View of generator N side

JV' ' :^y:;v,,;,A<f?'i?^; :gvr V f - : '

> , .;-.

'rr-it ^;^ r?^?S^|^*si^;^fey;^^^^'f.'**f.^V.

Description of view

5 Rotating rectifier 9.2 Regulator potentiometer

6 Choke coil 10 Antinoise capacitor
6.1 Choke coil terminal strip 11 Static current transformer
7 Current transformers T Terminal, strips Tl, T2,...
7.1 Current transformers terminal strip R Terminal strips Rl, R2,...
8 Stationary rectifier r31 Settling resistor
? Voltage regulator si Voltage surge protector
 Description ._^ . ,
1 Description
1.1 Design
The generators consist of
one inner-pole main machine with salient or non-salient pole rotor
one extemal-pole exciter with rotating rectifiers for transmission of the exciting power and
one exciter device with electronic voltage regulator.
Generator, exciter and all other components required for excitation and regulation are designed to form one compact
unit. The casing consists of the stator, the end shields and a hood to serve as a cover for the exciter uniton the N side.
In the standard design, the terminal box is at the top and can be turned by 180 . Both terminal box and casing have
specially designated earth connection points. The generators are made to comply with the regulations set in DIN EN
60034 / VDE 0530, all applicable IEC recommendations and order-specific customized classifications.
1.2 Storage
The system is equipped with spring-loaded deep groove ball bearings, cylindrical roller bearings or plain bearings as
defined in the order. In case of increased loads on the bearings, a cylindrical roller bearing is installed on the D side
while a deep groove ball bearinjg is on the N sid^to serve as counter bearing^ or, if necessary,^ double.bearing made up^
of a'^dylmclricaf rotief beara^ ahH" groove roUer beaaiiig iM&clunes iii veitirai design have an angular contact
ball bearing to serve as counter bearing All bearings are dust-proot are permanently lubricated up to shaft center
height 315 mm and are provided with relubrication devices with grease quantity regulation on both the D and the N
side as from, shaft center height:
ight 400. tnm. Relubricatipn. device Jar shaft .center height 315 imn .-are subject tgspecial

NOTE.,.. , ,..; S^:thrappndix.for.beaiin&.configu^ FQtrnamteiianceiBsitructins;see.section 6.2.

..' 1^3; C o o l i n g ^ ^ s y s t e m ' - ' ' - ^ - - - :'..%.. .-:.;: v :-^o-- --.-,...; . v - ; . : : . v - - . - v . ; . ' .^...-. -.,. ...-. ,-
The.machifli^feself-venStked'^thtiieirirutbiiig'^ : " ' '" V

NOTE Observe section 4.4 "Direction of rotation"!

Generators with higher protection systems (> IP23) are equipped withfiltersor pipe connection on their D and N sides
,,.(selfTy^tilgtioR;in.3C(icdaecewitihiIG34iOt3tf^
to-air iype heat exchangers (IC 81W7 or IC 81 AT).
1:4 Exciter unit

