WEG Turbogenerator 10174576 Manual English PDF

Motors | Automation | Energy | Paints
Turbogenerator
S Line
Installation, Operation and Maintenance Manual

www.weg.net
Installation, Operation and Maintenance Manual
Document No.: 9300.0050

Model: Line S Turbogenerator
Material: 10174576
Language: English
Revision 1
March, 2010
Line S Turbogenerator l 1
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February 2008
2 l Line S Turbogenerators
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Dear Customer
Thank you for purchasing a WEG generator. It is a product developed with high levels of
quality and efficiency to ensure excellent performance.
Electric energy plays an outstanding role in the comfort and well-being of humankind. Being
responsible for the production of this energy, the electric generator needs to be identified and
treated as a machine whose characteristics demand special care, particularly with regard to
storage, installation and maintenance procedures.
All efforts have been made to ensure that the information contained in this manual can be
reliably used for setting up and running the WEG generator.
So please read this manual carefully before the installation, operation or maintenance of your
generator for a continuous and safe operation and to ensure that all measures have been
taken for your safety and the safety of your facilities. If any doubts persist, please contact
WEG.
Keep this manual always close to the generator for prompt reference when required.
ATTENTION
1. It is absolutely necessary to follow the procedures contained in this manual for the warranty to be valid.
2. The generator installation, operation and maintenance must be executed by qualified personnel.
NOTES
1. The total or partial reproduction of the information supplied in this manual is authorized, provided that
reference is made to its source;
2. If this manual is lost, an electronic PDF file is available from our website www.weg.net or another
printed copy can be requested.
WEG EQUIPAMENTOS ELTRICOS S.A.
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CONTENTS
1 INTRODUCTION.........................................................................................................................................9
2 GENERAL INSTRUCTIONS.....................................................................................................................10
2.1 QUALIFIED PERSONNEL ....................................................................................................................................... 10
2.2 SAFETY INSTRUCTIONS........................................................................................................................................ 10
3 OPERATING CONDITIONS AND STANDARDS.....................................................................................11

3.1 STANDARDS............................................................................................................................................................ 11
3.2 ENVIRONMENT CHARACTERISTICS................................................................................................................... 11
3.3 OPERATING CONDITIONS .................................................................................................................................... 11
4 RECEIVING AND STORAGE...................................................................................................................12

4.1 RECEIVING............................................................................................................................................................... 12
4.2 STORAGE................................................................................................................................................................. 12
4.2.1 Indoor storage ....................................................................................................................................12
4.2.2 Outside storage ..................................................................................................................................12
5 LONG STORAGE PERIODS....................................................................................................................13

5.1 INTRODUCTION ...................................................................................................................................................... 13
5.2 GENERAL................................................................................................................................................................. 13
5.3 STORAGE LOCATION ............................................................................................................................................ 13
5.3.1 Indoor storage ....................................................................................................................................13
5.3.2 Outdoor storage .................................................................................................................................13
5.4 SEPARATE PARTS.................................................................................................................................................. 14
5.5 SPACE HEATER...................................................................................................................................................... 14
5.6 INSULATION RESISTANCE.................................................................................................................................... 14
5.7 EXPOSED MACHINED SURFACES ......................................................................................................................14
5.8 ROLLING BEARINGS.............................................................................................................................................. 14
5.8.1 Grease-lubricated bearing...................................................................................................................14
5.8.2 Oil-lubricated bearing..........................................................................................................................14
5.8.3 Sleeve Bearing....................................................................................................................................14
5.9 TERMINAL BOX....................................................................................................................................................... 15
5.10 PREPARATION FOR OPERATION AFTER LONG STORAGE ............................................................................ 15
5.10.1 Cleaning .............................................................................................................................................15
5.10.2 Bearing lubrication ..............................................................................................................................15
5.10.3 Checking the insulation resistance ......................................................................................................15
5.10.4 Others ................................................................................................................................................15
5.11 INSPECTIONS AND RECORDS DURING THE STORAGE .................................................................................15
5.12 MAINTENANCE PLAN TO BE FOLLOWED DURING THE STORAGE ..............................................................16
6 HANDLING ...............................................................................................................................................17
7 INSULATION RESISTANCE ....................................................................................................................18

7.1 SAFETY INSTRUCTIONS........................................................................................................................................ 18
7.2 GENERAL REMARKS ............................................................................................................................................. 18
7.3 STATOR WINDING MEASUREMENT.................................................................................................................... 18
7.4 MEASUREMENT OF THE ROTOR WINDING RESISTANCE, EXCITER WINDING RESISTANCE AND
ACCESSORIES..................................................................................................................................................................... 18
7.5 CONVERSION OF THE MEASURED VALUES.....................................................................................................19
7.6 MINIMUM INSULATION RESISTANCE..................................................................................................................19
7.7 POLARIZATION INDEX............................................................................................................................................ 19
8 CONSTRUCTION CHARACTERISTICS..................................................................................................20
8.1 STATOR.................................................................................................................................................................... 20
8.2 ROTOR ..................................................................................................................................................................... 20
8.3 EXCITER ................................................................................................................................................................... 20
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8.4 PERMANENT MAGNET GENERATOR (PMG)......................................................................................................20

8.5 DUMPING WINDING ...............................................................................................................................................20
8.6 BEARINGS................................................................................................................................................................20
8.7 HEAT EXCHANGER ................................................................................................................................................20
9 OPERATION PRINCIPLE ........................................................................................................................ 21

9.1 EXCITATION .............................................................................................................................................................21
9.2 DEEXCITATION........................................................................................................................................................21
9.3 VOLTAGE REGULATOR.........................................................................................................................................22
9.4 UNDERFREQUENCY (U/F) PROTECTION............................................................................................................22
10 INSTALLATION ....................................................................................................................................... 23
10.1 INSTALLATION SITE................................................................................................................................................23
10.2 PROTECTIONS........................................................................................................................................................23
10.3 DIRECTION OF ROTATION ...................................................................................................................................23
10.4 FOUNDATIONS........................................................................................................................................................23
10.5 ANCHOR PLATE SET .............................................................................................................................................24
10.6 ALIGNMENT / LEVELING........................................................................................................................................25
10.7 COUPLING ...............................................................................................................................................................25
10.8 ELECTRICAL AND GROUNDING CONNECTIONS .............................................................................................27
10.8.1 Main stator connections (power cables).............................................................................................. 27
10.8.2 Grounding.......................................................................................................................................... 27
10.8.3 Accessories ....................................................................................................................................... 27
10.9 THERMAL PROTECTIONS.....................................................................................................................................27
10.9.1 Protection location ............................................................................................................................. 27
10.9.2 Temperature sensors ......................................................................................................................... 27
10.9.3 Temperature limits for the windings .................................................................................................... 27
10.9.4 Thermal bearing protections............................................................................................................... 28
10.9.5 Alarm and disconnection temperatures .............................................................................................. 28
10.9.6 Ratio between temperature and the ohmic resistance of Pt 100 temperature sensors......................... 28
10.9.7 Space heater ..................................................................................................................................... 29
10.10 PANEL PROTECTIONS...........................................................................................................................................29
10.11 GENERATOR COOLING.........................................................................................................................................29
10.12 WATER RADIATORS...............................................................................................................................................30
11 ELECTRICAL CONNECTIONS AND ACCESSORIES ........................................................................... 31

11.1 TERMINAL MARKINGS...........................................................................................................................................31
11.2 WIRING DIAGRAMS................................................................................................................................................31
11.2.1 Thermal protection on main stator winding ......................................................................................... 32
11.2.2 Generator cooling system .................................................................................................................. 33
11.2.3 Bearings ............................................................................................................................................ 34
11.2.4 Space heater and exciter ................................................................................................................... 35
11.3 DESCRIPTION OF THE ACCESSORY FUNCTION..............................................................................................35
11.4 ACCESSORIES AND PROTECTIONS...................................................................................................................36
12 START-UP 37
12.1 BEFORE FIRST START-UP.....................................................................................................................................37
12.2 INITIAL MECHANICAL TURN .................................................................................................................................37
12.3 POWERING-UP .......................................................................................................................................................37
12.4 SYNCHRONIZATION AND LOAD..........................................................................................................................37
13 GENERATOR OPERATION .................................................................................................................... 38

13.1 SHAFT LIFTING SYSTEM (JACKING) ....................................................................................................................38
13.2 WATER RADIATORS...............................................................................................................................................38
13.3 BEARINGS................................................................................................................................................................38
13.4 VIBRATION LIMITS ..................................................................................................................................................38
13.5 SHAFT VIBRATION LIMITS .....................................................................................................................................38
13.6 STOP 39
14 MAINTENANCE ....................................................................................................................................... 40
14.1 GENERAL.................................................................................................................................................................40
14.2 GENERATOR CLEANING.......................................................................................................................................40
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14.3 STATOR, ROTOR AND EXCITER WINDING INSPECTIONS............................................................................... 40

14.4 WINDINGS CLEANING ........................................................................................................................................... 40
14.5 INSPECTION AND CLEANING OF RADIATORS.................................................................................................41
14.6 GENERATOR OUT OF SERVICE ...........................................................................................................................41
15 BEARINGS 42
15.1 SLEEVE BEARINGS ................................................................................................................................................ 42
15.1.1 Bearing connections ...........................................................................................................................42
15.1.2 Bearings data .....................................................................................................................................42
15.1.3 Bearings installation and operation......................................................................................................42
15.1.4 Hydrostatic jacking system .................................................................................................................42
15.1.5 Setting of the bearing protections .......................................................................................................42
15.1.6 Lubrication..........................................................................................................................................42
15.1.7 Sealing ...............................................................................................................................................43
15.1.8 Bearing maintenance ..........................................................................................................................43
15.2 OIL BEARINGS......................................................................................................................................................... 43
15.2.1 Lubrication guidelines .........................................................................................................................43
15.2.2 Bearing operations..............................................................................................................................43
15.2.3 Protection device settings ...................................................................................................................43
15.3 GREASE BEARINGS............................................................................................................................................... 44
15.3.1 Lubrication guidelines .........................................................................................................................44
15.3.2 Steps for bearing re-lubrication ...........................................................................................................44
15.3.3 Spring device for grease removal ........................................................................................................44
15.3.4 Protection settings ..............................................................................................................................44
15.3.5 Bearing replacement...........................................................................................................................45
16 EXCITER 46
16.1 EXCITER ................................................................................................................................................................... 46
16.2 DIODES TEST .......................................................................................................................................................... 46
16.3 DIODES REPLACEMENT ....................................................................................................................................... 47
16.4 VARISTORS TEST ................................................................................................................................................... 47
16.5 VARISTORS REPLACEMENT ................................................................................................................................ 47
17 GENERATOR PARTS ..............................................................................................................................48
18 MAINTENANCE SCHEDULE...................................................................................................................49
19 TROUBLESHOOTING..............................................................................................................................50
20 ACCESSORIES AND SPARE PARTS.....................................................................................................52
21 DOCUMENTS ...........................................................................................................................................53
22 WARRANTY CONDITIONS OF ENGINEERED PRODUCTS .................................................................54
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1 INTRODUCTION
THE TURBOGENERATOR
The turbogenerator is a machine that operates as an electric power generator when its shaft is driven by a turbine.
THE THERMAL ELECTRIC POWER GENERATION PROCESS

The fuel is burned in a boiler. The boiler heats a water volume, which changes into steam. The steam drives the turbine rotor
that turns the generator shaft. The electromagnetic action inside the generator generates electric power that is supplied to
the consumer network.
TERMINOLOGY
S P W 1250
S GENERATOR LINE
S Line
EXCITATION TYPE
P - Brushless with auxiliary exciter
S - Brushless without auxiliary exciter
COOLING SYSTEM
W - Air-water heat exchanger
A Open, self-ventilated
D - Self-ventilated by ducts, air inlet and outlet
T - Forced ventilation, air inlet and outlet by ducts
V - Forced ventilation, ventilation on the generator
F - Self-ventilated with air-to-air heat exchanger on top of generator
I - Forced ventilation in the internal and external air circuit, air-to-air heat exchanger
L - Air-to-water heat exchanger, forced ventilation in the internal air circuit
IEC FRAME SIZE

Shaft-end height in mm (450 to 5000)
SAFETY WARNINGS IN THE MANUAL
Following safety warnings are used in this manual:
DANGER
The noncompliance with the procedures recommended in this warning may result in death, serious injuries
and considerable material damages.
ATTENTION
The noncompliance with the procedures recommended in this warning may result in material damages.
NOTE
The purpose of this text is to supply important information for the correct and good performance of this
product.
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2 GENERAL INSTRUCTIONS
2.2 SAFETY INSTRUCTIONS

