.

Check windings I1/K1 for interruptions
using an ohmmeter. Eliminate faults.
DIG alternators (UN > 11.5 kV):

Interruption in exciter windings I1/K1
and/or I2/K2.

Check windings I1/K1 and I2/K2 for
interruptions using an ohmmeter. Eliminate faults.
Fault in regulator.
Check protective fuses and exchange

if necessary. Is the regulator receiving
excitation release and are the bridges
present at the double terminals I1/I1,
K1/K1, UH1/UH1 and WH1/WH1?
Check and eliminate fault.
Fault in the regulator connections.
Check all regulator connections, input

and output leads. Eliminate faults.
Regulator defective.
Exchange regulator.
Rotating diodes defective.
Check rotating diodes V1 and voltage

surge protector V3 and R11 and
exchange if necessary.
Incorrect regulator setting.
Adjust R1 carefully in the anticlockwise

direction and turn S1 one or two steps
to the right.
Periodic fluctuations in the alternator

voltage when operated singly (stability
limit)!
34
Malfunction
Cause
Remedy
Alternator voltage fluctuates at irregular

intervals.
Temporary interruption in one of the

regulator supply leads.
Check connecting leads to the regulator. Check connections at the terminal

board of the alternator. Tighten all contact screws and nuts.
Mechanical regulator of the driving

machine is sticking.
Check speed regulator of the driving

machine. Eliminate fault.
Droop set too low.
Adjust R7 slightly in the clockwise direction on the "COSIMAT N+".
Transformer connections k/I have

been bridged by the droop switch.
Open bridge.
Phase angle connection (k/I) of the

droop current transformer has been
wrongly positioned.
Check connecting leads from the alternator to the regulator. Interchange k/I
if necessary. The white secondary connection of the droop current transformer
is k.
Droop switch is not in alternator phase

V.
Install droop transformer in phase V.
Measuring voltage connections U, V,

W wrongly positioned.
Check the sensing lead. "COSIMAT

N+" requires a clockwise-rotating field.
Interchange U and W if necessary (in
the case of anticlockwise rotation).
Droop set too high.
Adjust R7 slightly in the anticlockwise

direction on the "COSIMAT N+".
Measuring voltage connections U, V,

W wrongly positioned
Check the sensing lead. "COSIMAT

N+" requires a clockwise-rotating field.
Interchange U and W if necessary (in
the case of anticlockwise rotation).
This is affected by the driving machine

only.
The "COSIMAT N+" affects only the
reactive power.
Check the drive motor and its regulator.
Reactive power output too high in parallel operation.
Reactive power output too low in parallel operation.
Active load not equally distributed.
We reserve the right to make technical changes.
35
12. List of figures
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
General arrangement diagram . . . . . . . . . . . . . . . . . .

Adjusting elements . . . . . . . . . . . . . . . . . . . . . . .
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Characteristic quantities . . . . . . . . . . . . . . . . . . . . .
Trend of the control property . . . . . . . . . . . . . . . . . . .
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . .
Droop characteristic . . . . . . . . . . . . . . . . . . . . . . .
P adjustment range . . . . . . . . . . . . . . . . . . . . . . .
Underspeed protection . . . . . . . . . . . . . . . . . . . . .
Equivalent control circuit diagram . . . . . . . . . . . . . . . . .
Additional module COS . . . . . . . . . . . . . . . . . . . . .
Additional module QPF A . . . . . . . . . . . . . . . . . . . .
Additional module QPF B . . . . . . . . . . . . . . . . . . . .
Additional module QPF C . . . . . . . . . . . . . . . . . . . .
Additional module SB2 . . . . . . . . . . . . . . . . . . . . .
Additional module TF1 . . . . . . . . . . . . . . . . . . . . .
Additional module ES . . . . . . . . . . . . . . . . . . . . . .
Additional module UF . . . . . . . . . . . . . . . . . . . . . .
Additional module UF3 . . . . . . . . . . . . . . . . . . . . .
Additional module SR2 . . . . . . . . . . . . . . . . . . . . .
Additional module EI . . . . . . . . . . . . . . . . . . . . . .
Additional module UDC2 . . . . . . . . . . . . . . . . . . . .
Additional module KP . . . . . . . . . . . . . . . . . . . . . .
Additional module ER1 . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal mounting, DSG alternators 52 74 . . . . . . . . . . . .
External mounting, DSG alternators 52 74 . . . . . . . . . . . .
Internal mounting, DSG alternators 86 125 . . . . . . . . . . .
External mounting, DSG alternators 86 125 . . . . . . . . . . .
Internal mounting, DIG medium-voltage alternators with UN 11.5 kV
External mounting, DIG medium-voltage alternators with UN 11.5 kV
Internal mounting, DIG medium-voltage alternators with UN > 11.5 kV
External mounting, DIG medium-voltage alternators with UN > 11.5 kV
De-excitation circuit . . . . . . . . . . . . . . . . . . . . . . .
Field current/field voltage monitoring . . . . . . . . . . . . . . .
Modes of operation of a synchronous machine . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. 3
. 4
. 5
. 6
. 6
. 7
. 9
. 10
. 10
. 12
. 14
. 14
. 14
. 14
. 15
. 15
. 15
. 15
. 16
. 16
. 16
. 16
. 17
. 17
. 19
. 21
. 21
. 22
. 22
. 23
. 23
. 24
. 24
. 25
. 25
. 31
36