The exciter unit consists of the following assembly groups (see ^jpended circuit diagram):
' choke [6]
' current transformer [7]
stationary rectifier stack [8] with settling resistor r31
electronic voltage regulator [9]
All imits are installed on a panel on the N side end shield. Exciter unit and rotating rectifier stack can be accessed l^
taking off the hood and opening the clamps (for instructions on how to take off the hood see section 6.2 "Maintenance ,
instructions").
Working principle
Theremanentvoltage produced in the stator windiog [1] of the generator causes a small current to flow through the
stator winding [4] of the exciter via choke [6] and rectifier stadc [8] thus setting off self-excitation.
The choke [6] limits the exciter current of the exciter. The exact value depends on the air gap between core and yoke
of the chdce. The required air gap is adjusted by adding insulating material. The load current flows through the
current transformer [Tj. When load is put on the generator, the secondary current of the current transformer [7] is
added to the choke current After rectification in the stationary rectifier stadc [8] - a six-pulse bridge circuit - , this
alternating exciter currentflowsto the stator winding [4] of the exciter. In order to protect the diodes against voltage
surges, both the stationary rectifier stack [8] and the rotattug recitifier stadc [5] are equipped with varistors [si], [s2].
Choke current and secondary current of the current transformer are adjusted such as to permanently maintain a
generator voltage of ^jprox. 10 % above the nominal generator voltage while the generator rotates at its nominal
speed and the voltageregulatoris disconnected.
Every lime the nominal generator voltage is exceeded, the voltage r^ulator [9] periodically switches on. settling
resistor r31 that is located in parallel to the stator winding of the exdter [4]. This ensures that the teminal voltage of
the generator is kept at the value set by the set-point adjuster '^r'':(:::..'y^-y-'--r:.--r::-;rn,,-:^-^ ^.y. ^; v v; :J:t: i: :
(NOTE The chosen t^^pings of the winding to choke and current transformer have been optimally adjusted
to the generator in the manufacturer's test shop. You should therefore always contact the
manufacturer prior to making any changes.
 r^T^T^-^r^i^S^^

Description
1.5 Voltage regulator
Design
The voltage regulator is located in a sealed casing protected against dust and dirt. The casings contains the
potentiometers for setting the various regulator functions.
The potentiometers are equipped with a self-locking multi-speed mandrel drive that is secured against overspeed by a
sliding clutch. The setting range is approximately 10 revolutions.
The following regulator types are used

R 10-K Standard type providing voltage regulation and staticization for parallel operation. Designed with
smoothing c^jacitor CK and varistor s2.
R 10-KC In addition to the R 10 K fimctions, this type provides a cos cp - regulation part. It can 6e used either as a
staticizing regulator or as a cos cp - regulator.
R 10-KF In addition to the R 10 K functions, this type provides a cascading, frequency-dependent voltage
regulation.

> V. -..-NOTE '' *" ^ ^egulator-type^'lO offers the-same-functions'as typeR-lO-K bufhas no-capaeitOTCK-of-vaistor si;-^
It can be replaced without exception by the other type; leave terminal 12 unoccupied in this case.
All R 10 series regulators have the same dimensions.

'" ;-TThe'vpIt^erelatorisconnctaviaspiii^-ioa^ 1 Jhll%etenfclietf-viifihgldig^

*' NTE' ".'For geetatt vbltafeSs hgher 500 V, the idter iS<nn^ Stator ydhdin'gk'"-:?
..: apptox.AO.y.. . . , . ^ .-. ; ' . : . , ' :.^. ;. :..

.,-..->..-, ^i-ArV^-ciiVr-^^--

350-490 V at 60Hz ISO r 290 V at 60 Hz

. cable 5 cable 5
!-.:.:;. .v'.'*''/)V* .-."- .,.:> JA-^ -. - V . ;. , ^ - - '^y. - : ^"* -^=*.'^-.*>-. .>;-/..>.-/,

U IV V
bl br bl br
RI R2 R1 ]EG
*?;i.'<t"K j'*>* :rdi\::^v^-r^'^^r:,--i<:^;^?iii^^;*iA::\-}:^
regulator y^ bl - bhie re'golajor
br - bro^Mi

Figure 1: Connectors for measuring and voltage siqiply

NOTE Use a cunent transformer in phase W for current registiation. Only some of thepaiallel winding
branches of the Stator winding are put through the converter. ' ..--,..
(observe v4en disassembling the exciter)

a) rotating right b) rotating left c) single operation

without staticization
cable? cable?
k I k put in
br bl br jumper
wm
regulator r^julator

Figure 2: Connectors for static transformer

For all other connectors see the enclosed wiring diagram.