ATTENTION
All the procedures and rules contained in
this manual must be followed accordingly DANGER
to ensure the good operation of the During operation of this equipment, there will
equipment and safety of the personnel be exposed energized or rotating parts with
involved in its operation. The compliance high voltage or high temperatures.
with these procedures is equally important Thus, its operation with open terminal boxes,
to ensure the application of the warranty unprotected couplings or erroneous handling,
terms on the back cover of this manual. without considering the operation standards,
We strongly recommend a detailed reading may cause serious personal injury and
of this manual before the generator property damage.
installation and operation. However, in
case any doubt persists, please contact
your nearest WEG representative. The people responsible for the installation safety must
assure that:
Only qualified personnel will perform the installation
For practical reasons, it is impossible to supply in this
and operation of the equipment;
manual all the details regarding possible construction
These people will have in hand this manual and other
alternatives. In addition, it is impossible to consider all the
documents supplied with the generator and will also
imaginable cases of operation or maintenance.
perform the works, strictly complying with the service
For this reason, this manual contains only the required
instructions, standards and the product specific
information so that qualified and trained personnel may
documentation;
perform the required services.
People not qualified will be forbidden to carry out
works on the electric equipment.
2.1 QUALIFIED PERSONNEL
The noncompliance with the installation and safety rules
People who, because of their education, experience, may void the product warranty.
instruction and knowledge of applicable standards and Firefighting equipment and first aid warnings will be
safety procedures about the corresponding service located in the work site in visible and accessible places.
conditions, are duly authorized to operate and monitor
the generator. They must also be knowledgeable about The following should also be observed:
first-aid procedures and be capable of providing these All technical data regarding the allowed applications
services if required. (operating conditions, connections and installation
It is assumed, that all commissioning, maintenance and environment) contained in the catalog, purchase order,
repair works will only be performed by qualified operating instructions, manuals and other documents;
personnel. The specific determinations and conditions for the local
installation;
The use of proper tools and equipment for handling
and transport;
That the protection devices of the components are
removed little before the installation;
The individual parts must be stored in vibration-free
rooms, preventing falls and assuring that they are
protected against rodents and/or may pose risks to
people safety.
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3 OPERATING CONDITIONS AND STANDARDS
3.1 STANDARDS
WEG turbogenerators are specified, designed, manufactured and tested according to the following standards:
IEC-60034.1
Specification NBR 5117
VDE-0530
Tests IEC-60034.2 NBR 5052
Degree of protection IEC-60034.5 NBR 6146
Cooling IEC-60034.6 NBR 5110
Mountings IEC-60034.7 NBR 5031
Noise IEC-60034.9 NBR 7565
Mechanical vibration IEC-60034.14 NBR 7094
Mechanical tolerances ISO 286 NBR 6158
Balancing ISO 1940 NBR 8008
Table 3.1: Standards
3.2 ENVIRONMENT CHARACTERISTICS
Turbogenerators are designed to be operated in following ambient conditions:

Ambient temperature: 15C to + 40C;
Altitudes: up to 1,000 m;
Environments without the presence of aggressive agents, such as: sea air, chemicals, etc.;
Environments according to the degree of protection of the generator.
ATTENTION
For turbogenerators fitted with air-to-water heat exchanger, ambient temperature should not be lower than +5C
and the cooling water temperature should be from +5C to +25C.
Special operation conditions can be met upon request and are indicated on the nameplate and data sheet specific for each
machine.
3.3 OPERATING CONDITIONS
The operating conditions of the generator must comply with the nameplate data, applicable standards and codes, as well as
with this manual in order to assure warranty coverage.
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4 RECEIVING AND STORAGE
4.1 RECEIVING 4.2 STORAGE
All generators are factory tested and supplied in perfect Any damage to the painting or to the rust protections on
operating conditions. The machined surfaces are the machined surfaces must be retouched.
corrosion protected. The box or container must be
inspected right after receipt and checked for any damages
that may be caused during the transport. ATTENTION
The space heaters must be switched ON
ATTENTION always the generator is not operating.
Any damage must be reported immediately to

the carrier, the insurance company and WEG. 4.2.1 Indoor storage
If such a condition is not reported, the
warranty will be void. When the generator is not unpacked immediately, the box
should be stored in a place protected against moisture,
vapors, sudden change of temperature, rodents and
ATTENTION insects.
The site must be free of vibrations to prevent bearing
Parts supplied in additional packages or
damage.
volumes must be checked when received
according the complete packing list.
4.2.2 Outside storage
When the package (or container) is lifted, following If possible, choose a dry site, free of floods and vibrations.
items must be checked: hoist components, the weight Repair all damages to the packages before storing the
indicated on the packaging or on the nameplate, hoist equipment. This is required to ensure the appropriate
capacity and operation. storage conditions.
Generators packed in wooden crates must be lifted Store the machines, devices and crates on pallets, wood
always by their own eyebolts or by suitable forklift and beams or foundations that provide protection against
never lifted by its wooden packing box. ground moisture.
Neither the generator nor its packaging should be Prevent the equipment from sinking into the soil. Assure
dropped or submitted to any impact. Place it on the free airflow under the equipment.
ground carefully (without impacts) to prevent bearing The covering or tarpaulin used to protect the equipment
damages. against the weather should not be in contact with the
Do not remove the protecting grease from the shaft end equipment surfaces. Assure appropriate air circulation by
nor the rubber seals or the plugs from the terminals placing wooden spacer blocks between the equipment
boxes. and the respective covering.
These protections items must be kept in place until the
final installation has been concluded. After unpacking,
make a complete visual inspection of the generator.
Remove the shaft-lock device and kept it safe for future
transport of the generator.
ATTENTION
If any damage is detected, it must be
photographed, documented and reported
immediately to the carrier company and to
your nearest WEG representative.
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5 LONG STORAGE PERIODS
5.1 INTRODUCTION 5.3.1 Indoor storage
The instructions for long storage periods described below Enclosed storage room with roof;
are valid for generators that are stored during long time The storage location must be protected against
before their commissioning and/or are not operated moisture, vapors, aggressive fume discharge, rodents
during long periods. and insects.
Room must be free of corrosive gases, such as:
5.2 GENERAL chlorine, sulfur dioxide or acids;
Location must be free of severe continuous or
The existing tendency, especially during the plant intermittent vibrations.
construction, of storing generators for long periods Storage room must be provided with ventilation
before their commissioning or when only some units are system and filter;
installed immediately, results in the fact that the generator Room temperature (5C, > t < 60C), with no sudden
is exposed to influences that may not be assessed in changes in temperature;
advance for that period. Relative air humidity <50%;
It is difficult to evaluate the atmospheric, chemical, Prevention against dirt and dust deposits;
thermal and mechanical stresses imposed on the Provided with a fire detection system.
generator that may occur during the storage, handling, Electric power supply for space heater and illumination
assembly, initial tests and waiting time until its definitive must be provided.
commissioning.
Another essential factor is its transport. For example, the If some of these requirements cannot be provided in the
general contractor may transport the generator or a unit storage room, WEG suggests that additional protection
complete with the generator as a joint transport to the measures should be incorporated into the generator
installation site. packaging during the storage period as follows:
The hollow spaces inside the generator, bearings and Storage the generator into a closed wooden box or
terminal box are exposed to the atmospheric air and similar with electrical installation that allow the
temperature fluctuations. Due to air moisture, connection of space heaters;
condensation of water may occur and, depending on the If there is any risk of fungus infestation and formation,
type and degree of contamination in the air, aggressive the packaging must be protected in the storage
substances can penetrate the hollow spaces. location by spraying or painting it with appropriate
As a result, after long storage periods, internal chemical agents.
components such as the bearings, may rust, the The packaging must be prepared carefully by an
insulation resistance may decrease to values below those experienced person. The company hired for this purpose
regarded as accepted and the characteristics of the shall be responsible for the machine packaging.
bearing lubricants are affected adversely. This influence
increases the damage risk before the plant 5.3.2 Outdoor storage
commissioning.
The outdoor storage of the generator is not
ATTENTION recommended.
If the outdoor storage is unavoidable, pack the generator
To keep the manufacturer's warranty valid, into a specific packaging for this condition, as described
you must assure that the preventive measures below:
described in this manual, such as: For outdoor storage, besides the packaging
construction aspects, preservation, recommended for indoor storage, cover the packaging
packaging, storage and inspections are completely with some protection against dust,
followed and recorded. moisture and other foreign matters by using a resistant
canvas or tarpaulin.
Store the packaging on pallets, wood beams or
5.3 STORAGE LOCATION
foundations that provide protection against the ground
moisture.
In order to provide the best storage conditions to the
Prevent the packing from sinking into the soil.
generator during long storage periods, the storage site
After covering the machine, a shelter must be built to
should comply strictly with the items below.
protect it from direct rain, snow and excessive sun
heat.
ATTENTION
It is recommended to check the storage place
and the generator conditions according to the
maintenance plan for long-term storage as
described in this manual.
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5.4 SEPARATE PARTS 5.8.2 Oil-lubricated bearing

Depending on its mounting position, the generator can
If parts have been supplied separately (terminal boxes, be transported with or without oil in the bearings.
heat exchanger, endshields, etc.), these parts must be The generator must be stored in its mounting position
packed as described above. with oil in the bearings;
The air relative humidity inside the packaging should The oil level must be respected, remaining in the sight
not exceed 50% until the machine is unpacked. glass half.
During the storage period, at every two months, the
5.5 SPACE HEATER shaft-locking device must be removed and the shaft
turned manually to keep the bearing in good lubrication
The space heaters installed in the generator must be condition.
energized during the storage period to prevent the After 6 months of storage and before starting the
moisture condensation inside the generator, thus operation, the bearings should be relubricated.
maintaining the winding insulation resistance at If the generator is stored for more than 2 years, the
acceptable levels. bearings must be washed, inspected and relubricated.
ATTENTION 5.8.3 Sleeve Bearing
The generator space heater must be Depending on the mounting position, the generator
mandatorily energized when the generator is can be transported with our without oil in the bearings
stored in a place with ambient temperature < and must be stored in its mounting with oil in the
5C and relative air humidity > 50%. bearings;
The oil level must be respected, remaining in the sight
glass half.
5.6 INSULATION RESISTANCE During the storage period, at every two months, the
shaft-locking device must be removed and the shaft
During the storage period and before installation, the rotated at 30 rpm to circulate the oil and keep the
insulation resistance of the generator winding should sleeve bearing in good lubrication condition.
be measured very 3 months and recorded according
to item 2.3.5 of this manual
Eventual decrease of insulation resistance must be NOTE
investigated. If it is not possible to rotate the generator
shaft, the following procedure should be
5.7 EXPOSED MACHINED SURFACES adopted to protect the sleeve bearing
internally and the contact surfaces against
All the exposed machined surfaces (for example, the corrosion.
shaft end and flanges) are protected at the factory by
temporary protection film (rust inhibitor).
Drain all the bearing oil;
This protective coating must be reapplied at least every
6 months. When this coating is removed and/or Disassemble the bearing following the procedure
damaged, it must be applied again. described in this manual.
Clean the bearing;
Recommended products: Apply the anticorrosive protection (for example, TECTIL
Name: Dasco Guard 400 TX AZ, Manufacturer: D.A. 511, Valvoline or Dasco Guard 400TXAZ) on top and
Stuart Ltda bottom bearing shell and on the generator shaft
Name: TARP, Manufacturer: Castrol contact surface;
Assemble the sleeve bearing following the procedure
5.8 ROLLING BEARINGS described in this manual;
Close all threaded holes with plugs;
Seal the gaps between the shaft and the bearing seal
5.8.1 Grease-lubricated bearing
by applying a waterproof adhesive tape;
All the flanges (for example, oil inlet and outlet) must
The bearings are factory lubricated for the performance
be protected with blind caps;
of the generator tests.
Remove the bearing top sight glass and spray
During the storage period, at every two months, the
anticorrosive protection inside the bearing;
shaft-locking device must be removed and the shaft
Put some desiccant (silica gel) bags inside the bearing.
turned manually to keep the bearing in good lubrication
The desiccant absorbs moisture and prevents water
conditions.
condensation inside the bearing;
After 6 months of storage and before starting the
Close the bearing with the top sight glass.
operation, the bearings should be relubricated.
If the generator is stored for more than 2 years, the If the storage period is longer than 6 months:
bearings must be washed, inspected and lubricated Repeat the above described procedure;
again. Place new desiccant (silica gel) bags inside the bearing
If the storage period is longer than 2 years:
Disassemble the bearing;
Preserve and store the bearing parts.
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5.9 TERMINAL BOX 5.10.3 Checking the insulation resistance
When the generator winding insulation resistance is Before starting the operation, the insulation resistance
checked, the main terminal box and additional must be checked following the procedure described in
terminal boxes must also be checked, particularly with this manual.
regard to the following aspects:
The terminal box inside must be dry and free of any 5.10.4 Others
dust deposit.
The contacts must be free of corrosion.
The seals must be in good condition. NOTE
The cable entries must be sealed correctly. Follow other procedures supplied in the
If any of these items is not correct, the parts must be "Commissioning" section in this manual
cleaned or replaced. before starting the machine operation.
5.10 PREPARATION FOR OPERATION AFTER 5.11 INSPECTIONS AND RECORDS DURING
LONG STORAGE THE STORAGE
5.10.1 Cleaning The stored generator must be inspected from time to
time and the inspection records must be filed. Check
The machine inside and outside must be free of oil, following aspects:
water, dust and dirt. The generator inside must be
1. Physical damages.
cleaned with compressed air at reduced pressure.
2. Cleaning.
Remove the rust inhibitor from the exposed surfaces
3. Signs of water condensation.
using a cloth soaked in a petroleum-based solvent.
4. Protective coating conditions.
Remove the existing protection between the grounding
5. Painting conditions.
brush and the generator shaft.
6. Signs of worms or insect action.
Make sure that the bearings and cavities used for 7. Satisfactory operation of the space heaters. It is
lubrication are free of dirt and that the cavity plugs are recommended to install a signaling or alarm system in
correctly sealed and tightened. Oxidations and marks on the storage location to detect any power failure
the bearing seats and shaft must be carefully removed. affecting the space heaters.
8. Record room temperature and the relative air
5.10.2 Bearing lubrication humidity around the machine, the winding
temperature (using RTDs), the insulation resistance
Use the grease or oil specified for bearing lubrication. and the polarization index.
This information is indicated on the bearing nameplate. 9. Inspect also the storage place that must comply with
The bearings must be lubricated as described in the the requirements described in the chapter LONG
"Maintenance" section of this manual according to the STORAGE" .
bearing type.
NOTES
Sleeve bearings, where the anticorrosive
protection and desiccant were applied, must
be disassembled according to the procedure
described in this manual. The anticorrosive
protection and the desiccant must be washed
out and removed.
Assemble the bearings as described in this
manual and lubricate them again.
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5.12 MAINTENANCE PLAN TO BE FOLLOWED DURING THE STORAGE
During the storage period, the generator maintenance must be performed and recorded according to the plan described in
the table 5.1:
Every 2 Every 6 Every Before