Bunsenstrae 17
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250

Dreieich branch
Benzstrae 47-49
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
Bearings Zollern
Power transmission
Plain bearings
Installation and Operating Instructions ZF
Parts List for Flange Mounted Bearing ZF
1.1
1.2
1.3
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
5.1
5.2
5.3
10
Upper bearing housing*

Lower bearing housing*
Bearing housing retaining screws*
Sealing plug with seal* (Oil inlet for circulated oil)
Sealing plug with seal*(Temperature sensor port)
Sealing plug with seal*
(Connection for heater, sump thermometer or cooler)
Sealing plug with seal* (drain)
Sealing plug with seal* (oil fill)
Oil level sight gauge (or oil outlet for circulated oil)
Oil sight window*
Eye Bolt*
Bearing shell upper half*
Bearing shell lower half*
Anti-rotation pin*
Loose oil ring
15.1
15.2
20.1
20.2
21.1
21.2
25.1
25.2
30.1
30.2
30.3
40.1
40.2
45
Seal carrier
Seal carrier retaining screws*
Floating labyrinth seal*
Spring key for floating labyrinth seal*
Floating labyrinth seal (machine side)*
Spring key for floating labyrinth seal (machine
side)*
Bolt on baffle
Bolt on baffle retaining screws*
Machine seal
Machine seal strip
Machine seal retaining screws*
Upper bearing housing retaining screws
Lower bearing housing retaining screws
Machine shield
*These parts can only be supplied as sub-assemblies. Spares parts are listed in section 11
990225/h520
Safety Recommendations
Zollern flange bearings (type ZF) are incorporated into various types of machinery, any safety regulations specific to the
machinery must be observed.
During bearing operation, assembly, maintenance and repair, accidents and injuries must be avoided at all costs. The following
points require special attention:
During maintenance and repair ensure that rotating machinery is at a standstill, isolated from electrical supply with
interlocks such the supply cannot be resumed unintentionally.
Loads and speeds must not exceed those specified in Zollerns data sheets, drawings or calculation sheets.
Rotating parts must be fixed so that accidental movement is not possible.
BEWARE: after use bearings will be hot, there is a danger from burning during repairs and maintenance if the bearing is
not allowed to cool.
The shaft tolerances set out in our specifications and drawings may not be exceeded.
The bearing may become detached if screws are allowed to loosen. Tighten the screws to the specified torque.
Alterations to the ZF bearing may only be carried out with the express permission of Zollern, who must also be consulted in the
event of load specifications being exceeded. Our qualified team of fitters can carry out repairs and service if required avoiding
errors caused by untrained personnel.
Bearing Types and Designations
Type
Bearing for horizontal mounted shaft
Housing
Finned end flange bearing
Cooling
Natural convection
Forced oil with external cooling
Water cooler in oil sump
Lubrication
Cylindrical bore with loose oil ring
Thrust bearing
Plain white metal with oil grooves
Tapered pad for bi-directional rotation
Tapered pad for uni-directional rotation
Round tilted pads, spring supported
Without thrust bearing
Note
Insulated bearing shells are designated insulated
Example :
Finned end flange bearing with forced oil lubrication externally cooled having plain
cylindrical bore with loose oil ring. Tapered thrust pad for bi-directional rotation size 9,
shaft diameter 90mm
ZFZLK 9-90
Introduction
Please pay careful attention to all points covered by this manual to ensure the safe and efficient operation of the bearing. Care
needs to be taken to keep all bearing parts and the workplace clean. Provision is made for thermometers (1.6, 1.7), oil level
gauges (1.10), oil inlet (1.5) and outlets to be fitted to either side of the bearing. These devices can be fitted to either left or the
right as required. Where a bearing is force oil lubricated, the oil outlet pipe is fitted into the tapping for the oil level gauge (1.10).
The oil drain plug (1.8), which can also act as an oil flow connection, is positioned at the centre underneath the bearing.
With electrically insulated bearings, there is a non-conductive layer on the spherical seat of the bearing housing. This layer is
both wear-resistant and temperature-resistant. The shaft seals (see chapter 6 - shaft seals) and the anti-rotating pins (5.3) are
manufactured from non-conductive material and prevent any spark erosion of either bearing shell or. Any temperature control
instrumentation installed by the user should be insulated using appropriate measures, such as isolated protective piping and
plastic screws. Zollern can, of course, provide help as and when required.
Eyebolts are fastened to the upper part of the bearing to assist handling of the complete and assembled bearing. It is important
to remember that they are not suitable for the handling of the assembled machine and that the eyebolts are only to be used as
tension elements.
Packing
All bearings are delivered fully assembled without oil. The oil ring (10) and other accessories are packed as separate items. The
bearings are protected against corrosion and other influences by a preserving film, according to individual application.
Installation
Once the upper housing (1.1), the seal carrier (15.1), the shaft seals (20.1) and the bearing seal (5.1 and 5.2) have been
dismantled, carefully clean the interior of the bearing and the bearing shell and check for any damage caused during transport.
Ensure that the shaft is clean and that dimensions and tolerances correspond to our recommendations. We recommend that the
appearance of the bearing surface on the shaft is checked and that it is checked that non-moving seals have not become
jammed in the shaft (see chapter 6 shaft seals).
Proceed with installation as follows:
Align the cleaned lower part of the housing (1.2) with the machine frame and fasten.
Secure the machine seal (30.1) inside the machine housing (the machine seal is not supplied as standard and must
therefore be ordered separately).
Apply a film of oil to both the spherical seats in the lower part of the bearing housing and to the lower part of the bearing