 Behaviour during operation and notes on use
2 Behaviour during operation and notes on use

Danger!
Observe during all setting and other work to be carried out on exciter and regulator that all
components carry mains potential. Only trained specialized stafT are allowed to change settings
using a suitable tool.
2.1 Excitation, de-energizing
Excitation
Self-excitation is provided by the remanent voltage.
If self-excitation of the generator does not work, excitation can be induced by briefly ^jplying an external voltage
(6 or 12 V battery) to terminals K3 (battery plus), K4 (battery minus) in the terminal box of the generator (Figure 3).

6-12V

^ . " < ^ ' - * .

[l-\t 250 y . . .
* \ ***.-...*,.'- V - ^ V . - -

10 A

i-i-::^-y,'S-:'^. T^: -KLM' t^, \K6^-y 'ti\ J4: # M^v^- ^i- V. :--C'-'f- J^-i '.- :A:!' .~V->-

;../, ; - : . " . . : ' e x q t a t i a n ''"'.%'' ' . . X ' ' ' ' :^" . d e - e o e r g i r i n ' g - . - " ' :::'--;' '; .,' '.;'" ".'" "'''^'"'~ ''' "-.'-.-v

\- ..Vt-'..'.,--."..;*:' -".>r-*- f-"<:i^' <'.\'"*>:y ^' ''V;-.--.jC,..'fcJ-.t,*-,*^;".' >' .-i! ' ..* ./-...^-w _.>_.'.,-.*.; /-i."'*. -r." r^*.i'.^A*vi>>' .'.i^-/.*. "> .-.,.T*-5^.'#

Danger! .
Measure the generator voltage during the excitation process. Remove the external voltage
source immediately, when the generator voltage rises. Danger of inverse voltage!
De-energizing .
Use a contactor or suitable switch to produce a jshort-circuit between terminals K3 and K4.
;CrBntlfi9d op^;C!!Wll^'?te'^< 1^^ Vo^V'^;::^V-T.r?^vv..^^;;';^^'^^^^^^^

Danger!
After de-energizing and while the drive is running, there is a residual voltage of up to 10 % of
the mains voltage on the generator terminals.

2.2 Setting range for voltages, set-point adjuster

rUse the "Voltage" potentiometer of .the;r%ulator to set the terminal voltage in a range of ^pprox. 10 % of the
nominal value. You may connect an external set-point a<$uster to terminals Kl and K2 in the terminal box of the
generator (rotary resistor 2.5-5 kii, load limit Bpptox, 1 W, test voltage > 2000 V). On the regulator, put jumper R7 -
R8 to R6 - R7. Use the external set-point a^uster to set the terminal voltage in a range of^^rox. 5 % of the
nominal value.

put b jumper R6 - R7

igiiUtarRl-K

potentiametcr

ft, A
stabiEty
statictzatkm
Figure 4: Connectors for external set-point adjuster
 Behaviour during operation and notes on use
Manual synchronization
Use the set-point adjuster to set the generator voltage to the mains voltage. After setting smallest frequency and phase
differences possible by means of a synchronoscope, the generator can be switched on. To avoid the occurrence of
inverse power after switching on the generator, the generator frequency should be about 0.2 Hz above the mains
frequency.
Quick synchronization
Use an electronic synchronization device to automatically adjust the system to smallest possible voltage, frequency and
phase differences that also takes switching delay times in the zero crossover range of the difference voltage into
account for switching on.
2.8.4 Parallel operation with statics
ATTENTION ! Check whether the jumper between terminals R4 and R5 of the regulator have been removed.
Depending on current and power fector, the generator voltage characteristics have a decline. The voltage drop can be
set by the "Statics" potentiometer on the regulator (Figure 4). The voltage drop is increased by turning the regulator
clockwise. In the factory, the statics is set to approx. 2 % (in relation to idle voltage) at nominal current and a power
J ^ o r of c o s ^ j^O.3.. Constgpt yo^tage dunwgjRrdlgl^<?pera^
static characteristics are nearly the same, the reactive power (in relation to the nominal power of ithe corresponding
generator) is distributed proportionally.
ATTENTION ! Make sure to do generator adjustment before starting operation. . .
;:i C*eckwh|thraU drives have.thes^ .>>.:

. v-i. . , : / Use the set-point adjuster.to.adjustthe.idle;VItg^^^^ , . . - . . . . . > . . . '.-. ^

Put noniinai load at nominal power facloit* on the generators in single operation if possible and

If you feid iai'ger'cffiferences, the s ^ d i ;restors must-be r e ^ u e d . tatics^^ues f.2 - .3 % at njnuul load and .
nomi'hl power fert6r"re"^iiffident for stable ^ j ^ ^ just usingnon- '
inductive load as this renders the statics inefBcient.
NOTE Proceed as follows to make a supplementary test if only non-inductive load operation is possible
- A v h < m h i M l g i B g . t ^ H ^ n g V t - . .V--V .-- -J - a---- :^^>.- \-. l:;- . .Pi:,,-.-;'.:.v^.;-.-..;;.^->.i-:-.''-'-:-c.>;.>.w.,!i<.^

1. Connect the blue cable from phase U to W and the brown cable from phase V to phase U
of cable 5 on the choke terminal strip [6.1].

3. The voltage drop corresponds to statics setting at cos 9 = 0.8 and normal switching conditions.
J
4. Reconnect all devices after the setiq) procedure.

cable 5 cabteS

bin bl ?-
l - p l \ dioke terminal / W U
strip [6.1]

choke [6]
o 00 0 6 60 6
normal switching conditions circuit for non-inductive k>ad

Figure 5: Terminal connection for statics setting at non-inductive load

ATTENTION! Only specialized staff must do these steps.

2.8.5 Parallel operation with compensating line

Generators with the same exciter voltage can work in parallel if there is a compensating line CFigure 6). -. ~
NOTE Put injuny)erR4-R5 on the voltage regulator. . j - . _.; :..^.iv;.
Compensation for statics resistors is not required. The compensating line is connected to terminals K3 and K4 in the
terminal box (make sure to connect only terminals of the same polarity). The max. compensating current is 2 A.
Provide auxiliary contacts on the generator power on/off switch to ensure that the compensating line is only active
during parallel operation. TJnder proportional non-inductive load distribution conditions, the compensating line
ensures an almost automatically proportional reactive load distribution. : ; ^:^.:: y - i :; ^":c-''^r''.::/\\::,,f':y'^<':

11
 Troubleshooting
9.2 Voltage problems
If the generator produces no voltage or unusual voltages, try to find the problem in the exciter, unless a winding has
' given up. The first step always is to check all connectors and cables in the terminal box and on the exciter components
for proper connections and safe contacts.
ATTENTION ! use the wiring diagram for troubleshooting. Observe wire numbers and colours.
9.3 Checking and replacing the rectifier diode
The test is made with a continuity check instrument. The diodes must forward the current in one direction and not do
so in the other direction.
Minimum values for spare rectifier modules:

Continuous on-state current IFAV Cut-off voltage URRM

Stationary rectifier stack [8] 10 A 600 V
Rotating rectifier stack [5] 80 A 600 V

Proceed as foUowST to carry out the check:- " - - ^^

Disconnect all poles of the unit prior to starting the check.
CarefiiUy pull off theflat-cableplugs.
V;- . Ghecfcthethrough-state^;^' . - ^ > ; \ . -

Stationary.rectifierstack [8]: ^ .....; : Rjstating rectifier stack [S] . ... . . .