Monthly Note
months months 2 years operation
Storage Location
Inspect the cleaning conditions X X
Inspect moisture conditions and the
X
temperature
Check for insect infestation signs X
Measure the vibration level X
Packaging
Inspect for physical damages X
Inspect the inner relative humidity X
Change the desiccant in the packaging
X When required
(if any)
Space heater
Check the operating conditions X
Complete Generator
Clean generator outside X X
Check painting conditions X
Check the oxidation inhibitor on the
X
exposed parts
Replace the oxidation inhibitor X
Windings
Measure insulation resistance X X
Measure polarization index X X
Terminal box and grounding terminals
Clean box inside X X
Inspect the seals and gaskets
Roller bearings, grease or oil lubricated
Rotate the shaft X
Relubricate the bearing X X
Disassemble and clean the bearing X
Sleeve bearing
Rotate the shaft X
Apply rust inhibitor and desiccant X
Clean and relubricate the bearings X
Disassemble and store the parts X
Table 5.1: Storage plan
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6 HANDLING
Figure 6.1: Lifting the generator by its eyebolts Figure 6.2: Lifting the generator by the base eyebolts
To lift the generator, use only the eyebolts on the top or at base of the generator provided for this purpose, as shown in
the figure 6.1 and 6.2.
Consider the generator weight. Lift the generator smoothly and do not place it abruptly on the base to prevent bearing
damages.
The eyebolts on the heat exchanger, covers, bearings, radiator, terminal boxes, exciter, etc., were designed only to lift
these components.
Never use the shaft to lift the generator by means of cables, etc.
To move the generator, its shaft must be locked using the locking device supplied with the generator
ATTENTION
Ropes, rings and lifting equipment must be capable to support the generator weight.
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7 INSULATION RESISTANCE
7.1 SAFETY INSTRUCTIONS The stator winding insulation resistance must be

measured in the main terminal box
The megohmmeter must be connected between the
DANGER generator frame and the winding. The frame must be
Before insulation resistance is measured, grounded.
machine must be switched off and stopped.
The winding under test must be connected to
the housing and the ground for a period until
all residual electrostatic charge has been
removed. Ground the capacitors (if supplied)
before disconnecting the lead terminals.
The noncompliance with these procedures
may result in personal injuries.
Figure 7.1: Megohmmeter connection
7.2 GENERAL REMARKS If the winding total measurement shows a value below the
recommended one, the neutral connections must be open
When the generator is commissioned immediately after and the insulation resistance of each phase must be
receipt, it should be protected against moisture, high measured separately.
temperature and dirt, thus preventing damages on the
insulation resistance. 7.4 MEASUREMENT OF THE ROTOR
The winding insulation resistance must be measured WINDING RESISTANCE, EXCITER
before the generator operation. WINDING RESISTANCE AND
If the ambient is very wet, the winding resistance must be ACCESSORIES
measured from time to time during the storage period. It is
difficult to prescribe fixed rules for the machine insulation Measurement of the rotor winding resistance:
resistance values, since they change according to the Disconnect the rotor cables from the diode set;
environment conditions (temperature, moisture), machine Record the winding temperature supplied by the
cleaning conditions (dust, oil, grease, and dirt), quality and PT 100;
conditions of the used insulating material. A considerable Connect the megohmmeter between the rotor winding
dose of common sense, resulted from experience, must and the generator shaft. The measured current cannot
be applied to conclude when a machine is or is not flow through the bearings.
suitable for service. Periodic records are useful for this
conclusion. Measurement of the stator winding resistance of the
exciter:
NOTE Disconnect the exciter power supply cables;
The insulation resistance must be measured Connect the megohmmeter between the exciter stator
using a MEGOHMMETER. winding (I and K terminals) and the generator frame.
Measurement of the rotor winding resistance of the

exciter:
7.3 STATOR WINDING MEASUREMENT
Disconnect the exciter rotor cables from the diode set;
The stator winding test voltage must comply with the table Connect the megohmmeter between the rotor winding
7.1 according to IEEE43 standard. and the generator shaft. The measured current can not
flow through the bearings
Rated winding Insulation resistance test
voltage (V) (Continuous voltage) (V) Measurement of the stator winding resistance of the PMG
< 1000 500 - SP model generators --_:
1000 - 2500 500 -1000 Disconnect the cables that connect the PMG to the
voltage regulator
2501 - 5000 1000 - 2500
Connect the megohmmeter between PMG stator
5001 - 12000 2500 - 5000
winding (terminals 13, 14 and 15) and the generator
> 12000 5000 - 10000 frame.
Table 7.1: Insulation resistance test voltage.
ATTENTION
Before measuring the stator winding, check following:
If the CT secondary connections are not open; After insulation resistance has been measured,
If all the power cables are disconnected; ground the tested winding to discharge it.
If the generator frame and the not measured windings The test voltage for the rotor, exciter, PMG and
are grounded; space heater must be 500 Vdc. The test
If the winding temperature has been measured; voltage for the accessories is 100 Vdc.
If all the temperature sensors are grounded; It is not recommended to measure the
insulation resistance of thermal protectors.
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7.5 CONVERSION OF THE MEASURED Insulation resistance Insulation evaluation

VALUES
2M or less Bad
If the test is conducted at a different temperature, the read < 50M Dangerous
values must be corrected to 40C by using an insulation 50...100M Regular
resistance variation curve according to the temperature 100...500M Good
measured on the machine under test. If this curve is not 500...1000M Very Good
available, you can an approximate correction, as indicated > 1000M Optimum
by the curve in Figure 7.2 as per NBR 5383 / IEEE43.
Table 7.2: Orientative limits for the insulation resistance of
electrical machines.
7.6 MINIMUM INSULATION RESISTANCE

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

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

1 or less Bad
< 1.5 Dangerous
1.5 to 2.0 Regular
2.0 to 3.0 Good
3.0 to 4.0 Very Good
> 4.0 Optimum
Table 7.3: Polarization index (ratio between 10 and 1 minute).
DANGER
Right after measuring the insulation
resistance, ground the winding to prevent
accidents.
Figure 7.2: Coefficient of insulation resistance variation with

temperature.
With old machines, during longer time in service, the read

values for the winding resistance will be usually higher.
The comparison with values measured in previous tests on
the same machine with similar load, temperature and
moisture conditions is regarded as a better indication of
the insulation conditions than the value obtained in a
single test. Any great or sudden reduction is regarded as
suspect.
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8 CONSTRUCTION CHARACTERISTICS
8.1 STATOR The rotor is induced by the flux from the exciter stator
using a three-phase AC voltage that is rectified in full wave
The stator lamination package, formed by silicon steel by the rotating rectifier.
laminations with insulation on both faces and low electric Two wires come from the rectifier to feed the main
losses, is pressed and fixed by metal beam or spar machine rotor (field).
system.
The windings of the high-voltage generators are NOTE
constructed with prefabricated rectangular wire coils with
class-F insulation resin and coated with mica tape The rectifier is made up of six diodes and a
insulation that, after heat treatment process, provides set of varistors for protection against reverse
high mechanical resistance to the winding. overvoltage in the diodes.
The coils are inserted into the stator slots and fixed by
fiberglass or magnetic wedges. The fixation of these 8.4 PERMANENT MAGNET GENERATOR
wedges is assured by the dovetail in slot and by using (PMG)
expandable fiberglass lamination.
Highly absorbing materials are used for binding the coil (Only for the SP_ model generator)
heads, thus ensuring the mechanical stiffness required to Installed at the non-drive end side of the generator, the
withstand to the most severe operating conditions. PMG generates alternate voltage for supplying the voltage
The high-voltage stators are then impregnated by the regulator power circuit.
epoxy VPI-impregnation system. The rotor is formed by permanent magnet poles inserted
into the lamination package mounted on the main
8.2 ROTOR generator shaft.
The stator is formed by a lamination package and a three-
The rotor accommodates the field winding whose poles phase winding that generates the voltage to supply the
are made of steel laminations. power circuit of the electronic voltage regulator.
A squirrel cage winding for absorbing purposes
compensates for parallel services and abnormal load 8.5 DUMPING WINDING
operation.
The rotor is dynamically balanced and designed to The dumping winding is constructed along the whole rotor
withstand to the electrical and mechanical effects of periphery, which is of fundamental importance for handling
overspeed as required by the applicable standard and of sudden loads, such as motor starts, OFF/ON procedures
the triggering according to the design. of heavy loads. The dumping winding has following
Manufactured with non-salient poles, the rotor has a functions:
constant air gap along the whole iron core periphery. The 1. Dumping of load input and output at generator
rotor has a cylindrical shape in whose periphery slots is terminals.
inserted the excitation winding. The field coils are made of 2. In case of an infinite busbar, the machine becomes
bars, wires or copper laminations insulated with a class-H more stability against abrupt voltage variations.
insulating material. 3. Absorption of zero sequence and negative sequence
The non-salient pole rotor of the turbogenerator is currents caused by load unbalance.
practically a monobloc with no overhangs or recesses. As 4. Loads with harmonic distortion of currents will also be
a result, it becomes sturdier and more resistant to absorbed by dumping bars according to standard.
overspeed and coil triggering. 5. They increase the abrupt short-circuit at the machine
terminals.
8.3 EXCITER
8.6 BEARINGS
Installed at the non-drive end side of the generator, the
exciter is formed by fixed poles that accommodate the The bearings are mounted at the frame ends and their
excitation field coils, the armature and the rotating rectifier purpose is to support the rotor mass and allow it to turn.
bridge. Its purpose is to supply direct voltage to exciter Sleeve bearings are lubricated with oil and the rolling
rotor. It supplies direct current controlled by the voltage bearings can be lubricated with grease or oil.
regulator according to the load requirements, thus Correct storage, operation and maintenance procedures
maintaining constant voltage for the main generator. are determinant for their performance and useful life.
Exciter Stator 8.7 HEAT EXCHANGER

The poles accommodate the field coils which are series
SPW and SSW turbo-generators are provided with an air-
connected, their ends being connected to the terminal
to-water exchanger installed at the bottom or top section
block (I(+) and K(-)). Its purpose is to supply the flux to the
of the generator. The SPF and SSF models are provided
exciter rotor. It is supplied with a direct current controlled
with air-to-air heat exchanger, normally installed on top
by the voltage regulator according to the load
side of the generator (see in this Manual the item "Cooling" ).
requirements, thus keeping the main generator voltage
constant.
Exciter Rotor
The exciter rotor is mounted on the main shaft of the
machine. The rotor is formed by laminations with slots that
accommodate a star-connected three-phase winding.
The phases are connected to the rotating rectifying diode
set.
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9 OPERATION PRINCIPLE
AVR: Automatic Voltage Regulator

EPT: Main three-phase exciter
PMG: Exciter with permanent magnets
Figure 9.1: Internal electrical circuits of the SP_ model generator
9.1 EXCITATION
After the primary machine is driven and reaches is rated DANGER

speed, starts the excitation process in the generator and When operated at no load with nominal speed
the voltage generated by PMG supplies the voltage and without excitation voltage there is a
regulator power circuit. residual voltage present in the synchronous
When the voltage regulator is enabled, it rectifies this generator terminals due to residual magnetism
voltage and supplies direct current to the stator of the in the exciter magnetic core.
generator exciter. These voltage levels can cause serious
The alternate current generated by the exciter rotor is accidents with risk of death. It is unwise to
rectified by the rotating diodes and supplied to the main manipulate the machine while the rotor is
rotor poles. turning.
The generator voltage increases as ramp automatically Generators with rated voltage of 440V,
from its residual value up to the pre-established rated usually present 180V of residual voltage;
voltage that is regulated by monitoring the reference Generators with rated voltage of 13800V
voltage in the electronic voltage regulator. easily present 1000V of residual voltage.
The reference voltage for the voltage regulator must be
obtained through reference TPs connected to the main 9.2 DEEXCITATION
terminals of the generator.
The SS_ model turbogenerators (Shunt) are not provided The generator full deexcitation is performed by the
with PMG and the voltage regulator power circuit is generator stoppage or voltage regulator shutdown.
supplied by the generator output voltage using power When the voltage regulator is shut down, the generator
TPs. deexcitation is performed by a free-wheel circuit installed
in the voltage regulator panel. The excitation current flows
ATTENTION through a discharge resistance that promotes a faster
deexcitation of the main machine.
To start the shunt generator excitation During the maintenance services, the machines must be
process, it may be necessary to use an stopped, since the deexcitation alone is not enough.
external pre-priming circuit (DC power
supply), since the residual generator
magnetism may not be sufficient for the
priming.
Check the procedures in the voltage regulator
manual for enabling this function during the
excitation process.
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9.3 VOLTAGE REGULATOR
The purpose of the electronic voltage regulator is to keep ATTENTION

the generator voltage constant, regardless of the load. Check for the correct wiring diagram in the
The generator excitation process starts from the moment regulator manual.
the voltage regulator is activated. This must always be An erroneous connection may burn the
done when the generator reaches at least 90% of its rated regulator and / or the generator windings.
speed, thus preventing overcurrent in the generator
excitation windings.
9.4 UNDERFREQUENCY (U/F) PROTECTION
Automatic operation mode
When the generator frequency drops below the
The voltage regulator is intended to keep the generator programmed value for U/F in the voltage regulator, the
output voltage equal to the previously programmed generator output voltage will decrease as programmed by
reference value. To perform this function, the regulator the Volt/Hz ratio.
must be operated in automatic mode, where the generator
output voltage is used as feedback.
During the automatic operation mode, the reference
voltage can be used by other controls, such as:
acceleration Ramp, F/U Operation, PF/Q Correction and
others.
Manual operation mode
In this operation mode, the generator excitation is