shell (5.2) (use the same oil as is to be used during operation of the bearing).
Place the lower part of the bearing shell onto the shaft seat and turn it to the correct position in the lower part of the
housing. Take care that thrust bearing surfaces are not damaged whilst the shell is turned.
Align the surface of the shell with that of the housing.
Now follows assembly of the loose oil ring (10), which must first be disassembled.
Position both halves of the oil ring on the shaft and around the lower half of the shell using the notch provided, then press
both halves together on the dowel pins. Following this, tighten the fixing screws to the following torque values:
Bearing Size
09 - 14
18 - 28
Torque (Nm)
1.4
2.7
Apply a film of oil to both the shaft seat and the upper part of the bearing shell (5.1). Lower the shaft into the lower part of
the shell (5.2) and place the upper part of the shell onto the lower part (it is impossible to turn both halves of the shell
together as they would become misaligned).
Insert the flange-side seal (21.1), this is usually a floating labyrinth seal (see chapter 6: shaft seals).
Coat the surface of the split line in the lower part of the bearing housing with a thin film of non-hardening sealing
compound.
Very slowly lower the upper part of the housing (1.1), rotate it in the machine frame and position it on the flange. Ensure
that during lowering the already assembled flange-side seal slides locate into the groove provided. Avoid jamming at all
costs. The upper part must be correctly aligned (to ensure this one possibility is to pass a rod through the upper through
hole and align accordingly). Tighten the cover screws (1.3) crossways and then tighten the flange screws (40.1) to the
following torque values :
Bearing size
11
14
18
22
28
Torque (Nm)
89
89
215
420
725
1450
The cover screws (1.3) are to be tightened crossways as follows:
Bearing size
11
14
18
22
28
Torque (Nm)
71
71
172
336
580
1160
With machines that are prone to vibration, it is essential that measures be taken to prevent screws from loosening. To this end
secure with Loctite or similar thread locking compound.
Prepare the exterior floating labyrinth seal (20.1) for assembly in the same way as the flange-side seal and attach to the
shaft before fastening the seal carrier (15.1) to the housing as follows.
Coat the split lines and flange surfaces of the seal carrier with non-hardening sealing compound.
Place the seal carrier around the floating labyrinth seal, push both into the bearing housing and tighten the seal carrier
screws (15.2) to the following torque values :
Bearing Size
09 - 14
18 - 28
Torque (Nm)
10.5
26
5.1
Additional Information for Bearings with External Oil Supply
When using an external oil supply the pipe diameters should be chosen such that the inlet flow does not exceed 1.5 m/s and the
outlet flow 0.15m/s.
If the inclination of the oil outlet pipes for structural or design reasons cannot be set to 15 , pipes with correspondingly larger
diameters need to be used. Pipes with inclinations or diameters which are too small may create back-flow, which could in turn
lead to overflowing or leakage.
Heat-treated (welded or hot-worked) pipes and/or those showing any signs of rust or dirt must be scoured and cleaned prior to
assembly. Following assembly of the pipes the entire oil circulating system must be flushed to prevent dirt entering the bearing
or fittings.
Prior to cleaning all measuring and switch fittings (pressure control, flow gauge) and their connections must be removed. The
bearings must not be left intact during cleaning, and following cleaning all filters must be rinsed. All connections to the bearing
must be free of vibration and tension.
5.2
Additional Information for Bearings with Water Cooler in the Oil Sump
When attaching the water cooler care must be taken to ensure that there are no leaks from the cooler or its connecting pipes.
The joint seals must not be damaged. During fitting a stop tap or valve should be provided in the inlet. Any oil should be free to
drain from the housing (no pressure should be required). The cooling flow can be in either direction.
Shaft Seals
Zollern bearings can be supplied with various seal types or seal systems depending on the required application, with seals
conforming to DIN 40050 or IEC 529. Special seals can be supplied for particular applications on request.
6.1
Floating Labyrinth Seals
For standard applications ZF bearings are equipped with floating labyrinth seals (see fig. 2) which achieve IP44. The labyrinth
seals float on the shaft at circumferential speeds above 100 m/s. They are manufactured from a rigid, unbreakable and
temperature resistant polymer. The seals are seated within a seal carrier or directly seated in the housing such that they are not
subject to loadings due to radial shaft displacements.
Oil drain holes are provided in the lower part of the floating labyrinth seal. An anti rotation pin on the split line prevents the seal
from being assembled incorrectly and damaged.
Build the seals up prior to bearing assembly so that the hook and eye of the spring key (20.2 & 21.2) are separated.
Prepare the seal for installation and coat the surface of the split line and the exterior of the spring guide (see fig. 2) with a
thin layer of non-hardening sealing compound.
Place the lower part of the seal onto the shaft and turn it into the correct position (the oil drain holes in the seal must be
facing towards the bearing and the anti rotating pin must sit in the groove of the split line).
Place the upper part of seal onto the lower
Insert the spring key through the sealing groove and lock into place.
Check the alignment of the seal and housing split line
6.2
Floating Labyrinth Seal with Bolt on Baffle
The bolt on baffle can be combined with either a floating labyrinth seal (chapter 6.1) or a rigid seal (chapter 6.4) to achieve IP55.
The inserted seal strip is temperature resistant withstanding high circumferential speed. The coefficient of friction is minimal as
is the stick/slip coefficient. The electrical insulation properties are very good and independent of temperature and
environmental influences.
Insertion to be done as follows:

Spread the sealing compound onto the surface of the split line and coat the movement surface with the seal carrier of the
floating labyrinth seal (fig. 3)
Next gently press the lower part (recognised by the drain hole) from underneath against the shaft and tighten the fixing
bolts equally.
Finally position the upper part, align on the split line and attach with the bolts.
6.3
Floating Labyrinth Seal with Labyrinth Ring
The labyrinth is clamped onto the shaft and inserted into a groove in the seal carrier of the floating labyrinth seal (fig. 4), thus
preventing dirt and water from entering the bearing. The groove can be filled with grease where necessary.
After placing onto the shaft the labyrinth ring must be so placed that it is not possible for it to run into the groove. The thrust
movement of the shaft is limited.
6.4
The Rigid Seal
Fig. 5 shows a rigid seal with two separate labyrinth systems. Where axial movement is minimal a shaft collar can be provided
between the labyrinths.
A thin layer of sealing compound initially retains the rigid seal. During assembly the lower half of the seal is lightly pressed
onto the shaft from below and the screws then tightened (during operation the shaft is raised).
ATTENTION The baffles must be removed during assembly and disassembly of the shaft or damage to the shaft may ensue.
Commissioning
Having removed the oil sight glass (1.11) or the plug (1.9) fill to level with the recommended oil grade. The oil is at the correct
level when it reaches the middle of the oil level glass (1.10). The minimum oil level is when the oil only reaches the lower part of
the sight level glass when the machine is stationary.
WARNING
Insufficient oil level will lead to ineffective lubrication, bearing overheating and subsequent damage leading to failure. Too high a
level of oil will not hinder the operation of the bearing, but could lead to leakage at the seals. Prior to commissioning of the
bearing it must be checked for leaks. All oil port plugs and securing screws are correctly fitted and tightened.
ATTENTION
Should, at any time during commissioning or operation, the bearing temperature exceed that specified by Zollern the machine
should be stopped and the causes investigated.
Maintenance
The oil level must be checked at regular intervals with the machine at standstill. The minimum oil level is when the oil only
reaches the lower part of the sight level glass.
The bearing housing must be kept clean as heat transfer can be hindered by dirt and dust leading to bearing overheating and
subsequent damage leading to failure.
Should, during operation, there be unusual variations in bearing temperature or oil level the causes must be investigated.
Our technicians are available should any assistance be required.
8.1
Oil change intervals
For self contained and bearings using mineral oils we recommend flushing and oil change after 8000 operating hours, for forced
oil lubricated bearings we recommend an interval of 20000 hours. Longer intervals may be possible subject to Zollern approval.
Shorter intervals are necessary where there is frequent starting or where oil temperatures are high or where there is an
excessively dirty environment. To change the oil, take out the oil drain port which is positioned at the centre beneath the bearing
(allow the oil to drain whilst hot). Should unusual oil discoloration or smell be apparent the causes must be investigated. Should
any chemical cleaning compounds be used these must be thoroughly flushed away prior to further operation.
The oil is refilled through the oil sight glass (1.11) or plug (1.9). Use only the recommended oil grade as shown by the
manufacturers plate. The oil is at the correct level when it reaches the middle of the oil level glass (1.10). There is always a
possibility of overfilling - too high a level of oil will hinder the operation of the bearing.
WARNING
If regular checks are not made there is a chance of insufficient oil leading to ineffective lubrication, bearing overheating and
subsequent damage leading to failure.
8.2
Inspection
Should unusual oil colour changes or increases in temperature be apparent an inspection must be made. Remove the upper
half of the bearing housing (1.1) leaving the lower half in place. Prior to disassembly thoroughly clean the bearing casing such
that no dirt can accidentally enter the bearing itself.
8.3
Disassembly
Loosen the fixing screws to the upper half of the bearing (40.1) and the split line screws (1.3) and the screws (15.2) on the
upper half of the seal carrier.
Raise the upper half of the housing such that the bearing is split then completely remove the upper bearing housing from
the frame.
Remove the upper part of the seal carrier (15.1).
Dismantle the floating labyrinth seals (20.1 & 21.1) by raising the upper half and tilting it then open the spring key and
dismantle together with the lower half.
Carefully raise the upper half of the bearing shell (5.1). Release the loose oil ring (10) screws, separate and remove both
parts.
Remove any probes or sensors if present.
Raise the shaft far enough to give sufficient clearance to turn the lower shell (5.2) half through 180 and lift it away.
8.4
Visual Check
During disassembly check that all bearing surfaces remain in good condition. Bearing in mind the length of bearing service the
shell should show consistent polishing of the surface. Any light score marks should be smoothed prior to rebuilding of the
bearing. The shaft seals should be changed should they show excessive wear or have broken edges.
Transport and Storage
During transportation of the machine the bearings should never be subject to shock loading, and must be protected from
environmental humidity. Care must be taken to prevent dry sliding within the bearing. Storage facilities must be dry and not
subject to severe variations in temperature or humidity. In good conditions the bearings can be stored for up to one year.
10 Troubleshooting
10.1 Increased Bearing Temperature
Cause : lack of lubrication
Solution : Regularly check the oil level, inspect the bearing surface for score marks. Check that the filter does not restrict oil
flow.
10.2 Excessive scoring of the bearing shell