Reverse the polarity of the continuity test The modules are standard components used by most
'' tn^tmeftffor tstfrig'diodfes- 4; 5 ffd XFig^ TI).' ''mhfectrCTs.'^Observe'the''dSricaI"mifl. 'i;*alea xvfih''
replacing a module (see table). Make sure not to exceed
..,,._. ....,,^,^rb...
....^ ..+- (hrfoirovsihgtor'qus'Whiertreaissenlbllng-^igtff'lO): ''"
Screws: . .5 Nm.
Terminals: 3 Nm -
<S)
^ ^

il i.2 i 3 3Nm y

n /^^

5Nm
^S. [ ^ f^^

o
n*j
-
pp^
w
+
Figure 11: Test instrument setting for stat rectifier
Figure 10: Test instnunent setting for rotating rectifier

9.4 Testing varistors

The test is made as described for the diodes, the difference being that varistors must cut off in both directions. If any
ciurent is forwarded, the Varistor is defect and needs to be replaced.
9.5 Replacing the regulator
Unscrew the 4 attachment screws and disconnect the wires. Replacing the unit is then possible without any problems.
Use a pen or screwdrive to open the terminals so that you can take out and disconnect the wires.
ATTENTION! Carefully observe the terminal assignment plan. Wrong connections damage the generator.
NOTE The system may have to be reac^usted (voltage, statics, stability) after replacing the regulator.

20
' Troubieshooting

Problem: Generator voltage drops considerably under load

1 Action Consequence Cause offidlure,further actions
Check speed of drive system adjust speed regulator
Check rectifier stacks [5] and [8] replace defect elements
(section 9.3)
Check transformer [7] and cable 2 hand in to service if winding damaged
repair coimectors
Check statics settings: put in generator voltage remove jumper for parallel operation and readjust
jumper between R4 and R5 and put must remain "Statics" potentiometer
load on generator constant

Problem: Generator voltage rises under load

Action Consequence Cause offeilure,further actions
Check connector of transformer connect-up properly
[11] and direction of rotation
(Figure 2)

Problem: Irregular generator voltage

1 Action Consequence Cause offeilure,further actions
Check speed of drive system adjust speed regulator.
Change "Stability" potentiometer of voltage continues to regulator defect
the regulator be irregular replace regulator
loose terminal
check coimectors

Problem; Generator voltage too hi ^h or too low when putting into operation
Action Consequence Cause offeilure,further actions
Check speed of drive system
Modify set-point voltage value voltage o.k.
voltage setting range check connector of external set-point adjuster
V
insufficient check jiunpers R6-R7 on the regulator (Figure 4)

Problem; Wrong current distribut on in parallel operation

Action Consequence
1 Check connector of transformer
[11] and direction of rot (Figure 2)
Measure transformer current under current = 0
load
Check performance-dependent
distribution of non-inductive load
Check setting of idling speed
voltage of all generators
Check yiiether statics setting is
even
For operation with compensating
kline: check the connection between
rgenerator terminal K3 - K4 and
1 compensating line
Cause offeiliu"e,further actions
remove jumper between R4 and R5 if it is in
connect up properly
replace transformer [11]
readjust speed regulator
use "Voltage" potentiometer or external set-point adjuster
use "Statics" potentiometer to readjust generator
Observe in any case : if one generator accepts too
much reactive load during parallel operation with
statics and increasing load, then you must increase its
statics setting or reduce that of the other generators
(do not fell below about 2 % at nominal current and
cos (fF=0.8) ! (Section 2.8.4)
check switch contact

22
 Internes etriebsiittel / Kleiien - /
internet electrical equipment terminal - Externes Betriebsnittel / external electrical equipient
tIefUhler Kabelfarbe Zielklenie Typ Leiste finsctiluierte /
sensor coble-color destination type strip techn. paraieter
XIOO E r r e g e r g e r t / exciting device
U8 br -R:G
-H- ext. Sollierteinsteller / ext. set-point adjuster 2,5 kfi III
bl -R:8
br -R:12
^ Erregung / exciting H I 12 V DC IR
U4 br -Gi4:Fl
-ff- Entregung / de-energizing _X_ 250 V DC 10 fl
bl -Gt<:F2
U3 Notbetrieb / eiergency operation - a - 100 fi 2fl
bl -R:9
-m-
bei cosr-Betrieb schlieen / close by p.f. operation <lfl
SI -R:II
-X!IO UicklungsUberiachung / nonitoring of lindings