conducted through the excitation voltage variation.
This operation mode is selected through a selector switch
(automatic/manual = open) and is used during the
generator commissioning tests.
For technical details, operation, functions, connections,
adjustments, abnormalities, etc., see the voltage
regulator manual.
The regulators are generally microprocessed and allow
parallel operation between two machines and with the
network. In this case, with power factor correction.
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10 INSTALLATION
10.1 INSTALLATION SITE When generator rotation direction is changed, the phase
sequence will be changed too and the reversal of the two
Electric machines must be installed in locations of ease phases will be required. Check the direction of rotation
access, allowing periodic inspections, local maintenance and the phase sequence before operating the generator.
services and, if required, the removal of equipment for
external maintenance services.
The following environmental characteristics must be
ATTENTION
ensured: Generators supplied with single direction of
Clean and well-ventilated place; rotation can only be operated in the specified
The installation of other equipment or walls should not direction of rotation. If inversion of the
obstruct generator cooling; direction of rotation is desired, you must
The space around and above the generator must be contact the factory through your nearest WEG
sufficient for its maintenance and handling; representative.
The environment must comply with the generator
protection class.
10.4 FOUNDATIONS
10.2 PROTECTIONS
The foundation or structure where the generator is to be
installed must be must be stiff enough, flat, free of
The generator is supplied with a shaft-locking device to
external vibrations and able to withstand to the
prevent damages to the bearings during the transport.
mechanical efforts to which it will be submitted during
This locking device must be removed before the generator
the start-up or in case of generator short-circuits.
installation.
The type of foundation chosen depends on soil
condition or on the floor resistance.
ATTENTION If the foundation dimensions are not executed
accurately, serious vibration problems may occur with
The shaft locking device must be used the generator and drive machine as a whole.
whenever the generator is removed from its The dimensioning of the foundation structure must be
base (decoupling from the drive machine) and executed by considering the dimensional drawing and
so prevent bearing damages during the the information about the mechanical efforts on the
transport. foundation, the anchoring procedures and the heat
The shaft end is protected by a protective exchanger details (if any).
grease coat. During the generator installation,
remove this shaft protection from the race
where the shaft grounding brush contacts it. ATTENTION
Provision must be made for a minimum
10.3 DIRECTION OF ROTATION clearance of 2 mm between the anchor plate
and the generator feet for inserting the
The generators are normally designed to operate in a compensation plates (wedges) used for the
single direction of rotation as indicated by the arrow on alignment adjustment.
the frame at the drive end side.
NOTE
The user is responsible for the foundation
dimensioning and construction.
DIRECTION OF
ROTATION
Figure 10.1: Direction of Rotation
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10.5 ANCHOR PLATE SET
The anchor plate set comprises anchor plate, leveling bolts, leveling wedges, alignment bolts and anchor bolts.
Procedure for the assembly, leveling and grouting of the anchor plates
Step 1
Construct the foundation (1) using anchor bars (2)
as per the dimensional drawing, considering the
efforts to which this base will be submitted as
shown in the drawing.
Step 2
Position the anchor bolts (3) in the anchor bars
and the leveling bolts on the primary concrete
surface.
Step 3
Place the anchor plates (5) on the leveling bolts.
Step 4
Level the anchor plates by using the required
instruments. Please consider a 2 mm clearance
between the anchor plates and the generator
base for inserting the leveling wedges required for
the generator alignment.
Step 5
After the anchor plates have been leveled, they
must be grouted (6) together with the anchor
bolts for their definitive fixation.
Step 6
After the grout cure, place the generator on the
anchor plates, align it by using the horizontal
alignment bolts (7 and 8) and fix it in place
through it base holes and anchor bolts.
Figure 10.2: Anchor Plate
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Leveling and grouting with the anchor plates fixed the The half of the maximum difference of the dial indicator
generator measurement in a full revolution represents the maximum
eccentricity.
The maximum allowed eccentricity for rigid or semi-rigid
coupling is 0.03 mm.
When flexible couplings are used, values higher than those
above are acceptable, however the value defined by the
coupling manufacturer should not be exceeded.
We recommend keeping a safety margin for these values.
Angular Alignment
Figure 10.3: The anchor plate and the generator
The anchor plates can be leveled and grouted after they

have been fastened to the generator base with the 2 mm
wedges between the generator base and the anchor Axial measurement
plates.
For this purpose, place the generator with the anchor
plates on the leveling cap bolts, level off the base using Figure 10.5: Angular misalignment
these leveling cap bolts and pre-align the generator using
Figure 10.5 shows the angular misalignment and a
the alignment bolts (7 and 8).
practical way for making the respective measurement.
Secure the generator in place using the anchor bolts and
The measurement is made at 4 different points displaced
grout the anchor plate and anchor bolts for its definitive by 90 each other with two half-couplings rotating
fixation. together in order to eliminate the effects caused by the
irregularities of the dial indicators on the contact surface.
10.6 ALIGNMENT / LEVELING Choosing the vertical top point 0, half of the measuring
difference of the dial indicator at the positions of 0 and
The generator must be aligned correctly with the driving 180 represents the vertical misalignment. This error must
machine, particularly in case of direct coupling. be corrected properly by adding or removing the assembly
An incorrect alignment may cause bearing damages, wedges. Half of the difference of the dial indicator
vibrations and even the shaft rupture. measurement at the positions of 90 and 270 represents
The alignment must be made according to the the horizontal misalignment.
recommendations of the coupling manufacturer. This must be properly corrected by side/angular moving of
It is necessary to make the machine parallel and angular the generator.
alignment as follows: Half of the maximum difference in the comparison clock
measurement in a full rotation represents the maximum
Parallel Alignment angular misalignment.
Half of the difference of the dial indicator measurement
during a complete revolution represents the maximum
angular misalignment.
The maximum allowed misalignment for the rigid or semi-
flexible coupling is 0.03 mm
When flexible couplings are used, values higher than those
Radial measurement above are acceptable, however the value defined by the
coupling manufacturer should not be exceeded.
Figure 10.4: Parallel misalignment We recommend keeping a safety margin for these values.
During the alignment/leveling procedures, consider the
Figure 10.4 shows the parallel misalignment of the two temperature effects of the generator and the driving
shaft ends and a practical way for making the machine. Different expansion levels of the coupled
measurements is by using proper dial indicators. machines can change the alignment/leveling during the
The measurement is made at 4 points at 90 with two operation
half-couplings rotating together in order to eliminate the
effects caused by contact irregularities of the dial 10.7 COUPLING
indicators. Choosing the vertical top point 0, half of the
measuring difference of the dial indicator at the positions Use only suitable couplings able to transmit pure torques
of 0 and 180 represents the vertical coaxial error. This without generating transverse forces.
error must be corrected properly by adding or removing The generator shaft and the driving machine centers must
the assembly wedges. Half of the difference of the dial be in a single line, both for the elastic and rigid couplings.
indicator measurement at the positions of 90 and 270 The elastic coupling are intended for mitigating the
represents the horizontal coaxial error. residual misalignment effects and preventing the vibration
This provides an indication when leveling (raising or transfer between the coupled machines, which is not the
lowering) or moving to the right or to the left at the drive case when rigid couplings are used.
end side is required to eliminate the coaxial error. The coupling must be assembled or removed only with the
use o appropriate devices and never by means of rustic
devices (hammer, mallet, etc.).
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Generators fitted with sleeve bearings
Figure 10.8: Coupling axial play.
NOTE
If the shaft cannot be turned, consider the
shaft position, the shaft forward displacement
(according to the shaft markings) and the axial
play recommended for the coupling.
Before starting the operation, check if generator shaft

allows the free axial movement in the above play
conditions.
During the operation, the arrow must be positioned on
the central mark (red) that indicates that the rotor is at
Figure 10.6: Sleeve Bearing the magnetic center.
The generators fitted with sleeve bearings must be At the start-up or even during the operation, the
coupled direct to the driving machine or by means of generator will be allowed to move freely between the
reducer. two markings.
The coupling by belts and pulleys is not allowed.
The shaft end has three markings, the central mark (red Under no circumstance, the generator will be allowed
painted) is an indication of the magnetic center and the to operate constantly with axial effort on the bearing.
two external markings indicate the limits of the rotor axial The used sleeve bearings are not designed to withstand
movement. constant axial efforts.
After the machine set has been aligned and checked ( in

cold and hot operating conditions) the generator must
be secured in place on the anchor plate as shown in the
figure below:
Welding at four points
Figure 10.9: Pin fastening of the generator to the anchor plate
ATTENTION
Figure 10.7: Magnetic center marking The pins, nuts, washers and leveling wedges
may be delivered with the generator upon the
For the correct coupling of the generator, the following customer request.
factors should be considered:
Bearing axial play;
The axial displacement of the machine coupled to the
NOTES
generator (turbine);
The maximum axial play of the opening allowed for the The user is responsible for the generator
coupling. installation.
WEG shall not be responsible for damages to
the generator, associated equipment and
ATTENTION installation occurred as a result of:
Displace the shaft fully to the front side to Excessive transmitted vibrations;
make correct measurement of the axial Precarious installations;
play; Alignment failures;
Align the shaft ends carefully by using a Improper storage conditions;
flexible coupling whenever possible, Noncompliance with the pre-operation
allowing a minimum axial play of 3 to 4 instructions;
mm between the couplings. Incorrect electrical connections.
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10.8 ELECTRICAL AND GROUNDING to the cable markings as shown in the generator-wiring
CONNECTIONS diagram.
10.9 THERMAL PROTECTIONS

ATTENTION
Make a careful analysis of the electric wiring 10.9.1 Protection location
diagram delivered with the generator before
connecting the power and ground cables as The turbogenerators are fitted with overtemperature
well as the accessories. protection devices installed in the main stator, on the
For the electrical connection of the auxiliary bearings and other components that require temperature
equipment (voltage regulator, hydraulic unit, monitoring and thermal protection.
etc.), please refer to the specific manuals of These devices must be connected to an external
these items. temperature monitoring and protection system.
10.9.2 Temperature sensors

10.8.1 Main stator connections (power cables)
The Resistance Temperature Detector (RTD) is a
The power cables are connected to insulator terminals in calibrated resistance element. Its operation is based on
the terminal box or to copper terminals, depending on the the principle that the electrical resistance of a metal
generator design. conductor varies linearly with the temperature. The
The location of the power and neutral terminals is detector terminals must be connected to a control panel,
identified in the specific dimensional drawings of each which includes a temperature meter.
generator.
The stator terminal connections must comply with the
stator wiring diagram specific for that generator. NOTE
Make sure that the connection cable cross-section and
The Resistance Temperature Detector (RTD)
connection cable insulation class are appropriate to the
can be monitored according to the absolute
generator current and voltage.
temperature supplied by its instantaneous
The stator terminal markings and their connections are
resistance value. Based on this information,
shown in the specific wiring diagram of each generator, in
the relay can read the temperature and
compliance with IEC60034-9 or NEMA MG1 standards.
define the alarm and disconnection
The phase sequence can be changed by inverting any two
parameters based on predefined
connections, however the generator must turn in the
temperatures.
direction of rotation specified in the wiring diagram and by
the indication arrow as viewed onto the shaft end to be
coupled. 10.9.3 Temperature limits for the windings
Generators with a single direction of rotation must turn
only in the indicated direction since fans and other devices The temperature of the winding hottest-spot must be kept
allow only single direction of rotation. below the thermal class limit. The total temperature is
If the generator should be operated in opposite direction equal to the sum of the room temperature with the
of rotation to the shown one, contact the factory through temperature rise (T) plus the difference that exists between
your nearest WEG representative. the winding average temperature and the hottest spot.
Before making the electrical connections between the According to the applicable standard, the maximum room
generator and the user power supply, check the winding temperature is 40C. Above that temperature, operating
insulation resistance and the phase sequence carefully. conditions are regarded as special.
Table 10.1 shows the numeric values and the admissible
10.8.2 Grounding temperature composition for the hottest spot:
The generator grounding terminal is located on the

Insulation class F H
generator frame or on its base and inside the main
terminal box or on the terminal strip. Ambient temperature C 40 40
These terminals should be used for connecting the T = temperature rise (resistance method) C 100 125
grounding cables and the shield as required by local Difference between the hottest spot and the
C 15 15
standards. average temperature
Total: hottest spot temperature C 155 180
10.8.3 Accessories Table 10.1: Insulation Class
The main accessories supplied with turbogenerators are:

Stator winding temperature sensors; ATTENTION
Bearing temperature sensors; If the generator operates with winding
Space heater; temperatures above thermal class limits, the
Water leak detector; insulation and, consequently, the generator
Water flow sensors; useful life will be reduced significantly. This
Oil flow sensors; may even result in the generator burnout.
Other accessories (if requested) are listed in the specific
WIRING DIAGRAM of the involved generator.
The accessories are connected to the connection strips
located inside the terminal box for accessories according
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10.9.4 Thermal bearing protections BEARINGS

Maximum temperatures for protection adjustments (C)
The temperature sensors installed on the bearings are Alarm Trip
used to protect them against damages caused by an 110 120
overtemperature operation. Table 10.3: Maximum bearing temperature
10.9.5 Alarm and disconnection temperatures