Cause : Dirt particles in oil
Solution : Change oil (possibly polish out scores on bearing surface). Change oil filter.
11 Ordering Spare Parts

Every bearing has a part and order number embossed onto the manufacturers plate. In order to ensure the delivery of the
correct parts please quote these numbers in all correspondence or return the part to Zollern for repair or replacement.
The following parts are supplied as sub-assemblies:
Sub-assembly
Position (fig. 1)
Bearing Shell
5.1 to 5.3
Seal carrier
Bearing housing (sizes 9-28) : 1.1 & 1.2
Loose oil ring
10
Seal Carrier
15.1
Floating labyrinth seal (machine side)
21.1 & 21.2
Floating labyrinth seal (exterior)
20.1 & 20.2
Bolt on baffle with Teflon bronze strips
25.1
Labyrinth ring
N/A
Machine seal with or without Teflon bronze strips
(30.1 & 30.2)
Zollern Vertriebs-GmbH + Co.

Werk Herbertingen
-GleitlagertechnikHeustr.1
D-88518 Herbertingen
Tel.: +49.7586.959-0
Fax: +49.7586.959-715
Zollern Vertriebs-GmbH + Co. KG

Lagertechnik
Heustrae 1
D-88518 Herbertingen
ISO
Viskositts
klasse
ISO
Viskositts
klasse
Kinematische
2
Viskositt [mm /s] [cSt]
40 C
Class of
viscosity
ISO
Schmierle fr
ZollernQPF
Z-Lager
100 C
Kinematische
2
Viskositt [mm /s] [cSt]
40 C
Kinematic
Viscosity [mm2/s] [cSt]
Class of
viscosity
ISO
40 C
100 C
VG 22
22
4,4
FLUID RSL
VG 32
32
5,5
VG 46
46
VG 68
100 C
Kinematic
TOTAL
ELF
FINA
40 C
100 C
VG 22
22
4,3
AZOLLA ZS
FLUID RSL
VG 32
32
5,4
AZOLLA ZS
6,9
FLUID RSL
VG 46
46
6,8
AZOLLA ZS
68
8,8
FLUID RSL
VG 68
68
68
8,7
8,8
AZOLLA ZS
CARTER EP
VG 100
100
11,2
FLUID RSL
VG 100
100
100
11,2
11,0
AZOLLA ZS
CARTER EP
VG 150
150
14,3
FLUID RSL
VG 150
150
15
CARTER EP
VG 220
220
18,3
FLUID RSL
VG 220
220
19
CARTER EP
AVIA
89003 Ulm
85258 Weichs / Mnchen
08451 Chrimmitschau
ISO
Viskositts
klasse
Telefon
(0731) 3999-0
(08136) 930820
(03762) 7002-0
Kinematische
Viskositt [mm2/s] [cSt]
40 C
Class of
viscosity
ISO
TOTALFINA Deutschland GmbH