B1I0 ^P^ PTC - He|JfUhler fibschaltung / sensor s i i t c h - o f f

^^P^^ PTC - HefUhler Abschaltung / sensor s i i t c h - o f f

X160 He-, Schutziandler / measuring, protecting t r o n s f o r n e r s

br -TI.U:SI
T1.U ^ Rchtung ! / Attention Phase U
bl -T1.U:S2
3000/1 fl
Sl/k br -T1.Y:SI Bei Ruslieferung
T1.V kurzgeschlossen. / Phase V <5Vfl
S2/1 bl -T1.:S2
Kl. 1
Sl/k br -T1.W:SI Short-circuited
TI.H
bl -T1.M:S2 D by delivery. Phase U

-X200 Stillstandsheizung / anti-condensation heater

230 V
E200
lox. 3 fl

Kleiienlegende / teriinalcode Kabelfarbe / cable-color Verteiler

Typ/ Bezeichner/ Hersteller / flfak./
Rnschluplan / connection diagram 1. S. 7, 8.12
tUPB designation anufacturer obbr. Farbe / color
0-14 264-7n UflGO br braun / brom 202-01-1
264-737 UflGO bl blau / blue Auftrag / order Datui Naie Blatt / page Rnhaltische
-04 249-llS URGO SI schiarz / black Bearbeiter 16.09.1337 Fro \ von / of 1 Elektroiotorenierk
d-04 264-731 URGO Ersatz fUr Dessau GibH
Attention! Hith ext. voltage adjuster: a I version ace. order:
bridge R7-R8 to R7-RG ^ L . ^ (see connection diagran)

XI10 lonitoring of tindings I

XI30 lonitoring of bearing >
XI50 lonitoring of cooling X
XiGO protection tronsfoner X
X200 ant i-condensation heater X

Stator Binding of the generator

LED flVR - R .
CO lours
rotor linding of the generator ^ a t RIOKF inly
br broin
rotor linding of the exciter
stotor Binding of the exciter
bl blue ^ 175 Ui
S I black U/f fKnick Spannung S t a t i k Stab i 1i tot I
rotary rectifier lith varistor SI
V/f ' break voltage s t a t i c stab i l i t y l
choice L
current tronsfoner
XOlOi X020: connections be fixed by test
stationary rectifier
R3I step-donn resistor
voltage regulator
radio noise suppression capacitor static current tronsforner

static current transfomer rotating field ci: k=R4i l=RS
protection transfomer rotating field cc: k=R5i l=R4

Ausgabe: 18.09.97 c i r c u i t diagram 097-002:220 E AEM

Ers. fUrfiusg.v. Jl^ i t h AVR RIOK/RIGKF Vert.: Id,8Fl2
scHsooao
Special feature - "V/f-control"

Setting instructions:

The R 10-KF controller has two potentiometers on its operation panel for setting of frequenqf-dependent control.

This potentiometer permits setting of the break point below which voltage drop shall occur. This setting is
possible in the range between 40 and 59 Hz. A LED is provided and lights as soon as break frequency falls
below the limit. For setting, the motor speed shall be changed until the desired value is reached and the
potentiometer be turned until the LED lights. Manufacturer's setting is 48.5 Hz for 50 Hz service and 58 Hz
for 60 Hz service.

U/f
This potentiometer is used to set the steepness of voltage drop below the break frequency. The range up to
AU/ An = 2 may be set. The manufacturer setting is a ratio of 1, i.e. 1 % of speed (frequency) drop
corresponds to 1 % of voltage drop (for instance, on the 400 V generator the voltage is lowered by 8 V per
1 Hz of frequency reduction).

R9 RIO R U
UN
Regulator R 10-KF

flattened out ^ r ^ LED

V/f ^ steeper (D) -(OrW

-\ 1 1 1 1
10 20 30 40 50
2-
f/Hz t
V/f
voltage stability
steeper | flattenp out statics
-^

lower I higher

figure 2: s^ing and connecting V/f-r^ulator

II