ATTENTION
The temperature level for the alarm and trip functions
The alarm and trip values can be defined
should be set as low a possible. This level can be
through experience, but they should never
determined by using the test results as reference or the
exceed the above ones.
generator operating temperature.
The alarm temperature can be set to 10C above the
machine operation temperature at full load considering the The generator protection devices are listed in WEG Wiring
highest ambient temperature. Diagram, specific for each generator.
The temperature set for the trip function should not The nonuse of these devices is the user's responsibility,
exceed the maximum allowed temperatures for the stator and in case of damages, may void the warranty.
winding (according to the insulation class) and for the
bearings (according to the used lubrication system). 10.9.6 Ratio between temperature and the
ohmic resistance of Pt 100 temperature
STATOR WINDING
sensors
Temperature Maximum temperatures for
Class protection adjustments (C)
Alarm Trip The table 10.4 shows the temperature values as function
F 140 155 of the ohmic resistance measured for Pt 100 temperature
H 155 180 sensors.
Table 10.2: Maximum stator temperature
Formula: - 100 = C
0.386
C 0 1 2 3 4 5 6 7 8 9
0 100.00 100.39 100.78 101.17 101.56 101.95 102.34 102.73 103.12 103.51
10 103.90 104.29 104.68 105.07 105.46 105.95 106.24 106.63 107.02 107.40
20 107.79 108.18 108.57 108.96 109.35 109.73 110.12 110.51 110.90 111.28
30 111.67 112.06 112.45 112.83 113.22 113.61 113.99 114.38 114.77 115.15
40 115.54 115.93 116.31 116.70 117.08 117.47 117.85 118.24 118.62 119.01
50 119.40 119.78 120.16 120.55 120.93 121.32 121.70 122.09 122.47 122.86
60 123.24 123.62 124.01 124.39 124.77 125.16 125.54 125.92 126.31 126.69
70 127.07 127.45 127.84 128.22 128.60 128.98 129.37 129.75 130.13 130.51
80 130.89 131.27 131.66 132.04 132.42 132.80 133.18 133.56 133.94 134.32
90 134.70 135.08 135.46 135.84 136.22 136.60 136.98 137.36 137.74 138.12
100 138.50 138.88 139.26 139.64 140.02 140.39 140.77 141.15 141.53 141.91
110 142.29 142.66 143.04 143.42 143.80 144.17 144.55 144.93 145.31 145.68
120 146.06 146.44 146.81 147.19 147.57 147.94 148.32 148.70 149.07 149.45
130 149.82 150.20 150.57 150.95 151.33 151.70 152.08 152.45 152.83 153.20
140 153.58 153.95 154.32 154.70 155.07 155.45 155.82 156.19 156.57 156.94
150 157.31 157.69 158.06 158.43 158.81 159.18 159.55 159.93 160.30 160.67
Table 10.4: Temperature X resistance (PT100)
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10.9.7 Space heater

The cooling air is provided by the internal (front and rear)
The space heaters in the generators are intended for fans, crosses the internal windings and exits through the
preventing water condensation when generators are not lower section of the generator where the radiator or the
operated for long periods. water radiators is(are) located.
These resistances must always be energized during the The hot air passes through these radiators, is cooled and
generator storage period and when the generator returns to the inside of the generator.
remains at standstill and switched off before the
generator operation is started again.
The specific WEG Wiring Diagram and the nameplate on
Air
the generator frame show the supply voltage and the Outlet
rated power of the installed resistances, as well as show
the terminal markings.
10.10 PANEL PROTECTIONS
In addition to the protection devices listed here, other

protection devices should installed in panel.
The panel protections are defined by the customer
according to his requirements. The table 10.5 lists the
usual protections devices for the control panels:
Cold
Warm Air
POWER PROTECTIONS Air Outlet
Up to 3000 kVA Medium CP-PR-27-32-49-50G-51V-
Cold
Voltage 52-59 Air
I l t
3000 to 7500kVA Medium CP-PR-32-40-46-49-50G-
Voltage 51V-52-59-87
Over 7500kVA Medium CP-PR-27-32-40-46-49-50G-
Voltage 51V-52-59-78-81-87
Table 10.5: Panel protections.
Symbols:
Radiators
CP - Capacitor Figure 10.10: Cooling by bottom heat exchanger (D5 and D6).
PR - Lightning arrester
27 - Undervoltage D5 and D6 Constructive Form:
32 - Inverse power Top heat exchanger
40 - Field loss The generator cooling consists of two internal fans and
46 - Current unbalance one or two water radiators installed in the air-to-water
49 - Overload heat exchanger on top of the generator.
50G - Ground overcurrent The cooling air is provided by the internal (front and rear)
50 - Instantaneous Overcurrent fans, crosses the internal windings and exits through the
51 - Timed overcurrent top section of the generator where the radiator or the
51V - Overcurrent with voltage locking water radiators is(are) located.
52 - Circuit Breaker The hot air passes through these radiators, is cooled and
59 - Overvoltage returns to the inside of the generator.
64 - Field ground
87 - Differential
78 - Phase Angle
81 - Frequency
86 - Blocking Relay
ATTENTION
Protection 59 (Overvoltage) is mandatory to
prevent damages to the generator and the
supplied load.
10.11 GENERATOR COOLING
D5 and D6 Constructive Form

Bottom heat exchanger
Two internal fans and one or two water radiators that
are supplied with the generator and must be installed
according to its specific dimensional drawing provide
the generator cooling.
Figure 10.11: Cooling by top heat exchanger (D5 and D6).
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Constructive Form B3:
The generator cooling is provided by internal axial fans ATTENTION

and the air-to-water heat exchanger located on top of the To prevent premature corrosion in case of
generator. cooling with seawater, the materials that get in
The ventilation provided by the internal fans, crosses the contact with water (pipes and tube sheets)
windings and exits through the generator upper section must be corrosion-resistant.
where the heat exchanger radiators are located. The hot In addition, the radiators must be fitted with
air passes through the radiators, is cooled, and returns to sacrificial anodes (for example, Zinc or
the inside of the generator. Magnesium), which are corroded during the
exchanger operation and so protect the
heads. As a result, these anodes must be
replaced from time to time according to the
corrosion degree shown, thus keeping the
head integrity.
The cooling system protection devices must be

monitored from time to time.
The air-to-water inlets and outlets should not be

obstructed. Otherwise, they can cause overheating
and even the generator burnout.
Figure 10.12: Cooling with the top heat exchanger (B3). ATTENTION
The data of the radiators that form the air-to-
water heat exchanger are indicated on the
NOTE radiator nameplate and in the generator
The usual types of turbogenerator cooling are dimensional drawing.
shown above. Other cooling types may be The data should be followed for correct
used according to the user's requirements. operation of the generator ventilation system
and to prevent overheating.
10.12 WATER RADIATORS
The radiator is a surface heat transmitter, designed to

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

and from the air to the water.
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11 ELECTRICAL CONNECTIONS AND ACCESSORIES
11.1 TERMINAL MARKINGS
U1, V1 and W1 Phases of main stator

U2, V2 and W2 Neutral cables of main stator
UR, VR, WR and N Reference voltage and power supply of voltage regulator.
13, 14 and 15 Phases of the PMG or auxiliary coil.
I and K Stator of main exciter I(+) and K(-)
16 to 19 Space heater
20 a 25 Temperature sensor (Pt 100) on stator winding.
26 - 27 Moisture sensor
68 to 69 Temperature sensor (Pt 100) on DE bearing.*
70 to 71 Temperature sensor (Pt 100) on NDE bearing.*
60 a 63 Thermometer for water
64 to 65 Diodes fault detector.
66 to 77 Current transformer.
88D to 91D Thermometer on DE bearing
88T to 91T Thermometer on NDE bearing
525 a 527 Water flow sensor
500 - 501 Water leak detector
579 to 586 Thermometer at water inlet and water outlet
636 to 643 Thermometer at air inlet and air outlet
ADDITIONAL ACCESSORIES In generators fitted with more than 1 Pt 100 on each bearing, the additional temperature
sensors are identified by the number 1 that corresponds to the first Pt 100 (1 for the first additional Pt 100) or 2 (for the
second additional Pt 100) and so on.
Example: NDE bearing fitted with 2 three-wires Pt 100 the first Pt 100 is identified by the numbers 70 - 70 - 71 and the
second one with the numbers 170 - 170 - 171.
Note: The terminal markings may differ from previous ones upon customer request or for special designs.
In addition to this manual, we recommend to refer also to the wiring diagrams supplied with generator.
11.2 WIRING DIAGRAMS
1. Following wiring diagram should be used or the electrical connections of the turbogenerator.
2. Terminal numbering refers to specific accessories.
3. The installed accessories as well as the number of accessories depend on the generator size and its application.
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11.2.1 Thermal protection on main stator winding
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11.2.2 Generator cooling system
WATER LEAK DETECTION RELAY

WATER FLOW SWITCH HUMIDITY DETECTOR
TO BE INSTALLED IN PANEL
THERMOMETERS (WATER) THERMOMETERS (AIR)
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11.2.3 Bearings
THERMAL PROTECTIONS OIL FLOW SWITCH
THERMOMETERS (OIL)
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11.2.4 Space heater and exciter
11.3 DESCRIPTION OF THE ACCESSORY FUNCTION
In order to get right understand of this description you is detected. If water shortage is detected in system
should check the wiring diagrams found in the previous during the generator operation, the generator
chapter. shutdown sequence should be started immediately.
1. PT 100 Temperature sensor with terminal numbers 20- 5. The terminals 26 and 27 are related to moisture
20-21, 22-22-23 and 24-24-25 are the main sensor. They are installed in some generators as an
sensors for measuring temperature and protecting additional device for detecting water leak in the
the generator stator winding and they should present radiator by means of the presence of moisture.
the following actuation point:
Alarm: 130C 6. The terminals 88D-88D-90D-91D are connected to
Shutdown: 155C the thermometer that contacts the DE bearing. The
Pt 100 temperature sensors with terminal numbers terminals 88T-88T-90T-91T are connected to the
20R-20R-21R, 22R-22R-23R and 24R-24R-25R thermometer that contacts the NDE bearing.
are reserve sensors and they will be activated in case
of failure of the main sensors. 7. The terminals 636-637-638-639 are connected to
the thermometer that contacts the generator air inlet.
2. Pt 100 temperature sensors with terminal number The terminals 640-641-642-643 are connected to
68-68-69 and 168-168-169 are sensors for the thermometer that contacts installed the generator
measuring the temperature and protecting the DE air outlet.
bearing, and the sensor with the numbers 70-70-71
and 170-170-171 are for measuring the 8. The terminals 579-580-581-582 are connected to
temperature and protecting the NDE bearing and the thermometer that contacts the water inlet of front
should be activated with following temperatures: radiator. The terminals 583-584-585-586 are
Alarm: 110C connected to the thermometer that contacts the
Shutdown: 120C water outlet of front radiator.
3. The terminal with numbers 500-501 are connected to 9. The switches with terminals 534-535 and 536-537
the electrode of the water leak detectors and to the corresponds to the contacts of oil flow sensor at the
bottom plate of water trough of the radiator support. oil inlet piping that lubricates and cools the DE and
These terminals should be connected to the terminals NDE bearings, respectively. These sensors detect the
that have the same numbering of the water leak presence or the lack of oil flow in these piping.
detector in the generator protection panel. The In case of oil shortage in inlet piping for one or both
generator shutdown sequence should be executed bearings during or after star-up procedure, the
immediately after a leakage in the heat exchanger is equipment shutdown sequence should be executed
detected. immediately in order to adopt the required corrective
actions.
4. The terminal with numbers 525-526-527 are related
to water flow sensor of radiators. The bearings cannot be without lubrication under
This sensor monitors the water flow and deactivates any circumstances while the shaft of generating
the generator drive as soon as the lack of water flow unit is operating, which may result in irreversible
damage to these bearings.
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10. The terminals 16-17 supply the space heaters, 11. The terminals I - K correspond to the main exciter
ensure moist removal inside the generator and stator and should always be powered by the
maintains the temperature inside the generator. The electronic voltage regulator.
space heaters should always be switched On during The main exciter generates a three-phase voltage in
longer standstills in order to ensure that temperature rotor that is rectified by diodes in the rotating rectifier
inside the generator remains always higher than the and supplies the main field of generator (main rotor).
ambient temperature. 12. The terminals 13-14-15 match PMG stator of
the turbogenerator Model SP_ and supply the power
circuit of voltage regulator.
11.4 ACCESSORIES AND PROTECTIONS
In order to get right understand of this description, check the generator wiring diagram.
Mea-
Description Location Operation point sured Function
value
STATOR
Thermal resistance Pt -100 (Phase Alarm=130C Measures stator temperature
Stator Winding
U) Shutdown = 311.00F (phase U)
Temperature sensor Pt 100 (Phase Alarm=130C Measures stator temperature
Stator Winding
V) Shutdown = 311.00F (phase V)
Temperature sensor Pt 100 (Phase Alarm=130C Measures stator temperature
Stator Winding
W) Shutdown = 311.00F (phase W)
FRONT AND REAR BEARING
Measures bearing temperature
Alarm=110C
Temperature sensor Pt 100 DE bearing and protects against
Shutdown = 248.00F
overtemperature
Measures bearing oil
Alarm=60C
Contact thermometer Bearing oil reservoir temperature and protects
Shutdown = 80C
against overtemperature
_
Oil flow switch Oil piping Detects oil flow on bearings
COOLING SYSTEM
_ Measures water inlet
Thermometer (water inlet) Water circuit
temperature in radiator
_ Measures water outlet
Thermometer (water outlet) Water circuit
temperature in radiator
_ Measures air inlet temperature in
Thermometer (air inlet) Heat exchanger
heat exchanger
_ Measures air outlet temperature
Thermometer (air outlet) Heat exchanger
in heat exchanger
Detects water leakage in
Water leak detector In each radiator _
radiators
In the generator control Detects water leakage in
Relay of water leakage detector _
panel radiators
Detects water flow in the cooling
Water flow sensor Water circuit _
system
Detects the presence of
Moisture Sensor _
moisture inside generator
OTHERS ACCESSORIES
Maintains winding temperatures
Inside the chamber or Turn on when generator is
Space heater and prevents water
generator enclosure at standstill
condensation
Terminal box of neutral _
CT for protection conductor or panel Differential protection
(separate supply)
Main Terminal box _
CT for measuring Measures the current
or panel (separate supply)
Terminal box of neutral
Lightning arrester _ Surge protection
conductor and surge cell
Terminal box of neutral
Capacitors _ Surge protection
conductor and surge cell
Table 11.1: Accessories and shields
The alarm temperature of bearings and stator windings should be set to 10C higher than rated operating temperature and
should not exceed the values indicated in the table 11.1.
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12 START-UP
12.1 BEFORE FIRST START-UP 10. Increase speed up to the rated speed so the oil film on
bearings is formed readily.
Before first start-up of generator or after long standstill 11. The hydraulic jacking system, if any, should be turned off
periods, check following items: when the acceleration of the generator set reaches 80 rpm.
1. Generator fixing bolts should be tightened. Feet 12. Keep generator operating at rated speed and record
should be anchored and pinned; the temperatures of the bearings in 1-minute intervals
2. Measure the winding insulation resistance. Assure that until the temperature becomes constant. Any sudden
the insulation resistance is according to specified increase of bearing temperature indicates abnormality
value; for the bearing lubrication or bearing contact surface.
3. Check if generator is clean and if package, measuring 13. Monitor temperature, oil level of bearings and vibration
instruments and alignment devices have been level. If there is a significant change, stop generator
removed from generator working area; start-up in order to evaluate possible causes.
4. The couplings should be in good conditions, properly 14. When temperatures on bearings become constant you can
tightened and lubricated, if required; proceed with the next steps of the generator operation.
5. The generator should be aligned correctly;
6. Check if bearings are properly lubricated. Lubricant 12.3 POWERING-UP
should be as specified on nameplate. Check oil level
of the generators fitted with oil lubricated bearings. With generator at rated speed, assure that all protection
Bearing with forced lubrication should have oil devices have been tested and are operating properly, and
pressure and flow as indicated on the nameplate; in case of some fault, they act immediately.
7. Inspect connections of accessory cables (thermal Generator is powered-up by setting the voltage regulator
protectors, space heaters, etc.) and how they act on to the automatic mode.
control panel; The voltage regulator maintains the output voltage of
8. Check if all electrical connections meet the generator generator at reference voltage.
wiring diagram;
9. Check if connections and parameter settings of the In manual operation mode, the generator can be
electronic voltage regulator are in accordance with the powered up in steps until the rated voltage is reached.
Installation Manual; This operation mode is usually selected by the
10. The line cables connected to main terminals should be automatic/manual selector switch and is used only for
proper tightened in order to prevent short-circuit or generator commissioning tests.
loosening; Refer to the manual of voltage regulator for correct use of
11. Check cooling system. On machines with water this operation mode as well as to know the protections
cooling system, check the operation of water supply that are not enabled for this- operation.
system in the radiators;
12. Assure that generator air inlet/outlet are not obstructed;
NOTE
13. Moving parts of generator should be protected in
All measuring and control instruments should
order to avoid accidents;
be watched in all times in order detect any
14. The terminal box covers should be fixed correctly;
change and adopt the prompt corrective
15. Test operation of shaft oil pressure operated lifting
actions.
system (hydrostatic jacking), if any, and assure that it
operates correctly.
12.2 INITIAL MECHANICAL TURN 12.4 SYNCHRONIZATION AND LOAD
To synchronize generator with network bus:

After checking all items mentioned above the following
1. Turn on voltage regulator and allow it controls
procedures should be carried out to get generator initial turn:
machine voltage, making the required settings.
1. Switch Off space heater;
2. To connect generator to power system, the voltage
2. Set circuit breaker to test position;
signal, frequency and phase sequence should be
3. Set voltage regulator parameters according to manual;
equivalent.
4. Turn on oil pressure pump for raising hydrostatic
3. Set the circuit breaker to original position and execute
jacking (if any) of the bearings;
the synchronization and the line connection.
5. Check oil level of oil lubricated bearings;
6. If bearings are fitted with forced lubrication system,
THE ACTIVE POWER CONTROL (kW) OF
turn oil circulation system on and check the level, oil
GENERATOR IS MADE BY TURBINE POWER
flow and oil pressure making sure that they meet the
VARIATION.
nameplate data.
GENERATOR REACTIVE POWER CONTROL (kVAR)
7. If system is fitted with oil flow sensors, wait for flow
AND ITS POWER FACTOR ARE CONTROLLED BY
return signal of the oil circulation system of both
VARIATION OF THE EXCITATION CURRENT.
bearings that ensure that the oil get into bearings;
8. Turn on industrial cooling water system, check
required water flow and water pressure (generators NOTE
fitted with air-to-water heater exchange);
9. Rotate the generator shaft slowly to make sure that there is These functions can be parameterized by the
no dragging part or abnormal noises; voltage regulator.
After this procedure has been completed, proceed with the For the parameter setting, refer to the Voltage
following steps for the generator start-up sequence; Regulator Manual.
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13 GENERATOR OPERATION
The operation procedures vary significantly due 13.4 VIBRATION LIMITS
machine application and used control equipment.
This section describes only the general procedures. WEG generators are factory balanced and meet the
For operation procedures of control system and vibration limits specified in the standards IEC60034-14,
voltage regulator, refer to the specific manuals of each NEMA MG1 - Part 7 and NBR 11390 (unless different
equipment. values have been agreed in the Purchase Agreement).
All measuring and control instruments should be
watched in all times in order detect any change and The vibration are measured on the DE and NDE, in
adopt the prompt corrective actions. horizontal and axial directions.
13.1 SHAFT LIFTING SYSTEM (JACKING) When costumer sends half-sleeve coupling to WEG, the
generator is balanced with half-sleeve mounted on shaft.
Turbogenerator bearings fitted with jacking option during Otherwise, according to standards mentioned above,
the start-up or stop process by oil pressure, this system generator is balanced with half shaft key (i. e., key slot is
is driven by an external oil pump and following filled out during balancing procedure with a bar of the
procedures should be adopted: same width, thickness and high as the key slot).
Maximum vibration levels recommended by WEG for

ATTENTION generators during operation are indicated in the table
The oil pressure system for jacking should 13.1. These values are only general orientative values so
be turned on before start-up (speed = 0 rpm) specific conditions should be considered for each
and turned off only after machine exceeds application:
80 rpm. This oil pressure system should be
turned on during the deceleration process Vibration Levels (mm/s RMS)
after the machine reaches 80 rpm and Rated speed
(rpm) 355 a
turned off after stop (speed = 0 rpm). Frame size < 355 > 630
630
Alarm 4,5 4,5 5,5

13.2 WATER RADIATORS 600 n 1800
Shutdown 7,0 7,0 8,0
Control the water temperature at radiator inlet/outlet and Alarm 3,5 4,5 5,5
correct the water flow, if required. Regulate the water 1800 < n 3600
pressure only if necessary to overcome the resistance in Shutdown 5,5 6,5 7,5
radiator pipes. Table 13.1: Vibration (RMS)
For operation control, provide thermometer at the
radiator air/water inlet/outlet and record the temperatures The most common vibration causes in field are:
in determined intervals. During the thermometer Misalignment between generator and driving machine;
installation, also signaling or recording instruments Improper fixation of the generator onto the base with
(horns, lamps) can be installed at specific locations. loose wedges under one or more feet of the
generator and loose securing bolts;
13.3 BEARINGS Improper base with poor stiffness;
External vibration transmitted by other equipment.
Watch closely the system start-up as well as its first
operating hours.
ATTENTION
Before start-up, check: Generator operation at higher vibration levels
If the jacking system (if any) of is turned on. than specified above may impair its useful life
If the external lubrication system (if any) is On. and/or performance).
If the used lubricant meets the specification.
The lubricant characteristics.
The oil level (oil lubricated bearings). 13.5 SHAFT VIBRATION LIMITS
The trip and alarm temperature set for the bearings.
During first start-up, pay attention to vibrations and Generators fitted with proximity sensor or with provision
noises. for the installation of these devices (normally used in
If bearings do not run smoothly and uniformly, turn the generator with sleeve bearings), the shaft surfaces are
generator OFF immediately. machined with special finishing in the areas adjacent to
The generator must operate during several hours until bearings in order to assure correct measurement of shaft
the temperature in bearings stabilizes and remains vibration.
within the temperature limits mentioned previously. The measured shaft vibration should meet IEC 34-14 or
In case of overtemperature, switch the generator OFF NEMA MG 1 standard.
immediately and check bearing temperature and The alarm and shutdown values in table 13.2 specify the
temperature sensors. maximum allowable vibration levels for electrical machine
After bearings have reached the operating temperature, coupled according to ISO7919-3 standard.
check plugs, joints and shaft end for leakage.
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These values above are only indicative and for each 13.6 STOP
application should be considered the specific site
conditions, such as the diametric clearance between (manual mode local)
shaft and bearing. To stop the generator:
1. Reduce generator load up to 5 - 10% of rated
Shaft Vibration (m - peak-to-peak) current;
Rated speed
(rpm) 280 e 355 a 2. Open armature circuit breaker;
Frame size > 450
315 450 3. Disable voltage regulator;
Alarm 110 130 150 4. Shutdown the primary machine;
1800 5. Enable the bearing jacking system (if any) when
Shutdown 140 160 190
speed reaches 80 rpm;
Alarm 85 100 120 6. After generator is stopped, shutdown jacking
3600
Shutdown 100 120 150 system (if any), close cooling water valve (if any) and
turn off bearing oil circulation system.
Table 13.2: Shaft vibration 7. Turn on space heater if generator will be idle by
extended time.
Generator operation with shaft vibration in the area of
alarm or shutdown levels may cause damage to the
bearing shell.
Main causes for increase of the shaft vibration are:
Unbalance, coupling or other problems that have an
indirect influence on the machine vibration;
Shaft machining problems during the manufacturing
process;
Stress or residual magnetism on the shaft surface
where measurements are made;
Scratches, knockings or variations in shaft finishing at
the measuring area.
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14 MAINTENANCE
14.1 GENERAL moisture) by cleaning and drying it for removing dust and
moisture.
The maintenance of generators applied correctly should
consider following procedures: 14.4 WINDINGS CLEANING
Keep generator and associated devices clean;
Check insulation levels periodically; In order to ensure high performance and longer useful life
Check overtemperature periodically (windings and for the machine, maintain windings free of dirt, oil, metal
bearings); dust, contaminants, etc.
Check wears, lubrication and useful life of bearings; Ensure that operation site is clean, make periodical
Check ventilation system and ensure correct air flow; inspections and clean the machine and if required
Inspect heat exchanger; impregnate the winding again (for this procedure contact
Check machine vibration levels; WEG ).
Inspect associated equipments (hydraulic unit, oil The windings may be cleaned with industrial vacuum
pressure system jacking, voltage regulator); cleaner with fine and non-metallic tips or by rubbing with
Inspect all accessories and generator protection dry cloth.
devices ensuring correct operation and connections. For extreme dust conditions it can be necessary to clean
Non-observance of one of the item above could result in with proper liquid solvent. This cleaning procedure should
unexpected stops of the equipment. The required executed as fast as possible to not expose windings to
inspection frequency depends on the local condition of solvent action for long times.
the application. After cleaning with solvent, windings should be dried
thoroughly. Measure insulation resistance and
If repair, recondition or overhaul of the generator or some polarization index to determine if windings are dried
part is required, please contact WEG. thoroughly.
In addition to its well-trained service centers, WEG Time required for winding drying process varies to
supplies all factory and engineering services in order to weather conditions such as temperature, moisture, etc.
provide full-service to your company.
DANGER
14.2 GENERATOR CLEANING
Most cleaning solvents are very toxic and
Maintain generator enclosure clean, free of oil and dust flammable.
and so improve the machine heat exchange to the Solvents should not be used on straight
surrounding medium. parts of coil since the protection against
Clean inner surfaces of the generator, removing dusts, corona effect may be damaged.
debris and oils.
Use for cleaning always clean cotton cloth. If the dust Inspections
is not abrasive, industrial vacuum cleaner can be used
for the cleaning procedure. Remove all dirt and dust Make following inspections after carefully cleaning of the
from the fan cover, fan blades and generator housing. windings:
Oil impregnated debris and moisture can be removed Check insulations of windings and connections.
with cloth soaked in properly solvent. Check fastening of spacers, winding head lashing, slot
Clean also the terminal boxes. Maintain terminals and wedges, bandages and supports.
connectors clean and free of oxidation and in good Assure that there is no cable breakage, poor welding,
conditions. Avoid grease or verdigris on connection or short-circuit between turns, against mass or
components. connections. If some is detected, contact WEG
Authorized Repair Shops.
NOTE Assure that cables are connected properly and
terminals are well tightened. Retighten, if required
If generators are used for no-breaks supplying,
they must be operated from 2 to 3 hours each Reimpregnation
month, depending on the moisture at the
installation site. If winding insulation (resin layer) has been damaged
during cleaning or inspection process, retouch the
damaged parts by using proper insulation resin (contact
14.3 STATOR, ROTOR AND EXCITER WEG).
WINDING INSPECTIONS
Insulation resistance
Stator, rotor and exciter winding insulation should be
The insulation resistance should be measured after all
measured in regular intervals, specially in wet weather or
maintenance procedures are completed.
after extended generator standstill.
Inspect windings visually in regular intervals, record and
repair all detected damages.
Low measured values or sudden variations of insulation
resistance should be investigated carefully.
The insulation resistance could be increased to proper
values when it is low (due to dust and excessive
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Radiator operation and performance