Kirchfeldstrae 61
40217 Dsseldorf
Tel.: 0211 / 9057-0
ISO
Viskositts
klasse
100 C
Kinematische
Viskositt [mm2/s] [cSt]
40 C
Kinematic
Class of
viscosity
ISO
40 C
100 C
VG 22
22
4,37
Shell Morlina 22
VG 46
46
6,85
VG 68
68
VG 100
100 C
Kinematic
40 C
100 C
VG 22
21
4,2
Mobil DTE 22
Shell Morlina 46
VG 32
30
5,3
Mobil DTE Oil Light
8,85
Shell Morlina 68
VG 46
43
6,7
Mobil DTE Oil

Medium
100
11,2
Shell Morlina 100
VG 68
64
8,6
Mobil DTE Oil

Heavy Medium
VG 150
150
15
Shell Morlina 150
VG 100
84
10
Mobil DTE Oil

Heavy
VG 220
220
18,3
Shell Morlina 220
VG 150
143
14
Mobil DTE Oil

Extra Heavy
VG 460
460
30
Shell Morlina 460
VG 220
204
18
Mobil DTE Oil BB
Deutsche Shell GmbH

berseering 35
2000 Hamburg 60
Tel.: (040) 6324-0
Mobil Schmierstoff GmbH

Neuhfer Brckenstrae 127 - 152
21107 Hamburg
Tel.: 040 / 75191-109
Spare Parts
Ersatzteile: 1.2.1 poE
Spare Parts: 1.2.1 poE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Flange plate (2 parts)

Endshield DS
Air baffle DS
Stator housing
Seal Retainer
Exciter Stator
Endshield NDS
Sleeve Bearing
Cover for seal carrier
PT100 NDS
Anti Condensation Heater
PT100 DS
Brush holder for Rotor Grounding
Brusches for Rotor Grounding
Flanschblech 2-teilig
Lagerschild AS
Luftblende AS
Statorgehuse
Maschinendichtung
Erreger-Stator
Lagerschild BS
Gleitlager
Abdeckhaube Diodentrger
PT100 BS
Stillstandsheizung
PT100 AS
Brstenhalter fr Rotorerdung
Kohlen fr Rotorerdung
infoav kin@newage-avkseg.com

Bunsenstr. 17
85053 INGOLSTADT
GERMANY
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250

Dreieich branch
Benzstr. 47-49
63303 Dreieich
GERMANY
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
Ersatzteile: 2.2.1 oE
1
2
3
4
5
6
7
8
9
10
11
12
Spare Parts: 2.2.1 oE
Ventilator
Ventilatorbuchse
Passfeder fr Ventilatorbuchse
Rotor komplett
Spulenhalter
Wellensicherungsring fr Erreger-Rotor
Passfeder fr Erreger-Rotor
Erreger-Rotor
Gleichrichtertrger
Rotierender Gleichrichter
berspannungs-Ableiter
Wellensicherungsring fr Hilfserreger-RotorBuchse
infoavkin@newage-avkseg.com
Fan
Fan hub
Key for fan hub
Rotor complete
Coil holder
Circlip for Exciter Rotor
Key for Exciter Rotor
Exciter Rotor
Rectifier Carrier
Rotating Rectifier
Overvoltage Arrestor
Circlip for Aux. Exciter Rotor Bushing

Bunsenstr. 17
85053 INGOLSTADT
GERMANY
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250

Dreieich branch
Benzstr. 47-49
63303 Dreieich
GERMANY
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
Ersatzteile: 3.0 NSoW
1
2
3
4
5
6
7
8
9
10
Spare Parts: 3.0 NSoW
Klemmkasten Unterteil
Isolator
Kupferschiene U1, V1, W1
Kupferschiene Sternpunkt
Isolatorbefestigungsbolzen
Statik Wandler
Klemmenkasten Deckel
Muffe Oberteil
Abschlussplatte
Muffe Unterteil
Terminal Box lower part

Insulator
Copper Bar U1, V1, W1
Copper Bar Star Point
Insulator Fixing Bolts
Static Transformer
Terminal box cover
Bushing upper part
Endcover Plate
Bushing Lower Part

Bunsenstr. 17
85053 INGOLSTADT
GERMANY
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250

Dreieich branch
Benzstr. 47-49
63303 Dreieich
GERMANY
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
Ersatzteile: 401
Spare Parts: 401
1
2
3
4
5
6
7
8
9
10
11
Auxiliar terminal box

Serial resistor
Rectifier
Fuse for Cosimat N
Voltage regulator Cosimat N
Power factor regulator
Additional module
Aux. terminal box cover
Terminal in a row
U - bar
Gland plate
Hilfsklemmenkasten
Vorwiderstand
Gleichrichter
Sicherung fr Cosimat N
Cosinus phi Regler
Zusatzbaustein
Deckel fr Hilfsklemmenkasten
Reihenklemmen
U-Schiene
Abschlussplatte