ATTENTION
Measure the insulation resistance of the To control the generator operation we recommend that
stator, rotor and exciter windings when water and air temperatures at radiator inlet and outlet are
generator was out of operation for longer measured and recorded periodically.
time and before it is powered-up again. The radiator performance is expressed by the
Ensure that measured values met the temperature differences between cold water and cold air
specified ones. during regular operation. This difference should be
controlled periodically. If this temperature difference
increases after a longer period of regular operation, this
14.5 INSPECTION AND CLEANING OF is a sign that the radiator should be cleaned.
RADIATORS Performance decrease or radiator damage may also be
caused due to the accumulation of air inside the radiator.
Guidelines for heat exchanger removal and In this case, a deaeration of radiator and water piping
maintenance may correct this problem.
Proceed as follows for removing the heat exchanger: The water pressure difference at the water inlet and outlet
1. Close all water inlet and outlet valves after stopping can be a sign that radiator cleaning is required.
ventilation; Measure and record the water pressure difference at the
2. Drain water from radiator through the drain plugs; water inlet and outlet. Compare periodically the
3. Unscrew the heads retaining cap screws, nuts and measured values with the first measured value. An
washers; increase of the pressure difference indicates that radiator
4. Scrub pipe inside surface of the pipes by using nylon cleaning is required.
brushes for removing all scales. If during the cleaning
process damages are detected in the radiator pipes, 14.6 GENERATOR OUT OF SERVICE
repair them.
The following procedures should be adopted when
Radiator storage after operation generator remains long periods out of service:
Turn the space heater on to ensure a slightly higher
When radiator is maintained out of operation during long temperature inside generator than the ambient
periods for maintenance procedures, drain out all water temperature, thus preventing water condensation and
and then dry it. Drying may be carried out with pre- consequent insulation resistance drop of the windings
heated compressed air. During the winter, when the and oxidation of metal parts.
water in the radiator pipes can freeze, drain all water out All water pipes should be drained in order to reduce
even for short standstill periods, in order to avoid pipe corrosion and deposition of suspended matter of the
deformation and damages. cooling water.
Follow also the procedures mentioned in chapter 5 of this
NOTE Manual Extended Storage
During short stops, when water is not drained

from radiator, maintain low water flow
circulating through the radiator pipes to
ensure that the harmful products such as
ammonia and hydrogen sulfates compounds
are purged out from the radiator.
Radiator maintenance
Radiator can be operated during many years without

requiring any cleaning when supplied by clean water.
When radiator is supplied by dirty water, a complete
cleaning is required every 12 months.
The increase of the air temperature may be a sign that
radiator is dirty.
When cold air temperature, at the same operation
condition, exceeds the specified value, you can assume
that pipes are dirty.
If any corrosion is detected, proper corrosion protection
(for example, zinc anode, plastic, epoxy covering or
covering by similar products) is required, in order to
prevent more damages to the affected parts.
The external coatings of all radiator parts should be
maintained in good conservation conditions.
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15 BEARINGS
15.1 SLEEVE BEARINGS
ATTENTION
Following temperatures should be set for the
bearing protection system:
ALARM 110C
SHUTDOWN 120C
The alarm temperature should be set 10 C
1 higher than rated operation temperature,
however should not exceed the limit of
2 110C.
3
4
NOTE
5
At no circumstance, water can leak into the
oil reservoir, since water results in oil
contamination.
Figure 15.1: Sleeve bearing
15.1.1 Bearing connections

15.1.6 Lubrication
1. Oil inlet pipe of the hydrostatic jacking system, if any.
Oil should be changed every 20.000 operation hours
2. Bearing oil inlet pipe.
when bearings are fitted with forced lubrication system
3. Connection of the temperature sensor on bearing
and every 8.000 operation hours when bearing are self-
shell.
lubricated, or always when the oil characteristics
4. Oil outlet pipe/Sight glass of oil level.
changed. Check periodically the oil viscosity and pH.
5. Connection of the oil thermometer.
15.1.2 Bearings data NOTE
Characteristic data: type, size and oil flow rate are Check oil level daily and maintain the oil level
indicated on the DE and NDE bearing nameplate and about center of the of sight glass.
must be followed strictly in order to prevent bearing
overheating and damage.
Bearings should be lubricated with the specified oil
Hydraulic installation and generator bearing oil supply is
considering the flow rates indicated on the nameplate.
users responsibility.
All unused screwed hole should be closed with plugs and
no connection may present any leakage.
15.1.3 Bearings installation and operation Oil level is reached when lubricant is at the center of the
sight glass. The addition of more oil than required does
For parts list, assembling and disassembling guidelines,
not damage the bearings, but may cause oil leakage
maintenance details, refer to bearing Installation,
through the shaft sealing.
Operation and Maintenance Manual.
15.1.4 Hydrostatic jacking system ATTENTION
Due to application and technical features of some Cares to be taken during the lubrication
generators, the use of an auxiliary Hydrostatic Jacking is process will determine the bearing lifetime
required for providing an oil film during generator start-up and generator operation safety. Thus
and deceleration process, or when generator is running consider following guidelines:
for long periods at low speed. The selected elected should have suitable
The installation and operation of the hydraulic pump for viscosity for bearing operation
the shaft jacking system is users responsibility. temperature. This should be checked
during oil change or during periodical
maintenance procedures.
ATTENTION Machine operation with too low oil level
means lack of lubricant and could damage
Ensure correct speed for the jacking pump, if bearing sleeves.
any (see chapter START-UP). Minimum required oil level is reached
when lubricant reaches the bottom part of
sight glass with generator at standstill.
15.1.5 Setting of the bearing protections
Each bearing is fitted with temperature sensors. These

devices should be connected to a control panel that
gives information on the bearing temperature and
prevents bearing damage due to overheating.
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15.1.7 Sealing Oil type: Type and quantity of oil to be used are indicated
on the nameplate fixed on generator next to bearing.
After bearing maintenance, both halves of seal labyrinth Oil change: Bearing oil change should be carried out at
should be fixed together by a circlip ring. following intervals considering the bearing operation
They must be inserted into the ring seat, so the locking temperatures, as shown in table below:
pin is fitted into the undercut of the upper half part of Below 75C = 20.000 hours
housing. Poor installation damages the sealing. Between 75 and 80C = 16.000 hours
Before seal assembling, clean carefully the contact Between 80 and 85C = 12.000 hours
surfaces of the ring and seating and coat the contact Between 85 and 95C = 8.000 hours
area with soft sealing compound. Drain holes at bottom Between 90 and 95C = 6.000 hours
half of the ring should be cleaned and cleared. When Between 95 and 100C = 4.000 hours
installing this halve of the sealing ring, press it slightly
against bottom shaft side.
ATTENTION
15.1.8 Bearing maintenance Bearing lifetime depend on generator
operation conditions, environment conditions
Sleeve bearing maintenance: and preventive procedures adopted by the
Check periodically lubricant level and conditions; maintenance people.
Check noise levels and bearing vibration, The following guidelines should be followed:
Follow up and record operation temperature and The selected oil for the application should
retighten all fixing bolts. has proper viscosity for expected bearing
Clean generator frame. Remove dust and oil from the operation temperature. The type of oil
frame outside to improve the heat exchange with the recommended by WEG already considers
environment. these criteria.
NDE bearing is electrically isolated. The spherical seat Insufficient amount of oil may damage
of the bearing shell is covered by an insulation material. bearing.
The locking pin is insulated and the seals are made of Minimum level of oil is reached when
non-conductive material. lubricant reaches the bottom part of sight
The temperature control devices that contact the glass with generator at standstill.
bearing shells are also insulated.
15.2 OIL BEARINGS

ATTENTION
1. Oil inlet pipe Oil level should be inspected daily and
4 maintained in the middle of oil sight glass.
2. Oil sight glass
1
3. Oil outlet 15.2.2 Bearing operations
2 4. Temperature The system start-up should be watched carefully
sensor. during the first hours of operation.
Before start-up check:
3 If used oil meets the specification on nameplate.
Figure 15.2: Oil bearings The lubricant characteristics.
Oil level.
15.2.1 Lubrication guidelines The bearing temperatures set for shutdown and alarm.
During first start-up check if the are abnormal vibrations
Oil removal: When oil change is required, remove the and noises. If bearings do not run smoothly and quietly,
plug from the oil outlet pipe (3) and drain all oil. stop generator immediately.
For oil filling proceed as follows: The generator must operate during several hours until the
Close oil outlet pipe with plug (3). bearing temperature stabilizes within the temperature
Remove plug from oil inlet pipe of filter (1) (if any). limits mentioned above. If an overtemperature is
detected, stop the generator and check bearings and
Add specified oil up to the level indicated in sight
temperature sensors.
glass.
After operating temperature has been reached, check
plugs, joints and shaft seals for oil leakage.
NOTES
15.2.3 Protection device settings
1. All unused screwed holes should be
closed with plugs and no connection The temperature sensors installed on bearings should be
may leak. connected to a control panel to monitor bearing
2. Oil level is reached when lubricant is in overheating and so protecting the bearings against
the middle of sight glass. damage due overtemperature during operation.
3. Addition of more oil than recommended
does not damage the bearings, but may
result in oil leakage through shaft sealing.
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ATTENTION
ATTENTION
Following temperatures should be set for the
bearing protection system: Clean grease nipples before greasing
ALARM 110C procedure in order to prevent that foreign
SHUTDOWN 120C matter are drawn into the bearings with the
The alarm temperature should be set 10C grease.
higher than normal operation temperature, For lubricating, use manual grease gun only.
however should not exceed the limit of
110C.
15.3.2 Steps for bearing re-lubrication
15.3 GREASE BEARINGS 1. Remove drain plug.

2. Clean the area around the grease nipple with cotton
Grease nipple cloth.
3. With running rotor, add grease with manual grease gun
until grease comes out the drain hole or until the total
amount of grease as specified in the table has been
applied.
4. Run the generator for a longer time in order to drain all
grease excess.
5. Check the bearing temperature in order ensure that no
significant temperature changes have occurred.
15.3.3 Spring device for grease removal
When operator cannot access grease relief valve, some

generators are fitted with an extended spring device for
grease removing during bearing relubrication procedures.
Steps for lubrication:

1. Clean grease nipple with cotton cloth before starting
bearing lubrication procedure;
Grease drain hole 2. Remove dipstick with spring, clean spring and insert it
again;
Figure 15.3: Grease-lubricated bearings
3. With rotor running, add quantity of grease specified on
bearings nameplate using manual grease gun.
15.3.1 Lubrication guidelines 4. Grease excess is expelled through bottom drain hole
and deposits on spring.
Lubrication system has been so designed that during
5. Operate generator during certain time so all grease
lubrication procedures the old grease is removed from
excess is expelled through bottom drain hole and
bearing race and expelled through drain hole that
deposits on spring.
prevents the ingress of dust or other harmful
6. Remove this grease excess by removing the dipstick
contaminants into bearing.
with the spring remove the grease from the spring.
This drain hole prevents bearing damage due to
Repeat this procedure as necessary so often as
overgreasing.
required till no grease is deposit on the spring.
Grease bearings with running generator in order to
7. Check bearing temperature to ensure that no
ensure grease renewal in the bearing housing.
significant temperature changes have occurred.
If this is not possible due to rotating parts next to the
grease nipples (pulleys, etc.) that can injure the
maintenance people, proceed as follows:
15.3.4 Protection settings
With grease gun, apply about the half of total specified
amount of grease and operate the generator around 1 ATTENTION
minute at full speed;
Stop generator and apply the remaining grease. Following temperatures should be set at
bearing protection system:
The injection of total amount of grease at one time with ALARM 110C
the generator at standstill can cause lubricant penetration SHUTDOWN 120C
into the generator inside through internal bearing seal. The alarm temperature should be set 10C
higher than rated operation temperature,
however should exceed the limit of 110C.
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15.3.5 Bearing replacement
In order to avoid damages to steel laminations, insert

cardboard shims in the air gap in the same thickness of
the air gap after endshield removal.
Bearing disassembly is very easy provided suitable tools
are used (with 3 grips according to figure15.4).
Figure 15.4: Bearing extractor.
The extractor grips must be applied on sidewall on the

inner ring to be stripped, or on an adjacent part.
In order to assure good operation and avoid bearing
damages, it is essential that assembly of bearing is
carried out under complete cleanliness and skilled
personnel.
New bearings should be removed only from packaging
just before the assembly. Before installing the new
bearing, remove any burrs and correct any knocks on
bearing seat onto the shaft.
During bearing assembly procedures do not apply direct
blows by hammer. We recommend to heat the bearing
by inductive heater in order expand the bearing inner ring
and thus facilitate the bearing assembly onto the shaft.
The press support should be applied on the inner ring.
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16 EXCITER
EXCITER DIODES SET
Figure 16.1: Exciter of Turbogenerator SP_
1. Pilot exciter with permanent 8. Diodes set

magnets (PMG) 9. Heat sink
2. Fan 10. Varistor wiring bridge
3. Stator of auxiliary exciter 11. Varistor
4. Rotor of main exciter 12. Diode
5. Stator of main exciter 13. Heat sink
6. Exciter housing 14. Stranded cable
7. NDE endshield of the exciter
16.1 EXCITER 16.2 DIODES TEST
For good performance of its components, the Rotary rectifier bridge housed on diode wheel is formed
compartment of generator exciter should be cleaned. by 3 anode diodes and e 3 cathode diodes.
Perform periodic cleaning according to procedures These diodes are components that have higher durability
mentioned on item 14.3 of this manual. and not require frequent tests.
If generator shows any fault that indicates diodes
Windings damages, for example an increase of field current for
Check periodically insulation resistance of main and pilot same load condition, then these diodes should be tested
exciter windings to determine their insulation conditions according to following procedure:
following procedures in item 7.4 of this manual. 1. Remove rear cover of exciter (7) to access diodes;
2. Loose flex cables of all 6 diodes;
3. With ohmmeter measure each diode resistance in both
directions.
Diode is in good condition when presents low ohmic
resistance (until 100) in its direct direction and high
resistance (approx. 1 M) in the reverse direction.
Faulty diodes will present ohmic resistance of 0 or
higher than 1 M in both measured directions.
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16.3 DIODES REPLACEMENT 16.4 VARISTORS TEST
For replacing any diode WEG recommends you to follow Varistors are devices installed between both halves of
following procedures: rectifier bridge disk where are installed diodes and their
1. Replace damaged diodes by new ones considering the purpose is to protect diodes against overvoltage.
position of each diode anode and diode cathode. In case of fault of these components, replace them.
2. Diodes are supplied with stranded insulated An ohmmeter can be use to test varistor conditions.
connection cable (13) and connection terminal; The resistance of varistor should be very high (20.000
3. Clean carefully heat sink (9 and 12) around the ohms).
mounting holes of diode. If varistor damage is detected or if its resistance is too
4. Ensure that mounting area is free of burrs than prevent low replaced it.
perfect diode insertion into the heat sink.
5. Check diode thread to make sure it is clean and free of 16.5 VARISTORS REPLACEMENT
burrs.
6. Install diode in its correct position by using torque For replacing any varistor, WEG recommends to follow
wrench and tighten it according to the torques the guidelines below:
recommended in the table 16.1: 1. Replace damaged varistors by new ones according to
generator manufacturer specification.
Diode Base Torque Meter Tightening 2. For replacing the varistor loose the bolts that fix it to
Thread Wrench Torque the heat sink and the bolt that fixes varistor wiring
(mm) (mm) (Nm) bridge (10) to heat sink.
M12 24 10 3. When removing varistor note how components are
M16 32 30 assembled in order to install the new varistor in the
M24 41 60 same way.
4. Before mounting new varistor, ensure that all
Table 16.1: Diodes Tightening Torque. component contact surfaces (heat sink, wedges,
insulations and varistor) are leveled and smooth so that
ATTENTION allow perfect contact.
5. Secure the new varistor, tighten the bolt hat fixes it to
It is important that specified tightening the heat sink by applying only sufficient tightening
torques are applied in order to not damage torque to ensure good electrical connection. Excessive
diodes during assemble procedures. tightening torque may cause varistor cracks and
damage.
6. Tighten also the bolt that fixes the varistor wiring bridge
1. After diodes have been fixed, connected stranded
to heat sink.
cables as shown in figure above.
NOTE
Diode polarity is indicated by an arrow on its
housing. During diode replacement, ensure
that they are installed on the heat sink with
correct polarity.
Current conduction should

occur only in the anode-
cathode direction, i.e., in direct
polarization condition.
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17 GENERATOR PARTS
Figure 17.1: Parts of model SP_ turbogenerator _
1. DE bearing 16. Internal NDE fan

2. Shaft 17. Closing of NDE endshield/frame
3. DE seal 18. NDE seal
4. Closing of DE endshield/frame 19. Exciter fan
5. Internal DE fan 20. Pilot exciter (PMG)
6. Stator winding 21. Exciter compartment
7. DE endshield 22. Main exciter
8. Stator winding 23. Rotary rectifier set
9. DE fan cover 24. Exciter cover
10. Rotor core 25. Anchor plate set
11. Stator core 26. Accessory terminal box
12. Frame 27. Intermediate base
13. Equalizer winding 28. Alignment cap screws
14. NDE fan cover 29. Anchor bolts
15. NDE endshield
NOTES
Parts identification and location may vary depend on turbogenerator model and mounting;
SS_ model Turbogenerators are not fitted with pilot exciter (PMG)
Turbogenerators for mounting B3_ have bearings fixed on DE and NDE endshields;
Heat exchanger can be installed on top or bottom side of generator as required by the costumer.
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18 MAINTENANCE SCHEDULE
The following maintenance schedule is a guideline and intervals between each maintenance procedure may vary according
to conditions and location of equipment operation.
For associated equipment such as hydraulic unit and voltage regulator we recommend to also refer their specific manuals.
Every 3 Every 6 Every 3

EQUIPMENT Weekly Monthly
month month
Yearly
Years
Note
STATOR
Visual inspection of stator x
Cleaning control x
Inspection of the slot wedges x
Stator terminal control x
Measure wing insulation resistance x
ROTOR
Cleaning control x
Check connection of poles and dumping
x
winding
Visual inspection and measurement of pole x
insulation resistance
EXCITER
Cleaning control x
Test diodes and varistors x
Inspect windings x
BEARINGS
Noise, vibration, oil flow, leakage and
x
temperature control
Checking of high pressure system (jacking) x
Oil quality control x

Inspection of sleeve shells and shaft race
x
(sleeve bearings)
As indicated on
Change lubricant
bearing nameplate
HEAT EXCHANGER
Radiator inspection x
Radiator cleaning x
Sacrificial anodes
Inspection of the radiators sacrificial anodes are used in
x
(if any) radiators that uses
salt water
CONTROL AND PROTECTION EQUIPMENTS
Performance inspection x
Value records x
Disassemble and test the operation
x
performance
COUPLING
Check after the first
Alignment inspection x
week of operation
Check after first
Fixation inspection x
week of operation
COMPLETE GENERATOR
Noise and vibration control x
Drain condensed water x
Retighten cap screws x
Clean terminal box x
Retighten electrical and ground
x
connections
Table 18.1: Maintenance Schedule
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19 TROUBLESHOOTING
Please find below a list of some abnormal conditions that can occur during generator as well some procedures for checking
and correcting these faults.
Generator does not excite or prime
ANOMALY PROCEDURE
Check the main panel and regulators modules for

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

Varistor of diodes protection is defective.
temporally.
Generator do not excite, until to rated voltage
ANOMALY PROCEDURE
Measure each rotating diode; replace damaged diode;

Rotating rectifiers defective.
eventually replace the whole set.
Check if the U/F function of voltage regulator is enabled.

Speed below to parameterized setting for U/F If U/F function is set above rated frequency, reset to 5%
function of the voltage regulator. lower.
Measure and set the speed.
Voltage reference set too low. Set the voltage reference.
Remote setting of voltage lower than the

Reset the remote pushbutton to correct value.
rated.
Generator does not excite up to the rated voltage
ANOMALY PROCEDURE
Power supply voltage of the voltage regulator

lower the desired voltage resulting in an Check if wiring is according to Voltage Regulator Manual.
output voltage lower than required.
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At no load generator excites up to until rated voltage, but collapses under load
ANOMALY PROCEDURE
Measure each rotating diode; replace damaged diode;

Rotating diodes are defective.
eventually replace the whole set.
Protection activation: overcurrent, overexcitation, Check if parameters are not set wrong and so activate
overvoltage. the protection in normal operation condition.
Activation of excitation current limit. Check the parameter settings.
Strong speed drop with enabling of U/F function or Check turbine speed control.
not. Check U/F function setting.
The generator, at no load, excites by overvoltage
ANOMALY PROCEDURE
For momentary overvoltage with immediate

Check fuse and wiring.
shutdown: opening of signal transformer circuit.
In remote mode: parameter setting errors by remote

pushbutton, with shutdown after a period of time Reset reference voltage.
(also adjusted with parameter setting).
On manual mode: parameter setting errors of the

Reset reference voltage.
reference voltage: protection will no be activated.
In local mode: parameter setting errors of reference

voltage, with shutdown after a period (also adjusted Reset reference voltage.
with parameter setting).
Generator voltage oscillations
ANOMALY PROCEDURE
Manual Mode: Poor adjusted stability. Adjust on parameterization of voltage regulator.
Automatic mode: Poor adjusted stability. Adjust on parameterization of voltage regulator.
Load variation. Check causes of variations.
Variations of the turbine speed. Check turbine speed control.
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20 ACCESSORIES AND SPARE PARTS

WEG recommend maintaining following spare in stock:
SPARE PARTS
Quant. Description
01 Sleeve bearing shell (upper and bottom) for the DE bearing with hydrostatic jacking (if any)
01 Sleeve bearing shell (upper and bottom) for the NDE bearing with hydrostatic jacking (if any)
03 Anode SKR Diode
03 Cathode SKN Diode
02 Space heater
Accessories listed below are standard supply for WEG turbogenerators.

Others accessories can be installed upon costumer request.
ACCESSORIES
Quantities
Cooling with 1 Cooling with 2 Description
radiator radiators
03 03 Air thermometer
02 04 Water thermometer
01 02 Water flow sight glass
02 02 Contactless thermometer for bearing
04 04 Space heater - Pt 100 - 3 wires - for bearing
1, 2 or 3 per phase Temperature sensor - Pt 100 - 3 wires - for coils*
01 02 Level indicator relay for water leak sensor in radiator
01 02 Rod electrode for water leakage sensor in radiator
01 02 Water fluxostat
02 02 Oil fluxostat
01 02 Water pressure relief valve
01 01 Shaft grounding brush
* Winding temperature sensors can not be replaced. This accessory can be replaced only during stator rewinding.
HOW TO PURCHASE:
For purchasing spare parts and accessories, user must inform to WEG the generator serial number.
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21 DOCUMENTS
For correct installation, operation and maintenance of generator, WEG recommends that in addition to recommendations
mentioned in this manual, following specific documents must be considered:
Generator connection diagram;
Generator dimensional drawing;
Pump drawing (Jacking pump), if any;
Bearings installation and operation manual;
Water radiators maintenance manual;
Voltage regulator manual;
Manual of the hydraulic unit for the bearing lubrication.
ATTENTION
All machines included in this manual are updated constantly, so any information given herewith my be changed
without prior notice.
More information about the parameter setting can be found in the voltage regulator manual.
www.weg.net
22 WARRANTY CONDITIONS OF ENGINEERED PRODUCTS
These products, when operated under the conditions stipulated by WEG in the operating manual for such
product, are warranted against defects in workmanship and materials for twelve (12) months from start-up date
or eighteen (18) months from manufacturer shipment date, whichever occurs first.
However, this warranty does not apply to any product which has been subject to misuse, misapplication,
neglect (including without limitation, inadequate maintenance, accident, improper installation, modification,
adjustment, repair or any other cases originated from inadequate applications).
The company will neither be responsible for any expenses incurred in installation, removal from service,
consequential expenses such as financial losses nor transportation costs as well as tickets and accommodation
expenses of a technician when this is requested by the customer.
The repair and/or replacement of parts or components, when effected by WEG within the Warranty period do
not give Warranty extension, unless otherwise expressed in writing by WEG.
This constitutes WEG's only warranty in connection with this sale and is in lieu of all other warranties, expressed
or implied, written or oral.
There are no implied warranties of merchantability or fitness for a particular purpose that apply to this sale.
No employee, agent, dealer, repair shop or other person is authorized to give any warranties on behalf of WEG
nor to assume for WEG any other liability in connection with any of its products.
In case this happens without WEG's authorization, Warranty is automatically cancelled.
LIABILITY
Except as specified in the foregoing paragraph entitled "Warranty Terms for Engineering Products", the
company shall have no obligation or liability whatsoever to the purchaser, including, without limitation, any
claims for consequential damages or labor costs, by reason of any breach of the express warranty described
therein.
The purchaser further hereby agrees to indemnify and hold the company harmless from any causes of action
(other than cost of replacing or repairing the defective product as specified in the foregoing paragraph entitled
"Warranty Terms for Engineering Products"), arising directly or indirectly from the acts, omissions or negligence
of the purchaser in connection with or arising out of the testing, use, operation, replacement or repair of any
product described in this quotation and sold or furnished by the company to the purchaser.
WEG Equipamentos Eltricos S.A.

International Division
Av. Prefeito Waldemar Grubba, 3000
89256-900 - Jaragu do Sul - SC - Brazil
Phone: 55 (47) 3276-4002
Fax: 55 (47) 3276-4060
www.weg.net
1013.03/0709
www.weg.net
NOTES
www.weg.net
WEG Equipamentos Eltricos S.A.
Internation Division
AV. Prefeito Waldemar Grubba, 3000
89256-900 - Jaragu do Sul - SC - Brasil
Phone: 55 (47) 3276-4002
Fax: 55(47) 3276-4060
www.weg.net

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Motors | Automation | Energy | Paints

Installation, Operation and Maintenance Manual

Installation, Operation and Maintenance Manual

Document No.: 9300.0050

WEG EQUIPAMENTOS ELTRICOS S.A.

3 OPERATING CONDITIONS AND STANDARDS.....................................................................................11

4 RECEIVING AND STORAGE...................................................................................................................12

5 LONG STORAGE PERIODS....................................................................................................................13

7 INSULATION RESISTANCE ....................................................................................................................18

8.4 PERMANENT MAGNET GENERATOR (PMG)......................................................................................................20

9 OPERATION PRINCIPLE ........................................................................................................................ 21

11 ELECTRICAL CONNECTIONS AND ACCESSORIES ........................................................................... 31

13 GENERATOR OPERATION .................................................................................................................... 38

14.3 STATOR, ROTOR AND EXCITER WINDING INSPECTIONS............................................................................... 40

17 GENERATOR PARTS ..............................................................................................................................48

20 ACCESSORIES AND SPARE PARTS.....................................................................................................52

22 WARRANTY CONDITIONS OF ENGINEERED PRODUCTS .................................................................54

THE THERMAL ELECTRIC POWER GENERATION PROCESS

IEC FRAME SIZE

SAFETY WARNINGS IN THE MANUAL

Following safety warnings are used in this manual:

2.2 SAFETY INSTRUCTIONS

3 OPERATING CONDITIONS AND STANDARDS

3.2 ENVIRONMENT CHARACTERISTICS

Turbogenerators are designed to be operated in following ambient conditions:

3.3 OPERATING CONDITIONS

4 RECEIVING AND STORAGE

4.1 RECEIVING 4.2 STORAGE

Any damage must be reported immediately to

5 LONG STORAGE PERIODS

5.1 INTRODUCTION 5.3.1 Indoor storage

5.4 SEPARATE PARTS 5.8.2 Oil-lubricated bearing

ATTENTION 5.8.3 Sleeve Bearing

5.9 TERMINAL BOX 5.10.3 Checking the insulation resistance

5.12 MAINTENANCE PLAN TO BE FOLLOWED DURING THE STORAGE

Every 2 Every 6 Every Before

7.1 SAFETY INSTRUCTIONS The stator winding insulation resistance must be

Measurement of the rotor winding resistance of the

7.5 CONVERSION OF THE MEASURED Insulation resistance Insulation evaluation

7.6 MINIMUM INSULATION RESISTANCE

7.7 POLARIZATION INDEX

The polarization index is traditionally defined as the ratio

Polarization index Insulation evaluation

Figure 7.2: Coefficient of insulation resistance variation with

With old machines, during longer time in service, the read

Exciter Stator 8.7 HEAT EXCHANGER

AVR: Automatic Voltage Regulator

Figure 9.1: Internal electrical circuits of the SP_ model generator

After the primary machine is driven and reaches is rated DANGER

9.3 VOLTAGE REGULATOR

The purpose of the electronic voltage regulator is to keep ATTENTION

Manual operation mode

In this operation mode, the generator excitation is

Figure 10.1: Direction of Rotation

10.5 ANCHOR PLATE SET

Figure 10.2: Anchor Plate

Figure 10.3: The anchor plate and the generator

The anchor plates can be leveled and grouted after they

Generators fitted with sleeve bearings

Figure 10.8: Coupling axial play.

Before starting the operation, check if generator shaft

After the machine set has been aligned and checked ( in

Welding at four points