Bunsenstr. 17
85053 INGOLSTADT
GERMANY
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250

Dreieich branch
Benzstr. 47-49
63303 Dreieich
GERMANY
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
Ersatzteile: 6.0 obi
Spare Parts: 6.0 obi
1
2
3
4
5
6
7
8
9
Copper Bar
Copper Bar
Copper Bar
Copper Bar
Over Voltage arrestor
Cable link
Rotating Rectifier
Holding device
Rectifier Carrier
Kupferschiene
Kupferschiene
Kupferschiene
Kupferschiene
berspannungsableiter
Kabelbrcke
Halterung
Gleichrichtertrger

Bunsenstr. 17
85053 INGOLSTADT
GERMANY
Phone: +49(0)841-792-0
Fax: +49(0)841-792-250

Dreieich branch
Benzstr. 47-49
63303 Dreieich
GERMANY
Phone: +49(0)6103-5039-0
Fax: +49(0)6103-5039-40
Technical Data
Technische Daten / technical data

Nenndaten / nominal data
Leistung SN:
1499 kVA
cos :
rating power
p.f.
Spannung U N:
DSG
L1-10
0,80
Strom IN:
450 V
voltage
99
1923 A
current
Frequenz f:
60 /s
10 polig
frequency
poles
Drehzahl n:
720 /min
speed
Reaktanzen und Zeitkonstanten / reactances and time constants

xd:
xq:
1,95 p.u.
0,98 p.u.
Td0':
1,86 s
xd':
0,285 p.u.
xq':
0,98 p.u.
Td':
0,27 s
xd'':
0,198 p.u.
xq'':
0,218 p.u.
Td'':
0,017 s
x2:
0,208 p.u.
x0:
0,059 p.u.
T a:
0,045 s
Wirkungsgrad / efficiency
1/4*PN
2/4*PN
3/4*PN
4/4*PN
[%] p.f.=0.8
93,60
95,30
95,40
95,40
[%] p.f.=0.9
93,80
95,85
96,10
96,10
[%] p.f.=1.0
94,00
96,40
96,80
96,80
Kurzschludaten / short circuit data

p.u.
Ik'':
9713 A
iS:
24722 A
Ik:
5770 A
Mk2:
Anfangskurzschluwechselstrom (3~) / initial short circuit current ( 3~)
5,05
Stokurzschlustrom (3~) / max. peak current (3~)
12,85
Dauerkurzschlustrom (3~) / sustained short circuit current (3~)
3,00
130,5 kNm
Stokurzschlumoment (2~) / initial short circuit torque (2~)
6,56
Mf:
280,6 kNm
Max.Fehlsynchronisationsmoment / max. faulty synchron.torque
MSN:
19,88 kNm
Nennscheinmoment / rated kVA torque=
1,00
MN:
dU':
dSmax.<=
15,91 kNm
-22,2 %
789 kVA
Nennmoment / rated torque
0,80
14,11
Transienter Spannungseinbruch bei Nennlaststo / TVD at rated load application

Max. Laststo bei p.f.0.2 mit dU'<=15% / Max. load application at p.f.0.2 for TVD<=15%
Sonstige Daten / other data

2
204 kgm
Trgheitmoment J:
moment of inertia
3
2,0 m /s
Khlluftmenge Q L:
cooling air volume
Schutzart:
enclosure
Gewicht m:
6700 kg*
weight
Khlmitteltemp.:
45 C
cooling medium temp
IP23
with air inlet filter
Isolationsklasse:
insulation class
Bemerkungen / remarks
AvK. No. 81 27280-81-82 A002
Temperature rise according to F
Voltage/Frequency range according to EN60034-1,zone A
Classification GL, 45C
Solas Ch.II-2
03.05.05
*exact values see valid drawing
Identical to AvK No. 81 26493/94/95/96 A002

Identical to AvK. No. 81 26106/107 A002
Ga
Alle Angaben sind gem VDE 0530, IEC600 34
All data are in accordance to VDE 0530, IEC600 34
Type:
Technische Daten selbstregelnden Drehstrom-Synchrongenerator

1.1
Rev.
0
technical data for self regulating three phase alternator
Projekt:
AvK-Order:
Cegielski
81 27280-81-82 A002
DSG 99 L1-10
Leistungsdiagramm / Capability diagramm

1
0,9
active power P (p.u.)
0,8
0,7
0,6
0,5
0,4
0,3
0,2
0,1
leading
Wirkleistung
AvK
Deutschland GmbH & Co.KG
Bunsenstr.17 85053 Ingolstadt
Cos phi 0,95
reactive power Q (p.u.)

Cos phi 0,9
cos phi 0,8
1,20
1,10
1,00
0,90
0,80
0,70
0,60
0,50
0,40
0,30
0,20
0,10
-0,1
0,00
-0,10
-0,20
-0,30
-0,40
-0,50
-0,60
-0,70
-0,80
lagging
cos phi 0,6
Datum / date :
cos phi 0,4
cos phi 0,2
Kontrolle TBR / controll TBR :

03.05.05
Gamo
2.1

Type:
DSG 99 L1-10
Projekt:
Cegielski
AvK-Order:
Rev. 0
81 27280-81-82 A002
Inversstrom / negative sequence current I2/IN = f(t)

1,5
1,4
1,3
I22 t = 20 p.u.
1,2
1,1
I2 / IN [p.u.]
1
0,9
0,8
0,7
0,6
0,5
0,4
0,3
0,2
I2 () = 0.08 p.u.
0,1
0
100
101
102
103
104
105
106
t [s]
Bemessungsdaten:
Type rating for this application and requirements:
SN/kVA
1499
Kriterien fr Inversstrom:
IN/A
1923
Criterias for negative sequence current:
UN/V
450
fN/Hz
60
Kurzzeitbetrieb
Transient operation:
Dauerbetrieb
Continuous operation:
nN/rpm
power factor
720
0,80
Protection
IP23
cooling air C
temp.rise
(I2/IN)2*t <=20s
I2/IN <= 0,08 p.u.
45
F
AvK
Datum / date :
03.05.05

Gamo

Type:
DSG 99 L1-10
Projekt:
AvK-Order:
Cegielski
3.1
Rev. 0
81 27280-81-82 A002
berlastbarkeit / overload capability I/IN = f(t)

5
4,5
4
I / IN
3,5
3
2,5
2
1,5
1 0
10
5s
SN/kVA
1499
IN/A
1923
UN/V
450
fN/Hz
nN/rpm
720
power factor
0,80
Protection
IP23
101
30 s
102
103
t [s]
45
temp.rise
AvK
Bunsenstr 17 85053 Ingolstadt
104
Strom/Zeit Kriterien:
Current/time characteristics:
2
(I/IN) *t =45s
1,5*IN fr 30s
1,1*IN fr 1 h in 6 h
60
cooling air C
60 min
Datum / date :
03.05.05

Gamo

Type:
Projekt:
DSG 99 L1-10
Cegielski
AvK-Order:
4.1
Rev. 0
81 27280-81-82 A002
Short circuit decrement curve ( symmetrical short circuit current envelope Ik`` )
12
10
Ik``/IN [ p.u.]
0
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
t [s]
Bemessungsdaten:
Short circuit decrement curve without AVR
Type rating for this application and requirements:
and with AVR (min. value at 3phase short circuit =300% In for max.5s)
SN/kVA
1499
IN/A
1923
UN/V
450
fN/Hz
60
nN/rpm
720
power factor
0,80
Protection
IP23
cooling air C
45
temp.rise
AvK
Datum / date :
03.05.05

Gamo

8127280a002 GB

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

8127280a002 GB

Uploaded by

Copyright:

Available Formats

Contents

General Notes and Instructions

General Notes and Instructions

Read this advice as well as

additional parts can be found in the

Besides these safety notes all local valid

Warning! Life in danger!

This sign is mounted when the installation

case the installation manual for the

Unprotected machine parts

Spare Parts are inside

It is not permitted to operate

2.2 Safety Devices

Maintenance should normally

After completion of the maintenance work,

They are only used as mounting device

The ring bolts can only be used for the

For transporting the machine, the

Cable and chains,

3.1 Safety precautions for transport

The shipment and the unloading of the

The lifting devices have to be designed

Follow the shipping instructions

The generator must only be supported

For the lifting of the generator, ring

It is not permitted to use

Moving the machine over rough

Ring bolts, that are mounted

The material used for the packing of the

If there are damages on the goods (open

AvK Deutschland GmbH & Co. KG

AvK Deutschland GmbH & Co. KG

AvK Deutschland GmbH & Co. KG / Service

AvK Checklist to Order No.

Bearing inspection performed:

AvK Deutschland GmbH & Co. KG / Service

AvK Checklist to Order No.

none, very little

AvK Deutschland GmbH & Co. KG / Service

light layer dirt

AvK Checklist to Order No.

Examination of cable entry and cable shoes

Examination of strain relief of connecting power cables

Check of fixation of transformers installed

Examination of cable entry and cable shoes

Check of strain relief of connection cables

Insulation test of stator windings

Stator winding phase U against ground

Stator winding phase V against ground

Stator winding phase W against ground

Insulation test of stator windings

Stator winding phase U against phase V

Stator winding phase U against phase W

Stator winding phase W against phase V

Resistance measurement of stator

AvK Deutschland GmbH & Co. KG / Service

AvK Checklist to Order No.

Check and re-tightening of all screws and nuts

Cleaning and examination of insulators for cracks

Re-tightening of contact screws and nuts on

Resistance measurement of auxiliary windings

Insulation test of auxiliary windings

Examination of anti-condensation heater